ABB SCK User guide

Sample conditioning for kiln
SCK
Sampling system for dry gas sampling
at rotary cement kiln gas exit and calciner gas exit
System manual 42/2381 EN Rev. 4

Sample conditioning for kiln
SCK
Sampling system for dry gas sampling
at rotary cement kiln gas exit and calciner gas exit
System manual
Publication No. 42/2381 EN
Revision 4
Edition November 2016

4 System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4
Contents
Chapter 1General .....................................................................................................................7
About these operating instructions ............................................................................8
Safety instructions in this document........................................................................10
System identification................................................................................................12
Service.....................................................................................................................15
Chapter 2Description of the sampling system....................................................................17
Technical data..........................................................................................................18
Intended conditions of use.......................................................................................19
Structure and function..............................................................................................20
Mode of functioning and operating modes ..............................................................21
Process monitoring..................................................................................................22
Controls and displays ..............................................................................................24
Probe retractor.........................................................................................................26
Gas sampling probe H.............................................................................................28
Gas sampling probe 60S .........................................................................................30
Cooling module........................................................................................................32
Transformer .............................................................................................................34
Compressed-air tank and pneumatic system ..........................................................35
Chapter 3Description of control system..............................................................................37
Structure and function of the control system ...........................................................38
User interface: Operation screen.............................................................................40
User interface: Trend screen ...................................................................................42
User interface: Message screen..............................................................................44
User interface: Parameter screen............................................................................46
Error message display.............................................................................................48
Access permissions.................................................................................................49
Default operating parameter settings ......................................................................50
Optimizing operating parameters ............................................................................53
Chapter 4Safety ......................................................................................................................55
Basic safety rules ....................................................................................................56
Overview of dangers................................................................................................58
Protective installations.............................................................................................60
Warning signs on the system ..................................................................................63
Requirements to be met by personnel, work places ...............................................65
Personal safety equipment ......................................................................................67
Safety measures: Transport and unpacking............................................................68
Safety measures: Installation ..................................................................................69
Safety measures: Start-up .......................................................................................72
Safety measures: Operation....................................................................................75
Safety measures: Maintenance and troubleshooting ..............................................78
Chapter 5Transport and unpacking......................................................................................83
General transport information..................................................................................84
Transport the system in the company .....................................................................87
Unpacking the system .............................................................................................89
Scope of delivery .....................................................................................................90

42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System 5
Chapter 6Installation..............................................................................................................91
Overview: installation...............................................................................................92
Checking site conditions..........................................................................................93
Installing the probe retractor....................................................................................95
Installing the control cabinet ....................................................................................98
Installing the compressed-air supply .......................................................................99
Installing the cooling module .................................................................................101
Installing the cooling water circuit..........................................................................103
Connecting the sample gas line to the retractor....................................................104
Connecting internal electric cables........................................................................105
Connecting external electric cables.......................................................................107
Chapter 7Start-up ................................................................................................................. 111
Overview: Start-up .................................................................................................112
Installation check ...................................................................................................113
Preparing the cooling-water circuit ........................................................................ 114
Preparing the compressed-air supply....................................................................116
Activation ...............................................................................................................118
After switching on: working on the cooling module ...............................................121
Checking the pneumatic system............................................................................123
Starting frequency converter and adapting control parameters ............................124
Checking/correcting operating parameters ...........................................................127
Checks to perform when using probe H ................................................................128
Inserting the probe and switching to automatic mode...........................................131
Chapter 8Operation..............................................................................................................135
Safety regulations for operation.............................................................................136
Monitoring automatic mode ...................................................................................138
Checking general condition ...................................................................................140
Cleaning gas sampling probe H ............................................................................142
Cleaning gas sampling probe 60S.........................................................................144
Using the EMERGENCY-STOP switch..................................................................146
Chapter 9Maintenance .........................................................................................................147
Maintenance plan ..................................................................................................148
Equipment layout plan ...........................................................................................152
Acquiring spare parts and wear parts ....................................................................155
Safety regulations for maintenance work ..............................................................156
Operating the service switch .................................................................................159
Checking the condition of the system, cleaning the system..................................161
Evaluating trend displays.......................................................................................164
Checking the residual current circuit breaker ........................................................165
Checking protective installations ...........................................................................167
Checking for leaks .................................................................................................171
Gas sampling probe H: Removing incrustations ...................................................174
Gas sampling probe H: Replacing the intake filter ................................................176
Gas sampling probe H: Replacing membrane pump membranes ........................179
Gas sampling probe 60S: Removing incrustations ...............................................182
Gas sampling probe 60S: Cleaning or replacing the outlet filter ...........................184
Gas sampling probe 60S: Replacing the seal set .................................................187
Probe retractor: Checking filter/pressure control combination ..............................189
Probe retractor: Checking and replacing the filter muffler .....................................191
Probe retractor: Checking and topping up the oiler...............................................193

6 System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4
Probe retractor: Checking and tightening the drive chain .....................................196
Probe retractor: Checking and, if necessary, adjusting the position of the probe .198
Probe retractor: Checking and, if necessary, adjusting the position indicator
(probe end position)...............................................................................................202
Probe retractor: Checking the bellows ..................................................................205
Cooling module: Vent the cooling-water circuit .....................................................206
Cooling module: Checking and topping up cooling water .....................................208
Pneumatic system: Replacing the compressed-air filter .......................................211
Chapter 10Errors ....................................................................................................................213
Errors and irregularities .........................................................................................214
Touchscreen error displays....................................................................................216
Handling error messages ......................................................................................221
Chapter 11Shutting down, storing, putting back into operation, disposal ......................223
Shutting down the system .....................................................................................224
Disassembling the system.....................................................................................227
Storing the system .................................................................................................229
Putting the system back into operation .................................................................230
Disposing of the system ........................................................................................231
Chapter 12Appendix ..............................................................................................................233
Pneumatic/hydraulic interface plan........................................................................234
Electrical connection plan......................................................................................236
Transformer connection plan .................................................................................238
Index 239

42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System 7
Chapter 1 General
Topic Page
About these operating instructions .................................................................... 8
Safety instructions in this document................................................................ 10
System identification........................................................................................ 12
Service............................................................................................................. 15

8 System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4
About these operating instructions
These operating instructions apply to the SCK gas sampling system, product num-
ber: 23919.
These operating instructions are intended to give all personnel handling the gas
sampling system the information required to perform the following tasks correctly
and safely:
Transport at the company (for first-time delivery, relocation, storage, putting
back into operation)
Set-up, unpacking and connection
Start-up
Operation
Diagnostics and troubleshooting
Maintenance
Shutting down, disassembly, putting back into operation, storage and disposal
These operating instructions are intended for the following groups:
Process engineers and design engineers (for preparation of the installation site)
Transporter
Assembly personnel
Start-up personnel
Operating personnel
Maintenance personnel
Storage personnel
Disposal personnel
The illustrations in the operating instructions do not always depict the actual layout
of a gas sampling system as delivered. Therefore, the drawings in the supplied
system documentation are always authoritative.
Failing to observe the information in this document can lead to a risk of damage to
property, injuries or even death.
In order to ensure safety, all personnel handling the gas sampling system must
have read and understood the following sections of this document before com-
mencing any work:
the section on Safety on page 55
the sections describing the work to be performed
The manufacturer retains copyright to these operating instructions:
ABB Automation GmbH
Geschäftsgebiet Analysentechnik
Stierstädter Straße 5
60488 Frankfurt am Main
GERMANY
These operating instructions contain regulations and drawings of a technical nature
that must not, either in part or in whole, be reproduced, disseminated or exploited
for the purpose of competition or passed on to third parties without permission.
The manufacturer is not liable for damage and disruptions resulting from a failure to
observe these operating instructions and other applicable documents.
Scope and purpose
Target group
Illustrations in the
operating
instructions
Copyright
Liability

42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System 9
Identifies safety information to be heeded when handling the
gas sampling system in order to avoid risks to the operator.
Identifies special information regarding handling of the gas
sampling system as well as use of these operating instruc-
tions.
1, 2, 3, ... Identifies reference numbers in the figures.
Further information on ABB Analytical products and services is available on the
Internet at "http://www.abb.com/analytical".
Symbols and
typefaces
Further information

10 System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4
Safety instructions in this document
Safety instructions are information intended to prevent physical injuries. Safety
instructions contain the following information:
Type of danger
Possible consequences if you fail to observe the instruction
Action to prevent physical injury
This document contains the following types of safety instruction:
Type of safety
instruction
Description Indicated by
Basic safety instruc-
tions
Generic safety instructions not
pertaining to a particular task:
They provide a general descrip-
tion of dangers and safety
measures when handling the
system.
They are intended to educate
the operator about existing
dangers and to instruct him in
general safety behavior.
They are suitable for safety
instruction of all personnel han-
dling the gas sampling system.
Indicated by the title
of the section.
Safety regulations
for specific sections
Safety instructions pertaining to all
tasks described in this section
Indicated by the title
of the section
Safety instructions at
the beginning of an
instruction
Safety instructions with specific
instructions pertaining to the entire
instruction
Safety instructions
on a particular step
Safety instructions with specific
instructions pertaining to one step
only
DANGER
WARNING
CAUTION
What are safety
instructions for?
Types of safety
instruction

42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System 11
The safety instructions pertaining to instructions and actions are indicated by a
danger word. The danger word stands for a particular danger level:
Type of safety
instruction
If the instruction is not fol-
lowed ...
And the consequence is
...
DANGER an accident occurs. serious bodily injury or
death.
WARNING the accident may occur. possibly serious bodily
injury or death.
CAUTION the accident will definitely or may
possibly occur.
major or minor bodily
injury.
Warnings of possible damage to property are marked by the word CAUTION in this
document if there is no danger of injury to persons.
Danger levels
Warning of damage to
property

12 System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4
System identification
The gas sampling system can be unambiguously identified by means of the speci-
fications on the nameplate. The nameplate is located on the left side wall of the
control cabinet. The nameplate is laid out as follows:
The individual areas of the nameplate have the following meaning:
No. Meaning
1Product name
2Product number
3Customer order number
4Production number
5Manufacturer's address
6Serial number of the retractor
7Serial number of the cooling module
8Year of manufacture of the system
9CE mark
10 Environment-Friendly Use Period (EFUP) mark
11 Warning triangle to DIN EN 61010: observe operating instructions
12 Electric connections
Nameplate

42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System 13
The gas sampling system can be identified by means of the product number on the
nameplate and the following table:
Product number
23919-0-
Value Characteristic Version
1st digit 1 Application SCK
2nd-4th digit 0 n.a.
5th digit 0 Compressed-air supply w/o compressed-air tank
1
with compressed-air tank
6th digit 1 Special type and length 60S; 1.5 m
2
60S; 2 m
3
60S; 2.5 m
4
60S; 3 m
5
60S; 3.5 m
6
H; 1.5 m
7
H; 2 m
8
H; 2.5 m
9
H; 3 m
A
H; 3.5 m
7th digit 1 Retractor Standard retractor 2.5 m
2
Standard retractor 3.5 m
3
Retractor with special length
8th digit 1 Sample gas line prepared for TBL01-C
2
prepared for heated sample gas line
3
prepared for unheated sample gas line
9th digit 0 n.a.
10th digit 1 Power supply 230 V/400 V, 50 Hz
2
230 V/400 V, 60 Hz
3
120 V/208 V, 60 Hz (incl. transformer)
4
230 V/400 V, 50 Hz prep. for UPS
5
230 V/400 V, 60 Hz prep. for UPS
6
120 V/208 V, 60 Hz (incl. transformer) prep.
for UPS
11th digit 1 External signal transfer Status signals as relay contacts
2
Profibus
3
Signals as relay contacts + Profibus
4
Connection to ACX via Modbus
5
Connection to ACX + signals as relay contact
12th digit 1 Certificates CE design
2
CSA design
Unique identification

14 System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4
The following table sums up other product versions. These are not, however, coded
in the product number.
Characteristic Versions
Retractor, special length (special) length of retractor according to customer
requirement
Sturdy control unit present/not present
Wire labeling present/not present
Circuit breakers, 2-pole present/not present
Residual current circuit
breaker for entire system
present/not present
Cable labeling present/not present
Engraved nameplates present/not present
Additional nameplates
(engraved)
No. 1 / 2 / 3 / 4 / 5
Orientation of probe S Sampling holes to the right / to the left
Additional versions

42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System 15
Service
Contact ABB Service in the following cases:
if you have any questions regarding handling of the gas sampling system that
are not dealt with in these operating instructions
for ordering spare parts
for ordering maintenance work
Contact your local ABB Service representative. For emergencies, please contact:
ABB Service, Telephone: [phone], Telefax: +49-(0)621-38193129031,
E-Mail: [email protected]m
Service
Service address

42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System 17
Chapter 2 Description of the sampling system
Topic Page
Technical data.................................................................................................. 18
Intended conditions of use............................................................................... 19
Structure and function...................................................................................... 20
Mode of functioning and operating modes ...................................................... 21
Process monitoring.......................................................................................... 22
Controls and displays ...................................................................................... 24
Probe retractor................................................................................................. 26
Gas sampling probe H..................................................................................... 28
Gas sampling probe 60S ................................................................................. 30
Cooling module................................................................................................ 32
Transformer ..................................................................................................... 34
Compressed-air tank and pneumatic system .................................................. 35

18 System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4
Technical data
The following sound emission may be expected when operating the retractor and
cooling module:
Retractor sound emission approx. 89 dB(A)
Cooling module sound emission approx. 89 dB(A)
The following table lists the dimensions and weights of the main modules of the
gas sampling system:
Retractor:
Dimensions Width 800 mm, Height 600 mm, Length 4500 / 5500 mm
Weight 450 / 500 kg
Probe H:
Weight 95 kg (for 3 m special length)
Probe 60S:
Weight 45 kg (for 3 m special length)
Control cabinet:
Dimensions Width 800 mm, Height 1000 mm, Depth 300 mm
Weight 75 kg
Cooling module:
Dimensions Width 1200 mm, Height 1500 mm, Depth 800 mm
Weight 250 kg
Transformer (optional):
Dimensions Width 634 mm, Height 953 mm (with base and transport
lugs), Depth 400 mm
Weight 140 kg
250-l compressed-air tank (optional):
Dimensions Height 1785 mm, Diameter 530 mm
Weight 140 kg
Sound emission
Dimensions and
weights

42/23-81 EN Rev. 4 System Manual SCK Gas Sampling System 19
Intended conditions of use
The gas sampling system is used to monitor process gas in cement production.
The gas sampling system is used for continuous sampling of sample gas
at primary firing at the gas outlet of the rotary kiln,
at secondary firing at the gas outlet of the calcinator.
Analysis of the sample gas is by means of a suitable analyzer system, for example
the ACX analysis system from ABB Automation GmbH.
The gas sampling system may not be used
to measure mixtures of gas/air or gas/oxygen that are capable of ignition during
normal service,
to measure flammable gas which may form an explosive mixture in combination
with air or oxygen,
in a potentially explosive atmosphere or in explosion-hazard areas,
to measure extremely toxic or extremely corrosive gases.
Purpose of the gas
sampling probe
Restrictions
on use

20 System Manual SCK Gas Sampling System 42/23-81 EN Rev. 4
Structure and function
The following diagram shows an overview of the SCK modules:
The individual modules of the gas sampling system have the following functions:
No. Designation Function
1Retractor mechanical movement of the probe
automatic removal of the probe when mal-
functions occur
2Gas sampling probe sampling of sample gas from the process
3Control cabinet control and monitoring
error display
4Cooling module cooling of the gas sampling probe
5Compressed-air tank
(optional)
back up probe movement if the on-site com-
pressed-air supply fails
The sampling system serves the purpose of continuous sampling of sample gas at
the measuring point, i.e. at the gas outlet of the rotary kiln or at the gas outlet of the
calcinator. The probe forms a unit with the pneumatic probe retractor. It is integrat-
ed in a closed cooling-water circuit with a heat exchanger (cooling module). The
retractor and probe can be controlled from the touchscreen on the control cabinet.
The sample gas is filtered in the probe and ducted into the sample gas line. Further
conditioning and analysis of the gas takes place in external equipment (not part of
the gas sampling system).
Illustration
Modules
Additional
explanations