ABB SCK User manual

—
ABB MEASUREMENT & ANALYTICS |
OPERATING INSTRUCTION | OI/SCK-EN REV. E
SCK
Sample
conditioning for kiln
—
ABB Measurement & Analytics
For your local ABB contact, visit:
www.abb.com/contacts
For more product information, visit:
www.abb.com/analytical
Sampling system for dry gas
sampling at rotary cement kiln gas
exit and calciner gas exit
Measurement made easy
OI/SCK
-EN Rev. E 07.2021 Original instruction
—
SCK
Introduction
The SCK is a sampling system for dry gas
sampling at rotary kiln exit and calciner gas exit.
The SCK sampling system is suitable for
applications in rough environmental conditions
and for outdoor installations thanks to a
complete protection
cover.
Additional Information
Additional documentation on SCK is available for
download free of charge at www.abb.com/analytical.
Alternatively simply scan this code:
—
We reserve the right to make technical changes or
modify the contents of this document
without prior
notice. With regard to purchase orders, the agreed particulars shall prevail.
ABB does not accept any
responsibility whatsoever for potential errors or possible lack of
information in this document.
We reserve all rights in this document and in the
subject matter and illustrations contained
therein.
Any reproduction, disclosure to third parties or utilization of its contents – in whole
or in parts
– is forbidden without prior written consent of ABB.
© ABB 2021 3KXG141003R4201

2 Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E
Contents
Chapter 1 General....................................................................................................................5
About these operating instructions .......................................................................... 6
Safety instructions in this document........................................................................ 8
System identification ..................................................................................................10
Service............................................................................................................................13
Chapter 2 Description of the sampling system ................................................................. 15
Technical data...............................................................................................................16
Intended conditions of use ........................................................................................17
Structure and function................................................................................................18
Mode of functioning and operating modes ............................................................19
Process monitoring .................................................................................................... 20
Controls and displays..................................................................................................22
Probe retractor............................................................................................................ 24
Gas sampling probe H................................................................................................ 26
Gas sampling probe 60S............................................................................................ 28
Cooling module ........................................................................................................... 30
Transformer ..................................................................................................................32
Compressed-air tank and pneumatic system.........................................................33
Chapter 3 Description of control system ........................................................................... 35
Structure and function of the control system ....................................................... 36
User interface: Operation screen ............................................................................. 38
User interface: Trend screen..................................................................................... 40
User interface: Message screen................................................................................ 42
User interface: Parameter screen............................................................................. 44
Error message display................................................................................................ 46
Access permissions .................................................................................................... 47
Default operating parameter settings.................................................................... 48
Optimizing operating parameters............................................................................51
Chapter 4 Safety.................................................................................................................... 53
Basic safety rules ........................................................................................................ 54
Overview of dangers....................................................................................................57
Protective installations .............................................................................................. 59
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 ......................................................................................76
Safety measures: Maintenance and troubleshooting .......................................... 80
Chapter 5 Transport and unpacking ...................................................................................85
General transport information ................................................................................. 86
Transport the system in the company .................................................................... 89
Unpacking the system.................................................................................................91

OI/SCK
-EN Rev. E Operating instruction SCK Gas Sampling System 3
Scope of delivery ......................................................................................................... 92
Chapter 6 Installation ...........................................................................................................93
Overview: installation................................................................................................. 94
Checking site conditions ........................................................................................... 95
Installing the probe retractor ....................................................................................97
Installing the control cabinet.................................................................................. 100
Installing the compressed-air supply .....................................................................101
Installing the cooling module.................................................................................. 103
Installing the cooling water circuit ........................................................................ 104
Connecting the sample gas line to the retractor ................................................ 105
Connecting internal electric cables ....................................................................... 106
Connecting external electric cables....................................................................... 108
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 ........................................................126
Checks to perform when using probe H ................................................................127
Inserting the probe and switching to automatic mode..................................... 130
Chapter 8 Operation ........................................................................................................... 135
Safety regulations for operation.............................................................................136
Monitoring automatic mode....................................................................................139
Checking general condition .....................................................................................141
Cleaning gas sampling probe H ..............................................................................143
Cleaning gas sampling probe 60S ......................................................................... 145
Using the EMERGENCY-STOP switch .....................................................................147
Chapter 9 Maintenance.......................................................................................................149
Maintenance plan ...................................................................................................... 150
Equipment layout plan ............................................................................................. 154
Acquiring spare parts and wear parts....................................................................157
Safety regulations for maintenance work.............................................................158
Operating the service switch...................................................................................161
Checking the condition of the system, cleaning the system.............................163
Evaluating trend displays ........................................................................................ 166
Checking the residual current circuit breaker.......................................................167
Checking protective installations .......................................................................... 169
Checking for leaks......................................................................................................173
Gas sampling probe H: Removing incrustations..................................................176
Gas sampling probe H: Replacing the intake filter ..............................................178
Gas sampling probe H: Replacing membrane pump membranes ....................181
Gas sampling probe 60S: Removing incrustations............................................. 184

4 Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E
Gas sampling probe 60S: Cleaning or replacing the outlet filter..................... 186
Gas sampling probe 60S: Replacing the seal set ................................................ 189
Probe retractor: Checking filter/pressure control combination....................... 191
Probe retractor: Checking and replacing the filter muffler................................193
Probe retractor: Checking and topping up the oiler............................................195
Probe retractor: Checking and tightening the drive chain................................ 198
Probe retractor: Checking and, if necessary, adjusting the position of the
probe ...........................................................................................................................200
Probe retractor: Checking and, if necessary, adjusting the position indicator
(probe end position)................................................................................................. 204
Probe retractor: Checking the bellows.................................................................. 207
Cooling module: Vent the cooling-water circuit.................................................. 208
Cooling module: Checking and topping up cooling water .................................210
Pneumatic system: Replacing the compressed-air filter....................................213
Chapter 10 Errors .................................................................................................................. 215
Errors and irregularities............................................................................................216
Touchscreen error displays ......................................................................................218
Handling error messages .........................................................................................223
Chapter 11 Shutting down, storing, putting back into operation, disposal................... 225
Shutting down the system ...................................................................................... 226
Disassembling the system ...................................................................................... 229
Storing the system.....................................................................................................232
Putting the system back into operation................................................................233
Disposing of the system.......................................................................................... 234
Chapter 12 Appendix ............................................................................................................ 235
Pneumatic/hydraulic interface plan ...................................................................... 236
Electrical connection plan........................................................................................ 238
Transformer connection plan .................................................................................240
Index .............................................................................................................................241

OI/SCK
-EN Rev. E Operating instruction SCK Gas Sampling System 5
Chapter 1 General
Topic Page
About these operating instructions ...................................................................6
Safety instructions in this document.................................................................8
System identification ..........................................................................................10
Service.................................................................................................................... 13

6 Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E
About these operating instructions
These operating instructions apply to the SCK gas sampling system, product
number: 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 dam-
age 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 commencing any work:
the section on Safety on page 53
the sections describing the work to be performed
Scope and purpose
Target group
Illustrations in the
operating
instructions

OI/SCK
-EN Rev. E Operating instruction SCK Gas Sampling System 7
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 docu-
ments.
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
instructions.
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".
Copyright
Liability
Symbols and
typefaces
Further information

8 Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E
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 in-
structions
Generic safety instructions not
pertaining to a particular task:
They provide a general de-
scription of dangers and
safety measures when han-
dling 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
handling the gas sampling
system.
Indicated by the
title of the section.
Safety regulations
for specific sec-
tions
Safety instructions pertaining to
all tasks described in this sec-
tion
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

OI/SCK
-EN Rev. E Operating instruction SCK Gas Sampling System 9
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

10 Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E
System identification
The gas sampling system can be unambiguously identified by means of the
specifications 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
1
Product name
2
Product number
3
Customer order number
4
Production number
5
Manufacturer's address
6
Serial number of the retractor
7
Serial number of the cooling module
8
Year of manufacture of the system
9
CE mark
10
Environment-Friendly Use Period (EFUP) mark
11
Warning triangle to DIN EN 61010: observe operating instruc-
tions
12
Electric connections
Nameplate

OI/SCK
-EN Rev. E Operating instruction SCK Gas Sampling System 11
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 con-
tact
12th digit 1 Certificates CE design
2 CSA design
Unique identification

12 Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E
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 cus-
tomer 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

OI/SCK
-EN Rev. E Operating instruction SCK Gas Sampling System 13
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 con-
tact:
ABB Service, Telephone: [phone], Telefax: +49-(0)621-
38193129031,
E-Mail: automation.servi[email protected].com
Service
Service address

OI/SCK
-EN Rev. E Operating instruction SCK Gas Sampling System 15
Chapter 2 Description of the sampling system
Topic Page
Technical data....................................................................................................... 16
Intended conditions of use ................................................................................ 17
Structure and function........................................................................................18
Mode of functioning and operating modes ....................................................19
Process monitoring .............................................................................................20
Controls and displays..........................................................................................22
Probe retractor.....................................................................................................24
Gas sampling probe H .........................................................................................26
Gas sampling probe 60S.....................................................................................28
Cooling module ....................................................................................................30
Transformer ..........................................................................................................32
Compressed-air tank and pneumatic system.................................................33

16 Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E
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

OI/SCK
-EN Rev. E Operating instruction SCK Gas Sampling System 17
Intended conditions of use
The gas sampling system is used to monitor process gas in cement produc-
tion.
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 combi-
nation 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

18 Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E
Structure and function
The following diagram shows an overview of the SCK modules:
The individual modules of the gas sampling system have the following func-
tions:
No.
Designation
Function
1
Retractor

mechanical movement of the probe
automatic removal of the probe when
malfunctions occur
2
Gas sampling
probe

sampling of sample gas from the
process
3
Control cabinet

control and monitoring

error display
4
Cooling module

cooling of the gas sampling probe
5
Compressed-air
tank (optional)

back up probe movement if the on-
site compressed-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 integrated in a closed cooling-water circuit with a heat ex-
changer (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

OI/SCK
-EN Rev. E Operating instruction SCK Gas Sampling System 19
Mode of functioning and operating modes
The following process takes place in order to sample gas during cement pro-
duction:
Phase
Description
1
The operator switches the system to manual mode.
2
The operator inserts the probe into the rotary kiln.
3
The cooling water is heated up to operating temperature.
4
Once the cooling water reaches the threshold temperature, the
controller activates gas flow.
Result: The gas sampling probe sucks the sample gas through
the sample gas line and passes it on to the connected analysis
system.
5
The operator switches to automatic mode.
6
The probe cleaning system cleans the probe after the set inter-
val.
7
The retractor moves the probe in and out after a set interval in
order to prevent it from sticking.
The following modes are possible:
Mode
Description
Automatic mode Allows continuous operation of the system for
sample gas sampling. Probe cleaning steps take
place after set intervals (these can be defined
using the controller).
Manual mode
Allows operation of the system in manual mode,
required for maintenance, for example.
Mode of functioning
Modes

20 Operating instruction SCK Gas Sampling System OI/SCK-EN Rev. E
Process monitoring
The process is monitored by the following devices:
Monitoring device
Purpose
Function
Inductive position
indicator Probe in-
serted

Ensures that front
end position is
reached
Monitoring of probe
travel time

Locks various follow-
up functions
Triggers the retrac-
tion program if probe
travel time is exceed-
ed
Inductive position
indicator Probe re-
tracted

Ensures that rear end
position is reached
Monitoring of probe
travel time

Locks various follow-
up functions
Triggers the retrac-
tion program if probe
travel time is exceed-
ed
Mechanical position
indicator Probe re-
tracted

Ensures that rear end
position is reached
Monitoring of probe
travel time
Additional signaling
option for customer
error management

Locks various follow-
up functions
Triggers the retrac-
tion program if probe
travel time is exceed-
ed
Provides a mechani-
cal switching contact
for error manage-
ment
Cooling water flow
temperature meas-
urement
Protects gas sam-
pling probe against
condensation build-
up inside
Locks various follow-
up functions during
start-up
Cooling water pres-
sure measurement

Protects the gas
sampling probe
against overheating

Triggers the retrac-
tion program if min-
imum cooling water
pressure is not
reached
Cooling-water circuit
leak monitoring
Cooling water flow
measurement

Protects the gas
sampling probe
against overheating
Monitors the cooling
water pump for ade-
quate pump power

Triggers the retrac-
tion program if max-
imum cooling water
temperature is ex-
ceeded
Cooling water pump
function check
Pressure switch Com-
pressed air
Ensures adequate
central compressed-
air supply
Triggers the retrac-
tion program if min-
imum input pressure
is not reached
Monitoring
devices