YOKOGAWA EXAxt ZR22G Manual

Technical
Information
ZR22G, ZR402G
Direct In Situ
Zirconia Oxygen Analyzer
(Applications Volume)
TI 11M12A01-01E
TI 11M12A01-01E
©Copyright Feb. 2004 (KP)
4th Edition Mar. 2017 (YK)
Yokogawa Electric Corporation
2-9-32, Nakacho, Musashino-shi, Tokyo, 180-8750 Japan
Tel.: [phone] Fax.: [phone]

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Toc-1
TI 11M12A01-01EAll Right Reserved Copyright © 2004, Yokogawa Electric Corporation
ZR22G, ZR402G
Direct In Situ Zirconia Oxygen Analyzer
(Applications Volume)
Mar. 14, 2017-00
CONTENTS
TI 11M12A01-01E 4th Edition
1. Overview.................................................................................................... 1-1
2. Installation Guide ..................................................................................... 2-1
2.1 Selecting an Installation Site ........................................................................... 2-1
3. SystemCongurations............................................................................ 3-1
3.1 ZR402G Direct In Situ Zirconia Oxygen Analyzer System Block Diagrams3-1
3.2 Selection According to Use ............................................................................. 3-2
3.3 Examples of System Component Selection
Based on Sample Gas Conditions .................................................................. 3-6
4. Applications.............................................................................................. 4-1
4.1 Boiler .................................................................................................................. 4-1
(1) Package boiler ................................................................................... 4-1
(2) Power generation boiler (Heavy oil, Gas).......................................... 4-2
(3) Pulverized coal boiler........................................................................ 4-3
(4) Black liquor recovery boiler................................................................ 4-4
4.2 Iron and Steel Furnaces ................................................................................... 4-5
(1) Iron & steel heating furnace ............................................................... 4-5
(2) Hot blast stove (blast furnace facility) ................................................ 4-6
(3) Coke oven facility............................................................................... 4-7
(4) Soaking pit ......................................................................................... 4-8
4.3
Ceramic, Brick, Glass & Cement Furnaces/Kilns) ..................................................... 4-9
(1) Rotary type lime kiln........................................................................... 4-9
(2) Cement kiln (cyclone outlet gas)...................................................... 4-10
4.4 PetroleumReningandPetrochemicalFiredHeaters ............................... 4-11
(1) Naphtha cracking furnace................................................................ 4-12
(2) Petroleumreneryprocessredheaterexample............................ 4-13
4.5 Garbage Incinerator........................................................................................ 4-14
4.6 Non-Combustion Applications...................................................................... 4-15
(1) Oxygen enrichment facility............................................................... 4-15
(2) Power generation boiler window box............................................... 4-16
(3) Aeration tank.................................................................................... 4-17
4.7 DifcultMeasurementApplications ............................................................. 4-18
(1) Calcination furnace .......................................................................... 4-18
(2) Facilities with reducing gas atmospheres........................................ 4-18

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TI 11M12A01-01EAll Right Reserved Copyright © 2004, Yokogawa Electric Corporation Mar. 14, 2017-00
Revision Information ...............................................................................................i

<1. Overview> 1-1
TI 11M12A01-01EAll Right Reserved Copyright © 2004, Yokogawa Electric Corporation Mar. 14, 2017-00
1. Overview
The EXAxt Zircon Oxygen Analyzer (Model ZR402G) is used to monitor and control the oxygen
concentration in combustion gases, in boilers and industrial furnaces, for wide application
in industries which consume considerable energy—such as steel, electric power, oil and
petrochemical, ceramics, pulp and paper, food, or textiles, as well as incinerators and medium/
small boilers. It can help conserve energy in these industries. The ZR402G also contributes
to preservation of the earth’s environment in preventing global warming and air pollution by
controlling complete combustion to reduce CO2SOx and NOx.
The ZR22G Detector uses a high-reliability Zirconia sensor, and its heater assembly can be
replacedonsite.Thedetectorismounted,forexample,onthewallofaueandcanmeasurethe
gases directly. For use in combustion gases at temperatures up to 1400°C, choose the general-
use 0.15m long detector, which is combined with ZO21P-H, the high-temperature probe adapter.
The ZR402G converter is equipped with an LCD touch screen which has various setting displays,
a calibration display, oxygen concentration trend display, with easier operation and improvement
of display functions.
The ZR402G converter is equipped with various standard functions such as measurement and
calculation as well as maintenance functions including self-test. Analyzer calibration can also be
fully automated— and ZR40H, an automatic calibration unit, is available. Choose the detector
version which best suits your needs so that an optimal combustion control system can be
obtained.
Use this TI as a system selection guide and application note.

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<2. Installation Guide> 2-1
TI 11M12A01-01E Mar. 14, 2017-00All Right Reserved Copyright © 2004, Yokogawa Electric Corporation
2. Installation Guide
2.1 Selecting an Installation Site
Improper installation of the detector may cause inaccurate measurement or damage in short-
term service.
(1) Easy access for inspection and maintenance.
(2) Ambient temperature does not exceed 150°C, and the terminal box is not exposed to
radiant heat.
(3) A clean environment free from corrosive gases.
(4) Minimum vibration.
Typical good/bad installation examples are shown below for your reference.
Bad Example Good Example
Duct Gas Flow
(Oriented obliquely against
the gas flow)
(Installed on a bend in the duct)
(Mounted above the horizontal)
(Subjected to condensation)
Probe Protector
Dust Guard Protector
F0201.ai
(A corrosive gas or flammable gas
is contained in the atmosphere)
Instrument air
(As reference gas)

<2. Installation Guide> 2-2
TI 11M12A01-01EAll Right Reserved Copyright © 2004, Yokogawa Electric Corporation Mar. 14, 2017-00
Installation Site of the Converter (in case of ZR402G)
1. Allows the operator to easily read the display and operate the keys.
2. Easy access for inspection and maintenance.
3. Ambient temperature does not exceed 55°C, and temperature variations are minimal.
4. Humidity is moderate (40 to 75% RH) and no corrosive gases are present.
5. Minimum vibration.
6. Near to the detector.
7. Not exposed to direct sun light.
Instrument air is used as the reference gas
EXAZR402G
~
ZR402G Converter
Check valve
or Stop valve
ZA8F Flow Setting Unit
ZR22G Detector
100 to
240 V AC
Air Set
Instrument air
Calibration gas
Reference gas
Flowmeter Needle
valve
Zero gas cylinder
Span gas
Contact input
Analog output, contact output
(Digital output HART)
Signal
(6-core shield cable)
Heater (2-core)
F0202.ai
1) Install the stop valve or check valve securely so that the gas does not leak.
2) Use the ZA8F flow setting unit and zero gas cylinder.
3) Use a shielded cable for the signal line.
Regulator
Ambient air is used as the reference gas
EXAZR402G
F0203.ai
~
~
ZR22G Detector
1) Install the stop valve securely so that the gas does not leak.
2) Use the ZO21S standard gas unit.
3) Use a shielded cable for the signal line.
ZR402G Converter
Stop valve
Calibration gas
ZO21S Standard gas unit
100 to
240 V AC
Contact input
Analog output, contact output
(Digital output HART)
Signal
(6-core shield cable)
Heater (2-core)

  <3.SystemCongurations> 3-1
TI 11M12A01-01E Mar. 14, 2017-00All Right Reserved Copyright © 2004, Yokogawa Electric Corporation
3. SystemCongurations
This section includes two types of system selection guides for direct in situ zirconia
oxygenanalyzers.Thereadershouldreferrsttheexamplesofsystemselection
by application, and then examine the system block diagram and component device
overviews.
3.1 ZR402G Direct In Situ Zirconia Oxygen
Analyzer System Block Diagrams
(1) System Selection Examples, by Application
Application
General-purpose detector
(0 to 700°C)
High-temperaturedetector
(700 to 1400°C)
System types Detector System types Detector
Common Boiler (fuel oil, gas) L1, L2, L3 D1, (D2) H2, H3
Boiler
(pulverizedcoal,uidized
bed)
L2, L3 D4 H2, H3
Boiler (bark, wood scrap) L2, L3 D3, (D1) H2, H3
Iron & steel Heating furnaces & soaking pits L2, L3 H2, H3 D5
Hot blast stove L2, L3 D1 H2, H3
Coke ovens & annealing
furnaces L2, L3 D1, (D2) H2, H3 D6, (D7)
Sintering furnace L2, L3 D1, (D4) H2, H3
Non-ferrous
metals
Heating, sintering & melting
furnaces L2, L3 D1, (D4) H2, H3 D5, (D6)
Ceramic,
brick,
glass &
cement
manufacture
Coal kilns (rotary & vertical) L2, L3 D4, (D3) H2, H3 (D5, D6)
Cement kilns (cyclone outlet) L2, L3 D4, (D3) H2, H3
Ceramicringfurnaces L2, L3 H2, H3 D5, (D6)
Petroleum/
Petrochemical
Fired heaters & cracking
furnaces L2, L3 D1, (D2) H2, H3 D5, (D6)
Pulp & paper Black liquor recovery boilers L2, L3 D3, (D4) H2, H3
Other Electrical generating boilers
(window box) L2, L3 D1 H2, H3
Garbage & sludge incinerators L2, L3 D1, D3 H2, H3 D5
Oxygen enrichment equipment L2, L3 H2, H3 D7*1
The meanings of these codes are explained on the pages that follow.
Note 1: Sampling system is required due to the high pressure.
The symbols such as L1 and D1, representing system types or detectors in the table above
and others in this manual, are only applicable in this Technical Information document for quick
reference.Theydonotappearinotherliteraturesincludingthebulletin,generalspecications,or
user’s manual.

  <3.SystemCongurations> 3-2
TI 11M12A01-01EAll Right Reserved Copyright © 2004, Yokogawa Electric Corporation Mar. 14, 2017-00
(2) System Block Diagram Types
Ο:Yes,: None
System
type No. Detector
System type
Remarks
Simple
type General type
—
Manual
Calibration
Automatic
Calibration
L1 General-purpose Ο  using ZO21S standard gas unit
L2 General-purpose Οusing instrument air & zero gas cylinder
L3 General-purpose   Οusing instrument air & zero gas cylinder
H1 High-temperature Ο  using standard gas unit
H2 High-temperature Οusing instrument air & zero gas cylinder
H3 High-temperature   Οusing instrument air & zero gas cylinder
3.2 Selection According to Use
Examples of selection according to use System type No.
For monitoring (package boilers, etc.) L1 / H1
For high precision measurement for control purposes, etc. L2 / H2
For automatic calibration options L3 / H3
(1) Type: L1 (simple measurement system)
EXAZR402G
F0301.ai
~
~
<1> ZR22G Detector <2> ZR402G Converter
Stop valve
Calibration gas
<3> ZO21S Standard gas unit
100 to
240 V AC
Contact input
Analog output, contact output
(Digital output HART)
Signal*1
(6-core shield cable)
Heater (2-core)
*1: Shield cable; Use shielded signal cables, and connect the shield to the FG terminal of the converter.

  <3.SystemCongurations> 3-3
TI 11M12A01-01E Mar. 14, 2017-00All Right Reserved Copyright © 2004, Yokogawa Electric Corporation
(2) Type: L2 (manual calibration)
EXAZR402G
~
<2> ZR402G Converter
Check valve
or Stop valve
<3> ZA8F Flow Setting Unit
<1> ZR22G Detector
100 to
240 V AC
Air Set
Instrument air
Calibration gas
Reference
gas
Flowmeter Needle
valve
Zero gas cylinder*2
Span gas
Check valve
Dust filter
Contact input
Analog output, contact output
(Digital output HART)
Signal*1
(6-core shield cable)
Heater (2-core)
Regulator
No. Check Sketch of shadeName
1
2
3
General-purpose detector (with check valve or stop valve)
Detector with probe protector (same as above)
Detector with filter (same as above)
Note : Detector can be selected from among the following
F0302.ai
See Section 3.3 for details concerning detectors.
(3) Type: L3 (automatic calibration)
F0303.ai
EXAZR402G
~
<1> ZR22G Detector <2> ZR402G Converter
Signal*1
(6-core shield cable)
Heater (2-core)
Reference gas
Calibration gas
Flowmeter Needle
valve
Zero gas cylinder*2
100 to 240 V AC
Check valve
<3> ZR40H Automatic
Calibration Unit
Contact input
Analog output, contact output
Digital output (HART)
lnstrument air
Regulator
Air Set
*1: Shield cable; Use shielded signal cables, and connect the shield to the FG terminal of the converter.
*2: When a zirconia oxygen analyzer is used, 100% N2gas cannot be used as the zero gas. Use approximately 1% of O2gas
(N2-based).

  <3.SystemCongurations> 3-4
TI 11M12A01-01EAll Right Reserved Copyright © 2004, Yokogawa Electric Corporation Mar. 14, 2017-00
(4) Type:H1(simplemeasurementsystem)
EXAZR402G
F0304.ai
~
~
<2> ZR402G Converter
<1> High-temperature detector ZR22G-015
Calibration gas
<3> ZO21S Standard gas unit
100 to
240 V AC
Contact input
Analog output,
contact output
(Digital output HART)
Signal
(6-core shield cable)
Air supply
(0.15MPa)
Note1
Note2
Ejector
Pressure gauge assembly
Heater (2-core)
Needle valve
(5) Type:H2(manualcalibration)
F0305.ai
Check
Vertical downward
mounting
Horizontal
mounting
Mounting
orientation
Maximum
temperature (ºC)
800
1400
SUS310S
—
SUS310S
SiC
Note 2: Selection of high temperature probe material
Check Needle
valve*1
Ejector
ASSY*2
Pressure
kPa
–0.5 or less*3
–0.5 to 0.05
0.05 to 0.5
0.5 to 5
*1: G7011XH/G7013XH
*2: E7046EC/E7046EN
*3: consult with YOKOGAWA
Note: Ejector assembly consists of Needle valve, Pressure gauge assembly and Ejector.
Note 1: Selection of Needle valve or Ejector assembly : Necessary
EXAZR402G
~
<2> ZR402G Converter
<3> ZA8F Flow Setting Unit
100 to
240 V AC
Air Set
Instrument air
Calibration gas
Regulator
Reference
gas
Flowmeter Needle
valve
Zero gas cylinder
Span gas
Contact input
Analog output,
contact output
(Digital output HART)
Signal
(6-core shield cable)
Heater (2-core)
<1> High-temperature detector ZR22G-015
Air supply
(0.15MPa)
Needle valve
Note2
Ejector
Pressure gauge assembly
Note1

  <3.SystemCongurations> 3-5
TI 11M12A01-01E Mar. 14, 2017-00All Right Reserved Copyright © 2004, Yokogawa Electric Corporation
(6) Type:H3(automaticcalibration)
F0306.ai
EXAZR402G
~
<1> High-temperature detector ZR22G-015
Air supply
(0.15MPa)
Needle valve
Ejector
Pressure gauge assembly <2> ZR402G Converter
Signal*1
(6-core shield cable)
Heater (2-core)
Reference gas
Calibration gas
Flowmeter Needle
valve
Zero gas cylinder*2
100 to 240 V AC
Check valve
<3> ZR40H Automatic
Calibration Unit
Contact input
Analog output, contact output
Digital output (HART)
lnstrument air
Regulator
Air Set
*1: Shield cable; Use shielded signal cables, and connect the shield to the FG terminal of the converter.
*2: When a zirconia oxygen analyzer is used, 100% N2gas cannot be used as the zero gas. Use

  <3.SystemCongurations> 3-6
TI 11M12A01-01EAll Right Reserved Copyright © 2004, Yokogawa Electric Corporation Mar. 14, 2017-00
3.3 Examples of System Component Selection
Based on Sample Gas Conditions
(1) Detector and accessories
F0307.ai
2 to 3 m
[D1] [D2]
[D4] [D3]
0.4 to 2 m
ZR22G
Low (0.5 g/Nm3or less)
Dust level
Pressure
Temperature (ºC)
High (10 g/Nm3or less)
Remarks
–5 to +250 kPa (Note 1)
Insertion length
When the detector is mounted horizontally, the ZO21R probe protector is used for enhance forth.
(Note) When the probe length is 2 m or more and sample gas contains high level dust, consult us.
General-purpose detector (Vertical downward mounting)
General-purpose detector ZR22G
General-purpose detector
General-purpose detector ZR22G with probe protector ZO21R-L
(Note 2)
Dust guard protector or Dust filter
(Note 1) When the pressure in the furnace exceeds 3 kPa, it is recommended that you compensate the pressure. When the pressure in the furnace exceeds 5 kPa, you must perform pressure compensation. For 0.15 m probe, 0.5 to 5 kPa. No pressure fluctuation in the furnace should be allowed. (Note 2) When dust guard protector (K9471UA) or dust filter (K9471UC) is mounted to the ZR22G of 2 m probe length, consult us.
0 to 700

  <3.SystemCongurations> 3-7
TI 11M12A01-01E Mar. 14, 2017-00All Right Reserved Copyright © 2004, Yokogawa Electric Corporation
F0308.ai
45°
[D5] [D6] [D7]
Over 700
Up to 1400
High-temperature probe adapter
Ejector for probe adapter (or needle valve)
High-
temperature
detector
Probe
(Note 1) Consult us if pressure is less than –0.5 kPa
Pressure
kPa
Probe
material
Maximum
temperature
(ºC)
Conditions & specifications
Dust level
Mounting orientation
Temperature (ºC)
Ejector for
probe adapter
Valve
Not
required
Required Not
required
Not
required required
Not
required
Valve Valve
Ejector for
probe adapter
Ejector for
probe adapter
–0.5 to +0.05 (Note 1)
+0.05 to +0.5 +0.5 to +5
Low (1 g/Nm2or less. Consult us if higher) Remarks
ZR22G-015 ZO21P-H-
ZR22G-015 ZO21P-H-
Needle valve not supplied
ZR22G-015 ZO21P-H- (E7046EC or E7046EN) The high-temperature probe adapter includes a standard material probe.
SUS310S
800
SUS310S
800
SiC
1400
Inconel 600
Not possible
1000
over
1000
Vertical downwardHorizontal
ZR22G-015 ZO21P-H- E7046EC or E7046EN Projection: 200 mm max.
Not standard, please consult us.

  <3.SystemCongurations> 3-8
TI 11M12A01-01EAll Right Reserved Copyright © 2004, Yokogawa Electric Corporation Mar. 14, 2017-00
(2) Converterandaccessories(owsettingunit,calibrationgas,etc.)
F0309.ai
EXAZR402G EXAZR402G EXAZR402G
~
Converter
Device
Use
ZR402G None
Same as above
GeneralExplosion-proof
For monitoringControl/alarmingControl/alarming
Without
automatic calibration
Without
automatic calibration
With
automatic calibration
Without
automatic calibration
ZR402G ZR402G ZS8C
Calibration gas
Flow setting unit/
Automatic calibration unit Remarks
ZO21S-
-
*A
(standard gas unit)
(air set not included)
Minimum configuration for small boiler monitoring, etc. Most common configuration. Solenoid valve unit for handling unburnt gas in available as an accessory system for petroleum or petrochemical fired heaters. This configuration automates the calibration operation. Sometimes required for petroleum and petrochemical, etc. Be sure to use with explosion-proof terminal box type detector.
ZA8F-
*C
ZA8F-
*C
(air set not included) (air set not included)
ZR40H
Cylinder: G7001ZC Regulator: G7014XF G7013XF Case: E7044KF Cylinder: G7001ZC Regulator: G7014XF G7013XF Case: E7044KF

<4. Applications> 4-1
TI 11M12A01-01E Mar. 14, 2017-00All Right Reserved Copyright © 2004, Yokogawa Electric Corporation
4. Applications
This section takes up typical application examples for the zirconia oxygen analyzer. These
individual applications are structured as follows.
Application examples: Overview of individual devices, and sample points.
Sample gas condition examples: Examples of sample gas conditions, and block diagrams and
type numbers for zirconia oxygen analyzer systems to be used
under those conditions.
4.1 Boiler
(1) Package boiler
This is the most common application. Although the system is generally used for combustion
monitoring, there are also cases in which it will be used for VVVF or other such combustion
control schemes.
Sample point System type Detector Objective
Boiler furnace outlet or
economizer outlet L1, (L2) D1, (D2) Combustion monitoring
Package boiler
Gas temperature: 150 to 300°C
Gas pressure: ±0.5 kPa
Dust: ≦1 g/Nm3
Fuel: Fuel oil, kerosene, or gas
F0401.ai
View Port
Main Tubing
Wall Tubing
Blower
Burner
Burner
Steam Drum
Water Drum
Soot Blower Nozzle
Gas flow
Flame
Combustion
chamber
Side View
Front View
Top View

<4. Applications> 4-2
TI 11M12A01-01EAll Right Reserved Copyright © 2004, Yokogawa Electric Corporation Mar. 14, 2017-00
(2) Powergenerationboiler(Heavyoil,Gas)
This is a large-scale facility in which use for combustion control is more common than for
combustion monitoring.
In cogeneration, the majority of cases involve measurement at a single point. In electric power
companies,measurementsareperformedatmultiplepointsinasingleue.
Sample point System type Detector Objective
Boiler furnace outlet or
economizer outlet L2, L3 D1, (D2) Combustion monitoring
O2control
F0402.ai
Heavy Oil
Gas
Forced Draft Fan
Air Preheater
Electric Precipitator
Fuel Pump
Feedwater
Economizer
Reheater
Water drum
Steam drum
To water drum
Steam To turbine
Power generation boiler
Gas temperature: 250 to 350°C
Gas pressure: –0.1 to –0.8 kPa
Dust: ≦1 g/Nm3
Fuel: Heavy oil (crude), gas

<4. Applications> 4-3
TI 11M12A01-01E Mar. 14, 2017-00All Right Reserved Copyright © 2004, Yokogawa Electric Corporation
(3) Pulverized coal boiler
These are almost always large facilities such as power generation boilers; the zirconia oxygen
analyzer is used for combustion monitoring and combustion control. Since the exhaust gas
entrains a rather large amount of ash dust, a detector with dust protector will be used.
Sample point System type Detector Objective
Economizer outlet
(economizer, feedwater
afterheater)
L2, L3
(detector with probe
protector)
D4 Combustion monitoring
O2control
F0403.ai
Ash
Steam
Boiler Main
Unit
Exhaust
Gas
Drum
Fuel
Superheater
Dust Guard
Horizontal Superheater
Abrasion Due to Dust
Probe Pipe
Probe Protector
Economizer
Air
Heater
Electric
Precipitator
Pulverized coal boiler
Gas temperature: 300 to 400°C
Gas pressure: –1.5 to +1.5 kPa
Dust: Approximately 15 g/Nm3
Fuel: Pulverized coal
Ash Centrifugal Force
High Density Dust
Dust Flow Direction : Optimum mounting position
: Second best mounting position

<4. Applications> 4-4
TI 11M12A01-01EAll Right Reserved Copyright © 2004, Yokogawa Electric Corporation Mar. 14, 2017-00
(4) Black liquor recovery boiler
The spent liquor in a pulp production process is commonly referred to as “black liquor”. The
sodium carbonate and sulfate components in this black liquor are recovered by burning it
and using the heat to generate steam. The oxygen analyzer is used to monitor or control the
combustion in the combustion facility (boiler). Since the exhaust gas includes large amounts of
dust(hydratedsodiumsulfate)andwatervapor,adetectorwithlterisselected.
Sample point System type Detector Objective
Economizer outlet
(economizer, feedwater
preheater)
L2, L3
(detectorwithlter) D3, (D4) Combustion monitoring
F0404.ai
Black liquor recovery boiler
Gas temperature: 170 to 200°C
Gas pressure: +2 kPa
Dust: 6 to 15 g/Nm3
Main dust components: Na2SO4 ≦90%
Na2CO3 ≧10%
Steam
Economizer Water Supply
To EP
AH
Ash
Secondary Air
Primary Air
Primary SH, High-temperature
Primary SH, Low-temperature
Secondary SH
Tertiary SH
Exhaust Gas
Steam
Drum
Auxiliary Heating Burners
2 units at Furnace Front
Secondary Air
Black Liquor Nozzles
Tertiary Air
Primary Air
Starter Burners
(4 units left and right)
Water
Drum