TDLS200 Tunable Diode Laser Analyzer Addendum Instruction Manual Furnaces, Heaters & Large Scale Combustion IM11Y01B01-12E-A 1st Edition
This ADDENDUM to Instruction Manual has been compiled for Owners/Operators of the Model TDLS200 Tunable Diode Laser Analyzer specifically for installations on Furnaces, Heaters and Large Scale Combustion process ©Copyright 2012 by Yokogawa Laser Analysis Division All Rights Reserved Product development is a continuous policy of Yokogawa Laser Analysis Division and therefore specifications may be subject to change without notice.
within this addendum supersede any conflicting statement contained within the standard Users Guide.
1 Combustion Overview 1.1 Introduction In this addendum to the Users Guide for TDLS200, the installation for combustion is detailed. This information pertains to oxygen and CO/CH4 analyzers. Some typical combustion related installations are outlined below: • Ethylene Cracking Furnaces, Refinery Heaters, Reformer Units, VCM Cracking Furnaces, Waste Incineration, Power Generation systems, etc.
In a standard TruePeak TDLS200 analyzer, the laser beam exiting the launch unit is normally collimated parallel before hitting the opposing detect unit. The collimated beam size is typically less than 1” diameter. However, this optical layout is not appropriate for long-path applications (the dimension of process is longer than 23’).
2 Installation 2.1 Process Measurement Point Considerations The following criteria should be considered when selecting the installation point in respect to the process conditions: • Process Gas Flow Conditions – Laminar, homogenous gas concentration distribution conditions across the measurement point are recommended. For circular ducts/stacks this condition is generally at least three unimpaired diameters (D) before and after a process bend.
Window Purge Gas Flow Adjustment – While there is no specific formula for this purge gas flow rate (due to the many variables/complexity), we include the following information that might help optimize the window purge gas flow rates actually at site. As mentioned in the User’s Guide, the window purge flow rate can vary by application from as little as 5 lts./min up to as much as 50 lts./min for typical process applications.
2.2 Position of Process Flanges for Launch and Detect Units: Process flanges should be located on the process such that the Launch and Detect Units can be installed, accessed removed in a safe and convenient manner.
Clearance for Launch Unit: Ensure there is sufficient clearance and access for the Launch unit: IM11Y01B01-12E-A 1st Edition
Clearance for Detect Unit: Ensure there is sufficient clearance and access for the Detect unit: IM11Y01B01-12E-A 1st Edition
Dimensions for combustion process interface devices: Above: 3” 150# ANSI RF (option for Launch unit alignment bellows) Above: 4” 150# ANSI RF (option for Launch unit alignment bellows) Above: 4” 150# ANSI RF Large Aperture Optics (detect side, LAO) IM11Y01B01-12E-A 1st Edition
The standard flange sizes are either 2” 3” or 4” 150# R.F. ANSI as well as DN50 and DN80. Please check the exact flange size specified and provided for the particular installation. Other flange sizes and a variety of materials (to suit the process) are available so please check these details prior to installing the flanges on the process.
Process Flange Welding Alignment and Line-Up The Launch and Detect units are provided with alignment mechanisms that allow for some manual adjustment of the laser beam direction in both planes. It is however recommended that the following angular tolerances be adhered to as closely as possible.
IM11Y01B01-12E-A 1st Edition
IM11Y01B01-12E-A 1st Edition
Details of supporting structural steel for long optical path length systems (>7m/21ft): It is important that the angle support steel (used for supporting the nozzle) be welded directly to both the walls and the adjacent heater/furnace structural steel as shown conceptually below – Note; horizontal/vertical bracing tied to the adjacent structural steel and walls of the unit: Diagram below shows the ‘preferred’ nozzle reinforcement method: NOTE: Ensure you have sufficient clearance behind the flange betw
The above preferred method may not be possible in every site specific situation. The actual dimensions may have to be adjusted to suit the practical installation considerations in each case but it should remain as close as possible to the above ‘preferred’ method.
Case A below shows this preferred method and case B below shows an alternative method if the ‘preferred’ method cannot be accommodated at the particular site installations: Above – Preferred angle mounting above – Alternate angle mounting Below: Image of actual installation as Case A – preferred method IM11Y01B01-12E-A 1st Edition
Mounting the Launch and Detect Units to the Process Flange Securely bolt the Launch and Detect (LAO) Units to the process flanges using the standard bolt holes/studs provided. Ensure the correct size bolts, nuts, and gasket are used in accordance with the flange specifications and in accordance with the process specifications when applicable.
3 Installation 3.1 Adjustment and Optimization of Alignment - <600oC (1100oF) Installations: The following procedure will aide in performing an alignment of the TDLS200 analyzer. The procedure will guide the technician through the necessary steps to align and optimize the signal of the analyzer. Please read the entire procedure before starting work and ask your local Yokogawa service group for further information if required.
IM11Y01B01-12E-A 1st Edition
Above: Zero Transmission/No Signal Above: 0.
• • • Once visual alignment is achieved on both the launch and detect and clean, dry purge gas has been flowing, power may be applied to the analyzer. Begin the alignment process by starting at the launch end; maximize the signal (using the transmission signal and value) by moving the launch around using the alignment bellows.
• • • The launch and detect alignment steps may need to be repeated several times to ensure maximum transmission. Once maximum transmission is achieved, move to the next step and ensure the laser is centered. This is done by “sweeping” the laser across the detector in both the horizontal and vertical axis. To accomplish this, use the nuts on the launch alignment bellows to “sweep” the beam.
IM11Y01B01-12E-A 1st Edition
IM11Y01B01-12E-A 1st Edition
IM11Y01B01-12E-A 1st Edition
3.2 Adjustment and Optimization of Alignment - <1200oC (2200oF) Installations: This section will aide in the alignment of the large aperture optics assembly in a high temperature (i.e. with variable degree of background radiation >800oC) application using an oscilloscope (or scope-meter). Please read the entire procedure before starting work and ask your local Yokogawa service group for further information if required.
IM11Y01B01-12E-A 1st Edition
IM11Y01B01-12E-A 1st Edition
IM11Y01B01-12E-A 1st Edition
• • • • • • Once visual alignment is achieved on both the launch and detect, power may be applied to the analyzer. Begin the alignment process by starting at the launch unit to maximize the signal by moving the launch around using the alignment bellows while watching the scope screen. . Once maximum signal is achieved, (Note that the signal may be very small initially, as low as 0.
IM11Y01B01-12E-A 1st Edition
IM11Y01B01-12E-A 1st Edition
IM11Y01B01-12E-A 1st Edition
Adjustment of Detector Gain after Optimization of Alignment – Please read these directions carefully before attempting work and contact your local Yokogawa service center if there is any doubt about how to perform this procedure. Alternatively, Yokogawa service personnel can perform this procedure – please contact you local service center for details, rates, availability, etc.
• Factory gain resistors on the detector board: R21 = ________; R22 = ________; R23 = ________. PROCEDURE 1. This procedure requires wearing a grounding strap connected to one of the grounding lugs of the analyzer to prevent any electrostatic damage. 2. Open the detector enclosure and put on a grounding strap. 3. Identify the gain resistors R21, R22 and R23 on the detector board as shown in the photo above.
high-process-temperature analyzer (with a capacitor on R3), the raw detector signal is within requirement if MIN is between -4.0 and -8.5. c. If the raw detector signal is too low (other than a and b), change either R22 or R23 to the next greater value available in the resistor bag, and then go back to STEP 7. How to decide which resistor to change: i. If the current R22 value is greater than the current R23 value, change R23 to the next greater value available in the resistor bag. ii.
4 Contact for Further Assistance Should you require any further information or details not contained herein, then please contact your local Yokogawa Office, Yokogawa Distributor or Yokogawa Sales Representative or Yokogawa Laser Analysis Division directly as listed below: Yokogawa Laser Analysis Division 910 Gemini Street Houston, Texas 77058 USA Telephone: Facsimile: SERVICE: 281 488 0409 281 488 4971 1 800 524 7378 (USA toll free) Service: website: TDLS website: support@us.yokogawa.com www.us.
