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TÀI LIỆU HƯỚNG DẪN - Hệ thống lấy mẫu phân tích khí lò quay - System Manual SCK Gas Sampling System (ABB)
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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. 42/2381 EN Revision 4
Edition November 2016
Contents
Chapter 1 General ..................................................................................................................... 7
About these operating instructions ............................................................................ 8
Safety instructions inthis 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 safetyequipment...................................................................................... 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 filtermuffler ..................................... 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 backinto operation,disposal ...................... 223
Shutting down the system ..................................................................................... 224
Disassembling the system ..................................................................................... 227
Storing the system ................................................................................................. 229
Putting the system backinto operation ................................................................. 230
Disposing of the system ........................................................................................ 231
Chapter 12 Appendix .............................................................................................................. 233
Pneumatic/hydraulic interface plan........................................................................ 234
Electrical connection plan ...................................................................................... 236
Transformer connection plan ................................................................................. 238
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. 42/2381 EN Revision 4
Edition November 2016
Contents
Chapter 1 General ..................................................................................................................... 7
About these operating instructions ............................................................................ 8
Safety instructions inthis 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 safetyequipment...................................................................................... 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 filtermuffler ..................................... 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 backinto operation,disposal ...................... 223
Shutting down the system ..................................................................................... 224
Disassembling the system ..................................................................................... 227
Storing the system ................................................................................................. 229
Putting the system backinto operation ................................................................. 230
Disposing of the system ........................................................................................ 231
Chapter 12 Appendix .............................................................................................................. 233
Pneumatic/hydraulic interface plan........................................................................ 234
Electrical connection plan ...................................................................................... 236
Transformer connection plan ................................................................................. 238
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