O Learning Handbook - Yokogawa
O2 Learning HandbookZirconia Crystal ClearTI 11M00A20-01E
Table of Contents1. Introduction.42. Theory.42.1 Why Measure O2?.52.2 Oxygen Measurement Principle and Theory.62.3 Humidity Measurement Principle and Theory.82.4 Units of Measure.82.4.1 Absolute Humidity.82.4.2 Relative Humidity.82.4.3 Dew Point.92.4.4 Mixing Ratio.92.4.5 Other Units.92.4.6 Accuracy of the Humidity Analyzer.92.5 Comparison and Advantage over Competitive O2 Principles.92.5.1 Paramagnetic.92.5.2 Electrochemical.102.5.3 Optical: Tunable Diode Laser Spectroscopy.103. Yokogawa Products and Features.123.1 Zirconia Oxygen Detector, Model ZR22.123.2 Construction and Features of a Zirconia Cell.123.3 Zirconia Oxygen Pressure Compensation, Model ZR22G-P.123.4 Zirconia Oxygen High Temperature Adapter.133.5 Calibration Equipment.143.6 Filters and Accessories.163.7 Probe Protectors and Probe Supports.173.8 Zirconia Oxygen Single Unit Analyzer, Model ZR402G.183.9 Zirconia Oxygen Multi Unit Averaging Analyzer, Model AV550G.183.10 Integral Type Zirconia Oxygen Detector and Analyzer, Model ZR202.193.11 Zirconia Oxygen Low Concentration Analyzer, Model OX400.193.12 Limiting Current Type Oxygen Analyzer.203.12.1 Model OX100.203.12.2 Model OX102.204. Application Notes.234.1 Boiler.264.1.1 Package boiler.264.1.2 Power generation boiler (Heavy oil, Gas).274.1.3 Pulverized coal boiler.284.1.4 Black liquor recovery boiler.294.2 Iron and Steel Furnaces.304.2.1 Iron & steel heating furnace.304.2.2 Hot blast stove (blast furnace facility).314.2.3 Coke oven facility.324.2.4 Soaking pit.334.3 Ceramic, Brick, Glass & Cement Furnaces/ Kilns).344.3.1 Rotary type lime kiln.344.3.2 Cement kiln (cyclone outlet gas).354.4 Petroleum Refining and Petrochemical Fired Heaters.364.4.1 Naphtha cracking furnace.374.4.2 Petroleum refinery process fired heater example.384.5 Garbage Incinerator.394.6 Non-Combustion Applications.404.6.1 Oxygen enrichment facility.404.6.2 Power generation boiler wind box.414.6.3 Aeration tank.424.7 Difficult Measurement Applications.434.7.1 Glass melting furnace (in-furnace gas).434.7.2 Calcination furnace.444.7.3 Facilities with reducing gas atmospheres.445. Installation Guide.445.1 What is in an Installation Loop.445.2 Zirconia Probe Installation.445.2.1 Location.445.2.2 Probe Insertion Hole.445.2.3 Installation of the Detector.455.3 Installation of Accessories and Parts.452www.yokogawa.com/us
5.3.1 Filters.455.3.2 Check Valve (Option Code “/CV”.465.3.3 Probe Protector.465.3.4 Calibration Units.475.4 Installation of the High Temp Tee (ZO21P/ZR22P).475.4.1 Probe Insertion Hole.475.4.2 Probe Adapter.475.5 Installation of the Analyzer (ZR402G/AV550G).485.6 Installation of the Integral Zirconia Oxygen Analyzer (ZR202*).485.7 Installation of the OX400.485.8 Installation of the OX100/ OX102.495.8.1 Installation of the Sensor.495.8.2 Installation of the Sampling Unit (K9424GA).496. Selection Guide.496.1 Oxygen analyzer selection flow chart.496.2 System configuration.526.2.1 ZR402G/ZR22 Direct In Situ Zirconia Oxygen.526.2.2 Selection According to Use.536.2.3 Examples of System Component Selection Based on Sample Gas Conditions.576.3 Compatibility between old and existing models.607. Basic Steps for Maintenance and Trouble Shooting.607.1 Maintenance for ZR22 and ZR202.607.1.1 Cleaning the Calibration Gas Tube.607.1.2 Replacing the Sensor Assembly.607.1.3 Replacing the Heater Assembly.607.1.4 Replacement of Dust Filter.607.1.5 Replacement of the Fly Ash Filter.617.1.6 Replacement of O-ring.617.2 Calibration.617.2.1 Best Practices for Calibration.627.2.2 Calibration of the Humidity Analyzer.627.3 Trouble Shooting.627.3.1 Error and Alarm.627.3.2 Basic Zirconia Probe Check.637.3.3 Testing O2 Cell.647.3.4 My detector is reading a high O2 level.647.3.5 My detector is reading a low O2 leve.657.3.6 Other Abnormal Values.657.3.7 Experiencing Erratic Reading.657.3.8 Probe Temperature low and not warming up.657.3.9 Probe Temperature Too High.667.3.10 High Impedance Reading (Zirconia cell & contact resistance & lead resistance).667.3.11 Short Sensor Life.667.3.12 Short Heater Life.667.3.13 Automatic Calibration Panel, Model AC8.668. Zirconia Analyzer – Question & Answers.678.1 Application.678.2 Installation.698.3 Maintenance.698.4 Accessories.738.5 Models.739. Lock Out Specifications.739.1 Oxygen Analyzer System Specification for a Single Channel Analyzer and Detector Requirements.739.2 Oxygen Analyzer System Specification for an Integrated type Oxygen Analyzer and Detector Requirements.759.3 Oxygen Analyzer System Specification for Multi-Channel Averaging Oxygen Analyzer and Detector Requirements.7610. Customer Application Data Sheet.79www.yokogawa.com/us3
1. Introductionthe moisture content; a type of humidity measurementthat is more commonly referred to as AbsoluteHumidity. It is important to note that moisture contentin anything other than air, i.e. combustion exhaust gas,cannot be measured.Successful industrial product sales requires strongtechnical and application knowledge of the equipmentinvolved as well as a comprehensive understating ofthe market ‘s competitive elements, such as features,benefits and pricing. This handbook has been designedas an ongoing sales tool, which will be updatedand amended on a regular basis to help keep the salesforce abreast of new market developments basedon process/application improvement as well as newproduct developments.However, no matter the desired measurement somecommon difficulties that you will face are: A variety of established competitors Conservative end-users who are reluctant to switchfrom one supplier to another A growing number of government regulationsOxygen concentration measurements are used in avariety of applications including, energy conservation,pollution reduction and process quality control andaccomplished using several different measurementprincipals. Even Governmental regulations to controlCO2 and NOx emissions, affect even small municipal,private and commercial utility boilers and furnaces asthey must be controlled or at least tested on a regularbasis. However, Zirconia-based Oxygen Analyzers aremost commonly used for combustion control, burneroptimization and to increase the efficiency of boilersand industrial heaters to achieve fuel conservation.Major end-users are found in the following industrialfields: 2. TheoryPlant boilers are closed vessels in which water underpressure is transformed into steam by the applicationof heat. In the boiler furnace, the chemical energy inthe fuel is converted into heat, and it is the function ofthe boiler to transfer this heat to the water it containsin the most efficient manner possible. Most often theboiler is designed to generate high quality steam foruse throughout the plant. The fuel that is used forheating the boiler may either be: Gaseous such asnatural gas, cokes-oven gas/ blast furnace gas; Liquid,such as heavy/light fuel oil, jet oil, liquefied petroleumgas, gasoline, nafta or chemical waste; or Solid such aswood/bark, coal, brown coal, or peat.Electrical Power GenerationChemical and PetrochemicalIron and Steel ManufacturingPetroleum RefineryPulp & PaperTextilesPerfect combustion occurs when the correct amountsof fuel and oxygen are combined so that both aretotally consumed, with no combustibles or uncombinedoxygen remaining in the resulting flue gas. Under idealconditions, combustion-reaction obeys the followingstoichiometric reaction equation:There are still countries where extractive oxygenanalyzer systems are in use for combustion control(paramagnetic, TDLS, thermo-magnetic, polarographic,electrochemical, fuel-cell). These offer an excellentsales opportunity since the advantages and benefits ofzirconia analyzers over extractive methods are easilydemonstrated. The following are some of the benefitsand features of the Yokogawa ZirconiaOxygen Analyzers:CxHy aC bCO (x ¼y a ½b) O2 (a b x) CO2 ½yH2O ΔHeatHowever, fuel may contain impurities and additives toimprove viscosity, therefore ideal combustion can onlybe achieved if all of the following requirements are metsimultaneously: Consistent fuel composition at all times Pure oxygen in used instead of simple plant air Complete molecular mixing of oxygen and fuel, at thesame temperature and pressure Unlimited reaction time and zone Constant in-outlet conditions (pressure, temperature,flow, composition) are maintained Consistent boiler/furnace load Compact design for flexible low-cost installation Long-life sensor Reduced maintenance and calibration usingself-diagnostics Excellent price/ performance correlationYokogawa’s Zirconia Oxygen analyzer can also be usedto measure humidity in specific applications. This is abenefit because most humidity analyzers are normallydesigned for ambient temperatures and not suitablefor the high temperatures that we find in bakeryovens, Pizza ovens, Paper driers or Plywood driers.The zirconia high temperature analyzer is designed tomeasure oxygen concentrations in the air and calculateIn practice, none of the above requirements arecompletely achieved due to the physical restrictionsin burner design, use of (economical) ambient airrather than expensive pure oxygen, and aging of boilerequipment.4www.yokogawa.com/us
When there is insufficient air for combustioncontrol, the fuel is not completely consumed andgives off smoke. This is a sign of energy loss andundesirable emissions. If left unchecked the buildupof combustibles will lead to a safety hazard. On theother hand, if excess air for combustion is supplied, theunused air is overheated and emitted from the stack,causing a heat loss. This increases the emissions ofNOx and SO2, which cause air pollution. In order toachieve complete combustion there must be a balanceor air-fuel ratio where the boiler is operating as close tozero “excess air” as possible.Figure 2.2 Efficiency Graph“Air-fuel ratio” or “Excess air” refers to the amountof air theoretically required to achieve completecombustion of the fuel supplied to the furnace of theboiler. The “air-fuel ratio” or “excess air” is used toachieve the highest efficiency for a system based oneach different fuel source. “Excess air” can be obtainedby measuring the oxygen concentration in the exhaustgas and calculated by:Figure 2.1 Example of Environmentn (1 / (21-Oxygen concentration)) x 212.1 Why Measure O2?Data is available that shows the various fuel sourcesand an indication of their typical value for excess air;shown in the table below are just a few of the commonfuel sources:Either the measurement of oxygen or carbon monoxidecan be used to determine the level of excess air.However, measuring CO alone will not define whichtype of an environment, fuel rich or air rich, a burneris operating in. Therefore combustion control needs tobe based on accurate and dependable Oxygen analysis.To ensure complete combustion chamber are suppliedwith excess air to increase the amount of oxygenand the probability of combustion of all fuel. Thecombustion efficient will increase with increased excessair, until the heat loss in the excess air is larger thanthe heat provided by more efficient combustion.FuelExcess of Air (%)Coke oven gas5-10Natural Gas5-10Coal, pulverized15-20Coal, stoker20-30Oil (No. 2 and No. 6)10-20Under actual operating conditions some amountof excess air is always necessary to bring thecombustibles level close to zero. The challenge isto minimize these effects by achieving completedcombustion with the lowest excess air levels possible. Itis important to accurately measure and control oxygenanalysis because: Insufficient air is a waste of fuel which is a waste ofmoney. As a rule of thumb each 10% excess O2 isequivalent to a 1% in wasted fuel.www.yokogawa.com/us5
basic measurement principles andthe advantages/disadvantages forparamagnetic, electrochemical andoptical measurement types.There are two different types ofZirconia measurement systems; theamperometric which is used inYokogawa products such as the OX100and OX102, and the most common typeis what is known as potentiometric.This type is used in Yokogawa productssuch as the ZR series and the OX400.Figure 2.5 shows a schematic ofthe amperometric system. Anampero
and features of the Yokogawa Zirconia Oxygen Analyzers: Compact design for flexible low-cost installation Long-life sensor Reduced maintenance and calibration using self-diagnostics Excellent price/ performance correlation Yokogawa’s Zirconia Oxygen analyzer can also be use
HART Communication Foundation Yokogawa Contact Information For customer Assistance Address Yokogawa Corporation of America 2 Dart Road Newnan, GA. 30265USA Telephone 1-800-888-6400 E-mail meters-instr@us.yokogawa.com . YHC5150X Series HART Communicator Overview
YOKOGAWA Yokogawa Corporation of America 2 Dart Road Newnan, GA 30265 To: Classis Controls From: Todd Garber, Yokogawa Corporation of America Date: December I, 2003 Subject: Classic Control’ s Yokogawa Territory Coverage This memo is to serve as verifica
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YPC 4010 HART Communicator / Calibrator - Base calibrator unit with HART capability (includes HART leads, and 250 ohm resistor) - see available sensor modules on next page ; use VMA0055 for 24Vdc loop supply Code Reserved -01 Yokogawa
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The food and beverage industry must produce safe, high-quality foods and beverages for consumers. In addition to quality control, the manufacturing processes include many challenges such as managing ingredients, improving efficiency, and han-dling global environmental issues. As a trusted partner, Yokogawa offers our expertise derived from .
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