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Combustion Analyzer to Add Extra Layer of Safety to Burner Management System

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The reliable identification of low combustion oxygen in a red heater or boiler has always been critical to the effectiveness of the Burner Management System for proper control and safety.
Low emission burners and aggressive ring control points to achieve increased efficiency and emission reductions have driven the industry to tighter control measures. But tighter control measures also hold a greater potential for combustion damage. Reducing the risk of a combustion event has become a priority and has led to the implementation of Safety Instrumented Systems (SIS). This additional layer of safety is added to the Basic Process Control System.

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Combustion Analyzer to Add Extra Layer of Safety to Burner Management System

  1. 1. A New Standard of Excellence
  2. 2. PREVENTION IS SO EASY... LIVING THROUGH A DISASTER IS NOT The reliable identification of low combustion oxygen in a fired heater or boiler has always been critical to the effectiveness of the Burner Management System for proper control and safety. Low emission burners and aggressive firing control points to achieve increased efficiency and emission reductions have driven the industry to tighter control measures. But tighter control measures also hold a greater potential for combustion damage. Reducing the risk of a combustion event has become a priority and has led to the implementation of Safety Instrumented Systems (SIS). This additional layer of safety is added to the Basic Process Control System. The WDG-V has been designed to provide an additional layer of safety with the measurement of excess O2 , Combustibles and Methane. These measurements are used to ensure the safe operation of the Burner Management System. The WDG-V Combustion Analyzer is designed to provide the complete solution for combustion process control and process control safety applications. The WDG-V Combustion Analyzer has built-in redundancy and diagnostics to monitor performance and health as well as provide the statistical data needed to implement predictive and proactive maintenance programs. In control and safety applications, it is critical that the analyzer is always operational. Precise control of low O2 setpoints with confidence CO detection for control interlocks and safety shutdown Predictive diagnostics SIL 2 capable for SIS implementation of IEC 61508/61511 into the burner management system
  3. 3. WDG-V COMBUSTION ANALYZER SENSOR RANGES: O2 0-1% to 0-100% COMBUSTIBLES 0-1000ppm with overrange 0-2000ppm to 0-5% HYDROCARBONS 0-1% to 0-5% RESPONSE: O2 90% < 11sec with Flame Arrestors ANALOG OUTPUT: (3) 4-20 mA ALARM OUTPUT: (5) Dry Contact PROCESS CONNECTION: 2”, 3” or 4” Flange AMBIENT TEMPERATURE: -25°C to 65°C DIGITAL INTERFACE: MODBUS RTU, Configuration Software ENCLOSURE: Class I, Div II, Gp B, C, D / ATEX Zone 2, T3, IP65 POWER REQUIREMENT: 115 VAC, ±10%, 47-63 Hz, 740 VA 230 VAC, ±10%, 47-63 Hz DIMENSIONS (LxWxD): 44.45 x 31.75 x 19.8 cm (17.5” x 12.5” x 7.8”) WEIGHT: 20 kg (44 lbs.) AMEVISION HMI COMMUNICATION: 2 Wire MODBUS DISPLAY: 4.2” Color 1/4W VGA with GUI KEYPAD: Alpha Numeric Membrane ENCLOSURE: Div 2, Zone 2, IP65 (NEMA 4X) POWER REQUIREMENT: 115 VAC or 230 VAC OUTPUTS: 2 or 4 Wire MODBUS RTU- Configurable, Ethernet-RJ45 connection with Web Server DIMENSIONS (LxWxD): 22.9 x 22.9 x 13.3 cm (9” x 9” x 5.25”) WDG-V COMBUSTION ANALYZER SYSTEM REMOTE CALIBRATION UNIT (RCU) GAS CAPABLE: Aspirator Air (Span) Optional Span O2 Zero O2 Combustible Span Hydrocarbon Span ENCLOSURE: IP65, NEMA 4X Class I, Div 2; ATEX Zone 2 POWER REQUIREMENT: None (Supplied from Analyzer) CONSTRUCTION: 316SS, Hard Piped DIMENSIONS (LxWxD): 26 x 31.2 x 13.3 cm (10.25” x 12.28” x 5.25”)
  4. 4. # COMPONENT SENSOR ENHANCEMENTS 1 Enclosure The Sensor enclosure size and weight has been reduced by over 30% and features a hinged door IP65 enclosure as standard. Lightweight, high “R” value blanket insulation inside the enclosure insures sensor temperature stability throughout wide ambient temperature cycles. 2 Sensor Heater Block High output single cartridge heater with improved thermal transfer radiant block maintains internal sensor and enclosure temperature to 235°C with only a 30% duty cycle leaving added capacity for extreme temperature environments. 3 Aspirator Block New Aspirator block design with increased orifice sizes reduce chances of particulate interference. Instrument Air or Nitrogen drive gas consumption is reduced by over 20% while directing more process convective flow to the sensors. Analyzer response time with sensor flame arresters is improved to levels of analyzers without flame arresters installed. 4 Combustible Sensor Combustible and Hydrocarbon detectors are installed in a thermally controlled flow block of substantial mass, independent of enclosure temperature, insuring precise temperature stability of detectors, reducing the effects of thermal drift. 5 Flame Arrestors Flame arrestors are incorporated into the convection flow loop so that they may be inspected or replaced in minutes. An upstream arrestor “cartridge” installed in the combustible flow sensor block can be inspected or replaced in minutes without disassembly of sensor piping. 6 Flow Sensor A flow sensor is incorporated into the sensor piping to detect and alarm when sensor flow is reduced or stopped to insure the sample transport integrity to the measurement sensors from inlet probe tip to exhaust port. 7 Zirconia Cell Furnace New cell furnace design reduces the size and susceptibility to vibration and environmental effects. Redundant thermocouples for cell temperature measurement improves reliability of the measurement. The re-orientation of the cell furnace parallel to the combustible sensor block efficiently utilizes cell furnace heat for maintaining combustible detector temperature stability. 8 Sensor Terminal Enclosure Modular snap in terminal strips with laser etched labels simplify wire connections. Recessed electronics and bottom conduit connections eliminate problems due to conduit stress, moisture egress, and improve the reliability and integrity of the sensor connection in high radiant heat areas.
  5. 5. • Sample Flow Verification • Calibration History • Cell & Detector Trending • ‘End of Life’ Prediction of Zirconium Oxide cell & combustible detector with Warning • Stability Indicator during the Calibration Process • Analog Output Verification • Individual Controls of Analog Outputs, Relays • Time Stamped Alarm/ Event Log • Trend Data Logging & Access by USB Port • Redundant Cell, Enclosure & Electronics Temperature Monitoring Enables the convenience of site calibration and communication with the analyzer • MODBUS RS485 • TCP/IP Ethernet • USB Port • 4.2” colorVGA display AME VISION Display Unit Interface DIAGNOSTICS & AMEVISION HMI
  6. 6. © 2013, by AMETEK, Inc. All rights reserved. Printed in the U.S.A. F-0409 Rev. 3 (1013) 150 Freeport Road, Pittsburgh, PA 15238 Ph. +1-412-828-9040, Fax +1-412-826-0399 www.ametekpi.com CONFIGURATION 2: STAND ALONE SENSOR WITH AMEVISION HMI CONFIGURATION 1: SENSOR - STAND ALONE, BPCS OR LOGIC SOLVER COMMUNICATION CONFIGURATION 3: MULTI-SENSOR with AMEVISION HMI

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