engineering tips for sampling systems [piramoon & buhler technologies], by pouriya niknam

Engineering tips in sampling systemswith

&

Pouriya Niknam , Dec 2016 Piramoonco.com

Table of content

• NOx converter• gas pump• Gas coolers• Filters

Performance Safety

Lifetime cost

installation maintenance

NOx converter

NOx converter

type Temp eff Max NO2 Content

Carbon Based

200C 95% 150ppm

Same PriceMetal Based

400C 97% 300ppm

•Maintenance calculator NOxCal for service life monitoring

NOX Converter

NOx converter types

No ATEX NOx converter, Purge the Cabinet to keep it ex-free400C-->450C: trick for temporarily reactivate the NOx, 3week…

NO2--- NO+O2Less Side effects:

◦ No O2 added to sample◦ No SO2 reduction◦ No CO Production◦ No Pressure Drop (140mbar)

Sample pumps

Basics: Pump head

300

-150- 90

60NL/H

Long distance from tapping point -- decrease flow rate

Pump bellows

-0.1 BAR

0 BAR

+0.2 BAR

+0.1 BAR

defective bellow

SUCTION FROM AMBIENT

For bellow Test

Decrease inlet flow

Increase outlet flow

Decrease va

cuum level

(increase absolute

underpressure manometer)

Pump

Compressor Cooler

Analyzer

Dual Stage Comp. Cooler

pump

Analyzer

Pump/Dual Stage Comp.

Cooler Analyzer

Low efficiency

Air suctio

nWrong data (O

2

measurement)

Dual stage:

over design…

High efficiency

Condense resistance

Auto drain possible

More possible flow

Some discussion about Components Order…

Condensate

suctio

n

?

PUMP INTERNAL BYPASS IN CASE OF BLOCKAGE AND CALIBRATION STATE

Not for m

ining

Zone 1 (outside pum

p)

Equipm

ent protection(Gas )

atmosphere

Zone 1 (inside pum

p)

Constructively Safe

Just for surrounding

Temperature R

ange (also cover T1/T

2)

Special

Pump Tips & Notes:These items will reduce lifetime: Operation with non atmospheric pressure Operation under high temperature condition

item sample pressure

Buhler Nox Converter <1.5 bar absolute

GMS800 –200 hPa ... 1,000 hPa

Siemens ultramat23 (BA5000) 0.5 to 1.5 bar absolute

Siemens OXYMAT 64 (High P) 2 000 hPa (abs.)(Low P) 30 hPa more than atmospheric

BA3 100 to 200 mbar (gauge)

BA 3500 Pressure 10 - 200 mbar

BA 6000-O2 0.5 to 1.5 bar absolute

Pump Tips & Notes: No ATEX version for 800L/hr pump New product with ATEX cert. as 700L/hr, but

◦ No option for head material◦ T3 only

Temperature will be limit by the bottleneck ATEX will be expired after 5 years (from production date and not

operation)◦ They can be used in non hazardous area for another 10 years

period.◦ Or sending to Buhler for complete service.

Membrane like KNF are using Glue (Acid, Solvent,…) Buhler specific Sample pump without any glue

◦ (Honeywell Changed from KNF to Buhler )

Pump Tips & Notes:The sample gas pump is suitable for gases only, not for liquids.The sample gas pump should be operated without pressure. A system pressure above 0.3bar is not allowed. The gas outlet must not be closed. The flow rate must be at least 50 l/h (150 l/h with system pressure

0.3 bar). If the flow rate continuously is throttled below 150 l/h during

operation, the flow rate must be controlled with a bypass valve.Extreme throttling reduces the life time of the bellow.If the pump is equipped with a bypass valve, the flow rate can be

adjustedrated current of the circuit breaker switch 230 V = 0.48 A, 115 V = 0.84 A, 24 V DC = 0.8 A

Peltier gas coolers (PKE) compact /one gas path Per Heat exchanger/cheaper than compressor coolers

standard application: volume flow of 150 l/h at 1 bar@ 70°C , inlet dew point of 40°C.

Compressor coolers (EGK)working principle as refrigerator/ more cooling power than peltier coolers.

Cooler selection

•  energy to cool the gas about doubles with a rise of dew point of 10°C• double pressure = double energy to cool •  the factory setting of the gas outlet temperature and dew point

of approximately 5°C

Exchanger material•Steel >the best choice•aggressive components > glass then•Only in certain applications PVDF

We suggest to limit the load on the heat exchanger to a range of 60..80%.

•For M&C glass type is cheaper than SS.•For Buhler SS is cheaper with better performance for non-corrosive cased

Cooler tipsBuhler double stream exchangers EGK 1/2, PKE 42 or EGK 2 Ex saves money and time for mounting

Cross-sensitivity is very low:Vari0ating one path in the whole energy range of the exchanger will variate the other path in a maximum of 0,5K! In case of same gas energies variations of the one streams outlet dewpoint by switching on and off the other stays below 0,2K

Self-Cleaning Sample Gas Filter

Compact size: approx. 250 x 220 x 200 mm Peltier cooler with 1 heat exchanger Adjustable dew point 3/5/10/15 °C Adjustable Delta T Control Analogue signal output Power supply 24 V DC Power max. 70 W

Save money, space,

time

Dual P. Pump