SICK SHC501 Gravimat Operating instructions

OPERATING INSTRUCTIONS

Description

Installation

Operation

Title

GRAVIMAT SHC501

Gravimetric Dust Concentration

Measuring System

2 GRAVIMAT SHC501 · Operating Instructions · 8007743 V1.0 · © SICK AG

Document Information

Described Product

Product name: GRAVIMAT SHC501

Document ID

Title: Operating Instructions GRAVIMAT SHC501

Part No.: 8007743

Version: 1.1

Release: 2014-01

Manufacturer

SICK AG

Erwin-Sick-Str. 1 · 79183 Waldkirch · Germany

Phone: +49 7641 469-0

Fax: +49 7641 469-1149

E-mail: info.pa@sick.de

Place of Manufacture

SICK Engineering GmbH

Bergener Ring 27 · 01458 Ottendorf-Okrilla · Germany

Trademarks

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Other product names used in this document may also be trade-

marks and are only used for identification purposes.

Original Documents

The English edition 8007743 of this document is an original docu-

ment of SICK AG.

SICK AG assumes no liability for the correctness of an unauthor-

ized translation.

Please contact the manufacturer or your local representative in

case of doubt.

Legal information

Subject to change without notice.

3

Contents

Introduction .................................................................................. 7

1 Safety instructions ............................................................. 101

1.1 Important safety notes ................................................................................... 101

1.2 Use in accordance with instructions, conditions of use .......... 1 02

1.2.1 Use ................................................................................................................. 1 02

1.2.2 Instructions for system safeguard ............................................. 1 02

1.3 Authorized users................................................................................................. 10 3

1.4 Safety precautions, protective measures ........................................... 1 03

1.4.1 Danger from items of electrical equipment ..................... 10 3

1.4.2 Preventative measures for safe operation.......................... 1 03

1.4.3 Detecting malfunctions.................................................................... 1 0 4

1.4.4 Avoiding consequential damage in the event of

equipment malfunction..................................................................... 104

1.5 Environmental information and instructions for disposal ............ 104

2 Device Description ............................................................ 201

2.1 Range of application......................................................................................... 2 0 1

2.2 Measuring principle ........................................................................................... 20 2

2.3 Technical measuring regulations (conformity) ............................... 2 0 3

2.4 System components......................................................................................... 2 04

2.4.1 Overview.................................................................................................... 2 0 4

2.4.2 GS 5 Filter head probe ................................................................... 20 5

2.4.2.1 Probe head ...........................................................................................2 0 6

2.4.2.2 Probe shaft ........................................................................................... 2 0 7

2.4.2.3 Multichannel hose ............................................................................ 20 7

2.4.3 Probe mount........................................................................................... 2 0 8

2.4.4 Dust collectors ...................................................................................... 2 0 9

2.4.4.1 LC dust collectors.......................................................................... 20 9

2.4.4.2 HC dust collectors ........................................................................ 21 0

2.4.4.3 Soot collector ................................................................................... 2 11

2.4.5 SHC-AE501 Evaluation unit......................................................... 2 1 2

2.4.5.1 Electronic unit .................................................................................... 2 13

2.4.5.2 Condensate separator .................................................................. 2 14

2.4.5.3 Extraction pump............................................................................... 2 1 4

2.4.6 GRAVIMAT SHC 501 basic functions ................................. 2 1 5

2.4.7 Accessories and optional extras ................................................ 2 16

3 Preparing for measurement ............................................ 301

3.1 Choosing a measuring site ............................................................................ 30 1

3.2 On-site preparation .......................................................................................... 30 1

4

Contents

3.3 Preparation of dust collectors ...................................................................... 302

3.3.1 General .........................................................................................................302

3.3.2 Fitting with filter material ................................................................... 302

3.3.2.1 LC dust collectors ..............................................................................302

3.3.2.2 HC collectors ........................................................................................ 304

3.3.3 Determining the empty mass of the prepared dust

collectors ..................................................................................................... 305

3.4 Transportation...................................................................................................... 3 0 6

3.5 Installing the measuring system.................................................................3 0 7

3.5.1 Installing the GS 5 filter head probe ...................................... 3 0 7

3.5.2 Inserting the dust collectors ......................................................... 3 0 7

3.5.3 Installing and connecting the evaluation unit .................... 3 0 8

3.5.4 Adaptation to the available supply voltage ....................... 3 09

3.6 Function test before measuring starts ................................................. 3 1 0

4 Measuring............................................................................. 401

4.1 General ...................................................................................................................... 40 1

4.2 Description of menu........................................................................................ 4 0 2

4.2.1 Menu "parameters" ............................................................................. 40 2

4.2.2 "Automatic" menu ............................................................................. 4 0 4

4.2.3 "Special functions" menu ............................................................... 4 0 5

4.3 Extraction measurement ............................................................................... 4 0 6

4.4 Manual operation................................................................................................ 4 0 8

5 Evaluating measurements ................................................ 501

5.1 Determining the gross weight of the dust collector ................. 5 01

5.2.1 Drying ........................................................................................................... 5 0 1

5.2.2 Weighing ..................................................................................................... 5 0 1

5.2 Calculating the dust concentration ........................................................ 5 02

6 Maintenance ........................................................................ 601

6.1 Maintenance of the GS 5 filter head probe.................................... 6 0 1

6.1.1 Regular maintenance ..........................................................................6 0 1

6.1.2 Leak check ................................................................................................. 6 0 2

6.2 Maintenance of the evaluation unit........................................................ 60 4

6.3 Calibration of the evaluation unit ........................................................... 6 0 5

6.3.1 Zero point setting ............................................................................... 6 06

6.3.2 Aperture constants ............................................................................. 60 6

6.3.3 Setting time and date for protocol ........................................ 60 6

7 Troubleshooting ................................................................. 701

7.1 No measurement possible ..........................................................................7 0 1

7.2 Troubleshooting table ....................................................................................7 0 1

5

Contents

8 Technical Data ..................................................................... 801

8.1 Overview of technical data ......................................................................... 80 1

8.2 GRAVIMAT SHC 500 standard design ............................................. 8 0 3

8.3 Accessories, optional extras ....................................................................... 8 0 3

8.4 Consumable parts .............................................................................................. 8 04

8.5 Spare parts .............................................................................................................. 80 4

8.6 Scale diagrams ........................................................................................................ 8 0 6

8.6.1 Filter head probe ............................................................................................ 8 0 6

8.6.2 AE-SHC501 Evaluation unit .................................................................... 8 0 6

9 Appendix .............................................................................. 901

9.1 Overview of formulae .................................................................................... 90 1

9.2 Physical composition........................................................................................ 9 03

6

Contents

7

Introduction

Notes on these instructions

These Operating Instructions contain basic information on safety,

system features, planning, installation, commissioning and regular

servicing of the device components. Short descriptions on the

measuring procedures as well as the function of the complete system

and its important parts are provided. They act as a support for the

level of knowledge that is requir-ed for accurate installation and

servicing of the measuring device. The comparison of characteristic

features in the system varieties available should be facilitated during

the planning phase, when deciding on the opti-mum configuration to

suit the given conditions.

The content of the Operating Instructions does not constitute a part

of any legal relationship. All obligations of SICK AG arise from the

purchase contract concerned, which also contains the complete and

solely applicable warranty provisions.

These Operating Instructions contain only the information required

for a standard application and associated installation and relate to the

technical data explained in the Appendix. For special applications, the

SICK subsidiary will provide you with the necessary support. It is

advisable to seek recommendation from SICK specialists in every case

of application.

SICK AG

Waldkirch

Germany

101

1 Safety instructions

The following symbols in these Operating Instructions are used to

denote important safety information for the user. It is essential that

these safety instructions, in particular the warnings, are noted and

obeyed accordingly.

Danger

indicates possible dangers to people, especially from items of electri-

cal equipment.

Danger

indicates possible hazards to people if system components are

handled incorrectly.

Warning

indicates risk to system components or possible impairment of

functions.

Note

contains important additional information for the user on the system

or system components and gives further advice.

1.1 Important safety notes

102

1 Safety instructions

1.2 Use in accordance with instructions, conditions of use

1.2.1 Use

It is assumed that installation planning, mounting, installation, com-

missioning, servicing and maintenance work will be carried out by

adequately trained staff, and that this work will be checked by

responsible qualified people. Operation of the measuring system should

only be in the manner intended by the manufacturer.

The responsible qualified staff must specifically ensure that:



All system components are used only for their intended purpose,



The application corresponds to the technical data and the details

on possible use, installation, connection, environmental and

operating conditions (to be obtained from the order documents,

the device summary data, type plates and documents supplied),



The general mounting and safety instructions are observed,



Work is carried out in accordance with the site and installation

specific factors, also taking into account hazards and rules due to

operational factors,



Tools, lifting and conveying equipment are correctly used,



System components with no protective system as supplied are

fitted with protective devices by the operator



There is sufficient safety equipment and personal protective

clothing and that this is properly utilized by staff

1.2.2 Instructions for system safeguard

The GRAVIMAT SHC 501 is a sophisticated electronic measuring

system which requires careful handling in all operations, transportation

and storage:

 The gas path and extraction pump must be dried after each

measurement is completed!



Never store the unit unprotected in the open!



Transport and store only in original packaging

 Store in a dry place

 Never leave cable ends or plugs unprotected. Always insulate cable

ends. When not in use, cable plugs must always be protected against

moisture and dirt with protective covers or suitable packaging

material. Corroded connectors lead to faults during operation!

103

1 Safety instructions

It is essential that those responsible for safety ensure that:



Installation design, assembly, installation, commissioning, servicing

and maintenance work are carried out only by trained and qualified

employees or qualified people and that this is checked by responsible

qualified staff.

Qualified employees are people conforming to DIN VDE 0105,

IEC364 or directly comparable standards. Qualified people have

been authorized to undertake this work by those responsible for

personal and equipment safety on the basis of their education and

training, experience or instruction, and their knowledge of the rele-

vant standards, instructions, accident prevention regulations and site

conditions. The important factor is that such people should be able

to recognize and avoid potential hazards promptly.

Knowledge of First Aid and of local rescue equipment is required and

assumed.



These people have accurate knowledge of operational hazards, for

example, risks due to toxic or pressurized gases, liquid gas

compounds or other media.



For work on power stations, unqualified persons must not be

employed (governed by DIN VDE 0105 or IEC 364).



Work on or at close proximity to hazardous system components

by unqualified people is forbidden.

1.3 Authorized users

1.4 Safety precautions, protective measures

1.4.1 Danger from items of electrical equipment

The GRAVIMAT SHC 501 is designed for use in industrial power

stations. During installation, commissioning, operation and mainten-

ance, it is possible for;



Open components or parts that are not insulated to be live at

dangerously high voltages,



Physical or material damage to be caused by unauthorized removal

of the necessary coverings, incorrect operation or insufficient

servicing of system components.

1.4.2 Preventative measures for safe operation

The operator must ensure that any malfunctions, shut down of the

Gravimat SHC 501 or faulty measurements do not lead to operating

conditions that are dangerous or that can cause unacceptable damage.

In order to prevent device malfunction, it is necessary that the pre-

scribed servicing and inspection is carried out regularly by qualified

and experienced staff.

104

1 Safety instructions

1.4.3 Detecting malfunctions

Variations from standard operations are indications of functional

restrictions and must be taken seriously. These include, among other

things:



Response of the monitoring devices,



Excessive drifting of the measuring results,



Increased power consumption,



Higher temperatures in system parts,



Unusually excessive vibrations,



Unusual operating noises,



Unusual odours or smoke.

1.4.4 Avoiding consequential damage in the event of

equipment malfunction

In order to avoid personal injury or physical damage caused directly or

indirectly through malfunction or breakdown of the GRAVIMAT SHC

501, the operator must ensure that:



The responsible servicing personnel are trained to recognise and

react correctly to faults in the device and any associated operat-

ional malfunctions,



Any necessary or accidental switching off of the GRAVIMAT SHC

501 does not lead to indirect consequential damage.

1.5 Environmental information and instructions for disposal

The GRAVIMAT SHC 501 modules are easily disassembled and they

contain no toxic or environmentally hazardous materials, with the

exception of a few elements of the printed circuit boards. The

principle components are steel, stainless steel, synthetics, aluminium

and wood, consequently posing no difficulties for future disposal.

A few electronic components contain slight traces of toxic materials.

Electronic scrap such as printed-circuit boards must therefore be

disposed of as problem waste.

201

2 Device Description

2.1 Range of application

The GRAVIMAT SHC 501 is a mobile measuring system for gravi-

metric determination of the dust content in ducted gas flows.

Dust-laden gas is extracted isokinetically (at the same speed of flow)

by means of the GS 5 filter head probe (internal filter probe). The

dust is retained by a dust collector with a plane filter and is

subsequently weighed.

Fig. 2101 GRAVIMAT SHC 501

Gravimetric measurements for determining dust concentrations are

required for:

 Checking dust emissions and keeping within the limit values accord-

ing to BImSchG (German emissions legislation)

 Functional checks of dedusting systems

 Acceptance testing for warranty certification of dust separators

 Assessing emission behaviour (e.g. for procedural changes, increase

of capacity)

 Checking process parameters

 The calibration of continually operating dust measuring equipment.

202

2 Device Description

2.2 Measuring principle

Based on fundamental gravimatrical processes, the dust content is

determined by:

time-limited extraction of partial gas quantity

measurement of the extracted partial gas quantity

separation and subsequent weighing of the dust contained therein.

In order to avoid measuring faults the partial volume flow must be

isokinetically extracted i.e. at the same velocity as the main volume

flow. This prevents apparent demixing and provides an exact and

representative dust quantity at the measuring site.

The velocity of the main volume flow is measured for isokinetic

extraction. The extracted partial volume flow is regulated in such a

way that the speed of entry into the dust collector's extraction orifice

corresponds to that of the main volume flow.

All dust particles in the partial volume flow are retained by the filter

in the dust collector. After extraction the filter is weighed together

with the extracted dust.

The basic requirements for ensuring accurate measurements, as well as

for very small measuring ranges of dust concentration, are:

constructive configuration of the extraction and dust retainment

system



correct preparation and after-care for the measuring filter



the resolution of the precision balance used.

For measuring the smallest dust contents with the GRAVIMAT SHC

501, an optimized retaining system (LC dust collector, see section

2.4.4) is used, which is weighed along with the extraction tube, filter

and collected dust. Uncontrollable dust losses or measuring errors

caused by unrecorded dust contamination in the extraction tube can

thus be completely prevented.

Due to the chosen method, as well as the low weight of the LC dust

collector, even the smallest of dust concentrations are accurately and

reliably detected with the GRAVIMAT SHC 501.

With a single point measurement the dust concentration in a dust-

laden gas stream is determined in g (dust) / m³ (gas) at the respective

measuring site.

Network measurements are required in order to obtain the

representative mean value concentrations of the main volume flow

across duct cross-sections. For this purpose the duct cross-section is

separated into several axes with various measuring points along these

axis. The mean value is determined by dust sampling across all these

network points (see VDI 2066 Sheet 1).

Isokinetic extraction

Dust collection

Single point measurement

Network measurement

203

2 Device Description

A basic requirement for accurate sampling with several dust collectors

are identical extraction times and extraction orifices at all network

points.

In the same it is possible to divide a network measurement in

individual measurements, completely independent of one another.

Information on dividing up the duct cross-section and arranging the

measuring points are contained in VDI 2066 Sheet 1.

2.3 Technical measuring regulations (conformity)

The most important regulations for measuring stationary particulate

emissions are contained in the following guidelines:

VDI 2066 Sheet 1 (Basics)

VDI 2066 Sheet 2 (4/12 m

3

/h - filter head unit)

VDI 2066 Sheet 3 (40 m

3

/h - filter head unit)

VDI 2066 Sheet 5 (grain size determination by impactor)

VDI 2066 Sheet 7 (1 m

3

/h- plane filter head unit)

ISO 9096 (corresponds to international standard)

CENprEN 264 (designed to European standard)

VDI 2066 Sheet 8 (soot spot measurement)

For the calibration of automatic emission measuring equipment (e.g.

dust measuring devices), additional regulations can be found in VDI

3950, Sheet 1.

Information on measurement planning, the selection of representative

measuring points in a measuring network, installation location and

evaluation methods are contained in VDI 2066, Sheet 1.

204

2 Device Description

Fig. 2401 GRAVIMAT SHC 501 system overview

The GS 5 filter head probe with integral dust collector is inserted into

the duct. The dust collector collects the extracted particles. The

probe head contains measuring orifices on the side of the dust

collector for measuring the gas velocity v, partial volume flow Q and

the sensor for measuring the gas temperature T in the duct.

The filter head probe is connected to the evaluation unit via a

multichannel hose with a safety lock connector.

2.4 System components

2.4.1 Overview

The GRAVIMAT SHC 501 (see Fig. 2401) consists of the following

components in the basic version:

 GS 5 Filter head probe

 Special case with dust collector set

l LC dust collectors for low dust contents

l HC dust collectors for high dust contents

 SHC-AE501 Evaluation unit

 Optional mounting parts (installation supports, probe mount).

GS 5 Filter head probe

Dust collector

Probe mount

Multichannel hose

Installation

support

Optional

(for evaluation)

Optional

SHC-AE501

Evaluation unit

see section 8.1

205

2 Device Description

The evaluation unit controls the isokinetic extraction and registers the

measured values. The necessary functional units (see section 2.4.4) are

housed in a robust flightcase.

Device functions are controlled using operation and evaluation

software contained in the evaluation unit.

Either a PC (laptop) or a serial printer for logging the measured

results can be connected to the RS 232-interface on the evaluation

unit.

2.4.2GS 5 Filter head probe

The filter head probe consists of the following components:

 Probe head with integrated extractor for the dust collector, with

pressure sensors for determining the gas velocity in the duct and

the partial volume flow, and with a Pt 100 temperature sensor for

accurate measurement of the exhaust gas temperature at the

extraction orifice.

 Stainless steel probe shaft

 Multichannel hose with extraction lline, pressure sensing lines for

conducting pressure signals to the pressure sensors in the

evaluation unit and integrated temperature sensing line.

Fig. 2402 Filter head probe with extension

The main construction of the GS 5 filter head probe is shown in Fig.

2403.

206

2 Device Description

1 2 45 67 8 9

P

4

P

5

P

2

10

1 Dust collector

2 Ring plug screw

3 Support plate

4 Filter housing

5 Measuring orifice

6 Extraction line

7 Pressure sensing line

8 Probe shaft

9 Multichannel hose

10 Temperature sensor

11 Temp. sensing line

12 Purge air duct

P

1

P

3

Fig. 2403 GS 5 Filter head probe

2.4.2.1 Probe head

The assembled dust collector (1) is inserted into the filter housing

(4). A ring plug screw (2) presses the collector at its outer edge

evenly onto a sealing washer via a filter diaphragm and a seam. The

filter diaphragm lies against a support plate (3), which prevents the

pressurized filter diaphragm from being destroyed. The support plate

with sealing washer can be used with gas temperatures up to 250 °C.

For higher gas temperatures (up to 400 °C or 600 °C with the HT

version) a support plate should be used without a sealing washer (see

Chapter 8). When using the support plate without a sealing washer,

an additional error up to a maximum of 3% should be expected in

the measurement of the partial volume flow.

A measuring orifice (5) with pressure sensing orifices p

4

and p

5

is

located behind the support plate, for measuring the pressure drop

across this orifice as a basis for determining partial volume flow.

Apart from the task of dust collecting, the probe head also has the

function of a dynamic pressure sensor. Pressure sensing orifices (p

1

, p

2

,

and p

3

) are arranged on the cylindrical outer surface of the filter

housing for determining the gas flow velocity in the duct, as well as

the angle of flow in the probe.

During installation of the dust collector, the extraction port is aligned

parallel to the total pressure port (p

1

). (Notch on the outer edge of

filter housing).

3

11

See section 2.4.3 for description

of dust collector

See section 3.3.2 for assembly

See Fig. 2407

6

12 11

12

207

2 Device Description

A Pt 100 temperature sensor (10) is provided for measuring the gas

temperature.

The probe head with extraction line (6) and the five pressure sensing

lines (7) is fixed to the probe sleeve (8). Lines (6 and 7) and the

temperature sensing line (11) run to the probe sleeve through a

multichannel hose (9).

The filter head probe and its sensors supply all measuring signals

required for checking and monitoring isokinetic extraction and for

extracted partial volume acquisition.

2.4.2.2 Probe shaft

The stainless steel probe sleeve (8) is 1 m in length as standard. Probe

extensions can be screwed on if longer penetration depths are required.

For ease of handling a grip is mounted at the end of the probe sleeve. A

support spring prevents the multichannel hose from kinking. A marking

on the grip piece indicates the position of the extraction port in the

duct (align correctly when assembling the probe!)

2.4.2.3 Multichannel hose

The multichannel hose conducts the partial volume flow and the

pressure and temperature sensing signals from the filter head probe to

the automatic control unit.

Connection to the automatic control unit takes place by means of a

safety lock, which guarantees the correct alignment of the respective

pressure sensing signals to the corresponding pressure sensors in the

automatic control unit. The standard length of the multi-channel hose

is 5m. An optional hose extension can also be connected. When

higher gas temperatures are involved (see section 8.1), two free

channels in the multichannel hose are supplied with cooling air. The

cooling air penetrates the probe shaft.

Fig. 2404 Multichannel hose with safety lock and plug for temperature sensor

See Chapter 8

See section 3.5

See Chapter 8 for data on cooling

air

208

2 Device Description

1

2

2.4.3 Probe mount

A probe mount and corresponding installation tube with the

appropriate dummy plug should be provided for the filter head probe

in the flue gas duct.

The cast-aluminium mount provides safe, smooth conduction and

fixing for the filter head probe. The protective sleeve on the mount

prevents damage to the collector during installation and handling of

the probe. The bayonet-type screw fitting on the probe mount allows

quick connection to the appropriate installation tube.

Suitable adapter fittings can be manufactured for existing on-site

installation tubes.

1 Installation tube (R89x4)

2 Probe mount with protective sleeve

3 Filter head probe with LC dust collector

3

Fig. 2405 Mount for filter head probe before measurement

Fig. 2406 Filter head probe in measuring position

Duct

Direction of flow

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SICK SHC501 Gravimat Operating instructions

SICK SHC501 Gravimat Operating instructions

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