Cross-duct sensors CD 6 and cables for non-Ex applications

The standard cross-duct sensor consists of a transmitter unit and a detector unit with the same dimensions. The transmitter unit provides a connector for the fiber-optic cable. The laser light is transmitted through this cable. The receiver unit contains a photodetector and an electronics PCB, and is connected to the detector unit by a sensor cable.

The sensors are mounted onto flanges. The easiest way to avoid condensation and dust deposits on the sensor windows is to use a purging gas, e.g. with instrument air. Purging must be selected depending on the application. The cross-duct sensors can therefore be configured for the respective situation. The application reference table provides recommendations for suitable purging with standard applications.

If a component is to be measured which is also present in measurable quantities in the purging medium - such as oxygen or moisture - it is necessary to use purging gases such as nitrogen, superheated process steam or similar. In such cases it is usually also necessary to purge the sensor heads, since the ambient air must also be displaced here out of the laser beam path. A differentiation is therefore made between purging on the process side and purging on the sensor side.

Note: For measurement of O₂ at gas temperatures above 600 °C, it may also be possible to tolerate air as the purging medium since its influence on the measurement can be compensated.

Applications with oxygen (high-pressure)

For oxygen measurements with a higher process gas pressure (1 to 5 bar), the sensor CD 6 can be used together with a high-pressure window flange as the process connection. This window flange is also available in the standard sizes DN 65/PN 6, DN 80/PN 16 or ANSI 4"/150 lbs. The optical surface to the process is made of borosilicate glass. High-pressure window flanges can be equipped with window purging, but without purging tubes. Possible purge modes for the window flanges are "A-C" (no purging or moderate purging on the process side). Window flanges are tested for leakage before delivery using overpressure, and show leakage rates of less than 10^-5 mbar·l/s.

For ordering this application, the MLFB code of the central unit with the application code letter "P" must be selected. The process interface suitable for the sensors can be chosen by selection of the corresponding code in the 6th configurable position of the MLFB number.

The most important sensor purging configurations are presented below:

Purging on the process side with moderate flow

Is selected e.g. for pure gas applications, emission monitoring, inerting monitoring. The purging gas flow can be adjusted between 0 and approx. 120 l/min at each sensor head using a needle valve (included in delivery).

Moderate purging on the process side

Purging on the process side with increased flow

Through omission of needle valve. This type of purging is selected in crude gas applications with higher concentrations of particles and/or condensation as well as in non-purified flue gases in combustion plants. The purging gas flow is typically set between 200 and 500 l/min on each sensor head depending on the input pressure of the purging medium.

Increased purging on the process side

Purging on the process side with high flow

Through use of air blower or dry process steam. Connectors with hose adapters are included in the delivery. An additional Swagelok adapter must be ordered if a high flow of steam or instrument air purging is required (option A27). This type of purging is selected in crude gas applications with very high concentrations of particles and/or condensation such as in the furnaces of combustion plants. If instrument air is not available, an air blower is also an alternative for purging in applications with lower demands. On the process side, dry steam can be used as the inert purging gas instead of nitrogen (Tmax. 240 °C). The purging gas flow is automatically set between 500 and <1 000 l/min on each sensor head depending on the purging air blower or the steam pressure.

Increased purging on the process side, with hose connection adapter

Purging on sensor side

Can be combined with any purging mode on the process side, and is always selected if the ambient air must never have an influence on the measurement. The volumes within the sensor head are then continuously purged with an O₂-free gas (with H₂O-free gas in the case of moisture measurement).

Note

With purging on the process side, it may be necessary to use non-return valves to ensure no process gas can enter the purging gas line in the event of failure of the purging gas supply. This applies especially in the case of cascaded process and sensor purging where there is otherwise the danger that, for example, corrosive process gases could enter the sensor enclosure.

Sensor configuration with high purging on the process side, with 6 mm joint for use with steam, and with N₂ purging on the sensor side

The purging media used on the process side flow through purging gas tubes into the process gas flow. The tubes extend a few centimeters into the process area, and usually receive a flow of process gas from the side. This results in a wedge being generated in the inlet zone of the purging gas. The effective measuring path in the process gas is therefore well-defined as the distance between the ends of the two purging gas inlet tubes.

Cross-duct sensor CD 6: Options and accessories

Sensor alignment kit

Includes a battery-operated visible light source, a centering aid with crosshair, and two hook spanners for opening the optics tube of the sensors.

Please note: the sensor alignment kit is not explosion protected.

Installation requirements for the cross-duct sensors CD 6, dimensions in mm

Purging air blower

Two purging air blowers are required to purge the sensor heads. Both 230 V AC and 115 V AC versions can be ordered.

Sensor configuration with purging air blower

Flow cell (available on special application)

For implementation of measuring configurations with bypass mode. The cell consists of a stainless steel tube whose internal surfaces are coated with PTFE to minimize surface effects. With an effective measuring path of 1 m, the inner volume is only 1.2 l, and fast gas displacement times can therefore be achieved. The flow of sample gas can be from the ends or from the center of the tube, since appropriate 6 mm joints are present here. The flow cell can be ordered in four configurations:

• Unheated, including assembly for wall mounting
• Unheated, including assembly for wall mounting and a 19" housing with an air jet pump with a delivery rate of max. 30 l/min
• As above, but can be heated up to approx. 200 °C
• As above, but can be heated up to approx 200 °C and mounted on a rack with wheels and integrated 19" frame

Optical bandpass filter (only for O₂-CD 6)

Serves to protect the light-sensitive detector in the receiver unit of the sensor from saturation by IR background radiation. Used with measurements in very hot process gases (T > 1 000 °C) or with unavoidable appearances of flames in the measurement path.