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Installation and commissioning
Installation of the FLK probe
A number of points must be observed to permit low-maintenance operation of the gas sampling equipment:
- Preferably installation at the side on the kiln intake chamber opposite the raw meal intake
- The probe must not pass through the material flow of the heat exchanger (danger of mechanical damage and baking of material on probe jacket)
- Take into account the possibility of falling material
- To avoid the sucking-in of incorrect air, the sampling point should be located approx. 30 cm behind the kiln seal
- The lateral distance from the kiln lining should not be less than 20 cm
- Depending on the design of the retraction unit, sufficient space must be provided behind the probe’s mounting location
In case of doubt, please consult an expert.
Installation of the heat exchanger
The heat exchanger should be installed close to the probe, and at the same level if possible. The coolant lines should be kept as short as possible to avoid falsification of the coolant temperature in the probe. Excessive heat radiation on the coolant lines can lead to overheating of the probe in the extreme case since the coolant temperature is measured in the heat exchanger. If the heat exchanger has to be installed further away from the probe for space reasons, the coolant lines must be insulated against heat loss.
Strictly observe the information in the manual when connecting the coolant lines.
The heat exchanger has a thermal output of up to 65 kW. Sufficient ventilation for dissipation of the heat must be provided. During operation, the surfaces of the heat exchanger can reach a temperature of up to 250 °C. To protect against touching by mistake, customers must provide a protective grid around the heat exchanger.
Installation of the retraction unit
A space of approx. 6 000 mm is required behind the probe's mounting location for installation of the retraction unit. If the required space is not available, the retraction unit can be shortened depending on the probe length. For a probe with an immersion depth of 2 500 mm, the minimum length of the retraction unit is approx. 4 700 mm.
The dust filter and valve manifold supplied separately must be fitted to the side of the retraction unit during the mounting.
Installation of the control cabinet
The control cabinet should preferably be installed in a dust-proof room, usually the analyzer room.
Routing of sample gas line
Particularly with non-heated sample gas lines, a continuous downward gradient must be provided from the sampling point to the analyzer cabinet in order to avoid water pockets. Any resulting condensation must be able to flow off before the analyzer cabinet.
A heated sample gas line is absolutely essential when measuring SO2 or if there is a danger of freezing.
In order to achieve T90 times which are as low as possible, the nominal diameter of the sample gas line should be selected as small as possible.
|
Flow |
for 1 m gas line upstream of gas analyzer |
|
|---|---|---|
|
Nominal diameter 4 mm |
Nominal diameter 6 mm |
|
|
0.5 l/min |
1.6 s |
4.3 s |
|
1.0 l/min |
0.8 s |
2.1 s |
|
1.5 l/min |
0.6 s |
1.5 s |
|
2.0 l/min |
0.4 s |
1.1 s |
Delayed display depending on flow rate
Compressed air connection
A compressed air connection with a pressure of 6 000 to 8 000 hPa is required to purge the probe and for operation of the pneumatic motor. The compressed air must be free of oil, water and dust. Moisture in the compressed air results in premature blockage of the pores in the dust filter and increased maintenance effort.
Oil in the compressed air can result in caking of the filter pores which can no longer be removed, necessitating replacement of the sintered metal filter.
Electrical connections
The electrical connections must be made according to the directives of the local power supply company and the directives of the respective country.
A period of approx. 5 days should be calculated for mounting. Mounting is usually carried out by the customer.
Commissioning
Starting up of the complete equipment should always be carried out by trained Siemens personnel. Prior to startup, the installation must be checked for observation of the directives according to the manuals.
Starting up should be carried out with the kiln in operation in order to carry out the required settings and optimization.
A period of approx. 3 to 5 days should be calculated for starting up.
Mode of operation