KilnLoq probe and Extraction device - Webshop, Gas Analysis ...

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Unit Operation InstructionKilnLoq probe & EXD8.3 FUNCTION DESCRIPTION EXTRACTION DEVICE8.3.1 AUTOMATIC INSERTION AND EXTRACTION OF KILNLOQ PROBEExtraction and insertion of probe is controlled by the GMU. Pneumatic cylinders M4.1 andM4.2 perform the mechanical stroke. The probe is inserted when the system is started andthere is no unit alarm. The probe is extracted if a unit alarm occurs. Furthermore the probeis extracted once every 6 th cleaning (default setting) of probe to remove any materials builtup on probe.There are three position switches 1B6 (position IN) and 1B8/1B9 (position OUT). They areused to indicate end positions of the cylinders.8.3.2 MANUAL INSERTION AND EXTRACTION OF KILNLOQ PROBEWhen the system is in test mode and the Extraction Device is switched to manual operation,see “System manual”, it is possible to move the probe in and out by means of the two pushbuttons located at the back end of the EXD. When the push buttons are active the indicationlamps inside will light up. If a Unit alarm is active it is still possible to insert the KilnLoqprobe with the “IN” button but when the button is released the probe moves automaticallyout. This gives the opportunity to move the probe during Unit alarm but it does not allowthe probe to be left in the kiln with out cooling water.8.3.3 POSITION STOP SYSTEMWith the position stop system it is possible to adjust the insertion length of the KilnLoqprobe. The purpose with the system is to keep the insertion as short as possible in order toincrease life time and performance of the sample end. The system consists ofThe adjustable lid mounted on the sample endA Movable boogie stop with two shock absorbers on I-profil. (4 steps of 0,3m)Sensor bar with step less adjustable sensor plate.Inductive sensor on filter housing.8.3.4 FUNCTIONWhen the probe moves in, the wheel boogie hits the shock absorbers and thus the boogiestop, when the decided insertion is achieved. The shock absorbers take down the velocity ofthe KilnLoq probe thus it hits the stop in a smooth way. When probe is in place the inductivesensor senses the sensor plate on sensor bar. The inductive sensor gives the position signalto the PLC. The adjustable lid seals to inner flange on EXD and thereby seals to process gas.The adjustable lid is fixed on the sample end.8.3.5 ADJUSTMENT8.3.5.1 To find the optimal insertion, the kiln must be running in a stable and“well known” condition. The extraction device must be switched to manualmode thus it is possible to move the probe in and out by mean of the pushbuttons on the extraction device. The gas sample pump must be runningthus the actual oxygen value from the kiln can be recorded on theanalyzer. To adjust the insertion:Start the KilnLoq system, see “System manual”Set system to test mode, see “System manual”Set extraction device to manual operation, see “System manual”. The push buttons on theextraction device lights up.Wait until the oxygen reading is stableUse the push buttons on the extraction device to move the probe out, in small steps at 10cm.Page 17 of 27
Unit Operation InstructionKilnLoq probe & EXDMonitor the oxygen level at each step.Determine at which step the oxygen value suddenly increases dramatically. Make a mark.Move the probe out to the end position.Use the push buttons on the extraction device to move the probe in, in small steps at 10cm.Monitor the oxygen level at each step.Determine at which step the oxygen value suddenly decreases dramatically. Make a mark.Move the probe to the mark nearest the kiln and then move the probe further 40cm into thekiln and make a mark. (Optimal insertion point archived!System is now ready to be adjusted!Stop system and prepare probe as described in section 8.6Remove side covers on the extraction device.Move the Moveable boogie stop with shock absorbers to nearest position against wheelboogie.Move boogie to contact boogie stop. (Shock absorbers compressed)Fine tune probe position by moving probe in probe clamp.Adjust sensor plate to activate position sensor 1B6.Move the adjustable lid against the entrance flange and fix it.Put on side covers.Set system to analysis mode, see “System manual”.The probe is now approximately 40cm inside the edge where it takes false air from thesealing and entrance hole. Due to changes in the process and wear of the kiln sealing theposition must be fine adjusted from time to time.Caution:Since this test has to be done with the system running and the side covers removed it is forsafety reasons recommended to be two persons present.8.3.6 EXTRACTION OF PROBE DURING POWER FAILUREIf a power failure occurs the solenoid valve Y4.1 will open and compressed air forces thesolenoid valve Y4.1 to extraction position and the probe will be extracted from process.8.3.7 FLANGE CLEANING SYSTEMSee layout drawing “KILNLOQ: P&I Diagram”In order to keep the kiln entrance clean from raw materials the Extraction Device isequipped with a special cleaning system. The system consists of ball valve, air filter, shut offsolenoid and cleaning nozzles located on the entrance flange. Due to safety reasons thesolenoid only opens for cleaning air when the KilnLoq probe is automatically operated by theGas Monitoring Unit. The cleaning air enters the entrance pipe with high speed andtransports dust and smaller pieces of build-up back into the process. This Allows the KilnLoqprobe to operate smooth in and out through the entrance pipe.8.3.8 EXTRACTION DEVICE ACCESSORIESThe EXD is supplied with following accessories to easy and safe maintenance.8.3.8.1 Cleaning Lance & Safety blow off for quick connectorThe Extraction device is supplied with a Cleaning Lance. The cleaning lance are located inlover right sidepiece of EXD It is accessed by removing lower back shields. The purpose ofthe cleaning lance is to ensure optimal use of the unique KilnLoq one pipe concept. Thecleaning lance comprise of a 8mm stainless steel pipe, valve and connections. The cleaninglance is to be used in conjunction with the “Safety blow off for quick connector”.8.3.8.2 Safety blow off for quick connectorIn back end of Extraction device is a “Safety Blow Off for quick connector” (BO) located.Page 18 of 27
Page 1: KilnLoq probe andExtraction deviceK
Page 4 and 5: Unit Operation InstructionKilnLoq p
Page 28 and 29: Document List:Unit ManualRevision L
Page 30 and 31: 5" Inner diametere.g. Pipe 141,3x6,
Page 32 and 33: Horizontal installation10030738 x
Page 34: 1004636Illustration:8 x Ø13 for 12
Page 40 and 41: Part listSample probe 2547Part ID P
Page 42 and 43: Part listSample probe 3797Part ID P
Page 44 and 45: Part listExtraction device 2000Part
Page 50 and 51: Part listRecommended spare parts 37

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