INSTRUMENTATION MANUAL IFFCO AONLA 09 TOPIC: ANALYTICAL INSTRUMENTS UKS ANALYTICAL INSTRUMENTS 1. Introduction to Analytical Parameters :The development and use of process analyzer for on stream applications has been a contributing factor to the growth of the chemical, petrochemical and refining industries in recent years. With proper design, installation and use, process analyzers have proven to be invaluable by providing better quality products and solutions to many process problems. The transition from laboratory use to process analysis and control, however, has not been without difficulty. Early model analyzers were merely adaptations of laboratory models , unsuitable for many of their assigned tasks and often poorly engineered from their conception. While today’s process analyzers perform capably and have been accepted by operating and management personnel, an improperly engineered installation can still lead to wastage of money, mistrust among operators and a maintenance headache. Analyzer installations require a great amount of study and appraisal if they are to be properly engineered. Some analyzer applications are straightforward and require practically no research in order to determine what type analyzer should be used and under what conditions they will operate. Mostly an investigative program must be undertaken to determine the best analyzer system to be used as per process conditions, state of the sample including it’s flow, temperature, pressure, viscosity, stream composition and steam contamination such as solids, oils, and water. This estimate, with savings data furnished by the process-engineering group, is used to determine the economic feasibility. Many analyzers today are justified on the basis of safety or pollution monitoring rather than economics. Basically the analyzers can be grouped as per the state of the sample into two i.e. Gas Analyzer & Liquid Analyzer. Before going deep into the different analyzer systems we must have some brief idea on the basic sampling system of the analyzers. Page 1 of 46 INSTRUMENTATION MANUAL IFFCO AONLA 09 TOPIC: ANALYTICAL INSTRUMENTS UKS Sample system: - The design of the sample system for an analyzer is equally as important as the application of the analyzer itself. The sample system may vary in complexity from a simple shutoff valve and single tubing connection to a complicated system consisting of solenoid valves, filters, vaporizers, regulators and other items. Basic principles of the sampling are as follows: 1. Extraction of a representation sample from the stream. 2. Cleaning the sample. 3. Minimizing the time lag in getting the sample to the analyzer. 4. Meeting the pressure, temperature and sample flow rate requirements of the analyzer as well as the vaporizing a liquid sample or removing water drops. 5. Disposition of the sample in a safe area. The application of these basic principles is discussed in the following paragraphs. Sample location The sample point must be in an active stream to assure that it provides the information required by the analysis. Sample points on process lines should always be installed on the top or side of the pipe, never on the bottom. This prevents the flow of condensed liquids in vapor streams from entering the sample valve and also eliminates the entrance of fine solids, which may be swept along the pipe. The side tap is preferred on liquid streams to minimize the chances of getting entrained vapors. The probe shown in below is commonly used to extract a sample from the center of the stream; thereby avoiding condensed liquids in a vapor stream and solids in a liquid stream. A clean stream is important to successful low maintenance operation of most analyzers. Page 2 of 46 INSTRUMENTATION MANUAL IFFCO AONLA 09 TOPIC: ANALYTICAL INSTRUMENTS UKS Filters It should be assumes that all sample streams contain solid contaminates such as rust particles, polymers, etc; therefore, minimum requirements call for a fine mesh wire filter. Extremely fine solids sometimes require the use of a porous metallic or ceramic filter. The gaskets and diaphragms of all pressure regulators, flow controllers, filters, etc., should be examined to determine that they will not deteriorate or absorb components from the stream. The filter might be considered as one of the most critical components in the sample conditioning system simply because so many other functions are performed after the stream has been cleaned. Some vapor samples contain so much entrained solids that filtration is not practical until the vapor is scrubbed either by bubbler devices or by small spray scrubbers. Sampling Time Lags Sampling time lags delay the analysis and may reduce the usefulness of the measurement. The analyzer needs to be located close to the sample point, but that is not always feasible. A bypass loop such as that shown in the figure below is often Sample Flowmeter Analyzer Bypass Rotameter used to reduce time lags in long sample runs where the analyzer will handle only a small flow rate. This system can be used on liquids or gases whenever there is a point of lower pressure for sample return or when the sample can be vented or run to a sewer. Installing it in raceway or thin-wall pipe should protect transport tubing. The tube should be sloped downward toward the analyzer to drain liquids, and no Page 3 of 46 INSTRUMENTATION MANUAL IFFCO AONLA 09 TOPIC: ANALYTICAL INSTRUMENTS UKS pockets should be left in the line without a condensate trap. Tube size is determined by flow conditions. Flow volume should be as low as possible and velocity should be as high as is practical to minimize lag time. Sample Conditioning An effort should be made to match the sample requirements of the analyzer to that of the stream, there by minimizing extra system components such as vaporizers, regulators, sample coolers, etc. If a liquid sample pressure is to be reduced , care should be taken that flashing does not occur. However, it is not always possible to match the analyzer to the process condition, and the sample must necessarily be conditioned to meet the analyzer requirements. The sample parameters like temperature, pressure, flow and etc. are very important when the sample is processing in to the analyzer . Temperature Many manufacturers make small heat exchangers to cool the sample. Cooling water may be allowed to flow unregulated through the exchanger, leaving the sample temperature uncontrolled. Some Analyzers are temperature sensitive, however, and the measurement can be improved by controlling the sample temperature. In some cases, close temperature control is essential to the separation and measurement of components. Pressure Pressure is also a common mismatch. Regulators are used to reduce high pressure and to regulate varying low pressure. To prevent maintenance problems and increase performance, the regulator should be preceded by a fine mesh strainer. Materials should be noncorrosive. Single stage regulation is usually sufficient for sample pressure reduction. On vapor systems the regulator is usually located at the sample point to keep a high sample velocity with a low flow rate. When the sample pressure increases then there may require a relief valve or rupture disc for overpressure protection. Page 4 of 46 INSTRUMENTATION MANUAL IFFCO AONLA 09 TOPIC: ANALYTICAL INSTRUMENTS UKS Flow Many analyzer are sensitive to velocity changes, and the sample flow rate must be monitored / controlled. Where sample conditions are constant, a simple rotameter suffices. When sample conditions are not constant, a rotameter ( constant differential regulator combination ) should be used. The instrument manufacturer recommends the flow rates of each instrument. Sample Disposal This is the last and most critical stage of the sampling system. Sample disposal sometimes presents significant problems. Safety has always been a consideration since many samples are either toxic or flammable or both. In some applications the sample may simply be dumped or vented to the atmosphere. In others, where venting becomes dangerous, other solutions are required. Liquids When disposing analyzed samples of water or other inexpensive, nonpolluting, nonhazardous liquids, the most common method is to run it to the sewer and then to the effluent plant. This method may also be used on hazardous or polluting samples if an appropriate chemical sewer is located nearby. If sample is expensive or cannot be conveniently run to the sewer, it is commonly returned to the process system at a point where the pressure is lower than the sample pressure and as steady as possible. Vapors Vapor samples present slightly different problems. Non-hazardous gases are normally vented to the atmosphere while hazardous gases are often vented to a flare header or returned to the system, whichever is more convenient. Gases, which cannot be vented to a flare header or returned to the system, may be scrubbed of the corrosive or toxic components and then vented to the atmosphere or flare header. Vent flow can be very critical to the successful performance of an analyzer. Page 5 of 46 INSTRUMENTATION MANUAL IFFCO AONLA 09 TOPIC: ANALYTICAL INSTRUMENTS UKS 2. Type of Analyzers in Fertilizer Industries In the Fertilizer field the most commonly used Analyzer can be grouped as below. This will mostly cover all type of Analyzers are used in a Chemical Plant like us. Type of Analyzers 2.1 Gas Analyzer 2.1A Process Gas 2.2 Liquid Analyzer 2.1B Flue Gas 2.1Ai S.G.Analyzer 2.2A BFW / Cooling Water/ Steam / Effluent pH 2.1Aii Gas mol % Analyzer 2.2B BFW / Steam Conductivity Analyzer 2.2C DM Water Silica Analyzer 2.2D Ammonia Analyzer 2.2E Dissolved O2 Analyzer 2.1Bi O2 Analyzer 2.1Bi a Paramagnetic Type 2.1Bii SOX Analyzer 2.1Biii NOX Analyzer 2.1Bi b Zirconium Type Page 6 of 46 INSTRUMENTATION MANUAL IFFCO AONLA 09 TOPIC: ANALYTICAL INSTRUMENTS UKS 2.1Ai Specific Gravity Analyzer Methodology There are basically three type of methods for measuring of Specific Gravity Analyzer. 1. Gas Density Detector 2. Gas Impulse Wheel Method 3.Metering Orifice Method Gas Density Detector A continuous type of measuring device , where a continuous flow of known Reference Gas as well as the Sample Gas are coming in contact with the two thermistors or hot wires vertically located at Upper and Lower branch / arms , finally wired to a Wheatstone Bridge , is balanced in exactly equal Density. If the Density of the sample gas exceeds even slightly than that of Reference Gas, there will be a Upper Branch Sample Inlet Gas Mixture OUT Reference Gas IN Lower Branch Detector Element tendency of Sinking of the Sample Gas into the Lower branch of the vertically located fluid bridge. This obstructs the flow path, causing a rise in Temperature of Lower Detector element and unbalancing the Wheatstone Bridge. So in the case of lighter Sample Gas, the Upper Detector element causes a rise in Temperature due to flow restriction of the Upper branch of the vertically located fluid bridge and unbalancing the Wheatstone Bridge . Page 7 of 46 INSTRUMENTATION MANUAL IFFCO AONLA 09 TOPIC: ANALYTICAL INSTRUMENTS UKS Gas Impulse Wheel Method In this method a continuous stream of gas sample is into the lower measuring into the lower measuring chamber of the instrument by a gas impulse wheel and put in whirling motion and driven against the blades of a companion impulse wheel located in the same chamber . Both wheels exert a torque on each other , each trying to rotate in an opposite direction . The result is net motion which depends on the difference in torque between the two impulse wheels and which position the indicator needle . As the difference between the opposing torque is a function of the specific gravity of the gas , it is indicated by the indicator needle. The impulse wheel in the air chamber is produced to compensate for changes in fan speed , temperature , humidity , and atmospheric pressure . To achieve this , gas sample and air are brought to the same temperature and humidity by passing them through separate compartments in the same humidifier . Because of the high rate of sampling and the small internal volume of the measuring chamber , response to the gas density changes is almost instantaneous. Metering Orifice Method: In this method a continuous sample is drawn from the process by a constant volume blower , through a pressure reducing valve which is set for constant volume blower, through a pressure reducing valve which is set for a constant down stream pressure of about 10cm of water column . In this way the variations in gas supply pressure are smoothed out , which other wises would affect the gas sampling accuracy. The sample is then passed through the metering orifice and then through a second orifice to atmosphere . Between the two orifices plates the line is tapped by a recycling line that connects back to the suction side of the blower . The atmospheric discharge is thus limited to about 30% of blower capacity . The differential pressure of the constant volume flow across the metering orifices varies with changes in the specific gravity of the sample . Page 8 of 46 INSTRUMENTATION MANUAL IFFCO AONLA 09 TOPIC: ANALYTICAL INSTRUMENTS UKS Functional Operation Here we are discussing the function of Solartron Make, Model NT3096 , which measure on the Metering Orifice Method. By definition , Molecular Weight of Gas Gas Specific Gravity (G) = MG = Molecular Weight of Standard Air MA Where MA is taken as 28.96469 The specific gravity transducer consists of a gas reference chamber, constructed such that it surrounds a vibrating cylinder gas density transducer, thereby helping to achieve good thermal equilibrium. The gas reference chamber has a fixed volume which is initially pressurised with the sample gas. It is then sealed by closing the reference chamber valve, thus retaining a fixed quantity of gas now known as the reference gas. The sample gas enters the instrument at the base plate and passes through a spiral heat exchanger so that it enters the gas density transducer at the equilibrium temperature. The gas then flows down to a pressure control valve chamber. The reference gas pressure acts through a separator diaphragm on the pressure control valve chamber so that the gas pressure on both sides of the diaphragm are equal, i.e. the gas pressures within the gas density transducer and the reference chamber are equal. As the ambient temperature changes, the pressure of the fixed volume of reference gas will change as defined by the Gas Laws. This change in pressure will affect the sample gas pressure within the density transducer such that the temperature and pressure changes are self-compensatory. If the sample gas pressure rises above that of the reference chamber pressure, the pressure control valve opens to vent the excess gas via the outlet connection in the base plate. In this manner the sample gas is made equal to the reference gas pressure. For gas to flow it is necessary that the supply pressure than the reference pressure which in turn must be greater than the vent pressure. Page 9 of 46 INSTRUMENTATION MANUAL IFFCO AONLA 09 TOPIC: ANALYTICAL INSTRUMENTS UKS Thermal Insulation Density Transducer To site Electronics Ref Chamber Valve Diaphragm Temp Stabilizer PRV Orifice PCV Filter Control Pressure Indicator C Outlet A Sample Gas Input B Calibration Gas Input NT 3096 Type Specific Gravity Measuring System Page 10 of 46 INSTRUMENTATION MANUAL IFFCO AONLA 09 TOPIC: ANALYTICAL INSTRUMENTS UKS A pressure gauge is fitted so that the gas pressure within the gas density transducer can be monitored. This is desirable when charging the reference chamber and general maintenance use. A thermal insulation cover is placed over the complete instrument so that rapid changes in ambient temperature will not upset the temperature equilibrium of the control assembly. The electrical connections to the transducer are taken to a terminal box located on the bottom surface of the base plate. Transducer Sensing Element The gas density transducer consists of a thin metal cylinder, which is activated so that it vibrates in a hoop mode at its natural frequency. The gas is passed over the inner and outer surface of the cylinder and is thus in contact with the vibrating walls. The mass of gas, which vibrates with the cylinder depends upon the gas density and, since increasing the vibrating mass decreases the natural frequency of vibration, the gas density for any particular frequency of vibration can be determined. A solid state amplifier, magnetically coupled to the sensing element, maintains the conditions of vibration and also provides the output signal. The amplifier and signal output circuits are encapsulated in epoxy resin. Page 11 of 46 INSTRUMENTATION MANUAL IFFCO AONLA 09 TOPIC: ANALYTICAL INSTRUMENTS UKS 2.1Aii Gas mol % Analyzer Thermal conductivity Type If a cylinder has a heated wire placed along its axis and the cylinder is filled with gas, the wire will lose heat to the surrounding walls by conduction, convection and radiation. The motion of the gas molecules is random and their average energy is proportional to the gas temperature. if some of these molecules collide with the hot wire, they will acquire an increase in energy, some or all of which may be lost if they subsequently collide with the cylinder walls. The amount of heat lost to the cylinder walls is a measure of thermal conductivity of the gas , depending on the number of molecules and their velocity and is determined by the gas pressure , density and mean temperature. Measurement of thermal conductivity Measurement of thermal conductivity of a pure gas ‘sample’ is relatively simple if the sample pressure is controlled , because the conductivity can then be compared against a “standard”. The behavior of a mixture of gases is not entirely predictable with respect to their total conductivity. The conductivity curves of many mixtures have been plotted experimentally but a standard is still required for use with the curves. Page 12 of 46 INSTRUMENTATION MANUAL IFFCO AONLA 09 TOPIC: ANALYTICAL INSTRUMENTS UKS Typical thermal conductivity cell The temperature of the wire in the cylinder is determined by the balance between the electrical heat energy supplied and the heat energy removed by the gas. The resistance of the wire is proportional to temperature and this resistance forms one arm of the Whetstone bridge. The wire through a similar cylinder containing a standard gas is used as another arm of the bridge. Only a small fraction of the total flow passes over the heated wire. Heated Wires Vent Flow Regulator Sample Gas Reference Gas The katharometer The katharometer , another name of the Thermal Conductivity Detector, differs from other cells in that it is independent of sample flow rate. The only contact the wire has with the sample is by gas diffusion through the glass capillary surrounding the hot wire. As the wire is heated electrically so one of the arms of a wheatstone brdge and as well as the thermal conductivity of the gas surrounding changes it’s temperature and resistance. These changes in resistance are converted into output voltage changes by the wheatstone bridge. This simple device is capable of detacting changes in the composition of a gas such as hydrogen or nitrogen in the order of 1 part per million. The katharometer employs a bridge circuit comprising two standard cells and two measuring cells, thus doubling the sensitivity. Page 13 of 46 INSTRUMENTATION MANUAL IFFCO AONLA 09 TOPIC: ANALYTICAL INSTRUMENTS UKS Simple Bridge system for determining Thermal Conductivity The two cells are hold vertically in a highly thermally conductive metal, so that their case temperature are the same and only their platinum resistance wires vary in temperature. The reference ( or standard cell ) is sealed, but the measuring cell is open to the sample gas. The pressure, inlet temperature and flow of the sample gas are usually controlled. Measuring Cell Reference Cell Thermal conductivity CO2 analyzer Although most commonly used as a CO2 analyzer for flue gas analysis this equipment could be used for any gas with a marked difference in thermal conductivity to that of reference gas. The reference gas would normally be same as the gas of the sample point but without having any of the gas being deleted in it. The two gas flows are drawn through the equipment by an aspirator at regulated flow rates. They first pass through a cooler to reduce the temperature (if necessary) of the sample and to ensure that both sample and reference are at the same temperature. Then the gases pass through humidifiers to ensure that they are both equally saturated. After passing through the rotameter the gases enter their respective detector blocks where their thermal conductivity are compared by four Page 14 of 46 INSTRUMENTATION MANUAL IFFCO AONLA 09 TOPIC: ANALYTICAL INSTRUMENTS UKS active elements. One piece of detector block ensures that the wall temperatures of the enclosures are same. Gas diffuses rather than flows into the chambers containing the detectors so that the actual flow over the wires is kept to a minimum. The two regulators maintain constant equal flow and keep side effects due to flow and pressure changes to a minimum. TO ASPIRATOR FLOW REGULATOR FLOW REGULATOR DETECTORS ROTAMETER COOLER SAMPLE REFERENCE HUMIDIFIERS Page 15 of 46 INSTRUMENTATION MANUAL IFFCO AONLA 09 TOPIC: ANALYTICAL INSTRUMENTS UKS 2.1Bi a Paramagnetic Type The physical property which distinguishes oxygen from most other common gases is it’s Paramagnetism. The only common gases having comparable Paramagnetic susceptibility are NO, NO2, and ClO2 . paramagnetic oxygen analyzer Faraday showed that all substances are affected by magnetic fields – those attracted into strong magnetic fields called Paramagnetic and those forced out of strong field called Diamagnetic. Some substances become magnetized in the opposite direction to an applied magnetic field and are therefore attracted in to magnetic field ( Paramagnetic ). Some materials are strongly paramagnetic and because of their magnetic similarity to iron are called Ferromagnetic materials. Most gases are diamagnetic (i.e they tends to move away from the most intense part of a magnetic field ) Oxygen is distinguished by being relatively strongly paramagnetic ( i.e. it is attracted by a magnetic field ). This difference makes it possible to analyze Oxygen by magnetic methods. The relative magnetic susceptibilities of a number of gases are given in the table below, normalized to a scale on which nitrogen = 0, GAS Oxygen = 100 . Percent relative susceptibility Nitrogen 0 Oxygen 100 Ammonia -0.26 Carbon dioxide -0.27 Carbon monoxide +0.01 Hydrogen +0.24 Methane -0.20 Nitric oxide +43.0 From the table it can be seen that oxygen cannot be analyzed in the presence of nitric oxide by this method. Page 16 of 46 INSTRUMENTATION MANUAL IFFCO AONLA 09 TOPIC: ANALYTICAL INSTRUMENTS UKS Magnetic Wind O2 Analyzer This instrument relies for its operation on the fact that oxygen becomes less paramagnetic with rise in temperature. The sample gas passes round a chamber and diffuses into the bypass pipe across its center. The heaters raise the temperature of the gas on the by pass pipe and if there is any oxygen present, its paramagnetism is reduced. Cool oxygen is drawn in to the bypass tube by the powerful magnet because it is more paramagnetic than the heated oxygen. The flow of gas thus created through the bypass tube causes the left hand heater to be cooler than the right hand and therefore for lower resistance. This puts the whetstone bridge supplying the current out of balance and generates an out of balance voltage that can be measured on a conventional mV ( V0 ) indicator. V0 Magnet Pole VI An increase in ambient temperature reduces the indication by about 1.5% C. This can be offset electronically using a resistance thermometer or by using a temperature controlled housing. The temperature of sample gas should not exceed 75 C and its pressure should be between 1 p.s.i. of the pressure at which the instrument has been calibrated. The other gases in the sample must be able to withstand 250 without degrading. Ranges between 0 to 3% and 0 to 25% are typical. Page 17 of 46 INSTRUMENTATION MANUAL IFFCO AONLA 09 TOPIC: ANALYTICAL INSTRUMENTS UKS 2.1Bi b Zirconium Type Principle of Operation The solid electrolyte (zirconium porcelain) exhibits conductivity to oxygen ions at high temperatures. Accordingly, if a zirconia element with platinum electrodes on the internal and external surface is heated and gases with different oxygen partial pressures are allowed to contact the surfaces, the zirconia element will exhibit the properties of an oxygen concentration cell. More specifically , oxygen molecules turn into oxygen ions with the addition of electrons at the electrode (cathode) with a higher oxygen partial pressure. The oxygen ions then move through the solid electrolyte to the anode where they release electrons and thus turn back into oxygen molcules. Cathode : O2 + 4e ------------ 2O2 Anode: 2O2 --------------- O2 + 4 Electromotive force E(emf) mV developed across the two electrodes through this reaction is obtained by Nernst ‘s formula as follows: E = - (RT/Nf )ln (PX/PA) Where , R = Gas constant T = Absolute Temperature N=4 F = Farady constant PX = Oxygen concentration (%) on comparison air for zirconia element PA = Oxygen concentration (%) on comparison air for zirconia element – normally 20.95% O2. If the cell set temperature is 750 ºC , the above formula is transformed as follows: E = - 50.74 log (PX/PA) Page 18 of 46 INSTRUMENTATION MANUAL IFFCO AONLA 09 TOPIC: Detector ANALYTICAL INSTRUMENTS UKS Heater Power Supply 4 ~ 20mA O/P Cell Output , 20.6% O2 T/C , Output , Ref.Junction Contact O/P Ejector Power Supply Stop Valve Air Supply / Zero Span Gas This analyzer heats the zirconia element to a specified temperature. The measurement gas then flows on side of the element and the reference air flows on the opposite side . Consequently , an emf proportionally to the ratio of oxygen concentration in the measurement gas to the oxygen concentration in the reference air is developed , which enables the oxygen concentration in the reference measurement gas to be measured . Page 19 of 46 INSTRUMENTATION MANUAL IFFCO AONLA 09 TOPIC: ANALYTICAL INSTRUMENTS UKS 2.1Bii SOX Analyzer The ultraviolet analyzer is designed to determine continuously the concentration of SO2 in a flowing gaseous mixture. The analyzer is capable of measurement in the 50 to 5000 ppm range. Here we discussed about the UV SO 2 Analyzer Rosemount Make, Model 890. Operational Principal The model 890 employs a pulsed UV lamp with peak wavelength generation from 225 to 650 nanometers. The pulsed lamp eliminates the requirement for a mechanical chopper and the attendant noise and stability problem. The ultraviolet source emits a pulsed (30Hz) beam of energy. This energy is split by a beam splitter, each beam being directed to pairs of detectors before and after the sample cell. One of the unique features of the model 890 is the use of spectrally selective, “Transflectance”, mirrors. These mirrors isolate the sample and reference spectral passbands for the detectors. They reflect energy below a wavelength region and transmit the remaining, higher wavelengths, all with much lower energy loss than the more commonly used bandpass interference filters. This measurement bench provides a number of unique advantages over conventional ultraviolet photometers. Increased radiation transmission at the measurement, reference and interferent compensation wavelengths provides 4 to 5 times the energy transmitted in conventional benches employing optical filters. This increase yields an extremely stable, sensitive and drift-free analysis. Four detectors are used in this system, two before the sample cell ( sample before [ Sb ] and reference before [ Rb ] ) and two after ( sample after [ Sa ] and reference after [ Ra ] ) . Sb and Sa receive energy in the 265 to 310 nm wavelength region, Rb and Ra in the 310 to 355 nm region. Page 20 of 46 INSTRUMENTATION MANUAL IFFCO AONLA 09 TOPIC: ANALYTICAL INSTRUMENTS UKS These four detectors measure SO2 concentration and correct for NO2 interference and UV lamp fluctuations. The difference between detector determinations is the SO2 concentration, following this formula : SO2 = [ f (Rb) – Sb ] - [ f (Ra) – Sa ] The sample gas is introduced to the sample cell, and the component of interest absorbs ultraviolet energy in proportion to the concentration in the gas. This difference between the signals of the detectors located at both ends of the sample cell determines the concentration of SO2 in the sample. Working Principal ( Optical Bench ) A collimating mirror is used to focus and direct the pulsed UV energy. Just prior to entering the sample cell, a planner, non-position-sensitive beam splitter is utilized to direct 50% of the transmitted energy to the first detector block assembly. In the detector block, transflective mirrors with selective wavelength reflection characteristics are used instead of optical filters. Theses mirrors further isolate the radiation into the required measurement and reference wavelengths, and reflect it onto a set of matched silicon photodiode detector assemblies. A second detector block located just after the sample cell is an exact duplicate of the first. This dual detector array allows the signal processing circuitry to yield a highly sensitive and accurate SO2 analysis. Additionally, utilizing this same technique on a second set of adjacent wavelengths allows accurate measurement and elimination of the effects of absorption by interferent gas or gases such as nitrogen dioxide. Coupled with the four-detector , multiple wavelength analysis technique described above, a unique detector output signal integration and de-integration signal Page 21 of 46 INSTRUMENTATION MANUAL IFFCO AONLA 09 TOPIC: ANALYTICAL INSTRUMENTS UKS DETECTOR DETECTOR Sb Ra Transflectance Mirrors Sa Beam Splitter Sample Cell Transflectance Mirrors U V Lamp Model 890 Optical bench processing scheme allows a continuous on-line correction of dark current and electronic noise errors. This effectively resets the electronic zero every 30 milliseconds, and yields a measurement which is virtually free of instability and drift. Additionally, the adjacent ( non - SO2 - absorbing) reference wavelengths are used as a baseline for measurement and correction of sample interferent components, particularly NO2 . Page 22 of 46 Rb INSTRUMENTATION MANUAL IFFCO AONLA 09 TOPIC: ANALYTICAL INSTRUMENTS UKS 2.1Biii NOX Analyzer Overview The NOX analyzer continuously analyzes a flowing gas sample for NO X nitric oxide ( NO ) plus nitrogen dioxide (NO2 ) . The sum of the concentrations is continuously reported as NOX. The analyzer is based on the chemiluminescence method of NO detection. The sample is continuously passed through a heated bed of vitreous carbon, in which NO2 is reduced to NO. Any NO initially present in the sample passes through the converter unchanged, and any NO2 is converted to an approximately equivalent ( 95%) amount of NO. . The analyzer is capable of measurement in the 50 to 5000 ppm range. Here we discussed about the UV SO2 Analyzer the NO is quantitatively converted to NO2 by gas-phase oxidation with molecular ozone produced within the analyzer from air supplied by an external cylinder. During this reaction, approximately 10% of the NO2 molecules are elevated to an electronically excited state, followed by immediate decay to the non-excited state, accompanied by emission of photons. These photons are detected by a photo multiplier tube, which in turn generates a DC current proportional to the concentration of NOX in the sample stream. The current is then amplified and used to drive a front panel display and to provide potentiometric and isolated current outputs. To minimize system response time, an internal sample by-pass feature provides high-velocity sample flow through the analyzer. The analyzer is capable of measurement in the 10 to 2500 ppm range. Here we discussed about the UV NO2 Analyzer Rosemount Make, Model 951C. Page 23 of 46 INSTRUMENTATION MANUAL IFFCO AONLA 09 TOPIC: ANALYTICAL INSTRUMENTS UKS Operational Principal The chemiluminescence method for detection of nitric oxide ( NO ) is based on its reaction with ozone ( O3 ) to produce nitrogen dioxide ( NO2 ) and oxygen ( O2 ). Some of the NO2 molecules thus produced are initially in an electronically excited state ( NO2* ). These revert immediately to the ground state, with emission of photons ( essentially red light ). The reactions involved are: NO + O3 NO2* + O2 NO2* NO2 + Red Light As NO and O3 mix in the reaction chamber, the intensity of the emitted red light is proportional to the concentration of NO . ( Any NO2 initially present in the sample is reduced to NO by a heated bed of vitreous carbon through which the sample is passed before being routed to the reaction chamber.) The intensity of the emitted red light is measured by a photo multiplier tube ( PMT ) , which produces a current of approximately 3 X 10‾9 amperes per part- per-million of NO in the reaction chamber. Ozone Generation Suitably pressurized air from an external cylinder is supplied to the rear panel AIR inlet. The proper pressure setting is 20 to 25 psig. Within the ozone generator, a portion of the oxygen in the air is converted to ozone by exposure to an ultraviolet lamp. The reaction is: 3O2 UV 2O3 From the generator, the Ozonized air flows into the reaction chamber for use in the chemiluminescence reaction. Page 24 of 46 INSTRUMENTATION MANUAL IFFCO AONLA 09 TOPIC: ANALYTICAL INSTRUMENTS UKS Signal Processing in Electronics System A block diagram of the Analyzer signal-processing electronics is shown in the figure below: SIGNAL / CONTROL PC BOARD Photomultiplier Tube PMT Programmable Amplifier Gain Amplifier Span Amplifier DISPLAY Potentiometric Output Zero Control Range Switch Span Control Isolated Current Output High Voltage Supply Voltage-to-Current Converter PART OF POWER SUPPLY PC BOARD Basic functions of these electronics are acceptance of PMT output and conversion of it to potentiometric and isolated current outputs, and providing a visual display of the concentration of the NOX in the sample stream. All function except the high-voltage source and the voltage-to-current converter are contained on the Signal Control PC board. The PMT drives a high input impedance amplifier which produces a voltage between 0 and approximately 5 volts. The zero control injects a small current into PMT amplifier to null any current from the PMT. The gain of the programmable gain amplifier ( PGA ) is controlled by the range switch as well as the Span Control switch. The Analyzer has a thermal system to provide a stable Thermal environment for the PMT. Page 25 of 46 INSTRUMENTATION MANUAL IFFCO AONLA 09 TOPIC: ANALYTICAL INSTRUMENTS UKS 2.2A BFW / Cooling Water/ Steam / Effluent pH Analyzer What is pH Value? pH, term indicating the hydrogen ion (positively charged hydrogen atom) concentration of a solution, a measure of the solution’s acidity. Hydrogen ions are usually represented by the symbol H+. The term (from French pouvoir hydrogène, “hydrogen power”) is defined as the negative logarithm of the concentration of H + ions: pH = -log10[H+], where [H+] is the concentration of H+ ions in moles per liter . Because H+ ions associate with water molecules to form hydronium (H3O+) ions , pH also is often expressed in terms of the concentration of hydronium ions. In pure water at 22° C (72° F), H3O+ and hydroxyl (OH-) ions exist in equal quantities; the concentration of each is 1 x 10 -7 moles/liter, creating a neutral solution. Consequently, the pH of pure water is –log (1 x 10-7), which equals log (1 x 107), or 7. If acid is added to water, however, an excess of H 3O+ ions is formed: H+ (acid) plus H2O (water) yields H3O+ (hydronium ions). When the concentration of H3O+ exceeds the concentration of OH-, the solution becomes acidic. In an acidic solution, the concentration of hydronium (H3O+) ions can range from 1 to 1 x 10-7 moles/liter (but not including 1 x 10-7), depending on the strength and amount of the acid. Therefore, acid solutions have a pH ranging from 0 up to, but not including, 7. Acids with lower numbers are stronger. Inversely, when the concentration of OHexceeds the concentration of H3O+, the solution becomes basic. In a basic solution, the concentration of hydroxyl (OH-) ions can range from 1 to 1 x 10-7 moles/liter (but not including 1 x 10-7). This corresponds to a concentration of hydronium ions that ranges from 1 x 10-14 to (but not including) 1 x 10-7 moles/liter. Therefore, basic solutions can have a pH ranging from 14 down to, but not including, 7. Bases with higher numbers are stronger. Page 26 of 46 INSTRUMENTATION MANUAL IFFCO AONLA 09 TOPIC: ANALYTICAL INSTRUMENTS UKS The pH of a solution can be measured by titration, which consists of the neutralization of the acid (or base) by a measured quantity of base (or acid) of known concentration, in the presence of an indicator (a compound the color of which depends on the pH). The pH of a solution can also be determined directly by measuring the electric potential arising at special electrodes immersed in the solution . Working Principle The most common industrial method of measuring pH is by glass-cell and calomelcell electrodes used with a potentiometer instrument. In brief, this method requires that an electrode be immersed in the solution. An electric potential is produced at the electrode which forms an electrolytic half-cell. This is the measuring cell. A second electrode is required to provide a standard potential and to complete the cell. This is the reference cell. The algebraic sum of the potentials of the two half-cells is proportional to the concentration of hydrogen ions in the solution. Glass Electrode The glass electrode is the measuring electrode in common use; it is shown in the figure below: Electrode Lead Glass Envelope Buffer Solution Platinum Wire Page 27 of 46 INSTRUMENTATION MANUAL IFFCO AONLA 09 TOPIC: ANALYTICAL INSTRUMENTS UKS The glass electrode operates on the principle that a potential is observed between two solutions of different hydrogen-ion concentration when they are separated by a thin glass wall. This potential is a function of the two concentrations. A buffer solution is contained in the permanently sealed glass electrode, which is surrounded by the solution whose pH is being measured. The buffer solution in the electrode has a constant hydrogen-ion concentration. The potential at the electrode therefore depends on the hydrogen-ion concentration of the measured solution. Reference Electrode The calomel electrode is the reference electrode in common use; it is shown in the figure below: Electrode Lead Glass Envelope KCl Solution Hg + HgCl Solution Ground-Glass Joint for Liquid Junction Page 28 of 46 INSTRUMENTATION MANUAL IFFCO AONLA 09 TOPIC: ANALYTICAL INSTRUMENTS UKS The calomel electrode is in common use as a reference electrode. The calomel ( mercury and mercurous chloride ) is contained in the inner tube and covers a platinum wire. The potassium chloride, a saturated solution, is in liquid contact with the measured solution, which surrounds the reference electrode. The liquid junction is provided by a small hole in the electrode, over which a ground-glass cap is placed, the junction to the outside provided by the liquid film in the glass joint. The potential at the reference electrode is constant. Cell Potential Measurement The cell potential is measured by means of a potentiometer type instrument operated from an amplifier connected to both electrodes. The amplifier is required because the cell potential is very small and because practically no current through the cell can be allowed. Page 29 of 46 INSTRUMENTATION MANUAL IFFCO AONLA 09 TOPIC: ANALYTICAL INSTRUMENTS UKS 2.2B BFW / Steam Conductivity Analyzer The measurement of conductivity Ohms law : For a circuit element Ohms law states that I = V / R where V is the potential difference in volts applied across resistor of resistance R in ohms to produce a current I in amperes. It is sometimes thought more convenient to write Ohms law as I = GV where G is the conductance (or conductivity ) in Siemens and G= I / R. Older texts refer to a siemens as Mho . Although applying equally as well as to liquids and solids for all the applications that follow it will be the conductivity of a liquid that is being measured . Specific conductivity : The conductivity of a liquid may be used to in for the amount of impurities that it contains .The conductivity of a particular sample depends on its size & shape .To make comparisons meaningful meters are designed to measure specific conductivity , K, where K is the conductivity of a cube of fluid each edge of which measures 1 cm. Page 30 of 46 INSTRUMENTATION MANUAL IFFCO AONLA 09 TOPIC: ANALYTICAL INSTRUMENTS UKS Cell Constant : The conductivity cell simply consists of two metal electrodes which will not corrode such as gold coated with platinum black, A voltage is applied to the cell and current is measured to find its conductance . The conductance depends upon the area , A , of the electrodes , their distance apart ,d , and the specific conductivity of the fluid , K , according to the formula G=KA/d Since G is measured but K is indicated the scaling of the instrument uses the formula in the form K= G d / A Where d / A is called cell constant. In a commercial cell k is impractical to find the cell constant by measuring A & d. The cell constant is determined using a standard fluid of known conductivity . The resistance of the cell can easily be measured over a range of 10 to 10,000 ohms but the conductivity’s vary over a much wider range than this so that it is necessary to have a cell constant from 0.1 to 100 . Polarization error : If a dc current is used in the measurement of conductivity the electrodes acquire local emf’s due to electrolysis which tends to reduce the current and the apparent conductivity . AC is the current used in measuring circuits to reduce the effects due to polarization . The higher the frequency and the larger the electrode area the less the polarization error. 1000 c/s is a suitable frequency ; above this value defects arise from stray capacitance in the leads , etc. Page 31 of 46 INSTRUMENTATION MANUAL IFFCO AONLA 09 TOPIC: ANALYTICAL INSTRUMENTS UKS Installation of conductivity analyzer Being generally mode of glass the cells are fragile and should be protected from buffering by pulsating flow or suspended solids . The holes in the glass cover should face the flow to ensure proper circulation and no air should be trapped in the cell . The electrodes should be periodically inspected for cleanliness and if they are not protected by a glass shield they must be inspected for shape and position as changes affect the cell constant. When installed downstream of conductivity correcting influent to the main stream sufficient space for adequate mixing must be allowed but at the same time the cells must be so far down stream as to introduce so large a distance velocity log that control becomes impossible . The cell should not be allowed to dry out as if the pipe is not always full the cell should be fitted pointing upwards at the bottom of U bend. The maximum permissible temperature is typically 100 C and the maximum pressure depends upon the seals used for the glass but say 40 psi . Consequently for many applications it is necessary to transport a cooled sample at the low pressure . Page 32 of 46 INSTRUMENTATION MANUAL IFFCO AONLA 09 TOPIC: ANALYTICAL INSTRUMENTS UKS Applications of conductivity analysis : Boiler Feed water ( BFW ) : Normal tap water contains dissolved salts that have to be removed before water can be boiled to provide steam for turbines , etc. , other wise the salts would be deposited on the surface of the heat exchangers or turbine blades , impairing their efficiency . In such very dilute solutions all the impurities are ionized and the conductivity is linearly proportional to the proportion of dissolved solid. It is possible to measure as little as 0.1 ppm of impurity . If, as in marine applications , sea water is used for cooling then the slightest leaks of salt water into the boiler water may be detected by the conductivity analyzer. Washing water : Continued washing of a product with fresh water after it is clean , washes both lime and water and places as necessary load on the effluent treatment plant . Comparison of wash water conductivity before and after a washing operation will indicate when the washing is complete. Acid manufacture : In the manufacture of sulphuric acid the optimum conditions require an acid strength in the process of 98.5 % . This can be controlled by a conductivity analyzer. Trace gas detection : Atmospheric impurity at a very low level can be detected by bubbling the air in the water and measuring its change in conductivity. Page 33 of 46 INSTRUMENTATION MANUAL IFFCO AONLA 09 TOPIC: ANALYTICAL INSTRUMENTS UKS Conductivity cell : The cell shown are Bishop cells and are just one of a number of types available. The two electrodes are insulated by glass and surrounded by a glass tube which helps to isolate the cell from the effect of conductive paths around it such as the pipe walls . The cell constant of the measuring cell can be adjusted in use by moving the position of tapered plug . The reference cell may be used for temperature compensation where required . Glass Holes REFERENCE CELL MEASURING CELL Page 34 of 46 INSTRUMENTATION MANUAL IFFCO AONLA 09 TOPIC: ANALYTICAL INSTRUMENTS UKS Potential difference method : W1 applies a voltage to the cell and the current that flows cause a P.D. across the resistor SR. The amplifier drives the slider along the slide wire S until it finds the same P.D. on S . The drive motor then stops as there is no input to the amplifier . W2 provides volts for the slide wire . T he actual voltage across it being set by the span resistor . W3 , RT , and its associated bridge supplies a small series voltage that varies with temperature and adjusts the range of measuring slide wire .This refers the indication of conductivity to a reference temperature .Rc is set for the temperature coefficient of the liquid under test . When the conductivity changes the out of balance voltage drives the slider to rebalance the bridge . The conductivity scale is marked out along the length of the slide wire . The reference cell contains a fluid with the same temperature coefficient as the fluid with under test so both the lower arms of the bridge are equally altered by temperature changes and there is no change in reading . If the true conductivity at process condition is required the reference cell is replaced by a resistor. SPAN S P A N W1 W 2 SR W3 M Page 35 of 46 INSTRUMENTATION MANUAL IFFCO AONLA 09 TOPIC: ANALYTICAL INSTRUMENTS UKS 2.2C DM Water Silica Analyzer Here we discussed about the Silica Analyzer HACH Make , Model 60000 used in our DM water plant. silica analyzer The series 5000 Silica analyzer is a continuous reading , wet – chemical , colorimetric analyzer for determining silica concentration in water . It has automatic decimal point positioning to provide optimum resolution over the total analysis range of 0 to 5,000 micrograms per litre ( µg/L or ppb) silica (SiO2) . Chemical analysis utilizes the Heteropoly blue method (also called molybdenum method ) adapted from Standard Methods for the examination of Water and Wastewater. Method of analysis : The Heteropoly blue method is used to measure molybdate –reactive silica. Molybdate 3 Reagent , an acidic molybdate solution , is added to the sample to react with any silica and phosphate present to form molybdosilicic and molybdophosphoric acids. Then , citric acid / surfactant reagent is added .Citric acid masks any molybdophosphoric acid present and reacts with excess molybdate . This prevents molybdate from producing an interfering blue – colored compound. The surfactant , a wetting agent , minimizes air bubble absorbance through formation on the sample walls . Light this solution is measured to determine a sample blank reference absorbance . Color formed at this point is identical to the final color of a 0 µg/L silica sample . This provides a zero reference and compensates for any background turbidity and color inherent in the sample , change colorimetric lamp output or contamination of the sample –cell walls. Amino acid F reagent is added to reduce molybdosilicic acid to a blue – colored solution .The amount of color formed is directly proportional to the silica concentration of the sample . Light absorbance through the solution is measured at 810 nm . This absrobance , and the silica concentration is calculated . Page 36 of 46 INSTRUMENTATION MANUAL IFFCO AONLA 09 TOPIC: ANALYTICAL INSTRUMENTS UKS Principle of operation : Operation series 5000 silica analyzer is semi continuous where discrete portions of sample are captured and analyzed in a time sequence .When an analysis is complete , new sample flow purges the sample cell , and the analysis cycle repeats automatically .If the sample is maintained at inlet temperature of 30 to 50 deg C by normal user or by a sample heater , set the measurement cycle time to 8.8 minutes to take advantage of the faster reaction time at this temperature. Otherwise , when the sample temperature is in the range of 5 to 40°C, set the measurement cycle time to 15 minutes to ensure adequate reagent / sample reaction times. Sample In Drain Block External Pr. Regulator Sample Pressure Sensor Sample Valve 1 2 3 4 5 Pr. Relif Exhaust Reagent Pr. Manifold Reagent Take-Up Tubing Sensor 1 2 3 4 Amino Acid F Reagent Citric Acid / Surfactant Reagent Molybo ate 3 Reagent Silica Standar d FLOW DIAGRAM Page 37 of 46 INSTRUMENTATION MANUAL IFFCO AONLA 09 TOPIC: ANALYTICAL INSTRUMENTS UKS A constant flow is directed through 2 way valve to the sample cell. To keep fresh sample available to the analyzer on a continual basis , a sample pressure conditioning kit is provided with an adjustable needle valve for by pass flow eliminating dead legs. A sample inlet pressure of 5+/- 3 psig (100 to 300 mL /min ) is required to ensure adequate flow . At the beginning of each measurement cycle , incoming sample flows is directed to the sample cell. The sample is cell filled 10 times. The excess sample flows through an overflow weir to drain . A precise sample volume is maintained by the overflow weir. Reagents are stored in containers pressurized at a nominal 12+/-3 psig. By monitoring reagent pressure and temperature , the analyzer can dispense reagents accurately by timing the opening of the solenoid valves. Once the sample cell has been filled , reagents are added in the sequence . A magnetic stirring motor is activated after reagents are added to ensure good mixing . It is turned off to allow sample to stabilize and air bubbles to rise before taking color measurements . During a calibration cycle , standard solution stored in a reagent bottle is added to sample cell in place of normal sample. exactly as The standard solution is analyzed , sample would be , and the result is used to calculate the slope of calibration curve. This slope factor is used in all future measurements to calculate sample concentration as shown in the following formula: SiO2 = Slope X log(Reference /Sample) Analysis module: The analysis module contains the solenoid valves controlling sample and reagent flow and the colorimetric measuring system. A sample measurement cell is placed between a light source and a photodetector and filtered to measure light 810 nm . Sample and reagents enter the cell through fittings in the cell cover , which prevents external contamination . A magnetic stirrer is activated during reagent additions to mix sample and reagents thoroughly . Page 38 of 46 INSTRUMENTATION MANUAL IFFCO AONLA 09 TOPIC: ANALYTICAL INSTRUMENTS UKS 2.2D Ammonia Analyzer ANALYSIS : AMMONIA RANGE : 0.5 ~ 10 ppm N SAMPLE : PROCESS WATER Principle The automated procedure for the determination of ammonia is based on the modified Berthelot reaction; ammonia is chlorinated to monochloramine which reacts with salicylate to 5-aminosalicylate. After oxidation and oxidative coupling a green colored complex is formed. The absorption of the formed complex is measured photometrically at 660 nm. Here we are discussing the On-line Ammonia Analyzer ,SKALAR Make, Model SA9000. The Analyzer is working on the principle of above Photochlorametrically. Working Principle Automatic segmented flow analysis is a method of chemical analysis in which a stream of reagent and samples are pump through a manifold where the stream is segmented with air bubbles. The segmented stream then enters the chemistry module where it is treated, examples of treatments are mixing, heating, dialysis etc. After treatment the stream enters a flow cell to be detected. The air segmentation is used to eliminate cross contamination and to provide an aliquot to mix different reagents. Sample Chemical Treatment Detection Data Handling Reagent The Principle of Segmented Flow Analysis Page 39 of 46 INSTRUMENTATION MANUAL IFFCO AONLA 09 TOPIC: ANALYTICAL INSTRUMENTS UKS Line Diagrams & Reagent Details 0.42 ml /min Waste Orange / Orange Sodium Dichlorolsocyanurate 40°C Reactor Flow Cell 10 mm Filter 660nm 6401 5522 0.32 ml /min Black / Black Sodium Nitroprusside 5246 0.23 ml /min 5201 Orange / White 5246 0.32 ml /min Sodium Salicylate Black / Black Sample / High st. 5246 0.16 ml /min / Low st. Orange / Yellow Air 0.23 ml /min Orange / White Buffer Solution 1.20 ml /min Yellow / Yellow 9245 5325 5201 5325 5201 Sodium Salicylate Required Chemicals: Sodium Hydroxide Sodium Salicylate NaOH C7H5NaO3 Distilled Water Sodium Nitroprusside Required Chemicals: Sodium Nitroprusside Na2 [ Fe ( CN )5 NO ]. 2H2O Distilled Water Sodium Dichloroisocyanurate Required Chemicals: Sodium Dichloroisocyanurate C3N3O3Cl2Na. 2H2O Distilled Water Page 40 of 46 5325 INSTRUMENTATION MANUAL IFFCO AONLA 09 TOPIC: ANALYTICAL INSTRUMENTS UKS Overview of the Process Analysis This on-line process analysis is divided into three parts: 1. Sampling, sample transport and sample pre-treatment 2. Analysis and measurement 3. Data acquisition. Sampling Pump Reservoir Sample TOC Monitor Pre-treatment SA 9000 Data Acquisition Computer Printer Filter This three parts involve the following: 1. Preconditioning of the sample may involve filtration, cooling to ambient, dilution, pressure regulation, transport to the analyzer system and multi point sample selection. 2. For the analysis system, reliability, response time, reproducibility, calibration and user friendliness are amongst the most important factors. 3. Analytical data may be presented in different ways, a visual display on the instrument showing the present status of the instrument and the measured value, an analog output , RS232C for connection to printers and/ or host computers with alarms for feedback. Page 41 of 46 INSTRUMENTATION MANUAL IFFCO AONLA 09 TOPIC: ANALYTICAL INSTRUMENTS UKS 2.2E Dissolved O2 Analyzer Elements of dissolved oxygen analyzer Application : The measuring equipment is mainly employed for oxygen measurement and supervision of various points in the water system of steam boilers. It is however equally suitable for oxygen measurements in heavy water of nuclear reactors. Principle of operation : The measuring principle is based on the characteristic of the lead type metal ,Thallium i.e It is only corroded by water if the water contains dissolved oxygen. The product of this reaction ,Thallium oxide ,Combines with water to form Thallium hydroxide which is well water soluble and is a very strong electrolyte. By allowing water with dissolved Oxygen to pass through a Cartridge containing Thallium fillings the electrical Conductivity of water Increases .The conductivity increase is a measure of Oxygen content. The Schematic arrangement of the measuring equipment ,comprising an analyzer and a measuring unit is shown. The main components of the analyzer and the thallium reactor (7) consisting of a cartridge filled with thallium filings and the connected conductivity measuring cell (8) .Up-stream of the Thallium reactor an ion exchanger cartridge (4) is provided which reduces the conductivity of the sample to between 0.01 and 0.1 micro mho/cm .(In the case of heavy water to 0.001 micro mho /Cm ) and keeps it practically constant. The low remaining water conductivity can be measured by means of the conductivity cell (5) and can be deducted electrically from the conductivity value measured behind the Thallium reactor by means of a potentiometer graduated in Mho/Cm .Thus only the conductivity of the water down stream of thallium reactor is evaluated as the measured value for the Dissolved oxygen. On the inflow side o\f the analyzer , a further conductivity meter (3) is provided by means of which the electrical conductivity of the incoming sample water stream can be measured. In the case of Page 42 of 46 INSTRUMENTATION MANUAL IFFCO AONLA 09 TOPIC: ANALYTICAL INSTRUMENTS UKS Boiler feed water with the hydrazine addition it is advisable to connect a cation exchanger in front of the analyzer. SAMPLE INLET 1. Solenoid Valve 1 2. Sieve 3. Conductivity Meter 4. Ion Exchanger Cartridge Bypass 2 5. Conductivity Cell 6. Conductivity Cell 7. Thallium Reactor 3 8. Conductivity Measuring Cell 9. Flow Controllor 10. Flow Indicator 10 4 9 8 7 5 To stop the sediments and dirt , a sieve (2) is connected in front of the conductivity cell (3) and to protect the ion exchanger filling as well as plastic pipe against too high temperatures , a temperature monitor is provided in the inflow pipe , consisting of solenoid vale (1) with bimetallic release. In the measuring branch a flow controller (9) and a flow indicator (11) are further more built in. The water flow must be within the range of 40 ~ 120 cc/ Min. Since a small flow extend the life of the cartridge, and of the thallium cartridge .The larger flow results in the more rapid response , a flow rate of 80 cc /Min should normally be selected. Page 43 of 46 INSTRUMENTATION MANUAL IFFCO AONLA 09 TOPIC: ANALYTICAL INSTRUMENTS UKS 3.GAS CHROMATOGRAPHY Gas chromatography is the name given to a method of analysis that permits the continuous measurement of the amounts of each constituent in a complex vapour or gas mixture. It is the method which physically separates and quantitatively identifies two or more components of a mixture. This method involves combining the sample gas with a carrier gas (such as helium , nitrogen , air or hydrogen and passing the combination of gasses through a packed chromatographic column , which is made of metal tubing and filled with an adsorbent such as activated alumina , silica gel , or activated carbon and operated at a suitable temperature . The rates at which individual components move through the column depend on their respective affinities for the column material . Therefore , the different components emerge from the column in a sequence which depends on the relative affinity of these components for the particular column packing . Generally the lighter components are swept always (eluted ) faster than the heavier. In other words as carrier gas transports the sample through the column , the column packing exerts a differential retarding effect on the sample components , separating and regrouping them so that all molecules of an individual component emerge in a discrete bunch . By use of the proper column length, the components are separated from each other , and the individual elution time serves to identify the particular component. The efficiency of separation depends on the size , composition and made of injection of the sample : type and rate of flow of carrier column length , area and packing material ; column temperature. Thus when a gasses passes through the column , its constituents get separated out and each constituents travels through the column at a different rate , because each is retained for a different period of time by the column adsorbent . A gas chromatograph neither identifies nor measures components directly. For this purpose it employs a device which detects each component as it emerges out of the column and sends a signal to recording device that records the effect as a physical Page 44 of 46 INSTRUMENTATION MANUAL IFFCO AONLA 09 TOPIC: SAMPLE GAS ANALYTICAL INSTRUMENTS UKS PACKED COLUMN Thermal Conductivity Detector CARRIER GAS Vent Gas Regulating Valve measurement (peak) which can be calibrated to yield a quantitative value. Thus identification of a component is made by measuring the time required for a component to move through a column operating under specified conditions; and a quantitative determination is made by measuring peak area or height . Calibration of peaks is accomplished by inferential methods like running a sample of known composition and comparing the results with those obtained by other analytical methods .Chromatograph consists of two basic sections : analysis which is located in the field near the sample point , and control section which is located in a central control room. The analysis portion consists of valves , columns , detectors etc. . The control room section consists of programmer , recorder, stream selector, peak picker memory unit, and other auxiliary units. The carrier gas is used to force the sample gas through the column and thus the constituents of the sample gas leave the column in combination with the carrier gas . For best results , the flow, pressure and temperature must be controlled and recorded. Page 45 of 46 INSTRUMENTATION MANUAL IFFCO AONLA 09 TOPIC: ANALYTICAL INSTRUMENTS Page 46 of 46 UKS