Perma Pure GASS-2040 User Manual

GASS

™

- 2040

Gas Analysis Sampling System

User Manual
v1.20

PERMA PURE

8 Executive Drive
Toms River, N.J. 08755
Phone: [phone]

732-244-0010
Fax: [phone]
e-mail: [e-mail]
Web Site: www.permapure.com

TABLE OF CONTENTS

GASS 2040

1. Introduction.....................................................................................................................6

2. Mini-GASS Components.................................................................................................7

2.1 Probe, Probe Filter, and Automatic Blowback (Optional)

2.2 Filtration

2.3 Automatic Filter Drain (Optional)

2.4

2.5 Nafion Dryer

2.6 Ammonia Scrubber (Optional)

2.7 Purge Air Dryer (Optional)

2.8 Purge Air Eductor (Optional)

2.9 Z-Purge (Optional)

3. Installation.....................................................................................................................10

3.1 Mounting

3.2 Electrical Connection

3.3 Plumbing

Sample Pump (Optional)

a. Power Wiring
b. I/O Wiring

a. Sample Connection
b. Purge Air Supply
c. Filter Drain Connection (Optional)
d. Purge Exhaust
e. Purge Eductor Inlet Connection (Optional)

4. Control System Operation ............................................................................................13

6. Maintenance..................................................................................................................19

4.1 General Information

4.2 Operator Interface

4.3 Systems Operation Monitoring
a. Alarm Output Operation
b. System Status Indicator Operation

4.4 Preheating the System

4.5 Automatic Filter Drain Control (Optional)

4.6 Automatic Probe and Filter Blowback Operation (Optional)

6.1 Filters

6.2 Dryers

6.3 Ammonia Scrubber

6.4 Fuse

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APPENDIX A............................................................................................................................21

1. Specifications

APPENDIX B............................................................................................................................22

1. PD Dryer Disassembly

2. PD Dryer Reassembly

APPENDIX C............................................................................................................................26

1. Replacement Parts List for GASS-2040

APPENDIX D............................................................................................................................27

1. Stack Mount Systems

1.1 Flange Mounting

1.2 Support Installation

APPENDIX E.............................................................................................................................29

1. Z-Purge Operation

2. Troubleshooting

3. Helpful Hints

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WARNING

Thank you for purchasing sample gas conditioning equipment from Perma Pure LLC. We want your new sample gas
conditioning equipment to operate safely. Anyone who installs or uses this equipment should read this publication
before installing or operating this equipment.

To minimize the risk of potential safety problems, you should follow all applicable local and national codes that regu­late the installation and operation of your equipment. These codes vary from area to area and usually change with
time. It is your responsibility to determine which codes should be followed and to verify the equipment, installation and
operation is in compliance with the latest revision of these codes.

At a minimum, you should follow all applicable sections of the National Fire Code, National Electrical Code, and the
codes of the National Electrical Manufacturer’s Association (NEMA). There may be local regulatory or government
offices that can also help determine which codes and standards are necessary for safe installation and operation.

Equipment damage or serious personal injury can result from the failure to follow all applicable codes and standards.
We do not guarantee the products described in this publication are suitable for your particular application, nor do we
assume any responsibility for your system design, installation or operation. This product should not be operated in any
manner that is inconsistent with its intended use.

If you have any questions concerning the installation or operation of this equipment, or you need additional informa­tion, please call us at 1-800-337-3762.

TRADEMARKS

This publication is based on information that was available at the time it was printed. At Perma Pure we constantly
strive to improve our products and services, so we reserve the right to make changes to the products and/or publica­tions at any time without notice and without any obligation. This publication may also discuss features that may not be
available in certain revisions of the product.

This equipment is to be installed and operated by trained personnel, with sufficient command of the English language
to clearly understand the instructions and safety warnings.

TRADEMARKS

Trademarks

Nafion® and Teflon® are registered trademarks of EI DuPont de Nemours

Copyright 1996-2005, Perma Pure LLC. All Rights Reserved.

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WARRANTY AND DISCLAIMERS:

Seller warrants that product supplied hereunder shall, at the time of delivery to Buyer, conform to the
published specifications of Seller and be free from defects in material and workmanship under normal use
and service. Seller’s sole obligation and liability under this warranty is limited to the repair or replacement at
its factory, at Seller’s option, of any such product which proves defective within one year after the date of
original shipment from seller’s factory (or for a normal usable lifetime if the product is a disposable or
expendable item) and is found to be defective in material or workmanship by Seller’s inspection.

Buyer agrees that (1) any technical advice, information, suggestions, or recommendations given to Buyer
by Seller or any representative of Seller with respect to the product or the suitability or desirability of the
product for any particular use or application are based solely on the general knowledge of Seller, are
intended for information guidance only, and do not constitute any representation or warranty by Seller that
the product shall in fact be suitable or desirable for any particular use or application; (2) Buyer takes sole
responsibility for the use and applications to which the product is put and Buyer shall conduct all testing
and analysis necessary to validate the use and application to which Buyer puts the product for which Buyer
may recommend the use or application of the product by others; and (3) the characteristics, specifications,
and/or properties of the product may be affected by the processing, treatment, handling, and/or
manufacturing of the product by Buyer or others and Seller takes no responsibility for the nature or
consequence of such operations or as to the suitability of the product for the purposes intended to be used
by Buyer or others after being subjected to such operations.

SELLER MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED, OF THE PRODUCT SUPPLIED
HEREUNDER, INCLUDING, WITHOUT LIMITATIONS, IMPLIED WARRANTIES OF MERCHANTABILITY
AND FITNESS FOR PARTICULAR PURPOSE, AND ALL SUCH WARRANTIES ARE HEREBY
EXPRESSLY EXCLUDED. SELLER SHALL HAVE NO LIABILITY FOR LOSS OF PROFITS, OR SPECIAL,
INCIDENTAL, OR CONSEQUENTIAL DAMAGES UNDER ANY CIRCUMSTANCES OR LEGAL THEORY,
WHETHER BASED ON NEGLIGENCE, BREACH OF WARRANTY, STRICT LIABILITY, TORT,
CONTRACT, OR OTHERWISE. SELLER SHALL IN NO EVENT BE LIABLE IN RESPECT OF THIS OR­DER AND OR PRODUCT DELIVERED ON ACCOUNT OF THIS ORDER FOR ANY AMOUNT GREATER
THAN THAT PAID TO SELLER ON ACCOUNT OF THIS ORDER.

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1. Introduction

Perma Pure GASS-2040 sample pre-conditioning systems are designed to prepare gas samples for
analysis. The GASS-2040 system will condition high-flow, high-moisture sample, eliminating acid mists or
ammonia if present without removing the compounds being monitored. Figure 1 below gives a general
overview of a GASS-2040 system.

Standard Features Include: Options:

- Heated Enclosure - Purge Air Heatless Dryer

- Filter(s) – Particulate and/or Coalescing - Heated Head Sample Pump

- Perma Pure Nafion Gas Dryer(s) - Filter Drain

- Temperature Controller - Ammonia Scrubber(s)

- Dryer Purge Flow Controls - Purge Air Eductor

- Z-Purge

- Probe and Automatic Blowback

- Probe Filter and Hatelloy Heat Exchanger

Figure 1

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2. GASS-2040 Components

2.1 Probe, Probe Filter and Automatic Blowback (optional):

The GASS-2040 system with integral probe filter eliminates the need for a high temperature
heated line by conditioning the gas sample at the sample gas extraction point on the stack. When
sample gas is drawn from the stack, it is passed through a 2 micron ceramic filter to remove oil
and acid aerosols. The sample gas is dried and cooled immediately after removal from stack to
minimize changes in sample composition (Refer to Appendix D for Installation Instructions).

The optional blowback assembly minimizes maintenance of the probe filter by periodically pass­ing compressed air back through the element. This action dislodges captured particles and forces
them back into the stack. Included with the blowback system is a calibration gas flow sensor
which prevents blowback from occurring while calibration gas is flowing.

2.2 Filtration:

The sample is passed through a 1μ filter to remove particulates and aerosols. The standard filter in
the GASS-2040 system has a borosilicate glass filter element with a fluorocarbon binder. This
element is disposable and will withstand high sample temperatures. In addition to removing
particulates, it coalesces liquid aerosols and droplets.

Two flow patterns are possible with this filter:

1. Particulate Filter: Filter installed with flow passing

from outside to the inside of the element. With this
installation, collected particulates will build up on
outside surface of the element allowing visual
inspection of its condition.

2. Coalescing and Particulate Filter (See Figure 2):

Filter is installed with flow passing from inside of
element to the outside. An automatic drain is usually
installed to remove the condensate.

2.3 Automatic Filter Drain (optional):

If coalescing is anticipated, system should be fitted with automatic filter drain to
periodically remove collected liquid mists. In most cases, these mists will be acid mists.
Automatic drain is available in vacuum or pressurized style.

1. Vacuum Configuration:

Figure 2

Collected liquid is withdrawn from filter drain port by a vacuum created by an eductor
expanding compressed air through a venturi. This is done in cycles and controlled
by adjustable digital timer that switches a solenoid valve controlling compressed air
supply.

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2. Pressurized Configuration:

An eductor is not required since a vacuum is not needed to withdraw the sample.
Therefore, condensate withdraw is directly controlled by the solenoid valve. Cycle
times can be varied and will be dependent on the amount of liquid present in sample.

2.4 Sample Pump (optional):

The sample pump draws the sample gas and supplies it to the analyzer. It supplies up to 10
liters per minute of sample gas flow. The pump is typically plumbed between the coalescing filter
and membrane dryer or between the coalescing filter and the ammonia scrubber (if present). The
head of the pump is located in the heated section of the system while the motor is located in the
control section. This configuration keeps pump head at a temperature above dew point of the
sample preventing condensation from forming. Included with the optional sample pump is a vortex
cooling tube that helps keep the control enclosure at an acceptable temperature. The PLC controls
the valve that supplies air to the vortex tube. Compressed air requirements are approximately 4
scfm @ 80psi.

2.5 Nafion®Dryer:

The Perma Pure Nafion membrane dryer is installed downstream of the filter. As sample
enters the dryer, flow splits into a number of small diameter Nafion tubes arranged in a parallel
bundle as shown in Figure 3 below. After sample enters one of these tubes it comes in contact with
the Nafion membrane walls. The membrane selectively removes water vapor from the sample by a
process of permeation distillation. Water vapor travels through the tubing walls driven by the
difference in partial water vapor pressure on the opposing sides of the membrane. As the sample
flows from inlet to outlet water is continually removed, reducing the sample dew point as it travels
through the dryer.

Figure 3

Dry purge gas enters the dryer at the sample outlet end and performs two functions:

1. Provides a medium for water vapor from the sample to be carried away.

2. Creates a temperature gradient along length of dryer.

Ambient purge air enters the dryer at sample outlet, keeping that portion of dryer cooled.
This counter current flow is required to produce a temperature gradient along the length of
the dryer. To effectively maintain the gradient, the temperature of purge gas exhaust is
monitored and controlled by an electronic temperature controller. As purge gas passes
through the dryer it is heated to the desired sample inlet temperature. This gradient allows for both
rapid vapor removal and decreased final dew point. If the purge gas temperature begins to fall
below the programmed temperature, the system’s backplate will heat. An aluminum heating block
will conduct energy from the backplate to the dryer’s shell tube. Purge gas traveling through the
dryer’s shell acquires heat from the shell. This process allows final temperature of the purge gas to
be closely controlled and a consistent temperature gradient will be maintained.

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It is important that the dryer removes water in vapor state only. If liquid water is introduced
into the dryer, efficiency will decline and the dryer could fail to perform altogether. Tubing
elongates approximately 10% over its dry length when saturated with liquid water causing
tubing to kink inside housing. Nafion dryers will operate most efficiently when a portion
of the dryer is heated to prevent sample from condensing.

2.6 Ammonia Scrubber (optional):

The optional ammonia scrubbing canister must be used when ammonia or urea is used for the
purpose of lowering NO

levels or any time ammonia is present in sample stream.

x

Ammonia salts can deposit in dryer tubes and cause permanent loss of drying efficiency if not
removed from the sample stream. An ammonia scrubber consists of a polysulfone and 316 SS
housing filled with a phosphoric acid based media and inert ceramic saddles. This media will
require periodic replacement. See section 6.3 for replacement instructions.

2.7 Purge Heatless Air Dryer (optional):

If -40°C dewpoint purge air is not available, a heatless air dryer can be installed
in the GASS-2040 to dry the compressed air supply. Outlet of heatless dryer will be connected
to standard purge gas flow controls. Operation of heatless dryer is fully automatic and
continuous, and should not require any maintenance as long as oil free compressed air is used.

2.8 Purge Air Eductor (optional):

When the sample is under more than five inches of water vacuum, a purge air eductor is required.
Eductor generates a vacuum to drop pressure of purge gas to prevent collapsing of Nafion tubing.

2.9 Z-Purge (optional):

For hazardous environments to meet Class I, Division II specifications (Refer to Appendix E).

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