Instruction Manual
HASFAE-IM-H
10/2009
Flame Arrestors Series FA
Instruction Manual
www.EmersonProcess.com
ESSENTIAL INSTRUCTIONS
READ THIS PAGE BEFORE PROCEEDING!
Emerson Process Management (Rosemount Analytical) designs, manufactures and
tests its products to meet many national and international standards. Because these
instruments are sophisticated technical products, you MUST properly install, use, and
maintain them to ensure they continue to operate within their normal specications.
The following instructions MUST be adhered to and integrated into your safety program
when installing, using and maintaining Emerson Process Management (Rosemount
Analytical) products. Failure to follow the proper instructions may cause any one of the
following situations to occur: Loss of life; personal injury; property damage; damage to
this instrument; and warranty invalidation.
• Read all instructions prior to installing, operating, and servicing the product.
• If you do not understand any of the instructions, contact your Emerson Process
Management (Rosemount Analytical) representative for clarication.
• Follow all warnings, cautions, and instructions marked on and supplied with the
product.
• Inform and educate your personnel in the proper installation, operation, and
maintenance of the product.
• Install your equipment as specied in the Installation Instructions of the
appropriate Instruction Manual and per applicable local and national codes.
Connect all products to the proper electrical and pressure sources.
• To ensure proper performance, use qualied personnel to install, operate, update,
program, and maintain the product.
• When replacement parts are required, ensure that qualied people use replacement
parts specied by Emerson Process Management (Rosemount Analytical).
Unauthorized parts and procedures can affect the product’s performance, place the
safe operation of your process at risk, and VOID YOUR WARRANTY. Look-alike
substitutions may result in re, electrical hazards, or improper operation.
• Ensure that all equipment doors are closed and protective covers are in place,
except when maintenance is being performed by qualied persons, to prevent
electrical shock and personal injury.
The information contained in this document is subject to change without notice.
3rd Edition 2009-10
Emerson Process Management GmbH & Co. OHG
Industriestrasse 1
D-63594 Hasselroth
Germany
T +49 (0) 6055 884-0
F +49 (0) 6055 884-209
Internet: www.EmersonProcess.com
Instruction Manual
HASFAE-IM-H
10/2009
FA 01/02/03
PREAMBLE
This instruction manual provides information about FA series ame arrestors concerning
functions, procedures, installation, operation and maintenance.
This instruction manual covers several FA series ame arrestor variations and therefore
may describe congurations and/or options not part of your arrestor.
DEFINITIONS
The following denitions apply to WARNINGS, CAUTIONS and NOTES found throughout
this publication.
Safety Instructions
Highlights an operation or maintenance procedure, practice, condition,
state-ment, etc.
If not strictly observed, could result in injury, death, or long-term health
hazards of personnel.
Highlights an operation or maintenance procedure, practice, condition,
state-ment, etc.
If not strictly observed, could result in damage to or destruction of equipment,
or loss of effectiveness.
NOTE
Highlights an essential operating procedure, condition or statement.
Emerson Process Management GmbH & Co. OHG S-1
FA 01/02/03
Instruction Manual
HASFAE-IM-H
10/2009
Emerson Process Management GmbH & Co. OHGS-2
IMPORTANT
Safety Instructions
The following safety instructions apply specically to all EU member states. They should be strictly
adhered to in order to assure compliance with the applicable directives for equipment to be used
in hazardous areas. Non-EU states should also comply with the following unless superseded by
local or National Standards.
1. Where equipment or covers are marked with the symbol to the right, refer
to the Instruction Manual for instructions.
2. Further graphical symbols used in this product:
Explosion Hazard!
All graphical symbols used in this product are from one or more of the following standards:
EN61010-1, IEC417, and ISO3864.
Harmful (to Health)!
Toxic!
Operating and Maintaining this Component
This component has left the factory in compliance with all applicable safety regulations.
To maintain this operating condition, the user
must strictly follow the instructions and consider the warnings in this manual or provided
on the component.
Substances hazardous to health may emerge
from the component‘s exhaust.
Please pay attention to the safety of your
operation personnel. Protective measures
must be taken, if required.
Instruction Manual
HASFAE-IM-H
10/2009
FA 01/02/03
Emerson Process Management GmbH & Co. OHG S-3
Safety Instructions
Safety Instructions
INTENDED USE STATEMENT
FA series ame arrestors are intended to be used as ame arrestors for industrial purposes. They must not be used in medical, diagnostic or life support applications nor as
safety devices, and no independent agency certications or approvals are to be implied
as covering such applications!
SAFETY SUMMARY
To avoid loss of life, personal injury and damage to this equipment and on-site property,
do not operate or service this equipment before reading and understanding this instruction
manual and receiving appropriate training. Save these instructions.
ExPLOSION HAzARD !
This component must be used in compliance with the conditions given in
a later section of this manual!
DANGER TO LIFE ! ExPLOSION HAzARD !
Verify all gas lines are connected as described within this manual and
tight!
Improper gas connections may cause explosion, serious injury or death!
Do not operate the ame arrestors outside the conditions, specied in the
Operating Conditions section of this manual.
• Exhaust lines must be installed in a descending way, need to be pressureless, frost-protected
and in compliance with applicable legislative requirements!
FA 01/02/03
Safety Instructions
Changes within this manual, compared to the 06/2006 edition
•
New EC Certicate of Compliance
New denition of how to carry out pressure •
drop test
Instruction Manual
HASFAE-IM-H
10/2009
Emerson Process Management GmbH & Co. OHGS-4
Instruction Manual
HASFAE-IM-H
10/2009
1 Operating Conditions, Installation, Maintenance
1-1 Use
The volume ame arrestors of type FA 01/02/03
comply with the standard EN 12874:2001 „ Flame Arrestors - Performance requirements, test methods and limits for use“.
The general suitability as a deagration ame
arrestor when used with ammable gas/air
mixtures of the explosion group IIC (maximum
gap < 0,5 mm) has been veried by tests
executed by FTZU (FYZIKÁLNÉ TECHNICKÝ
ZKUŠEBNÍ ÚSTAV) in Czech, European
ATEX Notied Body no. 1026.
The results are confirmed by the issued
EC Type Examination Certicate
FTZU 06 ATEX 0164.
FA 01/02/03
1-2 Construction
The ame arrestors of type FA 01/02/03 are
made of 2 parts: one inner massive cylinder
with three sections and a surrounding outer
tube. Both parts together form an annular
gap, meeting the specications for gas group
IIC, and are welded together.
Conditions for use
The following limits have to be considered
when using these ame arrestors:
•
maximum operational pressure:
110 kP abs.
maximum operational temperature: 60 °C.•
The basic safety requirements as given in the
directive 94/9/EC have been conrmed by
issuing the Declaration of Conformity, shipped
together with each ame arrestor as part of
this documentation.
The ame arrestor must only be installed and
operated in compliance with the conditions
for use given in the EC Type Examination
Certicate, any use outside these conditions
is prohibited.
Gas ttings (
1
⁄4“ or
1
⁄8“) provided at both ends
of the ame arrestors support connecting it
to stainless steel tubings with outer diame-
ters of 6,35 mm or 3,18 mm.
1
⁄4“ ttings may
optionally be supplied with clamping rings for
pipes of 6 mm diameter.
Three different variations of ame arrestors
are available, differing by the attached gas
ttings:
FA 01: one side 1⁄4“, the other side 1⁄8“
FA 02: both
FA 03: both
1
⁄4“
1
⁄8“
Note!
1
⁄4“ ttings may optionally be supplied with a
clamping ring for pipe diameters of 6 mm.
When not in use (e.g. during transport) the
ttings have to be sealed to protect the inside
from moisture and contamination.
Installation, Operation, Maintenance
Emerson Process Management GmbH & Co. OHG 1-1
Emerson Process Management GmbH & Co. OHG1-2
FA 01/02/03
Instruction Manual
HASFAE-IM-H
10/2009
1-3 Markings
1-3 Markings
The ame arrestors are marked with the following information:
Company Name:
Emerson Process Management, Industriestrasse 1, D-63594 Hasselroth
Type:
FA 01 or FA 02 or FA 03, depending on
conguration
Serial Number
Year of manufacturing
EC Type Examination:
0035 II G IIC
FTZU 06 ATEX 0164
Standard: EN 12874:2001
1-4 Operating Conditions
The basic operating conditions are:
Operating Temperature: -20 °C to +60 °C
Operating Pressure:
80 kPa < p0 < 110 kPa
Gas group: IIC acc. EN 12874
Not for gases and gas mixtures affecting
stainless steel (e.g. by corrosion).
There are no orientation limits for installation.
Each tting may either be used as inlet or
outlet.
The use as volume ame arrestors is limited
to type X-STREAM gas analyzers, manufac-
tured by EMERSON PROCESS MANAGE-
MENT GmbH & Co. OHG, Germany.
Emerson Process Management GmbH & Co. OHG 1-3
Instruction Manual
HASFAE-IM-H
10/2009
FA 01/02/03
Installation, Operation, Maintenance
1-5 Installation
1-5 Operating Conditions
Consider all applicable rules when arranging
and installing type FA ame arrestors.
Before connecting a pipe line remove the
sealing plug.
Depending on the ame arrestor model the
following pipe diameters are supported:
FA 01: one side
FA 02: both sides
FA 03: both sides
1
⁄8“, other side 1⁄4“
1
⁄4“
1
⁄8“
Note!
1
⁄4“ ttings may optionally be supplied with a
clamping ring for pipe diameters of 6 mm.
Installation of the FA is independent from the
direction of the in-coming ame (bi-directional
ame arrester).
When thightening the tting counterhold the
ame arrestor with a wrench placed at the
hexagon (items 5 of g. 1) next to the cap
nut (items 1, 4) to be tightened.
Always counterhold the ame
arrestor while thightening ttings; otherwise the ame arre-
stor may be damaged!
Vertical as well as horizontal mounting position is permitted.
The ame arrester can be mounted into a
female threat of M18 by means of its outside
threat. An o-ring seals the threat against the
enclosure. Place the wrench at hexagon item
6 of g. 1. Insert the ame arrestor from the
enclosure´s outside into the threat to protect
it against ambient (o-ring to come placed on
the enclosure´s outside; g. 2).
Exhaust lines must be installed in a descen-
ding way, need to be pressureless, frostprotected and in compliance with applicable
legislative requirements!
1 2 3 455 6
)
1: Gas tting
2: M18 male threat
3: O-ring
4: Gas tting
5: Hexagon for counter holding while
thightening
6: Hexagon for wrench when mounting into a M18 threat
*) FA 02 with
FA 03 with 1⁄8“ at both ends
1
⁄8“ *
1
⁄4 (alternative: 6 mm) “ *
1
⁄4“ at both ends
Fig. 1: Flame arrestor elements,
considering as example FA 01
)
Tools required for installing a FA :
1
•
⁄8“ tting: Wrench sizes
•1⁄4“ tting; Wrench sizes
• Enclosure hexagon: Wrench size 17 mm
7
⁄16“
1
⁄2“ and 9⁄16“
Fig. 2: Flame arrestor installed
into instrument enclosure
Emerson Process Management GmbH & Co. OHG1-4
FA 01/02/03
Instruction Manual
HASFAE-IM-H
10/2009
1-6 Maintenance
ExPLOSION HAzARD AND HAzARD FROM GASES !
Maintaining the FA shall be carried out considering all applicable safety
and legislative rules. Maintenance should be carried out by instructed and
trained personnel only!
Before opening gas paths they must be purged with ambient air or neutral
gas (N
to health sample gas components!
1-6 Maintenance
) to avoid hazards caused by toxic, ammable, explosive or harmful
2
Maintenance is limited to performing visual
inspections, leak testing and pressure drop
tests on at least a regular basis. The time
interval has to be operator dened, conside-
ring operating conditions and composition of
sup-plied gases.
The ame arrestor is completely welded, no
inner parts are user accessible. Therefore
the ame arrestor has to be replaced by a
new one, if
- a re occurred on the ame arrestor
element
- the housing or the ttings show visible
mechanical damages
- contamination of inner elements is
detected (e.g. by pressure drop test)
-
the ame arrestor did not pass leak testing
1-6-1 Leak Testing
The following procedure describes how to
perform a leak test with the ame arrestor
installed at the instrument.
Required tools
•
Manometer for max. 7.25 psi (500 mbar)
• Stop valve
Procedure
• Connect the manometer to the analyzer‘s
sample gas outlet to the ame arrestor´s
outlet tting (disconnect external gas
lines).
• Install the stop valve between gas inlet
tting and a Nitrogen (N
) supply.
2
• Open the stop valve until the internal gas
path is under pressure of approx. 0.725
psi/50 mbar (corresponding to approx.
19.7 inch/500 mm water column)
• Close the stop valve. After a short time for
the pressure to balance, the level must
not change over a time period of approx.
5 minutes!
When using a water lled u-tube
manometer prevent water from
entering backwards into the
ame arrestor!
Don‘t exceed the maximum
pressure applicable to the analyzer as specied in it´s instruction manual!
Emerson Process Management GmbH & Co. OHG 1-5
Instruction Manual
HASFAE-IM-H
10/2009
FA 01/02/03
Installation, Operation, Maintenance
1-6 Maintenance
Analyzer
ame ar-
stop
valve
Fig. 3: Leak Testing with U-tube Manometer
restors
Water
1-6-2 Pressure Drop Test
To measure the pressure drop at a ame
arrestor
disconnect internal and external gas
•
lines
connect a ow meter in series to the ame
•
arrestor
connect an air or nitrogen supply to the
•
ow meter
connect a manometer in a way to measu-
•
re the pressure at the ame arrestor inlet
against the outlet
• adjust the ow to 1 l/min and compare the
resulting pressure drop to the following
reference value: (5.1 ± 1) hPa.
overpressure approx.
ow meter
ame
arrestor
0.725 psi/50 mbar
Q = 1 l/min
P
manometer
Replace the ame arrestor if the measured
pressure value differs more than 10 % from
the reference value given above.
Fig. 4: Pressure Drop Test
Emerson Process Management GmbH & Co. OHG1-6
FA 01/02/03
Instruction Manual
HASFAE-IM-H
10/2009
1-7 Certicate
1-7 Certicate
Emerson Process Management GmbH & Co. OHG 1-7
Instruction Manual
HASFAE-IM-H
10/2009
FA 01/02/03
Installation, Operation, Maintenance
1-7 Certicate
Emerson Process Management GmbH & Co. OHG1-8
FA 01/02/03
Instruction Manual
HASFAE-IM-H
10/2009
1-7 Certicate
Emerson Process Management GmbH & Co. OHG 1-9
Instruction Manual
HASFAE-IM-H
10/2009
FA 01/02/03
Installation, Operation, Maintenance
1-7 Certicate
FA 01/02/03
Instruction Manual
HASFAE-IM-H
10/2009
Emerson Process Management GmbH & Co. OHG1-10
Instruction Manual
HASFAE-IM-H
10/2009
FA 01/02/03
FA 01/02/03
Instruction Manual
HASFAE-IM-H
10/2009
WORLD HEADQUARTERS
AND AMERICAS
Emerson Process Management
Rosemount Analytical Inc.
6565 P Davis Industrial Parkway
Solon, OH 44139 USA
T 440.914.1261
Toll Free in US and Canada 800.433.6076
F 440.914.1271
e-mail: gas.csc@EmersonProcess.com
www.raihome.com
National Response Center 800.654.7768
ASIA-PACIFIC
Emerson Process Management
Asia Pacic Private Limited
1 Pandan Crescent
Singapore 128461
Republic of Singapore
T 65 6 777 8211
F 65 6 777 0947
e-mail: analytical@ap.emersonprocess.com
ROSEMOUNT ANALYTICAL EUROPE
Emerson Process Management
GmbH & Co. OHG
Industriestrasse 1
63594 Hasselroth
Germany
T 49 6055 884 0
F 49 6055 884209
EUROPE
Emerson Process Management
Shared Services Limited
Heath Place
Bognor Regis
West Sussex PO22 9SH
England
T 44 1243 863121
F 44 1243 845354
MIDDLE EAST AND AFRICA
Emerson Process Management
EPM Building
P.O. Box 17033
Jebel Ali Free Zone
Dubai, United Arab Emirates
T 971 4 8835235
F 971 4 8835312
© 2006 Emerson Process Management GmbH & Co. OHG
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