In-Situ Gas Analyzer TDLS8000

Analyzer that realizes real-time feedback and adds value to users through active use such as process control and safety control

  • Energy-efficient furnaces, etc., and safety and stable operation contribute to improving OPEX and reducing environmental impact.
  • Rapid feedback of process output to the control program, which is essential for optimal operation.
  • Release of cumbersome sampling devices and drive components from maintenance.
  • Realization of direct measurement under severe process conditions such as high temperature and corrosiveness.

The TDLS8000 is an analyzer that can solve these problems.

 

The most trusted laser analyzer designed specifically to meet all of your requirements in one robust device that is easy to operate and maintain.

 

 

Your benefits

  • Measurement with a line using a laser does not miss dangerous thermal unevenness.
  • By using a reference cell, low concentration gas is also measured with high accuracy.
  • The optical path length can be measured up to 30 m and can be measured up to 1500℃ of hot gas.
  • It can also be installed in dangerous places by acquiring Japanese explosion proof authentication, IECEx certification, ATEX certification, FM (US, Canada), KOSHA certification, NEPSI certification, and EAC explosion proof certification.
  • The sampling device is unnecessary, and it is easy to install because of its compact design.
  • Non-contact type sensor without consumables, i.e. maintenance due to leakage or deterioration is unnecessary.
  • It is possible to replace the parts on the spot while they are still installed during repair, and it is possible to reduce the plant shutdown and repair costs due to downtime.

Features: Reasons for high reliability

Enable for safe operation, safety level SIL2, and explosion proof standards.

It conforms to the certification of the safety level SIL2 in accordance with the International standards IEC61508, and can also conform to the SIL3 by duplexing the analyzer.
In addition, the solid body conforms to various explosion proof standards of the area-segmented Zone2/Div2 or Zone1/Div1 and can be installed in dangerous places.

No PC is required for direct simple operation and maintenance with intuitive 7.5-inch color touch screen HMI.

It supports 10 languages: English, German, French, Spanish, Portuguese, Russian, Hungarian, Korean, Chinese, and Japanese.
Provides all information, including trend graphs, and can be remotely installed.
TDLS8000 TouchScreen

Standard communication functions that can be checked and adjusted both on-site and at remote locations. (Installation and maintenance cost reduction)

The HART and Modbus TCP communications standards are standardized and can be setup and adjusted by our FieldMate.

Fully field repairable with 50 days of data and spectra storage

Data for 50 days are stored, and can be analyzed when installed in the process.

Compact design for one-man installation without sacrificing ruggedness

Modular design allows replacement and re-operation of components at the site

System configuration according to the plant situation

System configuration according to the plant situation
By connecting to FieldMate via standard HART communication, setting and adjustment can be easily done without HMI. A small display is standard equipment at both ends (sensor control unit and laser unit). The transmittance required to adjust the light axis is always displayed, making it easy to adjust the light axis.

System Configuration with HMI
The 7.5-inch color touch screen HMI YH8000 can improve on-site monitoring and operability.

Multi Analyzer Configuration with Remote HMI
Up to 4 TDLS8000 can be connected per HMI for remote control.

System configuration according to the plant situation

Main specifications of TDLS8000

Measurement object O2, CO, CO or CH4, CO2, CO + CO2, H2O, NH3, NH3 + H2O, H2S, HCl concentration in combustion exhaust gas and process gas
Measured components and range Measured component Min. range Max. range
O2 0-1% 0-25%
CO(ppm) 0-200 ppm 0-10,000 ppm
CO+CH4 CO 0-200 ppm 0-10,000 ppm
CH4 0-5 %
NH3 0-30 ppm 0-50,000 ppm
H2O (ppm) in non HC 0-30 ppm 0-30,000 ppm
H2O (ppm) in HC 0-30 ppm 0-30,000 ppm
CO (%) 0-20 % 0-50 %
CO (%) + CO2 (%) 0-30 % 0-100 %
 NH3 + H2O NH3 0-30 ppm 0-5,000 ppm
H2O 0-5 % 0-50 %
H2S 0-5 % 0-100 %
CO2 (%) High Range 0-1 % 0-5 %
CO2 (%) Extend.Range 0-30 % 0-50 %
H2O (%) 0-10 % 0-100 %
HCl 0-50 ppm 0-5,000 ppm
Hazardous area classifications Division 1, Zone 1; Explosion-proof/ Flame-proof type; FM, cFM, ATEX, IECEx (Pending)
Division 2, Zone 2; Non-Incendive/Type n; FM, cFM, ATEX, IECEx, KOSHA, NEPSI
SIL Certification The TDLS8000 expect digital output (2 points), digital input (2 points), valve control output (2 points), and digital communications (HART, Modbus/TCP) are certified in compliance with the following standard. IEC 61508:Functional safety of Electrical/electronic/programmable electronic related systems; SIL 2 capability for single analyzer use, SIL 3 capability for dual analyzer use.

 

Main specifications of HMI : YH8000

Display Touchscreen 7.5 inch TFT color LCD panel, 640 x 480 (VGA)
Hazardous area
classifications
Division 2, Zone2: Non-Incendive/Type n; FM, cFM, ATEX, IECEx, KOSHA, NEPSI

 

The simple and robust TDLS8000 assures the reliable and less maintenance operation of the analysis.

Fired Heater Combustion Safety and Lifecycle Management

Yokogawa TDSL8000 and CO + CH4 measurements provide reliable information to achieve:

Fired Heater Combustion Safety and Lifecycle Management

  • Combustion efficiency improvement
  • Safety improvement
  • Longer lifetime of the coils and coil hangers
  • Higher throughout of the process heating

 

Limited O2 Concentration

O2 Measurement for Safety and Process Monitoring & Control Yokogawa TDLS8000 02 analyzer achieves:

Limited O2 Concentration

  • No sampling system operation
  • Fast response analysis
  • No interference analysis
  • Less maintenance operation

 

 

TDLS8000 Activity Example
In this way, we are making use of our products.

TDLS in Waste Incinerators

O2 and HCl measurement at waste incinerators
Since this is a non-contact measurement, the measurement of exhaust gas from waste incinerators, which have a large amount of dust and corrosive components, is not problematic with TDLS™. In addition, since measurement can be performed at high temperatures, measurement and high-speed control can be realized in the vicinity of the combustion section, thereby improving the operating efficiency.

    Real-time O2 Measurement at Garbage Incinerators Improves Combustion Efficiency and Reduction in NOx and CO

 

Safety and Quality Control at Chemical Plants and Steel Works

O2 was measured for safety and quality control at chemical plants and steel works.
The TDLS eliminates the problems of maintaining sampled filters, delaying responses, and interfering gases.

 

 

Pulverized Coal Storage

O2 and CO were measured to monitor the fire prevention of coal and pulverized coal storage.
Temperature and CO-measurements are essential for detecting the ignition of coal and bag filters in storage tanks.
The reference cell can stably measure low concentrations, which were Display at 0% in other products. High-speed measurement is possible without concern of dust clogging.

 

Paper Mill

Black liquor recovery boiler in paper mill and H2S and HCl measurement in distillation kettle.
The most suitable TDLS for measuring the H2S of the exhaust gas from a soda-recovery boiler is a non-contact, sampling-free, easy-to-maintain OOC that does not require any clogging, in order to monitor the sulfur components, which is the source of the odor, and to prevent explosions. In addition, HCl in the exhaust gas of boilers using waste as fuel is also measured at high speed and accurately.

   arrow Accurate, Maintenance-free Monitoring of H2S Quantities in a Black Liqor Recovery Boiler

 

For Various Moisture Monitoring

H2O measurement for various moisture monitoring.
Measure the water content of the drying oven, such as cellophane, gypsum, plywood, paint, and food, from the % level of water to the ppm level of water in the manufacturing process, which is unpleasant.

 

 

Measured in an Electric Furnace

O2 and CO were measured in an electric furnace.
It is possible to measure the O2 and CO of the exhaust gas generated in the electric furnace and perform melting without waste.
Exhaust gas from high-temperature and high-dust electric furnaces has proven to be an installation method to suppress the effects of the exhaust gas, and can be measured without problems.

>>> Other cases

Flow to Order

This is a basic flow, although it differs depending on the customer's area and plant.
For details, please contact us without concern.

Flow to Order

*Please tell us about the status of the plant in order to propose the best specifications for your application.
The items related to the status of the factory are as follows.

  • Application
  • Setting conditions, Optical path length
  • Gas pressures, Temperature
  • Dust amount
  • Gas composition (Measurement range and Gas concentration)

 

Maintenance Flow

Return to the repair shop is unnecessary during maintenance. Parts can be replaced at the site and restored immediately.
* Since the TDLS is equipped with a self-diagnosis function and supports predictive maintenance, sudden stop of the plant can be avoided in principle.

Other-company products

Other-company products-lost time and cost

TDLS8000 : Even in the event of an outbreak

Maintenance Flow TDLS8000-early recovery and costless

 

Other services

Enhancement of service network

Servicemans from all over the world are responsible for installation and installation.

 

Related products and Maintenance parts

[Related products]

IF8000:
The Process Insulation Flange protects the TDLS8000 from process gas pressures, heat, dust, and corrosive components from the process gas.
It can be used for protection during direct mounting or bypass mounting.

Use in the following cases.

  • When the process gas pressure exceeds 500 kPa
  • If the temperature of the process is high and the temperature of the process window exceeds 55℃ even if the process window is purged.
  •  If the process has a large amount of dust and the process windows are purged to prevent dust from adhering to the process windows or corrosive components from entering the process windows.

YC8000 Flow Cell : Used to sample and measure gases at any location.
Calibration cell : Used for offline calibration and validation.
Unit connection cable : Used to connect the sensor control unit and the laser unit.

[Maintenance parts]

O-ring : Replace the O-ring when it is removed for periodic inspection, etc.

Prehľad:

Fired heaters are used for various processes in oil refining and petrochemical plants.

Prehľad:

In maintaining and managing industrial plants, monitoring waste water pH/ORP is both a legal obligation and an unavoidable necessity for protecting the environment. Monitoring without an attentive eye can lead to severe consequences.

Odvetvia:
Prehľad:

Considering safety and environmental issues such as combustion efficiency and decreasing NOX and CO in exhaust gas, it has become important to control O2 concentration in garbage incineration processes.

Prehľad:

H2S management of exhaust gas in black liquor recovery boilers is required to meet an environmental regulations.

Prehľad:

Industrial Combustion sources such as thermal cracking furnaces and, process heaters play a critical role in the process industry.

Prehľad:

The ammonia (NH3) gas is injected to remove the NOx and thus reduce the NOx concentration in the stack flue gas. With conventional NH3 analyzers that perform measurements indirectly, NH3 concentrations are obtained through a sampling system. Therefore, there are problems with the maintenance and running costs of the sampling system, and time delays in measurement. The TDLS200 Laser Analyzer is the solution to all these problems.

Odvetvia:
Prehľad:

O2 measurement in hydrocarbon vapor is used for safety monitoring in vacuum distillation columns in petroleum refining. With conventional paramagnetic oxygen analyzers, O2 concentrations are obtained through an extractive sampling system, which conditions the sample prior to being analyzed.

Prehľad:

Storage tanks are used in a variety of industries ranging from holding crude oil to holding feedstock for vinyl chloride monomer (VCM).

Prehľad:

If water is present after the dry chlorine tower in brine electrolysis plants, the downstream compressor is corroded or the product quality is deteriorated. The moisture level is measured before and after the compressor to prevent the corrosion of the compressor and the deterioration of quality.

Prehľad:

O2 measurement is used to safely recover flue gas containing a high concentration of CO from a converter furnace. With conventional paramagnetic oxygen analyzers, O2 concentrations are obtained through a sampling system to recovery flue gas. Therefore, there are problems with the maintenance and running costs of the sampling system, and time delays in measurement.

Odvetvia:
Prehľad:

Spectrometric technology can assess many critical characteristics about products, but it has limits. It can be challenging to determine when the line has been crossed

Odvetvia:
Prehľad:

With fired heaters, users hope to get greater efficiency and reduced emissions but often are disappointed. Given the number of fired heaters operating every day and their importance in the process industries, any improvements realized across the board will have huge impacts. More units can reach their potential with some simple changes in work practices and technology upgrades.

Prehľad:

SABIC is a global manufacturer of polymer resins, film and sheet products, special additives, and chemical intermediates. With operations in more than 50 countries, the company has an enormous variety of processes and plant designs to make its range of products. With so many plants, processes and products, there are frequent opportunities to make improvements with hardware and instrumentation.

A case in point is a reaction process in which oxygen gas is sparged into the reactor, and there is a resulting outlet gas stream. Proper and timely measurement of the oxygen content in this outlet stream is of key importance for reaction control and safety. Reaction progress, control of raw materials input, and reaction sequencing are all affected and dependent on the value of the oxygen concentration reading. The reactor contents and outlet stream can also be in the flammable range depending on conditions, so safety and process considerations call for continuous monitoring of the vent line contents.

TDLS system

A Two-Fold Measuring Function

The safety considerations of monitoring oxygen content in the vent line are very important. As long as the oxygen level remains below a limit, the mixture can be kept below the flammable range and will not undergo combustion. If the process allows the concentration to exceed this limit, it shuts off the oxygen flow to the sparging headers. But this safety consideration is only one of the reasons the measurement is important.

Secondly, the amount of oxygen bubbling through the liquid is an indicator of what is happening in the reaction. Oxygen consumption depends on reaction chemistry and it is a direct indication of the status of the process. Accurate reading of overhead oxygen content is especially important for control of reactant addition and temperature control.

The Challenges of Consistent Measurement

Technologies to measure oxygen in a gas stream are not new, and there are countless applications in chemical manufacturing and other industries where oxygen levels need to be monitored. Combustion processes of any size invariably use some type of oxygen sensor in the flue gas stream to maintain efficiency.

SABIC’s situation proved to be more challenging than most typical applications due to a mix of specific conditions. For many years operators struggled while working with paramagnetic and electrochemical cell sensors due to degradation of the cells, moisture and debris from the process. These sensors are both very common and used in a wide variety of oxygen measuring applications, but they have some key limitations that became apparent when reviewing this process.

Paramagnetic analyzers are sensitive to vibrations and cross-contamination from other gases. Although the application for these reactors does not call for measuring trace amounts of oxygen, there are also sensitivity issues at very low concentrations. Electrochemical cells should be replaced routinely and have sensitivity to different pressures, temperatures and cross-contamination.

Our sampling systems experienced high failure rates with electrochemical components including sampling lines being plugged from the process, filter element clogging, and failing pumps. Moreover, since an individual test during production took more than two minutes, a possibility existed that a climbing oxygen level may not be identified soon enough.

Paramagnetic and electrochemical cell oxygen analyzers have a three-month verification frequency, and the manufacturers recommended maintaining this regimen precisely. Although the testing does not take long, production was delayed in some situations while performing the verification. Delays and Emergency work due to the failures of these types of analyzers resulted in a significant amount of lost production. Due to these and other issues, a more robust oxygen analyzer technology was required.

Tuning in to Laser Technologies

One technology used commonly in combustion processes is tunable diode laser (TDL) spectroscopy, capable of detecting and measuring a variety of gasses, including oxygen, within many contexts. Theoretically, it has the capability to measure oxygen when mixed with toluene, but there was some concern about it being practical for this specific application.

A TDL analyzer sends a beam with a controlled wavelength range through the gas being analyzed to determine which products are present based on which specific wavelengths of light are absorbed. The problem in this case related to the duct size, because the transmitter and receiver should be a minimum distance apart to ensure adequate absorption.

The duct diameter here was less than half the normally recommended distance, so there was some concern as to whether it would deliver its full degree of accuracy, or even work at all. SABIC’s engineers felt the potential benefits to be gained were more than enough to justify installing one analyzer as a test. The performance would be easy to evaluate since the existing sensors were still fully operational and working in parallel.

After two weeks of operation, it was clear the Yokogawa TDL analyzers were performing very well (Figure 1). It was true that they were not delivering the full degree of precision they were capable of due to the short scanning distance, but the precision was high enough to satisfy the needs of the process.

TDLS8000

Figure 1. While the duct size for this application was smaller than is usually recommended for TDL analyzers, the tunable diode lasers reliably provided readings with a high enough degree of accuracy for the application, while eliminating the maintenance problems associated with the earlier sensing technologies.

Once installed, the new analyzers proved very reliable and required far less validation and maintenance than the earlier technologies. One issue proved to be debris carried into the duct from the process blocking the light transmission path between the transmitter and receiver. Adjustments to a nitrogen purging system and better control of the process itself minimized this effect, leading to virtually trouble-free operation.

Facilitating the Safety Function

All of these TDL analyzers have been installed for over two years now, with no failures due to the TDLA’s to date. Some units were outfitted with the Yokogawa TDLS200 analyzer, while others were outfitted with the Yokogawa TDLS8000 models. There are other manufacturers of this technology but we chose Yokogawa for this application.

There have been occasional visibility blockage incidents, but these are rare after adjustments to the purge system. Overall, these TDL analyzers have supported higher levels of production, and added another layer of protection to the unit.

Prehľad:

Yokogawa Europe expert Arthur Groenbos discusses tunable diode laser gas analysis for combustion management in fired heaters. While fired heaters are used throughout refining and petrochemical processes as the source of process heat, they carry inherent risks and costs that make operating without current technologies problematic.

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