SO2 measurement on flue gas desulfurization systems

Instruction manual

2 Specifications
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1.1.

Ensure safety

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CAUTION
Danger of burning on hot surfaces!
> Allow the probe shaft to cool down after a measurement before
touching it or placing it in the transport packaging.
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SO2low sensor with special SO2low gas sampling probe andSO2low sensor with heated gas sampling system
Pos: 4 /TD/Sicherheit und Umwelt/Sicherheit gewährleisten/Temperaturangaben auf Sonden/Fühlern @ 0\mod_1175693293070_79.doc @ 610 @ @ 1> Temperatures given on probes/sensors relate only to themeasuring range of the sensors. Do not expose handles andfeed lines to any temperatures in excess of 70 °C unless they
are expressly permitted for higher temperatures.
Pos: 5 /TD/Sicherheit und Umwelt/Sicherheit gewährleisten/Nur beschriebene Wartungsarbeiten durchführen @ 0\mod_1175692705195_79.doc @ 601 @ @ 1> Carry out only the maintenance and repair work on thisinstrument that is described in the documentation. Follow theprescribed steps exactly. Use only original spare parts fromTesto.
Pos: 6 /TD/Sicherheit und Umwelt/Sicherheit gewährleisten/Nicht mit Lösungsmitteln lagern @ 0\mod_1175692375179_79.doc @ 583 @ @ 1> Do not store the product together with solvents. Do not use any
desiccants.
Pos: 7 /TD/Sicherheit und Umwelt/Sicherheit gewährleisten/Keine Messung an spannungsführenden Teilen @ 0\mod_1175692564164_79.doc @ 592 @ @ 1> Do not perform contact measurements on non-insulated, liveparts.
Pos: 8 /TD/Sicherheit und Umwelt/Sicherheit gewährleisten/Produkt bestimmungsgemäß verwenden @ 0\mod_1173781261848_79.doc @ 386 @ @ 1> Only operate the product properly, for its intended purpose andwithin the parameters specified in the technical data. Do not
use any force.
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SO2low sensor with heated gas sampling system> When connecting the probe ensure correct line voltage asspecified on the type plate.
> Pull out the mains plug before opening the probe housing.
> After assembling the probe check all screw joints for leaktightness.
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2Specifications

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2.1.

Use

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For the SO2low measurement on flue gas desulfurization systems
two sets are available:22 Specifications
SO2low sensor with special SO2low gas sampling probe(0563 1251) consisting of:•SO2low sensor:
0...200 ppm, resolution 0.1 ppm•special gas sampling probe for SO2low measurement:
Length of probe shaft 735 mm incl. cone, thermocouple NiCr-Ni,Tmax. Probe shaft 220 °C, hose length 2.35 m, diameter ofprobe shaft 8 mm

SO2low sensor with heated gas sampling system (0563 2251)
consisting of:•SO2low sensor:
0...200 ppm, resolution 0.1 ppm•

Heated gas sampling tube:
Electric power supply 230 V/50 Hz, material stainless steel
1.4571, heating: >+180 °C, electrical connection to heatedhandle; thermocouple NiCr-Ni, length 1.2 m•

Heated gas sampling hose
Hose length 4 m.

Both the SO2low sensor with special SO2low gas sampling probeand the SO2low sensor with heated gas sampling system havebeen specially developed for SO2low measurements in flue gas
desulfurization systems. A measurement requires the use ofa measuring system consisting of the flue gas analyser testo 350
fitted with a SO2low sensor and a Peltier gas preparation withperistaltic pump for automatic condensate drainage, and a special
SO2low gas sampling probe or a heated gas sampling system.

3

2 Specifications
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2.2.

Technical data

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2.2.1.

SO2low sensor
FeatureValuesMeasurement range 0...200 ppm
Accuracy± 2 ppm (0...39.9 ppm)
± 5 % of mv. (40.0...200 ppm)
In order to maintain the accuracy during themeasurement, the ambient temperature
should not fluctuate more than ±5 K and theinstrument temperature of the testo 350 not
more than >±3 K).
For achieving the highest possible accuracy
we additionally recommend to applycalibration gas (ideally a test gas
concentration in the range of the measured or
expected flue gas concentration is used forcalibration) at the probe tip of the SO2low gas
sampling probe without pressure. This way
the complete system (SO2low gas samplingprobe and flue gas analyser) is calibrated or
re-adjusted.

Response time (t90) 30 s
Resolution

2.2.2.

40.1 ppm

Special SO2low gas sampling probe
FeatureValues

Probe shaft length

735 mmProbe shaft
diameter

8 mm

Application range
temperature

max. +220 °C

Hose length

2.35 m (optional lengths up to max. 10 m)

2 Specifications
Thermocouple
FeatureValuesThermocouple

1 mm insulated

Sensor typeType K (NiCr-Ni), Tol. Class 1

Measurement range -60...+1000 °Cof thermocouple

2.2.3.

Heated gas sampling system
FeatureValuesAmbient
temperature-20 °C...+50 °C

Heated probe shaft
FeatureValuesGas temperature

Heated probe shafts max. +600 °C

Power supply

0600 7630: 230 V/50 Hz

Temperature of gas >180 °C
path
Dimensions

ø25 mm, Length 1 m

Weight2400 gPower consumption 650 W
Heated sampling hose
FeatureValuesHose length4m

Hose caliber

34 mm

Material

corrugated hose

Heating
temperature area>120 °C5

3 Product description
Thermocouple
FeatureValues

Thermocouple

1 mm insulated

Sensor typeType K (NiCr-Ni), Tol. Class 1

Measurement range Tmax: 1.200°Cof thermocouple
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3Product description

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3.1.

SO2low sensor with special SO2low gas
sampling probe1Thermocouple

2Probe handle

3 Detachable probe shaft
4Cone

5 Connecting plug for thermocouple
6 Connecting plug for flue gas probe7 Hose6

3 Product description

3.2.

SO2low sensor with heated gas samplingsystem

3.2.1.

Heated probe shaft

The heated sampling tube is operated with 230 V, 50 Hz line
voltage. Power consumption: 650 Watt.
The sampling tube consists of a coaxial tube (2) with a laterally
attached junction box (3).
The coaxial tube has an outer diameter of 25 mm and its end isfitted with a G1/4" threaded socket (4) for connecting the pre-filter
or for extending with an unheated sampling tube.
A helical tubular heater to heat up the sampling tube is arranged
inside the coaxial tube (2). A thermostat regulates the temperature
to 180 °C. The controller is installed inside the junction box (3). The
power supply cable with plug connector connects the system to theelectric power supply. The sampling tube is heated up together withthe handle within a heating up period of 20 min.

3.2.2.

Thermocouple (NiCr-Ni)

For measuring the flue gas temperature there is the possibility toinsert a NiCr-Ni thermocouple through the handle and the sampling
tube.

7

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4.1.

General notes on SO2low measurement
SO2low measurement in case of presence of NH3 in flue gas(only in connection with SCR catalysts)
The start-up of a system with flue gas desulfurization(incl. SCR catalyst (selective catalytic reduction)) can takeup to 2 hours. Reason: the temperature of the components
in contact with the flue gas is decisive for the correct timingof the NH3 injection. No SO2low measurement must be
executed during this time.
Shutting down a flue gas cleaning system incl. SCR
catalyst takes about 30 min. No SO2low measurement
must be executed during this phase.
In case of NH3 being present in the flue gas witha concentration of up to max. 100 ppm NH3, a SO2lowmeasurement can only be performed over max. 15 min. In
case of a longer exposure the SO2low probe may bedamaged or one may obtain incorrect measuring results.
In flue gas cleaning facilities in which high NH3
concentrations may most likely occur, a re-calibration of theSO2low sensor or of the entire system (see technical data)
should be carried out. If, in case of a re-calibration, the SO2
end value is not stable after a period of 3 minutes, thispoints to ´sensor damage and thus to an incorrect
measuring result.
Performing measurement/adjustment
Prerequisite for compliance with the meas. uncertainty:•a stable ambient temperature during the measurement(fluctuation <±5 °C)•a temperature stable instrument (change in instrument
temperature during measurement <±3 °C).

For a highly accurate SO2 measurement the complete systemshould be adjusted with test gas before the measurement isperformed.
> Use a suitable piece of hose to connect the test connection tothe SO2low probe:8

4 Using the product
Hose data:
FeatureValuesLength100 mmMaterials

Silicone

Wall thickness

2 mm

Inner diameter

6.5...7.5 mm> Push the silicon hose over the tip of the SO2low probe so thatthe openings are completely covered.
> Perform calibration (see operating instructions testo 350, recalibration / adjustment.
The measuring accuracy of the SO2low sensor can beincreased by adjusting the cross sensitivity against CO andNO2. This requires that the testo 350 is equipped with theCO and NO2 sensor. The cross sensitivity adjustment canbe executed via the easyEmission software.
> With CO concentrations >100 ppm perform a crossadjustment of the SO2low sensor against CO.
> With N2O concentrations >10 ppm perform a crossadjustment of the SO2low sensor against NO2.
With high CO values >500 ppm no COlow sensor should be
used.

4.2.

SO2low sensor with special SO2low gas
sampling probe
Checking the thermocouple> Make sure that the thermocouple of the flue gas probe does nottouch the probe basket. Bend the thermocouple back ifnecessary.
Aligning the flue gas probe> Turn the probe to align the thermocouple so that it is freely
exposed to the flue gas flow.
> Align the flue gas probe in the flue gas duct so that the tip is in
the hot spot (area of the highest flue gas temperature).

The set is delivered fully assembled

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5

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5.1.

Changing the thermocouple

5.1.1.

SO2low sensor with special SO2low gas samplingprobe
Before replacing the thermocouple disconnect the SO2low
probe from the meas. box.
Remove the thermocouple only if defective.

1. Loosen the hose clamps (1) on the hose.

2. Pull the bend protection spring (2) at the rear hose branch (3)off the hose connection by turning it anti-clockwise.

105 Maintaining the product3. Pull the hose out of the hose connection and the bend
protection spring (2).

4. Use a screwdriver (4) to pull the thermocouple out of the plastic
bracket (5) on the probe handle (6).

11

5 Maintaining the product5 Pull the bend protection spring (7) over the thermocouple (8)and remove the cable of the thermocouple (8) from the split
hose (9).
6. Slide the bend protection spring (7) over the new thermocouple(8) (only so far, that the cable of the thermocouple can becompletely inserted into the split hose (9).
Before assembling the thermocouple (8) cover the O-ringwith lubricant, e.g. grease, to prevent the O-ring fromgetting damaged.
When inserting the new thermocouple (8) into the handle
do not press against the cable of the thermocouple, butagainst the plastic bracket.
7. Carefully thread the thermocouple (8) through the probe handle
into the probe shaft, do not buckle the thermocouple (8) while
doing this.
8. Insert the cable of the new thermocouple into the split hose (9)and guide it through the bend protection spring (7).
9. Push thermocouple (8) and hose (9) into the hose connection.
10.Push the bend protection spring (7) over the hose connection
by pressing and simultaneously turning it clockwise.
11. Fasten the hose clamps (1) on the hose.
Tightness test
(only available via Meas. Box tab)
The leak test requires a plastic cap (0193 0039, comes with theSO2low probe).
Calling up the function:>[ ] → Instrument diagnose → [OK] → Gas path check →[OK].

or>[ i ] → Gas path check → [OK].

1. Place the plastic cap on the tip of the SO2low probe so that theopenings are completely covered.

12-

The pump flow is displayed.

-

Volumetric flow rate less than or equal to 0.04 l/min:
The gas paths are leak tight (traffic light in display lights green).

5 Maintaining the product-5.1.2.

Volumetric flow rate higher than 0.04 l/min:
The gas paths are leaking (traffic light in display lights red).
SO2low probe and meas. box must be checked for leaks.

SO2low sensor with heated gas sampling system

Before replacing the thermocouple, disconnect theindustrial flue gas probe from the Testo measuring
instrument.
1. Undo all hose clamps on the gas sampling hose.
2. Remove bend protection springs from the thermocouple
clamping screw.
3. Undo the thermocouple clamping screw using a wrench (sizeSW8).
4. Carefully pull out thermocouple.
5. Remove the thermocouple cable, starting at the instrument
plug, from the slotted tube.
ATTENTION
Never pull on the connection cable when removing thethermocouple from the handle.
Damage due to inappropriate handling!
> Hold thermocouple tightly in front of the ferrule and carefully
pull it out of the handle.
6. Remove bend protection spring from the thermocouple.
7. Attach bend protection spring to the new thermocouple.
8. Insert the new thermocouple cable, starting at the instrument
plug, into the slotted tube.
9. Push the bend protection spring over the tube.
136 Tips and assistance
10. Carefully thread the new thermocouple up to 50 mm throughthe clamping screw and the probe handle into the probe shaft.
11. Screw the clamping screw by hand as far as it will go. Thentighten using a wrench (size SW8) with 1 3/4 turns.
When refitting the same clamping screw, this is tightenedwith a 1/4 turn more.
12. Carefully bend thermocouple 90° between ferrule and clamping
screw connection. Do not kink the thermocouple.
13. Push bend protection springs over the clamping screw.
14. Fasten hose clamps to the gas sampling hose.
After the assembly procedure check the screw fittings forleak tightness.
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6

Tips and assistance

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6.1.

Questions and answers

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Question

Possible causes

After 3 minutes themeasurement value has
not reached a stable endvalue.

•Excessive exposure of sensor toNH3-concentration.

•Sensor damaged by too highNH3-values.

> Replace the sensor and avoid
measurements with high NH3values.
> Check NH3-concentration using
How can I determine
whether the flue gas
available measuring technology,
e.g. short-term tubes forcontains high NH3-values?
measuring NH3-concentration.
If we were not able to answered your question, please contact yourlocal dealer or Testo´s Customer Service. Contact data see back ofthis document or website www.testo.com/service-contact.

14

6 Tips and assistance
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6.2.

Accessories and spare parts

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6.2.1.

6.2.2.

SO2low sensor with special SO2low gas sampling
probe
Description

Article no.

SO2low sensor with special SO2low gas samplingprobe0563 1251

Spare thermocouple

0430 0053

Spare SO2low sensor

0393 0251SO2low sensor with heated gas sampling system
SO2low sensor with heated gas sampling system

0563 2251

Spare SO2low sensor

0393 0251

Heated sampling tube (230 V/50 Hz)
ø0.25 mm, length 1 m, stainless steel 1.4571,
heating controlled to 180 °C

0600 7820

Heated sampling hose (230 V 150 Hz)
0600 3502
Length 4 m, including filter element and retrofit
SO2low sensor, temperature range +5 °C ... +50 °C
Thermocouple NiCr-Ni
ø2.0 mm, length 1.2 m, with 4 m connecting cable

0430 0088

PTFE V-ring seal
for connecting fitting heated sampling tube

0135.0515

PTFE V-ring seal
for screw fitting thermocouple

0135.0516

G1/4" adapter for heated probe shafts

0400.0516=== Ende der Liste für Textmarke Inhalt ===15

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