&EPA
At-sea Incineration:
Evaluation of Waste Flow
and Combustion Gas
Monitoring
Instrumentation Onboard
the M/T Vulcanus
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RESEARCH REPORTING SERIES
Research reports of the Office of Research and Development, U.S. Environmental
Protection Agency, have been grouped into nine series. These nine broad cate-
gories were established to facilitate further development and application of en-
vironmental technology. Elimination of traditional grouping was consciously
planned to foster technology transfer and a maximum interface in related fields.
The nine series are:
1. Environmental Health Effects Research
2. Environmental Protection Technology
3. Ecological Research
4. Environmental Monitoring
5. Socioeconomic Environmental Studies
6. Scientific and Technical Assessment Reports (STAR)
7. Interagency Energy-Environment .Research and Development
8. "Special" Reports
9. Miscellaneous Reports
This report has been assigned to the ENVIRONMENTAL PROTECTION TECH-
NOLOGY series. This series describes research performed to develop and dem-
onstrate instrumentation, equipment, and methodology to repair or prevent en-
vironmental degradation from point and non-point sources of pollution. This work
provides the new or improved technology required for the control and treatment
of pollution sources to meet environmental quality standards.
EPA REVIEW NOTICE
This report has been reviewed by the U.S. Environmental Protection Agency, and
approved for publication. Approval does not signify that the contents necessarily
reflect the views and policy of the Agency, nor does mention of trade names or
commercial products constitute endorsement or recommendation for use.
This document is available to the public through the National Technical Informa-
tion Service, Springfield, Virginia 22161.
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EPA-600/2-79-137
July 1979
At-sea Incineration: Evaluation of Waste
Flow and Combustion Gas Monitoring
Instrumentation Onboard the M/T Vulcanus
by
D. A. Ackerman, R. J. Johnson, E. L Moon,
A. E. Samsonov, and K. H. Scheyer
TRW, Inc.
One Space Park
Redondo Beach, California 90278
Contract No. 68-02-2660
Program Element No. 1AB606
EPA Project Officer: Ronald A. Venezia
Industrial Environmental Research Laboratory
Office of Energy, Minerals, and Industry
Research Triangle Park, NC 27711
Prepared for
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Research and Development
Washington, DC 20460
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ACKNOWLEDGEMENTS
This effort was successfully accomplished because of the assistance and
cooperation of a large number of individuals and their respective organizations.
Equipment selection, definition of monitoring requirements, measurement of
waste flows, and analysis of combustion gases and subsequent evaluation were
accomplished by personnel from the Applied Technology and Environmental Engineer-
ing Divisions of TRW, Inc., Redondo Beach, California.
Engineering liaison to adapt test equipment for use onboard the M/T
Vulcanus was facilitated by the management of Ocean Combustion Services, B.V.,
of the Netherlands. Installation of this equipment was accomplished through
the assistance of the ship's officers and crew. Assistance in equipment
logistics was received from United Marine Services of Antwerp, Belgium.
Cooperation by the members of the French Atomic Energy Commission team is
acknowledged during the performance of the EPA supported experiments onboard
the M/T Vulcanus.
Technical direction and assistance in planning and implementation of this
program were received from several agencies within the U.S. Government. These
include the U. S. Environmental Protection Agency's Oil and Special Materials
Control Division (OSMCD), Washington D.C., and Industrial Environmental Research
Laboratory (IERL), Research Triangle Park, North Carolina.
The authors are indebted to the many individuals of all of these organi-
zations for their contribution.
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CONTENTS
Paqe
1 . INTRODUCTION, BACKGROUND AND SUMMARY 1
1.1 Introduction 1
1 .2 Background 2
1.3 Summary 3
2. DESCRIPTION OF THE M/T VULCANUS 5
2.1 General Description of Vessel and Incineration Equipment . . 5
2.2 Operational Equipment ... 8
2.2.1 Manual Sounding of Waste Tanks . . ' 8
2.2.2 Measurement of the Incinerator Wall Temperature ... 8
2.2.3 Emergency Automatic Waste Shutoff System. ..... 8
3. TEST INSTRUMENTATION 13
3.1 Flow Measurement System 13
3.1.1 Vortex Shedding Meter 15
3.1.2 Ultrasonic Meter 17
3.1.3 Equipment Costs 18
3.2 CO, C02, 02 Measurement System 18
3.2.1 Sample Probes and Lines 18
3.2.2 Gas Conditioner 20
3.2.3 Gas Analyzers 21
3.2.4 Equipment Costs 22
4. TEST OPERATIONS 23
4.1 Flow Measurement 24
4.1.1 First Burn Commentary 24
4.1.2 Second Burn Commentary 25
4.1.3 Third Burn Commentary 28
4.2 CO, C02, 02 Measurement 29
iii
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CONTENTS (Cont'd.)
Page
4.2.1 First Burn Commentary 29
4.2.2 Second Burn Commentary 31
4.2.3 Third Burn Commentary 32
4.2.4 Support of French Experiments 34
5. TEST RESULTS 36
5.1 Flow Measurement 36
5.2 CO, C02, 02 Measurement 38
5.3 Discussion of Results 41
5.3.1 Flow Measurement 41
5.3.2 CO, C02, 02 Measurement . 42
5.4 Post Test Condition of Equipment 43
5.4.1 Flow Measurement Equipment 43
5.4.2 CO, C02, 02 Measurement Equipment 43
6. REFERENCES 46
Appendix A: Operating and Maintenance Manual 47
Appendix B: Manufacturer's Operating Manuals 99
FIGURES
Number Page
1. M/T Vulcanus-Incinerator Vessel 5
2. Incinerator Feed Line Schematic 7
3. Optical Flameout Detector (Light Sensing Resistor) .... 9
4. Location of Flameout Detector 10
5. Flowmeter Installation Schematic 12
6. Flowmeters and Waste Piping in Incineration Control Room . 13
7. Test Instrumentation Installed in Ship's Meeting Room ... 14
8. Vortex Shedding Meter Schematic 15
iv
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CONTENTS (Cont'd.)
Number Page
9. Remote Flowmeter digital readouts located 1n Incineration
Control Room 16
10. Ultrasonic Meter Schematic ....... 17
11. CO/C02/02 Monitoring System Installation Schematic ... 19
12. Sampling Probe Assembly Installed Onboard Ship 20
13. Incineration Site Locations . . t 23
i>
14. Sample Strip Chart Records of Flowmeter Outputs . •. . . 26
15. Sample Strip Chart Records of CO, C02, 02 Analyzer Outputs . 40
TABLES
Number Page
1. On-Line Gas Analyzers and Conditioners 21
2. Comparison of Flowmeter vs. Sounding Tank #5 28
3. Flowmeter Data Summary 37
4. Gas Composition Data Summary 39
5. Post-Test Condition of On-Line Gas Analyzers and
Conditioners 44
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1. INTRODUCTION, BACKGROUND AND SUMMARY
1.1 INTRODUCTION
This report describes a program conducted by the U. S. Environmental Pro-
tection Agency (EPA)* onboard the M/T Vulcanus to measure waste flowrates and
concentrations of CO, C02, and 02 in the combustion gas during incineration of
industrial chemical waste. Specific objectives of the program were:
• Evaluate two types of waste flowmeters (operating on ultrasonic and
vortex shedding principles) in order to provide a more reliable and
accurate method of monitoring waste flowrates for incineration
onboard vessels.
• Evaluate a CO, C02, 02 measurement system installed to provide routine
monitoring of comoustion efficiency during waste incineration.
To accomplish these goals, the following tasks were performed:
• Evaluation and selection of available flow measurement devices, on-line
gas analyzers for CO, C02, and 02, and gas conditioners
• Procurement, assembly, and checkout of the selected flow measurement
and combustion gas analysis systems
• Shipment of all equipment to Europe and installation onboard the M/T
Vulcanus while in port for waste loading
• Operation of all equipment daily during waste incineration in the
designated North Sea burn area
• Analysis of data collected and determination of post-test condition of
all equipment
A brief background of the requirements for shipboard instrumentation and
a summary of the overall results of this evaluation are presented in this
section. Subsequent sections describe the M/T Vulcanus, selected instrumen-
tation, installation and operation of equipment, and detailed test results.
*Contract No. 68-02-2660
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1.2 BACKGROUND
The M/T Vulcanus, chartered by Ocean Combustion Services, B. V., of the
Netherlands, has been incinerating chemical wastes since 1972. The U. S. EPA
had previously contracted with TRW, Inc., to provide environmental monitoring
onboard the Vulcanus for the incineration of organochlorine wastes in the Gulf
of Mexico (Reference 1) and the destruction of Herbicide Orange off Johnston
Island in the Pacific Ocean (Reference 2). TRW personnel provided and operated
the combustion gas sampling systems for these burns and also became familiar
with the existing instrumentation and measurement methods used onboard the ship.
During at-sea incineration onboard the M/T Vulcanus, the total amount of
waste burned is usually determined by manually sounding (measuring with a tape)
the liquid level in each of 15 cargo tanks of known volumetric capacity. A
relatively accurate sounding of the tanks is accomplished at dockside before
and after each burn period. Accuracy of at-sea measurements is questionable
because the ship is subject to roll and pitch conditions. If sea conditions
become sufficiently rough, tank sounding becomes impractical and at times un-
safe. Another inaccuracy inherent in determining flow rates through tank
depletion is the fact that a residual quantity of waste is present in each tank
following a burn. This volume is increased during rough sea conditions because
of sloshing and periodic movement of the waste away from the drainage line in
the tank bottom.
For these reasons, a more reliable, direct, and accurate method of
establishing and monitoring waste feed rates is desirable. An evaluation of
commercially available flow measurement devices was conducted as part of this
overall program. As a result of this study (Reference 3), two different types
of flowmeters, ultrasonic and vortex shedding meters, were selected for
evaluation onboard the M/T Vulcanus. The objective of this evaluation was to
determine the capability of each of these meters to withstand the at-sea
environment and accurately and continuously measure waste flowrate during
incineration.
Experience in monitoring the incineration of organochlorine waste and
Herbicide Orange onboard the Vulcanus has shown that combustion efficiency is
a good indication of waste destruction efficiency. Combustion efficiency is
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one of the regulatory criteria for governing waste incineration at sea. CO
and C02 are the critical species to be determined in order to calculate
combustion efficiency. Effluent 02 concentration is also a relative indication
of combustion efficiency. A CO, C02, and 02 monitoring system for incineration
effluents from at-sea incineration was evaluated from the standpoint that the
monitoring system would be a standard piece of equipment onboard the ship and
operation would be accomplished routinely by regular shipbased personnel.
1.3 SUMMARY
The following are key accomplishments and conclusions of this test program:
1) The CO/COo/Oo monitoring equipment performed satisfactorily throughout
the test Burns onboard M/T Vulcanus. Equipment problems encountered
were minor in nature and easily resolved.
2) The combustion efficiency during the first burn was 99.983 ± 0.023%,
which was well within the Intergovernmental Maritime Consultative
Organization (IMCO) requirement of 99.95 + 0.05%. Third burn com-
bustion efficiency was 99.983 ± .017, demonstrating the consistency
of the measurement instrumentation and combustion gas composition.
3) Both the ultrasonic and vortex waste flowmeters performed satisfac-
torily, showing good agreement in flow readings and requiring no
maintenance.
4) Several days of training of personnel most likely to operate the
equipment (e.g., Chief Engineer) were sufficient to operate the CO/
C02/02 monitoring equipment satisfactorily. Only a few hours of
training were required in the operation of flowmeters.
was
5) The maximum duration of continuous CO/C02/02 equipment operation
12 hours. Based upon equipment performance, it is assumed that
continuous 24-hour operation can be achieved. Operator time can be
reduced significantly by adding automatic calibration capability to
each of the combustion gas analyzers.
6) Flowmeters were operated 24 hours per day without any problems. All
flowmeters were left on board, after the TRW crew departed the ship,
for operation by the ship's crew.
7) The estimated cost for purchase and installation of a
monitoring system based on 100% spare analyzer and gas conditioner
capability (using M/T Vulcanus experience) is approximately $40,000.
90% confidence that 99% of all data are within this range.
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8) The estimated cost for the waste flowmeters per waste flow line
(M/T Vulcanus used 3 waste flow lines) is approximately $6,000 for an
ultrasonic and $3,000 for a vortex flowmeter, including recording
equipment.
9} Based upon experience onboard M/T Vulcanus, the frequency and duration
of sampling for combustion efficiency could be reduced to three two-
hour test periods in a 24-hour day, each test period randomly selected
during one 8-hour shift operation.
10) In case of equipment breakdown, the minimum monitoring requirement to
ensure protection of the marine environment during equipment repair
is considered to be the incinerator temperature and Q£ measurement.
11) Post-test inspections of the analyzers, conditioners and flowmeters
revealed the following:
(a) Malfunction of electronic packages in two analyzers,
which were replaced with spares
(b) Evidence of wear on some conditioner valves
(c) Minor corrosion in some analyzer and conditioner
fittings
(d) Indication of gradual waste build-up in the vortex
flowmeter, which was easily cleaned
(e) No waste build-up in the piping of ultrasonic flowmeter
systems
Use of spare instruments ensured continued acquisition of combustion
efficiency data throughout the burns.
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2. DESCRIPTION OF THE M/T VULCANUS
2.1 GENERAL DESCRIPTION OF VESSEL AND INCINERATION EQUIPMENT
The M/T Vulcanus, originally a cargo ship, was converted in 1972 to a
chemical tanker fitted with two large incinerators located at the stern. The
vessel meets all applicable requirements of the Intergovernmental Maritime
Consultative Organization (IMCO) concerning transport of dangerous cargo by
tanker. Figure 1 is a picture of the vessel. Specifications and a detailed
description of the ship's equipment have been previously presented in "At-Sea
Incineration of Organochlorine Wastes Onboard the M/T Vulcanus" (Reference 1)
The following description is intended to briefly review the ship's equipment
noting any new changes or new information.
Figure 1. M/T Vulcanus-incinerator vessel
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Waste is carried in 15 cargo tanks which range in size from 115 to 574
3 3
cubic meters (m ) with an overall capacity of 3503 m . During normal operation
the waste tanks can be discharged only through the incinerator feed system.
There is, however, provision for discharging the cargo into the ocean if an
emergency arises. Piping system construction makes it possible for any tank to
be connected to either incinerator and for cargo to be transferred from one tank
to another.
Waste is burned in two identical refractory-lined furnaces located at the
stern. Each incinerator consists of two main sections, a combustion chamber
and a stack, through which the combusting gases pass sequentially. This dual
chamber configuration uses the first chamber for internal mixing and the second
for adequate residence time.
Combustion air is supplied by large fixed speed blowers with a rated maxi-
mum capacity of 90,000 cubic meters per hour for each incinerator. Although no
instrumentation is installed to monitor air flowrate, normal operation stated
by the ship's engineer is about 80,000 cubic meters per hour.
Liquid wastes are fed to the combustion system by means of electrically
driven pumps. The normal flowrate of waste is 2 to 3 cubic meters per hour per
burner. Three vortex type burners are located at the same level on the periphery
and near the base of each incinerator. Three-way valves are utilized on each
burner to provide either waste feed, fuel oil feed, or a shutoff condition.
Figure 2 is a schematic of the incinerator feed system, showing the piping and
instrumentation at one incinerator, with the other incinerator being identical.
Periodically during the incineration process the burners require cleaning.
Normally, each incinerator is shut down and the three burners are cleaned
sequentially. Sometimes single burner cleaning is performed (should only one
burner become plugged) while the remaining two burners fire waste. Cleaning is
easily accomplished, and the normal period of time to clean three burners is
less than one-half hour. During this time, incinerator temperature drop was
insufficient to warrant use of fuel oil for reheating the incinerator prior to
restart.
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FROM COMMON
FUEL OIL TANK
AUTOMATIC
SHUT-OFF
VALVE
THREE WAY VALVE
-tXj- SHUTOFF VALVE
HAND REGULATOR VALVE
FAST ACTING HAND SHUTOFF VALVE
SOLENOID VALVE
PISTON STROKE IGNITER
FLAME DETECTOR
Figure 2. Incinerator feed line schematic
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2.2 OPERATIONAL EQUIPMENT
Control of the incineration process is achieved by sounding of the waste
liquid level in the tanks currently feeding the incinerators and by measurement
of the wall temperature of the incinerator. An emergency automatic shutoff
system, which monitors various components of the incineration system for failure,
is also utilized.
2.2.1 Manual Sounding of Waste Tanks
Sounding of the liquid level in the tank is performed for two reasons.
One is to estimate the approximate time the tank will become empty, the second
is to monitor the liquid level as the level approaches the bottom of the tank.
This ensures that switching to a new tank is accomplished before a flame out
condition occurs. Normally, the center tanks on the ship are sounded when the
liquid level in the tanks is visually low. The wing tanks, however, are sounded
every hour because of their small capacity.
2.2.2 Measurement of the Incinerator Wall Temperature
Temperatures during operation of the incinerators are measured by two
platinum-platinum/10% rhodium thermocouples in each incinerator. Each pair is
located in the wall opposite one of the burners. One thermocouple provides
temperature information to the automatic waste shutoff system and is called
the controller thermocouple. A second thermocouple is referred to as the "indi-
cator" because it provides temperature information to a panel located in the
incinerator control room and to a panel ("black box") located on the bridge.
2.2.3 Emergency Automatic Waste Shutoff System
The following description of the automatic waste shutoff system utilized
by the M/T Vulcanus is based upon verbal description of the system given to the
contractor by the ship's crew.
The waste shutoff system consists of a number of different components
which can effect the closing of spring loaded solenoid valves which shut off
waste flow to each burner and simultaneously shut off power to the waste pumps.
These spring loaded solenoid valves are normally closed. During incineration,
the valves are held open by an electrically induced magnetic field. The waste
flows through the solenoid valves until the electrical current is interrupted
8
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INCINERATOR
WALL
LIGHT SENSING
RESISTOR
\
WASTE •
AIR •
VORTEX BURNER
T
\
INCINERATOR
AREA OF FLAME
VIEWED BY SENSOR
FLAME
Figure 3. Optical flameout detector (light sensing resistor)
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by a malfunction in the incineration system. Once interrupted, the malfunction
must be repaired and restart procedures implemented before incineration can
continue. These restart procedures require fuel oil startup if the incinerator
temperature has dropped below a specified minimum temperature.
The automatic waste shutoff system will stop waste flow (or fuel oil flow)
to the affected burner(s) and shut off power to the waste pumps when any one of
the following malfunctions occur:
• Waste pump overload
• Combustion air fan motor overload
• Burner pump overload
• Steering air (directs and shapes burner flame) or combustion air
failure to reach an incinerator burner
PORT FOR LIGHT SENSING RESISTOR
Figure 4. Location of flameout detector
10
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§ Open burner: A mechanical switch interrupts the electrical current
when the burner swings open away from the incinerator wall (usually
opened to remove residue during burner cleaning).
• Flame out: A light sensing resistor is located directly above each
burner to monitor the flame. This resistor operates by viewing the
flame and amplifying and conditioning the signal (see Figures 2, 3, and
4). Output of the sensor opens and closes several sets of contacts,
half of which are normally closed and half normally open (under no
flame condition). The normally closed contacts are not used in this
system. Wires which conduct the electrical current used to induce the
magnetic field for the waste shutoff valve are connected to the normal-
ly open position. During stable incineration the contacts are closed,
and the electrical current flows through the contacts, completing the
circuit which produces the magnetic field holding the waste shutoff
valve open. Upon flame blockage or electrical failure, the contacts
connected will return to normally open position, breaking the electrical
current and removing the magnetic field from the waste valve, which in
turn shuts by spring action.
• Temperature drops below minimum acceptable temperature: A thermocouple
controlled sensor interrupts the waste shutoff valve electrical current
when the incinerator temperature drops below a preselected minimum
temperature. The system used is the Plastomatic 2000 (supplied by
Withoff-Philips, Bremen, West Germany), previously discussed in
Reference 1.
Once flow has been stopped by the automatic shutoff system, any malfunctions
are repaired, and the following restart procedures are implemented:
• Manually restart waste pumps (or start fuel oil pumps if incinerator
temperatures are low enough to require fuel oil startup).
• Depress ignitor button to provide ignition flame.
• Manually open emergency shutoff valve to initiate waste (or fuel oil)
flow to burner.
t N After stable combustion is attained, deactivate manual override of the
emergency shutoff valves to return to automatic shutoff control con-
dition.
11
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08.1
MEETING ROOM
Ultrasonic Meter Controllers
.Digital
01357
Readouts
. Total izers'J"4_?J378
Vortex Meter
Controller
Readout
Totalizer
* and Data Logger
INCINERATOR ROOM
1-1/2" Vortex
Flowmeter
J
t
V Ultrasonic
Flowmeter
Transducers
~~l E
Waste Flow to Incinerator Burners
Figure 5. Flowmeter installation schematic
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3. TEST INSTRUMENTATION
Test instrumentation evaluated onboard the M/T Vulcanus included two types
of waste flow measurement devices and an on-line analyzer system for monitoring
CO, C02» and Op in the incinerator combustion gas. The following sections
describe each measurement system and its installation and operation.
3.1 FLOW MEASUREMENT SYSTEM
The flow measurement system consisted of flow sensors installed in the
ship's waste feed piping and flow readout and recording devices, as shown
schematically in Figure 5. Two basic types of flowmeters were selected for
shipboard evaluation: 1) vortex shedding, and 2) ultrasonic. Installation of
the flowmeters is shown in Figure 6. Location of the flowmeter controllers and
Figure 6. Flowmeters and waste piping in incineration control room
13
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VORTEX FLOWMETER CONTROLL
ULTRASONIC FLOWMETER CONTROLLERS
STRIP CHART RECORDERS
SODA LIME SCRUBBERS
GAS CONDITIONER
Figure 7. Test instrumentation installed in ship's meeting room
14
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recorders Is illustrated in Figure 7.
3.1.1 Vortex Shedding Meter
Vortex shedding meters are relatively new in the flow measurement field
but have become highly developed in a short time period. The basic principle
(Figure 8) is a well-known hydrodynamic phenomenon: flow past an unstreamlined
obstruction cannot follow the obstacle contours on the downstream side, and
separated layers become detached and roll into vortices in the low pressure
area behind the body. Vortices are shed periodically from alternate sides of
the body at a frequency proportional to flow velocity. A minimum pipe Reynolds
number of at least 10,000 is required to sustain formation of vortices. At
higher Reynolds numbers, the shedding frequency becomes independent of Reynolds
number and the following relationship applies:
where
f = k
r K h
f = shedding frequency
k = constant
V = fluid velocity
h = cylinder height
(1)
SHEDDING BODY
SHED VORTEX
FLOW
Figure 8. Vortex shedding meter schematic
Flow velocity is therefore directly proportional to shedding frequency.
number of methods have been developed to detect shedding frequency:
t Thermistors to detect changing direction of fluid path around
obstruction
15
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t Strain gage on tail of obstruction to detect deflection
• Ultrasonic sensing of vortices downstream of obstruction
Fischer and Porter's Series 10LV2000 liquid vortex flowmeter (Figure 6), selected
for this evaluation, utilizes a strain gage on the obstruction for detection of
shedding frequency. The meter output signal (m /hr) was displayed on the vortex
meter controller and recorded on the digital data logger and a strip chart in
the ship's meeting room (Figure 7). Flow readings (m /hr) were also displayed
on digital readouts in the incinerator room, as shown in Figure 9. Totalizers
for each meter also indicated accumulated total flow (m ) on displays in the
meeting room.
Figure 9. Remote flowmeter digital readouts located in incineration
control room
16
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3.1.2 Ultrasonic Meter
The Controlotron Series 240 ultrasonic flowmeter utilizes high frequency
sound waves to measure flow velocity by the following basic principle: the
resultant velocity of sound waves in a moving fluid is the vector sum of the
fluid velocity and the sound velocity in the fluid at rest.
TRANSDUCER
(1 OF 2)
FLOW
, v
\\
Figure 10. Ultrasonic meter schematic
As shown in Figure 10, two transducers, each capable of both sending and
receiving, alternately transmit ultrasonic pressure pulses against and then
with the direction of flow. The resultant pulse transit times can be expressed
as :
A _ (2)
C + Vcose
and t =
a u
C-Vcose
where :
t. = pulse transit time downstream
t = pulse transit time upstream
£ = distance between transducers
C = speed of sound in fluid
V = fluid velocity
e = angle between pipe axis and the acoustic path between transducers
Since frequency is the reciprocal of time period:
(3)
f . = C + Vcose
d - _
and f,, = C - Vcose
u
. - ,
and fd - fu
2Vcose
17
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where:
f. = frequency of downstream pulses
f = frequency of upstream pulses
Difference in transit time, or frequency of pulses, with and against flow is
proportional to fluid velocity and can be measured to determine flow velocity.
Installation of Controlotron flow transducers on two of the ship's waste
feed lines is shown in Figure 6. Meter controller displays, digital data logger,
and strip chart recorders are shown in Figure 7. Flow readings were also
displayed in the incinerator room for the convenience of the ship's crew
(Figure 9).
3.1.3 Equipment Costs
Costs of flowmeters and associated control and recording equipment
installed on the M/T Vulcanus were:
• Ultrasonic flowmeter controller, flow transducer cable, strip
chart recorder, mounting panels, remote flow indicator -
approximately $6,000 for each meter, plus 2-4 manhours
installation time
t Vortex flowmeter controller, flow sensor, cable, strip chart
recorder, mounting panels, remote flow indicator -
approximately $3,000 for each meter, plus 2 - 4 manhours
installation time
3.2 CO, C02, 02 MEASUREMENT SYSTEM
The on-line CO, C02, 02 measurement system consisted of sample probes and
lines, gas conditioner, calibration gases (CO, C02, 02, and zero air), purge
air line, and CO, C02, and 02 analyzers all schematically shown in Figure 11.
Figure 7 shows the system as it was installed in the meeting room onboard ship.
A soda lime scrubber was used to protect the 02 analyzer from hydrogen chloride
in the sample gas.
3.2.1 Sample Probes and Lines
The probes used for the on-line monitoring system were 1.27 cm OD (0.5 in.)
high temperature alumina tubes with a wall thickness of 1.6 mm. The alumina
material was inert and had been shown to operate well in similar environments.
Onetprobe was installed in each incinerator. Tefloir^lines connected the
18
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STACKS
Gas Sample
Cylinder Stored
Calibration Gases
MEETING ROOM
- Gas Conditioning
- Instrumentation
- Recording
(.Outside)
CO,
Analyzer
CO
Analyzer
°2
Analyzer
INCINERATOR ROOM
- Remote Digital
Readouts
* and Data Logger
Figure 11. CO/C02/02 monitoring system installation schematic
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probes to a three-way valve which was used to select either incinerator for gas
analysis. A Teflon line from the three-way valve was connected to the gas
conditioner. This system made it possible to monitor either incinerator,
although not both simultaneously. Figure 12 shows a probe installed onboard
ship.
TEFLON
INSULATED
SAMPLE
LINE
LOCATION OF
PROBE BREAK
(Burn #1
Figure 12. Sampling probe assembly installed onboard ship
3.2.2 Gas Conditioner
The gas conditioner was a Thermo Electron Corporation Model 600 sample
conditioning system which utilized a refrigeration system to remove condensate
and particulates from a continuous gas stream. This system was specifically
20
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designed to handle high concentrations of corrosive gases such as the high
hydrogen chloride content of the combustion gas sampled. The model 600 gas
conditioner supplied sufficient conditioned sample to operate all three (CO,
C02, and 02) analyzers in parallel. The dew point of the gas at the exit of
the gas conditioner is reduced to approximately 4°C (40°F).
3.2.3 Gas Analyzers
On-line monitoring of the concentrations of CO, C02, and 02 was accom-
plished by the use of two sets of gas analyzers. One set of analyzers was
installed in the system (primary analyzers), and one spare set was stored
onboard ship in case a primary analyzer malfunctioned and could not be repaired.
Besides the spare analyzers, spare parts were also carried onboard. The analy-
zers and their calibration ranges are shown in Table 1. Output signals from
each analyzer are displayed on strip charts and recorded by a digital data
logger (Figure 7).
Table 1. ON-LINE GAS ANALYZERS AND CONDITIONERS
Species Analyzed Mfg. and Analyzer Analyzer
Analyzed Model Type Range
Carbon monoxide (CO) Beckman 865 NDIR* 0-200 ppm
(primary and spare) 0-2000 ppm
0-2%
Carbon Dioxide (C02) Infrared Industries NDIR* 0-10%, 0-30%
(primary) 703
Carbon Dioxide Beckman 864 NDIR* 0-4%, 0-8%
(spare) 0-15%
Oxygen (02) Beckman 742 Electro-chemical 0-5%
(primary)
Oxygen Taylor 0247A Paramagnetic 0-5%, 0-10%
(spare) 0-25%
Gas Conditioner Thermoelectron 600
Gas Conditioner (spare) Thermoelectron 600
*Non-Dispersive Infra-red
21
-------
3.2.4 Equipment Costs
Costs of combustion gas analyzers and associated recording equipment
installed on the M/T Vulcanus were:
• CO, C02, 02 analyzers and sample gas conditioners (including 100%
spares;, sample probes, and heat trace lines, transformer, instru-
ment rack, strip chart recorders (3 plus 1 spare), remote
indicators - approximately $40,000
• Installation time - 48 manhours
22
-------
4. TEST OPERATIONS
The Vulcanus arrived at the Pan Ocean, B.V., dock located at Antwerp,
Belgium, on November 21, 1978. During the next two days, as waste was taken
onboard, the equipment for waste flowrate and combustion gas measurement was
loaded and most of it installed.
On November 23 the Vulcanus left port for the burn zone (burn zone #1, as
shown in Figure 13) and arrived early the morning of November 24. During the
travel period to the burn zone, equipment installation and final system
FEDERAL REPUBLIC
OF GERMANY
/ 2 - NEW DUTCH SURNSITE
' (BURN NO. 2)
Figure 13. Incineration site locations
23
-------
checkout and calibration were completed. Weather during the first burn was
cold and the seas were reasonably calm. The plume from the incinerator was
visible most of the time varying from a white-gray color to a slightly brown
tinted gray color. Burn #1 lasted from November 24 to December 1. The Vulcanus
arrived in port on December 4.
After loading waste for two days, the ship set out for the new burn zone
(burn zone #2, Figure 13) on December 6. Because of rough seas on the way to
the burn zone, sea water entered the lube oil and diesel fuel tanks. The ship
had to stop dead in the water to remove the seawater contaminated lube oil from
the engine. After replenishing with clean lube oil, the ship proceeded to the
burn zone. Incineration of the wastes (Burn #2) began on December 8 and
finished on December 16. The ship arrived in port on December 17.
For the third burn monitored by EPA, the ship completed waste loading
operations and left port for burn zone #1, arriving on February 3, 1979. Waste
incineration began on February 3 and was completed on February 10. Additional
data acquisition and durability evaluations were performed with both the flow-
meter and on-line gas analysis equipment. Stack emission data were also
acquired by a team from the French Atomic Energy Commission onboard for this
burn. After return to port, all of the flow measurement and combustion gas
analysis equipment was removed and shipped back to Redondo Beach, California,
for inspection, arriving on March 29, 1979.
4.1 FLOW MEASUREMENT
4.1.1 First Burn Commentary
The flowmeter system was not operational during the first burn. The
problem was found during initial startup of the flowmeters. When the valves
were opened to let waste pass through the flowmeters (see Figure 6), waste
would not flow. Pipes in the bypass system, where the flowmeters were installed,
had not been used for a long period and had become clogged. This precluded use
of the flowmeters during the first burn because the pipes could not be cleaned
during incineration. Between the first and second burn the pipes were thorough-
ly cleaned.
24
-------
4.1.2 Second Burn Commentary
During the second burn the flowmeters operated without difficulty. Once
in operation, the meters required no maintenance and were very reliable. The
following account of minor problems associated with the flowmeters is presented.
All of the problems encountered can be eliminated for future waste flow
measurement onboard an incineration vessel.
Two problems associated with the accuracy of the ultrasonic flowmeters
were found. The first relates to the inaccuracy of zeroing the flowmeter
onboard ship. There are two methods of zeroing the ultrasonic flowmeters. The
first involves zeroing under a no flow and full pipe condition. This could not
be accomplished because at no time were the waste pipes full and not flowing.
Pipes where the transducers were located are vertical, and they drain when
flow stops, A solution would be to put a valve on each end of the flowmeter
pipes so that waste could be trapped in the pipe to zero the instrument. It
might also be possible to zero the ultrasonic flowmeters if another section of
identical pipe could be filled with waste. Transducers could be placed on
this pipe, zeroed, and then transferred to the pipe in the incineration system.
However, tests would have to be performed to determine how accurate the trans-
fer procedure would be.
The second procedure for zeroing these flowmeters is to determine the
zero setting during normal flow conditions. This requires reversing the posi-
tion of the transducers on the pipe being measured. During this procedure
two signals (positive and negative) are produced which are displayed on the
digital readout of the flowmeter controller. Under normal conditions, zero is
set equal to the algebraic sum of these two signals. However, because of the
ship's pitching and rolling, an oscillating signal such as the one shown in
Figure 14 is produced on all three meters. This oscillation makes visual
averaging of the flows extremely difficult and inaccurate.
The other problem associated with the ultrasonic flowmeters is the in-
accuracy of adjusting the ultrasonic analog output (to recorders or remote
digital readouts) to match actual flow. The procedure is to set the analog
output for recording or remote digital display by adjusting the analog output
to represent a predetermined flow range as shown by the digital readout on the
25
-------
Vortex Meter
Ultrasonic Meter 'A'
(25 mm)
Ultrasonic Meter 'B'
(25 mm)
ro
CT
!- -: r-T-'-T - •-'- i- T4-(~fcr
gjjng^iptr
Sftirtt-T.';lT
Figure 14. Sample strip chart records of flowmeter outputs
-------
face of the controller. It was decided that a full scale setting of 0-10
m /hr would be ideal. Normally, with stable flow conditions, adjustment is
easily made. However, oscillating flow causes inaccuracy of setting the analog
scale. The adjustment difficulty is compounded because the computer digital
readout displays the flow every three seconds. The value presented may be at
any point on the oscillating data line (Figure 14), making visual averaging of
the maximum and minimum points very inaccurate. In the future, the analog
output could be adjusted prior to use onboard ship. In a laboratory under
stable conditions, the analog output could be adjusted with a high level of
accuracy.
Between the first and second burns when the ship was in port, two new
components for the ultrasonic flowmeters arrived and were installed. The new
components were two 50 mm (2") transducers and two matching plug-in signal
conditioning units. These components were supplied because there was a possi-
bility that the 25 mm (1") pipes installed previously (for 25 mm transducers
and conditioning units) may have caused excessive pressure drop, resulting in
too low a flowrate for the incinerators to function properly.
During the second burn, the 50 mm transducers were installed on the ship's
own 50 mm pipes. The 25 mm transducers had been placed on 25 mm standard
Schedule 40 carbon steel pipe specified by the flowmeter manufacturer and
supplied by the contractor. Operation of the 50 mm flowmeters (used only
during 2 days of Burn #2) produced data that was inaccurate wben compared with
the 25 mm transducer data and estimation of the flow by the ship's Chief
Engineer. This inaccuracy was possibly because the ship's piping was not
Schedule 40 carbon steel pipe. Inaccuracy could also have been caused by
corrosion or scaling of the inside of the pipe surface. Future tests could
eliminate this problem by supplying short sections of the proper type of pipes
and inspecting these pipes for corrosion or scaling on a periodic basis.
A comparison was made of flowrates measured by flowmeter readings and
tank depletion. This was accomplished by comparing flowmeter and tank sound-
ing data over a three hour test period. On December 15 the waste from tank 5
starboard (stb) passed through pipes 5 and 6 only which were monitored by the
ultrasonic flowmeter A (with 25 mm pipe transducer) and the vortex flowmeter,
respectively. From 1600 to 1900 hours flowmeter data and hourly tank soundings
27
-------
were taken. Table 2 presents the data obtained during this test period. The
accuracy of the tank sounding data was about + 1.0 m because of the ship's
rolling and pitching. Also, during the test period the ship's list changed
because of the waste removed from tank 5 stb. This added to the inaccuracy of
the tank sounding. As can be seen from Table 2, the flowrates obtained from
the flowmeters and tank sounding are within 1.0m. It can be concluded that
there is a reasonable correlation between the flowmeter measurements and the
tank sounding data.
TABLE 2. COMPARISON OF FLOWMETER VS. SOUNDING TANK #5
\. Time of
Flow ^v
Measurement^^
(m3) \
Ultrasonic
Flowmeter (25 mm)
Vortex
Flowmeter (38 mm)
Ultrasonic
and
Vortex
Tank
Sounding*
1600
0
o**
^ _
0**
1700
3.782
4.40
—. •-
8
1800
6.950
8.41
— _
16
1900
10.720
12.86
_ «.
26
Total o
Flow (mj)
1600-1900
10.720
12.86
23.58
26.0
Flow
Rate
nrVHR
—
--
7.86
8.6
1
*Tank sounding data has an approximate error of + 1 .0 m due to ship rolling
and pitching.
** Normalized to 0 at 1600 hrs.
4.1.3 Third Burn Commentary
Both the vortex and ultrasonic flowmeters operated satisfactorily during
the third burn period. No maintenance had been performed on these meters since
their installation on November 22, 1978, prior to the first test burn.
It was observed that the flowmeter locations utilized onboard the M/T
Vulcanus were not optimum for waste flow measurement for two reasons:
28
-------
• Flow to more than one burner was usually fed through a single
flowmeter line; therefore, separate flow to each burner could
not be directly measured.
• Some of the flowmeter lines were bypassed at times, and no
flow passed through these meters.
These conditions can be corrected by installing a flowmeter immediately
upstream of each of the six burners. Because the flowmeter measurements are
volumetric, both waste and oil mass flowrates can be measured, given the
specific gravity of the fluid. This installation would provide the following:
• Flow would be measured individually for each burner.
• Individual meter readings could be summarized to determine
total waste feedrate or for comparison with tank depletion
rates.
• Zero flow readings would indicate when each burner was shut
down for cleaning or at termination of incineration.
At the end of the third burn, the vortex flowmeter was removed from the
waste feed system. A buildup of solid residue was observed on the upstream
side of the blunt (non-streamlined) body within the vortex meter. Operation
of the vortex meter was not apparently affected by the amount of solid buildup,
but eventually inaccuracies or plugging might be expected as buildup increased.
This condition can be avoided by inspection of the meter on a monthly basis
and cleaning when necessary.
The 25 mm (1 inch) waste feed pipes used with the ultrasonic flowmeters
were also removed after completion of this burn. Neither solids buildup nor
any significant corrosion of the pipe interior were observed in either of the
two pipe sections. It is recommended that measurements of the pipe I.D. be
made to assure accuracy of the flow measurement.
4.2 CO, C02, 02 MEASUREMENT
4.2.1 First Burn Commentary
On-line gas sampling proceeded smoothly with only a few minor problems,
mostly associated with the new gas conditioning unit. Particulates in the
gas stream caused some internal plugging of sample tubing and rapid build-up
29
-------
of particles on the gas conditioner filter, which required frequent mainte-
nance, but did not present a real operational problem. Elimination of this
problem can be accomplished for future testing by addition of a particulate
filter upstream of the gas conditioner.
During operation the gas conditioner was found to contain a few nylon
tube fittings which eventually failed when exposed to high pressure corrosive
acid condensate. These fittings were replaced with stainless steel fittings
onboard ship. The stainless steel fittings were adequate for the length of
R
the sampling trips performed on this program, however, in the future, Teflonv-
fittings or stainless steel fittings with Teflon ^inserts should be used to
prevent corrosion problems during long continuous operating periods.
The ship's compressed air supply was inadequate for use in the gas
conditioner. The gas conditioner requires a continuous 90 psi air supply for
one minute to blow condensate from the condensate traps and to back purge the
sample line. The ship's air supply has too small a capacity and can deliver
up to about 130 psi for only a few seconds. For this reason, only condensate
blowdown was possible because there was not enough air for both condensate
blowdown and purging of the sample line. Compressed air bottles could be
supplied for this purpose, or a large capacity tank could be added to the system.
The primary carbon dioxide analyzer supplied by Infrared Industries, Inc
performed satisfactorily during the first day of sampling. During initial
start-up on the second day of testing, the analyzer would not span correctly.
After a period of troubleshooting, it was found that the instrument could not
be repaired onboard the ship. This analyzer was removed and the spare carbon
dioxide analyzer installed, a Beckman model 864.
On November 28, sampling of the port stack showed only ambient air was
entering the sampling system. Sampling was switched to the starboard incine-
rator stack for the remainder of the burn. Further investigation established
that the malfunction was located at either the probe, the connection of the
probe to the Teflon ^sample line, or the Teflon ^sample line itself. Because
of the high temperature near the incinerator, it was not possible to check
those areas during the burn. After the end of the burn when the incinerator
was cool, inspection showed that the probe had ruptured at the external wall
30
-------
of the port incinerator (see Figure 12).
One of the purposes of this program was to train ship's personnel to
operate the equipment. During this burn, no one was available for training
because of a shortage of engineers.
4.2.2 Second Burn Commentary
During the second burn, the Chief Engineer was available for training in
instrument operation. Three hours a day were spent in instructing how to
operate the instruments. After four days, the Chief Engineer understood how
to operate all of the equipment. If he had been available for subsequent
burns, he would have acquired enough experience to operate the instruments,
however, it is not known if he would have had enough time to operate instru-
ments along with his regular duty. In order to reduce the amount of operator
time required, automatic calibration capability could be readily incorporated
into each of the combustion gas analyzers. This could be accomplished by
adding three-way solenoid valves which would flow calibration gases through
each analyzer at selected intervals. Additional training would have been
required to be able to solve any malfunctions in the combustion gas monitoring
system other than the routine maintenance required. Members of the M/T Vulcanus
crew considered to be candidates for training and operation of the instruments
are listed below, along with a description of their present duties:
• Chief Engineer: 1) operation of incinerators, 2Opera-
tion of ship; stands 12-hour incinerator
watch
• Second Engineer: operation of engines, 6- or 12-hour
watches
• Third Engineer: operation of engines, 6- or 12-hour
watches
• Fourth Engineer: operation of incinerators; stands 12-
hour incinerator watch
• Assistant Engineers (4): 1) operation of incinerator, (2) opera-
tion of ship; stands 4-hour incinerator
watch and 4-hour engine room watch
31
-------
• Electrician: 1) operation of generators for incine-
rators,
2) maintenance of all electrical equip-
ment. |
t
Between burns, the broken probe in the port stack was replaced. The first
two days of CO, C02, and 02 measurements appeared normal (port stack only).
During the third sampling day, 02 readings were abnormally high and C02 readings
low, indicating an air leak in the sample acquisition system. Switching to the
starboard incinerator also detected high 02 levels, again indicating a definite
leak in that system as well. Investigation of the system revealed that a leak
was located at either the probes, sample lines, or connection of sample line
and probe. The leak was subsequently found to be at the sample line/probe
connection. The malfunction could not be corrected during incineration due to
the high temperatures near the probable location of the malfunction. This
problem may be resolved in the future by equipping personnel with a heat pro-
tection suit.
The on-line monitoring system could be operated continuously without any
significant operating problems. The CO analyzer was replaced with the spare
unit at the beginning of the second burn due to excessive drift. Calibration
and maintenance could be performed on a preselected schedule when on-line
monitoring would be shut down for a maximum of two hours daily (four half hour
calibration and maintenance periods). Other requirements would be the avail-
ability of personnel to monitor the instruments and perform any required
maintenance. This requires a visual inspection at least every two hours. If a
failure should occur, longer periods of ship personnel involvement would be
required to repair or remedy the failure.
4.2.3 Third Burn Commentary
Inspection of the incinerator stack sampling probes prior to the start of
the third burn revealed that both the port and starboard probes were either
broken off or burned off at the inner surface of the incinerator wall. This
could have occurred at any time between the second and third burns because the
probes were left in place during incineration while no contractor personnel were
onboard. The holes through the firebrick were plugged and had to be tapped open
32
-------
with a rod or drilled out before new probes could be inserted in the incine-
rators .
Calibration checks of the on-line gas analyzers were performed prior to
the third burn. During this checkout it was noted that two of the gas
conditioner valves were noisy and were very hot after a ten-minute calibration
period. To avoid potential problems at sea, the spare gas conditioner was
installed prior to departure for the burn site. Nylon fittings were also re-
placed by stainless steel fittings. This gas conditioner operated satisfactorily
during the burn period, requiring no maintenance other than periodic filter
changes and manual purges to remove condensate.
The CO, CC^. and C^ analyzers all performed well with only minor adjust-
ments during calibrations. Recorders operated satisfactorily and required no
maintenance other than cleaning pen tips on three or four occasions during the
entire burn.
On the sixth day of incineration, the stack sampling probes began plugging.
Purging the starboard probe with high pressure air did not unplug the probe,
but resulted in separation of the sample line from the probe. The port probe
also could not be unplugged by purging, although the sample line remained
attached. An air leak resulted in the port probe after purging which invali-
dated data acquired on the seventh day of the burn. After completion of burning
and cool down of the incinerators, it was observed that both probes were again
broken or burned off at the inner wall of the firebrick. It is more likely that
the probe had broken off because of vibration of the incinerators and had
become plugged by particles of firebrick from the incinerator wall. This
problem could be corrected by reducing the length of the probe inserted into
the incinerator, which was 38 cm (15 inches) for these tests. Previous sampling
tests (References 1 and 2) have indicated that representative samples can be
obtained at 10 to 15 cm (4 to 6 inches) from the incinerator wall.
Replacement of broken probes currently is not possible during incinerator
operation due to the high temperature near the incinerator. Replacement of
broken probes or correction of probe seal leaks could be accomplished at sea
by incorporating a retractable probe rather than a fixed probe. Mounting the
probe on a retracting mechanism, such as used for the water-cooled probes in
33
-------
previous shipboard tests (References 1 and 2), would enable repairs or replace-
ment of the probe without requiring cooldown of the incinerator. Another
approach would be to redesign the probe to provide improved load-bearing
capability and increase the fracture resistance of the probe.
4.2.4 Support of French Experiments
During the third burn, EPA supported the experiments performed by members
of the French Atomic Energy Commission team during the period of March 2 to
March 5. During this time the EPA gas sampling line and gas conditioners were
used to provide gas samples to the French instruments. A written procedure
was not provided by the French team, therefore the following description of
the experiments which they conducted is based upon verbal information received
by the contractor. A report will be available from the French, Centre D1Etudes
Nucleaires, Fontenay-Aux-Roses, Republfque Francaise.
Five (5) experiments were conducted as follows:
1) Shielded thermocouple was used to measure stack gas temperatures
for calibration of the "Pyro IV" unit (see Experiment #5).
2) Video recordings (color television camera and magnetoscope) were
made of the characteristic phases of incineration in order to obtain
a better correlation between visually observed phenomena (presence
of flame, smoke, or turbulence) and the measurement results. In
addition, gas velocities were estimated by obtaining convection
currents and particulate movement.
3) Helium was injected into the stack to obtain total gas flow by
measurement of the helium concentration in exit gas by means of a
spectrograph. Another objective of the helium trace experiment was
to determine the homogeneity of gases at the stack exit plane.
The objective of the above three experiments was to correlate the data so that,
having measurements from two of the three experiments, the results of the
third experiment could be predicted.
4) . A saturated sodium chloride solution was injected into the furnace
port and the color of the exit gases recorded on video tape to
obtain residence time in the furnace. Another objective was to
34
-------
obtain gas velocity by the use of a spectrometer and by contrasting
the video tape during injection with normal burning.
5) A "Pyro IV" unit was utilized during the test sequence. "Pyro IV"
is an apparatus designed to measure at a distance, by optical means,
the infrared radiation of a combustion gas at the stack exit. These
measurements allow a continuous determination of the gas temperature
and the concentration of CO and C$2- The basic principle of the
device is the use of selective narrow band pass filters and low pass
filters to isolate the emissions from gases such as CO (4.7 y) and
C02 (4.2 y). The unit is first calibrated against a black body and
the concentrations of CO and C02 estimated based on the intensity of
their emissions in these regions. The gas temperature is estimated
by observing the appearance (or relative brightness) of particulates
in the stack exit gases and by correcting for ambient effects and
calibration factors. The contractor provided the French with the
CO and C02 data taken during the same period for correlation with
the Pyro IV results.
35
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5. TEST RESULTS
This section presents the results of monitoring waste flowrates and com-
bustion gas composition during at-sea incineration. Flowmeter and CO, C02, 02
measurement data are summarized and discussed, and the post-test condition of
the equipment is described.
5.1 FLOW MEASUREMENT
Signal outputs from one vortex flowmeter and two ultrasonic flowmeters
were displayed visually and recorded on strip charts and an Esterline-Angus
digital data logging device (typical strip chart records of flowmeter outputs
are shown in Figure 14). Flowmeters and recording instruments used were
previously described in Section 3.1. All of the flowmeter data are summarized
in Table 3. No data were obtained during the first burn period because the
ship's by-pass lines were plugged (see Section 4.1.1).
Flowmeter readings were obtained with all meters during the second burn.
Each of the three lines being metered supplied waste to two of the ship's six
burners, as listed in the footnotes of Table 3. All meters operated continu-
ally whenever waste was flowing through the pipes, and strip chart and digital
data were acquired for 1 to 5 hour periods each day. Flow ranges and average
values for the three meters are listed in the table for each test day.
Normally, 25 mm (1") pipe size transducers were used with both ultrasonic
meters (A and B). The 50 mm (2") pipe size transducers were used with ultra-
sonic meter B as noted.
Burning rates were varied by ship personnel to compensate for changes in
the heat content of the waste being incinerated. Flowrates were increased
when a waste of lower heating value was burned, as occurred during the seventh
day of the second burn period. Waste flowrates to different burners are not
intended to be identical; each burner feed rate is individually adjusted by
the incinerator operator while observing the burner flame. Flowrates measured
36
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TABLE 3. FLOWMETER DATA SUMMARY
Burn Day
No . No .
1 1-7
2 3
2 3
2 4
2 5
2 6
2 7
2 8
3 1
3 2
3 4
3 5
3 6
3 7
Date
11/25-12/1 No
12/10 Range
Mean ,R
Std. Dev.ib
12/10 Range
Mean
Std. Dev.
12/11 Range
Mean
Std. Dev.
12/12 Range
Mean
Std. Dev.
12/13 Range
Mean
Std. Dev.
12/14 Range
Mean
Std. Dev.
12/15 Range
Mean
Std. Dev.
2/3 Range
Mean
Std. Dev.
2/4 Range
Mean
Std. Dev.
2/6 Range
Mean
Std. Dev.
2/7 Range
Mean
Std. Dev.
2/8 Range
Mean
Std. Dev.
2/9 Range
Mean
Std. Dev.
Vortex Meter (1). Ultrasonic Meter t
m3/hr [data pts]14' m3/hr [data pts]
I Ultrasonic Meter B '
m3/hr [data pts]
data - waste pipes to flowmeters plugged
3.0-3.5 [17] '
x 3.3
' J 0.16
-
5.9-7.0 [27]
6.4
+• 0.27
3.5-5.1 [5]
4.4
+ 0.68
4.0-4.6 [6]
4.4
+ 0.23
(8)
3.6-4.8 [23]
4.2
+ 0.33
4.0-5.4 [8]
4.7
4- 0.53
3.6-5.0 [45]
4.4
+ 0.36
2.6-7.1 [89]
4.3
+ 0.98
5.5-8.4 [120]
7.0
+ 0.66
4.8-10.6 [52]
7.7
+ 1.43
2.4-9.4 [42]
5.7
+ 1.78
4.5-4.6 [14]
4.58
+ 0.04
-
5.8 [1]
3.3-4.1 [5]
3.7
+• 0.36
4.9-5.4 [6]
5.2
+ 0.18
(8)
3.3-4.3 [23]
3.7
+ 0.41
7.8-8.0 [3]
7.9
+ 0.12
4.0-6.6 [52]
5.5
+ 0.80
2.5-7.0 [108]
4.6
+ 0.83
(8)
\u/
(8)
\v 1
(8)
,,,4.5-4.6 [14]
(5) 4.58
+ 0.04
,,,1.9-2.1 [12]
(7) 2.0
+ 0.08
m2.4-2.6 [8]
(7) 2.5
+ 0.06
,,,4.5-4.9 [5]
(6] 4.7
+ 0.14
,6,5.6-5.9 [6]
5.7
+ 0.10
(6)6-5-6.7 [5]
+ 0.08
,,,5.3-5.7 [8]
(6) 5.5
+ 0.13
,,,2.4-62. [55]
(0) 39
J 1.25
f8)
\u /
(8)
\u /
4.0-8.8 [54]
7.2
+ 0.97
7.1-7.4 [4]
7.2
+ 0.13
(8)
(1) Fischer & Porter series 10 LV 2000 liquid vortex flowmeter, 38 mm (1 1/2") pipe size,
in line #6 feeding burners #1 and #6.
(2) Controlotron Series 240 ultrasonic flowmeter, 25 mm (!"} pipe size transducer, on line #5
feeding burners #2 and 15.
(3) Controlotron Series 240 ultrasonic flowmeter, used on either 24 mm (1") or 50 mm (2") pipe
sizes, on line #4 or #3, respectively, feeding burners #3 and #4.
(4) Data points taken at 10 minute intervals [in brackets] from a continuous strip chart.,
(5) Standard Deviation
6) Ultrasonic flow transducer on 25 mm pipe provided by TRW.
7} Ultrasonic flow transducer on 50 mm ship's waste pipe.
8) Waste was not flowing in these pipes at this time.
37
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by both ultrasonic meters on the third day of the second burn are identical
because both meters were installed on the same line for comparison during this
period only.
Readings taken with the 50 mm (2") ultrasonic flow transducers (Burn #2,
days 3 and 4) were approximately one-half of the values expected. These trans-
ducers were installed on the ship's piping, which was not standard Schedule 40
carbon steel pipe as specified by the flowmeter manufacturer, or the pipe may
have been eroded or corroded internally (see Section 4.1.2), causing an error
in the calculated flowrates.
Flowmeter data obtained during the third burn are also listed in Table 3.
The vortex and ultrasonic meters operated continually whenever waste was flowing
through the pipes. Data were recorded for periods from 1 to 20 hours daily.
Waste flow was increased by ship personnel whenever a lower heating value waste
was incinerated, as during days 5 and 6 as shown in Table 3. The ultrasonic
meters registered zero flow on numerous occasions when flow was redirected
through other feed lines where meters were not installed (see Section 4.1.3).
5.2 CO, C02, 02 MEASUREMENT
Table 4 summarizes the combustion gas composition data acquired with the
on-line analyzers described in Section 3.2. Typical strip chart records of
analyzer outputs are shown in Figure 15. CO, COp, and Oo ranges and mean values
for each test day are listed in Table 4, along with the corresponding calcu-
lated combustion efficiencies. Combining all of the first burn data results
in a mean combustion efficiency of 99.983% with a 90% confidence level that
99% of the data will fall above 99.960%.
The total variance inherent in the measurement of a combustion gas
2
constituent, op can be expressed as the sum of several variances:
2
a = variance due to changes in sample composition
2
Instrument = varlance due to calibration errors, drift, etc.
2
cr Qa .. „ = variance due to reading data from charts, potentiometer
reading lag$j parallex> etc>
or, 0T = as + cinstruments + fading.
38
-------
TABLE 4. GAS COMPOSITION DATA SUMMARY
Burn Day
No. No.
1
1
1
1
1
1
1
1
1
2
3
4
5
6
7
1-7
Date
11/25
11/26
11/27
11/28
11/29
11/30
12/1
Points
5
13
28
18
24
30
38
11/25-156
(combined)! 2/1
2
2
2
3
3
3
3
3
3
3
1
3
4-7
1
2
4
5
6
7
1-6
12/8
12/10
13
12
(percent)
Range
Mean
Range
Mean
Range
Mean
Range
Mean
Range
Mean
Range
Mean
Range
Mean
Range
Mean
Std. Dev.
Tolerance
Band
Range
Mean
Range
Mean
12/11-14 Data invalid
2/3
2/4
2/6
2/7
2/8
2/9
2/3-3
4
54
11
10
25
Data
104
(combined)
Range
Mean
Range
Mean
Range
Mean
Range
Mean
Range
Mean
invalid -
Range
Mean
Std. Dev.
Tolerance
Band
8.4 - 8.9
8
6.3
7
.6
- 9.0
.6
7.6 - 11.8
9
.2
8.0 - 11.8
9
.9
9.0 - 15.6
11
.5
11 .0 - 16.3
13
.6
5.5 - 16.5
10
5.5
10
(3) + £
-
(4) + ?
9.0
10
14.1
14
.8
- 16.5
.7
.6
.2
- 12.0
.4
- 15.3
.6
-air leak into
5.4
7
3.8
7
10.4
12
8.0
9
4.3
8
air leak
3.8
(3) + 2.
<4> +7.
- 9.8
.3
- 10.2
.1
-16.8
.2
- 10.7
.7
- 18.1
.6
CO-
^ercent)
9.0 -
9.3
9.2
8.2 -
10.5
4.9 -
7.3
7.4 -
9.1
3.3 -
6.9
3.6 -
5.7
1.7 -
7.7
1.7 -
7.5
+ 2.5
+ 7.0
8.7 -
9.2
2.9 -
3.2
sampling
4.6 -
8.9
6.0 -
9.7
7.8 -
8.2
7.6 -
8.7
8.1 -
11.0
12.5
9.6
10.7
10.4
8.0
15.2
15.2
10.1
3.7
system
13.9
14.6
10.7
11 .0
14.6
CO
(ppm)
11 - 17
14
12-22
16
4-18
10
7 - 17
10
4 - 17.4
11
10-25
14
5 - 16
10
4 - 25
11
+
- 4
+ 11
2-10
6
8-14
11
18 - 28
22
8-37
19
9 - 16
12
8-14
12
17
12
Combustion
Efficiency
99.981-99
99.985
99.981-99
99.985
99.966-99
99.986
99.982-99
99.989
99.958-99
99.984
99.950-99
99.974
99.963-99
99.985
99.950-99
99.983
+ 0.008
+ 0.023
99.989-99
99.993
99.958-99
99.966
99.953-99
99.971
99.963-99
99.981
99.982-99
99.986
99.984-99
99.987
99.987-99
99.989
(2)
(X)
.988
.988
.995
.993
.995
.984
.994
.995
.998
.974
.984
.988
.990
.989
.991
into sampling system
- 18.9
8.3
5
3
4.6 -
9.8
+ 2.3
+ 6.5
14.6
7 - 37
16
+ 7
+ 19
99.953-99
99.983
+ 0.006
+ 0.017
.991
(1) Data points taken at 10 minute intervals
C0
C0
X 100 from a continuous strip chart.
(2) C.E.
(3) Standard Deviation
(4) There is 90% confidence that 99% of the data points fall within this range.
39
-------
CO Analyzer
C02 Analyzer
Analyzer
Figure 15. Sample strip chart records of CO, C02,02 analyzer outputs
-------
The calculation of variation of CO, C09, and 09 readings was made on an
2
overall basis, (i.e., aT), therefore, errors due to instruments, etc., have
already been included. This means that the true variation in CO, C00, and 00
2 2 9
(i.e., a ) will be less than OT. Therefore, the use of a£ to represent the
» i i
variance in combustion efficiency is conservative with respect to meeting IMCO
incineration regulations and guidelines.
Data are listed for only two sampling days during the second burn period.
After the third day it become evident that ambient air was leaking into the
system and subsequent data was invalid. The leak was isolated to an area near
the stack and could not be corrected while the incinerators were operating (see
Section 4.2.2).
Third burn data are also listed in Table 4. Gas composition data were
recorded for periods of up to 12 hours duration. Combined data from the third
burn indicate a mean combustion efficiency of 99.983% with a 90% confidence
level that 99% of the data will fall above 99.966%. These results are
essentially the same as the combined data from the first burn, performed over
two months previously, and effectively demonstrate the consistency of the com-
bustion gas composition and measurement instrumentation over that time period.
5.3 DISCUSSION OF RESULTS
5.3.1 Flow Measurement
Results of this evaluation indicate that both the vortex and ultrasonic
fiowmeters tested are capable of accurately measuring waste flowrates during
at-sea incineration. All of the meters tested performed satisfactorily, indi-
cating a good agreement in flow readings and requiring no maintenance during
the test burn. Operation of either flowmeter type, once installed, could be
performed by ship's personnel after only 3 to 4 hours training.
The vortex shedding flowmeter installed in the waste piping operated
continuously while internally exposed to the waste flow during the entire burn
period. This flowmeter does not require a "no flow" condition for setting
zero, and the meter controller has a built in calibration signal for adjusting
the analog output to recorders or remote readouts. Periodic inspections
(i.e., monthly) should be made of the internal components of the flow sensor
41
-------
which are in contact with the waste.
Ultrasonic flow transducers are externally clamped to the waste pipes and
do not contact the waste itself. A no-flow/full pipe condition for zeroing
these meters could be attained by the use of waste shutoff valves both upstream
and downstream of the transducer location. Because the accuracy of these
meters is affected by internal erosion or corrosion of the waste pipe, these
pipes should be inspected periodically, particularly after incineration of
very corrosive or particulate laden wastes. A short spool section of pipe
installed in the waste feed system would facilitate cleaning or replacement of
the pipe where the flow transducer is clamped.
5.3.2 CO, C02, 02 Measurement
The on-line combustion gas analyzers provided accurate and reproducible
CO, C02, and 02 readings during the test burns. Average combustion efficiency
calculated from CO and C02 data acquired during the first burn was 99.983 +
0.023%, well within the 99.95 + 0.05% range required by IMCO for at-sea incine-
ration of these wastes. Measurements during the latter part of the second burn
period were precluded by a leak in the sampling system near the stack which
could not be corrected while the incinerator was at operating temperature.
Third burn average combustion efficiency was 99.983 + .017, essentially identi-
cal to the first burn average and indicating the reproducibil ity of the
combustion gas composition and measurement instrumentation.
Providing spares for each of the gas analyzers proved to be a satisfactory
means of assuring continuation of data acquisition without requiring extensive
instrument repairs at sea. If both primary and backup analyzers should fail
and are not readily repairable, from a technical standpoint waste incineration
could continue only if 02 measurements and incineration temperatures, at a
minimum, were available (assuming that CO, C02 readings and combustion efficien-
cy were satisfactory prior to backup instrument failure and that no changes in
wastes or incineration conditions were initiated).
CO, C02, 02 monitoring equipment was operated continuously for periods
up to 12 hours duration without degradation of performance. It is estimated,
on this basis, that continuous 24-hour operation can be achieved. Based upon
42
-------
results obtained onboard the M/T Vulcanus, adequate data for combustion
efficiency verification could be acquired by three sampling periods, each two
hours long, during a 24-hour day. Each test period can be randomly selected
during a 8-hour shift period. This recommendation is supported by statistical
analysis of the data acquired during this program. The continuous strip charts
of each analyzer during each day were reviewed and the degree of drift esti-
mated. The maximum rate of drift observed was then converted to a maximum
change of combustion efficiency, calculated to be 9.3 X 10"4% per hour maximum
during one operating day. Results of this analysis indicated that the
recommended sampling frequency (once every shift or a maximum of 12 hours
between sampling periods) will provide adequate assurance that the combustion
efficiency will meet the IMCO requirement (99.95% + 0.05).
5.4 POST-TEST CONDITION OF EQUIPMENT
5.4.1 Flow Measurement Equipment
The vortex meter and the two ultrasonic meters tested were all operating
satisfactorily at the end of the third burn period. Flow readings were within
the expected range for both meter types. Meter controllers and recording
devices functioned properly at all times and provided continuous flow data
availability.
Post-test inspection of the vortex meter after nearly three months of
operation revealed a buildup of solid waste residue on the upstream side and
adjacent to the blunt sensing body. Inspection and cleaning of the vortex
meter on a monthly schedule would avoid extensive solids buildup.
The ultrasonic meter transducers were mounted externally on 25 cm (1 inch)
standard pipes, and remained in excellent condition. Inspection of the inside
of these pipes showed no solids buildup or significant corrosion. Without any
obstruction within the pipe, as with the vortex meter, there is no tendency for
waste buildup on the smooth pipe walls.
5.4.2 CO, C02, Og Measurement Equipment
After the return of the on-line analyzers and conditioners to the contrac-
tor, all equipment was inspected and some units refurbished as required. The
summary of the post-test condition of each instrument is presented in Table 5.
43
-------
Table 5. POST TEST CONDITION OF ON-LINE GAS ANALYZERS AND CONDITIONERS
Species
Analyzed
Carbon Monoxide
Primary
Spare
Carbon Dioxide
Primary
Spare
Oxygen
Primary
Spare
Conditioners
Primary
Spare
Mfg., Model
& (S/N)
Beckman 865
(0107963)
Beckman 864
I R-703
(369)
Beckman 864
(0101447)
Beckman 742
(0100222)
Taylor 024 7A
(272/498)
Thermoel ectron
600
(GCU-7794-95)
Thermoel ectron
600
(GCU-7795-95)
Ut
1
X
X
(1st
day)
X
X
-
X
ilizatic
Burn Nc
2
X
(1st
day)
X
X
X
-
X
)n
>.
3
X
X
X
-
X
Post-Test
Performance
Excessive drift
Good
Incorrect Span
Good
Good
N/A
Two noisy valves
but operable
one corroded valve
but operable
One noisy valve
but operable
Post-Test
Condition
No evidence of corrosion
Slight corrosion on
inlet and outlet fittings
No evidence of corrosion
Slight corrosion on
inlet and outlet fittings
Same as above
N/A
Replacement of three
valves and some fittings
required
Replacement of one valve
and some fittings
required.
Comments
Refurbishment
required for
electronic package.
Corrosion removed
by wire brushing
Refurbishment
required for
electronic package
Corrosion removed
by wire brushing
Same as above
Not used
Nylon fittings re-
placed by S/S during
test
Same as above
-------
Generally, only some of the analyzers showed slight evidence of corrosion due
to exposure to the sampled gases, which is an indication that the gas con-
ditioners performed their function well. The problems associated with analyzer
malfunction were located primarily in the electronic package. This again
re-emphasizes the need for spare instruments on board an incinerator ship
because the operator of the instruments would not be able to repair these kinds
of problems while on the ship. The conditioners showed the greatest extent of
wear and, therefore, a spare unit needs to be provided.
45
-------
6. REFERENCES
1. Clausen, J. F., H. J. Fisher, R. J. Johnson, E. L. Moon, C. C. Shin,
R. F. Tobias, and C. A. Zee. "At-Sea Incineration of Organochlorine
Wastes Onboard the M/T Vulcanus." EPA-600/2-77-196. September 1977.
NTIS PB272110/AS.
2. Ackerman, D. G., H. J. Fisher, R. J. Johnson, R. F. Maddalone, B. J. Matthews,
E. L. Moon, K. H. Scheyer, C. C. Shih, and R. F. Tobias. "At-Sea
Incineration of Herbicide Orange Onboard the M/T Vulcanus." EPA-600/2-78-
086. April 1978. NTIS PB281690/AS.
3. Johnson, R. J., "Evaluation of Waste Flow and Temperature Measurement for
Shipboard Incineration." Internal report prepared by TRW, Inc. for the
U. S. Environmental Protection Agency. May 1978.
46
-------
APPENDIX A
OPERATING AND MAINTENANCE MANUAL
47
-------
31497-6019-RU-OO
At-Sea Incineration
Shipboard Instrumentation Evaluation
EPA Contract No. 68-02-2660
Operating and Maintenance Manual
November 1978
Revised March 1979
Submitted By
TRW Defense and Space Systems Group
Applied Technology Division
01/2040, One Space Park
Redondo Beach, Ca. 90278
Approved by:
/£
A. E. Samsonov
Project Manager
Prepared For
Industrial and Environmental Research Laboratory
Office of Research and Development
Environmental Protection Agency
Research Triangle Park, N. C. 27711
48
-------
PREFACE
The Operating and Maintenance Manual was prepared to describe the CO, C0?,
and 02 and the flowmeter measurement systems, including sections on installation,
operation, sampling, data recording, data analysis, maintenance and trouble-
shooting. The manual was intended for use by the contractor during the initial
phases of the program and later by the ship's crew during a training period and
after departure of the contractor personnel.
An initial draft of the manual was used by the contractor during the first
two test burns, and was marked up based upon onboard experience. In order to
facilitate the use of the manual by the ship's crew, a German translation was
prepared and provided to the M/T Vulcanus personnel along with copies of the
equipment Manufacturer's Operating Manuals listed in Appendix B.
Additional updates of the Operating and Maintenance Manual were accom-
plished during the third test burn, and all corrections were incorporated into
the final version presented in the attached Appendix A.
49
-------
CONTENTS
1. INTRODUCTION 53
1.1 Purpose of Shipboard Measurements 53
1.1.1 Flow Measurement 53
1.1.2 CO/C02/02 Measurement 54
1.2 Test Strategy and Overall Procedures 54
1.2.1 Flow Measurement 54
1.2.2 CO/C02/02 Measurement 55
2. FLOW MEASUREMENT SYSTEM 56
2.1 Description of System 56
2.1.1 Vortex Meter 56
2.1.2 Ultrasonic Meter 56
2.2 Installation of System 56
2.2.1 Vortex Meter 57
2.2.2 Ultrasonic Meter 57
2.3 Operation 59
2.3.1 Vortex Meter 59
2.3.2 Ultrasonic Meter 60
2.4 Flowrate Calculation 61
2.4.1 Sample Calculations 61
2.4.2 Sample Data Sheet 62
2.5 Maintenance and Troubleshooting 62
2.5.1 Routine Maintenance 62
2.5.2 Troubleshooting and Repairs 64
3. CO, C02, AND 02 MEASUREMENT SYSTEM 65
3.1 Description of System 65
50
-------
CONTENTS (Cont'd.)
Page
3.1.2 Gas Conditioner 65
3.1.3 Calibration Gas and Purge Air System 65
3.1.4 CO, C02, 02 Analyzers 66
3.2 Installation of Systems 67
3.2.1 Sample Probes and Lines 67
3.2.2 Gas Conditioner 67
3.2.3 Calibration/Zero Gas and Purge Air System .... 73
3.2.4 CO, C02, 02 Analyzers 74
3.3 Calibration of System 74
3.3.1 Calibration of Primary Analyzers 75
3.3.2 Calibration of Spare Analyzers 81
3.4 Sampling 82
3.5 Combustion Efficiency Calculation
3.5.1 Sample Calculation 85
3.5.2 Sample Data Sheet 86
3.6 Maintenance and Troubleshooting 86
3.6.1 Maintenance 86
3.6.2 Troubleshooting and Repairs 89
4. DATA RECORDING SYSTEM 91
4.1 Description of System 91
4.1.1 Strip Chart Recorders 91
4.1.2 Data Logger 91
4.1.3 Remote Digital Readouts 91
4.2 Operation of the System 92
4.2.1 Operation of Strip Chart Recorders 92
4.2.2 Operation of Data Logger 92
4.2.3 Operation of Digital Readouts 94
4.3 Maintenance 94
4.3.1 Strip Chart Recorders 94
51
-------
CONTENTS (Cont'd.)
Page
4.3.2 Data Logger 95
4.4 Troubleshooting 97
5. REFERENCES 98
FIGURES
Number Page
2.1 Flowmeter Installation Schematic . 58
3.1 Physical Layout of Instrumentation in Meeting Room .... 68
3.2 Probe Holder 69
3.3 Gas Sample Line Path 70
3.4 Pathway for Lines from Meeting Room ......... 71
3.5 CO/C02/02 Monitoring System Installation Schematic .... 72
3.6 Beckman Oxygen Analyzer 77
3.7 Analyzer Controls and Adjustments 78
3.8 Infrared Analyzer Calibration and Data Sheet 83
3.9 Infrared Analyzer Calibration and Data Sheet 84
4.1 Front Panel View of Data Logger 93
4.2 Chart Loading Diagram 96
TABLES
Number Page
2-1 Vulcanus Tests - Flowmeter Data 63
3-1 Frequency of Calibration 76
3-2 Vulcanus Tests: On-Line Monitor Data 87
3-3 Frequency of Maintenance 88
52
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1. INTRODUCTION
This document presents the operating and maintenance procedures for
instruments to measure waste flowrate and combustion gas composition during
incineration of industrial chemical wastes onboard the M/T Vulcanus. Two
different types of waste flowmeters, operating on ultrasonic and vortex shedding
principles, will be evaluated as a more reliable and accurate method of monitor-
ing waste flows than previous techniques. Evaluation will also be made of a
CO/C02/02 monitoring system as compliance determination instrumentation to
provide routine monitoring of combustion efficiency during waste incineration.
1.1 PURPOSE OF SHIPBOARD MEASUREMENTS
The general purpose of shipboard measurement of waste flowrate and
combustion gas composition is described in the following paragraphs.
1.1.1 Flow Measurement
During at-sea incineration onboard the M/T Vulcanus, the total amount of
waste burned is determined by manually sounding (measuring with a tape) the
liquid level in each of 15 cargo tanks of known volumetric capacity. A
relatively accurate sounding of the tanks is accomplished at dockside before and
after each burn period. Accuracy of at-sea measurements is questionable because
the ship is subject to roll and pitch conditions. Also, as wing tanks deplete,
the ship's list changes and therefore causes inaccurate soundings. If sea
conditions become sufficiently rough, tank sounding becomes impractical and at
times unsafe. Another inaccuracy inherent in determining flow rates through
tank depletion is the fact that a residual quantity of waste is present in each
tank following a burn. This volume is increased during rough sea conditions
due to sloshing and periodic movement of the waste away from the drainage line
in the tank bottom.
For these reasons, a more reliable, direct, and accurate method of
establishing and monitoring waste feed rates is desirable. An evaluation of
commercially available flow measurement devices was conducted as part of this
53
-------
overall program. As a result of this study (Reference 1), two different types
of flowmeters, ultrasonic and vortex shedding meters, have been selected for
evaluation onboard the M/T Vulcanus. The objective of this evaluation is to
determine the capability of each of these meters to withstand the at-sea
environment and accurately and continuously measure flowrate of wastes during
incineration.
1.1.2 CO/C02/02 Measurement
Experience in the Vulcanus Shell Chemical Waste Incineration (Reference 2)
and the Herbicide Orange Incineration (Reference 3) Programs has shown that
combustion efficiency is a good indication of waste destruction efficiency.
Combustion efficiency may become one of the regulatory criteria for governing
future waste incineration at sea. CO and C02 are the critical species to be
determined in order to calculate combustion efficiency. Effluent 02 concen-
tration is also an indication of combustion efficiency. The objective of this
task is to evaluate a CO, C02, and 02 monitoring system for incineration
effluents from at-sea incineration. This system will be evaluated from the
standpoint that the monitoring system would ideally be a standard piece of
equipment onboard the ship, and operation would be accomplished by regular
shipbased personnel.
1.2 TEST STRATEGY AND OVERALL PROCEDURES
Test monitoring of waste feed rates and incinerator combustion products
will be conducted by TRW personnel during incineration of one shipload of wastes,
followed by further test monitoring by Vulcanus personnel during subsequent
burn periods for an estimated two months. During the initial burn period, TRW
personnel will instruct the ship's personnel in operation and maintenance of all
flow measurement and gas composition monitoring and recording instruments.
The overall goal is to monitor and record effluent gas composition and
waste flowrates for six hours each day during incineration.
1.2.1 Flow Measurement
Outputs of each flowmeter will be monitored by TRW or Vulcanus personnel
for up to six hours daily. The objective of this task is not to determine the
ship waste flow, but to evaluate the use of flowmeters under shipboard operating
54
-------
conditions. However, each flowmeter will be in continuous operation during
incineration and is equipped with a digital totalizer, allowing cumulative
flow readings to be checked against tank depletion times. Flow readings will
be recorded in the Vulcanus meeting room and also displayed in the incinerator
room for observation by ship's personnel.
1.2.2 CO/C02/02 Measurement
Combustion gas composition from either of the two incinerator stacks will
be monitored for up to six hours daily. However, the major objective of these
measurements is not to monitor incineration efficiency but to evaluate the
capability of the CO, C02, and 02 instruments to function effectively during
extended shipboard operational conditions.
55
-------
2. FLOW MEASUREMENT SYSTEM
The following sections describe the waste flow measurement system, its
installation and operation, flowrate calculations, and general maintenance
and troubleshooting procedures.
2.1 DESCRIPTION OF SYSTEM
The flow measurement system consists of flow sensors installed in the
waste feed piping, and flow readout and recording devices. Two basic types of
flowmeters were selected for shipboard evaluation: 1) ultrasonic and 2) vortex
shedding. Detailed descriptions and photographs of the specific flowmeters to
be used are contained in the manufacturer's operating manuals included in
Appendix B.
2.1.1 Vortex Meter
Fischer and Porter's Series 10LV2000 liquid vortex flowmeter operates by
a well-known hydrodynamic phenomenon: flow past a blunt body cannot follow
contours on the downstream side, and separated layers become detached and roll
into vortices in the low pressure area behind the body. Vortices are shed
periodically from alternate sides of the body at a frequency proportional to
flow velocity.
2.1.2 Ultrasonic Meter
The Controlotron Series 240 ultrasonic flowmeter utilizes high frequency
sound waves to measure flow velocity. Two transducers, each capable of both
sending and receiving, alternately transmit ultrasonic pressure pulses with
and then against the direction of flow. Difference in transit time results in
a frequency shift which is directly proportional to fluid velocity. Flow
transducers clamp on externally to piping.
2.2 INSTALLATION OF SYSTEM
This section describes the installation of the flow measurement
56
-------
system components onboard the M/T Vulcanus. Installation of all equipment
must occur while the ship is in port for waste loading. Figure 2.1 is a
schematic of the flowmeter and instrumentation installation. Shown in this
figure are the waste feed lines to the three burners of either incinerator.
2.2.1 Vortex Meter
A 1-1/2 inch vortex flowmeter is to be installed in one of the two-inch
burner feed lines (Figure 2.1) in the incinerator room. Direction of flow is
marked on the flowmeter body. A spacer section of 1-1/2 inch pipe, provided
by TRW, is required between the upper flowmeter flange and the ship's flow
valve, as shown in Figure 2.1. The upper flange of this spacer is left blank
to be match drilled onboard ship. Gaskets and bolts are to be provided by the
ship's crew. Electrical wiring to connect the meter to the controller is
provided by TRW. The flowmeter body must be grounded.
The vortex meter controller is to be installed in the ship's meeting room
near the top of the instrument rack, as shown in Figure 3.1. Connections to
120 volt AC power, vortex meter input signal, and 4-20 milliamp output signal
are to be made to the controller as shown in Figure 12, page 19 of the Fischer
and Porter Instruction Bulletin included in the Appendix of this document.
Installation of the strip chart recorders and remote readouts used with the
flowmeters is described in Section 4.
2.2.2 Ultrasonic Meter
Two one-inch ultrasonic flowmeters are to be installed in the remaining
two burner lines to the same incinerator as the vortex meter. It was originally
intended to install both a vortex and an ultrasonic meter in the same burner
feed line for comparison of flow readings, but a 1-1/2 inch vortex meter had to
be substituted for the 1-inch meter originally ordered because of production
problems. Therefore, it was decided to install one vortex and two ultrasonic
meters in the three burner lines to a single incinerator. This enables
measurement of the total flow to one incinerator, which may be compared to
flow rate as estimated from tank depletion times (if the tank is only feeding
one incinerator, not both, which can be done by option of the ship's crew).
Installation of the ultrasonic meters is shown in Figure 2.1. The meters
57
-------
en
oo
MEETING ROOM
Ultrasonic Meter Controllers
INCINERATOR ROOM
1" Pipe
Heat Shield
* and Data Logger
Waste Flow to Incinerator Burners
: Upper flange holes to be match drilled onboard ship
Figure 2.1 FLOWMETER INSTALLATION SCHEMATIC
-------
are clamped to. sections of 1-inch pipe. These pipe sections, provided by TRW,
have a drilled flange on one end and a blank flange on the other end. These
blank flanges are to be match drilled onboard ship. As with the vortex meter,
the gaskets and bolts are to be provided by the ship's crew.
Installation of the flow transducers is described in detail starting with
page 3-8 of the Clampitron Flowmeter Installation Manual included in the
Appendix. Setting of the spacer bar to match the sonic velocity of the waste
is performed as described in the manual. A sonic coupling compound, General
Electric RTV-118, is provided by the flowmeter manufacturer and recommended
for this application. Matched pairs of shielded cables, provided by TRW, must
be used to connect the flow transducers to the controllers.
The ultrasonic meter controllers are to be installed in the ship's meeting
room, as shown in Figure 3.1. Each controller has its own 120 volt AC power
plug, which is to be plugged into the transformer output. Cables from the
flow transducers are to be connected to the controller as marked ("upstream"
cable to "up" connector, etc.). Controller outputs to the recorders and remote
readouts are to be connected to the proper pins as listed in Table 3-3 of the
Clampitron Installation Manual. Recorder and remote readout installation is
described in Section 4.
2.3 OPERATION
This section describes the operation of the vortex and ultrasonic flow-
meters. Operation of the recorders and remote readouts used with the meters
is discussed in Section 4.2.
2.3.1 Vortex Meter
The vortex meter signal conditioner is factory preset according to the
input signal, output signal, and power source selected. After the 120 volts
AC power supply is energized, flow measurement will commence with flow through
the meter. Generally, the piping system will be purged of entrapped air after
several minutes of flow. During any period when there is flow through the
meter, the flowrate will be displayed on the "% of Full Scale" indicator, the
7-digit counter will register the cumulative volume, and the analog output will
be available for recording and remote display.
59
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No calibration is required for normal operation if the signal conditioner
.is used with the flowmeter body for which it was programmed at the factory.
Therefore, signal conditioners should be used with the proper meter body (as
identified by serial numbers) for maximum accuracy. For this evaluation pro-
gram, a different signal conditioner may be used only if it is not practical
to change the flowmeter body during a burn period.
Prior to operation of the meter and as a checkout after installation, an
internal check of the signal conditioner should be conducted. This procedure
is performed by moving the option screw from position 1 to position 2, as
described on page 22-23 of the Fischer and Porter Instruction Bulletin in the
Appendix. (Note: always de-energize the signal conditioner power supply before
changing programming screw options.) An internal test signal of 58.6 Hz will
thus be generated for verification of proper function of the "% of Full Scale"
indicator, the cumulative flow counter, and the analog output.
The two vortex flowmeters are originally set at 20 mill lamps output (full
3 3
scale or 100% flow) at .167 m /min or 10.0 m /hr. Nominal flow expected for
each burner onboard the M/T Vulcanus is approximately 2 to 3 m /hr, which would
give a reading of 60-90% of full scale because each flowmeter measures the flow
to two burners, one on each incinerator. If it is desired to change the full
scale span setting (within 33% to 115% of maximum meter capacity), this may be
accomplished by simply altering the numerical span factor screw positions
within the signal conditioner, as described in detail on page 25 of the Fischer
and Porter Instruction Bulletin.
2.3.2 Ultrasonic Meter
The ultrasonic meter flow display computer is factory programmed for the
specific pipe size and material provided: 1" carbon steel schedule 40 standard
pipe. Installation of the flow transducer on the pipe was previously
described in Section 2.2.2.
After the transducer and flow display computer are installed, and before
first turning power on, check the following:
1 . On the control panel , located at the upper right corner
of the flow display computer, check that:
a. SCALE switch set to INT.
60
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b. STAB switch set to INT.
c. AUT-HI switch set to AUT.
d. NR module in position and marked with appropriate
Reynold's Number range.
e. EMPTY potentiometer in counterclockwise position.
2. Check that all modules are fully inserted and all cable
connectors are engaged.
3. Ensure that the pipe is full and that the transducers are
mounted using proper coupling compound.
After a warm up period of at least three minutes, a check of the transducer
spacing should be performed to compensate for the sonic velocity of the
specific waste fluid to be incinerated. The spacer bar is to be initially set
at the index marking 7. If the voltmeter reading on the display coputer
panel reads different from 7, loosen the spacer bar clamp and one transducer
mounting strap. Slide the loose transducer (held tightly against the pipe)
until the spacer bar marking and the voltmeter reading are the same, then
tighten the spacer bar and transducer clamp.
Operation of the flowmeters is described in detail starting on page 4-1
of the Clampitron Instruction Manual. Particular attention should be made of
pages 4-7 and 4-8 for a step-by-step listing of the operating procedures.
2.4 FLOWRATE CALCULATION
2.4.1 Sample Calculations
Waste flowrates are either read directly from the meter display or
calculated for each flowmeter type as described below.
Vortex Meter
Flowrate at full scale (100% flow) and the flow volume for each totalizer
count are noted on the face of each vortex meter signal conditioner. Initial
setting of each meter is .167 m3/min (or 10 m /hr) at full scale and .01 m for
each totalizer count. If the % of full scale reading during testing is .40%,
then the flowrate is calculated as follows:
40% of full scale X 10 m3/hr, or 4 m /hr.
61
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Average flowrate may be calculated from the totalizer count change over a
known period of time. If the totalizer count change is 1500 over a six-hour
interval, for example, the average flow rate for that period is calculated as
fol1ows :
1500 counts X .01 m /count _ o cn m3/hv,
. — - •»—-j_," — - - - — £ B C3U in /iii •
hours
If the specific gravity (S.G.) of the waste is known, the mass flowrate
may be calculated from the volumetric flowrate:
m3
2.50 — X 1.2 S.G. = 3.00 tonnes/hr. (1.2 S.G. assumed)
Ultrasonic Meter
Flowrate is displayed directly in either liters/minute or m /hr fay the
ultrasonic meter flow computer. The range switch may be left on liters/minute
to obtain more significant digits, and converted to m /hour:
an fi liters Y 1 meter v 60 min _ 9 A^K m3,. „
40'6 -5Tn X 1000 liter X ~hF" ' 2'436 m /hr'
Average flowrate over extended time periods may be calculated from the
totalizer count change. Each count on the ultrasonic meters represents one
liter, or .001 m ,
16000 counts X .001 m3/count 0 C7 3..
6-FouFI = 2'67 m /hr'
The counter may also be set at "FASTOT," or one count = .0001 m3/hr.
Mass flowrate may be calculated from volumetric flowrate, knowing the
specific gravity (S.G.) of the waste =
2.67 m3/hr X 1.2 S.G. = 3.20 tonnes/hr.
2.4.2 Sample Data Sheet
Table 2.1 is a sample of the data sheets provided for recording flowmeter
readings. At the bottom of the data sheets are the equations for calculating
m /hr for the vortex meters, and the average volumetric and mass flow rate for
both meter types.
2.5 MAINTENANCE AND TROUBLESHOOTING
2.5.1 Routine Maintenance
Both of the meter types tested have no moving parts, and the ultrasonic
62
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DATE
Table 2.1
VULCANUS TESTS - FLOWMETER DATA
WASTE SPECIFIC GRAVITY
TIME
AVERAGE
FLOWRATE
VORTEX M
METER FA!
% FULL
SCALE
M3/
TON
RTFR *
".TOR RURNFR ^
M /LID \ * /
/ nt\
TOTALIZER
READING
HR(b>
ULTRASON
METER FA
% FULL
SCALE
M3,
rr MFTFR #
CTOR RURNFR #
M3/HR
TOTALIZER
READING
1
,HR(b)
TONNES/HR^
ULTRASONIC METER 1
METER FACTOR
% FULL
SCALE
M3/
TONf
BURNER f"
M3/HR
TOTALIZER
READING !
i
*
-^b)
(a) % FULL SCALE x MVHR FULL SCALE
(b) TOTALIZER COUNTS X METER FACTOR
TOTAL TIME
(c) M3/HR x SPECIFIC GRAVITY
-------
meter has no parts in contact with the waste fluid (ultrasonic transducers
clamp externally to the flow pipe). Maintenance is therefore minimal and
consists mainly of routine checks for loose connections or worn wiring between
the flowmeters and the flow controllers. Internal surfaces of the vortex meter
should be checked for buildup of solids or corrosion every month or two.
A spare vortex meter and controller are provided if one becomes inoperable.
As mentioned previously in Section 2.3.1, the vortex meter should be operated
with its matched controller; however, only slight accuracy is lost if a
different controller is substituted. This would be acceptable during a test
burn rather than attempt to change meter bodies in the waste piping, which
should be done only in port between burns.
Although both ultrasonic meters are intended to be used, operation of only
one would satisfy the objectives of this evaluation program. If one transducer
or flow display computer becomes inoperable, the other transducer or plug in
panels from the second unit may be substituted, as long as one ultrasonic
system is functioning.
2.5.2 Troubleshooting and Repairs
'i f
In order to identify causes of malfunctions and perform repairs of either
flowmeter type, a thorough understanding of the theory of operation is
required. A technical discussion of this type and a troubleshooting guide can
be found in the meter instruction manuals located in the appendix. The
intention of this section is to present some of the problems that may be
encountered during operation of the total system and solutions to these problems.
Vortex Flowmeter
No problems were encountered.
Ultrasonic Flowmeter
During initial startup of system, ensure that the transducers have been
placed on a clean and rust-free section of pipe. If the empty signal continues
after following the steps outlined in the Clampitron Manual, pull the power
supply board out and switch the signal power switch to the "Hi" position, then
proceed as described in the manual.
64
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3. CO, C02, AND 02 MEASUREMENT SYSTEM
The following sections describe the CO, C02, and 02 measurement system
and the installation, operation, maintenance, and troubleshooting of the
system. Also, examples of combustion efficiency calculations are included.
3.1 DESCRIPTION OF SYSTEM
The CO, C02, and 02 measurement system consists of sample probes and lines;
gas conditioner; calibration gas and purge air system; and CO, C02, and 02
analyzers.
3.1.1 Sample Probes and Lines
The probe to be used is a 1.27 cm OD high temperature alumina tube with
wall thickness of 1.6 mm. This ceramic material is inert and has been shown
to operate well in similar environments on previous programs. One of these
probes is to be installed in each incinerator stack. Insulated Teflon lines
connect these two probes to a three way stack gas select valve. This valve is
connected to the gas sample shut-off valve on the valve panel inside the
meeting room via a short piece of insulated Teflon line. The sample then flows
through a short piece of Teflon line to the gas conditioner.
3.1.2 Gas Conditioner
Thermo Electrons Model 600 input sample gas conditioning system is
designed to remove condensate and particulates from a continuous gas stream.
This system is specifically designed to handle high concentrations of corrosive
gases such as the high chloride content of the combustion gas to be sampled.
The model 600 gas conditioner can supply sufficient conditioned sample to
operate all three (CO, C02, and 02) analyzers in parallel. The dew point of
the gas at the exit of the gas conditioner is reduced to 4°C (40°F).
3.1.3 Calibration Gas and Purge Air System
Two high pressure gas cylinders contain the gases needed to calibrate and
65
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zero the three analyzers. One gas cylinder contains zero grade nitrogen for
zeroing all the analyzers. The other cylinder contains a mixture of gases:
100 parts per million (ppm) of CO, 12% C02, and 15% 02 in nitrogen. The
calibration gas mixture was ordered to calibrate the analyzers at the proper
range for each measured constituent, based on previous knowledge of the
approximate composition of the combustion gas.
The purge air needed by the gas conditioner is supplied by the ship's
compressed air supply. The high pressure air from the ship is stepped down to
100 psig (used by the gas conditioner) by a regulator located in the meeting
room. This regulator includes oil and water traps.
3.1.4 CO, C02, 02 Analyzers
There are two analyzers to measure each constituent (CO, C02> and 02) in
the combustion gas. The analyzers are split into primary and spare analyzers.
The primary analyzers consist of the Infrared Industries model 703 C02 analyzer,
the Beckman model 865 CO analyzer, and the Beckman model 742 Op analyzer.
The spare analyzers are Beckman model 864 C02 analyzer, another Beckman model
86.5 CO analyzer, and the Taylor model OA273 02 analyzer.
The CO and C02 analyzers operate under the principles of infrared absorp-
tion. During operation a portion of the infrared radiation is absorbed by the
component of interest in the sample, with the percentage of infrared radiation
absorbed being proportional to the component concentration. The amount
of absorption can then be measured, amplified, and the reading displayed which
is directly proportional to the amount of the component in the gas.
The Beckman model 742 02 analyzer consists of an amplifier unit and an
amperometric oxygen sensor (located directly behind the amplifier). The sensor
responds to the partial pressure of oxygen. The amplifier unit measures the
magnitude of the sensor signals, which is amplified and the reading
displayed.
The Taylor model OA273 02 analyzer operates on the paramagnetic properties
of the oxygen. The analyzer measures the intensity of the paramagnetic
properties of the gas stream which varies as the amount of oxygen varies in the
gas stream. The intensity is amplified, and the reading is displayed.
66
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3.2 INSTALLATION OF SYSTEMS
The installation of the CO, C02, and 02 measurement system is discussed
in the following subsections. Figures 3.1 through 3.5 are presented to show
the location of sample probes and lines, gas conditioner, calibration gases,
CO, C02, 02 analyzers, and recorders. Procedures to be used during installation
of this equipment are described.
3.2.1 Sample Probes and Lines
Sample probes (one in each stack) are held in place using the probe holders
shown in Figure 3.2. The probe holders are secured by bolts to the stack. The
ceramic probes are inserted through the probe holder and extend into the stack
so that approximately 15" of probe extends into the stack (towards the center)
beyond the inner wall.
The sample line connects to the ceramic probe with 1/2" stainless steel
swage lock fittings using asbestos packing for a seal. This line is first
tied securely to the railing surrounding the stack to minimize any movement
of the line that could fracture the fragile ceramic probe. The sample line
should be tied securely, but with no stress or pull upon the ceramic probe, as
this might also fracture the probe. The line should be tied at various points
along the path to the meeting room, and should be installed so that there are
no low points along the pathway from sample probe to the meeting room. This
is to ensure that liquid cannot remain in the line, freeze, and thereby obstruct
the flow of sample. The three-way valve used to select port or starboard
stack gases should be installed so that it is easily accessible from the bridge
deck. A proposed pathway for the sample lines and location of the three-way
valve is shown in Figures 3.3 and 3.4.
3.2.2 Gas Conditioner
The gas conditioner is to be installed in the meeting room next to the
instrument racks as shown in Figure 3.1.
Connections to the gas conditioner can be seen in Figure 3.5 and consist
of sample line, calibration gases, purge air, three separate outputs for
analyzers (one for each analyzer), one by-pass, two blowdowns, and a power
connection.
67
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FRONT VIEW
~r
7*"
28"
T 1
55"
24"
35"
VORTEX
CONTROLLER
SWITCH
PANEL
DATA LOGGER
. J_
I
RECORDERS
(8)
SODA LINE —
SCRUBBER
2
POR
ULTRASONIC
CONTROLLERS
—14" »[•• 14"-*- /
T
co2
ANALYZER
CO
ANALYZER
°2
ANALYZER
i
i
THOLE -^^
INSTRUMENT
RACK
SPARE
INSTRUMENT
STORAGE
CLOSET
«• — 22.8'J — »•
TRANSFORMER
G*5. VALVE
CON- >ANEL
DITIONER ANEl
REGULATORS
W 9-
-------
ANGLE BLOCK
Figure 3.2 Probe Holder
-------
INCINERATOR STACK
GAS SAMPLE LINES
Figure 3.3. Gas sample line path
-------
INCINERATOR STACK
DIGITAL READOUTS FLOWMETERS
,/ MEETING
I-'. ROOM
LEGEND:
—^ GAS SAMPLE LINE
- FLOWMETER LINES
— DIGITAL READOUT LINES
—— GAS CONDITIONER SLOWDOWN - INSTRUMENT VENT
Figure 3.4. Pathway for Lines from meeting room
-------
STACKS
Gas Sample
Cylinder Stored
Calibration Gases
MEETING ROOM
- Gas Conditioning
- Instrumentation
vent
t\3
INCINERATOR ROOM
- Remote Digital
Readouts
C02 Digital
Readout
CO Digital
Readout
02 Digital
Readout
* and Data Logger
Figure 3.5. CO/C02/02 monitoring system installation schematic
-------
Installation Procedure
1) Connect high pressure (100 psig) air from regulator to the fitting
labeled "purge air" on the rear panel.
2) Connect unit to 115V power supply from power converter and turn on
main power. Two to three hours of warm-up time is necessary (if bath
has not been previously cooled) for the water bath to cool to 37° to
40°F (pump will not work until temperature of bath is below 45°F).
3) Plumb sample line from valve panel to fitting marked "sample inlet" on
rear panel.
4) Plumb sample outlets marked 1, 2 and 3 to gas analyzers CO, C09, 0~
respectively. ^ i
5) Plumb calibration/zero gas line from valve panel through the 1/4"
swagelock Tee to the three inlets marked "span inlets" on rear panel.
6) Plumb the by-pass to the instrument outlet manifold located on the
lower rear side of the instrument rack nearest the gas conditioner.
7) Plumb both blowdowns to each drain line which exits via the stern wall.
a) Condensate from trap nearest the front of the gas conditioner
to line discharging directly from room.
b) Condensate from rear trap to container behind gas conditioner
with vent line exiting room. (This container must be emptied
manually-once a burn).
8) Turn pump on and adjust the flowmeter valves for about 4 CFH flowrate.
NOTE: Pump may not start unless flowmeter valves are open.
3.2.3 Calibration/Zero Gas and Purge Air System
Calibration gases which are used by the gas analyzers are located on the
walkway outside the meeting room as shown in Figure 3.1. The following
describes the connection of the calibration/zero gases in the gas cylinders to
the gas conditioner via the valve panel. This panel includes the calibration
gas shutoff valve, zero gas shutoff valve, and calibration/zero gas select valve.
Installation Procedure
1) Connect regulators to gas cylinders (using conversion fittings if
necessary).
2) Connect 1/4" polypropylene (pp) tubing from regulator through stern
wall of ship and connect to valve panel. Calibration gas and zero gas
cylinders should be connected to the calibration gas shutoff valves.
73
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3) Check to see that 1/4" pp tubing connects shutoff valves to
calibration/zero gas select valve; if not, connect as shown in
Figure 3.5.
4) Check to see that 1/4" pp tubing connects calibration/zero gas select
valve to 1/4" SS Swagelock tee and from the tee to the three "span"
inlets on the gas conditioner; if not, proceed to do so as shown in
Figure 3.5.
3.2.4 CO, C02, 02 Analyzers
Figure 3.1 shows the physical location of the three primary CO, C02, and
02 analyzers. In the case of back-up instruments, the only difference in
installation will be the Taylor 02 analyzer (comments concerning differences in
installation of the Taylor analyzer will be noted).
Connections to the instruments will include gas sample line from gas
conditioner, vent line to manifold system, output to recording instruments and
115V power to the analyzer.
Installation Procedure
1) Mount analyzer on rack as shown in Figure 3.1. Each analyzer has its
own type of front mounting plate (the Beckman Model 864 and 865, C02
and CO respectively, front plates are interchangeable) which is
attached to the rack to help support the analyzer. The backup Taylor
02 analyzer has no mounting plate but can be temporarily located on
top of the gas conditioner (taped down if necessary). During mounting
of the analyzers, the CO and 02 analyzers must be supported by runners
which support the length of the analyzer on each side. These runners
can be adjusted vertically with a wrench (loosen and slide, then
tighten).
2) After the instrument is mounted and secure, attach 1/4" pp sample
line to sample inlet.
3) Attach 1/4" pp vent line to manifold at bottom rear of instrument rack.
4) Attach recorder output lead (usually white) to terminal strip #A
(found near the top outside) on adjacent instrument rack.
5) Plug instrument into 115V power supply located on vertical strip
attached inside rear of instrument rack.
3.3 CALIBRATION OF SYSTEM
This section describes calibration of the CO, C02, and 02 analyzers. The
section is divided into two main parts. The first part covers calibration of the
74
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primary analyzers which include the Infrared Industries (II) model 703 C02
analyzer, the Beckman model 865 CO analyzer, and the Beckman model 742 02
analyzer. Part two describes calibration of the spare analyzers which include
the Beckman model 864 C02 analyzer and the Taylor model OA 272 analyzer. Both
primary and spare CO analyzers are Beckman model 865 CO analyzers; therefore,
description of calibration procedures for this analyzer are only discussed in
Calibration of Primary Analyzers.
Prior to calibration of analyzers, turn on calibration gases. This is
done by adjusting the regulators to 10 psi on the gas cylinders outside of the
meeting room. (Note: these regulators can be left open until the end of each
burn.) The gases can be shut off using the calibration/zero gas valves in the
meeting room.
3.3.1 Calibration of Primary Analyzers
Included in this subsection is Table 3.1 which summarizes the frequency
at which certain calibration procedures should be performed. Table 3.1 also
denotes which instrument functions and control settings should be frequently
checked and recorded.
02 Analyzer Calibration Procedure (Beckman 742)
Step # Procedure
1) Plug in analyzer and allow to equilibrate for 5 minutes.
2) Set on RANGE 0-25% (see Figure 3.6).
3) Set upscale calibration.
a) Pass calibration gas (or air) through analyzer. This is
accomplished by:
Calibration gas:
• turning calibration gas shut-off valve to on position
• turn calibration/zero gas select valve to calibration gas
• flip gas conditioner toggle switch #3 to span and adjust 02
flowmeter to 1 liter/min (2 SCFH).
Air:
• leave Sample/Span switch to on sample
§ flip Sample/Air switch to Air. (Note: Pump must be running)
75
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TABLE 3-1. FREQUENCY OF CALIBRATION
Analyzer
**
02'Beckman
CO-Beckman
C02~ Infrared
Industries**
02- Taylor
C02-Beckman
Step #
1-3
1
3
5
6
7
8
1
2
1
2
1
3
5
6
7
8
Task
Upscale calibration
Mechanical meter zero
Oscilator tune
Check bias adjustments
Source balance
Set zero
Upscale calibration
Set zero
Upscale calibration
Set zero
Upscale calibration
Mechanical meter zero
Oscilator tune
Check bias adjustments
Source balance
Set zero
Upscale calibration
Frequency of
Execution*
B,A
I
B
C
C
B,A
B,A
B,A
B,A
B,A
B,A
I
B
C
C
B,A
B,A
Record in
Log Book
Record scale reading
Record gain control
Record scale reading
Record gain control
*B-before each 6-hr sampling period, A-after each 6-hr sampling period, I-after
installation only, C-after period of no use for a few days or loss of sensitivity
of analyzer
**Primary analyzers
76
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MODEL 742
4. Readout Meter
5. RANGE Switch
6. CALIBRATE Control
Operating Controls
Figure 3.6. Beckman oxygen analyzer
77
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A. EXTERNAL CONTROLS AND ADJUSTMENTS
OD
6. Meter
Mechanical
Zero Screw
7. SOURCE BALANCE
Adjustment
8. OSC TUNE Adjustment
9. Source Voltage Adjustment
(On Rear Panel)
m
1. Meter
2. RANGE
Switch
•3. ZERO
Control
• 4. GAIN
Control
5. CALIB Pushbutton
(Optional)
OO-O
0:00
CONTROL
FUNCTION(S)
1. Meter
Readout of sample data or oscillator tuning check, depending on position of RANGE Switch (item 2).
During operation, a calibration curve is used to convert meter readings into concentration values. (Alter-
natively, linear readout of concentration values for a given operating range is obtainable through use of
the optional 633756 Linearizer Board.)
2. RANGE Switch
TUNE: Test position, used periodically to verify proper oscillator tuning. In TUNE mode, meter should
indicate the previously determined "Normal Tuning Value." If not. reset OSC TUNE Adjustment, item 8.
Position "1": Selects lowest-sensitivity operating range for readout on meter and recorder.
Position "2": Selects intermediate-sensitivity operating range.
Position "3": Selects highest-sensitivity operating range.
3. ZERO Control
Used to set zero point on meter scale or recorder chart. With RANGE Switch and GAIN Control at appropri-
ate settings and zero standard gas flowing through analyzer, the ZERO Control is adjusted for zero reading.
4. GAIN Control
Used to set fullscale or near-fullscale standard ooint on meter scale or recorder chart. With RANGE
Switch at 1, and an upscale standard gas appropriate to Range 1 flowing through the analyzer, GAIN
Control is set for correct reading. If analyzer incorporates optional calibration accessory, upscale gas may
be simulated by depressing CALIB Pushbutton (item 5). With GAIN Control at counterclockwise limit, gain
is zero. Clockwise rotation of 10.0 turns increases gain to maximum. Panel is marked at intervals of 1/10
turn to facilitate recording settings.
CALIB Pushbutton (Operative
only if analyzer has optional
calibration accessory)
When depressed, inserts a reflecting window into the sample beam, to simulate a specific concentration of
the measured component. Simulated concentration value is valid only for operation at a particular ambient
pressure. If barometric pressure changes significantly, calibration must be checked against upscale gas.
Meter Mechanical
Zero Screw
With analyzer power cord disconnected, meter should read zero. If not, this screw is adjusted to zero
the meter.
SOURCE BALANCE
Adjustment
Used to obtain proper balance between intensities of sample and reference sources, and to bias the optical
system into linearity. Procedures for initial adjustment and subsequent checkout of the SOURCE BALANCE
are included in Startup Procedure of Paragraph 3.1.
OSC TUNE Adjustment
Used to tune oscillator circuit, lo adjust tuning, insert a thin-bladed screwdriver through the front-panel
hole, through the cardboard guide tube, and into the slot of the adjustment screw.
During initial startup, RANGE Switch is placed at TUNE. The OSC TUNE Adjustment is set at counter-
clockwise limit, and then turned clockwise until a peak reading is obtained on the meter. Then, OSC TUNE
Adjustment is rotated counterclockwise until meter reading decreases to between 70% and 75% of the
peak reading previously obtained. The resultant meter reading, designated "Normal Meter Reading in
TUNE Mode," is noted for future reference.
During subsequent operation, oscillator tuning is checked periodically by turning RANGE Switch to
TUNE. Meter should read within a few scale divisions of "Normal Meter Reading in TUNE Mode." If meter
reading is outside the acceptable limit, repeat tuning procedure described above.
Source Voltage Adjustment
(On Analyzer Rear Panel)
Used to set the voltage applied to the two sources. Nominal setting is 30 volts.
Figure 3.7. Analyzer controls and adjustments
78
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b) After instrument has equilibrated, adjust the CALIBRATE control
(see Figure 3.6) to concentration of oxygen in the certified
calibration gas mixture (* 15%), or to 21.9% for air as noted
by the red line on the analyzer meter.
CO Analyzer Calibration Procedure (Beckman 865)
Step # Procedure
1) With power cord disconnected, verify that front-panel meter reads
zero. If not, adjust Meter Mechanical Zero Screw for zero reading.
(see Figure 3.7).
2) Turn on instrument.
3) Check oscillator tuning:
a) Turn RANGE Switch to TUNE.
b) If instrument has been in routine operation, compare present
meter reading with previous readings obtained in TUNE mode.
Present and past readings should agree to within a few of the
smallest scale divisions; if so, oscillator is properly tuned;
proceed directly to Step 4.
If analyzer has not yet been in operation, or if reading in TUNE
mode is not within the acceptable limits, tune oscillator per
instructions in instrument manual (Beckman 865).
4) Set Zero
a) Pass zero gas through instrument.
This is accomplished by:
• turning on zero gas shut-off valve.
• turning calibration zero gas select valve to zero gas.
• flip toggle switch II on gas conditioner to span and adjust
to 1 liter/min (2 SCFH).
b) Verify zero control is fully clockwise.
c) Set RANGE switch to position 3.
d) With zero gas flowing, increase GAIN control setting until
recorder reads 100% (or 10 large divisions). If 100% is not
obtainable, set GAIN control at maximum setting.
e) After allowing instrument to come to equilibrium, turn zero
control counterclockwise until meter reads exactly zero.
f) Tighten lock ring on zero control and turn off zero gas.
5) Setting Upscale Calibration
a) Set RANGE switch to position 3.
b) Pass calibration gas through analyzer. This is accomplished by:
t turning calibration gas shut-off valve to on position.
79
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• turn calibration/zero gas select valve to calibration gas.
• flip gas conditioner toggle switch #1 to span and set flowmeter
to 1 liter/min (2SCFH).
c) Adjust GAIN control to appropriate near-fullscale reading as
dictated by the calibration curve (Figure 3.8).
d) Tighten lock ring on GAIN control knob and turn off
calibration gas.
e) Pass zero gas through analyzer to verify zero has not shifted
during calibration.
f) Record GAIN control setting.
C02 Analyzer Calibration Procedure (Infrared Industries 703)
Step # Procedure
1) Zero Procedure
a) Turn the instrument on by rotating function switch clockwise
one position.
b) Allow zero gas to flow through cell at a flow rate of 2-4 SCFH.
This done by:
• turning zero gas shut-off valve to the on position
t turn calibration/zero gas select valve to zero gas
• flip C02 (#2) toggle switch on gas conditioner to span and
adjust C02 flowmeter to 2-4 SCFH
c) Allow 15 minutes warmup time. Flip sensitivity switch to low
position.
d) Rotate ZERO control until recorder reads zero.
2) Upscale Calibration with Internal Calibration Mechanism
a) Rotate function switch to span position.
b) Allow reading to stabilize and adjust the span control until
recorder reads 100% (10 larger divisions).
NOTE: With RANGE toggle switch on low position* instrument at
100% assimilates 10% C02 and at the high position the
100% reading assimilates 30%.
3) Upscale Calibration with a Calibration Gas
a) After instrument has been zeroed as detailed in Step 1, introduce
calibration gas. This performed by:
• turning calibration gas shut-off valve to the on position
• turn calibration/zero gas select valve to calibration gas
• flip toggle switch #2 (C0?) to the span position and adjust
C02 flowmeter to 2-4 SCFHT
80
-------
b) ?nr o?Nnn f"-* SWitCKh °" hl'9h for «11brat1on gas greater than
10% or on low if calibration gas is less than or equal to 10%
and set span control until recorder reads the same as the
certified concentration of C02 in calibration gas mixture.
3.3.2 Calibration of Spare Analyzers
Oxygen Analyzer Calibration Procedure - Taylor Model OA.272
Step # Procedure
1 ) Set Zero
a) Pass zero gas through analyzer.
b) Select 5% RANGE switch and wait for reading to stabilize.
c) Stop sample flow and adjust left-hand calibration screw to obtain
the correct zero reading on meter.
2) Upscale Calibration
a) Pass calibration gas through analyzer (see Section 3.3.1 02
calibration, Step 3a for this procedure).
b) Turn on and wait for reading to stabilize. Stop flow and adjust
right-hand calibration screw to obtain the correct reading (15%).
C0 Analyzer Calibration Procedure (Beckman 864)
Step # Procedure
1) With power cord disconnected, verify that front-panel meter reads
zero. If not, adjust Meter Mechanical Zero Screw for zero reading
(see Figure 3.7).
2) Turn on instrument.
3) Check oscillator tuning:
a) Turn RANGE switch to TUNE.
b) If instrument has been in routine operation, compare present
meter reading with previous readings obtained in TUNE mode.
Present and past readings should agree to within a few of the
smallest scale divisions; if so, oscillator is properly tuned;
proceed directly to Step 4.
If analyzer has not yet been in operation, or if reading in TUNE
mode is not within the acceptable limits, tune oscillator per
instructions in instrument manual found in Appendix.
4) Set Zero
a) Pass zero gas through instrument.
81
-------
This is accomplished by:
t turning on zero gas shut-off valve.
• turning calibration zero gas select valve to zero gas.
0 flip toggle switch #2 on gas conditioner to span and adjust
to 1 liter/min (2SCFH).
b) Verify zero control is fully clockwise.
c) With ZERO at clockwise limit, set RANGE switch to position 3.
d) With zero gas still flowing, increase GAIN control setting
until recorder reads 100% (or 10 large divisions). If 100% is
not obtainable, set GAIN control at maximum setting.
e) After allowing instrument to come to equilibrium, turn ZERO
control counterclockwise until meter reads exactly zero.
f) Tighten lock ring on ZERO control and turn off zero gas.
5) Setting Upscale Calibration
a) Set RANGE switch to position 3.
b) Pass calibration gas through analyzer. This is accomplished by:
• turning calibration gas shut-off valve to on position.
• turn calibration/zero gas select valve to calibration gas.
• flip gas conditioner toggle switch #2 to span and set fldw-
meter to 1 liter/min (2 SCFH).
c) Adjust GAIN control to appropriate near-full scale reading as
dictated by the calibration curve (Figure 3.9).
d) Tighten lock ring on GAIN control knob and turn off upscale
calibration gas.
e) Pass zero gas through analyzer to verify zero has not shifted
during calibration.
f) Record GAIN control setting in log book.
3.4 SAMPLING
Sampling follows directly after calibration of the analyzers. Sampling
is initiated only after calibration has been performed on the analyzers as
described in Section 3.3. The flowrate of the sample gas to the analyzers
should be at the same rate that each analyzer was calibrated at. All the
analyzers are operated the same way when analyzing the sample, therefore, only
one sampling procedure is presented.
82
-------
j Bookman*
FIGURE 3.8
INSTRUMENTS. INC.
PROCESS INSTRUMENT* DIVISION
• not
INFRARED ANALYZER CALIBRATION
* DATA SHEET
Customer: TRW
Address; Redondo Beach, Calif.
Application;
Ranges; 1.
2.
Uncalibrated Ltnearizer Range It;
2. Calibrated Linearizer Ranfie 1.1
|lefer to switch chart on schematic
SIL AFSY. CHii]
Calibration Curve i
S. Current Output Board f"
p. Bench Mounting Kit C. j
2* Stainless SteolTubinr-.C-T-J Te.flon Tubing
8. Air Purge Kit C=l
J). Explosion Proof Case C_—J
10. Remote Range Swttchin^l J
Repeatability; (In % of F.S.)
Typical Curve CH!
11. AC Power 50 H2C li 60 HZ
12. Motor Source Assembly Replacement;
Interference Gas Mol 3. Resp. Equiv.
1. CO.V
10%
Calibration Pressure:
22-22
PPK CO IN N. JiY VOL. 83
-------
Bsckman*; INSTRUMENTS, INC.
— ""* PROCESS INSTRUMENTS DIVISION
Figure 3.9
INFRARED ANALYZER CALIBRATION
& DATA SHEET
C-;5Vo-.er: TRW
'..•idrcss: '-fanhattan Bc?ach, California
Application: Carbon Dioxide
".arises :
1.
2.
3.
1. '.'ncallbrated Linearizer Range l|
2. Calibrated Linearizer Range 1 .- : 2 . d_j 3 . L_U
Pefer r.o switch chart on scherriajj^
C-as Free Calibration Assy.
Calibration Curve
Typical Curve
Current
Ronrd
Bench Mounting Kit
Stainless Steel Tubingl
Teflon Tubing F^
Air Purge Kit
9. Explosion Proof Case
10. Remote Range Switchin
11, AC Power 50 HZ!~~..J
HZ $2023.
12. Motor Source Assembly Replacement;
633773 IJS2LJ
638449
638450
638451
13. Calibration Pressure:
Atmospheric bpoc I Other C I
, REMARKS:
S.O. No. : RAPID 7396
P.O. No. :
G14892 CG7C
Model No. :
~867T
Serial No.: 101447
Detector Ser. No.: 3827F
Detector Part No.: 636857
Tag No. ;..
Configuration No.: 788923
Repeatability: (In % of F.S.)
Range I: ±1 % Range 3: +1 7.
Range 2; °L Range 4:
%
Interference Gas Mol % Resp. Equiv
1.
2.
3.
Engineer:
Jim Wilson
Date:
2/27/78
22-22.77.4.
-------
Sampli ng Procedure
1) Turn analyzers on to appropriate range as follows:
02 analyzers 0-25%
CO analyzers Range 3
C02 analyzer (Infrared Industries) High (0-30%)
C02 analyzer (Beckman) Range 1
2) Pass sample gas through analyzer. This is accomplished by the follow-
ing steps:
- turn sample shut-off valve to sample position
- turn on gas conditioner pump
- flip gas conditioner sample/span toggle switches to sample position
3) Ensure that the data recorders are operating correctly as described
in Section 4.2 (operation of data recording instruments).
System should now continuously monitor the combustion gas. At the end
of the measurement period the upscale calibration and zero should be
checked to ensure no drift has caused an error in measurement. If
there has been a drift, it should be noted in the instrument log book.
3.5 COMBUSTION EFFICIENCY CALCULATION
3.5.1 Sample Calculation
The following are the methods of defining and calculating combustion
efficiency.
Combustion Efficiency
°l CO - "la CO
Combustion efficiency is defined as % CE = 100 X 2
C02
where % C02 is the percentage C02 composition of the combustion effluent
measured by the C02 monitor, and % CO is the percentage CO composition of the
combustion effluent calculated from measurements by the CO monitor.
Sample Calculation
Assume the C02 monitor indicates that C02 is 9% of the combustion effluent.
Assume CO is 9 parts per million (ppm).
To convert parts per million to percent, multiply by 0.0001 (i.e., 1 x 10" )
Therefore, 9 ppm is 0.0009%.
85
-------
Combustion efficiency is
% C0? - % CO
% CE = „ rn x 10°
10 wUo
9 - O-0009 = 99.99%
3.5.2 Sample Data Sheet
The sample data sheet for recording combustion efficiency data is
presented in Table 3.2.
3.6 MAINTENANCE AND TROUBLESHOOTING
3.6.1 Maintenance
Maintenance consists of those procedures which are performed routinely on
all of the equipment. Table 3.3 shows the frequency that these maintenance
procedures should be performed.
Sample Probes and Lines
- Visual inspection should be made to see if probe is in good condition.
Gas Conditioner
- Check water level of bath.
- Monitor internal components for leaks by removing top panel and visually
inspect.
- Change filter - (signaled by dark gray or black appearance)
Filter will probably be changed every day.
Filter change procedure is as follows:
1) Remove filter housing from gas conditioner.
2) Loosen nut at bottom of filter housing and slide filter from
housing.
3) Insert new filter and attach to gas conditioner.
Calibration Gas and Purge Air System
- Visually inspect amount of gases in cylinders before each departure.
The gas cylinder should not be used if cylinder pressure is below 300 psi.
86
-------
OD
Table 3.2
VULCANUS TESTS: ON-LINE MONITOR DATA
DATE:
NCINERATOR:
TEST NO.
TIME
i
|
1
' % O2
CH. NO. .
•
;
•
% C02
CH. NO.
•"
!
PPM CO
CH. NO.
x
COMBUSTIONA
EFFICIENCY. %
*
,
-
• REMARKS
.
-
j
!
E
5
I
-
% CO2 ~ % CO
% C02
X 100
-------
TABLE 3-3. FREQUENCY OF MAINTENANCE
Equipment
Probes and sample lines
Gas conditioner
Calibration gas system
CO, C02 and 02 analyzers
Strip chart recorders
Data logger
Procedure
-Visual inspection
-Check water level of
cold bath
-Monitor iri termal
components for leaks
-Charge filter
-Check cylinder pressure*
-As per Table 3-1
-Check amount of strip
chart left
-Check level of ink in
cartridges
-Check amount of printer
paper
Frequency
After every burn
Before each test
period
Before each test
period
Every four weeks
of operation
Every 2-3 days
As per Table 3-1
After each test
period
After each test
period
After each test
period
*If cylinder pressure is below 300 psi , do not use, replace with new cylinder
88
-------
CO, C02, and 02 Analyzers
Beckman models 864 and 865, C02 and CO analyzers respectively:
- Daily reading of oscillator. Tune and gain control setting as described
in Section 3.3.
- Normally no maintenance will be required, however, should loss of
sensitivity occur (cannot calibrate with gain control on maximum set-
ting), the sensor should be recharged or replaced for recharging. See
Section 6.1, page 26 in manual.
• Infrared Industries model 703 C02 analyzer
- Requires no maintenance
• Taylor Industries model OA273 02 analyzer
- See page 1009 for battery replacement and filter replacement.
3.6.2 Troubleshooting and Repairs
Due to the highly technical nature of the instruments used, it is imprac-
ticable to present a discussion of troubleshooting and repair for each
individual instrument, and in most cases troubleshooting of each individual
analyzer is covered by its own instrument manual found in the appendix. Only
the gas conditioner is not covered thoroughly.
The following troubleshooting discussion is concerned with loss of flow
of the gas sample, which includes plugging of sample lines and the gas condi-
tioner.
If loss of flow is found (noted by a drop in by-pass flow or no flow
condition), the following procedure is employed to repair the system:
1) Remove sample inlet to gas conditioner. If no change in flow condition,
proceed to step two. If flow resumes normal flow, attach high pressure air to
sample line and flush sample line with high pressure air. If this fails,
search for plugged line or probe and replace. After clearing the line,
reattach sample line and resume sampling.
2) Disconnect line at valve between first condensate trap and filter.
If flow condition returns to normal, condensate trap or coil is plugged. To
repair, attach high pressure air to 1/4" line from trap and purge trap and
coil with high pressure air to remove plug. If flow condition does not return
to normal, replace filter in housing on front of gas conditioner. If this does
89
-------
not solve problem, check second condensate trap and coil for plugging. It is
possible that the temperature bath which the trap and coil are in is too cold
and water is frozen in the trap or coil lines. To correct, add warm water to
melt ice in the lines.
90
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4. DATA RECORDING SYSTEM
The data recording system consists of different types of instruments
capable of recording and/or displaying the output from the flowmeters and CO,
C02, and 02 analyzers.
4.1 DESCRIPTION OF SYSTEM
The data recording system consists of three different types of instruments:
strip chart recorders, a data logger, and remote digital readouts.
4.1.1 Strip Chart Recorders
There are eight strip chart recorders located in the meeting room as
shown in Figure 3.1. They are used to continuously monitor the outputs from
the instruments. Six of these recorders are to be used as primary recorders
for monitoring the six instruments (three flowmeters and three combustion gas
analyzers). Two recorders will be used as backups in case of primary recorder
failure. Two types of Hewlett Packard recorders are used, the Model 680 and
680M.
4.1.2 Data Logger
The data logger, located as shown in Figure 3.1, is to be used for two
functions: to log the output of the instruments at 20 minute intervals and to
provide digital readout of the output from the instruments. The data logger
accepts all the outputs from the instruments and will print out each input
signal on demand or on a preset time interval. The instrument can also be
switched manually from one input to another so that each input can be read out
digitally.
4.1.3 Remote Digital Readojjts_
Six digital readouts have been installed in the recording system so that
the output from each instrument (flowmeters or combustion analyzers) can be
read at a remote location in the combustion room. These digital readouts will
91
-------
be proportional to the analog signal displayed on the front panel of each
instrument.
4.2 OPERATION OF THE SYSTEM
When sampling begins, all three data recording and/or readout devices will
be operating simultaneously.
4.2.1 Operation of Strip Chart Recorders
1) Set voltage selection to 0-5 volts.
2) Turn recorder on (flip toggle switch to on).
3) Flip pen up/down switch to down position.
4) Flip primary/spare toggle switch at top right of instrument rack to
recorder being used as either primary or spare.
5) Set chart speed to 20 cm/hr (8 in/hr).
6) Calibration
a) Zeroing
- Apply zero signal to recorder - this can best be done at time
of zeroing flowmeter or combustion analyzer during calibration
(see Section 2.3 or 3.3).
- With zero signal applied, adjust zero control to zero on chart
output (simultaneously set zero on data logger-digital display).
b) Upscale calibration
- Check upscale calibration by applying an output from instrument
being recorded (can be done during upscale calibration of
instrument) and checking to see that the recorder reflects
approximately the same value as the instrument's own analog or
digital display readout (and exactly the same as data logger
digital display). If reading does not correspond, see
Section 5.23 in recorder manual.
7) Recorder can now be used to accurately monitor the output from an
instrument.
4.2.2 Operation of Data Logger
Numbers in parenthesis refer to Figure 4.1.
1) Turn on power switch (#10).
2) Set frame rate switch (#2) at 20 minutes.
3) Set day (#9) - example: 28th day of month - 028.
4) Set time. Flip TIME/MEASURE switch (#6) to TIME and set the
correct time: first press the SLOW/FAST switch (#7) to FAST to
92
-------
CO
Z-FOLD
PRINTER PAPER
DIGITAL
PRINTER
PAPER GUIDE &
TEAR-OFF BAR
OVERRANGE (OR)
INDICATOR
PRINTER
ACCESS COVER
4-TUBE
NIXIE DISPLAY
(-) POLARITY
INDICATOR
SLIDE-OUT DRAWER
CATCHER FOR PAPER
REFOLD
SNAP-DOWN
SUPPORT
Figure 4.1. Front panel view of data logger.
-------
set the approximate time, and then press the switch to SLOW to
set the exact time. When setting up, check jumper location on
the PC card to see that it conforms with the power line frequency
being applied. (See Ester!ine-Angus instruction manual appendix.)
5) Ensure that voltage select switches (14) are in 100 mV position.
6) Choose the desired readout and printouts by adjusting the channel
select switches (#5). The digitally displayed value corresponds
to the notation above the switch which is pressed in. All values
up to the depressed switch will be printed out. Normally switch
#5 should be depressed, so that all values will be printed out.
7) Instrument will now automatically printout the signals from the
instruments every 20 minutes.
Explanation of other switches:
- manual switch (#3) can be used to trigger data printout. (System
will printout to the channel select switch (#5 in our case) pushed
in.
- feed button (#8) when pushed in will advance printout tape.
4.2.3 Operation of Digital Readouts
Readouts need no operating procedure. When instruments (flowmeters or
combustion analyzers) put out a signal, the digital readouts will display a
signal proportional to the instruments output.
Example:
CO instrument - Beckman model 865
0-5 volts full scale. At 80% reading on analyzer analog display the
digital readout will display 4 volts (or 80% of 5 volts).
4.3 MAINTENANCE
The strip chart recorders and the data logger require maintenance while
the digital readout does not require any maintenance.
4.3.1 Strip Chart Recorders
Chart Paper Loading
Remove chart magazine as follows:
1) Depress the lever which is adjacent to the power switch at the
bottom of the control panel.
2) Raise the chart magazine to a horizontal position.
3) Slide magazine from the recorder.
94
-------
Install a roll of 6" width graph paper as follows: (Refer to
Figure 4.2).
1) Position the empty chart magazine as indicated in Figure 4.2.
2) Insert the supply roll between the upper spring loaded hubs with
the elongated drive holes of the paper to the right.
3) Thread paper from the new supply roll under the guide bar.
4) Bring the paper over the top of the sprocket drive drum and
engage the sprockets.
5) Pull the paper down across the face of the chart magazine and
feed through the slot at the bottom of the platen.
6) Rotate the drive gear so that the paper will feed through the slot.
7) The paper will now feed out through the bottom of the chart
magazine and may be torn off as the operator desires. If this
type of operation is desired, the chart paper magazine may be
installed in the recorder. For operation with the chart stored
on a take-up spool within the chart magazine, continue with
steps 8 and 9.
8) Install an empty take-up spool (supplied) between the two lower
hubs. Index the left end of the spool so the drive stud on the
left hub mates with the slot on the take-up spool.
9. Attach the end of the chart paper on the take-up spool with
adhesive tape. Rotate the drive gear until several turns of
paper are on the take-up spool. Inspect for proper chart tracking
without buckling and then install the chart magazine.
Install Ink Cartridge
Remove chart magazine as described in chart paper loading. Force the
cartridge over the piercing tube of the corresponding pen and screw all the way
on. The piercing tubes (up to two) are located in the same plane as the pen.
Depressing the primer will force ink from the cartridge to the pen tip.
4.3.2 Data Logger
Replacement of Printer Paper
Detailed instructions for loading of printer paper are graphically
illustrated on a decal affixed to the inside bottom surface of the slide-out
drawer that is used to catch the refolded paper.
To load, refer to Figure 4.1 and proceed as follows (numbers in paren-
thesis refer to figure):
95
-------
GUIDE BAR
SUPPLY ROLL
DRIVE
TAKE UP
FOR CHART FEEDOUT
OR TEAR OFF
Figure 4.2 Chart loading diagram.
96
-------
1) Place FRAME RATE switch (2) in one of the external triggering
positions (either EXT. TRIG, or AUX.). Then, turn on instrument
power (10).
NOTE: Positioning of the FRAME RATE switch in this manner inhibits
the printer (provided that there are no external incoming trigger
pulses being applied) when either loading the paper or setting the
time of the internal clock.
2) Snap out and remove the printer access cover.
3) Flip down the plastic paper guide/tear-off bar.
4) Perform the three steps as indicated by the loading instructions
on the decal inside the slide-out drawer.
5) Keep FEED pushbutton (8) depressed until paper feeds out front of
printer and beyond the plastic tear-off bar. Flip tear-off bar
back into position, and tear off one or two folds of paper.
6) Snap the printer access cover back into place.
7) The paper is now loaded and ready for printout operations.
4.4 TROUBLESHOOTING
Pen tip clogging (recorder will not ink properly)
- Remove chart paper cartridge
- Remove ink cartridge
*
- Flush ink system with water
- Dry ink system with air
- Add new ink cartridge
- Use syringe to suck ink to pen tip (if needed)
- If recorder still does not work, switch to spare recorder.
*Note: .If system will" not flush properly, use wire to unclog pen tip.
97
-------
5. REFERENCES
TRW Report "Evaluation of Waste Flow and Temperature Measurement for
Shipboard Incineration " dated May 1978
EPA-600/2-77-196 "At Sea Incineration of Organochlorine Wastes
Onboard the M/T Vulcanus" dated September 1977
EPA-600/2-78-068 "At-Sea Incineration of Herbicide Orange Onboard
the M/T Vulcanus" dated April 1978
98
-------
APPENDIX B
Manufacturer's Operating Manuals
10.
11
Instruction Bulletin for Series
10 LV 2000 Liquid Vortex Flowmeter
Series 240 Clampitron Flowmeter
Bulletin 240-IM Installation Manual
Instruction Manual Model 600 Dual
Input Sample Gas Conditioning System
Beckman Model 865 (CO) Infrared
Analyzers
Beckman Model 864 (C02) Infrared
Analyzers
IR/702/703 Gas Analyzer (C02)
Analog/Digital Operations Manual
Beckman Models 741 and 742
Oxygen Analyzers
Taylor Servomex Instruction
Manual Oxygen Analyzer Types
OA 272/273
Instruction Manual Model D-2020
Digital Data Acquisition System (DDAS)
Operating and Service Manual
Strip Chart Recorders (Includes
Metrics) 680/681/682/683
Weston Line Operated DPM
2460 Series Operators Manual
Fischer & Porter
Controlotron Corporation
Thermo Electron Corporation
Beckman Instruments, Inc.
Beckman Instruments, Inc
Infrared Industries, Inc
Beckman Instruments, Inc,
Taylor Servomex Limited
Ester!ine Angus
Hewlett Packard
Weston Instruments
99
-------
TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing)
\O.
EPA-600/2-79-137
2.
3. RECIPIENT'S ACCESSION-NO.
i 4 TITLE A\DSUBTITLE
At-sea Incineration: Evaluation of Waste Flow and
Combustion Gas Monitoring Instrumentation Onboard
the M/T Vulcanus
5 REPORT DATE
July 1979
6. PERFORMING ORGANIZATION CODE
7. AUTHOR1S!
8. PERFORMING ORGANIZATION REPORT NO
D.A.Ackerman. R.J.Johnson, E.L.Moon,
A.E.Samsonov. and K.H.Scheyer
9. PERFORMING ORGANIZATION NAME AND ADDRESS
TRW, Inc.
One Space Park
Redondo Beach, California 90278
10. PROGRAM ELEMENT NO.
1AB606
11. CONTRACT/GRANT NO.
68-02-2660
12. SPONSORING AGENCY NAME AND ADDRESS
EPA, Office of Research and Development
Industrial Environmental Research Laboratory
Research Triangle Park, NC 27711
13. TYPE OF REPORT AND Pf
Final; 9/77 - 5/79
PERIOD COVERED
14. SPONSORING AGENCY CODE
EPA/600/13
5. SUPPLEMENTARY NOTES IERL-RTP project officer is Ronald A. Venszia, Mail Drop 62,
919/541-2547.
16. ABSTRACT
The report describes the test operations and results of measuring organo-
chlorine waste flowrate and CO, CO2, and O2 in the effluent gas during incineration
of industrial chemical waste onboard the M/T Vulcanus. The data was obtained
during shipboard test burns in the North Sea during November and December 1978
and February 1979. Program objectives were to gather data on durability and accu-
racy of both the waste flowmeters and the CO, CO2, and O2 monitoring system when
used on a continuous routine basis. Combustion efficiency exceeded 99. 95% in all
cases, meeting IMCO requirements of 99. 95 + or - 0.05%. The ultrasonic and vor-
tex waste flowmeters and the CO, CO2, and O2 monitoring system performed satis-
factorily during the burns. The CO, CO2, and O2 equipment was operated contin-
uously for a maximum of 12 hours. The vortex flowmeters indicated gradual waste
buildup, although buildup did not occur in the ultrasonic flowmeter piping. Monthly
inspection and cleaning of the vortex meters would avoid extensive solids buildup.
Use of spare instruments ensured continuous acquisition of combustion data through-
out the burns. Post-test inspection of the analyzers indicated only minor corrosion
and wear.
7.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.lDENTIFIERS/OPEN ENDED TERMS
COS AT I Field/Group
Pollution
Chlorine Organic
Compounds
Incinerators
Oceans
Waste Disposal
Carbon Monoxide
Combustion
Evaluation
Instruments
Monitors
Flowmeters
Carbon Dioxide
Oxvgen
Pollution Control
Stationary Sources
Organochlorine
At-sea Incineration
Chemical Waste
13B
07C
08F,
07B
21B
14B
3. DISTRIBUTION STATEMENT
Release to Public
19. SECURITY CLASS (ThisReport)
Unclassified
21. NO. OF PAGES
105
20. SECURITY CLASS (Thispage)
Unclassified
22. PRICE
EPA Form 2220-1 (9-73)
100
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