Sick GM31

Multi-Component Gas Analyzer
for NO, NO22, SO22 and NH33
GM 31 Product File
SICK AG Phone (+7641) 4 69 - 0

Environmental Monitoring Fax (+7641) 4 69 - 11 49
Nimburger Str. 11 Telex 772 314
D-79276 Reute
GE02 GM 31 Gas Analyzer 11/99

Table of Contents
Presentation Probe Types
Market requirements Gas Permeable Probe
Applications Probe with directed purge air
Certificates Standard Probe
GM31 Versions Calibration Check

(Gas Filter box)
System Overview
Calibration Check
Optical System (acc. EPA)
Control Unit TCU Additional Information
Reliable application Connection and LED plan

GM31 - Measuring components
SO2
NH3
NO
Temp
NO2

GM31 - Versions
GM
GM31
31Models
Models Meas.
Meas.Components
Components
GM
GM31
31-1-1 SO2
SO2
GM
GM31
31-2-2 SO2
SO2and
andNO
NO
GM
GM31
31-3-3 SO2,
SO2,NONOand
andNO2
NO2
GM
GM31
31-4-4 NO
NO
GM
GM31
31-5-5 SO2,
SO2,NONOand
andNH3
NH3
GM
GM31
31-7-7 NO
NOand
andNO2
NO2

GM31 - Application Examples
 Power plants (stack, FGD, DeNox)
 Cement industry (stack, FGD, DeNOx)
 Waste incineration plants (stack, scrubber)
 Glass, plastics, sugar, pharmaceutical industry
 Paper industry (stack, FGD)
 Petrochemical industry (stack, catalyst)

GM31 - Application Examples
Power Plants
- Continuous emission monitoring
- DeNOx plants for NH3 slip control
- REA for lime load
Cement Industry
- Continuous emission monitoring
- SO2 and NOx generating processes
- NH3 slip determination
Waste Incineration Plants

- Continuous emission monitoting
- SO2 and NOx generating processes
- NH3 slip control
Other Branches
Petrochemical - Glas Industry
Industry - Paper Industry
- Continuous emission - Sugar Industry
monitoring - ...
- Process control
GM31 - Certificates
TÜV and GOST tested

US. EPA compliance
US. EPA

GM31 - The market requires:
Simple installation (from one side)
Small dimensions
Simple commissioning
High reliability
High dynamic measuring range
Cross-sensitivity free against other gases
Contents
GM31 System with Standard Components

GM31 System with optional O2 Sensor
Temperature
sensor

GM31 - System - Control Unit TCU
In/Outputs: Interfaces:
 RS232 (MEPA)
 up to 8 binary inputs  RS422 (T/R Connection)
(DC 24V, max. 11mA)  Modem interface
 up to 8 anlalog inputs
(0-20mA /50 Ohm)
 up to 8 analog outputs
(0,2,4 - 20mA,
max.700 Ohm)
 up to 12 relay outputs
(48V/1A)

GM31 - Absorption curves of SO2, NO, NO2 and NH3
Simulation
 SO2, NO and NH3

range of 205-235nm
 Variants with NO2
range of 219-249nm

GM31 - Optical System
Front window
Objective mirror Triple reflector
Condenser
UV
transmitter
lamp
Deflection mirror
Diode row
Optical grid

GM31 - Optical System
(1221 lines/mm concave)

GM31 - Optical System - Swivel Elements

GM31 - Control Cycle
During the control cycle the zero-point reflector remains in the light path.
The cycle is active for at least 4.5 min and is flagged with a status signal.
Zero point measurement

 the zero-point is directly determined
Reference point measurement

Grid filter
 Linearity check of diode array on a spectrally neutral basis
NO Cuvette
 Check of the spectral characteristics of diode array
Elimination of internal changes

Lamp power: Controlled and compensated automatically
Contamination of the optical surfaces has no influence (due to

DOAS principle)

GM31 - Optical System - Control Cycle

GM31 - Operational Concept

GM31 - Measuring Values - Conversion in TCU
The measured concentrations transmitted from GM31 to the TCU are actual values.
To configure the output of the TCU to standard values the following has to be done:
Conversion in general:
C[ppm]dry = C[mg/m³actual] * (273+T[°C]) /273 * 1013/p[hPa] * 100 /(100-H2O[%]) / Conversion factor
mg/m³Nwet mg/m³Ndry ppmdry
T = flue gas temperature

Conversion factor [mg/m³N/ppm]: p* = absolute pressure inside the flue gas
H2O* = humidity of the flue gas
1 ppm = mg/m³N
* normally used as constant values
SO2 2.92
NO 1.34
NO2 2.05
Examples
NH3 0.77

GM31 - Features
TÜV and GOST approved, EPA compliance
Cross-sensitivity free against other gases
Insensitive to dust and humidity due to measuring

principle
DOAS = Differential Optical Absorption Spectroscopy
Small dimensions
Simple installation (from one side)
Simple commissioning by means of MEPA
High dynamic measuring range

GM31 - Features
Direct and therefore delay-free representative
measuring value determination
High reliability and measurement precision by meansof

automatic self-test function
Simultaneous or individual measurement of SO2, NO,

NH3 or NO2 and temperature, (O2 optional)
Minimum maintenance costs due to long maintenance

free intervals
System diagnosis, recording and graphic display of

measuring data via MEPA
Remote diagnosis and Parameter setting via MEPA in

connection with a modem
GM31 - Reliable Application
 Probe length and active path min / max: see flange and probe type
 Wall thickness of flue gas channel max: acc. to probe type
 Ambient temperature: - 20°C to + 55°C
 Flue gas temperature max. : 500 °C

(purge air must be guaranteed)

GM31 - Reliable Application
 Measuring range min.: SO2 0 - 40 mg/m3actual * m

NO 0 - 70 mg/m3actual * m
NH3 0 - 16 mg/m3actual * m
NO2 0 - 200 mg/m3actual * m
 Sum concentration SO2+NO max.: 4000 mg/m3actual * m

(Ext. ca. 1.5)
 Ratio SO2: NO (only if NO measurement required):  10:1
 Accuracy TÜV Standard / GMBI (gov. published): 2%
 Protection class: IP 65
 Condition of overpressure at mounting location:

with air purging unit Standard: 2 BH13 max. + 10 hPa
with air purging unit Option: 2 BH14 max. + 30 hPa
 Condition
Contents of under pressure at mounting location: max. - 60 hPa
GM31 - Probe Types

GMP31 Directed purge air
Temperature sensor
Measuring components: SO2, NO, NO2 or NH3

Flue gas temperatur: < 550 °C (1022 °F)
Velocity of flue gas: > 1 m/s
Overpressure max: < 60 mbar
Duct diameter: > 300 mm
Gas concentration sum (g/m³act) < 14
Dust concentration (g/m³act) max: < 15
Available length of probe: 0,9 / 1,5 / 2,0 m
Available active measuring distance: 300 / 500 / 800 / 1250 mm
GMP31 Standard purge air (replaced by directed p.a.)
Temperature sensor
Measuring components: SO2, NO, NO2 or NH3

Flue gas temperatur: < 550 °C (1022°F)
Velocity of flue gas: > 7 m/s
Gas concentration sum (g/m³act) <8
Dust concentration (g/m³act) max: < 10
Available active measuring distance: 500 / 800 / 1250 mm
GPP31 Gas Permeable Probe
Filter element
Temperature sensor
Ceramic or
Teflon + Ceramic

GPP31 Gas Permeable Probe for Dry Gas
Ceramic filter
Temperature sensor
Measuring components: SO2, NO, NH3, NO2

Flue gas temperatur: < 260°C/500°F
Velocity of flue gas: > no limitation
Gas concentration sum (g/m³act) < 14
Dust concentration (g/m³B) max: < 30
Available active measuring distance: 300 / 500 mm

GPP31 Gas Permeable Probe for Wet Gas
Teflon + ceramic filter
Temperature sensor
Measuring components: SO2, NO, NH3, NO2

Flue gas temperatur: < 250 °C ( 482 °F )
Velocity of flue gas: > no limitation
Gas concentration sum (g/m³ B) < 14
Dust concentration (g/m³B) max: < 30
Available active measuring distance: 300 / 500 mm

GMP31 - Application Data of Probe types
GPP with
Directed GPP with EPA Probe
Teflon +
Purge Air Ceramic with Audit
Ceramic
Probe ( HT ) Filter Cell
Filter
Flue gas temperature [°C] <550 <260 <250 <250
Suitability of calibration with test
x x x
gases acc. EPA
Suitability for extreme disturbances
x x
of flow profile in the duct
Purge air requirement x x
Velocity of flue gas [m/s] >1 any any >7
Wet flue gas application x x x
Overpressure [hPa] <60 <120 <120 <60
SO2, NO, SO2, NO, SO2, NO, SO2, NO,
Measuring components
NO2, NH3 NO2, NH3 NO2, NH3 NO2*, NH3*
Duct diameter [mm] >300 >300 >300 >800
Gas concentration sum [g/m3B] <14 <14 <14 <8
Dust concentration [g/m3B] <15 <30 <30 <10
Available lengths of probes [m] 0.9/ 1.5/ 2.0 0.9/ 1.5/ 2.0 0.9/ 1.5/ 2.0 2.0
500
Available active measuring 1250/800/
300/ 500 300/ 500 (AuditCell
distances [mm] 500/ 300
300)
* upon request
GMP31 Probe Selection
n
Temp >550°C
• Calibration with test gases
acc EPA part 75 required ? n n
• High dust concentration ?
• Purge air not allowed ?
y • Gas velocity <1m/s ?
y
y
y
• Temp >260°C ?
y n
• Temp >260°C ?
n
GPP ?
y n
n
- Dry flue gas ?
y - Wet !
- Temp <250°C !
Extractive GPP with GPP with HT Probe with

method ceramic filter teflon filter directed purge air
GM31 with GPP31 ( Gas Permeable Probe )
Contents
GM31 with GPP31 (Gas Permeable Probe)
PT1000
Filter element
Flue gas

GM31 with GPP31 (Gas Permeable
Probe)
PT1000
Filter element
Flue gas

GPP31 Components
Details - heating / test gas leading
Heated window / reflector

up to approx. 75 °C
Leading Filter element

Leading (ceramics or
test gas heating teflon+ceramics)
Separated heating pads for front window and reflector

Heater
controller 2 gas connectors for
 reference gas supply
 pressure monitor for EPA measurement or
gas sampling for comparison measurement

GPP31 Heating
WATLOW
1
160 2
RDY
SET
SET <<
<< >>
>>
Window and reflector are heated up to 75°C
N Heater control Ni-CrNi

115/230 V Set Temper.
500 VA for the center of Window heating Triple heating
L1 the heating coil:
160°C
PT1000

GPP31 Features
 possibility of on-line testability with zero
gas and reference gases (zero-point and

span) provided by 2 gas connectors
 applicable as zero path, while the
measuring volume is filled with air or
nitrogen
 possibility of blowback for filter cleaning
 connection possibility for comparison
measurement
 Response time of the system < 60 s (T90)
 Gas consumption for 1 test point during gas test from 15 l on depending on the
application. Time necessary for 1 test point during gas test max. 65 s
 Overpressure inside of filter element during gas test approx.. 20 hPa

GPP31 - On-line cal. check with test gases - Installation
acc. EPA

GPP31 - On-line cal. check with test gases - Procedure
Equipment
• Test gas cylinders (N2 and measured gases);
concentrations corresponding to measuring range
• pressure gauge / pressure reducer
• leading 1/8‘‘ with connector
• pressure monitor, 1000 hPa, resolution 0.5 hPa
• Laptop with MEPA31 and RS232 cable
• 3.5‘‘ diskette for data recording
Procedure
• Connect the N2 gas.
• Start the MEPA31 programm, and record the current measuring data.
• Adjust pressure reducer to 0 bar, open the valve completely.
• Adjust pressure to 3 bar and wait approx. 30s.
• If reading has not dropped to zero increase pressure in steps until zero is reached.
• Increase pressure by approx. 0.5bar.
• Notice the pressure of the gauge and pressure monitor as default values.
The differential pressure will be between 2mbar and 30mbar.
• Close the valve on the pressure reducer.
• Connect the test gas and adjust the pressure default values.
• Wait for stabilizing of readings and record the measuring values.
• Repeat with other test gas concentrations if necessary.
Contents
GM31 - Gas Filter Box - Cal. Check

GM31 - Gas Filter Box - Test gas selection
The gas filter box is used for checking the systems with standard probe or
probe with directed purge air.
Which test gas should be provided and used?
In principle the product of the concentration measuring distance is tested.
probe 500mg/m³ * 0.8m = 400mg/m²
Ideally the measuring range should be calculated to 80° (in operation)
The test gas needed can be obtained by division of the filter box measuring range
thought the max. length of audit cell (150mm) and, if necessary, conversion to ppm:
400mg/m³ * m / 0.15 = 2.666mg/m³ (/2.92 = 913ppm in case of SO 2)
It should be avoided to use gases with higher concentrations in order to esure that no
testing out of the calibration range can take place.
The same principle is valid for the EPA probes
Contents
GM31 - Additional Information
continues

GM31 - Connection Plan

GM31 - T/R unit - LED´s
+5V
Peltier cooling +12V

PE-
Interfaces Heating +24V
PE+
TXD S.-R.unit
IF1 Deuterium lamp +100V
RXD Polychr
Impulse +500V
TXD Status
IF2
RXD Ignition -15V
Proc. clock Malfunction
Measuring Error +15V
Error
Purge air On
Reset Power supply
Reset Heating
Processor board
Proc. clock Lamp control
IO - Calculator
Measuring
Reset Status Malfunction
RS232 / Modem
Service
1 2
Service board 1 = Service
2 = Measuring
Contents
GPP31 - Maintenance - 1
Filter cartridge can be easily dismantled

and optical surfaces be cleaned

Easy dismantling of the probe

Reflector side with heating

Optics head side of filter element

Heating control
and
2 gas connectors
are easily accessible

Heating control is easily accessible

GPP31 - Maintenace - 7
Filter cartridge can be easily dismantled

and optical surfaces be cleaned
Contents
GM31 Control Unit TCU - Examples
Example GM 31-2 formulas in TCU:
for SO2 conversion:

RV01 = MV01 * (273+MV03)/273 * 1013/p [hPa] * 100/(100-H2O[%]) / 2.92
for NO conversion:
RV02 = MV02 * (273+MV03)/273 * 1013/p [hPa] * 100/(100-H2O[%]) / 1.34
with
MV01 = SO2 concentration in mg/m³actual transferred from GM31 to TCU

MV02 = NO concentration in mg/m³actual transferred from GM31 to TCU
MV03 = Temperature in K transferred from GM31-PT1000 to TCU
For p[hPa] and H2O[%] use either substitute values (fix values stated
by the customer) or values read in via analog inputs Al.
Reckoning values RV01 and RV02 can be proceedeed to the Analog Outputs
e.g. AO 1 and AO 2 of TCU in order to get analog outputs in ppm.
Convenient parameterisation using MEPA.

Information
The product file should support you in

your marketing activity. For opening the
files Power Point 97 is required.
In case of questions or ideas on the

optimisation of the product file please
inform us.

What should be added to the presentation ?
===> Suggestions please forward to [email protected]
Basics Evaluation Principle

Zero-point correction by ref. signal (CCY) and normalization constants (ZERO-ADJ)
DOAS
The way of extinction spectrum to the concentration output
Dieter‘s Blockschaltbilder
Ausführungen GM31 wie aus PL
Ausführungen GMP31/GPP31 wie aus PL
Auswahltabellen
PLs ohne Preise
kleinste MBs (Auflösung, Genauigkeit2% ---> kleinster MB)
größter MB (Hinweis auf Gasgemische, Verhältnisse)
Auflösung <---> Genauigkeit
Projektierungshilfe Gerät, Lanze (Material, Meßspalt...)
GM31-Kalkprog. Programm einarbeiten

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Multi-Component Gas Analyzer

for NO, NO22, SO22 and NH33

SICK AG Phone (+7641) 4 69 - 0

GE02 GM 31 Gas Analyzer 11/99

Presentation Probe Types

Market requirements Gas Permeable Probe

Applications Probe with directed purge air

Certificates Standard Probe

GM31 Versions Calibration Check

Reliable application Connection and LED plan

GE02 GM 31 Gas Analyzer 11/99

GE02 GM 31 Gas Analyzer 11/99

GE02 GM 31 Gas Analyzer 11/99

 Power plants (stack, FGD, DeNox)

 Cement industry (stack, FGD, DeNOx)

 Waste incineration plants (stack, scrubber)

 Glass, plastics, sugar, pharmaceutical industry

 Paper industry (stack, FGD)

 Petrochemical industry (stack, catalyst)

GE02 GM 31 Gas Analyzer 11/99

Waste Incineration Plants

TÜV and GOST tested

GE02 GM 31 Gas Analyzer 11/99

Simple installation (from one side)

High dynamic measuring range

Cross-sensitivity free against other gases

GE02 GM 31 Gas Analyzer 11/99

GE02 GM 31 Gas Analyzer 11/99

GE02 GM 31 Gas Analyzer 11/99

 SO2, NO and NH3

GE02 GM 31 Gas Analyzer 11/99

Objective mirror Triple reflector

GE02 GM 31 Gas Analyzer 11/99

(1221 lines/mm concave)

GE02 GM 31 Gas Analyzer 11/99

GE02 GM 31 Gas Analyzer 11/99

Zero point measurement

Reference point measurement

Elimination of internal changes

Contamination of the optical surfaces has no influence (due to

GE02 GM 31 Gas Analyzer 11/99

GE02 GM 31 Gas Analyzer 11/99

GE02 GM 31 Gas Analyzer 11/99

C[ppm]dry = C[mg/m³actual] * (273+T[°C]) /273 * 1013/p[hPa] * 100 /(100-H2O[%]) / Conversion factor

mg/m³Nwet mg/m³Ndry ppmdry

T = flue gas temperature

GE02 GM 31 Gas Analyzer 11/99

TÜV and GOST approved, EPA compliance

Cross-sensitivity free against other gases

Insensitive to dust and humidity due to measuring

Simple installation (from one side)

Simple commissioning by means of MEPA

High dynamic measuring range

GE02 GM 31 Gas Analyzer 11/99

High reliability and measurement precision by meansof

Simultaneous or individual measurement of SO2, NO,

Minimum maintenance costs due to long maintenance

System diagnosis, recording and graphic display of