ABB SCK User Manual

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ABB MEASUREMENT & ANALYTICS |
OPERATING INSTRUCTION | OI/SCK- EN REV. E
SCK
Sample
conditioning for kiln
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ABB Measurement & Analytics
For your local ABB contact, visit:
www.abb.com/contacts
For more product information, visit:
www.abb.com/analytical
Sampling system for dry gas
sampling at rotary cement kiln gas
exit and calciner gas exit
Measurement made easy
OI/SCK
-EN Rev. E 07.2021 Original instruction
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SCK
Introduction
The SCK is a sampling system for dry gas
sampling at rotary kiln exit and calciner gas exit.
The SCK sampling system is suitable for
applications in rough environmental conditions
and for outdoor installations thanks to a
complete protection
cover.
Additional Information
Additional documentation on SCK is available for
download free of charge at www.abb.com/analytical.
Alternatively simply scan this code:
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We reserve the right to make technical changes or
modify the contents of this document
without prior
notice. With regard to purchase orders, the agreed particulars shall prevail.
ABB does not accept any
responsibility whatsoever for potential errors or possible lack of
information in this document.
We reserve all rights in this document and in the
subject matter and illustrations contained
therein.
Any reproduction, disclosure to third parties or utilization of its contents – in whole
or in parts
– is forbidden without prior written consent of ABB.
© ABB 2021 3KXG141003R4201

ABB SCK Specifications

General

Brand	ABB
Model	SCK
Category	Industrial Equipment
Language	English

Summary

Chapter 1 General

About these operating instructions

Provides scope, purpose, and target audience for the operating instructions.

Safety Instructions in Document

Details the types of safety instructions and information they contain.

System Identification

Explains how to identify the gas sampling system using the nameplate.

Service and Support

Provides contact information for ABB Service for questions and support.

Chapter 2 Description of the Sampling System

Technical Data

Lists sound emission levels and dimensions/weights of system modules.

Intended Conditions of Use

Defines the system's purpose and lists restrictions on its use.

Structure and Function Overview

Diagram and description of SCK modules and their functions.

Operating Modes

Describes the Automatic and Manual modes of system operation.

Process Monitoring Devices

Details devices used for monitoring the process, like position indicators.

Controls and Displays on Control Cabinet

Overview of controls and displays on the central control cabinet.

Probe Retractor Components

Lists the main components and functions of the probe retractor.

Gas Sampling Probe H Details

Description and main components of the Gas Sampling Probe H.

Gas Sampling Probe 60S Details

Description and main components of the Gas Sampling Probe 60S.

Cooling Module Overview

Describes the cooling module's function in providing and monitoring cooling water.

Transformer Specifications

Details the characteristics and design features of the optional transformer.

Compressed-Air System Requirements

Minimum requirements for compressed air and details on the optional tank.

Chapter 3 Description of the Control System

Control System Structure and Function

Explains the system's operation via touchscreen and menu structure.

User Interface: Operation Screen

Details the components and functions of the operation screen.

User Interface: Trend Screen

Describes the trend screen for displaying measured values and alarm thresholds.

User Interface: Message Screen

Explains the message screen for viewing error and status messages.

User Interface: Parameter Screen

Details the parameter screen for viewing and editing system settings.

Error Message Display and Handling

How error messages are displayed on the touchscreen and stored in the logbook.

Access Permissions and Passwords

Explains the system's access levels and password structure.

Default Operating Parameter Settings

Lists the factory default settings for various operating parameters.

Optimizing Operating Parameters

Guidance on adjusting parameters to suit specific system conditions.

Chapter 4 Safety

Basic Safety Rules

General safety rules intended for all persons handling the gas sampling system.

Overview of Dangers

Information on residual risks and their effects associated with the system.

Protective Installations

Details the protective installations designed to protect the operator.

Warning Signs on the System

Explains the meaning and location of warning signs on system modules.

Personnel Qualifications and Work Places

Requirements for personnel handling the system and designated work areas.

Personal Safety Equipment (PPE)

Lists general and additional protective equipment required for work.

Safety Measures: Transport and Unpacking

Dangers during transport/unpacking and preventive actions.

Safety Measures: Installation

Dangers during installation and preventive actions.

Safety Measures: Start-up

Dangers during system start-up and preventive actions.

Safety Measures: Operation

Dangers during system operation and preventive actions.

Safety Measures: Maintenance and Troubleshooting

Dangers during maintenance/troubleshooting and preventive actions.

Chapter 5 Transport and Unpacking

General Transport Information

Guidelines for heavy transport units, mechanical dangers, and general remarks.

Transporting the Modules

Specific instructions for transporting individual system modules.

Environmental Conditions for Transport and Storage

Specifies ambient temperature and air humidity limits for transport.

Transporting the System Within the Company

Instructions for moving system components within company premises.

Unpacking the System

Step-by-step procedure for safely unpacking the gas sampling system.

Scope of Delivery

Lists standard and optional components included with the system delivery.

Chapter 6 Installation

Overview of Installation

Lists installation tasks and links to specific module instructions.

Checking Site Conditions

Ensures the installation site is correctly prepared before commencing work.

Installing the Probe Retractor

Step-by-step guide for installing the probe retractor.

Installing the Control Cabinet

Instructions for installing the control cabinet in a suitable location.

Installing the Compressed-Air Supply

Procedure for installing the compressed-air system and tank.

Installing the Cooling Module

Instructions for installing the cooling module and attaching drain pipes.

Installing the Cooling Water Circuit

Procedure for preparing and installing the cooling-water hoses.

Connecting Sample Gas Line to Retractor

Procedure for connecting the sample gas line to the probe retractor.

Connecting Internal Electric Cables

Details on connecting internal electrical wiring within the system.

Connecting External Electric Cables

Instructions for connecting external power and signal cables.

Chapter 7 Start-up

Overview of Start-up Procedure

Summarizes the essential steps for starting up the gas sampling system.

Installation Check

Verifies correct installation before the initial start-up.

Preparing the Cooling-Water Circuit

Instructions for filling the cooling-water circuit with water or anti-freeze.

Preparing the Compressed-Air Supply

Checks and preparation steps for the compressed-air system.

System Activation

Steps to activate the gas sampling system, including safety warnings.

Post-Activation: Cooling Module Checks

Checks and actions on the cooling module after system activation.

Checking the Pneumatic System

Procedures to check compressed-air settings and pressure switches.

Frequency Converter Start-up and Parameter Adaptation

Starting the frequency converter and adapting control parameters.

Checking and Correcting Operating Parameters

Modifying system parameters to suit specific conditions.

Specific Checks for Probe H

Additional checks required when using Gas Sampling Probe H.

Inserting Probe and Switching to Automatic Mode

Procedure for inserting the probe and enabling automatic operation.

Chapter 8 Operation

Safety Regulations for Operation

Operator must observe safety instructions during system operation.

Monitoring Automatic Mode

Switching to and monitoring the system in automatic mode.

Checking General System Condition

Daily monitoring of system components for damage, leaks, or wear.

Cleaning Gas Sampling Probe H

Procedures for cleaning Probe H in manual and automatic modes.

Cleaning Gas Sampling Probe 60S

Procedures for cleaning Probe 60S in manual and automatic modes.

Using the EMERGENCY-STOP Switch

Procedure for using the EMERGENCY-STOP switch to interrupt probe movement.

Chapter 9 Maintenance

Maintenance Plan Overview

Overview of regular maintenance work, requiring special training.

Maintenance: Gas Sampling Probe H

Maintenance intervals and tasks for Probe H (cleaning, filter, membranes).

Maintenance: Gas Sampling Probe 60S

Maintenance intervals and tasks for Probe 60S (cleaning, seals, filter).

Maintenance: Probe Retractor

Maintenance intervals and tasks for the probe retractor (filter, oiler, chain, bellows).

Maintenance: Cooling Module

Maintenance intervals and tasks for the cooling module (water, leaks).

Maintenance: Pneumatic System

Maintenance intervals and tasks for the pneumatic system (filter, leaks).

Equipment Layout Plan (Retractor)

Diagram showing location of maintenance-relevant equipment on the retractor.

Equipment Layout Plan (Control Cabinet)

Lists maintenance-relevant equipment within the control cabinet.

Equipment Layout Plan (Cooling Module)

Lists maintenance-relevant equipment on the cooling module.

Acquiring Spare and Wear Parts

Contact information for ordering spare parts and service from ABB.

Safety Regulations for Maintenance Work

Safety instructions for personnel performing maintenance tasks.

Operating the Service Switch

Procedure for putting the system into maintenance mode using the service switch.

Checking System Condition and Cleaning

Regular checks of system condition and cleaning procedures.

Evaluating Trend Displays

Steps to evaluate trend displays, requiring access level 2 password.

Checking Residual Current Circuit Breakers

Test procedure for residual current circuit breakers to simulate error.

Checking Protective Installations

Annual check of protective installations like EMERGENCY STOP switches.

Checking for Leaks

Regular checks for leaks in gas paths, compressed-air and cooling-water circuits.

Removing Incrustations: Gas Sampling Probe H

Procedure for mechanically removing incrustations from the probe tip.

Replacing Intake Filter: Gas Sampling Probe H

Procedure for replacing the intake filter on probe H.

Replacing Membrane Pump Membranes: Gas Sampling Probe H

Procedure for replacing the structural diaphragm of the presuction pump.

Removing Incrustations: Gas Sampling Probe 60S

Procedure for mechanically removing incrustations from probe 60S.

Cleaning/Replacing Outlet Filter: Gas Sampling Probe 60S

Procedure for cleaning or replacing the outlet filter on probe 60S.

Replacing Seal Set: Gas Sampling Probe 60S

Procedure for replacing the O-rings on the filter unit of probe 60S.

Checking Filter/Pressure Control Combination: Probe Retractor

Procedure to check the filter/pressure control combination on the probe retractor.

Checking/Replacing Filter Muffler: Probe Retractor

Procedure to check and replace the filter muffler on the compressed-air motor.

Checking and Topping Up Oiler: Probe Retractor

Checking oil level and delivery rate of the compressed-air oiler.

Checking and Tightening Drive Chain: Probe Retractor

Procedure to maintain adequate drive chain tension and prevent damage.

Adjusting Probe Position: Probe Retractor

Procedure to change probe position due to process or system changes.

Adjusting Position Indicators: Probe Retractor

Readjusting probe position indicators (inductive, mechanical) for correct signaling.

Checking the Bellows: Probe Retractor

Procedure for checking the condition of the retractor bellows for damage or abrasion.

Venting the Cooling-Water Circuit: Cooling Module

Procedure to vent the cooling-water circuit to remove air.

Checking and Topping Up Cooling Water: Cooling Module

Checking cooling water pressure/flow rate and topping up as needed.

Replacing Compressed-Air Filter: Pneumatic System

Procedure for replacing the compressed-air filter in the pneumatic box.

Chapter 10 Errors

Errors and Irregularities

Describes automatic error processes and remedies for common issues.

Touchscreen Error Displays

Explains error messages on the touchscreen and how to access details.

Handling Error Messages

Procedure to fix errors, emphasizing special training and safety precautions.

Chapter 11 Shutting Down, Storing, Putting Back into Operation, Disposal

Shutting Down the System

Instructions on how to safely shut down the gas sampling system.

Disassembling the System

Procedure for disassembling the system, including safety warnings.

Storing the System

Instructions and environmental conditions for storing system modules.

Putting the System Back into Operation

Follow start-up instructions to put the system back into operation.

Disposing of the System

Requirements and rules for the proper disposal of system components.

Chapter 12 Appendix

Pneumatic/Hydraulic Interface Plan

Diagram showing pneumatic and hydraulic connections of the system.

Electrical Connection Plan

Diagram showing electrical connections for the system modules.

Transformer Connection Plan

Diagram showing the electrical connections for the transformer.