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SCK

SCK

Product catalog summary

Overview: The SCK Sampling System is engineered for dry gas sampling at rotary cement kiln and calciner gas exits. It comprises three pre-assembled modules, facilitating quick installation and ensuring durability in challenging environments. The system is compatible with both ABB and third-party analyzer systems.

Key Features:

Pre-assembled tubes and bus cables for expedited installation.
Pneumatically driven probe retractor with dust cover and oven flap.
Water-cooled gas sampling probes with automatic cleaning and retraction.
Closed cooling water circuit with continuous monitoring.
Control unit with a color touch panel for operation, diagnosis, and maintenance.
Remote operation and diagnostic capabilities.

Application: Designed for sampling hot cement flue gas with high dust loads, the system is suitable for harsh environmental conditions and is ideally paired with ABB’s ACX analyzer system, though it can also integrate with third-party systems.

System Components:

Probe Retractor: Equipped with a pneumatic motor, chain-driven water-cooled probe, and automatic/manual oven flap, ensuring safe operation by retracting the probe during failures.
Gas Sampling Probes: Available in two types: Type H for hard encrustations and Type 60S for less hard encrustations, both designed to minimize deposits and maintain dust-free filters.
Cooling Unit: Supplies and monitors cooling water, featuring a speed-controlled heat exchanger and pump.
Control Unit: Includes a display and operator control unit for system monitoring and operation, with password-protected access levels.

Technical Specifications:

Power Supply: 230/400 VAC, 50/60 Hz, with UPS options.
Compressed Air: Clean, oil-free, and dry, with a positive pressure of 6 bar.
Cooling Water: Closed circuit with controlled temperature and pressure.
Material: Stainless steel for cooling tubes and inner gas pipes.

Installation Requirements: Specific power supply configurations, compressed air supply, and an emergency compressed-air tank are required for safe operation.

Cooling Water Supply:

Purpose: Cooling of the gas sampling probe.
Requirements: Drinking-water quality with an anti-freeze agent if ambient temperature is below 0°C (32°F). The agent should be oil-free and without anticorrosion properties.
Capacity: Initial fill of 50 to 60 liters at 1 to 2 bar pressure.
Ambient Conditions: Temperature range of 5 to 45°C (41 to 113°F), extendable to -20 to 45°C (-4 to 113°F) with anti-freeze. Compressed air tank option allows for -10 to 50°C (-14 to 122°F).
Transport and Storage: Temperature range of 5 to 55°C (41 to 131°F), extendable to -20 to 55°C (-4 to 131°F) after draining and drying.
Humidity: Up to 75% annual average, short-term up to 95% with slight condensation possible.
Installation Location: Maximum altitude of 2000 meters (6562 feet). Must be low-vibration and protected from direct sunlight, dust, and rain.

Process Gas Conditions:

Pressure: ±3 kPa (0.435 psi) relative to atmospheric pressure.
Temperature: Maximum of 1300°C (2372°F).
Dust Load: Maximum of 2000 g/m³ (874 grain/ft³).
Gas Velocity: Maximum of 20 m/s (65 ft/s) at the sampling point.

Power Supply and Signal Interfaces: Details on power supply and signal interfaces are provided but not specified in this summary.

Dimensions and Mounting:

Retractor Dimensions: Provided for retractors of various lengths (2.5m, 3.5m).
Cooling Unit and Control Unit Dimensions: Specific dimensions are provided but not detailed in this summary.
Mounting Instructions: Includes specifications for mounting bolts, pipes, and counter flanges, with all dimensions in millimeters.

General Information:

Manufacturer: ABB Automation GmbH, Measurement & Analytics, Frankfurt, Germany.
Contact: Email at [email protected], website at abb.com/analytical.
Disclaimer: Technical changes may occur without notice. ABB holds all rights to the document and its contents.

Catalog excerpts

SCK Sampling system for dry gas sampling at rotary cement kiln gas exit and calciner gas exit

Open the catalog to page 1

SCK SAMPLING SYSTEM | DS/SCK-EN REV. A — Application and system overview System overview The SCK sampling system is designed for sampling of hot cement flue gas with a high dust load for gas analysis. Usage sites are the rotary cement kiln gas exit and the calciner gas exit in dry process clinker kilns. The system is suitable for applications in rough environmental conditions. The SCK sampling system comprises the following modules: The SCK sampling system is preferably combined with ABB’s ACX analyzer system. The combination of SCK with analyzer systems of third-party manufacturers is also possible....

Open the catalog to page 3

SCK SAMPLING SYSTEM | DS/SCK-EN REV. A 12 3 1 Pneumatic box 2 Emergency stop button 'probe action' 3 Pneumatic motor 4 Terminal box for system-internal electric cables connections 5 Heated connection box for sample gas line connection 6 Automatically (pneumatically) or manually driven oven flap 7 Transport brackets (dismounted at installation site) 8 Gas sampling probe type H (see p. 5) or type 60S (see p. 6) 9 Internal heated sample gas line 10 Flashing lights 'probe action' 11 Cable drag chain 12 Probe cleaning unit Description The retractor with its pneumatic chain driver carries the gas sampling...

Open the catalog to page 4

SCK SAMPLING SYSTEM | DS/SCK-EN REV. A — Gas sampling probe type H 6 5 Control air connection G ¼ in Sample gas connection G ¼ in Compressed air connection for pipe nozzle with 18 mm outer diameter Cooling water connections G 1 in 5 Bleeding for cooling water circulation 6 Flange DN 150, PN 10 Technical data The water-cooled gas sampling probe type H is installed in kilns, where extremely hard encrustations are to be expected. Material Cooling tube: Stainless steel 1.4541 (AISI 321) Inner gas pipe: Stainless steel 1.4436 (AISI 316) By using the probe type H, long measuring periods without interruptions...

Open the catalog to page 5

SCK SAMPLING SYSTEM | DS/SCK-EN REV. A — Gas sampling probe type 60S ~60 1 Sample gas inlet ports 2 Thickened shank of probe tube 3 Cooling water connections L1 Probe tube length L2 Length of thickened shank: 800 mm for L1 ≤ 2000 mm, 1300 mm for L1 ≥ 2500 mm L3 200 mm with reinforced protection tube Technical data The water-cooled gas sampling probe type 60S is installed in kilns where less hard encrustations are to be expected. Material Cooling tube: Stainless steel 1.4541 (AISI 321) Inner gas pipe: Stainless steel 1.4571 (AISI 316Ti) By using the probe type 60S with two sample gas openings...

Open the catalog to page 6

SCK SAMPLING SYSTEM | DS/SCK-EN REV. A 1 Temperature sensor (return) 2 Cooling water return (brass, pipe connector 1 in) 3 Check valve 4 Shut-off valve cooling water 5 Cooling water inlet (brass, pipe connector 1 in) 6 Cooling water feed (brass, pipe connector 1 in) 7 Pressure controller 8 Temperature sensor (feed) 9 Safety relief valve outlet (brass, pipe connector 1 in) 10 Safety relief valve cooling water pressure 11 Surge tank 12 Fan motor heat exchanger 13 Heat exchanger 14 Cooling water pump 15 Analog input module 16 CAN bridge 17 Terminal strip power supply for motor and pump 18 Terminal...

Open the catalog to page 7

SCK SAMPLING SYSTEM | DS/SCK-EN REV. A 1 Maintenance switch (lockable) 2 Color touch panel 3 Buzzer 4 Main switches Description The control unit comprises the control system including the display and operator control unit for monitoring and operating the gas sampling system. Electrical power supply and all signals for the entire gas sampling system are fed-in and distributed in the control unit. The control program offers different levels which are partly password-protected. Various locking mechanisms prevent possible sampling probe damages caused by erroneous operation or failure of single modules. Operation Probe...

Open the catalog to page 8

SCK SAMPLING SYSTEM | DS/SCK-EN REV. A Cooling module Disposal tube from safety valve i Compressed air supply tube Cooling water feed pipe Heated sample gas line to analyzer system □ rxX J.7.IT. H 1 Safety relief valve outlet (bulkhead union brass with pipe connector 1 in) 2 Cooling water inlet (bulkhead union brass with pipe connector 1 in) 3 Cooling water feed (bulkhead union brass with pipe connector 1 in) 4 Cooling water return (bulkhead union brass with pipe connector 1 in) 5 Cooling water tube (25/39x7 mm 30 m incl. in delivery) 6 Compressed air tube (PA 18/14x2 mm 25 m incl. in delivery) 7...

Open the catalog to page 9

SCK SAMPLING SYSTEM | DS/SCK-EN REV. A Power supply Control unit 230/400 VAC supply lines: UPS 230 VAC supply lines (option): Control unit to retractor 230 VAC supply lines: 230 VAC supply lines (for probe type 60S): 24-30 VAC supply lines (for probe type H): 24 VDC supply lines: Control unit to cooling unit 400 VAC supply lines: 24 VDC supply lines: Declaration of conformity Electrical safety The regulations of European directive 2006/95/EC for low voltage are complied with. Electromagnetic compatibility The regulations of European directive 2004/108/EC for EMC are complied with. Machinery The...

Open the catalog to page 10

SCK SAMPLING SYSTEM | DS/SCK-EN REV. A Requirements at the installation site Power supply Operating voltage 230/400 VAC, ± 10 %, 50 Hz (fuses 3 x 20 A required), 3-phase connection (5 wires, N-conductor necessary) or 230/400 VAC, ± 10 %, 60 Hz (fuses 3 x 20 A required), 3-phase connection (5 wires, N-conductor necessary) or 3 x 208 VAC, ± 10 %, 60 Hz incl. transformer (fuses 3 x 20 A required), 3-phase connection (4 wires) Other voltages on request Power consumption Max. 6 kVA Option ‘UPS' 230 VAC or 120 VAC, ± 10 %, 50 to 60 Hz (fuse 1 x 6 A required) Compressed air supply Purpose For movement...

Open the catalog to page 11

SCK SAMPLING SYSTEM | DS/SCK-EN REV. A (as) snid Aiddns govnoA 1 ONHOdO IVIlNdlOd NOISSIl^lSNVai viva 3diM-a snid- viva nvMSNvai /3Ai303d d-axi/axy da snaidoad

Open the catalog to page 12

SCK SAMPLING SYSTEM | DS/SCK-EN REV. A -D30 u-REMOTE CAN COUPLER -D50 u-REMOTE CAN COUPLER -D70 u-REMOTE CAN COUPLER -E71 HEATER FILTER UNIT PFE3 (OPTION "60S") -E72 HEATER GAS SAMPLE PROBE H (OPTION "H”) -E73 HEATER GAS SAMPLE PROBE H (OPTION "H") -M51 COOLING WATER PUMP -M52 FAN MOTOR HEAT EXCHANGER -W30 MODBUS CABLE TO ANALYSIS SYSTEM ACX, LiYCY 3x0,25mm2 (OPTION "ACX") -W31 CONTROL CABINET -W32 POWER SUPPLY CABLE 230/400 VAC 5G4mm2 OR5xAWG10 -W33 UPS POWER SUPPLY CABLE 230 VAC 3G2,5mm20R3xAWG12 (OPTION "UPS") -W34 PROFIBUS CABLE AWG22/1, d=0,64mm (OPTION "PROFIBUS DP") -W35 PROFIBUS CABLE AWG22/1,...

Open the catalog to page 13

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Catalog excerpts

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