Document YjbNrMZ6oXxK2dR4nLKkBK19N

YCNet Vinyl Chloride Safety Awareness Training m 8^918 Instructed by Clyde Strong & Associates, Inc. College Station, Texas March 26 - 27,1992 March 28 - 29,1992 Lamar University Fire School Grounds Beaumont, Texas CHEMICAL MANUFACTURERS ASSOCIATION z SL 086616 o INSTRUCTION MANUAL TRACE GAS ANALYZER HNU MODEL PI 101 HNU Systems, Inc. 160 Charlemont St. Newton, MA 02161 December 1985 SL 086617 warnings The following warnings appear in this manual and are repeated here for emphasis. Do not look at the light source from closer than 6 inches with unprotected eyes. Observe only briefly. Continued exposure to ultraviolet energy generated by the light source can be harmful to eyesight. The instrument measures gases in the vicinity of the operator and a high reading when measuring toxic or explosive gases should be cause for immediate action for safety. txutme care must be taken in the handling of gas cylinders. Contents are under high pressure. In some cases, the contents may be hazardous. Many gas suppliers will provide data sheets for the mixtures upon request. Never open the valve on a gas container without a regulator attached. Turn the function switch on the control panel to the OFF position before disassembly. Otherwise, high voltages of 1200 V DC, will be present. Use great care when operating the analyzer with the readout assembly outside its case due to the presence of 1200 V DC. Be very careful to note the toxic levels and the Lower Explosive Limits for personal safety. The PI 101 is a nondestructive analyzer and must be used in a hood when calibrating with toxic or hazardous materials. The PI 101 is suitable for uses in Class I Division II ABCD areas except when using charger or when using recorder. 0B&618 SECTION 1 general information 1 1.1 INTRODUCTION This manual describes the operation, maintenance and parts list for the Trace Gas Analyzer, Model PI 101, HNU Systems Inc. 1.2 EQUIPMENT DESCRIPTION The Trace Gas Analyzer (see Figure 1-1), is a portable instrument used to detect, measure, and provide a direct reading of the concentration of a variety of trace gases in many industrial or plant atmospheres. The analyzer employs the principle of photoionization. , This process involves the absorption of ultra-violet light (a photon) by a gas molecule leading to ionization: RH + hv --> RH+ + e- in which RH = Trace gas hv = Photon with an energy level equal to or greater than the ionization potential of RH. The sensor consists of a sealed ultraviolet (UV) light source that emits photons with an energy level high enough to ionize many trace species, particularly organics, but not high enough to ionize the major components of air, 02, N2, CO, C02 or H20. A chamber exposed to the light source contains a pair of electrodes, one a bias electrode and the second a collector electrode. When a positive potential is applied to the bias electode a field is created in the chamber. Ions formed by the absorption of photons are driven to the collector electrode. The current produced is then measured and the corresponding concentration displayed on a meter directly in parts per million (ppm). To minimize absorption or decomposition of sample gases, rapid flow of sample gas is maintained thru the ion chamber, which is small, made of inert material and located at the sampling point. a The analyzer consists of a probe, a readout assembly, and a battery charger. The probe contains the sensing and amplifying circuitry; the readout assembly contains the meter, controls, power supply and rechargeable battery. The analyzer will operate from the battery for more than 10 hours or continuously when connected to the battery charger. PAGE 1-1 Si The PI 101 is designed for use with interchangeable probes with lamps of different energies. The analyzer is ready for use simply by connecting the probe to the readout assembly, setting the proper SPAN pot value, and then zeroing,the unit. Specific data is given in the calibration memo accompanying each probe. The standard probe uses a 10.2 eV lamp. Two optional probes use 9.5 and 11.7 eV lamps. Lamps of different eV ratings, ion chamber and amplifiers are not interchangeable between probes. Many applications make use of the principle that some compounds respond to the more energetic lamps and not to others. Figure 1-2 shows the responses for the analyzer with each of the three lamps. Literature explaining several such applications is available from HNU Systems Inc. An optional audible alarm is available giving an 85 decibel signal when a set concentration is exceeded. The alarm setting is variable and can be set from 0 to 100% of full scale of the meter reading. Power for the alarm is provided by the battery and does not significantly affect the rated use time of the analyzer. The alarm is non-latching and is set by a screw adjustment, preventing inadvertent changes. When in the stored condition, the probe is contained in the instrument cover (see Figure 1-3) which attaches to the readout assembly to form a single unit (see Figure 1-4). An optional recorder is available that can be directly attached to the readout assembly. It uses impact paper with a 2" wide chart and a speed of 2"/hour. The recorder is powered by the instrument battery and provides hard copy of the data. The analyzer will operate for approximately 4 hours with the recorder attached. Mounting information and illustration is given in Section 8. Specification data on the analyzer is given in Table 1-1. Physical characteristics of the equipment are given in Table 1-2. PAGE 1-3 SL 086620 FIGURE 1-4 TRACE GAS ANALYZER STORED CONDITION SL 086621 Page i INNER PANEL INSTRUMENT COVER (FOR STORAGE OF PROBE ) PROBE EXTENSION PUSH FASTENERS PROBE CABLE FIGURE 1-3 PROBE STORAGE INSTRUMENT COVER Repeated storage of probe in this manner is not recommended due to cable wear. Instrument cover may also be used lor storing battery charger. Si 86 ^22 Page 1 -5 FIGURE 1-1 TRACE GAS ANALYZER OPERATING CONDITION SL 086623 Page 1 -2 . BATTERY CHECK POSITION FIGURE 2-1 CONTROLS AND INDICATORS SL 086624 Page 2-2 SECTION 2 OPERATION 2.1 INTRODUCTION/UNPACKING Unpack the instrument carefully. The carton will contain the housing, straps, battery charger, additional probes, regulator and cylinder if ordered, spare parts, supplies and a manual. Be sure all items are removed before discarding the carton. Attached to the instrument is a warranty card which should be filled out completely and returned to HNU Systems. 2.2 CONTROLS AND INDICATORS The controls and indicators are located on the front panel of the readout assembly (see Figure 2-1) and are listed and described in Tables 2-1 and 2-2. 2.3 OPERATING PROCEDURES The following procedures are to be used in operating the analyzer: a. Unclamp the cover from the main readout assembly. b. Remove the inner lid from the cover by pulling out the two fasteners. c. Remove the probe, handle and cable from the cover. Attach the handle to the front part of the probe. d. Connect the probe cable plug to the 12 pin keyed socket on the readout assembly panel. Carefully match the alignment slot in the plug to the key in the connector. Screw down the probe connector until a distinct snap and lock is felt. e. Screw the probe extension into the probe end cap. The probe may be used without the extension if desired. f. Set the SPAN control for the probe being used (10.2, 9.5, or 11.7 eV) as specified by the initial factory calibration or by subsequent calibrations. PAGE 2-1 SL 086625 TABLE 2-1 CONTROLS Name Position Function Function Switch -----OFF batt (battery check) STANDBY ZERO 0-2000 0-200 0-20 ------ Controls the operation of the analyzer All operations OFF Checks the condition of the battery. If the meter needle is in the green arc, the battery is charged. If not the battery should be recharged. Charging can be done in any position, best in OFF; see directions on charger. All electronics ON, ultraviolet (UV) light source OFF. This position conserves power and extends battery life. This position is used to set the analyzer zero position. (i.e. no UV light, no signal) Sets range of meter at 0-2000 ppm. Sets range of meter at 0-200 ppm. Sets range of meter at 0-20 ppm. With the function switch in STANDBY position, this potentiometer is used to adjust the reading to zero. NOTE: See Figure 2-1 for locations. PAGE 2-3 SL 086626 table 2-1 cont. SPAN ------ This vernier potentiometer is use'd to set the gain of the amplifier to give direct readings of the trace gas concentrations in ppm. The whole number of the setting appears in the window of the control, decimal appears on the dial. A lock secures it at a specific setting. HI-VOLTAGE ------ This is a normally open microswitch. Open Switch is open when cable not connected, disconnecting high voltage for the UV lamp from the 12 pin connector as a safety precaution. Closed Switch is automatically closed when the cable is attached. This switch may also be closed manually during maintenance checks of the readout assembly without the probe cable attached. ALARM SET (optional) ------ Potentiometer with screw driver adjustment. Turns the audible alarm ON or OFF and sets the ppm level at which the alarm sounds. If alarm is low limit, it sounds when measured ppm falls below this value. If alarm is high limit it sounds when measured ppm exceeds this value. NOTE: See Figure 2-1 for locations. PAGE 2-4 SL 86627 TABLE 2-2 INDICATORS AND DISPLAYS Name Low Battery Indicator Light (red light) (see NOTE) Meter (see NOTE) Recorder (optional) (see Figures 2-1 And 8-3) Function Illuminates when battery is discharged, indicates need for recharge. Do not use unit when this light is ON. Readings may be taken while battery is being recharged. Indicates concentration of measured gas. Provides a record of readings while analyzer operates unattended. Recorder inputs 0 to -5 V DC. NOTE: See Figure 2-1 for locations,. PAGE 2-5 SL 086628 SECTION 2.3, OPERATING PROCEDURES cont. g. Turn the function switch to the BATT (battery check) position. The needle on the meter will go to the green zone if the battery is fully charged.. If the needle is below the green arc or if the Low Battery Indicator comes on, the battery must be recharged before the analyzer is used. h. Set SPAN pot to the desired value based on the gas to be used. i. Turn the function switch to the STANDBY position. Turn the zero adjustment until the meter needle is at zero. j. Calibrate the instrument daily as described in Section 3. Calibration on the selected operating range is desirable. k. If equipped with optional alarm, set or check the alarm setting at the level desired. Turn the function switch to the desired range, turn the zero adjustment control so the meter needle moves upscale thru the desired value. This simulates real conditions. Observe the reading when the alarm sounds. Adjust the ALARM SET, if required, with a screw driver. Turn the function switch to the STANDBY position and reset the zero position (para. h. above). If the range is to be changed, the alarm must be reset on that range. l. To operate with optional recorder, add the recorder bracket (see Figure 8-3). Remove the plug in the analyzer case and insert power cord into the recorder. Then connect the signal leads to the appropriate jacks in the control module. The recorder is now operational. NOTE: Ranges must be marked on the chart as the recorder prints the meter display as % of Full Scale. m. Turn the function switch to the appropriate operating position. Start with the 0-2000 position and then switch to the more sensitive ranges. The UV light source should be on, confirmed by briefly looking into the probe to observe a purple glow from the lamp. WARNING Do not look at the light source closer than 6 inches with unprotected eyes. Observe only if necessary, then only briefly. Continued exposure to ultraviolet energy generated by the light source can be harmful to eyesight-. PAGE 2-6 Si 8662g SECTION 2.3, OPERATING PROCEDURES cont. n. The .analyzer is now operational. o. Hold the probe so that the extension is at the point where the measurement is to be made. The instrument measures the concentration by drawing the gas in at the end of the extension, through the ionization chamber, and out the handle end of the probe. WARNING The instrument measures gases in the vicinity of the operator and a high reading when measuring toxic or explosive gases should be cause for action for operator safety. p. Take the reading or readings as desired taking into account that air currents or drafts in the vicinity of the probe tip may cause fluctuations in readings. Change the ranges as required. q. Check battery condition as required. If the Low Battery Indicator comes on, turn analyzer off and recharge. CAUTION Use only in an emergency with a low battery when on battery charge. PAGE 2-7 SECTION' 2.3, OPERATING PROCEDURES cont. r. After completion of use, check battery condition as described in para. g. s. Turn function switch to OFF position. t. When not operating, leave analyzer in assembled condition, and connected to battery charger. u. When transporting, disassemble probe and extension from readout assembly and return equipment to its stored condition. v. In case of emergency, turn function switch to OFF position . 2.4 BATTERY CHARGE Check the battery charge as described in paragraph 2-3 g during each period of operation, at least once daily. If the battery is low as indicated by the meter reading or the warning indicator, it is necessary to recharge the battery. To charge the battery, first insert the mini phone plug of the charger into the jack, J6, on the side of the bezel adjacent to the meter. Then insert the charger plug into a 120 or 230 V AC single phase, 50-60 cycle outlet. To ensure that the charger is functioning, turn the function switch, SI, to the battery check (BATT) position. The meter should deflect full scale if the charger is working and connections properly made. For normal battery charging, leave the function switch in the OFF position. The analyzer can be operated, however, while recharging by turning the function switch to the desired position. Such usage will extend the time required to completely recharge the battery. The battery charger is not Div. II approved. NOTE: On all Sira approved PI 101s it is necessary to connect the probe assembly before turning on the instrument and re-charging. Without following this procedure the instrument will not show battery check. PAGE 2-8 SL 086631 SECTION 3 )1 INTRODUCTION CALIBRATION The PI 101 Analyzer is designed for trace gas analysis in ambient air and is calibrated at HNU with certified standards of benzene, vinyl chloride and isobutylene. Other optional calibrations are available (e.g., ammonia, ethylene oxide, H2S, etc.). Calibration data is given in the data sheet. If a special calibration has been done, the data is given in the Application Data Sheet, which notes the sample source, type of calibration (see Section 8, Appendix), and other pertinent information. Good instrumentation practice calls for calibration on the species to be measured in the concentration range to be used. This procedure assures the operator that the analyzer is operating properly and will generate reliable data. Some general points to consider when calibrating the PI 101 are that the analyzer is designed for operation at ambient conditions and therefore the gas standards used for calibration should be delivered to the analyzer at ambient temperatures and pressure and at the proper flow rates. WARNING: The PI 101 is a non-destructive analyzer; calibrations using toxic or hazardous gases must be done in a hood. ) The frequency of calibration should be dictated by the usage of the analyzer and the toxicity of the species measured. If the analyzer has been serviced or repaired, calibration should be done to verify operation and performance. It is recommended that calibration be checked frequently at first (daily or every other day) and then regularly based on the confidence level developed. The normal meter scaleplate is 0 to 20. If the scaleplate is different, refer to the Application Data Sheet. If there are questions, consult the HNU representative before proceeding with calibration check. An accurate and reliable method of calibration check is to use an analyzed gas cylinder in a test setup as shown in Figure 3-1 and described below. Additional material on calibration is given in Section 8, Appendix. 3.2 ANALYZED GAS CYLINDER a. Concentration - The calibration gas cylinder is to contain the species of interest made up in an air matrix at or near the concentration to be analyzed. If the component is unstable in air, another matrix is to be used. The final calibration mixture should be similar to the sample the PI 101 will analyze. If the expected concentration is not known then a concentration should ) be chosen that will cause a scale displacement of 50 to 80% on the X10 range. Calibration on X10 range will provide accurate values on the XI range as well. PAGE 3-1 SL 086632 For use on the 0-2000 range, a two-standard calibration is preferred: one at 70 to 85% of the linear range and the other at 25 to 35% of the linear range. With the linear range of approximately 600 ppm for most compounds these points would lie between 420 to 510 ppm and 150 to 210 ppm, respectively. b. Stability - The calibration gas must be stable within the cylinder during the period of use. If the calibration is required in the field, then use of a small cylinder is recommended. In addition, the choice of cylinder material in contact with the gas must be considered (steel, aluminum or teflon). If there are any questions, the operator should request stability and usage information from the gas supplier. WARNING Extreme care must be taken in the handling of gas cylinders. Contents are under high pressure. In some cases, the contents may be hazardous. Many gas suppliers will provide data sheets for the mixtures upon request. c. Delivery - The cylinder containing the calibration mixture must be connected to a proper regulator. WARNING Never open the valve on a gas cylinder container without a regulator attached. Leak test all tank/regulator connections as well as the main cylinder valve to prevent toxic or hazardous materials from leaking into the work area. Care must be taken that the materials of construction of the regulator will not interact with the calibration gas. One method of sampling the calibration gas is illustrated in Figure 3-1. Connect the cylinder to one leg of the tee, a flow meter to the opposite leg, and the probe to the third leg. The flow meter does not require a valve. If there is a valve, it must be left wide open. the flowmeter is only to indicate excess flow. Adjust the flow from the regulator such that only a little excess flow is registered at the flowmeter. PAGE 3-2 SL 086633 SECTION 3.2, ANALYZED GAS CYLINDER cont. ) This insures that the PI 101 sees the calibration gas at atmospheric pressure and ambient temperature. d. Usage - Generally, a gas cylinder should not be used below 200-300 psi as pressure effects could cause concentration variations. The cylinder should not be used past the recommended age of the contents as indicated by the manufacturer. In case of difficulty, verify the contents and concentration of the gas cylinder . e. Alternate means of calibration are possible. For more information, contact the HNU Service Department. 3.3 PROBE a. Identify the probe by the lamp label. If a question exists, disassemble the probe and inspect the lamp. The energy of the lamp is etched into the glass envelope. b. Connect the probe to the readout assembly, making sure the red interlock switch is depressed by the ring on the connector. \ c. Set the SPAN pot to the proper value for the probe being * calibrated. Refer to the calibration memo accompanying the probe. d. Check the Ionization Potential (IP) of the calibration gas to be used. The IP of the calibration gas must be at or below the IP of the lamp. e. Proceed with the calibration as described in Section 3.4. Check the calibration memo for specific data. If any questions develop, call the HNU representative. f. NOTE: The 11.7eV lamp has a special cleaning compound. Do not use water or any other cleaning compound with the 11.7 eV lamp. Do not interchange ion chambers, amplifier boards or lamps between probes. (See Section 5.2). 3.4 PROCEDURE a. Battery check - Turn the function switch to BATT. The needle should be in the green region. If not, recharge the battery. ^ PAGE 3-3 SL 086634 c cm. b. Zero set - Turn the function switch to STANDBY. In this position the lamp is OFF and no signal is generated. Set the zero point with the ZERO set control. The zero can also be set with the function switch on the XI position and using a "Hydrocarbon-free" air. In this case "negative" readings are possible if the analyzer measures a cleaner sample when in service. c. 0-20 or 0-200 range -- For calibrating on the 0-20 or 0-200 range only one gas standard is required. Turn the function switch to the range position and note the meter reading. Adjust the SPAN control setting as required to read the ppm concentration of the standard. Recheck the zero setting (step b.). If readjustment is needed, repeat step c. This gives a two-point calibration; zero and the gas standard point. Additional calibration points can be generated by dilution of the standard with zero air if desired (see Section 8). d. 0-2000 range - For calibrating on the 0-2000 range, use of two standards is recommended as cited in Section 3.2a. First calibrate with the higher standard using the SPAN control for setting. Then calibrate with the lower standard using the ZERO adjustment. Repeat these several times to ensure that a good calibration is obtained. The analyzer will be appoximately linear to better than 600 ppm, (see Figure 3-2). If the analyzer is subsequently to be used on the 0-20 or 0-200 range, it must be recalibrated as described in steps b. and c. above. e. Lamp cleaning - If the span setting resulting from calibration is 0.0 or if calibration cannot be achieved, then the lamp must be cleaned (see Section 5.2). f. Lamp replacement - If the lamp output is too low or if the lamp has failed, it must be replaced (see Section 5.3) . 3.5 CALIBRATION CHECKING Rapid calibration checking in the field can be accomplished by use of a small disposable cylinder containing isobutylene. Immediately after a calibration has been completed, a reading is taken on a special isobutylene standard. This provides a reference concentration measurement for later checking in the field. This can be done at any time with a portable cylinder containing this same special standard, using this reference reading as a check, and making adjustments to the analyzer if necessary. In effect, this is an indirect method of calibration, one maintaining the calibration to give direct readings for the original gas mixture, but using the portable isobutylene cylinder. Details are given in Section 8.2 of the Appendix. PAGE 3-4 SL 086635 o FIGURE 3-1 CALIBRATION TEST SET UP SL 086636 Page 3 5 TABLE 8.3 ALKYL HALIDES Molecule HCI Cl2 ch4 methyl chloride dichloromethane trichloromethane tetrachloromethane ethyl chloride 1,2-dichloroethane I'Chloropropane 2-chloropropane 1,2-diChloropropane 1,3-dichloropropane 1-chlorobutane 2-chlorobutane 1 -chloro-2-methylpropane 2-chloro-2-methylpropane HBr Br2 methyl bromide dibromomethane tribomomethane CH2BrCI CHBr2CI ethyl bromide 1,1-dibromoethane 1 -bromo-2-chloroethane IP(eV) 12.74 11.48 12.98 11.28 11.35 11.42 11.47 10.98 11.12 10.82 10.78 10.87 10.85 10.67 10.65 10.66 10.61 11.62 10.55 10.53 10.49 10.51 10.77 10.59 10.29 10.19 10.63 TABLE 8.3 (continued) Molecule 1-bromopropane 2-bromopropane 1,3-dibromopropane 1 -bromobutane 2-bromobutane 1 -bromo-2-methylpropane 2-bromo-2-methylpropane 1 -bromopentane HI 2 methyl iodide diiodomethane ethyl iodide 1 -iodopropane 2-iodopropane 1 -iodobutane 2-iodobutane 1 -iodo-2-methylpropane 2-iodo-2-methylpropane 1-iodopentane f2 HF CFCI3 (Freon 11) CF2CI2(Freon 12) CF3CI (Freon 13) CHCIF2 (Freon 22) CFBr3 IP(eV) 10.18 10.075 10.07 10.13 9.98 10.09 9.89 10.10 10.38 9.28 9.54 9.34 9.33 9.26 9.17 9.21 9.09 9.18 9.02 9.19 15.7 15.77 11.77 12.31 12.91 12.45 10.67 PAGE 3-14 SL S6637 TABLE 8.9 OLEFINS, CYCLO-OLEFINS, ACETYLENES Molecule IP(eV) ethylene propylene i-butene 2-methytpropene 10515 9,73 9.58 9 23 trans-2-butene 9.13 CiS-2-butene 1-pentene 2-methyl*1 -butene 3-methyl-1 -butene 9.13 9.50 9.12 9.51 3-methyl-2-butene 1 -hexene 8.67 9.46 i.3-butadiene 9.07 Isoprene 8.845 cyclopentene 9.01 cyclohexene 8.945 ;-methylcyclohexene 8.91 4-cinylcylohexene 8.93 cyclo-octatetraene acetylene 7.99 1 1.41 propyne 1-butyne 10.36 10 18 TABLE 8.10 SOME DERIVATIVES OF OLEFINS Molecule vinyl chloride cis-dichloroethylene trans-dichloroethylene trichloroethylene tetrachloroethylene vinyl bromide 1,2-dibromoethylene tribromoethylene 3-chloropropene 2,3-dichloropropene 1 -bromopropene 3-bromopropene CF3CCI=CCICF3 n-CsFi i CF=CF2 acrolein crotonaldehyde mesityl oxide vinyl methyl ether allyl alcohol vinyl acetate IP (eV) 9 995 9 65 9 66 9 45 9 32 9.80 9 45 9 27 10 04 9.82 9.30 9.7 1036 10.48 10.10 9.73 9.08 8.93 9 67 9.19 SL 086638