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EVALUATION REPORT E 2720 K 01 Published by WIB, November 2001

Index classification 4.2

TESTA FID 123 analyser

Manufacturer: TESTA GmbH Germany

INTERNATIONAL INSTRUMENT USERS' ASSOCIATIONS SIREP-WIB-EXERA

Members of the international Instrumentation Evaluation Agreement Group of the European Organisation for Testing and Certification (EOTC). Registration No 0003

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CIRCULATION

This report has been produced for the in-house use of SIREP, WIB and EXERA members. The contents of the report must not be divulged to persons not employed by SIREP, WIB and EXERA member companies

without the express consent of the issuing organisation.

ABOUT SIREP-WIB-EXERA

SIREP-WIB-EXERA are international instrument users' associations who collaborate in the sponsoring, planning and organisation of instrument evaluation programmes. They have the long term objective of

encouraging improvements in the design, construction, performance and reliability of instrumentation and related equipment.

SIREP-WIB-EXERA are formally recognised by the European Organisation for Testing and Certification (EOTC) as the Agreement Group for International Instrumentation Evaluation, Registration No 0003.

The evaluation of the selected instruments is undertaken by approved, independent laboratories with respect to the manufacturers' performance specifications and to relevant international and national

standards.

Each evaluation report describes the assessment of the instrument concerned and the result of the testing. No approval or certification is intended or given. It is left to the reader to determine whether the instrument

is suitable for its intended application. All reports are circulated throughout the entire membership of SIREP-WIB-EXERA.

SIREP International Users' Association South Hill, Chislehurst, Kent, England BR7 5EH

International Instrument Users' Association WIB Prinsessegracht 26, 2514 AP, The Hague, The Netherlands

EXERA Association des Exploitants d'Equipment de Mesure, de Regulation et d'Automatisme, Parc Technologique ALATA, BP 2,

F-60550 Vernneuil en Halatte, France

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SIREP-WIB-EXERAMEMBERSHIP LIST

2001

Acetex Chimie ²Agences de BassinAir LiquideAir Products & Chemicals IncorporatedAkzo Nobel EngineeringBellt GCA ¹BNFLBP-Amoco CorporationBritish Energy plcCEACentre d’Essais des PropulseursChiyoda CorporationCogemaCorus Group BVDassault Aviation ²DOW BeneluxDSM Services Engineering-StamicarbonDupont de Nemours BV-NLEADS-LVECN/Netherlands Energy Research Foundation ¹Ekono OYElectricite de France (EDF)Ente Nazionale per l’Energia ElettricaEnviroment AgencyEquillon LCCEsso/Exxon/MobilFederelettricaFluor DanielGaz de FranceGEMCEA ²Générale des EauxGTIEHeineken Technical ServicesINERIS

Infraserv HoechstInstitut National de Recherche et de SécuritéItalcementi / CTGJacobs Engineering BV ¹KEMA Nederland BVLubrizol France ²Lyonnaise des EauxMobil Research & Development CorporationMossgas (Pty) LtdNancié ²Nederlands MeetinstituutNV Nederlandse GasunieNestec LtdProcess Management & Control ¹PSA Peugeot-CitroenRATPRenault SARhoditechRijks Instituut voor Kust en Zee (RIKZ)Saudi Arabian Oil CompanySevern-Trent Water LtdShell Global SolutionsSolvay BV BeneluxStiftelsen for Instrum. provningTec IngénierieTechnicatomeTexaco IncorporatedTotalFinaElfTrapilUKAEA

¹ Associate Member

² Small Medium Enterprises

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KEMA Nederland BV Utrechtseweg 310, 6812 AR Arnhem

P.O. Box 9035, 6800 ET Arnhem The Netherlands

Telephone +31 26 3 56 91 11 Telefax +31 26 3 51 56 06

KEMA is an independent company whose goal is to provide international professional

services and know-how, on a commercial basis, in the field of (electrical) energy systems and the environment, as well as in the area of quality related issues such as testing and certification.

Core activities of KEMA are:

* Research and Development * Plant & System Operation Support * Engineering and Consultancy * Testing and Certification

Subject EVALUATION OF THE TESTA FID 123 ANALYSER

Manufacturer TESTA GmbH

Report No E 2720 K 01

Index Classification 4.2

Sponsors International Instrument Users' Association WIB and the manufacturer

Author P.H.J. Gamelkoorn

EVALUATION UNDERTAKEN AND REPORT PREPARED BY KEMA NEDERLAND B.V.

Author P.H.J. Gamelkoorn

KEMA Approval J.H.M. Overbeek

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Section Page

1 INTRODUCTION 1

2 MAJOR FINDINGS AND COMMENTS 2 2.1 Instrument performance 2 2.2 Comments on construction and use 7 2.3 Comments on documentation 7 2.4 Cost of ownership 7 2.5 Manufacturer's comments 7

3 TEST RESULTS 8 3.1 Results' summary 8

4 MANUFACTURER'S DATA 18

5 OPERATING PRINCIPLE AND CONSTRUCTION 20 5.1 Operating principle 20 5.2 Mechanical construction 20

6 TEST METHODS AND REFERENCES 21 6.1 Test methods 21 6.2 References 25 6.3 Definitions 25

APPENDIX I EMC APPENDIX II Manufacturer's QA procedures and instrument status APPENDIX III Information on the product evaluated by WIB

FIGURES

Fig 1 External view of instrument 6Fig 2 Measured error, C2H4 12Fig 3 Conformity, C2H4 12 Fig 4 Dead band, C2H4 13 Fig 5 Ambient temperature variations 13Fig 6 Long term drift, C2H4 14 Fig 7 Sample pressure variation, C2H4 14 Fig 8 Sample temperature variation, C2H4 15Fig 9 Sample flow variation 15Fig 10 Start-up drift zero C2H4 16 Fig 11 Start-up drift span C2H4 16 Fig 12 Basic test arrangement 23Fig 13 Axes of vibration 23

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Fig 1 EXTERNAL VIEW OF INSTRUMENT

FID 123

The High Temperature Flame Ionisation Detector (FID) measures Total Hydro-Carbons in catalytic and thermal after-burner plants, waste gas industries, room and environmental air, solvent recovery plants and vehicle exhaust gases.

Special Benefits:

Max. sample temperature 300°C (572°F) Warm-up from room temperature to 300°C (572°F) in 20 minutes. Quick response time Combustion air from room or compressed air. Ready for operation quickly. Low maintenance costs. Little service. Pressure and flow independent over the range of 1,0 bar (14psi) overpressure and 0,3 bar (4psi) vacuum

FID - 123:

Corrosion resistant materials Sample transport by air-injector with 58 psi (input pressure).

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Flame-Ionisation-Detector FID 123

Mains connection: 220V/50Hz (110V/60Hz on request) Power input: 400W (approx.), without sample line Ambient temperature: Max. + 45°C (110°F) Reproducibility: Range 1 + 3% all other ranges + 1% Ranges: 5 measuring ranges 10/100/1000/10.000/100.000ppm (other ranges on customer request) Recorder output: 0-10V / 0-20mA or 2-10V / 4-20mA Lowest range: 0-10ppm relative to propane (calibration

gas=C3H8)Zero & Span gas consumption: 3-4 litres/min. Zero drift: + 1% in 24 hours Combustion gas: Either afterpurified Hydrogen or a

Helium/Hydrogen mixture (60/40%) Combustion gas consumption: H2 30-49ml/min; H2/He 80-100ml/min Supply for heated sample line: Regulated and controlled by thermocouple Max. sample temperature: 300°C (572°F) in continous operation Warm-up time: From room temperature to 300°C (572°F) in approx. 20 min Response time: 1-2 sec. from rear panel of unit Size: H=220mm; B=440mm; D=350mm for both desktop and 19" rack version Weight: 15kg (approx.) Combustion air consumption: 0,4 litres/min Flame control: With thermocouple, indicated by lamp

Optional Extras:

Automatic Zero & Span without intervention: Cycle intervall 30 min.; adjustable between 30 min. and 49,5h Span/Zero gas from 0,5 min. to 4,5min Alarm contacts: Between 0-10V continously adjustable, potentialfree contacts (24V/1A)

Automatic flame ignition and H2 cut off: By mains failure or "flame-out"

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TESTA FID 123 PROCESS ANALYSER

Author: P.H.J. Gamelkoorn

Reported by KEMA Nederland B.V. on behalf of International Instrument Users' Association WIB and the manufacturer

SIREP-WIB-EXERA Report E 2720 K 01 Index classification 4.2

The full report comprises 26 pages: the abridged report comprises the first 7 pages of the full report

November 2001

1 INTRODUCTION

This report describes the evaluation of a model Testa FID (Flame Ionisation Detector) Analysermanufactured by Testa GmbH. The instrument was a standard production model manufactured in Germany.

The instrument was evaluated to a test programme drawn up by WIB and KEMA Nederland B.V. and agreed with WIB and the manufacturer. The test programme was based on IEC 770 : Part 1 : 1984 “Methods of evaluating the performance of transmitters for use in industrial-process control systems”.

The evaluation report was based on the discussions with WIB members, the TNO memorandum (assessment of TÜV-Reports: HEC-MEMO-950031) and two reports performed by TÜV (references:Report no. 1529455 (according to the specifications in 13. BlmSchV) from August 1992 and the additional Report no. 24014741 (according to the specifications in 17. BlmSchV) from February 1996).

The tested analyser is designed for continuous on line measurement of hydrocarbon in gaseous processstreams.The tests were performed in the following concentration range:

C2H4 range 0 - 100 ppm(v) (about 0 - 100 mgC/m3).

All manufacturer's specifications are given as percentages of full scale, unless otherwise stated (dimensions given by the manufacturer): • linearity error : less than ±1% • zero drift : 1% in 24 hours • ambient temperature : max +45 °C • voltage : 220 V • frequency : 50 Hz • power : approx. 600 W without specimen line

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• sample flow : 3-4 l/min • sample temperature : max 200 °C • smallest measuring range : 0-10 ppm(v) C3H8

• warming-up time : from 20 °C to 200 °C approx. 15 min. • outputs : 0-10 V/0-20 mA or 2-10 V/4-20 mA • weight : approx. 15 kg.

The sample chamber and detector were thermostatted at 180 °C.

The instrument was delivered on 25 January 2001. The instrument was evaluated over a period of 6 months from January to July 2001. The draft report was issued in August 2001.

2 MAJOR FINDINGS AND COMMENTS

These findings are summarised for ready reference and to give an overview of the evaluation. For a complete assessment of the instrument the report must be read and considered as a whole.

2.1 Instrument performance

All errors and changes are expressed as percentage output span unless otherwise stated. Concen-trations are expressed as parts per million by volume (ppm(v)). Flow rates are expressed as l/h under normal conditions (0 °C and 1013.3 mbar (abs)).

All errors and changes are indicated as falling within arbitrary bands and compared with the manufacturer's specification as folllows:

within the manufacturer's specification x outside the manufacturer's specification

no manufacturer's specification

Page 2 of 26 E 2720 K 01

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<± 0.1 <± 0.5 <± 1.0 <± 5.0

Other results Manufacturer’sspecification

ACCURACY

Measured error

Conformity

Maximum hysteresis

Repeatability <1%

Dead band

at zero

at 25% span

at 40% span

Detection limit (3s)

ENVIRONMENTAL TESTS

Mounting position

zero shift

span change

Vibration

10 to 60 Hz at 0.2g amplitude

(axes are given in Fig 13)

zero shift

span change

Shock

zero shift

span change

Ambient temperature variations

temperature range of +5°C to +45°C

zero shift (as %/°C)

span change (as %/°C)

max. + 45 °C

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Results expressed as error % span Test

<± 0.1 <± 0.5 <± 1.0 <± 5.0

Other results Manufacturer’sspecification

ERRORS

Drift

• start up

zero shift at 5% span

5 min

1 h

4 h

power on after 15 min (ignition)

zero drift 1%/24hours

span change at 45% span

5 min

1 h

4 h

• long-term (limits over 33 days)

zero shift

span change

Over-range

zero shift

span change

OUTPUT SIGNAL INTERFERENCES

Electromagnetic Compatibility Appendix I

Isolation resistance > 100 M

DYNAMIC BEHAVIOUR

Step response

lag time (T10)

response time (T90)x (6 s)

x (10 s)

1-2 sec.

FUNCTIONAL TESTS

Sample pressure variation

(range 80 to 120 kPa)

zero shift (as %/mbar)

span change (as %/mbar)

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Results expressed as error % span Test

<± 0.1 <± 0.5 <± 1.0 <± 5.0

Other results Manufacturer’sspecification

Sample temperature variation

(range 25 to 250°C)

zero shift (as %/°C)

span change (as %/°C)

Sample flow variation

(range 666 ml/min to 1232 ml/min)

zero shift (as %/100 ml/min)

span change (as %/100 ml/min)

INTERFERENCE TESTS

Cross sensitivity

50.0 ppm(v) C2H4 in N2 reference

49.9 ppm(v) C2H4 in air

zero shift

span change

31.2 ppm(v) C4H10 in air

zero shift

span change + 10.1%

49.9 ppm(v) C2H4/101 ppm(v) NO2 in air

zero shift

span change

49.9 ppm(v) C2H4/101 ppm(v) NO2/

98.7 ppm(v) CO in air

zero shift

span shift

51.7 ppm(v) C2H4/10.2 vol% CO2 in air

zero shift

span change

49.9 ppm(v) C2H4/2.9 vol% H2O in air

zero shift

span change

span concentration 15 mgC/m3

15 vol% CO2 in N2

zero shift

span change

272 mg/m3 NO in N2

zero shift

span change

45 mg/m3 NO2 in N2

zero shift

span change

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Results expressed as error % span Test

<± 0.1 <± 0.5 <± 1.0 <± 5.0

Other results Manufacturer’sspecification

1216 mg/m3 SO2 in N2

zero shift

span change

229 mg/m3 NH3 in N2

zero shift

span change

80 mg/m3 HCl in N2

zero shift

span change

47 g/m3 H2O in N2

zero shift

span change

133 g/m3 H2O in N2

zero shift

span change

20.8 vol% O2 in N2

zero shift

span change

10.4 vol% O2 in N2

zero shift

span change

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2.2 Comments on construction and use

Construction

The analyser is housed in a metal casing. The analyser is robust and well constructed. The quality of materials and standard of finish appears to be good.

Installation and Commissioning

Installation, connection and use of the analyser were straightforward procedures.

2.3 Comments on documentation

The user manual (available in the English language as well as the German version) supplied with theinstrument gives comprehensive information on: • introduction • installation • commissioning • calibration diagram• flow diagram• spare parts list • technical specification• circuit diagram.

Only simplified circuit diagrams are included in the manual.The readableness of the manual was good.

2.4 Cost of ownership

After installation of the analyser, the cost of ownership is based on the following items:

frequency of regular maintenance of the analyzer

the costs and use of materials

the costs and use of spare parts

The manufacturer doesn’t specify the maintenance interval and frequency of changing filters etc.

2.5 Manufacturer's comments

Dynamic behaviour: Lag time and response time can be adjusted via bypass flow. If we increase the bypass stream we can get a response time up to 10 ms.

The presentation of the results as an error or deviation as percentage output-span is very confusing form of presentation. We ask herewith to present this in a better way. For example in absolute figures.

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3 TEST RESULTS

Unless otherwise stated, the tests were performed at 20 ± 2 °C, relative humidity 45 to 60 %, supply voltage 230 ± 2 V, frequency 50.0 ± 0.5 Hz at the concentration range for C2H4 0-100 ppm(v).

The analogue output 4-20 mA was recorded by means of a datalogger.

Unless otherwise stated, all errors are expressed as percent output span.Unless otherwise stated, the analyser was tested at 0% and 50% span.

The estimated uncertainties (of the test results) for the different tests were:

measured error : ± 0.2 % conformity : ± 0.2 %repeatability : ± 0.6 %dead band : ± 6 % drift : ± 11 %step response : ± 14 % sample pressure variation : ± 11 % sample flow variation : ± 11 % sample temperature variation : ± 11 % cross sensitivity : ± 11 %

The basic test gas concentration was about 50 ppm(v) C2H4 in N2.The uncertainty of the concentration of the gas used was ± 1 %.

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3.1 Results' summary

Test Test results Manufacturer's specification/ Report ref

ACCURACY

Measured errorlimits of average error average zero error average span error

Conformitylimits of average error

Maximum hysteresis

Repeatability

Dead bandat zero at 25% span at 40% span

Detection limit (3s)

ENVIRONMENTAL TESTS

Mounting position 10º right 10º left 10º back 10º front

Vibration10 to 60 Hz at 0.2g (axes are given in Fig11)

Shock

Ambient temperatures temperature range of +5°C to +45°Crange analyser 15 mgC/m3

maximum zero shift coefficient (from initial 25 °C) maximum span change coefficient (from initial 25 °C) maximum zero shift maximum span change final zero shift final span change

-0.07 to +0.04% < -0.01% < -0.01%

-0.07 to +0.04%

+0.05%

±0.06%

<± 0.1% <± 0.1% <± 0.1%

< ±0.1%

zero shift span change < ±0.1% < ±0.1% < ±0.1% +0.22%< ±0.1% +0.44%< ±0.1 - 0.20%

zero shift span change < ±0.1% +1.0%

zero shift span change < ±0.1% -0.2%

+0.06%/°C

+0.2%/°C

±0.6% (at +35°C and at +45°C)+2.3% (at +15°C)< 0.1% -1.8%

IEC 770; 6.1.2, (Fig 2)

IEC 770; 6.1.3, (Fig 3) < ±1%

IEC 770; 6.1.4

IEC 770; 6.1.5 < ±1%

IEC 770; 6.1.6, (Fig 4)

IEC 770; 6.2.12

IEC 770; 6.2.14 After vibrating, the analogue output lines inside the analyser were vibrated loose from the connector.

TÜV-Report No. 24014741; 5.2.2, 5.2.3 and 5.2.4 and TUV-Report No. 1529455; 5.2.2, 5.2.3 and 5.2.4 (Fig. 5)

Max. ambient temperature + 45°C

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Report ref

ERRORS

Drift• start-up

output after (relative to that after 4 h): after 15 min. warming-up time after switching power on, analyser could be ignited- +5 min- +1 h- +4 h

• long-term limits over 32 days

Over-rangezero shift span change

OUTPUT SIGNAL INTERFERENCES

Electromagnetic Compatibility

Isolation resistance

DYNAMIC BEHAVIOUR

Step response- lag time (T10)- response time (T90)

zero shift span change at 5% span at 45% span < ±0.1% +1.0%< ±0.1% < ±0.1% < ±0.1% < ±0.1%

zero shift span change +0.05% +4.3%

+0.05%+0.02%

each test > 100M

6 s

10 s

IEC 770; 6.3.1 (Fig 10 and 11)

reference

IEC 770; 6.3.2, (Fig 6)

IEC 770; 6.2.15 (performed at 2000% span)

Appendix 1

Germanischer Lloyd; Test SpecificationNr.1; chapter 7

(500 V applied between supply, output and input terminals)

TÜV-Bericht Nr. 24014741

1-2 seconds

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specification/Report ref

FUNCTIONAL TESTS

Sample pressure variation(range 800 to 1200 mbar (abs.)) zero shift span change regression formula y=ax+by=change, % x=pressure, mbar (abs.) factors at 0% span factors at 50% span

Sample temperature variation(range 25 to 250 °C)zero shift span change regression formula y=ax+by=change, % x=temperature, °Cfactors at 0% span factors at 50% span

Sample flow variation(range 666 ml/min to 1232 ml/min) zero shift span change regression formula y=ax+by=change, % x=sample flow ml/min factors at 0% span factors at 50% span

+0.00002 %/mbar +0.0006 %/mbar

a=+0.00002 b=+0.017 a=+0.0006 b=-0.64

+0.0007%/ °C-0.0004%/ °C

a=+0.0007 b=-0.026 a=-0.0004 b=+0.051

< 0.1%/ ml/min < 0.1%/ ml/min

a=0 b=0 a=-0.00004 b=+0.035

WIB test set-up, (Fig 7)

WIB test set-up, (Fig 8)

WIB test set-up, (Fig 9)

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specification/Report ref

INTERFERENCE TESTS

Cross sensitivity50.0 ppm(v) C2H4 in N2

49.9 ppm(v) C2H4 in air 31.2 ppm(v) C4H10 in air 49.9 ppm(v) C2H4/101 ppm(v) NO2 in air 49.9 ppm(v) C2H4/101 ppm(v) NO2/98.7 ppm(v) CO in air 51.7 ppm(v) C2H4/10.2 vol% CO2 in air49.9 ppm(v) C2H4/2.9 vol% H2O in air

span concentration 15 mgC/m3

15 vol% CO2 in N2

272 mg/m3 NO in N2

45 mg/m3 NO2 in N2

1216 mg/m3 SO2 in N2

229 mg/m3 NH3 in N2

80 mg/m3 HCl in N2

47 g/m3 H2O in N2

133 g/m3 H2O in N2

20,8 vol% O2 in N2

10,4 vol% O2 in N2

zero shift span change reference reference + 0.3% - 3.2% + 0.3% + 10.1% + 0.7% - 2.3%

+ 1.0% - 3.3% - 0.1% - 4.6% + 0.2% - 3.9%

< ± 0.5% < ± 0.5% < ± 0.5% < ± 0.5% < ± 0.5% < ± 0.5% < ± 0.5% < ± 0.5% < ± 0.5% < ± 0.5% < ± 0.5% < ± 0.5% + 0.5% + 0.9% + 0.6% + 1.3% + 1.6% + 1.1% + 0.6% < ± 0.5%

WIB test set-up

TÜV-Bericht Nr. 24014741

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-0,08

-0,06

-0,04

-0,02

0,00

0,02

0,04

0,06

0,08

0 10 20 30 40 50 60

Input (% span)

Aver

age

outp

ut e

rror (

%sp

an)

upscale

downscale

average

terminal-based straight line

Fig 2 Measured error, C2H4

-0,08

-0,06

-0,04

-0,02

0,00

0,02

0,04

0,06

0,08

0 20 40 60

Input (% span)

Aver

age

outp

ut e

rror (

% s

pan)

upscaledownscaleaverage

Fig 3 Conformity, C2H4

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-1

-0,8

-0,6

-0,4

-0,2

0

0,2

0,4

0,6

0,8

1

-1 -0,8 -0,6 -0,4 -0,2 0 0,2 0,4 0,6 0,8 1

Delta input (ppm(v))

Del

ta o

utpu

t (pp

m(v

))

at 0% spanat 25% spanat 40% span

Fig 4 Dead band, C2H4

-2,5

-1,5

-0,5

0,5

1,5

2,5

25 35 45 35 25 15 5 15 25

Temperature (°C)

Out

put e

rror (

% s

pan)

at 0% spanat 15% span

Fig 5 Ambient temperature

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-1,00

1,00

3,00

5,00

0 5 10 15 20 25 30 35

Time (days)

Aver

age

erro

r (%

spa

n)

at 0% spanat 50% span

Fig 6 Long term drift, C2H4

-0,20

-0,15

-0,10

-0,05

0,00

0,05

0,10

0,15

0,20

750 850 950 1050 1150 1250

Sample pressure (mbar)

Dev

iatio

n fro

m 1

013

mba

r (%

spa

n)

at 0% spanat 50% span

Fig 7 Sample pressure variation, C2H4

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-0,25

-0,20

-0,15

-0,10

-0,05

0,00

0,05

0,10

0,15

0,20

0,25

0 50 100 150 200 250 300

Sample temperature (°C)

Dev

iatio

n fro

m 2

5 °C

(% s

pan)

at 0% spanat 50% span

Fig 8 Sample temperature variation, C2H4

-0,04

-0,03

-0,02

-0,01

0,00

0,01

0,02

0,03

0,04

600 700 800 900 1000 1100 1200 1300

Sample flow (ml/min)

Dev

iatio

n fro

m 1

,2 l/

min

(%sp

an)

at 0% spanat 50% span

Fig 9 Flow variation, C2H4

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4,00

4,20

4,40

4,60

4,80

5,00

5,20

5,40

5,60

5,80

6,00

0 50 100 150 200 250

Time (min)

Out

put (

ppm

(v))

at 5% span

Fig 10 Start-up drift C2H4 at 0% span

39,50

40,00

40,50

41,00

41,50

42,00

42,50

0 50 100 150 200 250

Time (min)

Out

put (

ppm

(v))

at 45% span

Fig 11 Start-up drift C2H4 at 50% span

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4 MANUFACTURER'S DATA

Instrument specification and other details provided by the manufacturer

Manufacturer TESTA GmbH Kathi-Kobus-Strasse 15 80797 München Germany

Tel No : (0 89) 1293005 Fax : (0 89) 1298835

Instrument Analyser for measurement of total hydrocarbon concentration in proces gases

Model FID 123

Serial No 40/08/00

Consistency Range 1 less than 3% all other ranges less than 1%

Zero drift 1% in 24 hours

Ambient temperature Max. + 45 °C

Warm-up time From room temperature to 300 °C in approx. 20 min

Response time 1-2 sec. from rear panel of unit

Ranges 5 measuring ranges; 10/100/1000/10000/100000 ppm

Lowest range 0-10 ppm relative to propane (calibration gas=C3H8)

Recorder output 0-10 V/0-20 mA or 2-10 V/4-20 mA

Voltage 220 V

Frequency 50 Hz

Power approx. 600 W, without specimen line

Sample flow about 12 ml/min

Combustion gas consumption H2 30-40 ml/min; H2/He 80-100 ml/min

Flame control with thermocouple, indicated by lamp

Combustion air consumption 0,4 l/min

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Supply for heated sample line Regulated and controlled by thermocouple

Sample temperature 300 °C in continous operation

Dimensions (h x w x d) 220 x 440 x 350 mm

Weight 15 kg. (approx.)

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5 OPERATING PRINCIPLE AND CONSTRUCTION

5.1 Measuring principle

The gas concentration is converted into an electrical signal by means of a flame ionisation detector (FID). In the FID, a hydrogen flame burns in hydrocarbon-free air, called combustion air. An electric field is applied between jet and cylinder electrode by means of polarisation voltage. When the sample contains hydrocarbon molecules, they are heated in the flame and then crackedand stripped causing CH fragments to form. These fragments are oxidized by the oxygen in the combustion air and CHO+ ions form. The ion current can be measured and is proportional to the quantity of carbon atoms of organic compounds.

5.2 Mechanical construction

The flame ionization detector is proving to be an important tool for industry in the direct measurement of hydrocarbon concentration. It permits accurate measurements of concentration from a few parts per million (ppm) up to 100% and meets industrial requirements with regard to the speed with which it is ready to use, ease of installation and the low level of sophistication in its operation.In contrast to familiar designs, the test specimen in the TESTA-FID-1 is sucked through the detector. This provides the following advantages: - All moving parts are located behind the ionization chamber in the cold zone and are thus no

longer exposed to the high temperature of the specimen gas. - The path of the specimen from the measuring location to the burner nozzle contains no moving

parts and is thus completely maintenance-free. - Due the modified construction of the unit, there is perfect thermal equilibrium between the

specimen inlet and the burner nozzle. Since all parts coming into contact with the specimen are manufactured from metal, any depositing of hydrocarbons in the specimen path are not possible due to the high unit temperature.

- Thanks to the high specimen temperature of max. 300 °C, the unit is largely insensitive tovariations in room temperature. The proof of this is an extremely constant zero and calibration point.

- The FID-123 is fitted with an additional, heated specimen pump to eliminate measurement errors caused by variations in specimen pressure in the range between 1.0 bar pressure and 0.3 bar vacuum.

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6 TEST METHODS AND REFERENCES

6.1 Test methods

The test gases originated directly from compressed gas cylinders or were mixed from different gas cylinders by using a gas mixer based on dilution by mass flow controllers. The accuracy of the mass flow controllers had been established by calibration with a Brooks volumeter with a ring of mercury.

The estimated uncertainties (of the test results) of the different tests were: measured error : ± 0.2 %conformity : ± 0.2 %repeatability : ± 0.6 %dead band : ± 6 %drift : ± 11 %sample pressure variation : ± 11 % sample flow variation : ± 11 % sample temperature variation : ± 11 % cross sensitivity : ± 11 %

The basic test gas concentration was about 50 ppm(v) C2H4 in N2.The uncertainty of the concentration of the gas used was ± 1 %.

The output data of the analyser was recorded with a megalog datalogger. In most tests, the signal was measured with an average of 60 seconds.

Accuracy

An eleven point calibration (10% interval) with four runs at each point for up-scale readings and four runs at each point for down-scale readings, was carried out by diluting the basic test gas. From this test, average errors, conformity, hysteresis and repeatability were determined. At the start of the evaluation, the analyser was adjusted with calibration gas at about 50% span.

Dead band

The dead band was measured at lower and higher span values span by varying the concentration of thetest gas in steps of about 0.1 ppm(v) (= about 0.1 % span). The change in output was measured after a settling time of at least twice the response time.

Detection limit

The detection limit was calculated as three times the standard deviation of 30 recordings of the test gas at 0% span.

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Mounting position

The effect on the output of tilting the analyser through angles of ±10° in four mutually perpendicular planes was measured at 0% and 50% span.

Shock

The effect on the output was investigated by tilting the analyser about one bottom edge so that the distance between the opposite edge and the test surface is 100 mm. Before and after a freely fall onto the test surface the influence was measured at 0% and 50% span.

Vibration C2H4

Initial resonance search The analyser was vibrated over the frequency range of 10 to 60 Hz at 0.2g acceleration. The sweep rate was 0.2 octave per minute. The peak to peak amplitude was 0,14 mm. Vibration was applied in three directions (X,Y,Z). A resonance search was carried out.

Endurance conditioning The instrument was subjected to vibration for 45 minutes in each axis at the largest resonance frequencies.

Before and after the vibration tests measurements were carried out at 0% span and 50% span. Due to safety conditions of the vibration test lab, it was not allowed to operate the analyser with H2 and calibrationgas during vibration.

Start-up drift

The analyser was subjected to reference conditions for at least 24 h with the power supply switched off.The output of the analyser was recorded during the first 4 hours. The test was repeated using a test gas with a concentration of 0% span.

Long-term drift

During 32 days the analyser was operated continuously with a test gas of 0% span. After 0, 1, 4, 6, 8,11, 13, 15, 18, 20, 22, 26, 28 and 32 days, the output of the analyser was recorded with test gases of 0% and 50% span. The output was corrected for barometric and temperature influence.

Step response

The analyser was subjected to a sudden change from test gas with a concentration of 0% span to test gases of a concentration of 70% span. The output and corresponding time of the analyser was recorded.

Over-range

This test was carried out by measuring the changes in lower-range value and span which result from over-ranging at the minimum and maximum span (1950 ppm(v) C2H4).After the over-range has been applied for 1 minute, the input was reduced to the nominal lower range-value. After a further 5 minutes had elapsed, the lower range-value and the span was

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determined.Sample pressure variation

The analyser was fed with test gases of 0% and 50% span at pressure levels varying between 800 to 1200 mbar (abs.) at a steady flow of 2 l/min. The pressure was measured with a calibrated pressuretransmitter. The influence of the sample pressure was calculated by linear regression.

Sample temperature variation

The analyser was fed with test gases of 0% and 50% span at sample temperature varying between 25 to 250 °C at constant pressure. The sample temperature were measured with a calibrated temperature transmitter.

Sample flow variation

The analyser was fed with test gases of 0% and 50% span at flow variations of 666 ml/min to 1232 ml/min. The flow was measured with a Bios DryCal flowmeter (graphite composite piston).

Interference tests

The output of the analyser was recorded after application, at test gas concentrations of 0% and 50% span, of:- 50 ppm(v) C2H4 in N2 (reference) - 50 ppm(v) C2H4 in air - 30 ppm(v) C4H10 in air - 50 ppm(v) C2H4/100 ppm(v) NO2 in air - 50 ppm(v) C2H4/100 ppm(v) NO2/100 ppm(v) CO in air - 50 ppm(v) C2H4/10 vol% CO2 in air- 50 ppm(v) C2H4/2 vol% H2O in air

furthermore at test gas concentrations of 0% and 15 mgC/m3 with: - 15 vol% CO2 in N2 * - 272 mg/m3 NO in N2 *- 45 mg/m3 NO2 in N2 * - 1216 mg/m3 SO2 in N2 *- 229 mg/m3 NH3 in N2*- 80 mg/m3 HCl in N2 *- 47 g/m3 H2O in N2 * - 133 g/m3 H2O in N2 * - 20,8 vol% O2 in N2 *- 10,4 vol% O2 in N2 *

* Test results from the TÜV reports.

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analyser personal computer

T p

x x MC

WG MF MF MF

water test/interference gases in cylinders

MF : massflow controllerMC : mixing chamberp : pressure transmitterT : temperature transmitterWG : watervapour generatorx : disconnected if not used

Fig 12 Basic test arrangement

Z

Y

front X

Fig 13 Axes of vibration

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6.2 References

IEC 770: 1984. Methods of evaluating the perfomance of transmitters for use in industrial-process control systems

TÜV-Bericht 1529455, Bericht über die Eignungsprüfung einer Gesammtkohlenstoff-Messeinrichtung,August 1992

TÜV-Bericht 24014741, Bericht über die Ergänzungsprüfung einer Gesammtkohlenstoff-Messeinrichtung, Februar 1996

Memorandum HEC-MEMO-950031, TNO Centre for Evaluation of Instrumentation and Security Techniques (EIB), April 1995

6.3 Definitions

Reference operating conditions (IEC 902): The range of operating conditions within which theinfluence on the device by the changes in environmental conditions are disregarded.

Gas analyser: An analytical instrument that provides an output signal which is a monotonic function of the concentration, partial pressure or condensation temperature of one or more components of a gasmixture.

Stable test gas mixture: A mixture of gases (and/or vapour) in which the component to be measured is known and does not react with and is not adsorbed onto the containment system (e.g. cylinder). The concentrations of gases and their inaccuracy shall be known for the components of the gas mixture and commensurate with the criteria to be evaluated.

Zero gas: A gas mixture used to establish the zero point of a calibration curve when used with a given analytical procedure within a given calibration range.

Calibration gas: A stable test gas mixture of known concentration used for periodic calibration of the analyser and for various performance tests.

Range (IEC 770): The region between the limits within a quantity is measured; limits are given by stating the lower and upper range values.

Lower range value (IEC 770): The lowest value of the measured variable that a device is adjusted to measure.

Upper range value (IEC 770): The highest value of the measured variable that a device is adjusted to measure.

Span (IEC 902): The algebraic difference between the upper and lower limit values of a given range.

Error (IEC 902): The algebraic difference between the measured value and the true value of the

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measured variable.

Zero shift (IEC 902): The change of the output value, due to some influences, when the input variable is at the lower range value.

Span change (IEC 902): The change in output span due to some influences.

Average error: The arithmic mean of the errors at each point of measurement , for rising and fallinginputs separately.

Residual error: The algebraic difference between two output measurements at reference conditions, one before and one after an excursion from the reference condition.

Response time (T90): The time interval from the instant a step change occurs in the value of the property to be measured to the instant when the change in the indicated value passes (and remains beyond) 90% of its steady state amplitude difference, that is: T90 = T10 + Tr (or Tf).

Drift: The rate of change of error, stated over a specified time interval.

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APPENDIX II

Manufacturer’s QA procedures and instrument status

Basic Informations to TESTA GmbH-Quality Management System

Company/adress: Kathi-Kobus-street 15 80797 Munich, Germany

Parent company: --

Range of products: FID + Acessoires for FID

Organizational form: GmbH

Production premises: On 3 floors in above standing adress

Subsidiaries in Germany: --

Work force: 15 fix, 25 flexibel

Sales volume: 5 Mio. DM p.o.

Production and test facilities:

QM Standard: Test report for each analyser and accesoir

QM management representative: Dr. B. Ulrich

QM-manual: Existing

Certification: No

Further audits on Testa QM system: --

Approval by German authorities: TÜV, Germany

For more details please contact: Dr. B. Ulrich Kathi-Kobus-Strasse80797 MunichGermany

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Manufacturer’s QA procedures and instrument status

1 Quality Assurance

1.1 Has your company adopted a structured QA policy and if so, when was this fullyimplemented?

Yes, 1989

1.2 On which national/international standard is your QA system based? Is it registered under any particular scheme? If so, please state which.

DIN ISO 9001, not registered

1.3 Does it cover all aspects of design, manufacturer and installation?

No, only manufacture and installation

1.4 If your company is part of a corporate organisation, is your QA system subject to andcontrolled by a corporate QA policy?

No

1.5 Does your QA system cover all activities and products in your manufacturing facility? If not, please specify where it does apply.

Yes

1.6 How many times, and by whom, has your location or company been audited by anexternal organisation during the last 3 years?

Once by Siemens

1.7 Who required the audit to be carried out?

Siemens Germany

1.8 Are (corporate) products, if manufactured elsewhere in your organisation, also subject to an identical QA system?

Yes

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Information on the product evaluated by WIB

2.1 Is the product evaluated being produced elsewhere in your organisation? If so, please state where. Are all/any parts of the product fully interchangeable regardless of origin?

No, Yes fully interchangeable.

2.2 What is the expected lifetime of the product?

25-30 years.

2.3 What is the guarantee period for the hardware and software if applicable, of the productevaluated?

24 months.

2.4 For how long after manufacture of the product ceases will you provide service/maintenancefacilities and spare parts?

20 years guaranteed.

2.5 In what language are product documentation, manuals etc. written? Are they available in English,French and German?

English + German, French in process (available 2002).

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