Goodfellow EFSOP® Technology

IVACO for Tenova Core

Ontario, Canada

Tenova Goodfellow 8124 Single Stream EFSOP® System Manual

Revision History
Revision No. Revision Date Revised By Total Pages Revision Change Notes
0 Dec 11, 2012 HAL 67 Initial Release

CONFIDENTIAL
This document is confidential and is not to be copied or distributed without written permission from
Tenova Goodfellow Inc., Mississauga, Ontario.

TGI Internal Information

Project No. Document Version No. Customer No. System ID No.
iCON714 0.0 C138 9413 / 9414

Tenova Goodfellow Inc.

200-6711 Mississauga Road
Mississauga ON Canada L5N 2W3
Phone +(1) 905 567 3030
Fax +(1) 905 567 3899
info@tgti.ca
CONFIDENTIAL - This document is the confidential property of Tenova Goodfellow Inc.
8124 Single Stream EFSOP® System Manual – IVACO Page 2 of 67

TABLE of CONTENTS

1. Introduction ...................................................................................................................................... 4
Tenova Goodfellow EFSOP® System Overview ............................................................................... 4
Tenova Goodfellow EFSOP® Analyzer Overview ............................................................................ 6
EFSOP® Analyzer Standard Features ............................................................................................. 8

2. Safety Information............................................................................................................................ 9
Risk Assessment.............................................................................................................................. 9
General Hazards ............................................................................................................................ 10
Hazardous Gas Warning ................................................................................................................ 11
Analyzer Safety System ................................................................................................................. 11

3. EFSOP® Analyzer - Internal Sub-Systems ..................................................................................... 13

Overview of Internal Sub-Systems ................................................................................................. 13
Sample Conditioning Sub-System .................................................................................................. 16
Sample Conditioning System – Sample Flow ............................................................................. 16
Sample Conditioning System – Purge Function .......................................................................... 19
Sample Analysis Sub-System ........................................................................................................ 23
Analyzer Control System ................................................................................................................ 26
Purge Control ............................................................................................................................. 27
Analyzer Auto Calibration ........................................................................................................... 27

4. Analyzer Operation ........................................................................................................................ 30

Introduction .................................................................................................................................... 30
Analyzer Power up and Shutdown ................................................................................................. 32
Analyzer Power up State (S0)..................................................................................................... 32
Analyzer Shutdown..................................................................................................................... 32
Normal Operation States – Sampling, Purging and Calibration ...................................................... 33
Sampling State (S1) ................................................................................................................... 33
Purging State (S2) ...................................................................................................................... 34
State S2a - Barrel Purge for probe.............................................................................................. 34
State S2b - Filter Purge (without by-pass) for probe ................................................................... 34
State S2c - Filter Purge (with by-pass) for probe ........................................................................ 34
Calibration State (S3) ................................................................................................................. 34

5. Analyzer Human Machine Interface (HMI) ..................................................................................... 35

Overview ........................................................................................................................................ 35
User Accounts and Security ........................................................................................................... 35
HMI Navigation Map ....................................................................................................................... 36

6. Analyzer Installation....................................................................................................................... 37
CONFIDENTIAL - This document is the confidential property of Tenova Goodfellow Inc.
8124 Single Stream EFSOP® System Manual – IVACO Page 3 of 67

Overview ........................................................................................................................................ 37
Analyzer Environment and Operating Requirements ...................................................................... 37
Mechanical Connections ................................................................................................................ 38
Calibration Gas Connection ........................................................................................................ 40
Nitrogen Connection ................................................................................................................... 40
Vents, Exhaust and Drain ........................................................................................................... 40
Electrical and Instrumentation Connections.................................................................................... 41
Electrical Connection .................................................................................................................. 41
PLC Connectivity ........................................................................................................................ 41

7. Warranty ........................................................................................................................................ 43

8. Technical Support .......................................................................................................................... 43

Attachments
Attachment 1: 8124 Single Stream EFSOP® Analyzer Data Sheet
Attachment 2: 8124 Single Stream EFSOP® System Maintenance Schedule and Procedures
Attachment 3: 8124 Single Stream EFSOP® System Parts List
Attachment 4: 8124 Single Stream EFSOP® System Troubleshooting Guide
Attachment 5: 8124 Single Stream EFSOP® Engineering Drawing Package
Attachment 6: Material Safety Data Sheets
Attachment 7: 8124 Single Stream EFSOP® Risk Assessment
Attachment 8: 8124 Single Stream EFSOP® System Daily Maintenance Log
Attachment 9: 8124 Single Stream EFSOP® System Weekly Maintenance Log
Attachment 10: 8124 Single Stream EFSOP® System Additional Maintenance Log
Attachment 11: 8124 Single Stream EFSOP® Analyzer HMI Screens
Attachment 12: Other EFSOP® System Components
CONFIDENTIAL - This document is the confidential property of Tenova Goodfellow Inc.
8124 Single Stream EFSOP® System Manual – IVACO Page 4 of 67

1. Introduction
This manual provides a functional overview, start-up procedure, preventative maintenance and
general troubleshooting guide for the Tenova Goodfellow EFSOP® 8124 single stream equipment.

Tenova Goodfellow EFSOP® System Overview

The Tenova Goodfellow Expert Furnace System Optimization Process (EFSOP®) measures and
analyzes real-time off-gas chemistry from the forth-hole of the Electric Arc Furnace. The measured
off-gas enables the system to dynamically optimize the chemical energy consumption of the electric
arc furnace.

Figure 1.1 below gives a basic overview of how the system extracts the off-gas sample, analyzes the
sample and determines optimal furnace set-points through the SCADA computer. The optimal set-
points are sent from the SCADA computer to the Plant PLC to complete the dynamic control of the
furnace.

EFSOP Probe EFSOP Gas Analyzer

Patented water-cooled Off-Gas Measures levels of O2, CO, CO2 and
Sample probe continuously samples H2 and sends the data to the
the off-gas exhaust to be sent to the EFSOP® HMI & SCADA computer
EFSOP® gas analyzer located in the furnace control room

EFSOP
HMI & SCADA
Computer

Plant PLC

Processes
operational
.
information and
sends process
adjustments to
control and
optimize the
Plant PLC network communicates with the EFSOP® analyzer and furnace operation
EFSOP computer to receive new set-points for dynamic furnace control

Figure 1.1: EFSOP System Overview

CONFIDENTIAL - This document is the confidential property of Tenova Goodfellow Inc.
8124 Single Stream EFSOP® System Manual – IVACO Page 5 of 67

The major components of the system include; a patented water cooled probe, a heated sample line, a
multi-gas analyzer and the HMI/SCADA computer.

The off-gas sample is collected from the EFSOP® water cooled Off-Gas Sample Probe mounted in
the water cooled D1-duct. Figure 1.2 shows the components of the probe assembly which consist of
an outer water cooled jacket and a filter holder assembly. The sample gasses are drawn under
vacuum through the barrel of the water cooled jacket and into the filter holder assembly. The filter
holder assembly contains a filter which removes the bulk of the furnace dust that is extracted with the
furnace off-gases. Further details of the EFSOP® Off-Gas Probe are provided in Attachment 12 –
“Other EFSOP® System Components”.

Partial Unheated Sample Line Heated Sample Line

(If Required - Plant supply) (TGI supply)
Purge Line
Sample Flexible Line
(Plant supply)
(TGI supply)
Filter holder connection (NPT thread connection)
Purge Flexible Line
(TGI supply) Purge line connection (Swagelok)
Water supply & return connection (quick connects)
Probe filter (tied with wire to filter holder)

Mounting bracket (Plant supply)

®
EFSOP Probe (TGI supply)

Figure 1.2: EFSOP® Off-Gas Probe Assembly

The gases are then transported through a heated line for maintaining sample integrity until it reaches
the analyzer cabinet. Upon reaching the analyzer cabinet the sample is filtered for dust and removed
of moisture before reaching the multi-gas analyzer. The multi-gas analyzer measures levels of O2,
CO, CO2 and H2 and sends the data to the Plant PLC in the form of 4-20mA signals or to the plant
network through an Ethernet connection from the Analyzer PLC.
CONFIDENTIAL - This document is the confidential property of Tenova Goodfellow Inc.
8124 Single Stream EFSOP® System Manual – IVACO Page 6 of 67

The EFSOP® SCADA/HMI computer evaluates the analyzer data and determines the optimal set-
points for the furnace equipment (Burners, Injectors, Damper position, etc.) for dynamic closed loop
control. Refer to the EFSOP® SCADA/HMI manual for details on the EFSOP® SCADA/HMI.
Tenova Goodfellow EFSOP® Analyzer Overview
The EFSOP® Analyzer is a key component of the Tenova Goodfellow EFSOP® system. The
analyzer in the context of this manual refers to all components contained within the analyzer cabinet.
The EFSOP® Analyzer performs four main functions which are listed below:

1. Provide vacuum to extract the off-gas sample from the process.

2. Condition and analyze the composition of the off-gas sample.
3. Provide the analyzed data to the EFSOP® HMI/SCADA computer and plant PLC network for
logging and control.

4. Perform periodical purging of the EFSOP® probe, heated sample line and internal filters to
ensure reliable and continuous process analysis.

The analyzer must be installed in a controlled and monitored environment to ensure proper
functionality and safe operational practice related the processing of harmful gases. Refer to the
“Analyzer Environment and Operating Requirements” found in section 5 of this manual for more
details.

Harmful gases are vented and drained from the analyzer and these are to be transported to a safe
location outside of the analyzer room. A carbon dioxide monitor is provided inside the analyzer to
detect for internal leaks. In the event of a leak the analyzer pump will shut down to stop the extraction
of gases from the process.

The measurement accuracy of the analyzer is maintained through regular calibration. Calibration is
achieved through the use of calibration gases of known composition in pre-defined ranges.

The operation of the analyzer requires electrical power supply and nitrogen gas to activate the
pneumatic valves. Nitrogen is also used as the purge gas to clean both the EFSOP® probe and
sample extraction line between the probe and analyzer.

The analyzer off-gas composition data, alarms and other functional parameters are passed to the
plant PLC in the form of 4-20mA hard wire signals or to the plant network through an Ethernet
connection from the Analyzer PLC.

Figure 1:3 indicates the data pathways for the EFSOP® system and utility requirements for the
analyzer room.
CONFIDENTIAL - This document is the confidential property of Tenova Goodfellow Inc.
8124 Single Stream EFSOP® System Manual – IVACO Page 7 of 67

PLANT
SUPERVISORY
COMPUTER
Plant Level II Network
EFSOP® SYSTEM
AIR FILTRATION
N2 CAL. GASES SYSTEM
VENT LINE

Sample Line 8114 ANALYZER

PROBE (heated) EFSOP PLANT
System PLC COMPUTER HMI
Barrel Purge 110V
Line AC
220V
ANALYZER ROOM AC

AIR QUALITY AIR CONDITIONING

MONITORS/ AND TEMPERATURE
ALARMS CONTROL SYSTEM

I/O SIGNAL
PLANT LINES WIRED PLC
CONTROLS PLC 1 PLC 2 DCS TO PLC I/O I/O
SYSTEM CARDS RACKS

Figure 1:3: EFSOP® Analyzer Data communication Path and Analyzer Room Utilities
CONFIDENTIAL - This document is the confidential property of Tenova Goodfellow Inc.
8124 Single Stream EFSOP® System Manual – IVACO Page 8 of 67

EFSOP® Analyzer Standard Features

Standard features of the 8124 Single Stream EFSOP® Off-gas Analyzer:

1. Continuous measurement of four gases species, namely Oxygen, Carbon Monoxide,

Carbon Dioxide and Hydrogen. Measurement ranges for each gas are factory set. The
details are provided in Attachment 1 “EFSOP® Analyzer Data Sheet”.
2. High accuracy and repeatability, ±1%full scale with less than ±1% full scale drift daily over
the entire temperature range.
3. High performance sample gas filtration system (removes > 99.5% of particles with a
diameter > 0.1 micron)
4. Built-in automated probe purge control system with user configurable purge duration and
interval
5. System has high availability, uptime and low maintenance requirements
6. User friendly and full featured panel view HMI
7. Built-in safety system for detection of internal CO leaks; upon which an alarm will be
triggered and the sample extraction pump shut will be automatically shut off. A malfunction
of the internal CO detector will also shut down the sample pump.
8. Interface capabilities via industrial standard isolated current outputs 4-20mA, NO/NC relay
contacts and/or Ethernet connection option.
9. Built-in calibration sequence logic (triggered via local HMI)
10. Built-in auto detection/diagnostic features (alarming output signals to plant automation
system)
11. All operational functions of the analyzer are controlled and monitored by a control system
(PLC). Functional parameters of the analyzer are also configurable by the user through
the control system.
CONFIDENTIAL - This document is the confidential property of Tenova Goodfellow Inc.
8124 Single Stream EFSOP® System Manual – IVACO Page 9 of 67

2. Safety Information
This section of the manual provides important safety information regarding the installation and
®
operation of Tenova Goodfellow EFSOP System.

It is highly recommended that all plant employees/contractors involved in operating, maintenance and
installation of the EFSOP® system have read and understood the safety information provided below.
It is the responsibility of the plant to ensure that all local safety laws, regulations and company specific
rules, procedures and safety precautions are followed when operating, maintaining and installing the
Tenova Goodfellow EFSOP® equipment.

In addition to the safety information provided in this manual, Tenova Goodfellow provides on site,
hands on safety training during the installation and commissioning of the system and during each
EFSOP® system service visit. System service visits are recommended every six months.

Risk Assessment
Attachment 7 “8124 Single Stream EFSOP® Risk Assessment” provides details on the analyzer
safety measures and exposure risks.
CONFIDENTIAL - This document is the confidential property of Tenova Goodfellow Inc.
8124 Single Stream EFSOP® System Manual – IVACO Page 10 of 67

General Hazards
Table 2.1 provides safety and hazard labels used throughout the EFSOP® System to indicate safety
hazards and specific instructions regarding equipment/instrument/component setup and operation.

Table 2.1: EFSOP® System Safety Hazard Labels

Safety Label Type Specific Hazards Description

Hazardous voltage is present inside, keep away from Live

Circuits. Disconnect power cable and discharge circuits before
servicing the equipment. To avoid accidental power up, the
equipment should be handled with proper guidance and
supervision. To avoid shock hazard, the instrument must be
properly grounded.
WARNING
Before using any gas for calibration, the nature and the
properties of the gas should be reviewed. Please consult
supplier provided MSDS (material safety data sheets).
Generic examples of the MSDS are provided in Attachment 6
“Material Safety Data Sheets”

Do not substitute parts or modify this instrument to avoid

unnecessary risk of harm.

Hot surface. Avoid contact.

Surfaces are hot and may cause personal injury if touched.
HOT

The following warning signs contain important or helpful

information relating to the setup and/or operation of the
system.

Component replacement, internal adjustments and electrical

NOTE service must be made by qualified maintenance personnel.

The equipment is powered by two power supplies. Disconnect

power cable, discharge circuits and power to any other
equipment connected to the instrument before servicing. The
instrument must be connected to an electrical ground.
CONFIDENTIAL - This document is the confidential property of Tenova Goodfellow Inc.
8124 Single Stream EFSOP® System Manual – IVACO Page 11 of 67

Hazardous Gas Warning

Hazardous gases are discharged and exhausted from the EFSOP® analyzer as part of its normal
operation. There are five discharge/exhaust ports located on the analyzer; three gases vents one
liquid drain and one cabinet exhaust. All gases and liquids discharged/exhausted from the analyzer
are to be routed outside of the analyzer room, and are not to be vent into any confined spaces.

Hazardous gases processed by the analyzer are contained in the collected off-gas, purge medium
and in the gases used for calibration of the analyzer. These gases may contain high concentrations
of Carbon Monoxide, Carbon Dioxide, Hydrogen and Nitrogen. Table 2.2 below describes the harmful
nature of each gas species processed by the Analyzer.

Table 2.2: Hazardous Gas Description

Gas Gas Name Hazard

CO Carbon Monoxide Toxic and Flammable
CO2 Carbon Dioxide Asphyxiant
H2 Hydrogen Flammable
N2 Nitrogen Asphyxiant

Accumulation of these gases in confined spaces, both individually and in combination could be lethal
and/or dangerous (flammable and/or explosive). It is the responsibility of the plant to request Material
Safety Data Sheets (MSDS) from the calibration gas supplier. MSDS’s are to be prominently posted
near the EFSOP® Analyzer and the calibration gas cylinders. Examples of generic MSDS are
provided in Attachment 6 of this manual.

The analyzer room is considered to be a confined area; good engineering practice and local
regulations may require air-quality monitoring equipment to be installed. Any personnel using the
room or working with the analyzer should be informed about the risks of exposure to high
concentrations of CO, CO2 and an atmosphere containing less than 19% Oxygen.

Analyzer Safety System

The EFSOP® Analyzer is supplied with a carbon dioxide gas monitor for detection of CO leaks inside
of the analyzer. In the event of a CO leak an alarm will be triggered and the analyzer pump will shut-
off to prevent further accumulation of harmful gases inside of the analyzer and analyzer room. The
alarm level has been factory set to 250 ppm. A visual alarm is indicated on the analyzer cabinet and
the analyzer HMI. A digital signal is also sent to alarm on the EFSOP® computer.
CONFIDENTIAL - This document is the confidential property of Tenova Goodfellow Inc.
8124 Single Stream EFSOP® System Manual – IVACO Page 12 of 67

The analyzer is designed with two methods for automatically stopping the pump in the event of a high
CO alarm. Both methods will simultaneously interrupt power to the pump and are described below in
detail.

One method is through the analyzer PLC, where a 4-20mA signal is sent from the cabinet CO monitor
to the analyzer PLC to indicate the measured level of CO. The alarm level to trigger the pump shut off
is configured in the PLC through the analyzer HMI parameter setup screen (set to 250 ppm). Refer to
Attachment 11 “8124 Single Stream EFSOP Analyzer HMI Screens” for details on the HMI parameter
setup screen. When the measured CO level exceeds the set level on the PLC a contact relay is
triggered to cut off power to the pump. The pump can only be restarted by acknowledging the alarm
and manually re-starting the pump through the analyzer HMI. Refer to Attachment 2 “8124 Single
Stream EFSOP System Maintenance Schedule and Procedures” for details on acknowledging CO
alarm and restarting the pump. Note that only qualified trained personnel should acknowledge CO
alarms and restart the pump. The resolution for the source of the CO leak must be resolved before
proceeding to restart the pump.

A second fail safe method is made through a direct hardwire connection from the CO monitor to the
pump power circuit. A contact relay is triggered to cut power to the pump when the CO monitor
measures above the “HI” CO alarm level (250 ppm) set within the CO monitor. Power to the pump is
automatically restored when the CO monitor measures levels of CO below 250 ppm. It is important to
note that alarms triggered directly on the CO monitor are not recorded or displayed on the analyzer
HMI. In the event that the PLC does not recognize a high CO condition and the CO monitor has shut
of power to the pump; the analyzer HMI will alarm for “Low Sample Flow” and/or “Low Bulk Flow”. In
this situation refer to Attachment 4 “8124 Single Stream EFSOP System Troubleshooting Guide”.

The EFSOP analyzer is equipped with a third optional method to stop the pump based on the plant
provided room air quality monitors. A normally open digital contact labeled as “Pump Interlock” on the
terminal block (TB1) is available to interlock the pump from a powered in 2-wire digital input from the
plant PLC. The methodology sending and resetting the pump interlock signal will reside in the plant
PLC and at discretion of the plant to implement.

It is the responsibility of the plant to perform routine calibration and maintenance of the CO monitor to
ensure proper operation. An alarm is triggered on the Analyzer HMI when the Analyzer CO monitor is
malfunctioning or requires maintenance. This alarm event will also shut down the analyzer pump and
is triggered through the analyzer PLC.
 CONFIDENTIAL - This document is the confidential property of Tenova Goodfellow Inc.
8124 Single Stream EFSOP® System Manual – IVACO Page 13 of 67

3. EFSOP® Analyzer - Internal Sub-Systems

This section explains the major components and sub-systems of the EFSOP® Analyzer.

Overview of Internal Sub-Systems

The EFSOP® Analyzer is comprised of three Sub-Systems:
1. Sample Conditioning
2. Sample Analysis
3. Control System

Figure 3.1 indicates the general location of the analyzer Sub-systems

Control System
HMI

Sample
Conditioning Sample Analysis
sub-system sub-system

Control System
PLC

®
Figure 3.1: Tenova Goodfellow EFSOP Analyzer Sub-system location
CONFIDENTIAL - This document is the confidential property of Tenova Goodfellow Inc.
8124 Single Stream EFSOP® System Manual – IVACO Page 14 of 67

Figure 3.2, provides a visual overview of the major subsystems of the analyzer for an operational
perspective.

®
Figure 3.2: Tenova Goodfellow EFSOP Analyzer Functional Description
CONFIDENTIAL - This document is the confidential property of Tenova Goodfellow Inc.
8124 Single Stream EFSOP® System Manual – IVACO Page 15 of 67

The Sample Conditioning System draws the off-gas sample from the process through the EFSOP®
patented water-cooled probe and heated sample line via a dual headed vacuum pump. The system
then removes dust and moisture from the sample before passing a small portion to the Sample
Analysis System. The system generates by-products from its operation that are discharged from the
analyzer drain and off-gas vent port.

An internal dust filter located in the heated box of the sample conditioning system, along with the
EFSOP® probe filter and heated line are periodically purged with Nitrogen or an alternative gaseous
medium available in the plant (compressed air, CO2, etc.). The conditions for initiating the purge are
established through the Control System.

Pneumatic actuators in the sample conditioning system regulate sample flow and route the off-gas
sample through the conditioning areas. Pneumatic actuators are also used to route the purge gas for
cleaning and the calibration gases to the analyzer for calibration. The control of the pneumatic
actuators during purge and calibration are performed by the Control System.

The Sample Analysis System analyzes the polished off-gas sample supplied by the Sample
Conditioning System. The off-gas concentrations measured by the Analysis System are sent to the
Control System to be output to the plant automation system and analyzer HMI.

The operation of the Sample Analysis System and Sample Conditioning System is controlled by the
Control System. Output signals of the two systems are sent the Control System for monitoring and
control. These outputs are supply locally to provide visual information to the operator and are
available to interface with the plant automation system. All functions of the analyzer Control System
are realized using a programmable logic controller (PLC). User defined input parameters are entered
through a touch screen HMI which forms the final aspect of the Analyzer Control System.
CONFIDENTIAL - This document is the confidential property of Tenova Goodfellow Inc.
8124 Single Stream EFSOP® System Manual – IVACO Page 16 of 67

Sample Conditioning Sub-System

This section describes the flow of sample gas through the sample conditioning sub-system and the
purge function. Figure 3.3 below shows a P&ID schematic layout of the sample conditioning system
described in this section of the manual. Refer to Table 3.1 for full description of the components
indicated in the schematic.

Figure 3.3: P&ID Schematic Sample Conditioning System

Sample Conditioning System – Sample Flow

Figure 3.4 identifies and indicates the general location major components of the Sample Conditioning
System. The flow of the off-gas sample through the Sample Conditioning System is described below.
CONFIDENTIAL - This document is the confidential property of Tenova Goodfellow Inc.
8124 Single Stream EFSOP® System Manual – IVACO Page 17 of 67

Heated Box

Heated Box Vacuum Pump

Primary Filter

Heated Box
Secondary
Filter

Thermal Electric
TEC Water Cooler
collection bowl
Polished Sample
Filter

Figure 3.4: Sample Condition System

The off-gas sample extracted from the process reaches the sample conditioning sub-system through a
heated sample line. The sample is then drawn through filter elements located inside of a heated box
mounted external to the main analyzer cabinet. The temperature of the heated line and the heated
box is maintained to approximately 110 ºC by the analyzer PLC. The controlled temperature has
been factory set to ensure that moisture contained in the sample does not condense before particle
filtration. This temperature is configurable through the Analyzer HMI if required.
CONFIDENTIAL - This document is the confidential property of Tenova Goodfellow Inc.
8124 Single Stream EFSOP® System Manual – IVACO Page 18 of 67

A dual head vacuum pump provides the suction required for transporting the sample off-gas from the
EFSOP® probe through the heated line and heated box filters. The pump draws the off-gas sample
continuously at an average rate of 40 LPM under a vacuum pressure less than 18 inches Hg. The
sample will be under positive pressure once it passes through the head of the vacuum pump. This
arrangement permits all drains and vents from further processing to be under positive pressure. A
bulk flow meter and vacuum transmitter with pressure gauge, monitor the flow and vacuum produced
by the pump.

A small sample is then split from the bulk sample for further conditioning and chemical analysis. A
sample flow meter, sample pressure gauge and sample flow valve regulate the flow of the partitioned
sample to approximately 3 LPM. The remaining bulk sample is discarded through the off-gas vent.

The split sample for analysis then passes through a Thermal Electric Cooler (TEC), where it is dried to
less than 8oC dew-point with a control range not exceeding 2oC. The purpose of the TEC is to
condense and remove all water out of the sample prior to reaching the analysis cells. The condensed
water is captured into a bowl located below the cooler. A valve opens to evacuate the water out of the
analyzer through a drain port. This valve is controlled by the PLC and will only open during the probe
purge sequence and will remain closed during normal operation on the analyzer.

The dry and cooled sample then passes through a water slip detector to ensure all moisture is
removed. If water escapes past the TEC, the water slip detector will provide a contact closure to the
PLC. This will initiate an alarm and start the probe purge cycle causing the drain valve from TEC and
a second drain valve located at the water slip detector to open. Once the probe purge cycle has
been completed the drain valves will close and off-gas sampling will commence. If the water slip
detector alarms for more than three times during the course of an hour, then the vacuum pump is
automatically shut off by the control system.

After passing through the water slip detector, the dry cooled sample undergoes a final filtration to
remove any particulates or congealing prior to being delivered to the Analysis System. At this point
the off-gas sample is referred to as the polished off-gas sample. In order for the polished off-gas
sample to be analyzed accurately, the flow into the analysis system must be regulated while
maintaining a constant pressure. This allows the measurement cells to give a consistent output and
maintain a consistent lag time for the sample to travel from the pump to the analysis system (lag time
<5sec). It is important to note that the polished sample flow meter and pressure gauge regulate the
sample valve that splits the bulk sample just prior to the TEC in order to maintain the minimum
polished sample flow and pressure.
CONFIDENTIAL - This document is the confidential property of Tenova Goodfellow Inc.
8124 Single Stream EFSOP® System Manual – IVACO Page 19 of 67

Sample Conditioning System – Purge Function

During the normal course of operation, the EFSOP® Probe will plug as dust and debris accumulates
on the internal filter and on the inside walls of the probe (probe barrel). In order to ensure continuous
analysis, the probe is purged by the EFSOP® Analyzer during the periods of time when off-gas
analysis is not required (for example when the furnace is charged with scrap or tapping).

The analyzer purging function performs both a Probe Purge and Internal Probe Filter Purge. The
probe purge uses a dedicated purge line to the probe for cleaning the barrel of the probe. The filter
purge cleans the sample filter in the heated box and the filter sock in the probe through the heated
sample line. The analyzer has the capability of independently activating the probe and filter purges.
There is an option to have the purges initiated manually from the analyzer HMI as well as remotely
from the plant’s automation system using a dry relay contact closure. The purging medium (Nitrogen,
compressed air, CO2 or any other gas the plant has available for this purpose), is supplied by the
plant and regulated to a pressure of 6 to 7.5 bar (85-105psig). A flow of approximately 0.5Nm3/min
(18-20cfm) without pressure drop for approximately 5 minutes is required.

Table 3.1, provides the description and functionality of the major components in the sample
conditioning system. The component labels indicated in the P&ID schematic of Figure 3.3 are
provided below. This naming convention is used throughout this document, the analyzer HMI screens
and attached Engineering drawings. Please refer to Attachment 5 “8124 Single Stream EFSOP®
Engineering Drawing Package” for a complete flow schematic of the entire analyzer.
CONFIDENTIAL - This document is the confidential property of Tenova Goodfellow Inc.
8124 Single Stream EFSOP® System Manual – IVACO Page 20 of 67

Table 3.1: Sample Conditioning Sub-System - Component Description

P&ID
Component Description
Reference

The filter removes additional particulates from the

sample gas before it enters the 3-way blowback
Primary Heated Filter FILTER 101
valve (V102). This filter is periodically purged and
is located inside of the heated box.

Contains a finer filtration element and it is not

Secondary Heated Filter FILTER 102
purged. This filter is located in the heated box.

This valve is actuated via a pilot solenoid valve

(S101), controlled with Solid State Relays to
purge the sample line periodically through the
Three-way Blowback
V101 primary heated filter, heated sample line and
Valve – Pilot Operated
probe filter. When actuated, this three-way valve
automatically isolates the analyzer from the
process off-gas.

This valve is activated via pilot solenoid valve

(S102) and is used to purge the sample line and
Blowback Valve V102
probe filter, bypassing the primary heated box
filter.

The pump provides the vacuum necessary to

bring the sample gas from the water-cooled
Sample Pump M101 probe. The dual pump heads are kept hot in the
heated box, while the pump motor remains in the
cool side of the cabinet.

This component provides local indication as well

as electrical signal to the PLC indicating the bulk
Bulk Flow
FI101/FT101 flow extracted, it is located inside the analyzer
Indicator/Transmitter
cabinet.
CONFIDENTIAL - This document is the confidential property of Tenova Goodfellow Inc.
8124 Single Stream EFSOP® System Manual – IVACO Page 21 of 67

P&ID
Component Description
Reference

Manual valve used to isolate the pumping section

Manual Isolation Valve V104 for testing and maintenance needs. This
component is found in the heated box.

These components provide local indication as well

Vacuum Transmitter and PT101 and as electrical signals for the PLC indicating the
Vacuum Gauge PI101 pressure inside the extraction system (heated
line). Both are located inside the analyzer cabinet.

Reverse Regulator driven by the PLC to operate

valve V105 in order to keep the polished sample
Flow Controller FC106 flow constant through the analyzer by discarding
the excess sample to Drain/Vent instead of
continuing through the analyzer.

Located inside of the analyzer cabinet, the TEC

cools the portion of sample gas split from the bulk
flow to be analyzed. Any condensate that may
Thermal Electric Cooler VES103
result is discharged to a drain through a solenoid
valve (V107) actuated by the PLC as part of the
normal operation sequence of the analyzer.

Installed after the TEC, senses water in the

sample and gives an alarm if any water should
escape from the TEC in the sample flow towards
Water Slip Detector ZHA 101
the analyzer. The water is drained through PLC
actuated solenoid valve (V108) as part of the
normal operation sequence of the analyzer

This valve is activated by solenoid valve S103 to

blow out the barrel of the probe with dry nitrogen.
Purge (Blowback) Valve V103
The solenoid valve S103 is operated by the PLC
as part of the normal operation sequence of the
analyzer.
CONFIDENTIAL - This document is the confidential property of Tenova Goodfellow Inc.
8124 Single Stream EFSOP® System Manual – IVACO Page 22 of 67

P&ID
Component Description
Reference

Used to by-pass the primary heated filter in order

to better purge the filter of the sampling probe.
By-pass Valve V110 The valve is operated by the PLC controlled pilot
solenoid valve (V111) as part of the normal
operation sequence of the analyzer.

Removes any remaining particulate from the

Polished Sample Filter FILTER103
sample gas before it enters gas detectors.

Ensures that the flow of sample gas to the

detectors will remain at a constant pressure for
Pressure regulator PVC101
the purpose of flow regulation and measurement
consistency.

Refer to the Attachment 2 “8124 Single Stream EFSOP® System Maintenance Schedule and
Procedures” and Attachment 3 “8124 Single Stream EFSOP® System Parts List” for maintenance and
replacement part numbers.
CONFIDENTIAL - This document is the confidential property of Tenova Goodfellow Inc.
8124 Single Stream EFSOP® System Manual – IVACO Page 23 of 67

Sample Analysis Sub-System

Figure 3.5 shows the P&ID schematic for the major components of the Sample Analysis System.
Table 3.2 provides the description of components indicated in the schematic. Please refer to
Attachment 5 “8124 Single Stream EFSOP® Engineering Drawing Package” for a complete flow
schematic of the entire analyzer.

Figure 3.5: P&ID Schematic Sample Analysis Sub-System

 CONFIDENTIAL - This document is the confidential property of Tenova Goodfellow Inc.
8124 Single Stream EFSOP® System Manual – IVACO Page 24 of 67

Figure 3.6 shows a photo of the Sample Analysis System.

Analog (V to mA)
O2, H2, CO and converters
CO2 detectors

Figure 3.6: Sample Analysis Sub-System

The polished sample flow is split into a sample and bypass stream as it enters the Sample Analysis
System. The sample stream sends the polished sample flow for analysis and by pass flow to vent
outside the analyzer. The flow meters are manually set to allow for a minimum of 0.3 LPM sample to
reach the gas detectors for analysis. Flow meters are equipped on each stream with flow transmitters
to send information in form of 4-20 mA signals to the control system. The bypass aids in ensuring fast
response time of the analyzer by facilitating a larger volume through the sample analysis system.
The polished sample passes through a liquid block filter to remove and ensure no moisture enters the
gas detectors. The four gas detectors and liquid block filter are housed inside a 19” rack mounted
drawer.
The signal from the gas detectors is fed directly to the Analyzer PLC thru 4 analog (V to mA)
converters.
The analyzed sample and bypass sample are exhausted through the bench vent port of the analyzer.

Table 3.2: Sample Analysis Sub-System - Component Description

CONFIDENTIAL - This document is the confidential property of Tenova Goodfellow Inc.
8124 Single Stream EFSOP® System Manual – IVACO Page 25 of 67

P&ID
Component Description
Reference

This filtration element contains a 50 mm Teflon

membrane with pores that allow gas to flow but
will not allow liquid water to pass. This is to
ensure that no liquid moisture is allowed to
Liquid block LB
carry over into the gas detectors. When the
sample gas leaves the liquid block, it is now
clean and dry. This component is located in
the rack mount drawer.

0 to 5 LPM rotameter equipped with a manual

By-Pass Rotameter flow control valve. Visual indication of flow that
(visual indication flow- FIC102 is routed around the detectors. Mounted on
meter) the external surface of the drawer.

0 to 1 LPM rotameter equipped with a manual

Sample Rotameter flow control valve, visual indication of the flow
(visual indication flow- FIC103 through the detectors. Mounted on the
meter) external surface of the drawer.

The oxygen (O2) detector is a long life

electrochemical cell which is not affected by
the other components in the gas stream. The
detector produces a voltage output, directly
proportional to the amount of Oxygen sensed.
Oxygen Detector O2 Sensor A typical sensor output would be 12 mV with
air at 20.9% oxygen composition. This output is
then directed to the PLC. The oxygen
detector has a limited life span of 12 to 18
months.

P&ID
Component Description
Reference
CONFIDENTIAL - This document is the confidential property of Tenova Goodfellow Inc.
8124 Single Stream EFSOP® System Manual – IVACO Page 26 of 67

Hydrogen is detected by a temperature

controlled, thermal-conductivity cell (T/C cell).
The TC cell has a lifespan of approx. 5 years. It
is housed in a temperature controlled chamber
at ~120oF. This is to provide maximum stability
over time. A solid state temperature controller
maintains the chamber at the proper
temperature. This detector does not contain
any moving parts. It does not burn the sample
Hydrogen Detector H2 Sensor gas. Coarse zero and span potentiometers
(pots) are located on the pre-amp board which
is mounted directly on the top of the T/C cell.
These should never have to be adjusted but
are available if necessary. The T/C cell is also
affected in a predictable manner by the
presence of CO and CO2 in the sample gas.
To counteract the effect, the PLC will
compensate the signal based on the CO and
CO2 content of the gas sample.

The two gas species are measured in a dual

CO/CO2 NDIR Gas HMIR CO/CO2 microprocessor controlled NDIR cell.
Detector Sensor After signal processing CO and CO2 outputs
are directed to the PLC for further processing.

Refer to the Attachment 2 “8124 Single Stream EFSOP® System Maintenance Schedule and
Procedures” and Attachment 3 “8124 Single Stream EFSOP® System Parts List” for maintenance and
replacement part numbers.
Analyzer Control System
The Analyzer Control System consists of a PLC, HMI Panel View Touch Screen and outputs provided
by all the controllable components from the Sample Conditioning and Sample Analysis Sub-Systems
of the Analyzer. The aspects of the analyzer HMI will be discussed further in the “Analyzer Operation”
area of this manual.

Logic for the probe and filter purge sequence, water slip alarm, analyzer CO safety alarm, analyzer
calibration, sample flow regulation and temperature regulation are controlled by the analyzer control
system. Alarm threshold set points for flow, temperature and time are also configurable through the
Control system.
CONFIDENTIAL - This document is the confidential property of Tenova Goodfellow Inc.
8124 Single Stream EFSOP® System Manual – IVACO Page 27 of 67

Purge Control
The onset for the probe and filter purge is initiated by a signal that is received from the plant
automation system. This signal is typically sent for the EAF roof open status during charging of scrap
into the furnace. A forced purge signal can also be initiated from the analyzer HMI or remotely from
the EFSOP® computer. The purge sequence cycles between a probe purge and filter purge, the
duration for each cycle and number of cycles is configurable through the analyzer HMI.

During the probe purge the PLC activates solenoid valve S103 to open valve V103. This permits
nitrogen to travel from the analyzer through the purge line to the probe and clean the barrel of the
probe. Once the set duration for probe purge has expired the PLC will activate solenoid valve S103 to
close valve V103 to stop the flow of nitrogen to the probe. See figure 3.3, P&ID Schematic Sample
Conditioning System for valve locations.

The filter purge is configured to start after the probe purge. This purge operation is two staged
beginning with the purge starting through the primary heated box Filter101 to the probe filter for a set
duration. After the set duration has passed Filter101 will be bypassed and the nitrogen will flow to the
probe filter via the heated line. The duration for each stage of the filter purge is configurable through
the control system. When the filter purge is initiated, the PLC will activate solenoid valve S101 to
open 3-way valve V101 to a position that will isolate the sample stream just prior to heated box
Filter102. The position of the V101 valve will also permit nitrogen to flow through the primary heated
box filter through the heated sample line to the probe filter. After the set duration for purge with
primary Filter101 pass has expired the PLC will activate solenoid valve S102 to open valve V102.
This will permit the bulk of the nitrogen flow to bypass the primary heated box filter as it is the path of
least resistance. Once the duration for the filter purge has passed both solenoid valves S101 and
S102 will be activate by the PLC. Valve V102 will close and 3-way valve V101 will be positioned to
close of the nitrogen flow to the sample stream and permit sample off-gases to enter into analyzer.
See figure 3.3, P&ID Schematic Sample Conditioning System for valve locations.

Based on the number of purge sequence repeats configured by the Control System the purge cycle
for both probe and filter purge will continue until the last cycle is completed. The maximum number of
cycles is configured through the analyzer HMI.

Analyzer Auto Calibration

Figure 3.7 shows the P&ID schematic for the analyzer components described in the auto calibration
process.
CONFIDENTIAL - This document is the confidential property of Tenova Goodfellow Inc.
8124 Single Stream EFSOP® System Manual – IVACO Page 28 of 67

Figure 3.7: P&ID Schematic indicating Valve and Solenoids used during Auto Calibration

The analyzer auto calibration is triggered manually from the analyzer HMI. When the auto calibration
is triggered the PLC activates solenoid valve S109 to close valve V109. This isolates the Sample
Analysis System from the Sample Conditioning System preventing the sample off-gas from entering
into the analyzer bench. At the same instance the PLC activates solenoids S106 and S108 to open
valves V106 and V108. This will vent the sample off-gases being continuously processed through the
sample conditioning system. It is important to note that the off-gas sample continues to be collected
and processed through sample conditioning sub-system in order to minimize delays in sample
analysis once the calibration process has been completed.
CONFIDENTIAL - This document is the confidential property of Tenova Goodfellow Inc.
8124 Single Stream EFSOP® System Manual – IVACO Page 29 of 67

The zero calibration is initiated first by the PLC, which activates solenoid valve S116 to open valve
V116 to allow the zero gas to enter into the analyzer bench. The gas flows through the analyzer
bench for the configured purge time (typically 60 to 90 seconds) before zeroing all 3-gases and setting
the span value for oxygen. Once this is completed the Analyzer PLC initiates zero/span calibration for
H2 respectivelly O2 signals (coming directly from the cells thru the V to mA converters). This
procedure takes 12 seconds..Once this process is complete the PLC will close valve V116 through the
solenoid and open valve V117 to allow the Span gas to enter into the analyzer bench. The Span gas
will also purge the bench for the configured duration before setting the Span value for the remaining
three gases (CO, CO2 and H2). Once this is completed the Analyzer PLC initiates span/zero
calibration for H2 respectivelly O2 signals (coming directly from the cells thru the V to mA converters).
This procedure takes 12 seconds.. Once the calibration is complete the PLC closes the Span valve
and sample vent valves. Valve 109 will be also be opened and to allow the flow of the off-gas sample
into the analyzer bench for analysis.

During the auto calibration process a command signal from the PLC activates the zero and span
values individually on the NDIR board. This process is initiated after the set purge times have elapsed
for each of the calibration gases. When calibrating the span gas, the NDIR board compares the CO
and CO2 outputs to the entered pre-set values for each gas. Any deviation from the pre-set values is
automatically corrected in the NDIR board and then sent to the PLC as corrected 4-20 mA outputs.

The initiation of the calibration procedure requires the user to manually open the calibration cylinders
prior to commencing and closing of the cylinders after completion. Refer to Attachment 2 “8124
Single Stream EFSOP® System Maintenance Schedule and Procedures” for more details.
CONFIDENTIAL - This document is the confidential property of Tenova Goodfellow Inc.
8124 Single Stream EFSOP® System Manual – IVACO Page 30 of 67

4. Analyzer Operation

Introduction
The internal functions of the EFSOP® Analyzer are controlled by a PLC. Information regarding the
current state and operation of the analyzer is available through the analyzer HMI. Details regarding
the operation of the analyzer HMI are provided in section 6 “Analyzer HMI” of this manual.

The EFSOP® Analyzer operates in four basic functional states of operation. Table 4.1 below defines
the four functions states of operation.

Table 4.1: EFSOP® Analyzer States of Operation

Analyzer Operation State Description of Operation State

S0 Power Up
S1 Sampling
S2 Purging
S3 Calibration

The major functional states and transitions between states of operation of the analyzer are graphically
shown in Figure 4.1.
CONFIDENTIAL - This document is the confidential property of Tenova Goodfellow Inc.
8124 Single Stream EFSOP® System Manual – IVACO Page 31 of 67

8114 Analyzer Operation

(Stages Diagram)

Upon warming up the

analyzer starts operating by (S0)
default in in the state it was Warm Up
operating before power down

(S1) Analyzer Sampling

S3a – ZERO

No
Calibration

S3b – SPAN
Calibration
S2a – Barrel
Purge
Timer Or
External Signal
S2b – Filter
Purge (finished Yes
Purging Cycle)
S2c – Filter
Purge (by-
pass ON)

Figure 4.1: EFSOP® Analyzer operation states

CONFIDENTIAL - This document is the confidential property of Tenova Goodfellow Inc.
8124 Single Stream EFSOP® System Manual – IVACO Page 32 of 67

Analyzer Power up and Shutdown

This section describes the operational state S0-power up and the analyzer shut down procedure.

Analyzer Power up State (S0)

When the analyzer unit is powered-up it enters into a brief heating up sequence (aprox. 10 min.)
followed by a calibration sequence, where the user has three (3) choices:
1 – Push the Yes button on the screen which will start the zero calibration sequence (using the
calibration gas cylinder)
2 – Push the No button on the screen which will bypass the zero calibration sequence and an alarm
will be triggered (the alarm will reset by performing a zero calibration sequence).
3 – Do nothing and in this case the analyzer will wait for aprox. 10 minutes after which will perform a
zero calibration sequence by starting the vacuum pump and the valve V120 and closing the three way
valve V101.

Upon completion of warm up sequence, the analyzer will move to normal operation were off-gas
sampling will begin. At this point the functional operational state of the analyzer transitions from S0 to
S1 (Sampling). At this transition point the HMI screen will automatically display the MAIN screen, see
Attachment 11 “8124 Single Stream EFSOP® Analyzer HMI Screens” for examples of the Main
Screen.

Analyzer Shutdown
The EFSOP® Analyzer can be powered down without any problems by turning off the electrical power
to the unit. Although, all components of the analyzer are set to remain in a fail safe position when de-
energized, the operator should ensure that the unit will remain de-pressurized. As a precaution the
main Nitrogen supply lines should be closed and any nitrogen remaining in the lines should be vented.
CONFIDENTIAL - This document is the confidential property of Tenova Goodfellow Inc.
8124 Single Stream EFSOP® System Manual – IVACO Page 33 of 67

Normal Operation States – Sampling, Purging and Calibration

In this section the sampling, purging and calibration functional states of the analyzer are discussed.

Sampling State (S1)

Upon completion of warm up, the analyzer commences normal operation by entering in state S1.
Once the unit enters state S1, the sample off-gas flows through the sample conditioning and sample
analysis sub-systems described in section 3 “EFSOP® Analyzer – Internal Sub-Systems” of this
manual.

The sample pump draws the heated off-gas from the probe, through the heated line and into the
heated box. The sample passes through a dual stage heated filtration system. Once the gases pass
through the pump head they leave the vacuum side of the sample conditioning system and enter the
pressurized side on sample conditioning system.

Downstream of the pump the sample off-gas is split into two streams; one stream is vented while the
other continues through the analyzer. The flow through the remainder of the sample conditioning
system is regulated by a valve that controls the flow of sample gas with the aid of flow transmitter and
the PLC (control system).

The remaining gas sample travels through a Thermo Electric Cooler that reduces the temperature of
the sample. Any water vapour in the gas immediately condenses and drops by gravity flow to a
collection bowl below the cooler. The collection bowl is drained through a solenoid valve operated by
the PLC to open during the purging state (S2). If any water in the sample passes downstream of the
cooler, a water-slip detector will send an alarm to the PLC to force corrective actions to evacuate the
off-gas sample containing water.

The sample continues through a last filtration stage before reaching the Sample Analysis System. The
pressure of the sample is kept constant by a pressure regulator when entering into the sample
analysis system. Two rota-meters equipped with needle valves further divide the gas flow into a
sample to be measured stream and a by-pass stream. The measured stream passes through a liquid
block filter to remove any trace of water remaining in the sample before it enters the analyzing bench.
The analyzed stream and the by-pass stream once again join each other downstream of the analyzer
section and are vented outside of the analyzer.
CONFIDENTIAL - This document is the confidential property of Tenova Goodfellow Inc.
8124 Single Stream EFSOP® System Manual – IVACO Page 34 of 67

Purging State (S2)

The purging state consists of three sub-states to differentiate between the probe purge, filter purge
with heated box filter purge and filter purge by-passing the heated box filter. These states are
indentified on the analyzer operation states diagram shown in Figure 4.1.

State S2a - Barrel Purge for probe

High pressure N2 (6-7.5 bar), is directed through the pneumatically operated valve V103 towards the
barrel of the probe. The valve is operated by the PLC through a pilot solenoid valve S103, see Figure
3.3 for reference.

State S2b - Filter Purge (without by-pass) for probe

High pressure N2 (6-7.5 bar), is directed through a pneumatically operated three-way valve V101
towards the probe through the heated sample line. While in this state, valve V102 is closed to allow
the purge gas to back-purge FILTER101. In this state, pressure losses through the filter minimize the
force of purge nitrogen through the probe. The main purpose of this state is to purge the heated filter
FILTER101.

State S2c - Filter Purge (with by-pass) for probe

High pressure N2 (6-7.5 bar), is directed through a pneumatically operated three-way valve V101
towards the probe through the heated line thus cleaning the probe filter. While in this state,
FILTER101 is by-passed by pneumatically operated valve V102. As the purge gas does not pass
through FILTER101, the purge gas is delivered full force to the probe filter.

During the transition between S1 and S2 a signal is sent from the PLC to purge the condensate
accumulated in the Thermo Electric Cooler and the water slip detector out of the system. When a
water slip alarm is triggered the analyzer automatically triggers the purging state. This is performed
for three consecutive water slip alarms within the span of one hour, after which the vacuum pump will
be shut off.

Calibration State (S3)

During Calibration State (S3), the purge triggers are disabled so that the high pressure nitrogen does
not enter the system and accidentally released inside the analyzer. Valve V109 closes to stop the
sample gas flow into the sample analysis system. A zero gas is passed through the analyzer
detectors to zero carbon monoxide, carbon dioxide, hydrogen gases and to set the span for oxygen,
this is referred to as calibration state S3a. This is then followed calibration state S3b, where the Span
gas calibrates the value for the remaining three gases and sets the zero value for the oxygen detector.
CONFIDENTIAL - This document is the confidential property of Tenova Goodfellow Inc.
8124 Single Stream EFSOP® System Manual – IVACO Page 35 of 67

5. Analyzer Human Machine Interface (HMI)

This section describes the analyzer HMI screens and how to navigate through them.

Overview
The primary purpose of the HMI is to allow the operator to interact with the analyzer. The HMI
hardware platform is a touch-screen display. The HMI consists of 11 screens. The touch-screen
display communicates with the PLC and with the plant automation system via Ethernet connection.

User Accounts and Security

The security system built into the HMI allows for safe operation of the system with three levels of
access. Each level allows the logged user to perform pre-specified actions associated with level of
security indicated in Table 5.1 below. The system will revert to the lowest security level
(OPERATOR) if no actions have been performed for duration of 10min.

Table 5.1: HMI User Accounts and Accessibility

Username Password
User Group Accessibility and Security
(as delivered) (as delivered)
 View HMI screens
 Run Phases
OPERATOR OPER n/a
 Acknowledge alarms

 View HMI screens

 Run Phases
SUPERVISOR “super” *****  Acknowledge alarms
 Exit the system

 View HMI screens

 Run Phases
 Acknowledge alarms
ADMINISTRATOR “admin” *****  Change Operation Mode
 Execute Manual Control
 Modify setpoints
 Exit the system
CONFIDENTIAL - This document is the confidential property of Tenova Goodfellow Inc.
8124 Single Stream EFSOP® System Manual – IVACO Page 36 of 67

Passwords are hidden when entered into the HMI. The system will login as a default user at start-up
with view mode privileges only (OPERATOR). The system will automatically login as a Default user
after the logged user logs out.

HMI Navigation Map

The HMI screens are organized in a hierarchical structure indicated by the navigation map below, see
Figure 5.1.

S01 One button access to these

Initialization screens via standard button
Screen array (bottom of all screens)

S02 S03 S04 S07 S10

S08
Main Alarms Log Functions Menu P&ID Probe System
P&ID Bench
Screen Screen Screen Screen Screen

S05 S06 S11

Alarms History Parameters Setup System Configuration
Screen Screen Screen

S09
Calibration Progress
Screen

Figure 5.1: HMI Navigation Map

Refer to attachment 11 – “8124 Single Stream EFSOP® Analyzer HMI Screens” for details on
HMI screens indicated in the navigation map.
CONFIDENTIAL - This document is the confidential property of Tenova Goodfellow Inc.
8124 Single Stream EFSOP® System Manual – IVACO Page 37 of 67

6. Analyzer Installation
This section of the manual reviews the requirements for installing the Tenova Goodfellow EFSOP®
Analyzer. Refer to Attachment 12 – “Other EFSOP® System Components” for installation
requirements of other EFSOP® System components.
Overview
Installation requirements for the Tenova Goodfellow EFSOP® Analyzer are grouped into the following
three categories.

1. Analyzer Environment and Operating Requirements

2. Mechanical Connections
3. Electrical and Instrumentation Connections

Analyzer Environment and Operating Requirements

The EFSOP® Analyzer is installed in an enclosed room. Figure 6.1 shows the footprint of the
analyzer and minimum dimensions for the analyzer room.
3 m / 9 ft
24" 13" 50"
61 cm 33 cm 127 cm

Purge
Line
Connection

66 cm
26"
Sample
Line
Connection

63.5 cm
25"

Room Height: 96“ or 2.5 m Double Door

Figure 6.1: EFSOP® Analyzer Room Footprint

CONFIDENTIAL - This document is the confidential property of Tenova Goodfellow Inc.
8124 Single Stream EFSOP® System Manual – IVACO Page 38 of 67

The room is a controlled environment free of dust. Temperature should be maintained above 10ºC
(50 F) and below 30ºC (86 F), a room air conditioning and/or heating system may be required
depending on the location of the room.

The analyzer room is located such that the length of the sample line from the probe location is within
30 m or 100 ft in order to minimize sample response time. The analyzer room must be easily
accessible for maintenance purposes.

The EFSOP® Analyzer and related equipment needs to be safeguarded against EM disturbances and
mechanical vibrations.

All analyzer vents, drain and exhaust are to be routed outside of analyzer room to an approved
discharge location. Please see refer to Section 2 “Safety Information – Hazardous Gas Warning” of
this manual for more information.

It is highly recommended for the analyzer room to be equipped with an air quality monitoring station to
alarm for O2 depletion and presence of high CO. A room ventilation fan is recommended to be
operated by a switch located outside of the analyzer room or automated to start with the air quality
monitor alarm. Please consult local and regional health and safety laws and regulations.

Mechanical Connections
The EFSOP® Analyzer requires several external mechanical connections in order to be integrated
into the EFSOP® System. Table 6.1 lists the external connections and tube sizes for each connection
to the analyzer. Figure 6.2, indicates the approximate location of the external connections on the
analyzer.

Table 6.1: EFSOP® Analyzer Mechanical Connections

Tube Size
Analyze Connection
Metric Imperial
Off Gas Heated Sample Line In - 1/2”
Nitrogen Supply for Pneumatic Actuators 10 mm 3/8”
Nitrogen Supply for Purging Function 12 mm 1/2”
Nitrogen Vent from Pneumatic Actuators 10 mm 3/8”
Purge Line Connection Out to Probe 12 mm 1/2”
Calibration Gas Connection Zero 6 mm 1/4"
Calibration Gas Connection SPAN 6 mm 1/4"
Water Drain Out (downward slope only) 10 mm 3/8”
Off-Gas Vent Sample 10 mm 3/8”
Off-Gas Vent Bench 10 mm 3/8”
Cabinet Exhaust 50 mm 2”
CONFIDENTIAL - This document is the confidential property of Tenova Goodfellow Inc.
8124 Single Stream EFSOP® System Manual – IVACO Page 39 of 67

Figure 6.2: EFSOP® Analyzer External Connections

All pneumatic connections between the EFSOP® System components: analyzer, probe, heated
sample line, purge line, calibration gas cylinders are threaded compression fittings from Swagelok or
are 100% Swagelok compatible.

All mechanical connections to the analyzer are to be made under the supervision of TGI field
engineers during the initial installation.
CONFIDENTIAL - This document is the confidential property of Tenova Goodfellow Inc.
8124 Single Stream EFSOP® System Manual – IVACO Page 40 of 67

Calibration Gas Connection

Calibration gases cylinders with dual stage pressure regulators are to be supplied and are not part of
the scope of supply from Tenova Goodfellow. Please refer to the “Tenova Goodfellow EFSOP®
Analyzer Data Sheet” for calibration gas specifications.

The calibration gases are connected to the respective ZERO and SPAN connection ports. Gas
pressures should be set to 2 to 5 psig depending on the distance between the source and the
analyzer connection ports. The main goal is to ensure a flow of approximately 4 LPM of gas is
achieved without opening the Sample and Bypass rotameter flow valves mounted on the front panel of
the analyzer.

Nitrogen Connection
Nitrogen or other plant available purge gas is supplied to the analyzer room. The nitrogen is used for
activating internal pneumatic valves of the analyzer and for purging of the EFSOP® probe, heated line
and heated box filter. A 40mm (1.5”) header with supply pressure of at least 7 barg (100 psig) is
required. Two lines are split from the header, each equipped with a shut off valve and pressure
regulator set to 7 – bar (100 psig) maximum. As a safety precaution it is recommended to install a
primary shut off valve and solenoid valve on the nitrogen supply to the analyzer room. The solenoid
valve is automated to close when the plant supplied low oxygen alarm is triggered in the analyzer
room.

A 12 mm (1/2”) line from the nitrogen header is connected to the N2-Supply port of the analyzer and is
used for the high volume purge. The second 6 mm (14”) nitrogen line is connected to the N2-ACTS
In port and is used to activate the pneumatic valves inside the analyzer.

Vents, Exhaust and Drain

There are five discharge ports on the analyzer cabinet that are routed to a safe location outside of the
analyzer room. There are two 10 mm (3/8”) tubing ports labelled Off-Gas Vent and Bench Vent, which
are used for venting the collected off-gas. A third 10 mm (3/8”) vent labelled N2 Acts Out is used to
discharge nitrogen used for pneumatic valve activation.

A fourth 10 mm (3/8”) tubing port labelled Drain is used for discharging the condensed water from the
Thermal Electric Cooler condensate bowl and Water Slip drain. The routing of the drain should be
sloped downwards to facilitate the flow of water out of the analyzer.

The last discharge port from the analyzer is the exhaust vent; typically locate near the top of the
analyzer cabinet. The exhaust facilitates the flow of air through the analyzer for cooling and for the
venting of internal leaks. Air is drawn into the analyzer through the cabinet fan and is exhausted
through exhaust port.

The vent, drain and exhaust pipes/tubing are not to be joined together to form a single vent, water
from the drain can be force up into the analyzer leading to potential damage. The tube/pipe sizes
CONFIDENTIAL - This document is the confidential property of Tenova Goodfellow Inc.
8124 Single Stream EFSOP® System Manual – IVACO Page 41 of 67

should not be reduced to a smaller size. All analyzer discharge ports contain harmful gases and are
to be routed outside of the analyzer room to a safe location, please refer to the “Safety Information –
Hazardous Gas Warning” in section 2 of this manual for more information.

Electrical and Instrumentation Connections

Electrical Connection
The EFSOP® Analyzer needs to be supplied with electrical power, please refer to Attachment 1 -
“8124 Single Stream EFSOP® Analyzer Data Sheet” for power supply details. The main power
supplied to analyzer and analyzer room are to be equipped with easily accessible circuit breakers
located outside the analyzer room location. The analyzer electrical supply, room air quality monitor,
air conditioning unit and other room accessories are to be on individual circuits.

The details for connecting the main power supply to the analyzer are provided in Attachment 5 - “8124
Single Stream EFSOP® Engineer Drawing Package”. During installation is it important to ensure the
grounding of the analyzer is completed. All internal components of the analyzer operate under DC
power.

PLC Connectivity
Main interface to plant automation network (PLC) can be done through either analog/digital signals via
terminal block wiring or through industrial ETHERNET connection.

Ethernet connectivity is the preferred method of communication to the plant automation system. The
plant PLC may require a specific communication driver to communicate with the analyzer PLC, please
refer to the “Tenova Goodfellow EFSOP® Analyzer Data Sheet” for specific Analyzer PLC model.
Three digital dry contact relays from the plant PLC are required for Purge Initiation, Analyzer General
Fault Alarm and Analyzer Pump Interlock. Refer to the attached “Engineering Drawing Package” for
the location of the digital contact and Ethernet connection.

For Ethernet connectivity three IP addresses are required for the EFSOP® Analyzer PLC, Analyzer
HMI and one for a field service PC.

The EFSOP® Analyzer has the ability to use analog hard wire connections for minimal data
requirements as an alternative to Ethernet. Attachment 5 - “8124 Single Stream EFSOP®
Engineering Drawing Package” provides the details for the hard wire terminal block configuration.

Table 6.2 provides the details for the required hard wire signals for the analyzer process control
variables. Note that it is the responsibility of the plant to provide the required PLC I/O for analyzer
data requirements.
CONFIDENTIAL - This document is the confidential property of Tenova Goodfellow Inc.
8124 Single Stream EFSOP® System Manual – IVACO Page 42 of 67

Table 6.2: EFSOP® Analyzer Hardwire Connection Description

Process/Control Variables Type of output/input

Off-Gases Values (CO, CO2, O2, H2) 4 analog outputs, 4-20mA isolated
Heated Box temperature 1 analog output, 4-20mA isolated
Heated line temperature 1 analog output, 4-20mA isolated
Sample Vacuum in the heated line 1 analog output, 4-20mA isolated
Bulk Flow Rate 1 analog output, 4-20mA isolated
Temperature of Polished Sample 1 analog output, 4-20mA isolated
Polished Sample Flow 1 analog output, 4-20mA isolated
Polished Sample Pressure 1 analog output, 4-20mA isolated
Cabinet CO Monitor 1 analog output, 4-20mA isolated
Cabinet Temperature 1 analog output, 4-20mA isolated
General Fault Alarm (loss of power) dry relay contact
Analyzer in Calibration Mode dry relay contact
O2 Calibration Alarm 10% from previous dry relay contact
O2 Calibration Alarm 30% from original dry relay contact
O2 Calibration Error 40% from previous dry relay contact
Water Slip Alarm dry relay contact
Analyzer Cabinet CO Alarm dry relay contact
Low flow dry relay contact
Purge initiate dry relay contact
Pump Interlock dry relay contact
H2 Calibration Alarm 10% from previous dry relay contact
H2 Calibration Alarm 30% from original dry relay contact
H2 Calibration Error 40% from previous dry relay contact

The terminal strip containing all connections is labelled as TB1 in the Analyzer.
CONFIDENTIAL - This document is the confidential property of Tenova Goodfellow Inc.
8124 Single Stream EFSOP® System Manual – IVACO Page 43 of 67

7. Warranty
The Tenova Goodfellow EFSOP® System comes with a one year warranty from the equipment
installation date. The terms and conditions for claiming warranty for the EFSOP® System and
components require the proof of system maintenance. The attached “8124 Single Stream EFSOP®
System Maintenance Schedule and Procedures” provides details for maintaining the System.
EFSOP® system components and parts that have not been maintained according the recommended
schedule and procedures will be void of warranty.

Any defective components claimed under warranty must be returned to Tenova Goodfellow Inc.
offices in order to complete the warranty process. Failure to return components will result in
replacement components being invoiced to the plant under the current TGI price list.

8. Technical Support
For technical support please refer to the Attachment 4 - “8124 Single Stream EFSOP® System
Troubleshooting Guide”. Alternatively please contact Tenova Goodfellow Inc. Service and Support
through telephone or email.

Service and Support Contact Information

Vicky Gibson
Telephone: +(1) 905 567 3030 x323
Fax: +(1) 905 567 3899
Email: vicky.gibson@ca.tenovagroup.com

Mail: Tenova Goodfellow Inc.

170-7070 Mississauga Road
Mississauga, ON
Canada L5N 7G2
Tenova Goodfellow Inc.
200-6711 Mississauga Road
Mississauga ON Canada L5N 2W3
Phone +(1) 905 567 3030
Fax +(1) 905 567 3899
info@tgti.ca
 Attachment 1

Tenova Goodfellow Inc.

200-6711 Mississauga Road
Mississauga ON Canada L5N 2W3
Phone +(1) 905 567 3030
Fax +(1) 905 567 3899
info@tgti.ca
Tenova Goodfellow Inc.
200-6711 Mississauga Road
Mississauga ON Canada L5N 2W3
Phone +(1) 905 567 3030
Fax +(1) 905 567 3899
info@tgti.ca
 Attachment 2

Tenova Goodfellow Inc.

200-6711 Mississauga Road
Mississauga ON Canada L5N 2W3
Phone +(1) 905 567 3030
Fax +(1) 905 567 3899
info@tgti.ca
Tenova Goodfellow Inc.
200-6711 Mississauga Road
Mississauga ON Canada L5N 2W3
Phone +(1) 905 567 3030
Fax +(1) 905 567 3899
info@tgti.ca
 Attachment 3

Tenova Goodfellow Inc.

200-6711 Mississauga Road
Mississauga ON Canada L5N 2W3
Phone +(1) 905 567 3030
Fax +(1) 905 567 3899
info@tgti.ca
Tenova Goodfellow Inc.
200-6711 Mississauga Road
Mississauga ON Canada L5N 2W3
Phone +(1) 905 567 3030
Fax +(1) 905 567 3899
info@tgti.ca
 Attachment 4

Tenova Goodfellow Inc.

200-6711 Mississauga Road
Mississauga ON Canada L5N 2W3
Phone +(1) 905 567 3030
Fax +(1) 905 567 3899
info@tgti.ca
Tenova Goodfellow Inc.
200-6711 Mississauga Road
Mississauga ON Canada L5N 2W3
Phone +(1) 905 567 3030
Fax +(1) 905 567 3899
info@tgti.ca
 Attachment 5

Tenova Goodfellow Inc.

200-6711 Mississauga Road
Mississauga ON Canada L5N 2W3
Phone +(1) 905 567 3030
Fax +(1) 905 567 3899
info@tgti.ca
Tenova Goodfellow Inc.
200-6711 Mississauga Road
Mississauga ON Canada L5N 2W3
Phone +(1) 905 567 3030
Fax +(1) 905 567 3899
info@tgti.ca
 Attachment 6

Tenova Goodfellow Inc.

200-6711 Mississauga Road
Mississauga ON Canada L5N 2W3
Phone +(1) 905 567 3030
Fax +(1) 905 567 3899
info@tgti.ca
Tenova Goodfellow Inc.
200-6711 Mississauga Road
Mississauga ON Canada L5N 2W3
Phone +(1) 905 567 3030
Fax +(1) 905 567 3899
info@tgti.ca
 Attachment 7

Tenova Goodfellow Inc.

200-6711 Mississauga Road
Mississauga ON Canada L5N 2W3
Phone +(1) 905 567 3030
Fax +(1) 905 567 3899
info@tgti.ca
Tenova Goodfellow Inc.
200-6711 Mississauga Road
Mississauga ON Canada L5N 2W3
Phone +(1) 905 567 3030
Fax +(1) 905 567 3899
info@tgti.ca
 Attachment 8

Tenova Goodfellow Inc.

200-6711 Mississauga Road
Mississauga ON Canada L5N 2W3
Phone +(1) 905 567 3030
Fax +(1) 905 567 3899
info@tgti.ca
Tenova Goodfellow Inc.
200-6711 Mississauga Road
Mississauga ON Canada L5N 2W3
Phone +(1) 905 567 3030
Fax +(1) 905 567 3899
info@tgti.ca
 Attachment 9

Tenova Goodfellow Inc.

200-6711 Mississauga Road
Mississauga ON Canada L5N 2W3
Phone +(1) 905 567 3030
Fax +(1) 905 567 3899
info@tgti.ca
Tenova Goodfellow Inc.
200-6711 Mississauga Road
Mississauga ON Canada L5N 2W3
Phone +(1) 905 567 3030
Fax +(1) 905 567 3899
info@tgti.ca
 Attachment 10

Tenova Goodfellow Inc.

200-6711 Mississauga Road
Mississauga ON Canada L5N 2W3
Phone +(1) 905 567 3030
Fax +(1) 905 567 3899
info@tgti.ca
Tenova Goodfellow Inc.
200-6711 Mississauga Road
Mississauga ON Canada L5N 2W3
Phone +(1) 905 567 3030
Fax +(1) 905 567 3899
info@tgti.ca
 Attachment 11

Tenova Goodfellow Inc.

200-6711 Mississauga Road
Mississauga ON Canada L5N 2W3
Phone +(1) 905 567 3030
Fax +(1) 905 567 3899
info@tgti.ca
Tenova Goodfellow Inc.
200-6711 Mississauga Road
Mississauga ON Canada L5N 2W3
Phone +(1) 905 567 3030
Fax +(1) 905 567 3899
info@tgti.ca
Tenova Goodfellow Inc.
200-6711 Mississauga Road
Mississauga ON Canada L5N 2W3
Phone +(1) 905 567 3030
Fax +(1) 905 567 3899
info@tgti.ca