G1 4400 Manual 1009
G1 4400 Manual 1009
G1 4400 Manual 1009
TQ4400 TANKSCAN
GAS SAMPLING SYSTEM
OPERATING MANUAL
CONTENTS
1.0 INTRODUCTION 3
2.0 SYSTEM DESCRIPTION 5
2.1 Pneumatics: 5
2.2 Sensors 10
2.3 Control and Display Electronics. 10
2.4 Power Supply Change Over Unit 14
2.5 Watchdog 14
2.6 Outputs. 15
2.7 Technical Specification 15
3.0 OPERATION 16
3.1 System Start-up 16
3.2 Normal Operation 16
3.3 Panel Controls 17
3.4 Alarm Conditions 19
3.5 Time and Date 21
4.0 INSTALLATION 22
( instalation notes are not included in this version)
5.0 COMMISSIONING 22
( commissioning notes are not included in this version)
6.0 SCHEDULED MAINTENANCE 23
6.1 System Confidence Test Sequential Sampling Part 23
6.2 Filter Check 23
6.3 System Calibration (All Sensors) 24
6.4 Pump Service 24
6.5 Inspecting and Cleaning Snorkel Valves 24
6.6 Testing and Calibrating the TQ126F 25
Set up and Technician sub menus are not included in this version of the TQ 4400
operating manual. For all instructional on changing system parameters, further
calibration instructions etc. Please request the following document from TQ
Environmental sales office.
1.0 INTRODUCTION
The TQ4400 Tankscan extracts a gas sample from a desired location, via
transport lines to an analysing unit where the sample is monitored for
‘Flammable’, ‘Toxic’ or ‘Oxygen’ gases. This is a cost effective method of
gas detection, as only one sensor is required per gas detected.
Explosive Toxic
Table 2
With the ability to monitor for the gases indicated above, the system can be
configured to allow a ‘Pump Room Gas Monitoring System’ to be integrated
into the TQ4400, thus eliminating the need for two separate systems.
The TQ4400 Display Unit can be mounted within the cabinet or in a remote
location, if for instance the analysing unit is installed in an un-manned area.
The operator interface is via four push buttons and a backlit LCD. During
normal operation the LCD display will provide the ‘location’, ‘gas type’ and
sample ‘concentration’ for each individual location.
N.B. A separate SET UP Manual for changing ‘sample line’ No’s., ‘gas
range’ and ‘alarm levels’ is included. These are factory set to the customer’s
requirements, but can be altered on commissioning.
B.E Trunk WB
T
Port 1P
OR
T
Bulkhead
Filename: 4826/4826T5
Ships Air Supply
Cleaning
F.W.T
Sample Lines Penetrate
PORT
Pipe Trunk
into Main Control Unit in
Cargo Control Room Cleaning
(See Detail 'A') F.W.T
Lower
Stool Aft
Lower
Stool Fwd
STB
Vent Drain
Bulkhead
WBT 5 STB WBT 4 STB WBT 3 STB WBT 2 STB
HYDRAULIC ROOM
SHIPS AIR
SUPPLY DISPLAY UNIT
BULKHEAD
ANALYSING UNIT
SAMPLE LINE #1
SAMPLE LINE #2
SAMPLE LINE #3
SAMPLE LINE #6
SAMPLE LINE #7
SAMPLE LINE #8
DETAIL 'A'
SAFE AREA System Schematic
BULKHEAD
Page 4 of 25
TQ Environmental Plc
♦ Pneumatics
♦ Sensors
♦ Control & Display Unit
♦ Power Supply Change Over Unit
♦ Sample Line Accessories
♦ Outputs
♦ Technical Specification
2.1 Pneumatics:
Please refer to Fig 2, 3, 4 and 5, pages 8, 9, 11 and 12 respectively.
Every Sample Line from the relevant Location is firstly connected to its
respective external ‘Shut-off Valve’ to provide sample line isolation. The sample
then passes through a flame arrestor mounted externally on either side of the
cabinet, and into the Analyser Unit.
♦ Solenoid Valves
♦ Catch pot - water trap
♦ Particulate Filter
♦ Double Ended Pump
♦ Coalescing Filter
♦ Flow Meter
♦ Reverse Purge
♦ Leak Detection
2.1.1 The Solenoid Valves are mounted in blocks of eight onto a common
manifold. The manifolds are fitted in pairs to a gland plate, which allows
direct external connection to the input port of each valve.
Fitted onto each pair of manifolds is a Solenoid Driver Board. This board
receives data from the BTC board to operate the solenoid valves.
Each valve is complete with a 24V dc coil, and connection to each coil is
via 3 pole connector containing an LED and snubbing diode.
2.1.2 The Catch pot is fitted with a poly-carbonate bowl allowing visual
inspection of the water levels. In the event of the bowl becoming full a
float assembly will block the outlet, firstly to prevent water entering the
system and secondly to create a Flow Fail Alarm.
To empty the bowl, firstly stop the pump and open the drain valve at the
bottom of the bowl. When empty Ensure that the drain valve is fully
closed prior to re-energising the pump.
2.1.3 The Particulate Filter is fitted with a micro-fibre filter element, which
cannot be cleaned and therefore must be replaced when discoloured or is
suspected of reducing air flow. This unit is also fitted with a poly-
carbonate bowl to allow visual inspection of the filter element. Spare filter
elements can be supplied, refer to Section 7 for Part numbers.
2.1.4 The Pump is an Industrial Double Ended type with the two pumps
connected in series to ensure adequate flow rates for the larger
installations. As an example on transport tube dimensions of 4.0mm I/D,
flow rates in excess of 4 litres/min. are achievable for sample line lengths
up to 300 metres. Based on these figures, sample times for a 300 metre
sample line will be in the order of 1 minute, providing sharp bends and
fittings are kept to a minimum. A Pump Service Kit can be supplied, refer
to Section 7 for Part numbers.
2.1.5 The Coalescing Filter is of nylon construction and, as with the Particulate
filter, incorporates a clear bowl for visual inspection of the filter and
moisture level. Here again the element must be replaced when
discoloured. The drain outlet is fitted with a needle valve, which is opened
sufficiently to allow a small airflow through the Coalescing Filter all the
time the pump is running. This should drain any moisture that has
collected in the Filter bowl. Spare filter elements can be supplied, refer to
Section 7 for Part numbers.
2.1.6 The Flow Meter is fitted in the sample flow line to indicate airflow to the
sensors and works in conjunction with the Sample by-pass needle valve.
The steel float, sensing ring and control relay, are all part of the flow fail
device. If the float passes down through the sensor a Low Flow signal is
sent to its’ control relay. When flow returns the float will raise back
through the sensor and the signal to its’ control relay will revert to normal.
If the gas concentration within the enclosure exceeds 30% LEL the Power
Supply Change-over Unit will disconnect the supply to the TQ4400
Analysing Unit. The power supply cannot be re-connected until the gas
concentration has fallen below the alarm level and a manual reset at the
Power Supply Change-over Unit has been carried out.
2.1.9 Sample Line Equipment is available in several forms to suit the sample
location.
The In-Line Filter is a stainless steel unit that is suitable for attaching to a
stop-valve when fitted in a stop valve box. It is advisable to remove the In-
Line Filter complete for cleaning, as splitting the filter in situ may damage
the threads. Refer to the Installation section 4.5 for Filter Drawings.
Filename: 4826/4826T5
hand side of cabinet or right on request
Penetrations x N
Sample Lines Connect Directly on to Flame 4) Shut off valves and penetrations can
TQ4400 Ballast Tank & Water Ballast Pump Trunk/Upper Stool be supplied as an optional extras.
Arrestors Via Brass Compression Fittings Gas Sampling System
Page 8 of 25
PNEUMATIC/INSTRUMENT
SCHEMATIC DIAGRAM
AIR IN
(Min 6 Bar Max 10 Bar) Flame Arrestor Mounted
(See Note 2)
17 On Outside Of Cabinet Gas Gas
Detector Detector Hydrocarbon Monitor
Vent
Filename: 4826/4826T5
11A 11B
2A
12 Link To
3,1 Display
Unit
Stream 1
17 C NC BTC
1,1 2,1 NO BOARD
Pump Pump 15
13 8A
8B
5A 5B 6
9
4 Flow Fail
Signal
7
TQ Environmental Plc
NC
10
C NO C
NO
3,n
17 14 16
Stream n NC
Drain
1A
NOTES
1) All process connections Brass 3) n = No. of sample lines All system components are
housed in a single enclosure.
2) Air supply to be from dry
filtered instrument air supply.
Fig 3 Typical Pneumatic Schematic for TQ4400 Tankscan -Please see separate Spare
Parts List in Drawings section for Component identification an relevant part numbers.
Page 9 of 25
TQ Environmental Plc
2.2 Sensors
There are two type of sensors, the infrared type, for flammable gases, or the
electro-chemical type for Toxic and Oxygen gases. When a system comprises of
more than one sensor, they are connected in series in the sample line which then
is vented out from the enclosure through a flame arrestor.
The operation of the infrared sensor within the TQ4400 Tankscan system
has been developed from the infrared heat source detector utilised in the
thermal imaging cameras measuring infrared radiation. These detectors
have now developed into non-dispersive infrared analysers, for accurate
Flammable gas detection. Please see the separate GD 129 Manual for more
information and maintenance requirements.
These sensors typically monitor for Oxygen and Toxic Gases and because
of their properties have a life span of approximately 2 years.
The BTC board accepts hard wired inputs from the gas detectors, flow fail relay
and communicates the system status to the Display Unit via a RS 485 serial link.
System status consists of gas concentrations, system fault and alarm status, and
current sample locations.
The Display Unit analyses the information and transmits back to the controller
BTC board any system operations required, to operate gas concentration alarm
relays, sample-line or reverse purge solenoid valves.
RS485 Watchdog
Relay
Board
Both the Control PCB and the Display PCB are constantly monitored by an
individual watchdog unit. This alarms if the any or both of the processors
on the relevant Board fail.
During normal operation the Display Unit will show the current sample
location, gas type, gas concentration and fault alarm status, and generate
alarm outputs by communicating with the BTC board. Refer to section 3.3
for display operation.
This Display Unit can be installed in either the front door of the TQ4400
Analysing Unit, or, remotely as a wall mounted or console mounted unit.
The unit is supplied with plug and socket connections for ease of
installation and maintenance.
TQ ENVIRONMENTAL PLC
TQ4400 GAS DETECTION SYSTEM
218
ALARM ALARM SYSTEM WATCHDOG
1 2 HEALTHY
189
Filename: 4826/4826T5
POWER SUPPLY CHANGE-OVER UNIT
MAIN SUPPLY
STANDBY SUPPLY
GAS ALARM
322 380
RESET
570 580
TQ ENVIRONMENTAL PLC
Flanshaw Way, Wakefield, W Yorks
England, WF2 9LP
Tel: + 44 1924 380700
Fax: + 44 1924 361700
Email: sales@tqplc.com
website :http:// www.tqplc.com
Page 13 of 25
TQ Environmental Plc
The unit will accept 110 - 240V a.c, 50-60 Hz inputs, and will automatically
change back to ‘Main’ when the main supply is restored.
• Mains Supply On
• Emergency Supply On
• Internal Gas Alarm
•
2.5 Watchdog
This unit is mounted on the rear of the enclosure front door to monitor the main
processors in the control board and the display board.
In the event of either of these processors failing the LED and an audible buzzer
will activate.
WATCHDOG ALARM
UNIT
ALARM
MUTE
The audible buzzer can be extinguished using the mute button on the unit, but to
reset the fault the system has to be restarted by powering down from either the
fused isolator in the bottom right hand side of the cabinet or from the power
supply changeover unit.
2.6 Outputs.
• Two sets of Volt Free relay change-over contacts one for High and
one for Low Alarms for each sensor
• One set of Volt Free Change-over relay contacts for System Fault
Alarm.
• One set of Volt Free Change-over relay contacts for Mains Supply
Fail
• One set of Volt Free Change-over relay contacts for Common
Concentration Alarm
The Common Alarm relays can be configured to provide a 24V dc output for
each alarm level to drive audible/visual warning devices or remote indicators.
Relays can also be configured to provide outputs for individual location gas
alarms. These additional relay outputs must be specified prior to order
placement. Other serial communication techniques such as RS 485 Modbus
Protocol will be available shortly. For further information please contact TQ
Environmental Plc.
3.0 OPERATION
This section explains in detail the TQ4400 system operation and typical alarm
conditions. Four front panel push buttons are used for operator interface namely:
SKIP, HOLD, ACK, and RESET.
When power is applied to the system, the display will indicate System Set-up
mode, as below
SYSTEM SETUP
PLEASE WAIT
The system will stay in this mode for approximately 150 seconds.
After the ‘start-up’ delay the system will enter the normal operating mode.
CHAN 1
METHANE 00015%LEL
The top line of the display shows the channel location and the bottom line of the
display will show the gas sensor name, concentration of the gas, and the units of
the gas being analysed. The system will sequentially sample all of the channel
locations, displaying the appropriate data on the LCD.
At any time during the normal operating mode, the user has the option to GOTO,
Hold or Skip a channel. These functions are invoked by pressing down the
relevant push button, and are discussed further below:
The user may press down and hold the RESET and HOLD button until the
display reads GOTO, the user must then release the RESET and HOLD
button. You can then select which sample location to ‘GOTO’ by using
ACK to go up and RESET to go down through the sample locations.
Pressing Hold selects the desired channel.
Once the unit is sampling from the desired location you can then either
HOLD, SKIP or Reverse Purge the location.
The user may press down and hold the HOLD button until the display
reads HOLD CHANNEL, the user must then release the HOLD button.
CHAN 1
HOLD CHANNEL
This will invoke the Hold Channel function. The current Channel location
will be continuously sampled for a maximum period of 20 minutes after
which time the system will revert to sequential sampling. At any time the
user may release the channel and enable the system to revert back to
sequential sampling.
This is achieved by pressing down and holding the HOLD button until the
display reads RELEASE CHANNEL, the user must then release the HOLD
button.
CHAN 1
RELEASE CHANNEL
The user may press down and hold the SKIP button until the display reads
SKIP MODE, the user must then release the SKIP button.
CHAN 1
SKIP MODE
This will invoke the Skip Channel function. The current channel location
will be skipped when the system is sequentially sampling the channel
locations. When the system returns to the skipped channel, the LCD will
display SKIP MODE for 5 seconds and then proceed to the next sequential
channel. When the LCD displays SKIP MODE the user may revoke the
skip command by pressing down and holding the SKIP button until the
display reads NORMAL MODE, the user must then release the SKIP
button.
CHAN 1
NORMAL MODE
The user may press down and hold the ACK and RESET buttons until the
display reads GLOBAL REVERSE PURGE followed by REVERSE
PURGE. This initiates a global reverse purge where air is blown down
every sample line for a set period of time. The purge duration is factory set
and a ‘Button box’ is required to be interfaced to the controller BTC board
to change the value.
After the system has finished purging it will revert back to sampling.
the display reads REVERSE PURGE. This will purge the line for the set
duration, once completed revert back to sampling.
This is a reverse purge, for all sample points, which automatically initiates
after a set number of complete cycles of sample points. We recommend
this function to be enabled for an analyser unit which draws samples from
points where water can be found, such as ballast tanks. The purge
frequency is factory set and can only be altered using a ‘button box’ being
interfaced with the controller BTC board. The box can be obtained by
contacting TQ.
There are three possible fault conditions: Sensor Fault, Flow Fail and
Comms Failure. The sensor will be in fault if the output of the sensor falls
below a set value. When this occurs the LCD will display SENSOR
FAULT, the System Healthy LED will extinguish and the Fault relay will
be activated.
SENSOR FAULT
The Flow Fail will occur if the pressure through the system drops to a set
value. When this occurs the LCD will display FLOW FAIL, the System
Healthy led will extinguish and the Fault relay will be activated.
FLOW FAIL
To clear the Fault condition press and hold the RESET button until the
display reads RESET ALARM. At the same time, the System Healthy led
will illuminate and the Fault relay will be de-activated.
RESET ALARMS
COMMS FAILURE
This cannot be reset by the RESET button; the panel has to be opened and
powered down and back up again. However it is preferred to do this from
the power supply changeover unit.
There are two alarms on the system, a low level alarm, ALARM 1, and a
high level alarm, ALARM 2. When the gas concentration exceeds the set
levels, the appropriate alarms will be activated, and operate the appropriate
LED’s and alarm relays. The LCD will display the first channel to be in
alarm, together with the sensor gas type and relevant alarm condition. The
system will continue to sample the channels sequentially.
CHAN 1
CHAN 1 SYSTEM
HEALTHY
METHANE HI ALARM
The user may reset the alarmed channel by pressing the RESET button. At
which point the alarms for that channel will be cleared. If there are any
pending alarms then the LCD will display the next alarmed channel
information. The user must again press the RESET button to clear that
particular alarm. When no more alarms are present, the system will display
the concentration as normal.
The user may press the Ack button to clear the audible buzzer. This will
acknowledge the alarmed channel and display ALARM
ACKNOWLEDGED on the LCD.
CHAN 1
ACKNOWLEDGED ALARM
If there is a pending alarm the LCD will display the pending alarm information.
When all alarmed channels have been acknowledged, the system will display the
gas concentration sequentially, but will also display ALARM
ACKNOWLEDGED on the LCD for 5 seconds. To de-activate the alarm relays
the user must use the RESET function as described above.
RESET ALARMS
Each alarm is then reset on a channel per channel basis, i.e. if a particular
channel is in alarm then another channel comes into alarm, then the first channel
requires one reset and a second reset clears the next set of alarms in the second
channel.
If a printer is included at time of supply, to record concentration values. The time and
date can be set using the 4 x push button function keys on the front panel. The
instructions are included on an additional functions plaque, mounted adjacent to the
display. If no printer is included with the equipment, the time and date functions are
disabled as there is no means of displaying the information.
4.0 INSTALLATION
Installation guidance is not included in this web version of the operation manual.
Please contact TQ environmental for the complete Operating manual if
installation notes are required.
5.0 COMMISSIONING
Frequency: 6 Months
Ensure that the concentration of gas used is greater than that of the highest
alarm set point.
Description:
When sample locations are grouped into zones, and different zones activate
different alarms, ensure that all ‘zone alarm configurations’ are known so
that alarms can be checked.
Activate a flow fail alarm, this can be achieved by blocking the current
sample line through the ball stop valve. Once the alarm is activated,
acknowledge the alarm, refer to section 3.4.
Connect the test gas to the calibration point within the analysing unit but do
not turn the gas on. Ensure that the 3-Way valve is set on the ‘calibration’
position and turn the gas on at a rate of 1 litre / minute.
The system will now generate a gas alarm on the current sample location.
Ensure all relevant alarms are activated, for example any external beacons
and alarms on the Vessels alarm management system.
Ensure also that the display reads the same concentration as that of the
calibration gas used, i.e. 50% LEL if 50% LEL calibration gas is used.
It must be noted however that all calibration gases have a tolerance that
must be taken in to account.
Description: Refer to section 6.1 for applying test gas. Repeat for all
Sensors.
Note, if the calibration for any of the sensors requires
altering, a ‘button box’ and instructions is required from
TQ.
6.4 Pump Service
Frequency: 24 months
Description:
a) Power down the TQ4400 gas detection equipment. Visually inspect end
of line snorkel valves for dirt and silt build up. Hose down and clean the
valve as necessary.
Frequency: 12 months
Equipment Needed: Zero and Span Calibration Gas suitable for the
sensor used.
Span: 50% LEL or similar
Zero: Synthetic Air 0% LEL
Description:
Please refer to section 2.1.3 for an introduction to the TQ126F, and the
drawing showing the TQ 126F PCB Layout, Fig 14.
Ensure the correct voltage is across the gas sensor by measuring the voltage
across terminals 1 and 3 of the ‘PEL’ terminal connector, next to VR2,
within the sensor’s junction box. Adjust VR1 so the voltage is 2.00V d.c, +/-
0.1v.
Apply Zero gas to the sensor using a suitable gassing cap at a rate of 1
litre/minute, adjust VR2 so that the TQ126F display reads 0.00 %.
Apply Span gas to the sensor using the suitable gassing cap at a rate of 1
litre/minute; adjust VRoVM so that the TQ 126F display reads the same
value as the span gas, i.e. 50.00 %.
While applying gas to the sensor and ensure that the power to the Analysing
Unit is cut at 30 % LEL.
VR 2 VR 1
VRDVM
RL 1
VR 3
VR20MA S/W 1
VR4MA