Use And Maintenance Of 8T0910 Fuel Sulfur Analyzer Group{0786, 1280} Caterpillar

Introduction

This Special Instruction contains the procedure for use of the 8T0910 Fuel Sulfur Analyzer Group. Maintenance and testing procedures are provided to assure correct performance of the fuel sulfur analyzer.

During the operation of the fuel sulfur analyzer, a measured amount of diesel fuel is burned in a one liter chamber that is pressurized with oxygen. Any sulfur in the diesel fuel is converted to sulfur dioxide gas (SO₂). One hundred milliliters of the resulting gas/oxygen mixture in the tank, is then drawn through a syringe.

To determine the amount of sulfur in the fuel, a sulfur dioxide detector tube is used in this procedure. When sulfur dioxide (SO₂) gas is drawn through the detector tube, it will cause a stain (change of color) through the center of the detector tube. The length of this stain, and the procedure given in the topic entitled Testing for Sulfur in Diesel Fuel in this publication, are used to determine the percent of sulfur in the fuel.

NOTE: Under controlled conditions, accurate and repeatable results can be obtained with this fuel sulfur analyzer group. Any change from this procedure or careless operation, however, can result in incorrect readings.

8T0910 Fuel Sulfur Analyzer Group Components

Contents of the 8T0910 Fuel Sulfur Analyzer Group are as follows:

(1) 6V9449 Case (NEEG2145 Decal). (2) 8T5175 Timer. (3) 8T5166 Gauge. (4) SEHS8545 Special Instruction. (5) 8T5176 Switch (Circuit Breaker). (6) 8T5167 Igniter Assembly. (7) 8T5172 Thermometer. (8) 6V6045 Case (NEEG2061 Decal). (9) 8T5178 Sulfur Analyzing Maintenance Kit. (10) ^*8T5177 Sulfur Dioxide Gas Detector Tubes (20-300 PPM) [one box]. (11) ^**8T5171 Gas Sampling Syringe (100 ML). (12) 8T5174 Syringe (50 microliter). (13) 8T5170 Sampling Paper.

Located under the front panel, at the approximate locations indicated, are the items that follow: (A) 8T5168 Relief Valve. (B) 8T5169 Battery (two). (C) 8T5173 Battery Charger.

These tubes have a shelf life of approximately one year from date of manufacture. Because of this, only one box of tubes is included with each fuel sulfur analyzer group. Additional detector tubes can be obtained by ordering the Caterpillar part number from the Caterpillar Parts Department, or, by ordering from Matheson. A list of worldwide Matheson Sales Offices is given at the back of this instruction.

Before doing a sulfur dioxide gas test, it will be necessary to remove flow control orifice (14), located behind inlet nipple (15). Store orifice (14) in the maintenance kit, because it will be needed to perform a "Check For Correct Test Flow-Rate" as shown in this instruction.

Additional items needed that are not part of the 8T0910 Fuel Sulfur Analyzer Group are as follows:

* One cylinder of extra dry oxygen, 99.6% minimum purity; welding oxygen is permissible if it meets these requirements.

* Two-stage oxygen regulator (Matheson Model No. 3322) or equivalent.

(18) 8T5179, 1% Sulfur in Diesel Fuel Sample: This is a mixture of No. 2, 35 API, diesel fuel containing 1% sulfur. It is required to check the calibration of the sulfur analyzer, and the accuracy of the procedure.

* 8T5180 Needle Tip: This is the part number of a replacement needle tip for 8T5174 Syringe (12) in the sulfur analyzer group.

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There must be no smoking, or any other source of flame within 3.1 (10 ft) of an oxygen cylinder. Use pure oxygen only, no other gases. Avoid breathing fumes from the combustion tank of the fuel sulfur analyzer. Use the fuel sulfur analyzer with adequate ventilation to prevent an oxygen build-up that could cause an explosion. SLOWLY open an oxygen cylinder valve. When the valve is opened, never stand in front or behind the regulator, always stand at the side. DO NOT use oil on the regulator, valve, fittings, or gauge.

Combustion Tank Seasoning

Do the test procedure using the 8T5179 Fuel Sample (1% sulfur in standard diesel fuel) until the 8T5177 Sulfur Dioxide Gas Detector Tubes give a consistent 1 ± 0.1% sulfur in fuel reading.

The sulfur mixture does not have to be sampled after every test, however, it is recommended to do a sample check after every third test procedure is completed.

Pretest Procedure

1. Check the 8T5171 Gas Sampling Syringe for leaks and flow rate each day, before doing any test procedures. Refer to the topic entitled Checking Pump Performance in this instruction.

2. If the analyzer has not been used for one day, use oxygen to purge the tank. Use the 8T5179 Fuel Sample and make a few tests until an accurate test sample is obtained.

3. Each day, before normal test procedures are started, use the 8T5179 Fuel Sample to do a test to check the accuracy of the analyzer group, and to be sure the test procedure is correct. Do not perform a regular test procedure until the 8T5179 Fuel Sample gives a 1 ± 0.1% reading.

Testing For Sulfur In Diesel Fuel

Use the manufacturer's instructions to connect the oxygen regulator to the oxygen tank.

1. Connect one end of 4.7 mm Ø (.188"Ø) Tygon Tubing (1) to hose nipple (2) on the oxygen regulator. Connect the other end to oxygen inlet flange (3) on three-way valve (4). Put igniter (5) in the igniter port as shown. Tighten the igniter by hand.

2. Turn the handle on valve (4) so the arrow points toward the OFF position.

3. Turn pressure control handle (6) on oxygen regulator (7) fully counterclockwise (CCW). Slowly open cylinder valve (8) until full tank pressure is indicated on gauge (9). Open screw valve (10) on oxygen regulator (7).

Turn pressure control handle (6) clockwise (CW), on oxygen regulator (7), until delivery pressure gauge (11) indicates approximately 105 kPa (15 psi).

4. Turn the handle for valve (4) to the "02" position to permit oxygen to enter the tank. When combustion tank pressure reaches approximately 105 kPa (15 psi) on gauge (12), turn the handle for valve (4) toward "S02" to purge the combustion tank.

* Repeat this procedure approximately five times.

5. Remove igniter (5) from the combustion tank, then turn the handle for valve (4) toward "02" to permit oxygen to flow into the tank.

6. Use the following procedure to purge the combustion tank. Put the palm of the hand over the port where igniter (5) was removed, until the pressure at gauge (12) reads approximately 105 kPa (15 psi).

Remove the hand so pressure at gauge (12) drops to 0 kPa (0 psi). Continue to let oxygen flow into the combustion tank.

* Repeat this procedure five times to purge the combustion chamber in the tank.

7. Using the tube tip breaker on 8T5171 Gas Sampling Syringe (13), break off the tip at each end of a 8T5177 Sulfur Dioxide Gas Detector Tube (14) as shown.

8. Immediately connect the 20 PPM end of tube (14) to rubber outlet flange (15) connected to valve (4). Connect the other end of tube (14) to rubber inlet flange (16) on syringe (13).

Slide syringe (13) into the holder on the sulfur analyzer as shown.

9. With clean hands, fold a piece of 8T5170 Sampling Paper (17) and put it between the coils of igniter (5) as shown. (To get additional pieces of sampling paper, order part number 8T5170 from the Parts Department.)

10. Fill 8T5174 Syringe (18) with the fuel to be tested. Then push the plunger in to empty the syringe.

* Do this twice to flush the syringe.

11. Fill 8T5174 Syringe (18) to the 45 microliter mark with the fuel to be tested. Turn the syringe upside down (invert) to allow any air bubbles to rise to the base of the needle. Push the plunger in until it reaches the 35 microliter mark to remove the air bubbles from the syringe. Wipe the outside of the needle with a clean cloth.

12. Push the syringe plunger in and empty the fuel on sampling paper (17). Make sure the paper is not overly saturated in one place, so fuel does not drip off. If any fuel drips off, the test will not be correct.

NOTE: Never remove or install igniter (5) from the combustion tank with power lead (19) connected to the igniter.

13. After the procedure in steps 9 through 12 has been successfully completed, immediately put igniter (5) with fuel saturated wick (17) into the igniter port of the test instrument.

When pressure on gauge (12) gets to exactly 35 kPa (5 psi), [a pressure that is higher or lower than 35 kPa (5 psi) will affect test accuracy] turn the handle for valve (4) to the OFF position. Tighten igniter (5) by hand.

NOTE: If there are no leaks, pressure gauge (12) will remain at 35 kPa (5 psi). If there is a pressure loss, check for a leak in the tank at the igniter port, at valve (4) or the pipe fittings under panel (A). Any air leak will affect test accuracy.

14. Immediately connect igniter power lead (19) to igniter (5).

15. Push in igniter switch (20) until gauge (12) pressure goes above 35 kPa (5 psi), then release switch (20). (It is possible that the explosion in the tank will be heard.) The rise in temperature from the explosion will momentarily cause a pressure increase in the combustion tank.

NOTE: It may take 10-15 seconds for a sample to ignite. As battery voltage decreases, it takes longer to ignite the sample. Pressing in igniter switch (20) after ignition will only decrease battery life and make it necessary to charge the batteries more often. When the batteries become discharged, charge them according to the procedure given in the topic entitled Battery Charging, in this instruction.

16. After pressure in the tank has reached its peak, then returned to 35 kPa (5 psi), set timer (21) for one minute. [Press timer STOP/RESET button (B), then enter 1 (minute) and 00 (seconds).]

17. Turn the handle for valve (4) so the arrow points toward S02 (output position).

18. Put the red dot on handle (C) in alignment with the red dot on the back plate of 8T5171 Syringe (13), then pull handle (C) all the way out. Handle (C) will lock in the 100 cc position. Immediately start the timer by pressing timer START button (D).

NOTE: During this time, the sulfur dioxide gas mixture being sampled flows through tube (14) into syringe (13). If there is sulfur dioxide gas (SO₂) in the combustion tank, it will stain the reagent in the tube as it passes through. The more sulfur dioxide gas in the tank, the longer the stain. When the timer alarm sounds at the end of one minute, press timer STOP/RESET button (B) and turn the handle for valve (4) to the OFF position.

19. Release handle (C) of the syringe by turning it one-fourth turn in either direction.

NOTE: Handle (C) should not move in more than 5 cc [approximately 6.3 mm (.250")]. If the handle moves more than the 5 cc dimension when it is released the test results will be incorrect. Discard tube (14) and do the test again using a new tube (14).

20. Carefully remove tube (14) from flanges (15) and (16).

21. Make an approximate reading of the parts per million (ppm) from the stain mark in tube (14). [If the stain in tube (14) is at an angle, use the center of the stain as a reference point.]

22. The % sulfur in fuel can now be determined using one of the two methods that follow:

* The % sulfur in fuel = ppm ÷ 200.

Or use the chart above to:

* Locate the point on ppm scale (E), at the bottom of the chart, that is approximately the same as the reading taken from the stain on detector tube (14).* On the chart, make a perpendicular line from the point marked on scale (E) (see above). [This perpendicular line must be long enough to intersect diagonal line (F).]* Now, make a horizontal line that will intersect with the intersecting point determined above and with vertical line (G) at the left side of the chart.* The point where the horizontal line, made above, intersects with vertical line (G) indicates the % sulfur in the fuel being tested.

NOTE: For maximum accuracy during a test, oxygen supply syringe (13), tube (14) and the fuel sample must be at approximately the same temperature. No temperature correction is necessary at temperatures between 0°-40°C (32°-104°F), and no correction is necessary because of relative humidity.

23. Do the procedure from steps 4-22 twice for each fuel sample to be tested.

NOTE: If the length of the sulfur dioxide gas stain from two tests of the same fuel sample differ by more than 10%, do a third test and average the two samples that are closest.

The following information is a list of conditions that can affect the accuracy of the fuel sulfur analyzer and/or test.

* Incorrect seasoning of a new or reconditioned combustion tank.* Failure to purge the combustion tank correctly at startup and/or between each test, or, permitting surrounding (room) air to enter the combustion tank after it has been purged.* Failure to operate the fuel sulfur analyzer enough to get the 8T5179 Fuel Sample tests between the required 0.9-1.1%.* After testing a fuel sample that has a sulfur concentration greater than 1.25%, additional purging beyond the normal will be necessary for the combustion tank. It will also be necessary to test several samples to confirm analyzer accuracy.* Air leakage into the 8T5171 Syringe, or an internal defect in the syringe that causes variable flow rates.* Incorrect amount of diesel fuel used for the test procedure.* Incorrect oxygen quality, supply, or pressure in the combustion tank before a fuel sample is ignited.* Leakage at the tank, valves, fittings or rubber flanges.* The actual temperature of the fuel sample, oxygen source, sulfur dioxide gas detector tube, gas sampling syringe, or the combustion tank, is more than -7°C (20°F) different from ambient air.* Failure to draw the sulfur dioxide gas sample within 20 seconds after the pressure has returned to 35 kPa (5 psi). [The gas sample must be drawn through the detector tube as soon as possible after pressure in the combustion tank has reached its peak and returned to 35 kPa (5 psi). Failure to do this can cause incorrect test readings.]* The parts per million (ppm) reading from the detector tube is not being read quickly enough after gas sample has been taken.* Detector tubes are too old. Check the date on the side of the box. Do not use detector tubes that are older than the expiration date on the side of the storage box.

NOTE: After the test is complete, and if no more samples are to be tested for awhile, carefully flush the combustion tank with oxygen according to the procedure in steps 1 through 6 at the beginning of this topic. After this is finished, partially fill the combustion tank with 20-35 kPa (3-5 psi) of oxygen. This positive pressure will keep surrounding (room) air out of the combustion tank.

Maintenance Procedures

8T5178 Maintenance Kit

Parts included in the 8T5178 Maintenance Kit are as follows:

* Six rubber flanges,* Ten igniter coils.* One hex wrench.* One container of silicone grease for 8T5170 Gas Sampling Syringe.* One flow control orifice for 8T5171 Gas Sampling Syringe.* Two replacement O-ring seals for the 8T5167 Igniter Assembly.* Two replacement O-ring seals for the combustion tank.* One 8T5180 Needle Tip (package of three) for use with 8T5174 Syringe (50 Microliter).

Rubber Flange

Install a new rubber flange when rubber flange (1) on the 8T5171 Gas Sampling Syringe, or on the output side of the S02 valve, leaks or is damaged. (Replacement rubber flanges are included in the 8T5178 Maintenance Kit.)

Igniter Assembly Coil Replacement

1. Use hex head wrench (1) to remove screws (2).

2. Remove old coil (3), install new coil (4) and tighten screws (2). Replacement coils are included in the 8T5178 Maintenance Kit.

Igniter Assembly O-ring Seal Replacement

Replace O-ring seal (1) if it is worn or damaged and will no longer provide an air tight seal between the combustion tank and igniter assembly (2). Replacement O-ring seals are included in the 8T5178 Maintenance Kit.

Combustion Tank Maintenance

With normal use and conditions, it should not be necessary to clean the inside of combustion tank (1).

Any 8T5170 Sampling Paper that falls from the igniter assembly before it is burned, can be removed from the inside of the combustion tank through the igniter assembly port, or by removing end plug (2). Replace the O-ring seal for plug (2) if it is damaged. Replacement O-ring seals are included in the 8T5178 Maintenance Kit.

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Never use solvents to clean the inside of combustion tank (2). Vapor from solvents can cause an explosion.

Checking 8T5171 Gas Sampling Syringe Performance

Before testing for sulfur in diesel fuel, check the gas sampling syringe for correct performance. See the information that follows.

Leakage Test

1. Put an unused (sealed) sulfur dioxide gas detector tube in inlet (1) of syringe (2).

2. Pull handle (3) all the way out, and lock it in position.

3. Wait two minutes, then release handle (3).

When handle (3) is released, the piston inside should come all the way back to 0 cc. If it does not, the pump is not leak proof. The amount of leakage is indicated by the markings on handle (3) when it comes to rest. If there is more than 5 cc leakage in two minutes, the accuracy of any sulfur dioxide gas test will be subject to error.

If there is excessive leakage, it is usually at the area around inlet (1), or between the piston and internal cylinder wall. Leakage between the piston and cylinder is less likely than leakage around inlet (1). Leakage at inlet (1) can be the result of a poor seal between the detector tube and the rubber inlet flange, or between the flange of the rubber inlet and the syringe body.

4. Check for leakage at the tip by:

* Repositioning the sealed detector tube, or* Using another sealed tube and repeating steps 1 through 3 above.

If leakage continues, it is probably between the rubber inlet and the syringe body and can be corrected by tightening clamp nut (4). If this does not stop the leakage, remove the rubber flange and check for cracks, damage or foreign material. Either clean or replace the rubber flange, then repeat leak test steps 1 through 3.

Leakage between the piston and cylinder wall can usually be eliminated with cleaning and lubrication of the complete syringe. See the topic MAINTENANCE in this instruction.

Check For Correct Test-Flow Rate

NOTE: To perform this test, it is necessary to install flow control orifice (5) that was previously removed. Refer to the section entitled, ** 8T5171 Gas Sampling Syringe (50 Microliter) in the topic "8T0910 Fuel Sulfur Analyzer Group Components", in the front of this instruction. After the "Check for Correct Test-Flow Rate" is completed, again remove the orifice and store it for future use.

1. WITH NO sulfur dioxide gas detector tube in inlet (1) of syringe (2), pull handle (3) all the way out and lock it in position.

2. Wait exactly 30 seconds, then release pump handle (3).

When handle (3) is released, it should spring back part way toward its initial closed position. Handle (3) should come to rest at an intermediate position, with pressure on both sides of the piston being equal.

If the pump part of the syringe is operating correctly, and there are no obstructions around inlet (1), approximately 35-40 cc of air should enter the syringe in 30 seconds. [The volume of air that entered can be read from the markings on handle (3) when it comes to rest.]

If less than 35 cc of air was drawn in, the problem is most likely caused by a restriction of the inlet orifice. This can usually be removed by pumping handle (3) several times to flush out the syringe and orifice. If this does not solve the problem, either remove the orifice [inside the syringe, behind rubber flange of inlet (1)] and clean it, or install a new orifice from the maintenance kit.

Test Schedule

The "Leakage Check" and "Check for Correct Test Flow-Rate" should both be performed if the syringe has not been used recently. With normal use, both tests should be performed after every 10-12 sulfur tests to ensure accuracy and reliability.

Maintenance

In normal use, the syringe should be disassembled, cleaned and lubricated after 100-200 test samples have been taken.

1. Disassemble the syringe by removing end cover (6) from body (7).

2. Pull handle (3) OUT, until piston (8) leaves the inner cylinder of body (7).

3. Remove the inlet valve and pressure relief valve from the front of body (7).

4. Carefully use non-abrasive wipers and a good degreaser solvent to clean all contact surfaces.

5. Lubricate all metal-to-metal contact surfaces with the special silicone grease included in the 8T5178 Maintenance Kit.

6. Assemble the syringe carefully, making sure that any abrasive material that can score the inner cylinder wall of body (7) does not get inside the body.

7. Install and tighten end cover (6). Install the inlet valve and pressure relief valve.

* After performing this maintenance procedure, ALWAYS do the "Leakage Test" and the "Checking for Correct Test-Flow Rate" as given in this publication.

Battery

Battery Charging

The battery pack in the sulfur analyzer consists of two, 2 Volt, 8.5 ampere hour gel cell batteries, connected in parallel. It has an adequate charge capacity to power the analyzer for many hours before a recharge is necessary.

The battery charger operates on 120 or 230 Volts AC, and will charge the batteries to their full capacity in 14-20 hours. Do not charge the batteries for an extended period of time, as this could cause damage to them.

Battery Test Using A Voltmeter

Using a voltmeter across sockets A and C of the igniter power cable, press the igniter push button. If the voltage is 2.05 Volts DC or less, charge the batteries. A fully charged set of batteries should indicate 2.13 Volts DC at the terminals.

120 Volt Operation

The charger is shipped from the factory for use on 120 Volt power, 60 Hz operation. Plug the charger power cord into any 120 Volt, 60 Hz outlet and turn the battery charger ON/OFF switch to the ON position.

230 Volt Operation

1. Cut off the 120 Volt plug from the end of the charger power cord and connect the 230 Volt plug.

2. Use a screwdriver blade to remove plug (1).

3. Move switch (2) for the battery charger to the 230 Volt position. Install plug (1).

4. Connect the battery charger power cord to a 230 Volt 50/60 Hz outlet and turn the battery charger ON/OFF switch to the ON position.

Battery Circuit Schematic

Replacement Sulfur Dioxide Gas Detector Tube Ordering Information

Replacement 8T5177 Sulfur Dioxide Gas Detector Tubes can be ordered from the Caterpillar Parts Dept. using the normal parts ordering procedure.

NOTE: Detector tubes can also be ordered from:

The Kitigawa Precision Gas Detector Tubes, No. 103SC, can also be ordered from Matheson Gas Product Branch Offices at the following addresses:

United States

East

Midwest

West

To order replacement sulfur dioxide gas detector tubes outside the U.S.A., order Kitigawa Precision Gas Detector Tubes from:

If the above address is not convenient to your location, order the detector tubes from one of the following addresses:

Canada

Europe

Repair Information

For repair work (warranty or non-warranty) for 8T0910 Fuel Sulfur Analyzer Group, contact:

Outside of North America use Telex #404435

If the tool or any part of it is to be sent to Caterpillar for repair, be sure to first contact Caterpillar Service Technology Group as indicated. Before sending the tool, be sure to enclose a letter that describes the problem, and give the date of purchase from Caterpillar. Tools that are less than one year old will be repaired under warranty (except for abuse). The cost for out of warranty repair will be charged to the owner.

Mailing addresses are as follows:

UPS and EMERY only: