G-CEM 4100 Extractive Multi-Gas Analyser

Transcription

1 G-CEM 4100 Extractive Multi-Gas Analyser Installation, Commissioning, Operation and Maintenance Manual OPS. 090 CODEL

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3 CODEL International Ltd. is a UK company based in Bakewell, Derbyshire, specialising in the design and manufacture of high technology instrumentation for monitoring combustion processes and atmospheric pollution emissions. The company philosophy is simply, to design well-engineered, rugged and reliable equipment, capable of continuous operation over long periods with minimal maintenance. While every effort has been made to ensure that this manual is free from errors, CODEL supply all information without warranty. CODEL International Ltd. CODEL International Ltd. October 2002 Station Building, Station Road Bakewell, Derbyshire DE45 1GE England Tel : +44 (0) Fax : +44 (0) codel@codel.co.uk web site : co.uk We reserve the right to modify designs without prior notice. OPS. 090

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5 Table of Contents 1. CODEL G-CEM4100 Analyser Introduction Foreword G-CEM4100 Basic Principles Emission Monitoring and the G-CEM User Interface Analogue and Logic Inputs and Outputs CDC Serial Port - for use with the CODEL IEM system Analyser Protection 7 2. Summary Specification 8 3. Preparing for Installation Unpacking Additional Materials Ancillary/Additional Equipment Services Installation Selection of Measurement Position Installation of the G-CEM4100 Cabinet Installation of the Purge Air Supply Installation of the Sample Probe and Heated Sample Line Installation of GCU Connections Installation of Normalising Measurements (Oxygen, Temperature 29 and Pressure) 4.8. Installation of Calibration Gases 29 OPS. 090

6 5. Commissioning Pre-Commissioning Checks Power On Check Purge Air Supply Initial Set-Up Using SmartCOM Software Analyser Records Serial Numbers (Complete on First Inspection) Installation Records Commissioning Records Calibration and Measurement Verification Introduction Factory Calibration Verification Re-calibration Maintenance Fault Finding 63 Appendix 1 Setting Analyser Gains 64 List of Figures 65 OPS. 090

7 1. CODEL G-CEM4100 Analyser Introduction Please take a few minutes to read this section before proceeding with installation. It is designed to provide an overview of the analyser and its capabilities so that the information given later will be more easily understood Foreword SmartCEM is the ultimate solution for continuous monitoring of flue gas emissions. It is a fully integrated monitoring concept from the basic analysers and their calibration verification packages through to digital communications, data logging and automatic reporting. At the heart of this concept is the SmartCEM station containing all the analysers and monitors to provide comprehensive stack emission monitoring. The SmartCEM Station Control Unit (SCU) provides power to and communicates with the analysers and monitors within that station. Data from up to 32 SmartCEM stations is transmitted via a serial digital link (CODEL SmartBUS) to the Central Datapoint where it is logged on a dedicated pc or assembled for onward transmission to a plant computer or DCS. The arrangement of a typical SmartCEM system is illustrated in Figure 1. OPS

8 CODEL CODEL CODEL SmartCEM STATION Gas Calibration Unit Station Control Unit G-CE4100 CODELD-Cem2000 (Dust) Signal Processor Unit Signal Processor Unit V-Cem5000 (Flow) CENTRAL DATAPOINT Plant Computer Central Data Controller Figure 1 : Typical SmartCEM System Arrangement OPS

9 1.2. G-CEM4100 Basic Principles The G-CEM4100 is a hot extractive analyser for difficult flue gas monitoring applications. It uses infrared absorption spectroscopy to measure up to seven pollutant species in a single self-contained unit. Many conventional extractive systems require the sampled gas to be cleaned and dried to a very high standard prior to analysis invariably resulting in a highmaintenance demand. Such elaborate pre-conditioning is not required by the G-CEM4100. Process gases are continuously drawn through a coarse filtered probe located in the exhaust duct and transported to the measurement chamber via a short heated sample hose - without further conditioning. Figure 2 illustrates the arrangement. Figure 2 : G-CEM4100 General Arrangement OPS

10 The transceiver unit containing the infrared source and detector system, required to measure the received light energy after its passage through the gas, is located in a separate cabinet and is totally isolated from the flue gas. There is, therefore, no contact between the analyser electronics and the flue gas. Correctly installed and commissioned, this provides the opportunity to achieve very low maintenance factors and totally eliminates any possibility of altering the composition of the flue gases to be measured. The remaining components of a G-CEM4100 analyser are : The Gas Control Unit (GCU) that controls the input of zero and span calibration gases into the analyser. It contains the necessary compressed air filtration and drying equipment to ensure high quality air supply for the zero calibration and probe purge functions. An I/O CEM unit housed within the GCU controls the zero and span calibration functions. The Central Datapoint Controller (CDC) that accepts data from 1 to 16 SCUs and processes the data for onward transmission to a remote pc or SCADA system Emission Monitoring and the G-CEM4100 Although G-CEM4100 analysers can be used for process gas analysis, they have been primarily designed to monitor pollutant emissions from industrial stacks. Legislation governing such emissions usually requires data to be reported in very specific formats. G-CEM4100 analysers are therefore designed to fulfil this requirement without the need for external data manipulation. Although differing in detail from country to country, the essential demands of legislation are common world-wide Normalisation Emission limits are always defined under standard conditions of temperature, pressure and air dilution (air dilution is defined using the waste gas CO 2 or O 2 concentration). Most legislation also requires concentrations to be reported on a dry basis; i.e. water vapour in the flue gas is not permitted to dilute the measurement. The correction of the measurement from as measured conditions to standard conditions is known as normalisation. OPS

11 Like all extractive analysers, G-CEM4100 analysers measure concentrations of pollutant ppm (parts per million by volume) or %, under the conditions at the measurement position. This basic ppm measurement is always corrected for the measurement gas pressure and presented as vpm by the analyser. G-CEM4100 analysers have the capability for the outputs and display to be configured in vpm (or %) or mg/m 3 (which is a mathematical conversion depending on the molecular weight of the gas being measured and the flue gas temperature), or in mg/nm 3 (i.e. normalised to the required standard conditions). When the outputs are required to be normalised to a pre-defined O 2 concentration as opposed to a CO 2 level, then an external O mA signal representing Oxygen levels can be input into the G-CEM4100. All other normalising parameters i.e. pressure, temperature, and CO 2 are measured as standard by the G-CEM Verification It is important that the accuracy of measurement can be verified. Often, legislation requires the regular testing, reporting and correction of measurement zero and span. G-CEM4100 analysers are equipped with automatic zero verification and correction procedures that allows the measurement cell to be flooded with dry air (or Nitrogen) to provide a zero calibration or a certified calibration gas as a span verification User Interface The analyser is supplied with SmartCOM pc software that enables a pc connected to the SCU to display of all real-time measurements as well as the setting up and display of all the analysers configurable operating parameters. This interface includes a diagnostic mode that allows interrogation of the condition of the analysers critical functions for service and trouble-shooting purposes. A full description is provided in Section 5. OPS

12 1.5. Analogue and Logic Inputs and Outputs The G-CEM4100 SCU may be equipped with an analogue output (0/4-20mA) for each measurement channel (up to seven). Each output is freely configurable for any span (within the limits for that measurement, as given in Section 2. Summary Specification and measurement units (vpm or %, mg/m 3, mg/nm 3 ). Volt-free contact outputs (250V/10A) may be provided for data valid and measurement alarm level (common output for all measurement channel alarms). Three 4-20mA inputs are provided for normalisation measurements (273Ω input impedance, ±200V DC common mode voltage range). These inputs are also able to provide isolated 24V DC supplies to drive either 2 or 3- wire external normalisation measurement transducers CDC Serial Port - for use with the CODEL IEM system The CDC is equipped with a 2-way serial communications port for use with the CODEL IEM system. On a plant where more than one CODEL analyser is installed, this is the preferred method and, even for a single analyser installation, can provide significant benefits. The main ones are: Up to 32 SCUs can be connected to a CDC via a single data bus. No corruption of digital data, even over long distances. Common data (e.g., normalisation measurements and plant status) can be transmitted to all relevant measurement channels and analysers from a single input. Real time display can show all measurements simultaneously. Multi-level and period alarms can be freely configured for any measurement data set. Up to 5 years data can be logged and instantly recalled in graphical or tabular format. All processor user interface functions can be carried out from a central control point, i.e. once physical installation is complete, all OPS

13 commissioning operations can be carried out from the central control. Thereafter, real time analyser operating parameters, including diagnostic data, can be accessed at any time. All real time and historical data and diagnostics can be accessed remotely via a MODEM. Reports can be formatted to suit local legislation and printed automatically. Digital data can be transferred directly to the plant DCS or computer Analyser Protection G-CEM4100 analysers are designed for outdoor installation and all units are constructed to IP65 (NEMA 4) standards. The system should be housed such that the ambient temperature is as stable as possible around 20 o C. This may be achieved by housing the cabinet in an air-conditioned environment. If this is not practical, CODEL can supply a separate air-conditioned cabinet in which the system may be housed. OPS

14 2. Summary Specification Measurements Main measurement channels (1-7) any combination of up to seven gases from CO/CO 2 /NO/NO 2 /SO 2 /HCl/UHC/H 2 O Measurement Limits (maximum) CO 2 /H 2 O SO 2 others 50% (vol) ppm (vol) 6000 ppm (vol) Measurement Spans CO/NO/NO 2 /SO 2 /HCl/UHC selectable up to 9,999vpm CO 2 /H 2 O selectable up to 99% Note that although very low spans can be configured, this should not be done without consideration of the measurement uncertainty. Measurement Uncertainty CO 2 /H 2 O ± 0.2% Other gases ± 2ppm or ±2% of measurement (whichever is the greater). Measurement Temperature (Flue gas) Measurement Units dewpoint to 600 C (below dewpoint by arrangement) ppm (vol), mg/m 3, mg/nm 3 kg/h, tones/annum by arrangement OPS

15 Display Outputs Inputs via pc running SmartCom software real-time data historical trend data diagnostic data diagnostic trend data calibration data operating parameters set-up menus summary reports on-line support via MODEM Analogue up to 8 x 4-20mA (located in SCU) 200V common mode isolation 500Ω max. load Fully configurable for parameter, span, zero and response time Logic up to 8 x volt-free contacts (located in SCU) SPCO rated at 50V/1A Analogue 1 x 4-20mA for process gas temperature 1 x 4-20mA for remote O 2 measurement Serial Port (located in Station Control unit) For connection to bi-directional 4-wire data bus terminating at the CDC when installed as part of an integrated emission monitoring (IEM) system Ambient Temperature All units are designed to operate in ambient temperatures of 20 C OPS

16 Enclosures All units are sealed to IP65 (NEMA 4) standards and are suitable for outdoor installation Power Requirements Power Supply Unit or 240V AC Hz single phase - 600VA Purge Gas Requirements Sample Line V AC Hz single phase - 150VA per metre Compressed air/n 2 Clean and dry to -20 o C. Normal operation 100 l/min Calibration ( 10 minutes) 110 l/min OPS

17 3. Preparing for Installation 3.1. Unpacking. The analyser and any other items are normally protected for transportation by an expanded foam packing material. When unpacking, please ensure that smaller items are not discarded with the packing material. If any items are missing please inform CODEL or your local CODEL agent immediately The Basic Analyser - standard supplied items Figure 3 : Standard Supplied Items and Dimensions OPS

18 The transceiver, GCU and SCU, are supplied with blanking plugs fitted in the cable gland entry holes. Cable Glands are packed separately. Also included as standard are the following : - probe mounting flange and mounting bolts - trace heating & insulation for the rear (external) section of the probe - RS232 cable - SmartCom software CD! Some contracts require the mounting of all power supply, processing and control units in instrumentation panels. In such cases please refer to the additional system schematics supplied. These are always contract-specific. Although transceivers and GCUs are essentially interchangeable, analysers are configured and tested as complete systems in the factory. If more than one analyser is supplied, ensure that all units are matched Additional Materials The installation of a G-CEM4100 analyser will require a number of materials in addition to those supplied with the analyser. The following are intended to cover most possibilities, but not all listed materials will be required for all installations. Cables Unit Function No. of Cores G-CEM 4100 CDC (if required) Mains Supply Serial Comms Core Specification/ c.s. area 3 Multi-strand 16/0.2mm, 0.5mm 2 min. 4 Multi-strand 16/0.2mm, 0.5mm 2 min. Normalising inputs 2 Multi-strand 16/0.2mm, 0.5mm 2 min. Analogue 2 Multi-strand 16/0.2mm, outputs 0.5mm 2 min. Fault alarm 2 Multi-strand 16/0.2mm, 0.5mm 2 min. Serial 4 Multi-strand 16/0.2mm, Comms 0.5mm 2 min. O/D min/max 5mm/12.8mm 5mm/12.8mm 5mm/12.8mm 5mm/12.8mm 5mm/12.8mm 5mm/12.8mm Screened YES/NO No YES YES YES YES YES OPS

19 Note that screened cables should have the screen terminated as described in Section 4. Installation. If steel wire armoured cable is used the steel wire sheath should be earthed at the analyser end only. Other Materials Mounting brackets/panels, screws, bolts, etc. for GCU and CDC. Cable trays/conduits/ties and associated fixing materials. Compressed air supply (10 l/min cleaned and dry to -20 C) for (a) measurement cell purge (on demand) and (b) purging of dead zone (0.5 l/sec continuous). 10mm o/d. PTFE tube is required. Consideration should also be given to the possible need for temporary/permanent access platforms and lifting equipment. Customer Supply - Mains power cable Alarm output cable Analogue output cable Interconnecting cable, SCU to CDC Nylon tube to GCU (10mm o/d) 2 x Nylon tube, GCU to Probe (10mm o/d) Interconnecting cable G-CEM4100 to GCU Note : When calculating cable requirements, remember to take into account cable routing relative to equipment location, and also the need for conduit, cable trays, supports etc Ancillary/Additional Equipment The G-CEM4100 is rarely supplied alone. It is usually associated with other equipment that makes up an emission monitoring system. In planning installation, consideration should be given to the requirements of other equipment by consulting the specific manuals so that the whole system may be installed in the most cost effective and efficient way. If the complete system has been engineered by CODEL, detailed contract specific information and schematics will have been provided. OPS

20 Other equipment commonly provided may be: CODEL IEM system (system management, data display, logging and reporting) Other CODEL monitors/analysers Non-CODEL monitors/analysers Normalising measurement - oxygen 3.4. Services Electrical Power - Power Supply Unit or 240V AC Hz single phase - 600VA Compressed Air/N 2 5bar - Dry (to -20 C) - Clean (better than 10μm) - Consumption l/min during calibration 100 l/min continuous OPS

21 4. Installation PLEASE BE SURE TO READ SECTION 3. Preparing for Installation BEFORE PROCEEDING Installation of the units that make up a 4100 analyser may be carried out in any order. However, the recommended order, reflected in this manual, is: Selection of measurement position Installation of air-conditioned cabinet (if required see separate manual) Installation of the G-CEM4100 cabinet Installation of purge air supply Installation of sampling probe and heated sample line Installation of GCU Installation and connection of cables Installation of normalising measurements and input connections to the G- CEM4100 Installation of span verification gases 4.1. Selection of Measurement Position The analyser, mounted remotely in a steel cabinet, measures a sample of process gases drawn from the flue via a sampling probe. It is important therefore, to select a sampling position that will ensure representative results and positions where significant stratification might occur are best avoided. On most combustion plant, flue gas homogeneity can be guaranteed after the ID fan, so from this point of view, the selected position could be anywhere in the ductwork after the ID fan or in the stack. Use suitable protective clothing, including eye protection. Positive pressure in the duct will cause hot flue gases to be vented from the open port. OPS

22 Take care to ensure that duct vibration at the selected mounting point is minimal as severe vibration may cause malfunctioning of the instrument. The final factors to be considered in selection of measurement position are those of convenience and cost of installation. Access from existing platforms or walkways and proximity of existing services are obvious advantages, both for installation and subsequent commissioning and servicing. Drilling holes in metal ductwork or flues is easier than drilling concrete stacks. Conditions vary from plant to plant but, in general, the following guidelines should be followed: Firstly, look for a suitable location on ductwork between the ID fan and the stack. Large power plant with multiple flues having concrete wind-shields can provide good alternative mounting locations within the stack. Access stairs, lifts and working platforms at various levels usually exist. On smaller plant, mounting on metal stacks is acceptable, provided suitable access platforms exist. Only locate analysers on single flue concrete stacks if no other position is possible. Do not locate analysers any higher than necessary on stacks. There is no benefit to measurement quality and significant disadvantages for service personnel Installation of the G-CEM4100 Cabinet The G-CEM4100 cabinet is located local to the heated sample line and probe. The cabinet should be carried on a suitable load-bearing surface and, whilst designed as a free-standing unit, holes are provided in the base panel for bolting-down if required. If the cabinet is to be mounted in a CODEL supplied air-conditioned unit, please refer to the separate manual provided Installation of the Purge Air Supply OPS

23 The G-CEM4100 requires air supplies for the pre-measurement zone and to purge the measurement cell for zero verification. This supply should pass through a proprietary filter unit prior to entering the GCU for further distribution Installation of the Sample Probe and Heated Sample Line Fitting of Stub-Pipes and Mounting Flanges Referring to Figure 4 construct the stub-pipe assembly by welding the mild steel mounting flanges to a suitable pipe. Cut 'slip-fit' holes in the duct at the chosen position! UNDER NO CIRCUMSTANCES SHOULD HOLES BE CUT WITH THE PLANT OPERATIONAL IF FLUE GASES ARE UNDER POSITIVE PRESSURE WITH RESPECT TO ATMOSPHERE. EVEN IF PRESSURE IS BELIEVED TO BE NEGATIVE, GREAT CARE SHOULD BE EXERCISED AND ALL APPROPRIATE PROTECTIVE CLOTHING, INCLUDING EYE PROTECTION, SHOULD BE WORN Metal Ducts/Stacks Position the stub-pipe assembly horizontally and weld the inner end to the duct/stack. OPS

24 Figure 4 : Standard Site Mounting Flange Details If the sampling tube is not being fitted immediately it is advisable to close the stub-pipes with a blanking plate (not supplied) cut and drilled to suit the fitted flanges Installing the Sampling Probe The sampling probe, with connecting flange loosely fitted, is inserted into the duct through the mounting flange and stub-pipe assembly. Bolt the connecting flange to the mounting flange using the bolts provided. Connect the two wires from the temperature sensor (via a gland just below the sample line connections), to the terminals as shown in the connection schedule. OPS

25 Refer to section Check Miscellaneous Temperatures to establish if trace heating is required for the probe. If required, and with the probe secured in position, attach the trace heater and insulation to the rear (external) section of the probe using suitable adhesive tape. The trace heater should be connected to a permanent 240V/1A supply.! If the flue gas temperature exceeds 200 o C ensure that the probe is mounted such that the temperature of the sampled gas does not exceed 200 o C at the inlet to the heated sample line (this can be checked via the SmartCOM software). Seek advice from CODEL under these circumstances Installing the Sampling Line Attach the sampling line at one end to the sampling probe at the duct and at the other end to the cabinet. The sampling line comprises two inner pipes. One of the inner pipes bears a white mark at each end. This pipe should be connected to the corresponding fittings, also bearing white marks, at the probe and the cabinet. The exposed metal pipework of the sampling line at the inlet to the cabinet should be lagged with the black foam insulation and adhesive tape provided. The end of the sample line to connected to the G-CEM4100 cabinet is identified by conduit protruding from the sample line. This conduit should be connected to the cabinet by means of the PG9 cable gland provided. Note that the bend radius of the sampling line should not be less than 0.5m. Also the sample line should not have a low point below the inlet of the cabinet. The wires from the conduit should be connected as shown in the connection schedule Installation of GCU The GCU, shown below, is suitable for outdoor installation. Permissible ambient temperature range is 20 to +60 o C. OPS

26 air valve supply zero/span/ purge supply air mover supply all connections to probe plant air supply auto drains OUT air supply to main cabinet span gas input Figure 5 : GCU OPS

27 Mount the GCU to a suitable load bearing surface wall using 4 x M8 bolts. Mounting hole details are shown in Figure 3. Connect the compressed air input line to the input connector and the air lines from the GCU to the sample probe. Connect any span gases to the span inputs of the GCU 4.6. Connections WARNING!!! Wiring should only be undertaken by a qualified technician. The electrical schematic in Figure 6, Figure 7 and Figure 8 illustrates the connections for the G-CEM4100 and the GCU Installation and Connection of Cables The G-CEM4100 is supplied with all internal cables fitted. External cables supplied by the customer should be connected in accordance with the connection schedule. Decide routing for all non-power cables (both those supplied by CODEL and those sourced locally). Use common routing wherever possible and install leaving sufficient free-end length to make final connections. Power cables should be installed separately, using different routes if possible, to reduce the risk of cross-interference. Leave sufficient free-end length to make final connections.! POWER CABLES SHOULD ONLY BE INSTALLED AND CONNECTED BY SUITABLY QUALIFIED TECHNICIANS. OPS

28 TEMPORARY LAPTOP CONNECTION Figure 6 : Connection Schedule Sheet 1/3 OPS

29 Figure 7 : Connection Schedule Sheet 2/3 OPS

30 Figure 8 : Connection Schedule Sheet 3/3 OPS

31 All units are supplied with cable gland entries fitted with blanking plugs. Cable glands are packed separately. To fit a cable gland, remove the appropriate blanking plug with a spanner, remove the locking nut from the cable gland, screw the cable gland into the threaded hole from the outside and tighten by hand to compress the seal. Refit the locking nut from inside the case and tighten. Figure 9 illustrates the method of terminating cable screens at cable glands when required. Fit the required number of cable glands. Maximum overall cable diameter is 15mm. Figure 9 : Cable Gland Connect the tubing between the GCU, sample probe and the G-CEM4100 as shown in the following illustrations; take note to use the correct tubing material (see Figure 2). The regulators are actuated by lifting the black cap and turning; to lock press the cap down. The compressed air must be clean and dry as detailed in the Section 2. Summary Specification. The mains connection to the G-CEM4100 cabinet is shown below. OPS

32 Figure 10 : G-CEM4100 Mains Connection Note : This unit will be different if using a CODEL supplied air-conditioned cabinet see separate manual provided. OPS

33 Figure 11 : Connections at the G-CEM4100 Cabinet OPS

34 Figure 12 : Heated Sample Line Connections If analogue outputs are to be used connect user-supplied cables to the analogue output terminals in the G-CEM4100 cabinet, for each measurement channel in the analyser. If the analyser is part of a CODEL IEM (Integrated Emission Monitoring) system, this will require the connection of a 4-core cable, depending on the wiring configuration of the IEM system. The IEM manual and/or the overall wiring schematic will provide this information. Cable screens should be terminated in the cable glands but not electrically connected to the gland. Connect the external earthing bolt to a suitable plant earth point, using 4mm 2 (min) cable. OPS

35 4.7. Installation of Normalising Measurements (Oxygen, Temperature and Pressure) The G-CEM4100 is supplied with pressure and temperature inputs fitted as standard for normalising purposes. If external normalising measurements are to be used, either for the analyser itself or as the lead analyser in an IEM measurement group (refer to IEM manual for details), proceed as follows: Install all normalising measurements by reference to their individual manuals. The temperature and pressure sensors are supplied with the analyser. Connect the 4-20mA outputs from these measurements to the G-CEM4100. Figure 6 shows the terminal locations. Any of these inputs will accept independently powered current loop inputs. Input impedance is 237Ω and the common mode voltage range is ±200V DC. The temperature input is also able to provide power for either two- or three-wire transducers requiring a 24V DC supply. All cable screens should either be connected to the cable glands as illustrated in Figure 9 or terminated at the transducer. Screens must NOT be earthed at more than one point Installation of Calibration Gases If required, span verification may be carried out using certified test gases. This is achieved by the measurement cell with the required gas as shown in Figure 13. OPS

36 Figure 13 : Testing Span using Audit Gases OPS

37 5. Commissioning The analyser should now be fully installed and ready to be commissioned. This involves the following basic procedures that can be carried out with the plant on or off : analyser configuration (set-up) zero calibration span checks water vapour checks 5.1. Pre-Commissioning Checks Before proceeding the following checks should be carried out : - If wiring has been installed and connected by others (and particularly if no certification of connection accuracy exists), check all wiring and connections for conformity with the information provided in Section 4.6. Connections and 4.7. Installation of Normalising Measurements (Oxygen, Temperature and Pressure) Although the analyser is equipped with all practical safeguards against the consequences of incorrect wiring, it is not possible to provide total protection against all errors. Please be aware that damage arising from incorrect wiring will invalidate the warranty. It is also recommended that if unfamiliar with the G-CEM4100 analyser, read Section 1. CODEL G-CEM4100 Analyser Introduction before proceeding. This provides an overview of the analyser's capabilities and the uses of the parameters that will be configured during commissioning. OPS

38 5.2. Power On Switch on the power supply to the G-CEM4100. If final connection of power supplies has been left until the commissioning stage, note that the requirements are : Power Supply Unit 110 or 240V AC, 50-60, single phase! Although measurement values will now be displayed they will probably be meaningless and will remain so until the commissioning procedure is complete. The following commissioning instructions are provided in detail and are written for the first time user Check Purge Air Supply Referring to Figure 14, in the GCU check that the main plant air supply regulator is set to 60psi. Check that the air mover regulator is set as indicated on the gauge to 25psi* and that the air valve regulator is set as indicated on the gauge to 40psi * The air mover regulator pressure will require checking and adjusting see section 5.4. Initial Set-Up Using SmartCOM Software Switch on the air supply from the GCU to the G0CEM 4100 using the small ball valve the lever should be in the vertical position. In the G-CEM4100 cabinet the regulator that feeds the neutral zone should be set to 5psi. Once power is switched on to the unit the analyser will take up to 1 minute to start, after which the zero air solenoid will be activated. The flow meter should now register 10 l/min. this value is set at the factory but may be adjusted using the knob at the bottom of the flow meter. OPS

39 Air valve regulator air mover regulator plant air supply regulator ball valve zero air regulator Figure 14 : GCU Valve Locations OPS

40 5.4. Initial Set-Up Using SmartCOM Software Install SmartCOM software on a pc using the installation procedure. Connect the special interface cable between the pc serial port and the screw connector on the side of the G-CEM4100 cabinet. Start SmartCOM software and you will see the screen below. Set the correct pc comms port identity in the 'Comms validity indicator'. Figure 15 : Initial SmartCOM Screen OPS

41 Set sensor selector to SCU. Insert address of SCU at Address selector (this will probably be 1). Set sensor selector to GCEM4100 and set Data File selector to 'Read'. Click on 'read data control' and ensure the 'message received indicator' turns green and that data is deposited in the 'Data access window' where a binary stream should be visible. If not, try again, but if after several attempts nothing happens, check for good communications between the pc and SCU. The system should now be left for 4 hours to reach working temperature. If nothing further is done to the system at this point the analyser will automatically zero calibrate after four hours then automatically switch to normal running mode. However, it is good practice to check the following parameter data before normal measurements are taken using SmartCOM software Set Sample Flow Rate Select SCU in the sensor window; the select 4100 sample flow rate in the function window. The following screen will appear. OPS

42 Click on the Read button and the flow rate will be displayed in l/min. This value should be 5 l/min ±0.2. To adjust this reading, use the air mover regulator in the GCU (see Figure 14). Note that this adjustment can only be carried out when the purge air is switched off Check Thermistor Control Select 'Thermistor Control' at the Function selection and the following screen will appear. OPS

43 Click on 'Read' and the following screen should now show : Some of the data displayed is in hexadecimal (base 16) notation, not decimal (base 10). Check the values against the table below and change any that are incorrect. The 'Thermistor measured value' and 'Cooler current' should now display at values close to those selected. Variable Hex or decimal Value Thermistor target value Hex 3800* Proportional Gain Decimal 50 Integral Gain Decimal 70 Time Constant Decimal 1 * This value may vary depending upon factory set-up. OPS

44 Source Temperature Control Select Source Temp Control in the Function selector and the following screen should appear. Click Read to update the display values. Ensure that the green message received LED illuminates to confirm that the data is current. Check these values against those shown in the following table and adjust if necessary. Function Hex or Decimal Value Temperature target value Decimal 7500* Proportional constant Decimal 50 Integral Constant Decimal 70 Time Constant Decimal 2 * This value may vary depending upon factory set-up. OPS

45 Set Cell Oven Control Select 'Cell oven control' in Function selector and click on 'Read' to update the displayed values. Ensure that the green 'message received' LED activates to confirm that the data is current. Check these values against those shown in the following table and adjust if necessary. Please note that some are in hexadecimal and some in decimal notation. Function Hex or Decimal Value Temperature target value Decimal 5500* Proportional constant Decimal 128 Integral Constant Decimal 4 Time Constant Decimal 5 * This value may change depending on the application. To upload any new values, change the variable in the white box, ensure that 'Auto control' is set to 'On' and click on 'Apply'. Ensure the 'message received' LED goes to green. OPS

46 Detector levels To view the analyser detector levels select 'Detector Levels' in the Function selector and click on 'Read' to update the information. Finally, ensure the green 'message received' LED is activated. The detector values represent the amount of energy received at the photodetector as the gas wheel rotates. There may be zero values dependent on the number of detection channels the analyser is set-up for. Where there are values shown >0 they should be at least (decimal) ±2000 (if the purge air is on). If not, or if any of the saturation LEDs are red, first check the alignment and if this does not rectify the situation, contact your local CODEL Distributor or CODEL direct for further advice. To view the smoothed detector output, select 'smoothed' in the 'Type' box. OPS

47 Check Miscellaneous Temperatures It is necessary to check that the G-CEM4100 is up to working temperature using the Misc Temperatures function under SCU. Click on Read and the updated screen below will appear. When the G-CEM4100 is up to working temperature (up to 4 hours), the eight temperatures displayed should read as follows : Sample Line Temperatures The heated sample line has two internal PT100 temperature sensors - one at the probe end (far) and one at the cabinet end (near). These two temperatures are averaged to give the average sample line temperature and this is used for control purposes and when up to temperature should be controlling at 130 o C 150 o C dependent on factory settings. OPS

48 Gas Temperatures Within the G-CEM4100 is a measurement cell that has two temperature sensors - gas temperature #1 and gas temperature #2. The gas temperature is the average of these two and should be 120 o C 140 o C dependent on factory settings. Probe Temperature This is the measurement of the flue gas just prior to entering the heated sample line. This temperature MUST NOT exceed 200 o C and should not fall below the dewpoint of the plant (or 80 o C whichever is the greater). If the probe temperature is too high, remove the probe from the duct in small increments (i.e. 100mm) and re-tighten the clamps. As the probe is withdrawn it allows the gas to cool before entering the sample line. If the temperature is below the dewpoint of the plant then the probe should be entered further into the duct in small increments until the desired temperature is achieved. If the temperature is still not sufficiently high, then the trace heater and insulation must be fitted see section Installing the Sampling Probe. In the event of any uncertainty in this procedure please contact CODEL directly. Cabinet Temperature This is the temperature inside the G-CEM410 cabinet and should be slightly higher than the ambient temperature. If this temperature exceeds 50 o C, please contact CODEL directly for advice. OPS

49 Zero Calibration When the G-CEM4100 has achieved the correct temperature the system will automatically perform a calibration. If a manual calibration is required select 'Activate calibration' in the 'Type' box and the following screen should appear. Set the 'Purge time' to 300 seconds, set 'Number of Cal cycles' to 240, set 'Calibrate' to 'On', click on the 'Lock' tick to release it and click on 'Apply'. Clicking on 'Auto update' will show a clock decrementing through the remaining Cal cycles. To stop a calibration, which is not advisable, set 'Calibrate' to 'Off' and click on 'Apply'. Note : The analyser should also be set to perform routine automatic calibrations by selecting the Read/Set RTC function under the SCU heading. OPS

50 Read/Set RTC Referring to the screen illustrated below, set up the automatic calibration routine as follows : 1) 2) 4) 6) 3) 5) 1. Set the real time clock (RTC) in the SCU by clicking on the small box next Now. Select the date and time and click on Write RTC. 2. Click on Read Cal Data then click on the small box indicated above to edit the date to reflect that required for the first automatic calibration. 3. Select the reference hour at which is required the first automatic calibration. NB. Avoid using zero as this would be mid-night; 1 or 2 is usually set here indicating 1 or 2am. 4. In Head 1 only select the required calibration interval time 24 or 48 hours. OPS

51 5. Click on Write Cal Time to send the data. 6. It is good practice to read back this data by clicking on Read Next Cal. Line 1 should indicate when the next automatic calibration would take place. Note : When an automatic calibration is activated the G-CEM4100 will firstly back-purge the filter to clear any dust build-up on the probe filter. The parameters for this procedure are adjustable (see Setting Back-Purge Pulses) but are best left at standard factory settings. OPS

52 Current Data To check the instruments' current readings, select 'Output' in the Function selector. Click on 'Read' to update the screen and ensure the green 'message received' LED is actuated. To receive a continuous update set the 'Auto Update rate' and press 'Start'. This data is for information purposes only and represents the outputs of the various sensor channels and the current normalisation data. OPS

53 'Y' Values To view the 'Y' values, select this in the Function selector, click on 'Read' to update them and ensure the green 'message received' LED is activated. The 'Y' values should be in the region of (if the purge air is on). If they vary significantly from these values then please contact your CODEL distributor or CODEL direct. OPS

54 Span Verification The G-CEM4100 and GCU are equipped to enable the performing of span verification checks. This is achieved by connecting the required span gas bottle to the span gas input of the GCU (see Figure 13). Note that some GCUs may have more that one input. The span verification for each measurement channel should be carried out as part of the initial commissioning exercise. The gases used for this should be binary mixtures and have a concentration that is representative of the typical levels seen from the process at the point of installation. These checks should be repeated after the initial six months of operation and annually thereafter. Set the pressure on the relevant regulator to the same pressure indicated on the zero purge regulator. The control of span verification can be carried out either from SmartCOM or via the IEM for Windows R software (if using IEM for Windows R software refer to the IEM manual). Note: Before performing a span check it is good practice to carry out a zero calibration first as described in Section Zero Calibration. When using SmartCOM software : Select SCU in the sensor window. Select the SCU address usually 1. Select purge control in the Function window and the following screen should appear. Note that not all these functions are applicable to the G-CEM4100 span-check. OPS

55 2) 3) 10) 1) 4) 8) Comms. light 11 & 12 5) 6) 9) 7) 4) Read back the stored parameter data from the SCU by clicking Read. 5) Set the pre/post purge period to 5mins. 6) Set the gas period to 10mins or greater. 7) Click Apply. 8) Select span gas 1 unless number 2 input is being used. 9) Select ON. - Click Apply and make sure that the comms. Light turns green. OPS

56 Water Vapour Checks Water vapour checks should be carried out next; this is to check the analysers response to H2O and its effect on other measurement channels. It is recommended that these checks are carried out by a CODEL engineer, but if a CODEL Water Vapour Injector has been installed, please refer to the Operating Manual provided (OPS Supplement) and carry out the tests as described. The test results should then be forwarded to CODEL for analysis. It should be noted that these checks should be repeated after the initial six months of operation and annually thereafter Setting Back-Purge Pulses - Select the required number of cycles (usually 2 or 3) - Select the duration of the cycles (usually 1 second) and click Apply. This will now switch on zero air for 5 minutes to check the zero condition of the analyser. The zero air will then switch off and the span gas will switch on. At this point the flow must be checked on the flow meter; make sure that it is 10 l/min and adjust if required using the span gas regulator. Switch to the Data File in the Function box and the following screen will be displayed. OPS

57 Make sure that G-CEM4100 is selected and adjust the Auto update time to 20 seconds and click Start. The relevant gas channel value should start to increase to the value indicated on the span gas bottle (within tolerances). If this is not the case please contact CODEL or your local representative General Overview To obtain a general overview of the most important parameters, select SCU in Sensor Selector. Select 'General Data' in the Function selector, click on 'Read' to update them and ensure the green 'message received' LED is activated. To receive a continuous update set the 'Auto Update rate' and press 'Start'. OPS

58 Setting the Output Configuration The analogue outputs and alarm relay set points should be configured if required. On some systems using IEM for Windows R, this may be handled by the pc. Select SCU in the 'Sensor' selector and then select Outputs and the following screen will appear. Click on "Read" to update the displayed data. The data displayed now relates to the complete output set for a particular channel and is configured at the factory. At this point you should understand that this section is factory set and should be left alone under nearly all circumstances. OPS

59 Current output Abs. data location : the memory location of the source of the current output data (see drop down menu) 0-4mA : selects the starting value (in ma) for zero output Data invalid : Averaging value : Span : Zero : Zero the time period over which the output data is averaged in steps. Each step is 3 seconds and is input in hexadecimal. Some key values are shown below.* the upper point of the output data the lower start point of range Relay output Abs. data location : Averaging value : Direction : Alarm level : Source : the memory location of the source of the alarm output data the time period over which the output data is averaged as described above Normal = NO and Reverse (failsafe) in NC alarm threshold in decimal 2 byte * Averaging time values OPS

60 Time in minutes Hexadecimal value C C 8 00A0 9 00B C DC 12 00FO To deduce what the factory settings for the analyser channels are, employ the following method. Select 'Read' in the 'Function' box to view the following screen. Select 'Master' in the 'Target destination' box, type 7EF8 in the 'Start address' box and type 7 in the 'Number of bytes box. Click on 'Read' and data should appear in the Data Access Window. If not, click on 'Read' until it does. The data displayed in two number blocks relates to the species at each channel. 01 CO 02 CO2 03 NO 04 NO2 05 not used 06 SO2 07 not used 08 UHC/CH4 09 not used 0A H2O 0B HCL OPS

61 So using the example shown below : 7EF8; A 0B FF Channel 1 NO Channel 2 CO 2 Channel 3 CO Channel 4 SO2 Channel 5 H20 Channel 6 HCL Channel 7 Not used OPS

62 6. Analyser Records This section is provided to allow recording of analyser identity, installation and commissioning information, to facilitate any later fault diagnosis and rectification Serial Numbers (Complete on First Inspection) Transceiver : Gas Control Unit : Station Control Unit : 6.2. Installation Records Plant (name and location) : Plant Type/Process : Monitoring Position : Installation Date : 6.3. Commissioning Records Completion Date : OPS

63 Table 1 : Analyser Configuration Record - Parameters Parameters common to all channels Cal Interval (hrs) Parameters configured for Individual Channels Channel/Output No Gas Measured Identity (for IEM) Analogue output Zero: 0/4mA Average Units Span Fault Cond. Set Zero Set Span OPS

64 7. Calibration and Measurement Verification 7.1. Introduction The following sections provide information on the analyser calibration at the time of supply (Factory Calibration), methods by which measurement/calibration can be verified and, should it be necessary, facilities for calibration adjustment Factory Calibration G-CEM4100 analysers use very tightly controlled infrared wavebands that are specific to each of the gases measured. The scale-shape for each measurement (i.e. the relationship between concentration and output) is therefore uniquely defined and the output, at any measurement level, is only dependent on gas concentration, gas temperature and any system zero error. Flue gas temperature is a continuous measured input. Any zero error detected during commissioning is corrected as part of the commissioning procedure (Section 5. Commissioning) and any subsequent zero drift is automatically detected, measured and corrected (Section Automatic Zero Calibration). Factory test procedures ensure that analyser calibration is traceable to national standards and, with the inherent stability of scale-shape and automatic zero, only a significant fault (that would be detected by the analysers' diagnostic routines) or incorrect installation/commissioning can cause a calibration error. The analyser is equipped with means by which the factory calibration can be modified on site (Section 7.4. Re-calibration), but great care should be taken to ensure that calibration adjustment is necessary before proceeding with this routine as it will overwrite the factory calibration settings Verification Even though the G-CEM4100 is designed to maintain its calibration stability almost indefinitely, it is often necessary to verify measurement performance. This may be a routine check after an extended period of operation, to confirm unusual measurements or as an audit requirement by some external authority. OPS

65 These analysers have a range of verification options, designed to provide varying levels of independence from both the analyser itself and CODEL standards. Which one is chosen depends on the resources available and legislative demands. The different methods can be used in combination to minimise the amount of external work required to maintain performance confidence Automatic Zero Calibration This automatic procedure is carried out by the analyser itself and provides regular checking and, if necessary, adjustment of the zero for each measurement. The automatic zero calibration procedure provides a regular check on analyser performance without the need for operator intervention. The operation of this is covered in the IEM for Windows R manual Manual Zero Verification The zero of all measurement channels can be verified manually at any time after being powered-up for at least four hours. Important! The purge air must be dry to the specified level (-20 C). Any water vapour in the measurement path will show an offset not only on the water vapour measurement itself, but also on any other measurements that the analyser automatically corrects for cross-sensitivity to water vapour. Any calibration subsequently initiated to correct these apparent offsets will be incorrect. Ensure that the solenoid valve controlling the purge is powered and the control cable connected as described in Section 4.6. Connections. If an analyser error is still suspected, contact CODEL or the local service agent, but first consult Section 9. Fault Finding to establish what information to provide. OPS