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OPERATING AND MAINTENANCE INSTRUCTION


Document title:
ANALYSER SYSTEM

P/16040.M - Jayapura (Package 8), ES 4503622078 (Part VIII)


P/16054.M - PLTMG MPP Sultra (Kendari), ES 4503622146 (Part VIII)
P/16044.M - PLTMG MPP FLORES, ES 4503673873 (Part VII)
P/16047.M - PLTMG MPP NABIRE, ES 4503674094 (Part VII)
P/16045.M - PLTMG MPP TERNATE, ES 4503674100 (Part VII)
P/16046.M - PLTMG MPP KALTIM, ES 4503674078 (Part VII)

02 07.04.2017 Re-issued for approval ALI MHO JPO

01 27.02.2017 Issued for approval ALI MHO JPO

Rev. Issue date Description Org’d Chk'd Appr. Proj.


by by by Appr.

Contract number:
ES 4503622078, ES 4503622146,
Project number: FP398
ES 4503673873, ES 4503674094,
ES 4503674100, ES 4503674078

Package number: P/16040.M, P/16054.M,


Package title: See above
P/16044.M, P/16047.M, P/16045.M, P/16046.M

Supplier document number: Acceptance Date/Signature


code:
FP398-D21

Supplier logo: Customer logo:


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OPERATION AND MAINTENANCE


MANUAL

NA CEMS

FP398-D21 / Rev. 02
April 2017 © Suomi Analytics Oy
Status: Approved Confidential Document id: DBAE439260 - Page 4 (71)

Revision status

Revision Date Prepared Checked Approved


Rev. 01 27.02.2017 ALI MHO NMI

Rev. 02 07.04.2017 ALI MHO NMI

Document history
Revision Reason for issue
Rev. 01 First issue, preliminary

Rev. 02 Typo removed

Copyright
© Suomi Analytics OY
No part of this document may be reproduced, copied, modified or translated in any form or
by any means, without the prior written approval from Suomi Analytics OY.

Important
Before using the equipment, read all instructions thoroughly and follow all precautions and
warnings contained within this document. Improper use may cause personal injury and/or
damage to the equipment, and may void the warranty. Suomi Analytics OY disclaims any
responsibility for damage or injury caused by improper installation, use or maintenance of
the equipment.

Suomi Analytics OY
Ruukintie 3
02330 Espoo, Finland
Phone: +358 (0)20 7981040 Web:
www. suomianalytics.fi
E-mail: post@suomianalytics.fi
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Operation and Maintenance Instruction Analyser System

Table of contents
1 INTRODUCTION ................................................................................... 9
1.1 Purpose ...................................................................................................................................9
1.2 Contact details......................................................................................................................10
2 MAIN DATA ....................................................................................... 11
2.1 Scope of supply ....................................................................................................................11
2.2 Illustrated parts list .............................................................................................................12
2.3 Technical specifications ......................................................................................................19
2.3.1 Mechanical specifications .......................................................................................... 19
2.3.2 Power supply .............................................................................................................. 20
2.3.3 Power consumption ................................................................................................... 20
2.3.4 Interface signals Field/Analyser Shelter/Client .................................................... 20
2.3.5 Calibration gas specifications ................................................................................... 21
2.3.6 Measured components ............................................................................................... 21
2.4 General safety rules .............................................................................................................22
2.4.1 High voltage ................................................................................................................ 22
2.4.2 High pressure .............................................................................................................. 22
2.4.3 High temperatures ..................................................................................................... 22
2.4.4 Hazardous components ............................................................................................. 23
2.4.5 Heavy equipment ....................................................................................................... 23
2.5 Specific safety rules for NA CEMS....................................................................................24
2.5.1 Measuring gas ............................................................................................................. 24
2.5.2 Condensate .................................................................................................................. 24
3 FUNCTIONAL DESCRIPTION .................................................................... 25
3.1 System overview..................................................................................................................25
3.2 Functional description ........................................................................................................26
3.2.1 Overview ..................................................................................................................... 26
3.2.2 Sample extraction ....................................................................................................... 27
3.2.3 Sample transport......................................................................................................... 27
3.2.4 Sample conditioning .................................................................................................. 27
3.2.5 Auto calibration .......................................................................................................... 28
3.2.6 Calibration gases......................................................................................................... 29
3.2.7 NOX converter ............................................................................................................ 29
3.2.8 Sample analysis........................................................................................................... 30
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Operation and Maintenance Instruction Analyser System

3.2.9 LiMeDAS measuring service .................................................................................... 32


3.2.10 Durag D-R 220 Optical dust and opacity meter ..................................................... 32
4 OPERATION ....................................................................................... 33
4.1 User interface .......................................................................................................................33
4.2 Modes of operation .............................................................................................................33
4.2.1 Automatic mode ......................................................................................................... 33
4.2.2 Manual mode .............................................................................................................. 34
4.3 Operational procedures ......................................................................................................34
4.3.1 System start-up ........................................................................................................... 34
4.3.2 Normal operation ....................................................................................................... 35
4.3.3 Planned operational stop ........................................................................................... 35
4.3.4 Emergency stop........................................................................................................... 36
4.3.5 Zero gas calibration of Ultramat 23 Analyser......................................................... 37
4.3.6 Zero gas calibration of Teledyne T100H ................................................................. 37
4.3.7 Span gas calibration of Ultramat 23 Analyser ........................................................ 38
4.3.8 Span gas calibration of Teledyne T100H ................................................................. 39
4.3.9 Changing calibration interval on Ultramat 23 Analyser ....................................... 39
4.4 Disturbance of operation ....................................................................................................40
4.5 Corrective measures ............................................................................................................40
4.6 Hazards and protective measures .....................................................................................41
4.7 Qualification requirements ................................................................................................41
4.8 Air conditioner unit.............................................................................................................41
4.9 Calibration and zero gas .....................................................................................................41
4.10 NA CEMS analyser system ................................................................................................42
4.10.1 Siemens Ultramat 23 .................................................................................................. 42
4.10.2 Teledyne T100H .......................................................................................................... 42
4.10.3 NOx converter ............................................................................................................. 42
4.10.4 Wago HMI ................................................................................................................... 43
4.11 Field Item ..............................................................................................................................46
4.11.1 Heated sample probe ................................................................................................. 46
4.12 LiMeDAS ..............................................................................................................................46
4.12.1 Introduction ................................................................................................................. 46
4.12.2 Scope............................................................................................................................. 47
4.12.3 Data Visualisation and Alarming ............................................................................. 48
4.12.4 Data Validation ........................................................................................................... 49

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Operation and Maintenance Instruction Analyser System

4.12.5 Averaging .................................................................................................................... 51


4.12.6 Availability .................................................................................................................. 52
4.12.7 Standard Units ............................................................................................................ 53
4.12.8 Data Backfilling........................................................................................................... 54
4.12.9 Calibration Tracking .................................................................................................. 56
4.12.10 Out-Of-Control ....................................................................................................... 58
4.12.11 Emission Limit Tracking........................................................................................ 60
5 MAINTENANCE ................................................................................... 61
5.1 Maintenance philosophy ....................................................................................................61
5.2 Maintenance schedule.........................................................................................................61
5.2.1 Daily routine................................................................................................................ 62
5.2.2 Weekly routine ............................................................................................................ 62
5.2.3 Monthly routine .......................................................................................................... 63
5.2.4 Routine every six months .......................................................................................... 64
5.2.5 Yearly routine.............................................................................................................. 64
5.3 Maintenance procedures ....................................................................................................65
5.3.1 Cleaning cabinet exterior and surfaces.................................................................... 65
5.3.2 Replacement of gas cylinders ................................................................................... 65
5.3.3 Replacing the sample gas filter in NA CEMS ......................................................... 66
5.3.4 Replacing the Ultramat 23 condensate trap ............................................................ 66
5.3.5 Replacing internal parts in analysers and instruments ......................................... 67
5.3.6 Replacing the NOx converter cartridge................................................................... 67
5.3.7 Corrections, repairs and modifications ................................................................... 67
5.3.8 Fault-finding................................................................................................................ 68
5.3.9 General troubleshooting procedure ......................................................................... 68
6 REFERENCES ..................................................................................... 69
6.1 Drawings...............................................................................................................................69
6.2 Termination and wiring drawings ....................................................................................69
6.3 Flow and system diagrams ................................................................................................70
6.4 Manuals and documents ....................................................................................................70

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Operation and Maintenance Instruction Analyser System

Acronyms and abbreviations

CEMS Continuous Emission Monitoring

DCS Distribution Control System

HMI Human Machine Interface

PDP Power distribution panel

SAOY Suomi Analytics OY

UPS Uninterruptable Power Supply

Admonitions
Note Text set off in this manner presents clarifying information or specific instructions
relevant to the immediate instruction.

Caution Text set off in this manner provides a warning notice that failure to
follow the directions in this caution can result in damage to equipment.

Warning Text set off in this manner provides a warning notice that failure to
follow the directions in this warning can result in bodily harm or loss
of life and/or extensive damage to equipment.

DANGER TEXT SET OFF IN THIS MANNER PROVIDES A WARNING NOTICE THAT
FAILURE TO FOLLOW THE DIRECTIONS IN THIS WARNING WILL RESULT
IN BODILY HARM OR LOSS OF LIFE AND/OR EXTENSIVE DAMAGE TO
EQUIPMENT.

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Operation and Maintenance Instruction Analyser System

1 Introduction

1.1 Purpose
The purpose of this document is to provide the basic information required to operate and
maintain the Analyser System for Continuous Emission Monitoring (CEMS) delivered as
part of the Wartsila Power plant. The manual must be used with assistance of other
documents and drawings where such references are mentioned.
This manual is written as a generic document for six different installations where number
of NA CEMS and number of streams varies.

Number of NA Number of streams Total number of


CEMS in shelter per NA CEMS streams

PART VIII
P/16040.M - Jayapura 2 3 6
(Package 8),
ES 4503622078

P/16054.M - PLTMG 2 3 6
MPP Sultra (Kendari),
ES 4503622146

PART VII
P/16044.M - PLTMG 1 3 3
MPP FLORES,
ES 4503673873

P/16047.M - PLTMG 1 3 3
MPP NABIRE,
ES 4503674094

P/16045.M - PLTMG 1* 4* 4*
MPP TERNATE,
ES 4503674100

P/16046.M - PLTMG 1* 4* 4*
MPP KALTIM,
4503674078

The first stream is described as example for all systems and is referring to 3001-drawings.
In the four stream systems FI-4, NV-4, SV1.4 are added.

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Operation and Maintenance Instruction Analyser System

1.2 Contact details


Design, engineering and sales:
Suomi Analytics OY
Ruukintie 3
02330 Espoo
post@suomianalytics.fi
Phone: +358 (0)20 7981040

Manufacturing, assembly and testing:


Svensk Analys AB
Nyängsgatan 5
S-664 34 Grums, Sweden

Service, maintenance and spare parts:


Suomi Analytics OY
Ruukintie 3
02330 Espoo
post@suomianalytics.fi
Phone: +358 (0)20 7981040

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Operation and Maintenance Instruction Analyser System

2 Main data

2.1 Scope of supply


The complete Analyser System design includes the following main items:
• 10 foot container (2 pcs), each including:
o NA-CEMS
o Main door
o Ultramat 23 Analyser for NO and O2 analysis (internal part of NA-CEMS, AT-1)
o NOX Converter unit for NO2 to NO conversion (internal part of NA-CEMS,
AX-1 and AX-2)
o Teledyne T100H Analyser for SO2 analysis (AT-2)
o WAGO PLC Unit (internal part of NA-CEMS)
o Power distribution panel (PDP)
o Main power termination (MPT)
o Light fixture (LF)
o Light switch (LS)
o Service sockets (SS-1 and SS-2)
o 1 x air conditioning unit inside (AC-1)
• LiMeDAS (Limesoft)
• Heated sample probes (SP-1 to SP-6)
• Dust Concentration and Opacity Monitor (D−R 220)
• Heated sample lines (HSL-1 to HSL-6)
• Multi-stream system according to table in chapter 1.1.

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Operation and Maintenance Instruction Analyser System

2.2 Illustrated parts list


The table below lists main parts with reference to corresponding nameplates mounted on
the Analyser System. Pictures are added for easy identification of items where relevant.

Item Picture Name plate/TAG

FIELD ITEMS
Sample Probe GAS 222.17
SP-1 to SP-6
(with cal inlet)

Heated Sample Line HSL-1 to HSL-6

Dust Concentration and DP-B1+DP-A1+DP-SU1


Opacity Monitor (D−R 220) DP-B2+DP-A2+DP-SU2
DP-B3+DP-A3+DP-SU3
DP-B4+DP-A4+DP-SU4
DP-B5+DP-A5+DP-SU5
DP-B6+DP-A6+DP-SU6

(No tag)

Sample probe filter SPF


(No tag)

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Operation and Maintenance Instruction Analyser System

Item Picture Name plate/TAG

INSIDE SHELTER
Analyser Shelter Analyser shelter
(standard 10 foot
container)

NA CEMS NA CEMS
One or two NA CEMS are
inside the analyser shelter

Air conditioning unit, R410 AC


(no external unit)

Air conditioning, Remote AC-RC


Control

Light Switch LS

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Item Picture Name plate/TAG


Service Socket #1, #2 SS-1, SS-2

Main Fuse, Analyser MS-1


Shelter (inside box
MPT-1

Main Fuse, Power MF-1


Distribution

Solenoid valve SV-3.1, SV-3.2

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Operation and Maintenance Instruction Analyser System

Item Picture Name plate/TAG


PDP & NA CEMS Fuse F1, F2, F3, F4, F5, F6, F7, F8,
F9, F10, F11, F12

Terminals X1

Ball Valve BV-1.2

ANALYSER RACK
Sample pump P-1, P-2 and P-3

Moisture Sensor MS-1

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Operation and Maintenance Instruction Analyser System

Item Picture Name plate/TAG


Moisture Controller MC-1

Peristaltic pump PP-1, PP-2, PP-3 and PP-4


(typical)

Condensate Cooler Unit, EC-1, EC-2 and EC-3


typical

NOx Converter AX-1

Gas Analyser, Ultramat 23 AT-1

Gas Analyser, Teledyne AT-2


T100H

Human Machine Interface HMI

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Operation and Maintenance Instruction Analyser System

Item Picture Name plate/TAG


Main Switch NA CEMS MSC-1

FLKM Module FLKM

PLC unit PLC UNIT

24VDC Power Supply PSU

Needle Valve 1..5 NV-1, NV-2 and NV-3

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Item Picture Name plate/TAG


Ball Valve BV-1.1

Ventilation Fan NA CEMS FAN

Filters F-1

Condense trap F-2


(No tag)

Check valve CV-1, CV-2, CV-3, CV-4,


CV-5, CV-6 and CV-7
(No tag)

Solenoid valve SV-1.1, SV-1.2, SV-1.3


SV-2.1, SV-2.2, SV-2.3

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Operation and Maintenance Instruction Analyser System

Item Picture Name plate/TAG


PDP & NA CEMS Fuse F3.1, F3.2, F3.3, F3.4, F3.5,
F3.6, F3.7
F4.1, F4.2, F4.3, F4.4, F4.5,
F4.6, F4.7

Terminals X10, X15

2.3 Technical specifications


2.3.1 Mechanical specifications
Item Specification
Height 2591 mm

Width 2438 mm
Length 3029 mm

Weight
1 x NA CEMS inside shelter TBA kg
2 x NA CEMS inside shelter 2300 kg

Maximum roof load Approx. 100 kg


Materials:
Shelter structure Steel- framework, painted
Internal walls, ceiling Steel sheets
Isolation 50 mm rock wool
Tubing: sample tube is PTFE and 6mm
Piping, tubing SS316

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Operation and Maintenance Instruction Analyser System

Item Specification
Colors
Exterior RAL 7001
Internal walls Light grey
Corrosion category C5 (Paint system with high weather and
ageing resistance, suitable for urban and
industrial atmosphere.)

Ingress protection IP65

2.3.2 Power supply


Item Specification
Power feed from plant 400 VAC /50 Hz, 3-phase with neutral

2.3.3 Power consumption


Refer to:
→ FP398-D40-01 Power Consumption List

2.3.4 Interface signals Field/Analyser Shelter/Client


For hardwire signals between the analyser shelter and customers Distribution Control
System, DCP refer to termination and wiring drawings in chapter 6.2.

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Operation and Maintenance Instruction Analyser System

2.3.5 Calibration gas specifications


Item Specification
Span gas
Cylinder size 20 l (analyse uncertainty <2%)
Composition 160 ppm sulphur dioxide (SO2)
800 ppm carbon monoxide (CO)
1600 ppm nitrogen monoxide (NO)
Residual nitrogen (N2)

Zero gas
Cylinder size 20 l
Composition Nitrogen (N2) + Oxygen (O2) 20% qal 4.0

2.3.6 Measured components


Component Analyser Unit Range
NOX Ultramat 23 ppm (dry) 0 to 2000

CO Ultramat 23 ppm (dry) 0-1000

O2 Ultramat 23 vol% (dry) 0 to 25%

SO2 T100H ppm (dry) 0 to 200

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Operation and Maintenance Instruction Analyser System

2.4 General safety rules


Safety precautions must be followed at all times during installation, operation and
maintenance of the system.
Personnel shall be sufficiently qualified, and proper caution shall be taken to avoid
injuries or damage to life, health, environment, equipment and property.

2.4.1 High voltage

Warning The system operates at a potentially lethal AC voltage.

Always switch off all power before installation or maintenance. Adhere to safety
precautions and instructions as directed by company policy.
For safety reasons during troubleshooting on the equipment with power ON, two persons
must always be present.
Whenever installation or maintenance is carried out, it is essential that a first aid kit is
available, and that personnel are familiar with the first aid instructions for electrical
shock.

2.4.2 High pressure


Sample collection areas are operating at high pressures. Bleed off pressure before
servicing equipment.

Warning High pressure streams can pierce skin and tissues, and may cause
serious injury.

2.4.3 High temperatures


Sample collection areas are operating at high temperatures. Bleed off pressure before
servicing equipment.

Warning High temperature flue gas streams can pierce skin and tissues, and
may cause serious injury.

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Operation and Maintenance Instruction Analyser System

2.4.4 Hazardous components


The sample gas may contain trace amounts of hazardous components.

Warning Many toxic gases are colourless, odourless and non-irritating, and
may overcome exposed persons without notice.

Personnel should have a thorough knowledge and understanding of the physical


properties and safety precautions for the relevant gas samples before operating the
system.
Gas inlets and outlets are hot in heated analysers. Skin contact may result in serious burns
even for a long period after the equipment has been switched off.
The condensate from local vents and drains may be acid, depending on the composition
of the sample gas. Disposal of the condensate shall therefore be done with care. This also
applies when working on tubing and fittings.

Caution Eyes, skin and clothes must be properly protected.

It is recommended to wear protective clothing such as safety goggles, gloves and a


laboratory coat.

2.4.5 Heavy equipment


The Analyser Shelter and internal NA CEMS are heavy units.

Caution During installation or replacement of larger units, appropriate safety


clothing and certified lifting equipment must be used.

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Operation and Maintenance Instruction Analyser System

2.5 Specific safety rules for NA CEMS


2.5.1 Measuring gas
The measuring gas can be dangerous to health. Care must be taken to ensure that the gas
can be ducted away safely and not under pressure.
Health risks and danger to life may be posed by the following components of the
measuring gas:
Sulphur dioxide SO2:
Colourless , heavier than air, and can cause death by suffocation!
Nitrogen monoxide NO:
Colourless; oxidising agent; toxic; caustic for eyes and skin!
Nitrogen dioxide NO2:
Colourless; toxic; caustic for eyes and skin!
Measuring gas venting:
The exhaust gas must not be released inside buildings, unless a corresponding controlled
ventilation device is available.

2.5.2 Condensate
The condensate forming in the gas cooler is transported to the condensate outlet by the
condensate pump. Here the condensate must be collected for disposal via a corresponding
drainage line or in a condensate tank.
The condensate from the cooler and the possibly occurring condensate drops in the
sample line could be acidly, depending on the composition of the sample gas.
The pH-level depends on the gas composition, and particularly the concentration of the
acidic gas components NO and others. Litmus paper used as an indicator will turn red.
In most cases the condensate in the condensate collection tank is an acid with a pH-level
of approx. 3 to 4 (comparable to acetic acid). That is why disposal of the condensate has to
be taken out with care. Appropriate safety precautions must be followed. Also at
workings on the fittings, safety precautions must be followed.
Before disposal, the condensate must be diluted with tap-water until the litmus paper no
longer changes colour: pH-level 7 (neutral).
Alternatively the condensate can be neutralised before the disposal by a weak alkaline
solution (e.g. Na2CO3-solution) until no colouring of the Litmus paper occurs: pH-value 7
(neutral).

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Operation and Maintenance Instruction Analyser System

3 Functional description

3.1 System overview


The main purpose of the analyser system is to deliver continuous measurements of
emissions from stack of the power plant. This is performed by extracting and analysing
representative samples from the stack down to the Analyser Shelter.
The Analyser System is designed for unmonitored, continuous operation, but all system
units may also be manually operated. Only a limited number of operations are necessary
to use the system.
Sample gas is extracted from the stack by use of a heated sample probe mounted directly
on the stack.
The flow is measured by Dust Concentration and Opacity Monitor Durag D-R 220. It is
mounted on the stack above the location of the probe. Data of measured flow is sent to
PLC-1 and further to analysers AT-1 and AT-2.
The gas sample is transported to the Analyser Shelter for further conditioning and
analysis. The sample lines, from the sample point to the analyser, are heated to prevent
condensation and to secure that the sample temperature at any time is above dew point.
After the gas sample is analysed, the data is transferred to the reporting module
LiMeDAS installed on the PC for further processing and reporting. The same results are
transferred customer's PLC via OPC.
The Analyser Shelter is a prefabricated enclosure of plain coated steel designed to
establish a controlled and safe environment for equipment and personnel. The shelter
therefore includes necessary insulation, air conditioning (cooling) and illumination.
The Analyser Shelter is delivered as a complete unit, fully assembled with analyser,
auxiliary instruments and power and signal distribution. The analyser with associated
piping, tubing and cabling are located in the NA CEMS mounted inside the Analyser
Shelter. Sufficient space for analyser operation and maintenance has been provided.
The Analyser Shelter holds mounting brackets for calibration gas cylinder at the left of the
NA CEMS. The analyser shelter is equipped with pressure regulator and is connected to
the calibration gas using standard DIN connectors through flexible spiral tubes.
The wall opposite the main door holds the bulkhead transit plate used to create gas- and
watertight and fire resistant barriers. This plate is furnished with openings for heat-
shrinkable sleeve for the sample transport line, cable glands for electrical power and
instrument signal cables and fittings for atmospheric vents.

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Power control of the complete Analyser System is done using the main power switch. A
separate power switch is used to turn the internal light fixture on or off. NA CEMS and
individual instruments also hold separate power switches.
Two 230 VAC service socket outlets are available inside the shelter. One socket is reserved
for the Environmental System workstation. The Environmental System workstation is
located in shelter 2. If otherwise agreed, the Environmental System Workstation is located
in Shelter.
The air conditioning unit is used to maintain an acceptable indoor temperature. It is
mounted on the wall opposite to the main door. The internal operating temperature shall
be kept around +20 - 25 °C. There is a temperature sensor inside the Analyser Rack which
will give an alarm at a pre-configured maximum temperature.
The system performs continuous measurements of the following components:
• Nitrogen oxides (NOX)
• Carbon oxides (CO)
• Sulphur monoxide (SO2)
• Oxygen (O2)

3.2 Functional description


The functional description is for stream 1 entering the analyser shelter in N1. Follow the
same description for the other streams.

3.2.1 Overview
The functional design of the Analyser System is described in the following. For a full
understanding of this chapter, please examine the dedicated block diagrams in parallel:
→ [FP398-3001] - System diagram - Gas Flow

The Analyser System consists of five principal parts:


• Sample extraction
• Sample transport
• Sample conditioning
• Sample analysis
• Calibration gases

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Operation and Maintenance Instruction Analyser System

3.2.2 Sample extraction


The heated sample probe is installed to extract a representative sample
from stack. The sample probe contains a heated filter for separation of
dust and other larger particles. The filter element is heated above water
dew point to keep the filter porous, and to avoid clogging by wet
particles. The temperature is regulated at 180°C with a low temperature
alarm output.

3.2.3 Sample transport


The sample is transported to the NA CEMS via a heated sample line for sample
conditioning and analysis by the NA CEMS.
The heated sample line consists of a pre-assembled tube bundle with its own electrical
heat tracer cable. An aluminum jacket holds the heat cable and the sample tube (6mm
PFA) together. A high efficient insulation material is wound around the tracer and the
sample tube, and a weather protective outer sheet covers the entire tube bundle. The tube
bundle also includes an additional 6mm PFA tubes, is used for spare purposes.
The sample transport line must be heated at all times. This prevents condensation and any
loss of trace components to be measured. It also avoids expensive and time consuming
maintenance in cleaning the Analyser System components downstream.

3.2.4 Sample conditioning


When the sample gas enters the NA CEMS, the sample temperature is lowered to 5°C in
the first heat exchanger of the compressor cooler (EC-1 ). The condense water is
continuously pumped in the corresponding peristaltic pump, down to the drain outlet.
The pump (P-1) sucks the sample to solenoid valve SV-1.1. The needle valve NV-1 is used
reduce the sample flow to approx.. 1 l/min. In solenoid valve SV-1.1 the sample to be
analysed continues to three-way ball valve BV1.1 (sample from the streams that are not
analysed go to local vent).
With a dew point approx. 5°C the sample gas enters ball valve BV-1.1, the compressor
cooler EC-4 (some systems have a second stage cooling, refer to specific 3001 drawings)
and the fine filter (F-1) to remove any remaining particles in the sample gas. In the glass
bottle of this filter, there is a moisture sensor (MS-1) which is connected to the Moisture
Controller (MC-1) to protect the system in case of a water break-through.
After filter F-1 the sample gas enters the NOx converter AX-1. Here the NO2 is
transformed to NO (which can be analysed by NA CEMS). After this follows filter F-2 for
additional safety before the sample enters the analysers. Then the sample gas is lead in to
the NDIR-analyser AT-1 where NO, CO and O2 are analysed. After analysis in AT-1 the
sample is split. One part goes to AT-2 (for SO2 analysis) and one part goes to local vent.
After AT-2 analyse the sample goes to the same local vent.

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3.2.5 Auto calibration


Calibration is performed with both span gas and a zero gas. The normal auto calibration is
performed on a daily bases and the other auto calibration is performed when the
environmental reporting system, LiMeDAS, requests it due to incorrect measurements.

• Due to EPA regulations auto calibration is performed daily on both analysers and
the calibration is initiated by the reporting system.
The analysers AT-1 and AT-2 are auto calibrated at regular intervals to ensure the
measuring accuracy of the analysers. This is necessary and the operation is fully
automatic.
During these daily calibrations due to EPA regulations, calibration gas enters at
the calibration gas inlet at the probe and goes through the whole system before it
enters the analysers and calibration is performed.

• Apart from the daily auto calibration, the analysers sometimes need an extra
calibration.
We recommend to perform calibrations on a regular bases before LiMeDAS
requests it.
When the environmental reporting system notice that the analysers are “out of
control”, the operator needs to take action. The reporting system can also request
an auto calibration when calibration gas cylinders are replaced.
The procedure below reduces the amount of calibration gas needed since the way
through ball valves BV-1.2 and BV-1.1 is much shorter than through the sample
probes:
The operator must take action and there must be normal flow to the analyser.
Refer to chapters 4.3.5, 4.3.6, 4.3.7 and 4.3.8.
During auto calibration a signal is sent to environment reporting system and no
measurements of sample gas is valid during auto calibration.
For more information refer to manufacturer’s manual:
→ [FP398-D30] - User Manual Siemens Ultramat 23
AT-2 (Teledyne T100H) is calibrated manually. For more information refer to
manufacturer’s manual:
→ [FP398-D31] - User Manual Teledyne Model T100H

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3.2.6 Calibration gases


The Analyser Shelter holds mounting brackets for calibration gas
cylinders opposite the NA CEMS.
Calibration gases are used for calibration of analysers AT-1 and
AT-2. Automatic calibration is the standard setup due to EPA
regulation. During automatic calibration gas enters at the probe, at
the sample inlet, with an overflow of 3,5 l/h, it presses away the
sample gas at the probe, goes through the whole system and finally
meets the analyser, where the calibration is made.
The environmental reporting system, LiMeDAS, can request
calibration if incorrect measurements are suspected.
SPAN GAS
The span gas contains SO2 .The span gas cylinder is equipped with pressure regulator,
PCV-1 with set point 0.5 barg and use standard DIN connectors through flexible spiral
tube.
ZERO AIR
The span gas contains O2 and N2. The span gas cylinder is equipped with pressure
regulator, PCV-2 with set point 0.5 barg and use standard DIN connectors through
flexible spiral tube.
For more information, refer to:
→ [FP398-3001] - System Diagram Gas Flow

3.2.7 NOX converter


The NOx Converter unit is used to convert the NO2 content of the sample gas to NO by
means of a replaceable reactor cartridge. The resulting NO gas is then measurable by the
Ultramat 23 Analyser. The working temperature of the NOx converter is 200 or 400°C
depending on the cartridge. Standard supply cartridge is 400°C.
For more information, refer to:
→ [FP398-D34] - User Manual NOx converter

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3.2.8 Sample analysis

NOx CONVERTER

ULTRAMAT 23 ANALYSER, AT-1


(NO AND O2 ANALYSIS)

TELEDYNE T100 ANALYSER, AT-2


(SO2 ANALYSIS)

VALVES

WAGO HMI

CONDENSATE COOLER
EC-1, EC-2, EC-3 and EC-4

Figure 1 NA CEMS

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3.2.8.1 NA CEMS
The main purpose of the NA CEMS is to perform conditioning and analysis of the gas
sample extracted from the stack.
This extractive sampling system performs all measurements on dry gas. Each system
consists of the following main units:
• Compressor gas cooler to provide a dry sample gas to the analysers by cooling the
gas to +5 °C
• Peristaltic pumps to drain condensed water from the coolers to drain outlet
• Sample gas pumps for transport of sample gas from the probes
• Fine filter to ensure that the sample gas is clean before analysis
• The condensate trap is placed before the analysers as a protective measure if the
sample conditioning system should fail.
• Moisture sensor with controller in the sample gas to shut of the pumps in case of
humidity detection.
• Siemens Ultramat 23 Analyser for measurement of NOX, CO, and O2
• Teledyne T100H analyser for measurement of SO2
• PLC for automation of measurement tasks and alarms
• HMI touch panel for status, alarms, system interactions etc.
→ For more information on the NA CEMS, see Chapter 4.10.

3.2.8.2 Analysis of NOX, CO, O2and SO2


An Ultramat 23 Analyser can measure up to four gas components
at once: A maximum of three infrared sensitive gases such as
carbon monoxides, carbon dioxide and sulphur dioxide plus
oxygen with a paramagnetic oxygen measuring cell.
This project specific analyser measures NO, CO and O2.
For more information, refer to:
→ [FP398-D30] - User Manual Siemens Ultramat 23
Teledyne T100H analyser measures SO2.
The Model T100H uses the proven UV fluorescence principle,
coupled with a state of the art user interface to provide easy,
accurate, and dependable measurements of low level SO2
For more information, refer to:
→ [FP398-D31] - User Manual User Manual Teledyne Model T100H

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3.2.9 LiMeDAS measuring service


After analysis, the data is transferred to LiMeDAS Environmental reporting system for
further processing and reporting of NOx, CO, O2 and SO2.
The client also has access to the data via an OPC link.
LiMeDAS is a powerful and flexible tool to facilitate logging, viewing, reporting and
further processing of measured environmental data. The contract includes a desktop
computer with LCD monitor and USB backup storage. The desktops are integrated with
the customer's remote management using standard communications protocols.
Refer to chapter 4.12 for more information.

3.2.10 Durag D-R 220 Optical dust and opacity meter


Durag D-R 220 is mounted on the stack above the location of
the probe and is used to measure flow.
The dust probe consists of three parts;
• Optical measuring unit (e.g. DP-A1)
• Reflector (e.g. DP-B1)
• Supply box with purge air unit (e.g. DP-SU1)
The device operates using the double-pass method according to the auto-collimation
principle. The light beam traverses the measuring distance twice. The attenuation of the
light beam by the dust content in the measuring section is measured and evaluated.
When the light beam returns back to the optical measuring unit (e.g. DP-A1), it is sent to
the supply box. From the supply box, the data is sent to PLC-1 and to analysers AT-1 and
AT-2 for flow input.
The supply box has a fresh air intake and the purge unit is running continuously to keep
the measuring unit and the reflector clean at all times.

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4 Operation

4.1 User interface


Operating personnel can serve NA CEMS using the following systems and devices:
• Customer remote control centre
• LiMeDAS environmental reporting
• Ultramat 23 analyser screen
• Teledyne T100H analyser screen
• WAGO PLC device screen
NA CEMS transfers data, alarms and other information messages customer control centre
and to LiMeDAS. This makes it possible to monitor the system. The Customer is
responsible for setting up the control centre to achieve correct data.
Ultramat 23 and Teledyne T100H analyser are used to measure real-time data, while
WAGO PLC is used for local menu control during manual maintenance work and by
calibration routines. WAGO PLC unit is also responsible for sending alarms and other
messages to remote systems. Both Ultramat 23 analyser and WAGO PLC are operated
using the touch buttons on the front panels.
Simple text-based menu navigation also makes it possible for operating personnel to run
Ultramat and Teledyne T100H in advanced mode. For more information, refer to:
→ [FP398-D30] - User Manual Siemens Ultramat 23
→ [FP398-D31] - User Manual User Manual Teledyne Model T100H

4.2 Modes of operation


4.2.1 Automatic mode
The NA CEMS is designed to operate fully automatic under normal conditions.
Sample analysis is performed continuously and reported in the LiMeDAS.

Note Span gas calibration is a manual operation. When the analyser needs to calibrate,
it sends a request to the WAGO PLC. Calibration is started by operating the
Ultramat 23 Analyser display.

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4.2.2 Manual mode


The WAGO PLC is further described in chapter 4.10.4.

4.3 Operational procedures


As the NA CEMS is designed to for automatic and continuous operation, only a limited
number of procedures are applicable during normal system operation.

Caution Do not access the Ultramat 23 Analyser and Teledyne T100H menu for
other purposes than listed in this manual, as unskilled operation may
result in system malfunction or equipment damage.

It is recommended that all personnel have a thorough understanding of analyser


principles and functionality before operating the NA CEMS.

4.3.1 System start-up


This procedure is performed to set the system into operational mode. This procedure
must be followed both for initial system start-up and for normal start-up after a planned
or emergency stop of operation.
1) Power up the light fixture.
2) Ensure that the equipment is clean and intact. Clean or replace individual
components as required.
3) Power up the NA CEMS using the MSC-1 switch and check that all components
start up, including analysers, gas pumps and gas coolers. . Refer to Figure 1 on page
30.
4) Power up the air conditioning unit. Use the remote control to adjust temperature to
+20 °C. Depending on the season, set the fan to auto or cooling.
5) Carefully check by hand that the tube bundles are heated. The sample lines should
be noticeably warm at both the inlet and outlet.
6) Ensure that the isolation ball valve, BV-1.1, is in gas sample position.
7) Adjust calibration gas pressures to 0.5 barg using the pressure regulators. Verify by
checking the outlet gauge on the regulator.
8) Operate needle valve NV-1 to adjust sample flow to approx. 1 l/min.
9) Ensure that atmospheric vents are not restricted.
10) Apply power to the heated sample probes according to termination drawing.

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11) Verify that the collective fault messages generated by the WAGO PLC display are
automatically reset after the warm-up time of the analysers.
12) If required, rectify in accordance with individual fault messages.
13) Use the instrument displays to verify that the Ultramat 23 Analyser and Teledyne
T100H work correctly.
14) Verify signal exchange between NA CEMS and LiMeDAS.
15) Check for leakages in all fittings, tubing and single components.
16) If leakages or other malfunctions are detected, turn off power and/or restrict
sample flow for the sub-system affected. Rectify as required before restarting the
system.
17) When it has been verified that the NA CEMS and LiMeDAS are working as
required, close and lock the entrance door.

4.3.2 Normal operation


The NA CEMS is designed to provide continuous and uninterrupted measurements and
calculations without operator intervention. All processes may be remotely monitored and
controlled through the remote network.

4.3.3 Planned operational stop


A planned operational stop is performed for example prior to scheduled maintenance or
replacement of components.
1) If necessary, operate local valves or regulators to stop flow through components.
2) Shut down or pause the relevant analyser or instrument using the appropriate
functions on the instrument display(s).
3) Allow the pressure to bleed off prior to any disassembly.
4) Maintenance of all components may now be performed, for example cleaning of
units or replacement of filters.
5) When maintenance work is finished, restart instruments (if relevant) and reset the
position of all valves or regulators being operated.

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4.3.4 Emergency stop


An emergency stop shall be performed when disturbances of normal operation or other
system malfunctions are detected.

Warning If immediate action is not taken, system failure can lead to the
release of hazardous or flammable gases to the environment or
damage to equipment.

1) Immediately shut down system power using the main power termination, MPT-1.
Refer to figure below.

2) Locate the cause of failure. Use the trouble-shooting instructions supplied by the
respective manufacturers.
3) When the fault has been rectified, restart the system.
There are several methods of detecting operational disturbances or system malfunctions,
such as:
• A rapid increase of the inlet pressure
• Large deviations in sample temperature
• Failure indications transmitted by the Ultramat 23 Analyser and Teledyne T100H.

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4.3.5 Zero gas calibration of Ultramat 23 Analyser


The zero gas supplied by the gas cylinder is used for zero calibration.
The normal auto calibration is performed on a daily bases and is fully automatic and
initiated by the environmental reporting system, LiMeDAS.
If incorrect measurements are suspected, a zero gas calibration is requested by the
reporting system. The operator needs to take action as follows:
1) Open the three-way ball valves BV-1.2 and BV-1.1 manually for zero gas. The zero
gas takes a short way through the ball valves and to the analyser. (While opening
BV-1.1 for zero gas, it closes at the same time for sample gas.)
2) Press the “CAL” button on the instrument display.
A calibration request is now sent to the WAGO PLC.
3) The instrument auto calibrates after countdown of the time interval given.
4) Close BV-1.2 and BV-1.1 after calibration. Make sure BV-1.1 is open for sample gas.
For more information, refer to:
→ [FP398-3001] - System Diagram Gas Flow

4.3.6 Zero gas calibration of Teledyne T100H


The zero gas supplied by the gas cylinder is used for zero calibration.
The normal auto calibration is performed on a daily bases and is fully automatic and
initiated by the environmental reporting system, LiMeDAS.
If incorrect measurements are suspected, a zero gas calibration is requested by the
reporting system. The operator needs to take action as follows:
1) Open the three-way ball valves BV-1.2 and BV-1.1 manually for zero gas. The zero
gas takes a short way through the ball valves and to the analyser. (While opening
BV-1.1 for zero gas, it closes at the same time for sample gas.)
2) Wait for the analyser to stabilise and press CAL button at main display.
3) Press ZERO button and press ENTER.
4) Press EXIT to leave Calibration menu.
5) Close the three-way ball valves BV-1.2 and BV-1.1. Make sure BV-1.1 is open for
sample gas.
For more information, refer to:
→ [FP398-3001] - System Diagram Gas Flow

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4.3.7 Span gas calibration of Ultramat 23 Analyser


The gas mixture supplied by the gas cylinder is used for span gas calibration. This must
be executed at regular intervals as the analyser can lose sensitivity through normal
degradation.
The normal auto calibration is performed on a daily bases and is fully automatic and
initiated by the environmental reporting system, LiMeDAS.
If incorrect measurements are suspected, a span gas calibration is requested by the
reporting system. The operator needs to take action as follows:
1) Open the three-way ball valves BV-1.2 and BV-1.1 manually for span gas. From here
the span gas uses the same way as the sample into the analyser. (BV-1.1 closes at the
same time for sample gas.)
2) Press ENTER to access the Ultramat menu system.
3) Navigate with arrows to CALIBRATION, and then press ENTER.
4) Type the pin code “111”, and then press ENTER.
5) Select CALIBR IR-CHANNELS, and then press ENTER.
6) Select the gas component to be calibrated, for example NO, and then press ENTER.
7) Check NO- and CO- values (or any other gas component) from the gas cylinder’s
calibration certificate. The instrument stores the NO- and CO- values from the last
calibration performed, but these must be changed if the gas cylinder has been
replaced. Select SET SPAN GAS VALUES, and then press ENTER. Type new values,
and then press ENTER. It is only necessary to type the value in one of the lines, as
the other automatically will be adjusted to match.
8) Press ESC to return to calibration mode.
9) Press START CAL. MR1+2 M1, and then press ENTER.
10) Wait until the measurements are stable, and then press ENTER.
11) An error message will be displayed if the new calibration value falls outside the
acceptable calibration window. If the calibration is ok, press MEAS and then press
ENTER to accept the changes.
12) Press MEAS twice to return to the main menu.

Note This only calibrates the singular gas component selected in step 6).
Repeat the procedure for all gas components required.

13) Close the three-way ball valves BV-1.2 and BV-1.1. Make sure BV-1.1 is open for
sample gas.
For more information, refer to:
→ [FP398-3001] - System Diagram Gas Flow

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4.3.8 Span gas calibration of Teledyne T100H


The gas mixture supplied by the gas cylinder is used for span gas calibration. This must
be executed at regular intervals as the analyser can lose sensitivity through normal
degradation.
The normal auto calibration is performed on a daily bases and is fully automatic and
initiated by the environmental reporting system, LiMeDAS.
If incorrect measurements are suspected, a zero gas calibration is requested by the
reporting system. The operator needs to take action as follows:
1) Open the three-way ball valves BV-1.2 and BV-1.1 manually for span gas. From here
the span gas uses the same way as the sample into the analyser. (BV-1.1 closes at the
same time for sample gas.)
2) Press CAL button at main display.
3) Check the correct Span gas value at CONC menu. Adjust new bottle is changed.
Press EXIT.
4) Wait for the analyser to stabilise.
5) When analyser has stabilised and SPAN button activated, press ENTER.
6) Press EXIT to leave Calibration menu.
7) Close the three-way ball valves BV-1.2 and BV-1.1. Make sure BV-1.1 is open for
sample gas.
For more information, refer to:
→ [FP398-3001] - System Diagram Gas Flow

4.3.9 Changing calibration interval on Ultramat 23 Analyser


NA CEMS is delivered with a default interval for automatic zero calibration of the
Ultramat 23 Analyser. This interval may be reduced or extended as a consequence of
experienced-based use of the system.
To change the calibration interval, use function number 24 on the Ultramat U23 Analyser.
Refer to manufacturer’s manual for menu guidance.
→ [FP398-D30] - User Manual Siemens Ultramat 23

Note The Teledyne T100H analyser does not have the option to change calibration
interval.instruction.

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4.4 Disturbance of operation


Since there is no regular operator intervention during normal operation, any disturbances
of operation will first be detected by the analyser or the environmental software.
Operators will then be notified by fault alarms transmitted to the remote control system.
Operators shall then immediately attend the alarm situation by physically accessing the
NA CEMS.
Possible disturbances that may occur are:
• Obstruction of flow
• No flow
• Leaks
• Power failure
• Analyser failure
• Component concentration outside limits
• Communication failure
If the operational disturbance cannot be readily identified, traditional troubleshooting
shall be performed, as recommended in the Trouble shooting chapter 5.3.9.

4.5 Corrective measures


Necessary corrective actions to be undertaken are dependent on the severity of the fault
detected.
Operators and/or maintenance personnel should be qualified for most incidents such as
recovery of electrical power, cleaning and minor repairs, as described in the Maintenance
chapter 5.
When the fault has been rectified, restart the system as described in the System start-up
chapter.
Severe breakdown of components or recurring faults, however unlikely, shall be reported
to Suomi Analytics OY for further actions or assessment.

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4.6 Hazards and protective measures


The NA CEMS supplied is safe and reliable. Complying with supplier instructions is
therefore the best protective measure in order to avoid hazards to personnel or
equipment.

Note Suomi Analytics OY takes no responsibility for damage caused by improper use.

4.7 Qualification requirements


Efficient and precise work routines are important both for optimal process control and for
compliance with legal and environmental regulations.
The NA CEMS supplied is easy to understand and use for laboratory technicians or
process engineers with some experience of sampling, calibration and validation methods.
However, if needed, Suomi Analytics OY may offer a training course for operators.

4.8 Air conditioner unit


The Analyser Shelter is equipped with Technibel conditioning unit with cooling. Please
read the following chapter carefully before taking into operation.
Normal operational set-point for the unit is 20-22 degC.

For more information, refer manufacturer’s documentation:


→ [FP398-D32] – User Manual Air conditioner unit

4.9 Calibration and zero gas


Calibration and zero gas are installed inside the analyser shelter. The specification of the
gases is listed in chapter 2.3.5.

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4.10 NA CEMS analyser system


4.10.1 Siemens Ultramat 23
Siemens Ultramat 23 Analyser is installed in the NA CEMS analyser system. The analyser
analyse three different gases:
- NO and CO with separate NDIR cells
- O2 with paramagnetic dumbbell cell
Refer to Figure 1 on page 30 and to manufacturer’s documentation:
→ [FP398-D30] - User Manual Siemens Ultramat 23

4.10.2 Teledyne T100H


Teledyne analyses the SO2 values.
Refer to Figure 1 on page 30 and to manufacturer’s documentation:
→ [FP398-D31] – User Manual Teledyne Model T100H

4.10.3 NOx converter


The NOx converter starts when NA CEMS is turned on and performs conversion of NO2
sample gas to NO.
Refer to Figure 1 on page 30 and to manufacturer’s documentation:
→ [FP398-D34] - User Manual NOx converter

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4.10.4 Wago HMI


Refer to Figure 1 on page 30.
In the NA CEMS there is a Wago PLC programmed to secure the functionality of the
system. This PLC has a Human Machine Interface (HMI) by means of a Wago Touch
display.
This is the main interaction item with the Analyser system and the different functions are
described in this chapter.
PLC communicates to reporting system via standard protocol.

User interface
The operator can interact with NA CEMS using the following systems and instruments:
• Customer’s external control system (not part of this document)
• Ultramat U23 Analyser display (AT-1)
• Teledyne T100H Analyser display (AT-2)
• WAGO HMI touch display
The Gas analysers are used for reading of real-time measurements, whilst the WAGO PLC
display is used for menu operation when running manual maintenance and calibration
operations. The WAGO PLC is also responsible for sending remote alarms and
information messages. The WAGO HMI is operated using touch panel buttons.

4.10.4.1 Modes of operation


Automatic mode
The NA CEMS is designed to operate fully automatic under normal conditions.

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Manual mode
The NA CEMS HMI, WAGO PLC display unit holds one text line for system status and
five control touch buttons for manual operation.
The following chapter describes the content of the menus on the HMI.

The text line shows “SYSTEM OK Measuring


Engine 1” to indicate that there are no system
alarms and that sample from Engine 1 is
measured.
When no stream is selected the text line shows
“SYSTEM OK”
The display also shows the datem year and
clock

When an alarm is detected, the display turns


red and “Alarm” is displayed.
Then go to the trobleshooting chapter of this
manual to try rectify the couse of alarm.

Alarms button
Press this button to display alarm status.
Active alarms are shown with red text color.
All alarms are time-stamped.
Alarms are sent as a digital signal to plant DCS
as a common system alarm. If a malfunction is
detected, hence being transmitted as a system
alarm, the operator must access the WAGO
PLC display to examine which part of the
system has failed.
When the fault has been rectified, the relevant
alarm line will disappear and the system
returns to its normal operating mode.
Press “Exit” return to the main menu.

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Maintenance button
Press this button prior to performing
maintenance on system components, for
example filter replacement. This will send a
“Maintenance in progress” message and
reporting system that maintenance is in
progress and measured values should be
suppressed in reports and status signals
ignored.
Press “Exit” to turn off maintenance mode and
return to the main menu.
Maintenance in progress is transferred to DCS
as Warning.

Note This mode shall be used both during scheduled maintenance and when
troubleshooting or rectifying the system.

Service mode button


This menu enables manual control over each
Solenoid valve (SV-x) and the sample pump in
the system.
Press the red button to gain access to the
manual selection mode.

The Service mode button will turn green.


This is a special feature implemented to ease
fault finding and troubleshooting. Red button
indicates off (closed), green indicates on (open,
active, energised).
Before leaving this menu deactivate the
“service mode” by pressing the green top
button, then press “Exit” to turn off service
mode and return to the main menu.
It is possible to stay in service mode and leave
this menu to enter other menus in system. A
message will then notify in main screen system
is running in service mode. All solenoids and
pumps will then be controlled by state in
service mode NOT by system request.

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4.11 Field Item


4.11.1 Heated sample probe
The heated sample probe is typically mounted onto the exhaust stack using a flange.
Typical size of the flange is DIN standard DN 65, PN 6. The flange material used is
stainless steel SS316L, but other materials can be supplied, if
required.
The probe has a calibration gas inlet.
For more information, refer to:

→ [FP398-D33] – User Manual Sample Probe

4.12 LiMeDAS
4.12.1 Introduction
Continuous Emission Monitoring Systems (CEMS) are mandated by the local Ministry of
Environment to meet air quality permit requirements such as US EPA 40 CFR Part 60.
Data Acquisition Software (DAS) is a critical part of a turnkey CEMS, and must be given
serious consideration since data integrity and accuracy is important to avoiding any
potential fines and penalties.
The software is certified under MCERTS for environmental data management software
category to ensure the highest level of quality control.
LiMeDAS is able to integrate with hardware from various manufacturers.
For more information, refer to:

→ [FP398-D35] – User Manual Reporting System

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4.12.2 Scope
The system will consist of the following components:
• The data collection software (DCU) will acquire the data from the Norks CEM
system. The DCU is a virtual data logger that will act as a PLC to communicate with
analysers, acquire and store all analog and digital values, initiate and run calibration
control sequences. It will interface analyser hardware using Modbus or OPC DA
communication protocols and can use Digital and Analog I/O to read data and run
control sequences. The DCU will store all data in the SQL Server database and will
provide real-time data updates to the main LiMeDAS application.

• The main data analysis and reporting software (LiMeDAS) will process and validate
measured data values, calculate corrected gas concentrations, compute required
averages, provide data visualisation and reporting capabilities.

Both DCU and LiMeDAS can be installed either together on one PC, or on two separate
PC to form a distributed architecture. For example, DCU can be deployed on a
touchscreen panel near the analyser in the shelter, while LiMeDAS can be deployed on a
desktop in the control room.
Limesoft is able to combine and report the total emissions not just for each separate stack,
but for the entire facility or even multiple facilities, as long all the systems are on the same
network. All the reporting required to meet Part 60 regulations is included in the base
software price.

Figure 2 System Back and Restore

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4.12.3 Data Visualisation and Alarming


LiMeDAS Client is a Windows desktop application that is used for data visualisation and
real-time and historical data such as gas values and device alarms. It can be installed on a
standard PC in the control room or in the office.
On the left side of the main application screen, there are two tabs that list all components
(analog values such as gas concentrations, flow rates, process values, etc.) and conditions
(status information such as errors, service, calibration, etc.) organized by location. The
client can select an item in the channel tree control and drag the desired component to the
main display area on the right.
The right side of the screen is a dashboard that can host multiple pages with customized
widget windows to represent the data. Each widget window can be of a different type; the
user has total control of the data layout and organization. The widget types include: Data
Table, Trend Chart, Digital Status and Alarms, Calibration Snapshot, Calibration Drift,
and Component View.

Figure 3 LiMeDAS Client - Dashboard widget interface

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4.12.4 Data Validation


Systems such as PI or DCS are not designed to process environmental specific data. For
the purpose of tracking stationary source emissions the software has to validate analog
data against device operating states. The data acquired from analysers during
malfunction, maintenance and calibration periods has to be discarded and is excluded
from averaging. The remaining “good” data is then reduced to one-minute averages and
tested for a minimum required amount of “good” minutes to compute a “Valid Hour”.
The data is also flagged on screens and reports to highlight “invalid data” periods and for
the purpose of availability determination.
Please see below Component Data Report where four hours are marked as “Invalid” due
to a CEMS device calibration failure and maintenance events, as well as plant “Process
Down” state. The report summary section provides additional information concerning
data validity and availability.

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Figure 4 Component Data Report

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4.12.5 Averaging
Emissions monitoring regulations have a variety of reporting requirements based on
standard (fixed block), rolling (moving) or weighted averages. Our software has all
required capabilities to meet any such demanding requirement, with ability to compute
1, 6, 15, 30-minute averages, hourly averages, 2, 3 or 4-hour rolling averages, as well as
daily and monthly mass average and total values for NOx, SO2, CO, CO2 and other
pollutants.
Please see below Annual Summary Report that has total amount of SO2 emissions in each
calendar month with a running total number of tones of emissions in a year.

Figure 5 Annual Summary Report

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4.12.6 Availability
Data availability is a special calculation that is crucial for a compliant emissions
monitoring system.
It is determined as a percent of “valid hours” from the total number of hours the
generating unit was operational. Regulation authorities usually require a 95% system
availability in order to be in compliance. Our software will have all required facilities to
help you maintain availability, will have it computed and displayed on screens and in
reports.

Figure 6 Component Availability Report

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4.12.7 Standard Units


The data from gas analysers has to be converted to “units of standard”, where the final
result values has to be corrected to standard conditions.
Our software has all required capabilities to compute corrected gas concentrations,
specify formulas for flow normalisation, wet-to-dry and temperature corrections, mass
and energy emission rates determination, etc.
Please see below report for a set of values that are required to compute NOx Mass Rate
(kg/hr) value. First NO and NO2 as summed to compute NOx, then ppm units are
converted to mg/m3 at standard conditions and are multiplied by the Reference Flow
value that is corrected for moisture, temperature and pressure to be at standard
(reference) conditions.

Figure 7 Multi-Component Data Report

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4.12.8 Data Backfilling


Most of emissions monitoring regulations require backfilling (substitution) of missing
data. The backfilling procedure can be manual or automatic, there is also a requirement to
“flag” the backfilled data and exclude it from the unit availability calculation.

Figure 8 Data Backfill Window

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Below is a “Backfill Summary” report that can be used to find out when values were
backfilled.

Figure 9 Backfill Summary Report

The multi-component data report for the same time period shows that backfilled values
are excluded from the availability calculation:

Figure 10 Multi-Component Data Report with backfilled values for NOx and SO2 Mass
Rates

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4.12.9 Calibration Tracking


As a part of a Quality Assurance / Quality Control procedures, CEMS device calibrations
(daily checks) are performed regularly, usually every day. Our software is capable of
initiating device calibration and drift-checks, tracking all the data such as Zero and Span
values, and generating warning and out-of-control notifications. Limesoft can read
calibration results from the device, and if there is no capability to do so, track analyser
responses during the calibration test procedure and mathematically determine calibration
drifts. Below report shows CO component results where the drift for SPAN verification
point is higher than the drift specification.

Figure 11 Component Calibration report

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The Calibration Snapshot window can be used to display the result of the device
calibration with the ability to select a specific component or view multiple components on
a single trend chart screen.

Figure 12 Calibration Snapshot window

Calibration drifts are reported as a percent of full-scale (or percent of span) difference
between reference and measured values or as a deviation between those points in
Engineering Units.
The Calibration Drift trend chart can be plotted as either a bar or a line graph, where each
bar or point represents a value drift or a deviation from the reference value.
There are two scales that can be used for trend analysis: the right-hand scale (in
Engineering Units), and the left-hand one (in percent of full-scale).
The two upper and lower control limits are displayed as horizontal strip-lines to help the
user visualize the control chart trend.

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Figure 13 Calibration Drift window: Bar graph plotting style

4.12.10 Out-Of-Control
Part 60 states "If either the zero (or low-level) or high-level CD result exceeds twice the
applicable drift specification in appendix B for five, consecutive, daily periods, the CEMS
is out-of-control. If either the zero (or low-level) or high-level CD result exceeds four
times the applicable drift specification in appendix B during any CD check, the CEMS is
out-of-control. If the CEMS is out-of-control, take necessary corrective action. Following
corrective action, repeat the CD checks."
Below please see additional calibration reports that are available with our software:

Figure 14 Device Calibration report

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Figure 15 Calibration Report showing low and high level calibration drifts

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4.12.11 Emission Limit Tracking


The main purpose of the CEMS system is to be able to identify periods of emission limit
violations.
Our software has a variety of capabilities to configure, track, notify and report emission
exceedances. Limit values can be set on any analog pollutant or monitored value for a
specified averaging period. The system can generate alarms to notify operators of
abnormal conditions, a number of reports are available to display emissions.
Below report shows Opacity emission limit violations for a six-minute average value to
comply with the Ontario Regulation 419/05.

Figure 16 Exceedance values report

Refer to manufacturer’s documentation:


→ [FP398-D35] – User Manual Reporting System

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5 Maintenance

5.1 Maintenance philosophy


The maintenance philosophy recommended by Suomi Analytics OY is:
• Maintenance should be carried out by skilled personnel. The maintenance should
include the following:
o Calibrations and validations
o Functional tests
o Traditional troubleshooting based on a good knowledge of the system
• Replacement of faulty parts should be limited to the line replaceable units
recommended in the spare parts list.
Whenever a faulty unit has been replaced, the unserviceable unit should be sent to
Suomi Analytics OY, or an appointed dealer, for repair.
This is only applicable for units that are cost beneficial to repair, or as specified by project
requirements.

Note Always follow the recommended maintenance of the different units. System
performance and reliability may decline if these recommendations are not followed.

5.2 Maintenance schedule


Maintenance routines must be performed regularly as stated in the following table to
ensure optimal performance and a long operational life of the system and its components.
The preventive maintenance program shall, by defined time intervals, guide the
technician through an inspection, repair and replacement program. This will enable the
system to be operational, to reduce the number of expected alarms, to eliminate the
number of unexpected alarms and to conduct correct measurements.
The proposed maintenance schedule must be accommodated to authoritative legislation
and actual operational conditions. The customer should thus work out a local
maintenance plan.

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Note The maintenance schedule indicates the maximum recommended intervals between
which the various routines should be performed. Intervals should be decreased with
increased use of the system.

5.2.1 Daily routine

Unit Remarks
All components Inspect visually for deposits, damages, corrosion etc.

All instruments Inspect information messages, trends, logs and/or


chromatograms
Check for alarms and fault messages

Heated sample line Check temperature by hand


Sample tubes should be noticeably warm at all inlets and
outlets

Calibration gas cylinders Check that there is sufficient gas in both span gas and
zero gas cylinders. Check and adjust if necessary
pressure out using pressure regulators.

5.2.2 Weekly routine


Unit Remarks
Cabinet and component Clean all surfaces
exterior

All components Check that flow is constant and at set point


Adjust if necessary

Ventilation ducts and Check for buildup of dust and dirt


holes
Clean if required

Air conditioning unit Clean unit exterior


Check that air inlet and outlet vents are free from sand,
dust or other foreign matters

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5.2.3 Monthly routine


Unit Remarks
All components Inspect visually for deposits, damages, corrosion etc.

Sample tubing Inspect visually for condensation, contamination and


leaks

Gas Analyser Perform calibration monthly (or after replacement of gas


cylinders)
Intervals may be reduced if the deviation between each
control increases
Intervals may also be extended if the deviation is
insignificant

Sample lines inside Check all tubing visually for condensation


cabinet

Sample probe filter Check for contamination and physical damage


Clean or replace as required
Also check that the probe is hot

Gas filter Replace filter insert as required.

Gas cooler Check that drain condensation is in working order

Gas cylinders Check calibration certificate expiration date


Check that cylinder pressure is within acceptable limits
Replace if required

Condense trap Check condense trap behind analyser AT-1. Replace if


necessary. Write date on filter.

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5.2.4 Routine every six months


Unit Remarks
Sample probe filter Replace filter
May be replaced earlier if flow is reduced to such a level
that alarms are active

Sample gas filter Replace filter


May be replaced earlier if flow is reduced to such a level
that alarms are active

5.2.5 Yearly routine


Unit Remarks
All filters Replace filters
Replacement of filters within each sub-system should be
synchronized to minimize operational down-time

Condense trap Replace condense trap. Write date on filter.

NA CEMS Replace fine filter


Replace tubing in both peristaltic condensate pumps

Gas pump membrane Check physical condition


Replace if required

Solenoid valves Perform functional test


Perform leakage test

Heated sample line Check for moisture and contaminations


Clean if required

Ultramat 23 Analysers Replace condensate trap and safety filter

Teledyne T100H Replace the sample Filter


Replace Filters and O-rings at flow control
Check UV-source signal level

NOx Converter Replace cartridge

(*) Suomi Analytics OY recommends that annual periodic maintenance is performed by


qualified personnel only.

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5.3 Maintenance procedures


5.3.1 Cleaning cabinet exterior and surfaces
1) Clean the exterior of cabinets and other surfaces with a sponge or cloth soaked in
water contained cleansing agent.
2) Wipe down all surfaces afterward with a clean, damp cloth to remove the detergent.

Caution Make sure that no water enters instruments when cleaning.

3) If necessary, dust may be removed from the interior of cabinets by carefully using a
compressed air gun.

Caution When cleaning heater surfaces for build-up of deposits, do not scrape or
hammer the metal surfaces, as this can shorten the lifetime of the
heaters.

Warning Before opening junction boxes, make sure that power is disconnected.

5.3.2 Replacement of gas cylinders


The system is delivered with full gas cylinders and the Customer is responsible for
replacing empty cylinders calibration and zero gas.
This procedure is applicable for both calibration gas cylinders.

Note Prior to replacing a gas cylinder, check that the new cylinder has been properly
stored, as specified by its accompanying certificate.

1) Ensure that the valve controlling flow from the gas cylinder is closed.
2) Ensure that the gas cylinder’s outlet valve is firmly shut.
3) Unscrew the regulator fittings.
4) Remove all mechanical fasteners.

Caution Never allow gas cylinders to fall.

Caution Keep caps on while moving gas cylinders.

5) Replace the gas cylinder, and ensure that the new cylinder is properly fastened.
6) Adjust the regulator on the new gas cylinder to give correct flow to the relevant
instrument.

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7) Perform a leakage test of the new cylinder.

Note When replacing a calibration gas cylinder, the calibration blend values must
be updated in all instruments using the blend, as these values are used to
calculate correct response factors each time the instrument is calibrated.

8) Calibrate the analyser.

5.3.3 Replacing the sample gas filter in NA CEMS


The sample conditioning system inside the analyser system contains a filter elements
(F-1, F-2) made of an inert PTFE material. The filter element is passive, and does not add
or absorb any of the trace components to be measured.
1) Access the NA CEMS and use the maintenance switch provided to
set the system in its maintenance mode.
2) Gain access to the filter.
3) Visually check for moisture in the glass container and surrounding
tubes.
4) Open the filter housing by drawing out the plastic locking ring.
5) Pull the glass cup holding the filter straight down.
It is only pushed up onto the element holder.
6) Pull down and replace the filter.
7) Reassemble the sample gas filter unit.
8) Reset the system to its operating mode.
It is not necessary to shut off power or similar.

5.3.4 Replacing the Ultramat 23 condensate trap


The condensate trap in the Ultramat 23 must be replaced at least
yearly.
1) Access the NA CEMS and use the maintenance switch
provided to set the system in its maintenance mode.
2) Open the hinged door to gain access to the analyser rear.
3) Replace the condensate trap using a standard wrench.
4) Reset the system to its operating mode.

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5.3.5 Replacing internal parts in analysers and instruments


The analysers and other instruments are sensitive devices.
Replacing serviceable parts inside these units should therefore be performed by service
personnel authorised by Suomi Analytics OY or the instrument suppliers only.

5.3.6 Replacing the NOx converter cartridge


The reactor cartridge in NOx conversion unit should be replaced annually or when the
conversion rate of NO2 to NO drops below the required level.

Warning Use protective gloves to prevent burns. Reactor cartridge is hot


(up to 450°C).

Note The NOx converter can also be turned off and the cartridges cool down before
replacement. This takes at least an hour. Refer to User Manual NOx Converter
[FP398-D34].

1. Turn the handle to the reactor cartridge counter clockwise until it can be pulled
out.
2. Replace the entire cartridge with a spare and install the new part clockwise.

5.3.7 Corrections, repairs and modifications


The Analyser System is designed for unattended and continuous operation. Due to its
robust design, the need for major repairs or replacement of main units during the planned
lifespan is minimal.
In the unlikely event of a system breakdown, or if larger modifications of the Analyser
System is wanted, contact Suomi Analytics OY for further assessment.

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5.3.8 Fault-finding
The Analyser System is able to recognise system irregularities and will send messages
accordingly. All messages are displayed on the screen of the relevant analyser or gas
chromatograph. Fault alarms are also transmitted to the customer’s remote control
system.
More information on the malfunction detected is then available by accessing local
displays or by remote access.
Detailed information on possible alarms generated is given by the manufacturer's
manuals.
→ [FP398-D30] - User Manual Siemens Ultramat 23
→ [FP398-D31] - User Manual User Manual Teledyne Model T100H

5.3.9 General troubleshooting procedure


Effective troubleshooting is a methodical process acquired through good knowledge of
the analyser system. The following general procedure contains useful check points when
troubleshooting the system that should be incorporated when establishing a local
maintenance plan.
• Record the fault alarm received.
• Gain access to the relevant cabinet.
• Check for external power failure.
• Check that zero air inlet is not blocked.
• Check for loose wires inside the cabinets.
• Check terminations inside junction boxes.
• Check that the light fixture is working.
• Check for leaks in valves and fittings.
• Check for flow obstructions.
• Check that the analysers are working.
• Attend the fault and rectify the alarm condition as required.
Depending on the fault, undertake the necessary corrective action as described by the
Maintenance procedures chapter.
Contact Suomi Analytics OY for assessment or further actions.

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6 References

As additional in-depth and reference information to this manual, please refer to the
drawings and documents listed below.

6.1 Drawings
→ [FP398-1001] - GENERAL ARRANGEMENT ANALYSER SHELTER EXTERIOR
→ [FP398-1002] - GENERAL ARRANGEMENT ANALYSER SHELTER INTERIOR
→ [FP398-1011] - GENERAL ARRANGEMENT NA CEMS CABINET INTERIOR
→ [FP398-1012] - GENERAL ARRANGEMENT NA CEMS CABINET EXTERIOR
→ [FP398-1013] - GENERAL ARRANGEMENT POWER DISTRIBUTION PANEL
→ [FP398-1015] - GENERAL ARRANGEMENT PLC
→ [FP398-1016] - GENERAL ARRANGEMENT DUST PROBE D-R 220
→ [FP398-1017] - GENERAL ARRANGEMENT SAMPLE PROBE 222.17
→ [FP398-1018] - GENERAL ARRANGEMENT - COUNTER FLANGE MOUNTING
→ [FP398-2001] – FUNDATION DRAWING ANALYSER SHELTER

6.2 Termination and wiring drawings


→ [FP398-5001] - TERMINATION DRAWING - PLC
→ [FP398-5002] - TERMINATION DRAWING - PLC
→ [FP398-5003] - TERMINATION DRAWING - PLC
→ [FP398-5004] - TERMINATION DRAWING - PLC
→ [FP398-5005] - TERMINATION DRAWING - PLC
→ [FP398-5011] - TERMINATION DRAWING 24VDC NA CEMS
→ [FP398-8001] - SINGLE LINE - MAIN POWER TERMINATION
→ [FP398-8002] - SINGLE LINE - POWER DISTRIBUTION PANEL PAGE 1/2
→ [FP398-8003] - SINGLE LINE - POWER DISTRIBUTION PANEL PAGE 2/2

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→ [FP398-8010] - SINGLE LINE - NA CEMS NA-1 PAGE 1/2


→ [FP398-8011] - SINGLE LINE - NA CEMS NA-1 PAGE 2/2
→ [FP398-8017] - SINGLE LINE - SAMPLE PROBES NA-1 PAGE 1/2
→ [FP398-8018] - SINGLE LINE - SAMPLE PROBES NA-1 PAGE 2/2
→ [FP398-8020] - SINGLE LINE - NA CEMS NA-2 PAGE 1/2
→ [FP398-8021] - SINGLE LINE - NA CEMS NA-2 PAGE 2/2
→ [FP398-8027] - SINGLE LINE - SAMPLE PROBES NA-2 PAGE 1/2
→ [FP398-8028] - SINGLE LINE - SAMPLE PROBES NA-2 PAGE 2/2
→ [FP398-8201] - NETWORK MAP ANALYSER SHELTER

6.3 Flow and system diagrams


→ [FP398-3001] - SYSTEM DIAGRAM GAS FLOW

6.4 Manuals and documents


→ [FP398-D21] – OPERATION AND MAINTENANCE INSTRUCTION ANALYSER
SYSTEM
→ [FP398-D30] - USER MANUAL SIEMENS ULTRAMAT 23
→ [FP398-D31] - USER MANUAL TELEDYNE MODEL T100H
→ [FP398-D32] - USER MANUAL AIR CONDITIONER UNIT
→ [FP398-D33] - USER MANUAL SAMPLE PROBE
→ [FP398-D34] - USER MANUAL NOX CONVERTER
→ [FP398-D35] - USER MANUAL REPORTING SYSTEM
→ [FP398-D36] - USER MANUAL DUST PROBE
→ [FP398-D40] - POWER CONSUMPTION LIST
→ [FP398-D42] - DISPATCH, RECEIPT AND STORAGE INSTRUCTIONS
→ [FP398-D44] - FAT PROCEDURE ANALYSER SYSTEM
→ [FP398-D44] - FAT REPORT ANALYSER SYSTEM
→ [FP398-D201] – CABLE INDEX
→ [FP398-D204] – I/O SPECIFICATION

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