Online Flue Gas Continuously Monitoring

System Gasboard 9052

Users Manual

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1. Introduction
1.1System Feature
In the process of production or using of the flue gas, is widely used to monitor emissions and concentrations of
gaseous pollutants, combustion and emission technology is an important part. The Online Flue Gas Analysis
System Gasboard 9050 is used for monitoring flue gas composition.

On-line infrared flue gas analyzer is the core of the analysis system, the instrument adopts NDIR technology,
based on Lambert - Beer law, is able to analyze NO,SO2,CO gas component and its concentration. In addition, it
can be built-in electrochemical oxygen sensor.

1.2 System components

The analysis of the system is composed of sampling unit, pre-treatment unit, control unit, data analysis and
output units.
 Sampling unit: including sampling pipe and a manual valve two parts.
Sampling probe principal part is purify dust sampling probe, using sintered metal filter and filtration
precision up to 2 um, it can prevent dust of sample gas into the pipeline.
 The sample gas pre-treatment unit: including gas condenser, sampling pump and filters.
The sample gas must be remove the dust and water before enter the gas analyzer, because it directly affects
the monitoring results of accuracy, reliability and lifetime of gas sensor.
In the analysis of the system, first sample gas through the heating tube into the analysis cabinet. Sample gas
dust decreased significantly after sampling probe filter. The next step system uses a filtering accuracy of
1um of gas-water separator; filter the sample gas separation of the water at the same time. Finally, sample
gas through the 0.1 um precision filter, to ensure that clean and dry into the gas analyzer. The system uses a
dual compressor condenser to remove moisture in the sample gas. Output sample gas dew point: ≤5 ℃.
 Control unit: system controlled by a control box, power supply and sampling pump.
Control unit adopts Siemens S7-200 CPU222 small PLC as the core control system module, it can
automatically complete the sampling, blowback, pneumatic, switch and other functions, automatic
monitoring for 24 hours and reduce labor costs.
 Analysis and data output unit: comprised of an on-line infrared gas analyzer, is the core part of the analysis
of the system. Analysis instrument with 4 ~ 20mA DC output interface and RS232 serial interface, the gas
composition analysis data through a shielded cable to transmit to the user the central control unit.

1.3Working conditions
Installation site: The system is required to be installed indoors, non-corrosive gas, non-explosive environment
and with air conditioner, water and power supply etc.
Working condition：
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 Sampling distance：Less than 30 meters
 Sample gas dust concentration: ≤300 mg/m3
 Sample gas pressure: 0 kpa - 20 kpa
 Sample temperature: ≤600 ℃
 Sample gas humidity: ≤100%

Work environment:
 Analysis cabin: 2400 * 2400 * 2400mm (L * W * H), system should be installed in it, equipped with a gas
detection alarm, ventilation and lighting
 Ambient temperature: ≤50 ℃
 Relative humidity: ≤85%
 Environment pressure: less than 2500m altitude
 No sun direct radiation
 No strong electromagnetic interference
 No mechanical vibration
 Air velocity: ≤0.5 m/s
 Work location: horizontal
 Power supply: AC220V 50 Hz 3 kva

2. Working Flow
2.1 System flow chart

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2.2 The components in the system as follows:

Components Pictures Name / Function / Parameter

PLC
Model:CPU222
Parameter: Weight: 310 g
Dimensions: 90*80*62 mm (W*H*D)
Power consumption:17 W
Power supply: 100-230V AC
Digital input: 8 points, 24V DC input
Digital output: 6 points, relay output
Communication interface: RS485 interface

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 Relay
Model: MY2NJ24VDC
Parameter:
coil: 24 VDC
Contact: two open two closed, 5A / 250VAC, with LED

Denitration sampling probe

Function: The filter using sintered metal filter
filtration precision up to 2 um.
Heating temperature is about 260 ℃.
Parameter:
power supply: AC220V
Pipe port: φ6

FT1 filter
Function: Separation of moisture in sample gas and filter it.
Parameters: the highest working pressure: 1.0 MPa
Filtration precision: 1 um
Interface specifications: G3/8

Sampling pump PUM

Function: Provide sample gas transmission power
Parameters: Type: diaphragm pump
Power supply: AC220, 60 w
Flow: 5.5 L/min
Working pressure: - 160 mbar - 2.5 bar,
Port: G1/8

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 Gas Cooler
Function: Condensing the moisture in the sample gas is discharged by
the drain valve
Parameters: Type: compressor refrigeration principle
Power supply: AC220V, 150 w
Entrance sample gas dew point: Max 80 ℃
Export sample gas dew point: ≤5 ℃
Sample gas processing capacity: 250 NL/h

Drainage solenoid valve

Function: Discharge water in the sample gas
Parameters: Type: normally closed type solenoid valve
Power supply: DC24V
Power:6 w
Port: RC1/4"

Bypass flow meter LJ

Product description:
10L/min glass flow meter, connected to the by-pass.
Function:
This flow meter allows the sample gas that is pumped from the process
by the gas sampling pump to flow into the system at a higher flow rate
(generally 2-3L/min) than the requested flow needed for the gas
analysis (1L/min); this in order to shorten the gas transfer time from
the process to the gas analyzer and ensure a real-time measurement;
the gas overflow is directed to the by-pass and vented out.

Peristaltic pump P
Function: Continuously discharging water condensed in the condenser.
Parameters: Slow:0.3 NL/H
Port: φ6

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 Sampling valve
Function: When the system is powered during drainage and blowback,
te electromagnetic valve is closed to prevent abnormal sampling gas
into the gas analyzer.
Parameters: Type: Normally open solenoid valve
Power supply: DC24V
Power:6 w
Port: G1/4”

Precision filter FT2

Function: Precision filter sample gas
Parameters: Filter element material: Ceramics
Filtration precision:0.1um
Port: G1/4”

Switch valve V7/V8

Function: V7:Switch calibration
V8:Switch sampling/calibration
Parameters: Type: Manual two-way valve/manual three-way valve
Port: φ6 Gas mouth
Material: Stainless steel

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2.3. Sampling probe structure
As figure 1 illustrated

Figure 1

1. Probe is made of SS316 stainless steel with diameter of 12mm

2. Probe pad
3. Flange pad
4. Flange with DN65
5. Heating and filter chamber

Sampling probe dimensions：

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 240 360
14

DN65
DN65安装法兰
Flange

660

5
35
330

380

210 2 240
1

3 4 5 6

35

Figure 2

Sampling probe layout：

2
1

3 4 5 6

Upward view

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 13 7 10 11 12

1 2 3 4 5 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

T/C

8 9

7
11

8
1 2 3 4 5 6 7 8 9 10 11 12 13

12
T/C
13

14
1 2 3 4 5

10 加热器

Vertical installation Horizontal installation

Descriptions：
1. Heated line hole
2. Drainage hole
3. Power supply cable hole
4. Back flushing gas inlet
5. Back flushing control valve power supply cable hole
6. Alarm cable hole
7. Temperature controller
8. washing bottle
9. Peristaltic pump
10. Back flushing control solenoid valve VBF-b
11. Back flushing control solenoid valve VBF-b
12. Power supply wiring terminal
13. Back flushing pressure sensor
14. Back flushing control wiring terminal

Purging working diagram

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 B.P. Controller

Purge Gas In
Vent

Purge Gas In
1X10p
DC24V
VBF-a
60s
DC24V
VBF-b

Back flushing gas(N2 or air) should be prepared by the users themselves. Suggest back flushing time
interval is 4 hours and back flushing pressure is about 0.4-0.8Mpa.

Sampling probe working diagram

Installation

Sampling probe installation please refer to Figure 3.

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 Figure 3
1. Installation base plate (prepared by the user)
2. 4 pcs of M14 screws, fixing base place in the stack
3. Installation sleeve
4. Female Flange
5. Male Flange
6. Sealing pad
Sample probe should be fixed horizontally or -10℃ hang dawn.

Installation steps
a) Welding female flange and fixing the flange
As Figure 4 illustrated：

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 Figure 4
Please take notice sealing surface of female and male flange should be together and a sealing pad is also
needed.
b）Electricity connection
Horizontal installation electricity connection
1 2 3 6 7

PE L N Temp alarm
220AC/50HZ out

1 2 3 4 5

PE VBF-a VBF-b
DC24V DC24V

Vertical installation electricity connection

Low temperature alarm

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When sampling probe’s heating temperature is lower to 230℃，
terminal 9 and10is disconnected
 Warning
Temperature controller in the sampling probe was pre-set in the
factory. DO NOT TOUCH IT.

Warning
Please power off while connecting cables.

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3. Installation
3.1 Select sampling point
Location of sampling points should be considered according to the system working conditions.
If you want system response time is short, sampling point should be as close as possible to analysis
system.
Sampling point probe insert should avoid gas laminar flow, eddy current and reflux. Recommended
insertion depth of pipe diameter 1/2 - 1/3, sampling points do not have air leakage.

3.2 Gas analysis layout

3.3 Analysis cabin installation

After select analysis system installation position, you should build up a cabin in this location which shall
meet the following requirements:
 Daily temperature change is small, the room temperature difference between day and night shall not
be higher than 20 ℃,if need you can install air conditioner in the room
 Analysis room area recommended 4000 × 3500 X 3300mm, instrument analysis cabinet position
 Ventilation is good, you can install industrial exhaust fan

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3.4 Gas path connection

Sample gas entrance: Using φ8 heating sampling tube, connected through an interface with the sample
gas inlet entrance by joint.
Sample gas discharge port: Using φ6 PTFE tube, connected through an interface with the sample gas
discharge port by joint.
The exhaust gas can be directly discharged into the atmosphere, and the discharge port should be
selected in the safe area.
Drain port: Using φ6 PTFE tube, with the system at the bottom of the drain connections.
Install standard gas cylinder: it require fixed installation, and close to the system. At the same time install
pressure reducing valve, after the installation will be zero gas cylinders using φ6 PTFE tube with zero gas
inlet connection, and the span gas cylinders with φ6 PTFE tube connected to the span gas entrance.

3.5 Electricity connection

Electricity cables installation need information see the table below.

Items Model Length Remark

Analysis cabinet From user power to analysis Power ： AC 220V±1 ％

KVVR-3×2.5 mm2
power cable system cabinet Capacity：3kVA；

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 From the analysis cabinet to
KVVRP- 6× Used for state signal
Status signal line the user control room (or
1.0mm2 output
user specified location)

KVVRP- （ 2×component From the analysis cabinet to

Analog signal Used for the analysis of
number）× the user control room (or
line component data output
1.0mm2 user specified location)

3.6 Gasboard-9051 Installation Instruction

3.6.1 Sampling Probe

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 Connect metal changeable
diameter joint with heated line
(marked by yellow).

Condensing pipe
Heated line

Pressure reducer valve

PURGING connection: 1) terminal “IN” connect with manual ball valve

2) Terminal “OUT” connects with the stainless steel joint
3) Connect PTFE tube with back flushing inlet port of sampler

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 Sampling probe inside
terminal
System inside terminal

Sampling probe electricity connection: in accordance with the sampling probe

circuit connection drawing picture, lead the cable to the system internal 3-8
terminal, 1-2 terminal of the system is power supply for heated line

3.6.2 Cooler installation steps

Condensing pipe

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 Peristaltic pump

Connect PTFE tube 1-4 with condenser tube 1-4 corresponding

Connect 2 pcs condensing pipe with peristaltic pump (IN) at the bottom of the cabinet

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 The connecting pipe is connected with
the back end of the machine cabinet
at the other end of the tropical zone,
and the connecting wires of the two
power supply wires in the heat pipe
line are extended to the 1-2 terminal,
and the part of the air is exposed to
the INLET.

please lead PT100(connect with temperature

controller) to the outside of cabinet ,and put it into
heated line after open an interface 1m-1.5m cut
PT100 will be inserted into the tropical interior, with
heating wire, to ensure that with the tropical normal
heating, and then cut open the location of the parcel

4. System Operation
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4.1 Check before running
After completion of installation works, you shall carefully check the complete installation to ensure that:
 There is no gas of leakage
 All tubing/pipes are properly connected
 The power supply meets the technical requirements
 The cabinet grounding is connected
 Please also check the correct operation of the system before starting to measure.

4.2 Check the tightness of the sample gas

 Before the pump through the negative pressure leak detection: Close sampling valve, start pump,
sample gas flow rate should be reduced to zero;
 After pump in positive pressure leak detection gas analyzer pumping air: leak pressure 0.1MPa, not
more than 0.12Mpa.
Note: Leakage detecting not including gas analyzer when sampling gas pressure is positive, otherwise
gas analyzer will be damaged ,pls make sure disconnect gas analyzer when leakage detecting under
positive pressure

4.3Powering
Close the internal front door of the cabinet.
Turn on the circuit breakers for Power.

Put the power switch of the gas analyzer on I.

The gas analysis system will be ready for use after the required 800s warm-up time of the gas analyzer

Analyzer power switch in flow meter

position "I"
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4.4. Gas sampling
Turn on the power switch, the instrument start warm up and sampling pump start sampling ,adjust"bypass
vent flow regulating valve" LJ knob in order to have a flow of 2 to 3L/min,adjust the flow meter on the gas
analyzer in order to have a flow of 1L/min Wait a few second for stabilization before getting actual gas
measured values shown on the analyzer display.

Gas
Bypass
analyzer
flow
flow
meter LJ
meter

5. System maintenance
Regular inspection cycle is 1 ~ 2 days during the equipment commissioning period; equipment normal
operation after a month, inspection can be 3 to 5 days

5.1 Daily check of the analytical gas flow rate

 If the flow meter of the gas analyzer is lower than 0.7-1.0L/min, the measures will increase;
 if no flow, the measures is not correct; the reasons might be flow meter broken, or gas route leakage.
It is very dangerous.
Daily check
By reduce BYPASS FLOW meter LG to increase the flow of gas analyzer. Bypass flow meter and gas analyzer
flow meter should be higher than 2L/min. If not, the gas sampling pipe might be blocked or there might be
a gas leakage. To solve the problem, please check chapter 6 Trouble shooting.

5.2 System maintenance

The gas analysis cabinet contains instrumentation and electronics that can be affected in their good
working by the presence of dust and dirt. In order to preserve your gas monitoring system, we
recommend you to regularly clean the inside of the cabinet to remove dust accumulation.
 Fan set and/or air intakes (if present) should also be regularly cleaned to allow a good air flow inside
the cabinet. In normal operation we recommend to clean the cabinet with a dry cloth each 3 months

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 during a maintenance operation.
 Filter material FT1 FT2 should be replaced according to the actual pollution situation, such as black or
attached some dope, before you replace filter element should stop system sampling and ensure good
air tightness
 Should regularly inspect water storage device, if too much water in it ,you can press the "manual
drain" button on the control panel to discharge water, if water cannot be properly discharged, should
check whether the drainage pipeline blockage.
 When standard cylinder gas pressure less than 0.2Mpa should be replaced with a new one. Gas
cylinders should be placed strict accordance with the relevant requirements for gas cylinders to
prevent the occurrence of safety accidents.
 Inspect heating and drainage system is normal or not

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6. Trouble shooting
Symptom Failure description Solution

not working check the power supply of pump is normal or not

Diaphragm cracks, defects Change a new one

Sampling
Pump cooling fan shaft stuck Need to be cleaned and coated with lubricant
pump
problem Pump diaphragms clogged due to
Cleaning the diaphragm and remove dust in the pump
dust

Others If all above are not workable, it needs to replace a new pump

If the pump is normal, remove the inlet pipe from the sampling pump, if the gas flow returns to be normal, it can determine gas route before
the pump is blocked, in accordance with the following methods to troubleshoot.
Low or If remove the sampling probe outlet, the gas flow returns to be normal, it can determine sampling
no gas The
Sampling probe blocked probe is blocked.
flow sampling
Please checked the sampling probe, sampling valves in the pipe are normal.
pipe is
f remove the sampling probe, the gas flow is still low or no flow, then disconnect the sampling tube
blocked
Sampling pipe block from the external sampling point and check for any blockage. If the gas flow returns to be normal, it
(before the
need dredge or replacement of the sampling tube
pump)
According to other parts of the first part of a similar approach to troubleshoot pump and pipeline
Others failures, you need to dredge or replace the related parts or pipes. If it has Solenoid valves, pls check
its power supply is normal.

The After checking the sampling pipe before pump is working normally, the problem surely is some parts after the pump is blocked or leaks

sampling Block the inlet port of peristaltic pump, if the gas flow becomes normal, then you need change a new
Peristaltic pump leakage
pipe is one.

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 blocked or Open the gas chiller outlet, if the outlet has no gas flow, but it has gas flow after open the inlet of the
Gas chiller blockage
leaks gas chiller, it surely the gas chiller is blocked. Clean the gas chiller or replace a new one
(after the Exhaust gas pipe blockage Check the exhaust pipe, clean or replace it.
pump)
The same as above methods. If there are electromagnetic valves, please also check its power supply
Other parts or pipe
normal or not.

Symptom Failure description Solution

Check the power supply of peristaltic pump; if no problem, replace a new peristaltic
Drainage problem Peristaltic pump not working
pump.

Not enough warming up Normally, the gas needs warming up at least 30minutes

Sampling is not stable Check sampling system flow is normal or not.

Measures fluctuated, with big error
Gas analyzer has big drift or wrong
Users calibration is required
calibration

While doing calibration, the gas Gas sensor was destroyed by

Replace gas sensor
analyzer cannot be STABLE (normal for water or particulars
2mins) O2 sensor’s lifespan is over Replace a new one

Power supply of gas analyzer

Check the power supply of gas analyzer is OK, making sure 220V AC in and the fuse is OK
abnormal
LCD no display
LCD power cable is loose inside
Re-plug the LCD power cable based on the engineer’s instructions
the gas analyzer

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