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01b - CEMS Operation Manual PDF
01b - CEMS Operation Manual PDF
SOLWARE
GAS ANALYSIS SYSTEM
JOB
02.39.07.005
OPERATION
MANUAL
SW
SOLWARE
INTRODUCTION
SOLWARE srl
22070 LIMIDO COMASCO (CO) - VIA M. BIAGI, 4
All rights reserved. No part of this manual can be copied or transmitted to others in any form, without prior written
authorization of SOLWARE srl.
Every effort has been made in order to guarantee the accuracy of the information. Nevertheless in order to maintain our
technical experience at high levels, we reserve the right to update information without the need of prior information.
We decline any direct or indirect responsibility for any damage caused to things or people by the appropriate or
inappropriate use of the equipment.
1 INTRODUCTION 1
3 SYSTEM POWER UP 6
4 ANALYZERS CALIBRATIONS 9
6 MAIN MAINTENANCE 17
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SOLWARE
1 INTRODUCTION
The analysis system is used during the burning processes where, both for regulations and efficiency, is
required the measurement of the most important products of a combustion.
CEMS is composed by:
- Analyzers:
• N. 1 Ultramat 23 (A1): It measures gas concentration using this principle:
o CO: non-dispersive infrared rays cell (N.D.I.R); the scale field is set with a double 4-20mA
analogue output for the following: 0-625 mg / mc
o CO2: non-dispersive infrared rays cell (N.D.I.R); the scale field is set with a double 4-20mA
analogue output for the following: 0-20%
o O2: Paramagnetic cell the scale field is set with a double 4-20mA analogue output for the
following: 0-25%
• N. 1 NOx (A4): Molybdenum catalytic converter, heated at 350°, converts NO2 in NO.
- Field instrumentation for zone ATEX zone 2:
• Mt 50 Heated line for gas transportation
• N. 1 Heated sampling probe, 1000 mm tube length
• N. 1 probe for temperature measuring 0-1200°C
1
Figura 1
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SOLWARE
A lot of gases absorb IR radiation, so it’s often necessary to be careful to avoid wrong measures, for example
CO2 and H2O are almost on the same wavelength. When using this method, extract all the water from the
gas before measuring.
Figure 2
Instead, an analyzer based on the principle of paramagnetism is used, composed of a measuring cell of
symmetrical geometry, where a magnetic field is created between 2 poles. Two temperature probes (C and
D), supplied with electric current, are kept at a temperature of about 250 ° C.
The measuring cell exploits the paramagnetism of oxygen, a feature that clearly distinguishes it, as it is
significantly greater, from all other gases (all of which are diamagnetic, that is, rejected by a magnetic field,
except for NO). Oxygen is attracted to a strong non-linear magnetic field (paramagnetism) and this
particular behavior is the basis for obtaining an accurate measurement in a very short time.
The detector consists of two permanent magnets which generate a strongly uneven magnetic field. Between
the polar expansions of the magnets there is a rotating arm (platinum wire) which has at its ends two glass
spheres. The arm is held in axis with respect to the magnets thanks to an electric winding arranged along the
same spheres and covered by direct current.
During the analysis process, the gas containing O2 flows into the cell: O2 molecules, due to their
paramagnetism, tend to move to the center of the magnetic field generated by the cell
NOx
converter
Commands for
panel control
Analysers
Figure 1
The CEMS carries out the gas analysis in extractive configuration, taking the sample from the sampling point,
the fumes are suctioned through a heated line and analyzed, cold and dry, by the analysers installed directly
in the analysis cabinet.
The gas sampling probe and treatment line is unique and is composed of the following components:
• Heated probe mod. JES301ex (HR1) with a ceramic cartridge filter (2 m) and a tube in alumina; the
probe shall be positioned in the stack. The tube can be exposed at a maximum temperature of 1000° C.
On the probe, outside the stack, is installed the filter heated to 120° C electronically. This configuration
prevents the formation of condensation, that would affect the measure.
• Heated line (HR11) in PTFE, is used for the gas transport between heated probe and cabinet. It is heated
to 120° C by a thermo-regulator to prevent formation of acid condensation, that would affect the
measure. Inside the line there are no. 3 PTFE tubes. A first tube is used for suction the gas to the analysis
cabinet (8x6 mm), a second tube for calibrating throughout probe (6x4 mm) and a third tube for the
loop of return gas to the sampling point (6x4 mm):
• The heated line enters into the cabinet by the “IN1” and it is connected to the Heated Box (HB1). On the
box there is a filter in PTFE (FLT1) which shall eliminate a particulate in the gas. The box is heated with a
thermoregulator on the panel. The set of temperature is 120°C.
• Outside the box a humidity drain bottle (PRS1) is installed with peristaltic pump (PP3) to reduce the
condensation in wet flue gas. Condensed humidity is expelled through the outlet “OUT1”,
• Downstream the PRS1, the gas goes to the Gas cooler mod. JCT-2 (C 1_2). The gas cooler is necessary
to lower the dew-point to a temperature of +3°C, allowing all the water steam in the gas to become
condensed and to be continuously evacuated by the peristaltic pumps (PP1-PP2)”OUT2” before entering
into the analyzers. The gas cooler (chiller) is double-stage to allow the elimination of all the residual
humidity present in the gas.
Between the first and second stage of the chiller, the following components are installed:
• Three ways solenoid valve (EVZ). In normal configuration the gas passes between the first and
second stages of the chiller. When EVZ is energized, N2 gas or external air will enter into the
cabinet for “zero calibration” through “IN2”;
• Three ways solenoid valve (EVS1). In normal configuration the gas passes between the first and
second stages of the chiller. When EVS1 is energized, a span gas from outside “IN3 or IN4” will
enter into the cabinet for “span calibration”;
• The suction pump (PA1) KNF mod N811, which pumps the gas from the heated probe and the
heated line to the analyzers. The max flow of the pump is 11 l/min;
A discharge valve VS4 is installed to regulate and discharge the surplus gas.
Downstream the chiller, the gas is pumped into the following equipment:
• Condensation trap (GC1) is installed and used to detect the residual humidity presence and in case
the quantity is above to an internal threshold, it immediately blocks the suction pump introducing
ambient air into the system;
• Filter (FLT2) used to eliminate particulate; porosity is 5 µm;
• Digital gas flow meter (FL1) mod SMC with alarm signal for low flow;
• Manual valves (VS 1-2-3-4) to control the analysis flow:
o CO analyzer cell
o CO2 – O2 analyzer cell
o NO – SO2 analyzer cell
o Bypass
• Paper filters (FLT 3-4-5) used to capture the impurities before the analyzers. Porosity 5 µm;
• N° 1 NOx (A4) converter to convert the NO2 to NO before the NO analyzer cell;
• N° 2 Gas analyzers:
• N° 1 Siemens Ultramat 23 (A1) with 2 gas input and 2 analogic flow meters (the standard flow
shall be 1-1.2 l/min) for:
o CO NDIR Cell
o CO2 NDIR Cell and O2 paramagnetic sensor
• N° 1 Siemens Ultramat 23 (A2) with gas input for NDIR cell and 2 analogic flow meters (the
standard flow should be 1-1.2 l/min) for NO and SO2 analysis.
• Gas output from analyzers is conveyed to “OUT3” and returned to the sampling point via the heated
line.
• “IN2” gas input point for zero calibration (N2 or air); there is also a pressure reducer in line for the
inlet pressure and a reduction valve to control the flow. The incoming gas is then sent to the (EVZ) to
perform the calibration of zero point.
NOTE:
The Condensate output “OUT 1” and “OUT 2” are collected to the bottom of the cabinet and shall be
collected to an external drain pot.
N.B.: for further information about functions, use, and problem solutions,
please refer to instrument’s datasheet
3 SYSTEM POWER UP
First of all, power up the system by acting on the circuit breaker.
The system starts with the warm up phase while the various equipment reach the ideal condition for
operating. In detail, analyzers and the gas cooler need a warm-up and in this phase some alarm lamps are
active.
This section collects and describes the panel alarms. On the frontal side of the cabinet there is the lamp for
general alarm that include:
• Gas heating system low temp alarm: The heating system include : heated line and heated box. Signals
that regulated temperature has not yet reached the set value at set. A deviation larger than ±20°C from
set-point will result in alert. Heating time expected: about 20 minutes.
• Gas Cooler Alarm: this alarm starts because the compressor has to bring the heat exchanger to a
temperature of +3°C÷+5°C, so you can eliminate condensate traces in the gas to be analyzed, before
it reaches the analyzer. Heating time about 20÷30 minutes. If after that time the alarm remains on,
check the possible causes: check the protection switch.
If after 20 minutes the alarm doesn’t stop working it means that you have to check the functional parts
of the cooler (gas circuit, valves, etc.). Contact our technical support.
• Condensation detected Alarm: this alarm starts because there is a presence of traces of moisture at the
exit of the cooler. This fault automatically blocks the analysis cycle and then the suction pump. Check
that the switch breaker is correctly inserted inside the analysis square. If it works well try to check the
functionality of the suction pump.
If the problem persists, contact our technical support.
• Ultramat Analyzers Alarm: it happens when the analysis instrument has some errors on the OFFSET or
on the amplification. Check with the handbook, the type of error and try to eliminate it. Note that the
instrument has a diagnostic menu that explain clearly the cause of the alarm. In case of difficulty contact
our technical support.
• NOX alarm: signals that regulated temperature has not yet reached the set value. A deviation larger
than ±20°C from set-point will result in alert. Heating time expected: about 20 minutes. If after this time
period the temperature is not approximating the set-point value, check that the solid relay is working
correctly (into NOx rack). If it’s working, turn off the power supply and measure the resistance in the
NOx converter (approx. value 200_). If the problem persists, contact our technical support.
• Low flow alarm: alarm signal active in the presence of blocking alarms mentioned above
• Hight temperature cabinet alarm: active high temperature alarm signal inside the cabin (35 ° C). Check
the functioning of the installed air conditioners and possibly decrease the temperature setting
.
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SOLWARE
4D1 2 BOX Box temperature controller which allows to set the temperature of the
TEMEPRATURE heated line and gives alarms if the temperature is ±20°C of the set-point.
Normally the temperature set is 120°C.
60H1 30 ⚫ ZERO Four position selector. On MEAS the CEMS is in aspiration and
CALIBRATION measurement of the chimney smoke. In SPAN1 solenoid valve relative to
SPAN1 input IN 3 for SPAN calibration is open. On SPAN2 solenoid valve relative
SPAN2 to input IN 4 for SPAN calibration is open. On ZERO solenoid valve
MEAS relative to input IN 2 for zero calibration is open. The switch doesn’t
calibrate the instruments, but it’s useful to check if the analyzer needs a
calibration or not. To calibrate the analyzer you have to follow the
analyzer instruction.
60H2 25 ⚫ ZERO light activates when the selector is on ZERO, at the analyzer the incoming
CALIBRATION air from IN2 is brought
41S5 28 ⚫ SPAN light activates when the selector is on SPAN1, at the analyzer the incoming
CYLINDER 1 gas from IN3 is brought
41S5 22 ⚫ SPAN light activates when the selector is on SPAN2 at the analyzer the incoming
CYLINDER 2 gas from IN4 is brought
42S2 8 ⚫ CALIBRATION PROBE Two positions selector. If turned left (OFF), it means that the calibration is
OFF ON done by the cabinet. Turn it right (ON) to start a calibration managed by
the probe
60H4 18 ⚫ GENERAL Active in case of alarms referred to in the previous paragraph.
ALARM
41S8 12 ⚫ MAINTENANCE During the maintenance of the cabinet, the data from the analyzers may
OFF – ON be not valid. In this condition switch to “ON” position to give a signal to a
data acquisition system or similar (not included with the analysis cabinet).
6 Not used
VS2 2 FLOW REGULATION manual valve for regulating the flow of gas entering in the CO2
VALVE CO2 O2 O2 analyzer - Standard flow = 1,2-1,5 l/min
VS3 3 FLOW REGULATION manual valve for regulating the flow of gas entering in the NO
VALVE NO analyzer - Standard flow = 1,2-1,5 l/min
VS4 4 FLOW REGULATION manual valve for regulating the flow of vent gas in bypass
BYPASS
4 ANALYZERS CALIBRATIONS
The analyzers carries out an automatic calibration during the warm-up phase following switching-on. This
AUTOCAL adjusts the zero point and sensitivity of the IR channels.
A periodic zero calibration is also provided according to the time cycle set on the analyzer (see point 8.2 of
the analyzer manual).
In the case of analyzers with a paramagnetic O2 sensor, the input menu can be used to select whether the
AUTOCAL is to be carried out with air or N2.
The calibration inputs are positioned inside the pressurized panel. They are shown in the image below:
In this function you can use one or more calibration gases to calibrate the IR channels of the ULTRAMAT 23
and to readjust the zero point and sensitivity. In addition, you can calibrate the oxygen sensor and the
pressure sensor and also define the AUTOCAL parameters. The Fig shown below indicates the menu
sequence for an analyzer. The menu displays and their functions are described in the following sections. The
calibration functions can only be addressed if you have enabled code level 1.
This is the time between two AUTOCAL procedures triggered automatically by the analyzer. Valid cycle times
are from 0 to 24 hours. A cyclic AUTOCAL is not carried out if 0 hours is set. The fourth line indicates when
the next AUTOCAL will take place. If the flow during a cyclic zero adjustment is too low, this adjustment is
aborted and a fault is displayed. This procedure is entered in the logbook.
• PURGE TIME: Use this function to set or change the purge time. This is the duration of flow with sample
gas during an AUTOCAL procedure. Following calling of the purge time you can set or change the purge
time in the second line of the menu display. Valid purge times are:
o 60 to 600 seconds for analyzers with oxygen sensor
o 0 to 600 seconds for all other analyzer versions
• Connect a calibration bottle with known concentration to the inlet IN 3 or IN4 on the panel.
• Inject calibration gas with a flow rate of 1 ... 1.2 l/min
• Select the menu on the analyzer: Calibration: Infrared measuring range: Set span gas values
• Total cal.(raccomanded): In the first line of this dialog, you can select either a total or single
calibration. – ON means that one range is calibrated and that this calibration is used for the other
ranges (total calibration). – OFF means that each range is calibrated separately (single calibration, e.g.
with different calibration gases).
• With AUTOCAL: You can define here whether you wish to carry out an AUTOCAL prior to the
calibration procedure (YES or NO). An AUTOCAL is not necessary if it has
already been carried out shortly before the calibration procedure, e.g. a
calibration procedure has taken place directly previously.
• Span1, Span2: Here you can enter the setpoints for the individual
measuring ranges. These are usually the concentrations of the measured
components in the respective calibration gas. They should be set to a value
which is between 70% and 100% of the full-scale value. If Total cal.: ON has
been selected, the analyzer automatically uses the setpoint of range 2 for
range 1. With Total cal.: OFF any input is possible between the start-ofscale
and full-scale values of the respective range.
The analyzer interrupts the current measurement if you call one of these two
dialogs.
The values of the setpoint and actual-value calibrations are displayed in the
first two lines. If the analyzer recognizes a flow of calibration gas, the display changes as shown.
If the measured value in the second line remains constant for more than approx. 10 s or does not change
significantly, press the key.
The analyzer then compares the setpoint and actual value (measured value) of the calibration. If the
deviation between the values is within the tolerance, the adjacent message 'o.k.' is output.
If the actual value deviates by more than approx. 20% from the setpoint determined in the factory, the
message 'not o.k.' appears instead (no calibration possible).
NB: pay attention that the selection of the SPAN cylinder must correspond to the parameter to be
calibrated
• AUTOCAL O2 sens.
– YES (factory setting): The zero point or sensitivity of the paramagnetic oxygen sensor is set with each
AUTOCAL. Selection of zero point or sensitivity is carried out using the parameter in the 2nd line
'AUTOCAL with N2'.
– NO: No calibration of the paramagnetic oxygen sensor during an AUTOCAL.
• "AUTOCAL with N2"
– YES: The AUTOCAL is carried out with nitrogen, where the zero point of the sensor is calibrated.
– NO: (factory setting ) No calibration of the paramagnetic oxygen sensor during an AUTOCAL
• "Calib. O2 zero point" This function is used to calibrate the zero point of the paramagnetic sensor
• "Calib. O2 range" This function is used to calibrate the full-scale value or sensitivity of the paramagnetic
sensor and to set the setpoint.
You can calibrate the zero point of the paramagnetic oxygen sensor using this function. You must use
nitrogen as the zero gas (e.g the calibration bottles). Start the flow of nitrogen and wait until the displayed
value has stabilized. Subsequently begin the calibration by pressing the key. Calibration of the zero point
must be carried out regularly to guarantee the accuracy of the paramagnetic oxygen sensor.
You can calibrate the sensitivity of the paramagnetic oxygen sensor and set the setpoint using this function.
Functions
Component SET
Conditioner 1 Temp 28°C
6 MAIN MAINTENANCE
This chapter describes the recommended replacement parts and maintenance operations to be done
periodically to keep the system working without problems.
For more information about the maintenance procedure please consult the components user
manuals