SICK Sensor Intelligence. SMC-9021 Continuous Emission Monitoring System (CEMS) Operating Instructions Emission Monitoring SICK MAIHAK (Beijing) Co., Ltd.Content 1. Safety information. 4 4.4 Application objective 4 1.2 Authorized operator ...n0- 4 1.3 Safety rules and protection measures. 4 7 7 2. Product description 2.1 Property and application 2.2 Working principle and measurable variables. 9 2.3 Components. ne : 10 2.4 Product configuration. i 4 2.5 Technical specification... 12 3, Assembly and installation 3.1 Prerequisites for Assembly and Installation 15 3.2 Assembly.... eee 16 3.3 Installation fa 18 4. Initial start-up and parameter settings 44 General 22 4.2 Manual mode 22 4.3 Automatic mode... 25 4.4 Parameter setting... i 25 5. Maintenance 5.1 Genaral e 28 5.2 System dally maintenance 28 5.3 Infrared analyser maintenance 2 31 5.4 Individual equipment maintenance H 33 6. Trouble shooting .. 6.1 Trouble-shooting for sample probe. . Enos 6.2 Trouble-shooting for complex heating sampling pipe 36 6.3 Trouble-shooting for cabinet. 2 36 6.4 Trouble-shooting for other devices. 38 6.5 Trouble-shooting for DAS system 38 6.6 Alarm and malfunction information. 39 7. List of spare part... 7.4 Spare parts delivered with system .... at 7.2 Optional spare parts. ares at 7.3 Standard installation parts 42 7.4 Standard apparatus. : 42In the SMC-9021 Continuous Emission Monitoring System (CEMS), dust and other variables (such as Flow, Pressure, Temperature, Humidity, etc) can be monitored respectively, of which the measuring principles may vary due to different transmitter/sensor selected, we will not introduce these transmitter/sensors here in detail, please refer to their respective manual for how to operate and maintenance these transmitter and sensors. an eee etre or ee neeeneg memento foe FL MPa a ayer) et my eo pe jeer pee et me 1. Safety information 1.14 Application objective ‘The SMC-9021 Continuous Emission Monitoring System (CEMS) is specially used for flue gas emission monitoring. Maintenance must be carried out by acknowledged experts only. Please especially pay attention to the following points: ~ Operation and maintenance work should be done strictly following 1) the procedures mentioned in this manual; 2) the equipment parameters; 3) installation specifications and work condition requirements (refer to drawings, nameplate, other project documents) - Provide all the measuring data needed, such as data for maintenance and measurement 1.2 Unauthorized operator Comply to following regulations strictly, make sure the physical safety: - Operations should be performed by the authorized personnel. Operators should be qualified by experts (training, education and experience) and should be familiar with the system standards, accident prevention regulations and with the system characteristic. Moreover, he must be able to make timely judgments and take ‘emergency actions to avoid potential risk in time. Operators should be familiar and passed Industry standard of DIN VDEO105, IEC 364 or other equivalent standard. - Operators should know the possible risks during operation, such as hot, toxic gases, pressurized gases, gas-liquid mixture and other media. The operators must have received special training regarding these matters. 1.3 Safety rules and protection measures. Incorrect operations can lead to personal injury or equipment damage Please read this chapter carefully and strictly observe the SMC-9021 safety protection regulations as well as the warning tags in the instruction: = Following the safety rules and operation instructions before installation and ‘commission. - Consider cateful the working conditions and the environment during operation, prevent potential risks - Master the Operating Instructions and other documents, and observe the precautions in the document, to prevent equipment damage and personal injury - Wear suitable safety clothes to prevent potential personal injuryWARNING ‘COTTON 1.3.4 Power supply safety ‘The SMC9021 uses industry power supply (3-phase, 380VAC); system must be powered off during power supply connecting and parts replacement. 1.3.2 Dangers caused by hot, corrosive or pressurized gases ‘The sampling probe is installed directly on the stack. Refer to Operation Instructions and Safety Rules and ensure personnel safety during probe installation. warning: In order to prevent potential risk, dangorous sources ~such as toxic, overpressure, ‘overheat or explosion gas- must be shut off before replacing system parts. 1.3.3 Inspection and malfunction prevention During normal operation, any abnormality should be regarded as potential problem. ‘Special attention should be drawn on the following (but not limited to those points): - Over-range drift of measuring value - Sharp increase of power consumption = Temperature increase of system parts, = Trigger of the monitoring equipment = Abnormal vibration / abnormal loud noise of fan = Smoke or abnormal smell 1.3.4 Switch off, pause and store The whole system should be stored in a clean and dry location if the power is longer off than 7 days. 1.3.5 Symbols WARNING ‘Warning Toxic WARNING Warning: Hazard by voltage WARNING Hazard by explosive or combustible gases ‘CAUTION Hazard (general) ‘CRUTION Caoution: Hazard by voltage fy) Caution for this device © Important Notice cr) LLink to other information WARNING Warning of explosive substances /mixtures Electricity waming of this device @ ‘Supplemental information @ TipsSMC-9021 Continuous Emission Monitoring System for Flue Gas 2. Product Description Property and application Working principle and measurable variables Components Product configuration Technical Specification 2. Product Desc: 2.1 property and application SMC-9021 Continuous Emission Monitoring System for Flue Gas (CEMS) is designed according to the requirements of the National Environment Protection. SICK AG is one of leading companies in Analytical instruments, SMC-9021 CEMS system has been tested and approved by China's National Environment Protection Bureau (CNEP8), following Certificates have been awarded by CNEPB and other China's Institute Certificate License No China Metrology Certificate jlooo00234 State Environmental Protection Administration Certificate HR-157 Certificate from Apparatus Test Center of CNEPB Certificate of Environment Protection Product No.2007-018 CCAEPI-EP-2005-103 ‘SMC-9021 CEMS system complies with following regulations as well: 4) HJIT75-2007; 2) HNIT76-2007 Developed by SICK MAIHAK (Beijing) Co., Ltd., SMC-9021 CEMS is mainly used for online emission monitoring of Flue Gas, Different components can be selected (S02, NOx CO, 02.7, P, dust (mg/m*), humidity, etc) to meet different requirements. Measured data ‘can be transmitted via communication module (Modem, GPRS, CDMA) to Environmental Protection Office (EPO). SMC-9021 analytical system has been applied and adopted in various fields such as Continuous Emission Monitoring of Flue Gas, Desulfuration, Denitrogenation, CDM etc.epMaA 2.2 working principle and measurable variables SMC-9021 CEMS utlizes Extractive sampling method to extract flue gas from stack, via sampling probe, sampling line, pretreatment unit, finally transported into. Infrared Gas Analyzer. Concentration of measured gas components will be measured and displayed on front panel of Analyzer. Other pretreatment functions such as Back flushing, calibration, alarming can also be conducted by pressing related button on the front panel of cabinet, Particulate measuring can be performed by FW320 dust hunter ~one of SICK's leading product in the world. Other contamination components of Flue gas can be measured by other Gas Analyzer which can be housed in a similar cabinet as SMC-9021 CEMS system. a a CY — | y g r > E » 2.| fa = =o) g i La g — ee Nd 5 4 Zanes hireatecton ] B | e aS a tiem | 2 op >| E . >Hi press} 3 ie Real-time value and historical data can be fetched into and displayed on SMC-900 - the DAS system developed by SICK China. Various data report (daily / monthly quarterly report) can also be generated and printed out from SMC-900 DAS system, With Modem, GPRS, CDMA devices, real-time value and historical data can be transmitted to Environment Protection Administration from DAS system. 2.3 Components 2.3.4 Sampling unit Type Manufacture ‘SMB-202 SICK China P2000 M&C, Germany 2.3.2 Sampling line Type Manufacture ‘SMB-203, complex heat tracing pipe SICK China Obrien USA 2.3.3 Pre-treatment unit Pretreatment unit of SMC-9021 CEMS system contains: = The dimension of 2100*800x800(mm) - Filter, cooler, sampling pump, flow-meter- Calibration system (electromagnetic valve, pressure-regulated filter, span gas, etc) - Drainage system (peristaltic pump. drain tank, ete) - Back flushing system (electromagnetic valve, compressed-air tank, etc) = Power distribution & Control system ( PLC, 24V power supply, power switches, terminal blocks, etc ) 2.3.4 Gas analyzer $700 (SIDOR) series infrared gases analyzer have been used in many places with its newly modular design. Various components could be measured (such as $0, NOx,CO, O,,¢tc) 2.3.5 Particle monitoring unit FW300 Dust concentration measurement of — SICKMAIHAK 2.3.6 Measurement of other devices and DAS Velocity of flow measurement Pressure transmitter ‘Temperature transmitter Humidity transmitter ‘SMC-900 Data system 2.4 Product Configuration (1) Sampling probe 1 set (2) Complex sampling tube 1 set (3) System cabinet ‘Sampling gas pretreatment unit 1 set Back flushing unit 1 set Calibration unit 4 set ‘Analysis unit 1 set Control and data processing unit 1 set The above units make up of Gaseous Contaminant Monitoring System which could compose of CEMS with some optional parameter measurements as follows: © ¢ Dust density measurement 1 set Flow velocity measurement 1 set Pressure transmitter 1 set ‘Temperature transmitter 1 set Humidity transmitter 1 set SMC-900 DAS 1 set 2.5 Technical specifications Variables measured "” Gaseous contaminant ‘$02, NO, 02, CO, can be selected as needed Measuring range ‘Can be adjusted as real needed Measuring accuracy #1% Response time 7 <60s while the length of complex tube <30m. Application condition ‘Ambient temperature Qutdoors:-20-+50Degree C; Indoors:5-+35 Degree C Temp. inside the stack gas temperature =300 degree C Pressure inside the stack #10Kpa Signal connection Analog output Isolated output: 4-20mA; Maximum resistive load 7500. State Signal: Running, malfunction, back flushing, calibration, Relay output measuring range switching, etc; load capacity:48V, 1A Interface RS-485, for communication with DAS: Power supply” ‘SMB-202 sampling probe ‘220VACISOHZ —_ S00W ‘SMB-203 sampling tube 220VACIS0Hz _ 40wim ‘SMC-9021 cabinet 220VACIS0Hz 1000 ‘SMC-900 DAS: ‘220VACIS0Hz —_ 500W Dimension (width x height x thickness ) SMB-202 sampling probe SMB-203 sampling tube external diameter 263; number of tube and pipe diameter 2-08 SMC-9021 cabinet 2400*800%800 (mm) ‘SMC-900 DAS Host computer: 500*500*300 (mm) _display:17" | Weight ‘SMB-202 sampling probe 212k ‘| ‘SMB-203 sampling tube kgm ‘SMC-9021 cabinet 2300kg ‘SMC-900 DAS 220kg (Host computer, monitor, etc) [Others x Protection level Local equipment: IP65; System cabinet: [P45 Instrument gas (0.4~0.6Mpa, 50L/min (back flushing) requirementNote: C4 WARNING For technical specifications of Dust monitor and other auxiliary devices please refer to related User Manual 2) Response time is related to the length of complex tube, Advance clarification is needed for special application. “Power consumption does nat include dust monitor and other auxiliary devices. ©! Gas consumption does not include dust monitor and other auxiliary devices. This CEMS cabinet is forbidden to use in an explosive locations. SMC-9021 Continuous Emission Monitoring System for Flue Gas 3. Assembly and installation Prerequisites for Assembly and Installation Assembly Installation3. Assembly and Installation 3.1 Proroquisites for Assembly and Installation Information in below table provides details needed to be taken in order to guarantee proper installation and system performance, You can tick items needed from the table Task Requirement Procedures Mark | Identify sampling point and measuring point Reserve sufficient length for inlet and outlet, atleast Round and square Pipe: Dhediameter of pipe 3x'diameter’(Dh) Rectangular pipe: Dh=4xcross section / perimeter select a optimal Fixing point, if the inlet are too short, make sure that inlet >outlet Flow distribution of Flue Gas uniformity ‘Typical distribution of flue gas I possible, the pipe doesn't bend, Uniform cross-section area, no other parts at inlet and outlet ‘Make sure cross-section area to meet the requirement; select a optimal Fixing point Fixing point of ‘Sampling probe Don't fix on the bottom of horizontal stack select a optimal Fixing point The place easy to approach and should be protected accordingly Equipment should be installed in a location safe and easy to approach Platform should be provided No vibration at | installation point ‘Suitable measures: should be taken to eliminate/reduce vibration ‘application condition Refer to “technical parameter’ limit if necessary, equipping with protection cover; shieldingjisolating units from damage Select analytical cabinet, location Analytical cabinet should locate in the shelter, approaching to the probe and lower than it ‘Analytical cabinet can be located by weight of itself, or use the mounting holes under the cabinet Inside environment of shelter Refer to “technical parameter’ limit Clean gas source Low dustiness, without oil, moisture and corrosive gas ‘select a optimal inlet RUTION Minimal bend radius is 0.5m. From sampling Sanh probe to Gas Analyzer, the incline degree of complex sampling line should be higher than 19% Easy to approach | Convenientand safe | Providing platform Resorving rack er Try fo shorten the | no interfere with | keep enough distance Distance between | probe between the Environme Ne | this. reserved port measure point and watchdog | ord measure reserved port point (around 500mm) Plan | Power supply meet | Refer to paragraph | Guarantee 1) the power | requirement 25 “technical | cross-section area of supply parameters" power cable is big enough; 2) fuses capacity ‘CAUTION if other devices were installed, please consider their installation requirement in addition, 3.2 Assembly Following assembly work should be prepared and conducted: ~ Flange (with bushing) installing + Power cable/signal cable wiring = Sampling line installing Warning: 1) 2) 3) Safely rules and safety instructions in chapter 1 should be abided during installing and assembling, Dangerous sources should be shut off in dangerous location (high temperature, corrosive and explosive gases, high pressure inside stack) Suitable protection measures should be taken while operating in dangerous areas.‘CAUTION 3.2.1 Install flange with attached pipe Procedures ~ Affirm and mark installing point - Remove the seal (if have) Make a suitable hole on stack (refer to flange diameter) Note: Be careful not to drop parts into stack! ‘Stool Stack brick stack rd pee a = Peas Al sae Ta Fig 3.1 Flange (with attached pipe) installation thin-wall stack @ Insert flange (with pipe) into stack, pay attention to the position of fixed hole(Fig 3.1) © Weld flange into stack (Fig 3.1) © Seal flange holes quickly to prevent gases from leaking once installation completed @ IFpossible, heat preservation measures can be taken for parts exposed in air. 3.2.2 Assembly of complex sampling pipe Routing and mounting of sampling pipe: ‘Sampling pipe can be laid out in the power cable tray, but need to seperate from power cables. Sampling pipe should be fastened with cable tray every 2m in horizontal direction and every 1.5m in vertical direction, the minimal bending radius is 0.5m. in order to extend life time of sampling pipe please try to avoid the direct sunlight. From sampling probe to Gas Analyzer, the incline degree of complex sampling pipe should be higher than 1%, Or Binding sampling pipe with a steel rope, and fixing the steel rope on stack. Special measures need to be taken to guarantee the sampling pipe will not be scratched by stack wall ‘Sampling pipe and span gas pipe need to be back flushed at least 2 or 3 times before connecting into the system, a leakage test for the whole system must be conducted after these back flushing ‘WARNING 3.2.3 Assembly of system cabinet System cabinet is recommended to locate inside shelter where there is no strong electromagnetic and no mechanical vibration. In order to shorten response time system cabinet location should be as close as possible to the sampling point. The cabinet can be located by itself’s weight or by 4 bolts (M14) fixing on steel supporting baseplate. ‘Schematic figure of Cabinet fixing hole Ventilation pipe needs to be installed on the top of cabinet to ensure exhaust gas flow out into air Warning: exhaust gas may be toxic 3.3 Installation 3.3.1 Electric wiring 3.3.1.1 Electric wiring for probe Connecting PIN 1, 2, 3 of terminal block of probe to phase N, PE, L of power supply (220VAC) > 1 it 15 for probe's temperature state, PIN 4 and 5 will keep |---| Je] close when the temperature of the probe does not, reach preset target, and wil turn to open if the temperature reach preset target. (this signal is optional) i PIN 4 and 5 of terminal block of probe are DO signal = Ht) 3.3.1.2 Electric wiring for system cabinet 3.3.1.3 Power supply of system cabinet 2 set of Power supplies (220VAC) are provided for cabinet, e nr ne is for system (pretreatment system, control functions, apparatus, UPS 220VAC! S0HZIO00W ete), phase L.N,PE connect to PIN L.N,PE of terminal block X10.Another power supply (220VAC) is for Sampling pipe.(220VAC, 50Hz, 40Wim), phase LIN,PE connect to PIN L,N,PE of terminal block X20. 3.3.1.4 Signals of system cabinet Terminal board X41 REL: relay output; system running state ¥ 7 REL2: relay output; system data holding REL3: relay output; system back flushing state iF if fe) fel Of REL4: relay output; system calibration state 2 oe Is bods iDGS rau pela EL eu xt Terminal board X2_ to DCS woe as sl 25 OUT1:4-20mA SO, 3 Gopeh z OUT24~20mA CO ail OUT3:4~20mA NO. fe) OUT4:4~20mA O {eo sate No output signal if the gas component is not be measured) i ; Terminal board X38. to. DCS eu an new at REL1: relay output REL2: relay output REL3: relay oulput RELA: relay output No output signal if Gas Analyzer has no such function Terminal board X4 and XS are spare terminals Terminal board X7 IN4: 4~20ma, IN2: 4-20mA, INS: 4-20mA IN4: 4~20mAa, No input signal if these variables are not measured, Terminal board x9 OUTI: 4-20mA OUT 2: 4~20mA OUT 3: 4~20mA OUT 4: 4-20mA ‘No output signal if these variables are not measured. measuring range switch! measuring range switch2 % 8 spare wl i nok : L spare book ss i From working field t Dust Flow i el ‘Temperature rg Pressure | iT ure topes (4) Dust ey Flow a Temperature 1 Pressure : -_ WARNING Terminal board Xé From working feld wat pea ma INS: 4-20mA Hor02 “h a REL1: relay output Dust fault alarm [ REL2: relay output —_ spare REL3: relay output spare No input signal if these variables are not measured, x8 Terminal board XO toDcs mus. Lt wale a OUTS: 4~20mA H aaa a 3 B REL1: relay output Dust fault alarm iF 7 fl © REL2: relay output spare siete] x= Aa Aouad stoped ys de REL3: relay output spare | | No output signal if these variables are not measured xo Tetminal board X6 to working field meu fez a en RELI: relayoutput spare 3) md C= REL2: relay output equipment control 4 f ca of fe te cH fe + a REL3: relay output equipment control 2 pedaccbs We clsteete pr x6 Above introduced Input and Output signals of SMC-9021 CEMS system. Please refer project drawings for details. 3.3.2 Installaion of span gas cylinder ‘Span gas cylinder with relief valve need to be fixed on a suitable supporting rack and close to cabinet as much as possible. Attention: 1) Leak Testing should be conducted after installation completed 2)Span gas ma be toxic ,be cautious while operating,4. Initial start-up and parameter settings 4.1 General SMC-9021 «14 Poromt 1) Make sure electronics components are connected properly before startup. Continuous Emission Monitoring System for Flue Gas 2) Make sure pneumatic circuit are properly connected before start-up. Attention: Check Safety rules and earth conductor before system power on! 4.1.2 System power on Following below procedures to power on system: 1) Power on Sampling probe 2) Power on Sampling tube, 3) Switch on Main power supply in cabinet. power on Condenser & PLC & Sampling pump in sequence. Waiting few minutes for Condenser until targeted cooling temperature was reached (normally 2— 5 degree C) 4) Power on S710 gas analyzer, waiting few minutes for preheating and initiation. 5) Power on DAS computer. 6) Power on sensor (including Dust monitor, flow meter, pressure sensor, temperature transmitter, etc.) 4. Initial start-up and parameter settings General 4.1.3 Alarm troubleshooting/checking ‘After system power on, some alarms may occur and be displayed on Analyzer’s panel or on DAS computer, effort needs to be taken to solve the issue. Manual mode Automatic mode i Function test can be conducted if information (read from Analyzer’s panel and DAS Parameter setting computer) is OK. © ¢ 4.2 Manual mode Manual operation can be conducted by push buttons on front panel of cabinet (Manual operations also can be carried out on DAS computer), Following function can be performed by Manual buttons: Power LED State (Manual/Auto), Manual sampling, Manual back flushing, Manual calibration, Alarm System will be in Manual mode after the system start-up, Power LED will ight, allother push buttons are in up-position. Following functions can be conducted: 4.2.4 [Manual/Auto] switching Initial state is Manual mode (indicator is blind), pressing button [Manual/Auto] into ‘low-position’, indicator wil light and system switchs into Auto Mode. In Auto Mode, manual buttons are invalide. Manual buttons are invalid in Automatic Mode. 4.2.2 Manual sampling If the button [manual sampling] is pressed system will be in sampling mode to ‘examine whether the system sampling function is working well.In this period ,you can observe and adjust flowmeters to make gas flow meet requirment. Most of the cases,ajust sampling gases flow to 0.5 l/min, let excessive gases out from bypass. If gas flow does not meet requirement (0.5/min), then you need to examine the leakage of pneumatic tubing connection and deal with it. The chekcing sequence would be: sampling probe, probe filter element, sampling pipeline and sampling pump, condenser. 30 In this state, system alarms are valid except flow alram, please clear alarms before proceeding 4.2.3 Manual back flushing Pressing the button [manual back flushing] , the system will carry out the function of ‘manual back flushing to purge the pipeline and probe fitter element. There are two steps in this process. the first step is inflating ,then back flushing Two sampling lines can be back flushed by cooperating with {manual back flushing] button. ‘The function of Charge is carried out when charge valveCY1.2)is switch on. Compressed air is forced into the air holder, after 30 seconds (can be set up in the program) back flushing valve CY1.1) switches on. Before that, system is checking the state of sampling valve and other alarm statas (gas flow alarm is shielded). [1] 4.24 Mansa alibration 30% check up the balance gas N2 before manual calibration. Pressing bution [manual calibration} (indicator light will light). Choosing the component needs to be calibrated by pressing the corresponding button, Usually, the first step is to calibrate the zero point of standard gas. Press the button{ N2]. ValveCYt 4 will switch on so that balance gas Nz can be supplied to gas analyzer. In this case, gas flow can be adjusted by flow meter to meet requirement (gas flow indicator of the analyzer shows normal), then zero point calibration of analyzer can be carried out. Calibration | N, $0, NO OQ; CO/cO2 Press the button [N2] to Retum to the original state after zero point calibration( light off), then Gas Valve N2(Y1.4) switch off. Until now, zero-point calibration has been down. Below steps show how to perform span gas calibration: Step 2: Pressing button (O21 , Air valve (1.3) will switch on and sampling pump will startup, air pump abstract alr, when gas flow meets requirement of analyzer, span calibration can be carried out upon O2 module. After that, pressing the [O2] button ,gas valve 02 (Y1.3) will switch off and system returns to original state. Step 3: Pressing other Component buttons, the related component gas can be imported. Span calibration can be carry out in the analyzer and gas flow requirement also needs to be met in the process.Switch off the standard gas after calibration completed since it may be harmful to health. Special care is needed. After these procedures, return calibration button to original state by re-pressing button [manual calibration) Repeat above operations if you want to calibrate again \: Flow alarm is shielded during manual calibrating, that means operator should regulate a8 flow manually since no flow alarm will pop-up. 4.2.5 Remindings in Auto Mode 4.2.5.1 If more than two buttons are pressed simultaneously, the first pressed button will be performed, other buttons are invalid and of which the indicator will blink to remind operator that the operation is invalid, and need to be returned to ‘up-position! 4.2.5.2 In order to avoid malfunction new function should start and conduct after last function completed, 4.2.5.3 Auto Mode has top priority, meaning, Manual function will be interrupted and auto functions begin to start as soon as system switched into Auto Mode. Manual function will become invalid and related indicator will blink to remind reset fO6 If manual function indicator stil blinks after system switched back to Manual Mode, lease resot i 4.254 Any Manual function cannot be conducted in Auto Mode, and will be treated as invalid (the related indicator will bink) if Manual function button was pressed. Please reset the function if inthis case. 4.2.6 SMC-9021 DAS system With DAS system, Manul Funtions can also be carried out on screen display on DAS compouter. & System should be switched in Auto Mode if you want to operate functions on DAS screen display. 4.3 Automatic Mode System will switch to the Auto Mode if button {Manual/Auto } is pressed into ‘Low-position’ and the indicator becomes light. Following functions can be conducted in Auto Mode! ‘Auto sampling, Auto back flushing, Auto calibration, Auto alarm, etc. Additionally, SMC-9021 DAS system can transmit data to other DCS systems. | j 4.4 parameter setting 4.4.1 Set Interval for function of Auto Back Flushing: The Interval of Auto Back Flushing is related to operation condition such as dust concentration, temperature, humidity, ete. Generally Speaking, Auto Back Flushing is unnecessary if dust concentration is lower than < 50mgim*, the only thing needed to do is to replace probe filter every month. ® Interval of Auto Back Flushing according to Terminal block X15 is as following: : ® When X15-5, X15-6, X15-7 is not connected, Auto Back Flushing iS disabled. ® When X15-6, X15-7 connected, Function of Auto Back Flushing is enabled, internal is every 1 hour. ® When X15-5, X15-7conected, Function of Auto Back Flushing is enabled, interval is, every 6 hours ® when X15-5, X15-6, X15-7connected, Function of Auto Back Flushing is enabled, interval is every 24 hours Dust concentration (dry) | Toscktusting | Interval for probe filter replacement 50mgim® ~— <600mgim? | 24h According to. actual operation condition 3 | =500mgim® <5000mgim* | én ‘According to actual operation condition 4 | >s000mgim® th ‘According to actual operation condition Parameter seltings here are only for your reference, real parameter setting may vary according to actual operation condition. 4.4.2 Settings for function of Auto Calibration: © When X15-7, X15-8 disconnected, Auto Calibration is disabled ® When X15-7, X15-8 connected, Auto Calibration is, Enabled, default Interval is 24 hours. Note:(DAuto Calibration is optional function, and should be specified in Purchase | order if needed, Special care is needed for Auto CalibrationRO ate ee ye gehen gc sem er me eee SMC-9021 Continuous Emission Monitoring System For Flue Gas 5. Maintenance General System daily maintenance Infrared analyzer maintenance Individual Equipment maintenance 5. Maintenance 5.1 General Daily maintenance is a crucial job which insures safety and stable running of SMC-9021 CEMS system. From maihtenance point of view, preventive maintenance is always better than corrective action when issue happened CEMS system daily maintenance job contains: 1) patrol inspection; 2)periodic draining and cleaning; 3) heat preservation and heat tracing; 4) troubleshooting Interval of “daily maintenance” Interval time of maintenance - which is affected by dust concentration, type of dust, sampling gas temperature, programs developed and field environment - is set up by operators. Hence, this parameter setting should follow experts’ advice. Generally speaking, system maintenance should be carried out every 2-6weeks, and maintenance results should be documented. Maintenance protocol Periodic maintenance should be carried out by experienced operators, or this maintenance work can be contracted to SICKMAIHAK service team, SICKMAIHAK can provide out customer with professional maintenance services. 5.1.4 Patrol inspection > Checking system apparatus display and record (keeping in touch with operators to know system working status). > Checking power supply and gas source (including compress air, calibration gas). Checking heating strip inside sampling pipe. % Checking corrosion situation for components and connectors of pretreatment part, repair or replace defective parts. > Checking leakage for joint parts between CEMS system and stack v 5.1.2 Periodic draining and leaning Periodic draining and cleaning is not necessary for all parts. Maintenance period can be decided upon actual conditions. This task is mainly targets on sampling probe, sampling pipe, dust monitor, pressure! temperature transmitter, humidity sensor and so on. The measuring values will be affected direclly or indirectly since dust particulate, oil droplets will deposit in measuring pipe of these devicesaXNotice: (1) Before maintenance, related technologists and operators should be informed and certain permission should be gotten, (2) CEMS system should be put into Manual Mode, (3) Be careful for electric shock and high temperature during maintenance. (4) Seal al parts tightly after cleaning 5.2 System daily maintenance Periodic system maintenance is necessary to make sure proper running of SMC-9021 CEMS system, 5.2.4 Daily check-up The main task of daily check-up is patrol checking to find out systematic abnormity and solve it 5.2.1.1 Check up sampling gas flow volume before flowing into gas analyzer: ‘Sampling gas flow volume should be between 0.5 and 0.8L/min, and can be adjusted by needle valve on bypass line. It shows that sampling pipe has been blocked if adjusting needle valve still cannot drop back into the range, the common blockage cause Is probe filter, if this is the case probe fter needs to be replaced 5.2.1.2. Check up cooler’s temperature display Working temperature should be between 2 degree C and 5 degree C, if tomperature ‘exceeds this range, CEMS system shall be stopped immediately for trouble-shooting, otherwise Gas Analyzer may be damaged. 5.2.1.3 Inspection measuring value of Analyzer Aleakage is believed on gas line if the SO2 measurements show that measuring value is very low (or high oxygen content), suitable leak detection methods need to find a leak Point. If the system has no leak point and the measuring value is stil abnormal that Analyzer needs to be calibrated using the standard span gas 5.2.1.4 Check up the pressure of compressed air System may not work propery if the pressure is lower than 0.4 MPa. 5.2.2 Daily maintenance 5.2.2.1 Leak detection: Displayed value of Gas Analyzer is too lower, which may result from leakage of gas pipe. Leak testing should be conducted for the whole system. 5.2.2.2 During automatic sampling, disconnect the interfaces from the sampling pipe to thermostat valve box, block the import of gas import by hand, the system may have leak Point ifthe sample gas flow meter can not reduce to OL / min within about 1 minute. 5.2.2.3 Possible leak points and treatment: 1) The pipe in peristaltic pump is damaged. (The life of this pipe is about 1 year) Remove the peristaltic pump inlet and outlet connection tube, counter-clockwise twist pump pipe clamp and remove the pump tube to check if the pump tube is damaged, if so replace the pump tube. 2) Pneumatic connectors loose Check nut connectors, if loose, tighten the nut. 3} Plug the sampling gas inlet, startup sampling pump, it concludes that there is no leakage inside cabinet if low volume drop to 0.0 Limin within 30 seconds, and the leakage point should be inside sampling probe. 4) Generally, main cause for sampling probe leakage is poor sealing of filter element. Examine whether O-ring is distorted. If not, just tighten the bolt 5.2.2.4 Replacing the filter of sampling probe: robe since sampling Wearing heatresistant glove when replacing filer of samy ! probe has been heated to 130 Degree C during working, ‘Switch off the sampling pump before replacing tho probe filter! 41) Open the shield of probe, remove the heat preservation sleeve, anti-clockwise rotate the hose clip and take out fiter. 2) Grasp filter component, anti-clockwise rotate to loosen plunger ring, then split the filter element, 3) Cleaning the surface of filter 4) Replacing with new filter element according to above procedures in reverse direction 5) Examining O-ring of filter component; replacing the O-ring if damaged or there is damage or distorted. 6) Cleaning connection surface of probe 7) Assembling filter according to the ‘Arrow’ direction showing on filter surface, Tighten the bolt. 8) Assembling the heat preservation sleeve and cover the probe shield 5,2,2.5 Daily maintenance of other devices Daily maintenance for other devices please refer to related Instruction Manual5:2.3 SMC-9021 CESM system maintenance list tem Maintenance Task | tday | 7days | 30days | 120days | 180day 1 [Check up running) state of + SMC- 9021system 2 | manual calibration "for Y Zero point, measuring calibration cuvette 4 |The drainage of Water Y storage tank” 5 | Check up leakage of pipe 6 [Replace icheck up Y filter” 7 [Replacing pump diaphragm, peristaltic Pump tube” range 3 | Calibration for Y | | | system shutdown time exceeds 3 days, in order fo avoid water droplet enter into Gas Analyzer Back Flushing (in Manual Mode) should be conducted as soon as system re-startup. Remarks Calibration gas buying: Preparing to buy when gas pressure lower than (Ober, and stop using when gas pressure is lower than bar. Concentration of Calibration gas should be between 80% and 100% of full ‘measuring range, Note 1) increasing /reducing times if necessary Note 2) according to actual condition Note 3) according to actual condition Note 4) accorting to actual condition { 5.3 Infrared analyzer maintenance 5.3.4 Manual calibration for zero point and measuring range of infrared analyzer | Manual calibration of Infrared anal fre lyzer S700 (SIDOR) is (SIDOR) instruction in chapter 6.4 nee art Celbratonserametr stings ot iteted Inf analyzer $700 (SIDOR) is $700 (SIDOR) instruction in chapter 7.5.4. Pega 5.3.2 Zero point calibration 5.3.2.1 Carry out zero point calibration using (Nz) cylinder: Zero point calibration gas (N2) fr eo 9 from cylinder can calibrate zero point of all the First of all, press the button “state”, then, indicator light of “state” will shut off, system will ‘exit automatic mode (refer to:4.2.4 manual calibration) Adjust reducing valve of the calibration gas cylinder to make gas flow stay at 0.5L/min; enter S710 analyzer menu 42, input corresponding zero point number of standard component, start up zero point calibration by pressing button ‘Enter’, then operate according to the clue on the screen, Save the calibration result if done well or cancel the operation by pressing the button "Esc". 5.3.2.2 Carrying out zero point calibration using air: Attention: Air can only be used for infrared component zero point calibration. It can not be used as zero point calibration gas for 02 component. First, press the button “state” and the ‘Auto’ indicator light will tur off, in this case system cexit automatic running made. Then indicator light “calibration” will turn on, if the button “calibration” is pressed. Calibration gas flow is 0.SLImin; enter S710 analyzer menu 42, input infrared component zero point gas number 1. Start up zero point calibration by pressing button “Enter’, then operate according to the clue on the screen. Save the calibration result if done well or cancel the operation by pressing the button “Esc” 5.3.3 Measuring range calibration 5.3.3.4 Carrying out Infrared component calibration using gas eylinder: First, press the button ‘state” and the indicator light wil turn off, system will exit automatic running mode. Connect the calibration gas to “calibration gas inlet’, open the valve, then adjust reducing valve to make gas flow stay at 0.6L/min; enter analyzer S710 menu 42, input the calibration component number. Start up zero point calibration by pressing button “Enter, then, operate according to the clue on the screen. Save the calibration result if done well or cancel the operation by pressing the button “Esc” 5.3.3.2 Camying out Calibration of Oz. component measuring range using air. First, press the button “state” and the indicator light will tum off, system will exit automatic running mode. Then indicator light “calibration” will turn on, if the button “calibration” is. pressed. Calibration gas flow is 0.5Limin; enter S710 analyzer menu 42, input Oz component zero point gas number 6. Start up zero point calibration by pressing button “Enter’, then oparate according to the clue on the screen. Save the calibration result if done well or cancel the operation by pressing the button “Esc”. Attention: Check up calibration gas component before the job of calibration or it may cause malfunction. Press the button “Esc" if you find misoperation in the process; After the calibration process, the result is not optimal, display "z-drift #x. s-drift#x’ matfunction hint, you can get back to the menu 6942, and carry out calibration again. 5.3.4 Calibrating gas cuvette (refer to chapter 7.5.5) ‘Automatic calibration is using calibration gas cuvette - inside calibration source. Therefore, periodic calibration for calibration cuvette (every 6 months) is needed. First, calibrate zero point and measuring range of infrared component manually. Second, press the button ‘state’ and the indicator ight will turn off, system will exit automatic running mode. Then,ress the button ‘calibration’, the indicator ight will turn on. Calibration gas flow ought to be 0.5L/min or 50; observe the display of analyzer, on usually conditions, SO»,CO, NO is “0" and Opis "20.8", Enter 6327 menu, choose ‘check’ menu, input corresponding number, observe the display of analyzer until the value stable, Record every component value of UNOR/MULTOR, press the bution “ESC” back to menu 6327, display all he component data and input check value in the pull-down menu as new state, 5.4 Individual Equipment maintenance Maintenance of sampling probe (refer to: introduction of sampling probe ) Maintenance of Industry computer (refer to: introduction of Industry computer) Maintenance of other p equipments refer to introductions concemed. SMC-9021 Continuous Emission Monitoring System For Flue Gas 6 Trouble shooting Trouble-shooting for sampling probe Trouble-shooting for complex heating Sampling pipe Trouble-shooting for cabinet Trouble-shooting for other devices Trouble-shooting for DAS system Alarm and malfunction informationTO I ee 6.3 Trouble-shooting for cabinet ’ 6. Trouble shooting : Malfunction Possible cause Solution 6.1 Trouble shooting for sample probe phenomenon each i wuvanamuatle o Malfunction Possible cause Solution | power supply lost y dose not switch on ee oe | Power supply dos Check ON/OFF position for phenomenon in cabinet power supply switches itch z i 1) Power supply dose not switch on ae Favret ape ant | 1) Button (on | 1.Push Button broken Replacing push button | r 1) examining the short circuit ] front panel of |2.24VDC power supply damaged | Replacing 24VDC power aenetheatup —/2) Heating stip damaged inside | & bites | natin supply or open-circuit ‘Check wirin eae aarel cvcurred | multemeter, 2) replacing | function does | $24VDC power supply disconnected | Check wiring a the heating strip j not work block of probe | Poor maintenance Cleaning or replacing the And fiter probe filter 2) Channel block of probe | Dust concentration is fo0 high, effect | Cleaning indicator of all staff of Back Flushing is not good. 0 PLC input e i modules is Rancom ip oa | Shortens robe hecng by mutate at 2 Z switches Eee HT nvessary [1) Button (on | 7.PLC damaged Replacing PLC air switch broken Replace it 1). Bal load PLC program front panel of | 2 PLC program lost Downloar Brose 6.2 Trouble-shooting for complex heating Sampling pipe cabinet) function does Malfunction Possible cause Solution nat work phenomenon lana Wi 2) Some 1) Power supply dose not switch on ears Pee aa tx Channel do not heat u a i i ° |2) Heating stip damaged inside Examining it by mulizmeter, indicator : Identifying and eliminating sampling pipe replacing itif necessary. PLC Put] Alam ovoutred alarm is Cleaning: disconnect sampiing ne pipe from system on both ieee : sides, connect with Sault Block of pipe Poor maintenance cotrpesoed Inotaunent i d inser ie - camying out Back Flushing oer function, modules L bind 4) Button (on | 1.Devices controlled by PLC are front panel of | damaged cabinet) function does not work Replace damaged devices te 2) Some | 2.Power of devices controlled by PLC Channel _ | is lost indicator of PLC input modules Check wiringa ‘and ‘output value in calibration output environment, 2) if stil does not | modules work, return to factory for or is light, repair Leakage happened in sampling line, possible leaking point Signal isolator faut ‘Signal of Input and Output is Components before air pump, intake connector ferent Keo to replace, ‘Tube inside Peristaltic pump | Replace tube Signal cable misconnected Examine and modify it damaged ‘Measuring value drift since calibration | Calibrating analyzer Peristaltic pump installed incorrectly | reinstall ‘Abnormal is not carried aut for a long time Manual calibration valve stays on | Switching to ‘Close position to | | measuring data of | Analyzer chamber contaminated by | Retum to factory for repair Measuring value | ‘Open position’ for span gas cut off span gas S710 vapor is incorrect! Seal ring of sampling probe | Replacing seal ring / Analyzer parts damaged Retum to factory for repair S02, NO value | damaged | Cooker ‘Compressor fault Return to factory for repairit or looks lower or| Leakage happened on | Re Sealing performance drop | Cryogen leakage repair locally 02 looks | Back-Flushing connector | down = higher. Sampling magnetic valve 4.1] Replacing with new one : Temperature: temperature control unit fault Return to factory for repair damaged 0 . display show Leakage happened on sampling | Replacing with new one . under 0 degree C Magnetic valve Y1.1 Pump diaphragm damaged Replacing with new one 6.4 Trouble-shooting for other devices Connector of Negative pressure | Check, lighten or replace i loose or damaged Malfunction Possible cause Solution a phenomenon ‘Switch on power supply and fix Air pump diaphragm damaged Replace diaphragm Power supply lost rea re Air pump damaged Replace air pump Inlet diaphr of no measuring Examining by multi-meter and phragm of air pump | Replace inlet diaphragm Signals are not connected to terminal |e ae ight wire cece ce block or misconnected. ae 2Leakage happened on Sampling line, possible leaking point components behind air pump, connectors Device damaged Replace Manual calibration valve stays on | Shut off the calibration valve Poor maintenance ‘Conducting enamel ‘Open position’ for span gas He according to operating fats Sampling gas | Connector loose or damaged Check, tighten or replace @ ( Piao, sc stallion location imoroper era ee ear flow is too low corns ) one installation location Condenser alarm connector broken | Replace a} Device fault Handling as requirements 3.Sampling line blocked, possible points: probe filter Clean or replace / 6.5 Trouble-shooting for DAS system. "condensing eyinder————~—«dClean three-way electromagnetic valve _| Clean or replace if corroded Malfunction frossible cause Sree phenomenon Condering alam abow Cio or acs WF ced aa chon power supply and em DAS system can | Power supply correctly ; needle valve of flow meter blocked | Clean cen system damaged Return to factory for repair Display values | engineering range Setting is different | Modifying engineering range Measuring Data | Communication cable is loose or hike S232 communication are inconsistent | among $710, DAS and DCS ting, and mab cannot be | disconnect tong s7t0,| among S710,ORS =n OS tarefored tom | Emission mesurng data lacked | Check communication cable DAS and DCs Examining the analog output PLC to DAS | No measuring value of other devices, | Replace S710 analog output_channel failed. | channel, calibrating the analog system isolator damaged or PLC 10 module Debugging $770,damaged DAS system can Rot print report power supply lost ‘Switch on power supply and fix correctly ‘Communication cable disconnect Connect the communication cable tightly 6.6 Alarm and malt function information ‘Alarm information Possible cause Treatment water level alarm PLC M-1.0 port water level exceeds high limit in the water tank Drain out water and clean the sensor level sensor is contaminated Clean the sensor dew point alarm ‘There is vapor on the Dew point sensor Find out the reason and remove potential issues. | Otherwise it may cause PLC M07 port i So accident Dew point sensor is contaminated _| Clean the sensor ‘Temperature ‘Ambient temperature does not meet | Improve ambient temperature alarm: PLC M-0.4 port with requirement Condensed temperaiure does not meet with requirement Refer to 6.3 cooler Probe alarm: PLC M-0.6 port Probe temperature does not beyond limitation Refer to: 6.1 Equipment alarm PLC M-1.2 port Enter into analyzer menu, find out the cause of malfunction Refer to: 8700 (SIDOR) series modular gas analyzer manual chapter 11 Flow alarm: PLC MA1.tport Gas flow does not meet with requirement Refer to: 6.3 SMC-9021 Continuous Emission Monitoring System for Flue Gas 7. List of spare parts Spare parts delivered with system Opt Standard installation parts nal spare parts Standard apparatus7. List of spare parts 7.4 Spare parts delivered with system 2. There will be no SN 1~5,if sampling probe chosen ttom | Computer number name ref unt fauarty] supplement 1 | rorzzce eremic ter clement fosonize 1, bm-2025amping ue 2 7073553 [pring Gw3462.1-620 [7756.3 [piece] a bwe-202eamping und 3 | 773552 [Prine 6a5052.r220 f5:265 Joma] owe-202sarping 4 | 7073554 Joring coes2.1-020 esas |pece| <_fpeaeeetons &_|_ 072285 Fiterconent [os2=a0 [eco] «firmer 2 SS = [as Frese ies 5 foal on © | roret6s fovenorsted tube f eter] 8 frve-8021 sysom 10] _rorssr4 pion use 6 [mete 6 _pwo-o021 sytem 11 [rorsate picarosve sway fos] poco] 2 fowe-e02 armen JNote: 1. These parts from the table SN 1~11 was provided with a set of CEMS system for J vest. is not SiB-202 type 7.2 Optional spare parts Item {Computer number name 2 7070781 7070770 7077841 switch ié IMicdle Relay dale Ro 15 | rorrsaz [tele Roby 7074572 system a [specification ‘ype Fruzs-ot-a2| 0 2S-CL-DY puz2itz Note: 1. These parts from the table SN 12~19 are optional parts and not provided with GEMS} 7.3 Standard installation parts 7073705 _ Pressure ring [Note :1. Standard installation parts was provided associate ‘ie speciticat] tom [computer number name en’ | unit {auantiy] supplement ‘ype 7 [7071230 [Fleameproofterminal _JAYB-071 [pico] 1 Forhoativacng ube 2_| 7071231 _|Midele connection box [HYE-022|pioca] 1 foreatwaang tube 3 [7072011 fairongthenec tube |i" __|moter] _5_ [For emausi emission | _ 7073566 _ [Hose camp fp15-25 [piece] 1 [For exhaust omission ja Nylon tube ei s_| _rorasra x1 |r] 5 Fao 0 6 Sonnet 10 calibra 6 | zorates_ [EP ube Jos _|rneter]_5_| gas 7_|_roro7ae [screw cap 12.06 [nece| 4 8 7073704 Pressure ring fe6 [piece] 4 3 _|_7070762__ [Screw cap ricco] 4 poco] 4 1d with system. 7.4 Standard apparatus specification’ reservation in advance. tem [Compuisrrunber] name | it evry] suppor 7 |_rorexe Ranpina rote fowc-200 [pene 3 [eras Poureniner Frrore.200 [neces 3] _roveosa Persie pune (R25 ___|pieae 3 |__zovors0 fondeneor fracio [nce 7 7073345 pemplng Pane piece} fegulatng valve | 8 ‘7077313 jempling sas piece | fragnetc vave @ _[__ 7070208 _ irholder rece ae 70 [__oveane rua eading pot rice 2 of sep fowsmele ice GloLimin rack) 73 |__roro20s —ondenser alarm rice 4 |_To70808 witching power sours Pavey [pee 73 [7071668 _[eotaton Puaorer [rice standard apparatus can be replace during maintenance but you should be makTransportation and storage: Instrument needs rainproof and quakeproof packing for transportation and storage, and relative humidity shall be no higher than 80%, Besides, itis recommended not to check cabinet & analyzer& other devices outdoor forthe possibilty of any pars missing, Guarantee from Manufacturer: Manufacturer will repair or roplace parts for free of charge within a year ftom the date of shipment, in the condition of consumer operate following the regulations concemed and Product does not work for its quality. Appendix1 Technical documents of SMC-9021 CEMS system ‘SMC-9021 Continuous Emission Monitoring System Operating Instructions. 8700 (SIDOR) series modular gas analyzer manual ‘SMB-202 type sampling probe installation, operation instruction ‘SMB-203 type complex sampling tubes installation operation instruction ‘SMB-206 type compressed condenser installation operation instruction SMC-209 type flue gas hygrometer installation operation instruction ‘SMC-222 type Pitot tube current meter installation operation instruction ‘SMC-900 type Data processing system installation operation instruction FW-300 type Smoke detector installation operation instruction FLOWSIC100 type ultrasonic current meter installation operation instruction MAK10 type compressed condenser installation operation instructionbrbiiapetet easly ‘SICK MAIHAK (Beijing) Co., Ltd. + AE IRE R BR Add; Wenquan Haidian District oa, 100095 Beijing, 100095 PR. China iE. +86(0) 10 6240 6092 Tel, +86(0) 10 6240 6092 €HL, +86(0) 10 6240 6090 Fax, +86(0) 10 6240 6090