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CEMS Operating & Maintenance Manual
CEMS Operating & Maintenance Manual
Client document
Client rev.:
number:
Contract number:
ES 4503622078, ES 4503622146,
Project number: FP398
ES 4503673873, ES 4503674094,
ES 4503674100, ES 4503674078
NA CEMS
FP398-D21 / Rev. 02
April 2017 © Suomi Analytics Oy
Status: Approved Confidential Document id: DBAE439260 - Page 4 (71)
Revision status
Document history
Revision Reason for issue
Rev. 01 First issue, preliminary
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
Status: Approved Confidential Document id: DBAE439260 - Page 5 (71)
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
FP398-D21 / Rev. 01 Page 5 of 71
Status: Approved Confidential Document id: DBAE439260 - Page 6 (71)
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.
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.
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.
2 Main data
FIELD ITEMS
Sample Probe GAS 222.17
SP-1 to SP-6
(with cal inlet)
(No 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
Light Switch LS
Terminals X1
ANALYSER RACK
Sample pump P-1, P-2 and P-3
Filters F-1
Width 2438 mm
Length 3029 mm
Weight
1 x NA CEMS inside shelter TBA kg
2 x NA CEMS inside shelter 2300 kg
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.)
Zero gas
Cylinder size 20 l
Composition Nitrogen (N2) + Oxygen (O2) 20% qal 4.0
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.
Warning High pressure streams can pierce skin and tissues, and may cause
serious injury.
Warning High temperature flue gas streams can pierce skin and tissues, and
may cause serious injury.
Warning Many toxic gases are colourless, odourless and non-irritating, and
may overcome exposed persons without notice.
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).
3 Functional description
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)
3.2.1 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
• 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
NOx CONVERTER
VALVES
WAGO HMI
CONDENSATE COOLER
EC-1, EC-2, EC-3 and EC-4
Figure 1 NA CEMS
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.
4 Operation
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.
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.
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.
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.
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
Note The Teledyne T100H analyser does not have the option to change calibration
interval.instruction.
Note Suomi Analytics OY takes no responsibility for damage caused by improper use.
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.
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.
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.
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.
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:
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.
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.
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.
Below is a “Backfill Summary” report that can be used to find out when values were
backfilled.
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
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.
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.
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 15 Calibration Report showing low and high level calibration drifts
5 Maintenance
Note Always follow the recommended maintenance of the different units. System
performance and reliability may decline if these recommendations are not followed.
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.
Unit Remarks
All components Inspect visually for deposits, damages, corrosion etc.
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.
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.
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.
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.
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.
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.
5.3.8 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
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
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