FGAS-06 Series
（Malaysia Connaught Bridge）
Continuous Emission Monitoring System
(CEMS)
Instruction and Operating
Manual
Xiamen Greest Environmental Protection Technology Co.,Ltd
Content
Summary ................................................................................... 2
System characteristic ................................................................. 3
Technical specification .............................................................. 4
Applicable working conditions.................................................. 6
SO2\NOX\CO\CO2\O2 monitoring system ................................. 7
Routine maintenance ............................................................... 10
Flow/Tem./Pressure monitor ................................................... 12
Dust monitor ............................................................................ 13
DAS ......................................................................................... 14
1
Summary
FGAS-06 Series Continuous Emission Monitoring Systems(CEMS) is a gas analysis
system, it is made up of the particulate monitoring system, gas component monitoring
system, gas parameter monitoring system and the data acquisition system(DAS) It can
continuous monitoring the SO2,NO,CO,dust in gas, velocity of flow and temperature of
the gas. The DAS can acquisition the analysis component, and then transact, then creat
the day report, month report form and year report form. The DAS control the sample
probe sampling or back-flushing.
FGAS-06 CEMSis made up of following:
SO2\NO\CO\CO2\O2 monitoring system, model:FGAS-06
Dust monitor,mode:P-5C
Flow/Temperature/Pressure monitoring,model:HSPT-01
DAS, model:HE-DAS-2000
2
System characteristic
1. SO2\NOX\CO\CO2\O2 monitoring system,
Model:FGAS-06
The sampling principle is direct extractive, it has such characteristic:
a) dry measure;
b) The sample gas doesn’t dilution, the measure precision is higher and stable.
c) Using multi-component gas analyzer, can measure five gas in the same time,
reduce the invest cost;
d) The analyzer measure value is the fact concentration ;
e) Easy maintenance;
f) the heating pipe can keep the sample gas temperature, make it can’t condensation
and dewing during the tranfering;
h) the back-flushing system auto flushing the sample probe regularly;
The system is made up of the sample probe, heating sample pipe, sample gas transact unit,
calibration unit, back-flushing unit and gas analyzer.
The gas analyzer choose the ABB NDIR analyzer (model EL3020), it has following
excellence
multi-component analysis,
stabilization, long life, high analysis precision,
LCD display,
Self check-up;
Have RS232、RS485、Ethernet communication interface,
2. Dust monitor
Model:P-5C
The measure principle is Back scatter, it has following excellence:
Single stalling,
Fit for power plant gas analysis because its endure milling and rust design,
Less maintenance, display the measure reslt,
accord the U.S.A EPA requirement,
3. Flow monitor
Model：HSPT-01
Measure principle: Pitot pipe, different pressure :
Can analysis the gas temperature and pressure.
4. DAS
Model：HE-DAS-2000
3
Technical specification
1．SO2\NOX\CO\O2 monitoring system,
Mdoel：FGAS-06-IR
Analysis components：SO2，NO，CO，CO2，O2
3
Measure range：SO2：0 ∼ 1500 mg/Nm
3
NO：0 ∼ 150 mg/Nm
3
CO ：0 ∼ 1000 mg/Nm
CO2 ：0 ~ 10，25Vol.%
O2 ：0 ~ 10，25Vol.%
Zero drift:≤ ±1% of span per week
Sensitivity drift:≤ ±1% of span per week
Linearity drift:≤ ±2% of span
Repeatablity: ≤ ±2% of span
Response time T ≤ 35 seconds at 60 L/h sample gas flow rate
90
Output signal:4 ∼ 20mA isloated
Numeric signal: four state signal, passive contact:240V,2A
Warm-up time:≤ 30 minutes
Sample gas flow rate: 20 ∼ 120 L/h
Filter efficiency of sample probe:99.7% above 3μm
Power:240VAC；50Hz(L, N, PE)
Power consumption of the main cabinet：≤ 500W
Power consumption of the heating line：45W/M
2. Dust monitor
Model:P-5C
3
Measure range：0 ~1,000mg/m
3
Measure limit： 5 mg/m
Zero drift:≤ ±2% of span per day
Span drift:≤ ±2%FS of span per day,
≤ ±5%FS of span per week
Response tiem:1 second
Ambient temperature:-30 ~ 55℃
Proecess gas temperature:
to 260℃ standard,
to 375℃ with high temperature probe
Power: 240VAC，50Hz
Output: 4 ~ 20mADC,550 ohms maximum load
3. Flow&Temperature&Pressure monitor
Model：HSPT-01
Flow velocity range: 0 ~ 30m/s
4
Temperature range:0 ~ 200℃
Pressure：-2.5KPa ~ 2.5KPa
Output: 4 ~ 20mA
Ambient temperature:-45 ~ 65℃
Power:24VDC
Power consumption:50W
4 DAS:HE-DAS-2000
The DAS is made of ABB PM554 series PLC and PC into a body. The system of the
CEMS from the various parameters of automatic monitoring, and generate database and
statements. PLC programming software used to prepare the applications, operator
interface used to prepare the use of VB6.0 configuration interface monitoring, reporting
output data tables in line with the state pollutant discharge standards. Through the organic
combination of hardware and software, making the monitoring system to operate intuitive,
simple features.
5
Applicable working conditions
4.1 The flue gas parameter
Dust of gas: ≤20 g/m3
Sample gas temperature: ≤ 300° C
Limit the sample gas pressure: -200 hPa (less than atmospheric pressure)
Flue gas flow rate: 0 ~ 90m / s
Supply: 240VAC; 50Hz
Back-purge gas: air, 0.6 MPa, no oil, water, clean, air consumption of about 5 Nm3/h
Sampling points chosen:
CEMS ensuring the accuracy of the data and the installation location close. CEMS
users should try to provide countries with technical specifications of the sampling points
system to ensure that the data collected can be a true reflection of the actual conditions,
should take early and my company joint expert consultations to correct choice of
sampling points.
4.2 Analysis house and maintenance platform:
Analysis of house specific requirements as follows:
Environmental temperature: 5~ 45° C relative humidity: ≤ 85%
Power supply: 240 VAC, 50Hz (L,N , PE)
ground: for ground (ground resistance of less than 5 Ω)
host work here: the level, at work and no obvious vibration
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SO2\NOX\CO\CO2\O2 monitoring system
5.1 Working principles and processes（see the drawing HD06-07031-3.001）
After the gas was of GSP-04-type probe, the probe was first built-in filter which filters;
kind after a gas filter than pure gas, electric heating pipeline through access to anti-purge
device, and then in addition to the condenser Water, secondary filter and fine filter after
the end of instrument landing. GSP-04-sampling probe with electric heaters, exports from
the sampling probe instrument to counter the entrance of the sampling of the use of
electric heating of the sample, analysis of gas would be heated to 130 ~ 150 C, thus
avoiding the flue gas in the aquifer Were in the process of° condensation or transport
Jiedong, soluble in water to ensure that the gas components (such as SO2) accuracy of the
analysis. Instrument cabinet formed by three parts: the sample gas pretreatment
system, calibration of equipment and systems. At the counters of gas-like instrument
through the C,°condenser of the sample gas dehydration, like gas will be cooled to
about 3 condensing into liquid water after the inflow of water tank. So, like a gas dew
C of the dry gas, and then after the second filter and the°point for the 3 filter cut-off
valve manually entered after flow meters, flow meter comes with 60 litres /∼ the
needle-valve regulating the flow of gas samples, keep it in 40 hour, and a fine film like
air filters for the third time filtering, at this time, the sample gas into clean, anhydrous gas,
the flow meter into the final infrared analyzer, the kind of gas in the SO2 , NO, CO, O2
concentration, and 20 mA DC signal output. ∼ measured the concentration to 4
Calibration system from standard cylinders, pressure gauge, the needle-valve, steady flow
valve and the four-way valve components. The steady flow of gas calibration stability to
the needle-valve into the pressure of 0.1 MPa for the calibration of low pressure gas. 0:00
gas, the analysis component span calibration gas switch from four-way valve, followed
by a 0:00 into the analytical instruments and span calibration.
5.2 System installing
Before install the system, should be carefully read the installation diagram, instrument
room layout plans, understanding the system components and pipes, cables and
connectors preset method, in accordance with the site conditions and the requirements of
the respective sets of preferences and hoisting place. Note: before booting the system
should familiarize analyzer, condenser, PLC controllers and procedures pump out the use
of brochures, to avoid misuse, damage instruments
.
Installing the sample probe
a) open the box, took out the sampling probe to observe whether the damage during
transport, unloading the rear cover the probe to observe whether there is a loose filter
components, if so loose and should be Xuanjin to ensure air tightness.
b) the sampling probe inserted into the 1.5 solid bolts fastening the two flange, and
to×flue, with four sets of M12 ensure that it does not leak.
c) the sampling probe protection of gripping me with the attached screws were firmly
installed in the pipe lining.
d) the sampling probe Protection me through the sampling probe of a fixed base in the
gripping pieces, and with locking screw.
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e) the sampling probe heater jacket and thermocouple cable signal through the wire-line,
connect to the maintenance platform distribution box on the heater and thermocouple
Posts.
f) wear protective mask after me.
g) of the main instrument of the cabinet installation
h) instrument counters will be placed in the ground level,to screw feet.
i) the gas analyzer, condenser, the standard sample gas were installed in the appropriate
location, the gas analyzer and the power cord from the condenser instrument on the
cabinet Terminals.
j) pre-heating of the sample used high-pressure gas blowing and washing intracavity
leakage test, and then access "-like gas imports" joint and installed and that does not leak,
the pipeline will be sampling heating cable access instrument counters with the thermal
heating pipeline terminal. Snick with small knife with a coat of heat pipes, ripping out
insulation layer, the thermocouple installed in the heating pipes in the wall of PTFE, and
then re-package on the jacket and insulation layer, or use of thermal Guakai plastic
insulation to the mouth of re-Zhajin. Use teflon tube attached to one end of the
instruments received the 1 stainless steel,× 10 φkind of gas exports, the other end
connected to the stainless steel outdoor emissions, discharge point should not be less
than 2.5 meters high, the level of resettlement or slightly Tilt to the ground, not vertically
upward, to avoid water when it rains. Turn in the heating pipe joints clamping nut.
a). incidental use of standards in order to access the respective electromagnetic valve
instrument cabinet on N2, SO2, NO corresponding to export, turn nut to ensure that seal.
b). 240 V power will be received analytical instruments inside the cabinet wiring
L, N, Pe-side.
5.3 ready to run Multimeter measured by access to the supply voltage is 240 VAC,
confirmed that 240 VAC, the closure and leakage protection switch and all the air switch,
preheat state into the system at this time, about half an hour after the gas analyzer on the
yellow and red Lights off, the remaining green light lit; condenser the instructions of the
temperature-screen display for the numerical 3 ℃; heat with temperature control to
display the pipeline close to setting numerical temperature (130 ℃), plus or minus less
than 5 ℃, this system Preheating.
5.3 calibration Before must be put into operation in the calibration of the instruments,
its purpose is to maintain the system error in the analysis of technical indicators within
the scope of the output value of the signal can be monitored and adjusted as a reliable
basis.
5.3.1 school righteous path by corresponding with the group and the concentration of gas
cylinders, valves, needle-valve, steady flow valve and flow meter components.
5.3.2 0.1 calibration Calibration gas path will regulate the flow valve clockwise
direction of rotation in the end, and open the gas cylinder 0.1 (net N2), adjust the output
pressure valves, air pressure in its output 0.1 0.2 MPa between. At this point, can be
seen from the pressure gauges, pressure∼ on its output steady at 0.1 MPa (the factory
has good regulation). The four-way valve switch to the "N2" button, open the
needle-valve and flow meter Float attention to observe the location. To maintain the flow
in 40 to 60 litres / hour. At this time of operation for the menu, entered manually
calibration mode, select the "Zero Calibration" and then click "Enter", observed infrared
analyzer attention to the LCD display, its value should be instructed to gradually reduce
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to 0.1 near the question of measurement data LCD display Stability, according to
"ENTER" will show the value of the instruments for the preservation value of 0.1, 0.1
check completed.
5.3.3 infrared analyzer the span calibration EL3020 analysis (configuration Uras 14
non-dispersion infrared analysis module) for the multi-component analysis instrument,
while the maximum of four gas concentrations. For SO2 analysis, the correction of the
apparatus of the sample gas is N2 as the background of SO2 gas, its concentration and
analysis of the value range to match. calibration gas path will regulate the flowλ valve
clockwise direction of rotation in the end, and open the SO2 gas cylinders, pressure
regulating valve output, making it the 0.1 ~ 0.2 MPa, and at this time, can be seen from
the pressure gauges , The pressure on the stability of its output in the 0.1 MPa (the
factory has good regulation). The four-way valve switch to "SO2" button, open the
needle-valve and flow meter Float attention to observe the location so that the flow
remained at 40 to 60 litres / hour. At this point operating gas analyzer menu, enter the
SO2 span calibration, pay attention to observe the infrared analyzer showed that the
concentration of SO2, pending stability, the question LCD display measurement data
stability, according to "ENTER" will show the value of the instruments save , Span
calibration finished. According to the above method of checking the other components of
the span. manual calibration gas analyzer operation detailedλ analysis instrument
Manual. Note: the calibration gas components to beλ immediately closed after the
calibration of gas cylinders, and the four-way valve switch back to the "automatic
calibration" button to stop the calibration process.
5.3 Operation
5.3.1 connected to the power system, the operation panel on the "reset I" button, then 2
sampling probe into the sampling, and sampling probe into an anti-purge, and half an
hour after the system will automatically switch, sampling A sampling probe into the state,
the sampling probe into the 2-purge state. Sampling probe and a sampling probe the turn
of the 2 hours 30 minutes for each one, alternating time can be set according to actual
conditions, all the procedures by the PLC implementation, without human operators.
System into the sampling, and sampling indicator lights up, to slowly open the valve of
the instruments cabinet, will "regulate traffic sampling" needle-clock direction of rotation,
until the flow meter to maintain the flow in 40 to 60 litres / hour . At this point, infrared
analyzer display in the corresponding group is the concentration of gas in the various
groups in the concentration.
5.4 running and modify parameters
a) infrared analyzer can work from the LCD status reflected in the figures, can also use
the keyboard for the necessary parameters and status of the work of the condenser from
the state of digital LCD temperature reflected;
b) reset button switch to work with the state to amend the function, pressing reset switch,
the sample analysis immediately transferred to purge anti-state. This feature allows the
installation of running for the first time before the sampling probe the many purge, can
also be used for instantaneous ash in the air like a high sampling probe to plug the
hand-speaking anti-purge. Infrared analyzer various parameters of the amendment,
according to the statement attached to.
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Routine maintenance
6.1 for the first time in the week transported to the CEMS more observation and
adjustment, pay attention to observe the following:
a). Instruments measured the concentration of gases in line with the technical parameters,
or chemical analysis and comparison of data.
b). alarm if the traffic flow meter showed that the nominal value of stability.
c). kind of gas whether there is a change in pressure. If the pressure changes in larger and
will take appropriate adjustment needle-valve to adjust the flow.
d). condenser the temperature is controlled at around 3
e). systems work, attention to observe the electrical panel indicator shows whether or not
consistent with the set-up process
6.2 in the first put into operation the week, every two to three days of the instruments
must be carried out on 0.1 and span calibration, and record of 0.1 per drift and span drift
value of the instruments observe the 0:00 span drift and drift.
6.2.1 flue gas composition monitoring subsystem weekly maintenance:
6.2.1.1 calibration of the instruments once, if not drift of the instruments may extend the
calibration cycle.
6.2.1.2 purge of anti-check: according to reset switch to observe the anti-purge valve of
the device to work properly.
6.2.1.3 to check the quality of wind instruments: wind instrument unloaded filter below
nut, whether from the observation of condensed water.
6.3 Common method of exclusion and failure
malfunction reason debar
No power Fuse off Check whether the short-circuit lines, the
replacement fuse
AC contactor coil Open Inspection, the replacement of the coil
Contact connection is bad Replace the contact
The sample Road serious gas leak Step by step and try to replace the corresponding
flow is zero components leak
The sample gas transport Check points and plug the pipeline replacement
pipeline plug
Winter water in the sample Steam insulation
gas in the gas-gas pipeline
in Jiedong
Emissions of the plug Inspection and replacement of pipes
Normal flow, Normal flow, but no Check whether the leaking pipeline linking
but no instructions of the (Note does not allow high-pressure leak test
instructions of instruments equipment so as not to damage analysis)
the instruments
Analyzer failure Check whether the analyzer show failure
information and send the information to HEPEC
10
The sampling Filter of the sample probe Let system doing back-flushing four times
flow go down jammed
The back-flush air pressure isn’t enough,
slowness and
augment the pressure
the response
time lenghten It has water in the back-flush air
Examine the air and separate the water
Filter invalidation, Replacing the filter
The sample probe is back-flushing
theThe PLC The valve malfunction Examine the valve and its connection
The sample/ Loop of the relay turnoff Replacing the relay
back-flush or touch of the relay
can’t working badness
as the The voltage of 24VDC Check the voltage and imcrease it
preestablish power is to low
control program failure and Replacing the PLC
the PCU failure
The recompose program of Examine the program and mend it
the PLC is wrong
The output The gas analysis path leak Examine the leak point and mend it
instability out
The signal line doesn’t The signal grounding well
shield well
Installation environment Amend the installing condition
exists strong
electromagnetic
interference, a strong
vibration or environmental
temperature exceeds 45℃
11
Flow monitor
See the attach
《HSPT-01 Flow/Temperature/Pressure monitor user manual》
12
Dust monitor
See the attach
《Model P-5C Laser Backscatter Particulate Monitor Operations Manual 》
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DAS
This set of flue gas from the continuous monitoring system ABB PM554 series of
programmable logic controller and distributed a common industrial PC computer
monitoring system. The system of the flue gas emissions from the various parameters of
automatic monitoring, and generate database and statements. 1. Description After the
launch of the system there will be gas monitoring system of the main window. The tools
in the window of the system include the withdrawal, print, meters, instruments details,
alarm, log, management, diagnosis, control, trends, prescription, documents, music, time,
help, and so on the button. System interface for Engish language interface, the operating
system for Widow 7
Tiered system with encryption system to ensure the safety of operating system data;
immediate display of images on the measurement group of real-time data and equipment
running; in the same timeline on the same screen images of different colours, also
showed that four of the simulation trends. Auto-complete data processing, the formation
of statements in support of long-distance transmission; statements into the production:
when minutes mean statements, the statements mean when, on average, statements, the
statements on average, the concentration of dust calibration data statements and SO2
check time; system to supportλ printing, print statements; a loss of data processing
functions. data-processing functions in line with the state "thermal power plant flue gas
emissions continuous monitoring of technical specifications"
2. Help The operating system software that randomly with the help of a specific
document on. Mainly divided into 12 points.
2.1. Installation System Part of system software is divided into two parts: PLC
procedures and customer applications (Reporting System). First used PC / PPI cable
programmable logic controller (PLC) and computer, the PLC's work in the state set up
"STOP" state. Open your computer in the STEP 7-MicroWIN32 software, open the
CD-ROM (or drive) PLC procedures, click on the menu of the "Download" button, below
the window to show "DOWNLOAD SUCCESS". Open the CD-ROM, click on the
"continuous gas monitoring system. EXE" file, the system will automatically enter the
installation process, the installation has been completed, the entire process of data
collection system installed.
2.2 log operation When the operation began when the flue gas monitoring system, first
log into the screen, the window of a username and password field list field, the bottom
has a status bar, the user in the list of users has been chosen field of user name and
password again in typing this column User's password, click the OK button, such as user
name and password correctly, we can enter into the main screen, click Cancel button to
exit the application, such as the wrong password, login screen in the status bar of "invalid
password, try again!" The words, such as three errors were to withdraw from the
application.
2.3. Management operation If the current user rating is not an administrator, click the
button management, no reaction; only current user of the class as an administrator, click
the button icon management, the plan is to open the following screen, the screen displays
the current user name, the user column shows the user name , Password column shows
the password, the user column shows the class hierarchy; data operation buttons and four,
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respectively, as "a record" and "the previous record," and "a record", "The last record"
there are four operators Buttons were cancelled, the user changes, built new users, delete
users button.
2.4. Instrument Calibration Click on the button instrument calibration, validation
classification into the screen, you may choose to check meters or check the report.
Calibration instruments: the system of manually calibrate the instruments; checking the
report: correction can view the report.
2.5 System Settings Users can in this screen, change boiler, flue, and continuous
monitoring code.
2.6. Log records This application automatically record all of the information system
registry. Click on this button, the user can enter the picture, query and print.
2.7. Trend screen To enter this screen, can select the parameters measured view
real-time curves.
2.8. Documents screen Click this button to enter the day, month, the statements of the
index screen.
2.9. Time Management When the monitoring system of the host computer system
under the control of time and the crew at the same time, click on this button, the screen
into the next crew to amend the time, from top to bottom at the time of reunification.
Users can monitor system interface in the status bar to see the date and time fields under
the crew's time, as indicated at the time of the crew and not the same time, the process
can be modified following the crew's time.
2.10. Help screen In this screen the user can see the entire application process with the
help of
2.11. Application of information Click on this button, access to the data acquisition
system of information-related applications.
2.12. Chosen instrument Click on this button, according to the instrument of choice,
can be carried out on the corresponding instruments
2.13. Withdraw from the application Users from flue gas monitoring system.
2.14. Print statements
Click on this button, select a window, choose the following statements: Preservation
and quality assurance period After the arrival of user devices, attention should be paid to
CEMS cannot open, relative place, should be kept indoors, indoor temperature for 5 ~
45℃, humidity is less than 85 percent, the environment cannot be corrosive atmosphere.
The user to comply with the requirements of the use and custody cases, from the date of
shipment within 18 months as a result of poor manufacturing quality in damaged or
unable to work, the factory responsible for the free repair or replacement parts and
components.
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