CODEL SmartCem V-CEM5100 Technical Manual
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CODEL SmartCem V-CEM5100 Technical Manual

Flow monitor, emissions monitoring system
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TECHNICAL MANUAL
SmartCem Emissions Monitoring System
Model V-CEM5100
Flow Monitor
CODEL International Ltd.
Station Building, Station Road, Bakewell, Derbyshire DE45 1GE United Kingdom
t : +44 (0) 1629 814 351
f : +44 (0) 8700 566 307
e : codel@codel.co.uk
web : www.codel.co.uk
OPS.109
Issue : B
Rev. : 1
Date : 23/10/13
Doc. i/d : 0109/6
Ref. : 090028

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  • Page 1 TECHNICAL MANUAL SmartCem Emissions Monitoring System Model V-CEM5100 Flow Monitor CODEL International Ltd. Station Building, Station Road, Bakewell, Derbyshire DE45 1GE United Kingdom t : +44 (0) 1629 814 351 f : +44 (0) 8700 566 307 e : codel@codel.co.uk web : www.codel.co.uk...
  • Page 2 CODEL OPS.109 Issue : B Rev. : 1 Date : 23/10/13 Doc. i/d : 0109/6 Ref. : 090028...
  • Page 3 CODEL CODEL International Ltd is a UK company based in the heart of the Peak District National Park at Bakewell, Derbyshire. The company specialises in the design and manufacture of high-technology instrumentation for the monitoring of combustion processes and atmospheric pollutant emissions.
  • Page 4 CODEL OPS.109 Issue : B Rev. : 1 Date : 23/10/13 Doc. i/d : 0109/6 Ref. : 090028...

  • Page 5: Table Of Contents

    CODEL Technical Manual Contents 1. Overview of the CODEL Model V-CEM5100 Flow Monitor 1.1. Introduction 1.2. Transducer Units 1.3. Power Supply Unit (PSU) 1.4. Signal Processor Unit (SPU 1.5. Data Display Unit (DDU) 2. Measurement Principle 3. Specification 4. Installation 4.1.
  • Page 6 CODEL Technical Manual 7.6. Parameter Mode 7.6.1. Identification 7.6.2. Parameters 7.6.3. Averages 7.6.4. Output 7.6.5. Alarm 7.6.6. Plant Status 7.6.7. Clock 7.6.8. Cal Config 7.7. Normalisation 7.8. Diagnostic Mode 7.8.1. Detector Levels 7.8.2. System Gain 7.8.3. Displacement 7.8.4. Flow Data 7.8.5.
  • Page 7 CODEL Technical Manual IMPORTANT The warning signs (and meanings) shown below, are used throughout these instructions and are intended to ensure your safety while carrying out installation, operation and maintenance procedures. Please read these instructions fully before proceeding. Caution, risk of electric shock.
  • Page 8 CODEL Technical Manual OPS.109 Issue : B Rev. : 1 Date : 23/10/13 Doc. i/d : 0109/6 Ref. : 090028...

  • Page 9: Overview Of The Codel Model V-Cem5100 Flow Monitor

    Many methods require direct contact with the hot dirty gases resulting in high maintenance costs and potential unreliability. The CODEL Model V-CEM5100 Gas Velocity Monitor utilises an infrared cross-correlation technique that requires no contact with the flue gases.

  • Page 10: Transducer Units

    CODEL Technical Manual Page 2 1.2. Transducer Units Each transducer unit consists of a broad band infrared detector, a lens to focus the radiation received on the detector and a pre-amplification circuit board, all housed within a fully sealed, epoxy-coated aluminium enclosure.

  • Page 11: Measurement Principle

    CODEL Technical Manual Page 3 2. Measurement Principle Gas flow is rarely laminar. Turbulence in the flow produces a series of swirling eddies and vortices that are transported with the bulk flow. Infrared radiation, emitted by a hot gas system, is characterised by a flickering signal resulting from the swirling effect of these vortices.
  • Page 12 CODEL Technical Manual Page 4 Using the correlation function R () to operate on these two signals the following correlogram is obtained. NOTE: with  = 0 (i.e. no delay on signal A(t)) then R () = 0, and when A(t) has been delayed by six time- intervals R () is a maximum.
  • Page 13 CODEL Technical Manual Page 5 In the V-CEM5100 the correlogram is inverted as follows: Consequently in order to determine the  max. value the correlogram is scanned to find the minimum. The first element of the correlogram corresponds to a zero time delay and the 256th element corresponds to 255 time delay increments.

  • Page 14: Specification

    CODEL Technical Manual Page 6 3. Specification Measurement Range selectable to 50m/s Response selectable 10 seconds to 30 days  ±2% of measurement Accuracy Serial Port data bus I/P & O/P. Construction fully sealed (IP65) epoxy-coated aluminium enclosures Ambient Temperature Limits...

  • Page 15: Installation

    The analysers are supplied with standard 10m cables already connected. If any items are missing please inform CODEL or your local CODEL supplier immediately. The installation site should be free of all encumbrances and safety procedures should be observed at all times.

  • Page 16: Fitting Of Stub-Pipes And Mounting Flanges

    CODEL Technical Manual Page 8 4.3.1. Fitting of Stub-Pipes and Mounting Flanges Before proceeding further note that under no circumstances should holes be cut in the stack with the plant operational if flue gases are under positive pressure with respect to atmosphere.

  • Page 17: Air Purges

    5 litre/second (about 10cfm), against the working pressure of the duct. CODEL can specify a blower if required. The flange of the insertion tube is carried between the site mounting flange and the front flange of the air purge.

  • Page 18: Transducer Heads

    (supplied) fitted between them. The transducers will only fit in one position. Make sure that the nylon insulating bushes are fitted to the air purge flange – if not fitted, DO NOT attach the transducers and contact CODEL immediately. 4.3.4. PSU & SPU To mount the PSU &...

  • Page 19: Ddu

    CODEL Technical Manual Page 11 4.3.5. DDU To mount the DDU first remove the cover by loosening the four captive screws and unplug the ribbon cable from at the lid connection. The case is then secured to a firm support by use of the four mounting holes, one in each corner of the case.

  • Page 20: Electrical Connections

    Leave sufficient free-end length to make final connections. The maximum recommended cable length is 5m – if a greater length is required please contact CODEL before installation. CODEL supplied cables are provided with ferrite beads fitted to all cores to protect against interference and should not be modified without consulting CODEL.
  • Page 21 CODEL Technical Manual Page 13 Figure 6 : Connection Schedule OPS.109 Issue : B Rev. : 1 Date : 23/10/13 Doc. i/d : 0109/6 Ref. : 090028...
  • Page 22 CODEL Technical Manual Page 14 To DDU Keep links in place Figure 7 : Details of SPU Wiring Figure 8 : SPU Microprocessor Card OPS.109 Issue : B Rev. : 1 Date : 23/10/13 Doc. i/d : 0109/6 Ref. : 090028...
  • Page 23 CODEL Technical Manual Page 15 Address switch Figure 9 : DDU Microprocessor Card OPS.109 Issue : B Rev. : 1 Date : 23/10/13 Doc. i/d : 0109/6 Ref. : 090028...

  • Page 24: Commissioning

    CODEL Technical Manual Page 16 6. Commissioning The instrument should now be fully installed and ready to be commissioned. This involves the following basic procedures that should be carried out with the plant ON: 6.1. Pre-Commissioning Checks Before proceeding the following checks should be carried out : If wiring has been installed and connected by others (and particularly if no certification of connection accuracy exists), check all wiring and connections for conformity with the information provided.

  • Page 25: Detector Levels

    CODEL Technical Manual Page 17 Figure 10 : Adjustable Mount Details Minor adjustment may be necessary if the mounting flange has been welded incorrectly. 6.6. Detector Levels The system uses automatic gain control (AGC). The microprocessor in the signal processor continuously adjusts the gain of the signals from the two sensing heads to maintain an optimum level for both channels.

  • Page 26: Detector Levels

    CODEL Technical Manual Page 18 The table below gives the gain values represented by the dip switch settings. Gain Switch Gain Value Low gain 15.4 30.8 38.5 15.7 31.4 62.8 78.5 22.4 44.8 89.6 High gain 112.0 If with a software gain setting of 0 the rms value of channel ‘A’ is greater than 80 the hardware gain must be reduced.

  • Page 27: Ddu Operation

    CODEL Technical Manual Page 19 7. DDU Operation 7.1. Introduction After the instrument has been commissioned it will measure the flow velocity between the two transducers and produce an output proportional to gas velocity. An integral 32-character display shows the calculated levels.

  • Page 28: Key Operation

    CODEL Technical Manual Page 20 7.3. Key Operation Each mode is accessed sequentially by each push of the MODE key. Figure 12 illustrates the display and keys of the DDU. After a mode has been selected the  and  keys will select the various options within that mode.

  • Page 29: Operating Modes

    CODEL Technical Manual Page 21 Figure 13: Main Program Tree 7.5. Operating Modes NB. PLEASE NOTE THAT ANY DATA CONTAINED IN THE FOLLOWING DISPLAY ILLUSTRATIONS IS INTENDED TO BE REPRESENTATIVE ONLY. 7.5.1. Measurement Mode From this mode of operation the averaging time of the displayed flow may be altered to one of the other averaging stacks and the flow measurements observed.

  • Page 30: Calibration

    CODEL Technical Manual Page 22 To change the data displayed, press the ENTER key and a, flashing cursor will appear at the beginning of the /sec. The  and  keys will now change the highlighted parameter. Each concentration units, i.e. m/sec or m push of the ENTER key will select another of the parameters, in the following order: ...

  • Page 31: Averages

    CODEL Technical Manual Page 23 Cross Sectional Area The cross sectional area in m currently being used to calculate the volumetric flow. Data Rate Data Acquisition Rate of Measurement The system operates by reading and storing the data from the channel ‘A’ transducer at accurately timed intervals varying from 0.5 milliseconds to 4 milliseconds.

  • Page 32: Cal Config

    CODEL Technical Manual Page 24 Time hr * mins * secs Date day/month/year 7.6.8.Cal Config This option enables all the calibration configuration parameters to be displayed: Calibration interval in hours Logic initiation input ON or OFF Cal alarm actuation ON or OFF...

  • Page 33: Displacement

    CODEL Technical Manual Page 25 4 Det gain ChB gain 7.8.3. Displacement Displacement, which is the location on the correlogram of the minimum, is displayed along with the correlation coefficient. 4 DIAGNOSTICS Displacement The ‘displacement’ is the position in the correlation window at which the minimum correlation level is found. This value is determined every second by the analyser.

  • Page 34: Fault Condition

    CODEL Technical Manual Page 26 7.8.6. Fault Condition To display the current fault condition, press the ENTER key while this is displayed. This display mode is automatically selected by the instrument should a fault condition occur. The following fault conditions are recognised by the instrument.

  • Page 35: Security Code Entry

    4 SET UP MODE Security # 0000 The code number will be set to 0000 by CODEL at the factory; this should be changed by the user from within the set-up mode – see Figure 14 below. Figure 14: Program Tree for the Set-Up Mode.

  • Page 36: Configure O/P1

    CODEL Technical Manual Page 28 Press the ENTER key when this display is shown, the display will now show one of the averages. Use the  and  keys to select the average time that requires changing, and press the ENTER key to change it. The value can now be changed using the ...
  • Page 37 CODEL Technical Manual Page 29 7.9.3.2. Averaging Time of the Output Any of the four averaging stacks (seconds, minutes, hours or days) may be used for the analogue output. They are selected by the  and  keys and entered using the ENTER key.
  • Page 38 CODEL Technical Manual Page 30 When this is displayed the current output should be set to 0mA as measured with a calibrated current meter across the analogue current loop terminals. Nothing else should be connected to these terminals when the output is being set up.

  • Page 39: Alarm Hi

    CODEL Technical Manual Page 31 7.9.4.4. Output Span Select the required span using the  and  keys for each digit. The ENTER key is pressed to enter the value of each digit. The units will be displayed in either m/sec or m /sec, depending on what has been selected beforehand.

  • Page 40: Alarm Lo

    CODEL Technical Manual Page 32 7.9.5.1. Source The alarm can be configured to trigger from any one of the four averaged values (sec, mins, hours or days). 5 ALARM Hi Source 7.9.5.2. Units The units in which the alarm is operated can be set to m/sec or m /sec.

  • Page 41: Parameters

    CODEL Technical Manual Page 33 7.9.7. Parameters Select this option by pressing the ENTER key. The  and  keys will now display the available options from within this sub-mode, when the option that requires changing is displayed, press the ENTER key. When all required changes have been made, select the EXIT option and press ENTER.
  • Page 42 CODEL Technical Manual Page 34 For example, if the min. and max. expected flow velocities are 5m/s and 20m/s respectively with a transducer separation of 1000mm, then the max. TOF = 200 and then min. TOF = 50. Consequently the ideal DATA RATE is ms.

  • Page 43: Calibrate

    CODEL Technical Manual Page 35 5 Set clock Month Scroll month using   Enter 5 Set clock Days Scroll days using   Enter 5 Set clock Hours Scroll hours using   Enter 5 Set clock Minutes Scroll minutes using ...
  • Page 44 CODEL Technical Manual Page 36 5 CALIBRATE Hi cal 20.0m/sec  Enter Set the high span calibration target value, 1 digit at a time, using the  and  keys and Enter. 5 CALIBRATE Set # cycles = 50 Set the number of cycles used for calibration, 1 digit at a time, using the  and  keys and Enter.
  • Page 45 CODEL Technical Manual Page 37 Cal. Timer This enables calibration to be triggered at period intervals, from the real-time clock. Firstly the ‘interval’ should be set from 0 to 168 (1week) using the  and  keys. Note that a setting of 000 inhibits calibration initiation from the timer.

  • Page 46: Routine Maintenance

    CODEL Technical Manual Page 38 8. Routine Maintenance The equipment is designed to keep the levels of maintenance to an absolute minimum. 8.1. Cleaning Windows It is important that the windows at the transducers remain reasonably clean. They may be cleaned, by removing the transducer from the air purge, (by removing the three M6 socket head screws) and cleaning each window with a clean soft dry cloth.

  • Page 47: Basic Fault Finding

    In the absence of CODEL trained technicians on site it is strongly recommended that in the event of a fault CODEL or its local service agent be contacted immediately with the current information contained in the analyser records.

  • Page 48: List Of Figures

    CODEL Technical Manual Page 40 10. List of Figures Figure 1 : General Arrangement of the V-CEM5100 Figure 2 : Stub Pipe Arrangement Figure 3 : Adjustable Mount Details Figure 4 : PSU & SPU Mounting Details Figure 5 : DDU Mounting Details...

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