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CODEL GCEM4000 Technical Manual

Multi-gas analyser
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TECHNICAL MANUAL
GCEM4000 MCERTS
Multi-Gas Analyser
1m & 2m Probe Versions
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.080
Issue : C
Rev. :
Date : 16/7/08
Doc. i/d : 0080/6
Ref. : 080040

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  • Page 1 TECHNICAL MANUAL GCEM4000 MCERTS Multi-Gas Analyser 1m & 2m Probe Versions 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.080 Issue : C Rev. : Date : 16/7/08 Doc. i/d : 0080/6 Ref. : 080040...
  • 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.080 Issue : C Rev. : Date : 16/7/08 Doc. i/d : 0080/6 Ref. : 080040...

  • Page 5: Table Of Contents

    1.3. Emission Monitoring and the GCEM4000 1.3.1. Normalisation 1.3.2. Verification 1.4. User Interface 1.5. Analogue and Logic Inputs and Outputs 1.6. CDC Serial Port - for use with the CODEL SmartCEM system 1.7. Analyser Protection 2. Summary Specification 3. Preparing for Installation 3.1. Unpacking.
  • Page 6 CODEL Technical Manual 5.3.6. Cell Oven Control 5.3.7. Detector levels 5.3.8. Zero Calibration 5.3.9. Current Data 5.3.10. 'Y' Values 5.3.11. Plant Status Set-Up 5.3.12. Span Verification 5.3.13. Water Vapour Checks 5.3.14. General Overview 5.3.15. Setting the Output Configuration 5.3.16. Read/Set RTC 5.3.17.

  • Page 7: Codel Gcem4000 Analyser - Introduction

    Data from up to 32 SmartCEM stations is transmitted via a serial digital link (CODEL SmartBUS) to the Central Datapoint where it is logged on a dedicated pc or assembled for onward transmission to a plant computer or DCS.

  • Page 8: Gcem4000 Basic Principles

    1.2. GCEM4000 Basic Principles The GCEM4000 analyser uses an in-situ probe set into a duct to measure the concentration of gases of interest. Figure 2 illustrates the arrangement. The in-situ tube includes a section that allows the diffusion of flue gases into the measurement zone or the dispersion of purge or calibration gas out of the tube and into the duct.

  • Page 9: Emission Monitoring And The Gcem4000

    This basic ppm measurement is always corrected for the duct pressure and presented as vpm by the analyser. GCEM4000 analysers have the capability for the outputs and display to be configured in vpm (or %) or mg/m (which is a mathematical conversion depending on the molecular weight of the gas being measured and the flue gas temperature), or in mg/Nm (i.e.

  • Page 10: Cdc Serial Port - For Use With The Codel Smartcem System

    The CDC is equipped with a 2-way serial communications port for use with the CODEL SmartCEM system. On a plant where more than one CODEL analyser is installed, this is the preferred method and, even for a single analyser installation, can provide significant benefits. The main ones are: •...

  • Page 11: Summary Specification

    CODEL Technical Manual Page 5 2. Summary Specification Measurements • Main measurement channels (1-7) • any combination of up to seven gases from CO/CO /NO/NO /HCl/UHC/H Measurement Limits (maximum) • CO/NO/NO /HCl/UHC 6000 vppm.metres • SO 50000 vppm.metres • CO 40%.metres...
  • Page 12 CODEL Technical Manual Page 6 Enclosures All units are sealed to IP65 (NEMA 4) standards and are suitable for outdoor installation. Power Requirements Power Supply Unit 85-264V AC 47-62Hz 200VA Purge Gas Requirements • Compressed air/N Clean and dry to -20 Normal operation 5 l/min Calibration (≈10 minutes) 20 l/min...

  • Page 13: Preparing For Installation

    The analyser and any other items are normally protected for transportation by an expanded foam packing material. When unpacking, please ensure that smaller items are not discarded with the packing material. If any items are missing please inform CODEL or your local CODEL agent immediately. 3.1.1. The Basic Analyser...

  • Page 14: Transceiver Weather Cover

    CODEL Technical Manual Page 8 The transceiver, GCU and SCU, are supplied with blanking plugs fitted in the cable gland entry holes. Cable Glands are packed separately. Some contracts require the mounting of all power supply, processing and control units in instrumentation panels.

  • Page 15: Figure 5 : Codel Supplied Connections

    (20 litre/min during Cals) - Interconnecting cable SCU to CDC Figure 5 : CODEL Supplied Connections When calculating cable requirements remember to take into account cable routing relative to equipment location and also the need for conduit, cable trays, supports etc.

  • Page 16: Ancillary/Additional Equipment

    If the complete system has been engineered by CODEL, detailed contract specific information and schematics will have been provided.

  • Page 17: Installation

    Fitting of transceiver Installation of GCU and CDC Installation and connection of cables Installation of normalising measurements and input connections to the GCEM4000 Installation of span verification gases 4.1. Selection of Measurement Position This analyser measures the average concentration of gas across a significant proportion of the width of the stack or duct.

  • Page 18: Analyser Positioning

    CODEL Technical Manual Page 12 Conditions vary from plant to plant but, in general, the following guidelines should be followed: • Firstly, look for a suitable location on ductwork between the ID fan and the stack. • Large power plant with multiple flues having concrete wind-shields can provide good alternative mounting locations within the stack.

  • Page 19: Fitting Of Stub-Pipes And Mounting Flanges

    Figure 8 shows the recommended displacement limit. Figure 8 : Rectangular Ducts - Acceptable Position In many applications, the GCEM4000 analyser will be installed in close proximity to other analysers. Figure 9 shows the minimum separation required.

  • Page 20: Metal Ducts/Stacks

    Sections 4.3. Fitting of Stub-Pipes and Mounting Flanges and 4.3.1. Metal Ducts/Stacks may be followed. Such installations require particular care to be taken in establishing alignment of the two stub-pipes as once fixed they may be impossible to adjust. If in doubt, consult CODEL before commencing installation.

  • Page 21: Double Skin Stacks

    4.4. Installation of Purge Air Supply The GCEM4000 requires air supplies for the pre-measurement zone and to purge the measurement cell for zero verification. This supply should pass through a proprietary filter unit prior to entering the GCU for further distribution.

  • Page 22: Figure 12 : Beam Lifting Point

    CODEL Technical Manual Page 16 It may be advisable to erect a lifting beam above the proposed location of the analyser to enable easy ingress and egress of the probe using a hoist. The picture below shows an 'I' beam acting as a lifting point for a hoist to carry the load of the probe and transceiver.

  • Page 23: Fitting The Active Weather Cover And Sensor Head

    CODEL Technical Manual Page 17 The windows may be damaged by thermal shock. If the plant is operating slide the probe in gradually, pausing frequently to allow temperatures to stabilise. As soon as this phase of the installation is complete, air is required at the measurement zone purge air as quickly as possible to reduce the possibility of acid gases forming within the measurement zone.
  • Page 24 CODEL Technical Manual Page 18 Weather cover mounting bolts Sealing ‘O’ ring b) Remove the remaining flat washers and nuts from the alignment suds. c) Remove the four weather cover mounting bolts and spring washers. d) Remove the sealing ‘O’ ring from the sensor head mount.
  • Page 25 CODEL Technical Manual Page 19 Referring to the illustration below, secure the weather cover front plate to the sensor head mount using the four M8 x 20 bolts and spring washers. To each of the alignment studs fit an alignment nut and flat washer and re-fit the sealing ‘O’...
  • Page 26 CODEL Technical Manual Page 20 h) Referring to the illustration below, replace the sensor head mount and weather cover front plate onto the probe ensuring that it is in the same orientation as when it was removed. Secure in place with the M8 spring/flat washers and M8 x 1 pitch nuts.
  • Page 27 CODEL Technical Manual Page 21 Route the cable from the weather cover through the gland in the base of the weather cover and connect to the terminals. The weather cover may now be fitted over the sensor head and mounted to the front plate as shown below.

  • Page 28: Installation Of The Gcu

    4.9. Installation of Normalising Measurements (Oxygen, Temperature and Pressure) The GCEM4000 is supplied with a pressure and temperature inputs fitted as standard for normalising purposes. If oxygen is connected a normalising input signal is required. Referring to the contract-specific connection schedule, connect the 4-20mA output from the oxygen sensor to the GCU.

  • Page 29: System Connections

    Technical Manual Page 23 4.10. System Connections All pipes, tubing and cables between the GCEM4000 sensor head, GCU, active weather cover and probe are supplied by CODEL and are illustrated below. 8-Core CODEL local bus (+48V, MOSI, MISO & 0V, O2 Input &...

  • Page 30: Figure 16 : Sensor Head Connections

    CODEL Technical Manual Page 24 Spare Cable from sensor head Cable from pressure transducer Cable from thermocouple Figure 16 : Sensor Head Connections OPS.080 Issue : C Rev. : Date : 16/7/08 Doc. i/d : 0080/6 Ref. : 080040...

  • Page 31: Commissioning

    It is also recommended that: • If unfamiliar with the GCEM4000 analyser, read Section 1. CODEL GCEM4000 Analyser – Introduction before proceeding. This provides an overview of the analyser's capabilities and the uses of the parameters that will be configured during commissioning.
  • Page 32 CODEL Technical Manual Page 26 Sensor Data Function Selector File Selection Selector Buttons Address Comms. Transmit & Selector Validity Receive Indicator Indicators DATA DATA WIONDOW ACCESS WINDOW Report Auto Read Generator Stop/Start Control Read Data Control Set sensor selector to SCU. Insert address of SCU at Address selector (this will probably be 1).

  • Page 33: Adjust Alignment

    CODEL Technical Manual Page 27 5.3.1. Adjust Alignment The following procedure will ensure that the sensor head is in optimal alignment with the measurement probe, but before proceeding, allow 4-hour warm-up time after power-up. Switch on the purge air using the following procedure. Select 'Calibration' in the Function selector and the screen below should appear.

  • Page 34: Thermistor Control

    CODEL Technical Manual Page 28 Set 'Working Set Cal data' in the type box, click on 'Read' and ensure that the green 'message received' LED is activated. The required data will now fill the appropriate boxes. Select 'Activate calibration' in the 'Type' box and the following screen should appear.
  • Page 35 CODEL Technical Manual Page 29 Click on 'Read' and the following screen should now show: Some of the data displayed is in hexadecimal (base 16) notation, not decimal (base 10). OPS.080 Issue : C Rev. : Date : 16/7/08 Doc. i/d : 0080/6...

  • Page 36: Source Temperature Control

    * This value may vary depending upon factory set-up. When the measured value reaches the target value ensure that the cooler current is less than 10000. If it is not then a CODEL specialist should be contacted. 5.3.3. Source Temperature Control Select Source Temp Control in the Function selector and the following screen should appear.

  • Page 37: Cell Oven Control

    CODEL Technical Manual Page 31 5.3.4. Cell Oven Control Select 'Cell oven control' in Function selector and click on 'Read' to update the displayed values. Ensure that the green 'message received' LED activates to confirm that the data is current. Check these values against those shown in the following table and adjust if necessary.

  • Page 38: Cell Oven Control

    CODEL Technical Manual Page 32 Note that in the example shown, 9000 is equal to 9000-4000(software offset) = 5000 = 50 C. Similarly, 4999 = 49.99 5.3.6. AWC Temperature Control The active weather cover temperature is checked and adjusted via ‘Sensor-SCU’ and the temperature control via ‘Function’...
  • Page 39 CODEL Technical Manual Page 33 Select ‘Inlet zone’ from the drop-down menu and click on ‘Read’. The default target temperature should be 4000 C). This temperature may need to be changed to suit continuously elevated or lower climate conditions. The active weather cover has the capability to heat and cool the air within it, depending on climatic requirements.

  • Page 40: Figure 17 : Alignment Adjusters

    CODEL Technical Manual Page 34 This gap should be Sensor head mount equal all round Sensor head mounting bolts Sensor head Alignment flange alignment stud Thermal barrier Alignment nuts (note that these nuts are a different thread pitch to others used...
  • Page 41 Sample 2 end a. Select detector in the detection channel box (1). b. Select ‘Graph’ (2). c. Select ‘GCEM4000’ and ‘Detector waveforms’ (3). d. Read a detector waveform by pressing ‘Read’ (4); wait for the waveform to be displayed opposite.

  • Page 42: Detector Levels

    4 steps to ensure the analyser is working at its optimum. Having installed the GCEM4000, a zero calibration must be undertaken to ensure that the analyser gives meaningful data. Select 'Calibration' in the Function selector to view the screen below.
  • Page 43 The data shown in the final boxes is crucial to the performance of the analyser during calibration and must be equal to or greater than the data given below. If it is not, wait until the analyser warms to this temperature. If it fails to do so contact the CODEL Distributor or CODEL International direct. Oven temperature : 55.00...

  • Page 44: Current Data

    CODEL Technical Manual Page 38 Set the 'Purge time' to 600 seconds, set 'Number of Cal cycles' to 100, set 'Calibrate' to 'On', click on the 'Lock' tick to release it and click on 'Apply'. Clicking on 'Auto update' will show a clock, decrementing through the remaining Cal cycles.

  • Page 45: Y' Values

    'message received' LED is activated. The 'Y' values should be in the region of 10000 (if the purge air is on). If they vary significantly from these values check the alignment and if does not rectify the problem contact your CODEL Distributor or CODEL direct. OPS.080 Issue : C Rev.

  • Page 46: Plant Status Set-Up

    Page 40 5.3.11. Plant Status Set-Up The GCEM4000 monitors the plant running conditions or ‘Plant Status’. This enables the system to automatically purge the probe during shut-down, off and start-up conditions. This is necessary to ensure moisture does not form inside the probe and contaminate the optical surfaces.

  • Page 47: Span Verification

    5.3.12. Span Verification The GCEM4000 and GCU are equipped to enable the performing of span verification checks. This is achieved by connecting the required span gas bottle to the span gas input of the GCU. Note that some GCUs may have more that one input.
  • Page 48 Select the ‘SCU address’ (2) – usually 1. c) Select ‘Purge control’ in the ‘Function’ (3) window and the following screen should appear. Note that not all these functions are applicable to the GCEM4000 span check and therefore should not be used.
  • Page 49 CODEL Technical Manual Page 43 This will now switch on zero air for 5 minutes to check the zero condition of the analyser. The zero air will then switch OFF and the span gas will switch ON. At this point the flow must be checked on the flow rotometer; make sure that it is ≈20 l/min and adjust if required using the span gas regulator.

  • Page 50: Water Vapour Checks

    Technical Manual Page 44 Make sure that GCEM4000 is selected and adjust the Auto update time to ≈20 seconds and click ‘Start’. The relevant gas channel value should start to increase to the value indicated on the span gas bottle (within tolerances).

  • Page 51: Setting The Output Configuration

    CODEL Technical Manual Page 45 To receive a continuous update set the 'Auto Update rate' and press 'Start'. 5.3.15. Setting the Output Configuration The analogue outputs and alarm relay set points should be configured if required. On some systems this may be ®...
  • Page 52 00DC 00FO To reveal the channel configuration of the GCEM4000 using SmartCEM, select ‘GCEM400’ from the ‘Sensor’ list and from the ‘Function’ list select ‘Gas Channel Config’ as shown below. Click on the ‘Read’ button to identify channels 1 to 7.

  • Page 53: Read/Set Rtc

    CODEL Technical Manual Page 47 Having now clarified the parameter to channel relationship, select the output parameter being used vpm, mg/m mass flow, or other data (these are clearly shown at the top of the sheet). Select from the list the location address relating to the channel to be interrogated.
  • Page 54 The parameters for this procedure are adjustable but are best left at standard factory settings. If advised by a CODEL engineer the autocal data can be modified using SmartCEM under ‘Sensor GCEM4000’. Under ‘Function’...

  • Page 55: Memory Back-Up

    ‘Lock’ check box and then click ‘Apply’ to send the data to the sensor head. 5.3.17. Memory Back-Up When all set-up has been completed it is good practice to make a record of data stored in the GCEM4000 sensor head. Using SmartCOM select ‘GCEM4000’ from the ‘Sensor’ list and from the ‘Function’ list select ‘Memory Back-Up’.
  • Page 56 CODEL Technical Manual Page 50 OPS.080 Issue : C Rev. : Date : 16/7/08 Doc. i/d : 0080/6 Ref. : 080040...

  • Page 57: Analyser Records

    CODEL Technical Manual Page 51 6. Analyser Records This section is provided to allow recording of analyser identity, installation and commissioning information, to facilitate any later fault diagnosis and rectification. 6.1. Serial Numbers (Complete on First Inspection) Transceiver Gas Control Unit Station Control Unit 6.2.

  • Page 58: Calibration And Measurement Verification

    Any calibration subsequently initiated to correct these apparent offsets will be incorrect. If an analyser error is still suspected contact CODEL or the local service agent but, first consult Section 9. Fault Finding to establish what information to provide.

  • Page 59: Comparative Testing

    (initiating an automatic data invalid state) and likely to produce very large errors. When convinced that any discrepancy is due to an analyser problem contact CODEL or the local service agent but first consult Section 9. Fault Finding to determine what information to provide.

  • Page 60: Maintenance

    CODEL Technical Manual Page 54 8. Maintenance This version of the 4000 series requires no routine maintenance other than care of the air purge supplies. Ensure that all filters, dryers and automatic drain units are serviced and maintained according to the manufacturers' instructions.

  • Page 61: Fault Finding

    In the absence of any 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 equivalent current information contained in Tables 3 and 4.
  • Page 62 SCU from sensor head via SmartCom and ensure 48V LEDs are lit Is there now an output? No further action Contact CODEL for further technical support OPS.080 Issue : C Rev. : Date : 16/7/08 Doc. i/d : 0080/6...
  • Page 63 CODEL Technical Manual Page 57 Incorrect Readings OPS.080 Issue : C Rev. : Date : 16/7/08 Doc. i/d : 0080/6 Ref. : 080040...

  • Page 64: Appendix 1 - Setting Analyser Gains

    The need to reset gains after manufacture and testing is very rare, but if necessary, there are a number of methods that depend on the analysers' configuration and its date of manufacture. Consult CODEL to check that gain resetting is necessary and to obtain instructions for the appropriate method. The analysers' serial number should be quoted at this time.

  • Page 65: List Of Figures

    Technical Manual Page 59 List of Figures Figure 1 : Typical SmartCEM System Arrangement Figure 2 :GCEM4000 Analyser with 'in-situ' Probe Figure 3 : Standard Supplied Items and Dimensions Figure 4 : Active Weather Cover Figure 5 : CODEL Supplied Connections...

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