Consilium OPSIS M800 Commissioning Manual
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Consilium OPSIS M800 Commissioning Manual

Consilium OPSIS M800 Commissioning Manual

Continuous emission monitoring system
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OPSIS M800
Continuous Emission Monitoring System
Commissioning Manual

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Summary of Contents for Consilium OPSIS M800

  • Page 1 OPSIS M800 Continuous Emission Monitoring System Commissioning Manual...
  • Page 2 Spares: spares@consilium.se The contents of this document are subject to revision without notice due to continued progress in methodology, design and manufacturing. Consilium assumes no legal responsibility for any error or damage resulting from the usage of this document. February 2019 Document no.

  • Page 3: Table Of Contents

    Table of contents Table of Contents Table of Contents ............................ 1 Admonitions ............................1 Introduction ............................. 2 Purpose ............................ 2 General safety rules ......................... 3 High Voltage ........................... 3 Heavy equipment ........................3 Strong UV light ........................3 Hazardous components ......................3 Measuring path commissioning ......................
  • Page 4 Table of contents MX004 ..........................15 MX012 and MX009 ......................17 Setting up the analyzer software ....................19 Analyzer installation menu ....................19 9.1.1 Analyzer Measurement Setup ..................19 9.1.2 Analyzer measurement times ..................22 9.1.3 NTP-Correction ......................27 9.1.4 Calibration setup ......................

  • Page 5: Table Of Contents

    Commissioning Manual 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...

  • Page 6: Introduction

    Commissioning Manual 1 Introduction The different configurations on board different vessels with different scrubber makers will cause the commissioning of the M800 system to be slightly different from time to time. This manual is to ease the process for technician performing the commissioning. It will also help us be more consistent during commissioning.

  • Page 7: General Safety Rules

    During installation or replacement of larger units, appropriate safety clothing and certified lifting equipment must be used. 2.3 Strong UV light The CEMS OPSIS M800 emitter contains a high pressure light bulb that emits strong UV light. Caution Always use safety protection glasses with UV protection when working with or near the emitter.

  • Page 8: Measuring Path Commissioning

    Standard length of these pipes is 1000mm and they should be cut during the installation before the commissioning. The standard monitoring path is 300mm but can be different depending on project. If the pipes are not cut, see the CEMS OPSIS M800 installation manual for instructions.
  • Page 9 Commissioning Manual As we are measuring the number of molecules in the monitoring path, the distance of the monitoring path is crucial for correct measurement. When the pipes have been installed it is necessary to verify the monitoring path. One way is to use a carpenters ruler and a measuring tape.

  • Page 10: Emitter And Receiver Commissioning

    Commissioning Manual 4 Emitter and receiver commissioning 4.1 Install the emitter and receiver When the measuring pipes are aligned and the measuring path has been measured correct, then the emitter(s) and receiver(s) can be installed. The emitter(s) and receiver(s) are mounted with a quartz glass, purge air cassette and a ball valve at delivery.

  • Page 11: Emitter Power Cable

    The power cable between the power unit and emitter should already be terminated with AMP connection. If the power cable needs to be terminated, follow the instructions in the CEMS OPSIS M800 installation manual. Make sure that the mains power cable to the power unit is not connected. Connect the power cable on the power unit side as well as the emitter side.

  • Page 12: Purge Air Commissioning

    Oil Liquid, Aerosol & Vapor ≤ 0,1 mg/m The purge air is an essential part of the CEMS OPSIS M800 system. The purge air system lets clean and dry instrument in to the measuring pipes to prevent emission from building up in the pipes and thus contaminating the measurements (remember the importance of the measuring path length).

  • Page 13: Purge Air Settings

    5.3 Purge air settings The amount of purge air needed the CEMS OPSIS M800 system measuring pipes is 30 liters per minute per side (i.e. 60 liters per minute per measuring path. There should be just enough air to keep emission from entering the measuring pipes, but not so much air that it will blow away the emissions from the monitoring path.

  • Page 14: Installing The Analyzer

    This MUST be handled with care. If lifting the pallet with crane, make sure you have the weight centered. It is the customer’s responsibility to do this in a proper way. The analyzer box must not be opened by any other than Consilium technicians. 6.1.2 Power on the main cabinet The main cabinet is to be fed by 220VAC/16A.

  • Page 15: Install The Analyzer

    Commissioning Manual 6.1.3 Install the analyzer Remove the analyzer from its original package and carefully lift it into place in the cabinet. The analyzer should be placed on the shelf that slides out. 1. Connect the analyzer to a power outlet in the cabinet. 2.

  • Page 16: A Guide To Set The Light

    Commissioning Manual 7.2 A guide to set the light To adjust the angle of the mirrors there are four small allen screws (marked with red circles in the picture below) situated behind the mirrors. The four screws control the up- and-down, and side-to-side motion of the mirror.
  • Page 17 Commissioning Manual Focus the light the other way and the projection should first appear as stronger (with an ellipsis), and then go over to peach-shape again. Between the two peach shaped projection there is a decent base focus. What we call peach shaped is actually the reflection of the lightbulb itself. When the base focus is established, mount the emitter on the measuring pipe.
  • Page 18 Commissioning Manual paper in front of the fiber connection to see where the light beam is located. Adjust the mirror in the receiver to direct the light beam directly into the fiber connection. Up till now the description of the adjustments has been done without the help of a LUX- meter.

  • Page 19: Multiplexer Setup

    Commissioning Manual 8 Multiplexer setup 8.1 Multiplexor basics When more than one stack is to be measured a multiplexer needs to be installed. The Multiplexer is an optical switch which toggles the light from the different stacks to the analyzer. A Multiplexer is preferable to be installed inside the cabinet, but if needed it can be installed outside the cabinet.
  • Page 20 Commissioning Manual In the Peripheral Control Setup, make sure that MX004 is selected under Multiplexer Type. To change the type, move the marker with the arrow keys to the Type, and press Enter to change Type. Press “y” for yes and then Enter and the type will change. Move the marker to “Setup”...

  • Page 21: Mx012 And Mx009

    Commissioning Manual The MX004 is now adjusted and ready to be operated. 8.3 MX012 and MX009 The other multiplexer types (MX012, MX009) used for the marine market are of another type. Instead of a magnetic solenoid that controls the arm, there is a stepping motor controlling the arm.
  • Page 22 Commissioning Manual In the Peripheral Control Setup, make sure that MX 012 or MX024 is selected under Multiplexer Type. MX024 is selected when using multiplexor MX009. To change the type, move the marker with the arrow keys to the Type, and press Enter to change Type. Press “y”...

  • Page 23: Setting Up The Analyzer Software

    Commissioning Manual 9 Setting up the analyzer software When all external equipment as emitters, receivers, multiplexer, purge air etc. are setup it is time to look at the configuration of the analyzer itself. The Analyzer will analyze the light received from the monitoring paths and present the data in a useful manner. It does so based on the many variables entered, as path length, pressure, temperature and span, just to mention some variables.
  • Page 24 Commissioning Manual The below picture shows the path specification page. In this setup there are two monitoring paths. The cursor is moved with the arrow keys. To add a monitoring path press Ins (Insert) and to delete a path press Del (Delete). This guide will go through the settings that need to be configured one by one.
  • Page 25 Commissioning Manual Controlled by I/O: This option allows a path to be disabled by a signal from IO256. This can be used if monitoring is not desired for any reason, usually if the engine/scrubber is off-line. The analyzer can of course also measure on an off-line duct, then yielding pollutant concentrations close to zero, but it might be desirable to spend the available measurement time on ducts that are active - see discussion about cycle time below.

  • Page 26: Analyzer Measurement Times

    The rest of the settings can be left as is. 9.1.2 Analyzer measurement times The measure time for the CEMS OPSIS M800 system is relatively quick compared to sampling systems. This allows a high frequency of measurement results which can give a high time resolution on individual ducts and/or the ability to monitor several ducts using the same analyzer.
  • Page 27 Commissioning Manual The measurement times are set individually on each gas and each path. If no time is set for a specific gas on a specific path, the area for the time is blank and the analyzer will skip that specific gas on that specific path. To set a measurement time, move the cursor with the arrow keys to the area under path/gas and press enter.
  • Page 28 Commissioning Manual The times need to be entered for each gas on each path. See example below. The measurement time depends on several factors. One factor is the total cycle time. The cycle time is the total time when all gasses on all paths have been measured at least once. According to resolution MEPC .259(69) (adopted on 15 May 2015): 5.4.2 SO2(ppm) and CO2(%) to be continuously monitored and recorded onto a data recording and processing device at a rate which should not be less than 0.0035 Hz.
  • Page 29 Commissioning Manual The analyzer will measure the gasses on each path in a default sequence. By example, the analyzer will first measure the SO2 on all paths, then change the grating position to CO2 and measure the CO2 on all paths. This is to reduce the time for a complete cycle since the grating positioning takes a few seconds.
  • Page 30 Commissioning Manual Move the marker with the arrow keys to the line after the last SO2 measurement (in this example line 5) and press INS (Insert). Do the same for line 2, 3, 4 and place them after one another. The result in this example should look like this: The sequence for the measurements in this example is now the following: SO2 path 1,2,3,4, SO2 path 1,2,3,4 and then CO2 path 1,2,3,4.

  • Page 31: Ntp-Correction

    Commissioning Manual To delete an inserted (copied) measurement, move the marker to the corresponding line and press DEL (Delete) and the measurement is deleted. Note Changes within the grouping does not affect the cycle time on the measurement time page. If a custom grouping is activated, the total cycle time must be calculated manually (or checked in practice) and compared with the maximum allowed cycle time.
  • Page 32 Commissioning Manual From the analyzer root menu go to F1 Installation  F4 Communication setup. To change the settings in the Communication move the cursor with the arrow keys to the setting you wish to change and press ENTER. Configure the Communication setup as per the example below: Station address - default Transmit delay –...

  • Page 33: Output Signal Setup In The Analyzer Software

    Commissioning Manual 9.1.6 Output signal setup in the analyzer software The output signal setup is where the measurement results and status signals are communicated out from the analyzer. The measurement results and status signals are sent from the analyzer to the IO256 (described in chapter below) to make them accessible for connected external hardware such a scrubber PLC.

  • Page 34: Io256 - Input And Output Configuration

    Commissioning Manual 9.1.7 IO256 - Input and output configuration In the marine applications the data logger type is IO256. This is configured under the “Input signal setup”. IO256 handles all communication with external and internal signals. These signals could be for example temperatures and signals to control if measurements are to be made on a specific path.
  • Page 35 Commissioning Manual When entering the IO256 configuration program it will look like this: Input menu Under the input menu the input part of the IO256 is configured. - Serial Communication: Under this menu the COM-ports are configured. The COM port is defined with address and IRQ and baud rate.
  • Page 36 Commissioning Manual Sources: IO256 has sixteen input units and they are defined under the sources menu. Each input unit handles up to sixteen channels. 16x16 = 256  IO256. An input unit can be any of the already defined COM-ports earlier. It is also possible to use two or more input units on one COM-port.
  • Page 37 Commissioning Manual Channel setup: When entering this menu all channels are displayed. In the example below channel 18 is marked. The number 17 in the first box is the channel number. The “u02” in the second box is which input unit that is used. The “ch001” in the third box is which channel for input unit “u02”...
  • Page 38 Commissioning Manual Output menu Under the output menu the output part of IO256 is configured. - Serial communication This is where the serial communication for the output signals is defined. It is interconnected to the serial communication settings on the input side. If anything is changed on either side, it will reflect on the other side.
  • Page 39 Commissioning Manual In the example below, Unit A (COM4) with Modbus RTU is used for output unit 1 to 4. Update interval: The update interval is how often IO256 updates the values on the output units. In marine application it is usually 2 seconds. No of channels: This setting is how many channels to be used.
  • Page 40 Commissioning Manual Program Go to the “Program” button and press ENTER to save all changes made. Depending on what kind of changes made in the IO256 the software might ask you to restart the analyzer. It is normal and should be done for the changes to take effect. View input With this function it is possible to check current values on the input channels.

  • Page 41: Ioman Setup

    Commissioning Manual Info This displays system information. See example below: 9.1.8 IOMan Setup The IOMan is a system that allows signals from e.g. temperature sensors to be read by the IO256. In marine applications it is typically used for temperature sensors when temperature values are not provided via MODBUS.
  • Page 42 Commissioning Manual Communication Module CM001 The communication module handles the signals from the input modules to the IO256. In marine applications it should be connected with: - Ribbon cable from the PM020 - RS232 cable on pin 1-Tx, 2-Gnd, 3-Rx. - Chain out on pin 6.
  • Page 43 Commissioning Manual The IM001 has four LEDs describing the its status and operation. - Busy – The diode is lit green when traffic on the ribbon cable is directed to the module. Normally blinks every second or so. - Error –The diode is lit when hardware failure, communication failure or the most common a programming blunder in the IOMan configuration, causes an error.
  • Page 44 Commissioning Manual In the menu go to Input  Serial communication and select which input unit to be used for IOMan communication. In the example below it is unit B: Set the protocol to “IoMan” and continue to “IoMan configuration” Press F1 –...
  • Page 45 Commissioning Manual As mentioned earlier in the text 0-20mA Active Current is typically used in marine applications. In the example above the IM-001 module No. 2 is 0-20mA Passive current, and needs to be changed. To change, simply move the cursor in position at the module to change and press “ENTER”...

  • Page 46: Emulator Setup

    Commissioning Manual Go to menu “Program” and press “ENTER” to save the IO256 configuration. The IOMan can now be set up as "source units" under IO256 Inputs a The signals on the source unit channels are then to be tied to the IO256 input channels (available to the base analyzer sofware) as described above.

  • Page 47: Optimize Light

    Commissioning Manual 9.1.10 Optimize light The optimize light function allows the operator to see the light intensity as a percentage of the detector where 0% means there is not light at all, and 100% means that the detector is saturated. When this function is activated the grating is in the zero position. This means that this light cannot be compared to the light percentage when measuring a specific gas.
  • Page 48 The P1 and P2 has to do with the grating position and P3-P5 provide information about the detection system. At the end of every system check the analyzer will ask to “Permanent change of P4? (Y/N)”. Caution Always press “N” (no) on this question, unless directly instructed otherwise by Consilium HQ personnel! 5100396_OPSIS_M800_Commissioning Manual_M_EN_2019_B...

  • Page 49: Calibration

    Commissioning Manual If any of P1 to P5 fails the result should be reported back to Consilium HQ for further analyses. Below is a short description of the different P’s. P1 – This is the difference between the number of steps between the grating start position and the trigger position, and the stored number of steps.

  • Page 50: Check Wavelength Precision

    Commissioning Manual calibration path automatically is compensated for in the processing of the signals. Therefore, it is only necessary to do the calibrations once per system being commissioned, not once per monitoring path. This also has the advantage that during annual services, the service technicians only have to make one calibration, i.e.
  • Page 51 Commissioning Manual In “F1 Check wavelength precision”, select SO2 by pressing space and press ENTER to continue. Enter 30 in the measurement time and press ENTER to start the check. 5100396_OPSIS_M800_Commissioning Manual_M_EN_2019_B...
  • Page 52 Commissioning Manual When the measurement is complete the result is presented first as a graph with two curves. One curve is the pre-recorded spectrum and the other curve is the newly recorded spectrum. The second presentation is showed in text when pressing ESC. If the mercury spectrum is not shifted more than +- 3 channels, all is ok.

  • Page 53: Reference Calibration

    Commissioning Manual 10.2 Reference Calibration A reference calibration shall be performed in a calibration bench in a clean area outside of the stack. Reference calibrations performed inside a stack is absolutely NOT recommended since the atmosphere inside the stack is unknown. Do not take a chance on the atmosphere inside the stack being clean enough after shut-down of the engine: especially SO2 is a sticky gas that can stay in the stack long after the engines has been shut down.
  • Page 54 Commissioning Manual 2. The “Span/offset change” displays the current span and offset values. Make a note of the existing values. Prior to reference calibration they need to be reset. Move the cursor between the different boxes and click enter. Enter 1.00 on the span, and 0.00 on the offset on each gas and path.
  • Page 55 Commissioning Manual 4. In the “Reference calibration selection” select “Yes” on the “Skip reference check”. Make sure that both SO2 and CO2 are selected. Both “Manual cylinder control” and “Set calibration flag” are to be set to “No”. Click “Start Calibration”. 5.
  • Page 56 Please carefully repeat the reference calibration process. If this does not help, contact Consilium HQ for support. 7. After the reference calibration is performed and the results look correct, it is time to start the measurement cycle and prepare for span check.

  • Page 57: Span Calibration

    Commissioning Manual Run ten measurement cycles to confirm the close-to zero values on all gasses. As seen in the picture above the SO2 is reading 0.1ppm. This is such a low reading that it is consider negligible. If a reading of a couple of ppm is shown, then concerns should be raised and the reference calibration needs to be checked again.
  • Page 58 Commissioning Manual 4. When the temperature settings are done, start the measurements (Analyzer root menu  F4 Measurements) again and wait a couple of cycles until the zero values have stabilized. 5. Place the calibration cell in the calibration bench and open the flow regulator to approximately 1 lite/minute.
  • Page 59 Commissioning Manual 7. To set the span factors. Go from analyzer root menu F3 Calibration  F3 Change span/offset Set the calculated span factors for each gas (described earlier in this chapter). In this example 1.04 for SO2, and 0.90 for CO2 8.
  • Page 60 FOR ALL THOSE MOMENTS WHEN SAFETY MATTERS Consilium is a producer of safety and safety-related technologies for the marine, oil and gas, transport and building sectors. Our commitment goes beyond the products: We protect the lives of mothers and fathers, sisters and brothers, colleagues and friends. With representation in more than 25 countries in all time zones, we are always close to you.

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