Consilium CGS50/500 Installation Manual

Gas sampling system

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Gas Sampling System - CGS50/500

External equipment - Installation Manual

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Page 1 Gas Sampling System - CGS50/500 External equipment - Installation Manual...
Page 2 Juridics disclaimer 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. ...
Page 3: Table Of Contents
Table of contents Safety precautions ................Introduction..................Symbols used in the manual ............. Sampling points................. Sampling point location ..............Sampling points in oil cargo systems ..........Sampling points in LPG systems ............Sampling points in LNG systems............10 Switchable sampling point levels............11 Analysing unit ...................
Page 4 Viewing operation status..............39 Adjustment of flow ................39 Calibration..................41 System calibration for Salwico GD10 detectors....... 41 System calibration for Consilium ST series detectors ..... 44 Detector calibration of ST450 EC and ST650 EX ......47 Appendices..................51 Definitions and abbreviations............51 Pneumatic drawing examples............
Page 5: Safety Precautions
Failure to observe the safety precautions can result in injury or death. CAUTION! Installation, commissioning, and service of the CGS50/500 gas sampling system must be done by personnel trained for each separate purpose. CAUTION! Read and understand the manual before installing or operating the equipment.
Page 6: Electrical Safety
Safety precautions Installation Manual Electrical safety For electrical installations and connections, make sure to follow local and international rules and regulations on how electrical installation work shall be executed. Electrical work must always be performed by authorised personnel. • Never use equipment with frayed cords, damaged insulation or broken plugs. •...
Page 7 Installation Manual Safety precautions WARNING! If the gas sampling system has generated an AUTO SHUT-DOWN FAILED fault, immediately shut down the cabinet manually, either by pressing the OFF button on the power control box, or by breaking the power supply elseways. Close the isolation valves to shut off the sampling pipe system.
Page 8 Safety precautions Installation Manual Data for toxic gases Table 1. Toxic gases - limit concentrations in air Health hazard TWA STEL (CAS no.) 8-hour Short-Term Time-Weighted Exposure Limit Average (15 minutes) Ammonia, NH Respiratory distress, eye 25 ppm 35 ppm irritation (7664-41-7) Carbon dioxide, CO Asphyxiation...
Page 9: Introduction
This manual is intended for personnel installing and commissioning equipment for a CGS50 or CGS500 gas sampling system. CAUTION! Installation, commissioning, and service of the CGS50/500 gas sampling system must be done by personnel trained for each separate purpose. The manual contains information on the following procedures: •...
Page 10 1 Introduction Installation Manual 5103103_CGS50-500_Installation Manual_M_EN_2022_E...
Page 11: Sampling Points
Installation Manual 2 Sampling points 2 Sampling points 2.1 Sampling point location The following list exemplifies areas to be monitored by the permanently installed gas sampling system, as stipulated by the concerned regulatory instances and classification societies. • Cofferdams • Pipe tunnels •...
Page 12: Sampling Points In Oil Cargo Systems
2 Sampling points Installation Manual 2.2 Sampling points in oil cargo systems Below is an example of sampling point locations in an oil cargo ship. Figure 1. Example of sampling points in an oil cargo ship Table 3. Oil cargo sampling points Location Location 1, 2...
Page 13: Sampling Points In Lpg Systems
Installation Manual 2 Sampling points 2.3 Sampling points in LPG systems Below is an example of sampling point locations in an LPG cargo ship. Figure 2. Example of sampling points in an LPG cargo ship Table 4. LPG sampling points Location Location Tank 1, hold space fwd Tank 3, hold space aft...
Page 14: Sampling Points In Lng Systems
2 Sampling points Installation Manual 2.4 Sampling points in LNG systems Below is an example of sampling point locations in an LNG cargo ship. Figure 3. Example of sampling points in an LNG cargo ship Table 5. LNG sampling points Location Location Tank 1, primary insulation Fore peak, cofferdam...
Page 15: Switchable Sampling Point Levels
Installation Manual 2 Sampling points 2.5 Switchable sampling point levels For ballast tanks where the water level varies considerably, it may be necessary to have both an upper and lower sampling point , the use of which depends on whether the tank is full or empty. The sampling points are usually set up as two groups in the configuration, and the switch between the groups is done manually in the HMI.
Page 16 2 Sampling points Installation Manual Figure 6. Sampling points with manual switch between upper and lower point. NOTE! This setup does not allow for a disablement of only one of the pipes. The configuration program permits optional configuration of two pipes. The longer pipe length defines the Trip-level, to assure there are no no false clogging indications when the longer pipe is in use.
Page 17: Analysing Unit
Installation Manual 3 Analysing unit 3 Analysing unit 3.1 Cabinet location and space requirements The analysing unit should be installed in a location that fulfils the following requirements: • Safe area Hint! An example of a suitable location could be the cargo control room.
Page 18: Mounting Of Floor Cabinet
3 Analysing unit Installation Manual Figure 7. Suggested locations of cabinet (1: cargo control room) and repeater panel (2: bridge) 3.2 Mounting of floor cabinet Lift the floor cabinet using the four corner eyebolts. Figure 8. Lifting of floor cabinet Anchor the cabinet to the floor, placing it on four bolts that are screwed from the floor and through the bottom of the skirting.
Page 19 Installation Manual 3 Analysing unit Figure 9. Dimensions and hole pattern of skirting. Use the two brackets to attach the cabinet to the wall. NOTE! Leave no space between the back of the cabinet and the wall. Figure 10. Dimension drawing for floor cabinet 5103103_CGS50-500_Installation Manual_M_EN_2022_E...
Page 20: Cable Entry
3 Analysing unit Installation Manual Cable entry The cable inlet is of the adjustable plate type. When all cables are installed, seal the opening with foam or equivalent material to make it airtight. Figure 11. Cable inlet for floor cabinet 3.3 Mounting of wall cabinet Mount the wall cabinet using the six wall brackets.
Page 21: Pipe Connections On Analysing Unit
Installation Manual 3 Analysing unit Cable entry Figure 13. Cable inlets 3.4 Pipe connections on analysing unit Figure 14. Pipe connections (example) 1. Exhaust pipes 2. Fresh air inlet(s) 3. Sampling pipe inlets 4. Instrument air inlet 5. Water trap pipe outlet 6.
Page 22: Exhaust Pipe
3 Analysing unit Installation Manual The connection is done by means of the connection nipples on the flame arresters. Tighten the flame arrester connection nipples first by hand, then 1¼ turn (max) with a spanner. All pipe connections should be made according to regulations and meet the following general requirements: •...
Page 23: Compressed Air Supply
Installation Manual 3 Analysing unit Calibration gas inlet Connect the hose for the calibration gas bottle to the inlet marked TG on the distribution manifold (6). Avoid unnecessary strain on hose and couplings. Make sure that the hose is not pinched by the cabinet door. NOTE! The gas bottle must be supplied with a relief valve and a pressure gauge.
Page 24 3 Analysing unit Installation Manual 1. Main valve 2. Manometer 3. Regulator 4. Shut-off valve 5. Outlet (3 bar) CAUTION! Store the gas bottles in an upright position in a dedicated storage location, away from heat and ignition sources. WARNING! Do not store gas bottles in the cabinet. Connection of calibration gas Connect the hose for the calibration gas bottle to the inlet marked TG on the distribution manifold.
Page 25: Piping
• Prevention of progressive flooding upon failure: In the CGS50/500 system the valves are closed upon failure. • Self-draining: In the CGS50/500 system counter pressure is used to drain the pipe while not sampling the specific point. (No non-return valves are needed).
Page 26: Piping For Wet Or Inaccessible Spaces
4 Piping Installation Manual Related information: Pipe connections on analysing unit, page 17 4.2 Piping for wet or inaccessible spaces The below illustration shows the piping arrangement for a sampling point supplied with counter pressure, which is recommended when the sampling point is located in an area that may contain water, moisture, or debris.
Page 27: Piping For Dry And Accessible Spaces
Installation Manual 4 Piping 4.3 Piping for dry and accessible spaces The below illustration shows the piping arrangement for a sampling point location in a dry area. Figure 17. Piping for sampling points in dry spaces 1. Flame arrester/online filter 1/4” – 1/4” 2.
Page 28: Installation Of Air Pipe
4 Piping Installation Manual Figure 18. Piping for sampling system exhaust 1. Exhaust pipe: outer diameter 12 mm, inner diameter 10 mm (yard supply) 2. Coupling for 1/4” 3. Isolation valve: ball valve 1/4” – 1/4” 4. Nipple 1/4” – 1/4” 5.
Page 29: Installation Of Water Trap Pipe
Installation Manual 4 Piping Figure 19. Piping for air inlet 1. Coupling for 1/4” 2. Instrument air pipe: outer diameter 8 mm, inner diameter 6 mm (yard supply) 3. Fresh air pipe: outer diameter 8 mm, inner diameter 6 mm (yard supply) 4.6 Installation of water trap pipe The below illustration shows the piping arrangement for the drainage from the water traps.
Page 30: Pipe Couplings
4 Piping Installation Manual • Copper CAUTION! Copper pipes shall not be used where there is hydrogen sulfide gas, H • Corrosion resistant materials that are suited for the application CAUTION! The gas sampling lines shall not be made of aluminium. •...
Page 31 Installation Manual 4 Piping • The minimum distance from the bulkhead frame to the fixing of the pipe end is 0.1 m. • The minimum distance from the bottom of the sampling area to the pipe end is 0.5 m according to regulations. •...
Page 32: Bulkhead Passage
4 Piping Installation Manual Related information: Sampling point location, page 7 Switchable sampling point levels, page 11 4.11 Bulkhead passage Pipes passing through deck or bulkhead plates should be supplied with a welding socket according to the illustration below. Figure 22. Welded bulkhead passage 1.
Page 33 Installation Manual 4 Piping on an individual valve can be carried out without unnecessary dismounting of other pipes. 1. Cut holes and insert welding sleeves with an internal thread. 2. Screw on the isolating valves from inside the safe area. NOTE! Observe the pipe coupling manufacturer's individual recommendations on tightening.
Page 34: Installation Of Filters
4 Piping Installation Manual CAUTION! The isolation valves shall be closed for safety reasons in the following cases: • When the supply of compressed air is lost • When the pipes are mechanically disconnected between the analysing unit and the bulkhead 4.13 Installation of filters The installation of the sampling pipe filters must be done in such a way that the filters are easily accessible for replacement, without causing unnecessary strain on...
Page 35: External Connections
Installation Manual 5 External connections 5 External connections 5.1 Electrical connections for analysing unit Figure 23. Bottom view of cabinet with cable glands 5.2 Installation of Control M Gas External repeater panel Control M Gas External is a repeater panel which can be placed in an indoor location separate from the cabinet.
Page 36: Cable Requirements
5 External connections Installation Manual Figure 25. Terminals for connection of the Control M Gas External NOTE! See the datasheet for detailed information on installation requirements and connections. 5.3 Cable requirements Table 7. Cable requirements Cable for: Cable dimensions Maximum cable length Serial digital communication Min.
Page 37: External Interface Connections
Installation Manual 5 External connections Cable for: Cable dimensions Maximum cable length Power supply Min. 3 × 1.5 mm² NOTE! For maximum cable dimensions, see the datasheet for the device to be connected. Hint! A cable is considered to be shielded if the shielded part is longer than 10% of the total cable length.
Page 38: External Protocols
5 External connections Installation Manual Interface Outputs Max no. units in system CM-DI70-G 8 × digital inputs C-IC-GS 1 × alarm relay 1 × fault relay 5.5 External protocols The protocols used for communication out of the CCP system are Modbus and NMEA.
Page 39: Settings
NOTE! For complete information on the parameters and settings in the CCP configuration program, see the CGD50/500 & CGS50/500 Configuration Manual. 6.2 Determining the sampling time The transport time is the total time needed to transport the gas sample from the sampling point to the analysing unit, including a short time for startup of the suction.
Page 40 If the test results in a longer sampling time than expected, the adjusted value must be entered in the configuration program. NOTE! For complete information on the parameters and settings in the CCP configuration program, see the CGD50/500 & CGS50/500 Configuration Manual. 5103103_CGS50-500_Installation Manual_M_EN_2022_E...
Page 41: Testing And Commissioning
Installation Manual 7 Testing and commissioning 7 Testing and commissioning 7.1 System startup The two push-buttons for ON and OFF on the power control box operate the mains power to the cabinet. System power-up To start the sampling system, press the ON This will power on the entire button.
Page 42: System Stop
7 Testing and commissioning Installation Manual 7.2 System stop The two push-buttons ON and OFF on the power control box operate the mains power to the cabinet. System power-off A power-off of the cabinet will result in the following: • Sampling and gas detection is stopped •...
Page 43: Viewing Operation Status
This adjustment should be done during commissioning. NOTE! Choke valves adjustment screws: CCW opens, CW closes. NOTE! Flow meter for low flow is only used when having Consilium ST450/650 detectors and the high flow variant when having a PG11. 5103103_CGS50-500_Installation Manual_M_EN_2022_E...
Page 44 Open choke valve on the “low flow” flow meter so the meter reading (used for Consilium ST450/650 detectors) indicates a flow just below the maximum level. Change the manual sampling to the sampling point with the longest possible pipe length.
Page 45: Calibration
(bump test) or system calibration results in strange gas readings or a "Calibration failed" notification. For the Consilium ST detectors a gas response check should be carried out at least every three weeks, to determine whether it is necessary to perform a detector calibration.
Page 46 8 Calibration Installation Manual CAUTION! Never attempt to perform a calibration if there is an internal leakage fault in the system. Use an appropriate span gas cylinder with a constant flow regulator. For flammable gas calibration use a calibration gas concentration of between 25% LEL and 75% LEL to ensure that the required accuracy can be attained.
Page 47 The sampling machine can be manually enabled before that. The sampling sequence is resumed automatically after the calibration is finished. NOTE! If the system calibration for the GD10 detector resulted in a "Calibration failed" notification, contact Consilium for assistance. 5103103_CGS50-500_Installation Manual_M_EN_2022_E...
Page 48: System Calibration For Consilium St Series Detectors
• 5150129–5150142 ST450 EC • 5150151–5150222 ST650 EX Figure 28. A Consilium ST450 EC detector Figure 29. A Consilium ST450 EC detector with flow house Before starting the calibration It is recommended to carry out a gas response check (bump test) every three months to ensure correct operation of the gas detector.
Page 49 Installation Manual 8 Calibration Use an appropriate span gas cylinder with a constant flow regulator. For flammable gas calibration use a calibration gas concentration of between 25% LEL and 75% LEL to ensure that the required accuracy can be attained. For oxygen O detectors which are used for inerted atmospheres, the calibration procedure is inverted, i.e.
Page 50 8 Calibration Installation Manual Confirm the choice of fresh air or calibration For zero calibration of oxygen O gas. detectors nitrogen N gas is used. When requested, connect the calibration gas bottle. Open the main valve on the gas bottle and check that the flow meter reading is 20–30 litres/hour.
Page 51: Detector Calibration Of St450 Ec And St650 Ex
Detector calibration of ST450 EC and ST650 EX, page 47 8.4 Detector calibration of ST450 EC and ST650 NOTE! For calibration of other Consilium ST detector models than ST450 EC and ST650 EX, a different calibration setup or method may be required. Contact Consilium for further assistance.
Page 52: Zero Calibration
8 Calibration Installation Manual Confirm the interruption of the sampling CAUTION! The sampling machine is sequence before proceeding. disabled for up to 15 minutes. On the detector: A login is required to access the detector menu: Press and hold both arrow buttons simultaneously until ENTER PIN appears in the display.
Page 53 The sampling machine can be manually enabled before that. NOTE! Always follow up with a system calibration after having completed the sensing head calibration. Related information: System calibration for Consilium ST series detectors, page 44 5103103_CGS50-500_Installation Manual_M_EN_2022_E...
Page 54 8 Calibration Installation Manual 5103103_CGS50-500_Installation Manual_M_EN_2022_E...
Page 55: Appendices
Accommodation, space for passengers and crew Alarm condition The state of the system when a gas alarm is detected. Alarm levels The CGS50/500 gas sampling system has four different alarm levels: Gas alarm level 2, Gas alarm level 1, Gas pre-alarm, and Fault. Asphyxiation...
Page 56 9 Appendices Installation Manual Fault condition The state of a system when a fault is detected Group A group of sampling points, defined by their location or purpose Gas valve unit - a pressure regulating valve which adjusts the gas feed to the engine in LNG ships Hold space The space between the LPG cargo tank and the water ballast tank...
Page 57 Installation Manual 9 Appendices Terminal A physical point of connection, a pin Trip-level Lower limit of sampling pipe vacuum (negative pressure), below which the pipe is assumed to be clogged Time weighted average. A measure of long term exposure. The average exposure for 8 hours a day. UEL (%) Upper explosion limit.
Page 58: Pneumatic Drawing Examples
9 Appendices Installation Manual 9.2 Pneumatic drawing examples The following drawings exemplify the pneumatic flow for different systems. For an explanation of symbols and annotations, see Table 9 Pneumatic symbols and annotations at the end of this section. Two-pump system Red lines indicate air sample under analysis Light blue lines indicate subsequent air sample under transportation 5103103_CGS50-500_Installation Manual_M_EN_2022_E...
Page 59 Installation Manual 9 Appendices Two-pump system with counter pressure option The following three functions are performed simultaneously: • Analysis of air sample from sampling point SP3 • Transportation of subsequent air sample from sampling point SP4 • Counter pressure is applied for sampling points SP1, SP2, SP5 and SP6 Red lines indicate air sample under analysis Light blue lines indicate subsequent air sample under transportation Green lines indicate counter pressure system...
Page 60 9 Appendices Installation Manual Purging of water trap Purple lines indicate flow for purging 5103103_CGS50-500_Installation Manual_M_EN_2022_E...
Page 61 Installation Manual 9 Appendices Purging of sampling point Purple lines indicate flow for purging 5103103_CGS50-500_Installation Manual_M_EN_2022_E...
Page 62: Fault Code List
9 Appendices Installation Manual Table 9. Pneumatic symbols and annotations Sampling point Analysis pump Sampling point inside cabinet Transport pump internal Gas detector Dilution pump Valve Vacuum sensor 3-way valve Pressure sensor Open/closed valve Flame arrester Choke valve Water trap Check valve 9.3 Fault code list Listed in the table below are fault codes, their causes, and information on how an operator with knowledge of the system can solve the problem.
Page 63 Installation Manual 9 Appendices Fault Fault text Cause Remedy code BCM communication The Control M Gas The Control M Gas reporting the fault has lost reporting the error has been communication with the configured to be connected BusCon M Gas. to a BusCon M Gas: 1.
Page 64 9 Appendices Installation Manual Fault Fault text Cause Remedy code Configuration loaded A new configuration is Use menu option Service » but not applied copied from the USB Configuration » Apply memory. configuration (restart). Restart to apply the new configuration in the central. CM primary master The contact with the Ensure that module 1.1 is...
Page 65 Installation Manual 9 Appendices Fault Fault text Cause Remedy code Auto shut-down failed The sampling system has Immediately shut down the tried to do an emergency cabinet and evacuate shut-down of the cabinet possible gas from the and failed. cabinet. Repair the shut-down functionality.
Page 66 9 Appendices Installation Manual Fault Fault text Cause Remedy code Communication Two units have the same Check the unit addresses. problem address. Interference from an Locate the source of external source interference. Faulty unit Replace the unit. The communication within Check the connection a loop-line has failed for between the module and the more than 10% of the...
Page 67 Installation Manual 9 Appendices Fault Fault text Cause Remedy code Internal fault Fault generated by the Contact an authorised loop-unit itself when service office. performing a periodic BIST No answer ch 1 Fault generated when a Check the connections backbone module stops answering on between the backbone channel 1 on the backbone modules.
Page 68: Sensor Description
9 Appendices Installation Manual Fault Fault text Cause Remedy code Invalid application The loop unit firmware is Update the firmware. different from the CM-L-G module's major version. All loop units on a loop-line must have the same firmware. Wrong type of module The type of module found is Change the module or the found...
Page 69: Revision History
Installation Manual 10 Revision history 10 Revision history Version Date Change description Link 2019-03-01 First release 2019-06-18 Calibration sections updated System calibration for Salwico GD10 detectors, page 41 2021-09-27 Updated fault codes Fault code list, page 5103103_CGS50-500_Installation Manual_M_EN_2022_E...
Page 70: Index
Index Index Analysing unit, connections........GD10, system calibration........Analysing unit, location ......... IAS connections ............. Ballast water tanks ..........Instrument air inlet, piping........Bulkhead passage........... Instrument air, inlet .......... Cabinet, location ............ LNG sampling points..........Cable dimension.............
Page 71 Index Power supply............Water traps, drainage outlet ........Purging of sampling point, example ...... Welded passage ............ Purging of water trap, example ...... Zero calibration, GD10 .......... Repeater panel............Zero calibration, sensors ........ Revision history ............. Sampling pipes............
Page 72 For all those moments when safety matters Consilium is a producer of safety 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.