EnergyTech 100 Series 101/102 - Monitoring Solutions · 2020. 4. 28. · OPS. 141 Issue : A Revision : 1 Date : 14/06/18 Doc i/d : 0141/6 050028 CODEL EnergyTech 100 Series 101/102

OPS. 141 Issue : A Revision : 1 Date : 14/06/18 Doc i/d : 0141/6 050028

CODEL

EnergyTech 100 Series

101/102

Installation, Commissioning, Operation and Maintenance Manual

CODEL

OPS. 141 2 Issue : A Revision : 1 Date : 14/06/18 Doc i/d : 0141/6 050028

Total Solutions – Total Confidence

CODEL


CODEL International Ltd is a UK company based in the heart of the Peak District National Park in Bakewell, Derbyshire. The company specialises in the design and manufacture of high-technology instrumentation for monitoring combustion processes and atmospheric pollutant emissions. The constant search for new products and existing product improvement keeps CODEL one-step-ahead. With a simple strategy, to design well-engineered, rugged, reliable equipment, capable of continuous operation over long periods with minimal maintenance, CODEL has set standards both for itself and for the rest of the industry. All development and design work is carried out ‘in-house’ by experienced engineers using state-of-the-art CAD and software development techniques, while stringent assembly and test procedures ensure that the highest standards of product quality, synonymous with the CODEL name, are maintained. High priority is placed upon customer support. CODEL’s dedicated team of field and service engineers will assist with any application problem to ensure that the best possible use is derived from investment in CODEL quality products. If you require any further information about CODEL or its products, please contact us using one of the numbers below. CODEL International Ltd

Station Building, Station Road Bakewell, Derbyshire DE45 1GE England Tel : +44 (0) 1629 814 351 Fax : +44 (0) 8700 566 307 e-mail : [email protected] web site : www.codel.co.uk

CODEL


CODEL


Contents

1. System Description 1

1.1. Opacity Measurement 1

1.2. About this Manual 1

2. Installation 2

2.1. Unpacking the Equipment 2

2.2. Siting the Equipment 2

2.3. Duct Work 4

2.4. Air Purge 5

2.5. Transmitter & Receiver Units 6

2.6. Air Supply 6

2.7. Signal Processor and Power Supply Units 7

2.8. AC Supplies 7

2.9. Outputs 8

2.10. Normalising Inputs 8

2.11. Cable Requirements 8

2.12. Plant Status Input 9

2.13. Connection Schedule 9

3. Commissioning 11

3.1. Introduction 11

3.2. Turning the Power On 11

3.3. Key Pad Operation 12 3.3.1. Mode Key 12 3.3.2. Arrow Keys 12 3.3.3. Enter Key 12 3.3.4. LED Indication 13

3.4. Alignment 13

3.5. Gain Adjustment 15

CODEL


3.6. Basic Calibration 15 3.6.1. Initial Calibration 16

3.7. Operating Parameters 16 3.7.1. Setting Parameters after Initial Calibration 17 3.7.2. Example 1 : Smoke Monitor 20 3.7.3. Example 2 : Dust Monitor 21

3.8. Calibration Data 24

4. Operation 25

4.1. Introduction 25 4.1.1. Measurement 25 4.1.2. Calibration 25

4.2. Operating Modes 25

4.3. Program Tree 26

4.4. Operating Mode 28

4.5. Parameter Mode 28 4.5.1. Identification 29 4.5.2. Parameters 29 4.5.3. Averages 30 4.5.4. Outputs 30 4.5.5. Alarms 30 4.5.6. Plant Status 31

4.6. Normalisation 31 4.6.1. Display Format 32

4.7. Diagnostic Mode 32 4.7.1. Detector Outputs 34 4.7.2. Rx Gain 34 4.7.3. Calibration Data 34 4.7.4. Opacity Data 35 4.7.5. Fault Condition 35

4.8. Set-up Mode 36 4.8.1. Security Code Entry 37 4.8.2. Averages 39

CODEL


4.8.3. Configure O/P1 40 4.8.3.1. Output 41 4.8.3.2. Average 41 4.8.3.3. Units 41 4.8.3.4. Span 41 4.8.3.5. Fault Condition 42 4.8.3.6. Set mA Output 43

4.8.4. Configure O/P2 44 4.8.5. Alarm 1 44

4.8.5.1. Source 44 4.8.5.2. Units 45 4.8.5.3. Level 45 4.8.5.4. Exit 45

4.8.6. Alarm 2 45 4.8.7. Parameters 45

4.8.7.1. Security Number 46 4.8.7.2. Identity Number 46 4.8.7.3. Measurement Path Length 47 4.8.7.4. Dust Factor 47 4.8.7.5. Auto Zero 47

4.8.8. Normalisation 48 4.8.8.1. Setting the Normalising Parameters 50 4.8.8.2. Temperature 50 4.8.8.3. Oxygen 51 4.8.8.4. Pressure 51 4.8.8.5. Water Vapour 51

4.9. Calibrate 52 4.9.1. Set Detectors 52 4.9.2. Set Rx Gain 53 4.9.3. Calibrate 53

4.10. Calibration for Dust Measurement 54 4.10.1. Estimate of a Dust Factor 55

5. System Description 56

5.1. Transmitter 56

5.2. Receiver 56

5.3. Signal Processor Unit 56

5.4. Power Supply Unit 57

CODEL


6. Routine Maintenance 58

6.1. Cleaning Windows 58

6.2. Clean Flue Condition Available 58

7. Basic Fault Finding 59

7.1. Initial Checks 59

7.2. Data Valid LED Out 60

8. Specifications 61

Appendix A - Optical Transmissivity Measurement & Solid Content 63

Extinction Coefficient and Beer Lambert Relationship 64

Optical Density & Extinction 64

Mass Emission 65

Opacity/Ringelmann Correlation 65

Temperature Correction 67

Table of Figures 68

CODEL


1. System Description 1.1. Opacity Measurement Smoke and solid emissions have for a long time been recognised as major atmosphere pollutants, particularly since such emissions from stacks are clearly visible to an observer. There has been a requirement for monitoring and quantifying these emissions for some time, and a variety of instruments have been marketed throughout the world for this purpose. Instruments in the past have, however, generally proved to be either unreliable falling rapidly into disuse or to be so expensive and complex as to only be affordable by the very large users, such as power stations. The EnergyTech 100 Series 101/102 seeks to overcome these problems by providing a reliable, simple to use instrument with low maintenance requirements. 1.2. About this Manual This manual details the installation, commissioning, operation, routine maintenance and basic fault finding for the EnergyTech 100 Series Analyser.

CODEL


2. Installation 2.1. Unpacking the Equipment After the equipment has been unpacked, unless specifically requested by the customer, the following equipment items should be found :

• transmitter with 10m of cable (standard length)

• receiver with 10m of cable (standard length)

• signal processor

• power supply

• site mounting flange (2 off)

• air purge (2 off)

2.2. Siting the Equipment The equipment is designed for mounting on boiler ducting or stacks in position open to the weather. It is fully sealed to IP65 and requires no further enclosures or protection. The specific location of the instrument will depend upon the application and user requirements, but the following points should be considered when choosing a site :

• the site must be accessible at both sides of the duct for servicing the transmitter and the receiver.

• the site should be as free as possible from extremes of temperatures and vibration. Permissible ambient temperature ranges are -20oC to 800C for the transmitter and receiver and -20oC to 70oC for the signal processor.

! At low temperatures, condensation might occur on the lens of

the instrument causing an incorrect (high) opacity reading.

• there must be an uninterrupted sight path between the transmitter and the receiver.

• the signal processor and power supply units are normally mounted close to the transmitter and receiver, both of which are supplied with 10m of cable as standard.

CODEL


Figure 1 : General Arrangement

CODEL


2.3. Duct Work The transmitter and receiver units are mounted on opposite sides of the duct, and interface with the site mounting flange. To protect operators, it is recommended that an isolating valve is used for ducts that operate higher than atmospheric pressure. A stand-off pipe (not supplied), nominal bore 75mm should be used between the duct and the site mounting flange. The pipe should be long enough to keep the equipment clear of any duct lagging, and it also helps to insulate the equipment from any high duct temperatures. A hole should be cut, either side of the duct, to accept a slip fit with the stand-off pipe. A stand-off pipe should now be welded to each hole and a mounting flange welded to each pipe with the tapped holes four-square (it may be easier to weld the pipe and the flange together before they are fixed to the duct). To avoid vibration and movement, it may be necessary to fit spreader plates or bracing fillets.

Figure 2 : Site Mounting Flange Details

CODEL


2.4. Air Purge The purges mount directly onto the site mounting flanges. Separate the front flange from the air-purge by unscrewing the four retaining nuts. This should now be bolted to the site mounting flange with a rigid gasket fitted between them, using the four countersunk screws provided.

! Before mounting the air purges, ensure that air is supplied to

the air purge unit. If this precaution is not observed then the air purge and the optical surfaces may be severely contaminated.

The rear (adjustable) flange is then offered up to the front flange on to the protruding studs, taking care that the ‘O’ ring seal on the flange locates smoothly into the central aperture. This is then re-secured by the four nuts which screw down onto the rear flange. The arrangement should now appear as below.

Figure 3 : Adjustable Mount and Air Purge Details

CODEL


2.5. Transmitter & Receiver Units By means of three M6 hexagon head screws, the transmitter and receiver may be attached to the equipment mount with the flexible gasket supplied, fitted between them. Take care to locate the dowel.

Figure 4 : Transmitter/Receiver and Air Purge

! Before mounting the air purges and the transmitter and receiver,

ensure that compressed air is supplied to the air purge unit. If this precaution is not observed, then the air purge and the optical surfaces may be severely contaminated.

2.6. Air Supply The purpose of the air purges is to keep the windows of the transmitter and the receiver clean. Air may be supplied by one of two methods :

• Compressed Air : An air supply of 1.5bar is required, and the consumption is 0.25l/s.

• Blower Air : A blower may be used to provide the air to the air purge. Customers may specify their own blower; it should be able to deliver 1.5l/s against the working pressure of the duct. CODEL can specify a blower if required.

CODEL


2.7. Signal Processor and Power Supply Units To mount the signal processor first remove the cover by loosening the four captive screws, unplug the ribbon cable at the connector on the lid PCB. The case is then secured to a firm support by use of the four mounting holes found in the four corners of the case, outside the sealing rim. Since the mounting holes are located outside the seal of the case, it is not necessary to seal the mounting holes after installation, nor is it necessary to remove the circuitry from the case for installation. If commissioning is not to be carried out immediately, reattach the lid to the processor. Dimensions and mounting details are shown in Figure 5. Installation of the power supply unit is carried out similar to the above.

Figure 5 : Signal Processor/Power Supply Mounting Details

2.8. AC Supplies The instrument may be powered from an AC supply (50 or 60Hz) at voltages ranging from 88V to 264V. No voltage selection is necessary.

! When connecting the cores of the mains cable into the power

supply unit, ensure that the cable is disconnected from the mains power supply.

CODEL


2.9. Outputs Three forms of output are provided :

• two selectable current outputs (normally 4 to 20mA). Maximum

load is 500.

• single pole changeover relays for :

two alarm relays triggering at a threshold set in the signal

processor.

data valid indication, operating under power failure and any

equipment fault condition - see the Basic Fault section for

further details.

2.10. Normalising Inputs The dust measurement may be normalised to standard conditions. Normalising data can be brought into the instrument in one of two ways :

• entering a fixed value via the keypad.

• using the 4 to 20mA output from pressure, oxygen and

temperature transducers (Model 1001 only).

! Normalisation data is only required if the instrument is being used

as a dust monitor. 2.11. Cable Requirements Cable requirements from the customer are as follows :

• Current Loop Output : Any suitable 2-core cable. Maximum

length depends upon keeping output load within the 500

maximum load requirement.

CODEL


• Contact Outputs : Any 2-core cable capable of supplying the

power to the warning device/relay etc. (1A @ 30V DC, 0.3A @

120V AC, max. power resistive load 30W).

• AC Power : Any suitable 3-core power cable capable of carrying

50VA.

• Analogue Inputs : Any suitable 2-core cable. Maximum length

depends upon keeping the load within the specification of the

measurement transducer.

2.12. Plant Status Input Two terminals (34 & 17) are available within the processor to receive a plant status contact input (optional). This facility is to prevent the rolling averages being diluted by measurements made during periods where the plant is shut down. In normal operation (plant operating) these terminals should be left open circuit, if the terminals are shorted together, the averaging stacks will not be updated.

! For normal operation, terminals 34 & 17 must not be linked

together, if this facility is not to be used. 2.13. Connection Schedule The overall connection schedule is shown in figure 6. Cable glands are available to accept the cables - remove the blanking plugs before threading the cable through.

! Ensure that the transmitter and receiver are connected to the

correct terminals otherwise damage may result. When initialised, the 'DATA VALID' relay is automatically

switched to 'Normally Closed' to accept valid data.

CODEL


Figure 6 : Connection Schedule

CODEL


3. Commissioning 3.1. Introduction Commissioning the instrument can takes up to a couple of hours and is conducted as follows :

• Power Supply Voltage Selection : No selection is necessary.

• Applying Power : Switching the power on and observing the power supply rail indications.

• Alignment : Optically aligning the transmitter and receiver units using the integral adjustable mount.*

• Gain Adjustment : Adjusting the gain within the receiver head and the signal processor.*

• Calibration : Calibrate to a zero, or a known opacity level.*

• Operating Parameters : Setting the operating parameters within the micro-processor to provide correct instrument operation.

• Recording the Set-up and Calibration Data : It is strongly recommended that the operating parameters are recorded in the table at 3.7.3. Example 2 : Dust Monitor and the calibration data in the table at 3.8. Calibration Data.

* Preferably conducted when a clean stack condition exists. These commissioning procedures are now examined in detail. 3.2. Turning the Power On Switch the power on. Ensure that the power indication LED’s illuminate. If not, check the fuse and the supply. Replace the lid of the processor but do not fully tighten the signal processor screws until after commissioning. The instrument will automatically select the normal display mode.

CODEL


3.3. Key Pad Operation Each mode is accessed sequentially by each push of the MODE key. Figure 7 illustrates the display and keys of the signal processor. After a mode has been selected, the ARROW keys will select the various options within these modes. The ENTER key will input the displayed value, and may step the cursor to the next option, if this is applicable.

Figure 7 : Illustration of Signal Processor Unit display and keypad

3.3.1. Mode Key The MODE key will take the instrument to the next mode of operation, or take the instrument out of the current mode and back to mode 1. 3.3.2. Arrow Keys Pressing the ARROW keys will do one of two things, depending on the position in the program :

• it will increase or decrease the displayed value. If the key is

held down it will scroll quickly to the desired value, or

• it will step through the available options within a mode or sub mode.

3.3.3. Enter Key

CODEL


Pressing the ENTER key will do one of two things depending on the position in the program :

• it will input the displayed parameter value, or

• it will select the displayed mode or option from within a mode or sub mode.

! Allow time for the instrument to respond to a key instruction,

otherwise a double key entry may be recorded. 3.3.4. LED Indication The two LED’s (Data Valid & Alarm) indicate correct instrument operation and a high dust, opacity, Ringelmann level. They mirror the operation of the two contact relays. 3.4. Alignment The transmitter and receiver unit need to be in reasonable alignment in order for the instrument to operate satisfactorily. Some optical redundancy has been built in to the design, and this allows normal duct movements not to affect instrument operation. Carry out this alignment as follows :

• Press MODE 4 times to enter the SET UP MODE menu.

• Press ENTER 4 times to enter 0000 for the security code (this will be reset later).

• Press the DOWN ARROW to reach the CALIBRATE menu.

• Press ENTER to access Set Detectors option. The detector levels are now displayed in the LCD. Leave the display for the time being.

• Remove the receiver from its purge by removing the four M6 hexagon head bolts.

CODEL


• Adjust the alignment of the transmitter flange until the bright glow of the transmitter LED can be fully seen when viewed down the receiver orifice. Alignment is achieved by loosening the four locking nuts and adjusting the four adjusting nuts located between the front and the adjustable flanges - see Figure 8.

Figure 8 : Adjustable Mount Details

• When the LED is seen clearly through the receiver orifice, lock the assembly into position by tightening the four locking nuts.

• Re-attach the receiver to its purge and set the receiver gain - see below.

• Adjust the alignment of the receiver until a maximum level is given at the detector (Dr) - see bottom line of LCD.

• Once a maximum level at Dr has been found, secure the alignment by tightening the locking nuts on the adjustable flange at the receiver.

• Press ENTER to leave Set Detectors option.

• The alignment is now complete. Once this adjustment has been made there is rarely any need for further alignment adjustment. The optical design is capable of accommodating normal duct movements without any effect on the operation of the device.

CODEL


3.5. Gain Adjustment The receiver (Rx) gain has two stages. The first, adjustable via the keypad, is in the receiver head and consists of a low (x1) or high (x10) setting. The second stage is a variable gain within the signal processor (SP) and is adjustable using VR1 (VR2 is for Dt level). After the equipment has been aligned, the gain may be set as follows :

• Enter the SET-UP mode (mode 5) CALIBRATE menu - Set Rx Gain option.

• Rx gain can be scrolled HIGH or LOW by the UP and DOWN arrow keys and entered by the ENTER key.

• SP gain is adjusted using VR1.

• View the detector levels from set detectors within the CALIBRATE menu and progressively increase the gain until a detector level between 10,000 and 20,000 is obtained.

Note : Always try the RX gain HIGH setting first. If the caption ‘Rx Det Saturated’ appears, then switch to Rx LOW to remove the saturation.

! Should the instrument be commissioned when a high opacity is

present in the duct, reduce the level of Dr to between about 6,000 and 10,000. This is to prevent overloading if the opacity level reduces.

• Press ENTER to return to the CALIBRATE sub mode. Press MODE to return to the unit to operating condition, i.e. MODE 1.

3.6. Basic Calibration Before the instrument can calculate the correct opacity within the duct, a basic calibration routine must be conducted. Select the set up mode and conduct a basic calibration, detailed below. Section 4.9. Calibrate contains a fuller description. Record the calibration data in the table at 3.8. Calibration Data.

CODEL


Ideally the flue/ duct should be operating under clean conditions (zero opacity) for commissioning. If this is not practical, however, a target calibration opacity can be assumed, in which case, should a clean flue become available, the instrument must be re-calibrated.

! Before completing commissioning and leaving equipment

operational, ensure that the air supply to the purges is operating.

Allow enough time for each key press to action otherwise double keystrokes may be entered. 3.6.1. Initial Calibration

• Press MODE 4 times, to access SET UP mode.

• Press ENTER 4 times, to enter 0000 for the security code.

• Press DOWN arrow 8 times and ENTER once, to access CALIBRATE option.

• Press DOWN arrow twice and ENTER once to access CALIBRATE.

• Set opacity Target to zero (for clean duct) or assumed opacity. Do this by using the UP and DOWN arrow keys.

• Press ENTER, the menu will now enter the Cycles option. Set this to the required number (30 is recommended for this initial calibration).

• Press ENTER twice and the calibration will start, the calibration factor will be given at the end of the process and the instrument will return to normal operating mode.

3.7. Operating Parameters For the instrument to function as required, all operating parameters must be entered into the microprocessor within the signal processor. The operating parameters of the instrument are set from the set-up mode, they are then held in non-volatile memory and retained in the event of a power loss.

! All operating parameters are entered in the set-up mode - see

the ‘Operation’ section for details.

CODEL


To aid commissioning, and to record any subsequent changes to the operating parameters, the table at 3.7.3. Example 2 : Dust Monitor, displays all the options available and can be used as a record. Two example set-ups are also shown in this table. (Details at the end of this section). 3.7.1. Setting Parameters after Initial Calibration This is a step by step, keystroke by keystroke description of setting the parameters in the signal processor. All definitions of parameters are given in the operation section. It is strongly recommended that the operation details are read, and all required parameters for the process in hand determined before entry into the signal processor. The table at 3.7.3. Example 2 : Dust Monitor can be used to make a note of which parameter settings are to be used.

1. Press MODE until SET UP is displayed in the top left of the LCD (4 times).

2. Press ENTER (4 times). The security code has not yet been set, so it is still at the default factory setting of 0000. When the code has been set, after this section has been completed the 4 digit security code must be entered.

3. The first sub menu is AVERAGES.

4. Press ENTER to access this menu and the first option is seconds.

5. Press ENTER to access the values. Use the UP and DOWN arrow keys to select the average required. These can be chosen from 10 to 60 seconds in 10-second intervals.

6. When the required value is displayed press ENTER. The value has now been entered into memory.

7. The menu will automatically scroll down to the next option, which is the minutes average (minutes).

8. Press ENTER to access values for this average. It is set in the same way as for seconds.

! Remember that when ENTER is pressed after a value has been

selected this value is now set in the memory.

CODEL


9. Ranges for the averages are :

minute 01 to 60 in 1 minute intervals

hour 01 to 24 in 1 hour intervals

day 01 to 30 in 1 day intervals

10.When days has been entered the LCD will read RESET, select YES and the display will prompt SURE. Select YES and after the averages are reset the display will read EXIT. Press ENTER and the processor will return to the SET UP mode menu option AVERAGES.

11.Use DOWN arrow to show CONFIGURE O/P 1 (configure output 1). Press ENTER to access the menu. The first option is Output.

12.Press ENTER to access this option and use the UP and DOWN arrow keys to select either 0 or 4mA as the origin for current at the outputs. Press ENTER when the correct one has been selected.

13.The OUTPUT option is exited and the AVERAGES option is selected. Press ENTER to access the option and use UP and DOWN keys to select which average is to be displayed in the operating mode.

14.Press ENTER and Units is the next option. Press ENTER to access the option and use the UP and DOWN keys to select which units are displayed. The choices are:

%OP Optical Density mg/m3 mg/Nm3 Ringelmann

15.Press ENTER and Span is displayed. Press ENTER and select the span value required.

16.The first digit is selected by using the UP and DOWN arrow keys and pressing ENTER, the cursor then moves to the second and third digits in turn.

17.When all have been selected press ENTER.

18.The Span menu is exited and Fault Cond (condition) is viewed.

19.Press ENTER and select either :

CODEL


ZERO HOLD F.S. MEAS

by using the UP and DOWN keys. Press ENTER.

20.Set mA Output is the next option accessed. This option may not need setting as the output calibration will have been set at the factory - skip this and go to point 22 if preferred. Press ENTER and set zero appears on the LCD. Press and hold the UP or DOWN arrow keys to adjust until 0mA reads on the ammeter - see 5.9.3.6 for detail.

21.Press ENTER when the correct value is read. Similarly set span value for 20 mA.

22.Press ENTER and EXIT is shown. Press ENTER to return to MODE 5 menu.

23.Use the DOWN arrow key to access CONFIGURE O/P 2 and repeat points 11 to 21 (above) for output 2 of the signal processor.

24.Use the DOWN arrow key to access the ALARM 1 sub menu. Press ENTER and Source is shown on the display.

25.Select the averaging stack which is to be the source for the alarm for output 1. Use the arrow keys to select either seconds, minutes, hours or days and press ENTER.

26.The menu scrolls down to Units, similarly to above select the units for the alarm using the arrow keys, press ENTER when selection has been made.

27.The menu now scrolls down to Level. Select the level required for alarm 1. Press ENTER and the menu scrolls to EXIT. Press ENTER and use the down arrow key to move to ALARM 2.

28.Set the parameters for ALARM 2 (output 2) as in points 23 to 26 (above).

29.Use the DOWN arrow key to select the PARAMETERS sub menu, press ENTER.

30.The first option in this menu is SECURITY. Press ENTER and use the UP and DOWN arrow keys to adjust each digit in turn from left to right. Press ENTER when each digit is correctly selected. After the fourth digit is set the menu will return to SECURITY.

CODEL


! Make a note of this number; this is the security code required

every time the SET UP MODE is entered in the future.

31.Press the DOWN arrow key to select Identity, press ENTER. Use the arrow keys to scroll the device identity number between 01 to 255.

32.Press ENTER and the DOWN arrow to select Pathlength. Press ENTER.

33.As before alter each digit individually using the arrow keys; press ENTER when the correct value is selected. After the fourth digit the menu will return to Pathlength.

34.Use the DOWN arrow to select Dust Factor sub menu.

35.Press ENTER to access the option and use the arrow and ENTER keys as usual to select the value required.

36.Press ENTER when complete.

37.Use the DOWN arrow to access Auto Zero option. Set the figures to the required value.

38. Press the DOWN arrow and the EXIT option is accessed on the LCD. Press ENTER to leave the PARAMETERS menu. Use the DOWN arrow key to select the NORMALISATION menu.

39. Use the same key combinations to select all normalising parameters, if required. EXIT this menu to return to SET UP mode.

40. Use the DOWN arrow key to access the CALIBRATE menu. Press ENTER.

41. Use the DOWN arrow to select the CALIBRATE option. Proceed as described previously. See section 3.6. Basic Calibration.

42. Note the new Cal Factor and detector levels.

43. The unit is now fully commissioned. 3.7.2. Example 1 : Smoke Monitor The parameters shown below illustrate some typical settings to use the instrument as a smoke monitor. The salient settings are described below :

• Averages

CODEL


10-second, 10-minute, 1-hour and 30-day rolling averages are set-up.

• Output 1

The analogue output (4 - 20mA) represents Ringelmann 0 to 5, with a fast response time 10 seconds. Also, should a system fault occur, the instrument will still attempt to measure the Ringelmann value.

• Parameters

As the instrument is not being used as part of an integrated system, the device identity is not required.

The 1hour rolling average is used to provide an alarm at Ringelmann 2, where the change-over contact relay will operate.

Neither a pathlength, nor a dust factor are required for the calculation of a Ringelmann value.

The plant is in continuous operation so the auto zero facility cannot be used.

• Normalising Normalising parameters are not required for the calculation of a Ringelmann value.

3.7.3. Example 2 : Dust Monitor The parameters shown below illustrate some typical settings to use the instrument as a dust monitor, as part of an integrated system. The salient settings are described below :

• Averages 30-second, 10-minute, 1-hour and 7-day rolling averages are set-up.

• Output 1 The analogue output (4 - 20mA) represents 0 to 250mg/Nm3, and is a 1-hour rolling average. Should a system fault occur, the instrument will drive the analogue output full scale.

CODEL


• Parameters As the instrument is being used as part of an integrated system, the device identity has been set to 4. This value must be unique from other monitors in the system.

The 1-hour rolling average is also being used to provide an alarm at 50 mg/Nm3, where the change-over contact relay will operate.

A dust factor has been estimated at 5000 (2500/0.5m) until iso-kinetic sampling can be conducted.

The plant is shut down daily, so the auto zero facility can be used

to reset the zero of the instrument during these periods of inactivity. This value should be set as low as possible. 1%/day should be set initially, then if window fouling still causes a problem, increase this figure.

• Normalising The data is being normalised to standard conditions, 0oC, 3% oxygen, 101kPa pressure.

Normalising data for oxygen and pressure is relatively constant

(11% and 104kPa respectively) and each is entered into the instrument via the keypad.

The temperature within the duct, however, is variable, and is being

measured with a transducer that provides a 4 to 20mA output proportional to 0 to 400oC.

CODEL


Parameter Factory Site

Averages seconds 30

minutes 10

hours 1

days 1

Output 1 0 or 4mA base 4

units %Op

span 100

average 30s

fault condition FS

Output 2 0 or 4mA base 4

units %Op

span 100

average 30s

fault condition FS

Alarm 1 source 30s

units %Op

level

Alarm 2 source 30s

units %Op

level

Parameters security 100

identity number 01

pathlength 1000

dust factor 2500

auto zero 0%/day

Normalisation Temperature

standard level oC 0

analogue i/p @ 4mA

analogue i/p @ 20mA

keypad i/p oC 0

CODEL


Oxygen

standard level % 3

analogue i/p @ 4mA

analogue i/p @ 20mA

keypad i/p 3

Pressure

standard level kPa 101

analogue i/p @ 4mA

analogue i/p @ 20mA

keypad i/p kPa 101

Water Vapour

standard level % Dry

analogue i/p @ 4mA

analogue i/p @ 20mA

keypad i/p %

3.8. Calibration Data As a record of the instrument's initial calibration data, enter the diagnostic mode and record the levels of the calibration and measurement variables. This will then serve as a reference should a system complication occur, for future fault finding exercises.

Detector Outputs Site

D receiver

D transmitter

Calibration Data Site

kcal

kwkg

CODEL


4. Operation 4.1. Introduction After the instrument has been commissioned, it will measure the transmissivity between the transmitter and receiver, and produce an output proportional to either the opacity, dust, Ringelmann or extinction level. An integral 32-character display also shows the calculated levels. The instrument allows the operator to interrogate the micro-processor to observe the system parameters, and to change them if required. A menu based program is used and access is gained by four keys mounted on the lid of the signal processor. 4.1.1. Measurement To calculate the opacity, an LED light source is positioned on side of the duct, and a detector at the other. The light from the LED is modulated (to avoid interference from ambient light) and the level from the detector is a measure of the opacity in the duct. In addition, a detector within the transmitter constantly monitors the intensity to provide a reference. 4.1.2. Calibration During the commissioning procedure a calibration is conducted, which sets the system gain to produce a zero or known opacity. An automatic zero facility allows the instrument to compensate for a slow build-up of optical contamination. 4.2. Operating Modes The instrument has six modes of operation which are identified by a number in the top left-hand corner of the display :

1. Operating Mode - display average opacity, extinction, dust density or Ringelmann level.

2. Parameter Mode - display operating parameters.

3. Normalisation Data - display normalisation data.

4. Diagnostic Mode - investigate instrument operation.

CODEL


5. Set-up Mode - set operating parameters. The mode can only be accessed using a security code.

! The outputs of the instrument are unaffected by key operation in

all modes except the set-up mode. 4.3. Program Tree Figure 9 illustrates the main program of the instrument. Where an operating mode is complex, an extra program tree is given in this section.

CODEL


Figure 9 : Program Tree

CODEL


4.4. Operating Mode From this mode of operation the four averaging times, seconds, minutes, hours and days, may be displayed. The four concentration units, opacity, extinction, dust density and Ringelmann levels, may be altered and the measured/normalised measurements for dust density observed. When in this mode, the display will appear similar to that shown below. If the display is not similar to this, press the MODE key until number 1 appears in the top left corner of the display.

To change the data displayed, press the ENTER key and a flashing cursor will appear at the beginning of each of the four concentration units. The ARROW keys will now change the highlighted parameter. Each push of the ENTER key will select another of the parameters, in the following order :

• Concentration Units - opacity, optical density, dust density (mg/m3 or mg/Nm3), Ringelmann.

• Averaging Time - seconds, minutes, hours, or days. Once the display configuration is as required, press the ENTER key when the cursor is flashing on the averaging time, and the cursor will disappear from the display. The ENTER key may be pressed again if required to bring the cursor back onto the display. 4.5. Parameter Mode In this mode, the parameters set within the set-up mode may be examined, but not changed. Press the MODE key until the number 2 appears in the top left corner of the display, then press the ENTER key. The ARROW keys will now scroll through the available options, press the ENTER key to display the selected option. Press the ENTER key again to exit from each option. See the set-up mode for further details of the display information, and how to change the held parameters.

CODEL


4.5.1. Identification From this option, the analyser type, its program number, and the device identity of the instrument may be displayed.

• Instrument type - EnergyTech 100 Series 101/102

• EPROM number - will display the communications EPROM ID

• Identity - for factory set-up only 4.5.2. Parameters The following parameters are examined from this option, selected using the ARROW keys :

• Measurement Path Length The path length between the transmitter and receiver. This value is not used within the current program and is for reference only.

• Dust Factor A 'Dust Factor' is used to calculate the dust density; see section 5.12.

• Output Fault 1 Should a fault condition occur on output 1, the analogue output can be set from one of four options see the set-up mode. The selected option may be examined here.

• Output Fault 2 As above for output 2.

• Auto Zero The auto zero facility compensates for any optical contamination. Compensation ranges from 0.1% - 8% and can be displayed here. INHIBIT is displayed if the option is not selected.

CODEL


4.5.3. Averages Selecting this option will display the times set for each of the four averaging stacks. 4.5.4. Outputs

• Output 1 The base, span and averaging of analogue output 1 are displayed from this option.

• Output 2 As above for analogue output 2.

4.5.5. Alarms

• Alarm 1 A contact output is available within the processor to indicate high opacity, extinction, dust and Ringelmann levels. The level at which this output (analogue o/p1) is operated, and the averaging stack from which the concentration value is obtained, may be examined from this display.

CODEL


• Alarm 2 As above for alarm 2, analogue output 2.

4.5.6. Plant Status On entering this option the plant status condition is displayed, i.e. ON or OFF. Minutes, hours and days rolling averages are held and current outputs set to zero, with alarms deactivated.

4.6. Normalisation From this mode, the normalisation parameters that are currently being used can be displayed. Press the ENTER key to enter the routine, and use the ARROW keys to select which of the normalising parameters to display. Press the MODE key until the number 3 is seen in the top left corner of the display. When the required normalising parameter is displayed, press the ENTER key to display the normalisation data. Press the ENTER key again to exit the parameter. The available parameters are :

• temperature

• oxygen (wet or dry measured input)

• pressure

• water vapour

CODEL


4.6.1. Display Format For each of normalising parameters the display will appear similar to that shown below.

4.7. Diagnostic Mode The detector levels, Analogue to Digital (A-D) levels, receiver gain, calibration and opacity data may be examined from this mode. Press the MODE key until number 4 appears in the top left corner of the display, and push the ENTER key to enter the mode. The ARROW keys will now select from the following, press the ENTER key to select the displayed option. Error! Reference source not found. illustrates a program tree for this mode.

CODEL


CODEL


4.7.1. Detector Outputs The output levels from the detector within the receiver and within the transmitter are displayed here. Dt is the detector level at the transmitter and Dr is the detector level at the receiver. The level of Dr is typically between 15,000 and 25,000, and will vary according to duct width, the gain setting and the opacity in the duct, Dt (set by the transmitter pot) is typically similar to Dr.

4.7.2. Rx Gain The receiver gain factor is displayed here. This can be either high or low and is set during the commissioning procedure according to the duct width.

4.7.3. Calibration Data Kcal is the calibration gain factor calculated during the calibration routine. Kwkg is the gain factor including any auto zero adjustment that may have taken place.

CODEL


4.7.4. Opacity Data This display indicates the raw (Op0) and the 60 second average (Op60) opacity values. The 60 second smoothed value is used to generate the minutes, hours and days rolling averages.

4.7.5. 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:

• Tx Det. Low - Dt is less than 4096.

• Tx Det. Saturated - the detector level within the transmitter is too high for the current duct conditions. Dt is greater than 24,000.

• Rx Det. Saturated - the detector level gain within the receiver is too high for the current duct conditions. Dr is greater than 24,000.

• Dirty optics - the lens of either the transmitter or receiver are contaminated. Kwkg is approximately equal to twice Kcal.

• Kcal too high - calibration has produced a Kcal value >32,767 due to incorrectly set detector levels.

• All Clear - no fault condition. Also, the previous fault may be displayed by pressing the down arrow key.

CODEL


4.8. Set-up Mode All system parameters can be changed and a basic calibration initiated from this mode. To prevent any unauthorised changes, the user must enter a four number security code before the mode can be accessed.

! After this mode has been selected, the instrument will suspend

its operation. If no key is pressed within 5 seconds after selection of this mode, the instrument will revert to the normal operating mode.

Press the MODE key until the number 5 is displayed in the top left-hand corner. After the security code has been correctly entered, there are 8 sub-modes of operation, (see Figure ), from which the set-up parameters may be changed; these are :

• Set Averages The four averaging stack times (seconds, minutes, hours & days) may be set as required. The averages may also be reset from this menu.

• Configure O/P 1 The first analogue output is configured from this sub mode.

• Configure O/P 2 As above for analogue output 2.

• Alarm 1 The source, units and level of the alarm for output 1 are set here.

• Alarm 2 As above set for output 2.

• Parameters The following are set from this mode : security #, identity #, pathlength, dust factor, auto zero and plant status.

• Normalisation

CODEL


All normalisation parameters may be set up from this mode.

• Calibrate The outputs of the detectors and the basic calibration of the instrument can be set. After the correct code has been entered, the user may access each of the eight sub-modes (listed above) by using the ARROW keys and pressing ENTER when the required option is displayed.

! When a parameter has been altered and ENTER has been

pressed to exit the option, the changed parameter has been altered in the memory. There is no ‘confirm’ option for changed parameters.

4.8.1. Security Code Entry Once this display is shown, to gain access to the set-up mode, press the ENTER key. The cursor will now flash over the first digit of the presented code number, select the required first digit with the arrow keys and press ENTER. Repeat this procedure for the remaining three numbers. If the code is correct after the ENTER key is pressed on the last digit, then the sequence will be continued, if it is not correct, the instrument will return to the operating mode.

! 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.

CODEL


Figure 11: Program Tree for the Set-up Mode

CODEL


4.8.2. Averages Four separate averages are calculated within the instrument. These are defined in units of seconds, minutes, hours and days. Any of these four averaging stacks can be used to provide the analogue output of the instrument. Each averaging time is set within pre-defined limits.

Press the ENTER key when this display is shown, the display will now show seconds. Use the ARROW keys to select the average time that requires changing, and press the ENTER key to access it. The value can now be changed using the ARROW keys and input by pressing the ENTER key.

Set the seconds averaging stack to the required value. This is limited from 10 to 60 seconds in 10-second intervals.

Set the minutes averaging stack to the required value. This is limited from 1 to 60 minutes in 1-minute intervals.

Set the hours averaging stack to the required value. This is limited from 1 to 24 hours in 1-hour intervals.

CODEL


Set the days averaging stack to the required value. This is limited from 1 to 30 days in 1-day intervals.

The average values currently held in the four averaging stacks can be reset using this option. This will erase the current averages that are held in all of the stacks. Select either YES or NO using the arrow and enter keys. If YES is selected confirmation is requested before the averages are reset. If this option is selected, all data in the averaging stacks is reset and the data for as much as 30 days will be lost. 4.8.3. Configure O/P1 The analogue current loop output for output 1 is set up from this mode. Press the ENTER key while this display is shown, then press the ARROW keys to step through the available options. Press the ENTER key to enter each option; change the displayed parameter by using the arrow keys.

CODEL


4.8.3.1. Output An origin of 0 or 4mA can be set for the current loop output. The ARROW keys will toggle between these two options. Press the ENTER key to enter the new value.

4.8.3.2. Average Any of the four averaging stacks (seconds, minutes, hours or days) may be used for the analogue output. They are selected by the ARROW keys and entered using the ENTER key.

4.8.3.3. Units The analogue output can represent either a measure of: opacity, Ringelmann, extinction or dust. The ARROW keys will scroll through these options, press the ENTER key to chose the correct units. The dust is represented as either mg/m3 or mg/Nm3 the latter normalised to standard conditions.

4.8.3.4. Span

! Both the zero and span values default to zero one second after

being displayed - these must always be re-configured for the instrument to function properly.

CODEL


Press the ENTER key and the Zero value will need to be entered. Select using the ARROW keys for each digit. The ENTER key is pressed to enter the value of each digit. The units displayed will depend on what has been selected above.

The current value will be displayed for 1 second then the value will clear to zero. This must always be reset for the instrument to be configured correctly. When the zero value has been correctly selected press the ENTER key to access the next display which is Span. The upper limit of the span is set here in a similar manner to the zero and its value will depend on the maximum emission of the process being monitored. Once again the current value will be displayed for 1 second and will clear to zero. This must be reset for the instrument to be configured correctly.

4.8.3.5. Fault Condition Should a fault condition occur, the current output of the instrument may be set to any of the following options.

• Set the output at 0mA - ZERO.

• Adjust the output to the measured concentration even though a fault condition exists – MEAS

• Hold the last measurement - HOLD.

• Set the output to full scale (20mA) - F.S.

CODEL


One of these options can be selected by pressing the ARROW keys, when the desired option is displayed press the ENTER key. 4.8.3.6. Set mA Output

! This will already have been configured at the factory - do not alter

unless the calibration is suspected to be wrong. The current levels of the analogue output are set up in this option. Press the ENTER key to access the option and set the current levels at 0 and 20mA as prompted.

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 (47 and 48). Nothing else should be connected to these terminals when the output is being set up. The UP and DOWN arrow keys will take the current up and down respectively. Press the ENTER key when the correct output current is displayed on the ammeter. The limits for the display value are 0 to 4095. A typical value will be 40.

! Zero milliamps should be set up, irrespective of the selection for

the base of the current output.

CODEL


In a similar manner as above, the current output level should now be set to 20mA using terminals 47(+mA) or 48(0V).

The limits for the display are 0 to 4095. A typical value will be 3700. 4.8.4. Configure O/P2 This menu sets analogue output 2. Proceed as in section 4.8.3. Configure O/P1 For this output use terminals 23(+mA) and 24(0V) to set 0mA and 20mA outputs, if necessary.

4.8.5. Alarm 1 The alarm parameters for analogue output 1 are set in this sub menu.

4.8.5.1. Source Press ENTER and this option is displayed. Select the averaging source (averaging units) required for this source. These are selected in a similar manner as for Configure Outputs; see section 4.8.3. Configure O/P1 & 4.8.4. Configure O/P2 When the source is selected press ENTER to access the next option.

CODEL


4.8.5.2. Units This option is entered after Source has been completed. Select the units required for the alarm as in section 4.8.3.3. Units. When these have been selected press ENTER and the Level option is accessed.

4.8.5.3. Level Select the required level for ALARM 1. Note that the current value is displayed for 1 second, but then it defaults to zero and so must be re-entered for the alarm level to be properly configured.

4.8.5.4. Exit After the alarm level has been set press ENTER to reach this display. Press ENTER and the display exits to the ALARM 1 option.

4.8.6. Alarm 2 Use the DOWN arrow key to select this after ALARM 1 has been completed. The parameters for the alarm for analogue output 2 are selected here in a similar manner as for ALARM 1.

4.8.7. Parameters

CODEL


Select this option by pressing the ENTER key. The ARROW 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.

4.8.7.1. Security Number To prevent any unauthorised-authorised tampering with the set up information, it is important that the security code is changed from the factory setting. Each digit is selected with the ENTER key and changed with the ARROW keys.

! It is important to make a note of this number otherwise it will not

be possible to change the instrument set up. 4.8.7.2. Identity Number This facility is only intended for factory set-up and testing.

CODEL


4.8.7.3. Measurement Path Length

! When this option is accessed the value defaults to zero after 1

second. The path length entered is used for reference purposes only and should represent the length of the actual dust measurement, not the flange-to-flange dimension between the source and receiver. The current value is displayed for 1 second and then defaults to zero.

4.8.7.4. Dust Factor If the instrument is being used as a fine dust monitor, a dust factor is required to convert the opacity level to a measure of dust. A value up to 9999 may be selected.

4.8.7.5. Auto Zero To compensate for a slow build up of contamination on the lens of the receiver and the transmitter, the micro-processor can adjust the gain factor of the instrument effectively moving its zero position. This feature may be set from 0.1% to 8% opacity per day, or it may be inhibited by setting to 0%.

CODEL


4.8.8. Normalisation All of the normalisation inputs and parameters are set up from this mode. Press ENTER to access the mode and the ARROW keys will select which of the normalising inputs are to be changed, they are :

• Temperature.

• Oxygen.

• Pressure.

• Water Vapour.

! Normalising parameters are only required for the calculation of the

dust density.

After selecting the normalising parameter, the user may set the standard levels to which the measurement is to be normalised, and how the instrument reads the value, i.e., fixed keypad input (or 4 - 20mA input – Model 1001). Figure illustrates the program tree for entering the normalisation parameters.

CODEL


Figure 12 : Normalising Set-Up Program Tree

CODEL


4.8.8.1. Setting the Normalising Parameters After selecting the parameter to be set up, the ARROW keys will select between entering the standard levels, and how the normalisation data is to be brought into the instrument.

• Set Standard Levels Each normalising parameter normalises the measured dust concentration to standard conditions of temperature, oxygen, pressure and water vapour. These levels are set from within this option and are typically 00C, 3% Oxygen, 101kPa pressure, dry water vapour. Use the ARROW keys to change each displayed normalising standard value. Refer to the process guidance notes for the application in which this unit is being used, to determine the best normalisation values.

• Set Values The normalising data can be brought into the instrument in one of 3 ways :

by entering a fixed value via the keypad. This is suitable where

the value is stable to about 5%,

using the 4 - 20mA inputs within the processor to receive a measurement transducer data. The values at 4mA and at 20mA will be requested should this option be selected.

4.8.8.2. Temperature

CODEL


Enter the temperature of the flue gas at the point of the across the duct measurement. This value is used to normalise the dust measurement. 4.8.8.3. Oxygen To correct the data to standard levels of oxygen, an estimate of the oxygen at the point of measurement is required. If no normalisation for oxygen is required, then a fixed value should be used and the standard level brought to the same value. If the oxygen level is being continuously measured, connect the analogue output of the oxygen analyser into the CODEL analyser, and select the analogue input. A keypad input is assumed to be a DRY oxygen level. An analogue input level can be selected for a WET or DRY oxygen measurement instrument. Note that mode 4 displayed oxygen is always expressed as oxygen % DRY for the normalisation calculations. 4.8.8.4. Pressure To correct the data to a standard pressure normally 101kPa, the pressure at the point of measurement needs to be determined. If the flue pressure is relatively constant through all firing conditions, then a fixed input should be used. If the pressure is not constant, it should be measured and bought into the instrument via the 4 - 20mA input within the processor. With an integrated system the pressure data can be taken to the instrument via the serial data line. If no normalisation for pressure is required, then a fixed value should be used and the standard level brought to the same value. 4.8.8.5. Water Vapour The standard level is set to wet or dry. For the set values option the percentage water vapour in the flue gas needs to be determined and entered. This has a range of 0.0 to 30.0%. If the vapour concentration is relatively constant a fixed input should be used. If it is not it should be measured and brought into the instrument via the 4 - 20mA input in the processor. If no normalisation for water vapour is required, a fixed value should be used and the standard set to dry.

CODEL


4.9. Calibrate From this option the levels of the detector within the receiver and within the transmitter may be displayed. The basic calibration of the instrument is set by a ‘Gain Factor’ which can be calculated during a calibration routine.

Press the ENTER key while this is displayed and the following options are available : 4.9.1. Set Detectors Dt is the level from the detector within the transmitter, and Dr is the level from within the receiver. Fault conditions are displayed for each detector. Once aligned correctly increase receiver gain until the fault condition 'Rx saturated is displayed', then decrease receiver gain by one.

! If the receiver signal is extremely high, saturation of the

analogue to digital converter (ADC) within the processor may occur. As a result the fault condition 'Rx saturated' is displayed. If this fault should appear, then the receiver Gain should be reduced accordingly.

CODEL


4.9.2. Set Rx Gain Set the receiver gain initially to low. Changing to high will give an approximate tenfold (10x) increase in Dr.

4.9.3. Calibrate The basic calibration of the instrument can be calculated from this routine. It is preferable to conduct this operation with the plant shut down to ensure a zero opacity within the duct. If this is not possible, however, the instrument can calibrate to an estimate of the opacity the calibration target. Set the calibration target either to an estimate of the opacity or to zero, and set the desired number of cycles over which the calibration factor is determined (a minimum of 16 is recommended). The calibration should now be run and the display will show a count down during its execution. When the calibration is complete the instrument will exit the calibration routine.

CODEL


! The calibration routine must be run during commissioning,

otherwise the instrument will not be able to calculate the true level within the duct. DO NOT run the calibration routine unless reasonable conditions exist in the duct. If it is not the initial calibration, it is recommended that the Gain Factor is recorded from the parameters option, before the calibration is run.

4.10. Calibration for Dust Measurement For Opacity Monitors to provide a measure of the dust density, the relationship between opacity and the dust density needs to be established. For a particular measurement point in a particular flue, duct, or chimney, this can only be accomplished accurately by iso-kinetic sampling over a defined period. Over the same period, the opacity monitor will calculate the corresponding average extinction, which is directly proportional to the dust density The relationship between extinction and dust density may be described as the ‘Dust Factor’. Dust Density = Fine Dust Density/Extinction

Where : fine dust density = mg/m3 of dust by iso-kinetic sampling

extinction = average extinction for the same period.

This Dust Factor is input and held within the instrument to convert extinction to fine dust density. Some important points to note when calibrating the from iso-kinetic sampling results are given below.

Take care to ensure that the normalisation parameters temperature, oxygen, pressure & water vapour) are set to sensible values, and establish to what standard conditions the sampling results will be normalised to. Iso-kinetic results are automatically brought to ambient temperature as the flue sample cools through the sample line, and in general these are then normalised to 0C (273K). Normalisation to the other parameters is variable, and depends largely upon whether they are being measured at the same time as sampling.

It is reasonable to start with an estimate of the dust factor see the next page and ensure that at least the correct temperature is held within the instrument, entered via the keypad. If it is uncertain

CODEL


whether the sampled data will be normalised to the other conditions, they may be taken out of operation by bringing the measured values to the standard levels, e.g., O2 standard level 3%, value fixed at 3 %, Pressure standard level 101kPa, value fixed at 101kPa, Water Vapour standard level DRY, value fixed at 0 %.

While the sampling is being conducted, record the minutes average and normalised dust value mg/Nm3 preferably from a chart recorder, if used, (making sure of course, that the current output has been correctly configured). If not available, however, the displayed normalised dust value should be recorded regularly for comparison.

After the sampling has been conducted, the two results may be compared, and the dust factor adjusted if necessary, to bring the calibration to that measured by iso-kinetic sampling.

! Important, take care to compare only like with like with regard to the

normalising data. 4.10.1. Estimate of a Dust Factor For the EnergyTech 100 Series 101/102 to calculate the dust density from the opacity data, the Dust Factor needs to be determined by iso-kinetic sampling. However, if there is a delay before sampling can be conducted, an estimate of the dust factor may be used. Estimated Dust Factor = 2500 / pathlength in metres It must be emphasised that this approximation of the dust factor cannot be accurate and that it might be as much as a factor of 2 in error, particularly if the particle size is large.

CODEL


5. System Description 5.1. Transmitter The transmitter uses a high intensity light emitting diode (LED) as the light source. An internal detector monitors the transmitted light intensity. A lens in the front of the enclosure focuses the light from the LED across the duct. Current to the LED is modulated at a frequency of 512Hz. The wavelength of the light emitted is 637 nanometres which is in the red part of the visible spectrum and the source intensity is sufficient for duct widths up to six metres to be accommodated. A fully-sealed (to IP65) epoxy-coated aluminium enclosure houses the transmitter. 5.2. Receiver The receiver consists of a silicon cell detector and its associated electronics housed in an identical enclosure to the transmitter. A lens focuses the light received onto the detector. Because the light from the transmitter is modulated, the receiver is able to measure ambient light levels, and the levels compensated for within the signal processor. 5.3. Signal Processor Unit The signal processor unit is a remotely mounted and provides power for the transmitter and receiver, and produces an output of opacity from the receiver output signal. The following functions are provided by the processor:

It accepts power, 48V DC from the power supply unit, and provides the DC voltage rails required by the transmitter, receiver and micro-processor circuitry.

A measurement of Opacity is obtained from the receiver signal to provide a 0 or 4 to 20mA current output, proportional to either dust, Ringelmann, opacity or extinction.

Change-over contact relays are provided to warn of a high opacity level, and of a system complication.

CODEL


The processor is housed in a fully-sealed (designed to IP65) epoxy-coated aluminium enclosure. 5.4. Power Supply Unit The power supply unit receives mains power, 88V to 264V AC, and provides 48V DC to the signal processor unit. The power supply is housed in a fully-sealed (designed to IP65) epoxy-coated aluminium enclosure.

! Remember that mains voltages are present within the power supply

unit.

CODEL


6. Routine Maintenance The equipment is designed to keep the levels of maintenance to an absolute minimum. 6.1. Cleaning Windows It is important that the optical windows of both the transmitter and the receiver be kept reasonably clean and any mounting tubes free from build-up of dust and fly ash. This can be accomplished by removing the transmitter and receiver and wiping their windows with a soft, dry cloth. If the windows are cleaned, a calibration is advised afterwards. 6.2. Clean Flue Condition Available Should a clean flue condition become available and the instrument was commissioned with an opacity offset, it is recommended that a calibration be conducted to take advantage of this situation.

CODEL


7. Basic Fault Finding 7.1. Initial Checks The electronics require no routine maintenance. They are all solid state and undergo a rigorous factory burn-in procedure. If there is any doubt about the equipment performance, the signal processor may be interrogated from the keypad to determine whether or not the equipment is functioning normally. The typical display modes and the initial variable values shown will act as a guide to determine correct performance. This can be done at any time without interrupting or disturbing the analogue output of the equipment. Some points to note are explored below :

Detector Levels Check the detector levels via the keypad see the diagnostic mode.

Check window contamination Remove the transmitter and receiver from the duct and inspect the optical surfaces - clean with a soft dry cloth if necessary.

Optical Alignment If the units have been ‘knocked’ out of alignment, re-align them - see the commissioning section.

Purge Operation Check that the supply of compressed air is being maintained to the purges, and that the air-movers are drawing in ambient air they should be felt to suck from underneath.

Instrument Power Supply Check that the LED’s within the power supply unit are lit.

! Window contamination or misalignment will give positive

opacity readings with the plant off. If this situation arises, clean windows and realign system before proceeding further.

CODEL


7.2. Data Valid LED Out If one or more fault conditions occur, the data valid LED on the front panel will extinguish, the data valid relay will operate, and the instrument will automatically enter the diagnostic mode to display the fault condition. The following fault conditions are recognised by the instrument :

Transmitter detector saturated (DTH > 24,000), possible cause - transmitter signal failure or incorrect gain adjustment.

Receiver detector saturated (DRH > 24,000), possible causes :

high ambient lighting

incorrect detector gain adjustment

instrument calibrated during high opacity conditions which have now cleared

receiver signal failure

Low transmitter detector level (DT < 4,096), possible causes - transmitter signal failure

Window contamination when 2kcal > kwkg and Auto Zero is not inhibited, possible causes :

calibration conducted during unstable duct conditions

dirty windows

Incorrect signal levels for calibration Kcal >32767

! If a fault condition is recognised by the instrument, the minutes,

hours and days averages will not be updated.

CODEL


8. Specifications Span Fully selectable in terms of dust,

opacity, Ringelmann or extinction Response Time Selectable from 10 seconds to 30 day

rolling average Maximum Path Length 6 metres Construction Fully sealed to IP65 Ambient temperature limits Transmitter and Receiver

-20oC to +80oC

PSU/SPU 20oC to +70oC

Analogue Outputs 0 or 4 - 20mA linear, 500 max. Contact Outputs High Opacity/Dust alarm Data valid Both rated at 1A @ 30V DC, 0.3A

@ 120V AC, max. power resistive load 30W

Keypad Inputs Oxygen Temperature

Pressure Water Vapour

Analogue Inputs Oxygen 4 - 20mA (Optional input PCB Temperature 4 –20mA

required – Model 1001) Pressure 4 - 20mA Water Vapour 4 - 20mA Plant Status Optional Dust Calibration By independent analysis (by others)*

Accuracy 0.2% Opacity (with auto zero active)

1.0% Opacity (without auto zero)

CODEL


Power consumption 30VA, 88/264V, 50/60Hz Air purge consumption 0.25l/s @ 1.5bar

* In the absence of actual data, assume (250/x) mg/m3 of duct

generates 10% opacity in an x metre wide duct. This is not a fixed relationship and must be verified by iso-kinetic analysis.

CODEL


Appendix A - Optical Transmissivity Measurement & Solid Content

Since the aim of all optical transmissivity measurements is to assess the level of solids emission, it is important to consider the relationship between various optical measurements and the particulate content of the gas. It must first be recognised that the optical methods can only be applied if the particulate size is small enough for the mass of the solids to be considered as spread evenly over the cross section of the flue. In general this limits the optical techniques to particles of 20 micron or less diameter. Providing the particle size criterion is met, there are certain very specific relationships between the optical measurements and the particulate concentration.

Figure 13

CODEL


Extinction Coefficient and Beer Lambert Relationship The attenuation of light of a narrow waveband - such as visible or photopic light by fine particulate matter is very specific and is expressed mathematically by the Beer Lambert Relationship : Transmittance T = exp (-k.n.a.l) where : k is the extinction coefficient of the particles n is the number of particles per unit volume a is mean projected area of the particles l is the path length through the gas Thus Opacity = 100 [1 - exp ( -k.n.a.l)] % The extinction coefficient k determines precisely how much light is attenuated by the particles and depends totally on the physical and chemical nature of the particles. For a given flue gas, the particulate type and size distribution should be relatively constant so that the opacity measurement may, for a given path length l, be related to the particulate concentration n. Optical Density & Extinction Optical density and Extinction are different names for the same parameter. This parameter is useful in that assuming the nature and size distribution of the particles are constant, for a given path length, it is directly proportional to the particulate concentration n, and hence to particulate mass emission. Optical density is expressed : Optical Density = log10 1/T and, since T = exp (-k.n.a.l), Optical density = k.n.a.l loge10 The following table provides a simple conversion from measurements in terms of opacity or transmittance to optical density/extinction.

CODEL


Opacity % 0 10 20 30 50 70 90

Transmittance 1 0.9 0.8 0.7 0.5 0.3 0.1

Opacity (Log10) 0 0.05 0.1 0.15 0.3 0.52 1.00

Mass Emission While it is possible to provide an output for opacity monitors in terms of optical density/extinction, conversion of this parameter into a measurement of mass flow emission, in mg/m3 for example, requires an empirical calibration to be made for that particular installation and flue condition. This must be achieved by calibrating against specific measurements of solids emissions, which would have to be made by the iso-kinetic sampling technique described earlier. The resulting calibration would hold only for that particular flue and would need to be rechecked at least every six months by further sampling comparisons. Opacity/Ringelmann Correlation Ringelmann is a measurement of opacity at stack outlet. If the opacity measurement were also made at stack outlet the measurements would be exactly equivalent. However, it is normally more practical to measure opacity at some other point for ease of access. In this situation, the measurements will differ since the duct diameter at the measurement point will differ from that at the stack exit, and the measurement depends upon the length of the optical path. Opacity at the point of measurement Om = 100 [1 - exp (-k.n.a.lm)] % where m is the stack diameter at the point of measurement. Opacity at stack exit Ox = 100 [1 - exp (-k.n.a.lx)] % where lx is the stack exit diameter.

CODEL


Thus, Ox = 100 [1 - (1 - Om/100) exp lx/lm] % and is directly proportional to the Ringelmann scale range 0 to 5 (equivalent to 0 - 100%Ox) The following illustration shows typical relationships between opacity and Ringelmann for various stack exit diameter/measurement path length ratios (lx/lm).

Figure 14

CODEL


Temperature Correction Usually there is little change in temperature between the measured and exit points, but where it is appreciable the stack exit opacity will be modified. This is due to the gases reducing in volume while the particulate volume remains relatively constant. This correction is applied by expressing the effect in terms of measurement path length as follows : Lm = Lmm (273 + Tx) / (273 + Tm) Where : Lm = Temperature-corrected effective path length, Lmm = Actual measurement path length, Tm = Temperature oC at measurement, Tx = Temperature oC at stack exit.

CODEL


Table of Figures Figure 1 : General Arrangement 3

Figure 2 : Site Mounting Flange Details 4

Figure 3 : Adjustable Mount and Air Purge Details 5

Figure 4 : Transmitter/Receiver and Air Purge 6

Figure 5 : Signal Processor/Power Supply Mounting Details 7

Figure 6 : Connection Schedule 10

Figure 8 : Illustration of Signal Processor Unit display and keypad 12

Figure 7 : Adjustable Mount Details 14

Figure 9 : Program Tree 27

Figure 10 : Illustration of the Diagnostic Program 33

Figure 11 : Program Tree for the Set-up Mode 38

Figure 12 : Normalising Set-Up Program Tree 49

Figure 13 : Optical Measurement/Particulate Concentration 63

Figure 14: Opacity and Ringelmann relationship 66

Documents

EnergyTech 100 Series 101/102 - Monitoring Solutions · 2020. 4. 28. · OPS. 141 Issue : A Revision : 1 Date : 14/06/18 Doc i/d : 0141/6 050028 CODEL EnergyTech 100 Series 101/102