CEMS & NDIR Start Up Procedures

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CEMS START UP ADVANCE OPTIMA AO2000 SERIES (LIMAS-11 UV, MAGNOS-206 & URAS26): 1) Installation Check x Check that the gas analyzer has been correctly installed before the Starting it

up. Test x Is the gas analyzer securely fastened (see operator manual 42-24-10-10-EN

page #62 for detail)? x Are all gas lines including that of the pressure sensor correctly connected

(see operator manual 42-24-10-10-EN page #63 for details)? x Have all the signal, control and interface lines, the power supply lines and, if

applicable, the system bus been correctly laid and connected (See operator manual 42-24-10-10-EN page 90)?

x Are all devices needed for gas conditioning, calibration and waste Gas disposal correctly connected and ready for use?

2) Gas Path and Housing Initial Purge

Purge before Commissioning x The gas paths and if necessary, the system housing should be purged prior to

starting the gas analyzer. x Firstly this ensures that the gas paths and system housing are free from

Contaminants e.g. corrosive gases, and accumulations of dust on startup. x Secondly this prevents any explosive gas/air mixture present in the gas paths

or system housing being ignited when the power supply is connected. Purge gas x Nitrogen or instrument air should be used as a purge gas. Purge Gas Flow Rate during Initial Purge: x Please refer page #108. 3) Power Supply Activation NOTE:

The gas analyzer may not be calibrated until the warm-up phase has been concluded.

Power Supply Activation x Turn on the power supply of the gas analyzer with the external breaker

switch.

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x If necessary, turn on the separate 24-VDC power supply of the analyzer module.

x The following events will occur after the power supply is turned on. A. The three "Power", "Maint" and "Error" LEDs light up. B. The different booting phases are displayed on the screen. Also

the software version is displayed. C. After a brief time the screen switches to measurement mode. D. The soft key on the screen. This indicates the possibility of a

temperature or flow problem during the warm-up phase. By pressing the soft key the user can recall the status message summary and view status message.

4) Warm up Phase: x The duration of the warm-up phase depends on which analyzer module is

installed in the gas analyzer. Analyzer Module Duration of warm up phase Remarks LIMAS-11 Approx 2.5 hours. Magnos-206 Approx 1 Hour URAS-26 Approx 0.5/2 hours

without/with thermostat

Notes

The warm-up phase can take longer if the gas analyzer was not brought to room.

During the warm-up phase measurement values can be outside the ranges specified in the data sheet.

Warm-Up Phase Duration x The warm-up phase is deemed to be over when the measured value drift

indication is acceptable. x This depends on the size of the measurement range. 5) Operation Ready to Perform Measurements x At the end of the warm-up phase the gas analyzer is ready to carry out

measurements. Verify the calibration x The gas analyzer is calibrated ex works. However, transport stresses and the

pressure and temperature conditions at the installation site may influence the calibration. Thus it is recommended to verify the gas analyzer calibration at the installation location.

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Turn on the sample gas supply x The sample gas supply should be turned on only after calibration. Adjusting Sample Gas Flow Rate x Please refer approved sample conditioning systems drawings for calibration

pressure, flow rates and sample pressure and flow rates. Operating Specification: x Please refer the operator manual (42-24-10-10-EN page# 336) operating

specifications for LIMAS-11, MAGNOS-206 & URAS-26. Menu Tree

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x For reasons of brevity only the top level parameters and functions are shown; the menu branches more extensively at most menu items, e.g. into the various measurement components or into the selection and adjustment of values.

x Some menu items are analyzer-specific, i.e. they only appear when particular analyzer modules are integrated into the gas analyzer.

Password Level: User Group Access to password

levels Password

Every User 0 None Maintenance team 0, 1 471100 Specialist team 0, 1, 2 081500 Function block specialist 0, 1, 2, 3 325465 6) Calibration: Gas Analyzer Calibration Gas Analyzer Manual Calibration NOTE

A manual zero point calibration must always be carried out before a manual end-point calibration.

Gas Analyzer Manual Calibration 1. Select the Manual Calibration menu: MENU > Calibrate Manual

>Calibration. 2. For Single Calibration: Select Component and Measurement Range.

Zero calibration:

3. Select Zero Gas. 4. Turn on the zero gas supply. 5. If necessary, change the test gas concentration1 shown, ENTER. 6. When the sample value indication stabilizes, initiate zero calibration with

ENTER. 7. Accept the calibration result with ENTER

or REPEAT2 calibration (back to step 5) or reject calibration with Back (back to step 6) or reject calibration with Meas (back to measurement value readout).

Span Calibration:

8. Select Span Gas. 9. Turn on the span gas. 10. If necessary, change the test gas concentration3 shown, ENTER. 11. When the sample value indication stabilizes, initiate span calibration with

ENTER.

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12. Accept the calibration result with ENTER or REPEAT4 calibration (back to step 10) or reject calibration with Back (back to step 11) or reject calibration with Meas (back to measurement value readout).

13. For single calibration, repeat steps 2-12 for other components and measurement ranges.

Shut down CEMS Analyzers

1) Gas Analyzer Shutdown In the case of a temporary shutdown:

1 Turn off the sample gas supply and reference gas supply, if applicable. 2 Purge the gas lines and gas feed paths in the analyzer module with dry fresh air or nitrogen for at least 5 minutes.

Limas11 HW: Purge sample gas feed path gas lines and gas feed paths in the analyzer module with at least with clean and dust-free air for at least 1 hour.

3 Switch off the gas analyzer power supply.

In the case of a long-term shutdown, carry out the following in addition: 4 Remove the gas lines from the gas analyzer ports. Tightly seal the gas ports. 5 Disconnect the electrical leads from the gas analyzer.

Cooler & Feeding Unit Startup (SCC-C & SCC-F):

SCC-F: Start Up: CAUTION!

Before activating the power supply check once again that the operating voltage setting (see rating plate) matches the line voltage.

The sample gas flow should only be started after the lead time period.

1) Power Supply Activation x Activate the power supply using the externally installed breaker or the

switched outlet. x The diaphragm pumps and the dosing pump (and where applicable the

hose pumps in the sample gas cooler) start running. Lead Time

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x The lead time for the sample gas feed unit is approx. 10 minutes. However, the lead time of the connected sample gas cooler is of greater importance. In the case of the SCC-C sample gas cooler the lead time is approx. 15 minutes.

Status Signals x The flow alarms are present during the lead time. The condensate alarms

may also be present. Readiness x At the end of the lead time period the sample gas feed unit is ready for

operation.

2) Switch On Sample Gas: x The sample gas must not be switched on until the sample gas coolers lead

time has finished, i.e. until the sample gas outlet temperature lies within the limit values set in the factory.

Set Sample Gas Flow x Set the sample gas flow using the appropriate needle valve.

CAUTION!

The needle valves must never be closed completely. SCC-F: Shut Down: CAUTION!

Before the sample gas feed unit is shut down it must be purged to prevent the accumulation of condensate and deposits.

1) Step Action x Disconnect the power supply. x Shut off the sample gas supply to the sample gas feed unit. x Remove the gas pipes from the connections on the sample gas feed

unit. x Thoroughly purge the sample gas feed unit gas paths with an inert gas. x Fully tighten the gas connections. x Remove the electrical cables from the sample gas feed unit

connections.

Note: Make sure the sample gas feed unit is free of residual moisture that

can freeze if low temperatures are encountered during shipping and storage.

Ambient temperature for storage and transportation: 25 to +60 C. Please refer SCC-F operator manual for more details.

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SCC-C: Start Up: Warning: x The sample gas cooler must stand in operating position for about 24 hours

prior to commissioning. x Before activating the power supply check once again that the operating

voltage setting (see rating plate) matches the line voltage. x The sample gas flow should only be started after the lead time period.

1) Power Supply Activation x Activate the power supply using the externally installed breaker or the

switched outlet. x The peristaltic pumps start to run (counter clockwise). Lead Time x The lead time is approx 15 minutes. This allows the sample gas outlet

temperature of +3 deg c, which is set in the factory, to be reached.

Status Signal: x During the lead time the monitor will output the temperature alarm

signal.

Readiness: x At the end of the lead time period the sample gas cooler is ready for

operation. Sample gas supply: x The sample gas must not be switched on until the sample gas outlet

temperature lies within the limit values set in the factory, i.e when it has fallen below +6dec C.

SCC-C Shutdown:

x Disconnect the sample gas cooler power supply. x Shut off the sample gas supply to the sample gas cooler. x Loosen the sample gas and condensate lines from the sample gas

cooler ports. Note: The condensate that accumulates is often acidic. Neutralize the condensate if necessary and comply with regulations on disposal.

x Thoroughly purge the gas cooler paths with an inert gas. x Fully tighten the gas connections. x Remove the electrical lines from the connectors.

Note:

Please refer SCC-C operator manual for more details.

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Multiwave analyzer PIR3502 NDIR Analyzer: Start up Y Purge The Y Purge provides a constant, clean, dry air flow through the

enclosures. Y Purge allows the analyzer to operate in a Division I area. Loss of Y Purge air pressure causes an alarm display on the LCD, but there is no interruption of analyzer power.

Optical Purge On the bottom of the Source Enclosure (see Figure 2-1), at the Optical

Purge connection, there is a 1/4-18 NPT-F fitting for connecting an ISA Grade Air, Nitrogen, or other inert gas supply line (purge supply is application-specific). Set the supply regulator so the outlet gauge displays 15-30 psig. Set the Optical Purge regulator on the floor inside the Source Enclosure so the Optical Purge gauge on the front panel displays 8 psig. Start purge flow and leak check all connections along the purge flow path.

Start Up After all supplies have been connected, all connections have been tested

and verified, and purge flow continues, turn On the power switch on the power supply line to the analyzer. If the analyzer has X Purge, the X Purge must complete its timed cycle before the analyzer will receive power.

Allow at least 30 minutes for the analyzer to heat to operating temperature. During this time, clear alarms and warnings as they display. When the sample cell and casting reach their specified temperatures, those alarms discontinue automatically.

Verify 4 to 20 mA output connections and devices. Now the Analyzer can be calibrated.

MANUAL CALIBRATION PROCEDURE The Analyzer is calibrated at the factory, using zero and span samples

specified by the application. During installation it is vital that the customer calibrate the Analyzer with

local zero and span samples, using the zero and span information in the Data Package for comparison. Below Steps provides a quick reference procedure for manual calibration.

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1) Program zero and span sample concentrations in the factory set-up tables.

2) Go to CALIBRATE/BENCHMARK mode. 3) Zero analyzer. 4) Span analyzer.

Note:

Always calibrate zero first, then calibrate span. Verify Zero and Span Calibration Concentration Settings Before calibrating the analyzer, verify the zero and span settings in the

analyzer with the Data Package. If the local zero and span calibration supplies do not match the analyzer or the Data Package, the Set-up Tables must be modified to match the local calibration samples.

Select SET-UP TABLES on the front panel of the Detector Enclosure. Press MODIFY SET-UP (F2), then COMPONENT (F1), then

CALIBRATION (F2), then ZERO (F2). To change the zero concentration number press the appropriate soft keys.

Soft key F2 moves the cursor to the left, soft key F3 moves the cursor to the right; the up arrow increases the number above the cursor, and the down arrow decreases the number above the cursor.

After the correct concentration has been set, press ACCEPT (F1) and NEXT COMP. (soft key under F1), or ACCEPT (F1) and then EXIT (F4) if no other component concentrations need to be changed.

For Span changes, follow the same procedure except select SPAN (F3) instead of ZERO (F2).

Manual Zero (Single Component Applications) Verify zero and span calibration concentration settings (see "Verify Zero

and Span Calibration Concentration Settings"). Select DISPLAY CONCENTRATION on the front panel of the Detector

Enclosure. Actuate the Zero Selection Valve on the sample handling system to pass

the zero sample through the sample cell. Zero calibration is always performed before span calibration.

Allow time for the analyzer to stabilize as indicated by the sample concentration reading on the front panel display.

When the analyzer is stabilized, use the MODE SELECTION key to move to CALIBRATE/ BENCHMARK.

Select MANUAL CALIBRATION (F4) and then ZERO (F1). When the SAMPLE CONCENTRATION reading remains constant, press

ACCEPT (F3) and then EXIT (F4). Return the Zero Selection Valve to its original position. Note

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Zero Calibration readings must be accepted or the analyzer will revert to the previous setting and analysis results may be inaccurate.

It is good practice always to record zero and span readings before calibration, then record the calibration readings, the date performed, and any changes that may result. Zero calibration should be performed more often than span. How often zero is performed depends on the application. Always compare zero calibration readings with the last recorded zero calibration. If there is a significant difference please refer operator manual for troubleshooting.

Manual Span (Single Component Applications) Note:

Zero calibration is always performed before span calibration. Verify zero and span calibration concentration settings (see "Verify Zero

and Span Calibration Concentration Settings"). Actuate the Span Selection Valve on the sample handling system to pass

the span gas through the sample cell. Select SPAN (F2). When the SAMPLE CONCENTRATION reading remains constant, press

ACCEPT (F3) and then EXIT (F4). Return DISPLAY CONCENTRATION to the front panel of the Detector

enclosure. Return the Span Selection Valve to its original position. Open the Sample Valve to allow sample flow.

Note: Span Calibration readings must be accepted, or the analyzer will

revert to the previous setting and analysis results may be inaccurate.

Hot Start up: x First purge the optical path with 99.999% pure laboratory grade nitrogen, the

pressure should be set to 8 PSI as per data sheet. x Make sure that you have removed the black caps on the 1/16 - inch vents

near the sample cell. x In this condition leave the analyzer for purging at least 24 hours over night,

else on power up you may blow up the source due to moisture. x Check the power supply to the analyzer L-N = 120 VAC, N-G 0 VAC, L - G

120 VAC x Power ON the analyzer. Check all parameter settings and make sure that they

are as per data sheet. x Check the power supply voltages are OK. x Make sure that the casting and sample cell temperature reaches the set point

and is controlled.

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x Make sure that the sample system is perfect, no leaks and apply zero gases after analyzer has warmed up for at least 2 hours.

x Check zero, before adjusting note the absorbance and detector voltages. x Make a note of the zero and compare with data sheet. x Do not calibrate. x Apply span gas and again note down the absorbance and detector voltages. x Make a note of the response factor as well. x Calibrate zero and note the zero absorbance value and detector voltages. x Calibrate span and note the new response factor and absorbance value and

filter values. x Line up the process sample and sample pressure and flow as per SCS

drawings and note down the absorbance and detector voltages. Shutdown x The Analyzer does not have an On/Off button or switch, nor are there start

and stop commands. To stop the analyzer, simply remove power. It is not necessary to stop purge or sample flows before removing analyzer power.

To shut down the analyzer in an orderly fashion: x Turn off the sample flow at the Sample Inlet Valve. x Depending on the analyzer configuration and the reason for stopping the

analysis, it may or may not be necessary to stop the optical or enclosure purge flows; verify analyzer configuration with the analyzer identification tag on the side of the Detector Enclosure, or with the Data Package.

x See Section 4 for information on the X Purge Override operation, if applicable.

x Purge the sample cell with zero sample, or a non-hazardous sample if necessary; turn off the zero flow at the Zero Inlet Valve.

x Drain the sample cell. x Shut Off the power to the analyzer at the power supply circuit breaker. x Depending on the reason for stopping the analysis, shut off the other

supplies as appropriate. Note:

Please refer PIR3502 MW operator manual for more details.

CEMS & NDIR Start Up Procedures

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