FGAS-06 Series

PLTU 2Banten-Labuan

Continuous Emission Monitoring System

(CEMS)

Instruction and Operating

Manual

Xiamen Greest Environmental Protection Technology Co.,Ltd

 Content
一、Summary.............................................................................. 2

二、System characteristic .......................................................... 2

三、Technical specification........................................................ 3

四、Applicable working conditions .......................................... 4

五、SO2\NOX\CO\O2 monitoring system ............................... 5

六、Flow monitor ....................................................................... 9

七、Dust monitor........................................................................ 9

八、Humidity analyzer .............................................................. 9

九、DAS .................................................................................... 10

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一、 Summary
FGAS-06 Series Continuous Emission Monitoring Systems(CEMS) is a gas analysis
system, it is made up of the particulate monitoring system,gas component monitoring
system, gas parameter monitoring system and the data acquisition system(DAS) It can
continuous monitoring the SO2,NOX,CO,dust in gas, velocity of flow,humidity and
temperature of the gas. The DAS can acquisition the analysis component, and then
transact, then creat the day report form,month report form and year report form.The
DAS control the sample probe go sampling or back-flushing.
FGAS-06 CEMSis made up of following:
z SO2\NOX\CO\O2 monitoring system, model:FGAS-06
z Dust monitor,mode:P-5C
z flow monitoring,model:454FTB
z humidity analyzer,model: HMT330
z temperature analyzer,model:PE1000
z DAS, model:HE-DAS-2000

二、System characteristic
1. SO2\NOX\CO\O2 monitoring system,
Model:FGAS-06
The sampling principle is direct extractive, it has such characteristic:
a) dryness measure;
b) The sample gas doesn’t dilution, the mesure precision is higher and stable.
c) Using multi-componet gas analyzer,can measure four gas in the same time,
reduce the invest cost;
d) The analyzer measure value is the fact concentration ;
e) Easy maintenance;
f) the heating pipe can keep the sample gas temperature, make it can’t
condensation and dewing during the tranfering;
h) the back-flushing system auto flushing the sample probe regularly;
The system is made up of the sample probe,heating sample pipe,sample gas transact
unit,calibration unit,back-flushing unit and gas analyzer.
The gas analyzer choose the ABB NDIR analyzer (model EL3020), it has following
excellence
z multi-component analysis,
z stabilization,credibilitu,long life-span,high analysis precision,
z LCD display,
z Self check-up;

z Have RS232、RS485、Ethernet communication interface,

2. Dust monitor
Model:P-5C
The measure principle is Back scatter, it has following excellence:
z Single stalling,
z Fit for power plant gas analysis because its endur milling and rust design,
z Less maintenance,
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z mg/m display the measure reslt,
z accord the U.S.A EPA requirement,

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3. Flow monitor
Model：454FTB
Measure principle: heat exchange,its excellence:
z Fit for power plant gas analysis because its endur milling and rust design,
z Auto temperature compensate, keeping measure precision.
z Can analysis the gas temperature.
4. Humidity analyzer
Model：HMT330
Measure principle: Capacitance
5. Temperatur analyzer
Model：PE1000
Measure principle: Pt100
6. DAS
Model：HE-DAS-2000

三、Technical specification
1．SO2\NOX\CO\O2 monitoring system,
z Mdoel：FGAS-06-IR

z Analysis components：SO2，NOX，CO，O2

z Measure range：SO2 ：0 ∼ 1000，5000 mg/Nm

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NOX ：0 ∼ 3000 mg/Nm3

z CO ：0 ∼ 2000 mg/Nm3
O2 ：0 ~ 10，25Vol.%

Zero drift:≤ ±1% of span per week

Sensitivity drift:≤ ±1% of span per week
Linearity drift:≤ ±2% of span
Repeatablity: ≤ ±2% of span
z Response time T90 ≤ 35 seconds at 60 L/h sample gas flow rate
z Output signal:4 ∼ 20mA isloated
z Numeric signal: four state signal, passive contact:220V,2A
z Warm-up time:≤ 30 minutes
z Sample gas flow rate: 20 ∼ 120 L/h
z Filter efficiency of sample probe:99.7% above 3μm

z Power:220VAC；50Hz(L, N, PE)

z Power consumption of the main cabinet：≤ 500W

z Power consumption of the heating line：45W/M

2. Dust monitor
z Model:P-5C
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z Measure range： 0 ~1,000mg/m
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z Measure limit： 0.5 mg/m

z Zero drift:≤ ±2% of span per day

z Span drift:≤ ±2%FS of span per day,
≤ ±5%FS of span per week
z Response tiem:1 second

z Ambient temperature:-30 ~ 55℃

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 zProecess gas temperature:
to 260℃ standard,
to 375℃ with high temperature probe
z Power:220VAC，50Hz
z Output: 4 ~ 20mADC,550 ohms maximum load
3. Flow monitor
Model：454FTB
Measure principle: heat exchange,its excellence:
Measure range: 0 ~ 30m/s
Output: 4 ~ 20mA
Ambient temperature:-45 ~ 65℃
Power:24VDC
Power consumption:15W
a) Humidity analyzer
Model：HMT3305
Measure principle: Capacitance
b) Temperatur analyzer
Model：PE1000
Measure principle: Pt1000
c) DAS
Model：HE-DAS-2000

4. Temperatur analyzer
z Model：Pt100

z Measure range:0 ～ 200 ℃

z Output:4 ~ 20mA DC
z Power: 24V DC

z Output load: 600Ω

z Ambient temperature:-25℃ ~+ 70℃；

5. Humidity analyzer
z Model:HMT330

z Measure range:0 ～ 100%RH

z Power:24VDC
6. DAS:HE-DAS-2000
The DAS is made of SIEMENS S7 series PLC and PC into a body. The system of the
CEMS from the various parameters of automatic monitoring, and generate database and
statements. PLC (the PLC) MicroWin programming software used to prepare the
applications, operator interface used to prepare the use of VB6.0 configuration interface
monitoring, reporting output data tables in line with the state pollutant discharge
standards. Through the organic combination of hardware and software, making the
monitoring system to operate intuitive, simple features.

四、Applicable working conditions

4.1 The flue gas parameter
dust of gas: ≤20 g/m3
sample gas temperature: ≤ 300° C
limit theλ sample gas pressure: -200 hPa (less than atmospheric pressure)
flue gas flow rate: 0 ~ 90m / s
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 supply: 200VAC; 50Hzλ
back-purge gas: air, 0.6 MPa, no oil, water, clean, air consumption of about 5 Nm3/h
SAMPLing points chosen:
CEMS easuring the accuracy of the data and the installation location close.
CEMS users should try to provide countries with technical specifications of the
sampling points system to ensure that the data collected can be a true reflection of the
actual conditions, should take early and my company joint expert consultations to
correct choice of sampling points.
4.2 Analysis house and maintenance platform:
Analysis of house specific requirements are as follows:
° 45 ∼ C ° room temperature: 5 λ
relative humidity: ≤ 85%
Power supply: 220λ VAC, 50Hz (L, N, PE)
ground: for ground (ground resistance of less than λ )Ω
host work here: the level, at work and no obvious vibrationλ

五、SO2\NOX\CO\O2 monitoring system

5.1 Working principles and processes（see the drawing HD06-07031-3.001）
After the gas was of GSP-04-type probe, the probe was first built-in filter which filters;
kind after a gas filter than pure gas, electric heating pipeline through access to
anti-purge device, and then in addition to the condenser Water, secondary filter and fine
filter after the end of instrument landing. GSP-04-sampling probe with electric heaters,
exports from the sampling probe instrument to counter the entrance of the sampling of
the use of electric heating of the sample, analysis of gas would be heated to 130 ~ 150
C, thus avoiding the flue gas in the aquifer Were in the process of° condensation or
transport Jiedong, soluble in water to ensure that the gas components (such as SO2)
accuracy of the analysis.
Instrument cabinet formed by three parts: the sample gas pretreatment system,
calibration of equipment and systems. At the counters of gas-like instrument through the
C,°condenser of the sample gas dehydration, like gas will be cooled to about 3
condensing into liquid water after the inflow of water tank. So, like a gas dew C of the
dry gas, and then after the second filter and the°point for the 3 filter cut-off valve
manually entered after flow meters, flow meter comes with 60 litres /∼the
needle-valve regulating the flow of gas samples, keep it in 40 hour, and a fine film
like air filters for the third time filtering, at this time, the sample gas into clean,
anhydrous gas, the flow meter into the final infrared analyzer, the kind of gas in the
SO2 , NO, CO, O2 concentration, and 20 mA DC signal output.∼measured the
concentration to 4
Calibration system from standard cylinders, pressure gauge, the needle-valve, steady
flow valve and the four-way valve components. The steady flow of gas calibration
stability to the needle-valve into the pressure of 0.1 MPa for the calibration of low
pressure gas. 0:00 gas, the analysis component span calibration gas switch from
four-way valve, followed by a 0:00 into the analytical instruments and span calibration.

5.2 System installing

Before install the system, should be carefully read the installation diagram, instrument
room layout plans, understanding the system components and pipes, cables and
connectors preset method, in accordance with the site conditions and the requirements
of the respective sets of preferences and hoisting place.
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 Note: before booting the system should familiarize analyzer, condenser, PLC
controllers and procedures pump out the use of brochures, to avoid misuse, damage
instruments.
Installing the sample probe
a) open the box, took out the sampling probe to observe whether the damage during
transport, unloading the rear cover the probe to observe whether there is a loose filter
components, if so loose and should be Xuanjin to ensure air tightness.
b) the sampling probe inserted into the 1.5 solid bolts fastening the two flange, and
to×flue, with four sets of M12 ensure that it does not leak.
c) the sampling probe protection of gripping me with the attached screws were firmly
installed in the pipe lining.
d) the sampling probe Protection me through the sampling probe of a fixed base in the
gripping pieces, and with locking screw.
e) the sampling probe heater jacket and thermocouple cable signal through the wire-line,
connect to the maintenance platform distribution box on the heater and thermocouple
Posts.
f) wear protective mask after me.
g) of the main instrument of the cabinet installation
h) instrument counters will be placed in the ground level,上好 to screw feet.
i) the gas analyzer, condenser, the standard sample gas were installed in the appropriate
location, the gas analyzer and the power cord from the condenser instrument on the
cabinet Terminals.
j) pre-heating of the sample used high-pressure gas blowing and washing intracavity
leakage test, and then access "-like gas imports" joint and installed and that does not
leak, the pipeline will be sampling heating cable access instrument counters with the
thermal heating pipeline terminal Paishang. Guakai with small knife with a coat of heat
pipes, ripping out insulation layer, the thermocouple installed in the heating pipes in the
wall of PTFE, and then re-package on the jacket and insulation layer, or use of thermal
Guakai plastic insulation to the mouth of re-Zhajin. Use teflon tube attached to one end
of the instruments received the 1 stainless steel,× 10 φkind of gas exports, the other
end connected to the stainless steel outdoor emissions, discharge point should not be
less than 2.5 meters high, the level of resettlement or slightly Tilt to the ground, not
vertically upward, to avoid water when it rains. Turn in the heating pipe joints clamping
nut.
a). incidental use of standards in order to access the respective electromagnetic valve
instrument cabinet on N2, SO2, NO corresponding to export, Xuanjin joint nut to ensure
that seal.
b). 220 V power will be received analytical instruments inside the cabinet
wiring L, N, Pe-side.
5.3 ready to run
Multimeter measured by access to the supply voltage is 220 VAC, confirmed that 220
VAC, the closure and leakage protection switch and all the air switch, preheat state into
the system at this time, about half an hour after the gas analyzer on the yellow and red
Lights off, the remaining green light lit; condenser the instructions of the
temperature-screen display for the numerical 3 ℃; heat with temperature control to
display the pipeline close to setting numerical temperature (130 ℃), plus or minus less
than 5 ℃, this system Preheating.
5.3 calibration
Before must be put into operation in the calibration of the instruments, its purpose is to

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maintain the system error in the analysis of technical indicators within the scope of the
output value of the signal can be monitored and adjusted as a reliable basis.
5.3.1 school righteous path by corresponding with the group and the concentration of
gas cylinders, valves, needle-valve, steady flow valve and flow meter components.
5.3.2 0.1 calibration
Calibration gas path will regulate the flow valve clockwise direction of rotation in the
end, and open the gas cylinder 0.1 (net N2), adjust the output pressure valves, air
pressure in its output 0.1 0.2 MPa between. At this point, can be seen from the
pressure gauges, pressure∼ on its output steady at 0.1 MPa (the factory has good
regulation). The four-way valve switch to the "N2" button, open the needle-valve and
flow meter Float attention to observe the location. To maintain the flow in 40 to 60
litres / hour. At this time of operation for the menu, entered manually calibration mode,
select the "Zero Calibration" and then click "Enter", observed infrared analyzer
attention to the LCD display, its value should be instructed to gradually reduce to 0.1
near the question of measurement data LCD display Stability, according to "ENTER"
will show the value of the instruments for the preservation value of 0.1, 0.1 check
completed.
5.3.3 infrared analyzer the span calibration
EL3020 analysis (configuration Uras 14 non-dispersion infrared analysis module) for
the multi-component analysis instrument, while the maximum of four gas
concentrations. For SO2 analysis, the correction of the apparatus of the sample gas is
N2 as the background of SO2 gas, its concentration and analysis of the value range to
match.
calibration gas path will regulate the flowλ valve clockwise direction of rotation in the
end, and open the SO2 gas cylinders, pressure regulating valve output, making it the 0.1
~ 0.2 MPa, and at this time, can be seen from the pressure gauges , The pressure on the
stability of its output in the 0.1 MPa (the factory has good regulation). The four-way
valve switch to "SO2" button, open the needle-valve and flow meter Float attention to
observe the location so that the flow remained at 40 to 60 litres / hour. At this point
operating gas analyzer menu, enter the SO2 span calibration, pay attention to observe
the infrared analyzer showed that the concentration of SO2, pending stability, the
question LCD display measurement data stability, according to "ENTER" will show the
value of the instruments save , Span calibration finished. According to the above
method of checking the other components of the span.
manual calibration gas analyzer operation detailedλ analysis instrument Manual.
Note: the calibration gas components to beλ immediately closed after the calibration of
gas cylinders, and the four-way valve switch back to the "automatic calibration" button
to stop the calibration process.
5.3 Operation
5.3.1 connected to the power system, the operation panel on the "reset I" button, then 2
sampling probe into the sampling, and sampling probe into an anti-purge, and half an
hour after the system will automatically switch, sampling A sampling probe into the
state, the sampling probe into the 2-purge state. Sampling probe and a sampling probe
the turn of the 2 hours 30 minutes for each one, alternating time can be set according to
actual conditions, all the procedures by the PLC implementation, without human
operators. System into the sampling, and sampling indicator lights up, to slowly open
the valve of the instruments cabinet, will "regulate traffic sampling" needle-clock
direction of rotation, until the flow meter to maintain the flow in 40 to 60 litres / hour .
At this point, infrared analyzer display in the corresponding group is the concentration
of gas in the various groups in the concentration.
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5.4 running and modify parameters
a) infrared analyzer can work from the LCD status reflected in the figures, can also use
the keyboard for the necessary parameters and status of the work of the condenser from
the state of digital LCD temperature reflected;
b) reset button switch to work with the state to amend the function, pressing reset switch,
the sample analysis immediately transferred to purge anti-state. This feature allows the
installation of running for the first time before the sampling probe the many purge, can
also be used for instantaneous ash in the air like a high sampling probe to plug the
hand-speaking anti-purge. Infrared analyzer various parameters of the amendment,
according to the statement attached to.
6 routine maintenance
6.1 for the first time in the week transported to the CEMS more observation and
adjustment, pay attention to observe the following:
a). Instruments measured the concentration of gases in line with the technical
parameters, or chemical analysis and comparison of data.
b). alarm if the traffic flow meter showed that the nominal value of stability.
c). kind of gas whether there is a change in pressure. If the pressure changes in larger
and will take appropriate adjustment needle-valve to adjust the flow.
d). C.°condenser the temperature is controlled at around 3
e). systems work, attention to observe the electrical panel indicator shows whether or
not consistent with the set-up process
6.2 in the first put into operation the week, every two to three days of the instruments
must be carried out on 0.1 and span calibration, and record of 0.1 per drift and span drift
value of the instruments observe the 0:00 span drift and drift.
6.2.1 flue gas composition monitoring subsystem weekly maintenance:
6.2.1.1 calibration of the instruments once, if not drift of the instruments may extend the
calibration cycle.
6.2.1.2 purge of anti-check: according to reset switch to observe the anti-purge valve of
the device to work properly.
6.2.1.3 to check the quality of wind instruments: wind instrument unloaded filter below
nut, whether from the observation of condensed water.
6.3 Common method of exclusion and failure

malfunction reason debar

Fuse off Check whether the short-circuit lines,
the replacement fuse
No power AC contactor coil Open Inspection, the replacement of the coil
Contact connection is bad Replace the contact
Step by step and try to replace the
Road serious gas leak
corresponding components leak
The sample gas transport Check points and plug the pipeline
The sample pipeline plug replacement
flow is zero Winter water in the sample gas
Steam insulation
in the gas-gas pipeline in
Jiedong
Emissions of the plug Inspection and replacement of pipes

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 Check whether the leaking pipeline
Normal flow, but no instructions
Normal flow, linking (Note does not allow
of the instruments
but no high-pressure leak test equipment so as
instructions of not to damage analysis)
the instruments Check whether the analyzer show
Analyzer failure failure information and send the
information to HEPEC
Let system doing back-flushing four
times
The sampling The back-flush air pressure isn’t
flow go down enough, augment the pressure
Filter of the sample probe
slowness and It has water in the back-flush air
jammed
the response Examine the air and separate the water
time lenghten
Filter invalidation, Replacing the filter
The sample probe is back-flushing
The valve malfunction Examine the valve and its connection
Loop of the relay turnoff or
The sample/ the touch of the relay badness Replacing the relay
back-flush The voltage of 24VDC power is Check the voltage and imcrease it
can’t working to low
as the The PLC control program failure Replacing the PLC
preestablish and the PCU failure
The recompose program of the Examine the program and mend it
PLC is wrong
The gas analysis path leak out Examine the leak point and mend it
The signal line doesn’t shield The signal grounding well
well
The output Installation environment exists Amend the installing condition
instability strong electromagnetic
interference, a strong vibration
or environmental temperature
exceeds 45℃

六、Flow monitor
See the attach 《 454FTB single-point insertion thermal mass flow
transmitters usr’s guide》

七、Dust monitor
See the attach 《 Model P-5C Laser Backscatter Particulate Monitor
Operations Manual 》

八、Humidity analyzer
See the attach 《 Vaisala HUMICAP Humidity and Temperature
Transmitter Series HMT330 User’s Guide》
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九、DAS
This set of flue gas from the continuous monitoring system SIEMENS S7 series of
programmable logic controller and distributed a common industrial PC computer
monitoring system. The system of the flue gas emissions from the various parameters of
automatic monitoring, and generate database and statements.
1. Description
After the launch of the system there will be gas monitoring system of the main window.
The tools in the window of the system include the withdrawal, print, meters,
instruments details, alarm, log, management, diagnosis, control, trends, prescription,
documents, music, time, help, and so on the button. System interface for Engish
language interface, the operating system for WinXP
Tiered system with encryption system to ensure the safety of operating system data;
immediate display of images on the measurement group of real-time data and
equipment running; in the same timeline on the same screen images of different colours,
also showed that four of the simulation trends. Auto-complete data processing, the
formation of statements in support of long-distance transmission;
statements into the production: when minutes mean statements, the statements mean
when, on average, statements, the statements on average, the concentration of dust
calibration data statements and SO2 check time;
system to supportλ printing, print statements;
a loss of data processing functions.
data-processing functions in line with the state "thermal power plant flue gas emissions
continuous monitoring of technical specifications"
2. Help
The operating system software that randomly with the help of a specific document on.
Mainly divided into 12 points.
2.1. Installation System
Part of system software is divided into two parts: PLC procedures and customer
applications (Reporting System). First used PC / PPI cable programmable logic
controller (PLC) and computer, the PLC's work in the state set up "STOP" state. Open
your computer in the STEP 7-MicroWIN32 software, open the CD-ROM (or drive)
PLC procedures, click on the menu of the "Download" button, below the window to
show "DOWNLOAD SUCCESS". Open the CD-ROM, click on the "continuous gas
monitoring system. EXE" file, the system will automatically enter the installation
process, the installation has been completed, the entire process of data collection system
installed.
2.2 log operation
When the operation began when the flue gas monitoring system, first log into the screen,
the window of a username and password field list field, the bottom has a status bar, the
user in the list of users has been chosen field of user name and password again in typing
this column User's password, click the OK button, such as user name and password
correctly, we can enter into the main screen, click Cancel button to exit the application,
such as the wrong password, login screen in the status bar of "invalid password, try
again!" The words, such as three errors were to withdraw from the application.
2.3. Management operation
If the current user rating is not an administrator, click the button management, no
reaction; only current user of the class as an administrator, click the button icon
management, the plan is to open the following screen, the screen displays the current
user name, the user column shows the user name , Password column shows the

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password, the user column shows the class hierarchy; data operation buttons and four,
respectively, as "a record" and "the previous record," and "a record", "The last record"
there are four operators Buttons were cancelled, the user changes, built new users,
delete users button.
2.4. Instrument Calibration
Click on the button instrument calibration, validation classification into the screen, you
may choose to check meters or check the report.
Calibration instruments: the system of manually calibrate the instruments;
checking the report: correction can view the report.
2.5 System Settings
Users can in this screen, change boiler, flue, and continuous monitoring code.
2.6. Log records
This application automatically record all of the information system registry. Click on
this button, the user can enter the picture, query and print.
2.7. Trend screen
To enter this screen, can select the parameters measured view real-time curves.
2.8. Documents screen
Click this button to enter the day, month, the statements of the index screen.
2.9. Time Management
When the monitoring system of the host computer system under the control of time and
the crew at the same time, click on this button, the screen into the next crew to amend
the time, from top to bottom at the time of reunification.
Users can monitor system interface in the status bar to see the date and time fields under
the crew's time, as indicated at the time of the crew and not the same time, the process
can be modified following the crew's time.
2.10. Help screen
In this screen the user can see the entire application process with the help of
2.11. Application of information
Click on this button, access to the data acquisition system of information-related
applications.
2.12. Chosen instrument
Click on this button, according to the instrument of choice, can be carried out on the
corresponding instruments
2.13. Withdraw from the application
Users from flue gas monitoring system.
2.14. Print statements
Click on this button, select a window, choose the following statements:
Preservation and quality assurance period After the arrival of user devices, attention
should be paid to CEMS can not open C, relative°place, should be kept indoors,
indoor temperature for 5 ~ 45 humidity is less than 85 percent, the environment can
not be corrosive atmosphere. The user to comply with the requirements of the use and
custody cases, from the date of shipment within 18 months as a result of poor
manufacturing quality in damaged or unable to work, the factory responsible for the free
repair or replacement parts and components.

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