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CODEL EnergyTech 100 Series, Installation, Commissioning, Operation And Maintenance Manual

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CODEL EnergyTech 100 Series Installation, Commissioning, Operation And Maintenance Manual Download Page 66

CODEL

 

OPS. 141 

 

58

 

Issue : A 
Revision : 1 

 

Date : 14/06/18 
Doc i/d :

 

0141/6 

050028

 

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. 
 

Summary of Contents for EnergyTech 100 Series

Page 1: ...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...

Page 2: ...CODEL OPS 141 2 Issue A Revision 1 Date 14 06 18 Doc i d 0141 6 050028 Total Solutions Total Confidence...

Page 3: ...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 te...

Page 4: ...CODEL OPS 141 2 Issue A Revision 1 Date 14 06 18 Doc i d 0141 6 050028...

Page 5: ...urge 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 St...

Page 6: ...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 Ave...

Page 7: ...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 Parameter...

Page 8: ...ilable 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 La...

Page 9: ...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 an...

Page 10: ...cation 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...

Page 11: ...CODEL OPS 141 3 Issue A Revision 1 Date 14 06 18 Doc i d 0118 6 050028 Figure 1 General Arrangement...

Page 12: ...e 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 e...

Page 13: ...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 T...

Page 14: ...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 purg...

Page 15: ...sary 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...

Page 16: ...n 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 valu...

Page 17: ...s 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...

Page 18: ...CODEL OPS 141 10 Issue A Revision 1 Date 14 06 18 Doc i d 0141 6 050028 Figure 6 Connection Schedule...

Page 19: ...ty 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 t...

Page 20: ...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...

Page 21: ...or 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 redunda...

Page 22: ...e 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...

Page 23: ...u 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...

Page 24: ...e 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 EN...

Page 25: ...ke 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 sti...

Page 26: ...r 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 opti...

Page 27: ...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 se...

Page 28: ...l 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 access...

Page 29: ...ontact 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 No...

Page 30: ...he 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...

Page 31: ...p 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 secur...

Page 32: ...ter 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 level...

Page 33: ...e 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 de...

Page 34: ...rs 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...

Page 35: ...CODEL OPS 141 27 Issue A Revision 1 Date 14 06 18 Doc i d 0118 6 050028 Figure 9 Program Tree...

Page 36: ...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 ho...

Page 37: ...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 calc...

Page 38: ...pan 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 o...

Page 39: ...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...

Page 40: ...or 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 p...

Page 41: ...CODEL OPS 141 33 Issue A Revision 1 Date 14 06 18 Doc i d 0118 6 050028...

Page 42: ...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 f...

Page 43: ...ollowing 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...

Page 44: ...il 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 change...

Page 45: ...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 T...

Page 46: ...CODEL OPS 141 38 Issue A Revision 1 Date 14 06 18 Doc i d 0141 6 050028 Figure 11 Program Tree for the Set up Mode...

Page 47: ...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...

Page 48: ...ect 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...

Page 49: ...alogue 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 ke...

Page 50: ...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...

Page 51: ...e 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 loo...

Page 52: ...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...

Page 53: ...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 ala...

Page 54: ...e 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 change...

Page 55: ...he 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 t...

Page 56: ...ng 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...

Page 57: ...CODEL OPS 141 49 Issue A Revision 1 Date 14 06 18 Doc i d 0118 6 050028 Figure 12 Normalising Set Up Program Tree...

Page 58: ...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 no...

Page 59: ...re 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...

Page 60: ...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 co...

Page 61: ...e 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...

Page 62: ...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 extin...

Page 63: ...ust 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 m...

Page 64: ...d 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 measur...

Page 65: ...5 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 full...

Page 66: ...pt 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 th...

Page 67: ...nt 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...

Page 68: ...ignal 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 con...

Page 69: ...nd 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 lo...

Page 70: ...050028 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...

Page 71: ...nts 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...

Page 72: ...nd 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 ma...

Page 73: ...ed 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 Ri...

Page 74: ...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...

Page 75: ...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...

Page 76: ...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 Pro...

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