Consilium OPSIS M800 Quick start guide

OPSIS M800
Continuous Emission Monitoring System
Commissioning Manual

Consilium Marine & Safety AB
Fire & Gas Marine Division
Phone: [phone]
Fax: [phone]
E-mail: Service: ser[email protected]
Spares: [email protected]
The contents of this document are subject to revision without notice
due to continued progress in methodology, design and manufacturing.
Consilium assumes no legal responsibility for any error or damage
resulting from the usage of this document.
February 2019
Document no. 5100396_OPSIS_M800_Commissioning_Manual_M_EN_2019_B
Part no. 5100396
© Copyright 2019, Consilium Marine & Safety AB

Table of contents
5100396_OPSIS_M800_Commissioning Manual_M_EN_2019_B
Table of Contents
Table of Contents....................................................................................................................................1
Admonitions............................................................................................................................................ 1
1Introduction..................................................................................................................................... 2
1.1 Purpose.................................................................................................................................... 2
2General safety rules......................................................................................................................... 3
2.1 High Voltage........................................................................................................................... 3
2.2 Heavy equipment ....................................................................................................................3
2.3 Strong UV light.......................................................................................................................3
2.4 Hazardous components ...........................................................................................................3
3Measuring path commissioning ......................................................................................................4
3.1 Measuring path alignment.......................................................................................................4
3.2 Measuring path length............................................................................................................. 4
4Emitter and receiver commissioning...............................................................................................6
4.1 Install the emitter and receiver................................................................................................6
4.2 Install the light bulb in the emitter..........................................................................................6
4.3 Emitter power cable ................................................................................................................7
4.4 Receiver fiber optic cable .......................................................................................................7
4.5 Purge air.................................................................................................................................. 7
5Purge air commissioning.................................................................................................................8
5.1 Purge air station ......................................................................................................................8
5.2 Purge air hose commissioning ................................................................................................ 8
5.3 Purge air settings.....................................................................................................................9
6Installing the analyzer ...................................................................................................................10
6.1 Before installing the analyzer ...............................................................................................10
6.1.1 Analyzer transportation.................................................................................................10
6.1.2 Power on the main cabinet............................................................................................10
6.1.3 Install the analyzer ........................................................................................................11
7Aligning the light ..........................................................................................................................11
7.1 Aligning the light basics .......................................................................................................11
7.2 A guide to set the light ..........................................................................................................12
8Multiplexer setup ..........................................................................................................................15
8.1 Multiplexor basics.................................................................................................................15

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5100396_OPSIS_M800_Commissioning Manual_M_EN_2019_B
8.2 MX004 .................................................................................................................................. 15
8.3 MX012 and MX009..............................................................................................................17
9Setting up the analyzer software ...................................................................................................19
9.1 Analyzer installation menu ...................................................................................................19
9.1.1 Analyzer Measurement Setup .......................................................................................19
9.1.2 Analyzer measurement times ........................................................................................22
9.1.3 NTP-Correction............................................................................................................. 27
9.1.4 Calibration setup ...........................................................................................................27
9.1.5 Communication Setup...................................................................................................27
9.1.6 Output signal setup in the analyzer software ................................................................29
9.1.7 IO256 - Input and output configuration ........................................................................30
9.1.8 IOMan Setup.................................................................................................................37
9.1.9 Emulator setup .............................................................................................................. 42
9.1.10 Optimize light ...............................................................................................................43
9.2 System Check........................................................................................................................43
10 Calibration.................................................................................................................................45
10.1 Check wavelength precision .................................................................................................46
10.2 Reference Calibration ...........................................................................................................49
10.3 Span calibration ....................................................................................................................53

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Admonitions
Note Text set off in this manner presents clarifying information or specific instructions
relevant to the immediate instruction.
Caution Text set off in this manner provides a warning notice that failure to follow the
directions in this caution can result in damage to equipment.
Warning Text set off in this manner provides a warning notice that failure to
follow the directions in this warning can result in bodily harm or loss of
life and/or extensive damage to equipment.
DANGER TEXT SET OFF IN THIS MANNER PROVIDES A WARNING NOTICE THAT
DANGERFAILURE TO FOLLOW THE DIRECTIONS IN THIS WARNING
WILL RESULT IN BODILY HARM OR LOSS OF LIFE AND/OR EXTENSIVE
DAMAGE TO EQUIPMENT.

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1 Introduction
The different configurations on board different vessels with different scrubber makers
will cause the commissioning of the M800 system to be slightly different from time to
time. This manual is to ease the process for technician performing the commissioning. It
will also help us be more consistent during commissioning. This will help us with future
support and troubleshooting. The manual will contain the different stages of a
commissioning and all necessary checklists and documents are appendixes to this
document.
1.1 Purpose
The purpose of this commissioning manual is to provide all necessary information to the
service technician performing the commissioning.

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2 General safety rules
Safety precautions must be followed at all times during installation, operation and
maintenance of the system.
Personnel shall be sufficiently qualified, and proper caution shall be taken to avoid
injuries or damage to life, health, environment, equipment and property.
2.1 High Voltage
Always switch off all power before installation or maintenance.
Warning CEMS OPSIS M800 operates at a potentially lethal AC voltage.
2.2 Heavy equipment
The CEMS OPSIS M800 system cabinet is heavy.
Caution During installation or replacement of larger units, appropriate safety
clothing and certified lifting equipment must be used.
2.3 Strong UV light
The CEMS OPSIS M800 emitter contains a high pressure light bulb that emits strong UV light.
Caution Always use safety protection glasses with UV protection when working
with or near the emitter.
2.4 Hazardous components
The sample gas may contain trace amounts of hazardous components.
Warning Many toxic gases are colorless, odorless and non-irritating, and
may overcome exposed persons without notice.
Personnel should have a thorough knowledge and understanding of the physical
properties and safety precautions for the relevant gas samples before operating the
system.
Make sure the ventilation is good especially if the analyzer cabinet is in a small room.
Ensure that gas has access to free air.

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3 Measuring path commissioning
3.1 Measuring path alignment
The basics of the measuring equipment are that emitter and receiver is installed on a
measuring pipe which in turn is mounted on a welded pipe on the stack with a flange.
The most important thing with this installation is the alignment of the measuring pipes.
The welded flanges should have been welded in a good and aligned position, but
sometimes they are not. If the welded flanges are misaligned they need to be re-aligned.
One way of checking the alignment of the measuring pipes is to use a flashlight and
project the light cone on a piece of paper. If the emitter and receiver are installed they
need to be dismantled from the measuring pipes. Place a lit flashlight in the end of one of
the measuring pipes. Be careful not to push the flashlight too far into the measuring pipe.
Hold a piece of paper a few centimeters from the end of the opposite measuring pipe and
look at the projection from the flashlight. The projection should be a perfect round circle
when the alignment is good. If the projection is not a round circle the alignment needs to
be adjusted.
3.2 Measuring path length
The CEMS OPSIS M800 system is delivered with two measuring pipes for each stack.
Standard length of these pipes is 1000mm and they should be cut during the installation
before the commissioning. The standard monitoring path is 300mm but can be different
depending on project. If the pipes are not cut, see the CEMS OPSIS M800 installation
manual for instructions.
Measuring path
Measuring path

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As we are measuring the number of molecules in the monitoring path, the distance of the
monitoring path is crucial for correct measurement. When the pipes have been installed it
is necessary to verify the monitoring path. One way is to use a carpenters ruler and a
measuring tape.
1. Remove either emitter or receiver if they are already installed.
2. Insert the ruler (Blue line in picture below) from the open side of the measuring pipe,
and push it until it touches the edge of the opposing measuring pipe. Take a reading at
the pipe opening and write it down.
3. Insert the measuring tape (Red line in picture below) in the same pipe and use the
metal plate as a hook on the pipes end. Take a reading at the pipe opening and write it
down.
4. The monitoring path is the difference in the two readings. This value will be entered
into the analyzer for each path.
Note It must be measured and specified with a precision of +/- 0.5%, i.e.
(1.5 mm at path length 300 mm).

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4 Emitter and receiver commissioning
4.1 Install the emitter and receiver
When the measuring pipes are aligned and the measuring path has been measured correct, then
the emitter(s) and receiver(s) can be installed. The emitter(s) and receiver(s) are mounted with a
quartz glass, purge air cassette and a ball valve at delivery. The emitter and receiver are then
screwed on the 1½” thread on the measuring pipes. The emitter (yellow) needs to be positioned
with the round metal cap facing up. The receiver needs to be placed with the lid facing up. The
ball valve needs to be placed with the handle on the upper side. There is a 1½” counter nut
delivered with the system that makes the positioning easier.
4.2 Install the light bulb in the emitter
The light bulb is delivered separately from the emitter. This needs to be installed.
Start by inspecting the emitter mirror. There is a special coating on the emitter mirror making it
very sensitive for moist. Check for cracks, stains or marks.
Caution Do not touch or try to clean the mirror. This will only make it worse.
1.
2.
3.
4.
1.
Fasten the light bulb minus (-) pole to the
emitter base.
2.
Fasten the plus (+) cable the light bulb
plus (+) pole.

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4.3 Emitter power cable
The power cable between the power unit and emitter should already be terminated with
AMP connection. If the power cable needs to be terminated, follow the instructions in the
CEMS OPSIS M800 installation manual.
Make sure that the mains power cable to the power unit is not connected. Connect the
power cable on the power unit side as well as the emitter side.
4.4 Receiver fiber optic cable
The fiber cable is to be installed in the receiver. Start by inspecting the receiver mirror.
There is a special coating on the receiver mirror making it very sensitive for moist.
Check for cracks, stains or marks.
Note Do not touch or try to clean the mirror. This will only make it worse.
Be very careful not to touch the tip of the fiber cable. It is very sensitive and if it is
scratched, the light values will most probably drop.
4.5 Purge air
Both the emitter and receiver must be connected to purge air. Please note that there is a
pressure relief valve installed on one side of the purge air cassette. This is to prevent
overpressure on the quartz glass if the air pressure is left on by accident when the ball
valve is closed.
Note See chapter “5 Purge air commissioning” for more information.

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5 Purge air commissioning
5.1 Purge air station
Specification
Pressure
6-7 bar
Consumption
60-80 liter/minute for each
measuring point
Water (Vapor Pressure Dewpoint)
≤-20°C
Oil Liquid, Aerosol & Vapor
≤ 0,1 mg/m3
The purge air is an essential part of the CEMS OPSIS M800 system. The purge air
system lets clean and dry instrument in to the measuring pipes to prevent emission from
building up in the pipes and thus contaminating the measurements (remember the
importance of the measuring path length).
The purge air delivered from the vessel is not always according to specifications.
Therefore, a filter regulator is delivered with the system and should be installed on the
instrument supply line from vessel. The filter regulator is mounted on an air manifold
with six outlets with individual shut off valves.
5.2 Purge air hose commissioning
Each outlet provides one path with purge air. From an outlet on the air manifold air is led
to a T-junction to divide the air between emitter and receiver side for each path. For each
emitter and receiver, a flow meter should be installed to be able to adjust the air
individually between emitter and receiver. After the flow meter there is one more T-
junction located close to the purge air cassette on emitter/receiver side. The purge air
cassette has two inlets to reduce turbulence in the measuring pipe. It is of great
importance that the two hoses connected between the T-junction after the flow meter and
the purge air cassette are of equal length. If the hoses are of unequal length, turbulence
can occur in the measuring pipes and cause exhaust gases from the stack to enter the
measuring pipes. Likewise, the tube sets going from the T-junction closest to the
manifold, and to the T-junctions closest to the purge air cassettes (i.e. passing the flow

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meters), must also be of equal total lengths to allow the flows to the emitter and the
receiver sides to be equally controllable.
Specification
A tubes
A tubes must have equal length
B tubes
C tubes
B tubes must have equal length
C tubes must have equal length
On one of the inlets to the purge air cassette there is a pressure relief valve. The pressure
relief valves prevent damages to the quartz glass due to overpressure if the ball valve is
closed before the purge air is closed.
Check all connections to make sure that the Teflon hose is securely installed and not
sharply bent or cracked.
5.3 Purge air settings
The amount of purge air needed the CEMS OPSIS M800 system measuring pipes is
30 liters per minute per side (i.e. 60 liters per minute per measuring path. There should
be just enough air to keep emission from entering the measuring pipes, but not so much
air that it will blow away the emissions from the monitoring path.
To really see how much air is needed it has to be tested on site. The test needs to be
performed on a stack that is in steady-state operation. Start measurements and keep the
purge air flow meter at a too low setting and by that letting flue gas into the measuring
pipes. Since emissions are in the measurement pipes, the measured concentration will
increase (since the monitoring path de facto increases). Slowly increase the flow of purge
air to the measuring pipes and the measured concentrations will decrease. Continue to
increase the flow of purge air until the measured concentration does not decrease
anymore. At that point you have a good flow of purge air. Make a note on how many
liters per minute the setting is and report in on the checklist.
C
C

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6 Installing the analyzer
6.1 Before installing the analyzer
6.1.1 Analyzer transportation
The analyzer is not installed in the main cabinet. It should be left in its original packing.
If possible, make sure to transport the analyzer to the main cabinet in its original
packaging. This MUST be handled with care. If lifting the pallet with crane, make sure
you have the weight centered. It is the customer’s responsibility to do this in a proper
way. The analyzer box must not be opened by any other than Consilium technicians.
6.1.2 Power on the main cabinet
The main cabinet is to be fed by 220VAC/16A. Mains power is installed (but NOT
connected) in the upper left corner of the main cabinet. See the electrical drawing for
more information.
1. Check that the mains power to the main cabinet is according to specifications.
2. Then connect the wires.
Specification
Voltage Supply
230VAC (+6%/-10%), 50/60Hz
Power connection
Fused
Single phase
3 x 2,5mm2 (Phase/Neutral/Ground)
2 x 16 A
5. Check that the AC unit is connected as it should.
6. Then turn on the power to the main cabinet.
7. Check that everything is as it should.
8. Connect the power unit(s) to the electrical outlets (if in cabinet).

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6.1.3 Install the analyzer
Remove the analyzer from its original package and carefully lift it into place in the cabinet. The
analyzer should be placed on the shelf that slides out.
1. Connect the analyzer to a power outlet in the cabinet.
2. Connect the serial cables.
-Modbus RTU – COM4
-IOMan (if used) – COM3
3. Connect the multiplexer signal cable (if used) to the MX port.
(See chapter “8 Multiplexer setup” for more information).
7 Aligning the light
7.1 Aligning the light basics
Warning! Always use safety protection glasses with UV protection when adjusting the
light.
The mechanical alignment of measuring pipes is a prerequisite to enable a good light.
When this alignment is good and verified it is time to set adjust the mirrors and focus on
the emitter and receiver to get a high light value going through the measuring path.
The below picture is to ease the understanding on how the light is transferred from the
emitter to the receiver. In the emitter there is a lamp which produces a very strong light.
The light is then reflected and directed with a mirror situated behind the lamp. The light
is transferred through the monitoring path and is reflected by a mirror in the receiver to
the fiber cable connection situated on the side in the receiver. The mirrors angle can be
changed to align the light. The focus of the light beam can also be changed by moving
the mirror back and forth in the light beams path.
Adjusting the light will most probably be a time consuming process. It is however very
important to do the adjustments as good as possible to ensure good measurements.

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7.2 A guide to set the light
To adjust the angle of the mirrors there are four small allen screws (marked with red
circles in the picture below) situated behind the mirrors. The four screws control the up-
and-down, and side-to-side motion of the mirror. The screws work in pairs meaning that
if one screw is tightened, its counterpart needs to be loosened. There are also four allen
screws that hold the mirror assembly in place. These are not used to adjust the mirrors.
When adjusting the light a LUX meter is necessary for the fine aligning of the light. A
good start when setting the light is to establish a base focus on the emitter side. This can
be done by positioning the emitter to project the light on a wall with a distance between
the wall and the emitter that corresponds to the distance between emitter and receiver. By
adjusting the focus in the emitter the shape of the projection can be changed. Under good
conditions, it is possible to see an ellipsis in the center of the projection. When the
ellipsis changes from vertical to horizontal orientation the focus is good. If conditions are
not so good it might be difficult to see this change. If this is the case, then focus the light
until a peach-shaped projection occurs:

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Focus the light the other way and the projection should first appear as stronger (with an
ellipsis),
and then go over to peach-shape again.
Between the two peach shaped projection there is a decent base focus.
What we call peach shaped is actually the reflection of the lightbulb itself.
When the base focus is established, mount the emitter on the measuring pipe. Use the
four allen screws on the back of the emitter to align the light beam so it touches the
mirror in the receiver with a full circle. By placing a piece of paper in front of the
receiver mirror, it is easier to see the projection and to see which way to turn the mirror
in the emitter.
When a base focus is established, and a rough alignment to the receiver is obtained, the
next step is to direct the light in the receiver to the fiber connection. Use a small piece of

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paper in front of the fiber connection to see where the light beam is located. Adjust the
mirror in the receiver to direct the light beam directly into the fiber connection.
Up till now the description of the adjustments has been done without the help of a LUX-
meter. Depending on the installation it might be better to combine the adjustments with a
LUX-meter to quantify the adjustments.
To fine tune the light settings will take time, be prepared for that. The fine adjustments
are done by changing the mirror angle in small steps to see where the highest LUX can
be obtained Whenever the mirror angle is changed, the focus will need to be adjusted to
increase the LUX, and vice versa.
Install the LUX-meter with a fiber cable at the receiver. Start adjusting the focus on the
emitter until both ways until the highest LUX-value has been obtained. Then adjust focus
on receiver side to obtain high LUX. Make small adjustments on the mirrors to see where
the highest LUX-values is obtained, followed by adjusting focus. This process will take
time, but it is necessary for good light settings.
When good light has been obtained, make a note of the LUX value at the receiver, and
reconnect the fiber cable to analyzer or multiplexer. After completing all light
adjustments make a note of the LUX values for each path in to the analyzer.
Do not optimize the light adjustments to much. If the light adjustments are very sensitive,
it can be that LUX value easily drops because of the mirrors shift slightly due to
vibrations or similar. A better solution is to defocus slightly resulting in slightly less light
to start with but is more resistant against small shifts.
It is good praxis to recheck the LUX values when the equipment is operating in normal
operating conditions.

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8 Multiplexer setup
8.1 Multiplexor basics
When more than one stack is to be measured a multiplexer needs to be installed. The
Multiplexer is an optical switch which toggles the light from the different stacks to the
analyzer. A Multiplexer is preferable to be installed inside the cabinet, but if needed it
can be installed outside the cabinet. Fiber cables from the different stacks are connected
on one side of the multiplexer, and on the other side one fiber cable will be installed to
transfer the light from all paths to the analyzer. In the marine industry we use two types
of multiplexers. Both types operate by the same principle that the fiber cable connected
to the analyzer is installed on an arm that switches between the fiber cables from the
different receivers. Both types of multiplexers have an external 115/230VAC power
supply. A signal cable goes between the multiplexer and the MX-port on the analyzer.
8.2 MX004
The simplest type of multiplexer is called MX004 and is used when only two stacks are
measured. The arm is connected to a magnet that switches between two positions.
To adjust the MX004 there are two set screws on each side of the frame in between the
arm is moving. The screws are adjusted from factory but to play it safe, the adjustment
should be checked and fine-tuned at commissioning. Connect a lux-meter to the outlet
connection. Power up both emitters and connect fiber cables to the inlet connections.
To operate the multiplexer manually go from the analyzer root menu to
F1 Installation F2 Measurement setup F1 Peripheral control setup.

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In the Peripheral Control Setup, make sure that MX004 is selected under Multiplexer
Type. To change the type, move the marker with the arrow keys to the Type, and press
Enter to change Type. Press “y” for yes and then Enter and the type will change.
Move the marker to “Setup” and press Enter.
In the MX 004 Setup, current path is shown. Adjust the set screws for this path in the
multiplexer until you have obtained the highest possible LUX-value on the LUX-meter.
Fasten the set screw and move the arm to the next path by pressing F1 or F2 and repeat
the adjustment procedure on the other set screw.