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.