Green G7000 User manual

PART NUMBER: 03135
G7000 OPERATION MANUAL
CONTINUOUS EMISSION MONITORING SYSTEM

CEMS
Version 2.7 – Revision February 2021 3
Content
1INTRODUCTION..................................................................................................6
1.1 ABOUT THIS MANUAL ........................................................................................................ 6
1.2 INQUIRIES AND FEEDBACK................................................................................................. 7
1.3 ABOUT THE SYSTEM ......................................................................................................... 7
2SPECIFICATIONS................................................................................................9
3SAFETY ASPECTS ...........................................................................................11
4MENU STRUCTURE ..........................................................................................14
4.1 HOME ............................................................................................................................ 15
4.2 PROBE 1 - 5................................................................................................................... 15
4.3 LOG............................................................................................................................... 16
4.4 LOGIN............................................................................................................................ 18
4.5 STATUS.......................................................................................................................... 18
4.5.1 IO Status ......................................................................................................... 21
4.5.2 Manual Operating System Components......................................................... 24
4.5.3 Reset system .................................................................................................. 24
4.6 SETUP ........................................................................................................................... 24
4.6.1 Probe setting................................................................................................... 26
4.6.2 CO2 Low Alarm............................................................................................... 26
4.6.3 Alarm setting ................................................................................................... 27
4.6.4 Auto Calibration Setting .................................................................................. 27
4.6.5 Average Settings............................................................................................. 28
4.6.6 Change Password........................................................................................... 29
4.6.7 Change PLC IP address ................................................................................. 29
4.6.8 HMI Screen Setting......................................................................................... 30
5COMMISSIONING .............................................................................................31
5.1 PROBES......................................................................................................................... 31
5.2 HEATED SAMPLE LINES ................................................................................................... 31
5.3 MONITORING CABINET .................................................................................................... 32
5.4 INITIAL LEAK TEST BEFORE OPERATION............................................................................. 32
5.5 MOUNTING THE PROBE TUBES......................................................................................... 33
5.6 GAS FLOW ADJUSTMENT ................................................................................................ 33
6CALIBRATION & VALIDATION ............................................................................35
6.1 AUTO AND MANUAL CALIBRATION WITH INTERNAL CALIBRATION CELLS.............................. 35
6.2 ANNUAL CALIBRATION & VALIDATION ROUTINE WITH TEST GASES.................................... 36
6.2.1 Calibration & Validation................................................................................... 36
7OPERATION ....................................................................................................38
7.1 OPERATING THE CEMS .................................................................................................. 38
7.1.1 Air Conditioner ................................................................................................ 38
7.2 LEAK TEST ..................................................................................................................... 39

Content
4
8ROUTINE MAINTENANCE ................................................................................. 40
8.1 PLANNED MAINTENANCE PROGRAM .................................................................................41
8.2 AIR CONDITIONER............................................................................................................43
8.2.1 Preventative Maintenance ...............................................................................43
8.2.2 Air Filter Service ..............................................................................................43
9SPARE PARTS ................................................................................................ 45
10 PACKING OF GAS ANALYZER........................................................................... 52
10.1 PACKING ........................................................................................................................52
11 APPENDIX ...................................................................................................... 53
11.1 TECHNICAL DOCUMENTATION LIST ...................................................................................53
12 MAINTENANCE & TROUBLESHOOTING .............................................................. 54
IG-G7000-001 ................................................................................................................58
IG-G7000-002 ................................................................................................................60
IG-G7000-003 ................................................................................................................61
IG-G7000-004 ................................................................................................................62
IG-G7000-005 ................................................................................................................65
IG-G7000-006 ................................................................................................................66
IG-G7000-011.................................................................................................................67
IG-G7000-012 ................................................................................................................68
IG-G7000-013 ................................................................................................................70
IG-G7000-014 ................................................................................................................72
IG-G7000-017 ................................................................................................................74
IG-G7000-018 ................................................................................................................77
IG-G7000-019 ................................................................................................................79
IG-G7000-020 ................................................................................................................81
IG-G7000-021 ................................................................................................................82
IG-G7000-022 ................................................................................................................87
IG-G7000-023 ................................................................................................................92
IG-G7000-029 ................................................................................................................95

CEMS
Version 2.7 – Revision February 2021 5
Table of Figure
FIGURE 4-1: HOME MENU SCREEN...................................................................................................14
FIGURE 4-2: HOME ..........................................................................................................................15
FIGURE 4-3: PROBE 1 – PROBES AND ANALYZING CABINET IN MEASURING STATE .................................16
FIGURE 4-4: PROBE 1 – PROBES AND ANALYZING CABINET IN HEATING STATE......................................16
FIGURE 4-5: SO2 LOG SCREEN .......................................................................................................17
FIGURE 4-6 STATUS PAGE IN MEASURING MODE ...............................................................................19
FIGURE 4-7 ALARM LIST OVERVIEW..................................................................................................20
FIGURE 4-8: IO STATUS ...................................................................................................................22
FIGURE 4-9 RESET THE SYSTEM ......................................................................................................24
FIGURE 4-10: SETUP SCREEN ..........................................................................................................25
FIGURE 4-11 DEFAULT SETUP ..........................................................................................................25
FIGURE 4-12 CUSTOMIZED EXAMPLE................................................................................................25
FIGURE 4-13 PROBE SETUP.............................................................................................................26
FIGURE 4-14 CO2 LEVEL ALARM......................................................................................................26
FIGURE 4-15 ALARM SETUP .............................................................................................................27
FIGURE 4-16 AUTO CALIBRATION SETUP ..........................................................................................27
FIGURE 4-17 AVG MOVE SETTINGS................................................................................................28
FIGURE 4-18 T90 GRAPH FOR 200 PPM SO2 GAS .............................................................................28
FIGURE 4-19 CHANGE PASSWORD ...................................................................................................29
FIGURE 4-20 CONFIRM PASSWORD ..................................................................................................29
FIGURE 4-21 CHANGE PLC IP ADDRESS ..........................................................................................29
FIGURE 4-22 HMI SCREEN SETTING.................................................................................................30
FIGURE 5-1 REMOVE THE SEALED PLUG............................................................................................33
FIGURE 5-2: GAS FLOW ADJUSTING ..................................................................................................34
FIGURE 6-1 FLOW CHART OF REQUIRED STEP FOR VALIDATION AND CALIBRATION ...............................37
FIGURE 8-1: PLANNED MAINTENANCE PROGRAM FOR THE G7000 CEMS SYSTEM.............................43
FIGURE 10-1 ANALYZER HOSE CONNECTIONS....................................................................................52

Introduction
6
1Introduction
1.1 About this Manual
This manual contains data and instructions for the operation and maintenance of the G7000
Continuous Emission Monitoring System (CEMS). For the installation of the CEMS,
please refer to the installation manual.
The instructions have been made in general terms and do not take into consideration a
specific installation. Therefore, this manual should be seen as a general guideline. As such,
the manual is designed only for the CEMS. The instructions for the operation and
maintenance of the complete monitoring system will be discussed in this manual.
The manual does not describe all possible situations but only the most common and known
situations and cannot replace the necessary education of the personnel. Should situations
not described in the manual occur, which cannot be solved in accordance with normal
known practice and good workmanship, the operator should contact Green Instruments
A/S for instructions.
Attention
Before operation read all instructions and warnings within this manual and associated
documentation. Improper use may cause personal injury and/or damage of equipment
and may void the warranty. Green Instruments A/S disclaims any responsibility for
damage and/or injury caused by improper installation, use or maintenance of the
equipment.
Green Instruments A/S reserves the right to alterations and improvements owing to
developments without being obliged to enter the corresponding changes in this manual.
Green Instruments A/S reserves the copyright of the manual. Without prior written
permission from Green Instruments A/S, the manual may not be copied and given to
unauthorized people.

CEMS
Version 2.7 – Revision February 2021 7
1.2 Inquiries and Feedback
All claims and inquiries for spares shall be addressed to Green Instruments A/S or our
distributors. In all correspondence or when ordering spare parts, please carefully state the
equipment type and serial number, which can be found on the label of the equipment.
Green Instruments A/S appreciates all feedback and suggestions for improvement. If you
have any questions or find any errors in the manual, you are welcome to contact us at the
following address:
Green Instruments A/S
Erhvervsparken 29
DK-9700 Brønderslev
Denmark
Phone:
Fax:
[phone]
[phone]
E-mail:
Web:
[email protected]
www.greeninstruments.com
1.3 About the System
The modular design of the CEMS makes it possible to monitor different gases according
to customer specifications. The G7000 can monitor the SO2 and CO2 concentrations in
exhaust gas according to the requirements in IMO regulations – NOx Technical Code 2008
and the requirements in MEPC.259(68). It provides an accurate measurement of SO2 in
ppm, CO2 in percent and the SO2/CO2 ratio, and presents these values on both the HMI
and Modbus TCP for logging and customer processing.
The system consists of a sampling and sample conditioning system and -up to two Multigas
Analyzers.
The unique double sample conditioning unit prepares the next sample simultaneous with
measuring from the current sample and hereby ensures a fast response time. This unique
feature allows the system to sample from up to 5 different sample points per system via
the multiplexing device.
Furthermore, the system uses an air conditioner to maintain an optimum working
temperature inside the monitoring unit. All materials are specially selected to resist the wet

Introduction
8
and acidic exhaust gas after a scrubber. The robust design is aimed for harsh marine
applications and long intervals between services.
The CEMS is designed for easy calibration and maintenance. The system is arranged with
automatic calibration by means of Internal Calibration Glasses together with instrument
air. The system can also be verified by test gases in order to show compliance. To avoid
damage, due to condensation it is recommended to run the system continuously.

CEMS
Version 2.7 – Revision February 2021 9
2Specifications
CEMS
Function
Monitoring of SO2, CO2 and other required gases which
is compliant with IMO regulations –NOx Technical
Code 2008 and MEPC.259(68)
Equipment
Multigas analyzer, multiplexer in case of multiple
probes, gas cooler, gas pump, condensate pump, air
conditioner, HMI, PLC, Gas filter, Condensate alarm
Power Supply/ Consumption
Refer to electrical drawings
Display
7.5” TFT LCD color display with touch screen
External Communication
Modbus TCP/IP
Alarm Outputs
4 alarm relays for “System Warning”, “System Alarm”,
“Level Warning”and “Level Alarm”; NO/NC
Electrical Connection
Refer to electrical drawings
Gas and Fluid Connections
Up to 5 probes with heated hose connected to one
CEMS
Refer to Installation Layout
Instrument Air Consumption
Approx. 4 L/min per probe during calibration
Approx. 4 L/hour per probe during stand-by
Instrument Air Quality
ISO 8573-1 Class 2-2-2 Free from traces of measured
gases
Sample Flow
0.33…1.67 l/min
Ambient Temperature
Class A. 5…45 °C (Tested to 55 °C)
Humidity
Class B. RH up to 96% at all relevant temperatures
Vibration
Class A
EMC
Class A
Material/Enclosure
Painted mild steel RAL 7035 / IP55
Dimensions/Weight
Refer to Installation Layout
Gas Analyzer
Measuring Principle
NDIR
Measuring Range
SO2: 0…200 ppm & CO2: 0…10 %
Optional: SO2: 0…1000 ppm & CO2: 0…20%
Monitor other gases upon request
Accuracy/Linearity
≤ ±2 % of reading, or

Specifications
10
≤ ±0.3 % of full scale whichever is larger
Precision/Repeatability
≤ ±1 % of full scale above 100 ppm or
≤ ±2 % of full scale below 100 ppm
Noise, zero drift, span drift
Each ≤ ±2 % of full scale
Auto-Calibration
Zero Calibration: Automatic using compressed air.
Span Calibration: Automatic using Internal Calibration
Glasses and Compressed Air.
Annual Calibration &
Validation
Connect certified gases for annual verification &
calibration
Approvals & Certificates
DNV –GL, BV, Lloyd´s, Korean Register, NK & ABS
& CCS Type Approvals
Probes and Heated Sample Lines
Function
Extracts and filters Sample Gas. Heating elements keep
temperature above dew point
Equipment
Refer to Component Overview
Number of Probes
Up to 5 pcs. Refer to Installation Layout
Sample Line Length
4…25m. Hose lengths > 25m upon request
Exhaust gas pressure
-50…500 mm WC dependent on material
Probe Tube Material &
Exhaust Gas temperature
316TI (max. 600°C) or Hastelloy (max. 400°C)
(to be specified upon order)
Power Supply
Refer to Electrical Drawings
Gas Connections
Heated Hose connections (included in scope of supply)
Sample Gas return line (not included in scope of supply)
Refer to Installation Layout
Ambient Temperature
Class A. -20 °C…45 °C (Tested to 55 °C)
Humidity
Class B. RH up to 96% at all relevant temperatures
Vibration
Class B
EMC
Class A
Enclosure
IP55
Probe Dimensions/Weight
Refer to Installation Layout
Approvals & Certificates
Specifications are subject to changes without notice.