Maritime G7000 User manual

G7000
Continuous Emission
Monitoring System
Operation Manual
Document ID number.: 03135
Maritime

Page 2 of 92

CEMS
Version 2.9 – Revision March 2022 Page 3 of 92
Content
1INTRODUCTION..................................................................................................6
1.1 ABOUT THIS MANUAL......................................................................................................... 6
1.2 INQUIRIES AND FEEDBACK ................................................................................................. 7
1.3 ABOUT THE SYSTEM ......................................................................................................... 7
2SPECIFICATIONS................................................................................................8
3SAFETY ASPECTS ............................................................................................10
Attention.........................................................................................................................................................10
Hazardous voltage!.........................................................................................................................................10
Circuit breaker!...............................................................................................................................................10
Overload protection!.......................................................................................................................................10
Protective earth! .............................................................................................................................................11
Installation and fault finding! .........................................................................................................................11
EMC!..............................................................................................................................................................11
Probes and heated sample lines! .....................................................................................................................11
Blockage of the gas sampling system!............................................................................................................11
Leakage! .........................................................................................................................................................11
Harmful components!.....................................................................................................................................11
Recycling! ......................................................................................................................................................12
Symbol identification! ....................................................................................................................................12
4MENU STRUCTURE ..........................................................................................13
4.1 HOME ............................................................................................................................ 14
4.2 PROBE 1 - 5................................................................................................................... 14
4.3 LOG............................................................................................................................... 15
4.4 LOGIN............................................................................................................................ 17
4.5 STATUS.......................................................................................................................... 17
4.5.1 IO Status ......................................................................................................... 20
4.5.2 Manual operating system components ........................................................... 22
4.5.3 Reset system .................................................................................................. 23
4.6 SETUP ........................................................................................................................... 23
4.6.1 Probe setting................................................................................................... 24
4.6.2 CO2 low alarm ................................................................................................ 25
4.6.3 Alarm setting ................................................................................................... 25
4.6.4 Auto calibration settings.................................................................................. 26
4.6.5 Average settings ............................................................................................. 26
4.6.6 Change password ........................................................................................... 27
4.6.7 Change PLC IP address ................................................................................. 27
4.6.8 HMI screen setting .......................................................................................... 30
5COMMISSIONING .............................................................................................31
5.1 PROBES......................................................................................................................... 31
5.2 HEATED SAMPLE LINES ................................................................................................... 31
5.3 MONITORING CABINET .................................................................................................... 32

Content
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5.4 INITIAL LEAK TEST BEFORE OPERATION .............................................................................32
5.5 MOUNTING THE PROBE TUBES..........................................................................................33
5.6 GAS FLOW ADJUSTMENT ..................................................................................................33
6CALIBRATION & VALIDATION ............................................................................ 34
6.1 AUTO AND MANUAL CALIBRATION WITH INTERNAL CALIBRATION CELLS .................................34
6.2 ANNUAL CALIBRATION & VALIDATION .................................................................................35
6.2.1 Auto and manual calibration & validation ........................................................35
Validation and calibration required steps procedure....................................................................................... 36
7OPERATION .................................................................................................... 37
7.1 OPERATING THE CEMS...................................................................................................37
7.1.1 Air conditioner..................................................................................................38
7.2 LEAK TEST ......................................................................................................................38
8ROUTINE MAINTENANCE .................................................................................. 39
Attention ........................................................................................................................................................ 39
8.2 PLANNED MAINTENANCE PROGRAM ..................................................................................39
8.3 AIR CONDITIONER............................................................................................................42
8.3.1 Preventative maintenance ...............................................................................42
8.3.2 Air filter service ................................................................................................42
9SPARE PARTS ................................................................................................. 43
10 PACKING OF GAS ANALYZER ............................................................................ 51
10.1 PACKING ........................................................................................................................51
11 APPENDIX ...................................................................................................... 52
11.1 TECHNICAL DOCUMENTATION LIST ....................................................................................52
12 MAINTENANCE & TROUBLESHOOTING............................................................... 53
IG-G7000-001................................................................................................................................................ 57
IG-G7000-002................................................................................................................................................ 58
IG-G7000-003................................................................................................................................................ 59
IG-G7000-004................................................................................................................................................ 60
IG-G7000-005................................................................................................................................................ 62
IG-G7000-006................................................................................................................................................ 63
IG-G7000-011................................................................................................................................................ 64
IG-G7000-013................................................................................................................................................ 65
IG-G7000-014................................................................................................................................................ 67
IG-G7000-017................................................................................................................................................ 69
IG-G7000-018................................................................................................................................................ 71
IG-G7000-019................................................................................................................................................ 73
IG-G7000-020................................................................................................................................................ 75
IG-G7000-021................................................................................................................................................ 76
IG-G7000-022................................................................................................................................................ 79
IG-G7000-023................................................................................................................................................ 82
IG-G7000-029................................................................................................................................................ 84
IG-G7000-038................................................................................................................................................ 85
IG-G7000-039................................................................................................................................................ 86
IG-G7000-040................................................................................................................................................ 88
IG-G7000-041................................................................................................................................................ 89
IG-G7000-042................................................................................................................................................ 90

CEMS
Version 2.9 – Revision March 2022 Page 5 of 92
Table of Figure
FIGURE 4-1: HOME MENU SCREEN...................................................................................................13
FIGURE 4-2: HOME ..........................................................................................................................14
FIGURE 4-3: PROBE 1 – PROBES AND ANALYZING CABINET IN MEASURING STATE .................................15
FIGURE 4-4: PROBE 1 – PROBES AND ANALYZING CABINET IN HEATING STATE ......................................15
FIGURE 4-5: SO2 LOG SCREEN .......................................................................................................16
FIGURE 4-6 STATUS PAGE IN MEASURING MODE ...............................................................................18
FIGURE 4-7 ALARM LIST OVERVIEW..................................................................................................19
FIGURE 4-8: IO STATUS ...................................................................................................................20
FIGURE 4-9 RESET THE SYSTEM ......................................................................................................23
FIGURE 4-10: SETUP SCREEN ..........................................................................................................23
FIGURE 4-11 DEFAULT SETUP ..........................................................................................................24
FIGURE 4-12 CUSTOMIZED EXAMPLE................................................................................................24
FIGURE 4-13 PROBE SETUP.............................................................................................................24
FIGURE 4-14 CO2 LEVEL ALARM......................................................................................................25
FIGURE 4-15 ALARM SETUP .............................................................................................................25
FIGURE 4-16 AUTO CALIBRATION SETUP ..........................................................................................26
FIGURE 4-17 AVG SETTINGS ...........................................................................................................26
FIGURE 4-18: T90 GRAPH FOR 200 PPM SO2 GAS ............................................................................27
FIGURE 4-19 CHANGE PASSWORD ...................................................................................................27
FIGURE 4-20 CONFIRM PASSWORD ..................................................................................................27
FIGURE 4-21 CHANGE PLC IP ADDRESS ..........................................................................................28
FIGURE 4-22: STANDBY FLUSH .........................................................................................................28
FIGURE 4-23: CONDENSATE PUMP....................................................................................................29
FIGURE 4-24: CONDENSATE PUMP – POP UP .....................................................................................29
FIGURE 4-25: ANNUAL VALIDATION....................................................................................................30
FIGURE 4-26: ANNUAL CALIBRATION .................................................................................................30
FIGURE 4-27 HMI SCREEN SETTING.................................................................................................30
FIGURE 5-1 REMOVE THE SEALED PLUG............................................................................................33
FIGURE 5-2: GAS FLOW ADJUSTING ..................................................................................................33
FIGURE 6-1: VALIDATION AND CALIBRATION REQUIRED STEPS PROCEDURE .........................................36
FIGURE 8-1: PLANNED MAINTENANCE PROGRAM FOR THE G7000 CEMS SYSTEM.............................41
FIGURE 10-1 ANALYZER HOSE CONNECTIONS....................................................................................51

Introduction
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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 2.9 – Revision March 2022 Page 7 of 92
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, 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: [phone]
Fax: [phone]
Email: [email protected]
Web: 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 in accordance with 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 multi
gas 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
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 to show compliance. To avoid damage,
due to condensation it is recommended to run the system continuously.

Specifications
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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
Multi gas 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

CEMS
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≤ ±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
Refer to Green Instruments website
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
Refer to Green Instruments website
Specifications are subject to changes without notice.

Safety Aspects
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3Safety aspects
Before operating the system, please study this operation manual and the
technical drawings for each system in their entirety.
ATTENTION
•Please ensure correct connection of all power, signal cables and air supply before
operating the CEMS.
•The multiplexer, probes and sample lines will be hot during operation. Pay attention to
the risk of burn.
•Do not obstruct the circulation of supply/intake air by the air conditioner.
•The system is only suitable for installation in a safe, non-hazardous area and is not
suitable for use with flammable or explosive media.
•It should be pointed out that installation and operation of this system and associated
equipment must be carried out by skilled and trained personnel. Green Instruments A/S
does not take any responsibility for the operation of the equipment and associated
equipment whatsoever.
•If the system is used in a manner not approved by Green Instruments A/S, the function
and protection provided by the equipment may be impaired.
•Successful and safe operation of this equipment depends on proper handling,
installation, operation, and maintenance.
HAZARDOUS VOLTAGE!
Disconnect the power before installing or servicing the equipment. Ignoring this warning
may result in severe personal injury or material damage. Read the instruction carefully to
ensure correct connection of all power and signal leads.
Make sure that the correct voltage is connected to the system.
CIRCUIT BREAKER!
The installation must include a means of isolating electrical power by a clearly marked
switch or circuit breaker external to the system. The external switch or circuit breaker shall
be in close proximity to the system and within easy reach of the operator. The CEMS is
fitted with a safety switch, placed underneath the air condition unit, and this interrupts the
power to the downstream components.
OVERLOAD PROTECTION!
For compliance with the safety requirements IEC 61010-1 (2010), the installation must
include a means of overcurrent protection to provide protection against excessive energy
being drawn from the power supply system in case of a fault in the equipment.