Maritime G7000 Manuale utente

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 
Page 4 of 92 
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

Page 6 of 92

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: +45 9645 4500

Fax: +45 9645 4501

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

Page 8 of 92

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

Version 2.9 – Revision March 2022 Page 9 of 92

≤ ±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

Page 10 of 92

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.

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