HANLA IMS CO.,LTD. (MT-HGS-100NEW SYSTEM ‘1810-8 SONGJEONG-DONG GANGSED-GU BUSAN KOREA Rev. 9 win es mort Brai hanlathanlaims. co, kr Page 1/58 [SS pwd UNE I~ |, Yl (4 eR TE TECHNICAL MANUAL » Hydrocarbon Gas Sampling & Detection System HO (Vv) -HANLA IMS C0. LTD, WT-HaS-100NEW SYSTEM TEI SME GAESED-6 BUSHY KOREA Rev. 9 cl | 2010-07-13, YZ as fax: 8251-881-1880 MO 8 Enai| haniathan|ains. co. kr Table of Contents 1. INTRODUCTION -: 1.1. Operating Principle~ 13:1 BLOCK DIAGRAM 1.3. SPECIFICATIONS 13:1. ANALYZING UNIT- 1.3.2, CONTROL UNIT- 14. Technical Data for Each Component 14.1. ANALYZING UNIT 1.4.2. A/D Conversion and Alarm ~ 1.43, Communication 144 Gas detectors ~ 145, Solenoid valves 146. flowmeter, regulation valve, filter 147 Analyzing Unit adjacent equipments —--~ 148, CONTROL UNIT-—~ 2. OPERATION -- 2.1. NORMAL OPERATION MODE-- 2.11. Before switching power on ~ 212 Start-up 2.13, Control Unit's LCD Display arrangement. 2.14, Sampling and Purging sequences ~ 2.2 GAS CONCENTRATION ALARMS: 2.3. SYSTEM ALARMS 23.1 Typical system alarm sequence ~ 23.2. System Shutdown 233, Flow alarm ~ 2.34 Detector (Gas detector) fault 2.35. Sample leak--~ 2.3.6 Communication fault 2.4, MAIN MENU 2.4.1 PresentationHANLA TMS C0... LTD. NT-HGS-100NEN SYSTEM "10 SHEG-bvG inseam REA Rev. 9 ims Fae: $2051-831-1889 2010-0) Exai |” hanlathan| ais. ck Page 3/58 24.2 General notes 2.5, DISPLAY FUNCTION Fi ~ 2.6. ALARM ACKNOWLEDGEMENT F2- 2.7. CHANNEL MENU F3. 27.1 Normal mode 27.2 Handling mode 2.73 Channel Hold function: 2.7.4 Channel Skip function 275. Acknowledgement function~ 2.8 UTILITIES MENU Fé ~ 2.8.1. Gas Detector Status 2.82 filter Purge function ~ 283. Channel Purge function 284. Leak test 2.9 COMMAND SUMMARY. 3. INSTALLATION AND COMMISSIONING 3.1, MECHANICAL CONNECTIONS ~ 3.2, ELECTRICAL CONNECTIONS 3.3. COMMISSIONING 3.4 CONFIGURATION MENU F5 ~ 3.5. DETECTOR SETTING / calibration menu: 35.1, Detector setting mode ~ 3.52. Detector calibration menu 3.53. Calibration Unit. ~ 3.6. Gas detector for the BALLAST TANK HC(Hydrocarbon) Gas detector for the PUMP ROOM HC(Hydrocarbon) 3.8, Gas detector for the PUMP ROOM 02(Oxygen) 3.9. Gas detector for the PUMP ROOM H,S(Hydrogen Sulphide) 3.10. CHANNEL SETTING ----------- 3.10.1. sampling and purge duration setting-- 3.10.2. Detector 0-7 enable mode (FLOW) ~ 3.103, Pre-Alarm and Alarm limits setting(GAS) 3.11, HORN OUTPUT- 3.12, TIME SETTING. 3.13, MEMORY CONTROLHANLA IMS 09... LID. MT-H6S-100NEW SYSTEM 110-5, NGM bows CSED-CU BUSAN KOREA Rev.9 Fae: 231-89 10-0713 “Ena | panlathanle Page 4/58 3.14 SYSTEM CHECK USING "HOLD" FUNCTION. 3.14.1, Operating Procedure. 3.142. Sample LINE LEAK TEST using "HOLD" function. 3.143, FLOW ALARM TEST using "HOLD" function 3.144, GAS ALARM TEST using “HOLD” function 3.145, SYSTEM SHUTDOWN TEST using “HOLD” function 3.15. CHECK OF COMMISSIONING 3.15.1, CHECK OF INSTALLATION 3.15.2. CHECK OF POWER SUPPLY AND AIR SUPPLY 3.153. CHECK OF VALVES 3.154, CHECK OF AIR SUPPLY --~ 3.15.5. AC POWER SUPPLY 3.15.6. FLOW setting-- 3.15.7. CHECK OF BASIC FUNCTION 3.15.8 CHECK OF SYSTEM OPERATION, 3.15.9. Check the FLOW of each channel. 3.15.10. CALIBRATION OF GAS DETECTOR. 4. TROUBLE SHOOTING-.HANLA IMS 00. LTD, MT-HS-100NEN SYSTEM S05 SMG ot Guse-ay eu KoA Rev. 9 YZ was "Foe: 02:31-331-1050 io ees Enail haniathanlains. coke Page 5/58 1. INTRODUCTION The HGS-100 System is dedicated to analyze gases in tanks (ballast, cargo, . void spaces or any possible dangerous area, in order to detect any gas concentration level over or under safety limits and to monitor actions as visible and audible alarms. That system complies with ISGOTT regulation chap. 7.8 and 8.2 The HGS-100 System is a Gas Monitoring based on suction process sampling toward one or more common detector(s), combined with analog inputs from local gas detectors Controlled Gases are » Hydrocarbon gases > Onygen > Hydrogen Sulphide > Carbon monoxide > Sulphur dioxide > Nitrogen monoxide > Nitrogen dioxide > Ammonia » Chlorine > Hydrides > Other on request The sampling points for suction process are to be placed as close as possible to the gas emission source. However regarding the ballast tanks, they can be placed on tank top even bottom, in order to preserve the longest efficient period when ballast tanks are filing up, to ensure the fire prevention efficiency of the system as fire can be caused by gas coming out on desk from tank top, and also because gases are pushed toward top by tank filling (MO Sub-Committee on fire protection) the gas emission is in tank The local detectors can be placed in pump room, engine room, accommodations, venting ducts, air- conditioned ductsHANLA IMS C0... LTD. MT-HGS-100NEW SYSTEM 10-5 SGD GinsE-c0 BM KOREA Rev. 9 YF was Fox: 62-81-831-1650 2010-07-13 “Enai|= hanlaitantatns. co. kr Page 6/58 1.1. Operating Principle The hydrocarbon gas detector is an essential system in the cargo oil tanker, the gas carrier, the chemical cartier. The HGS-100 System is for monitoring the gas concentration in the ballast tank and void space caused by mechanical damage like crack. Continuous monitoring will occur the alarm when the gas concentration is increased over than preset value and show the visible and audible alarm, ———_ ite Sete: sm a HGS-100 covers the max. 48 channels for cargo oil tanker. The PARTL of this system is for 1 to 40 channels and used to monitor the gas of the ballast tanks. The PART2 is for monitoring the gas concentration of the pump room. Each PART uses the only one sensor. To monitor many sensing points, sequential sampling the gas through the line will be economic scheme. Generally, in the ballast tanks, the Hydrocarbon(HC) gas is monitored. . Infra-red type HC sensor is used for best reliability and maintenance-free. And, in the pump room, not only the hydrocarbon, but also the Oxygen(0,), Hydrogen sulfide(H,5) gases are monitored too. Type of these sensors are different that of Ballast tanker's one. These are solid type sensors. Type, number, gas-type of these sensors can be changed by user's demand. The analog signal is converted to digital signal by A/D converter of Analyzing board, The microprocessor of HGS-100 system control the 2 pumps, 52 solenoid valves, filter, graphic LCD displays the gas concentration, alarm, flow, leakage, and status of individual tanks.HANLA IMS 09. . LTD. MT-HGS~100NEW vot Pr a” a ‘aK I-1 2010-07-13 _— seinen coke Page 7/58 1.3.1 BLOCK DIAGRAM HGS-100 System has the Analyzing unit, Control unit, Repeater units. Analyzing and Control units are installed in the main panel ‘REPEATER ALARM UNIT MEASURING ti) ‘CALIBRATION ‘The block diagram of the systemHANLA IMS 00... LTD. NT-HGS-1OONEW SYSTEM IOS SMG Ginso-s) SM KOREA Rov 9 ims Fee: 62-81-851-1850 2010-07-13. YW “Ena hanoarann, 0 Ar Page 8/58 ‘To sample the gas of the BALLAST TANK, the sampling pump(P2) is used. To sample the gas of the PUMP ROOM, the sampling pump(P3) is prepared, Each channel is controlled by the solenoid valve control. To regulate the gas flow and check the flowrate the regulation valve and flowmeter are installed. The moisture from the suction of pipe lines is filtered by the filter and drained by compulsion The diagram of the gas flow Channel Sampling + EVI to EV40 and EVO-I allow the control ofthe sampling line for PART. + EV41 to EV48 and EV0-2 allow the control of the sampling line for PART2. * P2, P3 are the sampling pumps. + EV0-1 allows the cabinet internal atmosphere control, or the P2 pump discharge: In addition, a solenoid valve EVO-1 allows to control the internal atmosphere ofthe Analyzing Unit, named channel 0. Channel Purging *+ EVA, EVE allows to proceed to an air purge of selected channel; Aer suction sampling of a channel, an instrument air purge is started, in order to correct or prevent ingress of water, moisture, condensation, dust or foreign bodies. Calibration ‘+ EVB, EVF allow to drive the Calibration Gas to the detector(s). + EVC allows to purge the water trap. + Gas Detectors(GD) in Main Sampling Line(Ch.1~40): the Hydrocarbon gas Infrared detector pump(GD on above diagram); other detectors) is(are) placed downstream P2. + Gas Detectors(GD) in PUMP ROOM Sampling Line(Ch41~48): the Hydrocarbon, O; and HS gas detectors can be placed upstream P3 pump(GD on above diagram); other detector(s) is(are) placed downstream PS. placed upstream P2hin HANLA TMS 00... LTD, NT-HGS-100NEW SYSTEM "510-5 SONGJEQNG-DoWs GHNGSEO-GU BUSAN KOREA Rev.9 el sao 00 a cI -180 2010-07-13 eral" hanlashanlaine eo. ke Pay 9/58 1.3. SPECIFICATIONS 1.3.1. ANALYZING UNIT eoce Suction channels number ‘Suction capacity ‘Sampling exhaust output Circulation exhaust output Drain Water trap output Calibration Gas input Instrument air supply for purge 4-20mA Analog calibrated inputs for sampling or local detectors 4-20mA inputs accuracy Output power supply for detectors Internal Detector for Hydrocarbon Gas Other Detectors Gas concentration alarm levels ‘Alarm from Analyzing Unit, dry contact output Communication ports (Output power supply for Contral Units Operating/storage temperature for ‘Analyzing and Control Units Location for Analyzing and ‘Control Units Enclosure protection Power Supply Power consumption 1.3.2. CONTROL UNIT . LCD display Keypad indicators Alarm ‘Communication port front Power supply + up to 48, copper pipes 1p 10.400 meters 1.D. 6mm pipes nection to safe area connection to safe arca + connection to safe area -onnection with plastic tube 4Toars upto 20.1% :24Vde Infra-Red type, 420mA output + miscellaneous type according to gas type 4-20mA 2-wire or 3 wires output, safety class according to thei location 2 adjustable, Pre-Alarm and Alarm +1 for Gas Alarm | for System Alarm | for Power Supply failure 3 RS#8S, | isolated RS232 or RSA8S Default address 1; default baudrate 9600 24 Vde 10% 10470 Safe area in enclosed space (Control room, accommodations, bridge...) + 1P22 minimum 115/230 Vac 50/60 Hz (0 VA with one Control Unit 340 VA with two Control Units 16 lines, 40 columns, back-lighted tactile type, numerie + functions keys : front integrated color LED's = | intemal buzzer * Idry contact output 2 RSA8S = polyester film £24 Vde from Analyzing UnitHAMLA IMS 00, . LID. NT-HoS-100NEN SYSTEM IMO-S OED ol Gnso-0) BI KOREA Rev.9 Fax: 8-81-1050 Peng ~Enai |" hantathanl ing. co.kr Page 10/58 1.4. Technical Data for Each Component 1.4.1. ANALYZING UNIT ‘cabinet named "Anal for up to 48 channels Unit" includes the suction process, sampling gas detector(s) and pneumatic components ‘After suction sampling of a channel, an instrument air purge is started, in order to correet or prevent ingress of water, ‘moisture, condensation, dust or foreign bodies. The picture of analyzing board is following: In case of several sampling gas detectors, the sampled gas passes through each detector one after the other, so that all {gas concentrations are measured at the same time. An additional Gas detector can easily be installed further. Each Gas detector can be enabled or disabled at will, 1.4.2. A/D Conversion and Alarm ‘An electronic module supervises over the suction process, provides up to 8 analog inputs for gas detectors and flow sensor placed either in BALLAST TANK suction process sampling(2 channels) or in PUMP ROOM suction process sampling(4 channels). The local gas detectors are classed as additional individual channels as well as additional gas detectors by using remained 2 channels of AD converter. The analog signal processing by the differential amplification allows the high impedance and rejection of common-mode noise. To convert the current 4~20 mA to the voltage, the load resistor 200{2 is used That module periodically performs and saves all gas measurements, It provides a non-volatile memory for saving all data, alarm status and operating parameters. The Analyzing Unit provides two high or low gas concentration alarm levels on each channel and each gas (see7.4.2), ‘monitoring @ permanent "Gas alarm" dry contact output (see 6.2); © pre-alarm limit, to advise that a gas concentration approaches the alarm unit; (© alarm limit, with activation of another dry contact output dedicated to a horn/otating lamp, until alarm acknowledgement. ‘When some gas are without interest for some channels, the relevant alarm limits ean be set atthe extremities ofthe gas range, in order to avoid gas concentration alarm monitoring for that gas on these channels, ‘The Analyzing Unit provides selftests: sample flow, intemal gas concentration, internal leakproof, detectors current output, calibration gas flow, communication between Analyzing and Control Units, power supply. These tests monitor a "System fault" and "Power supply” dry contact outputs. 1.4.3. Communication “This module also manages 4 digital RS485 communication port Generally, one for contol unit. One for repeater SIL 100, Then, only 2 ports are avilable for user interface. MODBUS RTU) and one RS252(for downloading or MODBUS RRTU) isolated communication pot for connection to one or more remote Repeaters as described in synopsis, andor an extemal Monitoring System, using MODBUS RT protocol. The Analyzing Unit operates as slave.HANLA TMS CO.,LTD. Hes 1109 SGN Ginseo-a asi HORA nae renee bx: B2-51-831-1890 o0-ari3 Enel haniathantains. co. kr Page 11/58 1.44 Gas detectors The HGS-100 System uses two locations of Gas detectors: inside the Analyzing Unit, in suction process sampled Gas, and {in local areas to be controlled. Any gas detectors of Infrared, catalytic, electro-chemical or any other type, 4-20mA output, ‘can be connected to the Analyzing Unit. For Gas detectors located inside the Analyzing Unit, in suction process sampled Gas: detector dedicated to Hydrocarbon gases is Infrared type, for best reliability and maintenance-free. For Local Gas detectors: Same detectors can ‘be used, but installed with connection box. © To monitor the BALLAST TANK, infra-red type detector is used based on the principle of infra-red absorption. ‘The quantity of absorption of infra-red is changed by the type ofthe gas. Thus, the concentration can be determined by the ‘quantity ofthe gas. ‘© To monitor the PUMP ROOM, solid-state type Detector was adopted, ‘These detectors have the built-in microprocessor and output the 4~20mA current to interface the other equipments, Here, these current signals are converted to digital data by the A/D converter of Analyzing Board. Control Board displays those data from the analyzing board. 1.4.5. Solenoid valves ‘The 8 solenoid valves are installed on the manifold. The system uses the 9 sets of manifold for total 48 channels of the sampling points. The supply voltage and power consumption of valve is DC 24V, 4.4W, The maximum pressure is 145 psi and 2 way type. These solenoid valves are used to connect the air line to the sampling pump sequentially by the control ignal of Control Unit. 1.4.6. flowmeter, regulation valve, filter ‘Sampled air by the Sampling pump will low through the air filter to prevent the dust, water, humidity. The filter will drain the watcr and dust periodically. The Flowmeter shows the flowrate of suction air flows to the detector by the sampling pump. ‘The regulation valve controls this flowrate. 1.47 Analyzing Unit adjacent equipments Bulkhead penetrations for suction process channels: the number of bulkhead penetration set is defined by the umber of bulkhead to passthrough. For each channel fame-arestor EExd classi place at he limit between safe and hazardous area, on relevant bulkhead penetration; (© Shut-off valves foreach channel; © Flow-tegulting valve for cach channel allows to equilibrate the low whatever isthe length ofthe line, for best efficieny ofthe system; © Bulkhead penetrations for gas exhaust and filter drains (© Shut-of valve and manometer for instrument sr supply for channel purge.HANLA IMS CO... LTD. NT-H@S-100NEW SYSTEM 1810-8 SONGJEONG-DoNG GANGSEO-GU BUSAN KOREA Rev. 9 iv: I $BSt 401-3000 2010-07-13. Enai | hanlaéhen| ains. co. kr Page 12/58 1.4.8. CONTROL UNIT A panel named "Control Unit" includes a backlighted LCD screen for measurements and alarm display, LED indicators, buzzer/dry contact output for alarm and keyboard for System operation and configuration. The large LCD screen increases the data availability and the man-machine interface is simplified for easy access to functions and configuration using scrolling menus. It communicates with the Analyzing Unit using a Modbus protocol serial link RS485, operating as master in order to get all data and status from the Analyzing Unit, and to set any configuration change. The Control Unit is powered by 24 Vdc from the Analyzing Unit. One Control Unit can be incorporated in the Analyzing Unit or located in a remote box or in existing console. One or two others can be used as repeater(s), but HGS-100 also can have identical remote repeaters SIL-100 series by order As the common database (gas measurements, fault status, operating parameters) is saved in the Analyzing Unit, all Control Units display the same data. Remote repeaters SIl- 100 series display the summarized information. Control Unit front overview : HGS.100 2900 @206 ®660 2 go0aa8 sheen 7 IMPORTANT NOTE : the Analyzing Unit and Control Unit operate independently. So, in case of failure of communication with the Control Unit, the Gas Concentration alarms and System faults remain under control by way of the Analyzing Unit Gas Alarm and System fault relaysHANLA IMS 60... LTD. WT-H@S-100NEW SYSTEM 1510-5 SONGJEONG-DONG to upper line. F4, DOWN : moves the cursor ~ to lower line. F6, RTN : RETURN Horn output : sets the alarm contact forthe external alarm signal Horn out Part! P-Alarm? : sets the alarm contact for the Part! Pre-Alarm. F2. YES : enables FA. NO: disables, Horn out Partl Alarm? : sets the alarm contact for the Part! main Alarm. Horn out Part2 P-Alarm? : sets the alarm contact for the Part2 Pre-Alarm, Horn out Part2 Alarm? : sets the alarm contact for the Part2 main Alarm. F2, UP: moves the cursor > to upper line. F4, DOWN : moves the cursor > to lower line. 6, RTN : RETURN ‘Time setting : sets the time and date, ‘Year : to set the year. ‘Month ; to set the month, Day : to set the day. Hour : to set the hour. Minute : to set the minute. Second : to set the second. F2, UP: moves the cursor > to upper line F4, DOWN : moves the cursor > to lower line. F6. RTN: RETURN Memory : management of system parameters like parameter saving, loading, backup. ‘Alarm and fault clear : resets the all alarm. Displays “processing...” and “OK”. Configuration data backup : Saves data of the working memory(RAM) to the saving ‘memory(EEPROM). Configuration data reload : reloads data of the saving memory((EEPROM) to the working ‘memory(RAM). Configuration data default: Initialization, This do not deals the data of saving memory(EEPROM). Initialize only the working memory(RAM). F2. UP: moves the cursor > to upper line. F4. DOWN : moves the cursor + to lower line. F6. RTN : RETURN Exit, save configuration : to return to the previous menu from the configuration menu, F2, YES : saves. F4, NO : discards. not saved. ‘Caution : ARer operating the above “Memory...” menu, choose the “F4, NO” then “Enter”. Other ‘menus except the “Memory...” menu, choose the “F2, YES" F2, UP: moves the cursor to upper line, F4. DOWN : moves the cursor + to lower line. F6, RIN ; RETURN. key-in RITN in any situation allows to cancel and exit current operation,whan HANLA IMS 00... LTD. 60-5, SNEED 20 OAESEO-G BUSA KOREA ‘a-s1-60 2-51-a31- 1880 “Efai | har lathanlains. ca. kr NT-HGS-100NEW SYSTEM Rev. 9 2010-07-13. Page 35/58 3. INSTALLATION AND COMMISSIONING 3.1. MECHANICAL CONNECTIONS > The sampling pipes are connected to the channels’ inlets through the frame arrestors, the shut-off valves ‘and regulating valves, by respect to their identification and taking care to the perfect leakproof % Flame-arrestor & Valve should be installed to the direction of arrow. The end of vent line, which is connected to the panel. >» The exhaust pipes are connected to the relevant exhaust connections. > The clean and dry instrument air supply pipe is connected to the relevant inlet, through a shut-off valve with witness manometer > If possible, the bending points of sampling pipes should be reduced. If there is @ lot bending, the sampling line can clog up by condensation water. > The calibration gas cylinder is connected to the relevant inlet, Suction Channel a: Air supply port for Purge e000 b : Exhaust 1 c: Exhaust 2 d: Drain * Calibration gas port is prepared in panel inside.HANLA IMS 00. . LTD. WT-HGS~100NEW ra Tit eet Sie as if 9 GF ms “eis ristnfstes coke Page 36/88 — > The example of installation is as follow. AP CONTROL Panel EF FLAME ARRESTOR TCALIRATION UNIT B: CONTROL UNIT F SAFETY CHAMBER REMOTE DISPLAY UNIT C: CONTROL Paneliside view) | G: SUCTION MOUTHCTANK INSIDE | K: HORN & LIGHT D: REGULATING VALVE HAIR SUPPLY BOARD L: ON/OFF STOP VALVE. AC POWER SUPPLY AIR SUPPLY ss Installation Example of Fixed Gas Sampling System 3.2. ELECTRICAL CONNECTIONS > The 115/230 Vac power supply is connected to the relevant terminals; > ‘The local Gas Detector(s) is(are) connected to the relevant terminals on the PCB or to Zener barrier, through shield ‘grounded packing gland(s); > ‘The Remote Control Unit or Remote Repeater ifany is connected tothe relevant terminals, 24 Vde power supply and S485 communication line through shield grounded packing gland(s); > The Monitoring System RS232 or RS485 communication Tine is connected to the relevant connector or terminals through shield grounded packing gland; > Alarm on/off dry contact outputs are connected to the relevant terminals,HANLA IMS 60. LTD. MT-H6S-~100NEW SYSTEM TIO SONGNG-DNG CMSEO- LSA KOREA Rev.8 iu Be: Bestantes) goog is “ES ahamantatns co er Page 37/58 3.3. COMMISSIONING ‘The main commissioning operation for preparing the HGS-100 System configuration, is the equalization of the suction flow forall channels, Proceed as follow : “@ Hold on all channels one by one, and note the displayed flow value in Uh, after waiting for stabilization, © Check these values. ‘© Hold on all the channel one by one, and adjust the relevant regulating valve in order to get the lower flow +20 Uh 0, the suction flows forall channels will be identical at +20 [Uh] © Correct the adjustment of the low in the detectr(s), in order to get | [V'min] forthe common flow on all channels as set above (except channe! 0) ‘Take care to the presence of instrument air supply : open the shutoff valve and check the pressure on the manometer, in order to get efficient channel purge. 3.4 CONFIGURATION MENU F5 ‘© When pushing CEG key FS from the main menu, the system asks for the Engineer Password ie OOO cx sar @@O6 cm or . ©O® on Tes, con ee, eT ©@OO HeB008 «© type 1234 then “Enter, Ifthe password was properly entered, the Configuration menu is displayed. If not, the message "Invalid passwor layed, andthe system asks again for the Engineer Password. © Ifthe Configuration menu is entered by another Control Unit, the display shows "Configuration in progress’