CEMS FAT Precedure 7131506

P.T.CENTRALJAVAPOWERSUMITOMOCORPORATION

Project:

TANJUNGJATI'B'COALFIREDPOWERSTATION

UNITS3&42X660MW(NET) DocumentTitle:

SHOPINSPECTIONANDTESTPROCEDURE

FOR

CONTINUOUSEMISSIONMONITORINGSYSTEMDocumentNo.:

BuyersDocumentNo.:

SICKSDocumentNo.: 7131506.FAT.01

0 Jerry Yang Mi zhengqian

Version Prepared by Reviewed by Approved by Approved Date

Submittedby:

SICK MAIHAK(Beijing)Co.,Ltd

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Table of contents

1. Purpose

2. System configuration of FAT of CEMS

3. Certificates of Calibration Instruments

4. Calibration Certificate of Gas Analyzer and FlowSIC100

5. Reference Drawings

6. Test and Inspection items

7. Test and Inspection Procedures

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1. Purpose The project locates at Tanjung Jati, Central Java,Indonesia, SICKMAIHAI (Beijing) will supply 2 set of SMC-9021 system for SO2/NO2/CO/CO2 emission monitoring. This document describes the test and inspection contents and procedure of CEMS (Continuous Emission Monitoring System) for Tanjun-Jati B Coal-Fired Power Station Unit 3 & 4 2 x 660 MW. This test and inspection confirms that the customer requirement and the standard of our company are satisfied fundamentally. This procedure will be applied to FAT for CEMS

1.1 Test place Address:No. 160 Beijing Road, Wenquan Haidian District, Beijing, 100095 P.R.China Place: SICKMAIHAK (BEIJING) Co., Ltd.

1.2 Test Schedule

No Equipment Test Item Plan of Completion date 1 Hardware Equipments Hardware Inspection Apr. 1th 2th, 2010 2 Gas Analyzer Calibration Test Calibration Report Checking Apr. 1th 2th, 2010 3 CEMS Function Test Function Test Apr. 1th 2th, 2010

2 System configuration of FAT of CEMS

3 Certificates of Calibration Instruments Name Type/Serial No. Certificate No. Conclusion Comment Insulation Meter ZC25-4/092983 D210J-B0074 Grade 10.0 See Annex 1 Pressure Meter (0-0.16Mpa)/2528 09038971 Grade 2.5 See Annex 2 Oxygen Meter (0-25Mpa)/2007121097 10005356 Grade 2.5 See Annex 3 Universal Meter UT58E/3060247904 D110Z-A0101 See Annex 4

Unit3

CCR

Unit4

Local

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4. Calibration Certificate of Gas Analyzer and FlowSIC100 Name Type/Serial No. Measuring range Calibration Report Gas Analyzer S710/ SO2: 0-500-2000mg/m3

NO:0-1000mg/m3 CO:0-1000mg/m3 CO2:0-20%

See Annex 5

Gas Analyzer S710/ SO2: 0-500-2000mg/m3 NO:0-1000mg/m3 CO:0-1000mg/m3 CO2:0-20%

See Annex 6

Flow meter Flowsic100/10048555 See Annex 7 Flow meter Flowsic100/10048556 See Annex 8 5. Reference Drawings

DWGNO. TITLEISSUE

NO.

SUBMITTAL

DATE

7131506.00001 CEMSsystemconfigurationdrawing 3 20100112

7131506.00002 CEMSenclosurelayoutdrawing 3 20100112

7131506.00003 Samplingprobeflangeinstallationdrawing 3 20100112

7131506.00004 TemperatureprobeflangeInstallationdrawing 3 20100112

7131506.00005 Pressureprobeflangeinstallationdrawing 3 20100112

7131506.00006 Spareinstallationdrawing 3 20100112

7131506.00007 FlowAnalyzerInstallationdrawing 3 20100112

7131506.00008 CEMSMeasurepointlayoutdrawing 3 20100112

7131506.00009 CEMSsystemflowchart 3 20100112

7131506.00010 Unit4CEMSsystemflowchart(Notused) 1 20100122

7131506.00011 Powersupplyandairallotmentdiagram 3 20100112

7131506.00013 CEMSpowersupplysystemdrawing 3 20100112

7131506.00015 Unit3CEMSsignalterminalwiringdrawing 3 20100112

7131506.00016 Unit4CEMSsignalterminalwiringdrawing 3 20100112

7131506.00017 Oxygenprobeflangeinstallationdrawing 3 20100112

7131506.00018 Cableductwork 3 20100112

7131506.00019 Paneloutlinedimensiondrawing 2 20100112

7131506.00021 Controlpanellayoutdrawing 2 20100112

7131506.00023 Panelexternalconnectiondiagram 2 20100112

7131506.00024 Paneltubingandpipingdrawing 2 20100112

7131506.00025 Panelinternalarrangementdrawing 2 20100112

7131506.00028 FlowanalyzerControlunitLayoutdrawing 1 20100112

71315026.00029 OxygenanalyzerControlunitLayoutdrawing 1 20100112

6. Test and Inspection Items

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Item Category Inspection means 1 Hardware Inspection By witness 2 Documentation audit By certificate / report audit 3 Function Test inspection By Testing 7.Test and Inspection Procedures 7.1 Procedures

No. Equipment Component Witness Items

Reference document and/or acceptance standard

Witness Record

Inspection by

Sick Maihak

B &V SC/Fichtner

1. Hardware Inspection

1.1 S710 gas analyzer S710 3EVM-AX801 4EVM-AX801

Normal structure

checking,

appearance

checking

Document of

Method: By witness

Comply with: contract document and

technical specifications,

Conclusion: OK if no damage on

surface

1.3 FlowSICK100 3EVM-FX801 4EVM-FX801

Normal structure

checking,

appearance

checking

Document of

Method: By witness




surface

1.4 ZR22G Oxygen analyzer 3EVM-AX802 3EVM-AX802

Normal structure

checking,

appearance

checking

Document of

Method: By witness



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Witness Record

Inspection by

Sick Maihak

B &V SC/Fichtner


surface

1.5 Temp sensor 3EVM-TX801 4EVM-TX801

Normal structure

checking,

appearance

checking

Document of

Method: By witness




surface

1.6 Pressure transmitter 3EVM-PX801 4EVM-PX801

Normal structure

checking,

appearance

checking

Document of

Method: By witness




surface

1.7 AB PLC Normal structure

checking,

appearance

checking

Document of

Method: By witness




surface

1.8 Sampling line Normal structure

checking,

appearance

checking

Document of

Method: By witness




surface

2. Documentation audit

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Witness Record

Inspection by

Sick Maihak

B &V SC/Fichtner

2.1

S710 gas analyzer

1) Measuring range

check,

2) Linearization

checking;

3) Zero-point and

full-range

calibration;

4) Stability

checking;

S700 analyzer

calibration

manual

1)Comply with

contract and technical

specification

2)S700 analyzer

calibration report

2.2 FlowSICK 100 3EVM-FX801 4EVM-FX801

1)insulation

resistance testing

2) Length, angle,

cross-sectional area

setting

3)parameter setting

4)unit checking

5) analog signal

checking

1)Comply with

contract and technical

specification

2)Flowsic100 Testing

Report

2.3 AB PLC controller and IO module

TYPE approval

certificate

2.4 Condenser Mak10

Quality Certificate

2.5

Temperature transmitter 3EVM-TX801 4EVM-TX801

1)Quality Certificate

2) Logistic checking

record before

registering into ERP

system and put into

warehouse

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Witness Record

Inspection by

Sick Maihak

B &V SC/Fichtner

2.6

Pressure transmitter 3EVM-PX801 4EVM-PX801

1)Quality Certificate

2) Logistic checking

record before

registering into ERP

system and put into

warehouse

2.7 Cabinet 3EVM-PAN801 4EVM-PAN801

Production Record of

Cabinet assembly,

wiring and Function

Test.

2.8 Documents and Drawings

Documents and

Drawing reviewing

3. Function Test inspection

3.1 CEMS system

Pipeline leak testing

checking.

Function Test

Documents of

SMC-9021

CEMS system

Please refer 7.2.4

3.2 CEMS system

Function test

(auto/manu switching,

sampling, purging)

Function Test

Documents of

SMC-9021

CEMS system

Press relative buttons

on panel.

3.3 AB PLC

IO signal checking Function Test

Documents of

SMC-9021

CEMS system

Please refer 7.2.5

3.4 CEMS system

Testing with sample

gas (zero-point

checking, Full-range

checking).

Function Test

Documents of

SMC-9021

CEMS system

Please Refer 7.2.3

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7.2 Detailed Procedures

7.2.1 Linearity (this procedure was used during Gas analyzer calibration):

Calibration equipment: 1. Precise proportional pump 2. Span gas

Method: 1. Measuring 5 different point of span gas with different concentration (0%, 20%, 40%, 80%, 100%).

1. Calculating error for these 5 points [(Measuring value Span value)/max limit of Span gas]

Result: 1. Linearity will be marked OK if error of all 5 points are less than 2% (compared to max range limit)

2. Linearity will be marked Not OK if any error of 5 points is high than 2% (compared to max. range limit)

7.2.2 Stability (this procedure was used during Gas analyzer calibration): Calibration equipment: 1. Zero gas

2. Span gas

Method: 1. connecting Zero gas, waiting until the display reading become stable, writing down the display reading. 2. Connecting Span gas (concentration is between 90% - 105% of max range limit), waiting until the display reading becomes stable, writing down the display reading. 3. Repeating step 1) and 2) for 5 continuous days. 4. Calculating error for 5 days display readings.

Result: StabilitywillbemarkedOKifallcalculatederrors arelessthan1.5%(comparedtomax.rangelimit)

7.2.3 Calibration of Zero Point and Max limit point: Calibration equipment: 1. Zero gas

2. Span gas

Method: 1. Connecting Zero gas for Zero point calibration. 2. ConnectingSpangasforMax.limitpointcalibration

7.2.4 Gas leaking test Calibration equipment: 1. Compress air

2. Pressure meter

Method: 1. Connecting compress air(0.08Mpa) to inlet pipe. 2. Waiting10minutes.

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3. Monitoring outlet pressure of Drain pipe Result 1. OK if pressure decline is less than 0.005Mpa within

10 minutes

7.2.5 PLC IO checking:

Calibration equipment: 1. Universal meter, Type: UNI-T.

Method: 1. Setting target value (full range value) in PLC

2. Measuring output current by universal meter.

Result OK if output current error is less than 0.5%

jerry.yangAnnex 1

jerry.yangAnnex 2

jerry.yangAnnex 3

jerry.yangAnnex 4

jerry.yangAnnex 7

jerry.yangAnnex 8

IPT Precedure_7131506_v3.pdfCalibration Certificate_Insulation meter_2010.pdfCalibration Certificate_Pressure Meter_2010.pdfCalibration Certificate_Oxygen meter_2010.pdfCalibration Certificate_Universal meter_2010.pdfQM certificate_FlowSic100_unit 1_7131506.pdfQM certificate_FlowSic100_unit 2_7131506.pdf