ALCAN PACKAGING

ALCAN PACKAGING DUBLIN LTD.

Jamestown Road Finglas Dublin 11 Ireland

Tel.: + 353 1 8081000 Fax: + 353 1 8081111 www.alcan.com

Office of Licensing & Guidance, Environmental Protection Agency Headquarters, P.O. Box 3000, Johnstown Castle Estate, CO. WEXFORD.

26th October 2007

--- ---__ - - --- - - - _ _ _ _ _ _ _ - - _ _ - - _._ - Ref. Proposed Determination fqr a Licence Review Licence Register No.! P01119,-02 I '

Dear Sirs,

We acknowledge receipt of the Agency's notification of its Proposed Determination, dated October 5th 2007, on the application for a review of an IPPC licence made by Alcan Packaging Dublin Limited.

We have considered carefully the conditions in the Proposed Determination and we have decided to object to certain specific conditions. Our objections, and the reasons, considerations and arguments on which these objections are based, are set out overleaf.

We enclose our cheque for €253, being the statutory fee payable in respect of an objection by an applicant or licensee.

We hope that the Agency will consider our objections and supporting arguments

V "

- -favourabl$. 1

Yours faithfully,

Allan Radford EHS & Hygiene Specialist Alcan Packaging Dublin Limited

IS0 9000 Registered Office: Jamestown Road, Finglas, Dublin 11 Number 140350

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Alcan Packaging Dublin Proposed Determination No. PO1 19-02

Submission to EPA on Objections to Licence Conditions

I

Reference:

Subject: Objections to Licence Conditions Objector: Alcan Packaging Dublin Limited Address:

Proposed Determination for a Licence Review Licence Register No: PO119-02

Jamestown Road, Finglas, Dublin 11

Objection No. I Ref: Introduction to Licence

While we acknowledge that the Introduction to the licence is not part-of the licence and does not purport to be a legal interpretation of the licence, we request that an additional sentence be added to the Introduction to clarify the working hours at Alcan

I-- Packaging Dublin. \ ’

In our application for the licence review, we stated that our factory operates 24 hours/ day, Monday to Friday, with the last shift ending at 06.00 on Saturdays. We also stated that additional shifts may run at weekends to meet production requirements. See supporting document in Annex 1. The Agency acknowledged this statement in its Inspector’s Report on the licence application, dated September 14th 2007, under the section headed Company. See supporting document in Annex 1.

In order to inform any third party, who may read our licence, that we may operate production shifts on Saturdays and Sundays, we request that the following sentence be added at the end of the Introduction to the licence: “The factory may operate additional shifts at weekends to meet production requirements”.

Objection No. 2 Ref: Condition 3.9.1

We wish to object to the requirement in this condition that the temperature as measured within the combustion zone of the regenerative thermal oxidiser (RTO) be maintained at not less than 850°C.

A minimum combustion chamber temperature of 850°C has never featured in the design or the operation of the RTO at Alcan Packaging Dublin. The functional Design Specification for the RTO, which was produced at the design stage of the project (see Annex 2 for relevant extracts), lists the temperature control set point at 820°C, and the “process air on” temperature at 780°C. Since the RTO was commissioned in 2002, the unit has been optimised by the manufacturer in respect of environmental performance and energy efficiency, and the current set points are 800°C for control of the combustion chamber temperature and 770°C for “process air on” temperature (see Annex 2 for an extract from a 2006 service report on the RTO from the manufacturers, Diirr Environmental GmbH).

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Alcan Packaging Dublin Submission to EPA on .L Proposed Determination No. PO1 19-02 Objections to Licence Conditions

P .b?

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Annex 2 also contains a typical chart of the combustion chamber temperatures, which shows the temperature controlling at 800°C. The sample chart covers the period Sth to 20'" October 2007. It should be noted that, depending on the solvent load in the air stream to the RTO, the RTO may reach auto-thermal operation (in which case the natural gas burners shut off) and the combustion chamber temperature will rise above the set-point for the burner controls.

Interpretation Criteria

The operation of the RTO at the current temperature has delivered consistent compliance with the emission limit values in our licence. This can be seen from the summary of the continuous TOC monitoring results which are contained in our Annual Environmental Reports to the Agency. A summary of the compliance over the past three years is given in Table 1. In each year, the TOC emissions from the RTO have been compliant against each of the interpretation criteria. We submit that there is no justifiable reason to increase the combustion chamber temperature on the basis of the TOC emissions from the RTO.

Table 1: Summary of Continuous TQC Monitoring Results for RTO gram AE&) . ,

Licence Monitoring Results 2005 2006 Limit Value ' 2004

. -

Highest 24-hour mean value (mg/Nm3) No. of 24-hour mean values > 100 mgmm3 % of 30-minute mean values < 120 mgmm3 Highest 30-minute mean value

~~~~~~

100 78.6 83.4 90.3

0 0 0 0

>97% 99.95% 100% 99.8

200 136.5 113.8 127.7

No. of 30-minute mean values > 200 1 0 0 0 0 mgmm3

NOx (mgNm3)

Note: The method for interpreting the results of continuous TOC monitoring of the clean air stack on the RTO is set out in condition 3.1.1 of the licence, viz: - -

No 24-hour mean value shall exceed the emission limit value, i.e. 100 mg/Nm3; 97% of all 30-minute mean values taken continuously over an annual period shall not exceed 1.2 times the emission limit value, i.e. 120 mg/Nm3; No 30-minute mean value shall exceed twice the emission limit value, i.e. 200 mg/Nm3. -

Max. 6.3 I 75.1 I 20.8 100 Ave. 0.2 3.2 1.2

The CO and NO, emissions from the RTO have been well below the emission limit values in the licence on a consistent basis, as shown in Table 2. We submit that there is no justifiable reason to increase the combustion chamber temperature on the basis of the CO and NO, emissions from the RTO.

Table 2: Summary of CO and NO, Monitoring Data for RTO From AERs)

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I I I Max. I 0.2 I 5.1 1 2 3 I

261h October 2007 2

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Alcan Packaging Dublin Proposed Determination No. PO1 19-02

Submission to EPA on Objections to Licence Conditions

The design volumetric flow rate to the RTO is 15 1,300 Nm3/h. The design inlet temperature to the RTO is 43OC, and the design thermal efficiency of the RTO is 92% at the design flow rate.

The energy required to heat a specific quantity of air through a specific temperature range can be calculated from the equation:

Q = mCpAT

where Q = energy input (kw) m = mass flow rate of air (kg/s) Cp = specific heat of air (kJ/kg OK) AT = temperature rise (OK)

The energy required to heat the design flow rate of air from 43°C to 800°C (the current combustion chamber temperature) and to 850°C (the minimum temperature stated in condition 3.9.1 of the Proposed Determination) is calculated below. In each case, the additional combustion air (-2%) is neglected. The thermal efficiency of the RTO beds is taken at 92% for both scenarios, which is a conservative assumption in this context.

Energy required to heat 15 1,300 Nm3/h from 43°C to 800°C @ 92% thermal efficiency

: 3,794kW

Energy required to heat 15 1,300 Nm3/h from 43°C to 850°C @ 92% thermal efficiency

: 4,077 kW

Additional energy required to operate combustion chamber at 85OoC

283 kW

Taking the average operating hours for the RTO at 5,500 hours/year, and an average current gas cost of €0.04/kWhY the additional annual energy requirement would amount to 1,556,500 kWh, with an additional energy cost of €62,30O/year. In practice, the additional energy requirement and energy cost would be less than these values, for two reasons: (1) the RTO does not currently run at its maximum flow rate, and (2) the energy content of the solvent in the air stream to the RTO reduces the natural gas requirement. However, the calculations above are indicative of the significant impact which raising the combustion chamber temperature would have in terms of the energy efficiency on the Alcan Packaging Dublin site.

We submit to the Agency that there is no requirement within the design parameters for the RTO to operate at a minimum combustion chamber temperature of 850°C; that there is no justifiable environmental reason for specifying a minimum combustion chamber temperature of 850°C for our particular installation; and that a requirement on Alcan Packaging Dublin to operate at this temperature would give rise to a significant increase in the energy consumption on the site for no particular gain.

26”’ October 2007 3

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Alcan Packaging Dublin Proposed Determination No. PO1 19-02

Submission to EPA on Objections to Licence Conditions

-.

We submit that the performance of the RTO in respect of compliance with the emission limit value on TOC is demonstrated continuously by means of the TOC analyser in the stack and this, coupled with continuous monitoring of the combustion chamber temperatures, should be more than adequate to demonstrate satisfactory performance of the RTO to the Agency - as has been the case since the RTO was commissioned in 2002.

Objection No. 3 Ref: Condition 3.9.2

We wish to object to Condition 3.9.2 as it would not be applicable if our objection to Condition 3.9.1 is upheld by the Agency, and we request that this condition be deleted.

Objection No. 4 Ref: Condition 5.1 and Schedule Bl

We wish to object to the emission limit value of 150 mg/m3 for total organics (as C) for emission points A3 & A4 (VK4 machine).

The Agency has authorised the continued operation of the VK4 machine, without connection to the RTO, until December 3 1'' 2007, at which stage the machine will be shut down permanently. The emission limit value to which we are currently operating on the VK4 machine with the approval of the Agency is 38 kg/h. It is not possible to operate the VK4 machine within the emission limit value of 150 mg/Nm3 specified in Schedule 1 of the proposed Determination without abatement, i.e. without connection to the RTO. We therefore request the Agency to permit the current emission limit value of 38 kg/h until December 3 1'' 2007.

Objection No. 5 Ref: Condition 6.1 and Schedule C.1.2

We wish to object to the analysis method/technique required in Schedule C. 1.2 for continuous monitoring of total organics (as C) from the RTO stack (A64), which is stated to be flame ionisation detection. The continuous TOC analyser installed on the RTO at Alcan Packaging Dublin is manufactured by a German company, ADOS, and is a catalytic combustion analyser, not a flame ionisation detector (FID). The details on the analyser and its approval under T A Luft were provided to, and approved by, the Agency as part of the Notification we submitted for the RTO installation in 2001. A copy of the details of, and certification for, the ADOS analyser, as submitted with the Notification in 200 1 , is contained in Annex 3.

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EPA Export 25-07-2013:22:18:31

with the results from the Agency’s own FID monitoring. We submit that there is no justifiable reason for Alcan Packaging Dublin to have to replace the existing TOC I

Objection No. 6 Ref: Condition 6.1 and Schedule C.4

We wish to object to the requirement in Schedule C.4 that a h l l characterisation be made of each consignment of mixed solvents waste.

In any year, there would be approximately 15 consignments of waste ink/ink sludge/ solvent/adhesive shipped from Alcan Packaging Dublin, with an average 75 drums per consignment. Characterising each of these consignments, assuming a sample was required from only 10% of the drums, would require over 100 samples to be analysed for solvent content. This would amount to an additional charge on Alcan Packaging Dublin in excess of €20,000 per annum.

Alcan Packaging Dublin uses a variety of solvents in its inks but the relative percentages of these solvents is consistent year on year, and two solvents make up the vast bulk of the solvents used on site. As can be seen from the Pollution Emissions Registers provided to the Agency in our AERs, the make-up of the solvent usage is very consistent over the years and is typically:

Denatured ethanol (IMS) : 51% Ethyl acetate : 38% Heptane : 4.5% Other solvents (n-propyl acetate, ethoxy propanol, : 6.5% n-propanol, isopropanol, propoxy propanol)

This solvent breakdown is reflected in the waste inks/solvents/adhesives generated on site - there are no intermediate chemicals produced at Alcan Packaging Dublin.

The requirement to characterise each consignment of waste solvents would be a very onerous and costly one for Alcan Packaging Dublin and would not justified for the type of waste that is generated on site and the consistency of that waste. We have checked the requirements on waste monitoring in other recent IPPC licences for both surface coating and pharmaceutical activities, e.g. licences POOl 1-03, POOl 5-04 and PO366-02, and we submit to the Agency that an annual characterisation of the waste solvents stream would be more appropriate to Alcan Packaging Dublin’s activity. We request, therefore, that the frequency of characterisation be changed from “per consignment” to “annual” in Schedule C.4.

26th October 2007 5

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Alcan Packaging Dublin Proposed Determination No. PO1 19-02

Submission to EPA on Objections to Licence Conditions

AlIan Radford EHS & Hygiene Specialist Alcan Packaging Dublin Limited

26'h October 2007 6

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Alcan Packaging Dublin Proposed Determination No. PO1 19-02

Submission to EPA on Objections to Licence Conditions

Annex I

Extract from Application for Review of Licence dated June 2007

Extract from Inspector's Report on Licence Application dated 14fh September 2007

26Ih October 2007

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.. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alcan Packaging Dublin Application to EPA for IPC Licence Review

A. Non-Teclinical Summary

A. 1 Installation & Activities

Alcan Packaging Dublin is a major manufacturer of flexible packaging for the food and medical packaging sectors, and is part of the multinational group Alcan Inc. The company is located on Jamestown Road, Finglas, Dublin 1 1.

The company has been operating on the Jamestown Road site since 1952 and, currently, it employs 193 people. A map showing the location of the site is included in Attachment A. 1. This Attachment also contains a current Site Layout Plan, which shows the main production and services facilities on the site.

Alcan Packaging Dublin manufactures flexible packaging from a variety of substrates, e.g. paper, polypropylene, polyethylene, and polyester film. The substrates are printed using either the gravure or flexographic printing process. The company also has facilities for laminating, coating and waxing.

The company supplies markets in Ireland, UK and continental Europe, and its customer base includes companies such as Cadbury, Tayto, Mars, Nestle, Danone and Unilever. Around 55% of production is exported. The factory operates 24 hours/day, Monday to Friday. The last shift ends at 06.00 on Saturdays. Additional shifts may run at weekends to meet production requirements.

Alcan Packaging Dublin operates a comprehensive Environmental, Health & Safety Management system. This system is certified to both IS0 14001 and OHSAS 18001.

In 1996, the company applied for an IPC licence under Class 12.2 of the first schedule of the EPA Act, 1992, which covers “the use of coating materials in processes with a capacity to use at least 10 tonnes per year of organic solvent.” The company was granted an IPC licence in June 1997, IPC Register No. PO1 19-01. A drawing in Attachment A. 1 highlights the changes that have taken place on site in the period since the initial licence application was submitted.

In March 2007, following an internal, licence examination process conducted by the EPA to bring IPC licences into compliance with the requirements of the IPPC Directive, the Agency wrote to Alcan Packaging Dublin, requiring the company to submit this application for a licence review to the Agency.

A.2 Materials and Energy Usage

The principal raw materials used at Alcan Packaging Dublin are:

- Printing substrates, i.e. materials such as plastic film and paper on which the packaging images are printed

- Solvent-based printing inks - Solvent-based adhesives - Water-based sealants - Organic solvents

Doc. Ref. 267-X099 3 of41 June 2007

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LICENSING &RESOURCE USE

1 To: Directors I ENVIRONMENTAL

Section 90( I)(b) notice sent:

Licence application received:

Information under Section 90 received:

Site notice inspected:

Site visits:

12.2.1 The surface treatment of substances using organic solvents, in particular for printing, coating, degreasing and cleaning, with a consumption capacity of more than 150 kg per hour or more than 200 tonnes per year.

0 1 August 2007,16 August 2007

12 June 2007

23 August 2007,3 1 August 2007

3 1' July 2007

31 July 2007

CO m pa n y Alcan Packaging Dublin (formerly Lawson Mardon Superior Ltd.), located on Jamestown Road, Finglas, Dublin 11, is a major manufacturer of flexible packaging for the food and medical packaging sectors. The company supplies markets in Ireland, UK and continental Europe. Around 55% of production is exported. The products manufactured on site include flexible packaging from a variety of substrates, e.g. paper, polypropylene, polyethylene, and polyester film. The substrates are printed using either the gravure or flexographic printing process. The company has been operating on the Jamestown Road site since I952 and, currently employs I93 people. The factory operates 24 hours/day, Monday to Friday, however additional shifts may run at weekends if required. The company is lSO14001 certified. I n 1996 Lawson Mardon Superior I&. applied for an IPC licence under Class 12.2 of the first schedtile of the EPA Act, 1992, which covered "the use of coating materigls in processes with a capacity to use at least 10 tonnes per year of organic solvent." An IPC licence was granted in June 1997 (Register No. POI 19-01). This licence review was initiated by the Agency to enable modification of the existing licence to ensure compliance with the requirements of the IPPC Directive also being taken to incorpor-ate the requirements of the Snlvents

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Alcan Packaging Dublin Proposed Determination No. PO 1 19-02

Submission to EPA on Objections to Licence Conditions

Annex 2

Extract fiom Functional Design Specification for RTO from Dun: Environmental

Extract fiom Service Report on RTO from Durr Environmental

Graph of Recorded Combustion Chamber Temperatures

26Ih October 2007

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Document: Functional Design Specification Order-No.: 406 391 0 000 Doc. No.: 3EVT2547-FDS-RevE.doc Customer: Lawson Mardon Superior, Dublin R,,,:

Pollution abatement plant "Ecopure RTO and K P R P81D: OK800325

E Date: 3. December 2001 U RI Project:

I I I I

Functional Design

Specification

Pollution abatement plant "Ecopure RTO and KPW"

Sylvia Roehner Page 1 of 69 Doc Ref.: P \UWT\AUFTRAG\IAWSON-MARDON_SUPERIOR\406391 O\FUNKTiON\3EW2547-FDS_REVE DOC

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3.7 RTO Fresh air mode

Document: Functional Design Specification Order-No.: 406 391 0 000 Doc. No.: 3EVT2547-FDS-RevE.doc Customer: Lawson Mardon Superior, Dublin R ~ ~ :

Pollution abatement plant “Ecopure RTO and K P R

Project: E

Date: 3. December 2001 PLLID: OK800325

The system now energises the ‘Abatement plant ready’ signals for the enabled production machines. Those machines can then be started.

If in Mode 1 or 2 the KPR will now be enabled to start.

While in this mode the burners will be modulating to maintain the system temperature‘. If the burner chamber temperatures W26-TO5 and W26-TI 5 or W27-TO5 and W27-TI5 or W28-TO5 and W28-TI 5 exceed 840°C the referring RTO will enter the Autothermal mode (refer to section 7.2 “Autothermal mode”).

During this step the RTO can run indefinitely with fresh air while waiting for process air from the production machines connected to the RTO. f --\

\ i

As soon as one of the ‘Start / Stop process air’ signals (refer to section 5 “Hardwired Signal Exchange”) of K61 or K62 is energised the RTOs will automatically enter the PROCESS AIR MODE (refer to section 3.8 “RTO Process air mode”).

’ As long as the RTOs are not in Autothermal mode (refer to section 7.2 “Autothermal mode”) the burners are switched on and each combustion air damper (G53-MO6, G55-MO6, G57-MO6) is controlled by the referring controller TlRC (G53-Tl5, G55-TI5, G57-TI5) with setpoint 820°C.

Sylvia Roehner Page 31 of 69 Doc Ref.: P:\UW~UFTRAG\LAWSON~MARDON~SUPERIOR\406391O\FUNKTION\3EVr2547~FDS_REVE DOC

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1 Document: Functional Design Specification

Order-No.: 406 391 0 000 Doc. No. : 3EVT2547-FDS-RevE. doc Customer: Lawson Mardon Superior, Dublin R ~ ~ : E

Date: 3. December 2001 P81D: OK800325

Pollution abatement plant "Ecopure RTO and KPR"

PUiiRi Project:

3.6 RTO Heafing Mode

As long as no faults exist and the purge has been completed successfully, the RTOs will transition to Heating mode automatically.

This step is used to ramp the RTO temperature up to the desired operating temperature.

Therefore the burners will be started (refer to section 7.1 "Burner start"): 0

0

0 Mode 3: Burner G57-XI50.

Mode 1 and 4: Burner G53-XI 50, G55-XI 50 and G57-XI 50, Mode 2 and 5: Burner G53-XI 50 and G55-XI 50,

,,- . . 1

< , i As soon as the burners are in operation the following actions occur: 0 Depending on the operating mode TIRCs G53-TI 5, G55-TI 5 and G57-TI 5 start controlling

the referring combustion air damper G53-MO6, G55-MO6 and G57-MO6. The setpoint of TlRC G53-TI5 is now ramped from the actual temperature value to 820°C at a rate of setpoint increase of 3,33"C/min.

When the RTO burner chamber temperatures W26-TO5, W26-TI 5, W27-TO5, W27-TI 5, W28-TO5 and W28-TI 5 in Mode 1 and 4,

0 W26-TO5, W26-Tl5, W27-TO5 and W27-TI 5 in Mode 2 and 5, 0 W28-TO5 and W28-TI5 in Mode 3

are up to 780°C a timer is started and after 3 minutes the RTO is automatically entering (and waiting in) fresh air mode.

Sylvia Roehner Page 30 of 69 Doc Ref.: P:\UW~UFTRAG\LAWSON-MARDON_SUPERlOR\406391 O\FUNKTION\3EVr2547-FDS_REVE.DOC

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. . . ... .

Order-No.: , 406 391 0 000 Customer: Lawson Mardon Superior, Dublin

Pollution abatement plant “Ecopure RTO and K P R

,,-7

! * . .

Document: Functional Design Specification Doc. NO.: 3EVT2547-FDS-RevE.doc R ~ ~ : Date: 3. December 2001 PLLID: OK800325

E

3.8 RTO Process air mode

The RTO will automatically transition from Fresh air mode to the Process air mode when one of the ‘Start / Stop process air’ signals of K61 or K62 (refer to section 5 “Hardwired Signal Exchange”) is energised. The following actions occur:

Process air damper K63-K107 is driven opened. Minimum flow control FIC Vll-F22 is activated with setpoint -43 mbar and controls the fresh air damper K63-Kl17 (K63-VI7 energised). Dependent on the number of running RTOs the minimum air flow level is the following: Mode 1: 45000Nm3/h, Mode 2: 30000Nm3/h, Mode 3: 1 5000Nm3/h, Mode 4: 45000Nm3/h, Mode 5: 30000Nm3/h. QIC V11-QO4 is switched to Automatic. In case of a LEL concentration higher than the setpoint of 10 g the fresh air damper K63 K117 is driven opened (overrides FIC V I 1-F22). PIC V I 1-P42 starts controlling the running Process air fan V I 1-VI01 and / or V I 1-VI21 with setpoint - 4mbar (Mode 1-2 and 4-5: V101-V101 and Vl l -VI21 are running, Mode 3: V I 1 -VI 01 is running). The bypass stack damper of the production machine which energised its ‘Start / Stop process air’ is driven closed so that the process air is directed to the RTO. If the wash machine K62-K227 energises the ‘Start / Stop process air’ signal the dilution air damper K62-KI47 is driven opened. Only after K62-KI47 is opened the wash machine production damper K62-K227 is driven opened. This ensures a sufficient dilution of the high solvent concentration coming from the Wash machine. The Wash machine will stay on bypass in case of air flow to the RTO higher than 120000 Nm3/h in Mode 1 and 4. In Mode 2, 3 and 5 the Wash machine will be disabled at all times. If more than one ‘Start t Stop process air’ signals are energised at the same time one after the other bypass stack damper is time-delayed switched over to the Abatement plant. This is important for a smooth change over if two or more production machines are ready for operation at the same time.

The maximum air volume to the RTO is limited according to the selected operating mode. Only the enabled production machines will receive the “Abatement plant ready” signal (refer to section 3.2 “Abatement plant Start-up”). . .

While in this mode the burners will be modulating to maintain the system temperature’. If the burner chamber temperatures W26-TO5 and W26-TI5 or W27-TO5 and W27-TI5 or W28-TO5 and W28-TI 5 exceed 840°C the refering RTO will enter the Autothermal mode (refer to section 7.2 “Autothermal mode”).

The RTO will automatically switch back to fresh air mode in the following cases: - If all ‘Start / Stop process air’ signals of K61 and K62 are de-energised. - If there is a ‘IC” alarm (refer to section 4.1 “Alarm modes”).

The referring RTO will be stopped in the following cases: -

-

If one of the burner chamber temperatures (W26-TO5rTI 5, W27-TO5rT15, W28-TO5RI 5) falls below 750°C. If one of the burner chamber temperatures falls below 780°C for more than 300 sec.

’ As long as the RTOs are not in Autothermal mode (refer to section 7.2 “Autothermal mode”) the burners are switched on and each combustion air damper (G53-M06, G55-MO6, G57-M06) is controlled by the referring controller TlRC (G53-Tl5, G55-Tl5, G57-T15) with setpoint 820°C.

Sylvia Roehner Page 32 of 69 Doc Ref.: P \UWT\AUFTRAG\LAWSON~MARDON-SUPERIOR\406391 O\FUNKTION\3EVr2547-FDS-REVE DOC

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1

i i I

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lnspektionsprotokoll Inspection Report

Serial No.:

Type: Flow volume Vn :

Nr.1No'

EES - INSP / 89 / 06

09446

RTO 3060

163 000 m3dh

Betr I Ref

ALCAN Packaging Dublin Ltd

Order no.: 408 700 800 212 201 095 46 56

Diirr Systems GrnbH Dublin, lrland Otto-Diirr-StraBe 8

D- 70435 Stuttgart

11.-18. September 06

20. I O . 06 NL

Ort I Place:

Datum, Zeit / Date, Time:

Verfassungsdatum. Zeichen I Date of issue, Ref.: Tel: +49 711 136-0 k + 4 9 711 136-1016

Inspection of RTO oxidizer Repair of RTO compensators Calibration of ADOS

Verfasser, Unterschrifl / Issuer, Signature

Norbert Lindner Thomas Kaufmann

Teilnehmer / Participants:

Alcan Mr. Franz Maur Mr. Gerry Jackson Mr. Andy Lacey

Byrne 0 Cleirigh Mr. Ambrose Clarke

Wright Mr. Paddy Wright Environmental

DURR Hr. Thomas Kaufmann Hr. Norbert Lindner Team Kratz

Verteilerl Distribution ALCAN: Mr. Jackson

Byrne 6 Cleirigh Mr. Clarke

DURR: Hr. Rieder Hr. Zondler Hr, Rodrigues Hr. Kaufmann Laufwerk (P:\)

Summary: The RTO is in a good condition. The inspection was conducted, including all tests. The results are summarized in the following

RTO Unit

Order No.: I 406391 0 I Built: I 2001 1

~~~~ ~ ~~

Exhaust air inlet temperature: I 55°C I Combustion chamber temp. (cal.) 820 "C I Combustion chamber temp. (controller.): I 795°C I Instal. burner capacity : I 3 x 1.670 KW I Pressure drop (max.): I 5.500 Pa I

P \ENS\SewiceWuftragsbearbeitungWlcan Packaging Dublin Ltd\lnspektion 2006~Ados~Kompensatoren\Protokoll\lNSP-89- 06-201006-RTO-en doc

F

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lnspektionsprotokoll / Inspection Report Nr. / no.: EES - INSP / 89 / 06 Blatt / sheet - Nr. / no.: 26

Description

Process air temperature W26 okay

RTO common

Setpoint

770 "C

Temperature Autotherm W26 bed 2 start

Temperature Autotherm W26 bed 2 stop

I Temperature Autotherm W26 bed 1 start I 810°C I I

810 "C

800 "C

1 Temperature Autotherm W26 bed 1 stop I 800°C I I

Temperature Autotherm W27 bed 2 start

Temperature Autotherm W27 bed 2 stop

Process air temperature W28 okay

810 "C

800 "C

770 "C

( P E e s s air temperature W27 okay

Temperature Autotherm W28 bed 2 start

Temperature Autotherm W28 bed 2 stop

I 770°C I

810 "C

800 "C

1 Temperature Autotherm W27 bed 1 start I 810°C I I

Delay time heating temperature okay

Delay time heating temperature not okay

Shutdown time RTO

Time monitoring G53 safety chain K50

I Temperature Autotherm W27 bed 1 stop I 800 "C 1 I

60 sec.

270 sec.

50 sec.

5 min.

Time monitoring G57 safety chain K51

I Temperature Autotherm W28 bed 1 start I 810°C I I

30 min.

1 Temperature Autotherm W28 bed 1 stop I 800 "C I I

I Common timers I I I

I Time monitoring G53 safety chain K51 I 30 min. I I I Time monitoring G55 safety chain K50 I 5 min. I I I Time monitoring G55 safety chain K51 I 30 min. I I I Time monitoring G57 safety chain K50 I 5 min. 1 I

P:\ENS\Service\Auftrags bearbeitungwlcan Packaging Dublin Ltd\lnspektion 2006~Ados~Kornpensatoren\Protokoll\lNSP-89- 06-20? 006-RTO-en .doc

FQCUS

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EPA Export 25-07-2013:22:18:31

Alcan Packaging Dublin Proposed Determination No. PO 1 19-02

Submission to EPA on Objections to Licence Conditions

Annex 3

Extract from 2001 Notification to EPA for RTO Installation, containing:

Letter from ADOS re certification of TOC analyser (in German with English translation)

Extract from publication from the German Federal Ministry for Environment, Nature Conservation and Nuclear Safety on testing of continuous emission monitoring systems

Operating instructions for ADOS TOC analyser

26th October 2007

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EPA Export 25-07-2013:22:18:31

Lawson Mardon Superior, Licence No. 119 Notification to the EPA

Appendix 7 : Data on TOC Analyser

May 2001

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EPA Export 25-07-2013:22:18:31

Telefon 102 41) 97 69-0 Telefax (02 41) 97 69-16

ADOS GmbH Mess- und Regeltechnik Postfach 500 444 D-52088 Aachen E-mail Trierer Strasse 23-25 ados office@-online de < &\mb : *&if EN

2 3, Okt. 'ZOfiD

DOS GmbH Postfach 500 444 52088 Aachen

Firma Durr Systems GmbH z.Hd. Herrn Dertinger Otto-Durr-Str. 9

70435 Stuttgart

r' 'i Unser Zeichen: Schm/Ku . @ , I

Gasanalyse ta Urnweltschutz a0 Gaswarnung Warmetechnik

Datum: 20. Okt. 2000

Messgerat fur organische Verbindungen

Sehr geehrter Herr Dertinger,

unser Kohlenwasserstoff-Analysator KM 2-CnHm-EM, Mel3prinzip Warmetonung, wurde vom TUV Rheinland im Auftrag des Bundesministeriums des lnnern auf Eignung als Messgerat fur organische Verbindungen gepruft.

Die Pruf-Nr. des TUV lautet: 906804.

Die Veroffentlichung in der TA-Luft gilt automatisch als Zulassung zum Messgerat fur organische Verbindungen.

Diese Veroffentlichung erfolgte bereits im Jahre 1977 r , . .

Wahrend die EU 12619 nur eine Norm ist, ist die TA-Luft eine Auflage, die einem Gesetz entspricht.

Mit freundlichen GruBen

Geschahsfuhrer: Registergericht Dipl.-lng. Herbert Rutgers Aachen 20 HRB 5 Dresdner Bank Dip1 -Ing. Michael Rutgers Ust-Id-Nr : BLZ 390 800 05 Cn,,rhtrr+ond A l r h n n nc 171 cnn Q,IQ Y ~ ~ + ~ 7 t,?n Q I Q

Sparkasse Aachen B LZ 390 500 00 wnn+n 71 nn7

Postbank Koln BLZ 270 100 50 w.....- 1 1 C 1 " cnc

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EPA Export 25-07-2013:22:18:31

Telefax

+49 711 136 1163 S.Q2/ '07

1, ADOS iewr of 2 Q ~ Odbber 2000

Measuring device for organic compounds

Dear Mr. Dertingsr

Our hydrocarbonic analyser KM 2-CnHmEM, with the measuring principle of measuring the combustion heat, was tested by 'TOV Rheinland". The test was required by the German Ministry of inner affairs to give the allowance to use this measuring device for the measurement of organic compounds.

The test certirimte number is: 906804

The publication in the "TA-bftn is automatically valid as an official authorisation as measurement device for organic compounds,

This publication was already released in 1997.

While €U 12619 only la an European Standard, the "TA-Luft" is a restriction by the authorities with a meaning of a law.

Yours sincerely

ADO$ GmbH, Aachen

P,\UWWultragVawson Mardon superiorWO6391 MKORRESPOW;UNDE\OBOJOI_T~l~DOS.doc

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EPA Export 25-07-2013:22:18:31

Der Bundesminister fur Umwelt, Naturschutz und Reaktorsicherheit b - i

I

l 1

AIR POLLUTION CONTROL

The Federal Minister for the Environment, Nature Conservation and Nuclear Safety

MANUAL OF CONTINUOUS l l EMISSION MONITORI-NG

{ J

~

Regulations and Procedures for Emission Measurements 3rd Revised Edition

.

I

1992

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c

APPENDIX 2

SUITABILITY TESTED MEASUREMENT DEVICES

77

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EPA Export 25-07-2013:22:18:31

0 W N

.\ - m w m c5 W

U

%?-

P Y . n U d

L

,

n 2

5

U d b

PI

P >

de d 00 7 8 Z Z 0 .c 33 UPg

-0 NO

EE u u m ss W-

25 m 0

78

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EPA Export 25-07-2013:22:18:32

Hydrocarbon Monitoring System KM2 - CnHm - EM - ADOS

1. Field of Application Suitable for the summary measurement of hydrocarbon emis- sions of synthetic rubber production plants, plants for ena- meling, coating, impregnating and soaking of camer materials. All combustible gases can be principally measured or monitored, with the exception of chlorinated and sulfur- substituted hydrocarbons. Suitability test by the T U V Rheinland e.V. (Technical Inspection Service), Koln, (Report No. 9361804 006 of January 31, 1977). 1

2. 2.1 Complete System

Set-up and Mode of Operation

1 2 n

16

Gas flow diagram

I Samplegas inlet 2 Calibrationgasinlet 3 Primary-stageor

compensation fiter 4 Samplegaspump 5 Flow regulator 6 Flowmeter 7 Flowmonitor 8 Heating coil

9 IO 11 12 13 14 15 16 17

Catalyzer chamber Comparative measuring location Measuring location Reaction chamber Measuring amplifer Limit value indicator 1-4 Concentration indicator Heating jacket Temperature regulator

The sample gas is sucked in by the gas pump and proceeds via the compensation filter, flow regulator and flowmeter into the reaction chamber. The gas is heated up to a constant tem- perature with the aid of the heating coil and the heating jacket and subsequently burnt at a solids catalyzer.

2.2 Analyzer

Measuring - Concentration - La amplifier

Calibration ----c

go5

Inert mass Catalyzer

Analyzer

The analyzer functions on the basis of the catalytic com- bustion. The temperature differential between the measuring location and the comparative measuring location is taken as a measure of basis of the concentration of combustible sub- stances in the gas. The measuring location is exposed to the heated, non-burnt gas mixture, whereas the second probe of the thermal chain measures andor monitors the temperature of the burnt gas.

An impressed direct current of 0-20 mA is supplied as out- put signal for the connection of electrical measuring displays, recorders and limit indicators.

3. Equipment Design Structure

3.1 The Hydrocarbon monitoring system KM 2-CnHm- EM-ADOS is composed of the following 19" modules:

79

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8 -, I- - .

- Gas analyzer KM 2 with reaction chamber, electronics and up to 4 limit indicators

- Gassuction with pump, flowmeter, flow regulator, flow monitor, filter and heating system for the gas carrying routes

for the installation of a control panel or for wall- mounting purposes.

- Mounting cabinet

3.2 Accessories - CnHm-EM sampling probes, heated and unheated - Mounting flanges for the sampling operations - Heated sample gas lines - Calibration gas - Measured-value integrator - Recorder The measured-value integrator and recorder may be installed in the mounting cabinet.

4. TechnicalData 4.1 Results of the Suitability Test Reference quantity full scale (FS) Tested range 0-226,O-340,

0-675 mg Chn3 period of unattended

operation 4-8 weeks Reproducibility 38-100 Influence of the sample

flow rate 1% of FSllO l/h

Lower detection limit Ambient temperature rage Temperature dependence

of the zero Mint Temperature dependence

of the sensitivity Interference error; response

to stated levels of inter- fering substances present in the sample

CO 5,8 mdm3 H20 40 glm3

(time to 90% response) with 11 rn sampling line

CO* 9 Vol. %

Response time

Drift of the zero point

Drift of the sensitivity

Relative standard deviation of the evaluation factors

4.2 Further Technical Data

Signal output (for recorders or indicators)

Heating time Mains supply Dimensions (W x H x D) Weight

< 0.5% of FS + 5 to +45"C

not detectable

not detectable

< l % o f F S Measuring signal I mg Chn3 not detectable -

70 s 2% of FSlperiod of unat-

2% of FSlperiod of unat- tended operation

tended operation

11% .

Impressed direct current 0-20 mA 4-20 mA (optional) max. permissible burden or ohmic resistance: 300 ohm appr. 60 min. 220 V, 50 Hz, 130 VA 565 x 525 x 380 mm) appr. 30 kg

Manufacturer: ADOS GMBH AACHEN . MeB- und Regeltechnik . Trierer S t r ak 23-25 D5100 Aachen-Forst . Phone 02 41 I 5 90 41 - 43 . Telex 0 832 737 . Telefax 02 41 I 5 90 41

80

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EPA Export 25-07-2013:22:18:32

. .

1 1 ADOS" I

KM 2 CnHmEM

I/ i

Operating Instructions

i

Issue: 01/97 I I

I

Instrumentation and Control TEL: +49(0} 241 9769.0 i frierer StraUe 23-25 - 52078 Aachan FRG

I

I

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EPA Export 25-07-2013:22:18:32

ADOS GmbH

1.

3.

4.

5.

6.

7.

8.

9.

10.

10.1

10.2 . .

11.

KM 2 CnHmEM

Contents

Operating - Summary

Functioning

Equipment Description

Assembly

Operating

Test Gas - Function

Zero Point and Concentration Checks

Conversion Factors for Measurement Ran3e Calibration

Maintenance

Fault Rectification

Gas Feeds

Fault-finding

Technical Data

Dimensions

Fault monitors

Terminal Annotation

Page 1

Page

1

2

3

3

4

4

5

6

7

9

9

11

12

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ADOS GmbH KM 2 CnHrnEM Page 1

1l Operatim - Summary

There follows a short summary of the more important operating procedures which can be used for reference by those already familiar with using the equipment.

1.

2.

Before using the equipment. the Analyser and gas sampling system must be checked for any leakage.

Operate the Analyser as follows:

- Activate the mains supply switches for gas sampling (4), pump drive (5) and the

- The zero point check should be made when the control lamp of the temperature

Analyser (1 3).

controller (14) in the Analyser begins to flash at regular intervals. For this, feed the reference gas into the unit and use the potentiometer (1 9) for adjustment.

concentration. - Connect the gas for testing to the Analyser and calibrate the value of

1 2 3 4 5 6 7 8 9

10 11 12 13 14 15 16 17 18 I 9 20 21 22

Sampled gas infeed Test gas infeed Change-over, Sarnpled/Test gas Mains switch, Gas sampling Mains switch, Pump Flow-through adjustment Flow-through indicator LED - Gas sampling Ready LED - Gas sampling heating LER - Heating fault LED - Pump Ready LED - Fault, Flow-through Mains switch, Analyser Control lamp, Temperature reg. Control lamp, Fault Control lamp, Warning Concentration indicator Fuse Zero point adjustment Measurement range adjustment Limit value setting Gas outflow

12

--C

i i

17

a@@ 2 1 21 It 8

K M 2 CnHrnCrn AOOS Aochen

23b

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EPA Export 25-07-2013:22:18:32

ADOS GmbH

2, Fu nctionim

. % \

.~ KM 2 CnHmEM Page 2

The gas in the reaction chamber, heated to a constant temperature, is burnt in a solid matter catalyser. The increase in temperature resulting from the combustion, is measured In a thermopile syslem. The non-burned, heated sampled gas, is passed through a comparison measurement point whilst the measunng point IS subjected to the flow of the burnt sampled gas.

The resulting temperature difference of 2°C and more (with the smallest measurement range), produces a relatively large measurement effect

7

I 2

13 I +

1 2 r n

1

3

4 15

I

:Z

1 2 3 4 5 6 7 8 9

10 I 1 12 13 14 15 16 17 18 19 20 21

Flow meter Heating sleeve Reaction chamber Heating element Catalyser chamber Comparison measurement point Measuring point Flow regulator Sampled gas pump Resistance thermometer Temperature controller Measurement amplifier Limit value monitors, I - 4 Concentration indicator Filter or Comparison filter Sampled gas infeed Test gas infeeed Flow-through monitor Sampled gas outflow Resistance-thermometer Gas outlow

The reactionltemperature range of 100 to 450°C detected by the KM 2 CnHmEM Gas Analyser, in conjunction with a variety of catalysers, provides the solution to numerous measurement tasks.

For connecting electric indicators, plotters and limit value monitors, an output signal is available of 0-20 mA or 4-20 mA, proportional to the concentration.

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1

W O S GmbH 2 CniimEM Page 3

3. Eauimgent Descriution

A high degree of measurement accuracy is a result of the following construction features:.

-

-

A carefully constructed therrno-static reaction chamber.

Use of double and 4-fold thermopiles, that produce a large measurement voltage for connection to the amplifier.

Use of V4A (1.4571) and ceramic material for parts that come in contact with the sampled gas; this excludes any possibility of secondary reactions.

-

c - The complete KM 2 CnHmEM gas analysis system consists of the following component parts:

- Analyser

- Gas sampling and filtering

-

- Control unit (depending on type of order)

1 D* Flush or Wall-mounting housing.

The electric circuits are constructed using silicon semiconductors and integrated circuits (ICs).

4. Assembly

Choice of installation location:

The KM 2 CnHmEM should be mounted in the vicinity of the measunn point and protected from sources of direct heat (sunlight, ovens, boilers, etc.). The externai temperature must not exceed +40°C Mount the Analyser at a location free from vibration; alternatively, use rubberlmetal anti-vibration mountings for fixing the housing.

The gas connections are for 8 mrn cutting-ring screw-couplings or for hoses with a 6 mrn internal diameter.

i

Electric connection plan:

Observe local regulations concerning the use of electricity I

Observe the wiring and terminal layout, according to the conditions of the Order 1

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EPA Export 25-07-2013:22:18:32

F

ADOS GmbH

5. Operatirlg

Leakage check:

I . KM 2 CnHmEM Page 4

Close the gas sampling line wlth plugs. Connect a U-pipe to the gas output and check for leaks with a vacuum of about 1 bar (1 m head of water). When using a measuring point change-over switch, each measuring point must be tested individually. The test gas valve must be in the O-setting.

Mechanical Zero point adjustment:

Any externally connected analog indicators and plotters, must be set to 0 before operating.

Warm-up:

Switch on the mains switches for Gas sampling (4), Pump drive (5) and the Analyser (1 3).

* \ The control lamp of the lemperature Controller (14) flashes after about 40 min. for MAK and after about 60 min. fur LEL units, at a frequency of approx. 1 Hz. This indicates the Ready state of the Analyser.

6. Test Gas - Function

There are basically two methods of using t h e test gase:

The first possibility is a direct connection of the test gas to the Analyser, via a pressure reducer, a T- piece and about 2 m of hose. The T-piece is used to isolate excessive pressure from the Analyser.

Note:

The T-piece and flow meter should always be included in the test assembly, otherwise the flow regulator can be damaged.

The second possibility is connecting a balloon filled wilh the test gas, directly to the tesl gas connection of the Analyser.

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cz

~ , ADOS GrnbH KM 2 CnHmEM Page 5

A zero point check for this unit can also be made in circuit, by connecting a hose between the output of the Analyser (4) and the Test gas input (2), since the unit burns all combustible gases that the Analyser reacts to, by catalytic combustion.

r

onolyzer

lollon hose / LW 6 mrn

7. Zero Point and Concentration Checks

1 - Switch-overcock

2 - Test gas input

3 - Sampled gas input

4 - Gas output

According to clean-air recommendations, C-test units should be re-calibrated every 4 weeks.

Before checks are commenced, the gas flow through the Analyser is adjusted lo 125 I/h with the flow regulator (6), so that the flow meter indication lies between the red markings at 120 and 130 Ilh.

Zero point check:

Set the change-over cock (3) to the Test gas position.

Connect the Zero-reference gas to the test gas input.

After about 60 secs. or when the meter has settled, adjust the zero point with the potentiometer (8).

Set the change-over cock to the Sampled gas position.

Concentration check: Set the change-over cock (3) to the Test gas position.

Connect the Final-value gas to the test gas input.

After about 100 seconds, the indication must correspond. to the detail on the Analyser certificate. If the deviation is more than 2% f.s.d. of the measurement range, the sensitivity must be adjusted with the measurement range potentiometer. This check should be repeated 2-3 times.

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EPA Export 25-07-2013:22:18:32

ADOS GmbH KM 2 CnHmEM

Set the change-over cock to the Sampled gas position.

If there is no meter indication, refer to Fault Rectification,

1

1 I I__

Page 6

I

rng/rn3 N-Butan = 0.38575 ppm

ppn; N-Butan I = 2.592 mg N-Butaniml I 1

8. Conversion Factors for Measurement Ranqe Calibration

1 mg N-Butan I = 0.8258 rng C/m3

1 ppm N-Butan 1 = 2.14 mg ~ / m 3

Response factors for various gases

! 1

Ti

Conversion factors:

I 1

mgCO = 0.8007 ppm CO

ppmCO produces an indication 1

of 0.174 me N-3utan/m3

1 Hydrogen cyanide HCN 1.91 68

Ethanole ci !-&o 1.691

Butanol C,",OO 1.373 r J

I 1 f

Response factors referrred to N-Butan.

Application: .4 test ges with x ppm N-Bu?an produces an jndicatlon at the Analyser of:

~ r j gas = 2.14 x p,?m N-h!an x Response factx

e.g. a test gas with 50 ppm N-Butan, unit chiibraled for X y i d . (Z,H,,j

= 50 ppn; x 1.15 x 2.14 123.Cfr MQ iiidicaiion

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e 1

i i

I

ADOSGrnbH KM 2 CntimEM Page 7

trr I -2’ 2

1.15

1.1219

0.3584

0.9584

0.9386

0,9865

0.3622

9. iifaintenance

To retain its accuracy, the measurement system should bs completely overhauled and maintained, twice each year.

Gas ~ ~ U V J chock; The quantity of gas sucked into the Analyser, should be checked every 4 weeks anti if necessary, re- adjusted wi?h the flow regulator.

Zero mint chf&: This should he checked every 4 we.eks with the g2s flow check.

Maintertance of the gam^ ’C D .’ Depending on the purily of the ~ S S tc be measured, the sampling system should be disassembled approx. once par wsek. The ii!ters mti;gra!ed into the system are cieaned VI replaced if necessary. Check the sampling pipe for clesnl;nes;.

Maintenance of the sarnPLnci line In addition to the main!enance of the sarnpllng system, the sampling line should be purged with compressed air.

Procedure: The iine is removed from the Analyser and blown through in the opposite direction to the normal flow,

Calibration check Every 4 to 6 weeks with test gas.

W l y s e r r d a c e r r l m A replacement is necessary only when there is insufficient reaction to the introductton of the test gas

l or the Analyser has become too sluggish in its operation.

Proceed in the following sequence:

- Remove the rear panel of the housing. - Remove the insulated lid of the oven by loosening the M4 screws.

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c

i ADOS GmbH KM 2 CnHrnEM Page 6

- Carefully remove the insulating plate with a screwdriver. - Loosen the oven flange by unscrewing the V4A nuts. - Withdraw the sensor from the oven. - Remove the terminating filter with a small pointed tool and carefully remove the

- Carefully remove the intermediate filter by lightly tapprng with a small pointed tool. - Completely remove the black reaction mass. - Refill with new reaction mass and distribute evenly by lightly tapping. - Replace the intermediate filter and lightly press into place. - Refill the grey inert mass and distribute evenly by lightly tapping- - Press the terminating filter into place. - Insert the sensor into the unit - do not forget the seal ! - Re-calibrate the unit with test gas.

inert mass (greyish-white mass).

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ADOS GmbH

10. Fault Rectification

KMZCnHmEM - Page 9

10.1 Gas Feeds

If faults occur in the gas suction, the complete suction system should be replaced and the faulty item repaired at the factory.

Assembly and operating a new heated gas suction system.

- Disassemble the old suction system; remove the connecting cables from their terminals and insulate. There is a danger of short-circuits even when the unit is switched off. by the possibility of the ends corning in contact with the terminals.

- Assemble the naw gas suction ana complete the eiectrical connections.

Note: Grcitind cannactlons should be made at the rack unit and not on the p.c.b. - Possibility of introducing interference -

- Switch on the gas suction (Heating commences, gas D u r n 0 OQ.

- Check the gas Analyser for a clean flow of gas.

- Check the sensor for leakage; if necessary, tighten the three MS-nuts on the sensor flange

- Dtsassemble the gas s a m p h p : Remove the fdlef and blow through. Fit a new seal (52Sk6?).

Note: Adhere to the sequence of the components.

- Check the sampling pipe for cleanliness; clean if necessary.

- Before re-assembling the sampling sys:em; the sampling pipe should be blown through an.: checked for leakage

The sampling pipe must always be blown through from the Analyser to the sampling position, not in the opposite direction.

When the Setpoint temperature has been reached, indiczted by regular il\urnination of the t"-display, switch on the pump and adjust the flow with the controlier knob, !o 125 !!h f 5 Ilh. AI; iault reports on the Analyser a n d gsr; sampling mus! now be cleared.

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. j -i ADOS GmbH KM 2 CnHrnEM Page 10 -~

Exceedinci the rate of flow:

Connect a Fiow meter 100-15[5 I/h to the gas output of the gss suction. Adjust the flow controller for a value of 125 I/h.

- Connect the gas output of the gas suction directly to th: Analyser input

- Set the change-over cock on \he Analyser to Test gas. After approx. 10-15 minutes, adjust the zero point setting with the 10-turn helical polentiometer on the Analyser.

- Apply the test gas

This should be carried ou! even. 4 week5 for C-units, acccrdixj to clean air recommendation; (inax. intewal, 6 weeks).

After t h e indication has se:led. the Setpoint value of the test gas shcluld be adjusted with the measurement range pokrrtiornefer ($2) on the Ana!yser.

-

Check first;

-

‘ -, j ,

!nseR the sampling ,“$e and sei ths change-eyer cock t3 the Sampled gas POSiiion

Is the heating of the sam$ing pipe opeiaiing 3

For C-tast units with added computer:

- Befuit commencing wrth maintenance work, set the key switch (24) on the Analyser to t h e ”Maintenance” position.

- After completing the maintenance work, the key switch is returned to the “Operational” position.

Under no circumstances must this be forgotten t

If for any reason. repair work on the system is not possible on site, the hours of !he completed work must be noted on the work-report. The Custcmer receives 1 or 2 copies of this report.

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I .

2.

, I

3.

- - ADOS Gmbii W 2 CnHmEM Page 11

10-2 Fauit-findinq

4.

Meter indication always a? the Minus or Plus full-sczle-deflection (f.s.d) Sensor is either short-circuit or there is a break in the connections; check the senso: resistance; normal value is in the region of 6 to 14 ohm. In the case of a large deviation. replace the SBRSOf.

Meter InSicatian remaim at "0"

Sensor is short-circtrit. Break ::I the measurmeni circuit, check the meter for continuity with ai-i d-mt-eter. Short-circuit terminals 17 and '16; if the meter now functions, the faul! lies ir. the extenal meter' circuit.

Limit \.atus does not switch

Sensor and meter poiaiily reversed. keverse the connections at t h e sensor and if necessaw, a! the msier. Faul: rri ihs limii value monitor, Fault-fimdmg fotlowing the circuit diagramme

Roady indicator lamp always iir.

i-leaier sieeve burnt out. Normal resistance 200 Cl +lo%, Resistance thermometer is shcri-circuit - Triac and/or transistor Trl defect.

Ready indicator lamp does not light

Fuse blown - Temperature controfler defect - 8reak in resistance thermometer.

. - 6.

7.

Ready indicator lights irregularly

Bsd ton!acts ai the rcsistanrs thermometer- Re-adjust tho temperature cantroller.

Reac!ion chzmber remains coid

Cneck the fuse - heating sleeve burnt out - Temparatxe controller defect - W a k in resistance thermometer.

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- - AD3S GnbH KM 2 CnHmEM Page 12

11. Techriicaj Data

Measurable Substances:

All combustible gases can be measured. with the exzeption of chlorinated and sulphur sublimated hydrocarbons

Sensitvity:

The adiabalic combmion of the sampled gas must produce 2 temperature Increase of 2°C for the smallest measuremmt range 2°C. The larges? mearwernent range is given Sy the lows: irmit =rf :gnition of the gas for measurement.

,i- ~ Measurement pri?ci;le. M?aruremPn: 0: :he heat produced by cornoustion in a solid matter catalyser /

o - 106 mg am' in air, 4-fold switchable wilh the factor x2

?vlezsuremen: ranges; single: 0- I 50 mg c/m3 0-500 rng cim3

0-150 mg Urn3, 0- 300 rng Urn5 0-600 mg Clm', 0-1200 mg c/m3

swltchabie:

Sietection limit.

Cross sensitivity.

Output signal:

Settling time (Tmk

Accuracy.

Zero pin! deviation:

Permissable ambient temperature:

Temperature dependence oi the Zerc point and t ie sensitrvity.

Effect of barometric variations in air pressure

Measurement flow-tiirough:

Warm-up time:

Maintenance interval.

0.S mg C/m3

CO, <2% CO H,O None

5 ppm CO = 1 mg C/m3

0-(4)-20 rnA current interface max. permissable load 300 ohm

70 secs. (Szmpling pipe, approx. ? 1 m, Dead-tirne 10 secs.)

c 2% of !.s.ci. 3n !he smailesl r m g e

None

1.25 YO changes -+ accuracy 1 06

125 Ifh

approx. 60 rnins

4-8 weeks

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