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8/10/2019 Innovations in Cems
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Process Analytic Division
Revolutionary
Innovations inContinuous Emissions Monitoring Systems CEMS)
November 10, 2004
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In t roduct ion
Continuous Emissions Monitoring Systems(CEMS) are vital in power plant and processindustries.
These systems traditionally cause facilities to endure
high installation and maintenance costs. However, revolutionary innovations now present
significant cost-saving opportunities to CEMS users.
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New Inno vat ive CEMS
Recent CEMS advancements allow emissionmonitoring accuracy and data handling at asignificantly lower cost than with systems createdfrom discrete components through innovationslike:
Direct stack/duct enclosure mounting
Split systems
Smaller enclosures
Reduced enclosure power requirements
Plug and Play Ethernet Web-browser interfaces
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CEMS Designs
Shelter Approach$150K
CabinetApproach
$95K
Streamlined Field-Mount Approach
$75K
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Direct Enclosure Moun t ing
The elimination of a heated sample line between a sample probe and
a sample conditioning/analysis system can create significant costsavings and save considerable headaches and process downtime orviolations because:
The installed cost of heated sample lines is about $100 per foot (theaverage 150-foot line costs about $15,000).
Sample lines are delicate, require skilled installers and are oftendamaged during installation.
Sample lines require diligent maintenance on the sample probe.
Process upsets or process equipment failures can sometimes lead toplugging of the sample line, necessitating its replacement.
Heated sample lines are long lead-time items, often taking weeks toprocure even in emergency situations.
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Direct Enclosure Mounting (cont.) Real-time measurements are important for timely feedback on critical
emission levels.
With long sample lines the analysis process is delayed, causingpotentially harmful delays in emission level corrections.
However, close-coupled or direct mounting of sample handling and
analysis enclosures eliminates the need for a sample line andprovides the following advantages:
Reduced transport time for sample reading, providing a near-real-timemeasurement signal
Faster, continuous measurement for efficient pollution reduction system
control, quicker adjustments, and reduced emission limits violations Elimination of heated sample lines, providing energy savings as they
typically use 25-50% of energy consumed by the CEMS
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Spl i t Systems
Newer CEMS feature a split system architecture of:
A sample handling system (probe and conditioning station)
Analysis components
With sample handling systems mounted on the stack or
duct, analysis components can be mounted at: Stack
Base of stack
Ground level
Remote buildings
Other easy to access areas
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All SampleHandling locatedat base of stack
Probe Only
Ground Level Ins tal lat ion Opt ional
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Shelterless approach
Analys is EnclosureIns tallat ion
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Analys is EnclosureIns tallat ion
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Smal ler Enclosu res
Smaller, self-contained CEMS enclosures provide a
compact, field-mountable combustion exhaust gasmeasurement system and offer:
Installation in limited space locations
Ratings for unprotected outdoor exposure, eliminating the need
for concrete pad foundations and expensive shelters Compact, efficient cooling/heating control systems to maintain
constant temperatures
Reduce/eliminate building maintenance expenses
Significant energy savings
Easier, less expensive installation (cranes and other heavy liftingequipment no longer required)
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New Ins tal lat ion Opt ion s
Smaller system size makes Stainless Steelenclosures more affordable
Great for EMI/RFI environments
Meets spec requirements for petrochemical facilities
Skip the box and HVAC
2x2 Plate-mount for use in limited space situationson interior walls of existing shelters
Sample handling enclosure can be mounted onoutside of existing shelters.
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Sample handling directlylocated at the stack
Unheated sample linesbetween probe andanalyzer/detectors
Sample Condi t ion ing Enc losu reInstal lat ion
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Sample Condi t ion ing Enc losu reInstal lat ion
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Reduced Enclosu re PowerRequirements
CEMS users now recognize lower powerrequirements through:
Significant reduction of heating and cooling coststhrough elimination of shelter.
Lower power magnitudes than traditional systems(500 Watts versus 30,000 Volt-Amps)
Elimination of heated sample line power draw (18Watts/foot)
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Use Proven Techno log ies
New packaging of existing technology
Benefits of using proven technology:
Avoid situations where too many changes at one timelimits the diagnosis of root problem
New packaging is already available using currentlypreferred methods for both sample handling andanalysis.
Hassles and expenses related to variances or localEPA acceptance of unfamiliar methods are eliminated
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Proven Sample Hand l ing Techno log ies
Using proven sample handling techniques also eliminates
costly troubleshooting and maintenance on new technologies,especially since some new packaging options use the sameproven techniques as conventionally packaged systems.
Unproven techniques may result in higher costs and significant
lost uptime due to: Learning curves
Unavailability of trained and experienced service resources
Limitation on spare parts
Higher costs for exotic premium technologies
Slow service response
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Sample Cond i t ion ing Enclosu re w i thProven Techno log ies
Cal/Purge ValveProbe Connection
Sample Pump
Filters
Thermo Electric
CoolerPermeation Tube
AC
I/O Switch Box
Power Supply
Peristaltic Pump
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Proven Sensor Techno log ies
Eliminate costly diagnostics and maintenance on new
technologies New packaging options use the same proven techniques as
conventionally packaged systems
Use proven EPA Reference Methods
Proven detectors now available:
Chemiluminescent NOx
Nondispersive Infrared (NDIR) CO
Nondispersive Ultraviolet (NDUV) SO2
Paramagnetic O2
Electrochemical O2
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Electronics Section on Bottom
Physics Section on Top
Customer I/O Access
Gas Fitting Connections
ConstantTemperature
Control PeltierCooler/Heater
NEMA 4X Enclosure
Analys is Enclosu re Design
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PC/104 Controller
Pocket PC
23 amp UniversalPower Supply
Electronics
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Embedded PC
Choose a system utilizing an industrial computerstandard such as PC-104, as this controllerfeatures:
Resistance to plant environmental factors such as
radio frequency interference (RFI), heat and vibration Commercially available parts
Smaller form factors
Acceptance as an industrial standard
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Embedded PC (contd)
Built-in personal computers (PCs) with DASavailable on CEMS models that provide:
Automatic function controls
System limit and failure alarms
Data averaging for regulatory requirements (40 CFR 60)
Pollution calculations for diluent corrections, mass emissions
Status flags for all values, calculations, averages.
Calibration Logs, Alarm Logs, Emissions Logs
Calibration correction factors for each analyzer output
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Embedded PC (contd)
Months of data can be stored in the embedded PCs and
can be:
256 MB flash drive (no moving parts) can hold 3 months data
Downloaded via a handheld PC
Accessed remotely through an Ethernet network Network drive access through Windows Explorer
Windows drive mapping
Downloaded in Microsoft Excel or Microsoft Word format forfurther analysis and storage
Interfaced to DCS, Data Acquisition Systems, etc. through OPCServers
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Handheld PC Operator Interface
Advanced CEMS feature handheld PCs at theanalysis enclosure that offer:
Same access as remote web-browser displays
Drop-down menus that eliminate the need to scroll
through multiple levels for values or commands Operability outside the enclosure via a cable for more
comfortable and easier data reading
Leave it in the enclosure or take it with you
Password protection, software for CEMS operationsonlyensures the handheld stays with the CEMS
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Operate pocket PCwithout opening
cabinet
Connects throughserial port
External Connect ion for Pocket PC
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Plug and Play Ethernet Web-browser Interface Eliminating the need for custom software drivers to interface
with plant control systems, CEMS now feature: HTML Web-browser access to operating parameters, system
setup and process data (Internet Explorer)
No setup requiredtype IP address once and bookmark!
Access from any plant computer, home PC, or even from out-of-town corporate offices.
TCP-IP communications protocol for intranet and Internetcommunications
Simple message structure for easy programming, parsing by
OPC Servers, etc. Simple file format allows direct import into spreadsheets and
database without any modifications or programming
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Time Share Features
Software configuration of switching time, stacknames, individual calibration parameters for eachstack, etc.
Automatic status flags for all values, averages,
calculations, etc. for stack that is in by-pass (I.e.not being sampled)
Analog output hold for stack in bypass, digitalcontact out to indicate which stack is beingsampled.
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Time Share Option Benefits
Eliminates the cost of a second set of analyzers
Great for two stacks for multiple emissions sourceinstallations such as gas turbine plants, auxiliaryboilers, etc.
Great for before/after SCR control signals
Great for determining NH3 Slip using before/afterSCR NOx measurement and mass balance formula.
Perfect for automatic switch-over applications forbackup boilers, bypass stacks, etc.
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Steam Switching Box
Continuous time-share switching of conditionedsample streams
Needle valves for flow balancing multiple samplestreams
Needle valves for flow balancing calibration gases tomultiple sample probes
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Time Share Opt ion Steam Switch ing Box
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Hazardous Area Opt ion s
Sample Handling and/or Analyzer Enclosure can be upgraded for
Class 1 Div 2 areas: Z-purge enclosure
Class 1 Div 2 HVAC units
Class 1 Div 2 external power supply and cooling fan
Hazardous area rated junction box Good solution for petrochemical applications where hazardous area
rated shelters are too big/expensive
Sample handling enclosure at probe eliminates sample line andassociated hazardous area requirements
Many stack locations are above the maximum height of the hazardousareaallowing the use of general purpose sample handlingenclosures
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Hazardous Area Enc losures
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Futu re Enhancements
Additional enhancements are expected in CEMSdevelopment to simplify installation and operatingcosts even more, including:
NDIR CO2 Bench
Direct replacement for dilution systems with new low NOxlimits
Supports new CO2 monitoring and reporting requirements
Wireless remote access
Redundant hardware for mission-critical applications
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