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Process Analytic Division

Revolutionary Revolutionary Innovations inInnovations in

Continuous Emissions Monitoring Systems (CEMS)Continuous Emissions Monitoring Systems (CEMS)

November 10, 2004

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IntroductionIntroductionIntroductionIntroduction• Continuous Emissions Monitoring Systems

(CEMS) are vital in power plant and process industries.

• 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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Traditional CEMS RequirementsTraditional CEMS RequirementsTraditional CEMS RequirementsTraditional CEMS Requirements• A sampling probe mounted at the appropriate height on a

stack

• A heated sample line to transport moisture-laden gas samples to the analysis station

• A shelter building erected and maintained to provide the proper operating environment for the analysis equipment

• A programmable logic controller (PLC) to manage the monitoring process

• A suitable data acquisition system (DAS) to generate data, reports and records

• Installation costs up to $150,000 or more per stack

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New Innovative CEMSNew Innovative CEMSNew Innovative CEMSNew Innovative CEMS• Recent CEMS advancements allow emission

monitoring accuracy and data handling at a significantly lower cost than with systems created from discrete components through innovations like:

• 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 DesignsCEMS Designs

Shelter Approach$150K

Cabinet Approach

$95K

Streamlined Field- Mount Approach

$75K

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Direct Enclosure MountingDirect Enclosure MountingDirect Enclosure MountingDirect Enclosure Mounting• The elimination of a heated sample line between a sample probe and

a sample conditioning/analysis system can create significant cost savings and save considerable headaches and process downtime or violations because:

• The installed cost of heated sample lines is about $100 per foot (the average 150-foot line costs about $15,000).

• Sample lines are delicate, require skilled installers and are often damaged during installation.

• Sample lines require diligent maintenance on the sample probe.

• Process upsets or process equipment failures can sometimes lead to plugging of the sample line, necessitating its replacement.

• Heated sample lines are long lead-time items, often taking weeks to procure even in emergency situations.

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Direct Enclosure Mounting (con’t.)Direct Enclosure Mounting (con’t.)Direct Enclosure Mounting (con’t.)Direct Enclosure Mounting (con’t.)• Real-time measurements are important for timely feedback on critical

emission levels.

• With long sample lines the analysis process is delayed, causing potentially 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 and provides the following advantages:

• Reduced transport time for sample reading, providing a near-real-time measurement 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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Sample handling installedat the probe

No heat trace lines required

Analyzer mounted outside

CEMS InstallationCEMS InstallationCEMS InstallationCEMS Installation

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Split SystemsSplit SystemsSplit SystemsSplit 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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Standard Installation – FlexibilityStandard Installation – Flexibility

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All Sample Handling located at base of stack

Probe Only

Ground Level Installation – OptionalGround Level Installation – OptionalGround Level Installation – OptionalGround Level Installation – Optional

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Shelterless approach

Analysis Enclosure – InstallationAnalysis Enclosure – InstallationAnalysis Enclosure – InstallationAnalysis Enclosure – Installation

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Analysis Enclosure – InstallationAnalysis Enclosure – InstallationAnalysis Enclosure – InstallationAnalysis Enclosure – Installation

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Smaller EnclosuresSmaller EnclosuresSmaller EnclosuresSmaller Enclosures• Smaller, self-contained CEMS enclosures provide a

compact, field-mountable combustion exhaust gas measurement 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 lifting equipment no longer required)

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New Installation OptionsNew Installation OptionsNew Installation OptionsNew Installation Options• Smaller system size makes Stainless Steel

enclosures more affordable

• Great for EMI/RFI environments

• Meets spec requirements for petrochemical facilities

• Skip the box and HVAC

• 2’x2’ Plate-mount for use in limited space situations on interior walls of existing shelters

• Sample handling enclosure can be mounted on outside of existing shelters.

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•Sample handling directly located at the stack

•Unheated sample lines between probe and analyzer/detectors

Sample Conditioning Enclosure – Sample Conditioning Enclosure – InstallationInstallationSample Conditioning Enclosure – Sample Conditioning Enclosure – InstallationInstallation

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Sample Conditioning Enclosure – Sample Conditioning Enclosure – InstallationInstallationSample Conditioning Enclosure – Sample Conditioning Enclosure – InstallationInstallation

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Reduced Enclosure Power Reduced Enclosure Power RequirementsRequirementsReduced Enclosure Power Reduced Enclosure Power RequirementsRequirements

• CEMS users now recognize lower power requirements through:

• Significant reduction of heating and cooling costs through elimination of shelter.

• Lower power magnitudes than traditional systems (500 Watts versus 30,000 Volt-Amps)

• Elimination of heated sample line power draw (18 Watts/foot)

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Use Proven TechnologiesUse Proven TechnologiesUse Proven TechnologiesUse Proven Technologies• New packaging of existing technology

• Benefits of using proven technology:

• Avoid situations where too many changes at one time limits the diagnosis of root problem

• New packaging is already available using currently preferred methods for both sample handling and analysis.

• Hassles and expenses related to variances or local EPA acceptance of unfamiliar methods are eliminated

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Proven Sample Handling TechnologiesProven Sample Handling TechnologiesProven Sample Handling TechnologiesProven Sample Handling Technologies• Using proven sample handling techniques also eliminates

costly troubleshooting and maintenance on new technologies, especially since some new packaging options use the same proven 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 Conditioning Enclosure with Sample Conditioning Enclosure with Proven TechnologiesProven Technologies

•Cal/Purge Valve

•Probe Connection

•Sample Pump

•Filters

•Thermo Electric Cooler

•Permeation Tube

•AC

•I/O Switch Box

•Power Supply

•Peristaltic Pump

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Proven Sensor TechnologiesProven Sensor TechnologiesProven Sensor TechnologiesProven Sensor Technologies• 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

Constant Temperature

Control Peltier Cooler/Heater

NEMA 4X Enclosure

Analysis Enclosure DesignAnalysis Enclosure DesignAnalysis Enclosure DesignAnalysis Enclosure Design

24PC/104 Controller

Pocket PC

23 amp Universal Power Supply

ElectronicsElectronicsElectronicsElectronics

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Embedded PCEmbedded PCEmbedded PCEmbedded PC• Choose a system utilizing an industrial computer

standard such as PC-104, as this controller features:

• 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 (cont’d)Embedded PC (cont’d)Embedded PC (cont’d)Embedded PC (cont’d)• Built-in personal computers (PCs) with DAS

available 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 (cont’d)Embedded PC (cont’d)Embedded PC (cont’d)Embedded PC (cont’d)• 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 for further analysis and storage

• Interfaced to DCS, Data Acquisition Systems, etc. through OPC Servers

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Handheld PC Operator InterfaceHandheld PC Operator InterfaceHandheld PC Operator InterfaceHandheld PC Operator Interface• Advanced CEMS feature handheld PCs at the

analysis 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 operations only – ensures the handheld stays with the CEMS

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Operate pocket PC without opening cabinet

Connects through serial port

External Connection for Pocket PCExternal Connection for Pocket PCExternal Connection for Pocket PCExternal Connection for Pocket PC

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Plug and Play Ethernet Web-browser InterfacePlug and Play Ethernet Web-browser InterfacePlug and Play Ethernet Web-browser InterfacePlug 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 required – type 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 Internet communications

• 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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New Cost Efficient Time Share OptionNew Cost Efficient Time Share Option

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Time Share FeaturesTime Share FeaturesTime Share FeaturesTime Share Features• Software configuration of switching time, stack

names, individual calibration parameters for each stack, 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, digital contact out to indicate which stack is being sampled.

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Time Share Option BenefitsTime Share Option BenefitsTime Share Option BenefitsTime Share Option Benefits• Eliminates the cost of a second set of analyzers

• Great for two stacks for multiple emissions source installations such as gas turbine plants, auxiliary boilers, etc.

• Great for before/after SCR control signals

• Great for determining NH3 Slip using before/after SCR NOx measurement and mass balance formula.

• Perfect for automatic switch-over applications for backup boilers, bypass stacks, etc.

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Steam Switching BoxSteam Switching BoxSteam Switching BoxSteam Switching Box• Continuous time-share switching of conditioned

sample streams

• Needle valves for flow balancing multiple sample streams

• Needle valves for flow balancing calibration gases to multiple sample probes

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Time Share Option Steam Switching Time Share Option Steam Switching BoxBox

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Hazardous Area OptionsHazardous Area OptionsHazardous Area OptionsHazardous Area Options• 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 and associated hazardous area requirements

• Many stack locations are above the maximum height of the hazardous area – allowing the use of general purpose sample handling enclosures

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Hazardous Area EnclosuresHazardous Area Enclosures

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Future EnhancementsFuture EnhancementsFuture EnhancementsFuture Enhancements• Additional enhancements are expected in CEMS

development to simplify installation and operating costs even more, including:

• NDIR CO2 Bench

• Direct replacement for dilution systems with new low NOx limits

• Supports new CO2 monitoring and reporting requirements

• Wireless remote access

• Redundant hardware for mission-critical applications