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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Innovations in Cems