Process Analytic Division

Revolutionary
Innovations in

Continuous Emissions Monitoring Systems (CEMS)

November 10, 2004

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Introduction

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.

Traditional 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 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 Designs

Cabinet
Approach
$95K

Shelter Approach
$150K
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Streamlined FieldMount Approach

$75K

Direct 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.

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, 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

CEMS Installation
Sample handling installed
at the probe

No heat trace lines required

Analyzer mounted outside

Split 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 Flexibility

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Ground Level Installation Optional

Probe Only
All Sample
Handling located
at base of stack

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Analysis Enclosure Installation

Shelterless approach

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Analysis Enclosure Installation

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Smaller 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 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

2x2 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 Conditioning Enclosure

Installation

Sample handling directly

located at the stack
Unheated sample lines
between probe and
analyzer/detectors

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Sample Conditioning Enclosure

Installation

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Reduced Enclosure Power

Requirements

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 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 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

Proven 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 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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Analysis Enclosure Design

Constant
Temperature
Control Peltier
Cooler/Heater

Physics Section on Top

Electronics Section on Bottom

Customer I/O Access

Gas Fitting Connections

NEMA 4X Enclosure
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Electronics

Pocket PC
23 amp Universal
Power Supply

PC/104 Controller
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Embedded 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 (contd)

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 (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 for

further analysis and storage

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

Servers
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Handheld 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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External Connection for Pocket PC

Operate pocket PC
without opening
cabinet
Connects through
serial port

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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 required type IP address once and bookmark!

Access from any plant computer, home PC, or even from out-oftown 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 Option

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Time 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 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 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 Box

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Hazardous 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 Enclosures

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Future 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

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