Process Analytic Division Revolutionary Innovations in Continuous Emissions Monitoring Systems (CEMS) November 10, 2004

1. Process Analytic Division Revolutionary Innovations in Continuous Emissions Monitoring Systems (CEMS) November 10, 2004

2. 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.

3. 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

4. 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

5. CEMS Designs Streamlined Field- Mount Approach $75K Cabinet Approach $95K Shelter Approach $150K

6. 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.

7. 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

8. CEMS Installation Sample handling installed at the probe No heat trace lines required Analyzer mounted outside

9. 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

10. Standard Installation – Flexibility

11. Ground Level Installation – Optional Probe Only All Sample Handling located at base of stack

12. Analysis Enclosure – Installation Shelterless approach

13. Analysis Enclosure – Installation

14. 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)

15. 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 • 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.

16. Sample Conditioning Enclosure – Installation • Sample handling directly • located at the stack • Unheated sample lines • between probe and • analyzer/detectors

17. Sample Conditioning Enclosure – Installation

18. 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)

19. 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

20. 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

21. 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

22. 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

23. 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

24. Electronics Pocket PC 23 amp Universal Power Supply PC/104 Controller

25. 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

26. 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

27. 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

28. 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

29. External Connection for Pocket PC • Operate pocket PC without opening cabinet • Connects through serial port

30. 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-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

31. New Cost Efficient Time Share Option

32. 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.

33. 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.

34. 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

35. Time Share Option Steam Switching Box

36. 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

37. Hazardous Area Enclosures

38. 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