How to make extractive operatingCEMS more affordable

Guenter Haberzettl, ABB Analytical – PMU Frankfurt, May 2014

Legislation – The upcoming EN 14181, 2nd edition

QAL3 procedures

Time effective operation

Evaluation

Remote maintenance

Summary

Table of contents.

May 21, 2014 | Slide 2

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EN 14181 – The second editionType of plants involved

May 21, 2014 | Slide 3

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Directive 2010/75/EU

on Industrial Emissions

Integrated Pollution Prevention and Control (IPPC)

Directive 2000/76/EC WIP Waste Incineration & Co-Incineration

Directive 2001/80/EC LCPD Large Combustion Plant Directive

Technical Guidance Air Small Combustion Plants

Directive 2003/87/EC Greenhouse Gas Monitoring

EN 14181 – The second editionOngoing quality assurance during operation – QAL 3

May 21, 2014 | Slide 4

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Still the Target

Checking drift and precision of an AMS

What´s new ?

More frequent zero and span checks

Depending from the type of control chart is used

A third control chart will be permitted

EWMA Expotentially Weighted Moving Average Control Charts

A further method will be established for setting alarm limits

Using the maximun permissible uncertainty

European

Committee

for

Standardization

1. Doing a calculation by using the uncertainties values (Uc) collected at site / type approval

2. Doing a calculation based on the maximum permissible uncertainty

± 50 % of the max. permissible uncertainty can be used to set the alarm limits

± 25 % of the max. permissible uncertainty can be used to set the warning limits

Example

CO measurement / Value 100 mg/m³ / Max. perm. uncertainty 10%

ALimit = 100 mg/m³ x 10% = 10 mg/m³ x 50 %

Control chartsAlarm limits

May 21, 2014 | Slide 5

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22222

otherspresvolttempinstAMS uuuuus

Shewhart Control ChartsExample

May 21, 2014 | Slide 6

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Shewhart The most popular control chart

Out of control

t t1 t2 Maintenance interval

SAMS

t3

0

1

2

3

-1

-2

-3

t4 t5

Out of control

2 x SAMS / 50% perm. Uncert.

Upper alarm limit

Lower alarm limit

2,5 mg/m³

5 mg/m³

2,5 mg/m³

5 mg/m³ 2 x SAMS / 50% perm. Uncert.

EWMA Control ChartsExpotential Weight Moving Average Control Charts

May 21, 2014 | Slide 7

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Using the results of the measurements previous to the last check

Limit values identical according to Shewhart Control Charts

Out of control

t t1 t2 Maintenance interval

SAMS

t3

0

1

2

3

-1

-2

-3

t4 t5

Out of control

Upper alarm limit

Lower alarm limit

2,5 mg/m³

5 mg/m³

2,5 mg/m³

5 mg/m³

2 x SAMS / 50% perm. Uncert.

2 x SAMS / 50% perm. Uncert.

EN 14181 – QAL3Ongoing quality assurance during operation

May 21, 2014 | Slide 8

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AMS

Installation

Time

1 Year

QA

L 2

~ ~

Accredited

Test laboratory

QA

L 3

QA

L 3

QA

L 3

QA

L 3

QA

L 3

AS

T

AS

T

~ ~

QA

L 2

Max. 5 years

Carried out by operator

QA

L 3

Frequency

Once in the certified maintenance interval

More frequent checks are recommended

Reference Materials

Test gases Always possible

Surrogate materials Yes, if type approved

Cold / Dry extractive operating AMS Adjustment concepts

May 21, 2014 | Slide 9

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ExhaustAnalyzerSample Conditioning

Stable dew point

Sample Line

≥ 180°C

Sampling

≥ 180°C Stack

1

Probe

Test Gas

Test Gas

Ambient Air

Test Gas

Sample Conditioning

3

Gas Outlet

Adjustment

Cells4Single Point

Adjustment

O2

Analyzer

2

IR /UV Analyzer

Cold / Dry extractive operating AMSQAL 3 span check with test gases at the probe

May 21, 2014 | Slide 10

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Points to be considered Potential effects

• Long sample lines • Long adjustment cycles - Time

• Availabilty

• Low concentrations • Long adjustment cycles - Balance

• Availability

• Test gas cylinders are empty • Supply time

• Availability

Cold / Dry extractive operating AMS

Medium

Set of span gases CO / CO2 / SO2 / NO 4 test gas cylinders

Procedure

Frequency (Automatically controlled) 1 time / week

Quantity of test gas required for 1 check ~ 20 l / component

Test gas comsumption per year

20 l x 50 weeks = 1000 l / component 4 cylinders / year

Consider : Stability of test gases are limited

Costs

Test gas cylinders for 1 year operation 2.000 € / year

Labour for 1 year (if not running automatically) 2.000 € / year

QAL 3 span check with test gases

May 21, 2014 | Slide 11

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Cold / Dry extractive operating AMS

Technology

Gas filled adjustment cells with high tightness

1 cells for each measuring component

High stability also for critical gases like NO and NO2

Application

State of the art technology for span point checks used with

IR & UV Photometer

Savings

Think above the life cycle of an AMS

10 year operation a` 2.000 €/y 20.000 € Cost savings

Amortization

Appr. 1 year, compared to the costs for test gases, required for 1 year operation

QAL 3 span check with gas filled adjustment cells

May 21, 2014 | Slide 12

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Cold / Dry extractive operating AMSQAL 3 span check with gas filled adjustment cells

May 21, 2014 | Slide 13

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TUEV – Long term performance test

300

310

320

330

340

350

360

370

380

390

400

ppm

years

Analyzer 1 0.4 % / a

Analyzer 2

0.3 % / a

1 2 3 4 5

Maintenance interval by using gas filled adjustment cells

12 months certified e.g. for ABB adjustment cells

No test gases required between two AST

Zero Point adjustment

Ambient air, clean and dry

Cold / Dry extractive operating AMSQAL 3 - Single point adjustment

May 21, 2014 | Slide 14

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Indication

∆

0

Concentration

Paramagnetic O2 - Analyzer

Zero point – Single point adjustment

Checking the parallel shift

Analyzer behaviour – linear

Medium – Ambient air

Span Point

Absolute stable - no adjustment

Concentration0

∆

Indication

Electrochemical O2 - Analyzer

Span point – Single point adjustment

Checking the sensitivity

Medium - Ambient air

Zero Point

Absolute stable – no adjustment

Hot / Wet extractive operating AMS - FTIR

May 21, 2014 | Slide 15

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Adjustment concepts

ExhaustAnalyzer

≥ 180°C

Sample Conditioning

≥ 180°C

Sample Line

≥ 180°C

Sampling

≥ 180°C Stack

Test Gas

1

Probe

Test Gas

Adjustment

Cells

Gas Outlet

Instrument

Air

Air

Cleaner

Test Gas

3

2

Sample

Analyzer

Hot / Wet extractive operating AMS - FTIRQAL 3 span check with test gases at the probe

May 21, 2014 | Slide 16

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Points to be considered Potential effects

• Long sample lines • Long adjustment cycles - Time

• Availabilty

• Low concentrations • Long adjustment cycles - Balance

• Availability

• Operating a water vaporizer at the probe • Time intensive work

• Availability

• Test gas cylinders are empty • Supply time

• Availability

Hot / Wet extractive operating AMS - FTIR

Medium

Set of span gases for dry components 1 test gas / component

Water generator & solutions for soluble components

Procedure

Frequency (Automatically controlled) 1 time / week

Quantity of test gas required for 1 check ~ 200 l / component

Test gas comsumption per year

200 l x 50 weeks = 10.000 l / component 2 cylinders per comp. / year

Consider : Stability of test gases are limited

Costs

Test gas for each dry component 1.000 € per component / a

Water soluble components 2.000 € per component / a

QAL 3 span check with test gases

May 21, 2014 | Slide 17

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© ABB

21.05.2014 ACF-NT CEM | 18

Hot / Wet extractive operating AMS - FTIRAdjustment

+ x- x0

Intensity

Interferogram

Reference Spectra

+ x- x0

Intensity

Interferogram

Raw Spectra

Laser-Source

IR-Source

Measurement

x

IR-DetectorLaser-Detector

Adjustment

cells

Sample Gas

Laser-Source

IR-Source

Zero Point

Laser-Detector

x

IR-Detector

Adjustment

cells

Instrument Air

© ABB

21.05.2014 ACF-NT CEM | 19

Hot / Wet extractive operating AMS - FTIRAdjustment

+ x- x0

Intensity

Interferogram

Intensity

Spectral shift

+ x- x

DX

0

InterferogramInstrument Air

IR-Detector

IR-Source

Laser-Source

Laser-Detector

x

Adjustment

cellsSpectral shift

Laser-Source

IR-Source

IR-Detector

Laser-Detector

Span Check

x

Adjustment

cells

Instrument Air

Hot / Wet extractive operating AMS - FTIRQAL3 span check with film technology & gas filled cells

May 21, 2014 | Slide 20

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mg/m³

0 3 6 9 12 mo

Film Technology

Wide-band operating

Checking a number of components simultaneously with one film

Arrangement on a filter wheel

Gas filled adjustment cells

Narrow-band operating

Checking a single component with one cell

Checking the spectral shift

Long term performance test of films

Time effective operationExample - QAL 3 check procedure

May 21, 2014 | Slide 21

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1. Zero Point adjustment

2. Refer. Point adjustment

3. Purging

4. Measurement

240 s

(≤ 1200s)

60 s0

1

120 s0

1

60 s0

1

0

1

On/off

Target Avoid to lose half hourly average values

More than 5 half hourly rates per day unvaild The entirely day is unvalid

Evaluation and data loggingSolutions with integrated functionality

May 21, 2014 | Slide 22

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AnalyzeIT Explorer

QAL3 evaluation & reporting

Continuously recording & logging

Displays status & measuring values

Allow complete remote operation

Graphic and trend chart recorder

Logbook functionality

Inside the Analyzer

QAL3 functionality integrated

Remote maintenanceNetworking

May 21, 2014 | Slide 23

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Ethernet/TCP/IP

AnalyzeIT Explorer

QAL3 Quality

Control

Diagnosis

Datalogging

Service

Updating

Values

Status

I/O‘s

Trigger

Remote

Maintenance

UMTS-Aerial

Service

Using type approved reference materials instead of test gases

Running QAL3 procedures automatically

Predictive maintenance reduces maintenance costs

Conducting QAL3 evaluation by using software tools

Remote maintenance improves the required availabilty

SummaryMaking extractive operating CEMS more affordable

May 21, 2014 | Slide 24

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