EcoChem Analytics
description
Transcript of EcoChem Analytics
![Page 1: EcoChem Analytics](https://reader035.fdocuments.in/reader035/viewer/2022081721/568159a6550346895dc706d3/html5/thumbnails/1.jpg)
Experience with PADEP, CEM Experience with PADEP, CEM
Phase I Approval Under Rev 7Phase I Approval Under Rev 7
ARIPPA Technical SymposiumARIPPA Technical Symposium
July 27, 2005July 27, 2005
Jim Carroll & Ron BakerJim Carroll & Ron Baker
EcoChem AnalyticsEcoChem Analytics
![Page 2: EcoChem Analytics](https://reader035.fdocuments.in/reader035/viewer/2022081721/568159a6550346895dc706d3/html5/thumbnails/2.jpg)
2
2
Presentation OverviewPresentation Overview
• Project Scope• Hardware Description• Project Schedule• Application Experience• Interaction with the
Department• Recommendations• CEM Supplier
Perspective
![Page 3: EcoChem Analytics](https://reader035.fdocuments.in/reader035/viewer/2022081721/568159a6550346895dc706d3/html5/thumbnails/3.jpg)
3
3
CEM Project ScopeCEM Project Scope
• Install new stand alone CEMS enclosure
• Install two (2) new EcoChem MC3 multi-component analyzer packages
– NOx, SO2, CO, CO2, O2
• Two (2) new sample handling systems– Probes– Sample lines– Sample pumps
![Page 4: EcoChem Analytics](https://reader035.fdocuments.in/reader035/viewer/2022081721/568159a6550346895dc706d3/html5/thumbnails/4.jpg)
4
4
CEM Project Scope ( Cont’d)CEM Project Scope ( Cont’d)
• New DAS by ESC for PA STEMS (Part 60) and NOx Budget (Part 75) reporting
• Maintain use of existing stack flow monitors in new system
• Maintain use of existing Opacity Monitor (near term)
![Page 5: EcoChem Analytics](https://reader035.fdocuments.in/reader035/viewer/2022081721/568159a6550346895dc706d3/html5/thumbnails/5.jpg)
5
5
New EnclosureNew Enclosure
![Page 6: EcoChem Analytics](https://reader035.fdocuments.in/reader035/viewer/2022081721/568159a6550346895dc706d3/html5/thumbnails/6.jpg)
6
6
Heated Probe AssemblyHeated Probe Assembly
![Page 7: EcoChem Analytics](https://reader035.fdocuments.in/reader035/viewer/2022081721/568159a6550346895dc706d3/html5/thumbnails/7.jpg)
7
7
Heated Sample LineHeated Sample Line
Non-heated tubes (PFA-PTFE)
1. Calibration Gas (from calibration cylinder and solenoid valves to probe)
2. Isolation Air (isolation of probe from flue gas during calibration & temperature failures)
3. Blowback air (used for purging probe)
Heated tubes (185°C PFA)1. Sample gas from probe to
analyzer2. Spare
Heating element
Insulation
Power for probe
Power for sample line heating and temperature sensors
![Page 8: EcoChem Analytics](https://reader035.fdocuments.in/reader035/viewer/2022081721/568159a6550346895dc706d3/html5/thumbnails/8.jpg)
8
8
Heated PumpHeated Pump
![Page 9: EcoChem Analytics](https://reader035.fdocuments.in/reader035/viewer/2022081721/568159a6550346895dc706d3/html5/thumbnails/9.jpg)
9
9
CEM CabinetsCEM Cabinets
![Page 10: EcoChem Analytics](https://reader035.fdocuments.in/reader035/viewer/2022081721/568159a6550346895dc706d3/html5/thumbnails/10.jpg)
10
10
CEM Cabinet InteriorCEM Cabinet Interior
![Page 11: EcoChem Analytics](https://reader035.fdocuments.in/reader035/viewer/2022081721/568159a6550346895dc706d3/html5/thumbnails/11.jpg)
11
11
MC3 ConfigurationMC3 Configuration
Gas Range Interval
CO 0-200 PPM, 0-3000 PPM
SO2 0-150 PPM, 0 - 400 PPM
NOx 0-160 PPM
O2 0-25%
CO2 0-20%
H2O 0-30%
![Page 12: EcoChem Analytics](https://reader035.fdocuments.in/reader035/viewer/2022081721/568159a6550346895dc706d3/html5/thumbnails/12.jpg)
12
12
Touch Screen DisplayTouch Screen Display
![Page 13: EcoChem Analytics](https://reader035.fdocuments.in/reader035/viewer/2022081721/568159a6550346895dc706d3/html5/thumbnails/13.jpg)
13
13
Real-Time Strip ChartReal-Time Strip Chart
![Page 14: EcoChem Analytics](https://reader035.fdocuments.in/reader035/viewer/2022081721/568159a6550346895dc706d3/html5/thumbnails/14.jpg)
14
14
Project ScheduleProject Schedule
• Prelim Meeting - August 2003• New CEM Spec Issued –
August 2004• EcoChem Selected – Sept 2004• PO issued/Order placed – Sept
2004• Teleconference with PADEP –
Sept 2004• Phase I Submittal – Oct 2004
– Included a listing of project milestones (testing)
![Page 15: EcoChem Analytics](https://reader035.fdocuments.in/reader035/viewer/2022081721/568159a6550346895dc706d3/html5/thumbnails/15.jpg)
15
15
Project Schedule (Cont’d)Project Schedule (Cont’d)
• Phase II Submittal – Nov 2004• FAT Testing – Jan 2005• Installation/Commissioning –
Feb 2005• Phase I and II Status Request –
Feb 22• PADEP Response – Feb 24,
2005• Proposed Certification –
March 16, 2005• New Schedule Proposed –
March 17, 2005
![Page 16: EcoChem Analytics](https://reader035.fdocuments.in/reader035/viewer/2022081721/568159a6550346895dc706d3/html5/thumbnails/16.jpg)
16
16
Project Schedule (Cont’d)Project Schedule (Cont’d)
• Performance Testing – April 2005• RATA Testing – April 13 & 14, 2005• Phase I Approval – April 18, 2005• Submittal of Performance Testing
Data – May 2005• Submittal of Part 75 Certification
EDRs – May 2005• EDR Certification Data – App’d in
10 days • Phase III Acknowledgement Letter
– June 2, 2005 (Response by July 2, 2005)
• Certification is currently pending
![Page 17: EcoChem Analytics](https://reader035.fdocuments.in/reader035/viewer/2022081721/568159a6550346895dc706d3/html5/thumbnails/17.jpg)
17
17
Application ExperienceApplication Experience
• Opted to utilize the electronic Phase I forms
• Theory: Electronic submittal may expedite the approval process (Not!)
• Completed forms encompassed 41 pages
• Forms were cumbersome to work with
• Some requested data was not well defined
• Requested more fluff than stuff
![Page 18: EcoChem Analytics](https://reader035.fdocuments.in/reader035/viewer/2022081721/568159a6550346895dc706d3/html5/thumbnails/18.jpg)
18
18
Application Experience Application Experience (Cont’d)(Cont’d)
• Requested data aids in fulfilling the Department’s CEMS database
• ID codes, Result Codes, Source Codes, Analyzer Codes & CEMS Codes are meaningless to the preparer
• It’s difficult to keep them straight!
![Page 19: EcoChem Analytics](https://reader035.fdocuments.in/reader035/viewer/2022081721/568159a6550346895dc706d3/html5/thumbnails/19.jpg)
19
19
Application Experience Application Experience (Cont’d)(Cont’d)
• Regurgitate many of the standards in the CSMM
• Defining the Lowest Monitored Standard (LMS)
• LMES now replaces the old “Span”
![Page 20: EcoChem Analytics](https://reader035.fdocuments.in/reader035/viewer/2022081721/568159a6550346895dc706d3/html5/thumbnails/20.jpg)
20
20
Interaction with DepartmentInteraction with Department
• Phase I Pre-submittal teleconference is beneficial
• Also beneficial to speak with Bob Vollaro of EPA to review Part 75 issues
• There was little or no communication unless we initiated it
• Phone call follow-ups were initiated starting in December
![Page 21: EcoChem Analytics](https://reader035.fdocuments.in/reader035/viewer/2022081721/568159a6550346895dc706d3/html5/thumbnails/21.jpg)
21
21
Interaction with Department Interaction with Department (Cont’d)(Cont’d)
• Exchanged LMES calculations via FAX in January
• They opted not to visit the plant during installation or testing
• Communication via letter stimulated the best response
• The Department is still working to understand all the nuances of Rev 7.
• Their plates are FULL.
![Page 22: EcoChem Analytics](https://reader035.fdocuments.in/reader035/viewer/2022081721/568159a6550346895dc706d3/html5/thumbnails/22.jpg)
22
22
RecommendationsRecommendations
• Schedule an informal pre-submittal conference
• Build a lot of time into your schedule– 1 year from Phase I submittal to
Certification• Submit your project schedule with
the Phase I• Understand & be clear about your
LMES calculations in your Phase I
![Page 23: EcoChem Analytics](https://reader035.fdocuments.in/reader035/viewer/2022081721/568159a6550346895dc706d3/html5/thumbnails/23.jpg)
23
23
Recommendations (Cont’d)Recommendations (Cont’d)
• Keep your project on the radar screen after the Phase I is submitted
• Submit your Phase II early• Correspond with the Dept in
writing about project milestones• Make sure the Dept understands
your Part 75 issues
![Page 24: EcoChem Analytics](https://reader035.fdocuments.in/reader035/viewer/2022081721/568159a6550346895dc706d3/html5/thumbnails/24.jpg)
24
24
CEM Supplier Perspective on CEM Supplier Perspective on PADEP Rev. 7 PADEP Rev. 7
• Awaiting Responses Caused Project Delays
• Phase I Submittal Approval took >4 months
• Rev. 7 Phase I Electronic Version confusing
• Reconciling NOx Budget, Part 60 and PADEP overlapping requirements inefficient
• PADEP Going Thru Transition
![Page 25: EcoChem Analytics](https://reader035.fdocuments.in/reader035/viewer/2022081721/568159a6550346895dc706d3/html5/thumbnails/25.jpg)
25
25
Benefits of More Current CEMBenefits of More Current CEM Beside Simply Meeting Beside Simply Meeting
RegulationsRegulations• Hot-wet system provides
moisture concentrations – assists with auditing tube leaks
• New sample system and automatic audits reduces manual oversight
• Enhanced remote troubleshooting reduces frequency of lengthy E&I staff call-outs
• Convenient format and data access useful management tool
• Avoid total obsolescence
![Page 26: EcoChem Analytics](https://reader035.fdocuments.in/reader035/viewer/2022081721/568159a6550346895dc706d3/html5/thumbnails/26.jpg)
26
26
Operator Interface and Operator Interface and Remote System AccessRemote System Access
• Presents data in larger color screen
• Most functions 1-2 touch screen taps
• Provides meaningful system history to do troubleshooting right at the CEM location (fewer trips back and forth to control room or office)
• Can control the system remotely
Excel PC Anywhere
![Page 27: EcoChem Analytics](https://reader035.fdocuments.in/reader035/viewer/2022081721/568159a6550346895dc706d3/html5/thumbnails/27.jpg)
27
27
A Contrast in Case HistoriesA Contrast in Case Histories
• Removed old system and installed new CEM in three days – during scheduled outage
• No overlap with original CEM• RATA test within 10 days• No “Phase I” submittal
– letter notification• No NOx Budget Issues
Waste Coal Plant – Utah
![Page 28: EcoChem Analytics](https://reader035.fdocuments.in/reader035/viewer/2022081721/568159a6550346895dc706d3/html5/thumbnails/28.jpg)
28
28
EcoChem’s Suggestions EcoChem’s Suggestions for a “Win-Win” CEM Upgradefor a “Win-Win” CEM Upgrade
• Build in sufficient scheduling contingency - allow 9-12+ months depending upon scope
• Allow appropriate overlap with existing CEM – You usually don’t have a choice!
• Don’t forget training and spare parts inventory
• Use experienced CEM integrator & DAS vendor
• Pray for Rev 8 to be more efficient