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Continuous EmissionsMonitoring System II
Gasmet Technologies, April 2010
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INTRODUCTION
Continuous Emissions Monitoring System II
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Background
First Gasmet CEMS was introduced in2001
System and software has been modified
during last years but not dramatically Over 160 CEMS and 60 sub systems has
been supplied until today world wide
Continuous improvement is required toremain competitive
CEMS must be easier to use and maintain Legislation demands vary in different countries
Price competition
More FTIR competitors
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CEM II Introduction New sampling system
Controller and heated pump/filterpackage in one 19 enclosure
TCP/IP connection to computer
New I/O approach Beckhoff K-bus modules for analog
and digital I/O
PCI expansion cards are not needed
Smaller cabinet 600x600x2150mm
Air conditioning unit included inabove dimensions
Complete cabinet can be shipped on apallet (CX4000 in separate box)
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CEM II & CEMS Comparison
600 600 mm footprint
Entire sampling unit in 19 enclosure, 4 U high
Glass door, display visible when door closed
Height with air conditioning unit 2150 mm
800 800 mm footprint
Separate sampling unit controller and hot box
Door must be opened to see display
Height with air conditioning unit 2450 mm
CEM IICEMS
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600 600 mm footprint
Access space required for door opening:1800 600 mm
Clean side panels, no side clearancerequired
Two CEM II systems often fit in thespace required for one old CEM system
800 800 mm footprint
Access space required for door opening:2400 800 mm
Additional side clearance required formain switch and optional side-mounted airconditioning unit
Height with top mounted air conditioning
unit 2450 mm may be a problem
CEM II & CEMS Comparison
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BASIC STRUCTURE
Continuous Emissions Monitoring System II
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CEM II Basic Structure
Computer
Sampling System
ZrO2 analyzer
Keyboard
Gasmet CX-4000 FTIROption with TDL O2 laser
TFT Display
Cooling Unit
Sample Gas In
Sample Gas Outlet:
left or right side wall
3 x 16 A, 230 VAC
(opt. 115 VAC)
Analog inputs / outputs
Digital / Relay outputs
Fieldbus
Zero Gas In (N2)
Span Gas In
Instrument air In
Cabinet equipped with socle or wheels (option)
Drawer(s) for spare parts and manuals
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GASMET Cx-4000 FTIR Gas
Analyzer Gasmet GICCOR interferometer
Excellent temperature andvibration stability
High signal to noise ratio
Peltier cooled MCT detector
Heated sample cell 180 C
Option with TDL O2 laser
Optical paths 2.5m, 5m or 9.8m
Measuring ranges from low ppm up tohigh % level
RS-232 output to industrial computer
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ZrO2 Oxygen Analyzer
ZrO2 technology
TV approved
Detection limit < 1 ppm
4-20 mA output
Automated single point
calibration possible with CEM IIsampling system
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GASMET Industrial Computer Specifications:
2,4 GHz Pentium IV processor
512 MB memory
2 x 40 GB hard discs with rack
RAID I Disk operating system
1 x 40 GB empty spare disk
Windows Xp operating system
DVD-RW
Modem & Network card + PC
Anywhere Hardware watchdog support
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Sampling Unit One 19 rack mounted unit including all
valves, flow switch, pump, filter, flowmeters and a PLC controller
Sample flow and instrument air pressurealarms
PLC controller in sampling unit removesthe need for PCI slots in computer. All I/Ofrom computer is routed through the PLCin the sampling system (except RS-232)
Temperature controllers for heated sample
lines and oven are controlled by theCalcmet software.
Connected to Gasmet computer viaEthernet cable. Maintenance switch infront panel
Separate models for 100-115 VAC and 230VAC / 50 - 60 Hz
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Sample Probe M&C SP2000-H
Weather protection shield
Mounting flange DN 65 PN 6B
Operating temperature 0-180 C,
Dust loadings < 2 g/m3
Sample tube SP2000-SS
Material SS316
Lenght 1 m
Sample gas temperature 600 C
Heated probe tube recommended
in wet applications Higher temperatures and dust
loadings on request
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Heated Lines Specifications
Operating temperature up to 180 C
Teflon (PTFE) inner core, replaceable
6 mm outer diameter (4 mm ID)
Nylon braid external jacket
230 VAC power supply
Options
Rigid plastic jacket
115 VAC power supply
PFA tubing instead of PTFE
1/4 outer diameter tubing Integrated power and alarm cables for probe
Calibration gas tube for performing span and zero checks via probe
Color coding
230 VAC versions - red stripe
115 VAC versions - yellow stripe
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Cabinet (Standard)
Cabinet size600x600x2150mm
Cooling unit on the top
Front door and back door
Front door with window Standard door opening
directions shown
Other directions availablefor extra cost
Plinth or wheels below the
cabinet Connector plate behind the
TFT display
Easy access to terminals
1. Computer2. Keyboard3. Sampling Unit4. Oxygen analyser5. CX4000 FTIR analyser6. Air conditioning unit7. TFT display & Connector plate
8. Drawer for Spare parts
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Cabinet (Option)
Cabinet size600x800x2100mm
Cooling unit on the back door
Front door and back door
Front door with window Standard door opening
directions shown
Other directions withextra charge
Wheeled cabinet not available
Additional rack space for e.g.FID analyser
Deeper cabinet (800 mm)ensures that larger analyserswith more connectors in therear can be easily installed
1. Computer2. Keyboard3. Sampling Unit4. O2 analyzer5. CX40006. Air conditioning unit (rear door)7. TFT display & Connector plate
8. Drawer for Spare parts
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SAMPLING SYSTEM
Continuous Emissions Monitoring System II
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Sampling System Flow Diagram
Sample gas in
0.5 lpm to oxygenanalyzer4 lpm to FTIRanalyzer
Instrument air in Spangas in
Zero gas inTypically N2 (quality 5.0) or Synthetic air (N2 80%,O2 20%)
Instrument air backflush and spangas feed to probe are standard
features Instrument air must be connected
in order for the system to startmeasurement
Multipoint sampling and multiplespan gases are available as
external valve manifolds
White = NO, valve normally openBlack = NC, valve normally closed
Shuttle valve
Back blow
valves
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Sampling Unit
Sampling unit contains
Heated pump (180 C, PTFE membrane) Particle filter (sub-micron, sintered 316L steel)
Flow alarm sensors (FTIR & O2)
Solenoid and shuttle valves for controlling sample and test gas flow
Rotameters for adjusting flow of test and purge gases
Programmable controller with I/O interface to computer running Calcmet
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Sampling Unit Gas Connectors
GAS INPUTS
Sample gas (heated)
Span gas
Zero gas
Instrument air
GAS OUTPUTS
Sample out 1 (heated), FTIR
Sample out 2 (heated), O2
Span gas to probe
Interferometer purge air
O2 reference air
All gas connections are made using6 mm Swagelok fittings located onback panel
Line holders for heated lines (notshown)
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Sampling Unit Pump & Filter
FILTER
Bonded microfibre or sintered steel
filtration of particulates 2 m or 0,1 m
Temperature 180C
PUMP
Material ss-316
PTFE diaphragm
Flow 4 l/min
Temperature 180C
Sample gas pressure 1,5 bar max
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Sampling Unit Valves
INSTRUMENT AIR VALVES
Sample gas / backflush
SOLENOID VALVES
Span gas via sample out
Span gas via probe Zero gas
Safety air
BACK BLOW VALVES
Sample gas / backflush
Maintenance gases
Cracking pressure 0.14 bar
Automatic solenoid valves for
gas inlets and back blow valves
to avoid sample gas flow to
unheated side.
Sample gas/ flush gas valve isoperated using instrument air
Instrument air pressure range 0
- 10 bar (max.)
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Sampling Unit Flow meters
FLOW 4 l/min
Safety air
Zero gas
Span gas to sample out
FLOW 0.5 l/min
Interferometer purge
O2 analyser reference air
Adjustable flow meters for
unheated gases
Located on front panel
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Sampling Unit Temperature
Controllers TEMPERATURE CONTROLLERS Sampling unit includes
thermocouple analog inputs for
heated module and for three
sample lines.
Range 0 180 C
Type TcK
Sample line 1 connector has 24
VDC control for external solid
state relay.
Temperature display in Calcmetsoftware
Temperature control circuit in
Beckhoff BC9000 controller
inside sampling system
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Sampling Unit I/ODIGITAL OUTPUTS (24 DVC)
Alarm outputs are displayed onLED lights and unit hascorresponding digital outputs.
Alarm outputs are:
System alarm,
Service request,
Maintenance
(can be set also manually),
Concentration alarm,
Result valid Combination for each alarm can be
set in Calcmet.
Unit has digital output commandto start Oxygen analysercalibration
DIGITAL INPUTS
Digital inputs are:
Cabinet air condition unitcooling alarm,
Cabinet temperature,
Probe temperature,
Zero gas pressure,
Oxygen analyser alarm
It is also possible to activate spangas test via probe or System
standbyby digital input.
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Sampling Unit I/O to CalcmetCOUNTERS
Pump membrane age in hours
All valve ages in times
DIGITAL INPUTS
Cabinet air condition unit coolingalarm,
Cabinet temperature,
Probe temperature,
Zero gas pressure,
Oxygen analyser alarm
SENSORS
Sample out 1 flow low
Sample out 2 flow low
Instrument air pressure low
Maintenance switchTEMPERATURES
Sample Line 1 temp & alarm
Sample Line 2 temp & alarm
Sample Line 3 temp & alarm
Heated module temp & alarm
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