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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


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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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


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


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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


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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



Heated module temp & alarm

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