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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
© ABB Group
EN 14181 – The second editionType of plants involved
May 21, 2014 | Slide 3
© ABB Group
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
© ABB Group
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
© ABB Group
22222
otherspresvolttempinstAMS uuuuus
Shewhart Control ChartsExample
May 21, 2014 | Slide 6
© ABB Group
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
© ABB Group
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
© ABB Group
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
© ABB Group
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
© ABB Group
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
© ABB Group
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
© ABB Group
Cold / Dry extractive operating AMSQAL 3 span check with gas filled adjustment cells
May 21, 2014 | Slide 13
© ABB Group
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
© ABB Group
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
© ABB Group
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
© ABB Group
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
© ABB Group
© 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
© ABB Group
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
© ABB Group
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
© ABB Group
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
© ABB Group
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
© ABB Group