CEM. Continuous Emission Monitoring Systems NACT 221. Course Overview. National Air Compliance Training. CEM implementing regulations

Transcription

1 National Air Compliance Training Continuous Emission Monitoring Systems NACT 221 Course Overview CEM implementing regulations CEM basic theory and operation CEM system components System certification requirements Inspection and quality assurance Continuous Emission Monitoring Monitoring Methods VEE Manual CEM Extractive In-Situ Predictive 1

2 Purpose of CEMS Regulators View Determine emission compliance Identify periods of excess emissions Assess control equipment efficiency Monitor operating parameters Validate emission credits Public perception reports Haz. Waste Incinerators Municipal Waste Combustors APCD Purpose of CEMS Industry View Comply with regulations Demonstrate compliance Monitor control equipment Monitor process parameters Validate emission credits Complaint protection Plant safety PG&E CEM Systems & NSPS 2

3 CEM Systems & NSPS NSPS for many categories NOx, SOx, PM. PG&E Source Testing Reference Methods CEM Systems CEM Implementing Regulations Federal NSPS 40 CFR 60, App. B RCRA 40 CFR 264 & 266 CAAA (1990) 40 CFR 75 (Acid Rain Program) Credible Evidence Rule Compliance Assurance Monitoring (CAM) CEM Implementing Regulations State NSPS delegation SIP 40 CFR 51, App. P Operating Permits Discretionary programs Implicit programs CEM QA Manual CEM Guidance Document 3

4 NSPS CEM Requirements (Partial Listing) FFFSG (D) - Opacity, SO 2, NO x Portland Cement Plants (F) - Opacity Kraft Pulp Mills (BB) - Opacity, TRS Municipal Waste Combustors (Ea) - Opacity, SO 2, NO x, CO Part 75 Steam/Electric Generators - SO 2, NO x, Velocity, Opacity Parameter Monitoring : PEMS Fuel sensors (consumption) Water/fuel ratio (NOx reduction) Ambient TPH sensors (heat efficiency) Operational & EER Reports Apply RATA & PS NOx SOx CO PEMS Unit Graphic Courtesy of Solar Turbines 4

5 as Compliance Instruments Some NSPS Subparts : are designated as direct compliance instruments. California considers all at delegated NSPS sources to be direct compliance instruments. CEM: Compliance Instruments Federal Guidance Standards Setting Test Methods Performance Specifications 40 CFR 60, Appendix B 40 CFR 75, Appendix A Quality Assurance Criteria 40 CFR 60, Appendix F Enforcement Guidance Feds Always Write Simple Rules!! 5

6 Performance Specs : Gauge PS 1 - Opacity Monitors PS 2 - SO 2, NO x CEMS PS 3 - CO 2, O 2, CEMS PS 4 - CO CEMS PS 5 - Total Reduced Sulfur (TRS) CEMS PS 6 - Rate (Velocity) Monitors PS 7 - Hydrogen Sulfide (H 2 S) CEMS PS 8 - VOC CEMS PS 9 - Gas Chromatograph CEMS PS 11 - PM CEMS PS 12 - Hg CEMS PS 16 - PEMS (Predictive) NSPS 40 CFR 60 B Typical CEM Sources B & W Utility Boiler 6

7 Utility Boiler with Steam Turbine Cement Kiln Utility Boiler w/scr 7

8 Bio Mass Utility Boiler Municipal Solid Waste Boiler Rotary Kiln 8

9 Gas Turbine Power Plant Kraft Pulp Paper Mill FFFSG CEM Units 9

10 CEMS Monitors Opacity Sulfur Dioxide Nitrogen Oxides Carbon Dioxide Carbon Monoxide Oxygen VOC Hydrogen Chloride Ammonia Total Reduced Sulfur Hydrogen Sulfide Gas Velocity Mercury Systems Classifications Source Monitoring Systems Extractive Systems In-Situ Systems Predictive Systems Dilution Non-dilution (source level) Point Path In-Stack Out-of-Stack Dry Wet Single Pass Double Pass Extractive & In-Situ Systems 10

11 Extractive & In-Situ Systems Extractive Systems Gas extracted Transported to analyzer Concentration of pollutant is measured In-Situ Systems Point systems Path systems Let s Discuss CEM Opacity Monitors Opacity Transmissometer CEM System - Opacity Monitoring 11

12 Plume Opacity OPACITY The fraction of light that is attenuated by an optical medium (Op) TRANSMITTANCE The fraction of light that is transmitted through an optical medium (Tr) Op = 1 - Tr Plume Opacity Percent Transmission Percent Opacity Ringelmann 12

13 Transmissometer Opacity Transmissometer Opacity Monitor 13

14 Opacity Retro-reflector Double Pass Transmissometer Purge Air System 14

15 Dirty Air Blower System Double Pass Transmissometer Opacity Monitor Panel 15

16 Performance Specifications (PS1) Peak & Mean Spectral Responses Angle of View Angle of Projection Optical Alignment Sight Simulated Zero & Upscale Calibration System Design Specification Verification Test Each Analyzer OR Obtain Certificate of Conformance from Manufacturer Measurement Locations Representative Emissions Accessible Routine Maintenance Performance of Calibration Audits & Checks Downstream from Control Equipment No Condensation near Monitor No Presence of Ambient Light 16

17 Representative Sample and Accessibility Particle Stratification & Plane of the Bend Downstream from CE 17

18 Access Transmissometer Calibration 40 CFR 60 Appendix B Opacity Performance Specs Lab Tests Cal error < 3% opacity Response time < 10 s (0-95%) Field Tests Conditioning period Operational test period 24 h zero drift 24 h calibration drift Data recorder resolution 168 h 168 h < 2% opacity < 2% opacity < 0.5% opacity 18

19 Transmissometer Audit Audit Filters Self Calibration Error Check 19

20 Let s Discuss CEM Flow Monitors Emission Rate Monitoring CAAA Sec. 412 : Velocity Monitors PMR = C S A S V S PMR = Pollutant Mass Rate C S = Concentration A S = Stack Area V S = Stack Gas Velocity lbs/hr = (lb/ft 3 ) (ft 2 ) (ft/hr) Allowance Program Differential Pressure Measuring 20

21 Differential Pressure Measuring Standard Pitot Tube Type S Pitot Tube Stack Velocity Stratification 21

22 Annubar Used to Determine Flow Rate Thermal Flow Sensor Acoustic Velocity Measurement 22

23 Flow Monitor Let s Discuss CEM Extractive Systems CEM Extractive System 23

24 Extractive Systems Case by Case : No Best System Source Level - Direct Systems Cool - Dry Hot Wet Dilution Systems In - Stack Out - of - Stack Extractive Systems Advantages Versatile & Flexibility in Location Ease of Maintenance Disadvantages May Alter Sample Response Time May be Slow Maintenance Cost & Frequency CEM Stack Gas Probe Area 24

25 Extractive System Components Probe Particulate Filter Moisture Conditioning System Pump & Sample Line Controller Analyzer Data Analysis CEM Gas Sampling Probe External Probe Filters 25

26 Filter Blow Back Internal Coarse Filter Inertial Filter 26

27 Let s Discuss CEM Sample Lines Sample Line : Umbilical Assembly CEM Umbilical Cord 27

28 Refrigerated Condensers Moisture Removal Jet Stream Condenser Permeation Dryer 28

29 Sampling Pumps : Ejector Pump Diaphragm Pump Let s Discuss Dilution Systems 29

30 Dilution Systems Dilution Systems Dilution Probe Dilution Probe 30

31 Dilution Probe Q1 = Dilution Air Rate (Lit/min) Q2 = Sample Gas Flow Rate (Lit/min) Dilution Air Cleaning System Let s Discuss CEM Gas Analysis 31

32 CEM Analytical Techniques Infrared Methods Differential Absorption Gas Filter Correlation Fourier Transform Infrared Ultraviolet Methods Differential Absorption Second Derivative Spectroscopy Visible Light - Opacity Measurement Scattering & Absorption CEM Analytical Techniques Luminescence Methods Fluorescence & CVAFS Chemiluminescence Flame Photometry Electroanalytical Methods Polarography Electrocatalytic Paramagnetism Conductivity Normal Vibration of SO 2 Molecules 32

33 Beer-Lambert Law Absorption of light related to: Absorption coefficient dependencies Wavelength of light Properties of the pollutant molecule Number of molecules in light path Concentration Path length Simplified Stack Sample System I O I Calibration Plot Calibration Gas #1 ln 1/Tr Unknown Calibration Gas #3 Calibration Gas #2 Concentration of unknown Gas Concentration (c) 33

34 Non-Dispersive UV Analyzer I = 285 nm I O = 578 nm Fluorescence SO 2 Analyzer Non-Dispersive IR Analyzer I I O 34

35 Let s Discuss GFC CO Analyzer Gas Filter Correlation Analyzer I O I 35

36 Looking Inside a GFC CO Analyzer NOx & CO Analyzer Chemiluminescence NO x Analyzer 36

37 Thermo Environmental Chemiluminescence NOx Analyzer Electrocatalytic O 2 Analyzer O 2 = 3% O 2 = 20.9% O 2 & CO Analyzer 37

38 Sample Lines Key New Rules w/pm CEMS Measurement Options or Requirements Mercury Air Toxics Standards (MATS) for Utility Boilers (Subpart UUUUU) Compliance date 4/16/2015 Portland Cement MACT Compliance date 9/9/2015 Commercial/Industrial Incinerator MACT (CISWI) Compliance date 8/7/2013 Boiler MACT Compliance date 1/31/2016 Sewage Sludge Incinerator MACT (SSI) Earliest compliance date 3/21/2016 PM CEMS Analytical Techniques Beta Attenuation Light Scattering Hybrid with TEOM In Situ or Extractive Venders Sick Maihak ThermoFisher M & C Particle Tracker PCME MSI Teledyne-ML Altech Beta 38

39 PS11 for PM CEMS Certification Testing Requirements 7-day calibration drift test Measurement responses correlated to RM concentrations Correlation source-specific Key New Rules w/hg Measurement Requirements Mercury Air Toxics Standards (MATS) for Utility Boilers (Subpart UUUUU) Compliance date 4/16/2015 Portland Cement MACT Compliance date 9/9/2015 Commercial/Industrial Incinerator MACT (CISWI) Compliance date 8/7/2013 Boiler MACT Compliance date 1/31/2016 Sewage Sludge Incinerator MACT (SSI) Earliest compliance date 3/21/2016 Hg CEMS Measure gaseous Hg Elemental (Hg 0 ) Oxidized (Hg 2+ ) Almost all convert oxidized Hg to elemental Hg for measurement of total gaseous Hg Calibrate using NIST-traceable mercury gas generators or cylinders 39

40 PS12A for Hg CEMS Certification Testing Requirements 7-day calibration drift test -- with Hg 0 or Hg 2+ Measurement error test -- 3 levels with Hg 0 and Hg 2+ Relative accuracy against a RM Sorbent Trap Monitoring System Background Integrated sample measures total gaseous Hg For post-pm control locations Paired traps, in-stack w/3 sections Proportional sampling PS12B for Sorbent Trap Monitoring Systems Sampling/analytical requirements Sampling train and operations Sampling/sample QA Certification testing requirements Spike recovery study Sorbent capture capability Analytical capability Relative accuracy against a RM 40

41 Appendix F, Procedure 5 For Hg CEMS Daily calibrations -- with Hg 0 or Hg 2+ Weekly system integrity check with Hg 2+ Quarterly RAA or 3-level gas audit with Hg 0 and Hg 2+ Annual relative accuracy test audit (RATA) For sorbent trap monitoring systems Annual RATA PS12B, not Procedure 5, specifies routine QA/QC (leak checks, calibrations, paired train agreement, spike recovery, breakthrough) Control Panel Let s Discuss CEM Data Acquisition 41

42 CEM Data Acquisition System CEM DAS CEM System Interface 42

43 ROLLING AVERAGES 3 Hour Block and Rolling Averages 3-HOUR ROLLING AVERAGE HOUR 1 NO AVERAGE HOUR 2 NO AVERAGE HOUR 3 AVERAGE OF HOURS 1, 2 & 3 HOUR 4 AVERAGE OF HOURS 2, 3 & 4 HOUR 5 AVERAGE OF HOURS 3, 4 & 5 HOUR n AVERAGE OF HOURS n-2, n-1 & n 43

44 Subpart Da 30 Day Rolling Average US EPA ARB Emissions Reporting Air Districts Emission Data Summary Duration of excess emission reporting period due to: Startup & shutdown Control equipment problems Process problems Other known causes Unknown causes Total duration of excessive emissions divided by the source operating time x 100 = % 44

45 Monitoring System Performance Report CEM performance summary Monitor equipment malfunctions Non-monitor equipment malfunctions QA calibrations Other known causes Unknown causes Total CEM downtime divided by the the total source operating time X 100 = % downtime Let s Discuss CEM Gas Calibration CEM Dilution System Calibration 45

46 Probe Calibration Gas Points Extractive Systems Calibration Drift (Error) Test The tests examine the CEM system s ability to hold its calibration over a period of time. 40 CFR 60 Appendix B : Calibration Drift Test 40 CFR 75 Appendix A : Calibration Error Test (NIST Ref. Material gases) PST Calibration Drift Test Zero and high level drift tests examine a CEM s ability to hold calibration over a period of 168 hours with more than 50% of normal plant load 24-hr intervals for 7 consecutive days 46

47 Calibration Drift Criteria Cylinder gas reference value - Monitor value CD = Span value X 100 Calibration drift is calculated as a % CEM system may not exceed the drift specifications for any one of the 7 days of the test Zero (low-level) drift Span (high-level) drift Performance Drift Specs PS GASES CAL DRIFT 2 SO 2, NO X 2.5% of span value 3 O 2, CO 2 0.5% of gas reference value 4 CO 5% of span for 6 of 7 test days 5 TRS 5% of span for 6 of 7 test days 7 H 2 S 5% of span for 6 of 7 test days 8 VOC 2.5% of span value Out-of-Control Conditions 40 CFR 60 Appendix F Either the low or high level calibration check result is greater than 2 times the PS drift for 5 consecutive days or 4 times the drift for any one day 40 CFR 75 System is out of control if the drift exceeds 2 times the PS drift 47

48 Calibration Gas Hierarchy Calibration Gases Cal Gas Certificate Points Cylinder ID number Certified concentration Balance gas Cylinder pressure Certification date Expiration date Reference standard data Statement of procedures Lab and analyst ID Gas analyzer ID and cal date Analyzer readings & calc used Chronological cert record 48

49 Cal. Gas Certification Expired Calibration Gas Calibration Gases 49

50 Bird Nest?? Let s Discuss CEM Quality Assurance CEM QA Program A Total CEM System Quality Assurance Program Procurement Quality Control Installation & Certification Continuing Operation Record Keeping Preventive Maintenance Corrective Maintenance System Audits Audits Agency Audits Performance Audits 50

51 40 CFR 60.8 & Test Time Frame PST Pretest Meeting Plant operation at test time Control equipment status CEM operational status Test schedule Test procedures & cal gas used Exceptions Test report requirements Plant tour QA Program : 40 CFR 60 App. F & 40 CFR 75 App. B CEM system calibration and QC checks Calibration drift determination and system adjustment Preventative maintenance of system including spares Data recording, calculations, and reporting Accuracy audit procedures including sampling and analysis methods System malfunction corrective actions. 51

52 CEM AUDITS Systems Audit Qualitative Evaluation Performance Audit Quantitative Evaluation Relative Accuracy Test Audit (RATA) Cylinder Gas Audit (CGA) Relative Accuracy Audit (RAA) Cylinder Gas Audit (CGA) Required once per quarter One audit gas (NIST traceable) 20-30% of span The other gas (NIST traceable) 50-60% of span Challenge the CEM system 3 times with each gas CEM relative accuracy 15% (40 CFR 60) CEM relative accuracy 5% (40 CFR 75) 52

53 Relative Accuracy Test Audit Relative Accuracy Test Most important part of Performance Specs. Most expensive to perform Coordination is important RATA conducted to determine : if CEM system will give data that can be compared with data obtained using EPA Reference Methods Relative Accuracy Test Audit (RATA) vs. CEM 53

54 Typical Source Test CEM RATA Test CEM Shelter 54

55 Relative Accuracy RA = d + CC RM * x 100 *Or applicable subpart standard RATA Procedure Min. of 9 data sets obtained Each set of data : min. 12 data sets might be taken Tester may reject 3 data sets Rejected data must be reported See Handout for RATA Calculations Part 60 RATA Specs PS GASES RELATIVE ACCURACY 2 SO 2, NO X 20% of RM value in units of the standard 10% of applicable standard ( >130 ng/j) 15% of applicable standard ( >86 <130 ng/j) 20% of applicable standard (<86 ng/j) 3 O 2, CO 2 20% of RM value or 1.0% (whichever is greater) 4 CO 10% of RM mean value in units of the standard 5% of app. emission standard (whichever is greater) 5 TRS 20% of RM mean value in units of the standard 10% of app. emission standard (whichever is greater) 7 H 2 S 20% of RM mean value in units of the standard 10% of app. emission standard (whichever is greater) 55

56 CEM Inspection Probe Umbilical Conditioning Dilution Air Calibration Gas Analyzers DAS & Audits Data & Records Enforcement Using Emission violations Percentage reduction violations Data capture violations Operation and maintenance violations Procedural and reporting violations Thank You 56