<CEMS> - JDL Design, Engineering - Automation

INTRODUCTION:

JDL Design offers integrated solutions for various applications such as compliance monitoring, process control, etc. The system concept is based on the DAHS and PLC arrangement with specifically designed software to coordinate communications with all system components in order to meet all criteria of the EPA regulations. Open-architecture software and state-of-the-art equipment provide great flexibility, thus insuring certifications and meeting monitoring needs of SCAQMD RECLAIM DAHS/RTU 2011 &2012, SCAQMD 218 & 218.1, EPA CFR 40 parts 60 & 75 and other applicable regulatory requirements.

The JDL M800 is a third generation extractive CEMS that consists of a heated sample probe, controlled heated sample line, sample conditioner, vacuum pump, flow and pressure control system, programmable logic controller (PLC), data acquisition and handling system (DAHS), and set of analyzers and sensors based on customer application and system enclosure. Using the vacuum pump, the temperature controlled sample train removes particles and provides timely delivery of the sample gas to the sample conditioner, where moisture removal finalizes sample preparation. The flow and pressure control system is responsible for the distribution of the sample gas between different analyzers and sensors, the purge of the sample probe, and the directing of sample gases for remote and local calibration. The analyzers detect the concentration of each gas present at the sample and send the output to the PLC. The PLC performs signal conditioning, calculations, calibration sequencing, purging of the probe, and the distribution of the all signals and alarms to the DAHS.

SYSTEM OVERVIEW:

DAS. The JDL DAHS consists of a PowerEdge server using RAID 5 technology and multiple power supplies in order to ensure continuous operation during a system fault. Each DAHS system provides control, data calculation, data logging and EDR file generation for two JDL M-400 units. Control is provided using the web-enabled FactoryLink ECS Server software package, which allows the user to directly control valves, initiate and abort manual calibration (either to the sample line or locally to the analyzers only), view vital system parameters on trend screens, and view all system parameters as text. Calibration gas bottle values and identifications are entered here, providing a log of all calibration gas changes. The Alarm Log allows entry of comments for each individual alarm instance. All data is stored on a Microsoft SQL Server database. The system is sized so that up to 10 years of data may be stored on the hard disks. This data can be shared with most performance-monitoring systems or Distributed Control Systems.

EDR file generation is performed using the InfogenEPAXML software module. This module also handles the RATA and other test results entry.This package runs concurrently with the control package so that users may print historical reports from any data in the database.

JDL Design is now offering our 3rd generation software code name ECMPS XML embracing XML technology to meet the latest requirements by the EPA Acid Rain program. All EDR reports must be 100% XML compliant by the first quarter of 2008.

FUNCTIONAL DESCRIPTION:

PROBE. The sample probe consists of a flange, probe tube, exchangeable filter element, self-limited heater with low temperature alarm, and isolated inlets for the purge air and calibration gas. The sample probe design allows for 1) the purge filter and sample tube with high-pressure instrument air to blow off particulates that may restrict sample flow and 2) the injection the calibration gases into the probe to provide complete verification of the entire system. The versatile but low maintenance sample probe can be used for various applications depending upon the task to be performed. The sample probe housing material and filter element media are selected to fit each process specification for reliable operation.

HEATED SAMPLE LINE, VACUUM PUMP AND SAMPLE CONDITIONER. The heated sample line provides stable temperature transportation for the sample gas to prevent condensation from the sample probe to the sample conditioner and delivers calibration gases from the calibration manifold to the sample probe. It consists of several Teflon tubes, heater elements, thermal insulation, temperature sensors, and messenger wires. The vacuum pump provides a steady sample flow and pressure to insure maximum performance and optimum system response time. All parts and surface material in contact with the sample are always carefully selected to suit each application. The final sample preparation is completed by using an integrated sample conditioning system, which consists of a thermoelectric cooler, peristaltic pump, and moisture detection sensor.

FLOW AND PRESSURE CONTROL SYSTEM. The functions of this system are to provide switching between sample streams, calibration gases, purge air, and local and remote calibration on PLC commands. It consists of a set of flowmeters, gauges, regulators, and manifolds with solenoid valves. The flow diagram always depends on each application and the number of analyzers in the system.

GAS ANALYZERS. The process of the selection of the gas analyzers is based on the rules and regulations of the EPA. High performance, ease of use, low maintenance, reliability, and cost effectiveness are always the aspects by which these analyzers are selected, but the customer’s preferences are taken into consideration at all times.

SYSTEM ENCLOSURE.Several different sizing options are available depending on the needs of the application. The variations include: stand-alone, dual or single bay 19” rack mount cabinet, NEMA-12, -4 or 4X with HVAC, and a wall mounted cabinet with the same NEMA rating. Also it can be in a CEM shelter with HVAC to house the analyzer rack, PLC, DAHS, a workbench for CEM technicians and cylinder racks.