Purchase_Description;_Continuous_Emission_Monitoring_System_dtd_18_Decem....pdf

18 December 2018

Purchase Description

Continuous Emission Monitoring System

1) GENERAL REQUIREMENTS

a) PURPOSE OF THIS SPECIFICATION

To define a continuous emission monitoring system (CEMS) for measuring CO, and O2 which meets federal and state regulatory monitoring requirements for installation on the APE 1236 deactivation furnaces at Tooele Utah, Crane Indiana, McAlester Oklahoma and Kiwakama Japan.

b) RELATED DOCUMENTS

i) Must comply with federal regulation 40 CFR Part 60 appendix b and Appendix to Subpart

EEE of Part 63.

ii) Must comply with local operating permits

iii) Must comply with local Installation site drawings

c) SUMMARY OF SPECIFICATION

i) Part 2 of this Specification includes a description of the plant, process, and installation site conditions including composition of gas to be measured.

ii) Part 3 of this section of the Specification contains the technical and performance requirements of the continuous emission monitoring system.

iii) Part 4 of this section contains the requirements for services to be provided for each individual CEMS system. This includes but is not limited to:

(1) Services to be provided by CEMS supplier

(2) Work and material by others.

d) SUPPLIER QUALIFICATIONS

i) All suppliers of equipment supplied by this specification shall have an acceptable history of supplying satisfactory reliable systems in use for a period of at least five years.

ii) Acceptable bidders must be analyzer manufactures as well as system suppliers.

iii) Acceptable bidders must have ISO 9001 quality certification.

iv) Acceptable bidders must provide 24 hour telephone access to technical support personnel skilled with this instrumentation.

e) DELIVERY

i) The supplier shall deliver equipment to the project site in accordance with manufacturer’s shipping requirements. Project schedule requirements include:

(1) Drawing delivery 2 months after award

(2) Hardware delivery to site: 4 months after drawing approval and after factory acceptance test (FAT).

2) PART 2- PROCESS AND APPLICATION CONDITIONS

a) APE 1236 Deactivation Furnaces

b) Hazardous waste combustor flu gas at the stack with natural gas or fuel oil burners.

c) EMISSION CONTROL EQUIPMENT include a baghouse and id fan.

d) CEMS INSTALLATION SITE

i) Probe location in stack at least 15 feet from ground.

ii) Analyzer cabinet will be in an environmental controlled equipment shed.

iii) Sample line length will be less than 100 feet.

e) GAS CONDITIONS AT INSTALLATION SITE

i) Gases to be measured and measurement ranges

(1) CO : typical concentration 3 ppm, max concentration 3000 ppm, measurement range 0-

200 ppm and 0-3000 ppm.

(2) O2 : typical concentration 12%, max concentration 21%, measurement range 0-25%.

ii) Coexisting gases and concentrations

(1) H2O : typical concentration 10%, max concentration 40%

iii) Physical gas conditions

(1) Gas temp: 300-750 Deg F

(2) Gas press: Ambient

f) CONTROL SYSTEM INTERFACE

Must be able to communicate directly with existing APE 1236 programmable logic controller (PLC) over Ethernet. Existing PLCs are Allen Bradley Compact Logix protocol.

3) PART 3 - CEMS SYSTEM SPECIFICATIONS

a) REGULATORY REQUIREMENTS

i) The system must meet all the requirements of 40 CFR 75, 40 CFR 60, and all applicable Local Requirements as required by local operating permits.

b) GENERAL

i) The Continuous Emissions Monitoring System (CEMS) shall be of the conventional extractive type, which includes a heated sampling probe and filter (mounted on stack), heated sample line (controlled at 300 deg F), gas cooler/drier with sample conditioner, sample pump, calibration control valves and analyzers.

ii) The system shall be controlled by a programmable logic controller (PLC) and human machine interface (HMI) which provides a means for calibration of the system, periodically checking the calibration of the system, control and/or correction for temperature and pressure as applicable, and detection of faults.

Data shall be provided to allow access to the measurement system and to acquire, store, and process measurement information so as to prepare reports required by the regulatory agencies.

iii) Calibration checks of the system, both zero and span shall verify calibration at the sample probe, which checks the entire measurement system.

iv) Pollutant gas measurement techniques using Fourier Transform Infrared spectroscopy (FTIR), electrochemical analysis, dilution techniques, or systems which transport and measure gases in a hot wet state are specifically excluded as being non-responsive to this specification.

v) Gas cooler/dryers shall be of the thermoelectric type.

vi) The CEMS shall be designed and installed to ensure reliable operation with a minimum frequency and duration of system outages for maintenance and repair.

The system shall provide a minimum of 95% data availability when maintained according to factory recommended procedures and with factory trained personnel who have access to an adequate supply of spare parts.

vii) System shall incorporate Ethernet connectivity which will allow for the remote access to the PLC and Analyzer to ensure the highest level of remote system support.

viii) All system components shall be industrial quality and suitable for the type of plant environmental conditions to be encountered.

ix) All necessary signal cables requiring special connectors shall be supplied with the system.

x) Complete engineering documentation of the system, as built, shall be supplied with the system. Documentation shall include a description of all recommended maintenance procedures and spare parts.

xi) System PLC controller and CEMS shall be mounted in a self-standing 19” open rack enclosure (for cooling).

xii) Sample panel and conditioning plate will be panel mounted (not inside enclosure) for ease of access.

c) INPUT/OUTPUTS

i) The CEMS system shall provide process signals for each measured parameter and each of the calculated values listed below. These signals shall represent zero to full scale reading for each parameter. These will be displayed on the CEMS system HMI and made available to the APE1236 PLC over Ethernet communication. These signals will be for the owners use in addition to any required for the CEMS system operation.

(1) Carbon Monoxide Low (CO) in ppmdb, v/v (parts per million by volume dry basis)

(2) Carbon Monoxide High (CO) in ppmdb, v/v (parts per million by volume dry basis)

(3) Oxygen (O2) in percent (by volume dry basis)

ii) The CEMS system shall provide status signals for the sample plate equipment and CEMS analyzer. These will be displayed on the CEMS system HMI and made available to the APE1236 PLC over Ethernet communication. These signals will be for the owners use in addition to any required for the CEMS system operation.

(1) CEMS analyzer in modes: Fault, online, calibration, offline, alarms, etc.

(2) CEMS ancillary equipment status: Gas cooler temperature, pump status, sample plate status and alarms, sample valves position and status, sample line temperature alarm, etc.

d) GAS ANALYZER or CEMS

i) General

(1) The gas analyzer shall have internal data storage.

(2) The pollutant gas analyzer shall be multi-tasking, microprocessor based system with

Ethernet and/or RS-232 interfaces available to the system controller. (no analog to digital conversion)

(3) The gas analyzer system must have an auto-ranging capability selecting the optimum measurement range for display and data logging.

(4) The gas analyzer shall have a full range of status and predictive diagnostic capabilities such that if an operating parameter is out of limit, a message appears on the display as well as being sent to the system controller. Operating parameters must be saved for at least one hundred days making the prediction of failures possible.

(5) The analyzer must have sample inlet filters accessible from the front panel.

(6) The analyzer shall come with interface software allowing for remote access to analyzer data and diagnostics.

(7) The analyzer shall be equipped with a Ethernet and RS232 communication ports and be capable of multi-drop communications.

ii) Carbon Monoxide (CO) Channels

(1) The measurement principle shall meet the requirements of 40CFR60 Appendix B performance specification 4/4a and Appendix to Subpart EEE of Part 63. The acceptable method is Nondispersive infrared.

(2) Performance Requirements:

(a) Range: Low 0-200 ppm, High 0-3000 ppm as required by permit

(b) Zero Drift: 24 hours - Less than 3% FS (6 ppm Low, 90 ppm High)

(c) Span Drift: 24 hours - Less than 3% FS (6 ppm Low, 90 ppm High)

(d) Cal Error: 5%

(e) Response Time: 120 Seconds (95% of final value)

(f) Relative accuracy if using the reference method: 20%

iii) Oxygen Channel

(1) The measurement principle shall be paramagnetic.

(2) The measurement principle shall meet the requirements of 40CFR60 Appendix B performance specification 3 and Appendix to Subpart EEE of Part 63Range: 0-25% O2 full scale

(a) Zero Drift: 24 hours - Less than 0.5% O2

(b) Span Drift: 24 hours - Less than O.5% O2

(c) Cal Error: 0.5% O2

(d) Response Time: 120 Seconds (95% of final value)

(e) Relative accuracy if using the reference method: 20%

e) CEMS SYSTEM CONTROLLER

i) Provide a programmed PLC and HMI to perform all control functions of the CEMS. It shall have the following features:

(1) Control the calibration cycles. This includes drift tests, calibration and absolute calibration audit (ACA) test. The data of these tests will be stored in the system controller for access by the APE1236 PLC.

(2) Monitor system for faults.

(3) Time and date stamp all test data

(4) Local Interface. An alpha-numeric display with function keys to provide a user interface with the system PLC.

(5) Communicate directly with APE1236 system PLC over Ethernet (Allen Bradley Compact

Logix Controller). If not using a compatible Allen Bradley PLC then it is the responsibility of the supplier to develop the programming to pass the required data to and from the APE1236 PLC and system controller PLC, preferred Allen Bradley Compact Logix PLC for system controller).

ii) Input/Output (I/O)

(1) Provide data to APE1236 PLC (this can be in floating point and integer formats). This will include a continuous reading for all channels on the analyzer, a reading for all calibration gas values (drift test gasses and ACA test gasses), drift test results and aca test results.

(2) Provide system alarms (ie CEMS analyzer failure, temperature alarms, sample line alarms, sample probe alarm, etc.).

(3) Provide necessary I/O for monitoring and controlling CEMS system.

(4) Provide Ethernet and/or serial communications for CEMS analyzer.

(5) Provide Ethernet communications to APE 1236 PLC.

(6) The PLC shall be packaged as part of the CEMS.

4) PART 4 - SERVICES

a) SERVICES TO BE PROVIDED BY CEMS SUPPLIER:

i) A factory acceptance test (FAT) will be done before shipping CEMS system. This will show the system can meet the specification as shown in this document (ie CEMS measures CO at the low and high ranges, CEMS measures Oxygen, calibration process and data, drift test process and data, ACA test process and data, the transfer of CEMS data to and from the system controller and HMI, the transfer of data to and from the system controller to the APE1236 PLC, etc)

ii) At a later date the CEMS supplier may be asked for installation verification, certification testing and maintenance services.

b) WORK AND MATERIAL BY OTHERS:

Installation of all equipment and supply calibration gasses.