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Continuous Combustion Monitoring

Tracking Year on Year Performance Improvements for Boilers/Heaters, Etc.

Combustion MonitoringContinuous online monitoring of equipment operation is becoming both more important and easier to accomplish. Important because of increasing environmental reporting requirements but for other monitoring purposes as well. Easier because of continuing advances in computer technology and software capability. In order to provide up-to-date monitoring and reporting, we have developed a low cost suite of online modules designed to work with continuous monitoring devices located at the client's location. The resulting suite of dashboard tools is called IMCE (Internal Monitoring of Combustion Equipment). Performance measures for each boiler would be developed and maintained in IMCE.

  • For units equipped with plant information data systems, performance data (excess O2, boiler efficiency, fuel, feedwater, steam flow, etc.) can be accessed for daily, monthly, and annual review.
  • For units not so equipped, pertinent performance data can be manually collected and entered into IMCE for historical record and review.
  • Annual testing and tuning would be conducted to verify performance monitoring results.

IMCE is a cloud-based customer integration solution containing generalized modules for performing various system monitoring functions for implementation in very particular configurations. Client data collection modules are installed that collect the necessary information needed to monitor a variety of environmental conditions. The program works by continuously uploading data gathered from hardware installed at the client site and sending it to the ETEC cloud that process the information to display in dashboards and reporting tools.

Live Monitoring Approach

The program's design is modularized to perform generic routines for accomplishing the monitoring functions listed below:

  • Up-To-Date Data Processing
    The purpose of this function is to process input data to determine the value of parameters of interest. For instance, the current efficiency of a boiler as calculated on the basis of load, excess O2 , stack CO and exit gas temperature.
  • Monitoring of Trends
    This function enables the evaluation of processed data to determine trends of interest. As an example, current and past operation can be compared on a parametric or temporal basis.
  • Forecasting
    This function can be used for predicting the future value of a parameter based on current results and a user specified predictive algorithm. For example, future compliance with an emissions cap based on past performance and expected operation.
  • Correction for Loss of Input
    This function provides for the continued determination of a key parameter during a period of loss of input data. User specified algorithms are temporarily employed to determine an approximate value for a parameter using alternative continuing input data. This function also provides for the subsequent recalculation of the parameter value when the input data stream is restored.
  • Data Archiving
    This function provides for storage and data retrieval of complete achival data.
  • Reporting
    User Specified reports can be prepared on command or automatically on a periodic basis.

How Can It Be Used?

IMCE can be employed for a broad range of monitoring needs such as those listed below relating to air emissions.

Determination of unit/facility emissions

  • NOx, SOx, VOC's, other
  • Calculation of unit emissions by surrogate parameter monitoring (PEM)
  • Time averaging, facility bubbling, summing over time, BTU weighting
  • Missing data substitution

Monitoring of Emissions Compliance

  • Unit/facility emission limits
  • CAM
  • Title V enforceability conditions
  • Synthetic minor status
  • Special permit/consent decree conditions

Archiving of Emissions Data

  • Tracking of emission credits
  • Database retrieval
  • Recordkeeping

Analysis of Emission Trends

  • Forecasting emissions, compliance
  • Analysis of unit/facility emission trends, comparison with predictions/targets

Emissions Reporting

  • Automatic periodic reports
  • User defined special reports
  • Real time data displays

Many of the above tasks could be performed equally well for other purposes or simultaneously to serve multiple purposes. For instance, IMCE could be used to simultaneously track emissions and source performance, even employing the same input data stream if emissions were to be calculated on the basis of operational parameters. In the case of a boiler, NOx and SOx emissions and efficiency could all be determined by monitoring essentially the same group of operating parameters.

How Is It Implemented?

The implementation of IMCE involves simply providing for the necessary data input and configuring the program to the needs of the particular application.

  • Data Input
    Requirements include instrumentation to measure each parameter of interest and a data logging capability. In many instances, this equipment will be at least partially present, consisting of instrumentation for monitoring equipment operating parameters. IMCE can accept input from any type of computerized data retrieval or data logger.
  • Monitoring Configuration
    IMCE's monitoring functions are easily configurable to accommodate the needs of a particular application.

Scope of Services

We offer a full range of services to support the implementation of a IMCE system including providing turnkey installations.

  • System Design
    Starting with a client's list of needs, we will define a set of objectives and the best monitoring system design for their accomplishment.
  • Instrumentation
    We can evaluate your existing instrumentation to assess your needs and provide for any deficiencies that may exist.
  • Testing
    We can test your units to define the relationship between operating parameters and emissions and performance to develop algorithms for input to IMCE. We can also optimize performance and minimize emissions while were at it.
  • Configuration
    We will configure IMCE to accomplish your specific monitoring objectives and help you design output displays, reports and client server capabilities.

Technical Team

We are particularly well qualified to help industrial facilities establish monitoring systems to serve virtually any purpose. We possess experience, knowledge and capability relating to all facets of the required work:

  • Industrial equipment design & operation
  • Combustion & heat transfer
  • Equipment and plant operating procedures
  • Instrumentation design & operation
  • Testing & data analysis
  • Network & application systems
  • Custom Software Programming
  • Permitting
  • Environmental compliance