ECS/StackGuide

the most cost-efficient product to guarantee all emission monitoring and reporting requirements in cement and waste incineration industry

When was the last time emission reporting made you smile?

ECS /StackGuide
PP-7004.STG.0001

ECS /StackGuide

Continuous Emission Monitoring System

Combustion related plants such as cement and waste incineration plants all over the world are facing a growing number of regulations and demands by various authorities on how to report their emissions from the production. The term CEMS (Continuous Emission Monitoring System) is applied for a complex set of requirements on system configuration, monitoring rules, data validation and reporting methods. ECS/StackGuide is a CEMS package to accomplish the requirements for emission monitoring in cement and waste incineration plants. The main benefits of this package are:

Real-time monitoring ECS/StackGuide provides an environment in which plant operators can monitor current values of the emission. These values are not only the traditional raw values, but also the normalised and validated values that are eventually going to affect the historical emission report in the historian part of the system. With configurable alarm limits, the operators are be able to take corrective actions in the process to minimize any emission violations. The real-time part of the system is a natural part of the ECS control system. It can however also be integrated with other control systems with data imported and displayed in the existing control system environment. In case of events such as analyser failure, the real-time monitoring system will detect the condition and enable the operator to document the reason of the failure as a request in e.g. PCMAKT. The operators comments can later on be included in the emission reporting.

Minimized plant managements effort in studying and following the CEMS requirements Guaranteed implementation of any emission legislation required anywhere in the world Easy customisation to any special requirements for central, local or plant authorities Improved emission statistics by early warning of plant operators about any up-coming emission violation

Cost-efficient solution
Traditionally, the CEMS solutions have been developed on a highly plant-specific basis. In order to meet the demands for data validation and monitoring rules, parts of the solutions have been implemented at the PLC level with intensive programming effort resulting in functioning, but quite complex solutions that are difficult to maintain in long-term. Other parts of the solution are traditionally implemented as special data retrieval and reporting system with customised programming approaches. ECS/StackGuide is the most professional and cost-efficient CEMS application with the following advantages: CEMS know-how ECS/StackGuide is based on a joint development between FLSmidth Automation (system specialist) and FLSmidth Airloq (gas analysis and emission specialist). The product is therefore a result of highest possible quality and field expertise Built-in legislation library In order to meet the detailed requirements of CEMS legislations, ECS/StackGuide contains built-in standards such as EPA-40 CFR 60 and 2000/76/EU legislations. The library is continuously developed and supported for changes in the legislations. Configuration, not programming Data treatment, validation, aggregation and reporting statistics in ECS/StackGuide are performed by simple selections in the so-called work packages. Using the extensive set of selectable capabilities, a CEMS application becomes a matter of configuration instead of programming that is difficult to support and maintain in long-term. At the same time users with several plants at different locations can easily configure and support CEMS applications for their plants world-wide using the work package concept.

The platform for complete solutions

On top of CEMS requirements from the environmental authorities, other plant-related requirements may also be relevant for a given emission monitoring package. Some of these requirements are related to partial or complete control of the underlying analyzers such as remote calibration control, equipment start/stop control. Furthermore, other active control tasks such as wastefuel feeder interlocking upon critical emission violations might be desired in some cases. Combining the facilities of the underlying software platform, and FLSmidth Automations expertise in integrated solutions for process monitoring and control, ECS/ StackGuide can be extended with additional functionalities to

General Description

meet the actual requirements for a given plant. An integrated complete solution based on one single platform will potentially result in the most cost efficient solution for a given set of requirements. Unique data security with ECS control systems Inherited from the integration between ECS/StackGuide and ECS/ControlCenter, the customers having control system from FLSmidth Automation gain two unique advantages when using ECS/StackGuide as their emission reporting system: Firstly, ECS/StackGuide utilizes the redundant configuration of an ECS control system to maximize the data availability for emission reporting. Dedicated data collection drivers can automatically switch between ECS servers, in case of any of the servers are unavailable for maintenance or other reasons Secondly, ECS/StackGuide includes a catch-up function when integrated with ECS control systems. This means that if the data collection was interrupted, e.g. due to disconnection, the missing data will be collected automatically in order to avoid data holes in the CEMS database. Lack of data in CEMS database may cause penalties or high emission value replacement by the authorities. Flexible data retrieval If the data exists in a PLC system, e.g. the analyzer PLC, dedicated PLC drivers of ECS/StackGuide can collect the raw data with single or redundant configuration. In addition, standard OPC interface can be applied for data collection from any supported PLC, control system or any other data sources. Scalable data security Independent of the underlying PLC or control system type, ECS/StackGuide can be supplied in scalable levels of data security: When integrated with ECS control system, ECS/StackGuide offers the above mentioned unique data collection security. If the source of the emission data is not an ECS control system, but

a foreign control system with OPC interface, ECS/StackGuide can optionally be supplied with an extended configuration that enables the same high level security as with ECS control system. The extended configuration will contain two redundant ECS Data Log servers with the relevant I/O interfaces to the data supplier. This configuration ensures the CEMS of the highest data security, since the ECS Data Log set act as a temporary buffering area for the raw values, thus enabling automatic switch-over and catch-up functions mentioned earlier. All the retrieved raw data is kept intact. This means that the data validation of the raw values will only produce new data instead of deleting or manipulating the raw data. The data storage media of ECS/StackGuide is the industry-standard MS-SQL database system.

ECS/StackGuide can collect the raw emission data from a wide range of PLC systems and OPC-supported control systems.

Report print

Exported file or database

Office viewer

ECS/StackGuideTM
Real-time Monitoring for Control Room and Historic Analysis for Reporting

ECS Data Log 1

ECS Data Log 2

ECS Server 1

ECS Server 2

OPC-Based Control System

OPC-Based Control System

Analyzer PLC On top of ECS control system with built-in high data security

Analyzer PLC On top of foreign control systems

Analyzer PLC On top of foreign control systems, extended data security

ECS /StackGuide

General Features
Realtime emission control Historian emission control and reporting Store all emission data for years. Emission data type - Value Statistics - Spot/Trend values - Events (alarms, warnings and information) MS-SQL Server relational database Advanced data validation methods Data tournament for dual ECS control system sources Catch up. Retrieve lost data from down periods Firewall between plant control and administrative system Historical databases and data access Dedicated reporting package Built-in MS-Excel add-ins for report customisation Advanced trending software Dedicated PLC communication drivers for ABB, Siemens, Modicon, and Allen-Bradley Optional OPC data access Optional Web access Windows 2000, XP and 2003 Terminal server support for remote access from office PCs FLSmidth Automation service release and hotfix support

Data Engine Features

International emission standard support: - EU 2002 fixed intervals. Interval 1: 30 min, Interval 2: 24 h - USA rolling average. Interval 1: typically 6 min, interval 2: 24 h. Typical emissions: CO, SO2, NOx, HCL, HFN, Dust, TOC. Normalization with H2O, O2, T and P. Weight averages Coverage low limit Coverage required percent Optional discard of insufficient coverage intervals. Blocker points for validating each measurement spot value. - Blocker point 1. Typically kiln operation and calibration. - Blocker point 2. Typically instrument failure. - Both blocker points can be configured to penalize coverage and/or ignore interval.

Selectable measurement range cut-off limits with selectable replacement values. Optional replacement if no measurement value available. Selectable violation algorithms for accessing intervals Violation limits for EU methods A and B Fertile alarm limits (for EU method B) Selectable validation methods such as: EU 2003, Method A, EU 2003, Method B, EU 2003, Method - A, Dutch, EU 2003, Method B, Dutch, Rolling average, USA, Rolling average. Selectable rolling average calculation methods - Cascade, rolling averages calculated using rolling averages from smaller intervals - Direct, rolling averages calculated from spot values

Reporting and Export Features

Column-based emission reports. Associated trend graphics, alarm/events reporting, mimic graphics Multiple aggregation intervals: - Aggregation interval 1. Discrete and rolling average 1 hour, 1, 2, 3, 4, 5, 6, 10, 12, 15, 30, 60, 120, 180, 240, 360, 720, 1440 minutes, 10, 20, 30 seconds - Aggregation interval 2. Discrete and rolling average. None, 1, 2, 3, 4, 6, 8, 12, 24 hours - Aggregation interval 3. None, 1 day, 1 week, 1 month, 1, 2, 3, 4, 6, 8, 12 hours Standard day, week and month and year reports. Configurable first day of week Configurable statistical hour (report hour) per report. Combined interval reporting Over 30 statistical values for each emission item User-defined report algorithms Configurable summary statistics

Configurable weighting average. Coverage calculation Selectable rolling average reporting methods - Extract, Interval 3 reporting done by extracting Interval 1/2 results - Average, Interval 3 reporting done by averaging Interval 1/2 results Realized and predicted production graphs Multiple plot types, line, bar, etc. Multiple plot frames per report Time plots and XY plots User defined trace colours and symbols Rolling average support Printer configuration Output to printer and PDF print Export PDF, CSV, tab and Excel files Export via SQL to 3party database (MS-Access etc.) for customised reports Highlight feature, e.g. violations and alarms Automatic report scheduling

FLSmidth A/S Automation. All rights reserved. ECS/ProcessExpert, ECS/CEMulator, ECS/PlantGuide, QCX/RoboLab, QCX/OnStream, ECS/CemScanner, ECS/ACESYS, ECS/ControlCenter, ACE/Woodware, ECS/SmartStation, ECS/StackGuide, QCX/Laboratory, QCX/AutoSampling, QCX/AutoPrep, QCX/BlendExpert, QCX/BlendMaster and Kilnloq are either registered trademarks or trademarks of FLSmidth A/S Automation in the United States and /or other countries. All other trademarks are property of their respective owners. FLSmidth Automation reserves the right to change specifications without prior notice. Our brochure makes no offers, representations or warranties (express or implied), and information and data contained in this brochure are for general reference only and may change at any time. Please contact us for specific information or data that may relate to your interests.

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