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                                    DAHS for Emission Monitoring

DAHS for Emission Monitoring

Main Features

  • Data Validation according to Regulation's requirements
  • Real time checking events and evaluate against influencing the measurements
  • Real time corrections depend Oxygen Ref, Pressure, Temperature and Humidity
  • Calculations from first step volumetric to mass units.
  • QAL2 function entry and Manual or Automatic QAL3 management
  • CUSUM, EWMA, SHEWHART reporting related with QAL3 results
  • %100 Web Based Software Platform
  • Secure Database : inaccessable and unchangeable record
  • Two Level Authentication
  • Rich Reporting Tool : pdf - Excel
  • Connection to Authority
  • Data sharing with Automation Platforms

Introduction  

Stack v6 Software has developed specially for CEMS applications to cover all of requirements of Continuous Stack Gas Data Handling, Monitoring, Reporting and also real time communication with Authority system as part of eco system of CEMS.

It is mainly referred to European Regulatory Framework including EN14181; data validation, unit converstions, calculations and averaging management, also reporting all is well covering requirements.

Stack v6 has developed with experience of past 5 different version until today from 15 years at least.

Stack v6 Emission Monitoring Platform is also answering nowadays expectations of plants which they have from their Industry 4.0 and IIoT working. So Stack v6 is a good solution to take CEMS monitoring into Industry 4.0 workings.

v6 Emission Monitoring Software is a Platform that open to upgrade for local government requirement of countries, specially Real Time Data connectivity with Authority... Stack v6 supports many methods for that.

WHAT IS EMISSION MONITORING SOFTWARE?

Emission monitoring software is a part of CEMS ecosystem and has working between emission analysers and CEMS users including authority, and results produced by software platform has a great importance because it is directly related to environment and control of pollution degree and while bringing advantages for environment, it advises factories how they can take measure for less pollution for environment. Emission monitoring software works according to government regulations. Most common are EPA - USA and TUV norms of Europe. Emission monitoring is not only data collection and visualisation process. There are many operations like event based data validity, calculations and condition based reporting, also real time connection to the local authority systems.

 

DATA VALIDATION FOR AN EMISSION MONITORING SYSTEM?

Data validation is the first and one of the most important steps in the emission monitoring evaluation process. Any collected data may not indicate stack gas or dust or flow value due to some reasons or events which influence measurements. Also some events affect only some parameters as independent and this can create problem for further steps of calculations and also there are some requirements of the regulations for these cases including data getting periods and its averages.

 

CALCULATIONS

Calculations start after data validity and continue until almost the end of all operations. There are two different sides for calculations. One can be said for conversion of units staying with relation of event based data validity. These calculations start from ppm to kg/h values in chain for concentration measurements. There are other calculations for conversion of units for going to flow. And second calculations are related with real time averaging of validated and calculated all parameters in each unit steps and as continuation to calculation, condition based reporting and producing indications related with QAL3 based results can be other calculations within calculation procedures.

 

CALIBRATION

Calibration or routine checking process is one of the most important topics of CEMS. In the regulation, for long term measurement security, there are some routines called QAL, coded QAL1, QAL2 and QAL3. While QAL1 is related to the manufacturing process of the analyser, QAL2 and QAL3 are related to after commissioning of the CEMS or during operation. QAL2 is performed by an independent accredited laboratory and the results of QAL2 for each parameter are entered into the emission monitoring software, and QAL2 entry is directly related to measurements and also calculations. Let's note QAL2 here, and QAL3 done by CEMS system integrators or CEMS users, operation can be done by manual or automatic using reference gases. QAL3 results are fed into the emission monitoring software to make some calculations depending on previous QAL3 results... There are special reports like CUSUM, EWMA and SHEWHART... QAL3 reports give some comments to the user to perform re-calibration or maintenance of analysers.

 

REPORTING FOR EMISSON MONITORING

CEMS reporting requirements are completely different from regular data acquisition system reports. Apart from regular data reports between two dates, there are special reports that are event based or according to data validity. Report results determine both the health of CEMS with available data and how exceeded the limit for pollution of environment.

 

DATA SECURITY FOR EMISSON MONITORING SOFTWARE PLATFORM

Data security is a measure for collected, calculated emissions data. Electronic recording systems are often open to data manipulation. This is the point that it should have a look for an emission monitoring system and end user or authorities should periodically double check from analyser to software for data's correctness. While one point is data accuracy, another point is database security of the emission monitoring software. Software databases must be inaccessible or unalterable. Users and system integrators as well as authorities should take care of this point.

 

CYBER SECURITY FOR CEMS

Especially in the last 20 years, day by day, cyber security is becoming more and more important for the software working at network. Cyber security is also an important issue for the emission monitoring software because the importance of data results' evaluation or data availability or the requirement of last 5 years' data availability in the system are required to take the highest measures for the emission monitoring platforms. Inaccessible databases, password-protected connection or two-factor authentication and some other software measures can be points that we should take care of.

Data Acquisition and Handling System for Continuous Emission Monitoring

Software and Hardware bundle



Specifications 

Supported Analyzers - Instruments
  • ELAN Protocol
    It is mainly for Siemens Gas Analyzers such as Ultramat 23, Oxymat and other family members. Support both Rs485 and Ethernet for ELAN

  • Modbus Protocol
    it is for connection other all analyzers which Modbus output... Durag, ABB, Sick analyzer can easly be connected to system. Support both Rs485 and Ethernet for Modbus

  • ASCII Protocol
    for some analyzers which has ASCII output.

  • Other Automation Protocols
    system supports to integration of some automation protocols like Siemens S7 PLC etc.
Stack Number

Software Platform can be ordered from 1 Stack to 20 stacks version.

Monitoring Platform
  • %100 Web Based
  • Modern Visualisations
  • Highest Security measures
Database Inaccessable and Unchangeable Secure Database
Automatic Backup Supporting daily automatic backup via USB port to external memory
QAL2 and QAL3

Supports QAL2 and QAL3 result entries.

QAL3 has supporting as Manual and Automatic

QAL3 Reporting
  • CUSUM
  • EWMA
  • SHEWHART

 

Options

Mobile Web Visualisation Option
  • It is for monitoring on Mobile devices. this option related with Stack number.
  • Some functions are limited for mobile web.
Advanced Report Manager
  • It is mainly for making comparison between Stacks. for example, you need to check CO kg/h of Stacks in one report to compare.
  • This opsion can be ordered with more than one Stack Emission Monitoring Software.
Auto Report Manager
  • If you are taking perodically reports, no need to work on it. by this option, Stack v6 can take report and do attachment of an email and send receiver automatically when time came.
Data Sharing Manager
  • by this option, you can share all validated and calculated data with other automation platforms using protocol OPC UA Server.
SQL Export Manager
  • When you need your data in a SQL for your own using, This option is for this. Stack v6 Emission Monitoring Software can to automatically export to connected SQL database as daily.
Authority Connection Manager
  • Stack v6 can be connected real time to authorities in two ways connection using REST - Web Service, according to API document of Authority.
  • Also can supports OPC UA Server or MQTT for data sharing for both realtime and historical

    (This topic always opens to discussions.)
Internal QAL3 Manager
  • When QAL3 management needed control by Software, you can buy this option. This is managing Gas Cylinders and recording automatically for QAL3 reports
  • Please note that Stack v6 is supporting external QAL3 system in standard. please ask for more.

 

Datalogger and Gateway Unit

CEMx300

It uses between Gas Analyzers and Emission Monitoring Software. It has multiple mission in the CEMS ecosystem.



 

 

 

 

 

 

 


Gateway - Converter function

There are 4 x isolated Rs485 ports and 2 x Ethernet ports. Gas, Dust, Flow, all other analyzers and PLC of cabinet automation are connecting to CEMx300 Gateway. One Gateway provides best solution to carr raw data to Emission Software/Computer. 

 

Datalogger function

CEMx300 is not only a Converter. it is also Datalogger for all collected raw data. Data's loosing for the Emission monitoring systems is a big problem due to availability requirement and report reliability. All software carries risks associated with non-stop operation 24 hours a day, 365 days a year. Sometimes due to malfunction for computer or because of Operating System situations, Software may be crashed or as the other cases, IT people can do working on factory network... At that times, Emission data is starting to be loss until recover the Software. Against all of problematic situations, CEMx300 supports datalogging function. When network working properly or when Emission Software has back to normal, all raw data which didn't delivered to Software side in the CEMx300 is starting to transfer to the Emission Monitoring Software automatically. CEMx300 buffer capacity is only for last 2 days. CEMx300 is converting and logging only raw data.. there is no any calculation.

 

Network Isolator function

In case of installation of the Emission Software inside of factory network, CEM analyzers' data are coming via factory network. Imagine all analyzers are converting into Ethernet to come to Emission Software installed factory network, when occured any problem at factory network, the connection between CEM analyzers and Emission software is directly influensing. Not only network disconnections, with that configuration, as system inegrators, you are delivering the connection control to the factory IT people. Other mean of this is you are loosing your control in CEMS architecture. CEMx300 is good solution for seperating CEMS analyzers from the factory network. CEMx300 is directly collecting data of all analyzers in CEMS thanks to Rs485 ports and Ethernet port and delivering the data to network by second Ethernet port which has factory IP family. When there is any problem at factory network side, no need to worry, because CEMx300 is recording data to deliver all of them later when connection problem solved.

 

CEMx300 Specifications 

Supported Analyzers - Instruments
  • ELAN Protocol
    It is mainly for Siemens Gas Analyzers such as Ultramat 23, Oxymat and other family members. Support both Rs485 and Ethernet for ELAN

  • Modbus Protocol
    it is for connection other all analyzers which Modbus output... Durag, ABB, Sick analyzer can easly be connected to system. Support both Rs485 and Ethernet for Modbus

  • ASCII Protocol
    for some analyzers which has ASCII output.

  • Other Automation Protocols
    system supports to integration of some automation protocols like Siemens S7 PLC etc.
Serial Ports (to collect data)

2 x Rs232/485 ports (isolated)

2 x Rs485 ports (isolated)

Ethernet port (to collect data)

1 x Ethernet port

Ethernet port (to deliver data) 1 x Ethernet port
GSM Communication 1 x internal GSM LTE, for service operations of CEMS 
Buffer memory

2 days data

Sampling Rate

5 second for each channel

Power Requirement

10-30 Vdc

Mounting

Wall or DIN Rail

Working Temperature

-20...+60 ºC

 

 

Case 1 : CEMx300 Gateway is inside of CEMS Cabinet and Emission Software is located anywhere of factory network as away the CEMS.

  • This case is suitable for both single stack and multiple stack version of Emission Software.

 

Case 2 : Both CEMx300 Gateway and Emission Monitoring Software is inside of CEMS Cabinet.

  • This case depends according to if how many Stack Systems installed in one panel. In the market, mainly one stack is installed in one cabinet and sometimes this can increasing up to 3 stacks CEMS in one cabinet.
  • This case is suitable for up to 3 stacks CEMS in one cabinet operation.
  • For this case, We may mainly offering Emission Monitoring Software as installed in Box PC or Panel PC. The name is called as Emission Monitoring Software and PC bundle.

All in One Controller for CEMS

CEMx1000

(IO Module - Cabinet Control - Automatic QAL 3 Manager)

 


 

CEMx1000's software is specially developed for CEMS, it helps to System Integrators of CEMS. It collects all requirements like IO Module, Cabinet Control and the valve management of Automatic QAL3 in one solution.

 

 


IO Module function

CEMx1000 is equipped with more than enough of IO channels including Analog Inputs, Digital Inputs, Relay Outputs and Analog Outputs. All Input channels can be monitored on Emission Software.

 

Controller function for Sampling System and Cabinet

CEMx1000 has temperature controller function for Sampling line or cooling system temperature control if needed. Control outputs are selectable as Relay or Analog outputs.

 

Auto QAL3 Management

CEMx1000's 8 pcs Relay outputs are reserved for management of Automatic QAL3 procedure. When QAL3 time came, process is starting automatically in connection with Emission Software. You can configure the Auto QAL3 system up to 8 Gas Cylinder, single or mixed gases doesn't matter. You can easly idendify them in Emission Monitoring Software. QAL3 process is automatically starting and finishing by CEMx1000 and v6 Emission Software couple without need to engineer... and results of QAL3 are automatically recording in Emission Software to reporting, related with CUSUM, EWMA and SHEWHART.

 

CEMx1000 Specifications 

Display

7" Color - Touch Panel

Serial Ports

2 x 485 ports

(It is Slave in communication, to connect CEMx300 CEMS Gateway)

(1 x Rs485 is spare for the future)

Ethernet port

1 x Ethernet port

(It is Slave in communication, to connect CEMx300 CEMS Gateway)

Analog Inputs
  • 4 x Pt100
  • 2 x K Type Thermocouple
  • 4 x 4-20 mA
  • 1 x 0-10 Vdc
Analog Outputs
  • 4 x 4-20 mA
  • 4 x 0-10 Vdc
DI Channels
  • 18 x DI Channel for on-off status entries
DO Channels
  • 16 x Relay
  • 3 x DO
Working Temperature

0...+50 ºC

 

v6 Emission Monitoring Software and Computer Bundle

 

CEM System Integrators can use own Work Station or Server computer for Emission Monitoring Software installations. But 4Logit has solution PC bundled version to provide licenced and configured solution to help CEMS Integrators. Especially for up to the 3 stacks in one cabinet designs, Our Panel PC bundle and Box PC bundle versions will be good solution as all in one. We recommend this bundle options because computer previously tested for quality and performance in using with our v6 Emission Monitoring Software platform by us.

 

 

Panel PC bundle option


 

Panel PC Technical Details

 

  • 15,6" Touch Panel PC
  • It is first certified Panel PC in the World by the Siemens
  • 16GB Ram
  • 256 GB SSD
  • Windows 10 IoT
  • 2 Ethernet Ports
  • 4 USB 3.0
  • 1 USB 2.0
  • IP66 Aluminium front panel and Steel Chasis
  • Panel Mounting or Vesa 100x100 mounting

Comments for using with v6 Emission Software

 

  • This configuration specially created to performance of Emission Software
  • Thanks to 2 Ethernet ports, you can seperate networks between factory and CEMS
  • This Panel PC is available up to 3 Stack version of v6 Emission monitoring software. You can buy this bundle as 1 stack or 2 Stacks or 3 Stacks versions.
  • When you keep continuously one USB memory stick as connected to Panel PC, v6 Emission monitoring software will be automatically back-up daily for all emission data for future recorvery process.

 

 

Box PC bundle option

 

Panel PC Technical Details

 

  • Industrial Box PC
  • 16GB Ram
  • 256 GB SSD
  • Windows 10 IoT
  • 2 Ethernet Ports
  • 4 USB 3.0
  • 1 USB 2.0
  • Wall Mounting or Vesa 100x100 mounting

Comments for using with v6 Emission Software

 

  • This configuration specially created to performance of Emission Software
  • Thanks to 2 Ethernet ports, you can seperate networks between factory and CEMS
  • This Box PC is available up to 3 Stack version of v6 Emission monitoring software. You can buy this bundle as 1 stack or 2 Stacks or 3 Stacks versions.
  • When you keep continuously one USB memory stick as connected to Box PC, v6 Emission monitoring software will be automatically back-up daily for all emission data for future recorvery process.

 

  • v6 Emission Monitoring Software is released April of 2024 as a contiuation of version series,
  • v1 published at 2009, 15 years ago than v6.
  • only v5 has been working at more than 250 chimney.

 

You can follow revision history at below table to see improvements and fixed points during v6 operations.

 

     
     
April 2024 v6 Released
  • Emission Monitoring Software is more flexible
  • Cover nowadays requirements for data sharing and Cyber Security
  • and has better and better visualizations
  • has new report functions.
  • SHEWHART and EWMA reports are now available
  • Support to be open different kind of Authority connections
  • OPC UA Server is available for data sharing with other automation platforms
  • improvement mobile visualisation
  • new dashboards
  • now alarms are available for real time averages, e.g. email triggering against 1 hour average value.
  • now SMS alert is available
September 2016 v5 Released
  • Emission Monitoring Software is now Web based and Automatic QAL3 function added.
June 2015 v4 Released
  • Some improvements and adding functionality for real time authorit connections for Web Service communication
May 2012 v3 Released
  • Emission Software now has digital communication for ELAN, Siemens Gas Analyzers
Septemper 2010 v2 Released
  • it is parametric design version of v1
April 2009 v1 Released
  • It was mainly static design, need configuration according to stack conditions