Industry:  Electric Power
Project Type:  StackVision DAS Implementation
Scope:  4 Units/ Stacks
Driver:  Purchase of facility, need for new data controllers
Regulation(s):  40CFR60, 40CFR75 Appendix D
Parameter(s):  NOX, CO, O2
Location:  Indiana
Year:  2018

Project Description

This power plant is one of four purchased at the same time. Under the previous owner they were using a competing vendor’s (older) DAS software paired with ESC’s older model data controllers. When this facility was purchased several key employees stayed on at the facility. They wanted to upgrade the data controllers and indicated they were also having trouble with the installed DAS.

All four steam Electric Generating Units (EGUs) at this facility fall under 40CFR75 Appendix D and they burn Pipeline Natural Gas (PNG). Under their permit this means that only NOX, O2 and CO are directly monitored, but others are derived.

Problems or Requirements

First plant in four to change DAS
The Plant Manager for this facility came onboard with the new DAS project quickly, but the other sites had some turnover in their Environmental groups following the purchase. They decided to let everyone settle in and see how it went with this plant before making the change, so this became a pilot project.
Old model data controllers needed to be replaced
The ESC 8832 Data Controllers in use at the plant when it was sold had been obsolete for a few years. The electronics were old enough to be unrepairable. ESC data controllers are durable, so they had been getting by. However, several of the plants' personnel had been talking to us about new controllers even before the sale.
SO2 and heat input derived from fuel characteristics and fuel flow rate
Because the power plant has access to a supply of PNG, compliance is easier than it would be if shipments had to be brought in or if the type of the fuel varied. The fuel itself is by definition low-sulfur and of a consistent composition. Appendix D tests for the fuel characteristics only need to happen once a year, and results will likely not vary significantly.

Solutions and Outcomes

A second plant is nearly ready for install
Our engineer will soon sit down with the customer for a Factory Acceptance Test. Over a full day they'll walk through the configuration, with demonstrations, answering questions and noting down any follow-up items. The goal is for the customer to be well-informed about how their decisions and choices were implemented, so they can feel confident in the monitoring and reporting their DAS provides.
Demonstrations of the 8864 tipped the scale toward StackVision
Simply put, ESC data controllers provide I/O, initial validation and averaging of the data, plus backup in case of network outages. With StackVision as the software they are even more functional, with complex configuration and control. Since the plant personnel were familiar with the 8832, seeing how much more they could do with the 8864 connected to StackVision really helped their decision.
StackVision is simple to configure with new fuel factors and constant values
Even though the fuel characteristics will only need to be edited annually, it is good to realize that editing values like this is a task completely within the control of the environmental group. No programmers, controls specialists or operations experts needed.

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