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Industry:  Petroleum Refinery
Project Type:  StackVision (DAS) Implementation
Scope:  15 CEMS, 1 COMS on 2 Flares, 2 Boilers, 1 FCCU, 2 Heaters
Driver:  NSPS Subpart Ja Deadline
Regulation(s):  40CFR60 Subpart Ja
Parameter(s):  NOx, CO, CO2, SO2, O2, H2S, Flow, Opacity
Location:  Louisiana
Year:  2017

Project Description

The driver for this project was regulatory, but the environmental and controls groups were also ready for a change. Before installing StackVision each monitored parameter had to be set up in the DCS and linked to the MES, with EPA-required calculations set up in one or both systems. Maintaining these calculations and editing them were excessively difficult.

Problems or Requirements

Calculations difficult to set up and maintain
The DCS calculations required extensive efforts by the process control group to set up. The DCS was only capable of producing limited information that had to be pulled into the MES for additional EPA calculations to be performed.
Getting buy-in from management was tough
The concept of a DAS and the idea that the existing systems were unable to effectively meet the requirements of continuous monitoring was a hard sell, even after they’d documented the convoluted process of building the calculations and pointed out the time and potential for inaccuracies involved in building the reports in spreadsheets.
Re-use of existing PLC
They wanted the complex flare communication to come from the existing PLC in place instead of directly from the analyzers. This let them reduce the amount of re-work and was easy to accomplish through simple pass-through Modbus communication to the Data Controller.

Solutions and Outcomes

StackVision and the 8864 know how to do CEM
The ESC DAS is specifically programmed with all EPA regulatory-required methodologies and compliance requirements (including cal gas/ validation management, QAQC monitoring, and standardized EPA reports per NSPS and MACT requirements). This reduced the burden of compliance tremendously.
Calculations and Configuration editable by Environmental
The DAS pulls in the instrument readings and perform the calculations without the need to do programming in both the DCS and MES. If something needs to change like a constant value or even an analyzer swap and certification the environmental group can make the changes.
Convincing management luckily made easier
A sister site installed the StackVision DAS and could demonstrate success. This convinced everyone that it might be the better option. We are happy to arrange references to our existing clients and try to match up size and scope as well as possible, but this was a perfect match.

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