During this period of interruption, uncertainty and general madness, we actually took a deep dive to look within our operations and systems and put ourselves under the scrutiny of ISO9001 stage 1 and 2 audits.
With one of our stated Core Values being the determination to develop and maintain Trusted Partner status with our customers and suppliers, it was certainly a valuable exercise.
During the process we were guided and mentored by experts with many years experience - as a result, we learned a lot and we got better at doing what we do - as simple as that!
We also want to put a shout out to Brian Taylor - our ISOGuy.
ISO Guy was founded by Brian Taylor to help small organisation implement Management Systems that made a real difference to their profitability. Brian has over 25 years implementing ISO 9001 management System (previously BS5750).
The standard FGA900 series analysers provide accurate, reliable measurement of carbon monoxide, nitric oxide and oxygen in flue gases. It is an integrated solution for Continuous Emissions Monitoring Systems (CEMS) applications in smaller combustion processes.
Now available with an additional NO2 measurement channel, giving access to true NOx measurement, making it an ideal budget solution for for continuous measurement of NO:NO2 split. This makes the FGA952 an ideal gas turbine tuning system and allows operators to economically and dynamically auto-tune combustion systems with high excess air.
Easy to install and operate, the FGA also calculates values for combustion efficiency, NOx and carbon dioxide. This information allows better process control, which lowers fuel costs and keeps emissions within compliance levels.
A pair of sensors is used to analyse each of the species in the sampled flue gas, alternating every 30 minutes. This extends sensor lifetime and ensures a stable baseline, essential for low-level measurements, delivering high sensitivity and low drift.
The FGA can be used in any combustion process where the sulphur dioxide concentration is less than 50ppm, making it a vital solution for the gas-fired, biomass fired and mineral processing industries.
JELD-WEN has implemented AMETEK Land’s flue gas analysers and opacity and dust monitors at its door manufacturing facility in Penrith, United Kingdom, to help achieve emissions compliance.
JELD-WEN is one of the world’s largest manufacturers of windows and doors with operations in 20 countries, including five factories in the UK that manufacture timber windows and interior and exterior doors. The company is seen as a world leader in manufacturing energy efficient products and upholds high standards when it comes to sustainability. JELD-WEN’s door manufacturing facility in Penrith produces 35,000 timber and veneered doors every week, and as a result produces a large amount of wood waste.
As a high-volume manufacturer, JELD- WEN was keen to reduce its waste, lower emissions and implement a more sustainable fuel source. Working with a specialist energy contractor, JELD-WEN identified biomass boilers, utilizing waste wood from its manufacturing operations as the most suitable technology. However, as the site is governed by local authority legislation, the company is required to monitor and control the emissions from its boiler. This is where an AMETEK Land emission monitoring solution was required.
The company previously had an old gas fired boiler, which was fitted with an AMETEK Land FGA 930 flue gas analyser and a dust monitor. As part of the upgrade to biomass, the old boiler was decommissioned.
Two industrial biomass boilers were installed that would burn wood waste from JELD-WEN’s production process in order to heat its factory and offices, whilst enabling the company to reduce its waste output significantly and lower its carbon footprint. A brand-new steel framed plant room was built to house the new boilers, plus a new two-storey office complex, two new flues and a new fuel delivery system, with fuel stored in an external silo, adjacent to the factory.
The large steam boilers were customised to include a specially designed moving grate combustion chamber, modified to suit dusty fuel. With a continuous self-replenishing fuel source, a large shredder was also installed at the factory to enable the reject wood and timber waste product to be chopped up and transported to the main silos for storage.
Focal-Point Technology, an AMETEK Land distributor, supplied and installed an FGA 930 flue gas analyser and a 4400 opacity and dust monitor on each of the two new stacks. The data acquisition system was provided by EMACCS.
The FGA provides accurate, reliable measurement of carbon monoxide, nitric oxide and oxygen in flue gases. It is an integrated solution for Continuous Emissions Monitoring Systems (CEMS) applications in smaller combustion processes and is ideally suited to JELD-WEN’s biomass application. It allows them to benefit from better process control, which lowers fuel costs and keeps emissions within compliance levels.
A pair of sensors is used to analyse each of the species in the sampled flue gas, alternating every 30 minutes, which extends sensor lifetime and ensures a stable baseline, delivering high sensitivity and low drift.
The two new 4500 dust and opacity monitors are a cost-effective solution for the continuous monitoring of dust, smoke and particulates in industrial applications. The 4400 is lightweight design which made installation and positioning simple at the JELD-WEN plant. It offers them low-maintenance as it has no moving parts, which ensures it operates reliably and continuously for immediate cost and performance benefits.
The 4500 is a cross-duct design with a transceiver mounted on one side and a passive retro-reflector mounted on the other side of the stack. It uses AMETEK Land’s patented three-LED light source to effectively monitor the dust emissions. An air purge protects the delicate optical components from the hot, dirty process conditions.
All the signals from the analysers are fed into an EMACCS Continuous Emission Monitoring Data Acquisition System (EmiDAS) to allow consistent and accurate monitoring.
JELD-WEN’s site is in Penrith and regulated by the local authority. The AMETEK Land instruments monitor compliance to Process Guidance Note 1/12(13) for combustion of waste wood. This gives guidance on the conditions appropriate for the control of emissions into the air from the combustion of fuel manufactured from, or comprised of, waste wood in appliances.
Graham Clark, Focal Point Technology comments “This was a challenging project which required a robust and highly effective solution. The combination of FGAs and 4400 from AMETEK Land will provide peace of mind that JELD-WEN is complying with legislation and their emissions are being minimised. This equipment is suitable for use in many different industrial processes and is rapidly growing for use in biomass, waste wood combustion, and Small Waste Incineration Plant (SWIP) applications.”
AMETEK Land has appointed Focal-Point Technology, stack emission and process gas analysis specialist, as a UK distributor for its combustion and emissions monitors and as a global partner for its FGA 900 compact flue gas analysers (FGAs).
Focal-Point Technology, based in Derbyshire in the United Kingdom, is a leading supplier of specialist industrial gas analysis instrumentation, services and custom solutions for continuous emissions monitoring system (CEMS) applications. AMETEK Land’s FGA 900 range of 3-in-1 analysers provides accurate measurement of carbon monoxide (CO), nitric oxide (NO) and oxygen (O2) in flue gases. They are compact and provide effective flue gas measurement monitoring for CEMS (Continuous Emissions Monitoring System) applications on processes that burn natural gas and biomass. Featuring fully weatherproof enclosures sealed to IP65 standards and optional heating or cooling for extreme environments, these FGAs have TUV and MCERTS EN14181 QAL1 approval for emissions measurements in Europe and meet the requirements of U.S. EPA Performance Specifications 2, 3 and 4 for the relevant gases. Engineered for ease of maintenance, the FGA is simple to install, maintain and operate.
In addition to the global distribution agreement for the FGA 900 series of analysers, Focal-Point Technology has been authorised by AMETEK Land to provide sales and support in the United Kingdom for Land’s Lancom portable flue gas analysers and acid dewpoint monitors; 4000 Series particulates and opacity monitors; and Millwatch/Silowatch coal mill and silo CO detection
“The team at Focal-Point Technology has had a very close involvement in the technical testing of the latest FGA 900 product range, assisting us in achieving continued compliance with international standards. We, therefore, are very pleased to appoint them as an AMETEK Land global partner for this analyser,”comments Ben Wileman, Divisional Vice President – Global Sales and Marketing at AMETEK Land.
“Focal-Point Technology can offer a complete CEM management function covering every step of the process, from the moment a monitoring requirement is identified, right through to final handover and into normal operation. We are very pleased to combine the expertise of our two businesses to deliver monitoring solutions for our customers across a variety of industries.”
“Our technical sales team has extensive understanding and insight into the operation and application of FGA 900 analysers along with the strong demand for them, due to their consistently high accuracy, low drift, reliable, and long-term CEMS monitoring capabilities,” says Craig Day, Director of Focal Point Technology. “With the addition of sampling and conditioning systems (carefully selected for specific applications) along with complementary analyser technologies, data acquisition and reporting systems, this collaboration can now deliver total turnkey monitoring solutions.”
The Audit-Hub truly becomes the Focal Point of the the entire CEMS system and gives Operators visualisation of all instrument status in the system, historical trends, and control of calibration and audit gases either directly to analysers or via sample probes for complete system checks.
Calibration gases are connected to single entries into the Hub and diverted via actuation of internal valves to instruments directly or via sample probes. Interaction is through the touch-screen colour HMI with clear logical menus and options.
Instantaneous data can be viewed and data averaging can be performed right at the Hub. Data re-transmission to DAS via ethernet cuts down on any unnecessary signal cabling.
In this way, data and status from different types of instruments can collated in a single location, date stamped and validity imposed when in maintenance or calibration.
Our Graham commissioning a dust monitor on a cement silo in Malta – just in time for the arrival of a well-known cruise ship! Not only are cruise passengers being delivered, but also large quantities of cement to keep Malta building into port-side storage silos. Filter plant are fitted to the silos, but its important for Operators to know that the filters are doing their job and keeping the cement dust away from the tourists. EMS6 dust sensor and N3-ER datahub allow the Operator log dust emissions, view data remotely and receive warnings about emissions levels.