PETRONAS TECHNICAL STANDARDS

Selection And Installation Of Continuous Emission

Monitoring System (CEMS)

PTS 14.30.06
January 2017

© 2017 PETROLIAM NASIONAL BERHAD (PETRONAS)

All rights reserved. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form
or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright
owner. PETRONAS Technical Standards are Company’s internal standards and meant for authorized users only.
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FOREWORD

PETRONAS Technical Standards (PTS) has been developed based on the accumulated knowledge,
experience and best practices of the PETRONAS group supplementing National and International
standards where appropriate. The key objective of PTS is to ensure standard technical practice across
the PETRONAS group.

Compliance to PTS is compulsory for PETRONAS-operated facilities and Joint Ventures (JVs) where
PETRONAS has more than fifty percent (50%) shareholding and/or operational control, and includes
all phases of work activities.

Contractors/manufacturers/suppliers who use PTS are solely responsible in ensuring the quality of
work, goods and services meet the required design and engineering standards. In the case where
specific requirements are not covered in the PTS, it is the responsibility of the
Contractors/manufacturers/suppliers to propose other proven or internationally established
standards or practices of the same level of quality and integrity as reflected in the PTS.

In issuing and making the PTS available, PETRONAS is not making any warranty on the accuracy or
completeness of the information contained in PTS. The Contractors/manufacturers/suppliers shall
ensure accuracy and completeness of the PTS used for the intended design and engineering
requirement and shall inform the Owner for any conflicting requirement with other international
codes and technical standards before start of any work.

PETRONAS is the sole copyright holder of PTS. No part of this document may be reproduced, stored
in a retrieval system or transmitted in any form or by any means (electronic, mechanical, recording or
otherwise) or be disclosed by users to any company or person whomsoever, without the prior written
consent of PETRONAS.

The PTS shall be used exclusively for the authorised purpose. The users shall arrange for PTS to be
kept in safe custody and shall ensure its secrecy is maintained and provide satisfactory information to
PETRONAS that this requirement is met.
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ANNOUNCEMENT

As part of the recent transformation exercise, the PTS numbering system has been revised to 6-digit
numbers and drawings, forms and requisition to 7-digit numbers. All newly revised PTS will adopt this
new numbering system, and where required make reference to other PTS in its revised numbering to
ensure consistency. Users are requested to refer to PTS 00.01.01 (PTS Index) for mapping between
old and revised PTS numbers for clarity. For further inquiries, contact PTS administrator at
ptshelpdesk@petronas.com.my
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Table of Contents
1.0 INTRODUCTION ..................................................................................................... 5
1.1 SCOPE .............................................................................................................................. 5
1.2 GLOSSARY OF TERM ........................................................................................................ 5
1.3 SUMMARY OF CHANGES ................................................................................................. 8
2.0 REGULATION REQUIREMENTS ............................................................................... 9
3.0 MONITORING TECHNOLOGY (SAMPLING SYSTEM) ............................................... 10
3.1 EXTRACTIVE SAMPLING SYSTEMS METHOD ................................................................. 11
3.2 IN-SITU SYSTEMS ........................................................................................................... 13
4.0 CEMS INSTALLATIONS.......................................................................................... 14
5.0 ALTERNATIVE METHOD (PREDICTIVE EMISSIONS MONITORING) .......................... 15
6.0 CEMS-DATA INTERFACE SYSTEMS (CEMS-DIS) ...................................................... 16
6.1 HARDWARE ................................................................................................................... 16
6.2 DIS COMMUNICATION HARDWARE REQUIREMENT..................................................... 16
6.3 CEMS-DIS DATA HANDLING .......................................................................................... 16
7.0 BIBLIOGRAPHY .................................................................................................... 17
APPENDIX 1: DOE REGULATORY POLLUTANTS LIMITS ..................................................... 18
APPENDIX 2: TYPICAL BLOW-BACK SYSTEM FOR PROBE .................................................. 20
APPENDIX 3: TYPICAL EXTRACTIVE COLD DRY SYSTEM .................................................... 21
APPENDIX 4: TYPICAL EXTRACTIVE HOT WET SYSTEM ..................................................... 22
APPENDIX 5: CEMS MONITORING TECHNOLOGY: DILUTION SYSTEM ............................... 23
APPENDIX 6: TYPICAL OUT OF STACK DILUTION SYSTEM DRAWING ................................ 24
APPENDIX 7: CLOSED-COUPLE SYSTEM............................................................................ 25
APPENDIX 8: SAMPLE OF IN-STACK ANALYSER (IN-SITU).................................................. 26
APPENDIX 9: SAMPLE OF CROSS-DUCT SYSTEM............................................................... 27
APPENDIX 10: MEASUREMENT OF SAMPLING PROBE LOCATION ..................................... 28
APPENDIX 11: PROBE POINT LOCATION .......................................................................... 29
APPENDIX 12: IN-SITU SYSTEM: PATH (CROSS-DUCT) SYSTEMS (DOUBLE – PASS
TRANSMISSION METER).................................................................................................. 30
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1.0 INTRODUCTION

This PTS provides the minimum technical requirements for the design and construction of
Continuous Emissions Monitoring System (CEMS) to comply with local regulatory body of
Department of Environment (DOE) in accordance to the local Environmental Quality (Clean
Air) Regulations.

This PTS also describes the various methods used to continuously monitor pollutants emitted
from stationary sources based on PETRONAS lesson learnt and best practices.

1.1 SCOPE

1.1.1 This PTS covers the hardware for Continuous Emission Monitoring (CEM) and CEMS Data
Interface System (CEMS-DIS). It also includes the associated sampling system, shelter and
supporting utilities. The scope does not cover portable analysers.

PTS 14.30.01 shall be referred to for the design requirements of sampling system.

1.2 GLOSSARY OF TERM

1.2.1 General Definition of Terms & Abbreviations

Refer to PTS 00.01.03 for PTS Requirements, General Definition Of Terms, Abbreviations &
Reading Guide.

1.2.2 Specific Definition of Terms

No Term Definition

1 CSV Comma Separated Value. A file format is a

particular way to encode information for
storage in a computer file. Particularly, files
encoded using the CSV format is used to store
tabular data.

2 FTIR Fourier transform infrared spectroscopy is a

technique which is used to obtain an infrared
spectrum of absorption or emission of a solid,
liquid or gas.

3 NDIR Non-Dispersive Infrared uses a wider infrared

region of the electromagnetic spectrum.

4 NIR Near Infra-red is a spectroscopic method which

uses the near infrared region of the
electromagnetic spectrum (from about 800 nm
to 2500 nm)

5 Piping Class An assembly of piping components, suitable for

a defined service and design limits, in a piping
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No Term Definition
system. Piping classes for refining and chemicals
are contained in PTS 12.31.01; piping classes for
exploration and production are contained in PTS
12.31.02.

6 Process Line The piping used for transport of fluids (other

than sample lines)

7 Reference Method Any emission test method identified in a user

permit or DOE regulation

8 Relative Accuracy The absolute mean difference between the gas

concentrations by a CEMS and the value
determined by an appropriate Reference
Method. The relative accuracy provides a
measure of the systematic and random errors
associated with the data from the CEMS

9 Sample A representative portion of the product or

process stream having all relevant properties of
the product or the process stream itself.

10 Sample Conditioning One or more devices that properly prepare a

portion of the system sample from the sample
transport system for testing by the process
analyser to meet the requirements of the
analyser.

11 Sample Line The tube or pipe used for transporting the

sample.

12 Sample Probe A device (usually in the form of a special tube)

that is inserted into a defined point in the bulk
of the process stream to extract a small portion
as a sample

13 Sample recovery system A system that collects waste sample and/or by-
products from the analyser system for the
purpose to either returns them to an assigned
point of disposal or to a suitable point in the
process

14 Sample take-off connection A piping connection for the extraction of the

sample from the process line and through which
samples probe may be inserted into the process

15 Sample take-off point The exact location from where the sample is
extracted in the process, i.e., the location of
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No Term Definition
either the tip of the sample probe or the pipe
wall connection from where the sample fluid
leaves the process piping

16 Sample take-off system The system that includes the sample probe and
downstream components up to the connection
with the sample transport system

17 Sample transport system A system used to transport a sample from the

sample take-off either to the sample
conditioning system (and from there to the
analyser) or directly to the analyser, and to
return the waste sample, if any is collected,
from the sample conditioning system, either to
a suitable point in the process or to a suitable
utility system

18 TDLAS Tunable Diode Laser Absorption Spectroscopy.

A new technology using tunable laser as optical
source.
Table 1.1: Specific Definition of Terms

1.2.3 Specific Abbreviations

No Abbreviation Description

1 AMADAS Analyser Management and Data Acquisition

System

2 CEMS Continuous Emission Monitoring System

3 CEMS-DIS CEMS Data Interface System

4 DCS Distributed Control System

5 DOE Department of Environment

6 FID Flame Ionization Detector

7 HQ Head Quarters

8 MCERTS Monitoring Certification Scheme

9 NMVOC Non-Methane Volatile Organic Compound

10 PEMS Predictive Emissions Monitoring System

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No Abbreviation Description

11 RATA Relative Accuracy Test Audit

12 SCS Sample Conditioning System

13 TOC Total Organic Carbon

14 TPM Total Particulate Meter

15 TUV Technical Inspection Association

16 UV-VIS Ultraviolet Visible

Table 1.2: Specific Abbreviations

1.3 SUMMARY OF CHANGES

This PTS 14.30.06 (January 2017) replaces PTS 14.30.06 (July 2013).
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2.0 REGULATION REQUIREMENTS

The pollutants limit shall be based on emission standards for stationary sources as prescribe
in the Third Schedule, Regulation 13 of Environmental Quality (Clean Air) Regulations 2014
and its subsequent revisions.
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3.0 MONITORING TECHNOLOGY (SAMPLING SYSTEM)

Two main principles in monitoring pollutant emissions from stationary sources:

i. Extracting or locating a representative sample prior to analysing (Extractive)

ii. Analysing sample directly (In-situ)

The choice and design of CEMS depends on both the regulatory requirements and the types
of pollutants and/or parameters that are to be monitored.

The choice of sampling systems has to be compatible with the analysers used to measure the
analytes.

The design of the CEMS shall consider the requirement to perform verifications with
calibration gases that can prove the entire sample conditioning system and the specific gas
analyser function.

Types of Continuous Monitoring Methods

Extractive In-Situ

Source Level Dilution Path Point

Dry In-Stack Single pass Closed Couple

Wet Out-of-Stack Double Pass In-Stack Analyzer

Figure 3.1: Types of Continuous Monitoring Methods

The selected analyser shall be MCERTS or TUV certified for CEMS application.

Methods used to measure air pollutants are summarized as per Table 3.1. Selection of
analysers shall depend on type of gas monitored and DOE requirements.
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Pollutants Measurement Recommended Recommended

Technique Sampling System Type Application

CO NDIR, TDLAS, FTIR Extractive or In-situ Boiler, Combustion

turbines, Furnaces, Waste
incinerator

HCl TDLAS, FTIR In-situ Waste incinerator

OPACITY / Transmissometry In-situ Waste incinerator

TPM

NO2 Chemiluminescene, Extractive or In-situ Boiler, Combustion

FTIR turbines, Furnaces, Waste
incinerator

SO2 UV-VIS, FTIR, UV- Extractive or In-situ Waste incinerator

Fluorescence, TDLAS

NMVOC FID, FTIR Extractive Waste incinerator

HF TDLAS, FTIR Extractive or In-situ Waste incinerator

Table 3.1: List of Pollutants and Measurement Techniques

3.1 EXTRACTIVE SAMPLING SYSTEMS METHOD

Extractive sampling systems shall be designed and operated in a manner that provides
consistently representative samples to the analyser. The design of the sampling system should
minimize any reactions or loss of the medium of interest before they reach the analyser. To
achieve this, the sampling lines material selection and operating temperature and pressure
shall be considered.

High flow rates and short sampling will reduce the effects of analytes adsorption by minimizing
the residence time of the samples inside the line.

All cold spots within sampling lines such as connectors between heated lines segments shall
be eliminated.

There are two types of extractive methods:

i. Source level (Cool-Dry systems and Hot-Wet systems) (See Appendix 3 & 4)

ii. Dilution (in-stack and out-of-stack) (See Appendix 6)

3.1.1 Source level: Cool and Dry System

i. The sample conditioning system shall be installed as close as practically possible

to the sample take-off.
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ii. Note that by using this method, water soluble analytes such as HCl, NH3, VOC,
H2S, SO2 may be lost as part of water being knocked out from the condenser.

iii. Potential cold spots from take-off until SCS shall be eliminated or avoided (by
means of heating and insulations) to ensure no potential condensation can
happen along the sample transport line.

iv. Automatic sample cut-off can be considered to avoid the sampling clogging if
there’s any failure of the heat trace and insulation.

v. Flue gas emission contains a lot of particulates especially for waste incinerator
stack emission. Therefore, it is necessary to have auto-cleaning features of the
stack probe’s filter otherwise the probe’s filter will get clog easily. A typical self-
cleaning feature by means of auto blowback system using instrument air is shown
in Appendix 2.

vi. The solenoid valve’s open/close timer should be controlled by the plant DCS
system or alternatively be controlled using dedicated timer installed locally.

3.1.2 Source level: Hot and Wet Systems

i. Hot-Wet systems are systems that maintain the sample temperature above its
dew point throughout the sampling system and within the analyser. Selected
analyser shall be able to withstand hot and wet sample and its measuring
technology is insensitive to moisture content.

ii. The effects of temperature changes between the stack and the analyser shall be
considered.

3.1.3 Dilution Systems

i. This technique shall be used if the sample concentration is too high and beyond
analyser range or too corrosive and might damage the lines and analyser.

ii. To reduce the sample dew point to an acceptable value will typically require
dilution ratio within 50:1 to 100:1 depending on the moisture content and other
components in the stack.

iii. There are two types of dilution system: In-stack and out-of-stack.

iv. In-stack dilutions probes shall use critical orifice to ensure the sample extraction
flow rate is independence of the aspirator flow to give more constant sample flow
rate and consistent dilution (See Appendix 5).

v. Biases in monitoring results may occur where in-stack dilution probe is subjected
to varying stack temperature, pressure, or molecular weight. These parameters
may affect the sonic flow across the critical orifice thus the pressure drop across
it.
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vi. For the case of varying stack temperature, Out-of-stack dilution shall be used to
eliminate or minimize the stack variations by putting the temperature control
dilution box outside the stack and leaving only sample probe inside the stack (See
Appendix 5).

3.2 IN-SITU SYSTEMS

There are three types of in-situ systems: point (close-coupled), path (cross-duct) and path (in-
situ probe). The probes shall be kept clean by using blowback function (See Appendix 2).

3.2.1 Point (Close-coupled) Systems

i. The analysers shall be able to tolerate stack heat and harsh environment (See
Appendix 7)

ii. Accessibility and maintainability factors shall be considered in selecting this type
of system

3.2.2 In-stack (In-situ probe) CEMS Sensor

In stack (In-situ) probe is available for IR, UV and TDLAS. An IR or UV in-situ probe is able to
measure multiple components within the same spectrum. Whereas TDLAS in-situ probe is able
to measure single component.

Maintainability and accessibility of the probe shall be taken into consideration, for example,
probe to be taken off for maintenance.

3.2.3 Path (Cross-duct) Systems

An across-the-stack unit also applied for opacity/dust measurements. Self-alignment feature

shall be made available (see Appendix 9 &12).
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4.0 CEMS INSTALLATIONS

Each analysers and equipment installed as CEMS system shall be in compliance with TUV or
MCERTS.

The sampling location shall be accessible for system maintenance and repairs. For stack
installations of in-situ analysers (See Appendix 8), factors such as vibration, lightning, ambient
atmosphere and temperature extremes shall be considered (See Appendix 10).

The required CEMS probe location (See Appendix 11) and measurement point shall be
referred to DOE’s Volume 1: Guideline for Installation and Maintenance of Continuous
Monitoring Systems (CEMS) for Industrial Premises/Facilities.
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5.0 ALTERNATIVE METHOD (PREDICTIVE EMISSIONS MONITORING)

PEMS is an alternative method to hardware CEMS for monitoring emissions based on emission
model to predict emission and uses process operation data and ambient condition to calculate
(predict) the pollutant emitted.

DOE shall be consulted prior to applying this method.

An assessment is required to determine the viability of PEMS. The most prevalent pollutants
predicted in PEMS are nitrogen oxides (NOx), carbon monoxide (CO) and Sulphur Dioxide
(SOx). Regulations generally require that emissions be normalized to a common oxygen (O2)
or carbon dioxide (CO2) basis.

PEMS will require at least annual maintenance of the PEMS model to ensure it is in-line with
current process.

PEMS may subject to DOE testing and audit.

Provision for load change during modelling and audit is required.

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6.0 CEMS-DATA INTERFACE SYSTEMS (CEMS-DIS)

CEMS-DIS shall be based on DOE Volume II: Guideline for the Continuous Emission Monitoring
Systems - Data Interface System (CEMS-DIS) latest requirement.

The DIS system for the end-user can be divided into 2 main components:

i. Industrial premises’ CEMS equipment sensors, probes, data loggers, and data
acquisition system (DAS) or AMADAS (Analyser Management and Data Acquisition
Systems).

a) For User with CEMS but without Plant database system (i.e. DAS/AMADAS
System)

 If data is in analogue format, industrial premises shall have a proper

analogue-digital converter. For industries that don’t have DAS, a data
logger would be the alternative.

 Another alternative is to have the DCS vendor to create a program so

it can send the data in a format that can be received by DIS (for
example, ASCII’s CSV format)

b) For user with existing DAS or PIMS, the signal can be connected directly
to CEMS¬DIS server

ii. An intermediary component called CEMS Data Interfacing System (CEMS-DIS) to

store data from DAS and communicate with State DOE server for CEMS data
transferring purposes.

6.1 HARDWARE

The hardware requirements for DIS are:

i. A server or PC (that act as a server and preferable industrial or server type PC).

ii. Internet communication hardware to link to DOE’s HQ, Putrajaya.

6.2 DIS COMMUNICATION HARDWARE REQUIREMENT

DOE HQ, Putrajaya shall be given access to DIS PC at any time. The method used shall be via
internet connection (lease broadband line). Any other methods shall require Principal
approval.

6.3 CEMS-DIS DATA HANDLING

The industrial premises shall follow DOE Volume II: Guideline for the Continuous Emission
Monitoring Systems - Data Interface System (CEMS-DIS)

CEMS-DIS database shall be archived for at least five (5) years.

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7.0 BIBLIOGRAPHY

In this PTS, reference is made to the following Standards/Publications. Unless specifically

designated by date, the latest edition of each publication shall be used, together with any
supplements/revisions thereto:

PETRONAS TECHNICAL STANDARDS

Index to PTS PTS 00.01.01
PTS Requirements, General Definition of Terms, Abbreviations & PTS 00.01.03
Reading Guide
Index to Standard Drawings PTS 00.11.01
Piping Classes – Oil Refineries, Chemical And Gas Plants PTS 12.31.01
Piping Classes - Exploration And Production (Offshore) PTS 12.31.02
On-line Process Analyser Sampling System PTS 14.30.01
On-line Quality Measuring Instrument PTS 14.30.03

INTERNATIONAL STANDARDS
Environment Quality (Clean Air) Regulation June 2014
USEPA Handbook Vol. 2 and 3, 1997
Guideline for the Installation & Maintenance of Continuous Vol. 1 Version 6,
Emission Monitoring Systems (CEMS) for Industrial Nov 2009
Premises/Facilities
Guideline for the Continuous Emission Monitoring Systems – Data Vol. 2 Version 7,
Interface System (CEMS-DIS) for Industrial Premises/Facilities Mar 2014
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APPENDIX 1: DOE REGULATORY POLLUTANTS LIMITS

Source Source Limit Value

Fuel Type Pollutants Monitoring
Activities Capacity (mg/m3)

NO2 350
Boiler ≥ 10 Gaseous
MW fuels
Heat & CO 50
Power
Generation Combustion NO2 150
Gaseous
turbines ≥ 10
fuels
MW CO 100

Total PM 40
Oil & Gas Catalytic
industries: Cracking
SO2 1200 Continuous
Refineries
(all sizes)
Calcination Total PM 40

Total PM 100

NMVOC as
10
TOC

Waste
HCl 40
Waste
incinerator for
incinerators HF 1
all types
(all sizes)
SO2 50

NO2 200

CO 50

Reference: Environment Quality (Clean Air) Regulation June 2014

NOTE(S):
i. Boilers O2 reference content is 6% for solid fuels and 3% for others fuel
ii. Turbines O2 reference content is 15%
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iii. For Continuous monitoring (using CEMS) the data for reporting will be based on ½ hourly mean values
iv. The emission reading shall be corrected based on O2 concentration as specified in DOE CAR June, 2014
v. The requirements above are extracted from CAR DOE June 2014. Refer to the latest revision of DOE Clean Air
Regulation to comply with the latest requirements.
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APPENDIX 2: TYPICAL BLOW-BACK SYSTEM FOR PROBE

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APPENDIX 3: TYPICAL EXTRACTIVE COLD DRY SYSTEM

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APPENDIX 4: TYPICAL EXTRACTIVE HOT WET SYSTEM

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APPENDIX 5: CEMS MONITORING TECHNOLOGY: DILUTION SYSTEM

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APPENDIX 6: TYPICAL OUT OF STACK DILUTION SYSTEM DRAWING

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APPENDIX 7: CLOSED-COUPLE SYSTEM

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APPENDIX 8: SAMPLE OF IN-STACK ANALYSER (IN-SITU)

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APPENDIX 9: SAMPLE OF CROSS-DUCT SYSTEM

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APPENDIX 10: MEASUREMENT OF SAMPLING PROBE LOCATION

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APPENDIX 11: PROBE POINT LOCATION

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APPENDIX 12: IN-SITU SYSTEM: PATH (CROSS-DUCT) SYSTEMS (DOUBLE – PASS TRANSMISSION
METER)