Portable Emissions Testing Skids for Remote Multi-Stack Engines
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Solution Overview
Problem
Current exhaust emissions testing systems for stationary engines are inefficient and require significant personnel hours, as they can only conduct one test at a time and have limitations on the distance between tested stacks, necessitating multiple vehicles and technicians for simultaneous testing.
Innovation Solution
An electronically controlled, portable testing system with self-contained, automated testing skids that allow a single technician to concurrently test multiple exhaust stacks from a distance, utilizing a programmable logic controller and host computer for remote monitoring and data processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple vehicle-based analyzer systems are used to test multiple exhaust stacks simultaneously, then testing capacity increases, but device complexity and coordination requirements increase significantly
Solution Approach 1:
The patent combines multiple analyzer systems into a single integrated vehicle-mounted platform. The system includes multiple analyzers (FTIR, FID, GC, NDIR) and support equipment consolidated into one vehicle, allowing a single technician to operate all testing equipment simultaneously while reducing the coordination complexity of managing multiple separate vehicles and teams.
Solution Approach 2:
The vehicle-based system is designed as a universal testing platform that can test multiple exhaust stacks concurrently. The system incorporates multiple analyzers and sample line configurations that allow simultaneous testing of different engines and stack types, providing multi-functional capability in a single integrated system.
2Length of stationary object
If sample lines are extended to reach distant exhaust stacks, then testing distance increases, but sample gas condensation and measurement accuracy deteriorate
Solution Approach 1:
The system maintains sample gas temperature above the dew point throughout the sampling process by controlling thermal parameters. Heated sample lines and temperature-controlled environments prevent condensation, allowing sample lines to extend to distant exhaust stacks while preserving measurement accuracy. The system dynamically adjusts temperature parameters to prevent water condensation in the sample stream.
3Ease of operation
If manual calibration and setup procedures are used, then device portability is maintained, but testing efficiency and personnel hours required increase
Solution Approach 1:
The system incorporates automated calibration and setup procedures that reduce manual intervention. The analyzers perform self-calibration using internal reference standards, and the system automatically configures sample lines and testing parameters. This self-service capability maintains portability while significantly reducing the time and personnel hours required for setup and operation.
Solution Approach 2:
The system performs preliminary calibration and system checks automatically upon deployment. Sample lines are pre-configured with heating elements and temperature control is pre-established to prevent condensation. These preliminary actions are executed automatically before testing begins, reducing the manual time required for setup and calibration during field operations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution increases efficiency, accuracy, and repeatability of tests by enabling a single technician to monitor and control multiple tests remotely, reducing personnel hours and improving testing capabilities across greater distances.
Implementation Method 1
Fourier-transform infrared (FTIR) spectrometers
Implementation Method 2
flame ionization detectors (FID)
Implementation Method 3
non-dispersive infrared (NDIR) detectors
Implementation Method 4
a heated sample line to keep the sample gas from condensing in the sample line
Data Source
AI summary
An improved electronically controlled portable testing system provides one or more self-contained, automated testing skids configured to perform required tests on the exhaust output of a stationary engine. The testing skids are configured for easy transportation on a medium duty truck and in a preferred testing process, are deployed to the engine site (and reloaded on the truck after testing is complete) using a lift attached to the truck. Using these systems and methods, a single technician can concurrently test multiple exhaust stacks on engines separated by any distance, from 100 feet to miles apart. The testing skids provide the technician with wireless remote test control and monitoring. The disclosed systems and methods increase the efficiency, accuracy and repeatability of tests.