Abstract:
A system and method are provided for tracking and documenting environmental compliance in a pulp mill, related primarily to the bypassing of liquid hazardous pollutants from a capture and treatment system. The method and system provide continuous information regarding the input materials, the output products, and the operations of equipment in the pulping process. The continuous information is provided to a central processor for determindation of emission levels that exceed certain predetermined levels. The method and system permit personnel to verify compliance with environmental regulations, verify the reliability of pollutant collection and treatment equipment and record the actions taken to correct an inappropriate emission or equipment failure.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]     This application is a Non-provisional application of Provisional Application Ser. No. 60/344,216 filed Dec. 21, 2001. Priority is claimed based on the aforesaid Provisional application Ser. No. 60/344,216 and based on Ser. No. 10/324,680, filed Dec. 20, 2002. 
     
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT  
       [0002]     Not Applicable  
       FIELD OF INVENTION  
       [0003]     This invention relates to monitoring of emissions and/or waste streams from a production facility.  
       BACKGROUND OF INVENTION  
       [0004]     The United States Environmental Protection Agency (EPA), prior to the present invention, has required monitoring and reporting on individual sources of actual or potential undesirable emissions of gaseous matter or liquid matter. These requirements have heretofore been satisfied by “end of the line” monitoring techniques. Heretofore, there has been no known method or system for the environmental monitoring and reporting of a combination of gaseous and liquid emissions from a production facility.  
         [0005]     Of recent, the EPA combined air and water regulation applying to the pulp and paper industry, known as the Cluster Rule. This Cluster Rule was developed to minimize and control Hazardous Air Pollutant (HAP) emissions via direct air vents from non-condensable type gas systems (NCG) (referred to in the Rule as Low Volume High Concentration (LVHC) and High Volume Low concentration (HVLC systems), and from volatilization fro HAP bearing liquid streams originating in the pulping and evaporation processes. These liquid streams are produced from the condensation of relief or evaporation vapors in various direct and indirect condensing systems in the aforementioned areas. The Cluster Rule refers to these HAP bearing condensates as “named streams”.  
         [0006]     The Cluster Rule is unique in the history of the industry as It is the first Rule to require monitoring of significant process parameters in the mill proper, and the first Rule to require the daily/continuous inventory of HAP9 produced in the mill proper. Most regulations look at final emissions on end-of-pipe treatment systems and their respective treatment efficiencies (eq. wastewater treatment basins, steam strippers, recovery boiler electrostatic precipitators etc). The industry was faced for the first time with monitoring AND reporting in-process activity as relates to HAP evolution, in addition to treatment. Many of these process areas were never monitored to this extent in the past and in many cases, no instrumentation was even present to track required parameters. Many new condensate collections systems had to be built with new piping to transport condensates from evaporator and pulping condensers to a main collection tank prior to delivery to one or more treatment devices. Operation parameters in the evaporators such as liquor flow, liquor solids, conductivity, condensate flow, temperature and valve positions along the delivery piping (to confirm actual collection) had to be installed and connected to the mill distributed control system (DCS) and process information (PI) systems. Digester systems required monitoring of chip meter rotation as an Indicator of pulp production, conductivity, condensate flow, temperature and valve position. Many of the Cluster Rule requirements did not provide instruction on the development of the monitoring and tracking systems, only the final goals.  
         [0007]     On Apr. 15, 1998 the Environmental Protection Agency (EPA) promulgated the Cluster Rule for the pulp and paper industry. These rules establish the effluent guidelines and standards under the Clean Water Act and the national emission standards for EPA&#39;s designated hazardous air pollutants under the Clean Air Act and have a mill-wide effect on the affected International Paper mills.  
         [0008]     The Clean Air Act Amendments of 1990 designated certain substances as hazardous air pollutants (HAPs) and required the industry to reduce HAPs using Maximum Achievable Control Technology (MACT) control measures. MACT means the best demonstrated control technology or practices used by similar sources of air toxics, defined by law as the average pollutant reduction achieved by the best-performing 12 percent of mills. The MACT regulation for the pulp and paper mills is codified in 40 CFR Part 63 Subpart S.  
         [0009]     The regulation requires pulp and paper mills to control HAPs, using methanol and chlorine as surrogates in the mills&#39; condensate, LVHC/HVLC and bleach plant systems, respectively.  
       SUMMARY OF THE INVENTION  
       [0010]     This invention is directed to a method for the combined monitoring and reporting of actual and potential emissions of multiple phases of matter from a production facility which utilizes and/or generates such multiple phases of matter comprising the steps of: 
        a. identifying each of the potential sources of emission events of gaseous matter generated within the production facility and desired to be monitored and reported,     b. identifying each of the potential sources of emission events of liquid matter generated within the production facility and desired to be monitored and reported,     c. at each identified potential source of gaseous or liquid emission event, providing means for detecting an emission event occurring at said source and generating an event signal which is representative of a detected emission event of a respective one of gaseous or liquid emission events at said source, said signal being representative of at least the occasion of the emission event, the volumetric extent of the event, the timing of the event, and the location of the event with the production facility,     d. transmitting said event signal from its identified source thereof to at least one central location,     e. generating a further signal representative of an operational phase of the production facility which is associated with each identified potential source of an emission event,     f. transmitting said signal representative of an operational phase of the production facility to said at least one central location,     g. at said central location, monitoring said incoming signals from said sources of emission events and said signals representative of respective associated operational phases of operation of the production facility associated with said sources of emission events, comparing each of said signals from respective ones of said sources of emission events with said signals representative of a respective one or more operational phase of the production facility associated with said source of said emission event to determine the status of the operation of the production facility at the time of said emission event,     h. reporting as actual emission events only those emission events which positively correlate with an associated ongoing production phase of the production facility at the time of the reported emission event.       
 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0019]      FIG. 1  is an ASB Treatment Data Flow.  
         [0020]      FIG. 2  is the Condensate PTE and Daily Uptime Data Flow.  
         [0021]      FIG. 3  is the Daily Condensate Collection and Pulp Production Data Flow.  
         [0022]      FIG. 4  is the Daily Methanol Collection and Pulp Production Data Flow.  
         [0023]      FIG. 5  is the Is-Ray Methanol Collection and Pulp Production Data Flow.  
         [0024]      FIG. 6  is the Device CMS and Bypass EE Event Data Flow.  
         [0025]      FIG. 7  is the LVHC PTF and Daily Downtown Data Flow.  
         [0026]      FIG. 8  is the Destruction Device Treatment Status Data Flow.  
         [0027]      FIG. 9  is the Vent Data Flow.  
         [0028]      FIG. 10  is the Vent Data Flow with Optional Main Vent Filtering.  
         [0029]      FIG. 11  is the Destruction Device EE and CMS Data Flow.  
         [0030]      FIG. 12  is the Steam Stripper 92% Ratio Data Flow.  
         [0031]      FIG. 13  is the Steam Stripper 92% 3Hour Average Excess Emission Event Data Flow.  
         [0032]      FIG. 14  is the Steam Stripper 92% Overflow Bypass EE Events.  
         [0033]      FIG. 15  is the Steam Stripper 92% Bypass EE Events.  
         [0034]      FIG. 16  is the Steam Stripper 92% Treatment Up Stream Bypass EE Events  
         [0035]      FIG. 17  is the Steam Stripper 92% Bottom Flow EE Event.  
         [0036]      FIG. 18  is the Scrubber Recirculation Data Flow.  
         [0037]      FIG. 19  is the Scrubber Form Data Flow. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0038]     This invention relates to an automated monitoring, record keeping and reporting system to comply with the regulation. The project objective is to comply with the requirements of these Cluster Rule components. This document was developed to establish the design specifications and programming methodology for this data collection system.  
         [0039]     The purpose of this document is to describe the design of the record keeping and reporting system for condensate treatment using an aerated stabilization basin (ASB). The software is comprised of PI Data Archive software (which is used for automatic data collection from various process instrumentation and control systems) and Proficy software (which monitors and reports compliance based on the PI data and operator inputs). This documentation is directed toward system administrator level personnel but can be used for a basic understanding of how the system works.  
         [0040]     The following sections describe the general configuration of the standard biological condensate treatment monitoring system. Deviations from the standard model, configuration listings for specific lines, and mill-specific details are contained within the appendices.  
         [0041]     Foul condensate is collected in a central collection tank (Main Tank) from sources such as digesters, evaporators, and turpentine systems. For treatment in a biological system, the condensate is pumped through a hardpipe delivery system discharging below the surface of an aerated stabilization basin (ASB) (or some other device such as a UNOX system). In most cases, the flow from the Main Tank mixes with the remaining whole mill influent to create the total ASB influent flow. In a few cases, the total ASB Influent flow is equal to the hardpipe flow if the ASB is a dedicated condensate treatment system that receives no other wastewater. The metric used to determine ASB compliance is the Total ASB Influent soluble Chemical Oxygen Demand (sCOD) load relative to the basin processing capacity based on aeration horsepower (with the units of sCOD lbs/HP). sCOD is defined as the amount of oxygen required to oxidize all soluble compounds, both organic and inorganic, in water. sCOD is expressed in units of mg/l (ppm). Compliance is demonstrated by operating below the limit of sCOD lbs/HP determined in a Performance Test. Other measurements of ASB Influent Load such as to Total Organic Carbon (TOC) can be used in place of sCOD. (Specified as the alternative method in §63.463(j)2)  
         [0042]     When the ASB treatment performance metric falls below the limit set in the performance test, the mill will respond in accordance with the SSM Plan and may retest to show compliance at this new parameter range with the result that no excess emission event occurred. (§63.453(p)) The monitoring system logs the potential Excess Emission (EE) event and corresponding operator responses to the event. The responses record the operator determined Trouble, Cause, Correction (response), and Report Code (report categorization) for the event. The report categorization specifies if the event is considered an allowable excess emission if the emission is due to a Startup, Shutdown, or Malfunction (SSM). The events are compiled by the system and reported to the state regulatory agency on a semi-annual basis or more frequently as required (§63.10).  
         [0043]     For mills following this ASB Treatment methodology, a warning limit is attached to the 15 Day—MeOH Avg variable to warn the operator that MeOH collection is close to falling below the excess emission limit for condensate collection. If the methanol load remains lower than that collected and treated during the initial performance test, the facility may be required to raise the ASB efficiency (by lowering the sCOD lbs/HP target) following a required quarterly retest unless the methanol collection can be restored to original collection levels. The warning limit is specific to the mill based upon the biological treatment efficiency of the ASB at the sCOD lbs/HP upper limit for the ASB system. The value of the warning limit is calculated from the minimum f bio  (fraction bio-degraded) that correlates to the sCOD lbs/HP upper limit, determined during a performance test; the limit is set to 11.1/f bio  for bleached mills and 7.2/f bio  for non-bleached mills. This warning notifies the operator to inspect and troubleshoot the condensate closed collection and treatment systems to insure compliance during the next quarterly performance test. Therefore the lower warning flag on collection may not result in an immediate excess emission for collection or treatment as long as the ASB continues to meet its initial performance test sCOD lbs/HP target. However if methanol collection levels are not restored by the quarterly test, excess emissions could be recorded indefinitely (on a daily basis) until the ASB efficiency is increased or collection restored. (§63.446(e) &amp; (p))  
         [0044]     In addition to capturing and categorizing EE events, the monitoring system also captures and records failures (downtime) of the Continuous Monitoring System (CMS). All Condensate Treatment ASB CMS events are manually triggered and are 24 hours in duration. This event is summarized and reported to the state in a semi-annual CMS performance report or more frequently as required. The report categorization specifies if the event is considered allowable based on the specific regulations. (§63.8(c)2, §63.8(c)8 and §63.10)  
         [0045]     In addition to monitoring and recording the above, the monitoring system records and displays operating parameters (on the ASB Treatment Autolog) to insure that the ASB is running under normal operating conditions. These operating parameters are used with specification limits applied to notify the operator (through color coding) to take whatever action is necessary to restore the ASB to normal operating conditions. The parameters are used for display only and do not create any events. The sample location for the operating parameters will vary by mill, but the standard operating parameters for all ASB&#39;s are; sCOD, dissolved oxygen (DO), dissolved oxygen uptake rate (DOUR), mixed liquor suspended solids (MLVSS), and specific oxygen uptake rate (SOUR).  
         [0046]     The Total Influent Load to the ASB is monitored in three ways: 
        1) A sCOD lbs/day alarm (upper user specification limit displayed on the autolog), when the maximum sCOD lbs/day design capacity of the ASB system is exceeded, indicating a possible process malfunction.     2) A sCOD lbs/HP alarm (upper user specification limit displayed on the autolog), when the ratio of the total sCOD pounds per day to total aeration horsepower per day (sCOD lbs/HP) is 90% of the limit, indicating the operator should increase aeration horsepower or decrease influent load.     3) A sCOD lbs/HP event (upper warning specification limit displayed on the autolog and the event is created on the downtime display), when the sCOD lbs/HP exceeds the limit established in a performance test, indicating a potential Excess Emission (EE) event.        
 
         [0050]     The sCOD load is calculated by multiplying the total daily ASB influent (Gals) by the sCOD (ppm) with appropriate factors to convert the result into lbs/day delivered to the ASB. Aerator horsepower is the product of an aerator horsepower factor (a mill may have several different factors if they maintain different types of aerators) and the number of aerators of each type in service. Both Total ASB Influent flow and sCOD may require multiple calculations to first determine the contribution of the hardpipe and whole mill influent. The total sCOD (lbs/day) inlet load is divided by the total aerator horsepower (HP/day) to determine the sCOD lbs/HP for the day, or:  
         sCOD   ⁡     (     lbs   /   HP     )       =               ASB   ⁢           ⁢   Influent   ⁢           ⁢   Flow   ⁢           ⁢     (   gpm   )     *                 sCOD   ⁡     (   ppm   )       *   8.35   ⁢     (     lbs   ⁢     /     ⁢   gal     )     *   1440   ⁢     (     min   ⁢     /     ⁢   day     )                     (       (       HP   1     *   #   ⁢     Aerators   1       )     +     (       HP   2     *   #   ⁢     Aerators   2       )     +                     …   +     (       HP   n     *   #   ⁢     Aerators   n       )       )     *   1   ⁢     ,     ⁢   000   ⁢     ,     ⁢   000             .         
 
         [0051]     Proficy calculates the total sCOD lbs/day, the total aerator HP/day, and the sCOD lbs/HP ratio once an operator manually enters the type and number of aerators (and/or blower systems) running, a daily sCOD test(s), and the Total ASB Influent Flow (note: at certain mills Total ASB Influent flow may be automatically entered from PI as the sum of the whole mill influent and hard pipe flows). The parameters required to calculate sCOD lbs/day are the Continuous Monitoring System (CMS) parameters for ASB treatment.  
         [0052]     Proficy compares the sCOD lbs/HP against a upper specification warning limit established during a Performance Test to determine if a potential EE event has occurred. The duration of a potential EE event is 24 hours. Performance Tests, conducted quarterly, relate the sCOD lbs/HP ratio to a minimum required ASB MeOH removal efficiency (f bio ). A sCOD lbs/HP value greater than the warning limit indicates the ASB is outside of the operating range established during the Performance Test. This indicates that the ASB is potentially overloaded and the ASB removal efficiency may be less than required for compliance.  
         [0053]     When the potential EE event is created, the mill must respond in accordance with the SSM Plan and may retest to show compliance at this new parameter range with the result that no excess emission event occurred. The Proficy software logs the potential EE event and corresponding operator responses to the event. The responses record the operator determined Trouble, Cause, Correction (response), and Report Code (report categorization) for the event. The report categorization specifies if the event is considered an allowable excess emission if the emission is due to a Startup, Shutdown, or Malfunction (SSM). A comment is required to be entered in Proficy whenever a potential EE event occurs. 1  The events are compiled by the system and reported to the state regulatory agency on a semi-annual basis or more frequently as required.    1  This is accomplished by forcing an operator to enter comment on the Trouble reason code in the Proficy downtime event.    
         [0054]     For mills following this ASB Treatment methodology, a warning limit (the Proficy lower user specification limit) is attached to the 15 Day—MeOH Avg variable to warn the operator that MeOH collection is close to falling below the excess emission limit (the Proficy lower warning specification limit) for condensate collection. If the methanol load remains lower than that collected and treated during the initial performance test, the facility may be required to raise the ASB efficiency (by lowering the sCOD lbs/HP target) following a required quarterly retest unless the methanol collection can be restored to original collection levels. The Proficy lower user specification limit is specific to the mill based upon the biological treatment efficiency of the ASB at the sCOD lbs/HP upper limit in Proficy for the ASB system. The value of the warning limit (Proficy lower user specification limit) is calculated from the minimum f bio  (fraction biodegraded) that correlates to the sCOD lbs/HP upper limit, determined during a performance test; the limit is set to 11.1/f bio  for bleached mills and 7.2/f bio  for non-bleached mills. This warning notifies the operator to inspect and troubleshoot the condensate closed collection and treatment systems to insure compliance during the next quarterly performance test. Therefore the lower warning flag on collection may not result in an immediate excess emission for collection or treatment as long as the ASB continues to meet its initial performance test sCOD lbs/HP target. However if methanol collection levels are not restored by the quarterly test, excess emissions could be recorded indefinitely (on a daily basis) until the ASB efficiency is increased or collection restored.  
         [0055]     In addition to capturing and categorizing events, the Proficy system also captures and records failures (downtime) of the Continuous Monitoring System (CMS). All Condensate Treatment ASB CMS events are manually triggered and are 24 hours in duration. This event is summarized and reported to the state in a semi-annual CMS performance report or more frequently as required. The report categorization specifies if the event is considered allowable based on the specific regulations.  
         [0056]     In addition to monitoring and recording the above, Proficy records and displays operating parameters (on the ASB Treatment Autolog) to insure that the ASB is running under normal operating conditions. These operating parameters are used with specification limits applied to notify the operator (through color coding) to take whatever action is necessary to restore the ASB to normal operating conditions. The parameters are used for display only and do not create any events. The sample location for the operating parameters will vary by mill, but the standard operating parameters for all ASB&#39;s are; sCOD, dissolved oxygen (DO), dissolved oxygen uptake rate (DOUR), mixed liquor suspended solids (MLVSS), and specific oxygen uptake rate (SOUR).  
         [0057]     Table-1 gives the process inputs typically required for ASB systems, their engineering units, data source, and corresponding Proficy variable names.  
                                     TABLE 1                           Input Variables            Production                       Unit/Group   Proficy Variable   Eng Units   Data Source   Description               Treatment   Total ASB Influent   ppm   Manual entry   Daily COD influent from       Variables   sCOD           lab analysis. More than one                       input may be required.       Treatment   Total ASB Influent   Gals/day   Manual entry   Influent flow daily total.       Variables   Flow       or PI   More than one input may be                       required.       Treatment   # Of Aerators       Manual entry   Number of aerators in       Variables   Running           operation (for each aerator                       type).       Treatment   HP/Aerator   HP   Manual entry   Factor for power delivered       Variables               per aerator (for each aerator                       type).       Treatment CMS   ASB Treatment Data       Manual entry   Manual treatment CMS           Quality (CMS)           event trigger. A menu                       choice allows the selection                       of a 24 hour CMS event or                       to indicate that the                       condensate system was                       Shutdown.       Operating   Basin Temperature   Deg F.   Manual entry   Basin temperature       Parameters           or PI       Operating   Minimum %   %   Manual entry   Minimum required       Parameters   Treatment           treatment percentage (f bio ) -                       Correlates to sCOD/HP                       maximum established                       during a performance test       Operating   ASB sCOD   ppm   Manual entry   sCOD in the ASB       Parameters       Operating   ASB DO   %   Manual entry   Dissolved O2 (DO) in the       Parameters               ASB       Operating   ASB DOUR   mg/l/hr   Manual entry   Dissolved O2 Uptake       Parameters               (DOUR) Rate in the ASB       Operating   ASB MLVSS   mg/l   Manual entry   Mixed Liquor Volatile       Parameters               Suspended Solids                       (MLVSS) in the ASB                  
 
         [0058]     The percent treatment minimum limit (Minimum % Treatment) reflects the f bio  (fraction biodegraded) that correlates to the maximum sCOD lbs/HP ratio (Total LB COD/HP) that was measured during any performance test (initial or quarterly). This maximum ratio (displayed on the Max sCOD lbs/HP Upper Limit Autolog variable) is the Proficy upper warning specification limit attached to the variable Total sCOD lbs/HP (see table 2 below).  
         [0059]     Additionally each mill may define mill specific operating variables to be monitored in addition to those specified above. User Specification limits for the operating parameters are listed in the specification limits table in Section V. Table-2 lists typical calculated variables for the system and a brief description of each.  
                                 TABLE 2                           Calculated Variables            Production Unit   Proficy Variable   Eng Units   Description               Treatment   Calculated ASB Influent sCOD   sCOD   Daily calculated sCOD load.       Variables   Load   lbs/day       Treatment   Total Aeration HP   HP/day   Total aeration horsepower per day.       Variables       Treatment   Total sCOD lbs/HP   sCOD   Total sCOD per aeration horsepower.       Variables       lbs/HP   The value changes color when it                   exceeds a warning level (Proficy                   upper user limit) and a potential EE                   event level (Proficy upper warning                   limit)       Treatment   Max LBS sCOD lbs/HP Upper   sCOD   Upper warning limit that triggers a       Variables   Limit   lbs/HP   potential EE event for the High           (Display Only)       sCOD/HP load. This variable is for                   display only and the value is updated                   via the Proficy administrator                   specification entry tool on the                   variable Total sCOD lbs/HP.       High sCOD/HP   Treatment Events (High   Status   Displays a potential EE event (24-hr)       Potential EE   sCOD/HP)       whenever the Total sCOD lbs/HP                   exceeds its upper warning                   specification limit, representing the                   maximum sCOD lbs/HP load.       Treatment CMS   Treatment CMS Events   Status   Displays a CMS 24-hr CMS                   downtime event whenever the ASB                   Treatment Data Quality (CMS)                   variable selection is used to create the                   manual CMS event.       Operating   ASB SOUR   mg/   Specific O2 Uptake Rate (SOUR).       Parameters       gVSS/hr   Triggers a visible warning when the                   calculation falls below the configured                   lower user limit attached to it.       Reporting Unit   Run Time   Min   The daily running minutes of the                   Condensate Collection system.                  
 
         [0060]     The ASB Treatment Data Flow is depicted in  FIG. 1 . A detailed description of the flow is as follows:  
         [0061]     1) ASB Run State and PTE  
         [0062]     The ASB basin is considered to be running anytime that the Condensate Collection system is operating. Consequently the ASB potential to emit status (PTE status) is equivalent to the Condensate Collection potential to emit. Whenever the Condensate Collection system is shutdown for a majority of the day (&gt;80% of the potential runtime or 4.8 hours in a 24 hour period) the ASB is also considered shutdown. See the section below (Condensate System Shutdown) for a detailed explanation of how this is indicated within the system.  
         [0063]     The total reporting minutes of ASB operation, reported to the appropriate regulatory authority on a semi-annual or more frequent basis as required, correspond to the total source operating minutes of the Condensate Collection system.  
         [0064]     2) sCOD Load  
         [0065]     The whole mill influent flow and hard pipe flow (if separate streams exist) going into the ASB are sampled and analyzed daily for sCOD. The sCOD load (Calculated ASB Influent sCOD Load) is the sum of the two streams&#39; sCODs (Total ASB Influent sCOD) multiplied by their daily total flows (Total ASB Influent Flow). Some mills have two sCOD loading (one from condensate sources and one from mill influent sources) implying that the Calculated ASB Influent sCOD Load will be the sum of the products of the sCOD and flows from each source for the day.  
         [0066]     3) Total Aeration Horsepower  
         [0067]     A separate mill-specific Autolog will be designed to calculate the total aeration horsepower, Total Aeration HP. 2  For each type of aerator, the number of aerators in operation will be multiplied by their respective horsepower to calculate the total horsepower for that specific aerator type. The total horsepower&#39;s for all types of aerators in operation are then summed to calculate the total aeration horsepower (Total Aeration HP).    2  At some mills this will be directly incorporated into the main ASB autolog sheet.    
         [0068]     4) COD Load per Aerator Horsepower  
         [0069]     This value (Total sCOD lbs/HP) is an estimate of the sCOD load relative to the processing capacity of the basin and is calculated by dividing the ASB influent sCOD load (Calculated ASB Influent sCOD Load) by the total aeration horsepower (Total Aeration HP).  
         [0070]     5) ASB Treatment EE Events  
         [0071]     An excess emission event is generated under the following conditions: 
        the value of Total sCOD lbs/HP is greater than its configured upper warning specification limit (i.e., a high value), and     the value of the ASB Treatment Data Quality (CMS) is not “Bad Data—24-Hr CMS” and not “Shutdown.”       
 
         [0074]     If an event is created and the ASB Treatment Data Quality (CMS) variable is subsequently changed (to either “Bad Data—24-Hr CMS” or “Shutdown”) the recorded event remains in the system and must be answered appropriately.  
         [0075]     If the mill SSM plan allows for retesting of the ASB at the higher sCOD lbs/HP ratio and the testing of the ASB determines that the sCOD lbs/HP ratio resulted in maintaining the removal efficiency, the mill may report the event as No Excess Emission.  
         [0076]     If the parameter value is exceeded and the SSM plan allows for it, the mill may chose to run a performance test to show compliance at this new parameter range. If the removal efficiency was maintained the event may be reported as No Excess Emission. A comment in Proficy is required whenever this condition occurs.  
         [0077]     All ASB Treatment EE events are 24-hours in duration.  
         [0078]     6) ASB Treatment CMS Events  
         [0079]     A reportable 24-hour CMS downtime event is created whenever the operator or environmental contact chooses the “Bad Data—24-Hr CMS” selection on the pull-down menu of the ASB Treatment Data Quality (CMS) variable. Manually selecting this option results in the creation of a 24-hour CMS event. A 24-hour CMS event results whenever one of the following parameters (required to determine sCOD lbs/HP) cannot be determined for the day: 
        Total ASB Influent Flow (gals),     Total ASB Influent sCOD (ppm),     Number and Type of Aerators Running.        
 
         [0083]     All ASB Treatment CMS events are 24-hours in duration.  
         [0084]     7) Condensate System Shutdown  
         [0085]     Whenever the condensate system has been shutdown for greater than 80% of the day the operator or environmental contact should indicate the shutdown by selecting the “Shutdown” selection from the ASB Treatment Data Quality (CMS) variable.  
         [0086]     Guidelines For Use of Manual Pull-Down Selections  
                                   Running Condition   Appropriate Action                   &gt;20% of daily runtime   Enter manual values and           the calculations will complete.       &lt;20% runtime (4.8 hours or 288 min.)   Select “Shutdown”       over the production day       No method to determine aerators running,   Select “Bad Data -       Bad or missing flows with no approved   24 Hrs CMS”       alternate method of manually entering the       values                  
 
         [0087]     8) Specific O2 Uptake Rate  
         [0088]     The Specific Oxygen Uptake Rate (SOUR), also known as the oxygen consumption or respiration rate, is defined as the milligram of oxygen consumed per gram of volatile suspended solids per hour. The value is computed by dividing the Dissolved Oxygen Uptake Rate ([mg/l]/hr) by the Mixed Liquor Volatile Suspended Solids (mg/l) and then multiplied by 1000 (1000mg/1 g) yielding the units of [mg/g]/hr.  
         [0000]     Standard PI Model  
         [0089]     Typically, all inputs to the standard ASB treatment model are manual entries (with the possible exception of the ASB inlet flow); therefore PI tags are not required.  
         [0000]     Standard Proficy Model  
         [0090]     The Proficy model consists of input variables, calculated variables, stored procedures, and Visual Basic scripts (VB scripts). Variables and associated parameters for a typical ASB treatment plant and descriptions of the stored procedures and the VB scripts are included below. Complete listings of the Stored Procedures can be found in Appendix A.  
         [0091]     Proficy Input Variables  
                                                                                             Variable   Data   Eng   Event       Sampling   Sampling           Description   Source   Units   Type   Data Type   Interval   Offset 3     Precision                                Total ASB   AutoLog   ppm   Time   Float   1440   330   0       Influent COD       Total ASB   AutoLog   Gals   Time   Float   1440   330   0       Influent Flow       # of Aerators   AutoLog       Time   Integer   1440   330       Running       HP/Aerator   AutoLog   HP   Time   Float   1440   330   1       ASB Treatment   AutoLog       Time   Data Quality   1440   330       Data Quality       (CMS)       Basin Temperature   AutoLog   Deg F   Time   Float   1440   330   1       (F.)       Minimum %-   AutoLog   %   Time   Float   1440   330   1       Treatment       Minimum   AutoLog   %   Time   Float   1440   330   1       Dissolved O2       Dissolved O2   AutoLog   [mg/g]/hr   Time   Float   1440   330   1       Uptake Rate       Mixed Liquor   AutoLog   mg/l   Time   Float   1440   330   1       Volatile       Suspended Solids                   3 The sampling offset is determined by the mill-specific start of day time. The offset value is the number of minutes from midnight to the mill start of day.             
 
         [0092]     Proficy Calculated Variables  
                                                               Variable   Eng   Event   Data   Sampling   Sampling       Calc           Description   Units   Type   Type   Interval   Offset 4     Precision   Type   Calc Name                   Calculated   lbs COD   Time   Float   1440   330   0   Equation   Calc       ASB Influent                               (A * 8.34 * B/1000000)       COD Load       Total Aeration   HP   Time   Float   1440   330   0   Equation   Calc (A * B)       HP       Total LBS   lbs   Time   Float   1440   330   1   Equation   Calc (A/B)       COD/HP   COD/HP       Max LBS   lbs   Time   Float   1440   330   1   Equation   Upper Warning Spec       COD/HP   COD/HP                           Limit       Upper Limit       Treatment   Status   Time   String   1440   330   1   Stored   ASB Treatment EE       Events (High-                           Procedure   Events       High COD/HP)       Treatment   Status   Time   String   1440   330       Stored   ASB Treatment       CMS Events                           Procedure   CMS Events       Specific O2   [Mg/hr]   Time   Float   1440   330   1   Equation   ASB Treatment       Uptake Rate                   4 The sampling offset is determined by the mill-specific start of day time. The offset value is the number of minutes from midnight to the mill start of day.             
 
 Specification Limits 
 
         [0093]     Proficy has upper and lower specification limits that can be defined for every variable: entry limits, user limits, warning limits, and reject limits. The following descriptions define how Proficy uses these limits to trigger events and inform operators of impending events:  
         [0000]     User Limits  
         [0094]     Provides a visible warning that event trigger points are being approached by changing the font color of the variable on an Autolog sheet  
         [0000]     Warning Limits  
         [0095]     Trigger level for EE events  
         [0000]     Reject Limits  
         [0096]     Trigger level for CMS events or data quality limits  
         [0000]     Entry Limits  
         [0097]     Restricts the range of valid numerical entries used for a manual entry variable.  
         [0098]     9) Proficy Variables and Specification Limits  
         [0099]     All manually entered operating parameters have Upper and Lower Entry specification limits.  
                                                                                                 Total sCOD lbs/HP   Upper User   Color coded Autolog warning that the Max COD/HP load is               being approached           Upper Warning   Maximum COD/HP ratio determined during a performance               test. Triggers a 24 hour potential EE event       ASB sCOD   Upper User   Color coded Autolog warning that sCOD is above normal               conditions       ASB DO   Lower User   Color coded Autolog warning that DO is below normal               conditions       ASB DOUR   Lower User   Color coded Autolog warning that DOUR is below normal               conditions       ASB MLVSS   Lower User   Color coded Autolog warning that MLVSS is below normal               conditions       ASB SOUR (Specific O2   Lower User   Color coded Autolog warning that the SOUR is dropping       Uptake Rate)       below normal operating conditions                  
 
 Calculations 
 
         [0100]     ASB Treatment EE Events  
         [0000]     Type: Stored Procedure—spLocal_ASBTreatmentEvents  
         [0101]     This procedure reads the value of the dependent variable (Total LBS COD/HP) and compares it to the variable&#39;s upper warning specification limit, as specified in the calculation inputs. If this value is outside of the upper warning specification limit, then a 24-hr downtime event is created (appended if a contiguous event exists) on the variable&#39;s unit. Some mill systems may elect to specify warning limits (Lower Warning-LW and/or Upper Warning-UW) to provide operators with a visual indication on the Autolog sheet that the upper limit is being approached.  
         [0102]     ASB Treatment CMS Events  
         [0000]     Type: Stored Procedure—spLocal_ASBTreatmentCMS  
         [0103]     This stored procedure creates a 24-hour downtime event that is triggered by a manual input from the operator (via ASB Treatment Data Quality (CMS)) which is configured as the dependent variable).  
         [0104]     Calc (A *8.34*B/1000000)  
         [0000]     Type: Equation  
         [0105]     Calculates the value of Calculated ASB Influent COD Load from Total ASB Influent COD (input-A in ppm) and the Total ASB Influent Flow (input-B in Gals).  
         [0106]     Upper Warning Spec Limit  
         [0000]     Type: Equation  
         [0107]     Returns the upper warning specification limit for a designated variable. This calculation is used to display the limit for Total LBS COD/HP.  
         [0108]     Calc (A/B)  
         [0000]     Type: Equation  
         [0109]     Returns the quotient of the two inputs, A and B.  
         [0110]     Calc (A*B)  
         [0000]     Type: Equation  
         [0111]     Returns the product of the two inputs, A and B.  
         [0112]     Calc (A/B*1000)  
         [0000]     Type: Equation  
         [0113]     Calculates the value of the Specific O2 Uptake Rate (SOUR) by dividing the Dissolved Oxygen Uptake Rate (input-A in mg/l/hr) by the Mixed Liquor Volatile Suspended Solids (input-B in mg/l) and then multiplies by 1000 (1000 mg/g) to compute the SOUR in [mg/g]/hr.  
         [0000]     Stored Procedure Listings  
         [0000]     spLocal_ASBTreatmentEvents  
         [0000]     /*  
         [0000]     Procedure Name: spLocal ASBTreatmentEvents  
         [0114]     Copyright (C) 2001, International Paper Company  
         [0115]     Process Management Application Group  
         [0000]     General Description:  
         [0116]     This procedure reads the value of the dependent variable and compares it to the variable&#39;s designated specification limit (LR,LW,UW,UR). If this value is outside the limit and the data quality flag &lt; &gt; ‘Shutdown’ and &lt; &gt; ‘Bad Data 24 Hr CMS, then a 24-hr downtime event is created (or appended if a contiguous event exists) on this variables PU.  
         [0000]     Triggers:  
         [0117]     1. Calculation Manager: Time (based on sample interval for variable).  
         [0118]     2. Dependent variable value changes.  
         [0000]     Inputs and Depedencies:  
         [0119]     1. Inputs described in body of code.  
         [0120]     2. Dependent variable—Value to be tested (e.g., 15-day MeOH Lb/ODTP)  
         [0121]     Select 5, @PU_Id,  
         [0000]     @PU Id,NULL,NULL,NULL,NULL,NULL,NULL,@ProductionRate,@Duration,1,@EventStartTime,N ULL,0  
         [0122]     Select 5, @PU_Id,  
         [0000]     @PU_Id,NULL,NULL,NULL,NULL,NULL,NULL,@ProductionRate,@Duration,4,NULL,@Timestamp ,0  
         [0000]     End  
         [0000]     Else  
         [0000]     Begin  
         [0123]     Select 5, @PU_Id,  
         [0000]     @PU_Id,NULL,@TEFault_Id,@Reason1,@Reason2,@Reason3,@Reason4,NULL,NULL,2,@@Start_Time,@Timestamp,@TEDet_Id  
         [0124]     End  
         [0125]     Set @OutputValue=‘Event Created’ 
         [0000]     End  
         [0000]     */  
         [0126]     The purpose of this document is to describe the design of the record-keeping and reporting system for the Condensate Collection system. The software is comprised of PI Data Archive software (which is used for automatic data collection from various process instrumentation and control systems) and Proficy software (which monitors and reports compliance based on the PI data and operator inputs). This documentation is directed toward system administrator level personnel but is useful for gaining a basic understanding of how the system works.  
         [0127]     The following sections describe the general configuration of the standard condensate collection monitoring system. Deviations from the standard model, configuration listings for specific lines, and mill-specific details are contained within the appendices.  
         [0128]     Cluster Rule regulations require that affected sites maintain continuous compliance with one of the following options for condensate collection: 
        Named Stream, which is the collection of all named streams listed in the regulation (§63.446(c)1); or     65%, which is collection of all HVLC and LVHC condensate and condensates that contain at least 65% of the total HAP mass from the remaining named condensate streams using methanol (MeOH) as a surrogate (§63.446(c)2); or     lb/ton, which is the collection of at least 11.1/7.2 lb HAP/ton of oven dried pulp at the digester (bleached/unbleached respectively) from the named streams using methanol as a surrogate (§63.446(c)3).        
 
         [0132]     Sites must obtain regulatory agency approval for their proposed method of continuous compliance and the continuous monitoring system (CMS). This document details IP&#39;s primary approach for continuous compliance using the lb/ton method referenced herein as the “Main Tank” or “Main Tank Collection” method.  
         [0133]     The continuous monitoring system (CMS) is operated to measure the quantity of methanol (MeOH) collected in the main condensate collection tank relative to pulp production. The regulatory requirement (§63.446(c)3) for compliance is to collect a minimum quantity of methanol per oven dried ton of pulp produced at the digester (7.2 lbs/ODTP for a non-bleached mill and 11.1 lbs/ODTP for a bleached mill). The lbs/ODTP collected in the main tank is calculated over an averaging period (e.g. fifteen-days). The collection quantity is derived from three primary process variables: 
        Pulp Production (Oven Dried Tons Pulp per Day (ODTP/Day), determined from chip meter or blow rate;     Condensate Flow (gpm), determined from a flow meter on main tank outlet;     Condensate MeOH Concentration (ppm), determined from a lab test.        
 
         [0137]     The data for pulp production, condensate flow and MeOH concentration are collected on a daily basis. Regulatory requirements for reduction of monitoring data are defined in §63.8(g), which requires four or more data points equally spaced over each 1-hour period. We are using daily totals of pulp production and condensate flow to match the collection period of the daily composite sample, which is used to determine the average daily MeOH concentration: Because there are rather large variances in these process values on a day to day basis, a 15-day rolling average is used to determine the lbs/ODTP value for excess emission reporting.  
         [0138]     The monitoring system logs all Excess Emission (EE) events and operator responses to those events, on a daily basis. The responses recorded by the operator determined Trouble, Cause, Correction (response), and Report Code (report categorization) for the event. The report categorization specifies if the event is considered an allowable excess emission due to Startup, Shutdown, and Malfunction (SSM) provisions, as required in §63.6(e)3(iii). The events are compiled by the system and reported to the state regulatory agency on a semi-annual basis or more frequently as required (§63.10).  
         [0139]     In addition to capturing and categorizing EE and bypass events, the monitoring system also captures and records failures (downtime) of Continuous Monitoring System (CMS) devices, referred to as CMS events. CMS out of control conditions are defined in §63.8(c)7. Condensate collection CMS parameters include the MeOH Concentration, pulp production measurement (ODTP) and the daily total condensate flow. The monitoring system records these CMS events on a daily basis, along with the operator determined Trouble, Cause, Correction (response), and Report Code (report categorization) for the event, as required by §63.8(c)8. These events are summarized and reported to the state in a semi-annual CMS performance report or more frequently as required (§63.10).  
         [0000]     Program Design  
         [0140]     The data for pulp production and condensate flow is collected and archived by the PI system and made available to the Proficy system as daily totals. MeOH concentration data is received automatically, through a file transfer from the testing lab, or manually entered (as a fixed value or manual override) into Proficy. If the MeOH concentration is relatively stable, a fixed (factor) value for the concentration may be used in place of the lab daily analysis when approved by the appropriate regulatory authority.  
         [0141]     At the beginning of each mill day, Proficy computes the relative MeOH collection rate (lbs MeOH/ODTP) over a 15-day window by dividing the 15-day collected MeOH total by the 15-day pulp production total (using only days and values exhibiting good data quality). This 15-day average lbs/ODTP collected is compared against the lbs per ODTP required for compliance to determine if an Excess Emission (EE) event has occurred. EE events are captured and recorded by the system whenever the calculated 15 Day lbs/ODTP of MeOH falls below the required minimum. Since this is a daily calculation, when this occurs the system records 24-hours of EE.  
         [0142]     The Proficy software logs all EE events and operator responses to those events. The operator responses determine the Trouble, Cause, Correction (response), and Report Code (report categorization) for the event. The report categorization specifies if the event is considered an allowable excess emission due to Startup, Shutdown, and Malfunction (SSM) provisions. The events are compiled by the system and reported to the state regulatory agency on a semi-annual basis or more frequently as required.  
         [0143]     Proficy also monitors for “bypass events” from the condensate closed collection system. A bypass event occurs when a portion of the condensate flow is diverted away from the collection system while the area is in a running state (i.e., the potential to emit HAPS [PTE] existed). Diverts are typically a result of flow diversion to sewer due to high conductivity or vessel overflow due to a malfunction—although other reasons for diverts exist. Proficy records the duration of the bypass events along with the operator responses to those events. The operator responses determine the Trouble, Cause, Correction (response), and Report Code. Bypass event reports are maintained by the mill to help categorize excess emission events (and as supporting documentation for Leak Detection and Repair (LDR) record keeping).  
         [0144]     In addition to capturing and categorizing EE and bypass events, the Proficy system also captures and records failures (downtime) of Continuous Monitoring System (CMS) devices, referred to as CMS events. Condensate collection CMS parameters include the MeOH Concentration, pulp production measurement (ODTP determined from a chip meter or digester blows) and the daily total condensate flow. Whenever data for any of the parameters fails to meet preset criteria (out of range, poor instrument signal quality, flatline signal, or missing MeOH lab test results) the system suspends all calculations until intervention by an operator or the environmental contact. Intervention is made by either entering manual data or by selecting from a pull-down menu indicating that the system received Bad Data (creating a 24-hour CMS event and removing the day from the 15-day MeOH average calculation) or was Shutdown for greater than 80% of the production day (removing the day from the calculation but not creating a CMS event). Fields exist in the system to accommodate the manual data entry of the CMS parameters (using methods allowed by the state regulatory agency as a back up for instrumentation failures), resulting in no CMS event even when failures in automatic data collection occur.  
         [0145]     CMS events are created manually when an operator or environmental contact determines that one or more of the CMS parameters have failed to obtain sufficient data to compute Daily MeOH collection for a 24-hour period. The individual creates the 24-hour CMS event by selecting “Bad Data” from the pull down menu on the Main Tank Proficy Autolog sheet. The system records the operator determined Trouble, Cause, Correction (response), and Report Code (report categorization) for the event. These events are summarized and reported to the state in a semi-annual CMS performance report or more frequently as required. Again, the report categorization specifies if the event is considered allowable based on the specific regulations.  
         [0146]     Additionally Proficy provides a selection on the pull-down menu to indicate that the condensate sources were shutdown for more than 80% of the production day (i.e., operational for &lt;4.8 hours). As with the CMS “Bad Data” selection, this has the effect of removing the day from the 15 day MeOH average calculation. Details of this process and guidelines on utilizing the menu selections are explained in detail below.  
         [0147]     Table-1 provides the minimum required process inputs, their engineering units, associated PI tags (typical), and corresponding Proficy variable names. Italicized text represents mill-specific information.  
                                 TABLE 1                           Input Variables                Eng               Input   Units   PI Tagname   Proficy Variable               Daily pulp production   ODTP   CR-pulp_production.Day   Daily - PI Digester Tons       Daily condensate collection   Gals   CR-cond_collection.Day   Daily - PI Main Tank Totalized                   Flow       Condensate MeOH   ppm   N/A   LAB MeOH Conc Test Result       concentration       Pulp production data quality       CR-pulp_production.DQ   N/A (Used in event detection       flag           model)       Condensate flow       CR-cond_collection.DQ   N/A (Used in event detection       measurement data quality           model)       Pulp production percent   %   CR-pulp_production.PctGd   Daily - PI chip meter % Good       good       Condensate flow percent   %   CR-cond_collection.PctGd   Daily - PI Main Tank Flow Meter       good           % Good       Condensate bypass or divert       CR- devicename .Divert   N/A (Used in event detection       event indicator           model)       Process downtime (both   Mins/Day   CR-COND_Down.DAY   Down Time       digester and evaporator area       are down)                  
 
         [0148]     Proficy also calculates, and periodically writes to PI, the data shown in Table-2 or 2A:  
                                 TABLE 2                           Proficy Data Written to PI            Proficy                   Variable   Eng Units   PI Tagname   Description               15 Day -   Lbs/ODTP   CR-   15-Day average       MeOH Avg       MeOHCollection.15Day   MeOH collection       15 Day -   Lbs/ODTP   CR-MeOHCollection.LL   15-Day average       MeOH           MeOH collection       Avg Lower           lower specification       Limit           limit from Proficy                  
 
         [0149]    
       
         
               
             
               
               
               
               
             
           
               
                 TABLE 2A 
               
             
             
               
                   
               
               
                   
               
               
                 Proficy Data Written to PI 
               
               
                 For Mills following ASB Only Treatment Methods 
               
             
          
           
               
                 Proficy Variable 
                 Eng Units 
                 PI Tagname 
                 Description 
               
               
                   
               
               
                 15 Day - MeOH Avg 
                 Lbs/ODTP 
                 CR- 
                 15-Day average MeOH collection 
               
               
                 (Lb/ODTP) 
                   
                 MeOHCollection.15Day 
               
               
                 15 Day - MeOH Avg Lower 
                 Lbs/ODTP 
                 CR-MeOHCollection.LL 
                 15-Day average MeOH collection 
               
               
                 Limit 
                   
                   
                 Lower Warning specification limit from 
               
               
                   
                   
                   
                 Proficy 
               
               
                 15 Day - MeOH Avg 
                 Lbs/ODTP 
                 CR- 
                 15-Day average MeOH collection 
               
               
                 Warning Limit 
                   
                 MeOHCollection.LWL 
                 Lower User specification limit from 
               
               
                   
                   
                   
                 Proficy 
               
               
                   
               
             
          
         
       
     
         [0150]     Table-3 lists typical Proficy variables for the system and a brief description of each.  
                                                                                                                                                         TABLE 3                           Proficy Variables                    Data           Production Unit   Variable   Source   Description                    Production Line: Condensate Event (CMS)            Condensate Event   Condensate CMS Events   Calculation   Calculation that generates the 24-hour CMS       (CMS)           downtime event.       Condensate Event   Condensate Collection   AutoLog   Manual trigger for the 24-hour CMS downtime       (CMS)   Data Quality (CMS)       event.            Production Line: (mill specific)            (mill specific)   Daily - PI Chip   PI   Pulp production data quality indicator (event for           Meter       each digester).           % Good       (mill specific)   Daily - PI Main Tank   PI   Condensate flow data quality indicator.           Flow Meter % Good            Production Line: Main Tank Compliance            Main Tank   15 Day - Avg End Time   AutoLog   Displays the timestamp for the last data point used       Compliance           in the 15 Day MeOH Avg calculation.       Main Tank   15 Day - Avg Start Time   AutoLog   Displays the timestamp for the first data point       Compliance           used in the 15 Day MeOH Avg calculation.       Main Tank   15 Day - Digester Tons   Calculation   Total pulp production over the last 15-days where       Compliance           the corresponding data quality is good.       Main Tank   15 Day - MeOH   Calculation   Total lbs MeOH collected over the last 15-days       Compliance   Collected       where the corresponding data quality is good.       Main Tank   15 Day - MeOH Avg   Calculation   Average MeOH collection over the last 15-days       Compliance           where the data quality is good.       Main Tank   15 Day - MeOH Avg   Calculation   Lower limit to alert the operator or EHS that the       Compliance   Warning Limit       EE trigger point is being approached for MeOH                   collection (Lower User Specification Limit)       Main Tank   15 Day - MeOH Avg   Calculation   Trigger limit for MeOH Collection Excess       Compliance   Lower Limit       Emissions. Equals 11.1 (non-bleached) or 13.2                   (bleached). (Lower Warning Specification Limit).       Main Tank   Condensate EE Events   Calculation   Compares 15 Day - MeOH Avg (Lb/ODTP) to       Compliance           the Lower Warning specification limit. An 24-                   hour EE event is generated if the Avg is less than                   the limit.       Main Tank   Daily - LAB MeOH   Calculation   Daily Lab MeOH Concentration test result. If       Compliance   Conc       multiple samples are coded for a given day, equal                   to the last value received.       Main Tank   Fixed MeOH Conc   AutoLog   Manually entered Fixed MeOH Concentration.       Compliance       Main Tank   Concentration Method   AutoLog   Operator selectable as “Daily Sample” or “Fixed       Compliance           Conc”. This determines whether the Daily - LAB                   MeOH Conc or Fixed MeOH Conc is used in                   subsequent calculations       Main Tank   Fixed or LAB MeOH   Calculation   MeOH concentration value used (LAB or FIXED       Compliance   Conc       from above)       Main Tank   Daily - Manual MeOH   AutoLog   Manually entered MeOH concentration which       Compliance   Conc       overrides the calculated value.       Main Tank   Daily - MeOH Conc   Calculation   Selected MeOH concentration (Fixed or LAB       Compliance   Used for Avg       MeOH Conc or Daily - Manual MeOH Conc)                   used in the calculation of Daily - MeOH                   Collected.       Main Tank   Daily - PI Main Tank   PI   Totalized flow from the condensate tank. This       Compliance   Totalized Flow       may come directly from a single PI tag or is                   derived from multiple flow totals.       Main Tank   Daily - Manual Main   AutoLog   Manually entered daily flow value. If entered, the       Compliance   Tank Totalized Flow       value will override the PI value.       Main Tank   Daily - Main Tank   Calculation   The selected value used in subsequent       Compliance   Totalized Flow Used for       calculations.           Avg       Main Tank   Daily - MeOH Collected   Calculation   Calculated lbs MeOH collected. Inputs are Daily -       Compliance           MeOH Conc Used for Avg and Daily - Main                   Tank Totalized Flow Used for Avg.       Main Tank   Daily - PI Digester Tons   PI   Daily pulp production from PI (ODTP/day)       Compliance       Main Tank   Daily - Manual Digester   AutoLog   Manually entered daily pulp production value. If       Compliance   Tons       entered, the value will override the PI value.       Main Tank   Daily - Digester Tons   Calculation   Daily pulp production used in the calculation of       Compliance   Used for Avg       15 Day - Digester Tons (ODTP).       Main Tank   Daily - MeOH Avg   Calculation   Calculated daily MeOH collection (Daily - MeOH       Compliance           Collected)/(Daily - Digester Tons Used for Avg)            Production Line: Main Tank LAB MeOH Test Data            Main Tank LAB   LAB MeOH Conc Test   File   Condensate sample test results.       MeOH Test Data   Result   Transfer            Production Line: Reporting Unit            Reporting Unit   Condensate Daily   PI   Process downtime (mins)           Downtime       Reporting Unit   Running Time   Calculation   Calculated process uptime (1440- Down Time)                  
 
         [0151]     The following paragraphs describe the interrelationship between the PI and Proficy variables and how they work together to complete the calculation of the 15 day MeOH collection average.  
         [0000]     Digesters and Evaporators PTE State  
         [0152]     A performance equation calculates an individual area&#39;s potential to emit (PTE) status each minute in PI. The performance equation logic returns a state of “CanEmit” when condensate is present in the area&#39;s condensate collection system. This is normally during the period from startup of the area (digester or evaporator) until a mill specific period after the area stops operating and methanol has been cleared from the system. The digester area PTE-state (CR-Dig_PTE.STAT) is calculated each minute based upon mill specific criteria (such as chip meter feed or extraction flows for a continuous digester). Similarly, the evaporator area PTE-state (CR-Evap_PTE.STAT) is calculated each minute and is based upon mill specific criteria (typically steam or liquor flow).  
         [0000]     Condensate System PTE State  
         [0153]     The Condensate system&#39;s potential to emit (PTE) is determined in PI using a performance equation, CR-Cond_PTE.STAT which is calculated every minute. The equation logic returns a state of “CanEmit” when either the digester area or evaporator area has a potential to emit status of “CanEmit”. When both areas have a PTE status of “CanNotEmit” the condensate PTE tag returns a state of “CanNotEmit”.  
         [0000]     Condensate Daily Downtime Counter  
         [0154]     At the start of each mill day, a PI performance equation, CR-Cond_Down.Day, totals the “CanNotEmit” time for the condensate system (CR-Cond_PTE.Stat) over the previous 24-hour period. This value is read by Proficy and is used for both the daily display and daily calculation of condensate runtime (“CanEmit” for the daily period). The daily runtime minutes are kept in Proficy and are used to compute the total runtime minutes for the reporting period.  
         [0155]     The Evaporator Area PTE, Digester Area PTE, overall Condensate System PTE and Daily Downtime data flow is depicted in  FIG. 2 .  
         [0000]     Pulp Production Filtered Tag and Percent Good  
         [0156]     For every new snapshot value for the raw DCS PI tag, a PI performance equation, CR-pulp_production.Filt, filters the raw DCS tag for bad data quality or non-running status (PTE status of “CanNotEmit”). The check for a flat-lined signal is not required since most pulp production totals are calculated from the chip meter speed or the blow counter which are generally static values. If the PTE status is in a “CanEmit” state the value of the tag is compared against upper and lower reject limits (maintained in Proficy and written periodically to PI). If the tag is within the limits the raw value is archived; if the tag is outside the limits the text string “BAD” is archived instead. When the PTE status is “CanNotEmit” a value of 0 is archived representing no additional pulp production for the minute.  
         [0157]     At the millday rollover, a PI performance equation CR-pulp_production.PctGd, calculates the percentage of time that the CR-pulp_production.Filt tag had a valid numerical value over the previous mill day (1440 minutes). The CR-pulp_production.PctGd tag is read by Proficy and displayed on an Autolog sheet to help explain missing data and for monitoring by operators and the environmental contact.  
         [0158]     Daily pulp production data flow is depicted in  FIG. 3 .  
         [0000]     Daily Pulp Production  
         [0159]     At the start of each mill day a PI totalizer tag, CR-pulp_production.DAY, performs a time-weighted total of the digester pulp production rate filtered tag (CR-pulp_production.Filt, ODTP/min) over the previous 24-hour period. Only production rate values while the digester area&#39;s PTE status is “CanEmit” are included in the total.  
         [0160]     Proficy reads the pulp production daily total and stores the value in the variable Daily—PI Digester Tons. As long as 80% of the daily runtime minutes 5  for pulp production experienced good data quality, the PI system will extrapolate a production total based upon 100% of the runtime minutes. The operator can also manually enter a pulp production value (Daily—Manual Digester Tons) to override an incorrect or missing PI value in the calculation of the daily and 15 Day—Digester Tons.    5  The current implementation uses a totalizer period which is 24-hr for the daily runtime.    
         [0161]     Daily pulp production data flow is depicted in  FIG. 3 .  
         [0162]     Condensate Collection Filtered Tag and Percent Good  
         [0163]     For every new snapshot value for the raw DCS PI tag, a PI performance equation, CR-cond_collection.Filt, examines the raw DCS tag for bad data quality, a flat-lined signal, or non-running status (PTE status of “CanNotEmit”). If (1) the PTE status is in a “CanEmit” state, (2) the difference between the maximum value of the raw tag for the past three hours and the minimum value of the raw tag for the past three hours is greater than zero, and (3) the raw value is within upper and lower data quality limits the raw value is archived by the filter tag; if the value of the tag is outside the limits or the maximum value minus the minimum value over the three hour period is zero a value of “BAD” is archived by the tag instead. If the PTE status is “CanNotEmit” a value of 0 is archived representing no flow for the minute. At the millday rollover, a PI performance equation CR-cond_collection.PctGd calculates the percentage of time that the CR-cond_collection.Filt tag had a valid numerical value over the previous mill day (1440 minutes). The CR-cond_collection.PctGd tag is read by Proficy and displayed on an Autolog sheet to help explain missing data and for monitoring by operators and the environmental contact.  
         [0164]     Daily condensate data flow is depicted in  FIG. 3 .  
         [0165]     Daily Condensate Collection  
         [0166]     At the end of each mill day a PI totalizer tag, CR-cond_collection.DAY, calculates a time-weighted totalized flow out of the main collection tank (GPM) over the previous 24-hour period. Proficy reads the condensate daily total and stores the value in the variable Daily—PI Main Tank Totalized Flow. As long as 80% of the daily runtime minutes experienced good flow meter data quality, the PI system will extrapolate the flow total based upon 100% of the runtime minutes. The operator can also manually enter a flow value for the day (Daily—Manual Main Tank Totalized Flow) that will override an incorrect or missing PI value for daily flow. This value (and the Daily—MeOH Conc. Used for Avg value—see below) is used to calculate the daily collected MeOH (Daily—MeOH Collected). Daily collected MeOH is used in the calculation of 15 day collected MeOH (15 Day—MeOH Collected).  
         [0167]     Daily condensate data flow is depicted in  FIG. 3 .  
         [0000]     MeOH Concentration  
         [0168]     MeOH concentration is determined by lab analysis of samples taken from the main collection tank. The CRC lab analysis uses File Transfer Protocal (FTP) to automatically enter the lab determined MeOH concentration into the Main Tank Autolog variable Daily—Lab MeOH Conc for the period (mill day) from which the sample was taken (and applies to). For other labs, the daily concentration must be manually entered by the mill. Alternatively a second Autolog variable, Fixed MeOH Conc, can be used in place of the Daily—Lab MeOH Conc if the mill and state regulatory agency agree upon an approach to calculate and verify a fixed MeOH factor, referred to as the Fixed MeOH Conc (Fixed MeOH Concentration). A pull down selection (Concentration Method) is used to select between the use of the Daily—Lab MeOH Conc and the Fixed MeOH Conc. The Fixed MeOH Conc is a manually entered, repeating Autolog variable and is used whenever the pull down selection is set to FIXED CONC. The calculation of Daily MeOH Avg (lbs/ODTP) will immediately occur once the daily tons produced (ODTP) and daily totalized flows are entered in the system (either manually or automatically from PI data). Since this is a mill specific averaging period, the system administrator, in concert with the environmental contact, is responsible to manually update the value of Fixed MeOH Conc to accurately reflect the most current fixed factor MeOH concentration whenever the factor value changes (and in accordance with the regulatory agency agreed upon requirements). If the Concentration Method pull down is set to DAILY SAMPLE, the system will wait until a lab concentration is available in the Daily—LAB MeOH Conc field to compute the Daily MeOH Avg (lbs/ODTP).  
         [0169]     A third variable, Daily—Manual MeOH Conc, is available for the environmental contact to enter a manual concentration that will override the automatically entered value (either the Daily—LAB MeOH Conc [if Concentration Method is set to DAILY SAMPLE] or the Fixed MeOH Conc [if Concentration Method is set to FIXED CONC]) in case of an incorrect or missing concentration.  
         [0170]     Either the automatic or manually entered concentration (if entered) is copied into a fourth variable, Daily—MeOH Conc Used for Avg. The value initially is set to the automatically entered value (Daily—LAB MeOH Conc or Fixed MeOH Conc). The value updates when: 
        1) a value is added to the Daily—Manual MeOH Conc;     2) the Concentration Method flag changes (from/to DAILY SAMPLE to/from FIXED CONC); or     3) a previously entered manual value is deleted.        
 
         [0174]     Whenever the value in this variable changes, the system will re-compute the Daily MeOH Avg (lbs/ODTP) and affected 15 day averages using the new value.  
         [0175]     Security will be applied to the variables Fixed MeOH Conc and the Concentration Method selection field to prevent anyone except the designated person from modifying the method used (Daily or Fixed) or change the value of the repeating fixed concentration. This is usually accomplished by the security on the autolog display.  
         [0176]     Daily MeOH concentration data flow is depicted in  FIG. 4 .  
         [0177]     10) 15-Day Totals  
         [0178]     Fifteen-day totals for collected pounds MeOH (15 Day—MeOH Collected) and pulp production (15 Day—Digester Tons) are calculated in Proficy from the respective daily values. The calculation looks at the data over the last 30-days and sums the most recent 15 daily values where the corresponding data quality is good (as specified by the data quality flag, Condensate Collection Data Quality (CMS)). Fifteen values are required before a total is calculated. The 15-day average MeOH, 15 Day—MeOH Avg (lbs/ODTP), is calculated by dividing the 15-day collected MeOH total (15 Day—MeOH Collected) by the 15-day pulp production total (15 Day—Digester Tons).  
         [0179]     For mills following the ASB Treatment methodology, a warning limit (the Proficy lower user specification limit) is attached to the 15 Day—MeOH Avg variable to warn the operator that MeOH Collection is close to falling below the excess emission limit (the Proficy lower warning specification limit) for condensate collection. The Proficy lower user specification limit is specific to the mill based upon the biological treatment efficiency of the ASB at the sCOD/HP upper limit in Proficy for the ASB system. The value of the warning limit (Proficy lower user specification limit) is calculated from the minimum f bio  (fraction bio-degraded) that correlates to the sCOD/HP upper limit, determined during a performance test; the limit is set to 11.1/f bio  for bleached mills and 7.2/f bio  for non-bleached mills. This warning notifies the operator to inspect and troubleshoot the condensate closed collection and treatment systems to insure compliance during the next quarterly performance test.  
         [0180]     Data flow for 15-day totals is depicted in  FIG. 5 .  
         [0000]     Condensate Collection System EE  
         [0181]     A main tank condensate collection EE event is created whenever the 15 Day—MeOH Avg (lbs/ODTP) is less than its lower warning specification limit configured in Proficy. The event duration is 24-hours.  
         [0182]     Data flow for condensate system EE is depicted in  FIG. 6 .  
         [0183]     Condensate System Bypass Events  
         [0184]     Bypasses of the condensate closed collection system are monitored by PI. A typical bypass indicator is the state of a two-way divert valve (Open/Closed) or the state of a tank overflow indicator (Overflow/NotOverflow). For divert valves, a PI performance equation, CR-devicename.Divert, returns a value of “Collect” when flow through the device is directed toward the main condensate collection tank and returns a value of “Divert” when flow through the device is diverted from the main collection tank (while the device&#39;s area—digesters, evaporators or both—has a PTE status of “CanEmit”). These performance equations are calculated every minute. Bypass events are monitored for Leak Detection and Repair reporting and may contribute to an EE event if the 15-day average MeOH Lbs/ODTP collected at the main tank falls below the lower warning specification limit.  
         [0185]     Proficy monitors these tags using Proficy downtime model  200  with up to a 15 minute filter. Any PI value other than “Collect” begins a Bypass event. The Event ends when the PI value returns to “Collect”.  
         [0186]     Bypass Event data flow is depicted in  FIG. 6 .  
         [0000]     Condensate Data Quality Indicator Events  
         [0187]     For Data Quality indicator events, Proficy monitors the data quality status for the main tank flow meter and each digester production indicator (blow counters are usually exempt) using Proficy downtime Model- 200  with a mill specific delay filter. PI performance equations, CR-devicename.DQ, return a value of “Bad” when the instrument readings are outside the mill-specified instrument range while the respective area has a PTE status of “CanNotEmit” as indicated by the associated filtered (.Filt) tag; otherwise, the returned value is “Good”. Whenever Proficy reads any value from PI other than “Good,” a Data Quality Indicator event is started. The event ends when the PI value returns to “Good.” These events are not reportable to the state and are used for diagnostic troubleshooting of the closed condensate collection system.  
         [0188]     Missing MeOH concentration data due to problems with the sample or the lab test are captured with manual downtime events in Proficy. This event is not reportable to the state and is used for diagnostic troubleshooting of the closed collection system.  
         [0189]     Condensate CMS Events  
         [0190]     A reportable, 24-hour CMS downtime event is created whenever the operator sets the Condensate Collection Data Quality (CMS) pull-down selection to a value of “Bad Data—24Hr CMS”. This selection will be chosen when the MeOH Concentration, daily flow total, or daily digester production (ODTP) cannot be determined for the day. The operator will use the reasons assigned to the Data Quality Indicator events for the day to assign the appropriate reasons to the 24-hour CMS event. If the mill is using a fixed MeOH concentration factor (Concentration Method set to FIXED CONC), the absence of a daily MeOH concentration will no longer result in a reportable CMS event.  
         [0191]     Condensate System Shutdown  
         [0192]     Whenever the condensate system sources (digesters and evaporators) have been shutdown for a majority of the day (&lt;20% of the potential runtime minutes or &lt;4.8 hours per production day) the operator can manually select the option Shutdown from the pull-down selection on the Condensate Collection Data Quality (CMS) variable. This has the effect of eliminating the shutdown day data from use in computing subsequent 15-day rolling MeOH collection averages.  
         [0193]     When one or more of the required values to compute MeOH collection are missing, Proficy will suspend MeOH calculations until the values are available or operator intervention (through manual entry of a value or manual selection regarding data quality) is made. The table below reflects the appropriate action under differing runtime conditions and/or data quality conditions.  
         [0194]     Guidelines For Use of Manual Pull-Down Selections  
                                   Running Conditions   Appropriate Action                   &gt;20% of daily runtime and &gt;80%   No action required; values       Good data   automatically entered in           PI and read by Proficy.       &gt;20% runtime and &lt;80% Good data   Manual entry of ODTP,       (Bad or missing PI Data) and an   Total Flow, and/or MeOH       approved alternate method of obtaining   Concentration as required       ODTP, Flow, or MeOH Concentration       &lt;20% runtime (4.8 hours or 288 min.)   Select “Shutdown”       over the production day       &lt;80% Good Data for runtime min.   Select “Bad Data - 24 Hrs CMS”       with no approved alternate method of       ODTP, Flow, or MeOH Concentration                  
 
         [0195]     Standard PI Model  
         [0196]     Tag Name Specifications  
         [0197]     All Cluster Rule PI tags will begin with “CR-”.  
         [0000]     Digital State Set Specifications  
         [0198]     The following are the minimum required digital state sets in PI to support the Cluster Rule Bleach Plant model.  
                                                       Digital Set Name   State 0   State 1                           P2Emit   CanEmit   CanNotEmit           OK-EE   OK   EE           GOOD-BAD   Good   Bad           DivertCollect   Divert   Collect           Running   Running   NotRunning                      
 
 Scan Class Specifications 
 
         [0199]     The following scan classes must be available in PI. Note, the scan class number will vary from mill to mill.  
         [0200]     A one minute scan class offset 0 seconds from midnight;  
         [0201]     A twenty-four hour scan class offset to the start of mill day.  
         [0202]     Examples of the scan class syntax are as follows:  
                                                   /f=00:01:00, 00:00:00 (alternately /f=00:01:00, 0)           /f=24:00:00, 07:00:00 (alternately /f=24:00:00, 25200) for mill day           at 07:00am                      
 
         [0203]     PI Totalizer Configuration  
         [0204]     PI Totalizer tags are used to calculate daily totals from flow meters and production rate tags. In order to properly account for potential to emit status and percent good limits for the source tag, the following procedures are used to configure these totalizers: 
        1. The flow source tag, which is read directly from a DCS flow indicator, will be referred to as cond_collection (Condensate Flow Indicator). The pulp production source tag, which is read directly from a DCS chip meter or blow counter, will be referred to as pulp_production (total ODTP/d).     2. The totalizer souce tag needs to have cluster rule data quality criteria applied. This includes data quality limits (instrument range), flat-lined signal tests and PTE status. Some tags, such as chip meter RPM, may change so slowly that a flat-lined signal test is not applicable. Other tags, such as condensate flow, will check the difference in the maximum value and the minimum value over the previous three hours to insure that the tag is not flat-lined. When the PTE status is “CanNotEmit”, the Filt tag returns a value of 0 so that the Totalizer will total a value of 0 instead of an interpolated value. The FILT tag should be a PI PE tag, event scheduled, so that buffered DCS data will re-trigger the calculations so that the totalizer will compute a value within one minute of the end of the day, the raw DCS tag exception max attribute must be set to 60 seconds or less. This will help Proficy&#39;s ability to read the value at the mill day rollover.     3. Proficy will generate informational downtime events, when CMS instruments are not reading, which can be used to identify reasons for 24 hour CMS downtime, when totalizer values are missing because the % goodis less than 80%. These downtime events are generated from a .DQ tag which is “GOOD” if the .Filt tag has a numeric value and “BAD” when the .Filt tag&#39;s value is a digital state. The .DQ tag is an event scheduled PE tag, based on changes in the .FILT tag, so that it computes immediately whenever the process value changes.     4. A .PctGd PE tag will calculate daily percent good of the .FILT, but will not generate CMS events automatically. It will be read by Proficy and displayed for operator information. Daily CMS events are manually created by the environmental contact using a Proficy Autolog pull down menu.     5. The daily totalizer, .DAY, will use .FILT as its SourceTag using a %-good attribute of 80% (or other value negotiated with the state agency). The effect of this is that the totalizer only totalizes pulp_production or cond_collection when the status of the source tag is good (a numeric value), and there is a potential to emit (included in the .Filt tag logic). If the percent good of .FILT is greater than 80%, but less than 100%, the totalizer will extrapolate the available values to estimate a 100% daily total. If the percent good is less than 80%, the totalizer will not generate a valid daily total. When there is no potential to ermit, the .FILT tag will have a value of zero, so will contribute nothing to the daily total for that period. 
 
 PI Tag Configuration Specification 
       
 
         [0210]     Tables 4-1 and 4-2 provide tag configuration examples of performance equations for a typical condensate collection model. Tables 4-3 and 4-4 provide tag configuration examples of totalizers for a typical condensate collection model. Table 4-5 gives exception and compressions attribute standards for raw DCS PI tags.  
                       TABLE 4-1                       Tag               Name/Descriptor   Comments   Exdesc                   CR-Dig.Stat/CR-   Mill-Dependent   If (‘flow.PV’&lt;lowflowlimit...) then “NotRunning” else “Running”       Evaps.Stat 6         Running status       CR-Dig_PTE.STAT 7     CanEmit if the area is   if BadVal(TimeEQ(‘CR-Dig.STAT’, ‘*-delaytime, ‘*’, “Running”)) then PrevVal(‘CR-       Digesters Potential to   running, producing MeOH, or   Dig_PTE.STAT’, ‘*-delaytime’) else if TimeEQ(‘CR-Dig.STAT’, ‘*-delaytime’, ‘*’,       Emit Status   has been running and has not yet   “Running”) &gt;0 then “CanEmit” else           purged all MeOH from the   “CanNotEmit”           system       CR-Evaps_PTE.STAT 2     CanEmit if the area is   if BadVal(TimeEQ(‘CR-Evaps.STAT’, ‘*-delaytime’, ‘*’, “Running”)) then PrevVal(‘CR-       Evaporators   running, producing MeOH, or   Evaps_PTE.STAT’, ‘*-delaytime’) else if TimeEQ(‘CR-Evaps.STAT’, ‘*-delaytime’, ‘*’,       Potential to Emit Status   has been running and has not yet   “Running”) &gt; 0 then “CanEmit” else “CanNotEmit”           purged all MeOH from the           system       CR-Cond_PTE.STAT 2     CanEmit if either dig or   If ‘CR-Dig_PTE.STAT’ = “CanNotEmit” and ‘CR_Evaps_PTE.STAT =       Condensate   evaps area PTE is “CanEmit”;   “CanNotEmit” then “CanNotEmit” else “CanEmit”       Potential to Emit Status   CanNotEmit if both dig and           evaps area PTE is CanNotEmit       CR-Cond_Down.Day 8     Total minutes in the   TimeEq(‘CR-Cond_PTE.STAT’,‘Y+7H’,‘T+7H’,“CanNotEmit”)/60       Daily Condensate   CanNotEmit state for yesterdays       downtime   operating day       CR-   Filters raw DCS tag based on   Event=pulp_production,  if  ‘CR-Dig_PTE.STAT’=“CanEmit”  then  (if       pulp_production.Filt   upper and lower limits and PTE   (‘pulp_production’&gt;=lowlowlimit and ‘pulp_production’&lt;=hihilimit) then       Pulp production   status   ‘pulp_production’ else “Bad”) else 0       rate filtered       CR-   Filters raw DCS tag based on   Event=cond_collection,  if  ‘CR-Cond_PTE.STAT’=“CanEmit”  then  (if       cond_collection.Filt   upper and lower limts and PTE   (TagMax(‘cond_collection’,’*−3h’,’*’) − TagMin(‘cond_collection’,’*−3h’,’*’) &gt;       Condensate collection   status   0 and ‘cond_collection’&gt;=lowlowlimit and ‘ cond_collection’&lt;=hihilimit) then       filtered       ‘ cond_collection’ else “Bad”) else 0       CR-   BAD if .Filt tag has BAD value;   event=CR-pulp_production.Filt,if BadVal(‘ CR-pulp_production.Filt ’) then “Bad” else       pulp_production.DQ 4     GOOD is Filt tag has numeric   “Good”       Pulp production   value       rate data quality       CR-   BAD if .Filt tag has BAD value;   event=CR-pulp_production.Filt,if BadVal(‘ CR-pulp_production.Filt ’) then “Bad” else       cond_collection.DQ 9     GOOD is Filt tag has numeric   “Good”       Condensate Collection   value       Data Quality       CR-   Calculates the daily   If BadVal(PctGood(‘CR-pulp_production.Filt’,‘Y+420M’,‘T+420M’)) then 0 else       pulp_production.PctGd   percent good of the .Filt tag   PctGood(‘CR-pulp_production.Filt’,‘Y+420M’,‘T+420M’)       Pulp production       rate % Good       CR-   Calculates the daily   If BadVal(PctGood(‘CR-pulp_production.Filt’,‘Y+420M’,‘T+420M’)) then 0 else       cond_collection.PctGd   percent good of the .Filt tag   PctGood(‘CR-pulp_production.Filt’,‘Y+420M’,‘T+420M’)       Condensate collection %       Good       CR-   Monitor tank overflows and   For tank overflows - If (‘CR-Cond_PTE.STAT’=”CanNotEmit”) then “Collect” else if       devicename.Divert 10     diverts of condensate to   (‘tank_level.PV’ &lt;= HiHiLimit) then “Collect” else “Divert”       Bypass event   sewer for leak detection   For divert valves - If (‘CR-Cond_PTE.STAT’=”CanNotEmit”) then “Collect” else if           and repair reporting   (‘devicename.PV’ = “Open”) then “Collect” else “Divert”       CR-   15-Day Average MeOH       MeOHCollection.15Day   collection       CR-MeOHCollection.LL   15-Day Avg MeOH           collection Low Limit       CR-   15-Day Avg MeOH coll.       MeOHCollection.LWL 11     Low User Limit                   6 Running Status tag logic is to be defined so that any error conditions will default to the value of “Running” (final clause is else “Running”)              7 If delaytime is not required, running status logic is used in the PTE tag and the running status tag is not needed. PTE Status tag logic is defined so that the default value is “CanNotEmit” (final clause is else “CanNotEmit”)              8 Daily downtime tag logic, Y+7H refers to 7:00 am yesterday and T+7H refers to 7:00 am today for a mill-day rollover of 7:00 am (adjust for mill&#39;s actual rollover)              9 Data Quality (CMS) tag logic is defined so that any error conditions will default to the value of “BAD” (final clause is else “BAD”)              10 Bypass Divert tag logic is defined so that any error conditions will default to the value of “Divert” (final clause is else “Divert”)              11 Lower User Specification Limit is written to PI ONLY when ASB Treatment method is used.             
 
         [0211]    
       
         
               
               
               
               
               
               
               
             
               
               
               
               
               
               
               
               
               
             
           
               
                 TABLE 4-2 
               
               
                   
               
               
                   
               
             
             
               
                   
                   
                 Point 
                 Ppoint 
                   
                   
                 cComp 
               
               
                 Tag Name 
                 engunits 
                 source 
                 type 
                 DigitalSet 
                 LLocation4 
                 dev 
               
               
                   
               
               
                 
                   CR-Dig.Stat/CR-Evaps.Stat 
                 
                 Running/Not 
                 C 
                 Digital 
                 Running 
                 1 
                 Mill std 
               
               
                   
                 Running 
                   
                   
                   
                   
                   
               
               
                 CR-Dig_PTE.STAT 
                 CanEmit/Can 
                 C 
                 Digital 
                 P2EMIT 
                 1 
                 0 
               
               
                   
                 NotEmit 
               
               
                 CR-Evaps_PTE.STAT 
                 CanEmit/Can 
                 C 
                 Digital 
                 P2EMIT 
                 1 
                 0 
               
               
                   
                 NotEmit 
               
               
                 CR-Cond_PTE.STAT 
                 CanEmit/Can 
                 C 
                 Digital 
                 P2EMIT 
                 1 
                 0 
               
               
                   
                 NotEmit 
               
               
                 CR-Cond_Down.Day 
                 Min/Day 
                 C 
                 Float32 
                   
                 4 
                 0 
               
               
                 CR- pulp _ production .Filt 
                 ODTP/m 
                 C 
                 Float32 
                   
                 1 
                 0 
               
               
                 CR- 
                 GPM 
                 C 
                 Float32 
                   
                 1 
                 0 
               
               
                   cond _ collection _ tag .Filt 
               
               
                 CR- pulp _ production .DQ 
                 GOOD- 
                 C 
                 Digital 
                 BAD- 
                 1 
                 0 
               
               
                   
                 BAD 
                   
                   
                 GOOD 
               
               
                 CR- 
                 GOOD- 
                 C 
                 Digital 
                 BAD- 
                 1 
                 0 
               
               
                   cond _ collection _ tag.DQ   
                 BAD 
                   
                   
                 GOOD 
               
               
                 CR- 
                 % 
                 C 
                 Float32 
                   
                 4 
                 0 
               
               
                   pulp _ production .PctGd 
               
               
                 CR- 
                 % 
                 C 
                 Float32 
                   
                 4 
                 0 
               
               
                   cond _ collection _ tag .PctGd 
               
               
                 CR- devicename .Divert 
                 Divert- 
                 C 
                 Digital 
                 DivertCollect 
                 1 
                 0 
               
               
                   
                 Collect 
               
               
                 CR- 
                 Lbs/ODTP 
                 Lab 
                 Float32 
                   
                 1 
                 0 
               
               
                 MeOHCollection.15Day 
               
               
                 CR-MeOHCollection.LL 
                 Lbs/ODTP 
                 Lab 
                 Float32 
                   
                 1 
                 0 
               
               
                 CR-MeOHCollection.LWL 
                 Lbs/ODTP 
                 Lab 
                 Float32 
                   
                 1 
                 0 
               
               
                   
               
             
          
           
               
                   
                   
                 Comp 
                 Eexc 
                   
                   
                   
                   
                   
               
               
                 Tag Name 
                 Compressing 
                 Max 
                 dev 
                 excmax 
                 shutdown 
                 step 
                 zero 
                 Span 
               
               
                   
               
               
                 
                   CR-Dig.Stat/CR-Evaps.Stat 
                 
                 1 
                 Mill std 
                 Mill 
                 Mill std 
                 1 
                 0 
               
               
                   
                   
                   
                 std 
               
               
                 CR-Dig_PTE.STAT 
                 1 
                 28800 
                 00 
                 60 
                 1 
                 0 
               
               
                 CR-Evaps_PTE.STAT 
                 1 
                 28800 
                 00 
                 60 
                 1 
                 0 
               
               
                   
               
               
                 CR-Cond_PTE.STAT 
                 1 
                 28800 
                 00 
                 60 
                 1 
                 0 
               
               
                 CR-Cond_Down.Day 
                 1 
                 7200 
                 00 
                 60 
                 0 
                 1 
                 0 
                 1440 
               
               
                 CR- pulp _ production .Filt 
                 1 
                 Mill std 
                 0 
                 60 
                 1 
                 0 
                 ? 
                 ? 
               
               
                 CR- 
                 1 
                 Mill std 
                 0 
                 60 
                 1 
                 0 
                 ? 
                 ? 
               
               
                   cond _ collection _ tag .Filt 
               
               
                 CR- pulp _ production .DQ 
                 1 
                 28800 
                 0 
                 60 
                 0 
                 0 
               
               
                 CR- 
                 1 
                 28800 
                 0 
                 60 
                 0 
                 0 
               
               
                   cond _ collection _ tag.DQ   
               
               
                 CR- 
                 1 
                 7200 
                 00 
                 60 
                 1 
                 1 
                 0 
                 100 
               
               
                   pulp _ production .PctGd 
               
               
                 CR- 
                 1 
                 7200 
                 0 
                 60 
                 0 
                 1 
                 0 
                 100 
               
               
                   cond _ collection _ tag .PctGd 
               
               
                 CR- devicename .Divert 
                 1 
                 28800 
                 0 
                 60 
                 0 
                 1 
               
               
                 CR- 
                 1 
                 28800 
                 0 
                 600 
                 0 
                 1 
                 0 
                 15 
               
               
                 MeOHCollection.15Day 
               
               
                 CR-MeOHCollection.LL 
                 1 
                 28800 
                 0 
                 600 
                 0 
                 1 
                 0 
                 15 
               
               
                 CR-MeOHCollection.LWL 
                 1 
                 28800 
                 0 
                 600 
                 0 
                 1 
                 0 
                 15 
               
               
                   
               
               
                   Note:    
               
               
                   Italics print represents mill specific information.    
               
             
          
         
       
     
         [0212]    
       
         
               
               
               
               
               
               
               
             
           
               
                 TABLE 4-3 
               
               
                   
               
               
                   
               
               
                 Tag Name/Descriptor 
                 comments 
                 Eng units 
                 pointsource 
                 Pt class 
                 Sourcetag 
                 FilterExpr 
               
               
                   
               
             
             
               
                 CR- 
                 Totalizes filtered 
                 ODTPD 
                 T 
                 Totalizer 
                 CR-pulp_production_tag.Filt 
                 Must be 
               
               
                 pulp_production.DAY 
                 pulp production 
                   
                   
                   
                 (daily digester production) 
                 none 
               
               
                 Daily Total 
                 rate tag for 
               
               
                 Digester 
                 yesterday. Must 
               
               
                 Production 
                 have 80% of good 
               
               
                   
                 value 
               
               
                 CR- 
                 Totalizes 
                 Gal/Day 
                 T 
                 Totalizer 
                 CR-Cond_collection_tag.Filt 
                 Must be 
               
               
                 cond_collection 
                 filteredcondensate 
                   
                   
                   
                   
                 none 
               
               
                 DAY 
                 flow to treatment 
               
               
                 Daily Total 
                 for yesterday. 
               
               
                 Condensate to 
                 Must have 80% of 
               
               
                 Treatment 
                 good values 
               
               
                   
               
             
          
         
       
     
         [0213]    
       
         
               
               
               
               
               
               
               
               
               
             
           
               
                 TABLE 4-4 
               
               
                   
               
               
                   
               
               
                   
                 Rate 
                   
                   
                   
                   
                   
                   
                   
               
               
                   
                 Sample 
                 Total Close 
                 Report 
                   
                   
                   
                   
                 Pct 
               
               
                 Tag Name 
                 Mode 
                 Mode 
                 Mode 
                 Function 
                 CalcMode 
                 Period 
                 Offset 
                 Good 
               
               
                   
               
             
             
               
                 CR- 
                 Natural 
                 Clock 
                 Period End 
                 Total 
                 Time weighted 
                 +1 d 
                 +7 h 1   
                 80 
               
               
                   pulp _ production .DAY 
               
               
                 CR- 
                 Natural 
                 Clock 
                 Period End 
                 Total 
                 Time weighted 
                 +1 d 
                 +7 h 1   
                 80 
               
               
                   cond _ collection .DAY 
               
               
                   
               
               
                   Note:    
               
               
                   Italics print represents mill specific information.    
               
               
                     1 Totalizes values for yesterday&#39;s MILL day. Example shows offset for mill day rollover at 7:00 am.    
               
             
          
         
       
     
         [0214]                                            TABLE 4-5                                       Comp               Tag Name   Descriptor   ExcDev   ExcMax   Dev   Comp Max   Compressing                   pulp_production   Raw DCS tag for pulp   Mill std   60   Mill std   &lt;=3600   1           production       cond_collection   Raw DCS tag for main tank   Mill std   60   Mill std   &lt;=3600   1           flow       devicename.PV   Raw DCS tag for divert   Mill std   60   Mill std   Mill std   1           valve       tank_level.PV   Raw DCS tag for tank level   Mill std   60   Mill std   Mill std   1                    
 Standard Proficy Model 
 
         [0215]     The Proficy model consists of input variables (PI inputs), calculated variables, stored procedures, and Visual Basic scripts (VB scripts). Variables for a typical Condensate Main Tank Collection system and descriptions of the stored procedures and the VB scripts are included below. Complete listings of the Stored Procedures can be found herein.  
         [0216]     PI Interface Proficy Variables  
                                                                       Variable       Eng   Event   Data   Pre-   Sampling   Sampling   Sampling   Sampling           Description   DataSource   Units   Type   Type   cision   Window   Interval   Offset 1     Type   PI Tag                   15 Day - MeOH   Calculation   lbs/ODTP   Time   Float   2       1440   420       CR-       Avg       Warning Limit                                       MeOHCollection.LWL 2         15 Day - MeOH   Calculation   lbs/ODTP   Time   Float   2       1440   420       CR-MeOHCollection.LL 2         Avg Lower Limit       15 Day - MeOH   Calculation   lbs/ODTP   Time   Float   2       1440   420       CR-       Avg                                       MeOHCollection.15Day 2         Daily - PI   PI   ODTP   Time   Float   0   60   1440   420   Last Good   CR-pulp_production.DAY       Digester Tons                                   Value       Daily - PI Main   PI   Gals   Time   Float   0   60   1440   420   Last Good   CR-cond_collection.DAY       Tank Totalized                                   Value       Flow       Daily - PI Chip   PI   %   Time   Float   1   60   1440   420   Last Good   CR-       Meter % Good                                   Value   pulp_production.PctGd       Daily - PI Main   PI   %   Time   Float   1   60   1440   420   Last Good   CR-       Tank Flow                                   Value   cond_collection.PctGd       Meter % Good       Condensate Daily   PI   MMinutes   Time   Integer       60   1440   420   Last Good   CR-Cond_Down.Day       Downtime                                   Value                   1 The sampling offset is determined based upon the mill-specific start of day time. The offset value is the number of minutes from midnight to the mill start of day. Example shows mill day start at 7:00 am.              2 Values written to PI             
 
         [0217]    
       
         
               
               
               
               
               
               
               
               
               
               
             
           
               
                   
               
               
                   
               
               
                   
                 Eng 
                   
                 Data 
                   
                 Sampling 
                 Sampling 
                 Sampling 
                   
                   
               
               
                 Variable Description 
                 Units 
                 Event Type 
                 Type 
                 Precision 
                 Interval 
                 Offset 1   
                 Window 
                 Calc Type 
                 Calc Name 
               
               
                   
               
             
             
               
                 Condensate CMS Events 
                 Status 
                 Time 
                 String 
                   
                 1440 
                 420 
                   
                 Stored 
                 Condensate CMS 
               
               
                   
                   
                   
                   
                   
                   
                   
                   
                 Procedure 
                 Events 
               
               
                 15 Day - Digester Tons 
                 ODTP 
                 Time 
                 Float 
                 1 
                 1440 
                 420 
                 21599 
                 Stored 
                 15 Day Total 
               
               
                   
                   
                   
                   
                   
                   
                   
                   
                 Procedure 
               
               
                 15 Day - MeOH Avg 
                 lbs/ODTP 
                 Time 
                 Float 
                 2 
                 1440 
                 420 
                   
                 Equation 
                 Lower User Spec 
               
               
                 (Lb/ODTP) Warning Limit 
                   
                   
                   
                   
                   
                   
                   
                   
                 Limit 
               
               
                 15 Day - MeOH Avg 
                 lbs/ODTP 
                 Time 
                 Float 
                 2 
                 1440 
                 420 
                   
                 Equation 
                 Lower Warning Spec 
               
               
                 Lower Limit 
                   
                   
                   
                   
                   
                   
                   
                   
                 Limit 
               
               
                 15 Day -  
                 bs/ODTP 
                 Time 
                 Float 
                 2 
                 1440 
                 420 
                   
                 Equation 
                 Calc (A/B) 
               
               
                 MeOH Avg 
               
               
                 15 Day - MeOH Collected 
                 lbs 
                 Time 
                 Float 
                 0 
                 1440 
                 420 
                 21599 
                 Stored 
                 15 Day Total 
               
               
                   
                   
                   
                   
                   
                   
                   
                   
                 Procedure 
               
               
                 Condensate EE Events 
                 Status 
                 Time 
                 String 
                   
                 1440 
                 420 
                   
                 Stored 
                 Condensate EE Events 
               
               
                   
                   
                   
                   
                   
                   
                   
                   
                 Procedure 
               
               
                 Daily - Digester Tons Used 
                 ODTP 
                 Time 
                 Float 
                 1 
                 1440 
                 420 
                   
                 Stored 
                 Manual Update 
               
               
                 for Avg 
                   
                   
                   
                   
                   
                   
                   
                 Procedure 
               
               
                 Daily - LAB MeOH Conc 
                 ppm 
                 Time 
                 Float 
                 0 
                 1440 
                 420 
                   
                 Stored 
                 GetMeOHLabData 
               
               
                   
                   
                   
                   
                   
                   
                   
                   
                 Procedure 
               
               
                 Fixed or LAB MeOH Conc 
                 ppm 
                 Time 
                 Float 
                 0 
                 1440 
                 420 
                   
                 Stored 
                 Fixed or LAB MeOH 
               
               
                   
                   
                   
                   
                   
                   
                   
                   
                 Procedure 
                 Conc. 
               
               
                 Daily - MeOH Conc Used 
                 ppm 
                 Time 
                 Float 
                 0 
                 1440 
                 420 
                   
                 Stored 
                 Manual Update 
               
               
                 for Avg 
                   
                   
                   
                   
                   
                   
                   
                 Procedure 
               
               
                 Daily - Main Tank Totalized 
                 Gals 
                 Time 
                 Float 
                 0 
                 1440 
                 420 
                   
                 Stored 
                 Manual Update 
               
               
                 Flow Used for Avg 
                   
                   
                   
                   
                   
                   
                   
                 Procedure 
               
               
                 Daily - MeOH Collected 
                 lbs 
                 Time 
                 Float 
                 0 
                 1440 
                 420 
                   
                 Equation 
                 Calc (A * 8.34 * 
               
               
                   
                   
                   
                   
                   
                   
                   
                   
                   
                 B/1000000) 
               
               
                 Daily - MeOH Avg 
                 lbs/ODTP 
                 Time 
                 Float 
                 2 
                 1440 
                 420 
                   
                 Equation 
                 Calc (A/B) 
               
               
                 Condensate Daily UpTime 
                 Minutes 
                 Time 
                 Integer 
                   
                 1440 
                 420 
                   
                 Equation 
                 UpTime (Daily) 
               
               
                   
               
             
          
         
       
     
         [0218]                                                                                                                  Eng               Sampling   Sampling           Variable Description   DataSource   Units   Event Type   DataType   Precision   Interval   Offset 1     Repeating                                Condensate Collection Data   AutoLog   Status   Time   Data       1440   420           Quality (CMS)               Quality       15 Day - Avg End Time   AutoLog   Date   Time   String       1440   420       15 Day - Avg Start Time   AutoLog   Date   Time   String       1440   420       Daily - Manual Digester Tons   AutoLog   ODTP   Time   Float   1   1440   420       Fixed MeOH Conc   AutoLog   ppm   Time   Float   0   1440   420   Yes       Concentration Method   AutoLog   ppm   Time   Sampling       1440   420   Yes                       Method       Daily - Manual MeOH Conc   AutoLog   ppm   Time   Float   0   1440   420       LAB MeOH Conc Test Result   File   ppm   Production   Float   0   1           Transfer       Event                   1 The sampling offset is determined based upon the mill-specific start of day time. The offset value is the number of minutes from midnight to the mill start of day. Example shows mill day start at 7:00 am.               
 Specification Limits 
 
         [0219]     Proficy has upper and lower specification limits that can be defined for every variable: entry limits, user limits, warning limits, and reject limits.  
         [0220]     The following descriptions define how Proficy uses these limits to trigger events and inform operators of impending events: 
        User Limits 
            Provides a visible warning that event trigger points are being approached by changing the font color of the variable on an Autolog sheet    
            Warning Limits 
            Trigger level for EE events    
            Reject Limits 
            Trigger level for CMS events or data quality limits    
            Entry Limits 
            Restricts the range of valid numerical entries used for a manual entry variable.    
               
 
         [0229]     12) Proficy Variables and Specification limits  
                                                                                                 Daily - Manual Digester Tons   Lower Entry   Minimum possible daily digester tons           Upper Entry   Maximum possible daily digester tons (max ODTP/m*1440)       Fixed MeOH Concentration   Lower Entry   Minimum possible daily MeOH Concentration           Upper Entry   Maximum possible daily MeOH Concentration (max ppm*1440)       Daily - Manual MeOH Concentration   Lower Entry   Minimum possible daily MeOH Concentration           Upper Entry   Maximum possible daily MeOH Concentration (max ppm*1440)       Daily - Manual Main Tank Totalized Flow   Lower Entry   Minimum possible daily main tank flow           Upper Entry   Maximum possible daily main tank flow (max gpm*1440)       Daily - MeOH Avg   Lower User   Visible warning that EE limit is being approached           Lower Warning   Visible warning that EE limit for the day has been tripped (No EE               event is created)       15 Day - MeOH Avg   Lower User   Visible warning that EE limit is being approached           Lower Warning   Trigger 24 hour EE event       Daily - PI chip meter % Good   Lower Reject   Used to indicate bad data quality (value is always 80)       Daily - PI Main Tank Flow Meter % Good   Lower Reject   Used to indicate bad data quality (value is always 80)                  
 
 MeOH Test Data File Transfer 
 
         [0230]     MeOH concentration test results are imported from the testing lab host via file transfer. New test data is stored in a delimited ASCII file in a specified folder on the testing lab host. Proficy&#39;s FTP engine, at a specified frequency, looks for new files with a name matching a specified mask in the designated folder on the remote host. When the FTP engine detects a new file, the file is moved from the host to the folder “\Proficy\Incoming” folder on the Proficy server. Similarly, Proficy import Model-79 continuously monitors “\Proficy\Incoming” every minute for a new data file. If a new file is found, the data is parsed and transferred as inputs to the stored procedure spLocal_CRCEvent_Data where it is processed. The data file structure consists of four fields: the data source ID (e.g., example: CR-AU-MT-HP-IN where AU=mill Id), date, timestamp, and test result. The stored procedure runs once for every record in the file, creates a production event (event number format—mmddhhmmss from the data&#39;s date/time), and records the data in the TESTS table while retaining the data&#39;s relationship to the event number. If processing is successful, the file is moved to the folder “\Proficy\Processed” and the file name appended with a timestamp designating the processing date/time. If processing is unsuccessful, the file is moved to the folder “\Proficy\UnProcessed” and timestamped.  
         [0000]     Calculations  
         [0000]     15 Day Total  
         [0000]     Type: Stored Procedure—spLocal — 15DayTotal  
         [0231]     This procedure looks at daily data for a specified variable (either Daily—MeOH Collected Lbs) or Daily—Digester Tons Used for Avg (ODTP)) over the last 30-days and sums the most recent 15 daily values where the data quality is good (as specified by the data quality flag, Condensate Collection Data Quality (CMS)). Fifteen values are required before a total is calculated. Values with a timestamp that is not the mill-day rollover are excluded from the calculation.  
         [0000]     Condensate EE Events  
         [0000]     Type: Stored Procedure—spLocal_CondEvents  
         [0232]     This procedure reads the value of the dependent variable (15 Day—MeOH Avg (Lbs/ODTP)) and compares it to the variable&#39;s specification limit, as specified in the calculation inputs (LW, LR, etc.). If this value is outside of the limit, then a 24-hr downtime event is created (appended if a contiguous event exists) on the variable&#39;s unit. The following table lists the possible status messages and their definition. This status message is displayed on the Autolog display as the variable Condensate EE Events.  
                                   Status Message   Definition                   No Dep Var   Calculation is not configured correctly, dependant           variable is not configured       No Reject   Calculation is not configured correctly, reject limit           input constant is not configured.       Incorrect Reject   Calculation is not configured correctly, reject limit           is incorrect.       Bad Limit   The reject specification limit is NULL.       No Value   The dependant variable value is NULL       Event Created   A downtime event was created because the 15 day           MeOH Avg is less than the reject limit.       Event Updated   An existing event was extended because the next           day&#39;s 15 day MeOH Avg is still less than           the reject limit.                  
 
 Condensate CMS Events 
 
 Type: Stored Procedure—spLocal_CondCMSEvents 
 
         [0233]     This stored procedure creates a 24-hour downtime event that is triggered by a manual input from the operator (via Condensate Collection Data Quality (CMS) which is configured as the dependent variable). The following table lists the possible status messages and their definition. This status message is displayed on the Autolog display as the variable Condensate CMS Events.  
                                   Status Message   Definition                   No Dep Var   Calculation is not configured correctly, dependant           variable is not configured       No Event   A downtime event was not created.       Event Created   A downtime event was created when the “Bad Data -           24 hr CMS” option was chosen on the Autolog display.       Event Updated   An existing event was extended when the “Bad Data -           24 hr CMS” option was chosen on the Autolog           display for the next mill day.                  
 
 Calc (A*8.34*B/100000000) 
 
 Type: Equation 
 
         [0234]     Calculates the MeOH quantity (Lbs) from the MeOH concentration (A in ppm) and the condensate collection total (B in gals).  
         [0000]     ManualUpdate  
         [0000]     Type: Stored Procedure—spLocal_ManualUpdate  
         [0235]     This procedure uses one input and one dependent variable. This procedure performs a signal selection between a manually entered (dependent variable) value and another variable (the input). If the dependant variable value (the manually entered value) is NULL, the output is the value of the input variable. Otherwise, the output is set to the value of the dependant variable. The triggers for this procedure are time (based on the sample interval for the variable), value change for the dependant variable or value change for the input variable.  
         [0000]     Fixed or LAB MeOH Conc  
         [0000]     Type: Stored Procedure—spLocal_MeOHConcSelect  
         [0236]     This procedure selects the correct MeOH concentration value, Fixed MeOH Conc or Daily—LAB MeOH Conc based on the value of the pulldown selector, Concentration Method.  
         [0000]     GetMeOHLabData  
         [0000]     Type: Stored Procedure—spLocal_GetMeOHLabData  
         [0237]     This procedure returns the last value for LAB MeOH Conc. Test Result, from the previous 24-hour period.  
         [0000]     Uptime (Daily)  
         [0000]     Type: Equation  
         [0238]     Calculates the daily uptime in minutes (Condensate Daily UpTime) from the daily downtime received from PI (Condensate Daily Downtime)  
         [0000]     Lower Warning Spec Limit  
         [0000]     Type: Equation  
         [0239]     Returns the lower warning specification limit of the specified input variable.  
         [0000]     Lower User Spec Limit  
         [0000]     Type: Equation  
         [0240]     Returns the lower User specification limit of the specified input variable.  
         [0000]     Calc (A/B)  
         [0000]     Type: Equation  
         [0241]     Returns quotient of the two inputs, A and B.  
         [0000]     AutoLog Displays  
         [0242]     Main Tank Compliance  
                                       Unit   Variable   Title Text                           Mill Day       Reporting Unit   Mill Day               Pulp Production       Main Tank Compliance   Daily - PI Pine Digester Tons       Kamyr Chip Meter Data   Daily - PI Pine Chip Meter % Good       Quality       Main Tank Compliance   Daily - Manual Pine Digester Tons       Main Tank Compliance   Daily - Manual Hwd Digester Tons       Main Tank Compliance   Daily - Total Digester Tons               MeOH Concentration       Main Tank Compliance   Daily - LAB MeOH Conc       Main Tank Compliance   Fixed MeOH Conc       Main Tank Compliance   Concentration Method       Main Tank Compliance   Daily - Manual MeOH Conc       Main Tank Compliance   Daily - MeOH Conc Used for Avg               MeOH Collection       Main Tank Compliance   Daily - PI Main Tank Totalized Flow       Main Tank Compliance   Daily - PI Main Tank Flow Meter % Good       Main Tank Compliance   Daily - Manual Main Tank Totalized Flow       Main Tank Compliance   Daily - MeOH Collected       Main Tank Compliance   Daily - MeOH Avg               15 Day Averages       Main Tank Compliance   15 Day - MeOH Collected       Main Tank Compliance   15 Day - Digester Tons       Main Tank Compliance   15 Day - MeOH Avg       Main Tank Compliance   15 Day - Avg Start Time       Main Tank Compliance   15 Day - Avg End Time       Condensate Event (CMS)   Condensate Collection Data Quality (CMS)               Reporting       Reporting Unit   Down Time       Reporting Unit   Running Time                  
 
 THIS IS THE BEGINNING OF lvhc hvlc 
 
         [0243]     The purpose of this document is to describe the design of the record keeping and reporting system for the collection and destruction of Low Volume/High Concentration (LVHC) and High Volume/Low Concentration (HVLC) gases. The software is comprised of PI Data Archive software (which is used for automatic data collection from various process instrumentation and control systems) and Proficy software (which uses the data collected by PI in conjunction with manual inputs and business rules to monitor and report on the performance of the LVHC/HVLC collection and destruction system). This documentation is directed toward system administrator level personnel.  
         [0244]     The following sections describe the general configuration of the standard LVHC/HVLC monitoring system. Deviations from the standard model, configuration listings for specific areas, and mill-specific details are contained in the appendices.  
         [0245]     Low Volume/High Concentration (LVHC) and High Volume/Low Concentration gases from regulated sources (e.g., blow tanks, blow heat recovery, turpentine system, stripper off gas, diffusion washers, etc.) are collected by a closed vent system and treated by incineration in one or more of the following systems: 
    (a) Thermal oxidizer (incinerator),     (b) Power Boiler,     (c) Lime Kiln, or     (d) Flare.    
 
         [0250]     The Proficy system is used to track both Excess Emission (EE) and Continuous Monitoring System (CMS) DOWNTIME events. Excess emission events occur whenever LVHC/HVLC gases (also referred to as Non-Condensible Gases) are vented to the atmosphere, when gases are inadequately treated, and when no destruction device is operating while gases are being produced. PI monitors the state of each potential emission source (e.g., vent valves, rupture disks, relief valves, loop seals, etc.) while accounting for the area&#39;s Potential to Emit status and triggers Proficy to record an event anytime gases are vented. The recorded event includes the event start time, end time and duration. 12      12  As required by 40CFR §63.10(c). The regulations provide a non-SSM excess emissions allowance of 1% of operating time for the reporting period for LVHC systems before a violation is recorded (4% for HVLC systems) as stated in §63.443 (e).    
         [0251]     PI tags also monitor the state of all destruction devices. The PI tags trigger instantaneous excess emission events in Proficy whenever any individual destruction device stops operating while regulated gas is directed to it (as determined by mill-specific process input signals). Destruction device excess emissions are recorded by the system whenever 
        a thermal oxidizer is in use and the monitored parameter(s) fail to meet the required standard, 13  or    13  Thermal-oxidizer monitoring requirements are contained in 40 CFR §63.453(b) and §63.443(d)1-3.       no destruction device is operating while regulated gases are being produced.        
 
         [0254]     The Proficy system also captures and records failures (downtime) of Continuous Monitoring System (CMS) devices, referred to as CMS events. LVHC/HVLC CMS events are created only for applicable destruction devices (thermal oxidizers) and only when the device is in use as a destruction device. The system records failures whenever the data signal 
        is suspect (out of a specified data quality range or flat-lined),     cannot be determined due to signal malfunction, or     is unavailable due to maintenance calibration.        
 
         [0258]     The CMS events are summarized individually for each applicable control device and reported separately to the state in a semi-annual CMS performance report or more frequently as required.  
         [0259]     The Proficy software logs all excess emission and CMS events and operator responses to those events. The responses record the operator determined Trouble, Cause, Correction (response), and Report Code (report categorization) for the event. The report categorization specifies if the event is considered an allowable excess emission or CMS occurrence as the event may be allowed due to Startup, Shutdown, and Malfunction (SSM) provisions. The events for LVHC collection/treatment and HVLC collection/treatment are compiled separately by the system and reported separately to the state regulatory agency on a semi-annual basis or more frequently as required.  
         [0260]     The PI system also calculates and makes available to Proficy a “Daily Down Time” which is the time that the processes capable of producing regulated HAPs are not operating. Proficy, in turn calculates the process uptime. The total Daily Uptime for the reporting period becomes the denominator in determining if the mill has exceeded the excess emission allowance for the reporting period.  
         [0261]     Additionally, the PI system calculates the time each day that each LVHC CMS device (thermal oxidizer) is not used to treat gases (Daily Downtime). Proficy uses this daily calculation to calculate the thermal oxidizer uptime, which becomes the denominator in determining if the mill has exceeded the CMS allowance for the reporting period. 14      14 As required by 40CFR §63.454(b)(11)-(12) and §63.10(c)-(e). HVLC and LVHC CMS downtime is calculated and reported as a percentage of source runtime.    
         [0262]     Events and TCC answers are recorded within the Proficy system. On a periodic or scheduled basis, mill environmental personnel can run reports listing the events (start time, end time, and duration) and their TCC answers, summarizing the total duration of all events by specific report code, and calculating excess emissions and CMS downtime against the allowances. The reports are run from Microsoft Excel using an Excel VBA add-in specifically written and designed to generate environmental reports which meet the regulatory reporting requirements. 15      15  The regulatory record keeping and reporting requirements are codified in 40 CFR §63.6(e)(3), §63.8(c)(1), and §63.10.    
         [0263]     For HVLC and LVHC reporting simultaneous excess emission events answered with different report codes are allotted time in the report summaries according to the following report hierarchy: 16      16  The report code hierarchy is from top to bottom; that is, if one event is categorized Other Known Causes and a simultaneous event is categorized Process Problems, the event time is allocated and summarized as towards Other Known Causes.    
         [0264]     1. Other Unknown Causes 
        2. Other Known Causes     3. Process Problems     4. Control Equipment Problems     5. Startup/Shutdown        
 
         [0269]     Additionally a sixth report code, No Excess Emission, eliminates an event from inclusion in the report categorization hierarchy and indicates that the event was recorded by the system in error. When this report code is utilized, the user must have appropriate documentation that the event was created in error and that no excess emission occurred. The single event will be excluded from the report summarization but concurrent events, either unanswered or with different report codes will be included in the report summary.  
         [0270]     For excess emission events that contain incomplete or missing TCC answers, the report system allocates the event time to either Other Unknown Causes (in the case that there was no simultaneous event answered) or to the report code category of simultaneous events following the hierarchy above. 17      17  When the only existing simultaneous event is answered No Excess Emission, the unanswered event is categorized as Other Unknown Causes for the purposes of report code summarization.    
         [0271]     For HVLC and LVHC reporting, simultaneous CMS events answered with different report codes are allotted time according to the following report hierarchy: 
        1. Other Unknown Causes     2. Other Known Causes     3. Monitor Equipment Malfunctions     4. Non-Monitor Equipment Malfunctions     5. QA/OC Calibrations        
 
         [0277]     Additionally a sixth report code, No Monitor Downtime, eliminates an event from inclusion in the report categorization hierarchy and indicates that the event was recorded by the system in error. When this report code is utilized, the user must have appropriate documentation that the event was created in error and that monitoring of the thermal oxidizer was maintained. Unanswered events (or events with incomplete answers resulting in a missing report code) are categorized as Other Unknown Causes from a report summarization standpoint.  
         [0278]     Tables-1, 2 &amp; 3 give PI tag naming conventions and description for typical variables used in the standard model.  
                         TABLE 1                           Typical Emission Source PI Tags            Tag Format   Description               CR-millarea.STAT   Running/NotRunning status of mill area.       CR-millarea_PTE.STAT   Indicates when a mill area is capable of           producing regulated gases.       Ventvalve.PV   An emissions point device state indicator such       MainValve.PV   as a vent valve position.       CR-devicename.Vent   EE event trigger sent to Proficy.       CR-Main.Vent       CR-Rupture.Vent                  
 
         [0279]    
       
         
               
             
               
               
             
           
               
                 TABLE 2 
               
             
             
               
                   
               
               
                   
               
               
                 Typical Destruction Device PI Tags 
               
             
          
           
               
                 Tag Format 
                 Description 
               
               
                   
               
               
                 CR-destdevice.TREAT 
                 Indicates when the destruction device is 
               
               
                   
                 operating and that regulated gases are being 
               
               
                   
                 directed to a given destruction device. 
               
               
                 CR-LVHC.TREAT 
                 Indicates when at least one destruction device 
               
               
                 (or CR-HVLC.TREAT) 
                 in the LVHC (or HVLC) system is treating. 
               
               
                 CR-destdevice.EE 
                 Destruction device EE event trigger sent to 
               
               
                   
                 Proficy. 
               
               
                 CR-destdevice.DQ 
                 Indicates when the destruction device status 
               
               
                   
                 cannot be confirmed. This is the CMS 
               
               
                   
                 downtime event trigger monitored by Proficy. 
               
               
                 CR-destdeviceDown.Day 
                 Calculates total time for previous mill day that 
               
               
                   
                 the destruction device was not treating gases. 
               
               
                   
               
             
          
         
       
     
         [0280]    
       
         
               
             
               
               
             
           
               
                 TABLE 3 
               
             
             
               
                   
               
               
                   
               
               
                 Reporting PI Tags 
               
             
          
           
               
                 Tag Format 
                 Description 
               
               
                   
               
               
                 CR-HVLC_PTE.STAT 
                 Outputs “CanEmit” when any one HVLC area 
               
               
                   
                 has a PTE value of “CanEmit” 
               
               
                 CR-LVHC_PTE.STAT 
                 Outputs “CanEmit” when any one LVHC area 
               
               
                   
                 has a PTE value of “CanEmit” 
               
               
                 CR-HVLC_Down.Day 
                 Daily minutes of time when the HVLC system 
               
               
                   
                 is in a “CanNotEmit” state. 
               
               
                 CR-LVHC_Down.Day 
                 Daily minutes of time when the LVHC system 
               
               
                   
                 is in a “CanNotEmit” state. 
               
               
                   
               
             
          
         
       
     
         [0281]     The following sections describe in detail how the Proficy /LVHC/HVLC model triggers EE and CMS events.  
         [0000]     Mill Area State—PTE  
         [0282]     Each area that produces regulated gases has a potential to emit (PTE) performance equation tag in PI. The performance equation logic returns a state of “CanEmit” when HAPS are present, and can potentially be emitted when a vent valve is opened. This is normally during the period from startup of the area until a mill specified period after the area stops running, and regulated gases have been cleared from all areas of the system. The area PTE state is calculated each minute based upon mill specified, site specific criteria such as flow, motor running state or pump running state.  
         [0283]     A block diagram of potential to emit and daily downtime/uptime data flow is depicted in  FIG. 7 .  
         [0000]     Vent Source EE  
         [0284]     For each mill area that can produce regulated gases, PI receives raw DCS states for all of the possible emission points. Generally these are digital tags that give the state of the valve (open or closed) or rupture disk (if the source is a modulating valve, PI receives an analog value from the DCS that represents % open). An event-based performance equation, CR-devicename.VENT, determines when an emission point is venting to the atmosphere while the mill area has a potential to emit. This PI performance equation returns a value of “Vent” or “NotVent.” 
         [0285]     Vent Source EE events are created by Proficy using the Proficy downtime model  200 . Proficy monitors the digital tag, CR-devicename.VENT, for the fault value of “Vent”. Whenever the value enters the fault state (or remains in the fault state for a period longer than a specified filter time), an EE event is recorded by the system.  
         [0286]     A block diagram of the vent data flow is depicted in  FIGS. 9 and 10 .  
         [0000]     Main Vent Filtering (Optional)  
         [0287]     Main vent filtering is an additional configuration to each “.Vent” tag that attempts to reduce the number of events that operators must answer when a system-wide event occurs. All upstream vents points are filtered out in PI whenever the Main Vent tag has a value of “Vent.” The main vent is defined as the last vent before the gases are routed to the destruction devices (vents at the destruction devices are not main vents).  
         [0288]     A PI performance equation, CR-MainVent.Filt, outputs “Venting” when the main vent is “Venting” and continues to output “Venting” for a mill determined time after the main vent returns to “NotVenting.” This delay is intended to give operators time to close the upstream vents after they have closed the main vent. Each upstream vent tag is set to “NotVenting” whenever the CR-MainVent.Filt tag has the value of “Venting”.  
         [0000]     Destruction Device Treating LVHC/HVLC Gases and EE  
         [0289]     For destruction devices, a PI performance equation, CR-devicename.TREAT, determines if the device is accepting gases by verifying the correct operating conditions (operating flow, motor running, operating pressure or operating temperature), and that the appropriate valves are in position for LVHC/HVLC gases to be directed to the device. For thermal oxidizer devices (incinerators), where a burner management system (BMS) is connected to PI, the preferred running indicator is the BMS “Ready to Accept Gases” tag. The destruction device treating status is required for thermal oxidizer devices to determine running time for the CMS device on the reports. For other types of destruction devices, the device treating status is for other purposes. A block diagram of destruction device treatment status data flow is depicted in  FIG. 8 .  
         [0290]     For thermal oxidizer destruction devices, another performance equation, CR-destdevice.EE, returns the digital state “EE” whenever the PI logic determines that the device is not properly destroying HAPS while gases are being sent to it; otherwise the equation returns the value “OK”. This tag triggers an EE event when the flame temperature is less than the minimum acceptable temperature, there is the potential to emit, and the device is accepting gases. Proficy monitors this tag using the Proficy downtime model  200 . If the fault state of “EE” is detected (or remains for a period longer than a specified filter time) an EE event is triggered. A block diagram of destruction device EE and CMS data flow is depicted in  FIG. 11 .  
         [0000]     Destruction Device CMS  
         [0291]     Mills that utilize a thermal oxidizer as a destruction device for LVHC/HVLC gases must monitor the temperature of the incinerator and report CMS downtime whenever the incinerator is in use and the flame temperature sensor can not be read by PI. A PI performance equation, CR-devicename.DQ, calculates the value “Bad” when the temperature is out of range, or is in an error state, and the incinerator is selected for treatment; otherwise the value “Good” is calculated.  
         [0292]     Proficy uses the Proficy downtime model  200  to monitor CR-devicename.DQ for the fault state, “Bad”. Whenever the PI tag value “Bad” is detected (or remains for a period longer than a specified filter time), a CMS event is recorded by the system.  
         [0293]     A block diagram of destruction device EE and CMS data flow is depicted in  FIG. 11 .  
         [0000]     CMS Runtime Counter  
         [0294]     At the start of each mill day, a PI performance equation, CR-Incin_Down.Day, totals the “NotTreating” time for CR-Incin.TREAT over the previous 24-hour period. This value is read by Proficy and is used for both the daily display and daily calculation of Incinerator runtime (“Treating” for the daily period). The daily runtime minutes are kept in Proficy and used to compute the total incinerator treating runtime minutes for the reporting period.  
         [0000]     LVHC/HVLC PTE Downtime Counter  
         [0295]     Every minute, a PI performance equation, CR-LVHC_PTE.STAT/CR-HVLC_PTE.STAT, looks at each mill area PTE tag, CR-millarea_PTE.STAT. If any one mill area tag has a value of “CanEmit”, the equation returns the digital state “CanEmit”. If all of the mill area tags have a value of “CanNotEmit”, the equation returns the digital state “CanNotEmit”. At the start of each mill day, another PI performance equation, CR-LVHC_Down.Day/CR-VLC_Down.Day, totals the “CanNotEmit” time for CR-LVHC_PTE.STAT/CR-HVLC_PTE.STAT over the previous 24-hour period. This value is read by Proficy and is used for both the daily display and daily calculation of LVHC/HVLC runtime (“CanEmit” for the daily period). The daily runtime minutes are kept in Proficy and used to compute the total runtime minutes for the reporting period.  
         [0296]     A block diagram of potential to emit and daily downtime/uptime data flow is depicted in  FIG. 7 .  
         [0000]     Tag Name Specifications  
         [0297]     All Cluster Rule PI tags will begin with “CR-”.  
         [0000]     Digital State Set Specifications  
         [0298]     The following are the minimum required digital state sets in PI to support the Cluster Rule  
                                                 LVHC/HVLC model.                Digital Set Name   State 0   State 1                       P2Emit   CanEmit   CanNotEmit           OK-EE   OK   EE           GOOD-BAD   Good   Bad           VENT-NOTVENT   Vent   NotVent           Running   Running   NotRunning           TREATING   Treating   NotTreating           ACCEPTING   Accepting   NotAccepting                      
 
 Scan Class Specifications 
 
         [0299]     The following scan classes must be available in PI. Note, the scan class number will vary from mill to mill. 
        1. A one minute scan class offset 0 seconds from midnight;     2. A twenty-four hour scan class offset to the start of mill day.        
 
       Examples of the Scan Class Syntax are as Follows:  
       [0302]                                        1. /f = 00:01:00, 00:00:00 (alternately /f = 00:01:00, 0)       2. /f = 24:00:00, 07:00:00 (alternately /f = 24:00:00, 25200) for mill day       at 07:00 am                    
 PI Tag Configuration Specification 
 
         [0303]     Tables 4 and 5 provide tag configuration examples for a typical LVHC/HVLC model. Table 6 contains exception and compression statistic requirements for underlying DCS PI tags.  
                                                                                                                                                     TABLE 4                           Typical PI Tag Configuration            Tag Name/Descriptor   Comments   Exdesc                    Area + LVHC Statuses            CR-millarea.STAT 18     Extremely mill-dependent   If (‘flow.PV’&lt;lowflowlimit ...) then “NotRunning” else “Running”       Mill Area running status   (and area dependent)       (e.g. Evap, Dig, etc.       running status)       CR-millarea_PTE.STAT   CanEmit if the area is   If BadVal(TimeEq(‘CR-millarea.STAT’,’*-delaytime’,’*’,”Running”)) then PrevVal(‘CR-       Mill Area potential to   running, producing HAPS,   millarea_PTE.STAT’, ‘*-delaytime’) else if TimeEq(‘CR-millarea.STAT’, ‘*-delaytime’,       emit status   or has been running, and   ‘*’,”Running”)&gt;0 then “CanEmit” else “CanNotEmit”           has not yet purged all           HAPS from the system.       CR-LVHC_PTE.STAT   CanEmit if any one LVHC   If (‘CR-MillArea 1 _PTE.STAT’ = “CanNotEmit” and ‘CR-MillArea 2 _PTE.STAT’ = “CanNotEmit”       LVHC System PTE   production area is in the   and...and ‘CR-MillArea n _PTE.STAT’ = “CanNotEmit”) then “CanNotEmit” else “CanEmit”       Status   CanEmit state.            Treatment Device Status            CR-destdevice.TREAT 1     Treating if the thermo-   Event=BMS.ReadyToAccept,(If (BMS.ReadyToAccept &lt;&gt;”Ready”) then “NotTreating” else       Destruction Device   oxidizer device is at   “Treating”)       treating status (for   operating temperature, and   -- or you can use the following if you do not have a Burner Management System (BMS)--       incinerator, lime kiln,   is accepting NCG gases.   Event=temp.PV,(If (‘temp.PV’&lt;=lowtemplimit ...)then “NotTreating” else “Treating”)       power boiler, etc.)       -- or you can use the following --               Event= divertValve.PV ,(If (‘divertValve.PV’ = “Open”) then “Treating” else “NotTreating”)       CR-LVHC.TREAT   Treating if any one LVHC   If (CR-destdevice 1 .TREAT=”Treating”) or (CR-destdevice 2 .TREAT = “Treating”) or (CR-       Some Destruction Device   treatment device is   destdevice 3 .TREAT = “Treating”) then “Treating” else “NotTreating”       in the LVHC System is   Treating.       Treating NCGs   This is optional and for           display only.            Venting-Main &amp; Regular            CR-devicename.Vent 19,4     Vent if vent device is open   Event= divertValve.PV,(If (‘CR-millarea_PTE.STAT’ = “CanNotEmit”) or (’CR-       DeviceName venting EE   to the atmosphere, there is a   MainVent.FILT’=”Venting”) then “NotVent” else if (‘divertValve.PV’ = “Closed”) then       for Regular Vent   potential to emit in that   “NotVent” else “Vent”)           LVHC area, and at least   ---or for non-isolated area ---           one LVHC treatment   Event= VentValve.PV, (If (‘CR-LVHC_PTE.STAT’ = “CanNotEmit”) or (’CR-           device is Treating.   MainVent.FILT’=”Venting”) then “NotVent” else if (‘VentValve.PV’ = “Closed”)               then “NotVent” else “Vent”)       CR-Main.Vent   Vent if the main NCG vent   Event= MainVent.PV, (If (‘CR-LVHC_PTE.STAT’ = “CanNotEmit”) then “NotVent” else if       Main Vent Location   is open to the atmosphere,   (‘MainVent.PV’ = “Closed”) then “NotVent” else “Vent”)       Venting   and there is a potential to           emit       CR-MainVent.FILT   Extend Vent for mill-   event=CR-Main.Vent,if ‘CR-Main.Vent’=“Venting” then “Venting” else if TimeEq(‘CR-       Main Vent Location   specified time so that   Main.Vent’,‘*-delaytime’,‘*’,“NotVenting”)&lt;delaytime in sec then “Venting” else “NotVenting”       Venting extended   operators can close vents           upstream of the main vent           after the main vent is           closed. This does NOT           extend the recorded event.           Optional.       CR-Rupture.Vent   Same as device.Vent   Typically the same as CR-devicename.Vent (except that the logic must take into account that the       Rupture Disk       pressure differential may not return after a Rupture disk breaks)            Dest Device Vent (low Temp)            CR-destdevice.EE   EE if LVHC treatment   Event=temp.PV, (If (‘CR-LVHC_PTE.STAT’ = “CanNotEmit”) or (‘CR-       Destruction Device   device is accepting NCG   destdevice.TREAT’=”NotTreating”) then “OK” else if (‘temp.PV &gt;= ‘temp.TARGET’)       Excess Emission (for   gases, and there is potential   then “OK” else “EE”)       incinerator, lime kiln,   to emit, but the flame       power boiler, etc.)   temperature is less than the           minimum required to           sufficiently destroy HAPS.            Incinerator CMS            CR-destdevice.DQ 20,21,4     Bad if you cannot measure   Event= temp.PV ,(If (CR-destdevice.TREAT&lt;&gt;”Treating”) then “Good” else if       Destruction Device CMS   the incinerator flame   (TagMax(‘temp.PV’,’*−3h’,’*’)−TagMin(‘temp.PV’,’*−3h’,’*’) &gt; 0) and           temperature due to   (‘temp.PV’&gt;=lowlowtemplimit) and (‘temp.PV’&lt;=highhightemplimit) then “Good” else “Bad”)           instrumentation or data           collection problems           (detected by a flame temp.           reading either BAD or           outside of the reasonable           instrument range.)            Daily Down Minutes            CR-LVHC_Down.Day   Total minutes in the   TimeEq(‘CR-LVHC_PTE. STAT’,‘Y+7H’,‘T+7H’,“CanNotEmit”)/60 522         Daily LVHC Downtime   CanNotEmit state for           yesterdays operating day.       CR-Incin_Down.Day   Total minutes in the   TimeEq(‘CR-Incin.TREAT’, ’Y+7H’,’T+7H’,”NotTreating”)/60 5         Daily Incinerator Not   NotTreating state for       Treating Time   yesterday&#39;s operating day                   18 Define logic so that else “Running” (or “Treating”) is the final clause, so that any error conditions will result in a default value of “Running” (or “Treating”)              19 Define logic so that (else “Vent”) is the final clause, so that any error conditions will result in a default value of “Vent”             20 Define logic so that (else “Bad”) is the final clause, so that any error conditions will result in a default value of “Bad”.              21 Where possible, use event scheduled PE tags for EE and DQ tags. This will help guarantee that PE calculations are performed shortly after the underlying process values change. For time based PE tags, take care in assigning scan classes so that undue delays are not incurred waiting for multiple passes through the PE scans.              22 Y+7H refers to 7:00 AM Yesterday &amp; T+7H refers to 7:00 AM today (used when the mill start of day = 7:00)             
 
         [0304]    
       
         
               
               
               
               
               
               
               
               
             
               
               
               
               
               
               
               
               
               
             
           
               
                 TABLE 5 
               
               
                   
               
               
                   
               
             
             
               
                   
                   
                 point- 
                   
                   
                   
                   
                   
               
               
                 Tag Name 
                 engunits 
                 source 
                 Pointtype 
                 DigitalSet 
                 Location 4 
                 compdev 
                 compressing 
               
               
                   
               
               
                 CR-millarea.STAT 
                 Running/NotRunning 
                 C 
                 Digital 
                 Running 
                 1 
                 Mill std 
                 1 
               
               
                 CR- 
                 CanEmit/CanNotEmit 
                 C 
                 Digital 
                 P2EMIT 
                 1 
                 Mill std 
                 1 
               
               
                 millarea_PTE.STAT 
               
               
                 CR- 
                 CanEmit/CanNotEmit 
                 C 
                 Digital 
                 P2EMIT 
                 1 
                 0 
                 1 
               
               
                 LVHC_PTE.STAT 
               
               
                 CR- 
                 Treating 
                 C 
                 Digital 
                 Treating 
                 1 
                 0 
                 1 
               
               
                 destdevice.TREAT 
               
               
                 CR-LVHC.TREAT 
                 Treating 
                 C 
                 Digital 
                 Treating 
                 1 
                 0 
                 1 
               
               
                 CR- 
                 Vent/NotVent 
                 C 
                 Digital 
                 Vent/NotVent 
                 1 
                 0 
                 1 
               
               
                 devicename.Vent 
               
               
                 CR-Main.Vent 
                 Vent/NotVent 
                 C 
                 Digital 
                 Vent/NotVent 
                 1 
                 0 
                 1 
               
               
                 CR-MainVent.FILT 
                 Vent/NotVent 
                 C 
                 Digital 
                 Vent/NotVent 
                 1 
                 0 
                 1 
               
               
                 CR-Rupture.Vent 
                 Vent/NotVent 
                 C 
                 Digital 
                 Vent/NotVent 
                 1 
                 0 
                 1 
               
               
                 CR-destdevice.EE 
                 EE-OK 
                 C 
                 Digital 
                 EE-OK 
                 1 
                 0 
                 1 
               
               
                 CR-destdevice.DQ 
                 Bad/Good 
                 C 
                 Digital 
                 Bad-Good 
                 1 
                 0 
                 1 
               
               
                 CR- 
                 Min/Day 
                 C 
                 Float32 
                   
                 4 
                 0 
                 1 
               
               
                 LVHC_Down.Day 
               
               
                 CR- 
                 Min/Day 
                 C 
                 Float32 
                   
                 4 
                 0 
                 1 
               
               
                 Inicn_Down.Day 
               
               
                   
               
             
          
           
               
                   
                 Tag Name 
                 CompMax 
                 excdev 
                 excmax 
                 shutdown 
                 step 
                 zero 
                 span 
               
               
                   
                   
               
               
                   
                 CR-millarea.STAT 
                 Mill Std 
                 Mill 
                 Mill std 
                 1 
                 1 
               
               
                   
                   
                   
                 std 
               
               
                   
                 CR- 
                 Mill std 
                 Mill 
                 Mill std 
                 1 
                 1 
               
               
                   
                 millarea_PTE.STAT 
                   
                 std 
               
               
                   
                 CR- 
                 28800 
                 0 
                 60 
                 1 
                 1 
               
               
                   
                 LVHC_PTE.STAT 
               
               
                   
                 CR- 
                 28800 
                 0 
                 60 
                 1 
                 1 
               
               
                   
                 destdevice.TREAT 
               
               
                   
                 CR-LVHC.TREAT 
                 28800 
                 0 
                 60 
                 1 
                 1 
               
               
                   
                 CR- 
                 28800 
                 0 
                 60 
                 1 
                 1 
               
               
                   
                 devicename.Vent 
               
               
                   
                 CR-Main.Vent 
                 28800 
                 0 
                 60 
                 1 
                 1 
               
               
                   
                 CR-MainVent.FILT 
                 28800 
                 0 
                 60 
                 1 
                 1 
               
               
                   
                 CR-Rupture.Vent 
                 28800 
                 0 
                 60 
                 1 
                 1 
               
               
                   
                 CR-destdevice.EE 
                 28800 
                 0 
                 60 
                 1 
                 1 
               
               
                   
                 CR-destdevice.DQ 
                 28800 
                 0 
                 60 
                 1 
                 1 
               
               
                   
                 CR- 
                 7200 
                 1 
                 60 
                 0 
                 1 
                 0 
                 1440 
               
               
                   
                 LVHC_Down.Day 
               
               
                   
                 CR- 
                 7200 
                 1 
                 60 
                 0 
                 1 
                 0 
                 1440 
               
               
                   
                 Inicn_Down.Day 
               
               
                   
                   
               
             
          
         
       
     
         [0305]                                                TABLE 6                               Point-                           Tag Name   Descriptor   type   compdev   compressing   CompMax   excdev   excMax                   Vent.PV   Source (DCS) vent tag   Digital   Mill std   1   Mill Std   Mill std   60       Temp.PV   Incinerator Source (DCS)   Float32   Mill std   1   &lt;=3600   Millstd   60           tag                    
 1. VI. Standard Proficy Model 
 
         [0306]     The Proficy model consists of input variables (PI inputs), calculated variables and equations. Variables for a standard LVHC/HVLC collection system and descriptions of EE and CMS event logic are included below.  
         [0307]     PI Interface Proficy Variables  
                                                               Data       Sampling   Sampling   Sampling               Variable   Type   Precision   Interval   Offset   Window   Sampling Type   PI Tag                   Down Time   Integer       1440       420 1     15   Last Good Value   CR-LVHC_Down.Day       Down Time   Integer       1440   420   15   Last Good Value   CR-HVLC_Down.Day       Down Time   Integer       1440   420   15   Last Good Value   CR-Incin_Down.Day                   1 The sampling offset is determined based upon the mill Start of Day time. The offset value is the number of minutes from midnight to the mill start of day. In this example the start of day is 7:00 AM (as there are 420 minutes from midnight until 7:00 AM).             
 
         [0308]     Calculation Manager Proficy Variables  
                                                           Data       Sampling   Sampling               Variable   Type   Precision   Interval   Offset   Calc. Type   Calc. Name                   Running Time   Integer       1440   420   Equation   Uptime (Daily)       Running Time   Integer       1440   420   Equation   Uptime (Daily)       Running Time   Integer       1440   420   Equation   Uptime (Daily)                  
 
 EE Event Logic 
 
         [0309]     Emission source EE events are generated whenever a vent valve, rupture disk or other valve type opens to the atmosphere while the gas source(s) is operating as determined by PI. Likewise, destruction device EE events are generated whenever the device is not running and regulated gases are being directed to the device. Overlapping intervals from two or more EE events is counted as a single event for the duration of the overlap. Overlapping events are resolved at report creation by the report package and not by the Proficy or PI models. EE events are detected using downtime model- 200 , with an optional, mill specific delay filter.  
         [0000]     CMS Event Logic  
         [0310]     CMS downtime events are monitored only for particular destruction devices. Typically, the trigger is a PI tag that tests thermal oxidizer device temperature data quality. CMS events are detected using downtime model- 200 , with an optional, mill specific delay filter.  
       Include Autologs and Downtime Event Log Description  
       [0311]     Describe interaction between DCS/PI/Proficy as a part of the general overview. See Figures below. 
         
         
         
         
         
 
         [0312]     The purpose of this document is to describe the design of the Continuous Monitoring System for foul-condensate treatment monitoring operations. Specifically, the design of the monitoring system for a Steam Stripper column adhering to the 92% compliance option, as specified in §63.446(e)3, is addressed by this document.  
         [0313]     FIGS.  12  to  17  depict various steam stripper calculation data flows.  
         [0314]     The software is comprised of PI Data Archive software (which is used for automatic data collection from various process instrumentation and control systems) and Proficy software (which monitors and re ports compliance based on the PI data and operator inputs). This documentation is directed toward system administrator level personnel but can be used as a basic understanding of how the system works.  
         [0315]     The following sections describe the general configuration of a standard steam stripper monitoring system following the 92% efficiency option. Devi ations from the standard model, configuration listings for specific lines, and mill-specific details are contained within the appendices.  
         [0316]     Foul condensate is collected in a central collection tank (also referred to as a Main Foul Condensate Collection Tank or Stripper Feed Tank) from sources such as digesters, evaporators, and turpentine systems. From this tank, the condensate is usually heated in a stripper condensate pre-heater heat exchanger using hot, stripped condensate, before being fed to the steam stripper column. Strippers that operate at a vacuum and low temperatures may not have a pre-heater.  
         [0317]     Typically, low pressure steam is used to strip the MeOH out of the foul condensate however strippers can also use medium pressure steam, steam generated from a condensate re-boiler, or evaporator vapor to strip the MeOH from the condensate. The steam flow carries the vaporized MeOH out of the column to a reflux condenser that condenses most of the water vapor out of the MeOH/water vapor stream leaving the column. The concentrated MeOH vapor is often called stripper off gas (SOG). Hydrogen sulfide and other total reduced sulfer (TRS) compounds will be stripped along with the MeOH and are found in high concentrations in the SOG. The SOG is sent to an incinerator, boiler, or kiln where it is incinerated for disposal. The stripped condensate is collected in the bottom of the steam stripper and usually sent through the condensate preheater to heat the incoming condensate to within about 20° F. of the stripper column operating temperature. After exiting the pre-heater, the stripped condensate is either sent to a sewer or is used back in the process.  
         [0318]     Most steam stripper pre-heaters are designed to heat the inlet condensate temperature to within 20° F. of the outlet stripped condensate temperature. If the feed temperature is colder than design, more steam is consumed to preheat the condensate in the column, leaving less steam to actually strip (e.g. reducing the effective stripping steam). In this case, the total stripping steam required to accomplish the same degree of methanol removal should be increased to offset the portion of applied steam needed to further heat the colder incoming condensate. In general, the main reason why the inlet and outlet temperature gap widens over time is due to fouling of the condensate pre-heater.  
         [0319]     One of the treatment options for a steam stripper is to remove or strip 92% of the MeOH in the condensate entering the stripper. The efficiency of a steam stripper to remove MeOH correlates to the ratio of effective steam flow to condensate flow in the stripper. The minimum effective steam ratio to maintain a minimum 92% MeOH removal efficiency is established by the mill during a Performance Test and used as a lower limit to determine excess emissions events.  
         [0320]     Typically, 0.2 lbs of low pressure steam is needed for stripping to achieve 92% methanol removal per pound of foul condensate. This ratio can be expressed as a percentage, such as 20%. For a given condensate flow, inlet temperature, and MeOH concentration; the steam to foul condensate feed flow ratio is fairly constant to achieve a specific methanol removal. Some of the steam fed to the stripping column is condensed to heat the incoming foul condensate to the boiling temperature at the stripper operating pressure. The heating occurs quickly in the first feed tray of the column. About 0.001 pound of steam is needed to heat 1 pound of condensate by 1° F., or about 0.02 pounds of steam (0.02%) to heat the foul condensate 20° F. The steam that is actually doing the work to strip the methanol out of the condensate is referred to as effective steam. Every 10° F. drop in feed temperature takes 1% off the effective steam flow ratio. The effect steam ratio needed to get greater than 92% removal is approximately 0.18.  
         [0321]     Five parameters are required to compute the effective steam ratio, which includes the three parameters required by §63.453(g): 
        Foul Condensate Feed Flow, lbs/hr, (FCFF)     Stripper Steam Flow, lbs/hr, (SSF)     Stripper Bottom Temperature, degF, (SBT)     Foul Condensate Feed Temperature, degF,( FCFT)     Enthalpy of the condensing steam, Btu/lb, (H), τ1000 BTU/lb, usually assumed as a constant.        
 
         [0327]     Effective Steam Ratio (ESR) is computed as the ratio of effective steam flow divided by the foul condensate flow, or:  
             ESR   =       ⁢       Effective   ⁢           ⁢   Steam   ⁢           ⁢   Flow       Foul   ⁢           ⁢   Cond   ⁢           ⁢   Flow                   =       ⁢       SSF   -     (       (     FCFF   ×     (     SBT   -   FCFT     )     ×     (       1   ⁢           ⁢   BTU   ⁢     /     ⁢   lb     -   F     )       )     /   H     )       FCFF               
 
         [0328]     For example, assuming:  
         [0329]     Stripper Steam Flow (SSF)=10,000 lb/hr  
         [0330]     Foul Condensate Feed Flow (FCFF)=100 gpm (100 gpm×500 lb/hr/gpm=50,000 lb/hr)  
         [0331]     Stripper Bottom Temp (SBT)=275° F.  
         [0332]     Foul Condensate Feed Temp (FCFT)=255° F.  
         [0333]     Enthalpy (H)=1000 BTU/lb (assumed constant) yields an effective steam ratio of  
       ESR   =                 10   ⁢     ,     ⁢   000     -     (     (     (     50   ⁢     ,     ⁢   000   ×     (     275   -   225     )       )                           ×     (       1   ⁢           ⁢   BTU   ⁢     /     ⁢   lb     -   °F     )       )     /   1000     )           0.18     =       9000   ⁢           ⁢   lb   ⁢     /hr         50   ⁢     ,     ⁢   000   ⁢           ⁢   lb   ⁢     /hr               
 
         [0334]     As the effective steam flow ratio drops below its target, the operator can either increase steam flow to get the effective steam back up to its target level, or can reduce flow to the stripper at the same steam flow to restore the effective steam flow ratio target. The later method may result in slowing back production, or may risk sewering too much condensate per the collection requirements.  
         [0335]     These variables are collected and archived by the PI system and made available to the Proficy system to analyze against specific criteria to determine if an Excess Emission (EE) event has occurred. Two types of excess emission events can occur during the operation of a 92% Steam Stripper system: a low 3-hour rolling average stripper efficiency event (3-hour rolling average excess emission event) and a stripper bypass event (stripper excess emission bypass event). Excess emission events for steam stripper treatment are recorded by the system whenever: 
        the steam stripper has the potential to emit (PTE) pollutants (as defined in PI) and the three hour effective steam ratio average falls below the lower effective steam ratio limit (lower reject specification limit); or     the condensate system sources are operating and the collection tank (stripper feed tank) overflows while the stripper is not running; or     collected MeOH is diverted from steam stripper treatment, irrespective of whether the condensate sources and steam stripper are running or not.        
 
         [0339]     The steam stripper system has a 10% allowance against condensate runtime for all excess emission events, as specified in §63.446(g).  
         [0340]     The steam stripper treatment system has the potential to emit pollutants whenever the condensate sources are operating. Therefore the potential to emit runtime for the steam stripper system corresponds to the condensate collection operating time reported to the state regulatory agency on a semi-annual basis or more frequently as required.  
         [0341]     The PI system computes an effective steam flow and effective steam ratio every minute (CR-SS_EFFSteam.Filt and CR-SS_ESRatio.Filt) from the four parameters above (using 1000 as an enthalpy constant). The effective steam flow calculation flow is clamped at zero in the PI tag (CR-SS_ESRATIO.RAW). Additionally every fifteen minutes the related PI tag (CR-SS_ESRatio.Filt) compute what percentage of time the data quality of the effective steam ratio was good over the fifteen minute interval.  
         [0342]     The following table gives an overview of the minimum required process inputs, their engineering units, associated PI tags, and corresponding Proficy variable names.  
                                           Input   Eng Units   PI Tagname   Proficy Variable                   Steam Stripper Treating   Treating/Not   CR-SS-TREAT.STAT   Steam Stripper Treating       Status   Treating       (Potential to Emit) Status                   (Snapshot)       Steam Stripper Numeric   0/100   CR-SS_TREAT.NUM   Steam Stripper Treating       PTE Status           Status - Numeric       Condensate System PTE   CanEmit/   CR-Cond-PTE.Stat   Condensate System       Status   CanNotEmit       Potential to Emit                   (Snapshot)       Daily Steam Stripper   Min/day   CR-SS_Treat.Day   Stripper Daily Downtime       Not Treating minutes -       calculated at mill end of       day       Bottom Temperature   ° F.   CR-SS-BottomTemp.PV   N/A       Condensate Feed   ° F.   CR-SS-FeedTemp.PV   N/A       Temperature       Condensate Feed Flow 23     Lbs/hr   CR-SS-CondFlow.PV   N/A       Feed Steam Flow   Lbs/hr   CR-SS-FeedSteam.PV   N/A       Bottom Temperature   %   CR-SS-   Bottom Temperature 15 Min -       Data % Good       BottomTemp.PctGd   % Good       Condensate Feed   %   CR-SS-FeedTemp.PctGd   Feed Temperature 15 Min -       Temperature Data %           % Good       Good       Feed Steam Data %   %   CR-SS-   Feed Steam Flow 15 Min -       Good       FeedSteamFlow.PctGd   % Good       Condenate Feed Flow   %   CR-SS-CondFlow.PctGd   Condensate Flow 15 Min -       Data % Good           % Good       Effective Steam Flow   Lbs/hr   CR-SS_EFFSTEAM.Filt   N/A       Effective Steam Flow   Lbs/hr   CR-SS_ESRATIO.RAW   N/A       clamped to 0       Steam Stripper Ratio       CR-SS-ES_Ratio.Filt   Effective Steam Ratio 15 Min                   (Raw PI Avg)       Effective Steam Flow   %   CR-SS-ES_Ratio.PctGd   Effective Steam Ratio 15 min -       Data % Good           % Good (CMS)       Stripper Divert Valve   EE/OK   CR-SS-DivertValve.EE   Stripper Bypass EE Event       Indicator       Tank Overflow Indicator   EE/OK   CR-SS-TankOverflow.EE   Stripper Tank Overflow                   EE Event                   23 To complete the effective steam ratio calculation Condensate Feed Flow must be expressed in lbs/hr. To convert condensate flow to lbs/hr, multiply the flow rate (in gal/min) by 8.35 * 60.             
 
         [0343]     Data quality limits for the Bottom Temperature, Feed Temperature, Condensate Flow, and Steam Flow are maintained in Pi. These data quality limits are used by a PI performance equation to determine if the PI process value has “Good” or “Bad” signal quality and contribute to the overall data quality of the Effective Steam Ratio calculation. Anytime that the data quality of the four parameters results in a failure of the system to reliably calculate an effective steam ratio for the fifteen minute interval, the system records a Continuous Monitoring System (CMS) event (explained in detail below).  
         [0344]     The following sections describe in detail how the PI/Proficy steam stripper model computes effective steam and triggers Steam Stripper EE and CMS events.  
         [0000]     a) Steam Stripper PTE and Total Runtime  
         [0345]     In general, the steam stripper treatment system has a potential to emit pollutants whenever the condensate collection system or steam stripper column is operating. Specifically the steam stripper treatment system has three distinct potential to emit (PTE) conditions. First the steam stripper has potential to emit pollutants whenever it is operating (usually determined by a minimum flow on a flow meter and a “Running”/“NotRunning” indicator on the stripper). Under these conditions emissions occur whenever the 3 hour rolling average of stripper efficiency falls below 92%. Secondly steam stripper treatment emissions can occur whenever the condensate system is operating while the stripper is not operating. Under this condition overflows of the collection tank or foul condensate diverts upstream of the collection tank are considered steam stripper treatment excess emissions. Lastly emissions can occur if the foul condensate is present in the stripper feed tank (indicated by tank level) irrespective of stripper or condensate system operating status. In this case, emissions occur if the foul condensate is pumped out of the feed tank and towards a non-treated collection point (such as to sewer or through the column when steam is not present).  
         [0346]     The steam stripper system has a 10% emission allowance against source (condensate collection) operating time for all types of emissions. The total number of runtime minutes used to calculate this emission allowance corresponds to the total number of runtime minutes for the condensate collection system over the same period of time.  
         [0347]     The steam stripper is considered to be treating when the following three conditions are met: 
        Condensate Flow&gt;minimum value (set by mill but not far from zero)     Steam Flows&gt;minimum (set by mill; generally 1000 to 10000 lb/hr)     Bottom Temp&gt;minimum treating limit (generally 212)        
 
         [0351]     Each minute, the above conditions are monitored with the PI performance equation, CR-SS_Treat.Stat. This treating status is converted into a numeric value (0=NotTreating, 1=Treating) in the tag, CR-SS_Treat.NUM. This PI tag is averaged every 15 minutes and every hour by Proficy (SS % Time Treating (15 min) and SS % Time Treating (1 Hr)) to determine the average treating status over the previous 15 minutes and one hour. Proficy then translates the numeric average into a treating status using VBScript (SS CMS Treating Status (15 min) and SS EE Treating status (1 Hr)). These average treating statuses are used to filter out EE and CMS events during NotTreating time periods.  
         [0352]     On a daily basis, a PI tag (CR-SS_Treat.Day) computes the total number of minutes that the steam stripper was down during the previous production day. This value is used by Proficy to compute the daily total number of runtime minutes of the steam stripper system. These daily totals are used by the reporting system to compute the total number of steam stripper runtime minutes over the reporting period.  
         [0000]     b) Computing the Effective Steam Ratio  
         [0353]     The effective steam ratio is computed in PI each minute based upon the process data for the four process parameters above from the mill DCS system (and assuming a constant of 1000 for enthalpy). The raw value for each of the four parameters necessary to compute effective steam is first validated in PI against upper and lower specification limits (maintained in PI). If the value is within range (and not flat-lined), PI records the value into an intermediate variable (CR-SS-FeedSteam.FILT, CR-SS-CondFlow.FILT, CR-SS-BottomTemp.FILT, and CR-SS-CondTemp.FILT); if the value is out of range the intermediate variable records “Bad” instead. These PI performance equations are event based (calculated every time a new value enters the PI snapshot) so that data buffered in the PI interface will be captured and used regardless of its PI archive status. If all four process values exhibit good data quality, PI uses the intermediate values to compute an effective steam flow for the minute. PI stores this value in the PI tag CR-SS_EFFSTEAM.Filt. It is possible for the effective steam flow calculation to have a negative result during times of stripper upsets. Since negative values are theoretically impossible and can cause long periods of low three hour averages, the PI tag, CR-SS_ESRATIO.RAW clamps the effective steam ratio to 0 whenever the tag CR-SS_EFFSTEAM.Filt has a negative value. If all four process values exhibit good data quality, PI outputs the value from CR-SS_ESRATIO.RAW to Proficy.  
         [0000]     c) Steam Stripper CMS Events  
         [0354]     When the steam stripper system is running, failures to calculate the effective steam ratio of the stripper result in Continuous Monitoring System (CMS) events. Every fifteen minutes, Proficy computes a time-weighted average of the effective steam ratio calculation (CR-SS-SS_Ratio.Filt) over the previous fifteen minutes and stores the value in the variable Effective Steam Ratio—15 Min PI Avg. At the same time Proficy examines the CR-SS_ESRatio.PctGd tag to determine if CR-SS_ESRatio.Filt maintained “Good” data quality during at least 50% of the fifteen-minute period. If so, the computed fifteen-minute average is copied into the Proficy variable Effective Steam—15 Min Qualified Avg. If any fifteen-minute period fails to meet the 50% criteria while the SS CMS Treating Status (15 min) value is Treating, Proficy instead creates a fifteen-minute steam stripper CMS downtime event (via a stored procedure calculation) for the period or it appends fifteen-minutes to an existing CMS event (if a contiguous CMS event already exists).  
         [0355]     Every fifteen-minutes Proficy also reads and displays the data quality results (% Good) for each parameter required to complete the effective steam ratio calculation. These data-quality values assist the operator in determining which of the four signal(s) was (were) responsible if the effective steam ratio average could not be calculated (resulting in the CMS event). These values are displayed on the steam stripper display for diagnostic purposes but do not, by themselves, create CMS events.  
         [0356]     The Proficy software logs all Steam Stripper CMS events and operator responses to those events. The responses record the operator determined Trouble, Cause, Correction (response), and Report Code (report categorization) of the event. The events are compiled, measured against the stripper operating time for the reporting period, and reported to the state regulatory agency on a semi-annual basis or more frequently as required.  
         [0000]     d) Steam Stripper Excess Emission Events  
         [0357]     Two types of excess emission events can occur during the operation of a 92% Steam Stripper system: a 3-hour rolling average excess emission event and a stripper bypass excess emission event.  
         [0000]     13) 3-Hour Rolling Average Excess Emission Event  
         [0358]     Once per hour, Proficy examines all fifteen-minute qualified averages (Effective Steam Ratio—15 Min Qualified Avg) during the previous three-hour period. If greater than 50% of the averages exist and have good data quality, Proficy computes a 3-hour rolling average effective steam ratio (Effective Steam Ratio—3 HR Avg.) from all fifteen minute averages exhibiting Good data quality. This computed three hour average is compared against a lower limit (lower specification warning limit on the Effective Steam—3 HR Avg. variable) and if the value falls below the limit and the SS EE Treating Status (1 Hr) value is Treating, Proficy creates a one-hour Excess Emission downtime event or, in the case that a previous contiguous excess emission event existed, it appends one-hour to the existing event (via a stored procedure calculation). The value is also written back to the PI tag CR-SS_ESRatio.3H for trending within the mill.  
         [0359]     No manual entry of steam stripper effective steam ratio is available in the system.  
         [0360]     The Proficy software logs all Steam Stripper Rolling Average EE events and operator responses to those events. The responses record the operator determined Trouble, Cause, Correction (response), and Report Code (report categorization) of the event. All report categorizations except No Excess Emission are totaled and reported to the state regulatory agency on a semi-annual basis, or more frequently as required, against the 10% steam stripper emission allowance.  
         [0361]     14) Steam Stripper Excess Emission Bypass Events  
         [0362]     In addition to 3-hour rolling average excess emission events, a steam stripper column also incurs excess emissions if condensate bypasses the stripper column prior to or without treatment while the condensate collection system is operating or during stripper downtime if previously collected condensate is diverted to a non-treated collection point (such as sewer).  
         [0363]     The five types of PI calculations used to monitor steam stripper bypass excess emissions are described below. All of the following PI performance equations are evaluated at least once a minute and are monitored by the Proficy system using model 200 (with a mill specific filter applied). Proficy creates an (EE) event for each minute that the PI performance equations&#39; value is E.  
         [0364]     1. Main Collection Tank Overflow  
         [0365]     When the tank level is greater than a maximum while the condensate system is operating and the stripper is not running, the performance equation records the minute as a steam stripper bypass excess emission.  
         [0366]     2. Main Collection Tank Bypass before collection boundary  
         [0367]     When a bypass value located after the tank outlet and before the condensate collection boundary (flow meter) is open (bypassing) while the condensate system is operating and the stripper is not running, a performance equation records the minute as a steam stripper bypass excess emission.  
         [0368]     3. Main Collection Tank Upstream Bypass  
         [0369]     When the condensate system is operating, the stripper is not running, the main collection tank is not overflowing and all bypasses after the main collection tank outlet are not bypassing, a performance equation checks for any overflows or diverts upstream of the main collection tank If any upstream diverts occur under the described conditions, the performance equation records the minute as a steam stripper bypass excess emission.  
         [0370]     4. Main Collection Tank Bypass after collection boundary  
         [0371]     When the stripper is not running, a PI performance equation examines the state of any bypass valves past the collection tank (flow meter) but prior to the stripper column to determine if collected condensate is being directed away from the steam stripper column, which is recorded as a steam stripper bypass excess emission.  
         [0372]     5. Steam Stripper feed without steam flow  
         [0373]     When the condensate system is operating and the stripper is not running, a performance equation monitors the foul condensate feed flow to the column. If the condensate feed flow is greater than a minimum value, the performance equation records the minute as a steam stripper excess emission.  
         [0374]     The Proficy software logs all Steam Stripper EE Bypass events and operator responses to those events. The responses record the operator determined Trouble, Cause, Correction (response), and Report Code (report categorization) of the event. The steam stripper system has a 10% allowance against the overall condensate system runtime period. Events categorized as No Excess Emission are excluded from this calculation however all other report codes are included in it. The events are compiled and reported to the state regulatory agency on a semi-annual basis or more frequently as required.  
         [0375]     Should a bypass event occur simultaneously during the period when the steam stripper three-hour effective steam rolling average falls below the minimum effective steam limit, only one hour of excess emissions will be reported by the reporting system. That is, in any 24-hour period, there can be no more than 24 hours of total stream stripper excess emissions.  
         [0376]     Table-1 gives the process inputs required for a typical steam stripper system, their engineering units, data source, and corresponding Proficy variable names.  
                                     TABLE 1                           Input Variables                    Eng               Production Unit   Proficy Variable   Units   Data Source   Description               SS Treatment   Effective Steam Ratio (%   %   PI   15 min percent good effective       Variables   Good)           steam ratio calculation       SS Treatment   Effective Steam Ratio   ratio   PI   15 min Avg of one minute PI       Variables   (Raw 15 M Avg)           calculated effective steam                       ratio.       SS Treatment   Bottom Temperature 15 Min -   %   PI   15 min percent good of       Variables   % Good           Bottom Temperature. Used                       for display only.       SS Treatment   Feed Temperature 15 Min -   %   PI   15 min percent good of Cond       Variables   % Good           Feed Temperature. Used for                       display only.       SS Treatment   Cond Feed Flow 15 Min -   %   PI   15 min percent good of       Variables   % Good           Condensate Feed Flow. Used                       for display only.       SS Treatment   Feed Steam Flow 15 Min -   %   PI   15 min percent good of Feed       Variables   % Good           Steam Flow. Used for display                       only.       Reporting Unit   Steam Stripper Treating   Treating/   PI   snapshot of SS Treating           Status (snapshot)   NotTreating       Status. Used for display                       only.       Reporting Unit   SS % Time Treating (15 min)   %   PI   15 minute average of SS                       numeric treating status       Reporting Unit   SS % Time Treating (1 Hr)   %   PI   1 hour average of SS numeric                       treating status       Reporting Unit   Condensate Daily   Min   PI   Condensate System process           Downtime           downtime (mins)       Reporting Unit   Stripper Daily Downtime   Min   PI   Steam Stripper system                       downtime (mins)                  
 
         [0377]     Table-2 lists typical calculated variables for the system and a brief description of each.  
                                 TABLE 2                           Calculated Variables            Production Unit   Proficy Variable   Eng Units   Description               SS Treatment   Effective Steam Ratio 15 Min       Raw average of 15 min effective       Variables   Avg       steam       SS Treatment   Effective Steam Ratio 15 Min   Status   Data quality status of 15 min average       Variables   Avg (Status)       based on percent good over the 15                   minute window.       SS Treatment   Effective Steam Ratio 15 Min   Status   Qualified 15 minute average or the       Variables   Avg/Status (Used for 3 Hr Avg)       status if data quality criteria was not                   met.       SS Treatment   Effective Steam Ratio 3 Hr       Rolling 3 hour average, calculated       Variables   Rolling Avg       every hour, of 15 minute qualified                   averages.       SS Treatment   Effective Steam Ratio 3 Hr   Status   Status of 3 hour average (“OK”,       Variables   Rolling Avg (Status)       “Unit Down”, “No PTE”).       SS Treatment   Effective Steam Ratio Lower       Lower excess emission limit for 3       Variables   Limit       hour rolling average effective steam.                   This value is maintained as a Proficy                   Lower Warning Specification on the                   Effective Steam 3 Hr Rolling Avg                   variable.       Reporting Unit   SS CMS Treating Status (15 min)   Treating/   Treating status based on 15 min               NotTreating   treating average. Used in 15 minute                   calculations and CMS event creation,       Reporting Unit   SS EE Treating Status (1 Hr)   Treating/   Treating status based on 1 hour               NotTreating   treating average. Used in 3 hour                   calculations and EE event creation.                  
 
 e) Tag Name Specifications 
 
         [0378]     All Cluster Rule Steam Stripper PI tags will begin with the prefix “CR-SS”.  
         [0000]     f) Digital State Set Specifications  
         [0379]     The following are the minimum required digital state sets in PI to support the Cluster Rule Steam Stripper 92% model.  
                                                       Digital Set Name   State 0   State 1                           P2Emit   CanEmit   CanNotEmit           OK-EE   OK   EE           GOOD-BAD   Good   Bad           RUN-STOP   Run   Stop           Treat   Treating   NotTreating                      
 
 g) Scan Class Specifications 
 
         [0380]     The following scan classes must be available in P1. Note, the actual scan class number will vary by location.  
         [0381]     A one minute scan class offset 0 seconds from midnight;  
         [0382]     A fifteen minute scan class offset 0 seconds from midnight;  
         [0383]     A twenty-four hour scan class offset to the start of mill day.  
         [0384]     Examples of the scan class syntax is as follows:  
                                                   /f = 00:01:00, 00:00:00 (alternately /f = 00:01:00, 0)           /f = 00:15:00, 00:00:00 (alternately /f = 00:15:00, 0)           /f = 24:00:00, 07:00:00 (alternately /f = 24:00:00, 25200) for           mill day at 07:00 am                      
 
 h) PI Tag Configuration Specification 
 
         [0385]     The following tables provide the typical PI tags (and their configuration) required for a Steam Stripper Treatment system following the 92% treatment methodology and standard exception and compression attribute values for mill specific DCS PI tags.  
                                       Tag Name   Descriptor   exdesc                   CR-SS_TREAT.STAT   Steam Stripper Treating   if ‘CR-SS-CondFlow.PV’ &gt; LL and ‘CR-SS-SteamFlow.PV’ &gt; LL and ‘CR-SS-           Status   Bottom Temp.PV’ &gt; LL then “Treating” else “NotTreating”       CR-SS_TREAT.NUM   Numeric Steam Stripper   event=CR-SS_TREAT.STAT, if ′CR-SS_TREAT.STAT′ &lt;&gt; “Treating” and ′CR-               SS_TREAT.STAT′ &lt;&gt; =”NotTreating” then PrevVal(′CR-SS_TREAT.NUM′, ′*′) else if               ′CR-SS_TREAT.STAT′ &lt;&gt; “Treating” then 0 else 100       CR-Cond-PTE.STAT 24     Condensate System           Potential to Emit Status       CR-SS-TREAT.Day   Steam Stripper Daily Not   TimeEq(′CR-SS_TREAT.STAT′,′Y+7H′,′T+7H′,″CanNotEmit″)/60           Treating       CR-Cond-Down.Day   Condensate System   TimeEq(′CR-Cond.STAT′,′Y+7H′,‘T+7H′,″CanNotEmit″)/60           Potential to Emit           downtime/day       CR-SS_Overflow.EE   SS Overflow Excess   if ′CR-SS_TREAT.STAT′=”NotTreating” and ′CR-CONDSYS-PTE.STAT′=”CanEmit”           Emissions Status   then (if ′TankLevel.PV′ &gt; HHL then “EE” else “OK”) else “OK”       CR-SS_DivertValve.EE   SS Treatment Bypass EE   After Cond Coll Flow Meter           Status   if ′CR-CONDSYS-PTE.STAT′=”CanEmit” then (if ′DivertValve.PV′ = “Open” then “EE”               else “OK”) else “OK”               Before Cond Coll Flow Meter               if ′CR-SS_TREAT.STAT′=”NotTreating” and ′CR-CONDSYS-PTE.STAT′=”CanEmit”               then (if ′DivertValve.PV′ = “Open” then “EE” else “OK”) else “OK”       CR-SS_FlowEmissions.EE   Flow out of bottom of   if ′CR-SS_TREAT.STAT′ &lt;&gt; “Treating” and ′CR-SS-CondFlow.Filt′ &gt; min then “EE”           column EE Status   else “OK”       CR-SS-Cond.Divert   Any upstream condensate   If ‘CR-Valve1.Divert’=”Divert” or ‘CR-Level1.Divert’=”Divert” or . . . then “Divert” else           divert   “Collect”       CR-SS_CondDvrt.EE   Upstream condensate divert   if ′CR-SS_TREAT.STAT′=”NotTreating” and ′CR-CONDSYS-PTE.STAT′=∞CanEmit”           EE Status   and ‘CR-SS_Overflow.EE’=”OK” and ′CR-SS_DivertValve.EE’=”OK” then if ‘CR-SS-               Cond.Divert’=”Divert” then “EE” else “OK”       CR-SS-BottomTemp.Filt   SS Bottoms Temperature   event=CR-SS-BottomTemp.PV, if (TagMax(′CR-SS-BottomTemp.PV′,’*-3h’,’*’)-           Filter   TagMin(′CR-SS-BottomTemp.PV′,’*-3h’,’*’) &gt; 0) and (′CR -SS-BottomTemp.PV′ &gt; LLL)               and (′CR-SS-BottomTemp.PV′ &lt; HHL) then ′CR-SS-BottomTemp.PV′ else ″BAD″       CR-SS-FeedTemp.Filt   SS Condensate Feed   event=CR-SS-FeedTemp.PV, if (TagMax(′CR-SS-FeedTemp.PV′,’*-3h’,’*’)-           Temperature Filter   TagMin(′CR-SS-FeedTemp.PV′,’*-3h’,’*’) &gt; 0) and (′CR-SS-FeedTemp.PV′ &gt; LLL) and               (′CR-SS-FeedTemp.PV′ &lt; HHL) then ′CR-SS-FeedTemp.P′ else ″BAD″       CR-SS-FeedSteamFlow.Filt   SS Feed Steam Flow Filter   event=CR-SS-FeedSteam Flow.PV, if (TagMax(′CR-SS-FeedSteamFlow.PV′,’*-3h’,’*’)-               TagMin(′CR-SS-FeedSteamnFlow.PV′,’*-3h’,’*’) &gt; 0) and (′CR-SS-FeedSteamFlow.PV’&gt;               LLL) and (′CR-SS-FeedSteamFlow.PV′ &lt; HHL) then ′CR-SS-FeedSteamFlow.PV′ else               ″BAD″       CR-SS-CondFlow.Filt 25     SS Condendate Feed Flow   event=CR-SS-CondFlow.PV, if(TagMax(′CR-SS-CondFlow.PV′,’*-3h’,’*’)-           Filter   TagMin(′CR-SS-CondFlow.PV′,’*-3h’,’*’) &gt; 0) and (′CR-SS-CondFlow.PV′ &gt; LLL) and               (′CR-SS-CondFlow.PV′ &lt; HHL) then (′CR-SS-CondFlow.PV′ * 8.35 * 60 / 1000) else               ″BAD″       CR-SS-BottomTemp.PctGd   SS Bottoms Temperature %   if BadVal(PctGood(′CR-SS-BottomTemp.Filt′, ′*-15M′, ′*′)) then 0 else PctGood(′CR-SS-           Good   BottomTemp.Filt′, ′*-15M′, ′*′)       CR-SS-FeedTemp.PctGd   SS Feed Temperature %   if BadVal(PctGood(′CR-SS-FeedTemp.Filt′, ′*-15M′, ′*′)) then 0 else PctGood(′CR-SS-           Good   FeedTemp.Filt′, ′*-15′, ′*′)       CR-SS-   SS Feed Steam Flow %   if BadVal(PctGood(’CR-SS-FeedSteamFlow.Filt′, ′*-15M′, ′*′)) then 0 else PctGood(’CR-       FeedSteamFlow.PctGd   Good   SS-FeedSteamFlow.Filt′, ′*-15M′, ′*′)       CR-SS-CondFlow.PctGd   SS Condensate Feed Flow   if BadVal(PctGood(′CR-SS-CondFlow.Filt′, ′*-15M′, ′*′)) then 0 else PctGood(’CR-SS           % Good   CondFlow.Filt′, ′*-15M′, ′*′       CR-SS-EffSteam.Filt   SS One Minute Effective   if Bad Val(′CR-SS-BottomTemp.Filt′)or BadVal(′CR-SS-FeedTemp.Filt′) or BadVal(′CR-           Steam Filter   SS-CondFlow.Filt′)orBadVal(′CR-FeedSteamFlow.Filt′) then “Bad” else (′CR-SS-               FeedSteam.Filt′ - ((′CR-SS-BottomTemp.Filt′ - ′CR-SS-FeedTemp.Filt′)*′CR-SS-               CondFlow.Filt′/1000))       CR-SS_ESRATIO.RAW   SS One Minute Eff Steam   if ′CR-SS_EFFSTEAM.FILT′&lt;0 or ′CR-SS_CondFlow.FILT′&lt;0 then 0 else ′CR-           Ratio Raw Value   SS_EFFSTEAM.FILT′/′CR-SS_CondFlow.FILT′       CR-SS_ESRatio.Filt   SS One Minute Effective   if Bad Val(′CR-SS-BottomTemp.Filt′)or Bad Val(′CR-SS-FeedTemp.Filt′)or BadVal(′CR-           Steam Ratio Filter   SS-CondFlow.Filt′)or               BadVal(′CR-FeedSteamFlow.Filt′) then “Bad” else CR-SS_ESRATIO.RAW       CR-SS_ESRatio.PctGd   SS One Minute Effective   IfBad Val(If BadVal(PctGood(′CR-SS_ESRatio.Filt′, ′*-15M′, ′*′)) then 0 else           Steam Ratio % Good   PctGood(′CR-SS_ESRatio.Filt′, ′*-15M′, ′*′)       CR-SS-_ESRatio.15M   Effective Steam / Cond           Flow 15 Min Avg       CR-SS-_ESRatio.3H   Effective Steam / Cond           Flow 3 Hr Avg       CR-SS-_ESRatio.LL   Effective Steam / Cond           Flow Lower Limit                   24 The Condensate PTE tag (CR-Cond-PTE.STAT) is available and displayed in the Condensate Collection system. A unique tag for Steam Stripper treatment is not required.              25 This example assumes that the raw flow is expressed in M-gpm (1000&#39;s gal/min). Subsequent calculations require that the units of condensate flow (gpm) and feed steam rate (lbs/hr) match. To convert the condensate flow (in gpm) into lbs/hr, multiply the flow by 8.35*60. If flow is expressed in M-gpm, the conversion factor is further divided by 1000.             
 
         [0386]    
       
         
               
               
               
               
               
               
               
               
               
               
               
               
               
               
               
             
               
               
               
               
               
               
               
               
               
               
               
               
               
               
               
             
           
               
                   
               
               
                   
               
               
                   
                   
                 Point- 
                 point- 
                 Digital- 
                 Loca- 
                 comp- 
                 com- 
                 Comp- 
                 exc- 
                   
                 shut- 
                   
                   
                   
               
               
                 Tag Name 
                 engunits 
                 source 
                 type 
                 Set 
                 tion4 
                 dev 
                 pressing 
                 Max 
                 dev 
                 excmax 
                 down 
                 step 
                 zero 
                 span 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 CR-SS_TREAT.STAT 
                 Treating/ 
                 C 
                 Digital 
                 TREAT 
                 1 
                 0 
                 1 
                 28800 
                 0 
                 60 
                 1 
                 1 
                   
                   
               
               
                   
                 Not- 
               
               
                   
                 Treating 
               
               
                 CR-SS_TREAT.NUM 
                 0/100 
                 C 
                 Float32 
                   
                   
                 0 
                 1 
                 60 
                 0 
                 60 
                 1 
                 1 
                 0 
                 100 
               
               
                 CR-Cond-PTE.STAT 
                 CanEmit/ 
                 C 
               
               
                   
                 CanNot- 
               
               
                   
                 Emit 
               
               
                 CR-SS_Treat.Day 
                 Min/Day 
                 C 
                 Float32 
                   
                 4 
                 0 
                 1 
                 7200 
                 0 
                 60 
                 0 
                 1 
                 0 
                 1440 
               
               
                 CR-Cond-Down.Day 
                 Min/Day 
                 C 
               
               
                 CR-SS-Overflow.EE 
                 OK-EE 
                 C 
                 Digital 
                 OK-EE 
                 1 
                 0 
                 1 
                 28800 
                 0 
                 60 
                 1 
                 1 
               
               
                 CR-SS-DivertValve.EE 
                 OK-EE 
                 C 
                 Digital 
                 OK-EE 
                 1 
                 0 
                 1 
                 28800 
                 0 
                 60 
                 1 
                 1 
               
               
                 CR- 
                 OK-EE 
                 C 
                 Digital 
                 OK-EE 
                 1 
                 0 
                 1 
                 28800 
                 0 
                 60 
                 1 
                 1 
               
               
                 SS_FlowEmissions.EE 
               
               
                 CR-SS-Cond.Divert 
                 Divert- 
                 C 
                 Digital 
                 Divert- 
                 1 
                 0 
                 1 
                 28800 
                 0 
                 60 
                 1 
                 1 
               
               
                   
                 Collect 
                   
                   
                 Collect 
               
               
                 CR-SS_CondDvrt.EE 
                 OK-EE 
                 C 
                 Digital 
                 OK-EE 
                 1 
                 0 
                 1 
                 28800 
                 0 
                 60 
                 1 
                 1 
               
               
                 CR-SS-BottomTemp.Filt 
                 Deg F. 
                 C 
                 Float32 
                   
                 1 
                 0 
                 1 
                 840 
                 0 
                 60 
                 1 
                 0 
                 0 
                 2500 
               
               
                 CR-SS-FeedTemp.Filt 
                 Deg F. 
                 C 
                 Float32 
                   
                 1 
                 0 
                 1 
                 840 
                 0 
                 60 
                 1 
                 0 
                 0 
                 2500 
               
               
                 CR-SS- 
                 Lbs/hr 
                 C 
                 Float32 
                   
                 1 
                 0 
                 1 
                 840 
                 0 
                 60 
                 1 
                 0 
                 0 
                 20000 
               
               
                 FeedSteamFlow.Filt 
               
               
                 CR-SS-CondFlow.Filt 
                 Lbs/hr 
                 C 
                 Float32 
                   
                 1 
                 0 
                 1 
                 840 
                 0 
                 60 
                 1 
                 0 
                 0 
                 75000 
               
               
                 CR-SS- 
                 % 
                 C 
                 Float32 
                   
                 3 
                 0 
                 1 
                 600 
                 0 
                 60 
                 1 
                 1 
                 0 
                 100 
               
               
                 BottomTemp.PctGd 
               
               
                 CR-SS-FeedTemp.PctGd 
                 % 
                 C 
                 Float32 
                   
                 3 
                 0 
                 1 
                 600 
                 0 
                 60 
                 1 
                 1 
                 0 
                 100 
               
               
                 CR-SS- 
                 % 
                 C 
                 Float32 
                   
                 3 
                 0 
                 1 
                 600 
                 0 
                 60 
                 1 
                 1 
                 0 
                 100 
               
               
                 FeedSteamFlow.PctGd 
               
               
                 CR-SS-CondFlow.PctGd 
                 % 
                 C 
                 Float32 
                   
                 3 
                 0 
                 1 
                 600 
                 0 
                 60 
                 1 
                 1 
                 0 
                 100 
               
               
                 CR-SS-EffSteam.Filt 
                 Lbs/hr 
                 C 
                 Float32 
                   
                 1 
                 0 
                 1 
                 840 
                 0 
                 60 
                 1 
                 0 
                 0 
                 20000 
               
               
                 CR-SS_ESRATIO.RAW 
                   
                 C 
                 Float32 
                   
                 3 
                 0 
                 1 
                 600 
                 0 
                 60 
                 1 
                 1 
                 0 
                 1 
               
               
                 CR-SS-_ESRatio.Filt 
                   
                 C 
                 Float32 
                   
                 1 
                 0 
                 1 
                 600 
                 0 
                 60 
                 1 
                 0 
                 0 
                 1 
               
               
                 CR-SS-_ESRatio.PctGd 
                 % 
                 C 
                 Float32 
                   
                 3 
                 0 
                 1 
                 600 
                 0 
                 60 
                 1 
                 1 
                 0 
                 100 
               
               
                 CR-SS-SS_Ratio.15M 2   
                   
                 Lab 
                 Float32 
                   
                 1 
                 0 
                 1 
                 28800 
                 0 
                 600 
                 0 
                 1 
                 0 
                 1 
               
               
                 CR-SS-SS_Ratio.3H 2   
                   
                 Lab 
                 Float32 
                   
                 1 
                 0 
                 1 
                 28800 
                 0 
                 600 
                 0 
                 1 
                 0 
                 1 
               
               
                 CR-SS-SS_Ratio.LL 3   
                   
                 Lab 
                 Float32 
                   
                 1 
                 0 
                 1 
                 28800 
                 0 
                 600 
                 0 
                 1 
                 0 
                 1 
               
               
                   
               
               
                     2 Calculated in Proficy and written periodically to PI.    
               
               
                     3 Maintained in Proficy as a Specification Limit and written periodically from Proficy to PI    
               
             
          
         
       
     
         [0387]    
       
         
               
               
               
               
               
               
               
               
             
           
               
                   
               
               
                   
               
               
                 Tag Name 
                 Descriptor 
                 pointtype 
                 compdev 
                 compressing 
                 CompMax 
                 excdev 
                 excmax 
               
               
                   
               
             
             
               
                 Temp or Flow.PV 
                 Raw DCS Temp or Flow 
                 Float32 
                 Mill std 
                 1 
                 ≦3600 
                 Mill std 
                 60 
               
               
                   
                 Value 
               
               
                 Tank Level.PV 
                 Raw Coll Tank Level 
                 Float32 
                 Mill Std 
                 1 
                 Mill Std 
                 Mill Std 
                 60 
               
               
                 Divert Valve.PV 
                 Divert Valve Status 
                 Digital 
                 Mill Std 
                 1 
                 Mill Std 
                 Mill Std 
                 60 
               
               
                   
               
             
          
         
       
     
         [0388]     The Proficy model consists of input variables, calculated variables, stored procedures, and Visual Basic scripts (VB scripts). Variables and associated parameters for a typical 92% steam stripper treatment system and descriptions of the stored procedures and the VB scripts are included below. Complete listings of the Stored Procedures can be found in Appendix A.  
         [0389]     15) Proficy Input Variables (From PI)  
                                                                                                                                               Data       Sampling   Sampling   Sampling   Sampling           Variable Description   Type   Precision   Interval   Offset   Window   Type   PI Tag                                Used For Display Only            Bottom Temperature   Float   2   15    0   15   Last Good   CR-SS-       15 Min - % Good                       Value   BottomTemp.PctGd       Cond Feed Temperature   Float   2   15    0   15   Last Good   CR-SS-FeedTemp.PctGd       15 Min - % Good                       Value       Feed Steam Flow   Float   2   15    0   15   Last Good   CR-SS-       15 Min - % Good                       Value   FeedSteamFlow.PctGd       Condensate Flow   Float   2   15    0   15   Last Good   CR-SS-CondFlow.PctGd       15 Min - % Good                       Value       Condensate System   String       15    0   15   Interpolated   CR-Cond-PTE.STAT       Potential To Emit       (Snapshot)            Used In Proficy Calculations            SS % Time Treating (15 min)   Float   1   15    0   15   Average   CR-SS_Treat.Num       SS % Time Treating (1 Hr)   Float   1   60    0   60   Average   CR-SS_Treat.Num       Effective Steam Ratio   Float   2   15    0   0   Average   CR-SS_ESRatio.Filt       15 Min (Raw PI Avg)       Effective Steam Ratio   Float   2   15    0   15   LastGood   CR-SS_ESRatio.PctGd       15 Min - % Good                       Value       (CMS)       Effective Steam Ratio   Float   2   15    0   0       CR-SS_ESRatio.15M       15 Min Avg       Effective Steam Ratio   Float   2   60    0   0       CR-SS_ESRatio.3H       3 Hr Rolling Avg       Effective Steam Ratio   Float   2   15    0   0       CR-SS_ESRatio.LL       Lower Limit       Down Time   Integer   0   1440       420 26     15   LastGood   CR-SS-TREAT.Day                               Value                   26 The sampling offset is determined based upon the mill Start of Day time. The offset value is the number of minutes from midnight to the mill start of day. In this example the start of day is 7:00 AM (as there are 420 minutes from midnight until 7:00 AM).             
 
         [0390]     Proficy Calculated Variables  
                                                                                         Data       Sampling   Sampling               Variable   Type   Precision   Interval   Offset   Calc. Type   Calc. Name                                Effective Steam Ratio 15 Min   Float   1   15    0   VBScript   SS Qualified 15 Min Avg       Avg       Effective Steam Ratio 15 Min   String       15    0   VBScript   SS Qualified 15 Min Avg Status       Avg (Status)       Effective Steam Ratio 15 Min   String       15    0   VBScript   SS 15 Min Avg/Status Reassembly       Avg/Status (Used for 3 Hr       Avg)       Effective Steam Ratio 3 Hr   Float   2   60    0   Stored Procedure   StripperRollingAvg with AvgPTE       Rolling Avg       Effective Steam Ratio 3 Hr   String       60    0   Stored Procedure   StripperRollingAvgStatus with AvgPTE       Rolling Avg (Status)       Effective Steam Ratio Lower   Float   2   15    0   Equation   Effective Steam Ratio Lower Limit       Limit       Steam Ratio EE Events   String       60    0   Stored Procedure   SS Treatment Events       SS CMS Treating Status   String       15    0   VBScript   SS PTE CMS Status (15 Min)       (15 Min)       SS EE Treating Status (1 Hr)   String       60    0   VBScript   SS PTE EE Status (1 Hr)       Run Time   Integer   0   1440       420 1     Equation   Uptime (Daily)       Mill Day   String       15    0   Stored Procedure   MillDay                  
 
 Proficy Calculations 
 
         [0391]     EE Event Logic  
         [0392]     Steam Stripper Rolling Average Excess Emission events are created in one hour increments using the stored procedure spLocal_SSTreatmentEvents as described below. Bypass events (Treatment Bypass, Overflow bypass, Flow Emissions and Upstream Bypass) EE events are created using Proficy&#39;s downtime model  200  with a 61-second (or other mill specific) filter applied. The PI tags, CR-SS_Overflow.EE, CR-SS_CondDivert.EE, CR-SS_FlowEmissions.EE and CR-SS_Bypass.EE, trigger the start of an event whenever their state changes from OK (the normal running state) to EE (the fault state). The event ends when the state changes back to OK. If the state returns to OK within the filter period the state changes are ignored and no event is created in Proficy.  
         [0000]     CMS Event Logic  
         [0393]     CMS events for the Steam Stripper treatment system are created in fifteen minute intervals as described below in the stored procedure spLocal_SSTreatmentEvents. There are no CMS events associated with collection tank overflows or treatment bypass valves.  
         [0000]     SS Qualified 15 Min Avg  
         [0000]     Type: VBScript  
         [0394]     The inputs to this script are theSS CMS Treating Status (15 Min), the 15 minute raw PI average of Effective Steam ratio, the percent good value for the effective steam calculation over the fifteen minute window, and a lower reject specification limit attached to the percent good variable. This script is triggered by time (based on the sample interval for the variable—normally 15 minutes) or an input value change. This script filters the 15 minute average based on the 15 minute average Treating status and the percent good value for the average. If the percent good value is greater than required (lower reject limit) and the Treating status is Treating, the script outputs the average value for the period. If the Treating status is NotTreating or the percent good value is less than required, this script outputs a null value.  
         [0000]     SS Qualified 15 Min Avg Status  
         [0000]     Type: VBScript  
         [0395]     The inputs to this script are the effective steam 15 minute percent good value, the lower warning limit for percent good, the SS CMS Treating Status (15 Min) and the raw PI effective steam ratio 15 minute average. This script is triggered by time (based on the sample interval for the inputs) or an input value change. This script outputs the status of the Eff Steam Ratio 15 Min Avg (Status) for display on the Autolog display. If the Treating status is NotTreating, this script outputs Unit Down. If the percent good value is greater than 50% and the Treating status is Treating, this script outputs OK. If the percent good value is less than 50% and the Treating status is Treating, the script outputs Bad Val.  
         [0000]     SS 15 Min Avg/Status Reassembly  
         [0000]     Type: VBScript  
         [0396]     The inputs to this script are the Eff Steam Ratio 15 Min Avg and the Eff Steam Ratio 15 min Avg (Status). This script is triggered by time (based on the sample interval for the inputs) or by an input value change. This script combines the two inputs into one string value based on the string value of the Eff Steam Ratio 15 Min Avg (Status). If the Eff Steam Ratio 15 Min Avg (Status) is OK, this script outputs the Eff Steam Ratio 15 min Avg. If the Eff Steam Ratio 15 min Avg (Status) is Unit Down or Bad Val, this script outputs Unit Down or Bad Val.  
         [0000]     spLocal_StripperRollingAvg_wAvgPTE  
         [0000]     Type: Stored Procedure  
         [0397]     This procedure has twoinputs, the percent good value for effective steam ratio and the SS EE Treating Status (1 Hr), and one dependant variable, the reassembled 15 min avg/status for the effective steam ratio. This procedure calculates a 3 hour moving average of the dependant variable every hour from a minimum number of samples over the 3 hour interval. The requirement for a good average is that there must be more than 50% good samples. “Good” samples consist of valid numeric values taken while the EE Treating Status (1 Hr) is Treating and the percent good value is greater than 50%, as determined by the 15 min avg/status reassembly VB script. Values of Bad Val, Unit Down and NULL are excluded from the moving average. The triggers for this procedure are time (based on the sample interval for the variable), value change for the dependant variable or value change for the input variable.  
         [0000]     spLocal_StripperRollingAvgStatus_wAvgPTE  
         [0000]     Type: Stored Procedure  
         [0398]     This procedure has four inputs (the percent good value for the effective steam ratio, the lower warning limit for this variable, the effective steam ratio 3 Hr Rolling Avg and the SS EE Treating Status (1 Hr)) and one dependant variable (the reassembled 15 min avg/status for the effective steam ratio). This procedure generates a status string to compliment the 3 hour moving average calculation, spLocal_StripperRollingAvg_wAvgPte. The following table shows the possible outputs for this procedure and the sample types required to generate them.  
                                   Output   Condition Required                   OK   &gt;50% of samples have good numeric values, the average is           greater than the lower warning limit and the 1 Hr Treating           Status is Treating       EE   &gt;50% of samples have good numeric values, the average is           less than the lower warning limit and the 1 Hr Treating           Status is Treating       Null In   &gt;=50% of samples have Null value       Bad Data   &gt;=50% of samples have % good values &lt;50%       No Dep   Dependent variable is not configured       Variable       No Spec   The input variable from which specification limits are       Variable   retrieved is not configured.       No Limit   The Reject Limit Input constant is not configured       Bad Limit   The retrieved specification limit is NULL.       Bad PctGood   The lower reject limit of the % good variable is NULL       No PTE   The EE Treating Status (1 Hr) is NULL       Value       Too Many   The total count of samples (columns) exceeds the expected       Samples   number of samples (typ. 12).       No Value   The average of the samples is NULL       Unit Down   The 1 Hr EE Treating Status is NotTreating       Insuf Data   &lt;= 50% of samples have a good numeric values and there           is not a majority of these “bad” samples with the same           value OR the number of samples is less than the expected           number of samples       Insuf   &lt;=50% sample points       Columns                  
 
         [0399]     The triggers for this procedure are time (based on the sample interval for the variable), value change for the dependant variable or value change for the input variable.  
         [0000]     spLocal_SSTreatmentEvents  
         [0000]     Type: Stored Procedure  
         [0400]     This procedure is used to create CMS and EE events for the effective steam ratio. The inputs variables and dependant variables for both CMS and EE are shown in the following table.  
                                       Variables   EE   CMS                   Specification Limit   LW   LR       (Constant)       Event Duration (Constant)   60   15       PTE   SS EE Treating Status   SS CMS Treating           (1 Hr)   Status (15 Min)       EE or CMS (Constant)   EE   CMS       Dependant Variable   Eff Steam Ratio 3 Hr   Eff Steam Ratio           Rolling Avg   15 Min-% Good                  
 
         [0401]     This procedure tests for CMS or EE events by comparing the dependant variable value against a lower warning specification limit as specified in the calculation input. If the value is above the lower warning limit, a downtime event with duration as specified in the inputs is created. If an event exists for the previous time interval, the duration is appended to the existing event and the event end time is updated. The triggers for this procedure are time (based on the sample interval for the variable), value change for the dependant variable or value change for the input variable.  
         [0402]     The purpose of this document is to describe the design of the Continuous Emissions Monitoring System for Bleach Plant Scrubber monitoring operations. The software is comprised of PI Data Archive software (which is used for automatic data collection from various process instrumentation and control systems) and Proficy software (which uses the data collected by PI in conjunction with manual inputs and business rules to monitor and report on the performance of the scrubbing process). This documentation is directed toward system administrator level personnel.  
         [0403]     The following sections describe the general configuration of the standard bleach plant monitoring system. Deviations from the standard model, configuration listings for specific lines, and mill-specific details are contained within the appendices.  
         [0404]     Cluster Rule regulations require that a continuous monitoring system (CMS) be operated to measure the following parameters for each bleach plant gas scrubber: 
        Gas scrubber vent gas inlet flow rate (fan running status is an approved surrogate for this CMS),     ORP or pH, of the gas scrubber effluent and     Gas scrubber liquid influent flow rate (later referred to as recirculation flow).        
 
         [0408]     The data for these variables are collected and archived by the PI system and made available to the Proficy system to analyze against specific criteria to determine if an Excess Emission (EE) event has occurred. Excess Emission events, are recorded by the system when the bleach plant has the potential to emit (PTE) pollutants, as defined in PI, and one of the three monitored parameters does not meet the specified operating criteria. A bleach plant has the potential to emit pollutants when it is running or has been shutdown for less than a specified period of time (typically one hour) as defined by each facility. The potential to emit corresponds to the total source operating time reported to the state regulatory agency on a semi-annual basis or more frequently as required.  
         [0409]     The Proficy software logs all events and operator responses to those events. The responses record the operator determined Trouble, Cause, Correction (response), and Report Code (report categorization) for the event. The report categorization specifies if the event is considered an excess emission, as the emission may be allowed due to Startup, Shutdown, and Malfunction (SSM) provisions. The events are compiled by the system and reported to the state regulatory agency on a semi-annual basis or more frequently as required. In addition to capturing and categorizing events, the Proficy system also captures and records failures (downtime) of Continuous Monitoring System (CMS) devices, referred to as CMS events. The system records failures whenever the validity of the data is suspect or out of range. These are also summarized and reported to the state in a semi-annual CMS performance report or more frequently as required. Again, the report categorization specifies if the event is considered allowable based on the specific regulations.  
         [0410]     The following table gives an overview of the minimum required process inputs, their engineering units, associated PI tags, and corresponding Proficy variable names.  
                                           Input   Eng. Units   PI Tagname   Proficy Variable                   Bleach Plant PTE Status   CanEmit/   CR-BP-PTE.STAT   BP Potential to Emit           CanNotEmit       (Snapshot)       Bleach Plant Numeric   0 = CanNotEmit,   CR-BP-PTE.NUM   BP % Time CanEmit (15 Min)       PTE Status   100 = CanEmit       BP % Time CanEmit (1 Hr)       Daily Bleach Plant Non-   Min/day   CR-BP-PTEDown.Day   Down Time       PTE minutes -        calculated at mill end of       day       Bleach Plant Scrubber   pH (or ORP)   CR-BP-ScrubPH.Filt   pH 15 Min (Raw PI Avg)       pH (or ORP)       (or CR-BP-   (or ORP 15 Min Raw PI               ScrubORP.Filt)   Avg)       Bleach Plant Scrubber   %   CR-BP-ScrubPH.PctGd   pH 15 Min - % Good       pH (or ORP) Data %       (or CR-BP-   (CMS)       Good       ScrubORP.PctGd)   (or ORP 15 Min - % Good                   (CMS))       Bleach Plant Scrubber   GPM   CR-BP-ScrubRecirc.Filt   Recirc Flow 15 Min (Raw       Recirculation Flow           PI Avg)       Bleach Plant Scrubber   %   CR-BP-   Recirc Flow 15 Min - %       Recirculation Flow Data       ScrubRecirc.PctGd   Good (CMS)       % Good       Bleach Plant Scrubber   EE/OK   CR-BP-ScrubFan.EE   Fan EE (Snapshot)       Fan Status       Bleach Plant Scrubber   Good/Bad   CR-BP-ScrubFan.DQ   Fan Data Quality       Fan Data Quality           Snapshot (CMS)                  
 
         [0411]     Proficy also maintains, and periodically writes to PI, the specification limits (upper data quality limit, lower data quality limit, and excess emission limits) for the pH/ORP and recirculation flows. The data quality limits are used by PI to determine if the PI data has “Good” or “Bad” data quality while the excess emission limit is used by Proficy to determine when excess emission events occur.  
         [0412]     The following sections describe in detail how the Proficy bleach plant model triggers EE and CMS events.  
         [0000]     Bleach Plant State—PTE  
         [0413]     The bleach plant&#39;s potential to emit (PTE) is determined in PI using a performance equation. The performance equation logic returns a state of “CanEmit” during the period from startup of the bleach plant until a mill specified period after the bleach plant stops running. The bleach plant run-state is calculated each minute based upon mill specified criteria—typically CLO2 flow, motor running state, or pump running state.  
         [0414]     A PI performance equation translates the digital PTE status into a numeric value with 0=“CanNotEmit” and 100=“CanEmit”. Proficy averages this numeric PTE value of a specified time period and compares the average to a mill specified limit (usually 50) to determine if the bleach plant had a potential to emit over the desired time period. The Proficy variable, BP % Time CanEmit (15 min), averages the numeric PTE status over the previous 15 minute period. If this average is greater than or equal to the lower warning specification limit for this variable, the status is “CanEmit”. If the average is less than the lower warning specification limit, the status is “CanNotEmit”. This PTE status is used by Proficy to qualify the 15 min pH (or ORP) and recirculation flow 15 minute averages and to filter out CMS events when the status is “CanNotEmit”. The Proficy variable, BP % Time CanEmit (1 hr), averages the numeric PTE status over the previous hour. If this average is greater than the lower warning specification limit for this variable, the status is “CanEmit”. If the average is less than or equal to the lower warning specification limit, the status is “CanNotEmit”. This PTE status is used by Proficy to qualify the three hour rolling average.Bleach Plant PTE Counter  
         [0415]     At the start of each mill day, a PI performance equation totals the “CanNotEmit” time over the previous 24-hour period. This value is read by Proficy and is used for both daily display and daily calculation of bleach plant runtime (“CanEmit” for the daily period). The daily runtime minutes are kept in Proficy and used to compute the total runtime minutes for the reporting period.  
         [0000]     Recirculation Flow  
         [0416]     Bleach Plant scrubber recirculation flow is read by PI from the mill DCS system. The raw value is first validated in PI against the upper and lower specification limits provided by Proficy. If the value is within range PI records the value in an intermediate variable (CR-BP-ScrubRecirc.FILT); If the value is out of range the intermediate variable records “BAD” instead. This PI performance equation is event based (calculated every time a new value enters the PI snapshot) so that data buffered in the PI interface will be captured and used regardless of its PI archive status.  
         [0417]     Every 15 minutes, Proficy uses the filtered values to calculate a flow average over the 15-minute interval. Values marked “BAD” by PI are excluded from the calculated average.  
         [0418]     The PI system also calculates a data quality metric that provides Proficy with the information it needs to determine whether the measurement of the recirculation flow is reliable. The metric is determined within PI by examining the percentage of time over the 15-minute interval that the recirculation flow data has maintained “good” data quality. This same calculation tests for a flat-lined signal over an extended period of time and calculates a “% Good” of zero if the signal value has remained unchanged. Proficy samples this “%-Good” value every 15-minutes and generates a 15-minute CMS downtime event (via a stored procedure calculation) whenever the percentage falls below 50% within the 15 minute period.  
         [0419]     Recirculation flow EE events are triggered based upon a 3 hour rolling average calculation performed within Proficy. Once per hour, a stored procedure (spLocal_BleachRollingAvg) averages the previous twelve 15 Minute Averages for flow rate over the previous 3-hour window (3 Hr Rolling Avg). If the 3-hour average value is less than the lower warning specification limit configured in Proficy, a 1-hour EE event is generated by the stored procedure “spLocal_BleachEvents”. This 3-hour rolling average calculation excludes averages within periods that reflect a “%-Good” less than 50%, that had no Potential To Emit, and that contained NULL values. Therefore for a 3 Hour Average to be calculated and an EE Event to be created, a minimum of seven valid 15 Minute Averages (&gt;50%, or 7/12) must be present in the 3 hour window.  
         [0420]     Each 15-minute flow average (“Qualified 15 Min Avg”) is accompanied by a corresponding status message (“Qualified 15 Min Avg Status”) that is set to “OK” upon successful calculation of the average. Similarily the 3-hour rolling average has an equivalent variable (“3 Hr Rolling Avg Status”) that provides the status regarding calculation of the 3 hour rolling average. The status messages and their meanings are summarized in the tables below.  
         [0421]     Variable: “Qualified 5 Min Avg Status” 
                                   Status Message   Meaning                   OK   The 15 Min Avg was calculated       Unit Down   No Potential-to-Emit existed for the entire period. The           15 min avg is set to NULL.       Bad Val   The % Good for the period was calculated by PI as less           than 50%. The 15 min avg is set to NULL.                  
 
         [0422]     Variable: “3 Hr Rolling Avg Status” 
                                   Status           Message   Meaning                   OK   The 3 Hour Avg was calculated       Unit Down   At least six of twelve 15 Min Avgs reflect no Potential to           Emit       Bad Val   At least six of twelve 15 Min Avgs reflect &lt;50% Good data           quality       Null In   At least six of twelve 15 Min Avgs are NULL.       Insuf Data   At least six of twelve 15 Min Avgs have a combination of           NULL Value, &lt;50% Good data quality, or no Potential to           Emit.                  
 
         [0423]     A block diagram of scrubber recirculation data flow is depicted in  FIG. 18 .  
         [0000]     pH/ORP  
         [0424]     The monitoring of pH/ORP is exactly analogous to that for recirculation flow except that a manually entered pH or ORP value can override the Proficy calculated 15 minute average. Additionally ORP measurements are compared to an upper warning specification limit as opposed to a lower warning limit specification used for pH and recirculation flow.  
         [0425]     A block diagram of scrubber pH/ORP monitoring data flow is depicted in  FIG. 18 .  
         [0000]     Scrubber Fan  
         [0426]     Scrubber fan running status is determined within PI and communicated to Proficy through the use of a digital signal. Within PI, running status is determined by either comparing the scrubber fan amps to a minimum limit, by examining the differential pressure across the fan to be greater than a minimum limit, or by examining the scrubber motor status from the DCS (through the use of status from a zero speed switch or equivalent digital signal).  
         [0427]     Scrubber fan EE and CMS events are created by using the Proficy downtime model  200 . The Proficy model is typically configured with a 61 second filter (to eliminate signal noise) in conjunction with a PI performance equation to act as the event trigger.  
         [0428]     For excess emissions calculation, the PI tag CR-BP-ScrubFan.EE returns the digital state “EE” whenever the PI logic determines that the fan is not running while the system is in a “CanEmit” state; otherwise the equation returns the value “OK”. To determine CMS downtime, a second PI performance equation (CR-BP-ScrubFan.DQ) verifies that the fan amp value (or fan running switch status) is within range (or has a valid state) and returns the value “Good” If these conditions are not met, (and the PTE state of “CanEmit” exists) the equation instead returns the value “Bad.” 
         [0429]     Proficy monitors the two digital tags CR-BP-ScrubFan.EE and CR-BP-ScrubFan.DQ for the fault values of “EE” and “Bad” respectively. If either value remains in the fault state for longer than the filter time, an EE or CMS event is recorded by the system.  
         [0430]     A block diagram of scrubber fan monitoring data flow is depicted in  FIG. 19 .  
         [0000]     Tag Name Specifications  
         [0431]     All Cluster Rule PI tags will begin with “CR-”.  
         [0432]     For locations with multiple bleach lines, each line will be differentiated by CR-BPx, where x represents the mill naming convention. For example, Franklin will use CR-BPE for the E-Line and Augusta will use CR-BP1 for #1 Bleach Plant.  
         [0000]     Digital State Set Specifications  
         [0433]     The following are the minimum required digital state sets in PI to support the Cluster Rule Bleach Plant model.  
                                                       Digital Set Name   State 0   State 1                           P2Emit   CanEmit   CanNotEmit           OK-EE   OK   EE           GOOD-BAD   Good   Bad           RUN-STOP   Running   Stopped                      
 
 Scan Class Specifications 
 
         [0434]     The following scan classes must be available in PI. Note, the scan class number will vary from mill to mill.  
         [0435]     A one minute scan class offset 0 seconds from midnight;  
         [0436]     A fifteen minute scan class offset 0 seconds from midnight;  
         [0437]     A twenty-four hour scan class offset to the start of mill day.  
         [0438]     Examples of the scan class syntax are as follows:  
                                                   /f = 00:01:00, 00:00:00 (alternately /f = 00:01:00, 0)           /f = 00:15:00, 00:00:00 (alternately /f = 00:15:00, 0)           /f = 24:00:00, 07:00:00 (alternately /f = 24:00:00, 25200) for mill day           at 07:00 am                      
 
 PI Tag Configuration Specification 
 
         [0439]     The following tables provide tag configuration examples for a typical bleach plant model and the standard compression and exception attribute settings for the underlying mill tags.  
                                             Bleach Plant PI Tag Configuration Table 1            Tag Name   Descriptor   exdesc               CR-BP-   BP Potential to Emit   if BadVal(TimeEQ(‘         ’ ‘*−60M’, ‘*’, “         ”)) then PrevVal(‘CR-BP-PTE.STAT’,       PTE.STAT   Status   ‘*−60M’) else if TimeEQ(‘         ’ ‘*−60M’, ‘*’, “         ”) &gt; 0 then “CanEmit” else “CanNotEmit”       CR-BP-PTE-   BP Pot. To Emit   TimeEq(‘CR-BP-PTE.STAT’,‘Y+7H’,‘T+7H’,“CanNotEmit”)/60       Down.Day   downtime/day       CR-BP-   BP PTE Status -   event=CR-BP-PTE.STAT, if (‘CR-BP-PTE.STAT’ &lt;&gt; “CanEmit” and ‘CR-BP-PTE.STAT’ &lt;&gt;       PTE.NUM   Numeric   “CanNotEmit”) then PrevVal(‘CR-BP-PTE.NUM’,‘*’) else               if ‘CR-BP-PTE.STAT’ &lt;&gt; “CanEmit” then 0 else 100       CR-BP-   BP Scrubber Fan   if (‘         ’ &lt;&gt; “         ”) and (‘CR-BP-PTE.STAT’ = “CanEmit”) then “EE” else “OK”       ScrubFan.EE   Running Status       CR-BP-   BP Scrub Recirc PV   event=         , if (‘         ’ &gt; ‘CR-BP-ScrubRecirc.LLL’) and       ScrubRecirc.Filt   Filter   (‘         ’ &lt; ‘CR-BP-ScrubRecirc.HHL’) then ‘         ’ else “BAD”       CR-BP-   BP Scrub pH PV   event=         , if (‘         ’ &gt; ‘CR-BP-ScrubPH.LLL’) and (‘         ’ &lt; ‘CR-       ScrubPH.Filt   Filter   BP-ScrubPH.HHL’) then ‘         ’ else “BAD”       CR-BP-   BP Scrubber Fan   if (‘         ’ &lt;&gt; “         ” and ‘         ’ &lt;&gt; “         ”) and (‘CR-BP-PTE.STAT’ &lt;&gt;       ScrubFan.DQ   Data Quality   “CanNotEmit”) then “Bad” else “Good”       CR-BP-   BP Scrubber pH %   if (TagMax(‘CR-BP-ScrubPH.Filt’, ‘*−3H’, ‘*’) −TagMin(‘CR-BP-ScrubPH.Filt’, ‘*−3H’, ‘*’) =       ScrubPH.PctGd   Good Data   0) or BadVal(PctGood(‘CR-BP-ScrubPH.Filt’, ‘*−15M’, ‘*’)) then 0 else               PctGood(‘CR-BP-ScrubPH.Filt’, ‘*−15M’, ‘*’)       CR-BP-   BP Scrubber Recirc   if (TagMax(‘CR-BP-ScrubRecirc.Filt’, ‘*−3H’, ‘*’) − TagMin(‘CR-BP-ScrubRecirc.Filt’, ‘*−3H’,       ScrubRecirc.PctGd   % Good Data   ‘*’) = 0) or BadVal(PctGood(‘CR-BP-ScrubRecirc.Filt’, ‘*−15M’, ‘*’)) then 0 else               PctGood(‘CR-BP-ScrubRecirc.Filt’, ‘*−15M’, ‘*’)       CR-BP-   BP Scrubber pH       ScrubPH.HHL   High Lim DQ       CR-BP-ScrubPH.LL*   BP Scrubber pH           Low Lim       CR-BP-   BP Scrubber pH       ScrubPH.LLL   Low Lim DQ       CR-BP-   BP Scrubber Recirc       ScrubRecirc.HHL   High Lim DQ       CR-BP-   BP Scrubber Recirc       ScrubRecirc.LL   Low Lim       CR-BP-   BP Scrubber Recirc       ScrubRecirc.LLL   Low Lim DQ       CR-BP-   BP Scrubber pH 15 Min       ScrubPH.15M   Avg       CR-BP-   BP Scrubber pH 3 Hr       ScrubPH.3H   Avg       CR-BP-   BP Scrubber Recirc       ScrubRecirc.15M   15 Min Avg       CR-BP-   BP Scrubber Recirc       ScrubRecirc.3H   3 Hr Avg                 Note:            Italics bold print represents mill specific information.            *CR-BP-ScrubPH.LL will become CR-BP-ScrubORP.HL for a mill with ORP control. Other pH tags will change in a similar manner in this and subsequent tables.             
 
         [0440]    
       
         
               
             
               
               
               
               
               
               
               
               
               
               
               
               
               
               
               
             
               
               
               
               
               
               
               
               
               
               
               
               
               
               
               
             
           
               
                   
               
               
                   
               
               
                 Bleach Plant PI Tag Configuration Table 2 
               
             
          
           
               
                   
                   
                   
                   
                   
                   
                   
                 com- 
                   
                   
                   
                   
                   
                   
                   
               
               
                   
                   
                   
                   
                   
                 Loca- 
                   
                 press- 
                   
                   
                   
                 shut- 
                   
                   
                   
               
               
                 Tag Name 
                 engunits 
                 pointsource 
                 pointtype 
                 DigitalSet 
                 tion4 
                 compdev 
                 ing 
                 CompMax 
                 xcdev 
                 xcmax 
                 down 
                 tep 
                 ero 
                 pan 
               
               
                   
               
             
          
           
               
                 CR-BP- 
                 CanEmit/ 
                 C 
                 Digital 
                 P2EMIT 
                 1 
                 0 
                 1 
                 28800 
                   
                 0 
                 1 
                   
                   
                   
               
               
                 PTE.STAT 
                 CanNotEmit 
               
               
                 CR-BP-PTE- 
                 Min/Day 
                 C 
                 Float32 
                   
                 4 
                 0 
                 1 
                 7200 
                   
                 00 
                 0 
                   
                   
                 440 
               
               
                 Down.Day 
               
               
                 CR-BP- 
                 0/100 
                 C 
                 Float32 
                   
                   
                 0 
                 1 
                 60 
                   
                 0 
                 1 
                   
                   
                 00 
               
               
                 PTE.NUM 
               
               
                 CR-BP- 
                 OK-EE 
                 C 
                 Digital 
                 OK- 
                 1 
                 0 
                 1 
                 28800 
                   
                 0 
                 0 
               
               
                 ScrubFan.EE 
                   
                   
                   
                 EE 
               
               
                 CR-BP- 
                 GPM 
                 C 
                 Float32 
                   
                 1 
                 0 
                 1 
                 600 
                   
                 0 
                 1 
                   
                   
                 50 
               
               
                 ScrubRecirc.Filt 
               
               
                 CR-BP- 
                 pH 
                 C 
                 Float32 
                   
                 1 
                 0 
                 1 
                 600 
                   
                 0 
                 1 
                   
                   
                 4 
               
               
                 ScrubPH.Filt 
               
               
                 CR-BP- 
                 Bad/Good 
                 C 
                 Digital 
                 BAD- 
                 1 
                 0 
                 1 
                 28800 
                   
                 0 
                 0 
               
               
                 ScrubFan.DQ 
                   
                   
                   
                 GOOD 
               
               
                 CR-BP- 
                 % 
                 C 
                 Float32 
                   
                 3 
                 0 
                 1 
                 600 
                   
                 0 
                 1 
                   
                   
                 00 
               
               
                 ScrubPH. 
               
               
                 PctGd 
               
               
                 CR-BP- 
                 % 
                 C 
                 Float32 
                   
                 3 
                 0 
                 1 
                 600 
                   
                 0 
                 1 
                   
                   
                 00 
               
               
                 ScrubRecirc. 
               
               
                 PctGd 
               
               
                 CR-BP- 
                 pH 
                 Lab 
                 Float32 
                   
                 1 
                 0 
                 1 
                 28800 
                   
                 00 
                 0 
                   
                   
                 4 
               
               
                 ScrubPH.HHL 
               
               
                 CR-BP- 
                 pH 
                 Lab 
                 Float32 
                   
                 1 
                 0 
                 1 
                 28800 
                   
                 00 
                 0 
                   
                   
                 4 
               
               
                 ScrubPH.LL 
               
               
                 CR-BP- 
                 pH 
                 Lab 
                 Float32 
                   
                 1 
                 0 
                 1 
                 28800 
                   
                 00 
                 0 
                   
                   
                 4 
               
               
                 ScrubPH.LLL 
               
               
                 CR-BP- 
                 GPM 
                 Lab 
                 Float32 
                   
                 1 
                 0 
                 1 
                 28800 
                   
                 00 
                 0 
                   
                   
                 50 
               
               
                 ScrubRecirc.HHL 
               
               
                 CR-BP- 
                 GPM 
                 Lab 
                 Float32 
                   
                 1 
                 0 
                 1 
                 28800 
                   
                 00 
                 0 
                   
                   
                 50 
               
               
                 ScrubRecirc.LL 
               
               
                 CR-BP- 
                 GPM 
                 Lab 
                 Float32 
                   
                 1 
                 0 
                 1 
                 28800 
                   
                 00 
                 0 
                   
                   
                 50 
               
               
                 ScrubRecirc.LLL 
               
               
                 CR-BP- 
                 pH 
                 Lab 
                 Float32 
                   
                 1 
                 0 
                 1 
                 28800 
                   
                 00 
                 0 
                   
                   
                 4 
               
               
                 ScrubPH.15M 
               
               
                 CR-BP- 
                 pH 
                 Lab 
                 Float32 
                   
                 1 
                 0 
                 1 
                 28800 
                   
                 00 
                 0 
                   
                   
                 4 
               
               
                 ScrubPH.3H 
               
               
                 CR-BP- 
                 GPM 
                 Lab 
                 Float32 
                   
                 1 
                 0 
                 1 
                 28800 
                   
                 00 
                 0 
                   
                   
                 50 
               
               
                 ScrubRecirc.15M 
               
               
                 CR-BP- 
                 GPM 
                 Lab 
                 Float32 
                   
                 1 
                 0 
                 1 
                 28800 
                   
                 00 
                 0 
                   
                   
                 50 
               
               
                 ScrubRecirc.3H 
               
               
                   
               
             
          
         
       
     
         [0441]     Bleach Plant Mill Specific PI Tag Compression and Exception Attributes Table  
                                                               Tag                                       Name   Descriptor   pointtype   compdev   compressing   CompMax   xcdev   xcmax   Comments                   CR-   BP Running Status   Digital   Mill Std   1   Mill std   ill std   ill std   Mill should st attributes to get representative       BP.STAT                               values       CR-BPFan.PV   BP Fan Running   Digital   Mill std   1   7200   ill std   0   Mill should st attributes to get representative           Status                           values       CR-   BP Recirculation   Float32   Mill std   1   &lt;=3600   ill std   0   Archived values req; d for 3-hr std dev check       BPRecirc.PV   Flow DCS Value                           in the .Filt PE                                       ExcMax is set at 60 s to trigger event-based                                       .Filt PE       CR-   BP pH DCS Value   Float32   Mill std   1   &lt;=3600   ill std   0   Archived values req; d for 3-hr std dev check       BPpH.PV                               in the .Filt PE                                       ExcMax is set at 60 s to trigger event-based                                       .Filt PE                  
 
         [0442]     The Proficy model consists of input variables (PI inputs), calculated variables, stored procedures, and Visual Basic scripts (VB scripts). Variables for a typical bleach plant (monitoring pH) and descriptions of the stored procedures and the VB scripts are included below. Complete listings of the Stored Procedures can be found in Appendix A.  
         [0443]     PI Interface Proficy Variables  
                                                                                                 Data       Sampling   Sampling   Sampling               Variable   Type   Precision   Interval   Offset   Window   Sampling Type   PI Tag                                Recirc Flow 15 Min (Raw PI   Float   2   15   0   0   Average   CR-BP-ScrubRecirc.Filt       Avg)       Recirc Flow 15 Min - % Good   Float   2   15   0   15   LastGood Value   CR-BP-ScrubRecirc.PctGd       (CMS)       Recirc Flow 3 Hr Rolling Avg   Float   2   60   0   0       CR-BP-ScrubRecirc.3H       Recirc Flow 15 Min Avg   Float   2   15   0   0       CR-BP-ScrubRecirc.15M       Recirc Flow Lower Limit   Float   2   15   0   0       CR-BP-ScrubRecirc.LL       Recirc Flow Lower DQ Limit   Float   2   15   0   0       CR-BP-ScrubRecirc.LLL       Recirc Flow Upper DQ Limit   Float   2   15   0   0       CR-BP-ScrubRecirc.HHL       pH 15 Min - % Good (CMS)   Float   2   15   0   15   Last Good Value   CR-BP-ScrubpH.PctGd       pH 15 Min (Raw PI Avg)   Float   2   15   0   0   Average   CR-BP-ScrubPH.Filt       pH 15 Min Avg   Float   2   15   0   0       CR-BP-ScrubPH.15M       pH 3 Hr Rolling Avg   Float   2   60   0   0       CR-BP-ScrubPH.3H       pH Lower Limit 1     Float   2   15   0   0       CR-BP-ScrubPH.LL       pH Lower DQ Limit   Float   2   15   0   0       CR-BP-ScrubPH.LLL       pH Upper DQ Limit   Float   2   15   0   0       CR-BP-ScrubPH.HHL       Fan EE (Snapshot)   String       15   0   15   Interpolated   CR-BP-ScrubFan.EE       BP Potential To Emit   String       15   0   15   Interpolated   CR-BP-PTE.STAT       (Snapshot)       Down Time   Integer       1440   420 2       15   LastGood Value   CR-BP-PTE-Down.Day       Fan Data Quality Snapshot   String       15   0   15   Interpolated   CR-BP-ScrubFan.DQ       (CMS)       BP % Time CanEmit (15 min)   Float   1   15   0   15   Average   CR-BP-PTE.NUM       BP % Time CanEmit (1 hr)   Float   1   60   0   60   Average   CR-BP-PTE.NUM                   1 This example monitors pH of the effluent. When ORP (Oxygen Reduction Potential) of the effluent is monitored instead of pH, the pH Lower Limit is replaced by an ORP Upper Limit.              2 The sampling offset is determined based upon the mill Start of Day time. The offset value is the number of minutes from midnight to the mill start of day. In this example the start of day is 7:00 AM (as there are 420 minutes from midnight until 7:00 AM).             
 
         [0444]    
       
         
               
               
               
               
               
               
               
             
               
               
               
               
               
               
               
             
           
               
                   
               
               
                   
               
               
                   
                 Data 
                   
                 Sampling 
                 Sampling 
                   
                   
               
               
                 Variable 
                 Type 
                 Precision 
                 Interval 
                 Offset 
                 Calc. Type 
                 Calc. Name 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                 Recirc Flow 15 Min Avg 
                 Float 
                 1 
                 15 
                 0 
                 VBScript 
                 Qualified 15 Min Avg 
               
               
                 pH 15 Min Avg 
                 Float 
                 2 
                 15 
                 0 
                 VBScript 
                 Qualified 15 Min Avg 
               
               
                 Recirc Flow 15 Min Avg 
                 String 
                   
                 15 
                 0 
                 VBScript 
                 Qualified 15 Min Avg Status 
               
               
                 (Status) 
               
               
                 pH 15 Min Avg (Status) 
                 String 
                   
                 15 
                 0 
                 VBScript 
                 Qualified 15 Min Avg Status 
               
               
                 Recirc Flow 15 Min 
                 String 
                   
                 15 
                 0 
                 VBScript 
                 15 Min Avg/Status Reassembly 
               
               
                 Avg/Status (Used for 3 Hr 
               
               
                 Avg) 
               
               
                 pH 15 Min Avg or Status 
                 String 
                   
                 15 
                 0 
                 VBScript 
                 15 Min Avg/Status Reassembly 
               
               
                 (Reassembled) 
               
               
                 pH Manual/15 Min Avg (Used 
                 String 
                   
                 15 
                 0 
                 Stored Procedure 
                 ManualUpdate 
               
               
                 for 3 Hr Rolling Avg) 
               
               
                 Recirc Flow 3 Hr Rolling Avg 
                 Float 
                 1 
                 60 
                 0 
                 Stored Procedure 
                 BleachRollingAvg with AvgPTE 
               
               
                 pH 3 Hr Rolling Avg 
                 Float 
                 2 
                 60 
                 0 
                 Stored Procedure 
                 BleachRollingAvg with AvgPTE 
               
               
                 Recirc Flow 3 Hr Rolling Avg 
                 String 
                   
                 60 
                 0 
                 Stored Procedure 
                 BleachRollingAvgStatus with AvgPTE 
               
               
                 (Status) 
               
               
                 pH 3 Hr Rolling Avg (Status) 
                 String 
                   
                 60 
                 0 
                 Stored Procedure 
                 BleachRollingAvgStatus with AvgPTE 
               
               
                 Recirc Flow Lower Limit 
                 Float 
                 2 
                 15 
                 0 
                 Equation 
                 Scrubber Recirc Flow Lower Limit 
               
               
                 Recirc Flow Lower DQ Limit 
                 Float 
                 2 
                 15 
                 0 
                 Equation 
                 Scrubber Recirc Flow Lower DQ Limit 
               
               
                 Recirc Flow Upper DQ Limit 
                 Float 
                 2 
                 15 
                 0 
                 Equation 
                 Scrubber Recirc Flow Upper DQ Limit 
               
               
                 pH Lower Limit 1   
                 Float 
                 2 
                 15 
                 0 
                 Equation 
                 pH Measurement Lower Limit 
               
               
                 pH Lower DQ Limit 
                 Float 
                 2 
                 15 
                 0 
                 Equation 
                 pH Measurement Lower DQ Limit 
               
               
                 pH Upper DQ Limit 
                 Float 
                 2 
                 15 
                 0 
                 Equation 
                 pH Measurement Upper DQ Limit 
               
               
                 Recirc Flow EE Events 
                 String 
                   
                 60 
                 0 
                 Stored Procedure 
                 Bleach Events 
               
               
                 pH EE Events 
                 String 
                   
                 60 
                 0 
                 Stored Procedure 
                 Bleach Events 
               
               
                 Recirc Flow CMS Events 
                 String 
                   
                 15 
                 0 
                 Stored Procedure 
                 Bleach Events 
               
               
                 PH CMS Events 
                 String 
                   
                 15 
                 0 
                 Stored Procedure 
                 Bleach Events 
               
               
                 Running Time 
                 Integer 
                   
                 1440 
                 420 
                 Equation 
                 Uptime (Daily) 
               
               
                 Mill Day 
                 String 
                   
                 15 
                 0 
                 Stored Procedure 
                 MillDay 
               
               
                 BP CMS PTE Status (15 min) 
                 String 
                   
                 15 
                 0 
                 VBScript 
                 BP PTE CMS Status (15 min) 
               
               
                 BP EE PTE Status (1 hr) 
                 String 
                   
                 60 
                 0 
                 VBScript 
                 BP PTE EE Status (1 hr) 
               
               
                   
               
               
                     1 This example monitors pH of the effluent. When ORP (Oxygen Reduction Potential) of the effluent is monitored instead of pH, the pH Lower Limit is replaced by an ORP Upper Limit.    
               
             
          
         
       
     
       CMS Event Logic  
       [0445]     pH, ORP and flow CMS events are created from the stored procedure, BleachEvents, as described below. Scrubber fan CMS events are created using Proficy&#39;s downtime model  200  with a 61-second filter applied. The PI tag, CR-BP-ScrubFan.DQ, triggers the start of an event whenever its state changes from Good (the normal running state) to Bad (the fault state). The event ends when the state changes back to Good. If the state returns to Good within one minute, the change is ignored and an event is not created.  
       EE Event Logic  
       [0446]     pH, ORP and flow EE events are created from the stored procedure, BleachEvents, as described below. Scrubber fan EE events are created using Proficy&#39;s downtime model  200  with a 61-second filter applied. The PI tag, CR-BP-ScrubFan.DQ, triggers the start of an event whenever its state changes from OK (the normal running state) to EE (the fault state). The event ends when the state changes back to OK. If the state returns to OK within one minute, the change is ignored and an event is not created  
         [0000]     VB Script Descriptions  
         [0000]     BP PTE CMS Status (15 min)  
         [0447]     The inputs to this script are the BP % Time CanEmit (15 min) and the lower warning limit for BP % Time CanEmit (15 min). This script is triggered by time (based on the sample interval for the variable) or an input value change. This script compares the 15 min average numeric PTE value to its lower warning limit. If the % Time CanEmit (15 min) value is less than the lower warning limit (usually 50), the PTE status is CanNotEmit. If the % Time CanEmit (15 min) value is greater than or equal to the lower warning limit, the PTE status is CanEmit.  
         [0000]     BP PTE EE Status (1 Hr)  
         [0448]     The inputs to this script are the BP % Time CanEmit (1 Hr) and the lower warning limit for BP % Time CanEmit (1 Hr). This script is triggered by time (based on the sample interval for the variable) or an input value change. This script compares the 1 hr average numeric PTE value to its lower warning limit. If the % Time CanEmit (1 hr) value is less than or equal to the lower warning limit (usually 50), the PTE status is CanNotEmit. If the % Time CanEmit (1 Hr) value is greater than the lower warning limit, the PTE status is CanEmit.  
         [0000]     Qualified 15 Min Avg  
         [0449]     The inputs to this script are the BP CMS PTE Status (15 m), the 15 minute raw PI average for pH, ORP or flow, the percent good value for pH, ORP or flow and the lower warning limit for percent good. This script is triggered by time (based on the sample interval for the variable) or an input value change. This script filters the 15 minute average (pH, ORP or recirculation flow) based on the PTE status or the percent good value for the average. If the percent good value is greater than 50% and the PTE status is CanEmit, this script outputs the average value. If the PTE status is CanNotEmit or the percent good value is less than 50%, this script outputs a null value.  
         [0000]     Qualified 15 Min Avg Status  
         [0450]     The inputs to this script are the BP CMS PTE Status (15 min), the 15 minute raw PI average for pH, ORP or flow, the percent good value for pH, ORP or flow and the lower warning limit for percent good. This script is triggered by time (based on the sample interval for the inputs) or an input value change. This script outputs the status of the Qualified 15 minute Average (pH, ORP or recirculation flow) for display on the Autolog display. If the PTE status is CanNotEmit, this script outputs Unit Down. If the percent good value is greater than 50% and the PTE status is CanEmit, this script outputs OK. If the percent good value is less than 50% and the PTE status is CanEmit, the script outputs Bad Val.  
         [0000]     15 Min Avg/Status Reassembly  
         [0451]     The inputs to this script are the Qualified 15 min Avg and the Qualified 15 min Avg Status. This script is triggered by time (based on the sample interval for the inputs) or an input value change. This script combines the two inputs into one string value based on the string value of the Qualified 15 Min Avg Status. If the Qualified 15 Min Avg Status is OK, this script outputs the Qualified 15 min Avg. If the Qualified 15 min Avg Status is Unit Down or Bad Val, this script outputs Unit Down or Bad Val.  
         [0000]     Stored Procedure Descriptions  
         [0000]     ManualUpdate  
         [0452]     This procedure has one input, the 15 min raw PI avg for pH or ORP and one dependant variable, the manually entered value for pH or ORP. This procedure performs a signal selection between a manually entered value and another variable. If the dependant variable value (the manually entered value) is NULL, the output is the value of the input variable (the 15 min raw PI avg). Otherwise, the output is set to the value of the dependant variable. The triggers for this procedure are time (based on the sample interval for the variable), value change for the dependant variable or value change for the input variable.  
         [0000]     BleachRollingAvg with AvgPTE  
         [0453]     This procedure has two inputs, the percent good value for pH, ORP or flow and the BP EE PTE Status (1 Hr), and one dependant variable, the reassembled 15 min avg/status for pH, ORP or flow. This procedure calculates a 3 hour moving average of the dependant variable every hour from a minimum number of samples over the 3 hour interval if the average PTE status over the last hour is CanEmit. The requirement for a good average is that there must be more than 50% good samples. “Good” samples consist of valid numeric values taken while the PTE status is CanEmit and the percent good value is greater than 50%, as determined by the 15 min avg/status reassembly VB script. Values of Bad Val, Unit Down and NULL are excluded from the moving average. The triggers for this procedure are time (based on the sample interval for the variable), value change for the dependant variable or value change for the input variable.  
         [0000]     BleachRollingAvgStatus with AvgPTE  
         [0454]     This procedure has three inputs, the percent good value for pH, ORP or flow, the three hour rolling avg for pH, ORP or flow and the BP Ee PTE Status (I Hr), and one dependant variable, the reassembled 15 min avg/status for pH, ORP or flow. This procedure generates a status string to compliment the 3 hour moving average calculation, BleachRollingAvg. The following table shows the possible outputs for this procedure and the sample types required to generate them.  
                                   Output   Condition Required                   OK   &gt;50% of samples have good numeric values       Null In   &lt;=50% of samples have good numeric values and the           majority of these “bad” samples have a value of NULL       Bad Val   &lt;=50% of samples have good numeric values and the           majority of these “bad” samples have a value of Bad Val.       Unit Down   &lt;=50% of samples have good numeric values and the           majority of these “bad” samples have a value of Unit           Down or the BP EE PTE Status (1 Hr) is CanNotEmit.       Insuf Data   &lt;=50% of samples have a good numeric values and there           is not a majority of these “bad” samples with the same           value OR the number of samples is less than the expected           number of samples                  
 
         [0455]     The triggers for this procedure are time (based on the sample interval for the variable), value change for the dependant variable or value change for the input variable.  
         [0000]     BleachEvents  
         [0456]     This procedure is used to create CMS and EE events for pH, ORP and flow. This procedure has one input,the BP EE/CMS PTE Status (1 Hr/15 Min), and one dependant variable, the 3 hr rolling avg for pH, ORP or flow. This procedure tests for CMS or EE events when the average PTE status if CanEmit by comparing the dependant variable value against upper or lower specification limits as specified in the calculation inputs. If the value is above (below) the upper (lower) specification limit, a downtime event with duration as specified in the inputs is created. If an events exists for the previous time interval, the duration is appended to the existing event and the event end time is updated. The triggers for this procedure are time (based on the sample interval for the variable), value change for the dependant variable or value change for the input variable.  
         [0000]     SpLocal_BleachRollingAvg  
         [0000]     /*  
         [0000]     Procedure Name: spLocal_BleachRollingAvg  
         [0457]     Copyright (C) 2001, International Paper Company  
         [0458]     Revision History:  
                                                       Date   By   Description                           Jun. 30, 2001   SC (Entegreat, Inc.)   Initial release           Aug. 20, 2001   SC (Entegreat, Inc.)   Comments added                      
 
 General Description: 
 
         [0459]     This procedure calculates a 3-hour moving average of the dependent variable (typically ph, ORP or recirculation flow) value every hour from a minimum number of samples over the 3-hour interval.  
         [0460]     Currently, the requirement is that there must be more than 50% good samples in order for the average to be calculated. “Good” samples consist of valid numeric values taken while there was potential to emit (PTE) and where the data validity, as determined by the %-Good PI variable, is good. Null values and values where the %-Good requirment is not met are excluded from the moving average. Typically, for the standard model, this procedure calculates the average of the 15-minute ph, ORP, or recirculation flow values over the last 3-hours.  
         [0461]     Triggers: 
        1. Time (based on sample interval for variable)     2. Dependant variable value change     3. Input value change        
 
         [0465]     In order for the calculation to execute, non-optional calculation input values cannot be NULL.  
         [0466]     Inputs and Depedencies: 
        1. Requires configuration of the depedant variable which is the value to be tested (e.g., “pH 15-Min Avg Used for 3Hr Rolling Avg”).     2. Inputs described in body of code.        
 
         [0469]     Outputs:  
         [0470]     1. 3-Hour Average (float)  
         [0471]     Variables:  
         [0472]      
         [0473]     1. Described in body of code.  
         [0000]     Tables Modified:  
         [0474]     1. N/A  
                                   */       CREATE PROCEDURE spLocal_BleachRollingAvg       --Calculation Input and Output       @OutputValue float OUTPUT,         --Calculated 3-hour moving       average (output)       @Var_id int,         --Variable Id of this variable       @Start_Time varchar(30),         --Beginning of       the time interval over which the 3-hr average           --is calculated. Internally calculated by Proficy based on             --the sample window specified in the variable sheet.       @End_Time varchar(30),           --End       of the time interval over which the 3-hr average             --is calculated. Internally calculated by Proficy based on             --the sample window specified in the variable sheet.       @PctVar_Id int         --Variable Id of the corresponding %-Good variable             --that determines data validity.       AS       Declare         @DepVar_Id int,         --Dependent variable Id (the variable to be averaged).         @UnitDownCount int,             --       Number of samples with a status of “Unit Down”.         @BadDataCount int,              --       Number of samples with a status of “Bad Val”.         @NullCount int,         --Number of samples with NULL values.         @PctGood float,         --Lower reject limit of the %-Good variable.         @PctLimit float,         --Calculated upper limit on the number of invalid samples             --allowed in the 3-hr window.         @SampleSize float,         --Calculated expected number of samples over the interval             --to be averaged (typ 12=180/15).         @SampleVar int,         --Sampling window for this variable (typ 180 mins).         @SampleDepVar int, --       Sampling interval of the dependant variable (typ 15 mins).         @totalcount int         --Total number of samples found over the sample             --window (typ 12 samples over 3-hours).       --Get the variable Id of the dependant variable (i.e., the variable to be averaged)       Select @DepVar_Id = Var_Id        From Calculation_Instance_Dependencies        Where Result_Var_Id = @Var_Id       --Validate the dependant variable Id       If (@DepVar_Id is Null)       begin        Select @OutputValue = Null        Return       end       --Get the lower reject limit of the corresponding %-Good variable (typically 50%)       Select @PctGood = Convert(float,L_Reject)        from var_specs        where var_id = @PctVar_Id       --Get the sampling window for this variable (typically 180-mins)       Select @SampleVar = Sampling_Window        From Variables        Where Var_Id = @Var_Id       --Get the sampling interval of the dependant variable (typically 15-mins)       Select @SampleDepVar = Sampling_Interval        From Variables        Where Var_Id = @DepVar_Id       --Calculate the expected number of samples over the 3-hour interval (typically 12=180/15)       Set @SampleSize = Convert(float,@SampleVar)/Convert(float,@SampleDepVar)       --Calculate the upper limit for the number of invalid values allowed in the       --3-hour window (typically 6=50%*12)       Set @PctLimit = @SampleSize *(@PctGood/100.0)       --Store the values of the dependant variable (the variable to be averaged) over the       --3-hour window into a temporary table       Select Result        Into #Tests        From Tests        Where (Var_Id = @DepVar_Id) And (Result_On &gt; @Start_Time) And (Result_On &lt;= @End_Time)       --Count the number of samples over the 3-hour window       Select @totalcount = count(*)         From #tests       -- If there are less than the expected number samples (typically 12) over the window then quit       if @totalcount &lt; @samplesize         begin           Set @OutputValue = Null           Return         end       --Count the number of samples taken where the unit has no PTE       Select @UnitDownCount = Count(*)        From #Tests        Where Result = ‘Unit Down’       --Count the number of samples where the corresponding data %-Good variable       --indicates bad data (i.e., CMS event)       Select @BadDataCount = Count(*)        From #Tests        Where Result = ‘Bad Val’       --Count the number of samples with no value       Select @NullCount = Count(*)        From #Tests        Where Result is Null       Select @OutputValue = NULL       --If the “Unit Down Count” &gt;= the maximum allowable (typically 6) then       --quit - do not calculate the average       If Convert(float,@UnitDownCount) &gt;= @PctLimit         Return       --If the “Bad Data Count” &gt;= the maximum allowable (typically 6) then       --quit - do not calculate the average       If Convert(float,@BadDataCount) &gt;= @PctLimit         Return       --If the “No Value Count” &gt;= the maximum allowable (typically 6) then       --quit - do not calculate the average       If Convert(float,@NullCount) &gt;= @PctLimit         Return       --If the sum of the above counts &gt;= the maximum allowable (typically 6) then       --quit - do not calculate the average       If (Convert(float,@UnitDownCount+@BadDataCount+@NullCount)) &gt;= @PctLimit         Return       --Calculate the 3-hour average using only valid values       If (@BadDataCount &gt; 0) or (@UnitDownCount &gt; 0) or (@NullCount &gt; 0)        Select @OutputValue = SUM(Convert(float,Result))/(@SampleSize −        (Convert(float,@UnitDownCount+@BadDataCount+@NullCount)))           from #Tests           where (Result &lt;&gt; ‘Bad Val’ and Result &lt;&gt; ‘Unit Down’ and Result is NOT Null)       else        Select @OutputValue = SUM(Convert(float,Result))/@SampleSize           from #Tests           where (Result &lt;&gt; ‘Bad Val’ and Result &lt;&gt; ‘Unit Down’and Result is NOT Null)       --Drop the temporary table       Drop Table #Tests       SpLocal_BleachRollingAvgStatus       /*       Procedure Name:   spLocal_BleachRollingAvgStatus        Copyright (C) 2001, International Paper Company                  
 
         [0475]     Revision History:  
                                                       Date   By   Description                           Jun. 30, 2001   SC (Entegreat, Inc.)   Initial release           Aug. 21, 2001   SC (Entegreat, Inc.)   Comments added                      
 
 General Description: 
 
         [0476]     This procedure generates a status message to compliment the 3-hour moving average calculation result.  
         [0477]     Triggers: 
        1. Time (based on sample interval for variable)     2. Dependant variable value change     3. Input value change        
 
         [0481]     In order for the calculation to execute, non-optional calculation input values cannot be NULL.  
         [0482]     Inputs and Depedencies: 
        1. Requires configuration of the depedant variable which is the value to be tested (e.g., “pH 15-Min Avg Used for 3Hr Rolling Avg”).     2. Inputs described in body of code. 
 
 Outputs: 
       
 
         [0485]     Type: Status message (string)  
                                   Value   Occures when . . .                   “OK”   The 3-hour average was           successfully calculated. The result was inside           the specification limit and an EE event was not           generated.       “EE”   The 3-hour average was           successfully calculated. The result was outside           the specification limit and an EE wvent was           generated.       “Insuf Data”   The average was not calculated           because there was less than the minimum           required number of valid samples (typically 7)       “Unit Down”   The average was not calculated           because the unit was down (i.e.,           no potential to emit)           for half or more intervals over the 3-hour period.       “Bad Data”   Half or more of the %-Good           values were less than 50%.       “Null In”   Half or more of the samples were NULL.       “No Dep Variable”   The dependant variable is not configured.       “No Spec Variable”   The input variable from which           specification limits are retrieved           is not configured.       “No Limit”   The Reject_Limit input constant           is not configured (“LR”, “LW”, “UW” or “UR”).       “Bad Limit”   The retrieved specification limit is NULL.       “Bad PctGood”   The lower reject limit of the %-Good           variable is NULL.                  
 
         [0486]     Variables: 
        1. Described in body of code. 
 
 Tables Modified: 
       
 
         [0488]     1. N/A  
                                                   */       CREATE PROCEDURE spLocal_BleachRollingAvgStatus       --Input and Output       @OutputValue varchar(25) OUTPUT,       --Status message (output)       @Var_Id int,         --Variable Id of this variable       @Start_Time varchar(30),           --Beginning of       the time interval over which the 3-hr average           --is calculated. Internally calculated by Proficy based on the           --sample window specified in the variable sheet.       @End_Time varchar(30),           --End of the       time interval over which the 3-hr average           --is calculated. Internally calculated by Proficy based on the           --sample window specified in the variable sheet.       @PctVar_Id int,         --Variable Id of the corresponding %-Good variable that           --determines data validity.       @Reject_Limit varchar(2),       --Specification limit       applied in test           --(valid values: “LR”,“LW”,“UW” or “UR”)       @RejectVar_Id int                  --The       variable Id of the variable with the appropriate           --specifications.       AS       Declare        @DepVar_Id int,                  --       Dependent variable Id (the variable to be averaged).             @UnitDownCount int,   --Number of samples       with a status of “Unit Down”.        @BadDataCount int,     --Number of       samples with a status of “Bad Val”.        @NullCount int,       --       Number of samples with NULL values.        @PU_Id int,       --Unit       Id of this variable        @PctGood float,       --       Lower reject limit of the %-Good variable.        @PctLimit float,       --       Calculated upper limit on the number of invalid samples           --allowed in the 3-hr window.        @Average float,       --3-       hour rolling average value        @RejectVal float,       --       Specification limit value used to test for EE events        @SampleVar int,       --       Sampling window for this variable (typ 180 mins).        @SampleDepVar int,     --Sampling       interval of the dependant variable (typ 15 mins).        @SampleSize int,       --       Calculated expected number of samples over the interval           --to be averaged (typ 12=180/15).         @totalcount int       --Total            number of samples found over the sample window           --(typ 12 samples over 3-hours).       Set @OutputValue = ‘OK’       --Get dependant variable Id       Select @DepVar_Id = Var_Id        From Calculation_Instance_Dependencies        Where Result_Var_Id = @Var_Id       --Validate dependant variable Id       If (@DepVar_Id is Null)       begin        Select @OutputValue = ‘No Dep Variable’        Return       end       --Validate variable to which specification limits have been assigned       If (@RejectVar_Id is Null)       begin        Select @OutputValue = ‘No Spec Variable’        Return       end       --Get the unit Id for this variable       Select @PU_Id = PU_Id        From Variables        Where Var_Id = @Var_Id       --Validate specification limit used for comparison (“LR”,“LW”,“UW”, or “UR”)       if @Reject_Limit = NULL or @Reject_Limit = ‘’       begin        Set @OutputValue = ‘No Limit’        Return       end       Set @RejectVal = NULL       --Get designated specification limit value       if @Reject_Limit = ‘LR’         Select @RejectVal = L_Reject          from var_specs          where var_id = @RejectVar_Id       if @Reject_Limit = ‘LW’         Select @RejectVal = L_Warning          from var_specs          where var_id = @RejectVar_Id       if @Reject_Limit = ‘UW’         Select @RejectVal = U_Warning          from var_specs          where var_id = @RejectVar_Id       if @Reject_Limit = ‘UR’       Select @RejectVal = U_Reject          from var_specs          where var_id = @RejectVar_Id       --Validate specification limit value       if @RejectVal = NULL       begin        Select @OutputValue = ‘Bad Limit’        Return       end       --Get the sampling window for this variable (typically 180-mins)       Select @SampleVar = Sampling_Window        From Variables        Where Var_Id = @Var_Id       --Get the sampling interval of the dependant variable (typically 15-mins)       Select @SampleDepVar = Sampling_Interval        From Variables        Where Var_Id = @DepVar_Id       --Get the lower reject limit of the %-Good variable (typically 50%)       select @PctGood = Convert(float,L_Reject)          From var_specs          Where var_id = @PctVar_Id       --Validate the value of the lower reject limit of the %-Good variable       if @PctGood = NULL or @PctGood = ”       begin        Select @OutputValue = ‘Bad PctGood’        Return       end       --Calculate the expected number of samples over the 3-hour interval (typically 12=180/15)       Set @SampleSize = @SampleVar/@SampleDepVar       --Calculate the upper limit for the number of invalid values allowed in order for the 3-hour       --average to be calculated (typically 6=50%*12)       Set @PctLimit = Convert(float,@SampleSize)*(@PctGood/100.0)       --Store the sample values of the dependant variable over the 3-hour window into a temporary table       Select Result        Into #Tests        From Tests        Where (Var_Id = @DepVar_Id) And (Result_On &gt; @Start_Time) And (Result_On &lt;= @End_Time)       --Count the number of samples over the 3-hour window       Select @totalcount = count(*)          From #tests       --If there are less than the expected number of samples (typically 12) in the 3-hour window       --then send message and quit       if @totalcount &lt; @samplesize          Begin        Set @OutputValue = ‘Insuf Data’           Return         end       --Count the number of samples taken where the unit has no PTE       Select @UnitDownCount = Count(*)        From #Tests        Where Result = ‘Unit Down’       --Count the number of samples where the corresponding data %-Good variable indicates bad data (i.e.,       CMS event)       Select @BadDataCount = Count(*)        From #Tests        Where Result = ‘Bad Val’       --Count the number of samples with no value       Select @NullCount = Count(*)        From #Tests        Where Result is Null       --Calculate the 3-hour average using only valid samples       If (@BadDataCount &gt; 0) or (@UnitDownCount &gt; 0) or (@NullCount &gt; 0)        Select @Average = SUM(Convert(float,Result))/(@SampleSize −       (Convert(float,@UnitDownCount+@BadDataCount+@NullCount)))         from #Tests         where (Result &lt;&gt; ‘Bad Val’ and Result &lt;&gt; ‘Unit Down’ and Result is NOT Null)       else        Select @Average = SUM(Convert(float,Result))/@SampleSize         from #Tests         where (Result &lt;&gt; ‘Bad Val’ and Result &lt;&gt; ‘Unit Down’and Result is NOT Null)       --If the “Unit Down Count” &gt;= the maximum allowable (typically 6) then send message and quit.       If Convert(float,@UnitDownCount) &gt;= @PctLimit        Begin        Set @OutputValue = ‘Unit Down’        Return        End       --If the “BadDataCount” &gt;= the maximum allowable (typically 6) then send message and quit.       If Convert(float,@BadDataCount) &gt;= @PctLimit        Begin        Set @OutputValue = ‘Bad Val’        Return        End       --If the “NULL Count” &gt;= the maximum allowable (typically 6) then send message and quit.       If Convert(float,@NullCount) &gt;= @PctLimit        Begin        Set @OutputValue = ‘Null In’        Return        End       --If the sum of the above counts &gt;= the maximum allowable (typically 6) then send message and quit.       If (Convert(float,@UnitDownCount)+ Convert(float,@BadDataCount)+ Convert(float,@NullCount)) &gt;=       @PctLimit        Begin        Set @OutputValue = ‘Insuf Data’        Return        End       --If there is sufficient data then test for an EE event       If @Reject_Limit = ‘LR’ or @Reject_Limit =‘LW’       begin         if @Average &lt; @RejectVal         Set @OutputValue = ‘EE’         Return       end       If @Reject_Limit = ‘UW’ or @Reject_Limit =‘UR’       begin         if @Average &gt; @RejectVal         Set @OutputValue = ‘EE’         Return       end       Set @OutputValue = ‘OK’       Drop Table #Tests       SpLocal_ManualUpdate       /*       Procedure Name:   spLocal_ManualUpdate        Copyright (C) 2001, International Paper Company                  
 
         [0489]    
       
         
               
             
               
               
               
             
               
               
               
             
           
               
                   
               
               
                   
               
               
                 SpLocal_ManualUpdate 
               
               
                   
               
             
             
               
                   
               
             
          
           
               
                   
                 /* 
                   
               
               
                   
                 Procedure Name: 
                 spLocal_ManualUpdate 
               
             
          
           
               
                   
                 Copyright (C) 2001, International Paper Company 
               
               
                   
                   
               
             
          
         
       
     
         [0490]     Revision History:  
                                                       Date   By   Description                           Jun. 30, 2001   SC (Entegreat, Inc.)   Initial release           Aug. 21, 2001   SC (Entegreat, Inc.)   Comments added                      
 
 General Description: 
 
         [0491]     This procedure performs a signal selection between a manually entered value and another variable. If the dependant variable value (the manually entered value) is NULL, the output is the value of the input variable (the PI value). Otherwise, the output is set to the value of the dependant variable.  
         [0000]     Triggers:  
         [0492]     1. Time (based on sample interval for variable)  
         [0493]     2. Dependant variable value change (the manually entered value)  
         [0494]     3. Input value change (the PI variable)  
         [0495]     In order for the calculation to execute, non-optional calculation input values cannot be NULL.  
         [0000]     Inputs and Depedencies:  
         [0496]     1. Requires configuration of the depedant variable which is the manually entered value.  
         [0497]     2. Inputs described in body of code.  
         [0000]     Outputs:  
         [0498]     1. The manually entered value if it&#39;s value is not NULL, otherwise the input variable value.  
         [0000]     Variables:  
         [0499]     1. Described in body of code.  
         [0000]     Tables Modified:  
         [0500]     1. N/A  
                                   */       CREATE PROCEDURE spLocal_ManualUpdate       @Result varchar(25) OUTPUT,   --The value of the selected variable       @Var_Id int,                       --       Variable Id of this variable       @Timestamp datetime,         --Timestamp of this variable       @PIVar_Val varchar(25)           --Value of the PI       variable       AS       Declare       @ManualVar_Id int               --Variable Id of       the dependant variable (the manually entered value)       --Find the variable Id for the manually entered value (the dependant       variable)       Select @ManualVar_Id = Var_Id        From Calculation_Instance_Dependencies        Where Result_Var_Id = @Var_Id       --Validate the variable Id for the manually entered variable       If (@ManualVar_Id is NULL)        Begin         Set @Result = ‘Null Manual Var’         Return        End       --Get the current value of the manually entered variable       Select @Result = Result from Tests        where Var_Id = @ManualVar_Id and Result_On = @TimeStamp       --If the value of the manually entered variable is NULL, then output the       value of the input variable (PI variable)       If (@Result is NULL) or (@Result = ‘’)        Begin         Set @Result=@PIVar_Val        End       SpLocal_MillDay       /*       Procedure Name:  spLocal_MillDay         Copyright (C) 2001, International Paper Company         Process Management Application Group                  
 
         [0501]     Revision History:  
                                                       Date   By   Description                           Jun. 30, 2001   SC (Entegreat, Inc.)   Initial release           Aug. 21, 2001   SC (Entegreat, Inc.)   Comments added                      
 
 General Description: 
 
         [0502]     This procedure calculates a date string for display that coincides with the mill day. The time at which the mill day begins is hard-coded within this procedure (see comments below).  
         [0000]     Triggers:  
         [0503]     1. Time (based on sample interval for variable)  
         [0000]     Inputs and Depedencies:  
         [0504]     1. Inputs described in body of code.  
         [0000]     Outputs:  
         [0505]     1. Date string for the mill day.  
         [0000]     Variables:  
         [0506]     1. Described in body of code.  
         [0000]     Tables Modified:  
         [0507]     1. N/A  
                                                   */       CREATE PROCEDURE spLocal_MillDay            @Outputvalue varchar(255) OUTPUT,   --MillDay       @TimeStamp datetime       --Timestamp       for this variable       AS       Declare       @Day varchar(25),         --Day       part of mill day       @PreviousDay datetime,       --Timestamp       for previous day       @Month varchar(25),       --Month part of       mill day       @Year varchar(25),       --Year part of       mill day       @MillDay varchar(25),       --Mill day       string       @Hour varchar(25),       --Hour part of       timestamp       @Minute varchar(25),       --Minute part of            timestamp       @time float         --Time part of timestamp       --Initialize variables       Select @PreviousDay = ‘’       Select @Day = ‘’       Select @Month = ‘’       Select @Year = ‘’       --Strip hour and minute from timestamp       Select @Hour=DatePart(hh,@Timestamp)       Select @Minute=DatePart(mi,@Timestamp)       Select @time=100*@Hour+@Minute       --Calculate mill day with the new day beginning at on minute past       the mill day rollover       --The rollover time is hard-coded within the “If” statement below.       If ((@time&gt;=0) and (@time&lt;701))       Begin       Select @PreviousDay = DateAdd(dd,−1,@Timestamp)       Select @Day = DatePart(dd,@PreviousDay)       Select @Month = DatePart(mm,@PreviousDay)       Select @Year = DatePart(yyyy,@PreviousDay)       Select @MillDay = convert(varchar(25),@Month) +       ‘/’ + convert(varchar(25),@Day) + ‘/’ +       convert(varchar(25),@Year)       End       Else       Begin       Select @Day = DatePart(dd,@Timestamp)       Select @Month = DatePart(mm,@Timestamp)       Select @Year = DatePart(yyyy,@Timestamp)       Select @MillDay = convert(varchar(25),@Month) +       ‘/’ + convert(varchar(25),@Day) + ‘/’ +       convert(varchar(25),@Year)       End       Select @Outputvalue = @MillDay