Apex Instruments Automated MercSampler System Simplifies
Mercury Sampling and Frees up Resources

It eliminates the need for constant oversight during long sample runs. Once sampling is underway, stack technicians can increase their productivity and focus on other important tasks until testing is completed.

The automated XC-6000EPC MercSampler is a sorbent trap sampling system designed for continuous sampling of vapor-phase mercury emissions from stationary combustion sources.

Paired Hg samples are extracted from the flue gas and captured in sorbent traps over a desired time period – from minutes to several days. Samples are then analyzed to determine mercury concentration.

After sample acquisition runs are finalized, data recorded from the Console is easily downloaded to a PC for analysis and generating reports.

Our MercSampler System was designed to meet the requirements of CFR 40 Part 75, Appendix K.

Click HERE to read about Appendix K.

The XC-6000EPC MercSampler Console simplifies mercury emission sampling by automating:

• Display of Real-Time Data 
• Data Acquisition, Logging and Processing
  
• Management of Proportional Flow Control
  
• Leak Checks
  
• Calculations
  
• Temperature Control
  
• Calibrations
  
• Data Export for Report Generation

The MercSampler Console

The XC-6000EPC MercSampler Console captures all the data necessary for testing paired sorbent trap samples according to Appendix K and is fully automated.

The Console is versatile and engineered with the quality and durability you expect from Apex Instruments.

The MercSampler Console was custom engineered from the ground up to deliver accurate mercury sampling. Printed circuit boards and firmware were designed in-house to our specifications.

We chose not to use off-the-shelf modules for critical sub-systems. All control circuits, firmware, interfaces and software were custom-designed to work as an integrated Hg sampling system.

The MercSampler Console controls the sample flow rate in proportion with the stack gas-flow.

Two long-life brushless DC diaphragm vacuum pumps work in concert with proportional valves and mass flow sensors to extract gas samples pulled through sorbent traps in accordance with the requirements of Appendix K.

Optical encoders mounted in the dry gas meters provide precise sampling (accuracy to 1.0cc).

Temperature and barometric pressure measurements are then used to calculate the standardized volume in each dry gas meter.

All data captured by the MercSampler Console during sample acquisition runs is processed, then automatically recorded and saved to internal flash memory. The Console can store over 90 test-runs.

Key Design Features
of the MercSampler Console

• RISC Based Micro Controller Technology
  
• 14 Bit A/D Converter
• Custom Data Acquisition Control Board (TC/MUX & DAC)
  
• Eight 25KV Isolated Type-K TC Channels
• External Inputs: Moisture Analyzer, Stack Flow, Remote Pause
• Accepts External Analog Signal for Proportional Flow Control
• Multiple Alerts and Responses
• Manual or Automatic Restart Option after power loss
• Power: 2.5 Amps plus Probe requirement

Our standard XC-6000EPC MercSampler Console model is a 19” rack-mount unit integrated with an 8-U portable enclosure. [(H x W x D) 18" x 21" x 21"] It can be used with our standalone gas conditioning system such as the SGC-4000 HGP or SGC-4000 HG.

The MercSampler Console can be integrated with our SGC-4000 gas conditioning system into a single unit:

• Corrosive-resistant 16-U shockmount cabinet (for typical installation in a stack annulus, instrument shed or trailer). Reduces the affects of stack vibrations. Accepts a Vortex cooler. [(H x W x D) 37" x 21" x 21"]
   
• Powder-coated aluminum outdoor cabinet (optional temperature control with heater and/or A/C) [(H x W x D) 38" x 28" x 27"].
   
• Custom enclosures to accomplish your specific application needs.

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MercSampler Software
Provides Automated Sampling and Remote Control

Automated mercury sampling requires well engineered software, integrated with the sample acquisition console itself.

 

The XC-6000EPC Console ships standard with Apex Instruments MercSampler software. The software was designed specifically for automated mercury sampling, following two years of development and released after completing thorough system integration tests.
 

MercSampler software has a simple to use interface and is easy to configure. It was designed with the user in mind. Intuitive menus provide the necessary steps to start mercury sampling quickly to obtain thorough and accurate results.

Setup, running and completing a sample run is a 5-Step Process:

1. Select an existing test profile for upload to the XC-6000EPC Console or create a new profile for upload.
   
2. Next, perform a pre-leak check through an interface screen.
   
3. Next, begin and run the sample testing – from minutes to several days.
   
4. After testing is complete, perform a post-leak check from the software interface.
   
5. Download test results from the XC-6000EPC Console to your PC for analysis. Data reports are saved in standard .TXT and .CVS file formats.

   While testing is underway, the XC-6000EPC Console can be remotely accessed online to determine its current state or to monitor activities.

The MercSampler software interface is well-designed, intuitive and includes separate screens for:

• Main Menu Selection
  
• Configuration Utilities
  
• Loading Pre-Defined or New Profiles
  
• Pre-Leak Checks
  
• Trap ID and Dry Gas Meter Readings
  
• Test-Ready and Run
  
• Post-Leak Checks
  
• Export Data

Communication

Communication links from the XC-6000EPC MercSampler Console to the PC can include:

• Ethernet
  
• USB
  
• Optional Wireless Interface
  
• MODBUS Data Logging Option

Click HERE for more information about MODBUS.

MercSampler software is compatible with Microsoft Windows XP™ compatible computers – typically a laptop is used.

Call Apex Instruments today and ask for a MercSampler software demonstration.

Gas Conditioning (standalone)
for Use With the MercSampler Console

The extracted source sample must first be conditioned to deliver dry, acid-free gas to the MercSampler Console dry-gas meters (DGM).

Apex Instrument’s SGC-4000 Gas Conditioner (chiller) is a dual-channel gas conditioning system. This state-of-the-art Free Piston Stirling Cooler (FPSC) uses environmentally friendly helium for cooling and has only two moving parts. Its efficient design and large cooling capacity can chill a gas sample within seconds.

The SGC-4000 is lightweight, compact and available in two standalone configurations:

• SGC-4000 HGP is our standard portable version and is self-contained within a modular unit.
   
• SGC-4000 HG is a slide mounting version for 19” rack-mount cabinets

MercSampler Console and
SGC-4000 Gas Conditioner
Integrated Into One Unit

MercSampler Console installed in Rack Mount Cabinet

Mercury Sorbent Trap Sample Probes for Use with the MercSampler Console

Our Hg sample probes incorporate dual-traps and are custom designed to your specifications or manufactured to meet application requirements. Probes are produced from either stainless steel or Hastelloy C276.

Dual tubular heaters prevent condensation in sorbent traps. The probe head enclosure is insulated to minimize condensation at the junction where the probe and heated umbilical line connect.

The probe is inserted directly into the flue gas-stream. Paired sorbent traps mounted at the inlet end of the probe have leak-tight compression fittings.

Type K thermocouples are used to monitor stack, probe and sorbent trap temperatures.

Umbilical Lines Used With the MercSampler Console

Heated umbilical lines are custom designed and manufactured to meet specific application requirements. Umbilical lines are portable, lightweight and incorporate a self-regulating temperature control.

Umbilical sample lines that incorporate heavy-duty construction suitable for permanent installation are also available.