Challenge vs. Solution: Enhancing Emissions Data Review & Reporting with StackVision

Accurate air emissions data is critical for regulatory compliance–even small discrepancies can lead to reporting issues, audits, and penalties. While daily and weekly data reviews are not required by regulations, they provide a proactive approach rather than reactive to any data discrepancies.

What Does Your Emissions Data Include?

Emissions data consists of hourly readings for measured parameters, calculated emissions values for each hour, calibration data for instruments, and summarized aggregate data.

Your emissions file should cover one full calendar quarter of hourly and aggregate emissions measurements for a specific unit or group of units.

This includes your:

Monitoring Plan
Quality Assurance (QA) files (such as linearity, RATA, Gross Calorific Value, and QA Certification Events),
Any certification events related to CEMS maintenance. These events are necessary for activities like analyzer replacements, umbilical maintenance, or any other CEMS-related upkeep.

Quarterly Reporting Tip Don’t wait until the end of the quarter to generate your quality assurance and emissions files. Instead, generate and review your EDR files regularly throughout the year. This allows you to break the quarter into smaller, manageable parts, helping you catch issues early and make the final submission process smoother. Our Regulatory & Reporting team offer daily & weekly data review services.

Reviewing Emissions Data & Reporting With StackVision

StackVision, ESC Spectrum’s Data Acquisition System (DAS), simplifies emissions monitoring by automating data collection, processing, and reporting while mitigating risks associated with using traditional tools.

Challenge

Solution

Disorganized or Unclear Emissions Data

Analyzing emissions data across multiple systems including multiple spreadsheets can be complex and time-consuming, making it difficult to identify trends, discrepancies, or compliance risks.

StackVision’s Comprehensive Reporting Tools

StackVision offers a variety of automated reports that organize emissions data in an easy-to-read format. Users can select specific parameters and timeframes, making quarterly reporting reviews more efficient.

Identifying Calibration and QA Issues Early

Undetected calibration failures or QA issues can lead to reporting errors and regulatory non-compliance.

Daily Part 75 Review – Calibration Detail Report

Automatically compiles all calibration sequences—including daily calibrations, interference checks, and linearity checks. Problem values are color-coded for quick identification, ensuring immediate corrective action.

Missed Data Gaps or Compliance Exceedances

Unnoticed missing data, exceedances, or out-of-control conditions can lead to compliance violations and inaccurate reporting.

Exception Events Report

StackVision pulls detailed reports on missing data, exceedances, out-of-control events, invalid readings, and suspect data—helping facilities address issues proactively.

Identifying Significant Changes in Emissions Data

Tracking emissions data trends can be difficult when you need to detect gradual shifts or anomalies, increasing the risk of compliance issues.

Average Data Reports & Trending Reports

StackVision automatically calculates rolling and block averages (hourly, daily, monthly, yearly) to align with permit requirements. The Average Data Trending Report helps users quickly identify significant changes in data trends, allowing for early intervention and more proactive emissions management.

Tracking and Managing Missing Data Substitutions

Part 75 mandates that all missing emissions data be properly substituted, which can be difficult to track.

Missing Data Substitution Hours Report

Automatically monitors the number of substituted hours for a selected parameter, simplifying compliance tracking.

Ensuring Stack Flow Monitoring Accuracy for Coal Plants

Failing a flow-to-load test at the end of the quarter can cause compliance delays and reporting errors.

Daily Stack Flow Monitoring via ProcessNow

StackVision performs daily flow-to-load tests, ensuring continuous accuracy. Users can monitor test results and make adjustments throughout the quarter to prevent failures.

Ensuring Compliance with Part 60 Opacity Monitoring

Opacity exceedances and downtime events must be carefully tracked to comply with Part 60 regulations.

Opacity Matrix & Opacity Duration Reports

StackVision provides color-coded Opacity Matrix Reports, as well as automated Opacity Downtime & Exceedance Reports, making it easier to monitor and report required opacity data.

Troubleshooting and Editing Data Efficiently

Sifting through emissions data for troubleshooting can be tedious and error-prone.

DataLab for Advanced Data Analysis

StackVision’s DataLab allows users to:
View, edit, and export data to Excel
Apply linear adjustments and perform data replacements
Customize and save data views for faster daily reviews
Use color-coded flags for quick anomaly detection

Managing Large-Scale Data Processing for EDR Compliance

Ensuring that emissions data is correctly formatted and error-free for EPA/state reporting can be overwhelming.

Automated Data Processing & Compliance Management

StackVision’s feature, ProcessNow, is the way we transform data into a reportable format. Data is assembled into the records necessary to build an EDR or any permit reports – ideally on a daily basis. Maintaining error-free processed data ensures an easily generated XML EDR (or other reportable product) at the end of the quarter.

Communication failures between your DAS and CEMS

Data loss and inaccuracies

The industry-standard 8864 Data Controller

Acts as a powerful and reliable hardware bridge between StackVision and your emissions monitoring rack. The 8864 delivers consistent performance even in high-traffic and complex network environments ensuring seamless data acquisition and protection.

Customer Success Story: Preventing Reporting Discrepancies

One common reporting mistake occurs when data is modified after the official submission period without proper re-submission. ESC Spectrum recently helped a facility that faced a discrepancy in their NOx Percent Monitor Data Availability (PMA). Their internal database showed a 95% PMA, while the EPA’s records reflected only 80%.

After investigation, it was discovered that data was reprocessed after the submission deadline, but the updated files were never sent to the EPA’s Host System. Without correction, this type of oversight can lead to compliance issues or potential fines.

How StackVision’s Database Locking Wizard Helps Prevent Emissions Data Discrepancies

To prevent these types of errors, StackVision provides a Database Locking Wizard, which allows facilities to lock down their emissions database after submitting reports.

This ensures data integrity and prevents accidental modifications after the deadline. If adjustments are needed, users can unlock specific portions of the database in under five minutes.

Be Proactive with Your Emissions Data

Regular emissions data reviews help facilities stay ahead of potential issues rather than scrambling at the last minute. By using StackVision, facilities can streamline emissions data management, automate reporting, and reduce the risk of compliance errors.

Learn more about what the process would look like if your facility were to upgrade to StackVision.

Want to see how StackVision can simplify emissions monitoring for your facility? Contact us today.

Taylor Hempel - Marketing Specialist II

Taylor Hempel is a skilled marketer specializing in content creation, social media management, and driving customer engagement. With a BBA in Marketing from the University of Texas at San Antonio, she joined ESC Spectrum in February 2022. Taylor is adept at crafting informative content about continuous emissions monitoring systems, its components and data acquisition systems allowing her to craft content that educates and informs industry professionals.

Contact Taylor at thempel@escspectrum.com for questions or comments.