Mauro Ogido, ABB Measurement & Analytics, Mayo 2019 … · 2019. 6. 26. · place picture here...

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Extractive Operating CGASample Handling Components

Mauro Ogido, ABB Measurement & Analytics, Mayo 2019

© ABB20-06-2019 Sales Training Sample Handling | 2

PG 23Sample Handling Components

§ Why are sample handling components necessary ?

§ Always required for extractive operating analysis systems§ Analyzers needs a Sample Conditioning System (SCS)

§ Otherwise

§ No operation possible

§ Immediately damaged

§ Have in mind

§ The best analyzer cannot work, if the SCS

is not designed in accordance to the requirements

of the measuring task


Required Parameters for System desinging

Temperature

Gas composition& MeasuringComponents

Condensation

Aerosols

Corrosion

ConditionsAt site

Dust

Pressure

Absorbtion

SampleProbe

&

SampleConditioning

SystemEx - Area


Continuous Operating MethodsIn-Line / In-Situ

§ Continuous measurement directly

in the stack / process

§ ABB Laser LS25

On-line – Extractive

§ Continuous measurement

§ Sample gas conditioning and feeding

of the sample gas to the analyzer

§ AO2000 / EL3000

§ ACX and ACF-NT Systems

§ PGC

In-Line(Cross Stack)

Extractive

In-Situ


Designing an extractive operating CGA – SystemExample – Emission monitoring system


Extractive Operating CGA - SystemSystem components

Sample Line Sample ConditioningProbe System

Analyzer


Selection table for probe types


Probes Type 2, 40, 42, 60, HProduktportfolio

Type 40

Type 42 heated

Type 60, H

Type 2

Suitable in conjunction with filter units FE2, PFE2, PFE3


Probes Type 40, 42Produktportfolio

Suitable in conjunction with filter units FE2, PFE2, PFE3

Type 40

Type 42 heated

Probe tube 40 Process temperature < 1300 °C Silicon carbideProbe tube 40 Process temperature < 450 °C SS 1.4571Probe tube 40 Process temperature < 180 °C SS 1.4571 coatedProbe tube 40 Process temperature < 900 °C SS 1.4893

Probe tube 42, heated Operation temperatures lower than the dew point (max. 180°C)

Probe tube 40 Process temperature < 1300 °C Silicon carbideProbe tube 40 Process temperature < 450 °C SS 1.4571Probe tube 40 Process temperature < 180 °C SS 1.4571 coatedProbe tube 40 Process temperature < 900 °C SS 1.4893

Probe tube 42, heated Operation temperatures lower than the dew point (max. 180°C)


Modular Filter SystemFilter FE2

§ Component of the modular gas sampling probe system§ It is used for filtering gases containing dust§ Component of the modular gas sampling probe system§ It is used for filtering gases containing dust

Surface filter element

Sample gas outlet

Connectors for purgingFE2

RingHeater

© ABB| 11

Heatingsleeve

regulated

Insulationcover

FE2

Typical Applications

• Emission monitoring

• Small measuring ranges of SO2,

NOx and CnHm (Hydrocarbons)

Typical Applications

• Emission monitoring

• Small measuring ranges of SO2,

NOx and CnHm (Hydrocarbons)

Requirement

• Avoidance of a cold bridges

• Sample line directly connected to

a heated sample line

Requirement

• Avoidance of a cold bridges

• Sample line directly connected to

a heated sample line

Modular Filter SystemFilter FE2 with heating sleeve

Complete assembled

Modular Filter SystemFilter FE2 • Compare with predecessor

© ABB20-06-2019 Enter filename via "View - Header and Footer...". Apply to all. | 12

Predecessor model New model

Modular Filter SystemFilter FE2 New Model


1

2

3 4

5

Legend

1. Welded connectors for purging closed with blind plugs.Purge connectors cannot be assembled later if the FE2 is ordered without purge connectors.

2. New eccentric design of the head

3. The welded block for the sample gas outlet is removed

4. Sample gas outlet

5. Drills howls for two PT100


Modular Filter SystemFilter Unit PFE2

Filter unit FE 2 withRing heater

Filter unit FE2 withHeating sleeve

+

Temeraturecontroller

+ Filter Unit PFE2


Filter Unit PFE 2

§ Filter unit for outdoor application

§ Dust content > 3g/m3

§ Integrated back-purging valves

§ Filter heating

§ Controlled heating with external

temperature controller

Filter Unit PFE 2


PFE2 with protection box - Fully equipped

Pilot operating valve 2.1

Diaphragm valve 2.2Cleaning Valve

Pilot operating valve 1.1Pulsed Instrument air

Diaphragm valve 1.2Pulsed Instrument air

Instrument air Inlet

Calibration gas Inlet

Control air Inlet

Heated Sample Line

Pt100Power supply

Heatedshut-off valve

Protection box

Junction boc

Pilot operating valve 3.1Cleaning filter surface

Diaphragm valve 3.2Cleaning filter surface

Solenoid valveBleeding


Valve Circuit for Filter Back - Purging of PFE2

Pilot operating valveCleaning filter surface

Pilot operating valvePulsed air

Pilot operating valveCleaning filter

Sample Gas

Instrument air InletPurge air

Control air Inlet

Diaphragm valves

Diaphragm valveCleaning filter surface

FilterUnit

Solenoid valve

Bleeding


Back - Purging PFE2 • Operation diagram

1 Purging start2 Purging finished3 Purging cycle4 Pulsed air ( Valve 8 & 9 )5 Bleeding ( Valve 15 )6 Cleaning filter from inner side ( Valve 5 & 6 )7 Cleaning filter surface & probe tube ( Valve 16 & 17 )10 Control Air11 Compressed Air12 Sample Gas

1

4

5

6

7

3

2

o openc closed

© ABB20-06-2019 ACF5000 Probenahme | 19

Modular Filter SystemPFE2 with Coax – Valves & Heated Shut-off Valve

Valve closed

Valve open


PFE2 Back - Purging with Coax - Valves

Sample Gas outlet


FilterUnit


AB

B A

Cleaning filter surface

Cleaning filter from inserside

Coax valve

Coax valve

Heated solenoid valve


Back - Purging PFE2 • Operation diagram

1 Purging start2 Purging finished3 Purging cycle4 Pulsed air ( Valve 1)5 Cycle - Cleaning filter from inner side ( Valve 1 )6 Cleaning filter surface & probe tube ( Valve 2 )7 Compressed air8 Sample Gas ( Valve 3 )

o openc closed

1

4

5

6

7

3

2

4

5

6

8

FilterUnit

1

2

3

7

8

7

Modular Filter SystemFilter Unit PFE2 • Basic Protection Box NEW


Insulation at the inner side ofthe protection hood


Modular Filter SystemFilter Unit PFE3

n Very compact size

n Applicable for system solutionsn ACX

n Free designed systems

n 3 different heaters availablen Self regulated, max. 160 °C

n Ring Heater, uncontrolled

n Heating sleeve, max. 190°C

n Bulkhead unions for back purging

n 0,3 µm Filter

n Suitable for outdoor - installationFilter Unit PFE 3


PFE3 with protection box- Fully equipped

Test gas connector6mm

Purge air Inlet18mm


PFE3 with external Purge equipment

Filter Unit PFE 3n Suitable for PFE3 and Probe H

n External Control Unit required


Instrument Air for Back-PurgingRequired Quality and Quantity

Instrument air Based on ISO 8573-1 Class 2

Particle size <= 0,1 µmParticle density 1 mg/m3

Oil content <= 0.1 mg/m3

Dew point <= - 40 °C

Pabs

6000 to7000 hPa

(6.0 to 7.0 bar)

Dynamic

approx.

600 l/min.

Remark:Typically purge time

is <= 1 min.

FE2PFE2 & PFE3

Characteristic Inlet Pressure Flow


Sample Gas ProbeTypical Installation

Heated sample gas lineProbe tube

Wall

Wall tube

Filter Unit FE2 (PFE2 / PFE3)

Heating

Typical Application :

Emission monitoring in power plants andincineration plants

Mounting angle 8°... 90° downwards


Typical Place of installation


Gas Sampling Probe • Typical Installation

Insulationrequired


Gas Sampling SystemHeated Probe Tube 42

Application§ Low process temperature

in conjunction with a

high dewpoint

§ Stack with brick walls

in a tube in tube construction

Avoidance of cold spots


Gas Sampling ProbeExperience from the practice - Corrosion


Gas Sampling ProbeExperience from the practice – Bad insulation

Gas Sampling ProbeExperience from the practice - Vibration


Reasons:• Vibration at tapping point• High flow velocity

• Recommended : up to 12m/s > 1000mm max. 7 m/s

Mounting Locations of Measuring Systems

© ABBjun-19 CEM / Legislation | 34 Photos by TUV Sued


Engineering

Which criteriahas to be fulfilled

by the sample line ?

And what about gasconducted material ?


Piping Material • Ectract

For detail engineering please refer to special tables / diagrams or calculation tools


Piping Material • Extract


Heated Sample LinesProductportfolio

§ CGWB13 Base Line

Individual Solutions

§ TBL01-S Systems - ACF-NT & ACXMain used heated line

§ TBL01-E EasyLimited applications

§ TBL01-C Cement

Special type for ACK & ACMP

§ Material conducted with the measuring gas


Heated Sample Gas Line TBL01-S

§ 2 types of fixed resistor heater

§ 90 W/m, 200°C, temperature sensor PT100

§ 30 W/m, 100°C, self regulating, for frost protection only

§ Configuration features

§ Line will be delivered completely assembled.

Exact length is required for ordering.

§ Various range of power supplies

§ Special designs for ABB Systems ACF-NT and ACX

§ Mains lead length with appr. 5m for power and temperature sensor

Heated Sample Line TBL01-SFeatures & configuration


SS Connector

Test gas tube

Sample gas tube

Test gas tube

Sample gas tubeSS Connector

PT100

Power supply

Analyzer SystemFilter Unit


Pipe-end connection atcabinet / analyzer side

A B

Pipe-end connection atprobe side

Power supply

Temperaturfühler

250,0080,00

11,0011,00

Ø6

Ø6

24,0024

50,0

0

60,0

0

56,00

42,00

Ø6

49

A,B

49,00

300,00

1

2

6/4 x1 SS-nipple 6/4 x1 SS-nipple

Construction TBL01-S • Design with Flange / Metal Cap

Temperature sensor

Flange Metal cap

Cutaway view Cutaway view


Engineering

What aboutwater ?


Separating the Water • Dew Point table

Calculation

How many condensate per day ?

n Dew point Process : + 70°C

n Dew Point Cooler : + 3°C

n Flow System : 60 l/h

247 – 6,02 = 240,98 g/Nm³

60 l/h x 24 h = 1440 l/day

1000 l = 240,98 g

1440 l = x

x = 347 g H2O / day

Process

Dew Point Cooler


Sample Gas CoolerSCC-C

Technical features

§ Compact housingDimensions ½ 19 inch, 6 hight units

§ Mounting bracket for 19 inch or wall mounting

§ Heat exchanger changeable without tools

§ 2 gas paths

§ Constant dewpoint outlet with +3°C

§ Corrosion resistant ( Glass, PVDF, SS )Used for chemistry applications too

§ Peristaltic pump for discharging condensate

§ CSA certified, Class1, Div.2

§ ATEX Zone 2 according II 3G EEx nAC IIC T4


Sample Gas Feed UnitSCC-F

Technical features§ Design identical to Sample gas cooler SCC-C§ Indicating cooler temperature (display AO)

§ Monitoring§ cooler operation (cooling temperature)§ condensate penetration§ sample gas flow

§ Controlling external solenoid valve§ 4 digital inputs for monitoring external condensate/

acid vessels§ Control functions

§ Shut off sample gas pump on condensatepenetration

§ Shut off sample gas pump on excessive coolertemperature

§ CSA certified, Class1, Div. 2


Sample Gas Feed UnitSCC-F

Version 1

P1

P2

Version 2

Version 6

Version 3

Version 4

P1

Version 5


I/O – interface board

Gas Feed Unit SCC - F

Configuration with two diaphram pumps


Conditioning Components with System Bus

Advantages

§ Built your system by just „plug & play” asample gas conditioning

§ Reduces costs for system integration

§ Interface - card allows complete control andremote diagnosis

§ Makes operation more reliable and protectthe analysis system

Gas feed unit SCC-Fwith I/O interface - card

Sample gascooler SCC-C

BUS

AO2000 Serie


Analysis SystemUsing Version 1 of the Sample Gas Feed Unit SCC-F

CondensateH3PO4Dosing

AcidFilter

Analyzer Cabinet

SCC-C

Exhaust

Water trap

SCC-F

Uras 26

P

NO

SO2, CO

O2

AmbientAir

Filter UnitPFE2 / 3

HeatedSample line

TBL01-S

Sample Conditioning

Analyzer


Acid Filter

§ Features§ Collection of acid aerosols entrapped

in the sample gas§ Avoid of acid formation

§ Requirement§ SO3 content greater than 1 mg/m³§ SO2 content greater than 500 mg/m³

§ Applications§ Flue gas measurements from heavy-oil

or hard coal firings


Acid Filter

Gas-Outletto the sample gascooler.Straight-line bushingunion connector

Gas-InletStraight-line unionconnector


Acid Filter

SCC-FSCC-CAcid filter

Analyzer Cabinet

SCC-K

Probe with filter unit

Ambientair

NO

CO, SO2O2

Uras 26

P

Exhaust

Heated Sample Gas Line

NO

CO, SO2O2

Sample Conditioning System

Immersing Tube


Acid Filter

Inlet

Outlet

Dimensions (mm)

Connectperistaltic pump here

if used forPre-condensation


Water trap

§ Protection of the analyzer against damages caused by water

CO

SO2

O2 CO

SO2

O2

Sample In

Sample Out

Gases pass the diaphragmwithout influence

The coatingof the membranestops liquids immidiately


SCC-F Feed Performance Standard

0

50

100

150

200

250

-800 -600 -400 -200 0 200 400 600 800

P [mbar]

Flow

rate

[l/h

]

A B

A • Inlet : Negative pressure • Outlet : Atmospheric pressure

B • Inlet : According to Chart • Outlet : Gauge pressure


Pressure Drop Down • Typical Examples

Sample gas line:

Flow [l/h] internal diameter [mm] Pressure drop/ m [ mbar/m]

50 4 0,470 4 0,6100 4 0,850 6 0,0770 6 0,10100 6 0,15

Components:

Component Pressure drop [ mbar](70 l/h)

Filter unit FE 2* approx. 10 mbarSample gas cooler approx. 15 mbar

Condensate trap approx. 25 mbarUras approx. 20 mbar

Caldos approx. 5mbar

* clean condition

For detail engineering please refer to special tables / diagrams or calculation tools


Dead time

Dead time [s/m]

Nominal width

Dead time Calculation

The dead time can be calculated as following:

Dead time = Volume / Flow

Dead time t (sec) = Volume in Liter / Flow in Liter per sec

§ Example: Volume : 0,1 L (eg. Heatexchanger)Flow : 100 l/h

t (sec) = 0,1 L / (100 l/h / 3600)

t = 3,6 sec



Converter SCC-K

Technical Features

§ NO2 converting by catalysis into NO

to measure NOx indirectly

§ Catalyst: Carbon / molybdenum

§ High catalyst service life

§ Conversion rate > 95 %

§ Catalyst cartrigde can be changed

without tools


Converter SCC-KVersion with 4- way ball cock

D

C

A

B

Y1

E1

C°

400

400B 1.2

B 1.1

B 1.0 Y2

Y1

A Status signalB Power supplyC Sample gas inletD Sample gas outletE Heating furnace tube

Outlet to Analyzer

Inlet

Byp

ass


Converter SCC-KVersion with solenoid valves

Byp

ass

Inlet

Outlet to Analyzer

Cat

alys

t


Sample Handling System • Version 6 of SCC-F

SCC-F

SCC-C

CondensateH2O2Dosing

Acid filter

Analyzer Cabinet

Probe with Filter unitAmbient

air

Exhaust

Limas 11

SO2(Quartzcell)

P

NO2-/NO-Converter

Magnos 206

NOP

Uras 26

NO

Heated Sample Gas Line

Special Features :n SO2 - Measurement with LIMAS

n Elimination of SO2 with H2O2 - Dosing

for NO - Measurement.

Avoids cross sensivity

CO

O2

Condensatetrap

Probe PFE2/3

Probe Backpurgingwith Instrument air

Option

1

2

Sample Conditioning

Analyzers


Gas Conditioning - Aerosols • Dosing • Condensate

Demands Applications

§ Separation of Sulfur acid aerols > Acid filter(SO3 > 1 mg/m³)

§ Avoid of Acid formation > Acid filter( SO2 > 500 mg/m³ )

§ Avoidance of SO2 losses in condensate > Dosing system H3PO4

(SO2 < 500mg/m³)

§ Elimanation of SO2 > Dosing system H2O2

§ Constant gas dew point of +3°C > Sample gas cooler


Sample Handling System • Version 2

SCC-FSCC-C

Condensate

Analyzer Cabinet Exhaust

Condensate trap

P1

P2

Uras 26

CO

COP

Ambientair

Ambientair

Probes

with Filter Unit

Heated SampleGas Lines

p

Pressurized AirConditioning

forBackpuring

Probe withFilter unit

p

Probe withFilter unit

Sample Conditioning

Analyzer


Conditions

Dust content : max. 20 g/m³ without blow backmax. 100 g/m³ with blow back

Pressure : max. 400 kPa ( 4 bar )Flow rate : max. 2000 l/h

Temperature : < 130°C heated> 130°C < 450°C unheated

Application : Coal bin monitoring

OptionProtection box

Probe 2


Sample Handling System • Version 4

Gas feed unit SCC-FCooler SCC-C

Condensate

Acid filter(Option)

Analysis cabinet

Probe with Filter unit

Ambientair

NO

CO, SO2O2

Uras 26

P

BypassHeated sample Gas Line

Exhaust

O2 COAnalyzers

Sample Conditioningp

Mauro Ogido, ABB Measurement & Analytics, Mayo 2019 … · 2019. 6. 26. · place picture here...

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Transcript of Mauro Ogido, ABB Measurement & Analytics, Mayo 2019 … · 2019. 6. 26. · place picture here...