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Integrating flow measurement into ABB CEMS

Steve Donnelly - March 2013. Integrating flow measurement into ABB CEMS. CEMS Standards Flow metering. Stack emissions subject to legislation for many years Output in KTons/year has always been required, but standards did not specify how to establish

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Integrating flow measurement into ABB CEMS

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  1. Steve Donnelly - March 2013 Integrating flow measurement into ABB CEMS

  2. CEMS StandardsFlow metering • Stack emissions subject to legislation for many years • Output in KTons/year has always been required, but standards did not specify how to establish • Flow measurement sometimes but not always used – many mass flows are calculated • New standard will give requirements – and gives guidance on - flow metering techniques

  3. CEMS StandardsEurope • 2001… LCPD, WID ……..IED • EN 14181 Relevant European standard for on-going quality assurance of CEMS • EN 15267-3 Performance specifications and test procedures for CEMS • Must now measure the mass of pollutants released, not just the concentration • EN ISO16911 Will specify the requirements for flow measurement

  4. FPD580 StackFlowMasterFirst choice for CEMS flow metering • Uses proven Torbar averaging pitot flow metering technology. • Assures compliance • with new European & US EPA regulations • Optimises plant running hours • Simplifies installation • Reduces cost of ownership • Integrates into new and existing CEMS

  5. FPD580 StackFlowMasterWhy use Averaging Pitot for Stack Measurement • Low installation costs • Max two stabbings to be cut into stack(only one if not end supported version) • Available in a variety of materials • to suit different processes • Multi-port instrument • resistant to effects of changing flow profiles • Reliable, long term solution • no moving parts • no electronics within stack • Low risk of failure in the primary element

  6. Measures the mean fluid velocity without the need for traversing High Pressure Low Pressure Upstream HP sensing holes Upstream HP sensing holes How Averaging Pitot Tubes work TheABBaveragingpitot: • Multi-portmeteracrossfulldiameter‘auto-traverses’ • Resultantdifferentialpressure isproportionaltothesquareofthevolumeflowrate Differential Pressure OutputConnected to DP Measuring Instrument LP Inner Tube HP Inner Tube Outer Impact Tube Static LP pressure point

  7. Torbar Edge - Better performance and stability Profiledflats FPD580 StackFlowMaster • Profiled flats around the downstream hole • define the flow separation point • stable pressure area at downstream tapping • more constant coefficient at high velocities • very wide turndown • Provides a highly stable flow signal Low Pressure Tube

  8. Torbar Edge – Easier handling FPD580 StackFlowMaster • Easier handling for large diameter stacks • probes above 5 metres are in two pieces with centre coupling • simplifies shipping and handling; may simplify installation

  9. FPD580 StackFlowMasterWhy choose StackFlowMaster? • Averaging pitot tube technology • approved under the new standards • EN15267-3 & MCERTS approval • satisfies QAL1 & QAL3 requirements. • Optional automatic zero/span checks • no physical user intervention required • Supply with ABB CEMS analyser • enables purchase of complete package from single supplier/manufacturer • Enables CEMS upgrades • to meet the new legislation • Robust for long term use • minimal maintenance .

  10. FPD580 StackFlowMasterTorbar advantages • Easytoinstall • Requiresonlyasimpleone - or two - stabbinginsertion • Robust meterwithalongservicelife • Reducesriskofexpensivefailures • Stronger construction than those with special profiles • Offersgoodquality,stablemeasurement • Due to uniquesensorprofile • Special end support designs give greater integrity • From ABB's many years of experience

  11. FPD580 StackFlowMaster FPD585 Flow Probe with Automatic Interface • Torbar probe specifically designed for stacks • 25 or 60mm diameter • optional integral RTD • Multivariable transmitter • DP & absolute pressure measurementwith temperature input • remote mounted in interface unit • Automatic interface unit • 3 versions • MCERTS pending for automatic zero/span versions

  12. FPD580 StackFlowMasterFPD585 Automatic Interface Variants • Automatic zero/span checking option • No external equipment to be connected • Checks at the push of a button • Optional Enclosure Heater • For ambient temperatures below 0°C • Purging • Recommended for particulate concentrations > 30mg/m3 and up to 300 mg/m3

  13. Contaminated Flue Gas Data FPD580 StackFlowMasterPurging • Cleans probe ports using pressurised air • Enclosure contains multivariable transmitter for volume or mass flow measurement • Enclosure contains sequencing controls/valves for automatic (regular) purging or on-demand purging Purge Air Purge Air Purge Air

  14. FPD580 StackFlowMaster Key aspects of Installation 8D • Location:- • Requirements for upstream lengths of stack, expressed in terms of the actual stack internal diameter D • Minimum upstream straight length is 8D • Minor obstruction (sample probe) OK if > 3D upstream

  15. FPD580 StackFlowMaster ABB supplies complete CEMS Data acquisition and reporting Mass flow Dust O2 combustion SOx, NOx, CO, HCl, HF, NH3…

  16. FPD580 StackFlowMaster Benefits • Wide range of stack temperatures • suitable for stack gas temperatures up to 1200°C • Wide range of stack applications • Incinerator plants, power generators, refineries, metals processing, cement plants, crematoria • Up to 8m diameter • Handles solid contaminants • Up to 300mg/m3 • automatic or manual purging of probe portsavailable

  17. FPD580 StackFlowMaster Benefits • Handles corrosive contaminants • 316L, 321H or alloy 625 sensor • Hastelloy C transmitter diaphragms , PTFE seals; optional 316 transmitter housing • Easier installation in large diameter stacks • two piece probes with centre coupling • Simplifies handling, transportation, installation • Simplified QAL3 compliance • Automatic option for tx span check • No external equipment required • Simple to size and specify • Intuitive software for selection, sizing and coding • Auto-updating facilities

  18. Stands 47 and 48 Steve Donnelly, CEMS specialist

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