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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
© ABB20-06-2019 Sales Training Sample Handling | 3
Required Parameters for System desinging
Temperature
Gas composition& MeasuringComponents
Condensation
Aerosols
Corrosion
ConditionsAt site
Dust
Pressure
Absorbtion
SampleProbe
&
SampleConditioning
SystemEx - Area
© ABB20-06-2019 Sales Training Sample Handling | 4
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
© ABB20-06-2019 Sales Training Sample Handling | 5
Designing an extractive operating CGA – SystemExample – Emission monitoring system
© ABB20-06-2019 Sales Training Sample Handling | 6
Extractive Operating CGA - SystemSystem components
Sample Line Sample ConditioningProbe System
Analyzer
© ABB20-06-2019 Sales Training Sample Handling | 7
Selection table for probe types
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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
© ABB20-06-2019 Sales Training Sample Handling | 9
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)
© ABB20-06-2019 Sales Training Sample Handling | 10
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
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Predecessor model New model
Modular Filter SystemFilter FE2 New Model
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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
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Modular Filter SystemFilter Unit PFE2
Filter unit FE 2 withRing heater
Filter unit FE2 withHeating sleeve
+
Temeraturecontroller
+ Filter Unit PFE2
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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
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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
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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
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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
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Modular Filter SystemPFE2 with Coax – Valves & Heated Shut-off Valve
Valve closed
Valve open
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PFE2 Back - Purging with Coax - Valves
Sample Gas outlet
Instrument air Inlet
FilterUnit
Instrument air Inlet
AB
B A
Cleaning filter surface
Cleaning filter from inserside
Coax valve
Coax valve
Heated solenoid valve
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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
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Insulation at the inner side ofthe protection hood
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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
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PFE3 with protection box- Fully equipped
Test gas connector6mm
Purge air Inlet18mm
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PFE3 with external Purge equipment
Filter Unit PFE 3n Suitable for PFE3 and Probe H
n External Control Unit required
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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
© ABB20-06-2019 Sales Training Sample Handling | 27
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
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Typical Place of installation
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Gas Sampling Probe • Typical Installation
Insulationrequired
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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
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Gas Sampling ProbeExperience from the practice - Corrosion
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Gas Sampling ProbeExperience from the practice – Bad insulation
Gas Sampling ProbeExperience from the practice - Vibration
© ABB20-06-2019 Sales Training Sample Handling | 33
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
© ABB20-06-2019 Sales Training Sample Handling | 35
Engineering
Which criteriahas to be fulfilled
by the sample line ?
And what about gasconducted material ?
© ABB20-06-2019 Sales Training Sample Handling | 36
Piping Material • Ectract
For detail engineering please refer to special tables / diagrams or calculation tools
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Piping Material • Extract
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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
© ABB20-06-2019 Sales Training Sample Handling | 39
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
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SS Connector
Test gas tube
Sample gas tube
Test gas tube
Sample gas tubeSS Connector
PT100
Power supply
Analyzer SystemFilter Unit
© ABB20-06-2019 Sales Training Sample Handling | 41
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
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Engineering
What aboutwater ?
© ABB20-06-2019 Sales Training Sample Handling | 43
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
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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
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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
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Sample Gas Feed UnitSCC-F
Version 1
P1
P2
Version 2
Version 6
Version 3
Version 4
P1
Version 5
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I/O – interface board
Gas Feed Unit SCC - F
Configuration with two diaphram pumps
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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
© ABB20-06-2019 Sales Training Sample Handling | 49
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
Installation in an Analyzer House
© ABBjun-19 CEM / Legislation | 50
© ABB20-06-2019 Sales Training Sample Handling | 51
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
© ABB20-06-2019 Sales Training Sample Handling | 52
Acid Filter
Gas-Outletto the sample gascooler.Straight-line bushingunion connector
Gas-InletStraight-line unionconnector
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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
© ABB20-06-2019 Sales Training Sample Handling | 54
Acid Filter
Inlet
Outlet
Dimensions (mm)
Connectperistaltic pump here
if used forPre-condensation
© ABB20-06-2019 Sales Training Sample Handling | 55
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
© ABB20-06-2019 Sales Training Sample Handling | 56
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
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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
© ABB20-06-2019 Sales Training Sample Handling | 58
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
© ABB20-06-2019 Sales Training Sample Handling | 59
© ABB20-06-2019 Sales Training Sample Handling | 60
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
© ABB20-06-2019 Sales Training Sample Handling | 61
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
© ABB20-06-2019 Sales Training Sample Handling | 62
Converter SCC-KVersion with solenoid valves
Byp
ass
Inlet
Outlet to Analyzer
Cat
alys
t
© ABB20-06-2019 Sales Training Sample Handling | 63
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
© ABB20-06-2019 Sales Training Sample Handling | 64
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
© ABB20-06-2019 Sales Training Sample Handling | 65
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
© ABB20-06-2019 Sales Training Sample Handling | 66
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
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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