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ACXAdvanced CGA - System Solutions
Mauro Ogido, ABB Measurement & Analytics, Mayo 2019
© ABB20-06-2019 ACX | 2
ACXTable of Content
§ Application
§ System Design
§ Solutions
§ Communication & Remote Control
§ Features and Benefits
§ Documentation
§ Configuration
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ACXAdvanced CGA System Solution
§ A complete Analytical Measuring Systemfor different industrial applications
§ Monitoring and Operationvia the HMI in the front door
§ Bulkhead connectors for all mediums available
§ Interface connectors for Modbus / Profibusand Ethernet
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ACXApplications
Emission monitoring
§ Combustion of coal, oil and gas
§ Combustion of waste
§ Gasification
Cement Plants
§ Calciner Gas Exit
§ Wet Kiln Gas Exit
§ ESP Precipitator (Saftey relevant)
§ Coal bin and coal mill
Process Monitoring§ Optimization
§ Control
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Coal fired Power PlantsMeasurement Tasks Saftey
Monitoring
Denitrification( DeNOX ) Boiler
Coal bin
Coal MillElektrostatic-Precipitator
Desulphurisation( FGD )
EmissionMonitoring
NH3
Milk oflime
StackAir
EfficencyScrubber
EfficiencyDeNOx
ESP - SafteyMonitoring
CombustionControl
SafteyMonitoring
Generator
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ACXConcept
Continuously Operating System§ Using AO2000 series analyzers
§ Up to 6 components can be measuredsimultaneously
Sample Probe & Preparation§ Extractive Measurement
§ Complete product and support of application
Analysis based on ABB – TechnologyBest available technology using
§ IR & UV – Fotometer Uras and Limas
§ FID – Flame – Ionizations Analyzer MultiFID14
§ Paramagnetic O2 – Analyzer Magnosor O2 – sensor measurement
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ACXSystem Components
AO2040ABBPowerMaintError
IR
0
1 2 3
4 5 6
7 8 9
. _
MeasBack
ABB ABB
§ Advance Optima Analyzers§ Uras26
§ Limas11UV
§ Magnos206 / Magnos27
§ O2 - Sensor
§ MultiFID14
§ Sample Conditioning Components§ Probe tubes of the series 40 / 60 / H
§ Filter units PFE2 / PFE3
§ Heated sample lines TBL01-S and TBL01-C
§ SCC-C Cooler
§ SCC-F Gas feed unit
§ SCC-K NO2/NO - Converter
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ACXSystem Design
§ Installation in GENERAL PURPOSE (GP) areas
CSA approval (GP) available
§ Mounting plate • ambient temperature +5…+35°C
§ Preferred to use for installation in analyzer rooms
§ Steel sheet cabinet with ventilation fan • ambient temperature 0…+35°C
§ Steel sheet cabinet with cooling unit • ambient temperature 0…+50°C
§ Glass fibre cabinet with ventilation fan • ambient temperature -20…+35°C
§ Glass fibre cabinet with cooling unit • ambient temperatures -20…+50°C
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ACX System design
Electr.Distr.
Controller
Mounting plate Cabinet
AnalyzerModules
Converter
FIDAS
Valves
SCXSCC-Products
BottlesCond.Reag.Kat.
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ACXExterior and interior views
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ACX • Analyzer housing for 3 modules
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ACXSystem Components
Filters
PFE2
PFE3
Lines CoolerFeeding
SCC-CCooler
SCC-FGas Feed Unit
And more...
SCC-KNOx-Converter
Acid filter
Condensate trap
…..
TBL01-S
TBL01-S / C
Probes
Probe 40
Probe 60
Heated Probe 42
Probe 2
Probe H
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ACX • Emission MonitoringUsing Version 3 of the Sample Gas Feed Unit SCC-F
Analyzer Cabinet
SCC-FSCC-C
CondensateH3PO4Dosing
Acid filter
Water trap
SCC-KNO2-/NO
Ambientair
NO
CO, SO2O2
Uras 26P
Exhaust
NO
CO, SO2O2
Sample ConditioningFilter UnitPFE2 / 3
HeatedSample line
TBL01-S
Analyzer
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AO2000 Series Analyzers
Certified
Component Method Smallest Largest EN 15267
CO IR 75 mg/m³ 4000 mg/m³ yes
CO2 IR 20 Vol% yes
NO IR 100 mg/m³ 5000 mg/m³ yes
SO2 IR 75 mg/m³ 8000 mg/m³ yes
N2O IR 100 mg/m³ 6700 mg/m³ yes
O2 Sensor 10 Vol% 25 Vol% yes
Measuring Range
AO2000 Uras26
Certified
Component Method Smallest Largest EN 15267
O2 Paramagn. 10 Vol% 25 Vol% yes
AO2000 Magnos206 / 27
Measuring Ranges
Combination of components and ranges depends from the application
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AO2000 Series Analyzers
Certified
Component Method Smallest Largest EN 15267
VOC FID 15 mg/m³ 60 mg/m³ yes
AO2000 MultiFID14
Measuring Ranges
Certified
Component Method Smallest Largest EN 15267
NO UV 33,5 mg/m³ 200 mg/m³ yes
NO2 UV 125 mg/m³ yes
NOx 1) UV 50 mg/m³ 300 mg/m³ yes
SO2 UV 75 mg/m³ yes
O2 Sensor 10 Vol% 25 Vol% yes
1) Using NO/NO2 Converter SCC-K . Expressed as NO2
AO2000 Limas11
Measuring Ranges
Combination of components and ranges depends from the application
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Laser Analyzer Module LS25Easy Integration into ACX
Certified
Component Method Smallest Largest EN 15267
NH3 Laser 10 mg/m³ 15 mg/m³ yes
H2O Laser 30 Vol% 50 Vol% yes
1) With 1m gas path
Laser LS25
Measuring Ranges 1)
§ Single – line spectroscopy
§ Adujstment of the measuring ranges within the
physically ranges
§ Optical path length 0,5 – 6,0 m
§ Using AO2000 platform
§ Compatible with all AO2000 modules
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ACX Process Measurement • Example
M MM
P
P
External Analysis System
CATALYST
Instrument Air
Zero
Gas
Spa
n G
as
Bur
ner G
asProbe PFE2
with Back Purging
MultiFID14 SO2Limas11
NO
CO
Uras26
Magnos27O2
N2CnHm/
N2H2
Inst.Air
Analyzer Advance Optima
Analyzer Advance Optima
NO2/NOConverter
Samlpe GasCooler
Sample GasFeed Unit
Condensate DosingReagent
AcidFilter
Air
In
By
1
2
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ACXDual Sampling and Dual Switching
§ Dual switching at different sampling points
§ Dual switching at the same sampling point
§ Dual sampling at calciner exit
§ Dual simultaneous sampling
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ACX Dual Sampling / Switching
§ Dual Sampling§ 2 parallel measuring lines throughout the system (2x 100 l/h)
§ Optional: Automatic Back Purge
§ Uras with 2 gas in- and outputs; CO+CO; Option CO/NO + CO/NO
§ 2 additional Magnos 27 possible
§ Dual Switching§ 2 parallel probes/sample lines
§ Switching in front of SCC-C unit
§ Pre-Sampling unit
§ SCC-F unit with bypass (100 + 200 l/h)
§ Uras, Magnos, Limas…
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ACX Dual Sampling
Sample Gas Line L < 10m(recommended)
Dual Simultaneous Sampling
Steel Braided CompressedAir Lines, L= 6m
Sample Probe Type 2• Parallel Preheaters• Gas Ducts
P
5 Lit
T< 450°C
T< 450°C
Different Sampling points:• Parallel Preheaters and Gas Ducts• Within 10 m• Pneumatic Lines L= 6m• Automatic Back Purge Box in between
Compressed Air Requirement:4- 6 bar, free of oil-and water droplets; Dried to 5°Cbelow ambient temperature.Recommendation: Instrumental compressed air (-30°C)
• Common back purging (sample interruption)• Common Aut. Calibration
Back Purge Box 2.2
SCC-F
SCC-C
100 l/h100 l/h
ElectricDistribution& SystemController
IP 54
Mounting Plate
Installation in an air conditioned room
Condensate
Sample Gas
N2
ACX Dual Sampling
Uras 26Option:Magnos
Option:Magnos CO CO
Control Box
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ACX Dual Sampling
SCC-C
100L/h100L/h
Sample Gas Line L < 10m (recommended)
Sample Gas Line
Dual Simultaneous Sampling
Probe Type 40• 2 stages Back Purge
Steel BraidedCompressedAir Lines,L = 6m
ElectricDistribution& SystemController
IP 54
Mounting Plate
Installation in an air conditioned room
Condensate
ACX Dual Sampling
2 1B
P
5 Lit
SCC-F
• Common back purging (sample interruption)• Common Aut. Calibration
2 1
B
Different Sampling points• Within 10 m• Pneum. Lines L= 6m• Aut. BP Box in between• Parallel Preheaters and Gas Ducts
Uras 26CO CO
Option:Magnos
Option:Magnos
Sample Gas
N2
Compressed Air Requirement:4- 6 bar, free of oil-and water droplets; Dried to 5°Cbelow ambient temperature.Recommendation: Instrumental compressed air (-30°C)
Control BoxBack Purge Box 4.2
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ACX Dual Swichting
Sample Gas
ACX Dual Switching
CO NO
Condensate
SCC-C100L/h
Bypass
Same Sampling Point / No Sampling Interruption
Uras 26
100L/h
ElectricDistribution& SystemController
IP 54
N2
Mounting Plate
Installation in an air conditioned room
O2Magnos 27
Sample Gas Line < 10m
Steel BraidedCompressed AirLines, L = 6m
Same Sampling Point:• Preheater (ESP) Gas Duct• No sampling interruption• With L < 10 m and Tube < 1m :
CO T90-System time 30 sec approx.
Pre-Sampling
Safety Relevant measurementdue to no sampling interruption !
SCC-F2x Probe Type 40
2 1B
P
5 Lit
2 1
B
Back Purge Box 4.2
Compressed Air Requirement:4- 6 bar, free of oil-and water droplets; Dried to 5°Cbelow ambient temperature.Recommendation: Instrumental compressed air (-30°C)
Control Box
• Alternating Back Purge (No sampling interruption)• Common Aut. Calibration
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ACXAdjustment Concepts
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Extractive operating CGA – SystemAdjustment Concepts
Sample Line
Ambient AirZero Point & Single Point Adjustment
InternalAdjustment Cell
Sample ConditioningProbe System
Test Gas2
1
3
Analyzer
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Adjustment ConceptsTerminology
§ Adjustment§ Check of a CGA - System during normal operation at
§ Zero point§ Reference point
§ The typically check for QAL 3 monitoring in Emission monitoring
§ Required minimum 1 time per maintenance interval
§ Suitable standards
§ Gas filled adjustment cells§ Analyzer internal auto - facilities
§ Ambient air
§ Cylinder test gases (Flowing test gas)
Adjustment cell UV-Analyzer
Adjustment cell IR-Anaylzer
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Adjustment ConceptInternal auto-adjustment
§ Reference Point with gas filled quartz cells§ Melt quartz cells with high tightness
§ 1 cell for each measuring component
§ High stability also by critical gases like NO and NO2
§ Reference measurements shows high stable values
of the set point with < 0,4% per year
§ Long term stability test by the TÜV
§ Zero Point§ Ambient air, clean and dry
§ 12 months maintenance interval by using adjustment cells
§ Check with flowing test gas 1 time / year > AST
Adjustment cell UV-Analyzer
Adjustment cell IR-Anaylzer
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UV - AnalyzerStability of adjustment cells
years
Limas 10.4 % / a
Limas 20.3 % / a
Adjustment Cells NO
300
310
320
330
340
350
360
370
380
390
400
ppm
1 2 3 4 5
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Adjustment ConceptsInfeed of Test Gas in front of the Cooler
Sample Gas Probe
Test GasesSCC-FSCC-C
Analyzer
AmbientAir
External Analyzer Cabinet
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Adjustment ConceptsInfeed of Test Gas at Probe System acc. to US EPA
SCC-FSCC-C
Analyzer
AmbientAir
Sample Gas Probe
Test Gases
AmbientAir
External Analyzer Cabinet
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ACXAnalyzer adjustment
§ Auto calibration is standard
§ Uras26 and Limas11UV with
calibration cells
No test gas bottles required
§ Magnos206 and O2 - Sensor
Single - point calibration with ambient air
§ Magnos27 and MultiFID14 via streaming gasflow
Adjustment cell UV-Analyzer
Adjustment cell IR-Anaylzer
© ABB Dec-12 CEM / Technologies | ‹Nr.›
Extractive operating CGA – SystemSingle Point Calibration with Ambient Air
Magnos206Paramagnetic Oxygen analyzer
§ Analyzer has stable span point
§ The calibration method : single point
§ zero calibration with : ambient air
with well-known oxygen concentration,
e.g. ambient air 20.96 Vol%
Sensorsignal
Vol% O2
© ABB Dec-12 CEM / Technologies | ‹Nr.›
Extractive operating CGA – SystemSingle Point Calibration with Ambient Air
Electrochemical O2 sensor
§ Analyzer has stable zero point
§ The calibration method : single point
§ zero calibration with : ambient air
with well-known oxygen concentration,
e.g. ambient air 20.96 Vol%
Vol% O2
Sensor signal
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ACXControl & Maintenance
Maintenance
•Values•Status•I/O‘s
ModbusProfibus
• Control• Diagnosis• Datalogging• Service• Updating
Modem /ISDN-Router
Ethernet TCP/IP
Trigger
AOOPC-Server
RemoteMaintenance
RemoteMaintenance
• AnalyzeIT Explorer
• QAL3 Quality
Analog ( Output / Input )Digital ( Output / Input )
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AnalyzeIT ExplorerQAL3 Quality monitoring & Maintenance support
Continuously quality monitoring according EN 14181Supports Plant owners in monitoring and reporting Drift and Precision of an AMS
Evaluation according CUSUM or Shewhart Control charts
Fully automated for an AMS equipped with AO2000 analyzers
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ACXProfitability – Save money and time
Longest maintenance intervals§ Reduction of maintenance efforts
§ Auto-calibration with adjustment cells
Modern serial communication§ Ethernet, Profibus, Modbus
§ Saves cabling and engineering costsconnecting to your DCS or DAHS for CEM reporting
Remote monitoring§ Unattended operation through remote monitoring
via standard Ethernet and PC
§ Cost reduction for routine maintenance
Ethernet
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ACXFlexibility and Smartness
Easy changing of measuring ranges§ During the liftetime new measuring
ranges might be required
Function block programming§ Easy adaption of back-purge cycles for probes
§ Adding of external signals
Control
§ HMI in local languages (latin letters)
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ACXReliability
High availability§ Proven analyzers and components
Self monitoring§ Clear text warnings and alarms in case
of a malfunction before the system fails
Spare Parts§ 24 h availability of spare parts
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Ready for operation§ All you need is …
§ Electrial power supply
Maintenance costs§ Up to 50% reduced maintenance costs
by 6 months certified maintenance intervalcompared to competitor systems
Certified Service§ More than 60 manufacturer trained and certified
service engineers world-wide
ACXReliability
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ACX Documentation / Data Sheets / Questionnaire