mauro ogido, abb measurement & analytics, mayo 2019 acx

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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

© ABBjun-19 CEM / Technologies | 5

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


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


VOC FID 15 mg/m³ 60 mg/m³ yes

AO2000 MultiFID14

Measuring Ranges

Certified


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


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


IP 54

Mounting Plate


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


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


IP 54

N2

Mounting Plate


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


Control Box

• Alternating Back Purge (No sampling interruption)• Common Aut. Calibration

© ABBjun-19 CEM / Technologies | 23

ACXAdjustment Concepts

© ABB20-06-2019 ACX | 24

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



© ABB20-06-2019 ACX | 27

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



© 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

© ABB20-06-2019 ACX | 33

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

mauro ogido, abb measurement & analytics, mayo 2019 acx

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