ACF5000 Multi-component FTIR emission monitoring system

Transcription

1 Data sheet DS/ACF5000EN Rev. E ACF5000 Multicomponent FTIR emission monitoring system Measurement made easy From the pioneers in FTIR CEMS Continuous, quantitative and selective measurement of HCl, HF, H2O, CO, CO2, SO2, NO, NO2, CH4, NH, N2O, H2CO, O2 and VOC (other gases on request) Maximum 15 measuring components (standard), simple upgrade on request Proven hot wet extractive measurement technique High stability, accuracy and reliability through proven FTIR technology Fully integrated VOC and O2 analyzers (optional) Cleartext status messages and userfriendly operator interface on a large backlit display Measured value and status signal transmission to DCS and emission evaluators via Ethernet or Modbus TCP (analog and digital outputs, Modbus and PROFIBUS optional) Local control for service purposes via Ethernet and remote maintenance via UMTS Integration and display of signals from other detectors (e.g. dust, mercury, flow, pressure, temperature) Unique airdriven injector pump, no moving parts, low condensate to handle QAL automatic span drift check without test gas Low ownership, maintenance and installation cost through multicomponent measurement technology with only one sampling system Complete preengineered system, modest space requirement, compact and modular system design

2 ACF5000 Multicomponent FTIR emission monitoring system Introduction Application and design As a result of the growing requirements in the field of environmental monitoring, increasing number of pollutants and with lower concentrations has to be measured from combustion processes. World leader in stack gas monitoring systems for decades and pioneer in FTIR technology, ABB Analytical is offering an inexpensive and forwardlooking system with the ACF5000 multicomponent FTIR emission monitoring system. Recognized by the process industries for their ruggedness, the ABB FTIR spectrometers offer a measurement technology with the highest levels of accuracy, selectivity and reliability. As a result of the FTIR measurement principle, the spectrometer is free from drift and does not require frequent calibrations, therefore there is no need to hold stocks of expensive, dangerous and toxic test gases. Because it can easily be expanded through software to measure additional infraredactive components, the analysis system is also designed to expand with your future needs. The sampling probe, sampling line and analyzer cell are heated allowing water vapor to be measured along with extremely low detection levels of pollutant such as HCl, NH and HF. The sample gas feeding is using an electronically controlled air injector, which creates a vacuum. This draws the sample gas into the analyzer cell without the use of a mechanical pump. Thus, no moving part is used resulting in less maintenance. As a beneficial side effect, the sample gas is diluted at the analyzer cell outlet, condensation is reduced and disposal of the exhaust gas is safer. Applications Municipal waste incinerators Biomedical and sludge incinerators Hazardous waste incinerators at chemical plants Gasification and pyrolysis processes Cement kilns Solvent recovery and destruction DeNOx and DeSOx of power plants Crematoria Steel and aluminum smelters Brick, tiles and glass manufacturing Catalyst protection monitoring Combustion research System devices and subassemblies Sampling system Probe tube, optionally heated, lengths 500 to 2500 mm / 20 to 100 in. for process temperature up to 500 C / 92 F (optional up to 150 C / 2462 F) Filtering device, heated to 180 C / 56 F Sample gas lines, heated to 180 C / 56 F, length up to 60 m / 200 ft. (length depending on installation location altitude, other lengths and temperature on request) Protective cover for probe Probe back purge module (optional) Automatic injection of test gases at probe for drift check (optional) Sample gas conditioning unit Heated sample gas conditioning block with builtin stainless steel microporous filter Air driven aspirator pump module Connection and automatic switchover for zero and calibration gas supply Flow, pressure and temperature monitoring Analyzers FTIR spectrometer with heated sample cell Oxygen analyzer (ZrO2 detector, optional) VOC analyzer (FID detector, optional) Control and display units Display and operator control unit built into cabinet door AO2000 system controller Control module for the injector pump Interfaces for Measured values and status signals via Ethernet (OPC) and Modbus TCP (analog and digital outputs, Modbus and PROFIBUS optional) Remote diagnostics via Ethernet and UMTS (optional) Prepared for uninterrupted power supply of the most vital subassemblies (optional) Air purification unit A compressedair purification unit (molecular sieve) is used to provide zero gas for the FTIR spectrometer and reference gas for the oxygen analyzer. Purge air is also used by the spectrometer and also to purge the analysis system in the event of heating failure or loss of power. 2 DS/ACF5000EN Rev. E ACF5000

3 Operation The software installed in the system controller operates the analysis system completely automatically. It allows the following functions: Display of all measured results and clear status messages Manual operation of the system for commissioning and service Local operation for service purposes via Ethernet interface Remote diagnosis via UMTS Selfdiagnosis of the FTIR spectrometer and archival of the status signal and measured data Optional automatic correction for dry/wet basis and reference measurement (to a fixed O2 value) The FTIR results are updated approx. every 0 seconds. The system controller continuously monitors the temperature, pressure and gas flow to ensure automatic correction, reliability and precise measurement. If the temperature of any heated module of the analysis system falls below the minimum allowed, a stream of clean air purge is triggered to protect all subassemblies that are in contact with the sample gas. The Ethernet interface allows the analysis system to be coupled to the plant network for transfer of measured values and status signals. Data can be read using the AnalyzeIT Explorer or AOOPC Server software tools. The UMTS connections give access to the ABB Service Department (when enabled by the customer) for remote diagnosis and preventive maintenance scheduling which enables maximum system availability. Calibration All FTIR devicedependent factors are taken into account through the daily automatic recording of the zero spectrum. Since absorption spectra are absolute and do not drift, zero and span are effectively automatically corrected using zero gas only. N2 is used for zero calibration of the VOC analyzer. % of O2 is used for zero calibration of the O2 sensor. Manual calibration check with gases and water vapor can easily be done at the analyzer cell or at the sampling probe according to internationally recognized requirements. Validation unit for automatic span drift check without test gases The ACF5000 can be optionally equipped with a validation unit as an alternative to flowing test gas for the FTIR spectrometer. The validation unit is a disc with six holes of which five holes hold films or gas filled cells which can be swiveled into the optical path causing a spectral absorption for the corresponding components, e.g. HCl. Hence the validation unit can be used to monitor precision and drift, e.g. as part of a QAL procedure or any other driftmonitoring procedure. The benefit is that there is no need to introduce any test gases during normal operation. Only if a deviation between the expected value and the measuring value is detected, test gases are required to check the deviation. Certification (in preparation) CEM system certification according to EN Suitability for measurement tasks according to European Directives 2010/75/EC, 2000/76/EC, 2001/80/EC and quality assurance according to EN Compliance to US EPA 40 CFR 60 and 40 CFR 75 GOSTR certification ACF5000 DS/ACF5000EN Rev. E

4 ACF5000 Multicomponent FTIR emission monitoring system Technical data Measured components and measuring ranges FTIR 1) Low range High range H2O CO vol.% 0 0 vol.% CO 0 75 mg/m 0 60 ppm mg/m ppm NO mg/m ppm mg/m ppm NO mg/m 0 40 ppm mg/m 0 00 ppm N2O 0 50 mg/m 0 25 ppm mg/m ppm SO mg/m 0 25 ppm mg/m ppm NH 0 5 mg/m 0 7 ppm 0 20 mg/m 0 00 ppm HCl 0 15 mg/m 0 10 ppm mg/m ppm HF 0 mg/m 0 ppm 0 6 mg/m 0 7 ppm CH mg/m 0 10 ppm mg/m ppm CH2O 0 20 mg/m 0 15 ppm VOC 2) 0 0 mg/m 0 15 ppm 0 00 mg/m ppm FID VOC 0 15 mg/m 0 8 ppm 0 00 mg/m ppm O2 sensor O vol.% 1) FTIR spectrometer performance is based on an optical path length of.2 m / 126 in. 2) VOC measured with FTIR (for process measurement only) is composed of the organic compounds methane (CH4), ethane (C2H6), propane (CH8), benzene (C6H6), toluene (C7H8) and dichloromethane (CH2Cl2). Measuring ranges within ignition limits cannot be provided. Other measured components and measuring ranges on request. Performance for low measuring ranges in accordance with EN Crosssensitivity < 4 % of measuring range Linearity < 2 % of measuring range Sensitivity drift < % in maintenance interval Zero drift Corrected automatically Influence of ambient temperature changes < 5 % of measuring range per 10 K / 18 F temperature change Air pressure influence None (automatically corrected through internal pressure compensation) Limit of detection (2 ) 2 % of measuring range System design Design Free standing cabinet in sheet metal Air conditioning unit optional Protection class IP54 Dimensions See Section System design (exterior view), page 6 Weight Approx. 00 kg / 660 lb. Color Light gray (RAL 705) Input, output and status signals Measured signals Output via Ethernet or Modbus TCP (analog and digital outputs, Modbus and PROFIBUS optional) Status signals Output and status signals from the measured concentrations, gas transport, sample conditioning system and operation are displayed on the builtin LCD display Status signals: System failure, maintenance mode, maintenance request, oxygen analyzer error, VOC analyzer / ASP failure and FTIR failure Input signals Analog and digital signals possible Response time (analysis system) T90 < 200 seconds, T90 < 400 seconds for HCl, NH and HF 4 DS/ACF5000EN Rev. E ACF5000

5 Gas connections Sample gas inlet Special support for heated line in the right cabinet wall Screw fitting at ASP block for heated line TBL01 (4/6 x 1 mm) Sample gas outlet Screw fitting (steel) for pipe 12 mm or ½ in. Test gases Screw fittings for hose (PTFE) 4/6 x 1 mm or ¼ in. Instrument air Connected to the aspirator pump module and compressedair purification unit (hose 4/6 x 1 mm or ¼ in.). Quality: Based on ISO 8571:2001 Class 2 (max. particle size 1 5 μm, max. 10 particles/m, max. oil content 0.1 mg/m, max. vapor pressure dew point 40 C / 40 F). The requirement is for compressed air at bar / psi, l/h / cfm. Power supply Input voltage 20/400 V Ph, N, PE or 120/208 V Ph, N, PE or 100/200 V Ph, N, PE (optional, with transformer), 10 %, 48 to 62 Hz. Nonfloating PEN conductor not allowed. Power consumption System incl. probe filter at powerup during operation Heated probe tube type 42 Heated sampling line TBL01 Air conditioning unit (optional) Prepared for UPS (optional) approx W approx W approx. 800 W approx. 90 W/m approx W approx. 500 W Overvoltage category/pollution degree II/2 Service socket 20 VAC or 120 VAC, 48 to 62 Hz, max. 5 A (located in the cabinet light) Sample gas inlet conditions Temperature Controlled at C / 56.6 F Pressure Analysis cabinet inlet to sample gas conditioning block: hpa ( bar / 1 16 psi), lower pressure on request Flow rate Approx. 00 l/h / 0.18 cfm Environmental conditions Ambient temperature In operation without air conditioning unit 5 to 0 C / 41 to 86 F with air conditioning unit (optional) 5 to 45 C / 41 to 11 F During storage and transport 25 to 65 C / 1 to 149 F Relative humidity 75 % as an annual average, max. 95 % for short periods, occasional and light condensation is permissible, supposed powered and purged system Installation location The analysis system is intended for indoor use only. The analysis system should be protected against radiated heat, heavy concentrations of dust, corrosive atmospheres and vibrations. Minimum distances for analyzer cabinet installation: Right Left Front min. 500 mm / 20 in. for the connected cables and pipes min mm / 40 in. for the air conditioning unit (optional) min mm / 40 in. to open the door (hinged at left) Top min. 500 mm / 20 in. with air conditioning unit (optional) Installation location altitude max. 720 m / 260 ft. above sea level in accordance with EN (for length of sample gas line incl. probe = 60 m / 200 ft.); greater altitudes on request. Storage and transport It is mandatory that the cabinet or the FTIR spectrometer is hermetically sealed during storage and transport. Note The drawings on the following pages are for general information only. Each individual analysis system is delivered with a set of drawings specific to the order. ACF5000 DS/ACF5000EN Rev. E 5

6 ACF5000 Multicomponent FTIR emission monitoring system System design (exterior view) Dimensions in mm (inch) RIGHT SIDE LEFT SIDE min. 500 (19.7) ACF5000 SYSTEM CONTROLLER COOLING UNIT HEATED SAMPLE GAS LINE GAS INLETS / GAS OUTLETS ELECTRICAL INLETS / OUTLETS MAIN SWITCH POWER SUPPLY MAIN SWITCH UPS POWER SUPPLY SAMPLE GAS INLET SAMPLE GAS OUTLET BURNER GAS FID INSTRUMENT AIR IN PURGE GAS TO PROBE ZERO GAS O2 TEST GAS FTIR CABLE GLANDS SIGNALS CABLE GLANDS POWER SUPPLY BUS SIGNALS min (9.4) min. 500 (19.7) min (9.4) mm mm mm inch inch inch mm inch mm inch DS/ACF5000EN Rev. E ACF5000

7 System design (interior view) LEFT SIDE WALL, INSIDE DOOR OPENED RIGHT SIDE WALL, INSIDE ANALOG SIGNALS, STATUS SIGNALS CONTACTORS, RELAYS CIRCUIT BREAKERS NORMAL NET ETHERNET SWITCH TERMINALS, POWER SUPPLY 24VDC ACF5000 EBOX CIRCUIT BREAKERS UPS, FUSES, TERMINALS OXYGEN FID ANALYZER BOX ASP BLOCK FTIR CELL INTERFEROMETER BOX NEEDLE VALVES, PRESSURE CONTROLLERS, COCKS, FLOW METER VALIDATION UNIT FTIREBOX ACF5000 AIR PURIFIER 6 6 AIR DUCT ACF5000 DS/ACF5000EN Rev. E 7

8 ACF5000 Multicomponent FTIR emission monitoring system Pneumatics diagram EXTERNAL ANALYSIS CABINET EXTERNAL 5.5 bar INSTRUMENT SAMPLE GAS OUTLET AIR INLET FTIR SPECTROMETER bar FILTER 1μ OXYGEN FID DETECTOR 1.8 bar 4.5 bar 1.2 bar 2.0 bar HEATED FTIR CELL SAMPLE GAS IN COMBUSTION GAS BULKHEAD UNION PVDF 4/6x1 mm / ¼ BULKHEAD UNION SS16 6 mm / ¼ CONNECTOR SS16 6 mm / ¼ BULKHEAD UNION SS16 12 mm / ½ VOC ANALYZER VOC SAMPLE GAS INLET SAMPLE GAS OUT COMBUSTION AIR PURGE GAS ACF5000 AIR PURIFIER BULKHEAD UNION SS16 6 mm / ¼ WITH BUILTIN RESTRICTOR 10 l/h H2 SAMPLE POINT HEATED FILTER UNIT PFE2 ASP BLOCK INJECTOR PUMP PROBE HEATED SAMPLE TUBE GAS LINE TBL01 FOR CAL.GAS TYPE 42 CONNECTOR GENERATOR BLOCK HEATER ZERO GAS P COMBUSTION GAS FID H bar, 4 l/h PURGE GAS TO PROBE PURGING VALVE TEST GAS TEST GAS FTIR 1.5 bar DRIFT 1 DRIFT 2 DRIFT ZERO GAS O2 ZERO GAS FID ACF5000 EBOX SPAN GAS FID 8 DS/ACF5000EN Rev. E ACF5000

9 Connection diagram (power supply, CE version and CSA version) ANALYSIS CABINET CE VERSION, FUSES UNIPOLAR ANALYSIS CABINET CSA VERSION, FUSES UNIPOLAR POWER SUPPLY (BY CUSTOMER) FUSEPROTECTION EXTERNAL x 20 A CABLE 5x 6 mm2 (x 25 A) CABLE GLAND M2 (CABLE DIA. RANGE 715mm) X80 L1 L2 L N PE POWER SUPPLY 20/400 V ±10%, 4862 Hz (120/208 V ±10%, 4862 Hz) POWER SUPPLY (BY CUSTOMER) FUSEPROTECTION EXTERNAL x25a CABLE 5xAWG8 CABLE GLAND M2 (CABLE DIA. RANGE ") X80 L1 L2 L N PE POWER SUPPLY 120/208V ±10%, 50/60 Hz UPS POWER SUPPLY (BY CUSTOMER) FUSEPROTECTION EXTERNAL 20A CABLE x 2,5 mm2 (CABLE DIA. RANGE 61mm) X90 L1 N PE UPS POWER SUPPLY (BY CUSTOMER) FUSEPROTECTION EXTERNAL 20A CABLE xawg14 (CABLE DIA. RANGE ") X90 L1 N PE SAMPLE HEATER SAMPLE TUBE TYPE 42(E84/E85) CABLE x 1,5 mm2 (CABLE DIA. RANGE 61mm) CABLE x 0,75 mm2 (CABLE DIA. RANGE 510mm) CONNECTION VIA TERMINAL BOX ONSITE X81 1 X X l = 1 m: 400 W l = 1.5 m: 600 W l = 2 m: 800 W Pt 100 HEATING HEATED SAMPLE TUBE TEMPERATURE SAMPLE HEATER SAMPLE TUBE TYPE 42(E84/E85) CABLE xawg16 (CABLE DIA. RANGE ") CABLE xawg20 (CABLE DIA. RANGE ") X X l = 1 m: 400 W l = 1.5 m: 600 W l = 2 m: 800 W Pt 100 HEATING HEATED SAMPLE TUBE TEMPERATURE SAMPLE HEATER FILTER UNIT PFE2 (E86) CABLE x 1,5 mm2 (CABLE DIA. RANGE 510mm) X81 2 X W HEATING HEATED FILTER UNIT SAMPLE HEATER FILTER UNIT PFE2 (E86) CABLE xawg16 (CABLE DIA. RANGE ") X W HEATING HEATED FILTER UNIT CABLE x 0,75 mm2 (CABLE DIA. RANGE 510mm) CONNECTION VIA TERMINAL BOX ONSITE X Pt 100 TEMPERATURE CABLE xawg20 (CABLE DIA. RANGE ") X Pt 100 TEMPERATURE HEATED SAMPLE LINE TBL01 (E8) CABLE 5x2,5 mm2 OR x2,5mm2 (CABLE DIA. RANGE 61mm) CABLE x 0,75 mm2 (CABLE DIA. RANGE 510mm) X W/m *) 11 X X Pt 100 HEATING HEATED SAMPLE LINE TEMPERATURE HEATED SAMPLE LINE TBL01 (E8) CABLE 5xAWG14 OR xawg14 (CABLE DIA. RANGE ") CABLE xawg20 (CABLE DIA. RANGE ") X W/m *) X Pt 100 HEATING HEATED SAMPLE LINE TEMPERATURE SAMPLE SOLENOID VALVES BACK PURGING (Y.1/Y1.1/Y2.1/Y4/Y5) AND HEATER MEAS. GAS VALVE (E87/E88) CABLE 10x 1,5 mm2 (CABLE DIA. RANGE 61mm) X X W BACK PURGING VALVES WITH HEATED MEAS. GAS VALVE SAMPLE SOLENOID VALVES BACK PURGING (Y.1/Y1.1/Y2.1/Y4/Y5) AND HEATER MEAS. GAS VALVE (E87/E88) CABLE 10xAWG16 (CABLE DIA. RANGE ") X W BACK PURGING VALVES WITH HEATED MEAS. GAS VALVE *) max. 20/40 l 5 m [114.8 ft] (1 ~ ) l > m [ ft] ( ~ 120/208V l 15 m [49,2 ft] (1 ~ ) l > m [ ft] ( ~ ) *) max. 120/208V l 15 m [49.2 ft] (1 ~ ) l > m [ ft] ( ~ ) ACF5000 DS/ACF5000EN Rev. E 9

10 ACF5000 Multicomponent FTIR emission monitoring system Connection diagram (analog and digital outputs) ANALOG OUTPUT 1 ANALOG OUTPUT 2 ANALOG OUTPUT ANALOG OUTPUT 4 D81 ANALYSIS CABINET I1 A01 I2 I I4 A02 A0 A04 ANALOG OUTPUTS 420 ma LOAD MAX. 400 Ω ANALOG OUTPUT 5 ANALOG OUTPUT 6 ANALOG OUTPUT 7 ANALOG OUTPUT 8 D82 I1 I2 I I4 A01 A02 A0 A04 ANALOG OUTPUT 9 ANALOG OUTPUT 10 ANALOG OUTPUT 11 ANALOG OUTPUT 12 D8 I1 I2 I I4 A01 A02 A0 A04 ANALOG OUTPUT 1 ANALOG OUTPUT 14 ANALOG OUTPUT 15 ANALOG OUTPUT 16 D84 I1 I2 I I4 A01 A02 A0 A04 SYSTEM FAILURE SYSTEM MAINTENANCE MODE SYSTEM MAINTENANCE REQUEST O2 FAILURE COMMON POLE 1 D DIGITAL RELAYS OUTPUTS max. 110 V DC / 250 V AC, max. 1.5 A 60 W / 500 VA VOC/ASP BLOCK FAILURE FTIR FAILURE COMMON POLE DS/ACF5000EN Rev. E ACF5000

11 Connection diagram (analog and digital inputs, digital interfaces) ANALOG INPUT 1 (EXAMPLE: DUST) D89 ANALYSIS CABINET I1 AI1 ANALOG INPUT 2 (EXAMPLE: TEMPERATURE) ANALOG INPUT (EXAMPLE: FLOW) I2 I AI2 AI ANALOG INPUTS 420 ma R u = 100 kω R i < 125 Ω ANALOG INPUT 4 (EXAMPLE: PRESSURE) I4 AI4 SHIELD D91 DIGITAL INPUT 1 DIGITAL INPUT 2 DIGITAL INPUT DIGITAL INPUT 4 DIGITAL INPUT 5 DIGITAL INPUT 6 DIGITAL INPUT 7 DIGITAL INPUT DI1 DI2 DI DI4 DI5 DI6 DI7 DI8 DIGITAL INPUTS FLOATING CONTACTS Status 0: UL min / max 0 V DC / 5 V DC Status 1: UH min / max 11 V DC / 0 V DC IH min / max 2 ma / 4.5 ma PROFIBUS DP IN PROFIBUS DP OUT X87 DSUB 9Pin 8 X88 DSUB 9Pin 8 RxD/TxDP RxD/TxDN SHIELD RxD/TxDP RxD/TxDN SHIELD PROFIBUS MODBUS X89 DSUB 9Pin 2 RTxD RTxD 5 GND SHIELD MODBUS ETHERNET 10BASET X95 RJ TT 10TT 10TR 10TR ETHERNET VIA ROUTER UMTS ANTENNA U8 ANT REMOTE CONTROL VIA UMTS ROUTER ACF5000 DS/ACF5000EN Rev. E 11

12 Contact us ABB Limited Oldends Lane GL10 TA Stonehouse Gloucestershire, United Kingdom Phone: Fax: ABB Pte. Ltd. 2 Ayer Rajah Crescent 1995 Singapore, Singapore Phone: Fax: ABB Australia Pty Limited Bapaume Road 2170 Moorebank New South Wales, Australia Phone: Fax: ABB Ltd. 14 Mathura Road Faridabad, Haryana, India Phone: Fax: Note We reserve the right to make technical changes or modify the contents of this document without prior notice. With regard to purchase orders, the agreed particulars shall prevail. ABB does not accept any responsibility whatsoever for potential errors or possible lack of information in this document. We reserve all rights in this document and in the subject matter and illustrations contained therein. Any reproduction, disclosure to third parties or utilization of its contents in whole or in parts is forbidden without prior written consent of ABB. Copyright 2014 ABB All rights reserved DS/ACF5000EN Rev. E ABB Engineering Ltd. 10 Jiuxianqiao Lu Beijing, China Phone: Ext Fax: ABB Automation GmbH Stierstaedter Strasse Frankfurt am Main, Germany Fax: cga@de.abb.com Sales Service ABB Inc. 700 W Sam Houston Parkway South, Suite 600, Houston, TX 77042, USA Phone: