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

Flow measurement sometimes but not always used – many mass
flows are calculated

New standard will give requirements – and gives guidance on flow metering techniques
ABB Company Confidential
CEMS Standards
Europe

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
ABB Company Confidential
FPD580 StackFlowMaster
First 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
ABB Company Confidential
FPD580 StackFlowMaster
Why use Averaging Pitot for Stack Measurement

Low installation costs


Available in a variety of materials


to suit different processes
Multi-port instrument


Max two stabbings to be cut into stack
(only one if not end supported version)
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
ABB Company Confidential
How Averaging Pitot Tubes work
Measures the mean fluid velocity
without the need for traversing
Differential Pressure Output
Connected to DP Measuring Instrument
High
Pressure
Low
Pressure
LP Inner Tube
Upstream HP
sensing holes
Outer Impact
Tube
The ABB averaging pitot:

Multi-port meter across full diameter
‘auto-traverses’

Resultant differential pressure is
proportional to the square of the volume
flow rate
HP Inner Tube
Static LP
pressure point
Upstream HP
sensing holes
ABB Company Confidential
FPD580 StackFlowMaster
Torbar Edge - Better performance and stability

Profiled
flats
Low
Pressure
Tube

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
ABB Company Confidential
FPD580 StackFlowMaster
Torbar Edge – Easier handling

Easier handling for large diameter stacks

probes above 5 metres are in two pieces with centre coupling

simplifies shipping and handling; may simplify installation
ABB Company Confidential
FPD580 StackFlowMaster
Why choose StackFlowMaster?

Averaging pitot tube technology


EN15267-3 & MCERTS approval


enables purchase of complete package from
single supplier/manufacturer
Enables CEMS upgrades


no physical user intervention required
Supply with ABB CEMS analyser


satisfies QAL1 & QAL3 requirements.
Optional automatic zero/span checks


approved under the new standards
to meet the new legislation
Robust for long term use

minimal maintenance
.
ABB Company Confidential
FPD580 StackFlowMaster
Torbar advantages

Easy to install



Robust meter with a long service life

Reduces risk of expensive failures

Stronger construction than those with special
profiles
Offers good quality, stable measurement


Requires only a simple one - or two - stabbing
insertion
Due to unique sensor profile
Special end support designs give greater
integrity

From ABB's many years of experience
ABB Company Confidential
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 measurement
with temperature input
 remote mounted in interface unit
 Automatic interface unit
 3 versions
 MCERTS pending for automatic zero/span
versions
ABB Company Confidential
FPD580 StackFlowMaster
FPD585 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
ABB Company Confidential
FPD580 StackFlowMaster
Purging

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
Contaminated
Flue Gas
Purge Air
Data
ABB Company Confidential
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
ABB Company Confidential
FPD580 StackFlowMaster
ABB supplies complete CEMS
Data acquisition and reporting
Mass flow
Dust
O2 combustion
SOx, NOx, CO, HCl, HF, NH3…
ABB Company Confidential
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 ports
available
ABB Company Confidential
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
ABB Company Confidential
Stands 47 and 48
Steve Donnelly, CEMS specialist
ABB Company Confidential