2010-06-03 - Stringent European and UK legislation imposes statutory limits on gaseous and dust emissions to the atmosphere from industrial plant. Power generators must comply with the Large Combustion Plant Directive – LCPD (Directive 2001/80/EC), and incinerators of waste materials must comply with theWaste Incineration Directive –WID (Directive 2000/76/EC). ABB Process Analytics manufactures emissions monitoring solutions to help plant owners meet these compliance needs.
Operators of power plant of greater than 50 MW capacity are required to measure SOx and NOx emissions continuously. Operators of waste incinerators – which can range from small scale biomass plants of greater than 5MW to large-scale municipal waste incinerators greater than 200MW – are required to measure the same gases and also typically CO, HCl, NH3, TOC and sometimes HF.
The LCPD andWID directives place obligations on plant owners to ensure that CEMS are available for not less than 97%. Furthermore, owners of plant operating underWID are obliged to stop their processes – and therefore suffer a loss of revenue – if their CEMS fail for more than 4 hours.
ISO and EN standards define the performance, reliability and maintenance requirements of the gas analysers in CEMS. These requirements are regulated in the UK by the Environment Agency. Plant owners are obliged to report to the EA their annual emissions statistics, and also to report occasions when emissions limits are exceeded. Buyers of CEMS, therefore, attribute the greatest importance to meeting these legislative demands, and selecting gas analysers that provide the reliability and performance demanded. ABB Process Analytics gas analysers are approved under the EA’s type testing scheme called MCERTS, and they comply with the demands for ongoing Quality Assurance of CEMS defined by EN14181, so that buyers are assured that ABB provides instruments fit for purpose.
ABB Process Analytics gas analysers used for CEMS have been designed and manufactured for almost 100 years. Only proven analytical methods are used. For LCPD power generators, the AO2000 series of infra-red and ultra-violet photometric analysers are used, packaged into the ACX system.
For WID incineration processes, the ACF-NT Fourier Transform Infra-Red (FTIR) spectrometers are used. Both methods extract a sample of representative gas from the process – usually the final chimney – to a floor-mounted, accessible and weather-proofed analyser cabinet.
In either case, ABB Process Analytics custom-engineers each CEMS for each application at its UK engineering and build centre. ABB Process Analytics typically integrates into the emissions monitoring system dust measurements using MCERTS-approved particulate analysers, and flow measurements, so that mass flow emissions calculations can be offered to the EA. Furthermore, sophisticated data capture and reporting software is provided to make all the calculations required.
In order to meet the requirements for 97% availability, many plant owners duplicate their gas and dust analysers to provide duty and standby pairs. ABB Process Analytics often engineers duplicated systems, and takes care to duplicate power supplies, communication highways to plant control systems, and data capture systems.
Such systems, and even simple single analysers, are supplied by ABB Process Analytics in a self-contained analyser house, designed specifically to meet each site’s requirements. On-site installation and hook-up time is minimised.
All CEMS require maintenance, at least semi-annually as is the case for ABB analysers. Therefore, buyers also pay attention to the service capabilities of their selected CEMS vendor. ABB Process Analytics assures post-sales support for its customers by retaining a team of 13 service engineers and back-up staff, dedicated to the commissioning, maintenance and service of CEMS.
More than 40 ABB CEMS are installed at most of the major power generation companies in the UK. Recent contracts for new CEMS have been awarded for new power stations under construction on the Isle of Grain, and in Devon.
More than 70 ACF-NT CEMS are installed at waste incineration plants in the UK, and more than 1,000 have been installed worldwide. Recent contracts for new CEMS have been awarded for new municipal waste incinerators under construction in East Sussex and on the south bank of the Thames Estuary.
Uvisor SF810i flame scanner with SIL-2 certification
ABB has combined its two highly successful flame scanner product lines, Uvisor™and Safe Flame DFS, into a new advanced Flame Scanner, the Uvisor™SF810i. This is a multi-fuel, SIL-2 certified scanner designed to provide stable and reliable information on both the flame consistency and the flame quality in utility and industrial boiler burners.
In a single robust housing, the Uvisor™SF810i embeds state-of-the-art technology including:
Solid-state sensor module, covering the whole flame-radiant spectrum (UV-Vis-IR and dual sensor UVIR).
Signal Processor Unit – an extremely powerful module to run the ABB proprietary flame analysis process. Live measurement of the dynamic flame parameters are constantly subjected to an extensive fail-to-safe validation routine, prior to indicating the flame status.
Communication drivers. Two redundant Profibus DP-V1 links (or alternatively Modbus standard), are available to provide high-speed data transfer to an external monitoring and supervisory system.
Termination and configuration board.With local display and pushbuttons to allow the preliminary set-up and on-line aiming assistance. All I/Os terminations are available on screw-type removable connectors.
The Uvisor™SF810i flame scanner is available with accessories for the following installations:
Line of sight (LOS) for wall-fired burners boilers Fiber optic cable (FOC) with outer guide pipe, cooling hose and fitting flanges for corner-fired tilting burner boilers.
The PC-based Flame Explorer package provides extended set-up, parameter file archiving, groups view and advanced diagnostics, including flame raw data, real-time and historical trends of up to 254 networked scanner heads.