The equipment showcase section includes products from a variety of vendors that serve the power generation industry. POWER magazine will feature a different power-related equipment category in several issues this year. This month the focus is on instrumentation and control solutions.
Flow Switch/Monitor Performs Double Duty to Cut Costs
The dual-function FS10i Flow Switch/Monitor from Fluid Components International (FCI) delivers two functions in a single instrument, providing process and plant engineers a flow monitor for the price of a flow switch. The FS10i is designed to provide a dependable high- or low-trip-point alarm. It also includes an analog 4–20 mA output signal at no additional cost. Configured in the field, the FS10i also eliminates the burden of additional calibration costs that are normally associated with other flow measurement applications.
The full-range capability of the FS10i Flow Switch/Monitor (Figure 1) can be employed in gas applications, including hazardous gases. It is ideally suited to monitor for seal leaks or compressed air leaks, or verify purge air flow. The FS10i’s analog span is established by simulating low-flow and high-flow conditions in setup mode. The 4–20 mA output, though non-linear, will then track the flow through that range. The FS10i Flow Switch/Monitor’s analog output is ideal for trending flows, and it can provide an early warning of clogged filters, pipe fitting leaks, wearing seals, pump problems, and other causes of flow disruptions.
Designed for reliability and dependable measurement, the FS10i Flow/Switch Monitor is the only instrument of its type and in its price range to carry a SIL 2 compliance rating. It has no moving parts to clog or foul and requires no routine maintenance. Fluid Components International, San Marcos, California
Online Instrument Measures Corrosive Ions in Water, Steam
Chlorides and sulfates cause pitting and stress corrosion in power plant components such as turbines and boilers, which can lead to extensive maintenance and unplanned shutdowns. Monitoring these ions at low-ppb levels has been identified as a key measurement in power plant chemistry.
The METTLER TOLEDO Process Analytics Thornton 3000CS Analyzer (Figure 2) provides online, trace-level chloride and sulfate measurements for corrosion control. The 3000CS uses microfluidic capillary electrophoresis, an ionic separation technology, to provide an alternative to expensive offline methods such as ion chromatography and inductively coupled plasma. The unit features semi-automatic calibration and an intuitive touchscreen interface, allowing operation without the need for extensive training. METTLER TOLEDO’s Intelligent Sensor Management technology in the analyzer provides diagnostics that predict when maintenance or replacement of consumables will be required.
“The 3000CS provides accurate chloride and sulfate measurement every 45 minutes without any operator intervention,” said Akash Trivedi, product manager for analyzers at METTLER TOLEDO Process Analytics. “It provides continuous monitoring of harmful ions and delivers a rapid return on investment by eliminating the need for costly internal or external lab tests.” METTLER TOLEDO Process Analytics, Columbus, Ohio
New Detector Monitors Toxic, Combustible Gases
The new Vanguard WirelessHART gas detector (Figure 3) from United Electric Controls provides explosion-proof, intrinsically safe detection and monitoring of toxic and combustible gases. The WirelessHART technology eliminates the need for costly wiring. Additional performance improvement and cost reduction features include one-touch calibration; easy mounting capability; reliable, high-speed communications; seamless integration with open control networks; interchangeable sensors; plug-and-play interoperability; and high environmental resistance.
The cost of adding one new gas detector measurement point, including the cost and labor of obtaining hot work permits, running conduit for wires, burying them, and so on, can be about $10,000 per device for land-based systems and as much as five times more for offshore applications. Wireless technology can reduce that by up to 90% while also making the plant much safer. The design and installation of wireless technology makes it more cost-effective to add sensing devices at multiple locations, detecting leaks that a sparse array of wired units might not notice until the situation had advanced to more harmful levels. The Vanguard detector can be easily configured, calibrated, tested onsite, and mounted anywhere.United Electric Controls, Watertown, Massachusetts
Compact Emissions Monitoring System Serves Smaller Combustion Processes
AMETEK Land has reintroduced its FGA 900 Series, a compact and fully integrated continuous emissions monitoring system (CEMS) for flue gas measurements on processes burning natural gas and biomass. The FGA 900 Series (Figure 4) is an extractive sampling multi-gas analyzer that accurately measures carbon monoxide (CO), nitric oxide (NO), and oxygen (O2) in flue gases, and calculates carbon dioxide (CO2) and nitrogen oxide (NOx), allowing for better process control.
“Most combustion processes are subject to some form of environmental regulation. Our FGA 900 Series is a simple CEMS especially suited for smaller applications,” said Derek Stuart, global product manager—power at AMETEK Land. “Its all-in-one design offers an attractive alternative to the traditional CEMS, which often encompasses multiple analyzers and requires a large amount of time and skill to specify, build, and test. The FGA 900 Series integrates the sample conditioning, gas analysis calibration, and data processing functions into a single, weatherproof system, providing a robust, reliable, and simple emissions measurement for regulatory compliance in smaller combustion processes.”
The FGA 900 Series is suitable for indoor or outdoor use, with fully weatherproof housing and optional heating or cooling for extreme environments. It is easy to install, and no specialist skills are needed for routine servicing. AMETEK Land, Dronfield, UK
Device Offers Communication Between Processes and Sensors
Today’s competitive business landscape means companies must keep an eye on critical process factors, along with the challenges of distance and environment. The PLICSCOM display and adjustment module makes it easy to operate VEGA level sensors wirelessly via Bluetooth and ensures user-friendly, measured-value transmission, even in hard-to-reach places or under safety-critical conditions.
VEGA sensors (Figure 5) with Bluetooth function are ideal for use in tall silos or tanks, in remote areas, and even in ex-hazardous areas. PLICSCOM, which offers wind and weatherproof adjustment, offers simple placement—just snap it into place, then download the VEGA Tools app and get started. A magnetic pen allows contactless operation of the control keys right through the closed lid.
VEGAPULS 69 and 64 sensors with 80-GHz transmission frequency are proving their worth in bulk solid, as well as liquid, applications, even in media with poor reflective properties, in conveyance shafts up to 120 meters deep, and in silos with numerous internals generating strong false echoes. These sensors determine levels with high precision down to the bottom of any container. VEGA Americas Inc., Cincinnati, Ohio
Laser Provides Distance Measurements
Hawk Measurement Systems has launched its OptioLaser 200 Series, a distance/level sensor that can be used for blocked chute detection, barrier detection, machine detection, stockpile monitoring, and point level measurement. The 200 Series features infrared 905-nanometer laser technology, a time-of-flight laser technology that is key to providing reliable and accurate distance and level measurements.
The OptioLaser S200 Series (Figure 6) uses an infrared semiconductor, GaAs laser diode. A light energy wavelength of about 905 nanometers, with a beam divergence of 3 milliradians (equal to 3 feet at 1,000 feet), travels to the material being measured. Any solid or liquid target in its path will reflect back a certain percentage of the emitted energy. The OptioLaser calculates the distance, based on the laser pulse transit time to the material and back. The Optiolaser can measure to most targets within its specified range, even penetrating dust and fog. Other benefits of the product include instant warning of level and position detection, fully automated plant systems with reliable level monitoring, reduced site operational costs, and non-contact measurement up to 1,600 meters for natural materials.Hawk Measurement Systems (Hawk America), Lawrence, Massachusetts
Tunable Diode Laser Offers Analysis for NOx Reduction Systems
Servomex has developed the SERVOTOUGH Laser 3 Plus Ammonia, a small cross-stack Tunable Diode Laser (TDL) gas analyzer specifically optimized for ammonia (NH3) measurements.
Optimized for use in hydrocarbon processing and power generation applications, Laser 3 Plus Ammonia (Figure 7) monitors NH3 in catalytic or non-catalytic NOx reduction systems. The analyzer works in gas-fired, oil-fired, or coal-fired processes. It delivers highly stable, low-ppm measurements, especially in the 2–3 ppm range typically specified for NH3 slip in deNOx applications.
The accurate measurement of NH3 that slips past a catalytic NOx converter is process critical: high levels of unreacted NH3 are costly for the plant operator, and can plug the catalyst due to salt formation within the flue gas. Without direct NH3 measurements NOx emissions can reach beyond permitted levels, resulting in plant shutdowns and potential fines. With the Laser 3 Plus analyzer installed in situ on the process, a cross-duct installation means ammonia levels can be measured with much greater certainty than in extractive methods.
The Laser 3 Plus Ammonia offers several installation benefits, including a compact design occupying a footprint up to one-tenth the size of comparable products. Laser 3 Plus Ammonia’s measurement stability is assured by line lock technology that uses an NH3-filled, sealed cuvette for a constant measurement reference. Servomex, Egham, UK