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Measurement Made Easy: For Power Plants
Measurement Made Easy: For Power Plants
A B B M E A S U R E M E N T & A N A LY T I C S
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Expertise in measurement technology
Delivering increased productivity
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Trusted measurement solutions
Serving the power generation industry
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Measurement and analytical products for power
Accurate and reliable operation
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Measure where it matters
Protecting the environment
Waste to energy and biomass power plants Thermal solar power plants
In a waste to energy process, heat is produced Solar thermal energy is created by generating
from the incineration of waste, which is then used heat from solar energy. An increasing number of
to produce steam. A key concern surrounding the solar thermal energy power stations are being
operation of waste to energy plants is controlling built worldwide as nations seek to reduce their
the gas emissions and level of particulate matter dependence on fossil fuels, reduce their carbon
produced by the incineration of waste. These footprint and create alternative sources of
include ash, heavy metals and acid gases, all of energy. In a solar thermal energy process, solar
which need to be carefully monitored and energy collected by high temperature collectors is
regulated. As well as instruments for optimizing used to heat water and generate steam, which
the combustion and electricity generation can then be used to generate electricity in the
processes, ABB’s measurement products same way as in any other thermal power process.
portfolio includes a wide range of gas analyzers ABB’s measurement products play a key role in
which can offer continuous rate measurement of thermal solar power applications, measuring a
individual key pollutants within the gaseous variety of parameters including temperature,
emissions from waste to energy plants. flow, pressure and water quality.
6 ME ASUREMENT MADE E ASY FOR POWER PL ANTS
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Accurate measurement
Reliable performance
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01
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01 AZ20 combustion Deriving combustion efficiency Controlling boiler chemistry for
gas oxygen analyzer
— by monitoring flue gas emissions maximum steam quality
02 Accurate
measurement of
multiple chemical
parameters Efficient combustion of a fuel in any industrial Achieving optimum performance of a coal-fired
— process is essential in cutting operating costs power plant requires careful monitoring of water
03 Accurate pressure
measurement for up whilst reducing pollution to enable compliance and steam quality.
to 600 bar (8,706 psi) with environmental legislation.
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04 Contrac actuator The challenge of controlling chemical
on an air damper The challenge of finding the right air/fuel mix contamination in the boiler
The ratio of air to fuel is a critical factor in Multiple chemicals need to be monitored and
efficient combustion. Where there is just controlled for optimum steam raising efficiency.
sufficient oxygen to ensure complete Dissolved oxygen in the feedwater can cause
combustion, this ratio is known as the pitting in the boiler, reducing its operating life.
stoichiometric mixture, and lambda equals one. Dosing the feedwater with hydrazine reduces
This is a theoretical value which cannot normally oxygen to form nitrogen and water. Excess
be achieved in industrial combustion processes. hydrazine is wasteful and costly, whereas too
Values for lambda of around 1.1 and above are little is unable to adequately control dissolved
more usual. oxygen levels. At high temperatures and
pressures, it forms ammonia, which raises the
Controlling the air supplied to the combustion feed water pH level, increasing the risk of
process is a fine balancing act. Insufficient air will corrosion. Silica can hamper heat transfer
mean incomplete combustion of fuel, resulting in efficiency and increase the risk of turbine
fouling of heat transfer surfaces and emissions of malfunction by its precipitation on the blades.
soot, smoke and carbon monoxide. If air levels are Sodium is a key parameter measured on the
too high, heat efficiency is reduced as the extra boiler. A highly sensitive on-line sodium monitor
air carries more heat away in the flue gas, is needed to measure sodium levels in critical
reducing overall boiler efficiency. dissolved compounds.
The solution is to measure your flue gas oxygen The solution is to measure multiple chemical
The level of oxygen present in the combustion parameters
waste gas is a key indicator of the amount of ABB’s solution includes pH analyzers for
excess air supplied to the process. Oxygen monitoring feed water acidity or alkalinity and
measurement is therefore critical when conductivity analyzers to measure ionic content.
optimizing combustion control for maximum By indicating the level of contamination, these
efficiency. can be used to dictate the type and duration of
treatment. ABB’s Navigator 600 Silica accurately
ABB’s AZ20 combustion gas oxygen analyzers monitors concentrations from 0 to 5000 ppb and
accurately measure the combustion gas oxygen substantially cuts the costs and maintenance
content, with versions available for applications associated with silica monitoring. ABB’s 8037 and
from -20 to 800°C (-4 to 1472°F). The analyzers 9438 on-line analyzers are used to monitor
can be used in conjunction with ABB’s Sensyflow sodium and dissolved oxygen respectively. ABB‘s
thermal mass flowmeters to regulate the amount equipment can also be used to reduce iron levels
of air supplied to the burner. to help minimize boiler corrosion.
ME ASUREMENT MADE E ASY FOR POWER PL ANTS 7
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02 03 04
Tighter control and safety with Maintaining the right air/fuel mix
temperature and pressure through effective damper control
measurement
Striking the right balance of air and fuel in the
combustion process can have a major impact on
Pressure and temperature are two of the most
power station energy efficiency and effective
widely measured parameters in a power plant.
heat-rate. It is therefore important to achieve
Ensuring that processes remain within set
precise regulation of the final control elements
temperatures and pressures can have a major
handling the mix of fuel and air in order to
impact on optimizing efficiency.
optimize performance.
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Proven measurement technology
In control of the process
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02
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01 ABB’s gas Measuring calorific values of gas Optimizing combustion and
chromatographs
for natural gas reducing emissions through
composition analysis
Calorific value is the amount of heat energy
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02 Gas analyzers released by burning a single kilogram of a given
continuous monitoring
installed in an
fuel. As each fuel has its own specific calorific
analyzer house
— value, measuring the values of fuels in a power Gaseous emissions from the stack are one of the
03 Accurate level
generation process is an ideal way of assessing biggest sources of pollution produced from a
control for maximum
boiler efficiency combustion efficiency. In coal-fired processes, it typical power plant. Among the pollutants of
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can also be a useful indicator of pollution, as most concern are NOx, SO 2 and CO. With strict
04 ABB swirl meters
help to reduce steam lower calorific values tend to be linked to higher legislation governing emissions from power
losses and save costs
ash levels. plant, continuous emission monitoring systems
(CEMS) are required to measure the emissions
The challenge directly.
Calculating the calorific value of a sample of
natural gas requires information on the The challenge of reducing pollution
composition of the gas. Though natural gas is Modern combined cycle power plants meet
largely composed of methane, it also contains emission rules by applying optimized combustion
variable amounts of other gases such as ethane, technologies and employing sophisticated flue
butane and propane, as well as non-combustible gas cleaning lines. In waste to energy processes,
gases like nitrogen and carbon dioxide. plant operators must use Continuous Emissions
Monitoring Systems (CEMS) with the highest
The solution levels of availability. In extreme cases, failure of a
ABB’s PGC1000 field mounted gas CEMS can require a plant shut down, resulting in
chromatograph provides the ideal solution for potential loss of revenue.
analyzing the composition of natural gas in
combined cycle power plants. A sample of gas is The solution is continuous emissions monitoring
drawn from the gas stream from the combustion Using only proven analytical methods, ABB’s
process which is then passed to the PGC1000 for CEMS gas analyzers can help energy plant
analysis. This sample is first treated before being operators to comply with local legislation
tested using a chromatographic process which wherever they are. The modular Advance Optima
separates the constituent gases to assess the system and the EasyLine series can be equipped
overall calorific value of the gas. Data from the with infrared or ultraviolet photometric analyzers
analyzer is then used to inform other devices in and with a paramagnetic analyzer or
the combustion process, such as ABB‘s flow electrochemical cell for measuring NO, NO 2 , SO 2 ,
computer units, to help achieve optimum CO, CO 2 and O 2 . These analyzers are also the heart
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combustion conditions. of the turn-key system solution ACX, ABB’s
01
complete system for extractive continuous gas
analysis. For incineration processes, ABB’s
ACF-NT Fourier Transform Infra-Red (FT-IR)
spectrometer based turn-key system can be used.
Both methods extract a sample of representative
gas from the process, usually the final stack, to a
floor-mounted, accessible and weather-proofed
analyzer cabinet.
ME ASUREMENT MADE E ASY FOR POWER PL ANTS 9
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03 04
Feedwater heaters pre-heat feedwater before it Installation costs and accuracy are amongst the
passes to the steam drum or boiler to be most important factors to consider when
converted to steam. choosing a technology to measure steam flows.
Many technologies may be unsuitable because
The challenge of maximizing boiler efficiency their upstream and downstream piping
The feedwater heater is a series of tubes carrying requirements may reduce meter performance.
feedwater through a tank shell, into which steam
is injected to heat the water. The steam The challenge of accurately measuring
condenses in the shell, creating a liquid level of steam flows
condensate. The level is controlled to create a seal In steam applications, measuring mass rather
and prevent steam blow-through. Maximum than volume can more accurately indicate the
thermal transfer occurs when the largest tube amount of energy moving around the system.
area is exposed to the steam without allowing Traditional differential pressure meters need
steam blow-through condensate drains from the additional equipment including line pressure
shell through the normal drain. When the tubes transmitters, temperature sensors and a flow
become submerged, heat is transferred to the computer to produce mass readings for steam.
condensate. Even a small increase in condensate
level greatly reduces boiler fuel efficiency. The solution is ABB’s swirl flowmeters
Swirl meters have virtually zero maintenance
The solution is accurate level control requirements and offer greater accuracy,
ABB’s Magwave dual chamber level measurement especially where flow varies significantly. Swirl
system provides dependable, accurate meters offer accuracies of ±0.5 % of reading over
measurement. The Magwave has two tightly the entire flow range. Furthermore, the turndown
integrated but independent chambers. In the is up to ten times that of an orifice plate. ABB’s
primary chamber, level is indicated based on swirl flowmeters need just three pipe diameters
specific gravity. An externally mounted magnetic upstream and one downstream, eliminating
gauge visually indicates the level. In the pipework modifications normally required to read
secondary chamber, the MT5000 series guided accurately in lower flow situations. The meters
wave radar provides continuous level also have built-in temperature sensors and
measurement output and enables accurate level automatically compute reading to indicate steam
measurement even with changes in feedwater usage in pounds. ABB’s swirl meters can help
temperature. If redundant output is desired, the pinpoint system leaks and faulty steam traps,
patented AT200 magnetostrictive transmitter can minimizing both energy and overall operating
be fitted to the primary chamber. Both the costs. In a recent application, installing ABB swirl
MT5000 and AT200 are SIL2/3 certified. ABB’s meters not only cut installation costs, but also
solution typically allows users to manage level reduced steam losses to less than 5 %, with the
measurement with their control system to a set steam plant recovering over USD 1.25M in
point of nine inches, achieve a 5°C (8°F) increased billing.
differential on their heaters and improve
efficiency by six percent, saving fuel costs.
10 ME ASUREMENT MADE E ASY FOR POWER PL ANTS
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Putting the environment first
Sustainable power generation
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01 The control system Optimizing control of waste-to- Maximizing generating efficiency
for plant-wide control
of any process energy and biofuel power plants in solar thermal system
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02 Power and
automation solutions
installations
for solar power Waste-to-energy is the process of extracting
technologies energy in the form of electricity or heat from the
— Solar thermal energy (STE) uses thermal
03 ABB service includes incineration of a waste product, often biological
collectors to harness solar energy to produce
workshops and training in origin. Most waste-to-energy processes
— heat. High temperature collectors, which absorb
04 Measurement and produce electricity directly through combustion.
and concentrate sunlight using mirrors or lenses,
analytical products Alternatively, they can produce combustible fuels
service is available are generally used for electric power generation.
worldwide such as methane, methanol or synthetic fuels,
The latest technology is based on heat storage
either through thermal or non-thermal processes.
using molten salt as heat transfer fluid, to allow
Biofuels include fuels derived from biomass
steam production even at night. In a solar thermal
conversion, as well as solid fuels, liquid fuels and
energy process, solar energy is used to heat water
certain biogases.
and generate steam, which can then be used to
feed the turbines and generate electricity in the
The challenge of maximizing control and
same way as in any other thermal power process.
minimizing environmental impact
One of the major challenges is achieving a higher
The challenge of getting the most energy
ash quality through the use of optimized
from sunlight
combustion control, allowing the plant operator
To enable the maximum efficiency of the plant,
to ensure that the ash meets environmental
the transfer fluid pressure, temperature and flow
standards for disposal in landfill. Flue gas
needs to be measured reliably even at 550°C
treatment systems enable modern plants to
(1,022°F). In installations using ‘heat storage’
remain below the emission limits.
tanks, accurate pressure measurement is also
important. In these installations, the steam is
The solution is a control system offering a plant-
maintained at temperatures of around 285°C
wide overview
(545°F) by allowing the steam to condense and
ABB supplies its System 800xA or Symphony Plus
then ‘flash’ back to steam when the pressure
control platforms as a complete solution for the
is lowered.
control of waste to energy power plants. Offering
an easy-to-use and consistent user interface, they
The solution is a complete solar energy system
provide simple plant and enterprise-wide access
ABB’s measurement and analytical products can
to information while offering fast analysis of
play a key role in maximizing the efficiency of
process disturbances.
thermal solar power installations, through
accurate measurement of parameters including
flow, temperature and pressure. ABB’s expanded
offering also includes complete power and
automation solutions for all the main
concentrating solar power technologies –
parabolic trough, power towers, integrated solar
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01 02 combined cycle, heliostat solar concentrators,
stirling solar dish systems as well as combined
solar-biomass.
ME ASUREMENT MADE E ASY FOR POWER PL ANTS 11
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Services for measurement products
Performance optimization
Calibration services
• Both on-site or at factory
• Covers ABB’s flowmeters, water quality
analyzers, pressure and temperature
transmitters, valve actuators and positioners,
emissions monitoring systems, gas analyzers
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D I D YO U K N O W
ABB offers custom designed, engineered and pre-assembled water
and steam monitoring systems plus professional commissioning and
installation services. Each system can be tailored to meet individual
specifications, reducing installation time, testing and commissioning
while increasing ease of operation and efficiency.
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03 04
12 ME ASUREMENT MADE E ASY FOR POWER PL ANTS
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Measurement solutions 1/4
A comprehensive portfolio
Did you know? ABB is a world leader in the design, supply and lifecycle management
of power and automation technologies for power generation applications.
Temperature transmitter
Differential pressure
Pressure transmitter
Temperature sensor
Pneumatic actuator
Pneumatic actuator
PositionMaster
transmitter
Positioner
Positioner
Actuator
Fuel system l l l l l l l l
Coal bin
Coal mill l l l l l l
Feed storage
Fermenter l l l l
Gas storage l l l l
Solid dosage
Water treatment l l l l l l l l
Deaerator
Boiler feed water l l l l l l l l l
Boiler drum l l l l l l l l l
Boiler outlet l l l l l l
Steam line l l l l l l l l l
Cooling water l l l l l l l l l
system
Generator l l l l l l l l l
Turbo generator l l l l l l
Gas turbine outlet l l l l l l
Condenser l l l l l l l l l l
Gas cleaning
system l l l
FGD* l l l l l l l l l l
ESP**or fabric
filter
DeNOx l l l l l l
Economizer outlet
Residuals storage l l
Air preheater l l l l l l
Stack*** l l l
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Measurement solutions 2/4
Serving the steam loop
Did you know? ABB manufactures and supplies a wide range of chemical analyzers
that is used to eliminate the issues associated with poor boiler chemistry and
therefore helps to avoid corrosion, impaired efficiency and unplanned shutdowns.
Magnetostrictive
ProcessMaster
Magnetic level
WaterMaster
Vortex/Swirl
Flow Nozzle
Ultrasonic
VA meters
Torbar
Radar
Laser
Product series FPD FEP FEW FSV/FSS Various FCB PTC-6 MT5000 KMICRO KM26 LM80 AT
Product image
Fuel system l l l l l l l l
Coal bin l l l
Coal mill l l
Feed storage l l l
Fermenter l l l l l
Gas storage l l l l l l
Solid dosage l l l
Water treatment l l l l l l l
Deaerator l l l l
Boiler feed water l l l l l l
Boiler drum l l l
Boiler outlet l
Steam line l l l l
Cooling water l l l l l l l l
system
Generator
Turbo generator l
Gas turbine outlet
Condenser l l l l l l
Gas cleaning l l l l l l l
system
FGD* l l
ESP**or fabric l
filter
DeNOx l
Economizer outlet
Residuals storage l l l
Air preheater l
Stack*** l
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Measurement solutions 3/4
Extensive know-how and global reach
Did you know? ABB’s offering for solar thermal energy applications includes patented high-
precision programmable logic controllers for parabolic troughs, dishes or collectors, control
systems for thermal storage tanks and electrical balance of plant for the power block.
Chloride to Residual
Paperless recorders
Dissolved oxygen
Total Chlorine
Conductivity
Phosphate
Hydrazine
stations
Sodium
Silica
pH
Product series CM SM SR C1900 AX400 AX400 943 AHM550 AW400 AW600 AW600 ASO500
Product image
Fuel system l l l l
Coal bin
Coal mill l l l
Feed storage
Fermenter
Gas storage
Solid dosage
Water treatment l l l l l l l l
Deaerator l
Boiler feed water l l l l l l
Boiler drum l l l l l l
Boiler outlet l l l l
Steam line l l l l l l l l l
Cooling water l l l l l l
system
Generator
Turbo generator
Gas turbine outlet l l l l
Condenser l l l l l l l l l l
Gas cleaning l
system
FGD* l l
ESP**or fabric
filter
DeNOx l l l l
Economizer outlet
Residuals storage
Air preheater l l l l
Stack***
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Measurement solutions 4/4
The ideal partner for power generation
Did you know? ABB has been supplying technology for large-scale carbon capture
and storage projects since 1996.
Ex version of Uras,
plus combistibles
Hydrogen purity
control solution
Zirconia oxygen
Magnos, Caldos
(Katharometer)
Extractive gas
Index, SG
VOC, O2)
Product series AK100 AZ20 AZ40 ACX ACF PGC1000 AO2000 LS25 EL3000 EL3060
Product image
Fuel system l
Coal bin l l l l l l
Coal mill l l l l l
Feed storage
Fermenter l l
Gas storage l
Solid dosage
Water treatment
Deaerator
Boiler feed water
Boiler drum
Boiler outlet l l l l l l l
Steam line
Cooling water
system
Generator l l l l
Turbo generator l l l l
Gas turbine outlet l l l l l
Condenser
Gas cleaning l l l l l l l
system
FGD* l l l l l
ESP**or fabric l l l l l l l
filter
DeNOx l l l l l
Economizer outlet l l
Residuals storage l l
Air preheater l l l l l
Stack*** l l l l l l l