Wednesday, August 23, 2017

E-Book on Combustion Efficiency From Yokogawa

high temperature industrial operation fired heater
Industrial operations employing combustion as a heat source
can benefit from available modern technology for
maximizing efficiency.
Yokogawa, globally recognized leader in a number of process control fields, has authored an e-book which provides useful insight into how operators of combustion based equipment and systems can improve efficiency and enhance safety by employing modern technology.

[All quoted passages in this article are from the Yokogawa e-book "Combustion & Fired Heater Optimization"]

The Yokogawa e-book Combustion & Fired Heater Optimization offers “an analytical approach to improving safe & efficient operations” related to the use of combustion & fired heaters in the process industries. Through presenting an overview of combustion sources, such as furnaces and fired heaters, the book states that while “fired heaters pose a series of problems from safety risks to poor energy efficiency,” those problems “represent an opportunity for improved safety, control, energy efficiency and environmental compliance.” Fired heaters “account for 37% of the U.S. manufacturing energy end use.” Tunable Diode Laser Spectrometer (TDLS) technology helps mitigate safety concerns by “measuring average gas concentrations across the high temperature radiant sections.”

The book states that the four main concerns applicable to fired heaters are asset sustainability, inefficient operations, the operator skillset, and safety and compliance. Outdated diagnostics and controls have placed unnecessary stress on operator response, making sustainability of fired heaters difficult. The emissions of fired heaters are generally higher than designed, and can be coupled with control schemes for firing rates little changed over the past 40 years. Operators, generally, lack a clear understanding of design, and even engineering principles of heat transfer are not typically included in education related to fired heaters. Confounding the situation further, “many natural draft heaters do not meet this [safety regulation] guideline with existing instrumentation and control systems.” These complications combine to form a noticeable problem Yokogawa’s technology hopes to address. The company notes how the fired heater relies on natural draft instead of forced air, meaning the heaters “typically lack the degree of automation applied to other process units in the plant.” Offering a full detail of both the control state of most fired heaters and their systems defines the process situation currently considered common in the field, while emphasizing high excess air as providing a “false sense of safety.”

The proposed TDLS system allows for the measurement of “both the upper and lower conditions in a fired heater” by “simultaneously controlling the fuel and air supply based on fast sample intervals.” Safer burner monitoring and heater efficiency results from the TDLS measurements of CO, CH4, and O2. The optimization of air flow control reduces “O2 concentration … from 6% to 2%” and increases the furnace’s thermal efficiency. Combustion control is achieved by managing fuel flow and the arch draft. The TDLS integrated system works in tandem with already established logic solver systems in the plant. The TDLS technology works as a non-contacting measurement with “full diagnostic capability” and offers “distinct advantages over single point in situ analyzers” via reduction of false readings. Specific gas measurements, fast response time, optical measurement technology, and “high and variable light obstruction” are featured components of the TDLS system highlighted to show the technology’s durability and flexibility. The longevity and reliability of the system is showcased by how the TDLS combustion management system has been operational in a major refinery since 2010. The percentage of excess O2 in sample fired heaters has decreased by 1% to 1.5%. Measurements by the TDLS system have been verified by other gas analyzers. The furnace conditions in the plant are more efficiently monitored and controlled. As a result, the furnace in the functional environment is “now near its optimum operating point, using minimum excess air.”
Yokogawa presents a process-related problem, then details the key points of the problem while unpacking the causes. The e-book introduces Yokogawa’s technology, explains the mechanics, and demonstrates how TDLS acts as a solution to the problem, supported by a tangible example. The book offers great insight for both the operational principles of fired heaters and a new technology designed to maximize efficiency in the control process.

The e-book is included below. More detail is available from product application specialists, with whom you should share your combustion and fired heater related challenges. Combining your own facilities and process knowledge and experience with their product application expertise will lead to effective solutions.

Tuesday, August 15, 2017

Tunable Diode Laser Gas Analyzers Incorporated in CEMS

cabinetized extractable tunable diode laser emissions monitoring systems
TDL analyzers cabinetized in extractive
emissions monitoring system
Image courtesy CEMTEK Environmental
Tunable diode laser absorption spectrometers provide high sensitivity and specificity in the measurement of flue gas component concentration. They are well suited for continuous emissions monitoring systems used for EPA compliant or non-compliant applications. The rugged unit design and low maintenance requirement makes the TDL technology suitable for in situ monitoring of stack emissions.

TDL spectroscopy, packaged specifically for emissions monitoring applications, offers calibration stability and fast in situ measurement. It can also be applied in a manner that avoids interference from other gases present in the sample or stack. Industrial operations, whether for direct process control or emissions compliance monitoring, have a need for accurate, reliable measurement of specific gas concentrations within a flowing medium. Tunable diode laser spectroscopy, configured for industrial use, provides a number of substantially positive attributes for these applications.

More information is provided in the document included below. Share your combustion efficiency and emissions monitoring requirements and challenges with product application specialists, combining your own knowledge and experience with their product application expertise to develop an effective solution.

Wednesday, August 9, 2017

Industrial Wireless as Mainstream Connection Method For Process Measurement

industrial wireless modems
Industrial wireless modems, one of many options
when establishing wireless connections.
Image courtesy Eaton - ELPRO Technologies
Wireless connections to process instrumentation has evolved to a point where it is uncomplicated and inexpensive. Many facilities rely on wireless connections, either via a network (wifi) or point to point communications. The benefits of wireless are well known to those already among users of the technology.
  • Safety: Wireless connections can reduce personnel exposure to hazardous environments or situations that previously required human intervention or a manual gauge or instrument reading.
  • Easy Scale-up: Adding points on a network is generally a simple incremental process.
  • Operational Advantage: When deployed to replace manual instrument or gauge readings, real time data for diagnostics and efficiency measurements are now available. Information that is more accurate, timely, and consistent will produce better results.
  • Installation Savings: Installation of wireless connected assets has been reported to be up to 10 times less expensive than wired installation. The reduced space and planning for cables and conduit can make what were once complex and time consuming operations much quicker and easier.
  • Mobility: Wireless technology allows for real time connections to mobile platforms. Whether within a plant, on the road, or on the high seas, there are wireless products that can make the connection.
  • Distance: Don't just think WiFi, think radio, think satellite, think cellular. Connections can be established across very long distances using standard products from the industry.
  • Conversion of Legacy Devices: Many existing in-place devices can have their wired connections replaced with a wireless version. This accommodates a staged transition from wired to wireless in facility.
The transmission is accomplished in either the 900 MHz or 2.4 GHz band, delivering adequate range and power for most facility-wide applications. Obstructions can be overcome with the use of a strategically located repeater. Properly planned and configured, there are few limits to the distance a wireless connection can span.

Point to point wireless connections between, for example, a temperature transmitter and a recorder are easy to create. Most process sensors have very small power requirements, as do the Analynk transmission units. Power, if line voltage is not available at the location, can be provided by batteries, or combination of battery and photovoltaic. The 4-20 mA signal from the temperature transmitter serves as the input signal to the wireless transmitter. The analog signal is converted to a digital value and encrypted prior to transmission. A receiver at the recorder decrypts the digital signal and converts it back to a 4-20 mA analog output that serves as the input signal to the recorder. Wireless transmitter and receiver must be set to the same channel, but otherwise, the equipment handles all the work. If you can find your way around a smart phone, you can make a wireless point to point process connection.

There are likely many applications going unfulfilled because the cost or feasibility of making a wired connection is holding the project back. Reconsider the project using industrial wireless technology and you may find that the project becomes an attractive prospect.

Share your connectivity challenges with the application specialists at Arjay Automation, combining your own process knowledge and experience with their wireless communications expertise to develop an effective solution.