Combustible gas detection capabilities.

Lower explosive limit monitoring over WirelessHART, for greater hazard visibility without added power or signal wiring

The capabilities of Emerson's Rosemount™ 928 Wireless Gas Monitor have been expanded by adding combustible gas detection, enabling percent lower explosive limit (%LEL) monitoring over the secure WirelessHART® platform. The update helps users monitor combustible hazards in remote or hard‑to‑wire locations without the need for additional power or costly signal wiring.

“Adding combustible gas detection to the Rosemount 928 gives customers more flexibility as safety requirements evolve,” said Dave Ruhland, global flame and gas product manager for Emerson’s measurement instrumentation business. “Facilities can extend their wireless gas detection strategy to include combustible hazards on existing WirelessHART platforms – simplifying installation and supporting reliable monitoring in more hard-to-reach areas across their facilities.”

The updated Rosemount 928 device supports measurements from 0% to 100% LEL, which gives users early warning and complete visibility into combustible gas hazards, helping them detect risks sooner and respond more effectively as conditions escalate.

The combustible sensing technology is also designed to help reduce maintenance over time. Because the sensor does not rely on consumable elements, such as catalytic beads, that can degrade with repeated gas exposure, it can support longer service intervals and reduce the need for frequent recalibration.

Secure WirelessHART communication transmits combustible gas data in real time, enabling deployment with no added power or signal wiring in hard-to-reach areas. The update is intended to complement existing gas detection programmes by helping teams add monitoring points in locations that may be logistically impractical or too costly to hardwire.

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@EmersonExchange  @EMR_Automation @Emerson_News @HHC_Lewis #PAuto #Safety

Solutions for plant emissions control and monitoring.

In order to operate a combustion process at peak efficiency, it requires excess air to ensure complete combustion of the fuel. This presents a challenge, as too much or too little air will reduce the combustion efficiency and result in higher emissions, and a greater environmental impact.

Continuous monitoring of the amount of oxygen and combustibles in the flue gas is required to allow for prompt adjustments at the boiler control system to maintain peak efficiency. Servomex’s combustion gas analyzers and emissions gas monitoring equipment meet this challenge directly, saving up to 4% of fuel costs, lowering emissions, maintaining the highest standards of safety and a reduction in the environmental impact.

The SERVOTOUGH FluegasExact 2700 flue gas analyzer monitors both oxygen and combustibles(COe) in flue gases. Oxygen is measured using zirconium oxide sensor technology. A thick film catalytic sensor optimized for carbon monoxide is used to detect parts per million (ppm) levels of combustibles and monitor COe breakthrough.

In addition, to enable preventative maintenance, an optional flow sensor is available that monitors the flow up the analyzer’s probe and through the sensors. These sensors are housed in a heated sensor head mounted on the process wall to which a sample flue gas is aspirated via a sample probe.

Keith Warren, Head of IP&E Applications and Development, said: “Precise monitoring of plant equipment linked to a real-time process control strategy is crucial. Furnace combustion efficiency optimization tied to downstream gaseous emission levels leads not only to potential lower fuel costs but reduced CO, NOx, CO₂, SO₂ and particulate emissions, particularly during load changes and start-up and shutdown when the system temperatures are not ideal.

“We are the expert global partner, offering a total gas analysis solution, which includes the FluegasExact 2700 for optimizing combustion.”

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@Servomex @codacomms #PAuto

Support for R&D in combustion engineering.

Ametek Land is increasing its support for research and development in combustion engineering and technology by joining the British Flame Research Council (BFRC).

The BFRC is a unique network of companies, research organisations and universities which have a common interest in industrial combustion engineering and technology, to meet the demands on industrial combustion to become more efficient and safer, with minimal impact on the environment.

Ametek Land has long been focused on developing technologies and systems to help energy-intensive heavy industries reduce their carbon emissions. James Cross, Global Industry Manager, HPI, said: “Joining the British Flame Research Committee is a great opportunity for us. Our technologies and solutions are well aligned with the ambitious aims of the Committee, especially regarding research around increasing the quality of combustion monitoring technology and hydrogen combustion.”

Peter Droegmeller, Director of Innovation and Technology added: “Working alongside the Committee partners, our expert understanding of the industry as well as our existing connections to research organisations and academia will help to develop the technology, processes and systems needed to improve combustion efficiency and safety.”

@landinst @codacomms #PAuto #Britain #BFRC

Combustion optimization oxygen gas analyzer.

N.B.
This product is only available in the U.S.

A new, compact process, in-situ gas analyzer from Process Insights, measuring both combustibles (COe) and oxygen (O2), provides fast, optimal combustion control for many applications like refining and petrochemical, power, and steam generation, and in furnace and kilns.

Jim Belanger, VP Sales and Marketing - Americas, Process Insights said "Enabling engineers and plant operators to access these previously unachievable air levels is a significant benefit. Combined with improved sensors, superior design and better combustion performance, the COSA Xentaur O2CX gives our customers continuous, reliable gas measurements with greater accuracy and lower maintenance costs."

The COSA Xentaur O2CX allows the process to operate safely with a lower excess air ratio, which translates into higher fuel efficiencies. With greater accuracy and sensitivity below 10% O2, the O2CX doesn?t require dilution air, unlike others. Measuring combustible gas components, oxygen and COe, reliably minimizes safety issues. Measuring in-situ directly has many advantages and is ideal for process heaters, steam boilers, thermal oxidizers, and furnace optimization.

In addition, installation and service is easy, as the flow guidance tube design allows the sensors to be located near to the back of the transmitter, making for service and maintenance without the need to remove the entire assembly from the stack. The probe provides for both direct and continuous dual readings of oxygen and COe.

The COSA Xentaur O2CX is also versatile for various mounting requirements or difficult applications, including high temperature, dust, or hazardous installations.

@ProcessInsights @codacomms #Pauto #USA

Gas detectors protect workers and property.

Gas detectors trigger alarms for toxic and combustible gases across wide areas.

Two new open path gas detectors have been introduced by Emerson which increase safety and reduce downtime by offering performance reliability over wide areas in extreme environments and an easier, faster installation and commissioning process. Extreme environments include both heavy vibration conditions and operating temperatures ranging from -55C (-67F) up to 65C (149F) degrees commonly found in the oil and gas, refining, chemical, mining and large-scale refrigeration system operations.

The Rosemount™ 935 Open Path Combustible Gas Detector uses infrared technology to detect a wide range of highly combustible hydrocarbon gases, including methane, propane and ethylene. In the oil and gas industry alone, 22% of all fatalities come from explosions (combustion or fire) and exposure to hazardous gases, according to the latest statistics from the CDC’s (Centers for Disease Control and Prevention) US National Institute for Occupational Safety and Health.

The Rosemount 936 Open Path Toxic Gas Detector uses ultraviolet technology to detect hydrogen sulphide and ammonia, two of the most common toxic gases in industrial facilities. The US Occupational Safety and Health Administration considers hydrogen sulphide immediately dangerous to life and health at 100 ppm. Ammonia irritates skin, eyes, nose and the respiratory tract at 130 ppm. Both gases are fatal after exposure at certain levels.

Leveraging xenon flash technology, the Rosemount 936 enables greater installation flexibility versus the tunable diode laser (TDL) technology which needs perfect alignment between beam and receiver for high reliability. With nearly twice the tolerance for misalignment than TDL, users can save up to 30% of installation time and streamline project schedules.

Open path detection technology uses a source and a detector. The source sends a modulated light beam across the monitored space, and the detector senses the amount of light absorbed by the presence of gas. This approach provides a high degree of coverage across wide areas up to 200 metres (656 feet) in length with accurate measurement, even if the toxic or combustible gas cloud is drifting at any point between the devices or when 95% of the light beam is obscured by fog, rain or smog. The system also will alert if the path is blocked completely by a physical obstruction.

Both Open Path Gas Detectors can be used in combination with Emerson’s full portfolio of flame and gas detection products as part of a comprehensive safety system to ensure quick and positive detection. Many facilities benefit from the use of multiple technologies to achieve maximum protection.

@EMR_Automation @Rosemount_News @CDCgov @HHC_Lewis #PAuto

NOx measurement in combustion products & processes.

The need for monitoring NOx and  the factors behind the choice of technology. 

NOx is a generic term for the oxides of nitrogen that have significant effects on the environment and human health. These include nitric oxide (NO) and nitrogen dioxide (NO₂), which are mostly produced by the combustion of fossil fuels such as in vehicles and engines, as well as industrial processes such as power generation and cement manufacture. Consequently, NOx measurements are vital to minimise emissions and demonstrate compliance in applications such as engine development, combustion control, emissions abatement, stack testing, and in the development of any products or processes that burn hydrocarbon fuels. Examples include process boilers, gas turbines, stationary diesel engines, domestic boilers and wood burners.

Why are NOx emissions a problem?
Globally, a wide variety of organisations have published reports linking serious health effects with short- and long-term exposure to NO₂. For example, in 2015, the British Committee on the Medical Effects of Air Pollutants (COMEAP) reviewed the available evidence and concluded: Studies have shown associations of NO₂ in outdoor air with adverse effects on health, including reduced life expectancy. It has been unclear whether these effects are caused by NO₂ itself or by other pollutants emitted by the same sources (such as traffic). Evidence associating NO₂ with health effects has strengthened substantially in recent years and we now think that, on the balance of probability, NO₂ itself is responsible for some of the health impact found to be associated with it in epidemiological studies.

From an environmental perspective, NOx gases contribute to the formation of smog and acid rain, and NOx in the atmosphere contributes to nutrient pollution in coastal waters. Globally, emission limits for NOx are becoming more stringent as governments seek to address these concerns.

NOx measurement in product development
The designers of engines, boilers, turbines and incinerators seek to optimise combustion efficiency whilst minimising the harmful emissions of gases such as NOx. In many cases, this means that products have to be designed to comply with the local emission regulations, wherever they are sold.

Organisations conducting combustion research have a different monitoring requirement to plant operators and stack testers. This is because stack testers simply require analysers that comply with certain performance requirements, whereas those in R&D require highly accurate, definitive measurements of NO, NO₂ and NOx in order to fine-tune their designs and optimise the performance of their products. In addition, it will frequently be necessary for them to provide defensible measurement data in order to secure formal approvals in local markets. This is extremely important because the untimely discovery of any NOx measurement errors, interferences or excessive levels of uncertainty could prove costly.

Reference Method – chemiluminescence (CLD)
The European Standard EN 14792 specifies chemiluminescence as the standard reference method (SRM) for the measurement of NOx in stationary source emissions. However, the method cites several alternative CLD configurations but it only stipulates Chemiluminescence as the method of detection. The Standard does not specify whether the analyser should be heated or unheated, or whether the detector should be vacuum based or atmospheric. In addition, it does not specify whether the NO₂ component should be converted to NO prior to any water in the sample being condensed for removal. The EN standard reference method EN 14792 is intended for stack testing laboratories, to verify the installation of a Continuous Emissions Monitor on an industrial chimney stack.

Designing a true reference analyser - key considerations

1. Chemiluminescent photon detector The chemiluminescence reaction of Ozone and Nitric Oxide causes the oxidation of Nitric Oxide (NO) to Nitrogen Dioxide (NO2) which generates photons that are measured using a photomultiplier tube. To obtain maximum sensitivity from the photomultiplier tube it must be cooled so that its ‘dark current’ can be reduced (dark current is a small electric current that flows even when no photons are entering the device). It would be possible to increase the sample flow to the detector to increase its sensitivity, but it is necessary to keep the sample flow as low as practicable to achieve the quenching target. Typically, at Signal Group, the flows of Ozone and sample are set in a ratio of 10:1. Signal’s CLD instruments employ two detectors for continuous measurements of NO and NO2. The sample is passed directly to one of the detectors, and via the NO2 converter for the other. The NO2 value is derived by continuously subtracting the NO-only detector signal from the other detector’s signal. The reaction chamber design is particularly important with a vacuum based analyser because the reaction gases pass very quickly to the vacuum pump. 2. Advantages of a vacuum CLD Water vapour and Carbon Dioxide within a sample will reduce, or quench, the reading of NO, and combustion exhausts usually contain high levels of both. Signal Group has therefore developed a CLD with a vacuum in the reaction chamber, which eliminates the quenching effect, and increases the signal to noise ratio considerably. An additional advantage of the vacuum is that it allows for the delivery of a hot wet sample gas to the reaction chamber without the threat of condensation. 3. Ozonator design Ozone is necessary for the oxidation of NO, but a number of potential pitfalls exist in the choice of ozone generation technology. For example, high-voltage corona discharge lamps would oxidise any Nitrogen in the air feed to NO and NO2 artificially raising the readings and presenting a threat of corrosive Nitric Acid formation. This could be resolved by using pure Oxygen as the feed gas, but that would be prohibitively expensive. Signal Group therefore employs a soft-discharge neon lamp in its ozonator, which does not oxidise Nitrogen. 4. NO2 Converter The choice of NO2 converter material is an important consideration because at high temperatures stainless steel would oxidise any Ammonia in the sample to NO. Furthermore, if there is insufficient oxygen in the sample, it will be ‘robbed’ from NO2, so an oxygen bleed to the sample would be necessary. To avoid this unnecessary complication, the Signal Group CLD analysers use a vitrified type of carbon in a heated quartz vessel which has none of these characteristics, and lasts for at least two years of operation. 5. Vacuum pump Traditional oil filled rotary vane pumps are prone to problems caused by Ozone contaminating the oil. Signal Group therefore employs membrane pumps with a catalyst for removing Ozone.

With over 30 years of experience in the design and manufacture of reference CLD analysers, Signal Group has continually refined its product offering to ensure the highest levels of accuracy, sensitivity and repeatability. Recognising Signal’s experience and expertise in NOx analysis, James Clements, Signal Group MD, is now a member of the SAE E-31 Aircraft Exhaust Emissions Measurement committee.

In addition to the advantages of Signal’s core CLD technology, recent developments have included functionality enhancements such as compatibility with 3G, 4G, GPRS, Bluetooth, Wifi and satellite communications. Each instrument now has its own IP address and runs on Windows software; providing users with simple, secure access to their analysers at any time, from anywhere.

The most recent development is an option for a detachable screen. Customers will find this useful when it is necessary to install the analyser in a location with difficult access – such as: in an ATEX enclosure; in vehicle exhaust gas test cells; with a raised gantry on a stack; in a combustion test rig, or on any site where the location of analysis is not an ideal or safe working space.

@GasAnalysers @_Enviro_News #NOx #Environment #Pollution

Optical analysis added.

Kistler Instruments has added optical analysis to its extensive range of combustion analysis solutions with the acquisition of SMETEC.

The growing demands for zero-emission operation of combustion engines can only be met with high-performance measurement technology. To optimize engine designs, automobile manufacturers must rely on precise analyses of the combustion process. With the visual combustion analysis from SMETEC, processes in the combustion chamber can be visualized allowing the quality of the combustion process to be analysed in real time.

The new technology complements Kistler’s measurement technology, especially in the area of pressure sensors, and adds further options in combustion analysis. This technology provides engine development and research technicians with the widest combination of combustion analysis options for understanding and optimising the combustion process.

The foundation of the new optical measurement technology is a multifunction measuring spark plug combining cylinder pressure measurement and visual combustion analysis in one product. A range of support equipment includes highly sophisticated optical probes that precisely detect the origin of combustion knock, as well as the origin of pre-ignition events and even soot formation within the combustion chamber. Where needed, high-speed imaging cameras for recording fast injection events and flame propagation processes and high sensitivity light amplifiers for fibre optic applications with up to 16 light input channels may be specified. A high intensity, high-performance light source may be used as a continuous or pulsed light source to provide high light output and, in pulse mode, high repetition rate.

In addition to hardware and software, Kistler SMETEC can supply a range of engineering support services from advising users on the most effective techniques for applying optical measuring to the engine to a full on-site engineering service. Experienced combustion measurement engineers support the user from preparing the engine through advising and installing the measuring equipment to conducting the process on the test bed and on road followed by the presentation of a detailed analysis of the results. In addition, where the analysis equipment is required only for a short term project, both hardware and software may be rented so avoiding capital investment.

#Kistler #PAuto #SMETEC

Combustion control in crematoria!

Michell Instruments has released a new application featuring two case studies of combustion control in crematoria.

Cremator operators not only need to comply with local emissions guidelines, but also have to take into consideration the social and emotional well-being of local residents and mourners. Careful control of combustion plays an important part in reducing emissions as well as keeping costs and use of fuel to a minimum. The application note explores the unique challenges faced by cremator operators to monitor combustion including dealing with high temperatures and corrosive gases.

Two case studies also demonstrate how Michell’s XZR500 combustion analyser provides reliable and accurate measurements of oxygen in this application. The analyser has been designed specifically to withstand high temperatures and corrosive atmospheres, while still sampling directly from the stack.

• Michell Instrumentas are marketed in Ireland by Instrument Technology.

@Michell_Inst #PAuto

Oxygen analysis in boilers.

Michell Instruments has announced the launch of the XZR250 oxygen analyzer for monitoring combustion control in industrial boilers. It was developed to meet customer demand for a cost-effective, easy to operate instrument with a probe designed to cope with the high temperatures in the flue. Effective combustion control has growing importance for operators as it not only helps increase fuel efficiency but also ensures compliance with legislation on allowable emissions.

The XZR250 uses a zirconium-oxide sensor with a life span of up to seven years (depending on the fuel used) to maintenance to a minimum. A key benefit of the sensor is its fast response of less than fifteen seconds to changes in oxygen concentrations of 90% of the range. It is also accurate to less than 0.25% O2  allowing optimum combustion control.

The instrument is easy to install as it requires no specialised tools, it is also very light to handle and has a fast start-up routine. The probe can be inserted directly into boilers up to 700°C and uses the Pitot effect to ensure the sample gas is sufficiently cooled to protect the sensor from damage without the need for complex sample conditioning. As with any process instrument, regular calibration is necessary to ensure the accuracy of the measurements. It can use air as a calibration gas, making calibration highly cost effective and simple to perform.

The robust sensor ensures maintenance is minimal, but when it does need replacing, this can be done with minimal process downtime. The company has extended its popular sensor exchange programme for dew-point transmitters to customers of the XZR250. Under this scheme, operators order a new sensor block from Michell, which arrives ready to fit. Once fitted, the old sensor block can be returned in the same box and the customer receives a credit.

Typical applications for the XZR250 include oil, gas and biomass boilers.

• Michell products are marketed in Ireland through Instrument Technology.

Real time simulation platform

A&D Instruments Ltd have released a new range of hardware and software test solutions for dynamic automotive measurement and modelling. Procyon is a 32 core ultra-high-performance simulation and control platform.

Procyon is their next generation of high-speed real-time simulation and control platform that meets the demands of the Automotive and Engineering solution providers for running large, complex simulations in real-time. The open and configurable system architecture supports multiple CPU’s with multiple cores and user-programmable FPGA’s, as well as Hyper Transport, PCI Express and conventional PCI interconnections.

The Procyon gives advanced processing technology. Its features include:

• Multi-core and multi-CPU support (up to 32-core with 8 AMD Opterons)
  
• Direct connection of I/O interface to CPU
  
• Real-time application development environment with
  
• MATLAB/Simulink and Virtual Console
  
• Open system specification enables third-party I/O board development
  
• Flexible system configuration

Phil Hopper, A&D’s Business Development Manager said of the release ‘We are very excited about this step into the UK market; we have had great success globally with our products and have developed unique and powerful solutions unmatched by other suppliers. We have already had considerable interest in our solutions specifically developed for Hybrid Vehicle and Battery test development and we are looking forward to market feedback for all our products.’

A&D Instruments are a leader in the development of test, measurement, monitoring and control solutions across the world with over 30 years experience in this specialist field, the release of their integrated product suite forms part of a strategic plan to raise the profile of their existing extensive range of solutions in Britain.

Measurement Solutions include:

• Vehicle Measurement System
  
• Wheel Force Sensors
  
• Wheel Position Sensors
  
• Rotating Torque Sensor
  
• Combustion analysis
  
• Force Matrix Sensor
  
• WCA mini - portable FFT Analyser, data recorder, Noise and Vibration analysis.

Their range of complete solution and service development suite of products includes software, DSP hardware, sensors and related equipment, all part of A&D’s own product offering. Though initially targeted at the automotive sector the products clearly offer exceptional solutions in a wide variety of engineering applications.

As part of A&D Instruments Ltd’s process of continual product development and research, they have a long and key relationship with Birmingham City University where a fully equipped engine test and development cell is installed, providing a centrally located dynamic demonstration facility.

A&D uses Simulink and Model-Based Calibration Toolbox for calibration automation, hardware-in-the-loop (HIL) system models and real-time control applications. A&D are a Mathworks Connections Program Partner.

As the only modelling solution providers to offer a proven multi-core processing solution, A&D Instruments are setting new standards for vehicle and product development. For further information please contact