The PMI Dilution Probe for In-Situ Sample Conditioning of Stack Gases

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1 The PMI Dilution Probe for In-Situ Sample Conditioning of Stack Gases 1. Introduction The PMI Dilution Probe is designed to function as a sample conditioning and transport system for extracting flue gas from smokestacks. In doing so, it filters particulate from the sample, reduces moisture content to a level below the dewpoint, dilutes the sample to more accurately measured concentrations, and transports it under positive pressure to the analyzer(s). Diluting the sample overcomes many of the problems that can be encountered with in-situ, source level monitoring systems as well as those experienced with other extractive techniques. The low flow rate of sample extraction means that most particulate matter flows right past the Probe, helping keep filters from loading prematurely and minimizing particulate fouling of the sample system. Probe maintenance consists of periodic (approximately every 3 months) filter replacement. The sample from the stack is diluted with clean, dry air. Dilution renders corrosive samples inert, helping protect all downstream components and eliminating the need for special valves and tubing. There are no moving parts or electrical utilities in or on the stack to break or wear out, minimizing on stack maintenance time. Dilution reduces the moisture content of the sample to dewpoints typically within the range of -20 F to -40 F, eliminating the need for heated sample lines. The diluted sample is transported at positive pressure. A small leak in the sample transport line will not adversely affect the sample composition. Calibration gases are introduced at the same location and under the same conditions as those of the actual stack sample. Dilution Systems can be used with a wide variety of existing ambient air analyzers. Page 1

2 2. Principle of Operation The PMI Dilution Probe performs several functions to prepare the sample from the stack and permit precise and accurate measurement by the analyzer, as follows. A controlled amount of clean, pressurized dilution air is introduced through a nozzle at the front of an eductor pump (or air driven aspirator) into a venturi. A built-in heat exchanger preheats the pressurized air to the stack temperature. The flow of pressurized air through the nozzle creates a partial vacuum within a chamber. This chamber is connected to the low pressure end of a critical orifice. The vacuum creates suction that draws a sample of the flue gas into the probe. It passes through a coarse mesh filter at the inlet of the probe to remove particulate matter, and through a fine, quartz wool filter immediately before the critical orifice. After passing through the critical orifice to the venturi outlet, the cleaned sample is diluted by mixture with the clean, pressurized air. The diluted sample is then transported at positive pressure to the analyzer(s) via the outlet line. Calibration gas is supplied to the probe through a separate inlet. This inlet emerges into the front compartment of the probe assembly containing the critical orifice. This ensures that calibration gas is supplied at the same location and under the same temperature and pressure conditions at which stack sampling takes place. This line is also used to supply blow-back air to clean the coarse filter of particulate accumulation. The Critical Orifice The Critical Orifice determines the flow rate at which the sample is extracted from the stack as well as the ratio of dilution air to sample. It is typically made of glass and is functional at temperatures up to 750 F (400 C). The orifice is connected to the eductor pump with a stainless steel fitting and graphite ferrule. The front section of the orifice contains a fine filter, consisting of ultra pure quartz wool, to remove any remaining particulate from the gas flow. Special attention has been paid to the geometry of the bore in the orifice. In this bore, the speed of the gas reaches the speed of sound (this type of critical orifice is also known as a sonic orifice). When the pressure at the bore outlet becomes less than 53% of the inlet pressure, lowering the pressure further at the outlet cannot increase the flow rate. The pressure differential generated by the PMI Probe thus ensures a constant flow at the rate determined by the bore of the critical orifice. The dilution ratio is the product of the dilution air flow rate divided by the sample flow rate. E.g. If dilution air (Q1 above) is 5 liter/min and sample flow (Q2 above) is 50 ml/min, then the dilution ratio is 5,000:50, or 100:1. Page 2

3 3. Specification A) Material of construction: The eductor housing, mantle, filter cap and flange (the Wetted Parts ) are fabricated from Inconel 600, a corrosion resistant nickel-chromium alloy. The heat exchanger and the four inlet/outlet tubes are fabricated from grade 316 Stainless Steel. B) Maximum Operating Temperature: 750 F (400 C) with standard glass orifice. 1,100 F (600 C) with special metal orifice call PMI for details. C) Dimensions: Vacuum and Calibration lines OD Dilution Air and Sample out lines 0.25 OD All lines supplied with 0.25 OD tube fitting attached. CAL/SERVICE DILUTED SAMPLE VACUUM DILUTION AIR (INCHES) (INCHES) SUPPORT FLANGE DETAIL 90 Ø 7/32 (.21875") 4x ON 1.50" CIRCLE V DS S DA Ø 1.80 Page 3

4 4. Installation The PMI3200 Probe has a 1.8 diameter flange with 4 mounting holes on a 1.5 diameter circle for attachment to a user-supplied mounting on the smokestack. Important. For proper operation, the entire sampling length of the Probe must be inserted fully into the flue gas flow. This may require use of a steel extension pipe in certain situations, e.g. a lined smokestack with an annular space. The input and output lines are supplied with Swagelok fittings and are typically attached to transport lines connecting the Probe to the analyzer(s). The dilution air line is supplied with a 60 micron filter attached. Dilution air flow should be a minimum of 5 liters/min. The Probe may be installed by welding an extension pipe to a removable mounting flange (Figure 1) or with the use of a spool piece (Figure 2). The use of a spool piece will facilitate maintenance, as the main flange is not disturbed during subsequent removal of the Probe from the smokestack. Page 4

5 4"150# PORT FLANGE 9" OD FLANGE GASKET 4"150# RF MOUNTING FLANGE (BORED THRU FOR PIPE) STACK WALL WELDED EXTERNALLY (BOTH SIDES) IN-SITU PROBE TYP 1-1/2" NOM. SCHED 10 OR 40 WELDED, OD: 1.9" WELD ADAPTOR EXT TUBE-SET STACK FLOW 3/4" LOCKWASHER (8x) 3/4"-10 HEX NUT (8x) EXAMPLE: MOUNTING IN-SITU, UNHEATED DILUTION PROBE TO 4"150# PORT FLANGE 3/4"-10 x 3" SHCS (8x) *PROBE, PIPE & FLANGE REMOVED TOGETHER FOR MAINTENANCE. Figure 1 Page 5

6 4"150# PORT FLANGE 9" OD FLANGE GASKET 4"150# RF MOUNTING FLANGE (BORED THRU FOR PIPE, BOLT HOLES TAPPED FOR SPOOL) STACK WALL *CUSTOM SPOOL ASSEMBLY FOR REMOVING PROBE/PIPE WHILE FLANGE REMAINS IN PLACE. IN-SITU PROBE TYP 1-1/2" NOM. SCHED 10 OR 40 WELDED, OD: 1.9" WELD ADAPTOR EXT TUBE-SET STACK FLOW 3/4" LOCKWASHER (8x) 3/4"-10 HEX NUT (8x) EXAMPLE: MOUNTING IN-SITU, UNHEATED DILUTION PROBE TO 4"150# PORT FLANGE 3/4"-10 x 3" SHCS (8x) *PROBE & PIPE REMOVABLE FOR MAINTENANCE (FLANGE REMAINS) Figure 2 Page 6

7 5. Maintenance It is recommended that the filter screen in the filter cap assembly and the quartz wool filter in the critical orifice be replaced every 3 months A) Replacing the Filter screen: The PMI3200 probe is fitted with a 3-piece filter cap assembly consisting of the front cap (grooved to seat an O ring which is used when a heater is fitted), a filter union and a filter screen. Unscrew the front cap and remove the filter screen, which can be pushed out with the tip of a finger from the front of the cap, insert a new screen and replace the front cap. B) Removing the Critical Orifice: Hold the probe in an upright position with the filter cap upwards and unscrew the complete front mantle. Do not bump or jar the orifice. Remove the mantle by lifting upward. Hold the orifice in position and carefully loosen the retaining nut. Lift out the orifice complete with retaining nut and ferrule. C) Replacing the quartz wool filter: This procedure should be performed whilst wearing skin, eye and respiratory protection. Remove the spent quartz wool using tweezers. Inspect the orifice for any dirt or damage. Insert 0.7gm of clean quartz wool into the orifice using tweezers. Ensure the clean quartz wool is distributed as evenly as possible. D) Replacing the Critical Orifice: Place the retaining nut fitted with a new graphite ferrule over the stem of the orifice. Push the orifice firmly into place in the probe until it seats against the metal. Ease the orifice back away from the metal approx 1/32 to prevent chipping the glass stem. Finger-tighten the retaining nut, then with a wrench, tighten only 1/4 turn to secure the orifice. Replace the front mantle. The Probe operates in harsh conditions. From time to time when performing any of the above procedures, it is recommended that anti-seize grease be applied to the threads on the filter cap assembly and mantle. Page 7

8 6. Test procedure for the PMI Dilution Probe Pressurized air is supplied to the Probe dilution air inlet. The test pressures are set with a reducing valve. The air flow through the pump is measured with a mass flow meter, calibrated in liters/min. The pressure is set at 1 bar intervals and flow values are recorded. The partial vacuum generated by the aspirator at each flow rate is recorded. The connector for the critical orifice is capped off during this test, which is performed at room temperature; sample suction of the Probe is zero during this test because of this stop plug. An example of the tabulated results is shown here for illustration only; results may differ from probe to probe. Page 8

9 7. Spare Parts PMI recommends that the user keeps a spare orifice available and always has graphite ferrules, quartz wool filter and filter screens on hand for routine maintenance. Following is a list of parts with part numbers for ordering purposes. Part # PMI3120 PMI3150 PMI3190 Description Glass Orifice, 20 ml/min. Glass Orifice, 50 ml/min. Quartz Wool Filter, 10g PMI3199 Ferrule, Graphite, Box of 10 PMI3113 PMI3119 PMI3186 PMI3187 PMI3182 PMI3183 PMI3184 Filter Screen Anti-seize Compound Inline Filter, 60 micron Element, Filter, 60 micron Filter Cap Assy. (3 piece) Mantle End Cap * Orifices are available in a range of sizes from 20 ml/min to 250 ml/min. This manual Copyright 2005 Precision Monitors Inc F Lake Park Drive Smyrna, GA Ph: Fax: Page 9

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