power and energy industry user application guide · solving critical process applications for the...

User Appl i cat ion Guide

The mass flow experts for flow, level

and temperature instrumentation

Power and Energy Industry

YEARSOF

SERVICE

40

rom the early 1960s, Fluid Components Internationalrecognized the need for flow and level instrumentationwhich met specific customer requirements and

demands for the Power and Energy Industry. By utilizing ThermalDispersion and Coriolis technology exclusively in all FCI flow,level, interface, temperature switches and mass flow meters, ourproducts solve typical Power and Energy Industry applicationchallenges with standard product features such as: No moving parts All welded materials of construction Direct mass flow measurement No pressure drop Explosion-proof design Wide flow range Low flow capability

By closely monitoring the everchanging requirements for thePower and Energy Industry, FCI has maintained its reputation asthe technology leader with new product features such as: Modern digital communications with HART, Modbus,

Profibus, Ethernet and ASI Fail-safe mode selection per Namur NE43 Compliance with the latest approval requirements

of FM, CSA, CRN, ATEX, CE Mark and PED Application focused marketing and engineering research

and design Secondary sealed flow element sensor design Integral flow conditioners Two-wire loop-power flow, level and

interface detection

FCI Power and Energy Industry customers Detroit Edison Energy Northwest Duke Power First Energy Corporation Bridgeport Resco Duquesne Light Florida Power & Light Georgia Power GPU Nuclear Ameren/CIPS United Pacific Controls

FCI Power and Energy Industry customers forEngineering, Procurement & Construction (EPC) Bechtel Group Sargent & Lundy Black & Veatch Duke Engineering & Services Fluor Foster Wheeler VECO B.E. & K. Inc. Washington Group Intl Parsons Day & Zimmerman Intl Chicago Bridge & Iron

Solv ing cr i t i ca l process appl i cat ions for the Power and Energy Industry

Pulverized air flow

The measurement and control of mill air flow in coal-fired boilersto minimize pulverizer performance problems is an industry-widechallenge. Minimizing Nox and maximizing plant efficiency has nowtaken center stage for this task. Measurement of air flow is importantin controlling mill slugging, feeder runback and coal spillage. It is alsoa main factor in minimizing emissions and maximizing fuel responseto the furnace, thus maximizing efficiency for these plants. FCI’s MTSeries multipoint mass flow meters measure wide flow rate rangesin high temperature applications. The no moving parts design preventshighly corrosive fly ash from clogging or fouling.

Taiwan Power Korea Electric Power Comision Federal

De Electricidad Niagara Mohawk Gulf Power Houston Lighting

& Power General Electric American Combustion

Condenser air in-leakage

Changes in the discharge flow represents air in-leakage through thecompressor. The negative effects of air in-leakage in the vacuumsystem are well understood. FCI's GF90 Series mass flow meter detectssmall changes in flow that represent changes in efficiency of thecompressor. Pre-requirements for successful monitoring requirelow flow sensitivity, wide flow range measurement, repeatabilityand accuracy -- all of which are standard features of FCI thermalmass flow meters.

Hydrogen flow monitoring

Hydrogen is a commonly used cooling agent in power plant turbinegenerators. Leaking hydrogen gas can pose a safety concern in thepower plant. FCI’s GF90 Series mass flow meters detect increase inusage; thereby alerting operators of leaks. In addition to monitoringfor hydrogen leaks, plants need to measure the flow rate for custodytransfer billing verification from the gas supplier to the utility. Also,multiple plants typically draw from a common hydrogen supply byusing FCI’s GF92 inline unit. FCI’s GF Series mass flow meters measurethe flow at each location, so each plant can be assessed theirappropriate share of hydrogen usage.

Reverse flow vent monitoring

To ensure critical flows and detect changes in the direction of airpurge in and out of chemical plants, the solid-state RF83 bi-directionalflow monitor is the best suited instrument available. It may be mountedon the inlet ducts to monitor all flow into the building. If the flowreverses, safety alarms will trip for failure notification of the fans.

Pump protection

FCI’s FLT93S FlexSwitch® is the ideal instrument to protect pumpsfrom failure due to low flow operation. The no moving parts design,capable of low flow sensing, is well suited to identify a wide varietyof product flows in harsh industrial environments. The dual switchpoints may be set to alarm low flow or high temperature, both indi-cations of conditions that cause pump failure.

Compressed air flow monitoring

Frequently, in a plant environment, there is a controller that monitorsthe use of compressed air within the facility. The controller auto-matically determines the optimum number of compressor units thatneed to be in operation at any given time to handle the facility load. Byonly operating the units that the demand requires, a tremendousamount of energy is saved. The demand is determined by the totalmass flow of air used by the plant, and FCI’s ST98 FlexMASSter®

Series mass flow meters are designed specifically for this purpose.The controller then sets the compressor usage based on the massflow rate indicated by the ST98.

Seal gas detection

Coolant and lubricant seal leakage are a serious threat to the effi-ciency of pumping systems. Fluid contamination to the product andloss of product through damaged seals are avoided with FCI’sFLT93L inline FlexSwitch or FR78 inline low flow monitor. Even a leakas small as 1.0 cc/sec is detected by these highly sensitive instruments.Because the FCI sensor elements operate without obstructing the sealvent line, there is no excessive pressure drop if a severe seal ruptureoccurs. For slurry pumps, the dual switch point option may be usedto identify either a low seal water flow or a high flow seal rupture.

CI introduced the first thermalflow switch /monitor in 1964and has since established a

worldwide reputation for the design andproduction of precision high performanceflow, level and temperature instrumentation.With reliability second to none, FCI hasplaced over 200,000 units in the fieldcovering the full range of liquid, gas andslurry process requirements. FCI productsservice some of the world's most demandingprocesses in industries such as food &beverage, pharmaceutical, chemical, oiland gas, pulp and paper, power and energy,water and wastewater, nuclear power,aerospace and more. FCI offers a broadrange of instrumentation solutions andservices, from off-the-shelf devices to customengineered systems. FCI's engineeringstaff provides expertise in mechanical,electronic and thermo-dynamic disciplinesoffering innovative solutions to specializedcustomer application needs, configurationobjectives, software enhancements, andmaterial problems.

Thermal Dispersion principleThe typical sensing element contains twothermowell-protected precision platinumResistance Temperature Detectors (RTDs).When placed in the process stream, oneRTD is heated and the other RTD senses theprocess temperature. The temperaturedifference between the two RTDs is relatedto the process flow rate as well as the

properties of the process media. Higherflow rates or denser media cause increasedcooling of the heated RTD and a reductionin the RTD temperature difference.

FlexSwitch® FLT93 SeriesThe FLT93 Series utilizes proprietary thermaldispersion technology to provide the highestreliability in flow, level and temperaturedetection. The sensing element is composedof two matched RTD's. One RTD is prefer-entially heated. The other RTD is unheatedand thermally isolated to provide continuousprocess condition temperature and baselineindication. At no flow or under dry condi-tions, the temperature differential betweenthe two RTDs is greatest.

For flow / no flow detectionNo-flow conditions produce a large signal.As flow increases, the heated RTD iscooled and proportionally reduces thetemperature differential. Changes in flowvelocity directly affect this rate of heatdissipation. An electronic circuit normalizesthe differential measurement with theprocess media temperature and converts

the RTD temperature/resistance differentialinto a DC voltage signal. This signal isprovided at output terminals and used todrive two adjustable setpoint alarm circuitsthat are independently field configurablefor specific flow service applications.

For liquid level /interface detection Dry conditions (no liquids present) producethe greatest temperature differential. Thesignal decreases when the level element issubmerged as the cooling effects of thefluid drive the temperature /resistancedifferential downward. Since all processfluids have different thermo physicalproperties, different fluids exhibit uniqueheat transfer characteristics. Interfacedetection between non-miscible fluids canbe factory or field calibrated to alarmwhen the fluid changes from liquid tofoam, between two different fluids, orbetween fluid and rag layer or emulsion.

continued on back cover

Product development, testing and calibration are performed in FCI’s laboratory using NIST traceableequipment, which ensures highly reliable performance in hundreds of applications.

Thermal mass flow technology supports virtuallyall gas or air measurement needs. It is especiallywell suited for dirty gas because of its no-movingparts design with no orifices, bearings, or sealsto foul or fail.

HeatedSensor

UnheatedSensor

∆T

Serv ing cr i t i ca l process instrumentat ion needs around the wor ld

FCI’s complete line of flow, level and temperature instrumentation

Doc. No. 07SA011394A

� For temperature detectionThe unheated RTD serves as the baselinefor establishing the differential temperatureand continuous monitoring of the processtemperature. Being thermally isolated, theunheated RTD provides accurate indicationand detection of process fluid temperatures.Simultaneous temperature and flow andlevel detection can provide comprehensiveprocess monitoring as well as criticallysupplement operator process health andefficiency awareness.

NuTec® 2000 Series� 2-wire loop-power andnon-intrusive switchesExtraordinarily responsive and accurate,the versatile NuTec flow/ level switch seriesoffers superior reliability in extreme processconditions. The FS2000 and LS2000 switchesfeature the first 2-wire thermal flow/noflow and level detection switches. Theseinsertion switches are designed withFCI's proven thermal mass flow sensortechnology in a rugged package that iseasy to install and requires minimalmaintenance. The FS2000L inline flowswitch has an advanced non-intrusive sensordesign constructed of 316L stainless steelwith up to a 10 Ra electropolish finishapproved for 3A sanitary and high purityapplications. The FS2000L is available withinline sizes of 1/2 inch, 1 inch and 2 inchesfor easy installation using male NPT,butt-weld or sanitary flanges.

FlexMASSter® ST Seriesand GF Series mass flow metersBecause the relationship between flow rateand cooling effect directly relates to massflow in gas applications, FCI thermal massflow meters provide a highly repeatable andaccurate measurement of gas or air massflow rates. The ST98 Series "smart"electronics, equipped with advancedmicro-processor-based circuitry, enable

customers to reconfigure the signal outputseasily, as well as, display or alarm in thefield by using either a built-in key pad ora handheld communicator. The GF Seriesoffers wide turndown rations up to 800:1with multiple gas calibrations with analogelectronic circuitry.

FlexMASSter technology delivers perform-ance and value by offering the mostinnovative, accurate and cost effective gasmass flow measurement systems availablein the industrial flowmetering marketplacetoday. This highly reliable instrumentprovides the durability and speed requiredfor today's harsh process environmentsand delivers true direct mass flow meas-urement. FCI's FlexMASSter simplifies gasmass flowmetering with a single processpenetration, eliminating costly temperatureor pressure transmitters and a flow com-puter required with other technologies.

CMF FlexCOR® SeriesThe CMF FlexCOR Series Coriolis flowmeters push development a giant leapforward in Coriolis measurement tech-nology. Unaffected by variations in pressure,temperature, density, electrical conductivityand viscosity, the FlexCOR Series provideshighly accurate mass flow measurementover wide flow ranges while utilizing itsadvanced technology to achieve unsur-passed operational performance stressingsafety, reliability and quality.

VORTAB® flow conditionersFCI ensures the field performance of itshighly accurate mass flow meter productlines by offering VORTAB flow conditioners.VORTABs ensure accurate, repeatable gasflow measurement and are the efficientalternative to long lengths of straight pipingor ducting upstream of a flow meter instal-lation location. VORTAB units reduce oreliminate pressure drop, swirl, jetting and

more, while requiring just six diameters ofpipe upstream from the flow meter. Eachof the three available flow conditionerconfigurations consist of a short sectionof swirl reduction tabs combined withthree arrays of patented VORTAB profileconditioning tabs.

FCI’s extensive instrument testand calibration laboratoryFCI maintains an extensive, instrumenttest and calibration laboratory at its head-quarters in San Marcos, California.Utilizing the latest in advanced, computerizeddata acquisition systems and calibrationtest equipment, this facility permits com-prehensive product development, testing,and calibration. Any FCI product can becalibrated in accordance with customerspecifications. Laboratory standards aremaintained with NIST (National Instituteof Standards and Technology) traceableCavitating Venturis (CVs) and precisioncalibrated, pressure and temperaturecorrected turbine flow meters. Combustibleand non-combustible gas calibration flowstands allow for the calibration of FCIproducts in a wide range of gases as gasmixtures in flow stand sizes as small as1/8 inch to 30 inches [3 to 760 mm] indiameter. A variety of flow profiles fromlaminar to turbulent conditions aregenerated to duplicate actual field condi-tions. Flow rates from 0 to 20,000+ SCFM[0 to 34,000 NCMH], velocities from 0 to800 SFPS [0-240 NMPS], pressures fromvacuum to 3000 psig [200 bar(g)], andtemperatures from -100° to 850°F [-70°to + 454°C].

FCI on-site instrumentcalibration and trainingIn-situ calibration is available from FCI'sField Service Engineers where precise testand calibration is accomplished in actualmedia conditions.

©Copyright 2006 by Fluid Components International LLC. All rights reserved. Subject to change without notice.

Web: www.fluidcomponents.com 1755 La Costa Meadows Drive, San Marcos, California 92078 USA | Phone: 760-744-6950 | Toll free: 800-854-1993 | Fax: 760-736-6250

European Office: Persephonestraat 3-01 5047 TT Tilburg, The Netherlands | Phone: 31-13-5159989 | Fax: 31-13-5799036ISO 9001:2000 and AS9100 certified

Methane-to-Market

Greenhouse Gas Reduction

Biogas-to-Energy

Specifying Gas Flow Meters in Green Energy and Pollution Reduction Applications

g Landfill Gas Recovery

g Biogas/Organic Biomass Fermentation Systems

g Wastewater Treatment Plant Digester Gas

g Livestock and Dairy On-Farm Biogas Recovery

g Ethanol Production and Refining

g Coal Mine Methane Recovery

g Biomass Gasification

g Flare Gas Measurement

g Flue Gas Monitoring

FCI Green Energy Applications Guide

Emissions Measurement, Control & Reduction

Visit FCI online at www.FluidComponents.com | FCI is ISO 9001 and AS9100 Certified

FCI World Headquarters1755 La Costa Meadows DriveSan Marcos, California 92078 USAPhone: 760-744-6950 Toll Free (US): 800-854-1993 Fax: 760-736-6250

FCI EuropePersephonestraat 3-015047 TT Tilburg, The Netherlands Phone: 31-13-5159989Fax: 31-13-5799036

FCI Measurement and Control Technology (Beijing) Co., LTD www.fluidcomponents.cnRoom 107, Xianfeng Building II, No.7 Kaituo Road, Shangdi IT Industry Base, Haidian DistrictBeijing 100085, P. R. ChinaPhone: 86-10-82782381 Fax: 86-10-58851152

Fluid Components International (FCI) is a leading manufacturer and pioneer in applying thermal dispersion technology to gas flow measurement. FCI has been supplying gas flow meter solutions for traditional and alternative energy process controls, as well as for pollution and environmental management applications for decades.

FCI’s Green Energy Applications Guide describes several applications where FCI flow meters, flow switches and level switches are typically installed. FCI customers use our products to optimize process performance, measure and report for regulatory agency compliance and capture accurate data for carbon trading and greenhouse gas reduction incentives and credits.

There are many challenges to consider when specifying flow meters, including wet or dirty gases, mixed composition gases, potentially explosive gas installations, widely variable flow rates and other unique application conditions. Evaluating your specific application conditions can help you avoid implementing a poorly-designed system that creates excessive maintenance needs, may be dangerous to operate, and may require costly re-engineering. This guide is intended to provide you with a better understanding of these challenges and the flow metering solutions FCI offers to obtain the high performance and long service life that you want.

Detailed information and specifications for the products discussed in this guide can be downloaded from FCI’s web site or by contacting your local FCI representative.

www.fluidcomponents.com

Specifying Gas Flow Meters in Green Energy and Pollution Reduction Applications

CONTENTS

Landfill Gas Measurement and Recovery ................................................................................................. 3

Biogas: Organic Biomass Fermentation and Recovery ........................................................................... 4

Wastewater Treatment Plant Digester Gas............................................................................................... 5

On-Farm Methane, Biogas Recovery Systems ......................................................................................... 6

Ethanol Production and Refining ................................................................................................................ 7

Coal Mine Methane Recovery ..................................................................................................................... 8

Biomass Gasification .................................................................................................................................... 9

Flare Gas Flow Measurement, Monitoring and Leak Detection .......................................................... 10

Flue Gas Monitoring .................................................................................................................................... 11

FCI Gas Flow Measurement Solutions Overview ................................................................................... 12

3

Landfills produce a mixture of methane and carbon dioxide with traces of nitrogen, oxygen and other gases. These gases are extracted from multiple wellheads and collected through a network of pipes to a common header pipe. Typical systems also involve blowers, pumps, knock-out pots and a flare or oxidizer. The collected “greenhouse gas” may be disposed of or recovered as a fuel source for a co-generation engine to produce electric power.

An accurate measurement of the landfill gas flow through the system provides operators with informa-tion on the amount of gas being extracted for optimizing effectiveness, for reporting to environmental agencies and for carbon credit programs.

Accurate flow measurement requires performance under challenging application conditions such as:LFG Specialties is an industry leading supplier of landfill gas extraction and recovery systems. LFG installs FCI Model ST98 mass flow meters as the precision landfill gas flow meter in its systems. The ST98 provides flow rate and totalized flow from each well to ensure continuous operation and optimal data collection. The ST98 was selected because of its ease of installation, agency approvals for installation in hazardous gas locations (e.g. Division 1) and because FCI can calibrate the ST98 to specifications for the mixed composition gases unique to landfill gas applications.

Photo courtesy of LFG Specialties

Key Criteria For Flow Meter Selectiong Accurate and calibrated for mixed methane, landfill gas composition

g Temperature compensation

g No moving parts to clog or foul in the presence of wet, dirty gas

g Lowest cost and easiest to install in larger line sizes

g Wide turndown for accurate, repeatable measurement over wide flow range

g Excellent low flow sensitivity

g Agency approved for use in Division 2 [Zone 2] and often Division 1 [Zone 1] hazardous environments

g Multi-function – flow rate, totalized flow and temperature display outputs

FCI thermal dispersion flow meters, in both insertion and in-line styles are the landfill recovery industry’s most often selected solution and the preferred choice of the leading landfill gas collection and flare system manufacturers. With robust designs and a broad selection of product solutions that meet all of the criteria above it is easy to understand why FCI is the preferred solution.

For line sizes larger than 2.5" [63 mm]

Model ST51 Insertion Mass Flow Meter


Model ST100 Series Insertion Mass Flow Meters

For line sizes 2.0" [51 mm] and smaller

Model ST75 In-line Mass Flow Meter

Model ST98L In-line Mass Flow Meter


* FCI Model FLT93 switches provide level detection for Knock-Out Pot (KOP) applications.

Landfill Gas Measurement & Recovery

– Mixed composition gases

– Wet and/or dirty gas

– Potentially explosive installation environment

– Wide variations in flow rates

– Large swings in gas and ambient temperatures

– Large pipe sizes

4

Klärgastechnik Deutschland GmbH is a leading engineering designer, manufacturer and installer of biogas and digester gas processing systems headquartered in Germany.

After extensive testing and evaluation of various flow metering technologies, Klärgastechnik Deutschland GmbH selected and standardized FCI ST98 and ST51 flow meters for use within their gas systems.

Klärgastechnik Deutschland GmbH found that FCI’s no moving parts to plug or foul design, low pressure drop, biogas-specific calibration, hot tap ball valve installation and agency safety approvals provided the best engineered and most economical solution. Additionally, with FCI’s years of experience in biogas and digester gas applications, installations and ability to provide global service support, Klärgastechnik Deutschland GmbH was assured of delivering the highest level of satisfaction to their customers worldwide.

FCI ST Series thermal dispersion flow meters, in both insertion and in-line styles, are optimal for biogas flow measurement. In addition to meeting all of the key selection criteria above, FCI uses a constant power mea-suring technique that, because of a slight heating effect, actually dries condensate moisture off the sensor. This feature provides better performance and repeatability in moist biogas measuring applications. Where ever the installation along the biogas system, FCI has successfully applied ST Series gas flow meters.

g Mass flow measuring of both rate and totalized flow

g No moving parts or small holes to clog or foul in dirty or wet gas environments

g Biogas-specific calibrationg Low flow sensitivity, at least 0.6 FPS

[0,2 m/s] and wide turn-down of 100:1

g Pressure drop over flow element should be limited to 0.01Psi [1 mBar]

g All wetted parts resistant to H2S corrosion; minimum of 316L stainless steel

g Easy and safe removal under line pressure with simple ball valve

g System agency approvals for safe installation in Division 2 [Zone 2] or Division 1 [Zone 1]

Key Criteria For Flow Meter Selection

Organic industrial waste from food processing and slaughterhouses, food waste from restaurants and homes, manure collected from livestock, as well as energy crops can be digested in anerobic conditions in reactor tanks, also called fermentation towers. The output from this biomass digestion process is bio-gas, a mixture of methane (CH4), carbon dioxide (CO2), water and trace hydrogen sulfide (H2S). The entire process involves gas creation, cleansing, storage (tank or bag-type accumulator), and ultimately the use of biogas as a fuel source for heating or generating electricity. A ground flare is an integral part of the safety system for the process. Measuring biogas flow at several points in the system provides operators with critical information for optimal gas production, control, safety and reporting.

Biogas applications present several challenges in selecting the proper flow meter:

– Low flow sensitivity during start-up and for seasonal changes which produce lower flow rates– Temperature compensation for correct readings in varying temperatures– Calibration for mixed gas composition of CH4 + CO2 + trace gases– Wet, dirty gas with corrosive H2S content– Potentially flammable or explosive gas installation environment– Easy, low cost installation and low maintenance

Biogas: Organic Biomass Fermentation and Recovery









* FCI Model FLT93 switches provide level detection for Knock-Out Pot (KOP) and condensate pot applications.

5

Wastewater treatment plant (WWTP) digester processes produce digester gas, a combination of methane (CH4) and carbon dioxide (CO2) with a small percentage of other trace gases. The gas composition can vary with the process and temperature (e.g. seasonally) but a typical average is in the 65% (±5%) CH4 35% (±5%) CO2 range. Digester gas is also a wet and dirty gas, typically containing entrained hydrogen sulfides, which condense and deposit on pipe walls and anything else in the pipe.

Modern WWTP processes incorporate digester gas flow measurement for:

– Data on digester process performance and control– Compliance with environmental regulations to report, control and reduce greenhouse gas emissions– Data for greenhouse gas reduction or carbon credits– Process control of co-generation systems using digester gas as fuel source

In municipal and industrial

Wastewater Treatment

operations throughout the

world, FCI digester gas flow

meters are the industry’s

most installed solution.

WWTP engineers have

standardized FCI product

use because they have been

proven to deliver superior

calibrated accuracy for

digester gases. FCI’s unique

constant power technology

delivers the most repeatable

measurements and lowest

maintenance solution.

FCI is also the WWTP industry’s

leading supplier of thermal

dispersion flow measuring

instruments for aeration

systems, gas disinfection

systems and pump flow

assurance applications.

Wastewater Treatment Plant Digester Gas

Key Criteria For Flow Meter Selectiong No moving parts to clog or foul

g Simple threaded insertion for easy installation and easy wipe-off cleaning

g Wide turndown for accurate low and high flow rate measuring

g Agency approved for use in Division 2 [Zone 2] and often Division 1 [Zone 1] hazardous environments

g Specifically calibrated for digester gas compositions.

g Direct mass flow measuring

g Temperature compensated flow measurement for accuracy and repeatability in changing ambient and process gas temperatures.

FCI has a broad selection of thermal dispersion flow meters to provide the most effective solution wherever digester gas is measured. FCI flow meters for digester gas applications meet all of the above criteria and feature robust electronics and industrial transmitters that provide the longest service life in WWTP installations.









6

Decomposition of livestock waste and other agricultural operations are a major source of methane rich biogas being harvested as fuel gas. Rather than emit greenhouse gases into the environment, modern farm operations invest in a digester system to recover gases and reduce emissions. Recovered gases are used to fuel co-generation engines to power the facility, and often excess power is sold to the local electric power grid. Clean energy development credits (CDM) and certified emission reduction (CER) programs offer additional incentives to implement recovery systems.

In all biogas recovery systems, measuring flow rate is required to ensure effective and efficient operation of the digester process as well as providing tangible evidence of saved emissions in order to receive credits and incentives.

Biogas applications present several challenges in selecting the proper flow meter:

– Low flow sensitivity during start-up, and for seasonal changes which produce lower flow rates– Temperature compensation for correct readings in varying temperatures– Calibration for mixed gas composition of methane (CH4) + carbon dioxide (CO2) + trace gases– Wet, dirty gas with corrosive hydrogen sulfide (H2S) content

In addition to recovering

gases to be used as fuel for

the facility, biogas farming

and ranching operations are

rewarded with incentives

such as carbon offsets and

credit trading, clean energy

development credits (CDM)

and certified emission

reduction (CER) programs.

Bos Farms and Fair Oaks

Dairy Farms are innovative,

major farm operations located

in Indiana USA, utilizing

FCI gas flow meters in their

biogas recovery systems.

On-Farm Methane, Biogas Recovery Systems

FCI has the product line and more than 20 years of experience with thousands of installations to ensure that you will get the product and installation expertise you need for your application. FCI biogas flow meters combine patented thermal dispersion flow measurement technology, rugged packaging, biogas specific calibrations, simple installation, direct mass flow measurement, no moving parts and unequaled safety approvals on the entire instrument to bring you the most application effective, lowest installed cost and safest biogas flow meter solution.

g Accurate and calibrated for specific biogas composition

g Mass flow measurement (e.g. lbs/hr, kg/day, etc.)

g Low flow sensitivity, as low as 0.3 FPS [0.08 m/s]

g Wide ranging, 100:1 turndown

g Non-clogging, no moving parts for low maintenance

g No added pressure drop

g Approved for safe installation in explosive gas environment – system agency approvals for Division 1 [Zone 1, II2 GD Ex d IIC]










7

As costs of fossil fuels continue to climb and air pollution reduction regulations become more stringent, the production of ethanol fuel and fuel supplements grows. At the forefront of ethanol production is the need to continuously improve processes and reduce costs to maximize effectiveness and efficiency.

Ethanol production is a distillation process which involves boilers. Efficiency is optimized with measurement and control of air-to-fuel mixtures/ratios. The process may also utilize catalytic or thermal oxidizers to reduce emissions of greenhouse gases or VOCs. Accurate air and gas flow measurements in large pipes or duct applications are challenged by distorted flow profiles and swirls, varying air temperatures, installation costs, and accessibility for maintenance. Measuring gases vented from the process can provide information about process inefficiencies or other problems. Further, measurement and reporting may be mandated by local air pollution regulations.

ADM and Cargill are two

major producers and refiners

of ethanol fuels and fuel

additives who count on FCI

mass flow meters to optimize

their operations. Both

companies have improved and

optimized process combustion

efficiency with the installation

of FCI flow meters on air and

natural gas supplies.

Ethanol Production and Refining

Key Criteria For Flow Meter Selectiong Temperature compensated flow measurement for accuracy and repeatability

in changing ambient and process gas temperatures

g Easy to install and cost effective in large diameter pipes

g Non-clogging, no moving parts design for low maintenance

g Wide turndown for accurate low and high flow rate measuring

g Multi-parameter – flow rate, totalized flow and temperature in a single device

g Calibration matched to specific gas and application

g Multi-point sensing for accuracy in large pipes, stacks and ducts with distorted and/or swirling flow profiles

g Flow conditioning for limited straight-run application

FCI thermal dispersion, insertion mass flow meters in single-point and multi-point configurations for large line sizes and in-line styles for smaller line sizes provide cost effective and accurate engineering solutions throughout the ethanol process. In addition to meeting the above requirements, FCI flow meters feature robust transmitter electronics in rugged enclosures for long service life.

For line sizes larger than 2.5” [63 mm]

Model ST100 Series Insertion Mass Flow MetersModel ST102 A Dual-point AveragingInsertion Mass Flow Meter Models MT86 and MT91 Multi-pointInsertion Mass Flow MetersModel ST98 Insertion Mass Flow MeterVortab® Flow Conditioners


Model ST100L In-line Mass Flow MeterModel ST75 In-line Mass Flow MeterModel ST98L In-line Mass Flow MeterVortab® Flow Conditioners

* FCI Model FLT93 switches provide a level detection solution for slurry tanks.

8

An emerging application gaining attention from stakeholders in mining operations and from environmentalists is coal mine methane recovery. It has been estimated that 8% of the world’s anthropogenic methane air pollution is a by-product of coal mining. There are three major sources of coal mine methane (CMM): degasification systems (drainage) both pre-mine and gob; ventilation air (VAM); and abandon or closed mines. As technology, economics, environmental regulations and greenhouse gas reduction incentives increase, this gas is increas-ingly being captured and used as a fuel source. Gas flow meters are required to comply with regulations, to ensure efficient operation of co-gen engines or methane oxidizers, and to provide data for incentive credits.

Depending on the source application, concentration of methane in the extracted gas can be as little as 1% (e.g. VAM) to more than 20% in drainage systems. Other components in the gas include air, carbon dioxide (CO2) and/or nitrogen (N2) in various combinations depending on the site and source. Therefore proper flow meter calibration matched to the actual gas mix is critical for accurate performance. Additional consider-ations and challenges in this application include safe installation in an explosive atmosphere, low power consumption, low flow sensitivity and ease of installation in a variety of pipe sizes and locations.

Global activity for coal mine

methane recovery continues

to grow. Numerous projects

and various technologies are

being tested and deployed

around the world to capture

and utilize this methane as a

fuel source.

Whether to maximize the

process or report actual

methane captured, measuring

methane flow is integral to

ensuring the success of this

process. FCI provides the

accurate, reliable and safe

flow metering solution for

flow rate and total flow.

Coal Mine Methane Recovery

Key Criteria For Flow Meter Selectiong Agency approved for use in Division 1 [Zone 1] hazardous environment

g Specifically calibrated to match low concentration methane gas composition

g Temperature compensated flow measurement for accuracy and repeatability in changing ambient and gas temperatures

g Easy to install


g Wide turndown for wide flow range measuring and with low flow sensitivity

g Multi-parameter – flow rate, totalized flow and temperature in a single device

FCI thermal dispersion flow meters, in both insertion and in-line styles, are ideal for application in CMM recovery. They address all of the key criteria and solve the challenges of the application to provide an accurate, highly repeatable and cost effective solution. FCI calibration laboratory ensures a meter calibration matched to gas composition. FCI flow meters have global agency approvals on the complete instrument for installations in hazardous/explosive environments.









* FCI Model FLT93 switches provide level detection for Knock-Out Pot (KOP) and condensate pot applications.

9

For accurate and efficient process control, biomass gasification requires measurement and control of fuel, inlet air and measurement of the extract gas (outlet). The biomass gasification process produces a mixed composition gas consisting primarily of hydrogen (H2) and carbon monoxide (CO) with trace methane (CH4). The extracted gas stream will also contain water, tar or ash, so typical systems include a separator tank to remove these elements.

Biomass gasification applications present several challenges in selecting the proper flow meter:

– Ease of installation in a variety of pipe sizes and locations– Extracted gas may be wet, dirty and/or heated– Calibration for mixed gas composition of hydrogen (H2) + carbon monoxide (CO) + methane (CH4)– Mass flow with limited pipe run to add pressure and temperature sensors– Potentially flammable or explosive gas installation environment

Whether updraft, downdraft,

fluid-bed, circulating fluid-

bed, entrained flow or other

technologies for biomass

gasification, FCI flow and

level measurement solutions

are installed throughout the

process for optimization

and control.

Biomass Gasification

FCI thermal dispersion flow meters in an insertion-style or in-line configuration provide cost effective and accurate engineering solutions. In addition to meeting all of the above requirements FCI flow meters have comprehensive agency approvals for hazardous locations and feature robust transmitter electronics in rugged enclosure.

In systems with separators, the separated elements are often a mixture of water, suspended mass and other elements. When stored in a tank this often creates a combination of non-miscible fluids which can cause erroneous level readings resulting in over-filling or under-filling the tank.

g Accurate and calibrated for mixed gas composition

g Easy to install and cost effective in large diameter pipes


g Wide turndown for wide range flow measurement

g Safe for use in potentially explosive gas installation environment

g Direct mass flow measurement


* FCI Model FLT93 level switches provide accurate detection of level in the presence of mixed liquids and when applied as an interface sensor, can sense between liquids, foams and slurries.









10

c

b

b

b

b

aa

d

Flaring systems are used to burn-off waste or off-gases in both normal and upset process conditions. Many processes are outfitted with relief valves to safely vent process gases to the flare system under upset conditions. Flare systems can be a simple single pipe run or a complex series of feeder and header pipes. All flares are highly scrutinized as a source of air pollution and often subjected to stringent regula-tion to measure, record and report the amount of flared gases and to show continuous improvement to reduce the amount produced.

Flare gas applications present several challenges in selecting the proper flow meter:

– Both low flow and high flow conditions – low flow sensitivity is critical to capture leaking relief valves, while very high flows occur in upset conditions

– Mixed gases – flow meter calibration specifically for hydrocarbon mixed composition gases that match process conditions

– Installation ease and maintenance

You will find FCI flow meters

installed throughout flaring

systems around the world.

Refineries, both chemical

and petrochemical, have

applied FCI flow meters as

part of their process control,

alarm, leak detection, and

emissions monitoring and

reporting systems. These

companies include Dow, BP,

ConocoPhillips, Chevron,

Motiva, Shell, Aramco, Valero,

Total, Petrobras, Pemex,

Sinopec, and more.

Flare Gas Flow Measurement, Monitoring & Leak Detection

FCI thermal dispersion flow meters in an insertion-style configuration provide the preferred engineer-ing solution. In addition to meeting all of the above requirements, FCI flow meters have comprehensive agency approvals for hazardous locations, feature robust transmitter electronics in rugged enclosure, hot-tap installation options, and VeriCal™ – an industry exclusive in-situ calibration verification option. Additionally, these FCI flow meters are direct mass flow measuring so that unlike volumetric flow tech-niques, there are no additional sensors to be purchased or installed to obtain mass flow.

g Accurate and calibrated for mixed composition gases

g Multiple calibrations for variations in composition

g Mass flow measurement

g Wide turndown for both low flow and high flow rate

g Easy to install, single penetration


g Safe for use in potentially explosive gas installation environment


Model ST98 Insertion Mass Flow Meter Model ST100 Series Insertion Mass Flow Meters

Model ST102 A Dual-point AveragingInsertion Mass Flow Meter – up 1000:1 turndown, five calibrations, special flare split-range calibration, VeriCal in-situ calibration verification


a) FCI ST100 or ST102 A Flare Flow Meterb) FCI ST100 or ST98 Flow Metersc) FCI FLT, NutecTM Series Level Detection,

Valve Actuating Alarmsd) FCI FLT, Nutec Series Wet/Dry Interface

Detection Switches

11

Flue gases are the general name given to the mixed composition gases that are the by-product of a combustion process. A flue is typically a large pipe, duct, stack, chimney or other venting attached to a process system such as a boiler, furnace, steam generator, oven, etc. through which waste flue gases are exhausted from the combustion process.

Depending on the process, the fuel used and efficiency, flue gases can consist of nitrogen, carbon dioxide, trace amounts of oxygen and water vapor, and environmentally sensitive pollutants such as sulfur oxides, nitrogen oxide, carbon monoxide and particulates. In addition to measuring the flow of flue gases for process control data, reporting is often mandated by environmental and regional air quality regulations.

Flue gas applications present several challenges in selecting the proper flow meter:

– Mixed composition gases– Wet, hot and/or dirty gases– Large and difficult to access pipes– Wide flow range and distorted,

swirling flow profiles

Flue gases are exhausted

from many processes

including metals operations,

chemical, food processing,

petroleum processing,

pharmaceutical productions,

paper plants, power plants

and boilers.

FCI’s single- or multi-point

flow meters offer accurate

and cost effective solutions to

flue gas measurement.

Companies utilizing FCI

flow meters for flue gas

applications include US Steel,

Kraft Foods, Georgia-Pacific,

Dupont, Rohm & Haas,

Shijiazhuang Refinery, ELF

Atochem, Kemirea Pigments,

Fundia Wire, Noranda Mining,

and Foster-Wheeler Energy,

among others.

Flue Gas Monitoring

FCI thermal dispersion insertion flow meters provide a cost effective and accurate solution to flue gas flow measurement. These flow meters are designed to overcome the unique challenges of flue gas measurement and meet all of the above criteria. For line sizes up to 30 inches [760 mm], FCI single-point meters are typically applied. For larger line sizes, FCI multi-point systems provide up to 16 sensors to achieve flow averaging in large cross-sectional areas. Additionally, these FCI flow meters are direct mass flow measuring so that unlike volumetric flow techniques, there are no additional sensors to be purchased or installed to obtain mass flow.

g Accurate and calibrated for mixed composition gases

g Low cost installation in large diameter pipes

g Single-point and multi-point solutions

g Mass flow measurement


g Wide turndown for wide range flow measurement

g Remote mountable transmitter/electronics

g Temperature compensation





Model ST102 A Dual-point Averaging Insertion Mass Flow Meter

Models MT86 and MT91 Multi-point Insertion Mass Flow Meters

© Copyright 2008 by Fluid Components International LLC. All rights reserved. Manufactured in accordance with one or more of the following patents: US Patent Numbers: 4,929,088, 4,967,593, 4,981,368, 4,994,780, 5,111,692, 5,600,528, 5,780,737, 5,913,250, 6,208,254, 6,340,243, 6,628,202, 6,843,110, 7,191,645, 7,201,033. China Patent Numbers: ZL00815586.0, ZL03817053.1, ZL200710161083.2, ZL200710161084.7. FCI is a registered trademark of Fluid Components International LLC. Information subject to change without notice.

AG Green Energy 0512 2K

Visit FCI online at www.FluidComponents.com | FCI is ISO 9001 and AS9100 CertifiedFCI World Headquarters1755 La Costa Meadows Drive | San Marcos, California 92078 USA Phone: 760-744-6950 Toll Free (US): 800-854-1993 Fax: 760-736-6250

FCI EuropePersephonestraat 3-01 | 5047 TT Tilburg, The Netherlands | Phone: 31-13-5159989 Fax: 31-13-5799036

FCI Measurement and Control Technology (Beijing) Co., LTD | www.fluidcomponents.cnRoom 107, Xianfeng Building II, No.7 Kaituo Road, Shangdi IT Industry Base, Haidian District | Beijing 100085, P. R. ChinaPhone: 86-10-82782381 Fax: 86-10-58851152

Locally Represented By:

g Product selection to optimize flow meter for your application

– Single-point and multi-point solutions– Line sizes from 1/4" [6 mm] to 33' [10 m] diameter stacks– Analog and digital communications bus outputs– Multi-function flow, total flow and temperature– Single or multiple outputs– Integral and remote mounting– Gas temperatures to 850 °F [454 °C]– Widest selection of process connections available– Exclusive provider of Vortab flow conditioners

g ST51 is a compact, accurate, easy to install solution for measuring biogases, digester gases, methane and natural gas flow.

g MT86 and MT91 “multi-point” flow measuring systems can be configured with two (2) to sixteen (16) flow sensing elements to optimize measurements in the largest pipe and duct sizes.

g ST98 and ST98L combine high-performance measurement, an extensive selection of options and the widest selection of gas calibrations.

g ST75 is an in-line meter with extensive standard features that is the economical, easy-to-specify alternative to other maintenance intensive flow technologies.

g FLT93 Series is a robust and flexible line of flow/level/temperature switches for liquid, gas and slurry applications.

ST51

FLT93 Series

ST98/ST98L

ST75MT86 / MT91 Series

g ST100 Series – all gases, flow, temperature and pressure, multiple outputs, bus communications, graphical display, multiple calibrations, VeriCalTM, on-board data logger, and more.

ST100 Series

g Experience and expertise– Largest installed base in environmental

and greenhouse gas applications

g Superior flow meter calibrations– On-the-premises NIST certified

flow laboratory– Actual gas and process condition

calibrations– Mixed gas composition calibration

g Most extensive and comprehensive agency approvals for hazardous gas installations– Global approvals (FM, ATEX, IEC, CSA,

NEPSI, CPA, GOST/RTN, and more)– Complete instrument approvals:

Enclosure, electronics, sensor and seals

g Global sales and post-sale service support– Field service– Local repair and recalibration

depot service– Installation and start-up assistance– Local sales and application engineering

in more than 60 countries

FCI Thermal Dispersion Gas Flow Meters

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