Modernization of the TGTU III Gas Treatment Unit

MARCIN MASEK- GAS SAMPLE SP. Z O.O.

In the framework of the TGTU III (Tail Gas Treatment Unit) industrial plant modernization project, three advanced analytical systems were implemented: high-pressure superheated steam conductivity measurement, acidic water pH measurement, and two boiler blowdown conductivity systems.

A unique aspect of this project was the development of a dedicated diagnostic solution for sample flow signaling. This solution was created at the client's special request, enabling more precise and secure monitoring and control of the sample flow.

The system monitors steam at temperatures up to 300°C and a pressure of 32 bar. The sample is cooled and condensed, then measured with a conductivity probe. A key element of the system is the HACH Polymetron 9500 transmitter, which compensates for measurements based on sample temperature, ensuring accuracy in dynamic process conditions. The system was designed to fit into a thermally insulated and purged cabinet, which protects the measuring components from harmful environmental conditions, such as an H2S atmosphere.

Designed to operate with water at 92°C and a pressure of 5.8 bar, the system allows for continuous pH monitoring. Thanks to integrated cooling and filtration, the sample reaches the Hach 5336T probe under ideal measurement conditions. A key feature of this system is the ability to compensate for measurements based on temperature and to continuously monitor the sample's temperature and flow, which enables remote control of the system parameters.

Two conductivity systems for boiler blowdown were designed analogously to the above systems. Each system uses HACH technology for liquid conductivity measurements, as well as remote monitoring of sample temperature and flow. Each system also allows for a laboratory sample to be taken for diagnostic and service purposes.

One of the most interesting elements of the project was the creation of a proprietary flow diagnostic system for rotameters, which were not equipped with factory signaling.

At the client's request, a solution was created that enables the monitoring of sample flow and temperature. This allows for continuous tracking of the system's status through indirect measurements and monitoring via diagnostic algorithms.

The result is increased precision in the control of analytical systems and minimized risks associated with malfunctions or a lack of sample flow in the analytical system.

The implementation of modern analytical systems based on remote system diagnostics and the monitoring of sample temperature and flow has significantly improved the efficiency and safety of the industrial plant. The developed solutions, tailored to the user's specific needs, have enhanced the system's precision and reliability, minimizing the risk of downtime and failures.