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Global Leader In SNG Energy Systems

(Synthetic Natural Gas)

A F C

S N G

B l e n d e r

S e r i e s

Get what you deserve...


SNG consumers demand gas quality regardless of their ow prole. They demand an SNG blender equipped as standard with the critical safety and control functions available to them. These include Auto-Ratio-Control, Class 1 Division 1 Group D location suitability, ow meters to understand gas and air ows, pressure transmitters to understand their pressures and an HMI for ease of operation. The AFC provides what you demand and more!

Feed Forward Control Advantages


Only the AFC delivers an accurate LPG-air mix immediately upon start-up and under rapid load changes. When the AFC is started, the LPG ow meter sends a ow value to the control system. The control system responds instantaneously and predetermines the position of the air ow control valve relative to the LPG vapor owrate. Within seconds, the actual measured air ow rate is compared with the calculated ow rate and the control system makes the necessary adjustments. The AFC is now on line. Perfect gas quality no wild swings and no bad gas typical of old conventional mixing systems.

Probus PA Instrumentation A fully packaged, intelligent system designed to replace all existing mixing technologies

At low SNG ow rates, conventional mixing systems have turndown problems. The typical solution is to manually turn off the mixing system, manually adjust the regulator pressures to a lower setting and then manually restart the mixing system. The customer then operates the system at this lower SNG discharge

Mix with intelligence


AFC stands for Active Flow Control. In conventional feedback only blenders, poor gas quality is identied too late. Heat sensitive products, particularly glass, ceramics or food can be ruined by poor gas quality. The potential costs can be enormous. For SNG systems serving residences in a CityGas application, the concerns for gas quality are even more stringent. Why take a risk... The AFC eliminates after the fact problems. The AFC strategy. The intelligent control system pre-determines, instantaneously, the appropriate position of the air ow control valve to provide the correct air to LPG ratio. Simultaneously, actual air ow through the blenders air meter is compared with the calculated air ow required to the exact air to LPG ratio. The AFC performs this ne tuning perfectly and instantly.... The AFC has a process response cycle time of 600 milliseconds compared to 5 minutes or more in the case of conventional blenders using only a feedback signal!

pressure until there is a need to increase ow again. The AFCs Line Pak option allows pressure and ow parameters to be pre-set in the Control System. Mixing with intelligence, the AFC automatically closes the mixed gas outlet valve and then automatically reopens it at a lower down-stream pressure! No manual steps required and the concern of turndown is eliminated!
AFC Flow and Wobbe response curve
1,800
Flow Rate & Wobbe Index (Sm3/hr & BTU/SCF)

utilizes a combined feed-forward and feedback control

1,600 1,400 1,200 1,000 800 600 400 200 0 0 200 400 600 800 1000 Time (seconds)
Target Wobbe Setpoint Actual Wobbe Actual Value SNGFlowrate Flowrate MG

Graph illustrates the accuracy of the Actual Wobbe value versus the Target Wobbe value and the rapid correction of the Wobbe value when an SNG ow rate change occurs.

Key Components
7

LPG Vapor Automatic Safety Valve

14

SNG Discharge Safety Valve

18

Air Flow Control Valve

SNG Pressure Transmitter

17

SNG Outlet

Pressure Transmitters

LPG Vapor Inlet

Air Inlet

Local Junction Box

20

Operation

* Optional Line Pak


Flow Meter
5

The AFC blends LPG vapor and air at a specic ratio to perfectly simulate the combustion characteristics of natural gas. Pressure and temperature compensated ow meters, as shown in the schematic, measure the regulated ow of LPG and air. The volumetric ow of both gas streams are converted to their true molar values with a sophisticated gas ow algorithm that takes into account the system pressures, temperatures and compressibility factors. The ratio of the two ow rates is then compared to the calculated air to LPG ratio required for the Wobbe Index of the natural gas being simulated. Adjustments to the ratio are made only on the air side of the system. Adjustments are automatic and are performed by the Air Flow Control Valve. As the ow of SNG either increases or decreases, the Air Flow Control Valve modulates and maintains an exact and constant mixing ratio between the LPG and air streams. The result is a Wobbe value that typically varies < +/- 1%. Manual or automatic adjustments of the mixing ratio are performed from the touch screen of the HMI (Human Machine Interface) of the AFC.
1 2 8 9

12

Pressure Regulators (Not provided) Buttery-type Isolation Valve

16

Pressure Indicator (Displays mixed gas discharge pressure) Pressure Transmitter (Provides mixed gas discharge pressure signal to the control system) SNG Discharge Safety Valve (Pneumatically opens spring close; Valve closes when there is a safety violation) Buttery-type Isolation Valve Local Junction Box (Mounted on the AFC Blender) Probus Cable (Single cable link from the AFC Junction Box to the Control Panel) Control Panel (Simple Touch Screen design; Operator-friendly and compact)

17 3 10 4 11

Wafer-type Back Flow Check Valve Pressure Transmitters (Pressure correction of the ow data) Flow Meters (With temperature compensation)
19

18

5 12

Pressure regulators installed upstream of the AFC maintain constant pressure to both the vapor and air inlets. Therefore, the AFC responds much like a traditional regulator. When providing SNG in a piped network, as the gas distribution pressure decreases, the SNG ow rate will increase to maintain pressure. Likewise, when the gas distribution pressure rises, the SNG ow decreases. The LPG vapor regulator establishes the AFC discharge pressure.
15 7

Air Flow Control Valve (Controls air ow based on ow and control parameters) LPG Vapor Automatic Safety Valve (Pneumatically opens - spring close; Valve closes when there is a safety violation) Turbulators (Internal to header)

20

14

21

22

Pressure Transmitter (Used only * SNG with Line Pak option)

Dimensional Data:
MODEL Ft./In A2 A3 A4 mm Ft./In mm Ft./In mm Ft./In A5 A6 A7 mm Ft./In mm Ft./In mm

AFC MODEL DATA


A 6-0 1829 6-0 1829 7-0 2134 7-6 2286 9-6 2896 12-6 3810 B 2-6 762 2-6 762 3-3 991 3-3 991 4-0 1219 4-2 1270 C 1-6 457 1-6 457 2-1 635 2-1 635 2-6 762 2-6 762 D 2 2 3 4 6 8 E 2 2 3 4 6 8 F 4 4 6 6 8 10

150#RF 150#RF 150#RF 150#RF 150#RF 150#RF 150#RF 150#RF 150#RF 150#RF 150#RF 150#RF 150#RF 150#RF 150#RF 150#RF 150#RF 150#RF

F B E D C A
All dimensions in imperial and metric units

Ft./In Flange Types A8


SNG = 150#RF

mm

Contact Factory for Sizing and Dimensions Dimensions are not certied

LPG = 150#RF

Air = 150#RF

AFC CAPACITY GUIDE


CAPACITIES BASED ON HD5 PROPANE DISCHARGE PSIG 20 30 40 50 60 70 80 90 100 110 120 130 20 30 40 50 60 70 80 90 100 110 120 130 0.14 0.21 0.28 0.35 0.41 0.48 0.55 0.62 0.69 0.76 0.83 0.90 0.14 0.21 0.28 0.35 0.41 0.48 0.55 0.62 0.69 0.76 0.83 0.90 28 36 43 50 58 64 71 78 84 90 96 102 33 40 48 55 62 69 75 82 89 96 102 109 A2 NM3/ h 536 674 813 951 1090 1217 1341 1464 1584 1702 1818 1932 606 748 882 1017 1144 1278 1398 1526 1652 1776 1898 2018 70 88 106 124 142 158 175 191 206 222 237 252 80 99 117 135 152 169 185 202 219 235 251 267 A3 MMBTU/h NM3/ h 1317 1657 1998 2338 2678 2991 3297 3598 3894 4184 4170 4750 1490 1839 2168 2500 2813 3142 3436 3751 4061 4366 4666 4960 116 146 176 207 237 264 291 318 344 370 395 420 134 165 195 225 253 282 309 337 365 392 419 445 A4 MMBTU/h NM3/ h 2196 2764 3331 3899 4466 4987 5498 6000 6493 6978 7453 7921 2484 3067 3615 4169 4690 5240 5729 6255 6772 7280 7780 8271 261 329 396 463 531 593 654 713 772 829 886 941 300 371 437 504 567 633 692 756 818 880 940 999 Mpa MMBTU/h

MODEL
A5 MMBTU/h NM3/ h 4928 6202 7475 8748 10022 11191 12338 13464 14571 15657 16724 17773 5574 6881 8111 9354 10525 11757 12855 14035 15196 163361 17458 18560 452 569 686 803 920 1027 1132 1235 1337 1437 1534 1631 520 642 757 873 982 1097 1199 1309 1417 1524 1628 1731 A6 MMBTU/h NM3/ h 8537 10742 12948 15154 17360 19385 21372 23324 25240 27122 28971 30787 9655 11920 14050 16204 18231 20366 22268 24313 26322 28298 30241 32151 1029 1294 1560 1826 2092 2336 2575 2810 3041 3268 3491 3709 1183 1460 1721 1985 2233 2495 2728 2978 3224 3466 3704 3938 A7 MMBTU/h 19419 24437 29455 34473 39491 44096 48618 53057 57416 61697 65902 70034 21963 27116 31961 36861 41473 46329 50655 55307 59878 64373 68792 73137 A8 NM3/ h MMBTU/h NM3/ h

CONTACT FACTORY

CAPACITIES BASED ON 40% BUTANE / 60% PROPANE

CONTACT FACTORY

The nal sizing to be conrmed by Ely Energy Factory and may vary from typical sizing shown above Dimensions are non-certied and not for engineering or design use Product improvement is a continuing goal at Ely Energy. Design and specications are subject to change without notice

Intelligent Instruments:
IEC61158-2 digital eldbus communication is standard No analog scaling errors or drift: All data transmitted directly to the PLC via digital eldbus Values transmitted directly in 32-bit oating-point format; eliminates scaling errors Advanced diagnostic information: Process values transmitted with a diagnostic byte to indicate signal quality Alarms triggered when signal quality is questionable, no guess work! Integrated explosion-proof protection: Instruments are bus powered via Zone 0, Ex ia power supply
Standard Blender Evaluation
(Standard features on base unit) Class 1 Division 1 Group D Suitable Auto Ratio Control LPG Pressure Transmitter Air Pressure Transmitter Touch Screen Optional Voltage LPG Flow Measurement Air Flow Measurement SNG Flow Measurement Feed Forward and Feed Back Control Probus communication No wiring on skid! Design eliminates use of mixing valve? Design eliminates chance of sticking piston? Only one cable from Control Panel to Blender Can achieve ow rates of AFC Can achieve operating pressure of AFC YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES YES 17 pts Ely Energy AFC

Manufacturer
Mfg. X
YES NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO

Mfg. Y
NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO NO

Score

1 pt

0 pts

AFC or the other brand? You decide

Robust ow measurement:
Immune to: Vibration to over 1 g in all axis Thermal shock > 150 K/s Dirty media Permanent self-monitoring and diagnostic of electronics and sensor. No maintenance No moving parts No zero-point drift on ow sensor

Intelligent process control:


Automatic calculation of mixing ratio set-point to achieve the target Wobbe Index Automatic Ratio Adjustment when an optional Wobbe Index meter is used Adjustable alarm set-points and process response via HMI screens Alarm messages with process value stamps Extensive process value display for process diagnostics: For each ow stream the AFC can display: Real-time pressure Real-time temperature Real-time actual ow Real-time corrected ow at standard conditions Totalized ow at standard conditions Real-time molar ow Real-time gas stream velocity Real-time compressibility factor Real-time gas density Real-time volumetric ratio Real-time molar ratio Mixed gas pressure (available with Line-Pak optional) Mixed gas totalized ow at standard conditions Control valve throttle position Real-time Wobbe Index of mixed gas Communication interfaces available: RS-232 (ASCII, 3964R) RS-485 (MPI, Probus, Modbus, DF1, DH485) Ethernet (TCP/IP, Http, FTP, Web, OPC)

True digital ow control valve positioning:


Robust piezoelectric valve block is virtually wear proof Minimum air consumption required by piezoelectric valves One touch, push button self-tuning of valve positioner Local display of controller set-point and actual valve position Extended diagnostic information (e.g. positioner will even report lack of instrument air!)

F ro m

1 898

to

the

21st

Centur y... .

Ely Energys origin dates to 1898 when Energy Systems, Inc. (ESI), a company later acquired by Ely Energy, began as a mechanical contractor in Minnesota (USA). By the 1950s ESI had branched out into associated mechanical engineering activities that grew to include the design and manufacture of Synthetic Natural Gas (SNG) systems. In 1980 ESI was acquired by the RJ Ely Company of Tulsa, Oklahoma (USA) and began operations as Ely Energy Systems, and later as Ely Energy Inc., a subsidiary of the RJ Ely Company. In 1998, under a corporate consolidation, the corporation formerly changed to Ely Energy, Inc. (EEI) Today Ely Energy is an expanding, diversied designer and manufacturer of high quality process equipment for the global environmental, power and process markets. ITMation Ltd. (ITM) is a Hong Kong based partner of Ely Energy. ITM specializes in automation, process controls and providing innovative solutions to industrial and utility needs.


Tulsa

ITM Hong Kong

Blue dots represent global AFC user locations

Other Products:

STABILIZER LPG Pump Set

STEAM-FLO SV Series Vaporizer

Wobbe Index Meter (WI/A)

AFC is a trademark of ELY Energy, Inc. Ask for your free Ely Energy Corporate Prole
Represented by:

11385 E. 60th Place So. Tulsa, Oklahoma 74146, USA Phone: 918-250-6601 Fax: 918-254-5412 Visit us at: www.elyenergy.com Email: sales@elyenergy.com
Copyright 2005 Ely Energy Inc. Publication: AFC-8/05