ABB Stack gas flow metering system StackFlowMaster FPD580

Overview

The ABB StackFlowMaster FPD580 is a dedicated stack and duct gas flow metering system built around a Torbar multi-port self-averaging pitot sensor, engineered specifically for continuous emission monitoring on flue gas and process gas stacks – an application no compact pipeline flowmeter in ABB’s DP family is designed to serve. It is available in the FPD581, FPD583, and FPD585 variants to match different stack diameters, probe materials, and installation requirements, and is built around the ABB 267CS multivariable transmitter for a fully compensated flow output.

Seven Star LLC supplies the StackFlowMaster as a trusted supplier of ABB products in Oman and the GCC, sizing the probe material, diameter, and insertion length to the customer’s stack conditions and integrating it with ABB gas analyzers into a complete Continuous Emission Monitoring System (CEMS) package for environmental compliance reporting.

Operating Principle

The Torbar probe spans the stack or duct with multiple pressure-sensing ports along its length, averaging the velocity profile across the full diameter in the same way an averaging pitot does in a pressurized pipeline – but scaled, materially rated, and pressure-configured for hot flue-gas stack conditions rather than process piping. The probe’s high-pressure ports face into the gas flow while low-pressure ports read the downstream wake; the differential pressure this generates is proportional to the square of the gas velocity across a standard range of up to 50 m/s, or 3 to 35 m/s on MCERTS-approved configurations used for regulatory reporting.

The resulting differential pressure signal is converted to a real-time gas flow rate by the 267CS multivariable transmitter and, combined with the pollutant concentration reading from an integrated gas analyzer, is used to calculate the mass flowrate of pollutant discharged to atmosphere – the core measurement regulators require for emissions compliance reporting under frameworks aligned to EN 14181.

Engineering Design of the ABB StackFlowMaster FPD580

Probe material is selected to the stack’s actual gas temperature: 316L or 321H stainless steel covers service up to 550°C (up to 700°C with an optional bayonet fitting), while a UNS N06625 (Alloy 625) probe extends coverage to 900°C continuous duty and up to 1200°C for limited-life applications such as waste-incineration stacks. Probe diameters of 25 mm or 60 mm are available, mounted through flanges rated to ASME 150 lb RF or DIN PN10/PN16 RF, with asbestos-free or spiral-wound 316 stainless steel gasket options, and the system covers stacks from 1 to 8 metres (3.3 to 26.25 ft.) in diameter with optional end supports on larger stacks to prevent probe resonance and maintain mechanical stability in high-velocity flue gas.

A full-diameter probe is the standard configuration; a partial-insertion probe spanning less than half the stack diameter is available where weight or cost needs to be reduced. The 267CS transmitter is offered with a Hastelloy C276 sensor diaphragm, a DP span of 1 kPa or 6 kPa depending on expected velocity, and an aluminum-alloy or 316L stainless steel housing for corrosive stack environments. Options include a bayonet lock mechanism to minimize installation distortion, flanged fittings on both sides of the stack, automatic meter purging to handle particulate-laden gas, and automatic zero and span calibration to maintain measurement integrity between manual checks.

Key Features

• Torbar multi-port self-averaging pitot sensor purpose-built for stack and duct gas flow measurement
• System accuracy of ±2%, with repeatability ≤2% of measuring range and drift below 0.5%
• Probe material selectable for gas temperature: 316L/321H stainless steel to 550–700°C, or Alloy 625 to 900–1200°C
• Covers stack diameters from 1 to 8 metres (3.3 to 26.25 ft.) with velocity coverage up to 50 m/s
• MCERTS-approved configuration for 3–35 m/s, meeting EN 14181 and EN 15267-3
• Full-diameter or partial-insertion probe configurations to match weight and cost constraints
• ABB 267CS multivariable transmitter with Hastelloy C276 diaphragm and HART/4–20 mA plus Modbus RS485 output
• Automatic zero and span calibration and optional automatic meter purging for particulate-heavy gas streams
• Integrates directly with ABB gas analyzers into a complete, regulator-ready CEMS package

Industrial Applications

The StackFlowMaster is used at waste incineration plants, power stations, refineries, and chemical facilities across Muscat, Sohar, Salalah, and the wider GCC wherever continuous emission monitoring of stack or duct flue gas is required for environmental compliance reporting. The high-temperature Alloy 625 probe option is particularly relevant for waste-to-energy and process-heater stacks where flue-gas temperatures routinely exceed what a standard stainless steel probe can withstand.

As a trusted ABB supplier, Seven Star LLC supplies the correctly rated FPD581, FPD583, or FPD585 variant along with the compatible gas analyzer package needed to bring a stack into MCERTS-aligned compliance monitoring, supported by genuine ABB documentation and regional technical guidance from specification through commissioning.

Technical Specifications

Key technical specifications for the ABB StackFlowMaster FPD580 series are summarized below; contact Seven Star LLC for the full data sheet and model-specific ordering information.

Request a Quote for ABB Stack gas flow metering system StackFlowMaster FPD580

Contact Seven Star LLC to size an ABB StackFlowMaster FPD580 system for your stack or duct emission monitoring requirement in Oman and the GCC. As a trusted supplier of ABB products, we provide genuine equipment matched to your gas temperature and stack diameter, full MCERTS-aligned documentation, and complete CEMS integration support with compatible ABB gas analyzers.

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