Air Bechtel
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Transcript of Air Bechtel
we focus on your process
Page 1
MECONTROL SystemsMECONTROL SystemsMECONTROL AirMECONTROL Air
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Page 2
Our Target:
Reliable Drift Free Measurement
with
low maintenance, high accuracy
Presentation
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Page 4
Steam generator
BurnerS
econ
dary
air Air preheater
FD-Fans
Excess Air
Electricprecipitator
Intermed. Fly-ash bunker
Fly ash
Flue gas
Coal bunker
Coal mill
Pu
lveri
zed
fuel
Prim
ary
air
System Application for Boiler OptimizationMECONTROL
Air
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Page 5
Issues with Air Flow Measurement
Calibration?
Linearity?
Drift (Jamming)?
Accuracy in short pipe sections?
Flow straighteners (delta P loss)?
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Page 6
MECONTROL Air Measurement Principle „velocity“
Sensor 2
Air Duct or Pipe
Sensor 1S=const.
ExampleS=54 cmT=26 ms
w=20,8 m/s (average velocity of the air !)
Signal Sensor 1
Signal Sensor 2
“Signature”
Y(t)=X(t-T)X(t)
Time T
correlation “Correlation”
T=-26 ms Optimum of correlation
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Page 7
MECONTROL Air Installation overview
Air duct
Sensor 1
Sensor 2
Sensor box(per burner)
max. 4 Sensors/2 channels
Sensor 3/4
4 x Sensor signals
Power supply24 VAC
Measurement cabinet
Connection to the DCS
230 VDC Power supply
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Page 8
MECONTROL Air Sensor + Connecting Piece
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Page 9
Gas Flow Measurement Sensor
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Page 10
Sensor Mounting Adapter
Approx 1.5”
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Page 11
Local Sensor Box
• 2 Channel Capability– 16” x 12”
• Mounted within 50 feet of sensors
• Signal Amplification• NEMA 4 Rated• Located within 1000’
of Control Cabinet
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Page 12
Control Cabinet
• 48 Channel Capability– 63” x 24” x 79”
• 4, 8, 16 & 32 Channel also available
• Error Indicators• NEMA 4 Rated• Data Communication:
– Modem, FTP, PROFIBUS, MODBUS, Others upon request
• 40-80˚ F Temp Required
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Page 13
Single Air Flow Sensor LocationNiederaussem Station, Germany
Single Channel
2 sensors (antennas)
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Page 14
Multiple Air Flow Sensor Locations
Niederaussem Station, Germany
3 channels
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Page 15
PS Iskenderun, Turkey:
Main plant data: (2 x 600 MW), erected 2003/2004
24 burners, double wall fired:
Measurement of:
-windbox secondary air system,
-core air system with short duct runs,
-primary dirty air per burner.
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Page 16
Reference of Measurement against Venturi
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Page 17
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Page 18
Burner 31Burner 36
Burner 32Burner 35
Burner 33Burner 34
Damper
Challenges:- short inlet sections of secondary air- downstream flap dampers- air stratification in ducts
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Page 19
MECONTROL AirSecondary Air Measurement Channels
0
10000
20000
30000
40000
50000
60000
06:00 07:12 08:24 09:36 10:48 12:00
[m³/
h]
SecABrn32Out SecABrn32In SecABrn33Out SecABrn33In
SecABrn34Out SecABrn34In SecABrn35Upper SecABrn35lower
PROMECON we focus on your process
Iskenderun
04-10-27
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Page 20
Measuring core air into the burners:Challenges:extremely short measurement sections
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Page 21
Core air duct work:Installation of MECONTROL Air measurement:main core air duct individual burner core air
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Page 22
Air flow balance:
for proof of plausibilityplant demanded a balanceto be made of main ductmeasurements versus indi-vidual core air measurementat each burner.
Individual core air flow position
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Page 23
MECONTROL AirSummecheck Core Air
0
10000
20000
30000
40000
50000
60000
00:00 02:24 04:48 07:12 09:36 12:00 14:24 16:48 19:12 21:36 00:00
[m³/
h]
Sum Total core Air Front Sum burner core Air Front
Sum Total core Air Rear Sum burner core Air Rear
PROMECON we focus on your process
Iskenderun
04-10-17
Check of accuracy by mass flow balance
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Page 24
MECONTROL AirCore Air Burner
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
10000
06:00 07:12 08:24 09:36 10:48 12:00
[m³/
h]
CoreABrn31 CoreABrn32 CoreABrn33
CoreABrn34 CoreABrn35 CoreABrn36
PROMECON we focus on your process
Iskenderun
04-10-27
Uneven distribution of core air
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Page 25
Measurement of primary air out of the pulverizermeasurement of dirty air flow in indivual burner linessubtraction of steam.
MECONTROL AirPrimary Airflow
0
5000
10000
15000
20000
25000
06:00 07:12 08:24 09:36 10:48 12:00
[m³/
h]
Burner31 Burner32 Burner33 Burner34
Burner35 Burner36
PROMECON we focus on your process
Iskenderun
04-10-27
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Page 26
Final result of measurement:the secondary air windbox causes main air imbalance
31 32 33 34 35 36
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Page 27
Mill 30
Main Cabinet
Connection to the DCS
230 VAC Power supply
Primary AirPulverizedFuel
Mill 30
Main Cabinet
Connection to the DCS
230 VAC Power supply
Main Cabinet
Connection to the DCS
230 VAC Power supply
Primary AirPulverizedFuel
Coal mill at Vattenfall Europe: Power Station Reuter West/BerlinActual data from: September 2005
Reference: Mr. Thorsten Thimme
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Page 28
MECONTROL AirParticle Velocity Mill 30
0,0
5,0
10,0
15,0
20,0
25,0
30,0
00:00 01:12 02:24 03:36 04:48 06:00
0,0
20,0
40,0
60,0
80,0
100,0
120,0
140,0
160,0
180,0
200,0
Cla
ss T
emp
[°C
]
Burner 31 Burner 32 Burner 33 Burner 34 Class. Temp
11.09.2005
[Nm
³/h
]
PROMECON we focus on your process
Individual Air flows out of the mill at standardized T and P
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Page 29
MECONTROL AirPrimary Air and Particle Velocity Measurement Mill 30
0
5000
10000
15000
20000
25000
30000
35000
40000
45000
0:00:00 1:12:00 2:24:00 3:36:00 4:48:00 6:00:00
0,0
5,0
10,0
15,0
20,0
25,0
30,0
35,0
40,0
Fee
der
[t/
h]
Venturi Sum Coalpipes-Brüden Feeder
11.09.2005
Bewag_D_M30_PL
[Nm
³/h
]
PROMECON we focus on your process
Balance of Sum Coal Pipes and Venturi is equal
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Page 30
Track Record
Since 2001:
Over 200 installed
Never calibrated
Never cleaned
Temperatures up to 2000o F
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Page 31
MECONTROL Air References
• Schwenk Zementwerk in Bernburg 2002 measurement of 13 Air flows including Tertiary Air at 1100°C
• Vattenfall/BEWAG KW Reuter West Unit D, Berlin 2003 Replacement of all 32 conventional Venturi measurements, boiler safety relevant certification (AK3, SIL1) by TÜV Berlin
• Vattenfall/BEWAG KW Reuter West Unit E, Berlin 2003 Replacement of all 32 conventional Venturi measurements, boiler safety relevant certification (AK3, SIL1) by TÜV Berlin
• RWE/Rheinbraun KW Niederaußem Unit G,Bergh.2003 Retrofit of 48 measurement locations including primary and secondary air flows
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•RWE/Rheinbraun KW Niederaußem Unit A,Bergh.2004 Retrofit of 32 measurement locations including primary and secondary air flows
•RWE/Rheinbraun KW Niederaußem Unit E,Bergh.2004 Retrofit of 32 measurement locations including primary and secondary air flows
•HOLCIM Texas, Midlothian, 2005 Retrofit of 8 Measurement locations including raw gas and tertiary air
•Reliant Energy Niles Power Station, 2006 Measurement of 4 locations on the flue gas side
•Thyssen Krupp Steel, Werk Duisburg, 2006 7 measurement locations downstream of steel converter
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Page 33
•Southern Company 2005 Retrofit of exhaust gas measurement at 1000 oC and 25 bar pressure in refractory lined coal gasifier
•Ashgrove Cement Utah, 2005 Measurement of 8 locations, raw gas as well as tertiary air
•Dayton Power and Light, 2006 Retrofit of 8 mills with primary air flow measurement
•Vattenfall Kraftwerk Jänschwalde, Unit D2, 2005 Retrofit of 16 measurement locations including primary and secondary air on a ventilation mill by ALSTOM for mill balancing and intelligent control.
•EVN Kraftwerk Dürnrohr 2004, Retrofit of 32 burner pipes with velocity measurement for better primary air control.
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Page 34
•Steag/Isken Power Station Iskenderun, 2005 16 Measurements of secondary air as well as 6 measurements of coal flow and primary air for better Air balancing
•TXU, Power Station Monticello USA, 2 Units 2006 2 x 10 Measurements for primary air flow.
• E2 Power Station Stigsnaes, DK, 2006 12 Measurements for measurement of OFA installed by General Electric
•EDF, Power Station West Burton, 2005 16 measurements for measuring OFA of a reburn system (Installed by General Electric)
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Page 35
• RWE Kraftwerk Niederaußem, Unit H, 2006, measurement of 40 locations secondary as well as primary air flow
• Vattenfall Kraftwerk Reuter West Unit D, 2006, measurement of 4x PA before as well as 16x PA after the pulverizer
• Vattenfall Kraftwerk Reuter West Unit E, 2006, measurement of 4x PA before as well as 16x PA after the pulverizer