Coal Loop Extractive Presentation Coal Gen 2005

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COAL-GEN 2005August 17, 2005 – San Antonio, Texas

Pulverized Coal Extractive

Testing Methods

Evaluation at the EPRI Coal FlowLoop

Robert Mudry, P.E.Matthew FlemingAirflow Sciences Corporation

Livonia, Michigan

Richard BrownJose SanchezThe Electric Power Research

InstitutePalo Alto, California




Why Measure Primary Air and

Coal?

s Quantify Pipe to Pipe Balanceq Burner Performance

• Unburned Carbon

• NOx Emissionsq Overall Boiler Efficiencyq Diagnose Burner Line

Issues

s Assess Mill Performanceq Fineness




Coal Pipe Flow Measurement

Methods

s Online, continuous measurementq Real-time coal balance informationq Data over the load range

s Extractive measurementq Pipe to pipe air and coal flow balanceq

Data at select operating conditionsq Pulverized coal samples




EPRI Coal Flow Loop




EPRI Coal Flow Loops Built in Livonia, Michigan

s Construction Completed2003q 12” Schedule 40 Steel Pipeq Victaulic couplingsq Reconfigurable pipe sections




EPRI Coal Flow Loop (cont.)

s Precise Control & Measurement of Air and Coalq < 0.5% air flow measurementq < 1.0% coal flow measurement

s 10-120 ft/sec in-pipe Velocityq 1400-5600 CFM

s 1 to 4 Air/Coal Ratioq 2,000-20,000 lbm/hr coal flow

s Ambient to 180 °F Air/Coal Temperature




Particulate Flow After Double

Bend




Extractive Sampling Methods

Evaluated

s Dirty Air Velocity Probe

s ASME PTC 4.2 (“The ASME Method”)

s

ISO 9931 (“The Rotorprobe™

Method”)




Extractive Sampling Methodology

s Primary Air Flowq Mill Inlet or Coal Pipeq Flow Rate

q Velocityq Temperature

s “Clean Air” Testing

s “Dirty Air” Testing Coal pipe testing with Advanced Coal

Flow Measurement (ACFM) device




Extractive Sampling Methodology

s Coal Flowq Isokinetic sampling

based on primary air velocity

q Integrate coal flowrate based onsample weight andextraction time

q Dry vs. wet coalcomparison tofeeder




Extractive Test Matrix

s Examine effect of various parameters onaccuracyq Probe / Method Typeq Measurement Locationq Air / Coal Ratio Conditionsq Extraction Rate Sensitivityq Number of Test Ports Requiredq Number of Traverse Points Required




Clean Air Velocity Measurement

s The Dirty Air Velocity Probe traverseinitially read ~6% high compared tothe true pipe velocity profile measuredwith a pitot probe

s The deviation was found to be caused by probe blockage of the pipe cross section and incomplete measurement at thefar wall due to probe geometry

s With corrections for these two probe geometry influences, theDirty Air Probe traverse correlated to within 0.5% of the truepipe velocity profile




Clean Air Velocity MeasurementComparison of Velocity Profile

Pitot Tube And Dirty Air Probe

40.0

50.0

60.0

70.0

80.0

90.0

100.0

-6.00 -4.00 -2.00 0.00 2.00 4.00 6.00

Distance From Pipe Centerline (inches)

I n

d i c a t e d A i r V e l o c i t y ( f t / s )

Pitot Tube

Dirty Air Probe

Location 1V15

80 ft/secClean Air DA Probe integrates

flow rate ~6% high

compared to pitot




Pipe Blockage Correction Factor

P o i n t 1 : 8 . 6 8 % O f P i p e A r e a B l o c k e d B y P r o b eB l o c k a g e C F = 1 - 0 . 0 8 6 8 = 0 . 9 1 3 2

P o i n t 8 : 3 . 9 9 % O f P i p e A r e a B l o c k e d B y P r o b eB l o c k a g e C F = 1 - 0 . 0 3 9 9 = 0 . 9 6 0 1

P o i n t 1 5 : 0 . 6 1 % O f P i p e A r e a B l o c k e d B y P r o b eB l o c k a g e C F = 1 - 0 . 0 0 6 1 = 0 . 9 9 3 9

Note: The larger the pipe

diameter, the less impact

the probe blockage has on

the velocity measurement




Pipe Blockage Correction Factor Comparison of Velocity Profile


40.0

50.0

60.0

70.0

80.0

90.0

100.0

-6.00 -4.00 -2.00 0.00 2.00 4.00 6.00


I n d i c a t e d A i r V e l o c i t y ( f t / s )

Pitot Tube

Uncorrected DA Probe

Blockage Corrected DA Probe

Location 1V15

80 ft/secClean Air




Far Wall Correction Factor

T r a v e r s e P o i n t s

P r o b e M e a s u r e m e n t P o i n t




Far Wall Correction Factor Comparison of Velocity Profile


40.0

50.0

60.0

70.0

80.0

90.0

100.0

-6.00 -4.00 -2.00 0.00 2.00 4.00 6.00


I n d i c a t e d A i r V e l o c i t y ( f t / s )

Pitot Tube

Uncorrected DA Probe

Blockage Corrected DA Probe

Far Wall Corrected DA Probe

Location 1V1580 ft/sec

Clean Air

DA Probe correlates towithin 0.5% of pitot

after both corrections




Dirty Air Velocity Measurement

s Dirty Air Velocity Probe has now beencalibrated in clean air flow

s How accurately does it measure air

velocity in the presence of coal?s Test matrix:

Air Velocity

(ft/sec) 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 Clean75 X X X X X

95 X X X X X

110 X X X X X

Air/Coal Ratio





s Results indicate that the velocity readingis, in fact, influenced by the amount of coal flowing in the pipe

s It is hypothesized that the coal affects the pressure readingon each side of the probe’s disc

s This causes the Dirty Air Probe to read high compared to thetrue air flow rate

s A correction factor can be developed based on the coal massflow rate to restore accuracy to within 2%

s This creates a bit of a dilemma in setting the extraction ratefor isokinetic coal sampling, but corrections can be madepost-test





Effect of Air/Coal Ratio On Dirty Air Probe Accuracy

-5%

0%

5%

10%

15%

20%

25%

0.0 0.2 0.4 0.6 0.8 1.0 1.2

Coal/Air Ratio

D A P r o b e M e a s u r e m e

n t E r r o r ( % )

75 Ft/s

95 Ft/s

110 Ft/s

ec o r oa a o on r y r ro e




Effect of Air/Coal Ratio on Dirty Air Probe Accuracy

y = 0.2071x - 0.0018

R2

= 0.9773

-5.0%

0.0%

5.0%

10.0%

15.0%

20.0%

25.0%

0.000 0.200 0.400 0.600 0.800 1.000 1.200

Coal/Air Ratio

D A P r o b e M e a s u r e m e n t E r r o r ( % )

ec o r oa a o on r y r ro eAccuracy

D A

P R O B E M E A

S U R E M E N T

E R R O R

( % )

COAL/AIR RATIO




Coal Flow Rate Measurement



COAL-GEN 2005

August 17, 2005 – San Antonio, Texas

Coal Flow Rate Measurement

s For the ASME method, the accuracy (random error)of the coal flow measurement can be influenced bythe proximity to the upstream elbowq Accuracy ±9% at 15 diameters, 2 test portsq

Accuracy ±35% at 3 diameters, 2 test portsq Accuracy ±13% at 3 diameters, 4 test ports

s ISO 9931 method accuracy (random error) is fairlyconsistent at all test locationsq

Accuracy ±8%, 2 test ports



COAL-GEN 2005


Isokinetic Extraction Rate

Sensitivitys Accuracy of the coal flow measurement is degraded for both

methods if the isokinetic extraction rate is incorrect

s The ASME method is more sensitive to extraction rateq For every 10% change in the extraction rate, coal flow

measurement changes by ~7%

s The ISO 9931 method is less sensitive to extraction rateq For every 10% change in the extraction rate, coal flow

measurement changes by ~2.5%



COAL-GEN 2005


Number of Test Ports and

Traverse Points

9 0 . 0 °6 0 . 0 °

4 5 . 0 °3 0 . 0 ° 1 5 . 0 °

1 T e s t P o r t 2 T e s t P o r t s 3 T e s t P o r t s

4 T e s t P o r t s 6 T e s t P o r t s 1 2 T e s t P o r t s

Equivalent Port Location: up to

12 Traverses were performed spaced 15 degrees apart

15 Points were sampled

in each traverse



COAL-GEN 2005


Rotating Test Port for Extractive

Testings 180° Swivel

s String Potentiometer for Angle Alignment

s 180 Point Gridq 15 ° intervals = 12

traverses

s Linear Probe Actuator q 15 sampling

points/traverse



COAL-GEN 2005


Plot – effect of number of ports -

air

Effect of Number of Test Ports on Air Flow Measurement

Standard Dirty Air Probe - Location 1V15

0%

1%

2%

3%

4%

5%

1 2 3 4 5 6

Number of Test Ports

C h a n g e

R e l a t i v e t o 1 2 P o r t M e a s u r e m e n t

75 ft/s, Air/Coal=3

95 ft/s, Air/Coal=2.25

115 ft/s, Air/Coal=3


Average



COAL-GEN 2005


Plot – effect of number ports - coalEffect of Number of Test Ports on Coal Flow Measurement

ASC Coal Sampling Probe - Location 1V15

0%

1%

2%

3%

4%

5%

1 2 3 4 5 6


C h a n g e

R e l a t i v e t o 1 2 P o r t M e a s u r e m e n t

75 ft/s, Air/Coal=3

115 ft/s, Air/Coal=3


Average



COAL-GEN 2005


Plot – effect of number of ports -

air

Effect of Number of Test Ports on Air Flow Measurement


0%

1%

2%

3%

4%

5%

1 2 3 4 5 6


C h a n g e R

e l a t i v e t o 1 2 P o r t

M e a s u r e m e n t 75 ft/s, air/coal=3

75 ft/s, air/coal=1.5


115 ft/s, air/coal=3

No Data

Average



COAL-GEN 2005


Plot – effect of number ports - coalEffect of Number of Test Ports on Coal Flow Measurement


0%

10%

20%

30%

40%

50%

60%

70%

1 2 3 4 5 6


C h a n g e R e l a t i v e t o 1 2 P o r t

M e a s u r e m e n t

75 ft/s, air/coal=3




No Data

Average



COAL-GEN 2005


Air – effect of number of points

Effect of Number of Traverse Points on Air Flow Measurement


0%

1%

2%

3%

4%

5%

2 3 4 5 6 7 8 9 10 11 12 13 14 15

Number of Traverse Points

C h a n g e R e l a t i v e t o 1 5 P

o i n t T r a v e r s e

75 ft/s, air/coal=395 ft/s, air/coal=2.25



Average



COAL-GEN 2005


Coal – effect of number of pointsEffect of Number of Traverse Points on Coal Flow Measurement


-16%

-14%

-12%

-10%

-8%

-6%

-4%

-2%

0%

2%

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Number of Traverse Points

C h a n g e

R e l a t i v e t o 1 5 P o i n t T r a v e r s e

75 ft/s, air/coal=3



Average



COAL-GEN 2005


Number of Test Ports and

Traverse Points

s Results to date have been summarized

s Additional testing is still planned

s

For acceptable accuracy (within 2% on air, 5% oncoal):

Location


Required

Number of Traverse

Points Required

1V15 2 9

1V11 2 9

1V7 3-4 9

1V3 4 9

3V3 6 15



COAL-GEN 2005


In Summary, Results to Date Suggest…

s Dirty Air Probe can achieve dirty air flow measurement accuracyto within 2%q Proper correction factors are requiredq Velocity reading is dependent on air-to-coal ratio, complicating

calculation of isokinetic extraction rate

s For a single upstream bendq ASME method can achieve coal measurement accuracy within 10-13%q More test ports are required as test plane moves closer to an elbowq ISO 9931 method can achieve coal measurement accuracy to within 8%

s Accuracy of both methods is influenced by geometry of upstreamelbows (degree of roping)

s Rotorprobe is less sensitive to extraction rate than ASMEmethod

s Need to perform additional testing to complete the data analysisand create generalized correction factors



COAL-GEN 2005


Acknowledgements

s Companies that Initiated the Coal Loop Project:q American Electric Power – JJ Letcavitsq Alliant Energy – Gary Wallingq Ameren – Kevin Kerstingq Dairyland Power Coop. – Duane Hillq Dynegy Midwest Generation– Sam Korellisq Oglethrope Power Corp.– Kerry Faulkner q

TXU – Mark Smiths EPRI Program 71 Members



COAL-GEN 2005

August 17 2005 San Antonio Texas

Questions?

s For More Information Contact:q Rob Mudry (734) 525-0300 [email protected] Matt Fleming (734) 525-0300 [email protected]

Jose Sanchez (650) 855-2580 [email protected] Rich Brown (650) 855-2216 [email protected]

Coal Loop Extractive Presentation Coal Gen 2005

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