Air Bechtel

we focus on your process

MECONTROL SystemsMECONTROL SystemsMECONTROL AirMECONTROL Air


Our Target:

Reliable Drift Free Measurement

with

low maintenance, high accuracy

Presentation


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


Page 5

Issues with Air Flow Measurement

Calibration?

Linearity?

Drift (Jamming)?

Accuracy in short pipe sections?

Flow straighteners (delta P loss)?


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


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


Page 8

MECONTROL Air Sensor + Connecting Piece


Page 9

Gas Flow Measurement Sensor


Page 10

Sensor Mounting Adapter

Approx 1.5”


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


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


Page 13

Single Air Flow Sensor LocationNiederaussem Station, Germany

Single Channel

2 sensors (antennas)


Page 14

Multiple Air Flow Sensor Locations

Niederaussem Station, Germany

3 channels


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.


Page 16

Reference of Measurement against Venturi


Page 17


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


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


Page 20

Measuring core air into the burners:Challenges:extremely short measurement sections


Page 21

Core air duct work:Installation of MECONTROL Air measurement:main core air duct individual burner core air


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


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


Iskenderun

04-10-17

Check of accuracy by mass flow balance


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


Iskenderun

04-10-27

Uneven distribution of core air


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


Iskenderun

04-10-27


Page 26

Final result of measurement:the secondary air windbox causes main air imbalance

31 32 33 34 35 36


Page 27

Mill 30

Main Cabinet


230 VAC Power supply

Primary AirPulverizedFuel

Mill 30

Main Cabinet



Main Cabinet



Primary AirPulverizedFuel

Coal mill at Vattenfall Europe: Power Station Reuter West/BerlinActual data from: September 2005

Reference: Mr. Thorsten Thimme


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

]


Individual Air flows out of the mill at standardized T and P


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

]


Balance of Sum Coal Pipes and Venturi is equal


Page 30

Track Record

Since 2001:

Over 200 installed

Never calibrated

Never cleaned

Temperatures up to 2000o F


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


Page 32

•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


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.


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)


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

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