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
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COAL-GEN 2005August 17, 2005 – San Antonio, Texas
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
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COAL-GEN 2005August 17, 2005 – San Antonio, Texas
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
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COAL-GEN 2005August 17, 2005 – San Antonio, Texas
EPRI Coal Flow Loop
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COAL-GEN 2005August 17, 2005 – San Antonio, Texas
EPRI Coal Flow Loops Built in Livonia, Michigan
s Construction Completed2003q 12” Schedule 40 Steel Pipeq Victaulic couplingsq Reconfigurable pipe sections
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COAL-GEN 2005August 17, 2005 – San Antonio, Texas
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
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COAL-GEN 2005August 17, 2005 – San Antonio, Texas
Particulate Flow After Double
Bend
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COAL-GEN 2005August 17, 2005 – San Antonio, Texas
Extractive Sampling Methods
Evaluated
s Dirty Air Velocity Probe
s ASME PTC 4.2 (“The ASME Method”)
s
ISO 9931 (“The Rotorprobe™
Method”)
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COAL-GEN 2005August 17, 2005 – San Antonio, Texas
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
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COAL-GEN 2005August 17, 2005 – San Antonio, Texas
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
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COAL-GEN 2005August 17, 2005 – San Antonio, Texas
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
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COAL-GEN 2005August 17, 2005 – San Antonio, Texas
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
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COAL-GEN 2005August 17, 2005 – San Antonio, Texas
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
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COAL-GEN 2005August 17, 2005 – San Antonio, Texas
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
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COAL-GEN 2005August 17, 2005 – San Antonio, Texas
Pipe Blockage Correction Factor Comparison 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
Uncorrected DA Probe
Blockage Corrected DA Probe
Location 1V15
80 ft/secClean Air
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COAL-GEN 2005August 17, 2005 – San Antonio, Texas
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
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COAL-GEN 2005August 17, 2005 – San Antonio, Texas
Far Wall Correction Factor Comparison 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
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
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COAL-GEN 2005August 17, 2005 – San Antonio, Texas
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
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COAL-GEN 2005August 17, 2005 – San Antonio, Texas
Dirty Air Velocity Measurement
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
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COAL-GEN 2005August 17, 2005 – San Antonio, Texas
Dirty Air Velocity Measurement
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
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COAL-GEN 2005August 17, 2005 – San Antonio, Texas
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
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COAL-GEN 2005August 17, 2005 – San Antonio, Texas
Coal Flow Rate Measurement
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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
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COAL-GEN 2005
August 17, 2005 – San Antonio, Texas
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%
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COAL-GEN 2005
August 17, 2005 – San Antonio, Texas
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
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COAL-GEN 2005
August 17, 2005 – San Antonio, Texas
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
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COAL-GEN 2005
August 17, 2005 – San Antonio, Texas
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
115 ft/s, Air/Coal=1.5
Average
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COAL-GEN 2005
August 17, 2005 – San Antonio, Texas
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
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
115 ft/s, Air/Coal=3
115 ft/s, Air/Coal=1.5
Average
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COAL-GEN 2005
August 17, 2005 – San Antonio, Texas
Plot – effect of number of ports -
air
Effect of Number of Test Ports on Air Flow Measurement
Standard Dirty Air Probe - Location 1V3
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
75 ft/s, air/coal=1.5
95 ft/s, air/coal=2.25
115 ft/s, air/coal=3
No Data
Average
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COAL-GEN 2005
August 17, 2005 – San Antonio, Texas
Plot – effect of number ports - coalEffect of Number of Test Ports on Coal Flow Measurement
ASC Coal Sampling Probe - Location 1V3
0%
10%
20%
30%
40%
50%
60%
70%
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
75 ft/s, air/coal=1.5
95 ft/s, air/coal=2.25
115 ft/s, air/coal=3
No Data
Average
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COAL-GEN 2005
August 17, 2005 – San Antonio, Texas
Air – effect of number of points
Effect of Number of Traverse Points on Air Flow Measurement
Standard Dirty Air Probe - Location 1V15
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
115 ft/s, air/coal=3
115 ft/s, air/coal=1.5
Average
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COAL-GEN 2005
August 17, 2005 – San Antonio, Texas
Coal – effect of number of pointsEffect of Number of Traverse Points on Coal Flow Measurement
ASC Coal Sampling Probe - Location 1V15
-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
115 ft/s, air/coal=3
115 ft/s, air/coal=1.5
Average
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COAL-GEN 2005
August 17, 2005 – San Antonio, Texas
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
Number of Test Ports
Required
Number of Traverse
Points Required
1V15 2 9
1V11 2 9
1V7 3-4 9
1V3 4 9
3V3 6 15
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COAL-GEN 2005
August 17, 2005 – San Antonio, Texas
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
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COAL-GEN 2005
August 17, 2005 – San Antonio, Texas
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
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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]