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Product-Line

Feature of the Month

(1)

Acoustic Pyrometers, and Infrared and

Visible-Light Imaging Technology

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Process Sensor Business

(2)

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Industry Applications

• Coal-Fired Power Generation

• Pulp Chemical Recovery Boilers

• Biomass Power Boilers

• Steel

• (Waste-to-Energy)

• (Cement)

(3)

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• Sales Reps/Distribution Partners

• Sales Support Team

Full-Time

Part-Time

• Chad Cheney, Eric Pena

• Rich Hogle, Mike Anna, Dave Burslem

• George Kychakoff

Sales Approach

(4)

Shawn Smith Field Support

Heidi Haslinger Coordination

Sagar Naik Marketing

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• Imaging Products

− Mobile Inspection Cameras

− Fixed Installation Cameras

− Slag Indexing

− Temperature

− Multi-Wavelength (Kiln Cam) Infrared and Visible

• Acoustic Products

− Measurement Hardware

− Processing/Display Software

− Leak Detection

− WaveMetrix

Boiler Diagnostic Products

(5)

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Infrared Imaging in Recovery Boilers

Visible image through port

• Chemical Recovery in Pulp Manufacture

• Smelt Bed at Bottom of Boiler

• Smelt Water-Explosions

• View obscured by Particle Scattering

• Particle Scattering Decreases at Longer Wavelengths

• IR View obscured by Gas Molecular Emissions

(6)

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PyrOptix™ Boiler Inspection Camera

(7)

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Fixed Mount/Retract/Port Cleaner

(8)

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• Mount swivels around lens tube tip

• View selected by remote in control room

OptiTrack

(9)

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Recovery Boiler Video

(10)

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Power Boiler Video

(11)

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Grate-Fired Bark Boiler Video

(12)

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• Locations

− Enertechnix You Tube site

− https://www.youtube.com/user/Enertechnix

− Enertechnix Web Site:

− www.enertechnix.com

Other Video Resources

(13)

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• Improved Heat Transfer Efficiency

− Heat Rate Improvement

− Reduced CO2 Emission

− Reduced De-Rate

• Increased Life of Steam Tubes

− Identification of Tube Leaks

• Maintenance Reduction

• Improved Boiler Availability

− Load Stabilization

• Emissions Reduction

Benefits

(14)

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Image Processing Technology

~ Slag Indexing ~

(15)

Frame

Selection

Filtering and

Histogram

Adjustment

Cluster Pixels

with

Gaussian Mixture

Model

IR Camera Binary Mask

Selected Frame

Slag

Index

DCS

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Slag-Indexing Demonstration

Jan 30, 2015 (16) Confidential

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Data from 500 MW CE Unit

(17)

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15

20

25

30

35

3/25/2010 0:00 3/25/2010 12:00 3/26/2010 0:00 3/26/2010 12:00 3/27/2010 0:00

Slag Index Sootblower

Index

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Use of Thresholds

(18)

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3/25/2010 0:00 3/25/2010 12:00 3/26/2010 0:00 3/26/2010 12:00 3/27/2010 0:00

Slag Index Sootblower

Index

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• Heat Transfer to Superheater: 18 kBTU/hr-ft2

• Heat Transfer Degradation: Up to 20%

• Area Viewed: 4,000 ft2

• Time to Reach 100% Slag Coverage: 3 hrs

• Slag Coverage Growth Approx Linear in Time

• SI = 20 (0% Coverage) SI = 30 (100% Coverage)

• One SB Cycle Consumes 8,000 lb Steam

• 1,200 BTU/lb Steam

Energy Savings Example

(19)

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Energy Savings

(20)

Energy Savings from

Improved Heat Transfer

SB Energy Costs

Net Energy Savings

Optimum Set Pt

Slag Index

MB

TU

/h

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For 4,000 ft2 Superheater Surface

• Energy Savings = 4.0 MBTU/hr

• BTU/lb Steam = 1,200

• Steam Cost: $0.006/lb

• Savings = $175,000/year

Cost Savings

(21)

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• Through-the-Lens Pyrometer

• TempSentinel Software

− Uses TLP to Calibrate the Scene

Temperature Measurement

(22)

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Temperature Overlay

(23)

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• Smelt Bed Measurements

− Temp (& Bed Shape) Controls Reduction Efficiency

• Kiln Product Measurements

• Metal Surfaces (Steel)

Applications

(24)

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KilnCam Dual Wavelength

(25)

• Visible + IR + Temperature

IR Image Vis Image

Deeper Penetration More Detail

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Kiln Cam Video – IR & Vis

(26)

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• Established Manufacturers of Visible Cameras

• Recent Developments

− Hi-Resolution HD Visible Cameras

− All Digital Camera Technology

− Standard Internet Bandwidths Limited

• Robust Packaging – Stainless Steel, Air Cooled

Visible Cameras

(27)

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VisCam Video in Lime Kiln

(28)

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• 20’ Visible Inspection Camera for Tube Passes

• Release Complete in FY09

PyroRemote Camera

(29)

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• Camera Demo Experts on Staff

− Boiler Survey

− Routine Maintenance

− Leak Location

− Slag Observation

Camera Demo Capability

(30)

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(31)

Acoustic Pyrometry

• Universal Gas Law

p = RT

• Speed of Sound Related to Material Properties

c2 = p/

• Sound Speed Related to Temperature

c2 = RT

No Calibration

No Lengthy “Footnotes”

c.f. HVTs and Optical Methods

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Acoustic Pyrometry

2310 F

Transmitter Receiver

Furnace Cavity

(32)

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• Loud Sharp Sound Sources

− Using Plant Air Only

− Safe and Reliable

• ASG Acoustic

Signal

Generator

Enertechnix Approach

(33)

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(34)

Enertechnix Mark III Air

Amplifier

• Electrically Controlled Valve

− With Pilot Pressure

• Long Slow Strokes

• Heavy Duty Seals

• Greater than 1 Year

Maintenance Cycle

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(35)

Enertechnix Sound Generator

(Type II)

• Low Pressure (80 psi to 120 psi

• Suitable for Smaller Furnaces (Max Path Length < 25 ft)

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Example AP Installation

(36)

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• Latest Boiler Servicing Shanghai (1,000 MW)

International Example

Installation

(37)

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• Accelerated In-House Testing

− Now at 330,936 Shots (4-7 Yr Operation)

− All Known Problems Resolved

AP Hardware Testing

(38)

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• System Simulator Developed

• Can Accelerate Testing by > 100 Times

• Can Test Many Anomalies

• Released First Fully Tested AP Software

Software Reliability Testing

(39)

Acoustic Pyrometer

Control Computer System Simulator

Controls

Data

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New Product: TempVIEW

(40)

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Other TempVIEW Views

(41)

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(42)

Benefits (Claimed by Customers) • Reduces Tube Damage (Erosion, Slag Falls)

− Extends Time Between Outages

• Improves Efficiency

− Corrects Imbalances;

− Saves Fuel

• Verifies Performance Optimization

− Input to Neural Network/Supervisory Control Systems)\

• Optimizes Startup

• Reduces NOx Formation

Short Return on Investment

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• Immediate Benefits

− Reduced Tube Leaks

− Through Control of Furnace Exit Gas Temperature

− Critical for Variable Fuels

− Reduced Maintenance Costs

− Improved Up-Time

• Short-Term Benefits

− Improved Efficiency

− Balanced Temperature Distribution

− More Confident Startup

Benefits of AP Installation

(43)

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• Improved Control

− Performance Optimization

− Integration with Advanced Control Systems

• NOx Reduction

Longer Term Benefits

(44)

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• Simple Inexpensive Installation

− Tube Bends not Required for Receivers

− Only Two 48mm-Penetrations Needed for Generators

− May Already Exist

− Flexible Location of Generators(/Receivers)

− Generator may be 5-10 m from Port

− Can Use Existing Platforms

• No “Tuning” Required or Sootblower Interface

− Simplifies Scheduling, Reduces Cost

System Advantages I

(45)

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• Lower Maintenance Costs

− Simple Robust Equipment

− Mainly Mechanical Seal Changes

• Better Support

− Remote Diagnostics

− Experienced Dedicated Local Support

• Lower Equipment Cost

− Lower Expansion Cost

• Much Greater Depth of Coal-Fired Experience

− Complementary Suite of Equipment

• Lowest Cost and Best Performance Option

System Advantages II

(46)

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Acoustic Cleaning

Monitoring

(47)

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• Slag Control

• Tube Damage

• Pollutant Formation

• Boiler Efficiency

Our Products Fit with Combustion

Optimization

(48)

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• Initial Application: LMF

Steel Application

(49)

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Cement Clinker Cooler

• Need to Maximize Heat Recovery

(50)