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MECONTROL Systems MECONTROL Air

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Presentation

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Our Target: Reliable Drift Free Measurement with

low maintenance, high accuracy

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System Application for Boiler Optimization

MECONTROL
Steam generator

Air

Primary air

Secondary air

Burner

Air preheater

Electric precipitator

Flue gas

Coal bunker Pulverized fuel

Intermed. Flyash bunker

Fly ash Coal mill FD-Fans Excess Air

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Issues with Air Flow Measurement Calibration? Linearity? Drift (Jamming)? Accuracy in short pipe sections?

Flow straighteners (delta P loss)?

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MECONTROL Air Measurement Principle velocity

Signal Sensor 1
Air Duct or Pipe Signature Signal Sensor 2

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Sensor 1
X(t)

Sensor 2 S=const.
Y(t)=X(t-T)

correlation

Correlation

T=-26 ms Optimum of correlation

Time T Example S=54 cm T=26 ms w=20,8 m/s (average velocity of the air !)

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MECONTROL Air Installation overview

Air duct Measurement cabinet

Sensor 1

Sensor box (per burner)

max. 4 Sensors/2 channels 4 x Sensor signals

Sensor 2

Power supply 24 VAC

Sensor 3/4

230 VDC Power supply

Connection to the DCS

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MECONTROL Air Sensor + Connecting Piece

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Gas Flow Measurement Sensor

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Sensor Mounting Adapter

Approx 1.5

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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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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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Single Air Flow Sensor Location

Niederaussem Station, Germany

Single Channel
2 sensors (antennas)

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Multiple Air Flow Sensor Locations

Niederaussem Station, Germany

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3 channels

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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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Reference of Measurement against Venturi

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Challenges: - short inlet sections of secondary air - downstream flap dampers - air stratification in ducts

Damper

Burner 32 Burner 35 Burner 31 Burner 36

Burner 33 Burner 34

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Iskenderun

04-10-27
60000

MECONTROL Air Secondary Air Measurement Channels

PROMECON
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50000

40000

[m/h]

30000

20000

10000

0 06:00

07:12 SecABrn32Out SecABrn34Out

08:24 SecABrn32In SecABrn34In

09:36 SecABrn33Out SecABrn35Upper

10:48 SecABrn33In SecABrn35lower

12:00

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

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Core air duct work:

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

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Individual core air flow position

Air flow balance: for proof of plausibility plant demanded a balance to be made of main duct measurements versus individual core air measurement at each burner.

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Check of accuracy by mass flow balance

Iskenderun

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04-10-17
60000

MECONTROL Air Summecheck Core Air

PROMECON
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50000

40000

[m/h]

30000

20000

10000

0 00:00

02:24

04:48

07:12

09:36

12:00

14:24

16:48

19:12

21:36

00:00

Sum Total core Air Front Sum Total core Air Rear

Sum burner core Air Front Sum burner core Air Rear

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Uneven distribution of core air

Iskenderun

04-10-27
10000

MECONTROL Air Core Air Burner

PROMECON
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9000

8000

7000

6000
[m/h]

5000

4000

3000

2000

1000

0 06:00

07:12

08:24 CoreABrn31 CoreABrn34

09:36 CoreABrn32 CoreABrn35

10:48 CoreABrn33 CoreABrn36

12:00

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Measurement of primary air out of the pulverizer

Iskenderun

measurement of dirty air flow in indivual burner lines subtraction of steam.

MECONTROL Air Primary Airflow

PROMECON
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04-10-27
25000

20000

15000
[m/h]

10000

5000

0 06:00

07:12

08:24 Burner31 Burner35 Burner32 Burner36

09:36 Burner33

10:48 Burner34

12:00

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

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31

32

33

34

35

36
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Coal mill at Vattenfall Europe: Power Station Reuter West/Berlin Actual data from: September 2005
Pulverized Fuel Primary Air

Main Cabinet

Mill 30

Reference: Mr. Thorsten Thimme

230 VAC Power supply

Conne ction to the DCS

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

11.09.2005

MECONTROL Air Particle Velocity Mill 30

PROMECON
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30,0

200,0 180,0

25,0

160,0 140,0 120,0

[Nm/h]

15,0

100,0 80,0

10,0

60,0 40,0 20,0

5,0

0,0 00:00

01:12
Burner 31

02:24
Burner 32 Burner 33

03:36
Burner 34

04:48
Class. Temp

0,0 06:00

Class Temp [C]

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20,0

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Balance of Sum Coal Pipes and Venturi is equal

Bewag_D_M 30_PL 11.09.2005

PROMECON MECONTROL Air we foc us on your proc ess Primary Air and Particle Velocity Measurement Mill 30

45000 40000

40,0 35,0 30,0

Feeder [t/h]
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[Nm/h]

35000 30000 25000

25,0 20,0

20000 15000 10000 5000 0 0:00:00

Venturi

15,0 10,0 5,0 0,0 6:00:00

1:12:00

2:24:00

3:36:00

4:48:00
Feeder

Sum Coalpipes-Brden

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Track Record
Since 2001: Over 200 installed

Never calibrated
Never cleaned Temperatures up to 2000o F
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MECONTROL Air References

Schwenk Zementwerk in Bernburg 2002
measurement of 13 Air flows including Tertiary Air at 1100C

Vattenfall/BEWAG KW Reuter West Unit D, Berlin 2003

Replacement of all 32 conventional Venturi measurements, boiler safety relevant certification (AK3, SIL1) by TV Berlin

Vattenfall/BEWAG KW Reuter West Unit E, Berlin 2003

Replacement of all 32 conventional Venturi measurements, boiler safety relevant certification (AK3, SIL1) by TV Berlin

RWE/Rheinbraun KW Niederauem Unit G,Bergh.2003

Retrofit of 48 measurement locations including primary and secondary air flows
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RWE/Rheinbraun KW Niederauem Unit A,Bergh.2004

Retrofit of 32 measurement locations including primary and secondary air flows

RWE/Rheinbraun KW Niederauem 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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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 Jnschwalde, 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 Drnrohr 2004,

Retrofit of 32 burner pipes with velocity measurement for better primary air control.
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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

EDF, Power Station West Burton, 2005

16 measurements for measuring OFA of a reburn system (Installed by General Electric)

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

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RWE Kraftwerk Niederauem, 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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