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MECONTROL Systems MECONTROL Air. Presentation. Our Target: Reliable Drift Free Measurement with low maintenance, high accuracy. MECON TROL Air. Steam generator. Air preheater. Burner. Primary air. Secondary air. Electric precipitator . Flue gas. Coal bunker. Pulverized. fuel.

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presentation

Presentation

Our Target:

Reliable Drift Free Measurement

with

low maintenance, high accuracy

system application for boiler optimization

MECONTROL

Air

Steam generator

Air preheater

Burner

Primary air

Secondary air

Electric

precipitator

Flue gas

Coal bunker

Pulverized

fuel

Intermed. Fly-ash bunker

Fly ash

Excess Air

Coal mill

FD-Fans

System Application for Boiler Optimization

slide4

Issues with Air Flow Measurement

Calibration?

Linearity?

Drift (Jamming)?

Accuracy in short pipe sections?

Flow straighteners (delta P loss)?

mecon trol air measurement principle velocity

Signal Sensor 1

Air Duct or Pipe

“Signature”

Signal Sensor 2

Sensor 2

Sensor 1

X(t)

Y(t)=X(t-T)

S=const.

T=-26 ms

Optimum of

correlation

“Correlation”

correlation

Time T

Example

S=54 cm

T=26 ms

w=20,8 m/s (average velocity of the air !)

MECONTROL AirMeasurement Principle „velocity“
mecon trol air installation overview

Air duct

Measurement

cabinet

Sensor box

(per burner)

max. 4 Sensors/2 channels

Sensor 1

4 x Sensor signals

Sensor 2

Power supply

24 VAC

Sensor 3/4

230 VDC

Power

supply

Connection

to the DCS

MECONTROL AirInstallation overview
local sensor box
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
control cabinet
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
slide14

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.

slide17

Damper

Burner 33

Burner 34

Burner 32

Burner 35

Burner 31

Burner 36

Challenges:

- short inlet sections of secondary air

- downstream flap dampers

- air stratification in ducts

slide19

Measuring core air into the burners:

Challenges:

extremely short measurement sections

slide20

Core air duct work:

Installation of MECONTROL Air measurement:

main core air duct individual burner core air

slide21

Individual core air flow position

Air flow balance:

for proof of plausibility

plant demanded a balance

to be made of main duct

measurements versus indi-

vidual core air measurement

at each burner.

slide24

Measurement of primary air out of the pulverizer

measurement of dirty air flow in indivual burner lines

subtraction of steam.

slide25

Final result of measurement:

the secondary air windbox causes main air imbalance

31 32 33 34 35 36

slide26

Main Cabinet

230 VAC

Conne

Power

ction

supply

to the

DCS

Coal mill at Vattenfall Europe: Power Station Reuter West/Berlin

Actual data from: September 2005

Pulverized

Pulverized

Primary

Primary

Air

Air

Fuel

Fuel

Main Cabinet

Main Cabinet

Mill

Mill

30

30

230 VAC

230 VAC

Conne

Conne

Power

Power

Reference: Mr. Thorsten Thimme

ction

ction

supply

supply

to the

to the

DCS

DCS

slide29

Track Record

Since 2001:

Over 200 installed

Never calibrated

Never cleaned

Temperatures up to 2000o F

mecon trol air references
MECONTROL Air References
  • Schwenk Zementwerk in Bernburg 2002measurement of 13 Air flows including Tertiary Air at 1100°C
  • Vattenfall/BEWAG KW Reuter West Unit D, Berlin 2003Replacement of all 32 conventional Venturi measurements, boiler safety relevant certification (AK3, SIL1) by TÜV Berlin
  • Vattenfall/BEWAG KW Reuter West Unit E, Berlin 2003Replacement 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
slide31

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
slide32

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.
slide33

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
slide34
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