MATS. Compliance. Group A Service of Power & Industrial Services Corporation. Achieve MATS. Compliance. & Optimize Performance

Transcription

1 MATS Compliance Group A Service of Power & Industrial Services Corporation Achieve MATS Compliance & Optimize Performance

2 MATS Compliance Group A Service of Power & Industrial Services Corporation MATS Compliance Group is an expert team of experienced testing and combustion optimization engineers with the testing equipment and expertise to help customers achieve MATS compliance. Achieving MATS compliance can mean many things to power generators. From initial demonstration testing to ongoing compliance testing and inspections, it takes an integrated approach. The MATS Compliance Group provides a complete package of testing, inspection, calibration and boiler tuning services to assist in achieving compliance. With capabilities such as onsite mercury analysis, the experienced engineering staff of the MATS Compliance Group is well suited to provide both standalone testing services, as well as overall compliance consultation and project management plus EPA Approved Mercury Analyzer. 2

3 MATS Compliance Requirements Environmental Protection Agency 40 CFR Parts 63 Scan to visit EPA Website Subpart UUUUU- of Part 63 National Emissions Standards for Hazardous Air Pollutants: Coal and Oil Fired Electric Utility Steam Generating Units (EGU s) Table 3 to Subpart UUUUU of Part 63 Work Practice Standards Table 5 to Subpart UUUUU of Part 63 Performance Testing Requirements Appendix A to Subpart UUUUU of Part 63 Hg Monitoring Provisions Table 3 to Subpart UUUUU of Part 63 Work Practice Standards Summary Burner & combustion controls inspections (every months) Replace components as needed that affect CO & NO x Inspect flame pattern, optimize flame pattern Make adjustments to burner controls Observe damper operations, including Function of mill and/or cyclone loading Pulverizer coal feeder loadings or coal mill performance parameters, cyclone & sensors Evaluate windbox pressure & air proportion Make adjustments & repair Inspect system controlling air-to-fuel ratio Calibrate, function, calibration excess CO, adjusting OFA systems, calibrating associated actuators, dampers to ensure systems function as designed Repair or adjust if affects combustion Optimize combustion to minimize CO & NO x Best combustion engineering practices NO x optimization includes: burners, OFA controls, concentric firing system improvements, neural network or combustion efficiency software, control system calibrations, adjusting combustion zone temperature profiles and add-on controls such as SCR/SNCR & CO optimization includes: burners, OFA controls, concentric firing system improvements, neural network or combustion efficiency software, control system calibrations, adjusting combustion zone temperature profiles At full load measure the concentration in the effluent stream of CO and NO x in ppm, by volume, and oxygen in volume percent before and after tune-up adjustments Report pre & post initial compliance demonstration and start-up and shut-down data as required. 40 CFR CFR

4 COMBUSTION OPTIMIZATION EQUIPMENT Combustion Services: Tuning, QSTI Testing, Performance, Emissions At the heart of all fossil fuel fired boiler operations, is the Combustion Firing System. Achieving optimum performance with low emissions does not happen by accident. Power & Industrial Services has developed specialized services to provide a utility or industrial boiler operator with efficient and cost effective operation. With ever tightening emission regulations along with escalating costs, every owner desires to reduce emissions and improve efficiency that is exactly what Power & Industrial Services and MATS Compliance Group provides. Power & Industrial Services is not just gathering data; we can supply Engineered Solutions like Low NO x Burners, Over Fire Air Systems and other combustion improvement components as well as QSTI testing, engineering, parts supply, project management, start-up and tuning and long term combustion support. Power & Industrial Services is a full service combustion services and equipment supplier. Parameters Measured NO x, SO 2, O 2, CO 2, CO Filterable Particulate Matter Mercury, HCI, HF, & Metals Ohio Lumex Portable Analyzer Temperatures, Pressures, Flows Pulverizer Isokinetic Coal Sampling Coal Fineness Determination Pulverizer Clean Air/Dirty Air Services Provided Combustion Tuning Air Flow Measurements and Calibration (Primary, Secondary, OFA) Combustion Optimization Burner Inspections Overfire Air Port Inspections Cyclone Inspections Damper & Register Calibrations Flame Pattern Optimization Pulverizer Performance Air Heater Performance Relative Accuracy Test Audits (RATA) for Coal and Gas Fired Units (QSTI Certified) O 2 Probe Calibration LEHIGH University Boiler OP Intelligent Combustion Optimization Test Methods Provided Methods 1, 1A, 2, 3, 3A, 4 for Volumetric Flow Method 5 for Filterable PM Method 6+6C for SO 2 7, 7E for NO x 10 for CO 10A, 10B, M-12-Lead Emissions, M-17-Particulate EAM, M-20 NO x (Gas Turbines), 201A-PM-10 Emissions Method 26+26A for HCI and HF Method 29 for Metals Method 30B for Hg ASME PTC 4 ASME PTC 4.2 ASME PTC 4.3 EPA 40 CFR Part Air Flow Measurement 4 On-Site Mercury Testing Services Call to set up a test. Common Problems NO x drifting upward CO emissions above limits Higher than necessary O 2 Poor air flow-distribution Low accuracy in combustion air flow measurements High primary air Plugged coal lines Erroneous Rosin-Rambler results Slagging and fouling Combustion Tuning Goals Burner tuning OFA tuning NO x reduction (~5-20%) CO emission reduction Lower O 2 Improved heat rate Improve Boiler operation Improve L.O.I.

5 Combustion Testing Equipment Power & Industrial Services manufacturers economizer test grids, bubblers and valve sets to help test economizer outlet emissions. 5

6 Total Mercury Control Solution 50% Less Sorbent Use Reducing Annual O&M Costs Power & Industrial & Midwest Energy Emissions have teamed to offer Custom Designed Equipment Feed Systems (ACI/DSI) and long-term Mercury Capture Supply Program contracts supported with MATS guarantees. Complete EPC Contracts and Equipment Supply

7 COMBUSTION OPTIMIZATION EQUIPMENT Table of Contents Power & Industrial Services offers combustion optimzation solutions to assist in correcting problems found during testing. The goal is to help optimize combustion and boiler performance. LEHIGH Boiler OP Intelligent Combustion Optimization... Page 8 Eastern Instruments Primary & Secondary Combustion Air Measurement... Page 9 Coal Flow Analyzer Powered by MIC Real Time Pipe-to-Pipe Coal Flow Measurement... Page 12 LEHIGH Adjustable Riffle Coal Control Pipe-to-Pipe Coal Flow Balancing... Page 16 Power & Industrial Adjustable Orificing Valve... Page 16 EUtech EUcoalsizer Laser Coal Fineness Measurement... Page 17 EUtech EUflame FEGT Measurement... Page 18 7

8 COMBUSTION OPTIMIZATION EQUIPMENT COMBUSTION OPTIMIZATION EQUIPMENT Boiler OP Intelligent Combustion Optimization and Control New MATS Requirements The Work Practice Standards for Organic HAP Emissions of the EPA s MATS rule allows the use of automated boiler optimization tools such as artificial neural network software for compliance with the firing system tuning and combustion optimization part of the standard. Steam generators that install artificial intelligence-based software can delay tuning until 2016 and decrease the frequency of the tuning cycle to every four years, while achieving optimized operation of the boilers in terms of NO x and CO emissions. Boiler OP for MATS Boiler OP is an intelligent software package developed for combustion optimization and control. Boiler OP is based on the Lehigh University Energy Research Center s (ERC) combustion optimization approach, and it combines an expert system (general deduction methods), neural networks (that mimic the behavior of the human brain) and multi-objective optimization algorithms into a single program. The ERC s combustion optimization process considers the critical process variables affecting the combustion process and the process controlled parameters such as NOx and CO emissions, fly ash unburned carbon, unit heat rate, etc., and creates a dynamic model of the boiler operation over its operating range. Boiler OP requires on-line communication with the boiler DAS or DCS, identifies the best combinations of boiler control settings for optimal combustion and assist plant engineers and operators in fine-tuning boiler operations over the long term. The ERC s combustion optimization approach and Boiler OP have been used to optimize more than 30 tangentially- and wall-fired utility boilers, ranging in size from 80 to 750 MW that fire Eastern and Western fuels, including PRB, fuel blends, co-firing with fuel oil, natural gas and coke oven gas. Using control logic that was developed from results obtained by analyzing Boiler OP test data, the software uses relationships between emissions, unit heat rate, operational constrains and actual boiler control settings to provide real-time biases for manipulation of boiler control curves. Key Features of Boiler OP Reduces NO x and CO Emissions Reduces Fly Ash Loss on Ignition (LOI) Improves Boiler Efficiency Improves Net Unit Heat Rate Can Provide Constrained Operation to Control Boiler Slagging Can Adapt to Changes in Fuel Quality Works on Closed-Loop or an Advisory Mode Benefits Boiler OP provides an option to satisfy the MATS requirements for NO x emissions reduction and better CO control. In addition to the MATS compliance focus on those emissions, Boiler OP has also been demonstrated to improve unit performance, reduce slagging and minimize mercury emissions from coalfired utility boilers. The achieved results include: ENERGY RESEARCH CENTER 1. NOx emissions reduction from 5 to 35 percent 2. Performance improvement from 50 to 120 Btu/kWh 3. Mercury emission reduction from 30 to 80 percent The actual value of these performance, emissions and O&M benefits are highly site-specific and depend on factors such as unit size, operating conditions, fuel type and cost, cost of NO x emission credits; these factors need to be evaluated for each individual unit. 8

9 Combustion Tuning Equipment Accurate Airflow Measurement The trend to improve efficiency in today s power plants drives the need for effective boiler trim controls which, in turn, requires accurate airflow measurement. Airflow measurement that is not repeatable, accurate, or representative of mass flow can destabilize the airflow control loop. Eastern Instruments offers extremely accurate airflow measurement that is built on over 35 years of pitot development technology. VAP3 /PA PITOT Central to Flow Measurement VAP3 /PA Pitots have a unique velocity averaging, parallel plate, proprietary design which provides an accurate differential pressure output that allows for precise airflow measurement and control of the combustion phase of power generation. With no upstream ports, the VAP3 /PA Pitot is resistant to plugging caused by airborne particulate and is, therefore, perfect for measuring Primary, Secondary andover-fired airflow, especially when coupled with the High Beta Flow Conditioner. Key Features & Benefits Velocity Averaging Parallel Plate Design Multiple DP Sensing ports allow velocity averaging across the full traverse of the duct VAP3 /PA Pitot Configuration: Resists airborne particulate plugging Teflon Hard Anodized 6063 Aluminum Construction Hardened for long life expectancy Controlled Port Profiling Ensures repeatable measurement for higher degree of accuracy No Moving Parts Virtually no spare parts or maintenance costs Simple, Robust Design: Very few process penetrations with optional bolt-in installation High Beta Flow Conditioner Air Flow Measurement With Limited Straight Duct Runs The High Beta Flow Conditioner incorporates an array of VAP3 /PA Pitots with flow straightening vanes and a converging duct section to condition airflow at the point of measurement. Reducing the effects of turbulent, reverse and cyclonic air flow patterns in complex duct systems, the High Beta maximizes the accuracy of the flow measurement and is a great replacement for a wide variety of air flow measurement devices including airfoils. Secondary air cyclone burner windbox airflow measurement 9

10 COMBUSTION OPTIMIZATION EQUIPMENT Combustion Air Flow Measurement Secondary Air Applications Accurate airflow measurement Reduced pressure drop Virtually no straight duct runs are required Replaces airfoils and venturi Secondary air compartmentalized windbox airfoil replacement Secondary air common windbox airfoil replacement Key Features & Benefits Incorporates VAP3 Pitots Optimizes accuracy with little or no straight runs Integrated flow measurement Low-cost, high-speed in-duct installations Integral straightening vanes Stops cyclonic flow High beta ratio Low unrecovered pressure drop Conditions flow at the point of measurement Enables insertion near obstructions while still retaining accuracy Rugged construction Long life cycle with no spare parts or maintenance requirements Primary & Tempering Air Applications Accurate airflow measurement Greater air/fuel ratio control Improved pulverizer air inlet/outlet temperature control Improved primary air/fuel ratio over broader ranges More stable control of the mixed air amount Primary air-thermal distribution with High Beta Primary and tempering air flow measurement in a plenum 10 Tempering air flow measurement from an external air supply

11 Combustion Air Flow Measurement Improving Airflow Control and Accuracy Current practices include measuring primary airflow downstream of the hot and temperinglair duct mixing point Studies show that this measurement location has a high temperature stratification with differences in temperature as high as 400 F Extreme temperature stratification affects the air s density, making it vary drastically across the measurement plane For mass flow measurement calculations, a given density must be used and is often assumed to be the same across the measurement plane Primary airflow measurements can have errors as high as ±20% because of high temperature stratification and the use of a singular, assumed density value The High Beta Difference Install a High Beta in both the hot and the tempering ducts as shown (see bottom right) Installation in both locations allows for highly accurate airflow measurements for both the hot and the tempering air Airflow measurement prior to the mixing point is a great deal more accurate because these upstream ducts have very little temperature difference across the measurement plane A more uniform temperature profile allows for a much more accurate density compensation calculation More accurate density compensation means more accurate mass flow measurement in the hot and tempering air ducts Totalizing the signals from both the hot and the tempering air ducts will provide complete primary air flow measurement with a near perfect relative accuracy (98%) CFD showing temperature stratification across air measurement plane. Why Measure Primary Air? Greater air/fuel ratio control which improves NO x where primary air is the critical value Improved primary air/fuel ratio even during load changes and over broader ranges More stable control of the mass flow as well as temperature, of primary airflow Improved pulverizer inlet and exit temperatures which can reduce pulverizer fires Greater control of entire combustion phase Tempering Air Hot Air High Beta installation in duct sections upstream from the mixing point 11

12 COMBUSTION OPTIMIZATION EQUIPMENT Combustion Tuning Equipment Coal Flow Analyzer Online Pipe-to-Pipe Measurement and Control System Coal Flow Analyzer Powered by MIC The Coal Flow Analyzer is a real time pipe-to-pipe distribution monitoring system. Powered by MIC systems, this microwave based solution continuously omits waves into the coal piping. Variations in the mass flow of the coal are detected and the real-time pipe-to-pipe distribution is displayed on the local computer. When paired with either the P&I Adjustable Orifice Valve or the Lehigh CoalControl Adjustable Riffle, the Coal Flow Analyzer provides an accurate, reliable, and easy to use system for performance and combustion optimization. Based on pipe-to-pipe coal distribution data, each burner air register can be tuned to achieve the lowest possible NO x as well as reducing slag formation that can result with a heavily loaded pipe. Output displays Key Benefits Portable system can be used across multiple mills and multiple units EPRI Tested No pressure drop Does not need to be calibrated Highly accurate and reproducible Fits into existing sampling ports Helps reduce fuel consumption Can be directly tied into DCS Dust free fitting allows for clean testing Coal flow velocity measurement 12

13 Real Time Coal Flow Measurement Portable System The compact Portable System can be used to gather data on a per mill basis. Using existing sample ports, pipe-to-pipe distribution can be gathered in a few hours. Coal Flow Analyzer Powered by MIC The portable system tracks the signal from the feeders perfectly and can be easily taken to other units on the same site or to other plant sites. This system should be part of the equipment of every utility s combustion optimization team. Dustfree sensor adapter Max. 8 distance from coal pipe 13

14 COMBUSTION OPTIMIZATION EQUIPMENT COMBUSTION OPTIMIZATION EQUIPMENT Real Time Coal Flow Measurement Coal Flow Analyzer Powered by MIC Permanently Installed Full Unit System Sensors are mounted in every coal pipe and their signals are sent to control boxes, then to the DCS in the control room, or to a stand alone work station in the control room, or any other location per customer requirement. Three sensors per pipe give the most accurate data No special spools are needed for installation Probes can be installed or replaced while the unit is online resulting in major installation savings Nothing sticks into the coal flow resulting in the lowest maintenance cost of all suppliers of similar equipment Data can be used to size fixed orifices or to set adjustable orifices or adjustable riffles No calibration or temperature compensation needed resulting in fast installation and data acquisition Data can be used for diagnostic analysis of coal feeders and pulverizer changes and loadings. 2-year warranty on parts and service. Includes yearly plant visit to check equipment and free replacement of any sensor that fails during normal wear. 14

15 Real Time Coal Flow Measurement Permanently Installed Full Unit System Coal Flow Analyzer Powered by MIC Sensor installation Permanent installation control box 15

16 COMBUSTION OPTIMIZATION EQUIPMENT COMBUSTION OPTIMIZATION EQUIPMENT LEHIGH Adjustable Riffle CoalControl CoalControl Adjustable Coal Flow Controller Achieve balanced coal flow to burners by replacing primary and secondary riffles with the Lehigh CoalControl Adjustable Riffle package. Key Benefits Easy retrofit. CoalControl fits into existing riffle housing Low cost Reduced maintenance Very low pressure drop CoalControl is a trademark of Lehigh University Commercially Proven to Improve Burner Stoichiometry Reduced heat rates up to 1% Reduced CO and NO x emissions Pipe-to-pipe coal flow balance to within ±10% Better burner stability Reduced LOI No influence on primary air flow balance P&I Adjustable Orificing Valve Installed Adjustable Orificing Valves The Adjustable Orificing Valve is designed to provide a variable orifice in an existing fuel piping system to help correct pulverized fuel/air flow imbalance between burners due to pipe routing and mill outlet characteristics. Key Features Surface ground vacuum bounded alumina wear surfaces Opposed blade design for true orifice response Integrated gear box allows for easy gate movement 16

17 Coal Fineness EUcoalsizer Fineness Testing and Mill Optimization The coal particle size spectrum has a strong impact on the combustion process. It influences ignition delay, combustion efficiency, LOI, NO x & CO, as well as slagging and fouling. Despite the significance of this property, there has not yet been a robust and easy to handle system for the online measurement of coal fineness inside the pipe. Solution EUcoalsizer solves this problem. The laser based system measures the particle size distribution and the coal as well as PA/PF flow. By traversing the lance through the pipe, a particle size distribution along the cross-section of the coal pipe can be measured. The time of transition method covers a very wide range of particle sizes from 20 μm to 4 mm. The simultaneous measurement of coal and air flow proves to be an essential prerequisite for fuel line balancing and coal flow optimization. Specifications The EUcoalsizer system comes turn-key and can be directly applied via an adapter to the coal pipe. The system delivers results on-line and instantaneously. Handling is very easy via an intuitive graphical user interface. The system has many helpful features to support analysis and optimization (report generator, data base, etc.) Rugged industrial design for exposure to highly abrasive flow conditions Effective lance length > 1 m (covering pipe diameters up to ~625 mm / 25 ) Probe diameter 51 mm (2 ) Key Benefits On-line combustion optimization (reducing LOI, emissions, slagging) Pulverizer performance monitoring Condition-based pulverizer maintenance Coal flow and air/fuel distribution tuning Reduction of fuel consumption Real time, dynamic Rosin Rambler chart Accurate air/fuel ratio measurement Efficiency and heat rate gains, fast pay back 17

18 COMBUSTION OPTIMIZATION EQUIPMENT FEGT Measurement with EUFlame EUflame is: An integrated single-dual color pyrometer system that permits combined measurement of flame temperature, gas temperature, and opacity A flame temperature monitoring system for advanced control of furnace temperature and combustion process (emissions, LOI, slag) Designed to operate in small and large scale combustion chambers Robust design and easy to apply Part of advanced boiler control systems (e.g. EUcontrol) Key Features Continuous monitoring, localization and visualization of flame temperature distribution, temperature peaks, and fluctuations Early identification of problematic operating conditions and coal quality changes Self-monitoring on contamination Integration into optimization systems such as EUcontrol On-demand and selective initiation of on-load cleaning devices Why Use EUflame for FEGT? Simple installation Gain greater control of ash fusion temperatures Predict slagging and reduce outages Reduce material strain by monitoring for peak temperatures EUflame pyrometers offer superior accuracy when compared to acoustic pyrometers Reduce LOI Optimize sootblowing 1/4 the cost of similar products on the market Flame Ball Positioning Optimize Sootblowers Slagging Prediction Boiler Optimization 18

19 Combustion Optimization Equipment Info For more information or to request pricing on MATS Compliance Group s combustion optimzation solutions, call us at or visit us online at LEHIGH Boiler OP Intelligent Combustion Optimization Scan for more information Combustion Optimization Scan for more information Total Mercury Control MEEC Scan for more information Eastern Instruments Primary & Secondary Combustion Air Measurement Scan for more information Coal Flow Analyzer Powered by MIC Real Time Pipe-to-Pipe Coal Flow Measurement Scan for more information LEHIGH Adjustable Riffle Coal Control Pipe-to-Pipe Coal Flow Balancing Scan for more information P&I Adjustable Orificing Valve Scan for more information EUtech EUcoalSizer Laser Coal Fineness Measurement Scan for more information EUtech EUflame FEGT Measurement Scan for more information On-Site Mercury Testing Services Call to set up a test appointment. 19

20 MATS Compliance Group A Service of Power & Industrial Services Corporation 95 Washington Street Donora, PA P: F: