Demonstration of Advanced Boiler Instrumentation Technologies

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Demonstration of Advanced Boiler Instrumentation Technologies

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CONTENTS

1 INTRODUCTION ……………………………………………………………………………………………………..1-1
References for Section 1………………………………………………………………………………………….1-3
2 CO/OXYGEN SENSORS…………………………………………………………………………………………..2-1
Oxygen………………………………………………………………………………………………………………….2-1
Oxygen Measurement …………………………………………………………………………………………2-2
Oxygen – Zirconium Oxide …………………………………………………………………………………..2-3
Failure Mechanisms ……………………………………………………………………………………………2-6
Electrode Failure…………………………………………………………………………………………….2-6
Mechanical Failure………………………………………………………………………………………….2-6
Hot-Side O2 Measurement……………………………………………………………………………………2-7
Summary of Resulting Benefits …………………………………………………………………………….2-9
Applications by Plant Site…………………………………………………………………………………..2-10
TVA Johnsonville Fossil Plant…………………………………………………………………………2-10
Marathon High-Temperature Oxyfire ……………………………………………………………….2-10
Operation ………………………………………………………………………………………………..2-11
Installation Issues……………………………………………………………………………………..2-13
Results ……………………………………………………………………………………………………2-14
Yokogawa ZR22G High-Temperature Oxygen………………………………………………….2-15
Carbon Monoxide – Catalytic Combustibles and Infrared ……………………………………………2-16
Issues and Interferences ……………………………………………………………………………………2-17
Applications by Plant Site…………………………………………………………………………………..2-18
TVA Cumberland Fossil Plant…………………………………………………………………………2-18
Ametek Thermox WDG-HPIIC COe/O2 ……………………………………………………………2-19
Installation ……………………………………………………………………………………………….2-20
Issues – Historical …………………………………………………………………………………….2-22
Performance Test Results………………………………………………………………………….2-26
Summary…………………………………………………………………………………………………2-28
TVA Kingston Fossil Plant ……………………………………………………………………………..2-30
Servomex Xendos 2700 COe/O2 …………………………………………………………………….2-31
Installation ……………………………………………………………………………………………….2-31
Issues – Historical …………………………………………………………………………………….2-34
Performance Test Results………………………………………………………………………….2-36
Combustion Control with CO………………………………………………………………………2-42
Summary…………………………………………………………………………………………………2-43
TVA John Sevier Fossil Plant …………………………………………………………………………2-43
Background………………………………………………………………………………………………….2-44
Evaluation Specifications……………………………………………………………………………….2-45
Performance Test …………………………………………………………………………………………2-45
Rosemount OCX 4400 and OCX 8800 COe/O2 ………………………………………………..2-47
Historical Issues – OCX 4400 …………………………………………………………………….2-48
Rosemount OCX 8800 CO2/O2 …………………………………………………………………..2-49
Issues – OCX 8800 …………………………………………………………………………………..2-50
Performance Test Results………………………………………………………………………….2-52
Summary…………………………………………………………………………………………………2-56
Ametek WDG-IVC COe/O2 …………………………………………………………………………….2-57
Issues – Installation…………………………………………………………………………………..2-59
Performance Test Results………………………………………………………………………….2-60
Summary…………………………………………………………………………………………………2-63
Servomex Xendos 2700 …………………………………………………………………………………….2-63
Performance Test Results………………………………………………………………………….2-65
Summary…………………………………………………………………………………………………2-69
References for Section 2………………………………………………………………………………………..2-70
3 TUNABLE DIODE LASER ………………………………………………………………………………………..3-1
Discussion of Technology ………………………………………………………………………………………..3-1
Tunable Diode Laser Measurement Applications…………………………………………………………3-2
TVA NH3 Demonstration at Kingston …………………………………………………………………………3-3
Norsk Electro Optikk LaserGas …………………………………………………………………………….3-3
Unisearch Associates’ LasIR………………………………………………………………………………..3-4
Boreal Laser Inc.’s GasFinder FC …………………………………………………………………………3-4
Past EPRI Research ……………………………………………………………………………………………….3-4
EPA Environmental Technology Verification Report …………………………………………………….3-5
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Future Research Possibilities……………………………………………………………………………………3-5
Conclusion …………………………………………………………………………………………………………….3-6
Available Tunable Diode Laser Systems…………………………………………………………………….3-6
Boreal Laser GasFinder MC…………………………………………………………………………………3-6
Boreal Laser GasFinder FC………………………………………………………………………………….3-7
Norsk Elektro Optikk AS – Neo Monitors LaserGas II ………………………………………………3-8
Opsis LD500…………………………………………………………………………………………………….3-10
Siemens LDS 6…………………………………………………………………………………………………3-10
Unisearch LASIR………………………………………………………………………………………………3-11
ZoloBOSS………………………………………………………………………………………………………..3-11
MetroLaser LTS-100 Laser Temperature Sensor…………………………………………………..3-13
References for Section 3………………………………………………………………………………………..3-14
4 FURNACE EXIT GAS TEMPERATURE ……………………………………………………………………..4-1
Non-Contact FEGT Technologies ……………………………………………………………………………..4-1
Optical Pyrometer……………………………………………………………………………………………….4-1
Infrared CO2 Waveband Pyrometer……………………………………………………………………….4-3
Ash Particle Emission Spectroscopy ……………………………………………………………………..4-3
Acoustic Pyrometry……………………………………………………………………………………………..4-4
TVA Cumberland Fossil Plant Evaluation …………………………………………………………………..4-5
TVA Cumberland Fossil Plant Selection and Installation ………………………………………………4-5
High Velocity Thermocouple Verification Tests……………………………………………………………4-8
Automatic Port Rodding System ……………………………………………………………………………..4-10
Summary……………………………………………………………………………………………………………..4-11
Dairyland Power Cooperative’s John P. Madgett Station…………………………………………….4-12
Objective………………………………………………………………………………………………………….4-12
Testing…………………………………………………………………………………………………………….4-14
Results…………………………………………………………………………………………………………….4-15
References for Section 4………………………………………………………………………………………..4-20
5 STACK FLOW MEASUREMENT……………………………………………………………………………….5-1
Optical Flow Sensors ………………………………………………………………………………………………5-1
Plant Demonstration………………………………………………………………………………………………..5-2
Performance…………………………………………………………………………………………………………..5-4
Infrared………………………………………………………………………………………………………………….5-7
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Epsilon Technologies ………………………………………………………………………………………………5-8
6 MOISTURE……………………………………………………………………………………………………………..6-1
Kingston Cimtec Moisture Meter Installation ……………………………………………………………….6-1
A TVA CUF UNIT 2 PROFILE DATA…………………………………………………………………………… A-1
CUF Unit 2 HVT Traverses 11-19-03……………………………………………………………………….. A-1
Unit 2 Analzyer B Traverse 7th Floor ……………………………………………………………………….. A-2
B CO/O2 TEST PLANS………………………………………………………………………………………………. B-1
Test Plan for Evaluation of Servomex Xendos 2700 COe/O2 Analyzer at TVA
Kingston Fossil Plant……………………………………………………………………………………………… B-1
Introduction ………………………………………………………………………………………………………….. B-1
Background ………………………………………………………………………………………………………….. B-2
Analyzer Operating Principle ………………………………………………………………………………. B-2
Test Background ………………………………………………………………………………………………. B-3
Test Procedures……………………………………………………………………………………………………. B-3
Interferences…………………………………………………………………………………………………….. B-3
Pre-Test Procedures …………………………………………………………………………………………. B-3
Drift …………………………………………………………………………………………………………………. B-4
Repeatability/Linearity ……………………………………………………………………………………….. B-4
Relative Accuracy……………………………………………………………………………………………… B-5
Analyzer Location …………………………………………………………………………………………. B-5
HVT at Furnace Nose ……………………………………………………………………………………. B-6
References…………………………………………………………………………………………………………… B-6
C TVA CUMBERLAND FOSSIL PLANT AMETEK THERMOX WDG-HPIIC TEST
DATA AND RESULTS ………………………………………………………………………………………………. C-1
D TVA KINGSTON FOSSIL PLANT SERVOMEX XENDOS 2700 TEST DATA AND
RESULTS ………………………………………………………………………………………………………………… D-1
E TVA JOHN SEVIER FOSSIL PLANT ROSEMOUNT OCX 4400 SERVICE REPORT …….. E-1
Report on RMR 24706 TVA Unit Serial Number R01005008 ………………………………………. E-1
Initial Inspection of Unit ……………………………………………………………………………………… E-1
Paramater Settings as Received from TVA ………………………………………………………. E-2
Line Voltage: 115 Vac ……………………………………………………………………………………….. E-2
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Settings Changed So the Sensors Can Be Evaluated………………………………………… E-3
Vacuum Test and Initial Calibration Results………………………………………………………….. E-3
F TVA JOHN SEVIER FOSSIL PLANT ROSEMOUNT OCX 8800 TEST DATA AND
RESULTS ………………………………………………………………………………………………………………….F-1
G TVA JOHN SEVIER FOSSIL PLANT AMETEK THERMOX WDG-IVC TEST DATA
AND RESULTS …………………………………………………………………………………………………………G-1
H TVA JOHN SEVIER FOSSIL PLANT SERVOMEX XENDOS 2700 TEST DATA AND
RESULTS ………………………………………………………………………………………………………………… H-1
I DAIRYLAND JOHN P. MADGETT STATION FEGT TEST DATA AND RESULTS…………….I-1
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