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Sensor for Individual Burner Control of Firing Rate, Fuel-Air Ratio, and Coal Fineness Correlation, Quarterly Report: January-March 2005

Description: A no-cost time extension was requested, to permit additional laboratory testing prior to undertaking field data collection. This was received in this reporting period. To minimize program cost, this additional testing is planned to be performed in concert with EPRI-funded testing at the Coal Flow Test Facility. Since the EPRI schedule was undecided, a hiatus occurred in the test effort. Instead, a significant effort was exerted to analyze the available laboratory test data to see whether the source and nature of noise behaviors could be identified, or whether the key flow information could be extracted even in the presence of the noise. One analysis approach involved filtering the data numerically to reject dynamics outside of various frequency bands. By varying the center frequency and width of the band, the effect of signal frequency on flow dynamics could be examined. Essentially equivalent results were obtained for all frequency bands that excluded a neighborhood of the transducer resonance, indicating that there is little advantage to be gained by limiting the experimental frequency window. Another approach examined the variation of the dynamics over a series of 1-second windows of data, producing an improvement in the prediction of coal flow rate. Yet another approach compared the dynamics of a series of 1-second windows to those of a series of 5-second windows, producing still better results. These results will be developed further in the next reporting period, which should also include further laboratory testing at the Coal Flow Test Facility.
Date: April 2005
Creator: Hill, Wayne; Demler, Roger & Mudry, Robert G.
Partner: UNT Libraries Government Documents Department

Sensor for Individual Burner Control of Firing Rate, Fuel-Air Ratio, and Coal Fineness Correlation, Quarterly Report: April-June 2004

Description: The project's overall objective is to develop a commercially viable sensing system to infer the flow rate and fineness of pulverized coal flows using the dynamic signature from a pipe-mounted accelerometer. The preliminary calibration data for this effort will be obtained using a Coal Flow Test Facility built and operated by our subcontractor, Airflow Sciences Corporation, in support of an EPRI program. Airflow Sciences encountered significant difficulty getting the system up and running, with the final hurdles related to the system controls. These problems were resolved in this reporting period, so that the facility is ready for testing. Shakedown testing with our instrumentation package began late in the reporting period. Preliminary analysis of the resulting data indicates that there are problems with the instrumentation and/or test rig. Even with no flow passing through the test section, a power spectrum of the data shows strong frequency ''lines''. The data should be free of such behaviors, so the instrumentation must be recording behaviors that are unrelated to the flow. This issue must be resolved before calibration data are collected. A preliminary effort to debug the problem through long-distance consultation between Foster-Miller and Airflow Sciences personnel at the end of the reporting period did not discover the source of the problem. Consequently, a Foster-Miller engineer will visit the test facility early in the next reporting period. Assuming this effort is successful, preliminary testing and analysis should be completed in the next reporting period. Because of slack in the program schedule, there should be no net effect on the program scope, cost, or schedule.
Date: October 2004
Creator: Hill, Wayne
Partner: UNT Libraries Government Documents Department

Sensor for Individual Burner Control of Firing Rate, Fuel-Air Ratio, and Coal Fineness Correlation, Quarterly Report: July-September 2004

Description: Instrumentation difficulties encountered in the previous reporting period were addressed early in this reporting period, resulting in a new instrumentation configuration that appears to be free of the noise issues found previously. This permitted the collection of flow calibration data to begin. The first issues in question are the effects of the type and location of the transducer mount. Data were collected for 15 different transducer positions (upstream and downstream of an elbow in the pipe), with both a stud mount and a magnetic transducer mount, for each of seven combinations of air and coal flow. Analysis of these data shows that the effects of the transducer mount type and location on the resulting dynamics are complicated, and not easily captured in a single analysis. To maximize the practical value of the calibration data, further detailed calibration data will be collected with both the magnetic and stud mounts, but at a single mounting location just downstream of a pipe elbow. This testing will be performed in the Coal Flow Test Facility in the next reporting period. The program progress in this reporting period was sufficient to put us essentially back on schedule.
Date: October 2004
Creator: Hill, Wayne; Demler, Roger & Mudry, Robert G.
Partner: UNT Libraries Government Documents Department

Sensor for Individual Burner Control of Firing Rate, Fuel-Air Ratio, and Coal Fineness Correlation, Quarterly Report: October-December 2004

Description: Additional calibration data were collected in the Coal Flow Test Facility early in this reporting period. These data comprised a total of 181 tests for stud and magnetic accelerometer mounts, with two mounting locations relative to two different pipe elbows, and including some tests with out-of-plane elbows upstream of the test section to produce coal ''roping''. The results found in analyzing these new data were somewhat disappointing: correlations for coal flow rate for a given mount type and mounting location were less accurate than desired, and degraded badly when data from other locations were included in the same analysis. Reviewing all of the data files (from both the earlier testing and recent calibration testing) disclosed a significant fraction of cases with several forms of noise. Eliminating these cases improved the correlations somewhat, but the number of cases that remained did not permit general conclusions to be drawn. It was finally learned that yet another type of noise is present in some data files, producing a strong effect on the correlation accuracy. The cases not subject to this noise correlated very well. It would be desirable to collect additional data in the Coal Flow Test Facility prior to moving on to field data collection, a change in program direction that would require a no-cost time extension.
Date: January 2005
Creator: Hill, Wayne; Demler, Roger & Mudry, Robert G.
Partner: UNT Libraries Government Documents Department

Sensor for Individual Burner Control of Firing Rate, Fuel-Air Ratio, and Coal Fineness Correlation, Quarterly Report: October-December 2003

Description: The project's overall objective is to development a commercially viable dynamic signature based sensing system that is used to infer the flow rate and fineness of pulverized coal. This eighteen month effort will focus on developments required to transfer the measurement system from the laboratory to a field ready prototype system. This objective will be achieved through the completion of the laboratory development of the sensor and data algorithm followed by full scale field tests of a portable measurement system. The sensing system utilizes accelerometers attached externally to coal feeder pipes. Raw data is collected from the impingement of the coal particles as well as the acoustic noise generated from the flow and is transformed into characteristic signatures through proper calibration that are meaningful to the operator. The laboratory testing will use a portable version of the sensing system to collect signature data from a variety of flow conditions including coal flow rates, flow orientations, and coal particle characteristics. This work will be conducted at the Coal Flow Measurement Laboratory that is sponsored by EPRI and operated by Airflow Sciences. The data will be used to enhance the algorithm and neural network required to perform real time analysis of the non-specific signature data. The system will be installed at two full scale power plants to collect data in a real time operating scenario. These short term duration tests will evaluate the ability of the algorithm to accurately infer coal flow rates and determine if the measurement system can be used effectively in an active control loop for combustion diagnostics and burner balancing. At the completion of this project, prototype versions of both a portable system and a permanent installation will be available for final packaging and commercialization by one of the team members. Both types of systems will be marketed ...
Date: February 2004
Creator: Hill, Wayne
Partner: UNT Libraries Government Documents Department