SAS Global Diagnostic Testing and Combustion Tuning Services

Copyright © 2012 SAS Global Corporation Copyright © 2012 SAS Global Corporation

SAS Global Corporation, World Headquarters21601 Mullin Ave., Warren, MI 48089, USA • 248-414-4470 • Fax: 248-414-4480 • www.sasglobalcorp.comSAS GLOBAL POWER

Easy, Quick and Accurate 3D Flow Measurement

This system accurately measures both duct and stack flows, and combines high accuracy instrumentation with data acquisition. The 3D-DAFM is computer controlled to more accurately and efficiently perform 3D flow measurements. The computer provides complete test configuration information, data recording and reduction, report generation, and error checking. For example, Velocity testing is performed with the computerized data acquisition system, which guides the user through the Method 2 test procedures to ensure success. The 3D-DAFM takes 1000 readings per second and calculates averages instantly. There are no fluctuating gauges that a human operator needs to average.

The SAS crews can perform a wide range of tests for performance evaluation, emissions, compliance, or equipment guarantees, such as: • Velocity • Temperature • Total Flow • Pressure

3D-DAFM Data Acquisition Flow Measurement Services for Duct, Stack, and Fan

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3D-DAFM System

Applications: • Stack/RATA testing • Fan outlet ducts • Mill inlet ducts • General duct work/piping • Fully compliant with: EPA Method 2, 2F, 2G and 2H

Diagnostic Testing / Tuning Services• Coal Pipe Balance • Velocities • Coal Fineness • Fly Ash LOI • Boiler Camera Services •

• HVT Boiler Mapping / Testing • Multi-Stream Combustion Analyzers •

Fly Ash LOI Burnout High Temperature Boiler Camera Inspection

SAS GLOBAL POWER

Fineness Testing

HVT Boiler Mapping / TestingMulti-Stream Combustion AnalyzersACFM Extractive Fuel Pipe Testing

S-Type Probe

3D Probe

Reverse Impact Pitot Tube Probe

Copyright © 2012 SAS Global Corporation

SAS Global Corporation, World Headquarters21601 Mullin Ave., Warren, MI 48089, USA • 248-414-4470 • Fax: 248-414-4480 • www.sasglobalcorp.com SAS GLOBAL POWER

Do you know the True Status of your Mill Performance and Boiler Combustion? Coal and Fly Ash Analysis at the SAS Global Laboratory or On-Site

Due to recent strict EPA regulations, more stringent burdens will continue to fall upon our industry. Coupled with increasing competition, fossil fueled power plants are struggling to comply with government regulations and competing in a turbulent market. SAS Global Power is the only firm that has the experience to accurately assess your current operating conditions and provide the technology for you to effectively and efficiently produce power without exceeding emissions standards.

The SAS Global Performance Testing and Combustion Tuning Group specializes in the reliable examination of your fuel flows to the boiler, backpass emission mapping, visual flame conditions inside boiler, fly ash and coal analysis. Utilizing the collected data, a comprehensive report detailing current operating assessment will be provided. The report will include recommendations designed to improve combustion stoichiometry, while enhancing auxiliary efficiencies and reducing emissions.

The scope of the test report will depend upon your predetermined goals and system imbalances, which will be determined from your own custom test program.

Our service is unique to the specific requirements of each plant, price quotes are prepared on a location-by-location basis. Please contact us for a custom tailored proposal that meets all of your specific needs.

The SAS Global Fuel Analysis Lab is designed to provide you with accurate information concerning your fineness and fly ash LOI. Additional data concerning the properties of your fuel can be provided upon request.

SAS Global Performance Mill Testing and Combustion Tuning Services

Services Offered: (detailed information contained within)

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Fineness / Fly Ash LOI: At our facility or on-site at your Plant

Performance Testing: • Extractive Fuel Pipe Measurement• 100% Isokinetic Fuel Flow Measurement• Fuel Pipe Mass Flow & Balance• Coal Fineness and Fuel Analysis• HVT Boiler Testing• Multi-Stream Flue Gas Measurement• Fly Ash LOI Burnout• Boiler Camera Services

Combustion Tuning: • Tune Boiler for optimum O2 and CO levels• Lower NOX• Reduce LOI• Reduce Slagging• Improve Heat Rate

Data Obtained• Fineness• Fly Ash LOI• Fly Ash LOI on composite and passing 200 mesh to determine source of combustion issues

Key Features• Procedures follow ASTM D 197-87 Standard Test Method for Fineness Test of Pulverized Coal• Two (2) tests performed on each sample to ensure repeatable accurate results• Our two climate controlled labs provide an atmosphere capable of drying even the wettest of fuels

SAS Global Onsite Mobile Testing Lab



ACFM Testing: Advanced Coal Flow Measurement Computer Controlled ACFM Machine self adjusts to extract 100% Isokinetic.

SAS has four ACFM machines that accurately measure fuel flows in PF systems. These testing machines utilize the very latest in technology for fuel flow measurement.

The Advanced Coal Flow Measurement System (ACFM) was designed and developed strictly to measure air and fuel flows through coal pipes. It is a computer-controlled PC-based isokinetic extraction type testing system. It utilizes a dirty air probe for air flow measurement, and (3) types of advanced coal sampling probes. Probe types are shown to the lower left.

The computer controlled isokinetic extraction rate is adjusted point-by-point to maintain 100% isokinetic coal extraction across the pipe velocity profile. Each pipe is carefully tested to assure accuracy within 3% for air and 6% for coal. Any deviation out of this tolerance will nullify that particular test and restart another.

ACFM (Advance Coal Flow Measurement)

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Special Features• Fast and accurate test results

• Machine self adjusts to extract 100% Isokinetic

• All testing is computer controlled

• Fuel flows automatically moisture corrected

• Comprehensive report

• Easy to understand data format

• Rapid ROI of testing expenditure

Types of Extractive Probes UsedDepending on the testing situation, SAS can utilize different coal extracting probes to insure the best possible results. SAS Global utilizes (3) different style probes; an ASC Linear Probe, ASME Linear Probe, ASC Swivel Head Probe, or RotorProbeTM.

• Coal flow rate• Primary air flow• Air/coal ratio• Primary air velocity• Primary air temperature• Air Velocity Profile• Static & total pressure at the measurement location• Relative humidity• Dew point

• Coal and air flow rates• Coal pipe balance• Coal fineness• Comparison of measured flows to plant instrumentation• Suspected causes of problems• Air Velocity Profile• Recommendations• Presentation of proven means to maximize optimization of your system

Data Obtained Data Reported

ACFM Data Collection Example: CE Pressurized Mill with 8 Pipes

Pipe Variation from AverageMill 2-A

-25.0%-20.0%-15.0%-10.0%

-5.0%0.0%5.0%

10.0%15.0%20.0%25.0%30.0%

1 2 3 4 5 6 7 8

Pipe

% AirflowCoal flow

Mill 2-A 2/16/04Pipe #1 Pipe #4 Pipe #2 Pipe #3 Pipe #5 Pipe #8 Pipe #6 Pipe #7

Air-lbs/hr 40062 36091 36700 34810 39056 39091 40146 32630Deviation 5.2% -5.2% 2.6% -2.6% 0.0% 0.0% 10.3% -10.3%

Coal-lbs/hr 14655 17991 13640 13276 13074 15070 15589 19117Deviation -10.2% 10.2% 1.4% -1.4% -7.1% 7.1% -10.2% 10.2%

Air-lbs/hr Coal-lbs/hr Air-lbs/hr Coal-lbs/hr Air-lbs/hr Coal-lbs/hr Air-lbs/hr Coal-lbs/hrFlow 76153 32646 71509 26916 78148 28144 72776 34706

Deviation 2.0% 6.7% -4.2% -12.0% 4.7% -8.0% -2.5% 13.4%

Air-lbs/hr Coal-lbs/hr298585 122412Total Flow-Exiting Mill

Figure 1: Riffle Distributor Balance

Mill 2-A Control Room DataFeeder 66.5 Tons/Hour

Mill 2-A Estimated Flows Into MillAir-dry 282953 lbs/hrCoal-wet 133425 lbs/hrA/F Ratio 2.12

Mill 2-A Furnace SplitAir Coal

147662 59562 Total-1,2,3,4-1.1% -2.7% Balance1.1% 2.7% Balance

150923 62850 Total-5,6,7,8

Mill 2-APrimary Air Flow Rate Measurement (lbm/hr) Discarded

Pipe Test 1 Test 2 Test 3 Test Average Confidence1 39,291 40,832 42,418 40,062 3.2%2 36,640 36,759 36,700 0.3%3 36,767 35,985 36,376 1.8%4 35,653 36,530 36,091 2.0%5 39,155 38,958 39,056 0.4%6 40,721 39,571 40,146 2.4%7 32,845 32,415 32,630 1.1%8 38,726 39,457 39,091 1.5%

Coal Flow Rate Measurement (lbm/hr)1 14,683 14,627 17,256 14,655 0.3%2 13,363 13,916 13,640 3.3%3 13,036 13,516 13,276 3.0%4 17,803 18,179 17,991 1.7%5 13,459 12,689 13,074 4.8%6 16,026 15,152 15,589 4.6%7 19,845 18,389 19,117 6.3%8 15,276 14,864 15,070 2.2%

Table 2: Test Measurement Variability

ACFM provides an accurate measure of fuel flow by calculating the mositure lost during the drying process by measuring the humidity level in the pipe.

Mill 2-A Average Average AverageFlow Rate Balance Flow Rate Balance Value Balance Air Velocity Temp Static P

Pipe (lbm/hr) (lbm/hr) (ft/s) (°F) ("wc)1 40062 7.3% 14655 -4.2% 2.73 12.1% 91.0 133.7 2.582 36700 -1.7% 13640 -10.9% 2.69 10.3% 83.1 135.2 3.223 34810 -6.7% 13276 -13.2% 2.62 7.5% 78.9 134.5 2.594 36091 -3.3% 17991 17.6% 2.01 -17.8% 81.8 134.3 3.705 39056 4.6% 13074 -14.6% 2.99 22.5% 88.1 130.6 3.306 40146 7.6% 15589 1.9% 2.58 5.6% 91.1 134.1 2.387 32630 -12.6% 19117 24.9% 1.71 -30.0% 73.8 132.9 3.318 39091 4.7% 15070 -1.5% 2.59 6.3% 88.9 134.9 2.34

Total 298585 122412Average 37323 15301 2.44 84.6 133.7 2.93Max Dev. 20.1% 39.5% 52.5%

Air and Moisture Dry Coal Air/Coal RatioTable 3: Mill Pipe Summary

ASC Swivel Head Probe / RotorProbeTM

ASC Linear Probe

ASME Linear Probe



SAS Global Real-Time Multi-Stream Combustion Analyzer The MSCA greatly reduces testing time by analyzing up to fourteen (14) flue gas streams simultaneously.

Traditional flue gas sampling and analysis has involved tedious point-to-point sampling of individual flue gas stream for excess oxygen (O2), carbon monoxide (CO), and nitrogen oxides (NOx). Not only is the traditional process time consuming, which can involve sampling each point for several minutes, but also the probability exists that the combustion conditions will change significantly within the boiler during the test duration.

As an example, if the economizer exit/air heater inlet test grids consists of two ducts, and each duct contains twelve (12) points for a total of 24 sample streams, then a test duration of approximately 120 minutes (two hours) would be required for five minutes of data per point. Further, a pre-and post-test calibration and data reduction can increase the total test time by another thirty minutes. This total test time of 2-1/2 hours is often too long to maintain constant, steady-state test conditions for reliable and repeatable data.

Issues with Traditional Flue Gas Sampling & Analysis Method

The MSCA overcomes the time concerns by analyzing up to fourteen (14) flue gas streams simultaneously. This approach reduces the test duration by a factor fourteen. Further, the MSCA instrument maintains its accuracy, so no pre and post test calibration is required. In addition, the data is recorded in real time using a laptop computer, and custom software translates the data into results within a few minutes of the completion of the test. This short duration helps to better ensure all data and results are representative of the boiler’s firing conditions without the influence of slagging and fouling on emissions, such as NOx.

Another benefit is the ability to determine the cause-and-effect relationships of burner tuning almost in real time. The MSCA will allow the real time monitoring of a duct’s emissions while a plant representative makes operating changes, such as burner air register settings. Hence, the impact of only one (1) burner air register change can be visualized on the entire boiler within 3-5 minutes instead of hours with traditional sampling and analysis.

SAS Global Real-Time Multi-Stream Combustion Analyzers

The SAS MSCA allows our Combustion Optimization Group to provide measurable savings in resources when compared with firms that use only the traditional sampling and analysis approach.

These measurable savings include: 1. Reduced contractor labor, per diem and equipment rental fees 2. Reduced labor from the utility 3. More flexibility in operation since the boiler is not always locked at one firing condition 4. Increased time for sootblowing, load changes and other necessary operations 5. Increased variables can be studied within a given time constraint 6. Greater confidence in the data and results since operational variables (slagging and fouling) are reduced.

Capable of analyzing up to fourteen (14) flue gas streams simultaneously

Example Data:

Economizer Exit CO (ppm) Economizer Exit O2 (ppm) Economizer Exit NO (ppm)

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When was the last time you looked at the Performance of your Combustion?

Why is it important to perform HVT Testing in your Boiler?

HVT Testing will allow you identify the current combustion status of your boiler as close to the combustion zone as possible. The HVT probe accurately measures gas temperature, but also measures the different levels of gasses within the upper furnaces. The data collected during the HVT Test can determine:

• NOX and CO profiles • Oxygen profile • Oxygen levels • Temperature profile • Flue gas temperatures • Possible fuel imbalances between burners • Possible secondary air imbalances • Possible air leakage into the boiler (leading to excessive O2 levels)

SAS Global HVT (High Velocity Thermocouple) Services

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Example of Data Collected: HVT Contour and 3D Graphs of Upper Furnace Flue Gas

With the utilization of water cooled probes flue gas profiles were obtained with HVT (High Velocity Thermocouple) traverses. HVT traverses were completed on the 40’ wide X 38’ deep upper furnace utilizing four (4) ports. The following graphs illustrates the testing grid on a plan view. Note data is collected on 2 foot increments.

3D Graph - Temperature (F)

3D Graph - CO (ppm)

Contour Graph - Temperature (F)

3D Graph - O2 (%)

3D Graph - NOX (ppm)

Contour Graph - O2 (%)

Contour Graph - NOX (ppm)Contour Graph - CO (ppm)



What is your Fly Ash telling you about your Combustion? Have you seen your burner flames lately?

SAS Global High Volume Fly Ash Extraction/Testing Services

Fly Ash LOI Analysis

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SAS High Temperature Camera Services: View in Infrared Thermal and/or Standard Visible Light Spectrums

The SAS Global Power Burner Flame Evaluation Program utilizes the latest in high temperature cameras to digitally record the current performance of your burner flames. Standard visible light and infrared thermal camera systems are available. The recorded footage is used to evaluate the performance of your burners and given to you in DVD format.

There are many common problems that are easily identified by reviewing the real time burner footage including; • Flame instability/detachment • Tube leaks • Eyebrows • High-unburned carbon (LOI) • Slagging • Fuel and/or flame impingement on boiler walls • CO and O2 imbalance • Problems adjusting secondary air and low NOX burners

Recommendations to correct your specific problems (if any) are made once your performance issues have been identified.

Portable Battery Powered Boiler Camera Systems and Permanent Systems are also available for purchase from SAS Global Corporation.

LOI Sample Results

Ports

AFoil

mg

B Foil + Ash

(wet)mg

C Foil + Ash

(dry)mg

DFoil + AshResidue

mg

E Dry Ash

mg

F Ash

Residue

mg

G Loss on

Ign.

%

Avg LOI

%1 0.11 0.27 0.27 0.27 0.16 0.16 1.122 0.11 0.24 0.24 0.24 0.13 0.13 1.173 0.11 0.28 0.28 0.28 0.16 0.16 0.794 0.00 0.00 0.001 0.11 0.24 0.24 0.23 0.12 0.12 2.012 0.11 0.25 0.25 0.25 0.14 0.14 1.513 0.11 0.26 0.26 0.26 0.14 0.14 1.114 0.00 0.00 0.00

ComputationsWeighing Data

1.03

1.54KJ 5/31/2012

Personnel Test No.

Ash Sample ID

& Date Taken

KJ 5/31/2012North

South

Test Type

As-Received

As-Received

6/1/2012

6/1/2012

Date

It is easy to collect fly ash samples from the economizer ash hopper. However, hopper samples may or may not be a representative sample. Many factors are involved including: • Frequency of fly ash collection • Particle size • Duct configuration • Flue gas velocities

A High Volume Fly Ash Sample collection method ensures the sample is representative of actual ash in the flue gas stream. This also provides accurate fly ash LOI information that correlates with your actual combustion efficiency.

This analysis is performed based on ASTM D3174 with one exception. In place of the typical muffle oven used for the burnout process, we use a Hot Foil instrument. This analyzer uses an electrical charge to simulate the temperature range needed for a proper burnout. By using this equipment in place of a muffle oven, we reduce LOI analysis time to minutes instead of hours. This method is extremely helpful during combustion tuning to provide immediate LOI results.

Copyright © 2012 SAS Global Corporation Copyright © 2012 SAS Global Corporation


Easy, Quick and Accurate 3D Flow Measurement

This system accurately measures both duct and stack flows, and combines high accuracy instrumentation with data acquisition. The 3D-DAFM is computer controlled to more accurately and efficiently perform 3D flow measurements. The computer provides complete test configuration information, data recording and reduction, report generation, and error checking. For example, Velocity testing is performed with the computerized data acquisition system, which guides the user through the Method 2 test procedures to ensure success. The 3D-DAFM takes 1000 readings per second and calculates averages instantly. There are no fluctuating gauges that a human operator needs to average.

The SAS crews can perform a wide range of tests for performance evaluation, emissions, compliance, or equipment guarantees, such as: • Velocity • Temperature • Total Flow • Pressure

3D-DAFM Data Acquisition Flow Measurement Services for Duct, Stack, and Fan

Made in

the USAwith PRIDE

3D-DAFM System

Applications: • Stack/RATA testing • Fan outlet ducts • Mill inlet ducts • General duct work/piping • Fully compliant with: EPA Method 2, 2F, 2G and 2H

Diagnostic Testing / Tuning Services• Coal Pipe Balance • Velocities • Coal Fineness • Fly Ash LOI • Boiler Camera Services •

• HVT Boiler Mapping / Testing • Multi-Stream Combustion Analyzers •

Fly Ash LOI Burnout High Temperature Boiler Camera Inspection

SAS GLOBAL POWER

Fineness Testing

HVT Boiler Mapping / TestingMulti-Stream Combustion AnalyzersACFM Extractive Fuel Pipe Testing

S-Type Probe

3D Probe

Reverse Impact Pitot Tube Probe