FLY ASH EROSION CONTROL & PREVENTION RECENT...
Transcript of FLY ASH EROSION CONTROL & PREVENTION RECENT...
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www.electricpowerexpo.com May 15‐17, 2012 – Baltimore, MD
FLY ASH EROSIONFLY ASH EROSIONCONTROL & PREVENTIONCONTROL & PREVENTION
RECENT DEVELOPMENTSRECENT DEVELOPMENTS
JOHN DRENNEN, PEJOHN DRENNEN, PEDRENNEN ENGINEERING, INC.DRENNEN ENGINEERING, INC.
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FLY ASH EROSION (FAE)FLY ASH EROSION (FAE)
LEADING CAUSE OF BTF
PREVENTABLE…IN MOST CASES
OLD TECHNOLOGY…& NEW TOOLS
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FACTORS CONTRIBUTING FACTORS CONTRIBUTING TO INCREASED FAETO INCREASED FAE
GAPS, OPENINGSTURNS IN FLOW PATH
SOOTBLOWINGFUEL CHANGEHIGHER LOAD
PP CHANGESFUEL FIRING EQUIP
ASH PLUGGINGEROSION CONTROLS
LOWER FLOW RESISTANCECENTRIFUGAL SEPARATIONFLY ASH SURGES MORE ASHHIGHER FLOWPREFERENTIAL FLOWTIME-TEMP HISTORYDECREASE FLOW AREACAN MOVE PROBLEM
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FAE EQUATIONFAE EQUATION
E = C x M x Vnx Cp
E – Erosion Rate C – Correlation Const. M – Mass Flux V – Gas Velocity n – exponent (2.5 - 3.5) Cp – Particle Size Adjustment
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RELATIVE EROSIONRELATIVE EROSIONEE11/E/Eavgavg = (M= (M11/M/Maa) x (V) x (V11/V/Vaa))nn x (Cx (Cp1p1/C/Cpapa))
Relative Erosion Rates(E1/Eavg, n=2.4)
0.0
0.5
1.0
1.5
2.0
0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
Relative Velocity
Rel
ativ
e So
lide
Load
ing
(0.18) (0.47) (E1/Eavg=1.00)
(1.86)
(5.0)
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LARGE BOILERLARGE BOILER>750 MW>750 MW
FAE AREAS:FAE AREAS:PERIMETERPERIMETER
ININ--BANK BANK
APPROACH:APPROACH:CAVTCAVTCOMPUTER MODELCOMPUTER MODEL
FAE
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FLOW
FLOW
FLOW
FAE
MIDMID--SIZE BOILERSIZE BOILER200 200 -- 750 MW750 MW
FAE AREAS:FAE AREAS:REAR PASS NEARREAR PASS NEARREAR WALLREAR WALL
APPROACH:APPROACH:COMPUTER & PHYSICAL MODELCOMPUTER & PHYSICAL MODELFOLLOWFOLLOW--UP CAVTUP CAVT
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SMALL BOILERSMALL BOILER< 200 MW< 200 MW
FAE AREA:FAE AREA:ECON NEARECON NEARREAR WALLREAR WALL
APPROACH:APPROACH:COMPUTER MODELCOMPUTER MODEL
STEAMDRUM
FLOW(FROM STOKER)
MUDDRUM
FAE
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APPROACH TO FAE REDUCTIONAPPROACH TO FAE REDUCTION
IDENTIFY ROOT CAUSEGAS & ASH DISTRIBUTION, OTHER…
MEASURE / MODEL DISTRIBUTIONSCAVT, COMPUTER, PHYSICAL MODEL
REDISTRIBUTE FLOWSFLOW MODIFICATION BAFFLES
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COLD AIR VELOCITY TESTCOLD AIR VELOCITY TEST
Measure Gas Flow DistributionFULL SCALE PHYSICAL MODEL
Testing in Unit w/ Fans RunningMultiple Teams Flow Visualization
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COLD AIR VELOCITY TEST - Multiple Teams at Different Planes - One Person Measures, the Other Records Readings & Notes - Safety Person for Each Team Outside at Same Plane - Control Room Operator Sets and Monitors Flow and Other Equipment to Support Test.
Control Room
ni j k l mhgfedcba
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COLD AIR VELOCITY TESTCOLD AIR VELOCITY TEST
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FLOW VISUALIZATIONFLOW VISUALIZATION
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FLOW VISUALIZATIONFLOW VISUALIZATION
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CO
LD A
IR V
ELO
CIT
Y T
ES
TC
OLD
AIR
VE
LOC
ITY
TE
ST
n-Rear
mlkjihgfedcba-Front
Left2
34
56
Right
0.00
0.25
0.50
0.75
1.00
1.25
1.50
1.75
2.00
Nor
mal
ized
Vel
ocity
Front-to-Rear
Side-to-Side
Normalized Velocty vs. Position
Normalized Velocity vs. Position(Column Averages)
0.0
0.5
1.0
1.5
2.0
0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00
Relative Position (Left-to-Right)
Nor
mal
ized
Vel
ocity
Normalized Velocity vs. Position(Row Averages)
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.0
0.0 0.5 1.0 1.5 2.0
Normalized Velocities
Rel
ativ
e Po
sitio
n (F
ront
-to-
Rea
r)
Rear
Front
Left Right
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COMPUTER MODELINGCOMPUTER MODELINGCOMPUTER MODELING2-D OR 3-D
DEPENDS ON SYMMETRY
AMBIENT TEMPERATURE (CAVT)OPERATING CONDITIONS
W/ HEAT EXTRACTION
GROSS FLOW DISTRIBUTION GAS AND PARTICULATE
ESTIMATE RELATIVE FAE RATEDETAILED AREA MODELS
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Inlet
Outlet
Nominal 1 Ft Wide Slice
Model
Div Wall
2-1/2-D CFD Model Geometry
HTSH
FLOW
FLOW
FLOW
FAE
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3-D MODEL
PA DUCT EXTRACTIONASSYMETRIC
INLET
OUTLETTO AH
ECON BANKS
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Gas Velocity3-Baffles
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TEMPERATURE
INLET – 2350°FOUTLET – 700°F
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PARTICULATE
30 & 53 MICRON
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PARTICULATE
74, 88, 105 MICRON
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PARTICULATE
177, 210 MICRON
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0.0
1.0
2.0
3.0
4.0
5.0
0.000.100.200.300.400.500.600.700.800.901.00
Distance, Rear-to-Front (Ft)
Rel
ativ
e M
ass
& S
ize
Rat
io
No Baffles 3 Baffles
Relative Mass Loading w/ Size CorrectionRear Pass at Operating Conditions
40% REDUCTION
FrontRear
Uniform ash / size distribution = 1.0
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FLOW
FLOW
FLOW
FAE
MIDMID--SIZE BOILERSIZE BOILER200 200 -- 750 MW750 MW
FAE AREAS:FAE AREAS:REAR PASS NEARREAR PASS NEARREAR WALLREAR WALL
APPROACH:APPROACH:COMPUTER & PHYSICAL MODELCOMPUTER & PHYSICAL MODELFOLLOWFOLLOW--UP CAVTUP CAVT
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Hanger Tubes
Inlet
ScreenTubes
Outlet
LTSH
Nominal 1 Ft Wide Slice
Model
Div Wall
2-1/2-D CFD Model Geometry
HTSH
400 MW
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INLET
BASELINEPARTICULATE: 10, 100, 150 MICRON
OUTLET
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0
2
4
6
8
10
12
14
16
18
20
0.0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0
Distance, Front-to-Rear (Ft)
Rel
ativ
e E
rosi
on R
ate
Mass Wtd. Mass & Part.
Adjustment to Account for Larger Particle Shift
to Rear of Pass
Peak at Wall Gap 21x Ideal
BASELINE
RELATIVE FAE TOP LTSH BANK INLET
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FLOW
FLOW
1
2
3
5
4
6
7
CFD Model GeometryMAIN DIAGONAL SCREEN & TUBE BEND BAFFLES
Div Wall
LADDER VANEBAFFLE
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EMS BAFFLE10, 23, 100 Particle Tracks
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0.0
2.0
4.0
6.0
8.0
10.0
0.00 1.00 2.00 3.00 4.00 5.00 6.00 7.00 8.00 9.00 10.00 11.00 12.00 13.00
Distance, Front-to-Rear (Ft)
Real
itive
Ero
sion
Rat
e
Mass Wtd. Mass & Part.
Relative Erosion at Upper Rear LTSH Inlet
NEW FAE Controls
No Major Particle Shift to Rear
Rear Sect.Below Avg.
Peak in Front SectDue to Jet off Vanes
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SMALL BOILERSMALL BOILER< 200 MW< 200 MW
FAE AREA:FAE AREA:ECON NEARECON NEARREAR WALLREAR WALL
APPROACH:APPROACH:COMPUTER MODELCOMPUTER MODEL
STEAMDRUM
FLOW(FROM STOKER)
MUDDRUM
FAE
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FLOW VISUALIZATIONFLOW VISUALIZATION
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0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
11.0
12.0
13.0
14.0
15.0
16.0
17.0
18.0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Economizer Tube Row Number
Nor
mal
ized
Ero
sion
Rat
e
Trajectories for 10 Micron Ash Particles
Economizer Inlet Plane
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0.0
1.0
2.0
3.0
4.0
5.0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Economizer Tube Row Number
Nor
mal
ized
Ero
sion
Rat
e
Trajectories for10 Micron Ash Particles
Economizer Inlet Plane
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OTHER ISSUESOTHER ISSUES
IN BANK FAE
TUBE ALIGNMENT
PLUGGING
TEMPERATURE
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Particle Tracks Through Bank
Particle Sizes Shown () :44, 62, 88, 125, 177, 250, 420
HighestParticle Impact
Zone
Particles are deflected off of top rowand then again by 4th row intoRows 5-8, where the most seriousFAE occurs.
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FAE LOCATIONS
Particles are deflected by top rowand 4th row tubes into Row’s 5 - 8, where most serious FAE occurs.
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Particle Tracks at Top of Bank
Particle Sizes Shown () :44, 62, 88, 125, 177, 250, 420
Flow
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Sidewall
Offset SH tube
FLOW TO SIDEWALL GAP&
TUBE ALIGNMENT
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PLUGGING DUE TO SOOTBLOWINGPLUGGING DUE TO SOOTBLOWING
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PLUGGING DUE TO CARRYOVERPLUGGING DUE TO CARRYOVER
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ASH DEFLECTION SCREENSASH DEFLECTION SCREENS
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OVERHEATINGOVERHEATING
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SUMMARYSUMMARYSTEPS TO REDUCE FAE
IDENTIFY LOCATIONS – FAE – ROOT CAUSE
GET FLOW DISTRIBUTIONSGAS AND FLY ASH
CAVT, COMPUTER OR PHYSICAL MODEL
CORRELATE FAE TO FLOW DISTRIBUTIONS
SELECT BAFFLES TO REDISTRIBUTE FLOW
GET MODIFIED DISTRIBUTIONS W/ BAFFLES
CAUTIONARY ITEMSPLUGGING, TEMPERATURE
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FLY ASH EROSIONFLY ASH EROSIONCONTROL & PREVENTIONCONTROL & PREVENTION
J. DRENNENDRENNEN ENG, INC
QUESTIONS AND ANSWERS