Measurement of combustion airf low into burners in coal fired plants

Abstract

This research study is aimed at achieving accurate measurement of mass flow rates in large square industrial square ducts at Eskom’s boiler plants. For safe and efficient operation of Fossil Fuel Firing Boiler Plants, the utility has put in place the Fossil Fuel Firing Regulation Standard which requires that the Total Combustion Air flow be measured at exit from the air heaters, into the ducts. In this study, a sophisticated airflow measuring probe was acquired, herein the current study referred to the 14-hole Omniprobe. The accuracy was found to be within 5% in a free stream flow field. A Five-hole probe was calibrated in the free-stream wind tunnel. The calibration process enabled the derivation of the probe specific polynomials of Pitch, Yaw, Total Pressure, Static Pressure coefficients and velocity components. A prototype air duct was designed for the study to simulate air flow through square ducts with a 90⁰ bend as an abrupt flow disturbance. To achieve the objectives of the study, 6 planes were identified where air flow velocity profiles were generated using the equal area method. The modeling of the velocity profiles was conducted numerically, using CFD (Ansys Fluent), and experimental, using Pitot-static probe, Omniprobe, and a Five-hole probe. The mass flow rates as measured by the Pitot-static tube were found to be consistent at planes 1, 2, 5, and 6. The mass flow rate as calculated from the Pitot-static probe varied by 2.1% through the duct. This justified the selection of the Pitot-static probe as the reference for this study. The velocity profiles generated from the traverse measurements using the 14-hole Omniprobe showed an error in velocity measurements which are in the proximity of the wall. This can be attributed to the the wall effect. The mass flow rates of air calculated from the Five- hole probe measurements were found to be within 4% of the mass flow rate as calculated from the results of the reference probe in the 1st and 2nd planes upstream of the bend. After the 90⁰ flow disturbance bend, the accuracy drops to 13% at plane 5 and improved slightly at plane 6 to 11.7%. This is attributed to complex flow pattern at these planes. The study concludes that the Pitot-static tube remains the preferred instrument for use in measuring flow rates using the equal area method in large square ducts. The Five-hole probe can be applied where the flow field is not distorted in conjunction with CFD. The Omniprobe’s accuracy in measuring the velocity magnitude, and the angularity of the flow field was verified in an open stream wind tunnel. This study recommends exploring the use of an L-type 14-hole Omniprobe for application in large square industrial ducts.