Air Moniter

POWER CATALOG
Tab Document Name Part Number

1 TABLE OF CONTENTS.................................................................................................... N/A

2 COMBUSTION AIRFLOW APPLICATIONS
Measuring Combustion Airflow & Pulverized Coal Flow..................................................ICA-11
Measuring Primary Airflow...............................................................................................ICA-01
Measuring Bulk Secondary Airflow..................................................................................ICA-02
Measuring Bulk Secondary Airflow..................................................................................ICA-03
Measuring Individual Burner Airflow................................................................................ICA-06
Pf-FLO with Mill Inlet Diverter..........................................................................................ICA-09
Measuring Individual Burner Airflow................................................................................ICA-10

3 COMBUSTION AIRFLOW MEASURING SYSTEMS
VOLU-probe/SS Stainless Steel Pitot Airflow Traverse Probe.......................................125-068
Combustion Airflow (CA) Measurement Station.............................................................125-495
CAMS Combustion Airflow Management System..........................................................125-009
VELTRON DPT-plus Microprocessor Based Transmitter...............................................125-025

4 PULVERIZED COAL FLOW MEASURING SYSTEMS
Pf-FLO III
TM
Pulverized Coal Flow Measurement...........................................................125-196
Progress Energy Sutton 3 NO
x
Reduction through Combustion Optimization................ N/A
Pf-FLO
TM
Reference Test at the Martin-Luther University Halle-Wittenberg...................... N/A

5 INDIVIDUAL BURNER AIRFLOW MEASURING SYSTEMS
Individual Burner Airflow Measurement..........................................................................125-510
Accurate Burner Airflow Measurement for Low NO
x
Burners D.B. Riley........................ N/A

6 CONTINUOUS EMISSIONS MONITORING SYSTEMS
CEM Systems Continuous Emissions Monitoring........................................................125-491

Proven solutions for a tough industry

1050 Hopper Avenue www.airmonitor.com amcsales@airmonitor.com 707.544.2706 - P
Santa Rosa, CA 95403 707.526.9970 - F
AIR MONITOR
POWER DI VI SI ON
ICA-11
MEASURING COMBUSTION AIRFLOW
& PULVERIZED COAL FLOW
While the importance placed on combustion optimization for the purposes of reducing emissions and
improving efficiency varies by power plant, there are common applications at every power plant that would
greatly benefit from improved airflow measurement or the addition of pulverized coal flow measurement. Air
Monitor Power is both pioneer and leader in the development of systems to accurately and reliably measure
combustion air and coal flow, with thousands of installations at virtually every utility in the United States. The
accompanying application bulletins outline the methods and benefits of measuring air and coal flow at the
locations indicated in the boiler overview below.
When applied by themselves or in combination, the addition of air and coal flow measurements will directly
contribute to:

REDUCING CO, LOI & NO
X

REDUCING WATER WALL CORROSION

IMPROVING MILL & BURNER PERFORMANCE

ELIMINATING COAL LAYOUT, MILL PLUGGAGE, PIPE FIRES & SLAGGING

LOWERING SCR OPERATING COSTS & ACHIEVING DESIRED BURNER STOICHIOMETRY
CEM
SA
PA
Pf-FLO
IBAM
OFA
Proven sol uti ons for a tough i ndustry
AIR MONITOR
POWER DI VI SI ON
APPLICATION BULLETIN
P.O. Box 6358 Santa Rosa, CA 95406 707-544-2706 - P 707-526-9970 - F www.airmonitor.com
ICA-01
4/09, Rev.1
Ductwork providing primary air to a
pulverizer typically has limited straight
runs, control dampers, and a
convergence point of hot and
tempering air, all of which make the
selection and placement of the airflow
measurement device(s) critical to the
success of the installation. The
following three examples show the
use of Fechheimer-Pitot Combustion
Air (CA) stations and/or VOLU-probe/
SS arrays, and their optimum
locations.
In applications with at least 1
diameters of straight duct run between
the hot air/tempering air mixing point
and the elbow upstream of the
pulverizer control damper, a CA station
is used to measure total primary air.
See Figure 1.
while insufficient primary air results in
slagging, coal layout, pipe fires,
eyebrows, and burner pluggage.
Usable measurement of primary air
cannot be obtained from existing devices
such as venturis, foils, jamb tubes, etc.,
or instrumentation such as thermal
anemometers due to limited available
straight duct runs, low flow rates, broad
turndown range and high concentrations
of airborne particulate (flyash). The need
is airflow instrumentation capable of
overcoming these challenging operating
conditions, to optimize both mill operation
and burner performance.
MEASURING PRIMARY AIRFLOW
The objectives in the power industry
today are twofold; to lower emissions,
and increase plant performance.
Precise measurement of combustion
airflow and fuel rates positively
contributes to achieving those
objectives by providing the information
needed to optimize stoichiometric
ratios and facilitate more complete,
stable combustion.
The main functions of primary air are
to dry the coal and then pneumatically
convey the pulverized coal from the
mill to the individual burners. Primary
air also determines coal particle
velocity at the burner exit, in part
defining the flame position relative to
the burner tip and impacting flame
stability, both key factors in achieving
optimized burner performance.
Excessive primary air contributes to
high NO
x
formation and tube erosion,
The Challenge The Solution
Figure 1
CA Station w/Temperature Probe and Transmitter
CAMS Purge and Transmitter
Opposed Blade Damper
T.P. and S.P. Signal Tubing
4-20mADC from Temperature Sensor
4-20mADC Flow Signal to DCS (lbs/hr)
100 psi Plant Air
A
E
F
G
H
I
K
ash. The purge cycle can be
configured to operate on a
programmable interval or initiated via
a dry contact from the DCS. During
the purge cycle the CAMM maintains
a locked signal output to the DCS
while providing a dry contact
notification of purge cycle start and
finish.
These systems provide airflow
measurement accurate to within 3%
of actual airflow over a 10:1 turndown
range. The signals remain stable with
zero drift, and due to AUTO-purge the
flow elements can operate
continuously within the heavy
particulate environment. To date
thousands of these systems have
been installed within fossil fuel power
plants to help reduce NO
x
and CO,
improve flame stability, avoid coal pipe
layout, minimize LOI/UBC, increase
combustion efficiency, and reduce
waterwall corrosion.
Coal mass flow and particle velocity
data from a Pf-FLO coal flow
measurement system allow further
optimization of primary air by providing
the means of customizing a mills PA
to Feeder curve to meet the unique
operating conditions of each power
plant; curves that are dependent upon
variable coal type, moisture content,
coal pipe arrangement, and actual
fuel distribution.
the CAMS enclosure the pressure signals
plus airflow temperature are converted
by the CAMM into a density compensated
lbs/hr mass flow output to the DCS.
When two flow elements are supported
by a single CAMS, both the individual
and summed mass flow outputs are
made available to the DCS.
The CAMM also manages the AUTO-
purge
TM
system used to keep the airflow
station or probe array sensing ports and
signal lines clear of accumulating fly
Where insufficient straight duct run
exists downstream of the air mixing
point, or separate measurement of
hot and tempering air is desired to
control mill outlet temperature, CA
stations or VOLU-probe/SS arrays
can be installed in both air ducts
upstream of the control dampers, one
duct diameter for the CA Station and
two diameters for the VOLU-probe/
SS array. See Figure 2.
On exhauster mills the tempering air
is often not ducted but instead enters
via a barometric opening on the side
of the ductwork. For this application
an integrated bell mouth CA station
with extended casing is utilized to
create the necessary minimum run of
straight ductwork needed to
accurately measure the tempering
airflow. A control damper can also be
added. See Figure 3.
The total and static pressure signals
from one or both CA Stations or VOLU-
probe/SS arrays are routed to the
Combustion Airflow Management
System (CAMS) enclosure. Within
The Solution (con't)
Result
Figure 2
Figure 3
CA Station
CA Station w/Bellmouth
VOLU-probe/SS Array
Thermocouple Probe w/Temperature
Transmitter
Opposed Blade Damper
100 psi Plant Air
A
B
C
D
E
F
G
H
J
K
ICA-02
4/09, Rev.1
need for five to eight straight lengths
of duct runs at the point of installation
to obtain true accuracy and
repeatability, 4) Cannot achieve a
linear mass flow output over a broad
operating range with a single K-factor.
fuel ratio at varying load conditions.
Although airfoils and venturis have
provided adequate airflow measurement
in the past, achieving current emission
reduction mandates and performance
objectives require a more accurate and
cost effective means of airflow
measurement.
Venturis and airfoils have known
limitations: 1) Significant non-
recoverable pressure loss that wastes
power and can limit generated output; 2)
Decreased accuracy and noisy signals
at high turndown operating conditions
associated with low NO
x
retrofits; 3) The
MEASURING BULK SECONDARY AIRFLOW
stable combustion.
Traditional coal fired power plant
design utilized airfoils or venturis for
measurement of bulk primary and
secondary airflow for the purpose of
maintaining the correct boiler air to
The Challenge
The Solution
A Florida utility was engineering a low
NO
x
burner retrofit on their 300MW
gas/oil wall fired boiler. In order to gain
needed fan capacity and obtain a more
accurate measurement of airflow over
a higher range of turndown, Air Monitor
Powers Application Engineering
Department suggested the total air
venturi be removed and replaced with
a VOLU-probe/SS array. See Figure
1.
Figure 1
System (CAMS) enclosure. Within the
CAMS enclosure the pressure signals
plus airflow temperature are converted
by the CAMM into a density compensated
lbs/hr mass flow output to the DCS. The
two mass flow inputs, one from each
CAMM, were summed in the DCS to
arrive at a total bulk airflow.See Figure 2.
purge
TM
system used to keep the VOLU-
probe/SS sensing ports and signal lines
clear of accumulating fly ash. The purge
cycle can be configured to operate on a
programmable interval or initiated via a
dry contact from the DCS. During the
purge cycle the CAMM maintains a
locked signal output to the DCS while
providing a dry contact notification of
purge cycle start and finish.
The measuring location was a 40
long section of duct downstream of
twin forced draft (FD) fans and a
rotary air pre-heater. The two fans
joined into a common 5 x 75 duct
upstream of the pre-heater, and it
was believed that the flow rates on
either side of the duct would vary
depending on the load changes on
either fan.
Two side-by-side measurement
arrays, each having seven
Fechheimer-Pitot VOLU-probe/SS
measuring 60" in length, were
installed. For each array the VOLU-
probe/SS total and static pressure
signal connections were manifolded
together and routed to their own
Result The Solution
The removal of the venturi provided
the needed additional fan capacity,
while saving an estimated $10,000 in
reduced power consumed by each
FD fan. The installed VOLU-probe/
SS arrays achieved the desired 3%
measurement accuracy over the full
4:1 range of turndown. Due to the
CAMS sensitivity to small changes in
airflow, a cyclic drop in airflow was
detected and traced back to one of
the pre-heaters twelve sections being
plugged.
Subsequent to the initial installation,
Air Monitor Power assisted the
customer in reconfiguring the
manifolding of the two VOLU-probe/
SS arrays as in Figure 3. The revised
arrangement resulted in two fully
redundant systems, each measuring
the total bulk airflow without any
summing in the DCS. When one
system was performing a purge cycle,
the other system continued to provide
dynamic flow measurement.
VOLU-probe/SS Array
Thermocouple Probe w/Temperature Transmitter
100 psi Plant Air
A
B
C
D
E
F
G
Figure 2 Figure 3
ICA-03
4/09, Rev.1
Venturis and airfoils have known
limitations: 1) Significant non-
recoverable pressure loss that wastes
power and can limit generated output;
2) Decreased accuracy and noisy
signals at high turndown operating
conditions associated with low NO
x
retrofits; 3) The need for five to eight
straight lengths of duct run at the point
of installation to obtain true accuracy
and repeatability, 4) Cannot achieve a
linear mass flow output over a broad
operating range with a single K-factor.
Traditional coal fired power plant design
utilized airfoils or venturis for
measurement of bulk primary and
secondary airflows for the purpose of
maintaining the correct boiler air to fuel
ratio at varying load conditions. Although
airfoils and venturis have provided
adequate airflow measurement in the
past, achieving current emission
reduction mandates and performance
objectives require a more accurate and
cost effective means of airflow
measurement.
MEASURING BULK SECONDARY AIRFLOW
stable combustion.
The Challenge
notification of purge cycle start and finish.
FD fan operating costs were reduced
nearly $50,000 per year, resulting in a
21-month payback for the project. As a
result of the installed VOLU-probe/SS
arrays measurement accuracy was
greatly improved, to within 3% of actual
airflow over the 4:1 range of turndown.
Air Monitor Powers Application
Engineering Department was called
upon by a Georgia utility to design
and provide airflow measuring
systems to replace three airfoils and
one air dam within their 500MW, coal
fueled, T-fired boiler. The project
objective was to gain needed FD
capacity, with the cost justification
expected to come from a reduction in
energy required to operate the FD
fans.
Airfoils in three locations and an air
dam were removed one airfoil in
each of the 12 x 15 bulk secondary
air ducts, one airfoil in the 6 x 6 hot
primary air duct serving the mills, and
the air dam in the 5x 5 tempering air
duct. Fan curve data indicated the
total non-recoverable pressure loss
caused by the airfoils and air dam
was slightly more than 3" w.c., wasting
nearly 300 HP per fan.
An array of Fechheimer-Pitot VOLU-
probe/SS were installed in each of the
four measurement locations: Ten
probes 12 in length in each of the two
secondary air duct, five probes 6' in
length within the hot PA duct, and
four probes 5' in length in the
tempering air duct. For each array
the VOLU-probe/SS total and static
pressure signal connections were
manifolded together and routed to
their own Combustion Airflow
Management System (CAMS)
enclosure. Within the CAMS
enclosure the pressure signals plus
airflow temperature are converted by
the CAMM into a density
compensated lbs/hr mass flow output
to the DCS.
purge
TM
system used to keep the
VOLU-probe/SS sensing ports and
signal lines clear of accumulating fly
ash. The purge cycle can be
the purge cycle the CAMM maintains
Result The Solution
ICA-06
4/09, Rev.1
angles blades in each barrel, a
combination of fixed and/or adjustable
inlet sleeve/disk dampers, and in most
installations the burners were equipped
with actuators to facilitate DCS controlled
modulation of burner SA airflow
corresponding to varying fuel loads.
Unfortunately some low NO
x
burners
come equipped with a non-calibrated
airflow sensing device and most others
lack any means to determine how much
SA is entering the burner, resulting in the
need for extensive burner tuning targeted
at meeting the manufacturers NO
x
and
CO emissions guarantees but not
repeatable or maintainable long term
over varying load conditions.
J ust as there are variances in fuel
distribution to each burner, multiple
MEASURING INDIVIDUAL BURNER AIRFLOW
stable combustion.
Traditional coal fired power plant
designs lacked any means to measure
and control airflow into individual
burners. New burner designs
prompted by Clean Air Act attainment
levels for NO
x
reduction are typically
comprised of inner and outer airflow
barrels to introduce secondary air (SA)
to the flame ball, adjustable swirl
The Challenge
burners served by a common or
partitioned wind box can have
substantial burner-to-burner im-
balances in SA Accurate and
repeatable measurement of individual
burner SA requires airflow probes that
are economically feasible to retrofit
into existing burners and yet able to
accommodate a variety of design
challenges the absence of any
undisturbed cross section of airflow
passage; an installation location
typically downstream of a modulating
inlet sleeve or disk damper; a broad
range of boiler operating conditions;
the presence of fly ash particulate; and
the broad range of airflow pitch and
yaw vectors produced by the adjustable
swirl angle blades.
Customized IBAMs characterized in
the Air Monitor Power wind tunnel and
used in conjunction with a CAMS result
in individual burner SA measurement
accurate to within 5% of actual airflow
over the full range of boiler operation.
Statically balanced burner-to-burner
airflow is a critical first step in optimizing
boiler performance while simul-
taneously reducing undesirable
emissions. In several installations, just
balancing the airflow was sufficient to
achieve lower NO
x
emissions levels.
Further reductions in NO
x
levels are
obtained when continuous burner SA
measurement is combined with DCS
controlled modulation of airflow control
to dynamically maintain burner-to-
burner airflow balance or a burner
bias strategy corresponding to the
varying fuel loads.
Incorporating Pf-FLO coal flow
measurement for EACH burner
permits adjusting SA to reflect the
actual fuel being delivered to each
burner, thereby achieving the desired
fuel / air ratio, safely lowering overall
NO
x
while simultaneously reducing
areas of high CO that otherwise
produce undesirable slagging and
water wall corrosion.
Over-fire Airflow (OFA) measurement
is another common NO
x
reduction
technique that alone, or in conjunction
with SA measurement and control,
requires the accurate measurement
capabilities of the IBAM to ensure the
proper amount of OFA is used to
obtain the best possible NO
x
solution
via staged combustion, while
simultaneously minimizing CO and
LOI.
The IBAM signals are routed out of the
wind box to the Combustion Airflow
Management System (CAMS)
enclosure. Within the CAMS enclosure
the pressure signals plus airflow
temperature are converted by the CAMM
using the polynomial equation, into a
density compensated lbs/hr mass flow
output to the DCS.
purge
TM
system used to keep the IBAM
sensing ports and signal lines clear of
accumulating fly ash. The purge cycle
can be configured to operate on a
purge cycle the CAMM maintains a
Air Monitor Powers Individual Burner
Airflow Measurement (IBAM) probes,
a modified version of the VOLU-probe/
SS, are designed burner specific to
accurately measure burner SA.
Based upon the Fechheimer-Pitot
measurement technology, each IBAM
design draws from a broad array of
construction options: Quantity and
location of individual TP and SP
sensing holes; CW and/or CCW
rotation of the individual TP and SP
sensing probes; rotation of the entire
IBAM assembly; and the use of ultra
high temperature alloys and Tungsten
Carbide coatings. The configuration
of inner and outer airflow barrels,
along with the locations of the burner
registers and obstructions such as an
igniter, typically define the possible
IBAM mounting locations. Wind box
configuration and burner symmetry
guide the quantity of IBAMs needed
to obtain desired accuracy and
repeatability.
Each IBAM probe is extensively tested
and characterized in Air Monitor
Powers large scale test duct, installed
either in a full size burner mock-up or
the actual burner. Testing is
conducted over a broad matrix of
customer specific sleeve damper or
inlet disk positions, swirl angle
settings, and boiler operating
conditions. The result is a multi-order
polynomial equation, with one or two
variables, to accurately correlate the
total and static pressure signals from
the IBAMs into mass flow.
Result The Solution
ICA-09
4/09, Rev.0
non-repeatable tuning of burner settings
solely targeted at meeting the
manufacturers NO
x
and CO emissions
guarantees at a single load condition.
Such burner tuning did nothing to address
significant variances in fuel distribution
to each burner, while multiple burners
served by a common or partitioned wind
box continued to have substantial burner-
to-burner imbalances in secondary
airflow (SA). The result was little
sustainable improvement in overall boiler
operation over a range of load conditions.
A Southeast Utility wanted to implement
a comprehensive and sustainable
combustion optimization management
strategy for one of their wall-fired boilers,
recently upgraded with low NO
x
burners
that were not equipped with any means
Pf-FLO with MILL INLET DIVERTER
stable combustion.
Traditional designs of coal fired power
plants lack any means to measure
and control airflow into individual
burners. This practice changed when
NO
x
attainment levels mandated by
the Clean Air Act prompted installation
of low NO
x
burners which,
unfortunately, were frequently
accompanied by extensive and often
The Challenge
to measure burner SA. The scope of
the project involved upgrading mill
primary air measurement, installing
individual burner SA measurement,
and adding instrumentation to measure
the amount of pulverized coal being
delivered to each burner.
The boiler was equipped with Atrita
double ended mills, each fed by a
single duct providing both fuel and
primary air to the mill. See Figure 1
below. Each mill end fed an exhauster,
which in turn delivered fuel to a pair of
burners after passing through a primary
riffle box. Based upon their many
years of experience operating the Atrita
mills the Utilitys combustion
engineering group was convinced the
shared coal / PA duct configuration
produced variable end-to-end coal
imbalance, which in turn resulted in
two of each Mills four pipes getting
more pulverized coal than the other
two pipes. See Figure 2.
Figure 1
Air Monitor Power assisted the Utilitys
contractor in the development of new
control logic using the coal mass flow
measurements from each of the four
pipes served by a single mill; by
summing the two coal flow
measurements corresponding to each
mill end a control output was generated
to reposition the diverter damper,
automatically maintaining end-to-end
mill balance within 5%. Data from
the Pf-FLO system was also used to
guide the process of statically adjusting
each primary riffle box to balance the
fuel being delivered to both burners.
The combined effect of manual riffle
adjustment and implementation of
automatic diverter damper control was
successful in achieving the primary
objective of 10% coal delivery
balance to all burners over the normal
range of boiler operation.
In conjunction with the coal diverter a Pf-
FLO Coal Flow Measurement System
was installed on all 20 pipes, initially to
gather baseline coal distribution data
over the Units full range of load
conditions. By summing the mass flow
of pipes 1 & 2 served by the mills left end
and comparing it to the summed mass
flow of pipes 3 & 4 served by the mills
right end, the baseline data collected in
Pf-VU confirmed the existence of 20%
end-to-end imbalance at different load
conditions, and as much as 35% fuel
variance between the lightest and
heaviest loaded pipes. By means of
manually biasing the diverter blade
position the ability to achieve mill end-to-
end balance was demonstrated.
To address the end-to-end fuel
imbalance Air Monitor Powers
Application Engineering department
engineered a coal diverter with
actuator that was installed into the top
section of the existing coal / PA duct.
Diverter components directly exposed
to coal were constructed of wear
resistant alloys, with an overall design
that permitted ease of periodic
inspection for long term removal and
replacement. The diverter was
engineered to permit as much as
25% end-to end bias via a control
signal from the DCS. A divider plate
was also installed to maintain the coal
distribution from the diverter into the
mill entrance. See Figure 1.
Result The Solution
Figure 2
ICA-10
4/09, Rev.0
adjustment of the secondary airflow is to
be applied to each burner compartment.
Air Monitor Powers Application
Engineering department was called upon
by a Southeast utility to design a system
to measure airflow entering the individual
fuel and aux air compartments of their
tangentially fired 350MW plant, where
new low NO
x
burners were being installed
as part of a total boiler upgrade.
The design solution was based upon the
fact that airflow passing through a fixed
resistance element (louver, perforated
plate, orifice plate, etc.) produces a
measurable, repeatable pressure drop,
such that the airflow can be
mathematically expressed in the form of
a power curve or polynomial equation
using pressure drop as the variable. In
MEASURING INDIVIDUAL BURNER AIRFLOW
stable combustion.
Traditional designs of tangentially
fired, coal power plants lack any
means to measure secondary airflow
entering each fuel and aux air
compartment. Efforts to meet NO
x
attainment levels mandated by the
Clean Air Act were frequently achieved
by means of extensive and often non-
repeatable tuning of burner settings
solely targeted at meeting the NO
x
and CO emissions guarantees at a
single load condition. J ust as there
are variances in fuel distribution to
each burner, multiple burners served
by a common wind box ended up with
substantial burner-to-burner imbal-
ances in secondary airflow (SA).
On tangentially fired boilers the
modulating control damper at the
entrance to each secondary air inlet
has little if any straight duct run, not
providing a location where even just a
repeatable signal representative of
actual airflow can be obtained. Since
the secondary air inlets are not easily
accessed for maintenance or repair,
any airflow measuring instrumentation
must be durable and repeatable,
providing stable, accurate input
signals to the DCS if a combustion
optimization strategy using continuous
The Challenge
this tangentially fired application the
dampers are modulated to control
airflow, thereby making them variable
resistance elements whose
relationship to airflow becomes a
mathematical function of two variables
the measured pressure drop across
the damper and the damper position.
Each corner consisted of four burner
elevations with three blade control
dampers, five aux air compartments
with two blade dampers, plus a top air
and a bottom air compartment each
with a single damper blade. A full scale
mock-up of the wind box corner was
constructed, complete with physical
replications of the three different
damper configurations, equipped with
The Solution
An engineered solution consisting of
customized SAP sensors, detailed
damper characterizations and CAMS
resulted in individual compartment SA
measurement accurate to within 5%
of actual airflow over the full range of
boiler operation.
The ability to accurately balance and/
or bias individual corner airflow was a
critical first step in optimizing boiler
performance while simultaneously
reducing undesirable emissions.
Further reductions in NO
x
levels were
obtained when the continuous corner
SA measurements were combined
with nozzle tilt adjustments and DCS
controlled modulation of the control
dampers to dynamically maintain a
burner and aux air strategy at varying
fuel loads.
In addition to its essential contribution
to optimization of PA / Feeder curves,
incorporating Pf-FLO coal flow
measurement for EACH burner
allowed automatic adjustment of SA
to reflect the actual fuel being delivered
to each burner, thereby achieving the
desired fuel / air ratio for each burner
while safely lowering overall NO
x
and
reducing areas of high CO that
otherwise produce undesirable
slagging and water wall corrosion.
ruggedized version of Air Monitors SAP
(Static Air Probe) was engineering to
meet the application requirements.
The static pressure signals from the
upstream and downstream SAPs were
routed out of the wind box to the
System (CAMS) enclosure. Within the
CAMS enclosure the pressure signals,
airflow temperature, and damper position
input are converted by a CAMM/TFA
using the multi-order damper
characterization equations, into a fully
density compensated lbs/hr mass flow
output to the DCS.
The CAMM/TFA also manages the
AUTO-purge
TM
system used to keep the
SAP sensing ports and signal lines clear
of accumulating fly ash. The purge cycle
can be configured to operate on a
purge cycle the CAMM/TFA maintains a
the new actuators that were part of
the boiler upgrade, and attached to
Air Monitor Powers large scale test
duct. Based upon customer provided
current and future operating
parameters, a 286 point test matrix
consisting of three variables (windbox
static pressure, damper position,
damper size) was developed for
characterizing each damper
individually, followed by verification
testing of multiple dampers being
modulated simultaneously. The result
was a developed series of multi-order
polynomial equations correlating the
pressure drop signal and damper
position into air mass flow.
A key component of the project was
designing the static pressure sensors
required to measure the pressure drop
across the control dampers. The
sensors had to operate in the
presence of fly ash particulate, be
economically feasible to retrofit into
the existing compartments, and not
be adversely impacted by changing
airflow patterns downstream of the
modulating dampers. A custom
Result The Solution (con't)
ICA-12
4/09, Rev.1
by ASME, ASHRAE, and in fluid
mechanics textbooks.
Air Monitor Powers line of application
proven Combustion Airflow
Management Modules (CAMM) with
ultra-low spans (as low as 0.05" w.c.
Full Span) and high accuracy (0.1% of
Full Span) allows the engineering of
venturis with an optimized high .8 beta
factor one that optimizes the flow
profiling benefits as air is compressed
passing through the throat of the
venturi, against the unrecovered
pressure drop of the venturi itself. The
resultant Venturi/HB
TM
(High Beta)
maximizes the amount of primary air
available to the mill while providing
accurate airflow measurement over a
wide range of operation.
Venturis have long been used in power
generation to measure airflow because
of their ability to create a differential
pressure signal that could be field
characterized to represent lbs/hr of air.
Historically venturis with a .5 beta factor
(the ratio of venturi minimum cross
section to the full size upstream duct
cross section) were engineered to
produce the 20-30 inches of differential
pressure required by the differential
pressure transmitters of that era, but did
so at the expense of a high unrecovered
pressure drop, waste of energy and
imposed limit on available air for com-
bustion. The measurement performance
of traditional venturis was further
compromised by field calibration
methods relying on the use of the S-type
Pitot in duct locations far short of the
minimum requirements recommended
MEASURING PRIMARY AIRFLOW
stable combustion.
The main functions of primary air are
to dry the coal and then pneumatically
convey the pulverized coal from the
mill to the individual burners. Primary
air also determines coal particle
velocity at the burner exit, in part
defining the flame position relative to
the burner tip and impacting flame
stability, both key factors in achieving
optimized burner performance.
Excessive primary air contributes to
high NO
x
formation and tube erosion,
while insufficient primary air results in
slagging, coal layout, pipe fires,
eyebrows, and burner pluggage.
Short duct sections are commonplace
in coal fired power plants and Air
Monitor Power, with its Fechheimer-
Pitot Combustion Air (CA) stations
and/or VOLU-probe/SS arrays, has
demon-strated the ability to accurately
measure combustion airflow without
the need for field calibration. But
primary airflow typically combines hot
and tempering air supplies with control
dampers and limited straight duct
sections, resulting in ductwork
configurations that produce highly
distorted velocity profiles, often with
airflow angularity beyond the 30
degrees of pitch and/or yaw
measurement accuracy limitations of
a CA station or VOLU-probe/SS array.
The Challenge The Solution
VENTURI/HB
TM
Shown with optional
VOLU-probe/SS
Customized Venturi/HBs characterized
in Air Monitor Powers wind tunnel and
used with a CAMS will provide
measurement accuracy to within 3% of
actual primary airflow over the full range
of mill operation. The signals remain
stable with zero drift, and due to AUTO-
purge the flow elements can operate
continuously within the heavy particulate
environment. These systems help reduce
NO
x
and CO, improve flame stability,
avoid coal pipe layout, minimize LOI/
UBC, increase combustion efficiency,
and reduce waterwall corrosion.
Coal mass flow and particle velocity data
from a Pf-FLO coal flow measurement
system allow further optimization of
primary air by providing the means of
customizing a mills PA to Feeder curve
to meet the unique operating conditions
of each power plant; curves that are
dependent upon variable coal type,
moisture content, coal pipe arrangement,
and actual fuel distribution.
Each Venturi/HB is extensively tested
and calibrated in Air Monitor Powers
large scale test duct, with the test
arrangement constructed to match
the actual upstream and downstream
ductwork configuration, damper(s),
etc. Testing is conducted over the
customers full range of flow rates
and damper positions. The result is
typically a multi-order polynomial that
is programmed into the CAMM or
DCS to accurately determine density
compensated lbs/hr massflow using
measured venturi differential
pressure, airflow temperature, and
static pressure.
As optional construction for fully
maintenance free operation, the
CAMM would be part of a Combustion
Airflow Measurement System
(CAMS) that includes the AUTO-
purge
TM
system that uses compressed
air to keep the venturi sensing ports
and signal lines clear of accumulating
fly ash. The purge cycle can be
the purge cycle, the CAMM maintains
notification of purge cycle start and
completion.
The Venturi/HB comes standard
equipped with traverse ports located
in the throat area. As an optional
feature, an array of test duct calibrated
VOLU-probe/SS can be purchased
for a group of same sized Venturi/
HBs. The VOLU-probe/SS are
designed to mount in the venturi throat
via the traverse ports, permitting
simple periodic verification of each
venturis measurement accuracy
without the need to perform time
consuming field traversing.
The Solution (con't) Result
Construction Options
Rectangular & circular configurations
AUTO-purge for automatic sensing

port and signal line high pressure
purging
Bolt-on or permanently installed

traverse ports
Temperature probe port
Mating flanges for existing duckwork

VOLU-probe/SS
Stainless Steel Pitot Airf low Traverse Probes
Proven solutions for a tough industry AIR MONITOR
POWER DI VI SI ON
The VOLU-probe/SS Stainless Steel Pitot Airflow Traverse Probe
is ideally suited for new installations or retrofit applications
requiring accurate airflow measurement in locations having limited
straight duct runs. Multiple sets of total and static pressure sensing
ports along the entire length of the VOLU-probe/SS traverse the
airstream in a single line across the duct, and average the sensed
pressures in separate manifolds. An array of VOLU-probe/SS
probes are used to properly sense the typically stratified flow to
provide an equal area traverse of an entire duct cross-section. The
VOLU-probe/SS is suited for clean or harsh and particulate laden
applications, operating at temperatures ranging from 20 to 900F.
As a primary flow sensing means, the VOLU-probe/SS can be used
in industrial process applications ranging from power generation
(combustion airflow), fiber quenching, process drying, emission
monitoring, etc.
Product Description
VOLU-probe/SS
When installed per Air Monitor's Minimum I nstallation
Requirements (see back page), the minimum quantity and placement
of VOLU-probe/SS airflow traverse probes shown below will
produce assured measuring accuracies of 2-3% of actual airflow.
Accuracy
All recognized flow measurement standards (ASHRAE
Fundamentals, AMCA Publication 203, Industrial Ventilation
Manual, 40CFR60, etc.) agree that accurate airflow measurement
is highly dependent upon the quantity and pattern of sensing points
in the airstream, and the relative position of the sensing points to
upstream/downstream flow disturbances.
static sensor experiences a lower pressure (Ps part of Pt) of the
same magnitude, thereby canceling out the undesired effect of
partial total pressure (Pt). It is this unique design of offset static
pressure and chamfered total pressure sensors (see Figure 1) that
make the VOLU-probe/SS insensitive to approaching multi-
directional, rotating airflow with yaw and pitch up to 30 from
straight flow, thereby assuring the accurate measurement of the
sensed airflow rate without the presence of an airflow straightener
upstream. This unique design of the VOLU-probe/SS is covered
by U.S. Patent No. 4,559,835.
How It Works
The VOLU-probe/SS operates on the Fechheimer Pitot derivative
of the multi-point, self-averaging Pitot principle to measure the
total and static pressure components of airflow. Total pressure
sensing ports, with chamfered entrances to eliminate air direction
effects, are located on the leading surface of the VOLU-probe/SS
to sense the impact pressure (Pt) of the approaching airstream (see
Figure 2). Fechheimer pair of static pressure sensing ports,
positioned at designated angles offset from the flow normal vector,
minimize the error inducing effect of directionalized airflow. As
the flow direction veers from the normal, one static sensor is
exposed to a higher pressure (Ps +part of Pt), whereas the other
Figure 1 Figure 2
The VOLU-probe/1SS is designed for mounting in ducts or stacks
by drilling two holes in opposing walls, without the need to enter
those structures.
The VOLU-probe/1SS is furnished with a threaded end support,
gasketed washer and nut, and a mounting plate with signal take-off
FPT connections, all fabricated of type 316 stainless steel.
VOLU-probe/1SS Externally Mounted
VOLU-probe/1SS & 2SS
The VOLU-probe/2SS is designed for larger ducts or stacks where
the size permits entry for installation, or where duct external
accessibility or clearance is insufficient to permit probe mounting
from outside the duct.
The VOLU-probe/2SS is furnished with interior mounting and end
support plates, and midpoint signal take-off FPT connections, all
fabricated of type 316 stainless steel.
VOLU-probe/2SS Internally Mounted
VOLU-probe/SS Construction Options
VOLU-probe/SS Options
150 lb. Mounting Flange Probe End Supports
Temperature Probe Companion Mounting Plates
Construction Features
Stainless Steel Airf low Traverse Probes
Features
Provides for Equal Area Traverse. Each VOLU-probe/SS
contains multiple total and static pressure sensors specifically and
precisely located along the length of the probe to provide an equal
area traverse of ducted airflow. For rectangular duct configurations,
the sensors are spaced at equal distances along the probe. For
circular duct configurations, the sensors are located at the centers
of the equivalent concentric area along the probe.
True Velocity Pressure Measurement. The total and static
pressure components of airflow measured by the VOLU-probe/SS
can be directly converted in velocity pressure (and velocity) without
the use of correction factors, thereby facilitating flow verification
with a Pitot tube or other hand held instrumentation.
No Sensor Protrusions. The VOLU-probe/SS total and static
pressure sensors are all contained within the confines of the external
surface of the probe. There are no protruding sensors to be bent,
broken, or otherwise damaged during installation or possible
subsequent removal for inspection or cleaning.
Rugged Construction Assures Long Service Life. The standard
VOLU-probe/SS is fabricated from Type 316 stainless steel using
all welded construction. See Page 4 for construction options, and
contact Factory for alternate materials of construction such as
Hastelloy, Inconel, Kynar, PVC, etc.
No Air Straighteners Required. The VOLU-probe/SS unique
dual offset static pressure sensor and patented chamfered total
pressure sensor design permit the accurate measurement of the
airflow rate in highly turbulent flow locations (with directional
yaw and pitch varying up to 30 from the duct's longitudinal axis)
without the need for upstream air straightening means.
Offered in Two Models. The VOLU-probe/SS is offered in two
basic configurations to facilitate installation in new or existing
ducts or stacks; the Model 1 for external mounting, and the Model
2 for internal mounting.
Negligible Resistance to Airflow. The VOLU-probe/SS
cylindrical configuration and smooth surface free of external sensor
protrusions permit the airstream to flow unrestricted around and
between the installed traverse probes, creating a very minimal, if
not negligible resistance to airflow (Ex: 0.046 IN w.c. at 2000 fpm
air velocity).
Performs Equal-Weighted Averaging of Flow Signals. Through
the use of separate averaging manifolds, the VOLU-probe/SS
instantaneously averages, on an equal-weighted basis, the multiple
pressures sensed along the length of the probe, producing separate
"averaged" total pressure and static pressures at the probe's external
signal connections.
FPT Signal Connections
Offset Fechheimer Static Pressure Sensors
Integral 10 Gauge Mounting Plate
Chamfered Total Pressure Sensors
Note: VOLU-probe/SS locations shown are not ideal. The locations indicate the minimum clearance required from air turbulence producing
sources. Wherever possible, the VOLU-probe/SS should be installed where greater runs of straight duct (or clearances) than shown below
exist.
Minimum Installation Requirements
125-068 (1/99),
VOLU-probe/SS
Suggested Specification
Provide where indicated an array of airflow traverse probes capable
of continuously monitoring the stack or duct capacities (air volumes)
it serves.
Each airflow traverse probe shall contain multiple total and static
pressure sensors and internally connected to their respective
averaging manifolds. The flow sensors shall not protrude beyond
the surface of each probe, and shall be the offset (Fechheimer)
type for static pressure and the chamfered impact type for total
pressure measurement. The airflow sensing probe's measurement
accuracy shall not be affected by directional flow having pitch and/
or yaw angles up to 30.
Each airflow traverse probe shall be fabricated of type 316 stainless
steel, all welded construction, and shall be furnished with the flat
or curved plate mounting means. In addition, access ports and
accessory hardware shall be provided to facilitate external
installation of the probe and end support (if required), yet permitting
easy probe removal for inspection, etc.
The airflow traverse probe shall not induce a pressure drop in excess
of 0.046 IN w.c. at 2000 FPM, nor measurably contribute to sound
levels within the duct. Total and static pressure sensors shall be
located at the centers of equal areas (for rectangular duct) or at
equal concentric area centers (for circular ducts) along the probe
length. The airflow traverse probe shall be capable of producing
steady, non-pulsating signals of total and static pressure without
need for flow corrections or factors, with an accuracy of 2-3% of
actual flow, over a velocity range of 400 to 4000 FPM.
The airflow traverse probe(s) shall be the VOLU-probe [1SS, 2SS]
as manufactured by Air Monitor Corporation, Santa Rosa,
California.
3X 1.5X 5X 2X 1X 4X
CENTRIFUGAL FAN CENTRIFUGAL FAN VANE-AXIAL FAN DISCHARGE VANE-AXIAL FAN INLET
DISCHARGE INLET
FANS DAMPERS
ELBOWS TAKEOFFS
DUCT TRANSITIONS
X X
1.5X 2 2X 2
2X
90 VANED ELBOW ROUND SWEEP 3X
ELBOW
X
5X 1X 2X 2 3X 1X
90 UNVANED ELBOW SWEEP ELBOW
1 X
X
1X 2
X
X 1X 2
1X 2
TRANSITION ANGLE: <-15 TRANSITION ANGLE: <-15 TRANSITION ANGLE: <-15 TRANSITION ANGLE: <-15
X
2

Rectangular Duct: x = Circular Duct: x = Duct Diameter
2 H x W
H + W
P.O. Box 6358 Santa Rosa, CA 95406 TEL 800-AIRFLOW Fax 707-526-9970 www.airmonitor.com
AIR MONITOR
POWER DI VI SI ON
CA Station
Combustion Airflow Measurement Station
AIR MONITOR
POWER DI VI SI ON
CA Station
How It Works
The CA Station is also ideally suited to measure SA entering
each burner level of a partitioned windbox, SA being taken
out of a windbox to supply multiple OFA ports, at the ducted
inlet of FD fans, and bulk SA entering each windbox of a
corner fired unit.
The Need for Combustion Airflow Measurement
The objectives in the power industry today are twofold; to
lower emissions, and increase plant performance. Precise
measurement of combustion airflow and fuel rates positively
contributes to achieving those objectives, by providing the
information needed to optimize stoichiometric ratios and
facilitate more complete, stable combustion. Usable
measurements cannot be obtained from existing devices such
as venturis, foils, jamb tubes, etc., or instrumentation such
as thermal anemometers due to limited available straight duct
runs, low flow rates, proximity to modulating control dampers,
broad turndown range, and high concentrations of airborne
particulate (flyash).
Air Monitor Powers ruggedly constructed Combustion Air
(CA) Station, with both integral airflow processing cell and
Fechheimer-Pitot measurement technology, is engineered to
meet the challenging operating conditions of the typical power
plant while providing mass flow measurement of PA, SA, and
OFA within an accuracy of 2-3% of actual airflow.
While the main functions of primary air are to first dry and
then pneumatically convey the pulverized coal from the mill
to the individual burners, it also determines coal particle
velocity at the burner exit, influencing the flame position
relative to the burner tip and impacting flame stability, both
key factors in achieving optimized burner performance.
Accurate PA measurement obtained with a CA Station can
contribute to reducing NO
x
and CO, improving flame stability,
avoidance of coal pipe layout, minimizing LOI/UBC, reducing
waterwall corrosion, and increasing combustion efficiency.
Log-Tchebycheff Sensor Locat i on. A high concentration
of total and static pressure sensors positioned according to
the log-Tchebycheff rule sense the multiple and varying flow
components that constitute the airstream's velocity profile.
The log-Tchebycheff's perimeter weighted sensor pattern is
utilized to minimize the positive error (measurements greater
than actual) caused by the failure to account for slower
velocities at the duct wall when using traditional equal area
sensor locations. Spacing of total pressure sensors is per
the table below. Since the static pressure across the station
is relatively uniform, a lesser number of static pressure
sensors are utilized to minimize unrecovered pressure drop.
Fechhei mer Pi t ot Fl ow Measur ement. The CA Station
operates on the Fechheimer-Pitot derivative of the multi-point,
self-averaging Pitot principle to measure the total and static
pressure components of airflow. Total pressure sensing ports
with patented (U.S. Patent No. 4,559,835) chamfered
entrances, and Fechheimer pairs of offset static pressure
sensing ports combine to minimize the effect of directional
airflow. When located downstream of honeycomb airflow
processing cell, the Fechheimer Pitot method is extremely
effective at accurately measuring airflow in limited straight
duct runs.
Ai rf l ow Processi ng. To assure extremely high levels of
measuring accuracy (3% of actual flow) under extreme
conditions caused by turbulent, rotating, and multi-directional
airflows normally present near fan inlets, discharge ducts,
and directly downstream from duct elbows, transitions, etc.,
the CA Station uses open, parallel cell, honeycomb panels to
"process" the air into straightened flow just prior to the total
pressure measurement plane. These honeycomb panels
sharply reduce the need for long, straight runs of duct before
and after the station to obtain accurate flow measurement.
Negl i gi bl e Ai r f l ow Resi st ance. The CA Station airflow
measuring station is designed to function while producing a
minimum of resistance to airflow, due to the unique
honeycomb air straightener-equalizer section having a free
area of 96.6%. The unique, non-restrictive characteristic of
the CA Station is seen in the Resistance vs. Airflow Velocity
graph below. The values indicated are total resistance and
do not include any allowances for static regain (a potential
20% reduction to the values).
Denotes CA Station location
Duct / Station
Configuration
Rectangular
Circular
Quantity of Sensing Points
25 or more points, maximum 6" or 8" apart,
depending on duct size.
12 to 30 points, along 2 or 3 diameters.
Combustion Airflow Measurement Station
Specifications
Welded 3/16"
Carbon Steel Casing
90 Connection Flanges
12" Depth
24 ga. Carbon Steel
Airflow Straightener
Offset Fechheimer Static
Pressure Sensing Probe
Total Pressure Sensing Manifold
Conf i gurat i ons.
Rectangular, Circular, and Custom
Accuracy.
2-3% of actual flow
Operat i ng Temperat ures.
Continuous operation to 800F
Connect i on Fi t t i ngs.
1/2" FPT, Type 316 stainless steel
Stat i c and Total Pressure Sensi ng Mani f ol ds.
Type 316 stainless steel, welded construction
Ai rf l ow St rai ght ener.
1" hexagonal, parallel cell straightener, 3" deep,
24 ga. (.024") thick carbon steel
Casi ng and Fl anges.
3/16" carbon steel, continuous welded seams
Casing depth is 12"
Speci al Const ruct i on Opt i ons.
Sensing Manifold Cleanouts
Inlet Bell Mouth
Multi-point Temperature Measurement
Alternate Materials of Construction
Integral Control Damper
Optional Manifold Cleanouts
DAMPERS
BRANCH DUCT
BELLMOUTH / FAN INLET
CONVERGING
DUCTS
REDUCING TRANSITION EXPANDING TRANSITION UNVANED ELBOW ELBOW
VANED
125-495 (04-09)
P.O. Box 6358 Santa Rosa, CA 95406 P: 800-AIRFLOW F: 707-526-9970
www.airmonitor.com amcsales@airmonitor.com
Ai r Moni tor Power' s Product Fami l i es of Ai r & Coal Fl ow Measurement Systems
IBAM
TM
Individual Burner Airflow Measurement
The IBAM
TM
Individual Burner Airflow Measurement probe is ideally suited for new or
retrofit applications where a reduction in plant emissions and improvement in efficiency
can be obtained through accurate measurement of burner secondary airflow. The IBAM
TM
probe has been designed to accurately measure in the particulate laden, high operating
temperature conditions found in burner air passages.
CEMS
TM
Continuous Emissions Monitoring System
Air Monitor Power's CEMS
TM
Continuous Emissions Monitoring Systems assist in
complying with the Clean Air Acts stringent emission measurement standards and the
requirements of 40 CFR 75. Air Monitor has assembled a cost effective integrated system
consisting of in-stack flow measurement equipment and companion instrumentation to
provide continuous, accurate, and reliable volumetric airflow monitoring of stacks and ducts
of any size and configuration.
CAMS
TM
Combustion Airflow Management Systems.
The CAMS
TM
Combustion Airflow Management System has been designed to reliably
and accurately measure airflow in combustion airflow applications. The CAMS
TM
contains
the microprocessor based instrumentation to measure the airflow and manage the AUTO-
purge. The AUTO-purge is a high pressure air blowback system that protects the duct
mounted flow measurement device from any degradation in performance due to the
presence of airborne particulate (flyash).
Engineering & Testing Services. Air Monitor Power offers complete engineering and testing to analyze air and coal
delivery systems. Air Monitor Powers field testing services use 3D airflow traversing and Pf-FLO coal flow measurement
systems for the highest possible accuracy. To ensure cost effective and accurate solutions, Air Monitor Power has full scale
physical flow modeling capability and in house Computational Fluid Dynamics (CFD). CFD analysis is used to analyze flow
profiles and design/redesign ductwork to improve overall performance. Full scale model fabrication and certified wind tunnel
testing is used to develop application specific products that will measure accurately where no standard flow measurement can.
Pf-FLO
TM
Pulverized Fuel Flow Management
The Pf-FLO
TM
system performs continuous and accurate fuel flow measurement in
pulverized coal fired combustion applications, providing boiler operators with the real-time
data needed to balance coal mass distribution between burners. Balanced fuel improves
combustion efficiency and lowers emissions while reducing in-furnace slagging, coal layout,
fuel slagging, and coal pipe fires.
VOLU-probe/SS
TM
Stainless Steel Airflow Traverse Probes.
Multi-point, self-averaging, Pitot-Fechheimer airflow traverse probes with integral airflow
direction correcting design. Constructed of Type 316 stainless steel and available in
externally and internally mounted versions for harsh, corrosive or high temperature
applications such as fume hood, laboratory exhaust, pharmaceutical, and clean room
production and dirty industrial process applications.
AIR MONITOR
POWER DI VI SI ON
CAMS
Combustion Airf low Management System
The Air Monitor Power CAMS
TM
Combustion Airflow
Management System is designed to fulfill the need for a
reliable and accurate means of flow measurement in
combustion airflow applications. Combined into a single
engineered package are the CAMM
TM
Combustion Airflow
Management Module containing the microprocessor based
instrumentation to measure the airflow and manage the purge
cycle, and AUTO-purge to protect against any degradation in
performance of the duct mounted measurement device(s) due
to the presence of airborne particulate.
Product Descri pti on
CAMS Combustion Airf low Management System
TM
CAMM
TM
Performance Speci fi cati on
Accuracy. 0.1% of Natural Span, including non-linearity,
hysteresis, and non-repeatability.
Stabi l i ty. 0.5% of Natural Span for six months.
Temperature Effect. Zero. None; corrected by AUTO-zero.
Span. 0.015% of Full Span/F.
Mounti ng Posi ti on Effect. None; corrected by AUTO-zero.
Transducer Response Ti me. 0.5 second to reach 98% of a
step change.
Power Consumpti on. 35VA at 24VAC, 20VA at 24VDC,
and 42VA at 120VAC.
CAMM
TM
Functi onal Speci fi cati on
Di gi tal Output. Form "A" dry contacts (maintained) for
AUTO-purge activation and acknowledgment.
Di gi tal Inputs. External dry contact closure for AUTO-purge
external start and purge interrupt commands.
Anal og Outputs. Four outputs for flow, temperature,
absolute pressure, and special function individually
configurable via jumper for 0-5VDC, 0-10VDC or 4-20mADC.
Anal og Inputs. Dual inputs are field configurable via jumper
for 0-5VDC, 0-10VDC, or 4-20mADC. One is reserved for
temperature input; the other for use with optional special
function.
Network Communi cati on. Optional ModBus TCP/IP over
Ethernet.
AUTO-purge Management. The AUTO-purge cycle is
initiated via an external dry contact input, or via the CAMM
timer, with field selectable frequencies of 1 to 24 hours in 1
hour increments. A pair of CAMM dry contacts control the
AUTO-purge System, and third dry contact provides remote
purge activation acknowledgment.
Power Suppl y. Standard 24VAC (20-28VAC) or 24VDC
(20-40VDC), with automatic selection. Optional 120VAC
(100-132VAC) via external UL listed transformer.
Overpressure and Stati c Pressure Li mi t. 25 psig.
Low Pass Fi l trati on. Response time to reach 98% of a step
change is adjustable from 2.0 to 250.0 seconds.
Automati c Zeroi ng. Accuracy. Within 0.1% of calibrated
span. Frequency. Every 1 to 24 hours selectable on 1 hour
intervals.
Ci rcui t Protecti on. Power input is fused and reverse
polarity protected.
Span and Zero Adj ustment. Electronic adjustment via
keypad.
Di spl ay. Backlit, graphical LCD provides indication of up to
four process variables. Triple-size digits for main process
variable, standard size characters for the other process
variables.
Temperature Compensati on Sel ecti on. Push-button
selection of linearized or nonlinear input. Choice of
thermocouple (Type E, K, J , and T) or 100 ohm platinum
RTD temperature sensor type.
Pressure Compensati on. Absolute pressure (atmosphere
or duct static), up to 60"Hg.
Humi di ty Li mi ts. 0-95% RH, non-condensing.
Temperature Li mi ts. 20F to 180F Storage.
+40F to 140F Operating.
Speci al Funct i ons Power Cert i f i cat i on Rapi d Stop
Summed Flow 24VAC Standard Yes
Differential Flow 24VDC NIST Traceable No
120VAC
CAMM
TM
Constructi on Opti ons
Air Monitor Power's AUTO-purge is designed for applications
where the presence of airborne particulate might impair the
measurement accuracy of Air Monitor Power's Combustion
Air (CA) Station or VOLU-probe array. When activated by a
CAMM
TM
or distributed control system, a combination of fail-
safe valves are operated to introduce high pressure/high
volume air to the flow measuring device's sensing ports for a
short duration while simultaneously isolating the CAMM
TM
from
overpressurization. This periodic purging assists in
maintaining the sensing ports of the total and static pressure
manifolds in a clear, unobstructed condition.
Product Descri pti on
AUTO-purge
STANDARD CAPACITY
NEMA 4X Stainless Steel Enclosure
Vortex Cooler. Requires 80-100 psi air supply.
Rapid Stop
TM
Enclosure Heater. Requires 120VAC power supply.
Viewing Window
Power Capacity
24VAC Standard
24VDC Low Model SP
120VAC High Model HP
Opti onal Constructi on
Di mensi onal Speci fi cati ons
Brass and Copper Construction
All wetted tubing, fittings, and valves constructed of copper

and/or brass.
Enclosure is NEMA 4 painted steel.
External connection fittings are stainless steel FPT.

Stainless Steel Construction
All wetted tubing, fittings, and valves constructed of 316

stainless steel.
Enclosure is NEMA 4 painted steel.
External connection fittings are stainless steel FPT.

Standard Constructi on
BOTTOM VIEW
INTERIOR VIEW
AUTO-purge
Sequence of Operati on
Automatic purging at regular field selectable intervals utilizes
short duration, high pressure (up to 125 psig) air to maintain
signal lines and the sensing orifices of the total and static
pressure manifolds in a clean, unobstructed condition. For the
duration of the purge cycle the CAMM maintains the last
transmitted process outputs. At the start of the purge cycle the
CAMM first activates solenoid purge valves to isolate the
transmitter from the signal lines, then energizes a separate main
air purge valve, allowing the high pressure purge air to flow
through the shuttle valves, flushing out all particulate
contaminants in the signal ports of the airflow station or probe
array.
At the end of the timed purge cycle or upon receipt of a purge
interrupt signal the CAMM first de-energizes the main air valve
to shut off the supply of compressed air, followed by a short
period to allow the pressures in the signal lines to bleed down
to process levels, then the purge valves are shuttled to reconnect
the CAMM to the process signal lines. The final step in the
sequence releases the output signal hold, allowing the
resumption of transmitting active process information.
Purge Frequency & Cycl e Management
Instal l ati on Gui de
Accumul at or Tank (st rongl y recommended)
Requires coalescing filter, pressure regulator, and check

valve at the tank inlet.
120 gallons All CA stations.
120 gallons Multiple VOLU-probes having a combined
length greater than 10'.
80 gallons One or more VOLU-probes having a
combined length less than 10'.
Li ne f rom Accumul at or Tank t o AUTO-purge Panel
25' maximum length, 1/2" pipe (minimum).
Recommend locating accumulator tank as close as

possible to CAMS
TM
Panel.
El ect ri cal Power Requi rement
35VA at 24VAC; 20VA at 24VDC; 42VA at 120VAC.
120VAC, 10 amp when an optional enclosure heater is

installed.
Ai r Requi rement
80 to 125 psig at 100 CFM, oil and dirt free.

Li ne Si ze
If the distance from the CAMS

TM
Panel to Flow Measuring
Station or Probes is less than 25', tube size to be 1/2" O.D.
Wall thickness no greater than 0.065".

TM
Station or Probes is 25' to 50', tube size to be 3/4" O.D.
Wall thickness no greater than 0.065".

TM
Station or Probes is greater than 50', tube size to be 1.0"
O.D. Wall thickness no greater than 0.065".
Ambi ent Temperat ure
40F to 140F.
For ranges above or below this ambient temperature, the

use of an enclosure heater and/or cooler is required.
The CAMM can be configured to fully manage both the frequency
and duration of the purge cycle, or allow the DCS to control
either. When operating independently, and depending upon the
concentration of airborne particulate, the frequency of purge is
user selectable via set-up menu to activate as infrequently as
once every 24 hours, or as often as hourly. In a similar manner
the active purge duration is adjustable from 30 to 150 seconds,
while the combined purge plus recovery cycle is adjustable from
60 seconds to 10 minutes.
The CAMM can also be configured to allow the DCS to determine
the frequency or scheduling of the purge cycle, by means of
providing a dry contact purge start input to the CAMM. A
separate purge interrupt dry contact input from the DCS will
trigger the CAMM to terminate the purge cycle and return to
normal operation. When equipped with optional Rapid Stop
TM
valving, the resumption of active process measurement can be
reduced from a typical 30 seconds to as short as 5 seconds.
CAMM Combustion Airflow Management Module
TM
Features
ModBus Network Communication. Each analog input and
output signal can be individually configured for 0-5VDC, 0-10VDC
or 4-20mADC by means of a single jumper.
High Turndown Ratio Operation. The CAMM
TM
, with its high
level of accuracy and automatic zeroing circuitry, can maintain
linear output signals on applications requiring flow measurement
turndown of 10:1.
Primary Signal Noise Filter. To eliminate background noise and
pulsations from the flow signal, the CAMM
TM
is equipped with a
user selectable digital low pass filter.
Air Density Correction. The CAMM
TM
is capable of performing
density compensation for both air temperature and air pressure
variations. Temperature input is an analog signal from a remote
temperature transmitter; non-linear temperature inputs can be
linearized by the microprocessor. Process pressure is measured
by means of an internal absolute pressure transducer connected
to the transmitter static pressure signal input.
Optional Rapid Stop
TM
. The Rapid Stop
TM
valving combined with
purge sequence timing in the CAMM
TM
permits a reduction of the
recovery portion of an AUTO-purge cycle from a typical 30 seconds
to as short as 5 seconds.
Built-In Characterization Function. For installations requiring a
field characterization factor (K-factor) the CAMM has an integral
"K-factor" calculator with gain and/or bias, or multi-order polynomial
function to accurately match field testing results throughout flow
turndown.
Accuracy. The CAMM
TM
is designed to maintain a measurement
accuracy of 0.1% of Natural Span. For a span of 0 to 0.05 IN
w.c., this accuracy is equivalent to an output accuracy of 0.00005
IN w.c. differential pressure or 0.45 FPM velocity at Natural Span.
Continuous Display of Process. All CAMMs
TM
are equipped
with a large multi-line, backlit, graphical LCD for use during
transmitter configuration and calibration, and to display multiple
measured process variables (Flow, Temperature, Absolute
Pressure, Differential Pressure, or Special Function). For high
visibility, the main process variable (flow) is displayed with easy-
to-read, triple-size digits. Other process variables are displayed
with standard size digits. Each measured process variable is
individually scalable in user selectable engineering units.
Special Functions Capability. Built into the CAMM
TM
micro-
processor is the capability to perform special application functions
involving two transmitters. Using a second transmitter as an input,
the CAMM
TM
can compute the sum of, or differential between the
two measured flows. The special function output can be both
displayed and provided as an analog output signal.
Microprocessor Based Functionality. The CAMM's
TM
on-board
microprocessor performs the functions of operating parameter
selection, transmitter configuration, input/output and display signal
scaling, density correction, and transducer calibration.
Keypad. A cover mounted keypad provides instant access to all
CAMM configuration menus and calibration functions. The durable
membrane keypad is user configurable for password protection
Hinged removable
top cover
External, unitary
plug-in terminal
strips for field
wiring connections
ON-OFF power switch
Graphical backlit LCD
Aluminum NEMA 1
enclosure
Cover mounted
membrane keypad
125-009-00 (/)
IBAM
TM
The IBAM
TM
can be obtained through accurate measurement of burner secondary airflow. The IBAM
TM
probe has been designed to accurately measure in the particulate laden, high operating
temperature conditions found in burner air passages.
CEMS
TM
TM
complying with the Clean Air Acts stringent emission measurement standards and the
requirements of 40 CFR 75. Air Monitor has assembled a cost effective integrated system
consisting of in-stack flow measurement equipment and companion instrumentation to
provide continuous, accurate, and reliable volumetric airflow monitoring of stacks and ducts
of any size and configuration.
CA
TM
Combustion Airflow Measuring Station & VOLU-probe/SS
TM
Traverse Probes. Air Monitor Power's duct mounted airflow measurement devices
have been designed to accurately and repeatedly measure air mass flow in power plants.
The Combustion Air (CA) Station
TM
includes honeycomb air straightener to accurately
measure in shorter straight duct runs than any other flow measurement device. The VOLU-
probe/SS
TM
delivers accurate airflow measurement performance in the form of an insertion
probe. Both devices feature Type 316 stainless steel flow sensing arrays.
Engineering & Testing Services. Air Monitor Power offers complete engineering and testing to analyze air and coal
delivery systems. Air Monitor Powers field testing services use 3D airflow traversing and Pf-FLO coal flow measurement
systems for the highest possible accuracy. To ensure cost effective and accurate solutions, Air Monitor Power has full scale
physical flow modeling capability and in house Computational Fluid Dynamics (CFD). CFD analysis is used to analyze flow
profiles and design/redesign ductwork to improve overall performance. Full scale model fabrication and certified wind tunnel
testing is used to develop application specific products that will measure accurately where no standard flow measurement can.
Pf-FLO
TM
The Pf-FLO
TM
pulverized coal fired combustion applications, providing boiler operators with the real-time
data needed to balance coal mass distribution between burners. Balanced fuel improves
combustion efficiency and lowers emissions while reducing in-furnace slagging, coal layout,
fuel slagging, and coal pipe fires.
VOLU-probe/SS
TM
Stainless Steel Airflow Traverse Probes.
AIR MONITOR
POWER DI VI SI ON
VELTRON DPT-plus
Microprocessor Based Ultra-Low Range
Pressure & Flow " Smart" Transmitter
AIR MONITOR
POWER DI VI SI ON
The VELTRON DPT-plus transmitter is furnished with an
automatic zeroing circuit capable of electronically adjusting
the transmitter zero at predetermined time intervals while
simul-taneously holding the transmitter output signal.
The automatic zeroing circuit eliminates all output signal drift
due to thermal, electronic or mechanical effects, as well as
the need for initial or periodic transmitter zeroing. For
transmitters operating in a moderately steady temperature
location (thus no thermally induced span drift), this automatic
with Automatic Zeroing Circuit
VELTRON DPT-plus
Indication
Display. A backlit, graphical LCD providing three lines of
data display. Also used for programming.
Inputs/Outputs
Analog Inputs. Differential pressure (high and low), and 4-
20mA, 2-wire, internally or externally loop powered
temperature signal.
Anal og Out puts. Dual 4-20mA outputs, individually
configurable as internally powered/non-isolated, or externally
powered/isolated.
Digital Inputs. Digital contacts for AUTO-purge external start.
Digital Outputs. Dual Form A dry contacts rated for 3 amps
at 24VAC/VDC for optional HI/LO alarm; or dual Form A dry
contacts for AUTO-purge activation and acknowledgment.
Temper at ur e Compensat i on Sel ect i on. Pushbutton
selection of linearized or non-linear temperature transmitter
input for the following temperature sensing types:
Type E 50 to 1750F 50 to 950C
Type T 50 to 750F 50 to 400C
Type J 50 to 2000F 50 to 1090C
Type K 50 to 2000F 50 to 1090C
RTD 50 to 1500F 50 to 815C
Power
Power Supply.
Standard 24VAC (20-28VAC) or 24VDC (20-40VDC).
Optional 120VAC (100-132VAC), via external transformer.
Power Consumption.
Standard: 18VA at 24VAC; 13VA at 24VDC; 36VA at
120VAC. With AUTO-purge Management: 54VA at 24VAC;
48VA at 24VDC; 108VA at 120VAC.
Circuit Protection. Power input is fused and reverse
polarity protected.
Transmitter
Accuracy. 0.1% of Natural Span, including hysteresis,
deadband, non-linearity, and non-repeatability.
Type. Differential pressure, flow, and mass flow.
Ranges. Natural Spans Bi-Polar Natural Spans
0 to 25.00 IN w.c.
0 to 10.00 IN w.c. 10.00 to 10.00 IN w.c.
0 to 5.00 IN w.c. 5.00 to 5.00 IN w.c.
0 to 2.00 IN w.c. 2.00 to 2.00 IN w.c.
0 to 1.00 IN w.c. 1.00 to 1.00 IN w.c.
0 to 0.50 IN w.c. 0.50 to 0.50 IN w.c.
0 to 0.25 IN w.c. 0.25 to 0.25 IN w.c.
0 to 0.10 IN w.c. 0.10 to 0.10 IN w.c.
0 to 0.05 IN w.c. 0.05 to 0.05 IN w.c.
Span Rangeability. The calibrated span can be down
ranged to 40% of the Natural Span.
Stability. 0.5% of Natural Span for six months.
Temperature Effect. Zero. None; corrected by AUTO-
zero. Span. 0.015% of Natural Span/F.
Mounting Position Effect. None; corrected through
transmitter automatic zeroing.
Span and Zero Adjustment. Digital, via internally located
pushbuttons.
Low Pass Filtration. Response time to reach 98% of a
step change is adjustable from 2.0 to 250.0 seconds.
Overpressure and Static Pressure Limit. 25 psig.
Automatic Zeroing.
Accuracy. Within 0.1% of calibrated span.
Frequency.Every 1 to 24 hours on 1 hour intervals.
Temperature Limits.
20 to 180F Storage; +32 to 140F Operating.
Humidity Limits. 0-95% RH, non-condensing.
Performance Specifications
zeroing function essentially produces a "self-calibrating"
transmitter. The automatic zeroing circuit will re-zero the
transmitter to within 0.1% of its operating span; for a
transmitter with a 0.02 IN w.c. operating span, this represents
a zeroing capability within 0.00002 IN w.c.
To permit manual calibration of the VELTRON DPT-plus, an
electronic switch is provided to permit manual positioning of
the zeroing valve.
Ultra-Low Differential Pressure & Flow " Smart" Transmitter
Accuracy. The VELTRON DPT-plus is designed to maintain
an accuracy of 0.1% of Natural Span. For a span of 0 to 0.05
IN w.c., this accuracy is equivalent to an output accuracy of
0.00005 IN w.c. differential pressure or 0.90 FPM velocity.
Microprocessor Based Functionality. The VELTRON DPT-
plus on-board microprocessor performs the functions of
operating parameter selection, transmitter configuration, input/
output and display signal scaling, and transducer calibration.
Imbedded software performs span, flow, and 3-point "K" factor
calculations. Input to the microprocessor is via pushbuttons.
Electronic Respanning. The VELTRON DPT-plus operating
span can be electronically selected anywhere between the
Natural Span and 40% of Natural Span, without having to
perform recalibration involving an external pressure source.
Air Density Correction. The VELTRON DPT-plus is capable
of accepting a process temperature input to perform density
correction to volumetric or mass flow. Temperature input is a
4-20mA signal from a remote temperature transmitter; non-
linear temperature inputs can be linearized by the
microprocessor. Temperature sensor type is software
selectable from the following choices: Thermocouple types
E, T, J , and K; or Platinum RTD.
High Turndown Ratio Operation. The VELTRON DPT-plus,
with its high level of accuracy and automatic zeroing circuitry,
can maintain linear output signals on applications requiring
velocity turndown of 10 to 1 (equal to a velocity pressure
turndown of 100 to 1).
Features
Continuous Display of Process. The VELTRON DPT-plus
comes equipped with a multi-line, backlit, graphical LCD for
use during transmitter configuration and calibration, and to
display multiple measured processes in engineering units.
The LCD provides one line having 8 digits with double wide
and double high characters, two 20 digit lines having standard
size characters, and various descriptors for transmitter
operating status.
Primary Signal Noise Filter. To eliminate background noise
and pulsations from the flow signal, the VELTRON DPT-plus
has a user selectable low pass digital filter.
AUTO-pur ge Management (optional). For "dirty air"
applications requiring the use of an Air Monitor AUTO-purge
system, the VELTRON DPT-plus provides the capabilities of
establishing purge frequency and duration while giving the
user a choice of either internally timed cycle frequency or
externally triggered purge initiation. During the purge cycle
all transmitter outputs are maintained at their last value prior
to the start of the purge cycle.
Hazardous Locations. The VELTRON DPT-plus is Factory
Mutual approved for the following:
Explosion Proof: Class 1, Division 1, Groups B, C, D.
Dust Ignition Proof: Class II, III, Division 1, Groups E, F, G.
Suitable for indoor and outdoor NEMA Type 4X hazardous
locations.
Enclosure. The VELTRON DPT-plus is packaged in a NEMA
4X enclosure with standard industrial process connections.
High port
1/418 NPT for
pressure connection
3/414 NPT conduit
connections (2
places)
NEMA 4X
Field wiring
end
Low port 1/418 NPT
for pressure
connection
7.88
(Max)
2Z\,
6.75
(Max)
4.50
(Max)
Standard LCD
Graphical Display
Locknut
Calibration Port
Process Connections. Industry standard 1/4"-NPT ports
on 2-1/8" centers on flanges. 1/2"-NPT ports on bottom of
base.
Electrical Connections. Dual 3/4" conduit connections.
Terminal strip for field wiring and test points. External terminal
strip with plug-in connectors.
O-Rings. BUNA N.
Physical Specifications
Electrical Enclosure. NEMA 4X aluminum body with
Neoprene gaskets.
Paint. Polyurethane with epoxy primer.
Mounting. Flat and angle mounting brackets for 2" pipe.
Weight. 10.5 lbs.
125-025-00 (1/00)
VELTRON DPT-plus
Suggested Specification
The mass flow transmitter shall be capable of receiving flow
signals (total and static pressure) from an airflow station or
probe array equipped with a temperature sensing means,
internally perform density correction for the process
temperature, and produce individual outputs linear and scaled
for standard air volume or mass flow, and temperature.
The mass flow transmitter shall contain an integral graphic
LCD for use during the configuration and calibration process,
and be capable of indicating multiple process parameters
(temperature, flow, dp, etc.) during normal operating mode.
All transmitter parameter setting, zero and span calibration,
and display scaling will be performed digitally in the on-board
microprocessor via input pushbuttons.
The mass flow transmitter will be available in multiple natural
spans covering the range of 0.05 IN w.c. to 10.0 IN w.c. with
an accuracy of 0.1% of natural span. The transmitter shall be
furnished with a transducer automatic zeroing circuit and be
capable of maintaining linear output signals on applications
requiring 10 to 1 velocity (100 to 1 pressure) turndown. The
transmitter shall be capable of having its operating span
electronically selected without having to perform recalibration
involving an external pressure source.
(Optional) The transmitter will provide the means of managing
a system for automatic high pressure purge of the airflow
station or probe array, with user selectable purge frequency
and duration, while maintaining the last transmitter output
during the purge cycle.
The mass flow transmitter shall be the VELTRON DPT-plus
as manufactured by Air Monitor Corporation, Santa Rosa,
California.
Mounting Configurations with Optional Brackets
Angle Mount to Horizontal Pipe Vertical Mount to Horizontal Pipe Mount to Horizontal Channel
Mount to Flat Surface Vertical Mount to Vertical Pipe
Note: Mounting bracket kit includes
3/8-16 U-bolt, nuts, and washers for
2" Schedule 40 pipe, plus 4 bolts and
washers to attach the transmitter to
the mounting bracket.
AIR MONITOR
POWER DI VI SI ON
Pf-FLO III
Pulverized Coal Flow Measurement
The Pf-FLO III pulverized coal flow measurement system, introduced
in 1999, provides reliable and accurate mass flow measurement
in pulverized coal flow applications. The system provides boiler
operators with real time data of the amount of coal to each burner .
Analogous to the automotive industry, the Pf-FLO III system enables
coal fired power plants to advance beyond carburetion to fuel
injection.
Coal fired boilers require accurate pulverized fuel flow
measurement to balance coal mass distribution between burners.
Balancing the coal mass improves the burner-to-burner
stoichiometry, resulting in better plant performance and operating
efficiency. Equal coal mass distribution also reduces fuel delivery
issues, such as in-furnace slagging, coal layout, fuel slugging,
and coal pipe fires.
When Pf- FLO III is coupled with individual burner airflow
measurement, a boiler operator can use the system to fine tune
air-to-fuel ratios on a per burner basis. This makes the Pf-FLO III
system a very capable NOx reduction and boiler performance
optimization tool.
Product Description
Pf-FLO III
TM
! !! !! Real time on-line pulverized coal flow measurement
! !! !! 5% accuracy, independently tested, and proven
! !! !! System measures full pipe cross-section
! !! !! Simple Commissioning. No need for extractive sampling or field
testing to calibrate
! !! !! Ensures safe boiler operation by detecting fuel delivery problems
! !! !! Assists in minimizing primary air while maintaining minimum
transport velocity, to reduce CO emissions
! !! !! Industrial construction for long term durability
! !! !! Combustion optimization tool proven to increase efficiency
and reduce emissions
! !! !! Replaces manual methods of coal flow measurement
Performance Features
Velocity Measurement
The Pf-FLO III system utilizes a passive, cross-correlation method
to measure coal particle velocity in the pipe. The coal particles
travelling in the coal pipe produce a unique "signature" detected by
both the upstream and downstream Pf-FLO sensors.
These "signatures" are subjected to cross correlation processing
to determine the time of flight ("t) required for the signature to
pass from the upstream sensor to the downstream sensor. The
time of flight combined with the known distance between sensors
produces the coal particle velocity.
The Pf-FLO III system measures coal density via the relationship
between signal frequency shift and the amount of pulverized coal
present in the pipe. An increase in coal density produces a
measured shift of the microwave resonant signal to a lower
frequency.
This shift in resonant frequency is calculated with a patented
(U.S. Patent Nos. 6,109,097 and 6,771,080) dual slope measurement
algorithm and correlated to coal density.
Density Measurement
How It Works
The Pf-FLO III system determines the mass flow of pulverized coal
being transported in a pipe by independently measuring the
components of coal velocity and density . The system uses a
passive method to determine coal particle velocity, while the coal
density measurement uses a microwave based technology.
The Pf-FLO III system is comprised of a transmitter , sensors,
reflector rods, and sensor cabling. The transmitter mounts near
the measurement zone on the coal pipe and performs all processing
required to calculate the coal density, velocity, and mass flow. The
pipe mounted density , velocity, and temperature sensors are
connected to the transmitter with provided factory prepared
cabling. The reflector rods are installed upstream and downstream
of the sensors. The section of pipe within the sensors functions
as a wave guide, along which the microwave signal can propagate.
The reflector rods are installed to prevent reflected microwaves
from entering back into the measurement zone between sensors.
Reflected microwaves can interfere with the density measurement
in the form of microwave noise.
The Pf-FLO III transmitter provides direct coal velocity and mass
flow outputs to the DCS via 4-20mA signals, plus an Ethernet
connection to the PC which is used for data acquisition, data
historian, system commissioning, and configuration.
The drawing below illustrates the typical configuration for pipe
mounted components. There are four reflector rods and two
sensors per pipe.
Pf-FLO Features
Pf-FLO III
TM
Stand-Alone Measurement. Each Pf-FLO III coal flow transmitter
determines the mass flow rate and particle velocity of pulverized
coal, independent of a central processor and/or external inputs
such as mill feeder rate. The onboard microprocessor manages
the transmitter functionality and performs all data processing,
providing reliability with real-time performance.
Data Acquisition. The Pf-Vu data acquisition and archival software
provides the system operator with both dynamic and historic
graphical presentations of all measured parameters (particle
velocity, density, mass flow rate, and pipe temperature), logically
arranged by mill. Data can be selectively exported numerically into
spreadsheet software [in a delimited format] and/or continuously
communicated via an OPC or Modbus interface directly to a DCS or
PI platform.
Long Term Durability. All in-pipe mounted component s are
constructed of abrasion resistant Tungsten Carbide to ensure long
life, and are backed with a three year warranty.
Analog Communication. The Pf-FLO III transmitter provides
dual 4-20mADC analog outputs for mass flow rate and particle
velocity measurements, user configurable for isolated or non-
isolated operation.
Local, Central & Remote Configuration. Utilizing the Pf-PRO
software utility, parameterization and calibration of each Pf- FLO III
transmitter can be performed from a central PC over industry
standard Ethernet wiring, or locally at each transmitter utilizing a
laptop computer and a direct connect cable. With the addition of a
phone connection to the central PC, each transmitter can be
monitored and configured remotely.
Simplified Installation. Included weld-in threaded inserts for
pipe mounted components, plus Factory prepared and labeled cables
provide for fast and error free installation of the Pf-FLO III coal
flow system. Cable lengths of up to 50 allow for flexibility in the
mounting location of each transmitters NEMA 4 enclosure.
System Architecture
Pf-FLO III
TM
Pf-Vu software provides access to all system parameters (mass
flow, velocity, density, and temperature) for each mill.
Pf-Vu Features
Dynamic and historical data trending can be viewed through the
Pf-Vu interface.
Screen Selection Dynamic Trend
! !! !! Suitable for installation in vertical, inclined or horizontal pipe.
! !! !! Recommended installation in vertical section of pipe right out of
mill discharge or first horizontal section of pipe within three to
five diameters of the upstream elbow.
! !! !! Pipe must not have any flanges in the measurement zone.
! !! !! Test ports can be located anywhere except in the measurement
zone between the two sensors.
! !! !! Fixed or variable orifices and coal valves must be located outside
the reflector rods.
! !! !! Orifices and coal valves should be installed downstream of the
last reflector rod.
! !! !! Pipe must not have ceramic lining within the reflector rods.
! !! !! Vertical down flow is not a suit able installation for the Pf-FLO III
system.
Pf-FLO III
TM
Performance Specification
Accuracy
5% of mass flow (absolute units), combining velocity and
density accuracies.
Power Consumption
42 VA at 120 VAC
24 VA at 24 VAC/DC
Measurement Update Rate
Single Pipe System. Mass Flow: 2 to 3 seconds
Dual Pipe System. Mass Flow: 4 to 6 seconds
Pf-FLO III
TM
Functional Specification
Microprocessor Based Functionality
All functions and operations are performed by the
Pf-FLO III
TM
system on-board microprocessor.
Pf-FLO III
TM
to PC / DAS Connectivity
ModBus / TCPIP via Ethernet
Analog Outputs
Dual 4-20mADC isolated or non-isolated outputs
Output 1: Mass Flow
Output 2: Velocity
Analog Inputs
Isolated or non-isolated 4-20mADC inputs for mill feed rate
and mill primary airflow. Inputs are for data analysis only
and are not required for mass flow measurement.
Rolling Average Filter
Adjustable from 1 to 10 values
Velocity Measurement Range
20 to 200 ft/s
Pipe Temperature Measurement Range
0 to 300F
Density Measurement Range
0 to 200 absolute units (approximately 0 to 0.08 lb/ft
3
,
dependent upon coal type)
Power Supply Requirement
120 VAC, 24 VAC or 24 VDC
Circuit Protection
Power input is fused and reverse polarity protected
Temperature Limits.
20F to 180F Storage
0F to 140F Operating
Enclosure
NEMA 4
Sensor Antenna and In-Pipe Components
Tungsten carbide construction
Threaded Inserts
Weld-in 5/8-18
Pf-FLO III
TM
Pf-FLO III
TM
PC/DAS Functional Specification
Pf-Vu
Wonderware
TM
based software for data display and
extraction to Excel
TM
. [Optional] Pf-Vu/Plus to include
Burner Secondary Airflow Measurement.
Pf-PRO
System management software for local or central system
parameterization and commissioning.
Data Storage
Receive and archive data for all pipes: Density, Velocity,
Temperature, Mass Flow, Feeder, and PA.
Data Extraction
[Optional] OPC or Modbus communication of data to plant
DCS or PI system.
Remote Connectivity
PCAnywhere
TM
for remote operator access. Requires
phone connection.
Password Protection
Owner, Administrator, and Operator / User.
125-196 (7/07)
Air Monitor Power's Product Families of Airflow Measurement & Services
IBAM
TM
The IBAM
TM
can be obtained through accurate measurement of burner secondary airflow. The
IBAM
TM
probe has been designed to accurately measure in the particulate laden, high
operating temperature conditions found in burner air passages.
CAMS
TM
Combustion Airflow Management System
The CAMS
TM
TM
contains the microprocessor based instrumentation to measure the airflow and
manage the AUTO-purge. The AUTO-purge is a high pressure air blowback system
that protects the duct mounted flow measurement device from any degradation in
performance due to the presence of airborne particulate (flyash).
Air Monitor Power's duct mounted airflow measurement devices have been designed
to accurately and repeatedly measure air mass flow in power plants. The Combustion
Air (CA) Station
TM
includes honeycomb air straightener to accurately measure in shorter
straight duct runs than any other flow measurement device. The VOLU-probe/SS
TM
delivers accurate airflow measurement performance in the form of an insertion probe.
Both devices feature Type 316 stainless steel flow sensing arrays.
CEMS
TM
TM
Continuous Emissions Monitoring Systems assist
in complying with the Clean Air Acts stringent emission measurement standards
and the requirements of 40 CFR 75. Air Monitor Power has assembled a cost
effective integrated system consisting of in-stack flow measurement equipment
and companion instrumentation to provide continuous, accurate, and reliable
volumetric airflow monitoring of stacks and ducts of any size and configuration.
TM
Traverse Probes
Engineering & Testing Services. Air Monitor Power offers complete
engineering and testing to analyze air and coal delivery systems. Air Monitor
Powers field testing services use 3D airflow traversing and Pf-FLO coal flow
measurement systems for the highest possible accuracy. To ensure cost
effective and accurate solutions, Air Monitor Power has full scale physical
flow modeling capability and in house Computational Fluid Dynamics (CFD).
CFD analysis is used to analyze flow profiles and design/redesign ductwork
to improve overall performance. Full scale model fabrication and certified
wind tunnel testing is used to develop application specific products that will
measure accurately where no standard flow measurement can.
Coal Flow Technology Licensed From:
P.O. Box 6358 Santa Rosa, CA 95406 P: 800-AIRFLOW F: 707-526-9970 www.airmonitor.com amcsales@airmonitor.com
-i-
NOX RE DUCT I ON T HROUGH COMBUS T I ON
OP T I MI Z AT I ON ON A 4 2 0 MW WAL L - F I RE D UNI T AT
P ROGRE S S E NE RGY

A U T H O R S : P E T E R H O E F L I C H P R O G R E S S E N E R G Y
D AV E E A R L E Y, A MC P O WE R / C O MB U S T I O N
T E C H N O L O G I E S C O R P.

Abstract

As a result of increasingly stringent emissions limitations being imposed on coal-fired
power plants today, electric utilities are faced with having to make major compliance related
modifications to their existing power plants. Even when implementing the more expensive
post-combustion NO
x
reduction programs on some larger generating units, many utilities
are still finding themselves in need of further NOx reduction. This is often caused by higher
than expected NOx output after the SCR is installed (often at reduced loads) and higher
NOx from units that did not get SCRs. In-furnace NO
x
reduction offers a less expensive
alternative/complement and is suitable to any size boiler to reduce NO
x
while also
improving overall combustion. In-furnace NO
x
reduction strategies can also be effective
year-round (not just during ozone season). Since these strategies often result in improved
efficiency and elimination of some combustion problems (burner fires, slagging, mill
problems, etc) these programs also lead to more reliable generation. When implemented
in conjunction with an expensive post-combustion SCR program, initial capital requirements
and ongoing operating costs ( i.e. ammonia consumption ) can be cut to save utilities
millions of dollars.

For the purpose of developing a system-wide NO
x
reduction strategy, Progress Energy, a
southeastern U.S. utility applied pulverized coal flow measurement and control to one of its
units without an SCR. The purpose of this installation was to attempt to reduce NOX by at
least 10% (especially at reduced loads). Once successful, this led to the installation of a
more elaborate fuel and airflow measurement and control program on a larger Progress
Energy unit with a high NOx output. This control program was also combined with other
lower cost modifications for an overall larger NOx reduction.

In addition to getting over 20% NOx reduction from the combustion optimization alone, this
part of the project yielded other benefits such as 40% lower LOI. How this program
produced the NO
x
reduction and other benefits will be presented in detail in this paper. The
paper will also discuss the effects on excess O
2
, opacity, and steam temperature.
Page 1 of 14
I. INTRODUCTION

In an effort to reduce NO
x
emissions at some of its plants, Progress Energy initiated a
strategy of combining lower cost in-furnace NO
x
control technology with lower cost
post combustion NO
x
control technology. The goal was to achieve significant NO
x

reduction while avoiding the higher cost of more SCRs.

It has been well established that combustion tuning or optimizing can lead to NO
x

reduction while also helping to improve other parameters such as slagging, corrosion,
LOI and more. One of the technologies selected for in-furnace NO
x
control was on-
line pulverized coal flow measurement.

In 2002 Progress Energy/Strategic Engineering developed a plan to select, test and
then implement this technology for NO
x
control on a mid-size boiler.

II. COAL FLOW MEASUREMENT TECHNOLOGY

Several on-line coal flow measurement technologies were evaluated for performance
and the one selected was Pf-FLO by AMC Power (AMC) as it is the only commercially
available product that measures absolute (as opposed to relative) coal flow.

Pf-FLO uses microwave technology to measure the coal density between two sensors
installed in a coal pipe. It also uses electrostatic technology to simultaneously
measure the velocity of the moving coal particles through cross correlation and time of
flight. The product of density and velocity is mass flow. Both the mass flow and coal
velocity would be critical to combustion optimization and thus NO
x
reduction.

Review of Pf-FLO Technology

To obtain the mass flow of pulverized coal being transported to a burner, one needs to
know both the concentration
1
and the velocity of the coal in the burner pipe. The Pf-
FLO system measures both the coal concentration and velocity in each pipe,
independent of both the measurements performed on the other pipes and the coal
feeder information, resulting in coal velocity outputs for each pipe scaled in units of
feet per second and mass flow outputs directly proportional to the coal flow in each
pipe.

Pf-FLO is a unique technology for online coal flow measurement in that it provides an
accurate absolute measurement without need for in situ calibration. Other online coal
flow measurement systems require the use of field calibration methods such as
isokinetic sampling or rota-probing, which are known to be as inaccurate as 10%.
The result of utilizing these field calibration methods is a measurement system that
can indicate balanced coal pipes when the actual mass flow distribution can vary as
much as 20%. The Pf-FLO technology, requiring no calibration, produces an
extremely accurate measurement of the coal flow to each burner.

1
The term 'concentration' is meant as mass concentration or mass density in this report.
Page 2 of 14

III. TRIAL SYSTEM

Before applying the coal flow technology with the other technologies for optimum NO
x

reduction, a trial would be performed at the Mayo Station. Mayo consists of two
boilers operating one turbine. Pf-FLO was installed in each of sixteen (16) burners for
one of the two boilers. The goal was to achieve 10-15% NO
x
reduction using just the
Pf-FLO system. This low cost trial entailed renting a Pf-FLO system for the sixteen
pipes. No adjustable coal valves were purchased. The objective would be to adjust
burner airflows (though no airflow measurements were available) to the burners based
upon the coal mass flow in each pipe. Though no coal valves were purchased due to
cost limitations for this trial, the auxiliary air on each of the four coal mills was used to
act as an air curtain or restriction in each coal pipe. This allowed for better balancing
of the coal pipes of each mill.

Though Pf-FLO yielded the coal flow to each burner, the airflow to each burner was
unknown. The O
2
grid in the backpass was used in lieu of airflow to help identify
fuel:air ratio imbalances. Burner air registers were adjusted accordingly. As a result,
a 10% NO
x
reduction was achieved at full load and 15% reduction was achieved at
reduced load. These tests were repeated on different days to ensure repeatable
results. In addition, the improved combustion led to a reduction in opacity for all tests
and O
2
stratification was also minimized.

Through the Mayo trials, it was determined that individual burner airflow would be
helpful in future installations. Individual burner airflow would allow the users to tune
airflow to match coal flows directly. In addition, a more effective means of moving coal
flow between pipes was recommended.

IV. IMPLEMENTING A COMPLETE NO
X
CONTROL SYSTEM

Sutton 3 was selected for the integration of the lower cost NO
x
reduction systems. In
addition to the air and fuel control, low NO
x
burner modifications and SNCR were to be
implemented at Sutton.

A. Coal Adjustment and Air Flow

Sutton 3 has Riley double ended Atrita mills. These mills are known to produce
end to end imbalances. In addition, the output of each end of each mill would
split into two pipes through a riffle box. These riffle boxes are also known to
create imbalanced coal flow.

Diverter dampers were designed by AMC and installed during the April-May 2005
outage. The diverter dampers controlled the coal to each side of each mill. In
addition, new adjustable (for coal imbalance) riffle boxes were purchased through
FWEC.

AMC specializes in combustion airflow measurement and has supplied individual
burner airflow measurement systems (IBAMs) on several hundred low NO
x

Page 3 of 14
burners in the U.S. IBAMs were designed and tested in their wind tunnel for the
Sutton 3 burners. The IBAMS were installed in the burners during the April-May
2005 outage.

B. Sutton 3 Pre-Outage Tuning Improve Controls and Reduce NO
x

Prior to the April-May 2005 outage, baseline NO
x
(domestic coal) was 0.70
lb/MMBtu and baseline LOI was 20-25%.

In February, the AMC Pf-FLO system was installed in each of the 28 coal pipes
with the goal of obtaining baseline coal flow data and possibly performing
preliminary combustion optimizing.

For much of March, Pf-FLO coal flow data was often noisy. AMC recognized
this type of erratic coal flow behavior to be indicative of coal layout. After further
investigation, these coal flow problems were determined to be problems/errors in
the DCS programming for feeder and primary air control. As a result, new control
logic was downloaded and new primary air curves were developed. Upon the
downloading of the new controls software and proper PA/feeder curves (just after
the outage), the coal layout and otherwise erratic flows had subsided.

While burner airflow measurement systems (IBAMS) were not installed yet,
burner disks were adjusted before the outage to compensate for lean and rich
burners (as shown by Pf-FLO). In addition, feeders were biased for optimum
NO
x
control.

The result of this pre-outage optimization was a NO
x
reduction to 0.54 lb/MMBtu
(24% reduction). This level was maintained for twelve hours leading up to the
spring outage.

C. Post Outage Work

The controls and PA curve changes as outlined earlier were integrated just after
start up. This took several weeks. After several weeks of burner tuning by
FWEC, diverter damper and riffle box adjustments were performed in early June.

After burner tuning and coal pipe balancing, NO
x
levels were reduced to 0.42
lb/MMBtu. Further tuning with Pf-FLO also optimized boiler operation for this low
NO
x
condition by eliminating superheat and reheat temperature alarm conditions
which had resulted from the burner tuning with new burner modifications.

In August, diverter dampers were placed in automatic control. More tuning was
performed using the IBAM data and adjusting burner disks for proper fuel/air
ratios after the diverters had equalized the fuel. LOI levels were reduced from
above 20% to 12.69% (over a 37% LOI reduction).

In February 2006, the burner secondary air disks were put in automatic control.
Three Fuel/Air setpoints strategies were developed normal, overfire air and fuel
Page 4 of 14
rich. For each strategy, each row of burners was given a fuel/air setpoint. The
controls system looks at 2-minute averages of fuel/air ratios. If a burners fuel/air
ratio is above or below its setpoint by more than 10%, the secondary air disk is
moved open or close accordingly by an increment of 5%. Another 2-minute
average is then analyzed and changes are made accordingly.
The O2 across the back end improved and fuel air ratios are maintained. This
new control scheme would mean operators will spend less time trying to blindly
adjust burner air registers when there is a combustion problem (such as O2
imbalance or high CO).

V. RESULTS SUMMARY

The Pf-FLO coal flow system combined with the IBAM burner airflow systems, coal
diverters, and riffle boxes exceeded expectations for NO
x
control and other
combustion improvements (Better Boiler control, LOI, and O
2
) as outlined in the table
below.

PROJECT PERFORMANCE vs. GOALS

Modification Target Measured Remarks
Coal Flow and Air Flow
Balancing (Air Monitor
Corporation)
NO
x
< 0.595 lb/mmbtu
(15% reduction in NO
x
)
NO
x
= 0.54 lb/mmbtu
(23% reduction from
0.7 lb/mmbtu
baseline)
Measured values achieved April
21, 2005 with domestic coal.
Unit at Full Load 7 mill operation
(pre-outage).
Combined Coal Flow and
Air Flow Balancing (Air
Monitor Corporation) and
Low NO
x
Burner
Modifications (Foster
Wheeler)
NO
x
<0.482 lb/mmbtu
(34% reduction in NO
x
.)

AMC=15% reduction in NO
x

FW = 19% reduction in NO
x

LOI < 21%
NO
x
= 0.42 lb/mmbtu
(40% NOx reduction
from 0.7 lb/mmbtu
baseline)

LOI = 20%
Measured values achieved June
9, 2005 with domestic coal. Unit
at Full Load (VWO), 7 mill
operation (post outage).
Coal Flow and Air Flow
Balancing (Air Monitor
Corporation)
LOI = 12.6%

Page 5 of 14
APPENDIX

SUTTON 3 PROJECT

The Pf-FLO III coal flow measurement system was installed onto each of the 28
burner lines at Sutton Unit 3 in February 2005.

The location of the sensors is in the horizontal pipe sections downstream of the riffle
boxes. As shown below, the riffle boxes are to the lower right, the burners are to the
left of the riffle boxes.

Page 6 of 14

The plant has seven double ended Riley Atrita mills. Each mill provides coal to two
riffle boxes and each riffle box feeds two burners. The Riley Atrita mill has two
separate ends that operate like independent milling systems. Each riffle box is
supplied coal by a single pipe from one end of the mill (as shown below).

Because most of the coal imbalance is the result of the mill end-to-end imbalance, a
diverted damper was engineered to control the coal flow to each end of the mill, based
upon the comparison of the summed mass flow of each end (Pipes 1+2 vs Pipes 3+4).

Coal and Primary
Air into mill
To Pipes
1 and 2
To Pipes
3 and 4
Page 7 of 14

Additionally, the riffle boxes were replaced with new adjustable riffle boxes having the
capability to control and balance pipe-to-pipe fuel distribution without having to access
the internal components.

Page 8 of 14

A. Pre-Outage Testing
For much of March, the Pf-FLO data was often noisy, as reflected below. This
erratic behavior and coal layout was found to be the result of improper feeder and PA
control. New PA and Feeder control logic was developed and implemented. The
result was more stable mill operation and control.

Page 9 of 14
SUTTON 3 PROJECT

A. Pre-Outage Testing (cont)
Improper primary air control can often result in layout of coal in the coal pipes. The
plot below shows that on this mill, a decrease in load is matched by a decrease in coal
velocity, resulting in unstable coal transport and coal layout. This could be corrected
with higher PA at that load condition.

New Primary Air curves were developed for all mills to reduce layout and give optimum
velocity for burner performance.

C MIll Pipe Velocities
0
20
40
60
80
100
120
140
160
180
1
1
:
1
5
:
2
8
1
1
:
2
3
:
2
8
1
1
:
3
1
:
2
8
1
1
:
3
9
:
2
8
1
1
:
4
7
:
2
8
1
1
:
5
5
:
2
8
1
2
:
0
3
:
2
8
1
2
:
1
1
:
2
8
1
2
:
1
9
:
2
8
1
2
:
2
7
:
2
8
1
2
:
3
5
:
2
8
1
2
:
4
3
:
2
8
1
2
:
5
1
:
2
8
1
2
:
5
9
:
2
8
1
3
:
0
7
:
2
8
1
3
:
1
5
:
2
8
1
3
:
2
3
:
2
8
1
3
:
3
1
:
2
8
1
3
:
3
9
:
2
8
1
3
:
4
7
:
2
8
1
3
:
5
5
:
2
8
1
4
:
0
3
:
2
8
1
4
:
1
1
:
2
8
1
4
:
1
9
:
2
8
1
4
:
2
7
:
2
8
1
4
:
3
5
:
2
8
1
4
:
4
3
:
2
8
1
4
:
5
1
:
2
8
1
4
:
5
9
:
2
8
1
5
:
0
7
:
2
8
1
5
:
1
5
:
2
8
1
5
:
2
3
:
2
8
1
5
:
3
1
:
2
8
1
5
:
3
9
:
2
8
1
5
:
4
7
:
2
8
M003P001V
M003P002V
M003P003V
M003P004V
Page 10 of 15

A. Pre-Outage Testing (cont)
The result of this optimization was a NO
x
reduction from baseline of 0.71 lb/MMBtu to
0.54 lb/MMBtu, as shown from PI data below. This level was maintained for 12 hours
prior to the Spring outage.

SUTTON 3 PROJECT

B. Post-Outage Work
Below are examples of coal pipe balance changes due to diverter damper adjustment
pipes become more balanced. After burner tuning and coal pipe balancing, NO
x

levels were reduced to 0.42 lb/MMBtu.

Page 11 of 14
SUTTON 3 PROJECT (cont)

C. Post NO
x
Reduction Tuning

In addition to the online coal flow monitors, individual burner airflow
measurement (IBAMs) were installed in each of the 28 low NO
x
burners.

A full-scale mock up of the burner was tested for flow accuracy in AMCs wind
tunnel.

Page 12 of 14
SUTTON 3 PROJECT (cont)

C. Post NO
x
Reduction Tuning
The screen below is a new screen in the Sutton Control Room. This was used to
develop ideal burner fuel air ratios. In August, diverter dampers were placed in
automatic control. More tuning was performed using the screen below to achieve
proper fuel/air ratios after the diverters moved the fuel. LOI levels were reduced
from above 20% to 12.69%.

In addition the this main screen (above), new coal flwo screens were developed for the
control room. By clicking on Coal for any mill above, the coal balance for that mill can be
seen (below):

Page 13 of 14

Page 14 of 14
Below is the control room screen showing desired/automatic fuel/air ratios.

PF-FLO REFERENCE TEST
AT THE
MARTIN-LUTHER UNIVERSITY HALLE-WITTENBERG
Martin-Luther-Universitt Halle-Wittenberg AMC Power PROMECON
Fachbereich Ingenieurwissenschaften 1050 Hopper Avenue
Lehrstuhl fr Mechanische Verfahrenstechnik Santa Rosa, California 95403
06099 Halle (Saale) U.S.A.
Germany
PF-FLO REFERENCE TEST AT THE MARTIN-LUTHER UNIVERSITY
HALLE-WITTENBERG
CONTENTS Page
1. Introduction..................................................................................................... 1
2. Description of the Test Facilities..................................................................... 3
2.1 The Testing Plant ................................................................................... 3
2.2 The Pf-FLO Mass Flow Measurement .................................................... 4
2.2.1 Density measurement .................................................................. 4
2.2.2 Velocity measurement ................................................................. 5
2.2.3 Calculation of the Mass Flow....................................................... 6
2.3 Pf-FLO Test Configuration...................................................................... 6
2.4 The Test Medium.................................................................................... 8
2.5 Feeder Calibration.................................................................................. 9
3. Testing Procedure .......................................................................................... 11
4. Results ........................................................................................................... 14
4.1 Pf-FLO Measurement Accuracy ............................................................. 14
4.1.1 Absolute Deviation....................................................................... 15
4.1.2 Repeatability................................................................................ 16
4.2 Influence of the Particle Size.................................................................. 17
4.2.1 Velocity Measurement ................................................................. 17
4.2.2 Density Measurement .................................................................. 19
4.2.3 Mass flow measurement .............................................................. 20
5. Abstract .......................................................................................................... 23
Figures Page
Fig. 2.1: Schematic drawing of the test plant ............................................................. 3
Fig. 3.1: Range of pf-concentrations based on feeder mass flow and transport air
flow.............................................................................................................. 11
Fig. 3.2: Density measurement .................................................................................. 12
Fig. 3.3: Velocity measurement ................................................................................. 12
Fig. 3.4: Resulting mass flow and feeder signal......................................................... 12
Fig. 3.5: Mass flow of feeder versus Pf-FLO.............................................................. 12
Fig. 4.1: Evaluation of all test runs with 66 / 225 m particles ................................... 14
Fig. 4.2: Repeatability of channel 0 for 66 - 225 m particles.................................... 15
Fig. 4.3 Averaged particle velocities at channel 0..................................................... 17
Fig. 4.4: Acceleration along the test duct of the 225 m particles.............................. 18
Fig. 4.5: Influence of the mass flow on the velocity of the particle mix in Test IV-VI.. 18
Fig. 4.6: Density measurement with 66 m particles Test V. ..................................... 19
Fig. 4.7: Density measurement with 225 m particles Test I ..................................... 19
Fig. 4.8: Influence of the particle size on the Pf-FLO measurement .......................... 20
Fig. 4.9: Estimated deviation by modeled particle size distribution............................ 22
Tables Page
Table 2.1:Bulk density and frequency shift for fixed-bed powder of pulverized black
coal and glass particles................................................................................ 8
Table 3.1:Test run number for each particle size......................................................... 12
Table 4.1:Standard deviation and mean error for individual particle fractions ............. 15
Table 4.2:Standard deviation of the individual channels with 66 m particles ............. 16
Table 4.3:Standard deviation of the individual channels with 225 m particles ........... 16
Table 4.4:Standard deviation of the individual channels with 66-225 m particle mix . 16
Table 4.5:Ratio of arbitrary units to mass and the resulting mass frequency factor k
fd
for each particle fraction............................................................................... 21
1. Introduction
Measurement of particle concentration or mass flow rate in pipeline systems (i.e.
pneumatic conveying) is essential for numerous technical applications, such as
conveying of pulverized coal in power plants or conveying systems in cement
factories. Of major importance is the detection of the particulate flow in the entire
cross-section of a pipe. In the past this has generally only been achieved in pipe
elements where the particulate concentration is homogeneously distributed over the
entire cross-section. For such a measurement different techniques are available,
namely extractive methods utilizing probes and non-extractive methods employing
electromagnetic waves or particle charging. From the first inspection an isokinetic
sampling probe seems to be the simplest approach, however, in order to measure
the particulate flux in the entire pipe section it is necessary to systematically position
the extraction probe at defined locations across the entire pipe cross-section. Due to
probe erosion damage, extractive sampling is only suitable for periodic
measurement. For continuous measurement, non-extractive methods are more
favorable, where the sensing instrumentation is mounted in-situ. One approach is the
detection of the electrostatic charge of moving particles. Unfortunately, the resulting
signal is not only affected by particle concentration, but also by gas temperature and
particle velocity. The method used for the investigation documented in this report is
based on utilizing microwaves emitted and detected by screw-in sensors. The
generated microwave field covers the entire pipe cross-section and hence allows the
determination of the averaged particle concentration over that cross-section. The
principle of the method will be outlined below.
The microwave based experiments were conducted on an air-particle flow loop
established at the Lehrstuhl fr Mechanische Verfahrenstechnik of the Martin-Luther
University Halle- Wittenberg. In order to consider different conveying conditions,
probes were installed at multiple locations of the conveying pipe, namely in an
upward flow with almost homogeneous dust distribution, behind a vertical-horizontal
bend where roping is likely to occur, and in an almost fully developed state of a
horizontal pipe. The particle introduction was achieved using a calibrated screw
feeder, which also allowed the comparison of the particulate mass flow with the result
from the microwave instrument. Since the handling of pulverized coal could not be
safely performed at the test facility, spherical glass beads of two different mean
diameters were used as coal substitutes. It is acknowledged that the different
material density and particle shape of the glass particles results in a slightly different
conveying behavior, primarily in the form of lower particle velocities, but otherwise
the general flow behavior of coal and glass particle is extremely similar.
This report presents a description of the test facility and the measurement principle.
The measurements are presented in comparison with the calibrated screw feeder,
and a detailed discussion of the accuracy achieved with the microwave instrument is
provided.
2. Description of the Test Facilities
The reference test was carried out at the Merseburg test plant. The test facility is
designed with a closed loop for the particle flow and an open end for the transport air.
This arrangement ensures particle recycling via a cyclone back to the feeder without
significant particle mass loss, for re-introduction at a controlled rate/concentration.
For safety reasons the test plant was operated with glass beads of two different
diameters instead of pulverized coal. Particle load and transport air velocity were
varied during the test series in a range simulating that which naturally occurs with
pneumatically transported coal (see test matrix, Figure 3.1 and Table 3.1).
2.1 The Testing Plant
The test duct layout is drawn in Figure 2.1. Two rotary piston blowers, operating in
parallel and controlled by fan speed frequency converters, providing a velocity range
of about 46 to 92 ft/s for the transport air.

Cyclone
Rotary Valve
Screw Feeder
Bagfilter
Ch 3 Ch 2
Ch 1
Ch 0
Hopper
Air Outlet
16.5 ft.
10 ft.
A
i
r

I
n
l
e
t

Fig. 2.1: Schematic drawing of the test plant
The particles are introduced to the airflow by a screw feeder, transported through the
pipe and separated in a cyclone. Out of the cyclone the separated particles are fed
by a rotary valve back into the hopper of the screw feeder. The transport air is
exhausted through a bag filter.
The screw feeder is frequency controlled over a range of 0 350 rpm. The horizontal
run downstream of the feeder has a rectangular cross section, whereas the vertical
and the upper horizontal pipes where the Pf-FLO measurements are located are
round pipes having an inner diameter of 4.86.
The airflow velocity is measured by a multi-point Pitot probe positioned upstream of
the feeder. In addition, the airflow static pressure and temperature are also
monitored.
2.2 The Pf-FLO Mass Flow Measurement
The Pf-FLO system independently measures the density and velocity of pulverized
fuel in a two-phase flow. After a zero calibration of the empty transport pipe is
performed for the density measurement process, absolute mass flow can be
calculated using the product of the separate density and coal velocity signals.
2.2.1 Density measurement
Using the pipe as a wave-guide, the particulate concentration or density is measured
with transmitted microwaves that cover the full cross section of the pipe. Starting
with the known microwave transmission characteristic determined during empty pipe
zeroing, the varying dielectric load caused by changing pulverized fuel (pf)
concentrations produces a measurable frequency shift. The basics of this
measurement can be described as follows
1)
:
The cut-off frequency (
cut
) of a round wave-guide is in this application the frequency
of the H
11
mode. The wavelength of the H
11
mode is a function of the diameter of the
pipe.
Equation 1.
wherein D is the diameter of the pipe and X
mn
is the solution of the
Bessel function.

1)
Kummer: Grundlagen der Mikrowellentechnik, chapter 3.4 and 4.3; Berlin: 1986
D
D
mn
cut

71 . 1
The frequency () of the H

11
mode depends on the dielectric
r
and the magnetic
r
properties of the volume in the wave-guide.
Equation 2. where c is the constant for the speed of light
An unloaded pipe filled with air has a
r
of 1 and a
r
of 1. Hard coal has an
r
of 4
and
r
of 1. The volumetric ratio of pulverized coal to air at a coal concentration of
0.0312 lb/ft is 1 to 2500. Since the resulting
r
changes between loaded and empty
pipe in terms of 1/2500 the series expansion of Equation 2 can be used with its linear
term. This gives a linear relation between the frequency and pf load within the
concentration range typically found in coal fired power plants.
The Pf-FLO system couples microwaves in the range of the cut-off frequency into a
pipe section using a pair of sensors, one sensor functioning as the transmitter and a
second sensor as the receiver. The exact frequency of the H
11
mode is calculated by
scanning the transmitted microwave signal amplitudes.
A change in the concentration of pf in a given pipe changes the measured microwave
frequency: The higher the concentration, the lower the frequency. The frequency shift
caused by the pf is calculated by subtracting the frequency f
of the loaded pipe from

the frequency f
0
of the empty pipe. This frequency shift is transformed into a density
signal () by the frequency density factor k
fd
.
Equation 3.
Where f
0
is determined by the empty pipe zeroing process.
Changes in pipe diameter caused by temperature do affect the measured frequency.
Temperature compensation of the measured frequency uses the pipe surface
temperature and the linear expansion factor for that pipe material.
2.2.2 Velocity measurement
The velocity measurement uses a cross-correlation method for comparing the
stochastic signals of the electrostatic charged particles at two sensor locations of
known separation (see Figure 2.2). An evaluation of the velocity sensor signals gives
the time shift or time of flight (
m
). Using the distance between the sensors (L), solid
particle velocity (v
s
) can be calculated as follows:
Equation 4.
( )
fd
k f f

0
cut r r
c
f

m
s
L
v
By using this method only particle velocity is measured, which in most instances
differs from and is slower than the transport air velocity in a two-phase flow. This
difference, or velocity slip, is a function of such factors as pipe configuration, specific
weight and size of particles.
Signal 1
Signal 2
Cross-correlation
Fig. 2.2: Velocity measurement principle: signals and
resulting cross-correlation function
2.2.3 Calculation of the Mass Flow
The mass flow is calculated from the density and the particulate velocity
measurement as follows:
Equation 5.
The Pf-FLO system is calibrated to a known mass flow of the mill or pipe by adjusting
the frequency density factor k
fd
in Equation 3, which in turn depends on the pipe
diameter. The factor k
fd
is kept constant for all pipes with the same diameter.
2.3 Pf-FLO Test Configuration
The 4.86 diameter test duct pipe has a cut-off frequency of approximately 1.4 GHz.
The standard microwave generating unit of the Pf-FLO system has been selected to
provide frequencies up to only a 1 GHz level required for the range of larger coal pipe
s
v
dt
dm

,
_
dt
dm

Velocity = L /
m

5.25 D
rod
sensor
0.87 D 1.0 D 0.75 D 0.75 D 1.0 D 0.87 D
,
_
dt
dm
sizes found in power plants. For the test runs conducted it was necessary to replace
the standard model generator with a similar model having an extended frequency
range of up to 2.0 GHz.
Corresponding to the smaller inner diameter of the test duct, the sensor antenna was
also scaled down in length. Distances between sensors and rods in the test runs
were the standard distances based on a pipe having a diameter D, as show in Figure
2.3.
Fig. 2.3: Arrangement of sensors and rods at individual measurement locations
The Pf-FLO system uses wear resistant Tungsten Carbide rods to keep the
propagation of the microwaves within the certain measurement zone of the pipe.
Without the rods, the density measurement would be disturbed by reflected signals
caused by pipe bends, orifice plates, isolation valves, etc., located upstream and/or
downstream of the measurement zone. The optional fifth rod perpendicular to the
sensors and located at their midpoint provides an additional signal short cut for
depressing the propagation of 90 polarized H
11
modes.
Without knowing the actual mass frequency factor for the test pipe size, all channels
were initially set to
This factor was kept constant for all measurements in the test. The resulting units for
measured density () and mass flow are in arbitrary units [a.u.].
1
]
1
m Hz
a.u.
500
fd
k
2.4 The Test Medium
The test plant could not be used with black coal for safety reasons. Therefore, glass
spheres were used, with such properties as particle size, dielectric constant, and
electrostatic charging similar to pulverized coal.
Typically 85 % 95 % by weight of pulverized coal particles downstream of the mills
classifier are smaller than 90 m and 0.3 % or less are bigger than 225 m. The two
glass particle sizes of 66 m and 225 m used for this test represent the main
fraction and the biggest possible size fraction of particles in coal pipes.
The manufacturer of the glass beads specifies a glass density of 158.6 lb/ft and an
r
of 2.28 at visible light. The
r
may be slightly different for microwaves due to
dispersion.
The dielectric properties of milled coal and the glass spheres were tested in a
microwave resonator chamber. It was found that the frequency shift in this
measurement was dependent upon the dielectric properties on the bulk density of the
pulverized medium. By calculating the frequency shift per mass, the influence of the
sphere packing were eliminated. The results are displayed in Table 2.1.
Medium
Bulk density
[lbs/ft]
Frequency shift/
mass [MHz/lb]
Glass spheres 88.1 124.1
Black coal (Primero) 35.8 200.1
Black coal (Blumenthal) 35.8 193.9
Black coal (Knurrow) 41.8 193.5
Table 2.1: Bulk density and frequency shift for fixed-bed powder
of pulverized black coal and glass particles
The frequency shift at the same mass flow caused by glass is about 2/3 of the tested
coal. Therefore, the expected frequency shift for the mass flow measurement will
only be about 1/3 less for glass than for coal with the same mass. This ensures a
good comparability between the test data obtained with glass particles used as the
test medium versus that which would have been obtained had coal been able to be
used for the test medium.
The density for raw coal is between 78.0 and 81.8 lbs/ft. Taking this density into
account, glass particles of the same size are about two times heavier than coal
particles. The weight differential plus the shape of the particles, spherical for glass
and polyhedral for coal, give glass aerodynamic properties which result in a greater
velocity differential or slip between the airflow and the glass particles.
The electrostatic charging depends on particle collisions and particle conductivity.
The velocity measurement needs a certain amount of electrostatic charge to
correlate the sensor signals into a reliable time of flight measurement. Charging
signal strengths for both size glass beads and bead mixtures were sufficiently high to
obtain accurate time of flight measurements. Induced by the substantially greater
number of particle amount within the airflow, the signal strength of 66 m particles
was about five times higher than for the 225 m particles.
Gravimetric Particle Size Distribution
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
0 50 100 150 200 250 300
Particle size [m]
R
e
l
.

p
a
r
t
i
c
l
e

d
i
s
t
r
i
b
u
t
i
o
n

[
%
]
Fig. 2.4: Particle distribution as a function of particle size for the
50/50 mix of 66 m and 225 m particles
Beside the pure 66 m and 225 m particles, a 50/50 mix by weight was also tested.
Figure 2.4 shows the gravimetric distribution of particle sizes.
2.5 Feeder Calibration
To calibrate the feeder, glass beads were fed by the frequency controlled feeder into
a container for 30 seconds and their mass was weighed. This procedure was
repeated twice for each particle size in steps of 50 rpm from 0 to 350 rpm. The
average of both sets of measurements was used for the feeder calibration.
The repeatability of the feeder calibration was then tested by 10 individual
measurements with the 66 m particles at 150 rpm. They were all in the range of
t0.9 % by weight.
This was acceptable since the aim of the tests was not to examine the characteristics
of the screw feeder. And with all four sensor locations measuring physically the same
airflow/particle mixture, any scattering of the feeder is eliminated as a common
variable.
Feeder Calibration
0
.11
.22
.33
.44
.55
0 50 100 150 200 250 300 350 400
Feeder speed [rpm]
M
a
s
s

f
l
o
w

[
l
b
s
/
s
]
66 225 m
mix
225 m
66 m
Fig. 2.5: Mass flow versus feeder speed for different particle fractions
The mass flow of the feeder is shown in Figure 2.5 for the specific particle fractions.
The mass flow at a particular feeder speed depends on the particle size distribution.
The mix of the two size fractions has the tightest packing and thus shows the highest
mass flow. The 66 m and 225 m particles have different mass flows since for
particles <100 m, adhesion forces influence the flowability within the screw feeder.
3. Testing Procedure
The test runs have been made under the aspect of realistic airflow velocities and
particle concentrations.
Within the capacity of the fan, three velocity levels were chosen at 72 ft/s, 82 ft/s, and
92 ft/s, representing normal transport velocities in utility plants. With constant air
velocities the feeder speed was varied between 0 - 300 rpm in steps of 50 rpm.
Particle Concentration Range
0
0.006
0.013
0.019
0.025
0.031
0.037
0.044
0.050
0 50 100 150 200 250 300 350
Feeder speed [rpm]
C
o
n
c
e
n
t
r
a
t
i
o
n

[
l
b
s
/
f
t
]
Fig. 3.1: Range of pf-concentrations based on feeder mass flow and
transport air flow
The pf concentrations in utility plants usually range between 0.012 to 0.031 lbs/ft.
Figure 3.1 shows the range of the expected pf concentration based on the ratio of
feeder mass flow and the airflow during the tests.
Table 3.1 gives an overview of the different test runs: From the total number of 15
test runs there were six runs with the 66 m particles, six runs with the particle mix
and three runs with the 225 m particles.
Particle Size Test Numbers
66 m I,VI II,V III,IV
225 m I II III
66 - 225 m mix I,IV II,V III, VI
72 ft/s 82 ft/s 92 ft/s
Gas Velocity
Table 3.1: Test run number for each particle size
The following diagrams illustrate the data acquired for all test runs: Diagram
Figures 3.2 and 3.3 show density and velocity measurement, and Figure 3.4 shows
the resulting mass flow of the 66 225 m particles of Test Number V. Each feeder
step was kept constant for at least 15 minutes to get about 20 individual
measurements. From the last 15 measurements of each feeder step the average was
taken and plotted against the feeder mass flow in Figure 3.5.
0
6
12
18
24
30
36
42
48
54
61
1
3
:0
4
1
3
:1
2
1
3
:2
0
1
3
:2
9
1
3
:3
7
1
3
:
4
6
1
3
:
5
4
1
4
:
0
2
1
4
:
1
1
1
4
:
1
9
1
4
:
2
8
1
4
:
3
6
1
4
:
4
4
1
4
:
5
3
1
5
:
0
1
1
5
:
1
0
1
5
:
1
8
0
50
100
150
200
250
300
350
400
CH 0
CH 1
CH 2
CH 3
feeder
Densities 66 - 225 m, Test V
D
e
n
s
i
t
y

[
a
.
u
.
/
f
t
]
F
e
e
d
e
r

s
p
e
e
d

[
r
p
m
]
Fig. 3.2: Density measurement Fig. 3.3: Velocity measurement
0
500
1000
1500
2000
2500
3000
3500
4000
4500
1
3
:0
4
1
3
:1
1
1
3
:1
9
1
3
:
2
6
1
3
:
3
4
1
3
:4
1
1
3
:4
9
1
3
:5
7
1
4
:
0
4
1
4
:1
2
1
4
:1
9
1
4
:2
7
1
4
:
3
4
1
4
:
4
2
1
4
:4
9
1
4
:5
7
1
5
:0
5
1
5
:
1
2
1
5
:
2
0
0
50
100
150
200
250
300
350
CH 0
CH 1
CH 2
CH 3
feeder
M
a
s
s

f
l
o
w

[
a
.
u
.
/
s
]
Mass Flows 66 - 225 m, Test V
F
e
e
d
e
r

s
p
e
e
d

[
r
p
m
]
Fig. 3.4: Resulting mass flow and feeder signal Fig. 3.5: Mass flow of feeder versus Pf-FLO

0
16
33
49
66
82
98
1
3
:
0
4
1
3
:
1
1
1
3
:
1
9
1
3
:
2
6
1
3
:
3
4
1
3
:
4
1
1
3
:
4
9
1
3
:
5
7
1
4
:
0
4
1
4
:
1
2
1
4
:
1
9
1
4
:
2
7
1
4
:
3
4
1
4
:
4
2
1
4
:
4
9
1
4
:
5
7
1
5
:
0
5
1
5
:
1
2
1
5
:
2
0
CH 0
CH 1
CH 2
CH 3
Velocities 66 - 225 m, Test V
V
e
l
o
c
i
t
y

[
f
t
/
s
]

Mass Flow of Feeder vs.
Pf-FLO, 66 - 225 m, Test I - VI
0
500
1000
1500
2000
2500
3000
3500
4000
4500
0 198 397 595 793 992 1190 1389 1587
CH 0
CH 1
CH 2
CH 3
P
f
-
F
L
O

M
a
s
s

f
l
o
w

[
a
.
u
.
/
s
]
Feeder mass flow [lbs/hr]
All test runs have been plotted as displayed in Figure 3.5. As there is only a constant
factor between [a.u./s] and [g/s], a unified y-axis scaling was used to help evaluate
the influence of different particle sizes (see also Figure 4.8).
4. Results
4.1 Pf-FLO Measurement Accuracy
Figures 4.1 and 4.2 illustrate results only for the 50/50 particle mix. Results for other
particle fractions are listed in the tabulations in Sections 4.1.1 and 4.1.2.
Mass Flow of Feeder versus Pf-FLO; 66 - 225 m, Test I - VI
0
500
1000
1500
2000
2500
3000
3500
4000
4500
0 198 397 595 793 992 1190 1389 1587

P
f
-
F
L
O

m
a
s
s

f
l
o
w

[
a
.
u
/
s
]
Channel 0
Channel 1
Channel 2
Channel 3
lin average
Standard deviation [a.u./s]: 158
Fig. 4.1: Evaluation of all test runs with 66 / 225 m particles
The diagram in Figure 4.1 shows the evaluated results for all measuring channels
versus the feeder mass flow. The mass flow signals of all channels were averaged
for each feeder step and one particle fraction, and a linear coefficient was determined
for it. With this coefficient the linear average was calculated as it can be seen in the
diagram, indicated with lin. average. Based on the linear average the standard
deviation was determined for each measuring channel as listed in Table 4.1.
The repeatability of one channel for all tests and one particle size is exemplarily
displayed in Figure 4.2. For other measuring channels and particle fractions, see
tabulations in Section 4.1.2.

Repeatability of Channel 0; 66 225 m Particles, All Tests
0
500
100
1500
2000
2500
3000
3500
4000
4500
0 397 793
1190 1587

P
f
-
F
L
O

m
a
s
s

f
l
o
w

[
a
.
u
.
/
s
]

Test No. I 72 ft/s
Test No. II 82 ft/s
Test No. III 92 ft/s
Test No. IV 72 ft/s
Test No. V 82 ft/s
Test No. VI 92 ft/s
(Standard Deviation: 3.3 %)
Fig. 4.2: Repeatability of channel 0 for 66 - 225 m particles
4.1.1 Absolute Deviation
The standard deviation of one particle fraction from the linear average of all channels
is listed in Table 4.1. The errors in % refer to the maximum mass flow determined at
300 rpm feeder speed.
Particle Size Channel Test No.
Number of
Measurements
Standard
Deviation
[a.u./s]
Max. Mass
Flow
[a.u./s]
Mean
Error
%
66 m CH0 - CH3 Test I - VI 144 109 2462 4.4%
225 m CH0 - CH3 Test I - III 72 132 3520 3.8%
66 - 225 m CH0 - CH3 Test I - VI 144 158 4000 3.9%
Table 4.1: Standard deviation and mean error for individual particle fractions
4.1.2 Repeatability
The relative deviation of one channel in all tests shows its repeatability. This includes
the scattering of the feeder but excludes systematic deviations from one channel in
comparison to the others. Results for each channel are listed in the Tables 4.2 to 4.4.
Standard Deviation
To Linear
Average
Channel Test No.
Number of
Measurements [a.u./s]
Mean
Error
%
CH 0 Test I - VI 36 75.1 3.1%
CH 1 Test I - VI 36 92.5 3.8%
CH 2 Test I - VI 36 93.4 3.8%
CH 3 Test I - VI 36 72.9 3.0%
The error in % refers to the maximum mass flow at 300 rpm: 2462 [a.u./s]
Table 4.2: Standard deviation of the individual channels with 66 m particles
Standard Deviation
To Linear
Average
Channel Test No.
Number of
Mean
Error
%
CH 0 Test I - III 18 132.3 3.8%
CH 1 Test I - III 18 65.0 1.8%
CH 2 Test I - III 18 151.9 4.3%
CH 3 Test I - III 18 111.7 3.2%
Table 4.3: Standard deviation of the individual channels with 225 m particles
Standard Deviation
To Linear
Average
Channel Test No.
Number of
Mean
Error
%
CH 0 Test I - VI 36 131.7 3.3%
CH 1 Test I - VI 36 114.1 2.9%
CH 2 Test I - VI 36 163.9 4.1%
CH 3 Test I - VI 36 141.2 3.5%
Table 4.4: Standard deviation of the individual channels with 66-225 m particle mix
4.2 Influence of the Particle Size
Another purpose of the tests was to quantify the influence of particle sizes. As the
225 m particles can only be found in smaller percentages in pulverized coal, it is a
practical fraction to resolve particle size dependent influences on density and velocity
measurement. The transferability of the results to the operating condition of coal fired
power plants have to be viewed in relation to the real particle size distributions in coal
pipes. In Section 4.2.3 the results out of the tests are evaluated.
4.2.1 Velocity Measurement

Measured Particle Velocities at Channel 0
0
16
33
49
66
82
98
72 ft/s gas velocity 82 ft/s gas velocity 92 ft/s gas velocity
P
a
r
t
i
c
l
e

v
e
l
o
c
i
t
y

[
f
t
/
s
]

225m
66m
66-225 m mix
Fig. 4.3 Averaged particle velocities at channel 0
The measurements with 225 m particles showed a difference of about 16.4 ft/s
between airflow and particle velocity. This is due to the change in the aerodynamic
properties which increase the slip between particles and gas. The weight of particles
changes proportional to D but the cross section only changes proportional to D.
The velocity of the 66 m particles, as well as the 50/50 mix, was found to be very
close to the airflow velocity. The reason can be found by comparing the electrostatic
signal strength. The electrostatic signal strength of the 225 m particles was found to
be significantly lower than for 66 m. But the particle number increases with the
relation of particle diameters to the power of three (see above). With a 50/50 particle
mixture by weight, the number of 66 m particles is about 28 times greater than for
the 225 m particles. The cross correlation method resolves the time shift of the
sensor signals by comparing their highest identity. If the signal strength of two time
shifts is of the same order, it might be possible to distinguish between the two
velocities. In case of the particle mix the signal strength of the 225 m particles was
below the noise signal level of the 66 m particles. Therefore, it is obvious that only
the velocity of the 66 m particles has been measured. The error in relation to the
realistic particle size distribution is estimated in Section 4.2.3.

Velocities of the 225 m Particles
0
16
33
49
66
82
98
72 ft/s gas velocity 82 ft/s gas velocity 92 ft/s gas velocity
v
e
l
o
c
i
t
y

[
f
t
/
s
]

CH0
CH1
CH2
CH3
Fig. 4.4: Acceleration along the test duct of the 225 m particles
In the tests which measured 225 m particles only, channel 3 was found to have
higher velocities than the other channels. This can be explained by the position of
this sensor pair located at the end of the horizontal test duct with the longest straight
run after a bend (see Figure 2.1). This leads to a certain acceleration, especially for
the bigger sized particles.
Influence of Mass Flow on Velocity of the Particle Mix
67
72
79
85
92
98
0 397 793 1190 1587
Feeder [lbs/hr]
v
e
l
o
c
i
t
y

[
f
t
/
s
]
CH 0
CH 1
CH 2
CH 3
Fig. 4.5: Influence of the mass flow on the velocity of the particle mix in Test IV-VI
Figure 4.5 shows the influence of the mass flow on particle velocity. This effect, here
illustrated for the particle mix, is obvious when the averaged velocity of each feeder
step is plotted over the mass flow as it is done in Figure 4.5. Each bundle of the four
channels represents one step of the airflow velocity.
The higher the airflow velocity the higher the influence from pf load in the pipe.
Channel 2 with the shortest distance from a bend seems to be affected most. It is
assumed that this effect is related to particle interaction between 66 m and 225 m
particles, the latter having significantly lower velocities.
4.2.2 Density Measurement
Densities 66 m Particles, Test V
0
6.1
18.3
24.4
30.5
36.6
42.7
1
3
:
3
2
1
3
:
4
1
1
3
:
5
0
1
3
:
5
8
1
4
:
0
7
1
4
:
1
6
1
4
:
2
5
1
4
:
3
4
1
4
:
4
2
1
4
:
5
1
1
5
:
0
0
1
5
:
0
9
1
5
:
1
8
1
5
:
2
7
1
5
:
3
6
1
5
:
4
5
1
5
:
5
4
0
50
100
150
200
250
300
350
400
CH 0
CH 1
CH 2
CH 3
feeder
D
e
n
s
i
t
y

[
a
.
u
.
/
f
t
]
F
e
e
d
e
r

s
p
e
e
d

[
r
p
m
]
Fig. 4.6: Density measurement with 66 m particles Test V.
Densities 225 m Particles, Test I
0
15.2
30.5
45.7
61.0
76.2
1
0
:
1
4
1
0
:
2
0
1
0
:
2
7
1
0
:
3
3
1
0
:
4
0
1
0
:
4
6
1
0
:
5
3
1
0
:
5
9
1
1
:
0
6
1
1
:
1
2
1
1
:
1
9
1
1
:
2
5
1
1
:
3
2
1
1
:
3
8
1
1
:
4
5
1
1
:
5
1
1
1
:
5
8
1
2
:
0
4
1
2
:
1
1
1
2
:
1
7
0
50
100
150
200
250
300
350
400
CH 0
CH 1
CH 2
CH 3
feeder
D
e
n
s
i
t
y

[
a
.
u
.
/
f
t
]
F
e
e
d
e
r

s
p
e
e
d

[
r
p
m
]
Fig. 4.7: Density measurement with 225 m particles Test I
The diagrams in Figures 4.6 and 4.7 show the particle size dependent scattering of
the densities in two test runs. The more extended scattering of the density signal for
66 m particles also increases with the load or particle numbers. With the 225 m
particles there was less scattering although the densities in Figure 4.7 were nearly
twice as high. The fluctuation quantity for the particle mix is higher than the one for
the 225 m, but less than the one for the 66 m particles and was also influenced by
the load (see Figure 3.4).
The scattering of measurement is proved to be realistic and relates to the density
fluctuations of the particle flow. The different behavior can be explained with the
mean free path between particle collisions. The 66 m particles have less particle-
wall collisions but more particle-particle collisions in a smaller volume. Local high
and low density concentrations do not average out within the pipe volume that has
been measured.
4.2.3 Mass flow measurement

Influence of the Particle Size
0
500
1000
1500
2000
2500
3000
3500
4000
4500
0 198 397 595 793 992 1190 1389 1587
Feeder mass flow [lb/hr]
P
f
-
F
L
O

m
a
s
s

f
l
o
w

[
a
.
u
.
/
s
]

lin average 66 m
lin average 200 m
lin average 66 - 200 m
2.885
2.734
2.356
Ratio ([a.u.] to [lbs]):
Fig. 4.8: Influence of the particle size on the Pf-FLO measurement
The diagram in Fig. 4.8 shows the ratio of arbitrary units [a.u./sec] to mass [g] taken
from the linear averages of the four measurement channels. This factor was found to
be a function of the used particle fraction. The temporarily applied arbitrary units to
frequency factor of 500 (see section 2.3) has to be divided by this ratio to get the
calibrated mass flow signal for each particle fraction. The resulting k
fd
is displayed in
Table 4.5.
Particle Fraction ratio [a.u./lbs] k
fd
[g/m kHz]
66 m particles 2.3562 26.7
225 m particles 2.7342 23.0
66-225 m particle mix 2.8854 21.8
Table 4.5: Ratio of arbitrary units to mass and the resulting
mass frequency factor k
fd
for each particle fraction
The deviation of 13.8 % between the 66 and 225 m particles can be regarded as
dependent on particle size. The deviation of the 66 225 m particle mix is due to
the deviation of the velocity measurement described in Section 4.2.1.
The results have to be compared with the real particle size distribution in a coal pipe
after classifier. These deviations have influence only on the absolute accuracy but
not on the relative accuracy between several pipes of one mill since a segregation of
particle fractions between several pipes is not probable.
The following calculations are linear estimations of the error in real particle size
distributions within the results of the tests: For an examplary particle distribution of
15% >90 m and 0.2 % >225 m it was assumed to have a discrete mixture out of
84.8 % 66 m particles, 15 % 145 m particles and 0.2 % 225 m particles. The
relation of the diameters was taken to interpolate the velocity of the 145 m particles
linear between the velocities of the 66 m and 225 m particles. Also the relation of
the diameters was taken to interpolate the deviation of density measurement for
145 m particles linear between the densities of the 66 and 225 m particles.
Deviation caused by Particle Size
0
20
40
60
80
100
120
100% 66 m 89.9% 66m
10.0% 145m
0.1% 225m
84.8% 66m
15.0% 145m
0.2% 225m
79.0% 66m
20.0% 145m
1.0% 225m
R
e
l
a
t
i
v
e

m
a
s
s

f
l
o
w

[
%
]
225 m
145 m
66 m
100.0 101.2 101.8 102.5
Fig. 4.9: Estimated deviation by modeled particle size distribution
The results of the estimation are shown in Figure 4.9. If the distribution changes from
column 2 to 3, the estimated error is about 0.6 % of the mass flow. The distribution of
the last column shows a 2.5 % error but this change in particle distribution is meant
to be quite unrealistic in an optimized milling process and will also influence the
combustion badly.
5. Abstract
A reference test at the pneumatic conveying test plant of the Lehrstuhl fr
Mechanische Verfahrenstechnik at the University of Halle- Wittenberg was
established to prove the accuracy of a flow measurement system for air-solid flows.
The test facility consists of a calibrated screw feeder, a pipe system with vertical and
horizontal elements, and the particle separation equipment. Glass beads were used
as a test medium whose physical properties are comparable to coal dust if taking into
account the measurement principle. In addition to the single sized test materials with
diameters of 66 m and 225 m, a 50/50 mixture by weight of both particle sizes was
used. The experimental matrix for the tests covered the usual operational range for
the throughput and the velocity in coal pipes of power plants.
In total, four measurement instruments were located at two locations in the upward
run and two locations in the horizontal run of the test pipe. From the measured
density and velocity signals of the particles the mass flow was calculated in each
case and compared with the calibrated feeder signal. The measuring error was
related to a single standard deviation.
As a result, the measured deviation from the feeder signal is < 4.5 %; this applies to
the entirety of all four measuring points and all particle fractions. For individual
sensors the deviation lies in the range between 1.8 % to 4.3 %, and is in this case
not significantly dependent on the used particle size.
In addition, investigations of the influence of the particle size were carried out. Within
the wide range of the used particle fractions, the density and velocity measurement
showed some size dependencies. However, the measured differences have only little
influence on the accuracy (< 0.6 %) since in utility plants the grading of coal dust
usually changes only in a comparable small range.
IBAM
TM
AIR MONITOR
POWER DI VI SI ON
IBAM
Performance Benefits
combination of fixed and/or adjustable inlet sleeve/disk
dampers, and in most installations the burners are equipped
with actuators to facilitate DCS controlled modulation of burner
SA airflow corresponding to varying fuel loads. Unfortunately
some low NO
x
burners come equipped with a non-calibrated
airflow sensing device and most others lack any means to
determine how much SA is entering the burner, resulting in
the need for extensive burner tuning targeted at meeting the
manufacturers NO
x
and CO emissions guarantees but not
repeatable or maintainable long term over varying load
conditions.
J ust as there are variances in fuel distribution to each burner,
multiple burners served by a common or partitioned wind box
can have substantial burner-to-burner imbalances in SA.
Accurate and repeatable measurement of individual burner
SA requires Air Monitor Powers IBAMs, airflow probes that
are economically feasible to retrofit into existing burners and
yet able to accommodate a variety of design challenges
the absence of any undisturbed cross section of airflow
passage; an installation location typically downstream of a
modulating inlet sleeve, disk or damper; a broad range of
boiler operating conditions; the presence of fly ash particulate
and 1200F operating temperatures; and for wall fired burners
the broad range of airflow pitch and yaw vectors produced by
the adjustable swirl angle blades.
The Need for Burner Airflow Measurement
The objectives in the power industry today are twofold; to
lower emissions, and increase plant performance. Precise
measurement of combustion airflow and fuel rates positively
contributes to achieving those objectives by providing the
information needed to optimize burner stoichiometric ratios
and facilitate more complete, stable combustion. As indicated
by the following chart, optimization of the key combustion
parameters of NO
x
, O
2
, LOI, CO, and boiler efficiency only
occurs within a narrow range of air-to-fuel ratios.
Traditional coal fired power plants lacked any means to
measure and control airflow into individual burners. New
burner designs prompted by Clean Air Act attainment levels
for NO
x
reduction are typically comprised of inner and outer
airflow barrels to introduce secondary air (SA) to the flame
ball, adjustable swirl angles blades in each barrel, a
O
2
Provi des burner-to-burner relative secondary air

measurement to within 5% accuracy.
Faci l i t at es control of individual burner stoichiometry and

air-to-fuel ratio.
Increases the manageable range of burner turndown.
Reduces unburned carbon in flyash.
Permi t s burner-to-burner balancing of secondary airflow,

intentional burner airflow biasing, or burner plus OFA
combustion staging.
CO
NO
x
Reduces CO and the potential for corrosion in the lower

furnace.
Reduces NO
x
through furnace operation with less excess
air.
Reduces burner throat slagging.
Saf el y reduces excess O

2
.
Substantial reductions in NO
x
levels are obtained when the
IBAMs accurate SA measurement is integrated into DCS burner
control to dynamically maintain burner-to-burner airflow balance
or a bias strategy corresponding to the varying fuel loads. The
addition of a Pf-FLO System for coal flow measurement permits
control of SA to achieve individual burner stoichiometry
objectives, safely lowering overall NO
x
and excess O
2
while
simultaneously reducing areas of high CO that otherwise produce
undesirable slagging and water wall corrosion.
O
p
t
i
m
u
m

Z
o
n
e
C
o
m
f
o
r
t
Z
o
n
e
Design & Testing
Air Monitor Power IBAMs have been applied to virtually every
OEM and after-market burner design; each one custom
engineered to reflect the user's unique burner or OFA port,
and windbox configurtaion. Based upon the Fechheimer-Pitot
measurement technology, the IBAM design process draws
from a broad array of construction options: Quantity and
pattern of individual total pressure (TP) and static pressure
(SP) sensing holes, CW and/or CCW rotation of the individual
TP and SP sensing probes; rotation of the entire IBAM
assembly, special high temperature materials and abrasion
resistant Tungsten Carbide coatings. Wind box configuration
and burner symmetry guide the quantity of IBAMs needed to
obtain desired accuracy and repeatability.
Each IBAM design is extensively tested and characterized in
Air Monitor Powers large scale test duct using a full size
mock up of the wall fired burner or corner fired control damper,
with testing conducted over a broad matrix of customer
specific sleeve damper or inlet disk positions, swirl angle
settings, and boiler operating conditions. The result is a multi-
order polynomial equation, with one or two variables, to
accurately correlate the TP and SP signals from the IBAMs
plus damper or disk position into mass flow with an accuracy
of 5%.
CAMS
The Air Monitor Power CAMS
TM
Combustion Airflow
Management System is designed to fulfill the need for a
reliable and accurate means of flow measurement in
combustion airflow applications.
Combined into a single engineered package are the CAMM
TM
Combustion Airflow Management Module containing the
microprocessor based instrumentation to measure the airflow
and manage the purge cycle, and AUTO-purge to protect
against any degradation in performance of the duct mounted
measurement device(s) due to the presence of airborne
particulate.
IBAM Probe
For Wall Fired Applications
Offset Fechheimer static pressure sensors.
Chamfered total pressure sensors.
All welded Type 316 stainless steel.
Optional Inconel, 310SS, and Tungsten Carbide coated.

IBAM SAP/TFA
For Corner Fired Applications
Type 316 stainless steel pressure sensing chamber.
Reverse Fechheimer pressure sensing ports.
Bolted construction permits disassembly for long-term

maintenance.
Test Duct Windbox with Burner Mock-up
125-510 (04-09)
CEMS
TM
Conti nuous Emi ssi ons Moni tori ng System
TM
complying with the Clean Air Acts stringent emission measurement standards and
the requirements of 40 CFR 75. Air Monitor has assembled a cost effective integrated
system consisting of in-stack flow measurement equipment and companion
instrumentation to provide continuous, accurate, and reliable volumetric airflow
monitoring of stacks and ducts of any size and configuration.
CA
TM
Combusti on Ai rfl ow Measuri ng Stati on & VOLU-probe/SS
TM
Traverse Probes. Air Monitor Power's duct mounted airflow measurement devices
have been designed to accurately and repeatedly measure air mass flow in power
plants. The Combustion Air (CA) Station
TM
includes honeycomb air straightener to
accurately measure in shorter straight duct runs than any other flow measurement
device. The VOLU-probe/SS
TM
delivers accurate airflow measurement performance
in the form of an insertion probe. Both devices feature Type 316 stainless steel flow
sensing arrays.
Engi neeri ng & Testi ng Servi ces. Air Monitor Power offers complete engineering and testing to analyze air and
coal delivery systems. Air Monitor Powers field testing services use 3D airflow traversing and Pf-FLO coal flow
measurement systems for the highest possible accuracy. To ensure cost effective and accurate solutions, Air Monitor
Power has full scale physical flow modeling capability and in house Computational Fluid Dynamics (CFD). CFD analysis
is used to analyze flow profiles and design/redesign ductwork to improve overall performance. Full scale model fabrication
and certified wind tunnel testing is used to develop application specific products that will measure accurately where no
standard flow measurement can.
Pf-FLO
TM
Pul veri zed Fuel Fl ow Management
The Pf-FLO
TM
pulverized coal fired combustion applications, providing boiler operators with the real-
time data needed to balance coal mass distribution between burners. Balanced fuel
improves combustion efficiency and lowers emissions while reducing in-furnace
slagging, coal layout, fuel slagging, and coal pipe fires.
VOLU-probe/SS
TM
Stai nl ess Steel Ai rfl ow Traverse Probes.
Multi-point, self-averaging, Pitot-Fechheimer airflow traverse probes with integral
airflow direction correcting design. Constructed of Type 316 stainless steel and
available in externally and internally mounted versions for harsh, corrosive or high
temperature applications such as fume hood, laboratory exhaust, pharmaceutical,
and clean room production and dirty industrial process applications.
AIR MONITOR
POWER DI VI SI ON
A
A
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D
B
B
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R
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L
L
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E
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Post Office Box 15040
Worcester, MA 01615-0040
http://www.dbriley.com
Post Office Box 15040
Worcester, MA 01615-0040
http://www.dbriley.com
RST-153
ACCURATE BURNER
AIR FLOW MEASUREMENT
FOR LOW NO
x
BURNERS
by
Dave Earley
AMC Power
and
Craig Penterson
DBRiley, Inc.
Presented at the
Eighth International J oint ISA POWID/EPRI
Controls and Instrumentation Conference
J une 15-17, 1998
Scottsdale, Arizona
DB Ri l ey, I nc. 1998
ACCURATE BURNER AIR FLOW
MEASUREMENT FOR LOW NO
x
BURNERS
by
Dave Earley
AMC Power
and
Craig Penterson
DB Riley, Inc.
ABSTRACT
I n 1990, Congress enacted an amendment to the Clean Air Act that required reductions in
NO
x
emissions through the application of low NO
x
burner systems on fossil fueled utility
steam generators. For most of the existing steam generator population, the original burning
equipment incorporated highly turbulent burners that created significant in-furnace flame
interaction. Thus, the measurement and control of air flow to the individual burners was
much less critical than in recent years with low NO
x
combustion systems. With low NO
x
sys-
tems, the reduction of NO
x
emissions, as well as minimizing flyash unburned carbon levels,
is very much dependent on the ability to control the relative ratios of air and fuel on a per-
burner basis and their rate of mixing, particularly in the near burner zones.
AMC Power (AMC) and DB Riley, I nc. (DBR), and a large Midwestern electric utility have
successfully developed and applied AMCs equipment to low NO
x
coal burners in order to
enhance NO
x
control combustion systems. The results have improved burner optimization and
provided real time continuous air flow balancing capability and the control of individual burner
stoichiometries.
To date, these enhancements have been applied to wall-fired low NO
x
systems for balanc-
ing individual burner air flows in a common windbox and to staged combustion systems.
Most recently, calibration testing in a wind tunnel facility of AMCs individual burner air
measurement (I BAM) probes installed in DB Rileys low NO
x
CCVburners has demon-
strated the ability to produce reproducible and consistent air flow measurement accurate to
within 5%.
This paper will summarize this product development and quantify the benefits of its
application to low NO
x
combustion systems.
2
INTRODUCTION
I n an effort to provi de greater control of combusti on ai r fl ow and subsequent burner
stoichi ometry on mul ti pl e l ow NO
x
burner i nstal l ati ons, DB Ri l ey and AMC Power,
i n cooperati on wi th a l arge Mi dwestern el ectri c uti l i ty company, have devel oped a uni que
probe for accuratel y measuri ng burner ai r fl ow. These probes, referred to as i ndi vi dual burn-
er ai r measurement (I BAM ) probes, are currentl y used i n al l DB Ri l ey l ow NO
x
burners.
The benefi ts of better ai r fl ow control i n l ow NO
x
burner i nstal l ati ons i s the abi l i ty to oper-
ate at l ower NO
x
l evel s and/or l ower unburned carbon l evel s i n the fl yash.
Thi s paper focuses on the devel opment, appl i cati on and benefi ts of the I BAM probes
speci fi cal l y i n DB Ri l ey l ow NO
x
CCVcoal burners. The paper al so di scusses the benefi ts
of accuratel y measuri ng combusti on ai r fl ow i n other l ow NO
x
systems such as overfi re ai r
(OFA), secondary ai r i n cycl ones, and pri mary ai r i n pul veri zer systems.
REVIEW OF CCV BURNER TECHNOLOGY
DB Ri l ey has been usi ng CCVburners for reduci ng NO
x
emi ssi ons from pul veri zed coal
fi red uti l i ty boi l ers for many years. Wi th over 1500 l ow NO
x
coal burners bei ng suppl i ed to
the uti l i ty i ndustry si nce 1990, the CCVtechnol ogy has devel oped i nto a fami l y of l ow
NO
x
burners i ncl udi ng the CCVsi ngl e regi ster, dual ai r zone and cel l burner desi gns.
Thi s wi de range of desi gns al l ows the fl exi bi l i ty to sel ect a desi gn most sui tabl e for a par -
ti cul ar appl i cati on, based on NO
x
reducti on requi rements, boi l er confi gurati on, and budget
constrai nts.
Fi gure 1 shows schemati c drawi ngs of the three l ow NO
x
coal burner desi gns. Common
to these desi gns i s a uni que patented venturi coal nozzl e technol ogy (U.S. Patent No.
4,479,442) whi ch was devel oped i n the earl y 1980s for reduci ng NO
x
emi ssi ons on coal fi red
uti l i ty boi l ers. The venturi nozzl e, l ow swi rl coal spreader and secondary ai r di verter i n al l
of these desi gns produce a fuel ri ch fl ame core, the fundamental condi ti ons necessary for
mi ni mi zi ng the formati on of both fuel and thermal NO
x
2
.
The combusti on ai r si de of the CCVburner desi gn i s si mi l ar for si ngl e regi ster and cel l
burner appl i cati ons. Secondary ai r i ni ti al l y passes through the ai r regi ster, whi ch i mparts
swi rl , and then through the burner barrel and over the secondary ai r di verter. Secondary
ai r i s di verted away from the pri mary combusti on zone whi ch rei nforces the fuel ri ch fl ame
core produced by the venturi nozzl e for further control of NO
x
emi ssi ons.
As shown i n the schemati c, the ai r fl ow measurement devi ces or I BAM probes are radi -
al l y i nserted i nto the burner barrel for measuri ng secondary ai r fl ow on an i ndi vi dual burn-
er basi s. As di scussed l ater i n thi s paper, the probes were uni quel y desi gned and strategi -
cal l y l ocated to provi de accurate measurement of ai r fl ow i n thi s hi ghl y turbul ent, swi rl i ng,
non uni form fl ow fi el d produced by the ai r regi ster of si ngl e regi ster and cel l burner desi gns.
The ai r regi ster used on the CCVdual ai r zone burner desi gn contai ns axi al swi rl vanes
i nstal l ed i n both the secondary and terti ary ai r passages of the burner. The I BAM probes
for thi s desi gn are posi ti oned i mmedi atel y upstream of the axi al swi rl vanes where the fl ow
fi el d i s more uni form, axi al , and non-swi rl i ng. Accurate measurement of both secondary and
terti ary ai r fl ow on a per-burner basi s i s i mportant to establ i sh the proper fl ow spl i t for mi n-
i mi zi ng NO
x
i n thi s burner desi gn.
3
Figure 1 DB Riley Low-NO
x
CCV Burners
CCV Single Register Burner CCV Cell Burner
CCV Dual Air Zone Burner
REVIEW OF AMC POWER FLOW MEASUREMENT TECHNOLOGY
The fl ow measurement technol ogy used i n DB Ri l ey CCVburners i s based upon AMC
Powers VOLU-probedesi gn (U. S. Patent 4,559,835). The VOLU-probei s a mul ti pl e
poi nt, sel f-averagi ng pi tot tube requi ri ng very l i ttl e strai ght duct run to mai ntai n an accu-
rate fl ow si gnal .
The VOLU-probeoperates on the Fechhei mer Pi tot deri vati ve of the mul ti -poi nt, sel f-
averagi ng pi tot pri nci pl e to measure the total and stati c pressure components of ai rfl ow.
Total pressure sensi ng ports, wi th chamfered entrances to el i mi nate ai r di recti onal effects,
are l ocated on the l eadi ng surface of the VOLU-probeto sense the i mpact pressure (Pt) of
the approachi ng ai rstream (Fi gure 2). Fechhei mer stati c pressure sensi ng ports, posi ti oned
at desi gnated angl es offset from the fl ow normal vector, mi ni mi ze the error-i nduci ng effect
4
of di recti onal i zed, non-normal , ai rfl ow. As the fl ow di recti on veers from normal (Fi gure 3),
one stati c sensor i s exposed to a hi gher pressure (Ps + part of Pt) whi l e the other i s exposed
to a l ower pressure (Ps - part of Pt). For angul ar fl ow where a = 30 degrees offset from nor-
mal , these pressures are offsetti ng and the pressure sensed i s true stati c pressure. I t i s thi s
uni que desi gn of offset stati c pressure and chamfered total pressure sensors that make the
VOLU-probei nsensi ti ve to approachi ng mul ti -di recti onal , rotati ng ai rfl ow wi th yaw and
pi tch up to 30 degrees from normal , thereby assuri ng the accurate measurement of the
sensed ai rfl ow rate wi thout the presence of ai rfl ow strai ghteners upstream.
Figure 2 VOLU-probe With Total Pressure Sensing Ports
Figure 3 VOLU-probe with Static Pressure Sensing Ports
AMC Power then appl i ed these VOLU-probesto DB Ri l eys CCVburner desi gns.
The resul ti ng assembl y was referred to as I BAM or i ndi vi dual burner ai r measurement
probes. A photograph of a typi cal I BAM probe assembl y i s shown i n Fi gure 4. As shown
i n Fi gure 5, the mul ti pl e poi nt sensors used i n the I BAM probes al so mi ni mi zes the error
caused by fl ow strati fi cati on.
The Fechhei mer pi tot method of fl ow measurement i n a burner al l ows for true axi al fl ow
measurement even when fl ow vectors are non-axi al . Thi s i s where tradi ti onal fl ow measur-
i ng devi ces (stati c pressure compari sons, forward-reverse pi tot tubes, pi ezometer ri ngs, ther-
5
Figure 5 Burner Register Flow Stratification
Figure 4 Typical IBAM Probe Assembly for Burner Air Flow Measurement
mal anemometers and more) fal l short. I n fact, because many of these other devi ces cannot
di sti ngui sh axi al fl ow from swi rl i ng fl ow, the use of them can actual l y l ead to a user unbal -
anci ng previ ousl y bal anced burners. That i s, two (or more) burners may have the same true
axi al fl ow but because the fl ow vectors approach the fl ow measuri ng devi ces at varyi ng
angl es, the fl ows are i nterpreted as bei ng di fferent.
Thermal anemometers are not sui tabl e for burner bal anci ng because an RTD or resi s-
tance temperature detector i n a fl ow stream cannot determi ne angul ar fl ow from axi al fl ow.
That i s, thermal anemometers are cal i brated for certai n condi ti ons and i f these same condi -
ti ons are not met, the cal i brati on coeffi ci ents wi l l be i ncorrect. I f two anemometers for two
di fferent burners are cal i brated to the same fl ow condi ti on (i .e. axi al fl ow) and they have the
same axi al fl ows but thei r angul ar ori entati ons are di fferent, they may read di fferentl y.
6
The resul t i s that because burners l ack strai ght duct run and because fl ow i n burners
becomes di recti onal i zed from fl ow obstructi ons such as swi rl vanes and regi ster vanes, tra-
di ti onal fl ow-measuri ng devi ces have proven to be i neffecti ve.
INTEGRATION AND TESTING OF AN IBAM PROBES
IN DB RILEY CCV BURNERS
Fi gure 6 shows the typi cal appl i cati on of AMC Powers I BAM probes to a CCVsi ngl e
regi ster burner barrel . Two stai nl ess steel probe assembl i es, wi th both total and stati c pres-
sure tubes, are i nstal l ed perpendi cul ar to the burner barrel and connected by appropri ate
tubi ng to a l ocal pressure gage mounted on the burner front or to a fl ow transmi tter. The
probes are uni quel y desi gned and ori ented for accurate measurement of secondary ai r fl ow
i n the swi rl i ng non-uni form fl ow fi el d.
S
t
a
t
i
c

P
r
e
s
s
u
r
e
T
o
t
a
l

P
r
e
s
s
u
r
e
Typical
Probe Assembly
Figure 6 Application of IBAM Probes to DB Riley CCV Single Register Burner
Testi ng of the probes i n l ate 1995 on a 600 MW uti l i ty boi l er equi pped wi th DB Ri l ey
CCVsi ngl e regi ster cel l burners was performed to determi ne the number of probe assem-
bl i es that woul d actual l y be requi red to produce a representati ve fl ow i ndi cati on or mea-
surement. Data were col l ected for 2, 3, and 4 probe assembl i es. The resul ts suggested that
2 or 3 probe assembl i es were suffi ci ent provi ded the probes are careful l y l ocated to precl ude
any adverse effects of fl ow obstructi ons or di sturbances caused by i gni tors, scanner tubes,
and nozzl e support l egs. The actual accuracy of the probe measurement coul d not be eval u-
ated si nce onl y a smal l number of burners were equi pped wi th the I BAM probes. However,
the resul ts were found to be very repeatabl e duri ng subsequent tests several months l ater.
Testi ng of the I BAM probes i n a 100 mi l l i on Btu/hr (29 MW) CCVdual ai r zone test
burner at Ri l ey Research was performed i n mi d-1995 to eval uate probe l ocati on i n the burn-
er barrel and probe angl e or ori entati on wi th respect to the burner axi s when i nstal l ed
downstream of the axi al swi rl vanes i n the secondary ai r annul us. The DB Ri l ey Research
7
Combusti on Test Faci l i ty, shown i n Fi gure 7, can test a si ngl e ful l -scal e coal burner for a
wi de range of fi ri ng condi ti ons
3
.
Resul ts of l ocati ng one probe assembl y at 0, 120, or 240 CCW from top dead center
showed no si gni fi cant vari ati on i n the fl ow measurement. Thi s i ndi cated good peri pheral
di stri buti on of ai r wi thi n the secondary ai r annul us. However, the probe angl e was sensi ti ve
Figure 7 Aerial View of the Combustion Test Facility at
DB Riley Research, Worcester, Massachusetts
to the swi rl vane posi ti on i n regard to accurate fl ow measurement. Vari ous probe angl es
were tested whi ch resul ted i n an opti mum angl e that appeared to be the l east sensi ti ve to
swi rl vane angl e or posi ti oni ng. Wi th the probe ori ented and posi ti oned at opti mum setti ngs,
the error i n the I BAM probe ai r fl ow measurement rel ati ve to the ASME venturi fl ow mea-
surement was onl y +2%.
More recentl y, extensi ve testi ng was performed i n AMCs wi nd tunnel faci l i ty i n Santa
Rosa to actual l y cal i brate the I BAM probes i nstal l ed i n a CCVsi ngl e regi ster l ow NO
x
burner manufactured for subsequent i nstal l ati on i n a 260 MW Mi dwestern uti l i ty boi l er.
AMCs wi nd tunnel faci l i ty i s equi pped wi th mul ti pl e ASME fl ow nozzl es for preci se ai r fl ow
measurement. The purpose of the testi ng was to quanti fy the accuracy of the I BAM probes,
confi rm the opti mum probe angl e or ori entati on from previ ous fi el d and l aboratory testi ng,
and to eval uate the axi al posi ti oni ng of the I BAM probes rel ati ve to the ai r regi ster.
Fi gure 8 i s a photograph of the CCVburner i nstal l ed i n the AMC wi nd tunnel faci l i ty.
The I BAM probes were at the 1:30 and 6:00 cl ock posi ti ons i n the photograph. A Pl exi gl as
tube was used to si mul ate an oi l i gni tor whi l e a cardboard sono tube was used to si mul ate
the coal nozzl e.
As shown i n Fi gure 9, the resul ts i ndi cated the vari ance or error i n the I BAM fl ow
measurement, when compared to the fl ow measured usi ng the ASME nozzl es typi cal l y var-
i ed from -1% to +13% for a wi de range of burner setti ngs (vari ous regi ster vane and shroud
8
Figure 8 IBAM Probe Calibration Testing in AMCs Wind Tunnel Facility
Figure 9 IBAM Flow Variance for Various Shroud Position and Register Vane Settings
setti ngs) tested. The error band was reduced to +5% to +10% for more normal burner set-
ti ngs. Typi cal l y, on mul ti pl e burner i nstal l ati ons, regi ster or swi rl vanes are al l set to the
same angl e whi l e onl y the burner shrouds are mani pul ated to vari ous posi ti ons as necessary
to bal ance ai r fl ow burner to burner. So, for a gi ven regi ster setti ng of 25 the error band
reduces even more. The test resul ts confi rmed the probe angl e or ori entati on sel ected from
previ ous fi el d and l ab testi ng was sti l l val i d whi l e the axi al l ocati on of the probes rel ati ve to
the ai r regi ster was al so found to be i mportant. The data was observed to be extremel y
repeatabl e.
Future test pl ans are to cal i brate a CCVsi ngl e regi ster l ow NO
x
cel l burner equi pped
wi th I BAM probes i n AMCs wi nd tunnel faci l i ty agai n for subsequent i nstal l ati on i n a
1300 MW uti l i ty boi l er.
9
BENEFITS OF ACCURATE AIR FLOW MEASUREMENT
The benefi ts of havi ng the abi l i ty to accuratel y measure i ndi vi dual burner ai r fl ow i n a
mul ti pl e burner wi ndbox arrangement are si gni fi cant. The fol l owi ng l i sts the most i mpor-
tant benefi ts i n l ow NO
x
combusti on systems.
Capabi l i ty of bal anci ng secondary ai r fl ow burner to burner
Capabi l i ty to del i beratel y bi as ai r fl ow burner to burner i f desi red
I mproved control of NO
x
emi ssi ons and fl yash UBC
I mproved control of i ndi vi dual burner stoi chi ometry and ai r to fuel rati o
I mproved control of burner throat sl aggi ng
Lower excess ai r operati on for l ower NO
x
Greater burner turndown capabi l i ty
Reduces the potenti al for l ower furnace corrosi on
I n thi s regard, DB Ri l ey has standardi zed on the use of AMC Powers I BAM probes for
al l l ow NO
x
coal , oi l , and gas burner appl i cati ons.
The VOLU-probehas al so been successful l y used i n a vari ety of other combusti on ai r
fl ow appl i cati ons. Pul veri zer pri mary ai r fl ow measurement and control i s an i ntegral part
of most l ow NO
x
projects. AMC Power has suppl i ed the ai r fl ow probes for many of these
appl i cati ons, as shown i n Fi gure 10.
Opti mi zi ng ai rfl ow to the mi l l s has been i mportant not onl y for hel pi ng to reduce NOx,
but al so for reduci ng LOI . Pri mary ai rfl ow can ei ther be performed by measuri ng hot and
temperi ng ai rfl ows i ndependentl y or total i zed, after they mi x.
Figure 10 Primary Air Flow Measurement
10
I n an effort to i ncrease overal l boi l er effi ci ency, many pl ants are l ooki ng at ways to el i m-
i nate pressure drop from thei r systems. I n many i nstal l ati ons, ai rfoi l s, venturi s, and/or
dams can be removed from ducts and repl aced wi th VOLU-probes(Fi gure 11), provi di ng
the benefi ts of gai ni ng extra FD fan capaci ty, gai ni ng ai rfl ow, and i mprovi ng the fl ow mea-
surement, whi ch can l ead to control opti mi zati on.
DB Ri l ey and AMC are currentl y worki ng on a project to remove up to 10 w.c. of per-
manent pressure drop from exi sti ng cycl ones by removi ng exi sti ng ai rfl ow measuri ng
devi ces and repl aci ng them wi th devi ces desi gned by AMC. Thi s i mprovement wi l l yi el d
more needed ai rfl ow. I t wi l l al so al l ow for the bal anci ng of cycl ones, hel pi ng NO
x
and mai n-
tenance i ssues. Recentl y performed wi nd tunnel testi ng has shown that these new devi ces wi l l
al l ow for accurate cycl one ai rfl ow measurement as wel l as cycl one bal anci ng to wi thi n 3%.
Overfi re ai rfl ow i s another appl i cati on that has been successful l y performed by DB Ri l ey
and AMC as part of l ow NO
x
systems. Fi gure 12 shows an exampl e of how VOLU-probes
are i nstal l ed i n a typi cal OFA duct on a l ow NO
x
system. Accurate measurement of OFA fl ow
i n each duct provi des the abi l i ty to bal ance the fl ows to each port for better NO
x
and UBC
performance.
Figure 11 Secondary Air Flow Measurement
Flow
Measuring
Device
Figure 12
OFA Air Flow
Measurement
SUMMARY
AMC Power, DB Ri l ey, and a l arge Mi dwestern el ectri c uti l i ty have devel oped
i ndi vi dual burner ai r fl ow measurement probes for accurate measurement of combusti on ai r
fl ow i n DB Ri l ey l ow NO
x
CCVburners. Resul ts of extensi ve cal i brati on testi ng i n com-
busti on test furnaces and wi nd tunnel faci l i ti es have yi el ded measurement accuraci es to
wi thi n 5%. The major benefi t of accurate burner ai r fl ow measurement i s the abi l i ty to bal -
ance burner ai r fl ow and stoi chi ometry i n mul ti pl e burner common wi ndbox appl i cati ons,
CEM SYSTEMS
Continuous Emissions Monitoring
AIR MONITOR
POWER DI VI SI ON
40 CFR 75 Summary
On October 26, 1992, the Environmental ProtectionAgency (EPA)
signed into law Part 75 of the Code of Federal Regulations
governing Continuous Emission Monitoring. First proposed in
December 1991 and subjected to extensive public review, the
finalized version of 40 CFR 75 follows. The full version of 40
CFR 75 outlines the purpose, standards, certification process,
and recordkeeping requirements for monitoring seven emission
parameters:
SO
2
concentration Opacity
CO
2
concentration Volumetric flow
NO
x
concentration Diluent concentration (O
2
or CO
2
)
Moisture concentration
Volumetric Flow Monitoring Systems
Prior to receiving certification by the EPA, a flow monitoring
system must satisfy continuous emission monitoring requirements
via a detailed test procedure to verify that the performance and
system configuration is within the EPA mandated requirements
relative to:
Measurement Location
Interference Check
Calibration Error
Relative Accuracy
Bias
U.S. EPA Requirements for Continuous Emissions Monitoring (CEM)
Bias is a systematic error resulting in measurements that will be
consistently low or high relative to the true flow measurement.
Flow monitors that exhibit the need for low bias will not pass
certification. Flow monitors that exhibit the need for high bias
can have the monitor output values adjusted by a single
correction factor.
Bias
Effective January 1, 2000 the accuracy requirement for
volumetric flow was lowered to 10%. Flow monitors achieving
a relative accuracy of 7-1/2% were granted a reduction in RATA
testing frequency from semi-annually to annuall y.
Correct selection of probe location and quantit y, combined with
field calibration prior to certification permits the Air Monitor flow
monitoring system to achieve annual RATA frequencies.
Relative Accuracy
EPA defines an appropriate location for installation of a CEM
System by referencing 40 CFR 60, Appendix A, Method 2. The
desired location would be one with a minimum of eight stack or
duct diameters downstream and two diameters upstream of
any flow disturbance. Minimum siting requirements are two
downstream diameters and one-half upstream diameter of any
flow disturbances. Provisions are made in 40 CFR 75 to petition
the EPA for an alternate monitoring location when the minimum
site requirements cannot be met.
Measurement Location
Regardless of the technology used to measure flow, all flow
monitoring systems must include a means to ensure the in-stack
equipment remains free of obstructions that would affect
ongoing measurement accuracy. For differential pressure flow
monitors, the requirement is for an automatic timed, periodic
back purge using compressed air to keep the probe sensing
ports clean and expel condensation of wet gases.Air Monitor
meets this requirement with its AUTO-purge/CEM System.
Interference Check
Calibration error is calculated as the percentage differential
bet ween a ref erence val ue and t he act ual moni t or
instrumentation reading. Calibration error must be determined
during the certification process, then dail y, and periodically
thereafter. The daily check of calibration must verify that the
error has not deviated more than 3.0 percent from the reference
value, with excessive deviation necessitating instrumentation
recalibration. Air Monitor's instrumentation, consisting of its
MASS-tron/CEM transmitter with AUTO-cal function, provides
daily reporting of calibration flow outputs for calculation of
calibration error in the DAS.
Calibration Error
RATA FREQUENCY REQUIREMENTS
FOR FLOW MONITORING SYSTEMS
Relative Accuracy
10.0%
7.5%
Semi-Annual
Annual
Required RATA Frequency
To assist in complying with the CleanAir Act's stringent emission
measurement standards, Air Monitor has assembled a cost
effecti ve i ntegrated system consi sti ng of i n-stack fl ow
measurement equipment and companion instrumentation to
provide continuous, accurate, and reliable volumetric flow
monitoring for stacks and ducts of any size and configuration.
System Components
In-Stack Flow Traverse Probe(s)
Required is the means to accurately monitor the average flow
rate and temperature of the stack emissions. Flow rate monitoring
is performed by sensing individual flow components at multiple
points (traversing) across one or more diameters for circular
stacks or along multiple parallel traverses for rectangular stacks,
and averaging the obtained values. Average temperature
measurement is achieved using one or more temperature probes
to obtain a single full traverse of a stack.
The Air Monitor STACK-probe is an airflow traverse probe based
on differential pressure (Pitot-Fechheimer) technology for
measuring airflow; the same technology that will be used during
the certification process to verify relative accuracy of the flow
monitoring system. Each STACK-probe consists of two separate
round tube self-averaging manifolds; one to measure the stack
total pressure, and the other to measure stack static pressure.
Multiple Pitot-Fechheimer ports are positioned on each manifold
on an equal area basis (for rectangular stacks) or on an equal
concentric area (for circular stacks). Similarl y, average stack
temperature is measured using a temperature probe with
multiple sensing elements spaced along the probe length.
The engineered truss type design of the STACK-probe utilizes
tubular structural materials welded to a 6", 150# raised face
pipe flange, permitting cantilever probe mounting in even
extremely large stacks. Standard Type 316 stainless steel
construction ensures long-term durability and continuing
accuracy in most installations, with materials such as Hastelloy
C22 and Inconel available for extreme temperature and/or
severely corrosive applications.
As a basic instrument, the STACK-probe does not require any
initial or periodic calibration to measure flow accuratel y. As a
passive device with no moving parts or active electrical circuits,
removal of the STACK-probe from the stack after installation for
repair or calibration is not required.
Probe Back Purge
Required for differential pressure flow monitoring systems is a
back purging means to ensure that the in-stack flow monitor
probe has its pressure sensing ports and averaging manifold
maintained free of particulate build-up and vapor condensation.
When activated by Air Monitor's MASS-tron/CEM or the Data
Acquisition System (DAS), the AUTO-purge/CEM System
sequentially operates a combination of failsafe valves to
automatically back purge the sensing lines and the S TACK-
probes with high volume/high pressure compressed air for a
short duration, while simultaneously isolating the transmitter
from over-pressurization.
Standard AUTO-purge/CEM construction mounts all components
in a steel NEMA 4 rated enclosure, with all wetted parts made of
copper or brass. The AUTO-purge/CEM is optionally available in
a stainless steel NEMA 4X enclosure, with stainless steel wetted
parts for corrosive applications.
AUTO-purge/CEM MASS-tron/CEM
The Air Monitor MASS-tron/CEM multi-variable, ultra-low
differential pressure transmitter converts the temperature and
differential pressure flow signals received from the in-stack
traverse probe(s) into a continuous output signal representing
the volumetric flow in SCFM (wet or dry basis) being discharged
into the atmosphere.
To meet the calibration error reporting requirements of 40 CFR
75, the MASS-tron/CEM used in stack flow monitoring
applications is equipped withAUTO-cal circuitry. Once every
24 hours, the MASS-tron/CEM executes an AUTO-cal calibration
cycle, during which the transmitter output signal is held at the
last sensed flow level. Sequentially activated valves expose
the MASS-tron/CEM transmitter to reference pressures for zero
and span resulting in corresponding calibration flow outputs,
after which the MASS-tron/CEM resumes normal flow monitoring.
In addition to the local display of information, the MASS-tron/
CEM provides outputs to the DataAcquisition System (DAS) for:
Temperature F 4-20mADC
AUTO-cal Acknowledgment Dry Contact
AUTO-purge Acknowledgment Dry Contact
SCFM 4-20mADC*
Zero Calibration Error Signal 4-20mADC*
Span Calibration Error Signal 4-20mADC*
*Serial Output. See Figure below.
The MASS-tron/CEM is available in either a 19" rack mount or a
NEMA 4 enclosure, with a NEMA 4X stainless steel enclosure
optionally available.
Data Reporting
Data Reporting & Installation Requirements
T
0
T
1
T
2
T
3
T
4
T
0
MASS-tron/CEM internal timer or external dry contact from DAS initiates AUTO-cal cycle. Transmitter output signal for stack flow is
held at the last flow value during the AUTO-cal cycle.
T
1
AUTO-cal relay contact closes. Zero flow output signal begins.
T
2
AUTO-cal relay contact opens. Flow output signal goes to 4mADC.
T
3
AUTO-cal relay contact closes. Calibration flow output signal begins.
T
4
AUTO-cal relay contact opens. Calibration flow output signal ends. Transmitter returns to reporting actual stack flo w.
Purge Air Requirement. 80 to 125 psig at 100 CFM, oil and dirt
free. 1 to 24 purge cycles per day, with a duration of less than 2
minutes during which compressed air is released.
Instrument Air Requirement. 25 to 120 psig instrument air
supply. Per ISA S7.3, required forAUTO-span equipped MASS-
tron/CEM.
Ambient Temperature. 32F to 140F for the AUTO-purge/
CEM panel; 60F to 80F for the MASS-tron/CEM. Recommended
installation is within the environmentally controlled analyzer
instrumentation shelter.
Accumulator Tank (strongly recommended) . Requires
coalescing filter, pressure regulator, and check valve at the tank
inlet.
1 stack traverse 80 gallons
2 stack traverses 120 gallons
Electrical Power Requirements. 120VAC, 10 amp for heater
equipped AUTO-purge/CEM panel; 120VAC, 1 amp for MASS-
tron/CEM.
Line from Accumulator Tank to AUTO-purge/CEM Panel.
25' maximum length, 1/2" pipe (minimum). Recommend locating
accumulator tank as close as possible toAUTO-purge/CEM panel.
Line Size from AUTO-purge/CEM to STACK-probe.
Line from AUTO-purge/CEM Panel to MASS-tron/CEM Panel.
Via pre-manufactured umbilical or SS tubing.
Installation Requirements
AUTO-cal Relay Contact
Normal Flow Value
Flow and AUTO-cal Signals
Distance
Tube Size
< 25'
1/2" S.S. tube
25' to 50'
3/4" S.S. tube
> 50'
1" S.S. tube
Distance
Tube Size
< 25'
1/4" S.S. tube
25' to 200'
3/8" S.S. tube
> 200'
1/2" S.S. tube
Closed
Open
20.0mA (100%)
15.2mA (70%)
4.0mA (0%)
STACK-probe w/Temperature and Insert Port
Typical Installation
In-Stack Probe Configurations Single-Wall Stacks
Dual Traverse Schematic
Typical Installation
AUTO-purge/CEM Located on the Stack Platform
MASS-tron/CEM Located in the Instrumentation Enclosure
Flow Monitor Probe and Test Port Locations
STACK-probe Locations
NOTES:
1. Test ports should be located on a different axis
than flow monitor probe(s) to minimize disturbing
the flow being sensed by the probe(s) during
40CFR60, Appendix A, Method 2 testing.
2. The distance from the flow monitor probe(s) or
test ports to an upstream flow disturbance is 2D
minimum, 8D desirable. The distance from the
flow monitor probe(s) or test ports to
downstream flow disturbance is D/2 minimum, 2D
desirable.
3. The distance between the flow monitor probe(s)
and the test port planes is usually only 6" to 12"
due to practical limitations relative to stack
platform access. Flow disturbances created by
the test probe may affect flow monitor readings
during 40CFR60, Appendix A, Method 2 testing.
4. Considered as flow disturbances are:
Any stack mounted equipment or structure that
protrudes or extends out into the air stream.
Any dimensional changes in the stack.
Any directional changes in the stack.
NOTES:
1. Test ports should be located on the same plane or elevation as
the flow monitor probe(s) to minimize disturbing the flow being
sensed by the flow monitor probe(s) during 40CFR60,
Appendix A, Method 2 testing.
2. If test ports cannot be located on the same plane or elevation
as the flow monitor probe(s) due to insufficient space or
clearance, locate the test ports 2D upstream of the flow
monitor probe(s).
The distance from the flow monitor probe(s) or test ports to an
upstream flow disturbance is 2D minimum, 8D desirable. The
distance from the flow monitor probe(s) or test ports to
downstream flow disturbance is D/2 minimum, 2D desirable.
4. Considered as flow disturbances are:
Any stack mounted equipment or structure that protrudes
or extends out into the air stream.
Any dimensional changes in the stack.
Any directional changes in the stack.
125-491 (7/07)
Air Monitor's Product Families of Air & Coal Flow Measurement Systems
www.airmonitor.com amcsales@airmonito r.com
IBAM
TM
The IBAM
TM
can be obtained through accurate measurement of burner secondary airflo w. The
IBAM
TM
probe has been designed to accurately measure in the particulate laden, high
operating temperature conditions found in burner air passages.
CAMS
TM
Combustion Airflow Management System
The CAMS
TM
TM
contains the microprocessor based instrumentation to measure the airflow and
manage the AUTO-purge. The AUTO-purge is a high pressure air blowback system
that protects the duct mounted flow measurement device from any degradation in
performance due to the presence of airborne particulate (flyash).
Air Monitor's duct mounted airflow measurement devices have been designed to
accurately and repeatedly measure air mass flow in power plants. The Combustion
Air (CA) Station
TM
includes honeycomb air straightener to accurately measure in shorter
straight duct runs than any other flow measurement device. The VOLU-probe/SS
TM
delivers accurate airflow measurement performance in the form of an insertion probe.
Both devices feature Type 316 stainless steel flow sensing arrays.
TM
Traverse Probes
Pf-FLO
TM
The Pf-FLO
TM
pulverized coal fired combustion applications, providing boiler operators with the real-
time data needed to balance coal mass distribution between burners. Balanced fuel
improves combustion efficiency and lowers emissions while reducing in-furnace
slagging, coal layout, fuel slagging, and coal pipe fires.
VOLU-probe/SS
TM
Stainless Steel Airflow Traverse Probes
Engineering & Testing Services. Air Monitor offers complete engineering and testing to analyze air and coal
delivery systems. Air Monitor's field testing services use 3D airflow traversing and Pf- FLO coal flow measurement
systems for the highest possible accurac y. To ensure cost effective and accurate solutions, Air Monitor has full scale
physical flow modeling capability and in house Computational Fluid Dynamics (CFD). CFD analysis is used to analyze
flow profiles and design/redesign ductwork to improve overall performance. Full scale model fabrication and certified
wind tunnel testing is used to develop application specific products that will measure accurately where no standard flow
measurement can.

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POWER CATALOG

Tab Document Name Part Number

Rectangular & circular configurations

AUTO-purge for automatic sensing

Bolt-on or permanently installed

Temperature probe port

Mating flanges for existing duckwork

All wetted tubing, fittings, and valves constructed of copper

Enclosure is NEMA 4 painted steel.

External connection fittings are stainless steel FPT.

All wetted tubing, fittings, and valves constructed of 316

Enclosure is NEMA 4 painted steel.

External connection fittings are stainless steel FPT.

Requires coalescing filter, pressure regulator, and check

25' maximum length, 1/2" pipe (minimum).

Recommend locating accumulator tank as close as

35VA at 24VAC; 20VA at 24VDC; 42VA at 120VAC.

120VAC, 10 amp when an optional enclosure heater is

80 to 125 psig at 100 CFM, oil and dirt free.

If the distance from the CAMS

If the distance from the CAMS

If the distance from the CAMS

For ranges above or below this ambient temperature, the

The frequency () of the H

of the loaded pipe from

Provi des burner-to-burner relative secondary air

Faci l i t at es control of individual burner stoichiometry and

Increases the manageable range of burner turndown.

Reduces unburned carbon in flyash.

Permi t s burner-to-burner balancing of secondary airflow,

Reduces CO and the potential for corrosion in the lower

Reduces burner throat slagging.

Saf el y reduces excess O

Offset Fechheimer static pressure sensors.

Chamfered total pressure sensors.

All welded Type 316 stainless steel.

Optional Inconel, 310SS, and Tungsten Carbide coated.

Type 316 stainless steel pressure sensing chamber.

Reverse Fechheimer pressure sensing ports.

Bolted construction permits disassembly for long-term

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