STANDARD OPERATING MANUAL

ISOKINETEIC DIRTY AIR COAL SAMPLER

TECHMARK ENGINEERS & CONSULTANTS..…

2/5 Gupta Market, Lajpat Nagar – IV, New Delhi – 110 024
Tel. 46570392 – 94 Fax. (11) 41603925
E-Mail. [email protected]
www.techmark.co.in
 

            An ISO 9001 : 2008  Certified

Page 1
 

Table of Contents
1. Isokinetic Coal Sampling Introduction 3
2. Performing Dirty Air Pitot Test 4-5
3. Probe Marking with the ASME Performance 6
4. Static Pressure/Temperature Measurements 7
5. Dirty Air Velocity Measurement 8
6. Performing Coal Sampling 9
7. Coal Flow & Air/Fuel Ratio Calculation 10

Page 2
 

1.0 Isokinetic Coal Sampling

Isokinetic coal sampling is performed to accomplish the following:

1. Ascertain relative pipe to pipe fuel balance.
2. Quantify individual fuel line air to fuel ratios.
3. Quantify pulverizer air to fuel ratio.
4. Quantify individual fuel line velocity and air flow.
5. Ascertain pipe to pipe air flow balance.
6. Quantify fuel line temperature and static pressure.
7. Obtain representative fuel samples for coal fineness analysis.
Quantification of these parameters are required to ascertain pulverizer performance which is paramount in
achieving optimum unit performance. Optimum pulverizer performance would require the following
parameters to be achieved without compromise:

• Pipe to Pipe fuel balance within ±10% of the mean fuel flow.
• Pipe to Pipe dirty air flow balance within ±5% of the mean air flow.
• Optimized pulverizer Air to fuel ratio.
Pulverizer Type Lbs. Air per Lb. Coal
MPS and EL Mills 1.5 to 1.8
Raymond Bowl Mills 1.8 to 2.0
Ball Tube Mills 1.1 to 1.4
Attrita Mills 1.2 to 1.6
• Minimum fineness level >75% passing 200 Mesh and <0.3% remaining on 50 Mesh.
• Pulverizer to pulverizer mass air and fuel balance within ±5% of the mean.
• Pulverizer outlet temperature >155°F.
• Minimum fuel line velocity of 3250 Fpm.

Isokinetic coal sampling requires both the Dirty Air Probe and the Isokinetic Coal Sampler.

JET PUMP ASPIRATOR

NEEDLE VALVE FOR CHANGING
FLOW THROUGH SAMPLER

10" INCLINE
MANOMETER
ORIFICE FOR
DETERMINING FLOW

ASPIRATING
AIR SOURCE

CANISTER WITH FIBERGLASS

FLOW FILTER FOR TRAPPING "FINES"

CYCLONE
SEPERATOR

1 1/4" FULL-PORTED
BALL VALVE

ALUMINUM
DUSTLESS CONNECTOR

1" Ø COAL 1 GAL

SAMPLING PROBE PLASTIC JUG
SPRING REINFORCED
VARDEX HOSE

Figure 1 – Isokinetic or “Air/Fuel” type Coal Sampler

Page 3
 

1.0 Isokinetic Coal Sampling

1.1 Performing a Dirty Air Test

Dirty air velocities must be measured in each fuel line to establish proper sampling rate for the
Isokinetic Sampler and to determine air flow in each fuel line. The dirty air probe is a field proven
device which allows the measurement of air flow in a dust-laden environment with a minimum of
probe stoppage. The dirty air probe is illustrated by Figure 3. Dirty air velocity and fuel sampling
measurements will be on a minimum of two axes 90° apart on a vertical run of pipe. An increased
number of traverse planes will be utilized when taps are close to elbows or other flow
disturbances. Test taps in horizontal runs are to be avoided. Figure 4 illustrates the physical
effects of elbows and horizontal pipe runs on coal particles.

10' INCLINE
MANOMETER

FLOW
1 1/4" FULL-PORTED
BALL VALVE

ALUMINUM
DUSTLESS CONNECTOR

STATIC
(TOP)

DIRTY AIR
PROBE

IMPACT DETAIL DIRTY AIR PROBE

(BOTTOM) (BOTTOM VIEW)

Figure 3 – Dirty Air Probe

Figure 4 – Physical Effects of Elbow and Horizontal Pipe Runs

Page 4
 

1.0 Isokinetic Coal Sampling

1.1 Performing a Dirty Air Test

Coal line test taps, which facilitate insertion of dirty air probes, require 1¼" full -ported ball
valves. Use of a Rotorprobe™ will require installation of 2” full-ported ball valves. A minimum
of two ports at 90° apart will be required. Figure 5 specifies the number of test ports required,
depending on the proximity to elbows or other flow disturbances.

NO 1. NO. 2
10 DIAMETERS UPSTREAM 5 DIAMETERS UPSTREAM
5 DIAMETERS DOWNSTREAM 2 DIAMETERS DOWNSTREAM

45°
90°
45°
CLEAN AIR CONNECTIONS

1-1/4" NPT HALF COUPLING NO. 3

2 DIAMETERS UPSTREAM
1-1/4" NPT CLOSE NIPPLE 1 DIAMETER DOWNSTREAM

6" 1-1/4" NPT FULL PORT BALL VALVE

1/2" NPT PLUGS

30°
PIPE WALL DRILLED
WITH 45/64 DRILL (.703)

30°
30° 30°

NOTES:

1 -- THE 1 1/4" NPT CONNECTIONS MUST 2 -- THE COCK OR BALL VALVE SHOULD BE (+/-)1/8"
FIT A 1.050 SAMPLE PROBE OF THE SAME LENGTH FOR MAX. PRODUCTIVITY OF
TEST TEAM (TO AVOID DIFFERENCE IN PROBE MARKING)

Figure 5 -- Coal Sampling Test Tap Installation Standard

Page 5
 

1.0 Isokinetic Coal Sampling

1.1 Performing a Dirty Air Test

Coal samples, to obtain fineness, have been commonly extracted at the exhauster outlet on
units equipped with CE Raymond Bowl pulverizers. Although this practice has been widely
advocated, representative coal samples are not obtained. The kinetic energy of rotation
imparts centrifugal forces on larger coal particles which have higher mass. The resulting
propagation of a majority of the coarse coal particles to the outside of the exhauster scroll in a
very small zone facilitates occupation of the highest percentage of the traverse plane by fine
coal particles. With a high percentage of the traverse plane biased towards collection of fine
particles, fineness results are much higher than actual. Figure 6 illustrates the non-
representative sampling of pulverizer coal at the exhauster outlet. Due to the error associated
with sampling at the exhauster, we are adamant in recommending that all coal samples be
taken from the fuel lines.

Fine Particles

ROTATION
COAL SAMPLING PROBE

Large Coal Particles forced to outside of scroll

Figure 6 -- Coal Particle Distribution at the Exhauster Outlet

Page 6
 

1.0 Isokinetic Coal Sampling

1.1 Performing a Dirty Air Test

2. Traverse points on the dirty air probe are marked on an equal area grid in accordance with the ASME
Performance Test Code for traversing circular ducts. When marking the dirty air probe, be sure to offset
the first mark to accommodate for the length of the test port nipple, pipe wall and dustless connector.
This ASME standard, for pipes with 10" or larger diameters, is illustrated by the Figure 7.

47.9% 47.9%

43.3% 43.3%

38.2% 38.2% 47.4% 47.4%

32.2% 32.2%

25.0% 25.0%
41.7% 41.7%

35.2% 35.2%

27.3% 27.3%

14.4% 14.4%

15.7% 15.7%

5 ZONES
10"-11" PIPE
6 ZONES
12" OR LARGER
Figure 7 -- Equal Area Traverse Grid per ASME Performance Test Code
***Dimensions are "Percent of Pipe Diameter"

3. Two equal length "Tygon"™ tubing sections are cut to desired length. The tubing is then taped or bound
together and one tube is marked on both ends to identify it as the “high–pressure” (impact) line. The
remaining tube, which is unmarked, is identified as the “low–pressure” (static) line.

4. A 10" inclined-vertical manometer is set up on a level and stable location. Open the low and high
pressure valves for the manometer, ensure the manometer is level using the integral leveling bubble and
“Zero” the manometer. “Tygon”™ tubing is then attached to the correct sensing lines on the dirty air
probe and the manometer.

5. The following data should be recorded for each individual pipe dirty air test:
• Coal pipe designation
• Individual velocity heads for each traverse point (typically 24 points - (12) per port)
• Temperature and static pressure for each pipe

6. Prior to inserting the dirty air probe, ensure the manometer is level and “zeroed”.

7. Insert the dirty air probe into the dustless connector; open the full-ported ball valve and insert the dirty air
probe to the first mark with the probe’s pointer directed into the flow. The dirty air probe will seal the port.
Allow the incline manometer indication to stabilize, record and move to the next point. Repeat this
process for all (12) traverse points.

8. Between ports, disconnect the “Tygon”™ tubing from the probe; blow out the dirty air probe’s sensing
lines with the quick disconnect adapter on the coal sampler and repeat the traverse on the remaining
port(s).

Page 7
 

1.0 Isokinetic Coal Sampling

1.1 Performing a Dirty Air Test

9. Insert the static and temperature probe into one of the ports in the same manner that the dirty
air probe was inserted. When inserting the static-temperature probe, the U-tube should be
disconnected. The tight seal between the dustless connector and probe will compress the air
in the dustless connector and may blow out the U-tube fluid. Connecting the “Tygon”™ tubing
to the U-tube manometer after the ball valve is open and the probe inserted prevents loss of
U-tube fluid. Record static pressure indicated by a U-tube manometer and temperature
indicated by a digital thermometer. The static and temperature probe is illustrated by the
figure shown below.
TYPE "K" THERMOCOUPLE
1/4" S.S. TUBE FOR STATIC PRESSURE MEASUREMENT WITH U-TUBE MANOMETER

An example data sheet for recording dirty air traverse data is illustrated below.

Innovative Combustion Technologies, Coal Pipe I.D.

Tennessee Valley Coal Pipe Area Ft²
Colbert Steam Plant Unit No. 3 Barometric
Test No. Date: Pulverizer
Pipe: Pipe:
Point Port 1 Port 2 Point Port 1 Port 2
1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
9 9
10 10
11 11
12 12
K Factor K Factor
Sqrt Vh "w.c. Sqrt Vh "w.c.
ΔΡ " w.c. ΔΡ "w.c.
Temp. °F Temp. °F
Static "w.c. Static "w.c.
Density Lbs./Ft³ Density Lbs./Ft³
Velocity Fpm Velocity Fpm
Airflow Lbs./Hr. Airflow Lbs./Hr.
Grams Grams Grams Grams
Fuel Flow Lbs./Hr. Fuel Flow Lbs./Hr.
Pipe:
Point
1 Total Dirty Airflow Lbs./Hr.
2 Total Fuel Flow Lbs./Hr.
3 Air to Fuel Ratio -
4
5 Average Velocity Fpm
6
7 Air Fuel
8 Pipe No. % Dev. %Dev.
9
10
11
12
K Factor Mean
Sqrt Vh "w.c.
ΔΡ "w.c.
Temp. °F
Static "w.c.
Density Lbs./Ft³
Velocity Fpm
Airflow Lbs./Hr.
Grams Grams
Fuel Flow Lbs./Hr.

Page 8
 

1.0 Isokinetic Coal Sampling

1.1 Performing a Dirty Air Test

10. Calculating dirty air data is similar to reducing clean air data. The following equations
are utilized to reduce dirty air flow traverse data:
Sp " wc
Bp ' ' Hg +
δ= ° + ° ×
460 F 70 F Density ( 13.6
) × 0.075 lbs/ft³
460 °F + °F 29.92 " Hg

Velocity =1096 Avg vh × Probe K A vg vh =

∑
vh =1
n vh

δ n
Velocity - Average
% Deviation/ mean = Velocity ×100
Average Velocity
Volumetric Flow (Q) = Velocity(F PM) ×Pipe Cross Sectional Area (ft²)
Mass Flow (W) = Q (CFM) ×60 min/hr × Density (lb/ft³)
Bp = Barometric Pressure (" Hg)
Sp = Static Pressure (" wc)

11. After determination of the dirty air velocity in a given fuel line, isokinetic coal samples are
extracted. The coal sampling probe is marked identically to the dirty air probe. The figure
below illustrates the isokinetic coal sampler.

NEEDLE VALVE FOR CHANGING

JET PUMP ASPIRATOR
FLOW THROUGH SAMPLER

10" INCLINE
MANOMETER
ORIFICE FOR
DETERMINING FLOW

CANISTER WITH
FIBERGLASS FILTER
FOR TRAPPING "FINES"

FLOW CYCLONE

1 1/4" FULL-PORTED
SEPERATOR
BALL VALVE

1" Ø COAL
SAMPLING PROBE

1 GAL
ALUMINUM PLASTIC JUG
DUSTLESS CONNECTOR SPRING REINFORCED
HOSE

Figure 8 – Isokinetic or “Air/Fuel” type Coal Sampler

Page 9
 

1.0 Isokinetic Coal Sampling

1.1 Performing a Dirty Air Test

12. Calculate the sampler orifice differential pressure based on the dirty air velocity traverse.
Sampler differential is monitored by a standardized orifice and an inclined manometer. The
average square root velocity head observed by the dirty air probe is entered into the following
formula: ΔΡ = 1.573 × (avg. √Vh)² × (Probe K Factor)².

The simplified formula above indicates an orifice ΔΡ which will yield an average velocity
through the sampling tip equivalent to the average velocity of the coal and mixture passing
through the fuel line. This is referred to as isokinetic sampling.

The graph below illustrates sampler orifice differential at varying dirty air probe "K" factors.
Relationship of Vh and Coal Sampler Orifice Differential

9.00

8.00

7.00 Probe K = 0.95

Orifice Differential ("w.c.)

6.00 Probe K = 0.90

5.00 Probe K = 0.85

4.00

3.00

2.00

1.00

0.00
0.00 0.50 1.00 1.50 2.00 2.50
Avg. Square Root Velocity Head by Dirty Air Probe ("w.c.)

13. Connect the “Tygon”™ tubing to the incline manometer and the orifice sensing lines. The
orifice sensing line upstream of the orifice (closest to the filter canister) should be connected
to the high pressure side of the incline. The orifice sensing line downstream of the orifice is
connected to the low pressure side of the incline.

The desired differential pressure will be monitored and maintained at all times while the probe
is in the fuel line. A needle valve is placed on the air supply line to manipulate the differential
pressure. Prior to insertion of the sampling probe, place your hand over the aspirator
discharge to minimize collection of coal during insertion. Insert the sampling probe (with the
pointer 180° from the direction of flow) onto the first mark, rotate the probe pointer into the
direction of flow and simultaneously start the stop watch and establish proper orifice
differential by turning on the air and adjusting the needle valve.

14. The sample probe, which is marked in the same manner as the dirty air probe, will remain at
each traverse point for an equal and precise time. Sampling time is very critical and great care
should be taken to ensure the correct sampling time is obtained for each individual point. The
sample time (t) is determined by the number of sampling points that is determined by the
number of test ports. The following sampling times are typical:

(2) ports (24) traverse points (10) seconds/point (4) minutes total sample time

(3) ports (36) traverse points (7) seconds/point (4.2) minutes total sample time

Page 10
 

1.0 Isokinetic Coal Sampling

1.1 Performing a Dirty Air Test

15. After traversing each port, turn off the air supply and remove probe from pipe.

16. Once all ports have been traversed, disconnect “Tygon”™ from orifice sensing lines and turn
on air. Shake sample transport hose and tap cyclone to insure all coal sampled is evacuated.

17. Empty the sample collected in the sample jar and filter canister into a sample bag labeled with
the pipe designation, test number and date. Take care to ensure that the entire sample is
emptied into the sample bag. Sample weight will be utilized to calculate fuel flow.

18. Replace filter, sample jar and repeat process on the remaining fuel lines. In some cases,
especially while sampling high moisture coal, the sampler should be thoroughly cleared prior
to re-assembly of any residual coal dust or scum by blowing high pressure air through the
sampler components.

19. Determine sample weight in each of sample bags, record on data sheet and perform fineness
sieve analysis on all coal samples.

20. Formulas to reduce all Dirty Air and Isokinetic coal sampling data are as follows:

Sp "Hg
Bp' ' Hg +
Density( δ ) = 460°F +70°F × 13.6" wc/ "Hg ×0.075 lbs/ft³
460°F +°F 29.92"Hg
Avg vh ∑n vh
Velocity =1096 × Probe K Avg vh = vh=1

δ n
% Deviation/mean = Velocity - Average Velocity ×100
Average Velocity
Volumetric Flow (Q) = Velocity(FPM)×Pipe Cross Sectional Area (ft²)
Mass Flow (W) = Q(CFM)×60min/hr ×Density (lb/ft³)
Bp = Barometric Pressure ("Hg)
Sp = Static Pressure (" wc)
2 2
P (Sampler Orifice during Sampling) =1.573 ×(Avg vh) ×(ProbeFactor)
2
Sample Weight (grams) 60 Minutes/Hour Pipe Area(ft )
Coal Flow = × × 2
453.6grams/pound Total Sample Time(min) Sample Tip Area(ft )
2
Sample Tip Area = 0.0021ft
Air to Fuel Ratio = Air Flow in Pouds per Hour
Coal Flow in Pounds per Hour

Page 11