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B e r g m a n s M e c h a t r o n i c s L L C Progress in the Development of a TDLAS Sensor for Industrial Applications J.L. Bergmans i , & T.P. Jenkins ii i Bergmans Mechatronics LLC (Newport Beach, CA) ii MetroLaser, Inc. (Irvine, CA)

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SLIDE 1

Progress in the Development of a TDLAS Sensor for Industrial Applications

J.L. Bergmansi, & T.P. Jenkinsii

i Bergmans Mechatronics LLC (Newport Beach, CA) ii MetroLaser, Inc. (Irvine, CA)

American-Japanese Flame Research Committees International Symposium, Waikaloa, HI, Oct 22-24, 2007.

1616 Bedford Lane, Unit A Phone: 714-474-8956 Newport Beach, CA 92660 Fax: 949-646-1429

B e r g m a n s M e c h a t r o n i c s L L C

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SLIDE 2

Overview BML

  • Theory of Operation and System Description
  • Applications
  • Coal-Fired Power Plant
  • Oxy-Fuel Burner
  • Conclusions / Future Work
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SLIDE 3

Theory of Operation BML

LTS-100 Laser Temperature Sensor employs two-line TDLAS to measure temperature and H2O concentration Calibration testing using flat flame burner:

Detector Collimator Thermocouple Flat flame burner LTS-100 Fiber optic Coax cable

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SLIDE 4

Theory of Operation BML

1 2 3 4 5 6 50 100 150 200 250 300 350 400 450 500 Time (usec) Voltage Regions Used for Baseline Calculation Detector Signal Computed Baseline Feature 1 Feature 2

Detector signal during calibration (TC = 2578 °F, corrected) Absorbance:

( ) ( )⎟

⎟ ⎠ ⎞ ⎜ ⎜ ⎝ ⎛ − = λ λ αλ

  • I

I ln

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SLIDE 5

Theory of Operation BML

T = -1035.5*R2 + 3375.7*R + 719.14 1500.0 1700.0 1900.0 2100.0 2300.0 2500.0 2700.0 0.25 0.3 0.35 0.4 0.45 0.5 0.55 0.6 0.65 0.7 0.75 Absorption Ratio Corrected Temperature (deg F)

( ) ( )

T S T S A A R

2 1 2 1 ≈

=

Calibration Curve

  • 0.01

0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 50 100 150 200 250 300 350 400 450 Time (usec) Absorbance 1712 °F 2205 °F 2578 °F 2788 °F

Typical Calibration Spectra With constant temperature along beam path, ratio of absorbance under two absorption peaks is a function of temperature:

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SLIDE 6

Recent LTS-100 System Upgrades BML

  • Flange-mountable optical enclosures
  • Unified Processing Unit
  • Improved Laser Alignment System hardware and software
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SLIDE 7

Objectives of Power Plant Testing BML

  • To demonstrate extended-duration operation of the LTS-100

in a large scale setting

  • To compare LTS-100 temperature measurements with

expected temperature data

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SLIDE 8

Ameren Sioux Station Overview BML

  • Located north of St Louis, MO, on Mississippi river
  • Two, coal-fired, cyclone units
  • Each unit nominally rated at 485 MW
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SLIDE 9

Ameren Sioux Station Overview BML

  • LTS-100 tested on Unit 1
  • Beam passed from side to

side over 48 foot width of boiler

  • Testing performed from end
  • f Aug 2007 to beginning of

Sep 2007

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SLIDE 10

Installation at Sioux Station BML

Processing Unit Terminal Room Elevation: 446’ Boiler Fiber Optic Cable (1000’ length) Scanner Enclosure Detector Enclosure Coax Cable (500’ length) Elevation: 568’ 48’ Laser Light Detector Signal

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SLIDE 11

LTS-100 Hardware BML

Processing Unit in Terminal Room Detector Optics Enclosure

  • n Boiler
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SLIDE 12

Laser Alignment System BML

Incoming Beam Outgoing Beam Pivoting Mirror Pivoting Mirror

  • Computer controlled two-axis scanner
  • Angular resolution: 0.0069° (0.069” at 48 feet)
  • Range of motion: ±13.7°

48’=576” 0.0069° 0.069”

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SLIDE 13

Temperature and Load Data BML

2000 2100 2200 2300 2400 2500 2600 2700 2800 2900 3000 09/02/07 18:00 09/03/07 00:00 09/03/07 06:00 09/03/07 12:00 09/03/07 18:00 09/04/07 00:00 09/04/07 06:00 Date/Time Temperature (°F) 50 100 150 200 250 300 350 400 450 500

Load (MW)

LTS-100 Temperature Load Typical High Temp (T=2637 °F at 19:03:33 on 9/3/07)

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SLIDE 14

Temperature and Load Data BML

  • 600
  • 500
  • 400
  • 300
  • 200
  • 100

100 200 300 400 09/02/07 18:00 09/03/07 00:00 09/03/07 06:00 09/03/07 12:00 09/03/07 18:00 09/04/07 00:00 09/04/07 06:00 Date/Time Temperature Change (°F) 50 100 150 200 250 300 350 400 450 500

Load (MW)

LTS-100 Based Temperature Change Estimated Boiler Temperature Change Load Typical High Temp (T=2637 °F at 19:03:33 on 9/3/07)

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SLIDE 15

High Temperature Spectrum BML

  • 0.5

0.5 1 1.5 2 50 100 150 200 250 300 350 400 450 Time (usec) Absorbance Feature 2 Window Feature 1 Window

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SLIDE 16

High Temperature Spectrum BML

Comparison with Calibration Spectra

  • 0.5

0.5 1 1.5 2 2.5 50 100 150 200 250 300 350 400 450 Time (usec) Normalized Absorbance Full Scale, Measured 2637 °F Calibration, TC = 2271 °F Calibration, TC = 2578 °F Calibration, TC = 2788 °F Cal: 2271 °F Cal: 2788 °F Full Scale: 2637 °F Cal: 2578 °F

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SLIDE 17

High Temperature Spectrum BML

Comparison with Calibration Spectra (Feature 2)

  • 0.5

0.5 1 1.5 2 300 310 320 330 340 350 360 370 380 Time (usec) Normalized Absorbance Full Scale, Measured: 2637 °F Calibration, TC = 2271 °F Calibration, TC = 2578 °F Calibration, TC = 2788 °F Feature 2 Window Full Scale: 2637 °F Cal: 2788 °F Cal: 2271 °F Cal: 2578 °F

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SLIDE 18

Potential Error in Baseline Fit BML

Full scale detector signal and baseline at 2637 °F

0.01 0.02 0.03 0.04 0.05 0.06 0.07 50 100 150 200 250 300 350 400 450 500 Time (usec) Volts Regions Used for Baseline Calculation Detector Signal Computed Baseline Feature 1 Feature 2 Notional Improved Baseline

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SLIDE 19

Observations BML

  • Able to detect small changes in boiler temperatures due to load

changes

  • Absolute temperature levels are higher than expected values.

Possible causes include:

  • Improper baseline fit
  • Ambient H2O not removed during calibration
  • Possible temperature non-uniformities distorting temperature

measurement

  • Laser Alignment System functions nominally
  • No significant build-up on optical windows. Some loose slag

accumulated in instrumentation ports

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SLIDE 20

Oxy-Fuel Testing BML

Launch Optics Enclosure Detector Optics Enclosure Air Reduction Tubes (Purged with N2) Fiber Optic Cable Oxy-Fuel Combustor

  • GOx – JP8
  • Nominal heat

release: 18.8 MMBTU/hr

  • Path length: 194”
  • Burner ID: 6.5”
  • Beam 4”

downstream from exit plane

  • Single pass
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SLIDE 21

Oxy-Fuel Generator Firing BML

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SLIDE 22

Typical Initial Absorption Spectra BML

Effect on peaks due to variations in O/F ratio evident

  • 0.01
  • 0.005

0.005 0.01 0.015 0.02 0.025 0.03 4 9 14 19 24 29 34 39 Time (usec) Absorbance O/F=1.47 O/F=1.53 O/F=1.62 Feature 1 Feature 2

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SLIDE 23

Conclusions BML

  • System is nearly fully functional for coal-fired power plant

application

  • Initial Oxy-Fuel testing results suggest temperature measurements

are feasible with further system improvements

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SLIDE 24

Future Work BML

  • Additional studies regarding discrepancy between expected and

measured temperatures in power plant application

  • Improve baseline fit method
  • Multi-pass configuration for oxy-fuel to improve signal quality
  • System recalibration
  • Ambient absorption removed
  • New laser controller module
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SLIDE 25

Acknowledgements BML

  • Ken Stuckmeyer, Ameren
  • Ameren Sioux Station Personnel
  • Ron Mai and Thomas Rafferty, AES Huntington Beach
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SLIDE 26

Charles “Glen” May

Dec 11, 1962 – Jul 26, 2007

AES Huntington Beach, Huntington Beach, CA Jul 16, 2007

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SLIDE 27

Questions / Comments? BML

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SLIDE 28

Laser Alignment System BML

  • Alignment maintained during load changes
  • Raster Scan mode 11% of time
  • 1
  • 0.5

0.5 1 1.5 2 09/02/07 18:00 09/03/07 00:00 09/03/07 06:00 09/03/07 12:00 09/03/07 18:00 09/04/07 00:00 09/04/07 06:00 Date/Time Change in Scanner Angle (deg) 50 100 150 200 250 300 350 400 450 500 Load (MW) Tilt, Command Pan, Command Load