Boiler Tune-up and Compliance Test - Coal Fired Steam Generators
Boiler Efficiency Testing - Oil Fired Boiler
Emissions Compliance Testing - Experimental Gas/Oil Fired Turbine
Boiler Optimization Testing



Boiler Tune-up and Compliance Test - Coal Fired Steam Generators

APCC performed initial performance and guarantee tests on two 450-550 Mw pulverized coal fired utility steam generators and their associated air pollution control systems in Texas and Indonesia.

Steam generator tests, including ASME PTC 4.1 boiler efficiency and PTC 4.3 air heater leakage testing were performed to determine compliance with manufacturers guarantee contract margins. Testing was also performed to determine manufacturer guarantee tests for nitrogen oxide (NOx) concentrations, pressure drops, and draft loss. Composite coal, bottom ash, and flyash samples were drawn in conjunction with testing and ultimate/moisture analyses performed to be used with the respective efficiency calculations.

Pollution control devices including electrostatic precipitators, baghouses, and scrubbers were tested at their respective inlets and outlets in accordance with EPA Methods 1-5 and 17 for determination of removal efficiency. In conjunction with this testing oxygen (O2), carbon monoxide (CO), and carbon dioxide (CO2) concentrations were determined, as well as system pressure drops and mist droplet concentration for the scrubber systems.

Boiler Efficiency Testing - Oil Fired Boiler

ASME PTC 4.1 boiler efficiency and 4.3 air heater leakage testing was performed on a natural gas and No. 6 fuel oil fired boiler for a New York Utility. The facility consisted of three boilers and respective steam driven turbine/generators rated at approximately 135 Mw each. Boiler efficiency and air heater leakage was determined for a variety of boiler load and fuel firing conditions. Fuel oil samples were collected in conjunction with testing and ultimate analyses performed for use with the efficiency calculations. NOx and CO emission concentrations were also monitored throughout the testing program.

Emissions Compliance Testing - Experimental Gas/Oil Fired Turbine

APCC was retained by a major manufacturer of military and commercial aircraft engines to perform research and development emission testing on an experimental aeroderivative gas fired turbine destined for use in a cogeneration facility. The engine was situated in a test stand with no provisions for conventional stationary source emission testing. APCC worked with the client to design and build a sampling system capable of delivering multiple traverse point isokinetic particulate and sulfuric acid mist samples to a standard EPA Method 5 sampling train. The system used a series of dumps and by-passes in order to reduce the supersonic velocities at the engine exhaust to an acceptable velocity for isokinesis. Particulate and sulfuric acid mist testing was performed concurrently with continuous emission monitoring for sulfur dioxide, nitric oxides, carbon monoxide, total hydrocarbons, oxygen and carbon dioxide.

Two test programs were performed, one firing natural gas, and the second firing No. 2 fuel oil. Significant particulate emissions were detected during the second program, which led to an engine teardown that revealed misfiring burner cans and a heat warped interstage transition piece.

APCC also performed the start-up and compliance testing for the flagship facility. A test protocol was designed for the start-up program and a compliance test program negotiated with the state regulatory agency. Emission testing was performed for particulate matter, NOx, SO2, SO3, H2SO4, NH4, and CO under a number of operating conditions. Process air pollution control engineering was performed to optimize an ammonia injection catalyst and NOx reduction system to maximize NOx control and minimize ammonia slip.

Boiler Optimization Testing

APCC was retained to perform baseline emissions testing at a generating station for a Massachusetts municipal utility company. NOx characterization tests were performed on a boiler, gas turbine, and boiler and turbine effluent combined (normal firing configuration). These tests were performed on three different fuels at various load conditions and excess air levels. At each test condition, levels of O2, CO2, CO and NOx were monitored after the unit stabilized. Velocity traverses and cyclonic flow checks were also performed at the stack location. A second phase involved the characterization of NOx at the stack and economizer outlet on a second boiler. The boiler was also tested for O2, CO2, CO and NOx on one fuel at several load conditions and excess air levels. Velocity traverses and cyclonic flow checks were also performed at the stack location.




Home CementPulp and PaperWaste-to-EnergyPrinting and CoatingPower Generation
Chemical...PharmaceuticalOther About APCCServicesContact UsFrequently Asked Questions