Non-nulling protocols for fast, accurate, 3-D velocity measurements in stacks.

The authors present protocols for making fast, accurate, 3D velocity measurements in the stacks of coal-fired power plants. The measurements are traceable to internationally-recognized standards; therefore, they provide a rigorous basis for measuring and/or regulating the emissions from stacks. The authors used novel, five-hole, hemispherical, differential-pressure probes optimized for non-nulling (no-probe rotation) measurements. The probes resist plugging from ash and water droplets. Integrating the differential pressures for only 5 seconds determined the axial velocity Va with an expanded relative uncertainty Ur(Va) ≤ 2% of the axial velocity at the probe's location, the flow's pitch (α) and yaw (ß) angles with expanded uncertainties U(α) = U(ß) = 1 °, and the static pressure ps with Ur(ps) = 0.1% of the static pressure. This accuracy was achieved 1) by calibrating each probe in a wind tunnel at 130, strategically-chosen values of (Va, α, ß) spanning the conditions found in the majority of stacks (|α| ≤ 20 °; |ß| ≤ 40 °; 4.5 m/s ≤ Va ≤27 m/s), and 2) by using a long-forgotten definition of the pseudo-dynamic pressure that scales with the dynamic pressure. The resulting calibration functions span the probe-diameter Reynolds number range from 7,600 to 45,000.Implications: The continuous emissions monitoring systems (CEMS) that measure the flue gas flow rate in coal-fired power plant smokestacks are calibrated (at least) annually by a velocity profiling method. The stack axial velocity profile is measured by traversing S-type pitot probes (or one of the other EPA-sanctioned pitot probes) across two orthogonal, diametric chords in the stack cross-section. The average area-weighted axial velocity calculated from the pitot traverse quantifies the accuracy of the CEMS flow monitor. Therefore, the flow measurement accuracy of coal-fired power plants greenhouse gas (GHG) emissions depends on the accuracy of pitot probe velocity measurements. Coal-fired power plants overwhelmingly calibrate CEMS flow monitors using S-type pitot probes. Almost always, stack testers measure the velocity without rotating or nulling the probe (i.e., the non-nulling method). These 1D non-nulling velocity measurements take significantly less time than the corresponding 2D nulling measurements (or 3D nulling measurements for other probe types). However, the accuracy of the 1D non-nulling velocity measurements made using S-type probes depends on the pitch and yaw angles of the flow. Measured axial velocities are accurate at pitch and yaw angles near zero, but the accuracy degrades at larger pitch and yaw angles.The authors developed a 5-hole hemispherical pitot probe that accurately measures the velocity vector in coal-fired smokestacks without needing to rotate or null the probe. This non-nulling, 3D probe is designed with large diameter pressure ports to prevent water droplets (or particulates) from obstructing its pressure ports when applied in stack flow measurement applications. This manuscript presents a wind tunnel calibration procedure to determine the non-nulling calibration curves for 1) dynamic pressure; 2) pitch angle; 3) yaw angle; and 4) static pressure. These calibration curves are used to determine axial velocities from 6 m/s to 27 m/s, yaw angles between ±40°, and pitch angles between ±20°. The uncertainties at the 95% confidence limit for axial velocity, yaw angle, and pitch angle are 2% (or less), 1°, and 1°, respectively. Therefore, in contrast to existing EPA-sanctioned probes, the non-nulling hemispherical probe provides fast, low uncertainty velocity measurements independent of the pitch and yaw angles of the stack flow.

Facility for Calibrating Anemometers as a Function of Air Velocity Vector and Turbulence.

NIST calibrates anemometers as a function of airspeed vector and turbulence intensity (Tu). The vector capability (sometimes called "3-D") is particularly important for calibrating multi-hole differential-pressure probes that are often used to quantify pollution emitted by smokestacks of coal-burning electric power plants. Starting with a conventional "1-D" wind tunnel, we achieved vector and Tu capabilities by installing translation/rotation stages and removable turbulence generators (grids or flags). The calibration ranges are: yaw angle ±180°; pitch angle ±45°; airspeed 1 m/s to 30 m/s; turbulence intensity 0.07 ≤ Tu ≤ 0.25; average data collection rate: 300 points/hour at fixed Tu. The system's expanded uncertainties corresponding to 95 % confidence level are: airspeed 0.0045×|V|+(0.036/|V|)2 where |V| is the magnitude of the airspeed in m/s; pitch and yaw angles 0.3°; and turbulence intensity 0.03 Tu. The airspeed working standard is a Laser Doppler Anemometer that is traced to SI unit of velocity via a spinning disk. Calibrations are corrected for blockage by the instrument under test and its supports.