World Bank/ International Development Association

Municipality of Ulaanbaatar

ULAANBAATAR CLEAN AIR PROJECTProject Number: IDA 5039-MN

SMALL WATER HEATING BOILER TEST PROTOCOL

(draft)Prepared for

World Bank/ International Development Association

and

Ulaanbaatar Clean Air Project, Project Management Unit

by

ULAANBAATAR CITY16th March 2014

Mon-Energy Consult LLCPOB-10210030, Ulaanbaatar shuudan, Chinggeltei district, Horoo #6, L. Laagan street #57, Ulaanbaatar, Mongolia.Tel./Fax: +323167,77227788Mobile: 99169955E-mail: erdenedalai@mon.energy.mnWEB: www.mon.energy.mn

ABBREVIATIONS

ADB – Asian Development Bank

CT – Consulting Team

GC – Gas Chromo-graph

IHTIE – Institute for Heating Technology and Industrial Ecology

SWHB – Small water heating boiler (also LPBoiler)

MoE – Ministry of Energy

MEGD – Ministry of Environment and Green Development

MUB – Municipality of Ulaanbaatar

MUST – Mongolian University of Science and Technology

PM – Particulate Matter

PMU – Project Management Unit

SA – Scientific Advisor

SC – Steering Committee

SDC – Stove Development Center

SEET – Stove Emissions and Efficiency Testing laboratory

SWHB – Small water heating boilers

UB – Ulaanbaatar

USIP – Ulaanbaatar Services Improvement Project

UBCAP – Ulaanbaatar Clean Air Project

UB – Ulaanbaatar

Table of Contents

I. INTRODUCTION1.1 Background1.1 Purpose

II. PREPARATION AND INSTALLATION OF EQUIPMENTS2.1 Selection of Households2.2 Testing Equipments2.3 Tools

III. TYPES OF TESTS3.1. Emssion and Combustion Efficiency Test3.2. System Efficiency Test 3.3. Particulate Matter Test3.4. Surface Temperature Test

IV PROCEDURE4.1. Fuel4.2. Emssion and Combustion Efficiency Test Procedure 4.3 Particulate Matter Test Procedure4.4 System Efficiency Test Procedure

V. DATA AND PROCESSING5.1. Emssion and Combustion Efficiency Test Data5.2. System Efficiency Test Data 5.3 Particulate Matter Test Data5.4 Surface Temperature Test Data

VI. BOILER COMBUSTION PERFORMANCE VII. BOILER EFFICIENCY

I. INTRODUCTION

1.1 BackgroundThe Stove Emissions and Efficiency Testing (SEET) laboratory was established and enhanced within the framework of the Ulaanbaatar Clean Air Project (UBCAP) funded by World Bank/ International Development Association (IDA) to test Ger small stoves and make comparative analysis, and organize trainings for laboratory staff and the Stove Development Center (SDC) with an aim of improving the ger stoves. The Institute of Heat Technology and Industrial Ecology (IHTIE) is now operating the SEET laboratory. This laboratory will not only be used for testing of stoves using World bank technical assistance but we extend this laboratory for testing small low pressure boilers (LPB) or various small water heating boilers (SWHB) used for heating of small individual houses. This report describes about the small water heating boiler testing protocol.The SWHB testing bench is the following functions (i) make tests to determine heating capacity of low pressure boilers, efficiency and emissions, and assess the test results; and (ii) provide practical training to producers for development of better designs and manufacturing issues that affect performance, durability and consumer acceptance and give technical advice to them.

1.2 PurposeThe purpose of this laboratory (SWHB testing bench or laboratory) is to make tests for determining heat parameters, efficiency and emissions of stoves and low pressure water heating boilers, compare heat technological and ecological parameters determined. Based on the results of tests and analysis, the laboratory will provide a scientific data to the development of emissions standards with relevant authorities and provide information needed for technical passports or certificates issued by relevant agencies. The SEET lab produces results of tests and compared objectively against criteria.

II. TESTING INSTRUMENTS AND EQUIPMENT

2.1 Preparation and Assembly of Testing Bench in the Laboratory

The Monenergy consulting team (CT) has developed and designed the SWHB (or LPB) testing bench and its measuring methods, and prepared a list of the required instruments and equipment and installation schematics. The installation schematics are shown in Figure 1.

The CT together with the SEET laboratory staff are planning to assemble the test bench for testing low pressure boilers in the SEET laboratory.

The measuring instruments and test equipment will be installed using available two rooms in the SEET laboratory building.

The SWHB will be temporarily placed on the test bench and connected to the internal space heating system in the SEET laboratory building.

The internal heating system will be modified to adopt the LPB to testing bench and reconnect the existing heating system when the test is completed and not performed. The flexible water transmitting hoses will be used to temporarily connect to the heating system. The necessary shut-off valves will be installed on the existing heating water line. The portable instrument is used for measuring water flows and temperatures.

Figure 1. General flow diagram of the test measurement for the low pressure boiler

It includes the following instruments: Figure 2 Low Pressure Boiler, 2-Chimney, 3-Circulation Pump, 4-Heat Exchanger.

5-Heat meter, 6-Primary flow meter, 7-Primary pressure transducer, 8-Primary (inlet) temperature, 9-Portable ultrasonic flow meter (with LAN and USB), 10-Diluter, Agilent

multiplexer for temperature and analogue data recording, 11 а,b,c…-Thermo-couples, 12-Flue gas analyser TESTO-350XL/454 with flue velocity, 13-Existing set of gas measurement

equipment (2 channels, pumps, vortex chiller, filters etc), 13а-Emerson X-Stream, 13b- Dusttrak or GRIMM 11-R, 14-Flue gas velocity meter (the 454 part of the Testo), 15-Flame temperature

meter, 16-Computer, 16a-Network hub (8 ports), 17-Platform scale (Mettler 4-point), 18-External data archive.

The low pressure boilers shall be taken from the producers (or purchased), prepared and made ready for testing.

2.2 Testing Equipment and Measurements All equipment and instruments needed for carrying out the low-pressure boiler test are listed and specifications are shown in Tables 1.

Table 1. List of Necessary Equipment and Instruments

Item Specifications Quantity RemarksWorking Environment and Gases

1 CO2 Adsorber: Carbon Dioxide adsorber 20” towers 220VAC, Special orifice #31, VCD4-22-031

1 CO2 and water vapour removal

unit2 Calibration gas for the Red Line

CO2 10%, CO 5%, O2 1.8%, balance N2

2 Span gas CO2 and CO, ‘zero’ gas for O2

3 Calibration gas for the Diluter lineCO2 5%, balance N2 95% (or Argon)

2 Span gas for CO2, Zero for O2 and CO

4Regulators: Pressure and flow regulator for calibration

58/103 L preset flow regulators 2

Feed calibration gases into the system

5Compressor: Main air compressor

500 lit/minute 8 Bars, 50-70 litre tank 1

Air supply for the diluter

6Filters: Compact 1 micron gas and air filter housings

P32F Standard filter body, manual drain 4

Clean air for diluter, vortex; clean gases

7Filters: Compact 1 micron gas and air filter housings

P32F Standard filter body, auto drain 3

Clean air for diluter, vortex; clean gases

8Filters: Compact 1 micron gas and air filter elements

P32F 1.0 µm Particle filter element 15

Clean air for diluter, vortex; clean gases

9Filters: Compact 0.01 micron coalescing filters elements

Compact 0.01 micron coalescing filters elements 12

Clean air for diluter, vortex; clean gases

10

Regulator: Pressure regulatorsP32R Compact pressure regulator, 0-8 bar 3

Control max pressure in various lines

11

Regulator: Low pressure regulator

P32R low pressure regulator 0-2 bar (different spring) 1 Diluter supply

12

Gas Chiller: Vortex Tube

Vortex generator for cooling gas samples to 2°C 2

Cooling the gas samples

13 Gas Chiller: Condensing copper tube and manometer

Plastic housing and copper condenser 2

14Gas Chiller: Calibrated pump for taking filter samples

Pump, sample pipes, impactor, large diameter filter housing 1

Gravimetric measurement of PM

Sample handling15

Double head pump: Drying the stack gas sample (CO2-1, O2)

Sample pump drawing the gas from the sources to the analyser 1

16Repair kit

Mini Encapsulated repair kit 2 Spare parts

17Humidity sensor: TESTO 6381, Differential pressure RH and temperature

Monitors the pressure in the Red and Blue lines 2

Monitor gas pressure and dew point

18Humidity meter: Stack humidity (water vapour concentration)

Hot channel water vapour 0-15% H2O, >180 C 1

Determine the water vapour content in stack

19

Gas analyser: X-Stream

NDIR gas analyser with LAN connection. Rosemount X-Stream, dual channel, CO, O2, CO2x2 1

Measure gas concentrations

20Spares, filters

Filters (consumable per test) 50

21

Smoke diluter

Draw a smoke sample, dilute and cool it

Data acquisition22 Компьютер: Model: Dell ; Processor: i5;

RAM: 4 G Byte; Monitor: Two 24 inch monitors; Video card to support connection of two monitors DVI x 2; Hard disk drive – sizing of 1 Tbyte ( 2x500 Mbyte HDD); DVD RW

1 For 2nd line of testing low

pressure boilers

x 1;DVI cables for monitors- 2 set; Legal software Windows 7 32 bit Ultimate, Ver 6.1.7600; Official registered software (windows and MS office application) with original disks: Office 2007 with free upgrade to 2013.

23

Network printer A4, (SCX-4300)

1

Black white network printer is needed for everyday reports

24

1х8 port Ethernet Нub 1

To connect Network printer and other network devices

2517 Byte Hard disk

1For keeping valuable data for long time.

26

UPS 5 kW

1

Have repeat test ones electricity off, loosing whole data, labour and fuels

27

Agilent, Voltage and current logging instrument with 3 port

Data acquisition multiplexer, 34972A with

34901 temperature module

1

Record temperature, humidity and pressures

28Software, Benchlink Pro Reads the Agilent

multiplexer1

29 Control Panel

30Pressure gauges 2-1/2” oil-filled pressure

gauges, 10 PSI3

Measure gas sample pressure

31Vacuum gauges 2-1/2” oil-filled vacuum

gauges, -1 bar 2

Measure Nafion vacuum pressure

32Nylon 6mm high pressure tubing, 4 colours, 50m ea Small piping used for

conveying gases4

Connect instruments and controls

33Pneumatic gas routing valves.

Three position gas switches

2Change gas paths in real time, calibration

34Pneumatic gas routing valves.

Two position gas switches

2Supplies air or calibration gases to meters

356mm push-in x ¼” pipe thread connectors Standard 6mm push-in

fittings1

Connect equipment

366mm push-in Tee x ¼” pipe thread connectors Standard 6mm push-in

fittings1

Connect equipment

376mm push-in elbow ¼” pipe thread connectors Standard 6mm push-in

fittings1

Connect equipment

38 Pneumatic speed control valves Throttling valve `1 Manual needle

valve

39Back pressure valves Veriflo 2 port regulator

for gas lines (out) 2BCK PRES REG SS TFE 1-5 3 PRT

40Rotameters DK800S-6 25-250 litres

per hour8

Measure gas and air flows

41Thermocouples 8mm x 300 and 450mm

thermocouples10

Measure temperatures

42Thermocouple wire

50 mConnecting the thermocouples to logger

43Thermocouple plug ends

10Connecting the thermocouples to logger

Portable equipments

44

Gas analyzer TESTO 350XL/454 No. Items. Meas. Range.Resolution

1. CO2 0...25 % 0.01%

NDIR Cell2. O2 0...50 %

0.01%3. CO 0...10000 ppm

1 ppm4. NO 0...3000 ppm

1 ppm5. H2S 0...500 ppm

0.1 ppm6. H2 0...1000 ppm

0.1 ppm7. SO2 0...5000 ppm

1 ppm8. CH4 100...40000 ppm

±10ppm 9. Probe type 0...1600 ÎÑ 0.1 ÎÑ (NiCr-Ni)10. Ambient air, tа -25...+45 0Ñ 0.1 0Ñ11. Gas velocity , w 0...40 ì/ñ 0.1 ì/ñ

The Laboratory need for measuring NO, H2, H2S, SО2 and other pollutants’ during test of stove and low pressure boilers. It can also be used on site for spot checks to confirm the suitability of burn cycles employed during testing in the laboratory (field-based verification of methods)

44 con

t

454 unit (the part with the green screen above) 1. With pitot tube2. Pressure range: 0 to 20

hPa3. Pressure resolution:

0.001 hPa4. Pressure overload: 200

hPa5. Pressure accuracy (± 1

digit): 0.5% fsv6. Temperature range: 0 to

160°C7. Temperature resolution:

0.1°C8. Flow* range: +5 to +55

m/s9. Flow* resolution: 0.1

m/s

1set

-“-

45 Gravimetric filter instrument 1. Dust sampling prove (cup filter, nose prove, cylinder filter)

2. Medium filters3. cup filter -20 pc4. Pump

1set For measuring TSP in flue gas

5. Gas meter6. Down transformer

(220V -110V)7. Electron scale8. Dryer9. Silicon pipes10. Connection pipes

46

MULTICAL Energy meter as KAMSTRUP

[Please confirm that this unit can be read by the computer in real time via LAN or USB, otherwise it must be upgraded to a better model. CPP]

Temperature sensors Pt500-En 60 751Flow meter sizes qp 0.6…3 m3/hD=40 mmTemperature inputs T1, T2 and T3Temperature range: 0°C...165°C Differential range: 0K...160KDisplay resolution: 0.01KSensor type: Pt500 – EN 60 751Flow meter inputs V1 and V2 Input resistance: > 100 kΩPulse ON (< o.5 V): >0.5 msek.Pulse OFF (>2.0 V): >10 msek.Pulse frequency: <128 HzIntegration frequency: <1 Hz

1set

For measuring water flow rate, temperatures, pressure and heat capacity

47 Dust track GRIMM 11-R [Note: GRIMM 11-R is a viable alternative and has better real time communications capabilities. The problem of getting real time measurements from the DRX has not been solved. CPP]

Specifications are subject to change without notice.Sensor Type: 90° light scatteringRange: 8533 Desktop 0.001 to 400 mg/m3Display: Size Segregated Mass Fractions for PM1, PM2.5, Respirable, PM10 and Total. All displayedResolution: ±0.1% of reading of 0.001 mg/m3, whichever is greaterZero Stability: ±0.002 mg/m3 24 hours at 10 sec time constantParticle Size Range: Approximately 0.1 to 15 μmFlow Rate: 3.0 L/minFlow Accuracy: ±5% Internal flow controlledTemperature Coefficient: +0.001 mg/m3 per °COperational Temp: 0 to 50°CStorage Temp: -20 to 60°COperational Humidity: 0-95% RH, non-condensingTime Constant: Adjustable 1 to 60 secondsData Logging: <45 days at 1 minute samplesLog Interval: 1 second to 1 hourPhysical Size (HWD):

1

Handheld: 4.9 x 4.75 x 12.45 in. Desktop: 5.3 x 8.5 x 8.8 in. External Pump: 4.0 x 7.5 x 3.5 in.Weight: Handheld: 2.9 lb, 3.3 lb with battery Desktop: 3.45 lb, 4.45 lb – 1 battery, 5.45 lb – 2 batteries External Pump: 3.0 lbCommunications: 8533: USB (Host and Device) and Ethernet. Stored data accessible using thumb drive8534: USB (Host and Device). Stored data accessible using thumb drive.Power—DC: Handheld 12 VDC at 2A Desktop 24 VDC at 2.5A

48 Portable Ultrasonic Flowmeter, TTFM 1.0-A-1-A-1-B-1-A-2-A Transit Time Ultrasonic Flow Meter

Suggested that the Greyline TTFM-1 is a better choice because it can be read in real time via LAN. It is also portable and can be run on 12 VDC and 230 VAC.

APPLICATION: home water heating, 1-1 ¼” pipe, 90-110°C

A – power input – standard 100-240VAC 50/60Hz1 – enclosure – standard watertight NEMA4X (IP66) polycarbonateA – enclosure temperature – standard -5° to 140°F / -20° to 60°C1 – electronics protection – standard, not tropicalizedB – sensors – SE16B pair, clamp-on ultrasonic for ½” to 48” (12 – 1200 mm) ID pipes1 – rated non-incendive for Div 2, Groups A,B,C,DA – sensor cable – 25 ft / 7.6 m coaxial pair2 – 20 million point Data Logger with Windows software and USB output to Flash DriveA – control relays – qty 2 standard

*** with AP1W-30 High Temperature compound

- sensor installation kit with silicone coupling compound PC4 stainless steel brackets, clamps and alignment guide- display – backlit white LED, 1.7” x 2.4” (43 x 61 mm)- calibration – built-in 5-button programmer- sensitivity – keypad adjustable- outputs – isolated 4-20mA (1000 ohm)- 2 control relays – 5amp SPDT – programmable for flow proportional pulse output and/or flow alarm- electrical surge protection &

1 set For measuring water flow rate, temperatures

RFI filters – sensor, AC power input, 4-20mA output- installation & operation manual- CSA/C-US approved

49

Digital thermometer TX1001- Type K: -200 oC to 1372 oC [-328 oF to 2501 oF]

Temperature range: Thermocouple Type K: -200 oC to 1372 oC [-328 oF to 2501 oF] Resolution: -200 oC to 199.9 oC: 0.1 oC 200 oC or higher: 1 oC -200 oC to -100.1 oC: 0.1 % of rdg + 1.0 oC -100 oC to 199.9 oC: 0.1 % of rdg + 0.7 oC 200 oC or higher: 0.2

% of rdg + 1 oC

1set

50 Opus 20E Datalogger for External Sensors

The OPUS20E offers the highest flexibility and is excellent value for money. It allows the connection of up to 4 external temperature and relative humidity sensors, as well as 2 further analog sensors. Intelligent BUS sensors can be integrated via the OPUS20E’s RS485 interface (e.g. particle counter).

Dimensions 6½” x 3” x 1¼” (180mm x 78mm x 32mm)Measuring interval 10/30s, 1/10/12/15/30min, 1/3/6/12/24hStorage rate 1/10/12/15/30min, 1/3/6/12/24hConstruction Plastic housingOperating life (battery) <1 yearData storage 16 MB, 3,200,000 measured valuesLC-Display 3½” x 2½” (90 x 64mm)Weight 8 oz. (250g)Included in delivery PC-Windows Software SmartGraph 3 for graphical and numerical representation of measured values / Instructions/ data cable/ battery/ WAGO connector / DIN rail bracketInterface USB, LANbus interface RS485Power supply 4 x LR6 AA Mignon, USB, (POE opt.)Operating temperature -4 to 144°F (-20...50°C)Input voltage 0-1VMeasurement range 0....1VAccuracy ±200uV ±0.1% of measured valueResolution <500uVCurrent measurement

1set For measuring water temperature

Measurement range 2-wires: 4 ... 20mA,3-wires: 0...20mAAccuracy ±4uA ±0.1% of measured valueResolution <5uAResistance approx. 50 OhmThermocouple KMeasurement range -200°C...1200°CAccuracy °°± 1°C ± 0.5% of measured value at -200°C ... 0°C ± 1°C ± 0.2% of measured value at 0°C... 1200°CResolution < 0.2°C

51Thermocouple extension cable 20AWG stranded conductors

60For measuring temperature

52Small crusher (lab crusher)With screens for 13-40mm size selection for tests.

1For coal crushing

53

Welding apparatus

1

Needed for improving stove and low pressure boilers

Table 2: Measurements that can be taken

Metric Units Laboratory Test

Initial Mass of stove G ± 2 g

Ignition fuel(s) – description and sample where relevant for moisture analysis

G 1 g

Coal to be used burned in the initial load, keep a representative sample for ultimate analysis (including moisture content)

G 1 g

Coal to be added to the fire when refueling; where similar to ignition coal, no additional sample is needed. If refueling with a different fuel than the one(s) used for starting, keep a representative sample for ultimate analysis (including moisture content if different from the other fuel).

G 1 g

Ambient Air Gases

Ambient Oxygen level O2~1 % Optional

Metric Units Laboratory Test

Ambient Carbon Dioxide level CO2~1 % Optional

Ambient Carbon monoxide level CO~1 ppm Optional

Ambient Hydrogen Sulphide H2S~1 ppm Optional

Ambient Sulphur Dioxide SO2~1 ppm Optional

Ambient Nitrous Oxides NOx~1 (NO~1 and NO2~1) ppm Optional

Ambient relative humidity % Optional

Stack Gases

Oxygen level in the stack O2~2 % X

Carbon Dioxide level in the stack CO2~2 % X

Carbon monoxide level in the stack CO~2 ppm X

Relative humidity in the stack % Optional

Diluter Gases

Carbon Dioxide level in the diluter CO2~30 % X

Hydrogen in the stack H2~2 ppm Optional

Hydrogen Sulfide in the stack H2S~2 ppm Optional

Sulfur Dioxide in the stack SO2~2 ppm Optional

Nitrous Oxides in the stack NOx~2 (NO~2 and NO2~2)

ppm Optional

Hydrocarbons in the stack CxHy~2 ppm Optional

Volatile Organic Compounds in the stack VOC~2 µg/m3 Optional

Polycyclic Aromatic Hydrocarbons in the stack PAH~2

µg/m3 Optional

Particulates

PM measurements, all channels: PM 1.0, 2.5, 4.0 and mg/m3 X

Metric Units Laboratory Test

10

PM measurement on a filter using a calibrated pump for gravimetric confirmation

mg/m3 X

PM collected on a filter in addition to the light scattering system

mg/m3 Optional

Mass of the stove during the burn (continuous basis) g ± 2 g

Temperature measurements

Temperature of the ambient air in the room where the stove is sited, unheated by direct radiation from the stove. T1

C 1 deg

Temperature of the gases in the stack at the point where it leaves the ‘envelope’ (normally the chimney-roofline junction). T2

C 1 deg

Temperature of the gases in the stack at the top of the chimney (outside) T3

C 1 deg

Temperature of the gases in the stack at the bottom of the chimney T4

C 1 deg

The time of ignition 24hr basis hh:mm:ss

Time of significant events like smoke disappearing, flame out, collapse of the fuel pile, sudden smoke, flashbacks etc.

Notes X

Time of refueling 24hr basis X

Time of end of test 24hr basis X

Mass of ‘fuel remaining’ g X

Mass of ‘Ash remaining’ g X

Representative sample of ‘fuel remaining’ for ultimate analysis

g X

Other Observations

Fuel remaining g X

Metric Units Laboratory Test

Mass of ash remaining g X

Final mass of stove (empty) g ± 2 g

Calculated outputs

Thermal efficiency using the Siegert Formula % % X

Rate of fuel burned g/minute X

CO g/MJ and g/kg X

CO2 g/MJ and g/kg X

SO2 g/MJ and g/kg Optional

Hydrogen g/MJ and g/kg Optional

PM1.0 mg/MJ and mg/undiluted standard

m3

Optional

PM2.5 mg/MJ and mg/undiluted standard

m3

X

PM 4.0 (respirable) mg/MJ and mg/undiluted standard

m3

Optional

PM 10 mg/MJ and mg/undiluted standard

m3

X

TSP mg/MJ and mg/undiluted standard

m3

Optional

VOC µg/MJ and µg/undiluted standard

m3

Optional

PAH µg/MJ and µg/undiluted standard

m3

Optional

Data quality checks

Metric Units Laboratory Test

∑O2 in ppm, calculated by summing all the O2 contained in all the gases detected in the stack per measurement interval.

A perfect result = a horizontal line

X

∑Carbon(EF) values, calculated by summing the Carbon-containing gas emissions factors, per measurement interval.

A perfect result tracks ∑O2 line

X

If gas flow measurements are available, check for stability.

Litres per hr Optional

If pressure measurements are available, check for stability.

hPa Optional

2.3 Tools

A number of tools will be required to set up the tests. The tool kit will contain all items listed below:

1) Battery powered drill for making a hole in combustion vent. – 1 w/extra battery2) Caps for covering holes when test is complete. – 100 3) Tube of high temperature RTV for patching flues if needed. – 24) Drill bits (for fitting flue gas probe)-5 for steel flue pipe & 2 for masonry, plus full set5) File for removing corrosion, etc. to prepare strap on sensor sites (12 inch Mill Bastard

file). – 16) Plumbers’ tape (sanding tape) for removing corrosion, etc. to prepare strap on sensor sites.

– 17) Thermal contact gel.8) Pipe insulation, foam, two foot lengths, at each pipe size from 2 inch and up to 8 inches,

for covering the strap on sensors assuring good temp readings – 2 at each size9) Wire ties for strapping on the insulation: 20” & 10”- 100 at each size.10) Coil of steel wire for various purposes. 2 spools of 50 feet11) General tools: Linesman’s pliers, Needle nose, Channel locks, Vise grips, Socket set with

drivers and extensions, Assorted screwdrivers, Hammer, and small pry-bar.12) Gloves appropriate for handling hot boiler parts – 113) Mechanics rags – 2014) Stop watch 15) Clip Board16) Blank forms – one set per LPB

III TYPES OF TESTS3.1 Emissions Test

Volatile gasses (CO, CO2, NO2, SO2, O2, H2, , Tflue gas ) shall be measured and monitored inside LPB flue stack throughout a controlled time span.

3.2 Combustion Efficiency TestShall consist of a test point conducted at 100% ± 2% of the input to the boiler and shall yield an accounting of energy input in terms of products of combustion only.

3.3 Energy Flow TestShall consist of MULTICAL Energy meter as KAMSTRUP and an ultrasonic flow test point conducted at HWS output of the boiler and temperature test points conducted at HWS & HWR of the boiler. Results shall yield an accounting of energy output.

3.4 Surface Temperature TestShall consist of an infrared temperature test point conducted at the surface of the. Results shall yield an accounting of energy lost through the boiler shell in terms of products of combustion only.

IV. PROCEDURE

A. Each LPB is to be tested using each listed test device (listed above). Prior to the test procedures set out below, be sure to read all relevant equipment manuals to fully understand functions and operation of each instrument.

B. Tests must be recorded either by equipment data logging or manually completed test data forms.

Complete Table 1.1 prior to each test.

Boiler Manufacturer

Boiler Model

Boiler Capacity

[1]Date

(M/D/YR)

Tests Performe

d [2]

Start Time of

Test

End Time of

Test A B C D

[1] Indicate whether value is input or output[2] A) Emissions, B) System Efficiencies, C) Particulate Matter, D) Surface Temperature

D. Observe combustion upon arrival and establish steady state combustion. Direct the boiler operator to stoke the boiler normally to maintain operating conditions. If the boiler is coming up to temperature (eg: early morning warm up) do not start the tests until the HWS temperature exiting and HWR returning to the boiler have reached a steady state condition (+/- 5 Deg. F). It is the tester and operators responsibility to judge if the combustion is in the normal range.

4.1 Fuel

Use a fuel which has been analyzed for moisture and chemical content, or else keep a representative sample of it.

Fuel size is an important variable affecting stove performance. The fuel should be ‘characterized’ so that is it known what conditions and fuel produced the test results. At the least, the coal should be of a known size or mix of sizes.

Excessive dust and large coal are not considered suitable fuels for standard tests. If one is researching the effect of such fuels, then they should be characterized and reported along with the results.

Once the post-test fuel analysis is in place, a sample of fuel remaining at the end of the test is to be retained for ultimate analysis. This investigation may be stopped once the changes in fuel are characterized and if the residual coal composition is found to be consistent.

It is common to light coal stoves using paper and wood, small propane burners, diesel, rubber strips and garbage. Because the emissions from the ignition materials are highly varied it is important to record the mass and nature of igniting materials.

If a cleaner lighting technique is known to the tester, it is acceptable to use alternatives to that suggested by the manufacturer. Consultation with the manufacturer may result in an optimal ignition method.

4.2 Emissions Test Procedure

A. Procedure written for gas analyzer X-Stream

STEP 1: Check that the readings on the gas analyzer correspond to dry air: O2 = 20.945%, CO2 = 0.039% on both channels, CO to a low value. The ambient air CO level is normally under 5 ppm, usually 1 or 2 ppm.

STEP 2: Turn on all the pumps (3) and check that the vacuum levels are all about -0.5 bars, and the two gas paths about 3 psi and steady. The compressed air supply is always above 1 bar.

STEP 3: Check that the gas flow rate on the stack and diluter channels is 90 litres per hour, and 250 litres per hour on the diluter. If the stove is cold and unlit, the X-Stream should indicate clean ambient air gas values.

Figure 2 Procedure written for Testo 350

(*Note: The measurement program/solid fuel measurement must be activated prior to test.)

STEP 1: Ensure all system components/necessary probes & sensors are properly connected.

STEP 2: Insert flue gas probe (with probe pre-filter) into the flue gas pipe. Align the probe by turning it as required. The tip of the probe must be in the center of the flue gas flow (area of the highest flue gas temperature).

STEP 3: Set measurement run time criterion to 4 hours.

STEP 4: Start pump.

STEP 5: Observe measurement values until the O2 < 20%, in order for values to be calculated.

STEP 6: Start measurement program/solid fuel measurement.

STEP 7: After the test is finished, deactivate the measure program.

STEP 8: Rinse and clean flue gas probe.

4.3 Particulate Matter Test Procedure (*Procedure written for Dusttrack and Gram metric Filter)

STEP 1: Turn on instruments and let them run through their initialization sequence. Check for any error conditions: the Dusttrak DRX may for example need to have its internal filter changed.

STEP 2: Turn on the compressed air system and pass dry air through both channels of the gas analysis system. Do not use air drawn through to combustion gas filters near the test bench, only air coming from the compressed air supply to the diluter.

STEP 3: Check the time on the computer and internal clock of each device. Synchronize them with the computer clock any of them differs by more than 5 seconds.

STEP 4: Turn on the Dusttrak DRX particle counter. Perform a 0-calibration using the plug-on total filter.

STEP 5: Check the DRX displayed value of PM 2.5 to see that it is reasonable. On a clean day it may be 30 µg/m3.

4.4 System Efficiency Test Procedure (*Procedure written for Portable Ultrasonic Flowmeter, TTFM 1.0-A-1-A-1-B-1-A-2-A)

(*Note: For steps 1 through 6, refer to Figure 2.)

STEP 1: Ensure that the proposed location satisfies the distance requirements (straight length of pipe upstream of the transducers of at least 20 times the pipe diameter and 10 times the pipe diameter on the downstream side) otherwise the resulting accuracy of the flow readings may be affected.

STEP 2: Prepare the pipe by degreasing it and removing any loose material or flaking paint in order to obtain the best possible surface.

STEP 3: Slide the separation bar (D) into the front of the left hand guide rail, align the front edge of the guide rail with ‘0’ on the ruler scale (E) and secure it in place by tightening the thumbscrew ©.

STEP 4: Slide the other end of the separation bar into the front of the right hand guide rail, align the front edge of the guide rail to the required separation distance (obtained from the Portaflow instrument) on the ruler (F), then secure it in place by tightening the thumbscrew.

STEP 5: On each guide rail, attach one end of a securing chain to a hook on the tensioning bar (B), wrap the chain around the pipe (G) and then attach it to the hook on the other end of the tensioning bar whilst keeping the chain as tight as possible.

STEP 6: Rotate the complete guide rail assembly so that it is approximately 45° with respect to the top of the pipe. Then tighten the chain by turning the tensioning thumb-wheel (A) on each guide block until the assembly is securely attached to the pipe.

Figure 2 (guide rail attachment)STEP 7: Slide the transducer cover plate (A) fully towards the outside of the guide

assembly to allow sufficient access to fit the transducer.

STEP 8: Clean the face of the transducer, removing all traces of dirt and grease.

STEP 9: Apply a 1/8” (3mm) bead of ultrasonic couplant along the centre length of the transducer (E).

Figure 2.

(*Note: For steps 7 through 13, refer to Figure 3.)

STEP 10: Fit the transducer into the guide block – ensuring the lugs on the sides of the transducer are correctly located into the slots on the sides of the guide block (B).

STEP 11: Slide the transducer cover plate (A) over the top of the transducer and tighten the thumbscrew (C) finger tight to secure the transducer in place. When securing the cover plate take care to leave sufficient room around the transducer connector (D) to connect the cable.

STEP 12: Repeat steps 8 through 12 for the second transducer.

STEP 13: Connect the transducers to the Portaflow instrument using the coaxial cables provided. The RED cable must be connected to the upstream transducer and the BLUE cable to the downstream transducer.

Figure 3 (guide rail attachment)

STEP 14: Begin testing.

V. DATA AND PROCESSING

5.1 Emissions & Combustion Efficiency Data

At 10 second intervals data is to be printed, from the onboard data logger, for physical records. At completion time of test (4 hours), data is to be electronically stored on testing device for extraction and transfer to a computer, at a later time.

Turn on all the recording programmes: start the Scale reader(s) and look to see that the ‘Saved’ counter is increasing; the Agilent SCAN is running; the screen of the X-Stream blinks briefly as it saves a data set, and the Dusttrak DRX is running. If there is other software running on the computer that is capturing data, see that it is receiving the information. Do not light the stove until at least 1 minute after recording starts.

The following data shall be recorded:

Time (M/D/Y; Hr:Min:Sec)Weight of solid fuel (kg)Flue gas: CO, CO₂ (%), NO₂, SO₂, O2, H2, Temperature of flue gas (degrees F)Temperature of indoor (ambient) air (degrees oC)

*Complete blank data sheet found in Appendix 2 for blank data sheets incase of electronic data failure.

5.2 System Efficiency Data

At 10 minute intervals data is to be manually recorded, for physical records. At completion time of test (4 hours), data is to be electronically stored on testing device for extraction and transfer to a computer, at a later time.

The following data shall be recorded:

Time (M/D/Y; Hr:Min:Sec)Flow rate of water in pipe (l/min)Temperature of HWS and HWR (degrees oC)

*Complete blank data sheet found in Appendix 2 for blank data sheets incase of electronic data failure.

5.3 Particulate Matter Data

5.4 Surface Temperature Data

Appendix 1: Abbreviations

LPB …………… Low pressure BoilerMW ……………… MegawattHWS ………….. Hot Water SupplyHWR ………….. Hot Water Return

Appendix 2: Data Sheets

Appendix 3: Test Equipment Specifications

VI. BOILER COMBUSTION PERFORMANCE

Fuel consumption rate F=Fw/T (1)

Here: F: Fuel consumption, kg/h; Fw: Total fuel used, kg; T: fired time h.Grate combustion rate

r=F/Sf (2)Here: r: Grate combustion rate kg/(m2h); F: Fuel consumption kg/h; Sf: surface area of grate, m2.Furnace heat liberation

Hm=F*(Qir

+Qa)/(3600Vf) (3)

Here: Hv: Furnace heat liberation kW/m3; F: Fuel consumption kg/h; Qir

: Low heat value kJ/kg (kcal/kg); Vf: Furnace volume m3; Qa: heat by air kJ/kg,2. Heat capacity of hot water boiler

Q=W c (t1-t2) 10-6 (4)Here, Q: heat capacity of hot water boiler, Gcal/h; W: water flow rate kg/h; c=1 kcal/kgK=4.19 kJ/kgK- specific heat of water; t1: temperature of water outlet from boiler, oC; t2: temperature of inlet (returned) water to boiler, oC;

VII. BOILER EFFICIENCY (Direct heat balance method)

Boiler efficiency means the amount of heat that is absorbed in the heating of water relative to the total amount of heat supplied. The method of calculation boiler efficiency is as follows.

= Q 100/(3600FQir

) (5)Here, : boiler efficiency %; Q: heat capacity of hot water boiler, MW (Gcal/h); F: fuel

consumption kg/h; Qir

: Low heating value of fuel, MJ/kg (kcal/kg).

The calorific value is generally used for efficiency calculation. We have taken coal samples and determine the calorific value of combustion, volatile matter, moisture and ash content of coal in the laboratory.

We measure coal consumption, water flow rate, temperature of water outlet from boiler and temperature of inlet (returned) water to boiler for determining boiler efficiency by direct heat balance method.

Table 3. Test Result and Main Indices of LPBTest

# Name of LPBWater flow

rate, kg/h

Temperature of HWS, oC

Temperature of HWR,

oC

Average power,

KW

Fuel consumption,

kg/h

Thermal efficiency,

%

Table 4. Test Result for Emission factors of LPBTest Name of LPB CO/CO2 Dust, CO, NOx, SO2, Dust CO NOx SO2 Flue gas

# ratio, % g/ kg coal

g/ kg coal g/ kg coal g/ kg

coal mg/ MJ g/ MJ g/ MJ g/ MJ temperature, oC

Table 3. Comparison of LPB’sTest # Name of

LPB

Fuel saving,

%

Dust reduction,

%

CO reduc

tion, %

NOx reduction, %

SO2 reduction, %

Heating power, KW

Combustion control Life cycle