Third Quarter 2009 - Nox & Noise: Dealing With What Comes Out reprinted with permission subscriptions: [email protected] Windrock AutoBalance module Integral engine equipped with Windrock AutoBalance system (above) Integral engine equipped with Windrock AutoBalance system • Stepper-motor actuated fuel valves (replacing man- ual valves) • Pressure sensors on each monitor pressure on-line E-Guard Windrock • AutoBalance module to control fuel valve positions • System Description Components of the system include: All components are Class 1, Div 2 Balance system rated. is easy The and inexpensive Auto- to install. The system incorporates self-diagnostics and requires maintenance other no than semi-annual, on-engine sensor calibration during normal unit operation. - - - “The Windrock AutoBalance system was to be developed a more practical alternative. Compared to pressure high- systems, AutoBalance an system is economical and easy to install. And unlike balancing, it maintains constant engine balance over ex- manual tended periods without any human intervention.” suming and, in most cases, is not performed frequently enough to guarantee the units are always in compliance with their permits. Tighter emissions regulations will only add to the burden as operators are forced to ance bal- engines more frequently in an attempt to remain in date, regulatory the compliance. To only other option has been auto-balancing using high-pressure fuel injec tion systems, which are extremely expensive. “Manual engine balancing is labor-intensive, time-con Operators Operators of slow-speed, integral engines have a new option to help reduce emissions, cut fuel sumption, con- decrease wear and im- availability. machine overall prove All of these benefits result from a can and - engine balanced properly now be achieved using a recently introduced system Windrock from (a Dover Company). The technol “Engine operators in these applications face increasing pressure to reduce emissions,” says Steve Follmar, VP\ “Although the exact General im- Manager Windrock. of pact of upcoming emissions regulations remains to be seen, we anticipate a broader range of large, stationary engines will be required to comply with stringent emissions restrictions”. increasingly New Automatic Engine Balancing Technology Controls NOx and CO Emissions CO NOx and Controls Technology Balancing Engine Automatic New Windrock’s AutoBalance system provides continuous, peak-pres- sure balancing for large- natu- ral gas fired engines. The system is designed for slow- Clark/ Cooper-Bessemer, as such engines integral speed, and other two- or Worthington, Ingersoll-Rand, Dresser, four- engines with individual cylinder fuel justment valves. Typical applications ad- for these engines include natural gas gathering, transmission, processing and storage. ogy, ogy, called the system, AutoBalance™ automatically maintains engines 24/7. optimal balance on Third Quarter 2009 - Nox & Noise: Dealing With What Comes Out reprinted with permission subscriptions: [email protected] - About Windrock Windrock, Incorporated, provides monitoring and diagnostic equipment for machinery reciprocating in the oil, gas, marine and power generation industries. Founded in 1989, Windrock is based in Knoxville, Tennessee. an- portable distributes and manufactures engineers, Windrock techni provides also company The systems. online and alyzers Windrock contracts. service extended with services support cal informa- of variety a process and collect systems and analyzers tion, such as dynamic engine/compressor pressure, vibration, used is information This parameters. other and data ultrasonic to assess the mechanical condition of machinery and optimize maintenance practices. detonation detonation and uneven load distribution, dramatically improving reliability and reducing mechanical Precisely maintained wear. PFP balance also improves fuel from 1% to 5%. economy Combining Windrock’s AutoBalance system with im- proved air-fuel ratio control lev- to reduced be to emissions allows retrofits, chamber and/or pre-combustion but systems, injection fuel high-pressure approaching els cost. at a significantly lower As emission regulations tighten and companies look for - Win operate, to ways responsible environmentally more a practical solution. system offers AutoBalance drock’s - - Motor actuated fuel valves (right) By maintaining optimum mechanical operating dition, the con- AutoBalance system practically eliminates Eliminating unbalanced operation across all operating conditions enables the engine to run with the minimum possible NOx and CO emissions for the engine configu- >25% demonstrated has system AutoBalance The ration. reduction of NOx emissions (compared to standard con- trols), with emissions maintained at ± 5% of and average, speeds varying conditions, ambient differing despite changing loads. Results The E-Guard module measures peak (PFP) firing statistics and pressure angles for Proprietary each balancing algorithms power utilize PFP cylinder. feedback and combustion statistics to control fuel valve changes. These changes not only balance peak firing pressures, but also optimize the consistency of combustion. Peak pressures are continuously maintained at a consistent level across all power cylinders of the engine. ing intervals may vary from weekly, to month or quar terly, depending on operating company policies). The objective is to adjust fuel flow to each power cylinder in engine of 5% ± to pressures firing peak maintain to order average. The AutoBalance approach mimics traditional engine balancing, except that it is performed on a continuous basis instead of a regular time interval (manual balanc Principle of Operation Principle New Automatic Engine Balancing Technology Controls NOx and CO Emissions CO NOx and Controls Technology Balancing Engine Automatic New