Alternate Energy Systems, Inc.

2004 LP Symposium Des Moines, 12-13-14 July 2004

Automatic Wobbe Index Control for Peak Shaving Plants

Introduction
Wolfgang H Driftmeier
Alternate Energy Systems, Inc.
210 Prospect Park
Peachtree City, GA 30269
770-487-8596
770-631-4306
[email protected]
www.altenergy.com
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 Alternate Energy Systems, Inc.
2004 LP Symposium Des Moines, 12-13-14 July 2004
Automatic Wobbe Index Control for Peak Shaving Plants

Automatic
Wobbe Index Control
for
Peak Shaving Plants
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 Alternate Energy Systems, Inc.
2004 LP Symposium Des Moines, 12-13-14 July 2004
Automatic Wobbe Index Control for Peak Shaving Plants

Keywords
• Natural Gas • Applied Engineering
• Propane / Air; LP / Air • Algas / Sam Dick Industries
• Synthetic Natural Gas (SNG) • Algas-SDI
• Propane / Air / Natural Gas (PANG) • Alternate Energy Systems
• Interchangeability • Ely Energy
• Calorific Value • Ransome
• Specific Gravity • Ranarex (Chandler Eng.)
• Wobbe Index • Cosa Instruments
• Ratio Control • Delta Instrument
• Gravitometer • Hobre Instruments
• Calorimeter • Reineke Fuchs
• Union Apparatebau

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 Alternate Energy Systems, Inc.
2004 LP Symposium Des Moines, 12-13-14 July 2004
Automatic Wobbe Index Control for Peak Shaving Plants

Industry Situation

• Most Existing Peak Shaving and Base Load Plants

are from “the 70s” (built by Applied Engineering)
• Most are Flow-Controlled (manually)
• Most adjust the mixture by manually
changing the Air Flow
• Most are strictly Specific Gravity controlled (manually)
• Most use 30s Technology to measure Specific Gravity
(Ranarex Gravitometer)
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 Alternate Energy Systems, Inc.
2004 LP Symposium Des Moines, 12-13-14 July 2004
Automatic Wobbe Index Control for Peak Shaving Plants

Typical Existing Peak Shaving Plants

• Most existing Systems only have
2 upper and 2 lower SG Alarm Contacts
• First (upper or lower) Alarm is for
Operator Notification only
• Operator is supposed to make
Manual Adjustments
• Second (upper or lower)
Alarm Shuts System Down
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 Alternate Energy Systems, Inc.
2004 LP Symposium Des Moines, 12-13-14 July 2004
Automatic Wobbe Index Control for Peak Shaving Plants

Typical Mixed Gas Settings

SGSNG = 1.28 to 1.32
CVSNG = 1292 BTU/cuft @ 1.28
to 1476 BTU/cuft @ 1.32
RatioSNG = 51/49 Vapor/Air @ 1.28
to 58/42 Vapor/Air @ 1.32

SNG = Synthetic Natural Gas

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 Alternate Energy Systems, Inc.
2004 LP Symposium Des Moines, 12-13-14 July 2004
Automatic Wobbe Index Control for Peak Shaving Plants

Which Setting is the “right” Setting?

1.28 ?
1.30 ?
1.32 ?
1.xx ?
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 Alternate Energy Systems, Inc.
2004 LP Symposium Des Moines, 12-13-14 July 2004
Automatic Wobbe Index Control for Peak Shaving Plants

Which Setting is the “right” Setting?

That’s where the

Wobbe Index
comes in.
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 Alternate Energy Systems, Inc.
2004 LP Symposium Des Moines, 12-13-14 July 2004
Automatic Wobbe Index Control for Peak Shaving Plants

Who was Mr. Wobbe?

Goffredo Wobbe
Physicist
Bologna, Italy

In 1927 he had these thoughts:

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 Alternate Energy Systems, Inc.
2004 LP Symposium Des Moines, 12-13-14 July 2004
Automatic Wobbe Index Control for Peak Shaving Plants

Mr. Wobbe’s Thoughts

1.
The heat output of a burner
at constant gas pressure
at constant orifice size
is proportional to
the flow volume per time.
(The longer you run the burner, the more heat
is being put out.)
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 Alternate Energy Systems, Inc.
2004 LP Symposium Des Moines, 12-13-14 July 2004
Automatic Wobbe Index Control for Peak Shaving Plants

Mr. Wobbe’s Thoughts

2.
The flow velocity through a given orifice size
at constant pressure
is proportional to
the specific gravity (SG) of a gas.

(The lighter a gas molecule is, the more molecules

can pass through a fixed-size orifice.)
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 Alternate Energy Systems, Inc.
2004 LP Symposium Des Moines, 12-13-14 July 2004
Automatic Wobbe Index Control for Peak Shaving Plants

Mr. Wobbe’s Thoughts

3.
The calorific value (CV) of a gas
is proportional to its specific gravity (SG).

NG 1000 BTU/ft3 SG=0.61 à 1640

C3 2516 BTU/ft3 SG=1.53 à 1644
C4 3280 BTU/ft3 SG=2.00 à 1640
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 Alternate Energy Systems, Inc.
2004 LP Symposium Des Moines, 12-13-14 July 2004
Automatic Wobbe Index Control for Peak Shaving Plants

Mr. Wobbe’s Conclusion

If we combine the three thoughts, we can
come up with a formula that allows us to
compare the flow characteristics of two
gasses.
If we know their CVs or SGs, we can
determine whether they produce similar
heat outputs when used with the same
orifice.
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 Alternate Energy Systems, Inc.
2004 LP Symposium Des Moines, 12-13-14 July 2004
Automatic Wobbe Index Control for Peak Shaving Plants

Mr. Wobbe’s Formula

Calorific Value
Wobbe Index =
SG

He decided to keep the number dimension-less

to avoid confusion with CV.

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 Alternate Energy Systems, Inc.
2004 LP Symposium Des Moines, 12-13-14 July 2004
Automatic Wobbe Index Control for Peak Shaving Plants

Wobbe Index
Wobbe Index Explanation (from American Gas Association Bulletin No. 36)

The Wobbe number, or Wobbe index, of a fuel gas is found by dividing the
high heating value of the gas in Btu per standard cubic foot by the square
root of its specific gravity with respect to air. The higher a gases' Wobbe
number, the greater the heating value of the quantity of gas that will flow
though a hole of a given size in a given amount of time. It is customary to
give a Wobbe number without units–even though it has the dimensions
Btu per scf–because to do so would lead to confusion with the volumetric
heating value of the gas.
In almost all gas appliances, the flow of gas is regulated by making it
pass through a hole or orifice. The usefulness of the Wobbe number
is that for any given orifice, all gas mixtures that have the same
Wobbe number will deliver the same amount of heat. Pure methane
has a Wobbe number of 1363; natural gas as piped to homes in the
United States typically has a Wobbe number between 1310 and 1390.

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 Alternate Energy Systems, Inc.
2004 LP Symposium Des Moines, 12-13-14 July 2004
Automatic Wobbe Index Control for Peak Shaving Plants

A Closer Look
at the Wobbe Index !
Wobbe Index of Natural Gas
Calorific Value
Wobbe Index =
SG
1000 [BTU / cuft ] 1000
Wobbe Index = =
0.61 0.781

Wobbe Index of Natural Gas = 1280

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 Alternate Energy Systems, Inc.
2004 LP Symposium Des Moines, 12-13-14 July 2004
Automatic Wobbe Index Control for Peak Shaving Plants

A Closer Look
at the Wobbe Index !
Wobbe Index of Natural Gas
SG 0.59 0.6 0.61 0.62
Sqrt(SG) 0.7681 0.7746 0.7810 0.7874
CV Wobbe Index
950 1237 1226 1216 1207
980 1276 1265 1255 1245
1000 1302 1291 1280 1270
1050 1367 1356 1344 1334

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 Alternate Energy Systems, Inc.
2004 LP Symposium Des Moines, 12-13-14 July 2004
Automatic Wobbe Index Control for Peak Shaving Plants

Back to our earlier Question

Which Setting is the “right” Setting?
1.28 ?
1.30 ?
1.32 ?
1.xx ?

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 Alternate Energy Systems, Inc.
2004 LP Symposium Des Moines, 12-13-14 July 2004
Automatic Wobbe Index Control for Peak Shaving Plants

Wobbe Index of LPG/Air Mix

SGSNG = 1.28 to 1.32
√1.28 = 1.1313
√1.32 = 1.1489
CVSNG = 1292 BTU/cuft @ 1.28
to 1476 BTU/cuft @ 1.32
WobbeSNG = 1142 @ 1.28
to 1284 @ 1.32
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 Alternate Energy Systems, Inc.
2004 LP Symposium Des Moines, 12-13-14 July 2004
Automatic Wobbe Index Control for Peak Shaving Plants

Consider the Wobbe Index !

WobbeSNG = 1142 @ 1.28
to 1284 @ 1.32

CVNG = 1000 BTU/cuft

SGNG = 0.61
WobbeNG = 1280

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 Alternate Energy Systems, Inc.
2004 LP Symposium Des Moines, 12-13-14 July 2004
Automatic Wobbe Index Control for Peak Shaving Plants

Wobbe Index Changes

Natural Gas:
Seasonal Changes
Source may change

LPG:
Propane/Butane Composition

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 Alternate Energy Systems, Inc.
2004 LP Symposium Des Moines, 12-13-14 July 2004
Automatic Wobbe Index Control for Peak Shaving Plants

How much Wobbe Change

is Acceptable
• Less than 5% deviation is desired
• Depending on how much SNG you have in
your PANG*, the WobbeSNG should be
maintained at better than +/- 10%
*PANG = Propane Air Natural Gas
Typical max. LP/Air is 50% of total to
maintain the SGPANG lighter than Air.
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 Alternate Energy Systems, Inc.
2004 LP Symposium Des Moines, 12-13-14 July 2004
Automatic Wobbe Index Control for Peak Shaving Plants

How do we measure WOBBE

• Wobbe Analyzers offered by several
manufacturers (CV, SG, O2, …)
• AES uses the SG-based method
• Since we know the LP properties (HD-5),
SG gives us accurate SNG properties
• AES Gravitometer is GraviBlend™-3

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 Alternate Energy Systems, Inc.
2004 LP Symposium Des Moines, 12-13-14 July 2004
Automatic Wobbe Index Control for Peak Shaving Plants

PeakShaving Control Concepts

• Almost all Equipment Manufacturers* have
their own Control Concepts
• There is probably more than one “right”
solution

* US Manufacturers
Algas-SDI www.algas-sdi.com
Alternate Energy Systems www.altenergy.com
Ely Energy www.elyenergysystems.com
Ransome Manufacturing www.meeder.com/ransome_mfg_.htm
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 Alternate Energy Systems, Inc.
2004 LP Symposium Des Moines, 12-13-14 July 2004
Automatic Wobbe Index Control for Peak Shaving Plants

AES PeakShaving System (1)

• Consists of two main components
– LP/Air Blender with
Gravitometer (GraviBlend™-3) and
Automatic Gas Properties Control (AccuBlend™)
– Peak Shaving Controller

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 Alternate Energy Systems, Inc.
2004 LP Symposium Des Moines, 12-13-14 July 2004
Automatic Wobbe Index Control for Peak Shaving Plants

AES PeakShaving System (2-1)

LPG/Air Blender (POM Series)
• Sizes from 20 to 2000 MMBTU/h
• Turndown better than 50:1
• Sendout Pressures 10 to 200 psi
• AccuBlendTM Gas Properties Control
• GraviBlendTM Gravitometer with Wobbe Display
• Option: SG/CV/Wobbe Analyzer
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 Alternate Energy Systems, Inc.
2004 LP Symposium Des Moines, 12-13-14 July 2004
Automatic Wobbe Index Control for Peak Shaving Plants

AES PeakShaving System (2-2)

LPG/Air Blender (POM Series)
• Allen-Bradley PLC
• Rosemount Transmitters
• Color Touch Screen
• Local Trend Recording with Date/Time
• NFPA 58/59, FM, UL 508-A
• Skid Mounted
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 Alternate Energy Systems, Inc.
2004 LP Symposium Des Moines, 12-13-14 July 2004
Automatic Wobbe Index Control for Peak Shaving Plants

AES PeakShaving System (3-1)

Peak Shaving Controller
• Flow Rate (SNG as % of PANG)
• Flow Rate (SNG in cuft/h)
• Pressure (maintain min. Grid Pressure)
• Minimum Flow Through System
• Maximum Flow Through System
• Module Sequencing (Blender 1 - 2 - 3 - …)
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 Alternate Energy Systems, Inc.
2004 LP Symposium Des Moines, 12-13-14 July 2004
Automatic Wobbe Index Control for Peak Shaving Plants

AES PeakShaving System (3-2)

• Allen-Bradley PLC
• Rosemount Transmitters
• Color Touch Screen
• Local Trend Recording with Date/Time
• UL 508-A
• Remote Monitoring and Control
• Ethernet
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 Alternate Energy Systems, Inc.
2004 LP Symposium Des Moines, 12-13-14 July 2004
Automatic Wobbe Index Control for Peak Shaving Plants

PeakShaving System Components

Natural Gas Line
NG Flow Grid
Flow M Pressure
Control Valve
Meter X-mtr

SNG
Flow
Atlas-Copco Meter
Air Compressor
Main POM Outlet
M
Shutoff Valve

M GraviBlend™-3
Gravitometer

POM-40
Blender

WB-1500
Vaporizer Propane
Liquid Storage
Transfer Tanks
Pump

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 Alternate Energy Systems, Inc.
2004 LP Symposium Des Moines, 12-13-14 July 2004
Peak Shaving

Automatic Wobbe Index Control for Peak Shaving Plants

Main Power
ON

Main NO
Outlet
OPEN?

YES

System NO

Flow Chart
in AUTO
Mode?

YES

SNG Flow YES Set OPEN Flag

BELOW MIN Run POM Flow
POM Flow Routine

NO

Set CLOSE Flag SNG Flow

AES
Run POM Flow ABOVE MAX
Routine YES POM Flow

NO

Grid NO Set OPEN Flag

PeakShaving
ABOVE Run Pressure
MIN psi Routine

YES

NG Flow YES Set OPEN Flag

Controller
ABOVE Run NG Flow
MAX Routine

NO

NO NG Flow
BELOW 90%
of MAX

YES

Alternate Energy Systems, Inc.

Set CLOSE Flag YES Grid 210 Prospect Park
Run Pressure ABOVE Peachtree City, GA 30269
Routine MIN psi
Peak Shaving System -- Flow Chart
NO
31
 Alternate Energy Systems, Inc.
2004 LP Symposium Des Moines, 12-13-14 July 2004
Automatic Wobbe Index Control for Peak Shaving Plants

How much does it cost

More than you like - Less than you think
Example:
– 1,300 MMBTU/h @ 200 psi (30,000 dTh/day)
– 2 skids (2 x 650 MMBTU/h) (15,000 dTh/day)
– AccuBlendTM (Automatic Gas Properties Control)
– GraviBlendTM-3E (ex-proof)
– Ethernet
– On-Site Commissioning and Training
– < $200k
– 10 Weeks Lead Time
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 Alternate Energy Systems, Inc.
2004 LP Symposium Des Moines, 12-13-14 July 2004
Automatic Wobbe Index Control for Peak Shaving Plants

Thank You.

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 Alternate Energy Systems, Inc.
2004 LP Symposium Des Moines, 12-13-14 July 2004
Automatic Wobbe Index Control for Peak Shaving Plants

What Does It Look Like

Mixing Valve Cut-Away POM-40 Blending Skid

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 Alternate Energy Systems, Inc.
2004 LP Symposium Des Moines, 12-13-14 July 2004
Automatic Wobbe Index Control for Peak Shaving Plants

Dimensions in inches
How Big Is It
Dimensions in mm
WS LS LT H
54 72 92 53
POM-30
1372 1829 2337 1346
54 76 96 57
POM-40
1372 1930 2438 1448
54 84 103 64
POM-60
1372 2134 2616 1626

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 Alternate Energy Systems, Inc.
2004 LP Symposium Des Moines, 12-13-14 July 2004
Automatic Wobbe Index Control for Peak Shaving Plants

GraviBlend Gravitometer
TM

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 Alternate Energy Systems, Inc.
2004 LP Symposium Des Moines, 12-13-14 July 2004
Automatic Wobbe Index Control for Peak Shaving Plants

Does it really work ? (1)

• Between 20 and 40 systems per year
• Industrial Customers
– Automotive
– Chemical
– Metal
– Food
– Glass/Ceramic/Brick

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 Alternate Energy Systems, Inc.
2004 LP Symposium Des Moines, 12-13-14 July 2004
Automatic Wobbe Index Control for Peak Shaving Plants

Does it really work ? (2)

• Institutional Customers
– Schools/Colleges
– Hospitals
– Prisons
– Offices

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 Alternate Energy Systems, Inc.
2004 LP Symposium Des Moines, 12-13-14 July 2004
Automatic Wobbe Index Control for Peak Shaving Plants

Does it really work ? (3)

• Government
– Military Bases
– Demilitarization Processes

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 Alternate Energy Systems, Inc.
2004 LP Symposium Des Moines, 12-13-14 July 2004
Automatic Wobbe Index Control for Peak Shaving Plants

Does it really work ? (4)

• Export (Example: China)
– Primary Fuel Supply
– Peak Shaving
– Backup / Standby
– Approximately Systems per Year
– Unreliable LP Quality
– Wide Variety of Customers and Appliances
– All Systems are Wobbe-controlled
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 Alternate Energy Systems, Inc.
2004 LP Symposium Des Moines, 12-13-14 July 2004
Automatic Wobbe Index Control for Peak Shaving Plants

Who Is Alternate Energy Systems

After working for other manufacturers of LPG vaporizers
and LPG / air systems for several years, John E.
Hallberg founded Alternate Energy Systems, Inc. in 1974
in Peachtree City, located just 20 minutes south-west of
the Atlanta airport. He successfully set out to design and
manufacture products which were superior to those of his
competitors. As a result, AES became very quickly
known as the innovative manufacturer of quality
products. Soon, the customer list included a
representative cross-section of the Fortune 500
companies in the U.S
Through the years, AES has constantly added new products, and has further improved the design of existing
products, keeping us ahead of the competition. Several designs, including those for LPG/Air mixing systems, were
awarded national and international patents.
Today, AES is owned by Wolfgang Driftmeier. With his manufacturing background and his experience in sales
and marketing, the company focus is clearly on “... offering the best product design, combined with quality
workmanship, at a competitive price, to the full satisfaction of our customers, at all times ...”.
AES is committed to serve customers in the U.S. through a network of sales specialists, technical support
personnel, distributors and installers, and international customers in selected countries through qualified
representatives.

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 Alternate Energy Systems, Inc.
2004 LP Symposium Des Moines, 12-13-14 July 2004
Automatic Wobbe Index Control for Peak Shaving Plants

Thank You.

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 Alternate Energy Systems, Inc.
2004 LP Symposium Des Moines, 12-13-14 July 2004
Automatic Wobbe Index Control for Peak Shaving Plants

Thank You.

Really.

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