1Page TÜV SÜD AG ARIPPA Technical Symposium Block Grid Nozzle Modification By TÜV SÜD Industry...

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TÜV SÜD AG

ARIPPA Technical Symposium

Block Grid Nozzle ModificationBy

TÜV SÜD Industry Service, Inc.August 2009

TÜV SÜD Industry Service, Inc.

ARIPPA Technical SymposiumAugust, 2009

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TÜV SÜD AG

• TÜV SÜD Industry Service, Inc. is a subsidiary of TÜV SÜD America, Inc.

Parent Company Background

• TÜV SÜD America, Inc. is a subsidiary of TÜV SÜD AG.

• TÜV SÜD was established over 140 years ago as a steam boiler inspection association in Germany.

• Worldwide business approximately $1.4 Billion with over 10,000 employees.

• Operating in more than 30 countries worldwide

• TÜV participates in the Steam Boiler, Health Service, Medical, Automotive, Electromechanical, and Product Certification markets.

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TÜV SÜD AG

Translation of TÜV SÜD

TÜV (Technischer Überwachungsverein)

English translation: Technical Inspection Association

SÜD

English translation: South

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TÜV SÜD AG

• Established July 7, 2005 as wholly owned subsidiary of TÜV SÜD America Inc.

• Established as the steam generation equipment engineering and service subsidiary.

• Holders of ASME “S”, “U” ,“PP” and National Board “R” stamps.

• Key Management and Operation personnel with extensive service and management experience with all major Boiler OEM’s.

TÜV SÜD Industry Service, Inc. Background

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TÜV SÜD AG

TÜV SÜD Industry Service, Inc. Contact Information

Operations OfficeTÜV SÜD Industry Service, Inc.5910 Pacific Center Blvd., Suite 310San Diego, CA 92121(858) 550-4780 Fax (858) 638-723624 Hr. Emergency Service 1-800-873-9725www.tuvindustryservice.com

Corporate OfficeTÜV SÜD America, Inc.10 Centennial Drive Peabody, MA 01960 (978) 573-2500 Fax: (978) 762-7637

Regional Service Center - JesupTÜV SÜD Industry Service, Inc.810 E. Pine St.Jesup, GA 31546(912) 530-7195 Fax (912) 530-7133

Regional Service Center - FresnoTÜV SÜD Industry Service, Inc.3065 N. Sunnyside, Suite 101Fresno, CA 93727(559) 348-1500Fax (559) 348-1525

Regional Service Center - RidgecrestTÜV SÜD Industry Service, Inc.1126 B West Ward Ave.Ridgecrest, CA 93555(760) 446-7930 Fax (760) 446-7960

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TÜV SÜD AG


Arrowhead Nozzles

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TÜV SÜD AG


Bubble Cap Nozzles

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TÜV SÜD AG

TÜV SÜD Industry Service, Inc. Pigtail Nozzles

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TÜV SÜD AG

Block Nozzles


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TÜV SÜD AG

Block Grid Nozzles

• Design Advantages Include:

•Minimal Backsifting

•Pluggage Resistant

•Fuel Flexibility

•Eliminates the Riser Pipe

•Increased Wear Resistance

• Longer Life

• Alloy Selection for Problematic Fuels

• Ease of Replacement

• Improved Spacing on Grid for Maintenance

and Access

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TÜV SÜD AG


Benefits of Block Nozzles

Over Pigtail Over Bubble Cap Over Arrowhead Nozzles Nozzles Nozzles

Reduced Backsifting X

Reduced Plugging X XIncreased Wear Resistance of Nozzles

X X X

Fuel Flexibility X

Eliminates Riser Pipe X X XAlloy Selection for Problematic Fuels

X X

Ease of Replacement/Reduced Repair Duration

X X X

Improved Spacing on Grid for Maintenance and Access

X X

Reduction in Erosion of Refractory X

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TÜV SÜD AG


Dominion Energy North Branch

• Block Nozzle Conversion made in Fall, 2008

• Conversion of Pigtail Nozzles to Block nozzles

• Performance Significantly Improved

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TÜV SÜD AG

TÜVTÜV SÜD Industry Service, Inc.

Air Flow Reduced to 230,000 lb/hr (at 400° ̊F) 280,000 + lbs/hr (at 400° F)

Grid delta P 35" H20 @ 230,000 lb/hr 18" H20 @ 280,000 lb/hr

Steam Flow 350,000 lbs/hr 395,000 lbs/hr (*Increase of 10%)

Average Bed Temperature >1770° F 1680° F

Limestone Consumption

_ * Reduced by ~10% (no accurate measurement)

Before Conversion After Conversion

* Pre conversion load limited by NOx and High Bed Temperature.

Other: Greater flexibility to balance air distribution in the combustor due to increased grid air flow & reduced secondary air needs.

Dominion North BranchBefore / After Performance

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TÜV SÜD AG


Block Nozzle Details

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TÜV SÜD AG


Block Nozzle Arrangement

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TÜV SÜD AG


Block Nozzle Installation

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TÜV SÜD AG


Installation Tasks• Remove all existing grid refractory

• Remove membrane between the grid tubes where the block nozzles will be located.

• Remove or cut off remaining nozzle stubs. The cut off point for the stubs will be well below the surface of the replacement refractory.

• Plug tubes of cut off nozzle stubs, by installing plugs or bolts in tubes and welding, alternatively a plate can be welded to the cut nozzles.

• Apply sealing refractory to the base of the block nozzle. Note groves on the block for this.

• Set block nozzle in position on tray plenum, inserting the fixing rod down through the hole in tray plenum base. A locating bar is positioned on the tray as an assembly guide. Set the nozzle against the bar, and install the fixing washer against the spacer tube. Tack weld is required on the fixing washer to rod.

• Trays and nozzles can be assembled outside of the unit, in parallel with the removal of the existing refractory, thus reducing the installation schedule.

• Weld new tray/nozzle assemblies to the crown of the grid tubes with a full seal weld.

• Apply ceramic fiber paper or grease around the sides of the nozzle that are in contact with the replacement refractory to facilitate easy removal at a later date, if required.

• Pour refractory to the height indicated by the specific design drawings.

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TÜV SÜD AG

TÜV SÜD Industry Service, Inc. Installation Process

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TÜV SÜD AG


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TÜV SÜD AG


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TÜV SÜD AG

Installation Process


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TÜV SÜD AG


Installation Complete

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