Install Boiler 10 Natural Gas Burners
Transcript of Install Boiler 10 Natural Gas Burners
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Install Boiler 10 Natural Gas Burners 2014 IDEA Conference
February 19, 2014
Presented by:
Benjamin E. Anderson
P. Russell Price, PE
Kevin C. Voss, PE
PRVN CONSULTANTS, INC.
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Agenda
• Introductions
• Plant Overview and Gas Burner Need
• Permitting Strategy
• Project Design
• Project Construction
• Startup and Lessons Learned
• Conclusion
• Questions
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Overview
• University of Iowa – Main Power Plant
4 Boilers: 600+ klb/hr, 3 Turbine Generators - 24.7 MW
6 offsite natural gas and 1 biomass boilers
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Project Scope
• Install two (2) new low Nox gas burners with individual
air plenums in the existing pressure part openings.
• Install a new FD fan to support full-load natural gas
firing.
• Install an FGR system for:
lowering natural gas burner NOx emissions.
Cooling the natural gas burners during stoker firing
Cooling the stoker grate during natural gas firing
• Install an airflow measurement device to measure
combustion airflow to the natural gas burners.
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Project Scope (Cont.)
• Remove two (2) of the five (5) existing boiler ash
hoppers and associated reinjection lines.
• Monitor the SH steam and metal temperatures during
natural gas firing to prevent overheating of the
superheater outlet header and superheater tubes.
• Protect the grate via gravel or by being bricked over if the
University plans to fire solely natural gas. If stoker-firing
capability is to be retained at all times, cooling air or
cooling FGR can be passed through the stoker.
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Boiler 10 Performance
Parameter Boiler 3
Steam flow (lb/hr) 170,000
Steam temperature (°F) 760
Steam pressure (psia) 490
Feedwater temperature (°F) 360
Drum pressure (psia) ---
Superheat Attemperation Yes
Original fuel Coal
Firing arrangement Traveling grate
Spreader stoker
Superheat Yes
Air heater type Tubular
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Burner Operating Data
Fuel type Natural gas
Fuel flow per burner 108,000 schf
Design heat release per burner 108 MM Btu/hr
Minimum heat release per burner 9 MM Btu/hr
Total boiler heat release 218 MM Btu/hr
Burner turndown required 12:1
Excess air at design heat release 10%
Combustion airflow per burner 25,314 ACFM
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P&ID of Boiler 10 Prework
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P&ID of Boiler 10 Post Work
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New FD Fan
• The existing FD fan does not have sufficient static
pressure capability for full-load natural gas firing.
• A new FD fan is required for full-load natural gas
firing.
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Natural Gas FD Fan Sizing Criteria
Test Block 100% Boiler
MCR
Design Criteria Units +10% Flowrate,
+21% Static,
+25°F
0% FGR
Included
Combustion airflow rate lb/hr 189,200 172,000
Combustion air temperature °F 275 250
Volumetric flow rate ACFM 59,800 52,500
Total static pressure iwc 14.5 11.9
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One of Two New Gas Burners
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Natural Gas FD Fan Performance
Flow ACFM 59,800
Static Pressure in. WG 15
Speed RPM 1,780
Power BHP 176
Temperature °F 275
Elevation feet 650
Density lb/ft3 .0.527
Outlet velocity ft/min 3,902
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Breeching to the Burners was Modeled
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Tube Metal Temps & Pressure Part Mods
Parameter Units Boiler 3
Coal Natural Gas
Flue gas inlet temp °F 1,650 1,916
Flue gas outlet temp °F 1,240 1,337
Steam inlet temp °F 472 470
Steam outlet temp °F 775 820
Calculated tube midwall temp °F 827 902
Tube midwall temp limit °F 1,017 1,017
Calculated tube outer wall temp °F 829 904
Tube outer wall temp limit °F 900 900
Changing FEGT, absorption effectiveness, and flue gas flow cause some pressure part temps to rise and some to fall.
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Attemperator Flow
Parameter Units Boiler 3
Coal Natural Gas
Load %MCR 100 100
Type of attemperator station Spray
SH temp before spray °F 779 815
SH temp after spray °F 755 760
Total superheat steam flow lb/hr 159,485 170,000
Spray water temp °F 352 352
Spray water flow lb/hr 1,897 4,671
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Superheater Tube Temperature
Transmitters
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Furnace Exit Gas Temperature (°F)
0
500
1000
1500
2000
2500
Boiler 3
Coal
Natural Gas
Data is at 100% MCR load.
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Combustion Air & Flue Gas Flow Rates (lb/hr)
0
50,000
100,000
150,000
200,000
250,000
300,000
Boiler 3
Combustion Air: Coal
Combustion Air:
Natural Gas
Flue Gas: Coal
Flue Gas: Natural Gas
Data is at 100% MCR load.
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Total Boiler Losses on Efficiency (%)
0
2
4
6
8
10
12
14
16
18
Boiler 3
Coal
Natural Gas
Data is at 100% MCR load.
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New Breeching and Damper
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New Burner Fan
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New Breeching
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New Flow Meter
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New Gas Train