Community Legacy Grant Chesapeake City Streetscape Improvements.
Operational Improvements at the Grant Town Power Plant
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Transcript of Operational Improvements at the Grant Town Power Plant
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Operational Improvementsat the
Grant Town Power Plant
Presented By:Steve Friend
Sr. Plant EngineerEdison Mission O&M
2005 ARIPPA Technical Symposium
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Improvements at the Grant Town Power Plant
• Fuel Handling and ProcessingRo-Pro FacilitySilt System
• Ash HandlingBottom Ash Screw CoolersBottom Ash Piping
• Limestone ProcessingDFM
• BoilersGrid NozzlesTube ErosionCyclonesNOx Control
• DCSFoxboro Migration
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Fuel Processing and Handling
• Addition of the Ro-Pro facility has added flexibility to the fuel production process and additional means for final product cost
• Removal of the wet circuit equipment from the original preparation plant eliminated excessive reject and reduced costs of product – dewatering chemicals and equipment no longer used
• Silt system installation and modifications have allowed facility to maximize amount of lowest cost fuel to be added into final fuel blend – higher silt percentage = minimum fuel costs
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Ro-Pro Fuel Processing Facility
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Ro-Pro Screener
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Silt Feed System
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Bottom Ash Handling Improvements
• Screw Cooler capacity was approximately 20% lower than design with a 6” Pitch Auger – required running the screw cooler at higher RPM for adequate bed level control
• 7” Pitch Auger allowed screws to be slowed down – reduced erosion rates on the cooler components
• Addition of rifle bars has helped to control trough erosion but has increased wear rate on the auger
• Application of weld overlays, wear strips, and thicker materials has helped control auger wear
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Bottom Ash Screw Cooler Troughwith Rifle Bars
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Bottom Ash Screw CoolerInlet Section of Trough
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Bottom Ash Piping Modifications
• Initial design was sweep elbows on both the primary and redundant pressurized bottom ash conveying systems
• Sweep elbows had very low mean time between failures due to erosion – on the order of a few weeks
• Reconfiguration of the system using blinded tees for the direction transitions has reduced maintenance costs.
• Effective pipe rotation program has helped to further reduce ash conveying system maintenance costs
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Bottom Ash Blinded Tees
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Limestone Handling System
• Williams Direct Fired Mill for processing limestone for injection into the CFBs
• Velocity Cone did not have any impact on final product size
• Optimization of air flow though the mill has helped to produce more ideally sized product
• Installation of VFD on the product cyclone rotary valve has helped to minimize transport line pluggage and system processing delays
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DFM
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Boiler Modifications
• Erosion Control
– Sootblower lane shielding
– Economizer hanger tube tube monitoring/shielding/replacement
– Flame Spray
– Pad Welding
– Refractory Extensions
– Stainless Steel Overlay
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Combustor Tube Erosion
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Refractory Extensions
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Combustor Tube Weld Overlay
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Boiler Modifications
• Arrowhead Nozzles
– Provide nominal improvement in limestone utilization
– Backsifting is a BIG problem
– Internal stand pipe erosion now becoming a major concern
– Increased maintenance costs offsetting any benefit realized in reduced limestone consumption
– Considering repair/replacement options
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Arrowhead Nozzles
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New Nozzle being Considered as Arrowhead Replacement
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Boiler Modifications
• Cyclones
– Segmented Vortex Finders
– Narrowing of cyclone inlet opening
– Design of vertical bullnose on the cyclone inlet to narrow the opening about 10%
– Narrowing of the opening has increased inlet velocity to >75 ft/sec
– Both changes had major impacts on limestone consumption – improvement of about 20% in total when paired with the DFM optimizations.
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Vortex Finder Deformation
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Segmented Vortex Finder
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Bullnose Modification to Narrow Cyclone Opening
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Ammonia Unloading/Storage
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Ammonia Injection Skid
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DCS Modifications
• Foxboro Migration Package
– Poor availability of Bailey replacement parts and support
– Electrolytic capacitor failures
– No changes to I/O wiring
– Low cost alternative to wholesale DCS replacement
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I/O Rack
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DCS Processor Rack