Professional Documents
Culture Documents
Presented by: David King, Manager Steam Generation Equipment Engineering APP Site Visit October 30 November 4, 2006
Topics of Discussion
Steam Generator Upgrades & Maintenance
Steam flow balancing Air heater baskets & seals Component replacement upgrades (material & design) Online detonation cleaning Water Cannons/HydroJets Acoustic leak detection Weld overlay & coatings Balanced draft conversion on FGD units Nose installation on 800 MW units Boiler tube failure program 4th generation low NOx burners
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Topics of Discussion
Fuel Considerations
Matching steam generator design with fuel characteristics Benefits of washing coal Coal additive injection
Cleaning energy dissipates rapidly Cleaning media diverted around deposits Requires higher pressure for effective cleaning Higher risk of element damage from cleaning
Each channel acts like a closed pipe Cleaning energy cannot divert around deposits Deposits are readily removed, at lower pressures Lower risk of element damage from cleaning
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Component Upgrades
Total Platen Replacement Projects
Upgrade tube material to all stainless steel vs. in-kind material selection with croloy and stainless steel material transitions.
Improves the boilers slag shedding capability. Expands the types of coal a particular unit can burn.
Component Upgrades
New Alignment and Attachment Designs
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Problem: Excessive Ash Piles and Bridging Cause Delta P and Heat Transfer Impact Spatial Constraints Prevent Installation of Conventional Sootblowers
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Before SHOCKSystem
Ash Pile Accumulation Over Nine Months of Continuous Boiler Operation
After SHOCKSystem
First Two Ash Piles Removed After Two 13 Days of SHOCKSystem Operation
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Increased By 10%
Decreased By 30F
Water Cannons/HydroJets
Provides intelligent real-time cleaning of furnaces using water cleaning hardware and a closed-loop control system that utilizes sensors and software.
Displaces conventional wall blowers or water lances as the best available technology for furnace cleaning. Uses cross-furnace cleaning where a controlled water jet is transmitted across the firebox to the opposite or adjacent walls.
Water Cannon HydroJet
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Water Cannons/HydroJets
Gavin Unit 2 Water Cannon Performance Testing
Decreased by 112F
NOx Emissions
Heat Rate
Reduction of 8-10%
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Acceptance and reliance on acoustic leak detection has reduced forced outage durations from weeks to days. Provides better indication of tube leak than any other method, including older style acoustic leak systems and water loss tests.
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The industry is working to optimize the choice of overlay and metal spray materials. Computer Modeling and/or thickness surveys are utilized to identify the areas needing protection. The overlay and metal spray processes have been automated by the vendors.
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Utilizes multi-speed motors on existing FD fans and the application of variable pitch axial ID fans.
Provides the additional head to overcome the added resistance of the FGD. Optimizes unit efficiency over the load range and provides improved unit control. FD fan controls volume flow while ID fan maintains furnace pressure.
Requires upgrading steam generators to accommodate the extremes of balanced draft operation.
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All tube failures are routed through corporate engineering. Based on visual review, the failure samples may be forwarded to AEPs internal lab for further metallurgical and root cause analysis.
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