You are on page 1of 26

Steam Generator Upgrades & Maintenance

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
2

Topics of Discussion
Fuel Considerations
Matching steam generator design with fuel characteristics Benefits of washing coal Coal additive injection

Steam Flow Balancing


Aptech TubMod Analysis at Glen Lyn Unit 6
The unit experienced high temperature variations across the boiler, caused by tube circuit design and gas temperature/flow imbalances. TubMod analysis was performed to improve the temperature profile and extend the life of the superheater tubing. Through the TubMod process, temperature imbalances can be corrected by redistributing the steam flow. The result is an evening out of the tube metal temperature across the superheater elements, and a reduction in the temperature on the elements operating excessively hot.
4

Steam Flow Balancing

Air Heater Baskets


Modifications are necessary to accommodate high sulfur fuel switch programs and SCR retrofits.
Considerations to address high sulfur applications:
Increased attention to exit gas temperatures being maintained above the acid dew point.

Modifications to address SCR retrofits:


Redesign of the heat transfer surface arrangement.
3 layers reduced to 2 to envelope the ABS formation temperature within an area that can be cleaned with conventional sootblowing. The use of closed channel elements to better contain and focus the cleaning media to the areas of likely deposition. The utilization of multimedia blowers to facilitate both conventional on-line cleaning, and off-line washing.
6

Air Heater Baskets


ALSTOM Power Inc. Air Preheater Company Open Channel Surface Closed Channel Surface
Cleaning Media Discharge

Cleaning Media Inlet

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
7

Air Heater Seals


Paragon air heater seal installation at Welsh Unit 3
Air heater leakage across air heater radial seals can average as much as 15 to 20%. The air heater leakage results in excess FD and ID fan motor amps, with the recognizance that the fan motors are one of the largest auxiliary power consumers in the plant. Reducing air heater leakage will show immediate heat rate benefits. Welsh Unit 3 saw a 30% reduction in ID fan amps after the installation of the Paragon Airheater Technologies radial and circumferential/bypass seals.
8

Air Heater Seals


The Paragon DuraMax radial seals incorporate unique, selfadjusting bellows that ensure positive contact with the sealing surfaces. The Paragon DuraFlex high-performance circumferential and bypass seals use a patented revolutionary interlocking design which reduces the air gaps.

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.

Stainless Steel Weld Overlay for Shielding


Use SS weld overlay on new boiler tube components in lieu of tube shields at sootblower locations.
Spiral weld overlay has higher upfront cost, but minimal future O&M costs to maintain. AEP has some spiral weld overlay tubing in sootblower lanes with 10 years of service and no reported issues.
10

Component Upgrades
New Alignment and Attachment Designs

11

Online Detonation Cleaning


Pratt & Whitney SHOCKSystem Economizer Cleaning at Rockport Unit 2
Provides non-line-of-sight cleaning of tube bundles to remove bridging and platenization.
Middle Economizer Bundle North Wall

Lower Economizer Bundle

Ash Piles Extend Beyond Hangers

Problem: Excessive Ash Piles and Bridging Cause Delta P and Heat Transfer Impact Spatial Constraints Prevent Installation of Conventional Sootblowers

12

Online Detonation Cleaning


BEFORE AFTER

SHOCK Blasts SHOCK Blasts

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

Online Detonation Cleaning

Five Combustor Economizer Cleaner at Rockport Unit 2

14

Online Detonation Cleaning


Rockport Unit 2 Economizer Cleaning Installation Five Days of Intensive SHOCKSystem Operation
Delta T Across Economizer Increased By 15F

Effective Heat Transfer


Temperature of Gas to Airheater

Increased By 10%
Decreased By 30F

Temperature of Gas from Airheater

Decreased By 15F 240,000 Lbs


15

Weight of Ash Removed

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

16

Water Cannons/HydroJets
Gavin Unit 2 Water Cannon Performance Testing

Furnace Exit Gas Temperature

Decreased by 112F

NOx Emissions
Heat Rate

Reduction of 0.04 lb/MMBTU


Decreased by 25 BTU/kwh

S02 to S03 Conversion

Reduction of 8-10%

17

Acoustic Leak Detection


Acoustic leak detection system at Gavin Unit 1 & 2
Consists of 30 remote acoustic sensors attached to membrane of exterior furnace walls and penthouse roof. Ethernet daisy-chain provides communication to control room were central computer is located. Information is processed, filters applied (sootblowers, furnace penetration seal air, etc.) and information is displayed on operator PC screen. Alarms are established for each sensor and refined as leaks are detected.

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.
18

Acoustic Leak Detection


Gavin sensor layout along with HP heater screen which also have 1 acoustic leak detector per heater.

Leak detection screen and alarm indication threshold at 92 dB.

19

Weld Overlay & Coatings


Efforts to minimize NOx production have led to increases in furnace waterwall wastage, which has necessitated furnace corrosion protection. To combat high levels of corrosion, AEP currently reviewing various furnace protections including:
Weld overlay Metal spray coatings Ceramic coatings

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.
20

Balanced Draft Conversion


Converting positive pressure units to balanced draft operation while retrofitting FGDs.
Improves the work environment of the boiler house, thus increasing productivity and equipment longevity. Reduces the likelihood of fugitive emissions occurrences due to casing leaks.

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.
21

Furnace Nose Installation


Furnace nose installation on AEPs 800 MW units completed in conjunction with FGD retrofit. Reduces the peak temperatures leaving the furnace, thereby reducing the slagging potential with higher sulfur coals.
Serves to improve mixing and heat absorption in the furnace. Spreads the flue gas flow out over the leading edge surface of the pendants.

Installed a 10 foot long nose in a 39 x 80 furnace.


22

Furnace Nose Installation


Mitchell Unit 1&2 CFD Modeling Expected Performance
Furnace Exit Gas Temperature
Superheater Heat Absorption Boiler Efficiency Coal Consumption Loss on Ignition Aperture Floor Velocity Decreased by 17F Increased by 15% Improved by 0.07% Reduced by 0.12% Reduced by 0.05% Reduced from 200 fps to 56 fps
23

Boiler Tube Failure Program


Provides centralized boiler tube failure data and metallurgical analysis results.
Makes for easy access to information/data for capital replacement justification purposes or O&M repairs. Centralized boiler tube failure tracking helps to alert other like series units of potential related tube failure mechanisms or issues.

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.
24

4th Gen Low NOx Burners


Existing Low NOx Burners
25 hot tips/burner fires per year NOx emissions 0.75 lb/MMBTU Projected 135 hot tips/year with future coal (high sulfur and slagging)

New Low NOx Burners


0 hot tips to date NOx emissions 0.48 lb/MMBTU Potential urea cost reduction of $2,500,000/year @ $350/dry ton urea (365 day ozone control)
25

26

You might also like