Case Study: Duke Energy / Marshall Steam Station

1

North Carolina, 2009

Steve Davis

Case Study: Duke Energy / Marshall Steam Station

2

Agenda

Customer and Case1

Application Description2

FLEXIM Solution3

Customer Benefits4

3

Customer and Case

The Marshall Power Plant is a four unit, coal fired generating station in North

Carolina.

2090 MW capacity.

Marshall generates enough power for approximately 2 million homes.

Commissioned in 1965.

4

Agenda

Customer and Case1

Application Description2

FLEXIM Solution3

Customer Benefits4

5

Application - Customer Motivation

Marshall approached FLEXIM about a problem with premature boiler tube

failure. They need to measure feed water flow from the boiler drum to the boiler

tubes.

The problem seemed to be only at full load situations. Marshall, like other

power plants wanted to operate at peak conditions to get every MW out of the

unit.

Marshall and FLEXIM, as a team, decided to measure this flow on the 14”

vertical pipes using the Wave Injector.

6

Application - Measurement Point

The measurement points were on 14” carbon steel pipes with downward

vertical flow at 600 degrees F and 2450 psi.

Measurements were taken at the discharge of 3 circulating water pumps.

Original tested was conducted on the suction side of the pumps, but it was

concluded that this was a poor measurement point because of steam

entrainment from the steam drum.

7

Application - Technical Details

8

Agenda

Customer and Case1

Application Description2

FLEXIM Solution3

Customer Benefits4

9

Solution - Installation

The ADM 7407 was used with WI-400 Wave Injector and FSM Transducers.

Insulation was removed during testing and re-installed.

Cold testing was also done at the same measurement locations during

troubleshooting.

10

Solution - Performance

Initial testing showed high aeration during normal operation. FLEXIM

personnel used the diagnostics of the 7407 to help with troubleshooting.

After initial testing, it was determined that steam was being entrained into the

feed water from the steam drum.

FLEXIM and Marshall decided to increase drum level to determine if the

problem could be resolved.

11

Solution - Results

Marshall Power Plant was very happy with our performance and customer

support. They have 6 of these installations at the plant to help ensure that there

boiler is evenly supplied by the steam drum.

The communication and teamwork between FLEXIM and Marshall personnel

was a giant factor in the success of this application.

12

Agenda

Customer and Case1

Application Description2

FLEXIM Solution3

Customer Benefits4

13

Customer Benefits

Marshall now has decreased forced outages due to boiler tube failure. The

steam entrainment was causing poor heat transfer in the boiler.

The plant can now operate at peak conditions while monitoring boiler feed

water flows and ensuring the flow is distributed evenly.

The customer has increased their knowledge about their own equipment and

operating procedures.