DOE/MC/27229 -- 5007

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DOE/MC/27229 - - 5 0 0 7 473

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Quarterly Technical April - June 1995

Progress Report PAFBC295.RPT

Pulsed Atmospheric Fluidized Bed Combustor Design Report

Table of Contents

.., Executive Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

SECTION 1.0 DESIGN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ProcessDesign . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Mechanical Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.2.1 Fluid Bed Combustor and Piping . . . . . . . . . . . . . . . . . . . . . . . 1 1.2.2 Pulse Combustor Components . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.2.3 Feed System . . . . . . . . . . . . . . . , . . . . . . . . . . . . . . . . . . . . . . 1 1.2.4 Ash System . . . . . . . . . . . . . . . . . . . . . . . . . . . , . . . . . . . . . . . 7 Civil and Structural Design . . . . . . . . . . . . . . . . . . . . . . . . . , . . . . . . 7 Electrical Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Controls and Instrumentation Design . . . . . . . . . . . . . . . . . . . . . . . . . 7

1.1 1.2

1.3 1.4 1.5

Section 2.0 FABRICATION ACTIVITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maior Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10 10 2.1

Section 3.0 SITE CONSTRUCTION ACTIVITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Section 4.0 PLANNED ACTIVITIES FOR NEXT QUARTER . . . . . . . . . . . . . . . . . . . . Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fabrication.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Site Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12 12 12 12

4.1 4.2 4.3

Section 5.0 SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Section 6.0 THERMOCHEM SITE CORRESPONDENCE . . . . . . . . . . . . . . . . . . . . . . . 15

DISCLAIMER

This report was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsi- bility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Refer- ence herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recom-

mendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof.

1

DISCLAIMER

Portions of this document may be illegible in electronic image products. Images are produced from the best available original document.

I ' Quarterly Technical Progress Report April - June 1995

PAFBC295.RPT

LIST OF FIGURES

Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7

Air Distributor Bubble Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Target Cone Traversing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Pulse Combustor Water Jacket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Coal/Limestone Handling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Coal/Limestone Hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Functional Diagram - Combustion Control . . . . . . . . . . . . . . . . . . . . . 8 Clemson PAFBC Project Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . 14

.. 11

PAFBC295.RPT Quarterly Technical Progress Report Apnl - June 1995

Executive Sumina ry

The report of activities for the second quarter of 1995 is summarized below:

Design Activities

Process. No changes in the process design encountered during this period.

Mechanical. Stress analysis calculations were performed on the steam/water pressure

piping. Pipe support design and drawings were completed by Duke Flour Daniel. The Fluid bed distributor bubble cap design was revisited and changes made for ease of maintenance.

Civil and Structural. No changes in the civil and structural design encountered except adding approach ladders to coarse coal, fine coal and limestone feeder platforms.

Electrical and Instrumentation. Control and instrumentation scheme proposed

earlier, was based on independent single loop controllers. After careful review, it is decided

to go for state of art distributed control system (DCS) which uses programmable logic

con trollers (PLC).

Fabrication Activities

CoaVlimestone pickup hopper fabrication was completed during this period and shipped to site. The coal/lime stone floating caps have been made at MTCI and ready for shipping.

Site Construction Activities

All major equipments installation was completed. The pulse combustor steam/water

jacket and air plenum were installed. Construction of control room building was just completed.

I . .

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Quarterly Technical Progress Report April - June 1995

PAFBC295.RPT

Planned Activities for Next Quarter

Controls and instruments wiring drawings; installation of steam/water pressure piping; installation of coal, limestone, ash, natural gas and cooling water piping; electrical cabling

and lighting; Control and instrument wiring and fittings; installation of filter bags inside bag

house.

Schedule

Most of the site construction and testing tasks are squeezed to complete this project on time (from now until Mar 1996). With this change, the overall project is still on schedule.

iv

Quarterly Technical Progress Report ’ April - June 1995

SECTION 1.0 DESIGN

PAFI3C295.RPT

1.1 Process Design The process configuration remained unchanged during this quarter.

1.2 Mechanical Design

1.2.1 Fluid Bed Coiiibustor and Piping

The air distributer bubble cap design was modified for maintainability. The

present design facilitates installation through windbox and can be easily unscrewed

form inside windbox, without going inside the hot fluid bed (Figure 1). The steam/water mixture pipes connecting boiler drum to bed modules and pulse combustor jacket were analyzed for stresses arising from thermal expansion. Also the stress analysis for the underground steam piping connecting PAFBC plant to

Clemson header was completed by Duke Flour Daniel. The computer stress analysis

revealed the forces acting on all the three axis of steam pipe under operating

conditions. The design of hanger and anchor type pipe supports were completed and drawings made (Figures 2, 3, 4 and 5).

1.2.2 Pulse Conibustor Components

No changes were made in the pulse combustor components design during this

period.

1.2.3 Feed System

The roots blower connecting the Coal and limestone feed lines were previously selected for ambient inlet air conditions (14.5 psia). The same blower will now operate using air taken from combustor forced draft fan. This arrangement will

enhance the blower discharge pressure and ensure uninterrupted coal/limestone feed

supply thru under bed pneumatic conveying lines.

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z! w E: -l tD +

y--0.141' I2 HOLES IN EACH ROW REO'D

1) NO GRINDING REO'D AFTER WELDING END CAP TO NOZZLE

2) W E WELDING OF I T E M 2 TO 3 MUST NOT EFFECT THE OUTSIDE THREAD


PAFBC295.RFT

TEM YO. UO. R t O ' O DESCRIPTION I I \ ASTM j REMARKS

I 2 W 4 x 1 3 CUT TO SUIT I A36 2 2 I W4x13 CUT TO SUIT 1 436 1

I I

i I ! i I I I ! I I I I I I

PIPE 8-CWR-204-CS

11-2ys I

I EXIST-' W27

PLAN @ EL. 37'+101/4" A

Figure 2 Target Cone Traversing System

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PAFBC295.RPT

i I

5

F 8”B PIPE u/INSULATION

r EXIST i ,l W18 2

1l---

4 w4f

W27

SECTION A-A .--

W4’s ARE WELDED TO PIPE AND EXISTING STEEL BUT ARE NOT WELDED TO EACH OTHER.

EXIST W27

TYP CONN W4 TO W27

I I C - I

i

Figure 3 Pulse Combustor Water Jacket

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Quarterly Technical April - June 1995

Progress

___

Report PAFBC295.RPT

TEM NO. ' VO. REO'D DESCRIPTION

~~

I I i ASTM ; REMARKS '

NOTE:

%' CLEARENCE BETWEEN PIPE LUG AND CHANNEL FRAME TOP FLANGES OF W's NOT SHOWN FOR CLARITY.

EXIST- W16x31' j j j

TYP FRAME CONNECTIONS

kY PLAN @ EL. 25'+101/4"

! I 0 WOW' i IRELEASEO FOR CONSTRUCTION. 0 L i I ' I :?, !

Figure 4 Coal/Limestone Handling System

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PAFBC295.RPT

DESCRIPTION ASTM 1 REMARKS 1 1 2 g' FIG. 66 WELDED BEAM ATTACHMENT I 2 2 g' FIG. 2 9 0 WELOLESS EYE NUT I

3 , 6 I '/LL' HEAVY HEX NUT I I 4 ' 2 '/LL'B ROO (LENGTH TO SUIT) ' 5 1 1 I L 3~3x%x2'-53/4" LONG I A36 I 6 I 1 I % " x S " FIG. 137s U-BOLT D=13" I 7 1 1 i 8" FIG. 16% PROTECTION SADDLE I

TEM NO. ' JO. IREO'D

I A36

-\ r,

% PIPE 8-CWR-204-CS EL. 24'+0"

ELEV. LKG. EAST t NOTE] TACK WELD PROTECTION SAOOLE TO PIPE

LOCATION PLAN

Figure 5 Coal/Limestone Hopper

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Quarterly Technical April -June 1995

Progress Report PAFBC295.RPT

1.2.4 Ash System

The previously designed vacuum ash conveying system was reviewed for continuous trouble free operation. Ash pickup hoppers were provided below the

fluid bed ash screw feeders. An isometric layout showing all the ash carrying pipes

and catch points was drawn (Figure 6).

1.3 Civil and Structural Design In the structural steel design, approach ladders were added to access coarse coal, fine

coal and lime stone silo feeder platforms. These platforms were designed to comply OSHA safety requirements.

1.4 Electrical Design The lighting load calculations by Duke, Fluor and Daniel revealed the insufficient

lighting transformer capacity. The drawings were revised to incorporate the higher size transformer.

This transformer will also handle the load of control room HVAC and weld receptacles.

1.5 Controls and Instrumentation Design

The PAFBC system control logic discussed during last quarter was reviewed by

ThermoChern and DF&D personnel. The control system discussed during last quarter, was

based on using single loop PID controllers and numerous manual control systems, sensors

and interlocks (as discussed in the last quarter). Based on Duke Flour Daniel’s

recommendation, it is now decided to go with distributed control system (DCS) using programmable logic con trollers (PLC). The PLC based control system is advantageous for the following reasons.

a

a

easy to incorporate any new control scheme that arise during testing

helps to include all safety interlocks in the PLC programming and minimizes costly operator error

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PAFBC295 .RPT Quarterly Technical Progress Report April - June 1995

Figure 6 Functional Diagram - Combustion Control

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PAFBC295.RFT

in-built capability to store large number of data that can be used in data analysis

The P&ID's and the instrument tag list will be revised to incorporate the PLC based However there is no change in the control logic, startup/shutdown control scheme.

procedures, and operational sequence discussed during last quarter

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PAFBC295.RPT

Section 2.0 FABRICATION ACTIVITIES

2.1 Maior Equipment

As reported in the previous quarter, fabrication of all major equipments, gas ductings

and reconditioning of all the used equipments were completed and shipped.

The following equipment fabrication was completed, shipped and installed:

Pickup hopper to receive coarse coal and limestone platforms, gratings and hand rails for increased access and safety.

Coalflimestone feed pipe floating end caps were made at MTCI and ready for

shipping.

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PAFBC295.RPT

Section 3.0 SITE CONSTRUCTION ACTIVITIES

Installation of all the heavy equipments was completed as reported during last

quarter. Refractory lining on combustors and hot ducts was already done.

The installation of pulse combustor steam water jacket and its components (aero

valve, air plenum, coal/gas injector, combustor top plate) were completed. Construction of control room building was just completed. On the electrical side, perimeter ground loop resistance was measured and the test values (ohm) were within the allowable limits per

National Electrical Code(NEC).

The service engineer from the Bag house manufacturing company visited the site and

inspected the bag house dust collecting facility. His recommendations include replacement of some damaged bags, cages, venturi and blow pipes. Some of the sub system shake down

activities initiated during this quarter. Coal mill was started using temporary electrical

supply. The coal mill generated the specified size range however more tests are planned for the next quarter.

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PAFJ3C295.RPT

Section 4.0 PLANNED ACTIVITIES FOR NEXT QUARTER

4.1 Design 0

. 0

Revising the P&ID drawings to reflect PLC based control scheme.

The following sub tasks are planned, as a part of control and instrument design. - Drawings for control panel configuration

Spotting instrumentation taps on pipes

System point to point wiring diagrams -

The above work is currently being done by DukeFluor-Daniel.

4.2

4.3

Fabrication 0

0

Complete fabrication of all steam piping Complete fabrication of distributor bubble caps

Complete fabrication of coal, limestone, ash, gas and cooling water piping

Site Construction 0

0

0

Installation of pulse combustor, aero valve and air plenum

Installation of bed modules inside the fluid bed combustor Installation of steam/water pressure piping from and to boiler drum and

steam line to Clemson power house

Installation of coal, limestone, ash, gas and cooling water piping Installation of Approach ladders to access all feeders

Electrical cabling and lighting installation

Installation of control and instrument fittings and wiring Installation of filter bags inside the bag house

0

0

0

0

Site cleanup and painting 0 Insulation and cladding for the hot surfaces

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Quarterly Technical Progress Report April - J u n e 1995

Section 5.0 SCHEDULE

PAFBC295.RP-I

The schedule reflecting the above targets and milestones is provided in Figure 7.

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Quarterly Teclinical Progress Report April - June 1995

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Figure 7 Clemson PAFBC Project Schedule

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Quarterly Technical Progress Report April -June 1995

Section 6.0 THERMOCHEM SITE CORRESPONDENCE

All site correspondence can be addressed to the following address:

ThermoChem Clemson University Site Office

Central Energy Facility Klugh Avenue

Clemson SC 29634

Phone: (803) 656-7111 Fax : (803) 656-7112

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PAFBC295,RPT

Documents

DOE/MC/27229 -- 5007