Quarterly Report October December - digital.library.unt.edu/67531/metadc681260/m2/1/high... · Quarterly Report October - December 1994 ... Boiler Modification ... hopper size in

DOE/MC/27229 -- 4002 (DE9 500007 1 )

Pulsed Atmospheric Fluidized-Bed Combustion

Quarterly Report October - December 1994

January 1995

Work Performed Under Contract No.: DE-FC2 1 -90MC27229

For U.S. Department of Energy Office of Fossil Energy Morgantown Energy Technology Center Morgantown, West Virginia

BY ThermoChem, Inc. Columbia, Maryland

T

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 responsibility 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. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, 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.

This report has been reproduced directly from the best available copy.

Available to DOE and DOE contractors from the Office of Scientific and Technical Information, 175 Oak Ridge Turnpike, Oak Ridge, TN 37831; prices available at (615) 576-8401.

Available to the public from the National Technical Information Service, US. Department of Commerce, 5285 Port Royal Road, Springfield, VA 22161; phone orders accepted at (703) 487-4650.

DISCLAIMER

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

DOWMU27229 -- 4002 (DE9500007 1 )

Distribution Category UC-103

PuIsed Atmospheric Fluidized-Bed Combustion

Quarterly Report October - December 1994

Work Performed Under Contract No.: DE-FC2 1 -90MC27229

For U.S. Department of Energy

Office of Fossil Energy Morgantown Energy Technology Center

P.O. Box 880 Morgantown, West Virginia 26507-0880

BY ThermoChem, Inc.

5570 Sterrett Place, No. 2 1 0 Columbia, Maryland 2 1044

January 1995

.. Quarterly Technical Progress Report October . December 1994

PAFBC494.RPT

Pulsed Atmospheric Fluidized Bed Combustor Design Report

Table of Contents

Executive Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 1.0 1.1 1.2

1.3 1.4 1.5

Section 2.0 2.1 2.2

Section 3.0

Section 4.0 4.1 4.2 4.3

Section 5.0

Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Process Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.1 FluidBed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.2 Pulse Combustor Components . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.3 Feed System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2.4 Ash System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Civil and Structural Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controls and Instrumentation Design . . . . . . . . . . . . . . . . . . . . . . . . .

Fabrication Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Boiler Modification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Major Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Site Construction Activities .................................

Planned Activities for Next Quarter . . . . . . . . . . . . . . . . . . . . . . . . . . Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fabrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Site Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 6.0 ThermoChem Site Correspondence . . . . . . . . . . . . . . . . . . . . . . . . . . .

i

... 111

1 1 1 1 1 1 7 7 7 7

7 7

13

13

14 14 15 15

15

15

.

Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11

PAFBC494.RPT

LIST OF FIGURES

PAFBC Piping Plan . Steam Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Target Cone Traversing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Pulse Combustor Water Jacket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 CoaVLimestone Handling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 CoaVLimestone Hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Perimeter Ground Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Functional Diagram . Combustion Control . . . . . . . . . . . . . . . . . . . . . 9 Functional Diagram . Draft Control . . . . . . . . . . . . . . . . . . . . . . . . . 10 Functional Diagram . Drum Level Control . . . . . . . . . . . . . . . . . . . . 11 Functional Diagram . Pulse Combustor Temperature Control . . . . . . 12 Clemson PAFBC Project Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . 16

.. 11

_ ~ - Quarterly Technical Progress Report October - December 1994

PAFBC494.RPT

Executive Summary

The report of activities for the fourth quarter of 1994 is summarized below:

Design Activities

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

- Mechanical. Minor modifications were made in the steam/water pressure pipe routing from and to boiler shell. This was primarily done to accommodate the bed module orientation change reported in last quarter. Refractory target cone lifting arrangement was designed and drawing made. Few changes were made in the pulse combustor jacket tail pipe inlet configuration and coal feed system.

Civil and Structural. The ash silo pad elevation was lowered to match the nearest access road level. No changes in the structural design and drawings were made.

Electrical and Instrumentation. Grounding system drawing was revised to comply Duke Fluor Daniel’s recommendations. In the controls and instrumentation area, functional drawings showing major control schemes were completed.

Fabrication Activities. Major equipment fabrication and reconditioning was completed during this period. Pulse combustor components fabrication are in the final stages of completion.

Site Construction Activities. The foundation work was completed on Dec 31, 94 as scheduled. The underground electrical work was completed as well. The erection site was mobilized and the major equipment installation initiated. The refractory lining of some of the fabricated components was completed.

Planned Activities for Next Quarter. Erection of major equipmen ts, installation of perimeter ground loop, construction of Control Room Building, specifications for the above ground electrical work and detailed drawings for controls and instrumentation.

Schedule. The project is currently on schedule and there is no change in the schedule reported last quarter.

1..

111

SECTION 1.0 DESIGN

Quarterly Technical Progress Report October - December 1994

PAFBC494.R PT

1.1 Process Design

The process configuration remained unchanged during this quarter.

.-

1.2 Mechanical Design -

1.2.1 Fluid Bed

The steam/water mixture piping layout from and to boiler shell was modified

to reflect the revised bed module orientation. The steam/water mixture piping from

bed modules and pulse combustor jacket was designed to have equal pressure drop

and flexural rigidity (Figure 1). A rotating screw mechanism was designed to move

the refractory target cone vertically up inside fluid bed (Figure 2).

1.2.2 Pulse Combustor Components

Design modifications were incorporated in the pulse combustor water jacket design (Figure 3). Previous design had a removable stainless steel insert (reducer) at the tail pipe inlet. In the revised design, the same is replaced with an integral

reducer, attached to the tail pipe by butt welding. The reducer thickness is maintained same as the tail pipe (6" NB 120 sch). This modification work is

currently being executed by an A.S.M.E. code approved boiler manufacturing

company.

1.2.3 Feed System Coal feed distribution into the fluid bed via four independent feed points

using rotary isolation valve was discussed during the last quarter. The pick up

hopper size in the coal distribution drawing was modified to have lower angle of

repose (Figures 4 & 5). This revised arrangement will improve the coal flow from hopper to pneumatic lines.

1 of 16


Q

I I- C=-

52

PAFI3 C494.RPT

--rt

Figure 1 PAFBC Piping Plan - Steam Circuit

2 of 16


Figure 2 Target Cone Traversing System

3 of 16

~- - Quarterly Technical Progress Report October - December 1994

PAFBC494.RPT

Qq

Figure 3 Pulse Combustor Water Jacket

4 of 16

~

Quarterly Technical Progress Report October - Deceniber 1994

0 F! _I

4 s w LL

d

PAFBC494.Rl’T

Figure 4 CoaVLimestone Handling System

5 of 16

~~


PAFBC494. R PT

1.2.4 Ash System

No change in the ash feed system design are required, except the elbows on

the pneumatic conveying lines will be replaced by cross.

1.3 Civil and Structural Design

The ash silo pad elevation in the original foundation drawing was 3’ higher than the

access road level. The pad level was lowered to match the nearby access road level and this

will make the ash loading into the truck easier. Now the trucks can go directly under the silo and carry the collected ash.

-

1.4 Electrical Design

Duke Fluor Daniel’s Electrical Engineer visited the PAFBC site during this quarter

and inspected the under ground electrical work. After this visit, minor changes in the perimeter ground loop layout was recommended by Duke Fluor and the loop drawings are revised (Figure 6).

1.5 Controls and Instrumentation Design -

Functional diagrams showing the control schemes were made for combustion control,

draft control, drum level control and pulse combustor temperature control. Independent

single loop controllers combined with I/P converters are used in each of these control

schemes (Figures 7-10).

Section 2.0 FABRICATION ACTIVITIES

2.1 Maior EquiDment

Fabrication of major equipments, gas ductings and reconditioning of most of the used

Most of the heavy equipments were already shipped. equipments were completed.

Arrangements are being made to transport rest of the completed equipments to site.

7 of 16


1 :e ’I

PAFBC494.RPT

JJ

Figure 6 Perimeter Ground Loop

8 of 16


PAFBC INSTRUMENTATION FUNCTIONAL DIAGRAM -- COMBUSTION CONTROL

PRESSURE PRESSURE TRANSMITTER

I

I (4-2O)MA

I PID CONTROLLER SINGLE LOOP I

I I

i (4-2O)mA

AT 20 PSIG I/P CONYERTER

I : (3-15)PSIG. AIR 1 FLUIDIZING AIR FAN ACTUATOR

1 t

, TEMPERATURE SET CONTROLLER TEMPERATUR

c_

I

i (4-2O)d

COARSE COAL I FEEDER M l

I (0-lO0)V D.C.

CONTROLLER

t I

L 2 r L l FEEDER M3

Figure 7 Functional Diagram - Combustion Control

9 of 16

PAFB C494.R PT


PAFBC INSTRUMENTATION FUNCTIONAL DIAGRAM -- DRAFT CONTROL

FREEBOARD PRESSURE 7 SET

PRESSURE

I I I I

PRESSURE TRANSMITIXR

AIR AT 20 PSIG

I

1 (4-20)MA

PID CONTROLLER

I (4-2O)MA

-4 I/P CONVERTER

I

{ (3-15)PSIG. AIR

ID FAN ACTUATOR

(2-15)PSIG. AIR

I DRAFT INDICATOR I

Figure 8 Functional Diagram - Draft Control

P Am C494. R PT

10 of 16


PAFBC INSTRUMENTATION FUNCTIONAL DIAGRAM --DRUM LEVEL CONTROL

PAFBC494.RPT

DRUM LEVEL I LEVEL TRANSMITTER NORMAL. LEVEL I SET PT

I

I I (4-2O)MA

I PID CONTROLLER

I I (4-20)MA

AT 20 PSIG I/P CONVERTER

I

' (3-1 5)PSIG. AIR

FEED CONTROL

FEED WATER T O T W R

Figure 9 Functional Diagram - Drum Level Control

11 of 16

CI 0

I

%

PAFBC INSTRUMENTATION FUNCTIONAL DIAGRAM -- P U E E COMBUSTOR

TEMPERATURE CONTROL

TEMPERATURE

I I

CONTROLLER

I

-1 - - - - - - _ _ _ _ _ I I I I I I

MANUAL WADER FOR I I I MANUALLOADER I

FOR PC AIR I MANUAL LOADER FOR


PAFBC494.RPT

The following equipment fabrication is in the final stages of completion:

Pulse combustor air plenum Pulse combustor aero valves Pulse combustor fine coal injector Pulse combustor top plate

The following equipment reconditioning is in the final stages of completion: -

Screw conveyer connecting truck dump hopper to coal mill

Screw conveyer connecting classifier to bucket elevator

Fabrication of the structural steel coming around the combustor vessel was completed. The pulse combustor steam/water jacket was shipped to A.S.M.E. code shop, to modify the tail pipe inlet and add instrument connections.

2.2 Boiler Modification

The modifications on the boiler shell (enlargement and opening of new nozzles) were

carried out by an A.S.M.E. code approved boiler repairer. After the modification, the boiler shell was subjected to hydro static test a t 225 psig pressure and the test witnessed by code approved inspector.

Section 3.0 SITE CONSTRUCTION ACTIVITIES

The foundation work was completed on Dec 31, 1995 as scheduled. The work was

inspected by registered civil Engineering firm in the state of South Carolina. The underground electrical work €or the embedded conduits and grounding was completed as

well.

The erection site was mobilized with Thermochem opening its site office at Clemson

university.

The installation of following heavy equipments are already completed.

Combustor vessel

13 of 16


PAFBC494.R PT

Fine coal silo Lime stone silo Structural steel columns and beam

The following major equipments are already shipped and ready for installation.

Coarse coal sjlo Ash silo Economizer Bag house

Arrangements are being made to ship the following equipments within the next two

weeks.

Boiler inlet ash hopper Boiler outlet duct Economizer ash hopper Economizer outlet duct Distributor air inlet duct I.D. Fan outlet duct Exhaust stack

Refractory lining work on the following equiprnents are completed and will be shipped during next week.

4.1

Hot cyclone Inlet gas duct to cyclone Solids return duct (Dipleg and J valve) Refractory Target cone

Section 4.0 PLANNED ACTIVITIES FOR NEXT QUARTER

Design

0

0

Complete design and drawings €or controls and instrumentation

Design and drawings for control panel and wiring

Isometric drawing for steam/water mixture pressure piping

Review of piping, control and instrumentation drawings by Duke Fluor

14 of 16

PAFBC494.RPT _ ~ _ ~~~ Quarterly Technical Progress Report October - December 1994

4.2 Fabrication 0 Complete pulse combustor components fabrication

Complete reconditioning of all balance equipments

15 of 16

4.3 Site Construction

0

0

Shipping of balance components to Clemson site

Installation of rest of the heavy equipments and ductings

Installation of under ground perimeter ground loop 0

0

0

Refractory lining work for bed modules at vendors shop

Installation of pressure piping from and to boiler

Construction of control room building

Section 5.0 SCHEDULE

The schedule reflecting the above targets and milestones is provided in Figure 11. There is no change in the schedule submitted during last quarter.

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


Figure 11

....... . . . .

....... . . . . . . ....... . .

....... . . . . . . ....... . . . . ....... . . . . . . : . . . . .i___. . . : : . . . . . . ...... . . . . . . . . . . : - . . . : . . j : . . . . : : ..___. * , : - ....... , . , . i /

1 ; ....... 3 : / /

.*...,. . . i

. . . .

. . . . . . .......

. .

. . . . : :

: : : ....... . . . . . . . . ....... . . . . . : : / ....... . . . . . . . . . . . .

: ....... . . . . : :

. :

. . . . . . . . . . .......

. . . . . . : : : / . . ....... . . . . : : . . . . - : :

: : . . . . ....... : : . . . . / : . . ..__._ . . . . . . . . . . . : "-'I . . . . ..... . .

! / / : . . ..__._

. . . : : : . .

.................................... . . . .

. . . . : ..- . . . . . . . . . . . . . . . . . . . . i

. . .

. . . . . . . . . .

. . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . .

. . : ;

. . . . .

. . ... . . . . . . . . . . .

: : . . : . . ; < . . . . . . . . . . . . . . . . . . . . : . :

_i___i ................ . . . . . . . : . . . . : . i . . . : : . . . . . . . . . . . ...................... . . . . . . . C . . ' ' : : : : . : i : .

: : : : . . : .- .............-.... . . . .

. . . . . . . . . . . . . . . ._ . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................... .r

. . . . :

. . . . . . . . : . t .

.o .......... ~ ........ : . : : . < : . . . . : . . .

. . . . . . . . . . . . : : . : . : : : : : : : : . . . . . . . , i .

. . . . .

. . . . . ._ . . . . . . . . . . . .

. . . . . . . . . . . . . . . . .

. . . . . . . . . . . : . . . . : : . __ .......... j._-._i_ . . . . . . . . .

. . . . . . . . . . . . . . . . : . : . . . . . . . . . . . . . . . . . . . . . .. . . _& . . . . . . . : : : : . . : : : : . . . . . : : : : : : : : : : : . : : . . . . . . . .

. . . . . . . . .

.............................

............................. . .

. . ..... . . . . . . . . . . . . . . : : . . . .

. . . . . . . . . . : : . : . . ...- .. ̂ ...... : . . :

: : : : :

. . . . . : / /

. . . . . . . . . . .

. . . . . : : - . . . . . . . .

. . . . . . : : : : : ......._......

: :

: : : : : ......-.......

/ :

> : : . . . - i ! / . .

. . . ! / :

. . . . . . : : : : :

: : : : :

. . . ... . .

. . . . . . . . . . : j : . . : : ......_.. ..... . . . . . . . . . . . . . . . . . . . .

. . : : .. ...._....... : : : : . : : : . . : : i : . . :

. . .

. . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . : . : : . : : : : : : :

: : :

. . . ___i :___/

. . . . . . . . . . . . . . . : * i i

; : i /

i / / j

I / ; j

. . . . ..... . . . . . . . . . : : . . : .

. . . . . . . . . . . . . . . . : . : : : i : : : : : ............... : :

: : . : . . :

. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . ii . . . . . . . . . . . .

. . . . . . . . . . . . . . . . ......_....... :

: . . . . ......_....... : : : :

. . . . . . . . . . . . . . . . . . . / / : ; . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . : : : . : . .

. . . . :

. . : . . . . . . . .

/ : : : ............... : . . : : :

Clemsan PAFBC Project Schedule

16 of 16

PAFDC494.RPT

1' 1 a :I

Documents

Quarterly Report October December - digital.library.unt.edu/67531/metadc681260/m2/1/high... · Quarterly Report October - December 1994 ... Boiler Modification ... hopper size in