Paper Number: DOE/MC/25140-97/C0711 - Digital Library/67531/metadc682699/m2/1/high... · Paper Number: DOE/MC/25140-97/C0711 ... M.W. Kellogg (Kellogg), ... Design Issues First of

Paper Number:DOE/MC/25140-97/C0711

Title:Power Systems Development Facility: Design, Construction, and CommissioningStatus

Authors:C.A. PowllP. VimalchandH.L. HendrixP.M. Honeycut

Contractor:Southern Company ServicesP.O. Box 2625Birmingham, AL 35202

Contract Number:DE-FC21-90MC25140

Conference:Advanced Coal-Fired Power Systems '96 Review Meeting

Conference Location:Morgantown, West Virginia

Conference Dates:July 16-18, 1996

Conference Sponsor:U.S. DOE, Morgantown Energy Technology Center

Disclaimer

This report was prepared as an account of work sponsored by anagency of the United States Government. Neither the United StatesGovernment nor any agency thereof, nor any of their employees,makes any warranty, express or implied, or assumes any legal liabilityor responsibility for the accuracy, completeness, or usefulness of anyinformation, apparatus, product, or process disclosed, or representsthat its use would not infringe privately owned rights. Referenceherein to any specific commercial product, process, or service by tradename, trademark, manufacturer, or otherwise does not necessarilyconstitute or imply its endorsement, recommendation, or favoring bythe United States Government or any agency thereof. The views andopinions of authors expressed herein do not necessarily state or reflectthose of the United States Government or any agency thereof.

1.4 Power Systems Development Facility:Design, Construction, and Commissioning Status

Charles A, powe]l (charles.a.powell(ijscsnet,com; 205-669-5869)panna]al Vimalchand (p.vimalchand(ijscsnet,com; 205-669-5852)Howard L, Hendrix ([email protected]; 205-669-5876)Peter M. Honeycutt (peter.m.honeycuttfj!scsnet.tom; 205-669-5875)

Southern Company ServicesP.O. BOX 1069

Wilsonville,AL35186

Abstract

This paper will provide an introduction to the Power Systems Development Facility, aDepartment of Energy sponsored, engineering scale demonstration of two advanced coal-firedpower technologies; and discuss current status of design, construction and commissioning of thisfacility.

The Power Systems Development Facility (PSDF) will test and demonstrate a secondgeneration combined cycle pressurized circulating fluidized bed combustion system with a syn-gas fired topping cycle (APFBC); an advanced circulating fluidized bed transport reactor actingas either a combustor or as a gasifier; (presently) three different Hot Gas Clean-Up technologies(Particulate Control Devices or PCDS); and (in later years) fuel cells and desulfurizationtechnologies.

Design and construction of the Transport Reactor and required associated equipment willbe completed in early summer 1996, Design of the APFBC is over 95% complete, andconstruction has begun. Commissioning of the Transport reactor is presently underway, with theseparate components and sub-systems being fully operational and work focused on integrationissues for the entire reactor system. Commissioning of APFBC components should begin inearly 1997. The first ceramic candle filter vessel has been loaded and is undergoing testing attemperatures over 1000”F. Initial operation of the transport reactor will be as a combustor, withplans to test operation as a gasifier scheduled for thk Fall.

Construction of the Granular Bed Filter is presently underway, with plans for sub-systemcommissioning to begin this Fall. The first ceramic candle filter system will be tested on thetransport reactor before being relocated mid-next year to the APFBC train; at which time it willbe replaced by another candle filter system on the transport reactor.

Research sponsored by the U.S. Department of Energy’s Morgantown Energy Technology Center, undercontract DE-FC21 -90MC25 140 with Southern Company Services, Inc., P,O. Box 1069, Wilsonville, AL 35186;te]efax: 205-669-5843

Construction of the APFBC system, with the installation of the combustor vessels, heatexchangers and refractory lined piping is underway. The electrical design is being completedthis summer; as is the assembly of the major components of this system: The CombustionTurbine, The Topping Combustor, and the inlet/outlet piping for both, By using commonBalance of Plant facilities, the condensate, cooling, control air, purge and auxiliary fuel systemsare installed to support operation of the transport reactor and require only minimal work tosupport the APFBC operation.

Construction of the PSDF has presented several problems different from thoseencountered in constructing a traditional pulverized coal plant: Pneumatic pressure boundaries,fuel (and sorbent) injection under pressure, gas sampling under temperature and pressure, exoticmaterial procurement and fabrication, and complex piping due to the large number of fluidizinggas connections to the pressurized reactor.

POWER SYSTEMS DEVELOPMENT FACILITY

DOE Cooperative Agreement No. DE-FC21-90MC25140

Southern Company Services, Inc.Wilsonville, Alabama

Design, Construction, and Commissioning Status

1 of 0796CPMT.PRE/96089

The Southern Company Power Systems Development Facility

PSDF Program Objective

15 of 0296RRBM/96045Rev. 7/10/96

Develop advanced coal-based power

generation technologies that can produce

electricity at competitive cost and meet all

environmental standards.


PSDF Program Goal

4 of 0796RRWI.PRE/96118

The PSDF is a site where new process configurations and components for advanced power systems can be tested in an integrated process environment at sufficient size to provide data for scale-up toward commercialization. DOE’s intent is that:

The PSDF be recognized by equipment vendors, process developers, and generators of electric power as the best place to test new components and integrated process configurations for advanced power systems.

Data from the PSDF be recognized as a clear indicator of the usefulness of new components and integrated process configurations for advanced power systems and be sufficient to support commercial scale-up.

Public and private funding agencies recognize the PSDF as a readily accessible, politically neutral, cost effective testing location for advanced power system components and integrated process configurations.

The staff at the PSDF be recognized as experts in their respective technologies by all their customers.


Project Overview

4 of 0796CPMT.PRE/96090

METC sponsored project to demonstrate two Advanced Coal-fired Power Generation Technologies, three Hot Gas Clean-Up Technologies, and Fuel Cells (future)

Southern Company Services is acting as Prime Contractor and is responsible for Operation of the facility as well as Design of Balance of Plant (BOP) Equipment, Design Integration, Construction and Start-Up

M.W. Kellogg (Kellogg), Foster Wheeler (FW), Westinghouse (W), Combustion Power Corp. (CPC) and Industrial Filter and Pump (IF&P) are major participants.


Project Overview

5 of 0796CPMT.PRE/96091

Increased integration of process components

All possible components were commercially available to minimize scale up concerns and allow use of existing technologies if possible.

Kellogg is supplying a pressurized transport reactor that can be configured as either a combustor or a gasifier.

Foster Wheeler is supplying an integrated, Advanced Pressurized Fluidized Bed Combustion (APFBC) system, including a gas turbine equipped with a topping combustor supplied by Westinghouse.


Project Overview

6 of 0796CPMT.PRE/96092

Particulate Control Devices (or PCD’s) are supplied by Westinghouse, CPC, and IF&P.

Two are using ceramic candle filters (Westinghouse and IF&P).

CPC is supplying a Granular Bed Filter.

The ceramic candles are being supplied by several vendors.

PARTICIPANT RESPONSIBILITIES

3 of 0495RRBM.PRE/95027Revised 7/10/96

SouthernResearchInstitute

U. S. Departmentof Energy

Southern Company ServicesProject ManagementEngineering Coordination

SouthernCompany

Electric Power

Research Institute

APFBC/ Gas

Turbine

ParticulateCollectionDevices

Foster WheelerWestinghouse

Allison

M. W. Kellogg SouthernCompanyServices

B.O.P. and

Construction

SouthernCompanyServices

TransportModule

(Gasif./PFBC)Operate

ParticulateSampling

Combustion PowerIF&P

Westinghouse

SITE STAFF

SCS 40APC 43SRI 6-8DOE 3EPRI 1Spectrum 1Vendors 6-10

TOTAL 100-106

PSDF SITE ORGANIZATION

TechnicalManager

Sr.

SecretarySr.

Secretary

TimPinkston O & M

Mgr.

DarrellMoore

GloriaBuie

CherryDupree

FW Train Lead

Engineer

PCDLead

Engineer

MWK Train Lead Engineer

DataAnalysis

Lead Engineer

HowardHendrix

P.Vimalchand

DougMaxwell

JohnWheeldon(EPRI)

Lab. Superv. &

Technicians(SRI)

Engineers Engineers Engineers

Frank MortonDavid RomansPete Honeycutt

MatthewDavidson

Oliver DaviesGuohai Liu

Roxann LeonardEdwin Galloway

(DOE)

Brandon DavisBruce Harrington

(DOE)

Mary JaneSherbert

Manager

Planning &

Analysis

GaryStyles

DOE

Technical

Liason

DarrenMollot

4 Shift Coordinators

Wayne BarnettRay Lee

T.O. TarpleyShift Coord. #4

APC0

20 PCO8 APCO

2 EO

Maint.

Coordinator

I & C

Engineer

Mech.

EngineerDesigner

Maint.

Supervisor

CharlesPowell

TonyHicks

RichardHornbuckle

JimmyHorton

BrettWingard

8 Mech.

1 Welder

APC0

4 E & I

APC01 CEM

Mech.

(Spectrum)

DavidMims

Training

Coordinator

S:\PAPRPRES\DUPREE.PRE

Admin.

Ass’t.

RandallRush

ProjectDirector

DOEMETC

John VeazeyRandy Johnson

David Mann

CharlesCantrell

Adm/Proj

Support

Mgr

PurchasingAgent/

Coordinator

Env./Safety

Coordinator

3 W/H

Clerks

Sr.

Secretary

CharlesHenderson

BeckyWatters

HughTurner

Admin

Clerk

MaryMurphree

Cost/

Analysts/

Schedule

DavidPhilpot

RachelWilson

Document

Control

TerrySpinks

ParticulateTesting

(SRI)

Vendor

Engineers

MWKFW(W)

IF&PCPC

OthersEngineers

JerryBandura


Project Status

9 of 0796CPMT.PRE/96093

Design and Engineering are complete, except for electrical integration of Foster Wheeler equipment, which will be complete this fall.

Construction of Kellogg and Kellogg required BOP equipment is complete.

Start-up of BOP equipment began last September with the electrical station service.

Start-up of Kellogg’s transport reactor as a combustor is in the final stages.

Several design enhancements have been incorporated during construction to improve operability during system malfunctions.

The Southern Company Power Systems Development Facility10 of 0796CPMT.PRE/96094

Start-Up Bed Material Injection Spools

Propane Supply Option Spools

Steam Supply Piping Modifications

PCD Warm-Up Modifications

Using Primary Gas Cooler as a Condensation Heater

Using Sulfator Start-Up Heater

Using a Screw Cooler to Cool Pulverized Coal

Using Process Air to Fluidize the Combustion Heat Exchanger

Nitrogen Purge Connections

Design Enhancements


Systems Operational

11 of 0796CPMT.PRE/96095

Electrical Station Service

Distributed Control and Data Collection

Cooling Water Systems

Instrument, Control, and Service Air

Feedstock (Coal and Sorbent) Storage, Reclaim and Preparation

Condensate and Steam Generation

Kellogg Process and Transport Air

Reactor Aeration, Instrument Purge, Spoiling and Fluidization

Dense Phase Transport of Feedstock and Ash


Systems Operational

12 of 0796CPMT.PRE/96096

Burners on Thermal Oxidizer, Sulfator Start-up Heater and Transport Reactor Start-up Heater

Ash Cooler Heat Transfer Fluid and Screw Coolers

Recycle Gas Compressor

Westinghouse PCD Backpulse

Baghouse and Thermal Dilution Fan

Liquid Nitrogen Storage and Delivery

Propane Storage and Delivery

Backpulse Air


Issues Encountered

13 of 0796CPMT.PRE/96098

Piping and electrical conduit density in the process structure

First of a kind specification requirements

Aggressive schedule forcing design decisions

Exotic material requirements due to temperature, pressure and chemical activity

Designs for single case, limiting range of operation

Pneumatic pressure boundaries

Gas sampling at pressure and temperature

Feedstock injection into pressurized reactor

Suitable start-up bed materials for reactors


Design IssuesPiping Density in the Process Structure

14 of 0796CPMT.PRE/96099

Due to cost constraints, the structure was reduced in size by 20’ in both directions.

Every pressure tap must be supplied with a purge gas (Nitrogen) that must be metered and flow controlled to minimize biasing.

Fluidization requires many aeration nozzles to prevent layout of solids.

Staged combustion and controlled gasification require fine control of location and flow of combustion (oxidizing) air.

PSDF transport reactor has as many connections as a 150 MW unit would.


Design IssuesFirst of a Kind Specification Requirements

15 of 0796CPMT.PRE/96100

Specifications for coal and limestone size require additional equipment and feedstock wastage to achieve design requirements.

Conservativism in inclusion of alkalai getters, cyclones, baghouses, and sulfator into process designs

High Nitrogen usage, especially during start-ups and shut-downs

Requirements for specialized alloys of limited availability and high price

Incomplete or untried control configuration


Design IssuesAggressive Schedule

16 of 0796CPMT.PRE/96101

Aggressive schedule forcing design decisions

Coal (feedstock) prep building started before the pulverizers were purchased, requiring modification before installation could be completed.

Cooling water system redesign caused by increased requirements of Foster Wheeler, and other vendors’ equipment

Station service equipment being modified in response to increasing electrical loads

This aggressive schedule did force project to progress.


Design IssuesSpecialized Material Requirements Due to

Temperature, Pressure and Chemical Activity

17 of 0796CPMT.PRE/96102

Gas Analyzers

Recycle Gas Compressor Piping

Foster Wheeler’s Carbonizer Gas Valves and Piping

Reactor Emergency Pressure Let-down Piping

Gas Cooler Bypass Orifices


Design/Operation IssuesDesigns for Single Case, Limits Range of

Operation

18 of 0796CPMT.PRE/96103

Several instances of design short-comingsTransport reactor start-up burnerTransport reactor pressure control valveRecycle gas compressor control logicDense phase transport control logicTransport reactor process air compressor control logic

Kellogg Process Control is not yet integrated, unable to link process variables of different systems to allow smooth parametric changes


Design/Operation IssuesPneumatic Pressure Boundaries

19 of 0796CPMT.PRE/96104

Reactors using piping lined with two layers of refractory totaling 9 inches thick

Refractory lined piping 36" in diameter weigh several hundred pounds per running foot

Due to weight and size, the piping is difficult to assemble in place, requiring each joint to be caulked and sealed with flexatalic gaskets.

Flexatalic gaskets are fragile during storage and installation and are single use only.


Design/Operation IssuesPneumatic Pressure Boundaries

20 of 0796CPMT.PRE/96105

Refractory is hydroscopic and requires specialized curing procedures after thirty days at ambient air conditions.

Problems with long term storage of un-cured refractory required minor repairs.

Vessels and piping have rate of change restrictions on temperature and pressure to prevent cracking and failures

A pressure test is required after every inspection or maintenance.


Design/Operation IssuesGas Sampling at Pressure and Temperature

21 of 0796CPMT.PRE/96106

First of a kind engineering to extract dust- laden samples at temperature and pressure

Several gas components have dew points over 700F, and the liquid phase is highly corrosive.

Requires exotic alloys for strength and corrosion protection

Concentrations and compounds require specialized analyzers.


Design/Operation IssuesFeedstock Injection into Pressurized

Reactor

22 of 0796CPMT.PRE/96107

Tidd and Other PFBC Plants Use Hybrid Slurry Pumps to Inject Feedstock

Add water to processHigh maintenance items

PSDF Using Dense Phase Feed TechnologyDry conveying using Nitrogen or air as transport mediaMetering feedstock and transport mediaUsing pressures less than 20 psi higher than reactor


Operation IssuesSuitable Start-Up Bed Materials for

Transport Reactor

23 of 0796CPMT.PRE/96108

Friable Alumina Initially Procured and usedFluidizes well, and temperature resistantTwice as dense as other feedstocks, causing problems with dense phase equipmentVery hard and abrasive, causing failure of control valve

Spherical AluminaNonabrasive, fluidizes wellHard to procure, very dense


Operation IssuesSuitable Start-Up Bed Materials for

Reactors

24 of 0796CPMT.PRE/96109

River SandUsed at TiddHigh Silica will not withstand heat

Furnace AshDifficulty in finding adequate source

Conclusion: Use Alumina Until Enough Transport Reactor Ash is Generated.

Pre-sized, dry, inert, temperature resistant


Progress to Report

25 of 0796CPMT.PRE/96110

Passed reactor pressure test with no welds failing and few minor flange leaks

Candled Westinghouse PCD with no candle breakage

Thermal oxidizer refractory was cured to 1600F, and thermal oxidizer was nearly 1000 hours of operation

Sulfator/PCD warm-up heater refractory cured in 4 days of operation

Successfully balanced purge flows to zero differential pressure transmitters at three reactor pressure settings


Progress to Report

26 of 0796CPMT.PRE/96111

Successfully fired reactor start-up burner to cure reactor refractory lining to 1000F

Successfully fluidized reactor with alumina as start-up bed material; circulating bed material through the reactor, riser, and heat exchanger at circulation rates of up to 90,000 lbs/hr and velocities to 45 ft/sec

Demonstrated operation of feeders under pressure with alumina

Preparing for the Foster Wheeler combustor refractory cure

Currently firing with coal at 165 PSI


Future Plans

29 of 0796CPMT.PRE/96114

July - Aug: Operate transport reactor as combustor for shake-down trials

Sept - Oct: Operate transport reactor as combustor for parametric testing

Oct - Nov: Operate transport reactor as gasifier for shake-down trials

Nov - Mar ’97: Operate transport reactor as gasifier for parametric testing

Apr - May ’97: Operate transport reactor as combustor for shake-down trials of Combustion Power’s granular bed filter


Future Plans

30 of 0796CPMT.PRE/96116

Apr - May ’97: Foster Wheeler Combustion Turbine Start-Up

Sept - Oct ’97: PFBC Start-Up of Foster Wheeler

Jan - Feb ’98: APFBC Start-Up of Foster Wheeler

Documents

Paper Number: DOE/MC/25140-97/C0711 - Digital Library/67531/metadc682699/m2/1/high... · Paper Number: DOE/MC/25140-97/C0711 ... M.W. Kellogg (Kellogg), ... Design Issues First of