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Wabash River Coal Gasification Re Powering Project (Part 2)

Wabash River Coal Gasification Re Powering Project (Part 2)

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Wabash River Coal Gasification Repowering Project Final Technical Report
DE-FC21-92MC29310
5-1
5.0
TECHNICAL PERFORMANCE

The technical performance of the plant has been evaluated within this section primarily by a review of system and equipment reliability, availability and maintainability. Each major piece of equipment and process step has been evaluated over the best 12 months of operation during the Demonstration Period. At Wabash River this time period covers March 1, 1998 through February 28, 1999 and is referred to throughout the following section as the \u201cOperating Period\u201d. It is significant to note that this period represents the final full 12-month period of operations within the Demonstration Period and is immediately preceding the 100-day outage for the combustion turbine failure.

As the entire Operating Period is encompassed within the defined Demonstration Period for the Project, some of the information contained within this section is redundant when compared with information in Section 4.0 Demonstration Period. This redundancy is intentional, allowing these two sections of the Final Technical Report to be reviewed independently.

Reliability discussions included in Section 5.0 address the consistency in operation of specific equipment items, while the maintainability discussions are associated with specific equipment maintenance issues, which prevented consistent operation. The availability of all subsystems is defined as the percentage of hours that a subsystem was available for operation when compared to the total hours in the Operating Period minus the \u201cscheduled\u201d facility downtime hours. These numbers are compiled and reviewed in detail in Table 5.0A.

Wabash River Coal Gasification Repowering Project Final Technical Report
DE-FC21-92MC29310
5-2
Table 5.0A: WRCGRP Operating Period Downtime and Availability
Section 5
Reference
Area

Non-
Scheduled
Downtime
Hours

% of Non- Scheduled Downtime

Availability
5.1
Air Separation Unit*
285
12.5%
96.32%
5.1.1
Air Compression System
87
3.8%
98.87%
5.1.2
Water Wash System
61
2.7%
99.21%
5.1.3
Air Purification System
10
0.4%
99.87%
5.1.4
Air Cooling and Liquefaction System
0
0.0%
100.00%
5.1.5
Cryogenic Distillation System
77
3.4%
99.00%
5.1.6
Oxygen Mixing System
0
0.0%
100.00%
5.1.7
Nitrogen Handling and Storage System
15
0.7%
99.81%
5.1.8
Oxygen Compression System
70
3.1%
99.09%
5.2
Coal Handling
36
1.6%
99.54%
5.2.1
Coal Hopper System
0
0.0%
100.00%
5.2.2
Rod Mill System
0
0.0%
100.00%
5.2.3
Slurry Storage Tank System
3
0.1%
99.96%
5.2.4
Slurry Feed System
33
1.4%
99.58%
5.3
Gasification
1590
69.9%
79.45%
5.3.1
First Stage Gasifier
1001
44.0%
87.06%
5.3.2
Second Stage Gasifier
169
7.4%
97.82%
5.3.3
Raw Syngas Conditioning
0
0.0%
100.00%
5.3.4
Slag and Solids Handling
66
2.9%
99.15%
5.3.5
Syngas Cooling/Steam Generation
System
158
6.9%
97.96%
5.3.6
Particulate Removal System
152
6.7%
98.03%
5.3.7
Chloride Scrubbing System
10
0.4%
99.87%
5.3.8
COS Hydrolysis System
0
0.0%
100.00%
5.3.9
Low Temperature Heat Recovery
System
7
0.3%
99.90%
5.3.10
Syngas Moisturization System
0
0.0%
100.00%
5.3.11
Acid Gas Removal System
22
1.0%
99.72%
5.3.12
Sulfur Recovery System
5
0.2%
99.94%
5.3.13
Sour Water Treatment System
0
0.0%
100.00%
5.3.14
Cooling Tower System
0
0.0%
100.00%
5.4
Power Block
363
16.0%
95.30%
5.4.1
Combustion Turbine
140
6.1%
98.19%
5.4.2
Heat Recovery Steam Generator
201
8.8%
97.40%
5.4.3
Water Treatment Facility
13
0.6%
99.83%
5.4.4
Steam Turbine
9
0.4%
99.88%
Totals
2274
100.0%
70.61%
Coal Hours
5462
Hours for 3 scheduled outages
1022
Non-scheduled downtime hours
2274
Period Hours
8760
*Thirty-five hours of downtime affected both sections 5.1.1 and 5.1.8. It has been counted only once
in the ASU total but in each section independently.

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