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Enmas GB Power Systems Projects Limited

Plant : VEOLIA Bio Energy Facility - Cameronbridge

Title

: Proposed modification Schemes

Report status : Interim


Document No : EGB-RPT-Dalkia/SC / 003

0
Rev

28.10.1
5
Date

Satyajit

Satyajit

Originator

Verified

Approved

Implemente
d

Revision Summary
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Changes

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Reasons for Change

Enmas GB Power System Projects Limited


Doc No : EGB-RPT-Dalkia/ SC/ 003

Title : Proposed modification Schemes


Date : 28.10.15

Section 1: Introduction
This document should be read in conjunction with Doc No EGB-RPT-Dalkia/SC / 002 having
title : Visit report to the facility in September 2015.
Essentially it was opined by Veolia that the boiler will be de-rated to 40 tph and ways and
means to improve fluidizing velocity & bed temperature should be looked into.
Total 3 schemes were discussed, and it was agreed that Enmas GB will study these 3
schemes and come out with
a) Technical suitability
b) Advantage & Disadvantages over other schemes
c) Extent of modification & BOM
d) Approximate cost.
e) Delivery time.
f) Time to undertake the modification.
This issue of the report analyses the 3 schemes and lists the suitability as per a) to f) above.
After working out the details & feasibility, in each schemes, certain more modifications came
to light over and above those discussed during the meeting & reported in Doc No EGB-RPTDalkia/SC / 002.

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Enmas GB Power System Projects Limited


Doc No : EGB-RPT-Dalkia/ SC/ 003

Title : Proposed modification Schemes


Date : 28.10.15

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Enmas GB Power System Projects Limited


Doc No : EGB-RPT-Dalkia/ SC/ 003

Title : Proposed modification Schemes


Date : 28.10.15

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Enmas GB Power System Projects Limited


Doc No : EGB-RPT-Dalkia/ SC/ 003

Title : Proposed modification Schemes


Date : 28.10.15

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Enmas GB Power System Projects Limited


Doc No : EGB-RPT-Dalkia/ SC/ 003

Title : Proposed modification Schemes


Date : 28.10.15

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Enmas GB Power System Projects Limited


Doc No : EGB-RPT-Dalkia/ SC/ 003

Title : Proposed modification Schemes


Date : 28.10.15

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Enmas GB Power System Projects Limited


Doc No : EGB-RPT-Dalkia/ SC/ 003

Title : Proposed modification Schemes


Date : 28.10.15
SCHEME 1

SCHEME 2

SCHEME 3

DESCRIPTION

The bed area will be reduced by


applying sloped refractory over
bed tubes. Area between floor &
bed tubes will be filled with
refractory. Extra long Air nozzles
will be used & bed tube area will
be made in-effective.

The bed area will be reduced by


chopping off the flared portion of
the Side walls. Existing bed, floor
& air nozzles will be used. The
bed tubes will remain except that
they will be lesser in number due
to lesser width.

EXTENT OF MODIFICATION

The extent of modification was


presumed minimal. However on
detailed study, it was found that
extra long air nozzles can not be
passed as these will be blocked
by staggered pattern of bed
tubes. Therefore, the bed tubes
will have to be replaced and
made IN-Line with bare tubes.

Removing
bottom
level
buckstays, cutting & blocking
supply pipes & risers to the wing
headers permanently. Removing
4 nos spreaders & connections
permanently. Removing burners.
Removing 12 nos air ports
permanently. Cutting & removing
extended walls in front & rear
side permanently. Re-locating
side walls by spool panel inserts.
Welding spool panels in front &
rear wall for Secondary air
openings.
Relocating
burner
openings
by
welding
spool
inserts to suit new width.
Modification in floor support
beams. Modification in windbox.
Re-attaching
the
temporarily
removed parts.

The bed area will be reduced by


applying sloping refractory on
floor tubes. Bed tubes are
removed. Weight increase is
nominal & acceptable from
structural considerations. The
steel windbox is replaced by a
watercooled windbox floor.
Removal of existing bed & floor
tubes as well as the steel
windbox along with Ash drain
pipes, thermocouples & carrier
tubes, Differential pressure pipe
etc. Removing FD fan connection
for ease of installation.
Providing new Rear wall bottom
header, New windbox floor cum
bed
floor
tubes,
Providing
straight spool pieces in Front wall
local to old bed tube area,
providing
spool
piece
&
relocating Tee joints in rear wall.
Supply of windbox floor support
beams, misc items for bed floor
support beams, New air nozzles.
New
sloping
refractory
&
refractory over windbox floor
tubes.
New
Ash
drain
pipes,
thermocouples, carrier tubes etc.

The floor tubes will also have to


be replaced as cutting & welding
so
many
air
nozzles
is
impractical & chances to damage
to pressure parts is high.
Ash drain pipes, thermocouples
& carrier tubes, thermowells etc
will all have to be replaced.
Orifices & Y pieces will have to
be re-located to suit.

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Enmas GB Power System Projects Limited


Doc No : EGB-RPT-Dalkia/ SC/ 003

Title : Proposed modification Schemes


Date : 28.10.15
SCHEME 1

ADVANTAGE / DISADVANTAGE

TECHNICAL SUITABILITY

SCHEME 2

1. Least
extent
of
modification
2. May be restored to 55 tph
when required.
3. Existing furnace volume
retained.

Unfortunately,
the
additional
load due to refractory is over the
safe limit for the beams, slings in
top suspension & will cause
heavy local stress in header lugs.
Therefore,
though
this
scheme appeared to be the
most promising, but the
same
is
technically
not
suitable
from
structural
considerations.

1. Huge modification.
2. Burners will face each
other & can burn out /
cause fire.
3. Restoring to 55 tph will
again call for similar
exercise.
4. Lesser
number
of
spreaders
will
be
available.
5. Furnace volume will be
reduced,
can
upset
emission.
6. Bed tube surface will still
be in the expanded bed.
7. Will require long shut
down.
Though this scheme is feasible, it
is not preferred by Enmas GB as
1. The extent of modification
is massive.
2. There will be a reduction
in number of spreaders,
3. The burners will nearly
face each other.
4. Furnace
volume
will
decrease.
5. Bed tubes will still be
present which Veoila does
not want.
6. The boiler can not be
restored
back
to
its
original capacity easily.
Due to the above reasons
Enmas-GB does not prefer

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SCHEME 3
1. Manageable modification.
2. Structural load increase is
minimal and acceptable.
3. No bed tubes as desired.
4. Furnace volume is intact.
5. No alteration in fuel
feeding
or
burner
location.
6. Boiler can be brought
back to 55 tph generation
very easily.

This is the most promising


scheme as per Enmas GB.
This is the scheme which has
few negatives.

Enmas GB Power System Projects Limited


Doc No : EGB-RPT-Dalkia/ SC/ 003

Title : Proposed modification Schemes


Date : 28.10.15
this scheme.

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Enmas GB Power System Projects Limited


Doc No : EGB-RPT-Dalkia/ SC/ 003

Title : Proposed modification Schemes


Date : 28.10.15
SCHEME 1

REPLACEMENT ITEM

1.
2.
3.
4.

SCHEME 2

Floor tubes.
Bed tubes
Air Nozzles.
Attachments
local
to
support beams.
5. Bed
drains,
thermocouples & carrier
tubes, Diff Pressure tube.
6. Insulation & refractory

1. Various spool membrane


panels.
2. Cover plates for blocked
supplies & risers.
3. Modification
items for
buckstays, floor beams,
windbox
&
expansion
joints.
4. Modification items in Air
inlet connections (FD &
SA).
5. Modification
items for
relocating burners (air,
fuel, cables, instruments
etc).

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SCHEME 3
1. Floor tubes.
2. Windbox steel floor with
watercooled floor tubes
with supports.
3. Attachments
local
to
beams.
4. Air nozzles.
5. Bed
drains,
thermocouples & carrier
tubes, Diff Pressure tube.
6. Front & rear wall spool
piece inserts.
7. Rear wall header.
8. Insulation & refractory