Document ykkNJZjX55aE5Gd5LDdmJRME

--- _______ J________ `<*- dJJ^fLt y/ Pacemaker/ Plants/KARN 3 1 ./>0a / Designing crude-oil fuel systems Two large cycling boilers for the Consumers Power system have the flexibility to switch from crude to resid without changeout of equipment. Safety is of primary consideration in system design and operation Oil-flred (Cam 3 and 4 (right) were built adjacent to two existing coal-tired units. Plant's location on Saginaw Bay makes it possible to deliver crude or resid by tanker 1. Oil received at the plant is stored in four 225.000-bbl. cone-roof tanks fitted with internal floating pans. The 18.000-bbl Karr, day lank is ot the same design Several factors influenced Cer.-umers Power Co`s decision to add two 660-MW. crude-oil-fired cychns units at the Dan E Kam Plar.t. Most important, perhaps, was tha: the company required a large bird* of intermediate-load-factor getter.'. -g capability, and the karri Plan:, rear Essexville. Ml. is close to rr.a;or in dustrial loads. Further, a pipeline direct from the Canadian ot: r.elds passes within a few miles cf the plant, and its cargo, lov.-sulfur crude, is an environmental!} attraeuve fuel. The plant s location on Saginaw Bax also makes it rouble to deliver oil b} tanker. The two new units, designated Kam-3 and -4. were built alongside K.am-1 and -2. The eight-unit John C Weadock Plant is located on the same site. Ram-1 and -2 and tw o of the Weadock units (totaling approx imately S50 MW) bum coal, but the remainder of the units at Weadock (about 300 MW) have been con vened from coal to crude-oil firing. Although this discussion primar ily is related to K.arn-3 and -4. refer ence to Weadock is made because the same crude-oil-storage and for warding sxsiem supplies both plants. The Weadock conversion was completed about two years be fore kam-3 went on-line in Decem ber 1974. and the operating experi ence gained was applied to the two new uniis a> ii became available. Kam-4. stili under construction, is expected to sian up later inis vear. The cvc'.e selected lor each of the new cvclinc ur.ttb provides ISOO-psig steam at the "arbine: superheat and . reheal temperatures are 950 F. Ex traction steam from the Low-pres sure turbine i> used for the deaera tor. two feedwater heaters, the airheater and the boiler feedpump. RS-000269 1/17/02 NUECES 197S r-iPianboo* 1 Consumers Power and its archi right-of-way of a company trar.~- --" tect/engineer on the Karri project. mission line. Commonwealth Associates Inc. ex Oil received from the tap site t-. pended considerable effort at the stored in four 225.000-bbl cone-roof design stage fl) to ensure that the Unks equipped with internal float environmental impact of the new ing pans (Fig I). These tanks pro units would be minimal and (2) to vide approximately a 45-day supply solve any special problems in fuel of oil for both Weadock and Kara storage, handling and combustion at projected use rates. The floating associated with the use of crude oil. pans are essentially internal covers A major objective of Consumers' that float on the surface of the oil environmental-management pro and are free to move up and down gram was to prevent thermal pollu as the tank is filled and emptied. tion of Saginaw Bay and the marsh Seals around the edge of the pan lands surrounding the existing con and internal supports prevent expo denser-coolant discharge canal. This sure to atmosphere and the resulting was accomplished by installing me evaporation and deterioration of the chanical-draft cooling towers and crude oil. closed circulating-water systems for Each storage tank is located in a the new units. separate diked area. Sump pumps Stack emissions and crudc-oil-fir- discharge accumulated rainwater to 2. Foam Is pumped into the (ire-protection ing procedures were studied in a drainage pond, where any oil is system by a fire truck through a hose depth, and applicable experience of skimmed off before the water i* dis connection located outside of the dike major utilities burning crude in the charged to the ash-settling pond. L' S. Canada and Japan was applied The tanks have foam fire-proieci.on to the Kam design. As a result of systems, which discharge foam at these investigations, the companv the inner periphery of the walls and decided to use a single 450-ft stack direct the flow of foam down toward for both units. Gas-duct design al the seal between the floating pan lows for the addition of precipitators and the tank wall. Foam is pumped and dust collectors if experience and into the system by a fire track future fuel conditions dictate their through a hose connection or. the use. Boiler, gas duct and suck are outside of the dike at each tank i Fig designed for water washing of fur 2). Fire alarms are wired into the nace and gas passages. fuel-oil control-panel annunciator Fuel-handling, storage and com from each storage tank. The alarm bustion systems and equipment are also goes to the plant s fire-station designed with safety as a primarv alarm system. consideration. Designers also Storage tanks are equipped with allowed for the possible change to mixers that continuously agitate the residual oil as the economics of the oil to minimize (1) the formation of 3. Kam 3 and 4 each have five burner fuel fuel market dictate. All equipment sludge on the bottom and (2) the oil pumps--one is on standby--of the can handle crude and resid with a minimum of retrofitting, and con version to gas firing is also possible precipitation of wax on the tank walls during cold weather. Provi sions for a future change to residual positive-displacement, screw type -p---------- -- IF---------- if gas should become an economical oil include hangers for suspending alternative. the floating pan from the cone-roof Crude-oil handling suppiort structure and blanked-off flanged connections for the installa The Canadian crude burned at tion of steam healers. Steam heaters Kara is either a flu.xed-pitch crude also may be installed for crude-oil blend or a sweet mixed-crude blend storage if experience shows that tsee table). The former is 90^ crude. problems result from wax defv>tt> S'T pitch (similar to asphalt) and y~c on the lank walls in void weather. tint r'hago.'' which is similar to Oil-storage and dav tanks were in Light fuel oil). Oil is received bv the stalled without insulation. utility at a up site on the pipeline The fuel-forwardins pump s'.atton and is measured and stored in a can handle the requirements of 100.000-bbl g3ging tank there. After Kara and Weadock separated or delivers documenuuon is complete, simultaneous!'. b\ pumpine to the oil is forwarded seven miles to the Kara/Weadock storage tanks. The Ib-in.-diameter pipeline follows the day tanks, which are similar in all design aspects to the oil-storage tanks--except for size. The Weadock 4. Surge absorbers insure a constant fuel oil pressure to the burners. Four 100-gal surge absorbers are provided per unit 1 97S Genanaaoo Pt*nxx>* RS-000260 1/17(02 NUECE8 Pump motor control Accumulators-- 10.30.40. and 100 gat Q Simple* strainer Uotor Flowmeter Control element 6. Oil piping to the burners, both main oil header and igniter oil header, has an "S" form with inlets at the top to maintain continuous recirculation back to the day tank, so there will be no buildup of sludge or water in the tuel-oil lines a9 9 9 To Unit-4 pump suction Recirculation ra/ves (arrows show Urut-3 pumps operating. (Jrut-d pumps and auxiliary boilers not operating) TreocCirMcu-l4ation Tc Computer Untt-4 return tank holds 5000 bbl: the Kara tank. pumps in a building, but after the 18.000 bbl. These capacities repre ventilation requirements and neces sent about a six-hour supply for sary gas sensors and fire alarms each plant at the maximum use rate. were considered, it was decided that Burner fuel pumps--there are five a restricted area surrounded bv a for each of the new units--are posi fence was a better choice. Pump suc tive-displacement. screw-type (Fig tion lines, suction valves, strainers 3). and each can provide ZS'c of and all instrument lines are heat boiler requirements. Hence, during traced to prevent the formation of normal operation, four pumps will wax deposits. The tracing is explo be needed: the fifth will be on sion-proof electric with thermostatic standby. The pumps, which are suit control and is covered with weather- able for either crude or residual oiL resistant insulation. are sized on the basis of the lower Burners are arranged at three ele crude-oil pumping capability and vations on the front of the boiler. powered for the higher residual re The burner-front enclosure is venti quirements. lated continuously and equipped Strainer mesh is sized below the with foam fire-protection devices minimum orifice diameter of the (Fig 5) and a foam-drainage and burner nozzles. Single-basket -storage system. Cavities between strainers were selected because the the furnace hopper bottom and cas standby pump can be used when the ing are purged, by ventilation fans strainer on an operating pump must before each boiler start to remove be cleaned. This way. strainers can any gases that might have leaked be cleaned without reducing system through the furnace waterwall capacity. All strainers are equipped, membrane. This purge is a permis with differential-pressure switches sive that must be satisfied before to alarm and warn operators of ac burner light-off". Gas samplers lo cumulations of dirt or wax in the cated in the burner-front enclosure baskets. warn of any accumulation of explo Burner pumps are located outside sive vapors. the boiler house between the day- Oil piping to the burners, both tank and the building. Some main oil header and tenner oil thought was given to putting the header, is arranged in an "S" form 5. Burner-front enclosure is ventilated continuously and has loam fire protection with inlets at the top (Fig 6). Rea son: If continuous recirculation back to the day tank is maintained, there will be no accumulation of sludge or water in the oil lines. Burner design Burners are steam-atomized and have air-atomized crude-oil igniters (Fig 7). Provision for future resid firing has been made and requires only a supply of distillate oil to the igniter lines. Flexible metal hoses for oil and steam (eature__ilfliifclgwall construction and are equipped wuh a pressure gage for monitoring leaks i Fig 8). The hopper bottom is designed to 28 * 1 ?TS Generator* Pianooo* RS-000261 1/17/02 NUECE8 Design crude-oil fuel systems to these codes and standards Basic design approach tor a crude-oil fuel system rs to a.bib !uel lead's sq"s a_.c e. ration. If spiils and evaporation occur, the effects a-e minimized try d-air-age and v e". a tion. Fire protection and safety are primary considerations. and ' re-exf.ngu si r; 'a fire-detectoo equipment always should be instated Furthe'. st'.c: adhe'ence tc a.-.; and codes relating to fire protection must be practiced at all times The following 1 s; c` references is a basic library for the designer of a fuel-oil system Codes and regulations: NFPA 11--Standard fc.' foam extinguishing systems NFPA 30--Flammable and combustible liquids code NFPA 31--Standard fcr installation of ail-bumir.g equipment NFPA 51 --Welding and cutting NFPA 51S--Welding processes NFPA 70--National electric code NFPA 77--State electricity code NFPA 65D--Standard for prevention of furnace explosions in fuel-c.l-f.red multiple-bumer boiler furnaces 49 CFR 180--Carriers by pipelines 49 CFR 195--Transportation of liquids by pipeline Flammable liquids regulations--Applicable local and state ordinances Design standards: ANSI B31.1--Code for pressure piping: Power piping ANSI B31.4--Liquid petroleum transportation systems API Standard SL--Specification for line pipe API Standard 5LX--Specification for high-test line p pe API Standard 60--Specification tor pipeline valves API Standard 610--Centrifugal pumps tor general refinery services API Standard 650--Welded steel tanks for oil storage API Standard 1101--Measurement ol petroleum liquid hydrocarbons by pcs.t.ve- displacement meter API Standard 2531--Mechanical displacement-meter provers API Standard 2545--Method of gaging petroleum, and petroleum products API Standard 2550--Method lor measurement and calibration ot upright cylindrical tanks API RP50CC--Recommended practice for classification ol areas fcr electrical installations at petroleum- and gas-pipeline transportation facilities API RP540--Recommended practice tor electrical installation in petroleum refmer.es API RP2003--Recommended practice tor protection against ignitions ans.ng out =` static, lightning and stray currents API RP2533--Recommended practice for metenng viscous hydrocarbons 7. 8. Burners are steam-atomized (above). Flexible metpl hoses tor oil and steam have double-wall construction (bottom) NFPA--\corai Protecto** Aswcnon. 470 Arjtr.tx Ec^--r .MAC22'0 ANS --A.-er.cr Kjc-or.ai L-srrjte. 143C E.*CA^**y, \e* >=sn N't 10C` APJ--A.-ienca-i irszzjte. 16C1 K SJ KW DC 0006 CFP--Coce of Fean-*/ Te 49 re$iAaons *rcn Deparsnem o* Tr*r.s?cn4:.cn 40CSe.e_~ SW. \Aasrun^torv DC 20590 facilitate the collection of ash and water during boiler water-washing operations. Sootblower air piping has inlet connections for high-pres sure water, as well as the necessary' manual block and check valves. No modification of the sootblowing sys tem. or controls, was necessary to provide water-washing capability. Present plans call for periodic wa ter w ashing of the stack and boiler on weekends after initial boiler cool ing. Bear in mind that it is necessary to wash when internals are cool enough to avoid thermal-shock damage to refractory, but they must be warm enough to ensure rapid and complete drying. Water and ash from the boiler washing system are collected in a storage tank and pumped to the ash-settling pond. Operating experience will deter mine the frequency of the boiler and slack washing sequence. Control of the fuel-forwarding system is from a panel located in ihe Weadock Plant. An indicator on the Kara control panel indicates davtank oil level. Burner pumps are controlled from the boiler control rooms. The :uei system is either "on" or "off.'' In ihe "ofT" condition, no pumps are oper ating. In the "on" condition, one pump is always operating 10 pro* ;de a minimum recirculating flow Analysis of typical Canadian crude oil Parameter Specific gravity at 60 F API gravity at 60 F Density, lb / gal Flash pctnl. F F*re pcnt. F Cloud point F Pour po.nt, F Viscosity. SSU at 100 f Heating values. Gross. 6tu lb Net. Era lb Grcsc Bta gal Net. Etj gal Asn. % Carbon, wi j Hydrogen wt % Nitrogen, wt S Sulfur. % Hydrogen suitide wi -c V*ax content, vol S. Type ol crude oil Fluxed Sweet pitch mixed 0 833 33 36 6 945 50 5t -10 -15 39 3 0 826 39 80 6.686 52 53 -20 -28 36.8 19 672 19.645 1 a 464 18.SS9 135 622 136 652 125 222 127.997 C C062 0 C061 65 25 86 33 13 29 13 14 C * 25 0 13 0 34 0 35 ibie 32 29 197S GeoerzDon FHanDoo* RS-000262 1/17/02 NUECES through the oil lines. Oil flow i< con trolled b\ sensing oil pressure and b\-passing oil to the return line. On startup, a drop in pressure below burner requirements signals the start of another pump. When fuel requirements decrease, a pump is shut off by signals from a flow-mea suring element in the return line af ter flow exceeds the capacit\ of one pump. Loss of a pump signals the start of the standbx pump. A tire signal from the burner-front enclo sure shuts off all oil pumps to the af fected unit. Fuei-tv! control vabe responds to the demands of the combustionconiro! astern, maintaining oil flow to meet the requirements of throttle pressure, steam flow and combus tion air The boiler is operated in the boiler-followmg [the turbine] mode bv maintaining throttle pressure at the set pom; while the turbine is ad justing control valves m response to generator load demands. Boiler controls automaticaUv regulate drum iesei. furnace draft, steam temperatures, flue-gas oxvgen and mam-steam header pressure. The process computer performs the functions of scanning and alarming, logsing data, calculating perform ance. set-point control during unit startup, automatic turbine start and sequence monitoring during unit startup and shutdown. Clerics A Home. PE. of' Commonwealth Associates Inc. who has had considerable experience tn the design of fuel-oil and other uninv fluid sys tems. ^as instrumental in the prepa ration of this article. Unit 3 and 4,DE Kam Plant, Essexville, Ml, Consumers Power Co Turbine/generator and auxiliaries e*w* and carbon r.rers feeds two parapet trams of demmerahzer Turtoirve/generator. 1 (Unit-3)..........................................General Eiectnc Co equipment each rated at 200 gpm and consisting of a primary 605 MW. 1800 psig. 950/950 F. 3 in Hg ails. 3500 rpm tandem csUcn exchanger, vacuum degasiher, primary anion unit and compound, tour flow. 30~in. last-cow blades, three phase 60 Hz. 26 mixed-bed polishing dernneraUzer kV. 814 MVA (0.85 pf) at 60-ps*g H: pressure. 0 14 short-circuit ra tio, shaft-driven AC exciter and siTicon-diode rectifier Steam-generation equipment Turbine'generator. 1 (Unit-4)______AUjs-Chalmers Power Systems Inc 8c:'er. 1 per unit................................................................... Riley Stoker Corp 626 MW. 1800 ps*g. 950/950 F. 3.5 in Hg abs 3600 rpm tandem 4 650.000 tbfhr at 1930 psig and 995 995 F. oil fired, balanced- compound four flow. 30.2-tn. last-cow blades three phase 60 Hz. 26 kV. 835 MVA (0.85 pf) at 75-psig H: pressure. 0.58 short-circuit ratio, shaft-driven AC exciter and sEcon-dtode rectifier Man condenser, t per unit............................ .............OeLava*. Turb ne tnc draft. front-fired furnace, natural circulation, gas recirculation. 240.000-CU ft furnace volume. 51.660-sq tt boiler and waterwaU surface 532.OOQ-sq tt economizer surface Burners. 3D per unii._................................................Forney Engmeenng Corp Each single pass. 295.0OO-sq ft effective surface, smgte she." dual pressure. 3.395.00OAb/hrsteam How. 281 000-gpm c rpda:.ng-wa- Steam-atomized type with air-atomized igniters Burner management system. 1 per unit_____Fomey Engmeenng Corp ter flow at water temperature of 92 F. 70-tt effective tube length. Furnace cameras. 4 per unit..................................General Television Corp l-in.-dtam tubes Air neaters 2 per urut.....Yuba Industries Inc. Yuba Heat Transfer Div Circulating-water pumps, 4 per unit.................................ingersoir-Rand Co Each 68.250 gpm art 70-ff head, single stage, double suction hori Each 570.000 ctm at 4-F mlet and 259-F outlet temperatures, three coil banks per heater. 360.OOO-lbrhr steam at 86 psia/570 F (14th- zontaJ/y spirt pump casing; 3000-hp. 445-rpm motor drives two stage extraction) pumps at one time Forced-draft fans. 2 per unit......................................................................_............... Cooling towers. 1 per unit_______________________________________Martey Co . . . .Westinghouse Eiectnc Corp. Sturtevant Div Crossflow, mechanicaldraft 14 cells, created Doug'as tr construc Each airfoil type, oilet-rane and outlet-damper flow control. tion. 28-ft manually adjustable-pitch fans driven by 200-hp. single- 825.000 ctm at 20.2 tn. HAD static pressure and 125-F inlet air. speed motors; capacity per cefl. 21.000 gpm based on 7 ?6-F nof 39QO-Hp. 505-rpm motor drrve wafer and 92-F cold water at 74-F wet bulb Ind jeed-draft fans, 2 per unit........................................................................................ Turbine-ofl conditioner. 1 per urut-400gpm........................ FramCorp . . . Westmgbouse Eiectnc Corp. Sturtevant Drv Condenser vacuum pumps. 3 per unit____________tngersc:-Rar.d Co Each airfoil type, mlet-vane and outfer-damper flow control. Each 75 scfm at 1 in. Hg abs condenser pressure 7.650.000 ctm at 26 tn. HAD static pressure and S25-Finlet flue gas; Condensate and teedmter system 7000-hp, 705-rpm motor drive Gas recirculation fan. 1 per urut.............................................................................. Condensate pumps, 2 per unit________________ _ . ...Ingersoll-Rand Co Each 4 900 gpm. 1750-hp motor drive . . . .Westinghouse Eiectnc Corp. Slurtevant Div AirfoD type, int*t~van* nr.fi nirhf*+siamp*>r conlioL 228.000 dm Gland-steam condenser, 1 per unit_____________ ___General Eiectnc Co 600-pstg design QOO-sq ft surface at 20.6 in. H-O static pressure and 50O-F inlet flue gas; 1000-hp. 1180-rpm motor drrve First low-pressure heater, 1 per unft .Struthers Nuclear & Process Co 600-psig tube-side destgn, 100-psig vacuum she.-s.de design. 18.220-sq tt surface. 42.30O-tb'hr sfea/n flow at 7 psa 165 F (I6th-stage extraction) Second low pressure heater, 1 per unit.................................... ........... Sootblowers. 20..-..........................................Diamond Power Specialty Corp 7 6 /ong-re?raefa&.`e and four haX-retractatile air blowers with elect-ica iy operated sequenced controls Sootblowers can be used for water washing without mod.tt cation Aux.i.ary boilers. 2...............................................Combustion Engmeenng Inc . . . .Stnrthers Nuclear A Process Co 600-psig tube-side design. lOO-psig/vacuum she'J-srde design. 74.742-sq ti surface. 155.000-fbrhr steam flow at 76 ps*a r266 F (15th~stage extraction) Deaerator. 1 per unit_____________________Graver Water Cond.donmg Co Each shop-assembled. 225.000 lb - hr at 250pstg/525 F Bo.ler and stack water-wash system................................Goulds Pumps tnc Two pumps rated 400 gpm each at 400-psig discharge pressure Fue4-oH system 4 030.000 tb' hr at 207-F inlet and 357-F outlet water re-De fafures. 63.000~gaJ capacity. 12 ft x 107 ft storage tank w:r 2CE-pS'g de sign. 593.00Q-b/hr steam f.'ow af 140 psig/696 F (1 ltih-s:age ex traction) O.l storage tanks. 4...................................................Chicago Bndge A Iron Co Each cylindrical, urrnsulated. fixed-cone root with internal floating pan. 200 tt diam x 40 ft hgh. 225.000-btit capacity FueKxl day tank. 1...................................Graver Tank A Manufacturing Co Ma-n boiler -teed pump. 1 per unit............................................ ....... Cyf'r.dncal. fixed-cone noot with internal floating pan. 60 ft diam x . . . .Dresser Industries Inc. Pacrhc Pumps Dry 33 ft hrgh. 7 8.000-007 capacity 11.500 gpm at 189 4-psrg suction and 2359-psig discharge Main bouer-teed pump turbine drive. 1 per unit Fuei-o:l transfer pumps 4........................ .........................Goulds Pumps Inc ... Each vertical cr.e.ntaton. centrifugal type. 7 700 gpm. 50-0p motor . . . .Westing house Electee Corp 1 7.025 hp at 5600 rpm with 40-psig inlet steam arc 3 tn acs ex haust. electrohydraubc vanabtespeed control, exhaust s:ea m con densed in main condenser Standby boUer-feed pump, 1 per unis...................................................................... . . Dresser Industries Inc. Pac.fic Pw-ps 0:v 7 86.5--ps^g suction. 2024-psig discharge, five stages Demirreraizer____________________________________Crane Co. Coc^-ane Div 5OC-gprn primary-treatment tram with chlonnator. coic-..rrte sch- cr.ve. fide These pumps are Ces-gned for crude oil only F c \ pjTtps. 5 per un.t .G.ibarco Inc. S*cr-8ath Pump Div Each screw type 275 gpm at 400 psg 20C-hp. motor dnve Aj*.... = cy-bo ler tuei-o i pumps. 3. .. .G.ibarco Inc. S-ei-Bath Pump Div Each 40 gpm at 250 ps^. one pump per boiler vnth one standby un.t 25-hp. 1 SOO-rprr. motor dnve Sj'ge absorbers. . ..Greei Hydraulics tnc Greer Otaer Products Div Fee' 100-gal surgep.PscrPers per und. three 40-gal surge absorb ers ter auxiliary borers 30 1S7S Generator! Ranoook R8-000263 1/17/02 NUECES