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2nd IEA GHG Oxyfuel Combustion Conference - Tuesday, 13 September 2011 - Callide Oxyfuel Project – Commissioning Experience 1
Stage 1 – Capture at Callide A Power Station Commissioning Experience
Chris Spero, Lyle Chapman, Franco Montagner
2nd IEA GHG Oxyfuel Combustion Conference Tuesday, 13 September 2011 Plenary / Panel Session 01
2nd IEA GHG Oxyfuel Combustion Conference - Tuesday, 13 September 2011 - Callide Oxyfuel Project – Commissioning Experience 2
1.Statement of design intent – what is our target planned 2.Callide A site and retrofit issues – what we did 3.Commissioning activities boiler and ASU – post conversion
activity 4.Operational issues – what we have learnt
• Furnace pressure control • Safety systems • OH&S issues
5.Environmental Requirements – what are our precautions 6.CPU commissioning and overall program – what comes next 7.Site Activities to Date – SOME PICTURES
Presentation Outline
2nd IEA GHG Oxyfuel Combustion Conference - Tuesday, 13 September 2011 - Callide Oxyfuel Project – Commissioning Experience 3
Features of the Oxyfiring system: 1. The boiler has two operation /combustion modes; Air mode and Oxy mode
• Air mode - Coal is burned with air (as normal)
• Oxy mode - Coal is burned with the mixed gases of 98% pure oxygen produced with ASU and RFG (recirculated flue gas) instead of air.
2. Normal start and stop operation is conducted only in Air mode only
3. Overall plant operating target are as follows:
• Ramp rate in Oxy mode 1% / minute (nominal)
• Minimum load (Turndown) in Oxy mode 80%
• Mode change time (Air mode to Oxy mode) 60 minutes
• Mode change time (Oxy mode to Air mode) 60 minutes
4. Mode change can be conducted between 80%MCR and 100%MCR – No requirement for Oxy mode start/stop or low load.
Boiler Design Intent
2nd IEA GHG Oxyfuel Combustion Conference - Tuesday, 13 September 2011 - Callide Oxyfuel Project – Commissioning Experience 4
Pulverised Coal Consumption
5.5 kg/s 20 tph
Quality
CV 19MJ/kg a.r. Ash 21% a.r.
Sulfur 0.3% daf Anglo Callide Coal mine
Steam Flow 37.7kg/s or 136 t/h Pressure 4.1MPa, Temperature 460oC
Oxygen Gaseous
Purity 98%Vol Oxygen Pressure 180kPa(a)
Flow 7.6kg/s 2 x nominal 330 TPD
Air Liquide Sigma cryogenic ASUs
Recirculated Flue Gases
Flow 30kg/s CO2 ~67% mass
Chimney Stack Flow 13.2kg/s Height 76m
CO2 Purification and Compression CO2 Product 75t/day CO2 Purity 99.9% mol CO2 Temperature -20oC CO2 Pressure 1,600kPa
Road Transport B Double – 30t Single Tanker – 20t
Boiler Exit Flue Gases 350oC 44.9kg/s
Feed Gas to CO2 Plant Flue Gas Processed Flow 1.7kg/s Temp ~ 150oC
Callide A Demonstration – Mass Balances (Simplified)
2nd IEA GHG Oxyfuel Combustion Conference - Tuesday, 13 September 2011 - Callide Oxyfuel Project – Commissioning Experience 5
General Site Positives and Negatives
Site Layout
Parasitic Load
Cooling Requirements
Restarting a Stored Unit
Control System
Plant Identification
Industry Norms
Boiler Conversions
Retrofit Challenges/Issues for Callide A
2nd IEA GHG Oxyfuel Combustion Conference - Tuesday, 13 September 2011 - Callide Oxyfuel Project – Commissioning Experience 6
• Liabilities - Asbestos, Undocumented Underground Services, AS1657 – Stairs, walkways, ladders, Emergency Lighting, Ash Storage, Turbine Hall Crane, Bunding of Tanks, PCBs, Fire system Issues, Construction Site Amenities, Site Access for large loads
• Advantages – Size, it is available, Refurbished in 1998 and operated for 2-3years before mothballing in 2001, New control system installed in 1998, many support possibilities with Callide B/C nearby
General Site Positives and Negatives
2nd IEA GHG Oxyfuel Combustion Conference - Tuesday, 13 September 2011 - Callide Oxyfuel Project – Commissioning Experience 7
Callide A - Site Layout
2nd IEA GHG Oxyfuel Combustion Conference - Tuesday, 13 September 2011 - Callide Oxyfuel Project – Commissioning Experience 8
General Site Positives and Negatives
Site Layout
Parasitic Load
Cooling Requirements
Restarting a Stored Unit
Control System
Plant Identification
Industry Norms
Boiler Conversions
Retrofit Challenges/Issues for Callide A
2nd IEA GHG Oxyfuel Combustion Conference - Tuesday, 13 September 2011 - Callide Oxyfuel Project – Commissioning Experience 9
Control Systems
2nd IEA GHG Oxyfuel Combustion Conference - Tuesday, 13 September 2011 - Callide Oxyfuel Project – Commissioning Experience 10
General Site Positives and Negatives
Site Layout
Parasitic Load
Cooling Requirements
Restarting a Stored Unit
Control System
Plant Identification
Industry Norms
Boiler Conversions
Retrofit Challenges/Issues for Callide A
2nd IEA GHG Oxyfuel Combustion Conference - Tuesday, 13 September 2011 - Callide Oxyfuel Project – Commissioning Experience 11
Primary air heater • tubular type heat exchanger
• to avoid low temperature corrosion in PF pipes
FGLP heater • avoid high temperature damage to fabric filters
• heats feed water for efficiency
Feed water booster pumps
H2O remover
O2 pipe and injection points
Burners
Boiler Conversions
2nd IEA GHG Oxyfuel Combustion Conference - Tuesday, 13 September 2011 - Callide Oxyfuel Project – Commissioning Experience 12
Boiler Conversion
2nd IEA GHG Oxyfuel Combustion Conference - Tuesday, 13 September 2011 - Callide Oxyfuel Project – Commissioning Experience 13
Boiler Conversion
2nd IEA GHG Oxyfuel Combustion Conference - Tuesday, 13 September 2011 - Callide Oxyfuel Project – Commissioning Experience 14
Boiler Conversion
2nd IEA GHG Oxyfuel Combustion Conference - Tuesday, 13 September 2011 - Callide Oxyfuel Project – Commissioning Experience 15
Boiler Conversion
2nd IEA GHG Oxyfuel Combustion Conference - Tuesday, 13 September 2011 - Callide Oxyfuel Project – Commissioning Experience 16
Boiler Conversion
2nd IEA GHG Oxyfuel Combustion Conference - Tuesday, 13 September 2011 - Callide Oxyfuel Project – Commissioning Experience 17
Operating and Commissioning Status
2nd IEA GHG Oxyfuel Combustion Conference - Tuesday, 13 September 2011 - Callide Oxyfuel Project – Commissioning Experience 18
New boiler Draught fans – higher pressure FD fan ID FAN
OLD NEW OLD NEW 2 x 50% 1 x 100% 2 x 50% 1 x 100% 97 kW each 420 kW 179 kW each 530 kW 1340 m3/m ea 2380 m3/m 1950 m3/m ea 4220 m3/min 985 rpm 1485 rpm 980 rpm 1485 rpm 3.3 kPa 7.6 kPa 3.9 kPa 5.5 kPa 40 C 150 C 149 C 150 C
New control dampers – linkage backlash
Furnace press. control method – closed loop, feed forward
Original O2 trim logic – no bump-less switch
Tuning expertise – to confirm stability limit & control block
Furnace pressure control
2nd IEA GHG Oxyfuel Combustion Conference - Tuesday, 13 September 2011 - Callide Oxyfuel Project – Commissioning Experience 19
Pulverised Coal Mills
• Original Riley-Dodd hammer mill design
• 3 Mills per unit – 2 Duty and 1 standby
• generally 2 Mills in service at Loads between 40 and 100% in air firing
• Hammer mill type - 2,500 operating hours between major services
• Fuel Oil start up burners
Pulverised Coal Burners
• 6 Burners per Boiler – 4 duty and 2 standby
• 2 Burners per Mill
• C Row burners – Top – Existing design – Riley Dodds 1960s design
• A Row burners – Middle – New – IHI design replaced in 2010
• B Row burners – Bottom – Existing – Riley Dodds 1960s design
Coal Pulverising Mills/Burners
2nd IEA GHG Oxyfuel Combustion Conference - Tuesday, 13 September 2011 - Callide Oxyfuel Project – Commissioning Experience 20
Original boiler and turbine protection in DCS (Siemens Teleperm XP installed in 1998)
Compliance of the retrofitted plant in accordance with Queensland Legislation and the IEC EN 61508 & 61511 standards.
Process
Power Plant Safety System
HAZOP Safety Integrity Level (SIL) Study
Implementation Independent Functional Safety Assessment (FSA)
Safety Integrity Level (SIL) Study • Objectives
• target safety performance
• Boiler coal firing , for both Air / Oxyfiring modes, and ignition fuel oil
• Outcomes - 23 Safety Instrumented Functions (SIFS) identified for the Boiler • Air Firing - 13xSIL1, 5xSIL2
• Oxy Firing - 15xSIL1, 3xSIL2
Implementation • Fork in the Road
• Common Process control and protection system
• Standalone new safety system
• Standalone pathway chosen • Why? – least expensive option for short
term demonstration
• Duplication between boiler control and protection logic. This introduced ‘two masters’ resulted in more complex trip investigation as both systems required examination
2nd IEA GHG Oxyfuel Combustion Conference - Tuesday, 13 September 2011 - Callide Oxyfuel Project – Commissioning Experience 21
Control Systems
2nd IEA GHG Oxyfuel Combustion Conference - Tuesday, 13 September 2011 - Callide Oxyfuel Project – Commissioning Experience 22
Potential hazards identified as follows:
• OH&S issues with leakage of Recycle Flue Gas (CO2, CO, NO, NO2, SO2, SO3)
• OH&S and fire issues with leakage of O2
Nodes/systems identified:
• RFG from existing and new plant From furnace in the event of a
pressure excursion
Downstream of FD fan (Secondary gas and Primary gas )
• O2 from oxygen valve skid to point of entry to Secondary gas duct
RFG & O2 – Operational Hazard Assessments
2nd IEA GHG Oxyfuel Combustion Conference - Tuesday, 13 September 2011 - Callide Oxyfuel Project – Commissioning Experience 23
Assessment methodology
• Releases modelled based on Explosive Atmospheres method in AS/NZS 60079.10
• Assessment for RFG made on the basis of 4 parameters: Release rate (through a notional hole, crack, perforation, etc)
Notional volume into which the constituent is released (open, confined etc)
Short term exposure limits (STEL) for CO2, CO, NO2, etc.
Persistence time
• A standard likelihood and consequence of each hazard is identified
• Countermeasures are proposed to address the potential hazards
• Similar approach applied to oxygen based on a Lower Limit for a fire hazard of 23.5 mol%.
Hazard assessment methodology
2nd IEA GHG Oxyfuel Combustion Conference - Tuesday, 13 September 2011 - Callide Oxyfuel Project – Commissioning Experience 24
Callide A Power Station Construction Activities Site Hours as at 31 August 2011
2nd IEA GHG Oxyfuel Combustion Conference - Tuesday, 13 September 2011 - Callide Oxyfuel Project – Commissioning Experience 25
Operating and Commissioning Look Ahead
2nd IEA GHG Oxyfuel Combustion Conference - Tuesday, 13 September 2011 - Callide Oxyfuel Project – Commissioning Experience 26
Oxygen plant
CO2 capture plant
COP – Site Works – Oxygen and CO2 Capture Plant
2nd IEA GHG Oxyfuel Combustion Conference - Tuesday, 13 September 2011 - Callide Oxyfuel Project – Commissioning Experience 27
Heavy Lifts #1 – Boiler Primary Air Heater Lift - 27 Nov 2011
Triple Crane Lift • Weight: 64,000kg (not incl rigging)
• Final height – 18m above ground
Cranes • 280t Sumitomo Crawler
• 2x130t Grove All Terrain Cranes
27 Nov 2011 attempt cancelled due to high wind
Successfully completed on 29 Nov 2011.
2nd IEA GHG Oxyfuel Combustion Conference - Tuesday, 13 September 2011 - Callide Oxyfuel Project – Commissioning Experience 28
Heavy Lifts #2 - Oxygen Plant Cold Box Column Lift – 30 Apr 2010
Dual Crane Lift • Weight: 72,573kg (not incl rigging)
• 29.3mH x 4.8mW x 4.4mL
Cranes • 280t Sumitomo Crawler Crane
• 130t Grove All Terrain Crane
2nd IEA GHG Oxyfuel Combustion Conference - Tuesday, 13 September 2011 - Callide Oxyfuel Project – Commissioning Experience 29
Heavy Lifts #3 – Co2 Plant
Flue Gas Compressor • Compressor baseframe 33,000kg (gross)
• Compressor other 23,694kg
CPU Cold Box • 27,248kg
• 16m Tall
• 3.94m x 3.1m
Liquid CO2 Tank (capacity 100t) • 36,000kg
• 3.1m Internal diameter
2nd IEA GHG Oxyfuel Combustion Conference - Tuesday, 13 September 2011 - Callide Oxyfuel Project – Commissioning Experience 30
Callide A - Construction
2nd IEA GHG Oxyfuel Combustion Conference - Tuesday, 13 September 2011 - Callide Oxyfuel Project – Commissioning Experience 31
Concluding comments
1. Contracting strategy
• Terminal point management
• Flexible arrangements
2. Construction on an Operating Site
3. Multiple Stakeholder interests and expectations
2nd IEA GHG Oxyfuel Combustion Conference - Tuesday, 13 September 2011 - Callide Oxyfuel Project – Commissioning Experience 32
Thank you
for more information: www.callideoxyfuel.com
Callide Oxyfuel Project – Participants
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