MINUTES OF MEETING. Technical Committee on Multiple Burner Boilers

Transcription

1 MINUTES OF MEETING Technical Committee on Multiple Burner Boilers January 14-15, 2014 PERA Club Tempe, AZ I. Attendance: Principal Members/Staff: Mike Walz, Technical Committee Chair, Burns & McDonnell Engineering Co., MO Denise Beach, NFPA, MA Frank Bennett, GenOn Energy, Inc., MD John Bollinger, Babcock & Wilcox Company, OH Dale Dressel, Solutia Incorporated, MO John Eibl, The DuPont Company, Inc., TN Dale Evely, Southern Company Services, AL Kris Gamble, Black & Veatch Corporation, KS David King, American Electric Power Service, OH Daniel Lee, ABB Incorporated, OH W. Scott Matz, Invensys Process Systems, TX John O Rourke, ALSTOM Power Inc., CT (via teleconference) Michael Polagye, FM Global, MA Thomas Russell, Honeywell, Inc., TX Jimmie Schexnayder, Entergy Corporation, LA Celso Schmidt, UTC, TX Bill Smith, Exothermic Engineering LLC, MO Franklin Switzer, S-afe, Inc., IN Joseph Vavrek, Sargent & Lundy, LLC, IL Henry Wong, URS Corporation E&C, NJ Harold (Skip) Yates, HRY, Inc. Boiler Systems Consulting, MI Allan Zadiraka, OH (via teleconference) Alternates : Joseph Bittinger, American Electric Power Corporation, OH James Franks, XL Global Asset Protection Services, TN Jack Lehman, Exothermic Engineering LLC, NE Daniel May, Burns & McDonnell Engineering Company, MO Jeff Parker, Salt River Project, AZ John Stevens, HF Controls Corporation, TX Guests : D. Paul Cannon, Hurst Technologies Joseph Fehr, Sega, Inc. Frank Fowler, SmartBurn LLC Jerry Gilman, SIS-Tech Ted Jablkowski, Fives North American Combustion Sinming Kwong, Emerson Process Management (via teleconference) Edward Lightbourn, SmartBurn LLC Tony Niu, Guodian Longyuan Technology Austin Pool, Hurst Technologies Donald Zissa, SIS-Tech

2 II. Minutes of Meeting: 1. Call to order. The meeting was called to order at 8:30 am MST on Jan 14, Chairman Walz welcomed committee members and guests and thanked them for their participation. 2. Introduction. The Committee members and guests introduced themselves and identified their affiliation. 3. Minutes Approval. The minutes from the February 2013 meeting were approved as written. 4. NFPA Staff Report. The NFPA staff liaison reviewed the new document revision process and tools, including the new terminology, the revision cycle timeline, and the online public input submittal process. (Attachment A) NFPA staff reported that the NFPA Board of Directors approved a formal anti-trust policy at their November 2013 meeting (Attachment B). 5. Old Business. A. Referenced Documents in Fundamentals Chapters. Mr. Switzer reported that the reference to NFPA 54 is applicable and appropriate. B. Design Pressures Task Group. The task group scope has been expanded to include the following issues: i. Current applications have fan capabilities up to 80 in., but the duct work is addressed only in the annex as a consideration. Is it time to establish structural requirements for the duct work? ii. Does the committee need to review 35 in. limitation to reflect current designs/practices? iii. The fan requirement is based on cold, dense air. Is that a realistic requirement, or should the code reflect typical ambient conditions. iv. Should requirements be added to address positive pressure units that may be subjected to negative pressure when fuel valves close quickly on an MFT? v. NFPA 85 refers to test block capability and design pressure inconsistently. Review each section for appropriateness. The task group will continue to discuss these new questions for further consideration in the next revision cycle. The deadline for the task group report is the first quarter of 2015, or at least 8 weeks prior to the next scheduled meeting. The task group members are B. Smith (chair); D. Evely; J. Frazier; K. Gamble; D. King; J. Lehman; H. Wong; and A. Zadiraka. C. Annexes B and C (Supervised Manual Systems). A task group was established to discuss this issue further. The task group members are: D. Dressel (chair); J. Eibl ; S. Yates; and A. Zadiraka. The task group recommended that Annex C be removed from the document in the 2015 edition, and that Annex B be retained until the 2019 edition. In addition, committee members and NFPA staff will reach out to chemical and petroleum industry groups to advise them of the upcoming change. These groups include the American Chemistry Council, the Center for Chemical Process Safety, and the American Petroleum Institute. Committee members are encouraged to contact NFPA staff if they identify any other interest groups. The task group was discharged with thanks.

3 6. New Business A. Create Second Revision of Chapter 6. The committee reviewed the public comments and other requests and created Second Revisions in chapter 6 and related annex text. The committee actions will be available in the Second Draft Report, which will be published no later than July 18, B. Valve Leak Testing Task Group. In discussion on the Second Revisions, the committee recognized that there are two valve leakage tests: the tightness test performed annually and the leak test performed prior to every startup. A task group was established to review these requirements for oil and gas systems to identify the purpose of each test and determine if both are appropriate and applicable to current practices. The task group members are: J. Parker (chair); P. Cannon; J. Gilman; S. Matz; C. Schmidt; F. Switzer. C. Review BCS-FUN actions. The committee briefly discussed Fundamentals actions of interest. D. Boiler Enclosure Definition/Purge Times. It has been reported that some boilers are being purged for much longer than 5 minutes because of the volume calculation and the requirement for 5 air changes. A task group was established to review and create recommendations concerning the length of purge times and purge rates relative to the size of the unit. The members of the task group are: J. Franks (chair); G. Gilman; D. King; J. O Rourke; J. Parker; A. Zadiraka. The task group can consider developing a code fund project involving CFD modeling of basic furnace designs. The task group may also seek loss data from insurers, the National Board, and EPRI. 7. Plasma Arc Igniter. Edward Lightbourn and Frank Fowler of SmartBurn LLC presented information on plasma arc igniters (Attachment C). The committee discussed extensively the new technology. A task group was established to review igniter requirements in chapters 4 and 6 to determine what revisions, if any, would need to be made to recognize the application of plasma arc igniters. The task group members are: S. Yates (Chair); J. Eibl; K. Gamble; E. Lightbourn; S. Matz; M. Polagye; and B. Smith. The task group deadline is to provide recommendations at the proposed off-cycle meeting. 8. Other Items. The committee briefly discussed a recent application of a pressurized unit being converted from coal to gas. Preliminary modeling indicates that the pressure may go significantly negative when fuel valves close quickly on an MFT. Currently, pressurized units don t have to incorporate implosion protection. This issue was referred to the design pressures task group. 9. Next Meeting. The committee tentatively scheduled an off-cycle meeting in the second quarter of 2015 in conjunction with a planned meeting of the BCS-SBB committee. Details will be provided as they become available. 10. Adjournment. The meeting adjourned at 11:25 am MST on Jan. 15, 2014.

4 Attachment A: NFPA Staff Presentation

5 Welcome TC on Multiple Burner Boilers At this and all NFPA committee meetings we are concerned with your safety. If the fire alarm sounds, please proceed to an exit. January 14-15, 2014 PERA Club Tempe, AZ Members, please verify/update your contact information Use of tape recorders or other means capable of reproducing verbatim transcriptions of this or any NFPA meeting is not permitted Guests All guests are required to sign in and identify their affiliation. Participation is limited to TC members or those individuals who have previously requested time to address the committee. Other participation is granted at the discretion of the Chair. Guest chairs are located around the room as a courtesy. 1

6 Members categorized in ANY interest category who have been retained to represent the interests of ANOTHER interest category (with respect to a specific issue or issues that are to be addressed by a TC/CC) shall declare those interests to the committee and refrain from voting on any Public Input, Comment, or other matter relating to those issues throughout the process. General Procedures Follow Robert s Rules of Order. Discussion requires a motion. Motions for Ending Debate Previous Question or Call the Question Not in order when another has the floor Requires a second This motion is not debatable and DOES NOT automatically stop debate A 2/3 affirmative vote will immediately close debate and return to the original motion on the floor. Less then 2/3 will allow debate to continue. Committee member actions: Member addresses the chair. Receives recognition from the chair. Introduces the motion. Another member seconds the motion. 2

7 Committee chair actions: States the motion. Calls for discussion. Ensures all issues have been heard. Takes the vote. Announces the result of the vote. New Process What s New? New Term Input Stage Public Input First Draft Meeting Committee Input Committee Statement (CS) First Revision (FR) First Draft Report First Draft Changes in Terms: Old Term ROP Stage Proposal ROP Meeting Trial Balloon (or later, FR that fails ballot) Committee Statement Committee Proposal or Accepted Public Proposal ROP ROP Draft New Process What s New? New Term Comment Stage Public Comment Second Draft Meeting Committee Comment Second Revision Second Draft Report Second Draft Changes in Terms: Old Term ROC Stage Public Comment ROC Meeting Comment that Failed Ballot (Second Revision that failed ballot) Committee Comment or Accepted Public Comment ROC ROC Draft Technical Committee Actions: Resolving Public Comments Committee Action and Committee Statement Creating Second Revisions 3

8 Resolving Public Comments (See Regs ) Committee develops a Committee Action Accept Reject but see Reject Reject but Hold Committee Statements Committee must clearly indicate reasons for not accepting the recommendation and/or point to a relevant Second Revision All Public Comments Actions must have a Committee Statement Must include a valid technical reason No vague references to intent Explain how the submitter s substantiation is inadequate Neither PC Action nor Committee Statements get balloted Create a Second Revision (SR) Committee wants to make a change (to add, delete or modify) the First Draft. Committee develops a Committee Statement (CS) substantiating the change. Each SR gets balloted No new material after the Public Input Stage since it hasn t had the benefit of public review. What constitutes new material is decided by the TC or Correlating Committee. Adding new material at this Comments stage could successfully be challenged through appeal to the NFPA Standards Council 4

9 Formal voting Voting during meeting is used to establish a sense of agreement (simple majority) Secured by letter ballot (2/3 agreement) Only the results of the formal ballot determine the official position of the committee on the Second Draft Ballots are on the Second Revisions (SR) ONLY Public Comments and Committee Statements not balloted Reference materials are available - Second Draft, Public Comments, First Draft Report Ballot form allows you to vote: Affirmative on all SR Affirmative on all SR with exceptions specifically noted Ballot form provides a column for affirmative with comment Note: This box only needs to be checked if there is an accompanying comment. Reject or abstain requires a reason. Initial ballot Circulation of negatives and comments Members may change votes during circulation Second Revision that fails letter ballot shall be designated as a Committee Comment (in the 2 nd Draft Report), marked as Reject and deleted from the Second Draft. Electronic Balloting Ballots will be an online format Alternates are strongly encouraged to return ballots Ballot session will time out after 90 minutes Use submit to save your work 5

10 Electronic Balloting Click link on the ballot received Sign in with NFPA.org Committee Login and Password Electronic Balloting Select either Affirmative on All or Affirmative with Exception(s) Electronic Balloting Choosing AFFIRMATIVE ON ALL Use See FR/SR - # link to review all First/Second Revisions Use Edit election to change individual votes or to modify vote after submitting ballot. Electronic Balloting Choosing AFFIRMATIVE WITH EXCEPTION(S) Make selection: Affirmative with Comment, Negative, or Abstain No selection made-defaults to affirmative Must include comment on each vote. 6

11 Electronic Balloting To complete ballot click Participant Consent and Submit Return and edit any votes before ballot due date. TC Struggles with an Issue TC needs data on a new technology or emerging issue Two opposing views on an issue with no real data Data presented is not trusted by committee Code Fund Lends a Hand TC rep and/or staff liaison submits a Code Fund Request Requests are reviewed by a Panel and chosen based on need / feasibility Research Project Carried Out Funding for project is provided by the Code Fund and/or industry sponsors Project is completed and data is available to TC Legal Patent: Disclosures of essential patent claims should be made by the patent holder, but others may also notify NFPA if they believe that a proposed or existing NFPA standard includes an essential patent claim. Antitrust: the single most important provision-federal law prohibits contracts, combinations, or conspiracies which unreasonably restrain trade or commerce. Section 1 of the Sherman Act Legal Activities Disapproved by the Courts Packing meetings Hiding commercial interest throwing the committees out of balance Hiding scientific or technical information from committees No final decision-making authority to unbalanced Task Groups; include all interested parties. 7

12 Doc Info Pages Document Information Next Edition Technical Committee Document scope Current/Previous Edition information Issued TIAs, FIs and Errata Archived revision information Standard Council Decisions Articles and Reports Read only document Submit Public Input/Comments via Electronic Submission System. Meetings and Ballots ROP/ROC or First Draft Report and Second Draft Report NITMAMand Standard Council Decisions Private TC info Ballot circulations, informational ballots and other committee info Committee name, responsibility and scope Staff liaison Committee list Private committee contact information Current committee documents in PDF format Committees seeking members and committee online application Any questions? 8

13 Attachment B: NFPA Anti-Trust Policy

14 NFPA Antitrust Policy The NFPA is a not for profit organization with a mission of promoting the science and improving the methods of fire protection and prevention and electrical safety. The primary way in which the NFPA fulfills this mission is by developing and disseminating safety standards intended to minimize the possibility and effects of fire and other risks. The standards development process depends on volunteer participation by a diverse range of individuals on behalf of numerous stakeholders including participants representing business and industry. As a result, antitrust concerns can arise in connection with standards development activity. It is the policy of the NFPA to strictly comply with state and federal antitrust laws, and the NFPA expects all participants in NFPA standards development activities to conduct themselves in strict accordance with these laws. NFPA minimizes the risk of antitrust problems by providing a forum for standards activities that is based on the principles of openness, honesty, fairness and balance and that is conducted in accordance with published rules and regulations. Each participant in the standards development process has the obligation to adhere to all rules, regulations, and policies of the NFPA including, without limitation, the Regulations Governing the Development of NFPA Standards. In addition, participants can draw valuable guidance on how to conduct themselves by consulting NFPA s Guide for Conduct of Participants in the NFPA Standards Development Process. While compliance with NFPA s standards developments rules and regulations is essential, it alone is not sufficient to avoid conduct that may violate the antitrust laws. Participants must also avoid any conduct, conversations or agreements that would constitute an unreasonable restraint of trade or be otherwise illegal under the antitrust laws. Although it s not possible to identify every situation that could be found to be anticompetitive or a violation of antitrust laws, the following topics should NOT be addressed or discussed, even informally, by or among competitors or other individuals in the course of their NFPA involvement: - Profits, profit margins or cost data; - Prices, rates, and fees; - Selection, termination, division or allocation of customers, sales territories, or markets; or - Refusal to deal with a specific business entity. Participants in NFPA activities may receive antitrust training or advice from their employers or other organizations or entities they represent. This NFPA antitrust policy, as well as other information or presentations that NFPA may provide concerning the antitrust laws and standards development, are not intended to take the place of such training or advice; nor are they intended to constitute legal advice to participants. In addition to consulting with their legal counsel, however, participants can assist NFPA and their fellow participants by refusing to engage in inappropriate discussions and by speaking up if they have questions or concerns about any matter or discussion that occurs in the course of NFPA standards development activities. Participants should bring matters of concern to the attention of NFPA staff. Any participant may also raise questions regarding this policy to the NFPA s General Counsel.

15 Attachment C: SmartBurn LLC Presentation

16 Plasma Ignition & Combustion Stabilizing (PICS) Technology 1

17 Plasma Ignition Introduction System Benefits History of Adoption Plasma Ignition Basics Ignition Process NFPA Classification Next Steps Appendix 2

18 Objectives Introduce PICS to the NFPA MBB Technical Committee PICS is widely adopted in China YTLY is the leading manufacturer with over 90% market share Developed to achieve national goal to eliminate use of oil fuel for boiler startup/shutdowns PICS is of interest to U.S. utilities because of compelling benefits Discuss applicable NFPA Code Plasma ignition has been on the MBB Technical Committee agenda since at least 2012 Discuss next steps 3

19 Plasma Ignition Benefits to Coal Fired Generators Payback a combination of: Reduced use of igniter fuel typically oil for startup/shutdowns Better low-load performance from combustion stabilization Avoided generation cost during off-peak periods New build units can save oil systems, payback during commissioning PICS can supplement existing igniters w/o full replacement PM emissions lower & collection systems function better during startup Mitigates issues with loss of startup/shutdown exemption, if ESP Reduces PM collection system maintenance issues 4

20 Benefits to Coal EGUs- Oil Savings US EGUs spend up to $1B yearly in support fuel (EIA 2011 Data) Turndown savings may exceed startup cost savings 5

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22 Oil vs. PICS Warm-up Flame 7

23 PICS Application Milestones Yantai Longyuan began developing plasma ignition technology First oil-free startup using PICS in a 50 MWe unit First T-Fired application of PICS in a 600 MWe unit First Wall-Fired application of PICS in a 600 MWe unit First ultra-supercritical application of PICS in a 1000 MWe unit 8

24 Applications Outside of China NO Country Name Unit Capacity Retrofit / New Furnace Configuration Coal 1 S. Korea Samchonpo 560MW Retrofit T-firing Bituminous 2 S. Korea Yonghung 870MW New T-firing Bituminous 3 S. Korea Hadong 2 x 500MW New T-firing Bituminous 4 Russia Khabarovsk 3 rd 180MW Retrofit Side Wall opposed fired Bituminous 5 S. Korea Hadong 500MW New T-firing Bituminous 6 Indonesia Suralaya 600MW Retrofit Wall fired Subbituminous 7 Turkey Eren 2 x 600MW Retrofit Wall fired Bituminous 8 S. Korea Yonghung 2 x 870MW New T-firing Bituminous Over 650 Units and 275 GW Installed within China to date 9

25 Plasma Ignition Basics Plasma generates ionized gas produced by air flow through electric arc High temperature gas is used to directly ignite a portion of burner coal flow 10

26 Principle of PlCS--Plasma Burner Plasma Lance Stage Support Structure Coal Concentration Features Typical features of current burner shown diversity of physical designs from YTLY and others Coal abrasion & low NOx features retained Burner Stages 11

27 Plasma Ignition Basics Temperature (F) Side View Ignition Zone Coal Flame Igniter Zone Intermediate Zone Coal Flame Burner Zone Pulverized coal passes through the plasma arc with high temperature chemically active ions. Coal particles are rapidly gasified, releasing volatile matter which is ignited by the flame. 12

28 Plasma vs Conventional Ignition Conventional Coal Igniters Coal is not ignited until just outside the burner tip Coal devolatilization and pyrolysis occurs slowly as coal particles heat up Electromechanical device Max flame temperature (adiabatic, equivalence ratio ideal) 2100 C (oil) & 1960 C (natural gas) Plasma Igniter Portion of coal is lit downstream of the elbow. Initial ignition propagates through successive stages inside the burner. Flame moves to furnace when igniter turned off Concentrated 5000 C (typ) plasma arc quickly shatters & devolatilizes coal (low heating/drying time) Solid state device and control systems Plasma energy input of 1% of rated burner heat input sufficient to ensure combustion Coal is the igniter fuel, so heat input = fuel burned in burners w/ PICS > 10% of boiler heat input 13

29 Safety Considerations Combustion process is engineered ignition occurs in a controlled space (burner rings) rather than at front of burner in furnace cavity as with an oil/gas igniter PA velocity > coal flame propagation speed prevents flame from propagating backward same as conventional igniters Much higher flame temperature rather than oil/gas flame High degree of Plasma lit discrimination (high voltage & current condition) 14

30 Safety Considerations Plasma generator power supply => solid state reliability Multiple instruments verify PICS in service & burner flame: Current flow to PICS Visual camera Redundant main burner flame scanners on main burner (vs one on igniter & one on burner for oil) Performance to be verified by test under Typical problems of oil / gas igniters avoided No atomizer tip clogging No liquid flow control devices 15

31 Primary Air Requirements Primary Air characteristics can have a strong impact on performance of all igniters Since PICS works by first igniting the coal volatiles in primary air, an incorrect PA to coal ratio or PA flow rate will impair ability of PICS to complete ignition including char particles PICS PA requirements are similar to those of a standard PC boiler/mills Property PA Velocity (m/s) PA/Coal Ratio PICS ideal range PICS required range B&W mills required range* *Steam: its generation and use, ed. 41, pg

32 Classification Discussion PICS can accomplish all functions of a Class I Igniter, including ignition and combustion support Staged ignition of coal allows PICS to achieve stable coal ignition despite relatively low heat input Plasma temperature is sufficient to ignite coal under all credible combinations of fuel and air Testing under section will be performed for each installation rather than rely on general guidelines which are typically not tested A Many factors affect the classification of the igniters, including the characteristics of the main fuel, the combustion chamber and the burner design, and the igniter capacity and location relative to the main burner 10% Guideline result of intrinsic oil and gas flame characteristics Relatively low oil flame temperature, and exposed position in furnace, requires more energy input to ignite coal volatiles 17

33 Classification Discussion Class 1 Igniter. An igniter that is applied to ignite the fuel input through the burner and to support ignition under any burner light-off or operating conditions. Its location and capacity are such that it will provide sufficient ignition energy, generally in excess of 10 percent of full load burner input, at its associated burner to raise any credible combination of burner inputs of both fuel and air above the minimum ignition temperature. 18

34 Credible Combinations of Fuel and Air Credible Range - Cold Furnace Credible Range - Hot Furnace Propose defining credible combinations in terms of percent of the maximum primary air and coal flow for Cold and Hot furnaces For MPS 89 Mill propose +/- 3% Coal Flow and +/- 10% air flow uncertainty 19

35 Closing Remarks Plasma ignition offers opportunities to: Safely improve economic competiveness of coal fired generators Reduce emissions YTLY is discussing PICS with interested parties: NFPA Committee Prospective Clients (opportunistically) Demonstration projects to prove system value to EGU s and safety Carry out testing to demonstrate ignition under all credible combinations of air & fuel Insurers, AHJs & other YTLY and SmartBurn are seeking guidance from the committee on the next steps to commercialize the technology in the US. Does the MBB Technical Committee believe the current code is adequate? Discuss next steps 20

36 Contact Information SmartBurn, LLC Frank Fowler, V.P. Of Business Development , Edward Lightbourn, Engineering Manager , Guodian Longyuan Tech. USA Tony Niu, President , 21

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