April 9-12, 2006 APPA 2006 Engineering & Operations Technical Conference Sacramento, California Reduction of Rainwater Intrusion Into Deerhaven Unit 2 Coal Pile Reclaim System John B. (Jack) Miller – Black & Veatch Ali McDaniel – Gainesville Regional Utilities
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April 9-12, 2006 APPA 2006 Engineering & Operations Technical Conference Sacramento, California Reduction of Rainwater Intrusion Into Deerhaven Unit 2.
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Reduction of Rainwater Intrusion Into Deerhaven Unit 2 Coal Pile Reclaim System
John B. (Jack) Miller – Black & VeatchAli McDaniel – Gainesville Regional Utilities
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Overview
Describe the Process That Lead to the Decision to Install the Cover
Review the
Design Development
Design Features
Construction Process
Examine the Initial Measurements of Its Effectiveness
Gainesville Regional Utilities (GRU) Recently Installed a Rain Shield Over the Coal Reclaim for Their
Deerhaven Unit 2. This Presentation Will:
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About the Authors
Ali McDanielMaterial Science Engineer – GRU’s Project and Construction Manager for This Project
Jack MillerMechanical Engineer – Black & Veatch’s Project Manager for the Feasibility Study and Detailed Design
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About GRU
GRU Is a Municipally-Owned Utility Serving the City of Gainesville, Florida for 100 Years
Gainesville Is Located in North Central Florida
GRU Serves 87,000 Retail and Wholesale Customers
Owns and Operates Two Power Plants, John R. Kelly and Deerhaven Generating Stations
Installed Capacity of 611 MW to Serve a Peak Demand of 450 MW
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About Deerhaven Unit 2
Deerhaven Unit 2 Is a 235 MW Pulverized Coal-Fired Steam-Electric Generating Unit
Commissioned in 1982
Burns Low Sulfur East Kentucky Compliance Coal
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Aerial View of Deerhaven Generating Station Looking North Northeast
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Problem Definition
Rain!!
Wet Coal
O&M Impacts Plugging in the Reclaim, Conveying Storage and Milling Systems
Negative Impact to Thermal Efficiency
Can Cause Significant Unit Derates and Relatively Expensive Replacement Power
In 2003, Wet Coal Effects Directly Resulted in the Need for 12,879 MWh of Replacement Energy
Annually 58 inches max.48 inches avg.34 inches min.
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Overview of Coal Handling System
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Highlights ofCoal Handling Operations
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Highlights of Coal Handling Operations
Coal Is Delivered by Unit Trains Carrying About 11,000 Tons
Unloaded From Track Hopper at 3,000 TPH
Conveyed to Dual Discharge Fixed Boom Stacker
Can Build 1,800 Ton Conical Coal Pile on North and South Sides
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View of Stockout Tower Looking West
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Highlights of Coal Handling Operations
Reclaim System Operates at 500 TPH (2" x 0" Coal at 15% Moisture)
Four Below-Grade Hoppers: Three on the South (Active Reclaim)
One on the North (Emergency Reclaim)
Hoppers Feed a Common 30-Inch Belt Conveyor
Conveys Coal to the Six Storage Bunkers Via a Crusher Tower
Bunkers Hold 18 Hours of Fuel at Typical Burn Rate
Coal Is Fed to Burners Through B&W MPS 75N, DVS Rotating Classifier Pulverizers
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Graphic Display – Stockout and Reclaim System
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Coal Pile Management Equipment
Excess Coal Is Moved From Stockout Pile to Long-Term Storage Using Dozers and Front-End Loaders
Takes Three Machines Three Days to Move and Spread 11,000 Tons
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Analysis and Developmentof Solution
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Analysis and Development of Solution
Wet Coal Effects Had Been Manageable Until Coal Fines Content Increased
In Late '90s, Began Using Lower Sulfur East Kentucky Coal
Sizing Changed From Nominal 2" x 0" to ¾" x 0"
Fines Increased Considerably
More Conducive to Plugging When Wet
More Conducive to Excessive Ratholing Above the Reclaim Hopper
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Ratholing at the Center Reclaim Hopper
Ratholing Provides Direct Path for Rainfall and Runoff to Enter the Reclaim Hopper and Flow Directly Onto Reclaim Belt Primary Source of Entrained Water in the Coal and Attendant Problems
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GRU Study
Correlation Between Rainfall and Need for Replacement Energy Due to Unit Derates
Short-Term Rain Events of Greater Than 2 Inches Cause Derates on a Proportional Basis More Rain, More Replacement Energy Needed
Results for 2003
Months inWhich Derates
Occurred in 2003
20-Year Average Rainfall Recorded
at Deerhaven (Inches)
Actual RainfallRecorded at Deerhaven in 2003 (Inches)
Duration ofDerate (hrs)
Replacement Energy
Necessitated byDerate (MWh)
February 3.1 7.2 29 1,366
March 4.5 10.9 74 4,592
May 2.5 1.9 43 2,365
June 6.9 10.1 55 4,132
July 6.1 4.0 5 425
Totals 23.1 34.1 207 12,879
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B&V Study
Potential Solutions
Improve Pile Management Practices Reduce Fines Stratification