case study: duke energy / marshall steam station
TRANSCRIPT
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North Carolina, 2009
Steve Davis
Case Study: Duke Energy / Marshall Steam Station
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Agenda
Customer and Case1
Application Description2
FLEXIM Solution3
Customer Benefits4
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Customer and Case
The Marshall Power Plant is a four unit, coal fired generating station in North
Carolina.
2090 MW capacity.
Marshall generates enough power for approximately 2 million homes.
Commissioned in 1965.
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Agenda
Customer and Case1
Application Description2
FLEXIM Solution3
Customer Benefits4
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Application - Customer Motivation
Marshall approached FLEXIM about a problem with premature boiler tube
failure. They need to measure feed water flow from the boiler drum to the boiler
tubes.
The problem seemed to be only at full load situations. Marshall, like other
power plants wanted to operate at peak conditions to get every MW out of the
unit.
Marshall and FLEXIM, as a team, decided to measure this flow on the 14”
vertical pipes using the Wave Injector.
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Application - Measurement Point
The measurement points were on 14” carbon steel pipes with downward
vertical flow at 600 degrees F and 2450 psi.
Measurements were taken at the discharge of 3 circulating water pumps.
Original tested was conducted on the suction side of the pumps, but it was
concluded that this was a poor measurement point because of steam
entrainment from the steam drum.
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Application - Technical Details
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Agenda
Customer and Case1
Application Description2
FLEXIM Solution3
Customer Benefits4
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Solution - Installation
The ADM 7407 was used with WI-400 Wave Injector and FSM Transducers.
Insulation was removed during testing and re-installed.
Cold testing was also done at the same measurement locations during
troubleshooting.
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Solution - Performance
Initial testing showed high aeration during normal operation. FLEXIM
personnel used the diagnostics of the 7407 to help with troubleshooting.
After initial testing, it was determined that steam was being entrained into the
feed water from the steam drum.
FLEXIM and Marshall decided to increase drum level to determine if the
problem could be resolved.
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Solution - Results
Marshall Power Plant was very happy with our performance and customer
support. They have 6 of these installations at the plant to help ensure that there
boiler is evenly supplied by the steam drum.
The communication and teamwork between FLEXIM and Marshall personnel
was a giant factor in the success of this application.
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Agenda
Customer and Case1
Application Description2
FLEXIM Solution3
Customer Benefits4
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Customer Benefits
Marshall now has decreased forced outages due to boiler tube failure. The
steam entrainment was causing poor heat transfer in the boiler.
The plant can now operate at peak conditions while monitoring boiler feed
water flows and ensuring the flow is distributed evenly.
The customer has increased their knowledge about their own equipment and
operating procedures.