Multicell FIIFEWSI Bed Boiler Design --

Construction and Test Program

Quarterly Progress Status Report
for Period January - March 7979
Published - July 1979

Prepared For:
U.S. Department of Energy
Assistant Secretary for Energy Technology
Division of Fossil Fuel Utilization

Under Contract No: EX-76-C-01-1237

 DISCLAIMER

This report was prepared as an account of work sponsored by an

agency of the United States Government. Neither the United States
Government nor any agency Thereof, nor any of their employees,
makes any warranty, express or implied, or assumes any legal
liability or responsibility for the accuracy, completeness, or
usefulness of any information, apparatus, product, or process
disclosed, or represents that its use would not infringe privately
owned rights. Reference herein to any specific commercial product,
process, or service by trade name, trademark, manufacturer, or
otherwise does not necessarily constitute or imply its endorsement,
recommendation, or favoring by the United States Government or any
agency thereof. The views and opinions of authors expressed herein
do not necessarily state or reflect those of the United States
Government or any agency thereof.
 DISCLAIMER

Portions of this document may be illegible in

electronic image products. Images are produced
from the best available original document.
 DOE/ET/1237-01/15
Dist. Category-UC-9OE

Multicell Fluidized' Bed Boi,lerDesign

Construction and Test Program
Quarterly Progress Status Report
for Period January - March 7979
Published - July 1979

Prepared By:
Pope Evans and ~ o b b i n s Incorporated
,
New York, New York 10036

7
NOTICE
l l ~ hrcpon wa prepared as an account of work
spanrored by the United States Govcmment. Neither the
United Stater not the United States Department of
E n e r a , nor any of their employees, nor any of their
cantrnctors, subcontracton, or their employees, makes
any warranty, express or implied, or auumcs any legal
liability or rcspondbility for the accuracy, cornplrtenen
or usefulnes of any information, apparatus, product or
p r m n direloud, or rcprewno that i u use would hot
infring. ptimlrly nwmd riphl.

Prepared For:

U.S. Department of Energy

Assistant Secretary for Energy Technology
~ i v $ s i o of
n Fossil Fuel Utilization
Washington, D.C. 20585

Under Contract No: EX-76-C-0'1-1237

 . .
. .

Available from:
. . ..
National ~ e c h n i c a lInformation Service (NTIS),
, U.S. ~ e ~ a r t m e r iotf Commerce .'

5285 Port Royal Road

springf i e l d , Virginia 22161
. -
~ r . i c. e. : . printed copy: . - . $ 6.00.
Mic.rofiche : .$ 3 . 0 0
This r e p o r t was prepared i s a n a c c o u n t o f work s p o n r i r r e d by t h e
U n i t e d s t a t e s Government.. N e i t h e r t h e U n i t e d .States ilor t h e
U n i t e d S t a t q s DOj2, n o r a n y o,f . t h e i r . e m p l o y e e s , n o r any o f t1lei.r
contractors, subcont.ractora, o r . ' t h e i r e m p l o y e e s , .makes any wal:sc7.!ity
express or i.mpl.i.cd, or' assrlmes a n y l e g a l l i a b i l - i t . y o r r e s p o n s i b : i . l . s t y
f o r t h e accuracy, c o m p l e t e n e s s , o r u s e f u l l n e s s , o f a n y informa.ki.oj?l
apparktu.:;, p:?oduct, o r p;ocess .,disclosed,o r r e p r e s e n t s t h a t its
use \iould n c t i i ~ f r i n g epr:iwately owned r i g h t s . -
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~ l o b l e n l s T h e f :l..uj-dized-bed b o i l e r 1 q . i j . l p j - o \ ? i d e a P P r U X j - n a t e J ?
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3 0 9 . 0 0 0 P O U ~ ~ of S s t e a m pel: 116ur. fit-.eafil pre:;s,xe and tcmper:atr.;.;.r

c0naiti.ons s e l e c t e d to ~ ~ e r ee l ;tu i r c m e n t , o o f t i l e . . .
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 TABLE. OF 'CONTENTS
--

ABSTRACT

INTRODUCTION

SECTION

.
1 0' SUMMARY OF PERFORMED TASKS

1.1. Alexanc'lria, V a . L a b o r a t o r y O p e r a t i o n s '

1.2 R i v e s v i l l e MFB P l a n t Operati-011s '

1.3 N e w York .Of £ i c e E n g i n e e r i n g

1. Subcontract A c t i v i t i e s
1.4.1 MFB P l a n t A d v i s o r y O p e r a t i o n s
Assj.stance (Stone & Webster
~ n g i n e e r i hC~o r p o r a t i o n )
1 . 4 :2 M F D Stearil G e n e r a t o r D e v e l o p r i ~ e n t
( F o s t e r Wheeler Energy C o r p o r a t i o n )
1.5 Review o f s i g n i f i c a n t E v e n t s
1..6 Future Planning

A i r Distributor. Testing
( ~ c t i v i i - .No. ~ 114)
L a r g e S i z e C o a l F e e d - Minimun~
F l u i d i z a . L i o n ( A c t i v i t y TJo. 1 6 1 9 )
O i l F i r i n g ( A c t i v i t y No. 1 6 1 8 )
S u l f u r Capture ( A c t i v i t y N o . 1110)
2.4.1 Greer L i m e s t o n e T e s t s
2.4.2 L o w e l l v i l l e Limestone Test's
F l u e Gas B a g h o u s e P r o g r a m
.(Activity N o . 1620) '

. .
3.0 RIVESVILLE MFB PLANT OPERATIONS .

3.1. Gencral
3.2 P l a n t Outage
3.3 N e w D C - 1 Dampet
3.4 Bed M a t e r i a l T r a n s p o r t M o d i f i c a . t i o n s
3.5 Results.
3.5.1 Airflow. T e s t ~ c c o m ~ l i s h e d '
3.5.2 ~ e l Ft e e d e r - T e s t s C o m p l e t e
3.5.3 F u e l and. S o r b e n t
3.5.4 Test Plan
3.5.5' P l a n n i n g EPA T e s t P r o g r a m .
3.5.6 Modernization Engineering
3.5.7 .Operations
3.5.8 F D Fan ~ a i i . k ~ r r e
3.5.9 F o s t e r . Mlkec-:;.er ~ e v e l . , o ~ m e n t
Corpora!.kior~' . s M e t a l l u r g i c a l
Exami.naition ( P h a s e ' II )
 . . . .
. . . .
. . . . . . .
. . . , .,
..
, .
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T a b l e of C o n t e n t s / 2 , . . . .. .. . .
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. . , .
a .
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. .

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. . . . .
4.0 NEW Y. .O R K
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~ ~ O F F I C EENGINEGRING:.
. .. . ,
:. ,; . .' : Do,:
. . . ..
,

. . .. GO
4.1 S f a c k 'Sj.1ence.r~ n s t a l i. a g. i o n . :. : -..
.
4

. , . >. ..
. 68.
,
. . . .
4 . 2 . Redundancy S t u d y . 1 : . ., . . , . . . 68. . . . >

4.3 .~ot-.cx~ c r ' e e nR e l o c a t i o n . . . .68 .. . "

4.4 EPX ~ a ~ r t i d u l a t ~ . ' C o n f r To e: sl t '

. . . . . .
' . . . . . ,' . . ., '. sh
4 . 5 steam . V e n t ~ i l e n c g r ' ~ ~ x t e n s i o n s . . gcj ,--. - ,
I .

, '

4.G Control R o o m . ~ o d i f i c a t i . o k . : . . '. .. 63

4.7 ~ b n t r a lV a c u u m ~ l e. .a n . i n g. ' s $ s t e m. . ,
. :, $9'
4. 8 . I ~ i s t r u m e n t .Shop . . . . . . . . . ,. .
3
.
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. . .. . . ..
. . . ..
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3 .
, . , 9 ..
.
5.0 SUBCGNTI-GCT AC'Y'IVX'TIII;S . * ..: . . . . . . 9 6.. -, '

.. . . . . ( _ . .- , I . -. . .. . . . 0 . . '
I .

5.1 MPB P l a n t ~ d ~ i s o r ~ ~ ~ e r a' ~t si soi ns ts ~ n c e . 7 0

( S t o n e & N e b s t e r ~ n g i n e e r i nC~o r p .
. Sybcon,tract) . . . . ,

5.2 MFB :.steam ~ e n e r a t b ~ i e v e i o ~ m ~ n t .. 71 ~

(Foster W h e e l e r :Energy C o r p ~ r a t i o n , )
. . . ..
. , . .
. ,
. .. -. . . ..
, . .
I i .
INTRODUCTION . .
. ,
General
. .

The Government, i n o r d e r t o . i m p l e m e n t , r e s e a r c h a n d d e v e l o p m e n t
work o n a m u l t i c e l l f l u i d i z e d - b e d b o i l e r o p e r a t i n g u n d e r u t i l i t y
e l e c t ' r i c power g e n e r a t i o n c o n d i . t i o n s ,,a w a r d e d DoE/EKDA/OCR
C o n t r a c t No. EX-7,G-C-01-1237 t o P o p e , ~ k a n sa n d ~ o b b i n sI n c o r p o r a t e d
( P E R ) on O c t o b e r 5 , 1.9'12.. - The , w o r k u n d e ~
' : t h i scpntracf is a
f . o l l o h - u p t o work , p r e v i o u s l y b y PER u n d e r OCR c o n t r a c t .
No. - 14-01-0001-470 o s amended, a n d OCR. C p n t r a c t Jgo. 14-02-0001-
1229 which i n d i c a t e d t h a t c o n t i r i u q d : d e v e l o p m & n t : w o u l d h a v e a
high probability o f success. . . . ,

. .: '.' ,

Tasks and Phases . . .. .

. . .. . .

The o b j e c t i v e o f t h e program c o v e r e d b y ontract tract NO. EX-7G--

C-01-1237 j.s t o t e s t a multicell.fluidi.zed-bedb o i l e r a s a . .
p o l l u t i o n - f r e e method o f b u r n i n g h i g h - s u l f u r c o a l s o r h i g h l y
c o r r o s i v e c o + l s without excessi.ve maintenance. . ,
. . . .
. . ..- .-. .
The o b jec:tj.ve i s t o b e a c c o m p l i s h e d . b y desi.gninc; ;,: c o n s t r u c t i n g
and o p e r a t i n g a m u l t i c e l l f lui.di.zed-bfd, b o i l e r u n d e r u t i , l i t l r
e l e c t r i c power g e n e r a t i o n conditions i n f o u r t n m n : i c a l l y d i s -
t i n c t but c l i r u n o l o g i c a l l y o v e r l a p p i n g , p h a s e s :

Phase I MFB J 3 o i i e r a n d ' p l a n t ~ & s i ~ Pne f; f o r m a n c e o:f

~ x p & r i i p , e n C sin' t h e ~ l e x a n d k i a Va.
, ~ Laboratory
t o O p t i m i z e ~ ~ I 3 , ~ o iPleer fro r m a n c e .
. ,

P h a s e I1 F a b r i c a . t . i o n , I n s t a l l a t i o l ~. a n d .'Sh.al;edown S t a t u s
Operation.. . '

. . . . .

P h a s e I11 ~ e m o n s t r a t i . o nO' p e r a t i o n u n d e r S O 2 A c c e p t o r : o d e . ,

Phase I V P r e p a r a t i o n o f D e s i g n a n d O p e r a t i o n Manuals a n d
d e s i g n o f a f a c t o r y - a s s e ~ ~ ~ b l iendd u s t r i a l MFB
unit.

T h i s q u a r t e r l y R e p o r t c o v e r s wgrk p e r f o r m e d u n d e r P h a s e 1, 111
'and I V o f t h e c o n t r a c t i n t h e p e r i o d ' J a n u a r y , F e b r u a r y a n d
March 1 9 7 9 .
 1.0 SUMMARY OF PEIIFORMED TASKS

.
.1 1 A l e x a n d r i a , Va. L a b o r a t o r y O p e r a t i o n

Work i n t h e A l e x a n d r i a l a b o r a t o r y f o c u s e d p r i m a r i l y o n t h e
following :

A c t i v i t y No.
P
Description

114 A i r Di'stributor Testing

1619 ~ a r S~i zee C o a l F e e d -
Minimum F l u i d i z a t i o n
O i l Firing
S u l f u r Ca.pture

T h e Iullowing t : e s t s w e r e cornpl e t e d d u r i n g t ! ~ e r e p o r t i n g p e r i o d .

Test
- N o .- D
-. a t e --
Desc::t:.:l.p.tion -Dura1:-i
-.--_ on (Hrs) &&, ,

700-32 I l r i l l e d . b o l t . grid 7.0

p l a t e and b e d m a t e : ~ : i a l
samples
Shakedown 4.0
P r e l i m i r ~ a r y# 4 o i l -
firing
S h a k e d o ~ nc o a l f e e d
system changes
Dri1.l.ed I ~ l gt r i d ~ l i . l:1
c:

~ r i l l e db o l t g r i d p l a t e
Shakedown .
Drilled bolt grid plate
Lowellville limestone
Lowellville limestone
Lowellville limestone

1.2 ' R i v e s v i l l e MFR P l a n k O r > e r a ~ ' i o n s

R e p a i r , r e c o n s t r u c t i o n and p l a n t improvement a c t i v i t i e s w e r e
c o m p l e t e d a n d w e r e f o l l o w e d by e q u i p m e n t a n d s y s t e m s c h o c k - o u t ;
M o d i f i c a t i o n s mads t o t h e b e d m a t c r i a l / f l y a s h s y s t e m a n d
Beckman g a s a n a l y s i s s y s t e m were s i g n i f i c a n t i m p r o v e m e n t s .
The r e p l a c e m e n t n u t s a n d b o l t s d i s t r i b u t e r i n s t a l l e d i n C e l l D
o p e r a t e d s u c c e s s , f u l ~ y , . During January and February, c a l i b r a t i o n
t e s t s were p e r f o r m e d .on a l l a i r f l o w m e a s u r i n g d e v i c e s t o
ensure accuracy f o r f u t u r e performance t e s t i n g . Calibration
t e s t s w e r e a l s o r u n o n a l l b d l t f e e d e r s . T h e MFB u n i t .
r e s u m e d h o t f i r i n g o p e r a t ' i o n i n mid-!\jarch. The u n i t w a s
o p e r a t e d i n t e r m i t t e n t l - y t o t h e end of t h e r e p o r t i n g p e r i o d
t o i ' d e n t i f y and correct minor equipment o p e r a t i n g problems.
The u n i t was o p e r a t e d i n t h e f l y a s h r e i n j e c t i o n mode w h i c h
r e s u l t e d i n ' modif i.catio.ns t o t h e r e i n j e c t i o n s y s t e m f o r
improved c o n t r o l and o p e r a t i o n a l r e l i a b i l i t y .

Summary o f O p e r a t i n g H o u r s

CBC ( L i g h t - o f f o i l ' f i r e d b u r n e r s ) 37.33 h r s

CBC (c.oal f i r e d ) 11.8.51 h r s
Cell C 67-18 h r s
Cell B .67 h r s

1.3 N e w York O f f i c e E n g i n e e r i n g
'

The N e w York Of,fi.cc-? d e s i g n a n d e n g i p e e r i n g s ' t a f f c o n t i . n u . e d ' t o

p e r f osrn. . v a r i o u s t a s k s i n s u p p o r t o f resumed o p e r 2 t i o n o f tl-1.e
R i v e s v i l l e MFB B o i l e r P l a n t a n d i m p r o v e m e n t s f o r i n c r e a s e d
reliability. Tasks performed included:

s C o n f i r m e d , s t a b i l i t y o f t h e e x j - s t i p y s . t s c k i ~ / i : t hrie!\~.!
s i ; l e n c e r u n d e r c r i t i c . a l w i n d v e l o c i t y c'o:-~dlt i o n s , .

P r e p a r e d d.esig.11 c a l c u 1 a t j . o n . s a n d d r a w i n g s f o r
s t r u c t u r a l f r a m i n g t o accornnodate r e p l a c e n e n t b e l t
conveyor f o r Redler,

o Complet.ed s t u d y t o p r o v i d e f o r r e d u n d a n t FD a n d I D
f a n s and s e l e c t i v e u s e o f e l e c t r c s t a t i c p r e c i p i t a t c 2 r
or bayhouse f i l t e r ,

a . P r e p a r e d d e s i g n c a l c u l a t i o n s and. d r a w i n g s f o r i n s t a i l a . -
t i o n o f f l u e gas s a m p l e d u c t s t o s u p p o r ' t EPA t e s t
program,

e Prepared d e s i g n c a l c u l a t i o n s and drawings 'for s u p p o r t s

and guides f o r atmosplleric v e n t s i l e n c e r e x t e n t i o n s ,

c I n v e s t i g a t e d s t r u c t u r a l f r a m i n g a d d i t i o n s a n d modi-
f i c a t i o n s t o accommodate p r o p o s e d I n s t r u m e n t Shpp.

1.4 Subcontract A c t i v i t i e s

1'.4.1 . It
MFB P l a n t A d v i s o r y perat at ions A s s i s t a n c e
(Stone & W e b s t e r 1Zngineeri.ng C o r p o r a t i o n )

S&W c o n t i n u e d t o f u r n i s h o p e r a t i o n s a s s i s t a n c , e a t t ' h c R i v e s ~ j . l l e
MFB P l a n t 'and p r o v i d e e i ~ g i n e e r i n ga n d d e s. i g. n . s u p p o r t f o r t h e
p l a n t m o d e r n i z a t i o n program.
 Home o f f i c e e n g i n e e r i n g t a s k s performed i n c l u d e d c o o r d i n a t i o n
and procurement o$ FD and I D f a n v i b ~ r a t i o l li n s t r , u ~ n e n t a t i o ~ ~
and r e a d i n g s a t t h e s i t e t o e s t a b l i s h b a s e l i n e ciata)
e s t a b l . i . s h i n y . maximum~.acceptable. n o i s e l e v e l s . f o r t h e ail:
coolec: concienser and l l o i s e c o n t r o l . op-t+6ns f o r t h e ' tu,rbil?.e . '
by-pass system; c o m p l e t i o n o f s t u d i e s f o r a l t e r n a - t e coal-
and liines.Lone d j - s t x i b u t i o n and. f e e d s y s t e m s ; completed concepcua.1
d e s i g n of tulrbine by-pass s y s t e ~ n ;c o n t i n u e d work on C o n t r o l .
Rbom r e l o c a t i o n and inodernizat.ion; p~:ep.'il-ed.dray.i,ngs for ,

j . n s t a l . l a t i o n o f DC-I. by-pass damper; c o ~ n p l e t e d. P a r t i c u l a t e

Emission C o n t r o l and ' D r a f t Equip~ilentModernizati.on s t u d y ,
. .
' F i e l d A c t i v i t i e s incl-uded c h e c k o u t 0.f n u c l e a r so,urce heads
foi: p r e c i . p i . t a t o r hopper l e v e l d e t e c t o ~ : ;; . rn0di.f j . c a t , i p i ~ s,t@
.fl y a s h r e i n jectj..on systeln; d e s i g n e d and s p e c i f i.ed m a t e r i a l - , ,
f o r p r e c i y i t ~ a t o rhop]::)er heat'ing; :;.yZ.t;~rit; performi;!c'l : v e r i f i -
c a t i o i z a n a l - y s i s of ME" perforlnar1c:e caj.c.ul..al:.~one q u a t i o n s a?\::
recommended r e v i s i o n s t o cornp~l.teip&ogzan.ns: g a i - t i ci:l>atprl.
i n t e s t i n g Frogram d r y r u n s ; u p d a t ~ i d L e s L pli!.r~.

Conciucteil dai1.y s a f e t y t o u r s a n d ' j.nvestl.gation of minor

accj-dents.

1.4.. 2 MFB Steam G e n e r a t o r Development

(I-?oster Wheeler Encrgy Corpor'atiol-J)

Fester I d h e e l - e r Energy. C o r p o r a t i o n c11gagi2d. i i n t h e f o l l o w i n g

a c . t i v i . t i . e s i n s u p p o r t of t h e R j . v e s v i l l e bIF'L3 operzt.i.orl anc1
improve111en.t;

f a b r i c a t i o n of rcplacemen.t a:ir d i s t r i b u t ~ i -
f o r C e l l D and s h i p p e d t o s i t e ,

s Continued e n g i n e e r ~ . n ge v a l u a t j - o n of f u l l 1oa.d and

p a r t load performance of t h e R i v e s v i l l e b!FB ' u n i t , ,

Completed and i s s u e d t h e F l a t e r i . a l s . Survei.l.ance Report

on samples t a k e n from t h e R i v e s v i l l e M F U .
 . .
1.5 ~ e v j e wo f S i g n i f i c a n t ' E v e n t s

D u r i n g the. O c t o b e r 1 9 7 8 t h r o u g h March 1 9 7 9 . FY-79 c o n t r a c t

p e r i o d , t h e ~ f o l l o w i n gs i g n i f i c a n t e v e n t s o c c u r r e d :
\ '
. ..
vent '
. .
Date
. -
C o n d u c t e d . No. 6 ' o i l b u r n i n g t e s t s i n , t h e
A l e x a n d r i a PDU ' October 1978
Conducted Coal F i r i n g tests w i t h d r i l l e d
b o l t a i r d i s t r i b u t o r i n A l e x a n d r i a PDU November 1-378 .
Coilducted o i l - c o a l f i r i n g t e s t s w i t h
drilled bolt a i r 'distributor in
A l e x a n d r i a PDU'. . , - January 1979
Coinpl-eted. f i-re damage r e p a i r s a n d p l a n t '

i m p r o v e m e n t s o f R i v e s v i l l e MFB P l a n t February I.!? 7 9

,
Resumed h o t f i r i n g o p e r ' a t i o n o f t h e '

R i v e s v i l l e MFU unit..' blarch 3.379

1.6 Future Planning . '

The f o l l o w i n g a c t i v i t i e s a r e s c h e d u l e d f o r t h e A p r i l , May,
J u n e 1979 p e r i o d :

1)' ' complete h o t f i r i n g t e s t i n g o p e r a t i o n s a n d

i n s t r u m e n t c a l i b r a t i o n o f - R i v e s v i l l e MFB p l a n t .

2 ) Resume p e r f o r m a n c e a n d e m i s s i o n t e s t i n g o f
R i v e s v i 1 l . e FlFB p l a n t . .

3) S t a r t EPA e m i s s i o n c o n t r o l t e s t p r o g r a m a t
R i v e s v i l l e MFB p l a n t .

4) Conduct- f l y a s h . r e i n j e c t i o n performance t e s t s i n
the A l e x a n d r i a PDU.

5) .Conduct bayhoukc f i l t e r perforrrlance t e s t s a t t h e

A l e x a n d r i a PDU,

6) C o n d u c t - p e r f o r m a n c e t e s t s nn n e w soi1rc:e R i . v e o v i l l c
limesto17e in. t h e A l e x a n d r i a P D U .

7 ) . C o n t i n u e New ~ o r kO f f i c e e n g i n e e r i n g s u p p o r t t o
improve R i v e s v i l L e M F i 3 o p e r a t i o n a n d reliability.

8) Complete e v a l u a t i o n o f t h e R . i v e s v i l . l e E'IFl3 p c r f o r n l -
a n c e a t f u l l l o a d a n d p a r t l o a d c o n d i t i o n s . by FWEC.

9) Complete r e p o r t on s t u d i e s o f c o a l . a n d l i m e s t o n e
d i , s t r . i . b u t i o n and i n j e c t i o n s y ' s t e m s a n d f e e d t o
b u n k e r s by ScW.

10) Complete C o n t r o l ~ o o mm o d e r n i z a t i o n s t u d y by S & W .

11) valuate v e n d o r c o s t ,proposa'l.s f o r b a g h o u s e f i l t e r

and h e a t e x c h a n g e r s by S&N.
.. .i
;
2.0 ALEXANDRIA, VA. LABORATORY RESULTS

2.1 - A i r Distributor Testing (Activity No. 114) .

T e s t i n g of t h e d r i l l e d b o l t a i r d i s t r i b u t o r c o n t i n u e d i 1 1 a c c o r c l a n c e .
w i t h .the t e s t prograr!i,descr.ibed i n t h e previous q u a r t e r l y r e p o r t ,
No. 1 4 . . T h e 9 s q f t t e s t g r i d i s a p r o t o t y p e o f t h e g r i d d e s j . g n
now o p e r a t i n g i n D C e l l o f t h e R j - v e s v i l l e b3FB. I t c o n s i s t s of'
2784, 5/16" x 1 8 s t a i n l e s s s t e e l b o l t s on 0 . 7 2 4 " c e n t e r s o n a 1 / 4 "
thiclc carbon s t e e l base. Each b o l t p r o j e c t s 1 - 3 / 4 " a b o v e t h . e
p l a t & and i s d r i l l e d o u t t o 7/64" ( . 1 0 9 4 " ) a t t h e e n d p r o j e c t i n g
i n t o t h e becl., y i e l d i n g a p p r o x i m a t e l y 2 % o p e n a r e a .: E u r i n g opera.-'
t i o n , t h e becl m a t e r i a l a r o u n d t h e ' b o l t s i s n o t f . I u i d i z e d a n d fol-ins
a 1 - 3 / 4 " s t a g n a n t l a y e r w h i c h i ~ l s u l a t e st h e g r i d p l a t e f r o m thc:
h o t £ 1 - u i d i z e d p o r t i o n o f th.e b e d . An u p d a t e d summary. o f a i r
d i s t r i b u t o r t e s t s t h r o u g h T e s t No. 700-38 i s g i v e n i n T a b l e I-.
To d a . t e , a t o t a l o f 184 h o u r s o f h o t t e s t i n g i n c l u d i n g a p p r o x i -
n a t e l y 2 4 s t a r t - u p a n d . shutdown c y c l e s I-lave b e e n c c ~ ! ~ p l - e t e d .

S i n c e e a c h d r i l l e d b o l t r e p r e s e n t s a n o r i f i c e throu.yh t h e b a s e p l a t e ,
t h e p r e s s u r e d r o p a c r o s s t h e d r i l l e d b o l t a i r d i s t r i l ~ u t o rv a r i e s
d i r e c t l y a s t h e s q u a r e o f . t h e a i r ve1ocj.t.y. The . i n i t j . a l a.mbier,.t
t e s t withoul: b e d G a t e r i a l on t h e g r i d p1ci.k v e r i f i e d t h e ' o r i f i c e
e q u a t i o n a s AI? v a r y i n g with thci a i . r flovr r a t e t o t h e 1 . 9 8 8 p o w e r .
Usincj- t h i s r e l . a t i o n s h i p a s t h e b a s e l - i . n e g r i d p e r f o r m a n c e , aiiy
d e . v i a t i o n u s i n g t h e same t e s t c o n d i t i . o n s w o u l d , depe:lcling on ;the
d i r e c - L i o n o f t h e d e v i a t i o n , i n d i c a t e e i t h e r l e a k a y e 01: p l u g y a g e . . .
R e s u l - t s ' o f p r e s s u r e d r o p v e r s u s a i r £1-01x7 r a t e s f o r : t h r e e , no b e d ,
a m b i e n t t e m l ; ) c r a t u r e t e s t s f o l l o w i l s g 0 , ? 4 , and! 184 hours o f h o t
t e s t i n g a r e s11ox::n i n F i g u r e 1. A s sl-~ov!~.~ l ~ yt h e d.aiia, t h c d r i . l l z d
b o l t a i r d i s t l : i b u t o r h a s e x p e r i e ~ l c e dno . ~ i q n i f i c a n ' pt l u y g a c j e o r
l e a k a g e t o clate. F u r t h e r m o r e , r o u t i n e i n s p e c t i o n ; o f t h e plenun
inclicates s i f t i n g t o be minimal.
. . ..
I n T a b l e 2, t h e a v e r a g e t e m p e r a t u r e o f ' t h e g r i d p l a t e , t h e t?r.per.-
a t u r e i n . t h e m i d d l e o f . t h e i n s u l . a t i n g 1 - a y e r , a n d It-lze a v e r a g e ' b e d
t e m p e r a t u r e a r c summarized. From t h i s d a , t a i t c a n be seer1 t h a t
t h e s t a g n a n t l a y e r of bed m a t e r i a l s e r v e s t h e p u r p o s e of i n s x l a t -
i n g t h e g r i d from normal o p e r a t i n g bed t e m p e r a t u r e s .

Large S i c c C o a l Feed - Mi.nirnwn F l u - i d i z a t i o n

( A c t i v i t y No. 1613)

R e c e n t t r e n d s i n FBC t e c h n o l o g y a n d c o l d . l i g h t - o f f d i f f i c u l t i e s
have l e d t o a r e e v a l u a t i o n of t h e p r e d i c t i v e methods f o r c a l c u l a -
t i n g minimum f l u i d i z a t i o n v e l o c i t y . S p e c i f i c a l l y , t h e use of
l a r g e t o p s i z e c o a l w i t h overbed s t o k e r f e e d i n g and t h e t r e n d
toward lower d e s i g n s u p e r f i c i a l v e l o c i t i e s t o improve s u l f u r cap-
t u r e w i l l r e s u l t i n o p e r a t i o n n e a r t h e minimum f l u i d i z a t i o n
v e l o c i t y o f t h e bed. Also, c o l d l i g h t - o f f c o n d i t i o n s set t h e
 Table 1 -
. . ,

summary of D r i l l e d B o l t ' ~ i D
r istributor Tests I

.,

Date Description

'11/13/78 . . T e s t 7 0 0 - 2 6 ; 5 h r . r u n a t 1 5 5 0 ° F folloi,7ed
<
by o v e r n i g h t slump.

T e s t 600-27; 6 h r . r u n a t . 2 0 0 0 ° F f o l l o w e d
b y o v e r n i g h t slump. .. . ,
. I .

T e s t 700-2.82~;.4 4 hr. r u n - a t ,:1550°F i.nc:l.uSi- i

. .
ing t w o non-sc1:ieduled s l u m p s .

Test 700-2813; 1 6 hr. a t i S , 5 0 ° F .

Sl.umping t r a i n i n g f o r o p e r a t o r s ; 4 sluinps
a t 1550°F.

T e s t 700-29; 10 hrs: a t 1700°F.

I s o k i n e t i c ' h o t t e s t s , , 6 h r s . a t 155QO.F;

T e s t 700-30; 7 h r s . a t 1550°F.

T e s t 700-32; 7 , h r s . a t 1442°F.

.
T e s t 702-11; 7 h r . o i l f i r e .test at."1.452"~.
. \ ...

6 hr. shakedown t e s t a t 1419°F.

... . . .
. . n

T e s t 700-33; 6 h r . t e s t o f c a r b o n 1 i . m e s t o n e
. . ',
. a t '1644OF w i t h 3 u n s c h e d u l e d slumrjs.,
. ,
3/15/79 T e s t 700-36: 2 7 h r . C a r b o n L i m e s t o n e '
, ' Company t e s t : . I ...
_,I

T e s t 7 0 0 - 3 7 ; 6 h r . , a b o r t e d c a r S o n l h e .s,. t o n e
t e s t ; , l o s t 1imestoii.e feed *.. .. ,

3/23/79 T e s t 700-3R; 3 1 h r . c o r b b l - i ' > : . l i ~ a e s t o ntee s t

' a t Ca/S of 3 . 0 . .., . . ;
- . -- -. . . . . . .
....,
. . . . . . . . . . . . . : .,:+.* ,..: .
.*I*. . . . . . . . .. ., .... ..-., !..:
j,.. -...<' ;. ;;, $..-.:'<,,: -&7b-<>

T 0....t a E- h o t "&s'ff:,h&uqs
. . .- .,
: ....
I
8& ' . . . . . .. ... .; .. : . ,

. ~ .:
Approximate # of cyd'le~::.;~24 . . ,..: ~,:: . . ... : ..-.
.
:
.
. % : '.
', ... f : 1,.
 LB ;,six ;,.f373; : >;:.?:; 25. ;., \;
m ,,AIR
::;.s :;: ;.: L-..:::
FLOW, Ll3.

. G R I D PRESSUEE VERSES A I R FLObI ..

Figure 1
. . i:
9
 D r i l l e c l ' 1 3 o l t A i r ~ 1 s t r i b u t . o rT e m p e r a t u r e s a t
N o ~ m a lO p e r a t i n g c o n d i t i o n s * * * . ,

.-

T e s t No. Avg. Bed Avg.. A i r * Avy. Fli.d**

'Temp., '.OF D i s t . Temp., Dec76 !.one
"I? T
- I . . , 'F
700-28A 1528 3 5 1. 466

- .- -----
* Avg. of TC 11. # 2 . 6 5 a t t a c h e d from t h e u n d e r s i d e of t h e
I

g r i d 1/8" i n t o t h e b a s e .
** TC mounted P r u ~ lu~n a e r s i d e o f g r i d , p a s s ' i n g : t h r o u g h p l a t e an2
e x t e n c l i n g 7/8" i n t o d e a d zone o f b e d m a t e r i a l .
 d e s i g n volurrie r e q u i r e m e n t s f o r t h e f l u i d i z i n g a i r s i n c e m i x i n g by
f l u i d i z a t i o n o f t h e bed i s r e q u i r e d . O c c a s i o n a l l y , due t o d e s i g n
l i r i t a t i o n s , change i n l i m e s t o n e s u p p l y , o r mixing o f l a r g e c o a l
p a r t i c l e s i n t h e bed, t h e bed mean p a r t i c l e s i z e may become t o o
l a r g e t o h e f l u i d i z e d under s t a r t - u p c o n d i t i o n s . This s i t u a t i o n
h a s o c c u r r e d i n t h e R i v e s v i l l e E.WB and i l l u s t r a t e s t h e n e e d f o r
a c c u r a t e p r e d i c t i o n of t h e minimum f l u i d i z a t i o n v e l o c i t y o f t h e
bed. ,

T h e e q u a t i o n g e n e r a l l y used t o p r e d i c t t h e minimum f l u i d i z a t i o n
velocity is a m o d i f i e d form of t h e Ergun e q u a t i o n . In simplified
form, t h e l?rgun equi11:ion c a n be w r i t t e n a s ;

, where :

= minimurn f 1 u : i d i z a t i o n . v e l o c i t y
"mf
-
- gas v i s c o s i t y
5-1
. ,
= gas.density
Pg
D~ = p a r t i c l e diameter
G. = G a l i l e o number - Dp p g b S - ~~1c-T

g = g r a v i t a t . i o n a 1 , constant-.
- solid .density
ps

.. . .
= v o i d a g e . a t minimum f 1 u ' i d i z a t j . c n

. : Os . = . shape. f a c t o r ,.' . .'

. . . . $ . . - . .. . .

Well and YII' have s u q g e s t e d u s i n g ~ n ~ a @ p r o a i m a t i 6 n f 6 ra+n Sd E m...f "

such t h a t :
 , ..
I
. .
. .

:Th'is g i v e s v a l u e s of A-.and B i n e q u a t i o n :'(.I) of 3'3.7 and .0408 . .

respectively. The I n s t i t u t e o f Gas ~ e c h n 6 l o g ~i *n d e v e l o p i n g a
minimum f l u i d i z a t i o n v e l o c i t y c o r r e l a t i o G f o r m a t e r i a l iiormally
found i n ail FCC, r e c e n t l y c o r r e l a t e d a v. a. i l a b l e d a t a t o d e v e l o p
..t. h e f o l l o w i n g e m p i r i c a l v a l u e s :

, .
~ h k sg i v e s v a l u e s f o r t h e q u a n t i t i e s A and B o f 2 5 . 2 5 and 0.0649
r e s p e c tive1.y.

F i g u r e 2 shows a p l o t 'of t h e calcula.(;ed minimum f l u i d . i z a t . i o n

v e l o c i t i e s of l i m e s t o n e a s a f u n c t i o n of p a r t i c l e s i z e a c 80°P
an.d a t 1550°F f o r b o t h above c o r r 6 l a t i o n . s . The c u r v e s show a
r a t h c r Largc d i f f e r e n c e i n t h e p r e d . i c t e d min.i.m~im flhid:i'z7.atior1
velocities. I n p r - e ~ ~ i . 0c~o ~
l d; r;lii.iimuni. it-:/
11 i . d i z a t i o n - tests, t h e PDT7
, a n d t-.he FBPII haCv&yielded r e s i l l t s ill:a.gl-k.eme~*l with . ' % h o s ep r e d i c t e d
' .by t h e c u r r e l a t i o n of V7en and Yu. However, d u e t o o p e r a t i o n a l
.' d i f f i c t ~ l t i e s , t h e inini~num f l u i d . i z a t i . o n v e l o c i t y .coul.d n o t be
measured under h o t c o n d i t i o n s . To t e s t t h e c o r r e l n $ i o n s u n d e r
h o t c o n d i t i o n s a f o u r i n c h d i a ~ h e t e . r ,p r o p a n e fueled.', h o t c e l l w a s
, used t o ols.l-.ain t h e minimum f l u i d i , z a . t i o r l v e l o c i t y .st- 1 5 5 0 " ~.$rob.
. p r e s s u r e d r o p a c r o s s t h e bed d a t a . ' The t e s t s were a l s o r u n ' a t
80'1;' i n t h e same c e l l .
, '

Two s e r i e s o f t e s t s viere run':j.n t h e f o u r i n c h h o t c e l l u s i n q Carhc!n

1i.mestone i12 t h e f i r s t s e r i e s a n d G r e e r l i m e s ' t o n e i n t h e s e c o n d .
I n e a c h s e r i e s , t h e minimui* fluicl$zati.on v c l o c i t . ~was measured f i r s t
, a t 8 0 ° F 2nd t h e n after one ;llour :of o p e r a t i o n a't 1550°F'. A f t e r a
.'.. minimum f l u i d i z a t i o n veloc$t:y measurement, a .:sample was withd.r&vn
f o r d e n s i t y an2 mean p a r t i . & l e s i z e determina$,$ons, T h r e e t r i a l s
w e r e conducted i n e a c h s e r i e s u s i n g f r e s h l $ $ n s t o n e f o r each
. , trial. f.Iinili;lum fl u i d i z a t ' i o n was d e t e r m i n e d ' 5 1 1 a c o n v e ~ ~ t i o n .a l
,.' manner by p l o t t i n g bed p r e s s u r , e d r o p v ~ r s u s . ' s u p e r f i c i a l vel.ocj.ty.
.. ,' The
. r e s u l t s of t h e t e s t s , :a r e ,.shown i n Table:, 3 .
. . : I

able 4 shows .a compari,son 05.' measured mini-mun? f l u i d i z a t i o n . v e l o c i -

t i e s t o ' t h e v a l u e s p r e d i c t ~ d ~ bt y h e two;.correlations. I n calcu-
l a t i n g t h e p r e d i c t e d v a l u e s , : t h e measured.'mean p a r t i c l e s i z e s and
p z i r t i c l e d e n s i t i e s were use$$. I n this;:,wa$, e f f e c t s d u e to c a l. - .
c i n a t i o n of t h e ljmes.<6nc w e r e c o n s i d ~ r e d . The r e s u l t s i n t h e .

t a b : l e show t h a t t h e &6dict$ipn of Wen:: gnd Yu (Egua.t.ion (2)) . g&vc

r: . t
2: : ;
.., :?!

L.
I n s ti t u t e o f Gas .T-echnolpgy CoaJ, ,.Con~v.ers.ion~. Syst e m - T e c h n i c a l
Data 1978!:!!.:...,i;'$di.,j. ~ . . - 9 , . . " ~ ~ ~:;,:.
: 1 ..,., :4-.:.i.;,i.,.ii'\.
.....
.!;.: ,,,...
,
I...
 Tabie 3
' Summary of Xihinun Fluidization Tests
- -.. . .(Four Inch Diameter Bed) '

Test ater rial Bed Temperature

I ~arti'cle Minimum ~luidization
(C.F) ' Size . .
Veloci tles
(microns) 80'" F 1550°F*
.. . Cold . ' Hot I - (fps) (fps)
I
. . -. . . . ..
. .
I I ' --~ ,

Series I . .

Tr.ial 1 C a r h n LS * 80 1565 1724- . 2.6 3.69

3 It ,.,.
I
A .77 : 1540 . 1724 , ' 2.. 85' '3.13
ti
I' ' 3 88 1570 1724 2.5. 2.85**
I-'
.b
Avera.ge
, ..
81 ! i558
i
1724 2.65 ; 1' 3.72.

series ' 11 ' .

. .
Trial 1 Greer.LS 92 1590 17.85 2.65 3.0
2 2 .5.0
11
78 1535 . 1785 2.6**
.
3 It
:3 8 1560 1785 2.55 3..2

1
. .

Average 82 i561. 2.57 2,95 . .

-
* Superficial velocity under hot cocditions were calculated. using flue gas flow rates and
densities.
** Scatter of d a t ~due :o difficulty j-n. ~easuringfluidization yklocities.
. .
. . ' 0
 Table 4 . .
. . . .
summary of P r e d i c t e d a n d E x p e r i m e n t a l
Minimum F l u j - d i z a t i o n ' v e l o c i t i e s *

Test .Equation 2 Equation 3

Prediction P1:edict.ion

series I
S e r i e s I1

Series I
S e r i e s ' I1

.
...
. .a

I;:
!
.:
.
I,'
..
:
.- :
,- !
b e t t e r r e s u l t s under t h e c o l d c o n d i t i o n s . - T h i s i s c o n s i s t e n t
w i t h e a r l i e r measurements made i n t h e PDU and t h e FBM u n d e r c o l d
c o n d i t i o n s ; however, a t 15.50°F t h e I G T c o r ~ e l a t i o n[ E q u a t i o n . ( 3 ) ]
gave b e t t e r r e s u l t s .

S o l u t i o n of E q u a t i o n ( 2 ) f o r rj and emf, g i v e s v a l u e s o f $I = .57 '

S
and Emf = - .50. The I G T c o r r e l a t i o n g i v e s v a l u e s of bs. = ?82. and
€mf = . 5 2 . Thus t h e major d i f f e r e n c e i n , t h e two c o r r e l a t i o n s
l i e s i n t h e choice of shape f a c t o r s . The r e s u l t s of' 1;hese t e s t s
seem t o i n d i c a t e t h a t t h e s h a p e f a c t o r i s c h a n g e s b e t l ~ e e nc o l d
and h o t t e s t s . . . . - ..

.The sha-pe f a c t o r i s a measure o f t h e r o u n d n e s s of t h e p a r t ; - c l e .

P e r f e c t s p h e r e s have a s h a p e f a c t o r e q u a l t o o n e . The lower t h e
v a l u e o f q:, t h e more i r r e g u l a r t h e s h a p e . Since t h e calcined
l i m e s t o n e . i s s o f t e r t h a n raw l i m e s t o n e , a b r s s i o n n f t h e c a l c i n e d .
l i m e s t o n e ~ a i : t i c l e s c o u l d rresu1.l i n smoother part.i.cl.e,.: thereby
chdngj-ng. .their s h a p e f a c t o r .

The r e c i u l t s n F these t c 6 t s 2 h . o ~t h a t t h e c o i : r e l a t i o n of W e n arid

.
Yu i s acceptab1.e f o r u s e a-;l low t e i ~ ~ p e r a t u r e s E.Iok!evcr, t h e XGY
,

c o ~ r e 3 . a t i o aaj?pc:ai:s t o be more accura:te a t S550°F. I t i s lot

know17 ~ ~ h i c cl oi > : r e l a t i o n wo~rY;s best: a t i n t e r n ; e d i a t _ e tert~pc-raturc:s,
F u r t h e r test:incj v i l l be needed t o v e r i f y :the corre1nt:ion.s i i 7 t1.1"
.
i n te~:inedj.ate t c . r ~ p e r a . t u r cr e g i o ~ s
'

2.3 O i l F i r i n g ( A c t i v i t y No. 1Gi8)

A n a l y s e s of sampj.es froril o i l f i r i n y . T e s t 7 0 2 - 9 conduc.ted i n t h e

p r e v i o u s q u a r t e r were complet:ed. 7'11:~s t e s t was r u n ncii-ig No, 6
o i l a . f t e r minoi- m o d i f i c a . k i o n s t o the o i l f i r i n g s y s t e m were n1ad.e
b a s e d on p r e l i m j - n a r y t e s t s on No- 6 anci No. 2 f u e l oi.1.: T h i s
t e s t r u n was t h e l o n g e s t (11 h o u r s ) a n d m o s t e f f i c i e n t o i l fir:ixrg
test. Su.ff icj.'en.t d a t a w a s c o l l e c t e d t o measure comlausl-ton c f f i , -
ciency'and sulfur capture.

O p e r a t i n g c o n . d . i t i u n s f o r Tes.t 702-9 a r e g i v e n i n Table. 5. Based on

c h e m i c a l ana1.yses of t.he s a m p l e s , t h e cornbur~,tioi~ e f f i c i e n c : ' i ~ ~iil-ld
; -
c a l c i u m t o s u l - f u r m o l a r f e e d r a t i o s repo,rte'h i n T a b l e 5 were c a l -
culated. Using 9 8 % combustion e f f i c i e n c y , la h e a t bal.al.ice aroui3d.
t h e ked i n d i c a t e s t h . a t a b o u t 9 5 % o f .the f u e l i n p u t \?:as burned i.1-I
t h e bed. T h i s h i g h r a t e of i n b e d b u r n i n g wa's confii-med by vi.sua1
o b s e l r v a t i o n . d u r i n g t h e t e s t s i n c e v e r y l i t t l e above bed b u r n i n g .
cou1,d. h e s e e n .
. ... .. .

The s u l f u r c a p t u r e f o r T e s t 702-9 was found. t u bc 9 9 % . T h i s

h i q h . r a t e of m ~ l f u rcapLure was a p p a r e n t from t h e o:treme.ty
low .SO2 e m i s s i i i o s l e v e l d u r i n g t h e ' t e s t . Although a n a n a l y z e r
m a l f u l ~ c t i o nwas s u s p e c t e d , e v e r y e f f o r t t o : f i n d a .problem con-
firmed t h e gas a n a l y s i s . A s 'a f i n a l . confi.rm2tion. b f t h e 2 l u e
g a s a n a l y s i s , c o a l f i r i n g was re:surned a t t h e .end of t h e o i l
f i r i n g t e s t t o v a l i d a t e t h e f l u e g a s a n a l y s i s system r e a d i n g s .
 Table 5
O p e r a t i n g Conditions f o r T e s t 7 0 2 - 9 , 11/1/78

Q 2 i n f i u e gas, X

* D a t a not t a k e n .
** A d d i t i : l n a l Liyesccp.c f?:I to ,c:s!.:i.nP<i:: ;?e:. r - 7 . n 3, .
~ u teo t h e low SO2 e m i s s i o n s l e v e l , . t h e f u e l o i l w a s s e n t t o
two i n d e p e i ~ d e n tl a b o r a t o r i e s for a n a l y s i s . The ' r e s u l t s of
t h e s e . a n a l y s e s a r e shown i n T a b l e 6 . A s c a n be s e e n , t h e
a v e r a g c f u e l o i l s u l f u r c o n t e n t w a s 2 . 3 5 % and t h e vanadium
c o n t e n t was s j . g n i f i . c a n t . F o r t h i s r e a s o n , t h e bed m a t e r i a l was
a l s o a n a l y z e d f o r vanadium and t h e r e s u l t , i s shown i n T a b l e 6 .
S i n c e t h e f u e l o i l and bed m a t e r i a l c o n t a i n e d a s i g n i f i c a n t
amount o f vanadium, i t i s p o s s i b l e t h a t t h e h i g h s u l f u r c a p t u r e
r a t e was due t o . t h e i n f l u e n c e of v a n a d i u n on t h e s u l f u r c a p t u r e
reaction.
>.
' A n o t h e r i n t e r e s t i n g o b s e r v a t i o n from t h e t e s t was t h a t when c o a l "

f i r i n 9 was resume2 a t the end o f t h e t e s t , t h e SO2 c o n c e n t r a t i o r ;

i n t h e s t a c l i illcreased froin 1 0 ppm t o o n l y a b o u t 330 ppin a f t e r
a b o u t a n hour o f c o a l f e e d w i t h a. r e d u c e d C3/S f e e d r a t i o . Since
t h e S O 2 e m i s s i o n d i d n o t inirnediate1.y i n c r e a s e 011 t h e s w i t c h t o
c o a l f i r i n g , ancJ s i n c e t;he l e v e l . of e m i s s i o n w a s l o w e r t h a n .
expcctecl, a c t i v a t i o n of t h e l i m e s t o n e by t h e o i l was s u s p e c t e d .

To f u r t h e r exa.inj.ne t h e u n u s u a l l y h i ~ hs u l f u r c a p t u r e , s c a n n . i n g
e1,ec.tromicrog.raphs (SEi4) of samples o f s u l f a.tecl bed ~nat-rial
were'rnade, t o look f o r p h y s i c a l changes i n t h e m a t e r i a l . Due t o
t h e t i m e d e l a y between sal:~plj_nga n d t h e SEN work, sorne decomposi.-
t i o n of t h e bed m a t e r i a l w i l l o c c u r and o b s c u r e t h b s e c h a n y e s .
F i g u r e s 3 and 4 show some of t11.c electron?icrograa~311s .cchi.ch i:~ercr;l
.made., ~1ic:t:ocry.s.l:aIs of ca 1ciu.m carbonate show up as c h a r a c t e r - .
i s t i c p l a t e s on t h e s u r f a c e o f t h e x a t e r i . a l and a r e ii.el.1. definccl
i n a l l of t h e s e ' j . l l u s t r a t i o n s . These pj.ct1.1res d o n o t i n d i c a t e .
any s~-i?oo~t-.h r o u n d ' s u r f a c e s of bed m a t e r i a l t h a t woulc:! h e indi~-i.i:j.ve
o f a. " s a l t ' e f f e c t " . ~ u r t h e r m o r et i l e y do n o t a p p e a r different
frorn m i c r o q r a p h s of bed m a t e r i a l formed b y b u r n i n g c o a l . Thus
t h e o n l y e2.;planat:ion f o r t h e enhanced s u l f u r c a p t u r e i s due t o
some method of a c t i v a t i n g t h e l i m e s t o n e p a r t i c l e s by an e l e m e n t
i n tlie f u e l .

2.4 Gulf11:r..C a p t u r e ( A c t i v i t y No. 113..0)

;

D u r i n g t h e r e p o r t i n g , p e r i c d c h e m i c a l a n a l y s i s of s a r r ~ p l e sfrom
T e s t s 700-28B and 700-30 trere compl-eted. These t e s t s were r u n
during t h e previous q u a r t e r t o provide a d d i t i o n a l s u l f u r c a p t u r e
r e s u l t s using Greer limestone. Calcium t o s u l f u r n o l a r f e e d
r a t i o i n t h e s e t e s t s were s e l e c t e d a t t h e h i g h and low en.d o f
t h e r a . ; ~ g ..of
e i n t e r e s t t o supplement e a r l i e r . . t e s t d a t a . Sulfur
c a p t u r e t c s t s were a l s o s t a r t e d on L o w e l l v i l l e l i m e s t o n e from .
t h e Carbon Linizstone C,ompany o f L o w ~ l l v i l l c , c'lllio. ' This l i n e -
s t o n e i s cl.~ra:c&l~ t h e s o r b e n t m a t e r i a l suppl-iecl t o the Ritrcsville
MF'B .
 Table 6 '

416 O i l A n a l y s i s a n d B e d 1 4 a t e r i a l A n a l y s i s
T e s t 702-9, 11/1/78

Lab I L a b I1
Carbon, % 85.22 85.76 .
I-iydrogen, % 11.03 10.80
O x y g e n , %' , .'5 3 1;04
Nitrogen, % -19 . , .41
Sulfur, % 2.38 2.31
Ash, % .09 .10
High 1 3 e a t i n g V a l 18,286 18,310
B tux7
Trace Elements
v I PPln 455 690 ( a s V205)
W i , ppm 54 64 (as NiO)
F e , ppm 6 6 1 (as Fe203)
C1, PPm 238 590

Bed ater rial a t 1 4 0 0 h r s .

Sulfur, % 3.58-
Iron, % 2 ..03
Vanadium, % .07
. Calcium, % 38.16
 Test 702-9, 11/1/78

2-F 'r .·
re , 2..1,/4/P .M. 7--B, & 4, 1 .//0/641/·

·-''·.' .2„. '4

t. '.. *r.. 6.......!
4 ··. : ik..ER' 012
':* · .. Im...
-
... ..2... I'....... . *.
,
.......:.:2 ....... . . 9. -4
4 .
ts . 'a< ....1.- .... r
Id- 4
.« 14..AN.....Abil ,
\ 4/*M··/,·1B./....inhk*•' ... .
..... ". ..... ./A.--I
4 * ...':. ,«--,1=3'.'...2 9//+/
311111
.44
.-

f - f . +
r I -flil
1
-,t'. '

1
0 i - , 4 1' ":321 -r.
F#' 61, A"A'.....
A ///.1 -'. ·.
» 1
714 78,49#9*71,1,

Sample 2: Bed Material

(Magnified 10,000 times)

4 .A 4

P '+ 4 4 r -6 . 915
-44 -' #J

:Gis' .

I. I. "-.. .....
,

.1: - 1 , P, . 1',.. 1 g."i., 1,)121,

.
.Z=
1-"IM
»». '' ' I - f i

. . . . ....., 1,4%98' . . : 1 i[Sit.;''J ·'Irt .1 8, 141*--49. -:..'1- .1.11.t»"'

/r , : 9-Fl 'b,11-57' -1.1<Le, '1-Yi .P'itsr .;.

.* , ,- -1 J.4#.... . 2. ... , . , -1 1

„/A-i'-.ij. . .-,_+,21'M

------ - ...+1".,.1.-. -, , 1

Sample 2: Bed Material

(Magnified 10,000 times)
ELECTROMICPOGRAPI]S OF SULFATED BED MATERIAL
20
Figure 3

"
 Test 702-9, 11/1/78

Th:·, '='= ./·..r

·:4
1*

P JI I ,.1. t
I L.,). .

/
i ., : F *
I -

It*

*6. 4
4.

t. 4 . I.

V*-9.':·'1., 4 4....2 .... L i 9..... :1

/4 A .Fige 1./1//.I.Ir

Sample 1: Bed Material

(Magnified 10,000 times)

r:
.'.'.-
-
. i.'..
[¥#S, · ··.,· ·r.»

h.; 4*
4....

1
p.9
A Ye,
+

.=,

14
14

1 '..£

1: Bed Material (Magnified 10,000

Sample times)

ELECTROMICROGRAPHS OF SULFATED BED MATERIAL

21 Figure 4

a
 2.4.1 G r e e r Limestone T e s t s

Test 700-28B was started with &f material f r m T e s t 700-28A aiillrl w a s run for 16
h o u r s a t a n a v e r a g e Ca/S m o l a r f e e d r a t i o of 6 . 7 . The a v e r a g e
s u 1 f u . r c a p t u r e f o r t h e 16 h o u r s was a p p r o x i m a t e l y ' 8 5 8 and t h e
colnbustion e f f i c i e n c y was a b o u t . 8 4 % . Based on p r e v i o u s t e s t
r e s u l t s , 8 5 % s u l f u r c a p t u r e would b e a c h i e v e d a t a Ca/S m o l a r
f e e d r a t i o of a b o u t 3 wl-,en f i r i c g 4 . 5 p e r c e n t s u l f u r c o a l .
The s u l f u r c o n t e n t o f . t h e c o a l i n T e s t 700.-28B shoved a d e c . r e a s e
f r o n 3.4 t o 2.2% d u r i n g t h e . c o u r s e . o f t h e t e s t . This tends t o
l e n d 2ouh-t a s t o t h e a c t u a l s u l f u r c o n t e n t o f t h e c o a l d u r i n g
t h e ' t e s t and co1.1.l.d a f f e c t . t h c u s c f u l i ? e s s o f t h e r e s u l t s . Based
on a v e r a g e s f o r $he t e s t p e r i o d , 8 5 9 s u l f u r c a p t u r e a t t h e h i g h
Ca/S n.!olar f e e d ' i-at'ios may i n d i c a t e t h e e f f e c t o f v low c o n c e n t r a -
t i o n o f SO2 on t h e c a p t u r e r e a c t i o n .

The c h e m i c a l a r i a l y s e s , f o r T e s t 700-30 a r e . s h o w n i n Tal3l.e 7 .

T h i s t e s t was r u n 1-.n ol-1ir.ai.n .l;rancic?nt d u t n oil bed ~ ~ i a t . r ? r icnr?- ai
p o s i t i o n sr!d S O 3 , e m j . s s i o ; ~ sd u r i n g in.i.t..i.d n p e r a g i o n tr.i.th a fresh
l i m e s t o n e bed. The SO2 c o n c e n t r a t i o n i n the s t a c k g a s a s a
r
unction of h o u r s o f o p e r a t i o n is' p3.oS.t-r.r1 in P i q u r n 5 , Fro~n
tl'rese t e s t results . i t c a n be s e e n ' t h a t a s t e a d y l e v e l of m.issi.ons
had n o t been r e a c h e d a f t e r six h o u r s o f o p e r z t i o n on c o a l a t a
. Ca/S rno&ar f e e d . r a t i o o f 6 . To r e a c h . s t e a d y s t a t e e m i s s k o n s ,
e v e n a t ci.very h i . y h C a / S f e e d r a t i o ; a l o n g e r test e f f o r t i's
, "requ:ir-ed anfi s h o u l d be p l a n n e d f o r i n any 1imeston.e e v a l u . a . t i o n
test:;. Bed m a t e s i a l bamples showed no s i g n i f i c a n t change. in
sulfur content for t h e t e s t period.

2,4.2 L o w e l l v i l l e Limestone 'Tests

'Test 700-36 was t h e p r c l i r n i n a r y t e s t run. u s i n q Lowel-1~rill.e1-i~ne-

stone. O p r a t i n g cond:i.tions f o r t h e t e s t a r e give11 i.n T a b l e 8 .
Limestoile f e e d w a s e r r a t i c t11roughou.i t h e t e s t , however, anci" v.ra s
f i n a l l y l o s t a f t e r a p p r o x i m a t e l y f i v c t o s e v e n hours of s t e a d y
s t a t e operation. Thus, s u l ' f u r c a p t u r e r e s u l t s were n o t d e t e r -
mimed.. .The t e s t was c o n t i n u e d f o r a n o t h e r t w e l v e h o u r s w i t h r;o
l i m e s t o n e feecl t o a l l o w t h e bed t o r e a c h a s a t u r a t i o n p o i n t i n
terms of s u l f u r capture. During t h i s p e r i o d , f l y a s h s a m p l e s
were t a k e n a n d l a t . e r a n a l y z e d f o r c a l c i u m . S i n c c more t h a n 9 3 8
of ' a l l calcium i n p u t i s i n t h e limestone, t h e c a 2 c j . 1 ~ i n~ t h e
f l y a s h i s a means o f comparing l i m e s t o n e a t t r i t i o n c h a r a c t e r -
istics. F l y ash c a l c i u m v a l u e s f o r T e s t 700-36 ransjed from 1 2 . 5
t o 1 6 . 3 p e r c e n t , comparable t o t h o s e when t e s t i n g G r e e r limestone.
A more d e t a i l e d . comparison w i l l be rilade when r e s u l t s o f f u t u r e
tests are availahl~.

T e s t 700-38 was a L o w e l l v . i l l e l i m e s t o n e t e s t r u n a t a Ca/S rnolar

r a t i o of 3 . 0 . During t h i s 31 h o u r r u n , s e v e r a l s a m p l e s were
t a k e n t o p r o v i d e s u l f u r c a p t u r e and f1.y a s h c a l c i u m d a t a . A
' l i s t of o p e r a t i n g c o n d i t i o n s i s g i v e n i n T a b l e 9 . Samples a r e
c u r r e n t l y being analyzed.
 Chemical ~ n a l y s i sof Bed Material
Test 700-30, 12/28/78*
) ..
- - -
.Time . Calcium ' Sulfur .

-
-
'* All analisis are listed as percentages.
SO2 ECISSIONS VERSUS T I R E FOR TEST 709-30
. .

(Fresh Limestone Bed Light-0kf)

' Figure 5
 ...

..' . .
..... .
4 ,
-
'.T
T z b l e '8
......:, . . 3perating Co?4itions
., .
for Test 700-36, 3/15/73
.-
The, H r s . ] 1133 ;5- .,,!GO $
!!
I C ? ~ 1930
B
:lo? 'iL?d
0230
i.. ::
2
2 P:i li
i!
3 3
' !
1 pI!
Fuel f $ -:. i:' -d
0,
:1- 2
I! 1 i
ii 5 ;
i
3l.C T e q . ,

g 2 i n f l u e gas,,
k
.f
fi
lI63

I , , 4.0
< 1544
f

6.0
%
$
1556

6.0
jj
1
1563

6.0
11
1531

6.0
a
$ 6.0
5508

6.6
I 1543

5.0
11481

7.0
.-
reel f e e d i z t ~ ,lb/i.,r (Coal). '
- .
:: .
5jL
,,-:

'
$
332 I 329
Li

$ 970
!?
g
945
C
-!:
9E6 z
F
955
6
948. g 707
i'
8

3 : ~ash collection r a t s , Zb1.h"

--
-..- -- ..- - -.
- .
ra,ies:cnc f e e d rate, Ib/!lr .
. .-......
i's .G7.

~i! Zed draia rata, lbfi-r

, .
stac> d n s t rate, : b / h ~ .'. ......... ........
. . . . . . . . . . . . --.- -.
..,+-
xt 4 :air flow r z t 3 , Ib/hr
-,c:EL 2j-f f l o rctc,.
~ tbjhs

Sclerf$cizl velocit7, ~ ? / s c c '

-
. .

SO?;, ;pa
-
* 3ata n c t taken.
Gk No l i m e s t o n e f e e d , f e e d e r i n o p e r a t i.v e -.
 Table 9 .
Operating C o n A i t i o n s for Test 700-38,. 3 / 2 2 ; / 7 9

-~ a t a iair flow r a t e , 1b:h.r

* Data not taken \

2.5 F l u e Gas Baghouse Program ( A c t i v i t y No. 1620)
The i n s t a l l a t i o n of a f l u e g a s baghouse was completed d u r i n g t h e
r e p o r t i n g p e r i o d . 'This baghouse was d e s i g n e d and f u r n i s h e d by
B u e l l Emission C o n t r o l , D i v i s i o n o f E n v i r o t e c h , t o t e s t t h e
a p p l i c a t i o n of f a b r i c f i l t e r s t o t h e c o a l f i r e d f l u i d i z e d bed
p r o c e s s . Using a bag m a t e r i a l of t e f l o n c o a t e d f i b e r g l a s s ,
d i f f e r e n t c l e a n i n g methods and a i r t o c l o t h r a t i o s can b e
t e s t e d a t 400-500°P s t a c k t e m p e r a t u r e . I n i t i a l o p e r a t i o n of
t k e a s y s t e m w i l l u s e r e v e r s e . a i r and/or shake bag c l e a n i n g mode.
A d e s c r i p t i o n of t h e baghouse t e s t system i s g i v e n i n p r e v i o u s
Q u a r t e r l y Report, No, 1 4 .
Work c o n p l e t e d d u r i n g t h e r e p o r t i n g p e r i o d i n c l u d e d t h e r m a l
i n s u l a t i o n and i n s t a l l a t i o n of e l e c t r i c a l and pneumatic c o n t r o l s .
T h i s work w a s delayed a p p r o x i m a t e l y f o u r w e e k s due t o abnormally
s e v e r e w i n t e r and snow c o n d i t i o n s . T i e - i n of t h e e x i s t i n g
induced d r a f t f a n t o t h e c o x p l e t e d baghouse t e s t system i s i n
p r o g r e s s . The i n s t a l l e d equipment i s shown i n F i g u r e 6. The
p r o c e s s and i n s t r u m e n t flow diagram f o r t h e s y s t @ m i s shown i n
F i g u r e 7.
To o b t a i n u s e f u l i n f o r m a t i o n from o p e r a t i o n of t h e baghouse
w h i l e c o n d u c t i n g planned t e s t a c t i v i t i e s on improved s o r h e n t ,

u t i l i z a t i o n and l a r g e s i z e c o a l f e e d l a t r e n d toward i n c r e a s e d
d u r a t i o n t e s t r u n s i s planned. To meet t h e g o a l of l o n g e r d u r a -
t i o n t e s t r u n s on a r o u t i n e b a s i s , m o d i f i c a t i o n of t h e f l y a s h
h a n d l i n g system i s n e c e s s a r y t o s i m p l i f y d i s p o s a l . Depending on
t h e demand f o r s u l f a t e d l i m e s t o n e t o s u p p q r t u t i l i z a t i o n s t u d i e s ,
improvements i n spent bed d i s p o s a l may a l s o be n e c e s s a r y .
Planned m o d i f i c a t i o n s t o t h e f l y a s h system i n c l u d e r e c y c l e o f
f l y a s h from t h e main cyclone t o t h e PDU, r e l o c a t i o n of f l y a s h
weighing hopper t o t h e new f l u e g a s baghouse s o l i d s o u t l e t , and
t r a n s p o r t of f l y a s h t o a s u f f i c i e n t e l e v a t i o n f o r g r a v i t y d r o p
t o disposal bins. These changes a r e d e p i c t e d i n t h e f l o w diagram
i n F i g u r e 8. With t h e s e m o d i f i c a t i o n s , t h e need t o weigh t h e
main c y c l o n e c a t c h w i l l be e l i m i n a t e d ( f o r ' m o s t t e s t i n g ) and t h e
s e n s i t i v i t y of e f f i c i e n c y r e s u l t s t o flue g a s i s o k i n e t i c sampling
w i l l be g r e a t l y reduced. The o v e r a l l r e s u l t s h o u l d be s i m p l i f i e d
f l y a s h d i s p o s a l and reda.ced e f f o r t d u r i n g t h e c o l l e d t i o n of t e s t
data .
 6 ,

FLUE GAS BAGHOUSE AS INSTALLED AT ALEXANDRIA, V I R G I N I A

28 Figure 6
STACK' GAS BAGHOUSE FLObf DIAGPi4P!
 3.0 RIVESVILLE MFB PLANT OPERATIONS

3.1 General

The f i r s t q u a r t e r o f 1 9 7 9 .was a n o u t a g e - t o - o p e r a t i o n s
t r a n s i t i o n , p e r i o d , f o r t h e R i v e s v i l l e MFB. . he d e m o l i t i o n
a n d r e c o ~ ~ s t r u c t i ocnf , f o r t w a s r e p l a c e d b y a n o p e r a t i o n a l
check-out period. containing no unusual problems a s s o c i a t e d
' w i t h e q u i p m e n t ,' de,sj.gn, a n d c o n t r o l c h a n g e s .. - M o d i f i c a t i o n s
t o t h e b e d m a t e r i a l / f l y a s h s y s t e m a n d t h e Beckman g a s ,
. analysis sys~e$ cluring .the o u t a g e , provcd ' t o b e s i g n i f i c a n t
i m p r o v e m e n t s . ~ r e l i h i n a ro ~b s e r v a t i o n s i n d i c a t e d t h a t t h e .
" n u t s a n d l ~ o l t s "a i r d j - s t r i b u t o r i n t h e CUC w a s a. s u c c e s s f u l
d e s i g n change. A s equipment and inst.rumentation improvements
w e r e c o r n p l . . e t e d , e a c h s y s t e m was o p e r a . t e d a n d / o r t e s t e d t o
- i n s u r e p r o p e r i n st a l l a t i o n . T h e e q u i p l n e n t / s y s tenis: c11ecI~-o.ut
w a s f o l l o w e d i.1; mid-March b y a s u c c e s s f u l . l i g h t o f f .

3.2 P l a n t ,Outage

BueL1 cornp1.et.ed r e c o n s t r u c t i o n a n d a i r f l o w t e s t s o f t h e
e l e c t r o s t a t i c : p r e c i p i t a t o r o n 7. F e b r u a r y . The a f i r f l o w t e s t s
i n v o l v e d h a v i n g a s a f e t y - e q u i p p e d , man i l I s i . d e t h e b o i l e r
duri.ng c o l d a i r o p e r a t i o n o f t h e f a n s .

01;~: o f t h e l a s t r e n . ~ a i . n i n g t a s k s t o be a c c o m p l i s h e d . d u r i n g
t h e , o u t a g e w a s p ~ u r i n yo f a new i n s u l a t i n q . r o o f o n t h e p r e -
cipitator. ~ u b . - f ~ : & e z ti ei m ~~peratulres prcvenJed pourinq b u t
' o n . 1 5 F e b l 7 u a r y ,. t h e iciercul:lr r o s e a b o v e 32 OF . a n d the j o b was
completed.

C o m p l e t i o r i a n d ' b a l a n c i n g o f t h e new a n d ' l a r y e r ID f a n a s ,

w e l l a s . t h e FD f a n w a s . a c c o n i p l i " s h e d . i n ~ a n u a r y ' l T h e y w e r e ,

bumped, c o u p l e d , a n d a c c e p t e d o n 1 8 ' J a n u a r y .

V i b r a t i d n m o n i t o r i . n g h e a d s w e r e i n s t a l l - e d o n .the f a n f o u n d a t i . o r r s
d u r i n g J a n u a r y a n d , v i b r a t i o n r e a d i n g s r e c o r d e d o n 27 ~ a n u a r y .
They are l i s t e d below:
.. ......
. .
.I..D..
- ".
~
FAN. ".. .. .......
...
. Fan
... Motor ' - /

-
. . . . . . . . . . . . .
".
1ior'i.zoiital. 0.07 m i l s 0.i12 m i l s
Vertical : : .. . . . . . . ,.9 .4 2 mi.^.^.. .,-.. . . . . . . . . . _ . . ....*.
. . mils
. ..0,$2
Ax-ia 1 . .. , 1.4 mils .0.90 m i l s
...
.?.
. . . . . . . F,D. FAN

0.11 m i l s 0.08 m i l s
0.06 m i l s 0.04 m i l s
.-
Axial I

0.02 m i l s 0 . 0 3 mils
The ductwork was corripleted i n c l u d i n g 1-ead sheat.hing which
w i l l r e d u c e a m b i e n t . n o i s e o r i g i n a t i n g i n t h e ductwork.
. .

The steam s i l e n c e r s have been e x t e n d e d ' and r e d i r e c f e d t o . ''

r e d u c e ambient n o i s e l e v e l s and p r o v i d e s a f e a c c e s s t o t h e
s t a c k p l a t f o r m sampl-ing s t a t i o n . A s t a c k s i l e n c e r was a l s o
i n s t a l - l e d t o f u r t l l e ~reduce zmbient n o i s e l e v e l s . I
. .

Uuriny the out.age, t h e mal;e~zp f e e d w a t e r c a p a c i t y was i n c r e a s e d

6 0 % d u e :to r e l o c a t i o n and e x p a n s i o n of the Ecolochem c l e n ~ i n e r a l -
j - z a t i o n h e a d e r s .' The prevj-ous s e t u p (i.e . t h e Ecolocliem
t r u c k s ou.tsi.de, f i r e hose hooliup, e t c . ) a l l o t \ ~ e da ma>:im>lm flow
of 2 0 0 gn:L.l.ons per m i n u t e . There a r e now two p.ipe h e a d e r s
i - n s i d e t h e p l a n t , e a c h w i t h t h e c a p a c i t y of 1-60 g a l l o n s p e r
minute.

The a i r p r e h e a t e r (API.1) i n s . t a l l a t i c i l , i n c l u d i n g r o t o r ,
d r i v e motcir, o i l . 1~1o.t-.or, s,ul.enoid, and f i T t e r was compl.t~>ted
i n J ~ I I L I ~ I'rhe
C Y main
. d r i v e was bunipecl 2 2 J a n u a r y a n d con-
f i.rmed .to be o p e r a t i n g p r o p e r l y . I n i ~ ~ i d i , t i . o nthe
, Lieluge
~ y s t s mi 3 i n lace and o p e r a t i o n a l . .

The coal. 1-1al-idI.inc~ system was completed and o p e r a t i o n a l

i n c l u d i - n y i - e l o . c a t i c n o'f t h e Hotex s c r e e n , i n s t a l l a . t i o n o f
t h e 7 5 f o o t ) > e l - tconveyor r e p l . a c i n g . t h e 1 0 2 f o o t R e d l e r ,.
a n d r e l o c a t i o n o f t h e cod1 C I T U S I ~ . C ~ .

An extension of t h e d a t a 1.ogy.i.ny (!'>o:ric) egu..iprnent h a s )>eel7

added i n t h e C o n t r o l Room .to p r o v i d e a culnvc?nient secondarlr
read-out .

A f t e r b e i n g s u c c e s s f u l l y t e s t e d a t t h e Al.exa~?dria~ i b o k a t o r y , '

a decis,j.o~.i was made t o i n s t a l l a hollow b o l t a i r d i s t r i b u t o r

i n t h e CI3C o f ' t h e F11?13. The g r i d p l a t e . c o n s i s t s of t w e l v e .
s e c t i o n s compared t o n i n e . s e c t i o n s f o r t h e t h i n p l a t e .
E x h i b i t 1 i l l u < . t r a t e s .the 1101 l n w b o l t and h o l l o \ , ~b o ! . ~
cpac.i:ncj .

.The d u s t problem a s s o c i a t e d w l t h limestone d e l i v e r i e s h a s

been a l l e v i a t e d by i i ~ s t a l l a t i o nof a baghouse f i l t e r f o r t h e
l i m e s t o n e bunker t r a n s p o r k a i r d i s c h a r g e . Only' s m a l l
amounts of d u s t can iiow be d e t e c t e d o u t s i d e t h e e n c l o s e d
bunker a r e a .

A new Betalarm p a n e l h a s been i n s t a l l e d t o improve t h e '

s a f e t y and o p e r a t i o n a l rc?sponsc of the p l a n t . The p r e v i o u s ,
a n n u n c i a t o r had 6 0 alarm p o i n t s a v a i l a b l e . Alt!-~uugh a l l '

of t h e windows. i n t h e new p a n e l a r e n o t y e t c o n n e c t e d ,
1 1 5 have been l a b e l e d and 15 new a l a r m p o i n t s have been
. i n s t a l l e d and t e s t e d .
 -
IICJ.
:
tIOtLf181'tILSI U. . U I V .?'I33
A l t h o u g h t h e o u t a g e was e x t e n d e d d u e t o c e r t a i n " u n p r e -
d i c t a b l e ~ " , i t was d e c l a r e d o f f i c i a l l y e n d e d a t 1600 h o u r s ,
1 6 F e b r u a r y 1 9 7 9 . The " u n p r e d i c t a b l e s " c a u s i n g t h e 20 d a y
extension included;

a. B u e l l c o n s t r u c t e d a n u p d a t e d f l o w model a n d a s a
r e s u l t of a n a l y s i s , modified t h e i r o r i g i n a l flow
guide design.

b. . A new, l a r g e r I D F a n a n d a s s o c ' i - a t e d d u c t worl.;: was

designed, s p e c i f i e d , purchased and' i n s t a l . l e d .

c. D i s a s s e m b l y o f t h e a i r p r e l ~ e a t e rwas more cornpl-ex

t h a n o r i g i n a l l y a n t i c i p a t e c i . . R o t a t i n g p a r t s were
a n a l m o s t . t o t a l " m e l t down" a n d toolc t h r e e weelis
l o n g e r t h a n o r i g i n a l e s t i m a t e t o removc.f ~ r o mr o o f .

d. The o r i g i n a l 2 4 w e & s c h e d u l e had b e e n pr*c.r?dictecl

o n a 2 0 A u y u s t DOE releaso. While work w a s i n i t i a -
lied the f i r s t weel< i n Sep.teinber, t h e DOE r c l - e a s e
w a s . r e c e i v e d 18 October.

e. From 6 J a n u a r y , t h r o u g h t h e e n d o f the ~ r t o n t l ~t ,h e
o u t s i d e t e m p e r a t u r e was n e v e r a b o v e 3 2 " F , making
' i t i m p o s s i b l e t o p o u r , t h e r o o f of t h e e l e c . t r o s - t a t : i c
precipitator (ESP).

3.3 N e w DC-1 Damper

A t t h e t i m e t h e r e c o n s t r u c t i o n a n d moderni:zat.ion o u t a g e was
- --
compl.eted and t h e I\IPB u n i t was a v a i l a b l e $ o r o p e r a t i o n ; M o n o n g a l ~ c ? ~ ? ~ ,

P o w e r Company's # 7 b o i l e r was o u t o f s e r v i c e f o r an i n d e f i n i t e
p e r i o d o f t i m e d u e t-o f u e l . s h o r t a g e s . Because t h e u n a v a i l a b i l i t y
o f f e e d w a t e r p r e v e n t s MFB o p e r a t i o n , t h e u n i t w a s - d e c l a r e d
'

u n a v a i l a b l e a n d w o r k proc~+ededo n i n s , t a l l a t i o n o f t h e DC-1
damper.

The p u r p o s e o f t h e damper i s t o i m p r o v e t h e d u s t c o l l e c t o r
e f f i c i . e n c y a t low , l o a d s (when o n l y c e l l s D a n d C a r c i n s e r v i c e ) .
T h i s i s a c c o m p l i s h e d by i n c r e a s i n g t h e v e l o c i t y t h r o u g h t h e
d u s t col1ec:tor. v e n d o r d e l i v e r y prob'lems h a d d e l a y e d t h e
i n s t a l l a t i o n (See E x h i b i t 3 ) .
3.4 Bed M a t e r i a l T r a n s p o r t M o d i f i c a t i o n s

u u r i k g t h e o u t a g e ; m a j o r m o d i f . i . c ~ t i u r i owere made t o t h e bed

r n a L e r i r 1 .L;.cansport s y s t e m . Exhibit 4 i l l u s t r a t e s scnematically,
t h e modified system.

The c l a s s i f i e r ' w i t h t h e s c r e e n s removed, now s e r v e s o n l y a s a

t r a n s p o r t d u c t . The r o t a r y feede~:s a t e a c h e n d o f t h e c l a s s i f i e r
 EXISTING
Zx3ihit 4
. .
BED Y L ~ T E ~ U ATF2\BSHCRT
L i.43DIFICATIONS
h a v e b e e n removed. The b e d m a t e r i a l ' i s now t r a n s p o r t e d by
a n . u p s t r e a m . vacuum o f 2 " - 3.4" Hg c r e a t e d by t h e new s t e a m
e j e c t o r s u t . i l i z i n g 1 6 0 PSIG s t e a m . The C . B l o w e r w h i c h u s e d
t o s u p p l y t h i s t r a n s p o r t a i r i s now u s e d f o r a u x i l i a r y ,

purposes. . b

3.5 Results

3 . 5 . I- . A i r f l o w T e s t Accomplj-shed

D uring t h e months o f J a n u a r y a n d F e b r u a r y , c a l i b r a t i o n t e s t s
.were p e r f o r m e d o n a l l a i r f l o w m e a s u r i n g d e v i c e s i n the com-
b u s t i o n a i r and au,ij.liary a i r systems. 'These c a l i b r a t i o n s
w e r e made b e c a u s e sonle p r e v i o u s a i r f l o w m e a s u r e m e i ? , t s w e r e i n
doubt. T ? s t c o i ~ d i t i o n sf o r t h e Au;:il..iary F D F a n t e s t s a r e
shown i n E x h i h i t 5 a n d f o r t.he F D - I D -Fan .tes.ts i.n Ex11ibj.t 6 .

Test Procedures

I n ' b o t h s e t s o f a i r f 1 . o ~t e s t s , a p i t o t t r a v e r s e o f . t h e
a p p r o p r i a t e f a n d i s c h a ~ : . q ew a s l?erformccl. Sketches .of.
pi.to1: t r a v e r s e I . o e a t i o n s a n d poi.l.:ts a r e . shown . i n E x h i b i t s
7 t.hrougll 1 0 .
. - ,, ' 4

P r i o r t o t e s t i n g , a l l . serising l i n e s w e r e l e a k checked
a n d hl.own o u t . . A l l i i ~ s t r u r i ~ e n twere s z e r o e d a n d cl-iecked.
I n a1.1. c a s e s , bihere a p p l i c a b l e , j . n s t r u m e n . t s were p l . a c e d
a s close a s p o s s i b l e t o t h e measuriricj d e v i c e .

I n a l l t e s t . s , c o n d i t i o n s were a l l o w e d t o s t a b i l . j . z c b e f o r e
d a t ' a c o l . l . e c t i . o r ~bega.n. D a t a w a s talcen a . t f i v e m i n u t e
i n t e r v a l s and two c o m p l e t e p i t o t t r a v e r s e s w e r e p e r f o r m e d
f o r each condition.

11-1 o r d e r t o m a i n t a i n s i m i l a r c o n d i , t i o n s f o r v a r i o u s t e s t
r u n s , d u c t p r e s s u r e ' w a s c l c j s e l y r n c n i t o r e d .a n d. r e s t o r e d
t o same.'pressur.e f o r a l l c o n d i t i o n s . . .
'
Duck t c i ~ q p e r a t u ' r e swe..?-e m n n i t o r e d by a D o r i c D a t a l o g g e r
every f i v e minutes.

Test Results.

Equations used:

1. p = . a 9 6 5 8 [PD: + ' (PB) ( 1 3 . 5 9 5 ) ]/(TD' + 460)

where :
. . .

.
p - a i r density ( l b / f t 3) 3
. 0 9 6 5 8 - d e n s i t y c o n s t a n t @ 6 0 % RII ( l b / . f t . )
,

PD - ' d u c t p r e s s u r e ' ("'WC)

PB - ~ a k c i z r ~ o t ' r pi .:~r c s . s u r e ("Mg)
T D :- D.ugt temp,i?:r:.%urcr;:. (O.l?) . . . . .. . .
. , - . . .,
.. . , .
FD -- I D Fan T e s t s

1. Airfoil airflow

M ~ =
~ 1,333,256
. / ----.-.---
APAF. '

= a i r f o i l a i r f l o w (lb/hr)
M~~
= ' a i r f o i l d i f f e r e n t i a l ("NC)
"AF

pA17 =
air density a t a i r f o i l

,
2. C e l l Annubars
! . -

A cell
F

B, cell
1- . -I

where :

MX,,',jp;* = Ce1 1 a i r f l o v ~from ~ i i i i u b d r ( i b / ' h r )

*'XN
. .
- cell
..
n o r i h a n n u b a r ' d i f f e r e n t i a l ("WC)

= cell s o u t h annubar d i f f e r e n t i a l ("wc)

APxS
'. .
- D 1 a n n u b a r d i f f e r e n t i a l ("WC)
I .. . . . ..

3. G r i d p l a t e AP v s airf.1o.w
. , -:
. .

A cell
 where :
V
P
- p i t o t v e l o c i t y (fpmj (from rnfg's e q u a t i o n )
AP
P
- p i t o t d i f f e r e n t i a l p r e s s u r e ("WC.). . .

A u x i l i a r y FD Fan T e s t

..' 1. Aux.. FD Fan p i t o t - Venturi

where :

= a u x i l i a r y . 17.D. a i r f l o w ( l b / h r )
M~~~
3 '
= Aux F .D'. a i r densjty (lb/f t )
P~~~
=" Aux F . D . f a n p i t o t - v e n t u r i 2 i . f f e r e n -
A P ~ ~ ~ t i a l ("WC)

2. V i b r a t i n g F e e d e r Annubars

where :

MVF = a i r flow t o v i b r a t i n g f e e d e r (lb/hr)

= v i b r a t i n g f e e d e r annubar d i f f e r e n - -
A P ~ ~ t i a l ("WC) .
=.' vibrating feeder a i r density
'VF

3. Burner A i r f l o w ,
----.-

'BRN = 2 8 , 2 5 8 J a p I I N pRFD
_.'".. '

where :

= burner a i r f l o w .
M~~~
= b u r n e r . a n n u b a r . d i i f e r e n t i a l ( "WC)
A P ~ ~

S e a l a i r ' a n d b e l t f e e d e r l e a k a g e . a i r c o u l d not b e
determined. For t e s t i n g , seal. a i r w i l l be v a l v e d ' o u t .
 C cell

D cell

where:

'&GRID = c e l l a i r f l o w from g r i d p l a t e d i f f e r e n t i a l
(lb/hr) %

= a i r d e n s i t y based 011 undergrid press ("WC)

Px
APXG = c e l l g r i d plate d i I f e r e n t i a l ("i(qC)
, :

4. Main C e l l s A n ~ ~ u b a r

= main cells a n n u b a r a i r f l o w ( l b / h r )
Mi'4~
= Maill C e l l s ~ n h u b a r D
; i f f e r e n . t i . a l . ( "ifJC) . ,
"MN

5. D C e l l P.i.tot - Ventuxies

M~~
= D cell airflow frompitot - venturies

' A'DI.: = D cell, e a s t p i t o t - v e n t u r i . d i f f e r e n t i a l ("WC)

...
.....
= D c e l l w e s t p i t o t , . - vellrpr5 ' d i f f e r e n t i a l ("WC)
"DM . ..
, . . . ...
R e s u l t s a r e d e p i c t e d g r a p h i b ' ~ ~ las: y lilow R a t c v n . A?? i n ~ l r c
L u l l o w i n g s e L uf ' , g r a p h s , . , E x h i b i t s 11 t h r o u g h .2.2.
. . . . . ..
., .
. ~ o n c l ~ u s i o nasn d ~ e c b ; m m e n d a t i o n & . .
t . '
. .
Based on o b s e r v a . t i o n s made d u r i n g . t e s ~ s ,a i r f l o w
t e s t s a n d A l e x a n d r i a e x p e r i e n c e , t h e f o l l o w i n g recomrnendatiolls
i

a r e made: . ,

. ., ,.. . . .
., . ., . . .. ...
.. . .
.
.
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. - , .
L..,
.
'

. ,
. . . . . . . . ...............
,, . . . . . . . . .. . ... . .. . . . . . . . . .
 . .
-
AUSILX?xRY 7.Do !?Xi TEST CONDITIONS
1
..- .

1
I C O M M E N T S 1

" .
1-3s . . I-.
I
C.lL.E;;/79

Exhibit 5
FD-ID FAN TESTS C O N D I T I O N S & COlG1I%NTS

Exhibit 6
Main A i r S m n 2 l i 1 l g Location
Main A i r Due.';. Stimpling ~ o n ~ j . ~ ~ d t i o n

Traverse
Point

,-
I.'
 Aux A i r Duct Samp1.ing Location

Traverse P o i n t Nun3er on Dimet,er Traverse Point 'Location on Dirimetcr

(inches )
1.0
1..6
2.8
4.4
6.6
12.7
1lc.g
16.4
17.7
18;2'
EXHIBIT 11
EXEIXBIT 12
E X H I B I T 15
EXHIBIT 16
1. U n t i l f u r t h e r t e s t i n g can be performed on g r i d p l a t e
AP . v s . ' 2 i r f l o w , t h i s measurcinent s h o u l d n o t b e u s e d
w i t h ' a "hot." c e l l . B a s e d on d a t a a c c u m u l a t e d a t
A l e x a n d r i a , t h i s f u n c t i o n changes g r e a t l y between h o t
and c o l d c o n d i t i o n s . F u r t h e r tests w i l l be performed
o n g r i d p l a t e AP a s t h e u n i t i s p l a c e d i n s e r v i c e . .

2.' D u e . t o l e a k a g e r a t e s t h r o u g h k c e l l , A ' c e l l dampe.rs

s h o u l d . b e bl-anked p r i o r t o t e s t i n g .

3. A& FD f a n s e a l a i r s h o u l d r e m a i n v a l v e d o u t d u r i n g
testing. T h i s w i l l n o t i n h i b i t u n i t o p e r a t i o n and
' w i l l result i n less error i n t o t a l airflow.
,
. ..
Based on a r e v i e w o f a l l d a t a . ; t h e : e x p e c t e d e r r o r is. t 5 % .

Damper l e a k a g e s f o r e a c h c e l l a r e a s f o l l o w s :
. .
CELL LEAKAGE (lb/hr)

A 30,O.OO

B 23,500.

C 23,000

3..5.2 B e l t F e e d e r T e s t s Complete

A l l b e l t f e e d e r c a l i b r a t i o n : t e s t s have been conlpleted.

The f e e d e r s were c a l i b r a t e d s o t h a e t h e f o l l o w i n g ' t h r e e
r e a d i n g s would a g r e e a s c l o s e l y a s p o s s i b l e :

a. C o n t r o l Room Hand/Auto % S e t t i n g
b. SCR Motor V o l t a g e
c. S t r i p C h a r t . i n c o n t r o l Room

~ a c h : o ft h e s e was compared t o a n e m p i r i c a l v a l u e , i . e . , t h e
a c t u a l w e i g h t o f coa.1 i n o r d e r t o g e n e r a t e a c u r v e o f " L b s / h r
C o a l F e e d " v s . "Hand/Auto % S e t t i n g " .

3.5..3 F u e l and S o r b e n t

~ u r i n t h ~e f i r s t q u a r t e r o f 1 9 7 9 , 131.4 t o n s o f c o a l a n d 719
t o n s o f l i m e s t o n e were d e l i v e r e d t o t h e MFB. The f o l l o w i n g
t a b l e s u m m a r i z e s t h e a s - r e c e i v e d q u a l i t i e s o f t h e coa'l:

COAL

Total lloisture 2.05%

Carbon 71.16%
Hydrogen 5.16%
S1.a I. .F-'i)
r 2.91%
Ash 15.05%
Heating 'Value ( ~ t u / l b ) 12,717
 3.5.4 Test Plan

F i n a l - p r e p a r a t i o n s f o r t h e upcoming e m i s s i o n s a n d p e r f o r m a n c e
t e s t p l a n were f i n a l i z e d . I t e m s s u c h as s t a f f i n g , g a s
a n a l y s i s , o r g a n i z a t i o n , c o m p u t e r p r o g r a m s , e t c . , were com-
pleted. A summary l i s t f o l l o w s :

a. Approximately. 2 5 p a r t - t i m e temporary employees

w e r e h i r e d t o d o i s , o k i n e t i c work a n d d a t a g a t l l e r i i l g

b. S c l i d s sampling systems w e r e i n s t a l l e d and t e s t e d .

c. R o t a t i o n c o u n t e r s w e r e i n s t a l l e d on l i m e s t o n e a n d
drain rotary feeders.
- I! .:

d. T h e Beckman g a s a n a l y s i s s y s t e m p r o b l e m s h a v e b e e n
s o l v e d a ~ : d , i r i the case of many o f t h e a n a l y z e r s ,
redundailcy h a s been- added.

e. Data s h e e t s f o r t h e Data A c q u i s i t i o n P e r i o d s a r e
complete.

f. I s o k i n e t i c s t a t i o n s h a v e b e e n made r e a d y f o r u s e by,.
GCA C o r p o r a t i o n a n d t h e d a t a t e c h n i c i - a n s .

g. Computer p r o g r a n s a r e i n f i n a l f o r m .

3.5.5 P l a n n i n g EPA T e s t P r o g r a m

S i n c e J u n e , 1 9 7 8 , G.C:A., t h e c e n t r a l e n v i r o n m e n t a l contractor
w i t h EPA, h a s b e e n i n v o l v e d w i t h PER i n f o r m i n g a n o v e r a l l EPA
t e s t p l a n , an e x t e n s i v e , s e t o f e n v i r - o n m e n t a l t e s t s . p l a n n e d f o r
t h e R i v e s v i l l e MFB. The p u r p o s e o f . ' t h . e s e t e s t s i s t o a n a l y z e
t h e chemical, physical;and b i o l o g i c a 1 . p r o p e r t i e s o f a i r and
s o l i d w a s t e e m i s s i o n s f r o m t h e f l u i d i z e d bed h n i 1 . c ~and t o
s t u d y t h e p e r f o r m a n c e o f a i r pol1.1.1t.i.on c , ~ n t r o l s. y s t . e m ~ ,
r e l a t e d t o f l u i d i z e d b e d c o m b u . s t i o n . Most of t h e s e p o l l u t i o n
c o n t r o l t e s t s ' - a r e b e i n g s p o n s o r e d by t h e {J. S . E n v i r o n m e n t a l
, P r o t e c t i o n Agency, w i t h s o m e , c o r o l l a r y t e s t s b e i n g . d o n e by t h e
U.S. D e p a r t m e n t o f E n e r g y ' s Lawrence L i v e r m o r e L a b o r a t o i r y . Also
p a r t i c i p a t i ~ i gw i l l b e , P o p e , E v a n s a n d RobbSns, I n c . , G . C . A .
C o r p o r a t i o n , SoutI!ern R e s e a r c h I n s t i t u t e , a n d
. .
cur ex Corporation.

. .
. :,
' ,!
5)
 D u r i n g t h e i n t e r i m p e r i o d , PER d i s c u s s e d a n d a c t e d upon u n r e - -
s o l v e d i t ~ i n s ., p a r t i c u l a . r l y t h e r e s p p n s i b j - l i t i e s o f . , t h e p a r t i -
cipailts. A m e e t i n g was h e l d o n 2 8 F , e b r u a r y 1979 a t ~ o r ~ a n t o i q n. .
Energy R e s e a r c h C e n t e r , t o r e v i e w a n d comment on .the. s u b m i t t e d
EPA ~ e s Program. t T h i s m e e t i n g w a s a . t t e n d e d by D r . B r u c e f i e n s c h e l
o f EPA, D r . J o h n Wilson of DOE, D r . P a u l F e n n e l l y of GCA a n d
others. I t l e d t o t h e d i s t r i b u t i o n , o f t h e d r a f t copy o f t h e
T e s t P l a n f o r E n v i r o n m e n t a l Measurements a t t h e U.S. D e p a r t m e n t
o f E n e r g y ' s F l u i d i z e d Bed Combustion F a c i l i t y , R i v e s v i . l l e , West
V i r g i n i a (Spring/Sumn~er 1 9 7 9 ) w h i c h w a s p r e s e n t e d by G . C . A . .
C o r p o r a t i o n and d a t e d 2 8 March 1 9 7 9 . Comments. w i l l b e c o n s i c k r e d
and a f i n a l v e r s i o n o f t h e t e s t p l a n s u b m i t t e d i n A p r i l .
. '.?.
3.5.6 Modernization Engineemring
. ,
F o u r m a j o r a r e a s o f e n g i n e e r i n g s t u d y . a r e u n d e r w a y ' t o npgra.de
the liivesville plant. The o b j e c t i v e i s t o p r o v i d ' e a more
r e l i a b l e , v e r s a t i l e and environmental-ly a c c e p t a b l e t e s t f a c i l i t y
f o r long t e r m use. The e n g i n e e r i n g s t u d i e s w i . 1 1 r e s u l t i n
. r e p o r t s t h a t review a l l o p t i o n s , c l e a r l y d e p i c t c o n c e p t s , p r o -
v i d e e s t i m a t e s a n d s c h e d u l e s , p r o v i d e reconunendat.ions a n d
d r a f t purchase s p e c i f i c a t i o n s .

The f o u r a r e a s o f s t u d y a r e :

a. F l u e Gas F a b r i c F i l t e r

D e p a r t m e n t o f Energy i n m i d - 1 9 7 8 m a d e a committ.ment t o
t h e West V i r g i n ' i a A i r ; , P o l l u t i o n C o n t r o l Commission
t h a t ~ i v e s v i l l ewould b e b a c k - f i t t e d w i t h a . b a g . h o u s e
. . . a t the e a r l i e s t opportunity. This i s desirable both
t o e n s u r e con~pl'iance d u r i n g t r a n s i e n t c o n d i t i o n s ( b o t h
p u r p o s e f u 1 , a n d i n a d v e r t a n t ) a s y e l l a s t o permit evai--
u a t i o n o f t h i s : c o l l e c t ~ o n ' t e c h n i q u eon a f l u i d i z e d b e d .
boiler. T h i s s t u d y c o n s i d e r s a l t e r n a t i v e numbers o f .
f a n s and e v a l u a t e s v a r i o u s equipment arrangements. A
r e p o r t was s u b m i t t e d t o DOE J a n u a r y , F e b r u a r y a n d March
1979. . . ‘,,..
, ,

b. ' A i r Cooled ~ o n & n s e r

. . . . .. .
' ~ n d e p e n d e n c e from blPC1s s t e a m a n d f e e d w a t e r c y c l e s , i s
a n e c e s s i t y i f p r e d i c t a b l e performance programs a r e
t o b e accomplished. Independence can bes.t be pro-
v i d e d by a n a i r c o o l e d c o n d e n s e r o r d r y c o o l i n g t o w e r .
R e s u l t s o f t h i s s t u d y w e r e s u b m i t t e d t o DOE i n J a n u a r y ,
F e b r u a r y a n d March 1 9 7 9 .
 c. -------
C o n t r o l Ro'om R e v i s i o n and E x p a n s i o n

T h e o r i g i n a l i n s t r u m e n t a t i o n and c o n t r o l s y s t e m a n d
p h y s i c a l c o n t r o l room was b a s e d on an. e x p e r i m e n t a l
concept. A f u r t h e r i n s t r u m e n t a t i o n package h a s s i n c e
been added, b u t . t h e r e i s l i t t l e d a t a l o g g i n g , and t h e
p r e s e n t c o n t r o l room i s c o n s i d e r a b l y u n d e r s i z e d . A
s t u d y w i l l r e v i e w a l t e r n a t e c o n t r o l room a r r a n g e m e n t s
and l o c a t i o n s a s well a s a n a l y z e v a r i o u s i n s t r u m e n t a -
t i o n , c o n t r o l s , and d a t a q a t h e r i n g s c h e m e s . The s t u d y
w i l l b e c o m p l e t e by May 1 9 7 9 .

d. C o a l D e l i-v e r y , U n l o a d i n g , H a n d l i n g S y s t e m s
r ,I .
It i s g e n e r a l l y recognized t h a t s h a r i n g of u n c e r t a i n
c o a l h a n d l i n g f a c i l i t i e s w i t h PlPC h a s b e e n a s e r i o u s
hottlenecl:. P u s s i b i l i t i e s f o r independent f a c i l i t i e s
a r e 1 - i m i t e d by t h e s i t e l a y o u t . A r e p o r t on v a r i o u s
o p t i o n s , w:i. ll be c o m p l e t e d d u r j . n g . A p r i l 1 9 7 3 .

3.5.7 Operations

A t 0520 h r s 1 2 March c h e c k - o f f b e g a n f o r CBC s t a r t - u p . A t 1031

h r s b o t h b u r n e r s w e r e e s t a b l i s h e d a n d t h e g r a d u a l i n c r e a s e of b e d
t e m p e r a t u r e began. A f t e r t w o 500 l b . c o a l c h a r y e s , a t 1 1 4 6 and
1 3 0 5 h r s , bed t e m p e r a t u r e s were i n c r e a s i n g v e r y r a p i d l y . Coal
f e e d was e s t a b l i s h e d a t 1 4 2 5 . h r s . G0o.d s t a c k c o n d i t i o n s w e r e
observed. The b u r n e r s were h a c k e d o f f a n d t h e p r e c i p i t a t o r . .
energized. A t 1550 hrs c o a l f e e d was d i s c o n . t i n u e d d u e t o a s u s -
p e c t e d c l i . n k e r f o r m a t i o n i n t h e n o r t h w e s t c o r n e r o f the c e l l .
The u n i t was c o o l e d and t h e c l i n k e r s removed f r o m t h e CBC.

A t 2105 h s s 1 4 March t h e f u e l o i l b u r n e r s were a t h i g h f i r e a n d

p r e p a r a t i o n s .made t o . l i g h t o f f D c e l l . A f t e r 3 2 h o u r s o f f i r j . . n g
o i l , D c e l l was f .inalLy i g n i t e d .wit11coai. The lag t i m e was due.
t o many p r o b l e m s w i t h the T r a n e b u r n e r s a.nd d . i f f i c u l t y f l u i d i z i n g
with cold a i r .

On 1 5 March a t 1812 h r s CBC c o a l f i r e was e s < a b l j . s h e d . . ',B,ed

h e i g h t was i n c r e a s e d t o 3 0 " ( s t a t i c ) a n d h e l d u n t i l 0455 b r s
1 6 Plarch when. C c e l l was i g n i t e d . A t , 0 6 2 2 .h r s Monongahela Power
Company c a l l e d and o r d e r e d t h e PIFB o u t of ' s e r v i c e d u e t o low ,
w a t e r l e v e l s i n their d e a r a t i o n tan: a n d surge t a n k . Later,
w i t h p e r m i s s i o n t o r e l i g h t CBC, c o a l f i r e was o n c e a g a i n e s t a b -
l i s h e d a t 0834 h r s . P r e p a r a t i o n s were ' m a d e tc>r e l i g h t .C c e l l , b u t
f o u n d t h a t D C - 1 f l y a s h t r a n s p o r t s y s t e m h a d m a l f u r . l c t i o n e d and
needed r e p a i r i l l y b e f o r e . r e l i g h t i n g C ce.11. A t 2 2 4 3 , h r s , 1 6 March,
c o a l fires w e r e e s t a b l i s h e d i n C c e l l and m a i n t a i n e d u n t i l 0840
h r s t h e f o l l o w i n g d a y , when b o t h c ' e l l s were s h u t down t o . r e p a i r .
a b r o k e n s p r i n g and r e p l a c e t h e r h e o s t a t o n CBC v i b r a t i n g f e e d e r . ,
 At 1945 hrs 17 March these repairs.were completed and coal
fires were again established in CUC. At 2310 hrs 1.7 March,
C.cell was re-ignited on coal and fires maintained xntil
0404 hrs 18'March. Coal fire was interrupted to C cell due
to low auxiliary air flow on feed tubes. At 1108 11r'~18 March
.coal'fire in C cell was re-established and maintained until
1250 hrs th'at day when coal flow was again lost to Cell C.
Problem appears to have been coal jamming at the inlet of the
vibrating feeders. At 1330 hrs coal fire was banked in the
CBC and,the unit cooled for scheduled inspections.
After a short outage and unit inspection, the MFB was placed
back into service at 0545 hrs on 20 March with coal ignition
in the CBC. During the inspection, the general conditior. of '

the unit was found to be good with the exception of minor

mechanical problems with auxiliary equipment. Additional
sealing was done at the south-east corner of the CBC air dis-
tributor.
At 1220 hrs, the D-C slide gate was opened and a coal fire was
established in ce1l.C. During the afternoon and evening,
operation was hampered by flyash conveying problems. By 2200
hrs, these appeared solved. . A t 2000 hrs, an att.empt was made
to reinject flyash and from initial indications (oxygen, bed
. ,temperature) there was some reinjection. A high hopper level
in DC-1 prevented further testing and at 20.30 hrs, the rein-
jection:system was securdd. The unit maintained steady state.
ope~rationuntil.0405 hrs 21 March, when the CBC vibrating .
feeder motor and rheostat .burned out. The problem was in the
B phase of the circuit. C cell remained on line with the
.CBC slumped.
During the time of C cell operation, the D cell vibrating
feeder motor and rheostat were repaired and tested for proper
operation and the flyash reinjection system was cleaned out.
Also during operation of C c.ell alone it was found that oper-'
ating static bed heights greater than 25" contributed to coal ,
feed prablems by causil;g bridging above.belt feeders. Once
the bed height was lowered to 2 4 " , steady ~ t a t eoperation was
maintained'with no problems. At 1427 hrs on 21 March the
fuel oi1,burners were lit in order to re-light D cell. At ,

1452 hrs the unit received a master fuel trip (MFT) which
trips all runnin'g equipment. The alarm indication was FD and
ID fan power loss.
As fan power had not been lost, all equipment was restarted
and coal fires in D and D cells were re-established by 1506
Hrs; .The Control Room was notified that the cause of the trip ,
was due to a loose connection on the FD and ID fan power loss
relays.
A s e c o n d MFT. was e x p e r i e n c e d a t 1520 h r s w h i l e r e p a i r i n g
w i r i n g problems. C o a l f i r e s were r e - e s t a b l i s h e d a t 1526
i l r s . a n d t h e u n i t was b r o u g h t b a c k , t o s t a b l e c o n d i t i o n s . .

The u n i t m a i n t a i n e d s t e a d y s t a t e c o n d i t i o n s a n d f l y a s h r e i n -
j e c t i o n was a t t e m p t e d a t 1840 h r s . A t 2225 h r s . t h e r e i n - -
j e c t i o n s y s t e m was ' s h u t down s i n c e i t was e v i d e n t t h a t ' t h e
s y s t e m was d e f i c i e n t i n t r a n s p o r t i n g m a t e r i . a l .

A t 0720 hrs on 2 2 March, c o a l f e e d was c u t t o C . c e l l a n d t h e

c e l l t a k e n o u t o f o p e r a t i o n d u e t o a low Plon Power c o n d e n s a t e
tank level. The M F B u s a g e r a t e c o u p l e d w i t h Mon P o w e r ' s res-
t r i c t i o n o n t h e raw w a t e r s u p p l y t o t h e p o r t a b l e d e m i n e r a l i z e r s
does n o t permit 24 hour 2 c e l l operation.

T h e CBC m a i n t a i n e d s t e a d y o p e r a t i o n u n t i l 0 1 2 0 hrs 2 3 March

when t h e v i b r a t i n g f e e d e r (VF-DE) s u d d e n l y q u i t o p e r a t i - n c j .
The c e l l was slumped a n d t h c p r o b l e m was found t o be exposed
wires i n t h c m o t o r . At 0 5 2 8 hrs r% c o a l fire was r e - e s t a b l i s h e d
i n D c e l l . Two h o u r s l a t e r a c o a l f i r e was e s t a b l i s h e d i n C
cell.

F l y a s h r e i n j e c t i o n was a t t e m p t e d a t 0840 h r s a n d l o o k e d p r o m i s -
ing. C o a l f e e d was'c'ut' b a c k a n d t e m p e r a t u r e s a p p e a r e d good.
R e i n j e c t i o n c o n t i n u e d u n t i l 1006 h r s when DC #1 showed a h i g h
'level a l a r m .
At 1 3 1 5 h r s - a c o a l f i r e - w a s e s t a b l i s h e d i n B . c e l l t o b e e n d e d
f o r t y m i n u t e s l a t e r by a main f u e l t r i p and a g h i h stearn t r i p . ,
A l l c e l l s were s h u t down. The f a n s w e r e r a c k e d o u t a t 0 5 5 5 ' h r s
24. March a n d . a ' w e c l t e n d i n s p e c t i o n o f t h e u n i t b e g a n .

D u r i n g t h e weekend a. number o f i t e m s were r e p a i r e d i n c l u d i n g

the precipitator. C a n d D c e l l l i m e s t o n e r o t a r y f e e d e r s were
t e s t e d and c a l i b r a t e d . O n 2 6 March t h e , u n i t w a s r e l e a s e d f o r
s e r v i c e b u t s t a r t u p was d e f e r r e d u n t i 1 . 2 8 March d u e t o a Mon
Power t u b e l e a k i n B o i l e r # 7 .

On 2 8 March PER was n o t i f i e d n o t t o start:, u p , t h i s t i m e d u e t o

p r o b l e m s w i t h t h e Mon Power f l y a s h s y s t e m which t h r e a t e n e d t o
s h u t down b o t h t h e i r b o i l e r s . '

A t 1600 h r s 28 March r e l e a s e was g r a n t e d t o t h e MFB f o r s t a r t - '

up. Once a g a i n B ~ i l e r# 7 d e v e l o p e d a t u b e l e a k , t h i s t i m e a ,
very serious superheater leak. The u n i t was o u t o f s e r v i c c
f o r t h e r e m a i n d e r o f the month,

3.5.8 F D Pan F a i l u r e . ..
' 1'

On March 1 3 , . 1.979, a t 2200 h r s , a f a i l u r e o f . t h e a u x i l i a r y ' F D

m o t o r s t a r t e r wa,s r e p o r t e d a n d . t h e f o l l o w i n g r e c o r d e d 'in t h e
d a i l y l o g book:

" A t t e m p t e d t o s t a r t Aux. F . D . F a n , s t a r t e r , blew o ' u t ,

., .bloMing d o o r o p e n . . M.C.C:A., s e c t i o n A nia1,n b r e a k e r
t r i p p e d . l' . . . . .
_F.laj_ntenance.r e p o r t , d a . t c d K.a.sc11 1 3 , 1 9 7 9 , r e g a r d i n g
incident states i n part:

" D u r i n g o u r i n v e s t i g a t i o n o f t h e Aux. F.D. an

starter,.
w e fo u n d t h e main l i n e c o n t a c t s s e v e r e l y b u r n e d a n d
t h e main. c o i . 1 f u s e s b l o w n . " .

I t t u r n s o u t t h a t t h e curves of a c c e l e r a t i o n and thermal . '

o v e r l o a d r e l a y cross e a c h o t h e r . While t h e motor a c c e l e r a -
t i o n . t i m e i s 4 6 s e c o n d s , t h e t h e r m a l over1:oad r e l a y C ~ i l l
t r i p i n 15 t o 20 seconds. Present operational procedure
i s t o s t a r t t h e Aux. FD f a n a n d when t h e . t h e r m a l o v e r l o a d
t r i p s , t o r e s e t i t w h i l e t h e f a n i s s t i l l r o t a t i n g , a n d re-
s t a r t t h e motor. While t h i s pqocedure . p e r m i t s t h e f a n t o
b e s t a r t e d , i t . h a s a damaging e f f e c t on t h e s t a r . t j . n g e q u i p -
ment a n d m o t o r . B r i e f l y , t h i s i s w h a t h a p p e n s when a n ..
a t t e m p t i s made t o r e s t a r t t h e m o t o r w h i l e i t i s s t i l l
rotating. The i n s t a r i t tlie m o t o r i s d i s c o n n e c t e d ( t r i p p e d ) ,
i t a c t s as a s e l f e x c i t e d g e n e r a t o r t h a t d e l i v e r s s u b s t a n -
t i a l amounts o f c u r r e n t , because t h e magn.etic f l u x w i t h i n .
t h e a i r gap ,does n o t c o l l a p s e immediately. The r e s u l . t i n g
r e s i d u a l v o l t a g e d e c r e a s e s i n ampl.it.ude o : p o n e n t i . a l - l v . The .
l e n g t h o f time i t t a k e s f o r t h e r e s . i d u a 1 v o l t a g e . t o d r o p .
t o z e r o , depends on t h e m o t o r ' s open c i r c u i t t i m e c o n s t a n t .
I n a d d i t i o n <o t h e r e s i d u a l v o l t a g c . d e c r e a s i n g , the phase
a n g l e b e t w e e n the m o t o r v o l t a g e a n d s u p p l y v o l t a g e c h a n g e s .
R e c o n n e c t i n g a m o t o r t o a power s o u r c e w h i l e t h e m o t o r
r e s i d u a l v o l t a g e i s h i q h ( t h e motor r o t a t i n g a t s u b s t a n t i a l
speed a t t h e i n s t a n t of reconnection.), r e s u l t s i r i extremely
h i g h i n r u s h c u r r e n t s which c a n l e a d t o b r e a k e r t r i p p i n g ,
s t a r t e r c o n t a c t b u r n i n g , m o t o r damage a n d c o u p l T n y d a m a g e .

3.5.9 F o s t e r W h e e l e r D e v e l o p m e n t corporation'.^
M e t a l l u r g i c a l E x a m i n a t i o n ( P h a s e 11)

I n F e b r u a r y 1978 Ph a s e I o f a M a t e r i a l s S u r v e i l l a n c e Program -
was c o ~ d u c t e dby F o s t e r W h e e l e r Devel-opment C o r p o r a t i o n (FWDC)
f o r t u b e a n d t u b e s u p p o r t m a t e r i a . 1 ~i n t h e R i v e s v i l l e M u l t i -
c e l l F l u i d i z e d . Bed B o i l e r (MFBB) .
A complete metallurgica.1
a n a l y s i s of s i x l y - e i g h t . ( 6 8 ) . samples . w a s p e r f o r m e d . In .
a d d i t i o n , t u b e diameter and w a l l t h i c k n e s s measurements w e r e
t a l t e n t o e s t a b l i s h a b a s e s o f c o m p a r i s o n f o r f u t u r e rnec?sure-
ments, and a comparison o f subsequent w a l l t l i i c k n e s s measure-
m e n t s . a g a i n s t t h e b a s e v a l u e s w o u l d g i v e some i n d i c a t i o n o f
f i r e s i d e corrosion i f i t occurred.

I n S e p t e m b e r 1 9 7 8 a P l i a s e I1 p r o g r a m w a s p r o p o s e d by FWDC.
The p r i m a r y o b j e c t i v e s o f t h e P h a s e I1 a n a l y s i s - w e r e t w o f o l d :
..
a. . To d e t e r m i n e . i f a n y d e l - e t e r i o u s . .e f f e c t s o c c u r r e d .
d u r i n g t h e o p e r a t i n g p e r i o d f o l l o w i n g 'the Phase ' I
'study and, . . 1 1 . ..

b. To a s c e r t a i n i f t h e . b o i l e r c o m p o n e n t s : s u f f e h d
: ; .
' m c t ~ l l u r g i q a ! . d a m a g e k e c a u s e . 0 5 t h e sai.ii.-@reheater
f l > e w h i c h o c c u r r e d o n A u g u s t 9 , 1978.!':.-- :: ' ,
D u r i n g t h e w e e k o f November 6 - 1 0 , 1 9 7 8 , . a t o t a l o f t h i r t y -
n i n e s a m p l e s w e r e removed from s e l e c t e d a r e a s i n C e l l s A , ,

B, a n d C . The s a m p l e s i n c l u d e d t w e n t y - e i g h t ( 2 8 ) b o a t -
t y p e s from w a t e r w a l l . , ' b ? i l e r , and s u p e r h e a t e r t u b e s , e i g h t
( 8 ) c o r n e r s from l a d d e r s u p p o r t s , a n d t h r e e ( 3 ) wedges
from s l i d e g a t e s . T h e s e s a m p l e s w e r e s u b m i t t e d f o r com-
p l e t e a n a l y s i s a n d t h e r e s u l t s compared w i t h t h o s e o f t h e
Phase I program. Tube d i a m e t e r a n d u l t r a s o n i c t h i c k n e s s
m e a s u r e m e n t s w e r e made a t t h e s i t e s o f t h e P h a s e I t e s t s
t o d e t e r m i n e t h e amount o f g e n e r a l f i r e s i d e t u b e c o r r o s i o n
w h i c h may h a v e o c c u r r e d .

Most, o f t h e c u r r e n t r e a d i n g s r e v e a l e d a s m a l l d i f f e r e n c e
when c o m p a r e d t o t h e i n i t i a l m e a s u r e m e n t s ; t h i s d i f f e r e n c e .
b e i n g less than' 0 . 5 % . These d i f f e r e n c e s w e r e p r o b a b l y .
t h e r e s u 3 . t o f d e p o s i t s on t h e s u r f a c c s which c o u l d n o t b e
s e e n a!ld/or remove'd.

I n g e n e r a l , no s i g n i Y i c a n t d e t e l i u r a t i o n o f any o f t h e
s a m p l i n g l o c a t i o n s was o b s e r v e d - s i n c e t h e P h a s e I s t u d y .
The u n i t h a d o p e r a t e d t h e f o l l o w i n g h o u r s . s i n c e t h e P h a s e
I study:

A Cell. 3 1 ~ m r s , . .
B ceil 240 h o u r s
C Cell , ,465 h o u r s
D Cell 1050 h o u r s
 , ,

POPE, EVANS AND ,ROBBINS, I N C .

, RIlESVILI,E, LTST V I R G I N I A

-- MFB Q u a-
r-
terly O p c r a-
t i n ~Summary . ,

Perj.od J a n u a r y - M a r c h

OPERATING HOURS

Q uarter To Date
( L i g h t - o f f ,B u r n e r - --

O i l F i r e d )- CBC 3 7 -33 hrs. 1,566. 33 hrs.

Coal F i r e d - CBC 118.51 hrs. 2.364.0.6 hrs.

- C Cell 6.7.18 hrs. 798.75 hrs.

.67 . hrs. 346.57 hrs.

- A Cell 0 hrs. 5-15

Commercial O p e r a t i o n 0 hrs . 192.10 hrs.

T o t a l Coal Consumption

Total .Sorbent Consumption 4 4 f K L l b s . 1 6 - ~ o n s .

Approximate Feedwater C o ~ s u m p t i o p l1 57 f 69 l b s . , 11364,316 gals.

. .
Approximate Steam Vented 9 1262,330 l b s . 1 I 110 I 991 'p,als. o f BFW

Approximate Blow Down ~2,030,950 1 b s . 2 4 3 ~ 6 0 7 gals. o f BFW

C o m e r c i B l Steam G e n e r a t i o n 0 lbs . 0. ga1.s. of UF\:?

T o t a l F u e l O i l Consumptj.~n 10,856 .

'
Deminerali'zed Water C r e d i t

Nnmber o f S t a r t s M u l t i c e l l Operation

CBC 7 Dl:.6 1 - 9 7 h r s .

C Cell ] 7

DCB --* 6 7 h r s .
A Cell :o' ' - DCEA 0
' hrs.
10.64 h r s i n C: only.
4.0 NEW YORK O F F I C E - ENGINEERING
' T h e N e w Yorlc O f f i c e d e s i g n a n d e n g i n e e r i n g s t a f f h a s . b e e n
engaged i n v a r i o u s t a s k s i n s u p p o r t of t h e o v e r a l l program
a n d R i v e s v i l l e MFB P l a n t O p e r a t i o n s . These t a s k s i n c l u d e
s t u d i e s and e v a l u a t i o n s o f . s y . s t e m s a n d e q u i p m e n t a n d m o d i f i -
. c a t i o n s , t o t h e MFB p l a n t t o improve p e r f o r m a n c e a n d i n c r e a s e
r e l i a b i l i t y b a s e d on e x p e r i e n c e g a i n e d s i n c e i n i t i a l . s t a r t - ..
up and follow-on o p e r a t i o n . . .

D u r i n g t h i s q u a r t e r l y r e p o r t i n g p e r i o d t h e N e w Yor-k O f f i c e . .
engaged i n t h e f o l l o w i n g ,tasks:

4.1 Stack Silencer I n s t a l l a t i o n

Based on a r e v i e w 05 c a l c u . l a t i . o n s p r e p a r e d by S & W on t h e , .
s t a b i l i t y o f t h e e x i s t i n g s t a c k w i t h t h e new s i l e n c e r , i t . . w a s
d e t e r m i n e d t h a t t h e c r i t i c a l wind v e l o c i t y ( f o r i n s t a b i l i t y ) .
was g r e a t e r t h a n t h e 5 0 y e a r ma.ximum.rccorded i n t h e R i v e s v i l l e
a r e a . Maximum wind v e l o c i t i e s r e c o r d e d f o r t h e p e r i o d 1974
t h r o u g h 1978 i n t h e R i v e s v i l l e a r e a were o b t a i n e d from.NOFA
a n d i n d i c a t e d r e c o r d e d v e l o c i t i e s were b e l o w t h e c . a l c u l a t e d . .:
c r i t i c a l v e l o c i t y . . R i v e s v i l l e o p e r a t i o n s was a d v i s e d t h a t
s t r u c t u r a l r e i n f o r c i n g of t h e s t a c k due t o ' t h e a d d i t i o n o f
t h e s i l e n c e r was n o t r e q u i r c d .

4.2 Redundancy S t u d y

A s t u d y w a s conducted t o e v a l u a t e t h e . f e a s i b i 1 i t . y a n d . c o s t s , .
f o r FD a n d I D f a n r e d u n d a n c y a n d s e l e c t i v e u s e . o f : t h e . E S P o r :
baghouse. General arrangement drawings and c o s t . e s t i m a t e s
w e r e prepared-for four alternate configurations. The a l t e r -
n a t e s w e r e e v a l u a t e d a n d t h e s t u d y recommending t h e l o w e s t
c o s t scheme was r e l e a s e d f o r r e v i e w .

4.3 R o t e x S c r e e n Kelacati.on

To m i n i m i z e d e g r a d a t i o n o f d e l i v e r e d c o a l by t h e p l a n t h a n d l i n g
a n d t r a n s p o r t s y s t e m s , t h e 102 f t . h o r i z o n t a l R e d l e r c o n v e y o r
was r e p l - a c e d by a 24 i n . by 7 5 f t . b e l t c o n v e y o r ; t h e R o t e x
s c r e e n was r e l o c a t e d t o t h e h e a d o f t h e b e l t c o n v e y o r and t h e
crusher relocated adjacent t o the screen. This necessitated
c h a n g e s i n t h e e x i s t i n g s t r u c t u r a l s u p p o r t s y s t e m w h i c h was
c h e c k e d f o r a d e q u a c y a n d new members a d d e d . Design c a l c u l a -
t i o n s were up-dated and d r a w i n g s r e v i s e d t o r e f l e c t t h e
changes.

4.4 EPA P a r t i c u l a t e C o n t r o l T e s t

S t r e s s a n a l y s i s f o r t h e 6 i n . a n d 1 0 i n . d u c t r u n s w i t h and.
w i t h o u t e x p a n s i o n j o i n t s w a s carnpletcd. R e s u l t s i n d i c a t e d
t h a t . expansion j o i n t s were r e q u i r e d t o a v o i d o v e r s t r e s s .
D r a w i n g s were p r e p a r e d o f ' p i p i n g a r r a n g e m e r i t s w h i c h . i n c l u d e d
expansion j o i n t s , g u i d e s and anchors t o reduce s t r e s s e s t o
a l l o w a b l e l i m i t s and r e l e a s e d f o r c o n s t r u c t i o n .
4.5 Steam v e n t . S i l e n c e r Exterisl.ons

E x t e n s i o n s t o t h e e x i s t i n g stearn v e n t s i l e n c e r s were recom-

mended by S&W t o r e d u c e a m b i e n t n o i s e l e v e l s . Based on a
s k e t c h p r e p a r e d by S&W,% and t h r u s t i o a d s f r o m t h e s i l - e n c e r
vendor, s i l e n c e r s u p p o r t s and g u i d e s were degigned and a con-
s t r u c t i o n drawing prepared.

4;6. c o n t r o l Room
. . 14odifi c a t i o n
. .
S t r u c t u r a l infor,mation regarding t h e m o d i r i c a t i o n s r e q u i r e d
f o r e x t e n s i o n o f t h e p r e s e n t c o n t r o l r o o m . w a s p r o v i d e d S&W
f o r two a l t e r n a t e a r r a n y e m e n t s undef c o n s i d ~ e r a t i o n .

4.7 C e n t r a l Vacuum C l e a n i n g System

. .
P r e l i m i n a r y d e s i g n s ' f o r a c e n t r a l vacuum s y s t e m f o r a t h e . M F D
P l a n t were p r e . p a r e d a l o l l g w i t h a b u d g e t a r y c o s t e s t j - m a t e .
The p r e p a r e d m a t e r i a l was r e l e a s e d f o r ' r e v i e w a n d e v a l . u a t i o n .

4.8 ' . ~ n s t r u m e l l tShop,

The p r o p o s e d l o c a t i o n . o f t h e I n s t r u m e n t . 'shop a t E l . 91.1' -

111/4", ' e a s t of t h e ' e x i s t i n g MPC e l e v a t o r was r e v i e w e d .
D e s i y n . s k e t c h e s of additi.ona1 s t r u c t u r a l .framing r e q u i r e d
w e r e r e l e a s e d . t o Riv.esvj.l.le o p e r a t i o n s f o r i - m p l e m e n t a t i o n .
5.0 SUBCONll.WCT ACTIVITIES
5.1 MFB Plant Advisory Operations Assistance (Stone &
Webster Engineering Corp. Subcontract)
Stone & Webster provided support in areas directly related to
startup activities. Particular attention was directed to FD
and ID fan startup. Final bid specifi.cations for the Fabric
Filter (Haghouse) and for major equipment purchases for the
Turbine Bypass System were completed. A report entitled
"Particulate Emission Control and Draft Equipment ~odernization"
i.e., Baghouse study was issued. During this period the bulk
of S&W work was concentrated on mddernization studies to be
implemented during the summer outage.

-
BOSTON OFFICE ACTIVITIES

-
Noise ---. Review
- (EDR-02)
CoordinaLed PYocurement and installation of FD & ID fan vibra-
.tion instrumentation. Readings were taken at site to establish
baseline data. Data was analyzed and baseline parameters set.
Noise requirements were established for the Air Cooled Condenser
Specification and noise control options for the Turbine Bypass
System were defined.
Coal Delivery and .--Injection System (EDR-08)
studies were completed related to coal and limestone distribu-
.tion and injection systems and coal and limeskone feed to
bunkers. Final draft irl preparation for submittal.
Turbine Bypass System (EDR-10).
ConceptuaJ d e s i gn of the krypdss system was con~pleted. Final
bid specifications for purchase of major equipment were sub-
mitted to PER. Engineers visited site to review the proposed
installation location and to develop structural input for
geotechnical design criteria. Preparation of the Boiler Feed
Pump Specjfication was started as backup should the effort to
locate a used pump and motor. be unsuccessful.
.-
Control Room Modernj ~ a t i o i (EDK-14
~ )

MFB operatinq persnnnel wcrc inLerviewed to develop location of

controls for new main control p a n p l afiil additiolldl control
rcquiremel~ts. Listings were developed of instrumentation by
system to optimize plant operating efficiency. Alternate
board layouts were discussed with PER. Preliminary layouts
were developed together with control board dcsign to provide
improved functional arrangomcnt and tu determine optimum control
room size. Arrangements were made for an April. 5 meeting tc
discuss the philosophical and practical aspects of the Control
Room Modernization effort.
DC-1 Bypass (EDR-16)

P r e p a r e d and i s s u e d e n g i n e e r i n g s k e t c h e s d e t a i l i n g t h e m o d i f i -
c a t i o n s and d u c t f a b r i c a t i o n work r e q u i r e d t o i n s t a l l t h e
new b y p a s s damper i n t h e e x i s t i n g D C - 1 d u c t w o r k . Control
c Z r c u i t s a n d h a r d w a r e f o r damper c o n t r o l w e r e p r c v i d e d a n d a '
d e s i g n drawing developed from e n g i n e e r i n g s k e t c h e s .

G e n e r a l Arranq.einents and S i t e P l a n (EDR-17)

G e n e r a l A r r a n g e m e n t . a n d S i t e P l a n d r a w i n g s were i s s u e d o n
J a n u a r y 31.

Review Baghouse I n-.s t a l l a t i o n (EDR-23)

F i n a l c o p i e s of " P a r t i c u l a t e Emission C o n t r o l and D r a f t

Equipment M o d e r n i z a t i o n " s t u d y i s s u e d on F e b r u a r y 20.
F a b r i c F i l t e r Bid S p e c i f i c a t i - o n ( B a g h o u s e ) w e r e a i s s u e d to
PER.

FIELD ACTIVITIES
I

P r e c i p i t a t o r Revie'w (EDR-05)

A s s i s t e d vendor i n i n s t a l l a t i o n and checkout o f n u c l e a r

s o u r c e heads f o r p r e c i p i t a t o r hopper l e v e l d e t e c t o r s . Super- .
v i s e d modifications t o a s s u r e c o r r e c t o p e r a t i o n of equipment.

CBC F l y a -
s h R e i n j e c t i o n System (EDR-09) -
A s s i s t e d i n m o d i f i c a t i o n work on F l y a s h R e i n j e c t i o n Sys?tem.
T e s t e d s y s t e m and . m o d i f i e d t o m e e t d e s i g n r e q u . i r e m e n t s .

Water R e q u i r e m e n t s ' f o r Ecol'ochem Demi'n.e'r'a'l'Lze'r's'(FR-15 ) '

Routed s b p p l y and d i s c h a r g e l i n e s f o r t h e Ecolochem

demineralizer headers.
. .

Water S u p p l y f o r tlle APH D e l u y e 'Sys'tcm .'(FR-2'0)

.Supported d e s i g n , procurement, i n s t a l l a t i o n and check-

o u t of t h e deluge system.

APH & P l e n l ~ mD r a i n s '(FR-24) Y

A s s i s t e d i n p r o c u r e m e n t a n d i n s t a l l a t i o n o f t h e APH & Plenum

D r a i n s Systems .,,
Bed M a t e r i a l Letdown S y s t e m (EDR-1'3)

A s s i s t e d i n c o n v e r s i o n o f Bed ~ a t e r i a iLetdown s y s t e m t o
vacuum o p e r a t i o n .
Medium P r e s s u r e Steanl- Svstern
- . . -Review ( F R - 3 2 )

Designed a n d s p e c i f i e d m a t e r i a l f o r p r e c i p i t a t o r hopper
steam-h e a t e r s .

Resul. t s

R e s u l t s a c t i v i t i e s c e n t e r e d on s e t up a n d p e r f o r m a n c e t e s t s
o f c o a l f e e d e r s , a u x i l i a r y a i r a n d main a i r . Verification
a n a l y s i s o f p e r f o r m a n c e c a l c u l a t i o n e q u a t i o n s was u n d e r t a k e n .
isc cussed a'nd i m p l e m e n t e d w i t 1 1 PER p e r s o n n e l , recommended
r e v i s i o n s t o p e r f o r m a n c e c a l c u l a L i o n s i n c o m p u t e r program.
Completed p a r t i a l v e r i f i c a t i o n o f c o m p u t e r c h a n g e s v s . hand
calculation. P a r t i c i p a t e d i n t e s t i n g program d r y r u n s a t
s i t e . Upllated ~ e s Pt l a n .

___
Safety

C o n d u c t e d d a i l y s a f e t y t o u r s o f t h e p l a n t and i n v e s , L i y d t i o n s
of m i n o r accidcrits. D i s c u s s e d u n s a t i s f a c t o r y s a f e t y a r e a s
a t 2 February S t a f f Meeting. C o n d u c t e d a f i r e d r i l l on 1 4 . .
March. A t t e n d e d DOE m e e t i n g i n Morgantown r e l a t i v e t o
u n s a f e c o n d i t i o n s and r e s p o n s i b l e s u p e r v i s o r s were n o t i f i e d
v e r b a l l y o r i n w r i t i n g of v i o l a t i o n s .

5.2 MFB Steam G e n e r a t o r Development

( F o s E e r Wheeler E n e r g y C o r p o r a t i o n )

FWEC c o n t i n u e d t o p r o v i d e s u b c o n t r a c t . s e r v l c e s i n s u p p o r t o f
o p e r a t i o n a n d improvement i n p e r f o r m a n c e a n d r e l i a b i l i t y o f
t h e R i v e s v i l l e MFB u n i t . During t h i s q u a r t e r l y r e p o r t i n g
p e r i o d f a b r i c a t i o n of replacement a i r d i s t r i b u t o r s f o r C e l l
D was c o m p l e t e d a n d u n i t s d e l i v e r e d t o R i v e s v i l l e f o r
i n s t a l l a t i o n : e n g i n e e r i n g evaluation o f f u l l l o a d and p a r t . '
l o a d performance. o f t h o R i r ~ e s v i . l . l . eI&~'EI steam g e n e r a t o r wcre
o o n d u c t e d ; a M a t e r i a l s S u r v e i l l a n c e R e p o r t based on metal- .
l u r g i c a l sar~lplest a k e n from t h e R i v e s v i l l e MFB u n i t was
c o m p l e t e d .and i s s l i e d .

Systems Modification

The r e p l a c e m e n t a i r d i s t r i b u t o r f o r t h e R i - v e s v i l l e MFR C e l l :
D was d e l i v e r e d t o t h e j o h s i t c on 5 ,5anuary a n d s u b s e q u e n t . 1 ~
i n s t a l l e d by f i e l d p e r s o n n e l . Minor . f i t . u p p r o b l e m s w e r e
c o r r e c t e d a n d f a b r i c a t i o n d r a w i n g s for C e l l s C a n d B . r e p l a c e - :
m e l i t g r i d s c o r r e c t e d t o avoid r e o c c u r r a n e e .

L a b o r a t o r y e v a l u a t i o n o f m e t a l l u r g i c a l s a m p l e s t a k e n from
t h e R i . v e s v i l l e s t e a m g e n e r a t o r was c o m p l e t e d . A r e p o r t of
the r e s u l t s was completed a n d i s s u e d t o PER and DOE.
 . , . . . .
Conceptual designs and a c'ost' est.imate-' were prepared for
fabrication of economiacr b a f f l ~ sfor the Rivesville M F H
unit and submit'ted to PER for evaluation.
Systems Evaluation
Work continued on ;valuation pf the Rivesville MPB perform- ,

ance at full load and part lo.ad conditions. Evaluation at

full load operating condition., three cell operation and
service conditions has been completed and is being reviewed
for accuracy.

'U.S. WVfRNMENT PRINTING OFFICE: 1979 281-704/78

,. . .

Unit& States Postage and Fees Paid

U.S. Department of Energy
, Department of Energy DOE-3!50
Washington, DC 20545

Official Business
Penalty for Private Use, $300