Contributing Re.engineer Partner: KnightHawk Engineering
Challenge: Crushers and Slag grinders are often applied in Materials Handling and Gasification plants to reduce the size of quenched slag from the gasifier’s tap-hole or break clinkers from slow moving bed reactors. These clinkers are typically brittle and relatively easy to crush, but may be larger and very hard and abrasive when sintered during a reactor transient or upset conditions. Also, these crushers are often of toothed roller type, integrated in a pressure vessel subject to charge / discharge cycles, slow rotating yet transmitting very high torques and crushing forces. This makes it simultaneously a ‘machine’ and a ‘pressure vessel’.
A slag breaker dating from the 1970’s required replacement. The new design had to incorporate lessons learned in operations and maintenance, fit accurately into the existing structure and inlet-outlet flange face-to-face envelope, and re-use the existing drivetrain. The crusher must reduce slag as well as occasional refractory tiles or bricks, dislodged from the gasifier hot face, to no more than 1” in size to avoid bridging and arching in the outlet. The equipment must be designed, manufactured, tested and delivered to site under schedule constraints, in time for the next scheduled shutdown.
Solution: KnightHawk engineering digitized hand drawn blue-prints and developed 3D CAD models (below) applied in concept development, client reviews and manufacturer reviews and design. Detailed 2D CAD drawings and part lists as well as geometry and meshing for Finite Element (FEA) designs, were developed from this model. The pressure vessel was designed as per ASME VIII Division 1 with supplementory analysis by FEA as per ASME/API 579-1 Fitness for Service (FFS) by using the methods and guidelines from ASME VIII Division 2 Part 5. The rotating parts and breaker element were integrated into the pressure vessel by shaft, breaker tooth, breaker plates, gland seals, end bearings and a bolt-on cantilever drive unit (not shown) consisting of a motor, gearbox and coupling. The breaker element is protected from overpower, including an auto reverse, circuit breaker, shear pin and hydraulic coupling.
Results: Successful design was achieved by :
Contributing Re.engineer Author: Ralph Rio, ARC Advisory Group
(Read Case Study)
Challenge: Alliander provides energy transport and distribution for electricity, gas, and heat to a large part of the Netherlands. ARC had the opportunity to interview Walther Rasche, IT Manager, Operations and Jaak Rosendaal, SAP Solution Architect. Both are involved in applying the SAP Master Data Governance EAM extension by Utopia at Alliander N.V. Regulatory and competitive pressures led Alliander to start a condition-based maintenance program to improve asset reliability and the sustainability of the company.
Most of the electric power Alliander distributes is still produced by power stations, but this is changing. Grid complexity has been increasing due to:
Solution: Alliander has deployed the SAP Master Data Governance, enterprise asset management extension by Utopia software. This provided a solid foundation of asset information for a broad condition-based maintenance (CBM) program. Alliander is now on a path to reduce unplanned downtime and improve uptime with lower maintenance costs.
To serve as an effective planning and management tool for high uptime and safety, information in an EAM (enterprise asset management) system requires high data integrity. Key benefits of asset life-cycle information management (ALIM) include:
Results: Alliander’s CBM program recently finished its pilot acceptance of the Extension and achieved one of its primary goals for high quality data. The asset management system updates occur automatically using templates. This automated business process replaced manual data entry with its inherently unacceptably high error rate.
Data integrity is critical for a successful CBM program – particularly one with dynamic data models. Utilization of the Extension provided the needed governance, including traceability of changes to the data by who and when. This includes unstructured data like a comment about a tree being near a line and the location. The Extension reduced the time needed to register an asset in the SAP system from hours to a few minutes. It also enabled integration of the SAP EAM asset management system with NRG for critical GIS asset location data. According to Alliander, the Extension can deliver the software foundation needed to implement business processes that solve the company’s asset data quality and inconsistency issues.
Contributing Re.engineer Partner:
KnightHawk Engineering (KHE)
Challenge: A petrochemical plant has experienced several failures in the past few years in the tubes of a recycle gas cracking furnace. A root cause failure analysis shows the failures are likely caused by vaporization in the coils causing thermal fatigue cracking. KHE was asked to determine possible solutions to prevent future failures.
Solution: KHE created a heat and mass transfer model of the furnace. This model was used to predict outlet temperatures from the lower boiler feed water coil (LBFW) and showed that there was vaporization in the coils. KHE proposed the replacement of the bottom two rows of the LBFW with bare tubes instead of the preexisting finned tubes. Simulations showed the bare tubes increasing the overall efficiency of the furnace and preventing vaporization even under the worst case operating conditions.
Results: The client replaced the two bottom rows with bare tubes as recommended. As a result the unit has not experienced tube failures in almost 3 years of operation.
Contributing Re.engineer Partner: Noria Corporation (www.noria.com)
Challenge: Oklahoma Gas and Electric (OG&E) operates seven power plants throughout Oklahoma and for plants like Muskogee, the know-how and expertise with lubrication was lacking. While lubrication was not a strong focus at the Muskogee plant, it became a core strength with the integration of Noria's Lubrication Program Development.
Solution: Noria implemented their Lubrication Program Development system and helped OG&E transform the plant's lubrication procedures on all critical assets. Below are a few of the solutions that they executed:
Results: Achieved ROI sooner than expected and with best practices for lubrication in place, fewer unplanned outages are occurring at Muskogee. Noria has also helped OG&E be smarter about purchasing oil for lubrication. Previously, Muskogee used 23 different types of oil. That number was reduced to 16 after transitioning to best practices. As a result, OG&E has negotiating power with oil providers because fewer oil types are needed at the plant, and they know exact specifications to request. Here are more of their results: