Jamie HopkinsSwansea University

Year In Industry Review

Agenda• Projects Overview

Fuel Stock & Thermal Performance Manual & LP Development

Station Efficiency Losses Oil Optimisation Air Heaters Performance Analysis Works Power Analysis HP Heater Replacement Validity Biomass Throughput Tracking Additional Tasks

• Personal Development At Aberthaw• Further Questions

Fuel Stock & Thermal Performance Accounting

• Response to failing to close off monthly heat account

• Heat account run by one source• No procedure for heat accounting• Trailed and tested• EUETS support• Deliverables;

Document of manualsLocal procedure

Fuel Stock & Thermal Performance Accounting

Station Efficiency Analysis• Already evaluating of CPI losses and TEMP raw data

• Administrating heat account• Quantify losses• Required;

TEMP losses reportAnalysis tool

Unb

urnt

Car

bon

Leak

age

Con

dens

er V

acuu

m D

evia

tion

Fina

l Fee

d W

ater

Tem

p. D

evia

-tio

n

Unb

urnt

Gas

Los

s

Ste

am T

empe

ratu

re D

evia

tion

Reh

eat S

team

Tem

p. D

evia

tion

Exc

ess

Air

Gas

Tem

p R

ise

0100000200000300000400000500000

Station

Station

GJ

Station Efficiency Analysis

M01W01

M01W04

M02W03

M03W02

M04W01

M04W04

M05W03

M06W

02

M07W01

M07W04

M08W03

M09W02

M10W01

M10W04

M11W03

M12W02

0

1000

2000

3000

4000

5000

6000

7000

8000

Unit Leakage

Unit 7Unit 8Unit 9

GJ

2015

M08W1

2015

M08W4

2015

M09W3

2015

M10W2

2015

M11W1

2015

M11W4

2015

M12W3

2016

M01W2

2016

M02W1

2016

M02W4

2016

M03W3

2016

M04W2

2016

M05W1

2016

M05W4

2016

M06W3

2016

M07W2

0

1000

2000

3000

4000

5000

6000

7000

8000

Unit Leakage

Unit 7Unit 8Unit 9

GJ

• Improvement demonstration.

• Actions from losses• Surveys (on/off load)• Reduction in water

leakage as an example.

Oil Optimisation• Over usage on starts identified• On-load usage analysed to asses opportunity for tech

data changes• Target areas for further reductions

• U7 & 9 ashing• U8 PF temps• Established tech data

change

2016

M01

2016

M02

2016

M03

2016

M04

2016

M05

2016

M06

2016

M070.00%0.20%0.40%0.60%0.80%1.00%1.20%1.40%1.60%1.80%

Station Oil Usage

Station Oil UseTarget Onload Usage

Fire Change

Furnace Stability

Low Mill Temps

Ashing Load Support

Other0.0%5.0%

10.0%15.0%20.0%25.0%30.0%35.0%40.0%45.0%50.0%

Percentage Of Total Oil Burn

Unit 7Unit 8Unit 9

Oil Optimisation• Temperature difference analysis carried out on unit 9• No real value in pursuing• Identification of further work• Revisit post Hi-Vol

 

Average Temp. Diff.

CA Mill 2B Mill 2C Mill 3D Mill 3E Mill 5F Mill 5

Overall Average 3

Energy World Air Heater Performance

• Instrumentation route not viable• Testing strategy was reactive not

proactive• Requiring pre planned programme

10/25

/2002

10/25

/2003

10/25

/2004

10/25

/2005

10/25

/2006

10/25

/2007

10/25

/2008

10/25

/2009

10/25

/2010

10/25

/2011

10/25

/2012

10/25

/2013

10/25

/2014

10/25

/2015

0.0%

20.0%

40.0%

60.0%

80.0%

100.0%

120.0%

140.0%

Mill A/H A LeakageMill A/H B LeakageMain A/H A LeakageMain A/H B LeakageNormal MainNormal MillRepair MainRepair Mill

Lea

kage

(% O

2)

Energy World Air Heater Performance

• Weekly monitoring; o Cold side efficiencyo Hot air to mills o Main air heater outlet temperatureo Mill and main air heater diff. pressureso FD, ID & PA fan amps

Air Heater Ingress Assessment

Boiler Air Ingress

Assessment

Air Heater Leakage

Assessment

Imported Works Power• Assessment of station usage against business

plan

• 2016 consumption 11.7 MW

• FGD matrix control to be assessed

• 0.5 MW worth ~£600k[1] [2]

[1] Based on current works power prices of £35/MWh[2] Using 2017 – 2023 business plan running

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 280.0

5.0

10.0

15.0

20.0

25.0 Adjusted Works Power Usage 2016

Adjusted Total Works Power (MW) Adjusted TX 3 & 4 Usage (MW)FGD Usage (MW) Target (MW)

TEMP Week

MW

HP Heater Replacement Validity• Stations most common reliability issue• 2016 losses estimated at £300k• Approx. £800k losses from 2017 to 2023• Approx. £3.6 million for units heater replacement

  2017 2018 2019 2020 2021 2022 2023

Efficiency (£)Unit 7 £34,000 £38,000 £42,000 £7,000 £7,000 £7,000 £8,000Unit 8 £32,000 £32,000 £35,000 £6,000 £6,000 £6,000 £7,000Unit 9 £32,000 £36,000 £39,000 £6,000 £6,000 £7,000 £7,000

Reliability Cost (£)

Unit 7 £36,000 £40,000 £45,000 £7,000 £8,000 £8,000 £8,000Unit 8 £30,000 £23,000 £37,000 £6,000 £6,000 £6,000 £7,000Unit 9 £33,000 £28,000 £41,000 £6,000 £7,000 £7,000 £8,000

Total Annual Cost Station £197,000 £197,000 £239,000 £38,000 £40,000 £41,000 £45,000

Biomass Throughput Tracking

Janu

ary

Februa

ryMarc

hApri

lMay

June Ju

ly

Augus

t

Septem

ber

Octobe

r

Novem

ber

Decem

ber

0

1000

2000

3000

4000

5000

6000

0.0%10.0%20.0%30.0%40.0%50.0%60.0%70.0%80.0%90.0%100.0%

Actual Burn Target Burn % Of Target Burn

Tonn

es

% O

f Tar

get B

urnt

Janu

ary

Februa

ryMarc

hApri

lMay

June Ju

ly

Augus

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Septem

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Octobe

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Novem

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Decem

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0100020003000400050006000700080009000

0.0%10.0%20.0%30.0%40.0%50.0%60.0%70.0%80.0%90.0%100.0%

Actual Burn Target Burn % Of Target Burn

Tonn

es

% O

f Tar

get B

urn

• Budget constraints overtaken progression• Fuel availability issues going forward

Phase 1

Phase 2

Additional Tasks• TEMP data QA tool• Quarterly & annual weighbridge report.• Taking meeting minutes (Combustion CIG,

P&C Bi Weekly)• Damper checks (BSOD’s, SAD’s, TAD’s etc.)• Air heater cross leakage• Unit water leakage• Flowrate’s (CW to quick starts)• Unit 9 low NOx commissioning• 1 month secondment to operations• 2 weeks at Pembroke

My Personal Development At Aberthaw• Confidence & character building• Development of safety awareness• Improvement in presentation skills• Enhancement in computational skills• Exposure to commercial operations • Integration into problem solving

tasks• Handover process

Further Questions?