ESB International - O&M Case Study: Two-shift Studies
Background
A regulatory change required a plant to carry out two-shift operation with up to 20 starts per month. ESBI carried out a plant cycling study to identify any design weaknesses and modifications required to maintain plant reliability. This study assessed the design of each plant component and made recommendations to ensure that the plant could continue to deliver high performance with this unexpected operating regime.
Process
The historical method for attaching temporary thermocouples was to either peen or spot weld them onto pipework. Research showed that these methods were found to be unsuitable for a 2-shifting / cycling plant as the constant tube, pipe and header expansion and contraction caused the thermocouple to break off within several months. A cold metal spray method was implemented which has been found to be effective for several years in other plants.
Cold Metal Spray process
Outcome
Data is currently being gathered which is providing valuable engineering information to allow both design out of areas of weakness but also to modify start up and shut down procedures so as to minimise the effect of these cycles on the plant. This process has been shared with all other ESBI plants, implemented in one plant and is planned for implementation in another.
Thermocouple cables
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