Elliott Molnar
Intern-Engineer
August 5th, 2016
Intern Power DownEnd of Summer Presentation
Overview
1© [2016] NRG Energy, Inc. All rights reserved. / Proprietary and Confidential Information
Job Title
— Intern, Engineer
Education
— Texas A&M University, Senior, Mechanical Engineer
Purpose
— Provide Engineering Support to Plant Operations and Maintenance
Location
— W.A.Parish Generating Station
Hiring Manager
— Keith Nemec
Projects
2© [2016] NRG Energy, Inc. All rights reserved. / Proprietary and Confidential Information
Baghouse Failure Tracking Sheets
Main Coal Pile Dust Suppression
Fuel Handling Conveyor Bearing Failures
Other Tasks
— Use of PDP Viewer for Process History
— Design of Water-Filled Gravity Take-up Counterweights
— Intake Water Bleach System
— Bottom Ash HP Conveyor Pumps
Baghouse Tracking Sheets
3© [2016] NRG Energy, Inc. All rights reserved. / Proprietary and Confidential Information
Provide Baghouse Failure History
— There are ~15,000 Baghouse Filters for each Coal Unit
— Failures are difficult to track
— Details on bag failures are not recorded
— Tool needed to identify failure trends for root cause
Process
— Researched baghouse methodology and scale in manuals
— Identified Common Failure modes
— Developed Excel program using conditional and VBA
commands
— Developed new field reporting sheet for baghouse failures
Impact
— User-friendly input of reported failures
— Ability to identify failure trends
— Improve communication between field and administration
Coal Pile Dust Suppression
4© [2016] NRG Energy, Inc. All rights reserved. / Proprietary and Confidential Information
Dust Suppression needed on Inactive Main Coal Pile
— Fugitive emissions limited to 29 tons per year
— Water or Chemical Surfactants to be used
Process
— Identified alternatives for dust suppression which are currently permitted on site
— Contacted contractors for additional information and preliminary pricing
— Met with primary contractor to discuss scope of work
— Planned water and power supply infrastructure to be used on project
— Contacted engineering services contractor for development of a TSD for Bids
Impact
— Preliminary project planning for new environmental controls system
Conveyor Bearing Failures
5© [2016] NRG Energy, Inc. All rights reserved. / Proprietary and Confidential Information
Increase in conveyor outages for bearing replacement
— O&M costs and risk of heat stress for maintenance staff
— Possible outages of units, including U8 (FG supply for Petra Nova)
Process
— Spoke to maintenance personnel about what they have seen historically
— Developed and use tool for identifying failure trends based on SAP work orders
— Walked-down fuel handling system to identify possible root causes
— Inspected failed bearings for signs of wear and possible causes for failure
— Provided feedback and solutions to engineering, operations, and maintenance
Impact
— New grease chosen and installed
— Autogreasers and sensors being installed on troublesome systems
— Shared knowledge established between administration on the state of the system
Intake Water Bleach System
6© [2016] NRG Energy, Inc. All rights reserved. / Proprietary and Confidential Information
Improve safety and reliability of circulating water bleach system
— UV exposure leading to embrittlement
— Currently using Schedule 80 PC with quick-setting glue
Process
— Researched Pros and Cons to alternative materials
— Observed issues with existing system at WAP and compare to improved system at
Limestone
— Developed bill of materials and cost sheets for replacement of entire system
Impact
— CPVC to be used with Weld-On® 724 CPVC cement in the future
Fitting Description Quantity Sch 80 PVC Cost/Pack($/n) Pack Size (n) Cost ($) Sch 80 CPVC Cost/Pack($/n) Pack Size (n) Cost Red Kynar Cost Per ($) Pack Size (n) Cost
1 2" Flange to Pipe 1 NIBCO 39.85$ 12 3.32$ NIBCO 64.73$ 10 6.47$ NIBCO 375.00$ 2 187.50$
2,3 2" 90 degree 2 NIBCO 12.44$ 25 1.00$ NIBCO 37.53$ 10 7.51$ NIBCO 175.70$ 2 175.70$
4 2" to 1" reducer 2 NIBCO 17.80$ 25 1.42$ NIBCO 43.15$ 10 8.63$ NIBCO 180.50$ 5 72.20$
4 2" Tee 1 NIBCO 44.32$ 20 2.22$ NIBCO 50.03$ 10 5.00$ NIBCO 277.20$ 2 138.60$
5,6,9-11,17-20 1" 90 degree 11 NIBCO 7.20$ 50 1.58$ NIBCO 12.89$ 15 9.45$ NIBCO 92.89$ 5 204.36$
7,8,12-16 1" Tee 5 NIBCO 12.91$ 25 2.58$ NIBCO 18.59$ 10 9.30$ NIBCO 114.60$ 5 114.60$
Valve Description Quantity Sch 80 PVC Cost/Pack($/n) Pack Size (n) Cost ($) Sch 80 CPVC Cost/Pack($/n) Pack Size (n) Cost Red Kynar Cost Per ($) Pack Size (n) Cost
1 2" Valve 1 NIBCO 179.00$ 1 179.00$ NIBCO 281.70$ 1 281.70$ NIBCO 1,177.00$ 1 1,177.00$
2 2" Check Valve 1 NIBCO 213.60$ 1 213.60$ NIBCO 335.90$ 1 335.90$ NIBCO 994.00$ 1 994.00$
3-11 1" Valve 8 NIBCO 77.34$ 1 618.72$ NIBCO 128.30$ 1 1,026.40$ NIBCO 495.30$ 1 3,962.40$
Pipe Description Feet Sch 80 PVC Cost Per Foot ($/ft) Cost ($) Sch 80 CPVC Cost Per Foot ($/ft) Cost Red Kynar Cost Per Foot ($/ft) Cost
1-5 2" ID 6.5 PVC PIPE SUPP 1.35$ 8.78$ PVC PIPE SUPP 4.44$ 28.86$ NIBCO 97.18$ 631.67$
6-24 1" ID 70 PVC PIPE SUPP 0.65$ 45.50$ PVC PIPE SUPP 1.91$ 133.70$ NIBCO 43.84$ 3,068.80$
TOTAL 1,077.72$ TOTAL 1,852.92$ TOTAL 10,726.83$
PDP Process History Viewer
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PDP Viewer is an Intranet based system which takes process history
from PI Processbook and Honeywell PHD to create alarms
Used for:
— Reviewed bearing temperature data following a Primary Air Fan failure
o Inboard bearing temperature increase on startup should have tripped alarms
— Identifieda signal filter being used on a bad BFP turbine speed sensor
o Speed sensor is reading ~4000rpm when actual speed is ~5600rpm
o Later it was found that a filter was on the signal going to the control room
— Addressed alarms from units 4-6 as sensor or model parameter issues
Gravity Take-up Counterweights
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Conveyor counterweights weigh up to 17,000lb
— Must be supported by chain-falls for safety when replacing bearings
— Maintenance time for hanging chain-falls can be high
Process
— Identified weight necessary to tension belts
— Considered size limitations within structure
— Develop new design using a drainable water fill
— Produced first draft drawings for manufacturing of new counterweights
— Passed on to Maintenance Supervisor and Fuel Handling Crew Leader for review
Bottom Ash Conveyor Pumps
9© [year] NRG Energy, Inc. All rights reserved. / Proprietary and Confidential Information
Degraded or failed OEM pumps need to be replaced
— Replacement HP Pumps were purchased but not installed
Process
— Observed issues with system and compare purchased pumps to OEM pumps
— Contacted vendor of the new HP pumps to discuss concerns and request
information
— Plan piping routes for new system.
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