Case Studies

Case Study #1

The customer needed to retrofit their Riley TURBO™ Furnace CO boiler into a power boiler to meet stringent emissions limits.

The challenges included:

  • Modifications to the boiler to accept new burners to meet new emissions requirements
  • Decommissioning and removal of CO ports
  • Ultra low NOx and CO limits post retrofit
  • Varying refinery gas composition and natural gas firing
  • Combustion air ducting redesign

Hamworthy Peabody had successfully retrofitted Riley TURBO furnace units in the past so we were able to present a solid proposal for the project.

Prior to awarding the project to Hamworthy, the customer requested a burner test in our Advanced Technology Center in the UK. The ECOjet burner was test fired with the customers' exact refinery fuels constituency. The Advanced Technology Center has the ability to simulate any gaseous/liquid fuel. The burner was tested for several days as the customer observed the test. The test results were successful and we were awarded the project.

As part of the retrofit, Hamworthy Peabody conducted a SMARTflow airflow model. We were able to improve airflow to all burners by about 2%. We fully met the client’s needs, without redesign of the furnace walls using our unique combination of ECOjet Ultra-low NOx burners, STABLEflame technology, SMARTflow air-flow modeling and previous track record.

Documents

  • Case Study 1 (990KB)
    Challenge: Customer to retrofit their Riley TURBO™ Furnace CO boiler into a Power Boiler.

Case Study #2

The customer needed to retrofit their wall fired Distral boilers to improve reliability and emissions.

The challenges included:

  • Upgrading the existing burner registers on two boilers as part of the regular boiler maintenance planning cycle
  • Required emissions reduction
  • Yearly maintenance had become costly due to age of boilers and existing burners.

As part of the retrofit, Hamworthy Peabody conducted a SMARTflow airflow model. We provided MSC2 burner retrofit kits and adapted the new burner to an existing windbox. We fully met the client’s needs, without redesign to accommodate the burners using our unique combination of knowledge, engineering experience, STABLEflame technology, SMARTflow air-flow modeling and previous track record for reliability and emissions retrofits.

Documents

  • Case Study 2 (447KB)
    Challenge: Customer to retrofit Distral Boilers to improve emissions.

Case Study #3

The customer had operational issues with the current (non-HPC) low BTU burner technology as noted below:

  • Boiler would not fire as originally designed
    • Contract called for 95% BFG - 5% NG support fuel, but the boiler must be operated at 80% BFG and 20% NG split to achieve MCR
  • Severe vibration when firing above 80% of MCR
    • Measured as high as 20 G’s* on rear wall.
      • Limit of test instrument range*
  • All three boilers had reliability/availability issues due to burner stability
    • Averaging 1 boiler trip per shift

HPC assisted this customer with not only the burner upgrades, but also their BMS and Control System to have a fully optimized combustion system.

Documents

  • Case Study 3 (3.9MB)
    Challenge: Customer had issues with current (non-HPC) low BTU burner.

Case Study #4

Challenge: The customer had operational issues with the previous (non-HPC) 56 oil fired ignitors as noted below:

  • Operational Issues
    • Unable to simultaneously fire more than 2 elevations
    • Unreliable, unstable ignitor light offs
      • Insert/Retract mechanisms would hang up, preventing firing of burner groups.
      • Tips and plugs clogging or burning.
    • Prolonged boiler warm-up
    • Insufficient heat input
      • Existing ignitors were Class 1 but the inability to fire more than two elevations did not provide 10% of total burner heat input
      • Achieving 240MMBtu/hr versus required 840MMBtu/hr or 10% of total
      • One unplanned outage and the subsequent inability to restart prevented generation for two consecutive days.
        • Substantial loss of revenue.

HPC assisted this customer with a full turnkey replacement of the oil ignitors, plus new supply piping and design.

Documents

  • Case Study 4 (3.4MB)
    Challenge: The customer had operational issues with the previous (non-HPC) 56 oil fired ignitors as noted below: