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IGCC Plant Operates HTI Pumps for Critical Cooling Application
Commissioned in 2013, the Integrated Gasification Combined Cycle (IGCC) facility at Edwardsport, Indiana is one of the cleanest and most efficient coal-based power plants in the world. At 618 MWe, it is also one of the largest plants of its kind in the world.
The IGCC process is an advanced technology that converts coal to a synthesis gas (syngas) and removes pollutants from the syngas before it is combusted in a gas turbine to produce electricity. The gas cleaning units that remove the pollutants operate at much lower temperatures, and therefore the syngas needs to be cooled. As a function of the Radiant Syngas Cooler (RSC) system, hot syngas exiting the gasifier at temperatures up to 2,900 °F (1,600 °C) is passed through a radiant syngas cooling vessel to lower the gas temperature. The heat is also recovered. Inside the vessel, high pressure (~1,650 psi) steam is generated from circulating cooling water as the hot syngas transfers heat across a ring of tubes connected in a configuration called a waterwall. The steam generated is then sent to a heat recovery steam generator (HRSG) system and is used to power steam turbines for additional electricity production and improving the overall plant efficiency.
Featuring high operating temperatures and pressures, the RSC system is one of the most critical and highly-loaded components of the IGCC, and the RSC circulating pump is a crucial part of that system. Hayward Tyler’s high-performing circulating pumps were selected for this demanding application. Based on Hayward Tyler’s long-proven boiler circulating pump, the RSC vertical, wet stator circulating pumps supplied by Hayward Tyler, Inc. has operated reliably since the commissioning of the Edwardsport IGCC in 2013.
Project Summary
SITE/LOCATION:
- Edwardsport, IN, USA / Integrated Gasification Combined Cycle (IGCC) Plant
SOLUTIONS AND FEATURES:
- Sealless, Vertical, Single Stage Centrifugal Pump with Wet Stator Unit (WSU)
- No seals, no oil-lubricated bearings
- “Hot neck” casing design limits the transfer of heat from the pump to the motor
- XLPE insulated and PVC protected motor stator windings for high protection
- Designed for serviceability with a stator assembly that is easily removed for maintenance
BASIC PUMP/MOTOR DESIGN DETAILS:
- Rated Flow: 16,577 USgpm
- Rated Head: 41 ft
- Design Pressure: 3,303 psig
- Design Temp: 653 ° F
- Rated Power: 550 hp
- Power Supply: 4160 V/ 60 Hz / 3 ph
- Designed in accordance with ASME B&PV VIII Div 1
- Designed and manufactured in Colchester, Vermont, USA
Project Data Sheet
| Name | Edwardsport, IN |
| Product | Radiant Syngas Cooler (RSC) Circulating Pumps |
| Quantity | Four (4) |
Codes and Standards
| Design | ASME B&PV Section VIII Division I |
| Pump Test Standard | Hydraulic Institute 14.6 |
| Flange Standard | ANSI B16.5 |
| Materials Standard | ASME / ASTM |
| Welding Standard | ASME B&PV Section IX |
| Electrical Standard | IEEE 252 / NEMA MG1 |
Pump Details
| Pump Type | Centrifugal, Single Suction, Single Discharge |
| Pump Size | 24″ Suction x 24″ Discharge with 20” Impeller |
| Fluid Pumped | Demineralized Water |
| Rated Flow | 16,577 USgpm (3,765 m3 / hr) |
| Rated Head | 41 ft (12.45m) |
| Specific Gravity | 0.62 |
| Design Pressure | 2256 psi (155 bar) |
| Design Temperature | 653 °F (345 °C) |
| Hydrostatic Test Pressure | 3303 psi (228 bar) |
Motor Details
| Motor Rating | 550 hp (410kW) |
| Service Factor | 1.15 |
| Nominal Speed | 1750 rpm |
| Power Supply | 4160 V / 3 ph / 60 Hz |
| Motor Full Load Current | 78.2 Amps |
Heat Exchanger Details
| Design Code | ASME VIII, Division 1 |
| Cooling Water Flow | 22 USgpm (5 m3 / hr) |
| Cooling Water Temperature | 100 °F (38° C) |
Weights (Approximate Wet)
| Pump Case | 11,436 lbs (5,187 kg) |
| Motor Casing | 16,808 lbs (7,624 kg) |
| Rotating Assembly | 638 lbs (289 kg) |
| Bolting and Residuals | 1,527 lbs (693 kg) |
| Heat Exchanger Assembly | 558 lbs (253kg) |
| Total | 30,967 lbs (14,046 kg) |
