Conventional Coal Power Plant – Ash Hopper Retrofit in England

An important consideration throughout the design was the high ash content and close proximity to pressure parts in the operating environment.

Client: Ferrybridge C Power Plant

Ferrybridge C is one of three power plants built between 1917 and 1966. It consists of four 500 MW generating sets and two gas turbines with a combined capacity of 34 MW. Since opening, it has produced an estimated 462 TWh of electricity and at its peak, employed over 800 people.

Total Output:

2304 MW

Date Operational: 1966
Location: Knottingley, England
Primary Fuel: Coal

 

Original: Sealing system with dipper plate & water trough

The Ferrybridge power plant had an original dipper plate into a water trough installed to seal the bottom of the boiler to the ash hopper.

Regular problems caused by this design:
  • Contact and deformation of the dipper plate.
  • Distortion of the water trough.
  • Water leakage into the boiler house.
  • Corrosion to below equipment.

Solution: DEKOMTE Fabric Expansion Joint

DEKOMTE proposed a number of standard and high tech solutions to solve the problem. An important consideration throughout the design was the high ash content and close proximity to pressure parts in the operating environment. The DEKOMTE steel frame and fabric were custom-made to fit a new ash removal system, ensuring maximum gas tightness and smooth integration to the adjacent pressure parts.

The multi-layer formed fabric consisted of 6 layers, two of which were PTFE gas tight membranes. This, combined with a formed glass wool insulation bolster encapsulated in wire mesh, ensures longevity and reliability. Performance of the unit was critical to the plant’s combustion efficiency and provided an economic solution for the plant’s final 5-6 years of operation.

 

Dimensions:

32813mm x 9439mm

Boiler Internal Temperature: 900˚C
Temperature at Fabric: 300˚C
Movement: Axial: -200mm
Lateral: 80mm
Removal of old steel parts.
Repairing of boiler wall and refractory.
Installation of steel parts.
Installation of internal insulation bolster.
Installation of fabric expansion joint.
Fabric expansion joint in operation.
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