Kansas City Power & Light Iatan Station

Transcription

1 Kansas City Power & Light Iatan Station 2011 Plant of the Year Large Plant Category Presented By: Gary Brown

2 Great Plains Energy Corporate Structure

3 KCP&L services more than 800,000 customers in 47 northwestern Missouri and eastern Kansas counties - a service territory of approximately 18,000 square miles. Delivering that power requires 3,000 miles of transmission lines, over 24,000 miles of distribution lines and 320 substations.

4 KCPL Generation The Company operates 15 generating facilities providing power to our customers and selling into the wholesale market. We have over 6,100 megawatts of efficient generation assets in operation or under construction. Approximately 76 percent of our fuel costs are from lower cost coal.

5 KCPL Wind Generation In fall of 2006, the Spearville Wind Generation Facility was brought online to provide megawatts of renewable energy. An additional 48 MW of wind generation was added in MW addition is planned for 2012

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7 Iatan Station - Overview Unit Year Completed Location Energy Source Total MW KCP&L MW GMO MW GPE MW Operator Other Owners Iatan Iatan, MO Coal Kansas City Power & Light 70% 18% 88% Empire District Electric - EDE (85 MW) Iatan Iatan, MO Coal Kansas City Power & Light EDE (102 MW), KEPCO (30 MW) and 54.7% 18% 72.7% Missouri Joint Municipal Electric Utility Commission - MJMEUC (100 MW) Iatan 1 Retrofit installation of a new air quality control system (AQCS) on existing unit Sub-critical PC generating unit optimizing use of existing plant infrastructure Iatan 2 New 850 MW super critical pulverized coal (PC) generating unit Permit, design, construction, startup, testing and operational in-service

8 Missouri River December 2006 New Chimney Stack Iatan 2 Footprint

9 April 2007 Please excuse the photography angle Chimney Stack Campus Cooling Towers #2 Fabric Filter #2 #1 #1 Fabric Filter Boiler and SCR Iatan 1 Electrical Ductwork Excavation Panoramic view of Iatan #2 Footprint from atop Iatan #1

10 April 2007 Circulating Water Pipes Cooling Tower and Lay Down Areas Beyond Campus Lay down Area Cooling Tower Area Circulating Water Pipes Campus Excavated earth Turbine Location Powerhouse Footprint

11 October 2009 Reagent Prep Bldg Iatan 2 Absorber Cooling Tower Recycle Pump Building Construction Campus Iatan 1 SCR Iatan 2 SCR Iatan 2 Boiler Tank Farm and Coal Yard Gypsum Storage Iatan 2 Fabric Filter

12 March 2010 Tank Farm Unit 1 Conveyor 5B Coal Yard Additions Evaporators at ZLD Bldg Limestone Storage Limestone Conveyor New Conveyor 3B Gypsum Storage

13 April 2010 Crusher House ZLD Bldg Iatan 2 Back End Tank Farm

14 May 2010 April 27, 2010 May 17, 2010

15 October 2010

16 Comprehensive Energy Plan Fuel Yard Improvements Increased coal pile reserve storage to 1.2 million tons Increased track to allow 3 trains on site, additional siding, and a new bridge Installed a new dust collection system (closed loop) for stockout, handling and reclaim of coal. Installed a new dust suppression system at the head end of the primary stockout (2A) conveyor Installed 1 new conveyor for the stockout system of coal, increasing the redundant stockout systems from 2 sources to 3. Installed 15 new conveyors for the reclaim delivery of coal to the 2 power plants. This increased the redundant reclaim delivery system from 2 sources to 3. Added a new, 4 feeder primary surge pile, Installed a new 5B conveyor, capable of delivering 3,000 tons per hour to the plants and is the primary reclaim conveyor. Added a new conveyor 6B, increasing the Stacker/Reclaimer and Emergency Reclaim tons per hour and redundant capabilities.

17 Comprehensive Energy Plan (CEP) - Fuel Yard Improvements Added a new conveyor 7B for coal delivery from the Crusher House to the plants. This enabled a dual coal plant delivery system to the 2 power plants. Six new conveyors and a dual Car Tripper system were installed for coal delivery to the new Unit 2 boiler. Additional and new diversion gates, splitter gates, new transfer chutes and chute configurations were installed through out the system to accommodate the new delivery systems. Upgraded or replaced old fire protection equipment including: New electric motor driven pump. New jockey pump. New diesel driven pump for fire protection CO2 system for the Unit 2 silos Washdown and fire protection systems were installed. Numerous upgrades or replacements to existing equipment were made to handle the new systems.

18 Staffing 231 employees assigned to Iatan 23 fuel operators 3 fuel foreman Iatan Station Fuel operators are responsible for receiving and stocking fuel and bulk reagent Coal Both units designed for 100% PRB coal 20,000T/day All coal received by rail Currently have 132 car, distributed power trains in service Rotary car dumper has the capacity for trains up to 150 cars Fuel oil Both units use fuel oil igniters Fuel oil received by truck Limestone Both units are equipped with wet flue gas desulfurization units Local limestone is received by truck

19 Iatan Station Dedicated Fuel Training coordinator on site Updating procedures for new equipment Provides classroom instruction to new employees Provides refresher training to all fuel employees Facilitated New Equipment Start up meetings On site Safety coordinator Oversees red hold program Monthly safety meetings Bi-monthly in-plant & divisional joint health and safety meetings Near miss blasts Accident investigation teams DART fuel yard: 0 Recordable injury fuel yard: 0 Fuel yard days without an accident 3,506

20 Fuel Flow Overview

21 Fuel Unloading Rotary car dumper Dumper hopper >> Feeder Belt 1A >> 2 Belt (TT1) From Transfer Tower 1 the coal is either directed to the house or stacked out by: Conveyor 3A Emergency stack out Conveyor 4A Stacker/Reclaimer Conveyor 3B New reclaim surge pile

22 Rotary Car Dumper Dumper barrel replaced 4/2011 Improved dust suppression added at 1 to 2 belt transfer 4/2011 Wheel clamps added 4/2011 Dumper hopper has a capacity of 3 cars Feeder belt 1A has a VFD controlled motor and a capacity of up to 3300 TPH

23 Dumper Barrel Replacement

24 Primary Stackout Belt 3B (CEP addition) 72-3,500 TPH Telescoping spout over 4 feeders Skirt added 4/2011 Capable of stacking just over 2 trains for live storage

25 Stacker / Reclaimer Can run coal to both North (5 trains) and South side of conveyor 4A (3 trains) 72 3,500 TPH Can split between stockout and supplying house

26 Emergency Stackout Conveyor 3A from transfer tower 2 72 belt with a rated capacity of 3,500 TPH Telescopic chute and dust suppression at 1/2 for dust control East end of pile North of Stacker/Reclaimer

27 Fuel Reclaim to Crusher 5A (Emergency reclaim) >>TT2 >> 6A/B(new) >> Crusher Surge Hopper 1,750 TPH 4A (Stacker / Reclaimer) >>TT2 >> 6A/B(new) >> Crusher Surge Hopper 3,500 TPH 5B (New Surge Pile) >> Crusher Surge Hopper 3,500 TPH

28 Crusher to House Crusher 2x 250T hoppers 2x 1500 TPH crushers Crusher >> 7A/B(new) 2x 48 1,500 TPH 7A/B>>Unit 1 Plant Transfer Hopper >> Cascades >> Unit 1 Silos 7A/B>>8A/B (TT3) >> 9A/B >> 10A/B with Tripper >> Unit 2 Silos

29 Unit 1 Cascades

30 Unit 2 Trippers First coal to Unit 2 silos July 19, 2010

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32 Thank You