Testing And Startup Experiences With Rotating Equipment At Nation's First Commercial Scale Coal Gasification Plant.

Abstract

The Great Plains Gasification Plant in Beulah, North Dakota, converts lignite coal to pipeline quality synthetic natural gas (SNG) using high Btu technology. The rotating equipment for this grass root facility presented unique challenges, due to the process complexity and the size of the plant. The critical rotating equipment was sized and specified to maximize reliability and to minimize risks associated with extrapolation of field proven designs. The plant rotating equipment was brought on stream ahead of schedule and continues to operate without any major problems. In spite of financial clouds over the project, the plant was a technical success and continues to operate with predicted onstream factors. The equipment design audits were useful in identifying potential problems. Several problems encountered during the shop testing are discussed. These problems were resolved by working closely with the equipment vendors. The startup teams were organized early and were staffed with specialists from vendors and contractors to supplement the plant technical staff. Numerous startup problems were experienced and resolved expeditiously. These problems are briefly described along with observations for minimizing similar problems on future startups.