Guidelines tor Reporting. Operating Statistics tor. Gasification facilities. (Courtesy of The Gasification Technologies Council, Rev. February 5, 2002)
The objective of these guidelines is to present a standardized way for reporting the operating statistics of gasification facilities. The statistics are primarily time-based, however, a single flow-based indicator is also included. An example is included.
Gasification Facility Units
The gasification facility is divided into two units so that the operating statistics can be reported for each of these critical areas of the facility. The units are defined as follows:
• Gasification (including ASU and Acid Gas Removal Unit)
• Product Units
Figure D-1. Gasification Facility Units
о Power production block, and/or о Chemical production block
Authors are also asked to indicate the specific configurations of the units with regard to back-up and multiple trains.
Unit Operating Statistics—Measured
Figure D-2. Unit Operating Statistics—Measured
Definitions—Measured Statistics
• Product Not Required
о % of year that the product from the unit was not required and, therefore, the unit was not operated. The unit was generally available to run and not in a planned outage or forced outage.
• Planned Outages
о % of the year that the unit is not operated due to outages that were scheduled at least one month in advance. Includes yearly planned outages as well as maintenance outages with more than one month’s notice.
• Unplanned Outages
о % of the year that the unit was not operated due to forced outages that had less than one month’s notice. Includes immediate outages as well as maintenance outages with less than one month’s notice.
• On-Stream
о % of the year the unit was operating and supplying product in a quantity useful to the downstream unit or customer.
• Yearly Production
о Defined as the total quantity of product actually delivered from the unit in a calendar year. For the gasification unit the production is reported on the basis of total clean synthesis gas.
Unit Operating Statistics—Calculated
Figure D-3. Unit Operating Statistics—Calculated
Definitions—Calculated Statistics
• Forced Outage Rate
о Defined as the time during which the down-stream unit or customer did not receive product due to unplanned problems divided by the time during which they expected product, expressed as a percentage.
• Availability
о Defined as the sum of the time during which the unit was on stream plus an estimate of the time the unit could have run when product was not required, expressed as a percentage of the year. Assumption is that unit could have operated at the same Forced Outage Rate when product was not required.
• Annual Loading Factor
о Defined as the yearly production of the unit divided by the rated capacity, expressed as a percentage.
• Rated Capacity
о Defined as the design quantity that the unit would produce at the design rate over the calendar year when operated in an integrated manner. Calculated by multiplying 365 times the average annual daily design rate. Note that the Design Production can change over time as the plant is de-bottlenecked or re-rated.
Example
• Operating Unit is a gasification train that is designed to make 200MMscfd of syngas.
• Measured Unit Operating Statistics for this example:
о Product Not Required = 10% of year о Planned Outages = 8% of year о Unplanned Outages=4% of year
■ Breakdown of the 4% by Cause
■ Report # of interruptions
о Onstream=78% of year о Yearly production = 55,000 MMscf of syngas
• Resulting Calculated Unit Operating Statistics:
о Forced Outage Rate=4%/[78%+4%] = 4.9% о Availability = 78%+ 10% * [1 — (4.9%/l00%)] =78% + 9.5% = 87.5% о Rated Capacity = 365 d * 200 MMscfd=73,000 MMscf о Annual Loading Factor = 55,000MMscf/73,000MMscf=75.3%
Appendix E