MAPS 20/20

We Give You "Eyes" Within Your Hopper

At each power plant, the bottom ash hopper is a very unique and dynamic system affected by many variables. These variables include: coal quality, boiler performance, hopper water temperature, etc. As a result of these ever-changing conditions, it is essential to give the operator "sight within the hopper" at all times. The MAPS system provides these "eyes."

INCREASED OPERATOR KNOWLEDGE

For the first time, MAPS technology allows the ash system operator to visually understand the dynamics of the conveying system. With the ability to analyze the cause and effect relationships between boiler and ash system operating conditions, the operator will be more productive in reducing operational problems.

Empowered with this reliable and accurate information, the operator will be able to schedule conveying more efficiently. This will reduce the total time spent conveying bottom ash, and free up personnel to be more productive in other areas.

HOPPER REFRACTORY SAVINGS

At many plants, operators frequently lower hopper water levels to visually inspect the hopper interior with the unit on-line. This greatly reduces refractory life due to continual thermal cycling which cracks and "spalls" the lining resulting in mechanical failure. The maintenance of bottom ash hopper refractory potentially costs a plant more than $100,000.00 a year.

MAPS technology gives the operator confidence to convey bottom ash without lowering the hopper water level, thus keeping the refractory under water at all times at a constant temperature. Additionally, the information provided by MAPS allows the operator to see for himself whether the conveying procedure has successfully emptied the hopper, if ash has bridged, etc., thus eliminating the need for dangerous visual inspections.

CONVEYING INTERFACE

Plant operators can use MAPS information to convey bottom ash on an "as needed" basis only. The volume of ash (cubic feet) in each hopper section is visually displayed on the system monitor. This volume measurement can be used to determine when to begin the conveying sequence. Current MAPS users have found that personnel quickly learn to visually recognize consistent bottom ash collection patterns and are able to determine how much ash can be easily stored before conveying must be initiated. As a result, the conveying system will only be started when ash volumes warrant such action, reducing system wear and tear and auxiliary horsepower consumption.

A PROBLEM-SOLVING TOOL

While somewhat similar, each bottom ash hopper has a unique physical design. At many installations, these differences in design can inhibit ash flow from the hopper to the conveying line. With MAPS technology, these problems can be specifically identified and corrected by observation.