Case Study
Retrofit3D delivers award-winning performance for Griffith Energy
IMI
February 13, 2024
The Challenge
Griffith Energy operates a 653 MW gas-fired combined cycle generation facility near the California and Nevada border in Mohave County. It generates wholesale electricity for the growing Desert Southwest power market.
Before working with IMI, Griffith Energy typically spent well over $100,000 annually to rebuild its boiler feedwater control valves to accommodate operational wear and maintain high levels of availability and reliability.
The plant had been approached several times over the years to replace the original control valves with IMI DRAG® variants. However, in addition to the valve and actuator, such an upgrade would require board approval for capex, as well as for welding, non-destructive examination, cleaning of piping, a new spare parts inventory, drawing and manual updates.
Griffith Energy’s management had not pursued the installation of new valves – mainly due to project scope and cost – as at least 16 of the plant’s control valves could have been involved.
The plant’s engineers, however, were familiar with the benefits of using DRAG® technology – particularly within HP and hot-reheat steam bypass, spray attemperator, and desuperheater valves. This provided grounds for the management to explore new solutions for the site, especially those that were able to provide a clear return on investment.
The Solution
Over the past few years, advances in additive manufacturing processes – more commonly known as 3D printing – have become more cost-effective and IMI engineers have been able to design lower stack DRAG® valve trim to fit existing valve bodies, such as those used by Griffith Energy.
By using IMI’s Retrofit3D solution, the company would be able to install the new valve trim and change the part number in its computerised maintenance management system, avoiding the need for capex. IMI provided new valve tags with names, trim characteristics, and part numbers.
Griffith Energy subsequently entered a pilot programme with IMI to install the first Retrofit3D trim sets into four of the most critical and difficult applications. The company supplied IMI with the OEM’s valve data sheets and historical operating data to ensure accurate flow and pressure needs calculations across different plant operations.
The Benefits
The first trim sets were installed in 2019 and delivered immediate performance improvements. The new solution was inspected the following spring after roughly five months of operation, and operational performance matched that of newly installed valves.
Griffith upgraded all remaining valves on its heat recovery steam generator (HSRG) and re-inspected them after two years. As the second HSRG is consuming all of the remaining OEM and refurbished inventory, IMI parts will be replacing them as the existing parts are scrapped.
The Retrofit3D trim is comparable in cost to the refurbished OEM trim and is expected to last at least three years longer – possibly even more. This could equate to a $500,000 to $900,000 saving on parts, not including the annual labour cost of rebuilding.
This project has resulted in a reliable, long-life, low-cost operation that requires a simple change to the inventory record and library. As a result of the project’s success, Griffith has doubled the retrofitting order from seven to 14 valves in total. The plant has also received recognition for its efforts, claiming the 2022 Best Practice award from the reputable Combined Cycle Journal (CCJ).
Trim Upgrade
Retrofit3D
Enhance your control valves’ performance with Retrofit3D’s cost-effective, customised solutions. Our DRAG® technology-based design integrates seamlessly into your existing valve body, reducing differential pressure and eliminating erosion, vibration, and noise. No need for complete replacement.
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