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INDIA-TRAINING-01
China dating Technologies Engineering co ltd
PROJECT TITLE:
CLIENT:
LOCATION OF WORK:
The Desulfurization Project Phase I in India
China Datang Technologies & Engineering Co., Ltd.
October 2015
Approved by:
Examined by:
Prepared by:
NO.: CDTE-FGD.INDIA-TRAINING-01
China dating Technologies Engineering co ltd
Table of Contents
FGD ................................................................................................ 4
Chapter 1 Limestone-gypsum Wet FGD Process System ................................................................................. 4
.............................................................................................................................. 4
Section I Flue gas system .................................................................................................................... 4
........................................................................................................................ 12
Section II Absorber system ................................................................................................................. 12
............................................................................................................................ 25
Section III Slurry preparation system ................................................................................................... 25
.................................................................................................................... 28
Section IV Gypsum dewatering system ................................................................................................ 28
............................................................................................................................ 37
Section V Discharge system ................................................................................................................ 37
........................................................................................................................ 40
Section VI Process water system .......................................................................................................... 40
............................................................................................................................ 46
Section VII Wastewater treatment ......................................................................................................... 46
FGD ...................................................................................... 51
Chapter II Impact on FGD Unit from Variation Range of Fuel Characteristics .............................................. 51
............................................................................................ 51
Section I Impact on system from flue gas flow rate change .............................................................. 51
SO2 .................................................................................... 55
Section II Impact on system from SO2 concentration change of flue gas ........................................... 55
.................................................................................... 58
Section III Impact on system from dust concentration change of flue gas ........................................... 58
FGD .............................................................................. 63
Section IV Effect of chlorine content in coal on FGD unit design ....................................................... 63
FGD .............................................................................................. 66
Chapter III Non-metal Corrosion Prevention Materials of Wet FGD System .................................................. 66
.................................................................................... 66
Section I Technical Construction Requirements for Non-Metal Corrosion Prevention Materials..... 66
........................................................................................ 74
Section II Reasons for Damage of Rubber and Reinforced Resin Lining........................................... 74
........................................................................................................................................ 78
Chapter III Electrical System ............................................................................................................................ 78
NO.: CDTE-FGD.INDIA-TRAINING-01
China dating Technologies Engineering co ltd
................................................................................................ 78
Section I Electrical ElementaryWiring Diagram for Desulfurization System ................................... 78
.................................................................................... 81
Section II Desulfurization Service Voltage and Neutral Point Grounding Mode................................ 81
UPS ......................................................... 82
Section III AC Emergency Power Supply, DC System and Uninterruptible Power Supply (UPS) ..... 82
............................................................................ 84
Section IV Desulfurization System Load Calculation and Desulfurization Transformer Selection ..... 84
.................................................................................... 89
Section V Protective Load Statistics and Diesel Generator Selection................................................. 89
................................................................................................ 92
Section VI Selection and Layout of Desulfurization Electrical Equipment ......................................... 92
............................................................................................................ 93
Section VII Control, Protection and Measurement ................................................................................ 94
...................................................................................................................... 100
Section VIII Anti-thunder and Grounding ............................................................................................ 100
.............................................................................................. 100
Section IX Lighting, Overhaul and Slide Wire System ...................................................................... 100
.............................................................................. 101
Section X Cable, Cable Building and Cable Fireproof Plugging ...................................................... 101
.......................................................................................................................... 102
Section XI Communication System.................................................................................................... 102
...................................................................................................................................... 104
Chapter IV Thermal System............................................................................................................................ 104
.................................................................................................................................. 104
Section I Overview .......................................................................................................................... 104
KKS ......................................................................... 107
Section II KKS Identification System (Thermal Expertise Part) ...................................................... 107
...................................................................................................................116
Section III Distributed Control System ...............................................................................................117
...................................................................................... 121
Section IV Principles of Interlock Protection Logic, Control and Regulation ................................... 122
.................................................................................................................. 144
Section V Desulfurization Thermotechnical Instruments ................................................................. 144
CEMS ...................................................................... 150
Section VI CEMS System (Continuous Flue Gas Emission Monitoring System) ............................. 150
FGD ......................................................... 156
NO.: CDTE-FGD.INDIA-TRAINING-01
China dating Technologies Engineering co ltd
Section VII Monitoring and Analysis of All Measured Data in Normal Operation of FGD System ... 156
FGD ......................................................................................... 162
Chapter V Debugging, Operation and Performance Experiments of FGD System ....................................... 162
FGD ............................................................................................................. 162
Section I Debugging of FGD system ............................................................................................... 162
FGD ............................................................................................................. 224
Section II Operation of FGD System ................................................................................................ 224
FGD ..................................................................................................... 244
Section III Performance Test of FGD System ....................................................................................... 244
FGD ..................................................................................................... 260
Chapter VI Common Operation Problem Analysis of FGD System ............................................................. 260
FGD ..................................................................................................... 260
Section I Low desulfurization efficiency of FGD system................................................................ 260
FGD ................................................................................................. 269
Section II FGD system and stack corrosion .......................................................................................... 269
FGD ............................................................................................................... 282
Chapter VII FGD System Operation Management ....................................................................................... 282
FGD ......................................................................................... 282
Section I Required capacity of FGD operators ................................................................................ 282
FGD ......................................................................................................... 284
Section II FGD system operation adjustment .................................................................................... 284
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FGD
Chapter 1 Limestone-gypsum Wet FGD Process System
Section I Flue gas system
1
1. Process procedure
FGD
GGHFGD
The design of the flue gas system shall consider the normal operation of the
system and the operation in emergencies, including the big changes of flue gas
temperature in short time caused by the sudden changes in the upstream boiler.
Normally, the flue gas system is of the unit system (as for the FGD system of two
boilers and one tower, the flue gas system is the main pipe system), and each system
includes the booster fan, GGH, flue damper (FGD inlet raw gas damper, clean gas
damper, the bypass gas damper) and the corresponding flue, expansion joints, etc.
GGH
100
The raw flue gas from the boiler induced draft fan, pressurized by the adjustable
moving blade booster fan and cooled down by the GGH, then enters the absorber
system. The flue gas can also be directly discharged to the stack by the bypass flue,
namely the flue gas can 100% pass through the bypass.
SO2
GGH
The raw flue gas entering the absorber system would get through cooling and
saturation of the absorber, and the SO2 among it will be absorbed. The clean flue gas,
after spray washing and removal of fogdrop and then heated by the GGH, will enter
the flue and be discharged from the stack.
FGD 3
(1 1 1 )
FGD FGD
FGD
In order to separate the FGD system and the boiler system, each flue gas system
is set with three flue gas dampers (one raw gas damper, one clean gas damper, one
bypass gas damper). When the desulfurization system is in normal operation, the
bypass damper is closed and the raw gas damper and clean gas damper are open. The
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raw flue gas enters the FGD unit through the raw flue gas damper for desulfurization.
In emergency of requiring shutting down the FGD system, the bypass damper will
automatically and quickly open while the raw gas damper and the clean gas damper
will automatically shut down. The flue gas will be discharged directly into the stack
through the bypass flue and bypassing the FGD system.
All the dampers are equipped with seal air system, which will lead the seal air
into the blades of the dampers closed to block the flue gas flow on both sides of the
dampers.
2 100 FGD
5mbar
The damper seal air system consists of the seal fan and its seal air station. Each
set of flue gas system is set with a seal air station and two low pressure seal air fans
and the capacity of each is the maximum gas consumption of 100% single set of FGD
unit with one for operation and the other for standby. The seal gas pressure maintains
5mbar higher than the maximum pressure of the flue gas. The seal air station is
equipped with electric heater.
1
Figure 1 Typical flue gas system flow chart
Stack
Absorber
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Seal fan
Booster fan
2
2. Main equipment
GGH
Main equipment of the flue gas system including: booster fan, GGH, flue gas
damper, expansion joints, damper sealing systems, etc.
2.1
2.1 Booster fan
FGD
DL50002000 1.2 1.1
10
The booster fan is used to pressurize the flue gas to overcome the side resistance
of the flue gas of the FGD system. According to Technical Code for Designing Fossil
Fuel Power Plants DL5000-2000, the air pressure margin of the selected fan should
be 1.2, the flow margin 1.1, and plus 10 of temperature margin.
Since the booster fan is set at the sides of the hot flue gas, it avoids the corrosion
of the flue gas with low temperature so as to reduce the difficulty of fan
manufacturing and material selection. The fan blade materials mainly consider
preventing blade abrasion in order to ensure long-life operation; As for the structure,
consider the convenience of overhaul and replacement of the impeller and blade.
In the desulfurization system, the booster fans are mostly the axial flow fans. The
project adopts the adjustable moving blade axial flow fan.
DCS
The adjustable moving blade means the impeller is equipped with a set of
hydraulic device, which can adjust the blade installation angle in operating state so as
to change the output power of the fan under the condition of the boiler load change. It
mainly consists of the blade, wheel hub, hubcap, support cover and hydraulic
regulating device, etc. When the fan operates, the hydraulic regulating system
responds to the control signal from the DCS and drive the blade shaft to rotate to
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achieve the purpose of adjusting the blade installation angle. The wheel hubs are
usually of welded structure and the blade materials generally use the spheroidal
graphite cast iron or low alloy steel.
2.2
2.2 GGH
4560
80
The temperature of the clean flue gas from the desulfurization tower is 45-60
and the flue gas is in the wet saturation state. If directly discharged, it will cause two
adverse consequences: One is the low spread ability of the rising flue gas and the
water mist may be formed near the stack to pollute the environment, namely the
so-called the smoke plume downwash; The other is that since the flue gas temperature
is below the dew point, acid droplets will condense from the flue gas, namely the
so-called "raining", which not only pollutes the environment but also cause low
temperature corrosion to the equipment. Therefore, in the FGD system, the GGH is
usually set behind the desulfurization tower using the raw flue gas from the boiler to
heat the clean flue gas to at least above 80 and then discharged into the atmosphere
in order to increase the spread ability of the flue gas and avoid low temperature
corrosion.
gas-gas heater
GGH
The hot media of the GGH mainly include the raw flue gas, high-temperature
water, vapour or electricity. Usually, there are more methods of using the raw flue gas
to heat the clean flue gas, namely the gas-gas heater with the abbreviation of GGH.
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Ash ejector
center drive unit
Seal fan
Rotor
Top Structure
Clean flue gas side
End post
Seal air pipeline
Bottom beam
Raw flue gas side
Side post
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Rotor shell
Flue gas reheater layout drawing
FGD
The rotary type heat exchanger is the most commonly used type of heat
exchanger in the current FGD unit.
GGH
GGH GGH
80
Rotary GGH is with enamel piece as the heat exchanger element. The heat
exchanger element coated with enamel selects and uses the products with advanced
waveform and high heat transfer coefficient to reduce the total weight of GGH and
save expenses for the replacement of the heat exchanger unit. GGH uses the raw flue
gas from the boiler to heat the clean flue gas after desulfurization to make the lowest
temperature of the clean flue gas at the inlet of the stack above 80.
GGH
DCS
GGH GGH
() 30
50000
Each GGH is set with two electric drive units with one for main drive and the
other for standby, and all the motors adopt the form of air cooling. If the main drive is
out of work, the auxiliary drive will be automatically switched through the DCS to
prevent the rotor from stopping rotating. The GGH design can satisfy that the rotor
stops rotating without damage or deformation in the condition of power-losing of
auxiliary power. The overall service life of the GGH (shell, rotor and cell, drive unit)
is not less than 30 years while the service life of the heat exchanger element is more
than 50,000 hours.
GGH
GGH
,
10 FGD
GGH adopts the vertical layout of the main shaft, namely the airflow direction of
the raw flue gas is upward while the clean flue gas downward. Since the raw flue gas
contains the fly ash of a certain concentration, the fly ash may deposit on the inside of
the unit, and as time goes by, the efficiency of heat transfer may reduce. In order to
prevent the depositing and fouling between the GGH heat transfer surfaces which will
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influence the heat transfer efficiency, increase the resistance and air leakage rate and
reduce the service life, it is needed to use the compressed air to sweep or the
high-pressure water to clean regularly with the ash ejector, which is equipped with
one or two retractable spray guns. The spray gun is of two layers of the inner pipe and
outer pipe and can use two kinds of cleaning medium at the same time. The inner pipe
is the high-pressure water nozzle while the outer pipe is the compressed air or
low-pressure water nozzle. The high-pressure water pump wash is the online wash
(about 10 times a year, according to the operation of the unit). When FGD unit stops
running, the heat exchanger can be washed with the low-pressure water.
GGH
GGH GGH
GGH
The ash ejector is of the fully retractable type, which only exposes to the flue gas
at work. After the GGH finishes soot blowing, it will be retracted outside the GGH
shell. The seal air system ( ash ejector self-prepared) provides the seal air in the joint
of the ash ejector and GGH shell, and the main corrosion prevention measures to
prevent the overflow of the raw flue gas from GGH are as follows: The static module
with exposure to the flue gas are protected with the glass flake resin coating. The
rotary parts such as the rotor and cell as well as box bar adopt the Corten steel. The
sealing strip adopts advanced stainless steel and the heat exchanger element adopts
the low carbon steel coated with enamel.
2.3
2.3 Flue gas damper
FGD 3
/
Each set of FGD flue system totally has three flue gas dampers. All flue gas
dampers adopt double blades louver damper with the open/close function driven by a
motor.
:
The corrosion prevention measures for the damper are mainly guaranteed by the
correct selection of metal materials. See the list below for details of the materials of
main module:
List of the Main Design Parameters and Materials of the Flue Gas Damper
(preliminary)
Item Raw gas damper Clean gas damper Bypass damper
DIN1.4529 DIN1.4529
Q235-A
Q235-A
Carbon steel is coated with
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2
(1 1 ) 0.5kPa
The inlet and outlet flue gas damper and the bypass damper share a set of seal air
system including 2 seal fans (one for use and the other for backup) and an electric
heater. The seal air pressure is 0.5kPa higher than the flue gas pressure, and it is
considered in design that the fan should have sufficient capacity and pressure head.
The damper auxiliary equipments such as the seal fan and electric heater are all
supplied by the damper manufacturer with match.
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Section II Absorber system
1
1) Spray tower
Mist eliminator
Raw flue gas inlet
Clean flue gas outlet
Spray pipe
Absorber reaction tank
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pH
pH
Flue gas
Air vent to atmosphere
Process water
Flow meter
Mist eliminator and wash water
Gypsum hydrocyclone
pH PH meter
Densimeter
Limestone slurry
Emergency slurry tank
To the drainage pit of absorber
Absorber
Slurry circulation pump
Process water
To the drainage pit of absorber
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Oxidation fan
Process water
Process water
pH Measurement of pH value and density
To gypsum dewatering
Gypsum slurry discharge pump
To emergency slurry tank
Process water
Absorber blender
To the drainage pit of absorber
1.1
1.1 Overview
/
In the absorber, the circulating slurry fogdrop contacts with the reverse flue
gas flow to clean SO2, SO3, HF, HCl, dust and other noxious substances in the flue
gas while the calcium carbonate in the slurry reacts with SO2 and generates calcium
sulfite. The clean flue gas, after desulfurization and dust removal, is discharged out of
the absorber after the fogdrop in the flue gas are removed by the mist eliminator.
Inject air to the slurry collected in the absorber slurry pool (in the lower half
of the absorber acting as the reaction area of the absorber) to oxidize the calcium
sulfite to calcium sulfate and generate the gypsum crystals. In order to keep the
suspension of solid particles in the slurry and strengthen the oxidation reaction, four
blenders are configured in the absorber slurry pool.
During normal operation, the gypsum slurry discharge pump will deliver the
gypsum slurry to the gypsum hydrocyclone for dewatering.
FGD
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FGD
The exhaust gate is set at the top of the absorber and is closed during normal
operation. When FGD unit uses the bypass or is shutdown, the exhaust gate will open
to discharge the wet steam in the tower and the flue to maintain the pressure balance
inside and outside the flue gas system. When the bypass damper opens, the raw gas
damper and the clean gas damper will close, and then open the exhaust gate of the
absorber.
1.2
1.2 Reaction principle
SO2
The SO2 removal principle in the absorber is as follows:
SO2
SO2 in flue gas reacts with the calcium carbonate in the slurry to generate
calcium sulfite:
CaCO3 SO2 H 2 O CaSO3 H 2 O CO2 1
With the intermediate transition reaction of the oxygen in the flue gas and the
bisulfite, part of calcium sulfite changes into gypsum (dihydrate calcium sulfate) :
CaSO3 H 2 O SO2 H 2 O Ca(HSO3 ) 2 2
Ca( HSO3 )2 1 2O2 H 2 O CaSO4 2 H 2 O SO2 3
The remaining calcium sulfite in the absorber slurry pool oxidizes with the air
blown by the oxidation fan to generate calcium sulfate.
CaSO3 H 2 O 1 2O2 H 2 O CaSO4 2H 2 O 4
At the same time, some other chemical reactions also occur: The reaction of
sulphur trioxide, chlorine hydride and hydrofluoric acid with calcium carbonate
generates gypsum, calcium chloride and calcium fluoride:
CaCO3 SO3 2H 2 O CaSO4 2H 2 O CO2 5
CaCO3 2 HCl CaCl2 H 2 O CO2 6
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1.3
1.3 Procedure description
/
SO2 SO3 HCl
HF
CaSO42H2O
The hot flue gas from the induced draft fan of the boiler after pressurized by the
booster fan enters the spray absorber for desulfurization. In the absorber, the flue gas
contacts with the reverse limestone/gypsum slurry flow and is cooled to the adiabatic
saturation temperature. SO2 and SO3 in the flue gas react with the limestone in the
slurry to generate calcium sulfite and calcium sulfate, and the HCl and HF in the flue
gas also react with the limestone in the slurry and is absorbed. The saturated flue gas,
after desulfurization, is discharged into stack after fogdrop in it is removed by mist
eliminator on top of the absorber. The oxidation air fan blows air into slurry pool of
absorber, to oxidize calcium sulfite to calcium sulfate, and supersaturated calcium
sulfate solution crystallizes into gypsum (CaSO42H2O). The gypsum slurry is
continuously pumped out by the gypsum slurry discharge pump and sent to gypsum
hydrocyclone for concentration, and send the concentrated gypsum slurry to two-stage
dewatering system which generally uses belt-type vacuum dewatering machine. When
solid content in slurry inside the absorber is relatively lower, do not sent slurry for
two-stage dewatering.
1.4
1.4 Main equipment
1.4.1
1.4.1 Absorber
SO2
The absorber integrates SO2 washing and absorption, oxidation and gypsum
crystallization into one. Such tower model has been adopted more widely. The tower
model has advantages in terms of operation and maintenance workload, operation cost,
operation flexibility, being easy to improve, etc.:
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The absorber is generally designed in reverse flow mode, which can, to some
extent, hold liquid drops through rising flue gas to extend the time of liquid drop
staying in absorption area, thus intensifying complete contact between flue gas and
absorbent, improving the desulfurization efficiency.
The absorber can be equipped with standby spraying layer which can adapt to
changes of SO2 loaded by the unit, keep the operation flexible, and maintain stable
desulfurization efficiency.
The absorber for the project is characterized as follows:
192
80kPa
The absorber is set with five layers of spray systems, for each layer of spray system is
set with about 192 eccentric cone nozzles, nozzle inlet pressure head is about 80kPa,
and there is two-level mist eliminator set on spraying layer.
The absorber is of empty tower structure, which means low pressure drop
inside the tower.
No scaling or blocking problem on inner surface of the absorber.
FGD
pH //
FGD
The layout of spraying layer, nozzle, mist eliminator and flue gas inlet and
outlet in the absorber has referred to operation experience of FGD design, defining the
distance between spraying components according to effective spraying trace and
retention time of droplets. Meanwhile, it adopts appropriate pH value, liquid/gas ratio,
calcium/sulphur ratio, oxidation air quantity, slurry concentration, flue gas velocity
and other performance parameters, thus ensuring continuous, stable and economical
operation of FGD system.
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(CaSO42H2O)
4
The air release valve is set at the top of the absorber and the valve is closed
during normal operation. When FGD unit takes bypasses or it stops, open the air
release valve to discharge wet steam in tower so as to eliminate air differential
pressure due to cooling during operation or stopping of oxidation fan of absorber.
1.4.2
1.4.2 Absorber slurry circulation pump
Slurry recirculation system adopts unit system design, each spraying layer is
equipped with one set of slurry circulation pump, and each set of absorber is equipped
with five sets of slurry circulation pump. Quantity of operating slurry circulation
pump depends on change of boiler load and requirements for absorbed slurry flow, so
as to reach the required absorption efficiency. Since it can select the most economical
pump operation mode according to boiler load, the recirculation system can reduce
energy consumption under lower boiler load.
1.4.3
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/L/G 95%
The slurry spraying system consists of spraying components and nozzles. One
spraying layer consists of main pipe slurry distribution pipeline with connecting
branch pipes and nozzles; spraying components and nozzles are arranged in a cross
section evenly covering absorber and spraying slurry coverage rate reaching the
required value to make slurry contact with flue gas sufficiently, thus ensuring to
reliably realize 95% desulfurization efficiency under proper liquid/gas ratio (L/G) and
with no scaling on the inner surface of absorber.
FRP
Hollow cone nozzle and FRP spray pipeline made of silicon carbide can extend
operation time, with no corrosion, abrasion, gypsum scaling, blocking or other
problems.
1.4.4
1.4.4 Mist eliminator
FGD FGD
FGD
Mist eliminator is the key equipment in FGD system, for its performance can
directly influence continuous and reliable operation of the wet FGD system. Mist
eliminator fault will stop the desulfurization system. Therefore, scientific and rational
design and usage of mist eliminator have great significance to keep normal operation
of wet FGD system.
Main performance and design parameters of mist eliminator:
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System pressure drop. It refers to pressure loss when flue gas passes through
mist eliminator channel, and the more system pressure drop is, the higher the energy
consumption is. Pressure drop of demisting system is mainly related to factors of flue
gas velocity, blade structure, distance between blades, water load in smoke, etc. When
the mist eliminator blade is seriously scaled, system pressure drop will obviously
increase. Therefore, it is conductive to master system operation state by monitoring
changes of pressure drop, and find out problems and dispose in time.
3.55.5m/s
Flue gas velocity. Neither too high nor too low flue gas velocity on mist
eliminator section is beneficial to normal operation of mist eliminator. Too high flue
gas velocity is easy to cause secondary water in flue gas, thus reducing demisting
efficiency, and meanwhile, high velocity will cause larger system resistance and
higher energy consumption. Too low velocity on mist eliminator section is not
beneficial to liquid-gas separation, nor beneficial to improve demisting efficiency.
Besides, the lower the design velocity is, the larger the design absorber section will be
and so will the investment. Design flue gas velocity shall be close to the critical
velocity. According to different mist eliminator blade structures and layout forms,
design velocity is generally 3.5-5.5m/s.
SO2
2095mm
3050mm
Distance between mist eliminator blades. Selection of distance between mist
eliminator blades is quite important to ensure demisting efficiency and maintain stable
operation of demisting system. Large blade distance will cause lower demisting
efficiency and higher water content in flue gas, which is easy to cause fan fault and
lead to abnormal stop of the entire system. Besides increasing energy consumption,
too small blade distance can also reduce washing efficiency, cause scaling and
blocking on blade, and finally lead to system stop. Blade distance shall be selected
according to system's flue gas characteristics (flow velocity, SO2 content, water load,
dust concentration, etc.), absorbent utilization rate, blade structure and other
comprehensive factors. Blade distance is generally designed 20-95mm. Currently, the
mostly common mist eliminator blade distance in desulfurization system is 30-50mm.
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1m
Mist eliminator wash water pressure. Generally, the mist eliminator wash
water pressure is defined according to washing nozzle characteristics, distance
between nozzle and mist eliminator and other factors (distance between nozzle and
demister is generally less than or equal to 1m). Low wash water pressure will cause
bad washing effect while higher wash water pressure will be easier to increase the
water content in flue gas, and reduce blade service life at the same time.
14m3/m2h
Mist eliminator wash water volume. Besides the requirements for the mist
eliminator itself, selection of mist eliminator wash water amount also needs to
consider requirements for system water balance. It needs to use a large amount of
water to wash in short time under some conditions, while sometimes, it needs to use
small amount of water to wash in long time. The specific wash water amount shall be
defined according to working conditions, and generally, the transient wash water
consumption amount of demister section is about 1-4m3/m2h.
100300
Washing coverage rate. Washing coverage rate refers to the coverage degree
of wash water on mist eliminator section. According to different operation conditions,
the washing coverage rate is generally 100-300%.
35
2h
Mist eliminator washing cycle. Washing cycle refers to the time interval of
each washing of mist eliminator. Since mist eliminator washing will increase the
water content in flue gas (generally being 3-5 times of the content of non-washing),
washing should not be too frequent, but the interval shall not be too long, otherwise it
will be easy to cause scaling. Mist eliminator washing cycle is mainly defined
according to flue gas characteristics and absorbent, generally not exceeding 2h.
75mg/Nm3
The absorber is set with a two-level mist eliminator at the top of the last spraying
component on the absorber top. After passing the circulating slurry spraying layer, the
flue gas continuously flows through two-level mist eliminator to remove the
contained slurry fogdrop. In order to avoid mist eliminator blocking, it is equipped
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with flushing system. After the flue gas passing through the two-level mist eliminator,
the water content in flue gas is lower than 75mg/Nm3 (dry basis). Mist eliminator
cleaning system adopts intermittent operation and automatic control.
1.4.5
1.4.5 Oxidation air system
/ FGD
SO2
Wet limestone/gypsum FGD process is divided into forced oxidation and natural
oxidation. Small amount of SO2 absorbed by slurry is oxidized by oxygen in flue gas
in absorption area, which is called natural oxidation. Forced oxidation refers to
spraying air into oxidation area of the tank to promote to oxidize soluble sulfite to
sulfate, control scaling and finally crystallize to gypsum.
FGD
(CaSO31/2H2O)(CaSO42H2O)
In the FGD system, oxygen content in flue gas itself is not enough for oxidation
reaction to produce calcium sulfite. Therefore, it needs to provide forced oxidation
system to provide oxidation air for slurry of absorber. Oxidation air oxidizes
semi-water calcium sulfite (CaSO31/2H2O) generated in desulfurization reaction to
calcium sulfate and crystallize to gypsum (CaSO42H2O).
FGD
Oxidation air system consists of oxidation fan and oxidation air distribution
piping net in centralized arrangement. Generally, each set of FGD unit is equipped
with two sets of oxidation fans, one for operation and the other for standby.
n
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1.4.6
1.4.6 Discharge pump of absorber
1 1
Discharge pump of absorber (one for operation and one for standby) is installed
nearby the absorber. The discharge pump of absorber pumps out gypsum slurry from
slurry pool of absorber through pipelines and sends to gypsum hydrocyclone station.
Slurry pool side wall of absorber is installed with a high-low liquid level meter,
which can measure the density of slurry.
DCS
Density instrument sends the density signal to DCS, when the absorber is
switched on and the density reaches or approaches to the set value, the discharge
pump starts, and gypsum slurry is pumped into the gypsum hydrocyclone for
separation from the slurry pool of the absorber. Gypsum slurry is continuously
discharged, so liquid level of the absorber will decline, and then flushing valve or
water inlet valve of the mist eliminator will be opened to convey filtrate water into the
absorber to maintain the liquid level; by this time, the density of slurry in the absorber
will decrease, when it reaches the set value, underflow and overflow of the
hydrocyclone will return to the absorber, gypsum slurry enters the belt-type vacuum
dewatering machine, and the pipeline closes until that the density of gypsum reaches
or approaches to the set value.
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Discharge pump of the absorber may also empty the slurry pool of the absorber
into the emergency slurry tank so as to facilitate the overhaul for absorber, blender
rotary blades, nozzle, mist eliminator and wash water pipe of the mist eliminator.
1.4.7
1.4.7 Blender of absorber
34
(CaCO3 )
SO2
3-4 blenders are horizontally arranged in radial direction within the bottom slurry
pool of absorber; its function is to keep the slurry in the flow state, thereby also
maintain the desulfurization active substance (CaCO3 solid particle) in uniform
suspension state in the slurry, and ensure the absorption and reaction capacity of
slurry on SO2.
1.4.8 PH
1.4.8 PH meter
EDC 2
PH 2 pH pH DCS pH DCS pH
SO2
pH SO2 pH
pH
There is only 1 branch pipe to feed slurry in normal operation; when this section
of pipeline needs to exit or the circulation pump stops operation, open the pipeline
flushing valve of pH meter, after 2 minutes of flushing, open the electrically-operated
valve of pH meter direction, and close the electrically-operated valve at the branch
pipe inlet; inspectors need to close the manual valve of this branch pipe manually,
depositing the slurry for precipitation.
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Section III Slurry preparation system
FRP
Medium adopted by slurry preparation of the wet mill generally contain process
water and filtrate water. With different media, materials used by tank and pipeline in
slurry preparation system are different; when process water is adopted, carbon steel is
generally adopted for slurry pipeline; If filtrate water is used to make slurry, corrosion
prevention shall be considered due to the chloride ion content in the filtrate, adopt
materials such as carbon steel lined with rubber or FRP material. Task of slurry
preparation system is to offer qualified limestone slurry for absorber system.
1
1. Limestone wet-milling slurry preparation system
1.1
1.1 System description
FGD 90325
44m
The FGD system adopts limestone blocks wet-milling slurry preparation scheme;
request on the limestone particle size in slurry: 90325 meshes (44m).
(20mm)
,
Limestone (particle size 20mm) is sent to the unloading hopper by truck, to the
limestone silo via the feeder and bucket elevator, and then conveyed to the wet ball
mill by weighing feeder and ground into slurry. Limestone slurry is pumped into the
hydrocyclone, after separation, materials of large size re-circulate, and qualified
overflow materials are stored in the limestone slurry tank, and then delivered into the
absorber via the limestone slurry pump.
2.2
2.2 Main equipment
The system mainly includes unloading hopper, limestone silo, bucket elevator,
limestone mill, weighing feeder, mill slurry circulation pump, mill re-circulation tank,
hydrocyclone, limestone slurry pump, limestone slurry tank, slurry tank blender and
other equipment.
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2.2.1
2.2.1 Unloading hopper
FGD
To reduce the size and cost of wet mill, the plant won't conduct crushing
generally. Feeding limestone crushing size shall be usually not larger than 20mm.
Limestone transported by truck is discharged into the hopper, sent to the bucket
elevator passing the vibrator feeder with metal separator, and then sent to the
limestone silo through bucket elevator.
2.2.2
2.2.2 Limestone silo
The silo is designed with 2 discharge holes, separately feeding each set of mill;
the discharge hole is designed with air cannon anti-blocking measures.
On the top of limestone silo has been set with a sealed manhole door, which
should be quickly opened by hinge and handle, besides, there is exhaust gate on the
top.
50mg/Nm3
Ventilation & dust collector of the silo is bag-type dust collector, and the
maximum dust content in clean gas after dust removal is less than 50mg/Nm3.
Charge level indicator which is used to confirm the volume is equipped on the
silo, and also can be used for distant indication.
Necessary stair landing shall be designed for the convenience of overhaul and
maintenance of dust collector, charge level indicator, etc.
Each discharge hole of the silo should be installed with shut off valve.
32.2.4
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Weighing feeder is used to measure and transport the limestone to the ball mill,
and capacity of each set of the limestone belt weighing feeder shall be confirmed
based on the limestone feeding amount required by the limestone slurry preparation
system.
Feeder operates in a complete sealing state to prevent dust. Sealing of the feeder
is made of demountable plates, each of which is equipped with sealing gasket and
quickly opening plug pin that is convenient for maintenance.
The feeder is designed to discharge belt spilt and entrainment into the feeding
trough.
2.2.5
2.2.5 Limestone mill
(
) 100
The limestone milling system adopts the wet ball mill slurry preparation system.
Slurry preparation mode is the re-circulation mode (each set of mill is equipped with 1
set of rotational flow station). When 2 sets of the mills are adopted, the output of each
set of mill is designed based on 100% of total design output.
FGD SO2
44m(325 90)
()
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2.2.6 Hydrocyclone
(
)()
2530wt
Hydrocyclone is used to separate the limestone slurry at the wet mill outlet,
separated overflow slurry (including fine particles) will directly enter the limestone
slurry tank, and underflow (including large particles) returns to the wet mill. Each
hydrocyclone is installed with a separate manual valve. Hydrocyclone is in annular
layout, and the whole system is self-support framework, which entirely adopts steel
members. Each rotational flow station is set with a cyclone for standby. Each set of
mill is equipped with a group of limestone slurry hydrocyclones, and can meet the
requirement of limestone slurry fineness. Overflow slurry of each group of limestone
slurry hydrocyclones shall be able to enter the limestone slurry tank. Concentration of
limestone slurry can be correctly controlled in any concentration 25-30wt.
2.2.7
2.2.7 Pump, tank and blender
2 sets of mill slurry re-circulation pumps are equipped for each set of the mill
with one for operation and one for standby;
100BMCR 1~1.5
The limestone slurry pump is used to send the limestone slurry into the
absorber, and is set with frequency converter. Its capacity is designed based on 1-1.5
times of limestone slurry consumption needed by desulfurization under the working
conditions of 100% of BMCR of one boiler, and this pump is also equipped with
standby pump.
1 mill re-circulation tank for each set of mill;
68
2 limestone slurry tanks; The total capacity is designed as per the
consumption of 6-8h.
Section IVGypsum dewatering system
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Limestone slurry
Absorber
Raw flue gas
Gypsum slurry
Wastewater treatment system
Hydrocyclone
Dewatering machine
To gypsum stockpile
To slurry preparation system
1
1. One-stage dewatering system
SO2
1,0701,150kg/m3
15wt 3
4 50wt
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Gypsum crystals generated by reaction with SO2 in the absorber are continuously
sent to the gypsum hydrocyclone for primary separation by discharge pump of
gypsum slurry so as to ensure that the density in the absorber keeps 1,070-1,150kg/m3.
After primary separation of slurry with concentration about 15%wt from the absorber
in hydrocyclones, concentration of the top flow is generally 3-4%, and that of the
underflow is generally 50%wt. A part of the top slurry flow is sent to the wastewater
treatment system and another part returns to the absorber for cyclic utilization; the
underflow is sent to the two-stage dewatering system and dewatered into gypsum.
1.1
1.1 Gypsum slurry discharge pump
1015wt
FGD
Gypsum slurry discharge pump generally adopts centrifugal pump, and is set
with frequency converter. Its main function is to send the gypsum slurry with
concentration about 10-15%wt in the absorber into the hydrocyclone for primary
dewatering, and regulate the pump revolving speed via conversion of current
frequency to make the pressure at hydrocyclone inlet constant; Then regulate the sand
sinking nozzle of hydrocyclone to change the top flow slurry amount of hydrocyclone
so as to ensure the flow and concentration of hydrocyclone outlet. When an overhaul
is required for FGD system, the gypsum slurry discharge pump can be used to pump
the slurry in absorber into the emergency slurry tank.
1.2
1.2 Gypsum hydrocyclone
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Feeding port
Overflow nozzle
Overflow port
Staving
Taper pipe
Sand sinking nozzle
Feeding port
Staving
Taper pipe
Sand sinking nozzle
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2.3
2.3 Belt-type vacuum dewatering system
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50wt 90wt
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In FGD system, the drainage pit is usually located near the absorber, and is used
to collect the draw-off during normal operation, washing and overhaul of absorber
area. The drainage pit collects the flushing water and/or blowoff water of FGD unit. If
the drainage pit reaches certain liquid level, the pump will transport the slurry in it to
the absorber or emergency slurry tank.
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Emergency slurry tank is used to discharge and store the slurry in the absorber
slurry pool under the condition of overhaul, minor repair, stop or emergency of
absorber. Slurry in the absorber can be sent to the emergency slurry tank through the
absorber discharge pump; Slurry can be conveyed back to the absorber from the
emergency slurry tank via the emergency slurry pump.
1
Emergency slurry tank: 1
4
Emergency slurry tank blender: 4 sets (side-entry)
2
Emergency slurry pump: 2 sets
1
Drainage pit of absorber area: 1
1
Blender of drainage pit of absorber area, 1 set
2
Drainage pit pump of absorber area: 2 sets
1
Drainage pit of slurry preparation area: 1
1
Blender of drainage pit of slurry preparation area: 1 set
2
Drainage pit pump of slurry preparation area: 2 sets
1
Drainage pit at the dewatering area: 1
1
Blender of drainage pit at the dewatering area, 1 set
2
Drainage pit pump at the dewatering area: 2 sets
1
1. Emergency slurry tank
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Emergency slurry tank is generally set within the desulfurization island, and used
to collect the absorber slurry in case of accidents and maintenance work of
desulfurization island.
Capacity of the emergency slurry tank is usually designed slightly larger than the
absorber slurry pool, and blender is equipped and vertically installed on the top or
side wall. Blender is to maintain the rotating suspension of slurry in the pool to
prevent the sediment of solid particles.
2
2. Emergency slurry pump
Emergency slurry pump is used to discharge the slurry of the emergency slurry
tank.
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Drainage pit pump installed on the drainage pit top is used to transport the slurry
from the drainage pit to the absorber or emergency slurry tank.
Section VI Process water system
Process water system is used to offer the water required by system water
replenishing and flushing in the desulfurization island.
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FGD
Process water should be supplied to the process water tank set on FGD unit site.
Process water is supplied into all equipment needing process water from the process
water tank via the process water pump. Relevant process water pump is equipped with
100% of allowance.
Process water is mainly used to wash the absorber mist eliminator and prepare
limestone slurry, and also used as the flushing water for all conveying equipment and
slurry pipelines. Process water also can be used as the cooling water of partial
equipment of the desulfurization island.
1
1. Supply system of process water includes
1 FGD 1 FGD
1 FGD process water tank and 1 cooling water tank. Design volume of the water
tank shall ensure the safe operation of FGD unit.
Inlet control of process water tank includes the control signal and inlet valve.
All needed connecting pipe, supply, discharge, overflow and drainage, liquid
level control, inspection door, overflow pipe, drainage pipeline, and all other units
needed, flange, etc.
2 1001 1
2 sets of 100% process water pumps with one for operation and one for standby.
3 1002 1
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3 sets of 100% mist eliminator flushing pumps with two for operation one for
standby.
2 1001 1
2 sets of 100% cooling water pumps with one for operation and one for standby.
2 FGD
2. There are equipment and systems below consuming process water in FGD
unit.
Mist eliminator flushing unit
Limestone slurry preparation system
-
Two-stage dewatering (belt-type vacuum dewatering machine-vacuum pump)
and seal water
GGH
Flushing of heat exchanger elements of GGH
Absorber blender flushing under the emergency state
Flushing of pumps and pipelines
Oxidation air cooling
3 FGD
3. There are equipment and systems below consuming cooling water in FGD
device.
Circulation pump and oxidation fan
Booster fan
Wet mill
Other small pumps (process water may be adopted)
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4
4. Process water system diagram
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4
4. System water equilibrium diagram
5
5. Typical water quality requirement
Contents Unit Data Remarks
Process water
quality
kPa 50
Pressure
- SO4 2- mg/l 1280
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Contents Unit Data Remarks
- Cl - mg/l 250
1
-
mmol/l 1.005.00 Vacuum pump sealing is
- Hardness
required to be less than 1.
GGH
15
Suspended solid mg/l 2060 GGH washing and
particle oxidation air cooling are
required to be less than 15.
Average 20
temperature
- pH
67
- pH value
Quality of gypsum flushing water (the same as the process water quality)
Quality of equipment cooling water (the same as the process water quality)
Section VII Wastewater treatment
1
1. System determination
pH 46
CdHgCrAsPbNi
CuZn
FGD
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usually has a very larger difference, and even if wastewater quality extracted by the
same set of desulfurization unit in the different phases will be also different;
Wastewater is faintly acid with pH value of 4-6, and has a high content of suspended
solids (gypsum, monox, metal hydroxide and fly ash), soluble chloride, calcium
sulfate, magnesium sulfate and other salts; Desulfurization wastewater contains
the first class pollutants of heavy metal ions (Cd, Hg, Cr, As, Pb, Ni and other heavy
metal ions) and the second class pollutants (Cu, Zn, fluoride, sulfide, etc.); these metal
ions come from coal, absorbent and supplementary water of different producing areas,
so the concentration of individual heavy metal ion may have a great difference. Due to
moisture vaporization of FGD system and cycle use of recycled water, the
concentration of these metal ions in wastewater may be higher compared with the
wastewater discharge standard. Based on the above characteristics of desulfurization
wastewater, some countries with developed desulfurization technology have
formulated relevant water quality discharge standard.
DL/T-997-2006
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HCl
Process water system shall at least include water used by lime powder slurry
preparation system and dispensing of various dosing systems; Spray water; Flushing
water used when vessel, pump and pipeline of lime slurry preparation system stop
working; Flushing water of dewatering machine; Flushing water used when sludge
pump and pipeline stop working to wash pipelines, valves, etc..
Set necessary wastewater storage pool, wastewater pump, etc.
1 1
1 1
In order to make the system with high availability, various medical solution
storage tank shall be set with one for operation and one for standby; The measuring
box should be designed based on the capacity prepared by 1 time/day, and set with
one for operation and one for standby.
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Alkali needed by wastewater neutralizing will select the lime milk Ca(OH)2
prepared by lime powder, the added alkali amount is controlled by pH measured value,
dosage of other chemical substances (organic sulfur/flocculant (polymeric
iron)/coagulating support agent (polyelectrolyte)/ hydrochloric acid/oxidizing agent)
should be automatically adjusted in proportion to desulfurization wastewater quantity
and water quality. Wastewater flow meter shall be set in the system.
All pumps shall be installed with check valve at the discharge side, isolating
valve at the discharge and suction side, and evacuation protection device. The pump
should be selected by matching with the conveying medium and installment
environment.
/
PVC PP PTFE
Various dosing systems may realize the complete automatic control via the local
control cabinet, accept the control signal of PLC, and send the system state signal to
PLC DCS. Various dosing processes should be equipped with flow and pressure
measuring instrument.
All automatic valves are equipped with manual switch. All storage tanks are
equipped with liquid level indicators and liquid level touch switch preventing
overfilling, and are interlocked with other facilities.
PLC
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pH
6hr
Concentration and clarification tank has the combined action of coacervation,
clarification and sludge concentration, and is equipped with rotating sludge scraper.
Wastewater after flocculation enters the concentration and clarification tank for
further flocculation and sufficient precipitation, and the supernatant liquid overflows
into the neutralizing water pool; for bottom sludge generated, a part reflows to pH
adjusting box to enhance the effect of wastewater treatment and fully exert the
function of residual chemical agents, and the other part is periodically discharged and
treated with dewatering. The design retention time of the pool body shall be larger
than 6hr.
7
15
All chemicals required by desulfurization wastewater treatment process shall be
stored in storage and dosing unit that meets labor hygiene and drug safety standards; 7
days of storage amount should be considered for chemicals that can be purchased
from this locality, but 15 days of storage amount should be considered for chemicals
purchased from the different place.
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FGD
Chapter II Impact on FGD Unit from Variation Range of Fuel
Characteristics
Section I Impact on system from flue gas flow rate change
SO2 Cl- FGD
Apart from SO2 discharge and Cl- content, the physical property of untreated flue
gas is also a very crucial factor to design FGD system, and significant characteristics
of flue gas include flow, temperature and pressure, in which the flue gas flow has the
largest impact on FGD system design; just like determining the parameter of SO2
discharge, flue gas flow is one of the basic conditions to be determined in designing
FGD system, and is also a parameter difficult to determine. Because the smoke
exhaust rate of boiler not only changes along with coal properties, but is affected by
the factors below: Unit load, excess air quantity, outlet temperature of air pre-heater,
and air leakage of air pre-heater and other parts.
1
1. Impact on system related parameters from overload and underload.
125 75
100
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Desulfurization 95 93.81 91.78 97.15
efficiency
Outlet concentration of 85.8mg/Nm 102.4mg/Nm 132.7mg/Nm 67.2mg/Nm
absorber
m/s
Flue gas velocity in 3.82 4.77 5.85 2.86
absorber m/s
t/h
Limestone consumption 8.58 10.73 13.68 6.44
t/h
t/h
68.8 85.82 103.76 50.68
Water consumption: t/h
t/h
15.3 19.1 242 11.5
Gypsum output t/h
Nm3/h
Oxidation air demand 18972 23715 29328 14229
quantity Nm3/h
t/h
8.1 10.1 12.3 6.1
Wastewater output t/h
1.1.2
1.1.2 Result analysis
25 50 75
3000000
Item Increase 25 Increase 50 75 load
Desulfurization 1 1.3 3.4 2.3
efficiency in absorber
Outlet concentration of 1 19.3 54.7 21.7
absorber
Flue gas velocity in the 1 24.9 53.1 25.1
absorber
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t/h
Limestone consumption 1 25.1 59.4 25.0
t/h
t/h
1 24.7 50.8 26.3
Water consumption: t/h
t/h
1 24.8 58.2 24.8
Gypsum output t/h
Nm3/h
Oxidation air demand 1 251 54.5 25
quantity Nm3/h
t/h
1 24.7 51.9 24.7
Wastewater output t/h
Outlet temperature of 43 43 43 43
absorber
1.2 GGH
1.2 Cancellation of the GGH project data setting
25 50 75
3000000
Item Increase 25 Increase 50 75 load
Desulfurization 96.58 94.91 93.36 97.53
efficiency
Outlet concentration of 84.6mg/Nm 101.4mg/Nm 127.3mg/Nm 166.1mg/Nm
absorber
Flue gas velocity in the 3.99m/s 4.99m/s 5.99m/s 2.99m/s
absorber
t/h
Limestone consumption 8.6 10.76 13.68 6.46
t/h
t/h
108.5 136.1 154.3 81.0
Water consumption: t/h
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t/h
15.35 19.2 24.2 11.53
Gypsum output t/h
Nm3/h
Oxidation air demand 18972 23715 29328 14229
quantity Nm3/h
t/h
8.1 10.1 12.3 6.1
Wastewater output t/h
Outlet temperature of 47 47 47 47
absorber
1.2.2
1.2.2 Data analysis
GGH GGH
60%
It can be seen from comparison of relevant parameters of setting GGH and
cancelling GGH that except that process water consumption increase is relatively
more (about 60%), other data are basically fair compared with that before
transformation.
1.3
1.3 Analysis of impact on system from flue gas amount change
1.3.1
1.3.1 Direct impact brought by the increase of the flue gas amount:
1)
1) Flue gas velocity in absorber increases
2)
2) Slurry amount carried by the flue gas increases, which increases the weight
of flotsam
3)
3) Consumption of limestone and process water increases
4)
4) Gypsum output increases
5)
5) Oxidation air demand amount increases.
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1.3.2
1.3.2 Indirect impact brought by the increase of the flue gas amount:
1)
1) Flow resistance of the system increases
2)
2) Output demand of fan increases
3)
3) Flushing frequency demand of mist eliminator improves
4) GGH
4) GGH blocking probability increases and enlarges
5)
5) Scale formation and abrasion probability of the system increases
6)
6) Gypsum dewatering concentration increases
SO2
Section II Impact on system from SO2 concentration change of flue
gas
1SO2
1. Determination of SO2 concentration
1.1 DL/T5196-2004)
1.1 It is specified in Technical Code for Designing Flue Gas Desulfurization Plants of
Fossil Fuel Power Plants (DL/T5196-2004) that:
SO2
Since the sulfur content contained in design coal as received to be employed for
main project is generally at the average level, SO2 concentration (both design value
and check value) at the inlet of the FGD unit shall be fully investigated. Considering
the actual conditions of coal procurement and the change tendency of coal quality, the
higher value within the change limits shall be selected.
1.2 /HJ/T179-2005
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Design parameter of flue gas of newly built desulfurization unit should adopt the
flue gas parameter under the condition of BMCR and burning the design fuel, and the
proofread value should adopt the flue gas parameter under the condition of boiler
economic continuous rating (ECR) and burning the fuel with the largest sulphur
content.
When adding FGD unit to the built power plant, its design conditions and
proofread working condition should be confirmed based on the flue gas parameter
measured at the inlet of the desulfurization unit, besides, the variation trend of fuel
shall be fully considered.
3SO2
3. Impact on system from SO2 concentration change
3.1
3.1 Theoretical calculation condition
100SO2 2500mg/Nm3
GGH
100% load refers to the situations listed in aforesaid sample cases, SO2 content is
2500mg/Nm3, and system comparison in this section is considered as per GGH
system setting.
100% 125% 150% 200%
Item 100% load 125% load 150% load 200% load
%
Desulfurization efficiency 96.52% 95.30% 94.13% 91.95%
of the system %
mg/Nm3
Concentration at the 85.8 144.6 216.1 393.6
absorber outlet: mg/Nm3
kg/h
Limestone consumption 8,583 10,597 12,611 16,639
kg/h
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kg/h
68,808 71,468 74,738 80,786
Water consumption kg/h
kg/h
15,305 18,837 22,377 29,580
Gypsum output kg/h
%
Capacity of gypsum 23% 46.2% -93.3%
Benchmark
dewatering system %
Nm3/h
Oxidation air demand 19,368 24,210 29,052 38,736
quantity Nm3/h
-25% -50% -100%
Oxidation air allowance % Benchmark
m3/h
Required circulating 10,886.8 12,245 13,453 15,596
slurry amount m3/h
Circulating slurry 4.07 -7.47 -15.78 -27.35
allowance %
t/h
8,097 8,065 8,065 8,065
Wastewater output t/h
Flue gas temperature at 42.81 43.03 43.24 43.69
absorber outlet
3.2
3.2 Effect analysis
SO2
7.4715.78
27.35 25
It can be seen from the above table that the increase of the SO2 results in a
proportionate increase of demand of slurry preparation system, dewatering system and
oxidation air system; Growth of demand of circulating slurry amount is relatively
smaller, respectively being: 7.47, 15.78 and 27.35, equal to 25% of sulphur
content increase; System water consumption also increases at different levels.
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SO2
In actual projects, due to the basic completion of system configuration, especially the
limited capacity of slurry preparation system, the safety of the system equipment can
be guaranteed only through the decrease of desulfurization efficiency, reduction of the
flue gas amount and other measures in case of SO2 content increase. Sticking to
overall FGD, balance of the entire system will be damaged and will cause the
following problems:
Inadequate oxidation in the absorber, scaling and difficulty in gypsum
dewatering
SO2
SO2 concentration at absorber outlet cannot be ensured
Increase abrasion of system equipment
Gypsum quality cannot be ensured
Aggravate corrosion of system equipment, and service time is seriously
shortened
Section III Impact on system from dust concentration change of
flue gas
1
1. Dust influence on desulfurization system
Dust influences on the wet desulfurization system mainly include:
Reduce gypsum quality;
Aggravate slurry abrasion to equipment;
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The fourth influence is manifested during operation as that slurry pH value and
desulfurization efficiency decline, the pH value of slurry pool still cannot rise even
after injecting large flow of absorbent slurry into the absorber, and absorption
efficiency does not rise again obviously. It's mainly because of higher dust content in
absorber, lower pH value control during operation. The complex compound combined
with Al3+ in fly ash and F- in slurry reaches to certain concentration and is absorbed
on the absorbent solid particle surface, which "seals" absorbent activity and obviously
slows down absorbent dissolution rate.
N2CO2O2
SO2NOxHClHF NH3CH4CH3C1
Besides, other chemicals introduced to the system with fly ash, such as
magnesium and manganese, can work as oxidation catalyst, which is beneficial to
forced oxidation process, but harmful for inhibiting oxidation process. Besides
influencing chemical reaction of the process, some heavy metals brought in with fly
ash can also influence the quality of wastewater discharge. Therefore, it is generally
not expected to bring excessive fly ash into absorption system. Gas composition of the
inlet flue gas mainly includes N2, CO2, O2, water vapor, SO2, NOx, HCl, HF and
sulfuric acid vapor, and minor compound includes NH3, CH4, CH3Cl, etc. There are
some harmful microelements contained in flue gas or fly ash, such as the mercury and
mercury compound which are seriously treated at present.
Desulfurization gypsum with large amount of dust:
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3
3. Relevant theoretical data
100SO2 100mg/Nm3
GGH
The 100% load mentioned in this section refers to the design conditions of the
specified flue gas amount, SO2 content and dust concentration of 100mg/Nm3; the
system has considered GGH system setting.
100% 200% 300% 400% 500% 600% 700% 800%
Item 100% load 200% load 300% load 400% load 500% load 600% load 700% load 800% load
mg/Nm3
System dust content 100 200 300 400 500 600 700 800
mg/Nm3
kg/h
15,305 15,454 15,545 15,649 15,766 15,985 16,122 16,258
Gypsum output kg/h
kg/h
Dust content in 110.24 220.07 329.80 438.93 547.58 655.33 762.56 870.03
gypsum kg/h
CaSO4
92.00% 91.10% 90.59% 89.98% 89.31% 88.08% 87.35% 86.62%
CaSO4 content in
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gypsum
Dust content in 4.1% 4.9% 5.7% 6.5% 7.3% 8.1% 8.9% 9.6%
gypsum
Dust percentage in 0.72 1.42 2.12 2.80 3.47 4.10 4.73 5.35
gypsum %
/
Total quantity of dust 16.8% 19.6% 22.0% 25.2% 27.8% 29.9% 31.9% 34.0%
inert
substance/solid in the
slurry of absorber
3.50% 4.00% 4.50% 4.50% 4.80% 5.30% 5.50% 5.80%
Top solid content of
gypsum hydrocyclone
4.
4. Data analysis
It can be seen from the above table that with increase of dust content,
0.72%
5.35
The gypsum output of desulfurization system increases slightly, but dust ratio
in gypsum increases considerably from 0.72% to 5.35;
CaSO4 92 86.62
Gypsum quality gets worse obviously, in which CaSO4 content decreases
from 92 to 86.62
16.8 34
20
200mg/Nm3
The percentage of dust inert substance in the slurry of the absorber
increases from 16.8 to 34, namely increased by more than one time. For safe and
stable operation, percentage of dust inert substance in the slurry of the absorber
shall generally be less than 20%, and dust concentration at the inlet is basically
200mg/Nm3.
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FGD
Section IVEffect of chlorine content in coal on FGD unit design
FGD
L/G
The other characteristic of the significant effect of the fuel coal on FGD system
design is chlorine content in coal. Like coal sulphur content, coal chlorine content
varies with original coal district and coal forming time. Coal chlorine content has
quite broad changing range, ranging from lower than 0.02 to higher than 0.5.
During the burning process, over 80% chlorine in coal turns into HCl, and not lower
than 95% HCl will be removed by FGD unit, thus leaving soluble chloride of certain
concentration in circulating slurry. High-concentration chloride will reduce the
alkalinity of slurry and make slurry more corrosive, and alkalinity of slurry influences
L/G and absorbent use ratio required by the desulfurization rate, and the strength of
the slurry's corrosivity will affect the selection and maintenance expenses of the
structural materials.
FGD Cl-
Cl-
mg/kg Cl-
Cl- 500mg/L
Cl-
20g/L Cl- 15g/L
Since slurry volume in FGD system is larger, Cl- content in circulating slurry will
not change rapidly. Generally, it does not need to consider the normal daily change of
coal chlorine content influence on the Cl- concentration in circulating slurry.
Therefore, the average coal chlorine content (taking mg/kg coal as the unit) can be
used as design value. For desulfurization system relying on wastewater discharge to
control Cl- concentration, if waste discharge is interrupted, Cl- concentration will
increase rapidly, and its increasing speed exceeds 500mg/L per day. Therefore, when
confirming chloride ion concentration in slurry, it needs to consider to store certain
allowance, for example, if the Cl- concentration in the slurry is required not to exceed
20g/L, it can be designed according to 15g/L of Cl- concentration.
FGD
FGD
In special circumstances, other trace substances in fly ash and coal can also
influence FGD system performance. However, in normal circumstances, their
significance is much smaller than sulphur and chlorine content. The influence of these
compositions in coal on FGD system performance greatly depends on the efficiency
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Chloride in FGD process slurry originates from the fuel coal, industrial
supplementary water and absorbent. Generally, chlorine content in limestone is quite
small, chlorine content in industrial supplementary water is 1.2-150mg/L, the content
in most coals is not more than 0.05, the content in fewer coals is 0.05-0.15, and
the content in some high-ash coals can be up to 0.47. Therefore, most of the
chloride in FGD process slurry originates from fuel coal.
CI-
Cl- concentration in the slurry can be determined in process technology
specifications with the following methods.
FGD
Only provide chlorine content in the fuel and chloride content in industrial
water, and FGD suppliers determine design chloride concentration according to
results of material balance calculation results.
Power plant may specify the minimum and maximum values for the design
chloride concentration in process slurry.
If there are requirements for quality of gypsum byproducts, the maximum
chloride content in solid byproduct can be specified.
50g/L NTU
3040C1- L/G
FGD
FGD FGD
FGD C1-
C1-
C1-
According to test data, when slurry chloride concentration exceeds 50g/L, mass
transfer capacity (represented with NTU) of an absorber will reduce by 30-40.
Therefore, absorber with higher Cl- concentration needs higher L/G and more
limestone or needs to change other performance parameters of the FGD system to
neutralize chloride influence on desulfurization efficiency. If FGD system owners do
not allow discharging wastewater, FGD suppliers have to conduct FGD system design
according to the chloride content confirmed by material balance in the craft process,
no matter how high the obtained Cl- concentration is. If wastewater discharge is
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FGD
Chapter III Non-metal Corrosion Prevention Materials of Wet
FGD System
Section I Technical Construction Requirements for Non-Metal
Corrosion Prevention Materials
FGD
70
Investment cost, annual maintenance cost and system service life of wet flue gas
desulfurization system greatly depend on selection and construction of corrosion
prevention and anti-wearing materials of the system. Generally, people give more
attention to material selection, but little attention is given to construction influence on
corrosion prevention. According to the survey, 70% of corrosion prevention problems
of wet FGD are caused by construction quality or procedure. Therefore, technical
requirements for construction related to corrosion prevention and other aspects are
hereby briefly explained.
1
1. Site Corrosion Prevention for Rubber Liner
1.1
1.1 Construction Conditions
12
During the entire rubber liner process (sand blasting- mucilage coating- lining-
repair), ensure to record the construction environment temperature, temperature of
lining base surface, relative humidity and temperature of corresponding dew points
every 1-2 hours after each shift starts and during operation.
15oC
Minimum temperature for rubber plate is 15 oC.
10 oC 30 oC 3K
Base: When the optimum temperature range is between 10 oC and 30 oC,
the dew point distance shall not be less than 3K.
5 oC 10 oC 5K
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If the temperature range is between 5oC and 10oC, the dew point
distance shall not be less than 5K.
70
Relative humidity shall not be higher than 70%.
1.2
1.2 Rubber Liner Procedures
Construction flow chart for tank rubber liner
1. 4.
2. 3. 6..
1. Iron piece 4. Binder painting
2. Sand blasting 3. Base coat 6. Paint adhesive
acceptance
painting
9. 8. 7. 5.
9. Dismantle scaffold 8. Acceptance of 7. Paste rubber plate 5. Rubber plate
division acceptance polishing
1.3
1.3 Acceptance Standards for Lining Base
DIN 28053
10mm 10mm
3mm
Sa2
ISO8503-1
RZ50m.
After completing the steel base, Party A and Party B jointly conduct the
acceptance and deliver corrosion prevention work according to German standard DIN
28053 and drawing requirements. Equipment lining surface shall be locally flat,
corner point shall be smooth, fillet radius of the convex corner surface shall be more
than 10mm and that of the concave corner surface shall be more than 10mm. Local
(including welding seam) roughness shall be less than 3mm, and shell thickness, after
polishing, shall be larger than the designed minimum thickness of the equipment.
Pitting, crack, undercut, scratch, scale and other surface defects have to be polished
and removed, repair the parts needing to be polished through welding, and welding
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seam has to be polished neatly and smoothly without air hole. The steel surface
treatment grade shall reach to Sa2 after sand blasting, i.e., conduct the sand blasting
until metal white, completely remove oxide scale, rust and other sundries, only leave
spots or striped shadow, and clean up grinding materials and dust. Roughness shall
comply with the required roughness in "Base Surface Roughness" of ISO8503-1 (see
Appendix), RZ50m.
1.4
1.4 Rubber Liner Acceptance Standards
1.4.1
DIN
1.4.1 The entire rubber liner process (sand blasting- mucilage coating- lining- repair)
shall strictly comply with the rubber plate construction specifications of DIN
standard.
During the rubber liner process, all the construction equipment personnel shall
wear socks or soft-soled shoes, and cannot wear hard-soled shoes; when pasting
rubber, it is necessary to use chalk to draw net-shaped lines, roll from inside to
outside, discharge all the air in it, and rolling shall be compact without lack of
compaction. In order to ensure lining quality, represent each construction
personnel with one English letter, and register and file. It is required to mark the
rolled places with chalk during construction, and write down the letter
representing the construction personnel for quality tracking.
Rubber plate cannot be stretched or compressed at will, and ensure that the
lining between rubber plate and base surface is even and complete without air
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bubbles.
30mm
Minimum width for connection seam shall not be less than 30mm. Pay
attention to the liquid flow direction and rubber plate joint cannot go against with
the liquid flow direction.
Flange surface shall be fully lined, and try not to leave connection seam.
It is necessary to roll the rubber plate after lining strictly in accordance with
requirements to discharge the air between rubber plate and base surface.
Kerabutyl BS
In case of repair, it shall be conducted strictly as per the procedures, and refer
to the construction specifications for our Kerabutyl BS rubber plate for details.
100
After completion of the rubber liner, 100% electric spark testing and thickness
check for the lining surface shall be conducted under the presence of Party A's
personnel, and tension test and hardness test on test plate shall be done to check
whether the quality conforms to the construction specifications.
1.4.2
200100mm 46mm 600
1.4.2 Produce the test plate while conducting rubber liner, and materials used shall be
the same as materials of corrosion prevention equipment, and each test plate is
200100mm and 4-6mm in thickness. Complete corrosion prevention construction in
one piece of test plate in every 600m2 of corrosion prevention area, evaluate the test
plate and ensure that all the inspection items for the entire set of equipment are the
same as those for test plate. Rubber adhesive strength of the test plate shall comply
with requirements regulated in construction specifications, and meanwhile ensure that
the adhesive strength of construction lining rubber plate meets the requirements for
test plate. Test adhesive strength of test plate to ensure it meets the requirements and
specifications for coating construction.
2
2. Site Corrosion Prevention for Glass Flake
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2.1
2.1 Ambient Condition:
: :16C 22C10C30C
Material: The optimum temperature range is 16C to 22C. 10C in
minimum, 30C in maximum
: 10C 25C 10C30C
3
Base: The optimum is between 10C and 25C, the minimum is 10C,
the maximum is 30C, and 3C higher than air dew point at least.
2.2
2.2 Corrosion Prevention Construction Flow Chart for Site Flake
1. 2. 3.
1. Engine body acceptance 2. Machine surface treatment 3. Base coat painting
5. 6.
4. 6. Wear-resisting layer
5. Lining construction and check for construction and check
4. Lining construction and check treatment
for the first flake layer the second flake layer
7. FRP 8.
7. Intensified construction for FRP 8. Surface coating 9.
lining 9. Acceptance of division
10.
Project handover 10. Dismantle scaffold
12. 11.2
12. Overall 11. Acceptance of division
acceptance (2)
2.3
2.3 Key Points and Standards for Machine Acceptance
2.3.1
2.3.1 Key Points and Standards for Metal Shell Acceptance
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Surface of the lining of metal shell shall be flat, with no roughness more than
3mm.
2
For screw holes or lug holes of inner and outer liners, the hole diameter shall
be increased by 2 times of gross thickness of lining. And they shall be polished to
transit smoothly.
All the spare modules welded to shell shall be welded before lining, and
welding is strictly forbidden after lining.
The supporting ring and reinforcement bar and other internal modules in the
equipment shall be continuously and fully welded with cylinder and angular position
and welding seam shall be polished to be able to transit smoothly.
R 5mm 10mm
Metal shell of lining equipment is required to be flat and smooth; its edges
shall be in circular arc transition with convex and concave circular arc radius (R) not
less than 5mm and 10mm respectively.
R5 Above R5
g. DN25
DN25
g. The minimum caliber of pipe required for lining is DN25; the flange can
be designed as reduced flange if smaller connecting size is needed but the pipe caliber
shall be at least DN25.
h.
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The base of concrete tank should be smooth and dense after the mold of
concrete tank is removed and lining surface should be free from greasy dirt, slurry,
cement powder, porosity, honeycomb, pitted surface and any other superficial defects.
6
Its moisture content is below 6%.
The surface should be smooth and free from local concave-convex after being
leveled in a mechanical way (defects are not allowed to be recovered by cement
mortar filling or plaster).
R10mm R5mm
Circular arc transition of internal corner R is 10mm and circular arc
transition of external corner R is 5mm.
No hole, falloff or any other great concrete defects are allowed to be on the
concrete surface. If base surface and lining surface fail to reach the above
requirements, construction unit shall repair.
The welding seam surface of embedded steel parts should be smooth and free
from undercut, overlap and slag inclusion or any other defects.
4
4. Finished Product Protection
It is not allowed to make welding, fire cutting or any other operations on the
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All the construction tools and other personal belongings (spare modules
required for installation) are required to be handled with care and prevented from
collision on the surface of corrosion prevention in the installation and construction.
5mm 15mm
Section II Reasons for Damage of Rubber and Reinforced Resin
Lining
There are many reasons for damage of rubber and reinforced resin lining in the
process of use and here are some key reasons for damage in discussion by time of
damage.
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1
1. Reason for Premature Lining Damage
The most noteworthy reasons for premature damage of rubber and reinforced
resin lining include: incorrect technical specifications and product updates, resulting
in adoption of improper products and grave temperature and mechanical damage.
FGD
(EPRI FGD
FGD
FGD
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GF
As previously mentioned, in order to apply slab rubber and reinforce resin lining,
not only the raw materials are required to be up to standard but also their construction
quality counts. Any negligence in the construction may result in lining defects in early
scaling. For example, early local lining blister primarily results from: there are blisters,
pores and other defects on the base, which are not found or in improper treatment
before lining; local residual air is not removed when slab rubber is pressed, GF resin
daub is rolled or glass fiber cloth is lined; rust removal by sand blasting is not
complete or dust or any other dirt fall in the process of lining; equipment welding
seam or corner treatment fails to reach specified requirements. Blister or delaminating
in multiple locations or in large area may result from: slab rubber or resin expiration;
the mucilage for pasting rubber sheet is mixed with moisture or ineffective; improper
selection of resin curing agent; too high humidity, too low temperature, poor control
of interval between two procedures and other reasons in the lining construction.
2
4 FGD
180
FGD
Sharp temperature change in operation or accident, larger scaling block or
mechanical foreign substance in the slurry or mechanical collision in overhaul may
result in premature damage of rubber and resin lining. It is not allowed to hit the outer
walls of lining by iron hammer during overhaul and it is necessary to be particularly
careful and prevent damage of lining while clearing gypsum scaling on the lining
surface. During absorber overhaul, it is necessary to bind both ends of steel tubes of
scaffold with something soft, pad pipe fittings at the bottom of tank with wood sheet,
be particularly careful and prevent damage of lining while clearing sediment at the
bottom of slurry pool in the absorber. Once lining cracks, it will soon result in base
corrosion and perforating. In the spray tower, if the slurry sprayed out from the nozzle
directly faces the tower wall, the lining will be penetrated within a short time (2-4
months). The two kinds of lining applied in FGD unit have strict temperature limits,
and in case of abnormal working condition and abnormal high temperature, damage to
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the lining will gradually show up. Therefore, when smoke discharge temperature of
the boiler exceeds certain limit value (generally being 180 ), there shall be
automatic protection measures, such as rapidly separating FGD system or putting
emergency cooling units into operation to prevent the two kinds of lining being
damaged by high temperature.
During lining construction, most of the used solvents are flammable with quite
high fire risk. So it is necessary to intensify ventilation; especially, the attention shall
be paid to prevent flammable gas gathering to a dangerous extent. Besides, most of
the solidified reinforced resins and vulcanized film lining are flammable, and there
has once been serious fire disaster caused by welding on the internal or external wall
of absorber with lining. Therefore, the absorber lined with organic corrosion
prevention materials shall be hung with warning plate of "No Welding" in
conspicuous place. When it is necessary to conduct electric welding, there shall be
elaborate fire prevention measures.
2
2. Reasons for Final Lining Damage
VE
Linings of rubber plate and reinforced resin are semi-permeable protective layers.
One reason for final failure of these linings lies in that moisture penetrating in the
middle of lining and steel plate base causes delamination; the other reason lies in
material aging. In this aspect, the aging of rubber flake is faster than that of VE resin
of glass flake. That part of the coating layer or lining layer bumps up and bubble is
filled with gas and liquid, which proves the existence of penetration. That rubber
lining layer loses its original elasticity, becoming hard and even friable or cracked,
which is the characteristic of aging. Main factors influencing the emergence of bubble
include resistance to moisture penetration of materials, lining thickness and
temperature gradient through the lining. The influence of temperature gradient is
usually called "cold wall" effect. Besides, resin content of resin layer and scaling of
resin to reinforced materials can also influence the emerging time of bubble.
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Chapter III Electrical System
GGH
UPS
UPS
Working range of electrical system includes the electrical systems of flue gas
system, absorbent preparation system, absorber system, GGH system, gypsum
dewatering system, process water system, desulfurization wastewater discharge
system, compressed air system within dehydration scope, and emergency power
supply system, DC system and UPS system. Electrical system includes: power supply
and distribution system, electrical control and protection, DC system, AC emergency
power supply and AC uninterruptible power supply (UPS), lighting and overhaul
system, anti-thunder grounding system and safety sliding contact line, communication
system, cable and cable structures, electrical equipment layout, etc.
Design of electrical system for FGD project is conducted according to relevant
principles for coal-fired power plant design.
Section I Electrical Elementary Wiring Diagram for Desulfurization
System
1 11kV
1. Elementary Wiring of 11kV Desulfurization System
Elementary wiring of electrical system is the main and core part of electrical part
of desulfurization island. It is closely related to the reliability, economic efficiency
and other factors in the operation of desulfurization system, and has great influence on
the electrical equipment layout, equipment selection, relaying protection and control
method and so on. So it is necessary to combine with the specific situation of power
plant to make comprehensive analysis and comparison for the rational selection of
wiring scheme.
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Elementary wiring of electrical system shall comply with requirements for power
supply reliability and power quality of desulfurization equipment, requirements for
simple and clear wiring and simple operation and maintenance, requirements for the
initial operation and operation in the final scale of desulfurization island, requirements
for staging operation, and requirements for advanced technology and being
economically reasonable.
2x100%
According to the Technical Code for Designing Flue Gas Desulfurization Plants
of Fossil Fuel Power Plants, auxiliary power capacity for main plant of the new
power plant shall be considered to include desulfurization capacity and each set of
machine on desulfurization island is set with two sections of high-pressure
desulfurization busbars, with connection between the two sections which can be
mutually replaced by each other. The plant busbar of main plant supplies power for
two lines with 2x100% capacity.
Elementary Wiring for Electrical System (the Figure below)
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2 415V/240V
2. Elementary Wiring for 415V/240V Desulfurization System
415/240V PCPower CenterMCCMotor Control
Center()380V 75kW
100kW MCC PC
MCC
415/240V system adopts power supply modes of two levels: PC - Power Center
and MCC - Motor Control Center. 380V system is neutral point solid grounding
system. Power for 75kW and above motor circuit, 100kW and above static load circuit
and all MCC power circuits is supplied by PC, and power for other loads is supplied
by nearby MCC.
415/240V
AB 415/240V
()415/240V AB
/ 11kV
Desulfurization island is set with three 415/240V desulfurization power centers,
one for each unit and one for public area, and all of them are wired sectionally with
single busbars. Each desulfurization power center is set with A and B sections of
415/240V desulfurization busbars, electrified by two mutually-standby (dark standby)
low-voltage dry-type transformers. A and B 415/240V desulfurization sections are
respectively set with interconnection switches which turn on under normal situation
and trip off the incoming line of certain section in case of its power fault, and the
interconnection switches can switch manually/automatically. Power supplies for the
six sets of low-voltage dry-type transformers are respectively accessed from 11kV
desulfurization section.
MCC
90kW PC 90kW
MCC
The power of all MCCs shall be supplied with unconnected single busbar, and
coupled loads are respectively connected to the two sections. 90kW and above motor
circuit and feeder circuit connected to PC are adopted with air circuit-breaker, and
90kW and below motor circuit and feeder circuit on MCC are adopted with moulded
case circuit breaker.
Section II Desulfurization Service Voltage and Neutral Point
Grounding Mode
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11kV 415V
The high-pressure service voltage of desulfurization shall be determined
according to the auxiliary power supply voltage of main plant and the high pressure
and low pressure of service voltage for desulfurization island are 11kV and 415V
respectively.
11kV
300A
Neutral point grounding mode of desulfurization power distribution system is
consistent with that of the main plant: 11kV system is adopted with low-resistance
grounding with grounding current limited to be 300A, and low-voltage distribution
system is adopted with three-phase four-line neutral point solid grounding mode.
UPS
Section III AC Emergency Power Supply, DC System and
Uninterruptible Power Supply (UPS)
400kVA/320kW
PC A B
Emergency power supply system is for public use of desulfurization island to
ensure safe stopping and equipment safety after power failure on the desulfurization
island. The project is equipped with a specialized diesel generator set
(400kVA/320kW). Desulfurization emergency section is electrified by Section A or B
of desulfurization PC in normal situation, and is electrified by diesel generator set
after the power-lossing of the entire plant.
11kV
415V
220V
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Section IVDesulfurization System Load Calculation and
Desulfurization Transformer Selection
1
1. Desulfurization Load Classification
1.1
1.1 Classification by use
GGH
Desulfurization public load: It refers to the load of public power of the entire
desulfurization island, generally including gypsum dewatering system, slurry
preparation system, wastewater system and thermal control system, etc.
1.2
1.2 Classification according to significance degree
I
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Class I load: It refers to the load which may influence equipment safety
during short-term (required time to recover power supply through manual switching)
power failure, such as booster fan, slurry circulation pump, etc.;
II
Class II load: It refers to the loads that tolerate short-time power failure but
may cause damage to the equipment or affect the normal operation in case of far
long-term power failure, such as oxidation fan, wet mill, absorber blender, air
compressor, lighting, etc.;
III
Class III load: It refers to the load which will not directly influence operation
during long-term power failure, such as overhaul load, various submerged pumps of
drainage pit, etc.;
OI
DCS
Class OI load: It refers to the load which needs continuous power supply
during the operation of desulfurization equipment and in the process of stopping
(including emergency stopping) and during a time period even after stopping, such as
thermal control DCS cabinet, instrument power cabinet, fire alarm load, etc.;
OIII
Class OIII load: It refers to the load which provides power supply when the
entire desulfurization island is out of power to ensure that the desulfurization
equipment can be stopped safely and be re-started soon after that, such as various
motor lubrication pumps, cooling fan, wash pump, bypass gas damper, etc.
1.3
1.3 Classification according to operation mode
Loads with frequent continuous operation Loads with frequent
intermittent or short time operation
Loads with not frequent continuous operation Load with not frequent
intermittent or short time operation
2
Continuous - those continuously operating with loads for over 2 hours for each
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time;
2 10
Short time - those continuously operating with loads for more than 10 minutes
and less than 2 hours for each time;
10
Intermittent - those repeating periodic work from loading to stopping for each
time with each work period not exceeding 10 min;
Frequent - motors related to normal operation and generally used every day;
Not frequent - motors which are not used under normal situation and are only
used during overhaul, emergency or equipment starting and stopping
1.4
1.4 Classification according to layout location
MCC MCC MCC
Absorber unit MCC Gypsum dewatering MCC Slurry preparation
MCC
MCC MCC
Wastewater treatment MCC Electric control building MCC
1.5
1.5 Classification according to whether desulfurization load needs to be started
automatically
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10 50
The project is equipped with 6 sets of low-voltage dry desulfurization
transformers, among which two sets for 1#machine, two sets for 2#machine and two
sets for public area, and each two sets are for standby mutually. Capacity for each set
shall be selected according to sum of all the low-voltage calculating loads of the two
low-voltage desulfurization transformers, and it shall reserve 10% margin and ensure
that it can operate for short time in 50% overload situations.
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No. of units
Total
Sum
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No. of units
Total
Section V Protective Load Statistics and Diesel Generator Selection
1
1. Protective Load Classification
Protective load can be divided into two categories according to its properties:
A
( A1 )( A2 )
Class A protective load: It refers to the protective load which needs to be
promptly put into operation after power failure, the load which operates for
about half an hour (called Class A1) and the load which operates in uncertain
time (called Class A2).
B
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Class B protective load: It refers to the protective load which does not need
to be promptly put into operation after power failure and can operate half an hour to
one hour after power failure and operates in uncertain time.
Protective loads can be put into operation successively according to their
properties during emergency:
1-- A
1 - Put class A protective load into operation immediately after power
failure;
2-- A1 B A2
2 - Stop the operation of Class A1 load after half an hour of power failure,
put class B protective load into operation and keep the operation of Class A2 load.
2
2. Protective Load Statistics
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Section VI Selection and Layout of Desulfurization Electrical
Equipment
1
1. Selection of Desulfurization Electrical Equipment
Switch cabinet shall have five-prevention (prevent electric misoperation)
function, namely:
1
(1) Prevent loaded pulling (closing) isolating switch
2
(2) Prevent mis-pulling (closing) circuit-breaker
3
(3) Prevent laying ground wire with electricity
4
(4) Prevent closing the switch with ground wire
5
(5) Prevent entering electrified gap by mistake
2
2. Layout of Electrical Equipment
11kV PC PC/MCC
UPS
MCC MCC MCC MCC
MCC
DL/T51532014
This project is characterized by single electric control building in which is set
with 11kV section, PC section, security PC/MCC section, diesel generator room,
storage battery room and relaying protection room (UPS, DC and fast switching).
Besides electric control building, it is also equipped with local MCC distribution
room, such as unit MCC distribution room, wastewater MCC distribution room, slurry
preparation MCC distribution room and dewatering MCC distribution room. Room
layout of electric control building and equipment layout of distribution room shall
comply with regulations in the Technical Rule for Designing Auxiliary Power System
of Fossil Fuel Power Plants (DL/T5153-2014).
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There shall be two exits for switchgear room which is more than 7 meters
long, and one more when the length of the room exceeds 60m.
The door of auxiliary switchgear room shall be fireproof and open outwards,
with locks which can be unlocked from inside without keys, such as spring locks. The
door between the adjacent switchgear rooms shall be able to open from two
directions.
Pipelines or cables irrelevant to the switchgears shall not penetrate through
the auxiliary switchgear room.
2m 3m
Net height of cable interlayer shall not be less than 2m, but not more than 3m.
1.2m
Low voltage switchboard cabinet is arranged in single row and the min-width
of the operating walkway behind the switchboard shall be 1.2m.
2.3m
It shall add shield when the height of bare conductor of the walkway behind
screen is less than 2.3m.
1
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The fast switch device can be activated manually in startup and shutdown status
or during operational load change under normal situation for the purpose of operating
without power failure. The starting command can come from the remote control
center (PLC) and/or the local controller. The unit can be deployed by means of
hardwire or communication. Only when the key is turned to "Remote" position, the
fast switch device can be activated in remote by means of communication.
2.2.2
2.1.2 Emergency starting
The relaying protection device can detect and eliminate faults when they occur
on the incoming lines. Meanwhile, the relaying protection device can send out fast
switch activation command for the activation of fast switch in case of incoming line
faults.
A B
Upper switch trip or switch of incoming line trip caused by system fault shall
lead to power-lossing of the motor busbar. The busbar power switchover must be
activated by the fast switch unit with internal integrated abnormal detection criterion.
Keep in mind that latch the fast switch device to avoid mis-switch when manually
disconnect the power switch of incoming line.
The abnormal starting contains: LV starting, low frequency starting, slip starting,
reverse power starting and switch tripping starting.
2.2
2.2 Basic requirements on fast switch unit
The fast switch must be activated when one power supply loses voltage while
another is normal.
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The fast switch must be ensured to have minimum power interruption to enable
the easy starting for the motor automatically.
The fast switch shall be activated only for once to avoid severer incidents in case
that normal power is brought onto the faulty element more than once when continuous
faults occur to the busbar or the outgoing wire.
BZT
The fast switch should not be activated in the following cases: Potential
transformer (PT) fuse burnout, secondary circuit-breaker trip, PT switch pull-apart or
PT handcart pullout. By detecting the current of incoming line circuit-breaker, the
BZT only acts when there is no voltage and current on the side of incoming line.
The fast switch shall not be activated when the two-way power supply are out of
voltage.
The fast switch action must be away from the duration when the busbar voltage
is decreasing out of any cause. It means to recover the bus voltage in a short time, so
the delay time of fast switch must be longer than the maximum elimination time of
external fault.
3
3. Protection
3.1 11kV
3.1 Desulfurization 11kV section power supply
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11kV
11kV
Power supply line of the desulfurization 11kV section is adopted with
microcomputer line longitudinal differential protection (non-fiber). The protection
device is installed in the high-pressure cabinet at the beginning of desulfurization
11KV section power supply line, and is in the charge of main power house.
3.2
3.2 Low voltage desulfurization transformer
Low voltage desulfurization transformer (normally dry type) is adopted with
microcomputer protection device and the following protection measures shall be
deployed:
2MVA
Longitudinal differential protection (2MVA or above transformers)
Current quick-break protection
Overcurrent protection
Single-phase grounding protection
Temperature protection
The protection device is installed on the high-pressure cabinet of the low voltage
desulfurization transformer.
3.3
3.3 Protection of high-pressure auxiliary motors
The high-pressure auxiliary motor is adopted with microcomputer protection
device, and the following protection measures must be deployed:
1500kW
Longitudinal differential protection (for motors over or equal to 1500 kW)
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1 2 3
1) Overcurrent protection 2) Longitudinal differential protection 3)
Single-phase grounding protection
4
4. Measurement
PLC
PLC
420mA PLC
PLC
The control room of desulfurization island shall not be equipped with regular
stereo or optical character plate. All the switch state signal, electrical emergency
signal and warning signal are sent to the desulfurization island PLC. The control room
of desulfurization island shall not be equipped with regular measuring meters. As
prescribed by all the procedures, the electrical continuous measuring signals (current,
voltage, power, etc.) which need to be displayed on PLC should be transformed into
4-20mA by transmitter in the switch cabinet to send to the desulfurization island PLC.
It can also be transformed into digital signals by intelligent control module to send to
the desulfurization island PLC through communication interface in the form of bus
line. The measuring point shall be assigned by Technical Code for Designing
Electrical Measurement and Energy Metering Device:
4.1 DI
4.1 DI quantity
/
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4.4 AI
4.4 AI quantity
420mA
Signal of circuit 4-20mA analogue quantity
4.5 PI
4.5 PI quantity
Signal of circuit pulsed quantity
Section VIII Anti-thunder and Grounding
1
1. Anti-thunder Protection
2000mm PVC
The desulfurization unit is deployed within the protection scope of stack
lightning rod and does not need additional anti-thunder protection. However, it must
be checked in the project. Lightning protection zone must be set for units out of the
anti-thunder protection scope of the stack lightning rod. The downlead is wrapped
with reliable PVC protective tube at the 2000mm or less distance to the ground.
2
2. Grounding
The grounding of desulfurization area shall be deployed according to the
requirements of Grounding of AC Electrical Device.
The isolated closed grounding grid shall be built in the desulfurization area.
There must be at least four points in that closed grounding grid which are connected
electrically to the main grounding grid of power plant. The grounding resistance must
be up to the required value of the specification after the grounding grid in the
desulfurization island area and the main grounding grid are reliably connected.
Section IXLighting, Overhaul and Slide Wire System
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MCC MCC
The independent lighting and overhaul MCC section shall be set, which supplies
the lighting and overhaul power for all places.
The overhaul voltage of the absorber is 12V. The low-voltage 12V overhaul
lighting socket box shall be deployed along the platform of the absorber and near the
manhole. The multi-polar tube energy-saving slide wire shall be installed to the
electric hoist and electric lifting equipment.
Section X Cable, Cable Building and Cable Fireproof Plugging
1
1. Cable
ZRC-YJV22-11/110.4kV
ZRC-YJLV22-0.6/1.1
0.4kV
ZRC-YJV22-0.6/1.1
High-pressure cable is adopted with low-smoke fire-retardant steel-tape armored
copper conductor XLPE insulated PVC sheathed power cable (ZRC-YJV22-11/11)
with cross section greater than the minimum heat-stable cross section; 0.4kV power
cable is adopted with low-smoke fire-retardant steel-tape armored aluminum
conductor XLPE insulated PVC sheathed power cable (ZRC-YJLV22-0.6/1.1); 0.4KV
fire-proof power cable is adopted with fire-proof steel-tape armored copper conductor
XLPE insulated PVC sheathed power cable (ZRC-YJV22-0.6/1.1).
[ZRC-KVVP22-0.6/1.1]
[NH-KVVP22-0.6/1.1]
[ZRC- DJVPVP22-0.6/1.1]
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steel-tape armored copper conductor XLPE insulated PVC sheathed and total-shielded
power cable [NH-KVVP22-0.6/1.1]; low-smoke fire-retardant steel-tape armored
copper conductor XLPE insulated PVC sheathed and total-shielded copper wires are
used to weave individually screened power cable [ZRC- DJVPVP22-0.6/1.1].
PLC
220V24V
The cable to PLC thermal control cabinet shall be deployed one-for-one, and
different cables must be used for different purposes. 220V and 24V cables must be
separated and cores of control cable must be centralized.
2
2. Cable Building
11kV
0.4kV
The cable is mainly deployed by means of bridging. Partial area is deployed by
cable duct and pipe burying. 11kV power cable, 0.4kV power cable, control cable,
signal cable and so on shall be deployed layer by layer (or separately).
3
3. Cable Fireproof Plugging
The fireproof plugging to cable and cable building must be in compliance with
the requirements of procedure. Such plugging measures as arranging fireproof
partition board, plugging material in necessary places, cable tank and fire-resistant
partition board and brushing fire retardant coating to the cable must be taken.
Section XICommunication System
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Set up fixed speaker-phone in every local regional alarm panel and other
important places.
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Chapter IV Thermal System
Section I Overview
1
1. The Constitution of Thermal System in Desulfurization Island
DCS
Local instrument testing system is the base of thermal automation system, which
is mainly about monitoring, measuring and gathering the operating parameters of the
desulfurization island site and equipments and sends the signal to the DCS, providing
reliable data for desulfurization island to operate normally.
3DCS
3. Distributed Control System (DCS)
DCS DCS
DCS
DCS is the pivot of thermal automation system in the desulfurization island. The
operator collects the site data provided by site instrument by DCS and sends
command to each local equipment through DCS to adjust state and maintain the
normal operation of desulfurization island.
4
4. Other Supporting Systems
CEMS
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Other supporting systems include CEMS, industrial television, fire alarm, power
and air sources, etc.
5
5. The Control Mode and Level of Desulfurization Control System
5.1
5.1 Control mode and level
DL/T 5196-2004
DCS
Under the normal operation condition of the unit, the operating parameters
and conditions of desulfurization equipment can be monitored and controlled
effectively. And the total emission and emission concentration of pollutants like SOX
can be automatically maintained in normal limits to achieve environmental
requirements in the operational state of the boiler;
If there occurs working condition endangering the operation of the unit and
desulfurization process system, it can automatically start the interlock protection of
the system and shut off corresponding equipment or even the whole-set
desulfurization unit.
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CRT
It can complete the start and stop of the whole-set desulfurization system
with the cooperation of a few local inspectors. CRT and keyboard are the
monitoring means of normal operation of desulfurization system. There is no
regular control dial in the control room, only with a few emergency operating
buttons (to open the bypass damper).
23
Two to three operators on duty is to be allocated for the whole-set
desulfurization control (including inspectors).
5.2
5.2 The reliable measures of desulfurization thermal control system.
5.2.1
5.2.1 Signal detection
FGD FGD pH
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5.2.4 FGD
5.2.4 The system has a manual operation button for bypass dampers in FGD control
room where operators can open bypass dampers in case of accidents.
5.2.5 FGD
5.2.5 The exchange of major signals for protection between the FGD system and the
boiler is in the mode of hardwiring.
KKS
Section II KKS Identification System (Thermal Expertise Part)
1
1. Overview
KKS Krartwerk-Kennzeichen System
KKS
KKS is the abbreviation of the German term Kraftwerk-Kennzeichen System,
which means the power plant identification system. The KKS has three different types
of identifications, i.e., process-related identification, installation point identification
and location identification.
Every part and equipment component of a power plant usually has three kinds of
codes:
1.1
1.1 Process-related code
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macro structures.
1.3
1.3 Location code
0 1 2 3
Classification
Class 0 Class 1 Class 2 Class 3
number
Classification The whole
System code Equipment unit code Module code
title power plant
AN
Data character N AAA NN AA NNN A AA NN
A or N
type
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Prefix symbol
Process-related code
System classification
KKS
Dividing system and units by KKS identification letters
System No.
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Additional codes
Module classification
KKS
Dividing modules, signals or signal application (applying as
needed) according to KKS identification letters
Module No.
If the code is unique, then data characters in the bracket can be omitted. This point
above should be appointed by both parties of the project.
3 KKS
3. Main KKS Codes of Desulfurization System
3.1
3.1 Process system code
HT
Main function HT: Desulfurization (flue gas chemical processing system
includes residue removal and absorption)
HTA
HTA Flue gas pipeline system
HTB
HTB Flue gas side heat exchanger and flue gas heater
HTC
HTC Flue gas fan system
HTD
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HTL The solid unloading includes the pipeline system of dewatering and
backwater, not including concentration and solid dewatering system.
HTM
HTM The concentration and solid dewatering system
HTN
HTN The solid drying and compression system
HTP
HTP The gypsum transfer, storage and delivery system
HTQ FGD
HTQ The FGD water supplying and processing system
HTT
HTT Drainage system
HTW
HTW Sealing liquid supply system
HTY
HTY Control and protective instrument
3.2
3.2 Classification codes of the equipment (thermal control expertise part)
AA
AA Valves, dampers, etc., including the actuator and the manual
operation
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AB
AB The isolating module and air interlocks
AC
AC The thermal exchanger, heat transfer surface
AE
AE Rotating, driving, lifting, and rotational transmission units
(including manipulators)
AF
AF Continuous belt conveyor and feeder (including elevators)
AG
AG Generators
AH
AH Heating, cooling and air-condition
AJ
AJ Size segmentation equipment
AK
AK Compression and packing equipment
AM
AM Mixer and blender
AN
AN Compressor and fan
AP
AP Pump
AT
AT Cleaning, drying, filtering and separating equipment
AX
AX The checkout and monitoring equipment for the maintenance of
power plant
3.3
3.3 Classifications and codes of instrument control equipment
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AA
Classification AA of
Description
measuring equipment
CE
Electric variable
CF
Flow
CG
Position
CL
Liquid level
CM
Moisture or humidity
CP
Pressure
CQ
Analyzing variable
CS
Revolving speed
CT
Temperature
CY
Displacement, like vibration, etc.
3.4
3.4 Instrument control equipment No.
NNN
Equipment No.
Description
NNN
001-099
Analogue quantity remote transmission measurement (ANAL OG SIGNAL)
101199
Digit remote transmission measurement ( DIGIT SIGNAL)
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NNN
Equipment No.
Description
NNN
201299
Undefined (FREE)
301399
Undefined (FREE)
401499
Measuring point for inspection and evaluation
501599
Local indicator
601699
Undefined (FREE)
701799
Undefined (FREE)
801899
Undefined (FREE)
Combined
901999 operation measurement circuit (such as two out of three operating results
and multichannel recorder) ( COMBINED SIGNAL)
3.5
3.5 Cutline identification
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2 Explanation 2
3 Explanation 3
3.6
3.6 Examples
1
Example 1:
2 2
The equipment name of No.2 slurry circulation pump of No.2 unit flue gas
desulfurization system:
2 2 12
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WESTINGHOUSE OVATION
US Westinghouse (Westinghouse) - OVATION system
FOXBORO I/A
US Foxboro - I/A system
MAX maxDNA
Shanghai Instrument Max - maxDNA system (US)
HITACHI HIACS5000
HITACHI - HIACS5000 system
HONEYWELL
US Honeywell Corporation
DCS GE XDPS400
Domestic DCS manufacturers: Shanghai Xinhua (GE) - XDPS-400 system
MACS 3
HollySys - system MACS 3
EDPF2000
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21"LCD
SIS
1# 2# 3#
DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU
#1 #2
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Laser printer
Laser printer
Laser printer
Power cabinet
Terminal cabinet
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SIS
#1 #1 #2 #2
21"LCD 21"LCD 21"LCD 21"LCD
SIS SIS
#1 #2
#1 #1 #2 #2
1# N# 1# N#
#1DCS300MW DCS #2DCS300MW
DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU
Control network
#1 #1 unit screen
Laser printer
Laser printer
Redundant fiber
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#2 #2 unit screen
#2 #2 unit screen
Laser printer
Power cabinet
Terminal cabinet
Terminal cabinet
Terminal cabinet
Terminal cabinet
Terminal cabinet
Host unit
Desulfurization system
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A control system will be called open loop control system so long as it is granted
with constant impact output (controlled variable) in which controlled variable is
controlled by controlling variable only and controlled variable, on the contrary, is
unable to influence the controlling variables.
Open loop control system is shown in the schematic diagram of the structure in
the figure.
Controller Controlled object
Disturbing quantity
Input quantity Output quantity
ur ua n
1.2
1.2 Closed loop control system:
,
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ur ue ua n
Controller Controlled object
Input quantity Feedback
Test unit Output quantity
ucf
2
2. Key control parameters in limestone-gypsum wet-process FGD
,,,,
:
Flue gas desulfurization system is influenced by multiple factors as a system.
However, in system design and operation, the following factors shall be highlighted:
Ash content in the flue gas at the inlet. Too high ash content in the flue gas
may result in deteriorating system operation, reflecting the low efficiency of
absorption (it is called limestone absorbent poisoning since the increase of limestone
addition works little), difficulty in dewatering of belt conveyor, aggravating abrasion
of equipment, etc. What is noteworthy is that deteriorating system operation on that
account may take long time to be corrected.
pH 5.56.0
pH
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Temperature of flue gas at the outlet. Concerning GGH flue gas heating
system, flue gas at the outlet is required to be higher than 80 in
temperature to guarantee discharge of flue gas. Concerning no GGH flue gas
heating system, there is no special demand for flue gas at the outlet, but
corrosion prevention in the flue of outlet and stack is required.
S02
S02 pH
S02 content in flue gas at the outlet. It is necessary to keep an eye on the
parameter; in deviation, it is necessary to make a comprehensive analysis of boiler
load, S02 content of the flue gas at the inlet, number of working circulation pumps, pH
value of slurry and other influential factors.
3
3. Key regulation control system in desulfurization system
Mainly includes:
Automatic control of pressure at the inlet of booster fan
Automatic control of slurry feeding system in the absorber
Automatic control of liquid level in the absorber (control of mist eliminator)
Pressure regulation at the inlet of gypsum hydrocyclone
Regulation of water supply at the inlet of the mill
Regulation of water supply at the inlet of circulation tank of the mill
Automatic control of gypsum filter cake thickness in the gypsum dewatering
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system
3.1
3.1 Automatic control of pressure at the inlet of booster fan;
Based on the pressure of flue gas at the inlet of desulfurization system, regulate
the electric actuating mechanism of damper (or guide blade) of booster fan to regulate
the pressure rise in the booster fan to guarantee that the pressure of the flue gas is
capable of overcoming resistance in the desulfurization system. Introduce the location
of the moving blade of an induced draft fan of the boiler (or signal of negative
pressure of the boiler hearth) as a feed forward signal for modulating circuit. Location
of the actuator of booster fan is in feedback for feedback signal of modulating circuit.
3.2.
3.2. Automatic control of slurry feeding system in the absorber;
FGD SO2 FGD SO2 FGD
pH
Input signals: SO2 concentration at the inlet of FGD, SO2 concentration at the
outlet of FGD, oxygen content at the outlet of FGD, raw flue gas flow, pH value of
slurry in the absorber, flow of limestone slurry into the absorber and density of
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limestone slurry.
PID
Control Principles: Measure SO2 concentration in the raw flue gas and clean flue
gas, correct corresponding temperature, pressure, humidity and flue gas amount,
calculate desulfurization efficiency, multiple it by SO2 concentration in raw flue gas to
get SO2 load and multiple SO2 load by limestone purity and Ca/S coefficient to get the
required quantity of limestone slurry. Meanwhile, compare the pH value of slurry in
the absorber and the pH set value, output by PID regulator, set upper limit and lower
limit, correct regulated quantity of slurry supplied, output corrected demand for
limestone slurry and feedback to quantity of limestone slurry in the absorber for
comparison, and regulate the opening of regulating valve for supply of limestone
slurry by control of PID regulator to realize control of chemical reactions of
desulfurization system.
SO2 15
6% FGDSO2 C1
21FGD
If oxygen content is 6%, SO2 concentration at the inlet of FGD C1 = SO2
concentration at the inlet15/ (21-oxygen content at the outlet of FGD)
SO2 15
6% FGDSO2 C2
21FGD
If oxygen content is 6%, SO2 concentration at the outlet of FGD C2 = SO2
concentration at the outlet15/ (21-oxygen content at the outlet of FGD)
1C2 / C1 ) 100%
Desulfurization rate = (1-C2/C1) 100%
FGD K
K=0.93K
Blast capacity in the dry state at the inlet of FGD = K blast capacity at the inlet
of booster fan; (In design, K=0.93; actual K value may be adjusted depending on
measured moisture at the site)
SO2 FGD FGDSO2
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SO2 load = the blast capacity at the inlet of FGD (actual oxygen content in dry
state) SO2 concentration at the inlet of FGD (actual oxygen content in dry state)
3.3
3.3 Automatic control of liquid level in the absorber (control of mist eliminator)
Based on waiting time for change in liquid level in the absorber and flushing in
the mist eliminator layer, complete washing in the mist eliminator and realize control
of liquid level in the absorber.
3.4
3.4 Control of slurry discharge pump in the absorber
Regulate the revolving speed of the variable frequency regulation pump in the
slurry discharge pump in the absorber based on pressure at the inlet of gypsum
hydrocyclone and make the revolving speed of the variable frequency regulation
pump as a feedback signal for circuit regulation. Guarantee density of gypsum at the
outlet of hydrocyclone.
3.5
3.5 Regulation of water supply at the inlet of wet mill
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Based on the proportion of limestone quantity at the inlet of wet mill and water
supply, multiple feeding quantity of belt weigh feeder by proportion to get the
required quantity of water supply, compare it with the flow of water supply in the wet
mill, and regulate the opening of regulating valve for water supply at the inlet of the
wet mill by proportion in its output.
3.6
3.6 Regulation of water supply at the inlet of circulating slurry tank in the wet mill
Compare the actually measured density value at the outlet of the wet mill with
the set value of density, and calculate out the feedwater quantity that is needed to add
to the slurry circulation tank according to the deviation. Then, compare the needed
feedwater quantity with the feedwater flow being added to the slurry circulation tank
and control the output by regulating the opening of feedwater regulating valve at the
inlet of slurry circulation tank proportionally.
3.7
3.7 Automatic control of gypsum filter cake thickness in the gypsum dewatering
system
10
The belt speed is regulated by the variable frequency controller through the
thickness measure of gypsum filter cake, in order to achieve that the gypsum moisture
remains at 10% after dewatering.
4
4. Sequential control logic of desulfurization control system
4.1
4.1 Main functional groups of desulfurization control system
Functional group of flue gas system
Functional group of the absorber
Functional group of absorber mist eliminator
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Functional group of absorber slurry circulation pump
Functional group of pits in the absorber area
Functional group of absorber discharge system
Functional group of mist eliminator wash water system
Functional group of slurry feeding system of limestone slurry
Functional group of density measure of the limestone slurry system
Functional group of limestone slurry preparation system
Functional group of process water system
Functional group of belt-type vacuum dewatering system
Functional group of mill slurry preparation system, etc.
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FGD
Step sequence of FGD starting operation
Name of
1 functional group Process water system
-- 12
Module name of
functional group Preselected module - process water pump 1, 2
Give manual command: start manually (give manual
Command command: start automatically)
Name of
2 functional group Absorber pit
--
Module name of
functional group Sub-functional group - pump of the absorber pit
Command Give manual command: start automatically
Name of
3 functional group Slurry system of gypsum overflows
--
Module name of
functional group Preselected module - slurry pump of gypsum overflows
Command Give manual command: start manually
Name of
4 functional group Filtrate water system
-- 12
Module name of
functional group Preselected module - filtrate water pump 1, 2
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Command Give manual command: start manually
Name of
5 functional group Limestone slurry system
--
Module name of
functional group Preselected module - limestone slurry pump
Command Give manual command: start manually
Name of
functional group Density measure of the limestone slurry system
(Limestone slurry system sets automatic start)
Name of
6 functional group Limestone
--
Module name of Sub-functional group module - feeding of limestone slurry
functional group tank
Command Give manual command: start automatically
Name of
7 functional group Wastewater rotational flow system
-- 12
Module name of
functional group Preselected module - waste water hydroclone feed pump 1, 2
Command Give manual command: start manually
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Name of
8 functional group Wastewater system
-- 12
Module name of
functional group Preselected module - wastewater pump 1, 2
Command Give manual command: start automatically
Name of
9 functional group Process water system of mist eliminator
-- 12
Module name of
functional group Preselected module - wash pump of mist eliminator 1, 2
Command Give manual command: start manually
12
Name of Absorber system (oxidation fan 1, 2, blender, mist eliminator,
10 functional group limestone slurry supply)
--
Module name of
functional group Sub-functional group - absorber system
Command Give manual command: start manually
Name of
11 functional group Absorber gypsum slurry system
-- 12
Module name of
functional group Preselected module - discharge pump of gypsum slurry 1, 2
Command Give manual command: start manually
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1
Name of
12 functional group Absorber circulation pump 1
-- 1
Module name of
functional group Module of sub-functional group - absorber circulation pump 1
Command Give manual command: start manually
2
Name of
13 functional group Absorber circulation pump 2
-- 2
Module name of
functional group Module of sub-functional group - absorber circulation pump 2
Command Give manual command: start manually
3
Name of
14 functional group Absorber circulation pump 3
-- 3
Module name of
functional group Module of sub-functional group - absorber circulation pump 3
Command Give manual command: start manually
Name of
15 functional group Absorber flue gas system
--
GGH
Module of functional group - absorber flue gas system
Module name of (including: automatic start of booster fan, automatic start of
functional group GGH)
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Command Give manual command: start manually
Name of
16 functional group Gypsum dewatering system
Module name of
functional group
Command
Independent Name of
Emergency slurry tank system
system functional group
--
Module name of
functional group Module of functional group - emergency slurry tank system
Command Give manual command: start manually
If some of the above systems have started, continue the
execution by skipping them.
FGD
Step sequence of FGD stopping operation
Name of
1 functional group Absorber flue gas system
--
GGH
Module name of Module of functional group - absorber flue gas
functional group system (including: automatic start of booster
fan, automatic start of GGH)
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2
Name of
3 functional group Absorber circulation pump 2
-- 2
Module name of Module of sub-functional group - absorber
functional group circulation pump 2
Command Give manual command: stop manually
3
Name of
4 functional group Absorber circulation pump 3
-- 3
Module name of Module of sub-functional group - absorber
functional group circulation pump 3
Command Give manual command: stop manually
Name of
5 functional group Absorber gypsum slurry system
-- 12
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Name of
9 functional group Limestone slurry preparation system
--
Module name of Sub-functional group module - feeding of
functional group limestone slurry tank
Command Give manual command: stop automatically
Name of
10 functional group Slurry system of gypsum overflows
-- 334
Module name of Preselected module - slurry pump of gypsum
functional group overflows 3, 34
Command Give manual command: stop manually
Name of
11 functional group Wastewater rotational flow system
-- 12
Module name of Preselected module - waste water hydroclone
functional group feed pump 1, 2
Command Give manual command: stop manually
Name of
12 functional group Filtrate water system
-- 12
Module name of
functional group Preselected module - filtrate water pump 1, 2
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Command Give manual command: stop manually
Name of
13 functional group Wastewater system
-- 12
Module name of
functional group Preselected module - wastewater pump 1, 2
Command Give manual command: stop automatically
Name of
14 functional group Gypsum dewatering system
Module name of
functional group
Command
Independent Name of
system functional group Process water system
-- 12
Module name of
functional group Preselected module - process water pump 1, 2
Command Give manual command: stop manually
Independent Name of
system functional group Absorber pit
--
Sub-functional group - pump of the absorber pit
Module name of
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functional group
Command Give manual command: stop automatically
Independent Name of
system functional group Emergency slurry tank system
--
Module name of Module of functional group - emergency slurry
functional group tank system
Command Give manual command: stop manually
4.1.2
4.1.2 Start-stop sequence of functional groups of the flue gas system
:
Start the sequential control:
:
Allowable conditions of the sequential control: (with)
The operation of at least two slurry circulation pumps
The operation of any one oxidation fan
MFT
No MFT signal
The full operation of boiler electric precipitator
STEP1: 0
STEP1: Set the position of guide blade of the booster fan to the 0 place and turn it
into manual control;
STEP2:
STEP2: Open the clean gas damper; after opening the clean gas damper, close the
absorber discharge valve;
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STEP53: Turn off the guide blade of booster fan, and when the closing of guide blade
reaches below 5%, start the shutoff of booster fan functional group (shut off the sequential
control of booster fan);
STEP54:
STEP54: Close raw gas damper; after closing the raw gas damper, open the absorber
discharge valve;
STEP55:
STEP55: Close the clean gas damper;
STEP56: GGH GGH
STEP56: Stop GGH functional group (stop the sequential control of GGH);
STEP57:
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FGD
As one of the supporting systems of the whole unit, the desulfurization system
isn't generally set with a compulsory boiler trip signal. The protection of the boiler is
realized through its own protection (When there is no bypass flue, the compulsory
boiler trip signal shall be considered to set), and the protection of desulfurization unit
is realized through FGD trip and bypass operation mode.
FGD
FGD trip generally means the separation of flue gas system of the
desulfurization system from the host, with the flue gas going through the
bypass and the booster fan stopping.
Bypass operation generally means opening the bypass damper of the
desulfurization system, with other systems operating as usual and no
operation happening.
4.2.1 FGD
4.2.1 FGD trip conditions
FGD
FGD will trip with any of the following conditions
III
Inlet temperature of the raw flue gas is higher than the value of III;
III 3s >400Pa)
After the pressure of flue gas before raw gas damper is higher than the value
of III and delays for 3s; (>normal value+400Pa)
III 3s <1000Pa)
After the pressure of flue gas before raw gas damper is lower than the value
of III and delays for 3s; (<normal value-1000Pa);
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GGH GGH II
50s
No operation occurs to GGH main and auxiliary motors, or the revolving
speed of sensor in the GGH test box is lower that the value of II with raw gas
damper not closed and delaying for 50s;
30min
Any two of the three circulation pumps trip and delay for 30min, or the three
circulation pumps trip at the same time;
()
Booster fan trips (adopting the falling edge of the operation signal pulse);
MFT
Boiler MFT
4.2.2 FGD
4.2.2 Operation conditions of FGD bypass
FGD
FGD bypass operates with any of the following conditions.
II 3s
>400Pa)
After the pressure of flue gas before raw gas damper is higher than the value
of II and delay for 3s; (>normal value +400Pa);
II 3s <800Pa
After the pressure of flue gas before raw gas damper is lower than the value
of II and delay for 3s; (<normal value -800Pa);
FGD II (>200mg/Nm3 1 FGD
III (>230mg/Nm3)
FGD inlet flue dust is higher than the value of II (>200mg/Nm3 and delaying
for 1h) or higher than the value of III (>230mg/Nm3)
II>155
Temperature of raw flue gas is higher than the value of II (>155)
Boiler is in operation with oil
4.2.3 FGD
4.2.3 FGD and boiler exchanging signals
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Perfection of the DCS interlock protection logic
Management of the construction site
Section V Desulfurization Thermotechnical Instruments
1
1 Main instruments in the desulfurization system are as follows:
1.1
1.1 Local pressure gauge
Bourdon tube pressure gauge Diaphragm-type pressure gauge
1.2
1.2 Remote instrument
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420mA DC Pt100
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Thread-interface pressure transmitter Flange-interface diaphragm pressure transmitter
1.2.3
1.2.3 Mass flow meter and electromagnetic flow meter
1.2.3.1
1.2.3.1 Mass flow meter
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1.2.4 /
1.2.4 Ultrasonic material/radar liquid level meter
//
/
Ultrasonic material/radar liquid level meter runs in a way in which it radiates
ultrasonic wave/microwave pulse to the surface of measured substance and measures
interval between pulse wave transmission and reception to calculate feeding/liquid
level.
1.2.5
1.2.5 Guide wave radar material level meter
()
Guide wave radar material level meter adopts the law of microwave pulse
radiation but microwave pulse is transmitted by one (or two) guide wave substance(s)
extruded from top of tank to the bottom of tank instead of space. The guide wave
substance can be metal stiff stick or soft metal cable. Guide wave radar material level
meter possesses the following characteristics:
It is immune from impact of dust and steam;
It is immune from impact of change in medium characteristics, such as
density, particle size, humidity and angle of repose of materials;
The medium adhering to the guide wave stick has no impact on
measurement;
Therefore, the guide wave radar material level meter is the first choice in
measurement of material level in limestone powder silo.
1.2.6
1.2.6 Level switch
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radio frequency admittance (capacitance) material level switch and tuning fork
material level switch. Level switches are applicable to system alarm and protection
since they are simple, cheap and reliable. The radio frequency admittance material
level is generally applicable to high and low material level alarm in the limestone
(block) storage silo while tuning fork material level switch is primarily applicable to
high and low material level alarm in limestone powder silo, water level, etc.
1.2.7 pH
1.2.7 pH meter
pH
pH
PPPTFE
The pH meter is composed of electrodes, supports, and secondary instruments. It
makes measurement by bypass flow cell and its measuring points are generally
located on the measurement pipeline of bypass at the outlet of gypsum slurry
discharge pump. The pH supports are made from non-metal materials (PP, PTFE).
2
2. Installation of thermal instruments
2.1
2.1 Installation of pressure gauge and pressure transmitter in the slurry pipeline
Instrument pipeline
2.2.
2.2. Installation of pressure transmitter in flue
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Diagrams for flue gas pressure sampling and
piping are as follows:
Flow direction
Instrument pipeline
Instrument pipeline
2.3
2.3 Installation of differential pressure transmitter of mist eliminator
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meter adopts mode of measurement of flow cell in common in which gypsum slurry
flows in and out of side from bottom of flow cell and pH meter is inserted from top of
flow cell. Generally, pH meter and densimeter are placed on the same platform for
overhaul. The pH secondary meter is placed on the nearby railing supports in the
mode of wall-hung installation and secondary meter sets weather enclosure.
pH
The pH meter should be regularly marked and calibrated by standard liquid while
it is used.
Pipeline instrument
Instrument pipeline
2.5
2.5 Installation of flow measuring instrument
Flow measuring instruments have requirements for pipeline direction and length
of direct pipelines. Mass flow meter and electromagnetic flow meter are required to
be installed on vertical pipes and medium flows in a bottom-up way. Such a mode of
installation makes suspended solids in slurry sink to the pipelines and prevents
measuring pipelines from not filling.
CEMS
Section VI CEMS System (Continuous Flue Gas Emission Monitoring
System)
1 CEMS
1. CEMS system in desulfurization island measures the following flue gas
compositions:
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FGD SO2O2
FGD inlet: SO2, O2, dust;
FGD SO2O2NOXCO
FGD outlet: Flue gas flow, SO2, O2, NOX, dust, humidity, CO, temperature,
pressure.
Composition of flue gas on-line measurement unit
Sampling and pretreatment system
Analysis system
The subsystem for system control and data collection and treatment
Compressed air system
Instrument chamber and power supply
2CEMS
2. Introduction to CEMS extractive method
CEMS
CEMS extractive method mainly includes: Direct extractive and diluting
extractive.
2.1
2.1 Direct extractive
The method is the most traditional method of continuous flue gas analysis in
which it continuously extracts measured flue gas that flows into the gas analyzer after
undergoing probe filtration, heating and thermal insulation, condensation and
dewatering, and fine filtration.
120
15 11
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Direct extractive: Make rough filtration, heat, make thermal insulation (120)
dehumidify, make fine filtration, measure original concentration of pollutants in flue
gas (temperature of measured gas falls to 15 or is 11 lower than ambient
temperature), mark and make point measurement by zero gas and standard gas.
2.2
2.2 Extracting dilution
100
EPA
Extracting dilution refers to dilution of flue gas extracted in some multiple by
clean air (100 times for instance). In this way, it may prevent sophisticated sample
pretreatment system among ways of extractive without dewatering. Therefore, it is a
wet measurement, which is preferred by US Environmental Protection Agency (EPA)
and popular in the US. However, such a way is demanding for high-precision diluting
header that is required of regularly replacing filtration unit.
1:100
Diluting extractive: Internal and external (heating) dilution, typical dilution ratio
of 1:100, long distance of flue gas transmission, low dew point, measured
concentration of diluted flue gas pollutants, marking and point measurement by zero
gas and standard gas.
2.3 CEMS
2.3 Comparison with ways of monitoring gas pollutants in CEMS system
Sampling methods Advantages Disadvantages
Full1. 1.
extractive
1. Dry state measurement;
- dry base 1. Heating and sampling pipelines are
2. adopted in measurement of soluble gas;
NDIRNDUV
2. High reliability and measurement
GFCFTIR 2.
precision;
(NDIR, NDUV, 2. Sample gas should undergo
GFC, FTIR, etc.) 3. pretreatment in higher sample flow;
3.
3. Cost reduction by adoption of
multi-component analyzer;
3. The whole sampling and pretreatment
4. system requires measures of corrosion
prevention;
4. Fidelity in flue gas transmission
and consistency between displayed
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Sampling methods Advantages Disadvantages
measured component concentration
and output data;
5.
5. Convenient replacement of probe
filter;
6.
6. Simple system calibration and
auto calibration of analyzer and
system;
1.; 1.
Dilution Extractive
- wet base 1. Wet base measurement, the US
specifications and requirements; 1. It is necessary to equip diluting air
purification unit due to higher demand
2. quantity for diluting gas;
(,
) 2.
2. In most cases, tracing heat is not
(Ultraviolet required in gas transmission
fluorescence andpipelines; 2. Incomplete purification may result in
chemiluminescence) serious analysis error (local error);
3.
3.
3. Low sampling flow, less probe
blocking and no reverse purging
unit equipped for most; 3. It is necessary to monitor or correct
change in pressure of diluting air and
4.
temperature of sampling probe and often
mark diluting probe;
4. Longer distance of transmission
4.
between sampling probe and
analysis system;
4. It is necessary to configure multiple
5.
analyzers in multi-component gas
5. No need for condensation or analysis;
dehumidification.
3 CEMS
3. Principles of direct extractive in CEMS
CEMS
Flue gas CEMS is composed of flue gas sampling and pretreatment system, flue
gas auxiliary parameter measurement system (flue gas pressure, flow, temperature,
turbidity, etc.) and data collection and treatment subsystem.
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Flue
Probe case
Sampling probe
Standard gas
Blowoff
Filter
Sampling pump
Drainage
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Flow meter
Magnetic valve
Filter
Instrument
N2 N2 zero gas
O2 O2 standard gas
CO CO standard gas
Humidity meter
4CEMS
4. Simple daily maintenance of CEMS system
First of all, observe signal of flow alarm: If flow signal alarm, it will indicate
unsmooth gas circuit, blocking filtering gas, sintering sampling pipe, or gas leakage in
extracting pump, thus it will be advised to check one by one;
Check whether displayed values of analysis instruments and displayed values
of glass rotor flow meter are normal;
Check standard barometer and prevent leakage;
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Check whether there is paper jam or shortage of paper in the printer;
Check whether pressure of zero gas is up to standard;
O2
Check whether measured result of O2 concentration is too high, which
indicates leakage in the sampling pipeline;
Check whether all functions of graphic display and sheet printing are normal;
Check whether ambient temperature is normal;
FGD
Section VII Monitoring and Analysis of All Measured Data in
Normal Operation of FGD System
1
1. CO2 measurement
CO2 measurement should be calibrated every week. If value seems not reliable, it
shall be necessary to shorten interval of calibration.
2pH
2. pH measurement
The measuring equipment should be checked in the lab every week and
calibrated at least every four weeks.
3
3. Pressure measurement in flue
Flue pressure measurement and pipe connection should be checked and cleaned
every month.
4
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1 2
) )
p D
H e
n
v s
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a i
l t
u y
e :
:
G
G r
l a
a v
s i
s m
e
e t
l r
e i
c c
t
r m
o e
d t
e h
o
m d
e .
t
h
o
d
.
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4 5
4 5
) )
S P
o a
l r
i t
d i
c
c l
o e
n
t s
e i
n z
t e
: :
G G
r r
a a
v v
i i
m m
e e
t t
r r
i i
c c
m m
e e
t t
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h h
o o
d d
.
a
n
d
s
p
e
c
t
r
o
p
h
o
t
o
m
e
t
r
i
c
m
e
t
h
o
d
.
Requirements for parameter control:
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pH value and density are key indicators of slurry in absorber, thus it is necessary
to analyze pH value and density per shift and analyze slurry at 4 sampling ports per
time, including outlet of gypsum slurry discharge pump, underflow of gypsum
hydrocyclone, limestone slurry tank and filtrate case.
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FGD
Chapter VDebugging, Operation and Performance Experiments of
FGD System
FGD
Section I Debugging of FGD system
1
1. Debugging purpose and task
FGD FGD
It refers to the test run of a single set of equipment. Such as, for the slurry
circulation pump, monomer test run refers to the process to conduct the no-load test
run of the motor for 4 hours after the installment of the slurry circulation pump, then
to connect the motor to the pump and conduct the test run of the pump for 8 hours
when the liquid level in the absorber satisfies the circulation pump start-up allowable
conditions. During the test run, check whether the operation of the pump is steady and
whether the vibration, bearing temperature and motor coil temperature conform to
related acceptance specifications. After conforming to the specifications, handle the
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test run certificate and deliver it for subsystem test run. The monomer test run is
generally led by the construction unit with the cooperation of the debugging unit.
1.2
1.2 Test run of subsystem
GGH
It refers to the adjusting operation of each system based on water or air as the
medium after the completion of monomer equipment debugging. For example, in the
subsystem test run of the flue gas system, besides the booster fan, damper and GGH,
it also includes the operation of the slurry circulation pump located in the absorber
system. In the debugging of the flue gas system, it is necessary to test the regulating
characteristics of the booster fan, the resistance characteristics of the flue gas system,
the leakproofness of the damper and the resistance characteristics of the absorber, etc.
Sometimes, due to the time requirement, monomer debugging and subsystem
debugging can be carried out simultaneously, for example, the debugging of the flue
gas system and the monomer debugging of the slurry circulation pump, oxidation fan,
gypsum slurry discharge pump, the damper seal fan can be conducted simultaneously.
The subsystem test run is generally led by the debugging unit with the cooperation of
the construction unit.
1.3 FGD
1.3 Whole-set start-up debugging phase of FGD System
FGD 168h
It refers to the thermal-state debugging phase. It refers to the process from the
first flue gas discharge to 168h full-load operation, and to hand-over of FGD for trial
production. The whole-set start-up is generally led by the debugging unit with the
cooperation of the construction unit.
2
2. Submission of debugging materials
After entering the site, the debugging personnel shall first compile the
Debugging Outline which generally is compiled by the chief debugging engineer. The
Debugging Outline reflects the general arrangement and steps of the debugging and
guides the entire startup debugging. The Debugging Outline generally includes the
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following contents:
2.1
2.1 Project profile and equipment configuration.
FGD
It introduces the main design parameters of the FGD System, including the flue
gas parameter, limestone characteristics, and water quality characteristics. The
system's desulfurization efficiency, pressure loss, power consumption, water
consumption, limestone consumption, gypsum quality and other performance
guaranty parameters. It introduces the equipment composition and main
characteristics of each system.
2.2
2.2 Basis for debugging
In accordance with the requirements of Rules for Start-up and Final Acceptance
on Capital Construction Projects of Thermal Power Plant, establish the debugging
organization and define the tasks and responsibilities to the test run command team
which includes the installation, debugging and production personnel in the test run of
individual equipment and subsystem of FGD and whole-set start-up.
2.4
2.4 Scope of debugging
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It refers to the equipment and systems required in the startup of FGD system. It
defines the adjustment test items which should be completed in startup process
according to the requirements of debugging.
2.5
2.5 Debugging plan, principle and executing procedures. It contains debugging
management procedures in all phases of debugging.
2.6
2.6 Quality control of debugging.
/
It mainly contains the debugging quality and safety control policies, safeguard
measures, quality objectives, etc.
FGD
Generally, the Debugging Outline should be submitted within a week after the
arrival of debugging unit. Monomer debugging scheme is usually submitted by the
construction unit. The debugging unit should submit it one week before the subsystem
test run. The FGD system debugging scheme generally includes the following parts:
FGD
Power on debugging scheme for FGD
DCS
DCS debugging scheme
Flue gas system debugging scheme
Absorber system debugging scheme
Limestone slurry preparation system debugging scheme
Gypsum dewatering system debugging scheme
Wastewater treatment system debugging scheme
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Chemical analysis debugging scheme
FGD
FGD cold state debugging scheme
FGD
FGD whole-set start-up debugging scheme
Debugging scheme generally includes the following contents:
System introduction;
Debugging purpose;
Compiling basis;
Debugging conditions and environmental requirements;
Debugging contents, methods and procedures;
Debugging organizations, personnel requirements and division of labor;
Safety precautions;
Debugging quality control points;
Records and reports required.
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Compiling basis;
Debugging content and process;
Problems occurred in debugging and corresponding solutions;
Debugging conclusions and suggestions;
3
3. Test run of subsystem
FGD FGD
FGD
GGH
The test run of individual equipment and subsystem of the FGD system includes
monomer debugging and subsystem debugging. Monomer debugging is the test run of
single auxiliary equipment in the FGD system, including electric and thermal control
protection device. The work in this phase is finished by combining in the subsystem
debugging. Subsystem debugging refers to the debugging of a single system such as
process system and function system. It includes the debugging test run with flue gas
of all the equipments and systems such as power, measurement and control; i.e., the
cold state simulation test run of main components of the FGD system. Those systems
contain utility system (process water system and compressed air system), absorber
system, flue gas system (including booster fan, GGH and its auxiliary system),
limestone preparation system (including the limestone delivery system, limestone
slurry preparation system, limestone slurry feeding system), gypsum dewatering
system (including belt-type vacuum dewatering system), empty system (emergency
slurry tank and drainage pit system) and sampling system. Cold state debugging of the
flue gas system is the core of subsystem debugging, it is also an important part for the
overall check of the equipment condition and for system interlock and protection test.
3.1
3.1 Commissioning of electrical system
FGD
UPS
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6kV FGD
Electrification conditions for the auxiliary power: The monomer debugging for
electric switches of the 11kV or 415V systems have been finished, and it is qualified
and with the conditions for putting into operation; the DC system equipment
debugging has been finished, and it is qualified and with the conditions for putting
into operation; the grounding system debugging has been finished, and it is qualified
and with the conditions for putting into operation; the lighting and communication
debugging have been finished, and they are qualified and with the conditions for
putting into operation; the debugging for the affiliated firefighting system and
facilities of electrical system have been finished; the static debugging for the interlock
protection system of electrical system has been finished; the 6kV system of the power
plant side has been ready for the power supply of FGD system and can be put into
operation at any time.
11kV415V UPS DCS
11kV and 415V system is electrified; DC system and UPS system are put into
operation; and DCS system supplies power.
3.2
3.2 Commissioning of the thermal control system
FGD DCS SCS
,
MCS
Before the test run of individual equipment and subsystem and the whole-set
start-up of FGD, the SCS control range realized by DCS includes the monitoring and
control of all pumps, fans, valves and dampers in the unit control room and the
normal operation of the interlock protection of equipment. All MCS control circuits
are put into normal operation.
3.3
3.3 Test run of damper seal system
3.3.1
3.3.1 Check before debugging
The individual test run of motor of each fan is qualified.
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The installation of fan and all relevant air flues and instruments is completed.
The foundation of fan is firm, and all bolts have been tightened.
Check the air door of seal air system and the switch shall be flexible and
indication be correct.
The lubricating oil level of fan is normal and cooling water unblocked.
3.3.2
3.3.2 Test run of fan
DCS
Connect the coupling and start the fan with DCS for the first time. Stop with
the emergency button when the full speed is reached and observe whether there is
abnormal phenomenon or frication sound about each module. And the formal test run
can only be conducted after the confirmation of no problem.
Check the temperature and vibration of bearing periodically during test run.
Stop the test run at once if abnormal situation is founded, and continue the test run
after the abnormal situation is eliminated.
3.4
3.4 Test run of process water system
FGD
GGH
The process water provided for the FGD system has many purposes, and the
main purpose is to supplement the moisture which is taken away by the wastewater
system, evaporated in the absorber and taken away due to generation of the final
product "gypsum". Meanwhile, the process water is also used for cooling the
oxidation air and flushing GGH, discharge pipelines, gypsum filter cloth and filter
cake. The system generally comprises the process water pump and the mist eliminator
flushing pump.
3.4.1.
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The water source of process water tank comes from the outlet water of
circulating water, and a flow meter is arranged on the water inlet main pipeline. The
water enters the process water tank through the flow meter, filter screen and electric
door, and the supply of water and the shut-off operation are controlled by the electric
door. When water is injected into the process water tank for the first time, water
supplement shall be conducted through the filter screen which shall be cleaned in time.
The liquid level of the process water tank should be controlled automatically so as to
keep the normal water level of process water tank.
3.4.2
3.4.2 Check before test run of water pump
Individual test run of water pump motor is qualified;
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Connect the coupling, start the water pump with DCS for the first time and
then stop the water pump with the emergency button when reaching the full speed,
observe whether abnormal phenomenon and friction sound occur on each module and
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Check the temperature, vibration and sealing of the bearing periodically. Stop
the test run at once if abnormal situation is founded, and continue the test run after the
abnormal situation is eliminated.
3.4.5
3.4.5 Startup of process water system
Firstly, conduct local check on the equipment system, connect the mechanical
seal water of equipment and start the equipment after the inspection is completed.
Select a pump as the operation pump, and the other as the standby pump;
Start the sequential control start procedure of the process flushing pump;
Start the sequential control start procedure of the mist eliminator flushing
pump;
After the equipment is started, open the user valves for auto on, and confirm
whether the process water pump and the flushing pump of mist eliminator are within
the normal range.
3.4.6.
3.4.6. Stop of the process water system
All the other slurry pumps and pipelines shall be shut down, while the process
water system can only be stopped after all flushing is completed;
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b Cut the liquid level control of process water tank, stop the process water pump
and the flushing pump of mist eliminator, and empty the process water tank
completely if the system is shut down for a long time.
3.5
3.5 Test run of compressed air system
GGH
The air source of compressed air system is generally connected by the power
plant air compressor room, and the system is equipped with the instrument
compressed air tank and service compressed air tank according to the requirements.
The compressed air source comes from the main engine, and is mainly used for
equipment such as the pneumatic door, GGH soot blowing and bag-type dust
collector.
Check whether the pipelines, valves and instruments of the compressed air
system are installed completely;
Put into related instruments;
Blow and sweep the compressed air pipelines and tanks;
Inflate the compressed air pipes after blowing and sweeping, and dredge the
water at the bottom periodically;
Blow and sweep all gas pipelines;
Put into all gas pipelines.
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3.6
3.6 Test run of limestone delivery and slurry preparation system
3.6.1
3.6.1 Limestone delivery system
The limestone unloading silo and the limestone storage silo shall be cleaned
without leaving anything, and all manhole doors shall be closed after checking;
Put into relevant meters;
Interlock protection test of each set of equipment is completed;
Test run of the individual equipment is completed;
DCS
Conduct the no-load test run of limestone delivery system, and start the dust
collector, auxiliary equipment, metal separator and vibratory feeder of the limestone
storage silo with DCS in sequence. Check whether the limestone delivery system can
operate continuously and normally.
Conduct the on-load test run of limestone delivery system. Unload the limestone
to the limestone unloading hopper with a truck, and put into the dust collector and
auxiliary equipment of limestone unloading hopper before unloading. Then, the
procedure starts the limestone delivery system so as to feed for the limestone storage
silo.
3.6.2
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A set of limestone milling system adopts the wet ball mill slurry preparation
system. The handling capacity of each set of system is determined according to the
system design. The system generally comprises a limestone weighing feeder, a wet
ball mill, a slurry re-circulation tank matched for the ball mill, two slurry
re-circulation pumps of ball mill, a limestone hydrocyclones station and system
pipeline valves.
3.6.2.1
3.6.2.1 Test run of limestone weighing feeder
3.6.2.1.1
3.6.2.1.1 No-load test run
Preparations:
All bearings, transmission modules and reducers shall be filled with enough
oil;
Check whether other sundries exist in the feeder;
Completely check whether each part of the feeder is intact;
The electrical part installation and wiring of feeder are completed.
After the above preparation work is completed, plug in the power, jog the button
"test run", and conduct the no-load running if the running direction is correct.
During the no-load running, specially-assigned persons shall observe the running
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situation of the rubber belt, drive unit and bottom sweeping. Stop the machine
immediately if problems occur. The tightness degree of the rubber belt and sweeping
chain can be adjusted through corresponding tensioning screw rods. The above
situation is generally debugged before leaving the factory, and adjustment conducted
shall not be too much if no special situation occurs. Conduct the readjustment after
the machine runs for a period.
3.6.2.1.2
3.6.2.1.2 On-load running
After the no-load running is normal, on-load test shall be conducted on the feeder.
Firstly, start the feeder in a no-load mode, and runs with load after the operation is
normal.
3.6.2.1.3
3.6.2.1.3 Make the original record during test run, which comprises the voltage,
current and the revolving speed of rubber belt during no-load and on-load, and check
whether the record conforms to the design.
3.6.2.1.4
3.6.2.1.4 After the on-load running of feeder is normal, conduct the input and
calibration of the work parameter on the weighing instrument.
3.6.2.1.5
3.6.2.1.5 Operation of feeder
Conduct the no-load running for a certain time for each start.
35
The bottom sweeping unit should run for 3-5 minutes each time. There is no
special requirement for the start and stop.
The operator shall check the running situation of each part frequently, especially
whether the rubber belt is off-tracking and how is the tensioning situation, necessary
adjustment shall be conducted if problems occur, and the drive unit shall remain in a
normal state.
During the operation of feeder, the iron piece, large block of material and long
rod foreign bodies shall be prevented from entering the feeder so as to avoid damage
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Stop the feeder - stop the main motor - the high-pressure oil pump starts
automatically (if available) - after the ball mill stops rotating, stop the low-pressure oil
pump - stop the high-pressure oil pump according to the bearing temperature, and
start the high-pressure oil pump (manually) for 2 minutes every 30 minutes (till the
cylinder body is cooled to the room temperature).
The injection lubricating unit system will work automatically when the main
motor works. It shuts down automatically when the main motor stops.
When the main motor works, the low-speed drive unit cannot be started. When
the low-speed drive unit works, the main motor cannot be started.
3.6.2.2.2
3.6.2.2.2 Long-term mill stop
30 2
When mill stops for a long time, the cylinder body will be cooled and shrank
gradually, and slippage of the shaft neck occurs on the bearing bush. In order to
reduce the friction and the axial tensile force generated from shrinking of the cylinder
body, the high-pressure oil pump shall be opened for 2 minutes every 30 minutes after
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the mill stops so that a certain oil film thickness can be kept between the shaft neck
and the bearing bush.
When the mill stops in winter, the cooling water of the water cooling portion
shall be discharged completely (blown with compressed air) so as to avoid frost
cracking of relevant pipelines.
In general case, feeding shall be stopped before the mill stops so that the
operation of the mill can be stopped quickly.
If the machine is stopped for a long time, the steel ball shall be poured out so as
to avoid deformation of the cylinder body due to long time stopping.
3.6.2.2.3
3.6.2.2.3 Test run of mill
When the mill is started for the first time, optional stopping method must be
adopted.
a. 12
a. Enable the mill to rotate 1-2 circle slowly with the low-speed drive unit, and
check the situation of each part.
b. 4
b. The motor is idling (without the mill) and runs for 4 hours continuously.
c. 24
c. Drive the mill to run for 24 hours continuously (without the steel ball and
materials).
The no-load test run shall meet the following requirements:
a.
a. The lubricating situation of each lubricating point shall be normal and free of
leakage phenomenon.
b. 60
b. The main bearing temperature of mill shall not exceed 60.
c.
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c. The running of mill shall be stable, no abnormal noise shall exist during the
transmission of gear, and the contact of tooth flanks shall be good.
d.
d. The liner plate and each rotating part shall be free of loose phenomenon.
After the no-load running is qualified, add the steel ball into the mill cylinder
body. However, pay attention to avoid idling of the mill without any materials after
the steel ball is installed, so as to prevent the high temperature and impact from
damaging the liner plate.
3.6.2.3
3.6.2.3 Test run of blender (mill slurry re-circulation tank blender and limestone slurry
tank blender)
3.6.2.3.1
3.6.2.3.1 Check before test run
,
The installation of blender is completed, and the individual test run of motor is
qualified;
The oil level of lubricating oil is normal;
The water level of slurry tank is enough;
Rotate the blender manually and check whether the rotation is smooth;
Interlock protection test of blender.
3.6.2.3.2
3.6.2.3.2 Test run of blender
DCS
Jog the blender and observe whether the rotating direction is correct. After
starting the blender with DCS for the first time, stop it with the emergency button
when operation is smooth and observe whether there is abnormal phenomenon or
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frication sound about each module. And the formal test run can only be conducted
after the confirmation of no problem.
Check the temperature, vibration and sealing of the bearing periodically. Stop the
test run at once if abnormal situation is founded, and continue the test run after the
abnormal situation is eliminated.
3.6.2.4
3.6.2.4 Test run of pump (limestone slurry pump and mill slurry circulation pump)
3.6.2.4.1
3.6.2.4.1 Check before test run
Individual test run of pump motor is qualified;
The installation of pumps and relevant pipelines and valves are completed;
Flushing of pipelines with industrial water is completed;
The pump foundation is firm and the bolt is tight;
Switches of corresponding valves are flexible and position feedback is correct;
The lubricating oil level is normal and cooling water unblocked;
Rotate the pump manually to check whether the rotation is smooth;
Interlock protection test of pump.
3.6.2.4.2
3.6.2.4.2 Test run of pump
The water level of slurry tank is enough;
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DCS
Start pump with DCS for the first time. Stop it with the emergency button
when operation is smooth and observe whether there is abnormal phenomenon or
frication sound about each module. And the formal test run can only be conducted
after the confirmation of normality.
Record the current, the inlet pressure and the outlet pressure of pumps during
test run;
30
Record the temperature and vibration situation of the pump body, motor and
bearing, check whether there is abnormal sound, observe the lubricating oil level
changing situation and record the operation current and others every 30 minutes
during the test run. Stop the test run at once if abnormal situation is founded, and
continue the test run after the abnormal situation is eliminated.
3.6.2.5
3.6.2.5 Test run of the mill system
3.6.2.5.1
3.6.2.5.1 The conditions before test run:
Installation of each set of equipment of system is completed;
The interior of slurry re-circulation tank is cleaned without anything left, and
all manhole doors are closed after checking;
Flushing of each pipeline in the system is completed;
Put into relevant meters;
Interlock protection test of each set of equipment is completed;
Test run of the individual equipment is completed;
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3.6.2.5.2
3.6.2.5.2 Test run of the mill system
Before the test run of system, calibrate the weighing unit of belt feeder firstly so
that the proportion of limestone and water can be accurately controlled during
operation.
Put into the mill bearing and oil station cooling water, inject liquid for the
limestone slurry circulation tank with process water so as to start the blender after the
injected liquid is reaching a certain liquid level, jog the blender to be in the automatic
mode, inject the liquid to a certain height, start the mill slurry circulation pump and
enable the slurry preparation system to conduct inner circulation.
2030 50
30 10
24
During the on-load test run, add 20-30% steel balls into the mill, and 50% of the
total amount of materials, start the process water pump, start the low-pressure oil
pump, high-pressure oil pump and mill motor of the mill in sequence, open the
limestone blanking valve, start the weighing belt feeder, feed the mill, adjust the water
volume at the inlet and outlet of mill, put into corresponding instruments, add 10% of
the total amount of medium every 30 minutes when the mill is in normal running, feed
moderate materials continuously till the mill is in full load, and enable the mill to run
for 24 hours. Inject the slurry to the limestone slurry tank according to the liquid level
and density of the slurry in the mill slurry re-circulation tank.
SO2
2030Wt
After the limestone slurry is prepared, take the slurry sample from the limestone
slurry tank, conduct the laboratory analysis, observe whether the fineness of materials
can meet the requirements of the SO2 absorption system and whether the particle size
conforms to the design value, control the concentration of limestone slurry between
20% and 30% (Wt); abandon the limestone slurry if the requirements are not met,
otherwise, store the slurry in the limestone slurry tank and enable the system to be in
the standby state.
3.7
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Before the installation of absorber system is completed and put into operation,
ensure that the interior of the absorber and its relevant system are clean, and conduct
the water flushing work besides necessary mechanical sweeping.
Confirm that the installation of absorber system and the mechanical cleaning
work are completed;
Confirm that the test run of individual subsystem of the process water is
qualified and the pipeline of equipment is clean, and ensure that the supplied process
water is clean;
Select the drainage pit as the discharge point of flushing water (discharge the
water in the drainage pit to the rain water well system through a temporary pump);
Take temporary protection measures for each regulating valve and recover
them after flushing;
3.7.2
3.7.2 Test run of spraying layer, mist eliminator and its washing water system
3.7.2.1
3.7.2.1 Check before start
The installation and fastening of spraying layer and mist eliminator are
completed;
Cleaning of all sundries is completed;
Check whether there is a gap and local flue gas bypass in the mist eliminator
area;
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The installation and fastening of wash water pipeline are completed, the
switches of corresponding valves are flexible, and the indication is correct;
The installation directions of the spraying layer nozzle and the nozzles of all
layers of mist eliminator washing water are correct;
Open the flushing pump pipelines of the circulation pump and mist eliminator,
and check whether there is leakage phenomenon on the flange.
3.7.2.2
3.7.2.2 Interlock protection test of mist eliminator system
3.7.2.3
3.7.2.3 Cold state test of spraying layer, mist eliminator and its flushing water system
Open the flushing pump of mist eliminator and record the inlet pressure of
flushing water;
Start the circulation pump, check all nozzles and confirm whether the
direction is correct and whether the spraying water is enough;
Check the switch and flushing time of each valve of the washing water system.
The flushing time intervals shall meet the requirements;
Start the forced draft fan, induced draft fan and booster fan of the boiler in the
cold state, and record the pressure drop of each demist layer.
3.7.3
3.7.3 Test run of slurry circulation pump
3.7.3.1
3.7.3.1 Check before test run
The individual test run of circulation pump motor is qualified.
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The installation of the pump and relevant pipelines, valves and inlet filter
screen is completed;
Flushing of pipelines with industrial water is completed;
The pump foundation is firm and the bolt is tight;
The switches of corresponding valves shall be flexible, the position feedback
and the thermal protection signals shall be correct;
The lubricating oil level is normal and cooling water unblocked;
Rotate the pump manually to check whether the rotation is smooth;
Put into the mechanical seal water.
3.7.3.2
3.7.3.2 Interlock protection test of slurry circulation pump
3.7.3.3
3.7.3.3 Test run of circulation pump
The water level of the absorber is enough;
DCS
Connect the coupling, start the pump with DCS for the first time and then stop
it with the emergency button when it operating steadily, observe whether abnormal
phenomenon and friction sound occur on each module and conduct the test run after
confirming there is no problem;
Monitor the revolving speed, current, inlet and outlet pressure of the pump
during test run;
Check the temperature, vibration and sealing of the bearing periodically. Stop
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the test run at once if abnormal situation is founded, and continue the test run after the
abnormal situation is eliminated.
3.7.4
3.7.4 Test run of the gypsum slurry discharge pump
3.7.4.1
3.7.4.1 Check before test run
The individual test run of discharge pump motor is qualified.
The installation of the pump and relevant pipelines, valves and inlet filter
screen is completed;
Flushing of pipelines with industrial water is completed;
The pump foundation is firm and the bolt is tight;
The switches of corresponding valves shall be flexible, the position feedback
and the thermal protection signals shall be correct;
The lubricating oil level is normal and cooling water unblocked;
Rotate the pump manually to check whether the rotation is smooth;
Put into the mechanical seal water.
3.7.4.2
3.7.4.2 Interlock protection test of gypsum slurry discharge pump
3.7.4.3
3.7.4.3 Test run of the gypsum slurry discharge pump
The water level of the absorber is enough;
DCS
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Connect the coupling, start the pump with DCS for the first time and then stop
it with the emergency button when it operating steadily, observe whether abnormal
phenomenon and friction sound occur on each module and conduct the test run after
confirming there is no problem;
Monitor the revolving speed, current, inlet and outlet pressure of the pump
during test run;
Check the temperature, vibration and sealing of the bearing periodically. Stop
the test run at once if abnormal situation is founded, and continue the test run after the
abnormal situation is eliminated.
3.7.5
3.7.5 Test run of absorber blender
3.7.5.1
3.7.5.1 Check before test run
The installation of blender and its flushing water system are completed;
The oil level of lubricating oil is normal;
Rotate the blender manually and check whether it is smooth;
1m
The water level in the absorber shall be at least 1m higher than the blender
blade.
3.7.5.2
3.7.5.2 Interlock protection test of absorber blender
3.7.5.3
3.7.5.3 Test run of blender
DCS
After starting the blender with DCS for the first time, stop it with the emergency
button when operation is smooth and observe whether there is abnormal phenomenon
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or frication sound about each module. And the formal test run can only be conducted
after the confirmation of no problem.
Check the temperature, vibration and sealing of the bearing periodically. Stop the
test run at once if abnormal situation is founded, and continue the test run after the
abnormal situation is eliminated.
3.7.6.
3.7.6. Test run of oxidation fan
3.7.6.1
3.7.6.1 Check before test run
Individual test run of fan motor is qualified;
The installations of corresponding pipelines, valves and filter screens of fan is
completed, and the direction of outlet check valve shall be correct;
The foundation of fan and the bolt shall be firm;
The switches of corresponding valves shall be flexible, the position feedback
and the thermal protection signals shall be correct;
The lubricating oil level shall be located at the upper position of the center
line, and the cooling water shall be unblocked;
Rotate the fan manually to check whether the rotation is smooth.
3.7.6.2
3.7.6.2 Interlock protection test of oxidation fan
3.7.6.3
3.7.6.3 Test run of oxidation fan
The outlet valves shall be in full open before start;
DCS
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Connect the coupling and start the fan with DCS for the first time. Stop the
fan with the emergency button when the full speed is reached and observe whether
there is abnormal phenomenon or frication sound about each module. And the formal
test run can only be conducted after the confirmation of no problem.
Monitor the revolving speed, current, inlet pressure and outlet pressure of the
oxidation fan during test run;
Check the temperature, vibration and sealing of the bearing periodically;
The fan shall be stable in running and free of abnormal noise. Stop the test run
at once if abnormal situation is founded, and continue the test run after the abnormal
situation is eliminated.
3.7.7
3.7.7 Test run of absorber drainage pit pump
3.7.7.1
3.7.7.1 Check before test run
The individual test run of drainage pit pump motor is qualified;
The installation of pumps and relevant pipelines and valves is completed;
The pump foundation is firm and the bolt is tight;
Switches of corresponding valves are flexible and position feedback is
correct;
The oil level of lubricating oil is normal;
Rotate the pump manually to check whether the rotation is smooth.
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3.7.7.2
3.7.7.2 Interlock protection test of sewage pump of drainage pit
3.7.7.3
3.7.7.3 Test run of drainage pit pump
The water level of drainage pit shall be enough;
DCS
Connect the coupling, start the pump with DCS for the first time and then stop
it with the emergency button, observe whether abnormal phenomenon and friction
sound occur on each module and conduct the test run after confirming there is no
problem;
Monitor the revolving speed, current, inlet and outlet pressure of the pump
during test run;
Check the temperature, vibration and sealing of the bearing periodically. Stop
the test run at once if abnormal situation is founded, and continue the test run after the
abnormal situation is eliminated.
3.7.8
3.7.8 Test run of blender of drainage pit of absorber
3.7.8.1
3.7.8.1 Check before test run
The installation of blender is completed;
The oil level of lubricating oil is normal;
Rotate the blender manually and check whether the rotation is smooth.
3.7.8.2
3.7.7.2 Interlock protection test of blender of drainage pit
3.7.8.3
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After starting the blender with DCS for the first time, stop it with the emergency
button when operation is smooth and observe whether there is abnormal phenomenon
or frication sound about each module. And the formal test run can only be conducted
after the confirmation of no problem.
Check the temperature, vibration and sealing of the bearing periodically. Stop the
test run at once if abnormal situation is founded, and continue the test run after the
abnormal situation is eliminated.
3.7.9
3.7.9 Test run of emergency slurry tank pump
3.7.9.1
3.7.9.1 Check before test run
The individual test run of emergency slurry tank pump motor is qualified;
The installation of pumps and relevant pipelines and valves is completed;
Flushing of pipelines with industrial water is completed;
The pump foundation is firm and the bolt is tight;
Switches of corresponding valves are flexible and position feedback is
correct;
The lubricating oil level is normal and cooling water unblocked;
Rotate the pump manually to check whether the rotation is smooth;
Put into the mechanical seal water.
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3.7.9.2
3.7.9.2 Interlock protection test of emergency slurry tank
3.7.9.3
3.7.9.3 Test run of emergency slurry tank pump
The liquid level of emergency slurry tank is enough;
DCS
Connect the coupling, start the pump with DCS for the first time and then stop
the water pump with the emergency button, observe whether abnormal phenomenon
and friction sound occur on each module and conduct the test run after confirming
there is no problem;
Monitor the revolving speed, current, inlet and outlet pressure of the pump
during test run;
Check the temperature, vibration and sealing of the bearing periodically. Stop
the test run at once if abnormal situation is founded, and continue the test run after the
abnormal situation is eliminated.
3.7.10
3.7.10 Test run of emergency slurry tank blender
3.7.10.1
3.7.10.1 Check before test run
The installation of blender and its flushing water system are completed;
The oil level of lubricating oil is normal;
Rotate the blender manually and check whether the rotation is smooth;
The liquid level in the emergency slurry tank shall be higher than the
mechanical seal of blender.
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3.7.10.2
3.7.10.2 Interlock protection test of emergency slurry tank blender
3.7.10.3
3.7.10.3 Test run of blender
DCS
After starting the blender with DCS for the first time, stop it with the emergency
button when operation is smooth and observe whether there is abnormal phenomenon
or frication sound about each module. And the formal test run can only be conducted
after the confirmation of no problem.
Check the temperature, vibration and sealing of the bearing periodically. Stop the
test run at once if abnormal situation is founded, and continue the test run after the
abnormal situation is eliminated.
3.7.11
3.7.11 Start of absorber system
3.7.11.1
3.7.11.1 Liquid injection of absorber
The liquid injection of absorber shall have the following conditions:
Cleaning of sundries in the absorber is completed;
All flushing water pipes of absorber are closed;
The internal corrosion prevention and maintenance of absorber are finished;
All the water discharge valves at the bottom are closed;
The manhole door at the bottom of absorber is closed;
Put the liquid level meter into the absorber.
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Inject water into the slurry pool of absorber
The water injection of absorber is conducted through the mist eliminator
flushing water during the first start: Start the flushing pump of mist
eliminator in the sequential-control mode, open the main flushing water
control valve of mist eliminator, open a path of flushing water pneumatic
valve of mist eliminator and set it at the manual position, inject water into
the absorber, and stop the water injection when the liquid level of absorber is
suitable.
After the liquid injection is completed, the system is in the cold standby
state.
3.7.11.2
3.7.11.2 Start of drainage pit of absorber
Check the blender and drainage pit pump of the drainage pit of absorber
according to the requirements, put into the liquid level control system of drainage pit
of absorber, and set the blender of drainage pit and pump of the absorber to be in the
automatic state so that the liquid level of drainage pit can control the blender and
pump to start and stop automatically.
3.7.11.3
3.7.11.3 Start of absorber blender
4
Check the blender according to the starting requirements of blender. After the
starting conditions for blender are met, start the four blenders of the absorber in
sequence and check whether the operation of blenders is normal.
3.7.11.4
3.7.11.4 Start of absorber circulation pump
2
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60
Check the circulation pump according to its starting requirements and connect
mechanical seal water of circulation pump and cooling water of gear box. After the
starting conditions of circulation pump are met, start the sequential control starting
procedure of two absorber circulation pumps firstly, and determine whether to start
the sequential control starting procedure of the other absorber circulation pump
according to the situation of the desulfurization efficiency after the boiler is loaded
and the absorber is passed by flue gas. The circulation pump which is not started is
used for standby, and the starting interval shall be more than 60s.
3.7.11.5
3.7.11.5 Start of oxidation fan
1
Check the oxidation fan according to its starting requirements and connect the
cooling water of oxidation fan. After the starting conditions of oxidation fan are met,
start the sequential control starting procedure of one oxidation fan. After starting
equipment, check the operation situation of the equipment. The oxidation fan which is
not started is used for standby.
3.7.11.6
3.7.11.6 Start of gypsum slurry discharge pump of absorber
1
Check the gypsum slurry discharge pump according to its starting requirements,
and connect the mechanical seal water of the gypsum slurry discharge pump. Set one
gypsum slurry discharge pump as the operation pump and the other as the standby
pump. After the starting conditions are met, start the sequential control starting
procedure of one gypsum slurry discharge pump. After starting equipment, check the
operation situation of the equipment.
3.7.11.7 SO2 FGD SO2 95
3.7.11.7 Enable the SO2 removal rate control of absorber to be in the automatic state,
and set the SO2 removal rate of FGD to be 95%.
3.7.11.8
3.7.11.8 Enable the liquid level control of absorber to be in the automatic state
3.7.11.9
3.7.11.9 Sequential control start of absorber mist eliminator flushing water
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Set the flushing water control of mist eliminator at the automatic position. After
the operation conditions of mist eliminator are met, the mist eliminator will execute
sequential control flushing procedures automatically. The flushing waiting time of
mist eliminator is controlled by the liquid level control system of absorber.
3.7.11.10
3.7.11.10 Enable the slurry concentration control of absorber to be in the automatic
state
3.7.12
3.7.12 Deactivation of absorber system
3.7.12.1
3.7.12.1 Deactivation of oxidation air system
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C C
deactivate circulation pump C and conduct the drainage and flushing
procedures of the circulation pump C;
B B
deactivate circulation pump B and conduct the drainage and flushing
procedures of the circulation pump B;
A A
deactivate circulation pump A and conduct the drainage and flushing
procedures of the circulation pump A;
During the deactivation, the procedure of one pump must be completed before
the start of sequential control deactivation procedure of next deactivating pump (the
liquid level situation of drainage pit shall also be taken into account), so that overflow
of liquid due to excessive feeding of the drainage pit of absorber during the water
draining and flushing can be avoided.
3.7.12.3
3.7.12.3 Deactivation of washing of mist eliminator
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3.7.12.5
3.7.12.5 Emptying of absorber slurry
Start the sequential control starting procedure of gypsum slurry discharge pump
to discharge the slurry of absorber to emergency slurry tank after conducting the
pipeline from absorber to emergency slurry tank and implementing the liquid level
control system of emergency slurry tank. The deactivation of gypsum slurry discharge
pump and absorber blender is controlled by the liquid level control system of absorber,
and the starting of the blender of emergency slurry tank is controlled by the liquid
level control system of emergency slurry tank. Conducting the pipeline from the
drainage pit of absorber to emergency slurry tank after the protection of gypsum
slurry discharge pump is deactivated, and the residual liquid of absorber will be
injected into the emergency slurry tank by absorber drainage pit pump.
3.7.12.6
3.7.12.6 Checking and precautions after deactivation
Empty the slurry of the container and equipment to be maintained completely;
Make an inspection tour and check the operation situation of containers with
liquid levels such as the emergency slurry tank and others;
3.8
3.8 Test run of flue gas system
3.8.1
3.8.1 Debugging of flue gas damper
Check the blade, sealing gasket, connecting rod and corresponding actuator of
the flue gas damper, and the installation shall be completed without any damage.
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The installation of flue, corrosion prevention and leak test of flue are
completed, and sundries in the flue shall be cleaned.
Operate the flue gas damper in the remote control or manual mode
respectively. The switch of damper shall be flexible, and the switch indication and
feedback shall be correct.
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Connect the coupling and start the fan with DCS for the first time. Stop the fan with the
emergency button when the full speed is reached and observe whether there is abnormal
phenomenon or frication sound about each module. And the formal test run can only be conducted
after the confirmation of no problem.
Check the temperature and vibration of bearing periodically during test run.
Stop the test run at once if abnormal situation is founded, and continue the test run
after the abnormal situation is eliminated.
3.8.2.3
3.8.2.3 Starting and stopping procedures of low-leakage fan
See the following table for the starting and stopping
procedures of the low-leakage fan:
No. Starting No. Stopping
1 Close the inlet and the 1
Deactivate the fan
outlet dampers
2 2
Start the fan Close the inlet and the outlet dampers
10
3 3
Open the inlet and the outlet
dampers after delay for 10s
3.8.2.4
3.8.2.4 Interlocking test of fan
3.8.3
3.8.3 Test run of booster fan
3.8.3.1
3.8.3.1 Necessary conditions and checking contents before test run
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Fan and all corresponding flue gas pipelines shall be installed completely,
thermal signals shall be correct and individual test run of motor shall be qualified.
Confirm that all bolts are tightened and reliable, and check the leakproofness
of all pipelines, flanges and bolts.
Operation of blade adjusting structure are normal and indicating position is
correct with flexible motion and remote operation.
Fan rotor at the motor coupling shall be rotated manually, and the rotation
shall be smooth and easy. Check radial clearance between the top of impeller blade
and air duct; Check the axial clearance between impeller and core tube.
Strictly check the inside of the fan and the flue gas pipeline without leaving
any tools or sundries.
Close all manhole doors.
Check the oil level of main bearing box and oil supply unit and fuel up in case
of insufficient oil.
Check the coupling, drive motor and monitoring instrument.
The on/off of cooling fan is normal.
The function of emergency button is normal.
3.8.3.2
3.8.3.2 Starting procedure of fan:
Close the inlet damper;
Start the cooling fan of booster fan;
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Close the inlet guide blade;
DCS
Start the booster fan with DCS;
Open the inlet damper after the starting of fan;
Adjust the opening of inlet guide blade;
FGD
After the starting, adjust the guide blade and control in coordination with the
bypass damper to keep the inlet pressure of FGD within a certain range. Close the
bypass damper gradually, adjust the booster fan to a suitable position, and enable the
booster fan to be in automatic state after running is stable.
3.8.3.3
3.8.3.3 Deactivation procedure of fan:
Stop the motor of booster fan;
10
Close the guide blade slowly after delay for 10s;
2
Stop the seal cooling fan after delay for 2 hours.
3.8.3.4
3.8.3.4 Monitoring of the operation of fan
Daily check and record shall be conducted every one hour and all data shall be
recorded. Besides record, check shall be carried out to the following items: Noise
characteristics; Stability of operation; State of instrument, etc.
3.8.4 GGH
3.8.4 Test run of GGH high-pressure flushing pump
3.8.4.1
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The pump foundation is firm and the bolt is tight.
Switches of corresponding valves are flexible and position feedback is
correct.
The lubricating oil level is normal and cooling water unblocked.
Rotate the pump manually to check whether the rotation is smooth.
Confirm the inlet pressure of pump within the range of design value.
3.8.4.2
3.8.4.2 Test run of pump
Check whether the inlet pressure of pump is normal.
DCS
Connect the coupling and start the pump with DCS for the first time. Stop the pump
with the emergency button when operation is smooth and observe whether there is abnormal
phenomenon or frication sound about each module. And the formal test run can only be conducted
after the confirmation of normality.
Monitor the revolving speed, current, inlet and outlet pressure of the pump
during test run;
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Record the temperature and vibration situation of the pump body, motor and
bearing, check whether there is abnormal sound, observe the lubricating oil level
changing situation and record the operation current and others every 30 minutes
during the test run. Stop the test run at once if abnormal situation is founded, and
continue the test run after the abnormal situation is eliminated.
3.8.4.3
3.8.4.3 Flushing procedures of high pressure water
GGH 1.5 GGH
4
0.2MPa
When the pressure drop of GGH heat exchanger is 1.5 times of the design
pressure drop, flush the GGH heat exchanger with high-pressure flushing water. The
flushing time one time shall be about 4 hours, and the inlet pressure of high-pressure
wash pump during flushing shall be above 0.2 MPa.
3.8.4.4
3.8.4.4 Flushing procedures of low pressure water
0.4MPa
FGD
The low-pressure water flushing is mainly used for blowing out and overhaul. At
this moment, the inlet pressure of ash ejector shall be above 0.4 MPa, and the inlet
and outlet dampers of FGD shall be closed.
3.8.4.5GGH
3.8.4.5 Program control compressed air blow test of GGH
GGH GGH
1.4rpm 8 2
DCS FGD
When the GGH heat exchanger operates normally, conduct soot blowing with
compressed air. At this moment, the revolving speed of GGH rotor is about 1.4 rpm.
The compressed air soot blowing shall be conducted one time every 8 hours, and each
operation time is about 2 hours. The compressed air soot blowing procedure shall be
started on DCS manually by the operator. Compressed air comes from FGD public
compressed air system.
FGD
Compressed air for blowing shall be in the standby state for operation during
FGD operation. Manual valves in front of ash ejector shall be always in the open state
and only closed in a state of overhaul.
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When blowing soot, the ash ejector goes forward step by step and adopts the
continuous back to back.
3.8.5 GGH
3.8.5 GGH test run
3.8.5.1
3.8.5.1 Check items before test run
Each instrument, such as temperature, pressure, is qualified and can be put
into use. The thermal signal is correct.
The flue gas damper switch is flexible and indicates correctly.
The test run of seal fan and low-leakage fan is completed.
Check of lubricating oil system
The indicators for selected lubricating oil shall be in line with the
requirements;
All pipe joints, valves and packing cover of the oil pump and other easy
leakages places of the oil circulating system shall be sealed well;
Check the lubricating oil of guide bearing, axial bearing which shall be
sufficient and the oil level is normal;
Check of sealing unit
The rotor rotates one circle along the rotation direction by hand pushing.
Check whether there are other foreign matters affecting the rotor rotation or
jamming;
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The radial, axial and circumferential bypass seal clearance shall be in line
with the requirements of the manufacturer to installation clearance;
Cold and hot end of the rotor shall be no sundries and the sealing fin is intact
without damage when checking;
GGH
Check of GGH high and low pressure flushing water system
The installation of the flushing water pipeline is completed;
,
Each valve and instrument can be put into use along the flushing water
pipeline and there is no leakage phenomenon of the connection pipe;
The test run of high-pressure flushing pump is qualified;
Site check
GGH
There is no temporary pedal, steel frame and other spare parts in GGH and
ensure that all site welding has been completed.
The lighting equipment at work site is complete, the brightness is sufficient
and the emergency lighting is safe and reliable;
Stairs, platforms and railings are intact without damages and roads are clear;
GGH
GGH appearance is complete; the site control cabinet and the reducer unit
are good, which have the starting conditions.
3.8.5.2
3.8.5.2 Test
GGH
GGH locally start-stop test
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Put "local/remote control switch" on the local position, start the auxiliary
motor, the rotor rotation is correct, check whether there is jamming or
abnormal noise, and check whether the oil temperature, oil level and oil
pressure are normal;
GGH
Start GGH main motor and auxiliary motor shall be able to disengage
automatically, at the moment, recheck whether the above items are qualified
or not;
GGH
Manually stop GGH and the test shall be normal.
Emergency button is normal.
GGH
GGH interlocking test
GGH
Put "local/remote control switch" on the remote control position and start all seal
fans of GGH;
GGH
The start-stop procedure of GGH
The start-stop procedure is conducted as per the following table.
GGH
The start-stop procedure of GGH
No. Starting No. Stopping
GGH
GGH
1 1
Start GGH bearing seal fan and put into Stop GGH low-leakage fan
interlocking standby
GGH
GGH
2 Start GGH main motor and put the auxiliary 2
Stop GGH main drive motor
motor into interlocking standby
3 3 GGH
Start the sequential start procedure of the
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3.8.6.
3.8.6. Program control start-stop of flue gas system
Program control start-stop of the flue gas system is shown in the following table.
No. Starting No. Stopping
GGH
1 1 The pressure control of booster fan is switched
Start GGH sequential start procedure to manual mode as well as the inlet guide
blade
2 Open the flue gas damper at the outlet of the 2
Slowly open the flue gas bypass damper
clean flue gas manually, at the same time, slowly close inlet
guide blade of the booster fan.
3 3
Close ventilation valve of the absorber After all the bypass damper doors opening,
start the deactivation procedure of the booster
fan.
4 Start the sequential start procedure of the 4
Open the ventilation damper of the absorber
booster fan
30
FGD
5 5
After the guide blade of booster fan reaching Close the FGD outlet flue gas damper
30%, slowly close the bypass damper
FGD
GGH
6 6
Keep the FGD inlet flue gas pressure at the set Stop the GGH in order.
value, and adjust the guide blade until the
bypass damper is closed.
3.9 FGD
3.9 FGD flue gas system cold state adjustment test
3.9.1
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No overhaul in the hearth and flue, hearth negative pressure monitoring can
operate normally, the operator can print negative pressure change curve and opening
degree of fan and current curves.
MFT
Unit power load, dust concentration at the electric dust collector outlet,
electric dust collector running, opening degree of boiler induced draft fan stationary
guide blade, boiler MFT, boiler hearth negative pressure and other signals shall be
introduced to the desulfurization control system.
3.9.2.2 FGD
3.9.2.2 Conditions which shall be provided of the FGD system
The test run of booster fan system is completed, having conditions for
running.
The test run of the flue gas damper is completed which can be opened and closed
normally.
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GGH
GGH test run is completed.
Flue system installation and internal cleaning.
Flue gas system static interlocking test and flue gas system sequential control
start-stop test.
The installation and operation of the related instrument of flue gas system.
3.9.3
3.9.3 Test contents
FGD
Influence to boiler negative pressure while starting FGD flue gas system
program control system;
Booster fan pressure closed loop adjustment test in cold state;
FGD
Influence to boiler negative pressure while stopping FGD flue gas system
program control system;
FGD
Influence to boiler negative pressure while stopping the FGD system
protection (for example, the booster fan trips).
3.9.4
3.9.4 Test steps
Start the force draft fan and induced draft fan of the boiler, adjust the boiler to full load
operation state by boiler operators in the power plant, boiler negative pressure is in the set
value and induced draft fan stops operating automatically.
GGH
Start GGH.
FGD
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Start FGD flue gas system program control without any adjustment to the
boiler, observe and print hearth negative pressure change curve and fan parameter
change curve.
Conduct booster fan pressure closed loop adjustment test in cold state. Guide
blade of the booster fan is in the automatic state , change the working conditions of
the force draft fan and induced draft fan of the boiler, and auto-adjustment of booster
fan guide blade can be observed.
FGD
FGD flue gas system sequential control stops running, without adjustment to
the boiler, observe and print negative pressure change curve and fan parameter change
curve.
FGD
Adjust the boiler negative pressure to the set value, side fan of the boiler is
operating automatically, FGD flue gas system program control is started, observe and
print hearth negative pressure change curve and fan parameter change curve.
FGD
Adjust the boiler negative pressure to the set value, side fan of the boiler is
operating automatically, FGD flue gas system program control is stopped, observe
and print hearth negative pressure change curve and fan parameter change curve.
FGD
Adjust the boiler negative pressure to the set value, side fan of the boiler isn't
operating automatically, observe and print hearth negative pressure change curve and
fan parameter change curve when the FGD system protection stops (for example, the
booster fan trips).
FGD
Adjust the boiler negative pressure to the set value, side fan of the boiler is
operating automatically, observe and print hearth negative pressure change curve and
fan parameter change curve when the FGD system protection stops (for example, the
booster fan trips).
3.10
3.10 Test run of gypsum dewatering system
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3.10.1
3.10.1 The test run of the blender (blender of the filtrate water tank and wastewater
tank)
3.10.1.1
3.10.1.1 Check before test run
,
The installation of blender is completed, and the individual test run of motor
is qualified.
The oil level of lubricating oil is normal.
Rotate the blender manually and check whether the rotation is smooth.
The water level is high enough.
3.10.1.2
3.10.1.2 The operation of the blender
DCS
After starting the blender with DCS for the first time, stop the blender with the
emergency button when operation is smooth and observe whether there is abnormal
phenomenon or frication sound about each module. And the formal test run can only
be conducted after the confirmation of no problem.
Check the temperature, vibration and sealing of the bearing periodically. Stop the
test run at once if abnormal situation is founded, and continue the test run after the
abnormal situation is eliminated.
3.10.1.3
3.10.1.3 Interlocking test of the blender
3.10.2
3.10.2 Test run of the pump
3.10.2.1
3.10.2.1 Check before test run
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The installation of pumps and relevant pipelines and valves is completed.
Flushing of pipelines with industrial water is completed.
The pump foundation is firm and the bolt is tight.
Switches of corresponding valves are flexible and position feedback is
correct;
The lubricating oil level is normal and cooling water unblocked.
Rotate the pump manually to check whether the rotation is smooth:
3.10.2.2
3.10.2.2 Individual test run of motor
Measured motor insulation is qualified, disassemble the coupling or belt.
During the individual test run of the motor, the rotating direction shall be
correct, the emergency button shall be working correctly and reliably.
Detect motor temperature, vibration and current during the test run, stop it
immediately once abnormal situation happens, the test run can be conducted only
after it's normal again.
3.10.2.3
3.10.2.3 Test run of the pump
The water level is high enough.
DCS
Connect the coupling and start the pump with DCS for the first time. Stop it
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with the emergency button when operation is smooth and observe whether
there is abnormal phenomenon or frication sound about each module. And the
formal test run can only be conducted after the confirmation of no problem.
Monitor the revolving speed, current, inlet and outlet pressure of the pump
during test run;
Check the temperature, vibration and sealing of the bearing periodically. Stop
the test run at once if abnormal situation is founded, and continue the test run after the
abnormal situation is eliminated.
3.10.3
3.10.3 Test run of belt-type vacuum dewatering machine
2030mm
The belt-type vacuum dewatering machine is frequency control, controls the
thickness of gypsum on the dewatering machine by adjusting revolving speed,
generally ensure that the thickness of the filter cake in the dewatering machine is
20-30mm.
3.10.3.1
3.10.3.1 Allowable starting condition of belt-type vacuum dewatering machine
Filter cloth flushing water and dewatering machine lubricating water are
enough;
The vacuum pump operates normally;
No stop protection signal of dewatering machine.
3.10.3.2
3.10.3.2 Start-stop procedure of belt-type vacuum dewatering machine
Start-stop procedure of belt-type vacuum dewatering machine is shown in the
following table
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3min
1 1 Stop belt-type vacuum dewatering machine
Start vacuum pump
after 3min of stopping feeding.
2
2 Open the electrically-operated valve of 2 Delay 2min to stop filter cloth flushing
vacuum pump cooling water pump
60 #1
3 Delay 60s to start #1 filter cloth flushing 3
Stop vacuum pump
pump
30
4 Delay 30s to start belt-type vacuum 4 Close the electrically-operated valve of
dewatering machine vacuum pump cooling water
5 5
Start feeding
3.10.3.3
3.10.3.3 Interlock protection test of the belt-type vacuum dewatering machine
3.10.4.
3.10.4. System water injection test run
After injecting water of a certain level to the filtrate water tank, overflows slurry
tank, gypsum slurry tank, filter cloth flushing tank, filter cake flushing tank,
wastewater tank, start normally gypsum discharging pump, overflow slurry pump,
filtrate water pump, vacuum pump, Waste water hydroclone feed pump, waste water
pump, filter cloth flushing pump, belt-type vacuum dewatering machine, gypsum
slurry pump and other related equipment according to the normal operation, check all
parts of the system to guarantee the normal operation.
4FGD
4. Start the whole-set FGD system
FGD
168h
The whole-set start-up and test run means whole-set startup debugging and test
run of the FGD system unit after the completion of the test run of individual
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Replace slurry with water and replace flue gas with air during whole-set
debugging in the cold state. During the whole-set debugging in cold state, the
commissioning shall be conducted for the equipment that shall be put into operation
as per the normal operation, and the standby equipment shall be set in the automatic
standby state.
The more careful and comprehensive are subsystem debugging and test run, the
less left issues are there, the more smoothly and quickly to finish the whole-set
start-up and test run in the cold state. The main debugging job for whole-set start-up
and test run in cold state is the operation mode test, including:
4.1.1
4.1.1 Conduct the whole-set start-stop operation test as per three modes
(1)
(1) Start equipment in turn by manual operation to make the whole system in
operation state; then stop equipment in turn by manual operation to make whole
system stop running.
(2)
(2) Start subsystems in turn according to functions to make the whole system in
operation; then stop the whole system by stopping the various subsystems. It is
starting and stopping the whole system by small sequential control mode.
(3)
(3) Start and stop the whole system one time automatically by large sequential
control mode (if any).
After the whole system in is normal operation, mainly check the coordinated
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operation of equipment in the whole system, check whether the pressure and flow of
conveying medium are within design range, whether the medium flows smoothly,
whether liquid levels of tanks and pits are in control, and whether abnormal overflow
happens or the liquid level is too low.
4.1.2
4.1.2 Test for operation mode change
FGD
Generally the FGD system is designed with a special operation mode in case of
certain equipment or subsystem being not able to operate due to faults, and it is
supposed to conduct test for operation mode change according to the design. Such as
bypass dewatering system, test for slurry abandoning operation mode, etc.
After the test, discharge all the water in tanks, pools and pipelines, completely
clean up and check, and conduct overhaul according to equipment defects found in
whole-set debugging under the cold state. Subsequently, conduct whole-set debugging
under the thermal-state (flue gas entering) or flue gas entering test run, also called
feeding debugging.
4.2
4.2 Whole-set debugging under thermal-state (flue gas entering)
FGD
1
Whole-set debugging under thermal-state (flue gas entering) of the FGD system
consists of preparation before flue gas entering, flue gas entering debugging and
stopping check. The whole-set debugging under thermal-state (flue gas entering) takes
about 1 month.
Principle for thermal-state test run is manual operation first and then starting and
stopping through the procedure; Open the bypass door first and then stop; adjust flue
gas system first and then other systems; conduct load interlock protection test first and
then adjusting circuit test.
4.2.1.
4.2.1. Preparation before flue gas entering
1
Preparation for flue gas entering shall start 1 week before the first flue gas
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entering test run, and main preparations for flue gas entering are as follows:
4.2.1.1
4.2.1.1 Set up thermal-state whole-set debugging group
FGD
Industrial water, air and steam for instrument and other usages have been sent to
FGD system, and all the gas storage tank work under normal pressure. Fill water into
all the tanks and towers except for the retort of absorber and start the blender.
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Prepare gypsum crystal slurry in proper pit, such as a sump pit in the absorption
area, and then transfer to the retort of the absorber. One can also directly send a
certain amount of crystal into the retort of the absorber. If the side-inserting blender is
closer to tank bottom, it is supposed to try to place gypsum crystal in the middle of the
tank, add water, and timely start the stirring unit after water level rises to the certain
height. Slurry concentration in the retort prepared by these two methods shall not be
lower than 5%. After the liquid level in absorber reaching to the normal control value,
start the oxidation gas distribution unit at the proper time.
GGH GGH
If tubular GGH is adopted, it is supposed to fill hot medium water in the GGH
pipe bundle.
4.2.1.4
4.2.1.4 Equipment starting before flue gas enters in
100
100
100
Check the control system overall: 100% input online instrument, input the
originally set values, and the initial display value of instrument measured value shall
be correct; 100% input of the adjusting circuit, and have adopted the required
accommodation mode; 100% input of the interlock protection circuit.
Start the following equipment through manual operation or small sequential
control of the subsystem functional group:
Start process water, instrument air and compressed air system.
Start functional groups of each sump pit.
Start the absorption system, including circulation pump, blender and oxidation
unit and mist eliminator flushing procedures.
Start limestone slurry allocating or slurry preparing system, and manually operate
limestone slurry supply circulating circuit.
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Start pulp outlet pump of the absorber, and form a small circulation circuit
between the retort and one-stage dewatering unit (in some designs, the small
circulation circuit may not contain one-stage dewatering unit).
GGH GGH GGH
GGH
If rotary GGH is adopted, start the rotary GGH. If tubular GGH is adopted,
start hot medium water circulation pump, heat the hot medium water with steam,
preheat GGH pipe bundle, and control hot medium water temperature within certain
range.
Final check before flue gas entering
Confirm the correct position of each flue gas damper, auxiliary equipment of
booster fan has been started, and the equipment which is required to start is started
and works normally; Confirm that the operation mode selected by non-started
equipment (automatic, manual or standby) is correct; Liquid level of each tank and
other initial measured values are displayed normally; Confirm that the power supply
method is correct, and power switch for equipment to be start or standby equipment
has been turned on.
4.2.2
4.2.2 Flue gas entering debugging
FGD
12hFGD
From the perspective of safety, for the first flue gasentering test run, forcefully
and completely open bypass damper, introduce flue gas into FGD system through
manual operation step by step, gradually increase flue gas amount, and after each
equipment operates normally, all the main measured values have no abnormality and
tend to be stable, slurry density in the retort of absorber is basically stable and it is
able to continuously produce desulfurization gypsum, continuously observe for at
least 12h, and the first FGD flue gas entering succeeds. Then, one can start
debugging.
3 1
Initial debugging of flue gas entering is divided into 3 phases, which takes about
1 month.
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4.2.2.1
4.2.2.1 Debugging contents of the control system
Main items for initial debugging of the control system include:
Conduct the start-stop test for thermal-state manual operation, small
sequential control and large sequential control of the system.
CEMS pH
If necessary, repeat main interlock protection stopping test under load or just
repeat those incident main interlock protection tests.
After finishing debugging to flue gas flow adjusting circuit (also called booster
fan inlet pressure) and main protection interlock stopping test, close the bypass
damper for operation, and put flue gas flow adjusting circuit into automatic operation.
4.2.2.2
4.2.2.2 Initial performance debugging
FGD
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CEMS
CEMS
During the test, spend 1-2d time to stabilize the system, and flue gas flow and
SO2 concentration at the FGD inlet under each load shall stay as stable as possible.
Measure actual values of each guaranteed item under 3 boiler loads by changing
operating parameters, such as slurry set value of pH value, sets of the circulation
pump under commissioning, blown oxidation air amount and circulating slurry
density. Conduct sampling analysis to each kind of slurry (limestone slurry, absorber
circulating slurry, rotational underflow and overflow and wastewater) and gypsum
during this phase. If CEMS (continuous flue gas emission monitoring system) has
been measured for comparison and calibration in advance, CEMS data can be adopted
to describe flue gas characteristics.
4.2.2.3
4.2.2.3 Initial performance inspection
FGD FGD
Initially confirm the best operating parameters according to initial performance
debugging results, and then conduct initial performance inspection. Initial
performance inspection is divided into the following two aspects: Firstly, inspect the
FGD system performance under the confirmed optimum operating parameters and
stable boiler load; secondly, inspect the regulating characteristics of FGD system
following the boiler load change.
4.2.3
4.2.3 Stop checks
168h FGD
710
After finishing thermal-state whole-set debugging, since the system is under
hot-state operation for a long time for the first time, some equipment may show some
defects, and equipment and components in container or flue may show looseness,
falling or damage. Besides, in order to ensure success of the following 168h test run,
it is supposed to stop operation of the FGD system after finishing thermal-state
whole-set debugging, discharge all the slurry in tanks and pools of the system, store
slurry in absorber into the emergency slurry storage tank, and conduct overall check
and trouble-shooting of system equipment. The entire process takes about 7-10 days.
4.3 168h
4.3 168h full-load test run
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168h
168h full-load test run is the last examination item in FGD system debugging/test
run. Inspect whether the system is capable of stable operation under full-load working
condition and continuous operation overall via 168h test run; Examine the input rate
of auto-control instrument, adjusting circuit and interlock protection; Check main
system performances--if desulfurization efficiency can reach to the guarantee value;
Recordother system performance indexes which, however, is not regarded as a basis
to determine whether can 168h test run succeed.
168h FGD
FGD
After the successful 168h full-load test run, stop operation of the FGD system,
store slurry in the emergency slurry storage tank, conduct overall check on system
equipment and eliminate equipment defects. Then, put the system into operation again.
So far, FGD system has been fully transferred to Party A for management, it enters
commercial test run phase, and Party A shall issue temporary transfer certificate to
Party B.
FGD FGD
FGD 168h
168h
FGD
Section II Operation of FGD System
1FGD
1. State division of FGD system
FGD
FGD system state can be roughly divided into four categories: Normal
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Start process water and mist eliminator flushing system
Start compressed air system
Start limestone unloading system Start absorber circulation system: Crystal seed equipped to the absorber,
discharge system, oxidation air system, gypsum discharge system,
circulation pump system, and automatic slurry supply
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Start the slurry preparation system Put into mist eliminator automatic
flushing procedures
Start limestone slurry supply system
Start gypsum hydrocyclone system
GGH
Start flue gas system: Start GGH system and booster fan system
Start gypsum delivery system
Start belt-typevacuum dewatering
system
End
2.2 FGD
2.2 Main stopping steps of FGD system
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GGH
Stop flue gas system: Stop GGH system and booster fan system
Stop gypsum hydrocyclone system Stop mist eliminator automatic
flushing procedures Stop limestone unloading system
(according to material level in
limestone silo)
0
Stop belt-type vacuum dewatering
Turn the limestone slurry supply
system (according to slurry density in
regulating valve to 0, and stop the Stop the slurry preparation system
absorber)
automatic limestone slurry supply (according to liquid level in
limestone slurry tank)
Stop gypsum delivery system
Stop absorber circulation system: Stop limestone slurry supply system
Oxidation air system, gypsum
discharge system and circulation
pump system
If the absorber is empty, stop the blender and
discharge system according to the liquid level in the
absorber.
Stop compressed air system
Stop process water and mist eliminator
flushing system
End
FGD FGD
GGH
DCS FGD
Before normal starting of FGD, put the signal exchange system between boiler
and FGD into operation; Get through flue gas channel, manholes and overhaul holes
along each system and equipment shall be sealed up, and the system shall be well
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sealed; It shall be clean inside the flue gas system, and clean up flue, booster fan,
GGH, absorber and other systems and equipment; Put flue gas system and relevant
thermal measuring points into operation; Cold-state operation of the flue gas system
shall be qualified, and each system and equipment can be put into operation; Put
utility system into operation; Put the empty system into operation; Put limestone
slurry supply system into operation; Water injection to emergency dewatering system;
Water injection to absorber system; DCS system has completed debugging and been
put into operation; Put the electrical system into operation; Check to ensure that signal
exchange between boiler and FGD system and interlock protection work normally;
Static test and check to interlock protection of booster fan and its auxiliary equipment;
Confirm stable operation of the boiler; Put physical and chemical analysis laboratory
into operation, and prepare sufficient drugs; Prepare gypsum crystal seed; Check
absorber system, and start blender, oxidation fan and spraying layer in sequence;
Check empty system, and add gypsum crystal seed into the absorber; Check limestone
slurry preparation system, and prepare sufficient qualified limestone slurry for
standby use; Liquid injection to the absorber. The specific steps are as follows:
2.3
2.3 Start to blow flue gas into the system
2.3.1
2.3.1 Check before starting
FGD FGD
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Reliable power supply;
Sufficient required chemicals;
Fire protection and other safety measures are qualified;
Ensure that no flue gas enters and no flue gas damper is under operation when
checking flue and inner parts of the absorber. Check whether oxygen contents in
various tanks are sufficient when inspecting interior of tanks. Close manhole doors
after check.
2.3.2
2.3.2 Start
FGD
FGD
FGD
Before starting FGD system, firstly check and confirm that all the tanks are filled
with water, and that each liquid level satisfies starting requirements; the limestone
slurry preparation system completes working; All the utility systems stay in standby
state. Start FGD utility equipment, and start all the FGD systems in sequence.
2.3.2.1
2.3.2.1 Start utility system
2.3.2.1.1
2.3.2.1.1 Start compressed air system
0.6MPa
Check and confirm that the pressure of the compressed air storage tank reaches
to over 0.6MPa, and switch on the gas supply valve to supply gas to each gas
consuming point.
2.3.2.1.2
2.3.2.1.2 Start process water system
Firstly, conduct local checks on equipment system, after which start the
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equipment. Select a pump as the operation pump, and the other as the standby pump.
Start automatic control of liquid level in process water tank;
Start the sequential control start procedure of the process wash pump;
Start the sequential control starting procedure of the mist eliminator
flushing pump;
After starting the equipment, check and confirm that the pressure at the process
water pump outlet and the pressure at the mist eliminator flushing pump outlet are
normal.
2.3.2.2
2.3.2.2 Start limestone slurry preparation system
2.3.2.2.1
2.3.2.2.1 Start limestone wet-milling slurry preparation system
Start the filtrate water pump; sequentially start the low-pressure oil pump,
high-pressure oil pump and motor of the mill. Start weighing belt feeder to feed mill,
and adjust water amounts at mill inlet and outlet. Put corresponding instruments into
operation, and send slurry to limestone slurry tank according to liquid level and
density in mill limestone slurry re-circulation tank.
Start the blender of limestone slurry tank and input density measurement system
into the outlet of pump to be started. Make local check of the pump, connect
mechanical seal water of pump and start the equipment as soon as completing
inspection. Select a pump as the operation pump, and the other as the standby pump.
Make sequential control start of limestone slurry pump, check whether pressure at the
outlet of pump is normal and inject limestone slurry into the absorber.
2.3.2.2.2
2.3.2.2.2 Start of limestone dry-powder slurry preparation system
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Input fluidizing air system into the limestone powder silo, open the manual plug
door of one powder fall tube, start the blender of limestone slurry tank, input density
measurement system into the outlet of pump to be started, and open the electric plug
door of powder fall tube and spray valve of exhaust pipe of limestone slurry tank.
Firstly, conduct local check on the pump to be started connect the mechanical
seal water of pump and start the equipment after the inspection is completed. Make
sequential control start of limestone slurry pump.
Make sequential control start of feeding valve of powder fall tube in the
limestone powder silo and operators shall check whether exhaust pipe of the
limestone slurry tank overflows powder. If it does, the water injection valve of
exhaust pipe is necessary to be adjusted till no powder overflows.
30
1250kg/m3 1250kg/m3
Input limestone powder to the limestone slurry tank by feeder below the
limestone powder silo and the limestone powder in the limestone slurry tank and
filtrate water in the slurry recovery tank will mix into limestone slurry in the
concentration of 30% and density of about 1250kg/m3. After density of limestone
slurry reaches 1250kg/m3, the system will be automatically in the hot standby state
(available for operation whenever needed).
2.3.2.3 FGD
2.3.2.3 Start of seal system of FGD damper
FGD FGD
Check seal fans of FGD damper as required, select one for operation and the
other for standby, start a seal fan of FGD damper, and input the heating system of seal
air.
2.3.2.4
2.3.2.4 Enabling drainage pit of absorber
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Check the blender and drainage pit pump of the drainage pit of absorber as
required and set manual valve to make liquid in the pit of absorber be transmitted to
corresponding absorber.
Input liquid level control system of the drainage pit of absorber and set the
blender and pump of drainage pit of absorber in auto mode so that the on/off of
blender and pump shall be controlled automatically by the liquid level of drainage pit.
2.3.2.5
2.3.2.5 Commissioning of flue gas online monitoring system
FGD
Input the flue gas online monitoring system of FGD inlet.
2.4 FGD
2.4 Normal start of FGD units
200mg/Nm3FGD 90 160FGD
Start the equipment of FGD system in the following starting steps and start the
equipment by following starting steps respectively. After mastering and being familiar
with the above steps, it shall be advised to process according to program control.
2.4.1 GGH
2.4.1 Start of GGH system.
GGH GGH GGH
GGH GGH
Check GGH system according to the starting requirements of GGH system. If the
starting conditions for GGH system are met, start the GGH system sequential control
starting procedures and check whether GGH system is in normal operation.
2.4.2
2.4.2 Start of absorber blender
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4
Check the blender according to the starting requirements of blender. After the
starting conditions for blender are met, start the four blenders of the absorber in
sequence and check whether the operation of blenders is normal.
2.4.3
2.4.3 Start of oxidation fan
1
Check the oxidation fan according to its starting requirements and connect the
cooling water of oxidation fan. After the starting conditions of oxidation fan are met,
start the sequential control starting procedure of one oxidation fan. After starting
equipment, check the operation of equipment and set oxidation fan not started as
standby.
2.4.4
2.4.4 Sequential control start of general flushing procedures of absorber mist
eliminator
1
Check the gypsum slurry discharge pump according to its starting requirements,
and connect the mechanical seal water of the gypsum slurry discharge pump. Set one
gypsum slurry discharge pump as the operation pump and the other as the standby
pump. After the starting conditions are met, start the sequential control starting
procedure of one gypsum slurry discharge pump. After starting equipment, check the
operation situation of the equipment.
pH
Set pH meter measurement pipeline system in standby state before starting.
2.4.6
2.4.6 Commissioning limestone slurry discharge system
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SO2
SO2
pH
FGD SO2 95
The removal rate of SO2 depends on the additive amount of fresh limestone
slurry to the absorber, while the additive amount of newly prepared limestone slurry
to the absorber depends on the expected removal rate of SO2, boiler load and pH value
of absorber slurry. After the operation conditions for the limestone slurry discharge
system are reached, input the sequential control starting procedure of the limestone
slurry discharge system. Normally, the SO2 removal rate of the FGD will be set at
95%, and the regulating valve of limestone slurry supply shall be switched on and off
regularly to avoid valve bonding. It is advised that the on/off action shall be
conducted every two hours.
2.4.7
2.4.7 Start of the circulation pump of absorber
2 FGD
Check the circulation pump according to its starting requirements and connect
mechanical seal water of circulation pump and cooling water of gear box. After the
starting condition of the circulation pump is reached, start the sequential control
starting procedure of 2 sets of circulation pump of absorber first; after starting FGD
system, start other circulation pumps according to the absorber load condition and
desulfurization efficiency. After starting equipment, check the operation situation of
the equipment.
2.4.8 FGD
2.4.8 Start of FGD flue gas system
FGD FGD
After the conditions for connecting flue gas to FGD are reached, execute the
sequential control starting procedure of FGD flue gas system.
Open the electric damper at the outlet of clean flue gas;
Start the sequential control procedure of booster fan;
Open the raw flue gas damper;
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30
After the opening of guide blade at the inlet of booster fan reaches 30%, start
to close the electric damper of bypass slowly;
Continue to adjust the opening of guide blade at the inlet of booster fan, and
keep the flue gas pressure at the inlet of booster fan around the set value;
Finish after the electric damper of bypass is closed;
For the first start, the guide blade of booster fan shall be adjusted manually, and
after the control characteristic of the inlet guide blade is mastered, it can be controlled
automatically.
2.4.9
2.4.9 Enable the closed loop control of slurry concentration of absorber to be in the
automatic state
Enable the slurry concentration control of absorber to be in the automatic state.
2.4.10
2.4.10 Start of gypsum dewatering system
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During the deactivation of FGD system, especially the operation related to flue
gas system shall be connected with boiler operators closely and operated smoothly to
ensure the safety of operation of the boiler and the safe deactivation of FGD system.
The normal deactivation of FGD system is carried out in order. The first is to switch
the desulfurization unit from normal operation state to short-term deactivation state
and the last is to switch it from short-term deactivation state to long-term deactivation
state.
Normal operation state
BUF GGH
Start of bypass Stop BUF gradually Stop GGH
damper
Close the clean gas Turn off the oxidation Close the raw gas
damper gradually fan damper gradually
Short-term deactivation state Turn off the slurry
circulation pump
Deactivate limestone slurry
preparation system
Turn off the limestone
slurry pump
Turn off the gypsum dewatering
system
Turn off the gypsum
slurry discharge
pump
GGH
Flush GGH off-line
Empty absorber Turn off the utility
system
Empty limestone slurry tank
Long-term deactivation state
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2.5.1
2.5.1 Long-term deactivation
2.5.1.1
2.5.1.1 Preparation before long-term deactivation
List the equipments and parts which should be checked and maintained carefully
during the deactivation according to the equipment operation condition.
FGD
If the FGD is turned off, the liquid level of the limestone slurry tank should be
kept at the pump protecting deactivation level with empty of residual liquid.
Otherwise the limestone slurry preparation system shall keep the normal operation
state.
2.5.1.2 FGD
2.5.1.2 Deactivation of FGD flue gas system
When the opening of bypass damper reaches above 30%, start the sequential
control deactivation procedure of booster fan (guide blade of booster fan shall be
turned off slowly to make the airflow from induced draft fan steady and never
influence the operation of boiler);
Open the absorber ventilation electric valve;
Turn off the electric damper of clean flue gas outlet;
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Close the raw flue gas damper.
2.5.1.3
2.5.1.3 Deactivation of limestone slurry discharge system
Turn the electrically regulating valve of absorber limestone slurry into manual
control and open it;
Flush the slurry pipeline;
Turn off the electrically regulating valve of absorber limestone slurry;
2.5.1.4
2.5.1.4 Deactivation of gypsum slurry discharge pump
After the gypsum dewatering system is deactivated, stop the gypsum slurry
discharge pump. Set the equipment according to the requirements of sequential
control procedure before implementing sequential control "stop" and confirming the
following operations completed in sequence;
Deactivate the gypsum slurry discharge pump according to the sequential control
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2.5.1.8 GGH
2.5.1.8 Deactivation of GGH system
GGH
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During the deactivation, the procedure of one pump must be completed before
the start of sequential control deactivation procedure of next deactivation pump. And
the liquid level situation of drainage pit shall also be taken into account, so that
overflow of liquid due to excessive feeding of the drainage pit of absorber during the
water draining and flushing can be avoided.
2.5.1.10 FGD
2.5.1.10 Deactivation of limestone slurry preparation system (only when all FGD
systems are deactivated)
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Power off the equipment of deactivation system, but keep the power supply of
liquid level monitoring equipment and blender equipment such as box, tank and pit
which are with liquid level, and the blender of emergency slurry tank shall also be
provided with emergency power supply. The continuously operating equipment shall
be regularly inspected.
2.5.2
2.5.2 Short-term deactivation
2.5.2.1
2.5.2.1 Preparation before short-term deactivation
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FGD
Sequential control deactivation of the limestone slurry preparation system
(when all FGD is deactivated);
SO2
Turn the automatic control of removal rate control of SO2 in absorber into
manual control;
Turn the automatic control of slurry concentration control of absorber into
manual control;
2.5.2.2
2.5.2.2 Deactivation of absorber and flue gas system
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FGD
Section III Performance Test of FGD System
1
1, Purpose and content of performance test
FGD
168h 2 6
Performance assessment test, also known as handover acceptance test, is
designed to verify whether the completed FGD system has met the various technical
and economic indicators specified by the contract and to comprehensively evaluate
the performance of the system. Performance acceptance test shall be generally
conducted appropriately within 6 months after 2 months of the 168h operation being
transferred.
FGD
Technical contract of FGD system generally contains the following performance
guarantee items:
SO2 SO2
SO2 removal efficiency (or outlet SO2 emission rate).
HCIHF SO3
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SO2
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FGD
During the performance assessment test, the operation conditions of the power
plant boiler shall be as close as possible to the design conditions and the boiler shall
keep stable operation under all kinds of loads required by the test. The power plant
can store up coals supplied for fueling during the performance assessment in advance
with sulphur content close to that of design coal or assessment coal, so that the
content of SO2 in flue gas is as close as possible to the design concentration, which is
conducive to the power plant's assessment for FGD system performance.
FGD
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It shall be noted especially that the technical contract of FGD system shall be
clear about the requirements that, under the design conditions, the related
performances of FGD system shall reach the guarantee value at the same time. For
example, these three indicators of desulfurization efficiency, gypsum composition and
limestone consumption shall be assessed under the same operation conditions, which
could avoid the seller to choose the best parameters to meet individual guarantee
value in a certain period of time, and then change the system operating parameters to
meet some other guarantee items.
If the results of performance assessment test show that there is one or more items
of the system guarantee values which cannot meet the requirements, the seller is
allowed to re-conduct the performance assessment test through adjusting or
improvement with required cost borne by the seller.
2
2. Performance test procedures and data arrangement
2.1.
2.1. Procedures of performance assessment test
2.1.1
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FGD system of power plant is required to be provided with CEMS in the system
and stack inlet and some performance parameters during the test can be obtained from
the CEMS. Therefore, before the test, CEMS and other online instruments related to
the performance indexes such as densimeter, pH meter, flow meter of slurry, weighing
unit of limestone powder, gateway watt hour meter and water meter of measuring
electric power and water consumption shall be conducted with careful calibration and
checkout. The calibration includes calibration of zero point and measurement range
and correction calibration of measured value on instrument displayed value.
Flue gas parameters need to be calibrated:
FGD
CEMS DCS
CEMS 2
Flue gas flow calibration. Measure the flue gas flow of FGD unit inlet and
stack inlet using the grid method with pitot tube under the full-load stable working
condition of the boiler. Compare the two measured values to understand the accuracy
of the values. Develop the modified formula of the displayed value of DCS based on
the measured value and the indicating value of CEMS flue gas flow. That means
calibrating CEMS gas flow meter. The calibration must be conducted at least 2 times.
If possible, it should also be conducted under different boiler loads to get satisfactory
results.
GGH - DCS
Flue gas temperature calibration. Measure the flue gas temperature and the
flue gas flow at the same time. Normally the measured value of the raw flue gas
temperature and the online indicating value of the thermometer are very close, so
it does not need to be calibrated. However, clean flue gas stratification is possible,
especially when using tubular GGH or steam-gas heater. So the DCS indicating
value of the clean flue gas temperature must be calibrated to check the
temperature of the clean flue gas after heating.
O2
DCS
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Calibration of water content in the clean/raw flue gas. If CEMS has moisture
content measuring instrument, it also shall be measured at two measuring points in the
fracture surface of the flue. If no moisture content measuring instrument, the value
shall also be measured to calculate the flow of dry flue gas.
Calibration of industrial water flow meter. Calibrate the industrial water flow
meter by using the water consumption of the known volume of the industrial water
tank. Determine the correction factor and the modified formulas. Calibrate when
flushing the pipeline or injecting water into tanks since the total water volume is large
enough to ensure the accuracy of the calibration.
DCS
Calibration of limestone powder weighing and metering unit. Calibrate
according to the methods provided by the manufacturer. Get the limestone
consumption directly based on the displayed value of DCS or local metering value
during the performance assessment test.
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pH
2
Calibrate the densimeter, pH meter and slurry flow meter carefully before
starting the performance assessment test. Calibrate at least two times during the test to
ensure all important parameters are within the predetermined range.
7d
The above calibrations generally take about 7 days.
2.1.2
2.1.2 Check the design conditions of performance guarantee value
During the performance assessment test, the power plant shall provide test
conditions which aren't exceeding or less than the designed conditions. Main test
conditions include flue gas conditions, absorbent and industrial water quality.
FGD SO2SO3
HCIHF SO2
SO3HCIHF
FGD
SO2
DCS
Flue gas conditions include the inlet flue gas flow, temperature and concentration
of harmful composition concentration (SO2, SO3, HCI, HF and dust) of FGD system.
When calibrating and validating the online instruments, the flue gas flow, temperature,
SO2 and dust concentrations have been detected, so the concentration of SO3, HCL
and HF in flue gas shall be measured. These concentrations of the compositions shall
be within the designed range or not exceed too much. In the following performance
assessment test, these concentrations do not need to be measured again and can be
identified to meet the design conditions. If these concentrations of compositions
exceed the design criteria too much, which becomes the reason that the supplier of
FGD unit requires to amend some performance guarantee values or claims of not
meeting the guarantee. Therefore, the power plant shall avoid these situations when
providing design conditions. In addition, the power plant shall adjust combustion
conditions of the boiler, operation working conditions of the electric dust collector or
enable the flue gas flow, temperature, SO2 and dust concentration within design
conditions via the coal blending mode. During the performance assessment test, DCS
collected data for these test conditions of the flue gas shall prevail.
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3 1
Conduct the chemical analysis for absorbent and industrial water to check
whether they meet the design conditions. During the performance assessment test, the
absorbent quality shall be checked at least 3 times and industrial water quality once.
Parallel tests are necessary to check the accuracy of analysis results.
2.1.3
2.1.3 Performance assessment test
2d
pH
Before the official start of the performance assessment test, the stable operation
period of 2 days is needed. Observe the desulfurization efficiency, pH value changes
of absorber slurry, displayed values of the various online instruments and analyze the
compositions of various slurries and desulfurization gypsum to determine whether the
system operation has stabilized under the operation conditions agreed by three parties.
Once the system is stable then performance assessment test shall begin.
7d 24h
7d 24h
14d 12h
2 7d 810h 50 75
2h 10h
During the full-load performance assessment test, if the main unit can provide
the continuous full-load of 7d and 24h, more satisfactory data can be generally
collected. If the host fails to provide the continuous full-load of 7d and 24h, the time
of the performance assessment test is recommended to be extended to 14 days. The
main unit is required to provide 12h continuous full-load every daylight, and 8-10h 50%
and 75% stable load shall be provided at nights in two of 7 days respectively. 2 hours
after rising from a low load to full load, collect the data for 10 hours. The data will be
used as the basis of the full load performance assessment test and the data collected at
night will be used to assess the performance under the low load. In doing so, it can
leave out the correction of the boiler load factor to test results. The test results are
more reliable than results corrected by unauthenticated correction curve.
1d
50%4h 75%4h 100%4h 75%4h 50%4h
2/min
In addition, the variable load tracking test shall be conducted for 1 day, and the
time of the load changing and keeping of the boiler is:
50%4h 75%4h 100%4h 75%4h 50%4h , load change rates are as
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The design conditions of the FGD system guarantee value may be the continuous
economic operation condition of the boiler (ECR) specified in some project contracts.
It is required for the FGD system to run stably under maximum condition running
(MCR) of the boiler, but the guarantee value requirements are not required for the
system performance under MCR working condition. The FGD operation test under
MCR working condition will last 8-16h to assess whether the FGD system can
establish the new material balance and operate stably under reaching the certain
desulfurization efficiency, assess whether the main equipment is running unstably and
whether the output of the equipment is beyond design value, and whether the online
measured values are close to or even exceed the alarm level.
1424d
Therefore, the performance assessment test (including calibration of online
instruments) will last for 14-24 days, depending on the number of performance
assessment test projects.
2.2
2.2 Data arrangement of performance assessment test
2.2.1 SO2 SO2
2.2.1 SO2 removal efficiency and SO2 concentrations in the clean flue gas of system
outlet.
DCS SO2 O2
(1-7-1) 6O2 SO2
(1-18-1) SO2
Take the average concentration value of SO2 and O2 in raw flue gas of system
inlet and clean flue gas of outlet collected by DCS under full-load working condition.
And modify it with correction factor, convert the SO2 concentration under O2
concentration of 6% as per the formula (1-7-1), and calculate SO2 removal efficiency
according to formula (1-18-1), that is:
SO2 SO2
SO
2
SO2
so2= (the concentration of SO2 in raw flue gas of system inlet - the
concentration of SO2 in raw flue gas of system outlet) / the concentration of SO2 in
raw flue gas of system inlet
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SO2
Finally, calculate the corrected SO2 removal efficiency according to correction curve.
SO2
SO2 SO2
FGD SO2
DCS
SO2 SO2
SO2
SO2
SO2
SO2
If full-load working condition of the boiler is time-phased, then SO2 removal
efficiency shall be calculated time-phased, then get the average value to evaluate the
guarantee value of the SO2 removal efficiency. The corrected SO2 removal efficiency
obtained above shall be not less than the guarantee value specified in the contract. At
the same time, if the SO2 concentration in the raw flue gas of the FGD inlet is always
within the design range, then the uncalculated desulfurization efficiency displayed by
the DCS or SO2 concentration in the outlet clean flue gas of system shall be not less
than the guarantee value during the test. If the situation occurs where desulfurization
rate is lower than guarantee value or the concentration of SO2 of system outlet clean
flue gas is higher than guarantee value because of the SO2 concentration of the raw
flue gas is higher than the design value, the desulfurization rate or SO2 concentration
of the clean flue gas during this period shall be separately calculated and corrected.
The desulfurization efficiency or SO2 concentration of clean flue gas after corrected
based on the correction curve shall also not be lower than the guarantee value. Take
the average of desulfurization rate or SO2 concentration of the clean flue gas which is
lower than the guarantee value. This average is not reasonable apparently as the
assessment basis.
2.2.2 SO3HCl HF
2.2.2 SO3, HCI and HF removal efficiency
SO3HCL HF
SO3
CEMS
2 DCS
O2 6O2
Since the concentrations of SO3, HCI and HF in the discharged flue gas of power
plant boiler are normally low, their desulfurization efficiency variation range is
relatively large and the removal rate of SO3 is not mainly dependent on the design of
absorber, hence, normally the removal efficiency of these three toxic gases as the
guarantee value. But generally it is required to measure their removal efficiency as
inspection data. Since the CEMS adopted by power plant does not own the function to
measure the concentration of these three gases, it is necessary to use chemical
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SO2
Take the DCS data during full-load test period. The total industrial water
consumption is corrected by the correction factor. Total power consumption is directly
obtained from electric energy meter. Then calculate average water consumption and
electricity per hour as assessment data. Due to the concentration of SO2 in raw flue
gas of system inlet has little effect on water and electricity consumption. As long as
the amount of the circulation pump of absorber put in operation, there is no need to
revise with correction curve.
2.2.5
2.2.5 Quality of desulfurization gypsum
4
SO42- SO32-
CO32- Ca2+Mg22+
CaCO3 MgCO3 CaSO42H2O
CaSO42H2OCaSO31/2H2OCaCO3MgCO3
100
Sample during full-load test period. Do not revise analysis results. Evaluate
based on actual measured values. The importance is the amount of sampling analysis,
analyzing method and items as regard to the assessment of gypsum quality. The
analyzed sample amount shall not be less than four. It is best to analyze once a day.
The recommended analysis method is adopting weight measurement for total SO42-,
and additionally measure the content of SO32-, CO32- and acid non-soluble substance.
If the measurement of Ca2+ and Mg22+ content could be added, the content of CaCO3
and MgCO3 in gypsum could be separately calculated and checked mutually with the
CaSO42H2O content calculated from sulfenyl and calcium-base in gypsum. The
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DCS SO2 O2
CaSO42H2O
CaSO31/2H2O CaCO3
Currently there are two more adopted measurements of limestone consumption.
One is the FGD technology introduced from Germany which determines the
limestone consumption by calculation. To be specific, during the whole test period,
DCS collects the concentration values of SO2 and O2 in clean flue gas and raw flue
gas. Take the average and correct with correction factor. Take the sample from
limestone slurry tank to perform limestone purity analysis. Take gypsum to perform
analysis of CaSO42H2O, CaSO31/2H2O and CaCO3. Calculate the limestone
consumption by calcium-sulfur mole ratio and desulfurization amount.
The formula for limestone consumption calculation is
G R (c SO2 c SO2c ) M CaCO3 1
CaCO3 (Ca/S)
10 6 M SO2 F
mCaCO3kg/h
Wherein mCaCO3 - limestone consumption, kg/h;
GR 6O2m3/h
GR- raw flue gas volume flow rate (standard state dry flue gas, 6% O2), m3/h;
cSO2R SO2 6O2)mg/m3
cSO2R - SO2 concentration of raw flue gas (dry flue gas at the standard state, 6%
O2), mg/m3;
cSO2C SO2 6O2mg/m3
cSO2C - SO2 concentration of clean flue gas (dry flue gas at the standard state,
6% O2), mg/m3;
MCaCO3CaCO3 100.09kg/kmol
MCaCO3- CaCO3 kilomol mass, 100.09kg/kmol;
MSO2SO2 64.06kg/kmol
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SO2
GRcSO2R cSO2CCa/S
SO2
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method, the CaCO3 mol consumption per hour based on limestone purity and then the
SO2 desulfurization amount (kmol/h) based on design flue gas condition and
guarantee value of desulfurization efficiency. If the ratio Ca/S of these two values is
larger than 1 and is near design value of Ca/S, then the obtained limestone
consumption is pretty convincing. If Ca/S1, it cannot be quite trusted.
t/h cSO2R
t/h
t/h
FGD FGD
t/h
The other measurement method for limestone consumption is that, reach the
limestone consumption (t/h) based on the obtained weighted limestone powder
consumption under full-load working condition. Convert to the limestone
consumption (t/h) under design condition and assured desulfurization efficiency by
the percentage based on cSO2R, actual desulfurization rate and limestone quality.
Additionally, the limestone consumption (t/h) could be calculated based on limestone
slurry supply flow per hour of the absorber, slurry average density and solid content
under full-load working condition, so as to inspect the limestone consumption
obtained from weighing. If the limestone powder mixing system is shared by several
FGD systems or FGD system adopts wet grinded limestone, the limestone
consumption cannot be obtained from weighing and metering. It could also adopt the
latter method stated above to calculate the limestone consumption (t/h).
Based on experience, the latter method gives a more accurate result of limestone
consumption under test condition than the former method. The latter one avoids
taking the correction curve to revise and therefore the final value obtained has higher
credibility. Hence, the second method is recommended.
2.2.7 GGH
2.2.7 Leakage rate of GGH
GGH GGH GGH
GGH
The GGH leakage rate could be defined as the ratio of raw flue gas mass leaked
into the GGH clean flue gas side and clean flue gas entering GGH. Hence, the
formula for GGH leakage rate is:
AL (C2 C1 ) /(C C2 ) 100%
ALGGH
AL: Leakage rate of GGH, %;
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CGGH SO2
C: SO2 concentration at the GGH raw flue gas inlet;
C1GGH SO2
C1: SO2 concentration at the GGH clean flue gas inlet;
C2GGH SO2
C2: SO2 concentration at the GGH clean flue gas outlet;
GGH SO2
GGH SO2 GGH SO2
Since the SO2 concentration at the inlet and outlet of GGH could be unevenly
distributed, it is normally required to adopt grid method to measure the SO2 at the
inlet and outlet of GGH and reach the SO2 average concentration of flue gas at the
inlet and outlet of GGH.
2.2.8
2.2.8 Wet ball mill output test
8h
DCS
Before the test, when perform calibration over limestone belt weigher, adjust the
operating parameter of ball mill and after the slurry particle size and density and
others overflowing from the hydrocyclone to limestone slurry tank reach design
requirements, the ball mill operates over 8h. Take the average through the output of
ball mill collected by DCS.
2.2.9 FGD
2.2.9 Dust emission concentration of the FGD unit
mg/m3
The main measuring points shall be the positions with larger dust concentration,
for the wet grinding system, the measuring positions include the limestone unloading
house and the limestone unloading dust collector outlet and the belt conveyor. For the
limestone powder slurry preparation system, the main measuring positions include the
silo top of the limestone powder silo, the limestone power hopper manhole door, the
top of the limestone slurry tank and the limestone powder unloading location. The
measuring principle is: Adopt the qualified dust sampler to extract the dusty gas of a
certain volume, block the dust on the filter cylinder with known mass, and calculate
the dust concentration (mg/m3) according to the mass increment.
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2.2.10 FGD
2.2.10 FGD unit noise testing
FGD A FGD FGD
At present, the FGD noise testing generally applies the A sound level, during the
FGD system performance test, under full load of FGD system and normal operation
conditions of the equipment, make measurement by selecting position according to
the contract. The main measuring points generally include: booster fan, the slurry
circulation pump, the oxidation fan, the limestone mill, the vacuum pump and the
control room.
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FGD
Chapter VI Common Operation Problem Analysis of FGD System
FGD
Section I Low desulfurization efficiency of FGD system
- FGD
For the wet limestone-gypsum FGD process, lots of factors may influence the
desulfurization efficiency. The main causes generally include:
FGD L/G
Reason for FGD system design: Design for liquid-gas ratio (L/G),
retention time in the flue gas absorber, flue gas velocity in the absorber,
the retention time of slurry, oxidation air amount and layout mode,
airflow uniformity design and spraying layer design;
FGD SO2
FGD inlet flue gas parameters: Flue gas amount, inlet SO2 concentration and
flue gas dust content;
FGD
FGD absorbent: Limestone activity and particle size;
FGD pH
FGD operation control parameters: Absorber pH value and wastewater
discharge;
GGH
Other factors: Inaccuracy of the instrument display, leakage of GGH or bypass
damper, etc.
1
1. System design factors
1.1 L/G
1.1 Liquid-gas ratio (L/G)
1m3 L/m3
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general, it refers to the slurry volume required for washing 1m3 flue gas in L/m3. In
the desulfurization design, the liquid-gas ratio is the core element relating to the
design parameters below:
Sulphur content of the inlet flue gas
Design desulfurization efficiency
Retention time of the flue gas in the absorber
Flue gas velocity in the absorber
pH
Design pH value
Cl-
CI- concentration in the slurry pool
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The sulphur content of the inlet flue gas refers to the SO2 concentration in the
flue gas at the FGD inlet, generally calculated based on the dry basis, 6% of oxygen
content and standard condition. The sulfur content of the inlet flue gas is an important
factor in the calculation of the liquid-gas ratio. The liquid-gas ratio deviates a lot
under different sulphur contents of inlet flue gas. When the actual sulphur contents of
flue gas exceed the design value, the desulfurization efficiency will decrease.
1.1.2
1.1.2 Desulfurization efficiency
FGD SO2 95
SO2 5000mg/Nm3 95
SO2 250 mg/Nm3
Desulfurization efficiency refers to the SO2 removal ratio from the flue gas in the
FGD system. The value is generally designated as 95%, with the stricter requirements
of the national environmental laws; the SO2 emission concentration in the flue gas
required by the environmental requirements shall be considered during the
desulfurization efficiency design. When the inlet sulphur content exceeds
5000mg/Nm3, the desulfurization efficiency is calculated as per 95%, the outlet SO2
concentration will be 250 mg/Nm3, so it can't satisfy the new environmental emission
standard.
1.1.3
1.1.3 Retention time of flue gas in the absorber
SO2
3s4s
FGD
Retention time of flue gas in the absorber refers to the time period from flue gas
entering the absorber and mass transfer with spraying slurry to stopping contact with
circulating slurry, which represents the time of SO2 absorption reaction in the absorber.
Generally, the longer the absorption reaction time is, the higher the desulfurization
efficiency is; however, the larger the absorption area in absorber is and the higher the
cost of single absorber. Generally, typical designed retention time of flue gas in the
absorber is 3s-4s. When the amount of flue gas entering FGD system exceeds the
design value, the flue gas velocity in absorber will exceed the standard value and then
the retention time of flue gas will not be enough, which will cause a drop in
desulfurization efficiency. Similarly, when the unit load is relatively low, the retention
time of flue gas in the absorber will be higher than the design value, and actual
desulfurization efficiency will exceed the design value. At this time, the liquid-gas
ratio can be reduced by stopping the slurry circulation pump, so as to realize
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economic operation.
1.1.4
1.1.4 Flue gas velocity in absorber
3.5m/s4.2m/s
Flue gas velocity in absorber refers to the flue gas velocity in empty tower of
absorber. Generally, higher flue gas velocity is conductive to promote mass transfer
between slurry and flue gas and improve desulfurization efficiency. But it will also
shorten the retention time of flue gas in the absorber, reduce desulfurization efficiency,
increase slurry content in flue gas, and cause other problems. In typical
desulfurization design, flue gas velocity in spraying empty tower of absorber is
generally between 3.5m/s-4.2m/s.
1.1.5 pH
1.1.5 Design pH value
pH pH
SO2 CaSO3
CaSO3 pH pH
pH CaCO3
pH 5.25.8pH
CaCO3
PH value in the slurry pool of the absorber represents the power of hydrogen of
the slurry absorbed. Generally, the higher the pH value is, the higher the SO2
absorption capacity in flue gas will be. When oxidation air supply in absorber is not
sufficient, and CaSO3 is not fully oxidized, it will be easy to cause mild CaSO3 scale.
Lower pH value is beneficial to dissolve the mild scale, but too low pH value will
aggravate acid corrosion of the entire system. Higher pH value is easy to cause hard
CaCO3 scale. In the typical desulfurization design, pH value is generally between
5.2-5.8. Generally, pH value control is to try to reduce CaCO3 content in gypsum
slurry as much as possible on the premise of ensuring designed desulfurization
efficiency.
1.1.6 Cl-
1.1.6 C1- concentration in slurry pool
Cl- HCl
Cl- CaCO3
FGD Cl-
20000ppm Cl- Cl-
5000ppm
Cl- in slurry pool mainly comes from HCl in flue gas. With moisture in slurry in
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absorber taken away by flue gas, Cl- content in pulp will get higher, and when it
reaches a certain value, it will influence CaCO3 dissolution and ionization balance and
then influence desulfurization efficiency. In typical desulfurization design, Cl-
concentration in FGD system is generally required to be less than 20000ppm, but
higher Cl- concentration will aggravate corrosion of system materials. Cl-
concentration in absorber is suggested to be controlled within 5000ppm by increasing
wastewater discharge amount.
1.2
1.2 Retention time of slurry
SO2
CaSO3 CaSO4
CaSO3
4min6min
15h
Long retention time of slurry in reaction tank is beneficial for complete reaction
between limestone in slurry and SO2 and can gain sufficient time for oxidized CaSO3
to be oxidized to CaSO4, forming qualified desulfurization gypsum with larger
particle size and higher purity which is beneficial for dewatering. Therefore, there
should be a sufficient volume of slurry pool in the absorber to ensure limestone
dissolution time, CaSO3 oxidation space and gypsum crystal generation time and
space. However, over large slurry pool volume will increase construction cost.
Currently, typical designed slurry circulation retention time (ratio between slurry pool
volume and total flow of circulation pump) is between 4min-6min, and retention time
of slurry in the absorber (ratio between slurry pool volume and flow of gypsum slurry
discharge pump) is generally not less than 15h.
1.3
1.3 Oxidation air amount and layout mode
CaSO3 CaSO4
1mol SO2 0.5mol O2 O2
100 O2 O2
22.5
Currently, most of the domestic wet desulfurization technologies are generally
forced oxidation, namely that there is oxidation air pipe set at the bottom of slurry
pool of the absorber, input air for forced aeration of the slurry pool, so as to oxidize
CaSO3 to CaSO4 and finally generate gypsum. Theoretically, it needs 0.5mol O2 to
oxidize 1mol SO2, but actually, utilization rate of O2 cannot reach 100%, and there
shall be a certain amount left in design. In a typical design, the amount of O2 is 2-2.5
times of the theoretically required amount.
CaSO3
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600MW
16m
CaSO3 FGD
The insufficient Oxidation air amount will cause high CaSO3 content in slurry,
give rise to limestone shield, reduce desulfurization rate and make it difficult for
dewatering. Generally, there are pipe network type and gun spray type for oxidation
air pipe layout in desulfurization design. Oxidation air pipe in pipe network layout is
better than that in gun spray type in terms of even distribution of oxidation air in
absorber slurry pool. Especially for the absorber corresponding to 600MW unit, if
oxidation air pipe of gun spray type is adopted, it is quite difficult for blender to
distribute oxidation air evenly in slurry pool, since the tower diameter of part of slurry
pool is larger, generally larger than 16m, which is easy to cause higher CaSO3 content
in the absorber and reduce FGD dewatering efficiency.
1.4
1.4 Airflow uniformity design
Generally, the flue gas enters the absorber horizontally, and comes out of the
absorber horizontally or vertically. And the larger the tower cross section is, the
shorter the absorption area route is, which makes it difficult to evenly distribute speed
in absorption area. In case of uneven airflow distribution, desulfurization efficiency in
the area with high airflow rate will reduce, and desulfurization efficiency in the area
with low airflow rate will increase, which will directly influence the absorption
efficiency of the absorber on the whole. Generally, uniform spraying design of
absorber, width-height ratio at absorber inlet, upright design at absorber outlet and
other designs are beneficial for even airflow distribution in the absorber.
1.5
1.5 Design of spraying layer
180250FGD
Design of spraying layer contains two parts: Spraying coverage rate, and nozzle
type. Coverage rate of single spraying layer in absorber is generally 180%-250%, and
the higher the sulphur content in flue gas at FGD inlet is, the higher the coverage rate
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of spraying slurry will be. Even spraying coverage rate is beneficial for airflow
distribution in the absorber, which can improve desulfurization efficiency. Irrational
design of spraying layer or construction not complying with drawings will cause flue
gas escape at some parts. Pressures at different nozzle inlets are different, and so is the
spraying slurry amount, which therefore, reduces desulfurization efficiency.
Currently, there are generally several nozzle types as following: Hollow cone,
solid cone, screw type, etc.. Main performance parameters of nozzle include:
Spraying angle, nozzle flow and pressure drop of nozzle. Generally, blocking rate of
screw-type and solid-cone nozzles is higher than hollow-cone nozzle. Once the nozzle
is blocked, nozzle flow and streamline will change, which will reduce desulfurization
efficiency.
2FGD
2. Flue gas parameters at FGD inlet
2.1
2.1 Influence of flue gas amount at absorber inlet
FGD
L/G
L/G
The change in flue gas amount at the inlet is actually the change of liquid-gas
ratio. When the flue gas amount entering the FGD system reduces, and other
conditions remain unchanged, L/G ratio is theoretically larger than demand amount,
and desulfurization efficiency will increase automatically; when the flue gas amount
increases, L/G ratio is theoretically lower than demand amount, and desulfurization
efficiency will decrease automatically. During actual operation, when the flue gas
amount decreases to a certain value, one circulation pump can be stopped.
2.2 SO2
2.2 Influence of SO2 concentration in flue gas
SO2
SO2
SO2
SO2 SO2
SO2
According to chemical reaction kinetics, the absorption process can be reversible.
When SO2 concentration increases, impetus of mass transfer in gas phase will
increase, which is beneficial for SO2 to disperse into slurry through the slurry surface,
increase reaction speed, and improve desulfurization efficiency accordingly. However,
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with further growth of SO2 concentration, desulfurization efficiency will decline due
to limitation of absorption capacity of the liquid phase. Since there is balanced
concentration for SO2 at absorber outlet, and when SO2 concentration in flue gas is
quite low, SO2 concentration at absorber outlet cannot be less than the balanced
concentration. Therefore, it is quite difficult to obtain extremely high desulfurization
efficiency.
2.3
2.3 Dust content of flue gas
200mg/Nm3
PH
SO2
pH
SO2
The fume content in the boiler flue gas will greatly decline following electric
precipitator, generally lower than 200mg/Nm3. After washing in the absorber, fly ash
will be mostly left in the absorber and some substance in the fly ash will influence
dissolution of limestone, result in the fall of the PH value, and reduce the system's
desulfurization efficiency. Generally speaking, desulfurization efficiency has little to
do with the concentration of fly ash in the flue gas and it is relevant with ash content
in the gypsum slurry. If SO2 content is high in the flue gas, in order to control slurry
density in the absorber, speed of dewatering shall accelerate and ash content in the
gypsum slurry shall dewatering as well to control concentration of fly ash in the
absorber. As a result, it shall have little impact on pH value control and
desulfurization efficiency in the absorber. If SO2 content is low in the flue gas,
substantial fly ash will gather in the absorber due to slower increase in slurry density
in the absorber in spite of its low content of fly ash in the flue gas. As a result, its
desulfurization efficiency will decline.
3FGD
3. FGD absorbent parameters
3.1
3.1 Particle size of limestone
90%
250
The smaller the particle size of limestone is, the larger its specific surface area
will be and the more sufficient its solid-liquid contact will be. As a result, it shall be
enabled to more effectively reduce resistance of liquid film and result in better activity
of limestone. Generally, in typical desulfurization design, the particle size of
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limestone is required to be 90% of 250-mesh pass rate. If the particle size of limestone
is larger, it will increase limestone consumption and reduce desulfurization efficiency.
3.2
3.2 Limestone activity
CaCO3
CaCO3 CaCO3
pH
SO2 PH 4.0 SO2
PH value of slurry in the absorber is an important operating parameter in the
limestone wet FGD system whose characterization is power of hydrogen of slurry in
the absorber. If PH value of slurry rises, on one hand, rate of SO2 absorption will
grow due to rising liquid phase mass transfer coefficient; On the other hand, since PH
value is higher, CaSO3 dissolution resulting from desulfurization will sharply decline
and some undissolved calcium sulfite will be inclined to scale on the walls of the
absorber and surface of mist eliminator and separate out on the surface of the
limestone, influencing speed of limestone dissolution and reducing limestone
utilization. If pH value of slurry is too low, it will have immediate impact on SO 2
absorption; if pH value falls to below 4.0, the slurry will almost not absorb SO2 any
longer.
4.2
4.2 Wastewater discharge
HClHF
SO2
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HCl, HF, fly ash, etc. in the raw flue gas are absorbed in the slurry pool of the
absorber. After longtime operation, concentration of chloride ion in the slurry and
heavy metal ion constantly dissolved in fly ash in the absorber will gradually rise,
which will have a negative impact on SO2 takeoff in flue gas. Therefore, the faster the
hazardous substances gather in the absorber, the higher the discharge of wastewater
will be. According to the experience of actual operation, wastewater discharge to
some extent is conducive to a rise in desulfurization efficiency.
5
5. Other factors
FGD
During FGD operation, there are some other factors which have impact on
desulfurization efficiency.
FGD GGH CEMS
CEMS SO2 SO2
The leakage in FGD bypass damper gate and GGH will result in a reduction in
desulfurization efficiency of the whole unit. Inaccurate CEMS display, such as SO 2
content in the inlet flue gas is lower or SO2 content in the outlet is higher measured by
CEMS, will result in a reduction of desulfurization efficiency displayed.
FGD
FGD
Section II FGD system and stack corrosion
1FGD
1. Corrosion of FGD system
FGD
FGD
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In the wet FGD system, operation conditions are rather harsh with diversified
chemical, high and low temperature and mechanical corrosion and abrasion. In some
books of desulfurization, abrasion and corrosion are generally introduced separately.
In fact, chemical corrosion and mechanical abrasion in the FGD system interact with
each other. Corrosion, to start with, results in a disruption of oxide layer on the metal
surface, disrupted oxide layer is later corroded by particulate matter and new metal
surface is exposed which is corroded further. The interaction of corrosion and
abrasion is graver than sole corrosion or abrasion. Concerning the design of
desulfurization, given different locations and working conditions, emphases on
corrosion and abrasion and response measures will be different.
1.1 FGD
1.1 Types of metal corrosion in the FGD system generally include pitting corrosion,
crevice corrosion, stress corrosion, chemical corrosion and electrochemical corrosion.
1.1.1
1.1.1 Pitting corrosion:
Cl- F-
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It refers to corrosion where tensile stress on the metal surface is beyond critical
stress, inclined to result in disrupted metal crystal in external corrosive medium
conditions, which is a type of electrochemical corrosion.
1.1.4
1.1.4 Chemical corrosion
PH H+
It refers to low PH value corrosion, primarily reflected as H+ corrosion.
1.1.5
1.1.5 Electrochemical corrosion
If there are impurities and trace of other metals in the metal, since impurity and
other metals are different from the metal itself in activity and there is substantial
electrolyte in the slurry, it will result in primary galvanic corrosion.
FGD
Key corrosion environments for different parts in a typical FGD system are
shown in the following table:
FGD
Corrosion environments in a typical wet FGD system
Temperature
Location Corrosion substance Remarks
No. ()
SO2
GGH
SO3HFHCl
From untreated raw flue Since temperature is at
1 100150
High-temperature flue the acid dew point,
gas side to GGH heat
side gas contains SO2, SO3, corrosion prevention
HF, HCl, etc. cannot be taken into
account.
SO2
GGH
SO3HFHCl Since it is in a
temperature lower than
2 80100
From GGH untreated the acid dew point and
raw flue gas side to inlet Some wet flue gas higher humidity,
section of absorber contains SO2, SO3, HF, corrosion prevention
HCl moisture, etc. shall be taken into
account.
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Fluctuating temperature
3 Dry and wet interface at Spraying liquid, wet 45100 with conditions for
the inlet of absorber flue gas moisture condensation,
grave corrosion and
scaling
pH
pH Cl-
4 4555 Low pH value, ion
Absorber body Low pH value, Cl- and gathering, abrasion, etc.
other ion corrosion overlay to aggravate
corrosion
SO2
SO3 pH
GGH 2
5 From outlet of absorber Saturated moisture 4555 Where temperature is
to front of GGH (containing SO2 and lower than dew point,
SO3), residual ions in there is liquor
the spraying liquid and condensate and pH
liquor condensate value is below 2.
GGH
H2SO4
GGH SO2
SO3
6 7090 There may be moisture
From outlet of GGH to Moisture and residual condensation and
flue gas damper SO2, SO3, etc. scaling and
concentrated H2SO4 at
the bottom of GGH.
FGD
7 60150 There is moisture
Stack Moisture and residual condensation after FGD
acid substance operation.
8 Circulation pump and 4555 Abrasion and erosion
Spraying slurry
auxiliary pipeline corrosion
Cl-
9 Limestone slurry supply Cl- (filtrate water for Normal
Pitting and abrasion
system pulping), particulate temperature
matter
10 Gypsum slurry 2045 Grave erosion of
Gypsum slurry
treatment system particulate matter
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11 2045 Particulate matter
Pit All kinds of slurries
erosion
Cl-
Cl-
12 Wastewater treatment Concentrated Cl-
Normal
Cl- corrosion
system gathering area temperature
FGD
FGD FGD
GGH SO2SO3HF
HCl
1 From untreated raw flue
gas side to GGH heat High-temperature flue gas High-temperature glass flake
side contains SO2, SO3, HF, HCl, etc.
GGH
SO2SO3HF
HCl
2
From GGH untreated
Some wet flue gas contains SO2, High-temperature glass flake
raw flue gas side to inlet
SO3, HF, HCl moisture, etc.
section of absorber
3 Dry and wet interface at C276
Spraying liquid, wet flue gas
the inlet of absorber
pH Cl-
4 Low pH value, Cl- and other ion
Absorber body Butyl rubber or glass flake
corrosion
SO2SO3
GGH
5 From outlet of absorber Saturated moisture (containing
SO2 and SO3), residual ions in Glass flake
to front of GGH
the spraying liquid and liquor
condensate
GGH SO2SO3
6
Moisture and residual SO2, SO3,
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SO2SO3
7 Moisture and residual SO2, SO3,
From bypass damper to High-temperature glass flake
etc.
inlet of stack
OM
8 Moisture and residual acid
Stack Titanium alloy, pennguard,
substance foamed glass brick, OM
coating, etc.
+
9 Corrosive slurry and suspended Carbon steel pipeline + rubber
Slurry pipeline system
particle medium lining
+SiC
10 Corrosive slurry and large- Polyurethane or carbon steel +
Rotational flow station
particle suspended particle SiC lining
1.4529
11 Metal in the corrosion
Corrosive slurry and large-
Absorber agitator prevention level of 1.4529 or
particle suspended particle
equivalent
12 Corrosive slurry and suspended
Slurry tank Butyl rubber or glass flake
particle medium
1.4529
13 Metal in the corrosion
Corrosive low-temperature flue
Flue gas damper prevention level of 1.4529 or
gas
equivalent
14 Slurry pump and Corrosive slurry and large- Concentrated chromium
impeller particle suspended particle corrosion prevention alloy
FGD
Corrosion and abrasion of the FGD system
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Abrasion of fan blade in high dust conditions
Abrasion of the absorber agitator
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Abrasion of the absorber agitator
Corrosion of impeller of circulation pump
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Corrosion of circulation pump
Stress corrosion of polyurethane separator
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FGD
Corrosion of flue of the FGD system
FGD
Disrupted corrosion prevention coating in the FGD slurry pipeline
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Erosion corrosion on the walls of absorber
Erosion corrosion on the walls of absorber
1.2 Concerning most current cases of FGD system corrosion and abrasion, reasons for
FGD system corrosion are as follows:
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1.2.1
1.2.1 Corrosion result from unreasonable selection and layout of materials.
C276
C276
C276 is required at the inlet dry and wet interface of the absorber. Some firms
of desulfurization replace C276 metal by glass flake out of concerns on cost. Under
stress of cold and hot alteration, glass flake is inclined to fall off, resulting in
corrosion on the metal surface.
Nozzle layout in the spraying layer in the absorber is not reasonable and
spraying slurry directly erodes walls of absorber and bearing beam, resulting in
erosion corrosion on the walls of absorber and beam.
1.2.2
1.2.2 Corrosion resulting from unreasonable control of operating parameters
pH 5.05.8 pH
5.0 4.0 pH
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FGD
Chapter VII FGD System Operation Management
FGD
Section I Required capacity of FGD operators
45
FGD
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FGD
Functions and constitution of FGD equipment
FGD
Foundation of chemical analysis in FGD
FGD
Control concepts of FGD system
3
3. Basic knowledge of thermal power engineering in power plant
Basic concepts of power generation
Basic knowledge of power generation equipment (functions, basic structures
and performances)
Basic knowledge of fuel (coal classification, element analysis, industrial
analysis, etc.)
Characteristics and hazards of flue gas in power plant
4
4. Basic knowledge of mechanical equipment
Material crushing and classification
Fluid and airflow transmission
Separation of heterogeneous materials
Basic theories of heat and mass transfer
5
5. Basic electrical knowledge
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FGD
Section II FGD system operation adjustment
1FGD
1. Main tasks in FGD system operation adjustment
FGD
Generally speaking, FGD operation adjustment is divided into the following three
levels:
FGD
Maintain safe and steady operation of host and FGD device;
FGD
pH
Guarantee that all technical indicators of FGD system are within design scope
and that desulfurization efficiency, PH value of slurry, density, pulping density,
fineness, gypsum quality, wastewater quality, etc. in the absorber are within design
scope;
pH
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density of limestone slurry and limestone particle size] with the lowest energy
consumption of the system.
2FGD
2. FGD flue gas system operation adjustment
2.1
2.1 Booster fan adjustment
2.1.1
2.1.1 Target of adjustment
FGD
Maintain inlet pressure or make flue gas differential pressure on both sides of
FGD bypass damper within limits.
2.1.2
2.1.2 Aim of adjustment
FGD FGD
Operation output of booster fan just overcomes rising resistance in the FGD
system and whether FGD is put into operation or not has no impact on host's air and
flue gas system.
2.1.3
2.1.3 Difficulty of adjustment
If output of booster fan is too high, output of induced draft fan will decline; on
the contrary, if output of booster fan is too low, system resistance will be required of
rising output of induced draft fan to overcome. If host load fluctuates, flue gas amount
will fluctuate, flow rate of flue gas in the system will fluctuate, resistance of flue gas
will fluctuate, and output of booster fan will fluctuate. Thus, it shall be necessary to
adjust opening of booster fan based on negative pressure at the inlet.
2.1.4
2.1.4 Misunderstandings
High opening of booster fan tends to result in increase of flue gas amount in
the system and lowering opening of booster fan may result in a decrease of
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300MW 200MW
GGH GGH
GGH CaCO3
CaCO3 SO3 GGH
GGH
GGH
The content of outlet liquid is rather low after flue gas outflows from the
absorber, which is generally required to be lower than 75mg/m3. However, since GGH
is in longtime operation and its gross slurry and dust are higher, slurry and fume in
flue gas will stick on the elements of GGH heat exchange when they flow out of GGH,
moisture in the slurry will evaporate, gypsum and ash content will be in sediment and
gradually thicken till they block the channel of elements of GGH heat exchanger.
When the CaCO3 content in the absorber slurry is high, CaCO3 in the net slurry will
react with SO3 in the flue gas and generate gypsum crystal sticking to the surface of
GGH heat exchanger element. Generally speaking, high speed of flue gas flow in the
absorber will increase the flue gas capacity at the outlet of the mist eliminator and
accelerate GGH blocking. The slurry capacity in flue gas will increase because of the
unreasonable design of the spraying layer nozzle, the uneven distribution of flue gas
in the absorber and the high speed of flue gas flow in part of the mist eliminator. The
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SO3
SO3
SO3 SO3
SO2 O2
SO3 SO2 O2
GGH
If the flue gas at the outlet of the absorber is under supersaturated state with
certain moisture and the surface of GGH heat exchanger element cold side is damp,
most of the ash content in the air and in the liquid drop will stick to its surface.
Certain acid mist will exist in the clean flue gas at the outlet of the absorber (there are
two statements about SO3 at present: one is that after coming into the absorber, SO3
becomes thin sulfuric acid mist which cannot be wholly captured by the circulating
slurry causing SO3 at the outlet; another is that SO3 in the absorber is generally
captured by the circulating slurry, and the slurry surface at the outlet of the mist
eliminator will absorb certain SO2 and O2 that can generate sulfuric acid on the
surface of the liquid drop when the slurry is at low temperature with impurity whose
concentration is related to the concentration of SO2 and O2 in the flue gas rather than
SO3 at the inlet of the absorber), which will become concentrated acid mist via GGH
and generate silicate similar to cement after reacting with the ash. The silicate hardens
as operation time goes by, and this part will be seriously blocking when it contains
more ash for which it will be hard to be cleared even by high-pressure water.
2.2.6 GGH
2.2.6 Solutions for GGH blocking:
Keep the pressure of soot blowing steam and compressed air within the design
value to guarantee the effectiveness of soot blowing;
Wash the mist eliminator to reduce the slurry content carried by the flue gas
due to the blocking;
Control air leakage rate and coal quality of the host to prevent the flue gas
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Keep the absorber density within the design value to prevent precipitation and
systematic abrasion due to the high density, which will also increase the slurry
circulation pump current and consume more energy of the system.
2.3.1.2
2.3.1.2 Means of adjustment
Discharge the slurry out of the absorber and dewatering, and transport the filtrate
back.
2.3.1.3
2.3.1.3 Objective of adjustment
151090Kg/m31120 Kg/m3
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2.3.2.2 The main methods of controlling the liquid level in the absorber:
Controlling the flushing water volume of the mist eliminator, increase the interval
time of flushing when the absorber liquid level is at a high level, decrease the interval
time at a low level.
2.3.2.3
2.3.2.3 Factors may cause absorber overflows:
The decreased tension of the slurry surface makes the absorber foam;
The sulphur content will exceed when it is in low load, and the pulping water
and vacuum filter water consumption will increase;
Process water leaks into the slurry system;
When the system load is lower, the absorber inlet flue gas humidity will be
excessively high.
2.3.3
2.3.3 Adjustment of differential pressure of the mist eliminator
2.3.3.1
2.3.3.1 Objective of adjustment
GGH
If the mist eliminator is smooth with stable differential pressure, the method of
judging whether it is blocking is similar to that of GGH.
2.3.3.2
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Increase the flushing frequency of mist eliminator flushing water and control the
flushing water pressure between 1.8 and 2.3kg/cm3 in general. If the pressure is too
low, the flushing water of the mist eliminator will not cover enough space, and if the
pressure is too high, the flushing water will not work effectively due to atomization.
2.3.4 PH
2.3.4 Adjustment of pH value
2.3.4.1 pH pH
5.25.8 pH
2 1.03
2.3.4.1 Objective of adjustment: Different technologies require different pH values
and generally speaking, pH value should be 5.2 - 5.8 for wet desulfurization. The
control value of pH value is not fixed. Keep the limestone left in absorber gypsum
slurry as less as possible in principle on condition that desulfurization efficiency is
efficient. In general, limestone content left in gypsum is required to be no more than 2%
and calcium sulfur ration of the system should be controlled within 1.03.
2.3.4.2 pH
2.3.4.2 Factors influencing pH value control:
Absorber inlet flue gas amount;
Absorber inlet sulphur content;
Limestone activity;
Absorber inlet dust content;
Oxidation air amount;
Increase of inert substance precipitation and ionic concentration in the
absorber.
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2.3.4.2.1
pH
2.3.4.2.1 Variations of the total sulfur content: The sulfur content in the absorber
system beyond the processing capability of the system leads to quality deterioration of
the slurry, decrease of pH value and the reduced desulfurization efficiency of the
system;
2.3.4.2.2
2.3.4.2.2 Limestone activity
pH 10
pHt pH
pH
Low limestone activity will increase the calcium sulfur ration of the system and
the limestone content in the gypsum. Desulfurization rate will decrease under high
load and pH value will reduce while the limestone content in the gypsum will even
reach over 10%. The limestone activity is usually measured by means of pH-t, i.e.
titrating limestone with acid, and comparing the pH curve with the standard curve.
The acid dissolution rate will not meet the requirement when the pH of limestone with
low activity cannot last long.
2000mg/m3 1400mg/m3
9697 3
1400mg/m3 2300 mg/m3
75pH 4.6 15
pH
Case: The desulfurization efficiency of a power plant will reach 96% - 97%
when the design sulphur content is 2000mg/m3 and the full-load sulphur content is
about 1400mg/m3. And when the full-load sulphur content constantly rises to about
2300 mg/m3 from 1400mg/m3, the desulfurization efficiency will drop to the lowest
75%, pH decreases continuously to the lowest 4.6 and the limestone content in the
gypsum rises to 15%. When the bypass is opened and the guide blades of the booster
fan become small, stop supplementing slurry and pH value of slurry in the absorber
rises slowly again.
2.3.4.2.3
2.3.4.2.3 High dust content at the absorber inlet
50mg/Nm3
Al3+ F- Ca2+
CaCO3 H+ CaCO3
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300 mg/Nm3
150mg/Nm3
GGH
CaO CaSO4 GGH
For a successfully-designed absorber, most dust in the flue gas entering it will
be captured by the circulating slurry, and the dust content at the outlet basically has
nothing to do with that at the inlet, generally no more than 50mg/Nm3. The left dust
will be captured into the slurry. Al3+, F- and Ca2+ in the dust will combine together and
generate insoluble complex covering CaCO3 which thus prevents the combination of
H+ and CaCO3 in the slurry and causes "shielding of limestone" or the so called
"activity-loss of limestone". Meanwhile, the ash in the flue gas at the inlet will reduce
the activity of the slurry and make the absorber foam so that the desulfurization
efficiency will decrease. The influence of the ash on the desulfurization system is not
directly related to the dust content in the flue gas while it is indeed related to the ash
content in the slurry. For the flue gas with high sulphur content, the desulfurization
system's tolerance to dust is respectively high, and the system can stay in normal
operation when the dust content in the flue gas is more than 300mg/Nm3. In terms of
flue gas of low sulphur content, normal operation of desulfurization system may not
be guaranteed if fume content is around 150mg/Nm3. If dustiness in slurry is higher,
vitriolic mist in GGH will combine with active CaO in ash content and generate
highly adhesive CaSO4, blocking GGH.
pH
4 pH pH
6.2 4 5.4
NaOH 168
Case: During the 168-hour test run in one power plant, the pH value
continuously falls on the 3rd day from 5.4 to 4.4, desulfurization efficiency drops to 80%
and limestone content in slurry in the absorber is over 10%. By the time,
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automatically relieve supply of slurry in the absorber, stop slurry supply, increase
dewatering, increase wastewater discharge and substitute slurry in the absorber with
clean water. On the 4th day, the pH value in the absorber slowly picks up. Though
slurry supply is stopped, the pH value rises to 6.2, which continues to rise until the
afternoon on the 4th day. When it falls to 5.4, recover slurry supply. By the time,
limestone content in gypsum reaches the normal level. Concerning such a situation, it
is advised to add NaOH or lime while stopping slurry supply and slurry substitution to
enhance limestone activity and reduce time of adjustment. Reason analysis: Earlier in
the 168-hour test run, dust content in flue gas is high, density of absorber is not up to
dewatering demand, and substantial heavy metal ion and inert substance in fly ash
deposit, resulting in substances surrounding limestone and blocking limestone. Dilute
ion concentration in the slurry by substitution and continuous dewatering and separate
partially closed limestone from absorber by dewatering to recover slurry activity.
2.3.4.2.4
2.3.4.2.4 Oxidation air amount
pH
As the mill is in the intermittent operation mode and there is a limestone slurry
tank in the middle, it is expected that the mill is in full-load output to minimize power
consumption.
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Control proportion of limestone and process water (filtrate) in the mill and
ensure that feeding capacity of the mill is always in its maximum output;
Supplement steel balls timely if finding that the operating current of the mill
is lower than the set value in operation;
Control particle size of limestone in the mill within the range of design value.
If particle size of limestone is lower than the design value, it will be advised to
consider increase of feeding amount in the proper way to raise mill output;
Monitor closely whether the inlet pressure in the limestone rotational flow
station is within range of design value. If the pressure in the rotational flow station is
too high, it will result in lower density of overflows, decline of mill output and
difficulty in keeping water equilibrium in the absorber. If pressure is too low, it will
result in particle size of finished limestone slurry not up to design requirement, too
much limestone left in the absorber, rising calcium sulfur ratio and operation
diseconomy.
2.5
2.5 Adjustment of operation of the dewatering system
SO2
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High content of acid non-soluble substance in gypsum
To guarantee slurry quality in operation is the key to normal operation of
dewatering system.
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