&EPA
C.I
United Stales
Environmental Protection
Agency
Industrial Environmental Research
Laboratory
Research Triangle Park NC 2771")
60078101
January 1981
EPA Utility FGD Survey:
October - December 1980
Volume II. Design and
Performance Data for
Operational FGD Systems
Interagency
Energy/Environment
R&D Program Report
-------
EPA-600/7-81-0121
January 1981
EPA Utility FGD Survey:
October - December 1980
Volume II. Design and Performance Data
for Operational FGD Systems
by
M. Smith, M. Melia, N. Gregory, and K. Scalf
PEDCo Environmental, Inc.
11499 Chester Road
Cincinnati, Ohio 45246
Contract No. 68-02-3173
Task No. 17
Program Element No. 1NE828
EPA Project Officer: Norman Kaplan
Industrial Environmental Research Laboratory
Office of Environmental Engineering and Technology
Research Triangle Park, NC 27711
Prepared for
U.S. ENVIRONMENTAL PROTECTION AGENCY
,. _ _ . Office of Research and Development
u.b. Environmental Protection Agenqg i Washington, DC 20460
Region V, Library ~f
230 South Dearborn Street - and
Chicago, Illinois 60604
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Enforcement
Washington, DC 20460
-------
NOTICE
This report (prepared by PEDCo Environmental, Inc., Cincin-
nati, Ohio under EPA Contract No. 68-02-3173, Task No. 17) is
provided as an information transfer document. Data in this
report are supplied voluntarily by utility representatives; flue
gas desulfurization (FGD) system designers and suppliers; regula-
tory personnel; and others. Neither EPA nor the designated con-
tractor warrants the accuracy or completeness .of information
contained in this report.
Initial distribution of the report (generally one copy per
company) is limited to organizations and individuals indicating a
specific interest in the field of FGD technology. Additional
copies of this report and preceding issues can be purchased from
National Technical Information Service, Springfield, Virginia
22151.
This report presents a summary of 'the FGD system design and
performance data 'stored in the Flue Gas Desulfurization Infor-
mation System (FGDIS), a computerized data base from which it is
generated.. Plans are currently being formulated to allow access
to the FGDIS by private users (subject to the limitations ex-
pressed in the first paragraph above). It is anticipated that
this will be implemented during the first or second quarter,
1981, at which time the service will be available to the public
through the National Technical Information Service for a usage
charge (non-profit). Users will have the capability to access
the additional design and performance data stored within the data
base that cannot be conveniently printed in this report. Direct
access to the data base will allow statistical analyses of the
data (e.g., averages, maxima, minima, and standard deviation
of various parameters) and tabulation of the data to fit the
individual informational needs of the user. When this service
becomes available, the current recipients of this report will be
notified; and classes will be provided on the use of the system.
rwfronmenfaf Protection Agency
11
-------
USE OF THIS REPORT
This report is the first full compilation (not a supplement)
since the October-December 1979 report (EPA-600/7-80-029a). Be-
cause the next three reports are to be supplements, this issue
should be retained for reference throughout the year. Much of
the design and performance data contained in this issue will not
be published again until February 1982. Supplemental issues are
cumulative in nature, so that it is necessary only to retain the
latest issue and this report to have all the available informa-
tion.
It should be noted that along with the design and performance
data for operational FGD systems contained in Section 3, this
report also contains a number of tables presenting tabulations of
some of the key data. The Executive Summary contains the number
and capacity of FGD systems as of the end of December 1980,
future projections (December 1990) of controlled and uncontrolled
generating capacity, and unit by unit summaries of status changes
and performance during the period.
Appended to this report is a section containing reported and
adjusted cost data for U.S. FGD systems in which operational sys-
tems are stressed (Appendix A). . Also included in the appendices
are definitions, a table of unit notation, and FGD process flow
diagrams.
111
-------
ABSTRACT
This report, which is generated by a computerized data base
system, presents a survey of operational and planned domestic
utility flue gas desulfurization (FGD) systems, operational
domestic particle scrubbers, and Japanese coal-fired utility
boiler FGD installations. It summarizes information contributed
by the utility industry, system and equipment suppliers, system
designers, research organizations, and regulatory agencies. It
presents data on system design, fuel characteristics, operating
history and actual performance. Unit by unit dependability
parameters are included and problems and solutions associated
with the boilers, scrubbers, and FGD systems are discussed.
The domestic FGD systems are tabulated alphabetically by
development status (operational, under construction, or in the
planning stages), utility company, system supplier, process,
waste disposal practice, and regulatory class. FGD system
economic data, definitions, and a glossary of terms are appended
to the report. Current data for domestic FGD systems show 84
systems in operation, 34 systems under construction, and 105
planned systems. Projected 1990 FGD controlled capacity in the
U.S. is 106,846 MW.
IV
-------
CONTENTS
Notice
Use of This Report
Abstract
Tables
Executive Summary and Highlights
Section 1 Summary List of FGD Systems
Section 2 Status of FGD Systems
Section 3 Design and Performance Data for Operational
FGD Systems
Alabama Electric
. Tombigbee 2
Tombigbee 3
Arizona Electric Power
Apache 2
Apache 3
Arizona Public Service
Cholla 1
Cholla 2
Four Corners 1
Four Corners 2
Four Corners 3
Basin Electric Power Coop
Laramie River 1
Big Rivers Electric
Green 1
Green 2
Central Illinois Light
Duck Creek 1
Central Illinois Public Service
Newton 1
Colorado Ute Electric Assn.
Craig 1
Craig 2
Columbus & Southern Ohio Electric
Conesville 5
Conesville 6
These pages appear in Volume I. EPA-600/7-81-012a.
47
47
54
60
67
73
90
95
98
101
104
108
112
115
128
134
138
144
155
v
-------
CONTENTS (continued)
Commonwealth Edison
Powerton 51 163
Cooperative Power Association
Coal Creek 1 167
Coal Creek 2 172
Delmarva Power & Light
Delaware City 1 ' 175
Delaware City 2 179
Delaware City 3 183
Duquesne Light
Elrama 1-4 187
Phillips 1-6 200
Gulf Power
Scholz 1 220
Indianapolis Power & Light
Petersburg 3 222
Kansas City Power & Light
Hawthorn 3 230
Hawthorn 4 240
LaCygne 1 251
Kansas Power & Light
Jeffrey 1 272
Jeffrey 2 277
Lawrence 4 280
Lawrence 5 291
Kentucky Utilities
Green River 1-3 301
Louisville Gas & Electric
Cane Run 4 310
Cane Run 5 318
Cane Run 6 325
Mill Creek 1 331
Mill Creek 3 333
Paddy's Run 6 338
Minnesota Power & Light
Clay Boswell 4 349
Minnkota Power Cooperative
Milton R. Young 2 354
Monongahela Power
Pleasants 1 366
Pleasants 2 • 370
Montana Power
Colstrip 1 372
Colstrip 2 379
VI
-------
CONTENTS (continued)
Page
Nevada Power
Reid Gardner 1 385
Reid Gardner 2 399
Reid Gardner 3 _ 416
Northern Indiana Public Service
Dean H. Mitchell 11 428
Northern States Power
Riverside 6,7 439
Sherburne 1 442
Sherburne 2 459
Pacific Power & Light
Jim Bridger 4 472
Pennsylvania Power
Bruce Mansfield 1 476
Bruce Mansfield 2 489
Bruce Mansfield 3 497
Public Service Company of New Mexico
San Juan 1 500
San Juan 2 508
San Juan 3 516
Salt River Project
Coronado 1 521
Coronado 2 525
South Carolina Public Service Authority
Winyah 2 529
Winyah 3 536
South Mississippi Electric
R.D. Morrow, SR. 1 539
R.D. Morrow, SR. 2 546
Southern Illinois Power Coop
Marion 4 552
Southern Indiana Gas & Electric
A.B. Brown 1 558
Springfield City Utilities
Southwest 1 565
Springfield Water, Light & Power
Dallman 3 579
St. Joe Zinc
G.F. Weaton 1 582
Tennessee Valley Authority
Shawnee 10A 586
Shawnee 10B 588
Widows Creek 8 605
Texas Power & Light
Sandow 4 619
VII
-------
CONTENTS (continued)
Page
Texas Utilities
Martin Lake 1 621
Martin Lake 2 628
Martin Lake 3 634
Monticello 3 639
Utah Power & Light
Hunter 1 644
Hunter 2 648
Huntington 1 651
Summary of FGD Systems by Company 657*
Summary of FGD Systems by System Supplier 659*
Summary of FGD Systems by Process 661*
Summary of Operating FGD Systems by
Process and Unit 662*
Summary of End-Product Disposal
Practices for Operational FGD Systems 665*
Summary of FGD Systems in Operation 667*
Summary of FGD Systems Under Construction 671*
Summary of Contract Awarded FGD Systems 673*
Summary of Planned FGD Systems 675*
Total FGD Units and Capacity (MW)
Installed by Year 679*
Design and Performance Data for
Operational Particle Scrubbers 680*
Commonwealth Edison
Will County 1 680*
Detroit Edison
St. Clair 6 699*
Minnesota Power and Light
Clay Bqswell 3 707*
Syl Las'kin 1 710*
Syl Laskin 2 713*
Montana-Dakota Utilities
Lewis & Clark 1 . 716*
* These pages appear in Volume I. EPA-600/7-81-021a.
Section 4
Section 5
Section 6
Section 7
Section 8
Section 9
Section 10
Section 11
Section 12
Section 13
Section 14
Vlll
-------
CONTENTS (continued)
Section 15
Pacific Power and Light
Dave Johnston 4
Potomac Electric Power
Dickerson 1
Dickerson 2
Dickerson 3
Public Service of Colorado
Arapahoe 4
Cherokee 1
Cherokee 4
Valmont 5
Southwestern Public Service
Harrington 1
Design and Performance Data for
Operational Foreign FGD Systems
Chugoku Electric
Shimonoseki 1
Electric Power Development Company
Isogo 1
Isogo 2
Takasago 1
Takasago 2
Takehara 1
Hokkaido Electric Power
Tomakomai Thermal
Design and Performance Data for
Discontinued Domestic FGD Systems
Arizona Public Service
Four Corners 5A
Boston Edison
Mystic 6
Commonwealth Edison
Will County 1A
Dairyland Power Coop
Alma 5
Detroit Edison
St. Clair 6A
Gulf Power
Scholz 1A
Scholz 1B,2B
Scholz 1,2
Scholz 2A
These pages appear in Volume I. EPA-600/7-81-021a,
ix
Section 16
Page
719*
722*
724*
726*
733*
736*
739*
742*
749*
752*
752*
756*
761*
766*
773*
779*
784*
787*
787*
790*
794*
798*
800*
803*
807*
812*
816*
-------
Appendix A
Appendix B
Appendix C
Appendix D
CONTENTS (continued)
Illinois Power Company
Wood River 4
Key West Utility Board
Stock Island 1
Philadelphia Electric
Eddystone 1A
Potomac Electric Power
Dickerson 3A
Public Service of Colorado
Valmont 5A
Southern California Edison
Mohave 1A
Mohave 2A
Tennessee Valley Authority
Shawnee IOC
Union Electric
Meremac 2
FGD System Cost Data: Operational
and Nonoperational Systems
Introduction
Results of the Cost Analysis
Adjustment Procedure and Background
Costs for Operational FGD Systems
Costs for Nonoperational FGD Systems
Definitions
Table of Unit Notation
FGD Process Flow Diagrams
Page
819*
822*
826*
834*
837*
840*
843*
846*
848*
A-l*
A-2*
A-6*
A-9*
A-21*
A-31*
B-l
C-l
D-l
These pages appear in Volume I. EPA-600/7-81-021a,
x
-------
TABLES
No. Page
I Number and Total Capacity of FGD Systems xii
II Summary of Changes, October - December 1980 xiv
III Performance of Operational Units,
October - December 1980 xvii
FIGURE
No. . Page
1 Computerized Data Base Structure Diagram xiii
XI
-------
EXECUTIVE SUMMARY
This report is prepared quarterly (every three months) by
PEDCo Environmental, Inc., under contract to the Industrial
Environmental Research Laboratory/Research Triangle Park and the
Stationary Source Enforcement Division of the U.S. Environmental
Protection Agency. It is generated by a computerized data base
system, the structure of which is illustrated in Figure 1.
Table I summarizes the status of FGD systems in the United
States at the end of December 1980. Table II lists the units
that have changed status during the fourth quarter 1980, and
Table III shows the performance of operating units during this
period.
TABLE I. NUMBER AND TOTAL CAPACITY'OF FGD SYSTEMS
Status
Operational
Under construction
Planned:
Contract awarded
Letter of intent
Requesting/evaluating bids
Considering only FGD
systems
TOTAL
No. of
units
84
34
30
10
16
49
223
Total
controlled
capacity, MW*
31,109
14,888
14,903
7,515
8,735
29,696
106,846
Equivalent
scrubbed +
capacity, MW
28,214
14,285
14,890
7,515
8,735
29,360
102,999
* Total Controlled Capacity (TCC) is the summation of the gross unit
capacities (MW) brought into compliance with FGD systems regardless
of the percent of the flue gas scrubbed by the FGD system(s).
Equivalent Scrubbed Capacity (ESC) is the summation of the effective
scrubbed flue gas in equivalent MW based on the percent of flue gas
scrubbed by the FGD system(s).
t
-------
PART1CULATE
MATTER
CONTROL
1
AMICAL
ECTOfl
-•PE
PLIER
ML EFf
GN.'iP
1
ESP
TYPE
SUPPLIER
REMOVAL EFF
DESIGN \P
FABRIC FILTER
TYPE
SUPPLIER
REMOVAL EFF
GAS/CLOTH RAT
FQD
PRO<
SL
ST^
S
INF
PART'CULATE
MATTER SCRUBBER
TYPE
SUPPLIER
GAS FLOW RATE
L/G RATIO
REMOVAL EFF
JPPUEfl
'RETROFIT
iRT DATE
UNIT
PERFORMANCE
DATE
BOILER HOURS
BOILER AVAIL
FGD SYSTEM
PERFORMANCE
SERVICE MRS
AVAIL - %
QPER _ %
REL - %
UTIL -%
SOLUT
COMM
Figure 1. Computerized data base
structure diaqram.
TREATMENT
METHOD
DEVICE TYPE
INLET CHARACT
OUTIET CHARACT
DISPOSAL
INTERIM/FINAL
WPE
LOCATION
SITECAPACIT>
-------
TABLE II. SUMMARY OF CHANGES
OCTOBER - DECEMBER 1980
FGD status report
September 30, 1980
Big Rivers Electric
Green 2
Cajun Electric Power Coop
Chicot 1
Chicot 2
Chicot 3
Chicot 4
Oxbow 1
Oxbow 2
Colorado Ute Electric Assn.
Craig 1
East Kentucky Power Coop
J.K. Smith 1
O.K. Smith 2
Florida Power 8 Light
Martin 3
Martin 4
General Public
Coal 1
Coho 1
Gulf Power
Scholz 1
Houston Lighting t> Power
Limestone 1
Limestone 2
Operational
No.
76
+1
+ 1
+1
MWS
25,832
242
447
20
Under
construction
No.
39
-1
-1
MW«
16,442
242
447
Contract
awarded
No.
30
+1
+ 1
MW
14,164
750
750
Letter
of intent.
No.
7
+1
+ 1
MW
5,590
650
650
Requesting/
eval. bids
No.
18
+1
+1
-1
-1
-1
MW K
9,696b
540
625
690
750
' 750
Considering
FRO
No.
38
+1
+1
+ 1
+1
-1
+1
-1
-1
+1
+ 1
-1
MW°
23,000
540
540
540
540
540
540
€50
f50
800
800
625
Total
No.
208
+1
+1
+ 1
+1
+ 1
+1
4-1
-1
+ 1
MM" .
94,724
540
540
540
540
540
800
800
690
20
(o n.tinued)
-------
TABLE II (continued)
FGD status report
September 30, 1980
Kentucky Utilities
Hancock 1
Hancock 2
Louisville Gas & Electric
Hill Creek 1
Lower Colorado River Authority
Fayette Pwr Project 3
Marquette Board of Light
5. Pwr
Shiras 3
Michigan So. Central Pwr
Agency
Project 1
Monongahela Power
Pleasants 2
New York State Electric
?, Gas
Somerset 1
Northern States Power
Metro coal 1
Riverside 6, 7
Sherburne 3
Wisconsin coal 1
Philadelphia Electric
Cromby 1
Soy land Power Coop
Soy land 1
Operational
No.
76
+1
+1
+ 1
MW
25,832
358
618
110
Under
construction
No.
39
-1
+1
-1
-1
+1
MWa
16,442
358
55
618
110
150
Contract
awarded ,
tlo.
30
+1
-1
-1
I1W"
14,164
31
55
150
Letter
of intent
No.
7
-H
MW"
5,590
625
Requesting/
eval. bids
•lo.
18
-1
-1
MWaK
9,696b
31
625
Considering
• FGD
No.
38
<-1
+1
+1
+1
+1
+1
+1
MW°
23,000
650
650
435
200
850
670
500
Total .
No.
208
+•1
+1
+1
+ 1
+1
+ 1
+1
Mw h
94,724°
650
650
435
200
850
670
500
(continued)
-------
TABLE II (continued)
FGD status report
September 30, 1980
Springfield Water, Light
& Pwr
Dallman 3
Tennessee Valley Authority
Johnsonville 1-10
Texas Power t> Light
Sandow 4
Washington Water Power
Creston Coal 1
West Texas Utilities
Oklaunion 1
Oklaunion 2
Total
Operational
No.
76
+1
+1
84
MW3
25,832
205
382
28,214
Under
construction
No.
39
-1
-1
34
nw
16,442
205
382
14,285
Contract
awarded .
No.
30
-1
30
f*r
1 4 , 1 64
600
14,890
Letter
of intent.
No.
7
10
I1W"
5,590
7,515
Requesting/
eval . bids
Mo.
18
+1
16
MWa.
9,696b
720
8,735
Considering
FGH
No.
38
+1
-1
+1
49
MW"
23,000
570
720
720
29,360
Total .
No.
208
-1
+1
+1
223
MW" .
94,724°
600
570
720
102,999
s
Equivalent scrubbed capacity. •
This value was modified slightly due to a MW correction.
-------
TABLE III. PERFORMANCE OF OPERATIONAL UNITS
OCTOBER - DECEMBER 1980
Plant
Tombigbee 2
Tombigbee 3
Apache 2
Apache 3
Choi la 1
Choi la 2
Four Corners 1
Four Corners 2
Four Corners 3
Laramie River 1
Green 1
Green 2
Duck Creek 1
Newton 1
Craig 1
Craig 2
Conesville 5
Conesville 6
Powerton 51
Coal Creek 1
Coal Creek 2
Delaware City 1
Delaware City 2
Delaware City 3
Elrama 1-4
Phillips 1-6
Scholz 1
Petersburg 3
Hawthorn 3
Hawthorn 4
La Cygne 1
Jeffrey 1
Jeffrey 2
Lawrence 4
Lawrence 5
( Green River 1-3
FGD system
capacity,
Mvr
179
179
98
98
119
264
175
175
229
570
242
242
416
617
447
400
411
411
450
327
327
60
60
60
510
408
20
532
90
90
820
540
490
125
420
64
Flue gas
% scrubbed
70
70
50
50
100
100.
100
100
100
100
100
100
100
100
100
87
100
100
100
60
60
100
100
100
100
100
N/Ad
100
100
100
100
75
70
100
100
100
FGO capacity
on line
during
"£#•
179
179
98
98
570
242
416
617
447
400
411
411
327
327
60
60
60
510
408
20
90
90
820
540
490
125
420
No information
for this
period, MW
119
264
175
175
229
242
532
Shut down
throughout
period,
HWa
450
. 64
October 1980
Dependability %c'e
AVL
50
97
93
76
100
73
76
100
91
92
66
60
44
100
72
100
100
100
100
100
100
100
100
OPR
0
63
88
88
100
72
36
91
79
80'
0
46
68
66
60
44
97
70
100
100
0
100
100
100
100
REL
63
99
97
100
75
46
95
82
81
66
60
44
100
71
100
100
100
100
100
100
UTL
0
63
82
68
96
72
16
12
77
12
0
9
68
66
60
44
97
70
33
68
0
37
100
100
65
0
November 1980
Dependability %c'e
AVL
50
99
20
100
100
97
99
71
83
99
94
98
0
100
85
80
'72
99
100
100
100
100
100
OPR
37
86
22
96
98
89
85
74
50
87
0
43
61
96
98
0
99
84
100
100
87
100
100
100
100
REL
37
86
40
96
100
99
100
79
52
86
96
98
0
99
85
100
100
86
100
100
100
100
UTL
8
86
7
96
79
68
85
33
44
52
0
43
43
94
98
0
99
84
40
66
8
87
56
90
100
0
December 1980
Dependability %c>e
AVL
81
100
100
100
100
92
74
63
52
92
87
34
100
82
58
92
99
100
100
100
100
100
OPR
77
77
100
99
100
91
70
57
68
88
• 80
0
47
55
56
100
79
100
100
94
100
100
100
100
REL
77
77
100
100
100
94
85
79
70
87
80
56
100
79
100
100
98
100
100
100
100
UTL
73
77
100
97
93
91
69
55
51 •
81
80
0
46
54
31
100
79
76
25
59
65
99
63
98
100
0
X
<
H-
-------
TABLE III (continued)
Plant
Cane- Run 4
Cane Run 5
Cane Run 6
Mill Creek 1
Mill Creek 3
Paddy's Run 6
Clay Boswell 4
MIHon R. Young 2
Pleasants 1
Pleasants 2
Colstrip 1
Colstrip 2
Reid Gardner 1
Reid Gardner 2
Reid Gardner 3
Oean H. Mitchell ]
Riversidt 6, 7
Sherburne 1
Sherburne 2
Jim Bridger 4
Bruce Mansfield 1
Bruce Mansfield 2
Bruce Mansfield 3
San Juan 1
San Juan 2
San Juan 3
Coronado 1
Coronado 2
Winyah 2
Winyah 3
R.D. Morrow, Sr. 1
R.O. Morrow, Sr. 2
Marion 4
A.B. Brown 1
Southwest 1
FGD system
capacity,
188
200
299
358
442
72
475
185
618
618
360
360
125
125
125
I 115
110
740
740
550
917
917
917
361
350
534
280
280
280
280
124
124
173
265
194
Flue gas
% scrubbed
100
100
100
100
100
100
85
42
100
100
100
100
100
100
100
99
N/Ad
100
100
100
100
100
100
100
100
100
80
80
100
100
62
62
100
100
100
FGO capacity
on line
durinq
period,
MWa'°
188
200
299
358
442
475
185
618
618
125
125
125
115
110
740
740
550
917
917
917
361
350
534
280
280
124
124
173
265
194
No information
for this
period, MW
360
360
280
280
Shut down
throughout
period,
MW3
72
October 1980
Dependability % '
AVL
100
100
100
100
0
100
98
' 100
85
97
100
100
98
97
89
51
11
14
92
63
80
100
99
0
OPR
100
100
100
97
0
51
85
98
0
84
90
100
100
100
ino
100
73
25
93
94
94
99
100
96
0
REL
100
100
100
97
100
87
98
84
90
100
100
74
27
93
91
94
99
100
96
0
UTL
82
10
100
97
0
37
76
0
93
0
81
75
72
100
0
28
90
74
51
10
14
90
25
80
58
96
0
November 1980
Dependability %c'e
AVL
72
100
85
57
0
100
100
100
95
95
100
100
100
100
97
90
96
82
100
73
25
80
90
98
0
OPR
53
100
97
49
0
69
95
100
94
100
94
0
100
100
100
86
60
100
73
42
95
0
84
0
REL
53
100
97
49
100
99
100
92
95
94
100
96
60
100
73
42
95
0
85
0
UTL
35
25
55
42
0
63
91
36
62
95
86
0
100
0
83
63
78
38
100
73
11
75
0
55
0
December 1980
Dependability %c'e
AVL
100
100
60
45
100
0
100
72
81
100
100
93
100
100
95
100
98
91
100
86
99
95
100
50
80
99
43
OPR
100
100
6
99
100
0
88
63
77
99
96
63
100
100
77
100
100
90
52
99
97
99
93
78
96
6
REL
100
100
6
99
100
100
67
75
100
100
63
100
100
93
99
100
99
97
99
93
78
96
8
UTL
77
100
2
45
61
0
84
61
53
98
71
50
81
100
69
0
68
68
88
42
99
95
64
50
72
93
4
X
<
H-
H-
H-
-------
TABLE III (continued)
Plant
Dallman 3
G.F. Weaton 1
Shawnee 10A
Shawnee 108
Widows Creek 8
Sandow 4
Martin Lake 1
Martin Lake 2
Martin Lake 3
Monticello 3
Hunter 1
Hunter 2
Huntington 1
TOTAL
FGD system
capacity ,
MVP
205
60
10
10
550
382
595
595
595
800
360
360
366
28,21*
r 1 ue gas
% scrubbed
100
N/Ad
N/Ad
N/Ad
100
70
75
75
75
100
90
90
85
FGO Capacity
on line
during
period ,
MVT'C
205
60
10
10
382
595
595
595
800
360
360
366
24,062
No information
for this
period, MW
550
3,566
Shut down
throughout
period ,
MW3
586
October 1980
Dependability %c'e
AVL
OPR
100
100
100
REL
97
99
UTL
38
86
88
97
70
98
November 1980
Dependability % '
AVL
OPR
80
100
100
REL
98
100
UTL
14
87
64
76
98
100
December 1980
Dependability % '
AVL
OPR
97
100
100
REL
UTL
25
96
100
100
X
p-
X
Ij Equivalent scrubbed capacity.
c This category includes the flue gas capacity being handled by the FGD system at least part of the time during the report period.
d The percent figures listed are average values for all system scrubbing trains during the period.
Flue gas % scrubbed for prototype and demonstration units is not applicable unless the system is designed to bring a unit into compliance
with SOz emission standard.
Availability, operability, reliability, and utilization as defined in Appendix C of this report.
-------
Current projections indicate that the total power generating
capacity of the U.S. electric utility industry will be approxi-
mately 833 GW by the end of 1990.a (This value reflects the
annual loss resulting from the retirement of older units, which
is considered to be 0.4 percent of the average generating capac-
ity at the end of each year.k) Approximately 370 GW or 44 per-
cent of the 1990 total -will come from coal-fired units. The
distribution of power generation sources, both present (December
1979) and future (December 1990) is as follows:9
December 1979
December 1990
Coal
39%
44%
Nuclear
9%
14%
Oil
25%
20%
Hydro
13%
11%
Gas
13%
10%
Other
1%
1%
GW (total)
603
833
Based on the known commitments to FGD by utilities as presented
in Table I, the percentage of electrical generating capacity
controlled by FGD for both the present (December 1980) and the
future (December 1990) is as follows:
December 1980*
December 1990
Coal-fired generating
capacity, %
13.2
29.2
Total generating
capacity, %
5.2
12.8
In light of the revised New Source Performance Standards, actual
FGD control is expected to be greater than what is reflected by
the figures above. For example, about 40 to 50 systems repre-
senting approximately 20,000 to 25,000 MW of generating capacity
presently fall into the uncommitted category. These are systems
that cannot be included in the committed group at this time
because information regarding their status is not ready for
public release.
In an effort to show general FGD usage and projected usage
trends, the table below gives a current (December 1980) and a
projected (December 1990) breakdown of throwaway product systems
versus salable product systems as a percent of the total known
commitments to FGD as of the end of the fourth quarter 1980:
The number of committed FGD systems is as of December 1980;
however, the figure used for the total generating capacity and
coal-fired generating capacity is based on the available
December 1979 figures.
xx
-------
Throwaway product process
°Wet systems
L i me
Limestone
Dual alkali
Sodium carbonate
N/Aa
°Dry systems
Lime
Sodium carbonate
Salable product process
°Process °Byproduct
Aqueous carbonate/ Elemental sulfur
spray drying
Citrate Elemental sulfur
Lime Gypsum
Limestone Gypsum
Lime/limestone Gypsum
Magnesium oxide Sulfuric acid
Wellman Lord Sulfuric acid
Wellman Lord Elemental sulfur
Process undecided
Total
Percent of total MW
'"December
1980
40.5
45.9
4.2
3.3
-
0.5
-
-
0.2
-
-
-
-
2.5
2.9
-
100.0
December
1990
21.0
36.5
2.0
3.1
6.5
2.9
0.4
0.1
0.1
0.1
0.2
0.5
0.7
1.2
0.7
24.0
100.0
NA - Not available (these systems are committed to a .throwaway product
process; however, the actual process is unknown at this time).
HIGHLIGHTS: OCTOBER - DECEMBER 1980
The following paragraphs highlight FGD system developments during
the fourth quarter 1980.
Alabama Electric Cooperative reported that the Tombigbee 3 FGD
system achieved availabilities .of 97%, 99%, and 100% for the
months of October, November, and December, respectively. The
utility reported that no major problems occurred during this
period.
xxi
-------
The limestone FGD system installed at the Laramie River unit of
Basin Electric Power Cooperative achieved 100% availability
during the months of October, November, and December. The only
problems reported for this period were boiler related.
Big Rivers Electric announced that initial FGD operations at
Green 2 commenced in November 1980. The 242 MW (gross) boiler
fires bituminous coal with an average sulfur content of 3.75%.
The FGD system was supplied by American Air Filter and consists
of two lime spray towers designed to remove 90% of the inlet SC>2.
The system is preceded by a cold side ESP for primary particulate
matter removal. The unit is currently in the start-up phase of
operation; compliance testing is scheduled for the week of
January 18.
Cajun Electric Power Cooperative announced during November 1980
that bids were being requested for a dry scrubbing process to
control SC>2 emissions from Oxbow 1 (formerly Big Cajun III 1) .
Also included in the bid request is an option for five additional
dry scrubbing systems to be installed at the Oxbow 2 and Chicot
1-4 units. Oxbow 2 is to be located next to Oxbow 1 in De Soto
Parish, Louisiana. Each Oxbow unit will be rated at 540 MW
(gross) and will fire lignite with an average sulfur content of
0.6%. Oxbow 1 is scheduled for operation in 1985. No start up
date has been set for Unit 2. The Chicot 1-4 units are planned
to be constructed in Shreveport, Louisiana. Each 540 MW (gross)
unit will fire lignite with an average sulfur content of 1.7%.
The Chicot units are scheduled to commence operations in 1986,
1988, 1992, and 1994, respectively.
Initial FGD operations began at Craig 1 of Colorado Ute Electric
during October 1980. The unit is rated at 447 MW (gross) and
fires subbituminous coal with an average sulfur content of 0.45%.
The FGD system, supplied by Peabody Process Systems, utilizes
four magnesium promoted limestone spray towers for 85% SO2 re-
moval. A hot side ESP precedes the system for primary par'ticu-
late matter control. The stabilized sludge is disposed of in an
off site minefill operation. Some FGD system equipment problems
made it necessary to operate the unit at approximately 50 to 60%
of capacity during November; however, the problems were corrected
and the unit returned to full load during the last week of
December.
Duquesne Light reported that the Elrama FGD system achieved 100%
availability for the months of October and November, respec-
tively. Some absorber module liner repairs were performed during
the two month period but no major problems were encountered. In-
formation for the month of December was not available.
East Kentucky Power Cooperative announced that a letter of intent
was signed in April 1980 with Babcock and Wilcox for the instal-
lation of wet lime FGD systems to control S02 emissions from the
J.R. Smith units 1 and 2. The units will be rated at 650 MW
xxii
-------
(gross) each and will fire bituminous coal with an average sulfur
content of 1.5%. The FGD systems are scheduled to commence
operations in 1985 and 1987, respectively.
Florida Power and Light announced that FGD has been selected as
the S02 emission control strategy to be used at the Martin units
3 and 4. Each unit will be rated at 800 MW (gross). Projected
start-up is 1987 for unit 3 and 1989 for unit 4.
The dual alkali FGD system originally operated in 1975-1976 at
the Scholz station of Gulf Power was reactivated in August 1980
by Combustion Equipment Associates and Arthur D. Little. The
system is being utilized for an EPA sponsored test program aimed
at determining the feasibility of utilizing limestone rather than
lime as the source of calcium for the regeneration reactions.
The reactor system configuration was changed to a four stage
system with an increased residence time; however, no other major
system modifications were required. The system was operated in
the limestone mode for approximately 70% of December and ex-
hibited SO removal efficiencies reportedly in excess of 90%.
Houston Lighting and Power announced that a contract was awarded
to Combustion Engineering for wet limestone FGD systems to con-
trol SC>2 emissions from the new Limestone units 1 and 2. Each
unit will be rated at 750 MW (gross) and will fire coal with an
average sulfur content of 1.08%. A cold side ESP will be used
for primary particulate matter control. Scheduled start-up dates
are 1984 and 1985- for units 1 and 2, respectively.
Kansas City Power and Light reported that the limestone FGD sys-
tems at the La Cygne generating station achieved availabilities
of 100%, 99%, and 99% during October, November, and December,
respectively. A fire in the "D" module was the only major prob-
lem encountered during the quarter.
The FGD systems at Jeffrey 1 and 2 of Kansas Power and Light
achieved 100% availability for the fourth quarter 1980. The
limestone systems operated with no major problems being reported
during this period.
Kansas Power and Light also reported FGD system availabilities of
100% for the Lawrence 4 and 5 FGD systems during the months of
October, November, and December, respectively.
Kentucky Utilities announced plans to construct two new units,
Hancock 1 and 2, to be located in Hawsville, Kentucky. The units
are to be rated at 708 MW (gross) each and will fire a Western
Kentucky coal with an average sulfur content of 3.5%. ^he util-
ity is considering a wet limestone scrubbing system along with an
ESP to control SO2 and particulate matter emissions. Operations
are scheduled to commence in 1988 and 1994 for units 1 and 2,
respectively.
XXlll
-------
Louisville Gas and Electric reported that the lime scrubbing
system at the Cane Run 5 unit achieved 100% availability for the
months of October, November, and December. No operational prob-
lems were reported for this period.
Initial operation of the FGD system at Mill Creek 1 of Louisville
Gas and Electric commenced during December 1980. The 358 MW
(gross) unit fires pulverized coal with an average sulfur content
of 3.75%. The retrofitted wet lime scrubbing process was sup-
plied by Combustion Engineering and is designed to remove 85% of
the inlet S02-
Lower Colorado River Authority has announced plans to construct
Fayette Power Project 3 in La Grange, Texas. The 435 MW (gross)
unit will fire lignite with an average sulfur content of 1.7%.
SO2 emissions from this unit will be controlled by a FGD system
designed for 90% S02 removal efficiency. The system is scheduled
to commence operation in 1988.
Marquette Board of Light and Power announced that a contract has
been awarded to Buell Division, Envirotech for a lime/spray dry-
ing system to be installed on the Shiras 3 unit. The system will
include a fabric filter that will serve the dual function of
primary particulate matter control and spent reagent collection.
Initial FGD operations are scheduled to begin in October 1982.
Michigan South Central Power Agency announced that construction
on the Project 1 FGD system began in November 1980. This 55 MW
(gross) unit is being constructed in Litchfield, Michigan, and
will burn coal with an average sulfur content of 2.25%. The wet
limestone FGD system is being supplied by Babcock and wilcox and
is expected to begin operation in June 1982.
FGD operations began during October 1980 at the Pleasants 2 unit
of Monongahela Power. This unit, which is rated at 618 MW
(gross) fires bituminous coal with an average sulfur content of
4.5%. The lime FGD system was supplied by Babcock and Wilcox and
consists of four spray tower absorbers. For primary particulate
matter removal, an ESP precedes the FGD system. No initial
start-up problems were reported to have been encountered during
the October through December period.
Reid Gardner 2 of Nevada Power achieved availabilities of 100%,
95%, and 100% for the months of October, November, and December,
respectively. No major problems were reported during this
period.
New York State Electric and Gas announced that a letter of intent
was signed with Peabody Process Systems for a wet limestone FGD
system to be installed on the Somerset 1 unit. The system, which
will be preceded by a cold side ESP for primary particulate
matter control, will be designed for 90% SO2 removal. Initial
start-up of the system is expected in 1984.
xx iv
-------
Northern Indiana Public Service reported that the Dean H. Mitchell
11 Wellman Lord FGD system achieved availabilities of 97%, 100%,
and 93% for the October, November, and December period, respec-
tively. Minor problems were encountered with the S0? reduction
unit; however, no major problems were reported.
Northern States Power has announced plans to construct Metro Coal
1. This 200 MW (gross) unit will fire a Montana coal with an
average sulfur content of approximately 1%. The utility is
considering a lime/spray drying process for SC>2 emission control.
The expected start up is in 1990.
Initial operation of the demonstration lime/spray drying FGD
system installed at the Riverside station of Northern States
Power began during November 1980. The 110 MW (gross) system,
which was supplied by Joy Manufacturing/Niro Atomizer, consists
of a spray dryer followed by a baghouse. The spent absorbent is
disposed of in both on and off site landfills. The system
operated in a shakedown/debugging phase during November and
December.
Northern States Power reported that the limestone/alkaline flyash
systems installed at Sherburne 1 and 2 achieved 100% availabili-
ties for the fourth quarter 1980. Unit 1 was out of service in
November due to an annual boiler/turbine inspection.
Northern States Power has reaffirmed plans for a third unit,
Sherburne 3, to be located along with units 1 and 2 in Becker,
Minnesota. Current plans call for joint ownership of the facil-
ity with the Southern Minnesota Municipal Power Agency and the
United Minnesota Municipal Power Agency. The 850 MW (gross unit
will fire a Montana coal with a sulfur content of approximately
1%. The unit will utilize a lime/spray drying process for
control of S02 emissions and is scheduled to start operations in
1985.
Northern States Power also announced plans to construct a unit,
Wisconsin Coal 1, to be located in Durand, Wisconsin. The unit
will be rated at 670 MW (gross) and will fire coal with a sulfur
content of approximately 1%. The utility is considering con-
trolling S02 emissions from this unit by utilizing a lime/spray
drying process. The unit is scheduled to commence operations in
1991.
Philadelphia Electric announced that construction began in
September 1980 on the retrofit magnesium oxide FGD system being
supplied by United Engineers for the Cromby 1 unit. The 150 MW
(gross) unit fires coal with an average sulfur content of 3.0%.
Start-up of the FGD system is expected in May 1983.
xxv
-------
The dual alkali scrubbing system at the A.B. Brown 1 station of
Southern Indiana Gas and Electric achieved availabilities of 99%,
98%, and 99% during October, November, and December, respec-
tively. Other than some recurring water balance problems, no
major problems were reported for the three month period.
Soyland Power Cooperative has announced plans to construct
Soyland 1 in Illinois. The 500 MW-(gross) unit will fire an
Illinois coal with an average sulfur content of 3.0%. The
utility is currently considering FGD as a S02 control strategy.
Operations are scheduled to commence in 1987.
Initial FGD operations began at Dallman 3 of Springfield Water,
Light, and Power in October 1980. The unit is rated at 205 MW
(gross) and fires coal with an average sulfur content of 3.3%.
The limestone FGD system is preceded by a hot side ESP and in-
cludes one horizontal chevron mist eliminator per module. The
sludge is trucked off site to a landfill. No major initial
start-up problems were reported.
Tennessee Valley Authority has announced that low sulfur coal
will be burned at the Johnsonville 1-10 units. As a result,
plans for the installation of a magnesium oxide FGD system have
been cancelled.
Texas Power and Light announced that initial FGD operations at
the Sandow 4 unit began in December 1980. The 545 MW (gross)
unit fires lignite with an average sulfur content of 1.6%. The
three limestone spray towers supplied by Combustion Engineering
will be designed for a S02 removal efficiency of 75%. Primary
particulate matter removal is provided by a cold side ESP. The
system operated in a shakedown mode through the end of December.
Washington Water Power has announced plans to construct Creston
Coal 1 in Creston, Washington. The 570 MW (gross) unit is the
first of four coal fired units planned for this site. The
utility is considering a wet limestone scrubbing system for SO-
emission control. Construction at this site is scheduled to
commence in 1983 with initial operations expected to begin in •
1987.
West Texas Utilities has announced that bids are being requested
for a FGD system to be installed at the Oklaunion 1 unit; The
720 MW (gross) unit is to be located in Oklaunion, Texas and will
fire a subbituminous Wyoming coal with an average sulfur content
of 0.34%. The system will operate with a closed water loop.
Initial operations are scheduled for 1986.
West Texas Utilities also announced plans to construct a second
unit, Oklaunion 2. .This unit will be similar in design to Unit 1
with startup expected in 1990.
xxvi
-------
REFERENCES
a. U.S. Department of Energy. Energy Information Administra-
tion. Office of Coal and Electric Power Statistics. Elec-
tric Power Statistics Division. Inventory of Power Plants
in the United States, December 1979. Publ. No. DOE/EIA-0095
(79).
b. Rittenhouse, R.C. New Generating Capacity: When, Where,
and by Whom. Power Engineering 82(4) :57. April 1978.
xxvn
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICIPATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLA-JT GENERATING CAPACITY - MM
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVALCNT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER. SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7. '
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** ESP
NUMBER
TYPE
SUPPLIER
INLET FLUE GAS CAPACITY - CU.M/S
INLET FLUE GAS TEMPERATURE - C
PARTICLE REMOVAL EFFICENCY - 7.
** PARTICLE SCRUBBER
GENERIC TYPE
SPECIFIC TYPE
*** FGD SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
502 REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
UNIT DESIGN S02 REMOVAL EFFICIENCY - 7.
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
ALABAMA ELECTRIC COOP
TOMBIGBEE
2
LEROY
ALABAMA
B
****** (****** LB/MMBTU)
516. ( 1.200 LB/MMBTU)
****** (****** LB/MMBTU)
525
255
235
243
179
RILEY STOKER
PULVERIZED COAL
BASE
449.72 ( 953000 ACFM)
143.9 ( 291 F)
122. ( 400 FT)
CONCRETE
(***** FT)
( 11500 BTU/LB)
11000-12000
*******
COAL
BITUMINOUS
26749.
14.00
10-16
7.00
3.0-20.0
1.15
0.8-1.5
.04
******
1
HOT SIDE
RESEARCH-COTTRELL
449.7 ( 953000 ACFM)
143.9 ( 291 F)
99.3
NONE
N/A
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
NONE
PEABODY PROCESS SYSTEMS
BURNS & MCDONNELL
FULL SCALE
NEW
7. 99.30
59.50
1
9/78
9/78
-------
EPA UTILITY FGO SURVEY: OCTOBER - DECEMBER 1980
ALABAMA ELECTRIC COOP: TQMBIGBkE 2 (CONT.)
CQN1RACT AWARDED ' 8/75
** DE-5IGN AND OPERATING PARAME "ERS
•** ABSORBER
NUMBER
GFNERIC TYPE
SPECIFIC TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LtNER SPECIFIC MATERIAL
L,:NER MATERIAL TRADE NAME/COMMON TYPE
G..S CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
LTQUIO RECIRCULATION RATE - LITER/S
• L/6 RATIO - L/CU.M
6*S-S1DE PRESSURE DROP - KPA
St'PERFICAL GAS VELOCITY - M/SEC
INLET GAS FLOW - CD. M/S
INLET GAS TEMPERATURE - C
SO? REMOVAL EFFICIENCY - 7.
** MIST ELIMINATOR
PR .--MIST ELIMINATOR/MIST ELIMINATOR
NUIiBER PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
NUH3ER OF STAGES
NUMBER OF PASSES PER STAGE
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/S
CONSTRUCTION MATERIAL GENERIC TYPE
WASH WATER SOURCE
** REHEATER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
PERCENT GAS BYPASSED - AV6
TEMPERATURE INCREASE - C
INLET FLUE GAS FLOW RATE - CU. M/S
INLET FLUE GAS TEMPERATURE - C
NUMBER OF TUBES PER BUNDLE
CONSTRUCTION MATERIAL GENERIC TYPE
** FANS
NUMBER
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SPRAY TOWER
OPEN COUNTERCURRENT SPRAY
PEABODY PROCESS SYSTEMS
24 DIA X 90 HIGH
CARBON STEEL
AISI 1110
N/A
ORGANIC
NATURAL RUBBER
BLACK NATURAL RUBBER
NONE
6
1259.'
9.4
1.0
3.0
127.41
54.4
85.0
(19980 GPM)
( 70.0 GAL/1000 ACF)
( 4.0 IN-H20)
( 10.0 FT/S)
( 270000 ACFM)
I 130 F)
MIST ELIMINATOR
Z
IMPINGEMENT
BAFFLE
CHEVRON VANE
HORIZONTAL
1
1
.1 (
3.0 (
PLASTIC
COOLING TOWER SLOWDOWN
1
BYPASS
COLD SIDE
N/A
30.0
8.9
129.77
143.9
0
N/A
.5 IN-H20)
10.0 FT/S)
( 48 F)
( 275000 ACFM)
( 291 F)
( 477000 ACFM)
( 291 F)
CENTRIFUGAL
ZURN AIR SYSTEMS
UNIT
FORCED DRAFT
DRY
225.10
143.9
CARBON STEEL
SCRUBBER INLET
CARBON STEEL
NONE
SCRUBBER OUTLET TO STACK
CARBON STEEL
48
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
ALABAM4 ELECTRIC COOP: TOMBIGBEE Z (CONT.)
'.INER GENERIC MATERIAL TYPE
** RE\GENT PREPARATION EQUIPMENT
F JNCTIOH
DEVICE
KJMBER
F'JLL LOAD DRY FEED CAPACITY - M.TONS/HR
PRODUCT QUALITY - 7. SOLIDS
** TA>(KS
SERVICE
RECYCLE
LIMESTONE SLURRY
WASH MATER
** PLKI^S
SERVICE
ABSORBER RECIRCULATION
LIMESTONE MILL SLURRY RECIRCULATION
L?.MESTON'E SLURRY FEED
It'.ST ELIMINATOR WASH
WASTE SLURRY
SUPERNATE RETURN
** SO'.IDS CONCENTRATIN6/DEWATERING
DKVICE
NUMBER
*** SLUDGE
** TREATMENT
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE SERVICE LIFE - YRS
** PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS
PROCESS CONTROL MANNER
CXL 2000
LIMESTONE GRINDING
BALL MILL
1
9.1 ( 10 TPH)
35.0
NUMBER
NUMBER
THICKENER
I
FINAL
LINED POND
ON SITE
PUMPED
20
PH, SOLIDS
AUTOMATIC
** WATER BALANCE
WATER LOOP TYPE CLOSED
EVAPORATION HATER LOSS - LITER/S 8.2
POND SEEPAGE/RUNOFF WATER LOSS - LITERS/S 0
MAKEUP WATER ADDITION - LITERS/S
** CHEMICALS AND CONSUMPTION
FUNCTION
NAME
CONSUMPTION
** FSD SPARE CAPACITY INDICES
ABSORBER - 7.
** FGD SPARE COMPONENT INDICES
ABSORBER
8.8
( 130 GPM)
( 140 GPMI
ABSORBENT
LIMESTONE
1.1 MOL/MOL SOS
.0
.0
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
ALABAMA ELECTRIC COOP: TOMBIGBEE Z (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
9/78
10/78
11/78
12/78
1/79
2/79
3/79
4/79
A
B
SYSTEM
81.4
63.9
72.7
20.7
16.3
18.5
720 183
133
** PROBLEMS/SOLUTIONS/COMMENTS
INITIAL OPERATION OF THE FGD SYSTEM BEGAN ON SEPTEMBER 23. THE SCRUBBER
MODULES WERE FORCED OUT OF SERVICE 34 HOURS WHEN, AFTER CLOSING THE
SYSTEM ISOLATION DAMPERS THE UTILITY WAS UNABLE TO OPEN THEM AGAIN.
A
B
SYSTEM
57.0
57.7
57.4
66.3
** PROBLEMS/SOLUTIONS/COMMENTS
BOILED SHUTDOWN.
45.7
46.2
46.0
744 596
342
ON OCT'BER 18 THE SUPERNATE LINE STARTED LEAKING. REPAIRS WERE MADE TO
THE FI3ERGLASS PIPING.
B
SYSTEM
32.4
49.3
65.9
88.9
** PROBLEMS/SOLUTIONS/COMMENTS
78.2
46.8
62.5
720 684
450
IN LATE OCTOBER AND EARLY NOVEMBER A FIBERGLASS ELBOW IN THE WASTE SLURRY
PIPE RUPTURED AND HAD TO BE REPLACED.
THE WASTE SLURRY AND SUPERNATE PIPING FAILURES WERE CORRECTED BY THE
ARCHITECT-ENGINEER.
A
B
SYSTEM
97.6
93.2
95.4
91.8
87.6
89.7
744 700
97.8
** PROBLEMS/SOLUTIONS/COMMENTS-
DOWNTIME DURING DECEMBER WAS NOT ATTRIBUTABLE TO THE FGD SYSTEM.
668
A
B
SYSTEM
75.3
65.8
70.6
69.2
«* PROBLEMS/SOLUTIONS/COMMENTS
75.1
65.6
70.4
744 742
524
SOME PLUGGING WAS ENCOUNTERED IN THE MIST ELIMINATOR DUE TO AN ESP OUTAGE.
THE SYSTEM WAS DOWN FOR 75 HOURS SO THAT THE MIST ELIMINATORS COULD BE
CLEANED.
A
B
SYSTEM
A
B
SYSTEM
A
B
SYSTEM
98.4
94.5
100.0
95.0
96.3
95.7
93.1
94.4
93.8
100.0
100.0
100.0
42.0
42.6
42.3
92.2
93.6
92.9
40.6
40.6
40.6
672 297
744 737
720 292
284
691
292
50
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
ALABAMA ELECTRIC COOP: TOMBIGBEE 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
5/79
6/79
7/79
8/79
9/79
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY HAS REPORTED THAT NO UNUSUAL PROBLEMS HAVE OCCURRED.
A
B
SYSTEM
A
B
SYSTEM
92.7
48.8
58.9
53.9
1.8
95.4
48.6
98.3
** PROBLEMS/SOLUTIONS/COHMENTS
47.6
57.4
52.5
1.0
51.8
26.4
744 725
720 391
391
190
THE UTILITY REPORTED THAT THE FGD SYSTEM OPERATED WELL DURING MAY AND JUNE
WITH THE EXCEPTION OF DOWN TIME REQUIRED TO REPLACE THE MIST ELIMINATORS.
THE MIST ELIMINATORS WERE DEFORMED DURING A TEMPERATURE EXCURSION.
A
B
SYSTEM
A
B
SYSTEM
93.0
21.0
70.9
46.0
88.9
24.9
56.9
99.2
** PROBLEMS/SOLUTIONS/COMMENTS
16.5
55.9
36.2
67.6
19.0
43.3
744 587
744 566
270
322
THE SCRUBBER WAS NOT OPERATED FOR /.BOUT 6 HOURS DUE TO A NECESSARY
ADJUSFMENT TO THE MODICON CONTROLLER.
THE SCRUBBER WAS BYPASSED FOR ABOUT 37 HOURS DUE TO AN ESP OUTAGE.
A
B
S1STEM
83.3
£1.8
52.6
100.0
** PRQBLEMS/SOLUTIONS/COMMENTS
68.3
17.9
43.1
720 591
311
THE UTILITY REPORTED THAT THE SYSTEM WAS AVAILABLE AT ALL TIMES DURING
SEPTEMBER.
.0
744
10/79 SYSTEM 100.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT NO. 2 GENERATOR WAS DOWN THE ENTIRE MONTH OF OCTOBER.
11/79 SYSTEM 100.0 .0 720 0
** PROBLEMS/SOLUTIONS/COMMENTS
THE GENERATOR REMAINED DOWN THROUGH NOVEMBER.
12/79
A
B
SYSTEM
22.6
6.0
14.3
4.0
1.1
2.6
744 133
19
96.7
»* PROBLEMS/SOLUTIONS/COMMENTS
THE OPERABILITY OF THE FGD UNIT WAS LOW DUE TO THE START-UP OF THE BOILER.
THE FGD SYSTEM WAS NOT AVAILABLE FOR 24 HOURS DUE TO A RUPTURED WASTE
51
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
ALABAMA ELECTRIC COOP: TOMBIGBEE Z (CONT.5
_____ PERFORMANCE DATA
PERIOD. MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
1/80
2/80
3/80
4/80
5/80
6/80
7/80
A
B
SYSTEM
SLURRY LINE.
35.8
56.7
46.3
90.7
** PROBLEMS/SOLUTIONS/COMMENTS
21.1
33.5
27.3
744 439
203
DURING JANUARY UNIT 2 WAS UNAVAILABLE 69 HOURS DUE TO REPAIRS NEEDED ON
AN ABRADED EXPANSION JOINT AND A RUPTURED WASTE SLURRY LINE.
A
B
SYSTEM
84.3
74.7
79.5
99.3
** PROBLEMS/SOLUTIONS/COMMENTS
84.3
74.7
79.5
696 696
554
THE UNIT 2 FGD SYSTEM OPERATED ALL BUT 5 HOURS DURING FEBRUARY, IN WHICH
TIME THE BOILER WAS BEING BROUGHT ON-LINE.
A
B
SYSTEM
81.6
79.4
80.5
100.0
** PROBLEMS/SOLUTIONS/COMMENTS
75.0
73.0
74.0
744 684
551
NO FGD SYSTEM PROBLEMS WERE ENCOUNTERED DURING MARCH. THE FGD SYSTEM WAS
AVAILABLE 100Z OF THE TIME.
A
8
SYSTEM
61.3
86.6
74.0
100.0
** PROBLEMS/SOLUTIONS/COMMENTS
61.3
86.5
73.9
720 719
532
THE UTILITY REPORTED THAT FOR THE MONTH OF APRIL THE SYSTEM WAS
AVAILABLE 100X OF THE TIME.
A
B
SYSTEM
34.9
92.8
63.9
34.7
92.2
63.5
100.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE FID SYSTEM WAS AVAILABLE 100X OF THE MONTH OF MAY.
744 739
472
A
B
SYSTEM
100.0
.0
50.0
38.0
.0
Vt.O
100.0
.0
50.0
11.0
.0
5.5
720
90
40 7.0
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE B WAS OUT OF SERVICE THE ENTIRE MONTH OF JUNE DUE TO A DAMAGED
DAMPER DRIVE MOTOR.
MODULE A WAS AVAILABLE FOR OPERATION THE ENTIRE MONTH, BUT WAS NEEDED
ONLY 79 HOURS.
A
B
SYSTEM
100.0
.0
50.0
97.6
.0
48.8
100.0
.0
50.0
54.5
.0
27.3
744 415
203 26.7
52
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
ALABAMA ELECTRIC COOP: TOHBIGBEE 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE B-MODULE REMAINED OUT OF SERVICE THROUGH JULY DUE TO THE DAMAGED
DAMPER DRIVE MOTOR.
THE A-MODULE OPERATED ON AN AS NEEDED BASIS WITH NO PROBLEMS.
8/80 A
B
SYSTEM
100.0
.0
50.0
84.0
.0
42.0
84.0
.0
42.0
18.3
.0
9.2
744 162
68 14.9
** PROBLEMS/SOLUTIONS/COMMENTS
DURING AUGUST MODULE B REMAINED OUT OF SERVICE DUE TO DAMAGED DAMPER
OPERATOR MOTORS.
9/80 A
B
SYSTEM
100.0
.0
50.0
78.4
.0
39.2
78.4
.0
39.2
45.4
.0
22.7
720 417
164 42.8
** PROBLEMS/SOLUTIONS/COMMENTS
DURING SEPTEMBER MODULE B DID NOT OPERATE DUE TO A BURNED-UP DAMPER DRIVE
MOTOR.
10/80 A
B
SYSTEM
100.0
.0
50.0
.0
.0
.0
.0
.0
.0
744
.0
** PROBL-EMS/SOLUTIONS/COMMENTS
DURING OCTOBER THE UNIT MAS OUT OF SERVICE FOR A TURBINE/GENERATOR
INSPECTION.
REPAIR ON MODULE B DAMPER MOTOR DRIVE CONTINUED THROUGHOUT THE MONTH.
11/80
12/80
A
B
SYSTEM
A
B
SYSTEM
100.0
.0
50.0
100.0
62.4
81.2
74.3
.0
37.2
90.5
62.9
76.7
74.3
.0
37.2
90.5
62.9
76.7
15.5
.0
7.S
86.4
60.1
73.2
720 150
744 710
56 10.0
545 45.9
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE B DAMPER REPAIRS WERE COMPLETED BY MID-DECEMBER. THE UTILITY
REPORTED THAT NO OTHER MAJOR PROBLEMS WERE ENCOUNTERED DURING THE FOURTH
QUARTER 1980.
53
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT HAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MM
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - '/.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - '/.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** ESP
NUMBER
TYPE
SUPPLIER
INLET FLUE GAS CAPACITY - CU.M/S
INLET FLUE GAS TEMPERATURE - C
PARTICLE REMOVAL EFFICENCY - 7.
** PARTICLE SCRUBBER
GENERIC TYPE
SPECIFIC TYPE
*** FGD SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
£-E FIRM
DEVELOPMENT LEVEL
I;EW/RETROFIT
LNIT DESIGN PARTICLE REMOVAL EFFICIENCY
UNIT DESIGN SOS REMOVAL EFFICIENCY - 7.
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
ALABAMA ELECTRIC COOP
TOMBIGBEE
3
LEROY
ALABAMA
B
****** ( ****** LB/MMBTU )
516. ° ( 1.200 LB/MMBTU)
****** ( ****** LB/MMBTU )
*****
255
235
179
RILEY STOKER
PULVERIZED COAL
BASE
449.72 (
143.9 (
122. (
******
953000 ACFM)
291 F)
400 FT)
(***** FT)
( 11500 BTU/LB)
11000-12000
*******
COAL
BITUMINOUS
26749.
14.00
10-16
7.00
3.0-20.0
1.15
0.8-1.5
.04
******
HOT SIDE
RESEARCH-COTTRELL
449.7 ( 953000 ACFM)
143.9 ( 291 F)
99.3
NONE
N/A
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
NONE
PEABODY PROCESS SYSTEMS
BURNS & MCDONNELL
FULL SCALE
NEW
7. 99.30
59.50
1
6/79
6/79
54
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
ALABAMV ELECTRIC COOP: TOMBIGBEE 3 (CONT.)
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
** ABSORBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SI'ELL MATERIAL TRADE NAME/COMMON TYPE
L:.NER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
GAS CONTACTING DEVICE TYPE
Nl'fiBER OF CONTACTING ZONES
LIQUID RECIRCUUTION RATE - LITER/S
L/G RATIO - L/CU.M
GAS-SIDE PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/SEC
IhLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
S02 REMOVAL EFFICIENCY - 7.
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES PER STAGE
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/S
WASH WATER SOURCE
** REHEATER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
PERCENT GAS BYPASSED - AVG
TEMPERATURE INCREASE - C
INLET FLUE GAS FLOW RATE - CU. M/S
INLET FLUE GAS TEMPERATURE - C
NUMBER OF TUBES PER BUNDLE
CONSTRUCTION MATERIAL GENERIC TYPE
** FANS
NUMBER
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
8/75
SPRAY TOWER
OPEN COUNTERCURRENT SPRAY
PEABODY PROCESS SYSTEMS
24 DIA X 90 HIGH
CARBON STEEL
AISI 1110
N/A
ORGANIC
NATURAL RUBBER
BLACK NATURAL RUBBER
NONE
6
1259.
9.4
1.0
3.0
127.41
54.4
85.0
(19980 GPM)
( 70.0 GAL/1000 ACF)
4.0 IN-H20)
10.0 FT/S)
270000 ACFM)
130 F)
MIST ELIMINATOR
2
IMPINGEMENT
BAFFLE
CHEVRON VANE
HORIZONTAL
1
1
.1
3.0
( .5 IN-H20)
( 10.0 FT/S)
COOLING TOWER SLOWDOWN
1
BYPASS
COLD SIDE
N/A
30.0
8.9
129.30
143.9
0
N/A
( 48 F)
( 274000 ACFM)
( 291 F)
CENTRIFUGAL
ZURN AIR SYSTEMS
UNIT
FORCED DRAFT
DRY
225.10 ( 477000 ACFM)
143.9 ( 291 F)
CARBON STEEL
SCRUBBER INLET
CARBON STEEL
NONE
SCRUBBER OUTLET TO STACK
CARBON STEEL
CXL 2000
55
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
ALABAMA ELECTRIC COOP: TOMBIGBEE 3 (CONT.)
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
NUMLER
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
PRODUCT QUALITY - X SOLIDS
** TAMKS
SERVICE
R -XYCLE
LCMESTONE SLURRY
W\SH WATER
** PU'IPS
SERVICE
A3SORBER RECIRCULATION
MILL RECIRCULATION
SLURRY FEED
MIST ELIMINATOR WASH
WASTE SLURRY
SUPERNATE RETURN
** SOLIDS CONCENTRATING/DEWATERINS
DEVICE
NUMBER
*** SLLDGE
** TREATMENT
** DISPOSAL
NArURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE SERVICE LIFE - YRS
** PROCESS CONTROL AND .INSTRUMENTATION
CHEMICAL PARAMETERS-
PROCESS CONTROL MANNER
** WATER BALANCE
WATER LOOP TYPE
EVAPORATION WATER
LIMESTONE GRINDING
BALL MILL
I
9.1 t 10 TPH)
35.0
NUMBER
NUMBER
6
2
2
3
Z
1
THICKENER
1
FINAL
LINED POND
ON SITE
PUMPED
20
PH, SOLIDS
AUTOMATIC
LOSS - LITER/S
CLOSED
8.2
POND SEEPAGE/RUNOFF WATER LOSS - LITERS/S 0
MAKEUP WATER ADDITION - LITERS/S
8.8
( 130 GPM)
( 1*0 GPM)
** CHEMICALS AND CONSUMPTION
FUNCTION
NAME
CONSUMPTION
** FGD SPARE CAPACITY INDICES
ABSORBER - 7.
** FGD SPARE COMPONENT INDICES
ABSORBER
ABSORBENT
LIMESTONE
1.1 MOL/MOL S02
.0
.0
56
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
ALABAMA ELECTRIC COOP: TOMBIGBEE 3 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
7/79 A
B
SYSTEM
9/79
11/79
12/79
23.7
27.8
25.8
11.0
10.2
744 295
76
72.7
** PROBLEMS/SOLUTIONS/COMMENTS
THE PGD SYSTEM IS CURRENTLY UNDERGOING SHAKEDOWN/DEBUGGING OPERATIONS.
8/79 A
B
SYSTEM
59.4
V4.5
52.0
99.7
** PROBLEMS/SOLUTIONS/CCdMENTS
39.1
£9.'i
34.2
744 490
255
AN ADJUSTMENT TO THE MODICON CONTROLLER CAUSED A SCRUBBER OUTAGE OF ABOUT
TWO HOURS.
THE SCRUBBER WAS DOWN DURING AN ESP OUTAGE FOR APPROXIMATELY 34 HOURS.
A
B
SYSTEM
73.0
11.0
42.0
100.0
** PROBLEMS/SOLUTIONS/COMMENTS
13.9
2.1
8.0
720 137
58
CONTINUING GENERATOR PROBLEMS RESULTED IN LOW FGD SYSTEM UTILIZATION
DURING SEPTEMBER.
10/79 A
B
SYSTEM
82.7
90.9
86.8
99.5
** PROBLEMS/SOLUTIONS/COMMENTS
82.7
90.9
86.8
744 744
646
THE FGD SYSTEM WAS SHUT DOWN FOR 37 HOURS FOR BOILER START-UPS AND
ESP TESTS.
PROBLEMS WITH THE LIMESTONE BALL MILL LUBRICATION SYSTEMi WHICH CAUSED
A SHORTAGE OF REAGENT SLURRY, KEPT THE FGD SYSTEM OFF LINE FOR 4 HOURS.
A
8
SYSTEM
78.6
89.3
84.0
96.7
** PROBLEMS/SOLUTIONS/COMMENTS
78.6
89.3
84.0
720 720
605
DURING NOVEMBER THE FGD UNIT WAS DOWN 23 HOURS BECAUSE THE ESP FLYASH
HANDLING SYSTEM JAMMED AND THE ESP WAS SHUT DOWN.
THE WASTE SLURRY LINE RUPTURED, FORCING THE UNIT OUT OF SERVICE FOR
24 HOURS.
A
B
SYSTEM
78.4
87.6
83.0
100.0
** PROBLEMS/SOLUTIONS/COMMENTS
68.7
76.8
72.8
744 652
541
NO FGD SYSTEM PROBLEMS WERE ENCOUNTERED DURING DECEMBER. THE FGD SYSTEM
WAS AVAILABLE FOR THE ENTIRE MONTH.
1/80 A
69.2
30.5
57
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
ALABAMA ELECTRIC COOP: TOHBIGBEE 3 (CONT.)
__„ PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FSD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
B
SYSTEM
45.4
57.3
20.0
25.3
100.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JANUARY UNIT 3 WAS AVAILABLE THE ENTIRE MONTH.
744 328
188
2/80 A
B
SYSTEM
33.3
100.0
66.7
100.0
** PROBLEMS/SOLUTIONS/COMKENTS
3.5
2.4
696
24
16
DURINS FEBRUARY THE UNIT 3 BOILER AND FGD SYSTEM OPERATED ONLY 24 HOURS.
THE FGD SYSTEM WAS AVAILABLE THE ENTIRE MONTH.
3/80 SYSTEM 100.0
** PROBLEMS/SOLUTIONS/COMMENTS
.0
744
.0
DURIh'G MARCH THE UNIT 3 GENERATOR HAS KEPT OUT OF SERVICE. THE FGD SYSTEM
WAS A/AILABLE THE ENTIRE MONTH.
4/80 SI STEM .(i 720 0
** PROBLEMS/SOLUTIONS/C01MENTS
THE UTILITY REPORTED THAT DURING APRIL THE BOILER DID NOT OPERATE.
.0
5/80 A
B
SYSTEM
8.3
.0
4.2
95.8
** PROBLEMS/SOLUTIONS/COMMENTS
.7
.0
.3
744
60
THE FGD SYSTEM WAS AVAILABLE 713 HOURS DURING MAY; HOWEVER, THE BOILER ONLY
OPERATED 60 HOURS DUE TO BOILER RELATED PROBLEMS.
THE B MODULE WAS OUT FOR 31 HOURS WHEN THE INLET DAMPER SWITCH FAILED
CAUSING THE DRIVE MOTOR TO BURN OUT.
6/80 A
B
SYSTEM
100.0
100.0
100.0
59.1
58.6
58.9
100.0
100.0
100.0
52.8
52.4
52.6
720 643 379 52.0
** PROBLEMS/SOLUTIONS/COMMENTS
NO FGD SYSTEM-RELATED PROBLEMS WERE ENCOUNTERED DURING JUNE.
7/80 A
3
SYSTEM
100.0
100.0
100.0
45.5
90.0
67.8
100.0
100.0
100.0
39.7
78.6
59.2
744 650
440 47.8
•:t* PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS AVAILABLE FOR OPERATION THE ENTIRE MONTH OF JULY. THE
MODULES ARE UTILIZED ON AN AS NEEDED BASIS.
8/80 A
B
SYSTEM
100.0
100.0
100.0
95.7
91.6
93.7
100.0
100.0
100.0
75.8
72.6
74.2
744 590
552 63.4
58
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
ALABAMA ELECTRIC COOP: TOMBIGBEE 3 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
9/80
10/80
11/80
NO FGD-RELATED PROBLEMS WERE ENCOUNTERED DURING THE MONTH OF AUGUST.
A
B
SYSTEM
A
B
SYSTEM
A
B
SYSTEM
90.6
90.6
90.6
97.4
97.4
97. 4
99.3
99.3
99.3
91.4
73.7
82.4
68.4
60.9
63.4
83.6
87.9
85.7
91.4
73.7
82.4
68.4
60.9
63.4
83.6
87.9
85.7
46.8
37.8
42.2
68.4
60.9
63.4
83.6
87.9
85.7
720 369 304 32.4
69.4
720 720 617 55.4
** PROBLEMS/SOLUTIONS/COMMENTS
DURING SEPTEMBER THROUGH NOVEMBER PROBLEMS WERE ENCOUNTERED WITH THE
PROGRAMABLE CONTROLLER. THE UTILITY REPLACED THE CENTRAL PROCESSING
UNIT IN OCTOBER AND IN NOVEMBER A NEW PROGRAM WAS RUN. THE UTILITY
REPORTED THAT NO OTHER MAJOR FGD-RELATED PROBLEMS WERE EXPERIENCED DURING
THIS TIME.
12/80
A
B
SYSTEM
100.0
100.0
100.0
88.8
66.0
77.4
88.8
66.0
77.4
88.8
66.0
77.4
744 744
576 41.2
** PROBLEMS/SOLUTIONS/COMMENTS
NO PROBLEMS WERE ENCOUNTERED WITH THE UNIT OR THE FGD SYSTEM DURING DEC-
EMBER.
59
-------
EPA UTILITY FED SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT .NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MM
NET UNIT GENERATING CAPACITY W/FGO - MW
NET UNIT GENERATING CAPACITY HO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7.
RANSE MOISTURE CONTENT - 7,
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7..
*** PARTICLE CONTROL
** ES?
NUMBER
TYPE
SUPPLIER
IULET FLUE GAS CAPACITY - CU.M/S
INLET FLUE. GAS TEMPERATURE - C
PRESSURE DROP - KPA
PARTICLE .REMOVAL EFFICENCY - 7.
** PAHTICLE SCRUBBER
GENERIC TYPE
SPECIFIC TYPE
*** Fen s
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DfVELOPMENT LEVEL
NEW/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
U11IT DESIGN S02 REMOVAL EFFICIENCY - 7.
CURRENT STATUS
COMMERCIAL START-UP
ARIZONA ELECTRIC POWER COOP
APACHE
2
COCHISE
ARIZONA
43.
344.
( .100 LB/MMBTU)
( .800 LB/MMBTU)
(*»**** LB/MMBTU)
530
195
175
183
98
RILEY STOKER
PULVERIZED COAL
BASE
346.85 (
118.3 (
122. (
CONCRETE
4.9 (
735000 ACFM)
245 F)
400 FT)
16.2 FT)
COAL
BITUMINOUS
23260. ( 10000 BTU/LB)
10000-11000
17.00
16.8-17.2
12.00
9.0-15.0
.50
.4-.6
.00
.00-.03
HOT SIDE
AIR CORRECTION DIVISION, UOP
94.4 ( 200000 ACFM)
371.1 ( 700 F)
.0 (0. IN-H20)
99.6
NONE
N/A
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
NONE
RESEARCH-COTTRELL
BURNS & MCDONNELL
FULL SCALE
NEW
7. 99.50
42.50
1
1/79
60
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
ARIZONA ELECTRIC POWER COOP: APACHE 2 (CONT. )
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
** ABSORBER
NUII3ER
NUM3ER OF.SPARES
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
GAS CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
DISTANCE BETWEEN GAS CONTACTING ZONES - CM
LIQUID RECIRCULATION RATE - LITER/S
L/G RATIO - L/CU.M
GAS-SIDE PRESSURE DROP - KPA
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
SOS REMOVAL EFFICIENCY - X
** MIST ELIMINATOR
FRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES PER STAGE
DISTANCE BETWEEN VANES - CM
VANE ANGLES - DEGREES
CONSTRUCTION MATERIAL GENERIC TYPE
WASH WATER SOURCE
** REHEATER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
** FANS
NUMBER
NUMBER OF SPARES
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
OBSTRUCTION MATERIAL GENERIC TYPE
** D
LXATION
DIMENSIONS
"HELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
** DUCTWORK
LOCATION
D CMEN3IONS
SHELL GENERIC MATERIAL TVPE
LINiR GENERIC MATERIAL TY^E
8/78
7/74
2
1
COMBINATION
SPRAY/PACKED
RESEARCH-COTTRELL
30 DIA, X 80 HT.
CARBON STEEL
AISI 1110
N/A
ORGANIC
GLASS-FLEX
MUNTERS PACKING
1
121.9 ( 4S.OIN)
1260. (20000 GPM)
2.8 t 20.6 GAL/1000 ACF)
1.5 ( 6.0 IN-H20)
183.76 ( 400000 ACFM)
132.2 ( 270 F)
97.0
MIST ELIMINATOR
4
IMPINGEMENT
BAFFLE
CHEVRON VANE
HORIZONTAL
2
3
10.2
45
POLYPROPYLENE
FRESH WATER
0
NONE
N/A
N/A
2
0
CENTRIFUGAL
ALLIS CHALMERS
UNIT
FORCED DRAFT
DRY
94 ..38
132.2
CARBON STEEL
( 4.00 IN)
( 200000 ACFM)
( 270 F)
SCRUBBER INLET
12 X 16
CARBON STEEL
NONE
SCRUBBER OUTLET
12 X 16
CARBON STEEL
CXL 100
61
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
ARIZONA ELECTRIC POWER COOP: APACHE 2 (CONT.)
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
MANUFACTURER
NUMBER
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
PRODUCT QUALITY - 7. SOLIDS
.** TANKS
SEIJVICE
ABSORBER FEED
** PUMPS
SERVICE
PACKING
QUENCHER
SLURRY SUMP
*** SLUDGE
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE DIMENSIONS
SITE CAPACITY - CU.M
SITE SERVICE LIFE - YRS
** UATER BALANCE
WATER LOOP TYPE
MAKEUP WATER ADDITION - LITERS/S
** FGD SPARE CAPACITY INDICES
ABSORBER - X
** FGD SPARE COMPONENT INDICES
ABSORBER
LIMESTONE GRINDING
BALL MILL
KENNEDY VAN SAUN
1
4.5 ( 5 TPH)
48.0
NUMBER
1
NUMBER
FINAL
POND
ON SITE
PUMPED
85 ACRES X. 18 FT DEEP
484308 C 396.0 ACRE-FT)
30
OPEN
115.9
100.0
1.0
( 1840 GPM)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
SOZ PART. HOURS HOURS HOURS FACTOR
8/78 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
744
INITIAL OPERATIONS BEGAN IN AUGUST WITH. THE BOILER AND SCRUBBER SYSTEM
FOR TESTING PURPOSES.
9/78 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
720
SCRUBBER AND BOILER TESTING CONTINUED THROUGH SEPTEMBER. FINAL FACILITY
CONSTRUCTION SHOULD BE COMPLETE BY OCTOBER.
10/78 SYSTEM
744 303
59.5
-------
EPA UTILITY F:GD SURVEY: OCTOBER - DECEMBER 1980
ARIZONA ELECTRIC POWER COOP: APtCHE 2 (CONT.)
—u. PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
_______ __._.__ _«______.___>«. _.._.._»_____ ___....___ ___ ________•___ _____ _____ _____ ______ _.._»._ __«,«.«»
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS SHUTDOWN IN EARLY OCTOBER TO MAKE ADDITIONAL BOILER MODIFI-
CATIONS. NO PROBLEMS WERE REPORTED FOR THE FGD SYSTEM. COMPLIANCE TESTING
IS SCHEDULED FOR EARLY NOVEMBER. THE UTILITY HAS DECIDED THAT IN APPROX-
IMATELY A YEAR THE SCRUBBER INLET DUCTWORK WILL BE CHANGED FROM CARBON
STEEL TO STAINLESS STEEL.
11/78 4 24.8 16.8
3 43.7 39.6
SYSTEM 68.5 46.4 720 488 334 82.8
•«* PROBLEMS/SOLUTIONS/COMMENTS
THE S02 STACK MONITORS HAVE NEVER BEEN OPERABLE. THE MONITORS HAVE BEEN
SENT BACK TO THE FACTORY AND ARE NOT EXPECTED BACK ON SITE UNTIL LATE
DECEMBER.
THE LIMESTONE CRUSHER HAS BEEN UNABLE TO OPERATE AT DESIGN CAPACITY.
A COMPLIANCE TEST WAS COMPLETED BUT THE RESULTS ARE NOT YET AVAILABLE.
THE ACCEPTANCE IS SCHEDULED FOR THE BEGINNING OF 1979.
12/78 SYSTEM .0 .0 744 512 0
** PROBLEMS/SOLUTIONS/COMMENTS
RESULTS OF THE RECENT COMPLIANCE TEST INDICATED THAT S02 EMISSIONS WERE
BETWEEN 1.2 LB/MM BTU, THE FEDERAL APPLICABLE STANDARD; AND 0.8 LB/MM BTU,
THE STATE STANDARD, WITHOUT THE FGD SYSTEM.' THE UTILITY IS CURRENTLY BURN-
ING LOW SULFUR COAL (0.6X S). IT IS BELIEVED THAT THE STATE STANDARD COULD
BE MET WITHOUT FGD SYSTEM OPERATION WHEN THE FURNACE IS "FINE TUNED".
A 30 HOUR OUTAGE OCCURRED DUE TO A RUPTURE IN THE REAGENT FEED LINE.
1/79 SYSTEM .0 .0 744 662 0
** PROBLEMS/SOLUTIONS/COMMENTS
SHAKEDOWN/DEBUGGING OPERATION CONTINUED THROUGH JANUARY.
COMMERCIAL OPERATIONS BEGAN ON JANUARY 15.
2/79 SYSTEM .0 .0 672 504 0
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS NOT IN SERVICE DURING DECEMBER, JANUARY, OR FEBRUARY DUE
TO VARIOUS SHAKEDOWN/DEBUGGING PROBLEMS ESPECIALLY IN MAINTAINING RECYCLE
PUMP OPERATION.
3/79 SYSTEM .0 .0 744 372 0
** PROBLEMS/SOLUTIONS/COMMENTS
A BOILER EXPLOSION AT THE BURNER FACE CAUSED THE UNIT TO BE DOWN FROM THE
LAST WEEK IN FEBRUARY THROUGH THE MIDDLE OF MARCH.
4/79 SYSTEM 720 720
63
-------
EPA UriLITY FGD SURVEY: OCTOBER - DECEMBER 1980
ARIZONA ELECTRIC POWER COOP: APACHE 2 (CQNT. )
„ __j . PERFORMANCE DATA-
PERIOD MODULE AVAILABILITY OP^RABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
»«.___.. — _. ___ »___».»...._«.__ __________.„ _™_~___.= — __ ______«.««.._ — ____ ____ — ™_ ___ __«,_»«.«. _____ ___—=._
** PROBLEMS/SOLUTIONS/CO. 1MENTS
COMPLIANCE TESTS WERE RUN ON THIS UNIT LAST NOVEMBER AND THE UNIT WAS
DECLAR:D COMMERCIAL IN FEBRUARY. THE FGD SYSTEM OPERATES ONLY ABOUT so
X OF THE BOILER HOURS BECAUSE THE UNIT OPERATES AT SUCH A LOW RATING
SOX OF THE TIME THAT THE FGD SYSTEM IS NOT NEEDED.
5/79 SYSTEM 744
6/79 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
IN GENERAL THE FGD SYSTEM AND BOILER OPERATED WELL THROUGH MAY AND JUNE.
THE FRP REAGENT FEED PIPING HAS BEEN A CONTINUAL PROBLEM AREA. THE FRP
HAS BEEN RUPTURING PARTICULARLY AT PIPING CONNECTIONS. THE UTILITY IS IN
THE PROCESS OF REPLACING THE FRP PIPING WITH CARBON STEEL PIPING.
THE BALL MILL APPEARS TO HAVE BEEN UNDERDESIGNED. THE MILL PRODUCES
4 TONS/HOUR OF GROUND LIMESTONE AT BEST ALTHOUGH IT WAS RATED AT 5 TON/HOUR
CAPACITY.
7/79 SYSTEM 744
8/79 3YSTEM 744
«* PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED HAVING EXTENSIVE PROBLEMS WITH THE REAGENT HANDLING
SYSTEM PARTICULARLY WITH RESPECT TO FEED LINE FAILURES, PIPING PLUGGING
AND GRINDING OPERATIONS. THE REAGENT HANDLING SYSTEM ACCOMODATES BOTH
UNITS 2 AND 3.
9/79 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE THIRD QUARTER OF 1979 THE BOILER AND FGD SYSTEM ONLY OPERATED
ABOUT 25X OF THE TIME BECAUSE OF CONTINUING PROBLEMS WITH THE REAGENT FEED
LINE. THE FRP SECTION FROM THE GRINDER TO THE SCRUBBERS FAILED. THE LINE
WAS REPAIRED AT THE END OF SEPTEMBER.
ON NOVEMBER 3 THE UNIT WILL BE SHUT DOWN FOR A FOUR TO SIX WEEK SCHEDULED
OUTAGE.
10/79 SYSTEM .0 .0 .0 744 0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY IS IN THE PROCESS OF REPLACING THE REAGENT HANDLING SYSTEM;
THEREFORE, THE FGD SYSTEM DID NOT OPERATE DURING OCTOBER.
11/79 SYSTEM 100.0 100.0 100.0 6.3 720 41 41 2.9
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS OUT OF SERVICE FOR MOST OF NOVEMBER FOR AN ANNUAL INSPECTION.
12/79 SYSTEM 100.0 .0 .0 .0 744 130 0 5.7
64
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
ARIZONA ELECTRIC POWER COOP: APACHE Z (CONT.)
PERFORMANCE DATA —
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
.«•___. _„____ .._______.___ ___«.»__»,».•- — .» «.— __, — _.„_-, — _ _»„»»_„_,«...» «__»» __*.»_ — .,—,_.- »._-_... •___.«••» _r.w»~>—_>
** PROBLEMS/SOLUTIONS/COMMENTS
' THE EXTENSIVE PROBLEMS ENCOUNTERED EARLIER WITH THE REAGENT HANDLING SYSTEM
HAVE BEEN RESOLVED. THE SYSTEM REPLACEMENT WAS COMPLETED IN DECEMBER.
DURING DECEMBER THE BOILER OPERATED 130 HOURS FOR WHICH THE SCRUBBER WAS
AVAILABLE 100X OF THE TIME.
THE BOILER ENCOUNTERED DAMPER PROBLLMS THAT ACCOUNTED FOR MOST OF THE
DECEMBER DOWN TIME.
1/80 SYSTEM 91.0 58.3 83.8 57.3 97.40 744 731 426 56.1
** PROBLEMS/SOLUTIONS/CO1MENTS
DURINS JANUARY SOME OUTAGE TIME WAS DUE TO A PUMP MALFUNCTION.
OUTAGF. TIME WAS ALSO CAUSED BY A BROKEN FEED BELT TO THE LIMESTONE BALL
MILL.
2/80 SYSTEM 92.8 96.7 92.8 92.8 97.40 696 668 646 87.4
** PROBLEMS/SOLUTIONS/COMMENTS
DURING FEBRUARY OUTAGE TIME RESULTED FROM AN ESP FAILURE.
FORCED OUTAGE TIME WAS ALSO CAUSED BY A PUMP MALFUNCTION.
3/80 SYSTEM 99.1 99.1 99.0 99.1 97.40 744 744 738 74.1
** PROBLEMS/SOLUTIONS/COMMENTS
SOME OF THE OUTAGE TIME DURING MARCH OCCURRED BECAUSE OF PUMP FAILURES.
OUTAGE TIME RESULTED FROM STICKING VALVES AND LIMESTONE FEED-BELT
PROBLEMS..
4/80 SYSTEM 67.2 65.2 65.2 61.4 720 678 442
** PROBLEMS/SOLUTIONS/COHMENTS
DURINS APRIL THE FGD SYSTEM WAS FORCED DOWN DUE TO PUMP FAILURES AND A
RUPTURE IN THE SLURRY RECIRCULATION LINE.
5/80 SYSTEM 90.5 90.5 90.5 90.5 744 744 673
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MAY THE UNIT WAS FORCED OFF LINE WHEN THE LIMESTONE CRUSHER
MALFUNCTIONED.
THE UNIT WAS ALSO FORCED OUT DUE TO PUMP AND VALVE FAILURES.
6/80 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE DATA FOR THE MONTH OF JUNE HAS BEEN
MISPLACED.
7/80 202 100.0 .0 .0
203 85.0 85.7 85.7 85.0
SYSTEM 100.0 85.7 85.7 85.0 744 738 633 77.8
65
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
ARIZONA ELECTRIC POWER COOP-' APACHE Z (CONT.)
__. PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE 202 WAS AVAILABLE THE ENTIRE MONTH, BUT WAS NOT OPERATED.
THE FGD SYSTEM WAS DOWN IN JULY BECAUSE OF A CIRCUIT BREAKER MALFUNCTION.
FAILURE OF BOTH THE BYPASS DAMPER AND THE PACKING PUMP ALSO CAUSED OUTAGE
TIME DURING THE MONTH.
8/80 202 .0 .0 .0
203 96.8 66.0 95.2 63.3
SYSTEM 96.8 66.0 95.2 63.3 . 744 714 471 61.0
** PROBLEMS/SOLUTIONS/COMMENTS
TOWER 202 WAS UNAVAILABLE IN AUGUST BECAUSE OF THE LINER BEING REPLACED.
A SAMPLE LINE FAILURE CAUSED TOWER 203 TO GO DOWN FOR 24 HOURS.
THE OPERATION OF THE FGD SYSTEM WAS REDUCED BECAUSE OF LOW LOAD CAPACITY.
9/80 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
. NO INfORMATION WAS AVAILABLE FOR SEPTEMBER 1980.
10/80 202 .0 .0 .0
2C3 92.6 37.7 98.6 82.4
SYSTEM 92.7 J7.7 98.6 82.4 97.40 744 699 613 62.4
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE 202 WAS NOT OPERATED DURING THE MONTH OF OCTOBER DUE TO A SCHEDULED
ANNUAL OVERHAUL.
DURING OCTOBER FORCED OUTAGES OCCURRED AS A RESULT OF PH INSTABILITY IN THE
SYSTEM.
THE LOSS OF OPERATION TIME ON MODULE 203 WAS PRIMARILY DUE TO REDUCED
LOAD CAPACITY DURING OCTOBER.
11/80 202 20.0 22.4 40.0 6.7
203 .0 ..0 .0
SYSTEM 20.0 22.4 40.0 6.7 720 214 48 25.1
** PROBLEMS/SOLUTIONS/COMMENTS
DURING NOVEMBER THE BOILER WAS NOT IN SERVICE THE FIRST 21 DAYS. THE
BOILER WAS OPERATED AT REDUCED LOAD FOR THE F^RST 96 HOURS AFTER STARTUP
UNTIL THE FGD SYSTEM WAS ON-LINE.
FAILURE OF THE LIMESTONE BALLMILL ACCOUNTED FOR 72 HOURS OF OUTAGE TIME.
12/80 202 100.0 100.0 100.0 99.9
eos .0 .0 .0
SYSTEM 100.0 100.0 100.0 99.9 744 743 743 87.2
** PROBLEMS/SOLUTIONS/COMMENTS
NO FGD-RELATED PROBLEMS WERE ENCOUNTERED DURING THE MONTH OF DECEMBER.
66
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NQX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - KW
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - -MM
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
*# FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - X
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
*** P/RTICLE CONTROL
** ESP
NUMBER
TYPE
SUPPLIER
INLFT FLUE GAS CAPACITY - CU.M/S •
INLhT FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
PARTICLE REMOVAL EFFICENCY - X
** PARTICLE SCRUBBER
G€NERIC TYPE
SPECIFIC TYPE
*** FG') SYSTEM
** GENERAL DATA
S\LEABLE FRODUCT/THROWAWAY PRODUCT
S32 REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
SKSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
HUM/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
UIIIT DESIGN S02 REMOVAL EFFICIENCY - X
Cl-RRENT STATUS
COMMERCIAL START-UP
ARIZONA ELECTRIC POWER COOP
APACHE
3
COCHISE
ARIZONA
( .100 LB/MMBTU)
( .800 LB/MMBTU)
(****** LB/MMBTU)
43.
344.
*******
530
195
175
183
98
RILEY STOKER
PULVERIZED COAL
BASE
346.85 (
118.3 (
122. (
CONCRETE
4.9 ( 16.2 FT)
735000 ACFM)
245 F)
400 FT)
( 10000 BTU/LB)
10000-11000
COAL
BITUMINOUS
£3260.
17.00
16.8-17.2
12.00
9.0-15.0
.50
.4-.6
.00
.00-.03
HOT SIDE
AIR CORRECTION DIVISION, UOP
94.4 ( 200000 ACFM)
( 700 F)
( 0. IN-H20)
371.1
.0
99.6
NONE
N/A
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
NONE
RESEARCH-COTTRELL
BURNS & MCDONNELL
FULL SCALE
NEW
X 99.50
42.50
1
4/79
67
-------
EPA UTILITY FGO SURVEY: OCTOBER - DECEMBER 1980
ARIZONA ELECTRIC POWER COOP: APACHE 3 (CONT.)
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
** ABSORBER
NUftBER
NUMBER OF SPARES
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
GAS CONTACTING DEVICE TYPE
NUnBER OF CONTACTING ZONES
DISTANCE BETWEEN GAS CONTACTING ZONES - CM
LIQUID RECIRCULATION RATE - LITER/S
L/G RATIO - L/CU.H
GAS-SIDE PRESSURE DROP - KPA
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
S02 REMOVAL EFFICIENCY - X
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATO.R
NU!1BER PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES PER STAGE
DISTANCE BETWEEN VANES - CM
VANE ANGLES - DEGREES
CONSTRUCTION MATERIAL GENERIC TYPE
WASH WATER SOURCE
** REHEATER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
** F/NS
NUMBER
NUHBER OF SPARES
DESIGN
SUPPLIER
FUNCTION
CONSTRUCTION MATERIAL GENERIC TYPE
** DUCTWORK
LOCATION
DIMENSIONS
SHELL GENERIC MATERIAL VYPE
LINcR GENERIC MATERIAL TYPE
** DUCTI.ORK
LOCATION
DIMENSIONS
SHELL GENERIC MATERIAL TYPE
U1IER GENERIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPhENT
FUNCTION
D :VICE
MANUFACTURER
6/79
8/74
Z
1
COMBINATION
SPRAY/PACKED
RESEARCH-COTTRELL
30 DIA. X 80 HT.
CARBON STEEL
AISI 1110
N/A
ORGANIC
GLASS-FLEX
HUNTERS PACKING
1
121.9
1260.
2.8
1.5
188.76
132.2
97.0
( 48.0IN)
(20000 GPM)
( 20.6 GAL/1000 ACF)
( 6.0 IN-H20)
( 400000 ACFM)
( 270 F)
MIST ELIMINATOR
4
IMPINGEMENT
BAFFLE
CHEVRON VANE
HORIZONTAL
2
3
10.2
45
POLYPROPYLENE
FRESH WATER
0
NONE
N/A
N/A
2
0
CENTRIFUGAL
ALLIS CHALMERS
UNIT
CARBON STEEL
SCRUBBER INLET
12 X 16
CABON STEEL
NONE
SCRUBBER OUTLET
12 X 16
CARBON STEEL
CXL 100
LIMESTONE GRINDING
BALL MILL
KENNEDY VAN SAUN
( 4.00 IN)
68
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
ARIZONA ELECTRIC POWER COOP: APACHE 3 (CONT.)
NUMBER
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
PRODUCT QUALITY - X SOLIDS
** TANKS
SERVICE
ABSORBER FEED
** PUMPS
SERVICE
PACKING
QUENCHER
SLURRY SUMP
*** SLUDGE
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE DIMENSIONS
SITE CAPACITY - CU.M
SITE SERVICE LIFE - YRS
** WATER BALANCE
WATER LOOP TYPE
MAKEUP WATER ADDITION - LITERS/S
** FGD SPARE CAPACITY INDICES
ABSORBER - 7.
** FGD SPARE COMPONENT INDICES
ABSORBER
4.5 ( 5 TPH)
48.0
NUMBER
1
NUMBER
3
4
2
FINAL
POND
OH SITE
PUMPED
85 ACRES X 18 FT DEEP
484308 ( 396.0 ACRE-FT)
30
OPEN
115.9
100.0
1.0
( 1840 GPM)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
6/79 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
720
7/79 SYSTEM
8/79 SYSTEM
THE APACHE 3 BOILER AND FGD SYSTEM BEGAN OPERATIONS DURING JUNE. THE
UTILITY REPORTED THAT THE START-UP WAS TYPICAL WITH NUMEROUS MINOR
SHAKEDOWN PROBLEMS.
744
744
** PROBLEMS/SOLUTIONS/COMMENTS
9/79 SYSTEM
THE UTILITY REPORTED THAT EXTENSIVE PROBLEMS WITH THE REAGENT HANDLING
SYSTEM ARE CONTINUING PARTICULARLY WITH RESPECT TO FEED LINE FAILURES,
PIPING PLUGGING AND GRINDING OPERATIONS. THE REAGENT HANDLING SYSTEM
ACCOMODATES BOTH UNITS 2 AND 3.
720
69
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
ARIZONA ELECTRIC POWER COOP: APACHE 3 (CONT.)
. PERFORMANCE DATA •
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE THIRD QUARTER OF 1979 THE BOILER AND FGD SYSTEM ONLY OPERATED
ABOUT Z57. OF THE TIME BECAUSE OF CONTINUING PROBLEMS WITH THE REAGENT FEED
LINE. THE FRP SECTION FROM THE GRINDER TO THE SCRUBBERS FAILED. THE LINE
WAS REPAIRED AT THE END OF SEPTEMBER.
COMMERCIAL OPERATIONS AT APACHE 3 BEGAN ON SEPTEMBER 1.
10/79 SYSTEM .0 .0 .0 744 0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY IS IN THE PROCESS OF REPLACING THE REAGENT HANDLING SYSTEM;
THEREFORE, THE FGD SYSTEM DID NOT OPERATE DURING OCTOBER.
11/79 A 89.4 39.8 39.4 39.4
B 89.4 50.5 50.0 50.0
SYSTEM 100.0 90.3 89.4 89.4 720 713 644 92.7
12/79 SYSTEM 99.5 99.5 99.5 99.5 744 744 741 95.4
** PROBLEMS/SOLUTIONS/COMMENTS
THE REAGENT HANDLING SYSTEM REPLACEMENT WAS COMPLETED IN DECEMBER.
THE OUTAGE TIME DURING DECEMBER WAS CAUSED BY A FAULTY BOILER FLUE
DAMPER.
1/80 SYSTEM 91.7 91.7 91.7 91.7 97.40 744 744 682 89.7
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JANUARY SOME OUTAGE TIME WAS DUE TO A PUMP MALFUNCTION.
OUTAGE TIME WAS ALSO CAUSED BY A BROKEN FEED BELT TO THE LIMESTONE BALL
MILL.
2/80 SYSTEM 95.6 74.1 96.0 71.4 97.40 696 671 497 83.5
** PROBLEMS/SOLUTIONS/COMMENTS
DURING FEBRUARY OUTAGE TIME RESULTED FROM AN ESP FAILURE.
FORCED OUTAGE TIME WAS ALSO CAUSED BY A PUMP MALFUNCTION.
3/80 SYSTEM 90.9 90.9 90.9 90.9 744 744 677 91.1
** PROBLEMS/SOLUTIONS/COMMENTS
SOME OF THE OUTAGE TIME DURING MARCH OCCURRED BECAUSE OF PUMP FAILURES.
OUTAGE TIME RESULTED FROM STICKING VALVES AND LIMESTONE FEED-BELT
PROBLEMS.
4/80 SYSTEM 99.0 96.9 96.9 30.6 720 227 220
** PROBLEMS/SOLUTIONS/COMMENTS
DURING APRIL THE FGD SYSTEM WAS FORCED DOWN DUE TO PUMP FAILURES AND A
RUPTURE IN THE SLURRY RECIRCULATION LINE.
5/80 SYSTEM .0 .0 .0 744 39 0
70
-------
EPA UTILITY FF.D SURVEY: OCTOBER - DECEMBER 1980
ARIZONA ELECTRIC POWER COOP: At ACHE 3 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
— -——— —___—_ — _____— __ _ —___
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER AND FGD SYSTEM WERE DOWN FOR A SCHEDULED OVERHAUL. THE LINERS
IN THE ABSORBER QUENCHER HAD TO BE REPAIRED. THE BOILER RETURNED TO SER-
VICE BEFORE REPAIR WORK FOR THE FGD SYSTEM WAS COMPLETE. THE FGD SYSTEM
WAS UNAVAILABLE IN MAY BECAUSE OF THIS OVERHAUL.
6/80 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE DATA FOR THE MONTH OF JUNE HAS BEEN
MISPLACED.
7/80 302 29.0 30.0 90.0 29.0
303 .0 .0 .0
SYSTEM 29.0 30.0 . 90.0 89.0 744 721 216 49.3
** PROBLEMS/SOLUTIONS/COMMENTS
BOTH MODULES WERE UNAVAILABLE BECAUSE OF REPLACEMENT OF THE ABSORBER LINER.
MODULE 302 WAS OUT OF SERVICE FOR 22 DAYS, WHILE MODULE 303 WAS OUT OF
SERVICE DURING ALL OF JULY.
A PACKING PUMP FAILURE CAUSED THE FGD SYSTEM TO GO DOWN.
8/80 302 98.5 47.8 96.3 38.4
303 98.5 19.3 91.3 15.5
SYSTEM 98.5 67.1 94.8 54.0 744 599 402 41.5
** PROBLEMS/SOLUTIONS/COMMENTS
TOWER 302 WAS UNAVAILABLE DURING PART OF AUGUST BECAUSE OF A QUENCHER
PUMP FAILURE.
DUE TO A SAMPLING LINE FAILURE IN AUGUST, TOWER 303 WAS SHUT DOWN FOR
PART OF THE MONTH.
THE REDUCED RATE OF FGD OPERATION IN AUGUST WAS A RESULT OF BOILER UNIT
PROBLEMS AND REDUCED LOAD CAPACITY.
9/80 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
NO INFORMATION WAS AVAILABLE FOR SEPTEMBER 1980.
10/80 302 76.2 87.7 97.1 68.1
303 .0 .0 .0
SYSTEM 76.2 87.7 97.1 68.1 744 567 507 52.5
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS OPERATED AT A REDUCED LOAD FOR 60 HOURS
AND WAS TAKEN OFF LINE FOR SIX DAYS DURING OCTOBER.
UNAVAILABLE FGD SYSTEM TIME WAS DUE TO A QUENCHER PUMP FAILURE AND PH
INSTABILITY.
11/80 302 78.4 78.1 95.4 77.8
303 100.0 17.8 100.0 17.8
SYSTEM 100.0 96.0 96.3 95.6 744 717 688 99.6
71
-------
EPA UTILITY FSD SURVEY: OCTOBER - DECEMBER 1980
ARIZONA ELECTRIC POWER COOP: APACKE 3 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER F6D CAP.
SOZ PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
DURIN3 NOVEMBER THE FGD SYSTEM WAS FORCED OUT OF SERVICE DUE TO FAILURE
OF THr QUENCHER PUMPS, SAMPLE LINE AND TRANSFORMER.
THE BOCLER UNIT TRIPPED CAUSING APPROXIMATELY FIVE HOURS OF OUTAGE TIME
DURING THE MONTH.
12/80 3C2 .0 .0 .0
303 100.0 93.6 100..0 96.6
SYSTEM 100.0 98.6 100.0 96.6 744 729 719 86.3
** PROBLEMS/SOLUTIONS/COMMENTS
NO FGD-REUTED PROBLEMS WERE ENCOUNTERED DURING THE MONTH OF DECEMBER.
72
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MM
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
EOILER TYPE
B3ILER SERVICE LOAD
DHSIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUHL DATA
F'JEl TYPE
F-'Et GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - z
AVERAGE MOISTURE CONTENT - 7.
R.iNGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** MECHANICAL COLLECTOR
TVPE
SUPPLIER
PARTICLE REMOVAL EFFICENCY -7.
** PARTICLE SCRUBBER
NUMBER
GENERIC TYPE .
SPECIFIC TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LI"!ER SPECIFIC MATERIAL
NUMBER OF CONTACTING ZONES
LIQUID RECIRCULATION RATE - LITER/S
L/G RATIO - LITER/CU.M
PRESSURE DROP - KPA
INLET GAS FLOW RATE - CU.M/S
INLET GAS TEMPERATURE - C
PARTICLE REMOVAL EFFICIENCY - 7.
*** FGD SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
SOZ REMOVAL MODE
ARIZONA PUBLIC SERVICE
CHOLLA
1
JOSEPH CITY
ARIZONA
C
85. (
43Q. (
******
.198 LB/MMBTU)
1.000 LB/MMBTU)
LB/MMBTU)
615
119
115
119
119
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
£45.39 (
136.7 (
78. (
CONCRETE
3.7
520000 ACFM)
278 F)
256 FT)
COAL
BITUMINOUS
23609.
13.50
9.7-22.5
15.00
( 12.0 FT)
( 10150 BTU/LB)
9650-10600
.50
0.44-1.0
.02
0.01-0.04
CYCLONES
RESEARCH-COTTRELL
75.0
VENTURI TOWER
VARIABLE-THROAT/BOTTOM-ENTRY LIQUID DISTRIBUTION
RESEARCH-COTTRELL
6 DIA X 45 HIGH
STAINLESS STEEL
AUSTENITIC
ORGANIC
GLASS FLAKE-FILLED POLYESTER
136.7
1.4
3.7
99.1
136.7
99.2
( 2170 GPM)
(10.1 6AL/1000ACF)
(15.0 IN-H20)
( 210100 ACFM)
( 278 F)
THROWAWAY PRODUCT
WET SCRUBBING
73
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
ARIZONA PUBLIC SERVICE: CHOLLA 1 (CONT.)
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY - X
UNIT DESIGN S02 REMOVAL EFFICIENCY - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
** ABSORBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
UNER SPECIFIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
GAS CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
DISTANCE BETWEEN GAS CONTACTING ZONES - CM
LIQUID RECIRCULATION RATE - LITER/S '
L'G RATIO - L/CU.M
GAS-SIDE PRESSURE DROP - KPA
S'JPERFICAL GAS VELOCITY - M/SEC
ISLET GAS FLOW - CU. M/S
I-^LET GAS TEMPERATURE - C
SJ2 REMOVAL EFFICIENCY - X
PARTXCLE REMOVAL EFFICENC* - X
** ABSOKSER
NJMEER
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
L :NER GENERIC MATERIAL
LiNER SPECIFIC MATERIAL
L::NER MATERIAL TRADE NAME/COMMON TYPE
GAS CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
LIQUID RECIRCULATION RATE - LITER/S
L'G RATIO - L/CU.M
GAS-SIDE PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/SEC
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
SC2 REMOVAL EFFICIENCY - X
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NU1BER PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
TR*DE NAME/COMMON TYPE
CONFIGURATION
NUMBER OF STAGES
NUKBER OF PASSES PER STAGE
FREEBOARD DISTANCE - M
LIMESTONE
NONE
RESEARCH-COTTRELL
EBASCO
FULL SCALE
RETROFIT
80.00
58.50
1
12/73
10/73
7/71
COMBINATION
SPRAY/PACKED
RESEARCH-COTTRELL
22 DIA X 70 HIGH
STAINLESS STEEL
AUSTENITIC
TYPE 316L
NONE
N/A
N/A
MUNTERS T 2-81 (POLYPROPYLENE)
1
61.0
630.
6.5
.1
2.1
113.26
135.6
92.0
( 24.0IN)
(10000 GPM)
( 48.9 GAL/1000 ACF)
.5 IN-H20)
6.9 FT/S)
240000 ACFM)
276 F)
99.7
SPRAY TOWER
OPEN COUNTERCURRENT SPRAY
RESEARCH-COTTRELL
ZZ DIA X 70 HIGH
STAINLESS STEEL
AUSTENITIC
TYPE 316L
NONE
N/A
N/A
NONE
1
630. (10000 GPM)
6.5 I 48.9 GAL/1000 ACF)
.1 ( .5 IN-H20)
2.1 ( 6.9 FT/S)
113.26 ( 240000 ACFM)
135.6 ( 276 F)
25.0
MIST ELIMINATOR
4
IMPINGEMENT
BAFFLE
CHEVRON VANE
HORIZONTAL
2
2
4.11 (13.5 FT)
74
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
ARIZONA PUBLIC SERVICE: CHOLLA 1 (CONT.)
DISTANCE BETWEEN STAGES - CM
DISTANCE BETWEEN VANES - CM
VANE ANGLES - DEGREES
PRESSURE DROP - KPA
CONSTRUCTION MATERIAL GENERIC TYPE
WASH WATER SOURCE
** REHEATER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TEMPERATURE INCREASE - C
INLET FLUE GAS FLOW RATE - CU. M/S
INLET FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** FANS
NUMBER
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DcVICE
N JMBER
** TAMKS
S£RVICE
2.54
3.8
( 1.0 IN)
( 1.50 IN)
SCP.UBBER RECYCLE
SLUDGE HOLDUP
A3SORBER TOWER HOLDUP
LIMESTONE SLURRY MAKEUP
** PUflPS
SERVICE
S7RLBBER RECIRCULATION
ABSORBER RECIRCULATION
*** SLUDGE
** DISPOSAL
N;.TURE
r. PE
S: TE TRANSPORTATION METHOD
SITE DIMENSIONS
SITE CAPACITY - CU.M
** PROCESS CONTROL AND INSTRUMENTATION
PROCESS CONTROL MANNER
45
.1 ( .5 IN-H20)
POLYPROPYLENE
MAKEUP WATER FROM WELL
Z
IN-LINE
STEAM
4.4 ( 40 F)
115.62 ( 245000 ACFM)
48.9 ( 120 F)
316L SS
WESTINGHOUSE
240000 ACFM)
276 F)
CENTRIFUGAL
STURTEVANT DIV.,
BOOSTER
FORCED DRAFT
DRY
113.26 (
135.6 (
CARBON STEEL
SCRUBBER INLET
CARBON STEEL
PLASITE
SCRUBBER OUTLET TO STACK
CARBON STEEL
PLASITE
LIMESTONE GRINDING
BALL MILL
1
NUMBER
NUMBER
2
2
FINAL
POND
PUMPED
70-100 ACRES X 6 FT DEEP
623730 ( 510.0 ACRE-FT)
MANUAL
75
-------
EPA UTILITY FGD SURVEY-' OCTOBER - DECEMBER 1980
ARIZONA PUBLIC SERVICE: CHOLLA 1 (CONT.)
** WATER BALANCE
WATER LOOP TYPE
MAKEUP WATER ADDITION - LITERS/S
** FGD SPARE CAPACITY INDICES
ABSORBER - X
** FGD SPARE COMPONENT INDICES
ABSORBER
OPEN
7.6
.0
.0
( 120 GPM)
. PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
10/73 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
744
11/73 SYSTEM
12/73 SYSTEM
INITIAL TESTING OF THE FGD SYSTEM BEGAN ON OCTOBER 2, 1973. THE SYSTEM
OPERATED UNTI'L THE SCHEDULED SHUTDOWN DATE OF OCTOBER 21. DURING THE THREE
WEEK TEST PERIOD, PARTICULATE MATTER AND S02 REMOVAL EFFICIENCIES, MIST
.CARRYOVER FROM THE TOWERS, MAXIMUM PROCESS GAS FLOW RATES, AND BYPASS GAS
LEAKAGE RATES WERE DETERMINED.
THE DATA COLLECTED INCLUDED THE FOLLOWING:
FLOODED DISC SCRUBBER S02 REMOVAL EFFICIENCY (MODULE A): 92X
SPRAY TOWER SCRUBBER S02 REMOVAL EFFICIENCY (MODULE B): 25X
UNIT OVERALL S02 REMOVAL EFFICIENCY: 58.5X
. MIST CARRYOVER FROM MODULES A AND B: OX
SOLIDS CARRYOVER FROM MODULE A: 0.005 GR/SCF
AIR LEAKAGE INTO SYSTEM DOWNSTREAM OF SCRUBBERS: 18,400 ACFM
CHLORIDE ION CONCENTRATION IN FLOODED DISC SCRUBBER RECIRCULATION:
1600 PPM
CHLORIDE ION CONCENTRATION IN SPRAY TOWER RECIRCULATION: 575 PPM
CHLORIDE ION CONCENTRATION IN SCRUBBER MAKEUP WATER (COOLING TOWER
SLOWDOWN): 933 PPM
CHLORIDE LEVELS ARE SUFFICIENT TO CAUSE PITTING CORROSION IN LOCALIZED
AREAS WHEN TEMPERATURES ARE GREATER THAN 140F AND PH IS LESS THAN
3.0.
720
** PROBLEMS/SOLUTIONS/COMMENTS
THE CONSTRUCTION AND INITIAL TESTING OF THE SYSTEM WERE COMPLETED ON
DECEMBER 3. COMMERCIAL OPERATIONS BEGAN ON DECEMBER 14.
BECAUSE OF A DIFFERENCE IN THE SIZE OF THE MAIN DUCT AND REHEATED TRANS-
ITION DUCT, THE GAS FLOW PRODUCES HARMONIC VIBRATIONS IN THE REHEATER.
THE VIBRATIONS WERE PARTIALLY DAMPENED BY INSTALLATION OF BAFFLES.
ONE OF THE REHEATER BUNDLES WAS BADLY CORRODED BY ACID THAT CONDENSED IN
THE UNINSULATED DUCT UPSTREAM OF THE REHEATERS. THE TUBE BUNDLE WAS RE-
PLACED AND A BAFFLE WAS INSTALLED TO DIVERT CONDENSED ACID FROM REHEATER
TUBES.
THE DUCT UPSTREAM OF THE REHEATER WAS INSULATED. THE ACID CONDENSATION
OCCURRED ONLY IN THE B-MODULE WHICH CONTAINS NO INTERNAL PACKING AND
CONSEQUENTLY HAS A LOWER DEGREE OF SULFUR DIOXIDE REMOVAL (25X).
SOME .INES PLUGGED, PARTICULARLY WHEN THE SYSTEM OPERATED AT LOW FLOW
RATES
SOLID'5 SETTLED OUT IN STANDBY PUMPS, AND EXCESSIVE FAN VIBRATIONS OCCURRED
BECALSE OF ACCUMULATION OF SCALE BUILDUP WHEN THE UNIT WAS IDLE. TO
SOLVE THESE PROBLEMS THE PACKING GLAND POSITION WAS REVERSED (INSTALLED
76
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
ARIZONA PUBLIC SERVICE: CHOLU 1 (CONT.)
PERFORMANCE DATA
PERIOD i-IODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
______ ,.__.„_ _________ — .._ _________«-. ___________ _~w________ _____ _____ _____ ______ _____ ______
UPSIDE DOWN). THE FAN WAS SANDBLASTED. THE PIPING WAS MODIFIED TO .
ELIMINATE STAGNANT POCKETS, AND PUMPS WERE FLUSHED IMMEDIATELY AFTER
REMOVAL FROM SERVICE.
THE UTILITY EXPERIENCED SOLIDS BUILDUP IN THE FDS STUFFING GLAND BOX AND
ON TOP OF THE SPRAY DOME.
A
B
SYSTEM
2/74 A
B
SYSTEM
3/74 A
B
SYSTEM
4/74 A
B
SYSTEM
97.0
90.0
93.5
100.0
94.0
97.0
100.0
66.0
83.0
66.0
57.0
61.5
744
672
744
720
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM PERFORMED SATISFACTORILY FROM DECEMBER 15, 1973 TO APRIL
15, 1974. ALTHOUGH SEVERAL UPSETS CAUSED SHUTDOWN OF ONE OR BOTH MODULES
FOR SHORT PERIODS SYSTEM AVAILABILITY AVERAGED 92.6X DURING THAT PERIOD.
THE SCRUBBER MODULES WERE SHUTDOWN FOR SHORT PERIODS IN APRIL TO REPLACE
CORRODED COR-TEN STEEL EXPANSION' JOINTS ON THE REHEATER BUNDLES. MODULE
A WAS DOWN APRIL 17 THROUGH 27. MODULE B WAS DOWN APRIL 15 THROUGH 28.
5/74 A
B
SYSTEM
6/74 A
B
SYSTEM
7/74 A
B
SYSTEM
8/74 A
B
SYSTEM
97.
98.
100.0
98.0
94.5
100.0
97.3
98.0
99.0
98.5
100.0
100.0
100.0
97.0
92.0
94.5
97.0
100.0
98.5
97.
98.
98.0
94.5
100.0
97.3
744 744
720
744 744
744 744
729
724
** PROBLEMS/SOLUTIONS/COMMENTS
EACH MODULE WAS OUT OF SERVICE ONE DAY OVER THE MONTH FOR THE INSTALLATION
OF BAFFLE PLATES IN THE INLET DUCT OF EACH REHEATER. THE BAFFLE INSTALLA-
TIONS WERE PARTLY SUCCESSFUL IN STOPPING REHEATER VIBRATION PROBLEMS.
9/74 A
B
SYSTEM
10/74 A
B
SYSTEM
95.0
99.0
97.0
83.0
68.0
75.5
720
744
77
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1930
ARIZONA PUBLIC SERVICE: CHOLLA 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE SYSTEM WAS SHUT DOWN IN LATE OCTOBER FOR AN ANNUAL BOILER AND FED
SYSTEM OVERHAUL.
DURING THE OUTAGE SEVERAL INSTANCES OF PITTING CORROSION WERE DISCOVERED
IN THE 316L SS FLOODED DICS SCRUBBER WALLS.
REHEATER TUBE LEAKS WERE DISCOVERED IN THE B-SIDE REHEATER DURING THE
OUTAGE.
11/74 A 100.0
B 98.0
SYSTEM 99.0 720
12/74 A 100.0
B 100.0
SYSTEM 100.0 744
1/75 A 97.7 97.7 .97.7
B 98.7 98.7 98.7
SYSTEM 98.2 98.2 98.2 744 744 730
** PROBLEMS/SOLUTIONS/COMMENTS
OPERATION OF THE SYSTEM THROUGHOUT 1975 AND 1976 WAS ACCOMPANIED BY A NUM-
BER OF MINOR PROBLEM AREAS INCLUDING: SIGNIFICANT CORROSION ATTACK IN THE
VESSEL WALLS OF THE VENTURI FLOODED-DISC PARTICULATE SCRUBBER MODULE; ACID
CORROSION IN THE B-SIDE REHEATER HOUSING; SCALE BUILDUP IN THE PIPE OUTLET
AT THE SLUDGE/FLYASH EVAPORATION POND; PLUGGING IN THE SCRUBBER TOWER PACK
ING AND MIST ELIMINATOR; EROSION IN THE PUMPS; CORROSION IN THE BOILER EX-
HAUST ELBOW OF THE DUCTWORK LEADING FROM THE SCRUBBERS TO THE STACK.
DURING JANUARY THE BYPASS SYSTEM EXPERIENCED CONTROL PROBLEMS. NO
SOLUTION HAS YET BEEN FOUND.
A LEAK IN THE B-SIDE ABSORBER TOWER WAS WELDED IN JANUARY.
SOME LEAKS WERE DISCOVERED OVER THE MOUTH ON THE A-SIDE VENTURI THROATS.
THE LEAKS WERE ATTRIBUTED TO NORMAL WEAR.
LEAKS WERE DISCOVERED IN THE B-SIDE REHEATER DUCTS IN JAUNARY.
2/75 A 95.5 95.5 95.5
B 91.4 91.4 91.4
SYSTEM 93.5 93.5 93.5 672 672 628
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT PROBLEMS WITH VESSAL LEAKS CONTINUED THROUGH
FEBRUARY.
SOME OUTAGE TIME WAS REQUIRED FOR RECYCLE PUMP REPAIRS OVER THE MONTH.
THE UTILITY DISCOVERED SOME ADDITIONAL EROSION/CORROSION PROBLEMS IN THE
FGD SYSTEM IN FEBRUARY.
3/75 SYSTEM 744
78
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
ARIZONA PUBLIC SERVICE: CHOLU 1 (CONT.)
PERFORMANCE DATA
PERIOD MCOULE AVAILABILITY OPER.iBILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
"•"•"""•"""'"" *~ ~* ~ — — — —•— •_•_•_•_ ______ ____.*_•____ .•..,.«....„.•._...„,„ ___________ «.____ ______ _____ «M •.__? _____ ___ w..
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT BUILDUP OF SEDIMENT HAS OCCURRED SEVERAL TIMES
SINCE STARTUP IN DEAD SPACES, IN PIPE LINES, AND VALVES OF IDLE PUMPS AS
WELL AS IN PROCESS LINES DURING PERIODS OF REDUCED OPERATING RATE.
SOME PIPE LINERS HAVE EXPERIENCED EROSION SINCE STARTUP. THE EROSION WAS
DUE IN SOME CASES TO UNSATISFACTORY LINER MATERIALS AND IN OTHER CASES TO
HIGH VELOCITIES THROUGH PIPES AND FITTINGS. PIPING MODIFICATIONS HELPED
TO REDUCE THE EROSION PROBLEM. CRACKING OF THE RUBBER LINING IN SOME
PIPES WAS DUE TO DEFECTS IN FABRICATION.
SOME FLOODED DISC SCRUBBER PACKING PLUGGING HAS OCCURRED. IT APPEARS
THAT THIS IS A RESULT OF THE GRADE OF COAL BURNED. THE "WETTED FILM
CONTACTOR" PACKING LIFE HAS BEEN REDUCED.
4/75 A 88.5 88.5 82.*
3 65.2 65.2 60.7
SYSTEM 76.9 76.9 71.6 720 670 515
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THERE ARE STILL PROBLEMS WITH THE BYPASS SYSTEM
CONTROLS.
SOME DOWN TIME WAS REQUIRED TO REPAIR VALVES AND PIPING AND TO UNPLUG
SECTIONS OF THE A MODULE TOWER PACKING (MUNTERS).
THE REHEATER SECTION WAS AGAIN PATCHED WITH CEILCOTE DURING APRIL.
5/75 A 47.5 47.5 47.5
B 39.9 39.9 39.9
SYSTEM 43.7 43.7 43.7 744 744 325
** PROBLEMS/SOLUTIONS/COMMENTS
BOTH MODULES WERE OUT OF SERVICE FOR MOST OF THE MONTH SO THAT SCHEDULED
REPAIRS AND CLEANING COULD BE UNDERTAKEN.
6/75 A 100.0 100.0 100.0 100.0
B 100.0 100.0 100.0 100.0
SYSTEM 100.0 100.0 100.0 100.0 720 720 720
** PROBLEMS/SOLUTIONS/COMMENTS
A SUBSTANTIAL AMOUNT OF PLUGGING WAS OBSERVED IN THE MODULE A ABSORBER
TOWER PACKING.
PLUGGING OCCURRED IN MIST ELIMINATORS.
NO MAJOR PROBLEMS WERE ENCOUNTERED DURING THE PERIOD.
7/75 A 97.5 97.5 97.5
B 98.5 98.5 98.5
SYSTEM 98.0 98.0 98.0 744 744 729
** PROBLEMS/SOLUTIONS/COMMENTS
MODULES WERE SHUT DOWN TO CLEAN FLOW RESTRICTIONS IN FLOODED-DISC RECIR-
CULATION LINES.
8/75 A 94.5 94.5 94.5
79
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
ARIZONA PUBLIC SERVICE: CHOLLA 1 (CONT.)
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY
B
SYSTEM
100.0 100.0
97.3
100.0
97.3
«,C U« 1 A
UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
100.0
97.3
744 744 724
** PROBLEMS/SO LUTIONS/COKMENTS
9/75 A
B
SYSTEM
THE A-SIDE WAS
64.5
93.0
78.8
SHUT DOWN
97.6
97. 4
97.5
FOR INSPECTION.
64.5
93.0
78.8
720 720 567
** PROBLEMS/SOLUTIONS/COIIMENTS
MINOR OUTAGE RESULTED FROM PLUGGED FLOODED DISC SCRUBBER RECIRCULATION
LINES.
10/75 A 78.0 84.0 56.4
B 24.6 54.8 17.8
SYSTEM 51.3 69.4 37.1 744 538 276
** PROBLEMS/SOLUTIONS/COMMENTS
OUTAGES RESULTED FROM SCHEDULED EQUIPMENT OVERHAULS AND RECOATING OF VES-
SELS.
617
11/75
A
B
SYSTEM
100.0
71.4
85.7
100.0
80.0
90.0
100.0
71.4
85.7 720 720
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR OUTAGES OR PROBLEMS OCCURRED DURING THE REPORT PERIOD.
12/75
A
3
SYSTEM
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0 744 744
744
-f* PROBLEMS/SOLUTIONS/COMMENTS
MINOR PROBLEMS ENCOUNTERED REQUIRED RECYCLE PUMP REBUILDING.
THE B-SIDE REHEATER COIL MALFUNCTIONED BUT NO OUTAGE TIME WAS REQUIRED.
1/76 A 96.0 98.9 96.0
B 87.9 98.6 89.9
SYSTEM 92.0 98.8 92.0 744 744 684
** PROBLEMS/SOLUTIONS/COMMENTS
MINOR VALVE PLUGGING OCCURRED.
MINOR RECIRCULATION LINE PLUGGING OCCURRED.
MODULE B OPERATING HOURS WERE LOWER BECAUSE OF REDUCED SYSTEM REQUIREMENTS
2/76 SYSTEM 696
3/76 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE MONTHS OF FEBRUARY AND MARCH.
4/76 A 99.0
80
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
ARIZONA PUBLIC SERVICE •' CHOLLA 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
SOZ PART. HOURS HOURS HOURS FACTOR
B 97.4
SYSTEM 98.2 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM IS CURRENTLY EXPERIENCEING COATING FAILURES IN THE ELBOW OF
THE SCRUBBER EXHAUST DUCT LEADING TO THE STACK.
THE UTILITY PERFORMED SOME MINOR REPAIRS TO THE HOUSING OF THE B-SIDE
REHEATER.
5/76 A 76.4
B 99.6
SYSTEM 88.0 744
** PROBLEMS/SOLUTIONS/COMMENTS
CORROSION AND PLUGGING PROBLEMS OCCURRED ON THE A-SIDE REHEATER
TUBES.
THE UTILITY REPORTED THAT PLUGGING OCCURRED IN THE FLOODED DISC SCRUBBER
RECIi'CULATION LINES.
PLUGG ING OCCURRED IN THE FLOODED DISC SCRUBBER PACKING.
PLUGGING OCCURRED TN THE MIST ELIMINATORS.
HEAVY PUMP MAINTENANCE WAS REQUIRED IN MAY. THE UTILITY NOW CONSIDERS
HEAVf PUMP MAINTENANCE NORMAL FOR THE CHOLLA 1 SCRUBBER.
6/76 A 64.1
B 39.4
SYSTEM 51.8 720
** PROBLEMS/SOLUTIONS/COMMENTS
LOW RELIABILITY FACTORS FOR THE MONTH OF JUNE RESULTED FROM A SCHEDULED
MID-YEAR SCRUBBER SHUTDOWN FOR MAINTENANCE, INSPECTION AND REPAIRS.
SOME SCALING AND CORROSION PROBLEMS WERE UNCOVERED IN THE SCRUBBING SYSTEM
RECYCLE TANKS.
7/76 A 100.0
B 97.5
SYSTEM 98.8 744
8/76 A 100.0
B 100.0
SYSTEM 100.0 744
•** PROBLEMS/SOLUTIONS/COMMENTS
REPAIRS TO THE COATING IN THE ELBOW OF THE SCRUBBER EXHAUST DUCT WERE COM-
PLETED OVER THE JULY-AUGUST PERIOD.
A MALFUNCTIONING SOLENOID VALVE IN THE B-SIDE MIST ELIMINATOR WASH SYSTEM
PREVENTING ADEQUATE WASHING, RESULTED IN A MINOR SCRUBBER OUTAGE DURING
THE JULY-AUGUST PERIOD.
9/76 A 100.0 100.0 100.0 100.0
B 93.9 100.0 93.9
SYSTEM 97.0 100.0 97.0 720 720 698
81
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
ARIZONA PUBLIC SERVICE: CHOLLA 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COmENTS
THE BOILER WAS IN SERVICE THE ENTIRE MONTH.
PROBLEMS WERE REPORTED.
NO SIGNIFICANT SCRUBBER
10/76
A
B
SYSTEM
11/76 A
B
SYSTEM
99.5
66.4
83.0
94.8
77.2
86.1
56.0
56.0
56.0
95.8
97.6
96.7
55.8
37.2
46.5
94.8
77. 2
86.1
744 417
346
619
720 720
«* PROBLEMS/SOLUTIONS/COMMENTS
TWO MINOR FORCED SCRUBBER OUTAGES OCCURRED DURING THE PERIOD.
A REHEATER STEAM LEAK CAUSED A MINOR FORCED OUTAGE.
AN INLET GAS DAMPER ADJUSTMENT PROBLEM IN BOTH THE A-SIDE AND B-SIDE
SCRUBBING TRAINS CAUSED A MINOR OUTAGE.
12/76 A
B
SYSTEM
99.8
67.0
99.9
99.7
100.0
99.0
99.8
67.0
83.4
744 744
620
** PROBLEMS/SOLUTIONS/COMMENTS
ONE OUTAGE WAS REPORTED. THE OUTAGE WAS THE RESULT OF AN ADDITIONAL AD-
JUSTMENT TO THE A-SIDE GAS INLET DAMPER.
1/77 A
B
SYCTEM
71.6
91.9
81.8
72.3
93.4
82.9
71.6
91.9
81.8
744 744
608
** PROBLEMS/SOLUTIONS/CO, 1MENTS
BAD C3't71 ****
THE PERFORMANCE INDEX VALUES CONTAINED IN THESE TABLES ARE BASED UPON THE
MODULI ACTUAL SERVICE TIME FOR THE PERIOD VERSUS THE NUMBER OF HOURS THE
MODULES ARE CALLED UPON TO OPERATE FOR THE SAME PERIOD. THE MODULES OPER-
ATE ON A DEMAND-ONLY BASIS. FLUE GAS IS BYPASSED AROUND THE MODULES WHEN
THEY ARE NOT REQUIRED FOR SERVICE.
THE HUNTERS PACKING IN THE A-SIDE TOWER WAS REPLACED IN JANUARY.
MINOR CORROSION OCCURRED IN THE SYSTEM.
MINOR PLUGGING OF SCRUBBER INTERNALS OCCURRED. THE TOWERS WERE CLEANED.
SOME PROBLEMS OCCURRED WITH THE LIQUID PIPING.
AVERAGE S02 INLET AND OUTLET CONCENTRATIONS DURING JANUARY WERE 350 PPM
AND 175 PPM RESPECTIVELY.
2/77
A
B
SYSTEM
96.5
88.0
92.2
98.8
99.6
99.2
96.5
88.0
92.2
672 672
620
82
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
ARIZONA PUBLIC SERVICE: CHOLLA 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THERE WERE MECHANICAL DIFFICULTIES WITH THE BY-PASS DAMPERS.
AVERAGE 502 INLET AND OUTLET VALUES DURING FEBRUARY WERE 350 PPM AND 175
PPM RESPECTIVELY.
3/77 A 71.6 72.3 71.6
B 91.9 93.4 91.9
SYSTEM 81.8 82.9 81.8 744 744 608
** PROBLEMS/SOLUTIONS/COMMENTS
THE A-SIDE TOWER PACKING WAS REPLACED DURING MARCH.
BOTH MODULES WERE OUT OF SERVICE FOR CLEANING OF AREAS OF PLUGGING
IN THE SCRUBBER INTERNALS DURING THE MONTH.
4/77 A 99.6 100.0 88.2
B 98.6 100.0 87.3
SYSTEM 99.1 100.0 87.8 720 638 632
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED NO MAJOR PROBLEMS OCCURRED DURING APRIL.
5/77 A 100.0 87.0 86.7
B 100.0 87.0 86.7
SYSTEM 100.0 87.0 86.7 744 645 645
** PROBLEMS/SOLUTIONS/COMMENTS
OUTAGE TIME FOR THE BOILER AND FGD SYSTEM WAS A RESULT OF THE SCHEDULED
MID-YEAR SCRUBBER CLEANOUT.
DURING MAY RESEARCH-COTTRELL PERSONNEL CONDUCTED FORCED OXIDATION TESTS BY
BLOWING AIR INTO THE FLOODED DISC SCRUBBER AND CONVERTING ALL CAS03 TO
CAS04 YIELDING SUPERIOR SLUDGE DEWATERING HANDLING AND SCALE-FREE
OPERATION.
6/77 A 100.0 100.0 100.0 100.0
B 100.0 100.0 100.0 100.0
SYSTEM 100.0 100.0 100.0 100.0 720 720 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE JTILITY REPORTED NO MAJOR PROBLEMS FOR THE MONTH OF JUNE.
7/77 A 97.0
B 99.0
SYSTEM 98.0 744 744
** PROBLEMS/SOLUTIONS/CCMMENTS
A MINOR LEAK OCCURRED IN THE LIMESTONE SLURRY TANK.
A MINOR LEAK OCCURRED IN THE B-SIDE RETURN LINE FROM THE FLOODED DISC
SCRUBBER TO THE SCRUBBER TANK.
RESEARCH-COTTRELL PERSONNEL ARE STILL ON THE PLANT SITE CONTINUING FORCEDD
OXIDATION STUDIES.
8/77 A 97.2 97.2 97.2
83
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
ARIZONA PUBLIC SERVICE: CHOLLA 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
B
SYSTEM
98.6
97.9
98.6
97.9
98.6
97.9
744
744
739
** PROBLEMS/SOLUTIONS/COMMENTS
DOWN TIME WAS REQUIRED TO REPAIR LEAKS IN THE SLURRY DISPOSAL TANK AND THE
FLOODED DISC SCRUBBER RETURN LINE BETWEEN THE TOWER AND THE SCRUBBER
RECYCLE TANK.
9/77 A 100.0 99.7 100.0 99.7
B 100.0 99.7 100.0 99.7
SYSTEM 100.0 99.7 100.0 99.7 720 720 718
** PROBLEMS/SOLUTIONS/COMMENTS
ONLY ROUTINE MAINTENANCE MAS REQUIRED FOR THE SCRUBBING SYSTEM DURING
SEPTEMBER.
10/77 A 100.0 99.9 100.0 99.9
B 100.0 99.9 100.0 99.9
SYSTEM 100.0 92.1 98.7 99.9 744 744 743
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED NO MAJOR PROBLEMS FOR OCTOBER.
11/77 A 100.0 99.7 100.0 23.3
B 97.4 84.5 97.4 19.7
SYSTEM 93.7 92.0 99.0 21.5 720 169 155
** PROBLEMS/SOLUTIONS/COMMENTS
THE B-SIDE OUTAGE WAS DUE TO- LEAKS IN THE VENTURI SECTION OF THE SCRUBBER
AND AN EXPANSION JOINT FAILURE IN A RECYCLE PUMP.
THE BOILER OPERATED ONLY 168.5 HOURS BECAUSE OF A SHUTDOWN FOR OVERHAUL
IN THE LAST HALF OF NOVEMBER. THE UNIT IS SCHEDULED TO START UP IN MID-
DECEMBER.
12/77 SYSTEM .0 .0 744 0
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER AND SCRUBBING SYSTEM WERE OUT OF SERVICE THROUGH DECEMBER AS
THE OVERHAUL PERIOD CONTINUED.
OVER THE PAST YEAR EVIDENCE OF CHLORIDE ATTACK WAS NOTED IN THE LIQUID-GAS
CENTRIFUGAL SEPARATOR SHELL BELOW THE ABSORBER. THE INTERIOR OF THE VES-
SEL WAS COATED WITH AN EPOXY MATERIAL BY THE SYSTEM SUPPLIER AS A REMEDY
BUT THIS ERODED IN SPOTS AND HAD TO BE REPAIRED. THE EPOXY MATERIAL ALSO
ERODED AND DISBONDED BELOW THE SCRUBBER DISC.
DURING 1977 EVIDENCE OF ADDITIONAL CHLORIDE ATTACK WAS NOTED ON THE MODULE
B REHEATER TUBES. THE SPRAY DISTRIBUTION DEFLECTOR ABOVE THE FLOODED
DISC FAILED BECAUSE OF STRESS-CORROSION CRACKING. THE DEFLECTOR WAS
REDESIGNED BY THE SYSTEM SUPPLIER.
EXTENSIVE CORROSION WAS RECENTLY DISCOVERED IN THE DUCTWORK LEADING FROM
THE MODULE B ABSORBER TOWER EXHAUST ELBOW TO THE REHEAT TUBE BUNDLE. THE
UTILITY HAS RECOATED THE ELBOW SEVERAL TIMES WITH A CEILCOTE LINER. AN
APPLICATION PROBLEM CAUSED REPEATED FAILURE OF THE LINER. THIS PROBLEM
HAS NOT BEEN FULLY RESOLVED.
1/78 A J7.0 97.0 17.0
84
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
ARIZONA PUBLIC SERVICE: CHOLLA 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
Z/7&
3/78
4/78
5/78
6/78
7/78
8/78
B
SYSTEM
90.9
94.0
96.9
97.0
16.5
17.1
135
127
** PROBLEMS/SOLUTIONS/COMMENTS
THE FLOODED DISC SCRUBBER TANK HEADER FOR THE LIMESTONE SLURRY MAS REPAIR-
ED AFTER BEING DAMAGED DURING THE OVERHAUL.
THE BOILER AND SCRUBBER WERE OUT OF SERVICE MOST OF JANUARY AS THE
SCHEDULED OVERHAUL CONTINUED.
A
B
SYSTEM
99.1
87.9
93.5
100.0
100.0
100.0
94.7
84.0
89.4
672 642
600
** PROBLEMS/SOLUTIONS/COMMENTS
SOME MINOR LEAK REPAIRS WERE REQUIRED DURING FEBRUARY AFTER THE TWO MONTH
OVERHAUL/CLEANING WAS COMPLETED IN JANUARY.
A
B
SYSTEM
100.0
98.8
99.4
74.4
74.4
74.4
100.0
98.8
99.4
744 744
** PROBLEMS/SOLUTIONS/COMMENTS
ONE FORCED SHUTDOWN OCCURRED ON THE A-SIDE SCRUBBING TRAIN.
739
A
B
SYSTEM
100.0
92.7
100.0
96.4
99.9
100.0
100.0
92.7
100.0
96.4
720 720
694
** PROBLEMS/SOLUTIONS/COMMENTS
A MINOR LEAK REPAIR WAS NECESSARY AGAIN AFTER THE NOVEMBER-JANUARY
OVERHAUL/CLEANING.
A
B
SYSTEM
86.7
96.2
91.5
86.7
98.1
92.4
86.7
96. Z
91.5
744 744
680
** PROBLEMS/SOLUTIONS/COMMENTS
THERE WERE NO SIGNIFICANT PROBLEMS REPORTED. ONLY GENERAL MAINTENANCE WAS
PERFORMED ON THE SYSTEM DURING MAY.
A
B
SYSTEM
100.0
99.2
99.6
100.0
100.0
100.0
100.0
99.2
99.6
100.0
99.2 100.0 99.2
720 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED NO MAJOR PROBLEMS FOR THE MONTH OF JUNE.
717
A
B
SYSTEM
100.0
99.4
100.0
99.7
99.4
100.0
99.7
99.4
100.0
99.7
744 744 742
** PROBLEMS/SOLUTIONS/COMMENTS
ONLY ROUTINE MAINTENANCE WAS REQUIRED ON THE SCRUBBER FOR JULY.
A 100.0 100.0 100.0 100.0
85
-------
EPA UTILITY F6D SURVEY: OCTOBE* - DECEMBER 1980
ARIZON* PUBLIC SERVICE: CHOLLA 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
— — — — — — — — — — — — ____________ ___________ — — _ — _______ WHIM <•»«•«»_ _____ _____ _____ —__ — — — __ —__ ______
B 95.1 95.1 95.1
SYSTEM 97.6 97.6 97.6 744 744 726
** PROBLEMS/SOLUTIONS/COMMENTS
REPAIRS WERE NECESSARY TO PLUGGED B-SIDE REHEAT COILS. THE COILS WERE
REPLACED.
9/78 A 100.0 100.0 100.0 100.0
B 97.8 100.0 97.8
SYSTEM 98.9 100.0 98.9 720 720 712
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED NO MAJOR PROBLEMS FOR THE MONTH OF SEPTEMBER.
10/78 \ 100.0 100.0 58.4
B 95..9 100.0 56.0
•SYSTEM 98.0 100.0 57.2 744 434 425
** PROBLEMS/SOLUTIONS/COMMENTS
ONLY ROUTINE MAINTENANCE WAS REQUIRED ON THE SCRUBBER IN OCTOBER.
11/78 A 100.0 100.0 100.0 100.0
B 91.3 100.0 91.3
SYSTEM 95.7 100.0 95.7 720 720 688
** PROBLEMS/SOLUTIONS/COHMENTS
THE UTILITY REPORTED NO MAJOR PROBLEMS FOR THE MONTH OF NOVEMBER.
12/78 A 88.1 88.1 88.1
B 85.6 88.3 85.6
SYSTEM 86.9 88.2 86.9 744 744 646
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY HAS REPORTED THAT THE FGD SYSTEM EXPERIENCED CONTROL PROB-
LEMS DURING DECEMBER.
744 744 741
672 672 672
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED NO MAJOR PROBLEMS FOR THE MONTH OF FEBRUARY.
3/79 A 95.2 95.0 95.2
B 100.0 100.0 100.0 100.0
SYSTEM 97.6 97.5 97.6 744 744 726
** PROBLEMS/SOLUTICNS/COMMENTS
THE UTILITY HAS EXPERIENCED PLUGGED REHEAT TUBES. THE OLD TUBES, IN UN-
SECTIONALIZED BUNDLES, WERE REPLACED WITH NEW TUBES OF SPLIT COIL CON-
STRUCTION AND MADE OF 316L SS. THE NEW TYPE OF TUBES ALONG WITH BETTER
MAINTENANCE PROCEDURES HAS ADDED TO THE REHEAT TUBE LIFE AND REHEATER
AVAILABILITY.
86
1/79 A
B
SYSTEM
2/79 A
B
SYSTEM
100.0
100.0
100.0
100.0
99.1
100.0
99.6
100.0
100.0
100.0
99.1
100.0
99.6
100.0
100.0
100.0
99.1
100.0
99.6
100.0
100.0
100.0
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
ARIZONA PUBLIC SERVICE: CHOLLA 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
4/79 A 100.0 1)0.0 100.0 100.0
B 100.0 1JO.O 100.0 100.3
SYSTEM 100.0 100.0 100.0 100.0
720 720 720
5/79
*» PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED NO PROBLEMS FOR THE MONTH OF APRIL.
99.1
71.6 71.8 71.6 744 744
** PROBLEMS/SOLUTIONS/COMMENTS
A
B
SYSTEM
99.4
44.1
71.8
99.1
44.1
71.6
533
CORRODED DUCTWORK ON MODULE B FROM THE TOWER TO THE STACK WAS REPLACED
DURING MAY.
REPAIRS WERE MADE TO THE MODULE B SCRUBBER LINING AND THE PACKING WAS
REPLACED.
6/79
A
B
SYSTEM
100.0
78.2
100.0
89.1
78.0
100.0
89.0
78.2
100.0
89.1
720 720 642
** PROBLEMS/SOLUTIONS/COMMENTS
THE MODULE A ABSORBER TOWER HUNTERS PACKING WAS REPLACED DURING JUNE.
EMERGENCY MAINTENANCE WAS PERFORMED JUNE 23 ON THE MODULE A COMMON DIS-
CHARGE HEADER.
7/79 -SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
NO INFORMATION WAS AVAILABLE FOR THE MONTH OF JULY.
744
8/79
A
B
SYSTEM
95.7
95.7
95.7
95.6
95.7
95.7
95.7
95.7
95.7
744 744
712
** PROBLEMS/SOLUTIONS/COMMENTS
DURING AUGUST GENERAL MAINTENANCE WAS PERFORMED ON THE FLOODED DISC
SCRUBBER.
9/79 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS NOT AVAILABLE FOR THE MONTH OF SEPTEMBER.
10/79
A
B
SYSTEM
97.8
94.3
96.1
100.0
98.0
99.0
45.0
43.3
44.2
744 342 328
** PROBLEMS/SOLUTIONS/COMMENTS
DURING OCTOBER ROUTINE MAINTENANCE WAS PERFORMED ON THE FGD SYSTEM.
11/79
A
B
SYSTEM
77.0
98.5
87.8
77.0
98.5
87.8
720 720
632
87
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
ARIZONA PUBLIC SERVICE: CHOLLA 1 (CONT.)
PERIOD
12/79
1/80
2/80
3/80
MODULE AVAILABILITY
A
B
SYSTEM
A
B
SYSTEM
A 100.0
B
SYSTEM
A
B
SYSTEM
rcKruKHAr
OPERABILITY RELIABILITY
94.0
86.7
90.4
95.5
99.1
97.3
100.0 100.0
99.4
99.7
99.1
»3.1
?6.1
SUE UAIA
UTILIZATION
94.0
86.7
90.4
95.5
99.1
97.3
100.0
99.4
99.7
99.1
93.3
96. :i
X REMOVAL PER BOILER
S02 PART. HOURS HOURS
744 744
744 744
696 696
744 744
FGD
HOURS
672
724
694
715
CAP.
FACTOR
91.7
92.1
88.6
** PROBLEMS/SOLUTIONS/CO'fflENTS
NO FORCED OUTAGES WERE REPORTED BY THE UTILITY FOR THE FIVE MONTH PERIOD
OF NOVEMBER 1979 THROUGH MARCH 1980. SOME SCHEDULED OUTAGE TIME WAS
REQUIRED FOR REPAIR OF THE REHEATER DUCTWORK.
4/80 A 100.0 100.0 100.0 100.0
B 100.0 100.0 100.0 100.0
SYSTEM 100.0 100.0 3 -.0 100.0 720 720 720 82.8
** PROBLEMS/SOLUTIONS/COMMENTS
NO FGD-REUTED PROBLEMS WERE REPORTED FOR THE MONTH OF APRIL.
5/80 A 100.0 100.0 100.0 100.0
B 99.2 99.2 99.2 99.2
SYSTEM 99.6 99.6 99.6 99.6 744 744 741 87.6
** PROBLEMS/SOLUTIONS/COMMENTS
THE B-MODULE OUTAGE TIME IN MAY WAS CAUSED BY PROBLEMS WITH THE BOOSTER
FAN.
6/80 A 100.0 80.7 100.0 68.7
tt 99.3 87.7 99.1 74.6
(JYSTEM 99.7 84.2 99.6 71.7 720 613 516 67.5
«* PROBLEMS/SOLUTIONS/COMMENTS
DURING JUNE SCHEDULED MAINTENANCE WAS PERFORMED ON THE BOILER. THE
SCHEDULED OUTAGE TIME WAS NECESSARY TO ACID WASH THE CONDENSERS.
THE ONLY FGD-RELATED OUTAGE OCCURRED WHEN A BLOCK VALVE MALFUNCTIONED.
THE B-MODULE WAS OUT OF SERVICE FOR FIVE HOURS.
7/80 A 100.0 100.0 100.0 100.0
B 100.0 93.6 100.0 98.6
SYSTEM 100.0 99.3 100.0 99.3 744 744 739 95.8
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS AVAILABLE 100X OF THE TIME IN JULY. MODULE B WAS NOT
UTILIZED FOR PART OF THE MONTH DUE TO LOW BOILER LOAD.
8/80 SYSTEM 744
9/80 SYSTEM 720
88
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
ARIZONA PUBLIC SERVICE: CHOLLA 1 (CONT. )
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
_•.__.._ __«__ ,•>• — — •••«•••• •«••••••• _».____.«•»»•_ •.__.«•»__«« __»»<• v_w«__ «•__«, <_«_V«, B_«w ____««. _.W_ W_M_«
** PROBLEMS/SOLUTIONS/COMMENTS
DATA FOR THE AUGUST AND SEPTEMBER MONTHS WERE NOT AVAILABLE DUE TO
PERSONNEL CHANGES.
10/80 SYSTEM 744
11/80 SYSTEM 720
12/80 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY HAS REPORTED THAT THE AVAILABILITY FIGURES FOR AUGUST THROUGH
DECEMBER ARE NOT AVAILABLE AT THIS TIME.
DURING THE FOURTH QUARTER THE DUCTWORK DOWNSTREAM OF THE B TRAIN SCRUBBERS
HAD TO BE REPLACED.
89
-------
EPA .UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MM
GROSS UNIT GENERATING CAPACITY - MM
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND .STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
A"ERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
A'/ERAGE CHLORIDE CONTENT - 7,
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL .
»* MECHANICAL COLLECTOR
PARTICLE REMOVAL EFFICENCY -7.
** PARTICLE SCRUBBER
NUMB-ZR
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
D:':IE >ISIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
L/G RATIO - LITER/CU.M
PRESSURE DROP - KPA
INLET GAS FLOW RATE - CU.M/S
B-'LET GAS TEMPERATURE - C
*** FGt- SYSTEM
** GENERAL DATA
S;LEABLE PRODUCT/THROWAWAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
( .167 LB/MMBTU)
( .800 LB/MMBTU)
(****** LB/MMBTU)
ARIZONA PUBLIC SERVICE
CHOLLA
2
JOSEPH CITY
ARIZONA
C
72.
344.
******
615
264
235
*****
264
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
******** (******* ACFM)
******* (**** F)
168. ( 550 FT)
CONCRETE
4.5 ( 14.7 FT)
( 10150 BTU/LB)
9650-10600
COAL
BITUMINOUS
23609.
13.50
9.7-22.5
. 15.00
******
.50
0.44-1.0
.02
0.01-0.04
75.0
VENTURI TOkER
VARIABLE-THROAT/BOTTOM-ENTRY LIQUID DISTRIBUTION
RESEARCH-COTTRELL
6 (DIA) X 45
STAINLESS STEEL
AUSTENITIC
ORGANIC
GLASS FLAKE-FILLED POLYESTER
1.4 (10.1 GAL/1000ACF)
3.7 (15.0 IN-H20)
185.0 ( 392000 ACFM)
50.0 ( 122 F)
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
NONE
RESEARCH-COTTRELL
EBASCO
FULL SCALE
90
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
ARIZONA PUBLIC SERVICE: CHOLLA 2 (CONT.)
NEW/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
UNIT DESIGN S02 REMOVAL EFFICIENCY - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
** ABSORBER
NUMBER
NUMBER OF SPARES
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
L/G RATIO - L/CU.M
GAS-SIDE PRESSURE DROP - KPA '
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
S02 REMOVAL EFFICIENCY - X
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
** REHEATER
GENERIC TYPE
SPECIFIC TYPE
TEMPERATURE INCREASE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** FANS
DESIGN
FUNCTION
APPLICATION
SERVICE
CONSTRUCTION MATERIAL GENERIC TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
NUMBER
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
*** SL'JDGE
** DISPOSAL
NATURE
TYPE
LOCATION
** WATER BALANCE
WATER LOOP TYPE
MAKEJP WATER ADDITION - LI"ERS/S
** FGD SPARE CAPACITY INDICES
AE-SORBER - X
NEW
X 99.70
75.00
1
6/78
4/78
12/74
4
1
COMBINATION
SPRAY/PACKED
RESEARCH-COTTRELL
22 (DIA) X 70
STAINLESS STEEL
AUSTENITIC
TYPE 316L
NONE
N/A
N/A
6.5
.1
184.98
50.0
85.0
( 48.9 GAL/1000 ACF)
( .5 IN-H20)
( 392000 ACFM)
( 122 F)
MIST ELIMINATOR
IMPINGEMENT
BAFFLE
CHEVRON VANE
IN-LINE
STEAM
4.4 ( 40 F)
INCONEL 625
CENTRIFUGAL
BOOSTER
FORCED DRAFT
DRY
CARBON STEEL
LIMESTONE GRINDING
BALL MILL
2
6.4 ( 7 TPH)
FINAL
UNLINED PONT
ON SITE
OPEN
7.6
33.0
( 120 6PM)
91
-------
EPA UTILITY FGO SURVEY: OCTOBER - DECEMBER 1980
ARIZONA PUBLIC SERVICE: CHOLLA 2 (CONT.)
** F6D SPARE COMPONENT INDICES
ABSORBER 1.0
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
4/78 SYSTEM 720
5/78 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
INITIAL SCRUBBING OPERATIONS BEGAN IN APRIL 1978. THE SCRUBBER REPORTEDLY
OPERATES MOST OF THE TIME, HOWEVER, SOME PROBLEMS HAVE OCCURRED WITH
VIBRATIONS THROUGHOUT THE SYSTEM.
THE EPA HAS RECENTLY GRANTED THE UTILITY AN EXTENSION FOR COMPLIANCE.
FULL COMMERCIAL OPERATIONS ARE EXPECTED TO BEGIN SOMETIME AFTER MID-
AUGUST. THE COMPLIANCE TEST WILL BE COMPLETED BY AUGUST 15. THE UTILITY
EXPECTS TO HAVE THE FGD SYSTEM SHAKEDOWN PROBLEMS CLEARED UP BY THEN.
6/78 SYSTEM 720
7/78 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
SHAKEDOWN/DEBUGGING OPERATIONS ARE CONTINUING.
THE SLURRY RECYCLE PIPING HAS EXPERIENCED CONTINUAL VIBRATION PROBLEMS.
THE CONTRACTOR HAS BEEN INJECTING NITROGEN GAS INTO THE LINES TO DAMPEN
THE VIBRATIONS (AIR WAS NOT USED BECAUSE THE SULFITE WOULD BE OXIDIZED TO
SULFATE AND RESULT IN SCALE FORMATION).
THE CORROSION RESISTANT COATING IN THE DOWNCOMER AREA IN ONE OF THE
ABSORBER MODULES HAS BEEN PEELING AWAY.
8/78 SYSTEM 744
9/78 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE SLURRY RECYCLE SYSTEM COMPONENTS ARE STILL EXPERIENCING RESONANT
VIBRATIONS.
THE COMPLIANCE TEST WAS PERFORMED THE WEEK OF AUGUST 7. ALTHOUGH OFFICIAL
WORD HAS NOT BEEN RECEIVED BY THE UTILITY IT APPEARS THAT THE UNIT IS IN
COMPLIANCE WITH RESPECT TO S02, PARTICULATE MATTER, OPACITY AND NOX.
SHAKEDOWN/DEBUGGING OPERATIONS ARE CONTINUING.
10/78 SYSTEM 744
11/78 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
SHAKEDOWN DEBUGGING OPERATIONS ARE CONTINUING. SOME SCRUBBER COMPONENTS
ARE STILL MANNED BY BECHTEL STAFF, ARIZONA PUBLIC SERVICE PERSONNEL ARE
OPERATING MOST OF THE SYSTEM AT THIS TIME.
12/78 SYSTEM 744
1/79 SYSTEM 744
92
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
ARIZONA PUBLIC SERVICE: CHOLLA Z (CONT. )
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIQNS/CONMENTS
DECEMBER-JANUARY INFORMATION IS UNAVAILABLE AT THIS TIME FOR CHOLLA 2.
THE UTILITY REPORTED THAT IT WOULD SOON BE KEEPING PERFORMANCE RECORDS.
2/79 SYSTEM 672
3/79 SYSTEM 744
4/79 SYSTEM 720
5/79 SYSTEM 744
6/79 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
OPERATION PARAMATERS ARE STILL UNAVAILABLE FOR THIS UNIT.
7/79 SYSTEM 744
8/79 SYSTEM 744
9/79 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
NO INFORMATION WAS AVAILABLE FROM THE UTILITY FOR THIS PERIOD. THE UTILITY
INDICATED THAT DATA WOULD BE AVAILABLE FOR THE FOURTH QUARTER REPORT.
10/79 SYSTEM 744
11/79 SYSTEM 720
12/79 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
NO INFORMATION WAS AVAILABLE FOR THE FOURTH QUARTER OF 1979.
1/80 SYSTEM 744
2/80 SYSTEM 696
3/80 SYSTEM 744
*# PROBLEMS/SOLUTIONS/COMMENTS
NO INFORMATION IS AVAILABLE AS OF YET WITH RESPECT TO THE CHOLLA 2 FGD
OPERATIONS.
4/80 SYSTEM 720
5/80 SYSTEM 744
6/80 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM PERFORMANCE DATA FOR THE APRIL-JUNE PERIOD ARE NOT AVAILABLE
AT THIS TIME.
7/80 SYSTEM 744
93
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
ARIZONA PUBLIC SERVICE: CHOLLA ? (CONT.)
, PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S03 PART. HOURS HOURS HOURS FACTOR
8/80 SYSTEM 744
9/80 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE THIRD QUARTER UPDATE INFORMATION IS NOT AVAILABLE FOR RELEASE AT THIS
TIME.
10/80 SYSTEM ' 744
11/80 SYSTEM 720
12/80 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
PERFORMANCE DATA FOR THIS UNIT IS NOT AVAILABLE FOR PUBLICATION AT THIS
TIME.
94
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANf NAME
PLANT -WIE
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - N6/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UN3T GENERATING CAPACITY • MM
NET UNIT GENERATING CAPACITY W/:GD - MW
NET UNIT GENERATING CAPACITY WO/FGD - MM
EQUIVALENT SCRUBBED CAPACITY - 1W
** UNTT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOM - CU.M/S
BJILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FU:L DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RaNSE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
R*NGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** PARTICLE SCRUBBER
NUMBER
GENERIC TYPE
SUPPLIER
S02 REMOVAL EFFICENCY - 7.
*** FGD SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
UNIT DESIGN S02 REMOVAL EFFICIENCY - 7.
CURRENT STATUS
INITIAL START-UP
** DESIGN AND OPERATING PARAMETERS
** ABSORBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
SHELL GENERIC MATERIAL
ARIZONA PUBLIC SERVICE
FOUR CORNERS
1
FARMINGTON
NEM MEXICO
C
****** (****** LB/MMBTU)
258. ( .600 LB/MMBTU)
****** (****** LB/MMBTU)
2089
175
175
*****
175
RILEY STOKER
PULVERIZED COAL
BASE
384.13
171.1
******
( 814000 ACFM)
( 340 F)
(**** FT)
(***** FT)
( 8600 BTU/LB)
8300-9000
*******
COAL
SUBBITUMINOUS
20004.
22.00
******
12.30
******
.75
******
.07
VENTURI TOWER
CHEMICO
30.0
THROWAWAY PRODUCT
WET SCRUBBING
LIME/ALKALINE FLYASH
CHEMICO DIVISION, ENVIROTECH
IN-HOUSE
FULL SCALE
RETROFIT
7. 99.00
80.00
1
11/79
VENTURI TOWER
VARIABLE-THROAT/TOP-ENTRY PLUMB BOB
CARBON STEEL
95
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
ARIZONA PUBLIC SERVICE: FOUR CORNERS 1 (CONT.)
SHELL SPECIFIC MATERIAL AISI 1110
SHELL MATERIAL TRADE NAME/COMMON TYPE N/A
S02 REMOVAL EFFICIENCY - X 67.5
** REHEATER
GENERIC TYPE , NONE
SPECIFIC TYPE N/A
TRADE NAME/COMMON TYPE N/A
** FANS
GeSIGN CENTRIFUGAL
fERVICE WET
** SCLIDS CONCENTRATING/DEWATERING
CEVICE THICKENER
NUMBER 1
** FGD SPARE CAPACITY INDICES
ABSORBER - X .0
** FED SPARE COMPONENT INDICES
ABSORBER .0
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPER4BILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
11/79 SYSTEM 720
12/79 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
INITIAL OPERATIONS STARTED IN NOVEMBER 1979.
1/80 SYSTEM 744
2/80 SYSTEM 696
3/80 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT IS PRESENTLY IN THE SHAKEDOWN/DEBUGGING PHASE OF OPERATION.
4/80 SYSTEM 720
5/80 SYSTEM 744
6/80 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
ALTHOUGH THE FGD SYSTEM PERFORMANCE DATA ARE BEING LOGGED, THE UTILITY
REPORTED THAT IT IS UNAVAILABLE FOS RELEASE AT THIS TIME.
7/80 SYSTEM 744
8/80 SYSTEM 744
9/80 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE THIRD QUARTER UPDATE INFORMATION IS NOT YET AVAILABLE.
10/80 SYSTEM 744
11/80 SYSTEM 720
96
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
ARIZONA PUBLIC SERVICE: FOUR CORNERS 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
12/80 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
PERFORMANCE DATA FOR THIS UNIT IS NOT AVAILABLE FOR PUBLICATION AT THIS
TIME.
97
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WQ/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
I VERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
**# PARTICLE CONTROL
** PARTICLE SCRUBBER
NUMBER
C-ENERIC TYPE
SUPPLIER
S02 REMOVAL EFFICENCY - 7.
*** FCD S.STEM
** GENERAL DATA
SAL1.ABLE PRODUCT/THROWAWAY PRODUCT
502 REMOVAL MODE
PROC.ESS TYPE
SYSTEM SUPPLIER
A-E FIRM
DHVELOPMENT LEVEL
NcW/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
UJIT DESIGN S02 REMOVAL EFFICIENCY - 7.
CURRENT STATUS
INITIAL START-UP
»» DESIGN AND OPERATING PARAMETERS
** ABSORBER
NJMBER
GENERIC TYPE
SPECIFIC TYPE
SHELL GENERIC MATERIAL
ARIZONA PUBLIC SERVICE
FOUR CORNERS
2
FARMINGTON
NEW MEXICO
C
******
258.
******
2089
175
175
175
RILEY STOKER
PULVERIZED COAL
BASE
(****** LB/MMBTU)
( .600 LB/MMBTU)
(****** LB/MMBTU)
( 814000 ACFM)
( 340 F)
(**** FT)
(***** FT)
( 8600 BTU/LB)
8300-9000
384.13
171.1
******
******
*******
COAL
SUBBITUMINOUS
20004.
22.00
******
12.30
******
.75
******
.07
******
VENTURI TOWER
CHEMICO
30.0
THROWAWAY PRODUCT
WET SCRUBBING
LIME/ALKALINE FLYASH
CHEMICO DIVISION, ENVIROTECH
IN-HOUSE
FULL SCALE
RETROFIT
7. 99.00
80.00
1
11/79
VENTURI TOWER
VARIABLE-THROAT/TOP-ENTRY PLUMB BOB
CARBON STEEL
98
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
ARIZONA PUBLIC SERVICE: FOUR CORKERS Z (CONT.)
SHELL SPECIFIC MATERIAL AISI 1110
SHELL MATERIAL TRADE NAME/COMMON TYPE N/A
S02 REMOVAL EFFICIENCY - X 67.5
** REHEATER
GENERIC TYPE NONE
SPECIFIC TYPE N/A
TRADE NAME/COMMON TYPE N/A
** FANS
DESIGN CENTRIFUGAL
SERVICE WET
** SOLIDS CONCENTRATING/DEWATERING
DEVICE THICKENER
NUMBER 1
** FGD SPARE CAPACITY INDICES
ABSORBER - X .0
** FGD SPARE COMPONENT INDICES
ABSORBER .0
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
11/79 SYSTEM 720
12/79 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
INITIAL OPERATIONS STARTED IN NOVEMBER 1979.
1/80 SYSTEM 744
2/80 SYSTEM 696
3/80 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT IS PRESENTLY IN THE SHAKEDOWN/DEBUGGING PHASE OF OPERATION.
4/80 SYSTEM 720
5/80 SYSTEM 744
6/80 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
ALTHOUGH THE FGD SYSTEM PERFORMANCE DATA ARE BEING LOGGED, THE UTILITY
REPORTED THAT IT IS UNAVAILABLE FOR RELEASE AT THIS TIME.
7/80 SYSTEM 744
8/80 SYSTEM 744
9/80 SYSTEM 720
*••• PROBLEMS/SOLUTIONS/CO1MENTS
THE THIRD QUARTER UPDATE INFORMATION IS NOT YET AVAILABLE.
10/80 SYSTEM 744
11/80 SYSTEM 720
99
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
ARIZON/ PUBLIC SERVICE: FOUR CORNERS 2 (CONT.)
PERFORMANCE DATA
PERIOD ,-IODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
______ —-1_ —_ _ ________ — -. — _ ___________ ..__._______ ___ — _, — — ___— ____ — _____ — — — — — __«___ —-, — — — _____«.
12/80 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
PERFORMANCE DATA FOR THIS UNIT IS NOT AVAILABLE FOR PUBLICATION AT THIS
TIME.
100
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANf NAME
PLANT NAME
UNIT NJMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PUNT GENERATING CAPACITY - MW
GROSS LNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BCILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** PARTICLE SCRUBBER
NUMBER
GENERIC TYPE
SUPPLIER
S02 REMOVAL EFFICENCY - 7.
*** FGD SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
UNIT DESIGN S02 REMOVAL EFFICIENCY - 7.
CURRENT STATUS
INITIAL START-UP
** DESIGN AND OPERATING PARAMETERS
** ABSORBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
SHELL GENERIC MATERIAL
ARIZONA PUBLIC SERVICE
FOUR CORNERS
3
FARMINGTON
NEW MEXICO
C
******
258.
******
2089
229
229
*****
229
FOSTER WHEELER
PULVERIZED COAL
BASE
486.06
171.1
******
******
*******
(****** LB/MMBTU)
t .600 LB/MMBTU)
(****** LB/MMBTU)
(1030000 ACFM)
( 340 F)
(**** FT)
(***** FT)
COAL
SUBBITUMINOUS
20004.
22.00
******
12.30
******
.75
( 8600 BTU/LB)
8300-9000
.07
******
VENTURI TOWER
CHEMICO
30.0
THROWAWAY PRODUCT
WET SCRUBBING
LIME/ALKALINE FLYASH
CHEMICO DIVISION, ENVIROTECH
IN-HOUSE
FULL SCALE
RETROFIT
7. 99.00
80.00
1
11/79
VENTURI TOWER
VARIABLE-THROAT/TOP-ENTRY PLUMB BOB
CARBON STEEL
101
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
ARIZONA PUBLIC SERVICE: FOUR CORNERS 3 (CONT.)
S4ELI SPECIFIC MATERIAL AISI 1110
SHELL MATERIAL TRADE NAME/COMMON TYPE N/A
S02 REMOVAL EFFICIENCY - >. 67.5
** REME/.TER
GENERIC TYPE NONE
SPECIFIC TYPE N/A
TKACE NAME/COMMON TYPE N/A
** FANS
DHSIGN CENTRIFUGAL
SERVICE WET
** SO'.IDS CONCENTRATING/DEWATERING
DEVICE THICKENER
NUMBER 1
** FG>) SPARE CAPACITY INDICES
ABSORBER - X .0
»* FGiJ SPARE COMPONENT INDICES
ABSORBER .0
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
11/79 SYSTEM 720
12/79 3YSTEM 744
«* PROBLEMS/SOLUTIONS/COMMENTS
INITIAL OPERATIONS STARTED IN NOVEMBER 1979.
1/80 SYSTEM 744
2/80 SYSTEM 696
3/80 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT IS PRESENTLY IN THE SHAKEDOWN/DEBUGGING PHASE OF OPERATION.
4/80 SYSTEM 720
5/80 SYSTEM 744
6/80 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
ALTHOUGH THE FGD SYSTEM PERFORMANCE DATA ARE BEING LOGGED, THE UTILITY
REPORTED THAT IT IS UNAVAILABLE FOR RELEASE AT THIS TIME.
7/80 SYSTEM 744
8/80 SYSTEM 744
9/80 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
NO INFORMATION WAS AVAILABLE FOR THE THIRD QUARTER 1980.
10/80 SYSTEM 744
11/80 SYSTEM 720
102
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
ARIZONA PUBLIC SERVICE: FOUR CORNERS 3 tCONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
502 PART. HOURS HOURS HOURS FACTOR
12/80 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
PERFORMANCE DATA FOR THIS UNIT IS NOT AVAILABLE FOR PUBLICATION AT THIS
TIME.
103
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PUNT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
SOS EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** UN.IT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BDILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FU:;L DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/IB
AVERAGE ASH CONTENT - 7.
Rn'JG'5 ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7.
IW'NGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
R/NGE SULFUR CONTENT - 7.
A^ ERAGE CHLORIDE CONTENT - 7.
R/NGE CHLORIDE CONTENT - 7.
*** PAPTICLE CONTROL
** ESP
NUMBER
TYPE
SUPPLIER
INLET FLUE GAS CAPACITY - CU.M/S
INLET FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
PARTICLE REMOVAL EFFICENCY - 7.
** PARTICLE SCRUBBER
GENERIC TYPE
SPECIFIC TYPE
*** FGD SYSTEM
** GENKRAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
SO,': REMOVAL MODE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
UNIT DESIGN S02 REMOVAL EFFICIENCY - 7.
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
BASIN ELECTRIC POWER COOP
LARAMIE RIVER
1
WHEATLAND
WYOMING
86.
******
1500
570
550
550
570
BABCOCK & WILCOX
PULVERIZED COAL
BASE
( .100 LB/MMBTU)
( .200 LB/MMBTU)
(*-***** LB/MMBTU)
(2800000 ACFM)
( 133 F)
( 600 FT)
( 28.6 FT)
( 8139 BTU/LB)
******
1321.32
56.1
183.
CONCRETE
8.7
COAL
SUBBITUMINOUS
18931.
7.89
28.92
******
.81
.15-.81
.0*
COLD SIDE
BABCOCK X WILCOX
1085.4 (2300000 ACFM)
141.1 ( 286 F)
.8 ( 3. IN-H20)
99.6
NONE
N/A
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
RESEARCH-COTTRELL
BURNS & MCDONNELL
FULL SCALE
NEW
•/. 99.60
90.00
1
7/80
7/80
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
BASIN ELECTRIC POWER COOP: LARAMIE RIVER 1 (CONT.)
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
** ABSORBER
NUtBER
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
GAS CONTACTING DEVICE TYPE
DISTANCE BETWEEN GAS CONTACTING ZONES - CM
L/G RATIO - L/CU.M
SUPERFICAL GAS VELOCITY - M/SEC
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
SOS REMOVAL EFFICIENCY - X
PARTICLE REMOVAL EFFICENCY - 7.
** MIST ELIMINATOR
FRE-MIST ELIMINATOR/MIST ELIMINATOR
GENERIC TYPE
SPECIFIC TYPE
T^ADE NAME/COMMON TYPE
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES PER STAGE
** REHEATER
GENERIC TYPE
S°ECIFIC TYPE
TRADE NAME/COMMON TYPE
** FA iS
N'JMBtR
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
CONSTRUCTION MATERIAL GENERIC TYPE
** REwGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
NUMBER
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
PRODUCT QUALITY - 7. SOLIDS
** SO'.IDS CONCENTRATING/DEWATERING
OHVICE
NUMBER
NUMBER OF SPARES
DIMENSIONS - FT
SHELL GENERIC MATERIAL TYPE
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
*** SALEABLE BYPRODUCTS
1/77
COMBINATION
SPRAY/PACKED
RESEARCH-COTTRELL
30 X 30 X 88
STAINLESS STEEL,HIGH ALLOY
AUSTENITIC
TIPE 316L,UDDEHOLM 904L
NONE
N/A
N/A
POLYPROPYLENE HONEYCOMB TYPE
61.0 ( 34.0IN)
8.0 ( 60.0 GAL/1000 ACF)
3.0 ( 10.0 FT/S)
1085.37 (E300000 ACFM)
1*1.1 ( 286 F)
90.0
.0
MIST ELIMINATOR
IMPINGEMENT
BAFFLE
CHEVRON VANE
VERTICAL
1
1
NONE
N/A
N/A
CENTRIFUGAL
BABCOCK 4 HILCOX
UNIT
FORCED DRA:T
DRY
CARBON STEEL
LIMESTONE GRINDING
BALL MILL
2
13.6 t 15 TPH)
30.0
THICKENER
3
1
110 (DIA) X 10 (DEPTH)
CONCRETE
CENTRIFUGE
1
35X SOLIDS
607. SOLIDS
105
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
BASIN ELECTRIC POWER COOP: LARAMIE RIVER 1 (CONT.)
#** SLUDGE
** TREATMENT
METHOD
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE SERVICE LIFE - YRS
** PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS
PROCESS CONTROL MANNER
** WATER BALANCE
WATER LOOP TYPE
MAKEUP WATER ADDITION - LITERS/S
** FGD SPARE CAPACITY INDICES
ABSORBER - X
** FGD SPARE COMPONENT INDICES
ABSORBER
FORCED OXIDATION
FINAL
LANDFILL
ON SITE
CONVEYOR BELT
35
PH, SOLIDS, S02 INLET, ACFM, S02 OUTLET
AUTOMATIC
CLOSED
16.9
25.0
1.0
( 269 GPM)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
7/80 SYSTEM
744
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT BEGAN INITIAL AND COMMERCIAL OPERATIONS ON JULY 1, 1980.
PROBLEMS WERE REPORTED DURING STARTUP.
NO MAJOR
8/80 SYSTEM
9/80 SYSTEM
720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT IS STILL IN THE STARTUP PHASE OF OPERATIONS.
ARE CURRENTLY AVAILABLE.
NO PERFORMANCE DATA
10/80 A
B
C
D
E
SYSTEM
100.0
100.0
100.0
21.5
100.0
100.0
99.7
99.6
99.7
22.6
81.*
100.0
100.0
100.0
100.0
100.0
100.0
100.0
95.0
94.9
95.0
21.5
77.5
96.0
92.00 99.70 744 709
715 85.8
*»• PROBLEMS/SOLUTIONS/CO 1MENTS
DURING OCTOBER MODULE D WAS DOWN FOR MAINTENANCE ON WELDS IN THE QUENCHER
SECTION DUE TO CORROSION OF THE UDDEHOLM 904L. THE OUTAGE LASTED 584 HOURS.
11/80 A
B
C
D
E
SYSTEM
100.0
100.0
100.0
1.9
100.0
100.0
57.8
96.2
72.5
2.3
98.3
98.2
100.0
100.0
100.0
100.0
100.0
100.0
46.4
77.2
58.2
1.9
78.9
78.9
720 578
568 67.1
106
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
BASIN E.ECTRIC POWER COOP: LARAMIE RIVER 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
SOZ PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
DURING NOVEMBER THE BOILER MAS OUT OF SERVICE APPROXIMATELY 120 HOURS DUE
TO REPAIRS.
DURING THE MONTH MODULE D WAS OFF LINE 30 DAYS FOR REPAIRS.
12/80 A
B
C
D
E
SYSTEM
19.6
100.0
100.0
75.7
100.0
100.0
21.1
94.4
96.7
81.2
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
19.6
87.9
90.0
75.7
93.0
93.0
693
692 87.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING DECEMBER MODULES A AND D WERE OUT OF SERVICE FOR MAINTENANCE ON
THE WELDS IN THE QUENCHER SECTION DUE TO CORROSION OF UDDEHOLM 904L.
107
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANv NAME
PLANT KAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - N6/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLA,rr GENERATING CAPACITY - MW
GROSS U.^IT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** ESP
NUMBER
TYPE
SUPPLIER
INLET FLUE GAS CAPACITY - CU.M/S
INLET FLUE GAS TEMPERATURE - C
PARTICLE REMOVAL EFFICENCY - 7.
** PARTICLE SCRUBBER
GENERIC TYPE
SPECIFIC TYPE
*** FGD SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
t.-JIT DESIGN 502 REMOVAL EFFICIENCY - 7.
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
BIG RIVERS ELECTRIC
GREEN
1
SEBREE
KENTUCKY
B
516.
******
484
£42
200
*****
242
BABCOCK & WILCOX
PULVERIZED COAL
BASE
(****** LB/MMBTU)
( 1.200 LB/MMBTU)
(****** LB/MMBTU)
(1000000 ACFM)
( 300 F)
( 350 FT)
(***** FT)
( 9750 BTU/LB)
9000-10500
471.90
148.9
107.
CONCRETE
*******
COAL
BITUMINOUS
22678.
20.00
15-25
11.00
8-14
3.75
3.4-4.0
.05
COLD SIDE
AMERICAN AIR FILTER
471.9 (1000000 ACFM)
148.9 ( 300 F)
99.6
NONE
N/A
THROWAWAY PRODUCT
WET SCRUBBING
LIME
MG PROMOTED
AMERICAN AIR FILTER
BURNS & ROE
FULL SCALE
NEW
7. 99.00
90.00
1
12/79
12/79
108
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
BIG RIVERS ELECTRIC: GREEN i (LOUT.)
C3NTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
** AB.50RBER
NUMBER
G£NERIC TYPE
SPECIFIC TYPE
SJPPLIER
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
L/G RATIO - L/CU.M
II'LET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
SC2 REMOVAL EFFICIENCY - 7.
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NIMBER PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
TR1DE NAME/COMMON TYPE
** REIIEATER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
TEMPERATURE INCREASE - C
** FANS
NUMBER
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
CONSTRUCTION MATERIAL GENERIC TYPE
** FANS
NUMBER
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
CONSTRUCTION MATERIAL GENERIC TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
MANUFACTURER
NUMBER
** TAHKS
SERVICE
10/76
SPRAY TOWER
OPEN COUNTERCURRENT SPRAY
AMERICAN AIR FILTER
CARBON STEEL
AISI 1110
N/A
INORGANIC
HYDRAULICALLY-BONDED CEMENT
CALCIUM ALUMINATE CEMENT
6.0 ( 45.0 GAL/1000 ACF)
471.90 (1000000 ACFM)
148.9 ( 300 F)
90.0
MIST ELIMINATOR
2
IMPINGEMENT
BAFFLE
CHEVRON VANE
INDIRECT HOT AIR
EXTERNAL HEAT EXCHANGER
STEAM TUBE BUNDLES
-3.9 ( 25 F)
CENTRIFUGAL
WESTINGHOUSE ELECTRIC CORP.
UNIT
FORCED DRAFT
DRY
CARBON STEEL
CENTRIFUGAL
WESTINGHOUSE ELECTRIC CORP.
UNIT
INDUCED DR&FT
DRY
CARBON STEEL
REHEATER
CARBON STEEL
GUNITE
LIME SLAKING
SLAKER
PEHNHALT
4
NUMBER
THICKENER OVERFLOW
REACTION
SCREEN
*#**
2
2
109
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
BIG RIVERS ELECTRIC: GREEN i (CONT.)
** PLMPS
SERVICE
SLURRY RECIRCULATION
SLURRY BLEED
THICKENER UNDERFLOW
VACI'UM FILTER
THICKENER RETURN
SLUf.'RY
** SO IICS CONCENTRATING/DEWATr.RING
DEVICE
N'JHBER
** SO .IDS CONCENTRATING/DEWATERING
DiVICE
NUMBER
NUMBER OF SPARES
*** SALEABLE BYPRODUCTS
QJALITY - X
*** SLJDGE
** TREATMENT
METHOD
** DISPOSAL
NATURE
T>PE
LOCATION
SITE TRANSPORTATION METHOD
** WATER BALANCE
WATER LOOP TYPE
** FGD SPARE CAPACITY INDICES
ABSORBER - X
** FGP SPARE COMPONENT INDICES
ABSORBER
NUMBER
3
4
4
3
****
**#*
VACUUM FILTER
3
THICKENER
Z
0
25.0
POZ-0-TEC
FINAL
LANDFILL
ON SITE
TRUCK
CLOSED
30.0
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
12/79 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
1/80 SYSTEM
2/80 SYSTEM
3/80 SYSTEM
THE FGD OPERATION COMMENCED IN MID-DECEMBER 1979. THE UNIT OPERATED IN A
STARTUP PHASE DURING THIS PERIOD.
696
744
110
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
BIG RIVERS ELECTRIC: GREEN i CCONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
NO INFORMATION WAS AVAILABLE FOR THE FIRST QUARTER, 1980.
4/80
A
B
SYSTEM
65.0
65.0
65.0
56.0
56.0
56.0
78.8
79.0
79.0
45.0
45.0
45.0
720 576
324
** PROBLEMS/SOLUTIONS/COMMENTS
THE FALLOWING FIVE OUTAGES OCCURRED IN APRIL AND ACCOUNTED FOR THE LOW
AVAILABILITY OF THE FGD SYSTEM.
1. LOW ADDITIVE IN TANK
2. INSTRUMENT TROUBLE
3. WATER IN THE PANEL
4. LOW ON LIME IN THE HOLDING TANKS
5. THE ESPS TRIPPED
5/80
A
B
SYSTEM
73.7
73.7
73.7
76.1
76.0
76.1
79.0
78.9
79.0
73.7
73.5
73.7
744 720
548
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MAY THE FGD SYSTEM WAS OFF LINE FOR APPROXIMATELY 548 HOURS DUE
TO THE FOLLOWING PROBLEMS.
1. SULFUR OXIDES TOO HIGH
2. LOW LEVEL IN ADDITIVE TANK
3. INSTRUMENT TROUBLE
4. SCHEDULED MAINTENANCE OUTAGE
5. SOLIDS ON CARRY OVER
6. SOLID HASTE PROBLEM
7. UNIT TRIPPED
8. CONSTRUCTION WORK
6/80 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS NOT AVAILABLE FOR THE MONTH OF JUNE.
7/80 'SYSTEM 744
8/80 'SYSTEM 744
9/80 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
NO INFORMATION WAS AVAILABLE FOR THE THIRD QUARTER 1980.
10/80 SYSTEM 744
11/80 SYSTEM 720
12/80 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION FOR THE FOURTH QUARTER 1980 IS NOT AVAILABLE AT THIS TIME.
Ill
-------
EPA UTILITY FGO SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - N6/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MM
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
EOILER SERVICE LOAD
D£SIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/S
R\NGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANG: ASH CONTENT - 7.
AVEFAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PAFTICLE CONTROL
** ESP
NUMBER
TVPE
SUPPLIER
INLET FLUE GAS CAPACITY - CU.M/S
IMLET FLUE GAS TEMPERATURE - C
P/.RTICLE REMOVAL EFFICENCY - 7.
*# PARTICLE SCRUBBER
GENERIC TYPE
SPECIFIC TYPE
*** FGD SYSTEM
*» GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
S0> REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-H FIRM
DEVELOPMENT LEVEL
NEN/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
UNIT DESIGN S02 REMOVAL EFFICIENCY - 7.
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
BIG RIVERS ELECTRIC
GREEN
2
SEBREE
KENTUCKY
B
****** (****** LB/MMBTU)
516. ( 1.200 LB/MMBTU)
****** (****** LB/MMBTU)
434
242
200
*****
242
BABCOCK & WILCOX
PULVERIZED COAL
BASE
(1000000 ACFM)
( 300 F)
( 350 FT)
(***** FT)
( 9750 BTU/LB)
9000-10500
471.90
148.9
107.
CONCRETE
*******
COAL
BITUMINOUS
22678.
20.00
15-25
11.00
8-14
3.75
3.4-4.0
.05
******
COLD SIDE
AMERICAN AIR FILTER
471.9 (1000000 ACFM)
148.9 ( 300 F)
99.6
NONE
N/A
THROHAWAY PRODUCT
WET SCRUBBING
LIME
MG PROMOTED
AMERICAN AIR FILTER
BURNS 8 ROE
FULL SCALE
NEW
7. 99.00
90.00
1
12/80
11/80
112
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
BIG RIVERS ELECTRIC: GREEN 2 (CONT.J
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
** ABSORBER
HUMBER
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
L/G RATIO - L/CU.M
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
S02 REMOVAL EFFICIENCY - X
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
** REHEATER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
TEMPERATURE INCREASE - C
** FA^iS
NjriBER
DcSIGN
SUPPLIER
F'JNCTION
APPLICATION
CONSTRUCTION MATERIAL GENERIC TYPE
** FANS
NUMBER
D'iSIGN
SUPPLIER
FUNCTION
APPLICATION
CONSTRUCTION MATERIAL GENERIC TYPE
** DUCTW3RK
LOCATION
I.HELL GENERIC MATERIAL r»PE
LINER GENERIC MATERIAL TYPE
#* RE/.GENT PREPARATION EQUIPMENT
FlNCTION
DIVICE
MANUFACTURER
NUMBER
** TANKS
SLRVICE
5/77
SPRAY TOWER
OPEN COUNTERCURRENT SPRAY
AMERICAN AIR FILTER
CARBON STEEL
AISI 1110
N/A
INORGANIC
HYDRAULICALLY-BONDED CEMENT
CALCIUM ALUMINATE CEMENT
6.0 ( 45.0 GAL/1000 ACF)
471.90 (1000000 ACFM)
148.9 ( 300 F)
90.0
MIST ELIMINATOR
2
IMPINGEMENT
BAFFLE
CHEVRON VANE
INDIRECT HOT AIR
EXTERNAL HEAT' EXCHANGER
STEAM TUBE BUNDLES
-3.9 ( 25 F)
CENTRIFUGAL
WESTINGHOUSE ELECTRIC CORP.
UNIT
FORCED DRAFT
CARBON STEEL
CENTRIFUGAL
WESTINGHOUSF ELECTRIC CORP.
UNIT
INDUCED DRAFT
CARBON STEEL
REHEATER
CARBON STEEL
GUNITE
LIME SLAKING
SLAKER
PENNWALT
NUMBER
THICKENER OVERFLOW
RLACTION
SCREEN
****
2
2
113
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
BIS RIVERS ELECTRIC: GREEN z tconr.)
** PUMPS
SERVICE
SLURRY RECIRCULATION
SLURRY BLEED
THICKENER UNDERFLOW
VACUUM FILTER
SLURRY
THICKENER RETURN
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
*** SALEABLE BYPRODUCTS
QUALITY - X
*** SLUDGE
** TREATMENT
METHOD
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
** WATER BALANCE
WATER LOOP TYPE
NUMBER
3
3
##**
VACUUM FILTER
3
THICKENER
2
25.0
POZ-0-TEC
FINAL
LANDFILL
ON SITE
TRUCK
CLOSED
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
11/80 SYSTEM
12/80 SYSTEM
720
** PROBLEMS/SOLUTIONS/COMMENTS
OPERATION OF THE FGD SYSTEM COMMENCED IN NOVEMBER 1980. THE SYSTEM IS IN
THE STARTUP PHASE OF OPERATION.
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT N/J1E
UNIT NU1BER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - MM
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - 7.
AVERAGE • SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** ESP
NUMBER
TYPE
SUPPLIER
INLET FLUE GAS CAPACITY - CU.M/S
INLET FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
PARTICLE REMOVAL EFFICENCY - 7.
** PARTICLE SCRUBBER
GENERIC TYPE
SPECIFIC TYPE
*** FGD SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
S32 REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
SCSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
U,«T DESIGN S02 REMOVAL EFFICIENCY - 7.
CJRRENT STATUS
COMMERCIAL START-UP
INITTftL START-UP
CENTRAL ILLINOIS LIGHT
DUCK CREEK
1
CANTON
ILLINOIS
B
43.
516.
( .100 LB/MMBTU)
( 1.200 LB/MMBTU)
( ****** LB/MMBTU )
778
416
378
390
416
RILEY STOKER
PULVERIZED COAL
CYCLING
717.29
135.0
152.
CONCRETE
5.8
(1520000 ACFM)
( 275 F)
( 500 FT)
( 19.0 FT)
COAL
BITUMINOUS
24181. ( 10396 BTU/LB)
******
9.77
15.43
23.
3.66
2.4-4.0
.06
.1
COLD SIDE
POLLUTION CONTROL-WALTHER
358.6 ( 760000 ACFM)
135.0 ( 275 F)
.0 (0. IN-H20)
99.8
NONE
N/A
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
NONE
ENVIRONEERING, RILEY STOKER
GILBERT/COMMONWEALTH ASSOCIATES
FULL SCALE
NEW
85.00
1
8/78
7/76
115
-------
EPA ITILITY F6D SURVEY: OCTOBER - DECEMBER 1980
CENTRAL ILLINOIS LIGHT: DUCK CREEK 1 (CONT.)
CONTRACT AWARDED 8/73
** DESIGN AND OPERATING PARAMETERS
** ABSORBER
NUMBER
NUMBER OF SPARES
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
SUPPLIER
DIMENSIONS - FT
SH = LL GENERIC MATERIAL
SH£LL SPECIFIC MATERIAL
SHZLL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LIUER SPECIFIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
GAS CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
DISTANCE BETWEEN GAS CONTACTING ZONES
LIQUID RECIRCULATION RATE - LITER/S
L/G RATIO - L/CU.M
GAS-SIDE PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/SEC
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
S02 REMOVAL EFFICIENCY - 7.
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES PER STAGE
FREEBOARD DISTANCE - M
DISTANCE BETWEEN STAGES - CM
DISTANCE BETWEEN VANES - CM
VANE ANGLES - DEGREES
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/S
CONSTRUCTION MATERIAL GENERIC TYPE
WASH WATER SOURCE
WASH FREQUENCY
WASH RATE - L/S
** REHEATER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
** FANS
NUMBER
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
4
0
PACKED TOWER
ROD DECK
VENTRI-SORBER
ENVIRONEERING, RILEY STOKER
40 X 5 X 40
CARBON STEEL
AISI 1110
N/A
HIGH ALLOY
NICKEL BASE/CHROMIUM-IRON-COPPER MOLYBDENUM
HASTELLOY G
ROD DECKS
7
CM 2.5
945.
6.7
2.0
4.0
167.01
135.0
85.0
t l.OIN)
(15000 GPM)
( 50.0 GAL/1000 ACF)
(8.0 IN-H20)
( 13.0 FT/S)
( 353900 ACFM)
( 275 F)
MIST ELIMINATOR
4
IMPINGEMENT
BAFFLE
CHEVRON VANE
VERTICAL
2
3
3.66
2.03
6.3
90
.2
4.0
HASTALLOY G
FRESH AND POND
CONTINUOUS
102.8
(12.0 FT)
( .8 IN)
( 2.50 IN)
( 1.0 IN-H20)
( 13.0 FT/S)
OVERFLOW
( 1630 GAL/MIN)
0
NONE
N/A
N/A
CENTRIFUGAL
BUFFALO FORGE
UNIT
INDUCED DRAFT
DRY
205.28
148.9
CARBON STEEL
( 435000 ACFM)
( 300 F)
SCRUBBER INLET
CARBON STEEL
NONE
116
-------
CENTRAL ILLINOIS LIGHT: DUCK CR'EK 1 (CONT.)
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
** DUCTWORK
LOCATION
•SHELL GENERIC MATERIAL TYPE
•.INER GENERIC MATERIAL TYPE
** REvGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
MANUFACTURER
N'JMBER
NJH3ER OF SPARES
FJLL LOAD DRY FEED CAPACITY - M.TONS/HR
P70DUCT QUALITY - X SOLIDS
** TA-1KS
SERVICE
RECYCLE
WASTE COLLECTION
L7MESTONE SLURRY
M.E. WASH
** PUt" PS
SERVICE
POMD RETURN
WASTE SLURRY
MIST ELIMINATOR WASH
ABSORBER RECIRCULATION
SLURRY TRANSFER
*** SLUDGE
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE CAPACITY - CU.M
** PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS
PROCESS CONTROL MANNER
PROCESS CHEMISTRY MODE
** WATER BALANCE
WATER LOOP TYPE
MAKEUP HATER ADDITION - LITERS/S
** FGD SPARE CAPACITY INDICES
ABSORBER - X
** FGD SPARE COMPONENT INDICES
ABSORBER
SCRUBBER OUTLET TO STACK
HASTALLOY G
NONE
LIMESTONE GRINDING
BALL MILL
KENNEDY VAN SAUN
Z
1
36.3 ( 40 TPH)
65.0
NUMBER
4
1
1
4
NUMBER
3
Z
8
12
2
FINAL
LINED POND
ON SITE
PUMPED
125969
( 103.0 ACRE-FT)
PH, SOLIDS CONTENT OF SLURRY, LEVEL CONTROL
AUTOMATIC
FEEDBACK
CLOSED
37.8
.0
.0
( 600 GPM)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
7/76 SYSTEM
1.1
744
117
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
CENTRAL ILLINOIS LIGHT: DUCK CREEK 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
CONSTRUCTION OF DUCK CREEK 1 BEGAN IN EARLY 1972 AND WAS VIRTUALLY
COMPLETED BY SPRING 1976. COMMERCIAL OPERATION WAS INITIATED IN JUNE 1976
WITH THE ESP MODULES IN THE GAS PVTH. THE FIRST MODULE OF THE 4-MODULE
SCRUBBING SYSTEM WAS INSTALLED BY JUNE 1976 AND START-UP FOR SHAKEDOWN/OE-
BUGGIN3 PURPOSES OCCURRED IN JULY 1976. THE REMAINING THREE MODULES WILL
BE INSTALLED LATER WITH A 4-MODULE START-UP SCHEDULED FOR THE SUMMER
OF 1978.
INITIAL OPERATION OF THE FIRST SCRUBBER MODULE FOR SHAKEDOWN AND DEBUGGING
PURPOSES OCCURRED DURING THE MONTH. LIMITED SERVICE TIME RESULTED FROM
PROBLEMS WITH BAD WELDS, FAULTY PIPE HANGERS, AND ABSORBER LEAKS.
8/76 SYSTEM 2.4 744 18
** PROBLEHS/SOLUTIONS/COMMENTS
LIMITED OPERATIONS CONTINUED THROUGHOUT AUGUST BECAUSE OF THE START-UP AND
CONSTRUCTION PROBLEMS MENTIONED FOR JULY, 1976. THE MODULE WAS TAKEN OUT
OF THE GAS PATH AT THIS POINT TO CONCENTRATE ON RESOLVING THESE PROBLEM
AREAS.
9/76 SYSTEM 50.0 744 360
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE RESTART OCCURRED ON SEPTEMBER 9. OPERATION CONTINUED THROUGHOUT THE
REMAINDER OF THE MONTH ON AN INTERMITTANT BASIS. MAJOR PROBLEMS INCLUDED
PIPE BREAKING, PUMP LINER FAILURES, PLUGGING AND SCALING OF MIST
ELIMINATORS, AND SOME BOILER-RELATED PROBLEMS. THE MODULE REMAINED IN SER-
VICE FOR APPROXIMATELY 15 DAYS OF NON-CONTINUOUS OPERATION. THE ESP
MODULES HAVE REMAINED IN SERVICE WITHOUT THE OCCURRENCE OF ANY MAJOR
PROBLEMS.
10/76 SYSTEM 51.8 744 385
** PROBLEMS/SOLUTIONS/COMMENTS
TOTAL OPERATION TIME DURING THE MONTH WAS APPROXIMATELY 16 DAYS (NON-
CONTINUOUS). THE MAJOR PROBLEM AREA WAS THE CONTINUATION OF MASSIVE SCALE
DEVELOPMENT ON THE MIST ELIMINATORS, RESULTING IN PLUGGING OF THE PIPING
AND NOZZLES TO THE COMPONENTS SPRAY SYSTEM.
11/76 SYSTEM 3.3 720 24
** PROBLEMS/SOLUTIONS/COMMENTS
SPORADIC OPERATION RESULTED FROM CONTINUED SCALING PROBLEMS IN THE MIST
ELIMINATOR SECTION. RILEY AND CILCO INITIATED MODIFICATIONS TO THE DESIGN
OF THE MODULE. SPECIFICALLY, A ROD DECK HAS CHANGED IN THE ABSORBER,
PRESSURE DROP ACROSS THE ABSORBER WAS INCREASED, PIPING AND PUMP LINER
MATERIALS WERE MODIFIED/REPLACED, AND A FRESH WATER WASH SYSTEM WAS IN-
STALLED FOR THE MIST ELIMINATOR.
12/76 SYSTEM .0 744 0
** PROBLEMS/SOLUTIONS/COMMENTS
THE MODULE REMAINED OUT OF SERVICE THE ENTIRE MONTH. DURING THIS TIME,
THE BOILER FIRED LOW SULFUR C0.6X) KENTUCKY COAL.
1/77 SYSTEM .0 744 0 0 .0
118
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEIVER 1980
CENTRAL ILLINOIS LIGHT: DUCK CREEK 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
2/77 SYSTEM .0 672 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
THE NO. 1 UNIT WAS DOWN THROUGHOUT THE ENTIRE JANUARY-FEBRUARY PERIOD FOR
TURBINE/BOILER OVERHAUL. DURING THE UNIT OUTAGE, A NUMBER OF MODIFICA-
TIONS WERE MADE TO THE SCRUBBER.
3/77 SYSTEM 47.0 744 350
** PROBLEMS/SOLUTIONS/COMMENTS
THE NO. 1 UNIT HAS RETURNED TO SERVICE IN MID-MARCH. THE SCRUBBER WAS
PLACED IN SERVICE TO TEST THE MODIFICATIONS MADE DURING THE PRECEDING OUT-
AGE. THESE MODIFICATIONS INCLUDED;
THE MIST ELIMINATOR SPRAY WASH SYSTEM PIPING WAS CHANGED FROM PVC TO
FRP MATERIALS. ALSO, AN ADDITIONAL SPRAY HEADER WAS ADDED.
THE SLURRY CIRCULATION SYSTEM WAS REVAMPED.
NEOPRENE PUMP LINERS HAVE REPLACED THE ORIGINAL RUBBER LINERS.
FLUSH/DRAIN SYSTEMS HAVE BEEN INCLUDED TO MINIMIZE SOLIDS BUILD UP.
PIPING VALVES MOVED CLOSER TO THE RECYCLE TANK.
SLURRY STORAGE TANKS EQUIPPED WITH FLUSH/DRAIN SYSTEMS.
ADDITIONAL MIXERS ADDED FOR GREATER AGITATION TO PROMOTE PROCESS
CHEMISTRY.
DURING THE LAST PART OF MARCH THE MODULE REMAINED IN SERVICE ON A CONTINUAL
BASIS WITH THE EXCEPTION OF A FEW MINOR BOILER OUTAGES. CILCO INTENDS TO
CONTINUE EXPERIMENTAL OPERATIONS THROUGHOUT THE APRIL-MAY PERIOD, TESTING
THE MECHANICAL MODIFICATIONS AND THE AUTOMATIC CONTROL LOOPS (SYSTEM
CHEMISTRY WILL BE CONTROLLED BY INLET/OUTLET S02 LOADING, SOLUTION PH,
SOLUTION SOLIDS. OPERATION UP TO THIS POINT HAS PROCEEDED IN A MANUAL
CONTROL MODE). CONTINUED OPERATION BEYOND THIS TIME FRAME WILL DEPEND
UPON THE SUCCESS OF EXPERIMENTAL OPERATIONS. CILCO HAS THE OPTION OF
FIRING LOW SULFUR COAL UNTIL THE ENTIRE 4-MODULE SCRUBBER PLANT IS READY
FOR SERVICE IN AUGUST 1978.
4/77 SYSTEM .0 720 0
5/77 SYSTEM .0 744 0
6/77 SYSTEM .0 720 0
7/77 SYSTEM .0 744 0
8/77 SYSTEM .0 744 0
9/77 SYSTEM .0 720 0
10/77 SYSTEM .0 744 0
11/77 SYSTEM .0 720 0
12/77 SYSTEM .0 744 o
1/78 SYSTEM .0 744 o
2/78 SYSTEM .0 672 0
3/78 SYSTEM .0 744 o
4/78 SYSTEM .0 720 0
5/78 SYSTEM .0 744 Q
6/78 SYSTEM .0 720 0 0 .0
119
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
CENTRAL ILLINOIS LIGHT: DUCK CREEK 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/CCMMENTS
THE UNIT CONTINUED TO FIRE LOW-SULFUR COLORADO COAL DURING THE REPORT
PERIOD. THE RESTART OF SCRUBBER OPERATIONS CONTINUES TO BE SCHEDULED FOR
AUGUST 1978.
7/78 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
ALL FOUR MODULES BECAME OPERATIONAL ON JULY 24.
MODIFICATIONS WERE MADE TO THE UNDER DESIGNED SLURRY TRANSFER TANK.
A PLUGGING PROBLEM CAUSED BY COAL FINES IN THE SLURRY WAS EXPERIENCED.
THE FINES RESULTED FROM A COMMON COAL AND LIMESTONE HANDLING SYSTEM.
8/78 SYSTEM
9/78 SYSTEM
45.0
46.0
46.0
46.0
46.0
46.0
42.0
44.0
744 691
720 691
315 62.5
317 62.5
** PROBLEMS/SOLUTIONS/COMMENTS
SCREEN BASKETS WERE USED TO KEEP COAL PARTICLES FROM THE LIMESTONE, THE
COAL PARTICLES RESULT FROM THE COMMON COAL-LIMESTONE HANDLING
SYSTEM.
THE SLURRY TRANSFER SYSTEM PREVENTED PROPER SLURRY FLOW DUE TO UNDER
DES13N. THE OLD SYSTEM WAS REPLACED WITH A NEW PIPING SYSTEM.
PLUGGING OF THE RECYCLE PUMP SHUT-OFF VALVES OCCURED. THE VALVES ARE
BEING REPLACED WITH PINCH VALVES.
THE SCRUBBER WASTE WATER SUMP PUMPS HAVE BEEN PLUGGING. NEW PUMPS ARE
BEINb INVESTIGATED.
10/78
A
B
C
D
SYSTEM
19.1
ZZ.S
.8
20.5
15.7
31.6
37.2
1.3
33.9
26.0
31.6
37. Z
1.3
33.9
26.0
19.1
ZZ.S
.8
20.5
15.7
744 449
117 32.9
** PROBLEMS/SOLUTIONS/COMMENTS
THE MAJOR CAUSES FOR DOWNTIME OCCURRING IN OCTOBER WERE VALVE LEAKS AND
SUBSEQUENT RECYCLE GLAND SEAL CONTAMINATION AND THE INSTALLATION OF A
LIQUID/SOLID SEPARATOR.
A LEAKING VALVE RESULTED IN CONTAMINATION OF THE RECYCLE PUMP GLAND SEAL_
WATER SYSTEM WITH POND RETURN WATER CAUSING SCALING AND PLUGGING FORCING
SHUTDOWN OF THE RECYCLE PUMPS. A NEW VALVE SYSTEM WAS INSTALLED AND THE
OPERATING PRESSURES WERE CHANGED TO PREVENT RECURRANCE OF THE
CONTAMINATION.
THE RECYCLE PUMPS WERE SHUT DOWN WHEN CONTAMINATION OF THE GLAND SEAL
WATER SYSTEM CAUSED BY A FAULTY VALVE OCCURRED.
A FLOW CONTROL VALVE ON THE D-MODULE WAS REMOVED BECAUSE IT CAUSED
ABRASION AND FAILURE OF THE RECYCLE HEADER. NONE OF THE MODULES NOW
UTILIZE FLOW CONTROL VALVES.
THE MIST ELIMINATOR SPRAY NOZZLES PLUGGED BY COAL PARTICLES WERE CLEANED
THE COAL PARTICLES RESULT FROM A COMMON COAL/LIMESTONE HANDLING SYSTEM.
120
-------
EPA UTILITY F60 SURVEY: OCTOBER - DECEMBER 1980
CENTRAL ILLINOIS LIGHT: DUCK CREEK 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
A LIQUID/SOLID SEPARATOR HAS BEEN INSTALLED IN THE SLURRY SYSTEM TO PRE-
VENT RECURRENCE.
EXCESSIVE LIMESTONE CARRYOVER TO THE MIST ELIMINATOR WAS NOTED. THE TOP
ROD DECK WAS REMOVED TO IMPROVE GAS FLOW AND ELIMINATE THE CARRYOVER
PROBLEM.
BLANK OFF PLATES HERE ADDED TO THE LOWER SEVEN ROD DECKS TO MAINTAIN
PRESSURE DROP REQUIREMENTS. THIS HAS BEEN FOUND TO BE AN ACCEPTABLE
SOLUTION AT OTHER ENVIRONEERING FGD SYSTEM INSTALLATIONS.
11/78
A
B
C
D
SYSTEM
8.1
8.1
8.1
8.1
8.1
8.8
8.8
8.8
8.8
8.8
8.8
8.8
8.8
8.8
8.8
8.1
8.1
8.1
8.1
8.1
720 661
59 63.6
** PROBLEMS/SOLUTIONS/COMMENTS
THE IB SLURRY TANK PUMP LINER EXPERIENCED A FAILURE RESULTING IN SCRUBBING
SYSTEM SHUTDOWN FOR 84 HOURS. THE LINER FAILED AFTER ONLY THREE MONTHS.
THE SPARE PUMP WAS ALREADY OUT OF SERVICE FOR A MOTOR REPLACEMENT.
A SPARE SLURRY TANK PUMP WAS OUT OF SERVICE TO REPLACE THE ORIGINAL 50-HP
MOTOR WITH A 75-HP MOTOR.
THE PINION BEARING ON THE BALL MILL DRIVE FAILED. THE FAILURE IS BEING
INVESTIGATED. FGD SYSTEM OPERATION HAS HALTED DUE TO THE FAILURE. THIS
ACCOUNTED FOR MOST OF THE NOVEMBER OUTAGE TIME.
THE LEVEL AND DENSITY INSTRUMENTS ON RECYCLE TANKS ARE BEING MODIFIED.
THE LEEDS & NORTHRUP LEVEL AND DENSITY TRANSMITTERS ARE BEING REPLACED
WITH ROSEMOUNT TRANSMITTERS.
12/78
A
B
C
D
SYSTEM
23.3
26.2
21.3
10.2
20.3
24.5
27.6
22.5
10.8
21. 4
24.5
27.6
22.5
10.8
21.4
23.3
26.2
21.3
10.2
20.3
744 706
151 70.3
** PROBLEMS/SOLUTIONS/COMMENTS
ISOLATION DAMPER FAILURES AND SLURRY RECYCLE DISCHARGE VALVE FAILURES
OCCURR7D DURING DECEMBER.
LIMESTONE MILL PROBLEMS AND A PLUGGED LIMESTONE FEEDER HAMPERED SCRUBBER
OPERATIONS DURING DECEMBER.
THE SYSTEM EXPERIENCED FROZEN INSTRUMENT CONTROL LINES IN DECEMBER. THIS
WAS THE MAJOR CAUSE OF THE DECEMBER SCRUBBER UNAVAILABILITY.
1/79 SYSTEM .0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
.0
.0
744 738
0 77.0
2/79 SYSTEM
.0
FROZEN INSTRUMENT CONTROL LINES, RECYCLE TANK SUCTION LINES, MAIN MODULE
DRAIN LINES AND MIST ELIMINATOR DRAIN LINES WERE MAJOR PROBLEM AREAS
DURING JANUARY.
SLURRY RECYCLE VALVE PLUGGING AND SLURRY TRANSFER PUMP FAILURE CONTRIBUTED
TO THE SYSTEM OUTAGE TIME.
.0
.0
.0
672 533
0 63.8
121
-------
EPA U1ILITY F6D SURVEY: OCTOBER - DECEMBER 1980
CENTRAL ILLINOIS LIGHT: DUCK CREEK 1 (CCNT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
RECYCLE PUMP SUCTION VALVE FAILURES AND A SLURRY TRANSFER PUMP FAILURE
CONTRIBUTED TO THE NON-OPERATION OF THE FGD SYSTEM.
FROZEN MIST ELIMINATOR DRAINS, ABSORBER DRAINS AND INSTRUMENT LINES WERE
A MAJOR PROBLEM DURIN'S FEBRUARY.
3/79 A
B
C
D
SYSTEM
33.7
6.7
.0
.0
10.1
31.1
6.7
.0
.0
9.5
31.1
6.7
.0
.0
9.5
31.1
6.7
.0
.0
9.5
744 744 70
** PROBLEMS/SOLUTIONS/COMMENTS
FREEZING PROBLEMS CONTINUED TO HAMPER FGD OPERATIONS DURING MARCH. THE
C AND D MODULE WERE STILL NOT BACK IN SERVICE DUE TO MAJOR CLEAN-UP FROM
THE FREEZING PROBLEMS.
BROKEN MIST ELIMINATOR SPRAY LINES AND PLUGGED MIST ELIMINATOR NOZZLES
WERE PROBLEM AREAS DURING MARCH.
RECYCLE PUMP FAILURES AND WASTE WATER PUMP FAILURES WERE EXPERIENCED
DURING MARCH.
PLUGGED SLURRY NOZZLES AND GENERAL INSTRUMENTATION PROBLEMS WERE REPORTED
BY THE UTILITY.
4/79 A
B
C
D
SYSTEM
100.0
84.3
86.5
21.3
73.0
71.9
50.5
81.2
22.7
56.6
100.0
75.0
84.9
21.3
70.3
67.3
47.3
76.0
21.3
53.0
720 674 380 55.9
** PROBLEMS/SOLUTIONS/COMMENTS
INLET DAMPER MALFUNCTIONS HINDERED FGD OPERATION DURING APRIL.
PLUGGED MIST ELIMINATOR SPRAY NOZZLES DURING APRIL HINDERED FGD OPERATION.
SLURRY CONTROL VALVE MALFUNCTIONS WERE REPORTED BY THE UTILITY.
RECYCLE TANK MIXER FAILURES WERE EXPERIENCED DURING APRIL.
RECYCLE PUMP BELT AND BEARING FAILURES AND SLURRY SUPPLY LINE FAILURES
WERE REPORTED BY THE UTILITY.
5/79 A
B
C
D
SYSTEM
95.7
95.7
94.7
1.3
71.9
37.4
44.2
41.8
5.0
32.1
69.7
73.2
71.1
1.3
53.8
9.9
11.7
11.1
1.3
8.5
744 197 63 14.8
** PROBLEMS/SOLUTIONS/C1MMENTS
MIST E .IMINATOR PUMP MALFUNCTIONS WERE REPORTED DURING MAY. MODULE D
WAS UNAVAILABLE DUE TO A MIST ELIMINATOR WASH LINE FAILURE.
MILL SHAKER BASKET DRIVE MOTOR FAILURES WERE ENCOUNTERED.
SLURRY SUPPLY LINE FAILURES OCCURRED DURING THE MONTH.
122
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
CENTRAL ILLINOIS LIGHT: DUCK CREEK 1 (CONT. )
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
STACK LINER BLISTERING WAS DISCOVERED DURING A SPRING INSPECTION. RE-
PAIRS WERE MADE. THE STACK WILL BE INSPECTED AGAIN IN MARCH 1980.
6/79
A
B
C
D
SYSTEM
81.9
89.2
86.6
92.0
76.9
86.9
83.0
90.0
64.2
79.6
88.1
85.1
91.1
86.0
70.6
79.8
76.2
82.7
77.3
720 661
557 70.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JUNE SOME PROBLEMS WITH THE MIST ELIMINATOR WERE ENCOUNTERED. THESE
PROBLEMS INCLUDED PLUGGING IN THE MIST ELIMINATOR AND THE MIST ELIMINATOR
LINES AND A BROKEN MIST ELIMINATOR RETURN LINE.
THE UTILITY REPORTED STORAGE PUMP LEAKS, RECYCLE PUMP FAILURES, SLURRY
SUPPLY LINE PLUGGING AND DAMPER AND M.ILL SHAKER BASKET FAILURES.
7/79
A
B
C
D
SYSTEM
93.1
94.9
95.8
96.1
95.0
85.6
88.3
87.9
86.4
87.1
89.7
92.3
93.6
93.9
92.4
59.9
61.7
61.5
60.4
60.9
744 520
453 48.7
** PROBLEMS/SOLUTIONS/COMMENTS
IN JULY THE MIST EITMINATOR PLUGGED CAUSING OPERATIONAL PROBLEMS.
RECYCLE PUMP FAILURES WERE ENCOUNTERED DURING THE PERIOD.
8/79
A
B
C
D
SYSTEM
3.0
26.1
13.6
9.5
13.1
4.0
31.4
18.3
12.7
16.6
3.0
24.0
13.6
9.5
12.5
3.0
23.4
13.6
9.5
12.4
744 555
92 53.8
** PROBLEMS/SOLUTIONS/COMMENTS
IN AUGUST THE MIST ELIMINATOR AND THE MIST ELIMINATOR DRAIN LINES PLUGGED
CAUSING EXTENSIVE DOWNTIME FOR MODULE CLEANING.
FAILURES WITH THE LIMESTONE SLURRV FORWARDING PUMP AND THE RECYCLE PUMP
WERE ENCOUNTERED.
DAMPER MALFUNCTIONS WERE REPORTED BY THE UTILITY.
9/79 A
B
C
D
SYSTEM
63.9
61.2
49.0
88.8
65.7
53.9
48.4
38.9
86.2
56.9
58.0
53.5
41.4
87.6
60.1
49.8
44.7
35.9
79.6
52.5
720 665
378 69.1
** PROBLEMS/SOLUTIONS/COMMENTS
PLUGGING IN THE MIST ELIMINATOR, MIST ELIMINATOR HEADER AND NOZZLES
WERE ENCOUNTERED IN AUGUST CONTINUED IN SEPTEMBER.
THE DAMPER FAILED CAUSING A PROBLEM DURING SEPTCMBER.
THE UTILITY REPORTED MIST ELIMINATOR PUMP CAVITATION PROBLEMS RELATED
TO MIST ELIMINATOR PROBLEMS ENCOUNTERED IN AUGUST.
PLUGGED SLURRY NOZZLES AND LIMESTONE CONVEYOR FAILURES CONTRIBUTED TO THE
OUTAGES EXPERIENCED.
123
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
CENTRAL ILLINOIS LIGHT: DUCK CREEK 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL
S02 PART.
PER BOILER FGD CAP.
HOURS HOURS HOURS FACTOR
SCRUBBER UNAVAILABILITY WAS PRIMARILY A RESULT OF CARRY-OVER PLUGGING
PROBLEMS FROM AUGUST AND SUBSEQUENT CLEAN-UP.
10/79
A
3
C
a
3YSTEM
84.8
93.7
91.7
93.5
90.9
82.3
86.2
75.8
91.9
84.1
89.2
92.4
90.5
93.4
91.4
82.3
86.2
75.8
91.9
84.1
744 744
625 72.4
••** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE MONTH OF OCTOBER PROBLEMS WERE ENCOUNTERED WITH THE MIST
ELIMINATOR SECTIONS. THE MIST ELIMINATOR PUMP MALFUNCTIONED, THE LINES
PLUGGED AND A HEADER FLANGE GASKET FAILED.
OUTAGE TIME RESULTED FROM THE MODULE ISOLATION DAMPER FAILURE INCLUDING
DAMPER MOTOR MALFUNCTION.
THE SLURRY SUPPLY LINE NEEDED REPAIRS.
11/79
A
B
C
D
SYSTEM
43.1
12.4
22.4
51.0
32. 2
52.1
15.3
22.6
61.9
38.0
52.1
18.8
24.9
62.0
39.5
42.2
12.4
18.3
50.1
30.8
720 583
221 61.2
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE ISOLATION DAMPER PROBLEMS CONTINUED DURING NOVEMBER.
THE MIST ELIMINATOR AND THE MIST ELIMINATOR DRAIN PLUGGED CAUSING DOWN
TIME.
ALL RECYCLE PUMP SUCTION VALVES WERE REPLACED DURING THE MONTH. THIS
WAS THE PRIMARY CAUSE FOR THE LOW SYSTEM AVAILABILITY.
SLURRY SUPPLY LINES FAILED AGAIN, DURING NOVEMBER.
12/79
A
B
C
D
SYSTEM
54.5
35.1
43.0
25.5
39.5
72.6
47.6
58.4
34.6
53.3
77.6
51.0
61.9
40.9
57.9
53.5
35.1
43.0
25.5
39.3
744 548
292 60.8
** PROBLEMS/SOLUTIONS/COMMENTS
THE ISOLATION DAMPER FAILURES CONTINUED.
THE MIST ELIMINATOR PROBLEMS WITH PLUGGING AND HEADER RUPTURES OCCURRED
DURING DECEMBER.
THE MODULE B AND D RECYCLE TANK LINERS WERE REPAIRED AND TANK COVERS WERE
INSTALLED.
MIST ELIMINATOR PLUGGING AND RECYCLE TANK REPAIRS ACCOUNTED FOR MOST OF
THE DECEMBER SCRUBBER OUTAGE TIME.
1/80
A
B
C
D
SYSTEM
24.8
58.5
17.1
29.2
32.4
27.0
63.6
18.6
31.8
35.3
29.8
65.9
20.3
35.3
37.8
24.8
58.5
17.1
29.3
32.4
744 684
241 81.6
124
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
CENTRAL ILLINOIS LIGHT: DUCK CREEK 1 (CONT.)
PERFORMANCE DATA
PERIOD MCDULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
MOST OF THE JANUARY OUTAGE-TIME WAS REQUIRED FOR RECYCLE TANK COVERING
WORK.
THE MIST ELIMINATOR SECTION PLUGGED ALONG WITH THE NOZZLES HINDERING
SYSTEM OPERATIONS. THE MIST ELIMINATOR DRAIN LINE WAS MODIFIED ALSO
CAUSING OUTAGE TIME.
OTHER PROBLEMS ENCOUNTERED DURING THE MONTH INCLUDED A PLUGGED LIMESTONE
FEEDER, INLET DAMPER PROBLEMS, SLURRY SUPPLY HEADER LEAKS AND STORAGE
PUMP DISCHARGE VALVE REPAIRS.
2/80
4/80
A
B
C
0
SYSTEM
11.8
72.7
70.7
41.3
49.1
11.8
72.7
70.7
41.3
49.1
12.5
73.5
71.5
47.9
51.4
11.8
72.7
70.7
41.3
49.1
696 696
342 73.5
** PROBLEMS/SOLUTIONS/COMMENTS
DURING FEBRUARY SOME OUTAGE TIME WAS DUE TO MODULE D CLEANING AND THE
CLEANING OF THE MODULE D MIST ELIMINATOR SECTION.
THE INLET DAMPER DRIVE WAS REPLACED DURING THE MONTH.
REPAIR OF THE FIBERGLASS ON THE SLURRY RECYCLE LINE HINDERED OPER-
ATIONS DURING THIS MONTH.
THE MODULES A AND D RECYCLE DISCHARGE VALVE WERE REPLACED CAUSING EXTENSIVE
DOWN TIME.
3/80
A
B
C
D
SYSTEM
52.9
73.2
51.0
34.0
52.8
62.5
86.6
60.3
40.2
62.4
64.7
86.9
60.5
45.9
65.1
52.9
73.2
51.0
34.0
52.8
744 629
393 68.6
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MARCH NEW RECYCLE PUMP DISCHARGE VALVES WERE INSTALLED IN ORDER TO
ELIMINATE RESTRICTED FLOW OF THE OLD VALVES.
CARRIER BEARINGS ON THE INLET DAMPER WERE REPLACED IN ORDER TO MAINTAIN
MODULE ISOLATION CAPABILITY.
THE MIST ELIMINATOR WASH SYSTEM WAS CONVERTED TO RETURN WATER IN ORDER
TO ACHIEVE A HIGHER QUALITY ELIMINATION WASH WATER.
FIBERGLASS LINES ON THE RECYCLE PUMP DISCHARGE WERE ALSO REPAIRED DURING
EXTENSIVE
A
B
C
D
SYSTEM
53.0
54.2
57.2
26.0
47.6
81.7
83.6
88.3
40.1
73.4
95.9
87.5
95.3
71.9
89.2
52.9
54.2
57.2
26.0
47.6
720 466
342 35.3
** PROBLEMS/SOLUTIONS/COMMENTS
THE MAJOR PROBLEM HINDERING SYSTEM OPERATIONS DURING APRIL WAS THE REBUILD
OF THE RECYCLE TANK MIXER.
125
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
CENTRAL ILLINOIS LIGHT: DUCK CREEK 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
5/80 A
B
C
D
SYbTEM
44.6
45.7
34.7
43.6
42.1
MINOR PROBLEMS DURINS THE MONTH WERE CAUSED BY THE
LIMESTONE HANDLING SYSTEM.
68.6 72.0 44.6
70.3 73.5 45.7
53.3 59.1 34.7
67.0 73.9 43.6
64.8 69.7 42.1
IHOPERABILITY OF THE
744 484 314 49.4
6/80
PROBLEMS/SOLUTIONS/CO 1MENTS
DURING MAY REPAIRS WERE MADE TO THE RECYCLE TANK RUBBER LINER.
EXPANSION JOINT LEAKS WERE ALSO REPAIRED DURING THE MONTH.
OTHER OPERATIONAL PROBLEMS INCLUDED THE REPLACEMENT OF THE LIMESTONE
STORAGE TANK MIXER MOTOR, MODIFICATION OF ROD DECKS TO REDUCE SYSTEM
DIFFERENTIAL PRESSURE AND REPAIR OF THE LIMESTONE FEEDER SYSTEM.
A
B
C
D
SYSTEM
87.6
86.8
84.5
80.0
84.8
82.3
82.6
81.4
73.1
79.9
87.1
86.0
84.3
75.8
84.3
82.1
82.3
81.1
72.9
79.6
720 718
573 78.5
** PROBLEMS/SOLUTIONS/COMMENTS
A LEAK WAS REPAIRED IN THE SLURRY SUPPLY HEADER DURING JUNE.
WORK CONTINUED ON THE MODIFICATIONS BEING DONE ON THE ROD DECKS IN THE
ABSORBER MODULES.
7/80
A
B
C
D
3YSTEM
91.2
83.5
90.5
87.5
88.2
81.0
70.0
78.8
74.9
76.2
87.6
80.0
86.4
85.4
84.9
70.1
60.6
68.2
64.8
65.9
744 644
490 67.4
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JULY FGD SYSTEM OUTAGE TIME RESULTED FROM THE NECESSARY REPAIR
OF THE SLURRY SUPPLY LINE AND REPAIR OF THE MALFUNCTIONING CLUTCH IN THE
MILL SYSTEM.
ADDITIONAL OUTAGE TIME OCCURRED SO REPAIRS TO THE IB STORAGE TANK PUMP
DISCHARGE VALVES AND THE STORAGE TANK MIXER MOTOR COULD BE COMPLETED.
8/80
A
B
C
D
SYSTEM
88.6
91.4
91.3
90.6
90.5
85.4
86.3
84.6
85.1
85.4
92.7
90.8
88.9
90.1
90.7
81.9
82.7
81.0
81.6
81.9
744 713 609 76.5
** PROBLEMS/SOLUTIONS/COMMENTS
THE SLURRY SUPPLY ISOLATION VALVE WAS REPAIRED IN AUGUST.
THE POND WATER RETURN LINE WAS ALSO REPAIRED DURING THE MONTH.
REPAIRS WERE MADE TO THE ELECTRICAL SYSTEM AFTER A POWER FAILURE IN THE
WASTEWATER BUILDING.
9/80 A
43.1
39.2
41.5
39.2
126
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
CENTRAL ILLINOIS LIGHT: DUCK CREEK 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
10/80
11/80
X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
B
C
D
SYSTEM
47
45
46
45
.8
.6
.3
.6
47
43
46
43
.2
.2
.0
.9
48.2
45.9
47.6
45.9
47.
43.
46.
43.
2
2
0
9
720
720
316
81.3
** PR03LEMS/SOLUTIONS/COMMENTS
MAJOR PROBLEMS DURING SEPTEMBER INCLUDED REPAIR OF THE LIMESTONE BALL MILL.
AFTER IT WAS REPAIRED, THE BALL MILL MOTOR BURNED OUT AND HAD TO BE RE-
PLACED.
SLURRY CONTAMINATION OF THE MILL BEARING OIL AND REPAIR OF THE RECYCLE PUMP
SUCTION SCREEN CAUSED THE FGD SYSTEM TO BE DOWN FOR SEVERAL HOURS DURING
THE MONTH.
A
B
C
D
SYSTEM
73.0
73.3
74.2
73.4
72.8
73.0
65.9
74.1
73.2
71.5
75.9
71.8
75.8
76.6
75.1
73.0
65.9
74.1
73.2
71.6
744
532 64.6
** PROBLEMS/SOLUTIONS/CC'MMENTS
DURING OCTOBER THE FGD SYSTEM HAS DOWN APPROXIMATELY 168 HOURS DUE TO
PROBLEMS WITH THE LIMESTONE BALL MILL MOTOR.
SOME OUTAGE TIME DURING THE MONTH WAS DUE TO NECESSARY REPAIRS TO THE
RECYCLE TANK PUMP AND PROBLEMS WITH THE DISCHARGE VALVE ON THE STORAGE
TANK PUMP.
A
B
C
D
SYSTEM
98.9
96.2
99.2
95.4
97.4
92.3
83.1
91.8
82.7
88.7
100.0
97.2
99.6
100.0
99.2
70.3
67.1
69.9
62.9
67.5
720 548
486 50.1
** PROBLEMS/SOLUTIONS/COMMENTS
DURING NOVEMBER THE FGD SYSTEM WAS OFF LINE FOR APPROXIMATELY 192 HOURS
DUE TO A PLANT OUTAGE (BOILER RELATED).
THE FRESH WATER FLUSH VALVE IN THE MIST ELIMINATOR FAILED ADDING TO THE
OUTAGE TIME DURING NOVEMBER.
REPAIRS WERE MADE TO THE RECYCLE TANK SUCTION SCREEN CAUSING SOME OUTAGE
TIME.
12/80
A
B
3
SYSTEM
93.5
94.9
87.2
94.0
92.4
92.6
93.9
86.0
93.0
91.4
94.1
95.9
90.7
96.0
94.2
92.2
93.5
85.6
92.6
91.0
744 741
677 79.7
** PROBLEMS/SOLUTIONS/COMMENTS
MINOR PROBLEMS WERE REPORTED FOR DECEMBER, INCLUDING PLUGGING OF RECYCLE
TANK PUMP SUCTION SCREENS. REPAIRS WERE MADE DURING THE MONTH TO THE "B"
MODULE OUTLET DAMPER AND THE "C" MODULE INLET DAMPER.
127
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
SOS EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MM
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGD - MM
EQUIVALENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
CENTRAL ILLINOIS PUBLIC SERV
NEWTON
1
NEWTON
ILLINOIS
B
516.
( .100 LB/MMBTU)
( 1.200 LB/MMBTU)
(****** LB/MMBTU)
575
617
575
590
617
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
1020.95
163.9
162.
CONCRETE
******* (***** FT)
(2163480 ACFM)
( 327 F)
( 530 FT)
** FLcL DATA
FUEL TYPE
F-UEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - '/.
PANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGr CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
COAL
BITUMINOUS
25353.
12.70
******
9.50
******
2.25
2.0-2.5
.20
******
( 10900 BTU/LB)
******
** MECHnNICAL COLLECTOR
NJMt'ER
TYPt
** FABRIC FILTER
NJMBER
TfPE
** ES3
NJM3ER
TYPE
SUPPLIER
INLET FLUE GAS CAPACITY - CU.M/S
ULET FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
PARTICLE REMOVAL EFFICENCY - '/.
** PARTICLE SCRUBBER
GENERIC TYPE
SPECIFIC TYPE
0
NONE
0
NONE
COLD SIDE
RESEARCH-COTTRELL
1080.7 (2290000 ACFM)
162.8 ( 325 F)
.0 ( 0. IN-H20)
99.5
NONE
N/A
*** FGD SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
SC2 REMOVAL MODE
PROCESS TYPE
SYSTEM SUPPLIER
THROWAWAY PRODUCT
WET SCRUBBING
DUAL ALKALI
BUELL DIVISION, ENVIROTECH
128
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
CENTRAL ILLINOIS PUBLIC SERV: NEWTON 1 (CONT.)
A-E FIRM BUELL DIVISION, ENVIROTECH
DEVELOPMENT LEVEL FULL SCALE
NEW/RETROFIT NEW
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY - X 99.50
UNIT DESIGN S02 REMOVAL EFFICIENCY - 7. 90.00
CURRENT STATUS 1
COMMERCIAL START-UP 12/79
INITIAL START-UP 9/79
CONTRACT AWARDED 8/75
** DESIGN AND OPERATING PARAMETERS
** ABSORBER
NUMBER
NUMBER OF SPARES
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
GAS CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
DISTANCE BETWEEN GAS CONTACTING ZONES - CM
LIQUID RECIRCULATION RATE - LITER/S
L/G RATIO - L/CU.M
GAS-SIDE PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/SEC
S02 REMOVAL EFFICIENCY - X
PACKED TOWER
MOBILE BED PACKING
POLYSPHERE SCRUBBER
BUELL DIVISION, ENVIROTECH
18 X 48 X 72
MILD STEEL
AISI 1110
N/A
ORGANIC
GLASS FLAKE-FILLED POLYESTER
CEILCOTE
POLYSPHERE BALLS
1
45.7 (
148.
1.3
1.5
2.5
90.0
18.0IN)
( 2351 GPM)
( 10.0 GAL/1000 ACF)
( 6.0 IN-H20)
( 8.3 FT/S)
#* MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
T2ADE NAME/COMMON TYPE
CONFIGURATION
** REHEATER
K'JMSER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
** FANS
KUMBER
DESIGN
FUNCTION
APPLICATION
SERVICE
CONfTRUCTION MATERIAL GENERIC TYPE
** SOLIDS CONCENTRATING/DEWATE3ING
DEVICE
N'jME.ER
** SO'.IDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
DIMENSIONS - FT
SHELL GENERIC MATERIAL TYPE
** SOLIDS CONCENTRATING/DEWATERING
DtVICE
NJMBER
DIMENSIONS - FT
MIST ELIMINATOR
8
IMPINGEMENT
BAFFLE
CHEVRON VANE
VERTICAL
1
BYPASS
COLD SIDE
N/A
CENTRIFUGAL
BOOSTER
FORCED DRAFT
DRY
CARBON STELL
VACUUM FILTER
1
THICKENER
2
100 (DIA)
CONCRETE
THICKENER
1
50 (DIA)
129
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
CENTRAL ILLINOIS PUBLIC SERV: NEWTON 1 (CONT.)
SHELL GENERIC MATERIAL TYPE STEEL
*** SLUDGE
** TREATMENT
METHOD POZ-0-TEC
PROPRIETARY PROCESS IUCS
** WATER BALANCE
WATER LOOP TYPE CLOSED
** FGD SPARE CAPACITY INDICES
ABSORBER - 7. .0
** FGD SPARE COMPONENT INDICES
ABSORBER .0
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
9/79 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
INITIAL OPERATIONS BEGAN AT THIS UNIT ON SEPTEMBER 1 WHEN FLUE GAS WAS
PASSED THROUGH THE INDIVIDUAL FGD MODULES FOR TESTING PURPOSES. TESTING
OF THE SYSTEM IN AN INTEGRATED MODE IS EXPECTED TO BEGIN IN DECEMBER.
10/79 SYSTEM 744
11/79 SYSTEM 730
** PROBLEMS/SOLUTIONS/COMMENTS
TESTING OPERATIONS CONTINUED THROUGH OCTOBER AND NOVEMBER.
12/79 SYSTEM 75.3 60.1 74.1 59.0 744 730 439
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT BEGAN BURNING HIGH SULFUR COAL ON NOVEMBER 18-19 AT WHICH TIME
THE FGD SYSTEM BEGAN OPERATIONS IN AN INTEGRATED MODE FOR THE FIRST TIME.
INITIAL START UP PROBLEMS HAVE INCHED MIST ELIMINATOR PLUGGING.
LINING FAILURES HAVE ALSO BEEN ENCOUNTERED DURING START UP PHASE.
THE UNIT PASSED A COMPLIANCE TEST ON DECEMBER 5, 1979. IT WAS DETERMINED
THAT THE FGD SYSTEM CONTROLLED S02 EMISSIONS TO WELL BELOW THE ALLOWABLE
1.2 LB/MM BTU STANDARD.
1/80
A
B
C
D
SYSTEM
68.3
66.4
52.2
21.0
52.0
57.1
60.6
48.8
19.1
46.4
63.5
64.9
60.5
26.3
53.8
55.5
58.9
47.4
18.5
45.1
744 723 336
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JANUARY TESTS WERE CONDUCTED TO CERTIFY THE GAS EMISSIONS MONITOR
AT r.'EWTON.
PRESATURATOR CORROSION AND EXPANSION JOINT REPAIRS AND A DEPLETION OF THE
FLYASi1 USED FOR SLUDGE STABILIZATION ACCOUNTED FOR THE LOW JANUARY
DEPENDABILITY FIGURES.
130
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
CENTRAL ILLINOIS PUBLIC SERV: NEWTON 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL
S02 PART.
PER BOILER FGD CAP.
HOURS HOURS HOURS FACTOR
2/80
"J
C
')
SYSTEM
61.1
74.4
78.2
.0
53.4
42.4
55.7
58.5
.0
39.2
45.0
57.7
59.1
.0
40.4
42.4
55.7
58.5
.0
39.2
696 696
273
** PROBLEMS/SOLUTIONS/COMMENTS
DURING FEBRUARY THE D-MODULE WAS UNAVAILABLE DUE TO THE COLLAPSE OF THE
PRECOOLER MIST ELIMINATORS CAUSED BY A TEMPERATURE EXCURSION.
REPAIR WORK ON THE PRESATURATOR CORROSION AND EXPANSION JOINTS AS WELL AS
THE FLYASH DEPLETION PROBLEM CONTINUED TO YIELD LOW DEPENDABILITY FIGURES
FOR FEBRUARY.
3/80
A
B
C
D
SYSTEM
53.4
47.0
44.5
.0
36.2
52.6
42.3
41.1
.0
34.0
53.1
48.0
46.5
.0
36.9
52.3
42.1
41.0
.0
33.9
744 740
252
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE FIRST QUARTER, 1980, THE FOLLOWING PROBLEMS WERE ENCOUNTERED:
THE VALVES AND PIPING IN THE PRECOOLER LOOP EXPERIENCED CORROSION.
THE MIST ELIMINATOR ON THE D MODULE FAILED.
THE FLY ASH SUPPLIES DEPLETED.
RUBBER LINING AND DUCTWORK LINING FAILURES OCCURRED.
BOOSTER FAN EXPANSION JOINT FAILURE OCCURRED.
THE THICKENER EXPERIENCED PLUGGING.
THESE COMBINED PROBLEMS ACCOUNTED FOR THE LOW MARCH PERFORMANCE FIGURES.
FOR THE QUARTER, THE TOTAL SYSTEM WAS AVAILABLE 47.27. AND WAS UTILIZED
39.4X OF THE TIME.
4/80
A
B
C
D
SYSTEM
33.8
35.4
37.4
26.1
33.2
31.3
25.8
35.6
21.8
28.6
31.4
25.8
35.6
21.8
28.6
31.3
25.8
35.6
21.8
28.6
720 720
206
** PROBLEMS/SOLUTIONS/COMMENTS
THE NEWTON 1 FGD SYSTEM WAS OUT OF SERVICE DURING THE FIRST 12 DAYS OF
APRIL FOR NECESSARY REPAIRS ON THE OUTLET DUCT LININGS. THE UTILITY INDI-
CATED THAT THE LINING FAILURES MAY HAVE RESULTED FROM IMPROPER APPLICATION.
DURING THE LAST 18 DAYS OF APRIL MINOR PROBLEMS WERE EXPERIENCED WITH
THE OCCURANCE OF PLUGGING IN THE SODIUM CARBONATE THICKENER AND CORROSION
OF THE VALVES IN THE PRESATURATOR CIRCUIT.
5/80
A
B
C
D
SYSTEM
.0
9.7
9.7
.0
4.8
.0
9.6
9.6
.0
4.8
.0
9.6
9.6
.0
4.8
.0
6.2
6.2
.0
3.1
744 477
23 45.5
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MAY, THE FGD SYSTEM WAS DOWN BECAUSE THE FLUIDIZING STONES WERE
CAKED WITH FLY ASH. THIS WAS CAUSED BY IMPROPER WIRING OF THE HEATER WHICH
BLOUS OVER THE STONES. THE HEATER WAS REWIRED AND THE FLUIDIZING STONES
REPLACED. FLUIDIZING STONES ARE LOCATED IN THE FLYASH SILO. HEATED AIR
PASSES THROUGH THESE POROUS STONES TO AERATE OR "FLUIDIZE" THE FLYASH SO
131
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
CENTRAL ILLINOIS PUBLIC SERV: NEWTON 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
THAT IT CAN BE CONVEYED TO THE FLYASH/SLUDGE MIXER. WHEN THE FLYASH
SUPPLY IS DEPLETED OR THE MATERIAL CANNOT BE DELIVERED TO THE MIXER THE
SCRUBBING SYSTEM IS SHUT DOWN. THE SLUDGE MUST BE TREATED WITH FLYASH
BEFORE DISPOSAL.
6/80 A
B
C
0
SYSTEM
9/80
.0
40.3
40.4
.0
20.2
.0
40.3
40.4
.0
20.2
.0
40.3
40.4
.0
20.2
.0
40.3
40.4
.0
20.2
720 720
145 63.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JUNE THE A AND D MODULES WERE UNAVAILABLE FOR OPERATION BECAUSE
THE MIST ELIMINATORS COLLAPSED.
THE SYSTEM WAS SHUTDOWN DURING THE FIRST HALF OF THE MONTH TO REPAIR THE
DRY FLYASH COLLECTION SYSTEM WHICH ACCOUNTED FOR THE LOW B AND C MODULE
FIGURES.
7/80 A
B
C
D
SYSTEM
3.5
3.6
.0
.0
1.8
3.7
3.9
.0
.0
1.9
3.7
3.9
.0
.0
1.9
3.5
3.6
.0
.0
1.8
744 698
13 67.8
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JULY PROBLEMS WERE ENCOUNTERED WITH THE MIST ELIMINATORS.
SOME OF THE SYSTEM OUTAGE TIME RESULTED FROM REPAIRS MADE NECESSARY BY THE
OCCURRENCE OF CORROSION IN THE PRESATURATOR.
SCRUBBER PLUGGING DURING JULY CONTRIBUTED TO THE LOW FGD SYSTEM
AVAILABILITY.
8/80 A
B
C
D
SYSTEM
.0
64.7
51.2
37.6
53.8
.0
50.2
34.1
21.9
36.4
.0
50.2
36.9
24.0
39.9
.0
49.3
33.5
21.5
35.8
744 731
266 68.2
** PROBLEMS/SOLUTIONS/COMMENTS
PLUGGING PROBLEMS WITHIN THE FGD SYSTEM WERE THE CAUSE OF DOWN TIME IN
AUGUST.
BECAUSE OF CHANGES IN SYSTEM OPERATIONS, ONLY 3 MODULES ARE NEEDED TO MEET
CURRENT S02 REGULATIONS.
A
B
C
D
SYSTEM
69.0
99.6
96.9
99.6
99.1
20.3
74.6
35.8
80.8
67.8
48.6
80.3
66.8
60.8
82.5
10.0
36.8
17.6
39.9
33.4
720 355
241 33.2
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS TAKEN OUT OF SERVICE ON SEPTEMBER 16, 1980 FOR A SCHEDULED
MAINTENANCE OUTAGE.
10/80 A
B
75.9
83.7
38.5
47.9
46.3
56.5
16.9
21.1
132
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
CENTRAL ILLINOIS PUBLIC SERV: NEWTON 1 (CONT.)
PERFORMANCE DATA
PERIOD MOCJLE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
'/. REMOVAL PER BOILER FGD CAP.
SOS PART. HOURS HOURS HOURS FACTOR
c
D
SYSTEM
81
62
75
.0
.4
.8
.•;i.6
7.0
S6.3
54.5 22.7
13.7 3.X
46.3 16.0
^
744
328
119
30
.4
** PROBLEMS/SOLUTIONS/COMMENTS
DURIN3 OCTOBER THE FGD SYSTEM AVAILABILITY WAS LOW AS A RESULT OF LOW
LIQUOR TEMPERATURES IN THE SCRUBBER FOLLOWING THE FOUR WEEK BOILER OUTAGE.
THE LIQUOR WAS PREHEATED WITH STEAM TO PREVENT PLUGGING DUE TO THE
"SALTING OUT" OF REAGENTS AT LOW TEMPERATURES.
11/80
A
B
C
D
SYSTEM
93.6
79.6
89.4
79.6
99.3
69.9
59.9
58.8
70.1
64.9
98.2
100.0
97.2
99.0
100.0
69.9
59.9
58.8
70.0
84.8
720 719
465 69.6
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR OUTAGES OCCURRED DURING NOVEMBER.
12/80 ft
3
C
•3
JYSTEM
64.5
71.5
72.7
71.5
74.1
45.9
68.7
42.1
52.8
69.5
63.8
72.2
63.4
66.7
84.8
45.7
68.4
41.9
52.6
69.3
744 741
70.7
,;* PROBLEMS/SOLUTIONS/COMMENTS
FGD SYSTEM AVAILABILITY WAS LOWERED DURING DECEMBER AS A RESULT OF
THICKENER PLUGGING PROBLEMS.
133
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICIPATE EMISSION LIMITATION - NG/J
502 EMISSION LIMITATION - NG/J
NOX EMCSSION LIMITATION - NG/J
NET PUNT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** UN.tT PVTA - BOILER AND STACK
BOILES SUPPLIER
BOILtR TYPE
BOILIR SERVICE LOAD
DESIGN BOILER FLUE GAS FLOll - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
S"AC.< HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FIEL TYPE
Fl EL GRADE
A\ERAGE HEAT CONTENT - J/G
R/1NGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** ESP
NU.1BER
TYi'E
SUPPLIER
IN..ET FLUE GAS CAPACITY - CU.M/S
INI.ET FLUE GAS TEMPERATURE - C
PRLSSURE DROP - KPA
PARTICLE REMOVAL EFFICENCY - 7.
** PARTICLE SCRUBBER
GENERIC TYPE
SPECIFIC TYPE
*** FGD SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
UNIT DESIGN S02 REMOVAL EFFICIENCY - 7.
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
COLORADO UTE ELECTRIC ASSN
CRAIG
1
CRAIG
COLORADO
D
****** (****** LB/MMBTU)
****** (****** LB/MMBTU)
****** (****** LB/MMBTU)
900
447
400
424
447
BABCOCK 8 WILCOX
PULVERIZED COAL
BASE
722.29 (1530600 ACFM)
398.9 ( 750 F)
183. ( 600 FT)
CONCRETE
10.9 ( 35.8 FT)
( 10000 BTU/LB)
9100-10300
COAL
SUBBITUMINOUS
23260.
8.00
10-12
16.00
10-12
.45
.4-.5
.00
.0-.02
HOT SIDE
BELCO
1392.1
398.9
.7
99.9
NONE
N/A
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
PEABODY PROCESS SYSTEMS
STEARNS-ROGER
FULL SCALE
NEW
7. 99.80
85.00
1
8/80
10/80
(2950000 ACFM)
( 750 F)
( 3. IN-H20)
134
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
COLORADO UTE ELECTRIC ASSN: CRAIG 1 (CONT.)
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
SPACE REQUIREMENTS - SQ M
OPER. & MAINT. REQUIREMENT - MANHR/DAY
** ABSORBER
NUMBER
NUMBER OF SPARES
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
G,,S CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
L'G RATIO - L/CU.M
GAS-SIDE PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/SEC
INLET GAS FLOP! - CU. M/S
INLET GAS TEMPERATURE - C
SOS REMOVAL EFFICIENCY - X
PARTICLE REMOVAL EFFICENCY - 'X
** MI.5T ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBF? PER SYSTEM
G1ENEPIC TYPE
SPECIFIC TYPE
TRAD3 NAME/COMMON TYPE
CONFIGURATION
NUM3ER OF STAGES
NUMBER OF PASSES PER STAGE
Ff £E30ARD DISTANCE - M
D7STANCE BETWEEN STAGES - CM
DISTANCE BETWEEN VANES - CM
V/NE ANGLES - DEGREES
PRESSURE DROP - KPA
St'PERFICAL GAS VELOCITY - M/S
CONSTRUCTION MATERIAL GENERIC TYPE
Wf.SH WATER SOURCE
WASH RATE - L/S
** REHEATER
NUMBER
GENERIC TYPE
SfECIFIC TYPE
TRADE NAME/COMMON TYPE
TEMPERATURE INCREASE - C
INLET FLUE GAS FLOW RATE - CU. M/S
IKLET FLUE GAS TEMPERATURE - C
NU-3ER OF TUBES PER BW4DLE
CONSTRUCTION MATERIAL GENERIC TYPE
5/77
12140.2 ( 130680 SQ FT)
264.0
4
1
SPRAY TOWER
OPEN COUNTERCURRENT SPRAY
PEABODY PROCESS SYSTEMS
32 DIA X 52.5 HIGH
CARBON STEEL
AISI 1110
N/A
ORGANIC
RUBBER
SPRAY MIST
1
6.7
1.6
3.0
896.61
121.1
85.0
50.0
(50.0 GAL/1000 ACF)
(6.5 IN-H20)
( 10.0 FT/S)
(1900000 ACFM)
( 250 F)
MIST ELIMINATOR
4
IMPINGEMENT
BAFFLE
CHEVRON VASE
HORIZONTAL
1
1
1.52
2.54
3.0
45
.2
3.0
NORYL PLASTIC
RAW WATER
6.3
5.0
1.0
1.20
1.0
10.0
( 100
FT)
IN)
IN)
IN-H20)
FT/S)
GAL/MI
BYPASS
COLO SIDE
N/A
10.0
38.37
121.1
422
316 STAINLESS ST^EEL
( 50 F)
( 81300 ACFM)
( 250 F)
** FANS
NUMBER
NU.1BER OF SPARES
SUPPLIER
FUNCTION
SEFIVICE
FLUE GAS FLOW RATE - CU.M/S
CONSTRUCTION MATERIAL GENERIC TYPE
** FANS
NUMBER
NU13ER OF SPARES
DESIGN
4
0
BUFFALO FORGE
DIRECT REHEAT
DRY
46.03 (
CARBON STEEL
4
1
AXIAL
97545 ACFM)
135
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
COLORADO UTE ELECTRIC ASSN: CRAIG 1 (CONT.)
SUPPLIER
FUNCTION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** DUCTWORK
LOCATION
DIMENSIONS
SHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
MANUFACTURER
NUMBER
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
PRODUCT QUALITY - X SOLIDS
** TANKS
SERVICE
RECIRCULATION
LIMESTONE SLURRY STORAGE
SUPERHATE
WASH SLURRY
POLYELECTROLYTE
WASTE SLURRY SUMP
** SO'.IDS CONCENTRATING/DEWATERING
DEVICE
N'JMBER
DWEHSIONS - FT
C\PACITY
FZED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
N'JMBER
NUMBER OF SPARES
CONFIGURATION
DIMENSIONS - FT
SHELL GENERIC MATERIAL TYI-E
FCEC STREAM CHARACTERISTIC>
O'JTIET STREAM CHARACTERIST .CS
*** SA'.EASLE BYPRODUCTS
*** SLUDGE
** DISPOSAL
N/.TURE
TVPE
LOCATION
SITE TRANSPORTATION METHOD
S'JTE SERVICE LIFE - YRS
** PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS
CONTROL LEVELS
MUNITOR LOCATION
PROCESS CONTROL MANNER
PROCESS CHEMISTRY MODE
BUFFALO FORGE
BOOSTER
DRY
373.80 ( 790000 ACFM)
121.1 ( 250 F)
CARBON STEEL
INLET TO PLENUM
23 X 13
.25 IN. CARBON STEEL PLATE
NONE
LIMESTONE GRINDING
BALL MILL
KENNEDY VAN SAUN
1
9.1 (10 TPH)
35.0
NUMBER
CENTRIFUGE
1
3 (DIA) X 6
126 GPM
35X SOLIDS
60X SOLIDS
THICKENER
1
0
CENTER DRAM
75 (DIA) X 15
CARBON STEEL
57. SOLIDS
35X SOLIDS
(LENGTH)
(DEPTH)
FINAL
MINEFILL
OFF SITE
TRUCK
35
PH 8 DENSITY
PH 5.6-6.1, SOLIDS 12-15X
AT MODULE RECYCLE TANK
AUTOMATIC
FEEDBACK/FEED FORWARD
136
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
COLORADO UTE ELECTRIC ASSN: CRAIG 1 (CONT.)
** WATER BALANCE
WATER LOOP TYPE
EVAPORATION WATER LOSS - LITER/S
MAKEUP WATER ADDITION - LITERS/S
** CHEMICALS AND CONSUMPTION
FUNCTION
NAME
PRINCIPAL CONSTITUENT
CONSUMPTION
POINT OF ADDITION
** FGD SPARE CAPACITY INDICES
ABSORBER - X
** FGD SPARE COMPONENT INDICES
ABSORBER
CLOSED
19.7
19.9
ABSORBENT
LIMESTONE
CAC03
14162 LB/HR
RECYCLE TANK
33.3
1.0
312 GPM)
316 GPM)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
10/80 SYSTEM
*« PROBLEMS/SOLUTIONS/COMMENTS
744
THE FGD SYSTEM BEGAN INITIAL OPERATIONS ON OCTOBER 9, 1980 WHEN MODULE D
CAME ON LINE. HOWEVER MODULE'S A THROUGH C ARE STILL UNDER CONSTRUCTION.
11/80 D
SYSTEM
48.6
44.7
38.5
46.00
720 619
47.3
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER OPERATED AT ABOUT 50 TO 60X LOAD CAPACITY DURING NOVEMBER. ONLY
ONE MODULE IS REQUIRED FOR COMPLIANCE WHEN OPERATING UNDER THE REDUCED
LOAD CONDITION.
12/80
A
B
C
D
SYSTEM
.0
53.8
73.9
60.5
62.7
.0
44.3
70.4
56.0
56.8
70.4
84.0
80.2
78.7
.0
42.6
67.7
53.9
54.7
56.50
744 716
407 63.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM EQUIPMENT CHECKOUT CONTINUED THROUGH DECEMBER. MODULE A
NEEDED MECHANICAL PARTS FOR REPAIR. AS OF DECEMBER 23, THE PROBLEMS
CAUSING LOAD RESTRICTION WERE CORRECTED AND THE UNIT INCREASED TO FULL
LOAD.
137
-------
EPA U1ILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - '/.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** ESP
NUMBER
TYPE
SUPPLIER
INLET FLUE GAS CAPACITY - CU.M/S
INLET FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
PARTICLE REMOVAL EFFICENCY - 7.
** PARTICLE SCRUBBER
GENERIC TYPE
SPECIFIC TYPE
*** FGD SYSTEM
** GENERAL DATA
JALEABLE PRODUCT/THROWAWAY PRODUCT
£02 REMOVAL MODE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
KEW/RETROFIT
INIT DESIGN PARTICLE REMOVAL EFFICIENCY
UNIT DESIGN S02 REMOVAL EFFICIENCY - 7.
CURRENT STATUS
COMMERCIAL START-UP
INITxAL START-UP
COLORADO UTE ELECTRIC ASSN
CRAIG
2
CRAIG
COLORADO
.100 LB/MMBTU)
.400 LB/MMBTU)
.700 LB/MMBTU)
43. (
172. (
301. (
900
455
415
422
400
BABCOCK & WILCOX
PULVERIZED COAL
BASE
722.29 (1530600 ACFM)
398.9 ( 750 F)
183. t 600 FT)
CONCRETE
10.9 ( 35.8 FT)
( 10000 BTU/LB)
9100-10300
COAL
SUBBITUMINOUS
23260.
8.00
10-12
16.00
10-12
.45
.4-.5
.00
.0-.02
HOT SIDE
BELCO
1392.1
398.9
.1
99.9
NONE
N/A
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
PEABODY PROCESS SYSTEMS
STEARNS-ROGER
FULL SCALE
NEW
7. 99.80
85.00
1
5/80
12/79
(2950000 ACFM)
( 750 F)
( 0. IN-H20)
138
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
COLORADO UTE ELECTRIC ASSN: CRAIG 2 (CONT.)
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
SPACE REQUIREMENTS - SQ M
OPER. & MAINT. REQUIREMENT - MANHR/DAY
** AB'ORBER
NUMBER
NUMBER OF SPARES
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LXNER MATERIAL TRADE NAME/COMMON TYPE
GAS CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
L/G RATIO - L/CU.M
GAS-SIDE PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/SEC
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
S02 REMOVAL EFFICIENCY - '/.
PARTICLE REMOVAL EFFICENCY - 7.
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES PER STAGE
FREEBOARD DISTANCE - M
DISTANCE BETWEEN STAGES - CM
DISTANCE BETWEEN VANES - CM
VANE ANGLES - DEGREES
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/S
CONSTRUCTION MATERIAL GENERIC TYPE
WASH WATER SOURCE
WASH RATE - L/S
** REHEATER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
PERCENT GAS BYPASSED - AVG
TEMPERATURE INCREASE - C
INLET FLUE GAS FLOW RATE - CU. M/S
INLET FLUE GAS TEMPERATURE - C
NUMBER OF TUBES PER BUNDLE
CONSTRUCTION MATERIAL GENERIC TYPE
** FANS
NUMBER
NUMBER OF SPARES
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
CONSTRUCTION MATERIAL GENERIC TYPE
5/77
12140. Z
360.0
< 130680 SQ FT)
SPRAY TOWER
OPEN COUNTERCURRENT SPRAY
PEABODY PROCESS SYSTEMS
32 DIA X 52.5 HIGH
CARBON STEEL
AISI 1110
N/A
ORGANIC
RUBBER
SPRAY MIST
1
6.7
1.6
3.0
896.61
121.1
85.0
50.0
( 50.0 GAL/1000 ACF)
( 6.5 IN-H20)
( 10.0 FT/S)
(1900000 ACFM)
( 250 F)
MIST ELIMINATOR
4
IMPINGEMENT
BAFFLE
CHEVRON VANE
HORIZONTAL
1
1
1.52 (
2.54 (
3.0 (
45
.2 C
3.0 (
NORYL PLASTIC
RAW WATER
6.3 (
5.0 FT)
1.0 IN)
1.20 IN)
1.0 IN-H20)
10.0 FT/S)
100 GAL/MII
4
BYPASS
COLD SIDE
N/A
12.0
10.0
38.37
121.1
422
316 STAINLESS ST*EEL
( 50 F)
( 81300 ACFM)
( 250 F)
4
0
BUFFALO FORGE
DIRECT REHEAT
DWDI CENTRIFUGAL
DRY
46.03 ( 97545 ACFM)
CARBON STEEL
139
-------
EPA UTILITY FGO SURVEY: OCTOBER - DECEMBER 1980
COLORADO UTE ELECTRIC ASSN: CRAIG Z (CONT.)
** FANS
NJHUER
NJM8ER OF SPARES
DESIGN
SJPPLIER
F JNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** DU3TWORK
LOCATION
DIMENSIONS
SHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DtVICE
MANUFACTURER
NIMBER
FLLL LOAD DRY FEED CAPACITY - M.TONS/HR
PRODUCT QUALITY - 7. SOLIDS
** TANKS
SERVICE
RE.CIRCULATION
LIMESTONE SLURRY STORAGE
SUPERNATE
WASH SLURRY
POLYELECTROLYTE
WASTE SLURRY SUMP
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
DIMENSIONS - FT
CAPACITY
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
CONFIGURATION
DIMENSIONS - FT
SHELL GENERIC MATERIAL TYPE
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
*** SLUDGE
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE SERVICE LIFE - YRS
** PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS
CONTROL LEVELS
MONITOR LOCATION
PROCESS CONTROL MANNER
4
1
AXIAL
BUFFALO FORGE
BOOSTER
FORCED DRAFT
DRY
372.80
121.1
CARBON STEEL
( 790000 ACFM)
( 250 F)
INLET TO PLENUM
23 X 13
.25 IN. CARBON STEEL PLATE
NONE
LIMESTONE GRINDING
BALL MILL
KENNEDY VAN SAUN
1
9.1 ( 10 TPH)
35.0
NUMBER
1
1
4
1
1
CENTRIFUGE
1
3(DIA) X 6CLENGTH)
126 GPM
35X SOLIDS
60Z SOLIDS
THICKENER
1
0
CENTER DRAW
75(DIA) X 15CDEPTH)
CARBON STEEL
5X SOLIDS
35X SOLIDS
FINAL
MINEFILL
OFF SITE
TRUCK
35
PH 8 DENSITY
PH 5.6-6.1, SOLIDS 13-152
AT MODULE RECYCLE TANK
AUTOMATIC
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
COLORADO UTE ELECTRIC ASSN: CRAIG Z (CONT.)
PROCESS CHEMISTRY MODE FEEDBACK/FEED FORWARD
** W#TER BALANCE
WATER LOOP TYPE CLOSED
EVAPORATION WATER LOSS - LITER/S 19.7 ( 312 6PM)
hAKEUP WATER ADDITION - LITERS/S 19.9 ( 316 6PM)
** CHEMICALS AND CONSUMPTION
FUNCTION ABSORBENT
NAME LIMESTONE
CONSUMPTION 1*162 LB/HR
POII.T OF ADDITION RECYCLE TANK
** FGD f.PARE CAPACITY INDICES
ABSCRBER - X 33.3
** FET SPARE COMPONENT INDICES
A3SORBER 1.0
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
______ ______ ____________ ___________ ___ ______ ___________ _____ _____ _____ ______ _____ _ ___
7/79 SYSTEM 744
8/79 SYSTEM 744
9/79 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM AT CRAI6 2 WAS UNDERGOING TESTING IN JULY. INITIAL
TESTING WITH THE SYSTEM OPERATING ON FLUE GAS TOOK PLACE IN AUGUST 1979.
COMMERCIAL OPERATIONS ARE SCHEDULED FOR NOVEMBER 1979.
10/79 SYSTEM 744
11/79 SYSTEM 720
12/79 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE CRAIG 2 SCRUBBING SYSTEM COMMENCED INITIAL OPERATION OFFICIALLY IN
DECEMBER 1979.
THE SYSTEM WAS TAKEN OUT OF SERVICE ON DECEMBER 3 FOR INSPECTION AND
SCHEDULED MAINTENANCE. THE FINE SCREEN ON THE TURBINE THROTTLE VALVE WAS
REMOVED AND CLEANED. THE BOILER WAS PUT BACK ON LINE ON DECEMBER 9 AT
FULL LOAD. THE FGD SYSTEM WAS PUT BACK ON LINE ON DECEMBER 19. SHAKEDOWN
OPERATIONS ARE CONTINUING.
1/80 SYSTEM 744
2/80 SYSTEM 696
3/80 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS DOWN AT THE END OF THE PERIOD DUE TO TURBINE RELATED
PROBLEMS.
WHEN FULL LOAD OPERATIONS WERE ATTEMPTED CONTROL PROBLEMS WERE ENCOUNTERED
WITH THE SCRUBBER.
PROBLEMS WITH OPENING/CLOSING THE BYPASS DAMPER HAVE BEEN ENCOUNTERED.
LARGER OPERATORS ARE BEING TESTED THAT MAY SOLVE THE PROBLEM.
141
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
COLORADO UTE ELECTRIC ASSN: CRAIG 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
4/80 SYSTEM
720
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM IS STILL IN THE STARTUP PHASE OF OPERATIONS. TESTING IS
BEING PERFORMED ON THE SYSTEM, BUT THERE HAS BEEN NO OPERATIONAL DATA
REPORTED.
5/80 A
B
C
D
SYSTEM
38.4
42.5
47.0
30.0
52.6
27.5
32.1
37.2
18.0
38.3
28.4
33.1
38.4
18.6
39.5
24.5
28.5
33.1
16.0
34.0
64.70
640 661
253 76.8
** PROBLEMS/SOLUTIONS/COMMENTS
THE CRMG 2 UNIT (BOILER AND SCRUbBER) COMMENCED COMMERCIAL OPERATION ON
MAY 4, 1980.
NOTE: THIS SYSTEM EFFECTIVELY HAS ONE SPARE MODULE SO THAT ONLY THREE ARE
CURRENTLY NEEDED AT FULL LOAD TO MAINTAIN COMPLIANCE WITH S02 EMIS-
SION REGULATIONS. WHEN THE CURRENT LOW SULFUR COAL SOURCE IS
EXHAUSTED (SEVERAL YEARS FROM NOW) GREATER SCRUBBING CAPACITY WILL
BE REQUIRED SO THAT THERE WILL NO LONGER BE AN ENTIRE MODULE SET
ASIDE AS A SPARE DURING FULL LOAD BOILER OPERATIONS. THE "SYSTEM-
DEPENDABILITY FACTORS WILL BE BASED ON THREE MODULES UNTIL THE
CURRENT COA.L SOURCE IS EXHAUSTED.
6/80
A
B
C
D
SYSTEM
47.6
53.9
61.1
34.6
65.7
41.2
48.0
55.8
27.0
57.3
42.0
48.9
56.9
27.5
58.4
37.9
44.2
51.4
24.9
52.8
65.70
720 663
380 68.5
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MAY AND JUNE, PROBLEMS WERE ENCOUNTERED WITH PLUGGING OF THE
ABSORBER SPRAY NOZZLES.
A PROBLEM WAS ALSO ENCOUNTERED DURING INITIATION OF COMMERCIAL OPERATION
WITH A HIGH PH LEVEL IN THE THICKENER UNDERFLOW.
THE SCRUBBING SYSTEM IS STILL UNDERGOING SHAKEDOWN OPERATIONS.
7/80
\
3
C
SYSTEM
59.1
61.8
37.6
43.7
67.4
51.0
54.1
26.0
33.0
54.7
51.7
54.9
26.3
33.5
55.5
43.8
46.5
22:3
28.4
47.0
65.60
744 640
350 65.8
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JULY, FGD OUTAGE TIME WAS CAUSED BY PLUGGED ABSORBER SPRAY NOZZLES.
8/80
A
B
C
D
SYSTEM
50.0
50.0
50.0
50.0
66.7
46.7
48.4
47.5
52.3
65.0
48.3
50.0
49.1
54.0
67.1
42.2
43.7
42.9
47.2
58.7
65.60
744 672
327 75.6
142
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
COLORADO UTE ELECTRIC ASSN: CRAIG 2 CCONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL
S02 PART.
PER BOILER F6D CAP.
HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
DURING AUGUST THE FGD SYSTEM EXPERIENCED ASSORTED MECHANICAL PROBLEMS.
SPRAY NOZZLE PLUGGING OCCURRED, CAUSING ADDITIONAL OUTAGE TIME WHICH ADDED
TO THE LOW AVAILABILITY FACTOR DURING THE MONTH.
9/80
10/80
11/80
A
B
C
D
SYSTEM
48.6
58.2
61.1
67.*
78. 4
47.5
58.8
59.6
66.2
77.4
48.4
59.9
60.7
67.4
78.8
47.1
58.2
59.0
65.6
76.6
65.70
720 713
552 85.2
** PROBLEMS/SOLUTIONS/COMMENTS
THE SPRAY NOZZLES IN THE ABSORBER MODULE CONTINUED TO PLUG UP DURING SEP-
TEMBER.
A
B
C
D
SYSTEM
99.
99.
99,
99.
99.
89.4
91.5
88.
92.
90.
.4
.5
.5
93.7
95.8
92.6
96.8
94.7
11.9
12.2
11.8
12.4
12.1
744
99
90 12.2
** PROBLEMS/SOLUTIONS/COMMENTS
THE POILER WAS TAKEN OFF LINE ON OCTOBER 5 FOR A FIVE WEEK SCHEDULED
OUTAGi.
AN IN-.INE SPOT CHECK PERFORMED ON OCTOBER 4 INDICATED THAT THE FGD
SYSTEM WAS ACHIEVING A 66.2X S02 REMOVAL EFFICIENCY. THE STACK OPACITY
WAS MEASURED AT 5.72.
A
B
C
D
SYSTEM
69.4
.0
70.8
72.2
70.8
61.
71.
89.
74.1
66.0
.0
76.0
96.0
79.3
27.5
.0
31.6
40.0
33.0
31.30
720 321
38.8
** PROBLEMS/SOLUTIONS/COMMENTS
12/80 A
B
C
D
SYSTEM
43.0
.0
53.8
60.5
52.4
THE FGD SYSTEM WAS RETURNED TO SERVICE ON NOVEMBER 10 AFTER A FIVE WEEK
SCHEDULED MAINTENANCE OUTAGE.
MODULE B WAS TAKEN OFF LINE DURING NOVEMBER DUE TO BOOSTER FAN PROBLEMS.
58.7
57.5
.0
69.3
78.4
68.4
70.7
80.0
69.8
42.6
.0
51.3
58.1
50.7
62.70
744 551
377 54.6
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE B REMAINED OFF LINE DURING DECEMBER DUE TO BOOSTER FAN BLADE
PITCH PROBLEMS.
143
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
SOS EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NS/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
COLUMBUS & SOUTHERN OHIO ELEC
CONESVILLE
5
CONESVILLE
OHIO
D
43.
516.
******
1950
411
375
391
411
( .100 LB/MMBTU)
( 1.200 LB/MMBTU)
(****** LB/MMBTU)
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/6
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - V.
AVERAGE MOISTURE CONTENT - 7.
R*.NGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - '/.
R4NGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PAl'TICLE CONTROL
** ESP
MJMBER
TYPE
SUPPLIER
INLET FLUE GAS CAPACITY - CU.M/S
IULET FLUE GAS TEMPERATURE - C
PARTICLE REMOVAL EFFICENCV - 7.
** PARTICLE SCRUBBER
GrNE3IC TYPE
SPECIFIC TYPE
*** FGD SYSTEM
** GEKERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
SI STEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NF.W/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
Ut'lT DESIGN S02 REMOVAL EFFICIENCY - 7.
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
COMBUSTION ENGINEERING
PULVERIZED COAL
CYCLING
657.78 (1393893 ACFM)
146.7 ( 296 F)
244. C 800 FT)
CONCRETE
7.9 ( 26.0 FT)
( 10850 BTU/LB)
10000-12000
COAL
BITUMINOUS
25237.
15.10
10-24
7.50
5-18
4.67
4.2-5.1
.01
.01-.11
COLD SIDE
RESEARCH-COTTRELL
657.8 (1393893 ACFM)
146.7 ( 296 F)
99.6
NONE
N/A
THROWAWAY PRODUCT
WET SCRUBBING
LIME
MG PROMOTED
AIR CORRECTION DIVISION, UOP
BLACK & VEATCH
FULL SCALE
NEW
7. .00
89.50
1
2/77
1/77
-------
EPA UTILITY FED SURVEY: OCTOBER - DECEMBER 1980
COLUMBUS & SOUTHERN OHIO ELEC: CONESVILLE 5 (COHT.)
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
OPER. & MAINT. REQUIREMENT - MANHR/DAY
** QUENCHER/PRESATURATOR
** ABSORBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
GAS CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
DISTANCE BETWEEN GAS CONTACTING ZONES - CM
LIQUID RECIRCULATION RATE - LITER/S
L/G RATIO - L/CU.M
GAS-SIDE PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/SEC
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
S02 REMOVAL EFFICIENCY - 7.
** ABSORBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
GAS CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
DISTANCE BETWEEN GAS CONTACTING ZONES - CM
LIQUID RECIRCULATION RATE - LITER/S
L/G RATIO - L/CU.M
6AS-SIDE PRESSURE DROP - KPA
SJPERFICAL GAS VELOCITY - M/SEC
IULET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
S02 REMOVAL EFFICIENCY - X
** MIoT ELIMINATOR
PilE-MIST ELIMINATOR/MIST ELIMINATOR
NJMBER PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES PER STAGE
FREEBOARD DISTANCE - M
DISTANCE BETWEEN STAGES - CM
D'STWCE BETWEEN VANES - CU
VANE ANGLES - DEGREES
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/S
CONSTRUCTION MATERIAL GENERIC TYPE
10/74
84.0
PACKED TOWER
MOBILE BED PACKING
TURBULENT CONTACT ABSORBER
AIR CORRECTION DIVISION, UOP
45. X 17.5 X 79.5 (HT)
CARBON STEEL
AISI 1110
N/A
ORGANIC
SYNTHETIC RUBBER
CHLOROBUTYL
NITRILE RUBBER BALLS (1.5 IN. DIA. )
4
17.8 ( 7.0IN)
1988. (31560 GPM)
6.7 (50.0 GAL/1000 ACF)
2.0 ( 8.1 IN-H20)
4.1 ( 13.5 FT/S)
301.81 ( 639568 ACFM)
141.1 ( 286 F)
89.7
PACKED TOWER
MOBILE BED PACKING
TURBULENT CONTACT ABSORBER
AIR CORRECTION DIVISION, UOP
45. X 17.5 X 79.5 (HT)
CARBON STEEL
AISI 1110
N/A
ORGANIC
SYNTHETIC RUBBER
CHLORCBUTYL
NITRILE RUBBER BALLS (1.5 IN. DIA.)
4
17.8 ( 7.0IN)
1988. (31560 GPM)
6.7 ( 50.0 GAL/1000 ACF)
2.0 ( 8.1 IN-H2O)
4.1 ( 13.5 FT/S)
301.81 ( 639568 ACFM)
141.1 ( 286 F)
89.7
MIST ELIMINATOR
1
IMPINGEMENT
BAFFLE
CHEVRON VANE
HORIZONTAL
2
7
3.05 (10.0 FT)
11.43 ( 4.5 IN)
5.1 ( 2.00 IN)
90
.5 (1.9 IN-H20)
4.2 ( 13.7 FT/S)
FIBERGLASS
145
-------
EPA UTILITY FSD SURVEY: OCTOBER - DECEMBER 1980
COLUMBUS & SOUTHERN OHIO ELEC: CONESVILLE 5 (CONT.)
WA?H WATER SOURCE
WA3H RATE - L/S
** REH:;ATER
GENERIC TYPE
SPFCIFIC TYPE
TRADE NAME/COMMON TYPE
** FANS
NUMBER
NUMBER OF SPARES
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
»* DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
MANUFACTURER
NUMBER
** TANKS
SERVICE
RECYCLE
RECLAIMED WATER
SLURRY TRANSFER
SLURRY STORAGE
M.E. WASH
** PUMPS
SERVICE
ABSORBER RECIRCULATION
LIME SLURRY TRANSFER
SLURRY MAKEUP
RECYCLE TANK DRAWOFF
MIST ELIMINATOR WASH
RECLAIM WATER
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
SHELL GENERIC MATERIAL TYPE
BELT GENERIC MATERIAL TYPE
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
** SO'.IDS CONCENTRATING/DEWATERING
DliVICE
NUMBER
NJMBER OF SPARES
DIMENSIONS - FT
SMELL GENERIC MATERIAL TYPE
OJTLET STREAM CHARACTERISTICS
FRESH MAKEUP (RIVER)
63.1 ( 1000 GAL/MIN)
NONE
N/A
N/A
Z
0
CENTRIFUGAL
GREEN FAN
UNIT
INDUCED DRAFT
DRY
401.11
( 850000 ACFM)
( 386 F)
CARBON STEEL
SCRUBBER INLET
CARBON STEEL
NONE
SCRUBBER OUTLET
CARBON STEEL
ACID RESISTANT GUNITE
LIME SLAKING
SLAKER
WALLACE & TIERNAN
NUMBER
NUMBER
10
2
3
VACUUM FILTER
3
1
CARBON STEEL
POLYPROPYLENE
35X SOLIDS
SOX SOLIDS
THICKENER
1
0
145(DIA) X 16(DEPTH)
CARBON STEEL
35X SOLIDS
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
COLUMBl'S & SOUTHERN OHIO ELEC: CONESVILLE 5 (CONT.)
*** SLl
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
COLUMBUS & SOUTHERN OHIO ELEC: CONESVILLE 5 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPER^BILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
502 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
COMMERCIAL START-UP OF MODULE B OCCURRED ON FEBRUARY 13, 1977. THE LONG-
EST PERIOD OF CONTINUOUS OPERATION WAS 132 HOURS.
THE UTILITY REPORTED THAT THE ESP OPERATED SATISFACTORILY.
PRESSURE SURGES OCCURRED IN THE PRESATURATOR PIPING.
THE CONTINUOUS S02 ANALYZERS OPERATED UNSATISFACTORILY.
MODULE B EXPERIENCED POOR VELOCITY DISTRIBUTION THROUGH THE TCA BEDS.
SCRUBBING LIQUOR WAS CARRYING OVER INTO THE MIST ELIMINATOR SECTION.
72.9 50.9
3/77 B
SYSTEM
4/77 B
SYSTEM
41.8
40.0
40.5
37.4
744 520
720 685
«t PROBLEMS/SOLUTIONS/COMMENTS
A STACK OUTLET TEMPERATURE OF 200 F IS BEING MAINTAINED IN ORDER TO MIN-
IMIZE ACID RAINOUT AND STACK CORROSION PROBLEMS.
THE 316 SS PRESATURATOR AREA HAS EXPERIENCED CORROSION.
THE RUBBER LINER IN THE RECYCLE TANK HAS BEEN PEELING AWAY. THE PROBLEM
APPEARED TO BE APPLICATION-RELATED.
SOME PLUGGING HAS OCCURRED IN THE TUBE THICKENERS.
THE QUALITY OF THE LIME SLURRY HAS BEEN A PROBLEM AREA. ROCKS UP TO FIVE
INCHES IN DIAMETER HAVE BEEN DETECTED. THIS HAS PROMPTED DRAVO TO INSTALL
MECHANICAL SEPARATORS AND METAL DETECTORS AT THE LIME SHIPMENT FACILITY.
5/77 B
SYSTEM
6/77 B
SYSTEM
7/77 B
SYSTEM
58.0
66.0
.0
50.0
59.0
.0
51.0
60.0
.0
48.0
58.0
.0
744 712
720 713
744 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE B-SIDE MODULE DID NOT OPERATE THE ENTIRE MONTH PENDING COMPLETION
OF A NUMBER OF NECESSARY MODIFICATIONS AND REPAIRS.
MODIFICATIONS WERE MADE TO THE UNIT PROCESS CONTROL SYSTEM.
MODIFICATIONS WERE MADE TO THE UNIT INSTRUMENTATION SYSTEM.
REPAIRS WERE MADE TO THE ABSORBER LINER.
REPAIRS WERE MADE TO THE PIPING BETWEEN THE THICKENER AND IUCS BUILDING.
THE UTILITY IS CURRENTLY PLANNING TO CONDUCT A PARTICULATE DROP TEST
SCHEDULED FOR SEPTEMBER 1977.
THE REPLACEMENT A-SIDE TCA MODULE REPLACING THE ORIGINAL MODULE DESTROYED
148
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
COLUMBUS & SOUTHERN OHIO ELEC: CONESVILLE 5 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
BY FIRE IN DECEMBER 1976 IS EXPECTED TO BE AVAILABLE FOR COMMERCIAL
SERVICE IN JANUARY 1978.
8/77 B .0 .0 .0 .0
SYSTEM 744 613
9/77 B 52.9 39.9 46.9 26.0
SYSTEM 720 469
**-• PROS LEMS/SO LUTIONS/CO 1MENTS
THE PARTICUUTE DROP TEST SCHEDULED FOR SEPTEMBER 1977 WAS PUSHED BACK TO
THE UEEK OF OCTOBER 24 1977.
THE SCRUBBER WAS NOT OPERATED THE ENTIRE MONTH OF AUGUST. REPAIRS AND
MODIFICATIONS CONTINUED UNTIL SEPTEMBER 13. THERE WERE SOME WEATHER-
RELATED DELAYS.
25.0 18.0
744 559
10/77 B
SYSTEM
11/77 A
B
SYSTEM
32.0
10.0
33.0
21.5
24.0
4.0
33.0
18.5
25.0
4.0
33.0
18.5
18.0
4.0
33.0
18.5
720 715 133
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE A WENT ON .LINE NOVEMBER 21. DURING LOW LOAD PERIODS SOLIDS
BUILD UP TENDED TO CAUSE PLUGGING BECAUSE OF LOW FLOW RATES. DURING THE
LOW LOAD PERIODS ALL GAS WAS DUCTED THROUGH ONE MODULE WHILE THE OTHER WAS
SHUT DOWN.
THE SCRUBBER WAS DOWN FROM OCTOBER 10 TO NOVEMBER 10 FOR RELINING
WITH NEOPRENE RUBBER.
12/77 * 93.0 64.0 62.0 22.0
3 97.0 79.0 76.0 27.0
SYSTEM 95.0 71.5 69.0 24.5 744 252 180
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WENT DOWN DECEMBER 12 FOR A 3-MONTH SCHEDULED OUTAGE. MODULE A
BEGAN COMMERCIAL OPERATIONS DECEMBER 3 OPERATING AS MUCH AS POSSIBLE
THROUGH DECEMBER 12. MODULE B OPERATED DECEMBER 1 THROUGH 12. DURING THE
SHUTDOWN THE UTILITY WILL DECIDE IF THE SYSTEM SUPPLIERS HAVE MET SPECS
ON THE BOILER AND TURBINES. THE UNIT IS SCHEDULED TO BE BACK ON LINE IN
MID-MARCH BUT THIS MAY BE PUSHED BACK TO APRIL 1.
DURING THE DECEMBER TO MARCH 1978 SHUTDOWN THE CARBON STEEL FLUE WILL BE
REPLACED WITH AN ACID-BRICK LINING.
744 0 0 .0
672 0 0 .0
1/78 SYSTEM
2/78 SYSTEM
3/78 A
B
SYSTEM
.0
.0
20.0
20.0
20.0
19.0
15.8
17.4
64.0
54.0
59.0
.0
.0
10.0
8.0
9.0
744 379 66
#* PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT STARTED UP AGAIN ON MARCH 16.
PH CONTROLS AND S02 ANALYZERS HAVE EXPERIENCED OPERATIONAL PROBLEMS.
149
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
COLUMBUS & SOUTHERN OHIO ELEC: CONESVILLE 5 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
4/78
5/78
6/78
7/78
8/78
9/78
10/78
IMPURITIES IN THE LIME HAVE CAUSED PLUGGING PROBLEMS.
A
B
SYSTEM
67.0
65.0
66.0
58.0
59.0
58.5
61.0
63.0
62.0
58.0
59.0
58.5
720 716 421
#* PROBLEMS/SOLUTIONS/COMMENTS
THE SYSTEM WAS DOWN DUE TO AN EXCESS OF FLOCCULANT IN THE THICKENER.
EXCESS FLOCCULANT IN THE THICKENER YIELDED A HIGH SOLIDS LEVEL IN THE
OVERFLOW AND RESULTED IN PLUGGING PROBLEMS IN THE ABSORBER MODULES.
A
B
SYSTEM
52.0
54.0
53.0
45.0
50.0
47.5
45.0
51.0
48.0
44.0
69.0
56.5
744 720
420
** PROBLEMS/SOLUTIONS/COMMENTS
THE SYSTEM WAS TAKEN OUT OF SERVICE BECAUSE OF CONTINUED PROBLEMS WITH THE
FLOCl'.ULANT FEED SYSTEM. THE THICKENER WAS EMPTIED TO RESTORE PROPER FLOC-
CULAKT BALANCE.
A
B
Si STEM
48.0
30.0
39.0
37.0
30.0
33.5
37.0
30.0
33.5
37.0
30.0
33.5
720 720 243
** PROBLEMS/SOLUTIONS/COMMENTS
AN FRP PIPING FAILURE IN THE MIST ELIMINATOR WASH SYSTEM OCCURRED.
A
B
SYSTEM
66.0
43.0
54.5
66.0
33.0
49.5
66.0
33.0
49.5
64.0
32.0
49.0
744 727
359
** PROBLEMS/SOLUTIONS/COMMENTS
OUTAGE TIME WAS DUE TO PLUGGING IN THE MIST ELIMINATOR AND SCRUBBER BALL
REGIONS.
A
B
SYSTEM
18.0
18.0
18.0
20.0
21.0
20.5
20.0
21.0
20.5
18.0
18.0
18.0
744 667
135
** PROBLEMS/SOLUTIONS/COMMENTS
THE FORCED OUTAGE TIME WAS DUE, IN PART, TO TIME REQUIRED TO REMOVE SCALE
FROM THE MIST ELIMINATOR.
THE FORCED OUTAGE TIME WAS DUE, IN PART, TO TIME REQUIRED TO REPLACE SOME
OF THE PING PONG BALLS IN THE MODULES.
THE UTILITY EXPERIENCED BYPASS DAMPER PROBLEMS DURING THE PERIOD.
PROBLEMS OCCURRED RELATED TO BROKEN SLUDGE LINES AND PLUGGING IN THE LIME
SLURRY FEED LINES.
A
B
SYSTEM
A
B
SYSTEM
61.0
54.0
57.5
72.0
82.0
77.0
46.0
44.0
45.0
37.0
46.0
41.5
55.0
53.0
54.0
38.0
47.0
42.5
45.0
43.0
44.0
36.0
45.0
40.5
720 707
744 713
316
301
150
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
COLUMBUS & SOUTHERN OHIO ELEC: CONESVILLE 5 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
11/78
12/78
1/79
2/79
** PROBLEMS/SOLUTIONS/COMMENTS
DAMPER DRIVE PROBLEMS WERE REPORTED BY THE UTILITY.
MINIMAL RUBBER LINER FAILURE WAS OBSERVED AT THE TOP OF ONE OF THE
SCRUBBER MODULES AND JUST AFTER THE PRESATURATOR.
720 642 331
744 609 112
** PROBLEMS/SOLUTIONS/COMMENTS
THE LOW HOURS FOR THIS PERIOD ARE ATTRIBUTED TO FREEZE UPS.
SYSTEM .0 .0 .0 .0 744 602 0
SYSTEM .0 .0 .0 .0 672 629 0
** PROBLEMS/SOLUTIONS/COMMENTS
THE SYSTEM WAS UNAV/MLABLE DURING JANUARY AND FEBRUARY BECAUSE OF SEVERE
WINTER WEATHER.
A
B
SYSTEM
A
B
SYSTEM
43.0
84.0
63.5
6.6
33.1
19.8
29.0
74.0
51.5
.3
36.3
18.3
29.0
75.0
52.0
.3
36.6
18.4
25.0
66.0
45.5
.3
30.0
15.1
3/79
4/79
A
B
SYSTEM
A
B
SYSTEM
50.0
.0
25.0
17.0
.0
8.5
49.0
.0
24.5
58.0
.0
2.9.0
50.0
.0
25.0
73.0
.0
36.5
43.0
.0
21.5
12. C
.0
6.0
744 652
720 149
160
43
**; PROBLEMS/SOLUTIONS/CC1MENTS
MODULE B DID NOT OPERATE DURING MARCH AND APRIL BECAUSE OF SEVERE CORRO-
SION AT THE PRESATURATOR INLET DUCT. IIHICH IS BEING REPAIRED BY UOP.
5/79
744 744
SYSTEM .0 .0 .0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
REPAIRS WERE MADE TO THE SEAL BETWEEN THE THICKENER BASE AND SIDEWALL.
THE FGD SYSTEM WAS DOWN DURING MAY FOR AN ANNUAL OUTAGE.
6/79
A
B
SYSTEM
69.0
50.0
59.5
35.0
21.0
28.0
36.0
22.0
29.0
33.0
20.0
26.5
7/79
720 670 191
** PROBLEMS/SOLUTIONS/COMMENTS
PLUGGED PH LINES WERE A PROBLEM DURING MAY AND JUNE.
FLYASH CONVEYING PROBLEMS RESULTED IN ABOUT A TWO DAY OUTAGE.
OUTLET DAMPER PROBLEMS WERE REPORTED BY THE UTILITY.
A 75.3 76.3 77.6 69.0
151
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
COLUMBUS & SOUTHERN OHIO ELEC: CONESVILLE 5 (CONT.)
PERIOD
8/79
9/79
10/79
11/79
12/79
MODULE
B
SYSTEM
A
B
SYSTEM
A
B
SYSTEM
A
B
SYSTEM
A
B
SYSTEM
SYSTEM
•AVAILABILITY
93.*
84.4
86.6
85.6
86.1
89.3
95.9
92.6
53.2
47.8
50.5
74.0
70.0
72.0
.0
OPER ABILITY
89.8
82.8
24.7
22.7
23.7
52.6
51.3
51.9
76.3
77.4
76.9
90.0
88.0
89.0
RELIABILITY
90.8
84.2
25.0
23.0
24.0
59.5
58.0
58.8
77.0
78.1
77.6
91.0
89.0
90.0
UTILIZATION
80.6
74.8
10.1
9.3
9.7
27.9
27.2
27.6
45.4
46.1
45.8
52.0
51.0
51.2
.0
X REMOVAL PER
S02 PART. HOURS
744
744
720
744
720
744
BOILER
HOURS
672
305
383
443
414
0
FGD CAP.
HOURS FACTOR
557
72
199
341
369
0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE LAST HALF OF 1979 THE UNIT EXPERIENCED PROBLEMS WITH THE LIME
BLOWER COMPRESSOR MOTOR.
CAVITATION WAS SITED IN THE SLUDGE PUMP.
THE FLYASH CONVEYOR SYSTEM CAUSED PROBLEMS DURING THE LATTER HALF OF THE
YEAR.
PLUGGING IN THE REAGENT CIRCULATION SYSTEMS WAS ENCOUNTERED.
THERE WERE PROBLEMS WITH THE GUIDE BARS AND SEALS IN THE INLET DAMPER
DURING THE LAST HALF OF 1979.
1/80 A 89.0 38.0 45.0 13.0
B 93.0 50.0 59.0 17.0
SYSTEM 91.0 44.0 52.0 15.0 744 257 113 21.4
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JANUARY A BOILER OUTAGE OCCURRED FROM THE FIRST OF THE MONTH TO
JANUARY 20, DURING WHICH TIME MAINTENANCE WAS PERFORMED ON THE FGD SYSTEM.
2/80 A 90.0 63.0 77.0 31.0
B 93.0 69.0 84.0 34.0
SYSTEM 92.0 $6.0 81.0 33.P 696 343 226 31.4
*»•• PROBLEMS/SOLUTIONS/COilMENTS
A BOI!ER OUTAGE LASTING APPROXIMATELY 17 DAYS ALSO OCCURRED DURING
FEBRUARY.
IN FEBRUARY, MIST ELIMINATOR NOZZLE PLUGGING OCCURRED CAUSING SOME FGD
SYSTEM OUTAGE TIME.
3/80 A 88.0 82.0 82.0 82.0
B 88.0 81.0 82.0 81.0
SYSTEM 88.0 82.0 82.0 82.0 744 744 606 75.4
152
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
COLUMBUS & SOUTHERN OHIO ELEC-' CONESVILLE 5 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MARCH PROBLEMS WERE EXPERIENCED WITH THE IUCS SLUDGE STABILIZATION
PROCESS AND SOME OUTAGE TIME RESULTED. ALSO DURING MARCH SOME GRID RODS
REQUIRED REPLACING AND SOME RUBBER LINER FAILURES OCCURRED.
THE MAJORITY OF THE MARCH FGD SYSTEM OUTAGE TIME WAS DUE TO CONTINUING
PROBLEMS WITH THE MIST ELIMINATOR NOZZLES.
4/80 A 94.6 84.4 87.7 78.9
B 74.9 65.8 68.4 61.5
SYSTEM 84.7 75.2 78.0 70.3 720 673 506 63.1
** PROBLEMS/SOLUTIONS/COMMENTS
CONTINUAL PROBLEMS WITH THE DAMPERS, PRESATURATOR HOSES, AND NOZZLES WERE
THE CAUSES OF FGD SYSTEM OUTAGE TIME IN APRIL.
5/80 A 92.1 86.2 86.2 86.2
B 90.3 84.3 84.3 84.3
SYSTEM 91.3 85.2 85.2 85.2 744 744 634 69.5
** PRCBLEMS/SOLUTIONS/COMMENTS
IN MAY, CONTROLS AND INSTRUMENTATION DEVELOPED PROBLEMS THAT CAUSED SOME
OUTAGE TIME.
6/80 A 89.6 71.0 71.0 70.7
B 94.3 74.8 74.8 74.4
SYSTEM 86.4 72.9 72.9 72.6 720 717 523 65.1
** PROBLEMS/SOLUTIONS/COMMENTS
EXTERNAL CAUSES (IUCS DISPOSAL FACILITY, LOW UNIT DEMAND, SERVICE WATER
PROBLEMS, ETC. ) WERE RESPONSIBLE FOR THE MAJORITY OF THE JUNE OUTAGES.
7/80 A 90.6 70.7 72.4 43.8
B 88.8 82.0 84.0 50.8
SYSTEM 89.7 76.4 78.2 47.3 744 461 352 36.6
** PROBLEMS/SOLUTIONS/COMMENTS
THE PRESATURATOR HOSES AND NOZZLES PLUGGED CAUSING THE UNIT TO SHUT DOWN
FOR PART OF JULY.
8/80 A 98.0 83.5 84.9 48.5
B 95.4 88.8 90.4 51.6
SYSTEM 96.7 86.2 87.6 50.1 744 432 373 40.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT PROBLEMS WITH THE RECLAIM WATER SYSTEM OCCURRED
IN AUGUST CAUSING SOME OUTAGE TIME.
9/80 A 84.8 73.4 74.4 73.1
B 85.9 85.1 86.3 82.0
SYSTEM 88.2 79.2 80.3 78.9 720 717 568 71.5
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE JULY-SEPTEMBER PERIOD .TNLET DAMPER SEAL LEAKING WAS A MAJOR
PROBLE1.
153
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EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
COLUMBUS & SOUTHERN OHIO ELEC: CONESVILLE 5 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
THE PRESATURATOR PROBLEMS CONTINUED IN SEPTEMBER CAUSING ADDITIONAL OUTAGE
TIME FOR THE FGD SYSTEM.
10/80 A 93.7 77.8 80.8 75.7
>} 89.2 80.0 82.9 77.7
SYSTEM 91.0 78.9 81.9 76.7 95.80 744 723 571 59.7
** PROBLEMS/SOLUTIONS/COMMENTS
DURING OCTOBER MINOR OUTAGES WERE THE RESULT OF DAMPER AND AGITATOR MOTOR
PROBLEMS.
11/80 A 79.0 35.7 36.9 31.3
B 86.1 64.6 66.8 56.5
SYSTEM 82.6 50.1 51.9 43.9 95.80 720 630 316 35.9
** PROBLEMS/SOLUTIONS/COMMENTS
THE LOW SYSTEM AVAILABILITY DURING THE MONTH OF NOVEMBER WAS A DIRECT RE-
SULT OF A 28 HOUR OUTAGE ATTRIBUTED TO LIME SLURRY TRANSFER TANK AND
AGITATOR MOTOR PROBLEMS.
ADDITIONAL MINOR PROBLEMS WERE ENCOUNTERED WITH THE PRESATURATOR HOSES,
TEMPERATURE PROBES, THICKENERS AND SERVICE WATER DURING THE MONTH OF
NOVEMBER.
12/80 A 93.1 88.8 89.2 82.2
B 90.9 86.6 85.3 80.2
SYSTEM 92.0 87.7 87.2 81.2 95.80 .06 744 689 604 72.6
** PROBLEMS/SOLUTIONS/COMMENTS
DURING DECEMBER THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS
WERE ENCOUNTERED.
154
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EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFDRMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANV NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICIPATE EMISSION LIMITATION - NG/J
SOS EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - MM
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
BO£LER SUPPLIER
BOILER TYPE
BO.aER SERVICE LOAD
DEtiIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
ST/.CK SHELL
STACK TOP DIAMETER - M
** FUCL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** ESP
NUMBER
TYPE
SUPPLIER
INLET FLUE GAS CAPACITY - CU.M/S
INLET FLUE GAS TEMPERATURE - C
PARTICLE REMOVAL EFFICENCY - 7.
** PARTICLE SCRUBBER
GENERIC TYPE
SPECIFIC TYPE
** PARTICLE SCRUBBER
GENERIC TYPE
SPECIFIC TYPE
*** FGD SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
( .100 LB/MMBTU)
( 1.200 LB/MMBTU)
(****** LB/MMBTU)
COLUMBUS « SOUTHERN OHIO ELEC
CONESVILLE
6
CONESVILLE
OHIO
D
43.
516.
******
1950
375
391
411
COMBUSTION ENGINEERING
PULVERIZED COAL
CYCLING
657.78 (1393893 ACFM)
146.7 ( 296 F)
244. ( 800 FT)
CONCRETE
7.9 ( 26.0 FT)
( 10850 BTU/LB)
10000-12000
COAL
BITUMINOUS
25237.
15.10
10-24
7.50
5-18
4.67
4.2-5.1
.01
.01-.11
COLD SIDE
RESEARCH-COTTRELL
657.8 (1393893 ACFM)
146.7 ( 296 F)
99.6
NONE
N/A
NONE
N/A
THROWAWAY PRODUCT
WET SCRUBBING
LIME
MG PROMOTED
AIR CORRECTION DIVISION, UOP
BLACK & VEATCH
FULL SCALE
NEW
7. .00
155
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
COLUMBUS & SOUTHERN OHIO ELEC: CONESVILLE 6 (CONT.)
UNIT DESIGN SOS REMOVAL EFFICIENCY - X
CJRRENT STATUS
COMMERCIAL START-UP
IiJITHL START-UP
C3NTFACT AWARDED
** DESIG i AND OPERATING PARAME "ERS
OPEK. & MAINT. REQUIREMENT - MANHR/DAY
** QUiiNC.HER/PRESATURATOR
** ABSORBER
NUIBER
GENERIC TYPE
SrECIFIC TYPE
TTADE NAME/COMMON TYPE
SUPPLIER
DIMENSIONS - FT
SKELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
Sf.'ELL MATERIAL TRADE NAME/COMMON TYPE
L:NER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
GAS CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
DISTANCE BETWEEN GAS CONTACTING ZONES - CM
LIQUID RECIRCULATION RATE - LITER/S
L/3 RATIO - L/CU.M
GAS-SIDE PRESSURE DROP - KPA
SU^ERFICAL GAS VELOCITY - M/SEC
INLET GAS FLOW - CU. M/S
IN'.ET GAS TEMPERATURE - C
SO.' REMOVAL EFFICIENCY - 7.
*# MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES PER STAGE
FREEBOARD DISTANCE - M
DISTANCE BETWEEN STAGES - CM
DISTANCE BETWEEN VANES - CM
VANE ANGLES - DEGREES
SUPERFICAL GAS VELOCITY - M/S
CONSTRUCTION MATERIAL GENERIC TYPE
WASH WATER SOURCE
WASH RATE - L/S
** REHEATER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
** FANS
NUMBER
NUMBER OF SPARES
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
89.50
1
7/78
6/78
10/74
84.0
PACKED TOWER
MOBILE BED PACKING
TURBULENT CONTACT ABSORBER
AIR CORRECTION DIVISION, UOP
45. X 17.5 X 79.5 (HT)
CARBON STEEL (CARPENTER 20 PRESATURATOR)
AISI 1110
N/A
ORGANIC
SYNTHETIC RUBBER
CHLOROBUTYL
NITRILE RUBBER BALLS (1.5 IN. DIA. )
4
17.8 ( 7.0IN)
1988. (31560 GPM)
6.7 ( 50.0 GAL/1000 ACF)
2.0 ( 8.1 IN-H20)
4.1 ( 13.5 FT/S)
301.81 ( 639568 ACFM)
141.1 ( 286 F)
89.5
MIST ELIMINATOR
1
IMPINGEMENT
BAFFLE
CHEVRON VANE
HORIZONTAL
Z
7
3.05
11.43
5.1
90
4.2
FIBERGLASS
FRESH MAKEUP (RIVER)
31.5
(10.0 FT)
( 4.5 IN)
( 2.00 IN)
( 13.7 FT/S)
( 500 GAL/MIN)
NONE
N/A
N/A
2
0
CENTRIFUGAL
GREEN FAN
UNIT
FORCED DRAFT
DRY
401.11
141.1
CARBON STEEL
( 850000 ACFM)
( 286 F)
156
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
COLUMBUS & SOUTHERN OHIO ELEC: CONESVILLE 6 (CONT.)
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
,_INER GENERIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
.INER GENERIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
MANUFACTURER
NUMBER
** TAI4KS
SERVICE
RECYCLE
RCCLUMED WATER
SLURRY TRANSFER
SLURRY STORAGE
M.E. WASH
** PUT-PS
SFRVICE
Af.SORBER RECIRCULATION
LJtIE SLURRY TRANSFER
SLURRY MAKEUP
RfcCYCLE TANK DRAWOFF
Ji:ST ELIMINATOR WASH
RtCLAIM WATER
** SOLIDS CONCENTDATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
SHELL GENERIC MATERIAL TYPE
BELT GENERIC MATERIAL TYPE
OUTLET STREAM CHARACTERISTICS
** SOLiDS CONCENTRATING/DEWATERING
DEVICE
NU11BER
NUtiBER OF SPARES
DIMENSIONS - FT
SHE'LL GENERIC MATERIAL TYPE
OU"LET STREAM CHARACTERISTICS
*** SLUDGE
** TREATMENT
METHOD
PROPRIETARY PROCESS
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
** PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS
CONTROL LEVELS
MONITOR LOCATION
PROCESS CONTROL MANNER
SCRUBBER INLET
CARBON STEEL
NONE
SCRUBBER OUTLET
CARBON STEEL
ACID RESISTANT GUNITE
LIME SLAKING
SLAKER
WALLACE * TIERNAN
5
NUMBER
NUMBER
10
2
3
VACUUM FILTER
3
1
CARBON STEEL
POLYPROPYLENE
BOX SOLIDS
THICKENER
1
0
145COIA) X 16(DEPTH)
CARBON STEEL
35X SOLIDS
POZ-0-TEC
IUCS
FINAL
POND
ON SITE
PUMPED/CONVEYED
MODULE PH & RECYCLE TANK LEVEL
25-100X OUTLET PH 5.6-6.0
SLURRY DISCHARGE FROM MODULE
AUTOMATIC
157
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EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
COLUMBUS & SOUTHERN OHIO ELEC: CONESVILLE 6 (CONT.)
PROCESS CHEMISTRY MODE FEEDBACK
*» WATER BALANCE
WATER LOOP TYPE OPEN
MAKEUP WATER ADDITION - LITERS/S 31.5 ( 500 6PM)
** CHEMICALS AND CONSUMPTION
FUNCTION ABSORBENT
NAME LIME
CONSUMPTION 16 TPH
POINT OF ADDITION RECYCLE TANK
** FGD SPARE CAPACITY INDICES
ABSORBER - 7. .0
** FGD SPARE COMPONENT INDICES
ABSORBER -0
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
6/78 A
B
SYSTEM
56.0
44.0
50.0
49.0
33.0
41.0
51.0
34.0
42.5
42.0
30.0
36.0
720 524 174
*« PROBLEMS/SOLUTIONS/COMMENTS
INITIAL OPERATIONS OF THE CONESVILLE 6 FGD SYSTEM BEGAN IN JUNE.
CONTROL OF THE LO'V'ERED DAMPER Or THE BYPASS SYSTEM WAS LOST. THE
RESULT WAS BACK PktSSURE BUILDUP THAT AUTOMATICALLY SHUT DOWN THE BOILER.
SCRUF3ER CONTROLS WERE NOT OPERATING PROPERLY AND NEEDED ADJUSTMENT.
7/78 A 83.0 37.0 63.0 25.0
B 70.0 19.0 33.0 13.0
SYSTEM 76.5 28.0 48.0 19.0 744 502 141
** PROBLEMS/SOLUTIONS/COMMENTS
THE LOUVERED DAMPER PROBLEM CONTINUED.
THE FRP TRANSFER LINE FROM THE THICKENER TO THE IUCS SYSTEM RUPTURED AS A
RESULT OF WATER HAMMER IN THE LIMF.AND HAD TO BE REPAIRED.
8/78 A 47.0 50.0 66.0 43.0
B 62.0 60.0 81.0 52.0
SYSTEM 54.5 55.0 73.5 47.5 744 642 354
** PROBLEMS/SOLUTIONS/COMMENTS
PROBLEMS WERE ENCOUNTERED WITH THE SLUDGE LINE. THE UTILITY REPORTED
THAT THIS IS TYPICALLY A HIGH MAINTENANCE AREA.
PROBLEMS WERE ENCOUNTERED WITH THE BYPASS CONTROL DAMPERS. THE UTILITY
REPORTED THAT THIS IS TYPICALLY A HIGH MAINTENANCE AREA.
9/78 A 55.0 50.0 53.0 49.0
R 69.0 55.0 57.0 54.0
SYSTEM 62.0 52.5 55.0 51.5 720 706 372
** PROBLEMS/SOLUTIONS/COMMENTS
A PROBLEM AREA WAS THE PLUGGING OF THE LIME SLURRY FEED LINES.
BYPASS DAMPER CONTROL PROBLEMS CONTINUED THROUGH SEPTEMBER.
158
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EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
COLUMBUS & SOUTHERN OHIO ELEC: CONESVILLE 6 (COST.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
10/78 A
B
SYSTEM
98.0
37.0
67.5
29.0
35.0
32.0
30.0
36.0
33.0
24.0
29.0
26.5
744 603 199
** PROBLEMS/SOLUTIONS/COMMENTS
PROBLEMS WITH DAMPER SEALS AND 6UIDEBARS WERE ENCOUNTERED. THE UTILITY
PLANS TO REPLACE THEM DURING THE NEXT BOILER OUTAGE.
11/78
A
B
SYSTEM
26.0
26.0
26.0
3.0
9.0
6.0
3.0
9.0
6.0
2.0
8.0
5.0
12/78
1/79
720 600
** PROBLEMS/SOLUTIONS/COMMENTS
LIME TRANSFER BAGHOUSE SHAKER PROBLEMS WERE EXPERIENCED.
THE THICKENER RAKE MOTOR BURNED OUT AND HAD TO BE REWOUND.
744 672
36
A
B
SYSTEM
A
B
SYSTEM
34.8
26.6
30.7
5.0
.0
2.5
26.3
19.0
22.6
2.0
.0
1.0
26.8
19.3
23.0
2.0
.0
1.0
24.2
17.5
20.8
2.0
.0
1.0
155
744 730 8
** PROBLEMS/SOLUTIONS/COMMENTS
FREEZE UPS WERE A SERIOUS PROBLEM DURING THE DECEMBER-JANUARY PERIOD.
2/79 SYSTEM .0 .0 .0 .0 672 629 0
** PROBLEMS/SOLUTIONS/COMMENTS
THE FSD SYSTEM DID NOT OPERATE DURING FEBRUARY DUE TO SEVERE WINTER WEATHER
CAUSII'G SYSTEM FREEZE UPS.
3/79
4/79
5/79
A
B
S>STEM
A
B
SYSTEM
43.0
32.0
37.5
82.0
72.0
77.0
57.0
28.0
52.5
79.0
59.0
69.0
39.0
29.0
34.0
79.0
59.0
69.0
33.')
25.0
29.0
78.0
58.0
68.0
744 664
.0
720
744
711
0
216
489
0
SYSTEM 100.0
** PROBLEMS/SOLUTIONS/COMMENTS
REPAIRS WERE MADE TO THE SEAL BETWEEN THE THICKENER BASE AND SIDEWALL.
THE BOILER DID NOT OPERATE DURING MAY DUE TO A SCHEDULED ANNUAL
OUTAGE.
.0
6/79
A
B
SYSTEM
43.0
49.0
46.0
37.0
49.0
43.0
39.0
52.0
45.5
27.0
31.0
29.0
720 433
209
159
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EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
COLUMBUS & SOUTHERN OHIO ELEC: CONESVILLE 6 (CONT.)
htKI-UKHANUt UAIA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
FLY ASH CONVEYING PROBLEMS RESULTED IN ABOUT A TWO DAY OUTAGE.
PLUGGED PH LINES WERE A
7/79
8/79
9/79
10/79
11/79
12/79
A
B
SYSTEM
A
B
SYSTEM
A
B
SYSTEM
A
B
SYSTEM
A
B
SYSTEM
A
B
SYSTEM
83.9
88.7
86.3
76.2
77.6
76.9
87.6
86.5
87.0
75.9
43.1
59.5
67.0
52.0
59.5
84.0
91.0
87.5
29.5
41.2
35.4
40.8
42.6
41.7
58.5
55.5
57.0
66.2
23.6
44.9
58.0
49.0
53.5
76.0
87.0
81.5
29.7
41.4
35.6
40.8
42.6
41.7
57.4
56.2
56.8
66.5
23.7
45.1
58.0
49.0
53.5
76.0
87.0
81.5
PROBLEM DURING THIS PERIOD.
22.0
30.8
26.4 744 554 196
40.8
42.6
41.7 744 744 310
54.4
53.3
53.9 720 681 388
63.3
22.6
43.0 744 713 320
48.0
41.0
44.5 720 599 320
76.0
87.0
81.5 744 744 606
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE LAST HALF OF
BLOWER COMPRESSOR MOTOR.
CAVITATION WAS
SITED IN
1979 THE UNIT EXPERIENCED PROBLEMS WITH THE LIME
THE SLUDGE PUMP.
THE FLYASH CONVEYOR SYSTEM CAUSED PROBLEMS DURING THE LATTER HALF OF THE
YEAR.
PLUGGING IN THE
REAGENT
THERE WERE PROBLEMS WITH
DURING THE LAST HALF OF
1/80
A
B
SYSTEM
88.0
89.0
89.0
74.0
78. 0
76.0
74.0
78.0
76.0
CIRCULATION SYSTEMS WAS ENCOUNTERED.
THE GUIDE BARS AND SEALS IN THE INLET DAMPER
1979.
74.0
78.0
76.0 744 744 566 73.9
** PROBLEMS/SOLUTIONS/C1MMENTS
NO MAJ5R FGD SYSTEM RELATED PROBLEMS WERE REPORTED FOR JANUARY.
2/80
A
B
SYSTEM
87.0
92.0
90.0
75.0
81.0
78.0
78.0
85.0
82.0
69.0
75.0
72.0 696 648 503 70.8
** PROBLEMS/SOLUTIONS/COMMENTS
IN FEBRUARY, MIST ELIMINATOR NOZZLE PLUGGING OCCURRED CAUSING SOME OUTAGE
TIME.
3/80 A
93.0
69.0
69.0
15.0
160
-------
EPA UTILITY FED SURVEY: OCTOBER - DECEMBER 1980
COLUMBUS & SOUTHERN OHIO ELEC: CONESVILLE 6 (CONT.)
l-'tKI-UKnAMl.e UAIA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
B
SYSTEM
94.0 76.0 76.0 16.0
94.0 73.0 73.0 16.0 744 160 117
17.6
** PROBLEMS/SOLUTIONS/COMMENTS
4/80
A
B
SYSTEM
THE BOILER WENT DOWN ON MARCH 9 FOR A BOILER/TURBINE INSPECTION AND
REMAINED OUT OF SERVICE THROUGH THE END OF THE MONTH.
98.8 25.6 29.4 11.1
98.9 54.2 62.1 23.5
98.9 40.1 45.8 17.4 720 312 125
19.8
** PROBLEMS/SOLUTIONS/COMMENTS
5/80
A
B
SYSTEM
CONTINUOUS PROBLEMS WITH DAMPERS, PRESATURATOR HOSES, AND NOZZLES
ACCOUNTED FOR MOST OF THE APRIL FGD SYSTEM OUTAGES.
96.9 5S.3 63.8 55.0
96.1 33.8 37.0 31.9
96.5 46.1 50.4 43.4 744 701 323
39.1
** PROBLEMS/SOLUTIONS/COMMENTS
CONTROL AND INSTRUMENTATION PROBLEMS THAT DEVELOPED IN MAY WERE RESPONSI-
BLE FOR SOME FGD SYSTEM OUTAGE TIME.
6/80
A
B
SYSTEM
97.1 73.6 73.4 73.1
97.1 50.5 50.3 50.1
97.1 62.1 61.9 61.7 720 715 444
52.5
** PROBLEMS/SOLUTIONS/COMMENTS
7/80
A
B
SYSTEM
THE MAJORITY OF THE JUNE FGD SYSTEM OUTAGES WERE A RESULT OF EXTERNAL
CAUSES (IUCS DISPOSAL SYSTEM, LOW UNIT DEMAND, SERVICE WATER, ETC.).
96.0 85.1 85.9 82.7
99.1 89.1 89.9 86.6
97.5 87.1 87.9 84.6 744 722 630
61.7
** PROBLEMS/SOLUTIONS/COMMENTS
8/80
A
B
SYSTEM
THE FGD SYSTEM EXPERIENCED PROCESS CONTROL PROBLEMS DURING JULY.
PROBLEMS WITH LEAKING INLET DAMPER SEALS ALSO OCCURRED DURING JULY.
90.2 65.4 67.3 30.1
97.4 85.5 88.0 39.4
93.8 75.5 77.6 34.7 744 343 259
28.3
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT PROBLEMS WERE ENCOUNTERED WITH THE RECLAIM WATER
AND THE RECYCLE SLURRY SYSTEMS DURING AUGUST.
9/80
A
B
SYSTEM
93.6 88.2 88.5 87.8
94.2 90.7 91.0 90.3
93.9 89.5 89.8 89.0 720 716 641
72.6
** PROBLEMS/SOLUTIONS/COMMENTS
THE INLET DAMPER SEAL PROBLEM CONTINUED THROUGH AUGUST AND SEPTEMBER.
EXTERNAL PROBLEMS WERE EXPERIENCED WITH THE IUCS SYSTEM.
161
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EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
COLUMB'JS & SOUTHERN OHIO ELEC: CONESVILLE 6 (CONT. )
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
10/80 A 89.2 72.0 72.6 64.9
B 94.1 87.6 88.3 78.9
SYSTEM 91.7 79.8 80.5 71.9 92.30 744 670 535 57.2
** PROBLEMS/SOLUTIONS/COMMENTS
BAD C3471 ****
BAD C3471 ****
EXTERNAL PROBLEMS WERE EXPERIENCED WITH THE IUCS SYSTEM.
11/80 A 99.6 92.9 91.1 55.4
B 98.2 81.5 79.9 48.6
SYSTEM 98.9 87.3 85.5 51.9 92.30 720 429 374 43.1
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING OCTOBER AND NOVEMBER.
12/80 A 86.0 84.0 84.0 84.0
B 87.6 76.7 76.7 76.7
SYSTEM 86.8 80.3 80.3 80.3 92.30 .12 744 744 744 79.1
** PROBLEMS/SOLUTIONS/COMMENTS
DURING DECEMBER SYSTEM AVAILABILITY WAS LOW DUE TO NECESSARY REPAIRS
TO THE RECLAIM WATER TANK.
162
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EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT i-lAME
UNIT NJMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTIOJLATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PL
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
COMMONWEALTH EDISON: POMERTON 51 (CONT.)
NEW/RETROFIT
UMIT DESIGN S02 REMOVAL EFFICIENCY - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
** ABSOR3ER
N'JMF ER
6ENt.RIC TYPE
SPECIFIC TYPE
T^ACE NAME/COMMON TYPE
SUPPLIER
DCNENSIONS - FT
SMELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SMELL MATERIAL TRADE NAME/COMMON TYPE
LtNER GENERIC MATERIAL
L;NER SPECIFIC MATERIAL
LTNER MATERIAL TRADE NAME/COMMON TYPE
G\S CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
LIQUID RECIRCULATION RATE - LITER/S
L'G RATIO - L/CU.M
GAS-SIDE PRESSURE DROP - KPA
S'JPERFICAL GAS VELOCITY - M/SEC
INLET GAS FLOW - CU. M/S
IULET GAS TEMPERATURE - C
502 REMOVAL EFFICIENCY - X
** MI£T ELIMINATOR
PFE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CO -.'FIGURATION
EU^ERFICAL GAS VELOCITY - M/S
CONSTRUCTION MATERIAL GENERIC TYPE
** REHEATER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
TEMPERATURE INCREASE - C
INLET FLUE GAS FLOW RATE - CU. M/S
INLET FLUE GAS TEMPERATURE - C
** FANS
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
MANUFACTURER
NUMBER
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
** TANKS
SERVICE
RETROFIT
75.50
1
6/81
4/80
2/76
PACKED TOWcR
MOBILE BED PACKING
TURBULENT CONTACT ABSORBER
AIR CORRECTION DIVISION, UOP
55 X 30 X 18
CARBON STEEL
AISI 1110
N/A
ORGANIC
SYNTHETIC RUBBER
NEOPRENE
SPHERES
3
1575.
8.0
3.0
3.8
240.73
157.2
75.5
(25000 GPM)
( 60.0 GAL/1000 ACF)
(12.0 IN-H20)
( 12.5 FT/S)
( 510123 ACFM)
( 315 F)
MIST ELIMINATOR
2
IMPINGEMENT
BAFFLE
CHEVRON VANE
HORIZONTAL
2.7
( 9.0 FT/S)
FIBERGLASS REINFORCED PLASTIC
INDIRECT HOT AIR
EXTERNAL HEAT EXCHANGER
STEAM TUBE BUNDLES
-3.9 ( 25 F)
583.28 (1236021 ACFM)
54.4 ( 130 F)
CENTRIFUGAL
GREEN FAN
BOOSTER
FORCED DRAFT
DRY
LIMESTONE GRINDING
BALL MILL
KOPPERS
2
20.0 ( 22 TPH)
NUMBER
RECYCLE
SLURRY MAKE-UP
M.E. WASH
WASTE SLURRY
164
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
COMMONWEALTH EDISON: POWERTON 51 (CONT.)
LIMESTONE TRANSFER
RECLAIMED WATER
** SOLIDS CONCENTRATING/DEWATERING -
DEVICE
NUMBER
NUMBER OF SPARES
SHELL GENERIC MATERIAL TYPE
O'JTLET STREAM CHARACTERISTICS
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
N'JHBER
DIMENSIONS - FT
SmL GENERIC MATERIAL TYPE
OUTLET STREAM CHARACTERISTICS
*** SLUDGE
** TRfATMENT
METHOD
PROPRIETARY PROCESS
INLET QUALITY - X
** DISPCSAL
NATLRE
TlfPE
** DISPOSAL
NATURE
T"PE
LOCATION
S::TE CAPACITY - CU.M
** PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS
PUOCESS CONTROL MANNER
PROCESS CHEMISTRY MODE
** WATER BALANCE
W,,TER LOOP TYPE
MAKEUP WATER ADDITION - LITERS/S
VACUUM FILTER
3
1
CARBON STEEL
55X SOLIDS
THICKENER
1
170 (DIA) X 10 (DEPTH)
CARBON STEEL
35X SOLIDS
POZ-0-TEC
IUCS
35.0
FINAL
LANDFILL
INTERIM
LINED POND
ON SITE
122300
100.0 ACRE-FT)
S02, GAS FLOW, PH
AUTOMATIC
FEEDBACK/FEED FORWARD
CLOSED
35.3
( 560 GPM)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
4/80 SYSTEM
5/80 SYSTEM
6/80 'SYSTEM
720
744
** PROBLEMS/SOLUTIONS/COMMENTS
7/80 SYSTEM
THE POWERTON 51 FGD SYSTEM BEGAN INITIAL OPERATIONS IN A TESTING MODE IN
APRIL. ALTHOUGH THE SYSTEM IS NOW AVAILABLE FOR OPERATION, THE UTILITY IS
UNCERTAIN AS TO WHETHER IT WILL BE USED COMMERCIALLY OR NOT. THE SYSTEM WAS
INSTALLED TO BRINS THE UNIT INTO COMPLIANCE WITH ILLINOIS EMISSION REG-
ULATIONS; HOWEVER DURING THE LATTER PART OF CONSTRUCTION THE FEDERAL NSPS
WAS IMPLEMENTED AND THE UTILITY BEGAN UTILIZING LOW SULFUR COAL AS A COM-
PLIANCE STRATEGY. LOW SULFUR COAL ""•" BEEN USED SINCE MAKING OPERATION OF
THE FGD SYSTEM UNNECESSARY. UTILITY COST ANALYSES HAVE INDICATED THAT
UTILIZING LOW SULFUR COAL WILL PROVE TO BE LESS EXPENSIVE THAN OPERATING
THE FGD SYSTEM.
744
165
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
COMMONWEALTH EDISON: POWERTON 51 (CQNT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
8/80 SYSTEM 744
9/80 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
NO DECISION HAS BEEN MADE TO START COMMERCIAL OPERATIONS. THERE ARE NO FGD
OPERATIONS EXCEPT TESTING IN ONE MODULE. PERFORMANCE DATA WILL BE AVAIL-
ABLE WHEN THE FGD SYSTEM GOES INTO COMMERCIAL OPERATION.
10/80 SYSTEM .0 .0 744 0
11/80 SYSTEM .0 .0 720 0
12/80 SYSTEM .0 .0 744 0
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS NOT OPERATED AT ALL DURING THE FOURTH QUARTER 1980.
AN EXPLOSION AND FIRE AT THIS UNIT OCCURRED DURING THE LATTER PART OF
NOVEMBER CAUSING THE BOILER TO GO OFF LINE THROUGH THE END OF THE
QUARTER.
166
-------
EPA UTILITY F6D SURVEY-' OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGD - MM
EQUIVALENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** ES3
NUMBER
T'PE
SUPPLIER
INLET FLUE GAS CAPACITY - CU.M/S
INLET FLUE GAS TEMPERATURf - C
PARTICLE REMOVAL EFFICENCY - 7.
** PAHTICLE SCRUBBER
GENERIC TYPE
TYPE
( .100 LB/MMBTU)
( 1.200 LB/MMBTU)
(****** LB/MMBTU)
COOPERATIVE POWER ASSOCIATION
COAL CREEK
1
UNDERKOOD
NORTH DAKOTA
B
43.
516.
******
1100
545
495
*****
327
COMBUSTION ENGINEERING
PULVERIZED LIGNITE
BASE
********
160.0
198.
CONCRETE
6.7
(*»***** ACFM)
( 320 F)
( 650 FT)
( 22.0 FT)
( 6258 BTU/LB)
3068-7660
COAL
LIGNITE
14556.
7.14
3.89-15.95
39.83
27.78-52.55
.63
0.18-1.41
.02
0.00-0.08
COLD SIDE
WHEELABRATOR-FRYE
1090.1 (2310000 ACFM)
160.6 ( 321 F)
99.5
NONE
N/A
*** FGL SYSTEM
** GEhERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
SC2 REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NtW/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
UNIT DESIGN S02 REMOVAL EFFICIENCY - 7.
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
THROWAWAY PRODUCT
WET SCRUBBING
LIME/ALKALINE FLYASH
NONE
COMBUSTION ENGINEERING
BLACK & VEATCH
FULL SCALE
NEW
7. 99.50
54.00
1
8/79
7/79
167
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
COOPERATIVE POWER ASSOCIATION: COAL CREEK 1 (CCNT.)
** DESIGN AND OPERATING PARAMETERS
SPACE REQUIREMENTS - SQ M
OPER. & MAINT. REQUIREMENT - MANHR/DAY
** ABSORBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
NUttBER OF CONTACTING ZONES
L/G RATIO - L/CU.M
S02 REMOVAL EFFICIENCY - X
** MIST ELIMINATOR
FRE-MIST ELIMINATOR/HIST ELIMINATOR
NUMBER PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
NUMBER OF STAGES
CONSTRUCTION MATERIAL GENERIC TYPE
** REHEATER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
PERCENT GAS BYPASSED - AVG
TEMPERATURE INCREASE - C
** FANS
NUMBER
FUNCTION
APPLICATION
SERVICE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
NUMBER
*# TANKS
SERVICE
3716.0
72.0
( 40000 SQ FT)
R,:ACTION-RECYCLE-THICKENER
FI.YASH WETTING
L :ME FEED
** PUMPS
SERVICE
SPRAY TOWER
OPEN COUNTERCURRENT SPRAY
COMBUSTION ENGINEERING
ZZ X 22 X 20
STAINLESS STEEL
AUSTENITIC
TYPE 3I6L
NONE
N/A
N/A
3
8.0
90.0
( 60.0 GAL/1000 ACF)
MIST ELIMINATOR
1
IMPINGEMENT
BAFFLE
CHEVRON VANE
2
FIBERGLASS REINFORCED PLASTIC
BYPASS
COLD SIDE
N/A
40.0
29.4 ( 85 F)
BALANCED DRAFT
FORCED DRAFT
DRY
LIME SLAKING
SLAKER
I
NUMBER
Bi.EED STREAM
S'-URRY FEED
REACTION TANK TRANSFER
2
****
****
NUMBER
3
****
6
*** SLUDG';
** TREATMENT
MhTHOD
FLYASH STABILIZATION
168
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
COOPERATIVE POWER ASSOCIATION: COAL CREEK 1 (CONT.)
** DISPOSAL
NA"URE FINAL
TYPE LINED POND
** WATER BALANCE
WA^ER LOOP TYPE OPEN
** FGD SPARE CAPACITY INDICES
ABSORBER - X .0
** FGD SPARE COMPONENT INDICES
ABSORBER .0
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
—————— — — — — — — _ — — .. — _ — — — — _.— .. — .. — — — — — — — _ —__«.__ — — _ — — — — — _.. — — — — — — __ —— _ — __ —«.__„ _.» — _ — .. — — — — — — — — — — —
7/79 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER BEGAN OPERATIONS IN MAY 1979. WET TEST RUNS WERE MADE WITH THE
SCRUBBERS DURING THE SECOND WEEK OF JULY AND THE SYSTEM WAS OPERATED WITH
LIME SLURRY DURING THE THIRD WEEK OF JULY. THE UTILITY BEGAN INITIAL FGD
SYSTEM OPERATIONS AS DEFINED BY THE UTILITY (24-HOUR MINIUM PERIOD) ON
JULY 19.
8/79 SYSTEM 744
9/79 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THIS UNIT STARTED COMMERCIAL OPERATIONS ON AUGUST 1, 1979. SOME MINOR
SHAKEDOWN PROBLEMS WERE REPORTED FOR THE AUGUST-SEPTEMBER PERIOD.
10/79 SYSTEM 744 711
11/79 SYSTEM 720 703
12/79 SYSTEM 744 719
** PROBLEMS/SOLUTIONS/COMMENTS
SINCE STARTUP THE UNIT HAS EXPERIENCED NUMEROUS SHAKEDOWN PROBLEMS BOTH
BOILER AND FGD SYSTEM-RELATED. AFTER THE NEXT SCHEDULED OUTAGE IN APRIL,
THE UTILITY EXPECTS STABLE FGD OPERATIONS TO BE ESTABLISHED.
DURING DECEMBER TWO OF THE EIGHT COAL PULVERIZERS WERE OUT OF SERVICE DUE
TO A PRIMARY AIR DUCT EXPLOSION. LITTLE DOWN TIME RESULTED, HOWEVER, THE
UNIT HAD TO OPERATE AT A REDUCED LOAD. NO FGD SYSTEM PROBLEMS WERE
REPORTED.
1/80 SYSTEM 100.0 96.1 74* 715 715
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JANUARY TWO MODULES AT A TIME WERE TAKEN OFF-LINE FOR INSPECTION
AND CLEANING. SOME CRACKED NOZZLES AND PLUGGING PROBLEMS WERE FOUND
DURING THE INSPECTION. THE BOILER WAS OPERATED AT A REDUCED LOAD.
SOME OUTAGE TIME DURING THE MONTH WAS CAUSED BY BOILER-RELATED PROBLEMS.
A BOILER TRIP WAS CAUSED BY A TURBINE ELECTRICIAL RELAY ON JANUARY 13.
AN HOUR OF OUTAGE TIME RESULTED FROM A LOSS OF POWER TO THE CONTROL
SYSTEM AND AN ABNORMAL BOILER DRUM LEVEL WAS ALSO ENCOUNTERED ON JANUARY
16.
169
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
COOPERATIVE POWER ASSOCIATION: COAL CREEK 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
7. REMOVAL
S02 PART.
PER BOILER FGD CAP.
HOURS HOURS HOURS FACTOR
A THREE TO FOUR HOUR OUTAGE WAS SCHEDULED ON JANUARY 27 TO MAKE REPAIRS ON
FGD SYSTEM EQUIPMENT.
2/80 SYSTEM
99.9
696 695
** PROBLEMS/SOLUTIONS/COMMENTS
WHILE THE BOILER WAS OUT OF SERVICE DUE TO ID FAN PROBLEMS CAUSED BY
ELECTRICAL GROUNDING, TWO MODULES WERE TAKEN OUT OF SERVICE SO CALIBRA-
TIONS COULD BE DONE.
3/80 SYSTEM
100.0
96.1
715
715
•** PROBLEMS/SOLUTIONS/COMMENTS
BOILER TRIPS OCCURRED THREE TIMES DURING THE MONTH. ONE TRIP WAS DUE
TO THE CUT DOWN OF TRANSMISSION POWER ON MARCH 12.
THE FGD SYSTEM WAS SHUTDOWN WITH THE BOILER FOR FOUR HOURS TO CLEAN THE
FILTER ON THE BOILER STATOR COOLING PUMPS.
DURING MARCH STACK EMISSION TESTS WERE UNDERTAKEN. THE SYSTEM OPERATED
WITH ONE MODULE DOWN DURING TESTING.
4/80 11
12
13
14
SYSTEM
96.7
100.0
100.0
100.0
99.2
58.3
81.7
96.1
96.9
83.3
100.0
100.0
100.0
100.0
100.0
21.4
30.0
35.3
35.6
30.6
720 264
220 26.2
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS OFF LINE FOR APPROXIMATELY 19 DAYS FOR THE ANNUAL UNIT OUT-
AGE. THE SCRUBBING SYSTEM WAS AVAILABLE DURING THE BOILER OUTAGE.
5/80 11
12
13
14
SYSTEM
88.3
79.3
91.9
91.3
87.7
68.8
18.6
79.6
35.5
50.6
100.0
100.0
100.0
100.0
100.0
34.4
9.3
39.8
17.7
25.3
744 372
188 28.2
** PROBLEMS/SOLUTIONS/COMMENTS
THE ANNUAL UNIT OUTAGE WAS COMPLETED IN THE BEGINNING OF THE MONTH. THERE
WERE PROBLEMS WITH BOILER STARTUP AFTER THIS OUTAGE CAUSING LOW OPERABILITY
OF THE FGD SYSTEM.
6/80 11
12
13
14
SYSTEM
92.9
98.5
74.7
93.5
89.9
49.3
47.6
42.2
73.0
53.0
100.0
100.0
100.0
100.0
100.0
49.2
47.5
42.1
72.8
52.9
720 718
331 58.5
»* PROBLEMS/SOLUTIONS/COMMENTS
THERE WERE NO MAJOR PROBLEMS REPORTED DURING JUNE. ROUTINE MAINTENANCE
AND REPAIRS WERE DONE THROUGHOUT THE MONTH.
7/80 SYSTEM
100.0
100.0
100.0
87.1
744
648
648 47.1
170
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
COOPERATIVE POWER ASSOCIATION' COAL CREEK 1 (CONT.)
—PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
______ ______ ____________ _•_ ________ _____ ______ ____ _______ _____ _____ _____ ______ _____ ______
** PROBLEMS/SOLUTIONS/COMMENTS
IN JULY, NO PROBLEMS WERE ENCOUNTERED WITH THE FGD SYSTEM.
8/80 11
12
13
14
SYSTEM
43.5
42.7
78.9
47.5
17.5
30.6
30.1
55.6
33.5
744 525
249 31.8
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING AUGUST.
9/80 SYSTEM .0
** PROBLEMS/SOLUTIONS/COMMENTS
.0
720
.0
THE UNIT DID NOT OPERATE DURING SEPTEMBER DUE TO A TURBINE BEARING FAILURE.
10/80 tl
14
SYSTEM
65.6
80.3
2.7
36.1
46.2
13.2
16.1
.0
7.3
9.3
744 149
69 12.1
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MOST OF OCTOBER THE UNIT DID NOT OPERATE DUE TO THE REPAIRS BEING
PERFORMED ON THE TURBINE BEARINGS. THE UNIT OPERATED APPROXIMATELY 150
HOURS DURING THE MONTH.
11/80 11
12
13
14
SYSTEM
46.7
48.1
33.7
45.0
43.4
45.8
47.2
33.1
44.2
42.6
12/80
11
12
13
14
SYSTEM
60.6
30.3
85.0
10.0
46.6
60.2
30.1
84.4
9.9
46.2
720 707
744 739
307 30.8
344 72.2
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR PROBLEMS WERE ENCOUNTERED DURING NOVEMBER AND DECEMBER.
171
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT MAME
UNIT NJMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTIC'JLATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PL5.NT GENERATING CAPACITY - MW
GROSS JNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO 'FGD - MW
EQUIVALENT SCRUBBED CAPACITY - 1W
** UNIT DATA - BOILER AND STAC(
BOIIER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
SrACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FU£L DATA
F'JEL TYPE
F'JEL GRADE
AVERAGE HEAT CONTENT - J/G
R.iNGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - '/.
RjiHGE ASH CONTENT - '/.
AVERAGE MOISTURE CONTENT - 7.
R/NGE MOISTURE CONTENT - 7.
A\ERAGE SULFUR CONTENT - 7.
R/NGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** ESP
NUMBER
TY=E
SUPPLIER
IK LET FLUE GAS CAPACITY - CU.M/S
INLET FLUE GAS TEMPERATURE - C
PARTICLE REMOVAL EFFICENCY - 7.
** PARTICLE SCRUBBER
GENERIC TYPE
SPECIFIC TYPE
*** FGD SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
SOS REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
UNIT DESIGN S02 REMOVAL EFFICIENCY - 7.
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
COOPERATIVE POWER ASSOCIATION
COAL CREEK
2
UNDERWOOD
NORTH DAKOTA
B
( .100 LB/MMBTU)
( 1.200 LB/MMBTU)
f****** LB/MMBTU)
516.
******
1100
545
495
*****
327
COMBUSTION ENGINEERING
PULVERIZED LIGNITE
BASE
******** (******* ACFM)
160.0 t 320 F)
198. ( 650 FT)
CONCRETE
6.7 t 22.0 FT)
( 6258 BTU/LB)
3068-7660
COAL
LIGNITE
14556.
7.14
3.89-15.95
39.83
27.78-52.55
.63
0.18-1.41
.02
0.00-0.08
COLD SIDE
WHEELABRATOR-FRYE
1090.1 (2310000 ACFM)
,160.6 ( 321 F)
99.5
NONE
N/A
THROWAWAY PRODUCT
WET SCRUBBING
LIME/ALKALINE FLYASH
NONE
COMBUSTION ENGINEERING
BLACK fc VEATCH
FULL SCALE
NEW
'/. 99.50
54.00
1
9/80
7/80
172
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
COOPERATIVE POWER ASSOCIATION: COAL CREEK 2 (CONT.)
** DESIGN AND OPERATING PARAMETERS
** ABSORBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
UNER SPECIFIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
NUMBER OF CONTACTING ZONES
L/G RATIO - L/CU.M
S32 REMOVAL EFFICIENCY - X
** MIST ELIMINATOR
FRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
NUM3FR OF STAGES
CONSTRUCTION MATERIAL GENfRIC TYPE
** REHE/.TER
GENERIC TYPE
SPECIFIC TYPE
T^AUE NAME/COMMON TYPE
PERCENT GAS BYPASSED - AVG
TEMPERATURE INCREASE - C
** FAMS
NJMBER
FUNCTION
APPLICATION
S:RVICE
** RE4GENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
NJMBER
** TANKS
SERVICE
Rt ACTION-RECYCLE-THICKENER
FI.YASH WETTING
LIME FEED
** PUf.PS
SERVICE
BLEED STREAM
SL'JRRY FEED
REACTION TANK
*** SLUDGE
*# TREATMENT
METHOD
** DISPOSAL
NATURE
TYPE
SPRAY TOWER
OPEN COUNTERCURRENT SPRAY
COMBUSTION ENGINEERING
22 X 22 X 20
STAINLESS STEEL
AUSTENITIC
TYPE 316L
NONE
N/A
N/A
3
8.0
90.0
( 60.0 GAL/1000 ACF)
MIST ELIMINATOR
1
IMPINGEMENT
BAFFLE
CHEVRON VANf.
2
FIBERGLASS REINFORCED PLASTIC
BYPASS
COLD SIDE
N/A
40.0
29.4 ( 85 F)
BALANCED DRAFT
FORCED DRAFT
DRY
LIME SLAKING
SLAKER
1
NUMBER
2
**»*
****
NUMBER
3
****
6
FLYASH STABILIZATION
FINAL
LINED POND
173
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
COOPERATIVE POWER ASSOCIATION: COAL CREEK 2 (CONT.)
** WATER BALANCE
WATER LOOP TYPE
OPEN
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
7/80
8/80
21
22
23
24
SYSTEM
61.8
18.7
25.0
52.9
39.6
52.4
15.9
21.2
44.9
33.6
744 631
250 34.5
** PROBLEMS/SOLUTIONS/COMMENTS
INITIAL OPERATION OF THE FGD SYSTEM BEGAN IN JULY 1980.
PROBLEMS WERE REPORTED.
NO MAJOR START UP
21
22
23
24
SYSTEM
15.5
29.7
25.4
46.3
58.5
11.8
22.6
19.4
35.2
44.5
744 566
331 36.1
** PROBLEMS/SOLUTIONS/COMMENTS
THE SYSTEM HAS BEEN EXPERIENCING PROBLEMS WITH THE LIME HANDLING CONVEYOR
BELT. THIS HAS NOT RESTRICTED OPERATION OF THE SYSTEM; HOWEVER THE
UTILITY HAS PLANS TO INSTALL A VIBRATOR CONVEYOR IN JANUARY.
9/80 21
22
23
24
SYoTEM
10/80 2J.
2!.
23
2<-
SYSTEM
11/80 21
22
23
24
SYSTEM
12/80 21
22
23
24
SYSTEM
56.8
49.0
76.9
65.7
80.0
56.7
48.9
76.7
65.6
720 718 472 59.1
92.0
36.3
22.1
70.4
63.1
77.0
25.0
77.8
58.7
51.3
22.2
89.4
55.4
91.7
86..)
22.0
70.2
44.2
53.9
17.5
54.4
57.5
50.3
21.8
87.6
54.3
744 742
720 504
70.0
41.0
744 730 404 65.2
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR PROBLEMS HAVE BEEN ENCOUNTERED FOR THE MONTHS OF SEPTEMBER
THROUGH DECEMBER.
174
-------
EPA UTILITY FGO SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - '/.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** MECHANICAL COLLECTOR
KUMBER
TYPE
SUPPLIER
PARTICLE REMOVAL EFFICENCY -7.
** FABRIC FILTER
TYPE
TYPICAL GAS/CLOTH RATIO - M/MIN
** ESP
NJMf ER
SUPPLIER
INLFT FLUE GAS CAPACITY - CU.M/S
IHLfT FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
PARTICLE REMOVAL EFFICENCY - 7.
** PARTICLE SCRUBBER
N:JMBER
G-INERIC TYPE
SPECIFIC TYPE
SUPPLIER
DCMENSIONS - FT
SHELL GENERIC MATERIAL
S.1ELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
DELMARVA POWER & LIGHT
DELAWARE CITY
1
DELAWARE CITY
DELAWARE
129.
( .300 LB/MMBTU)
(****** LB/MMBTU)
(****** LB/MMBTU)
******
180
60
*****
60
RILEY STOKER
PULVERIZED COKE
BASE
139.21 ( 295000 ACFM)
215.6 ( 420 F)
152. ( 500 FT)
CONCRETE
6.1 ( 20.0 FT)
COKE
FLUID PETROLEUM COKE
32564.
.50
.3-.7
.70
.5-1.2
7.00
5-8
********
3
TUBULAR
PRAT-DANIEL
92.0
( 14000 BTU/LB)
13500-14500
NONE
.6
WESTERN PREC.
104.3
54.4
.2
95.0
( 2.0 FT/MIN)
DIVISION, JOY
( 221000 ACFM)
( 130 F)
( 1. IN-H20)
VENTURI TOWER
VARIABLE-THROAT/BOTTOM-ENTRY PLUMB BOB
AIRPOL
20 DIA X 70 HIGH
CARBON STEEL
AISI 1110
ORGANIC,INORGANIC
GLASS FLAKE-FILLED POLYESTER, ACID-RESISTANT BRI
175
-------
EPA UTILITY FGO SURVEY: OCTOBER - DECEMBER 1980
DELMARVA POWER & LIGHT: DELAWARE CITY 1 (CONT. )
NUMBER OF CONTACTING ZONES
LIQUID RECIRCULATION RATE - LITER/S
PRESSURE DROP - KPA
INLET GAS FLOW RATE - CU.M/S
INLET GAS TEMPERATURE - C
S02 REMOVAL EFFICENCY - X
PARTICLE REMOVAL EFFICIENCY - X
*** FED SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
UNIT DESIGN S02 REMOVAL EFFICIENCY - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
SPACE REQUIREMENTS - SQ M
OPER. & MAINT. REQUIREMENT - MANHR/DAY
** ABSORBER
NUMBER
NUMBER OF SPARES
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
GAS CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
LIQUID RECIRCULATION RATE - LITER/S
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
PARTICLE REMOVAL EFFICENCY - X
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
GcNERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES PER STAGE
FREEBOARD DISTANCE - M
DISTANCE BETWEEN STAGES - CM
PRESSURE DROP - KPA
CONSTRUCTION MATERIAL GENERIC TYPE
WASH WATER SOURCE
WASH RATE - L/S
** REHEA7ER
NUMBER
GEN! RIC TYPE
SPECIFIC TYPE
TRACE NAME/COMMON TYPE
TEMPERATURE INCREASE - C
315.0
.5
139.2
215.6
.0
81.5
( 5000 GPM)
( 2.0 IN-H20)
( 295000 ACFM)
( 420 F)
SALEABLE PRODUCT
WET SCRUBBING
WELLMAN LORD
DAVY MCKEE
DAVY MCKEE
FULL SCALE
RETROFIT
7. 90.00
90.00
1
5/80
5/80
9/77
24280.3
( 261360 SQ FT)
3
0
TRAY TOWER
VALVE TRAY
BUBBLE CAP TRAY TOWER
DAVY MCKEE
20 X 20
INORGANIC
REINFORCED CONCRETE
N/A
INORGANIC
TILE
VALVE TRAY
4
25.
103.82
54.4
.0
400 GPM)
220000 ACFM)
130 F)
MIST ELIMINATOR
3
IMPINGEMENT
BAFFLE
CHEVRON VANE
HORIZONTAL
1
1
1.83
19.05
.1 (
NORYL PLASTIC
COOLED CONDENSATE
3.2 (
( 6.0 FT)
( 7.5 IN)
( .3 IN-H20)
50 GAL/MIN)
DIRECT COMBUSTION
EXTERNAL COMBUSTION CHAMBER
NATURAL GAS
10.0 ( 50 F)
176
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
DELMARVA POWER & LIGHT: DELAWARE CITY 1 (CONT.)
Ih'LET FLUE GAS FLOW RATE - CU. M/S
INLET FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** FANS
NUMBER
NUMBER OF SPARES
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** DUCTWORK
DIMENSIONS
SHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
*** SALEABLE BYPRODUCTS
NATURE
FULL LOAD QUANTITY - M T/H
QUALITY - X
DISPOSITION
*** SLUDGE
** TREATMENT
METHOD
** DISPOSAL
NATURE
TYPE
** PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS
MONITOR LOCATION
PROCESS CONTROL MANNER
PROCESS CHEMISTRY MODE
** WATER BALANCE
WATER LOOP TYPE
108.54 ( 230000 ACFM)
54.4 ( 130 F)
CARBON STEEL - FIRE BRICK
3
0
CENTRIFUGAL
ROBINSON
BOOSTER
INDUCED DRAFT
DRY
139.21
215.6
CARBON STEEL
( 295000 ACFM)
( 420 F)
8X8
CARBON STEEL
FRP
SULFUR1C ACID
11.34
93.0
MARKETED
t 12.50 TPH)
NEUTRALIZATION
FINAL
LINED POND
PH, SOLIDS, SP.G., CONC.
GAS OUTLET, SOLUTION OUTLET
AUTOMATIC
FEEDBACK
CLOSED
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
5/80 SYSTEM 100.0 100.0
** PROBLEMS/SOLUTIONS/COMMENTS
100.0
32.3
744 240
240
THE FGD SYSTEM BEGAN INITIAL AND COMMERCIAL OPERATIONS ON MAY 22, 1980.
NO MAJOR PROBLEMS WERE ENCOUNTERED FROM STARTUP THROUGH THE END OF
THE MONTH.
6/80 SYSTEM 98.9 98.9 98.9 98.9 720 720
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR PROBLEMS WERE ENCOUNTERED DURING JUNE.
7/80 SYSTEM 97.2 97.0 97.0 90.7 744 696
712
675
177
-------
EPA U7IIITY FGD SURVEY: OCTOBLR - DECEMBER 1980
DELMARVA POWER & LIGHT: DELAWARE CITY 1 (CONT. )
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS DOWN FOR PART OF THE MONTH IN JULY TO REPAIR A LEAK IN
THE MIST ELIMINATOR.
8/80 SYSTEM 99.9 99.9 99.9 99.9 744 7V* 743
** PROBLEMS/SOLUTIONS/COMMENTS
NO FGD-REUTED PROBLEMS WERE REPORTED DURING AUGUST.
9/80 -SYSTEM 78.3 78.3 78.3 78.3 720 720 564
H* PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS OFF LINE DURING SEPTEMBER DUE TO NECESSARY REPAIR OF
THE CIRCULATING PUMPS AND THE MIST ELIMINATOR.
FGD SYSTEM OUTAGE TIME OCCURRED DUE TO INLET DUCT EXPANSION JOINT REPAIRS.
10/80 SYSTEM 66.1 66.1 66.1 66.1 7*4 744 492
** PROBLEMS/SOLUTIONS/COMMENTS
DURING OCTOBER SOME OF THE OUTAGE TIME WAS DUE TO PLUGGED SPRAY HEADERS
ON THE MIST ELIMINATOR.
PROBLEMS WITH LEAKING CIRCULATING PUMPS OCCURRED IN OCTOBER.
OTHER OUTAGE TIME WAS DUE TO THE FAILURE OF ESP DISTRIBUTOR BAFFLES.
11/80 SYSTEM 93.8 96.0 96.0 93.8 720 704 676
** PROBLEMS/SOLUTIONS/COMMENTS
FAILURE OF PRESCRUBBER RECIRCULATION PUMPS CAUSED OUTAGE TIME IN NOVEMBER.
12/80 SYSTEM 33.9 55.9 55.9 30.6 744 408 228
** PROBLEMS/SOLUTIONS/COMMENTS
DURING DECEMBER THE BOILER WAS OUT OF SERVICE DUE TO A SCHEDULED MAINTE-
NANCE OVERHAUL FOR APPROXIMATELY 360 HOURS. START-UP OF THE FGD SYSTEM
WAS DELAYED ABOUT FIVE DAYS DUE TO MATERIAL DELIVERY PROBLEMS.
178
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT 'W1F
UNIT NUMBI-:R
CITY
STATE
REGULAVORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET Pit NT GENERATING CAPACITY - MW
GROSS fNIT GENERATING CAPACITY - MW
NET UN7T GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGD - MM
EQUIVALENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DfcSIGN BOILER FLUE GAS FLOW - CU.M/S
BtILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FUSL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - '/.
AVERAGE MOISTURE CONTENT - 7.
RAMGE MOISTURE CONTENT - 7.
AVI RAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
*** PARTICLE CONTROL
** MECHANICAL COLLECTOR
NUMBER
TYPE
SUPPLIER
PARTICLE REMOVAL EFFICENCY -X
** FABRIC FILTER
TYPE
TYPICAL GAS/CLOTH RATIO - M/MIN
** ESP
NUMBER
SUPPLIER
INLET FLUE GAS CAPACITY - CU.M/S
INLET FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
PARTICLE REMOVAL EFFICENCY - X
** PARTICLE SCRUBBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
DELMARVA POWER & LIGHT
DELAWARE CITY
2
DELAWARE CITY
DELAWARE
129.
( .300 LB/MMBTU)
(****** LB/MMBTU)
(****** LB/MMBTU)
******
180
60
*****
*****
60
RILEY STOKER
PULVERIZED COKE
BASE
139.21 ( 295000 ACFM)
215.6 ( 420 F)
152. ( 500 FT)
CONCRETE
6.1 ( 20.0 FT)
COKE
FLUID PETROLEUM COKE
32564. ( 14000 BTU/LB)
13500-14500
.50
.3-.7
.70
.5-1.2
7.00
5-8
********
******
3
TUBULAR
PRAT-DANIEL
92.0
NONE
.6
( 2.0 FT/MIN)
WESTERN PREC. DIVISION, JOY
104.3 ( 221000 ACFM)
54.4 ( 130 F)
.2 ( 1. IN-H20)
95.0
VENTURI TOWER
VARIABLE-THROAT/BOTTOM-ENTRY PLUMB BOB
AIRPOL
20 DIA X 70 HIGH
CARBON STEEL
AISI 1110
ORGANIC,INORGANIC
GLASS FLAKE-FILLED POLYESTER, ACID-RESISTANT BRI
179
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
DELMARVA POWER 4 LIGHT: DELAWARE CITY 2 (CONT.)
NUMBER OF CONTACTING ZONES
LIQUID RECIRCULATION RATE - LITER/S
PRESSURE DROP - KPA
IMLET GAS FLOW RATE - CU.M/S
I'JLET GAS TEMPERATURE - C
SK REMOVAL EFFICENCY - 7.
PARTICLE REMOVAL EFFICIENCY - X
*** FGi) SYSTEM
** GENERAL DATA
SALEABLE PROOUCT/THROWAWAY PRODUCT
SJ2 REMOVAL MODE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
UUIT DESIGN PARTICLE REMOVAL EFFICIENCY
UNIT DESIGN S02 REMOVAL EF1 ICIENCY - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
SPACE REQUIREMENTS - SQ M
OrER. & MAINT. REQUIREMENT - MANHR/DAY
** ABSORBER
NUMBER
NLMBER OF SPARES
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LUER GENERIC MATERIAL
LI^ER MATERIAL TRADE NAME/COMMON TYPE
GA'3 CONTACTING DEVICE TYPE
NU11BER OF CONTACTING ZONES
LIQUID RECIRCULATION RATE - LITER/S
IN'.ET GAS FLOW - CU. M/S
INS.ET GAS TEMPERATURE - C
PAPTICLE REMOVAL EFFICENCY - X
** MIS-' ELIMINATOR
PRf:'-MIST ELIMINATOR/MIST ELIMINATOR
NU'IBER PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES PER STAGE
FREEBOARD DISTANCE - M
DISTANCE BETWEEN STAGES - CM
PRESSURE DROP - KPA
CONSTRUCTION MATERIAL GENERIC TYPE
WASH WATER SOURCE
WASH RATE - L/S
** REHEATER
NUHBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
TEMPERATURE INCREASE - C
315.0
.5
139.2
215.6
.0
81.5
( 5000 6PM)
t 2.0 IN-H20)
( 295000 ACFM)
( 420 F)
SALEABLE PRODUCT
WET SCRUBBING
WELLMAN LORD
DAVY MCKEE
DAVY MCKEE
FULL SCALE
RETROFIT
X 90.00
90.00
1
5/80
5/80
9/77
24280.3
( 261360 SQ FT)
3
0
TRAY TOWER
VALVE TRAY
BUBBLE CAP TRAY TOWER
DAVY MCKEE
20 X 20
INORGANIC
REINFORCED CONCRETE
N/A
INORGANIC
TILE
VALVE TRAY
4
25.
103.82
54.4
.0
I 400 6PM)
( 220000 ACFM)
( 130 F)
MIST ELIMINATOR
3
IMPINGEMENT
BAFFLE
CHEVRON VANE
HORIZONTAL
1
1
1.83 ( 6
19.05 ( 7
.1 (
NORYL PLASTIC
COOLED CONDENSATE
3.2 (
.0
.5
.3
50
FT)
IN)
IN-H20)
GAL/MIN)
DIRECT COMBUSTION
EXTERNAL COMBUSTION CHAMBER
NATURAL GAS
10.0 ( 50 F)
180
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
DELMARVA POWER & LIGHT: DELAWARE CITY Z CCONT.)
INLET FLUE GAS FLOW RATE - CU. M/S
INLET FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** FANS
NUMBER
NUMBER OF SPARES
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
*» DUCTWORK
DIMENSIONS
SHELL GENERIC MATERIAL TYPE
'.INER GENERIC MATERIAL TYPE
*** SA'.EABLE BYPRODUCTS
NATURE
FJLL LOAD QUANTITY - M T/H
QJALITY - X
DISPOSITION
*** SLUDGE
** TR'£AThENT
METHOD
** DISPC3AL
NATURE
TYPE
** PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS
MONITOR LOCATION
PROCESS CONTROL MANNER
PROCESS CHEMISTRY MODE
** WAVER BALANCE
WATER LOOP TYPE
108.54 ( 230000 ACFM)
54.4 ( 130 F)
CARBON STEEL - FIRE BRICK
3
0
CENTRIFUGAL
ROBINSON
BOOSTER
INDUCED DRAFT
DRY
139.21
215.6
CARBON STEEL
( 295000 ACFM)
( 420 F)
8X8
CARBON STEEL
FRP
SULFURIC ACID
11.34
93.0
MARKETED
( 12.50 TPH)
NEUTRALIZATION
FINAL
LINED POND
PH, SOLIDS, SP.G., CONC.
GAS OUTLET, SOLUTION OUTLET
AUTOMATIC
FEEDBACK
CLOSED
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
5/80 SYSTEM 100.0 100.0
** PROBLEMS/SOLUTIONS/COMMENTS
100.0
32.3
744 240
240
THE FGD SYSTEM BEGAN INITIAL AND COMMERCIAL OPERATIONS ON MAY 22, 1980.
NO MAJOR PROBLEMS WERE ENCOUNTERED DURING STARTUP OR THROUGH THE REST OF
THE MONTH.
6/80 ^5YSTEM 80.4 80.4
** PROBLEMS/SOLUTIONS/COMMENTS
80.4
80.4
720 720
579
THE CHEVRON PACKING IN THE MIST ELIMINATOR FAILED CAUSING SOME FGD SYSTEM
OUTAGE TIME DURING JUNE.
181
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
DELMARVA POWER & LIGHT: DELAWARE CITY 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
FAILURE OF THE CIRCULATION PUMPS ALSO CAUSED OUTAGE TIME DURING THE MONTH.
7/80 SYSTEM 50.1 50.1 50.1 50.1 744 7*4 373
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS DOWN FOR PART OF THE MONTH TO REPAIR A LEAK IN THE MIST
ELIMINATOR. IT WAS ALSO DOWN TO REBUILD THE CHEVRON PACKING.
8/80 SYSTEM 92.9 92.9 92.9 92.9 744 744 691
** PROBLEMS/SOLUTIONS/COMMENTS
REPAIRS WERE MADE TO THE ESP DURING AUGUST.
9/80 SYSTEM 78.2 78.2 78.2 78.2 720 720 563
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS OFF LINE DURING SEPTEMBER DUE TO NECESSARY REPAIR OF
THE CIRCULATING PUMPS AND THE MIST ELIMINATOR.
FGD SYSTEM OUTAGE TIME OCCURRED DUE TO INLET DUCT EXPANSION JOINT REPAIRS.
10/80 SYSTEM 60.0 60.0 60.0 60.0 744 743 445
** PROBLEMS/SOLUTIONS/COMMENTS
DURING OCTOBER THE MAJORITY OF DOWN TIME WAS DUE TO THE ACID PLANT BEING
DOWN. IT WAS UNABLE TO PROCESS S02 FROM THE WELLMAN LORD SOLUTION
REGENERATION SECTION.
11/80 SYSTEM 98.3 98.3 98.3 98.3 720 720 708
** PROBLEMS/SOLUTIONS/COMMENTS
DURING NOVEMBER OUTAGE TIME HAS REQUIRED TO REPAIR LEAKS IN THE PRE-
SCRUBB'ER.
12/80 SYSTEM 100.0 1JO.O 100.0 100.1 744 744 744
** PROBLEMS/SOLUTIONS/C0.1MENTS
THE UFILITY REPORTED NO FGD-RELATED PROBLEMS DURING THE MONTH OF DECEMBER.
182
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EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MM
GROSS UNIT GENERATING CAPACITY - MM
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7. '
*** PARTICLE CONTROL
** MECHANICAL COLLECTOR
tUMBER
TYPE
SUPPLIER
PARTICLE REMOVAL EFFICENCY -7.
** FABRIC FILTER
TYPE
TYPICAL GAS/CLOTH RATIO - M/MIN
** ESP
K'UMBER
SUPPLIER
INLEi FLUE GAS CAPACITY - CU.M/S
INLFT FLUE GAS TEMPERATURE - C
PfiE! SURE DROP - KPA
FARVICLE REMOVAL EFFICENCY - 7.
** PA3T3CLE SCRUBBER
NUMBER
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
LCNER GENERIC MATERIAL
N-JMBER OF CONTACTING ZONES
LIQUID RECIRCULATION RATE - LITER/S
PRESSURE DROP - KPA
INLET GAS FLOW RATE - CU.M/S
DELMARVA POWER & LIGHT
DELAWARE CITY
3
DELAWARE CITY
DELAWARE
129.
( .300 LB/MMBTU)
(****** LB/MMBTU)
(****** LB/MMBTU)
******
180
60
60
RILEY STOKER
PULVERIZED COKE
BASE
139.21 ( 295000 ACFM)
215.6 ( 420 F)
152. ( 500 FT)
CONCRETE
6.1 ( 20.0 FT)
COKE
FLUID PETROLEUM COKE
3256*. ( 14000 BTU/LB)
13500-14500
.50
.3-.7
.70
.5-1.2
7.00
5-8
********
******
3
TUBULAR
PRAT-DANIEL
92.0
NONE
.6
WESTERN PREC.
104.3
54.4
.2
95.0
( 2.0 FT/MIN)
DIVISION, JOY
( 221000 ACFM)
( 130 F)
( 1. IN-H20)
3
AIRPOL
20 DIA X 70 HIGH
CARBON STEEL
GLASS FLAKE, ACID BRICK, CAROBRAX BRICK
315.0
.5
139.2
5000 GPM)
2.0 IN-H20)
295000 ACFM)
183
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
DELMARVA POWER fc LIGHT: DELAWARE CITY 3 (CONT.)
INLET GAS TEMPERATURE - C
S02 REMOVAL EFFICENCY - X
PARTICLE REMOVAL EFFICIENCY - X
*** FGO SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
SOS REMOVAL MODE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
UNIT DESIGN S02 REMOVAL EFFICIENCY - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
SPACE REQUIREMENTS - SQ M
OPER. & MAINT. REQUIREMENT - MANHR/DAY
** ABSORBER
NUMBER
NUMBER OF SPARES
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
GAS CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
LIQUID RECIRCULATION RATE - LITER/S
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
PARTICLE REMOVAL EFFICENCY - X
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES PER STAGE
FREEBOARD DISTANCE - M
DISTANCE BETWEEN STAGES - CM
PRESSURE DROP - KPA
CONSTRUCTION MATERIAL GENERIC TYPE
I-ASH WATER SOURCE
WASH RATE - L/S
** REHEATER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
TEMPERATURE INCREASE - C
INLET FLUE GAS FLOW RATt - CU. M/S
1NLE- FLUE GAS TEMPERATURE - C
CONSVRUCTION MATERIAL GEKERIC TYPE
215.6
.0
81.5
( 420 F)
SALEABLE PRODUCT
WET SCRUBBING
WELLMAN LORD
DAVY MCKEE
DAVY MCKEE
FULL SCALE
RETROFIT
X 90.00
90.00
1
5/80
5/80
9/77
34280.3
144.0
( 261360 SQ FT)
3
0
TRAY TOWER
VALVE TRAY
BUBBLE CAP TRAY TOWER
DAVY MCKEE
20 X 20
INORGANIC
REINFORCED CONCRETE
N/A
INORGANIC
TILE
VALVE TRAY
4
£5.
103.82
54.4
.0
400 GPM)
220000 ACFM)
130 F)
MIST ELIMINATOR
3
IMPINGEMENT
BAFFLE
CHEVRON VANE
HORIZONTAL
1
1
1.83 ( 6
19.05 ( 7
.1 (
NORYL PLASTIC
COOLED CONDENSATE
3.2 (
.0 FT)
.5 IN)
.3 IN-H20)
50 GAL/MII
DIRECT COMBUSTION
EXTERNAL COMBUSTION CHAMBER
NATURAL GAS
10.0 ( 50 F)
108.54 ( 230000 ACFM)
54.4 ( 130 F)
CARBON STEEL - FIRE BRICK
184
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
DELMARVA POWER t LIGHT: DELAWARE CITY 3 (CONT.)
** FANS
NUMBER
NUMBER OF SPARES
DI'SIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FlUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** DUCTWORK
DIMENSIONS
JHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
*** SALEABLE BYPRODUCTS
NATURE
FULL LOAD QUANTITY - M T/H
QUALITY - X
DISPOSITION
*** SLUDGE
** TREATMENT
METHOD
** DISPOSAL
NATURE
TYPE
** PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS
MONITOR LOCATION
PROCESS CONTROL MANNER
PROCESS CHEMISTRY MODE
** WATER BALANCE
WATER LOOP TYPE
3
0
CENTRIFUGAL
ROBINSON
BOOSTER
INDUCED DRAFT
DRY
139.21
215.6
CARBON STEEL
8X8
CARBON STEEL
FRP
SULFURIC ACID
11.34
93.0
MARKETED
( 295000 ACFM)
( 420 F)
I 12.50 TPH)
NEUTRALIZATION
FINAL
LINED POND
PH, SOLIDS, SP.G., CONC.
GAS OUTLET, SOLUTION OUTLET
AUTOMATIC
FEEDBACK
CLOSED
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
5/80 SYSTEM 100.0 100.0 100.0
** PROBLEMS/SOLUTIONS/COMMENTS
32.3
744 240 £40
THE FGD SYSTEM BEGAN INITIAL AND COMMERCIAL OPERATIONS ON MAY 22, 1980.
NO MAJOR PROBLEMS WERE ENCOUNTERED DURING STARTUP OR THROUGH THE REST OF
THE MONTH.
6/80 SYSTEM 86.4 86.4
** PROBLEMS/SOLUTIONS/COMMENTS
86.4
86.4
720 720 622
REPAIRS WERE MADE TO A LEAK AND DAMAGED CHEVRON PACKING IN THE MIST ELIM-
INATOR DURING JUNE.
7/80 SYSTEM 95.3
95.3
95.3
95.3
744 744 709
185
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
DELMARVA POWER & LIGHT: DELAWARE CITY 3 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
#* PROBLEMS/SOLUTIONS/COMMENTS
SOME FGD SYSTEM OUTAGE TIME DURING THE MONTH WAS CAUSED BY LEAKS IN THE
MIST ELIMINATOR THAT NEEDED REPAIR.
AN ELECTRICAL FAILURE IN THE SHUTDOWN INSTRUMENTATION CAUSED THE FGD SYSTEM
TO BE OUT OF SERVICE PART OF THE MONTH.
8/80 SYSTEM 73.3 73.3 73.3 73.3 744 744 545
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS OUT OF SERVICE FOR PART OF THE MONTH TO REPAIR THE
PRESCRUBBER MIST ELIMINATOR.
9/80 SYSTEM 46.4 46.4 46.4 46.4 720 720 334
** PROBLEMS/SOLUTIONS/COHMENTS
FGD SYSTEM OUTAGE TIME OCCURRED DUE TO THE NECESSARY REPAIR OF THE INLET
EXPANSION JOINTS DURING SEPTEMBER.
PROBLEMS WERE ENCOUNTERED WITH THE PRE-MIST ELIMINATOR CAUSING
ADDITIONAL OUTAGE TIME.
ADDITIONAL OUTAGE TIME WAS NECESSARY TO MAKE REPAIRS TO THE BOOSTER BLOWER
ROTOR.
10/80 SYSTEM 44.2 44.2 44.2 44.2 744 744 329
** PROBLEMS/SOLUTIONS/COMMENTS
DURING OCTOBER SOME OF THE OUTAGE TIME WAS DUE TO REPAIRS OF THE BOOSTER
BLOWER ROTOR.
REPAIR WORK ON THE DUCT EXPANSION JOINTS ALSO CAUSED SOME OUTAGE TIME
DURING THE MONTH.
DURING OCTOBER PROBLEMS WERE ENCOUNTERED WITH THE MIST ELIMINATORS.
11/80 SYSTEM .0 .0 .0 .0 720 279 0
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS OUT OF SERVICE FOR APPROXIMATELY 465 HOURS FOR AN ANNUAL
SCHEDULED MAINTENANCE OVERHAUL DURING NOVEMBER. START-UP OF THE FGD
SYSTEM WAS DELAYED DUE TO THE LATE DELIVERY OF PIECES OF THE MIST ELIMINA-
TOR INTERNALS.
12/80 SYSTEM 82.4 79.2 79.2 79.2 744 744 589
** PROBLEMS/SOLUTIONS/COMMENTS
APPROXIMATELY 107 HOURS OF OUTAGE TIME IN DECEMBER WERE DUE TO LEAKS IN
THE PRESATURATOR CIRCULATING PIPING.
186
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT h'UMSER
CITY
STATE
REGULATORV CLASSIFICATION
PARTICULAR EMISSION LIMITATION - NG/J
S02 EMISflON LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UN3T GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W, FGD - MW
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** UNCT DATA - BOILER AND STACK
B3ILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
D3SIGN BOILER FLUE GAS FLOW - CU.M/S
BJILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
R/NGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RJN'GE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RA^GE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** MECHANICAL COLLECTOR
SUPPLIER
** ESP
NUMBER
TYPE
SUPPLIER
** PARTICLE SCRUBBER
GENERIC TYPE
SPECIFIC TYPE
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER SPECIFIC MATERIAL
*** FGD SYSTEM
** GENERAL DATA
SALEABLE FRODUCT/THROWAWAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
UNIT DESIGN 302 REMOVAL EFFICIENCY - 7.
CURRENT STATUS
DUQUESNE LIGHT
ELRAMA
1-4
ELRAMA
PENNSYLVANIA
D
43.
258.
******
494
510
475
493
5lb
BABCOCK « WILCOX
PULVERIZED COAL
BASE
( .100 LB/MMBTU)
( .600 LB/MMBTU)
(****** LB/MMBTU)
********
*******
******
CONCRETE
******* (***** FT)
(******* ACFM)
(**** F)
(**** FT)
( 11350 BTU/LB)
******
COAL
******
26400.
21.00
******
********
******
2.20
1.0-2.8
********
******
RESEARCH-COTTRELL
COLD SIDE
RESEARCH-COTTRELL
VENTURI TOWER
VARIABLE-THROAT/SIDE-MOVABLE BLADES
CARBON STEEL
AISI 1110
GLASS FLAKE-FILLED POLYESTER
THROWAWAY PRODUCT
WET SCRUBBING
LIME
CHEMICO DIVISION, ENVIROTECH
GIBBS & HILL
FULL SCALE
RETROFIT
7. 99.00
83.00
1
187
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
OUQUESNE LIGHT: ELRAMA 1-4 (CONT.)
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
** ABSORBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
S1ELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
G4S CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
LIQUID RECIRCULATION RATE - LITER/S
L/G kATIO - L/CU.M
GAS-SIDE PRESSURE DROP - 1'PA
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
S02 REMOVAL EFFICIENCY - X
PARTICLE REMOVAL EFFICENCY - X
** MIST ELIMINATOR
PPE-MIST ELIMINATOR/MIST ELIMINATOR
GENERIC TYPE
SPECIFIC TYPE
TIRADE NAME/COMMON TYPE
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES PER STAGE
FI!EEBOARD DISTANCE - M
DISTANCE BETWEEN VANES - CM
VANE ANGLES - DEGREES
S'JPERFICAL GAS VELOCITY - M/S
CONSTRUCTION MATERIAL GENERIC TYPE
WASH WATER SOURCE
** REHEATER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
TEMPERATURE INCREASE - C
** FANS
NU1BER
NU'ISER OF SPARES
DE'ilGN
FUNCTION
APF'LICATION
SERVICE
CONSTRUCTION MATERIAL GENERIC TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
10/75
10/75
12/70
VENTURI TOWER
VARIABLE-THROAT/TOP-ENTRY PLUMB BOB
CHEHICO DIVISION, ENVIROTECH
30 DIA. X 60 HIGH
CARBON STEEL
AISI 1110
N/A
ORGANIC
CEILCOTE
BULL AND SPRAY NOZZLES
1
1008.
5.3
254.83
150.6
86.0
99.0
(16000 GPM)
( 40.0 GAL/1000 ACF)
(16.0 IN-H20)
( 540000 ACFM)
( 303 F)
MIST ELIMINATOR
IMPINGEMENT
BAFFLE
CHEVRON VANE
HORIZONTAL
a
3
1.37
.0
90
.3
4.5 FT)
.00 IN)
( 1.0 FT/S)
FIBERGLASS REINFORCED PLASTIC
THICKENER OVERFLOW
DIRECT COMBUSTION
IN-LINE BURNER
OIL
-1.1 ( 30 F)
5
1
CENTRIFUGAL
BOOSTER
INDUCED DRAFT
WET
HIGH ALLOY
SCRUBBER INLET
CARBON STEEL
NONE
SCRUBBER OUTLET
CARBON STEEL
FLAKEGLASS
188
-------
DUQUESNE LIGHT: ELRAMA 1-4 (CONT.)
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
** PUMPS
SERVICE
SCRUBBER/ABSORBER RECIRCULATION
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
OUTLET STREAM CHARACTERISTICS
NUMBER
10
THICKENER
2
32X SOLIDS
*** SLUDGE
** TREATMENT
METHOD
PROPRIETARY PROCESS
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
** WATER BALANCE
WATER LOOP TYPE
POZ-0-TEC
IUCS
FINAL
LANDFILL
OFF SITE
TRUCK
OPEN
** FG) SPARE CAPACITY INDICES
A3SORBER - X
25.0
** FG3 SPARE COMPONENT INDICES
ABSORBER
1.0
PERFORMANCE DATA
PERIOD MO'JULE AVAILABILITY OPER \BILITY RELIABILITY UTILIZATION
7. REMOVAL
S02 PART.
PER BOILER FGD CAP.
HOURS HOURS HOURS FACTOR
0/75 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
THE FIRST ELRAMA SCRUBBER WAS PLACED IN SERVICE ON OCTOBER E6, 1975. IT
HAD BEEN SCHEDULED FOR AN EARLIER STARTUP DATE BUT BECAUSE OF THE SEVERITY
AND NUMBER OF PROBLEMS ENCOUNTERED AT PHILLIPS, STARTUP WAS DELAYED UNTIL
MANY OF THE PROBLEMS AT PHILLIPS WERE RESOLVED AND THE MODIFICATIONS COULD
BE INCORPORATED AT BOTH STATIONS.
BOILER NO. 2 WAS INITIALLY CONNECTED TO THE FGD SYSTEM. THIS BOILER HAS
AN EQUIVALENT CAPACITY OF APPROXIMATELY 100 MU AND THE EMISSIONS CAN BE
HANDLED BY ONE SCRUBBER. HOWEVER, TO ENSURE RELIABILITY IN THE CASE
OF A SCRUBBER MALFUNCTION, TWO SCRUBBERS ARE OPERATED AT PARTIAL
LOAD TO PROTECT THE BOILER AND TURBINE GENERATOR AGAINST A TRIP-OFF.
THE BOILER OPERATED CONTINUOUSLY ON THE SCRUBBER SYSTEM THROUGH JANUARY
1976 WITH THE EXCEPTION OF TWO MINOR OUTAGES. ON FEBRUARY 4, 1976 A
SECOND BOILER WAS COUPLED INTO THE SCRUBBER COMPLEX. PRESENTLY, TWO
UNITS ARE THE MAXIMUM THAT CAN BE TIED INTO THE SCRUBBER PLANT. TO DATE,
THE UTILITY HAS ENCOUNTERED THE USUAL MINOR STARTUP PROBLEMS AND SOME
MAJOR PROBLEMS AS WELL. THE MAJOR PROBLEMS HAVE BEEN WITH FROZEN PIPES
AND THICKENERS, THE LATTER INVOLVING HARDWARE AND DESIGN PROBLEMS
ASSOCIATED WITH RECIRCULATION OF THE SLUDGE WITHIN THE THICKENERS TO
ATTAIN 30 TO 40X SOLIDS CONCENTRATION.
10/75 SYSTEM
189
-------
EPA UTILITY FGO SURVEY: OCTOBER - DECEMBER 1980
DUQUESNE LIGHT: ELRAMA 1-4 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE SCRUBBING SYSTEM BEGAN OPERATIONS WITH ONE BOILER CONNECTED TO THE
SYSTEM (100 MW) DURING THE MONTH. THE SCRUBBING SYSTEM IS CURRENTLY IN
THE SHAKEDOWN PHASE OF OPERATION.
11/75 SYSTEM 720 720
12/75 SYSTEM 744 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE SYSTEM IS STILL OPERATING WITH ONE BOILER CONNECTED. THE UTILITY IS
PLANNING TO CONNECT ONE OR TWO ADDITIONAL BOILERS TO THE SYSTEM IN LATE
JANUARY.
1/76 SYSTEM 744 744
** PROBLEMS/SOLUTIONS/COMMENTS
FOUR OF THE FIVE SCRUBBER VESSELS HAVE BEEN IN SERVICE IN VARIOUS COMBINA-
TIONS, AND THE SERVICE HOURS THROUGH JANUARY 31, 1976 ARE:
NO. 1 - 69 HOURS
NO. 2 - 1508 HOURS
NO. 3 - 976 HOURS
NO. 4 - 838 HOURS
THE FIFTH VESSEL HAS NOT BEEN IN SERVICE BECAUSE IT IS BEING SERVICED FOR
THE TRIAL INSTALLATION OF RUBBER LINED RECYCLE PUMPS.
2/76 SYSTEM 696 696
3/76 SYSTEM 744 744
4/76 SYSTEM 720 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE SYSTEM OPERATED DURING MARCH A.-TO APRIL WITH TWO BOILERS COUPLED INTO
THE SCRUBBING SYSTEM. REVISIONS TO THE FIFTH SCRUBBING VESSEL HAVE BEEN
COMP..ETED AND OPERATIONS ARE PROCEEDING WITH TWO RUBBER-LINED RECYCLE
PUMPS.
5/76 SYSTEM 744 744
6/76 SYSTEM 720 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE SYSTEM IS STILL OPERATING WITH TWO BOILERS COUPLED INTO THE SCRUBBING
SYSTEM. THE IUCS SLUDGE FIXATION SYSTEM IS CONTINUING TO OPERATE AT THIS
STATION.
THE FIFTH SCRUBBING VESSEL WAS TAKEN OUT OF SERVICE FOR REPAIRS AND
MODIFICATIONS REQUIRED FOR THE RUBBER-LINED RECYCLE PUMPS.
THE UTILITY IS CURRENTLY CONDUCTING A PERFORMANCE TEST ON TH£ SCRUBBING
SYSTEM IN THE TWO BOILER OPERATION MODE.
7/76 SYSTEM 744 744
8/76 SYSTEM 744 744
190
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
DUQUESNE LIGHT: ELRAMA 1-4 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
— — _ — „___
/
f
** PROBLEMS/SOLUTIONS/COMMENTS
THE FIFTH SCRUBBING VESSEL EMPLOYING TWO RUBBER-LINED RECYCLE PUMPS WAS
OPERATIONAL FOR A SHORT PERIOD OF TIME DURING THE REPORTING MONTHS. TWO
BOILERS REMAIN COUPLED INTO THE SCRUBBING SYSTEM. THE CONSTRUCTION OF AD-
DITIONAL LIME STORAGE SILOS AND A THICKENER WILL BE REQUIRED FOR FULL
SCALE OPERATION. THE UTILITY HAS SIGNED A LETTER OF INTENT WITH IUCS FOR
A LONG TERM SLUDGE FIXATION SYSTEM. HIGH CALCIUM LIME IS STILL BEING
EMPLOYED IN THE SCRUBBING SYSTEM.
9/76 SYSTEM 720 730
10/76 SYSTEM 744 744
** PROBLEMS/SOLUTIONS/COMMENTS
OPERATIONS AT THIS STATION DURING THE REPORT PERIOD PROCEEDED WITH TWO
BOILERS COUPLED INTO THE FIVE-MODULE SCRUBBING SYSTEM. THE FIFTH SCRUB-
BING VESSEL WAS OPERATIONAL DURING THE REPORT PERIOD WITH THE RUBBER-LINED
RECYCLE PUMPS IN SERVICE. OPERATIONS ARE STILL PROCEEDING ON AN OPEN
WATER-LOOP BASIS. PART OF THE THICKENER OVERFLOW IS STILL BEING DIVERTED
TO THE ASH POND AND NOT RECYCLED BACK TO THE PROCESS. BECAUSE BOTH
BEAVER VALLEY AND BRUCE MANSFIELD STATIONS ARE FULLY OPERATIONAL, THIS
STATION HAS BEEN RELEGATED TO PEAK LOAD OPERATIONS. GENERAL LOAD OPERA-
TIONS ARE FULL CAPACITY IN THE DAYTIME AND 50 TO 60X REDUCTION AT NIGHT.
TESTS WERE CONDUCTED DURING THE PERIOD TO DETERMINE PARTICULATE AND S02
REMOVAL EFFICIENCIES. S02 REMOVAL EFFICIENCY WAS SOX. PARTICULATE
EMISSIONS WERE BEING REDUCED WELL BELOW 0.1 LB/MM BTU STANDARD (ACTUAL
RESULTS; 0.04 LB/MM BTUK THESE RESULTS WERE BASED ON TWO BOILERS
COUPLED INTO THE FIVE SCRUBBING MODULES WHILE BURNING MEDIUM-SULFUR (1.0
TO 2.8X) COAL. THE MECHANICAL COLLECTORS AND ESP'S WERE IN SERVICE
DURING THE TESTS.
11/76 SYSTEM 720 720
12/76 SYSTEM 744. 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE SCRUBBER REMAINED IN SERVICE THROUGHOUT THE REPORT PERIOD WITH TWO
BOILERS COUPLED INTO THE SCRUBBING SYSTEM. A RECYCLE PUMP EVALUATION IS
BEING CONDUCTED BY THE UTILITY AT BOTH PHILLIPS AND ELRAMA STATIONS.
OBSERVATIONS OF THE RUBBER-LINED RECYCLE PUMPS INDICATE SOME SEVERE ABRAS-
ION AND GOUGING HAVE OCCURRED AFTER 1000 HOURS OF SERVICE TIME.
1/77 SYSTEM 744 744
2/77 SYSTEM 672 672
3/77 SYSTEM 744 744
** PROBLEMS/SOLUTIONS/CCMMENTS
TESTIHG WITH THIOSORBIC LIME WAS CONDUCTED DURING THE PERIOD.
THE SJRUBBER PLANT CONTINUED OPERATIONS DURING JANUARY AND FEBRUARY WITH
TWO BOILERS COUPLED INTO THE SYSTEM. INSTALLATION OF THE ADDITIONAL
THICKENER LIME FEEDERS AND SILOS IS STILL IN PROGRESS. FULL COMPLIANCE
OPERATION FOR THIS STATION IS SCHEDULED FOR EARLY 1978. THE FULL COMPLI-
ANCE STRATEGY WILL CONSIST OF THE FOLLOWING: 83X S02 REMOVAL FOR 2X SULFUR
COAL UTILIZING THIOSORBIC LIME (6-12X MG), FIXATING THE SCRUBBER SLUDGE
191
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
DUQUESNE LIGHT: ELRAMA 1-4 CCONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
WITH THE IUCS POZ-0-TEC STABILIZATION METHOD AND HAULING THIS MATERIAL TO
AN OFFSITE DISPOSAL/LANDFILL AREA. CURRENT S02 AND PARTICULATE REMOVAL
EFFICIENCIES ARE 50 AND 99+X, RESPECTIVELY. THE INTERIM IUCS UNIT NOW IN
SERVICE CONSISTS OF THE OLD MOHAVE PROTOTYPE PLUS A VACUUM FILTER. THE
STABILIZATION MATERIAL HAS BEEN UTILIZED IN A PARKING LOT CONSTRUCTION
PROJECT. IUCS HAS BEEN AWARDED A 10-YEAR CONTRACT FOR THE CONTINUED USE
OF THIS SYSTEM FOR FUTURE PLANT OPERATIONS.
4/77 SYSTEM 720 720
5/77 SYSTEM 744 744
** PROBLEMS/SOLUTIONS/COMMENTS
CONSTRUCTION OF TWO 120-FOOT DIAMETER THICKENERS IS CONTINUING. DUE TO
THE GOUGING OF THE RUBBER-LINED RECYCLE PUMPS DURING THEIR TESTING, THEY
HAVE BEEN REMOVED. THE UTILITY IS CONSIDERING TRYING ANOTHER SET OF
RUSBER-LINED PUMPS. DUQUESNE LIGHT ALSO IS CONTINUING EFFORTS TO OBTAIN
ALTERNATE LANDFILL AREAS FOR SLUDGE DISPOSAL.
6/77 SYSTEM 720 720
7/77 SYSTEM 744 744
** PROBLEMS/SOLUTIONS/COMMENTS
DUQUESNE LIGHT REPORTED THE FOLLOWING ITEMS FOR THE ELRAMA SCRUBBER PLANT
DURING THE REPORT PERIOD:
-TWO BOILERS (200 MW) KERE COUPLED INTO THE SCRUBBER PLANT.
-THE INTERIM IUCS STABILIZATION UNIT (MOHAVE PROTOTYPE) CONTINUED TO FIX-
ATE SCRUBBER WASTES.
-CONSTRUCTION OF THE TWO ADDITIONAL THICKENERS CONTINUED (CONSTRUCTION IS
ON SCHEDULE).
-FULL PUNT COMPLIANCE IS PROJECTED FOR FEBRUARY 1978.
-S02 REMOVAL EFFICIENCY IS APPROXIMATELY SOX.
-ELRAMA IS OPERATING IN A BASE/INTERMEDIATE LOAD MODE (FULL LOAD DAYTIME/
HALF LOAD NIGHT-TIME). 1976 CAPACITY FACTOR WAS 69.57..
8/77 SYSTEM 744 744
9/77 SYSTEM 720 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE TWO ADDITIONAL THICKENERS WERE COMPLETELY INSTALLED. THE IUCS SYSTEM
WAS UPGRADED. CONSTRUCTION COMPLETION IS PROJECTED FOR FEBRUARY 1978.
FULL PLANT COMPLIANCE IS PROJECTED FOR APRIL 1978.
10/77 SYSTEM 744 744
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE 101 WAS UNAVAILABLE ON OCTOBER 4 DUE TO A BLEED VALVE LEAK AND WAS
TAKEN OUT OF SERVICE AT THE END OF THE MONTH FOR CLEANUP.
MODULE 201 WAS AVAILABLE FOR THE ENTIRE MONTH OF OCTOBER.
MODULE 301 AND 401 HAD OUTAGES IN OCTOBER RESULTING FROM A RUBBER LINING
FAILURE ON AN ID FAN.
MODULE 501 EXPERIENCED RECYCLE PUMP OUTAGES IN LATE NOVEMBER.
NEW RUBBER LINED WOKMEN RECYCLE PUMPS WERE INSTALLED. THE LIME HANDLING
SYSTEM INSTALLATION WORK CONTINUED. THE LAST TWO BOILERS ARE EXPECTED TO
192
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
DUQUESHE LIGHT: ELRAMA 1-4 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
BE TIED INTO THE FGO SYSTEM BY JANUARY 1978.
11/77 101
201
301
501
SYSTEM
.0
11.7
93.3
23.5
59.2
46.7
.0
11.7
93.3
22.5
59.2
46.7
720 720
336
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE 101, 201 AND 401 HAVE LOW OPERATIONAL HOURS BECAUSE ONLY TWO BOILER
ARE TIED INTO THE FGD SYSTEM TO DATE.
THE SLUDGE HANDLING SYSTEM IS FUNCTIONING PROPERLY AND IS NOW IN FULL SER-
VICE.
TUBE LEAKS FORCED A BOILER OUTAGE IN NOVEMBER.
12/77
1/78
SYSTEM
101
201
301
401
501
SYSTEM
744 744
94.1
90.5
5.1
24.3
3.5
54.4
94.1
90.5
5.1
24.3
3.5
54.4
744 744
405
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE PERIOD THE UTILITY REPORTED THAT A NEW WORMEN RECYCLE PUMP
INSTALLED IN NOVEMBER EXPERIENCED JACK SHAFT BEARING PROBLEMS RESULTING
IN REMOVAL OF SCRUBBER TRAIN 501 FROM SERVICE.
BOILER NO. 4 WAS CONNECTED,
TO THE FGD SYSTEM.
ADDING AN ADDITIONAL 176 MW OF FLUE GAS LOAD
THE IUCS SLUDGE DISPOSAL FACILITY IS IN SERVICE PRODUCING GOOD PRODUCT.
LOW LOAD AND A COAL STRIKE HAVE HAMPERED GOOD SCRUBBER OPERATIONS. SOME
OUTAGE TIME HAS BEEN SCHEDULED FOR MARCH.
2/78 101
201
301
401
501
SYSTEM
3/78 SYSTEM
70.8
96.2
.0
37.2
40.0
61.1
.0
30.4
41.2
.0
15.9
18.0
£6.4
.0
672 288
744 216
177
141
** PROBLEMS/SOLUTIONS/COMMENTS
THE SYSTEM WAS SHUTDOWN ON FEBRUARY 11 AS A RESULT OF A COAL SHORTAGE.
BOILERS 1, 2 AND 4 ARE NOW COMPLETELY CONNECTED TO THE FGD SYSTEM. BOILER
3 IS UNDERGOING AN EXTENSIVE OVERHAUL AND WILL BE CONNECTED TO THE SYSTEM
IN LATE APRIL.
BOILER EXIT DAMPERS WERE LINED WITH 316 S3 ON AREAS OF HIGH EROSION CAUSED
BY FLYASH IMPINGEMENT DURING THE OUTAGE.
EXPANSION JOINTS IN THE UPSTREAM DUCTWORK WERE SHIELDED BY METAL PLATES
WHICH UERE 1,'El.DED AT ONE EKD DURING THE FEBRUARY-MARCH PERIOD. EXPANSION
JOINTS IN THE DOWNSTREAM DUCTWORK WERE COMPLETELY REPLACED. THE DOWN-
STREAM DUCTWORK WAS RELINED WITH CEILCOTE.
193
-------
EPA UTILITY F6D SURVEY: OCTC3ER - DECEMBER 1980
DUQUESNE MGHT: ELRAMA 1-4
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
DUQUESNE LIGHT: ELRAMA 1-"* (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
SG2 PART. HOURS HOURS HOURS FACTOR
A PARTICLE EMISSION COMPLIANCE TEST WAS RUN IN DECEMBER WHICH SHOWED THE
UNIT TO BE IN COMPLIANCE.
10/78
101
201
301
4C.1
5"!
100.0
93.9
100.0
80.5
78.6
76.6
98.9
?00.0
80.5
78.6
100.0
98.9
100.0
80.5
78.6
76.6
98.9
100.0
80.! T-
78. -i
SYSTEM 100.0 100.0 100.0 100.0 744 744 744
11/78
1C1
201
301
401
501
SYSTEM
100.0
100.0
100.0
100.0
81.1
100.0
T00.0
78.4
84. i
86.8
62.5
100.0
100.0
100.0
100.0
100.0
76.8
100.0
100.0
78.4
84. Z
86.8
62.5
100.0
720 720 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE PARTICLE EMISSION TEST RUN IN AUGUST SHOWED THAT THE UNIT MET STATE
STANDARDS. THE S02 TEST WILL HAVE TO BE RERUN BECAUSE OF SAMPLING
ERRORS.
THE UTILITY REPORTED DURING THE OCTOBER-NOVEMBER PERIOD THAT IT HAS HAD
SOME PROBLEMS WITH AN INSUFFICIENT LIME SUPPLY.
12/78
101
201
301
401
501
100.0
76.3
93.0
68.0
97.9
94.7
72.7
85.6
64.8
69.5
100.0
75.4
92.5
66.9
97.0
94.7
72.7
85.6
64.8
69.5
SYSTEM 100.0 100.0 100.0 96.8 744 744 720
** PROBLEMS/SOLUTIONS/COMMENTS
DURING DECEMBER A S02 EMISSION COMPLIANCE TEST WAS RUN AND THE UNIT WAS
FOUND TO BE WITHIN THE ALLOWABLE STANDARD OF 0.6 LB/MM BTU.
101
201
301
401
501
44.7
100.0
67.8
100.0
100.0
39.8
95.2
60.2
100.0
100.0
41.9
100.0
65.3
100.0
100.0
39.8
95.2
60.2
100.0
100.0
1/79
SYSTEM 100.0 100.0 100.0 98.8 744 744 735
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY HAS STARTED HAULING SLUDSE OFF-SITE TO AN AREA ABOUT 10 MILES
AWAY.
2/79 101 100.0 100.0 100.0 100.0
672 672 672
3/79
201 100.0 91.0 100.0 91.0
301 77.7 73.8 76.8 73.8
401 54.5 39.2 46.3 39.2
501 70.4 65.9 69.0 65.9
744 744 680
195
201
301
401
501
SYSTEM
101
201
301
401
501
SYSTEM
90.2
14.1
97,8
100.0
100.0
98.9
100.0
77.7
54.5
70.4
100.0
90.2
14.1
97.3
100.0
100.0
95.4
91.0
73.8
39.2
65.9
100.0
90.2
14.1
97.8
100.0
100.0
98.8
100.0
76.8
46.3
69.0
97.7
90.2
14.1
97.3
100.0
100.0
95.4
91.0
73.8
39.2
65.9
91.4
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
DUQUESNE LIGHT: ELRAMA 1-4 JCONT.)
PERIOD
4/79
5/79
6/79
7/79
8/79
9/79
10/79
11/79
12/79
MODULE
101
£01
301
401
501
SYSTEM
101
201
301
401
501
SYSTEM
101
201
30*
40i.
5C1
SN STEM
1C1
201
301
401
501
SYSTEM
101
201
301
401
501
SYSTEM
101
201
301
401
501
SYSTEM
101
201
301
401
501
SYSTEM
L01
201
301
401
501
SYSTEM
101
201
301
401
501
SYSTEM
AVAILABILITY
64.1
57.4
100.0
100.0
92.8
100.0
100.0
97.8
100.0
100.0
51.6
100.0
100.0
93.5
93.3
100.0
100.0
100.0
100.0
100.0
86.0
100.0
40.7
100.0
100.0
100.0
100.0
41.2
72.8
100.0
44.0
100.0
100.0
90.0
76.9
100.0
100.0
100.0
47.8
94.4
84.4
100.0
100.0
15.3
92.4
100.0
95.0
100.0
100.0
100.0
100.0
83.1
100.0
100.0
OPERABILITY
61.9
53.5
99.3
89.9
90.4
95.6
100.0
97.8
83.1
100.0
21.4
100.0
100.0
58.5
40.0
100. 0
100.0
130.0
31.0
94.8
86.0
99.3
40.7
100.0
98.7
100.0
96.5
33.3
72.8
100.0
35.0
93.3
86.6
90.0
70.0
93.8
100.0
96.1
34.6
87.3
84.5
100.0
100.0
15.2
92.5
98.3
93.9
100.0
51.6
90.9
100.0
68.6
100.0
100.0
rtKI-UKPIAr
RELIABILITY
63.3
55.7
100.0
100.0
92.6
100.0
100.0
97.8
100.0
100.0
30.6
100.0
100.0
97.5
85.7
100.0
100.0
100.0
100.0
100.0
86.0
100.0
40.7
100.0
100.0
100.0
100.0
36.2
72.8
100.0
38.4
100.0
100.0
90.0
75.2
100.0
100.0
100.0
39.1
94.0
84.4
100.0
100.0
15.3
92.4
100.0
94.9
100.0
100.0
100.0
96.1
84.4
100.0
100.0
iUt UAI A
UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
61.9
53.5
99.3
89.9
90.4
95.6 720 720 688
100.0
97.8
83.1
100.0
21.4
100.0 744 744 744
100.0
58.5
40.0
100.0
100.0
99. (y 720 720 717
81.0
94.8
86.0
99.3
40.7
100.0 744 744 744
98.7
100.0
96.5
33.3
72.8
100.0 744 744 744
35.0
93.3
86.6
90,0
70.0
93.8 720 720 675
100.0
96.1
34.6
87.3
84.5
100.0 744 744 744
100.0
15.2
92.5
98.3
93.9
100.0 720 720 720
48.5
85.5
100.0
64.5
100.0
98.7 744 700 734
196
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER I960
DUQUESNE LIGHT: ELRAMA 1-4 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FSD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THERE MERE NO SCRUBBER-RELATED OUTAGES DURING THE SEPTEMBER THROUGH
DECEMBER PERIOD.
A NEW S02 MONITOR, WHICH WAS INSTALLED IN OCTOBER, HAS PLUGGED ONLY ONCE
SINCE INSTALLATION AND HAS REQUIRED ONLY FOUR HOURS OF MAINTENANCE PER
WEEK.
1/80
2/80
101
201
301
401
501
SYSTEM
101
201
301
401
501
SYSTEM
95.8
87.1
84.6
86.4
100.0
100.0
100.0
100.0
100.0
1QO.O
77.6
100.0
91.2
100.0
100.0
55.6
100.0
100.0
85.4
100.0
100.0
100.0
56.8
100.0
94.8
87.1
84.6
77.1
100.0
100.0
100.0
100.0
100.0
100.0
64.0
100.0
75.2
87.1
84.6
45.8
100.0
98.2
60.5
96.6
100.0
70.7
40.2
92.0
744 613
528
696 493
427
*# PROBLEMS/SOLUTIONS/COMMENTS
THE NEW S02 MONITOR INSTALLED LAST OCTOBER IS STILL OPERATING WELL AND
HAS LOGGED SIX MONTHS OF OPERATION.
THE HIGH AVAILABILITIES ARE DUE TO THE 5TH MODULE BEING A TRUE SPARE.
AS OF FEBRUARY 1980 AND ARE STILL OPERATING WITHOUT ANY MAJOR PROBLEMS.
THE TVO RUBBER LINED WORMEN RECYCLE PUMPS HAVE NOW LOGGED 14,000 HOURS
3/80 HU
2fl
301
401
501
SYSTEM
100.0
100.0
73.7
100.0
78.1
100.0
130.0
100.0
73.7
48.4
78.1
100.0
100.0
100.0
73.7
100.0
78.1
100.0
100.0
100.0
73.7
48.4
78.1
100.0
744 744
595
*« PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS AVAILABLE FOR OPERATION THE ENTIRE MONTH OF MARCH.
4/80
101
201
301
401
501
SYSTEM
40.3
72.3
87.3
100.0
100.0
99.4
38.1
72.3
87.3
100.0
100.0
99.4
40.0
72.3
87.3
100.0
100.0
100.0
40.0
72.3
87.3
100.0
100.0
99.4
720 720
572
** PROBLEMS/SOLUTIONS/COMMENTS
DURING APRIL THE 101 AND 201 RECYCLE PUMP IMPELLERS HAD TO BE REPLACED.
THIS CAUSED EIGHT HOURS OF OUTAGE TIME FOR THESE TWO MODULES. NO OTHER FGD
SYSTEM OUTAGES OCCURRED.
5/80 101
201
301
301
3YSTEM
100.0
40.1
94.1
90.3
96.8
100.0
100.0
37.1
89.0
71.2
96.8
98.5
100.0
38.2
93.8
88.0
96.8
100.0
100.0
37.1
89.0
71.2
96.8
98.5
744 744
586
197
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
DUQUESNE LIGHT: ELRAMA 1-4 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL PER BOILER F60 CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MAY THE FGD SYSTEM HAS AVAILABLE FOR OPERATION THE ENTIRE MOUTH.
6/80
101
201
301
401
501
SYSTEM
100.0
100.0
100.0
.0
100.0
100.0
100.0
97.8
96.7
.0
100.0
98.6
100.0
100.0
100.0
.0
100.0
99.7
100.0
97.8
96.7
.0
100.0
98.6
720 720
710 61.6
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JUNE MODULE 401 WAS CLEANED AND THE CEILCOTE LINER WAS REPLACED.
THIS IS THE FIRST TIME SINCE START UP (APPROXIMATELY 17,000 OPERATING
HOURS) THAT ANY MODULE NEEDED RELINED.
DURING JUNE NO FGO-RELATED PROBLEMS OCCURRED ON MODULES 101, 201, 301 OR
501.
7/80
101
201
301
401
501
SYSTEM
100.0
100.0
98.5
75.8
35.5
100.0
64.9
91.1
85.6
75.8
12.9
82.6
100.0
100.0
98.3
75.8
16.7
97.7
64.9
91.1
85.6
75.8
12.9
82.6
744 744
615 66.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE RELINING OF MODULE 401 CONTINUED INTO PART OF JULY.
8/80
101
201
301
401
501
SYSTEM
30.9
100.0
100.0
99.1
83.9
100.0
21.2
94.8
93.3
99.1
82.5
97.7
23.5
100.0
100.0
99.1
83.7
100.0
21.2
94.8
93.3
99.1
82.5
97.7
744 744
727 65.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE RELINING WITH CEILCOTE ON MODULE 501 COMMENCED IN JULY AND CONTINUED
FOR APPROXIMATELY 120 HOURS IN AUGUST.
THE R.ELINING OF MODULE 101 WITH CEILCOTE STARTED IN AUGUST ACCOUNTING
FOR THE LOW AVAILABILITY DURING THE MONTH.
9/80
10/80
11/80
1C1
201
301
401
501
SYSTEM
101
201
301
401
501
SYSTEM
101
201
59.7
39.0
100.0
100.0
100.0
99.7
97.9
32.4
98.5
90.5
98.5
100.0
68.8
96.4
,9.7
22.8
1)0.0
100.0
99.2
95.4
95.8
23.3
98.5
72.7
96.5
96.8
68.8
96.4
59.7
27.2
100.0
100.0
100.0
96.8
97.8
25.6
98.5
88.3
98.4
100.0
68.8
96.4
59.7
22.8
96.0
100.0
99.2
94.4
95.8
23.3
93.5
72.7
96.5
96.8
68.8
96.4
720 720
680 64.5
744 744
720 75.1
198
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
DUQUESNE LIGHT: ELRAMA l-
-------
EPA UTILITY FSO SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
SQZ EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGD - MM
EQUIVALENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** MECHANICAL COLLECTOR
NUMBER
TYPE
SUPPLIER
** ESP
NUMBER
SUPPLIER
PARTICLE REMOVAL EFFICENCY - 7.
** PARTICLE SCRUBBER
GENERIC TYPE
SPECIFIC TYPE
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER SPECIFIC MATERIAL
*** FGD SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
S.'STEM SUPPLIER
A--E FIRM
DEVELOPMENT LEVEL
N):W/RETROFIT
( .080 LB/MMBTU)
( .600 LB/MMBTU)
(****** LB/MMBTU)
DUQUESNE LIGHT
PHILLIPS
1-6
SOUTH HEIGHT
PENNSYLVANIA
D
258.
******
387
408
373
387
408
FOSTER WHEELER
PULVERIZED COAL
BASE
873.01
182. Z
104.
CONCRETE
******* (***** FT)
(1850000 ACFM)
( 360 F)
( 340 FT)
( 11535 BTU/LB)
******
COAL
BITUMINOUS
26830.
16.27
******
5.02
******
1.92
i.o-e.e
********
******
MULTICLONES
RESEARCH-COTTRELL
RESEARCH-COTTRELL
80.0
VENTURI TOWER
VARIABLE-THROAT/SIDE-MOVABLE BLADES
CARBON STEEL
AISI 1110
GLASS FLAKE-FILLED POLYESTER
THROWAWAY PRODUCT
WET SCRUBBING
LIME
NONE
CHEMICO DIVISION, ENVIROTECH
GIBBS & HILL
FULL SCALE
RETROFIT
200
-------
EPA UTILITY FED SURVEY: OCTOBER - DECEMBER 1980
DUQUESKE LIGHT-' PHILLIPS 1-6 ENVIROTECH
40 DIA. X 66 HIGH
CARBON STEEL
AISI 1110
N/A
ORGANIC
CEILCOTE
BULL AND SPRAY NOZZLES
520.
5.3
4.0
12.2
258.13
171.1
90.0
99.0
( 8250 GPM)
( 40.0 GAL/1000 ACFJ
(16.0 IN-H20)
( 40.0 FT/S)
( 547000 ACFM)
( 340 F)
VENTURI TOWER
VARIABLE-THKDAT/TOP-ENTRY PLUMB BOB
CHEMICO DIVISION, ENVIROTECH
40 DIA. X 66 HIGH
CARBON STEEL
AISI 1110
N/A
ORGANIC
CEILCOTE
BULL AND SPRAY NOZZLES
1
( 3300 6PM)
( 40.0 GAL/1000 ACF)
(16.0 IN-H20)
( 40.0 FT/S)
( 547000 ACFM)
( 340 F)
£08.
5.3
4.0
12.2
258.13
171.1
90.0
90.0
MIST ELIMINATOR
8
IMPINGEMENT
BAFFLE
CHEVRON VANE
HORIZONTAL
1
90
3
1.37
3
1.0
( 4.5 FT)
( 4.0 IN-H20)
.3 ( 1.0 FT/S)
FIBERGLASS REINFORCED PLASTIC
12.0 ( 190 GAL/MIN)
201
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
DUQUESME LIGHT: PHILLIPS 1-6 ICONT.)
** REMEATER
NIJMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
TO1PERATURE INCREASE - C
** FAM3
NUMBER
NUMBER OF SPARES
DESIGN
FUNCTION
AFPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FlUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** DUCTWORK
LOCATION
CHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
*« DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
** TANKS
SERVICE
RECYCLE
SUiKER TRANSFER
THICKENER OVERFLOW
SLUDGE STABILIZATION MIXING
** PUMPS
SERVICE
SCRUBBER RECIRCULATION
THICKENER OVERFLOW
THICKENER UNDERFLOW
SLURRY FEED
MAKE-UP WATER
ABSORBER RECIRCULATION
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
CAPACITY
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
DIMENSIONS - FT
SHELL GENERIC MATERIAL TYPE
OUTLET STREAM CHARACTERISTICS
*** SLUDGE
** TREATMENT
METHOD
PROPRIETARY PROCESS
** DISPOSAL
NATURE
TYPE
LOCATION
DIRECT COMBUSTION
IN-LINE BURNER
OIL
-1.1 ( 30 FJ
5
1
CENTRIFUGAL
BOOSTER
INDUCED DRAFT
WET
235.95
171.1
HIGH ALLOY
( 500000 ACFM)
( 340 F)
SCRUBBER INLET
CARBON STEEL
NONE
SCRUBBER OUTLET
CARBON STEEL
FLAKEGLASS
NUMBER
1
1
1
1
NUMBER
10
6
1
5
1
2
VACUUM FILTER
1
600 TON/DAY
THICKENER
Z
75 DIA
MILD STEEL
32X SOLIDS
POZ-0-TEC
IUCS
INTERIM
LINED POND
ON SITE
202
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
DUQUESNE LIGHT: PHILLIPS 1-6 (CONT.)
SITE CAPACITY - CU.M
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION HETHOO
** WATER BALANCE
MATER LOOP TYPE
** FG3 SPARE CAPACITY INDICES
AtJSORBER - X
** FGi: SPARE COMPONENT INDICES
A'JSORBER
*892 ( 4.0 ACRE-FT)
FINAL
LANDFILL
OFF SITE
TRUCK
OPEN
.0
.0
PERFORMANCE DATA
PERIOD M03ULE AVAILABILITY OPER^BILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGO CAP,
S02 PART, HOURS HOURS HOURS FACTOR
0/73 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
DETERMINATION OF THE AVAILABILITY OF THE PHILLIPS SYSTEM HAS BEEN DIF-
FICULT. UNTIL ALL BOILERS WERE CONNECTED TO THE SCRUBBERS, THERE WAS AT
LEAST ONE SPARE TRAIN AND AS MUCH AS 100X SPARE SCRUBBER CAPACITY.
THEREFORE HAVING A TRAIN OUT OF SERVICE FOR MAINTENANCE DID NOT REDUCE
THE CAPABILITY OF THE SCRUBBER SYSTEM. UNTIL ALL SIX BOILERS WERE CON-
NECTED , MEANINGFUL AVAILABILITY FACTORS COULD NOT BE COMPUTED. ON MARCH
17, 1975, THE SIXTH BOILER WAS CONNECTED, AND ALL FOUR SCRUBBER TRAINS-
WERE REQUIRED TO BE IN SERVICE. OPERATION IN THAT MODE CONTINUED UNTIL
AUGUST 4, 1975, WHEN THE NO. 6 BOILER WAS REMOVED FROM THE SCRUBBER
SYSTEM BECAUSE THE PH LEVEL COULD NOT BE MAINTAINED AND DEPOSITS BECAME
UNMANAGEABLE TO THE POINT THAT SCRUBBER OUTAGES WERE REDUCING GENERATING
CAPABILITY OF THE STATION.
81.0
31.2
7/73 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
SCRUBBING OPERATIONS BEGAN DURING JULY.
8/73 SYSTEM
9/73 SYSTEM
10/73 SYSTEM
11/73 SYSTEM
12/73 SYSTEM
SYSTEM
2/7* SYSTEM
3/7* SYSTEM
7*4
720
744
720
744
74*
672
7*4
** PROBLEMS/SOLUTIONS/COMMENTS
STARTUP OF A PORTION OF THE PHILLIPS SCRUBBER SYSTEM BEGAN JULY 1973.
SEVERAL PROBLEMS THEN DEVELOPED IN THE FORM OF EROSION OF FANS AND THE
LIME FEED SYSTEM CAUSING OUTAGES OF THE SCRUBBER SYSTEM. AFTER AND EX-
TENDED OUTAGE, THE SCRUBBER SYSTEM WAS RETURNED TO SERVICE IN MARCH 197*.
THE SYSTEM HAS BEEN OPERATING CONTINUOUSLY SINCE IT RETURNED TO SERVICE
WITH VARIOUS NUMBERS OF BOILERS CONNECTED TO THE SCRUBBER SYSTEM AND
203
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
DUQUESNE LIGHT: PHILLIPS 1-6 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FED CAP.
S02 PART. HOURS HOURS HOURS FACTOR
SCRUBBER TRAINS IN SERVICE.
4/74 SYSTEM 720
5/74 SYSTEM 744
6/74 SYSTEM 730
7/74 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE F6D SYSTEM CONSISTS OF I TWO-STAGE AND 3 ONE-STAGE VENTURI SCRUBBERS.
PRESENTLY ONLY THE TWO-STAGE AND 1 ONE-STAGE TRAIN ARE IN SERVICE TREATING
FLUE GAS FROM BOILERS 2, 3,AND 4 (ABOUT 40X OF THE STATION CAPACITY).
CHRONIC PROBLEMS INCLUDE PUMP EROSION AND FAN VIBRATION.
8/74 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM EXPERIENCED PLUSGINO PROBLEMS IN EARLY AUGUST. THE UTILITY
IS CURRENTLY INVOLVED IN A RECYCLE PUMP STUDY. CONSIDERATIONS FOR PUMP
DESIGN AND MATERIALS ARE BEING MADE TO IMPROVE PUMP LIVE.
9/74 S^STEM 720
10/74 SYSTEM 744
11/74 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
SINCE STARTUP IN SEPTEMBER 1973 THE FGD SYSTEM HAS OPERATED AT REDUCED
CAPACITY WITH ONLY 2 OR 3 OF THE 4 TRAINS OPERATING AT ANY TIME TREATING
FLUE GAS FROM 4 BOILERS (ABOUT 40X OF THE STATION CAPACITY). THE TIE IN
OF BOILER NO. 5 DURING NOVEMBER HAS BOOSTED THE FGD SYSTEMS LOAD TO ABOUT
62X OF THE STATION CAPACITY. OVERALL SO2 REMOVAL EFFICIENCY IS 60X. THE
TWO-STAGE TRAIN ITSELF REMOVES 60X OF THE INLET S02. TESTS WITH MAGNESIUM
PROMOTED LIME INDICATE THAT S02 REMOVAL EFFICIENCY CAN BE BOOSTED BY 60X
OVER COMMERCIAL LIME.
DURING THE PERIOD REBRACING OF FAN BLADES WAS IN PROGRESS.
12/74 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
DURING DECEMBER REPAIRS HERE MADE TO HOLES IN THE MIST ELIMINATORS WITH
CEILCOTE APPLICATIONS.
FOUR TONS OF SLUDGE WERE REMOVED FROM ONE SCRUBBER BASE. THE VENTURI
DAMPERS WERE SEIZING AS A RESULT OF SOLIDS BUILDUP.
THE UTILITY IS AWAITING THE DELIVERY OF SPARE RECYCLE PUMPS.
1/75 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THREE SCRUBBING TRAINS OPERATED ON TWO THIRDS OF THE BOILER FLUE GAS
OUTPUT. THE SCRUBBING SYSTEM OPERATED ON FLUE GAS FROM FIVE BOILERS
THROUGHOUT JANUARY WITH NEARLY 1002 FGD SYSTEM AVAILABILITY. OVERALL
S02 REMOVAL EFFICIENCY WAS APPROXIMATELY 60X.
204
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
DUQUESNE LIGHT: PHILLIPS i-6 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
BECAUSE OF SOLIDS BUILDUP THE DAMPERS WERE SEIZING. THE UTILITY HAS BEEN
EXERCISING THE DAMPERS MORE FREQUENTLY AS A RESULT AND THIS SEEMS TO
HAVE IMPROVED DAMPER OPERATIONS.
DUE TO COLD WINTER WEATHER AND RELATED CONDITIONS THE SLUDGE STABILIZATION
PROCESS REQUIRES A LONGER PERIOD OF TIME. THE SLUDGE PONDS HAVE BEEN
FILLING IN 8 TO 9 DAYS. 6 TO 7 DAYS ARE REQUIRED TO EMPTY PONDS. THE
CURRENT SLUDGE PRODUCT HAS BEEN A SOUPY CONSISTENCY REQUIRING A CLAMSHELL
TYPE DREDGE FOR THE POND. PLUGGING IN THE STABILIZING AGENT INJECTION
LINES IS THOUGHT TO HAVE CONTRIBUTED TO THE POOR SLUDGE QUALITY.
SOME WET SIDE S02 MONITORS FAILED DURING THE PERIOD. THEY ARE CURRENTLY
BEING MODIFIED BY THE MANUFACTURER.
THE REHEATERS HAVE NOT YET BEEN TESTED.
2/75 SYSTEM 672
3/75 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE FOURTH FGD TRAIN AND THE SIXTH BOILER WERE TIED IN ON MARCH 17, 1975.
ONE OF THE BOILERS MAS DOWN FOR MAINTENANCE SO THE SCRUBBING SYSTEM DID
NOT OPERATE ON FLUE GAS FROM ALL SIX BOILERS.
DURING MARCH THE PROGRAM TO IMPROVE SCRUBBER RECYCLE PUMP PERFORMANCE
CONTINUED. FOUR OUT OF SIX NEW PUMPS HAVE BEEN INSTALLED.
THE CALCILOX INJECTION SYSTEM LINES HAVE BEEN PLUGGING FREQUENTLY. THE
UTILITY IS CONSIDERING A NEW PNEUMATIC DELIVERY SYSTEM FOR CALCILOX.
THE UTILITY IS CURRENTLY LOOKING FOR NEW SLUDGE DISPOSAL SITES.
4/75 SYCTEM 720
** PROBLEMS/SOLUTIONS/CC'MMENTS
THE PRESSURE DROP INSTRUMENTATION AT THE VENTURIS HAS BEEN A PROBLEM AREA.
THE D/flPERS HAVE STILL BEEN SEIZINS BECAUSE OF SOLIDS BUILDUP.
ALL SIX BOILERS AND FOUR SCRUBBING TRAINS OPERATED IN AN INTEGRATED MODE
IN APRIL. SOME SOLIDS BUILDUP HAS BEEN DISCOVERED AGAIN IN THE SCRUBBING
TRAINS.
BECAUSE OF EROSION AND PLUGGING PROBLEMS, A CONTINUOUS WASH IS NOW
PERFORMED ON THE MIST ELIMINATORS.
5/75 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
PRELIMINARY PARTICULATE MATTER REMOVAL EFFICIENCY TESTS SHOWED THAT THE
UNIT MEETS THE 0.8 LB/MM BTU ALLEGHENY COUNTY STANDARD. THE OUTLET
LOADINGS IN MAY WERE IN THE 0.04 LB/MM BTU RANGE.
A HOLE WAS DISCOVERED IN A SCRUBBER LINER DURING MAY. A PREVIOUSLY
PATCHED AREA HAD FAILED AGAIN.
6/75 SYSTEM 720
205
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
DUQUESNE LIGHT: PHILLIPS 1-6 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
_____« »_«___ ~,~m,f~mi.i~*mt—<^~,• — —-.._«<_ _M«*._—_i_«i_ M_MIWW THIOSORBIC LIME SCRUBBING WAS INITIATED IN THE PHILLIPS
SINGLE-STAGE SCRUBBING TRAINS ON AN EXPERIMENTAL BASIS. THE UTILITY IS
STUDYING COMPLIANCE FEASIBILITY, S02 REMOVAL EFFICIENCY, AND QUALITY OF
THE SLUDGE GENERATED BY THE SINGLE-STAGE SCRUBBING TRAINS.
PRESENTLY ONLY 4 OF THE 6 BOILERS ARE TIED INTO THE FGD SYSTEM.
11/75 101 86.9 86.9
206
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
DUQUESNE LIGHT: PHILLIPS 1-6 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
201
301
401
SYSTEM
100.0
.0
10.*
49.3
100.0
.0
10.4
49.3
720
720
355
12/75 101
201
301
401
SYSTEM
50.8
93.2
25.7
54.4
56.0
48.4
88.8
24.5
51.9
53.4
744 709
397
#* PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY CONCLUDED THE THIOSORBIC LIME TESTING PROGRAM IN MID-DECEMBER.
FOUR BOILERS WERE COUPLED TO THE SCRUBBING SYSTEM DURING THE RUN. THE
UTILITY IS NOW ANALYZING THE DATA GENERATED DURING THE TEST PROGRAM. THE
SCRUBBERS HAVE BEEN PUT BACK ON REGULAR LIME. NO UNUSUAL PROBLEMS WERE
ENCOUNTERED DURING THE TEST RUN. THE UTILITY HAS STARTED CONSTRUCTION ON
AN ADDITIONAL LIME SLAKER FOR FULL SCALE MAGNESIUM PROMOTED LIME OPERA-
TION. THE THICKENER MAY REQUIRE REDESIGN TO ACCOMODATE INCREASED
CAPACITY.
1/76 101
201
301
401
SYSTEM
38.4
74.2
14.0
97.9
56.1
37.2
72.0
13.6
95.0
54.4
744 722
405
** PROBLEMS/SOLUTIONS/COMMENTS
THE 2.5-MONTH TEST PROGRAM WITH THIOSORBIC LIME INCLUDED 1612 HOURS ON ONE
TRAIN AND 1309 HOURS ON ANOTHER TRAIN. RESULTS INDICATE THAT THE REQUIRED
DEGREE OF S02 REMOVAL (83X) CAN BE OBTAINED WITH AN MGO CONTENT OF
8-10X IN THE LIME WITH SINGLE-STAGE SCRUBBING.
97.8
98.5
24.7
60.4
70.4
2/76 101
201
301
401
SYSTEM
3/76 101
201
301
401
SYSTEM
4/76 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
94.4
95.1
23.9
58.3
67.9
93.4
47.5
88.6
62.0
72.9
696 672
744
720
472
542
THE UTILITY IS STILL EXPERIENCING PROBLEMS WITH SOLIDS DEPOSITION IN THE
VENTURI THROAT OF THE SCRUBBING TRAINS, CAUSING MOVEMENT INHIBITION AND
GREATER PRESSURE DROPS.
THE SLUDGE STABILIZATION PRACTICES ARE STILL CONTINUING AT THIS FACILITY.
PLANT OPERATION IS PROCEEDING WITH A TOTAL OF FOUR BOILERS COUPLED INTO
THE SCRUBBING SYSTEM (EQUALING 336 MW, WHICH IS 87X OF THE TOTAL PLANT
CAPACITY). THE FGD SYSTEM OPERATED ON HIGH CALCIUM LIME DURING THE REPORT
PERTOD. THE GENERAL OPERATION MODE AT THIS FACILITY HAS ONE OF THE FOUR
SCRL3BING TRAINS OUT CONTINUALLY FOR REPAIRS, CLEANING, AND PREVENTIVE
MAINTENANCE. THE FGD SYSTEM AVAILABILITY FOR THE FIRST QUARTER OF 1976
WAS 7?X.
207
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
DUQUESrlE LIGHT: PHILLIPS 1-6 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOI
5/76 SYSTEM 744
6/76 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
REDUCED LOAD OPERATIONS WERE REPORTED BY THE UTILITY FOR THE MAY-JUNE
PERIOD BECAUSE OF A SCHEDULED TURBINE OVERHAUL ON BOILER NO. 6.
THE UTILITY IS PROCEEDING WITH THE INSTALLATION OF THREE ADDITIONAL LIME
STORAGE SILOS AND A THIRD THICKENER.
THE SCRUBBING SYSTEM WAS SHUT DOWN ON JUNE 27 FOR A SCHEDULED FOUR WEEK
REPAIR PERIOD. THE MAJORITY OF THE WORK WILL BE CONCENTRATED ON THE STACK
ASSOCIATED DUCTWORK AND BOILER DAMPERS. THE ACID BRICK FLUE HAS BEEN
LEAKING PARTICULARLY IN THE MORTAR JOINTS AND STEEL BANDS SUPPORTING THE
BRICK HAVE BEEN CORRODING. CORROSION HAS OCCURRED IN THE DUCTWORK IN THE
EXPANSION JOINT AREA WHERE THE DUCT ENTERS THE STACK.
THE SLUDGE IS CURRENTLY BEING STABILIZED WITH A CALCILOX ADDITION AT A
RATE OF APPROXIMATELY 10X BY WEIGHT OF SLUDGE. THE UTILITY IS PLANNING TO
CONTRACT IUCS FOR SLUDGE STABILIZATION IN APPROXIMATELY A YEAR.
7/76 SYSTEM 744
8/76 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE FOUR-WEEK SYSTEM OVERHAUL WAS COMPLETED JULY 25. THE THREE ADDITIONAL
LIME STORAGE SILOS AND THE FOUNDATION FOR THE ADDITIONAL 75-FOOT DIAMETER
THICKENER HAVE BEEN INSTALLED. WHEN THE NEW EQUIPMENT IS INSTALLED THE
UTILITY WILL SWITCH FROM LIME TO MAGNESIUM PROMOTED (THIOSORBIC) LIME.
THE UTILITY HAS SIGNED A LETTER OF INTENT WITH IUCS FOR A LONG-TERM SLUDGE
TREATMENT SYSTEM.
REPAIRS WERE MADE ON THE TURNING VANES TO THE SCRUBBER MIST ELIMINATORS.
THE CEILCOTE COATING ON MODULE 401 FAILED (ORIGINAL COAT ERODDEO AWAY AND
CORROSION HAD SET IN).
REPAIR WORK WAS COMPLETED ON THE EXPANSION JOINT SEAL WHERE THE DUCTWORK
TIES INTO THE MAIN STACK.
THE STEEL BANDS AROUND THE INNER STACK STRUCTURE WERE REPAIRED.
THE SCRUBBERS ID FANS WERE OVERHAULED.
THE BOILER EXIT DAMPERS WERE REPAIRED.
REPAIRS WERE MADE TO STOP LEAKING IN THE ACID-BRICK FLUE OF THE MAIN
STACK.
9/76 SYSTEM 720
10/76 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
BOILER NUMBERS 2 THROUGH 6 WERE COUPLED INTO THE SCRUBBING SYSTEM. BOILER
NO. 1 IS DOWN FOR OVERHAUL AND REPAIRS. THE IUCS INTERIM SLUDGE PROCESS-
ING PLANT IS UNDER CONSTRUCTION AND WILL BE IN SERVICE BY DECEMBER 1976.
THE TEMPORARY FACILITIES WILL PROCESS THE THICKENER UNDERFLOW AND PONDED
SLUDGE UNTIL THE POND IS DEPLETED OF SLUDGE AND THE PERMANENT FACILITY HAS
208
-------
EPA UTILITY fGO SURVEY: OCTOBER - DECEMBER 1980
DUQUESNE LIGHT: PHILLIPS 1-6 CCQNT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
BEEN INSTALLED. SCRUBBING OPERATIONS ARE STILL PROCEEDING IN AN OPEN WA-
TER LOOP MODE WITH PART OF THE THICKENER OVERFLOW BEING DIVERTED TO THE
ASH POND. BECAUSE BOTH THE BEAVER VALLEY AND BRUCE MANSFIELD STATIONS ARE
FULLY OPERATIONAL, THIS STATION HAS BEEN RELEGATED TO PEAK LOAD OPERA-
TIONS. GENERAL LOAD OPERATIONS ARE FULL LOAD CAPACITY IN THE DAYTIME AND
50 TO 67X LOAD REDUCTION AT NIGHT.
TOTAL SCRUBBER HOURS: 23,274 THE FIGURES AT THE LEFT WERE COMPILED
TOTAL BOILER HOURS: 83,642 BY THE UTILITY FOR SYSTEM OPERATIONS
TOTAL SCRUBBER OUTAGE TIME: 5,500 FOR THE PERIOD FOLLOWING START-UP IN
TOTAL SCRUBBER AVAILABLE JULY 1973 INCLUSIVE TO OCTOBER 1976.
HOURS: 23,274 THE TOTAL SCRUBBER HOURS VALUE IN-
AVERAGE MM LOAD/SCRUBBER OPERATION CLUDES OPERATION TIME WHEN ONE OR
HOUR: 243 MORE OF THE MODULES WERE IN SERVICE.
TOTAL OPERABILITY INDEX: 28X TOTAL BOILER AND UNAVAILABILITY VAL-
TOTAL RELIABILITY INDEX: 81/C UES APPLY FOR ALL THE CORRESPONDING
UNITS. THE TOTAL SCRUBBER AVAILABIL-
TY INDEX INCLUDES THE TIME WHEN ONE
OR MORE MODULES WERE AVAILABLE FOR
SERVICE.
11/76 SYSTEM 720
12/76 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE IUCS SLUDGE STABILIZATION FACILITY AT PHILLIPS WAS INSTALLED AND
STARTED UP IN DECEMBER. THE FACILITY INCLUDES EQUIPMENT FOR DEWATERING,
ESP-COLLECTED FLYASH ADDITION AND TRANSPORT TO THE OFF-SITE LANDFILL.
THE RECYCLE PUMP EVALUATION IS CONTINUING. AFTER 2500 HOURS OF OPERATION
THE PUMPS USING CARBORUNDUM WEAR RINGS AND CD4 MCU IMPELLERS WERE HOLDING
UP WELL. THEY HAVE NOW ACCUMULATED 2800 HOURS OF OPERATION (THEY WERE
INSPECTED AFTER 2500 HOURS). AFTER 2900 HOURS OF OPERATION PUMPS USING
CARBORUNDUM WEAR RINGS AND TITANIUM IMPELLERS WERE PERFORMING WELL.
BOILERS 2 THROUGH 6 WERE COUPLED INTO THE SYSTEM THROUGHOUT THE PERIOD.
BOILER 1 REMAINED SHUT DOWN.
THE FIRST NEW SLAKER (PASTE TYPE SLAKER), ONE OF FOUR NEW UNITS CAME ON
LINE DURING THE PERIOD. HIGHER STOICHIOMETRIC RATIOS, HIGHER PH VALUES
AND INCREASED S02 REMOVAL EFFICIENCY RESULTED IN THE SYSTEMS.
IN ORDER TO ENHANCE SETTLING IN THE TWO 75-FOOT DIAMETER THICKENERS A
POLYELECTROLYTE MATERIAL WILL BE ADDED ON A TEMPORARY BASIS. WHEN THE
NEW 75-FOOT THICKENER IS BROUGHT ON LINE THE POLYELECTROLYTE ADDITION IS
EXPECTED TO BE TERMINATED.
THE CONTRACT WITH DRAVO FOR THIOSORBIC LIME (MG-PROMOTED LIME) HAS BEEN
FINALIZED. THE SWITCH TO MAGNESIUM PROMOTED LIME WILL TAKE PLACE WHEN
THE LAST THICKENER IS COUPLED INTO THE SYSTEM.
THE VENTURIS ARE ENCOUNTERING A GREAT DEAL OF SCALING. PRESSURE DROPS
ACROSS THE VENTURIS ARE REGISTERING TWICE THE NORMAL PRESSURE DROP AT
12 INCHES H20(6 INCHES H20 IS DESIGN).
1/77 SYSTEM 744
2/77 SYSTEM 672
209
-------
EPA UriLITY F6D SURVEY: OCTOBER - DECEMBER I960
DUQUESNE LIGHT: PHILLIPS 1-6 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOf
** PROBLEMS/SOLUTIONS/COVIMENTS
1977 I:ULL COMPLIANCE OPERATIONS MILL INCLUDE 83X S02 REMOVAL FOR Z7. SULFUR
COAL UTILIZING THIOSORBIC LIME (6-12X MG) AND FIXATING THE SCRUBBER WASTES
WITH THE IUCS POZ-0-TEC METHOD. THE FIXATED MATTER WILL BE HAULED AWAY TO
AN OFF-SITE DISPOSAL AND LANDFILL. IUCS HAS BEEN AWARDED A TEN YEAR CON-
TRACT FOR THE USE OF THIS METHOD.
3/77 SYSTEM 74
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
DUQUESNE LIGHT: PHILLIPS 1-6 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
7/77 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
ALL SIX BOILERS ARE COUPLED INTO THE SCRUBBER PLANT. FLUE GAS FROM FIVE
OF THESE UNITS IS BEING TREATED BY THE SCRUBBERS. ONLY FOUR OF THE SIX
BOILERS ARE ACTUALLY OPERATING BECAUSE OF THE CURRENT TURBINE REPAIR
OUTAGE. OPERATIONS ARE PROCEEDING WITH ONE SCRUBBING TRAIN OUT OF SERVICE
AT ALL TIMES FOR MAINTENANCE AND CIEANOUT. SOE REMOVAL EFFICIENCY IS
APPROXIMATELY 50X.
BOILER 6 HAS BEEN OUT OF SERVICE kHILE-TURBINE REPAIRS ARE BEING MADE.
THE RECYCLE PUMP EVALUATION STUDY CONTINUED DURING THE PERIOD. COMPONENTS
BEING EVALUATED INCLUDE: CARBORUNDUM IMPELLERS, CARBORUNDUM WEAR RINGS,
TITANIUM IMPELLERS, 317SS WEAR R'NGS AND STELLITE TIPPED IMPELLERS.
A THIJSORBIC LIME TEST WAS PREMATURELY TERMINATED BECAUSE OF SOME MINOR
SUKER/FEEDER PROBLEMS. HIGH CALCIUM VIRGIN LIME WAS UTILIZED DURING THE
MAJORITY OF OPERATIONS THROUGHOUT THE PERIOD.
8/77 SYSTEM 744
9/77 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
LIME HANDLING AND SOLID WASTE DISPOSAL FACILITIES WERE BEINS SCALED UP TO
HANDLE FULL CAPACITY AND A THIRD THICKENER WAS INSTALLED AND BROUGHT INTO
SERVICE DURING THIS REPORT PERIOD. THE IUCS SYSTEM IS STILL PERFORMING
INTERIM PHASE OPERATIONS. WASTE WATER IS BEING MIXED WITH FLYASH AND
DISPOSED WITHOUT FIXATIVE ADDITION. CURRENT CONSTRUCTION WORK IS EXPECTED
TO BE COMPLETED BY THE END OF JANUARY WHEN ALL SIX BOILERS WILL BE BACK ON
LINE FOR A TWO MONTH TEST PERIOD. THIOSORBIC LIME IS STILL BEING TESTED.
RESULTS ARE NOT YET AVAILABLE. THE FGD SYSTEM WILL BE DOWN FOR THE FIRST
WEEKEND OF NOVEMBER. THE SYSTEM WILL ALSO BE CHECKED FOR MAIN DUCT LEAKS
AT THIS TIME. THE SCRUBBER AND STACK LININGS AND RECYCLE PUMPS WILL BE
THOROUGHLY CHECKED AS WELL. NECESSARY REPLACEMENTS AND REPAIRS WILL BE
CARRIED OUT. CURRENT S02 REMOVAL EFFICIENCY IS SOX. BY EARLY APRIL 1978
THE SYSTEM IS EXPECTED TO REACH COMPLIANCE WITH AN SOS REMOVAL EFFICIENCY
OF 83X.
10/77 HOI 93.6 92.6
iiOl 4.0 4.0
:i01 88.3 88.3
'•01 87.7 87.7
SYSTEM 744 744 507
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE 101 WAS DOWN A TOTAL OF 113 HOURS IN OCTOBER FOR REGULAR MAINTEN-
ANCE AND REPAIRS.
MODULE 201 WAS PUT IN SERVICE ON OCTOBER 26 AFTER EXTENSIVE CLEAN UP.
ALSO REPAIRS TO THE ID FAN HOUSING RUBBER LINING WERE MADE AND THE FAN WAS
BALANCED.
MODULE 301 WAS DOWN A TOTAL OF 57 HOURS IN OCTOBER FOR MAINTENANCE AND
REPAIRS.
MODULE 401 WAS DOWN A TOTAL OF 36 HOURS IN OCTOBER FOR REPAIR OF HOLES IN
THE ID FAN LINING AND FOR THE TIE-IN OF THE THICKENER BLEED LINE.
211
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
DUQUESNE LIGHT: PHILLIPS 1-6 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
11/77 101
201
301
401
SYSTEM
92.1
91.6
28.1
56.3
67.0
92.1
91.6
28.1
56.3
67.0
720 720 483
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE SHUTDOWN OUTLET DUCT LEAKS WERE REPAIRED.
BOILER EXIT DAMPERS WERE REPLACED. THE OLD DAMPERS FAILED DUE TO FLYASH
EROSION,
CORROSION OF STEEL BANDS IN STACK WAS DISCOVERED DURING THE PERIOD. THE
CORROSION IS A RESULT OF CONDENSED MOISTURE SEEPING THROUGH THE MORTAR.
SLUDGE HANDLING PROBLEMS HAVE OCCURRED BECAUSE DEWATERING OPERATIONS ARE
NOT WORKING PROPERLY.
THE RESULTS FROM THIOSORBIC LIME USE CAN NOT YET BE QUANTIFIED DUE TO LIME
FEED SYSTEM PROBLEMS.
LIME FEED SYSTEM PROBLEMS OCCURRED OVER THE PERIOD.
THE MIST ELIMINATORS WERE CLEANED DURING NOVEMBER.
12/77 SYSTEM 744
1/78 Itl ))4.3 84.-$
201 77.2 77.2
301 .0 .0
4C1 65.1 65.1
SYSTEM 56.6 56.7 744 744 421
** PROBLEMS/SOLUTIONS/COMMENTS
CUMULATIVE HOURS FOR JANUARY 1, 1977 THROUGH JANUARY 8, 1978 WERE 22391
FOR MODULE 101, 20998 FOR MODULE 201, 22229 FOR MODULE 301 AND 22259 FOR
MODULE 401.
SCRUBBER TRAIN 301 WAS DOWN FOR AN OVERHAUL FROM NOVEMBER 17 TO FEBRUARY
6, 1978 WHEN IT WAS RETURNED TO SERVICE.
SCRUBBER TRAIN 401 WAS REMOVED FROM SERVICE ON FEBRUARY 6.
THE IUCS INTERIM SLUDGE TREATMENT SYSTEM HAS SOME DEWATERINS PROBLEMS.
DURING DECEMBER PHILLIPS EXPERIENCED POOR SLUDGE REMOVAL. THE IUCS PLANT
IS WORKING ON A PART TIME BASIS. FULL OPERATIONS ARE EXPECTED LATE THIS
SPRING. THE POOR QUALITY SLUDGE IS SENT TO AN EMERGENCY POND AND THEN RE-
CIRCULATED BACK TO THE THICKENER.
TESTING WITH THIOSORBIC LIME AT SX M60 HAS SHOWN THAT THE M60 CONCENTRA-
TION IS NOT GREAT ENOUGH TO EFFECT ADEQUATE S02 REMOVAL ON A SINGLE STAGE
SCRUBBER. THE UTILITY IS GOING TO TEST AT A GREATER MGO CONCENTRATION BY
STARTING AT 10X AND THEN DROPPING BACK UNTIL THE CONCENTRATION IS SATIS-
FACTORY. THIS TESTING, AS WELL AS SCRUBBER OPERATIONS, HAVE, HOWEVER,
BEEN HAMPERED BY LOW LOADS AS A RESULT OF THE COAL STRIKE.
AN OUTAGE HAS BEEN SCHEDULED AT PHILLIPS TO REPLACE THE CARBON STEEL
SUPPORT BANDS IN THE STACK WITH STAINLESS STEEL BANDS.
2/78 101 43.5 31.1
212
-------
EPA UTILITY FSD SURVEY: OCTOBER - DECEMBER 1980
DUQUESNE LIGHT'- PHILLIPS 1-6 (CONT.J
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
201 58.5
301 3.8
401 31.7
SYSTEM 34.4
3/78 SYSTEM .0
41.8
2.7
22.6
24.6
.0
672
744
480
0
167
0
** PROBLEMS/SOLUTIONS/COMMENTS
4/76 SYSTEM
5/78 S^ STEM
AN OUTAGE OCCURRED BETWEEN JANUARY 6 AND JANUARY 8 WHEN THE STACK DRAIN
LEAKS WERE REPAIRED BY SANDBLASTING THE OUTER WALL AND REPLACING THE CAR-
BON STEEL BANDS WITH STAINLESS STEEL BANDS.
THE SYSTEM WAS SHUTDOWN ON FEBRUARY 11 DUE TO THE COAL SHORTAGE. THE OUT-
AGE CONTINUED THROUGH MARCH AND THE SYSTEM IS SCHEDULED TO BE ON LINE BY
APRIL 15. DURING THE OUTAGE A NUMBER OF REPAIRS AND MODIFICATIONS WERE
MADE.
THE BOILER EXIT DAMPERS WERE LINED WITH 3I6SS ON AREAS OF HIGH EROSION
CAUSED BY FLYASH IMPINGEMENT.
EXPANSION JOINTS ON THE INLET DUCTWORK WERE SHIELED BY METAL PLATES WHICH
WERE WELDED AT ONE END.
NUMEROUS HOLES IN THE WET GAS DUCT WORK WERE REPAIRED AND THE DUCTS WERE
RELINED WITH CEILCOTE.
THE VENTURI THROAT DAMPERS WERE CLEANED ON ALL THE SCRUBBERS.
INTERNAL MIST ELIMINATORS WERE CLEANED. THE EXTERNAL MIST ELIMINATORS,
WHICH ARE BADLY DETERIORATED, MAY BE REPLACED.
THE STACK ACID BRICK FLUE WAS INSPECTED AND SOME BRICKS WERE REPLACED AT
THE TOP OF THE STACK.
CONSTRUCTION WORK ON ADDITIONAL EQUIPMENT SUCH AS THE THICKENER AND SILOS
IS ALMOST COMPLETE. IT WAS NOTED THAT THE CEILCOTE LINER COROLINE 505AR
HAS HELD UP WELL OVER THREE YEARS ON THE CONICAL APEX Of MODULE 401.
720 528
744 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE 1 GD SYSTEM CAME BACK ON LINE AFTER THE COAL STRIKE IN LATE MARCH. IT
IS NOT OPERATING AT FULL LOAD BECAUSE THE NO. 6 BOILER IS STILL OUT AND
SHOULD BE BACK ON LINE IN MID-JULY. COMPLIANCE TESTS WILL TAKE PLACE IN
JULY, AFTER BOILER 6 IS BACK ON LINE, TO SEE IF THE SYSTEM IS MEETING THE
83/C S02 REMOVAL REQUIREMENT FOR 2X SULFUR COAL. THERE WERE NO HOURS RE-
PORTED FOR THIS PERIOD BECAUSE OF PRELIMINARY TESTING BEING CONDUCTING IN
PREPARATION FOR THE COMPLIANCE TESTS. SO FAR, TESTS INDICATE THAT THE
SYSTEM WILL COMPLY WITH THE REQUIRED STANDARDS. THE OPERABILITY FOR ALL
FOUR TRAINS WAS BETWEEN 65 AND 75X.
6/78 SYSTEM
7/78 101
201
301
401
SYSTEM
48.3
43.9
85.7
82.5
65.1
48.3
43.9
78.7
76.0
61.7
48,3
43.9
78.7
76.0
61.7
720 720
744
459
213
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
DUQUESNE LIGHT: PHILLIPS 1-6 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE INTERNAL MIST ELIMINATOR OH MODULE 201 WAS REPLACED AND THE MODULE 301
MIST ELIMINATORS WERE CLEANED OVER THE PERIOD.
THE FGD SYSTEM HAS ACCUMULATED APPROXIMATELY 24000 HOURS OF OPERATION ON
ALL FOUR MODULES SINCE START-UP.
MATER BALANCE PROBLEMS HAVE CONTRIBUTED TO THE OCCURRANCE OF LOW PH, RE-
SULTING IN MIST ELIMINATOR PLUGGING.
THE MIST ELIMINATOR PLUGGING IS ALSO RELATED TO LOW PH RESULTING FROM LIME
HANDLING AND SLURRY PREPARATION SYSTEM FAILURE.
THE UTILITY IS CURRENTLY STUDYING MAYS TO TIGHTEN THE HATER BALANCE BY
USING THICKENER SUPERNATANT INTERMITTENTLY WITH CLEAR SERVICE WATER FOR
THE MIST ELIMINATORS.
THE LIME HANDLING FACILITY DOES NOT INCLUDE A GRIT REMOVAL STAGE. GRIT
IS CAUSING PLUGGING IN THE SLURRY HANDLING SYSTEM AND MIXING EQUIPMENT.
PROCESS CHEMISTRY CONTROL IS A CHRONIC PROBLEM AT PHILLIPS DUE IN PART TO
TO HATER BALANCE AND LIME HANDLING EQUIPMENT.
WHEN HATER BALANCE IS ACHIEVED THE FGD SYSTEM EXPERIENCES A BUILD UP OF
SALTS.
8/78 101
201
301
100.0
73.2
100.0
92.4
91.4
97.3
71.9
88.8
85.0
85.8
97.3
71.9
88.8
85.0
85.8
744 744
SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
THE RUBBER LINING IN MODULE 101 HAS REPAIRED.
HIGH PRESSURE HATER CLEANING HAS PERFORMED ON MODULES 101 AND 401.
62.4
75.6
67.5
55.7
65.3
** PROBLEMS/SOLUTIONS/COMMENTS
638
9/78 101
201
301
401
SYSTEM
63.7
62.7
83.9
65.6
74.0
62.4
75.6
67.5
55.7
65.3
720 720
470
DURING THE AUGUST-SEPTEMBER PERIOD MIST ELIMINATOR CLEANING TOOK PLACE IN
ORDER TO CORRECT THE PLUGGING PROBLEM.
IN AUGUST THE INTERNAL MIST ELIMINATOR ON MODULE 201 WAS REPLACED.
THE L. ME MIXING BASIN HAD TO BE SHUT DOWN OVER A WEEKEND SO THAT EXCESSIVE
GRIT A^D SOLID PARTICLES THAT HAD BUILT UP COULD BE CLEANED OUT.
HIGH PRESSURE WATER CLEANING HAS PERFORMED ON MODULES 101 AND 401.
THE RUBBER LINING IN MODULE 101 HAS REPAIRED.
A MAJOR PROBLEM AREA DURING THE PERIOD WAS CAUSED BY INSUFFICIENT SUPPLIES
OF DRY FLY ASH TO MIX WITH THE SLUDGE. AS A RESULT THE SLUDGE HAS BEEN
LEAKING OUT OF THE TRANSPORT TRUCKS WHILE IN TRANSIT TO THE FINAL DISPOSAL
SITE. APPARENTLY NOT ENOUGH FLYASH IS BEING COLLECTED WITH THE PRESENT
214
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
DUQUESKE LIGHT: PHILLIPS 1-6 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
SYSTEM.
10/78
11/76
101
201
301
401
SYSTEM
101
201
301
401
SYSTEM
100.0
97.7
95.3
4.8
74.5
44.0
100.0
91.7
71.3
76.8
96.1
87.5
87.9
2.2
68.4
41.1
100.0
88.9
69.0
74.8
96.1
87.5
87.9
Z.Z
68.4
41.1
100.0
88.9
69.0
74.8
744 744 509
720 720 538
** PROBLEMS/SOLUTIONS/COMMENTS
S02 AND PARTICULATE MATTER REMOVAL EFFICIENCY TESTS INDICATE THAT THE
STATION NOW MEETS STATE STANDARDS.
THE FGD SYSTEM IS EXPERIENCING A URGE AMOUNT OF SCALING BECAUSE OF THE
HIGH EXCESS AIR ENTERING THE SYSTEM FROM THE BOILERS OXIDIZING THE SOFT
SULFITE TO SULFATE ON THE SCRUBBER INTERNALS.
12/78 101
201
301
401
SYSTEM
91.7
98.0
30.3
90.4
77.6
90.8
88.1
27.8
87.5
73.6
90.8
88.1
27.8
87.5
73.6
744 744
547
** PROBLEMS/SOLUTIONS/COMHENTS
1/79
2/79
101
201
301
401
SYSTEM
101
201
301
401
SYSTEM
89.0
77.9
50.1
86.1
75.8
38.9
72.1
88.3
100.0
74.8
86.8
69.2
50.0
83.7
72.4
38.9
72.1
88.3
100.0
74.8
DURING THE PERIOD A LACK OF FLYASH FOR MIXING WITH SLUDGE RESULTED IN A
WET SLUDGE PRODUCT THAT MUST BE LEFT ON SITE TO DRY BEFORE TRANSPORT TO
THE LANDFMLL.
86.8
69.2
50.0
83.7
72.4
38.9
72.1
88.3
100.0
74.8
744 744
672 672
539
503
** PROBLEMS/SOLUTIONS/COMMENTS
3/79
4/79
101
201
301
401
SYSTEM
101
201
301
401
SYSTEM
.0
96.6
97.6
100.0
73.6
89.9
5.9
97.6
89.0
70.6
.0
96.3
88.0
100.0
71.1
86.8
5.9
85.0
84.9
65.7
EXCESSIVE SCALING IN THE MODULE 101 EXIT DUCT CAUSED SUPPORT COLUMNS TO
COLLAPSE. THE SCALE WAS REMOVED AND THE SUPPORT COLUMNS WERE SHORED UP.
.0
96.3
68.0
100.0
71.1
86.8
5.9
85.0
84.9
65.7
744 744
720 720
529
473
215
-------
OCTOBER - DECEHBER 1980
DUQUESME LIGHT: PHILLIPS 1-6 (CONT.,
5/79 101
201
301
401
SYSTEM
6/79 101
301
SYSTEM
7/79 101
201
301
SYSTEM
8/79 101
201
301
401
SYSTEM
9/79 101
201
301
401
SYSTEM
10/79 101
201
301
401
SYSTEM
11/79 101
201
301
401
SYSTEM
12/79 101
201
301
401
SYSTEM
100.0
.0
99.3
99.4
74.7
70.8
28.8
85.6
85.5
67.7
100.0
98.5
72.7
29.9
75.3
100.0
97.6
100.0
.0
74.4
88.8
94.8
99.6
.0
70.8
99.4
86.5
93.8
.0
69.9
53.0
99.0
83.6
11.5
61.8
. 0
100. *0
90.7
77.7
67.1
100.0
.0
96.6
99.2
74.0
70.5
22.2
83.7
77.2
63.4
98.6
95.8
71.4
25.5
72.8
100.0
89.5
89.3
69.7
81.8
80.3
85.5
61.9
97.0
86.6
93.0
69.2
50.7
99.0
83.6
11.5
61.2
.0
98.6
89.6
72.9
65.3
88.8
93.9
99.6
.0
70.4
99.3
86.6
93.7
.0
69.9
51.9
99.0
83.6
11.6
61.5
.0
100.0
90.6
76.6
66.8
100.0
.0
96.6
99.2
74.0
70.5
22.2
83.7
77.2
63.4
98.6
95.8
71.4
25.5
72.8
100.0
89.5
89.3
.0
69.7
81.8
80.3
85.5
.0
61.9
97.0
86.6
93.0
.0
69.2
50.7
99.0
83.6
11.5
61.2
.0
98.6
89.6
72.9
65.3
** PROBLEMS/SOLUTIONS/COMMENTS
744 744 550
720 720 457
744 744 542
744 744 519
720 720 446
744 696 515
720 720 441
744 486
SSM
THE SCRUBBER FAN HOUSING LINERS ARE BEING REPLACED
SI WMEETHSAC°LLECTORS ARE BE^ ««ED TO IMPR
1/80 101
201
301
TO IMPROVE THE QUALITY OF
.0
98.1
100.0
.0
93.3
99.0
.0
98.0
100.0
.0
93.3
99.0
216
-------
EPA UTILITY FED SURVEY: OCTOBER - DECEMBER 1980
DUQUESNE LIGHT: PHILLIPS 1-6 (CONT.)
„---.—---».—*.„*».«.«.»w_.—-«-----—-. ------———--PERFORMANCE
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION '/. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
401
SYSTEM
97.6
73.9
95.8
72.0
97.5
73.9
95.8
72.0
744
744
536
2/80 101
201
301
401
SYSTEM
13.7
91.6
86.2
94.2
71.4
13.7
91.6
84.6
90.5
70.1
13.7
91.7
86.0
94.0
71.4
13.7
91.6
84.6
90.5
70.1
696 696
488
** PROBLEMS/SOLUTIONS/COMMEMTS
SODIUM THIOSULFATE ADDITION CONTINUED THROUGH THE FIRST QUARTER RESULTING
IN A INCIDENCE OF SIGNIFICANTLY REDUCED MIST ELIMINATOR SCALING. 2000-
5000 HOURS OF OPERATION HAVE BEEN LOGGED WITHOUT MIST ELIMINATOR SCALE
ACCUMULATION. THE UTILITY REPORTED THAT S02 REMOVAL EFFICIENCY HAS
IMPROVED 3X DUE TO THE SODIUM THIOSULFATE ADDITION. THE UTILITY IS LOOKING
INTO SODIUM THIOSULFATE ADDITION AT ELRAMA.
THE FAN RUBBER LINERS HAVE BEEN A CONTINUAL PROBLEM. TWO FANS WILL BE
REPLACED WITH INCONEL THE NEXT TIME THE RUBBER LINERS FAIL.
THE PHILLIPS FGD SYSTEM HAD A SYSTEM AVAILABILITY OF 71.8X FOR THE YEAR
1979.
3/80 101
201
301
401
SYSTEM
94.7
59.0
48.4
95.4
60.3
64.0
53.9
40.3
95.3
54.7
94.0
56.8
43.8
99.8
73.6
84.0
53.9
40.3
95.3
54.7
744 744
407
** PROBLEMS/SOLUTIONS/COMMENTS
PROBLEMS WERE ENCOUNTERED WITH THE MODULE 101 ID FAN. THE MODULE HAS
TAKEN OFF LINE SO THE ID FAN COULD BE BALANCED.
PROBLEMS WERE ENCOUNTERED WITH THE HUB BOLTS ON THE ID FAN OF MODULE 201,
CAUSING THE MODULE TO COME OFF LINE FOR 11 DAYS.
THE RUBBER LINING ON THE ID FAN HOUSING OF MODULE 301 NEEDED REPAIR DURING
MARCH.
MODULE 401 WAS TAKEN OFF LINE FOR APPROXIMATELY 2 HOURS SO REPAIRS COULD
BE MADE ON THE SCRUBBER MAKE-UP VALVES.
4/80
101
201
301
401
SYSTEM
92.6
14.2
99.2
95.8
96.9
89.4
10.0
99.0
94.6
73.3
92.4
10.5
99.8
98.6
75.6
89.4
10.0
99.0
94.6
73.3
720 720
527
** PROBLEMS/SOLUTIONS/COMMENTS
ON APRIL 5 MODULE 101 WAS TAKEN OFF LINE DUE TO ID FAN BEARING PROBLEMS.
LATER IN THE MONTH THE MODULE WAS SHUTDOWN DUE TO AN ID FAN INSTRUMENTATION
PRESSURE SWITCH PROBLEM.
TOWARDS THE LATTER PART OF APRIL, MODULE 201 WAS SHUTDOWN DUE TO ID FAN
BEARING PROBLEMS. THIS PROBLEM WAS CORRECTED BY BALANCING THE FAN.
MODULE 301 WAS REMOVED FROM OPERATION ON APRIL 11 DUE TO AN ID FAN MOTOR
MALFUNCTION.
THE RECYCLE PUMP PACKING ON MODULE 401 NEEDED TO BE REPLACED DURING THE
MONTH.
217
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
LIGHT: PHILLIPS 1-6 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOf
5/80
101
201
301
40;.
SYSTEM
67.5
81.6
91.7
92. Z
83.2
53.9
69.0
73.1
75.9
68.0
62.3
78.9
89.8
90.6
80.2
53.9
69.0
73.1
75.9
68.0
744 744 506
** PROBLEMS/SOLUTIONS/COIMENTS
MODULE 101 CAME OFF LINE IN MAY SO REPAIRS COULD BE MADE ON THE CONTROL
OAMPEk AND TO INSTRUMENTATION.
DURINS MAY MODULE 201 EXPERIENCED PROBLEMS WITH THE MIST ELIMINATOR AND
THE ID FAN. THE MODULE WAS TAKEN OFF LINE FOR APPROXIMATELY TWO DAYS TO
WASH THE MISTELIMINATOR INTERNALS AND ONE DAY TO REPAIR THE ID FAN BEARING.
MODULE 301 EXPERIENCED ID FAN PROBLEMS AND MAS TAKEN OFF LINE WHILE THE
ID FAN WAS BALANCED.
MODULE 401 WAS SHUTDOWN APPROXIMATELY 58 HOURS SO THAT THE ID FAN CONTROL
DAMPERS COULD BE INSPECTED.
6/80
101
201
301
401
SYSTEM
97.1
100.0
75.5
100.0
93.2
86.3
81.7
69.4
76.5
78.5
96.5
100.0
72.6
100.0
91.5
80.5
76.2
64.8
71.4
73.2
720 672
527 55.3
** PROBLEMS/SOLUTIONS/COMMENTS
THE MODULE 101 MIST ELIMINATOR WAS CLEANED DURING JUNE.
DURING JUNE MODULE 301 WAS DOWN FOR ID FAN HOUSING REPAIRS (RUBBER LINING)
CAUSING APPROXIMATELY 176 HOURS DOWN TIME.
7/80 101
'.'01
301
401
SYSTEM
94.0
100.0
94.7
91.1
94.9
86.2
94.7
84.1
83.5
87.1
93.5
100.0
94.0
90.3
94.5
86.2
94.7
84.1
83.5
87.1
744 744
648 71.4
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JULY THE RECYCLE PUMP IMPELLERS WERE REPLACED ON ALL THE MODULES
EXCEPT FOR MODULE 201.
8/80 101
201
301
401
SYSTEM
91.1
96.9
87.6
92.3
92.0
72.9
85.8
85.3
86.1
82.5
90.6
96.5
89.6
91.8
91.5
72.9
85.8
85.3
86.1
82.5
744 744
614 58.5
** PROBLEMS/SOLUTIONS/COMMENTS
DURING AUGUST MODULE 401 EXPERIENCED PACKING PROBLEMS WITH THE RECYCLE
PUMP.
DURING THE PERIOD OF JUNE THROUGH AUGUST THE RUBBER LININGS ON THE FAN
HOUSINGS WERE REPAIRED.
9/80 101
201
301
55.8
46.1
54.9
55.8
41.7
46.2
60.9
43.6
50.6
55.8
41.7
46.2
218
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
DUWESNE LIGHT-. PHILLIPS i-e (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
SOS PART. HOURS HOURS HOURS FACTOR
401
SYSTEM
60.6
54.4
32.9
47.3
45.5
47.0
32.9
44.2
720 720
318 30.1
** PROBLEMS/SOLUTIONS/COMMENTS
ON SEPTEMBER 20 THE ENTIRE PLANT WAS SHUTDOWN FOR A SCRUBBER INSPECTION.
THE INSPECTION REVEALED THAT THERE IS EXTENSIVE MORTAR DETERIORATION IN
THE STACK AND THAT REPAIRS WILL BE NECESSARY WITHIN THE NEXT TWO YEARS.
THE INSPECTION LASTED UNTIL OCTOBER 1 DUE TO THE NECESSARY REPAIR OF A
DUCT EXPANSION JOINT AND THE REPAIR OF THE UPPER PORTION OF THE STACK
JOINTS.
10/80
101
201
301
401
SYSTEM
94.2
93.9
4.0
93.8
71.5
94.2
90.1
4.0
92.6
70.2
94.2
93.5
4.0
93.6
71.3
94.2
90.1
4.0
92.6
70.2
744 720
523 58.2
** PROBLEMS/SOLUTIONS/CO, IMENTS
DURING OCTOBER SCRUBBER MODULES 301 AND 401 WERE RELINED WITH CEILCOTE
CORALIME 505 AR LINERS.
11/80 101
201
301
401
SYSTEM
51.5
100.0
95.3
92.3
64.8
50.8
99.9
93.5
91.6
84.0
51.2
99.9
95.2
92.2
84.6
50.8
99.9
93,5
91.6
84.0
604 72.1
720 720
** PROBLEMS/SOLUTIONS/COMMENTS
DURING NOVEMBER MODULE 101 HAS RELINED WITH CEILCOTE CORALINE 505 AR LINER.
12/80 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION FOR THE MONTH OF DECEMBER WAS NOT AVAILABLE AT THIS TIME.
219
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FED SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MM
GROSS UNIT GENERATING CAPACITY - MM
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/F6D - MM
EQUIVALENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FU:-:L DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - Z
RANGE ASH CONTENT - 'A.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - K
A 'ER#3E SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGI CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
»* ESP
NUMBER
*** FGC SYSTEM
** GEMERAL DATA
SALEABLE PRODUCT/THROUAHAY PRODUCT
SC2 REMOVAL MODE
PFOCESS TYPE
SYSTEM SUPPLIER
A--E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
CURRENT STATUS
INITIAL START-UP
** DESIGN AND OPERATING PARAMETERS
** ABS3RBER
GENERIC TYPE
** REHiATER
GENERIC TYPE
TEMPERATURE INCREASE - C
** SOLIDS CONCEHTRATING/DEMATERING
DEVICE
NUMBER
GULF POWER
SCHOU
I
SNEADS
FLORIDA
E
(«***** LB/MMBTU)
(**«*** LB/MMBTUJ
(****** LB/MMBTU)
******
******
80
20
*****
*****
20
BABCOCK & MILCOX
PULVERIZED COAL
BASE
50.02 ( 106000 ACFM)
******* (**** F)
****** (**** FT)
******* (***** FT)
COAL
30005.
******
3.25
3-3.5
********
******
( 12900 BTU/LB)
******
THROHAUAY PRODUCT
NET SCRUBBING
DUAL ALKALI/LIMESTONE
COMBUSTION EQUIP ASSOCIATES
A.D. LITTLE
DEMONSTRATION
RETROFIT
1
8/80
TRAY TOMER
INDIRECT HOT AIR
*.* t 40 F)
CENTRIFUGE
4
220
-------
GULF POWER: SCHOLZ 1 (CONT.)
SHELL SPECIFIC MATERIAL TYPE
** SOLIDS CONCENTRATIN6/DEWATERING
DEVICE
NUMBER
SHELL GENERIC MATERIAL TYPE
FEED STREAM CHARACTERISTICS
** WATER BALANCE
WATER LOOP TYPE
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
STAINLESS STEEL
CENTRIFUGE
4
STAINLESS STEEL
10X. SOLIDS
CLOSED
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
8/80 SYSTEM 744
** PROBLEKS/SOLUTIONS/COMMENTS
INITIAL OPERATION OF THIS DEMONSTRATION LIMESTONE DUAL ALKALI SYSTEM BEGAN
ON AUGUST 20. OPERATIONS DURING THE REST OF THE MONTH WERE INTERMITTENT
AS MECHANICAL PROBLEMS WERE RECTIFIED.
9/80 SYSTEM
10/60 SYSTEM
11/80 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
720
720
THE FGD SYSTEM CONTINUED TO OPERATE THROUGH NOVEMBER IN A DEBUGGING MODE
OF OPERATION.
12/80 SYSTEM
*« PROBLEMS/SOLUTIONS/COMMENTS
75.9
565
DURING DECEMBER THE DEMONSTRATION FGD SYSTEM OPERATED CONTINUOUSLY FOR
TWO EIGHT DAY PERIODS. DURING THIS TIME THE SYSTEM S02 REMOVAL EFFICIENCY
WAS FOUND TO BE GREATER THAN 90X.
THE FGD SYSTEM HAS FORCED TO REMAIN OFF LINE FOR 6-8 DAYS IN DECEMBER
DUE TO AN UNAVAILABILITY OF RAM MATERIALS.
221
-------
EPA UTILITY FED SURVEY: OCTOBER - DECEMBER I960
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MM
NET UNIT GENERATING CAPACITY M/FGD - MM
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MM
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOH - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** ESP
NUMBER
TYPE
SUPPLIER
INLET FLUE GAS CAPACITY - CU.M/S
INLET FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
P'UmCLE REMOVAL EFFICENCY - 7.
** PARTICLE SCRUBBER
G.iNERIC TYPE
SPECIFIC TYPE
*** FGU SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAHAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
UNIT DESIGN S02 REMOVAL EFFICIENCY - 7.
CIHRSNT STATUS
COMMERCIAL START-UP
INDIANAPOLIS POWER & LIGHT
PETERSBURG
3
PETERSBURG
INDIANA
B
( .100 LB/MMBTU)
( 1.200 LB/MMBTU)
(****** LB/MMBTU)
516.
******
1180
532
515
528
532
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
928.23 (1967000 ACFM)
137.2 ( 279 F)
188. ( 616 FT)
CONCRETE
6.1 ( 20.0 FT)
COAL
BITUMINOUS
25004.
( 10750 BTU/LB)
9-10
********
10.5-16.5
3.25
1.5-4.5
********
******
COLD SIDE
RESEARCH-COTTRELL
928.2 (1967000 ACFM)
137.2 ( 279 F)
.4 ( 2. IN-H20)
99.3
NONE
N/A
THROWAMAY PRODUCT
WET SCRUBBING
LIMESTONE
NONE
AIR CORRECTION DIVISION, UOP
GIBBS 8 HILL
FULL SCALE
NEW
7. 99.30
85.00
1
12/77
222
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
INDIANAPOLIS POWER 4 LIGHT: PETERSBURG 3 (CONT.)
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
** ABSORBER
NUHBER
NUMBER OF SPARES
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
GAS CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
DISTANCE BETWEEN GAS CONTACTING ZONES - CM
LIQUID RECIRCULATION RATE - LITER/S
L/G RATIO - L/CU.M
GAS-SIDE PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/SEC
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
S02 REMOVAL EFFICIENCY - X
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES PER STAGE
FREEBOARD DISTANCE - M
CONSTRUCTION MATERIAL GENERIC TYPE
WASH WATER SOURCE
** REHEATER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
PERCENT GAS BYPASSED - AVS
TEMPERATURE INCREASE - C
INLET FLUE GAS FLOW RATE - CU. M/S
INLET FLUE GAS TEMPERATURE - C
NUMBER OF TUBES PER BUNDLE
CONSTRUCTION MATERIAL GENERIC TYPE
** FANS
NUMBER
NUMBER OF SPARES
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** DUCTWORK
LOCATION
DIMENSIONS
SHELL GENERIC MATERIAL TYPE
12/77
1/75
4
0
PACKED TOWER
MOBILE BED PACKING
TURBULENT CONTACT ABSORBER
AIR CORRECTION DIVISION> UOP
30 X 30 X 100
CARBON STEEL
AISI 1110
N/A
ORGANIC
SYNTHETIC RUBBER
NEOPRENE
1.5 INCH DIA RUBBER BALLS
3
30.5
5947.
6.7
1.7
4.4
176.96
47.8
85.0
( 12.0IN)
(94400 GPM)
50.0 GAL/1000 ACF)
7.0 IN-H20)
14.5 FT/S)
375000 ACFM)
118 F)
MIST ELIMINATOR
8
IMPINGEMENT
BAFFLE
CHEVRON VANE
HORIZONTAL
2
7
.37 ( 1.2 FT)
PLASTIC
THICKENER OVERFLOW AND MAKEUP
INDIRECT HOT AIR
EXTERNAL HEAT EXCHANGER
STEAM TUBE BUNDLES
.0
-1.1 ( 30 F)
149.59 ( 317000 ACFM)
21.1 C 70 F)
565
CARBON STEEL
2
0
CENTRIFUGAL
STURTEVANT DIV., WESTINGHOUSE
BOOSTER
FORCED DRAFT
DRY
224.15 (
137.2 (
CARBON STEEL
475000 ACFM)
279 F)
SCRUBBER INLET
10 X 10
CARBON STEEL
223
-------
EPA UTILITY FGO SURVEY'- OCTOBER - DECEMBER 1980
INDIANAPOLIS POWER & LIGHT: PETERSBURG 3 (CONT.)
i.INER GENERIC MATERIAL TYPE
** DUCTWORK
LOCATION
DIMENSIONS
SHELL GENERIC MATERIAL TYPE
UNER GENERIC MATERIAL TYPE
*# REAGENT PREPARATION EQUIPMENT
FACTION
DEVICE
MANUFACTURER
NUMBER
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
PRODUCT QUALITY - 7. SOLIDS
** TANXS
SERVICE
LII1ESTONE SLURRY
WASTE SLURRY
RECYCLE
THJXKENER OVERFLOW
** PUMPS
SERVICE
ABSORBER RECIRCULATION
SLURRY TRANSFER
WASTE SLURRY
WASTE SLURRY BOOSTER
** SOLIDS CONCENTRATINS/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
DIMENSIONS - FT
SHELL GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
*** SLUDGE
** TREATMENT
METHOD
PROPRIETARY PROCESS
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
** PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS
CONTROL LEVELS
MONITOR LOCATION
PROCESS CONTROL MANNER
PROCESS CHEMISTRY MODE
** WATER BALANCE
WATER LOOP TYPE
MAKEUP WATER ADDITION - LITERS/S
NONE
SCRUBBER OUTLET
10 X 10
CARBON STEEL
RESISTIFLAKE 1150
LIMESTONE GRINDING
BALL MILL
KENNEDY VAN SAUN
1
38.1 ( 42 TPH)
48.8
NUMBER
NUMBER
12
2
2
2
VACUUM FILTER
2
0
THICKENER
1
0
165 DIA.
CARBON STEEL
RUBBER
10.6X SOLIDS
35X SOLIDS
POZ-0-TEC
IUCS
FINAL
LANDFILL
ON SITE
TRUCK
PH, FLUE GAS OUTLET FLOW,
PH 5.5-5.9
RECYCLE SLURRY LINE
MANUAL
FEEDBACK
INLET SOS CONCENTRATIO
CLOSED
55.6
( 882 GPM)
224
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
INDIANAPOLIS POWER i LIGHT'. PETERSBURG 3 (CONT.)
** CHEMICALS AND CONSUMPTION
FUNCi ION ABSORBENT
NAME LIMESTONE
CONSUMPTION 8*300 IB/HP
** FGV) SPARE CAPACITY INDICES
A3SOHBER - X .0
** FGD SPARE COMPONENT INDICES
ADSORBER .0
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
502 PART. HOURS HOURS HOURS FACTOR
12/77 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER BEGAN COMMERCIAL OPERATIONS ON NOVEMBER 29, 1977.
OPERATION OF ALL FOUR MODULES COMMENCED DURING DECEMBER. CURRENTLY
PH ADJUSTMENTS AND OTHER SHAKEDOWN PROCEDURES ARE IN PROGRESS.
REPAIRS TO THE RECYCLE TANK AGITATOR WERE REQUIRED.
COLD WEATHER ARRIVED EARLIER THAN EXPECTED. TEMPORARY ENCLOSURES MERE
CONSTRUCTED AROUND SOME FSD COMPONENTS. THESE ENCLOSURES WILL BE
REMOVED WHEN INSTALLATION OF HEAT TRACING CAN BE COMPLETED.
1/78 SYSTEM 74* 0
** PROBLEMS/SOLUTIONS/COMMENTS
INSTALLATION OF HEAT TRACING ON FGO SYSTEM COMPONENTS HAS COMPLETED
DURING THE PERIOD.
e/78 SYSTEM 67Z 0
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS TAKEN OFF LINE ON FEBRUARY E4 TO ALLOW CORRECTION OF
THE PROBLEMS ASSOCIATED WITH THE FLYASH REMOVAL SYSTEM.
PIPE AND VALVE FREEZE-UP DAMAGE HAS ENCOUNTERED AND REPAIRED.
REPAIRS HERE MADE ON THE ISOLATION DAMPERS.
3/78 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
INSULATION HAS INSTALLED ON FGD SYSTEM COMPONENTS DURING A SCHDEULED
SYSTEM OUTAGE.
A BROKEN PINION GEAR IN THE THICKENER HAS REPAIRED DURING THE SYSTEM
OUTAGE.
INSTRUMENTATION MAINTENANCE HAS PERFORMED DURING THE SYSTEM OUTAGE.
PROBLEMS HITH THE FLYASH HANDLING SYSTEM HAVE NOT YET BEEN SOLVED.
4/78 SYSTEM 7ZO
ZZS
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
INDIANAPOLIS POWER & LIGHT: PETERSBURG 3 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM MAS PUT BACK ON LINE IN MID-APRIL.
ALL CONTROL VALVES WERE RETURNED TO THE FACTORY FOR MODIFICATIONS. BOTH
CONVROL VALVES AND PIPING HAVE BEEN PROBLEM AREAS FOR THIS SYSTEM.
5/76 SYSTEM 744
*H PROBLEMS/SOLUTIONS/CO 1MENTS
THE MAIN POWER TRANSFORMER FAULTED CAUSING THE SYSTEM TO SHUTDOWN.
6/78 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE SYSTEM SHUTDOWN RESULTING FROM THE MAIN POWER TRANSFORMER FAILURE
IN MAY. LASTED THROUGH JUNE 16.
7/78 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM IS STILL EXPERIENCING SHAKEDOWN PROBLEMS. DURING THIS
PERIOD SOME DESIGN CHANGES HAVE BEEN MADE TO IMPROVE OPERATIONS.
VALVE PROBLEMS WERE ENCOUNTERED DURING JULY. MANY VALVES HAD TO BE
REMOVED AND REPAIRED.
8/78 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
PROBLEMS HAVE BEEN EXPERIENCED WITH INSTRUMENTATION.
CRACKING PROBLEMS HAVE BEEN EXPERIENCED WITH FIBERGLASS PIPING. THE PROB-
LEM WAS SOLVED BY REPLACING SECTIONS WITH RUBBER LINED STEEL PIPING, NEW
FRP PIPING, AND PROVIDING ADDITIONAL PIPE SUPPORTS.
9/78 SYSTEM 720
10/78 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
BYPASS DAMPER PROBLEMS HERE EXPERIENCED.
AN S02 COMPLIANCE TEST WAS INVALID DUE TO BYPASS DAMPER PROBLEMS.
11/78 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
FREEZE-UPS IN THE LIME DELIVERY SYSTEM WERE EXPERIENCED.
AN INSTRUMENTATION POWER TRANSFORMER FAILURE FORCED THE SYSTEM OUT OF
SERVICE FOR ABOUT SIX DAYS.
12/78 SYSTEM 744
226
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
INDIANAPOLIS POWER & LIGHT: PETERSBURG 3 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
MONTHLY OPERATIONAL HOURS ARE NOT YET AVAILABLE. THE UTILITY REPORTED
THAT THE SYSTEM HAS NOT YET PASSED AN ACCEPTANCE TEST.
THE FOLLOWING CUMULATIVE FGD SYSTEM UTILIZATION FIGURES FOR THE PERIOD
SEPTEMBER 15 THROUGH DECEMBER 29, 1978 WERE CALCULATED BASED UPON UTILITY
REPORTED FGD SYSTEM HOURS FOR THE SAME PERIOD.
A MODULE 22. IX
B MODULE 21.7X
C MODULE 34.6X
D MODULE 34.IX
SYSTEM 28.IX
REPORTED FGD SYSTEM HOURS FOR THIS PERIOD MERE 562, 551, 880 AND 868 FOR
MODULES A, B, C AND D RESPECTIVELY.
1/79 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS SHUTDOWN ON JANUARY 1, 1979 AS A RESULT OF SEVERE
WINTtR WEATHER CONDITIONS.
2/79 SYSTEM 672
3/79 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS DOWN FROM JANUARY 1 TO MARCH 15 DUE TO SEVERE WINTER
WEATHER.
4/79 SYSTEM 722
** PROBLEMS/SOLUTIONS/COMMENTS
DUE TO THE FORMER STACK LINING PEELING AWAY, THE STEEL
SHELL WAS SAND BLASTED AND RIGIFLAKE 4850 APPLIED BY TROWEL.
ALL MIST ELIMINATORS WERE CLEANED DUE TO SEVERE SCALING PROBLEMS.
EXTENSIVE REPAIRS WERE MADE TO THE INLET DAMPERS, THE OUTLET DUCTS WERE
LINED WITH RESISTIFLAKE 1150, AND MAJOR REPAIRS WERE MADE TO BONNETS
BECAUSE OF ACID CORROSION.
THE SYSTEM HAS BEEN DOWN SINCE MID-MARCH FOR INSPECTION AND MAINTENANCE.
5/79 SYSTEM 744
6/79 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE SYSTEM RAN ABOUT THREE DAYS TOTAL DURING THIS
THIS PERIOD.
PROCESS CONTROL HAS BEEN A MAJOR PROBLEM AREA SINCE THE SYSTEM BEGAN
INITIAL OPERATIONS.
MIST ELIMINATOR PLUGGING CONTRIBUTED TO THE OUTAGE TIME ACCUMULATED DURING
THIS PERIOD.
7/79 SYSTEM 744
227
-------
EPA UTILITY F6G SURVEY: OCTOBER - DECEMBER 1980
INDIANAPOLIS POWER & LIGHT: PETERSBURG 3 (CONT.)
------------------------------------------ PERFORMANCE DATA ------------------------------------------
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FED CAP.
502 PART, HOURS HOURS HOURS FACTO*
8/79 SYSTEM
9/79 SYSTEM .0 720 0 0.0
** PROBLEMS/SOLUTIONS/COMMEMTS
THE UNIT WAS SHUTDOWN FOR A SCHEDULED BOILER AND SCRUBBER OVERHAUL IN
SEPTEMBER.
10/79 SYSTEM .0 7
-------
EPA UTILITY FGD SURVEY^ OCTOBER - DECEMBER 1980
INDIANAPOLIS POWER & LIGHT: PETERSBURG 3 ICONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
NO INFORMATION WAS AVAILABLE FOR THE PERIOD APRIL 1980 THROUGH JUNE
1980.
7/80 SYSTEM 744
8/80 SYSTEM 744
9/80 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE OPERATIONAL DATA FOR THE THIRD QUARTER 1980 WERE NOT AVAILABLE FOR
PUBLICATION.
10/80 SYSTEM 744
11/80 SYSTEM 7ZO
12/80 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED OTHAT OPERATIONAL DATA FOR F6D OPERATIONS AT
PETERSBURS 3 ARE STILL UNAVAILABLE FOR RELEASE.
ZZ9
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC F6D SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MM
GROSS UNIT GENERATING CAPACITY - MM
NET UNIT GENERATING CAPACITY H/FGD - MM
NET UNIT GENERATING CAPACITY WO/FGO - MM
EQUIVALENT SCRUBBED CAPACITY - MM
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOM - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - X
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** PARTICLE SCRUBBER
GENERIC TYPE
SPECIFIC TYPE
S1ELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
*** FGO SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAHAY PRODUCT
SD2 REMOVAL MODE
PROCfcSS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
KANSAS CITY POMER & LIGHT
HAWTHORN
3
KANSAS CITY
MISSOURI
D
64.
******
******
836
90
85
87
90
COMBUSTION ENGINEERING
PULVERIZED COAL
( .ISO LB/MMBTU)
(****** LB/MMBTU)
(#***** LB/MMBTU)
CYCLING
335.95
148.9
61.
CARBON STEEL
5.5
( 500000 ACFM)
( 300 F)
( 200 FT)
( 18.0 FT)
COAL
BITUMINOUS
22795.
11.00
******
********
.60
( 9800 BTU/LB)
( 11400 BTU/LB)
COAL
BITUMINOUS
26516.
14.00
******
3.00
******
********
PACKED TOWER
STATIC BED PACKING
CARBON STEEL
AISI 1110
THROMAWAY PRODUCT
MET SCRUBBING
LIME
NONE
COMBUSTION ENGINEERING
230
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
KANSAS CITY POWER & LIGHT: HAWTHORN 3 (COKT.)
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
UK IT DESIGN PARTICLE REMOVAL EFFICIENCY -
UNIT DESIGN S02 REMOVAL EFFICIENCY - '/.
CURRENT STATUS
INITIAL START-UP
CONTRACT AWARDED
** DESCGN AND OPERATING PARAMETERS
** ABSORBER
NIBIBER
GEMERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER.GENERIC MATERIAL
LINER SPECIFIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
GAS CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
DISTANCE BETWEEN GAS CONTACTING ZONES - CM
L/G RATIO - L/CU.M
GAS-SIDE PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/SEC
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
S02 REMOVAL EFFICIENCY - X
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES PER STAGE
FREEBOARD DISTANCE - M
DISTANCE BETWEEN STAGES - CH
DISTANCE BETWEEN VANES - CM
VANE ANGLES - DEGREES
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/S
CONSTRUCTION MATERIAL GENERIC TYPE
WASH WATER SOURCE
WASH RATE - L/S
** REHEATER
GENERIC TYPE
SPECIFIC TYPE
TEMPERATURE INCREASE - C
NUMBER OF TUBES PER BUNDLE
CONSTRUCTION MATERIAL GENERIC TYPE
** FANS
NUMBER
DESIGN
FUNCTION
APPLICATION
SERVICE
FLUE GAS TEMPERATURE - C
** DUCTWORK
LOCATION
5HELL GENERIC MATERIAL TYPE
BLACK & VEATCH
FULL SCALE
RETROFIT
X 99.00
70.00
1
11/72
0/71
PACKED TOWER
STATIC BED PACKING
MARBLE BED SCRUBBER
COMBUSTION ENGINEERING
18 X 26 X 56
STAINLESS STEEL,CARBON STEEL
AISI lllO.AUSTENITIC
TYPE 316L.N/A
ORGANIC
GLASS FLAKE-FILLED POLYESTER
CEILCOTE FLAKEGLASS
0.75 IN DIA GLASS MARBLES IN A 3 TO 4 IN BED
1
( 4.0IN)
(26.0 GAL/1000 ACFJ
(11.0 IN-H20)
( 10.0 FT/S)
( 162000 ACFM)
( 122 F)
10.2
3.5
2.7
3.0
76.45
50.0
70.0
MIST ELIMINATOR
2
IMPINGEMENT
BAFFLE
CHEVRON VANE
HORIZONTAL
2
2
3.05
15.24
7.6
45
.3
3.0
(10.0 FT)
( 6.0 IN)
( 3.00 IN)
(1.2 IN-H20)
( 10.0 FT/S)
FIBERGLASS REINFORCED PLASTIC
BLENDED RIVER AND THICKENER OVERFLOW WATER
126.2 , ( 2000 GAL/MIN)
IN-LINE
HOT WATER
10.0
2
CARBON STEEL
( 50 F)
CENTRIFUGAL
BOOSTER
INDUCED DRAFT
DRY
79.4 (
SCRUBBER INLET
COR-TEN STEEL
175 F)
231
-------
EPA UriLITY FSD SURVEY: OCTOBEI! - DECEMBER 1980
KANSAS CITY POWER 4 LIGHT: HAWTiORN 3 (CONT.)
LINER GENERIC MATERIAL TYPE
** DUCTWORK
LICATION
:HELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DCVICE
NUMBER
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
** TANKS
SERVICE
S02 SCRUBBER TOWER HOLDUP
** SOLIDS CONCENTRATING/DEWATERINS
DEVICE
NU-1BER
DIMENSIONS - FT
*** SLUDGE
** TREATMENT
METHOD
** DISPOSAL
NATURE
TYPE
LOCATION
SITE CAPACITY - CU.M
** PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS
CONTROL LEVELS
** WATER BALANCE
MATER LOOP TYPE
** FGD SPARE CAPACITY INDICES
ABSORBER - '/.
** FGD SPARE COMPONENT INDICES
ABSORBER
GUNITE (2 IN)
SCRUBBER OUTLET
COR-TEN STEEL
GUNITE (2 IN)
LIME SLAKING
SLAKER
1
51.7
t 57 TPH)
NUMBER
THICKENER
1
115 (DIA) X 10 (DEPTH)
FLYASH STABILIZATION
FINAL
POND
ON SITE
3130880
( 2560.0 ACRE-FT)
PH
4.5-6.5
CLOSED
.0
.0
. PERFORMANCE DATA •
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
SOS PART. HOURS HOURS HOURS FACTOR
0/72 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
7/75 3A
3B
SYSTEM
THE ORIGINAL FGD SYSTEM INSTALLED ON THE HAWTHORN 3 UNIT BEGAN INITIAL
OPERATIONS IN NOVEMBER 1972. THE PROCESS CONSISTED OF DRY LIMESTONE
INJECTION INTO THE BOILER FURNACE WHERE THE LIMESTONE WAS CALCINED TO
LIME. THE FURNACE CALCINED LIMESTONE AND BOILER FLUE GAS WERE THEN DIS-
CHARGED TO A TAIL-END WET SCRUBBING SYSTEM CONSISTING OF TWO MARBLE-BED
ABSORBERS WHERE PARTICLES AND S02 WERE REMOVED FROM THE GAS STREAM. EACH
ABSORBER WAS CAPABLE OF TREATING 500.000 ACFM OF FLUE GAS AT 300 F.
.0
42.0
21.0
.0
33.2
16.6
584
123
232
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
KANSAS CITY POWER & LIGHT: HAWTHORN 3 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
*» PROBLEMS/SOLUTIONS/COI IMENTS
PROBLEMS WITH THE 3A MODULE DURING JULY INCLUDED A LEAK IN THE CITY
WATER LINE, A PLUGGED DUCT TO THE ID FAN, AND A MALFUNCTIONING OUTLET
DAMPER FROM THE SCRUBBER. IN MODULE 3B SOME MARBLES WERE LOST FROM THE
BED AND A SPRAY HEADER WAS BROKEN.
8/75 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
.0
744
.0
THE ID FAN FOR HALF THE BOILER WAS LOST DURING AUGUST.
THE PROBLEMS ENCOUNTERED IN JULY CONTINUED INTO AUGUST FORCING THE FGD
SYSTEM TO REMAIN OFF LINE FOR THE MONTH.
9/75
3A
3B
SYSTEM
69.0
83.0
46.0
34.3
11.3
22.8
720 358
164
** PROBLEMS/SOLUTIONS/COMMENTS
AN OUTAGE DUE TO CLEANING AND MECHANICAL REPAIRS OCCURRED. POTS, COVERS,
AND MARBLES IN THE MARBLE BED OF MODULE 3B WERE REPLACED. THE BOILER
HOURS OF OPERATION ARE BASED ON THE NUMBER OF HOURS OF COAL FIRED
OPERATION (I.E., TIME DURING WHICH THE BOILER FIRED NATURAL GAS IS NOT
INCLUDED J.
10/75 .JA
3B
SYSTEM
65.0
81.0
73.0
15.7
19.5
17.6
744 180 131
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE 3A OUTAGE HAS DUE LARGELY TO REPLACEMENT OF A RECYCLE PUMP MOTOR.
A SCHEDULED BOILER OVERHAUL REDUCED BOILER OPERATION HOURS DURING
OCTOBER.
11/75 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
.0
720
.0
THE BOILERS AND SCRUBBERS WERE SHUT DOWN FOR A SCHEDULED TURBINE
OVERHAUL. THE SYSTEM IS SCHEDULED TO GO BACK ON-LINE IN JANUARY 1976.
12/75 SYSTEM
1/76 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
.0
.0
744
744
0
0
.0
.0
THE FGD SYSTEM REMAINED OFF LINE THROUGH JANUARY DUE TO FROZEN EQUIPMENT
AND LINES, LACK OF HEAT TRACING AND A LACK OF MANPOWER DUE TO A BOILER
AND TURBINE OVERHAUL ON THE NO. 5 BOILER.
2/76 3A
3B
SYSTEM
29.4
1.4
15.4
21.3
1.0
11.2
696 503
77
233
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
KANSAS CITY POWER £ LIGHT: HAWTHORN 3 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
SCRUBBER OUTAGES IN FEBRUARY RESULTED FROM PLUGGING IN THE SCRUBBER BED,
STEMMING FROM THE CONVERSION FROM AN UNDER-BED TO OVER-BED SPRAY SYSTEM.
3/76 SYSTEM .0 744 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS INOPERATIVE DURING MARCH DUE TO MANPOWER CONSTRAINTS
AND INCLEMENT WEATHER. THE UTILITY WAS UNABLE TO PERFORM NECESSARY
MAINTENANCE.
RECON 'ERSION OF THE MODULE 3B SPPAY SYSTEM TO AN UNDER-BED CONFIGURATION
HAS B'-EN COMPLETED.
THE BYPASS SYSTEM WILL BE MODIFIED AND CHANGED TO A SLIDE-GATE DAMPER
ARRANGEMENT.
4/76 SYSTEM .0 720 0 0 .0
5/76 SYSTEM .0 744 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
THE SYSTEM REMAINED DOWN THROUGH MAY DUE TO THE CONTINUATION OF MAN-
POWER SHORTAGE PROBLEMS. THE UTILITY PERFORMED SOME CLEANING AND REPAIRS
DURING THE MONTH.
6/76 3A 39.0 27.6
3B 44.0 30.4
SYSTEM 41.5 29.0 720 505 209
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY IS IN THE PROCESS OF MODIFYING THE MIST ELIMINATOR WASH SYSTEM
ON BOTH UNITS 3 AND 4. THE WATER LANCES ARE BEING CHANGED FROM FRP TO
CARBON STEEL IN AN ATTEMPT TO PREVENT THE LOSS OF THE NOZZLE INSERTS AND
THE SUBSEQUENT SHATTERING OF THE LANCES.
7/76 SYSTEM .0 744 0 0 .0
w* PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY BEGAN CONVERTING THIS SYSTEM FROM LIMESTONE INJECTION AND
TAIL END SCRUBBING TO A LIME SLURRY BASED SCRUBBING SYSTEM DURING JULY.
8/76 SYSTEM .0 744 0 0 .0
9/76 SYSTEM .0 720 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
THE SYSTEM WAS VIRTUALLY OUT OF SERVICE THE ENTIRE JULY-SEPTEMBER PERIOD
DUE TO CONTINUING SYSTEM MODIFICATIONS. MANPOWER COMMITMENTS WERE SER-
IOUSLY HAMPERED BY A MAJOR EXPLOSION WHICH OCCURRED IN THE COAL MILL
PULVERIZING AREA OF HAWTHORN NO. 5.
10/76 SYSTEM .0 744 0 0 .0
11/76 SYSTEM .0 720 0 0 .0
234
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
KANSAS CITY POWER & LIGHT: HAWTHORN 3 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
502 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT DID NOT OPERATE BECAUSE OF THE ONGOING MAJOR MODIFICATIONS BEING
IMPLEMENTED ON THE SCRUBBING SYSTEM. THE SYSTEM SHOULD BE READY FOR OPER-
ATION FEB 1. THE UNIT MUST UNDERGO A SERIES OF TESTS TO INSURE COMPLIANCE
WITH CITY AND FEDERAL REGULATIONS.
12/76 SYSTEM .0 744 0 0 .0
1/77 SYSTEM .0 744 0 0 .0
2/77 3A 67.6 50.1
3B 68.8 39.3
SYSTEM 78.3 44.7 672 383 300
** PROBLEMS/SOLUTIONS/COMMENTS
UNIT NO. 3 WAS DOWN FOR THE ENTIRE DECEMBER-JANUARY PERIOD FOR THE COMPLE-
TION OF MODIFICATIONS AND REPAIRS ON THE SCRUBBERS AND BOILER. THE UNIT
BECAME AVAILABLE FOR SERVICE AND TESTING ON FEBRUARY 7. THE PARTICULATE
EMISSION LEVEL MEASURED AT THE SCRUBBER OUTLET WAS 0.12 LB/MM BTU (WELL
BELOW THE REQUIRED 0.17 LB/MM BTU) BURNING APPROXIMATELY 2.0 7. SULFUR
COAi.. THE CONVERSION FROM LIMESTONE TO LIME HAS GONE SMOOTHLY. SOME
INITIAL PROBLEMS WITH PROCESS CHEMISTRY CONTROL HAVE BEEN CORRECTED.
OTHE-? MINOR PROBLFHS INCLUDED PUMP MALFUNCTIONS AND LOSS OF SLAKING WATER
PRESSURE. SYSTEM OPERATIONS ARE CONTINUING AT OX SOLIDS AND 10QX SLOWDOWN
WITH A FRESH WATER MAKE-UP OF APPROXIMATELY 7.0 SPM/MW.
3/77 3A 9B.8 64.0
3B 35.3 55.2
SYSTEM 92.1 59.6 744 462 443
4/77 3A 56.7 56.7
3B 56.7 56.7
SYSTEM 56.7 56.7 720 720 408
5/77 3A 58.0 40.6
3B 58.0 40.6
SYSTEM 58.0 40.6 744 736 302
** PROBLEMS/SOLUTIONS/COHMENTS
THE SYSTEM IS NOW OPERATING AT ABOUT 15-25X SLOWDOWN. THE PH CONTROL
SYSTEM OPERATIONS HAVE BEEN EXCELLENT. DURING MAY THE BOILER BURNED GAS
FOR 216 HOURS (NOT INCLUDED IN OPERABILITY FIGURES). S02 REMOVAL EFFICI-
ENCY IS ESTIMATED AT 50-60X FOR BOTH MODULES. ALTHOUGH ACTUAL TESTS HAVE
NOT BEEN RUN FOR ABOUT A YEAR AND A HALF. BOTH MODULES ARE CURRENTLY
OPERATING SIMULTANEOUSLY.
6/77 3A 100.0 10.0
3B 100.0 10.0
SYSTEM 100.0 10.0 720 72 72
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT FIRED NATURAL GAS THROUGHOUT JUNE WITH THE EXCEPTION OF A
72-HOUR PERIOD DURING WHICH COAL WAS FIRED AND THE SCRUBBERS WERE OPERATED
FOR SCRUBBER PERSONNEL PURPOSES ONLY. (GAS OPERATION IS NOT INCLUDED
IN THE OPERABILITY FIGURES).
7/77 SYSTEM .0 744 0 0
8/77 SYSTEM .0 744 0 0
235
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
KANSAS CITY POWER & LIGHT: HAWTHORN 3 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
502 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT FIRED NATURAL GAS FOR THE ENTIRE JULY-AUGUST PERIOD,
MAKING SCRUBBER OPERATION UNNECESSARY.
9/77 SYSTEM .0 720 0 0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT CONTINUED TO FIRE NATURAL GAS THROUGH THE SEPTEMBER REPORT
PERIOD.
10/77 SYSTEM .0 744 0 0 .0
11/77 SYSTEM 100.0 57.1 720 411 411
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS SHUT DOWN IN OCTOBER DUE TO A LACK OF NATURAL GAS AND
REMAINED DOWN UNTIL NOVEMBER 3, WHEN IT RE-STARTED FIRING COAL.
DURING THE BOILER DOWN TIME, THE REACTION TANKS AND SPRAY HEADERS WERE
REPLACED BY STAINLESS STEEL COMPONENTS} THE INTERCONNECTING PIPING IS
RUBBER LINED.
12/77 SYSTEM 100.0 72.1 744 541 541
1/78 SYSTEM 100.0 46.5 744 346 346
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD MODULES WERE CLEANED DURING BOILER OUTAGES (THERE HERE NO FGD-
RELATED OUTAGES).
SOME LEAKS IN THE FGD PIPING WERE REPAIRED DURING DECEMBER.
2/78 SYSTEM 100.0 24.9 672 167 167
3/78 SYSTEM JOO.O 54.6 744 406 406
** PROBLEMS/SOLUTIONS/CO 1MENTS
DURING FEBRUARY THE UNIT WAS DOWN FOUR TIMES WITH ECONOMIZER AND WATER
WALL LEAKS (504 HOURS TOTAL). WATER WALL LEAK REPAIR AS WELL AS ACID
CLEANING OF THE BOILER CAUSED ADDITIONAL OUTAGE TIME DURING THE LAST MEEK
OF MARCH.
A TWO WEEK OUTAGE WAS SCHEDULED DURING MARCH FOR SEASONAL MAINTENANCE.
4/78 SYSTEM 40.1 30.6 720 548 220
5/78 SYSTEM 100.0 54.2 744 403 403
** PROBLEMS/SOLUTIONS/COMMENTS
AN AIR PREHEATER FIRE DISCOVERED ON MAY 12 CAUSED DAMAGES THAT FORCED
MODULE A TO BE DOWN THE REST OF THE MONTH.
6/78 SYSTEM 720
7/78 SYSTEM 744
236
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
KANSAS CITY POWER & LIGHT: HAWTHORN 3 (CONT.)
------------------------------------------ PERFORMANCE DATA ------------------------------------------
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
SOZ PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
NO INFORMATION WAS AVAILABLE FOR THE JUNE- JULY REPORT PERIOD DUE TO A
PLANT STRIKE; HOWEVER, THE FGD SYSTEM HAS OPERATED AND is BEING RUN
BY SUPERVISORY PERSONNEL.
8/78 SYSTEM 744
9/78 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE SCRUBBER SYSTEM IS OPERATING EVEN THOUGH THE UTILITY IS STILL IN THE
MIDST OF A STRIKE. FGD PERFORMANCE FIGURES ARE NOT AVAILABLE SINCE THE
UTILITY IS NOT RECORDING FGD SYSTEM OPERATING HOURS DURING THE STRIKE.
10/78 SYSTEM
11/78 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
ALTHOUGH THE STRIKE IS OVER, OPERATIONAL DATA IS STILL UNAVAILABLE. THE
FGD SYSTEM IS IN OPERATION.
12/78 SYSTEM 744
1/79 SYSTEM 744
*« PROBLEMS/SOLUTIONS/COMMENTS
HOURS OF OPERATION ARE STILL NOT AVAILABLE. THE FGD SYSTEM IS IN
OPERATION BUT AT PRESENT PERSONNEL ARE BEING REASSIGNED PREVENTING
ACCURATE DATA RECORDING.
2/79 SYSTEM 672
3/79 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
OPERATING INFORMATION IS STILL NOT AVAILABLE FOR UNIT 3.
4/79 SYSTEM 100.0 18.1 720 130 130 9.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER MAS DOWN IN APRIL FOR 543 HOURS FOR TURBINE OVERHAUL.
5/79 SYSTEM 100.0 55.0 744 409 409 29.0
** PROBLEMS/SOLUTIONS/COMMENTS
IN MAY THE BOILER OUTAGE TIME WAS DUE TO TUBE LEAKS.
6/79 SYSTEM 720 696
7/79 SYSTEM 744 744
8/79 SYSTEM 744 558
9/79 SYSTEM 100.0 84.0 720 605 605
237
-------
EPA UTILITY FSD SURVEY: OCTOBER - DECEMBER 1980
KANSAS CITY POWER & LIGHT: HAWTHORN 3 CCONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY BURNED PRIMARILY GAS DURING JUNE, JULY AND AUGUST. THE UNIT
RETURNED TO FIRING ALL COAL IN SEPTEMBER. THE SCRUBBER WAS LARGELY
AVAILABLE BUT WAS NOT NEEDED FOR MOST OF THE PERIOD. THE UTILITY REPORTED
ONLY REGULAR MAINTENANCE TOOK PLACE WITH NO PROBLEMS ENCOUNTERED.
10/79 SYSTEM 100.0 91.0 744 677 677
11/79 SYSTEM 100.0 38.1 720 274 274
12/79 SYSTEM 100.0 91.9 744 684 664
1/80 SYSTEM 100.0 93.0 744 692 692
2/80 SYSTEM 100.0 100.0 696 696 696
3/80 SYSTEM 100.0 100.0 744 744 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS AVAILABLE 100X OF THE TIME THE BOILER OPERATED. NO
PROBLEMS WERE ENCOUNTERED.
4/80 SYSTEM 68.0 720 490
5/80 SYSTEM 60.0 744 446
6/80 SYSTEM 66.0 720 475
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT 3 BOILER EXPERIENCED SUPERHEATER AND ECONOMIZER LEAKS DURING THE
APRIL-JUNE PERIOD ACCOUNTING FOR THE LOW SCRUBBER UTILIZATION FIGURES.
7/80 SYSTEM 100.0 65.0 744 484 484 45.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE OUTAGE TIME DURING JULY WAS CAUSED BY BOILER TUBE LEAKS. NO FGD-
RELATED PROBLEMS WERE ENCOUNTERED.
8/80 SYSTEM 744 642 49.4
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE FGD SYSTEM IS NOW CERTIFIED, THEREFORE THE
SCRUBBER OPERATING HOURS ARE NO LONGER RECORDED.
THE FGD SYSTEM WAS SHUT DOWN FOR 10 HOURS DURING AUGUST TO REPAIR REHEATER
TUBE LEAKS.
9/80 SYSTEM 720 248 13.9
** PROBLEMS/SOLUTIONS/COMMENTS
DURING SEPTEMBER BOILER OPERATION WAS LIMITED DUE TO A SCHEDULED OVERHAUL.
DURING THE MONTH 67 HOURS OF SCRUBBER OUTAGE TIME WERE DUE TO REQUIRED
CLEANING OF THE SCRUBBER MODULES.
10/80 SYSTEM 100.0 100.0 100.0 32.9 744 245 245 12.0
238
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
KAKSAS CITY POWER £ LIGHT: HAWTHORN 3 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FED CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
DURING OCTOBER THE UNIT MAS SHUTDOWN FOR A FALL OUTAGE WHICH LASTED
APPROXIMATELY 359 HOURS.
ONE HOUR OF OUTAGE TIME WAS REQUIRED DURING THE MONTH TO REPAIR A SUPER
HEATER TUBE LEAK.
11/80 SYSTEM 80.X 100.0 100.0 40.0 720 288 288 32.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING NOVEMBER 143 HOURS OF OUTAGE TIME WERE REQUIRED TO CLEAN THE
SCRUBBER MODULES.
AN ECONOMIZER LEAK CAUSED THE UNIT TO SHUTDOWN FOR 108 HOURS.
THE UNIT DID NOT OPERATE 181 HOURS DURING THE MONTH DUE TO LACK OF DEMAND.
12/80 SYSTEM 57.9 100.0 100.0 24.5 744 182 182 15.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS OUT OF SERVICE 82 HOURS IN DECEMBER SO THAT THE
MODULES COULD BE CLEANED.
THE UNIT DID NOT OPERATE 249 HOURS DURING DECEMBER. OF THE 249 HOURS 114
HOURS WERE DUE TO LACK OF DEMAND AND 135 HOURS WERE THE RESULT OF A FUEL
SUPPLY LIMITATION.
239
-------
EPA UTILITY FED SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFOJMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY SAME
PUNT NAME
UNIT NMMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTIDJLATE EMISSION LIMITATION - NG/J
502 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PUNT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/F6D - MM
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BCILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BCILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FU£L TYPE
FU!:L GRADE
AV2RAGE HEAT CONTENT - J/G
RANSE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - Y.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** PARTICLE SCRUBBER
GENERIC TYPE
SPECIFIC TYPE
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
*** FGD SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
502 REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
KANSAS CITY POWER & LIGHT
HAWTHORN
KANSAS CITY
MISSOURI
D
64.
******
******
836
90
85
87
90
( .150 LB/MMBTU)
(****** LB/MMBTU)
(****** LB/MMBTU)
COMBUSTION ENGINEERING
PULVERIZED COAL
CYCLING
235.95 C
148.9 (
61. (
CARBON STEEL
5.5
500000 ACFM)
300 F)
200 FT)
t 18.0 FT)
( 9800 BTU/LB)
******
( 11400 BTU/LB)
COAL
BITUMINOUS
22795.
11.00
******
******
.60
******
********
COAL
BITUMINOUS
26516.
14.00
******
********
******
3.00
******
******
PACKED TOWER
STATIC BED PACKING
CARBON STEEL
AISI 1110
THROWAWAY PRODUCT
WET SCRUBBING
LIME
NONE
COMBUSTION ENGINEERING
240
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
KANSAS CITY POWER & LIGHT: HAWTHORN 4 (CONT.)
A-E FIRM
DEVELOPMENT LEVEL
N-IW/RETROFIT
U'-lIT DESIGN PARTICLE REMOVAL EFFICIENCY -
UNIT DESIGN S02 REMOVAL EFFICIENCY - X
CURRENT STATUS
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
** ABSORBER
NUMEER
GENERIC TYPE
SPECIFIC TYPE
TOADE NAME/COMMON TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LMHER GENERIC MATERIAL
L::NER SPECIFIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
GAS CONTACTING DEVICE TYPE
DISTANCE BETWEEN GAS CONTACTING ZONES - CM
L/G RATIO - L/CU.M
GAS-SIDE PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/SEC
INLET GAS FLOW - CU. M/S
IHLET GAS TEMPERATURE - C
S02 REMOVAL EFFICIENCY - X
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
TRUDE NAME/COMMON TYPE
CONFIGURATION
NUMBER OF STAGES
KU1IBER OF PASSES PER STAGE
FREEBOARD DISTANCE - M
DISTANCE BETWEEN STAGES - CM
DISTANCE BETWEEN VANES - CM
VANE ANGLES - DEGREES
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/S
CONSTRUCTION MATERIAL GENERIC TYPE
WASH WATER SOURCE
WASH RATE - L/S
** REHEATER
GENERIC TYPE
SPECIFIC TYPE
TEMPERATURE INCREASE - C
NUMBER OF TUBES PER BUNDLE
CONSTRUCTION MATERIAL GENERIC TYPE
** FANS
NUMBER
FUNCTION
APPLICATION
SERVICE
FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
BLACK 8, VEATCH
FULL SCALE
RETROFIT
X 99.00
70.00
1
8/72
0/71
PACKED TOWKR
STATIC BED PACKING
MARBLE BED SCRUBBER
COMBUSTION ENGINEERING
18 X £6 X 56
STAINLESS STEEL,CARBON STEEL
AISI lllO.AUSTENITIC
TYPE 316L.N/A
ORGANIC
GLASS FLAKE-FILLED POLYESTER
CEILCOTE FLAKEGLASS
0.75 IN. DIA GLASS MARBLES IN A 3 TO 4 IN. BED
10.2 ( 4.0IN)
3.5 (26.0 GAL/1000 ACF)
2.7 (11.0 IN-H20)
3.0 ( 10.0 FT/S)
76.« ( 162000 ACFM)
50.0 ( 122 F)
70.0
MIST ELIMINATOR
2
IMPINGEMENT
BAFFLE
CHEVRON VANE
HORIZONTAL
2
Z
3.05 (10.0 FT)
15.24 ( 6.0 IN)
7.6 ( 3.00 IN)
.3 ( 1.2 IN-H20)
3.0 ( 10.0 FT/S)
FIBERGLASS REINFORCED PLASTIC
BLENDED RIVER AND THICKENER OVERFLOW MATER
126.2 ( 2000 GAL/MIN)
IN-LINE
HOT WATER
10.0
2
CARBON STEEL
2
BOOSTER
INDUCED DRAFT
DRY
79.
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
KANSAS CITY POWER ft LIGHT: HAWTHORN 4 (CONT.)
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
NUKBER
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
** TA.4KS
SERVICE
302 SCRUBBER TOWER HOLDUP
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
DIMENSIONS - FT
*** SLUDGE
** TREATMENT
METHOD
** DISPOSAL
NATURE
TY.JE
LOCATION
SITE CAPACITY - CU.M
** PRCCESS CONTROL AND INSTRUMENTATION
D'EMICAL PARAMETERS
CCNTROL LEVELS
*# tWER BALANCE
WATER LOOP TYPE
** FSD SPARE CAPACITY INDICES
ABSORBER - X
** FGD SPARE COMPONENT INDICES
ABSORBER
SCRUBBER OUTLET
COR-TEN STEEL
GUNITE
LIME SLAKING
SLAKER
1
51.7 ( 57 TPH)
NUMBER
***#
THICKENER
1
115 (DIA) X 10 (DEPTH)
FLYASH STABILIZATION
FINAL
POND
ON SITE
3130880
t 2560.0 ACRE-FT)
PH
4.5-6.5
CLOSED
.0
.0
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
0/72 SYSTEM
»'* PROBLEMS/SOLUTIONS/COMMENTS
7/75
THE ORIGINAL FGD SYSTEM INSTALLED ON THE HAWTHORN 4 UNIT BEGAN INITIAL
OPERATIONS IN AUGUST 1972. THE PROCESS CONSISTED OF DRY LIMESTONE INJEC-
TION INTO THE BOILER FURNACE WHERE THE LIMESTONE WAS CALCINED TO LIME.
THE FURNACE CALCINED LIME AND BOILER FLUE GAS WERE THEN DISCHARGED TO A
TAIL-END WET SCRUBBING SYSTEM CONSISTING OF TWO MARBLE-BED ABSORBERS
WHERE PARTICLES AND S02 WERE REMOVED FROM THE GAS STREAM. BECAUSE OF
BOILER TUBE PLUGGING ATTRIBUTED TO THE LIMESTONE INJECTION, THE MODE OF
OPERATION WAS MODIFIED IN LATE 1972 TO LIMESTONE INJECTION INTO THE FLUE
GAS DUCT NEAR THE INLET TO THE MARBLE-BED ABSORBERS.
8.0
5.5
242
-------
EPA UTILITY F6D SURVEY-' OCTOBER - DECEMBER 1980
KANSAS CITY POWER & LIGHT: HAWTHORN 4 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
4B 25.0 17.2
SYSTEM 16.3 11.4 744 518 84
** PROBLEMS/SOLUTIONS/COMMENTS
BOTH MODULES ENCOUNTERED MARBLE BED PLUGGING AND STRAINER PROBLEMS.
8/75 4A 22.6
4B 28.5
SYSTEM 25.5 744 190
** PROBLEMS/SOLUTIONS/COMMENTS
A NEW PROCESS CHEMISTRY IS BEING TRIED- ATTEMPTING TO RUN AT 100X SLOWDOWN
AND NEAR OX SOLIDS WITH PH BEING MAINTAINED AT 5 WITHOUT LIMESTONE
INJECTION. EMPHASIS IS BEING PLACED ON PARTICULATE CONTROL.
LOST HALF OF BOILER TO ID FAN OUTAGE CAUSING BOTH FGD MODULES TO BE SHUT
DOWN TO PREVENT LOSS OF THE ENTIRE UNIT.
9/75 4A 52.2 28.6
4B 53.2 29.2
SYSTEM 52.7 28.9 720 395 208
** PROBLEMS/SOLUTIONS/COMMENTS
SCRUBBER MODULES WERE RETURNED TO SERVICE ON SEPTEMBER 21 AFTER REPLACE-
MENT THE ORIGINAL ID FAN ON MODULE 4B.
THE MARBLE BED WAS REMOVED FROM MODULE A AND REPLACED WITH A STAINLESS
STEEL PERFORATED BED. THE MARBLES WERE REMOVED BECAUSE OF CONTINUING
OPERATIONAL DIFFICULTIES. THE NEW DESIGN RESULTED IN INCREASED
AVAILABILITY AND CONTINUED HIGH PARTICULATE EFFICIENCY (97X).
10/75 4A 59.5 57.7
48 91.0 88.2
SYSTEM 75.3 73.0 744 721 543
** PROBLEMS/SOLUTIONS/COMMENTS
THE EXPERIMENT WITH A PROCESS CHEMISTRY OF 100X SLOWDOWN AND OX
SOLIDS IS STILL IN PROGRESS. S02 REMOVAL EFFICIENCY IS IN THE 50 TO 60X
RANGE. KCP&L IS CONCENTRATING ON PARTICULATE CONTROL.
THERE WAS A MINOR BOILER RESTRICTION ON THE A-SIDE BETWEEN THE ECONOMIZER
AND THE INLET DRAFT DUCT RESULTING IN A LOSS OF FLUE GAS VELOCITY.
11/75 4A .0 .0
4B 99.0 99.0
SYSTEM 49.5 49.5 720 720 357
12/75 4A .0 .0
4B 16.1 13.8
SYSTEM 8.1 6.9 744 640 52
** PROBLEMS/SOLUTIONS/COMMENTS
A BOILER OUTAGE OF 5 DAYS IN DECEMBER WAS DUE TO A SCHEDULED OVERHAUL.
MODULE 4A WAS SHUT DOWN DURING THE NOVEMBER-DECEMBER PERIOD DUE TO LOSS
OF DRAFT THROUGH THE DUCTWORK FROM THE ECONOMIZER TO THE AIR PREHEATER,
WHICH WAS RESULTING IN FREQUENT PLUGGING OF THE REHEATER.
1/76 SYSTEM .0 744 0 0 .0
243
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
KANSAS CITY POWER & LIGHT: HAWTHORN 4 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS DOWN ALL MONTH DUE TO FROZEN EQUIPMENT AND LINES; MANPOWER
WAS ASSIGNED TO A BOILER AND TURBINE OVERHAUL ON UNIT 5.
2/76 4A .0 .0
4B 77.7 64.7
SYSTEM 38.9 32.3 696 579 225
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE 4A WAS SHUT DOWN THE ENTIRE MONTH BECAUSE OF CONTINUING LOSS OF
DRAFT THROUGH THE DUCTWORK FROM THE ECONOMIZER TO THE AIR PREHEATER.
MODULE B EXPERIENCED PLUGGING IN THE MARBLE BED.
A RECYCLE PUMP MALFUNCTIONED ON THE B-SIDE.
3/76 4A .0 .0
4B 3.4 3.2
SYSTEM 1.7 1.6 744 706 12
4/76 4A 42.0 32.1
4B 40.0 30.6
SYSTEM 41.0 31.4 720 550 226
#* PROBLEMS/SOLUTIONS/COMMENTS
THE SC7UBBER BYPASS SEALS WERE REPLACED WITH SLIDE-GATE DAMPERS ON APRIL 1.
5/76 4A J9.3 26.7
4B 'V3.5 29.6
SYSTEM 41.4 28.2 744 506 209
** PROBLEMS/SOLUTIONS/COMMENTS
CURRENTLY, THE UTILITY IS IN THE PROCESS OF MODIFYING THE SCRUBBING SYSTEM
FROM A LIMESTONE INJECTION AND TAIL-END SCRUBBING BASED SYSTEM TO A LIME
SLURRY BASED SYSTEM.
6/76 4A 63.9 40.8
4B 5.0 3.2
SYSTEM 34.5 22.0 720 460 158
** PROBLEMS/SOLUTIONS/COMMENTS
PLUGGING IN THE B-SIDE REHEATER WAS EXPERIENCED DURING JUNE AND ONE
SECTION OF REHEAT TUBES WERE REMOVED TO FACILITATE CLEANING AND
MAINTENANCE WORK.
7/76 SYSTEM .0 744 0 0 .0
8/76 SYSTEM .0 744 0 0 .0
9/76 SYSTEM .0 720 0 0 .0
«* PROBLEMS/SOLUTIONS/COMMENTS
THE SYSTEM WAS OUT OF SERVICE VIRTUALLY THE ENTIRE JULY-SEPTEMBER PERIOD
DUE TO THE ON-GOING SYSTEM MODIFICATIONS AND A MAJOR EXPLOSION WHICH
OCCURRED IN THE COAL MILL PULVERIZING AREA OF UNIT 5, WHICH SERIOUSLY
HAMPERED MANPOWER COMMITMENTS.
10/76 SYSTEM .0 744 0 0 .0
244
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
KANSAS CITY POWER & LIGHT: HAWTHORN $ (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
11/76 4A 90.8
4B .0
SYSTEM 45.5
61.*
.0
30.7 720 486 221
12/76 SYSTEM
1/77
.0
.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE A-SIDE OPERATED 442 HOURS IN NOVEMBER WHILE BOTH MODULES REMAINED
OUT OF SERVICE IN DECEMBER DUE TO THE FGD SYSTEM MODIFICATIONS BEING
PERFORMED.
85.3
4B
SYSTEM
85.0
74.1
79.7
65.6
57.0
61.3
744 572
456
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT BECAME AVAILABLE FOR SERVICE IN THE LIME SCRUBBING MODE ON
JANUARY 5, 1977. TESTING FOR COMPLIANCE WITH PARTICULATE CODES OCCURRED
DURING THE MONTH. THE UNIT WAS FOUND TO MEET THE EMISSION REGULATION OF
0.17 LB/MM BTU BURNING 2.OX SULFUR COAL. SYSTEM OPERATIONS ARE STILL
CONTINUING AT OX SOLIDS AND 100X SLOWDOWN. THE FRESH WATER MAKE-UP
REQUIREMENT IS 770 GPM/MM.
2/77 4A
4B
SYSTEM
3/77 4A
4B
SYSTEM
79.2
49.4
64.3
61.6
97.4
89.5
69.6
43.5
56.6
59.1
70.6
64.9
672 591
744 539
380
482
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE FEBRUARY-MARCH PERIOD PROBLEMS WERE ENCOUNTERED WITH PLUGGING
ON THE SUCTION SIDE OF THE SCRUBBEP RECYCLE TANK.
4/77 4A
4B
SYSTEM
43.2
43.2
43.2
43.2
43.2
43.2
720 720
311
*» PROBLEMS/SOLUTIONS/CO IMENTS
THE SYSTEM IS NOW OPERATING WELL AT ABOUT 15-25X SLOWDOWN. THE PH CONTROL
SYSTE.1 OPERATIONS HAVE BEEN EXCELLENT. DURING MAY THE BOILER BURNED GAS
FOR 408 HOURS I NOT INCLUDED IN THE OPERABILITY VALUES). SO2 REMOVAL
EFFICIENCY IS ESTIMATED AT 50-60X FOR BOTH MODULES. ALTHOUGH ACTUAL TESTS
HAVE NOT BEEN RUN FOR ONE-AND-A-HALF YEARS. CURRENTLY BOTH MODULES ARE
BEING OPERATED SIMULTANEOUSLY.
5/77 4A
4B
SYSTEM
6/77 SYSTEM
54.2
54.2
54.2
24.2
24.2
24.2
.0
744 740 180
720 0 0
** PROBLEMS/SOLUTIONS/COMMENTS
UNIT NO. 4 FIRED GAS THROUGHOUT THE MONTH, ALLOWING THE SCRUBBER PLANT TO
BE SHUT DOWN FOR MODIFICATIONS DURING THE PERIOD.
MODIFICATIONS TO THE SCRUBBER MODULES INCLUDED: REPLACEMENT OF THE UNDER-
245
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
KANSAS CITY POWER & LIGHT: HAWTHORN 4 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
BED SPRAY HEADERS WITH 316L SS, INSTALLATION OF A NEW REACTION
TANK LINER, AND REPLACEMENT OF THE ORIGINAL CARBON STEEL PIPING WITH
RUBBER-LINED PIPING (FROM THE RECYCLE PUMPS TO THE SPRAY MANIFOLD).
7/77 4A 17.Z 16.1
4B 17.a 16.1
SYSTEM 17.Z 16.1 744 696 120
** PROBLEMS/SOLUTIONS/COMMENTS
THE STAINLESS STEEL MODIFICATIONS WERE COMPLETED BY JULY 25 AND THE UNIT
RESUMED COAL FIRING. THE SCRUBBER MODULES WERE IN SERVICE APPROXIMATELY
120 HOURS FOR THE REMAINDER OF THE MONTH. THE SYSTEM SUCCESSFULLY COM-
PLETED FEDERAL PARTICULATE REMOVAL TESTS (0.15 LB/MM BTU MEASURED) DURING
THIS TIME, WHILE BURNING HIGH SULFUR, HIGH ASH (PEABOOY-OKLAHOMA) COAL.
OPACITY TESTS FOR BOTH UNITS 3 AND 4 WILL BE CONDUCTED IN SEPTEMBER.
8/77 4A 100.0 73.9
4B 100.0 73.9
SYSTEM 100.0 73.9 744 550 550
9/77 4A 100.0 72.Z
4B 100.0 72.Z
SYSTEM 100.0 72.2 720 589 520
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE LATTER PART OF SEPTEMBER THE CLARIFIER BECAME PLUGGED. THE
UNIT FIRED NATURAL GAS UNTIL THE CLARIFIER WAS CLEANED. THE BOILER HOURS
DURING WHICH GAS WAS FIRED WERE NOT INCLUDED IN THE OPERABILITY FIGURES.
10/77 SYSTEM 100.0 73.9 744 550 550
11/77 SYSTEM 100.0 68.9 720 496 496
*# PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WENT DOWN FOR PART OF OCTOBER DUE TO A PROBLEM WITH THE
GENERATOR EXCITER.
SOME FGD SYSTEM OUTAGE TIME IN OCTOBER WAS DUE TO A PLUGGED HEADER.
AN FGD SYSTEM OUTAGE ALSO OCCURRED IN OCTOBER WHEN THE LIQUID LEVEL IN THE
INTERNAL REACTION TANK EXCEEDED THE CONTROL LEVEL, RESULTING IN PLUGGING
OF THE INLET GAS DUCT TO THE SCRUBBER.
DURING NOVEMBER THERE WERE TWO INSTANCES OF PLUGGED UNDER BED NOZZLES ON
THE 4A MODULE.
ON NOVEMBER 10 AN EPA OPACITY TEST WAS RUN ON UNITS 3 AND 4. THE AVERAGE
OPACITY WAS 16.76X RUNNING AT OR NEAR FULL LOAD. THE UNITS ARE NOW
CERTIFIED FOR PARTICULATE AND OPACITY.
12/77 SYCTEM 100.0 69.9 744 520 520
1/78 SYSTEM 100.0 68.3 744 508 508
** PROBLEMS/SOLUTIONS/CO1MENTS
DURINF JANUARY SPRAY NOZZLE PLUGGING WAS ENCOUNTERED. SOME NEW
SPRAY NOZZLES WERE INSTALLED.
THE STRAINER ON THE RECYCLE PUMP MALFUNCTIONED CAUSING DOWN TIME.
246
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
KANSAS CITY POWER 4 LIGHT: HAWTHORN 4 (CONT.)
PERFORMANCE DATA
PERIOD rtODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S03 PART. HOURS HOURS HOURS FACTOR
THERE WERE SEVERAL BOILER RELATED OUTAGES IN JANUARY.
2/78 SYSTEM 100.0 29.5 672 198 198
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS DOWN THREE TIMES DURING FEBRUARY FOR NON-SCRUBBER RELATED
PROBLEMS AND ONCE FOR A FUEL SAFETY TRIP.
3/78 SYSTEM 100.0 63.3 744 471 471
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MARCH THERE WERE THREE ECONOMIZER LEAK OUTAGES (231 HOURS) AND THE
ABSORBER REQUIRED AN ADDITIONAL 32 HOURS OF OUTAGE FOR MAINTENANCE.
4/78 SYSTEM 100.0 40.0 720 288 288
** PROBLEMS/SOLUTIONS/COMMENTS
APRIL OUTAGE TIME WAS FOR SCHEDULED GENERAL MAINTENANCE AND CLEANING.
5/78 SYSTEM 100.0 56.6 744 421 421
** PROBLEMS/SOLUTIONS/COMMENTS
FGD OUTAGE IN MAY WAS DUE TO CLARIFIER PLUGGING.
6/78 SYSTEM 720
7/78 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
NO INFORMATION WAS AVAILABLE FOR THE JUNE-JULY PERIOD BECAUSE OF A PLANT
STRIKE.
8/78 SYSTEM 744
9/78 SYSTEM 720
** PROBLEMS/SOLUTIONS/COHMENTS
THE SCRUBBING SYSTEM IS OPERATING ALTHOUGH THE UTILITY IS STILL IN THE
MIDST OF A STRIKE. FGD PERFORMANCE FIGURES ARE NOT AVAILABLE BECAUSE THE
UTILITY IS NOT RECORDING FGD OPERATION HOURS DURING THE STRIKE.
10/78 SYSTEM 744
11/78 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
ALTHOUGH THE STRIKE IS OVER NO OPERATIONAL DATA ARE YET AVAILABLE. THE
FGD SYSTEM IS OPERATIONAL.
12/78 SYSTEM 744
1/79 SYSTEM 744
247
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
KANSAS CITY POWER & LIGHT: HAWTHORN 4 (COHT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
HOURS OF OPERATION ARE STILL NOT AVAILABLE. THE FGD SYSTEM IS OPERATION-
AL BUT AT PRESENT PERSONNEL ARE BEING REASSIGNED PREVENTING ACCURATE DATA
RECORDING.
2/79 SYSTEM 672
3/79 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
OPERATING INFORMATION FOR UNIT 4 IS STILL NOT AVAILABLE.
4/79 SYSTEM 100.0 56.9 720 410 410 30.0
** PROBLEMS/SOLUTIONS/COMMENTS
AN EXCITER FAILURE ON THE GENERATOR CAUSED THE APRIL BOILER OUTAGE TIME.
5/79 SYSTEM 100.0 94.0 744 699 699 49.0
** PROBLEMS/SOLUTIONS/COMMENTS
MAY OUTAGE TIME MAS FOR SCRUBBER CLEANING AND GENERAL MAINTENANCE.
6/79 SYSTEM 100.0 14.0 720 101 101
** PROBLEMS/SOLUTIONS/COMMENTS
THE LOW BOILER HOURS IN JUNE MERE A RESULT OF A SCHEDULED BOILER OVERHAUL.
7/79 SYSTEM 744 692
8/79 SYSTEM 744 744
9/79 SYSTEM 720 497
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JULY AND AUGUST MOSTLY GAS WAS FIRED. THERE WERE NO MAJOR SCRUBBER
PROBLEMS DURING THE JULY-SEPTEMBER PERIOD.
10/79 SYSTEM 100.0 91.0 744 677 677
11/79 SYSTEM 100.0 38.1 720 274 274
12/79 SYSTEM 100.0 91.9 744 684 684
1/80 SYSTEM .0 744 0 0 .0
2/80 SYSTEM .0 696 0 0 .0
3/80 SYSTEM .0 744 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT REMAINED OFF LINE THROUGH THE FIRST QUARTER OF 1980 BECAUSE OF A
TURBINE GENERATOR OVERHAUL.
4/80 SYSTEM 65.0 720 468
248
-------
EPA UTILITY FG'J SURVEY: OCTOBER - DECEMBER 1980
KANSAS CITY POWER & LIGHT: HAWTHORN 4 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
__»..«._« _«_«__ .»____>. — — — <— — — ——_—.__ WMP-* — — _ — — — .^ — — —. — *-— _V »..__>__•«••.» «_.___ _-»_«.. __.».W*~ •. .p. HP M. Mr •• ^ HP- — — — »• — — — — —
** PROBLEMS/SOLUTIONS/COMMENTS
LOW APRIL SCRUBBER UTILIZATION FIGURES OCCURRED BECAUSE THE BOILER MAS OUT
OF SERVICE FOR SCHEDULED MAINTENANCE DURING PART OF THE MONTH.
5/80 SYSTEM 90.1 744 670
6/80 SYSTEM 98.1 720 706
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO UNUSUAL FGD SYSTEM PROBLEMS OCCURRED DURING
MAY AND JUNE.
7/80 SYSTEM 100.0 78.0 744 580 580 55.0
** PROBLEMS/SOLUTIONS/COMMENTS
NECESSARY REPAIRS TO THE GENERATOR COLLECTOR RING CAUSED SYSTEM OUTAGE
TIME DURING JULY.
A 53 HOUR OUTAGE WAS DUE TO THE REPLACING OF THE UNDER BED SPRAY HEADERS
ON THE 4A MODULE. THIS WAS THE ONLY FGD-REUTED PROBLEM DURING JULY.
8/80 SYSTEM 744 569 47.4
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE FGD SYSTEM IS NOW CERTIFIED, THEREFORE THE
SCRUBBER OPERATING HOURS ARE NO LONGER RECORDED.
DURING AUGUST APPROXIMATELY 66 HOURS WERE NECESSARY TO PERFORM GENERAL
MAINTENANCE ON THE SYSTEM.
9/80 SYSTEM 720 111 9.4
** PROBLEMS/SOLUTIONS/COMMENTS
LOW BOILER UTILIZATION DURING SEPTEMBER WAS DUE TO A LACK OF DEMAND.
NO FGD SYSTEM PROBLEMS WERE REPORTED FOR THE MONTH OF SEPTEMBER.
10/80 SYSTEM 100.0 100.0 100.0 68.4 744 509 509 31.0
#* PROBLEMS/SOLUTIONS/COMMENTS
DURING OCTOBER THE BOILER DID NOT OPERATE 155 HOURS DUE TO A LACK OF
DEMAND.
AN ECONOMIZER LEAK CAUSED THE UNIT TO COME OFF LINE APPROXIMATELY 48 HOURS.
11/80 SYSTEM 71.8 100.0 100.0 65.8 720 474 474 53.0
** PROBLEMS/SOLUTIONS/COMMENTS
A 203 HOUR OUTAGE WAS NECESSARY DURING NOVEMBER TO CLEAN THE SCRUBBER AND
TO REPAIR A RECYCLE PIPING SLOWDOWN LINE LEAK.
DURING THE MONTH THE UNIT WAS OFF LINE 43 HOURS DUE TO A LACK OF DEMAND.
12/80 SYSTEM 92.1 100.0 100.0 59.1 744 440 440 41.0
249
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
KANSAS CITY POWER fi LIGHT: HAWTHORN 4 (CONT.)
PERFORMANCE DATA
PERIOC MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
SOZ PART. HOURS HOURS HOURS FACTOR
_ __
** PROBLEMS/SOLUTIONS/COMMENTS
DUR7NG DECEMBER 16Z HOURS OUTAGE TIME WAS NECESSARY TO REPAIR A WATER
WALL TUBE LEAK.
DURING THE MONTH THE SYSTEM WAS OFF LINE FOR 59 HOURS FOR CLEANING.
THE UKIT DID NOT OPERATE 81 HOURS DUE TO LACK OF DEMAND.
250
-------
EPA UTILITY FED SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC F6D SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UMIT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** Ut-'IT DATA - BOILER AND STACK
EOILER SUPPLIER
EOILER TYPE
EOILER SERVICE LOAD
f'ESIGN BOILER FLUE GAS FLOW - CU.M/S
EOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACix TOP DIAMETER - M
** FUEL DATA
FUE . TYPE
FUE.. GRADE
AVEFAGE HEAT CONTENT - J/G
R0NOE HEAT CONTENT - BTU/IB
AVERAGE ASH CONTENT - '/.
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7,
RWGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RWGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - '/,
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** PARTICLE SCRUBBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
DIMENSIONS - FT
SJ ELL GENERIC MATERIAL
SKELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
LIQUID RECIRCULATION RATE - LITER/S
L/5 RATIO - LITER/CU.M
PRESSURE DROP - KPA
SUPERFICIAL GAS VELOCITY - M/S
INLET GAS FLOW RATE - CU.M/S
INLET GAS TEMPERATURE - C
PARTICLE REMOVAL EFFICIENCY - 7.
*** FGD SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
KANSAS CITY POWER 8. LIGHT
LA CYGNE
LA CYGNE
KANSAS
E
55.
645.
( .128 LB/MMBTU)
( 1.500 LB/MMBTU)
(****** LB/MMBTU)
1450
820
820
820
BABCOCK * WILCOX
CYCLONE
BASE
1302.44
140.6
213.
CONCRETE
7.0
(2760000 ACFM)
( 285 F)
( 700 FT)
( 23.0 FT)
( 9421 BTU/LB)
9000-9700
COAL
SUBBITUMIKOUS
21913.
24.36
24-25
8.60
9-10
5.39
5-6
.03
0.02-0.03
8
VENTURI TOWER
VARIABLE-THROAT/SIDE-MOVABLE BLOCKS
BABCOCK & WILCOX
21.5 LONG X 1.83 WIDE
STAINLESS STEEL
AUSTENITIC
INORGANIC
HYDRAULICALLY-BONDED CEMENT
NONE
315.0
1.6
1.7
39.6
162.8
140.6
98.2
( 5000 GPM)
(12.0 GAL/1000ACF)
I 7.0 IN-H20)
( 130.0 FT/S)
( 345000 ACFM)
( 285 F)
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
NONE
BABCOCK & WILCOX
251
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
KANSAS CITY POWER & LIGHT: u CYGNE 1 (CONT.)
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
UNIT DESIGN SOS REMOVAL EFFICIENCY - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
** ABSORBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
NUMBER OF CONTACTING ZONES
LIQUID RECIRCULATION RATE - LITER/S
L/G RATIO - L/CU.M
C.AS-SIDE PRESSURE DROP - KPA
JUPERFICAL GAS VELOCITY - M/SEC
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
£02 REMOVAL EFFICIENCY - X
** MIST ELIMINATOR
FRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
T3ADF NAME/COMMON TYPE
CONFIGURATION
CONSTRUCTION MATERIAL GENIRIC TYPE
** REHE>.TER
NJMPER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
TEMPERATURE INCREASE - C
IHLET FLUE GAS FLOW RATE - CU. M/S
INLET FLUE GAS TEMPERATURE - C
N'JMBER OF TUBES PER BUNDLE
CONSTRUCTION MATERIAL GENERIC TYPE
** FA'JS
NUMBER
SJPPLIER
F.JNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** FAtxS
NLMBER
FUNCTION
APPLICATION
SERVICE
BLACK & VEATCH
FULL SCALE
NEW
•/. 99.50
80.00
I
6/73
2/73
3/71
8
TRAY TOWER
SIEVE TRAY
BABCOCK 4 MILCOX
32 X 16 X 65
STAINLESS STEEL
AUSTENITIC
TYPE 316L
NONE
N/A
N/A
1
567.
5.0
1.5
4.6
112.55
50.0
80.0
(
(
(
(
(
(
9000 GPM)
37.7 GAL/1000 ACF)
6.0 IN-H20)
15.0 FT/S)
238500 ACFM)
122 F)
PRE-MIST ELIMINATOR
8
BULK SEPARATION
PERFORATED FLATE
SIEVE TRAY
HORIZONTAL
SS
4
IN-LINE
STEAM
BARE TUBE
15.6 ( 60 F)
.145.11 ( 307500 ACFM)
50.0 < 122 F)
32
ORIGINALLY 304 SS CHANGED TO 316L SS
STURTEVANT DIV.
BALANCED DRAFT
INDUCED DRAFT
DRY
210.09
77.8
WESTINGHOUSE
445200 ACFM)
172 F)
CARBON STEEL WITH SS CLAD BLADES; THE HOUSINGS A
BALANCED DRAFT
BOILER I.D.
DRY
252
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
KANSAS CITY POWER & LIGHT: LA CYGNE 1 (CONT.)
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
MANUFACTURER
NUMBER
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
PRODUCT QUALITY - X SOLIDS
** TANKS
SERVICE
LIMESTONE SLURRY MAKEUP
RECYCLE
DILUTION
** PUMPS
SERVICE
POND RETURN
SLURRY FEED
ABSORBER RECIRCULATION
SCRUBBER RECIRCULATION
*** SLUDGE
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE DIMENSIONS
SITE CAPACITY - CU.M
«* PROCESS CONTROL AND INSTRUMENTATION
COMICAL PARAMETERS
CONTROL LEVELS
MONITOR LOCATION
PROCESS CONTROL MANNER
** WATER BALANCE
W4TER LOOP TYPE
MAKEI'P WATER ADDITION - LITERS/S
** FGD JPARE CAPACITY INDICES
ABSORBER - X
** FGO SPARE COMPONENT INDICES
AftSCRBER
SCRUBBER INLET
CARBON STEEL
NONE
FROM PLENUM THROUGH STACK
CARBON STEEL
DERAKANE
LIMESTONE GRINDING
BALL MILL
KOPPERS
2
99.9 ( 110 TPH)
66.0
NUMBER
Z
8
Z
NUMBER
Z
1
8
8
FINAL
UNLINED POND
ON SITE
PUMPED
160 ACRES X 11 FT DEEP
2152480 ( 1760.0 ACRE-FT)
PH, SOLIDS X
PW5.6-5.8)
PH AT VENTURI, SOLIDS AT VENTURI RECIRC. LINE
AUTOMATIC
CLOSED
72.3
.0
.0
( 1148 GPM)
253
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
KANSAS CITY POWER & LIGHT: LA CYGNE 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
IE/72 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE FIRST TRIAL OPERATION BEGAN ON DECEMBER 26, 1972 AND WAS PLAGUED WITH
NUMEROUS PROBLEMS. SOME OF THESE PROBLEMS, SUCH AS VIBRATIONS OF THE
INDUCED-DRAFT FANS AND THEIR SENSITIVITY TO IMBALANCE, OCCURRED EVEN BE-
FORE THE BOILER WAS FIRED. AS THESE FABRICATION PROBLEMS WERE CORRECTED
ANT) THE FGD SYSTEM WENT INTO OPERATION TWO OTHER TYPES OF PROBLEMS AP-
PEARED. THE FIRST TYPE ASSOCIATED WITH THE WET LIMESTONE PROCESS, IN-
CLUDED PLUGGING OF THE MIST ELIMINATORS AND STRAINERS. THE CORROSION
ASSOCIATED WITH CONDENSATION OF ACID VAPORS FROM THE GAS ON THE REHEATER
TUBE BUNDLES WAS CONTROLLED BY INJECTION OF SLIP STREAMS OF HOT AIR FROM
THE BOILER COMBUSTION AIR HEATER INTO THE SCRUBBED FLUE GASES AT THE INLET
TO THE REHEATER UNITS. THIS PRACTICE WHICH REDUCED THE MAXIMUM GENERAT-
ING CAPACITY OF THE BOILER BY LIMITING THE AIR AVAILABLE FOR COAL COMBUS-
TION, IS NO LONGER NECESSARY BECAUSE OF SYSTEM DESIGN MODIFICATIONS.
6/73 A 20.0
B 21.0
C 40.0
D 21.0
E 27.0
F 30.0
G 23.0
SYSTEM 64.0 26.0 720 294 187 15.2
7/73 A 7.0
B 24.0
C 25.0
D 41.0
E 27.0
F 25.0
G 31.0
SYSTEM 64.0 26.0 744 303 195 15.2
8/73 A 79.0
B 64.0
C 65.0
D 74.0
E 47.0
F 48.0
G 70.0
SYSTEM 68.0 64.0 744 699 476 42.1
9/73 A 13.0
B .0
C 13.0
D 13.0
E 13.0
F .0
G .0
SYSTEM 53.0 7.0 720 95 50 3.5
10/73 A 28.0
B 41.0
C 34.0
D 54.0
E 33.0
F 3.0
G 46. C
SYSTEM !>6.0 34.0 744 452 253 19.7
254
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
KANSAS CITY POWER i LIGHT: LA CYGNE 1 (CONT.)
PERIOD
11/73
12/73
MODULE AVAILABILITY
A
El
C
IJ
E
F
G
SYSTEM
A
B
C
E
D
F
G
SYSTEM
rcKruKriRm,c UHIH
OPERABILITY RELIABILITY UTILIZATION
48.0
1.0
38.0
4.0
63.0
59.0
49.0
57.0 37.0
42.0
20.0
5.0
26.0
31.0
11.0
32.0
53.0 24.0
X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
720 463 266 18.1
744 339 179 10.3
0/74 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
1/74 A
B
C
D
E
F
G
SYSTEM
2/74 A
B
C
D
E
F
G
SYSTEM
3/74 SYSTEM
THE 1974 FIGURES ARE BASED UPON ACTUAL SYSTEM OPERATION HOURS AS A
FUNCTION OF ACTUAL BOILER HOURS
49.0
32.0
44.0
87.0
23.0
37.0
81.0
50.0
24.0
744 364
182 6.0
66.0
68.0
59.0
76.0
52.0
100.0
65.0
69.0
37,0
.0
672 364
744 0
251 16.0
0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS SHUTDOWN FOR THE ENTIRE MONTH OF MARCH.
4/74 A
B
C
D
E
f
G
SYSTEM
5/74 A
B
C
D
67.
70.
75.
88.
74.
100.
88.
80.0
69.0
83.0
78.0
85.0
37.0
720 332
266 15.0
255
-------
EPA UTJUTY FGD SURVEY: OCTOBER - DECEMBER 1980
KANSAS CITY POWER & LIGHT! LA CYGNE 1 (CONT.)
PERIOD
6/74
7/74
8/74
9/74
10/74
11/74
12/74
0/75
MODULE
E
F
G
SYSTEM
A
B
r
a
E
r
o
SYSTEM
A
B
r;
0
E
F
G
SYSTEM
A
B
C
D
E
F
G
SYSTEM
A
B
C
D
E
F
G
SYSTEM
A
B
C
D
E
F
G
SYSTEM
A
B
C
D
E
F
G
SYSTEM
SYSTEM
SYSTEM
AVAILABILITY OPER ABILITY
78.0
84.0
80.0
80.0
92.0
84.0
83.0
90.0
82.0
83.0
87.0
86.0
75.0
80.0
80.0
81.0
85 .'0
79.0
77.0
80.0
90.0
90.0
73.0
81.0
81.0
78.0
99.0
85.0
69.0
83.0
73.0
76.0
83.0
89.0
86.0
81.0
71.0
61.0
59.0
81.0
79.0
93.0
89.0
76.0
90.0
71.0
60.0
61.0
84.0
85.0
84.0
76.0
rtKruKnANue OAIA
RELIABILITY UTILIZATION
54.0
57.0
34.0
65.0
68.0
68.0
41.0
.0
X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
744 500 400 27.0
720 480 413 32.0
744 313 250 19.0
744 571 485 39.0
720 606 491 36.0
744 662 503 39.0
720 386 293 23.0
744 0 0 .0
256
-------
EPA UTILITY FGO SURVEY: OCTOBER - DECEMBER 1980
KANSAS CITY POWER & LIGHT'• LA CYGNE I (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPEPABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
5/75
6/75
7/75
** PROBLEMS/SOLUTIONS/CO 1MENTS
THE 1975 FIGURES ARE BASED UPON SYSTEM AVAILABLE HOURS AS A FUNCTION OF
HOURS IN THE PERIOD.
1/75 SYSTEM 100.0
** PROBLEMS/SOLUTIONS/COMMENTS
.0
.0
THE BOILER WAS SHUTDOWN DURING JANUARY AND FEBRUARY FOR TURBINE/GENERATOR
REPAIR.
2/75 SYSTEM
3/75
100.0
.0
672
.0
A
B
C
D
E
F
G
SYSTEM
82.0
96.0
90.0
77.0
93.0
92.0
96.0
89.0
694
41.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING REDUCED LOAD CONDITIONS SOME OF THE MODULES WERE NOT REQUIRED AND
THEREFORE SHUT DOUN ALTHOUGH THEY WERE AVAILABLE. AVAILABILITY WAS THERE-
FOR HIGHER THAN SOME OF THE POSTED FIGURES INDICATE.
4/75 SYSTEM 100.0
** PROBLEMS/SOLUTIONS/COMMENTS
720
3.4
DURING APRIL THE BOILER MAS OFF LINE FOR 25 DAYS DUE TO NECESSARY GENERATOR
REPAIRS.
A
B
C
0
E
F
G
SYSTEM
A
B
C
D
E
F
G
SYSTEM
A
B
C
D
E
F
G
SYSTEM
95.0
85.0
94.0
90.0
90.0
89.0
83.0
89.0
88.0
85.0
84.0
85.0
84.0
86.0
89.0
86.0
78.0
90.0
90.0
84.0
85.0
87.0
85.0
86.0
744 683
56.0
720 667
56.0
744 590
50.0
257
-------
EPA UTILITY FED SURVEY: OCTOBER - DECEMBER 1980
KANSAS CITY POWER & LIGHT: LA CYGNE 1 (CONT.)
------------------------------------------ PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL PER BOILER FGD CAP.
SOa PART. HOURS HOURS HOURS FACTOR
8/75 A
B
C
D
E
F
G
SYSTEM
75.0
88.0
87.0
78.0
93.0
85.0
83.0
84.0
744 630
50.0
** PROBLEMS/SOLUTIONS/COMMENTS
MODULES A AND D ARE USED FOR RESEARCH TESTS.
EACH EVENING FOR CLEANING.
ONE MODULE IS SHUT DOWN
9/75
10/75
11/75
A
B
C
D
E
F
G
SYSTEM
A
B
C
D
E
F
G
SYSTEM
A
B
C
D
E
F
3
SYSTEM
78.0
84.0
84.0
85.0
79.0
78.0
74.0
80.0
66.0
77.0
46.0
74.0
73.0
73.0
65.0
68.0
93.0
91.0
80.0
93.0
96.0
89.0
94.0
91.0
720 610
744 E31
13.0
720 346
39.0
•** PROBLEMS/SOLUTIONS/COMMENTS
THE SYSTEM WAS DOWN OCTOBER 16 TO NOVEMBER 13 OWING TO PROBLEMS WITH
THE GENERATOR AND ID AIR FAN.
AVAILABILITY FIGURES FOR OCTOBER AND NOVEMBER DO NOT INCLUDE THE OUTAGE
TIME FROM OCTOBER 16 TO NOVEMBER 13.
13/75 A
B
C
D
E
F
G
SYSTEM
91.0
87.0
81.0
85.0
87.0
89.0
84.0
86.0
744 597
47.0
** PROBLEMS/SOLUTIONS/COMMENTS
THREE BOILER OUTAGES OCCURRED DURING DECEMBER.
1/76 A 86.0
Z58
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
KANSAS CITY POWER & LIGHT: LA CYGNE 1 (CONT.>
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
B
C
D
E
F
6
SYSTEM
85.0
91.0
72.0
84.0
82.0
84.0
83.0
744
51.0
2/76
3/76
4/76
A
B
C
D
E
F
G
SYSTEM
A
B
C
D
E
F
6
SYSTEM
A
B
C
D
E
F
G
SYSTEM
94.0
90.0
86.0
91.0
92.0
93.0
95.0
92.0
92.0
90.0
88.0
93.0
94.0
91.0
91.0
91.0
92.0
91.0
89.0
97.0
96.0
98.0
95.0
94.0
696 595
55.0
744 643
57.0
720 143
13.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE SYSTEM WAS SHUT DOWN ON APRIL 6 FOR A SCHEDULED BOILER AIR PREHEATERi
AND STACK BREECHING OVERHAUL. THE UNIT WAS RESTARTED ON MAY 10.
DURING THE OUTAGE SOME MAINTENANCE WAS PERFORMED ON THE SCRUBBER DUCTWORK,
PRIMARILY BECAUSE OF CORROSION PROBLEMS.
5/76 A
B
C
D
E
F
G
SYSTEM
97.0
92.0
94.0
96.0
89.0
95.0
96.0
94.0
744 436
38.0
** PROBLEMS/SOLUTIONS/COMMENTS
FROM MAY 10 TO THE END OF THE MONTH FOUR UNIT OUTAGES WERE ENCOUNTERED.
6/76 A
B
C
D
E
F
G
SYSTEM
93.0
94.0
94.0
95.0
92.0
94.0
91.0
93.0
720 656
56.0
259
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
KANSAS CITY POWER & LIGHT: LA CYGNE 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
•/. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACT01
** PROBLEMS/SOLUTIONS/COMMENTS
7/76
8/76
FOUR FORCED MINOR SCRUBBER OUTAGES OCCURRED DURING JUNE.
A
B
C
D
E
f
G
SYSTEM
96.0
95.0
92.0
93.0
93.0
94.0
94.0
94.0
744 688
60.0
** PROBLEMS/SOLUTIONS/COMMENTS
TWO MINOR SCRUBBER OUTAGES OCCURRED DURING JULY.
THE UNIT RECORDED ITS LARGEST MW-HOUR MONTH SINCE INITIATION OF COMMERCIAL
OPERATION (359,028).
A
B
C
D
E
F
G
SYSTEM
94.0
93.0
92.0
93.0
92.0
90.0
88.0
92.0
744 521
46.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT MAS TAKEN OUT OF SERVICE AUGUST 24 FOR REPAIR OF A TURBINE BLADE.
THE UNIT WAS RETURNED TO SERVICE OU OCTOBER 20. OPERATION WAS INTERMIT-
TENT PENDING TURBINE BLADE REBALAKCING AND REESTABLISHMENT OF NORMAL
OPERATING CONDITIONS.
DURIiJG THE TURBINE REPAIR PERIOD THE UTILITY COATED THE STACK INNER
STRUCTURE WITH PLASTITE 4005.
THE AUGUST AVAILABILITY FIGURES DO NOT INCLUDE THE OUTAGE TIME.
9/76 SI STEM 100.0 .0 720 0
** PROBLEMS/SOLUTIONS/COMMENTS
THE SYSTEM WAS DOWN DUE TO TURBINE REPAIR.
.0
10/76 A
B
C
D
E
F
SYSTEM
11/76 A
B
C
D
E
F
97.0
97.0
98.0
89.0
96.0
96.0
96.0
96.0
95.0
93.0
94.0
95.0
94.0
91.0
744 256
15.0
260
-------
EPA UTILITY FGO SURVEY: OCTOBER - DECEMBER 1980
KANSAS CITY POWER & LIGHT: LA CYGNE 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD. CAP.
S02 PART. HOURS HOURS HOURS FACTOR
G
SYSTEM
12/76 A
B
C
D
E
F
G
SYSTEM
94,0
94.0
87.0
89.0
81.0
94.0
94.0
95.0
91.0
90.0
720 627
59.0
744 706
60.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE A-MODULE VENTURI RECYCLE PUMP EXPERIENCED SOME PROBLEMS AND WAS
REPAIRED.
THE C-MODULE REHEAT STEAM TUBE BUNDLES WERE INCREASED IN NUMBER FROM
FOUR TO EIGHT.
1/77 A
B
C
0
E
F
G
SYSTEM
2/77 A
B
C
D
E
F
G
SYSTEM
3/77 A
B
C
D
E
F
G
SYSTEM
94.0
90.0
95.0
95.0
95.0
92.0
90.0
93.0
93.0
93.0
93.0
94.0
93.0
94.0
88.0
93.0
94.0
92.0
86.0
94.0
91.0
94.0
90.0
92.0
744 539
43.0
672 590
58.0
744 558
50.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE EIGHTH MODULE HAS BEEN INSTALLED.
THE MST ELIMINATORS IN TWO MODULES HAVE BEEN MODIFIED TO THE POINT WHERE
THEY HAVE BEEN OPERATING CONTINUOUSLY CLEAN.
ADDITIONAL BANKS OF STEAM TUBE BUNDLES HAVE BEEN INSTALLED IN SOME
MCDUf ES. 50 F OF REHEAT HAS BEEN DETERMINED AS THE NECESSARY TEMPERATURE
BOOST AT LA CYGNE TO PRECLUDE STACK PROBLEMS RELATED TO ACID DEW POINT.
THE WATER LOOP IS NOW 95X CLOSED.
A NEW SETTLING POND IS BEING INSTALLED AT THE PUNT.
THE PLANT IS STILL GENERATING 700-720 MW DURING THE DAY AND 500-570 MW
AT NIGHT.
261
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
KANSAS CITY POWER * LIGHT: LA CY6NE 1 (CONT.)
PERIOD
ft/77
MODULE
A
B
C
D
E
f
G
SYSTEM
rcKruKnANue UAI A
AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
96.0
94.0
97.0
94.0
95.0
96.0
95.0
95.0
7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
720 384 31.0
*# PROBLEMS/SOLUTIONS/COMMENTS
THE EIGHTH MODULE HAS BEEN RUN FOR TWO DAYS.
5/77 SYSTEM 100.0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
744
.0
THE UNIT WAS SHUT DOWN IN MAY DUE TO TURBINE PROBLEMS. THE UNIT RESTARTED
JULY 5, 1977.
THE MIST ELIMATOR WASHING CONFIGURATION IS BEING CHANGED TO WORK
COUNTERCURRENT TO THE GAS FLOW.
ADDITIONAL STEAM TUBE BUNDLES ARE BEING ADDED TO INCREASE THE REHEAT AREA.
THE NEW SETTLING POND IS STILL BEING DRAWN UP. EXCAVATION HAS NOT BEGUN.
6/77 SYSTEM 100.0 .0 720 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
MINOR CLEANOUT AND REPAIR WORK WAS DONE ON THE SCRUBBING SYSTEM DURING
THE TURBINE OUTAGE.
7/77 A
B
C
D
E
F
G
H
SYSTEM
95.0
93.0
94.0
95.0
95.0
95.0
95.0
95.0
95.0
744 485
36.0
** PROBLEMS/SOLUTIONS/COMMENTS
RESUMPTION OF OPERATIONS WAS CONDUCTED WITH EIGHT SCRUBBER MODULES IN THE
FLUE GAS PATH, ENABLING THE UNIT TO OPERATE AT A MAXIMUM CONTINUOUS LOAD
CAPACITY OF 800-820 MW.
8/77 A
B
C
D
E
F
G
H
SYSTEM
89.0
55.0
93.0
93.0
90.0
93.0
93.0
93.0
87.0
744 501
43.0
262
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
KANSAS CITY POWER & LIGHTS LA CYGNE 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
11/77
12/77
PARTICLE REMOVAL TESTS WERE CONDUCTED IN LATE AUGUST AND UNIT NO.l HAS
PASSED THE COMPLIANCE REQUIREMENTS 10.13 LB/MM BTU).
MODULE B HAD LOW AVAILABILITY DUE TO THE BURNING OF THE MOTOR ON
THE RECIRCULATING PUMP. IT WAS REMOVED FROM SERVICE AND STARTED AGAIN
AFTER 12 DAYS.
9/77 A
B
C
D
E
F
G
H
SYSTEM
10/77 A
B
C
D
E
F
6
H
SYSTEM
93.0
94.0
89.0
90.0
93.0
95.0
92.0
93.0
92.0
91.0
96.0
89.0
94.0
93.0
94.0
89.0
93.0
92.0
72.80
720 524
50.0
744 457
** PROBLEMS/SOLUTIONS/COMMENTS
A 12 DAY OUTAGE IN OCTOBER WAS REQUIRED TO DESLAG THE BOILER.
A
B
C
D
E
F
G
H
SYSTEM
93.0
96.0
93.0
94.0
92.0
93.0
96.0
95.0
94.0
720 234
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS SHUT DOWN NOVEMBER 15 BECAUSE OF A NECESSARY TURBINE
OVERHAUL. THE BOILER WENT BACK ON LINE DECEMBER 25.
A
B
C
D
E
F
G
H
SYSTEM
98.0
98.0
96.0
96.0
96.0
97.0
98.0
99.0
97.0
744 300
** PROBLEMS/SOLUTIONS/COMMENTS
THERE WERE A FEW SMALL BOILER RELATED OUTAGES IN DECEMBER.
1/78 A
90.0
263
-------
EPA UTILITY FGD SURVEY: OCTOBE1 - DECEMBER 1980
KANSAS CITY POWER & LIGHT: LA CYGNE 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL
S02 PART.
PER BOILER FGD CAP.
HOURS HOURS HOURS FACTOR
B
C
D
E
F
G
H
SYSTEM
95.0
95.0
95.0
93.0
94.0
94.0
94.0
94.0
744 597
** PROBLEMS/SOLUTIONS/COMMENTS
THERE WERE SOME BOILER RELATED OUTAGES IN JANUARY, TOTALING ABOUT 50
HOURS.
THE FGD SYSTEM CONTINUED TO OPERATE WITHOUT ANY PROBLEMS.
2/78
3/78
4/78
A
IJ
0
u
f;
;••
3
H
SYSTEM
A
B
C
D
E
F
6
H
SYSTEM
A
B
C
D
E
F
G
H
SYSTEM
92.0
93.0
95.0
94.0
91.0
97.0
96.0
93.0
94.0
95.0
95.0
90.0
95.0
94,0
95.0
69.0
93.0
93.0
91.0
92.0
93.0
91.0
90.0
92.0
91.0
91.0
91.0
672 578
58.0
744 741
62.0
720 620
** PROBLEMS/SOLUTJONS/COMMENTS
THE BOILER WAS DOWN A TOTAL OF 100 HOURS IN APRIL. THIS TIME INCLUDED
THREE OUTAGES DUE TO BOILER LEAKS AND LACK OF LOAD REQUIREMENT.
DURING THE BOILER OUTAGES MODIFICATIONS TO THE FGD SYSTEM INCLUDED
CHANGING THE REHEAT TUBE BUNDLES.
5/78 A
B
C
D
E
F
G
H
SYSTEM
89.0
92.0
92.0
93.0
92.0
91.0
93.0
86.0
91.0
744 593
264
-------
EPA UTILITY FSD SURVEY: OCTOBER - DECEMBER 1980
KANSAS CITY POWER fc LIGHT: LA CY6NE 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
IN MA ' THE BOILER MAS DOWN TWICE FOR A TOTAL OF 151 HOURS. OUTAGES WERE
AGAIN CAUSED BY BOILER LEAKS.
GENERiL MAINTENANCE AND REPAIRS ON THE FGD SYSTEM CONTINUED.
6/78 SYSTEM
720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS UP FOR ONLY 15 HOURS IN JUNE. IN THE FIRST PART OF JUNE
THERE WERE BOILER TUBE LEAKS. FROM JUNE 8 TO JUNE 17 A BOILER OUTAGE WAS
NECESSARY FOR GENERATOR REPAIR.
7/78 A
B
C
D
E
F
G
H
SYSTEM
8/78 A
9
0
i;
H
SYSTEM
88.0
97.0
92.0
94.0
88.0
93.0
93.0
95.0
93.0
92.0
93.0
95.0
96.0
93.0
94.0
95.0
95.0
94.0
744 341
744 577
** PROBLEMS/SOLUTIONS/COMMENTS
THERE WERE TWO BOILER OUTAGES IN AUGUST.
THE UTILITY IS EXPERIMENTING WITH A 3-STAGE MIST ELIMINATOR AND SOME
DOUBLE STAGE MIST ELIMINATORS. BETTER MIST ELIMINATION AT THE SCRUBBER
EXIT WOULD REDUCE THE FREQUENCY OF REHEATER CLEANING.
9/78 A
B
C
D
E
f
6
H
SYSTEM
96.0
96.0
96.0
96.0
96.0
96.0
95.0
97.0
96.0
720 720
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE JULY-SEPTEMBER PERIOD TWO ID FAN ROTERS WERE REPLACED.
10/78 A
B
C
0
E
96.0
96.0
98.0
97.0
97.0
265
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
KANSAS CITY POWER & LIGHT: LA CYGNE I (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
F
6
H
SYSTEM
98.0
97.0
96.0
97.0
744 255
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO UNUSUAL OPERATING PROBLEMS WERE ENCOUNTERED
DURING OCTOBER AND NOVEMBER.
11/78 A
B
C
0
E
F
G
H
SYSTEM
92.0
95.0
94.0
93.0
94.0
93.0
94.0
96.0
94.0
720 720
** PROBLEMS/SOLUTIONS/CCMMENTS
THE 'JTILITY REPORTED THAT NO UNUSUAL OPERATING PROBLEMS WERE ENCOUNTERED
DURING OCTOBER AND NOVEMBER.
12/78
1/79
A
B
C
D
E
F
G
H
SYSTEM
A
B
C
0
E
F
15
H
SYSTEM
93.9
92.9
94.0
95.0
94.7
90.5
94.4
94.7
93.6
95.6
96.5
97.2
96.3
90.7
97.2
97.2
95.4
95.8
744 239
744 205
•s* PROBLEMS/SOLUTIONS/COMMENTS
DURING THE DECEMBER-JANUARY PERIOD THE UNIT EXPERIENCED A MULTITUDE OF
BOILER OUTAGES.
2/79
3/79
A
B
C
D
E
F
G
H
SYSTEM
A
B
C
95.0
94.6
92.6
93.5
95.1
94.3
94.1
93.8
94.1
96.1
96.0
93.2
672 342
266
-------
EPA UTILITY FGD SURVEY'- OCTOBER - DECEMBER 1980
KANSAS CITY POWER 8 LIGHT: LA CYGNE 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
D
E
F
G
H
SYSTEM
95.
96.
94.8
95.7
93. 4
95.2
744 314
*# PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR FGD SYSTEM PROBLEMS WERE REPORTED BY THE UTILITY FOR FEBRUARY OR
MARCH.
THE UTILITY HAS REPORTED THAT MANY TUBE LEAKS AND CYCLONE LEAKS WERE
EXPERIENCED WITH THE BOILER.
4/79
5/79
A
B
C
D
E
F
G
H
SYSTEM
A
B
C
D
E
F
G
H
SYSTEM
95.5
95.7
94.4
91.4
95.5
96.2
95.9
95.7
95.0
96.5
96.3
96.7
95.3
95.4
95.7
96.3
95.5
96.0
720 638
744 476
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD PROBLEMS HAD OCCURRED.
6/79 SYSTEM 100.0 .0 720 0 0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS REMOVED FROM SERVICE THE LATTER PART OF MAY FOR SCHEDULED
BOILER OVERHAUL AND REMAINED OUT OF SERVICE THROUGH JUNE.
.0
7/79 SYSTEM 100.0
** PROBLEMS/SOLUTIONS/COMMENTS
.0
744
THE TURBINE WAS OVERHAULED DURING JULY. DURING THE OUTAGE SOME MINOR
MAINTENANCE WAS PERFORMED ON THE SCRUBBING SYSTEM.
8/79 A
3
C
G
H
SYSTEM
9/79 A
86.8
95.9
96.3
96.3
95.9
96.2
88.5
96.9
94.1
96.0
744 231
267
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
KANSAS CITY POWER & LIGHT: LA CYGNE 1 (CONT.)
PERIOD MODULE
B
C
D
E
f
G
H
SYSTEM
AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
96.1
95.6
94.3
96.7
96.1
96.0
96.9
96.0
7. REMOVAL PER BOILER FGD CAP.
SOZ PART. HOURS HOURS HOURS FACTOR
720 618
2/80
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD UNITS OPERATED WITH NO MAJOR PROBLEMS AND ONLY REGULAR MAINTENANCE
WAS PERFORMED DURING AUGUST AND SEPTEMBER.
10/79
A
B
C
0
E
f
G
H
SYSTEM
95.3
95.8
94.7
92.7
94.4
94.9
94.7
94.5
94.6
11/79 SYSTEM
12/79 SYSTEM
.0
.0
.0
.0
744 436
720
744
.0
.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WENT DOWN FOR AH OVERHAUL ON OCTOBER 19 AND MAS OUT OF SERVICE
THROUGH DECEMBER.
EXTENSIVE MAINTENANCE WORK BEGAN ON THE FGD SYSTEM LATE IN OCTOBER CAUSING
THE SYSTEM TO BE UNAVAILABLE DURING NOVEMBER AND DECEMBER. SOME ITEMS
INCLUDED IN THE MAINTENANCE WERE:
THE INSTALLATION OF TWO NEW SPRAY HEADERS IN SIX OF THE MODULESi RE-
PLACEMENT OF THE ABSORBER SIDEWALLS, REPLACEMENT OF THE MODULE OUTLET
DUCTS AND DAMPERS, AND VARIOUS 1UCTWORK PATCHING.
1/80 SYSTEM
.0
744
.0
** PROBLEMS/SOLUTIONS/CG1MENTS
THE BOILER AND FGD SYSTEM REMAINED UNAVAILABLE DURING JANUARY DUE TO THE
ON-GOUG GENERATOR/TURBINE OVERHAUL AND THE EXTENSIVE FGD SYSTEM MOD-
IFICATIONS BEING PERFORMED.
A
B
C
D
E
F
G
H
SYSTEM
98.2
98.2
97.4
99.1
98.2
99.1
99.1
99.6
98.6
84.1
58.3
66.2
45,9
93.0
91.7
91.7
92.4
77.7
95.7
92.9
89.7
92.3
97.3
97.3
97.3
97.3
95.3
20.0
13.2
14.9
10.3
21.0
20.7
20.7
20.8
17.5
696 157
122 10.9
** PROBLEMS/SOLUTIONS/COMMENTS
THE TURBINE/GENERATOR OVERHAUL WAS COMPLETED IN FEBRUARY AND THE BOILER
AND FGD SYSTEM RETURNED TO SERVICE ON FEBRUARY 20. THE FGD SYSTEM WAS
AVAILABLE FOR OPERATION MOST OF THE MONTH.
268
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
KANSAS CITY POWER & LIGHT: LA CYGNE 1 (CONT. )
PERIOD MODULE AVAILABILITY
3/80 A
B
C
D
E
F
G
H
SYSTEM
94.6
96.2
96.1
96.1
95.8
94.7
93.3
95.7
95.3
OPERABILITY
100.0
100.0
100.0
100.0
93.8
53.1
31.3
.0
72.3
RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
4.3
4.3
4.3
4.3
4.0
2.3
1.3
.0
3.1 744 32 23 1.7
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS OPERATED FOR ONLY 23 HOURS IN MARCH AS A RESULT OF
GENERATOR/TURBINE PROBLEMS. SOME ROUTINE CLEANING AND INSPECTIONS OF THE
FGD SYSTEM WERE PERFORMED DURING THE OUTAGE TIME.
4/80
5/80
6/80
A
B
C
D
E
F
6
H
SYSTEM
A
B
C
D
E
F
G
H
SYSTEM
A
B
C
D
E
F
6
H
SYSTEM
96.3
95.1
95.0
96.7
95.3
92.5
97.0
97.0
95.6
96.4
94.6
95.7
95.9
96.1
96.5
96.1
96.8
96.0
98.2
98.1
97.4
98.1
98.1
98.3
98.8
99.3
98.3
94.1
78.4
97.5
93.6
86.0
76.3
68.4
62.9
82.2
89.4
87.9
88.3
83.9
84.4
89.3
96.0
82.3
87.7
89.5
90.3
96.8
92.5
87.6
91.1
88.2
87.3
90.4
94.5
91.4
92.9
94.8
92.3
87.2
93.9
93.4
92.6
96.0
93.9
95.2
95.1
95.3
96.2
94.0
96.2
95.5
97.2
96.8
96.7
98.0
97.9
98.5
97.3
98.6
98.9
61.7
51.4
63.9
61.4
56.4
50.0
44.9
41.3
53.9
84.1
82.7
83.1
78.9
79.4
84.0
90.3
77.4
82.5
46.0
46.4
49.7
47.5
45.0
46.8
45.3
44.9
46.4
720 472
388 37.6
744 700
614 49.9
720 370
334 35.5
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR FGD RELATED PROBLEMS WERE REPORTED FOR THE SECOND QUARTER OF 1980.
7/80
A
B
C
D
E
F
G
H
SYSTEM
89.7
97.8
97.3
98.1
98.2
98.6
98.1
97.7
96.9
86.9
97.6
96.9
98.0
97.6
98.6
97.9
96.9
96.3
87.1
97.3
96.6
97.7
97.8
98.3
97.6
97.1
96.2
69.9
78.5
77.9
78.8
78.4
79.1
78.7
77.9
77.4
744 598
576 60.9
269
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
KANSAS CITY POWER & LIGHT: LA CYGNE 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR FGD-RELATED PROBLEMS WERE REPORTED FOR JULY.
8/80 A
B
C
D
E
F
6
H
SYSTEM
94.6
97.9
98.1
97.7
97.2
98.7
97.6
97.3
97. 4
92.7
97.3
97.3
96.8
96.2
97.2
96.9
96.4
96.4
93.9
97.2
97.3
97.4
96.7
98.1
96.7
96.3
96.7
66.9
70.3
70.3
69.9
69.5
70.2
69.9
69.6
69.6
744 537
518 54.7
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR PROBLEMS MERE ENCOUNTERED DURING THE
MONTH OF AUGUST.
9/80 A
B
C
D
E
F
G
H
SYSTEM
98.9
98.6
97.8
94.9
98.6
99.2
99.2
98.8
98.2
90.4
91.1
90.7
84.8
91.1
93.0
93.0
90.2
90.7
98.0
97.5
96.0
90.8
97.5
98.5
.98.5
97.7
97.0
53.9
54.3
54.0
50.6
54.3
55.4
55.4
53.8
54.0
720 429
389 43.3
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS TAKEN OFF LINE SEVERAL TIMES FOR A TOTAL OF 118 HOURS
BECAUSE OF BOILER TUBE LEAKS.
THE BOILER WENT DOWN ON SEPTEMBER 27, 1980 FOR A SCHEDULED MAINTENANCE
OVERHAUL. THE FGD SYSTEM WAS AVAILABLE DURING THIS TIME.
10/80 SYSTEM
100.0
.0
744
.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING OCTOBER THE BOILER REMAINED OUT OF SERVICE DUE TO AN ANNUAL TURBINE/
BOILER OVERHAUL. THE FGD SYSTEM WAS AVAILABLE DURING THIS TIME.
11/80 A
B
C
D
E
F
G
H
SYSTEM
99.9
100.0
100.0
.0
100.0
100.0
99.7
100.0
98.7
92.1
100.0
100.0
.0
100.0
100.0
85.7
59.5
87.3
98.3
100.0
100.0
.0
100.0
100.0
96.4
100.0
85.9
8.0
io;o
10.0
.0
10.0
10.0
7.5
5.2
7.6
720
63
55 8.7
** PROBLEMS/SOLUTIONS/COMMENTS
DURING NOVEMBER THE BOILER WAS IN SERVICE APPROXIMATELY 63 HOURS DUE TO
THE ANNUAL TURBINE/BOILER OVERHAUL. THE FGD SYSTEM WAS AVAILABLE 98.7X
DURING THIS TIME.
MODULE D WAS OUT OF SERVICE DUE TO REPAIRS CAUSED BY FIRE DAMAGE RECEIVED
ON OCTOBER 13, 1980.
270
-------
EPA UTItlTY FED SURVEY: OCTOBER - DECEMBER 1980
KANSAS CITY POWER & LIGHT: |_A CYGNE 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
12/80 A
B
C
D
E
F
G
1
SYSTEM
97.8
98.0
98.1
.0
98.5
98.2
95.2
98.9
98.9
96.7
96.3
97.1
.0
97.7
93.8
90.6
93.6
93.6
96.9
97.0
97.3
.0
97.8
97.4
92.8
98.1
98.1
66.7
66.4
66.9
.0
67.3
64.6
62.5
64.5
64.5 720 513 427 45.2
•«* PROBLEMS/SOLUTIONS/COMMENTS
MODULE D REMAINED OUT OF SERVICE THE ENTIRE MONTH DUE TO THE NECESSARY
REPAIRS CAUSED BY FIRE DAMAGE IN OCTOBER.
THE UTILITY REPORTED NO MAJOR FGD-REUTED PROBLEMS OCCURRED DURING THE
MONTH OF DECEMBER.
271
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAF.E
UNIT NJME.ER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICIPATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PUNT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MW
NET UNCT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVA.ENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FU:L TYPE
FU£L GRADE
AVERAGE HEAT CONTENT - J/S
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - '/.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** ESP
NUMBER
TYPE
SUPPLIER
INLET FLUE GAS CAPACITY - CU.M/S
INLET FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
PARTICLE REMOVAL EFFICENCY - 7.
** PARTICLE SCRUBBER
GENERIC TYPE
SPECIFIC TYPE
*** FGD SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAHAY PRODUCT
502 REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
UNIT DESIGN S02 REMOVAL EFFICIENCY - 7.
CURRENT STATUS
INITIAL START-UP
( .100 LB/MMBTU)
( .300 LB/MMBTU)
(*#**** LB/MMBTU)
KANSAS POWER S LIGHT
JEFFREY
1
WAMEGO
KANSAS
D
43.
129.
******
2720
720
680
*****
5*0
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
******** (**«**** ACFM)
135.6 ( 276 F)
183. ( 600 FT)
CONCRETE
7.9 ( 26.0 FT)
COAL
18899.
5.80
******
28.00
******
.32
******
.01
******
COLD SIDE
C.E. WALTHEf?.
1327.9
139.4
.0
98.6
NONE
N/A
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
NONE
COMBUSTION ENGINEERING
BLACK & VEATCH
FULL SCALE
NEW
X 99.00
80.00
1
8/78
( 8125 BTU/LB)
******
(2814000 ACFM)
( 283 F)
( 0. IN-H20)
272
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
KANSAS POWER & LIGHT: JEFFREY 1 (CONT.)
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
** ABSORBER
NJM8ER
NUMBER OF SPARES
GENERIC TYPE
SPECIFIC TYPE
SJFPLIER
S JELL GENERIC MATERIAL
SiELI SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME 'COMMON TYPE
LINE'^ GENERIC MATERIAL
LINER SPECIFIC MATERIAL
LINER MATERIAL TRADE NAME/ COMMON TYPE
L/G RATIO - L/CU.M
CIS-SIDE PRESSURE DROP - K 'A
SOa REMOVAL EFFICIENCY - I.
7/73
6
1
SPRAY TOWER
OPEN COUNTERCURRENT SPRAY
COMBUSTION ENGINEERING
STAINLESS STcEL
AUSTENITIC
TYPE 316L
NONE
N/A
N/A
1.0
60.0
( 30.4 GAL/1000 ACF)
( 4.0 IN-H20)
** MIJiT ELIMINATOR
PPE-MIST ELIMINATOR/MIST ELIMINATOR
GF.N'ERIC TYPE
SPECIFIC TYPE
THADE NAME/COMMON TYPE
CONFIGURATION
NUMBER OF STAGES
NUIT3ER OF PASSES PER STAGE
FI.'EEBOARD DISTANCE - M
DISTANCE BETWEEN VANES - CM
V>\HE ANGLES - DEGREES
SUPERFICAL GAS VELOCITY - M/S
CONSTRUCTION MATERIAL GENERIC TYPE
WASH WATER SOURCE
** REHEATER
NIMBER
GENERIC TYPE
SPECIFIC TYPE
TRXDE NAME/COMMON TYPE
PERCENT GAS BYPASSED - AVG
TE.1FERATURE INCREASE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** FANS
NUMBER
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
#* DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
#* REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
NUMBER
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
MIST ELIMINATOR
IMPINGEMENT
BAFFLE
CHEVRON VANE
HORIZONTAL
Z
Z
1.22
5.1
45
.3
FIBERGLASS
POND WATER
1
BYPASS
COLD SIDE
N/A
25.0
7.2
FRP
4.0 FT)
2.00 IN)
( 1.0 FT/S)
( 45 F)
GREEN FAN
BALANCED DRAFT
BOILER I.D.
DRY
135.6 ( 276 F)
CARBON STEEL
SCRUBBER INLET
CARBON STEEL
NONE
SCRUBBER OUTLET TO STACK
CARBON STEEL
GUNITE FROM BYPASS REHEAT SECTION TO STACK
LIMESTONE GRINDING
BALL MILL
1
10.9 ( 12 TPH)
273
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
KANSAS POWER & LIGHT: JEFFREY 1 (CONT.)
** TANKS
SERVICE
REACTION
** PUMPS
SERVICE
ABSORBER RECIRCULATION
*** SLUDGE
** TREATMENT
** DISPOSAL
NVTURE
T'PE
LOCATION
SITE TRANSPORTATION METHOD
** WATER BALANCE
WVTER LOOP TYPE
MAKEUP WATER ADDITION - MTERS/S
** FG;> SPARE CAPACITY INDICES
ABSORBER - X
** FGD SPARE COMPONENT INDICES
AKS03BER
NUMBER
4
NUMBER
6
FINAL
POND
OH SITE
PUMPED
CLOSED
35.1
ZQ.O
1.0
( 557 6PM)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
8/78 SYSTEM
744
** PROBLEMS/SOLUTIONS/COMMENTS
9/78 SYSTEM
10/78 SYSTEM
11/78 SYSTEM
12/78 JlYSTEM
THE BOILER AND TURBINE WERE SYNCHRONIZED ON JUNE 11 AND THE BOILER IS
NOW OPERATIONAL.
THE FGD SYSTEM IS IN THE SHAKEDOWN PHASE OF OPERATION. EACH OF THE SIX
MODULES OPERATED DURING THIS PERIOD. NO MAJOR PROBLEMS WERE REPCSTED.
INTEGRATED OPERATION OF THE SYSTEM IS EXPECTED DURING THE FIRST HALF OF
OCTOBER.
720
720
744
»•* PROBLEMS/SOLUTIONS/COMMF.NTS
1/79 SYSTEM
2/79 SYSTEM
3/79 SYSTEM
INTEGRATED OPERATION FOR THIS UNIT HAS NOT YET BEEN ACHIEVED. A CERTIF-
ICATION TEST WHICH HAD BEEN SCHEDULED WAS CANCELLED DUE TO A BOILER
OUTAGE. AT THIS TIME THE COLD WEATHER HAS FORCED POSTPOHMENT OF THE TEST
INDEFINITELY. INTERMITTENT FGD OPERATIONS ARE CONTINUING.
744
672
744
274
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
KANSAS POWER & LIGHT: JEFFREY 1 (CONT.)
------------------------------------------ PERFORMANCE DATA ------------------------------------------
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
— — — — — — M «.«•»•>• *• ____________ ___________ ___________ ___•_,._._...•• _____ _____ _____ ______ — ..___ ______
** PROBLEMS/SOLUTIONS/COMMENTS
NO BOILER OR FGD SYSTEM PROBLEMS WERE REPORTED FOR FEBRUARY OR MARCH.
4/79 SYSTEM .0 720 0 0 .0
5/79 SYSTEM .0 744 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS SHUT DOWN FOR WARRANTY INSPECTION ON APRIL 1 AND REMAINED
OUT OF SERVICE DURING MAY.
6/79 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE UNIT RETURNED TO SERVICE THE FIRST WEEK OF
JUNE AND HAS SUFFERED NO OPERATIONAL DIFFICULTIES SINCE RESTART.
7/79 SYSTEM
8/79 SYSTEM
9/79 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
NO UNUSUAL BOILER OR FGD SYSTEM PROBLEMS WERE ENCOUNTERED DURING JULY OR
AUGUST. THE UNIT PASSED THE COMPLIANCE TEST DURING THE JUNE-JULY PERIOD.
THE UMIT WILL SHUT DOWN IN MID-SEPTEMBER FOR THE NORMAL TWO WEEK INSPECTION
AND MAINTENANCE OUTAGE. THE UNIT XS EXPECTED BACK ON LINE ON OCTOBER 1.
10/79 SYSTEM 744
11/79 SY5TEM 720
12/79 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY HAS REPORTED THAT THERE HAS BEEN NO MAJOR OPERATING PROBLEMS
DURING THIS REPORT PERIOD. EXCESSIVE BALL WEAR IN THE LIMESTONE BALL
MILL WAS DETECTED.
AGITATOR FAILURES IN THE REACTION TANK HAVE OCCURRED. THE AGITATORS HAVE
EXPERIENCED MOTOR FAILURES, PADDLE ARM DETACHMENTS AND SHAFT BREAKING.
1/80 SYSTEM 744
2/80 SYSTEM 696
3/80 SYSTEM 100.0 100.0 100.0 67.7 744 504 504
«* PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WENT OFF LINE FOR TEN DAYS IN MARCH FOR A SCHEDULED INSPECTION.
DURING THE BOILER OUTAGE GENERAL MAINTENANCE WAS PERFORMED ON THE FGD
SYSTEM. OTHER THAN THIS OUTAGE, THE FGD UNIT OPERATED 100X OF THE TIME
IN MARCH.
4/80 SYSTEM 100.0 100.0 100.0 100.0 720 720 720
5/80 SYSTEM 100.0 100.0 100.0 100.0 744 744 744
275
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
KANSAS POWER & LIGHT: JEFFREY 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
6/80 SYSTEM 100.0 100.0 100.0 100.0 720 720 720
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE APRIL THROUGH JUNE PERIOD THE FGD SYSTEM OPERATED 100X OF THE
TIME.
7/80 SYSTEM 100.0 100.0 100.0 69.1 744 514 514 49.3
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JULY A 230 HOUR OUTAGE OCCURRED DUE TO A REHEATER TUBE LEAK IN
THE BOILER. NO FGD-RELATED PROBLEMS OCCURRED DURING THE MONTH.
8/80 SYSTEM 100.0 100.0 100.0 84.8 744 631 631 42.8
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS TAKEN OUT OF SERVICE FOR PART OF AUGUST SO REPAIRS
COULD BE CONDUCTED ON A BOILER REHEAT TUBE.
9/80 SYSTEM 100.0 100.0 100.0 100.0 720 720 720 67.7
** PROBLEMS/SOLUTIONS/COMMENTS
NO PROBLEMS WITH THE BOILER OR THE FGD SYSTEM WERE ENCOUNTERED DURING
SEPTEMBER.
10/80 SYSTEM 100.0 100.0 100.0 37.4 744 278 278
** PROBLEMS/SOLUTIONS/COMMENTS
DURING OCTOBER THE BOILER DID NOT OPERATE FOR APPROXIMATELY 466 HOURS DUE
TO A SCHEDULED INSPECTION.
11/80 SYSTEM 99.9 99.8 99.8 86.8 720 626 625
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS OUT OF SERVICE APPROXIMATELY 94 HOURS DUE TO BOILER
INSPECTION AND BEARING FAILURES.
THE FGD SYSTEM WAS DOWN APPROXIMATELY ONE HOUR DUE TO AN AUTOMATIC DAMPER
MALFUNCTION.
12/80 SYSTEM 100.0 110.0 100.0 98.5 744 733 733
** PROBLEMS/SOLUTIONS/C01IMENTS
DURING DECEMBER THE FGD SYSTEM WAS AVAILABLE 1002.
A BOILER OUTAGE DURING THE MONTH WAS DUE TO A AIR PREHEATER PROBLEM.
Z76
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MM
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY KO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** ESP
NUMBER
TYPE
SUPPLIER
INLET FLUE GAS CAPACITY - CU.M/S
INLET FLUE GAS TEMPERATURE - C
PARTICLE REMOVAL EFFICENCY - 7.
** PARTICLE SCRUBBER
GcNERIC TYPE
SPECIFIC TYPE
*** FG3 SYSTEM
** GENERAL DATA
SALEABLE PPODUCT/THROWAWAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEH/r.ETROFIT
UNIT DESIGN S02 REMOVAL EFFICIENCY - 7.
CURRENT STATUS
COMt.ERCIAL START-UP
IMI1IAL START-UP
CONTRACT AWARDED
KANSAS POWER & LIGHT
JEFFREY
2
WAMEGO
KANSAS
<****** LB/MMBTU)
(****** LB/MMBTU)
(****** LB/MMBTU)
******
******
*****
700
680
*****
490
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
******** (******* ACFM)
******* (**** F)
183. ( 600 FT)
******
******* (***** FT)
COAL
******
188*1. ( 8100 BTU/LB)
******
5.80
7-8
38.00
******
.30
******
********
******
COLD SIDE
COMBUSTION ENGINEERING
1327.9 (2814000 ACFM)
139.4 ( 283 F)
98.6
NONE
N/A
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
COMBUSTION ENGINEERING
BLACK 8 VEATCH
FULL SCALE
NEW
80.00
1
1/80
4/80
7/73
277
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
KANSAS POWER & LIGHT: JEFFREY 2 CCONT.)
** DES.IGN AND OPERATING PARAMETERS
** ABSORBER
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SH'iLL MATERIAL TRADE NAME/COMMON TYPE
LI-JER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
L/G RATIO - L/CU.M
S02 REMOVAL EFFICIENCY - X
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
** REHEATER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
PERCENT GAS BYPASSED - AVG
TEMPERATURE INCREASE - C
*** SLUDGE
** TREATMENT
METHOD
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
** WATER BALANCE
WATER LOOP TYPE
SPRAY TOWER
OPEN COUNTERCURRENT SPRAY
COMBUSTION ENGINEERING
STAINLESS STEEL
AUSTENITIC
TYPE 316L
NONE
N/A
N/A
( 30.4 GAL/1000 ACF)
60.0
MIST ELIMINATOR
IMPINGEMENT
BAFFLE
CHEVRON VANE
BYPASS
COLD SIDE
N/A
30.0
7.2
F)
BOTTOM ASH STABILIZATION
FINAL
LINED POND
ON SITE
PUMPED
CLOSED
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
1/80 SYSTEM
2/80 SYSTEM
3/80 SYSTEM
** PROBLEMS/SOLUTIONS/COHMENTS
744
696
744
INITIAL OPERATIONS AT JEFFREY 2 BEGAN IN JANUARY 1980. NO MAJOR PROBLEMS
HAVE BEEN ENCOUNTERED SINCE STARTUP.
4/80 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
DURING APRIL THE SYSTEM KAS STILL IN THE SHAKEDOWN/DEBUGGING PHASE.
5/80 SYSTEM 100.0 100.0 100.0 100.0 744 744 744
6/80 SYSTEM 100.0 100.0 100.0 100.0 720 720 720
278
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER I960
KANSAS POWER & LIGHT: JEFFREY Z (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
— —
** PROBLEMS/SOLUTIONS/COMMENTS
COMMERCIAL OPERATIONS BEGAN ON MAY 1, 1980. SINCE THEN THERE HAVE BEEN
NO PROBLEMS ENCOUNTERED WITH THE FGD SYSTEM. THE UNIT HAS OPERATED 100Z
OF THE TIME.
7/80 SYSTEM 100.0 100.0 100.0 95.3 744 709 709 81.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JULY A 35 HOUR OUTAGE OCCURRED DUE TO A REHEATER TUBE LEAK IN THE
BOILER. NO FGD-RELATED OUTAGES OCCURRED DURING THE MONTH.
8/80 SYSTEM 100.0 100.0 100.0 100.0 744 744 744 80.1
9/80 SYSTEM 100.0 100.0 100.0 100.0 730 720 720 73.3
** PROBLEMS/SOLUTIONS/COMMENTS
NO PROBLEMS WERE ENCOUNTERED WITH THE BOILER OR THE FGD SYSTEM DURING THE
AUGUST AND SEPTEMBER PERIOD.
10/80 SYSTEM 100.0 100.0 100.0 100.0 744 744 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR PROBLEMS WERE ENCOUNTERED DURING THE
MONTH OF OCTOBER.
11/80 SYSTEM 100.0 100.0 100.0 56.1 720 404 404
** PROBLEMS/SOLUTIONS/COMMENTS
DURING NOVEMBER NO MAJOR FGD-RELATED PROBLEMS OCCURRED. HOWEVER, THE BOIL-
ER WAS OUT OF SERVICE APPROXIMATELY 316 HOURS DUE TO A SCHEDULE OUTAGE.
12/80 SYSTEM 100.0 100.0 100.0 62.9 744 468 468
** PROBLEMS/SOLUTIONS/COMMENTS
DURING DECEMBER THE BOILER WAS OUT OF SERVICE DUE TO SUPERHEATER TUBE PROB-
LEMS. DURING THIS TIME THE FGD SYSTEM WAS 100X AVAILABLE.
?79
-------
EPA ITILITY F6D SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY N'ME
PLANT NAM-
UNIT NUM2ER
CITY
STATE
REGULATOPY CLASSIFICATION
PARTICUL/TE EMISSION LIMITATION - NG/J
502 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLWT GENERATING CAPACITY - HW
GROSS 'JNIT GENERATING CAPACITY - MW
NET UNCT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.tt/S
BJILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUt L DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
R/NGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RA.iGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - '/.
RA's'GE MOISTURE CONTENT - '/.
AVERAGE SULFUR CONTENT - 7.
RjSNGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - "/.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** ESP
NUMBER
TYPE
INLET FLUE GAS CAPACITY - CU.M/S
INLET FLUE GAS TEMPERATURE - C
PARTICLE REMOVAL EFFICENCY - 7.
** PARTICLE SCRUBBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
LIQUID RECIRCULATION RATE - LITER/S
L/G RATIO - LITER/CU.M
PRESSURE DROP - KPA
INLET GAS FLOW RATE - CU.M/S
INLET GAS TEMPERATURE - C
*** FGD SYSTEM
KANSAS POWEH 8 LIGHT
LAURENCE
4
LAWRENCE
KANSAS
D
43.
129.
( .100 LB/MMBTU)
( .300 LB/MMBTU)
(****** LB/MMBTU)
576
125
115
125
COMBUSTION ENGINEERING
PULVERIZED COAL
CYCLING
190.18
137.8
37.
CARBON STEEL
2.4
f 403000 ACFM)
( 280 F)
( 120 FT)
( 8.0 FT)
COAL
******
23260.
9.80
12.00
******
.55
******
.03
******
COLD SIDE
165.2
147.2
99.0
( 10000 BTU/LB)
******
( 350000 ACFM)
( 297 F)
VENTURI TOWER
VARIABLE-THROAT/VERTICALLY-ADJUSTABLE ROD DECKS
COMBUSTION ENGINEERING
3 X 23
STAINLESS STEEL
AUSTENITIC
NONE
N/A
RUBBER COATED FIBERGLASS (NORYL) RODS tSPRAY NOZ
226.8
2.4
2.2
95.1
137.8
( 3600 GPM)
(18.0 GAL/1000ACF)
( 9.0 IN-H20)
( 201500 ACFM)
( 280 F)
280
-------
KANSAS POWER & LIGHT: LAWRENCE 4 (CONT. )
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
FROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
LNIT DESIGN S02 REMOVAL EFFICIENCY - X
CURRENT STATUS
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
** ABSOPBER
NUflHER
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
SHELL GENERIC MATERIAL
S1ELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LCNER SPECIFIC MATERIAL
LCNER MATERIAL TRADE NAME/COMMON TYPE
GAS CONTACTING DEVICE TYPE
NJHBER OF CONTACTING ZONES
LIQUID RECIRCULATION RATE - LITER/S
L/C RATIO - L/CU.M
G^S-SIDE PRESSURE DROP - KPA
I.^LET GAS FLOW - CU. M/S
I.4LET GAS TEMPERATURE - C
S02 REMOVAL EFFICIENCY - X
PARTICLE REMOVAL EFFICENCY - X
** MIST ELIMINATOR
PfE-MIST ELIMINATOR/MIST ELIMINATOR
Nl'flSES PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
NU13ER OF STAGES
NUMBER OF PASSES PER STAGE
FREEBOARD DISTANCE - M
DISTANCE BETWEEN STAGES - CM
DISTANCE BETWEEN VANES - CM
VANE ANGLES - DEGREES
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/S
CONSTRUCTION MATERIAL GENERIC TYPE
WASH WATER SOURCE
WASH RATE - L/S
** REHEATER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
TEMPERATURE INCREASE - C
INLET FLUE GAS FLOU RATE - CU. M/S
INLET FLUE GAS TEMPERATURE - C
NUMBER OF TUBES PER BUNDLE
CONSTRUCTION MATERIAL GENERIC TYPE
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
NONE
COMBUSTION ENGINEERING
BLACK & VEATCH
FULL SCALE
RETROFIT
X 98.90
73.00
1
1/77
12/68
SPRAY TOWER
OPEN COUNTERCURRENT SPRAY
COMBUSTION ENGINEERING
STAINLESS STEEL
AUSTENITIC
TYPE 316L
NONE
N/A
N/A
7 IN DIA. RODS
2
334.
4.0
.6
82.35
51.1
73.0
98.9
( 5300 GPM)
( 30.0 GAL/1000 ACF)
( 2.5 IN-H20)
( 174500 ACFM)
( 124 F)
MIST ELIMINATOR
8
IMPINGEMENT
BAFFLE
CHEVRON VANE
HORIZONTAL
2
2
1.07 (
2.54 (
8.9 (
90
.2 (
1.8 (
3.5 FT)
1.0 IN)
3.50 IN)
1.0 IN-H20)
6.0 FT/S)
FIBERGLASS REINFORCED PLASTIC
COOLING TOWER SLOWDOWN
315.4 ( 5000 GAL/MIN)
1
IN-LINE
HOT WATER
FIN TUBE
10.0
171.30
62.2
66
CARBON STEEL
( 50 F)
( 363000 ACFM)
( 144 F)
281
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
KANSAS POWER 4 LIGHT: LAWRENCE 4 (CONT.)
** FANS
NUMBER
SUPPLIER
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S &
FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
** DUCTKORK
LOCATION
SHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DcVICE
NUMBER
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
** TA\"KS
SERVICE
T3'r!Efc RECIRCULATION TANK
VENTURI RECYCLE
CLARIFICATION & COLLECTION TANK
DILUTION
REACTION BLEED TANK
BUFFALO FORGE
BOILER I.D.
DRY
80.22 ( 170000 ACFM)
62.2 ( 144 F)
CARBON STEEL
SCRUBBER INLET
CARBON STEEL
NONE
SCRUBBER OUTLET
CARBON STEEL
NONE
LIMESTONE GRINDING
BALL MILL
2
5.4 ( 6 TPH)
NUMBER
SERVICE
SLURRY FEED
M..ST ELIMINATOR WASH
M;LL SLURRY
CLASSIFICATION TANK TRANSFER
VcNTURI RECIRCULATION
ABSORBER RECIRCULATION
** SO'.IDS CONCENTRATING/DEWATERING
D.ZVICE
N'JflBER
*** SLUDGE
** TREATMENT
METHOD
IKLET QUALITY - X
** DISPOSAL
NATURE
TYPE
LOCATION
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
** DISPOSAL
NATURE
TYPE
NUMBER
6
THICKENER
1
FORCED OXIDATION
32.5
INTERIM
POND
ON SITE
FINAL
POND
ON SITE
OVERFLOW FROM INTERIM SLUDGE POND
FINAL
POND
282
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
KANSAS POWER & LIGHT: LAWRENCE 4 (CONT.)
LOCATION ON SITE
SITE TRANSPORTATION METHOD OVERFLOW FROM INTERIM SLUDGE POND
** DISPOSAL
NATURE FINAL
TYPE POND
LOCATION ON SITE
** DISPOSAL
NATURE FINAL
TYPE POND
LOCATION ON SITE
** PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS SOZ, SLURRY FLOWS, PH, X SOLIDS, PRESSURE DROP
CONTROL LEVELS PH = 5.5-5.7
MONITOR LOCATION PH PROBES IN REACTION TANKS
PROCESS CONTROL MANNER AUTOMATIC
PROCESS CHEMISTRY MODE FEEDBACK
** WATER BALANCE
WATER LOOP TYPE CLOSED
** FGD SPARE CAPACITY INDICES
ABSORBER - X .0
** FGD SPARE COMPONENT INDICES
ABSORBER .0
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
0/69 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
PROBLEMS WITH THE FGD SYSTEM ON BOILER NO. 4 INCLUDED BUILDUP AND PLUGGING
OF THE INLET DUCT WHERE HOT GASES ENTER THE SCRUBBERS, EROSION OF SCRUBBER
WALLS, CORROSION OF SCRUBBERS INTERNALS, BUILDUP ON ID FAN ROTORS, AST)
PLUGGING OF DRAIN LINES, MARBLE BEDS, AND MIST ELIMINATORS. LOW SOS
REMOVAL WAS CAUSED BY OVERBURNING OF THE LIMESTONE AND DROPOUT OF THE LIME
WITH "HE ASH IN THE BOTTOM OF THr SCRUBBER.
THE SCRUBBERS WERE MODIFIED IN 1969 BY RAISING THE MIST ELIMINATOR AND
ADDIK'3 SOOT BLOWERS IN THE INLET DUCT AND REHEATER TO REDUCE PLUGGING.
NEW SPRAY NOZZLES WERE ALSO INSTALLED. REHEATER PLUGGING WAS ELIMINATED
BY REPLACING COPPER REHEAT COILS WITH A CARBON STEEL UNIT HAVING WIDELY
SPACED FINS.
0/70 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
MAJOR MODIFICATIONS IN 1970 WERE SANDBLASTING AND COATING OF THE INTERIOR
OF THE SCRUBBERS, REPLACEMENT OF ALL INTERNAL STEEL PIPES WITH PLASTIC AND
FIBERGLASS, AND REPLACEMENT OF STAINLESS STEEL MIST ELIMINATORS WITH
FIBERGLASS. SINCE MIST ELIMINATOR PLUGGING WAS NOT COMPLETELY STOPPED,
THE UNIT WAS WASHED MANUALLY EVERY NIGHT TO MAINTAIN THE REQUIRED MODULE
SERVICE.
0/72 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
THE MODIFICATIONS IN THE SUMMER OF 1972 ON THE TWO FGD MODULES INCLUDED
ENLARGEMENT OF THE CRYSTALLIZATION TANK, AND INSTALLATION OF NEW PLASTIC
SPRAY NOZZLES, NEW SLURRY PUMPS AND STRAINERS, AND NEW MULTIPLE MIXERS
283
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
KANSAS POWER & LIGHT: LAWRENCE 4 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
IN THE TANK. PROBLEMS THAT REMAINED INCLUDED CORROSION, INEFFICIENT
DAMPERS, EXPANSION JOINT FAILURE, MIST ELIMINATOR FOULING, RAPID EROSION
OF THE SLURRY PUMP, AND VALVE FAILURE.
0/73 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
OPERATION OF THE FGD SYSTEM SINCE THE FALL OF 1973 HAS BEEN THE MOST
SUCCESSFUL TO DATE.
0/74 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
IN 1974 THIS UNIT WAS AVAILABLE FOR OPERATION 343 DAYS. 50X OF THE FUEL
CONSUMED WAS COAL, 2X FUEL OIL, AND 48X NATURAL GAS.
0/75 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
DURING 1975 THIS UNIT WAS AVAILABLE FOR OPERATION 333 DAYS. 64X OF THE
FUEL CONSUMED WAS COAL, 33X FUEL OIL, AND 33X NATURAL GAS.
THE UTILITY COMPLETED NEGOTIATIONS FOR A LOW-SULFUR COAL SUPPLY FROM
SOUTHEAST WYOMING .(MEDICINE BOW) IN 1974. THE HIGH-SULFUR KANSAS COAL WAS
COMPLETELY PHASED OUT BY LATE SPRING OF 1975. THIS IMPROVED SCRUBBER OPER-
ATIONS BECAUSE OF REDUCED SULFUR REMOVAL REQUIREMENTS AND THE ALKALINE
SPECIES IN THE NEW COAL REDUCED THE AMOUNT OF NECESSARY LIMESTONE
ADDITION.
6/75 SYSTEM 7ZO
** PROBLEMS/SOLUTIONS/COMMENTS
STATION LOAD IS REDUCED TO SOX EVERY NIGHT. THEREFORE, ONE OF THE
MODULES CAN BE TAKEN OFF-LINE NIGHTLY FOR CLEANING OR REPAIR. WYOMING
COAL (0.5X SULFUR) IS NOW BEING BURNED IN THE BOILER FURNACE. SOME
NATURAL GAS HAS BEEN BURNED SINCE JUNE 20, 1975.
7/75 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
EACH MODULE HAS BEEN SHUT DOWN ONCF PER WEEK FOR INSPECTION AND CLEAN-
UP.
8/75 SYSTEM 744
9/75 SYSTEM 720
10/75 SKSTEM 744
11/75 SYSTEM 720
12/75 SYSTEM 744
1/76 SYSTEM 744
284
-------
EPA UTILITY FGO SURVEY: OCTOBER - DECEMBER 1980
KANSAS i'OWER & LIGHT: LAWRENCE 4 (CONT.)
------------------------------------------ PERFORMANCE DATA ------------------------------------------
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
502 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY IS REPLACING THE LINESTONE INJECTION FGD SYSTEM WITH A ROD-
DECK VENTURI/SPRAY TOWER FGD SYSTEM. THE NEW SYSTEM WILL BE BROUGHT ON
LINE IN EARLY JANUARY 1977.
2/76 SYSTEM
696
3/76 SYSTEM
4/76 SYSTEM
5/76 SYSTEM
6/76 SYSTEM
7/76 SYSTEM
8/76 SYSTEM
9/76 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
720
744
720
744
744
720
10/76 SYSTEM
11/76 SYSTEM
12/76 SYSTEM
1/77 SYSTEM
A SCHEDULED UNIT OUTAGE BEGAN IN MID-SEPTEMBER FOR A TURBINE OVERHAUL.
THE UNIT IS SCHEDULED TO COME BACK ON LINE IN EARLY JANUARY.
744
720
744
744
*# PROBLEMS/SOLUTIONS/COMMENTS
2/77 SYSTEM
3/77 SYSTEM
THE NEW LIMESTONE FGD SYSTEM BECAME COMMERCIALLY OPERABLE IN EARLY
JANUARY 1977. THE UTILITY REPORTED THAT BOTH PARTICULATE AND S02 REMOVALS
IN THE ROD-DECK VENTURI/SPRAY TOWER SCRUBBING UNIT ARE QUITE SATISFACTORY.
672
744
** PROBLEMS/SOLUTIONS/COMMENTS
4/77 SYSTEM
MINOR PROBLEMS HAVE BEEN RELATED TO MAINTAINING DESIRED SOLIDS LEVEL IN
THE MAKE-UP TANK. MODIFICATION PLANS INCLUDE CESSATION OF SLURRY DILU-
TION, WHICH CURRENTLY PRECEDES THE INTRODUCTION OF THE FRESH LIMESTONE
SLURRY INTO THE RECIRCULATION LOOP. THE UTILITY PLANS TO PUMP THE 35X
SOLIDS SLURRY DIRECTLY FROM THE SLURRY TANK INTO THE RECIRCULATION LOOP.
CURRENTLY SEVERAL DIFFERENT MAKES OF SLURRY PUMPS ARE BEING USED. ALL
ARE FUNCTIONING WELL SO FAR. THE PUMPS HAVE NOT BEEN IN SERVICE LONG
ENOUGH FOR COMPARISONS TO BE DRAWN.
720
285
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
KANSAS POWER & LIGHT: LAWRENCE 4 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
»* PROBLEMS/SOLUTIONS/COMMENTS
THE SCRUBBER WAS NOT REQUIRED FOR SERVICE DURING THE REPORT PERIOD BECAUSE
NATURAL GAS WAS FIRED IN THE BOILER.
5/77 SYSTEM 744
6/77 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
MIST ELIMINATOR CRACKS HAVE BEEN A PROBLEM.
A COMPRESSOR BREAKDOWN IN THE RECYCLE TANK AIR AGITATION SYSTEM AND THE
RECYCLE TANK STRAINER SCREEN WASH HAVE BEEN PROBLEM AREAS. THE WASH
SYSTEM HAS BEEN TWISTING OFF UNDER WATER PRESSURE.
SOOT BLOWER PROBLEMS WERE ENCOUNTERED.
THE DENVER SLURRY PUMPS ARE EXPERIENCING SOME ON-GOING PROBLEMS, WHILE
THE ALLEN-SHERMAN-HOFF PUMPS ARE OPERATING SATISFACTORILY.
7/77 SYSTEM 744
8/77 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER BURNED NATURAL GAS THROUGHOUT AUGUST.
THE MIST ELIMINATOR CRACKS HAVE BEEN REPAIRED.
THE RECYCLE TANK STRAINER PROBLEMS PERSISTED AMD THE AIR AGITATION SYSTEM
COMPRESSOR WAS MALFUNCTIONING RESULTING IN SOLIDS SETTLING IN THE RECYCLE
TANK.
THE DENVER SLURRY PUMPS ARE FUNCTIONING ADEQUATELY AT PRESENT. THE PUMP
GLAND PACKINGS ARE BEING REDESIGNED.
9/77 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE NO. 4 BOILER HAS BEEN FIRING 100X NATURAL GAS FOR ALL BUT 8 TO 10
DAYS SINCE THE BEGINNING OF APRIL 1977. AS OF SEPTEMBER 15 THE UNIT
BEGAN BURNING COAL AGAIN.
10/77 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE SYSTEM LOAD WAS CUT BACK TO SOX IN OCTOBER BECAUSE A NEW COOLING
TOWER IS BEING CONSTRUCTED.
11/77 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
ON NOVEMBER 15 A MAJOR FGD SYSTEM OVERHAUL TOOK PLACE WHILE THE TURBINE
WAS DOUN FOR INSPECTION AND THE NEW COOLING TOWER WAS BEING CONNECTED.
12/77 SYSTEM 744
286
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
KANSAS POWER & LIGHT: LAWRENCE •'» CCONT.)
------------------------------------------- PERFORMANCE DATA ------------------------------------------
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
— — — — — — __<____ ____________ — — — — — — _ — ___ — — — —^ — — — — — ^ — — ——, — — .• — _^_ _____ _ — — —.. «_ — — _ ______ _ — — — — _.__ — __
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT CAME BACK ON LINE DECEMBER 20 AT FULL CAPACITY. THE TURBINES
WERE BALANCED DURING DECEMBER.
1/78 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM OPERATED WITHOUT ANY PROBLEMS OTHER THAU SOME FREEZING OF
THE PIPELINES.
THICKENER DISCHARGE LINE FREEZING CAUSED CLARIFIER PLUGGING.
2/78 SYSTEM 672
** PROBLEMS/SOLUTIONS/COMMENTS
THE THICKENER UNDERFLOW LINE IS STILL FROZEN AND TWO 3 INCH DIAMETER FIRE
HOSES ARE BEING USED TO PUMP THE UNDERFLOW SOLIDS TO THE POND.
3/78 SYSTEM
4/78
5/78
6/78
7/78
A
B
SYSTEM
A
B
SYSTEM
A
B
SYSTEM
A
B
SYSTEM
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0 720 720 720
100.0
100.0
100.0 744 744 744
100.0
100.0
100.0 720 720 720
100.0
100.0
100.0 744 744 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER AND FGD SYSTEM BOTH OPERATED THROUGHOUT JUNE AND JULY WITHOUT
ANY FORCED OUTAGES.
8/78 A 100.0 100.0 100.0
B 100.0 100.0 100.0
SYSTEM 100.0 100.0 100.0 744 744 744
9/78 A 100.0 100.0 63.0
B 100.0 100.0 63.0
SYSTEM 100.0 100.0 63.0 720 456 456
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE SYSTEM RAN WITH NO FORCED OUTAGES DURING
AUGUST AND SEPTEMBER.
THE UNIT WAS DOWN THE LAST WEEK AND A HALF IN SEPTEMBER FOR A SCHEDULED
FALL TURBINE/BOILER OUTAGE. ROUTINE MAINTENANCE INCLUDED BOILER AND
TURBINE CLEANING AND REPAIR.
10/78 SYSTEM 744 576
11/78 SYSTEM 720 720
287
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
KANSAS POWER & LIGHT: LAWRENCE 4 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
12/78 SYSTEM 744 744
*» PROBLEMS/SOLUTIONS/CO1MENTS
AN EP4 SPONSORED CONTINUOUS MONITORING TEST BEGAN AT THIS UNIT AT THE
BEGIIiNING OF DECEMBER AND WILL CONTINUE THROUGH THE END OF JANUARY. THE
TEST INVOLVES 24 HOUR MONITORING OF 502, OPACITY AND NOX.
1/79 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
AN ID FAN WAS FORCED OUT OF SERVICE ON JANUARY B FORCING THE UNIT TO
OPERATE AT SOX CAPACITY. THE FAN IS EXPECTED TO BE REPLACED BY
JANUARY 12.
2/79 A 96.0 96.0 96.0
B 71.0 71.0 71.0
SYSTEM 84.0 84.0 84.0 672 672 564
** PROBLEMS/SOLUTIONS/COMMENTS
ONE MODULE WAS FORCED OUT OF SERVICE FOR TWO DAYS WHEN ITS TANK AGITATOR
FAILED.
ONE MODULE WAS FORCED OUT OF SERVICE FOR AN EIGHT DAY PERIOD DUE TO A FAN
MOTOR MALFUNCTION
3/79 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
UNIT 4 EXPERIENCED A MOTOR FAILURE ON AN ID FAN DURING THE FEBRUARY-
MARCH PERIOD.
4/79 SYSTEM 720
5/79 SYSTEM 744
6/79 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE SYSTEM RAN WELL. THE ONLY FGD SYSTEM RELATED
OUTAGES WERE DUE TOA MIXER FAILURE AND GENERAL MAINTENANCE.
7/79 SYSTEM 744
8/79 SYSTEM 744
9/79 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE THIRD QUARTER AN OUTAGE WAS CAUSED BY MIXER MOTOR AND OTHER
MIXER RELATED PROBLEMS. DURING THE OUTAGE MAINTENANCE WAS DONE ON THE
BOILER AND SCRUBBERS AND REPAIR WORK WAS DONE ON THE MIXERS.
10/79 SYSTEM 744
288
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
KANSAS POWER & LIGHT: LAWRENCE 4 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
SOS PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS OPERATED AT HALF LOAD DURING THE LAST WEEK OF SEPTEMBER AND
WAS SHUT DOWN COMPLETELY IN EARLY OCTOBER FOR THE ANNUAL FALL OUTAGE.
11/79 SYSTEM 720
12/79 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS DOWN FOR APPROXIMATELY 10 DAYS OF SCHEDULED OUTAGE FOR FALL
MAINTENANCE.
SOME AGITATOR SHAFT FAILURES OCCUTRED IN THE REACTION TANK CAUSING
MAINTENANCE ATTENTION.
1/80 SYSTEM 100.0 100.0 744 744 744
2/80 SYSTEM 100.0 100.0 696 696 696
3/80 SYSTEM 100.0 100.0 744 744 744
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR PROBLEMS WERE REPORTED FOR THE LAWRENCE 4 SCRUBBER DURING
THE FIRST QUARTER 1980.
4/80 SYSTEM 100.0 100.0 100.0 80.0 720 576 576
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS OFF LINE FOR SIX DAYS IN APRIL FOR A SCHEDULED INSPECTION.
DURING THE BOILER OUTAGE GENERAL MAINTENANCE WAS PERFORMED ON THE FGD
SYSTEM.
5/80 SYSTEM 100.0 100.0 100.0 100.0 744 744 744
6/80 SYSTEM 100.0 100.0 100.0 100.0 720 720 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE FGD SYSTEM OPERATED 100X OF THE TIME IN
MAY AND JUNE.
7/80 SYSTEM 96.8 96.8 96.8 96.8 744 744 720 54.8
** PROBLEMS/SOLUTIONS/COMMENTS
A STORAGE TANK ERODED COMPLETELY THROUGH CAUSING A TWO DAY OUTAGE IN
JULY.
8/80 SYSTEM 100.0 100.0 100.0 100.0 744 744 744 50.2
** PROBLEMS/SOLUTIONS/COW1ENTS
NO PROBLEMS WERE ENCOUNTERED WITH THE FGD SYSTEM OR THE BOILER DURING
AUGUST.
9/80 SYSTEM 96.9 100.0 100.0 40.3 720 290 290 16.4
289
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
KANSAS POWER & LIGHT: LAWRENCE 4 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
SOS PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS OUT OF SERVICE FOR APPROXIMATELY 17 DAYS FOR A BOILER
INSPECTION.
ECONOMIZER WELD REPAIRS CAUSED THE SYSTEM TO REMAIN OUT OF SERVICE FOR
22 HOURS.
10/80 SYSTEM 100.0 100.0 100.0 100.0 744 744 744
** PROBLEMS/SOLUTIONS/COMT1ENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE MONTH OF OCTOBER.
11/80 SYSTEM 100.0 100.0 100.0 89.7 720 646 646
** PROBLEMS/SOLUTIONS/COMMENTS
DURING NOVEMBER THE BOILER WAS OUT OF SERVICE APPROXIMATELY 74 HOURS
DUE TO TUBE LEAKS. THE FGD SYSTEM WAS AVAILABLE 100X DURING THIS TIME.
12/80 SYSTEM 100.0 100.0 100.0 98.1 744 730 730
** PROBLEMS/SOLUTIONS/COMMENTS
DURING DECEMBER 14 HOURS OF OUTAGE TIME WAS DUE TO TRANSFORMER PROBLEMS.
THE FtD SYSTEM WAS AVAILABLE THE FNTIRE MONTH.
290
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7,
FANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** PARTICLE SCRUBBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
NJMBER OF CONTACTING ZONES
LIQUID RECIRCULATION RATE - LITER/S
L/G RATIO - LITER/CU.M
PRESSURE DROP - KPA
IMLET GAS FLOW RATE - CU.M/S
INLET GAS TEMPERATURE - C
*** FG) SYSTEM
** GE.-iERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
S'32 REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A--E FIRM
DEVELOPMENT LEVEL
KANSAS POWER & LIGHT
LAWRENCE
5
LAWRENCE
KANSAS
D
43.
215.
******
58
400
*****
420
COMBUSTION ENGINEERING
PULVERIZED COAL
CYCLING
599.78
148.9
114.
CARBON STEEL
4.9
( .100 LB/MMBTU)
( .500 LB/MMBTU)
(****** LB/MMBTU)
(1271000 ACFM)
( 300 F)
( 375 FT)
( 16.0 FT)
( 10000 BTU/LB)
******
COAL
******
23260.
9.80
******
12.00
******
.55
******
.03
******
VENTURI TOWER
VARIABLE-THNOAT/VERTICALLY-ADJUSTABLE ROD DECKS
COMBUSTION ENGINEERING
5 X 37
STAINLESS T5TEEL
AUSTENITIC
NONE
N/A
316L SS RODS, 2 LEVELS OF SPRAY NOZZLES
655.2
2.1
2.2
299.7
148.9
(10400 GPM)
(16.0 GAL/1000ACF)
( 9.0 IN-H20)
( 635000 ACFM)
( 300 F)
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
NONE
COMBUSTION ENGINEERING
BLACK & VEATCH
FULL SCALE
291
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
KANSAS POWER & LIGHT: LAWRENCE 5 (CONT.)
NEW/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
UNIT DESIGN S02 REMOVAL EFFICIENCY - 7.
CURRENT STATUS
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
** ABSORBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
NUMBER OF CONTACTING ZONES
LIQUID RECIRCULATION RATE - LITER/S
L/G RATIO - L/CU.M
GAS-SIDE PRESSURE DROP - KPA
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
S02 REMOVAL EFFICIENCY - X
PARTICLE REMOVAL EFFICENCY - X
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES PER STAGE
FREEBOARD DISTANCE - M
DISTANCE BETWEEN VANES - CM
VANE ANGLES - DEGREES
PRESSURE DROP - KPA
CONSTRUCTION MATERIAL GENERIC TYPE
WASH WATER SOURCE
WASH RATE - L/S
** REHEATER
NJMBER
GENERIC TYPE
SPECIFIC TYPE
T3ADE NAME/COMMON TYPE
TcMPERATURE INCREASE - C
I^iLET FLUE GAS FLOW RATE - CU. M/S
I'.UET FLUE GAS TEMPERATURE - C
NUMBER OF TUBES PER BUNDLE
CONSTRUCTION MATERIAL GENERIC TYPE
RETROFIT
X 98.90
52.00
1
4/78
9/69
SPRAY TOWER
OPEN COUNTERCURRENT SPRAY
COMBUSTION ENGINEERING
STAINLESS STEEL
AUSTENITIC
TYPE 316 L
NONE
N/A
N/A
1
655.
2.5
.6
256.71
52.2
52.0
98.9
(10400 GPM)
t 19.0 GAL/1000 ACF)
( 2.5 IN-H20)
( 544000 ACFM)
( 126 F)
MIST ELIMINATOR
4
IMPINGEMENT
BAFFLE
CHEVRON VANE
HORIZONTAL
2
07
8.9
3.5 FT)
3.50 IN)
90
(1.0 IN-H20)
FIBERGLASS REINFORCED PLASTIC
COOLING TOWER SLOWDOWN
315.4 ( 5000 GAL/MIN)
1
IN-LINE
HOT WATER
FIN TUBE
10.0
551.18
68.9
66
CARBON STEEL
( 50 F)
(1168000 ACFM)
( 156 F)
#*
NUMBER
SJPPLIER
APPLICATION
SERVICE
FOJf GAS FLOW RATE - CU.M/i
F'.Ut GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** DUCTKORK
LOCATION
SHELL GENERIC MATERIAL TYPE
I.INER GENERIC MATERIAL TYPE
AMERICAN STANDARD
BOILER I.D.
DRY
283.14
52.2
CARBON STEEL
SCRUBBER INLET
CARBON STEEL
NONE
( 600000 ACFM)
( 126 F)
292
-------
KANSAS POWER & LIGHT: LAWRENCE 5 (CONT.)
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
L:;NER GENERIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
NUMBER
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
PRODUCT QUALITY - X SOLIDS
*# TANKS
SERVICE
CLARIFICATION X COLLECTION
DILUTION & STORAGE
** PUMPS
SERVICE
REACTION/RECYCLE TANK BLEED
VENTURI RECIRCULATION
SLURRY FEED
MIST ELIMINATOR WASH
MILL SLURRY
CLASSIFICATION TANK TRANSFER
ABSORBER RECIRCULATION
*** SLUDGE
** TREATMENT
METHOD
INLET QUALITY - X
*« DISPOSAL
NATURE
TYPE
LOCATION
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
** PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS
CONTROL LEVELS
MONITOR LOCATION
PROCESS CONTROL MANNER
PROCESS CHEMISTRY HODE
** WA/ER BALANCE
WATER LOOP TYPE
** FG'.) SPARE CAPACITY INDICES
ABSORBER - X
** FG1) SPARE COMPONENT INDICES
ABSORBER
SCRUBBER OUTLET
CARBON STEEL
NONE
LIMESTONE GRINDING
BALL MILL
2
21.8 ( 24 TPH)
60.0
NUMBER
NUMBER
****
2
3
****
2
2
2
FORCED OXIDATION
10.0
INTERIM
POND
ON SITE
FINAL
POND
ON SITE
OVERFLOW FROM INTERIM SLUDGE POND
FINAL
POND
ON SITE
OVERFLOW FROM INTERIM SLUDGE POND
S02, SLURRY FLOWS, PH, X SOLIDS, PRESSURE CHANGE
PH=5.5-5.7
PH PROBES IN REACTION TANKS
AUTOMATIC
FEEDBACK
CLOSED
.0
.0
293
-------
EPA IT'ILITY FGD SURVEY: OCTOBER - DECEMBER 1980
KANSAS POWER & LIGHT: LAWRENCE 5 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
0/74 SYSTEM
»* PROBLEMS/SOLUTIONS/COMMENTS
THE LAWRENCE 5 BOILER WAS ORIGINALLY EQUIPPED WITH A LIMESTON INJECTION
FGD SYSTEM MODELED AFTER THE FGD SYSTEM RETROFITTED ONTO THE LAURENCE 4
BOILER. CONSTRUCTION OF THE LAURENCE 5 BOILER AND SCRUBBING SYSTEM BEGAN
IN MARCH 1968 AND PROCEEDED SIMULTANEOUSLY WITH THE RETROFIT UORK ON
LAWRENCE 4. INITIAL OPERATION OF THE LAWRENCE 5 BOILER AND SCRUBBING
SYSTEM OCCURRED IN MARCH 1977. COMMERCIAL OPERATIONS WERE ACHIEVED IN
NOVEMBER 1971 WITH THE COMPLETION OF THE SHAKEDOWN PHASE OF OPERATIONS.
THE LIMESTONE INJECTION FGD SYSTEM INCLUDED FACILITIES FOR PULVERIZING
LIMESTONE AND THEN INJECTING IT INTO THE BOILER FURNACE CHAMBER FOR
CALCINATION. THE FLUE GAS TRANSPORTS THE CALCINED LIMESTONE AND FLYASH TO
THE SCRUBBER MODULES, EACH CONSISTING OF A SINGLE MARBLE BED EQUIPPED WITH
OVERFLOW POTS FOR DRAINAGE OF RECIRCULATING SLURRY, FOR PARTICLE AND SULFUR
DIOXIDE REMOVAL. THE CLEANED GASES THEN PASSED THROUGH A SET OF MIST
ELIMINATORS, REHEATERS, AND INDUCED DRAFT FANS BEFORE BEING DISCHARGED
THROUGH THE STACKS TO THE ATMOSPHERE.
ALTHOUGH THE CONFIGURATION OF THIS ORIGINAL SYSTEM WAS FAIRLY SIMPLE,
MANY OPERATING PROBLEMS AND DESIGN INADEQUACIES WERE ENCOUNTERED. IN THE
INJECTION PROCESS IT WAS DIFFICULT TO ACHIEVE SATISFACTORY CONTROL OF THE
LIMESTONE CALCINATION AS WELL AS THE AMOUNT OF LIME/LIMESTONE CARRIED BY
THE FLUE GAS INTO THE TAIL-END SCRUBBERS. THIS PROBLEM WAS FURTHER COM-
PLICATED WHEN THE BOILER WAS FIRED WITH A VARIABLE COMBINATION OF COAL,
NATURAL GAS AND OIL.
THE FGD SYSTEM WAS MODIFIED A NUMBER OF TIMES THROUGHOUT ITS LIFE AND
WAS LATER ABANDONED FOR A NEW SECOND-GENERATION SCRUBBER DESIGN DEVELOPED
BY THE SYSTEM SUPPLIER. THE LIMESTONE INJECTION SYSTEM OPERATED UNTIL
MARCH 20, 1978 WHEN IT WAS SHUTDOWN TO TIE THE NEW ROD DECK-VENTURI/SPRAY
TOWER SCRUBBING SYSTEM INTO THE FLUE GAS PATH.
8/74 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
ONE MODULE WAS ISOLATED TO PERFORM FLOW DISTRIBUTION TESTS THROUGH THE
MARBLE BED IN AUGUST.
THE MIST ELIMINATOR WASH SYSTEM IS NOT EFFECTIVE. THE MIST ELIMINATORS
HAVE HAD TO BE CLEANED MANUALLY.
THE BOILER IS CURRENTLY BEING FIRED WITH GAS AND OIL.
9/74 SYSTEM 720
10/74 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT OPERATED ON GAS AND OIL UNTIL OCTOBER IE WHEN COAL WAS BURNED.
AGAIN.
POOR GAS DISTRIBUTION THROUGH THE MARBLE BEDS AND AMONG THE EIGHT MODULES
IS STILL A PROBLEM AREA. THE SYSTEM SUPPLIER HAS COMPLETED THE GAS DISTRI-
BUTION TEST AND IS CURRENTLY MODIFYING THE GAS FLOW PATTERN THROUGH THE
MODULES.
11/74 SYSTEM 720
294
-------
EPA UTILITY FG'J SURVEY: OCTOBER - DECEMBER 1980
KANSAS POKER & LIGHT: LAWRENCE 5 (CONT.>
PERFORMANCE DATA
PERIOD .1CJULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS AVAILABLE NEARLY 100X. OF NOVEMBER. GAS DISTRIBUTION
PROBLEMS ARE CONTINUING.
12/74 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
SINCE OCTOBER 12 THE UNIT HAS OPERATED ON A BLEND OF KANSAS AND WYOMING
COAL. THE FGD SYSTEM HAS BEEN AVAILABLE APPROXIMATELY 97X OF THE OCTOBER-
DECEMBER PERIOD. S02 REMOVAL EFFICIENCY HAS BEEN APPROXIMATELY 75X.
MODIFICATIONS TO IMPROVE GAS DISTRIBUTION WITHIN AND AMONG THE MODULES
HAVE NOT COMPLETELY SOLVED THE PROBLEM.
PUMP RUBBER LINING FAILURES OCCURRED DURING DECEMBER. SCRAPS OF RUBBER
WERE DISCOVERED AT THE DISCHARGE PIPE OF THE SLURRY RECYCLE PUMPS.
1/75 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT BURNED A MIXTURE OF 70X WYOMING AND 30X KANSAS COAL DURING JAN-
UARY.
2/75 SYSTEM 672
3/75 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT BURNED WYOMING COAL HAVING 0.5X SULFUR DURING MARCH.
4/75 SYSTEM 720
5/75 SYSTEM 744
6/75 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM SHUTDOWN FOR MOST OF JUNE FOR A MAJOR REBUILD OF THE SPRAY
SYSTEMS IN ALL EIGHT MODULES. THE BOILER WAS FIRED WITH OIL AND THE FGD
SYSTEM WAS BYPASSED.
7/75 SYSTEM .0 744 744 0
8/75 SYSTEM .0 744 744 0
** PROBLEMS/SOLUTIONS/COMMENTS
OIL AND GAS WERE FIRED IN JULY AND AUGUST, RESULTING IN NO FGD OPERATION.
9/75 SYSTEM 720
10/75 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE SEPTEMBER-OCTOBER PERIOD THE BOILER WAS SHUT DOWN FOR A SHORT
TIME TO PERFORM A BOILER INSPECTION AND TO MAKE SOME TURBINE REPAIRS.
DURING PART OF THE PERIOD GAS AND OIL WERE BURNED IN THE BOILER FURNACE.
295
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
KANSAS POUER & LIGHT: LAWRENCE 5 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
SLURRY RECYCLE TANK SCREENS WERE REPLACED DURING THE SEPTEMBER-OCTOBER
PERIOD.
11/75 SYSTEM 720
** PROBLEMS/SOLUTIONS/CCMMENTS
PROJECTIONS BY THE UTILITY FOR THIS UNIT CALL FOR 330 DAYS OF OPERATION
ON 1976 WITH FUEL CONSUMPTION BEING 60X COAL, 25X FUEL OIL, AND
15X NATURAL GAS.
LIKE UNIT 4 THIS UNIT MAY BE CONVERTED TO A ROD-DECK VENTURI AND SPRAY
TOWER SCRUBBING SYSTEM.
12/75 SYSTEM 744
1/76 SYSTEM 744
2/76 SYSTEM 696
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY HAS DECIDED TO INSTALL A NEW ROD DECK-VENTURI/SPRAY TOWER FGD
SYSTEM AT LAWRENCE 5.
3/76 SYSTEM 744
4/76 SYSTEM 720
5/76 SYSTEM 744
6/76 SYSTEM 720
7/76 SYSTEM 744
8/76 SYSTEM 744
9/76 ?JYSTEM 720
10/76 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE INSTALLATION OF THE NEW ROD AND SPRAY TOWER
SCRUBBING SYSTEM IS NOW IN PROGRESS. THE SYSTEM WILL CONSIST OF TWO
SCRUBBING TRAINS EACH HANDLING BOX OF THE FLUE GAS CAPACITY. FOUNDATION
AND STRUCTURAL STEEL ERECTION HAS BEEN COMPLETED, AND SOME OF THE BREECH-
ING HAS BEEN INSTALLED. THE UNIT WILL OPERATE IN A FULLY AUTOMATIC MODE.
THE BOILER HAS BEEN OPERATING NO. 2 FUEL OIL IN ADDITION TO LOW SULFUR
WYOMING COAL WHILE THE NEW SCRUBBING FACILITIES ARE BEING INSTALLED. THE
ORIGINAL LIMESTONE INJECTION AMD TAIL-END SCRUBBING SYSTEM IS STILL AVAIL-
ABLE FOR SERVICE AND IS OPERATED WHEN THE UNIT FIRES COAL. THE SYSTEM
TREATS FLUE GAS RESULTING FROM THE BURNING OF LOW SULFUR (0.5X) WYOMING
COAL.
THE UTILITY REPORTED THAT C-E HAS ENCOUNTERED SOME PROBLEMS WORKING OUT
AND FINE TUNING SOME OF THE INSTRUMENTATION LOGIC CIRCUITS.
11/76 SYSTEM 720
12/76 SYSTEM 744
296
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
KANSAS POWER £ LIGHT: LAWRENCE 5 tCONT.)
_ PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
KP&L REPORTED THAT CONSTRUCTION OF THE NEW SCRUBBING SYSTEM IS STILL IN
PROGRESS. THE ERECTION OF THE STRUCTURAL STEEL AND BREECHING IS
CONTINUING. THE MODULES ARE NOW BEING ERECTED AT THE PLANT SITE,
PARALLEL TO THE EXISTING MARBLE-BED SYSTEM.
1/77 SYSTEM 744
2/77 SYSTEM 672
3/77 SYSTEM 744
4/77 SYSTEM 720
5/77 SYSTEM 744
6/77 SYSTEM 720
*i; PROBLEMS/SOLUTIONS/CO 1MENTS
OPERATION OF THE EXISTING MARBLE BED SCRUBBERS HAS BEEN QUITE SATISFACTORY
AND \ EARLY PROBLEM FREE. THE CONNECTING DUCTWORK IS CURRENTLY BEING IN-
STALLED AS CONSTRUCTION CONTINUES ON THE NEW FGD SYSTEM. THE TWO PARALLEL
SCRUBBING MODULES EACH DESIGNED TO HANDLE 200 MM OF GENERATING CAPACITY
ARE INSTALLED, AS ARE THE REHEATER TUBE BUNDLES. THE EXISTING MARBLE BED
SCRUBBERS WILL BE REMOVED WHEN THE NEW SCRUBBING SYSTEM IS READY FOR
SCRUBBING OPERATION.
7/77 SYSTEM 744
8/77 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
SOME OF THE NEW DUCTWORK IS IN PLACE. THE NEW SCRUBBER MODULES ARE IN
IN PLACE AS ARE THE REHEATER TUBES. THE NO. 1 AND 8 MARBLE BED MODULES
WILL SOON BE REMOVED BECAUSE THE SPACE IS NEEDED FOR FURTHER CONSTRUCTION.
OPERATIONS OF THE EXISTING FGD SYSTEM THROUGHOUT AUGUST HAVE BEEN GOOD.
9/77 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE CONSTRUCTION ON THE NEW SCRUBBER PLANT IS CONTINUING ACCORDING TO
SCHEDULE AND IS EXPECTED TO BE COMPLETE BY APRIL 1978.
10/77 SYSTEM 744
11/77 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE SYSTEM OPERATED ACCEPTABLY THROUGHOUT OCTOBER AND NOVEMBER.
12/77 SYSTEM 744
1/78 SYSTEM 744
297
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
KANSAS POWER & LIGHT: LAWRENCE 5 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEHS/SOLUTIONS/COMMENTS
THE CONSTRUCTION OF THE ROD-DECK SCRUBBERS IS NOW COMPLETE. THE INLET
DUCTWORK IS BEING INSTALLED, AND THE OUTLET DECTWORK WILL BE INSTALLED
ALONG WITH ADDITIONAL CONTROLS DURING THE SCHEDULED OUTAGE IN APRIL 1978,
THE EXISTING FGD SYSTEM OPERATED WITHOUT SERIOUS PROBLEMS THROUGHOUT
DECEMBER AND JANUARY. ONLY SIX MODULES ARE LEFT ON THE EXISTING SYSTEM.
TWO WERE REMOVED TO MAKE ROOM FOR THE NEW SYSTEM.
2/78 SYSTEM 672
3/78 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE ORIGINAL FGD SYSTEM WAS PULLED OFF LINE ON MARCH 20 SO THAT THE NEW
SCRUBBER-ABSORBER SYSTEM COULD BE TIED INTO THE GAS PATH. THIS NEW SYSTEM
CONSISTS OF TWO MODULES EACH WITH A ROD SCCTION FOR PARTICULATE REMOVAL
AND A SPRAY TOWER FOR S02 REMOVAL. THE CAPACITY IS 210 MW EACH MODULE.
INITAL OPERATION SHOULD BEGIN BY THE FIRST OF MAY.
4/78 SYSTEM 720
5/78 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE NEW UNIT WENT IN SERVICE ON AF'RIL 14 AND HAS OPERATED WITH NO OUTAGES
SINCE START-UP.
6/78 SYSTEM 100.0 100.0 100.0 720
7/78 SYSTEM 100.0 100.0 100.0 744
** PROBLEMS/SOLUTIONS/CCMMENTS
THE BOILER OPERATED ALL BUT TWO DAYS OF THE JUNE-JULY PERIOD, WHEN A
BOILER DRAIN LINE LEAK CAUSED AN OUTAGE.
THE FGD SYSTEM OPERATED THE ENTIRE TIME THE BOILER WAS ON-LINE, WITH NO
REPORTED PROBLEMS.
8/78 SYSTEM 744
9/78 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE SYSTEM OPERATED WITH NO FORCED OUTAGES DURING THE AUGUST-SEPTEMBER
PERIOD. THE UNIT WAS TAKEN OUT OF SERVICE AT THE END OF SEPTEMBER FOR A
SCHEDULED TURBINE/BOILER INSPECTION. ROUTINE MAINTENANCE IS BEING PER-
FORMED ON THE BOILER AND TURBINE.
10/78 SYSTEM 744
11/78 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM OPERATED THROUGHOUT OCTOBER AND NOVEMBER WITH ONLY ONE
OUTAGE IN OCTOBER FOR AN ANNUAL ONE-WEEK BOILER/TURBINE INSPECTION.
12/78 SYSTEM 95.5 744 642
298
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
KANSAS POWER & LIGHT: LAWRENCE 5 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
1/79 SYSTEM 744
2/79 SYSTEM 673
** PROBLEMS/SOLUTIONS/COMMENTS
A 30 HOUR OUTAGE WAS REQUIRED IN FEBRUARY TO REPAIR A RUPTURED PIPE IN THE
FGD SYSTEM.
3/79 SYSTEM 744
4/79 SYSTEM 720
5/79 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS BROUGHT DOWN TO SOX CAPACITY FOR A SCHEDULED THREE WEEK
OUTAGE IN MAY TO REBUILD AN AIR PREHEATER FAN MOTOR.
6/79 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE SYSTEM OPERATED WELL THROUGH JUNE. THE ONLY
FGD SYSTEM RELATED OUTAGES WERE DUE TO RECYCLE TANK AGITATOR FAILURE AND
GENERAL MAINTENANCE.
7/79 SYSTEM 744
8/79 SYSTEM 744
9/79 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT OPERATED NORMALLY THROUGHOUT THE THIRD QUARTER OF 1979. THE UNIT
WILL BE SHUT DOWN FOR AN ANNUAL FALL OUTAGE ON OCTOBER 15. DURING
THE OUTAGE SOME BOILER WORK WILL BE DONE. THE SCRUBBER WILL BE CLEANED AND
MAINTENANCE WORK WILL BE PERFORMED ON THE RECYCLE TANK AGITATORS. THE
OUTAGE IS TO LAST TWO WEEKS.
10/79 SYC.TEM 744
11/79 SYSTEM 720
12/79 SYSTEM 744
** PROBLEMS/SOLUTIONS/CCrtMENTS
THE UNIT WAS DOWN FOR APPROXIMATELY 10 DAYS OF SCHEDULED OUTAGE FOR FALL
MAINTENANCE DURING THE SECOND QUARTER OF 1979.
SOME AGITATOR SHAFT FAILURES OCCURRED IN THE REACTION TANK CAUSING
MAINTENANCE ATTENTION DURING THE PERIOD.
1/80 SYSTEM 100.0 100.0 744 744 744
2/80 SYSTEM 100.0 51.7 696 360 360
3/80 SYSTEM 100.0 54.8 744 408 408
299
-------
4/80 SYSTEM
5/80 SYSTEM
6/80 SYSTEM
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
80.6
100.0
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
KANSAS POWER & LIGHT: LAWRENCE 5 tCONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM OPERATED WITHOUT ANY MAJOR PROBLEMS DURING THE FIRST
QUARTER OF 1980. THE BOILER WAS DOWN FROM MID-FEBRUARY TO MID-MARCH
FOR TURBINE REPAIRS, DURING WHICH TIME GENERAL SCRUBBER MAINTENANCE
WAS PERFORMED.
720 720 720
744 600 600
720 720 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS DOWN FOR SIX DAYS DURING MAY FOR A SCHEDULED INSPECTION.
DURING THIS TIME GENERAL MAINTENANCE WAS PERFORMED ON THE FGD SYSTEM.
OTHER THAN THIS TIME, THE FGD SYSTEM OPERATED 100X OF THE TIME DURING
THE APRIL-JUNE PERIOD.
7/80 SYSTEM 100.0 100.0 100.0 96.1 74* 715 715 54.8
** PROBLEMS/SOLUTIONS/COMMENTS
A 29 HOUR OUTAGE fr^URRED AS A RESULT OF A REHEATER TUBE LEAK IN THE
BOILER. NO FGD SYSTEM-RELATED PROBLEMS OCCURRED DURING JULY.
8/80 SYSTEM 100.0 100.0 100.0 81.5 744 606 606 43.3
** PROBLEMS/SOLUTIONS/COMMENTS
THE OUTAGE TIME IN AUGUST WAS DUE TO NECESSARY REPAIR OF A BOILER REHEAT
TUBE.
9/80 SYSTEM 100.0 100.0 100.0 95.7 720 689 689 38.7
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS OUT OF SERVICE FOR APPROXIMATELY 31 HOURS FOR A SCHEDULED
INSPECTION.
10/80 SYSTEM 100.0 100.0 100.0 65.2 744 485 485
** PROBLEMS/SOLUTIONS/COMMENTS
DURING OCTOBER THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS
WERE ENCOUNTERED.
THE BOILER WAS OUT OF SERVICE 259 HOURS DUE TO A SCHEDULED INSPECTION.
11/80 SYSTEM 100.0 100.0 100.0 100.0 720 720 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS OUT OF SERVICE 259 HOURS DUE TO A SCHEDULED INSPECTION.
12/80 SYSTEM 100.0 100.0 100.0 100.0 744 744 744
** PROBLEMS/SOLUTIONS/CO 1MENTS
DURING NOVEMBER AND DECEMBER THE UTILITY REPORTED THAT NO MAJOR FGD-
RELATEJ PROBLEMS OCCURRED.
300
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICU.ATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - MM
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** MECHANICAL COLLECTOR
TYPE
SUPPLIER
INLET FLUE GAS CAPACITY - CU.M/S
PRESSURE DROP - KPA
PARTICLE REMOVAL EFFICENCY -7.
** PARTICLE SCRUBBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
LIQUID RECIRCULATION RATE - LITER/S
L/G RATIO - LITER/CU.M
PRESSURE DROP - KPA
INLET GAS FLOW RATE - CU.M/S
INLET GAS TEMPERATURE - C
KENTUCKY UTILITIES
GREEN RIVER
1-3
CENTRAL CITY
KENTUCKY
E
42.
718.
******
242
64
60
62
64
BABCOCK 4 WILCOX
PULVERIZED COAL
PEAK
169.88
148.9
50.
CONCRETE
4.9
( .097 LB/MMBTU)
( 1.670 LB/MMBTU)
(****** LB/MMBTU)
360000 ACFM)
300 F)
165 FT)
( 16.0 FT)
( 11000 BTU/LB)
COAL
BITUMINOUS
25586.
13.40
******
12.10
******
4.00
******
********
******
CYCLONES
WESTERN PRECIPITATION
49.5 ( 105000 ACFM)
.0 ( 0. IN-H20)
85.0
VENTURI TOWER
VARIABLE-THROAT/TOP-ENTRY PLUMB BOB
AMERICAN AIR FILTER
CARBON STEEL
AISI 1110
INORGANIC
HYDRAULICALLY-BONDED CEMENT
STAINLESS STEEL THROAT
1
85.7 ( 1360 GPM)
4.6 (34.5 GAL/1000ACF)
.0 ( .1 IN-H20)
136.0 ( 288200 ACFM)
52.2 ( 126 F)
*** FGD SYSTEM
301
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
KENTUCKY UTILITIES: GREEN RIVER 1-3 (CONT.)
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
S')2 REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
UNIT DESIGN S02 REMOVAL EFFICIENCY - X
CLRRENT STATUS
COMMERCIAL START-UP
IMTIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
** ABSORBER
NU1BER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
GAS CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
LIQUID RECIRCULATION RATE - LITER/S
L/G RATIO - L/CU.M
GAS-SIDE PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/SEC
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
SOS REMOVAL EFFICIENCY - X
** REHEATER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
PERCENT GAS BYPASSED - AVG
TEMPERATURE INCREASE - C
INLET FLUE GAS FLOW RATE - CU. M/S
INLET FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** FANS
NUMBER
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
THROWAWAY PRODUCT
WET SCRUBBING
LIME
NONE
AMERICAN AIR FILTER
AMERICAN AIR FILTER
FULL SCALE
RETROFIT
X 99.50
80.00
1
6/76
9/75
6/73
PACKED TOWER
ENTRAINED PACKING
MOBILE BED CONTACTOR
AMERICAN AIR FILTER
20X20X27.5
CARBON STEEL
AISI 1110
N/A
INORGANIC
HYDRAULICALLY-BONDED CEMENT
CALCIUM ALUMINATE CEMENT
PVC J POLYETHYLENE SOLID SPHERES
614.
4.5
1.0
4.3
136.00
52.2
80.0
9750 GPM)
34.0 GAL/1000 ACF)
4.0 IN-H20)
14.0 FT/S)
288200 ACFM)
126 F)
( 40 F)
( 288200 ACFM)
( 130 F)
INDIRECT HOT AIR
EXTERNAL HEAT EXCHANGER
STEAM TUBE BUNDLES
.0
4.4
136.00
54.4
CARBON STEEL
BUFFALO FORGE
BOOSTER
FORCED DRAFT
DRY
169.88
148.9
CARBON STEEL
( 360000 ACFM)
( 300 F)
SCRUBBER INLET
CARBON STEEL
NONE
302
-------
KENTUCKY UTILITIES: GREEN RIVER 1-3
-------
EPA UTILITY FGO SURVEY: OCTOBER - DECEMBER 1980
KENTUCKY UTILITIES: GREEN RIVER 1-3 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
' S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
A MAJOR PROBLEM WAS FAILURE OF THE RECYCLE PUMPS.
THAWING AND REPAIR OF NUMEROUS FROZEN LINES WAS REQUIRED.
SHUTDOWN OF SUMP PUMPS WAS NECESSARY.
A MAJOR PROBLEM AREA WAS THE FEED TANK AGITATOR.
2/76 SYSTEM 70.0 <2.0 42.0 30.P 696 499 211
** PROBLEMS/SOLUTIONS/COtIMENTS
REPAIRS WERE MADE TO THE TANK AGITATORS, SLAKE TANKS AND MIX-HOLD TANKS
CONTRIBUTING TO OUTAGE TIME.
REPAIRS AND CLEANOUT OF REACTANT PUMPS CONTRIBUTATED TO OUTAGE TIME.
3/76 SYSTEM 97.0 85.0 95.0 52.0 744 458 386
** PROBLEMS/SOLUTIONS/COMMENTS
ALL RUBBER-LINED IMPELLERS WERE REPLACED IN THE PUMPS.
720 552 552
744 456 456
720 597 589
744 584 574
744 744 722
** PROBLEMS/SOLUTIONS/COMMENTS
VIBRATION IN THE SCRUBBER BOOSTER ID FAN NECESSITATED A 22 HOUR SYSTEM
SHUTDOWN FOR REPAIR DURING AUGUST.
9/76 SYSTEM 86.0 100.0 100.0 79.0 720 571 571
** PROBLEMS/SOLUTIONS/COMMENTS
MINOR FAN PROBLEMS OCCURRED BUT NO FORCED OUTAGE TIME WAS REQUIRED.
HALF-LOAD OPERATIONS WERE CONDUCTED THROUGHOUT THI* PERIOD BECAUSE OF
BEARING PROBLEMS WITH ONE OF .THE TWO TURBINE GENERATING UNITS.
10/76 SYSTEM 100.0 100.0 100.0 94.0 744 699 699
** PROBLEMS/SOLUTIONS/COMMENTS
MINOR FAN PROBLEMS OCCURRED BUT NO FORCED OUTAGE TIME WAS REQUIRED.
".'-I, ; HALF-LOAD OPERATIONS WERE CONDUCTED THROUGHOUT THE PERIOD BECAUSE OF
;", . , . . BEARING PROBLEMS WITH ONE OF THE TWO TURBINE GENERATING UNITS.
»4i/,7^'..SYSTEM 100.0 100.0 98.0 98.0 720 704 704
12/76 SYSTEM ,7lLO .97.0. 87.0 70.0 744 536 517
4/76
5/76
6/76
7/76
8/76
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
90.0
81.0
100.0
90.0
97.0
100.0
100.0
99.0
98.0
97.0
100.0
100.0
99.0
99.0
97.0
77.0
61.0
82.0
77.0
97.0
304
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
KENTUCKY UTILITIES: GREEN RIVER 1-3 (CONT.)
. PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
DURING NOVEMBER AND DECEMBER, 1976 SOME FLUE GAS WAS BY-PASSED AROUND
THE SYSTEM WHILE THE UTILITY CONDUCTED A CHECKOUT OF THE.SCRUBBER INTERNAL
AND REPLACED SOME OF THE PACKING SPHERES IN THE MOBILE BED.
1/77 SYSTEM 94.0 94.0 94.0 94.0 744 744 698
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE MONTH OF JANUARY NO PROBLEMS OCCURRED.
2/77 SYSTEM 36.0 91.0 91.0 36.0 672 266 243
3/77 SYSTEM .0 .0 744 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE MONTH OF FEBRUARY IT WAS FOUND THAT THE CARBOLINE STACK LINER
WAS BADLY DETERIORATED. SCRUBBER AND BOILER OPERATIONS WERE TERMINATED
UNTIL THE STACK LINING WAS REPAIRED. THE STACK WAS REPAIRED FIRST BY
WELDII'G A BACKUP METAL PLATE TO THE PORTIONS OF THE STACK WHERE PITTING
OCCURRED. THE ENTIRE STACK WAS THEN LINED WITH A REFRACTORY COATING
CALLED PRECRETE G-8 BY AAF. THE REPAIRS WERE COMPLETED MARCH 7.
THE BOILER IS NOT OPERATED WITHOUT THE SCRUBBER BECAUSE THERE IS NO ESP
FOR P/dTICUUTE CONTROL.
720 167 164
744 527 513
720 34 34
** PROBLEMS/SOLUTIONS/COMMENTS
WORK ON THE SCRUBBER MODULE INCLUDED REPAIRS TO THE UNDERBED DAMPER
SYSTEM AND LEAKING IN THE VENTURI.
LIME SLAKING OPERATIONS WAS REPAIRED.
7/77 SYSTEM 100.0 .0 744 ' 0 0 .0
** PROBLENS/SOLUTIONS/COMMENTS
A STRIKE BY PLANT OPERATING PERSONNEL RESULTED IN BOILER AND FGD SYSTEM
SHUTDOWN WHICH CONTINUED THROUGH THE END OF OCTOBER.
8/77 SYSTEM 100.0 .0 744 0 0 .0
9/77 SYSTEM 100.0 .0 720 0 0 .0
10/77 SYSTEM 100.0 .0 744 0 0 .0
11/77 SYSTEM 86.0 91.0 91.0 41.0 720 332 301
** PROBLEMS/SOLUTIONS/COMMENTS
PROBLEMS WERE ENCOUNTERED WITH LEAKS IN RECYCLE PUMP IMPELLER COATINGS
AND PUMP FAILURES. TWO PUMPS WERE DOWN AND BEING BYPASSED.
SUMP PUMP FAILURES WERE NOTED.
305
4/77 SYSTEM
5/77 SYSTEM
6/77 SYSTEM
40.0
99.0
100.0
98.0
98.0
100.0
98.0
98.0
100.0
23.0
69.0
5.0
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
KENTUCKY UTILITIES: GREEN RIVER 1-3 (CONT.)
------------------------------------------ PERFORMANCE DATA ------------------------------------------
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
LEAKS IN THE PACKING WERE NOTED.
12/77 SYSTEM 50.0 63.0 91.0 50.0 744 596 375
** PROBLEMS/SOLUTIONS/COMMENTS
NUMEROUS FREEZE UPS WERE ENCOUNTERED DURING DECEMBER CAUSING FGD SYSTEM
OUTAGE TIME.
1/78 SYSTEM 31.0 32.0 32.0 23.0 7*4 537 170
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WENT DOWN AFTER APPROXIMATELY 170 HOURS OF OPERATION IN JANUARY.
THIS WAS CAUSED BY THE FREEZING OF THE SLURRY LINE TO THE POND.
2/78 SYSTEM 97.0 .0 .0 672 672 0
3/78 SYSTEM 97.0 .0 .0 744 669 0
** PROBLEMS/SOLUTIONS/COMMENTS
THE SYSTEM COULD HAVE BEEN CONSIDERED AVAILABLE THROUGHOUT MOST OF THE
WINTER PERIOD BUT BECAUSE EMERGENCY CONDITIONS THE UTILITY CHOSE TO
CONCENTRATE THEIR MAINTENANCE CREWS ON POWER GENERATION RATHER THAN FGD
OPERATION. UNDER NORMAL CONDITIONS THE RELATIVELY MINOR FGD SYSTEM
PROBLEMS WOULD HAVE BEEN SOLVED MORE QUICKLY.
DURING THE FREEZE UPS NUMEROUS GASKETS WERE TORN THROUGHOUT THE SYSTEM.
THE SYSTEM WAS SHUT DOWN COMPLETELY FOR REPAIR WORK DURING FEBRUARY
AND MARCH.
4/78 SYSTEM 41.0 99.0 99.0 41.0 720 296 295
5/78 SYbTEM 64.0 100.0 98.0 64.0 744 474 474
** PROBLEMS/SOLUTIONS/CC1MENTS
THE SCREENS ON THE SUCTION SIDE OF THE PUMPS THAT PUMP THE SLURRY FROM THE
PREP 100M TO THE NOZZLES EXPERIENCED PLUGGING PROBLEMS. THE SCREENS GET
PLUGPED WITH LARGE GRIT IN THE SLURRY AND ARE SUCKED OUT OF POSITION BY
THE PUMPS. THE UTILITY REPORTED THAT THIS TENDS TO BE A RECURRING
PROBLEM.
6/78 SYSTEM 73.0 100.0 100.0 73.0 720 525 524
7/78 SYSTEM 13.0 96.0 100.0 13.0 744 103 99
** PROBLEMS/SOLUTIONS/COMMENTS
BOILER AND FGD SYSTEM OUTAGES DURING JUNE AND JULY WERE FOR ROUTINE
MAINTENANCE.
8/78 SYSTEM 61.0 99.0 99.0 28.0 744 207 205
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS DOWN FROM AUGUST 1 THROUGH AUGUST 12 AS A RESULT OF BLEED
PUMP PROBLEMS.
9/78 SYSTEM 76.0 98.0 100.0 41.0 720 303 298
306
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
KENTUCKY UTILITIES: GREEN RIVER 1-3 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
BECAUSE OF PLUGGING PROBLEMS THE FGD SYSTEM WAS OPERATED AT APPROXIMATELY
ONE THIRD OF TOTAL CAPACITY THE LAST TWO WEEKS OF SEPTEMBER.
10/78 SYSTEM 30.0 94.0 96.0 30.0 744 236 222
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM EXPERIENCED RECYCLE TANK SCREEN PLUGGING.
THE FGD SYSTEM EXPERIENCED VIBRATING FAN PROBLEMS.
11/78 SYSTEM 24.0 100.0 ,74.0 24.0 720 175 175
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS DOWN THE LAST TWO WEEKS OF NOVEMBER DUE TO LOW LOAD DEMAND.
12/78 SYSTEM .0 .0 744 0 0 .0
1/79 SYSTEM .0 • .0 .0 .0 744 1 0
2/79 SYSTEM .0 .0 672 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS UNAVAILABLE IN DECEMBER, JANUARY AND FEBRUARY AS A
RESULT OF FREEZING WEATHER WHICH CAUSED FROZEN PIPES, ETC.
3/79 SYSTEM 11.Z 100.0 100.0 11.2 744 83 83
4/79 SYSTEM 18.2 100.0 100.0 18.2 720 131 131
** PROBLEMS/SOLUTIONS/COMMENTS
THE LOW OPERATIONAL HOURS FOR MARCH AND APRIL WERE DUE TO RECYCLE PUMP
PROBLEMS.
5/79 SYSTEM 100.0 .0 744 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS TAKEN DOWN IN MAY FOR REPAIRS THAT ARE PROJECTED TO LAST
THROUGH THE END OF SEPTEMBER. DURING THIS OUTAGE AN INDIRECT STEAM REHEAT
SYSTEM WILL BE INSTALLED TO BOOST 1WE TEMPERATURE OF THE EXITING FLUE GAS.
THIS WAS FOUND TO BE NECESSARY DUE TO EXCESSIVE MOISTURE IN THE AREA.
6/79 SYSTEM 100.0 .0 720 0 0 .0
** PROBLEMS/SOLUTIONS/CO.H1ENTS
THE UMT REMAINED OUT OF SERVICE DURING JUNE FOR BOILER REPAIRS. IT IS
NOT EXPECTED TO RETURN TO SERVICE UNTIL OCTOBER OR NOVEMBER.
7/79 SYSTEM 100.0 .0 744 0 0 .0
8/79 SYSTEM 100.0 .0 744 0 0 .0
9/79 SYSTEM 100.0 .0 720 0 0 .0
307
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
KENTUCKY UTILITIES: GREEN RIVER 1-3 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER REMAINED OUT OF SERVICE DURING JULY, AUGUST AND SEPTEMBER. THE
BOILER TEMPERATURE VALVES AND PIPING BETWEEN THE PRIMARY AND SECONDARY
SUPERHEATERS MUST STILL BE REPLACED. THE BOILER IS NOT EXPECTED TO RETURN
ON LINE UNTIL THE FIRST OF THE YEAR OR POSSIBLY AS LATE AS MARCH.
THE NEW INDIRECT REHEAT SYSTEM IS IN PLACE AND READY FOR OPERATION AS SOON
AS THE BOILER RETURNS TO SERVICE.
10/79 SYSTEM 100.0 .0 744 0 0 .0
11/79 SYSTEM 100.0 .0 720 0 0 .0
12/79 SYSTEM 100.0 .0 744 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
WORK IS CONTINUING ON THE REPAIRS OF THE OLD BOILER. THE UNIT MAY BE
SHUT DOWN INTO MARCH 1980. THE FGD SYSTEM WAS AVAILABLE THROUGHOUT THE
PERIOD BUT WAS NOT OPERATED.
1/80 SYSTEM 100.0 .0 744 0 0 .0
2/80 SYSTEM 100.0 .0 696 0 0 .0
3/80 SYSTEM 100.0 .0 744 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER REMAINED OUT OF SERVICE DUE TO BOILER REPAIRS. THE UNIT IS
EXPECTED TO BE OPERATING IN MAY.
4/80 SYSTEM 100.0 .0 720 0 0 .0
5/80 SYSTEM 100.0 .0 744 0 0 .0
6/80 SYSTEM 100.0 .0 720 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM REMAINED OFF LINE DURING THE SECOND QUARTER OF 1980 AS A
RESULT OF THE ON-GOING BOILER REPAIRS. COMPLETION OF THE BOILER REPAIRS
HAS BEEN DELAYED BY THE UNAVAILABILITY OF SOME NEEDED PARTS.
7/80 SYSTEM 100.0 .0 744 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER REPAIRS HAVE BEEN COMPLETED; HOWEVER, THE BOILER DID NOT
OPERATE DUE TO REPAIR WORK BEING DONE ON THE TURBINE.
8/80 SYSTEM 100.0 .0 744 0 0 .0
9/80 SYSTEM 100.0 .0 720 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
TURBINE REPAIRS CONTINUED THROUGH AUGUST AND SEPTEMBER. THE FGD SYSTEM
WAS AVAILABLE FOR OPERATION.
10/80 SYSTEM 100.0 .0 744 0 0 .0
11/80 S"STEM 100.0 .0 720 0 0 .0
308
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
KENTUCKY UTILITIES: GREEN RIVER 1-3 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
1Z/80 SYSTEM 100.0 .0 744 0 0 •.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE FOURTH QUARTER THE TURBINE REPAIRS CONTINUED. AN ATTEMPT TO
RESTART THE BOILER IN MID-DECEMBER RESULTED IN A BLOWN GENERATOR CAUSED
BY FAULTY INSULATORS. THE UTILITY IS PRESENTLY WAITING ON NEW INSULATORS.
DURING THE PERIOD THE BOILER CONTROL VALVES HAD TO BE REPLACED.
THE FGD SYSTEM WAS AVAILABLE 100X OF THE TIME DURING THE FOURTH QUARTER.
309
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICJLATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS iJNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - MM
NET UN^T GENERATING CAPACITY MO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** UN3T DATA - BOILER AND STACK
BC'ILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
ST\CK HEIGHT - M
ST\CK SHELL
STACK TOP DIAMETER - M
»* FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** ESP
NUMBER
TYPE
INLET FLUE GAS CAPACITY - CU.M/S
INLET FLUE GAS TEMPERATURE - C
PARTICLE REMOVAL EFFICENCY - 7.
** PARTICLE SCRUBBER
GENERIC TYPE
SPECIFIC TYPE
*** FGD SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
UNIT DESIGN SOS REMOVAL EFFICIENCY - 7.
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
ELECTRIC
t .116 LB/MMBTU)
( 1.200 LB/MMBTU)
(****** LB/MMBTU)
LOUISVILLE GAS &
CANE RUN
4
LOUISVILLE
KENTUCKY
D
50.
516.
******
992
188
175
178
188
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
346.37 t 734000 ACFM)
160.0 ( 320 F)
76. ( 250 FT)
CONCRETE
******* (***** FT)
COAL
BITUMINOUS
26749.
17.10
15.5-24.5
9.00
8.0-10.75
3.75
3.5-4.0
.04
0.03-0.06
COLD SIDE
346.4
160.0
99.0
NONE
N/A
THROWAWAY PRODUCT
WET SCRUBBING
LIME
AMERICAN AIR FILTER
FLUOR - PIONEER
FULL SCALE
RETROFIT
7. 99.00
85.00
1
8/77
8/76
4/74
( 11500 BTU/LB)
10,400-llf900
( 734000 ACFM)
( 320 F)
310
-------
EPA UTILITY FSD SURVEY: OCTOBER - DECEMBER 1980
LOUISVILLE GAS & ELECTRIC: CANE RUN 4 (CONT.)
** DESIGN AND OPERATING PARAMETERS
** ABSORBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SMELL SPECIFIC MATERIAL
SHHLL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
L/NER SPECIFIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
GAS CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
L:QUID RECIRCULATION RATE - LITER/S
L/G RATIO - L/CU.M
GAS-SIDE PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/SEC
II1LET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
S02 REMOVAL EFFICIENCY - X
** MIST ELIMINATOR
PFE-MIST ELIMINATOR/MIST ELIMINATOR
NL'MBER PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
NU1BER OF STAGES
NUMBER OF PASSES PER STAGE
FREEBOARD DISTANCE - M
DISTANCE BETWEEN VANES - CM
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/S
CONSTRUCTION MATERIAL GENERIC TYPE
WA-3H WATER SOURCE
WASH RATE - L/S
** REHEATER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
PERCENT GAS BYPASSED - AVG
TEMPERATURE INCREASE - C
INLET FLUE GAS FLOW RATE - CU.
INLET FLUE GAS TEMPERATURE
M/S
- C
*» FANS
NUMBER
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
PACKED TOWER
ENTRAINED PACKING
MOBILE BED CONTACTOR
AMERICAN AIR FILTER
20 X 20 X f;7.5
CARBON STE^L
AISI 1110
N/A
INORGANIC,ORGANIC
HYDRAULICALLY-BONDED CEMENT,VINYL ESTER
PREKRETE.PLASITE
1.25 IN. DIA. POLYURETHANE BALLS
1
(17625 GPM)
60.0 GAL/1000 ACF)
4.0 IN-H20)
11.5 FT/S)
367700 ACFM)
320 F)
1110.
8.0
1.0
3.5
173.52
160.0
87.5
MIST ELIMINATOR
4
IMPINGEMENT
BAFFLE
CHEVRON VANE
HORIZONTAL
2
3
1.83
3.0
.2
3.0
6.0 FT)
1.20 IN)
.8 IN-H20)
10.0 FT/S)
SS, PLASITE 4005 LINING (DUCT AREA)
FRESH MAKEUP (RIVER)
5.0 ( 80 GAL/MIN)
DIRECT COMBUSTION
EXTERNAL COMBUSTION CHAMBER
OIL
.0
10.0 ( 50 F)
275.12 ( 583000 ACFM)
52.8 ( 127 F)
BUFFALO FORGE/AMERICAN STANDARD FLUID DRIVES
BOOSTER
FORCED DRAFT
DRY
( 367000 ACFM)
( 325 F)
173.19
162.8
CARBON STEEL
SCRUBBER INLET
CARBON STEEL
NONE
SCRUBBER TO STACK
CARBON STEEL
311
-------
EPA UTILITY FGO SURVEY: OCTOBER - DECEMBER I960
LOUISVILLE GAS & ELECTRIC: CANE RUN 4 (CONT.)
LINER GENERIC MATERIAL TYPE
** TANKS
SERVICE
REACTION, RECIRCULATION AND BLEED
** PUMPS
SERVICE
ABSORBER RECIRCULATION
THICKENER UNDERFLOW
THICKENER OVERFLOW
** SO'.IDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
CONFIGURATION
DIMENSIONS - FT
SHELi. GENERIC MATERIAL TYP,"
LINER SPECIFIC MATERIAL TYPE
FfcED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
*** SLUDGE
** TREATMENT
PROPRIETARY PROCESS
** DISPOSAL
NATURE
TVPE
LCCATION
S.T.TE TRANSPORTATION METHOD
** PROCESS CONTROL AND INSTRUMENTATION
D'EMICAL PARAMETERS
CONTROL LEVELS
MC'NITOR LOCATION
PROCESS CONTROL MANNER
** WAT5R BALANCE
WATER LOOP TYPE
MAKEUP WATER ADDITION - LITERS/S
** FGD SPARE CAPACITY INDICES
ABSORBER - X
** FGD SPARE COMPONENT INDICES
ABSORBER
PLASITE 4005
NUMBER
****
NUMBER
6
2.
Z
6
THICKENER
1
0
CIRCULAR
85 (DIA) X X4 (DEPTH)
CARBON STEEL
RUBBER
10X SOLIDS
Z57. SOLIDS
IUCS
FINAL
LINED POND
ON SITE
PIPELINE
PH
4-6; REACTION TANK RETURN
REACTION TANK
AUTOMATIC
OPEN
6.3
.0
.0
( 100 GPM)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
PART. HOURS HOURS HOURS FACTOR
8/76 SYSTEM 90.0
** PROBLEMS/SOLUTIONS/COMMENTS
89.5
744 740
666
INITIAL OPERATIONS OF THE CANE RUN 4 FGD SYSTEM BEGAN IN AUGUST WITH
THE SYSTEM OPERATING 90Z OF THE 740 HOURS THE BOILER WAS ON LINE.
OUTAGE TIME DURING THE MONTH WAS DUE PRIMARILY TO EQUIPMENT INSPECTIONS,
REPAIR/REPLACEMENT OF AUXILIARY MOTOR PARTS, AND DEPLETION OF ABSORBENT
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
LOUISVILLE GAS & ELECTRIC: CANE RUN 4 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
SUPPLY BECAUSE OF A LATE BARGE DELIVERY.
THE SCRUBBING SYSTEM HAS BEEN GENERALLY OPERATING AT APPROXIMATELY 50 TO
SOX FLUE GAS CAPACITY.
SOME MINOR PROBLEMS HAVE BEEN ENCOUNTERED WITH AUXILIARY EQUIPMENT MOTORS.
SOME MINOR PROBLEMS HAVE BEEN ENCOUNTERED WITH SPRAY NOZZLES IN THE MOBILE
BED CONTACTOR. THE SPRAY NOZZLES ARE SPINNER-VANE COMPONENTS ORIGINALLY
CONSTRUCTED OF PLASTIC. OPERATING TEMPERATURES AND PRESSURES HAVE CAUSED
THE PLASTIC HOUSING TO EXPAND RESULTING IN THE VANES EXTRUDING OUT THE
FRONT END, SUBSEQUENTLY CAUSING A BLOCKAGE OF THE SLURRY FEED. THE
NOZZLES HAVE BEEN REPLACED WITH CERAMIC CONSTRUCTED COMPONENTS.
9/76 SYSTEM 90.0 90.0 720 720 648
10/76 SYSTEM 90.0 72.6 744 600 540
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS TAKEN OUT OF SERVICE ON OCTOBER 25, 1976 TO IMPLEMENT
ADDITIONAL MODIFICATIONS TO THE SCRUBBING SYSTEM. MAJOR SYSTEM MODIFICA-
TIONS INCLUDE INCREASING PUMP CAPACITY AND DECREASING PRESSURE DROP.
THESE TWO PROBLEMS HAVE HINDERED OPERATION OF THE UNIT AT FULL LOAD
CAPACITY.
11/76 SYSTEM 95.0 79.2 720 600 570
12/76 SYSTEM "0.0 72.? 744 598 538
** PROBLEMS/SOLUTIONS/COUMENTS
THE UNIT OPERATED ON CARBIDE LIME DURING THE NOVEMBER-DECEMBER PERIOD.
1/77 SYSTEM 37.7 33.7 744 666 251
** PROBLEMS/SOLUTIONS/COMMENTS
DUE TO OHIO RIVER FREEZE UP BARGE DELIVERIES OF LIME CEASED CAUSING THE
THE FGD SYSTEM TO BE TAKEN OFF LINE ON JANUARY 12.
2/77 SYSTEM 1.2 672 0 8 .0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING FEBRUARY, THE SCRUBBER WAS ONLY OPERATED FOR TWO 4-HOUR PERIODS
TO PREVENT TOTAL FREEZE-UP.
3/77 SYSTEM 82.9 48.1 744 432 358
** PROBLEMS/SOLUTIONS/COMMENTS
THE SCRUBBER CAME BACK ON-LINE ON MARCH 14, 1977.
DC POWER SUPPLY TO THE BYPASS DAMPER FAILED. THE SCRUBBER SYSTEM WAS
BYPASSED WHILE REPAIRS WERE MADE.
4/77 SYSTEM 92.7 60.0 720 466 432
5/77 SYSTEM .0 744 0
6/77 SYSTEM .0 720 0
313
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
LOUISVILLE GAS & ELECTRIC: CANE RUN 4 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE SCRUBBING SYSTEM WAS DOWN FOR MODIFICATIONS FROM APRIL 19 TO JULY 17,
1977.
A CHEVRON TYPE MIST ELIMINATOR WAS INSTALLED DURING THE OUTAGE.
A NEW SPRAY HEADER WAS ADDED TO INCREASE THE L/G RATIO DURING THE OUTAGE.
DIRECT OIL-FIRED REHEAT WAS ADDED.
THE LINING IN THE SYSTEM FROM THE MIST ELIMINATOR TO THE STACK WAS RE-
PLACED WITH PLASITE 4005 (THE ORIGINAL LINING WAS BUBBLING, BUT HAD NOT
YET FAILED, FAILURE SEEMED IMMINENT WITHIN 4-5 MONTHS). THE NEW LINING
WAS INSTALLED BY GENERAL COATINGS.
7/77 SYSTEM 90.0 43.5 80.70 744 360 324
** PROBLEMS/SOLUTIONS/COMMENTS
THE SYSTEM WAS PLACED BACK IN SERVICE ON JULY 17, 1977 AFTER SYSTEM
MODIFICATIONS WERE COMPLETED.
8/77 SYSTEM 79.0 89.5 79.0 83.90 744 657 588
9/77 SYSTEM 98.9 99.1 72.8 720 529 524
** PROBLEMS/SOLUTIONS/COMMENTS
COMPLIANCE TESTING OCCURED DURING AUGUST AND SEPTEMBER 1977 BY EPA
PERSONNEL AND WAS OFFICIALLY APPROVED TO HAVE ACHIEVED COMPLIANCE.
10/77
11/77
12/77
SYSTEM
SYSTEM
SYSTEM
98.1
69.9
85.0
97.8
94.0
85.0
99
94
100
.0
.0
.0
89.0
62.9
81.7
84
83
.30
.70
744
720
744
677
483
715
662
453
603
** PROBLEMS/SOLUTIONS/COMMENTS
DURINU DECEMBER, "AIRCO", THE Lit'. SUPPLIER, HAD 1200 FT OF THEIR FEED
LINE BREEZE UP CAUSING LIME TO BECOME UNAVAILABLE FOR A SHORT TIME.
1/78 SYSTEM 66.4 j6.6 87.0 66.4 744 742 494
2/78 SYSTEM 100.0 .0 672 0 0 .0
3/78 SYSTEM 100.0 33.5 33.5 744 744 249
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS DOWN THE ENTIRE MONTH OF FEBRUARY DUE TO A COAL SHORTAGE
AND A LACK OF AVAILABLE LIME RESULTING FROM THE SEVERE WINTER WEATHER.
THE UNIT CAME BACK ON LINE MARCH 21, 1978.
4/78 SYSTEM 100.0 100.0 100.0 42.1 720 303 303
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS DOWN PART OF APRIL FOR REPAIRS.
5/78 SYSTEM 31.0 32.7 35.0 15.5 744 352 115
314
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
LOUISVILLE GAS ft ELECTRIC: CANE RUN 5 (CONT.)
** DESIGN AND OPERATING PARAMETERS
** ABSORBER
DUMBER
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME.'COMMON TYPE
LINFR GENERIC MATERIAL
LINl.R SPECIFIC MATERIAL
LINfR MATERIAL TRADE NAME/COMMON TYPE
GAS CONTACTING DEVICE TYPE
N'.'MEER OF CONTACTING ZONEf.
LIQUID RECIRCULATION RATE - LITER/S
L'G RATIO - L/CU.M
GAS-SIDE PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/SEC
I'-ILET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
S02 REMOVAL EFFICIENCY - X
** MI3T ELIMINATOR
F5E-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
G£NERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES PER STAGE
PfESSURE DROP - KPA
Sl'PERFICAL GAS VELOCITY - M/S
CONSTRUCTION MATERIAL GENERIC TYPE
WASH WATER SOURCE
WASH RATE - L/S
** REHSATER
NU1BER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
PFRCENT GAS BYPASSED - AVG
TEMPERATURE INCREASE - C
INLET FLUE GAS FLOW RATE - CU. M/S
INLET FLUE GAS TEMPERATURE - C
NUMBER OF TUBES PER BUNDLE
CONSTRUCTION MATERIAL GENERIC TYPE
** FANS
NUMBER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** FANS
NUMBER
FUNCTION
APPLICATION
CONSTRUCTION MATERIAL GENERIC TYPE
SPRAY TOWER
OPEN COUNTERCURRENT SPRAY
COMBUSTION ENGINEERING
26 (DIA) X 71
STAINLESS STEEL
AUSTENITIC
TYPE 316L
INORGANIC
HYDRAULICA.LY-BONDED CEMENT
PREKRETE
NONE
3
1102.
7.4
153.37
162.8
91.0
(17500 GPM)
( 55.0 GAL/1000 ACF)
( .5 IN-H20)
( 7.0 FT/S)
( 325000 ACFM)
( 325 F)
MIST ELIMINATOR
2
IMPINGEMENT
BAFFLE
CHEVRON VANE
HORIZONTAL
2
2
.1 ( .5 IN-H20)
2.1 ( 7.0 FT/S)
FIBERGLASS REINFORCED PLASTIC
RIVER
31.5 ( 500 GAL/MIN)
2
IN-LINE
STEAM
FIN TUBE
.0
4.4 ( 40 F)
265.21 ( 562000 ACFM)
52.2 ( 126 F)
34
CARBON STEEL
BALANCED DRAFT
FORCED DRAFT
DRY
165.16
154.4
CARBON STEEL
t 350000 ACFM)
( 310 F)
2
BOOSTER
INDUCED DRAFT
CARBON STEEL
319
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
LOUISVILLE GAS & ELECTRIC: CANE RUN 5 (CONT.)
** TANKS
SERVICE
RECYCLE
REACTION
LIME FEED
** PUMPS
SERVICE
ABSORBER RECIRCULATION
JPRAY PUMP
LIME FEED
THICKENER UNDERFLOW
WVTER RECYCLE
MIST ELIMINATOR WASH
** SOLIDS CONCENTR ATING/D EWATER INS
DEVICE
tOBER
NUMBER OF SPARES
CONFIGURATION
DIMENSIONS - FT
SHEL". GENERIC MATERIAL TYPE
LINE* SPECIFIC MATERIAL TY^E
FEEC STREAM CHARACTERISTIC!
OUTLET STREAM CHARACTERISTICS
NUMBER
1
1
****
NUMBER
2
2
2
2
2
THICKENER
1
0
CIRCULAR
110 DIA
CARBON STEEL
RUBBER
10X SOLIDS
25X SOLIDS
***
** TREATMENT
MFTHOD
PROPRIETARY PROCESS
** DISPOSAL
NATURE
r'pE
LOCATION
S.:TE TRANSPORTATION METHOD
** PROCESS CONTROL AND INSTRUMENTATION
CI'EMICAL PARAMETERS
CONTROL LEVELS
MONITOR LOCATION
PROCESS CONTROL MANNER
** WATER BALANCE
WATER LOOP TYPE
** FGD SPARE CAPACITY INDICES
ABSORBER - X
** FGD SPARE COMPONENT INDICES
AB.'SORBER
POZ-0-TEC
IUCS
FINAL
LINED POND
ON SITE
PIPELINE
PH
9-10 (RECYCLE SLURRY)
REACTION TANK
AUTOMATIC
OPEN
.0
.0
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
12/77 SYSTEM
320
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
LOUISVILLE GAS & ELECTRIC: CANE RUN 5 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
SOS PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
OPERATION OF THE FGD SYSTEM, ON A TRIAL BASIS, BEGAN ON DECEMBER 29,
1977. INITIAL OPERATIONS WERE NOT CONTINUOUS AND THE SYSTEM WAS TAKEN
OFF LINE FOR NECESSARY MODIFICATIONS.
1/78 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
MODIFICATIONS, ESPECIALLY TO CONTROLS THAT WERE NOT OPERATING PROPERLY,
CONTINUED THROUGH JANUARY AND THE FGD SYSTEM REMAINED OFF LINE.
2/78 SYSTEM 672
3/78 SYSTEM 50.0 12.2 744 182 91
** PROBLEMS/SOLUTIONS/COMMENTS
THE PLANT REMAINED OFF LINE THROUGHOUT FEBRUARY AND RESTARTED ON MARCH 24.
VARIOUS INITIAL START-UP PROBLEMS WERE STILL BEING ENCOUNTERED CAUSING
FGD SYSTEM OUTAGES.
4/78 SYSTEM 96.9 90.0 720 669 648
5/78 SYSTEM 84.3 48.9 744 432 364
** PROBLEMS/SOLUTIONS/COMMENTS
FGD SYTTEM MODIFICATIONS WERE MADE DURING THE APRIL-MAY PERIOD IN PREP-
ARATIOH FOR PERFORMANCE TESTS. T\-E TESTS WERE PERFORMED; HOWEVER, THE
TEST MUTHODS WERE NOT FOLLOWED ACCURATELY AND THE DATA WAS INCONCLUSIVE.
6/78 SYSTEM 86.8 36.1 81.9 720 685 590
7/78 SYSTEM 83.1 80.1 68.0 744 632 506
** PROBLEMS/SOLUTIONS/COMMENTS
THE STEAM REHEAT COIL INSTALLATION HAS BEEN A CHRONIC PROBLEM AREA. WELOS
HAVE BEEN FAILING EVER SINCE INITIAL OPERATIONS.
8/78 SYSTEM 85.9 62.4 744 540 464
9/78 SYSTEM 79.6 67.4 720 609 485
** PROBLEMS/SOLUTIONS/COMMENTS
PROBLEMS CONTINUED WITH THE REHEAT COILS.
10/78 SYSTEM 96.2 68.5 744 530 510
11/78 SYSTEM 93.7 32.9 720 253 237
<* PROBLEMS/SOLUTIONS/COMMENTS
THE SYSTEM WAS SHUTDOWN IN NOVEMBER FOR REPAIRS TO THE STEAM REHEATER
COILS. THE OUTAGE LASTED ABOUT TWO WEEKS.
12/78 SYSTEM 52.7 46.2 40.6 744 654 302
1/79 SYSTEM 69.6 67.2 62.8 744 693 467
321
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
LOUISVILLE GAS & ELECTRIC: CANE RUN 5 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
2/79 SYSTEM 70.6 50.1 672 477 337
** PROBLEMS/SOLUTIONS/COMMENTS
DURING FEBRUARY FREEZING CAUSED PROBLEMS WITH LIME DELIVERY.
3/79 SYSTEM 71.8 57.5 744 596 428
4/79 SYSTEM 99.2 49.6 720 360 357
** PROBLEMS/SOLUTIONS/COMMENTS
SOME PROBLEMS WERE EXPERIENCED WITH DAMPERS AND THERE WERE PUMP FAILURES.
5/79 SYSTEM 84.3 49.1 744 433 365
** PROBLEMS/SOLUTIONS/COMMENTS
COMPLIANCE TESTING WAS AGAIN PERFORMED AT THIS UNIT ON MAY 15 AND 19
AND A S02 REMOVAL EFFICIENCY OF 93X WAS DEMONSTRATED. THE UNIT WAS
DECLARED COMMERCIAL UPON COMPLETION OF THE TESTS.
6/79 SYSTEM 77.0 58.2 720 544 419
** PROBLEMS/SOLUTIONS/COMMENTS
THE ONLY PROBLEMS REPORTED BY THE UTILITY FOR THE MAY-JUNE PERIOD WERE
SPRAY PUMP PACKING FAILURES AND WELDING FAILURES ON THE REHEATER.
7/79 SYSTEM 72.0 56.5 744 583 420
8/79 SYSTEM 88.1 72.6 744 613 540
9/79 SYSTEM 83.6 54.4 720 469 392
** PROBLEMS/SOLUTIONS/COMMENTS
THE WELDING PROBLEMS WITH THE REHEATER MERE ENCOUNTERED IN JULY AND
SEPTEMBER. THE FAILURES ARE CONTINUING AND ARE EXPECTED TO BE RESOLVED
BY THIS WINTER.
10/79 SYSTEM 83.7 65.6 744 583 488
11/79 SY3TEM 95.2 46.4 720 351 334
12/79 SYSTEM (32.2 63. <> 744 574 472
** PROBLEMS/SOLUTIONS/CO11MENTS
DURING THE FOURTH QUARTER OF 1979 THE UTILITY REPORTED THAT NO MAJOR
PROBLEMS OCCURRED. THE UNIT REQUIRED ONLY NORMAL MAINTENANCE.
1/80 SYSTEM 92.1 72.2 744 583 537
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JANUARY NO OPERATIONAL PROBLEMS WERE ENCOUNTERED.
2/80 SYSTEM 71.9 49.7 696 431 346
322
-------
6/78 SYSTEM
7/78 SYSTEM
8/78 SYSTEM
9/78 SYSTEM
99.3
98.8
99.3 • 99.3
98.7 98.7
94.2
100.0
99.3
91.1
94.2
19.2
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
LOUISVILLE GAS & ELECTRIC: CANE RUN 4 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS DOWN AGAIN DURING PART OF MAY FOR REPAIRS.
DURING THE MAY BOILER OUTAGE A NUMBER OF MODIFICATIONS WERE MADE TO THE
DAMPERS IN THE FGD SYSTEM.
720 720 715
744 687 678
744 744 701
720 138 138
** PROBLEMS/SOLUTIONS/COMMENTS
THERE WERE NO FGD FORCED OUTAGES DURING THE AUGUST-SEPTEMBER PERIOD.
THE BOILER WENT DOWN IN SEPTEMBER AFTER 138 HOURS OF OPERATION FOR
TUBE REPAIRS.
10/78 SYSTEM 100.0 .0 744 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER REMAINED OFF LINE DURING OCTOBER FOR CONTINUATION OF THE TUBE
REPAIRS.
11/78 SYSTEM 97.2 58.3 720 432 420
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER AND FGD SYSTEM CAME BACK ON LINE DURING THE SECOND WEEK OF
NOVEMBER WITH NO OPERATIONAL PROBLEMS REPORTED FOR THE FGD SYSTEM.
12/78
SYSTEM 100.0 .0 744 . 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING DECEMBER A TURBINE BECAME UNOPERATIONAL. THE UNIT IS EXPECTED
TO BE OFF LINE UNTIL APRIL.
1/79 SYSTEM 100.0 .0 744 0 0 .0
2/79 SYSTEM 100.0 .0 672 0 0 .0
3/79 SYSTEM 100.0 .0 744 0 0 .0
4/79 SYSTEM 100.0 .0 720 0 0 .0
** PROBLEMS/SOLUTIONS/CCMMENTS
THE UNCT DID NOT OPERATE DURING TNESE MONTHS BECAUSE THE BOILER WAS STILL
DOWN FOR TURBINE REPAIR AND TUBE LEAK REPAIRS.
5/79 SYSTEM 100.0 .0 744 0 0 .0
6/79 SYSTEM 46.2 17.1 720 266 123
315
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
LOUISVILLE GAS « ELECTRIC: CANE RUN 4 (CONT.)
PERFORMANCE DATA
PERIOD .10DULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT REMAINED DOWN DURING MAY FOR CONTINUED TURBINE AND BOILER TUBE
REPAIRS. THE UNIT WAS PLACED BACK IN SERVICE IN JUNE.
7/79 SYSTEM 98.7 93.0 744 701 692
8/79 SYSTEM 89.2 89.2 744 744 664
9/79 SYSTEM .0 .0 720 168 0
** PROBLEMS/SOLUTIONS/COMMENTS
THE ONLY MAJOR PROBLEMS OCCURRED DURING SEPTEMBER. TUBE FAILURES WERE
ENCOUNTERED CAUSING THE BOILER OUTAGE AND MECHANICAL FAILURE WITH THE
DAMPER GATES CAUSED THE SCRUBBER TO BE OFF LINE DURING THE MONTH.
10/79 SYSTEM 30.1 12.0 744 296 89
11/79 SYSTEM 93.9 58.1 720 445 418
12/79 SYSTEM 38.5 20.2 744 390 150
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE FOURTH QUARTER 1979 THERE WERE NO MAJOR PROBLEMS. THE LOW
SCRUBBER HOURS WERE A RESULT OF NECESSARY MAINTENANCE.
1/80 SYSTEM 100.0 95.6 744 711 711
2/80 SYSTEM 99.8 66.7 696 465 464
3/80 SYSTEM 80.5 74.3 744 687 553
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR OPERATIONAL PROBLEMS WERE REPORTED FOR THE FIRST QUARTER OF 1980
WITH EITHER THE BOILER OR THE FGD SYSTEM.
4/80 SYSTEM 99.0 98.8 98.8 79.9 720 582 575
** PROBLEMS/SOLUTIONS/COMMENTS
DURING APRIL SPRAY PUMP PROBLEMS CAUSED SEVEN HOURS OF OUTAGE TIME.
5/80 SYSTEM 96.8 100.0 100.0 7.0 744 52 52
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS NOT NEEDED MOST OF MAY, THIS ACCOUNTS FOR THE LOW
UTILIZATION OF THE FGD SYSTEM.
ONE DAY OF OUTAGE TIME IN MAY WAS CAUSED BY A LEAK IN A SPRAY PUMP
SEAL.
6/80 SYSTEM .0 .0 .0 720 350 0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING PART OF JUNE THE BOILER WAS ON RESERVE, IN WHICH TIME THE SCRUBBER
DUCTWORK AND LININGS WERE REPAIRED.
REPAIRS WERE MADE TO MODULE LININGS AND DUCTWORK. DUCTWORK REPAIRS/
316
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
LOUISVILLE GAS » ELECTRIC: CANE RUN 4 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
REPLACEMENTS WERE MADE WITH 316 SS.
ALSO DURING THE DOWN TIME THE EXPANSION JOINT LOCATED AT THE DISCHARGE
OF THE BOOSTER PUMP WAS REPLACED.
7/80 A 85.7 92.8 92.8 85.7
B 85.7 92.8 92.8 85.7
SYSTEM 85.7 92.8 92.8 85.7 87.00 99.00 744 687 638
** PROBLEMS/SOLUTIONS/COMMENTS
PROBLEMS WERE ENCOUNTERED WITH THE OIL REHEAT SYSTEM DURING JULY.
SPRAY PUMP AND VALVE FAILURES ENCOUNTERED DURING THE MONTH ACCOUNTED FOR
SOME OF THE FGD SYSTEM DOWN TIME.
8/80 SYSTEM 100.0 99.3 99.3 76.9 86.00 99.00 744 576 572 50.0
9/80 SYSTEM 100.0 100.0 100.0 35.7 86.00 99.00 720 257 257 50.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR OUTAGES OCCURRED DURING AUGUST AND
SEPTEMBER.
10/80 SYSTEM 100.0 100.0 100.0 82.1 744 611 611 50.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE MONTH OF OCTOBER.
11/80 SYSTEM 71.8 52.8 52.8 35.2 720 572 254 50.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING NOVEMBER DUCTWORK FAILURE CAUSED SOME OUTAGE TIME.
ALSO DURING THE MONTH PROBLEMS WERE ENCOUNTERED WHEN THE MIST ELIMINATORS
FAILED.
12/80 SYSTEM 100.0 100.0 100.0 76.8 744 572 572 50.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING DECEMBER THE UTILITY REPORTED THAT NO FGD-RELATED PROBLEMS OCCURRED.
317
-------
EPA ITILTTY FGD SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFC9MANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY 11AME
PLANT SAtiE
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICJLATE EMISSION LIMITATION - NG/J
302 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLUNT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - MM
NET UNIT GENERATING CAPACITY KO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BCHLER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** ESP
NUMBER
TYPE
INLET FLUE GAS CAPACITY - CU.M/S
INLET FLUE GAS TEMPERATURE - C
PARTICLE REMOVAL EFFICENCY - 7.
** PARTICLE SCRUBBER
GENERIC TYPE
SPECIFIC TYPE
*** FGD SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
UNIT DESIGN S02 REMOVAL EFFICIENCY - 7.
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
LOUISVILLE GAS & ELECTRIC
CANE RUN
LOUISVILLE
KENTUCKY
D
50.
516.
******
992
200
192
195
200
( .116 LB/MMBTU)
( 1.200 LB/MMBTU)
(****** LB/MMBTU)
RILEY STOKER
PULVERIZED COAL
BASE
306.73 (
162.8 (
76. (
CONCRETE
650000 ACFM)
325 F)
250 FT)
(***** FT)
( 11500 BTU/LB)
10,400-11,900
COAL
BITUMINOUS
267*9.
17.10
15.5-24.5
9.00
8.0-10.75
3.75
3.5-4.0
.04
0.03-0.06
COLD SIDE
306.7
162.8
99.0
NONE
N/A
THROWAWAY PRODUCT
WET SCRUBBING
LIME
COMBUSTION ENGINEERING
FLUOR - PIONEER
FULL SCALE
RETROFIT
7. 99.00
85.00
1
7/78
12/77
4/75
( 650000 ACFM)
( 325 F)
318
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
LOUISVILLE GAS & ELECTRIC: CANE RUN 5 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
IN FEBRUARY THE UTILITY RAN OUT OF CARBIDE LIME CAUSING INTERRUPTION OF
THE FGD SYSTEM OPERATION. THE UNAVAILABILITY OF LIME WAS CAUSED BY FREEZE
UPS ENCOUNTERED BY AIRCO, THE LIME SUPPLIER.
3/80 SYSTEM 44.5 27.2 744 $54 202
** PROBLEMS/SOLUTIONS/COMMENTS
REHEATER TUBE PROBLEMS WERE ENCOUNTERED IN FEBRUARY AND CONTINUED
THROUGH MARCH. THE UTILITY HOPES TO REPLACE THE TUBE BUNDLES IN THE
SUMMER.
4/80 SYSTEM .0 .0 720 0 0 .0
#« PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS OFF LINE THE ENTIRE MONTH OF APRIL TO INSTALL
STAINLESS STEEL (316 SS) IN THE DUCTWORK AND IN THE MODULES.
5/80 SYSTEM 95.3 94.5 94.5 80.2 744 632 597
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MAY ONE DAY OF OUTAGE TIME WAS NECESSARY TO COMPLETE THE INSTALLA-
TION OF THE STAINLESS STEEL IN THE DUCTWORK AND MODULES.
A PUMP SEAL ON THE RECIRCULATION PUMP FAILED CAUSING APPROXIMATELY 10
HOURS OF OUTAGE TIME.
6/80 SYSTEM 78.8 74.4 74.4 61.8 720 598 445
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JUNE THE SYSTEM HAD TO BE TAKEN OFF LINE FOR 153 HOURS DUE TO THE
POOR WELDS ON THE TUBE BUNDLES IN THE REHEATER. THE TUBE BUNDLES HAVE
BEEN A CONSTANT PROBLEM AND THE MANUFACTURER IS SCHEDULED TO REPLACE
THEM IN THE FALL.
7/80 SYSTEM 78.7 87.6 87.6 78.7 85.00 99.00 744 669 586
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JULY THE REHEAT TUBE EXCHANGERS FAILED. TWO NEW EXCHANGERS ARE
NOW ON SITE AND ARE SCHEDULED TO BE INSTALLED IN NOVEMBER OR DECEMBER 1980.
A THREE DAY OUTAGE OCCURRED IN JULY DUE TO A LIMESTONE ROCK DISABLING
THE THICKENER.
8/80 SYSTEM 49.6 58.4 58.4 49.6 90.00 99.00 744 632 369 50.0
9/80 SYSTEM 87.2 97.5 97.5 87.2 90.00 99.00 720 644 628 50.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE OUTAGE TIME DURING AUGUST AND SEPTEMBER WAS CAUSED BY A REHEAT TUBE
BUNDLE FAILURE. THE BUNDLES ARE PRESENTLY BEING REPLACED IN BOTH MODULES.
744 72 72 50.0
720 177 177 50.0
744 743 742 50.0
323
10/80 SYSTEM
11/80 SYSTEM
12/80 SYSTEM
100.0
100.0
100.0
110.0
100.0
100.0
100.0
100.0
100.0
10.0
25.0
99.8
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
LOUISVILLE GAS & ELECTRIC: CANE RUN 5 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
SOZ PART. HOURS HOURS HOURS FACTOR
•** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO FGD-REUTED PROBLEMS WERE ENCOUNTERED DURING
THE FOURTH QUARTER 1980.
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC F6D SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PUNT GENERATING CAPACITY - MW
GROSS INIT GENERATING CAPACITY - MM
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGD - MM
EQUIVALENT SCRUBBED CAPACITY - MM
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** MECHANICAL COLLECTOR
NUMBER
TYPE
** FABRIC FILTER
NUMBER
TYPE
»* ESP
NUMBER
TYPE
INLET FLUE GAS CAPACITY - CU.M/S
INLET FLUE GAS TEMPERATURE - C
PARTICLE REMOVAL EFFICENCY - 7.
*# PARTICLE SCRUBBER
GENERIC TYPE
SPECIFIC TYPE
*** FGD SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
( .116 LB/MMBTU)
( 1.200 LB/MMBTU)
(****** LB/MMBTU)
LOUISVILLE GAS & ELECTRIC
CANE RUN
6
LOUISVILLE
KENTUCKY
D
50.
516.
******
992
299
277
280
299
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
502.57 (1065000 ACFM)
148.9 ( 300 F)
158. ( 518 FT)
CONCRETE
4.9 ( 16.0 FT)
( 11000 BTU/LB)
10,400-11>900
COAL
BITUMINOUS
25586.
17.06
15.5-24.5
8.95
8.0-10.75
4.80
3.5-6.3
.04
0.03-0.06
0
NONE
0
NONE
COLD SIDE
502.6
148.9
99.4
NONE
N/A
THROWAWAY PRODUCT
WET SCRUBBING
DUAL ALKALI
COMBUSTION EQUIP ASSOCIATES
FLUOR - PIONEER
DEMONSTRATION
(1065000 ACFM)
( 300 F)
325
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
LOUISVILLE GAS & ELECTRIC: CANE RUN 6 (CONT.)
NEW/RETROFIT RETROFIT
OMIT DESIGN PARTICLE REMCVAL EFFICIENCY - X 99.00
UNIT DESIGN S02 REMOVAL EfFICIENCY - X 95.00
CURF'ENT STATUS 1
INFTAL START-UP 4/79
CONTRACT AWARDED 10/76
** DESIC.N AND OPERATING PARAMF.TERS
** ABSORBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
DIMENSIONS - FT
SiiELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
G\S CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
LIQUID RECIRCULATION RATE - LITER/S
L/G RATIO - L/CU.M
GAS-SIDE PRESSURE DROP - KPA
SIPERFICAL GAS VELOCITY - M/SEC
INLET GAS FLOW - CU. M/S
Ih'LET GAS TEMPERATURE - C
SC2 REMOVAL EFFICIENCY - X
** MIST ELIMINATOR
PR—MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES PER STAGE
FREEBOARD DISTANCE - M
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/S
CONSTRUCTION MATERIAL GENERIC TYPE
** REHEATER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
PERCENT GAS BYPASSED - AVG
TEMPERATURE INCREASE - C
INLET FLUE GAS FLOW RATE - CU. M/S
INLET FLUE GAS TEMPERATURE - C
** FANS
NUMBER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
TRAY TOWER
SIEVE TRAY
COMBUSTION EQUIP ASSOCIATES
32 DIA X 45
CARBON STEEL
A-283
N/A
ORGANIC
MICA FLAKE-FILLED POLYESTER
SIEVE TRAY
272.
1.3
2.5
2.7
251.52
148.9
94.2
( 4318 GPM)
( 10.0 GAL/1000 ACF)
( 9.9 IN-H20)
( 9.0 FT/S)
( 533000 ACFM)
( 300 F)
MIST ELIMINATOR
2
IMPINGEMENT
BAFFLE
CHEVRON VANE
HORIZONTAL
1
4
1.52 (
.2 (
2.7 (
POLYPROPYLENE
5.0 FT)
1.0 IN-H20)
9.0 FT/S)
DIRECT COMBUSTION
EXTERNAL COMBUSTION CHAMBER
OIL
.0
10.0 ( 50 F)
205.98 ( 436500 ACFM)
51.7 ( 125 F)
2
BOOSTER
FORCED DRAFT
DRY
251.52
148.9
( 533000 ACFM)
( 300 F)
A441 CARBON STEEL
SCRUBBER INLET
CARBON STEEL
NONE
SCRUBBER TO REHEATER
CARBON STEEL
326
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
LOUISVILLE GAS & ELECTRIC: CANE RUN 6 CCONT.)
LINER GENERIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
** DUZTWORK
LOCATION
3HELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
FRP
REHEATER TO STACK
317L SS
NONE
BYPASS/TRANSITION DUCT
CARBON STEEL
NONE
** TA:-JKS
SERVICE
PRIMARY REACTION TANK
SECCNDARY REACTION TANK
FEEt FORWARD TANK
FILTRATE SUMP
THICKENER HOLD TANK
SOD* ASH SOLUTION TANK
SODA ASH SILO
** SOLIDS CONCENTRATING/DEWATERING
DKVICE
NUMBER
NUMBER OF SPARES
CAPACITY
Bi:LT SPECIFIC MATERIAL TYPE
F'JED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
** SOLIDS CONCENTRATINS/DEWATERING
DEVICE
NUMBER
CCNFIGURATION
DIMENSIONS - FT
SHELL GENERIC MATERIAL TYPE
OtTLET STREAM CHARACTERISTICS
*** SLUDGE
** TREATMENT
PROPRIETARY PROCESS
** DISPOSAL
NATURE
TY'3E
LOCATION
SITE TRANSPORTATION METHOD
** PROCESS CONTROL AND INSTRUMENTATION
PHYSICAL VARIABLES
MONITOR LOCATION
PROCESS CONTROL MANNER
PROCESS CHEMISTRY MODE
** WATER BALANCE
WATER LOOP TYPE
EVAPORATION WATER LOSS - LITER/S
** FGD SPARE CAPACITY INDICES
ABSORBER - X
FAN - X
RECIRCULATION PUMP - X
** FGO SPARE COMPONENT INDICES
ABSORBER
FAN
NUMBER
2
2
****
3
1
1
1
VACUUM FILTER
3
1
3 TON/DAY
FIBER-REINFORCED
25X SOLIDS
63X SOLIDS
POLYESTER
THICKENER
1
CYLINDRICAL
125 (DIA) X 23 (DEPTH)
CARBON STEEL
25X SOLIDS
IUCS
FINAL
LANDFILL
ON SITE
TRUCK
PH
ABSORBER BLEED LIQUOR
AUTOMATIC
FEED FORWARD
CLOSED
17.5
20.0
.0
100.0
.3
.0
( 278 GPM)
327
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
LOUISVILLE GAS & ELECTRIC: CANE RUN 6 (CONT.)
RECIRCULATION PUMP 1.0
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
4/79 SYSTEM 49.9 32.9 720 475 237
** PROBLEMS/SOLUTIONS/COMMENTS
THIS UNIT STARTED OPERATING ON APRIL 4, 1979. COMPLIANCE TESTING IS
SCHEDULED FOR THE WEEK OF JUNE 3.
5/79 SYSTEM 21.5 14.7 744 506 109
6/79 SYSTEM 12.3 10.3 720 601 74
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE SYSTEM IS STILL CONSIDERED IN START-UP AND
THAT NO UNUSUAL PROCESS PROBLEMS HAVE BEEN ENCOUNTERED. HOWEVER THE SYS-
TEM IS NOW OUT OF SERVICE DUE TO THE COMPLETE FAILURE OF THE MIST ELIM-
INATORS. IT IS EXPECTED TO BE DOWN FOR A MONTH.
7/79 SYSTEM .0 .0 744 529 0
** PROBLEMS/SOLUTIONS/CO.IMENTS
THE UNXT DID NOT OPERATE IN JULY US PROCEDURES CONTINUED TO REPLACE THE
MIST ELIMINATORS.
8/79 SYSTEM 7.0 7.0 744 683 51
9/79 SYSTEM 60.0 44.0 720 531 317
** PROBLEMS/SOLUTIONS/COMMENTS
DURING AUGUST AND SEPTEMBER THE UNIT DOWNTIME WAS DUE TO THE COMPLETE
FAILURE OF FIVE PUMPS. THE PUMP PROBLEMS WERE THE LOSS OF THE IMPELLERS
OFF OF THE SHAFTS.
10/79 SYSTEM 81.4 28.9 744 246 215
11/79 SYSTEM 97.7 63.5 720 468 457
12/79 SYSTEM 94.9 89.7 744 703 667
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR PROBLEMS OCCURRED DURING THE FOURTH
QUARTER OF 1979. THE UNIT REQUIRED ONLY NORMAL MAINTENANCE.
1/80 SYSTEM 49.0 13.8 744 210 103
?<* PROBLEMS/SOLUTIONS/COMMENTS
FGD SYSTEM OUTAGE TIME IN JANUARY WAS CAUSED BY A THICKENER FAILURE.
THE RAKE BECAME INOPERABLE BECAUSE OF HIGH SOLIDS AND THE THICKENER HAD
TO BE CLEANED OUT.
2/80 SYSTEM 84.7 47.0 696 386 327
3/80 SYSTEM 70.0 64.5 744 686 480
328
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
LOUISVILLE GAS & ELECTRIC: CANE RUN 6 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
IN FEBRUARY AND MARCH OUTAGE TIME WAS CAUSED BY PROBLEMS WITH THE RECYCLE
PUMPS.
4/80 SYSTEM 98.8 91.5 97.7 73.9 95.00 99.00 720 581 531
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER OUTAGES IN APRIL WERE A RESULT OF THE LOSS OF ONE OF THE BOILER
FEED PUMPS AND BECAUSE THE LOAD WAS NOT NEEDED.
THE FGD OUTAGES WERE A RESULT OF HIGH BOOSTER FAN SUCTION TRIPS, REPAIRS
TO THE IUCS SYSTEM, REPAIRS TO THE THICKENER UNDERFLOW LINE AND A PLANNED
INSPECTION OF THE TRAYS. THE TRAY PLUGGING PROBLEM WAS SOLVED BY A
SLIGHT PH ADJUSTMENT IN THE REACTORS.
5/80 SYSTEM 99.9 99.9 99.9 99.5 744 741 740
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MAY THE PRESSURE RELIEF VALVE ON THE BOOSTER FAN MALFUNCTIONED
FORCING THE FGD SYSTEM OUT OF SERVICE.
6/80 SYSTEM 99.9 99.7 99.9 88.9 720 642 640
** PROBLEMS/SOLUTIONS/COMMENTS
A SPRAY PUMP MALFUNCTION CAUSED THE SYSTEM TO SHUTDOWN. APPROXIMATELY
ONE HOUR WAS NEEDED TO PUT THE SPARE INTO SERVICE.
THE BOILER WAS OFF FOR REPAIRS TO T^ CLINKER GRINDER AND TO REPAIR A
BOILES TUBE LEAK.
IMPROVEMENTS TO THE PH CONTROL CIRCUITRY HAVE LEAD TO IMPROVED CARBIDE
LIME U ILIZATION.
EXPERIHENTATION WITH A NEW FILTER CLOTH HAS SHOWN AN IMPROVEMENT IN SODA
ASH CONSUMPTION.
SULFUR DIOXIDE EMISSIONS AVERAGED LESS THAN 200 PPM FOR JUNE.
7/80 SYSTEM 99.9 99.7 99.9 82.9 744 618 617
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE PERIOD FROM JULY 17 THROUGH JULY 28 AN ACCEPTANCE TEST WAS RUN.
DURING THE TEST THE FGD SYSTEM EXPERIENCED NO MAJOR PROBLEMS OR OUTAGE
TIME. THE AVERAGE S02 REMOVAL EFFICIENCY DURING THE TEST WAS 93.9Z.
DURING NORMAL OPERATION IN JULY NO MAJOR FGD RELATED PROBLEMS WERE
ENCOUNTERED.
8/80 SYSTEM 99.3 94.6 94.6 84.5 95.00 99.00 744 665 628 50.0
9/80 SYSTEM 94.0 98.6 98.7 86.9 95.00 99.00 720 635 626 50.0
«* PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR PROBLEMS OCCURRED DURING THE MONTHS OF
AUGUST AND SEPTEMBER.
10/80 SYSTEM 99.8 99.8 99.8 99.8 744 743 743 33.0
329
-------
EPA UTILITY FSD SURVEY: OCTOBER - DECEMBER 1980
LOUISVILLE GAS & ELECTRIC: CANE RUN 6 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR PROBLEMS OCCURRED DURING THE MONTHS OF
11/80 SYSTEM 85.1 96.8 96.8 55.1 720 409 397 33.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING OCTOBER AND NOVEMBER THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED
PROBLEMS WERE ENCOUNTERED.
12/80 SYSTEM 60.0 6.0 6.0 1.9 744 240 14 50.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING DECEMBER THE THICKENER RACK SHAFT WAS SHEARED-OFF CAUSING THE SYSTEM
TO SHUTDOWN FOR APPROXIMATELY 226 HOURS.
330
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - N6/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY M/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
LOUISVILLE GJ
MILL CREEK
1
LOUISVILLE
KENTUCKY
E
43.
516.
******
*****
358
334
339
358
VS & ELECTRIC
( .100 LB/MMBTU)
( 1.200 LB/MMBTU)
(**#*** LB/MMBTU)
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** PARTICLE SCRUBBER
GENERIC TYPE
SPECIFIC TYPE
*** FGD SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
N^W/RETROFIT
UMIT DESIGN SOS REMOVAL EFFICIENCY - 7.
CJRRENT STATUS
OMMERCIAL START-UP
INITIAL START-UP
** DESIGN AND OPERATING PARAMETERS
** ABSORBER
SUPPLIER
L/G P4TIO - L/CU.M
SJ2 REMOVAL EFFICIENCY - .'.
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
******** (******* ACFM)
******* (**** f)
****** (**** FT)
******
******* (***** FT)
t 11500 BTU/LB)
******
COAL
26749.
11.50
******
********
******
3.75
3.5-4.0
.06
NONE
N/A
THROWAWAY PRODUCT
WET SCRUBBING
LIME
COMBUSTION ENGINEERING
FLUOR - PIONEER
FULL SCALE
RETROFIT
85.00
1
4/81
12/80
COMBUSTION ENGINEERING
12.7 (95.0 GAL/1000 ACF)
86.6
331
-------
EPA ITILITY FGD SURVEY: OCTOBER - DECEMBER 1980
LOUISVILLE GAS & ELECTRIC: MILL CREEK 1 (CONT.)
** REHEATER
TEMPERATURE INCREASE - C
*** SLUDGE
** TREATMENT
PROPRIETARY PROCESS
** DISPOSAL
LOCATION
10.0
IUCS
ON SITE
( 50 F)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
SOZ PART. HOURS HOURS HOURS FACTOR
12/80 SYSTEM 45.2 98.5
** PROBLEMS/SOLUTIONS/COMMENTS
98.5
744 336
331 60.0
THE FGD SYSTEM IS PRESENTLY IN THE STARTUP PHASE. OPERATIONS BEGAN ON
DECEMBER 17, 1980 AND NO MAJOR PROBLEMS WERE REPORTED.
332
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC F6D SYSTEMS
COMPAN" NAME
PLANT HAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTIC'JLATE EMISSION LIMITATION - NG/J
S02 EMCSSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MM
GROSS UNIT GENERATING CAPACITY - MM
NET UN^T GENERATING CAPACITY M/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGD - MM
EQUIVALENT SCRUBBED CAPACITY - MM
** UNIT DATA - BOILER AND STACK
BCILER SUPPLIER
BOILER TYPE
BCILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOM - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
ST4CK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - X
RANGE ASH CONTENT - '/.
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
*** PARTICLE CONTROL
** ESP
NUMBER
TYPE
SUPPLIER
** PARTICLE SCRUBBER
GENERIC TYPE
SPECIFIC TYPE
*** FGD SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
UNIT DESIGN S02 REMOVAL EFFICIENCY - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
LOUISVILLE GAS & ELECTRIC
MILL CREEK
3
LOUISVILLE
KENTUCKY
D
43.
516.
( .100 LB/MMBTU)
( 1.200 LB/MMBTU)
(****** LB/MMBTU)
1079
442
420
427
442
BABCOCK & MILCOX
PULVERIZED COAL
BASE
********
*******
183.
CONCRETE
6.4
COAL
BITUMINOUS
26749.
11.50
******
********
******
3.75
3.5-4.0
.04
COLD SIDE
AMERICAN AIR FILTER
NONE
N/A
THROWAWAY PRODUCT
WET SCRUBBING
LIME
AMERICAN AIR FILTER
FLUOR - PIONEER
FULL SCALE
NEM
- X 99.00
85.00
1
3/79
8/78
7/74
(******* ACFM)
(**** F)
( 600 FT)
( 21.0 FT)
( 11500 BTU/LB)
333
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
LOUISVILLE GAS A ELECTRIC: MILL CREEK 3 (CONT.)
** DESIGN AND OPERATING PARAMETERS
** ABSORBER
NUMBFR
GENERIC TYPE
SPECIFIC TYPE
T^AfE NAME/COMMON TYPE
SUPPLIER
SHEIL GENERIC MATERIAL
SHEIL SPECIFIC MATERIAL
SSE1.L MATERIAL TRADE NAME. COMMON TYPE
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
GiS CONTACTING DEVICE TYPE
L/G RATIO - L/CU.M
G\S-SIDE PRESSURE DROP - KPA
INLET GAS FLOW - CU. M/S
I'-ILET GAS TEMPERATURE - C
S02 REMOVAL EFFICIENCY - X
** MIST ELIMINATOR
P3E-MIST ELIMINATOR/MIST ELIMINATOR
NJMBER PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
NU1BER OF STAGES
NUMBER OF PASSES PER STAGE
CCNSTRUCTION MATERIAL GENERIC TYPE
** REPEATER
GENERIC TYPE
SPECIFIC TYPE
TR4DE NAME/COMMON TYPE
TEMPERATURE INCREASE - C
INLET FLUE GAS TEMPERATURE - C
CCNSTRUCTION MATERIAL GENERIC TYPE
** FANS
NUMBER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
*** SLUDGE
** TREATMENT
METHOD
** DISPOSAL
NATURE
TYPE
LOCATION
PACKED TOWER
ENTRAINED PACKING
MOBILE BED CONTACTOR
AMERICAN AIR FILTER
CARBON STEEL
AISI 1110
N/A
INORGANIC
HYDRAULICALLY-BONDED CEMENT
PREKRETE
POLYURETHANE SPHERES, SOLID
8.7 ( 65.0 GAL/1000 ACF)
1.6 ( 6.5 IN-H20)
212.35 ( 450000 ACFM)
148.9 ( 300 F)
85.7
MIST ELIMINATOR
4
IMPINGEMENT
BAFFLE
CHEVRON VANE
HORIZONTAL
Z
2
PLASTIC
IN-LINE
STEAM
FIN TUBE
10.0 ( 50 F)
54.4 { 130 F)
CARBON STEEL TUBES;316 SS TUBE SHEETS
BALANCED DRAFT
FORCED DRAFT
DRY
212.35 ( 450000 ACFM)
SCRUBBER INLET
CARBON STEEL
PRECRETE
SCRUBBER OUTLET
CARBON STEEL
PRECRETE
FLYASH/LIME STABILIZATION
FINAL
POND
ON SITE
334
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
LOUISVILLE GAS & ELECTRIC: MILL CREEK 3 (CONT.)
** WATER BALANCE
WATER LOOP TYPE
MAKEUP WATER ADDITION - LITERS/S
** FGO SPARE CAPACITY INDICES
ABSORBER - X
** F(?D SPARE COMPONENT INDICES
ABSORBER
OPEN
9.4
.0
( 150 GPM)
PERFORMANCE DATA
PERIOC MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
8/78
SYSTEM
*Jf PROBLEMS/SOLUTIONS/CO1MENTS
744
INITIAL FGD OPERATIONS BEGAN ON AUGUST 13, 1978. OPERATIONAL HOURS WERE
NOT AVAILABLE FOR AUGUST.
9/78 SYSTEM 80.7 80.0
** PROBLEMS/SOLUTIONS/COMMENTS
FRP PIPING PROBLEMS WERE ENCOUNTERED.
720
576
SOME BEARING AND SHAFT RELATED PUMP PROBLEMS WERE ALSO ENCOUNTERED
DURING SEPTEMBER.
10/78 SYSTEM 85.5
11/78 SYSTEM 85.2
** PROBLEMS/SOLUTIONS/COMMENTS
81.6
41.5
744
720
710
351
607
299
THE UNIT WAS SHUT DOWN NOVEMBER 18, 1978 FOR SCHEDULED INSPECTION.
RESTART IS PROJECTED FOR FEBRUARY 1, 1979.
12/78 SYSTEM .0 744 0 0
1/79 SYSTEM .0 744 0 0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT DID NOT OPERATE DURING DECEMBER OR JANUARY.
2/79 SYSTEM 18.0 17.4 672 651 117
3/79 SYSTEM 53.1 52.4 744 735 390
** PROBLEMS/SOLUTIONS/COMMENTS
COMPLIANCE TESTING WAS PERFORMED DURING MARCH AND THE UNIT WAS DECLARED
COMMERCIAL.
4/79 SYSTEM 63.6 44.4 720 503 320
** PROBLEMS/SOLUTIONS/COMMENTS
THE ONLY PROBLEMS REPORTED WERE WITH DAMPERS AND PUMP FAILURES.
5/79 SYSTEM 97.8 64.7 744 492 481
6/79 SYSTEM 51.9 47.9 720 665 345
.0
.0
335
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
LOUISVILLE GAS & ELECTRIC: MILL CREEK 3 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO UNUSUAL OPERATING PROBLEMS WERE ENCOUNTERED
DURING MAY OR JUNE.
7/79 SYSTEM 59.9 55. 2 7V* 686 411
8/79 SYSTEM 68.0 50.3 744 550 374
** PROBLEMS/SOLUTIONS/COMMENTS
IN JULY AND AUGUST REHEATER PROBLEMS WERE ENCOUNTERED. THE REHEATER WILL
HAVE TO BE REPLACED DURING EITHER NOVEMBER OR DECEMBER OF THIS YEAR.
9/79 SYSTEM 90.6 83.9 720 667 604
10/79 SYSTEM 82.0 76.1 744 690 566
** PROBLEMS/SOLUTIONS/COMMENTS
AT THE END OF OCTOBER THE UNIT WENT DOWN FOR A TURBINE OVERHAUL AND IS
SCHEDULED TO BE DOWN UNTIL LATE JANUARY OR EARLY FEBRUARY.
11/79 SYSTEM .0 720 0 0 .0
IE/79 SYSTEM .0 744 0 0 .0
1/80 SYSTEM .0 744 0 0 .0
*»< PROBLEMS/SOLUTIONS/CrMMENTS
DURING THE OVERHAUL GENERAL SCRUBBER MAINTENANCE WAS DONE BUT NO MAJOR
MODIFICATIONS WERE MADE.
2/80 SYSTEM 36.1 26.6 696 512 185
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT CAME BACK ON LINE ON FEBRUARY 10 AFTER THE TURBINE OVERHAUL
WORK WAS COMPLETED.
3/80 SYSTEM 36.9 30.6 744 618 228
** PROBLEMS/SOLUTIONS/COMMENTS
PROBLEMS ENCOUNTERED DURING FEBRUARY AND MARCH WITH THE FGD SYSTEM
OPERATION INCLUDED FROZEN WATER LINES AND WORN GASKETS BLOWING IN THE
REHEATER FLANGES.
THE UTILITY IS IN THE PROCESS OF REPLACING THE REHEATER TUBES.
4/80 SYSTEM 42.9 42.5 42.5 42.2 85.00 99.40 720 715 304
** PROBLEMS/SOLUTIONS/COMMENTS
THE REHEATER TUBE REPLACEMENT CONTINUED INTO APRIL.
THE OTHER OUTAGE TIME ENCOUNTERED DURING APRIL WAS CAUSED BY A BLOWN
GASKET IN THE CONDENSATE PUMP.
5/80 SYSTEM 67.5 51.4 51.4 34.4 744 498 256
336
-------
EPA UTILITY FED SURVEY: OCTOBER - DECEMBER 1980
LOUISVILLE EAS 8 ELECTRIC: MILL CREEK 3 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MAY THE PLASTIC MIST ELIMINATOR COMPONENTS WERE REPLACED WITH
STAINLESS STEEL. THIS KEPT THE SYSTEM OFF LINE FOR APPROXIMATELY 10 DAYS.
REHEATER TUBE LEAKS WERE ALSO ENCOUNTERED IN MAY.
6/80 SYSTEM 88.2 .0 .0 .0 720 85 0
** PROBLEMS/SOLUTIONS/COMMENTS
IN LATE MAY THE TURBINE LOST TWO BLADES CAUSING THE SYSTEM TO SHUTDOWN
UNTIL THE LATTER PART OF JUNE. DURING THE OUTAGE THE UTILITY DECIDED
TO REPLACE THE LIME STORAGE TANK LINES WITH LARGER ONES TO SERVICE THE
NEW UNITS. THE WORK WAS NOT COMPLETED WHEN THE BOILER WAS RETURNED
TO SERVICE; THUS, THE FGD UNIT DID NOT OPERATE DURING THE MONTH.
7/80 SYSTEM 92.0 91.3 91.3 83.9 744 684 625
** PROBLEMS/SOLUTIONS/COMMENTS
RECYCLE PUMP FAILURES CAUSED THE FGD SYSTEM TO SHUTDOWN FOR PART OF JULY.
8/80 SYSTEM 58.7 81.7 81.7 58.7 80.00 99.00 744 535 437 60.0
9/80 SYSTEM 57.2 60.4 60.4 57.2 80.00 99.00 720 682 412 60.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE AUGUST THROUGH SEPTEMBER PERIOD THE PUMP HOUSE WAS FLOODED
DUE TO THE FAILURE OF THE BLEED PUMP FRP PIPE LINE. BECAUSE OF THIS
FAILURE, 23 PUMPS AND 23 PUMP MOTORS WERE DAMAGED.
10/80 SYSTEM 100.0 97.1 97.1 96.9 744 742 721 99.7
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURINC THE MONTH OF OCTOBER.
11/80 S1STEM 57.1 i9.4 49.4 41.9 720 611 302 60.0
** PROBLEMS/SOLUTIONS/C0.1MENTS
DURING NOVEMBER OPERATION OF THE FGD SYSTEM WAS LOW DUE TO PUMP DAMAGES
WHICH RESULTED FROM THE PUMP HOUSE FLOODING IN AUGUST.
12/80 SYSTEM 100.0 100.0 100.0 61.1 744 455 455 60.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE MONTH OF DECEMBER.
337
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NS/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY NO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RAKGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7.
RAKGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** ESP
NUMBER
SUPPLIER
PARTICLE REMOVAL EFFICENCY - 7.
** PARTICLE SCRUBBER
GENERIC TYPE
SPECIFIC TYPE
*** FGO SYSTEM
** GENERAL DATA
SALEABLE FRODUCT/THROWAWAY PRODUCT
S02 REMOVAL MODE
P.70CFSS TYPE
SfSTCM SUPPLIER
A-E <-IRM
DEVELOPMENT LEVEL
N~W/RETROFIT
UlilT DESIGN PARTICLE REMOVAL EFFICIENCY
UUIT DESIGN S02 REMOVAL EFFICIENCY - 7.
CUSRENT STATUS
INITIAL START-UP
CONTRACT AWARDED
** DEMGN AND OPERATING PARAMETERS
LOUISVILLE GAS & ELECTRIC
PADDY'S RUN
6
LOUISVILLE
KENTUCKY
E
43.
516.
******
( .100 LB/MMBTU)
( 1.200 LB/MMBTU)
(****** LB/MMBTU)
302
72
67
69
72
FOSTER WHEELER
PULVERIZED COAL
PEAK
188.76
179.4
76.
******
******* (***** FT)
( 400000 ACFM)
( 355 F)
( 250 FT)
( 11500 BTU/LB)
******
COAL
BITUMINOUS
26749.
11.50
******
********
******
2.50
2.0-3.5
********
******
RESEARCH-COTTRELL
99.1
NONE
N/A
THROWAWAY PRODUCT
WET SCRUBBIK3
LIME
COfiSUSTION ENGINEERING
FLUOR - PIONEER
FULL SCALE
RETROFIT
7. 99.10
90.00
1
4/73
7/71
338
-------
EPA UTILITY FSD SURVEY: OCTOBER - DECEMBER 1980
LOUISVILLE GAS & ELECTRIC: PADDY'S RUN 6 (CONT.)
** ABSORBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
DISTANCE BETWEEN GAS CONTACTING ZONES - CM
L/G RATIO - L/CU.M
GAS-SIDE PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/SEC
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
S02 REMOVAL EFFICIENCY - 7.
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES PER STAGE
FREEBOARD DISTANCE - M
DISTANCE BETWEEN STAGES - CM
DISTANCE BETWEEN VANES - CM
VANE ANGLES - DEGREES
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/S
CONSTRUCTION MATERIAL GENERIC TYPE
WASH RATE - L/S
** REHEATER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
TEMPERATURE INCREASE - C
INLET FLUE GAS TEMPERATURE - C
** FANS
NUMBER
SUPPLIER
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
** TANKS
SERVICE
REACTION
SCRUBBER RECYCLE
REACTION SURGE TANK
ADDITIVE SLURRY TANK
** PU1PS
S'ERVICE
PACKED TOWER
STATIC BED PACKING
MARBLE BED SCRUBBER
COMBUSTION ENGINEERING
17X18X50 HIGH
CARBON STEEL
AISI 1110
N/A
ORGANIC
FIBER-REINFORCED POLYESTER
1 INCH DIA MARBLES (GLASS)
2
7.6
2.2
2.9
Z.7
82.58
176.7
90.0
( 3.0IN)
( 16.5 GAL/1000 ACF)
(11.5 IN-H20)
( 9.0 FT/S)
( 175000 ACFM)
( 350 F)
MIST ELIMINATOR
2
IMPINGEMENT
BAFFLE
CHEVRON VANE
HORIZONTAL
2
3
1.37
12.70
4.3
.4
3.0
FIBERGLASS
8.8
4.5 FT)
5.0 IN)
1.70 IN)
( 1.5 IN-H20)
( 10.0 FT/S)
( 140 GAL/MIN)
DIRECT COMBUSTION
IN-LINE BURNER
NATURAL GAS
3.9 ( 39 F)
52.2 ( 126 F)
GREEN FAN
DRY
82.58
71.1
NUMBER
175000 ACFM)
160 F)
** SO'.IDS CONCENTRATING/DEWATERING
DEVICE
N.JMBF9
****
****
****
**#*
NUMBER
3
VACUUM FILTER
2
339
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
LOUISVILLE GAS & ELECTRIC: PADDY'S RUN 6 (CONT.)
CAPACITY 240 TON/DAY
BELT SPECIFIC MATERIAL TYPE NYLON
FLED STREAM CHARACTERISTICS 22X SOLIDS
OUTLET STREAM CHARACTERISTICS 45X SOLIDS
** SOLIDS CONCENTRATING/DEWATERING
DEVICE THICKENER
Nb'tBER I
DIMENSIONS - FT 50 DIA
FEED STREAM CHARACTERISTICS 10X SOLIDS
OUTLET STREAM CHARACTERISTICS 22X SOLIDS
*** SLUICE
** TREwTMENT
METHOD
** DISPOSAL
NATURE
TYPE
SITE TRANSPORTATION METHOD
SITE CAPACITY - CU.M
** WATER BALANCE
WATER LOOP TYPE
MAKEUP WATER ADDITION - LITERS/S
** FGD SPARE CAPACITY INDICES
ABSORBER - 7.
** FGD SPARE COMPONENT INDICES
ABSORBER
LIME STABILIZATION
FINAL
POND
TRUCK
30575
25.0 ApRE-FT)
CLOSED
3.1
.0
.0
50 GPM)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
4/73
6A
6B
SYSTEM
18.0
56.0
37.0
8.0
24.9
16.5
720 320
118
** PROBLEMS/SOLUTIONS/COMMENTS
INITIAL OPERATION OF THE FGD SYSTEM AT PADDY'S RUN BEGAN IN APRIL. THE
MODULES WERE OPERATED ONE AT A TIME, WITH FREQUENT SHUTDOWNS FOR INSPEC-
TION OF EQUIPMENT AND MINOR REPAIRS.
5/73
6A
6B
SYSTEM
11.0
65.0
38.0
3.9
23.1
13.5
744 265
101
** PROBLEMS/SOLUTIONS/COMMENTS
6/73 6A
6B
SYSTEM
7/73 6A
6B
SYSTEM
SINGLE-MODULE OPERATION CONTINUED THROUGH MAY 19, WHEN THE UNIT WAS SHUT
DOWN FOR MODIFICATIONS.
EQUIPMENT WAS INSTALLED FOR INJECTION OF A FLOCCULATING AGENT INTO THE
CLARIFIER TANK.
.1
6.0
3.1
21.0
21.0
21.0
.0
2.1
1.1
6.7
6.7
6.7
720 255
744 240
50
340
-------
EPA UTILITY FKD SURVEY: OCTOBER - DECEMBER 1980
LOUISVILIE GAS t ELECTRIC: PADD"S RUN 6 (CONT. )
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
DURING A SCHEDULED OUTAGE FROM JULY 12 TROUGH AUGUST 1, SEVERAL REPAIRS
WERE MADE TO THE LIME SLURRY MAKE-UP SYSTEM. A DISINTEGRATOR UNIT WAS
INSTALLED TO REDUCE PLUGGING OF STRAINERS AND SLURRY CONTROL VALVES.
OPERATION WAS INTERMITTENT FROM JUNE 19 TO JULY 11 BECAUSE OF MECHANICAL
PROBLEMS WITH THE SLURRY PUMPS.
8/73 6A 53.0 23.5
6B 64.0 28.4
SYSTEM 58.5 26.0 744 330 193
** PROBLEMS/SOLUTIONS/COMMENTS
THE OPERATION WAS CONTINUOUS FROM AUGUST 2 TO AUGUST 18 EXCEPT FOR A BRIEF
SHUTDOWN DUE TO A BOILER-RELATED PROBLEM.
FROM AUGUST 19 TO SEPTEMBER 5, THE SYSTEM WAS SHUT DOWN TO REPLACE THE
CLARIFIER UNDERFLOW LINE WITH ONE OF LARGER DIAMETER AND TO INSTALL
ADDITIONAL PUMP CAPACITY IN THE CLARIFIER OVERFLOW SYSTEM.
9/73 6A 85.0 46.1
6B 72.0 39.0
SYSTEM 78.5 42.6 720 390 306
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT OPERATED CONTINUOUSLY BETWEEN SEPTEMBER 6 AND 20 EXCEPT FOR A
7-HOUR SHUTDOWN TO REPAIR A MARBLE BED SUPPORT PLATE.
THE UNIT WAS SHUT DOWN FROM SEPTEMBER 20 TO THE END OF THE MONTH.
10/73 6 A 49.0 45.4
6B 94.0 87.2
SYSTEM 71.5 66.3 744 690 493
11/73 6A 35.0 35.0
6B 100.0 100.0
SYSTEM 67.5 67.5 720 720 486
12/73 6A 44.0 11.3
6B 78.0 19.9
SYSTEM 61.0 15.6 744 190 116
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS OPERATED UNTIL DECEMBER 20 AFTER WHICH THE BOILER AND
THE SCRUBBER MODULES WERE SHUT DOWN BECAUSE OF A LACK OF DEMAND (THIS IS
A PEAKING-LOAD BOILER).
1/74 SYSTEM .0 744 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS SHUT DOWN DUE TO A LACK OF DEMAND.
2/74 SYSTEM .0 672 0 0 .0
3/74 SYSTEM .0 744 0 0 .0
4/74 SYSTEM .0 720 0 0 .0
5/74 SYSTEM .0 744 0 0 .0
341
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
LOUISVILLE GAS & ELECTRIC: PADDY'S RUN 6 (CONT.)
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FED CAP.
S02 PART. HOURS HOURS HOURS FACTOR
6/74 SY?TEM
7/74 6A
6F
SYSTEM
8/74 6/
6E
SYSTEM
51.0
31. 0
>6.0
50.0
77.0
63.5
.0
21.0
33.:,
27.2
2.1
3.2
2.7
720 0 0
744 306 202
744 31 20
.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT HAS BEEN ON AND OFF FREQUENTLY DUE TO FLUCTUATION IN POWER
DEMAND.
9/74 SYSTEM
.0
.0
720 43 0
** PROBLEMS/SOLUTIONS/COMMENTS
10/74 6A
6B
SYSTEM
THE BOILER WAS
100.0
100.0
100.0
SHUT DOWN BECAUSE OF
32.9
32.9
32.9
A LACK OF DEMAND.
744 245 245
** PROBLEMS/SOLUTIONS/COMMENTS
11/74 SYSTEM
THE BOILER WAS
.0
OPERATED TO PERFORM
.0
LIMESTONE TESTS ON THE FGD SYSTEM.
720 122 0
** PROBLEMS/SOLUTIONS/COMMENTS
12/74 SYSTEM
1/75 SYSTEM
2/75 SYSTEM
3/75 SYSTEM
4/75 SYSTEM
5/75 SYSTEM
6/75 SYSTEM
7/75 SYSTEM
8/75 SYSTEM
9/75 6A
6B
SYSTEM
10/75 6A
6B
SYSTEM
THE BOILER WAS
100.0
100.0
100.0
100.0
100.0
100.0
SHUT DOWN BECAUSE OF
.0
.0
.0
.0
.0
.0
.0
.0
.0
100.0
100.0
100.0
100.0
100.0
100.0
A LACK OF DEMAND.
744 0 0
744 0 0
672 0 0
744 0 0
720 0 0
744 0 0
720 0 0
744 0 0
744 0 0
720 720 720
744 744 744
.0
.0
.0
.0
.0
.0
.0
.0
.0
342
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
LOUISVILLE GAS & ELECTRIC: PADDY'S RUN 6 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER AND FGD SYSTEM WERE OPERATIONAL ALL OF SEPTEMBER AND THE FIRST
TWO WEEKS IN OCTOBER. OPERABILITY FOR BOTH MODULES DURING THE OPERATIONAL
PERIOD WAS 100X (BASED UPON LGSE'S PEAK LOAD DETERMINATION). S02 REMOVAL
WAS REPORTED TO BE OVER 93X.
SYSTEM OUTAGE IN THE LAST TWO WEEKS OF OCTOBER WAS DUE PRIMARILY TO
PROBLEMS WITH THE BREECHING IN THE BOILER SECTION.
11/75 6A 100.0 100.0
68 100.0 100.0
SYSTEM 100.0 100.0 720 720 730
** PROBLEMS/SOLUTIONS/COMMENTS
THE E3ILER AND SCRUBBER SYSTEM OPERATED MOST OF THE REPORT PERIOD ON A
MONDA IT-FRIDAY BASIS.
12/75 6* 90.1 90.1
6E 90.1 90.1
SYSTEM 90.1 90.1 7V* 744 670
** PROBLEMS/SOLUTIONS/COMMENTS
TWO MINOR OUTAGES IN DECEMBER WERE DUE TO MALFUNCTION AND REPAIR OF THE
DUAL STRAINER SWITCH SHAFT IN THE BOTTOM OF THE SCRUBBER MODULE.
1/76 SYSTEM 53.5 18.7 744 260 139
** PROBLEMS/SOLUTIONS/COMMENTS
S02 REMOVAL EFFICIENCY WAS REPORTED TO BE 99X DURING JANUARY.
2/76 SYSTEM 66.7 9.8 696 102 68
** PROBLEMS/SOLUTIONS/COMMENTS
THE SYSTEM WAS SHUTDOWN IN EARLY FEBRUARY IN PREPARATION FOR AN EXTENSIVE
SLUDGE STUDY TO MONITOR FIXATION, LEACHATES, AND SEASONAL VARIATIONS.
THE STUDY IS SCHEDULED TO BEGIN IN JUNE OR JULY. THE SCRUBBER WILL NOT
BE OPERATED UNTIL THE START OF THE PROGRAM UNLESS THE BOILER IS
REQUIRED FOR PEAKING POWER DEMANDS. HIGHLIGHTS OF THE SCRUBBER/SLUDGE
STUDY PROGRAM ARE AS FOLLOWS:
-SIX MONTHS DURATION.
-ONE SCHEDULED SHUTDOWN FOR TEST MODIFICATIONS.
-DELIBERATE HIGH CHLORIDE CONCENTRATION OPERATION.
-MGO INNOCULATION.
3/76 SYSTEM .0 744 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT REMAINED OFF LINE DURING MARCH IN PREPARATION FOR THE
EPA SCRUBBER/SLUDGE STUDY. THE UTILITY IS NOW COMPLETING SYSTEM MODIFICA-
TIONS NECESSARY FOR THE OPERATION OF THE TEST PROGRAM.
4/76 SYSTEM .0 .0 720 2 0
5/76 SYSTEM 85.0 2.3 744 20 17
6/76 SYSTEM 95.0 21.3 720 161 153
343
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
LOUISVILLE GAS & ELECTRIC: PADDY'S RUN 6 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
______ ______ ____________ ___________ ___________ ___________ _____ _____ _____ ______ _____ ______
** PROBLEMS/SOLUTIONS/COMMENTS
THIS PEAK LOAD UNIT WAS OPERATED PART OF THE TIME DURING THE REPORT PERIOD
(APPROXIMATELY 2 WEEKS IN MAY AND TWO WEEKS IN JUNE). THE SCRUBBER WAS
AVAILABLE TO THE BOILER 100X OF THE TIME AND S02 REMOVAL EFFICIENCY
WAS 98 TO 99X DURING THIS OPERATING SEGMENT.
7/76 SYSTEM 87.7 30.8 744 261 229
8/76 SYSTEM 92.8 8.6 744 69 64
** PROBLEMS/SOLUTIONS/COMMENTS
THIS UNIT WAS OPERATIONAL PART OF THE TIME DURING THE JULY-AUGUST PERIOD.
THE SCRUBBING SYSTEM WAS AVAILABLE TO THE BOILER ON A 100X BASIS.
NO MAJOR SCRUBBER-RELATED PROBLEMS WERE ENCOUNTERED.
9/76 SYSTEM .0 720 0 0 .0
10/76 SYSTEM 94.6 21.2 744 167 158
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT DID NOT OPERATE THROUGHOUT SEPTEMBER AND THE FIRST THREE WEEKS
IN OCTOBER. THE EPA-FUNDED SCRUBBER/SLUDGE STUDY PROGRAM COMMENCED OCTO-
BER 25. THE INITIAL PHASE OF THE PROGRAM CALLS FOR OPERATIONS TO PROCEED
FOR A 20-30 DAY PERIOD WITH CARBICE LIME SCRUBBING ABSORBENT. FOLLOWING
COMPLETION OF THIS RUN, THE UNIT NILL BE SHUT DOWN AND MODIFICATIONS WILL
BE INCORPORATED INTO THE SYSTEM FOR OPERATION WITH COMMERCIAL GRADE (HIGH
CALCIUM) LIME.
11/76 SYSTEM 99.3 99.3 720 720 715
** PROBLEMS/SOLUTIONS/CCMMENTS
THE UNIT WAS IN SERVICE DURING THE REPORT PERIOD. THE SCRUBBING SYSTEM
OPERATED 99.5X OF THE TIME THAT THE BOILER WAS IN SERVICE. CARBIDE LIME
WAS EMPLOYED AS THE S02 ABSORBENT. THE HIGH CALCIUM (VIRGIN) LIME RUN,
SCHEDULED AS PART OF THE SCRUBBER/SLUDGE STUDY, WILL COMMENCE ON MARCH 1,
1977.
12/76 SYSTEM 98.5 71.4 744 539 531
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS IN SERVICE DURING THE REPORT PERIOD. THE SCRUBBING SYSTEM
OPERATED 99.57. OF THE TIME THAT THE BOILER WAS IN SERVICE. CARBIDE LIME
WAS EMPLOYED AS THE S02 ABSORBENT. THE HIGH CALCIUM (VIRGIN) LIME RUN,
SCHEDULED AS PART OF THE SCRUBBER/SLUDGE STUDY, WILL COMMENCE ON MARCH 1,
1977.
1/77 SYSTEM .0 .0 744 103 0
2/77 SYSTEM .0 .0 672 62 0
3/77 SYSTEM 79.2 41.4 744 389 308
** PROBLEMS/SOLUTIONS/COMMENTS
BECAUSE OF SEVERE WEATHER CONDITIONS THERE WERE NO BOILER OPERATIONS AND
NO SCRUBBER OPERATIONS (SINCE DECEMBER 31) UNTIL MARCH 15, 1977.
4/77 SYSTEM 93.6 42.6 720 328 307
344
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
LOUISVILLE GAS & ELECTRIC: PADDY'S RUN 6 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
5/77 SYSTEM 42.5 16.0 744 280 119
** PROBLEMS/SOLUTIONS/COMMENTS
IN MID MARCH LGSE BEGAN TESTS FOR EPA WITH REGULAR LIME SINCE ONE OF THE
OBJECTIVES OF THE TEST WAS TO DETERMINE WHETHER THERE WERE APPRECIABLE
DIFFERENCES BETWEEN REGULAR LIME AND CARBIDE LIME AT THIS FACILITY.
DURING OPERATION WITH REGULAR LIME, SCALING PROBLEMS OCCURRED, INDICATING
THAT THE SCALING RESULTED FROM INCREASED OXIDATION LEVELS. AVAILABLE
OPTIONS FOR CONTROLLING SCALING WERE LIMITED BY THE FIXED DESIGN FEATURES
OF THE SCRUBBER HARDWARE. THE OPTION SELECTED WAS ADDITION OF MGO TO THE
SCRUBBING MEDIUM. WHEN MGO WAS ADDED, THE SCALING PROBLEM WAS ELIMINATED,
ALLOWING COMPLETION OF THE TEST PROGRAM.
6/77 SYSTEM 93.4 43.3 720 334 312
** PROBLEMS/SOLUTIONS/COMMENTS
THE SCRUBBER/SLUDGE EVALUATION STUDY CONTINUED DURING THE PERIOD. THE
SCRUBBER PLANT (ONE MODULE IS BEING UTILIZED FOR THIS EXPERIMENTAL PRO-
GRAM) WAS IN SERVICE ON A VIRTUALLY CONTINUOUS BASIS FROM JUNE 18 TO
AUGUST 8 OPERATING ON MAGNESIUM INNOCULATED COMMERCIAL LIME. SYSTEM OPER-
ABILITY DURING THIS PERIOD WAS APPROXIMATELY 96X. S02 REMOVAL EFFICIENCY
WAS MEASURED IN EXCESS OF 99.5X. THE SYSTEM WAS SHUT DOWN AT THIS POINT
TO PERFORM A NUMBER OF SCHEDULED MODIFICATIONS TO THE SYSTEM FOR TEST
PURPOSES. SPECIFICALLY, MODIFICATIONS ARE BEING IMPLEMENTED TO THE SYSTEM
IN ORDER TO BYPASS THE REACTION TANK SO A SHORT TERM RETENTION TIME TEST
COULD BE CONDUCTED. THE TESTING WAS COMPLETED IN AUGUST 1977 AFTER THE
MODIFICATIONS WERE MADE.
7/77 SYSTEM 96.9 95.8 744 736 713
8/77 SYSTEM 94.0 73.5 744 582 547
9/77 SYSTEM 25.9 5.8 720 162 42
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT IS CURRENTLY NOT OPERATING DUE TO THE LACK OF POWER REQUIREMENT.
10/77 SYC.TEM 46.9 2.0 744 32 15
11/77 SYSTEM .0 720 0 0 .0
12/77 SYSTEM .0 744 0 0 .0
1/78 S>STEM .0 744 0 0 .0
2/78 SYSTEM .0 672 0 0 .0
3/78 SYSTEM .0 744 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS OUT OF SERVICE FROM NOVEMBER THROUGH MARCH IN PART BECAUSE OF
LOW DEMAND AND IN PART AS A RESULT OF PROBLEMS RELATED TO COLD WEATHER.
4/78 SYSTEM .0 720 0 0 .0
5/78 SYSTEM .0 744 0 0 .0
6/78 SYSTEM 98.1 7.1 720 52 51
345
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
LOUISVILLE GAS & ELECTRIC: PADDY'S RUN 6 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
___„,__ ______ ____________ ___________ ___________ ___________ _____ _____ _____ ______ _____ ______
** PROBLEMS/SOLUTIONS/COMMENTS
PADDY'S RUN WAS ON LINE ONLY A FEW HOURS DURING THIS PERIOD. NO
OPERATIONAL PROBLEMS WERE REPORTED BY THE UTILITY.
7/78 SYSTEM 99.5 25.* 744 190 189
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT RAN INTERMITTENTLY FOR ABOUT EIGHT TO TEN DAYS OVER THIS PERIOD.
8/78 SYSTEM .0 744 0 0 .0
9/78 SYSTEM 100.0 47.1 720 339 339
** PROBLEMS/SOLUTIONS/COMMENTS
THIS UNIT WAS OPERATED FOR TWO WEEKS IN SEPTEMBER SO THAT TESTING OF A
NEW FLOCCULANT COULD BE CARRIED OUT. THE RESULTS OF THESE TESTS WILL
DETERMINE THE TYPE OF FLOCCULANT THAT WILL BE USED IN THE FUTURE AT THE
OTHER LG&E UNITS.
10/78 SYSTEM .0 744 0 0 .0
11/78 SYSTEM .0 720 0 0 ' .0
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS NOT OPERATED DURING OCTOBER OR NOVEMBER.
12/78 SYSTEM .0 744 0 0 .0
1/79 SYSTEM .0 744 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS NOT OPERATED DURING DECEMBER OR JANUARY.
2/79 SYSTEM .0 672 0 0 .0
3/79 SYSTEM .0 744 0 0 .0
4/79 SYSTEM .0 720 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS NOT OPERATED DURING THESE MONTHS BECAUSE OF LACK OF DEMAND.
5/79 SYSTEM .0 744 0 0 .0
6/79 SYSTEM .0 720 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE UNIT DID NOT OPERATE DURING MAY OR JUNE DUE
TO INSUFFICIENT DEMAND.
7/79 SYSTEM .0 .0 744 19 0 .0
8/79 SYSTEM 45.0 13.0 744 218 99 .0
9/79 SYSTEM .0 .0 720 36 0 .0
346
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
LOUISVILLE GAS & ELECTRIC: PADDY'S RUN 6 (CONT.)
PERFORMANCE DATA
PERIOD 10DULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
NO PROBLEMS WERE REPORTED WITH RESPECT TO OPERATION AT THIS UNIT DURING THE
THIRD QUARTER 1979.
10/79 SYSTEM .0 744 0 0 .0
11/79 SYSTEM .0 720 0 0 .0
12/79 SYSTEM .0 744 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT DID NOT OPERATE DURING THE FOURTH QUARTER OF 1979 BECAUSE OF THE
LACK OF DEMAND.
1/80 SYSTEM .0 744 0 0 .0
2/80 SYSTEM .0 696 0 0 .0
3/80 SYSTEM .0 744 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
THIS UNIT DID NOT OPERATE DURING THE FOURTH QUARTER OF 1979 OR THE FIRST
QUARTER OF 1980 DUE TO A LACK OF DEMAND. THIS UNIT IS USED AS A PEAKING
UNIT AND WILL BE RETIRED SOMETIME IN 1987.
4/80 SYSTEM 100.0 .0 720 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING APRIL THE FGD SYSTEM WAS AVAILABLE 100X OF THE TIME BUT WAS NOT
OPERATED DUE TO A BOILER RELATED PROBLEM.
5/80 SYSTEM 100.0 86.6 86.6 7.8 744 67 58
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MAY, NINE HOURS OF OUTAGE TIME RESULTED FROM THE UNAVAILABLITY OF
THE LIME SLURRY.
6/80 SYSTEM 100.0 94.1 94.1 6.7 720 51 48
** PROBLEMS/SOLUTIONS/COMMENTS
THE THREE HOURS THE SCRUBBERS DID NOT OPERATE IN JUNE WAS DUE TO THE FACT
THAT THE BOILER WAS BROUGHT ON LINE BEFORE THE SCRUBBER OPERATORS WERE
ON DUTY.
7/80 A 100.0 .0
B 100.0 .0
SYSTEM 100.0 .0 744 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER AND FGD SYSTEM DID NOT OPERATE DURING THE MONTH OF JULY DUE TO
A LACK OF DEMAND.
8/80 SYSTEM 100.0 .0 90.00 99.00 744 0 0 .0
9/80 SYSTEM 100.0 .0 90.00 99.00 720 0 0 .0
347
-------
EPA irriLITY FGD SURVEY: OCTOBER - DECEMBER 1980
LOUISV.CLLE GAS & ELECTRIC: PADDY'S RUN 6 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER DID NOT OPERATE DURING AUGUST AND SEPTEMBER. THE FGD SYSTEM
WAS AVAILABLE 100X OF THE TIME.
10/80 SYSTEM 100.0 .0 744 0 0 .0
11/80 SYSTEM 100.0 .0 720 0 0 .0
12/80 SYSTEM 100.0 .0 744 0 0 .0
•Ht PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS NOT OPERATED DURING THE FOURTH QUARTER 1980 DUE TO THE LACK
OF DEMAND.
348
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY KAME
PLANT NAhE
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICIPATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EM:.SSION LIMITATION - NG/J
NET PL.KNT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UN:.T GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** UN^T DATA - BOILER AND STACK
BOILER SUPPLIER
BUILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BUILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEi. DATA
FUEL TYPE
FU = L GRADE
AVERAGE HEAT CONTENT - J/G
RAI1GE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - X
RAIIGE ASH CONTENT - 7.
AVcRAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
*** PARTICLE CONTROL
** ESP
NUMBER
TYPE
SUPPLIER
INLET FLUE GAS CAPACITY - CU.M/S
INLET FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
PARTICLE REMOVAL EFFICENCY - X
** PARTICLE SCRUBBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
LIQUID RECIRCULATION RATE - LITER/S
L/G RATIO - LITER/CU.M
PRESSURE DROP - KPA
INLET GAS FLOW RATE - CU.M/S
INLET GAS TEMPERATURE - C
S02 REMOVAL EFFICENCY - X
PARTICLE REMOVAL EFFICIENCY - X
43.
516.
MINNESOTA FOWER & LIGHT
CLAY BOSWELL
4
COHASSET
MINNESOTA
B
( .100 LB/MflBTU)
( 1.200 LB/MMBTU)
(****** LB/MMBTU)
1000
554
504
511
475
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
1086.40 (2302181 ACFM)
148.9 ( 300 F)
183. ( 600 FT)
CONCRETE
11.3 ( 37.0 FT)
COAL
SUBBITUMINOUS
19276.
9.40
4.81 - 15.99
24.50
20.30 - 28.31
.94
0 - 4.55
.01
0 - 0.07
( 8287 BTU/LB)
7509 - 9923
HOT SIDE
WESTERN PREC.
94.4
398.9
.6
99.7
DIVISION, JOY
( 200000 ACFM)
( 750 F)
( 3. IN-H20)
VENTURI TOWER
VARIABLE-THROAT/ADJUSTABLE DRUM
PEABODY PROCESS SYSTEMS
30 FT. DIA; 40 FT. HIGH
STAINLESS STEEL
AUSTENITIC
ORGANIC
RUBBER
STAINLESS STEEL
1
841.7 (13360 GPM)
2.7 (20.0 GAL/1000ACF)
3.0 (12.0 IN-H20)
394.4 ( 835840 ACFM)
148.9 ( 300 F)
89.0
99.7
349
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
MINNESOTA POWER & LIGHT: CLAY BOSWELL 4 (CONT.)
*** FGO SYSTEM
** GENERAL DATA
S \LEABLE PRODUCT/THROWAWAY PRODUCT
S'32 REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
SfSTEM SUPPLIER
A-E FIRM
D'-IVELOPflENT LEVEL
Ni:W/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
UNIT DESIGN S02 REMOVAL E TFICIENCY - X
CURRENT STATUS
INITIAL START-UP
** DESIGN AND OPERATING PARAMETERS
THROWAWAY PRODUCT
MET SCRUBBING
LIME/ALKALINE FLYASH
NONE
PEABODY PROCESS SYSTEMS
EBASCO
FULL SCALE
NEW
X 99.73
84.55
1
4/80
NUMBER
NUMBER OF SPARES
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SKELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
L:.NER GENERIC MATERIAL
LT.NER MATERIAL TRADE NAME/COMMON TYPE
NUMBER OF CONTACTINS ZONES
L:-QUID RECIRCULATION RATE - LITER/S
L/G RATIO - L/CU.M
G/S-SIDE PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/SEC
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
S02 REMOVAL EFFICIENCY - 7.
** MIST ELIMINATOR
PR>£-MIST ELIMINATOR/MIST ELIMINATOR
GENERIC TYPE
SPECIFIC TYPE
TR,,DE NAME/COMMON TYPE
4
1
SPRAY TOWER
OPEN COUNTERCURRENT SPRAY
PEABODY PROCESS SYSTEMS
DIA 35' HT 60'
CARBON STEEL
AISI 1110
N/A
ORGANIC
RUBBER
4
2104.
6.7
5.0
3.7
302.03
53.3
89.0
(33400 GPM)
( 50.0 GAL/1000 ACF)
(20.0 IN-H20)
( 12.0 FT/S)
( 640130 ACFM)
( 128 F)
PRE-MIST ELIMINATOR
BULK SEPARATION
PERFORATED PLATE
SIEVE TRAY
** REHtATER
NUfiBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
PERCENT GAS BYPASSED - AVG
TEMPERATURE INCREASE - C
INLET FLUE GAS FLOW RATE - CU.
INLET FLUE GAS TEMPERATURE
M/S
- C
CONSTRUCTION MATERIAL GENERIC TYPE
** FANS
NUMBER
NUMBER OF SPARES
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** DUCTWORK
LOCATION
DIMENSIONS
4
BYPASS
HOT SIDE
N/A
5.0
-3.3
74.02
426.7
INCONEL 625
( 26 F)
( 156850 ACFM)
( 800 F)
4
1
GREEN FAN
BALANCED DRAFT
CENTRIFUGAL RADIAL TIP
WET
320.33 ( 678800 ACFM)
62.2 ( 144 F)
INCONEL 625 & INCOLY 825
ABSORBER TO REHEATER
12 DIA.
350
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
MINNESOTA POWER & LIGHT: CLAY BOSWELL 4 (CONT.)
SHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
MANUFACTURER
NUMBER
PRODUCT QUALITY - 7. SOLIDS
** TANKS
SERVICE
RECYCLE
ALKALI STORAGE
WiSH WATER
F.'.Y ASH STORAGE
** PUT1PS
S.-IRVICE
AJCALI FEED
F'.Y ASH SLURRY FEED
V'fNTURI RECYCLE
ABSORBER RECYCLE
WXSH WATER
*** SLUDGE
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SJTE DIMENSIONS
SITE CAPACITY - CU.M
S3TE SERVICE LIFE - YRS
** PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS
CONTROL LEVELS
MONITOR LOCATION
PHOCESS CONTROL MANNER
PHOCESS CHEMISTRY MODE
** WA'ER BALANCE
HATER LOOP TYPE
EVAPORATION WATER LOSS - LITER/S
M/KEUP WATER ADDITION - LITERS/S
** FGD SPARE CAPACITY INDICES
ABSORBER - 7.
*» FGD SPARE COMPONENT INDICES
AB30RBER
CARBON STEEL
FLAKE GLASS LINED
LIME SLAKING
SLAKER
PEABODY PROCESS SYSTEMS
4
20.0
NUMBER
NUMBER
2
Z
8
12
Z
FINAL
LINED POND
1 MILE WNW OF UNIT
PIPE
4000 X 3000 FT
9556522 t 7814.0 ACRE-FT)
35
PH-DENSITY IN RECYCLE TANKS
3-6 PH; 7-9X DENSITY
RECYCLE TANKS
AUTOMATIC
FEEDBACK
CLOSED
23.9
56.4
33.0
1.0
( 380 GPM)
( 895 GPM)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
4/80 SYSTEM
720
351
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
MINNESOTA POWER & LIGHT: CLAY BOSWELL 4 (CONT.)
_ _ PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
SOS PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
7/80
8/80
9/80
10/80
THE BOILER BEGAN OPERATIONS ON FEBRUARY 26, 1980 AND FIRED OIL THROUGH THE
MONTH OF MARCH. INITIAL FGD SYSTEM OPERATIONS BEGAN IN EARLY APRIL WITH
THE BOILER FIRING COAL FOR TESTING PURPOSES. THE UNIT WAS SHUTDOWN IN
MID-APRIL TO RECTIFY MINOR SHAKEDOWN PROBLEMS. A TRIAL RUN OF THE FGD
SYSTEM IN AN INTEGRATED MODE OCCURRED IN LATE APRIL.
5/80 SYSTEM
6/80 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
744
720
SHAKEDOK'N OPERATIONS CONTINUED THROUGH THE SECOND QUARTER OF 1980. THE
FGD SYSTEM WILL BE FINE TUNED TO MEET DESIGN CRITERIA THROUGH JULY. TO
DATE THE UTILITY REPORTED THAT, ALTHOUGH MANY TYPICAL STARTUP PROBLEMS
ATTRIBUTABLE TO OPERATOR ERROR AS WELL AS MECHANICAL MALFUNCTIONS HAVE
OCCURRED, NO UNUSUAL PROBLEMS HAVE OCCURRED. THE COMPLIANCE TEST IS
SCHEDULED FOR EARLY SEPTEHBER.
1
Z
3
4
SYSTEM
1
2
3
4
SYSTEM
1
Z
3
4
SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
87.8
97.8
100.0
.0
96.1
71.8
75.5
29.4
49.7
75.5
71.6
.)9.6
,4.7
.,5.1
30.3
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
86.8
96.7
100.0
.0
95.0
62.9
66.1
25.8
43.5
66.1
71.0
88.7
14. ;i
64.5
79.6
720 712
744 652
744 737
684 79.0
492 61.7
592 73.7
THE FGD SYSTEM IS STILL IN THE DEBUGGING PHASE OF OPERATION.
EQUIPMENT IS STILL BEING WORKED ON AND TESTED.
MUCH OF THE
1
2
3
4
SYSTEM
31.6
38.4
.0
83.6
51.2
100.0
100.0
100.0
100.0
22.6
27.4
.0
59.7
36.6
744 531
272 59.1
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE AVAILABLE HOURS AND UNAVAILABLE HOURS DURING
OCTOBER WERE NOT RECORDED.
THE UNIT OUTAGE TIME WAS DUE TO MISCELLANEOUS MAINTENANCE AND AN INSPEC-
TION.
11/80 I
2
3
SYSTEM
94.4
85.6
98.1
55.4
100.0
67.2
55.5
59.1
26.0
69.2
100.0
100.0
100.0
100.0
100.0
60.7
50.1
53.3
23.4
62.5
720 650
450 60.8
352
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1930
MINNESOTA POWER & LIGHT: CLAY BOSWELL 4 (COHT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL
S03 PART.
PER BOILER FGD CAP.
HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
IE/80 1
Z
3
SYSTEM
100.0
93.4
19.4
96.5
100.0
MODULE A OUTAGE TIME DURING NOVEMBER MAS DUE TO NECESSARY CLEANING AND
GENERAL REPAIRS.
100.0
62.0
2.4
87.6
87.6
100.0
100.0
100.0
100.0
100.0
** PROBLEMS/SOLUTIONS/COMMENTS
100.0
61.3
2.4
86.6
83.5
744 735
621 89.7
DURING DECEMBER MODULE 3 OUTAGE TIME WAS DUE TO GENERAL MAINTENANCE AND
REPAIRS TO THE VENTURI LINER.
353
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FED SYSTEMS
COMPANY NAME
PUNT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MM
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RAKGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7,
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** FABRIC FILTER
NUMBER
** ESP
NUMBER
TYPE
SUPPLIER
INLET FLUE GAS CAPACITY - CU.M/S
INLET FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
PARTICLE REMOVAL EFFICENCY - 7.
** PARTICLE SCRUBBER
GENERIC TYPE
SPECIFIC TYPE
*** FCO SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
P20CLSS ADDITIVES
SYSTLM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
SEW/RETROFIT
Wll DESIGN PARTICLE REMOVdL EFFICIENCY
MINNKOTA POWER COOPERATIVE
MILTON R. YOUNG
Z
CENTER
NORTH DAKOTA
D
43. (
516.
100 LB/MMBTU)
{ 1.200 LB/MMBTU)
(****** LB/MMBTU)
690
440
402
409
185
BABCOCK & WILCOX
CYCLONE
BASE
953.90
179.4
168.
CONCRETE
7.6
(2021400 ACFM)
( 355 F)
( 550 FT)
( 25.0 FT)
COAL
LIGNITE
15119.
6.50
5-8
38.00
32-43
.70
.35-1.3
.01
( 6500 BTU/LB)
5800-7200
COLD SIDE
WHEELABRATOR-FRYE
1038.2 (2200000 ACFM)
193.3 ( 380 F)
.1 ( 1. IN-H20)
99.6
NONE
N/A
THROWAWAY PRODUCT
WET SCRUBBING
LIME/ALKALINE FLYASH
NONE
COMBUSTION EQUIP ASSOCIATES
SANDERSON » PORTER
FULL SCALE
NEW
7. 99.60
354
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
MINNKO"A POWER COOPERATIVE: MILTON R. YOUNG 2 (CONT.)
UNIT DESIGN 302 REMOVAL EFFICIENCY - '/.
CIRRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
** ABS3RBER
NUMBER
NU'IBER OF SPARES
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
NUMBER OF CONTACTING ZONES
LIQUID RECIRCULATION RATE - LITER/S
L/G RATIO - L/CU.M
GAS-SIDE PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/SEC
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
S02 REMOVAL EFFICIENCY - X
PARTICLE REMOVAL EFFICENCY - X
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES PER STAGE
FREEBOARD DISTANCE - M
DISTANCE BETWEEN STAGES - CM
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
WASH WATER SOURCE
WASH RATE - L/S
36.13
1
6/78
9/77
4/75
2
1
SPRAY TOWER
OPEN COUNTERCURRENT SPRAY
COMBUSTION EQUIP ASSOCIATES
40 DIA X 120
CARBON STEEL
AISI 1110
N/A
ORGANIC
FLAKEGLASS
6
2740.
10.7
2.0
2.8
405.36
168.3
85.0
70.0
(43500 GPM)
( 80.0 GAL/1000 ACF)
( 8.0 IN-H20)
( 9.1 FT/S)
( 859000 ACFM)
( 335 F)
MIST ELIMINATOR
Z
IMPINGEMENT
BAFFLE
CHEVRON VANE
HORIZONTAL
1
4
2.44 (
5.08 (
.2 (
2.8 (
FLAKELINED 316L SS
POLYETHELYNE
PART FRESH - PART TRAY
44.2 ( 700 GAL/MIN)
J.O FT)
J.O IN)
L.O IN-H20)
9.1 FT/S)
** REHEATER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
PERCENT GAS BYPASSED - AVG
TEMPERATURE INCREASE - C
INLET FLUE GAS FLOW RATE - CU. M/S
INLET FLUE GAS TEMPERATURE - C
NUMBER OF TUBES PER BUNDLE
CONSTRUCTION MATERIAL GENERIC TYPE
2
BYPASS
COLD SIDE
N/A
15.0
4.4
70.78
176.7
0
CARBON STEEL
( 40 F)
( 150000 ACFM)
( 350 F)
** FANS
NUMBER
NUMBER OF SPARES
SUPPLIER
FUNCTION
APPLICATION
SERVICE
fLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
2
1
BUFFALO FORGE
BOOSTER
BOILER ID, AXIAL
DRY
519.09 (1100000 ACFM)
176.7 ( 350 F)
CARBON STEEL
355
-------
EPA UTILITY FGD SURVEY: OCTOBF* - DECEMBER 1980
MINNKOTA POWER COOPERATIVE: MILTON R. YOUNS 2 (CONT.)
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
MANUFACTURER
NUMBER
PRODUCT QUALITY - 7. SOLIDS
** TAWS
SHRVICE
REACTION/RECYCLE
MIX TANK
******
** PUT'PS
SLRVICE
ABSORBER RECIRCULATION
SPRAY RECIRCULATION
TRAY RECIRCULATION
TRAY SPRAY (CLARIFIER OVERFLOW)
THICKENER UNDERFLOW
THICKENER OVERFLOW
LIME SLAKER TRANSFER
LIME SLURRY FEED
FLYASH SLURRY FEED
MIST ELIMINATOR SPRAY
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
SHELL SPECIFIC MATERIAL TYPE
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
CAPACITY
SHELL GENERIC MATERIAL TYPE
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
*** SLUDGE
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
** PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS
CONTROL LEVELS
PROCESS CONTROL MANNER
#* WATER BALANCE
WATER LOOP TYPE
EVAPORATION WATER LOSS - LITER/S
MAKEUP WATER ADDITION - LITERS/S
LIME SLAKING
SLAKER
WALLACE 8 TIERNAN
1
12.0
NUMBER
2
1
4
NUMBER
10
10
4
2
2
2
2
2
2
2
CENTRIFUGE
2
THICKENER
2
CONCRETE
12X SOLIDS
40X SOLIDS
VACUUM FILTER
2
0
750 TON/DAY
MILD STEEL
30X SOLIDS
60X SOLIDS
FINAL
MINEFILL
OFF SITE
TRUCK
PH, SOLIDS
SOLIDS 5.5-12X5
MANUAL
PH 4.0-5.5
CLOSED
34.6
44.1
550 GPM)
700 GPM)
356
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
MINNKOTA POWER COOPERATIVE: MILTON R. YOUNG Z (CONT.)
** FGD SPARE CAPACITY INDICES
ABSORBER - X 100.0
** FGD SnARE COMPONENT INDICES
ABSORBER 1.0
PERFORMANCE DATA
PERIOD MC.DULE AVAILABILITY OPEl.ABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
SOS. PART. HOURS HOURS HOURS FACTOR
_
0/77 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
ALTHOUGH THE MILTON R YOUNG Z SCRUBBING SYSTEM ORIGINAL DESIGN DID NOT IN-
CLUDE SPARE FGD CAPACITY, THE SYSTEM DOES, IN ACTUALITY, GENERALLY HAVE A
SPARE MODULE AS A CONSEQUENCE OF THE VARIABILITY IN LIGNITE SULFUR CONTENT.
THE LIGNITE BLEND AT M.R.YOUNG Z VARIES IN SULFUR CONTENT FROM 0.35 TO
1.3X. WHEN THE SULFUR CONTENT RISES TO 1.3X BOTH SCRUBBING TOWERS ARE RE-
QUIRED (WITH 5 TO I5X OF THE FLUE GAS BYPASSED FOR REHEATJ. WHEN THE
SULFUR CONTENT DROPS TO 0.7X OR BELOW ONLY ONE TOWER IS REQUIRED. 0.7X
SULFUR IS TYPICAL FOR THE M.R.YOUNG 2 LIGNITE BLEND. BECAUSE OF THE EFFEC-
TIVE SPARE MODULE THE SYSTEM DEPENDABILITY FIGURES THAT APPEAR IN THIS
SECTION WILL GENERALLY NOT BE EQUIVALENT TO THE AVERAGE OF THE MODULAR DE-
PENDABILITIES (E.G. WITH 0.7X SULFUR LIGNITE THERE IS 100X SPARE CAPACITY.
IF A-MODULE OPERATES THE FIRST HALF OF THE MONTH (SOX) AND B-MODULE THE
SECOND HALF OF THE MONTH (SOX) THE TOTAL SYSTEM UTILIZATION WILL BE 100X).
9/77 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
INITIAL SCRUBBING OPERATIONS BEGAN IN SEPTEMBER. THE FGD SYSTEM IS
EXPECTED TO BE OPERATING IN AN INTEGRATED MODE IN LATE OCTOBER, HOWEVER,
A SCRUBBER LINING FAILURE MAY RESULT IN SOME DELAYS. THE UTILITY EXPECTS
THE SYSTEM OPERATIONS TO STABILIZE BY MID-NOVEMBER.
10/77 SYSTEM 744
11/77 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED INTERMITTENT FGD SYSTEM OPERATIONS SINCE START-UP.
MAJOR OPERATIONAL PROBLEMS HAVE OCCURRED AS A RESULT OF SEVERE WINTER
WEATHER CONDITIONS, PARTICULARLY NUMEROUS INSTANCES OF FROZEN AND RUPTURED
LINES. THE SYSTEM WAS SHUT DOWN DURING THE FIRST PART OF THE MONTH OF
DECEMBER TO INSTALL HEAT TRACING IN THE LIQUID CIRCUIT.
SOME MINOR PROBLEMS HAVE OCCURRED WITH THE FLOW METERS (ROTAMETERS).
THE UTILITY ENCOUNTERED PROBLEMS WITH GUILLOTINE GAS DAMPER GUIDES DURING
OCTOBER AND NOVEMBER.
12/77 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THERE WAS AN EMERGENCY SHUTDOWN ON DECEMBER 5 AS A RESULT OF TURBINE
BEARING DAMAGE. THE SHUTDOWN CONTINUED SO THAT A COMPLETE TURBINE
INSPECTION COULD BE MADE.
WORK CONTINUED ON INSTALLATION OF ELECTRICAL HEAT TRACING ON SLURRY LINES
AND WATER PIPING.
1/78 SYSTEM 744
357
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
MINNKOTA POWER COOPERATIVE: MILTON R. YOUNG 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
BECAUSE OF THE TURBINE BEARING PROBLEMS THE COMPLIANCE TEST ORIGINALLY
SCHEDULED FOR THE DECEMBER-JANUARY PERIOD WAS TENTATIVELY RESCHEDULED
WITH THE EPA FOR THE END OF MARCH. THE UTILITY EXPECTS THE FGD SYSTEM TO
ACHIEVE EQUILIBRIUM (WATER BALANCE) WHEN THE UNIT COMES BACK ON LINE
IN FEBRUARY.
2/78 SYSTEM 672
*# PROBLEMS/SOLUTIONS/COMMENTS
BOTH rHE BOILER AND FGD SYSTEM C.«1E BACK ON LINE FEBRUARY 21 AFTER COM-
PLETION OF THE TURBINE REPAIRS. THE COMPLIANCE TEST HAS AGAIN BEEN RE-
SCHEDJLED WITH EPA FOR THE END OF MAY.
ONE FORCED-DRAFT FAN (UPSTREAM OF THE FGD SYSTEM) HAD AN OIL LEAK AND A
SHAFT ALIGNMENT PROBLEM. THE FAN WAS TAKEN OFF LINE AND SHIPPED TO
BUFFALO FORGE FOR REPAIRS.
THE VACUUM FILTER MALFUNCTIONED, ALLOWING LARGER SIZE PARTICLES TO ESCAPE
THE FILTER. THIS CAUSED THE RUBBER LINING DOWN STREAM TO PEEL WHICH, IN
TURN, CREATED A PLUGGING PROBLEM. EIMCO ENGINEERS ARE PRESENTLY STUDYING
THE PROBLEM AND HOPE TO INCORPORATE MODIFICATIONS TO IMPROVE THE PERFOR-
MANCE OF THE FILTERS.
3/78 SYSTEM 744
4/78 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE DAMAGED FD FAN WAS REINSTALLED DURING APRIL. THE AFFECTED MODULE
WAS DOWN FROM FEBRUARY 23 THROUGH APRIL 10.
5/78 SYSTEM 744
6/78 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
COMPLIANCE TESTING TOOK PLACE DURING THE WEEK OF JUNE 5. THE REPORT
SHOULD BE AVAILABLE TO THE UTILITY BY THE END OF JUNE.
THE UNIT WAS DOWN WITH DAMPER PROBLEMS (DOWN ON THE 24TH OF JUNE). AP-
PARENTLY THE CHAINS THAT PULL THE GUILLOTINE DAMPERS WERE UNDERDESIGNED
AND PRONE TO FAILURE. THE CHAINS ARE CURRENTLY BEING REPLACED.
7/78 SYSTEM 744
8/78 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
OFFICIAL RESULTS OF THE COMPLIANCE TEST PERFORMED ON JUNE 6 ARE STILL NOT
AVAILABLE. BECAUSE OF INTERMITTENT OPERATION, FGD SYSTEM PERFORMANCE
FIGURES ARE NOT YET AVAILABLE.
9/78 SYSTEM 720
10/78 SYSTEM 744
358
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
MINNKOTA POWER COOPERATIVE: MILTON R. YOUNG 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
______ ______ ____________ ___________ ___________ _______ __ _____ _____ _____ ______ _____ ______
** PROBLEMS/SOLUTIONS/COMMENTS
THE THICKENER HAS BEEN A MAJOR PROBLEM AREA. THE POLYETHYLENE LINER WAS
ACCIDENTLY PIERCED WHILE REPAIRS WERE BEING MADE TO SOME OTHER COMPONENTS.
THE LINER IS CURRENTLY BEING PATCHED.
THE UTILITY REPORTED THAT OPERATION OF THE BOILER AND FGD SYSTEM CONTINUED
ON AN INTERMITTENT BASIS THROUGHOUT THE PERIOD.
11/78 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THICKENER PROBLEMS ARE CONTINUING. THE RUBBER LINER HAS BEEN DETATCHING
FROM THE THICKENER CONE. THE THICKENER MUST BE DRAINED TO MAKE THE
REPAIRS.
FAN PROBLEMS OCCURRED DURING THE PERIOD. THERE IS NO DAMPER BETWEEN THE
MODULE AND FAN. UNDER SOME OPERATING CONDITIONS WET GAS CAN BACK INTO
THE FAN AREA RESULTING IN CORROSION AND OTHER MOISTURE RELATED PROBLEMS.
12/78 A 4.6 5.1 4.6
B 37.7 28.4 25.7
SYSTEM 42.3 33.5 33.8 30.3 744 673 225 54.0
**• PROBLEMS/SOLUTIONS/CO 1MENTS
MINNKOTA POWER COOP REPORTED THE FOLLOWING STATISTICS FOR THE YEAR OF 1978:
TCTAL PERIOD HOURS: 8760
TOTAL BOILER HOURS: 6926
TOTAL A-MODULE HOURS: 1790
TOTAL B-MODULE HOURS: £UO
ANNUAL BOILER CAPACITY FACTOR: 66.7X
FGD SYSTEM PERFORMANCE:
A-MODULE B-MODULE SYSTEM
AVAILABILITY 92.3 28.5 46.1
OPERABILITY 28.0 25.9 52.7
RELIABILITY 53.9
UTILIZATION 22.2 20.4 41.7
THE B-TOWER WAS OUT OF SERVICE DURING DECEMBER DUE TO PLUGGING OF THE
THICKENER UNDERFLOW BY RUBBER LINING. THE THICKENER WAS PUMPED OUT AND
REPAIRED.
1/79 A 4.6 5.1 4.6
B 37.7 28.4 25.7
SYSTEM 42.3 33.5 33.8 30.3 744 673 225 54.0
»« PROBLEMS/SOLUTIONS/COMMENTS
SOME WEATHER-RELATED PROBLEMS OCCURRED WITH FGD SYSTEM PIPING
FREEZE-UPS.
THE UTILITY REPORTED THAT THE A-TOWER WAS OUT OF SERVICE FOR A PERIOD IN
JANUARY DUE TO BROKEN INLET ISOLATION DAMPER CHAINS.
THE A-TOWER WAS OUT OF SERVICE TO REPAIR A BOOSTER FAN SERVO MECHANISM
THROUGH JANUARY 28.
THE B-TOWER WAS OUT OF SERVICE FROM DECEMBER 27 THROUGH JANUARY 31 DUE
TO A FAN MOTOR FAILURE.
THE UTILITY REPORTED THAT EROSION PROBLEMS IN THE SCRUBBER TOWERS ARE
359
-------
EPA UTILITY F60 SURVEY: OCTOBER - DECEMBER 1980
MINNKOTA POWER COOPERATIVE' MILTON R. YDUN3 Z CCCNT.S
_ _ ____ PERFORMANCE DATA—————— — •-
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FSD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
2/79
3/79
A
B
SYSTEM
A
B
SYSTEM
19.
32.
51.
19.
32.
51.
4
1
5
4
I
5
SEVERE ENOUGH
26.5
44.0
70.5
26.5
44.0
70.5
THAT HOLES
70
70
.5
.5
HAVE BEEN DISCOVERED
19.4
32.1
51.5
19.4
32.1
51.5
IN TOWER
672
744
WALLS.
491
543
346 58.1
383 58.1
** PRCBLEMS/SOLUTIQNS/COMMENTS
TWO DAYS OF DOWN TIME MERE REQUIRED TO REMOVE LOOSE RUBBER FROM THE
THICKENER PIPING DURING THE FEBRUARY-MARCH PERIOD.
A BOOSTER FAN MOTOR FIRE OCCURRED IN THE A-MODULE.
HOLES IN THE B-SIDE ABSORBER TOWEB WERE REPAIRED DURING THE PERIOD.
COLD WEATHER INHIBITED SCRUBBER STARTUPS AFTER REPAIRS WERE MADE DURING
THE PERIOD.
4/79 A 3.0 3.2 3.0
B 57.1 61.6 57.1
SYSTEM 60.1 64.8 65.4 60.1 720 668 432 69.4
5/79 A 3.0 3.2 3.0
B 57,1 61.6 57.1
SYSTEM 60.1 64.S 65.4 60.1 74-4 690 448 88.4
** PROBLEMS/SOLUTIONS/COMMENTS
THE A-MODULE IS STILL EXPERIENCING FAN PROBLEMS. DURING APRIL AND MAY
THE FAN HAD ALIGNMENT PROBLEMS POSSIBLY RELATED TO THE FAN FOUNDATION.
DURING APRIL AND MAY HOLES WERE REPAIRED IN THE ABSORBER WALLS, VALVE
REPAIRS MERE MADE, AND REPAIRS WERL HADE ON A THICKENER DRIVE GEAR.
6/79 A 17.2 X7.2 17.2
B 36.3 >6.3 36.r,
SYSTEM 52.8 J2.8 52.8 52.3 720 720 330 88.7
** PROBLEMS/SOLUTIONS/CC.IMENTS
THE A-TOWER WAS DOWN FOR REPAIR TO THE FLAKE LINING.
THE FGD SYSTEM WAS DOWN FOR PART OF THE MONTH FOR REPAIRS AFTER EXCESS
SOLIDS ENTERING THE TRAY RECYCLE LOOP OVERLOADED THE CLARIFIES.
AN A-TOWER TRAY RECYCLE DISTRIBUTION HEADER WAS CLEANED DURING JUNE.
THE SYSTEM WAS FORCED OUT OF SERVICE WHEN BOILER PROBLEMS CAUSED AN EX-
CESSIVE AMOUNT OF HEAVY PARTICLES (SLAG CARRYOVER) TO ENTER THE FGD SYSTEM
RESULTING IN THE PLUGGING OF SEVERAL LINES AND STOPPING THE THICKENER RAKE.
SLUDGE HAD TO BE DREDGED AND HAULED OUT FROM THE TOP OF THE THICKENER.
THE A-TOWER WAS OUT OF SERVICE DUE TO PROBLEMS WITH THE WATER BALANCE AND
THE VACUUM FILTERS AS WELL AS TO UNPLUG THE ABSORBER BLEED LINE. LIME
WAS USED FOR SEVERAL DAYS AS MAKE UP CHEMICAL US OPPOSED TO PRIMARILY
ALKALINE FLYASH) TO EASE THE HIGH SOLIDS PROBLEM.
A-TOWER AGITATOR GEARS WHICH FAILED AS A RESULT OF A CLARIFIER OVERLOAD
WERE REPLACED DURING THE PERIOD.
360
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1930
POWER COOPERATIVE: MILTON R. YOUNS 2 CCOiVT.)
__. „ „___..___..... PERFORMANCE DATA _-_—___ _ ______ „__
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
SG2 PART. HOURS HOURS HOURS FACTOR
7/79 A 44.5 44.5 44.5
B .0 .0 .0
SYSTEM 44.0 44.0 44.0 44.0
744 744 331 86.7
** PROBLEMS/SOLUTIONS/COMHENTS
THE UTILITY HAS REPORTED THAT A TRAY RECYCLE CONTROL VALVE AND AN ABSORBER
TRAIN VALVE FAILED DURING JULY.
THE UTILITY REPORTED PROBLEMS WITH PLUGGING IN THE MIST ELIMINATORS,
THE THICKENER AND IN THE ABSORBER FEED LINE.
THE UNIT EXPERIENCED A BOOSTER FAN TRIP IN JULY.
PROBLEMS WITH THE VACUUM FILTERS AND THE SEAL WATER PUMP WERE ENCOUNTERED.
THE ABSORBER AGITATOR WAS REPLACED DURINS JULY.
8/79 A 28,7 £8.7 £8.7
B 10.6 10.6 10.6
SYSTEM 39.0 39.0 39.0 39.0 744 744 £93 92.3
** PROBLEMS/SOLUTIONS/COMMENTS
DURINS AUGUST EXCESSIVE VIBRATION AND HIGH BEARING TEMPERATURE IN THE
A-SIDE BOOSTER FAN WERE ENCOUNTERED CAUSING SOME DOWN TIME.
THE INABILITY TO ADD ALKALI (FLYASH OR LIME) TO THE SYSTEM CAUSED SOME
OPERATIONAL PROBLEMS ON THE A-SIDE SCRUBBER.
DURING AUGUST THE B-SIDE THICKENER RAKE WAS BURIED IN THE SLUDGE. THE
SLUDGE HAD TO BE REMOVED BY MINING IT FROM THE TOP.
PLUGGING OF THE FLYASH TANK AND THE LIME SLURRY FEED LINE CAUSED SOME
B-SIDE OUTAGE TIME DURING AUGUST.
DUE TO A LACK OF LIME (THE UTILITY SUPPLY WAS EXHAUSTED) THE FGD SYSTEM
HAD TO SHUT DOWN.
THE HOLES IN THE SIDES OF THE B-SIDE ABSORBER TOWER HAD TO BE REPAIRED
CAUSING SOME OUTAGE TIME IN AUGUST.
9/79 A 21.4 21.5 21.4
B 1.2 1.2 1.2
SYSTEM 23.0 23.0 23.0 23.0 720 717 163 96.6
** PROBLEMS/SOLUTIONS/COMMENTS
DURING SEPTEMBER THE A-SIDE WAS DOl-.N DUE TO HEAVY SOLIDS IN THE THICKENER
AND Ci-ARIFIER. HIGH VIBRATIONS WERE EXPERIENCED WITH THE BOOSTER FAN.
THE B-SIDE REMAINED OUT OF SERVICE DUE TO PROBLEMS WITH THE THICKENER AND
CLARIF::ER.
10/79 A .0 .0 .0
B 31.3 31.4 31.3
SYSTEM 31.3 31.4 31.4 31.3 744 743 233 89.7
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY IS IN THE PROCESS OF CLEANING THE CURIFIER.
THE CLARIFIER AGITATOR DRIVE GEAR FAILED CAUSING DOWN TIME FOR REPAIR IN
361
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
MINNKOTA POWER COOPERATIVE: MILTON R. YOUNG Z (CONT.)
PERFORMANCE DATA •
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
OCTOBER.
THE BLEED LINE TO THE THICKENER PLUGGED AND NEEDED MAINTENANCE.
THE GEAR HOUSING FAILED ON THE THICKENER LIFT MECHANISM CAUSING OUTAGE
TIME FOR REPAIR.
11/79 A .6 .7 .6
B 15.4 16.7 15.4
SYSTEM 16.0 17.4 17.4 16.0 720 661 115 80.0
** PROBLEMS/SOLUTIONS/COMMENTS
AN EXCESS OF SOLIDS CAUSED PLUGGING IN THE THICKENER AND THE CLARIFIER
DURING NOVEMBER.
12/79 A 26.6 31.5 26.6
B 9.7 11.5 9.7
SYSTEM 36.3 43.0 43.0 36.3 744 628 270 67.2
** PROBLEMS/SOLUTIONS/COMMENTS
PLUGGING OF THE SEAL WATER SYSTEM RESULTED IN SOME OUTAGE TIME DURING
DECEMBER.
BOOSTER FAN PROBLEMS RELATED TO EXCESSIVE VIBRATION WERE ENCOUNTERED ON
MODULE B IN DECEMBER.
A HOLE IN A BLOCKING VALVE RESULTED IN SOME DOWNTIME.
THE GEAR HOUSING FAILED ON THE THICKENER LIFT MECHANISM.
1/80 A 7.1 10.5 7.1
B .0 .0 .0
SYSTEM 7.1 10.5 10.5 7.1 744 504 53 58.5
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JANUARY A COLD WEATHER CAUSED SOME PIPE LINES AND A BOOSTER
FAN ICE UP.
A HIGH PERCENTAGE OF COARSE SOLIDS IN THE THICKENER CAUSED SOME OUTAGE
TIME. THE WORM GEAR ON THE THICKENER FAILED ADDING TO THE OUTAGE TIME.
CLEANING AND REPAIR OF THE THICKENER WAS COMPLICATED BY SUB-ZERO AMBIENT
TEMPERATURES.
2/80 SYSTEM .0 .0 .0 696 696 0 97.1
** PROBLEMS/SOLUTIONS/COMMENTS
PROBLEMS RELATED TO THE COLD WEATHER CONTINUED THROUGH FEBRUARY. ICE
ON THE BOOSTER FAN HAD TO BE MELTED BEFORE IT COULD BE OPERATED.
SHAFT SLEEVES ON SEVERAL SPRAY RECYCLE PUMPS WERE REPLACED DURING
FEBRUARY.
THE GEAR REDUCER FAILED ON THE B-SIDE ABSORBER AGITATOR PREVENTING SCRUB-
BER OPERATION.
THE ISOLATION DAMPER CHAINS BROKE DURING THE MONTH.
3/80 A 22.6 22.6 22.6
362
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
MINNKOVA POWER COOPERATIVE: MILTON R. YOUNG 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER F6D CAP.
502 PART. HOURS HOURS HOURS FACTOR
4/80
5/80
6/80
6
SYSTEM
6.2
28.9
6.2
28.8
6.2
28.8
743
214 89.1
28.8 28.8 744
<* PROBLEMS/SOLUTIONS/COMMENTS
DURING MARCH COLD WEATHER CONTINUED TO BE A PROBLEM.
THE TORQUE SWITCHES ON THE ISOLATION DAMPERS WERE REPLACED. THE DAMPER
PROBLEMS CAUSED THE BOOSTER FAN TO TRIP. THE OUTAGE TIME WAS EXTENDED
BECAUSE THE UTILITY HAD TO WAIT FOR THE SWITCHES TO BE DELIVERED.
AN EXCESSIVE AMOUNT OF COARSE PARTICLES IN THE THICKENER CONTINUED TO BE
A PROBLEM. PLUGGED BLEED LINES FROM THE ABSORBER TO THE THICKENER WERE
ALSO ENCOUNTERED.
THE A-SIDE ABSORBER AGITATOR ANCHOR BOLTS SHEARED DURING MARCH CAUSING
MODULE DOWN TIME.
THE SHAFT SLEEVES ON THE SPRAY RECYCLE PUMPS WOULD NOT HOLD THE PUMP GLAND
PACKING. THE SHAFT SLEEVES ARE CURRENTLY BEING REPLACED.
A
B
SYSTEM
100.0
.0
100.0
.0
.0
.0
.0
.0
.0
.0
.0
720 154
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS DOWN (OP APPROXIMATELY 3 WEEKS FOR THE ANNUAL UNIT OUTAGE
DURING APRIL.
PLUGGED BLEED LINES AND THE REPLACEMENT OF THE SHAFT SLEEVES ON THE
RECYCLE PUMPS CAUSED THE FGD SYSTEM TO REMAIN OFF LINE DURING THE TIME
THE BOILER OPERATED.
A
B
SYSTEM
.0
47.2
47.2
.0
48.4
48.4
50.6
50.6
.0
45.6
45.6
744 700
339
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE B WAS OPERATED DURING MAY IJHJi.E REPAIR WORK WAS BEING DONE ON MODULE
A.
THE REPAIRS ON MODULE A INCLUDED WORK ON THE SPRAY RECYCLE NOZZLE PIPING,
AND THE RECYCLE HEADER.
THE VALVES ON BOTH THE SPRAY RECYCLE PUMP AND THE DISCHARGE SPRAY CYCLE
PUMP WERE REPAIRED.
THE ABSORBER LINING HAS STARTED TO WEAR AND IS NOW BEING REPAIRED.
HIGH SOLIDS RESULTED IN THICKNER LINE PLUGGING. HIGH SOLIDS ALSO CAUSED
PROBLEMS WITH THE RAKE AND CONE. BOTH THE THICKNER AND THE CLARIFIER HAD
TO BE DRAINED AND CLEANED.
THE ABSORBER AGITATOR TUNNEL WAS ALSO CLEANED DURING THE MONTH.
A
B
SYSTEM
.0
41.8
41.8
.0
40.4
40.4
41.4
41.4
.0
39.3
39.3
720 701
283
363
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
MINNKOTA POWER COOPERATIVE: MIL"ON R. YOUNG 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE B CONTINUED TO OPERATE THROUGH JUNE.
PROBLEMS WITH THE THICKNER CONTINUED THROUGH THE MONTH. HIGH SOLIDS CAUSED
PROBLEMS WITH THE RAKE MECHANISM AND THE LIMIT SWITCH.
TROUBLE WAS ENCOUNTERED DURING JUNE WITH THE VACUUM FILTER.
THE REPAIR WORK CONTINUED ON THE ABSORBER FLAKE LININGS.
MODULE A REPAIR WORK CONTINUED DURING JUNE.
7/80
A
13
SYSTEM
.0
65.3
65.3
.0
64.5
64.5
65.8
65.8
.0
52.0
52.0
744 600
387 60.0
«* PROBLEMS/SOLUTIONS/COMMENTS
PROBLEMS WITH THE RAKE MECHANISM AND UNDERFLOW PUMPS IN THE THICKENER CON-
TINUED IN JULY. HIGH SOLIDS IN THE THICKENER ARE CAUSED WHEN FLY ASH IS
ADDED TO THE LIME IN THE ABSORBER TOWER. THE ABSORBER REAGENT IS CHANGED
TO STRAIGHT LIME WHEN THIS OCCURS.
PROBLEMS WERE ENCOUNTERED WITH THE TWO VACUUM FILTER PUMPS. ONE WAS BEING
REBUILT WHILE THE OTHER FUNCTIONED POORLY.
REPAIRS WERE MADE TO THE LEAK IN THE ABSORBER TOWER.
PROBLEMS WERE REPORTED WITH THE MOTOR AND DISCHARGE VALVE ON THE TRAY
RECYCLE PUMPS.
THE FGD SYSTEM WAS NOT PLACED IN SERVICE WHEN THE BOILER WAS RUN AT REDUCED
LOAD DURING THE MONTH.
8/80 A
B
SYSTEM
90.7
56.9
99.2
54.3
44.2
98.6
98.8
99.4
99.2
53.9
44.0
98.0
744 739
729 92.8
** PROS LEMS/SO LUTIONS/COMflENTS
BOTH MODULES WERE OPERATED DURING AUGUST.
DURING THE MONTH, MAINTENANCE WORK WAS DONE ON THE TEFLON PACKING OF THE
SPRAY RECYCLE PUMPS. THE VACUUM FILTER DRUM, SPRAY NOZZLES, THE ABSORBER
AGITATOR, THE CLARIFIER CONE, AND THE THICKNER RAKE MECHANISM.
9/80
A
B
SYSTEM
70.1
66.7
100.0
72.6
25.1
97.9
100.0
100.0
100.0
66.9
23.2
90.3
650 78.5
10/80 A
B
SYSTEM
720 664
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS AVAILABLE DURING ALL OF SEPTEMBER.
BOTH MODULES WERE OPERATED DURING THE MONTH.
87.1
87.1 76.2 744 664 744 75.7
90.4
17.7
100.0
85.4
.0
85.4
76.2
.0
76.2
364
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
MINNKOfA POWER COOPERATIVE: MILTON R. YOUNG 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/C1MMENTS
DURING OCTOBER AVAILABILITY FOR MCOULE B MAS LOW DUE TO LEAKS IN THE TOWER.
11/80 A 42.2 40.4 100.0 38.7
B 98.6 >4.0 96.* 50.1
3Y5TEM 100.0 94.5 99.1 90.6 720 690 720 88.6
** PROBLEMS/SOLUTIONS/COMMENTS
AVAILABILITY HAS LOW FOR MODULE A DUE TO LEAKS IN THE TOWER DURING THE
MONTH OF NOVEMBER.
12/80 A 41.5 33.2 54.5 40.0
B 30.0 29.5 88.6 28.4
SYSTEM 71.5 62.8 66.7 60.5 744 716 450 92.4
** PROBLEMS/SOLUTIONS/COMMENTS
DURING DECEMBER AVAILABILITY WAS LOW DUE TO DOWN TIME NECESSARY TO CONVERT
FROM A THICKENER TO SLUDGE PONDS AND PROBLEMS WITH THE OVERFLOW LEVEL
CONTROL OF THE ABSORBER.
ISOLATION DAMPER PROBLEMS DURING THE MONTH DELAYED THE STARTUP OF THE
FGD SYSTEM.
365
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTIC'JLATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EMSSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MM
NET UNIT GENERATING CAPACITY M/FGD - MM
NET UNIT GENERATING CAPACITY WO/FGD - MM
EQUIVALENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FlOW - CU.M/S
BOILER FLUE GAS TEMPERATUPE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** ESP
NUMBER
T1PE
SUPPLIER
INLET FLUE GAS CAPACITY - CU.M/S
INLET FLUE GAS TEMPERATURE - C
** PARTICLE SCRUBBER
GENERIC TYPE
SPECIFIC TYPE
*** FGD SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAHAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
UNIT DESIGN SOS REMOVAL EFFICIENCY - 7.
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AMARDED
MONONGAHELA POMER
PLEASANTS
1
BELMONT
WEST VIRGINIA
B
21.
516.
******
1250
618
580
*****
618
FOSTER WHEELER
PULVERIZED COAL
BASE
1152.85
132.2
366.
CONCRETE
6.1
( .050 LB/MMBTU)
( 1.200 LB/MMBTU)
t****** LB/MMBTU)
(2443000 ACFM)
( 270 F)
(1200 FT)
( 20.0 FT)
( 12000 BTU/LB)
11,000-13,300
COAL
BITUMINOUS
27912.
********
******
15.00
10-20
3.70
2-4.5
********
COLO SIDE
AIR CORRECTION DIVISION, UOP
1152.9 (2443000 ACFM)
132.2 ( 270 F)
NONE
N/A
THROMAHAY PRODUCT
WET SCRUBBING
LIME
MG PROMOTED
BABCOCK & WILCOX
UNITED ENGINEERS & CONSTRUCTORS
FULL SCALE
NEW
7. 99.55
90.00
1
3/79
3/79
9/75
366
-------
MONONGAHELA POWER: PLEASANTS 1 (CONT.)
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
»* DESIGN AND OPERATING PARAMETERS
** ABSORBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
GAS CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
L/G RATIO - L/CU.M
GAS-SIDE PRESSURE DROP - KPA
INLET CAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
S02 REMOVAL EFFICIENCY - X
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
HUMBER PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
CONSTRUCTION MATERIAL GENERIC TYPE
kASH WATER SOURCE
I-'ASH RATE - L/S
** REHEATER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
PERCENT GAS BYPASSED - AVt
TEMI-ERATURE INCREASE - C
»** SLUDC'E
** DISPOSAL
TfPE
LOCATION
** WATER BALANCE
WVTER LOOP TYPE
*# FE) SPARE CAPACITY INDICES
A3SORBER - X
** FGO SPARE COMPONENT INDICES
A3SORBER
TRAY TOWER
SIEVE TRAY
BABCOCK & WILCOX
CARBON STEEL
AISI 1110
N/A
ORGANIC
RUBBER
SIEVE TRAY
1
7.4
1.2
242.10
132.2
90.0
(55.0 GAL/1000 ACF)
t 5.0 IN-H20)
( 513030 ACFM)
( 270 F)
MIST ELIMINATOR
4
IMPINGEMENT
BAFFLE
CHEVRON VANE
HORIZONTAL
FIBERGLASS REINFORCED PLASTIC
BLENDED FRESH MAKEUP AND THICKENER OVERFLOW
107.2 ( 1700 GAL/MIN)
BYPASS
COLD SIDE
N/A
16.5
-6.7 ( 20 F)
POND
ON SITE
CLOSED
.0
.0
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
3/79 SYSTEM
4/79 SYSTEM
744
720
367
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
HONONGAHELA POWER: PLEASANTS 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
SOZ PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT STARTED ON MARCH 7, 1979. NO HOURS ARE YET AVAILABLE BECAUSE OF
THE RECENT OPERATING STATUS.
THE A-MODULE HAS BEEN REMOVED FROM SERVICE DUE TO A HELD FAILURE ON THE
ABSORBER DOWNCOMER SECTION.
5/79 SYSTEM 744
6/79 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE UNIT WAS TAKEN OUT OF SERVICE ON JUNE 19
DUE TO SEVERE STACK LINER FAILURE. THE UNIT IS PROJECTED TO BE OUT OF
SERVICE UNTIL THE MIDDLE OF AUGUST.
7/79 SYSTEM .0 .0 744 0 0 .0
8/79 SYSTEM .0 .0 744 0 0 .0
9/79 SYSTEM .0 .0 720 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT RESTARTED. IN LATE SEPTEMBER AFTER COMPLETION OF THE STACK
RELINING.
10/79 SYSTEM 744
11/79 SYSTEM 720
12/79 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
NO INFORMATION HAS AVAILABLE FOR THIS REPORT PERIOD.
1/80 SYSTEM 744
2/80 SYSTEM 690
3/80 SYSTEM 744
** PROBLEMS/SOLUTIONS/CCMMENTS
NO INFORMATION HAS AVAILABLE ON THE OPERATIONS AT PLEASANTS 1 FOR THE
FIRST QUARTER OF 1980.
4/80 SYSTEM 720
5/80 SYSTEM 744
6/80 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION HAS UNAVAILABLE FOR THE SECOND QUARTER 1980 REPORT PERIOD.
7/80 SYSTEM 744
8/80 A 96.3 27.9
368
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
MONONGAHELA POWER: PLEASANTS 1 (CONT.)
PERIOD
9/80
MODULE AVAILABILITY
B
C
D
SYSTEM
SYSTEM
OPER ABILITY
98.1
.0
98.1
73.1
.0
— --^CKrUKnAril»C UAI«
RELIABILITY UTILIZATION
28.5
.0
28.5
21.2
.0
X REMOVAL PER
S02 PART. HOURS
744
720
BOILER
HOURS
216
0
FGO
HOURS
158
0
CAP.
FACTOR
23.2
.0
** PROBLEMS/SOLUTIONS/COMMENTS
AN EIGHT WEEK BOILER AND FGD SYSTEM SCHEDULED OUTAGE BEGAN DURING THE WEEK
OF AUGUST 11. THE FGD SYSTEM WAS EXPECTED TO BE OUT OF SERVICE FOR 8-12
WEEKS.
1.
2.
3.
4.
5.
6.
DURING THE OUTAGE THE FOLLOWING REPAIRS WERE TO BE PERFORMED:
REPLACE FABRIC EXPANSION JOINTS WITH ELASTOMER JOINTS
REPLACE GUNITE LININGS ON OUTLET DUCTWORK
BEGIN RE-LINING S02 MODULES RUBBER LINING DUE TO SEVERE BLISTERING
COAT THICKENER OVERFLOW TANK WITH COAL TAR EPOXY
MISCELLANEOUS PUMP AND VALVE MAINTENANCE
UPGRADE THE ISOLATION DAMPERS
10/80 SYSTEM
.0
.0
744
.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE PLEASANTS 1 FGD SYSTEM REMAINED OFF LINE THROUGH THE MONTH OF OCTOBER.
11/80 SYSTEM 720
12/60 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION FOR THE MONTHS OF NOVEMBER AND DECEMBER WAS NOT AVAILABLE.
369
-------
EPA U1ILITY FED SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NftME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MM
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGD - MM
EQUIVALENT SCRUBBED CAPACITY - MM
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** ESP
NUMBER
TYPE
SUPPLIER
INLET FLUE GAS CAPACITY - CU.M/S
INLET FLUE GAS TEMPERATURE - C
** PARTICLE SCRUBBER
GENERIC TYPE
SPECIFIC TYPE
*** FGD SYSTEM
MONONGAHELA POWER
PLEASANTS
Z
BELMONT
WEST VIRGINIA
B
21. ( .050 LB/MMBTU)
516. ( 1.200 LB/MMBTU)
****** (****** LB/MMBTU)
*****
618
580
*****
618
FOSTER WHEELER
PULVERIZED COAL
BASE
(2443000 ACFM)
( 270 F)
(1200 FT)
(***** FT)
(****** BTU/LB)
11,000-13,300
1152.85
132.2
366.
******
*******
COAL
BITUMINOUS
******
********
******
********
10-20
4.50
2-4.5
.03
COLD SIDE
AIR CORRECTION DIVISION, UOP
1132.6 (2400000 ACFM)
132.2 ( 270 F)
NONE
N/A
** GENERAL DATA
SALEABLE PRODUCT/THROWAHAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
U^IT DESIGN S02 REMOVAL EFFICIENCY - X
C'JRRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
THROWAWAY PRODUCT
WET SCRUBBING
LIME
MS PROMOTED
BABCOCK & WILCOX
UNITED ENGINEERS & CONSTRUCTORS
FULL SCALE
NEW
X 99.55
90.00
1
0/81
10/80
9/75
370
-------
MONONSAHELA POWER: PLEASANTS 2 (CONT.)
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
** DESIGN AND OPERATING PARAMETERS
** ABoORBER
NUMBER 4
GENERIC TYPE TRAY TOWER
SPECIFIC TYPE SIEVE TRAY
SHELL SPECIFIC MATERIAL AISI 1110
SHELL MATERIAL TRADE NAME/COMMON TYPE N/A
LINER GENERIC MATERIAL ORGANIC
LINER MATERIAL TRADE NAME/COMMON TYPE RUBBER
NUMBER OF CONTACTING ZONES 1
L/G RATIO - L/CU.M 7.4
INLET GAS TEMPERATURE - C 132.2
S02 REMOVAL EFFICIENCY - X 90.0
** MIST ELIMINATOR
PR£-MIST ELIMINATOR/MIST ELIMINATOR
GENERIC TYPE
SPZCIFIC TYPE
TRADE NAME/COMMON TYPE
** REHEATER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
PERCENT GAS BYPASSED - AVG
TEMPERATURE INCREASE - C
**« SLUDGE
** DISPOSAL
TYPE POND
LOCATION ON SITE
** WATER BALANCE
WATER LOOP TYPE OPEN
(55.0 GAL/1000 ACF)
( 270 F)
MIST ELIMINATOR
IMPINGEMENT
BAFFLE
CHEVRON VANE
BYPASS
COLD SIDE
N/A
16.5
-6.7
( 20 F)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
10/80 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
INITIAL OPERATION OF THE FGD SYSTEM COMMENCED IN LATE OCTOBER 1980.
11/80 SYSTEM 720
12/80 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD PROBLEMS HAVE BEEN ENCOUNTERED.
371
-------
EPA UriLITY F6D SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY KAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
SOS EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MM
GROSS UNIT GENERATING CAPACITY - MM
NET UN^T GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGD - MM
EQUIVALENT SCRUBBED CAPACITY - MW
** UNrr DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FU-.L TYPE
FU'IL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVI-RAGE ASH CONTENT - 7.
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - 7,
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** PARTICLE SCRUBBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
LIQUID RECIRCULATION RATE - LITER/S
L/G RATIO - LITER/CU.M
PRESSURE DROP - KPA
SUPERFICIAL GAS VELOCITY - M/S
INLET GAS FLOW RATE - CU.M/S
INLET GAS TEMPERATURE - C
PARTICLE REMOVAL EFFICIENCY - 7.
*** FGD SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
( .100 LB/MMBTU)
( 1.200 LB/MMBTU)
(*«**** LB/MMBTU)
MONTANA POWER
COLSTRIP
1
COLSTRIP
MONTANA
B
43.
516.
******
664
360
332
344
360
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
674.82 (1430000 ACFM)
143.9 ( 291 F)
152. ( 500 FT)
CONCRETE
5.0 ( 16.5 FT)
( 8843 BTU/LB)
8,162-8,8967
COAL
SUBBITUMINOUS
20569.
8.60
6.1-12.6
23.90
21.6-28.8
.77
0.4-1.0
.01
******
VENTURI TOWER
VARIABLE-THROAT/TOP-ENTRY PLUMB BOB
COMBUSTION EQUIPMENT ASSOCIATES
15 DIA THROAT
CARBON STEEL
AISI 1110
INORGANIC
ACID-RESISTANT BRICK t MORTAR
316 SS PLUMB BOB, CERAMIC NOZZLES
1
415.8 ( 6600 GPM)
2.0 (15.0 GAL/1000ACF)
4.2 (17.0 IN-H20)
61.0 ( 200.0 FT/S)
224.9 ( 476667 ACFM)
143.9 ( 291 F)
99.5
THROWAWAY PRODUCT
MET SCRUBBING
LIME/ALKALINE FLYASH
NONE
COMBUSTION EQUIP ASSOCIATES
372
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
MONTANA POWER: COLSTRIP 1 (CONT.)
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
U.JIT DESIGN S02 REMOVAL EFFICIENCY - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
** AB.50RBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
DTMENSIONS - FT
SUZLL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LJNER SPECIFIC MATERIAL
L:NER MATERIAL TRADE NAME/COMMON TYPE
G/.S CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
LXQUID RECIRCUUTION RATE - LITER/S
L/G RATIO - L/CU.M
G>iS-SIDE PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/SEC
INLET GAS FLOW - CU. M/S
II!LET GAS TEMPERATURE - C
S02 REMOVAL EFFICIENCY - X
PARTICLE REMOVAL EFFICENCY - X
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
GEMERIC TYPE
SPECIFIC TYPE
TR4DE NAME/COMMON TYPE
CONFIGURATION
NUJ1BER OF STAGES
NUIIBER OF PASSES PER STAGE
FREEBOARD DISTANCE - M
DISTANCE BETWEEN STAGES - CM
DISTANCE BETWEEN VANES - CM
VANE ANGLES - DEGREES
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/S
CONSTRUCTION MATERIAL GENERIC TYPE
WASH WATER SOURCE
WASH RATE - L/S
** REHEATER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TEMPERATURE INCREASE - C
INLET FLUE GAS FLOW RATE - CU. M/S
INLET FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** FANS
NUMBER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
BECHTEL
FULL SCALE
NEW
X 99.50
60.00
1
11/75
9/75
10/72
COMBINATION
VENTURI/SPF.AY
COMBUSTION EQUIP ASSOCIATES
70.5 X 35 DIA.
CARBON STEEL
AISI 1110
N/A
ORGANIC
GLASS FLAKE-FILLED POLYESTER,VINYL ESTER
FLAKEGLASS.PLASITE
CLEAR WATER TRAY (KOCH VALVE TRAY)
479.
2.4
.1
2.7
201.31
48.9
60.0
99.5
( 7600 GPM)
( 18.0 GAL/1000 ACF)
( .5 IN-H20)
( 8.7 FT/S)
( 426600 ACFM)
( 120 F)
MIST ELIMINATOR
1
IMPINGEMENT
BAFFLE
CHEVRON VANE
HORIZONTAL
1
4
3.96 (13.0 FT)
2.54 ( 1.0 IN)
2.5 ( 1.00 IN)
120
.6 ( 2.3 IN-H20)
2.7 ( 8.7 FT/S)
NORYL PLASTIC
POND OVERFLOW, RIVER WATER AND FRESH WATER
26.5 ( 420 GAL/MIN)
3
IN-LINE
STEAM
10.0
201.31
48.9
( 50 F)
( 426600 ACFM)
( 120 F)
INLET;INCONEL 625 - OUTLET;HASTELLOY 6
BALANCED DRAFT
INDUCED DRAFT
DRY
223.21 ( 473000 ACFM)
76.7 ( 170 F)
CARBON STEEL IMPELLER, RUBBER-LINED HOUSING
373
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
MONTANA POWER: COLSTRIP 1 (CONT.)
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
** TANKS
SFRVICE
VcNTURI/ABSORBER RECYCLE TANK
** PU11PS
SERVICE
VcNTURI RECIRCULATION
A3SORBER RECIRCULATION
*** SLUDGE
** DISPOSAL
NATURE
TYPE
LOCA riON
SITE TRANSPORTATION METHOD
S:
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
MONTANA POWER: COLSTRIP I (CONT.)
PERIOD
9/75
10/75
11/75
12/75
1/76
2/76
3/76
4/76
5/76
6/76
7/76
8/76
9/76
10/76
rCKrUKIlANOC UAI A
MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
.0
.0
.0
.0
90.0
98.0
97.6
74.2
96.8
.0
93.2
94.7
88.6
79.9
720
744
720
744
744
696
744
720
744
.0 720
744
744
720
744
72
456
576
720
672
624
576
672
336
0
480
552
720
720
.5
19.4
42.2
59.9
63.8
65.4
57.0
49.9
26.0
0 .0
28.0
37.8
64.5
73.1
** PROBLEMS/SOLUTIONS/COMMENTS
A TEMPERATURE EXCURSION RESULTED IN DAMAGE TO SYSTEM COMPONENTS CAUSING
SYSTCM DOWNTIME.
THE EIIERGENCY SCRUBBER QUENCH WA"> ER SUPPLY SYSTEM FAILED TO OPERATE
DURING A TEMPERATURE EXCURSION RESULTING IN INTERNAL DAMAGE.
THE IININGS WERE DAMAGED DURING THE OCTOBER TEMPERATURE EXCURSION.
MIST ELIMINATOR DAMAGE OCCURRED AS THE RESULT OF THE TEMPERATURE EXCURSION
IN OCTOBER.
11/76 SYSTEM 62.7 720 720 55.6
** PROBLEMS/SOLUTIONS/COMMENTS
A FAILURE OF AN ID FAN MOTOR OCCURRED IN NOVEMBER.
12/76 SYSTEM 73.8 744 744 67.2
1/77 SYSTEM 92.5 744 744 72.9
2/77 SYSTEM 95.4 672 48 3.0
3/77 SYSTEM .0 .0 744 0 0 .0
4/77 SYSTEM 83.0 720 600 49.9
5/77 SYSTEM 85.4 744 624 64.1
6/77 SYSTEM 87.4 720 672 68.6
7/77 'SYSTEM 85.1 744 696 71.8
8/77 SYSTEM 93.3 744
375
-------
EPA UTILITY FGO SURVEY: OCTOBER - DECEMBER 1980
MONTANA POWER: COLSTRIP 1 (CONT.)
DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
9/77
10/77
11/77
12/77
1/78
2/78
3/78
4/78
5/78
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
92.5
95.6
96.3
98.3
95.7
99.5
92.0
99.8
66.0
1.3
720
744
720
744
672
744
720
744
10
** PROBLEMS/SOLUTIONS/COMMENTS
THE 66X MAY AVAILABILITY IS BASED UPON 9.92 HOURS OF OPERATION ON TWO
SCRUBBERS WHILE THE UNIT WAS BEING BROUGHT BACK ON LINE AFTER COMPLETION
OF ITS ANNUAL OVERHAUL.
THE ID FAN MOTOR FOR MODULE 1A WAS NOT AVAILABLE DURING UNIT RESTART IN
MAY.
6/78
7/78
8/78
9/78
10/78
11/78
12/78
1/79
2/79
3/79
4/79
5/79
6/79
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
76.0
95.7
97.0
96.0
95.0
91.0
96.7
97.6
90.3
97.3
98.9 38.4 80.2
89.7
95.2
720
744
744
720
744
720
744
744
672
744
720 597
744
720
** PROBLEMS/SOLUTIONS/COMMENTS
7/79
8/79
9/79
SYSTEM
SYSTEM
SYSTEM
DURING MAY AND JUNE THE UNIT WAS BEING
THESE PERIODS IS BASED UPON OPERATIONS
98.0
97.3
95.2
OVERHAULED. THE AVAILABILITY FOR
BEFORE AND AFTER OVERHAUL.
744
744
720
376
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
MONTANA POWER: COLSTRIP 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
10/79 SYSTEM 92.9 744
11/79 SYSTEM 97.5 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE ROUTINE MAINTENANCE CAN BE PERFORMED WHILE THE MODULES ARE ON LINE
SO THE AVAILABILITY REMAINS HIGH.
12/79 SYSTEM 95.9 744
1/80 SYSTEM 96.5 744
2/80 SYSTEM 97.4 696
3/80 SYSTEM 95.4 744
** PROBLEMS/SOLUTIONS/COMMENTS
TOTAL SYSTEM AVAILABILITY CONTINUES TO BE HIGH WITH NO MAJOR FGD SYSTEM
PROBLEMS REPORTED DURING THE FIRST QUARTER OF 1980.
4/80 SYSTEM 99.8 720
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR PROBLEMS WITH THE FGD SYSTEM WERE REPORTED BY THE UTILITY DURING
APRIL.
5/80 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
NO AVAILABILITY DATA WERE REPORTED BY THE UTILITY BECAUSE OF A SCHEDULED
BOILER AND FGD SYSTEM OUTAGE FOR ROUTINE MAINTENANCE.
6/80 SYSTEM 77.7 720
** PROBLEMS/SOLUTIONS/COMMENTS
LOW AVAILABILITY DURING JUNE WAS A RESULT OF THE ANNUAL BOILER AND FGD
SYSTEM MAINTENANCE OUTAGE.
7/80 SYSTEM 98.6 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR PROBLEMS WERE ENCOUNTERED DURING JULY.
8/80 SYSTEM 99.3 744
9/80 SYSTEM 98.3 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
FOR THE MONTHS OF AUGUST AND SEPTEMBER.
10/80 SYSTEM 744
11/80 SYSTEM 720
12/80 SYSTEM 744
377
-------
EPA UTILITY FGO SURVEY: OCTOBER - DECEMBER 1980
MONTANA POWER: COLSTRIP 1 CCONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION FOR THE FOURTH QUARTER 1980 IS NOT AVAILABLE AT THIS TIME.
378
-------
EPA UTILITY FSD SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC F6D SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICIPATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PUNT GENERATING CAPACITY - MM
GROSS UNIT GENERATING CAPACITY - MM
NET UNIT GENERATING CAPACITY W/FGD - MM
NET UNIT GENERATING CAPACITY WO/FGD - MM
EQUIVALENT SCRUBBED CAPACITY - MM
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOH - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
ST^CK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** PARTICLE SCRUBBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
LIQUID RECIRCULATION RATE - LITER/S
L/G RATIO - LITER/CU.M
PRESSURE DROP - KPA
SUPERFICIAL GAS VELOCITY - M/S
INLET GAS FLOM RATE - CU.M/S
INLET GAS TEMPERATURE - C
PARTICLE REMOVAL EFFICIENCY - 7.
*** FGD SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROHAWAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
.100 LB/MMBTU)
.200 LB/MMBTU)
(*#**** LB/MMBTU)
MONTANA POHER
COLSTRIP
2
COLSTRIP
MONTANA
B
43.
516.
******
664
360
332
344
360
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
674.82 (1430000 ACFM)
143.9 ( 291 F)
152. ( 500 FT)
CONCRETE
5.0 ( 16.5 FT)
COAL
SUBBITUMINOUS
20569.
8.60
6.1-12.6
23.90
21.6-28.8
.77
0.4-1.0
.01
( 8843 BTU/LB)
8,162-8,8967
VENTURI TOWER
VARIABLE-THROAT/TOP-ENTRY PLUMB BOB
COMBUSTION EQUIPMENT ASSOCIATES
15 DIA THROAT
CARBON STEEL
AISI 1110
INORGANIC
ACID-RESISTANT BRICK & MORTAR
316 SS PLUMB BOB, CERAMIC NOZZLES
1
415.8 ( 6600 GPM)
2.0 (15.0 GAL/1000ACF)
4.2 (17.0 IN-H20)
61.0 ( 200.0 FT/S)
224.9 ( 476667 ACFM)
143.9 ( 291 F)
99.5
THROWAWAY PRODUCT
WET SCRUBBING
LIME/ALKALINE FLYASH
NONE
COMBUSTION EQUIP ASSOCIATES
379
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
MONTANA POWER: COLSTRIP 2 (CONT.)
A-E FIRM
DEVELOPMENT LEVEL
NEW/PETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
UNIT DESIGN S02 REMOVAL EfFICIENCY - X
CURFENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTACT AWARDED
** DESIGN AND OPERATING PARAMETERS
** ABSORBER
NUMBER
G'-INERIC TYPE
SPECIFIC TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SMELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LTNER SPECIFIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
GAS CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
L3QUID RECIRCULATION RATE - LITER/S
L/G RATIO - L/CU.M
GAS-SIDE PRESSURE DROP - KPA
SL'PERFICAL GAS VELOCITY - M/SEC
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
S02 REMOVAL EFFICIENCY - 7.
PARTICLE REMOVAL EFFICENCY - X
** MIST ELIMINATOR
PR:-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
GFNERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES PER STAGE
FREEBOARD DISTANCE - M
DISTANCE BETWEEN STAGES - CM
DISTANCE BETWEEN VANES - CM
VANE ANGLES - DEGREES
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/S
CONSTRUCTION MATERIAL GENERIC TYPE
WASH WATER SOURCE
** REHEATER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TEMPERATURE INCREASE - C
INLET FLUE GAS FLOW RATE - CU. M/S
INLET FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** FANS
NUMBER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
BECHTEL
FULL SCALE
NEW
'/. 99.50
60.00
1
10/76
5/76
10/72
COMBINATION
VENTURI/SPRAY
COMBUSTION EQUIP ASSOCIATES
70.5 X 35 DIA.
CARBON STEEL
AISI 1110
N/A
ORGANIC
GLASS FLAKE-FILLED POLYESTER,VINYL ESTER
FLAKEGLASS.PLASITE
CLEAR WATER TRAY (KOCH VALVE TRAY)
479.
2.4
.1
2.7
201.31
48.9
60.0
99.5
( 7600 GPM)
( 18.0 GAL/1000 ACF)
( .5 IN-H20)
t 8.7 FT/S)
( 426600 ACFM)
( 120 F)
MIST ELIMINATOR
1
IMPINGEMENT
BAFFLE
CHEVRON VANE
HORIZONTAL
1
4
3.96 (13.0 FT)
2.54 ( 1.0 IN)
2.5 ( 1.00 IN)
120
.6 ( 2.3 IN-H20)
2.7 ( 8.7 FT/S)
NORYL PLASTIC
POND OVERFLOW, RIVER WATER AND FRESH WATER
3
IN-LINE
STEAM
10.0
201.31
43.9
( 50 F)
( 426600 ACFM)
( 120 F)
INLET INCONEL 625/OUTLET HASTELLOY S
BALANCED DRAFT
INDUCED DRAFT
DRY
223.21 ( 473000 ACFM)
76.7 ( 170 F)
CARBON STEEL IMPELLER, RUBBER-LINED HOUSING
380
-------
MONTANA POWER: COLSTRIP 2 (CONT.)
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
** TANKS
SERVICE
VENTURI/ABSORBER RECYCLE TANK
*# PUMPS
SERVICE
VEN->URI RECIRCULATION
ABSORBER RECIRCULATION
*** SL'JDC'E
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE DIMENSIONS
SITE CAPACITY - CU.M
SITE SERVICE LIFE - YRS
** DISPOSAL
NATURE
TYPE
LOCATION
S'TE TRANSPORTATION METHOD
SITE DIMENSIONS
SJ:TE CAPACITY - CU.M
** DISPOSAL
NATURE
T»PE
LOCATION
SITE TRANSPORTATION METHOD
SITE DIMENSIONS
SITE CAPACITY - CU.M
SITE SERVICE LIFE - YRS
** PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS
CONTROL LEVELS
MONITOR LOCATION
PROCESS CONTROL MANNER
PROCESS CHEMISTRY MODE
SCRUBBER INLET
CARBON STEEL
NONE
SCRUBBER TO REHEATER AND REHEATER TO STACK
CARBON STEEL
HEIL FLAKEGLASS
NUMBER
3
NUMBER
INTERIM
DIKED LINED POND
ON SITE
PUMPED
20 FT. DEEP
635960 (
10
520.0 ACRE-FT)
INTERIM
DIKED LINED POND
ON SITE
PUMPED
20 FT. DEEP
635960 (
FINAL
POND
OFF SITE
PUMPED
20 FT. DEEP
2590314
18
520.0 ACRE-FT)
( 2118.0 ACRE-FT)
PH
4.0 TO 5.0
RECIRCULATION TANK
MANUAL
FEEDBACK
** MATER BALANCE
WATER LOOP TYPE CLOSED
EVAPORATION WATER LOSS - LITER/S 18.9
POND SEEPAGE/RUNOFF WATER LOSS - LITERS/S 0
MAKEUP WATER ADDITION - LITERS/S 23.3
( 300 GPM)
( 370 GPM)
»* FGD SPARE CAPACITY INDICES
ABSORBER - X
** FGD SPARE COMPONENT INDICES
ABSORBER
20.0
.5
381
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
MONTANA POWER: COLSTRIP 2 (CONT.)
PERIOD
5/76
6/76
7/76
8/76
9/76
10/76
11/76
12/76
1/77
2/77
3/77
4/77
5/77
6/77
7/77
8/77
9/77
10/77
MODULE AVAILABILITY OPERABILITY RELIABILITY
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
S". STEM
SV STEM
S>STEM
SYSTEM
SYSTEM
SYSTEM
100.
99.
98.
95.
98.
90.
94.
92.
83.
93.
96.
84.
63.
87.
90.
81.
89.
77.
0
7
7
8
3
3
1
5
4
8
7
5
0
8
6
0
8
0
UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
744
720
744
744
720
744
720
744
744
672
744
720
744
720
744
744
720
744
72
384
312
240
720
744
720
744
720
648
672
696
312
672
672
1
23
19
13
64
77
79
82
68
75
71
68
23
61
57
.3
.2
.5
.0
.6
.0
.7
.3
.2
.3
.3
.2
.3
.4
.5
** PROBLEMS/SOLUTIONS/COMMENTS
THE 77X OCTOBER AVAILABILITY FOR THIS SYSTEM INCLUDES NON-AVAILABLE HOURS
DURING A BOILER OUTAGE. SCRUBBER MAINTENANCE WAS PERFORMED FOR PART OF
THIS OUTAGE TIME. THE FIGURE COMES TO 98.IX WHEN THE BOILER OUTAGE
OUTAGE TIME IS EXCLUDED FROM THE AVERAGING PERIOD.
11/77 SYSTEM 98.0 720
12/77 SYSTEM 98.4 744
1/78 SYSTEM 97.3 744
2/78 SYSTEM 94.5 672
3/78 SYSTEM 89.1 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS SHUT DOWN FOR AN ANNUAL OVERHAUL ON APRIL 18.
THE UTILITY REPORTED AN AVAILABILITY OF 89.17. FOR MARCH BASED ON 17 DAYS
OF OPERATION BEFORE THE UNIT SHUTDOWN FOR THE ANNUAL BOILER OVERHAUL. IF
THE SCRUBBING SYSTEM IS ASSUMED TO BE AVAILABLE, I.E. NOT UNDERGOING MAJOR
REPAIRS DURING THE BOILER OVERHAUL, THE AVAILABILITY COMES TO 93.8X.
4/78 SYSTEM 86.9 720
382
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
MONTANA POWER: COLSTRIP 2 (CONT.)
FtKrUKnAMUL UAI A — • -"" ~
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
SOZ PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED AN AVAILABILITY OF 86. 9X FOR APRIL BASED ON EIGHT
DAYS OF OPERATION AFTER THE UNIT SHUTDOWN FOR THE ANNUAL BOILER OVERHAUL.
IF THE SCRUBBING SYSTEM IS ASSUMED TO BE AVAILABLE, I.E. NOT UNDERGOING
MAJOR REPAIRS DURING THE BOILER OVERHAUL, THE AVAILABILITY COMES TO 96. 5X.
5/78 SYSTEM
6/78 SYSTEM
7/78 SYSTEM
8/78 SYSTEM
9/78 SYSTEM
10/78 SYSTEM
11/78 SYSTEM
12/78 SYSTEM
1/79 SYSTEM
2/79 SYSTEM
3/79 SYSTEM
4/79 SYSTEM
99.1
97.4
96.4
99.0 .0
94.0 .0
99.0 .0
99.0 .0
91.2
94.3
98.3
94.3
100.0
744
720
744
744 0
720 0
744 0
720 0
744
744
672
744
720
0
0
0
0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING APRIL THE UNIT MAS BEING OVERHAULED. THE AVAILABILITY FOR
TIME IS BASED UPON OPERATIONS BEFORE AND AFTER THE OVERHAUL.
5/79 SYSTEM
6/79 SYSTEM
7/79 SYSTEM
8/79 SYSTEM
9/79 SYSTEM
10/79 SYSTEM
11/79 SYSTEM
94.4
98.4
96.4
99.3
92.3
92.9
98.4
744
720
744
744
720
744
720
THIS
** PROBLEMS/SOLUTIONS/COMMENTS
12/79 SYSTEM
1/80 SYSTEM
2/80 SYSTEM
3/80 SYSTEM
THE ROUTINE MAINTENANCE CAN BE PERFORMED WHILE THE
SO THE AVAILABILITY REMAINS HIGH.
95.8
92.7
98.1
98.2
MODULES ARE ON
744
744
696
744
LINE
383
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
MONTANA POWER: COLSTRIP 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
TOTAL FGD SYSTEM AVAILABILITY CONTINUES TO BE HIGH WITH NO MAJOR PROBLEMS
REPORTED FOR THE FIRST QUARTER OF 1980.
4/80 SYSTEM 720
** PROBLEMS/SOLUTIOHS/COMMENTS
NO AVAILABILITY DATA MERE REPORTED BY THE UTILITY BECAUSE OF A BOILER AND
FGD SYSTEM OUTAGE THAT WAS SCHEDULED FOR ROUTINE MAINTENANCE.
5/80 SYSTEM 93.5 744
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR PROBLEMS WITH THE FGD SYSTEM WERE REPORTED BY THE UTILITY DURING
MAY.
6/80 SYSTEM 96.0 720
7/80 SYSTEM 99.7 744
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR PROBLEMS kTRE ENCOUNTERED DURING THE JUNE-JULY PERIOD.
8/80 SYSTEM 96.2 744
9/80 SYSTEM 90.5 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-REUTED PROBLEMS WERE ENCOUNTERED
DURING THE MONTHS OF AUGUST AND SEPTEMBER.
10/80 SYSTEM 744
11/80 SYSTEM 720
12/80 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION FOR THE FOURTH QUARTER 7.980 IS NOT AVAILABLE AT THIS TIME.
384
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC F6D SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NS/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MM
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** MECHANICAL COLLECTOR
TYPE
SUPPLIER
PARTICLE REMOVAL EFFICENCY -7.
** PARTICLE SCRUBBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
LIQUID RECIRCULATION RATE - LITER/5
L/G RATIO - LITER/CU.M
PRESSURE DROP - KPA
SUPERFICIAL GAS VELOCITY - M/S
INLET GAS FLOW RATE - CU.M/S
INLET GAS TEMPERATURE - C
PARTICLE REMOVAL EFFICIENCY - 7.
*** FGO SVSTEM
NEVADA POWER
REID GARDNER
1
MOAPA
NEVADA
B
43.
516.
******
111
125
110
( .100 LB/MMBTU)
( 1.200 LB/MMBTU)
(****** LB/MMBTU)
125
FOSTER WHEELER
PULVERIZED COAL
BASE
223.21 ( 473000 ACFM)
176.7 ( 350 F)
61. ( 200 FT)
CONCRETE
3.8 ( 12.6 FT)
( 12450 BTU/LB)
11500-12500
COAL
BITUMINOUS
28959.
8.00
8.-10.
5.50
5.5
.50
0.5-1.0
.05
MULTICLONES
RESEARCH-COTTRELL
75.0
VENTURI TOWER
FIXED-THROAT
ADL/COMBUSTION EQUIP ASSOCIATES
1.5 DIA. X 18 LONG AT THROAT
CARBON STEEL, HIGH ALLOY
AISI 1110, AUSTENITIC
NONE, ORGANIC
N/A, RUBBER
TWIN VARIABLE THROATS
1
157.5
1.3
4.6
50.3
223.2
176.7
97.0
( 2500 GPM)
(10.0 GAL/1000ACF)
(18.5 IN-H20)
( 165.0 FT/S)
( 473000 ACFM)
( 350 F)
385
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
NEVADA POWER: REID GARDNER 1 (CONT.)
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
UNIT DESIGN S02 REMOVAL EFFICIENCY - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
** ABSORBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
GAS CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
LIQUID RECIRCULATION RATE - LITER/S
L/G RATIO - L/CU.M
GAS-SIDE PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/SEC
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES PER STAGE
PRESSURE DROP - KPA
CONSTRUCTION MATERIAL GENERIC TYPE
** REHEATER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
TEMPERATURE INCREASE - C
INLET FLUE GAS TEMPERATURE - C
NUMBER OF TUBES PER BUNDLE
CONSTRUCTION MATERIAL GENERIC TYPE
** FANS
NUMBER
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
THROWAWAY PRODUCT
WET SCRUBBING
SODIUM CARBONATE
NONE
COMBUSTION EQUIP ASSOCIATES
BECHTEL
FULL SCALE
RETROFIT
/. 97.00
90.00
1
4/74
3/74
7/71
TRAY TOWER
SIEVE TRAY
COMBUSTION EQUIP ASSOCIATES
30 DIA.
CARBON STEEL
AISI 1110
N/A
ORGANIC
RUBBER
SINGLE SIEVE TRAY WITH 3/16 IN HOLES
38.
.2
.7
3.4
( 600 6PM)
( 1.6 GAL/1000 ACF)
( 3.0 IN-H20)
( 11.0 FT/S)
MIST ELIMINATOR
1
CENTRIFUGAL
RADIAL VANE
HORIZONTAL
1
1
.1 ( .5 IN-H20)
316L SS (BOTH ME AND WASH TRAY)
INDIRECT HOT AIR
EXTERNAL HEAT EXCHANGER
STEAM TUBE BUNDLES
10.0 ( 50 F)
48.3 ( 119 F)
24
CARBON STEEL
BUFFALO FORGE
BALANCED DRAFT
FORCED DRAFT
DRY
223.21 ( 473000 ACFM)
176.7 ( 350 F)
CARBON STEEL
SCRUBBER INLET
CARBON STEEL
NONE
386
-------
NEVADA POWER: REID GARDNER 1 (CONT.)
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
MNER GENERIC MATERIAL TYPE
** TAWS
SERVICE
V£NTURI RECYCLE
** PU'IPS
S£RVICE
SCRUBBER RECIRCUUTION
ADSORBER RECIRCUUTION
*** SLICGE
** DISPOSAL
NATURE
TYPE
LOCATION
** DISPOSAL
NATURE
TYPE
LO:ATION
SITE TRANSPORTATION METHOD
** WATER BALANCE
WATER LOOP TYPE
MAKEUP WATER ADDITION - LITERS/S
** FGD SPARE CAPACITY INDICES
ABSORBER - X
** FGD SPARE COMPONENT INDICES
ABSORBER
SCRUBBER OUTLET
CARBON STEEL
PLASITE 4004-S
NUMBER
1
NUMBER
INTERIM
LINED POND
ON SITE
FINAL
LINED POND
ON SITE
GRAVITY FLOW FROM INTERIM SLUDGE POND
CLOSED
9.8
.0
.0
( 155 GPM)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
4/74 SYSTEM
*# PROBLEMS/SOLUTIONS/COMMENTS
720
5/74 SYSTEM
6/74 SYSTEM
7/74 SYSTEM
8/74 SYSTEM
9/74 SYSTEM
10/74 SYSTEM
11/74 SYSTEM
12/74 SYSTEM
THE SYSTEM WAS FIRST PLACED IN SERVICE IN APRIL 1974. THE SCRUBBING UNIT
DESIGN WAS BASED ON INFORMATION AND DATA OBTAINED FROM AN 8000-ACFM PILOT
PLANT PROGRAM CONDUCTED AT REID GARDNER STATION IN 1971 AND 1972.
744
720
744
744
720
744
720
744
387
-------
EPA LTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
NEVADA POWER: REID GARDNER 1 (CONT.)
_ PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGQ CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE F6J SYSTEM HAS PERFORMED ACCEPTABLY SINCE START UP IN APRIL 1974.
SYSTEM AVAILABILITY HAS BEEN GREATER THAN 90X AND OPERATIONS HAVE ONLY BEEN
INTERRJPTED BY LACK OF TRONA. S02 REMOVAL EFFICIENCY HAS BEEN
APPRO?IMATELY 85X. BECAUSE OF A COAL STRIKE THE BOILER ONLY OPERATED ABOUT
TWO WEEKS IN NOVEMBER AND DURING THOSE TWO WEEKS IT OPERATED AT LOW LOAD.
DELIVERY OF TRONA WAS SUFFICIENT TO MAINTAIN FGD SYSTEM OPERATION. THERE
ARE NO OUTSTANDING MECHANICAL OR PROCESS PROBLEMS.
1/75 SYSTEM 65.0 744
** PROBLEMS/SOLUTIONS/COMMENTS
FROZEN SODIUM CARBONATE FEED LINES ACCOUNTED FOR MOST OF THE JANUARY OUTAGE
TIME. THE FGD SYSTEM HAS BEEN OPERATING WITH TRONA SUPPLEMENTED BY SODIUM
CARBONATE BRINE.
2/75 SYSTEM 95.0 672
«* PROBLEMS/SOLUTIONS/COMMENTS
A 2-DAY LACK OF CHEMICALS RESULTED IN OUTAGE TIME DURING FEBRUARY.
3/75 100.0 100.0
SYSTEM 744
4/75 SYSTEM 100.0 100.0 720
«* PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS SHUT DOWN APRIL 13 FOR ROUTINE MAINTENANCE. THE UNIT IS
SCHEDULED TO BE BACK IN SERVICE IN EARLY MAY.
5/75 SYSTEM 744
*« PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER AND FGD SYSTEM WERE PLACED BACK IN SERVICE ON MAY 12.
THE UTILITY REPORTED THAT A HIGH ASH CONTENT OF UP TO 20X BY WEIGHT OF THE
COAL BURNED RECENTLY HAD NO EFFECT ON EMISSIONS.
THE UTILITY REPORTED PROBLEMS WITH ABRASION OF THE PIPING RUBBER LINING AND
ROUTINE MECHANICAL PROBLEMS.
INSTRUMENTATION PROBLEMS WERE ENCOUNTERED OVER THE APRIL-MAY PERIOD.
6/75 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
ROUTINE MECHANICAL PROBLEMS CONTINUED THROUGH JUNE.
MINOR INSTRUMENTATION PROBLEMS CONTINUED THROUGH JUNE.
THE UTILITY HAS REPORTED THAT A SECOND PERFORMANCE TEST HAS RECENTLY
COMPLETED AND PASSED.
7/75 SYSTEM 85.0 744
8/75 SYSTEM 744
9/75 SYSTEM 78.1 77.6 720 716 559
388
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
NEVADA POWER: REID GARDNER I (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
FOUR FORCED OUTAGES OCCURED DURING SEPTEMBER. THREE OF THE FOUR WERE
SCRUBBER-RELATED. DETAILS WERE NOT AVAILABLE FROM THE UTILITY.
10/75 SYSTEM 35.0 14.0 744 303 106
** PROBLEMS/SOLUTIONS/COMMENTS
LOW OPERATING TIME DURING OCTOBER WAS DUE TO SCHEDULED BOILER MAINTENANCE.
ONE OUTAGE WAS DUE TO THE MALFUNCTION OF A SODA ASH BLOWER.
11/75 SYSTEM 60.3 54.7 720 654 394
**• PROBLEMS/SO LUTIONS/CO1MENTS
OPERABILITY WAS LOW FOR THE MONTH OF NOVEMBER BECAUSE OF DELAYS IN THE
DELIVFRY OF REPAIR MATERIALS.
12/75 SYSTEM 744
1/76 SYSTEM 26.7 30.6 30.6 26.7 744 647 198
** PROBLEMS/SOLUTIONS/COMMENTS
THE COLLAPSE OF A VENTURI STRAINER RESULTED IN FGD SYSTEM OUTAGE DURING
JANUARY.
REHEATER STEAM LEAKS CAUSED AN OUTAGE DURING JANUARY. REPAIRS COULD NOT BE
MADE WITH THE BOILER IN SERVICE.
A FROZEN CARBONATE LINE RESULTED IN AN FGO SYSTEM OUTAGE DURING JANUARY.
THE SYSTEM WAS SHUT DOWN FOR 16 DAYS IN JANUARY FOR COMPLETION OF PIPING
CONVERSION. THIS OUTAGE WAS NOT DUE TO A SCRUBBER MALFUNCTION.
2/76 SYSTEM 89.3 74.6 80.7 71.2 696 664 496
** PROBLEMS/SOLUTIONS/COMMENTS
A DEPLETION OF CHEMICALS DURING FEBRUARY ACCOUNTED FOR NEARLY 44 HOURS OF
SCRUBBER OUTAGE TIME.
FIVE SCRUBBER INOPERATIVE PERIODS WERE REPORTED DURING FEBRUARY. THREE OF
THESE OUTAGES WERE NOT RELATED TO THE F6D SYSTEM.
SEAL WATER PROBLEMS WERE REPORTED DURING FEBRUARY.
CHEMICAL LINE PLUGGING PROBLEMS WERE NOTED DURING FEBRUARY.
3/76 SYSTEM 99.2 71.9 99.2 38.5 744 398 287
** PROBLEMS/SOLUTIONS/COMMENTS
ONE FORCED SCRUBBER OUTAGE WAS CAUSED BY A VENTURI LEAK.
4/76 SYSTEM 100.0 91.1 100.0 13.4 720 106 97
389
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
NEVADA POWER: REID GARDNER 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
SOZ PART. HOURS HOURS HOURS FACTOR
»* PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS TAKEN OUT OF SERVICE IN APRIL FOR INSPECTION OF VALVES AND
COAL CONDUITS.
5/76 SYSTEM 100.0 .0 744 0 0
6/76 SYSTEM 100.0 .0 720 0 0
7/76 SYSTEM 100.0 .0 744 0 0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS SHUT DOWN FOR A SCHEDULED TURBINE OVERHAUL AND BURNER LINE
CONDUIT REPLACMENT THROUGH MAY, JUNE, AND JULY.
8/76 SYSTEM 96.6 65.7 93.3 46.9 744 531 349
** PROBLEMS/SOLUTIONS/COMMENTS
TURBINE VIBRATION CHECKS CONTINUED THROUGH AUGUST 8. THE SCRUBBER WAS NOT
OPERATED UNTIL AUGUST 12.
PLUGGING IN THE THICKNER CAUSED AN OUTAGE DURING AUGUST.
PLUGGING IN THE TRAY RECYCLE TANK fJURING AUGUST RESULTED IN AN FGD OUTAGE.
9/76 SYSTEM 96.6 96.4 96.4 91.3 720 681 656
**'• PROBLEMS/SOLUTIONS/C0.1MENTS
BOILER-RELATED PROBLEMS ACCOUNTED FOR APPROXIMATELY 40 HOURS OF THE FGD
SYSTEM DOWNTIME IN SEPTEMBER.
PLUGGING IN THE VENTURI SPRAY HEADERS CAUSED A SCRUBBER OUTAGE.
AN ID FAN MALFUNCTION RESULTED IN SCRUBBER OUTAGE DURING SEPTEMBER.
10/76 SYSTEM 97.9 96.5 97.7 87.9 744 678 654
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS OUT OF SERVICE FOR 75 HOURS IN OCTOBER TO REPLACE A BURNER.
SCRUBBER OUTAGE TIME WAS REQUIRED FOR INSTALLATION OF A NEW CARBONATE FEED
LINE.
A MINOR SCRUBBER TRIP WAS CAUSED BY PLUGGING IN THE SCRUBBER EFFLUENT
SUCTION LINE.
11/76 SYSTEM 86.5 84.2 84.8 75.3 720 644 542
** PROBLEMS/SOLUTIONS/COMMENTS
ONE 97 HOUR SCRUBBER OUTAGE OCCURED BECAUSE OF A SCREW CONVEYOR FAILURE,
RESULTING IN AN INABILITY TO MIX THE CHEMICAL ABSORBENT.
12/76 SYSTEM 92.8 90.6 91.9 82.1 744 675 611
390
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
NEVADA POWER: REID GARDNER 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
SOS PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
BOILER RELATED PROBLEMS ACCOUNTED FOR 79 HOURS OF THE DECEMBER OUTAGE TIME.
A FORCED FGD OUTAGE RESULTED FROM CHEMICAL DEPLETION.
A PLUGGED SENSING LINE FORCED AN FGD OUTAGE DURING DECEMBER.
1/77 SYSTEM 68.4 62.8 63.9 56.0 744 663 416
** PROBLEMS/SOLUTIONS/COMMENTS
RUBBER LINING REPAIRS WERE INITIATED IN THE SEPARATOR SECTION OF THE
SCRUBBING MODULE ON JANUARY 22. THE LINING WAS DAMAGED BY A HIGH
TEMPERATURE EXCURSION RESULTING FROM A MALFUNCTION IN THE BOILER AIR
PREHEATER.
2/77 SYSTEM .0 .0 .0 .0 672 599 0
** PROBLEMS/SOLUTIONS/COMMENTS
RUBBER LINING WORK CONTINUED ON THE SCRUBBER DURING FEBRUARY. THE BOILER
WAS DOWN PART OF THE PERIOD BECAUSE OF A STRIKE.
3/77 SYSTEM .0 .0 .0 .0 744 669 0
** PROBLEMS/SOLUTIONS/COMMENTS
SCRUBBER RUBBER LINING REPAIRS CONTINUED.
4/77 SYSTEM .0 .0 .0 .0 720 400 0
** PROBLEMS/SOLUTIONS/COMMENTS
SCRUBBER RUBBER LINING REPAIRS CONTINUED.
5/77 SYSTEM .0 .0 .0 .0 744 705 0
** PROBLEMS/SOLUTIONS/COMMENTS
SCRUBEER RUBBER LINING REPAIRS CONTINUED.
6/77 S1STEM 47.1 W.4 48.4 47.1 720 701 339
** PROBLEMS/SOLUTIONS/CC.1MENTS
REPAIRS ON THE DAMAGED RUBBER LINING WERE COMPLETED BY MID-JUNE AND THE
SYSTEM REMAINED IN SERVICE THROUGHOUT THE MAJORITY OF THE MONTH.
A MINOR FORCED OUTAGE RESULTED FROM A HIGH-LOW PRESSURE TRIP CAUSED BY A
PLUGGED SENSING LINE.
7/77 SYSTEM 99.5 99.5 99.5 99.5 744 744 740
*# PROBLEMS/SOLUTIONS/COMMENTS
THE SYSTEM WAS TAKEN OUT OF THE GAS PATH ONLY ONCE DURING THE MONTH
BECAUSE OF A SCHEDULED INSPECTION OF THE NEWLY REPLACED RUBBER LINER IN
THE SCRUBBER SEPARATOR SECTION.
8/77 SYSTEM 13.8 15.5 15.5 13.8 744 662 102
391
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
NEVADA POWER: REID GARDNER 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE SCRUBBER WAS OUT OF SERVICE MOST OF AUGUST FOR ID FAN VIBRATION
PROBLEMS.
INSTALLATION OF ID FAN RELAYS ACCOUNTED FOR SOME DOWNTIME DURING AUGUST.
9/77 SYSTEM 84.4 73.4 69.3 35.0 720 344 252
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS OUT OF SERVICE FOR MOST OF SEPTEMBER FOR NON-SCRUBBER
RELATED PROBLEMS.
THE SCRUBBER HAD LIMIT SWITCH PROBLEMS WITH 14 A & B GULLOTINE DAMPERS.
10/77 SYSTEM 99.3 94.4 99.2 84.7 744 668 630
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS DOWN FOR FIVE HOURS DURING OCTOBER TO REPAIR AN ID FAN LEAK.
11/77 SYSTEM 78.7 81.5 81.5 78.1 720 690 562
** PROBLEMS/SOLUTIONS/COMMENTS
SCREEN PLUGGING IN THE RECYCLE TANK WAS A PROBLEM DURING NOVEMBER.
SCRUBBER INSTRUMENTATION DIFFICULTY WAS EXPERIENCED DURING NOVEMBER.
THE SYSTEM WAS DOWN FOR THE INSTALLATION OF AN OUTLET NOZZLE IN THE BOOSTER
TANK.
12/77 SYSTEM 85.4 80.6 82.8 70.2 744 648 522
** PROBLEMS/SOLUTIONS/COMMENTS
THE SCRUBBER WAS OFF-LINE FOR APPROXIMATELY 109 HOURS DUE TO HIGH TRAY
DIFFERENTIAL PRESSURE AND SOME PLUGGING IN THE ID FAN SENSING LINE.
THE BOILER WAS DOWN ABOUT 113 HOURS IN DECEMBER FOR NON-SCRUBBER RELATED
PROBLEMS.
1/78 SYSTEM 67.7 67.5 67.5 55.9 744 616 416
** PROBLEMS/SOLUTIONS/COMMENTS
TWO OUTAGES WERE CAUSED BY PROBLEMS RELATED TO HIGH TRAY DIFFERENTIAL
PRESSURES.
ELECTRICAL PROBLEMS IN THE 1A FORCED DRAFT FAN CAUSED AN FGD SYSTEM OUTAGE.
AIR F3ESSURE FAILURE TO AN ID FAN DAMPER ACCOUNTED FOR SOME JANUARY
DOWNTIME.
2/78 SYSTEM 97.4 74.9 94.3 43.4 672 389 292
** PROBLEMS/SOLUTIONS/CQ1MENTS
A DUCT HI-LO PRESSURE TRIP CONTRIBUTED TO THE FEBRUARY OUTAGE TIME.
THE BOILER WENT OUT OF SERVICE ON FEBRUARY 17 FOR A THREE WEEK OUTAGE.
392
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
NEVADA POWER: REID GARDNER 1 (CONT.)
PERFORMANCE DATA
PERIOD HODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
„„_ „„,_, _,_ ____ «, — ___ — — _-.•._— ___ — __„,_ — -._ „.•_, — „___..-._ ____«-». — _ — — -. ____ — — __.__ ___ — — ____—— _ —___ __——__
PLUGGED SENSING LINES CONTRIBUTED TO THE OUTAGE TIME DURING FEBRUARY.
3/78 SYSTEM 76.2 58.3 58.3 27.8 744 355 207
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS OFF LINE UNTIL MARCH 16.
A PROBLEM WAS ENCOUNTERED WITH THE REHEAT STEAM REGULATOR DURING MARCH.
PROBLEMS WITH THE GUILLOTINE SWITCHES DELAYED START-UP OF THE FGD SYSTEM
UNTIL MARCH 22.
4/78 SYSTEM 100.0 96.7 100.0 75.2 720 560 541
** PROBLEMS/SOLUTIONS/COMMENTS
THERE WERE NO FGD SYSTEM FORCED OUTAGES. ALL DOWNTIME WAS BOILER RELATED
(179 HOURS).
5/78 SYSTEM 97.0 92.4 96.3 78.2 744 630 582
** PROBLEMS/SOtUTIONS/COMMENTS
THE REPAIRS TO THE CONDENSER AND PRODUCTION CONTROL CONTRIBUTED TO THE
BOILER OUTAGES.
HIGH TEMPERATURE ON AN ID FAN BEARING CAUSED AN OUTAGE.
6/78 SYSTEM 91.8 91.8 91.8 91.8 720 720 661
** PROBLEMS/SOLUTIONS/COMMENTS
A 31 HOUR OUTAGE WAS REQUIRED TO CHANGE THE OIL ON THE ID FAN.
A HIGH DUCT PRESSURE TRIP OCCURED DURING JUNE ACCOUNTING FOR SOME DOWNTIME.
OUTAGE TIME WAS REQUIRED TO CLEAN AN ABSORBER TRAY.
7/78 SYSTEM 99.0 99.0 99.0 99.0 744 744 736
** PROBLEMS/SOLUTIONS/COMMENTS
FGD OUTAGE TIME WAS REQUIRED TO RECTIFY A HIGH TRAY DIFFERENTIAL PRESSURE
PROBLEM. THE TRAY WAS CLEANED OUT DURING THE OUTAGE.
8/78 SYSTEM 94.5 93.6 94.2 88.8 744 706 661
*# PROBLEMS/SOLUTIONS/COMMENTS
THE SCRUBBER WAS FORCED OFF LINE ON AUGUST 5 BECAUSE OF A LOSS OF THE
ASH PANEL CONTROL POWER. THIS LEFT THE UNIT WITHOUT EMERGENCY SPRAY TO
THE SCRUBBERS.
A FORCED OUTAGE OCCURED ON AUGUST 20 WHEN THERE WAS A SCRUBBER VENTURI
HIGH TEMPERATURE ALARM. THE EXACT CAUSE WAS NOT KNOWN BUT A BOILER TUBE
LEAK WAS SUSPECTED.
THERE WAS ONE SCHEDULED OUTAGE DURING THE MONTH TO CLEAN AN ABSORBER TRAY.
9/78 SYSTEM 99.3 97.2 99.2 86.9 720 644 626
393
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
NEVADA POWER: REID GARDNER 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THERE WERE THREE BOILER RELATED OUTAGES DURING SEPTEMBER. A BOILER TUBE
LEAK AND BOILER BURNER WERE REPAIRED.
DURING THE MONTH A BOILER TRIP OCCURRED WHICH WAS CAUSED BY SCRUBBER
HIGH DUCT PRESSURE. SCRUBBER PRESSURE SENSING LINES WERE CLEANED.
10/78 SYSTEM 100.0 99.8 100.0 89.6 744 668 667
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS OFF LINE FOR ABOUT 77 HOURS FOR REMOVAL OF AN ASH CLINKER.
11/78 SYSTEM 90.4 88.9 89.9 84.7 720 686 610
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS DOWN FOR 9 HOURS TO REPAIR SCRUBBER OUTLET TEMPERATURE
PROBES.
OUTAGE TIME RESULTED FROM BOILER BOTTOM HOPPER PROBLEMS. A HIGH
TEMPERATURE TRIP AT THE VENTURI GAS OUTLET OCCURRED BECAUSE OF THE BOILER
PROBLEMS.
SOME OUTAGE TIME RESULTED FROM A HIGH SCRUBBER EFFLUENT SOLIDS LEVEL.
12/78 SYSTEM 95.6 92.8 95.4 92.0 744 738 685
** PROBLEMS/SOLUTIONS/COMMENTS
THE SCRUBBING SYSTEM WAS OUT OF SERVICE TO REPAIR A LEAK IN A VENTURI LINE.
THE FGD SYSTEM WAS DOWN TO CLEAN THE VENTURI SPRAY COLLAR (RACE TRACK)
AND CLEAN PRESSURE SENSING LINES.
THE BOILER WAS OFF LINE APPROXIMATELY ONE DAY FOR PULVERIZER REPAIRS.
1/79 SYSTEM 83.9 73.7 80.8 67.5 744 682 502 73.7
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS DOWN ABOUT FIVE DAYS TO REMOVE A CLINKER FROM THE BOTTOM
HOPPER.
A 58 HOUR SCRUBBER OUTAGE WAS CAUSED WHEN A SCRUBBER POWER CIRCUIT TRIPPED
RESULTING IN LOSS OF POWER TO TRAY SPRAY PUMP. REPAIRS WERE MADE ON THE
TRAY AND SPRAY SYSTEMS.
THE FGD SYSTEM WAS DOWN FOR A SHORT PERIOD TO INSPECT THE ID FAN BEARINGS.
THE FGD SYSTEM WAS DOWN FOR 48 HOURS TO REPAIR A LEAK IN THE VENTURI LINE.
2/79 SYSTEM 85.6 85.9 85.9 85.6 672 670 575 79.7
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS DOWN TO CLEAN THE VENTURI SPRAY COLLAR (RACE TRACK)
NOZZLES, CLEAN THE EFFLUENT LINE AND REPAIR A LEAK IN THE VENTURI LINE.
A BREAK IN THE BOTTOM ASH CIRCULATING WATER LINE RESULTING IN LOSS OF EMER-
GENCY COOLING WATER FORCED THE FGD SYSTEM OFF LINE.
3/79 SYSTEM 97.9 96.5 97.4 78.3 744 604 583 84.9
394
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
NEVADA POWER: REID GARDNER 1 CCONT.)
PERFORMANCE DATA
PERIOD MtDULE AVAILABILITY OPEFABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
_______ ______ _________„-,_ ___...._.-____ ___________ ___________ -.____ _____ _____ ______ _____ ______
»* PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS OFF TO UNPLUG VENTURI NOZZLES AND TO CLEAN SENSING
LINES. THE DOWNTIME WAS ABOUT 15 HOURS.
THE FGD SYSTEM WAS OFF FOR ABOUT 146 HOURS FOR REPAIR OF BOILER TUBE LEAKS.
4/79 SYSTEM 100.0 98.6 100.0 25.7 720 188 185 86.1
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER AND FGD SYSTEM WERE OFF FOR APPROXIMATELY 535 HOURS FOR
SCHEDULED MAINTENANCE.
5/79 SYSTEM 99.8 74.4 99.4 27.5 744 275 204 84.8
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER AND SCRUBBER WERE RETURNED TO SERVICE MAY 22 AFTER COMPLETING
SCHEDULED MAINTENANCE.
THE BOILER WAS FORCED OUT OF SERVICE TO REPAIR A COAL LEAK ON THE *8
BURNER LINE.
THE SCRUBBER WAS OFF LINE APPROXIMATELY ONE HOUR TO CLEAN A RECYCLE TANK
RETURN LINE.
6/79 SYSTEM 97.9 95.2 97.6 84.7 720 641 610 86.9
** PROBLEMS/SOLUTIONS/COMMENTS
A 94 HOUR OUTAGE WAS REQUIRED TO REPAIR A BOILER TUBE LEAK.
OUTAGE TIME WAS REQUIRED TO UNPLUG A VENTURI LINE.
TRAY SPRAY VALVES WERE REPLACED DURING JUNE.
7/79 SYSTEM 82.1 80.5 81.0 80.3 744 742 597 85.7
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER AND FGD SYSTEM WAS FORCED OFF LINE DURING A TURBINE OVERSPEED
GOVERNOR TEST. THE DOWNTIME WAS ABOUT SEVEN HOURS.
THE SCRUBBER WAS OFF ABOUT 67 HOURS TO CLEAN THE SCRUBBER TRAYS.
THE LOSS OF INSTRUMENT AIR TO THE SCRUBBER CONTROLS RESULTED FROM A
SCRUBBER AIR COMPRESSOR POWER FAILURE. THE SCRUBBER WAS OFF-LINE FOR ABOUT
74 HOURS.
8/79 SYSTEM 96.9 96.9 96.9 96.9 744 744 721 87.5
** PROBLEMS/SOLUTIONS/COMMENTS
THE SCRUBBER WAS REMOVED FROM SERVICE TO CLEAN THE SCRUBBER PRESSURE
SENSING LINES. THE SCRUBBER WAS DOWN FOR ABOUT 11 HOURS.
THE SCRUBBER WAS DOWN AT THE END OF THE MONTH AGAIN TO CLEAN THE PRESSURE
SENSING LINE ON THE SCRUBBER. THE SCRUBBER WAS OFF LINE FOR ABOUT THREE
HOURS.
9/79 SYSTEM 100.0 100.0 100.0 53.2 720 383 383 88.5
395
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
NEVADA POWER: REID GARDNER 1 (CONT.)
_ _, PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER, TURBINE, AND SCRUBBER kERE SHUT DOWN FOR SCHEDULED
MAIN1ENANCE ON SEPTEMBER 16.
10/79 SYSTEM 79.6 '»8.2 71.0 49.? 744 545 372 85.8
** PROBLEMS/SOLUTIONS/CO,1MENTS
THE SCRUBBER WAS OFF LINE WITH THE BOILER AND TURBINE FOR SCHEDULED
MAINTENANCE THROUGH OCTOBER 8.
PLUGGING OF THE VENTURI AND EFFLUENT LINE CAUSED THREE OUTAGES DURING THE
MONTH.
THE SCRUBBER WAS SHUT DOWN SO THAT REPAIRS COULD BE MADE TO THE ID FAN
DAMPER.
THE SCRUBBER WAS SHUT DOWN BECAUSE OF A BOILER TURBINE PROBLEM.
11/79 SYSTEM 99.4 96.8 99.4 88.2 720 656 635 87.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE SCRUBBER WENT OFF-LINE WITH THE BOILER TO REPAIR TURBINE POWER
SWITCHES.
TWO OUTAGES DURING NOVEMBER WERE CAUSED BY A BOILER TUBE LEAK.
THE SCRUBBER WAS SHUT DOWN SO THAT THE VENTURI SPRAY COLLECTOR (RACE TRACK)
NOZZLES COULD BE CLEANED.
TWICE DURING THE MONTH THE TURBINE TRIPPED CAUSING THE SECTION IB BREAKER
TO BE LOST. ON THE SECOND TRIP A COOLING TOWER FAN MOTOR SHORTED TO
GROUND.
12/79 SYSTEM 98.5 98.5 98.5 98.5 744 744 733 88.2
#* PROBLEMS/SOLUTIONS/COMMENTS
DURING DECEMBER THE SCRUBBER WAS TAKEN OFF LINE TO REPAIR A MALFUNCTIONING
VALVE ON THE EMERGENCY SPRAY SYSTEM.
1/80 SYSTEM 100.0 100.0 100.0 100.0 744 744 744 100.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER AND FGD SYSTEM OPERATED THE ENTIRE MONTH OF JANUARY WITH NO
OUTAGES.
2/80 SYSTEM 100.0 100.0 100.0 100.0 696 696 696 100.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER AND FGD SYSTEM OPERATED THE ENTIRE MONTH OF FEBRUARY
WITH NO OUTAGES.
3/80 SYSTEM 93.8 83.3 84.4 33.6 744 300 250 97.0
396
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
NEVADA POWER: REID GARDNER 1 (CONT.)
. PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE FIRST OF MARCH THE FGD SYSTEM WAS OFF LINE FOR A SCHEDULED
OVERHAUL.
THE FGD UNIT WAS FORCED DOWN ONCE TO REPAIR A VENTURI PUMP AND SIX
OTHER TIMES DUE TO RESTRICTED VENTURI GAS FLOW.
4/80 SYSTEM 97.3 96.4 96.8 82.7 720 618 596 97.5
** PROBLEMS/SOLUTIONS/COMMENTS
LEAKS IN THE VENTURI LINE FORCED THE FGD SYSTEM OUT OF SERICE TWICE
DURING APRIL.
A THERMOCOUPLE SHORTED OUT DUE TO HIGH VENTURI GAS OUTLET TEMPERATURES.
THIS FORCED THE FGD SYSTEM OUT OF SERVICE FOR SEVERAL HOURS.
THE BOILER WAS OUT OF SERVICE FOR 117 HOURS DUE TO BOILER TUBE LEAKS.
5/80 SYSTEM 97.7 *3.9 97.4 84.7 744 672 630 96.7
** PROBLEMS/SOLUTIONS/CC.1MENTS
THE FGD SYSTEM WAS DOWN THREE TIMES IN MAY BECAUSE OF LOW FLOW THROUGH THE
VENTURI.
A BOILER TRIP CAUSED THE FGD SYSTEM TO BE OUT APPROXIMATELY 97 HOURS.
6/80 SYSTEM 92.1 92.7 92.7 88.3 720 686 636 95.9
** PROBLEMS/SOLUTIONS/COMMENTS
THE NOZZLES IN THE VENTURI RACE TRACK HAD TO BE CLEANED SEVERAL TIMES THIS
MONTH. TOTAL OUTAGE FOR THIS WAS APPROXIMATELY 48 HOURS.
THE FGD SYSTEM WAS FORCED OUT OF SERVICE WHEN THE EMERGENCY SPRAY SYSTEM
FAILED.
THE FGD SYSTEM WAS OUT OF SERVICE TWICE DURING JUNE DUE TO BOILER OUTAGES.
7/80 SYSTEM 87.1 94.9 86.7 84.0 744 658 625 95.8
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS RETURNED TO SERVICE ON JULY 3, 1980 AFTER THE BOILER
TRIPPED THE SYSTEM OFF LINE. THE GUILLOTINE DAMPER HAD TO BE REPAIRED
BEFORE THE FGD SYSTEM COULD RETURN TO SERVICE.
THE FGD SYSTEM WAS OFF LINE FOR SEVERAL HOURS TO UNPLUG THE VENTURI TRAY
AND RACETRACK. MAINTENANCE WORK WAS ALSO DONE ON THE VENTURI LINE.
A SCHEDULED BOILER OUTAGE CAUSED THE FGD SYSTEM TO BE OFF LINE FOR ONE
DAY.
THE FGD SYSTEM WAS FORCED OUT OF SERVICE WHEN THE EMERGENCY SPRAY SYSTEM
FAILED. THE ASH SLUICE PUMP SHAFT WAS REPAIRED DURING THIS TIME.
8/80 SYSTEM 86.1 85.5 83.7 71.5 744 62E 532 94.3
397
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
NEVADA POWER: REID GARDNER 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM HAS OUT OF SERVICE FOR ALMOST 60 HOURS FOR ROUTINE CLEANING
AND MAINTENANCE.
LOSS OF EMERGENCY SPRAY KEPT THE FGD SYSTEM OFF LINE FOR SEVERAL HOURS.
BOILER RELATED OUTAGES CAUSED THE FGD SYSTEM NOT TO OPERATE FOR OVER 100
HOURS.
THE TRAY SPRAY PUMP BELTS MERE REPAIRED.
A DAMPER THAT FAILED TO CLOSE TRIPPED THE FGD SYSTEM OFF LINE DURING THE
MONTH.
9/80 SYSTEM 91.3 91.0 91.1 89.6 720 709 645 93.9
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WENT OFF LINE SEVERAL TIMES IN SEPTEMBER FOR ROUTINE CLEAN-
ING AND MAINTENANCE. THIS ROUTINE WORK INCLUDED CLEANING THE TRAYS AND
REPAIRING VENTURI, ASH, AND EFFLUENT LINES.
A BOILER OUTAGE KEPT THE FGD SYSTEM OFF LINE FOR SEVERAL HOURS.
10/80 SYSTEM 98.2 97.6 97.9 93.0 744 708 692
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS FORCED OUT OF SERVICE DUE TO A FAILURE OF THE ASH SLUICE
SYSTEI1 WHICH LEAVES THE SYSTEM WITH NO FIRE PROTECTION.
REPAIR:! TO THE ID FAN EXPANSION JOINT CAUSED APPROXIMATELY SEVEN HOURS
OF OUTAGE TIME.
DURING NOVEMBER THE FGD SYSTEM WAS SHUTDOWN WITH THE BOILER FOR A
SCHEDULED OUTAGE THAT LASTED SIX HOURS.
THE UNIT WAS FORCED OFF-LINE ONCE DURING THE MONTH FOR APPROXIMATELY TWO
HOURS.
11/80 SYSTEM 100.0 100.0 100.0 36.3 720 262 262
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM AND THE BOILER WERE SHUTDOWN ON NOVEMBER 11 FOR A SCHEDULED
OVERHAUL.
12/80 SYSTEM 80.7 77.* 74.8 52.5 744 505 391
** PROBLEMS/SOLUTIONS/COMMENTS
FORCED OUTAGE TIME DURING DECEMBER WAS CAUSED BY A VENTURI LINE LEAK, AND
A POWER INTERRUPTION.
A SCHEDULED OUTAGE KEPT THE UNIT OFF LINE UNTIL DECEMBER 9. ANOTHER
OUTAGE WAS SCHEDULED TO RESET THE ID FAN WHICH LASTED APPROXIMATELY TWO
HOURS.
398
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/6
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7,
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** MECHANICAL COLLECTOR
TYPE
SUPPLIER
PARTICLE REMOVAL EFFICENCY -7.
** PARTICLE SCRUBBER
N"JMBER
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
Di'MMSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LCNET GENERIC MATERIAL
LINER SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
LIQUID RECIRCULATION RATE - LITER/S
L/G RATIO - LITER/CU.M
PF'ESSURE DROP - KPA
SUPERFICIAL GAS VELOCITY - M/S
IHLET GAS FLOW RATE - CU.M/S
INLET GAS TEMPERATURE - C
PARTICLE REMOVAL EFFICIENCY - 7.
*** FGD SYSTEM
( .100 LB/MMBTU)
( 1.200 LB/MMBTU)
(****** LB/MMBTU)
NEVADA POWER
REID GARDNER
2
MOAPA
NEVADA
B
43.
516.
******
331
125
110
*****
125
FOSTER WHEELER
PULVERIZED COAL
BASE
223.21 ( 473000 ACFM)
176.7 ( 350 F)
61. ( 200 FT)
CONCRETE
3.8 ( 12.6 FT)
( 12450 BTU/LB)
COAL
BITUMINOUS
28959.
8.00
8.-10.
5.50
5-6
.50
0.5-1.0
.05
MULTICLONES
RESEARCH-COTTRELL
75.0
VENTURI TOWER
FIXED-THROAT
ADL/COMBUSTION EQUIP ASSOCIATES
1.5 DIA. X 18 LONG AT THROAT
CARBON STEt:L, HIGH ALLOY
AISI 1110, AUSTENITIC
NONE, ORGANIC
N/A, RUBBER
TWIN VARIABLE THROATS
1
157.5 ( 2500 GPM)
1.3 (10.0 GAL/1000ACF)
4.6 (18.5 IN-H20)
50.3 ( 165.0 FT/S)
223.2 ( 473000 ACFM)
176.7 ( 350 F)
97.0
399
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
NEVADA POWERS REID GARDNER 2 (CONT.)
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
UNIT DESIGN S02 REMOVAL EFFICIENCY - 7.
CURRENT STATUS
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
** ABSORBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
GAS CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
LIQUID RECIRCULATION RATE - LITER/S
L/G RATIO - L/CU.M
GAS-SIDE PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/SEC
S02 REMOVAL EFFICIENCY - X
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES PER STAGE
PRESSURE DROP - KPA
CONSTRUCTION MATERIAL GENERIC TYPE
** REHEATER
GENERIC TYPE
SPECIFIC TYPE
T^ADE NAME/COMMON TYPE
TEMPERATURE INCREASE - C
ISLET FLUE GAS TEMPERATURE - C
NJMBER OF TUBES PER BUNDLE
CONSTRUCTION MATERIAL GENERIC TYPE
** FANS
NUMBER
SUPPLIER
FUNCTION
APPLICATION
SERVICE
F'.UE GAS FLOW RATE - CU.P/S
FOJE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENbRIC TYPE
** DUCTKORK
LOCATION
SHELL GENERIC MATERIAL TY"E
GENERIC MATERIAL T»PE
THROWAWAY PRODUCT
WET SCRUBBING
SODIUM CARBONATE
NONE
COMBUSTION EQUIP ASSOCIATES
BECHTEL
FULL SCALE
RETROFIT
•f. 97.00
90.00
1
4/74
9/71
TRAY TOWER
SIEVE TRAY
COMBUSTION EQUIP ASSOCIATES
30 DIA,
CARBON STEEL
AISI 1110
N/A
ORGANIC
RUBBER
SINGLE SIEVE TRAY WITH 3/16 INCH HOLES
38.
.2
.7
3.4
91.2
( 600 GPM)
( 1.6 GAL/1000 ACF)
( 3.0 IN-H20)
( 11.0 FT/S)
MIST ELIMINATOR
1
CENTRIFUGAL
RADIAL VANE
HORIZONTAL
1
1
.1
( .5 IN-H20J
316L SS (BOTH ME AND WASH TRAY)
INDIRECT HOT AIR
EXTERNAL HEAT EXCHANGER
STEAM TUBE BUNDLES
10.0 ( 50 F)
48.3 ( 119 F)
24
CARBON STEEL
BUFFALO FORGE
BALANCED DRAFT
FORCED DRAFT
DRY
223.21
176.7
CARBON STEEL
( 473000 ACFM)
( 350 F)
SCRUBBER INLET
CARBON STEEL
NONE
400
-------
NEVADA POWER: REID GARDNER 2 CCONT.)
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
** DUCTWORK
LOCATION
S.iELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
** TAH-CS
SEi'VICE
VEUTURI RECYCLE
** PUKPS
SERVICE
SCRUBBER RECIRCUUTION
ABSORBER RECIRCULATION
*** SLUDGE
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
*« DISPOSAL
NATURE
TYPE
LOCATION
** WATER BALANCE
WATER LOOP TYPE
MAKEUP WATER ADDITION - LITERS/S
** FGD SPARE CAPACITY INDICES
ABSORBER - 7.
** FGD SPARE COMPONENT INDICES
ABSORBER
SCRUBBER OUTLET
CARBON STEEL
PLASITE 4004-S
NUMBER
1
NUMBER
FINAL
LINED POND
ON SITE
GRAVITY FLOW FROM INTERIM SLUDGE POND
INTERIM
LINED POND
ON SITE
CLOSED
9.8
.0
.0
( 155 GPM)
_ PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
SOS PART. HOURS HOURS HOURS FACTOR
4/74 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
720
5/74 SYSTEM
6/74 SYSTEM
7/74 SYSTEM
8/74 SYSTEM
9/74 SYSTEM
10/74 SYSTEM
THE FGD SYSTEM WAS PLACED IN SERVICE IN APRIL 1974. THE SCRUBBING SYSTEM
DESIGN WAS BASED ON INFORMATION AND DATA OBTAINED FROM AN 8000-ACPM PILOT
PLANT PROGRAM CONDUCTED AT REID GARDNER IN 1971 AND 1972.
744
720
744
744
720
744
401
-------
EPA UTILITY FGO SURVEY: OCTOBER - DECEMBER 1980
NEVADA POWER: REID GARDNER 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR PROBLEMS OCCURED SINCE STARTUP IN APRIL.
CURRENT OPERABILITIES ARE GREATER THAN 90X WHEN TRONA IS AVAILABLE. WHEN
THE TRONA SUPPLY IS EXHAUSTED THE SCRUBBER IS SHUT DOWN.
11/7* SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
F6D SYSTEM OPERATIONS HAVE ONLY BEEN INTERRUPTED BY INSUFFICIENT TRONA
SUPPLIES. S02 REMOVAL EFFICENCIES HAVE BEEN IN THE 85X RANGE. BECAUSE
OF A COAL STRIKE THE BOILER ONLY OPERATED TWO WEEKS IN NOVEMBER AND THEN AT
REDUCED LOAD. THERE ARE NO OUTSTANDING MECHANICAL OR PROCESS PROBLEMS.
12/74 SYSTEM 74*
1/75 SYSTEM 94.0 744
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JANUARY THE FGD SYSTEM OPERATED WITH A 94X OPERABILITY ON TRONA
SUPPLEMENTED WITH SODIUM CARBONATE-BRINE. THE UTILITY REPORTED NO MAJOR
PROBLEMS FOR THE DECEMBER-JANUARY PERIOD. THERE WAS, HOWEVER, A MINOR
PROBLEM WITH FREEZING SODIUM CARBONATE FEED LINES.
2/75 SYSTEM 90.0 672
** PROBLEMS/SOLUTIONS/COMMENTS
ROUTINE MECHANICAL PROBLEMS WERE ENCOUNTERED DURING FEBRUARY.
ROUTINE INSTRUMENTAL PROBLEMS WERE EXPERIENCED.
ABRASION OF RUBBER-LINED PIPES ACCOUNTED FOR SOME DOWNTIME.
THE FGD SYSTEM PASSED A SECOND PERFORMANCE TEST DURING THE PERIOD.
SEAL WATER FILTERS WERE REPLACED IN FEBRUARY.
BOILER CONTROLS ACCOUNTED FOR SOME DOWNTIME IN FEBRUARY.
RECYCLE LINE STRAINER PLUGGING WAS A PROBLEM DURING THE PERIOD.
3/75 SYSTEM 100.0 .0 744 0
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS OUT OF SERVICE THROUGHOUT MARCH FOR A TURBINE OVERHAUL.
4/75 100.0 .0
SYSTEM 720 0
5/75 SYSTEM 100.0 .0 744 0
6/75 SYSTEM 100.0 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER AND SCRUBBER WERE PLACED BACK IN SERVICE IN LATE JUNE AFTER THE
TURBINE OVERHAUL. THE FGD SYSTEM ACCEPTANCE TEST HAS BEEN SCHEDULED FOR
JULY.
7/75 SYSTEM 85.0 744
402
-------
EPA UTILITY FSD SURVEY: OCTOBER - DECEMBER 1980
NEVADA POWER: REID GARDNER 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPER4BILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FED CAP.
S02 PART. HOURS HOURS HOURS FACTOR
8/75 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
A BROKEN BUCKET ELEVATOR CAUSED A FORCED FGD OUTAGE.
WORN RECIRCULATION PIPING CONTRIBUTED TO THE FORCED FGD OUTAGE TIME.
A FORCED FGD OUTAGE WAS CAUSED BY A PUMP RUBBER LINER FAILURE.
STRAINER PLUGGING CONTRIBUTED TO THE FORCED FGD OUTAGE TIME.
9/75 SYSTEM 76.9 69.0 720 645 496
10/75 SYSTEM 87.4 62.0 744 531 464
** PROBLEMS/SOLUTIONS/COMMENTS
THREE FORCED OUTAGES OCCURED DURING SEPTEMBER AND OCTOBER.
A NECESSARY PUMP REPAIR FORCED THE FGD SYSTEM OUT OF SERVICE DURING THE
OCTOBER - NOVEMBER PERIOD.
INSTRUMENT PLUGGING CAUSED AN FGD OUTAGE.
REPAIR OF PIPING LEAKAGE NECESSITATED AN FGD OUTAGE.
11/75 SYSTEM 98.8 82.7 720 603 596
12/75 SYSTEM 744
1/76 SYSTEM 68.7 66.3 66.3 61.,6 744 691 458
** PROBLEMS/SOLUTIONS/COMMENTS
FROZEN CARBONATE LINES CONTRIBUTED TO FGD OUTAGE TIME.
A FGD OUTAGE MAS CAUSED BY A PLUGGED PRESSURE-SENSING LINES.
DUCT PRESSURE TRIPS CONTRIBUTED TO FGD OUTAGE TIME.
AN OVERHAUL OF A TRAY RECYCLE PUMP WAS NECESSARY DURING DECEMBER.
2/76 SYSTEM 90.4 85.6 85.6 83.1 696 675 578
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED FOUR SCRUBBER INACTIVE PERIODS DURING FEBRUARY, THREE
OF WHICH WERE SCRUBBER-RELATED OUTAGES.
34 HOURS OF OUTAGE TIME WERE REQUIRED TO UNPLUG A VENTURI PUMP.
CHEMICAL DEPLETION CONTRIBUTED TO FGD OUTAGE TIME.
SEAL WATER PROBLEMS WERE ENCOUNTERED DURING FEBRUARY.
3/76 SYSTEM 68.1 59.9 62.5 53.1 744 660 395
** PROBLEMS/SOLUTIONS/COMMENTS
TWO FGO FORCED OUTAGES OCCURED DURING MARCH.
AN ELECTRICAL FAILURE RESULTED IN A 16 HOUR FGD SYSTEM OUTAGE.
403
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
NEVADA POWER: REID GARDNER 2 (CONT.)
_ PERFORMANCE DATA— •
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
PLUGGING IN THE TRAY SYSTEM RESULTED IN A SUBSEQUENT OVERHAUL OF THE TRAY
CYCLE PUMPS, REQUIRING 221 HOURS OF DOWNTIME.
4/76 SYSTEM 86.6 77.5 83.4 67.7 720 630 488
** PROBLEMS/SOLUTIONS/COMMENTS
FOUR FORCED SCRUBBER OUTAGES WERE REPORTED BY THE UTILITY FOR APRIL.
PLUGGFD SENSING LINES RESULTED IN FGD OUTAGE TIME.
A REHEVTER LEAK DURING APRIL CAUSED DOWN TIME FOR REPAIRS.
A VENTJRI RECYCLE PUMP SPOOL REPLACEMENT REQUIRED FGD OUTAGE TIME.
A VENTURI RECYCLE TANK NEEDED PATCHING DURING THE MONTH.
5/76 SYSTEM 99.0 83.0 98.0 79.0 744
6/76 SYSTEM 95.3 86.8 87.0 82.2 720 682 592
** PROBLEMS/SOLUTIONS/COMMENTS
PLUGGED VENTURI LINES ACCOUNTED FOR 6 HOURS DURING MAY.
A 6 HOUR OUTAGE RESULTED FROM PLUGGED SENSING LINES.
THE SCRUBBING SYSTEM WAS SHUTDOWN FOR 54 HOURS WHILE CEMENT WAS BEING
POURED IN THE SCRUBBER AREA.
7/76 SYSTEM 94.2 82.3 91.2 59.9 744 542 446
** PROBLEMS/SOLUTIONS/COmENTS
A PROBLEM WITH A HIGH SOLIDS CONCENTRATION IN THE VENTURI SCRUBBING CYCLE
CONTRIBUTED TO FGD OUTAGE TIME.
THE REPLACMENT OF A RUBBER-LINED PIPE IN THE VENTURI SCRUBBER WAS
NECESSARY DURING JULY.
BOILER RELATED OUTAGES ACCOUNTED FOR 256 HOURS OF FGD SYSTEM DOWNTIME.
8/76 SYSTEM 91.7 69.1 70.8 65.8 744 709 490
** PROBLEMS/SOLUTIONS/COMMENTS
DEPLETION OF CHEMICAL ABSORBENT (TRONA) CONTRIBUTED TO FGD OUTAGE
TIME (141 HOURS).
THE FGD SYSTEM WAS OUT OF SERVICE 52 HOURS FOR BOILER RELATED PROBLEMS.
VENTURI RECYCLE LINE LEAKING ACCOUNTED FOR 27 HOURS OF SCRUBBER
OUTAGE TIME.
THE THICKENER PLUGGED CAUSING 34 HOURS OF FGD SYSTEM DOWN TIME.
9/76 SYSTEM 92.4 90.2 91.9 85.2 720 681 614
** PROBLEMS/SOLUTIONS/COMMENTS
PLUGGING IN THE 10 FAN REFERENCE LINES RESULTED IN 36 HOURS OF OUTAGE TIKE.
A 19 HOUR FGD SYSTEM SHUTDOWN WAS CAUSED BY A FALSE HIGH TEMPERATURE
READING IN THE VENTURI DUE TO WATER IN THE INSTRUMENT.
404
-------
EPA UTILITY FGO SURVEY: OCTOBER - DECEMBER 1980
NEVADA POWER: REID GARDNER 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
10/76 SYSTEM 95. Z 92.6 94.7 86.4 744 694 643
** PROBLEMS/SOLUTIONS/COMMENTS
FIVE HOURS OF SCRUBBER OUTAGE TIME MAS CAUSED BY VENTURI GAS DAMPER
PROBLEMS.
REPLACEMENT OF THE CARBONATE FEED LINE ACCOUNTED FOR 16 HOURS OF FGD
SYSTEM OUTAGE.
PLUGGING IN THE SCRUBBER EFFLUENT LINE CONTRIBUTED TO FGD SYSTEM
DOWN TIME.
SCRUBBER OUTAGE TIME DUE TO BOILER-RELATED PROBLEMS AMOUNTED TO
APPROXIMATELY 66 HOURS.
11/76 SYSTEM 51.9 60.1 60.1 51.9 720 621 374
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS DOWN FOR REPAIR OF A CONDENSER TUBE LEAK AND BOTTOM ASH
NOZZL1-.
DURING THE BOILER OUTAGE THE SCRIBBER GUILLOTINE DAMPERS WERE BADLY
DAMA6EO WHEN LIMIT SWITCH ADJUSTMENTS WERE BEING MADE. THE SCRUBBER
REMAINED OUT OF Sr«2VICE FROM NOVEMBER 16 THROUGH THE END OF THE MONTH.
12/76 SYSTEM .0 .0 744 275 0
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS DOWN THE ENTIRE MONTH OF DECEMBER FOR A SCHEDULED OVERHAUL.
THE FGD SYSTEM WAS UNAVAILABLE THROUGH DECEMBER AS DAMPER REPAIRS HAD
NOT YET BEEN MADE. FGD SYSTEM SERVICES WERE NOT REQUIRED DURING THE
PERIOD.
1/77 SYSTEM 100.0 .0 744 0 0
** PROBLEMS/SOLUTIONS/COMMENTS
THE SCHEDULED BOILER OVERHAUL CONTINUED THROUGH JANUARY.
2/77 SYSTEM 92.7 79.0 89.3 60.8 672 517 409
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS PUT BACK IN SERVICE ON FEBRUARY 7 AFTER COMPLETION OF
THE SCHEDULED BOILER OVERHAUL.
A MINOR SCRUBBER OUTAGE RESULTED FROM A VENTURI PIPING LEAK.
DURING THE LAST TWO DAYS OF FEBRUARY SOME FGD SYSTEM ELECTRICAL PROBLEMS
OCCURRED.
A MINOR SCRUBBER OUTAGE WAS REQUIRED TO CLEAN THE RECYCLE TANK WASH TRAY.
3/77 SYSTEM 88.5 86.3 86.9 76.4 744 659 569
405
-------
EPA UTILITY FGO SURVEY: OCTOBER - DECEMBER 1980
NEVADA POWER: REID GARDNER 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
A PLUGGED ABSORBER TRAY CONTRIBUTED TO THE FGD SYSTEM OUTAGE TIME.
ELECTRICAL PROBLEMS IN THE FGD SYSTEM WERE EXPERIENCED DURING MARCH.
DUCT HI/LO PRESSURE SENSORS TRIGGERED A NINE HOUR FGD SYSTEM SHUTDOWN.
ID FAN PRESSURE SENSORS FORCED THE FGO SYSTEM OFF LINE FOR 28 HOURS
IN MARCH.
4/77 SYSTEM 94.8 94.8 94.8 94.8 7ZO 720 683
** PROBLEMS/SOLUTIONS/COMMENTS
37 HOURS OF FORCED FGD SYSTEM OUTAGE TIME RESULTED FROM A LEAK IN THE
VENTURI DISCHARGE LINE.
5/77 SYSTEM 98.7 89.8 96.1 63.2 744 524 470
** PROBLEMS/SOLUTIONS/COMMENTS
BOILER-RELATED OUTAGES ACCOUNTED FOR 255 HOURS OF FGD SYSTEM DOWNTIME
IN MAY.
BOILER ASH SLUICE PUMPS WERE OUT OF SERVICE FOR APPROXIMATELY 10 HOURS
IN MAY. BECAUSE THE EMERGENCY SPRAY SYSTEM WAS UNAVAILABLE THE FGD SYSTEM
WAS FORCED OUT OF SERVICE.
6/77 SYSTEM 95.1 93.3 94.4 82.8 720 639 596
** PROBLEMS/SOLUTIONS/COMMENTS
ID FAN SENSING LINE PLUGGING FORCED THE SYSTEM OUT OF SERVICE FOR SEVEN
HOURS IN JUNE.
A BREACER TRIP RESULTED IN A LOSS OF BOILER CONTROL POWER FOR FIVE HOURS.
THE SP3AY NOZZLES IN THE VENTURI PLUGGED CAUSING 28 HOURS OF FGD SYSTEM
OUTAGF.
7/77 SYSTEM 40.0 41.6 40.6 40.0 744 733 298
** PROBLEMS/SOLUTIONS/COMMENTS
SEVEN FORCED FGD OUTAGES WERE DUE TO SCRUBBER DUCT HI/LO PRESSURE TRIPS
DURING JULY.
ONE TWO HOUR OUTAGE WAS REQUIRED TO CORRECT A PLUGGING PROBLEM IN THE
VENTURI SPRAY NOZZLES DURING JULY.
8/77 SYSTEM 88.0 91.3 86.8 79.4 744 646 591
** PROBLEMS/SOLUTIONS/COMMENTS
A LEAK IN THE VENTURI RECYCLE HEADER RESULTED IN AN FGD SYSTEM OUTAGE.
A SCRUBBER DUCT HIGH/LOW BOILER TRIP OCCURRED RESULTING IN 35 HOURS OF
SCRUBBER OUTAGE TIME.
THERE WAS ONE 64 HOUR BOILER-RELATED OUTAGE DURING AUGUST.
9/77 SYSTEM 67.7 64.4 66.5 64.1 720 716 461
406
-------
EPA UTILITY FGO SURVEY: OCTOBER - DECEMBER 1980
NEVADA POWER: REID GARDNER 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
A LEAK IN THE VENTURI RECYCLE LINES RESULTED IN FORCED FGD SYSTEM OUTAGE
TIME.
TRAY RECYCLE PUMP REPAIR NECESSITATED NEARLY SIX HOURS OF FGD SYSTEM
OUTAGE TIME.
DUCT HI/LO PRESSURE SENSOR LINE PLUGGING PROBLEMS ACCOUNTED FOR 58 HOURS
OF FORCED FGD SYSTEM OUTAGE.
26 HOURS OF OUTAGE TIME OCCURRED WHEN THE ASH SLUICE SYSTEM WENT OUT OF
SERVICE. THE FGD SYSTEM IS LEFT WITHOUT EMERGENCY SPRAYS WHEN THIS OCCURRS
SINCE THEY ARE INTEGRATED SYSTEMS.
TRAY PLUGGING RESULTED IN 96 HOURS OF FGD SYSTEM OUTAGE WHICH BEGAN ON
SEPTEMBER 27 AND CONTINUED THROUGH THE END OF THE MONTH.
THE FGD SYSTEM WAS TAKEN OFF-LINE TO ALLOW CLEANING OF A SUCTION SCREEN
IN THE TRAY RECYCLE TANK.
10/77 SYSTEM 79.2 83.2 79.1 78.8 744 704 586
** PROBLEMS/SOLUTIONS/COMMENTS
FGD SYSTEM OUTAGE TIME WAS NEEDED TO CLEAN A PLUGGED ABSORBER RECYCLE
TANK SCREEN.
A VENTURI TANK SEPARATOR REQUIRED CLEANING CAUSING FGD SYSTEM DOWN TIME.
A HIGH SOLIDS LEVEL IN THE VENTURI RECYCLE SYSTEM REQUIRED THREE HOURS OF
DOWNTIME TO MAKE CORRECTIONS.
A SCRUBBER DUCT HIGH/LOW PRESSURE TRIP FORCED THE BOILER AND SCRUBBER
OUT OF SERVICE FOR 42 HOURS.
ID FAN LEAKS WERE PATCHED DURING OCTOBER.
11/77 SYSTEM 80.7 .0 .0 .0 720 98 0
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS OUT OF SERVICE FROM OCTOBER 31 UNTIL NOVEMBER 26 TO INSTALL
A NEW PRIMARY AIR FAN.
THE SCRUBBER WAS OUT OF SERVICE FOR AN ID FAN ROTOR REPAIR.
12/77 SYFTEM .0 .0 .0 .0 744 742 0
** PROBLEMS/SOLUTIONS/CO fllENTS
THE SCRUBBER MODULE WAS OUT OF SERVICE TO INSTALL NEW WEAR PLATES ON AN
ID FAN ROTOR.
1/78 SYSTEM 71.7 73.9 73.9 67.0 744 675 499
** PROBLEMS/SOLUTIONS/COMMENTS
THE SCRUBBER WENT BACK ON LINE JANUARY 4 AFTER THE INSTALLATION OF WEAR
PLATES ON AN ID FAN ROTOR.
REPAIRS ON THE THICKNER OVERFLOW PUMP CONTRIBUTED TO FGD SYSTEM OUTAGE
TIME.
407
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
NEVADA i'OWER: REID GARDNER 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
SOME SOLIDS BUILD UP IN THE VENTURI WAS ENCOUNTERED DURING JANUARY.
2/78 SYSTEM 92.9 91.9 92.5 87.0 672 636 585
** PROBLEMS/SOLUTIONS/COMMENTS
A DUCT HIGH/LOW PRESSURE TRIP CONTRIBUTED TO THE FGD SYSTEM OUTAGE TIME.
THE BOILER WAS OUT OF SERVICE FOR 40 HOURS DURING FEBRUARY.
3/78 SYSTEM 100.0 88.7 100.0 80.2 744 672 5%
** PROBLEMS/SOLUTIONS/COMMENTS
THERE WERE NO FORCED FGD SYSTEM OUTAGES DURING MARCH HOWEVER, THE SYSTEM
WAS SHUTDOk-N FOR 18 HOURS WHEN THE BOILER OPERATED AT LOW LOAD AND STABLE
FGD SYSTEM OPERATIONS WERE NOT ATTAINABLE.
4/78 SYSTEM 100.0 98.7 100.0 44.1 720 321 317
** PROBLEMS/SOLUTIONS/COMMENTS
THERE WERE NO FGD SYSTEM RELATED OUTAGES DURING APRIL. THE BOILER WAS OUT
OF SERVICE FOR 403 HOURS IN APRIL.
5/78 SYSTEM 99.8 99.7 99.8 97.4 744 727 724
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS OFF FOR APPROXIMATELY 18 HOURS FOR REPAIRS ON THE COAL MILL
SPOKES.
A SCRUBBER CIRCUIT BREAKER TRIPPED AND CAUSED AN FGD SYSTEM OUTAGE OF
ABOUT ONE HOUR.
6/78 SYSTEM 89.4 89.4 89.4 89.4 720 720 644
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS OUT OF SERVICE FOR 76 HOURS FOR REPAIR OF A VENTURI
WATER BOX LEAK.
7/78 SYSTEM 80.1 81.8 78.9 74.3 744 676 553
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS OUT OF SERVICE FOR 43 HOURS DUE TO A BOILER TUBE LEAK.
HIGH DUCT PRESSURE WAS THE CAUSE OF A BOILER TRIP. THE HIGH DUCT PRESSURE
WAS CAUSED BY A FAULTY POSITIONER ON THE ID FAN CONTROLLER.
THE ID FAN EXPANSION JOINT ON THE SCRUBBER SIDE WAS REPLACED.
AN FGD OUTAGE OCCURRED WHEN A BOLT, WHICH FELL FROM THE FAN, CAUSED
VIBRATIONS.
A SECOND BOILER TRIP DURING JULY WAS CAUSED BY AN UNDETERMINED SOURCE.
THE SUCTION LINE FROM THE VENTURI DISCHARGE LINE TO THE EFFLUENT PUMPS HAD
TO B= CLEANED BECAUSE OF PLUGGING.
8/78 SYSTEM 81.4 82.2 82.4 81.1 744 733 403
408
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
NEVADA POWER: REID GARDNER Z CCONT.)
. PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
TWO SCHEDULED OUTAGES DURING AUGUST WERE NECESSARY TO CLEAN THE SCRUBBER
TRAY.
A SCHEDULED OUTAGE WAS NECESSARY TO CLEAN THE NOZZLES ON THE SCRUBBER
SPRAY RACK. THE STAINLESS STEEL PIPE TO THE TRAY SPRAY NOZZLES WAS ALSO
REPLACED.
ON AUGUST 1 THE SCRUBBER EXPERIENCED HIGH DUCT PRESSURE. DURING THE
SUBSEQUENT OUTAGE A CLINKER WAS REMOVED FROM THE BOILER BOTTOM HOPPER.
ON AUGUST 3 IT WAS NECESSARY TO TAKE THE SCRUBBER OFF LINE TO REPACK THE
VENTURI PUMPS.
A THIRD OUTAGE IN AUGUST WAS CAUSED BY A LOSS OF THE BOILER ASH PANEL
CONTROL POWER. THIS LEFT THE SCRUBBER WITHOUT EMERGENCY SPRAY.
9/78 SYSTEM 98.5 97.4 98.4 93.8 720 693 675
** PROBLEMS/SOLUTIONS/COMHENTS
A SCRUBBER OUTAGE WAS NECESSARY DURING SEPTEMBER IN ORDER TO CLEAN THE
TRAY RECYCLE TANK AS WELL AS THE TRAY AND SOME OF THE LINES.
THREE BOILER RELATED OUTAGES WERE CAUSED BY PROBLEMS WITH A 10-KW
GENERATOR. CONTROL POWER SURGES WERE BEING CAUSED BY OVERVOLTAGE
MOTOR TRIPS.
10/78 SYSTEM 96.2 95.0 96.0 92.1 744 722 685
** PROBLEMS/SOLUTIONS/COMMENTS
DURING OCTOBER SCRUBBER INSTRUMENTATION REPAIRS WERE PERFORMED.
THE BOILER WAS FORCED OUT OF SERVICE FOR ABOUT 28 HOURS BECAUSE OF
BOILER DRUM WATER LEVEL PROBLEMS.
11/78 SYSTEM 97.5 93.2 93.6 35.9 720 277 259
** PROBLEMS/SOLUTIONS/COMMENTS
A FORCED FGD SYSTEM OUTAGE OCCURRED DUE TO HIGH DUCT PRESSURE.
WORK WAS DONE ON ID FAN CONTROLS DURING NOVEMBER.
THE UNIT WAS SHUTDOWN ON NOVEMBER 12 FOR SCHEDULED BOILER MAINTENANCE.
THE UNIT REMAINED OUT OF SERVICE THROUGH THE END OF THE MONTH.
12/78 SYSTEM 95.9 44.9 100.0 13.3 744 221 99
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS OFF LINE UNTIL DECEMBER 26 WHEN A SCHEDULED MAINTENANCE
OUTAGE WAS COMPLETED.
THE SCRUBBER WAS TAKEN OUT OF SERVICE FOR 30 HOURS TO UNPLUG AN EFFLUENT
LINE.
WHILE THE SCRUBBER WAS DOWN THE BOILER WAS OUT OF SERVICE SO THAT
PULVERIZER REPAIRS COULD BE MADE.
1/79 SYSTEM 82.9 81.3 81.3 73.9 744 676 550 81.3
409
-------
EPA UTILITY F6D SURVEY: OCTOBEI! - DECEMBER 1980
NEVADA POWER: REID GARDNER 2 (CIINT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS TAKEN OUT OF SERVICE TO CLEAN A TRAY SCREEN.
THE FGD SYSTEM WAS TAKEN OUT OF SERVICE TO REPAIR A LEAK IN THE VENTURI
RECYCLE LINE.
THE BOILER WAS DOWN 67 HOURS FOR TUBE LEAK REPAIRS.
REPAIRS WERE MADE ON THE TRAY AND SPRAY PUMP SYSTEMS.
A HIGH DUCT PRESSURE TRIP WAS RESPONSIBLE FOR A SIX HOUR OUTAGE. THE
PRESSURE SENSING LINES WERE CLEANED.
THE SCRUBBER TRAY PUMP MOTOR SHORTED TO GROUND. THE 2C LOAD TRIPPED AND
POWER TO THE VENTURI RECYCLE PUMP WAS LOST. THERE WAS AN ADDITIONAL
SCRUBBER TRIP DUE TO HIGH DUCT PRESSURE DURING THIS SAME PERIOD.
2/79 SYSTEM 96.2 93.1 93.2 87.9 672 634 591 87.0
*# PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS TAKEN OUT OF SERVICE TO REPAIR A LEAK IN THE VENTURI
LINE.
THE FGD SYSTEM WAS FORCED OUT OF SERVICE BY A SCRUBBER POWER FAILURE.
THE SCRUBBER WAS TAKEN OUT OF SERVICE BECAUSE A BREAK IN THE ASH WATER
CIRCULATING WATER LINE RESULTED IN A LOSS OF EMERGENCY COOLING WATER.
THE FGD SYSTEM WAS FORCED OUT OF SERVICE BY A LEAK ON THE VENTURI RACE
TRACK SPRAY SECTION. THE VENTURI RACE TRACK NOZZLES WERE CLEANED DURING
THE OUTAGE.
THE BOILER WAS OUT OF SERVICE 38 HOURS FOR TUBE LEAK REPAIRS.
3/79 SYSTEM 97.9 96.7 100.0 89.4 744 688 665 90.3
** PROBLEMS/SOLUTIONS/COMMENTS
THE SCRUBBER WAS OUT OF SERVICE 63 HOURS WHILE BOILER TUBE LEAK REPAIRS
MERE MADE.
THE BOILER WAS FORCED OUT BY A HIGH FURNACE PRESSURE TRIP. WHILE THE
BOILER WAS DOWN, SENSING LINES WERE CLEANED ON THE SCRUBBER.
4/79 SYSTEM 89.1 96.0 98.9 88.8 720 666 639 91.0
** PROBLEMS/SOLUTIONS/COMMENTS
A HIGH PRESSURE ALARM ON THE SCRUBBER DUCT TRIPPED THE SCRUBBER OFF LINE.
THE SCRUBBER PRESSURE SENSING LINES WERE CLEANED. THIS OCCURRED TWICE
DURING THE MONTH OF APRIL AND ACCOUNTED FOR 79 HOURS OF OUTAGE TIME.
A BOILER FURNACE BURNER WAS CLEANED DURING A 71 HOUR SCRUBBER OUTAGE
RESULTING FROM A HIGH PRESSURE ALARM.
A CONTROL POWER FAILURE OCCURRED CAUSING A SCRUBBER TRIP WHEN A 10 KW
GENERATOR WAS PUT BACK IN SERVICE.
5/79 SYSTEM 99.8 99.5 99.7 83.9 744 627 624 93.2
410
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
NEVADA POWER: REID GARDNER Z (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OP^RABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COilMENTS
THE BOILER WAS OUT OF SERVICE FOR ABOUT FIVE DAYS TO REPAIR TUBE LEAKS.
PRESSURE SENSING LINES ON THE SCRUBBER CONTROLS WERE CLEANED DURING
A TWO HOUR OUTAGE AFTER THE SCRUBBER BEGAN HAVING CONTROL PROBLEMS.
6/79 SYSTEM 91.1 87.1 89.2 73.5 720 607 529 92.2
*# PROBLEMS/SOLUTIONS/COMMENTS
THE SCRUBBER WAS FORCED OUT OF SERVICE DUE TO A VENTURI PUMP POWER LOSS.
20 HOURS OF SCRUBBER OUTAGE TIME WAS REQUIRED TO REPAIR VENTURI PUMP
DISCHARGE VALVES.
THE BOILER WAS OUT OF SERVICE 127 HOURS DURING JUNE TO REPAIR HIGH
PRESSURE HEATER TUBE LEAKS, TO WELD A CAP ON THE HIGH PRESSURE HEATER,
TO WORK ON PRIMARY AIR FANS, AND TO REPAIR A BOILER TUBE LEAK.
SCRUBBER OUTAGE TIME WAS REQUIRED TO CLEAN PRESSURE SENSING LINES.
THE SCRUBBER WAS FORCED OUT OF SERVICE JUNE 30 BY A HIGH VENTURI OUTLET
TEMPERATURE TRIP.
7/79 SYSTEM 84.3 90.0 93.* 77.6 7** 6*2 578 92.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE SCRUBBER OUTAGE WHICH BEGAN JUNE 30 CONTINUED UNTIL JULY *. DURING
THE OUTAGE A BAD VENTURI TEMPERATURE PROBE WAS REPLACED. SOME BOILER TUBE
REPAIRS WERE MADE AT THIS TIME.
THE BOILER AND SCRUBBER WERE OFF FOR 50 HOURS TO REPAIR A BOILER TUBE LEAK.
SCRUBBER AND BOILER TRIPPED OFF FOR ABOUT 50 HOURS. THIS OUTAGE WAS
CAUSED BY A LOSS OF CONTROL AIR TO THE SCRUBBER AND A POWER LOSS TO THE
SCRUBBER AIR COMPRESSOR.
THE SENSING LINES ON THE SCRUBBER WERE CLEANED TO PREVENT HIGH SCRUBBER
DUCT PRESSURE. THE SYSTEM WAS OUT FOR ABOUT 33 HOURS.
8/79 SYSTEM 98.5 98.9 98.* 93.2 74* 701 693 92.9
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS SHUTDOWN FOR ABOUT *0 HOURS TO REPAIR A BOILER TUBE LEAK.
THE SCRUBBER WAS OFF TO REPAIR A LEAK IN A VENTURI PUMP DISCHARGE BODY.
THE REPAIR REQUIRED ABOUT 9 HOURS.
HIGH PRESSURE IN SCRUBBER DUCT FORCED THE SCRUBBER OUT OF SERVICE.
THE SCRUBBER PRESSURE SENSING LINES WERE CLEANED.
9/79 SYSTEM 86.0 83.8 82.5 66.2 720 569 *77 92.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING SEPTEMBER THE SCRUBBER WENT OFF LINE WITH THE BOILER TO REPAIR
BOILER TUBE LEAKS. THIS OCCURRED TWICE CAUSING A TOTAL OF 126 HOURS OF
DOWN TIME.
SOME OUTAGE TIME WAS REQUIRED TO UNPLUG EFFLUENT AND VENTURI LINES AND
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
NEVADA POWER: REID GARDNER 2 (CONT.)
__ PERFORMANCE DATA •
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
TO CLEAN THE VENTURI RACE TRACK SPRAY SECTIONS.
HIGH PRESSURE WAS ENCOUNTERED TWICE IN THE SCRUBBER DUCT AND ONCE IN THE
BOILER FURNACE. THIS CAUSED SOME OUTAGE TIME TO CLEAN THE SCRUBBER
PRESSURE SENSING LINES.
THE SCRUBBER WAS DOS*! WITH THE BOILER SO REPAIRS TO THE MAIN STEAM DRAIN
LINE COULD BE CONDUCTED.
THE SCRUBBER WAS DOWN FOR APPROXIMATELY SEVEN HOURS TO MAKE REPAIRS ON THE
CONTROL SYSTEM.
10/79 SYSTEM 100.0 88.3 100.0 31.3 744 263 233 91.8
** PROBLEMS/SOLUTIONS/CO1MENTS
THE SCRUBBER WAS DOWN FOR 13 HOUR!} WITH THE BOILER DUE TO A MASTER FUEL
TRIP Oil THE BOILER AND LATER FOR 41 HOURS FOR BOILER TUBE REPAIRS.
A BOILER TRIP OCCURRED ON OCTOBER IZ BECAUSE OF HIGH FURNACE PRESSURE. AN
EXPLOSION BLEW AN EXPANSION JOINT ON THE DISCHARGE OF A PRIMARY AIR FAN.
THE BOILER OUTAGE CONTINUED THROUGH THE END OF THE MONTH AS GENERAL
MAINTENANCE WAS PERFORMED.
11/79 SYSTEM 98.8 96.0 97.3 43.3 720 325 312 92.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE SCRUBBER AND BOILER DID NOT OPERATE UNTIL NOVEMBER 17 WHEN THE
SCHEDULED MAINTENANCE WAS COMPLETED.
THE SCRUBBER WAS FORCED OUT OF SERVICE FOR APPROXIMATELY THREE HOURS TO
RECTIFY A VIBRATIONS PROBLEM IN THE REHEATER FAN.
THE SCRUBBER WENT OFF LINE WHEN A TRAY SPRAY PUMP SHORTED TO GROUND
TRIPPING A SCRUBBER POWER LOAD CENTER.
12/79 SYSTEM 97.9 97.7 97.9 97.7 744 744 727 92.6
** PROBLEMS/SOLUTIONS/COMMENTS
A BOILER/SCRUBBER HIGH DUCT PRESSURE TRIP OCCURRED. THE SCRUBBER PRESSURE
SENSING LINES WERE CLEANED. THE TRIP ACCOUNTED FOR A LITTLE OVER AN HOUR
OF OUTAGE TIME.
THE CONTROL SYSTEM ON THE VENTURI DAMPER REQUIRED REPAIRS WHICH RESULTED
IN APPROXIMATELY THREE HOURS OF DOWN TIME.
THE SCRUBBER WAS SHUT DOWN TO MAKE REPAIRS ON THE EMERGENCY SPRAY SYSTEM
AND A REHEATER FAN BEARING.
DURING A MAINTENANCE CHECK FOR D. C. GROUNDING THE BOILER AND SCRUBBER
WERE FORCED OUT OF SERVICE FOR TWO HOURS.
1/80 SYSTEM 97.4 94.5 96.9 81.6 744 642 607 94.5
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JANUARY THE SCRUBBER WAS TAKEN OFF LINE WITH THE BOILER TO REPLACE
THE REBUILT BOILER HIGH PRESSURE HEATER. THIS OUTAGE LASTED APPROXIMATELY
112 HOURS.
REPAIRS WERE NEEDED ON THE LEFT HAND INTERCEPT VALVE ON THE TURBINE CAUSING
THE SCRUBBER TO BE TAKEN OFF LINE ONCE AGAIN WITH THE BOILER.
412
-------
EPA UTILITY FSD SURVEY: OCTOBER - DECEMBER 1980
NEVADA POWER: REID GARDNER 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
THE CLEANING OF THE VENTURI RACE TRACK NOZZLES ACCOUNTED FOR TWO SCRUBBER
OUTAGES TOTALLING 15 HOURS.
THE SCRUBBER WAS TAKEN OFF LINE FOR FOUR HOURS SO MAINTENANCE COULD BE PER-
FORMED ON THE ID FAN DAMPER CONTROLS.
2/80 SYSTEM 96.9 96.9 96.9 96.9 696 696 675 95.7
** PROBLEMS/SOLUTIONS/COMMENTS
THE SCRUBBER WAS TAKEN OFF-LINE TWICE DURING FEBRUARY DUE TO A MALFUNCTION
OF THE ID FAN CONTROLS. THE PRESSURE SENSING LINES WERE CLEANED DURING
THE OUTAGE.
THE SCRUBBER RACE TRACK NOZZLES HAD TO BE CLEANED TWICE, REQUIRING APPROX-
IMATELY FOUR HOURS OF OUTAGE TIME.
THE DISCHARGE VALVE ON THE VENTURI RECYCLE PUMP WAS REPLACED DURING
FEBRUARY.
REPAIRS WERE MADE ON THE SCRUBBER EMERGENCY SPRAY LINE RESULTING IN ABOUT
FOUR HOURS OF OUTAGE TIME.
THE SCRUBBER HAD TO BE SHUT DOWN SO REPAIRS ON THE ID FAN DAMPER CONTROLS
COULD BE MADE.
3/80 SYSTEM 98.4 97.5 97.5 97.5 74* 744 725 96.3
*» PROBLEMS/SOLUTIONS/CO'1MENTS
DURING MARCH THE SCRUBBER WAS TAKEN OFF LINE DUE TO THE UNAVAILABILITY OF
THE EMERGENCY SPRAY SYSTEM. DURING THIS TIME MAINTENANCE WAS DONE ON THE
A AND B ASH SLUICE PUMPS.
LATER IN THE MONTH AN OUTAGE WAS CAUSED BY A LEAK IN THE EMERGENCY SPRAY
LINE.
PROBLEMS RELATED TO A LOW VENTURI FLOW CAUSED FOUR HOURS OF OUTAGE TIME IN
MARCH. NO CAUSE FOR THE FLOW PROBLEM WAS REPORTED.
4/80 SYSTEM 99.0 99.0 99.0 93.5 720 680 673 97.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS UNAVAILABLE FOR 7 HOURS TO UNPLUG THE VENTURI RACE
TRACK.
THE BOILER WAS OUT OF SERVICE FOR 40 HOURS DUE TO BOILER TUBE LEAKS.
5/80 SYSTEM 100.0 86.3 100.0 14.3 744 124 107 96.5
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD OVERHAUL WAS COMPLETED EARLY IN MAY.
A BOILER OVERHAUL WAS STARTED AND COMPLETED DURING MAY. THIS OUTAGE LASTED
ALMOST 23 DAYS.
6/80 SYSTEM 99.6 97.5 99.5 73.4 720 541 528 96.6
413
-------
EPA UTILITY FSD SURVEY: OCTOBER - DECEMBER 1980
NEVADA POWER: REID GARDNER 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS OUT OF SERVICE SEVERAL TIMES DURING JUNE. THIS CAUSED THE
FGD SYSTEM TO BE OUT APPROXIMATELY 80 HOURS.
VENTURI RACE TRACK NOZZLES NEEDED TO BE UNPLUGGED CAUSING THE FGD SYSTEM
OUT OF SERVICE FOR SEVERAL HOURS.
7/80 SYSTEM 88.1 77.2 86.2 74.5 744 718 554 93.3
** PROBLEMS/SOLUTIONS/COMMENTS
BOILER RELATED OUTAGES KEPT THE FGD SYSTEM OUT OF SERVICE FOR OVER 100
HOURS DURING JUNE. OVER HALF OF THIS OUTAGE TIME MAS A RESULT OF CONTROL
PROBLEMS WITH THE BOILER AND FGD SYSTEM. THE BOILER WAS RUN WITHOUT THE
FGD SYSTEM IN ORDER TO DETERMINE IF THE CONTROL PROBLEMS WERE FGD OR BOILER
RELATED. PROBLEMS WERE REPAIRED IN BOTH CONTROL SYSTEMS. THIS ALSO CAUSED
OVER 60 HOURS OF FGD SYSTEM RELATED DOWN TIME.
PROBLEMS WITH THE BOTTOM HOPPER SEALS CAUSED THE FGD SYSTEM TO GO DOWN.
THE FGD SYSTEM NEEDED TO BE OFF LINE FOR 13 HOURS FOR INSTRUMENT CHECKS
AND MAINTENANCE.
THE FGD SYSTEM WAS FORCED OUT OF SERVICE WHEN THE EMERGENCY SPRAY SYSTEM
FAILED. THE ASH SLUICE PUMP SHAFT WAS REPAIRED DURING THIS TIME.
8/80 SYSTEM 97.0 96.3 96.4 79.7 744 613 591 93.9
** PROBLEMS/SOLUTIONS/COMMENTS
LOSS OF EMERGENCY SPRAY KEPT THE FGD SYSTEM OFF LINE FOR ALMOST 20 HOURS.
BOILER RELATED OUTAGES CAUSED THE FGD SYSTEM NOT TO OPERATE FOR OVER 130
HOURS.
9/80 SYSTEM 100.0 .0 720 0 0
** PROBLEMS/SOLUTIONS/COMMENTS
THE FG3 SYSTEM WAS 100/C AVAILABLE DURING A SCHEDULED BOILER OVERHAUL IN
SEPTEM3ER.
10/80 SYSTEM 100.0 .0 .0 744 0 0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT OVERHAUL CONTINUED THROUGH THE MONTH OF OCTOBER.
11/80 SYSTEM 94.5 93.6 91.9 62.0 720 273 447
** PROBLEMS/SOLUTIONS/COMMENTS
THE SCHEDULED OUTAGE CONTINUED UNTIL NOVEMBER 10. THE UNIT WAS BROUGHT
ON LINE AND REMAINED ON LINE UNTIL NOVEMBER 26 WHEN THE BOILER AND FGD
SYSTEM WERE FORCED OUT OF SERVICE TWICE.
12/80 SYSTEM 99.5 99.2 99.5 97.8 744 733 728
414
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
NEVADA POWER: REID GARDNER Z (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
DURING DECEMBER THE SYSTEM WAS SHUTDOWN APPROXIMATELY 12 HOURS FOR
SCHEDULED OUTAGES.
TWO FORCED OUTAGES OCCURRED DURING THE MONTH WHICH CAUSED THE SYSTEM TO
SHUT DOWN FOR APPROXIMATELY FOUR HOURS.
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PUNT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** MECHANICAL COLLECTOR
TYPE
SUPPLIER
PARTICLE REMOVAL EFFICENCY -7.
** PARTICLE SCRUBBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
LIQUID RECIRCULATION RATE - LITER/S
t/G RATIO - LITER/CU.M
PRESSURE DROP - KPA
SUPERFICIAL GAS VELOCITY - M/S
INLET GAS FLOW RATE - CU.M/S
INLET GAS TEMPERATURE - C
PARTICLE REMOVAL EFFICIENCY - 7.
*** FCD SYSTEM
t .100 LB/MMBTUJ
( 1.200 LB/MMBTU)
(****** LB/MMBTU)
NEVADA POWER
REID GARDNER
3
MOAPA
NEVADA
B
43.
516.
******
105
125
110
*****
125
FOSTER WHEELER
PULVERIZED COAL
BASE
223.21 ( 473000 ACFM)
176.7 ( 350 F)
61. ( 200 FT)
CONCRETE
6.3 ( 20.6 FT)
( 12450 BTU/LB)
******
COAL
BITUMINOUS
28959.
8.00
8.-10.
9.00
5.5
.50
0.5-1.0
.05
MULTICLONES
RESEARCH-COTTRELL
75.0
VENTURI TOWER
FIXED-THROAT
AOL/COMBUSTION EQUIP ASSOCIATES
1.5 DIA. X 18 LONG AT THROAT
CARBON STEEL, HIGH ALLOY
AISI 1110> AUSTENITIC
NONE, ORGANIC
N/A, RUBBER
TWIN VARIABLE THROATS
1
157.5 I 2500 GPM)
1.3 (10.0 GAL/1000ACF)
.8 ( 3.3 IN-H20)
50.3
223.2
176.7
97.0
( 165.0 FT/S)
( 473000 ACFM)
( 350 F)
416
-------
NEVADA POWER: REID GARDNER 3 (CONT.)
EPA UTILITY FED SURVEY: OCTOBER - DECEMBER 1980
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
S32 REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DtVELOPKENT LEVEL
NE.H/RETRCFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
U! IT DESIGN S02 REMOVAL EFFICIENCY - 7.
CURRENT STATUS
CC11MERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
** ABSORBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
GAS CONTACTING DEVICE TYPE
NUMBER Of CONTACTING ZONES
LIQUID RECIRCULATION RATE - LITER/S
L/G RATIO - L/CU.M
GAS-SIDE PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/SEC
SQ2 REMOVAL EFFICIENCY - 7.
** MIST ELIMINATOR
FRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES PER STAGE
PRESSURE DROP - KPA
CONSTRUCTION MATERIAL GENERIC TYPE
** REHEATER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
TEMPERATURE INCREASE - C
INLET FLUE GAS TEMPERATURE - C
NUMBER OF TUSES PER BUNDLE
CONSTRUCTION MATERIAL GENERIC TYPE
** FANS
NUMBER
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
THROWAWAY PRODUCT
WET SCRUBBING
SODIUM CARBONATE
NONE
COMBUSTION EQUIP ASSOCIATES
BECHTEL
FULL SCALE
NEW
X 99.00
85.00
I
7/76
7/76
7/73
TRAY TOWER
SIEVE TRAY
COMBUSTION EQUIP ASSOCIATES
30 OIA.
CARBON STEEL
AISI 1110
N/A
ORGANIC
RUBBER
SINGLE SIEVE TRAY WITH 3/16 IN HOLES
1
( 600 GPM)
( 1.6 GAL/1000 ACF)
( 3.0 IN-H20)
38.
.2
.7
3.4
91.2
( 11.0 FT/S)
MIST ELIMINATOR
1
CENTRIFUGAL
RADIAL VANE
HORIZONTAL
1
1
.1 ( .5 IN-H20)
316L SS (BOTH ME AND WASH TRAY)
INDIRECT HOT AIR
EXTERNAL HEAT EXCHANGER
STEAM TUBE BUNDLES
10.0 ( SO F)
48.3 ( 119 F)
24
CARBON STEEL
BUFFALO FORGE
BALANCED DRAFT
FORCED DRAFT
DRY
223.21
176.7
CARBON STEEL
( 473000 ACFM)
( 350 F)
SCRUBBER INLET
CARBON STEEL
417
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
NEVADA POMER: REID GARDNER 3 (~ONT.)
LIhER GENERIC MATERIAL TY?E
** DUCTWORK
Lrc; TION
SHtLL GENERIC MATERIAL TYPE
'.INER GENERIC MATERIAL TYPE
** TAUKS
SERVICE
VtNTURI RECYCLE
** PU1PS
SERVICE
S:RUBBER RECIRCULATION
ABSORBER RECIRCULATION
*** SLUDGE
** DISPOSAL
NATURE
TYPE
LOCATION
** DISPOSAL
NATURE
LO:ATION
SITE TRANSPORTATION METHOD
** WATER BALANCE
WATER LOOP TYPE
MAKEUP WATER ADDITION - LITERS/S
** FGD SPARE CAPACITY INDICES
ABSORBER - 7.
** FGD SPARE COMPONENT INDICES
ABSORBER
NONE
SCRUBBER OUTLET
CARBON STEEL
PLASITE 4004-S
NUMBER
1
NUMBER
3
3
INTERIM
LINED POND
ON SITE
FINAL
LINED POND
ON SITE
GRAVITY FLOW FROM INTERIM SLUDGE POND
CLOSED
9.8
.0
.0
( 155 GPM)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
7/76 SYSTEM 82.0 45.9
** PROBLEMS/SOLUTIONS/COMMENTS
70.4
42.7
692
318
8/76 SYSTEM
43. 2
INITIAL BOILER TESTING OPERATIONS BEGAN IN EARLY APRIL 1976. INITIAL FLUE
GAS SCRUBBING SYSTEM TESTING BEGAN IN LATE JUNE 1976.
THE UNIT 3 SCRUBBING SYSTEM WAS PLACED IN OPERATION ON JULY 12, 1976. THE
SYSTEM DESIGN WAS BASED ON INFORMATION AND DATA OBTAINED FROM AN 8000-ACFM
PILOT PLANT PROGRAM CONDUCTED AT THIS STATION IN 1971 AND 1972.
A HIGH SOLIDS CONCENTRATION IN THE VENTURI SCRUBBING SOLUTION CYCLE WAS
A PROBLEM DURING JULY.
FOUR OUTAGES WERE REPORTED FOR THE MONTH, THREE OF WHICH WERE FORCED
SCRUBBER OUTAGES.
A BUCKET ELEVATOR MALFUNCTION WAS A PROBLEM DURING JULY FORCING THE SYSTEM
OUT OF SERVICE FOR 109 HOURS.
43.
43.2
43.2
744 744
321
418
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
NEVADA POWER: REID GARDNER 3 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
A RtHEATER MOTOR BURNOUT OCCURRED IN AUGUST.
THE VENTURI FLOOR WAS EFFECTIVELY DESTROYED DURING AUGUST.
SCRUB3ER OUTAGE TIME WAS REQUIRED TO REPAIR AN ID FAN ELECTRICAL
MALFUNCTION AND TO INSTALL ID FAN INSULATION.
THICKENER TANK PLUGGING CAUSED FGD DOWN TIME.
SCRUBBER OUTAGES TOTALLED 423 HOURS IN AUGUST.
9/76 SYSTEM 50.6 46.2 46.9 43.6 720 679 31*
** PROBLEMS/SOLUTIONS/COMMENTS
THE SYSTEM WAS PLACED BACK IN SERVICE ON SEPTEMBER 14 IN FOLLOWING EXTEN-
SIVE REPAIRS AND MODIFICATIONS FROM THE PRECEEDING MONTH.
A VENTURI VIBRATION TRIP RESULTED IN NEARLY 14 HOURS OF FGD SYSTEM OUTAGE
TIME.
TWO REHEATER FAN TRIPS OCCURRED IN SEPTEMBER ACCOUNTING FOR 14 HOURS OF
FGD SYSTEM OUTAGE TIME.
10/76 SYSTEM 21.0 28.4 28.4 20.9 744 548 155
*# PROBLEMS/SOLUTIONS/COMMENTS
HIGH SOLIDS CONTENT IN THE VENTURI RECYCLE SOLUTION RESULTED IN 26 HOURS
OF SCRUBBER OUTAGE TIME.
A SCRUBBER GAS DAMPER MALFUNCTION FORCED THE FGD SYSTEM OUT OF SERVICE FOR
FOUR HOURS.
VENTURI BOX LEAKS WERE ENCOUNTERED FORCING THE SCRUBBER OUT OF SERVICE
FROM OCTOBER 8 THROUGH THE END OF THE MONTH.
11/76 SYSTEM 28.5 68.7 68.7 £8.5 720 298 205
** PROBLEMS/SOLUTIONS/COMMENTS
THE SCRUBBING SYSTEM WAS OUT OF SERVICE THE FIRST HALF OF NOVEMBER AS
REPAIRS OF LEAKS IN THE VENTURI SCRUBBER BOX CONTINUED. THE SYSTEM WAS
RESTARTED ON NOVEMBER 19.
A SCREW CONVEYOR MALFUNCTION (PREVENTING CHEMICAL MIXING) RESULTING IN
68 HOURS OF SCRUBBER OUTAGE TIME.
12/76 SYSTEM 99.0 97.0 98.9 97.0 744 744 722
** PROBLEMS/SOLUTIONS/COMMENTS
A BOILER HIGH TEMPERATURE TRIP FORCED THE SCRUBBER OUT OF SERVICE FOR 14
HOURS EARLY IN DECEMBER.
ONE MINOR EIGHT HOUR SCRUBBER OUTAGE OCCURRED WHEN REPAIRS WERE MADE ON
THE ID FAN EXPANSION JOINT.
1/77 SYSTEM 98.3 98.3 98.3 97.1 744 735 723
419
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
NEVADA POWER: REID GARDNER 3 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS OUT OF SERVICE NEARLY NINE HOURS FOR BOILER-RELATED
PROBLEMS.
A PLUGGED TRAY OCCURRED IN JANUARY RESULTING IN 3.5 HOURS OF FGD SYSTEM
OUTAGE TIME.
A REHEATER STEAM LEAK RESULTED IN A MINOR NINE HOUR FGD SYSTEM FORCED
OUTAGE.
2/77 SYSTEM 74.5 69.7 70.0 59.6 672 575 400
*» PROBLEMS/SOLUTIONS/COMMENTS
THREE FORCED SCRUBBER OUTAGES WERF CAUSED BY HIGH DIFFERENTIAL PRESSURE
PROB..EMS IN THE SCRUBBER TRAY AMMOUNTING TO 117 HOURS.
A 54 KOUR OUTAGE WAS REQUIRED TO CLEAN OUT A SODIUM CARBONATE LINE.
3/77 SYSTEM 43.5 !a.6 51.6 43.5 744 627 324
** PROBLEMS/SOLUTIONS/COMMENTS
THE RUBBER LINING IN THE SEPARATOR REQUIRED 167 HOURS OF DOWNTIME IN
MARCH FOR CURING.
THE SCRUBBER FAN EXPANSION JOINT BLEW OUT CAUSING 225 HOURS OF OUTAGE
TIME.
A 25 HOUR OUTAGE WAS REQUIRED TO CLEAN A PLUGGED TRAY.
A SCRUBBER LIMIT SWITCH TRIPPED THE SCRUBBER OFF FOR THREE HOURS DURING
MARCH.
4/77 SYSTEM 85.8 84.6 85.5 83.3 720 709 600
** PROBLEMS/SOLUTIONS/COMMENTS
A HIGH TRAY DIFFERENTAL PRESSURE RESULTED IN 86 HOURS OF FGD SYSTEM
DOWN TIME.
A PLUGGED STRAINER IN THE TRAY RECYCLE TANK OCCURRED CAUSING 16 HOURS OF
OUTAGE TIME.
THE SCRUBBER WAS OFF LINE 18 HOURS FOR BOILER-RELATED PROBLEMS IN EARLY
APRIL.
5/77 5-YSTEM 62.8 26.3 97.7 16.6 744 470 124
<* PROBLEMS/SOLUTIONS/COMMENTS
THE MODULE WAS UNAVAILABLE DURING THE FIRST THREE WEEKS OF THE MONTH
BECAUSE OF A FORCED OUTAGE REQUIRED FOR THE REPLACEMENT OF THE FRP LINER
IN THE SCRUBBER SEPARATOR SECTION. MOST OF THIS SCRUBBER OUTAGE TIME
COINCIDED WITH A BOILER OUTAGE.
APPROXIMATELY 1.4 HOURS OF SCRUBBER OUTAGE TIME WERE REQUIRED TO REWIRE
A REHEATER FAN CIRCUIT BREAKER.
REPAIR OF VENTURI DAMPER CONTROLS REQUIRED 1.5 HOURS OF SCRUBBER OUTAGE
TIME.
6/77 SYSTEM 65.6 64.5 64.8 63.1 720 705 455
420
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
NEVADA POWER: REID GARDNER 3 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
HIGH TRAY DIFFERENTIAL PRESSURE READINGS RESULTED IN 192 HOURS OF SCRUBBER
OUTAGE TIME TO MAKE CORRECTIONS.
A VENTURI RECYCLE LINE THROTTLE VALVE MALFUNCTIONED DURING JANUARY FORCING
THE SCRUBBER OUT OF SERVICE 56 HOURS.
THE SCRUBBER WAS OUT OF SERVICE 18 HOURS BECAUSE OF BOILER-RELATED
PROBLEMS.
7/77 SYSTEM 72.9 72.9 72.9 72.9 744 744 542
** PROBLEMS/SOLUTIONS/COMMENTS
PROBLEMS RELATED TO HIGH DIFFERENTIAL TRAY PRESSURE ACCOUNTED FOR 160
HOURS OF THE JULY SCRUBBER OUTAGE TIME.
REPAIRS TO A VENTURI DISCHARGE VALVE CONTRIBUTED 19 HOURS TO FGD SYSTEM
OUTAGE TIME.
SCRUBBER FAN VIBRATION PROBLEMS CAUSED 23 HOURS OF SCRUBBER OUTAGE TIME.
8/77 SYSTEM 69.7 59.7 62.5 50.4 744 629 375
** PROBLEMS/SOLUTIONS/COMMENTS
PROdLEMS RELATED TO HIGH DIFFERENTIAL PRESSURE READINGS AT THE SCRUBBER
TRAY SECTION CONTINUED INTO EARLY AUGUST AND ACCOUNTED FOR 59 HOURS OF
SCRUJBER OUTAGE TIME.
THE SCRUBBING SYSTEM WAS FORCED OUT OF SERVICE 147 HOURS IN AUGUST TO
MAKE IIEPAIRS MADE NECESSARY BY A VENTURI RECYCLE LINE LEAK.
A SCRUBBER OUTLET HIGH TEMPERATURE FALSE ALARM CAUSED A 19 HOUR SYSTEM
SHUTDOWN.
THE 30ILER WAS OUT OF SERVICE FOR 144 HOURS DURING AUGUST.
9/77 SYSTEM 89.7 89.7 98.8 89.7 720 720 646
** PROBLEMS/SOLUTIONS/COMMENTS
HIGH SOLIDS IN THE VENTURI RECYCLE SYSTEM CAUSED EIGHT HOURS OF SCRUBBER
OUTAGE TIME IN SEPTEMBER.
NEW EFFLUENT AND POST NEUTRALIZATION LINES WERE INSTALLED DURING SEPTEMBER
REQUIRING 66 HOURS OF SCHEDULED SCRUBBER OUTAGE TIME.
10/77 SYSTEM 99.4 90.0 99.0 61.2 744 506 455
** PROBLEMS/SOLUTIONS/COMMENTS
THE SCRUBBER WAS DOWN 284 HOURS DURING OCTOBER BECAUSE OF A SCHEDULED
BOILER OUTAGE.
4.5 HOURS OF OUTAGE TIME OCCURRED AS A RESULT OF HIGH VIBRATION PROBLEMS
ON A SCRUBBER FAN.
11/77 SYSTEM 88.8 88.0 88.6 86.7 720 710 624
421
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
NEVADA POWER: REID GARDNER 3 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE SCRUBBER WAS OUT OF SERVICE 80 HOURS FOR THE INSTALLATION OF AN OUTLET
NOZZLE IN THE BOOSTER TANK.
THE BOILER WAS OUT OF SERVICE APPROXIMATELY 15 HOURS IN NOVEMBER.
12/77 SYSTEM 84.8 90.1 93.1 83.8 744 692 623
** PROBLEMS/SOLUTIONS/COMMENTS
A FAULTY SYSTEM THERMOCOUPLE FORCED THE SCRUBBER OUT OF SERVICE 4.4
HOURS.
BOILER OUTAGE TIME AMOUNTED TO 75 HOURS IN DECEMBER.
THE INSTALLATION OF TRAY SPRAY STRAINER REQUIRED SOME SCRUBBER OUTAGE
TIME.
THE FGD SYSTEM WAS OFF LINE TO INSTALL NEW SENSING LINES.
1/78 SYSTEM 99.5 99.5 99.5 99.5 744 744 740
** PROBLEMS/SOLUTIONS/COMMENTS
A PLUGGED VENTURI NOZZLE RESULTED IN FOUR HOURS OF SCRUBBER OUTAGE TIME
DURING JANUARY.
2/78 SYSTEM 95.5 95.0 95.1 87.5 672 619 588
** PROBLEMS/SOLUTIONS/COMMENTS
A 16 HOUR FGD SYSTEM OUTAGE DUE TO A HIGH VENTURI TEMPERATURE READING
(CAUSED BY FAULTY WIRING) OCCURRED DURING FEBRUARY.
A MINOR 13 HOUR OUTAGE WAS NECESSARY TO CHECK THE VENTURI TEMPERATURE
INDICATOR.
THE FGD SYSTEM WAS FORCED OUT OF SERVICE BY MIX TANK PLUGGING KHICH MADE
IT IMPOSSIBLE TO MIX CHEMICALS IN LATE FEBRUARY.
3/78 SYSTEM 97.3 96.9 97.2 96.5 744 741 718
** PROBLEMS/SOLUTIONS/CLMMENTS
THE MCX TANK PROBLEM WHICH BEGAN IN LATE FEBRUARY CONTINUED INTO MARCH
CAUSING THE ONLY FGD DOWNTIME FOrt THE MONTH. THE MIX TANK OUTAGE FOR
BOTH ilONTHS COMBINED TOTALLED 22 HOURS.
A FURNACE HIGH/LOW PRESSURE TRIP CAUSED A BOILER OUTAGE OF SIX HOURS.
4/78 SYSTEM 97.1 89.3 96.8 87.3 720 705 629
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS DOWN 21 HOURS FOR REPAIRS ON THE VENTURI EMERGENCY
SPRAY SYSTEM.
THE BOILER WAS DOWN APPROXIMATELY 70 HOURS DURING APRIL FOR NON-SCRUBBER
RELATED PROBLEMS.
5/78 SYSTEM 97.4 76.5 96.2 66.4 744 646 494
422
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
NEVADA POWER: REID GARDNER 3 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
*# PROBLEMS/SOLUTIONS/COMMENTS
THERE WAS A SCHEDULED OUTAGE OF 230 HOURS FOR BOILER MAINTENANCE DURING
MAY.
A 20 HOUR SCRUBBER FORCED OUTAGE RESULTED FROM A FAULTY TEMPERATURE PROBE
AT THE VENTURI DURING MAY.
6/78 SYSTEM 95.9 95.6 95.9 95.2 720 715 686
** PROBLEMS/SOLUTIONS/COMMENTS
A HIGH/LOW FURNACE PRESSURE TRIP RESULTED IN A FIVE HOUR BOILER OUTAGE.
A 29 HOUR FGD SYSTEM OUTAGE OCCURRED WHEN THE FIRE SPRAY SYSTEM WAS OUT OF
SERVICE.
7/78 SYSTEM 81.1 80.3 80.5 78.4 744 726 583
** PROBLEMS/SOLUTIONS/COMMENTS
LOW VENTURI FLOW CAUSED A 16 HOUR FGD OUTAGE. THIS WAS CORRECTED WHEN
THE RACE TRACK SPRAY COLLAR AND NOZZLES WERE CLEANED.
A SCHEDULED OUTAGE TO CLEAN THE BOILER TURBINE LUBE OIL COOLERS OCCURRED
DURING JULY TAKING THE SCRUBBER AND BOILER OUT OF SERVICE FOR 20 HOURS.
AN OUTAGE WAS REQUIRED FOR INSPECTION OF THE VENTURI TANK AND VENTURI RACE
TRACK COLLAR. DURING THE OUTAGE THE TANK AND RACE TRACK NOZZLES WERE
CLEANED AND THE RUBBER LINING ON THE VENTURI SPOOL WAS REPLACED.
A 36 HOUR SCRUBBER OUTAGE WAS REQUIRED TO CLEAN THE VENTURI RACE TRACK
SPRAY COLLAR.
8/78 SYSTEM 98.2 97.1 98.2 97.1 744 744 722
** PROBLEMS/SOLUTIONS/COMMENTS
ONE EIGHT HOUR FORCED BOILER OUTAGE OCCURRED DUE TO HIGH FURNACE PRESSURE
READING.
THE SCRUBBER WAS FORCED OFF LINE ON AUGUST 28 DUE TO HIGH SCRUBBER FAN
OUTLET PRESSURE FOR APPROXIMATELY NINE HOURS. THE SCRUBBER PRESSURE
SENSING LINE WAS CLEANED.
ON AUGUST 29 THE SCRUBBER EFFLUENT SOLIDS LEVEL WAS HIGH CAUSING AN OUTAGE
OF APPROXIMATELY FIVE HOURS. THE SYSTEM WAS FLUSHED TO CORRECT THE
PROBLEM.
9/78 SYSTEM 100.0 96.4 100.0 31.6 720 236 228
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS TAKEN OUT OF SERVICE ON SEPTEMBER 10 FOR A TURBINE OVERHAUL
WHICH LASTED THROUGH THE END OF THE MONTH.
10/78 SYSTEM 100.0 .0 744 0 0
** PROBLEMS/SOLUTIONS/CO 1MENTS
THE U«T WAS DOWN THE ENTIRE MONTH OF OCTOBER AS THE TURBINE OVERHAUL
CONTINUED.
11/78 SYSTEM 98.4 92.6 97.6 66.3 720 515 477
423
-------
EPA IT'ILITY FGD SURVEY: OCTOBER - DECEMBER 1980
NEVADA POWER: REID GARDNER 3 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
»* PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS BROUGHT BACK ON LINE NOVEMBER 10 AFTER COMPLETION OF THE
SCHEDULED TURBINE OVERHAUL.
THE FGD SYSTEM WAS OUT OF SERVICE FOR ABOUT 12 HOURS FOR REPAIRING VENTURI
TEMPERATURE PROBES.
12/78 SYSTEM 100.0 100.0 100.0 100.0 744 744 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO FGD SYSTEM OUTAGES OCCURRED DURING DECEMBER.
1/79 SYSTEM 66.4 67.2 67.2 66.4 744 735 494 67.2
** PROBLEMS/SOLUTIONS/COMMENTS
95 HOURS OF SCRUBBER OUTAGE TIME WAS NECESSARY TO REPAIR A HOLE IN THE
VENTURI BOX.
TWO FORCED OUTAGES OCCURRED BECAUSE OF A HIGH EFFLUENT SOLIDS LEVEL. THE
RECYCLE SYSTEM WAS CLEANED. PROBLEMS WITH HIGH EFFLUENT SOLIDS ACCOUNTED
FOR 154 HOURS OF OUTAGE TIME.
2/79 SYSTEM 48.7 45.7 46.7 44.9 672 661 302 57.0
** PROBLEMS/SOLUTIONS/COMMENTS
A STEAM LEAK IN THE SCRUBBER REHEATER COIL RESULTED IN A 54 HOUR SCRUBBER
OUTAGE.
THE FGD SYSTEM WAS OFF FOR A FEW HOURS TO REPAIR A LEAK IN THE VENTURI
LINE.
THE SCRUBBER WAS OUT OF SERVICE 139 HOURS TO REPAIR LEAKS IN EFFLUENT AND
VENTURI LINES.
THE SCRUBBER WAS OFF WITH THE BOILER BECAUSE OF A HIGH FURNACE PRESSURE
BOILER TRIP.
THE VENTURI RACE TRACK NOZZLES WERE CLEANED DURING THE 25 HOUR FEBRUARY
BOILER OUTAGE.
REPAIRS RESULTING FROM A REHEATER FAN BURN UP ACCOUNTED FOR 151 HOURS OF
THE FEBRUARY SCRUBBER OUTAGE TIME.
3/79 SYSTEM 100.0 97.9 100.0 32.3 744 246 241 63.1
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER AND FGD SYSTEM WERE OFF-LINE FOR 39 HOURS SO THAT A BOILER ID
FAN COULD BE REPAIRED AND BALANCED.
THE BOILER AND FGD SYSTEM WERE OFF-LINE 465 HOURS FOR SCHEDULED MAIN-
TENANCE.
4/79 SYSTEM 100.0 100.0 100.0 100.0 720 720 720 74.3
424
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
NEVADA POWER: REID GARDNER 3 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO SCRUBBER OUTAGES OCCURRED DURING APRIL.
5/79 SYSTEM 98.8 97.7 97.7 97.5 744 742 725 79.9
** PROBLEMS/SOLUTIONS/COMMENTS
THE SCRUBBER WAS INADVERTENTLY REMOVED FROM SERVICE. SINCE THE SCRUBBER
WAS NOT OPERATING THE UTILITY TOOK THE OPPORTUNITY TO CLEAN THE SCRUBBER
PRESSURE SENSING LINES. THE SYSTEM WAS OUT OF SERVICE FOR ABOUT 10 HOURS.
THE SCRUBBER PRESSURE SENSING LINES WERE CLEANED AGAIN AFTER A BOILER TRIP
ON HIGH FURNACE PRESSURE. THIS OUTAGE LASTED ABOUT NINE HOURS.
6/79 SYSTEM 94.2 91.3 93.5 83.5 720 659 602 81.9
** PROBLEMS/SOLUTIONS/COMMENTS
77 HOURS OF BOILER OUTAGE TIME WAS REQUIRED DURING JUNE TO REPAIR A BOILER
TUBE LEAK.
THE SCRUBBER WAS OUT OF SERVICE WHILE REPAIRS WERE MADE ON THE FIRE WATER
EMERGENCY SPRAY SYSTEM.
7/79 SYSTEM 93.2 93.2 93.2 93.2 744 744 694 83.8
** PROBLEMS/SOLUTIONS/COMMEtrrS
THE 3A VENTURI RECYCLE PUMP HAD A BAD PUMP CASING LEAK CAUSING ABOUT 50
HOURS OF OFF TIME.
THE 3B VENTURI PUMP WAS OUT OF SERVICE FOR MAINTENANCE.
8/79 SYSTEM 87.6 93.0 92.6 87.6 744 701 652 84.5
** PROBLEMS/SOLUTIONS/COMMENTS
THE SCRUBBER AND BOILER WERE BOTH SHUT DOWN 52 HOURS. THE EXPANSION JOINTS
ON THE BOILER CIRCULATING WATER PUMPS WERE REPLACED.
THE SCRUBBER WAS OFF TO CLEAN TRAY AND VENTURI RACE TRACK NOZZLES. THE
SCRUBBER WAS DOWN FOR ABOUT 31 HOURS.
THE SCRUBBER WAS OFF TO REPAIR BROKEN FIRE LINES. THE SCRUBBER WAS LEFT
WITHOUT AN EMERGENCY SPRAY SYSTEM.
9/79 SYSTEM 100.0 98.8 100.0 90.2 720 658 650 86.1
#* PROBLEMS/SOLUTIONS/COMMENTS
DURING SEPTEMBER THE SCRUBBER WENT OFF LINE WITH THE BOILER TO REPAIR
BOILER TUBE LEAKS.
10/79 SYSTEM 97.2 97.2 97.2 97.2 744 744 723 87.4
** PROBLEMS/SOLUTIONS/COMMENTS
DURING OCTOBER THE SCRUBBER WENT OFF LINE BECAUSE THERE WAS NO EMERGENCY
SPRAY TO THE SCRUBBER. THE 2A LOAD CENTER WAS OUT FOR MAINTENANCE AND
THERE WAS NO POWER TO OPERATE THE FIRE PUMP.
11/79 SYSTEM 100.0 98.7 100.0 80.4 720 587 579 88.0
425
-------
EPA LTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
NEVADA POWER: REID GARDNER 3 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPER4BILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
TWO OUTAGES OCCURRED DURING NOVEMBER DUE TO HIGH FURNACE PRESSURE CAUSING
A BOILER TRIP. THE BOILER TRIP OUTAGES TOTALLED 32 HOURS.
THE SCRUBBER AND BOILER WERE TAKEN OFF LINE ON NOVEMBER 25 FOR SCHEDULED
MAINTENANCE.
12/79 SYSTEM 86.6 72.4 74.8 39.7 744 408 295 87.1
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS OFF FOR THE FIRST TWO WEEKS OF DECEMBER FOR SCHEDULED
MAINTENANCE.
TWO SCRUBBER OUTAGES OCCURRED LATER IN THE MONTH DUE TO THE REHEATER BLOWER
MOTOR BURN OUTS. THESE OUTAGES TOTALLED 100 HOURS.
1/80 SYSTEM 100.0 99.Q 100.0 91.4 744 681 680 99.7
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JANUARY THE SCRUBBER AND BOILER WERE OFF LINE FOR APPROXIMATELY
64 HOURS SO THAT THE BOILER ID FAN COULD BE REPAIRED AND BALANCED.
2/80 SYSTEM 100.0 98.1 1 '.0 77.9 696 552 542 99.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING FEBRUARY THE BOILER AND SCRUBBER WERE OFF LINE ONCE AT THE BEGINNING
AND ONCE AT THE END OF THE MONTH TO BALANCE THE BOILER ID FAN. BOILER ID
FAN BALANCING ACCOUNTED FOR 121 HOURS OF THE SCRUBBER OUTAGE TIME.
THE SCRUBBER AND BOILER WERE TAKEN OFF LINE SO THAT COAL LEAKS ON THE
BURNER LINES COULD BE REPAIRED.
HIGH FURNACE PRESSURE TRIPPED THE BOILER OFF LINE. THIS CAUSED THE
SCRUBBER TO BE OFF LINE FOR SEVEN HOURS.
3/80 SYSTEM 100.0 99.6 100.0 60.J 744 450 448 99.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER AND SCRUBBER WERE TAKEN OFF-LINE TWICE DURING MARCH. THE FIRST
OUTAGE WAS TO BALANCE THE BOILER ID FAN. LATER IN THE MONTH THE ID FANS
AND THE ESPS HAD TO BE REPAIRED. THE BOILER OUTAGES KEPT THE SCRUBBER
OFF-LINE 296 HOURS IN MARCH.
4/80 SYSTEM 100.0 .0 720 0 0
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS AVAILABLE 100X DURING APRIL, HOWEVER, DID NOT OPERATE
DUE TO THE OVERHAUL OF BOTH THE DUST COLLECTOR AND THE ID FAN.
5/80 SYSTEM .0 .0 .0 .0 744 462 0 77.8
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS DOWN THE ENTIRE MONTH FOR THE OVERHAUL OF THE FGD ID
FANS. BECAUSE OF THIS, THE SYSTEM AVAILABILITY WAS ZERO FOR MAY.
6/80 SYSTEM 75.2 81.4 81.4 72.2 720 639 520 78.9
426
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
NEVADA POWER: REID GARDNER 3 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION '/. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE ID FAN OVERHAUL WAS COMPLETED EARLY IN JUNE.
THE BOILER WAS OUT OF SERVICE FOR 21 HOURS.
7/80 SYSTEM 95.7 96.4 95.7 95.2 744 735 721 82.6
** PROBLEMS/SOLUTIONS/CC'MMENTS
BOILER RELATED OUTAGES KEPT THE FSD SYSTEM OFF LINE FOR SEVERAL HOURS.
A HIGH VENTURI OUTLET TEMPERATURE FORCED THE FGD SYSTEM OFF LINE DURING
PART OF JULY.
A HIGH VENTURI OUTLET TEMPERATURE FORCED THE FGD SYSTEM OFF LINE DURING
8/80 SYSTEM 100.0 100.0 100.0 100.0 744 744 744 85.7
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS AVAILABLE DURING ALL OF AUGUST.
9/80 SYSTEM 96.8 96.8 96.8 96.8 720 720 697 87.3
** PROBLEMS/SOLUTIONS/COHMENTS
THE FGD SYSTEM WAS OUT OF SERVICE IN SEPTEMBER BECAUSE OF ROUTINE CLEANING
AND MAINTENANCE.
10/80 SYSTEM 85.0 84.0 84.4 80.7 744 715 600
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS TAKEN OFF-LINE DURING THE BEGINNING OF OCTOBER DUE TO
A SCHEDULED UNIT OUTAGE.
DURING THE MONTH TWO OUTAGES AMOUNTING TO 111 HOURS OF OUTAGE TIME WERE
CAUSED BY PROBLEMS WITH THE REHEATER FAN MOTOR.
11/80 SYSTEM 94.8 100.0 94.8 94.8 720 682 682
** PROBLEMS/SOLUTIONS/COMMENTS
DURING NOVEMBER A SHEARED PIN ON THE AIR PREHEATER COUPLING FORCED THE
SYSTEM OUT OF SERVICE FOR APPROXIMATELY SEVEN HOURS.
PROBLEMS WITH A TUBE LEAK FORCED THE SYSTEM DOWN SO THAT NECESSARY REPAIRS
COULD BE PERFORMED.
12/80 SYSTEM 100.0 95.7 99.5 71.4 744 531 531
** PROBLEMS/SOLUTIONS/COMMENTS
DURING DECEMBER THE SYSTEM WAS SHUTDOWN FOR A SCHEDULED OUTAGE WHICH
LASTED APPROXIMATELY 210 HOURS.
427
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL TATA
FUEL TYPE
FUEL GRADE
AVEFAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/L3
Ai/E&AGE ASH CONTENT - 7.
RANGE ASH CONTENT - Y.
A/EFAGE MOISTURE CONTENT - 7.
RWGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RWGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RXNGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** ESP
NJMBER
TYPE
SUPPLIER
** PARTICLE SCRUBBER
NUMBER
GUNERIC TYPE
SF'ECIFIC TYPE
SfELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
INLET GAS TEMPERATURE - C
*** FGD SYSTEM
** GENIRAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
SO2 REMOVAL MODE
PFCOCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
UNIT DESIGN S02 REMOVAL EFFICIENCY - 7.
CURRENT STATUS
NORTHERN INDIANA PUB SERVICE
DEAN H. MITCHELL
11
GARY
INDIANA
E
43. ( .100 LB/MMBTU)
516. ( 1.200 LB/MMBTU)
****** (****** LB/MMBTU)
505
116
94
108
115
BABCOCK & WILCOX
PULVERIZED COAL
BASE
COAL
******
25586 .
********
( 420000 ACFM)
( 288 F)
( 168 FT)
(***** FT)
( 11000 BTU/LB)
11.00
******
3.50
3.2-3.5
********
******
COLD SIDE
AMERICAN STANDARD
VENTURI TOWER
VARIABLE-THROAT/BOTTOM-ENTRY PLUMB BOB
CARBON STEEL
AISI 1110
1 LEVEL OF SPRAYS
1
142.2 ( 288 F)
SALEABLE PRODUCT
WET SCRUBBING
WELLMAN LORD
DAVY MCKEE
DAVY MCKEE
DEMONSTRATION
RETROFIT
7. 98.50
90.00
1
428
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
NORTHERN INDIANA PUB SERVICE: DEAN H. MITCHELL 11 (CONT.)
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
** ABSORBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
SUPPLIER
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
GAS CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
GAS-SIDE PRESSURE DROP - KPA
INLET GAS FLOW - CU. M/S
S02 REMOVAL EFFICIENCY - X
** REHEATER
GENERIC TYPE
TRADE NAME/COMMON TYPE
TEMPERATURE INCREASE - C
INLET FLUE GAS TEMPERATURE - C
** FANS
NJMBER
FUNCTION
APPLICATION
S£RVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** FA--IS
NJMBFR
FJNCTION
APPLICATION
SER\ ICE
** DUCTkORK
LOCATION
SHELL GENERIC MATERIAL T> PE
LINER GENERIC MATERIAL TYPE
** TANKS
Sr.RVICE
ADSORBER FEED
ABSORBER SURGE
NAC03 MAKEUP
** PUI1PS
SERVICE
DISSOLVING TANK TO ABSORBER FEED TAN
FLYASH PURGE TO POND TRANSFER
AF.SORBER RECIRCULATION
EVAPORATOR-CRYSTALLIZER FEED
SlURRY FEED
** SOIIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
6/77
7/76
6/72
TRAY TOWER
VALVE TRAY
BUBBLE CAP TRAY TOWER
DAVY MCKEE
CARBON STEEL
AISI 1110
N/A
INORGANIC
ACID-RESISTANT BRICK & MORTAR
PREFIRED BRICK
KOCH FLEXITRAY VALVE TRAYS WITH COLLECTOR TRAYS
3.0
198.20
91.0
(12.0 IN-H20)
( 420000 ACFM)
DIRECT COMBUSTION
NATURAL GAS
10.0 ( 50 F)
54.4 ( 130 F)
1
BOOSTER
FORCED DRAFT
DRY
198.20
142.2
( 420000 ACFM)
( 288 F)
INCONEL SHIELDS ON BLADE EDGES
2
BOOSTER
BOILER I.D.
DRY
SCRUBBER INLET
CARBON STEEL
NONE
NUMBER
***•*
****
****
NUMBER
****
****
3
****
**#*
CENTRIFUGE
1
429
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
NORTHERN INDIANA PUB SERVICE: DEAN H. MITCHELL 11 (CONT.)
*** SALEABLE BYPRODUCTS
NATURE
QUALITY - X
** WATER BALANCE
WATER LOOP TYPE
** FGD SPARE CAPACITY INDICES
ABSORBER - X
** FGD SPARE COMPONENT INDICES
ABSORBER
ELEMENTAL SULFUR
99.9
CLOSED
.0
.0
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
11/76 SYSTEM
720
** PROBLEMS/SOLUTIONS/COMMENTS
12/76
1/77
2/77
3/77
4/77
5/77
6/77
7/77
8/77
SYSTEM
SYSTEM
SYSTEM
SYSTEM
Sir STEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
FOLLOWING COMPLETION OF CONSTRUCTION IN MID-1976, START-UP OF THE VARIOUS
SUBSYSTEMS AND COMPONENT PARTS WAS INITIATED. DURING THE JULY THROUGH
NOVEMBER PERIOD, THREE SUSTAINED RUNS OF THE S02 ABSORBER AND REGENERA-
TION SYSTEM UNDER NORMAL OPERATING CONDITIONS WERE ACHIEVED. S02 REMOVAL
EFFICIENCY WAS EQUAL TO OR GREATER THAN THE 90X PERFORMANCE CRITERIA.
THE UNIT 11 BOILER OPERATED 121 FULL DAYS AND 10 PARTIAL DAYS. THE WELL-
MAN LORD S02 RECOVERY UNIT OPERATED 71 FULL DAYS AND 23 PARTIAL DAYS.
DURING THIS PERIOD, NUMEROUS MODIFICATIONS AND CORRECTIONS TO THE SYSTEM
WERE COMPLETED. THESE INCLUDED MODIFYING THE ABSORBER KOCH VALVE TRAYS
TO IMPROVE TURNDOWN, RUBBER LINING THE BOTTOM ABSORBER COLLECTOR TRAY,
RELOCATING AND IMPROVING TEMPERATURE CONTROL OF THE LOW PRESSURE STEAM
SUPPLY, INSTALLING IMPROVED S02 SAMPLE PROBES AND SEVERAL REPLACEMENTS
AND MODIFICATIONS TO THE PURGE SALT RECOVERY AREA. FULLY INTEGRATED
OPERATIONS INCLUDING S02 REDUCTION AND SULFUR RECOVERY OCCURRED IN NOVEM-
BER, 1976. FROM JANUARY THROUGH MAY 1977, THE UNIT 11 BOILER WAS OUT OF
SERVICE FOR ABOUT FIVE MONTHS FOLLOWING A BOILER -RELATED MISHAP WHICH
OCCURRED ON JANUARY 15, 1977 DURING START-UP AFTER A SCHEDULED
MAINTENANCE TURN AROUND.
ON JUNE 13, 1977 FGD OPERATIONS RESUMED FOLLOWING RETURN TO FULL SERVICE
OF THE UNIT 11 BOILER. BY JUNE 15 FULLY INTEGRATED OPERATION OF THE
ENTIRE FGD PLANT WAS ACHIEVED. THROUGH JUNE AND JULY, SEVERAL HUNDRED
HOURS OF TOTAL SYSTEM OPERATION AT BOTH PARTIAL AND FULL LOAD WERE
ACCRUED.
744
672
744
720
744
720
744
89.80 744
430
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
NORTHERN INDIANA PUB SERVICE: DEAN H. MITCHELL 11 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
502 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
PERFORMANCE TESTS COMMENCED ON AUGUST 29, 1977 AND WERE SUCCESSFULLY COM-
PLETED ON SEPTEMBER 14, 1977. THE TEST PERIOD INCLUDED 12 DAYS AT 92 MW
FLUE GAS EQUIVALENT AND 3.5 DAYS AT 110 MW FLUE GAS EQUIVALENT. DURING
THIS PERIOD, 91X OF THE S02 WAS REMOVED WHILE BURNING COAL CONTAINING 3X
SULFUR AND 204 TONS OF ELEMENTAL SULFUR WERE RECOVERED. ALL PERFORMANCE
CRITERIA WERE MET INCLUDING S02 REMOVAL, PARTICULATE EMISSION, RAW
MATERIAL AND UTILITY CONSUMPTIONS AND RECOVERED SULFUR QUALITY. THE FGD
UNIT SHUT DOWN SEPTEMBER 19 AND REMAINED IDLE THROUGH SEPTEMBER 30 DUE TO
COAL FEED PROBLEMS RESULTING FROM WET COAL.
9/77 SYSTEM 720
10/77 SYSTEM 91.00 744
** PROBLEMS/SOLUTIONS/COMMENTS
A DEMONSTRATION PERIOD OF ONE YEAR BEGAN SEPTEMBER 16. IN OCTOBER, THE
FGD UNIT OPERATED 132 HOURS. OPERATIONS WERE INTERUPTED WHILE HEAT BAL-
ANCE TESTS WERE CONDUCTED ON THE BOILER BY NIPSCO AND TRW AND WERE
INTERRUPTED FURTHER TO MAKE REPAIRS TO THE S02 REDUCTION SECTION, THE
EVAPORATOR, AND THE UNIT 11 BOILER.
NOTE: BEGINNING NOVEMBER 1977, PERIOD HOURS REPORTED BY THE UTILITY
WERE GIVEN IN 30 DAY AVERAGES FOR EACH MONTH EXCEPT DECEMBER TO WHICH
ADDITIONAL DAYS ARE ADDED TO BRING THE ANNUAL TO 365 DAYS. FOR THE
PURPOSES OF THIS REPORT INCREMENTED PERIODS CORRESPOND EXACTLY TO
THE APPROPRIATE CALENDAR MONTHS. FOR THIS REASON THE PRINTED UTILIZA-
TION FIGURES WILL NOT BE IDENTICAL TO A FIGURE CALCULATED ON THE
BASIS OF THE PRINTED FGD AND PERIOD HOURS.
11/77 SYSTEM 74.0 72.0 59.0 90.00 720 428
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD UNIT OPERATED FOR 18 CONSECUTIVE DAYS, AVERAGING 90X S02 REMOVAL
WITH 285 LONG TONS OF SULFUR RECOVERED. FGD OPERATION WAS INTERRUPTED BY
BOILER TUBE LEAK AND RESUMPTION OF FGD OPERATION WAS FURTHER DELAYED
BY NECESSARY MAINTENANCE IN THE EVAPORATOR SECTION.
THE FLUE GAS ISOLATION DAMPER NEEDED REPAIRS.
MAINTENANCE WAS PERFORMED ON THE FLUE GAS BOOSTER BLOWER.
THE S02 REDUCTION SECTION REQUIRED MAINTENANCE DURING NOVEMBER.
12/77 SYSTEM 49.0 .0 744 0
** PROBLEMS/SOLUTIONS/COMMENTS
THE FLUE GAS BOOSTER BLOWER MALFUNCTIONED CAUSING MAINTENANCE ATTENTION.
MAINTENANCE WAS PERFORMED ON THE ABSORBER SOLUTION REGENERATION SECTION.
THE FGD SYSTEM WAS NOT OPERATED DURING THIS PERIOD DUE TO ABNORMAL BOILER
OPERATING CONDITIONS RELATED TO HIGH SILICA LEVELS IN THE FEED WATER. THE
HIGH SILICA LEVELS RESULTED FROM HIGH MAKE-UP WATER REQUIREMENTS DUE IN
PART TO A HIGHER THAN NORMAL FGD PLANT USAGE, AS WELL AS A BOILER COAL
FEED PROBLEM AND AN ESP MALFUNCTION.
1/78 SYSTEM 80.0 .0 .0 744 0
431
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
NORTHEPN INDIANA PUB SERVICE'- DEAN H. MITCHELL 11 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
SOa PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM REMAINED DOWN THROUGHOUT JANUARY AS HIGH SILICA LEVELS IN
THE UNIT 11 BOILER FEED WATER PERSISTED.
MAINTENANCE WAS PERFORMED ON THE ESP.
PROBLEMS CONTINUED WITH THE FLUE GAS BOOSTER BLOWER.
THE F6D SYSTEM S02 COMPRESSOR MALFUNCTIONED AND NEEDED MAINTENANCE.
2/78 SYSTEM 47.0 .0 672 0
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS NOT OPERATED DUE TO ABNORMAL BOILER OPERATING
CONDITIONS RELATED TO HIGH SILICA LEVELS IN THE BOILER FEED WATER,
COUPLED WITH UNIT 11 COAL FEED PROBLEMS, STOP VALVE PROBLEMS, AN ESP
MALFUNCTION AND A LEAKING BOILER TUBE.
MAINTENANCE WAS PERFORMED ON THE FLUE GAS BOOSTER BLOWER.
THE FLUE GAS ISOLATION DAMPER WAS REPAIRED DURING FEBRUARY.
THE EVAPORATOR CIRCIRCULATING PUMP NEEDED MAINTENANCE ATTENTION.
THE S02 SUPERHEATER PIPING REPAIRS WERE PERFORMED DURING THE MONTH.
3/78 SYSTEM 90.0 77.0 30.0 744 215
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM OPERATED FOR TEN DAYS. OPERATION WAS INTERRUPTED BY A
SHUTDOWN OF THE UNIT 11 BOILER FOR REPAIR OF COAL GRINDING MILLS AND
ESPS. PROPER CONDITIONS COULD NOT BE RE-ESTABLISHED FOR RE-START
OF THE FGD OPERATION BECAUSE OF COAL FEED AND GRINDING PROBLEMS CAUSED BY
EXTREMELY POOR QUALITY COAL.
MAINTENANCE WAS PERFORMED ON THE BOOSTER BLOWER.
OPERATING PROBLEMS WERE AGAIN ENCOUNTERED WITH THE FLUE GAS ISOLATION
DAMPER.
4/78 SYSTEM .0 .0 .0 720 0
** PROBLEMS/SOLUTIONS/COMMENTS
THE FLUE GAS BOOSTER BLOWER WAS OUT OF SERVICE FOR THIS ENTIRE PERIOD FOR
REBLADING. THE FGD SYSTEM WAS INOPERABLE.
A FAILURE OF THE FLUE GAS ISOLATION DAMPER OCCURRED.
A NEW SUPPLY OF HIGH SULFUR COAL WAS OBTAINED AND SUCCESSFULLY TESTED ON
UNIT 11 BOILER. THIS COAL IS EXPECTED TO ALLEVIATE PAST DIFFICULTIES WITH
THE COAL FEED AND GRINDING SYSTEM.
MAINTENANCE WAS PERFORMED ON THE BOILER ID FANS.
THE FGD ABSORBER REQUIRED MAINTENANCE DURING APRIL.
5/78 SYSTEM 51.0 50.0 37.0 744 263
432
-------
EPA UTILITY j-"GD SURVEY: OCTOBER - DECEMBER 1980
NORTHERN INDIANA PUB SERVICE: T£AN H. MITCHELL 11 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE S02 RECOVERY PORTION OF THE FGD SYSTEM OPERATED FOR 26 DAYS. THE
FGD SYSTEM AS A WHOLE OPERATED FOR 11 DAYS.
FGD OPERATIONS WERE INTERRUPTED BY FAILURE OF THE FLUE GAS ISOLATION DAMP-
ER.
FGD OPERATIONS WERE INTERRUPTED BY PROBLEMS WITH WET COAL WHICH REQUIRED
THE BOILER TO OPERATE ON LOW SULFUR COAL FOR A SHORT PERIOD.
PLUGGING OF AN ENTRAINMENT SEPARATOR IN THE S02 REDUCTION UNIT CAUSED
PROBLEMS DURING MAY.
6/78 SYSTEM 13.0 1.0 .0 720 3
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGO PROCESS FACILITIES, CONSISTING OF THE ABSORBER, EVAPORATOR, S02
REDUCTION AND PURGE TREATMENT UNITS, WERE AVAILABLE FOR OPERATION FOR
ESSENTIALLY THE ENTIRE PERIOD.
OPERATION OF THE FGD SYSTEM WAS LIMITED BY FAILURE OF THE BOOSTER BLOWER
DRIVE TURBINE.
OPERATION OF THE : a SYSTEM WAS LIMITED DUE, IN PART, TO THE INABILITY OF
THE ISOLATION DAMPER TO OPERATE.
7/78 SYSTEM 6.0 4.0 2.0 744 17
** PROBLEMS/SOLUTIONS/COMMENTS
OPERATION OF THE FGD SYSTEM WAS LIMITED BY IMBALANCE OF THE BOOSTER BLOWER
DUE TO INABILITY OF THE ISOLATION DAMPER TO OPERATE. THIS CONDITION
COULD NOT BE CORRECTED UNTIL POWER DEMANDS PERMITTED A SHUT DOWN OF THE
UNIT 11 BOILER. FLUE GAS BOOSTER BLOWER PROBLEMS INCLUDED LOW OIL PRES-
SURE, LEAKING BEARING OIL SEALS AND DRIVE TURBINE GOVERNOR MALFUNCTION.
RECURRING FLUCTUATIONS IN THE PRESSURE OF THE MAIN STEAM SUPPLY TO THE FGD
SYSTEM LIMITED FGD OPERATIONS.
THE FGD PROCESS FACILITIES WERE AVAILABLE FOR OPERATION FOR THE ENTIRE
PERIOD.
8/78 SYSTEM 98.0 98.0 98.0 744 707
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT 11 BOILER OPERATED CONTINUOUSLY ON HIGH SULFUR COAL THROUGHOUT
THE PERIOD. THE FGD SYSTEM ACHIEVED FULL OPERATION ON THE FIRST DAY OF
THE PERIOD. AFTER PROBLEMS WITH THE BOOSTER BLOWER WERE CORRECTED, IT
REMAINED IN FULL OPERATION FOR THE BALANCE OF THE PERIOD WITH THE EXCEP-
TION OF ONE TWO-HOUR INTERRUPTION DUE TO AN ELECTRICAL MOTOR MALFUNCTION.
MINOR BOOSTER BLOWER PROBLEMS OCCURRED OVER THE PERIOD.
9/78 SYSTEM 44.0 99.0 44.0 720 319
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT 11 BOILER OPERATED ON HIGH SULFUR COAL UNTIL SEPTEMBER 12 WHEN IT
WAS SHUT DOWN FOR AN ANNUAL OVERHAUL. THE BOILER REMAINED DOUN THROUGH
THE END OF THE PERIOD. THE FGD SYSTEM CONTINUED IN FULL OPERATION UNTIL
433
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
NORTHERN INDIANA PUB SERVICE: DEAN H. MITCHELL 11 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
SEPTEMBER 12, WITH THE EXCEPTION OF ONE TWO-HOUR INTERRUPTION, AND WAS
THEN 5HUT DOWN CURRENTLY WITH THI: BOILER.
A GOVERNOR MALFUNCTION OCCURRED ON THE SOZ COMPRESSOR DRIVE TURBINE CAUS-
ING / TWO-HOUR OUTAGE ON THE FGD OPERATIONS.
10/78 SYSTEM 44.0 73.0 73.0 44.0 744 506 369
** PROBLEMS/SOLUTIONS/COMMENTS
THIS PERIOD COVERS SEPTEMBER 29 THROUGH NOVEMBER 2. FOLLOWING THE ANNUAL
TURNAROUND, THE UNIT 11 BOILER RESTARTED ON OCTOBER 6. A NEW BASELINE
TEST WAS RUN ON THE BOILER OCTOBER 7 THROUGH 12. BALANCING OF THE FLUE
GAS BOOSTER BLOWER WAS THEN COMPLETED AFTER WHICH THE FGD SYSTEM WAS
STARTED ON OCTOBER 18.
11/78 SYSTEM 99.0 99.0 99.0 98.0 720 716 709
** PROBLEMS/SOLUTIONS/COMMENTS
PROBLEMS WERE ENCOUNTERED WITH THE SODIUM SULFATE PURGE DRYER WHICH
NECESSITATED DISPOSING OF PART OF THE SULFATE PURGE TO THE BOTTOM ASH
POND FOR A PORTION OF THE PERIOD.
THE UNIT 11 BOILER OPERATED CONTINUOUSLY ON HIGH SULFUR COAL EXCEPT FOR
ONE THREE-HOUR OUTAGE FOR REPAIR OF A STEAM CONTROL VALVE. VARIATIONS IN
THE PRESSURE OF THE STEAM SUPPLY TO FGD OCCURRED DUE TO HIGH SILICA IN
THE BOILER MAKE-UP WATER.
12/78 SYSTEM 64.0 72.0 72.0 64.0 744 642 462
•** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS SHUT DOWN FROM DECEMBER 14 TO 17 TO CLEAN THE AIR
PREHEATERS.
THE BOILER OPERATED ON HIGH SULFUR COAL DURING DECEMBER.
AN INSTRUMENT MALFUNCTION DUE TO FREEZING RESULTED IN THE PLUGGING OF A
HEAT EXCHANGER IN THE S02 REGENERATION UNIT. THE FGD SYSTEM WAS DOWN FOR
THREE DAYS WHILE THE HEAT EXCHANGER WAS CLEANED.
1/79 SYSTEM 90.0 28.0 90.0 28.0 744 198
** PROBLEMS/SOLUTIONS/COMtlENTS
THE BOILER OPERATED ON HIGH SULFUR COAL FROM JANUARY 2 THROUGH 14 AND
LOW SULFUR COAL FROM JANUARY 15 THROUGH 31.
INTIGRATED OPERATION OF THE FGD SYSTEM CONTINUED TO JANUARY 10 WHEN THE
S02 REDUCTION UNIT WAS SHUT DOWN FOR REPAIR OF A SULFUR CONDENSER INCLU-
DING CORRECTIVE MEASURES TO AVOID FUTURE PROBLEMS WITH THE CONDENSER.
THE ABSORPTION AND REGENERATION UNITS CONTINUED IN OPERATION TO JANUARY
29 WITH RECYCLE OF S02 TO THE ABSORBER INLET. THE FGD SYSTEM REMAINED
DOWN THROUGH JANUARY 31.
2/79 SYSTEM 7.0 1.0 1.0 1.0 672 500 5
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER OPERATED ON LOW SULFUR COAL FEBRUARY 1 THROUGH 12 AND HIGH
SULFUR COAL FEBRUARY 13 THROUGH MARCH 2. THE FGD SYSTEM REMAINED DOWN
THROUGH FEBRUARY ZZ FOR COMPLETION OF SULFUR CONDENSER REPAIRS FOLLOWED BY
REPAIR OF EXPANSION JOINT LEAKS.
434
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
NORTHERN INDIANA PUB SERVICE: DEAN H. MITCHELL 11 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
______ ______ ____________ ___________ ___________ ___________ _____ _____ _____ ______ _____ ______
A POWER INTERRUPTION ON FEBRUARY 24 RESULTED IN LOSS OF SEAL WATER TO THE
EVAPORATOR PUMP AND PACKING FAILURE. THE FGD SYSTEM REMAINED DOWN THROUGH
MARCH 2.
3/79 SYSTEM 47.0 43.0 44.0 43.0 744 716 308
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER OPERATED ON HIGH SULFUR COAL DURING THE MONTH.
THE FGD SYSTEM WAS SHUT DOWN DUE TO HIGH LEAKING IN THE EVAPORATOR CIR-
CULA-TING PUMP PACKING GLAND. THE f'UMP SHAFT SLEEVE WAS REPLACED AND THE
PUMP REALIGNED. THE SYSTEM WAS DOWN FOR ABOUT 16 DAYS.
4/79 S STEM 73.0 73.0 73.0 73.0 720 722 527
*»: PROBLEMS/SOLUTIONS/CCMMENTS
FGD OUTAGES IN THE EVAPORATOR SYSTEM RESULTED FROM HIGH VIBRATION IN THE
CIRCULATING PUMP, PARTIAL PLUGGING OF THE HEATER TUBES AND A LEAK IN THE
S02 SUPERHEATER. FGD OUTAGES IN THE S02 REDUCTION SYSTEM RESULTED FROM
PLUGGING OF THE TAIL GAS LINE AND MALFUNCTION OF THE INCINERATOR
COMBUSTION CONTROLS.
5/79 SYSTEM 86.0 74.0 76.0 69.0 744 674 499
** PROBLEMS/SOLUTIONS/COMMENTS
FGD OUTAGES IN THE EVAPORATOR SYSTEM RESULTED FROM A CONTINUATION OF THE
CIRCULATING PUMP VIBRATION AND THE S02 SUPERHEATER GASKET LEAK.
BOILER OUTAGES WERE REQUIRED FOR REPAIR OF A BOILER STEAM TUBE LEAK AND
FOR REPAIR OF A STEAM STOP VALVE.
6/79 SYSTEM 91.0 75.0 80.0 63.0 720 607 455
** FROBLEMS/SOLUTIONS/COMMENTS
THE UNIT 11 BOILER OPERATED PART OF THE PERIOD ON HIGH SULFUR COAL AND
PART ON A MIXTURE OF HIGH AND MEDIUM SULFUR COALS.
AN OUTAGE WAS REQUIRED FOR REPAIR OF A REHEAT STOP VALVE AND THE OPERATING
RATE WAS LIMITED DUE TO AN ID FAN BEARING PROBLEM AND A FD FAN FAILURE.
LOW MAIN STEAM PRESSURE AND LOW S02 IN THE FLUE GAS CAUSED FGD OUTAGES.
FGD OUTAGES ALSO RESULTED FROM A FLUE LEAK, A PLUGGED WATER VALVE AND
REPAIR OF AN EXPANSION JOINT.
7/79 SYSTEM 90.0 80.0 82.0 79.0 744 673 538
** PROBLEMS/SOLUTIONS/COMMENTS
UNIT 11 BOILER OPERATED ON HIGH SULFUR COAL. OUTAGES OCCURRED FOR REPACK-
ING OF THE STEAM PRESSURE REGULATOR VALVE WHICH SUPPLIES FGD AND AN ELEC-
TRICAL GROUND SPECIAL TESTING OF THE UNIT 11 FGD SYSTEM WAS CONDUCTED BY
TRW FOR EPA FROM JULY 1 THROUGH 28 WHICH REQUIRED THAT THE BOILER RATE BE
VARIED AND THAT THE S02 REDUCTION UNIT BE DOKN FOR A PORTION OF THE PERIOD.
IN ADDITION TO THE FGD OUTAGE REQUIRED BY THE TRW TESTING, FGD OUTAGES
RESULTED FROM INSPECTION OF THE BOOSTER BLOWER SPEED REDUCER AND HIGH FLOW
RESISTANCE IN THE 502 REDUCTION UNIT.
8/79 SYSTEM 96.0 80.0 80.0 60.0 720 536 429
435
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
NORTHERN INDIANA PUB SERVICE: DEAN H. MITCHELL 11 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
DURING AUGUST THE UNIT 11 BOILER OPERATED ON HIGH SULFUR COAL. BOILER
OUTAGES OCCURRED DUE TO FAILURE OF AN ELECTRICAL BUSS BREAKER AND WATER
HAMMER IN A TURBINE REHEAT LINE.
THE FGD SYSTEM OUTAGES DURING AUGUST RESULTED FROM LOW OIL PRESSURE IN THE
BOOSTER BLOWER LUBE SYSTEM AND HIGH FLOW RESISTANCE IN THE SOS REDUCTION
UNIT.
9/79 SYSTEM 91.0 75.0 75.0 73.0 720 697 523
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE MONTH OF SEPTEMBER THE UNIT 11 BOILER OPERATED ON HIGH SULFUR
COAL. BOILER OUTAGES OCCURRED DUE TO AN ELECTRICAL SYSTEM MALFUNCTION
AND A STEAM LEAK.
FGD OUTAGES DURING SEPTEMBER RESULTED FROM INSTRUMENT AND DRIVE TURBINE
GOVERNOR PROBLEMS WITH THE BOOSTER BLOWER, A LEAK IN THE S02 SUPERHEATER
AND AN INTERRUPTION IN THE INSTRUMENT AIR SUPPLY TO THE SYSTEM.
10/79 SYSTEM 81.0 72.0 72.0 71.0 744 594 428
** PROBLEMS/SOLUTIONS/COriMENTS
THE BCILER OPERATED ON HIGH SULFUR COAL UNTIL OCTOBER 22 WHEN THE UNIT
SHUTDC-JN DUE TO A TURBINE BLADE FAILURE. IT WAS DECIDED TO START THE
ANNUAL TURNAROUND AT THAT TIME.
FGD S- STEM OUTAGES WERE REQUIRED FOR REPAIR OF THE BOOSTER BLOWER
DRIVE GOVERNOR, AN ORFICE CONTACTOR CONTROL VALVE AND A GAS LEAK IN THE
S02 REDUCTION UNIT.
11/79 SYSTEM .0 .0 720 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER AND FGD SYSTEM ANNUAL TURNAROUND WAS IN PROGRESS THROUGHOUT
THE PERIOD. THE FGD SYSTEM WAS UNAVAILABLE THE ENTIRE PERIOD.
12/79 SYSTEM .0 .0 744 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
THE TURNAROUND ON UNIT 11 WAS COMPLETED ON DECEMBER 14, HOWEVER, THE STEAM
SUPPLY TO THE REGENERATION FACILITY WAS NOT AVAILABLE IN DECEMBER. THE
FGD SYSTEM DID NOT OPERATE THE ENTIRE MONTH.
1/80 SYSTEM 17.3 .0 744 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
THE STEAM SUPPLY TO THE REGENERATION FACILITY WAS MADE AVAILABLE ON
JANUARY 15. THE FGD SYSTEM WAS OPERATIONAL ON JANUARY 22 AFTER THE
OVERHAUL OF THE BOOSTER BLOWER DRIVE WAS COMPLETED.
THE REGENERATION FACILITY WAS FORCED OUT SEVERAL TIMES DUE TO PROBLEMS
WITH THE CONDENSATE RETURN.
2/80 SYSTEM 46.3 27.0 26.5 23.3 696 600 162
436
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
NORTHERN INDIANA PUB SERVICE'- DEAN H. MITCHELL 11 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS SHUT DOWN ON FEBRUARY 27 DUE TO A HYDROGEN LEAK.
THE FGD SYSTEM WAS FORCED OUT DUE TO CONTINUED PROBLEMS WITH THE CONDENSATE
RETURN. GAS LEAKS IN THE FLUE AND VESSEL SHELL IN THE S02 REDUCTION UNIT
ALSO CAUSED THE SYSTEM TO GO DOWN.
3/80 SYSTEM 75.4 20.4 24.9 14.5 744 529 108
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS OPERATIONAL ON MARCH 1 AFTER THE HYDROGEN LEAKS WERE
REPAIRED. THE BOILER WAS DOWN FROM MARCH 18 TO 23 SO THAT THE TURBINE
STOP VALVES COULD BE PULLED AND THE HYDROGEN SEALS COULD BE INSPECTED.
THE FGD SYSTEM WAS FORCED OUT OF SERVICE WHEN A COMPRESSOR FAILED AND
AGAIN LATER AFTER AN INSTRUMENT MALFUNCTION. THERE WAS A COMPLETE POWER
IN THE FGD AREA WHICH FORCED THE SYSTEM DOWN FROM MARCH 26 THROUGH 27.
4/80 SYSTEM 63.3 52.6 53.4 50.3 720 702 362
** PROBLEMS/SOLUTIONS/COMMENTS
FGD SYSTEM OPERATIONS DURING APRIL WERE INTERRUPTED BY SULFUR ACCUMULA-
TION AND BLOCKAGE IN THE CLAUS CONVERTER UNIT.
5/80 SYSTEM 62.8 23.5 26.4 15.5 744 490 115
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM REGENERATION FACILITY EXPERIENCED A DRIVE MOTOR FAILURE ON
THE EVAPORATOR CIRCULATING PUMP DURING MAY.
6/80 SYSTEM 53.3 .0 .0 .0 720 211 0
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS OFF LINE MOST OF JUNE DUE TO LOW SYSTEM POWER DEMAND.
THE AVAILABILITY OF THE FGD SYSTEM WAS LIMITED BY PROBLEMS WITH THE
BOOSTER BLOWER DRIVE AND LOOSENINS OF A SUPPORT BEAM IN THE ABSORBER.
7/80 SI STEM 100.0 .0 .0 744 331 0
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER OPERATED ON LOW SULFUR COAL DURING JULY. THE BOILER WAS OFF
LINE FOR APPROXIMATELY 17 DAYS DUE TO LOW SYSTEM POWER DEMAND.
8/80 SYSTEM 83.9 65.6 65.6 31.0 744 352 231
** PROBLEMS/SOLUTIONS/COMMENTS
FROM AUGUST 1 TO AUGUST 13 THE BOILER FIRED LOW SULFUR COAL OR WAS
OPERATED AT LOW LOAD. FGD SYSTEM OPERATION WAS NOT NECESSARY DURING THIS
TIME.
FROM AUGUST 14 TO AUGUST 31, HIGH SULFUR COAL WAS FIRED MAKING FGD
SYSTEM OPERATION NECESSARY. PROBLEMS WITH THE BOOSTER BLOWER WERE
ENCOUNTERED WHEN THE UTILITY ATTEMPTED TO BRING THE SYSTEM ON LINE. THE
BLOWER EXPERIENCED LOW OIL PRESSURE CAUSING THE SYSTEM NOT TO BE OPERABLE
UNTIL AUGUST 19.
437
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EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
NORTHERN INDIANA PUB SERVICE: DEAN H. MITCHELL 11 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
9/80 SYSTEM 68.6 53.1 53.1 45.1 720 612 325
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOOSTER BLOWER BEARING AND GOVERNOR REPAIRS ACCOUNTED FOR SOME OUTAGE
TIME DURING SEPTEMBER.
THE SULFUR CONDENSERS IN THE SOS REDUCTION UNIT WERE AN ADDITIONAL PROBLEM
DURING SEPTEMBER.
10/80 SYSTEM 97.0 90.1 90.1 75.0 744 616 555
** PROBLEMS/SOLUTIONS/COMMENTS
DURING OCTOBER A PROBLEM WAS ENCOUNTERED WITH A LEVEL INDICATOR ON THE FGD
SYSTEM EVAPORATOR CAUSING 25 HOURS OF OUTAGE TIME.
11/80 SYSTEM 100.0 93.9 93.9 86.2 720 661
** PROBLEMS/SOLUTIONS/COMMENTS
DURING NOVEMBER THE UTILITY REPORTED NO MAJOR PROBLEMS WERE ENCOUNTERED
WITH THE FGD SYSTEM.
12/80 SYSTEM 92.5 62.6 62.6 50.1 744 596 373
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS FORCED OUT OF SERVICE DUE TO A HIGH PRESSURE DROP IN
THE S02 REDUCTION CLAUS UNIT AND PROBLEMS WITH THE INCINERATOR INSTRUMENT.
DURING DECEMBER THE BOILER WAS OUT OF SERVICE FOR APPROXIMATELY 148 HOURS
DUE TO CHANGE OVER TO LOW SULFUR COAL.
438
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EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC F6D SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NU"1BER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NS/J
S02 EMISSION LIMITATION - N6/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** MECHANICAL COLLECTOR
NUMBER
TYPE
*» FABRIC FILTER
NUMBER
TYPE
SUPPLIER
INLET FLUE GAS CAPACITY - CU.M/S
PRESSURE DROP - KPA
PARTICLE REMOVAL EFFICENCY - 7.
** ESP
NUMBER
TYPE
** PARTICLE SCRUBBER
GENERIC TYPE
SPECIFIC TYPE
*** FGD SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
NORTHERN STATES POWER
RIVERSIDE
6,7
MINNEAPOLIS
MINNESOTA
E
172.
172.
350
110
103
( .400 LB/MMBTU)
( .400 LB/MMBTU)
(****** LB/MMBTU)
110
BABCOCK £ WILCOX
PULVERIZED COAL
PEAK
320.89
176.7
680000 ACFM)
350 F)
275 FT)
CONCRETE
3.7
COAL
SUBBITUMINOUS
21632.
8.00
7.92-8.08
22.00
20-24
1.20
.9-1.5
0
NONE
REVERSE AIR
JOY MFC
320.9
1.5
99.5
0
NONE
NONE
N/A
THROWAWAY PRODUCT
SPRAY DRYING
LIME/SPRAY DRYING
JOY MFG/NIRO ATOMIZER
BLACK & VEATCH
( 12.0 FT)
( 9300 BTU/LB)
9100-9500
( 680000 ACFM)
( 6.0 IN-H20)
439
-------
EPA UTILITY FGO SURVEY: OCTOBER - DECEMBER 1980
NORTHERN STATES POWER: RIVERSIDE 6,7 (CONT.)
DEVELOPMENT LEVEL
NLW/RETROFIT
Ut'IT DESIGN PARTICLE REMOVAL EFFICIENCY
UNIT DESIGN SOZ REMOVAL EFFICIENCY - 7.
Cl/RRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
** ABSORBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
DIMENSIONS - FT
SHIiLL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
GAS CONTACTING DEVICE TYPE
GAS-SIDE PRESSURE DROP - KPA
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
SOS REMOVAL EFFICIENCY - X
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
** REHEATER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
** FANS
NUMBER
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
CONSTRUCTION MATERIAL GENERIC TYPE
** REAGENT PREPARATION EQUIPMENT
DEVICE
MANUFACTURER
NUMBER
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
MANUFACTURER
NUMBER
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
PRODUCT QUALITY - X SOLIDS
** TANKS
SERVICE
MIXING
** PUMPS
SERVICE
DEMONSTRATION
RETROFIT
7. 99.50
90.00
1
12/80
11/80
10/79
SPRAY DRYER
CROSSFLOW
NIRO ATOMIZER
40' X 105'
STAINLESS STEEL
AUSTENITIC
NONE
N/A
N/A
ATOMIZER
.5
320.89
176.7 '
90.0
NONE
0
0
NONE
N/A
N/A
WESTINGHOUSE
BALANCED DRAFT
INDUCED DRAFT
DRY
160.45 ( 340000 ACFM)
STEEL
BALL MILL
JOY/DENVER
1
9.1
2.0 IN-H20)
680000 ACFM)
350 F)
10 TPH)
SLURRY TRANSFER
LIME SLAKING
SLAKER
JOY/DENVER
1
4.5 (
35.0
NUMBER
Z
NUMBER
5
5 TPH)
440
-------
NORTHERN STATES POWER: RIVERSID," 6,7 (CONT.)
EPA UTILITY FCO SURVEY: OCTOBER - DECEMBER 1980
*** SLUDGE
** TREATMENT
MLTHOD
** DISPOSAL
WTURE
T>PE
LOCATION
SITE TRANSPORTATION METHOD
** PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS
MONITOR LOCATION
PROCESS CONTROL MANNER
PROCESS CHEMISTRY MODE
NONE
FINAL
LANDFILL
OFF SITE
TRUCKED
OUTLET TEMP
DRYER OUTLET
AUTOMATIC
FEEDBACK
------------------------------------------ PERFORMANCE DATA ------------------------------------------
PERIOD '.10DULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S03 PART. HOURS HOURS HOURS FACTOR
11/80 SYSTEM 720
if* PROBLEMS/SOLUTIONS/COMMENTS
OPERATIONS AT THE RIVERSIDE UNIT COMMENCED IN NOVEMBER 1980.
13/80 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE SYSTEM IS PRESENTLY IN THE SHAKEDOWN/DEBUGGING PHASE OF OPERATION.
-------
EPA UTILITY FGO SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NMMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
503 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY •• MW
NET UNIT GENERATING CAPACITY W/CGD - MW
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - 'IW
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
S"'ACK SHELL
STACK TOP DIAMETER - M
** FUIX DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RASGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RAIIGE CHLORIDE CONTENT - X
*** PARTICLE CONTROL
** PARTICLE SCRUBBER
NIT1BER
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
LIQUID RECIRCULATION RATE - LITER/S
L/G RATIO - LITER/CU.M
PRESSURE DROP - KPA
SUPERFICIAL GAS VELOCITY - M/S
INLET GAS FLOW RATE - CU.M/S
INLET GAS TEMPERATURE - C
*** FGD SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
37.
413.
NORTHERN STATES POWER
SHERBURNE
1
BECKER
MINNESOTA
D
( .087 LB/MMBTU)
( .960 LB/MMBTU)
(****** LB/MMBTU)
2191
7*0
700
720
740
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
1349.16 (2659000 ACFM)
154.4 ( 310 F)
198. ( 650 FT)
CONCRETE
9.9 ( 32.6 FT)
COAL
SUBBITUMINOUS
19771.
9.00
Mf
25.00
( 8500 BTU/LB)
.80
******
.03
12
VENTURI TOWER
VARIABLE-THROAT/VERTICALLY-ADJUSTABLE ROD DECKS
COMBUSTION ENGINEERING
3 X 25.5 THROAT (5 SECTIONS OF 3 X5)
STAINLESS STEEL
AUSTENITIC
NONE
N/A
316L SS RODS /CERAMIC NOZZLES
2
223.0 ( 3540 GPM)
2.3 (17.0 GAL/1000ACF)
3.2 (13.0 IN-H20)
24.4 ( 80.0 FT/S)
122.6 ( 259900 ACFM)
154.4 ( 310 F)
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE/ALKALINE FLYASH
NONE
COMBUSTION ENGINEERING
BLACK & VEATCH
442
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
NORTHERN STATES POWER: SHERBURNE 1 (CONT.)
DEVELOPMENT LEVEL FULL SCALE
NEW/RETROFIT NEW
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY - X 99.00
UNIT DESIGN S02 REMOVAL EFFICIENCY - X 50.00
CURRENT STATUS 1
COMMERCIAL START-UP 5/76
INITIAL START-UP 3/76
CONTRACT AWARDED 0/71
** DESIGN AND OPERATING PARAMETERS
SPACE REQUIREMENTS - SQ M
OPER. & MAINT. REQUIREMENT - MANHR/DAY
** ABSORBER
NUMBER
GcNERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
SUPPLIER
DIMENSIONS - FT
SMELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELI MATERIAL TRADE NAME/COMMON TYPE
LIHEF GENERIC MATERIAL
LINER SPECIFIC MATERIAL
LINES MATERIAL TRADE NAME/~OMMON TYPE
G*S CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
DISTANCE BETWEEN SAS CONTACTING ZONES - CM
LIQIID RECIRCULATION RATE - LITER/S
L/G RATIO - L/CU.M
G,iS-SIDE PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/SEC
INLET GAS FLOW - CU. M/S
IIILET GAS TEMPERATURE - C
S')2 REMOVAL EFFICIENCY - X
PARTICLE REMOVAL EFFICENCY - X
** ABSORBER
NUMBER
G:-:NERIC TYPE
SPECIFIC TYPE
SUPPLIER
DIMENSIONS - FT
SKELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER SPECIFIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
L/G RATIO - L/CU.M
GA5-SIDE PRESSURE DROP - KPA
INLET GAS FLOW - CU. M/S
IN'.ET GAS TEMPERATURE - C
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NU11BER PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES PER STAGE
FREEBOARD DISTANCE - M
DISTANCE BETWEEN STAGES - CM
DISTANCE BETWEEN VANES - CM
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/S
CONSTRUCTION MATERIAL GENERIC TYPE
WASH WATER SOURCE
26303.7
150.0
( 283140 SQ FT)
11
PACKED TOWER
STATIC BED PACKING
MARBLE BED SCRUBBER
COMBUSTION ENGINEERING
18 X 26.5 X 60
CARBON STEEL
AISI 1110
N/A
ORGANIC
GLASS FLAKE-FILLED POLYESTER
CEILCOTE FLAKEGLASS
13/16 IN. fiLASS SPHERES
1
10.2
120.
1.3
.5
94.38
54.4
50.0
99.0
( 4.0IN)
( 1900 GPM)
( 10.0 GAL/1000 ACF)
( 2.0 IN-H20)
( 31.0 FT/S)
( 200000 ACFM)
( 130 F)
SPRAY TOWER
STATIC BED PACKING
COMBUSTION ENGINEERING
26 X 18 X 60
CARBON STEEL
AISI 1110
N/A
GLASS FLAKE-FILLED POLYESTER
CEILCOTE FLAKEGLASS
1.3 (10.0 GAL/1000 ACF)
.5 ( 2.0 IN-H20)
94.38 ( 200000 ACFM)
54.4 ( 130 F)
MIST ELIMINATOR
12
IMPINGEMENT
BAFFLE
CHEVRON VANE
HORIZONTAL
2
3
4.27
25.40
10.2
.1
9.4
(14.0 FT)
(10.0 IN)
( 4.00 IN)
( .5 IN-H20)
( 31.0 FT/S)
FIBERGLASS REINFORCED PLASTIC
THICKENER OVERFLOW AND COOLING TOWER SLOWDOWN
443
-------
EPA UTILITY FSB SURVEY: OCTOBER - DECEMBER 1980
NORTHERN STATES POWER: SHERBURHE 1 (CONT.)
** REHEATER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
TEMPERATURE INCREASE - C
INLET FLUE GAS FLOW RATE - CU. H/S
INLET FLUE 6AS TEMPERATURE - C
NUMBER OF TUBES PER BUNDLE
CONSTRUCTION MATERIAL GENERIC TYPE
** FANS
NUMBER
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
»* DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL SEHERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
a* REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
MANUFACTURER
NUMBER
FULL LOAD DRY FEED CAPACirY - M.TONS/HR
PWf'UCT QUALITY - 7. SOLIDS
** TASKS
SERVICE
REACTION
MAKE-UP WATER
S'.URRY MAKE-UP
DILUTION
** PU11PS
SERVICE
POND RETURN
T-ilCKENER UNDERFLOW
MAKE-UP WATER
REHEAT WATER
A3SORBER RECIRCULATION
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
DIMENSIONS - FT
SHELL SPECIFIC MATERIAL TYPE
OUTLET STREAM CHARACTERISTICS
** SOIIDS CONCENTRATINS/DEWATERINS
DEVICE
NUMBER
DIMENSIONS - FT
SH^LL GENERIC MATERIAL TYPE
OUTLET STREAM CHARACTERISTICS
11
IN-LINE
HOT WATER
FIN TUBE
4.4
94.38
54.4
45
CARBON STEEL
( 40 F)
( 200000 ACFM)
C 130 F)
GREEN FAN
BALANCED DRAFT
INDUCED DRAFT
DRY
94.38 C 200000 ACFM)
82.Z ( 180 F)
CARBON STEEL
SCRUBBER INLET
CARBON STEEL
NONE
REHEATER TO STACK
CARBON STEEL
NONE
LIMESTONE GRINDING
BALL MILL
ALLIS CHALMF.RS
1
21.8 C £4 TPH)
60.0
NUMBER
NUMBER
1
I
1
Z
2
THICKENER
1
160 (DIA) X 10 (DEPTH)
CARBON STEEL
28X SOLIDS
THICKENER
1
160 (DIA) X 10 (DEPTH)
CARBON STEEL
£8X SOLIDS
444
-------
NORTHERN STATES POWER: SHERBURNE 1 (CONT.)
EPA UTILITY FGD SURVEY; OCTOBER - DECEMBER 1980
*** SLUDGE
** TREATMENT
METHOD
*» DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE CAPACITY - CU.M
»* PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS
CONTROL LEVELS
PROCESS CONTROL MANNER
PROCESS CHEMISTRY MODE
*« HATER BALANCE
WATER LOOP TYPE
** FSO SPARE CAPACITY INDICES
ABSORBER - X
** FGD SPARE COMPONENT INDICES
ABSORBER
FORCED OXIDATION
FINAL
LINED POND
ON SITE
PUMPED
30575000
( 25000.0 ACRE-FT)
SLURRY PH & SOLIDS/TANK LEVELS/PRESSURE DROP/S02
PRESSURE DROP 12 IN H20, 10X SOLIDS, PH=5-5.5
AUTOMATIC
FEEDBACK
CLOSED
9.0
1.0
. __________ PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
3/76 SYSTEM
4/76 SYSTEM
744
720
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JANUARY A PRELIMINARY SYSTEM CHECKOUT MAS SUCCESFULLY COMPLETED BY
PASSING AIR AND WATER THROUGH THE SYSTEM. THE SCRUBBING SYSTEM BEGAN FGD
OPERATIONS ON MARCH 16. THE SHAKEDOWN PHASE OF OPERATIONS CONTINUED
THROUGH APRIL.
5/76 101
102
103
105
If >6
108
109
120
111
112
SYSTEM
S6.0
62.0
83.0
81.0
59.0
72.0
90.0
57.0
69.0
60.0
75.0
72.0
67.0
77.0
55.0
73.0
72.0
52.0
64.0
80.0
50. '3
61.0
53.0
66.0
64.0
59.0
68.1
744 657
506 57.8
** PROBLEMS/SOLUTIONS/COMMENTS
6/76 SYSTEM
84.0
FIRST COMMERCIAL OPERATION COMMENCED MAY 1, 1976. THIS IS AN INTERMEDIATE
LOAD UNIT OPERATING NEAR FULL CAPACITY DURING THE DAY AND 35X
CAPACITY AT NIGHT.
720 688 69,9
445
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
NORTHERN STATES POWER: SHERBURNE 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
MODIFICATIONS ARE CONTINUING ON THE SPRAY SYSTEM, SPRAY NOZZLES AND
STRAINER SYSTEM.
SINCE APRIL THE UTILITY AND SYSTEM SUPPLIER HAVE BEEN MAKING CONTINUAL
SYSTEM MODIFICATIONS, REQUIRING THE UNIT TO OPERATE AT NO GREATER THAN
80X CAPACITY.
7/76
101
102
103
105
106
107
108
109
110
111
112
SYSTEM
84.0
80.0
62.0
71.0
81.0
80.0
68.0
81.0
75.0
79.0
63.0
91.0
69.0
81.8
55.0
43.0
49.0
56.0
55.0
47.0
56.0
52.0
54.0
43.0
63.0
48.0
56.5
744 512
419 49.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE SLURRY NOZZLES ARE FREQUENTLY PLUGGED BY PARTICLES ABOVE QUARTER INCH
SIZE. STRAINER MODIFICATIONS ARE PUNNED TO ALLEVIATE THIS PROBLEM.
HARD SCALE GYPSUM FORMATION ON THE VESSEL WALLS HAS LEVELED OFF. THE
CLEANING PROCESS CALLS FOR THREE TO FOUR MODULES TO BE TAKEN OUT OF
SERVICE EACH NIGHT. THUS, EACH MODULE IS CLEANED ONCE EVERY THREE DAYS.
A 70-MAN CREW IS REQUIRED TO MAINTAIN SCRUBBER OPERATIONS.
THE DEPOSITION OF SOFT SOLIDS IS STILL CONTINUING IN THE REHEATERS.
SOFT SOLIDS ACCUMULATION IN THE MIST ELIMINATORS IS STILL CAUSING
PROBLEMS.
8/76 101
102
103
104
105
106
107
108
109
110
111
112
SYSTEM
94.0
9/76 101
103
1C4
11.5
106
1(7
IPS
109
46.0
93.0
51.0
84.0
83.0
76.0
71.0
84.0
81.0
76.0
87.0
91.0
83.9
87.0
90.0
93.0
76.0
76.0
79.0
35.0
79.0
85.0
44.0
88.0
48.0
80.0
79.0
72.0
67.0
80.0
77.0
72.0
82.0
86.0
79.6
68.0
71.0
73.0
60.P
60.0
62.0
69.0
62.0
67.0
744 705
592 76.5
446
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
NORTHERN STATES POWER: SHERBURNE 1 (CONT.)
PERFORMANCE DATA
PERIOD 10DULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
110
111
112
SYSTEM
95.0
80.0
92.0
96.0
92.6
63.0
72.0
76.0
73.0
720 566
524 65.6
** PROBLEMS/SOLUTIONS/COMMENTS
THE STRAINER SYSTEM IS BEING MODIFIED. THE DUPLEX UNITS ARE TO BE
REPLACED BY IN-TANK SCREENS AND SOOT BLOWERS. BOTH ARE LOCATED AT THE
SUCTION SIDE OF THE SPRAY WATER PUMP.
CARBON STEEL FIN TUBE REHEAT BUNDLES ARE AN AREA OF CONCERN.
FAILURES IN FOUR UNITS HAVE BEEN EXPERIENCED.
MULTIPLE
10/76
101
102
103
104
105
106
107
108
109
110
111
112
SYSTEM
92.9
97.0
84.0
96.0
96.0
95.0
30.0
74.0
76.0
91.0
81.0
100.0
87.0
91.6
79.0
68.0
78.0
78.0
77.0
24.0
60.0
62.0
74.0
66.0
81.0
71.0
74.4
744 606
554
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY IS CONSIDERING MODIFYING THE DESIGN OF THE SHERBURNE 1 AND
FGD SYSTEMS FROM MARBLE BED TO SPRAY TOWER ABSORBERS. AT PRESENT ONE
MODULE AT SHERBURNE 1 HAS BEEN CONVERTED TO A SPRAY TOWER ON AN EXPER-
IMENTAL BASIS.
11/76
12/76
101
102
103
104
105
106
107
108
109
110
111
112
SYSTEM
101
102
103
104
105
106
107
108
109
110
111
112
SYSTEM
93.0
94.7
83.0
80.0
87.0
79.0
92.0
80.0
93.0
89.0
69.0
78.0
73.0
93.0
90.6
88.0
64.0
87.0
80.0
71.0
97.0
91.0
95.0
94.0
88.0
73.0
75.0
93.0
83.0
80.0
87.0
79.0
92.0
80.0
93.0
89.0
69.0
78.0
73.0
93.0
90.6
85.0
82.0
84.0
78.0
69.0
94.0
88.0
92.0
91.0
85.0
71.0
73.0
90.2
720 720
652 88.4
744 722
671 87.4
447
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
NORTHERN STATES POWER: SHERBURNE 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY IS NOW CONDUCTING A FULL-LOAD EVALUATION STUDY, ANALYZING
SYSTEM OPERATION ON 10 MODULES VS. THE DESIGNED 11 MODULES.
APPROXIMATELY ONE-THIRD OF THE STRAINER MODIFICATIONS ON MODULE 101 ARE
COMPLETED.
THE UNIT IS CURRENTLY HAVING DIFFICULTY COMPLYING WITH THE 20* OPACITY
REGULATION DUE TO THE EXTREMELY FINE FLY ASH BEING EMITTED (70X LESS THAN
1 MICRON).
1/77
2/77
3/77
i02
103
105
106
107
108
109
110
111
112
SYSTEM
101
102
103
104
105
106
107
108
109
110
111
112
SYSTEM
101
102
103
104
105
106
107
108
109
110
111
112
SYSTEM
90.0
91.0
95.0
94.0
75.0
99.0
76.0
96.0
77.0
70.0
92.0
81.0
40.0
75.0
95.0
88.2
89.0
99.0
64.0
96.0
64.0
99.0
81.0
62.0
98.0
93.0
98.0
61.0
91.3
47.0
92.0
95.0
93.0
93.0
95.0
83.0
93.0
95.0
83.0
78.0
72.0
93.1
** PROBLEMS/SOLUTIONS/COMMENTS
77.0
61.0
81.0
62.0
78.0
63.0
57.0
75.0
66.0
33.0
61.0
76.0
71.8
81.0
90.0
58.0
87.0
58.0
90.0
73.0
56.0
89.0
84.0
89.0
55.0
82.7
47.0
92.0
95.0
93.0
93.0
95.0
88.0
93.0
95.0
83.0
78.0
72.0
93.0
744 607
535 70.1
672 609
556 79.5
744 743
692 92.8
ALL MODULES ARE NOW FITTED WITH IN-TANK STRAINERS. LOW JANUARY-MARCH
OPERABILITIES RESULTED FROM COMPLETION OF STRAINER MODIFICATIONS.
4/77
101
102
103
84.4
65.3
92.5
84.2
65.1
92.2
448
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
NORTHERN STATES POWER: SHERBURNE 1 (CONT.)
PERIOD MODULE AVAILABILITY
1C4
105
106
107
108
109
110
111
112
SYSTEM 95.0
5/77 101
102
103
104
105
106
107
103
109
110
ill
112
3YSTEM 92.0
6/77 101
;.02
103
104
105
106
107
108
109
110
111
112
SYSTEM 92.0
OPERABILITY
95.4
96.2
62.2
72.8
91.4
58.5
92.9
90.4
87.9
90.0
96.5
48.1
92.3
87.2
94.9
96.5
81.4
97.8
95.8
77.9
34.9
86.9
90.0
76.0
77.0
75.0
75.0
30.0
87.0
58.0
44.0
61.0
80.0
.0
83.0
67.8
KtKrUKHANUt UAIA
RELIABILITY UTILIZATION
95.1
96.0
62.1
72.6
91.1
58.3
92.6
90.1
87.6
89.7
40.5
20.2
38.7
36.6
39.8
40.5
34.1
41.0
40.2
32.7
14.7
36.4
37.8
26.0
27.0
26.0
26.0
10.0
30.0
20.0
15.0
21.0
28.0
.0
29.0
23.4
X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
720 718 646 86.4
744 312 281 35.6
720 248 168 23.9
** PROBLEMS/SOLUTIONS/COMMENTS
A SCHEDULED TURBINE OVERHAUL LASTED FROM MAY 14 TO JUNE 18.
THE EVALUATION STUDY INITIATED DURING THE NOVEMBER-DECEMBER PERIOD WAS
TEMPORARILY TERMINATED SO THAT STRAINER MODIFICATIONS COULD BE COMPLETED.
THE STUDY SHOULD BEGIN AGAIN IN THE NEAR FUTURE.
7/77
101
102
103
104
105
106
107
108
109
110
111
112
SYSTEM
97.0
93.0
66.0
92.0
90.0
92.0
94.0
91.0
17.0
94.0
83.0
78.0
83.0
88.5
92.0
65.0
91.0
89.0
91.0
93.0
90.0
17.0
93.0
82.0
77.0
82.0
87.5
744 736
651 86.6
449
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
NORTHERN STATES POWER: SHERBURNE 1 (CONT.)
------------------------------------------ PERFORMANCE DATA ------------------------------------------
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROB LEMS/SO LUTIONS/COMMENTS
SOME STAINLWSS STEEL MODIFICATIONS TOOK PLACE.
uE THE UNIT WAS OUT IN JUNE THE FGD SYSTEM WAS CLEANED. THIS CLEANING
WAS CREDITED FOR ONE OF THE HIGHEST AVAILABILITIES EVER DEMONSTRATED ON
THIS UNIT.
8/77
101
1C2
103
104
105
106
107
108
109
110
111
112
SYSTEM
95.0
U9.0
66.0
<>5.0
31.0
90.0
83.0
79.0
72.0
85.0
90.0
66.0
85.6
73.C
77.0
57.0
47.0
70.0
77.0
71.0
68.0
62.0
73.0
77.0
57.0
73.6
74* 640
548 64.9
** PROBLEMS/SOLUTIONS/COMMENTS
ONLY REGULAR MAINTENANCE WAS REQUIRED ON THE FGD SYSTEM IN AUGUST.
9/77
101
102
103
104
105
106
107
108
109
:uo
SYSTEM
95.0
86.0
85.0
88.0
92.0
88.0
44.0
83.0
90.0
84.0
77.0
77.0
82.0
88.7
82.0
81.0
84.0
88.0
84.0
42.0
79.0
86.0
80.0
73.0
73.0
78.0
84.6
720 686
609 78.2
••«* PROBLEMS/SOLUTIONS/COMMENTS
TWENTY-FOUR PUMPS ARE BEING COMPLETELY OVERHAULED.
THE MODULE 106 SPRAY WATER PUMP WAS OVERHAULED IN SEPTEMBER.
SOME ANGLES WERE INSTALLED ON THE PRIMARY CONTACTOR RODS TO RESIST
EROSION.
10/77
101
102
103
104
105
106
107
108
109
110
111
112
SYSTEM
88.0
70.0
81.0
95.0
97.0
63.0
35.0
87.0
99.0
96.0
39.0
58.0
96.0
83.3
57.0
66.0
78.0
79.0
52.0
29.0
71.0
81.0
79.0
32.0
47.0
79.0
68.2
744 609
507 65.5
450
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
NORTHERN STATES POWER: SHERBURNE 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
STRAINER/WASHER SCREEN EROSION HAS BEEN A PROBLEM. REPAIR AND REPLACEMENT
HAS BEEN CONTINUALLY NECESSARY. 3I6L SS MATERIAL WILL BE USED IN THE
FUTURE.
11/77
101
102
103
1.04
105
106
107
108
109
110
111
112
SYSTEM
92.0
77.0
91.0
42.0
86.0
79.0
82.0
87.0
91.0
89.0
89.0
92.0
52.0
87.0
76.0
89.0
41.0
84.0
77.0
80.0
85.0
89.0
87.0
87.0
90.0
51.0
85.1
720 705
613 77.4
** PROBLEMS/SOLUTIONS/CGHMENTS
THE REPLACEMENT PROGRAM WILL BEGIN ON DECEMBER 21, 1977. IT TAKES FOUR TO
SIX DAYS FOR WORK ON EACH MODULE TO REPLACE THE STRAINER SYSTEM.
LOW MODULE OPERABILITIES WERE PRIMARILY A RESULT OF SPRAY WATER PUMP OVER-
HAULS WHICH ARE CONTINUING AT A RATE OF ONE TO TWO A WEEK (THERE ARE 24
PUMPS ON THE SYSTEM).
12/77
101
102
103
104
105
106
107
108
109
110
111
112
SYSTEM
93.0
97.0
90.0
95.0
94.0
71.0
92.0
26.0
67.0
96.0
98.0
95.0
90.0
91.9
73.0
67.0
71.0
70.0
53.0
69.0
20.0
50.0
72.0
74.0
71.0
67.0
68.8
744 557
512 59.0
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE 107 REQUIRED EXTENSIVE MAINTENANCE ALONG WITH DOWNTIME FOR STRAINER
REPLACEMENT.
PUMP OVERHAULS AND REPLACEMENT OF CARBON STEEL STRAINERS WITH 316L SS
WERE PERFORMED ON MODULE 107 IN DECEMBER.
1/78 3.01
:.02
103
104
105
106
107
108
109
110
111
83.0
63.0
88.0
73.0
84.0
84.0
92.0
64.0
91.0
80.0
88.0
72.0
55.0
77.0
64.0
73.0
73.0
80.0
56.0
79.0
70.0
77.0
451
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
NORTHERN STATES POWER: SHERBURNE 1 (CONT.)
PERIOD
2/78
MODULE
112
SYSTEM
101
102
103
104
105
106
107
108
109
110
111
112
SYSTEM
AVAILABILITY OPER ABILITY
82.0
92.0 88.4
.0
93.0
92.0
89.0
74.0
85.0
89.0
88.0
76.0
86.0
83.0
87.0
92.0 86.1
RELIABILITY UTILIZATION
71.0
77.0
.0
88.0
87.0
84.0
70.0
81.0
84.0
83.0
72.0
82.0
83.0
82.0
81.5
X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
744 648 573 68.0
672 636 548 73.6
** PROBLEMS/SOLUTIONS/COMMENTS
MODULES WHICH ARE SHOWING AVAILABILITY OF LESS THAN 80X, ARE
THOSE IN WHICH THE STRAINER MODIFICATIONS WERE PERFOMED.
A BULK ENTRAINMENT SEPARATOR WAS INSTALLED ALONG WITH A KOCH WASH TRAY
DURING THE PERIOD.
MODULE 101 WAS DOWN IN FEBRUARY FOR MODIFICATIONS TO THE SPRAY TOWER
ABSORBER. MODIFICATIONS INCLUDED INSTALLATION OF A NEW PRE-MIST ELIMINA-
TOR (KOCH WASH TRAY), NEW SPRAY NOZZLES AND REPLACEMENT OF TWO INCH
DIAMETER STAINLESS STEEL RODS WITH 6.625-INCH DIAMETER CERAMIC-COATED
CARBON STEEL RODS IN A MODULE PRIMARY CONTACTOR.
3/78 101
102
103
104
105
1C6
107
108
109
110
111
112
4/78
SYSTEM
101
102
103
104
105
106
107
108
109
110
111
112
SYSTEM
92.0
95.0
71.0
83.0
64.0
89.0
^0.0
i»3.0
62.0
i*9.0
97.0
71.0
79.0
90.0
88.0
92.0
87.0
87.0
44.0
81.0
85.0
91.0
86.0
92.0
91.0
87.0
52.0
88.6
65.0
75.0
58.0
81.0
82.C
75. &
56.0
81.0
88.0
65.0
72.0
82.0
80.0
91.0
86,0
86.0
44.0
80.0
84.0
90.0
85.0
91.0
90.0
86.0
52.0
87.7
744 676
595 76.9
720 713
632 87.2
** PROBLEMS/SOLUTIONS/COMMENTS
STRAINER MODIFICATIONS WERE PERFORMED ON MODULES 104 AND 112 WHICH
ACCOUNTED FOR THE LOW MODULE OPERABILITIES.
452
-------
EPA UTILITY FGO SURVEY: OCTOBER - DECEMBER 1980
NORTHERN STATES POWER: SHERBURNE 1 (CONT.)
PERFORMANCE DATA--
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL
S02 PART.
PER BOILER
HOURS HOURS
FGD CAP.
HOURS FACTOR
5/78 101
102
103
104
105
106
107
108
109
110
111
112
SYSTEM
6/78 101
102
103
10*
105
106
107
108
109
110
111
112
SYSTEM
7/78 101
102
103
104
105
106
107
108
109
110
111
112
SYSTEM
95.0
93.0
95.0
61.0
86.0
85.0
86.0
89.0
64.0
62.0
83.0
82.0
71.0
87.0
79.0
65.0
50.0
84.0
85.0
85.0
62.0
78.0
55.0
83.0
88.0
82.0
72.0
95.0
83.6
82.0
76.0
71.0
74.0
75.0
52.0
75.0
63.0
62.0
72.0
66.0
73.0
76.5
** PROBLEMS/SOLUTIONS/COMMENTS
52.0
73.0
73.0
73.0
76.0
55.0
53.0
71.0
70.0
61.0
74.0
67.0
72.6
50.0
84.0
84.0
84.0
62.0
78.0
55.0
83.0
87.0
82.0
72.0
94.0
83.2
76.0
71.0
66.0
69.0
70.0
49.0
70.0
59.0
58.0
67.0
62.0
68.0
71.4
744 635
540 69.0
720 717
599 77.8
744 694
531 71.7
THE OCCURRANCE OF PLUGGING PROBLEMS IN THE MIST ELIMINATOR HAS BEEN MORE
FREGj'JENT THAN NORMAL.
THE STRAINER MODIFICATIONS CONTOTJED IN JUNE AND JULY.
THE UTILITY IS EVALUATING NEW RU3BER LINED PUMPS (8000 GPM) TO HELP
CORRECT THE REHEATER AND MIST ELIMINATOR PLUGGING PROBLEMS.
THE OCCURANCE OF PLUGGING PROBLEMS IN THE REHEATER HAS BEEN MORE
FREQUENT THAN NORMAL
THE UTILITY IS PREPARING FOR THE STATE COMPLIANCE DEADLINE ON NOVEMBER 1,
1978. CURRENTLY TESTING HAS BEEN PROCEEDING ON DIFFERENT MODULES IN AN
EFFORT TO FINE TUNE THE SYSTEM.
THE FGD SYSTEM HAS BEEN EXPERIENCING PRIMARY CONTACTOR WALL AND MARBLE BED
WEAR.
THE UTILITY IS EVALUATING NEW STAINLESS STEEL MIST ELIMINATOR WASH
453
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
NORTHERN STATES POWER: SHERBURNE 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
LANCES (REPLACING THE ORIGINAL FIBERGLASS LANCES) TO HELP CORRECT THE
REHEATER AND MIST ELIMINATOR PLUGGING PROBLEMS. THE FIBERGLASS WASH
LANCES RUPTURE DURING PRESSURE SURGES.
8/78 101
102
103
104
105
106
107
108
109
110
111
112
SYSTEM
9/78 101
102
103
104
105
106
107
108
109
110
111
112
SYSTEM
91.0
97.0
64.0
65.0
73.0
63.0
65.0
80.0
81.0
73.0
63.0
73.0
64.0
83.0
77.0
89,0
62.0
77.0
77.0
58.0
82.0
68.0
68.0
80.0
80.0
55.0
75.0
79.2
64.0
65.0
73.0
63.0
65.0
79.0
80.0
73.0
63.0
72.0
64.0
83.0
76.7
44.0
31.0
38.0
38.0
29.0
41.0
34.0
34.0
40.0
40.0
27.0
37.0
39.4
744 742
571 75.7
720 357
283 34.9
** PROBLEMS/SOLUTIONS/COMMENTS
DIFFERENT MIST ELIMINATOR SPRAY PATTERNS ARE BEING TESTED AS POSSIBLE
SOLUTION TO THE MIST ELIMINATOR PLUGGING PROBLEM REFERRED TO IN JULY.
THE BOILER WAS TAKEN OFF LINE ON SEPTEMBER 15, 1978 FOR A SCHEDULED
ANNUAL BOILER AND TURBINE INSPECTION. THE BOILER CAME BACK ON LINE IN
THE MIDDLE OF OCTOBER.
THE RUBBER LINED PUMPS THAT THE UTILITY WAS INVESTIGATING IN JULY, 1978
HAVE BEEN ORDERED. FOUR OF THE PUMPS HAVE BEEN RECEIVED AND ONE IS
INSTALLED. THE OTHERS WILL BE INSTALLED AS THEY ARE RECEIVED.
10/78 101
102
103
104
105
106
107
108
109
110
111
112
SYSTEM
92.0
95.0
65.0
80.0
17.0
66.0
88.0
53.0
72.0
88.0
70.0
85.0
73.0
77.5
48.0
33.0
40.0
9.0
33.0
45.0
27.0
36.0
44.0
35.0
43.0
37.0
39.1
744 375
291 35.6
** PROBLEMS/SOLUTIONS/COMMENTS
MODULES 104 AND 107 WERE DOWN IN OCTOBER AND MODULE 110 HAS DOWN IN OCTO-
BER A-ID NOVEMBER FOR THE INSTALLATION OF THE NEW 8000 GPM SPRAY PUMPS
MENTIONED EARLIER.
454
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
NORTHERN STATES POWER: SHERBURNE 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
THE BOILER AND SCRUBBER SHOWED LOW OPERATING HOURS FOR OCTOBER BECAUSE
THE BOILER/TURBINE OVERHAUL CONTINUED THROUGH THE FIRST HALF OF OCTOBER.
11/78
101
102
103
104
105
106
107
108
109
110
111
lie
SYSTEM
92.0
42.0
51.0
88.0
81.0
71.0
78.0
77.0
63.0
85.0
61.0
84.0
70.0
77.4
42.0
51.0
87.0
80.0
70.0
77.0
76.0
63.0
84.0
61.0
83.0
70.0
76.7
720 714
552 76.2
** PROBLEMS/SOLUTIONS/COMMENTS
IN NOVEMBER MODULE 101 MAS DOWN (THE CONVERTED ROD SCRUBBER TEST MODULE)
FOR PUMP WORK AND INTERNAL HEADER CONVERSION. THE MODULE IS BEING
PREPAIRED FOR FURTHER TESTING.
12/78
1/79
101
102
103
104
105
106
107
108
109
110
111
112
SYSTEM
101
102
103
104
105
106
107
108
109
110
111
112
SYSTEM
94.0
94.0
77.0
73.0
77.0
73.0
86.0
87.0
93.0
85.0
93.0
86.0
90.0
88.0
91.6
72.0
39.0
76.0
95.0
73.0
95.0
81.0
89.0
96.0
92.0
83.0
93.0
89.5
76.0
72.0
76.0
72.0
85.0
86.0
91.0
84.0
91.0
85.0
89.0
87.0
90.4
66.0
36.0
70.0
88.0
68.0
88.0
75.0
82.0
89.0
85.0
77.0
86.0
82.7
744 733
672 73.4
744 688
615 63.2
*# PROBLEMS/SOLUTIONS/COMMENTS
THERE WERE PROBLEMS WITH THE COAL FEEDER BELTS RESULTING IN MOVING WET
COAL FROM OLDER COAL STOCKPILES TO THE BOILER DURING THE DECEMBER-JANUARY
PERIOD.
THE TESTING ON MODULE 101 HAS BEEN COMPLETED BUT NO RESULTS ARE YET
AVAILABLE.
THE PROBLEMS ENCOUNTERED WERE MAINLY WEATHER RELATED IN DECEMBER AND
JANUARY.
2/79 101
78.0
78.0
455
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
NORTHERN STATES POWER: SHERBURNE 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTO
102
103
104
105
106
107
108
109
110
111
112
SYSTEM 89.0
73.0
70.0
76.0
50.0
91.0
92.0
92.0
75.0
77.0
66.0
93.0
84.8
73.0
70.0
76.0
50.0
88.0
92.0
92.0
75.0
77.0
66.0
93.0
84.8 672 672 570 64.2
3/79
101
102
103
104
105
106
107
108
109
110
111
112
SYSTEM
92.0
61.0
88.0
45.0
86.0
94.0
71.0
91.0
73.0
91.0
80.0
89.0
80.0
86.3
60.0
87.0
44.0
85.0
93.0
70.0
90.0
72,0
90.0
79.0
88.0
79.0
85.2
744 734
634 56.2
** PROBLEMS/SOLUTIONS/COMMENTS
THE ONLY MAJOR PROBLEMS REPORTED BY THE UTILITY DURING FEBRUARY AND MARCH
WERE BOILER REUTED-SPECIFICALLY PROBLEMS WITH WET COAL.
CURRENTLY THE UTILITY IS INCREASING THE RECYCLE PUMP CAPACITY BY INSTAL-
LING 8000 GPM WORTHINGTON RECYCLE PUMPS. DURING THIS PERIOD THEY HAVE
BEEN INSTALLED ON MODULES 101,103,104,105,107, AND 110.
4/79 SYSTEM
93.0
7EO
622
64.7
»* PROBLEMS/SOLUTIONS/COMMENTS
AS OF NOVEMBER 1979 THE UTILITY DECIDED THAT IT WILL NO LONGER REPORT
MODULAR INFORMATION.
5/79 SYSTEM 98.0
** PROBLEMS/SOLUTIONS/COMMENTS
744 678
70.1
THE UTILITY REPORTED THAT NO FGD SYSTEM PROBLEMS OCCURRED DURING APRIL OR
MAY.
6/79 SYSTEM 93.0
** PROBLEMS/SOLUTIONS/COMMENTS
720 701
70.0
THE UTILITY REPORTED THAT SOME GENERAL PLUGGING WAS EXPERIENCED DURING
JUNE BUT IT WAS NOT SERIOUS.
7/79 SYSTEM 93.0 744 695 72.0
8/79 SYSTEM 95.0 744 744 74.4
9/79 SYSTEM 92.0 720 166 17.1
456
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
NORTHERN STATES POWER: SHERBURNE 1 (CONT.)
PERFORMANCE DATA
PERIOD MOPULE AVAILABILITY OPFiRABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
SOS PART. HOURS HOURS HOURS FACTOR
*>f PROBLEMS/SOLUTIONS/C01MENTS
ON SEPTEMBER 8 THE UNIT WENT DOWN FOR THE ANNUAL BOILER/TURBINE INSPECTION
AND I'o EXPECTED TO BE OFF LINE UNTIL THE LAST WEEK OF OCTOBER.
10/79 SYSTEM 77.0 744 9 .0
11/79 SYSTEM 97.0 730 522 58.6
12/79 SYSTEM 95.0 744 744 82.3
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS SUPPOSED TO BE BACK ON LINE IN OCTOBER AFTER THE ANNUAL
BOILER/TURBINE INSPECTION, BUT CONTAMINANTS IN THE MAIN TURBINE OIL MADE
IT NECESSARY TO CONTINUE THE OUTAGE UNTIL THE SECOND WEEK OF NOVEMBER.
PRESENTLY THE UTILITY IS SELECTIVELY REMOVING MARBLE BEDS FROM SERVICE
TO TEST THE FEASIBILITY OF CONVERTING THE FGD MODULES TO SPRAY TOWERS.
ALL PIPING HAS BEEN CONVERTED FROM CARBON STEEL TO FIBERGLASS.
1/80 SYSTEM 97.0 744 793 90.8
2/80 SYSTEM 97.0 696 687 66.2
3/80 SYSTEM 98.0 744 685 84.1
»* PROBLEMS/SOLUTIONS/COMMENTS
DURING THE FIRST QUARTER OF 1980 NO MAJOR PROBLEMS WERE ENCOUNTERED WITH
THE FGD SYSTEM.
FROM MID-SEPTEMBER TO MID-OCTOBER THE UTILITY HAS SCHEDULED A BOILER
OUTAGE AT WHICH TIME THE MARBLE BEDS WILL BE INSPECTED.
THE UTILITY HAS DECIDED TO CONVERT THE ENTIRE MARBLE BED SCRUBBING SYSTEM
TO A SPRAY TOWER SYSTEM BY REMOVING THE MARBLE BEDS AND MODIFYING THE SPRAY
ARRANGEMENT. TESTS CONDUCTED IN 1978 AND 1979 SHOW THAT MOST OF THE S02
IS COLLECTED IN THE VENTURI SECTION OF THE SCRUBBING TRAINS AND THAT
ALTHOUGH THE MARBLE BEDS IN THE ABSORBER SECTIONS IMPROVE INTIMATE S02/
SLURRY MIXING, S02 REMOVAL EFFICIENCY OF THE SCRUBBING TRAINS IS NOT
MARKEDLY DIFFERENT WHEN MARBLE BEDS ARE REMOVED.
4/80 SYSTEM 97.0 720 720 79.4
5/80 SYSTEM 96.0 744 720 78.1
6/80 SYSTEM 96.0 720 697 74.7
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR OPERATIONAL PROBLEMS WERE REPORTED DURING THE SECOND QUARTER
OF 1980.
7/80 SYSTEM 100.0 100.0 100.0 100.0 744 744 744 82.1
** PROBLEMS/SOLUTIONS/COMMENTS
NO OPERATIONAL PROBLEMS WERE ENCOUNTERED IN JULY.
8/80 SYSTEM 100.0 100.0 100.0 99.2 744 738 738 69.1
457
-------
EPA UTILITY FED SURVEY: OCTOBER - DECEMBER 1980
NORTHERN STATES POWER: SHERBURNE 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
— — — — — — — — — — — — — — .-_ — — — —_ — — — — — — — — .- — — — — _ — — — — — — — — — —— — — — — ,. — — — — — .. — — — — — — — — _— — — — — _ — — — — ..— — —— — — _ — _ — — >.
** PROBLEMS/SOLUTIONS/COMMENTS
THERE WERE TWO SHORT TERM OUTAGES IN JULY DUE TO BOILER RELATED TRIPS.
9/80 SYSTEM 100.0 100.0 100.0 99.6 730 717 717 76.8
** PROBLEMS/SOLUTIONS/COMMENTS
A BCILER RELATED PROBLEM CAUSED THE ONLY OUTAGE TIME IN SEPTEMBER.
10/80 SYSTEM 100.0 100.0 71.9 744 535 535 57.7
11/80 SVSTEM 100.0 .0 .0 720 0 0 .0
12/80 SYSTEM 100.0 100.0 100.0 81.0 744 603 603 51.1
*» PROBLEMS/SOLUTIONS/crMMENTS
DURIHG THE OCTOBER-DECEMBER PERIOD THE UNIT WAS SHUTDOWN FOR THE ANNUAL
BOILER/TURBINE INSPECTION. THE OUTAGE EXTENDED LONGER THAN EXPECTED
DUE TO SOME BOILER TUBE LEAKS.
DURING THE ANNUAL BOILER/TURBINE INSPECTION GENERAL MAINTENANCE WAS PER-
FORMED ON THE SCRUBBING SYSTEM. THE MAINTENANCE INCLUDED THE OVERHAUL
OF THE SPRAY PUMPS AND THE REBUILDING OF THE PC RODS.
458
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC F6D SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY M/FGD - MM
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FJEL GRADE
AVERAGE HEAT CONTENT - J/6
R4NGF HEAT CONTENT - BTU/IB
AVERAGE ASH CONTENT - 7.
RANPE ASH CONTENT - '/.
AVEf AGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - '/.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PAFJTICLE CONTROL
** PAP.TICLE SCRUBBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
Nl'MBER OF CONTACTING ZONES
LIQUID RECIRCULATION RATE - LITER/S
L/G RATIO - LITER/CU.M
PRESSURE DROP - KPA
SUPERFICIAL GAS VELOCITY - M/S
INLET GAS FLOW RATE - CU.M/S
INLET GAS TEMPERATURE - C
*** FGD SYSTEM
** GEN'-IRAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
NORTHERN STATES POWER
SHERBURNE
Z
BECKER
MINNESOTA
D
37.
( .087 LB/MMBTU)
( .960 LB/MMBTU)
(****** LB/MMBTU)
2191
740
700
720
740
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
1349.16 (2859000 ACFM)
154.4 ( 310 F)
198. ( 650 FT)
CONCRETE
9.9 ( 32.6 FT)
COAL
SUBBITUMINOUS
19771.
9.00
******
25.00
******
.80
******
.03
( 8500 BTU/LB)
******
12
VENTURI TOWER
VARIABLE-THROAT/VERTICALLY-ADJUSTABLE ROD DECKS
COMBUSTION ENGINEERING
3 X 25.5 THROAT (5 SECTIONS OF 3X5)
STAINLESS STEEL
AUSTENITIC
NONE
N/A
316L SS RODS/CERAMIC NOZZLES
2
223.0 ( 3540 GPM)
2.3 (17.0 GAL/1000ACF)
3.2 (13.0 IN-H20)
24.4 ( 80.0 FT/S)
122.6 ( 259900 ACFM)
154.4 ( 310 F)
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE/ALKALINE FLYASH
NONE
COMBUSTION ENGINEERING
BLACK & VEATCH
459
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
NORTHERN STATES POWER: SHERBURNE 2 (CONT.)
DEVELOPMENT LEVEL FULL SCALE
NEW/RETROFIT NEW
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY - X 99.00
UNIT DESIGN S02 REMOVAL EFFICIENCY - X 50.00
CURRENT STATUS 1
COMMERCIAL START-UP 4/77
INITIAL START-UP 3/77
CONTRACT AWARDED 0/71
** DESIGN AND OPERATING PARAMETERS
SPACE REQUIREMENTS - SQ M
OPER. & MAINT. REQUIREMENT - MANHR/DAY
** ABSORBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
GAS CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
DISTANCE BETWEEN GAS CONTACTING ZONES - CM
LIQUID RECIRCULATION RATE - LITER/S
L/G RATIO - L/CU.M
GAS-SIDE PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/SEC
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
S02 REMOVAL EFFICIENCY - X
PARTICLE REMOVAL EFFICENCY - 7,
** MIST ELIMINATOR
PrtE-MIST ELIMINATOR/MIST ELIMINATOR
NJMBER PER SYSTEM
Ei-INERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
NUMBFR OF STAGES
NUMBER OF PASSES PER STAGE
FREEBOARD DISTANCE - M
DISTANCE BETWEEN VANES - CM
PRESSURE DROP - KPA
SIPE'JFICAL GAS VELOCITY - 1/S
CONSTRUCTION MATERIAL GENERIC TYPE
W*<.SH WATER SOURCE
** REhEATER
NUMBER
GtNERIC TYPE
SPECIFIC TYPE
TK'AOE NAME/COMMON TYPE
TLMPERATURE INCREASE - C
INLET FLUE GAS FLOW RATE - CU. M/S
INLET FLUE GAS TEMPERATURE - C
NUMBER OF TUBES PER BUNDLE
CONSTRUCTION MATERIAL GENERIC TYPE
26303.7
150.0
** FANS
NUMBER
SUPPLIER
FUNCTION
APPLICATION
SERVICE
( 2831*0 SQ FT)
12
PACKED TOWER
STATIC BED PACKING
MARBLE BED SCRUBBER
COMBUSTION ENGINEERING
18 X 26.5 X 60
CARBON STEEL
AISI 1110
N/A
ORGANIC
GLASS FLAKE-FILLED POLYESTER
CEILCOTE FLAKEGLASS
13/16 IN. GLASS SPHERES
1
10.2
120.
1.3
94.38
54.4
50.0
99.0
( 4.0IN)
( 1900 GPM)
( 10.0 GAL/1000 ACF)
( 2.0 IN-H20)
( 31.0 FT/S)
( 200000 ACFM)
( 130 F)
MIST ELIMINATOR
12
IMPINGEMENT
BAFFLE
CHEVRON VANE
HORIZONTAL
2
3
4.27 (14.0 FT)
10.2 ( 4.00 IN)
.1 ( .5 IN-H20)
9.4 ( 31.0 FT/S)
FIBERGLASS REINFORCED PLASTIC
THICKENER OVERFLOW AND COOLING TOWER SLOWDOWN
11
IN-LINE
HOT WATER
FIN TUBE
4.4
94.38
54.4
45
CARBON STEEL
( 40 F)
( 200000 ACFM)
( 130 F)
GREEN FAN
BALANCED DRAFT
INDUCED DRAFT
DRY
460
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
NORTHERN STATES POWER: SHERBURNE Z (CONT.)
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
MANUFACTURER
NUMBER
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
PRODUCT QUALITY - X SOLIDS
** TANKS
SERVICE
REACTION
MAKE-UP WATER
SLURRY MAKE-UP
DILUTION
** PUMPS
SERVICE
POND RETURN
THICKENER UNDERFLOW
MAKE-UP WATER
REHEAT WATER
SCRUBBER RECIRCULATION
ABSORBER RECIRCULATION
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
DIMENSIONS - FT
OUTLET STREAM CHARACTERISTICS
*** SL'JDGE
** TREATMENT
METHOD
** DISPOSAL
NATURE
TfPE
LOCATION
S^TE TRANSPORTATION METHOD
S.'.TE CAPACITY - CU.M
** PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS
CONTROL LEVELS
PPOCESS CONTROL MANNER
PROCESS CHEMISTRY MODE
** WATER BALANCE
WATER LOOP TYPE
82.2
CARBON STEEL
( 200000 ACFM)
( 180 F)
SCRUBBER INLET
CARBON STEEL
NONE
REHEATER TO STACK
CARBON STEEL
NONE
LIMESTONE GRINDING
BALL MILL
ALLIS CHALMERS
1
21.8 ( 24 TPH)
60.0
NUMBER
NUMBER
1
1
1
2
2
12
THICKENER
1
160 (OIA) X 10 (DEPTH)
28X SOLIDS
FORCED OXIDATION
FINAL
LINED POND
ON SITE
PUMPED
30575000
t 25000.0 ACRE-FT)
SLURRY PH 8 SOLIDS/TANK LEVELS/PRESSURE DROP/S02
PRESSURE DFOP 12 IN H20, 10X SOLIDS, PH=5-5.5
AUTOMATIC
FEEDBACK
OPEN
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
NORTHERN STATES POWER: SHERBURNE 2 (CONT.)
** FED SPARE CAPACITY INDICES
ABSORBER - X
** FGD SPARE COMPONENT INDICES
ABSORBER
9.0
1.0
PERIOD
4/77
MODULE AVAILABILITY
Z01
202
203
204
205
206
207
208
209
210
211
212
SYSTEM 92.0
OPER ABILITY
.0
95.0
93.3
87.4
82.6
83.8
93.7
73.9
90.5
86.8
84.7
85.5
87.0
HCKrUKnANUt UAIA
RELIABILITY UTILIZATION
.0
91.9
90.3
84.6
80.0
81.1
90.7
71.5
87.6
84.0
81.9
82.8
84.2
•/. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
720 697 590 83.0
5/77
201
202
203
204
205
206
207
208
209
210
211
212
SYSTEM
91.0
32.9
100.0
44.4
94.6
93.9
100.0
75.9
98.0
93.9
92.2
91.2
97.8
92.3
28.5
86.6
38.4
81.9
81.3
86.6
65.7
84.8
81.3
79.6
78.9
64.7
79.9
744 644
594 76.5
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM BEGAN OPERATIONS IN APRIL 1977. ONLY MINOR PROBLEMS
OCCURRED DURING APRIL AND MAY. THE SYSTEM IS CURRENTLY IN A SHAKEDOWN
PHASE OF OPERATION.
6/77
201
202
203
204
205
206
207
208
209
210
211
£12
SYSTEM
96.0
92.0
76.0
78.0
79.0
89.0
74.0
67.0
88.0
88.0
78.0
45.0
85.0
85.4
92.0
76.0
78.0
79.0
89.0
74.0
67.0
88.0
88.0
78.0
45.0
85.0
85.4
720 720
615 79.5
** PROBLEMS/SOLUTIONS/COMMENTS
CRACKING AND BUBBLING OF THE CEILCOTE LINING HAS BEEN OBSERVED ABOVE THE
LIQUID LEVEL OF THE INTERNAL RECYCLE TANK.
7/77
201
202
203
96.0
87.0
86.0
78.0
70.0
70.0
462
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
NORTHEPN STATES POWER: SHERBURNE Z (CONT.)
PERIOD MODULE AVAILABILITY
204
205
206
207
208
;>09
,!10
idll
j:i2
SYSTEM 97.0
8/77 201
202
203
20*
205
206
207
203
209
210
211
212
SYSTEM 93.0
OPERABILITY
97.0
96.0
88.0
88.0
95.0
57.0
93.0
94.0
87.0
96.7
88.0
75.0
67.0
82.0
84.0
35.0
81.0
80.0
56.0
79.0
71.0
33.0
75.6
HtKI-UKnANUt UAIA
RELIABILITY UTILIZATION
79.0
78.0
71.0
71.0
77.0
46.0
75.0
76.0
70.0
78.3
80.0
68.0
61.0
74.0
76.0
32.0
74.0
73.0
51.0
72.0
64.0
30.0
68.6
X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
744 602 531 69.6
744 675 510 66.6
** PROBLEMS/SOLUTIONS/COMMENTS
THE SPRAY PUMPS WERE OVERHAULED DURING AUGUST ON MODULES 206 AND 209.
THE SPRAY NOZZLES ON MODULES 206 AND 209 REQUIRED EXTENSIVE CLEANING.
9/77 201
202
203
204
205
206
207
208
209
210
211
212
SYSTEM
94.0
89.0
61.0
82.0
90.0
81.0
86.0
52.0
8S.O
56.0
87.0
73.0
86.0
84.6
89.0
61.0
82.0
90.0
81.0
86.0
52.0
88.0
56.0
87.0
73.0
86.0
84.6
720 717
609 79.4
** PROBLEMS/SOLUTIONS/COMMENTS
THE STRAINERS IN THE MODULE 207 AND 209 REACTION TANKS HAVE STARTED
ERODING. THE UTILITY ANTICIPATES REPLACING THEM VERY SOON.
10/77 201
202
203
204
205
206
207
208
209
210
211
212
SYSTEM
95.0
98.0
89.0
87.0
86.0
62.0
99.0
98.0
93.0
96.0
96.0
70.0
81.0
95.9
90.0
82.0
80.0
79.0
57.0
91.0
90.0
86.0
88.0
88.0
64.0
75.0
88.2
744 684
656 81.6
463
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER I960
NORTHERN STATES POWER: SHERBURN; 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL
SOS PART.
PER BOILER FED CAP.
HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE LOW OPERABILITIES ARE DUE TO SPRAY MATER PUMP OVERHAULS.
ARE BEING OVERHAULED.
24 PUMPS
STRAINER/WASHER SCREEN EROSION HAS BEEN A PROBLEM. 316 SS MATERIAL WILL
BE USED IN THE FUTURE. REPLACEMENT MATERIAL IS EXPECTED TO ARRIVE IN
DECEMBER AND WORK IS EXPECTED TO LAST FOR THREE MONTHS.
11/77 201
202
203
204
205
206
207
208
309
SYSTEM
12/77 201
202
203
204
205
206
207
208
209
210
211
212
SYSTEM
1/78 201
202
203
204
205
206
207
203
209
210
211
212
SYSTEM
91.0
93.0
92.0
65.0
93.0
68.0
80.0
93.0
73.0
75.0
66.0
94.0
77.0
91.0
65.0
87.3
53.0
93.0
94.0
87.0
89.0
95.0
93.0
83.0
62.0
82.0
90.0
92.0
92.1
91.0
75.0
64.0
72.0
74.0
67.0
91.0
88.0
77.0
72.0
73.0
84.0
84.4
** PROBLEMS/SOLUTIONS/COMMENTS
84.0
92.0
68.0
79.0
92.0
73.0
75.0
66.0
93.0
77.0
90.0
65.0
86.7
52.0
92.0
93.0
86.0
88.0
94.0
92.0
82.0
61.0
81.0
89.0
91.0
91.0
83.0
69.0
59.0
66.0
68.0
61.0
83.0
81.0
71.0
66.0
70.0
77.0
77.6
720 715
624 81.7
744 733
677 80.6
744 682
577 70.3
THE REPLACEMENT OF STRAINER SCREENS BEGAN ON DECEMBER 21. FOUR TO SIX
DAYS OF WORK ON EACH MODULE ARE REQUIRED TO MAKE STRAINER SCREEN
REPLACEMENTS.
2/78 201
202
203
204
205
83.0
85.0
55.0
91.0
89.0
77.0
78.0
51.0
84.0
82.0
464
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
NORTHERN STATES POWER: SHERBURNE 2 (COST.)
PERIOD MODULE
206
20^
20,1
209
2: o
2:a
232
SVSTEM
AVAILABILITY OPERABILITY
76.0
71.0
89.0
85.0
31.0
97.0
60.0
92.0 37. 4
RELIABILITY UTILIZATION
70.0
66.0
82.0
78. C
75. \l
90.0
55.0
80.7
X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
672 620 542 73.8
** PROBLEMS/SOLUTIONS/COMMENTS
STRAINER MODIFICATIONS WERE PERFORMED ON MODULES 203 AND 212.
3/78
201
202
203
204
205
206
207
208
209
210
211
212
SYSTEM
97.0
82.0
92.0
90.0
83.0
78.0
85.0
91.0
62.0
83.0
78.0
88.0
89.0
91.0
82.0
92.0
90.0
83.0
78.0
85.0
91.0
62.0
83.0
78.0
88.0
89.0
91.0
744
677 87.9
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT GENERATED MAXIMUM MEGAWATT-HOURS AND THE FGD SYSTEM TIED THE
HIGHEST RECORDED AVAILABILITY OF 972.
STRAINER MODIFICATIONS WERE PERFORMED ON MODULES 208 AND 210.
4/78
201
202
203
204
205
206
207
208
209
210
211
212
SYSTEM
92.0
70.0
82.0
90.0
84.0
91.0
83.0
84.0
86.0
78.0
90.0
67.0
85.0
90.0
70.0
82.0
90.0
84.0
91.0
83.0
84.0
86.0
78.0
90.0
67.0
85.0
90.0
720 719
648 81.9
** PROBLEMS/SOLUTIONS/COMMENTS
FROM FULL SCALE STARTUP ON APRIL 1, THE SYSTEM HAS BEEN OPERATING VERY
WELL WITH NO MAJOR PROBLEMS ENCOUNTERED. THE UTILITY IS MAINTAINING A
SCHEDULE OF NIGHTLY CLEANING ON THE SCRUBBERS. THE CURRENT SCHEME IS SUCH
THAT EACH MODULE IS CLEANED AFTER SEVEN OR EIGHT DAYS OF OPERATION.
MODULE 201 WAS CONVERTED TO A SPRAY TOWER DURING APRIL.
5/78 201
202
203
204
205
206
97.0
94.0
80.0
90.0
90.0
89.0
16.0
15,0
13.0
15.0
15.0
14.0
465
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
NORTHERN STATES POWER: SHERBURNE 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
207
208
209
210
211
212
SYSTEM 91.0
90.0
92.0
28.0
91.0
78.0
14.0
84.8
15.0
15.0
5.0
15.0
13.0
2.0
13.9
7*4 120 103 12.7
»* PROBLEMS/SOLUTIONS/COMMENTS
THERE WERE LINER FAILURES (CEILCOTE) IN MOST OF THE MODULES DURING APRIL
AND MAY. THE LINERS WERE REPAIRED BY THE CEILCOTE COMPANY AT THEIR OWN
EXPENSE.
THE UNIT WENT DOWN ON MAY 6 FOR THE FIRST YEAR BOILER AND TURBINE INSPEC-
TIOK AND WAS DOWN THE REMAINDER OF MAY.
6/78
7/78
2M
202
203
2d4
2(,5
206
207
208
209
210
211
212
SYSTEM
201
202
203
204
205
206
207
208
209
210
211
212
SYSTEM
95.0
95.0
77.0
46 .'0
41.0
67.0
62.0
62.0
72.0
78.0
60.0
62.0
76.0
75.0
70.7
87.0
89.0
62.0
93.0
90.0
64.0
86.0
67.0
64.0
81.0
73.0
71.0
84.3
61.0
37.J
33.0
53.0
49.0
49.0
57.0
62.0
48.0
49.0
60.0
60.0
56. Z
82.0
83.0
58.0
87.0
84.0
60.0
81.0
63.0
60.0
76.0
68.0
67.0
79.0
720 572
405 61.3
744 697
588 71.5
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY IS EVALUATING NEW RUBBER LINED PUMPS (8000 GPM) AS POSSIBLE
SOLUTIONS TO THE MIST ELIMINATOR AND REHEATER PLUGGING PROBLEMS.
THE UTILITY IS EVALUATING NEW STAINLESS STEEL MIST ELIMINATOR WASH LANCES
(TO REPLACE ORIGINAL FIBERGLASS LANCES).
THE FGD SYSTEM HAS BEEN EXPERIENCING PRIMARY CONTACTOR WALL AND MARBLE
BED WEAR.
THE UTILITY IS PREPARING FOR THE STATE COMPLIANCE DEADLINE ON NOVEMBER 1.
CURRENTLY TESTING HAS BEEN PROCEEDING ON DIFFERENT MODULES IN AN EFFORT
TO FINE TUNE THE SYSTEM.
PLUGGING PROBLEMS IN THE REHEATER HAVE BEEN MORE FREQUENT THAN NORMAL.
THE UTILITY IS IN THE PROCESS OF REPLACING THE ORIGINAL ZURN DUPLEX
STRAINERS WITH 316 SS STRAINERS.
466
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEHBER 1980
NORTHERN STATES POWER: SHERBURNE Z (CONT.J
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
THE INLET SEAL STRIPS WERE REPAIRED.
PLUGGING PROBLEMS IN THE MIST ELIMINATOR HAVE BEEN MORE FREQUENT THAN
NORMAL.
8/78
9/78
201
202
£03
204
205
206
207
208
209
210
211
212
SYSTEM
201
202
203
20*
205
206
207
208
20"
2in
211
2:2
S'STEM
93.0
96.0
88.0
100.0
48.0
79.0
81.0
72.0
64.0
87.0
54.0
76.0
80.0
71.0
81.8
72.0
82.0
70.0
61.0
74.0
64.0
82.0
72.0
75.0
78.0
82.0
68.0
30.0
82.0
93.0
45.0
74.0
76.0
67.0
60.0
81.0
50.0
71.0
75.0
66.0
76.4
72.0
82.0
70.0
61.0
74.0
64.0
82.0
72.0
75.0
78.0
82.C
68.0
80.0
744 695
569 69.8
720 720
576 74.4
*: PROBLEMS/SOLUTIONS/CC1MENTS
THE RUBBER LINED PUMPS THAT THE UTILITY WAS INVESTIGATING HAVE BEEN
ORDERED. FOUR OF THE PUMPS HAVE BEEN RECEIVED AND ONE IS INSTALLED. THE
OTHERS WILL BE INSTALLED AS THEY ARE RECEIVED.
DIFFERENT MIST ELIMINATOR SPRAY PATTERNS ARE BEING TESTED TO MINIMIZE
PLUGGING OCCURRENCES.
NO FGD RELATED OUTAGES WERE REPORTED BY THE UTILITY FOR THE AUGUST-
SEPTEMBER REPORT PERIOD.
10/78 201
202
203
204
205
206
207
208
209
210
211
212
SYSTEM
94.0
90.0
79.0
59.0
73.0
69.0
64.0
78.0
76.0
72.0
69.0
72.0
82.0
80.3
83.0
73.0
55.0
68.0
64.0
59.0
72.0
70.0
67.0
64.0
67.0
76.0
74.4
744 688
553 68.8
** PROBLEMS/SOLUTIONS/COMMENTS
DURING OCTOBER MODULE 203 EXPERIENCED STRAINER PLUGGING.
DURING OCTOBER MODULE 203 EXPERIENCED REHEATER PROBLEMS WHICH TOGETHER
467
-------
EPA UTILITY FED SURVEY: OCTOBER - DECEMBER 1980
NORTHERN STATES POWER: SHERBURNE 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
WITH STRAINER PLUGGING CAUSED A FOUR TO FIVE DAY OUTAGE.
11/78
201
202
203
204
205
206
207
208
209
210
211
212
SYSTEM
92.0
84.0
45.0
82.0
80.0
75.0
58.0
77.0
75.0
83.0
83.0
72.0
47.0
78.3
55.0
30.0
54.0
52.0
49.0
38.0
51.0
49.0
54.0
54.0
47.0
31.0
51.3
720 472
369 44.6
** PROBLEMS/SOLUTIONS/COMMENTS
LOW NOVEMBER BOILER HOURS RESULTED FROM A NECESSARY TURBINE INSPECTION.
NORMAL OVERHAUL MAINTENANCE WAS PERFORMED ON THE SPRAY PUMPS OF MODULES
202 AND 212.
12/78
1/79
201
202
203
204
205
206
207
208
209
210
211
212
SYSTEM
201
202
203
204
2 OS
20S
2C7
2»>a
209
230
231
212
SYSTEM
94.0
85.0
92.0
89.0
84.0
84.0
84.0
96.0
88.0
78.0
92.0
81.0
94.0
95.2
57.0
89.0
91.0
85.0
92.0
82.0
75.0
37.0
74.0
38.0
700.0
90.0
94.0
92.7
84.0
91.0
88.0
83.0
83.0
83.0
95.0
87.0
77.0
91.0
80.0
93.0
94.0
53.0
82.0
84.0
79.0
85.0
76.0
69. f
90.0
68.0
81.0
92.0
83.0
85.6
744 733
698 74.0
744 688
638 66.9
** PROBLEMS/SOLUTIONS/COMMENTS
THE PROBLEMS ENCOUNTERED IN DECEMBER AND JANUARY WERE MAINLY WEATHER
RELATED.
THERE WERE PROBLEMS WITH THE COAL FEEDER BELTS RESULTING IN MOVING WET
COAL FROM OLDER COAL STOCKPILES TO THE BOILER DURING THE DECEMBER-JANUARY
PERIOD.
2/79 201
202
203
86.0
84.0
73.0
86.0
84.0
73.0
468
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
NORTHERN STATES POWER: SHERBURNE 2 (COKT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
502 PART. HOURS HOURS HOURS FACTOR
204
205
206
207
208
209
210
211
212
SYSTEM 93.0
89.0
59.0
76.0
72.0
68.0
80.0
75.0
92.0
65.0
83.6
89.0
59.0
76.0
72.0
68.0
80.0
75.0
92.0
65.0
83.5 672 671 561 66.2
3/79
201
202
203
204
205
206
207
208
209
210
211
212
SYSTEM
85.0
69.0
78.0
47.0
71.0
76.0
90.0
78.0
50.0
85.0
57.0
86.0
79.3
91.0
** PROBLEMS/SOLUTIONS/COMMENTS
85.0
69.0
78.0
47.0
71.0
76.0
90.0
78.0
50.0
85.0
57.0
86.0
79.3
590 53.7
THE ONLY PROBLEMS ENCOUNTERED DURING FEBRUARY AND MARCH WERE BOILER-RELATED
PROBLEMS RESULTING FROM WET COAL.
THE RECYCLE PUMPS ARE BEING REPLACED WITH LARGER 8000 GPM WORTHINGTON
PUMPS. DURING THIS PERIOD THE PUMPS MERE INSTALLED ON MODULES 204 AND
206.
4/79 SYSTEM 95.0
** PROBLEMS/SOLUTIONS/COMMENTS
720 717
71.8
AS OF APRIL 1979 THE UTILITY HAS DECIDED THAT IT HILL ONLY REPORT THE
AVAILABILITY OF THE TOTAL SYSTEM FOR THIS REPORT.
5/79
SYSTEM 99.0
** PROBLEMS/SOLUTIONS/COMMENTS
744 263
28.1
THE LOW BOILER HOURS IN MAY WERE DUE TO COMMENCEMENT OF THE ANNUAL BOILER
AND TURBINE INSPECTION.
ALL PIPING HAS BEEN CHANGED TO FIBERGLASS.
6/79 SYSTEM 90.0
** PROBLEMS/SOLUTIONS/COMMENTS
720 454
38.7
THE ONLY PROBLEM REPORTED BY THE UTILITY WAS THE LOSS OF A BOILER SURGE
PUMP AFTER THE UNIT RESTARTED.
7/79
8/79
9/79
SI STEM
SYSTEM
SYSTEM
95.0
96.0
95.0
744
744
720
741
740
657
78.9
72.3
68.9
469
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
NORTHERN STATES POWER: SHERBURNE Z (CONT.)
PERFORMANCE DATA
PERIOD iTODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
SOS PART. HOURS HOURS HOURS FACTOF
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR OPERATIONAL PROBLEMS HAVE BEEN ENCOUNTERED WITH THIS UNIT SINCE
IT CAME BACK ON LINE AFTER THE ANNUAL BOILER/TURBINE OVERHAUL IN MAY.
10/79 SYSTEM 94.0 744 732
11/79 SYSTEM 97.0 720 719
12/79 SYSTEM 97.0 744 662
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR BOILER OR FGD OPERATIONAL PROBLEMS WERE ENCOUNTERED DURING
THE FOURTH QUARTER OF 1979.
1/80 SYSTEM 97.0 744 744 90.1
2/80 SYSTEM 96.0 696 696 91.8
3/80 SYSTEM 98.0 744 744 91.9
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE FIRST QUARTER OF 1980 THE FGD SYSTEM EXPERIENCED NO MAJOR
PROBLEMS.
A FOUR WEEK BOILER OUTAGE IS SCHEDULED FOR MAY AT WHICH TIME THE MARBLE
BEDS WILL BE REMOVED FROM THE FGD SYSTEM.
THE UTILITY HAS DECIDED TO CONVERT THE ENTIRE MARBLE BED SCRUBBING SYSTEM
TO A SPRAY TOWER SYSTEM BY REMOVING THE MARBLE BEDS AND MODIFYING THE SPRAY
ARRANGEMENT. TESTS CONDUCTED AT UNIT 1 IN 1978 AND 1979 SHOW THAT MOST OF
THE 502 IS COLLECTED IN THE VENTURI SECTION OF THE SCRUBBING TRAINS AND
THAT ALTHOUGH THE MARBLE BEDS IN THE ABSORBER SECTIONS IMPROVE INTIMATE
S02/SLURRY MIXING, S02 REMOVAL EFFICIENCY OF THE SCRUBBING TRAINS IS NOT
MARKEDLY DIFFERENT WHEN MARBLE BEDS ARE REMOVED.
4/80 SYSTEM 96.0 720 704 68.6
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR OPERATIONAL PROBLEMS WERE ENCOUNTERED IN APRIL.
5/80 SYSTEM 96.0 744 214 24.2
6/80 SYSTEM 100.0 720 51 2.8
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS OUT OF SERIVE MOST OF MAY AND JUNE BECAUSE OF THE ANNUAL
BOILER AND TURBINE INSPECTION.
7/80 SYSTEM 100.0 100.0 100.0 82.7 744 615 615 63.8
** PROBLEMS/SOLUTIONS/COMMENTS
BOILER TUBE LEAKS CAUSED THE BOILER NOT TO OPERATE FOR 73 HOURS IN JULY.
BOTTOM ASH PLUGGING ALSO FORCED THE BOILER DOWN FOR 56 HOURS.
8/80 SYSTEM 100.0 100.0 100.0 100.0 744 744 744 70.7
9/80 SYSTEM 100.0 100.0 100.0 100.0 720 720 720 100.0
470
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
NORTHERN STATES POWER: SHERBURNE 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER AND FGD SYSTEM RAN CONTINUOUSLY THROUGH AUGUST AND SEPTEMBER
WITHOUT ANY PROBLEMS.
744 742 742 81.9
720 720 720 82.2
744 744 744 79.2
*•* PROBLEMS/SOLUTIONS/COMMENTS
DURING THE OCTOBER-DECEMBER PERIOD THE FGD SYSTEM WAS AVAILABLE 100X OF
THE TIME.
10/80 SYSTEM
11/80 SYSTEM
12/80 SYSTEM
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
99.7
100.0
100.0
471
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY N\ME
PLANT NAKE
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICIPATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS INIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - MM
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
ST4CK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUE- DATA
FUr.L TYPE
FUl:L GRADE
AVf.RAGE HEAT CONTENT - J/G
RAHGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RAHGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7,
*** PARTICLE CONTROL
** ESP
TYPE
SUPPLIER
INLET FLUE GAS CAPACITY - CU.M/S
INLET FLUE GAS TEMPERATURE - C
PARTICLE REMOVAL EFFICENCY - 7.
** PARTICLE SCRUBBER
GENERIC TYPE
SPECIFIC TYPE
*** FGD SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
UNIT DESIGN S02 REMOVAL EFFICIENCY - 7.
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
PACIFIC POWER i LIGHT
JIM BRIOGEP.
4
ROCK SPRINGS
WYOMING
D
43.
86.
t .100 LB/MMBTU)
( .200 LB/MMBTU)
(****** LB/MMBTU)
2034
550
508
509
550
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
1283.57 (2720000 ACFM)
******* (**** F)
152. ( 500 FT)
CONCRETE
******* (***** FT)
COAL
SUBBITUMINOUS
21632. ( 9300 BTU/LB)
******
9.00
******
18.00
******
.56
******
.01
COLD SIDE
CARBORUNDUM
1099.9 (2330890 ACFM)
121.1 ( 250 F)
99.0
NONE
N/A
THROWAWAY PRODUCT
WET SCRUBBING
SODIUM CARBONATE
NONE
AIR CORRECTION DIVISION, UOP
BECHTEL
FULL SCALE
NEW
- 7. 99.00
91.00
1
2/80
9/79
10/76
472
-------
PACIFIC POWER « LIGHT: JIM BRIDGER 4 (CONT.)
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER I960
** DESIGN AND OPERATING PARAMETERS
** AB'50RBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LINER MATERIAL TRADE NAMI/COMMON TYPE
N:JMBF,
** MIST ELIMINATOR
PFiE-MIST ELIMINATOR/MIST Ef.IMINATOR
VANE ANGLES - DEGREES
** PUMPS
SfRVICE
AFSORBER RECIRCUUTION
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
OUTLET STREAM CHARACTERISTICS
*** SLUDGE
** DISPOSAL
NATURE
TYPE
LCCATION
SITE TRANSPORTATION METHOD
SITE SERVICE LIFE - YRS
** WATER BALANCE
WATER LOOP TYPE
** FGD SPARE CAPACITY INDICES
ABSORBER - X
** FGD SPARE COMPONENT INDICES
ABSORBER
TRAY TOWER
SIEVE TRAY
CARBON STEEL
AISI 1110
N/A
ORGANIC
RUBBER
1
2.7
91.0
( 20.0 GAL/1000 ACF)
MIST ELIMINATOR
45
NUMBER
****
THICKENER
18X SOLIDS
FINAL
LINED POND
ON SITE
PUMPED
11
CLOSED
.0
.0
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
9/79 SYSTEM
720
** PROBLEMS/SOLUTIONS/COMMENTS
10/79 SYSTEM
11/79 SYSTEM
THE UNIT STARTED OPERATIONS AS SCHEDULED IN SEPTEMBER 1979. PRESENTLY
THE FGD SYSTEM IS IN THE START UP PHASE WITH COMMERCIAL OPERATION SCHEDULED
FOR DECEMBER.
THE UTILITY IS IN THE PROCESS OF CHECKING INTERLOCKS AND OTHER COMPONENTS
BUILT INTO THE FGD SYSTEM TO PROTECT THE BOILER. FLUE GAS IS PASSING
THROUGH MODULES ON AN INDIVIDUAL BASIS. THE FGD SYSTEM WILL NOT BE
OPERATED IN AN INTEGRATED MODE UNTIL LATE OCTOBER.
720
473
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
PACIFIC POWER & LIGHT: JIM BRIDGER 4 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL
so2 PART.
PER BOILER FGD CAP.
HOURS HOURS HOURS FACTOI
12/79 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
SHAKEDOWN OPERATIONS CONTINUED THROUGHOUT THE FOURTH QUARTER OF 1979.
1/80 SYSTEM 744
2/80 SYSTEM 696
3/80 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT IS STILL IN THE SHAKEDOWN PHASE OF OPERATIONS. A NUMBER OF
MECHANICAL PROBLEMS AND SOME CONTROL PROBLEMS HAVE BEEN ENCOUNTERED.
NO PROCESS-RELATED PROBLEMS HAVE OCCURRED.
4/80
41
42
4?
SYSTEM
27.5
24.0
26.6
26.0
18.4
23.9
?4.0
,:5.4
22.3
26.3
34.2
27.6
14.2
18.4
26.1
19.6
720 553
141
** PROBLEMS/SOLUTIONS/COI1MENTS
ALL THREE MODULES WERE OUT OF SERVICE THE FIRST 21 DAYS OF APRIL WHILE THE
UTILITY WAITED FOR DELIVERY OF NEW SPRAY NOZZLES. SOME PLUGGING HAD OCCUR-
RED IN THE ORIGINAL NOZZLES. THE NEW NOZZLES WERE INSTALLED FOR TESTING
PURPOSES.
5/80
41
42
43
SYSTEM
95.2
72.4
100.0
89.2
46.0
75.1
81.6
67.6
92.6
71.7
100.0
88.1
42.9
70.1
76.1
63.0
744 694
469
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE 42 WAS FORCED OUT OF SERVICE FOR EIGHT DAYS IN MAY WHILE A VORTEX
BREAKER WAS INSTALLED IN THE ABSORBER VESSEL. THE VESSEL WAS DRAINING
BEFORE REACHING DESIGN FLUID LEVELS.
VORTEX BREAKERS WERE INSTALLED IN MODULES 41 AND 43 AS WELL BUT INSTALLA-
TION IN THESE MODULES WAS NOT UNDERTAKEN DURING PERIODS WHEN MODULE SERVICE
WAS REQUIRED.
6/80
U
42
«
SYSTEM
81.2
89.2
86.0
85.5
77.7
100.0
75.0
87.1
66.5
85.1
73.6
75.4
30.9
43.2
29.8
34.6
744 296
258
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGO SYSTEM WAS DOWN FOR 5 DAYS TO REPAIR A RECIRCULATION PUMP BREAKER
ON MODULE 41.
MODULES 41 AND 42 WERE UNAVAILABLE FOR A COMBINED TOTAL OF 6 DAYS DUE TO
THE REPLACING OF THE PH CONTROL PIPING.
7/80 41
42
43
SYSTEM
97.3
97.4
99.4
98.0
67.2
91.2
90.2
82.9
96.0
97.1
99.3
97.6
64.8
87.8
86.9
79.8
744 717
594
474
-------
EPA UTILITY FGO SURVEY: OCTOBER - DECEMBER 1980
PACIFIC POWER & LIGHT: JIM BRID6ER 4 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/CONMENTS
NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED IN JULY.
8/80 41 99.7 92.8 99.7 86.1
42 94.1 92.3 93.6 85.6
43 94.7 68.4 92.4 63.5
SYSTEM 96.2 84.5 95.2 78.4 74* 690 583
** PROBLEMS/SOLUTIONS/COMMENTS
NO FGD RELATED PROBLEMS WERE REPORTED FOR THE MONTH OF AUGUST.
9/80 SYSTEM .0 720 0 0
10/80 SYSTEM .0 744 0 0
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER AND FGD SYSTEM WERE OUT OF SERVICE DURING THE MONTHS OF SEPTEM-
BER AND OCTOBER FOR THE ANNUAL BOILER OUTAGE.
11/80 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
NO INFORMATION WAS AVAILABLE FOR NOVEMBER 1980.
12/80 41 100.0 85.9 100.0 77.2
42 91.7 74.6 88.9 66.9
43 93.0 71.6 90.4 64.2
SYSTEM 94.9 77.4 93.1 69.4 744 668 517
*» PROBLEMS/SOLUTIONS/CO1MENTS
SCALING PROBLEMS WERE ENCOUNTERED DURING DECEMBER. NO OTHER MAJOR FGD-
RELATE) PROBLEMS WERE REPORTED FOR THE MONTH.
475
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NS/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/F6D - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - '/.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - '/.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** PARTICLE SCRUBBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINEK SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYP5
NUMFER OF CONTACTING ZONES
LIQUID RECIRCUUTION RATE - LITER/S
L/G RATIO - LITER/CU.M
PREJ.SURE DROP - KPA
Sl'PFRFICIAL GAS VELOCITY - M/S
INLtT GAS FLOW RATE - CU.M/S
INLET GAS TEMPERATURE - C
S02 REMOVAL EFFICENCY - 7.
PARTICLE REMOVAL EFFICIENCY - 7.
*** FG5 SYSTEM
** GEMERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
PENNSYLVANIA POWER
BRUCE MANSFIELD
1
SHIPPINGPORT
PENNSYLVANIA
D
15. ( .035 LB/MMBTU)
258. ( .600 LB/MMBTU)
****** (****** LB/MMBTU)
2751
917
825
880
917
FOSTER WHEELER
PULVERIZED COAL
BASE
(3350000 ACFM)
( 285 F)
t 950 FT)
( 19.0 FT)
t 11500 BTU/LB)
11000-11950
1580.86
140.6
290.
CONCRETE
5.8
COAL
BITUMINOUS
26749.
12.90
11.5-13.5
7.00
5.5-8.5
3.00
1.75-3.75
VENTURI TOWER
VARIABLE-THROAT/TOP-ENTRY PLUMB BOB
CHEMICO
35.5 DIA X 52 HIGH
CARBON STEEL
AISI 1110
ORGANIC
GLASS FLAKE-FILLED POLYESTER
PLUMB BOB AND 2 SETS OF SPRAYS, 317 SS AND 316 S
2
(22000 GPM)
(40.0 GAL/1000ACF)
( 2.3 IN-H20)
( 200.0 FT/S)
( 558333 ACFM)
( 285 F)
1386.0
5.3
.6
61.0
263.5
140.6
70.0
99.8
THROWAWAY PRODUCT
WET SCRUBBING
LIME
MG PROMOTED
476
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
PENNSYLVANIA POWER: BRUCE MANSFIELD 1 (CONT.)
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY -
UNIT DESIGN S02 REMOVAL EFFICIENCY - X
CURRENT STATUS
TERMINATION
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
** ABSORBER
NUrJBER
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
NUMBER OF CONTACTING ZONES
LIQUID RECIRCUUTION RATE - LITER/S
L/G RATIO - L/CU.M
GAS-SIDE PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/SEC
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
S02 REMOVAL EFFICIENCY - 7.
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES PER STAGE
DISTANCE BETWEEN VANES - CM
VANE ANGLES - DEGREES
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/S
CONSTRUCTION MATERIAL GENERIC TYPE
WASH WATER SOURCE
WASH RATE - L/S
** FANS
NUMBER
NUMBER OF SPARES
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
LINLR GENERIC MATERIAL 7YPE
** DUCTVORK
LOC. TION
SHI-:LL GENERIC MATERIAL TYPE
LIMER GENERIC MATERIAL TYPE
CHEMICO DIVISION, ENVIROTECH
GILBERT/COMMONWEALTH ASSOCIATES
FULL SCALE
NEW
•/. 99.80
93.10
1
**/77
6/76
12/75
10/74
VENTURI TOWER
FIXED THROAT
CHEMICO DIVISION, ENVIROTECH
34 DIA X 51.5 HIGH
CARBON STEEL
AISI 1110
N/A
ORGANIC
POLYESTER FLAKEGLASS
1
1222.
6.0
2.0
30.5
201.31
52.8
92.1
(19400 GPM)
( 45.0 GAL/1000 ACF)
( 8.0 IN-H20)
(100.0 FT/S)
( 426600 ACFM)
( 127 F)
MIST ELIMINATOR
6
IMPINGEMENT
BAFFLE
CHEVRON VANE
HORIZONTAL
1
4
7.6
( 3.00 IN)
90
.1 ( .6 IN-H20)
3.0 ( 10.0 FT/S)
FIBERGLASS REINFORCED PLASTIC
THICKENER OVERFLOW
3.8 ( 60 GAL/MIN)
12
6
GREEN FAN
BALANCED DRAFT
BOILER I.D.
WET
263.32
47.8
( 558000 ACFM)
( 118 F)
INCOLOY 825 ON HOUSINGS; INCONEL 625 SCROLLS AND
SCRUBBER INLET
CARBON STEEL
POLYESTER FIAKEGLASS
SCRUBBER O'JTLET
CARBON STEEL
POLYESTER FLAKEGLASS
477
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
PENNSYLVANIA POWER: BRUCE MANSFIELD 1 (CONT.)
** REAGENT PREPARATION EQUIPMENT
FACTION
DtVICE
M/NUFACTURER
NLNBER
FLLL LOAD DRY FEED CAPACITY - M.TONS/HR
** TANKS
SERVICE
THICKENER UNDERFLOW
MIXING TANK ICALCILOX 4 THCKNR UNDRF
SLUDGE TRANSFER
MIXING TANK ISPENT SLURRY & FLYASH]
RECYCLE (SCRUBBER)
RECYCLE (ABSORBER)
** PUMPS
SERVICE
VENTURI RECIRCULATION
SLURRY FEED
LIME SLURRY RECIRCULATION
ABSORBER RECIRCULATION
THICKENER UNDERFLOW
THICKENER TRANSFER
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
CONFIGURATION
DIMENSIONS - FT
SHELL GENERIC MATERIAL TYPE
OUTLET STREAM CHARACTERISTICS
*** SLUDGE
** TREATMENT
METHOD
PROPRIETARY PROCESS
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE CAPACITY - CU.M
** PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS
CONTROL LEVELS
MONITOR LOCATION
PROCESS CONTROL MANNER
PROCESS CHEMISTRY MODE
** WATER BALANCE
MATER LOOP TYPE
** FGD SPARE CAPACITY INDICES
ABSORBER - '/.
** FGD SPARE COMPONENT INDICES
ABSORBER
LIME SLAKING
SLAKER
DORR-OLIVER
2
20.0
NUMBER
( ZZ TPH)
****
2
****
****
6
6
NUMBER
24
4
4
THICKENER
1
CYLINDRICAL
200 DIA
CARBON STEEL
30X SOLIDS
CALCILOX
DRAVO
FINAL
LANDFILL
OFF SITE
PUMPED
59927000
t 49000.0 ACRE-FT)
PH SLURRY SOLIDSt LIQUID LEVELi LIQUID FLOW
PH 6.8-7.2
PH-RECIRCULATINS LINES AND THICKENER
AUTOMATIC
FEEDBACK
OPEN
.0
.0
478
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
PENNSYLVANIA POWER: BRUCE MANSFIELD 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
12/75 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
744
INITIAL OPERATION (SHAKEDOWN AND DEBUGGING) FOR PART OF THE SYSTEM COM-
MENCED IN DECEMBER 1975.
0/76 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
SINCE THE UNIT COMMENCED SCRUBBING OPERATIONS A NUMBER OF PROBLEM
AREAS HAVE BEEN ENCOUNTERED. MAJOR AREAS OF CONCERN ARE SPECIFIED
BELOW:
1. EXCESSIVE MAINTENANCE PROBLEMS WITH THE WET ID FAN HOUSINGS.
Z. EXCESSIVE WATER ENTRAINMENT AND CARRY OVER OUT OF THE STACK CAUSING A
STACK RAIN PROBLEM.
3. REHEAT BURNER PROBLEMS.
4. STACK FLUE LINER FAILURES.
1/76 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT SHUT DOWN FOR ONE WEEK DUE TO PLUGGED MIST ELIMINATORS.
AN ID FAN HOUSING VIBRATION CAUSED PART OF THE ONE WEEK OUTAGE, ALONG
WITH THE MIST ELIMINATOR PROBLEMS.
2/76 SYSTEM
3/76 SYSTEM
696
744
** PROBLEMS/SOLUTIONS/COMMENTS
4/76 SYSTEM
FIRST ATTEMPTS AT STARTING UP THE REHEAT BURNERS WERE MADE THIS MONTH.
SO MANY PROBLEMS WERE ENCOUNTERED THAT THE SYSTEM SUPPLIER IS GOING TO
REDESIGN NEW REHEAT BURNERS.
720 506
** PROBLEMS/SOLUTIONS/COMMENTS
THE INSTALLATION BEGAN PARTIAL COMMERICAL OPERATION ON APRIL 5.
TOTAL OPERATING HOURS ACCUMULATED TO DATE ARE AS FOLLOWS: 0, 210, 984,
2147, 2808, AND 2427 FOR MODULES A THROUGH F RESPECTIVELY. THE SCRUBBING
SYSTEM IS CURRENTLY HANDLING FLUE GAS AT A TOTAL EQUIVALENT CAPACITY OF
APPROXIMATELY 640 MW (GROSS).
5/76
A
B
C
D
E
F
SYSTEM
80.0
35.1
100.0
99.5
82.7
100.0
82.9
83.4
28.
81.
79.6
66
83
66
67.5
744 595
502
** PROBLEMS/SOLUTIONS/COMMENTS
THE LAST SCRUBBER TRAIN WAS PLACED IN SERVICE DURING THE MONTH. DURING
OFF PEAK HOURS ON THE WEEKENDS WHEN THE UNIT IS OPERATING AT REDUCED
LOADS, MAINTENANCE IS PERFORMED ON THE SHUT DOWN FGD MODULES SO THAT THEY
479
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
PENNSYLVANIA POWER: BRUCE MANSFIELD 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPE.^ABILITY RELIABILITY UTILIZATION
X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTO
WILL 3E IN OPERATING CONDITION FOR FULL LOAD OPERATION DURING THE HIGH
DEMAND.
6/76 A
B
C
D
E
F
SYSTEM
100.0
99.2
94.4
97.4
93.6
97.9
79.6
93.7
99.2
94.4
97.4
93.6
97.9
79.6
93.7
720 720
675
** PROBLEMS/SOLUTIONS/COMMENTS
7/76
8/76
THE UNIT WAS DECLARED COMMERCIALLY AVAILABLE FOR, FULL LOAD OPERATION AT
825 MW (NET) ON JUNE 1, 1976. OVER THE PERIOD A REVISED SCRUBBER BAFFLE
SYSTEM WAS INSTALLED IN AN EFFORT TO CORRECT SCRUBBER RECYCLE PUMP CA-
VITATION PROBLEMS.
A
B
C
0
E
F
jYSTEM
90.0
79.8
87.7
90.0
94.7
98.4
98.2
91.5
72.2
79.3
81.5
85.6
88.9
88.8
82.7
744 673
615
•«* PROBLEMS/SOLUTIONS/COMMENTS
THE SYSTEM SUPPLIER IS STILL TRYING TO SOLVE THE REHEAT BURNER PROBLEMS.
TESTS CONDUCTED THIS MONTH SHOWED THAT THE FGD SYSTEM MIST ELIMINATORS ARE
NOT PERFORMING TO DESIGN AND THAT THERE IS EXCESSIVE WATER ENTRAINED IN
THE CLEANED FLUE GASSES CAUSING A STACK RAIN PROBLEM. CHEMICO IS WORKING
ON THE DESIGN OF ADDITIONAL MIST ELIMINATORS THAT WILL REMOVE THIS EXCESS
WATER.
A
B
C
D
E
F
SYSTEM
95.0
95.3
87.9
92.6
75.9
70.9
94.8
86.2
90.3
83.3
87.8
71.9
67.2
89.8
81.7
744 705
608
** PROBLEMS/SOLUTIONS/COMMENTS
SECONDARY VERTICAL MIST ELIMINATORS WERE INSTALLED IN THE ABSORBER DIS-
CHARGE DUCT IN AN ATTEMPT TO REDUCE THE EXCESSIVE ENTRAINED WATER. THEY
DID NOT WORK BECAUSE THE FLUE GAS BLEW THEM APART IN A FEW MINUTES OF OP-
ERATION.
9/76 A
B
C
D
E
F
SYSTEM
10/76 A
B
C
D
100.0
98.
85.
96.
96.
82.8
64.4
87.3
96.1
74.3
85.4
83.8
98.3
85.7
96.3
96.5
82.8
64.4
87.3
95.4
73.8
84.8
83.2
720 720
629
480
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
PENNSYLVANIA POWER: BRUCE MANSFIELD 1 CCONT.)
PERIOD
11/76
MODULE
E
F
SYSTEM
A
B
C
D
E
F
SYSTEM
AVAILABILITY OPER ABILITY
93.5
93.5
99.0 87.8
97.5
100.0
100.0
40.8
57. ft
88.8
38.0 80.8
rcKi-UKnAMi-c u« i «
RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
92.9
92.9
87.2 744 739 649
37.5
38.6
39.2
15.7
22.1
34.2
31.2 720 277 225
1/77
** PROBLEMS/SOLUTIONS/CO;iMENTS
A THRFiE WEEK OUTAGE OCCURRED DUE TO A FURNACE IMPLOSION.
DURIKS THE OUTAGE SCALE THROUGHOUT THE FGD SYSTEM WAS REMOVED.
DURING THE THREE MEEK OUTAGE THE UNIT 1 CHIMNEY FLUES WERE INSPECTED. THE
A-SIOE FLUE POLYESTER LINING MATERIAL WAS FLAKING OFF AND ACID ATTACK WAS
STARTING TO CORRODE THE CARBON STEEL FLUE. THE LINING SUPPLIER IS
INVESTIGATING THE PROBLEM.
DURING THE OUTAGE THE PLUGGED MIST ELIMINATORS WERE CLEANED.
12/76 A
B
C
D
E
F
SYSTEM
80.9
100.0
94.7
60.0
86.1
86.7
3
f*
3
£
C
SYSTEM
100.0
95.0
92.0
77.0
95.0
92.0
91.0
90.3
84.7
98.0
91.0
74.0
98.0
93.0
91.0
90.8
78.5
97.5
91.9
58.2
83.6
84.1
82.3
744 722
612
89.0
82.0
68.0
89.0
84.0
83.0
82.5
744 675
614
PROBLEMS/SOLUTIONS/COMMENTS
SEVERE WINTER WEATHER MADE OPERATION OF THE OUTDOOR FGD SYSTEM VERY DIFFI-
FICULT AND AFFECTED THE RELIABILITY OF THE UNIT.
DURING THE FIRST PART OF THE MONTH THE THICKENER RAKE MECHANISM JAMMED AND
COULD NOT BE REPAIRED. THE THICKENER WAS OPERATED FOR APPROXIMATELY THREE
WEEKS WITH THE RAKE STOPPED UNTIL THE UNIT 2 THICKENER COULD BE PUT INTO
EMERGENCY SERVICE.
2/77 A
77.0
81.0
B
C
D
E
F
SYSTEM
69.0
77.0
86.0
92.0
81.0
80.3
70.0
81.0
96.0
100.0
84.0
85.3
65.0
56.0
65.0
77.0
81.0
67.0
68.5
672 540
460
** PROBLEMS/SOLUTIONS/COMMENTS
A SECOND SET OF VERTICAL SECONDARY MIST ELIMINATORS WAS INSTALLED IN THE
ABSORBER DISCHARGE DUCT BUT THE FLUE GAS BLEW THEM OUT BEFORE THEIR EFFI-
CIENCY FOR REMOVING ENTRAINED WATER IN THE FLUE GAS COULD BE TESTED.
481
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
PENNSYLVANIA POWER: BRUCE MANSFIELD 1 (CONT.)
PERIOD
3/77
MODULE
A
B
C
D
E
F
SYSTEM
AVAILABILITY
99.0
100.0
58.0
95.0
97.0
80.0
88.2
OPER ABILITY
98.0
100.0
58.0
95.0
97.0
77.0
87.5
PtKfUKnAW,!: DAI A
RELIABILITY UTILIZATION
34.8
35.5
20.4
33.9
34.5
27.2
31.1
•/. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
744 264 231
** PROBLEMS/SOLUTIONS/COMMENTS
4/77 SYSTEM
5/77 A
B
C
D
E
.0
.0
.0
100.0
100.0
AT MIDNIGHT ON MARCH 12, THE UNIT MAS SHUT DOWN FOR A 10-WEEK TURBINE
OVERHAUL OUTAGE.
DURING THE MARCH OUTAGE REPAIRS WERE STARTED ON THE A-SIDE CHIMNEY FLUE
WHICH WILL NOT BE COMPLETED UNTIL THE END OF AUGUST. AN INSPECTION OF THE
B-SIDE CHIMNEY FLUE SHOWED THE SAME TYPE OF REPAIRS WOULD BE NEEDED, BUT
WORK WILL NOT START ON THE B-SIDE UNTIL THE A-SIDE FLUE HAS BEEN REPAIRED.
BECAUSE OF THESE REPAIRS THE UNIT WILL BE OPERATING AT APPROXIMATELY HALF
LOAD FOR ROUGHLY ONE YEAR.
BECiUSE OF THE EXCESSIVE MAINTENANCE REQUIRED ON THE RUBBER LINED CARBON
STEEL ID FAN HOUSINGS FROM PIECES OF SCRUBBER SCALE DAMAGING THE LINING
AND CORROSION OF THE CARBON STEEL, INCONEL PLATE WILL BE INSTALLED ON THE
SCROLL AREA OF EACH OF THE SIX FANS DURING THE OUTAGE.
A NEWLY DESIGNED -JiXONDARY VERTICAL MIST ELIMINATOR WILL BE INSTALLED IN
THE ABSORBER DISCHARGE DUCT OF ONE OF THE SCRUBBER MODULES DURING THE OUT-
AGE.
DURING THE OUTAGE ALL SCRUBBING VESSELS, DUCTS, PIPING AND MIST ELIMINATOR
WILL BE CLEANED AND ALL THE SCALE REMOVED.
DURING OPERATION OF THE FGD SYSTEM THE PH CONTROL COULD NOT BE AUTOMATED
BECAUSE OF POOR DESIGN AND OPERATIONAL PROBLEMS WITH THE PROVIDED CONTROL
SYSTEM. PH CONTROL WAS MANUALLY SAMPLED AND CONTROLLED OVER APPROXIMATELY
ONE YEAR OF OPERATION. THE PH CONTROL AND MONITORING SYSTEM ARE BEING RE-
VISED BY OPERATING PERSONNEL DURING THE OUTAGE IN AN EFFORT TO IMPROVE THE
THE PH CONTROL SYSTEM.
THE LIME ADDITION PIPING IS BEING REVISED IN EACH OF THE SCRUBBER VESSELS
DUE TO THE SEVERE SCALING OCCURRING WITH THE CURRENT LIME ADDITION SYSTEM.
THE SYSTEM SUPPLIER IS REDESIGNING THE EXISTING MIST ELIMINATOR SPRAY PIP-
ING IN AN EFFORT TO CORRECT THE EXCESSIVE SCALING AND PLUGGING OF THE MIST
ELIMINATORS.
CHANGES IN FLUSH WATER AND SEAL MATER PIPING ARE BEING MADE IN AN EFFORT
TO CLOSE THE WATER LOOP.
NEWLY MODIFIED REHEAT BURNERS MILL BE INSTALLED DURING THE OUTAGE AND
TESTED ON THE B-SIDE REHEATER WHEN THE UNIT STARTS UP IN MAY.
THE UNIT 1 THICKENER WAS CLEANED OUT AND THE JAMMED RAKE DRIVE MECHANISM
WAS REPAIRED DURING THE OUTAGE.
.0
.0
.0
84.0
84.8
.0
.0
.0
.0
13.7
13.8
720
.0
482
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
PENNSYLVANIA POWER: BRUCE MANSFIELD 1 CCONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
F
SYSTEM
47.2
41.2
41.2
35.0
6.7
5.7
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS STARTED UP ON MAY 23 USING D,
BEING MADE TO THE A-SIDE CHIMNEY FLUE.
744 121
E, AND F MODULES DUE TO REPAIRS
THERE WERE PROBLEMS SLAKING LIME AND GETTING MAGNESIUM LEVELS BUILT UP IN
THE SCRUBBER RECYCLE LOOPS AFTER STARTUP.
6/77
A
B
C
D
E
F
SYSTEM
.0
.0
.0
94.0
95.0
90.0
46.5
.0
.0
.0
100.0
100.0
97.0
49.5
.0
.0
.0
94.0
95.1
90.0
46.5
720 669
335
** PROBLEMS/SOLUTIONS/COMMENTS
HORIZONTAL MIST ELIMINATOR PRESSURE DROPS INCREASED TO THE POINT THAT NEW
MIST ELIMINATORS HAD TO BE INSTALLED IN JUNE ON THE D, E AND F SCRUBBERS
AND THE D AND E ABSORBERS.
7/77 A
B
C
D
E
F
SYSTEM
.0
.0
.0
99.0
99.0
100.0
49.7
.0
.0
.0
100.0
100.0
100.0
50.0
.0
.0
.0
66.0
66.0
63.0
32.5
744 473
242
** PROBLEMS/SOLUTIONS/COMMENTS
UNIT 1 WAS DOWN FROM JULY 1 THROUGH JULY 12 TO MAKE SOME MODIFICATIONS TO
THE GENERATOR COOLING SYSTEM. ON JULY 19 AND 20 THE PENNSYLVANIA DEPART-
MENT OF ENVIRONMENTAL RESOURCES TESTED THE S02 AND PARTICLE EMISSIONS FROM
THE U4IT 1 FGD SYSTEM. S02 EMISSIONS WERE 0.44 LB/MM BTU AND 1.26 LB/MM
BTU FUR THE TWO TESTS RESPECTIVELY. FGD S02 REMOVAL EFFICIENCY VARIED
FROM ?B7. TO 89X FOR THE MONTH.
8/77
A
B
C
D
E
F
SYSTEM
55.0
53.0
31.0
96.0
95.0
68.0
69.7
57.0
56.0
31.0
100.0
100.0
95.0
73.2
52.0
50.0
28.0
93.0
93.0
85.0
66.8
744 692
497
** PROBLEMS/SOLUTIONS/COMMENTS
UNIT 1 WAS DOWN FROM AUGUST 13 TO 15 BECAUSE OF BOILER TUBE LEAKS.
ON AUGUST 16 THE 1A CHIMNEY FLUE LINER REPAIRS WERE COMPLETED AND THE A,
B AND C TRAINS WERE STARTED UP.
SEVERAL REPAIRS WERE MADE TO THE ID FAN HOUSING THIS MONTH.
THE AVERAGE S02 REMOVAL EFFICIENCY FOR THE MONTH WAS 86.7Z BASED ON THREE
GRAB SAMPLES.
YORK RESEARCH BEGAN SETTING UP EQUIPMENT TO CONTINUOUSLY MONITOR THE S02
REMOVAL EFFICIENCIES AS PART OF AN EPA RESEARCH PROJECT TO DETERMINE FEA-
483
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
PENNSYLVANIA POWER: BRUCE MANSFIELD 1 (CONT.)
------------------------------------------ PERFORMANCE DATA -----------------------------------------
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
SOE PART. HOURS HOURS HOURS FACTOI
SIBLE NSPS FOR FGD.
EXTENSIVE MODIFICATIONS ARE BEING MADE IN THE PH CONTROL SYSTEMS IN AN EF
FORT TO DEVISE A WORKABLE PH CONTROL SYSTEM.
75.0
73.0
76.0
46.0
44.0
9/77 A
B
C
D
E
F
SYSTEM
84.0
82.0
81.0
53.0
50.0
43.0
65.5
97.0
95.0
98.0
60.0
56.0
44.0
75.0
58.0
720 558
418
*# PROBLEMS/SOLUTIONS/COMMENTS
10/77 A
B
C
D
E
F
SYSTEM
93.0
98.0
87.0
.0
.0
.0
46.3
96.0
100.0
90.0
.0
.0
.0
47.7
FROM SEPTEMBER 17 TO 22 THE UNIT WAS DOWN TO INSTALL RIGGING IN THE IB
CHIMNEY FLUE TO BEGIN FLUE LINER REPAIRS. D, E AND F TRAINS WERE OFF
THE REMAINDER OF THE MONTH.
THE AVERAGE S02 REMOVAL EFFICIENCIES FOR THE MONTH WERE 93. Z'/. BASED ON
FOUR GRAB SAMPLE TESTS.
A BOILER TUBE LEAK CAUSED THE UNIT TO BE DOWN SEPTEMBER 10 TO 12.
93.0
98.0
87.0
.0
.0
.0
46.3 77.50 744 720 344
** PROBLEMS/SOLUTIONS/COMMENTS
11/77 A
B
C
D
E
F
SYSTEM
95.0
99.0
91.0
.0
.0
.0
47.5
95.0
99.0
91.0
.0
.0
.0
47.5
THE C-MODULE MIST ELIMINATOR SPRAY NOZZLES AND MIST ELIMINATOR ITSELF WERE
CLEANED.
ASS STACK REPAIRS ON UNIT 2 NECESSITATED TAKING UNIT 1 DOWN FOR TWO DAYS.
(A PROTECTIVE CAP HAD TO BE PUT OVER THE 2B FLUE BY HELICOPTER. PREVAIL-
ING WINDS NECESSITATED TAKING UNIT 1 OFF IN ORDER TO DO THIS.)
95.0
99.0
91.0
.0
.0
.0
47.5 85.00 720 720 342
** PROB LEMS/SO LUTIONS/COMMENTS
12/77 4
B
C
D
E
F
SYSTEM
100.0
93.0
99.0
.0
.0
.0
48.7
JOO.O
94.0
100.0
.0
.0
.0
49.0
REMOVAL OF THE OLD COATING AND PRIMING OF THE FLUE LINING IN FLUE 18 IS
PROCEEDING SLOWER THAN ANTICIPATFB . IT IS EXPECTED THAT TOTAL WORK ON THE
FLUE i
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
PENNSYLVANIA POWER: BRUCE MANSFIELD 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART, HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
SANDBLASTING OF UNIT IB FLUE IS NEARIN6 COMPLETION.
LINED WITH CXL-2000.
THE FLUE HILL BE RE-
0/78 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
NOTE: AN ATTEMPT IS ALWAYS MADE TO BEGIN OPERATION OF THE BOILER AND FGD
SYSTEM SIMULTANEOUSLY AT BRUCE MANSFIELD. OCCASIONALLY PROBLEMS DE-
LAY BOILER STARTUP MAKING IT POSSIBLE FOR MONTHLY FGD MODULE HOURS
TO EXCEED ACTUAL BOILER HOURS.
1/78 A
B
C
0
E
F
SYSTEM
100.0
.0
100.0
.0
.0
.0
33.3
100.0
.0
100.0
.0
.0
.0
33.3
58.0
.0
58.0
.0
.0
.0
19.3
331
144
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT TRIPPED SEVERAL TIMES DUE TO DIFFICULTIES IN BURNING WET STOCK-
PILE COAL.
THERE WERE PROBLEMS WITH THE IB FAN WHICH NECESSITATED EXTENSIVE REPAIRS.
LINING ABRASION AND DISBONDMENT IN THE FAN CAUSED CORROSION OF UNDERLYING-
SUPPORT METAL.
8/78 A
B
C
D
E
F
SYSTEM
79.0
61.0
82.0
.0
.0
.0
37.0
100.0
80.0
100.0
.0
.0
.0
46.7
79.0
61.0
82.0
.0
.0
.0
37.0
672 514
249
** PROBLEMS/SOLUTIONS/COMMENTS
EXTENSIVE REPAIRS TO THE IB ID FAN AND THE EMERGENCY NEED FOR LOAD FROM
THE PLANT DURING THE COAL STRIKE TEMPORARILY OVERLOADED THE 1A AND 1C
TRAINS. THE 1C MIST ELIMINATORS WILL BE REPLACED AS A RESULT OF THIS.
THE IB FLUE RELINING CONTINUED.
3/78 A
B
C
D
E
F
SYSTEM
43.0
91.0
90.0
65.0
50.0
60.0
66.5
47.0
98.0
97.0
70.0
54.0
65.0
71.8
43.0
91.0
90.0
65.0
50.0
60.0
66.5
744 689
495
** PROBLEMS/SOLUTIONS/COMMENTS
REPLACEMENT OF THE LINING IN THE IB CHIMNEY WITH CXL 2000 WAS COMPLETED.
REPAIRS WERE MADE ON THE A, B AND C FAN HOUSINGS.
4/78 A 74.0 74.0 74.0
485
-------
EPA UriLITY FGD SURVEY: OCTOBER - DECEMBER 1980
PENNSYLVANIA POWER: BRUCE MANSFIELD 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTO
B
C
D
E
F
SYSTEM
88.0
49.0
87.0
97.0
94.0
81.5
88.0
49.0
87.0
97.0
94.0
81.5
88.0
49.0
87.0
97.0
94.0
81.5
720 720 587
5/78 A
B
C
D
E
F
SYSTEM
98.0
.0
98.0
91.0
92.0
92.0
78.5
97.0
.0
97.0
85.0
84.0
86.0
74.8
** PROBLEMS/SOLUTIONS/COMMENTS
FAN HOUSINGS LEAK REPAIRS WERE MADE DURING APRIL.
MISCELLANEOUS LEAK REPAIRS WERE MADE TO DUCTS.
59.0
.0
59.0
52.0
52.0
53.0
45.8 744 457 341
** PROBLEMS/SOLUTIONS/COMMENTS
THE ANNUAL BOILER INSPECTION OUTAGE BEGAN ON MAY 20.
EXTENSIVE REPAIRS WERE MADE ON THE IB FAN.
6/78 A .0
B .0
C 100.0
D 100.0
E 100.0
F 100.0
SYSTEM 66.7 .0 720 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER INSPECTION AND GENERATOR STATOR COOLER REPAIRS CONTINUED
THROUGH JUNE.
7/78 SYSTEM 744
8/78 SYSTEM 744
9/78 SYSTEM 720
10/78 SYSTEM 96.3 744 671
11/78 SYSTEM 720
12/78 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
NO INFORMATION WAS AVAILABLE FOR THIS REPORT PERIOD.
1/79 SYSTEM 744
2/79 SYSTEM 672
3/79 SYSTEM 744
4/79 SYSTEM 720
5/79 SYSTEM 744
486
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
PENNSYLVANIA POWER: BRUCE MANSFIELD 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
UNIT 1 IS CURRENTLY DOWN FOR A BOILER OVERHAUL.
SIX OF THE TWELVE FAN HOUSINGS HAVE BEEN CHANGED FROM CARBON STEEL TO
INCOLLOY 825.
6/79 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
720
THE UTILITY REPORTS THAT THE AVAILABILITY FROM JANUARY 1, 1979 THROUGH
MAY 31, 1979 WAS 92.OX.
THE UTILITY REPORTED THAT FAN MOTOR FAILURES WERE A MAJOR PROBLEM AREA
DURING THE FIRST HALF OF 1979.
7/79
8/79
9/79
SYSTEM
SYSTEM
SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
720
10/79
11/79
12/79
SYSTEM
SYSTEM
SYSTEM
96.1
90.S
99.8
FAN HOUSING WORK (.CHANGING FROM LINED CARBON STEEL TO INCOLLOY 825) IS
CONTINUING.
NEW PH MONITOR MODIFICATIONS HAVE YIELDED PROMISING RESULTS WITH RESPECT
TO MONITOR AVAILABILITY.
THE FGD SYSTEM ATTRIBUTED 17.42 OF THE TOTAL UNIT UNAVAILABILITY FOR 1979
TO DATE. THE BREAKDOWN IS AS FOLLOWS:
7.6X SCRUBBER ID FAN WORK/PROBLEMS
8.3X GENERAL SCRUBBER PROBLEMS AND MAINTENANCE
l.OX REAGENT HANDLING PROBLEMS (LIME SLAKER AND PIPING)
0.5X MIST ELIMINATOR PLUGGING
744
720
744
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE PERIOD AN ADDITIONAL FAN HOUSING MAS REPLACED WITH THE NEW
INCOLLOY 825. BY THE END OF 1980 ALL THE FAN HOUSINGS WILL BE REPLACED
WITH THE NEW MATERIAL.
WHERE THE NEW PH MONITORS HAVE BEEN INSTALLED, THE PROBE MAINTENANCE
HAS BEEN CUT SOX, AND THE MIST ELIMINATORS HAVE BEEN LESS OF A PROBLEM
TO MAINTAIN.
THE SLUDGE PUMPS HAVE BEEN A PROBLEM. THE PUMPS REQUIRE AN OVERHAUL
EVERY 1000 HOURS AND HAVE FREQUENT VALVE FAILURES. NEW VALVE MANIFOLDS MAY
BE INSTALLED TO IMPROVE PUMP SERVICE BY ALLOWING ACCESS TO INDIVIDUAL BALL
VALVES.
1/80
2/80
SYSTEM
SYSTEM
98.6
98.4
100.0
100.0
73.1
74.9
744
696
544
521
544
521
487
-------
EPA UTILITY FGO SURVEY: OCTOBER - DECEMBER 1980
PENNSYLVANIA POWER: BRUCE MANSFIELD 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP
S02 PART. HOURS HOURS HOURS FACT<
»* PROBLEMS/SOLUTIONS/CDMMENTS
NO MAJTO FGD-RELATED PROBLEMS OCCURRED DURING JANUARY AND FEBRUARY.
3/80 SYSTEM 98.8 100.0 72.6 744 540 540
*» PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER MAS OUT OF SERVICE ONE MEEK IN MARCH DUE TO A PLUGGED AIR
PREHEATER. NO MAJOR FGD-RELATED PROBLEMS MERE REPORTED FOR MARCH.
4/80 SYSTEM 91.1 100.0 81.4 720 586 586
5/80 SYSTEM 744
6/80 SYSTEM 7ZO
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION FOR THE MONTHS OF MAY AND JUNE IS NOT YET AVAILABLE.
7/80 SYSTEM 98.4 100.0 85.9 744 639 639
8/80 SYSTEM 98.9 100.0 55.4 744 412 412
9/80 SYSTEM 95.3 100.0 74.0 720 533 533
10/80 SYSTEM 98.3 100.0 28.1 744 209 209
** PROBLEMS/SOLUTIONS/COMMENTS
ON OCTOBER 10 THE UNIT HAS TAKEN OUT OF SERVICE FOR A TURBINE OVERHAUL.
DURING THIS OUTAGE THE UTILITY COMMENCED THE INSTALLATION OF A MANIFOLD
SYSTEM IN THE STACK. THE OUTAGE IS SCHEDULED TO LAST APPROXIMATELY 12
MEEKS.
11/80 SYSTEM .0 .0 720 0 0
12/80 SYSTEM .0 .0 744 0 0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE YEAR MINOR EROSION PROBLEMS WITH THE ID FAN ROTORS HERE EN-
COUNTERED. FOUR OF THE SIX ID FAN ROTORS HAVE BEEN REPAIRED.
BRUCE MANSFIELD 1 REMAINED OFF LINE DURING NOVEMBER AND DECEMBER AS A
RESULT OF THE TURBINE OVERHAUL.
488
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTIC'JLATE EMISSION LIMITATION - NG/J
502 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MM
GROSS 'JNIT GENERATING CAPACITY - MM
NET UNIT GENERATING CAPACITY W/FGD - MM
NET UNIT GENERATING CAPACITY WO/FGD - MM
EQUIVALENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
B3ILER SUPPLIER
BOILER TYPE
BOILFR SERVICE LOAD
D£SICN BOILER FLUE GAS FLJW - CU.M/S
BOILER FLUE GAS TEMPERATUkE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUi".L DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - '/.
R/iNGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** PARTICLE SCRUBBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SH-.LL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LIIIER SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
NUI1BER OF CONTACTING ZONES
LIQUID RECIRCUUTION RATE - LITER/S
L/G RATIO - LITER/CU.M
PRESSURE DROP - KPA
SUPERFICIAL GAS VELOCITY - M/S
INLET GAS FLOW RATE - CU.M/S
INLET GAS TEMPERATURE - C
S02 REMOVAL EFFICENCY - 7.
PARTICLE REMOVAL EFFICIENCY - 7.
*** FGD SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
PENNSYLVANIA POWER
BRUCE MANSFIELD
2
SHIPPINGPORT
PENNSYLVANIA
D
15. ( .035 LB/MMBTU)
258. ( .600 LB/MMBTU)
****** (****** LB/MMBTU)
2751
917
825
880
917
FOSTER WHEELER
PULVERIZED CJAL
BASE
1580.86
140.6
290.
CONCRETE
5.8
COAL
BITUMINOUS
26749.
12.90
11.5-13.5
7.00
5.5-8.5
3.00
1.75-3.75
(3350000 ACFM)
( 285 F)
( 950 FT)
( 19.0 FT)
( 11500 BTU/LB)
11000-11950
******
VENTURI TOWER
VARIABLE-TH^OAT/TOP-ENTRY PLUMB BOB
CHEMICO
35.5 DIA X 52 HIGH
CARBON STEEL
AISI 1110
ORGANIC
GLASS FLAKE-FILLED POLYESTER
PLUM BOB AND 2 SETS OF SPRAYS, 317 SS AND 316 S3
1386.0
5.3
5.7
61.0
263.5
140.6
70.0
99.8
(22000 GPM)
(40.0 SAL/1000ACF)
(23.0 IN-H20)
( 200.0 FT/S)
( 558333 ACFM)
( 285 F)
THROWAWAY PRODUCT
WET SCRUBBING
LIME
MG PROMOTED
489
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
PENNSYLVANIA POWER: BRUCE MANSFIELD 2 (CONT.)
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY -
UNIT DESIGN S02 REMOVAL EFFICIENCY - X
CURRENT STATUS
TERMINATION
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
** ABSORBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LTNER MATERIAL TRADE NAME/COMMON TYPE
NUMBER OF CONTACTING ZONES
L.TQUID RECIRCULATION RATE - LITER/S
L/G RATIO - L/CU.M
GAS-SIDE PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/SEC
IHLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
SOS REMOVAL EFFICIENCY - X
** MI.5T ELIMINATOR
PRE-HIST ELIMINATOR/MIST LLIMINATOR
NUMB-:R PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
NUMBER OF STAGES
Nl'MBER OF PASSES PER STAGE
DISTANCE BETWEEN VANES - CM
WNE ANGLES - DEGREES
PFESSURE DROP - KPA
SIPERFICAL GAS VELOCITY - M/S
CONSTRUCTION MATERIAL GENERIC TYPE
WASH WATER SOURCE
WASH RATE - L/S
** FANS
NUMBER
NL'MBER OF SPARES
SUPPLIER
FL'NCTION
APPLICATION
SERVICE
FLJE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
L:NER GENERIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
CHEMICO DIVISION, ENVIROTECH
GILBERT/COMMONWEALTH ASSOCIATES
FULL SCALE
NEW
X 99.80
92.10
1
10/77
10/77
7/77
10/74
VENTURI TOWER
FIXED THROAT
CHEMICO DIVISION, ENVIROTECH
34 DIA X 51.5 HIGH
CARBON STEEL
AISI 1110
N/A
ORGANIC
POLYESTER FLAKEGLASS
1
(19400 GPM)
(45.0 GAL/1000 ACF)
( 8.0 IN-H20)
(100.0 FT/S)
( 426600 ACFM)
( 127 F)
1222.
6.0
2.0
30.5
201.31
52.8
92.1
MIST ELIMINATOR
6
IMPINGEMENT
BAFFLE
CHEVRON VANE
HORIZONTAL
1
4
7.6
90
.1
3.0
( 3.00 IN)
( .6 IN-H20)
( 10.0 FT/S)
FIBERGLASS REINFORCED PLASTIC
THICKENER OVERFLOW
3.8 ( 60 GAL/MIN)
12
6
GREEN FAN
BALANCED DRAFT
BOILER I.D.
WET
263.32
47.8
( 558000 ACFM)
( 118 F)
HOUSINGS 5INCOLOY 825 - BLADESJINCONEL 625
SCRUBBER INLET
CARBON STEEL
POLYESTER FLAKEGLASS
SCRUBBER OUTLET
CARBON STEEL
POLYESTER FLAKEGLASS
490
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
PENNSYLVANIA POWER: BRUCE MANSFIELD 2 (CONT.)
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
MANUFACTURER
NUMBER
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
** TANKS
SERVICE
THICKENER UNDERFLOW
MIXING TANK ICALCILOX & THCKNR UNDRF
SLUDGE TRANSFER
MIXING TANK [SPENT SLURRY & FLYASH1
RECYCLE (SCRUBBER)
RECYCLE (ABSORBER)
** PUMPS
SERVICE
VENTURI RECIRCULATION
SLURRY FEED
LIME SLURRY RECIRCULATION
ABSORBER RECIRCULATION
THICKENER UNDERFLOW
THICKENER TRANSFER
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
CONFIGURATION
DIMENSIONS - FT
SHELL GENERIC MATERIAL TYPE
OUTLET STREAM CHARACTERISTICS
*#* SLJDGE
** TREATMENT
MSTHOD
PROPRIETARY PROCESS
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
S:;TE CAPACITY - CU.M
** PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS
CONTROL LEVELS
MONITOR LOCATION
PPOCfSS CONTROL MANNER
PROCESS CHEMISTRY MODE
** WATER BALANCE
WATER LOOP TYPE
** FGC SPARE CAPACITY INDICES
ABSORBER - '/.
** FGt: SPARE COMPONENT INDICES
ABSORBER
LIME SLAKING
SLAKER
DORR-OLIVER
2
20.0
NUMBER
( 22 TPH)
****
2
****
****
6
6
NUMBER
12
4
4
24
4
4
THICKENER
1
CYLINDRICAL
200 DIA
CARBON STEEt
30X SOLIDS
CALCILOX
DRAVO
FINAL
LANDFILL
OFF SITE
PUMPED
59927000
C 49000.0 ACRE-FT)
PH SLURRY fOLIDS, LIQUID LEVEL, LIQUID FLOW
PH 6.8-7.2
PH-RECIRCULATING LINES AND THICKENER
AUTOMATIC
FEEDBACK
OPEN
.0
.0
491
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
PENNSYLVANIA POWER: BRUCE MANSFIELD Z (CONT.)
PERIOD
10/77
MODULE
2A
2B
2C
2D
2E
2F
SYSTEM
AVAILABILITY
94.0
97.0
98.0
63.0
66.0
61.0
79.8
OPER ABILITY
100.0
100.0
100.0
61.0
59.0
51.0
78.5
^CKTUKnAN^C Uftl A
RELIABILITY UTILIZATION Y. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTO
83.0
88.0
87.0
48.0
47.0
41.0
65.7 744 595 4S9
** PROBLEMS/SOLUTIONS/COMHENTS
11/77 2A
2B
2C
2D
2E
2F
SYSTEM
100.0
96.0
88.0
47.0
55.0
47.0
72.2
100.0
100.0
92.0
57.0
52.0
42.0
73.8
UNIT 2 WAS DECLARED AVAILABLE FOR COMMERCIAL OPERATION AT 825 MM ON
OCTOBER 1, 1977.
THE SPRAYS IN THE 2F FAN WERE CLEANED.
REPAIRS WERE MADE TO THE 2B FLUE STACK LINING BECAUSE OF PREMATURE
FAILURE OF SEVERAL TEST PATCHES.
THE UNIT TRIPPED DUE TO FAULTY GENERATOR CONTROL TRANSFORMERS.
83.0
81.0
74.0
46.0
42.0
34.0
60.0 720 581 432
** PROBLEMS/SOLUTIONS/COMMENTS
PROBLEMS ASSOCIATED WITH THE STATION POWER TRANSFORMERS CAUSED LIMITATION
IN LOAD ON UNIT Z. THREE OF THE SIX STATION POWER TRANSFORMERS FOR UNIT
2 WERE DESTROYED.
63.0
86.0
83.0
86.0
69.0
76.0
77.2 744 607 57*
** PROBLEMS/SOLUTIONS/COMMENTS
COLD WEATHER CAUSED SOME FREEZING PROBLEMS WITH PROCESS PIPING.
12/77
2A
2B
2C
2D
2E
2F
SYSTEM
74.0
99.0
98.0
100.0
89.0
99.0
93.2
77.0
100.0
100.0
100.0
85.0
93.0
92.5
1/78 2A
2B
2C
2D
2E
2F
SYSTEM
95.0
100.0
96.0
94.0
99.0
99.0
97.2
58.0
100.0
56.0
100.0
100.0
96.0
85.0
31.0
76.0
29.0
70.0
64.0
50.0
53.3
744 391
397
** PROBLEMS/SOLUTIONS/CO 1MENTS
THE UHIT TRIPPED SEVERAL TIMES DUE TO DIFFICULTIES IN BURNING WET STOCK-
PILE COAL. WHEN THE UNIT WAS ON LINE DURING THIS MONTH, THE WET COAL ALSO
PREVENTED FULL LOAD OPERATION OF COAL MILLS.
BOILER CONTROL VALVE ("W" VALVE) PROBLEMS COMPOUNDED START-UP
DIFFICULTIES.
492
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
PENNSYLVANIA POWER: BRUCE MANSFIELD 2 (CONT.)
l-'CKrUKnANUC UA 1 A
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
2/78 2A
2B
2C
20
2E
2F
SYSTEM
84.0
87.0
89.0
97.0
99.0
78.0
89.0
46.0
68.0
88.0
71.0
99.0
78.0
75.0
48.0
68.0
88.0
71.0
99.0
78.0
75.3 672 672 506
** PROBLEMS/SOLUTIONS/COMMENTS
3/78 2A
2B
2C
20
2E
2F
SYSTEM
100.0
93.0
13.0
95.0
95.0
97.0
82.2
MANY PROBLEMS OCCURRED WITH
100.0
91.0
10.0
100.0
96.0
99.0
82.7
ID FAN COOLERS DUE TO INCLEMENT WEATHER.
67.0
60.0
13.0
68.0
64.0
65.0
56.2 744 494 418
5/78
** PROBLEMS/SOLUTIONS/COMMENTS
EXTENSIVE ID FAN HOUSING REPAIRS WERE PERFORMED ON THE 2C FAN.
A BOILER TUBE LEAK CAUSED SEVERAL DAYS OUTAGE.
81.0
81.0
59.0
15.0
14.0
13.0
43.8 720 713
** PROBLEMS/SOLUTIONS/COMMENTS
4/78 2A
2B
2C
2D
2E
2F
SYSTEM
100.0
100.0
59.0
15.0
14.0
13.0
50.2
82.0
82.0
59.0
15.0
14.0
13.0
44.2
315
2A
2B
2C
20
2E
2F
SYSTEM
100.0
100.0
100.0
.0
.0
.0
50.0
100.0
100.0
100.0
.0
.0
.0
50.0
FLUE LINING REPAIRS ON THE 2B CHIMNEY BEGAN ON APRIL 5.
EXTENSIVE REPAIRS WERE MADE ON THE 2C ID FAN, CAUSING IT TO BE DOWN FROM
MARCH 6 THROUGH APRIL 13.
37.0
37.0
37. C
.0
.0
.0
18.5 744 270 138
#* PROBLEMS/SOLUTIONS/COMMENTS
6/78 2A
2B
2C
20
2E
2F
SYSTEM
70.0
69.0
66.0
.0
.0
.0
34.2
100.0
100.0
100.0
.0
.0
.0
50.0
THE UNIT WAS OFF-LINE FOR THREE WEEKS FOR REPAIRS TO THE 2C ID FAN,
INCLUDING COVERING THE HOUSING WITH INCOLOY 825.
2B STACK LINING REPAIRS CONTINUED.
70.0
69.0
66.0
.0
.0
.0
34.2 720 417 246
493
-------
EPA UYILITY F6D SURVEY: OCTOBER - DECEMBER 1980
PENNSYLVANIA POWER: BRUCE MANSFIELD 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTG
** PROBLEMS/SOLUTIONS/COMMENTS
2B STACK LINING REPAIRS CONTINUED.
-NOTE: AN ATTEMPT is ALWAYS MADE TO BEGIN OPERATION OF THE BOILER AND FGD
SYSTEM SIMULTANEOUSLY AT BRUCE MANSFIELD. OCCASIONALLY PROBLEMS
DELAY BOILER START-UP, MAKING IT POSSIBLE FOR MONTHLY FGD MODULE
HOURS TO EXCEED ACTUAL BOILER HOURS.
7/78 SYSTEM 744
8/78 SYSTEM 744
9/78 SYSTEM 720
10/78 SYSTEM 99.3 744 144
11/78 SYSTEM 720
12/78 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
NO INFORMATION WAS AVAILABLE FOR THIS PERIOD.
1/79 SYSTEM 744
2/79 SYSTEM 672
3/79 SYSTEM 744
4/79 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
NO INFORMATION WAS REPORTED FOR THIS PERIOD BY THE UTILITY.
5/79 SYSTEM 744
6/79 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE AVAILABILITY FOR JANUARY 1, 1979 THROUGH
MAY 31, 1979 WAS 88.8X.
THE UTILITY REPORTED THAT SOME FAN PROBLEMS WERE RECENTLY ENCOUNTERED.
7/79 SYSTEM 744
8/79 SYSTEM 744
9/79 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
CHIMNEY LINING WORK (APPLICATION OF CXL 2000) WAS COMPLETED IN EARLY 1979.
FAN HOUSING WORK (CHANGING FROM LINED CARBON STEEL TO INCOLLOY 825) IS
CONTINUING.
NEW PH MONITOR MODIFICATIONS HAVE YIELDED PROMISING RESULTS WITH RESPECT
TO MONITOR AVAILABILITY.
494
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
PENNSYLVANIA POWER: BRUCE MANSFIELD 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPEPABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
THE FGD SYSTEM ATTRIBUTED 10.8X OF THE TOTAL UNIT UNAVAILABILITY FOR 1979
TO DATE. THE BREAKDOWN IS AS FOLLOWS:
5.OX CHIMNEY (FINISHED CXL 2000 APPLICATION)
1.3X GENERAL SCRUBBER PROBLEMS AND MAINTENANCE
1.5X ID FAN WORK/PROBLEMS
2.OX MIST ELIMINATOR PLUGGING
l.OX EMISSION VIOLATION (CUT BACK OF BOILER LOAD BECAUSE OF LOW S02
REMOVAL EFFICIENCY).
10/79 SYSTEM 97.5 744
11/79 SYSTEM 100.0 720
12/79 SYSTEM 96.5 744
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE PERIOD AN ADDITIONAL FAN HOUSING MAS REPLACED WITH THE NEW
INCOLLOY 825. BY THE END OF 1980 ALL THE FAN HOUSINGS WILL BE REPLACED
WITH THE NEW MATERIAL.
WHERE THE NEW PH MONITORS HAVE BEEN INSTALLED, PROBE MAINTENANCE
HAS BEEN CUT SOX, AND MIST ELIMINATOR MAINTENANCE HAS BEEN LESS OF A
PROBLEM.
THE SLUDGE PUMPS HAVE BEEN A PROBLEM. THE PUMPS REQUIRE AN OVERHAUL
EVERY 1000 HOURS AND HAVE FREQUENT VALVE FAILURES. NEW VALVE MANIFOLDS MAY
BE INSTALLED TO IMPROVE PUMP SERVICE BY ALLOWING ACCESS TO INDIVIDUAL
BALL VALVES.
1/80 SYSTEM 97.1 100.0 75.7 744 563 563
2/80 SYSTEM 94.7 100.0 89.3 696 622 622
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM EXPERIENCED NO MAJOR PROBLEMS DURING JANUARY AND FEBRUARY.
3/80 SYSTEM 98.4 100.0 47.4 744 353 353
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS OUT OF SERVICE 16 DAYS IN MARCH FOR A SCHEDULED BOILER
INSPECTION. NO MAJOR FGD-RELATEO PROBLEMS WERE REPORTED.
4/80 SYSTEM 89.5 100.0 87.0 720 626 626
5/80 SYSTEM 744
6/80 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION FOR THE MONTHS OF MAY AND JUNE IS NOT YET AVAILABLE.
7/80 SYSTEM 95.4 100.0 76.8 744 571 571
8/80 SYSTEM 93.9 100.0 74.1 744 551 551
9/80 SYSTEM 97.9 100.0 75.1 720 541 541
10/80 SYSTEM 97.2 100.0 90.3 744 672 672
11/80 SYSTEM 97.2 100.0 82.5 720 594 594
495
-------
EPA UTILITY FSD SURVEY: OCTOBER - DECEMBER 1980
PENNSYLVANIA POWER: BRUCE MANSFIELD 2 (CONT.)
PERFORMANCE DATA
PERIOC MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION '/. REMOVAL PER BOILER F6D CAP.
SOZ PART. HOURS HOURS HOURS FACTC
12/80 SYSTEM 97.9 100.0 68.1 744 507 507
** PROBLEMS/SOLUTIONS/COMMENTS
DURING A TURBINE OVERHAUL OF UNIT 1, A MANIFOLD SYSTEM WAS BEING INSTALLED
IN THl STACK. UNIT Z IS SCHEDULED TO BE SHUTDOWN IN LATE 1981 OR EARLY
1982 S3 THAT THE MANIFOLD SYSTEM CAN BE COMPLETED. DURING THIS OUTAGE
THE ID FAN ROTORS, WHICH HAVE ERODED, ARE SCHEDULED TO BE REPLACED.
496
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MM
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGD - MM
EQUIV/LENT SCRUBBED CAPACITY - MW
** UMT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
POILER SERVICE LOAD
LESIGN BOILER FLUE GAS FLOW - CU.M/S
EOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STAC". TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUE1, GRADE
AVEF'AGE HEAT CONTENT - J/C
Ri
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
PENNSYLVANIA POWER: BRUCE MANSFIELD 3 (CONT.)
** ABSORBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
SUPPLIER
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
NUMBER OF CONTACTING ZONES
6AS-SIDE PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/SEC
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
** REHEATER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
** FANS
MJMBER
APPLICATION
SERVICE
** TAfJKS
SERVICE
REACTION
LIME SLURRY
** PUMPS
SERVICE
SLUFRY RECIRCULATION
** SOCICS CONCENTRATING/DEMATERING
DEVICE
N.71EER
*** SUJDGE
** TREATMENT
M':THOD
** FGD SPARE CAPACITY INDICES
AIJSORBER - X
** FG3 SPARE COMPONENT INDICES
ABSORBER
SPRAY TOWER
OPEN CROSSCURRENT SPRAY
HEIR HORIZONTAL SPRAY CHAMBER
PULLMAN KELLOGG
AISI 1110
N/A
ORGANIC
RUBBER
2.8 IN-H20)
22.0 FT/S)
.7 (
6.7 (
MIST ELIMINATOR
IMPINGEMENT
BAFFLE
CHEVRON VANE
NONE
N/A
N/A
CENTRIFUGAL RADIAL TIP
DRY
NUMBER
****
NUMBER
****
THICKENER
1
FLYASH STABILIZATION
2.5
1.0
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL
S02 PART.
PER BOILER
HOURS HOURS
FGD CAP.
HOURS FACTOR
6/80 SYSTEM
720
498
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
PENNSYLVANIA POWER: BRUCE MANSFIELD 3 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FED CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
INITIAL OPERATION OF THE FGD SYSTEM COMMENCED ON JUNE 9, 1980. THE
UTILITY REPORTED THAT IT IS PRESENTLY IN THE PROCESS OF DEBUGGING THE
SYSTEM.
7/80 SYSTEM 744
8/80 SYSTEM 744
9/80 SYSTEM 100.0 100.0 100.0 720 720 720
** PROBLEMS/SOLUTIONS/COMMENTS
COMMERCIAL OPERATION OF UNIT 3 COMMENCED ON SEPTEMBER 29, 1980.
10/80 SYSTEM 89.1 100.0 74.1 744 551 551
11/80 SYSTEM 90.3 100.0 63.2 720 455 455
12/80 SYSTEM 91.1 100.0 68.0 744 506 506
** PROBLEMS/SOLUTIONS/COMMENTS
SINCE STARTUP THE UTILITY HAS EXPERIENCED PROBLEMS WITH THE CEILCOTE
LINER WEARING ON THE ABSORBER MALLS.
PROBLEMS WITH MIST CARRYOVER HAVE RESULTED IN THE INSTALLATION OF BAFFLES
AT THE MIST ELIMINATOR TROUGHS.
SINCE STARTUP PROBLEMS HAVE OCCURRED AS A RESULT OF H2S GAS GENERATION IN
DEAD SPOTS OF THE REACTION TANKS. THE TANK AGITATORS ARE BEING RELOCATED.
499
-------
EPA UTILITY FED SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC F6D SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NS/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - '/.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
#* ESP
NUMBER
TYPE
SUPPLIER
INLET FLUE GAS CAPACITY - CU.M/S
INLET FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
PARTICLE REMOVAL EFFICENCY - 7.
** PARTICLE SCRUBBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
DIMENSIONS - FT
SMELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
G4S CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
LIQUID RECIRCULATION RATE - LITER/S
L/G RATIO - LITER/CU.M
PRESSURE DROP - KPA
SUPERFICIAL GAS VELOCITY -• M/S
INLET GAS FLOW RATE - CU.M'S
INLET GAS TEMPERATURE - C
PARTICLE REMOVAL EFFICIENCY - 7.
PUBLIC SERVICE OF NEW MEXICO
SAN JUAN
WATER FLOW
NEW MEXICO
C
9.
279.
******
1560
361
( .020 LB/MMBTU)
( .650 LB/MMBTU)
(****** LB/MMBTU)
330
361
FOSTER WHEELER
PULVERIZED COAL
BASE
750.32
122.8
122.
CONCRETE
6.1
(1590000 ACFM)
{ 253 F)
( 400 FT)
( 20.0 FT)
COAL
SUBBITUMINOUS
20934.
22.00
12.59-22.45
14.82
10.5
.80
.6-1.3
.03
0-0.09
( 9000 BTU/LB)
8000-11628
HOT SIDE
WESTERN PREC.
943.8
371.1
.6
99.8
DIVISION, JOY
(2000000 ACFM)
( 700 F)
( 3. IN-H20)
VENTURI TOWER
VARIABLE-THROAT/BOTTOM-ENTRY PLUMB BOB
DAVY MCKEE
12'6" DIA X 28' 0" HIGH
CARBON STEEL
AISI 1110
ACID BRICK
224.9
.9
3.1
48.8
237.4
134.4
75.0
( 3570 GPM)
( 7.1 GAL/1000ACF)
(12.5 IN-H20)
( 160.0 FT/S)
( 503000 ACFM)
( 274 F)
500
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
PUBLIC SERVICE OF NEW MEXICO: SAN JUAN 1 (CONT.).
*** FED SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-F: FIRM
DEVELOPMENT LEVEL
NE^/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
UNIT DESIGN S02 REMOVAL EFFICIENCY - 7.
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
** ABSORBER
NUMBER
NUMBER OF SPARES
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
GAS CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
DISTANCE BETWEEN GAS CONTACTING ZONES - CM
LIQUID RECIRCULATION RATE - LITER/S
L/G RATIO - L/CU.M
GAS-SIDE PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/SEC
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
S02 REMOVAL EFFICIENCY - '/.
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
NUMBER OF PASSES PER STAGE
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/S
CONSTRUCTION MATERIAL GENERIC TYPE
WASH WATER SOURCE
WASH RATE - L/S
** REHEATER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
TEMPERATURE INCREASE - C
INLET FLUE GAS FLOW RATE - CU. M/S
IHLET FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
SALEABLE PRODUCT
WET SCRUBBING
WELLMAN LORD
NONE
DAVY MCKEE
STEARNS-ROGER '
FULL SCALE
RETROFIT
7. 99.SO
90.00
1
4/78
4/78
2/74
4
1
TRAY TOWER
VALVE TRAY
BUBBLE CAP TRAY TOWER
DAVY MCKEE
24' X 29' X 79' HIGH
INORGANIC
REINFORCED CONCRETE
N/A
INORGANIC
ACID-RESISTANT BRICK & MORTAR
PREFIRED BRICK
5-LEVELS OF VALVE TRAYS (KOCH FLEXITRAYS)
5
5.1 ( 2.0IN)
47. t 750 GPM)
(1.7 GAL/1000 ACF)
(16.0 IN-H20)
( 10.8 FT/S)
t 435000 ACFM)
( 120 F)
.Z
4.0
3.3
205.28
48.9
90.0
MIST ELIMINATOR
8
IMPINGEMENT
BAFFLE
CHEVRON VANE
HORIZONTAL
1
.0
3.2
NORYL PLASTIC
TREATED WATER
3.8
.0 IN-H20)
10.5 FT/S)
( 60 GAL/MIN)
INDIRECT HOT AIR
EXTERNAL HEAT EXCHANGER
STEAM TUBE BUNDLES
10.0 ( 50 F)
647.45 (1372000 ACFM)
51.7 ( 125 F)
304 SS
501
-------
EPA UTILITY FGO SURVEY: OCTOBER - DECEMBER 1980
PUBLIC SERVICE OF NEW MEXICO: SAN JUAN 1 (CONT.)
** FAIIS
NUMBER
SUPPLIER
FUNCTION
APPLICATION
SURVICE
FLUE GAS FLOW RATE - CU.M/S
FKUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** DUCTWORK
LOCATION
DIMENSIONS
SHELL GENERIC MATERIAL TYPE
** TANKS
SERVICE
ABSORBER PRODUCT PUMP
** PUMPS
SERVICE
ABSORBER PRODUCT TRANSFER
SCRUBBER RECIRCUUTION
ABSORBER RECIRCULATION
ABSORBER SPRAY RECIRCUUTION
*** SALEABLE BYPRODUCTS
NATURE
FULL LOAD QUANTITY - M T/H
QUALITY - 7.
DISPOSITION
*** SLUDGE
BUFFALO FORGE
BOOSTER
FORCED DRAFT
DRY
276.06
122.8
CARBON STEEL
ESP TO FANS
16 X 24
CARBON STEEL
NUMBER
1
NUMBER
( 585000 ACFM)
( 253 F)
2
4
20
8
ELEMENTAL SULFUR
1.45 (
99.0
MARKETED
1.60 TPH)
** TREATMENT
METHOD
** DISPOSAL
** DISPOSAL
TYPE
** PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS
CONTROL LEVELS
MONITOR LOCATION
PROCESS CONTROL MANNER
** WATER BALANCE
WATER LOOP TYPE
POND SEEPAGE/RUNOFF WATER LOSS - LITERS/S
MAKEUP WATER ADDITION - LITERS/S
** FGD SPARE CAPACITY INDICES
ABSORBER - X
** FGD SPARE COMPONENT INDICES
ABSORBER
NONE
NONE
PH & DENSITY
PH 5.5-6.5; SP. GR. 1.2-1.3
ABSORBER FEED AND PRODUCT SOLUTION
MANUAL
CLOSED
45
23.0
33.3
2.0
( 365 GPM)
502
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
PUBLIC SERVICE OF NEW MEXICO: SAN JUAN 1 (CONT.)
PERFORMANCE DATA—
PERIOD MODULE AVAILABILITY OPER\BILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
0/78 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
NOTE: ALTHOUGH THIS FSD SYSTEM IS DESIGNED TO BRING THE BOILER INTO COM-
PLIANCE WITH A 0.34 LB/MM BTU S02 EMISSION STANDARD, THE STATE HAS
INITIALLY ONLY REQUIRED A 1.2 LB/MM BTU S02 CONTROL LEVEL. SAN
JUAN 1 WILL BE REQUIRED TO MEET THE MORE STRINGENT S02 EMISSION
LIMITATION VALUE BY SEPTEMBER 1, 1980. THE UNIT ONLY REQUIRES TWO
OF THE FOUR SCRUBBING TRAINS TO MEET THE 1.2 LB/MM BTU LIMITATION
VALUE; HOWEVER, THREE ARE REQUIRED FOR THE MORE STRINGENT LIMITATION
VALUE (THE SYSTEM IS DESIGNED TO INCLUDE ONE SPARE SCRUBBING TRAIN
WHEN MEETING THE 0.34 LB/MM BTU S02 EMISSION STANDARD). BECAUSE
OF THIS CHANGE IN EMISSION LIMITATION VALUES THE FGD SYSTEM WILL
EFFECTIVELY HAVE AN ABSORBER SPARE COMPONENT INDEX OF 2.0 (100X
SPARE CAPACITY FOR THIS SYSTEM) THROUGH AUGUST, 1980 AND 1.0
(33.3X SPARE CAPACITY FOR THIS SYSTEM) THEREAFTER. CONSEQUENTLY
THE "SYSTEM" DEPENDABILITY FACTORS WILL BE CALCULATED AS:
MODULAR AVERAGE X 2.00
THROUGH AUGUST, 1980 AND:
MODULAR AVERAGE X 1.33
THEREAFTER.
4/78 SYSTEM 720
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
PUBLIC SERVICE OF NEW MEXICO: SAN JUAN 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTC
** PROBLEMS/SOLUTIONS/COMMENTS
A FIRE IN THE START-UP TRANSFORMER DUCT BANK CAUSED A TWO WEEK BOILER
OUTAGE.
10/78 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
HEAT TRACING FAILURES ALLOWED LINE FREEZING TO OCCUR.
SOME SULFUR PRODUCT HAS BEEN PRODUCED BUT THE CHEMICAL PLANT OPERATIONS
HAVE NOT YET BEEN OPTOMIZED.
SHAKIDOWN/DEBUG6ING OPERATIONS ARE CONTINUING.
11/78 SYSTEM 720
12/78 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
ALTHOUGH THE FGD SYSTEM HAS BEEN OPERATING, WEATHER-RELATED PROBLEMS HAVE
LIMITED OPERATIONS TO TWO MODULES.
1/79 SYSTEM 744
2/79 SYSTEM 672
** PROBLEMS/SOLUTIONS/COMMENTS
FREEZE UPS RESULTED IN REHEATER LEAKS LIMITING ABSORBER OPERATIONS.
3/79 SYSTEM 744
4/79 SYSTEM 720
5/79 -SYSTEM 744
•-HJ PROBLEMS/SOUJTIONS/COMMENTS
HOURS ARE NOT YET AVAILABLE BECAUSE THE UTILITY IS CONCENTRATING EFFORTS
ON OPERATION OF THIS NEW UNIT. THE UTILITY REPORTED THAT THE SCRUBBING
MODULES THEMSELVES ARE OPERATING ACCEPTABLY. ALSO THE CHEMICAL PLANT IS
AVAILABLE AND THERE IS NO SYSTEM PLUGGING WHATSOEVER.
THE MAJOR PROBLEM ENCOUNTERED WAS FAN VIBRATION, THE UTILITY HAS BEEN
WORKING WITH THE SUPPLIER IN AN EFFORT TO DISCOVER WHY FAN BALANCE HAS
BEEN DIFFICULT TO MAINTAIN.
7/79 SYSTEM 744
8/79 SYSTEM 744
9/79 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE THIRD QUARTER THE UNIT OPERATED WITH TWO ABSORBERS. ALL FOUR
ABSORBERS HAVE BEEN LARGELY AVAILABLE. ONE ABSORBER WAS DOWN DUE TO
BOOSTER BLOWER VIBRATION PROBLEMS.
10/79 SYSTEM 744
504
-------
EPA UTILITY FED SURVEY: OCTOBER - DECEMBER 1980
PUBLIC SERVICE OF NEW MEXICO: SAN JUAN 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
11/79 SYSTEM
12/79 A
B
C
D
SYSTEM
94.0
100.0
.0
30.0
100.0
79.0
67.4
.0
5.8
76.1
23.8
20.3
.0
1.8
23.0
720
744 224
171
** PROBLEMS/SOLUTIONS/COMMENTS
NOTE: SEE COMMENTS FOR 00/78 EXPLAINING SYSTEM DEPENDABILITY CALCULATIONS.
A REHEATER PROBLEM HAS LIMITED SCRUBBING OPERATIONS TO TWO TO THE FOUR
ABSORBER MODULES. IF THE BOILER WERE TO OPERATE AT A HIGHER LOAD THE
REHEATERS WOULD BE UNABLE TO BOOST THE TEMPERATURE OF THE FLUE GAS ABOVE
DEW POINT. THE FGD SYSTEM HAS BEEN LIMITING UNIT MWH PRODUCTION.
1/80 A
B
C
D
SYSTEM
2/80 A
B
C
D
SYSTEM
3/80
A
B
C
D
SYSTEM
81.0
96.0
.0
83.0
100.0
.0
99.0
3.0
99.0
100.0
.0
100.0
58.1
97.5
100.0
51.0
42.3
79.
86.
2.5
97.6
97.2
.0
50.4
82.8
85.5
100.0
100.0
41.8
34.7
.0
65.1
70.8
.t
85.?
2.3
88.9
88.6
.0
17.6
29.2
30.1
38.5
744 610
696 634
744 262
527
616
286 31.0
** PROBLEMS/SOLUTIONS/COMMENTS
SCRUBBER OPERATIONS AT UNIT ONE ARE STILL LIMITED TO TWO MODULES BECAUSE
OF THE CURRENT LACK OF REHEATER CAPACITY.
4/80
A
B
C
D
SYSTEM
.0
98.2
50.0
91.7
100.0
.0
71.5
7.2
71.5
75.1
100.0
.0
48.2
4.9
48.2
50.7
720 485
365 55.8
** PROBLEMS/SOLUTIONS/COMMENTS
ONLY TWO MODULES ARE NEEDED AT THE PRESENT TIME TO MEET CURRENT S02
EMISSION REGULATIONS (SEE COMMENTS FOR 00/78).
A. TUBE WALL LEAK FORCED THE BOILER OUT OF SERVICE DURING APRIL.
HIGH VIBRATIONS IN THE BOOSTER BLOWER IN MODULE D FOLLOWED AFTER THE UNIT
OUTAGE.
HIGH VIBRATIONS IN THE BOOSTER BLOWER CAUSED MODULE A TO BE UNAVAILABLE
THE ENTIRE MONTH.
REPAIR AND MAINTENANCE OF THE BOOSTER BLOWER AND ISOLATION DAMPERS IN
MODULE C WERE PERFORMED DURING APRIL.
5/80 A
73.1
62.1
55.9
505
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
PUBLIC SERVICE OF NEW MEXICO: SAN JUAN I (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER F6D CAP.
502 PART. HOURS HOURS HOURS FACTOl
B
C
D
SYSTEM
99.7
75.5
80.2
100.0
37.2
71.8
19.9
95.5
100.0
33.5
64.7
17.9
86.0
744 670
640 87.4
6/80
7/80
8/80
9/80
** PROBLEMS/SOLUTIONS/COMMENTS
BOOSTER BLOWER VIBRATIONS ARE CONTINUING IN ALL THE MODULES.
THERE WAS A UNIT OUTAGE SO THAT REPAIR WORK COULD BE UNDERTAKEN ON THE ESP,
A
B
C
D
SYSTEM
2.8
96.9
82.5
.1
91.2
2.5
92.0
79.2
.2
87.0
2.1
75.6
65.0
.1
79.8 71.4
720 591 514 65.4
** PROBLEMS/SOLUTIONS/COMMENTS
A BOILER TUBE LEAK FORCED THE UNIT OUT OF SERVICE IN JUNE.
REPAIR WORK MAS DONE ON THE ISOLATION DAMPERS DURING JUNE.
744 744 683 91.7
A
B
C
D
SYSTEM
.0
30.4
89.2
82.8
100.0
.0
16.0
87.9
79.6
91.7
.0
16.0
87.9
79.6
91.7
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE A WAS UNAVAILABLE IN JULY BECAUSE OF REPAIRS MADE TO THE ISOLATION
DAMPER AND THE LOWER CHIMNEY SEAL.
MODULE B WAS FORCED OUT BECAUSE OF HIGH VIBRATIONS IN THE BOOSTER BLOWER.
VIBR/TIONAL PROBLEMS ALSO KEPT MODULE D OFF LINE UNTIL JULY 4, WHEN THE
BOOSTER BLOWER WAS BALANCED.
A
B
C
D
SYSTEM
.0
21.5
91.1
94.4
100.0
.0
21.5
77.8
90.1
94.7
.0
21.5
77.8
90.1
93.2 94.7
744 744
704 82.0
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE A DID NOT OPERATE IN AUGUST BECAUSE OF REPAIRS MADE TO THE LOWER
CHIMNEY SEAL.
MODULE B WAS OUT OF SERVICE FOR OVER 3 WEEKS TO CLEAN, PAINT, AND BALANCE
THE BOOSTER BLOWER ROTOR.
CRACKED WELDS ON THE WATER INLET NOZZLES WERE REPAIRED ON MODULE C.
A
B
C
D
SYSTEM
.0
37.2
39.4
45.1
60.9
.0
57.4
56.1
71.8
92.7
.0
31.4
30.7
39.3
94.8 50.7
720 394
365 43.5
506
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
PUBLIC SERVICE OF NEW MEXICO: SAN JUAN 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
HIGH VIBRATIONS IN THE BOOSTER BLOWER CAUSED MODULE C TO SHUT DOWN FOR
PART OF SEPTEMBER.
THE FGD SYSTEM HAS DOWN FOR SEVERAL DAYS BECAUSE OF BOILER RELATED
PROBLEMS.
THE BOILER AND FGD SYSTEM WENT DOWN ON SEPTEMBER 18, 1980 FOR SCHEDULED
MAINTENANCE AND WERE UNAVAILABLE THE REST OF THE MONTH.
10/80
A
B
C
D
SYSTEM
27.0
48.9
48.5
37.6
50.8
38.4
68.2
69.6
17.1
73.3
73.7
26.5
47.0
48.0
11.8
50.0
744 513
376 58.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS OUT OF SERVICE FROM OCTOBER 1 TO OCTOBER 3 FOR A
SCHEDULED OVERHAUL.
A REHEAT TUBE LEAK CAUSED THE UNIT TO SHUTDOWN FROM OCTOBER 5 TO OCTOBER
11. SCRUBBER MODULES B AND C WERE RETURNED TO OPERATION ON OCTOBER 14.
MAINTENANCE ON MODULE D WAS NOT COMPLETED UNTIL OCTOBER 19 AND MODULE A
ON OCTOBER 23.
11/80 A
B
C
D
SYSTEM
88.6
91.1
94.9
93.6
96.1
53.7
84.4
59.4
86.4
86.4
95.8
48.8
76.5
53.9
19.3
78.3
720 653
564 69.6
** PROBLEMS/SOLUTIONS/COMMENTS
ALL FOUR ABSORBER MODULES WERE AVAILABLE FOR MOST OF NOVEMBER EXCEPT FOR
MINOR OUTAGES CAUSED BY COMPUTER PROBLEMS.
A TOTAL POWER FAILURE OCCURRED ON NOVEMBER 14 CAUSING THE UNIT TO BE OFF
LINE FOR FOUR DAYS.
12/80
A
B
C
D
SYSTEM
96.4
85.6
96.5
.0
100.0
83.0
80.2
75.3
.0
90.1
99.4
81.3
78.6
73.8
.0
88.3
744 729
657 73.3
** PROBLEMS/SOLUTIONS/fOMMENTS
UNIT 1 WAS DOWN FROM DECEMBER 20 TO 22 IN ORDER TO TIE IN THE UNIT 4 MAIN
TRANSFORMER.
THE "D" MODULE WAS DOWN THE ENTIRE MONTH SO THAT THE BOOSTER BLOWER ROTOR
COULD BE CLEANED AND BALANCED. THE ABSORBER RECIRCULATING PUMP DISCHARGE
VALVE WAS ALSO REPAIRED DURING THE MONTH.
507
-------
EPA UTILITY FGO SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FSB SYSTEMS
COMPANV NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY M/FGD - MM
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - %
AVERAGE MOISTURE CONTENT - '/.
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** ESP
NUMBER
TYPE
SUPPLIER
INLET FLUE GAS CAPACITY - CU.M/S
INLET FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
PARTICLE REMOVAL EFFICENCY - 7.
** PARTICLE SCRUBBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
CIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
LIQUID RECIRCULATION RATE - LITER/S
L/G RATIO - LITER/CU.M
PRESSURE DROP - KPA
SUPERFICIAL GAS VELOCITY - M/S
INLET GAS FLOW RATE - CU.M/S
INLET GAS TEMPERATURE - C
PARTiCLE REMOVAL EFFICIENCY - 7.
PUBLIC SERVICE OF NEW MEXICO
SAN JUAN
WATERFLOW
NEW MEXICO
C
21.
£28.
******
1560
350
306
322
350
( .050 LB/MMBTU)
t .530 LB/MMBTU)
(****** LB/MMBTU)
FOSTER WHEELER
PULVERIZED COAL
BASE
725.78
122.8
122.
CONCRETE
6.1
(1538000 ACFM)
( 253 F)
t 400 FT)
( 20.0 FT)
( 9000 BTU/LB)
8000-11628
COAL
SUBBITUMINOUS
20934.
22.00
12.59-22.45
10.50
8.1-15.01
.80
.6-1.3
.03
0-0.09
HOT SIDE
WESTERN PREC. DIVISION, JOY
943.8 (2000000 ACFM)
( 700 F)
( 3. IN-H20)
371.1
.6
99.5
VENTURI TOWER
VARIABLE-THROAT/BOTTOM-ENTRY PLUMB BOB
DAVY MCKEE
12'6" DIA X 28' 0" HIGH
CARBON STEEL
AISI 1110
ACID BRICK
1
224.9 3570 GPM)
.9 7.1 GAL/1000ACF)
3.1 12.5 IN-H20)
48.8 160.0 FT/S)
229.8 487000 ACFM)
134.4 274 F)
75.0
508
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
PUBLIC SERVICE OF NEW MEXICO: SAN JUAN Z (CONT.)
*** FGD SYSTEM
** GENERAL DATA
S/LEABLE PRODUCT/THROWAWAY PRODUCT
503 REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEJ/RETROFIT
UNIT DESIGN S02 REMOVAL EFFICIENCY - 7.
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
** ABSORBER
NUMBER
NUMBER OF SPARES
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
GAS CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
DISTANCE BETWEEN GAS CONTACTING ZONES - CM
LIQUID RECIRCULATION RATE - LITER/S
L/G RATIO - L/CU.M
GAS-SIDE PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/SEC
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
S02 REMOVAL EFFICIENCY - 7.
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
NUMBER OF PASSES PER STAGE
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/S
CONSTRUCTION MATERIAL GENERIC TYPE
WASH WATER SOURCE
WASH RATE - L/S
** REHEATER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
TEMPERATURE INCREASE - C
INLET FLUE GAS FLOW RATE - CU. M/S
INLET FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
SALEABLE PRODUCT
WET SCRUBBING
WELLMAN LORD
NONE
DAVY MCKEE
STEARNS-ROGER
FULL SCALE
RETROFIT
90.00
1
8/78
8/78
2/74
4
1
TRAY TOWER
VALVE TRAY
BUBBLE CAP TRAY TOWER
DAVY MCKEE
24' X 29' X 79' HIGH
INORGANIC
REINFORCED CONCRETE
N/A
INORGANIC
ACID-RESISTANT BRICK & MORTAR
PREFIRED BRICK
5-LEVELS OF VALVE TRAYS (KOCH FLEXITRAYS)
5
5.1 ( 2.0IN)
VI. ( 750 GPM)
.2 (1.7 GAL/1000 ACF)
4.0 (16.0 IN-H20)
3.3 ( 10.8 FT/S)
198.67 ( 421000 ACFM)
48.9 ( 120 F)
90.0
MIST ELIMINATOR
8
IMPINGEMENT
BAFFLE
CHEVRON VANE
HORIZONTAL
1
.0
3.2
NORYL PLASTIC
TREATED WATER
3.8
.0 IN-H20)
10.5 FT/S)
( 60 GAL/MIN)
INDIRECT HOT AIR
EXTERNAL HEAT EXCHANGER
STEAM TUBE BUNDLES
10.0 ( 50 F)
62.67 ( 132800 ACFM)
48.9 ( 120 F)
304 SS
509
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
PUBLIC SERVICE OF NEW MEXICO: SWJ JUAN 2 (CONT.)
** FAUS
NUMBER
SUPPLIER
FUNCTION
APPLICATION
ScRVICE
F'OIE GAS FLOW RATE - CU.M/S
F'.UE SAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** DUCTWORK
LOCATION
DIMENSIONS
SHELL GENERIC MATERIAL TYPE
** TAUKS
SERVICE
ABSORBER PRODUCT PUMP
** PUMPS
SERVICE
ABSORBER PRODUCT TRANSFER
SCRUBBER RECIRCULATION
ABSORBER RECIRCULATION
ABSORBER SPRAY RECIRCULATION
*** SALEABLE BYPRODUCTS
NATURE
FULL LOAD QUANTITY - M T/H
QUALITY - •/.
DISPOSITION
*** SLUDGE
** DISPOSAL
** PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS
CONTROL LEVELS
MONITOR LOCATION
PROCESS CONTROL MANNER
** WATER BALANCE
WATER LOOP TYPE
POND SEEPAGE/RUNOFF WATER LOSS - LITERS/S
MAKEUP WATER ADDITION - LITERS/S
** FGD SPARE CAPACITY INDICES
ABSORBER - X
** FGD SPARE COMPONENT INDICES
ABSORBER
BUFFALO FORGE
BOOSTER
FORCED DRAFT
DRY
276.06
122.8
CARBON STEEL
ESP TO FANS
16 X 2*
CARBON STEEL
NUMBER
1
NUMBER
( 585000 ACFM)
( 253 F)
2
4
20
8
ELEMENTAL SULFUR
1.36 ( 1.50 TPH)
99.5
MARKETED
PH & DENSITY
PH 5.5-6.5; SP. 6R. 1.2-1.3
ABSORBER FEED AND PRODUCT SOLUTION
MANUAL
CLOSED
45
22.4
33.0
1.0
( 355 GPM)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
7. REMOVAL PER BOILER FGD CAP.
502 PART. HOURS HOURS HOURS FACTOR
0/78 SYSTEM
510
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
PUBLIC SERVICE OF NEW MEXICO: SAN JUAN 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/CCTMENTS
NOTE: ALTHOUGH THIS FGD SYSTEM IS DESIGNED TO BRING THE BOILER INTO COM-
PLIANCE WITH A 0.34 IB/MM BTU S02 EMISSION STANDARD, THE STATE HAS
INITIALLY ONLY REQUIRED A 1.2 LB/MM BTU S02 CONTROL LEVEL. SAN
JUAN 2 WILL BE REQUIRED TO MEET THE MORE STRINGENT S02 EMISSION
LIMITATION VALUE BY APRIL 18, 1980. THE UNIT ONLY REQUIRES TWO
OF THE FOUR SCRUBBING TRAINS TO MEET THE 1.2 LB/MM BTU LIMITATION
VALUE; HOWEVER, THREE ARE REQUIRED FOR THE MORE STRINGENT LIMITATION
VALUE (THE SYSTEM IS DESIGNED TO INCLUDE ONE SPARE SCRUBBING TRAIN
WHEN MEETING THE 0.34 LB/MM BTU S02 EMISSION STANDARD). BECAUSE
OF THIS CHANGE IN EMISSION LIMITATION VALUES THE FGD SYSTEM WILL
EFFECTIVELY HAVE AN ABSORBER SPARE COMPONENT INDEX OF 2.0 (100X
SPARE CAPACITY FOR THIS SYSTEM) THROUGH APRIL 17, 1980 AND 1.0
(33.3X SPARE CAPACITY FOR THIS SYSTEM) THEREAFTER. CONSEQUENTLY
THE "SYSTEM" DEPENDABILITY FACTORS WILL BE CALCULATED AS:
MODULAR AVERAGE X 2.0
THROUGH APRIL 17, 1980 AND:
MODULAR AVERAGE X 1.33
THEREAFTER.
8/78 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
INITIAL FGD OPERATIONS BEGAN IN LATE AUGUST. SHAKEDOWN/DEBUGGING OPERA-
TIONS CONTINUED THROUGH AUGUST.
PROBLEMS WERE ENCOUNTERED WITH THE BOOSTER FAN CONTROL DAMPER.
9/78 SYSTEM 720
•** PROBLEMS/SOLUTIONS/COMMENTS
ALL THREE MODULES OPERATED SIMULTANEOUSLY FOR THE FIRST TIME IN
SEPTEMBER.
A TWO WEEK BOILER OUTAGE WAS CAUSED BY A FIRE IN THE START-UP TRANSFORMER
DUCT BANK. PROBLEMS WERE ALSO ENCOUNTERED WITH BOILER DAMPERS.
NO FGD SYSTEM PROBLEMS WERE REPORTED FOR SEPTEMBER.
10/78 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
HEAT TRACING FAILURES ALLOWED LINE FREEZING TO OCCUR.
A TEMPORARY HIGH FLYASH LOADING WAS THE RESULT OF AN ESP MALFUNCTION.
THE FGD SYSTEM IS STILL EXPERIENCING ROUTINE START UP PHASE PROBLEMS.
11/78 SYSTEM 720
12/78 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
ALTHOUGH FGD THE SYSTEM HAS BEEN OPERATING, WEATHER-RELATED PROBLEMS HAVE
LIMITED OPERATIONS TO TWO MODULES. REHEATER LEAKS OCCURRED DURING THE
PERIOD.
1/79 SYSTEM 744
511
-------
EPA UTILITY FSD SURVEY: OCTOBER - DECEMBER 1980
PUBLIC SERVICE OF NEW MEXICO: SAN JUAN 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
7. REMOVAL
S02 PART.
PER BOILER
HOURS HOURS
FGD CAP.
HOURS FACTOP
2/79 SYSTEM
3/79 SYSTEM
4/79 SYSTEM
5/79 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
672
744
720
744
HOUR3 ARE NOT YET AVAILABLE BECAUSE THE UTILITY IS CONCENTRATING EFFORTS
ON OPERATION OF THIS NEW UNIT. THE UTILITY REPORTED THAT THE SCRUBBING
MODULJS THEMSELVES ARE OPERATING ACCEPTABLY. ALSO THE CHEMICAL PLANT IS
AVAILABLE AND THERE IS NO SYSTEM PLUGGING WHATSOEVER.
THE MAJOR PROBLEM ENCOUNTERED WAS FAN VIBRATION. THE UTILITY HAS BEEN
WORKING WITH THE SUPPLIER IN AN EFFORT TO DISCOVER WHY FAN BALANCE HAS
BEEN DIFFICULT TO MAINTAIN.
7/79 SYSTEM
8/79 SYSTEM
9/79 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
744
744
720
10/79 SYSTEM
11/79 SYSTEM
DURING THE THIRD QUARTER TWO OF THE FOUR ABSORBERS WERE DOWN DUE TO
BOOSTER BLOWER VIBRATION PROBLEMS.
744
720
12/79
E
F
S
H
SYSTEM
100.0
100.0
.0
.0
100.0
80.1
73.3
.0
.0
76.7
66.9
61.3
.0
.0
64.1
744 622 477
** PROBLEMS/SOLUTIONS/COMMENTS
NOTE: SEE COMMENTS FOR 00/78 EXPLAINING SYSTEM DEPENDABILITY CALCULATIONS.
DURING DECEMBER TWO MODULES WERE DOWN COMPLETELY AS A RESULT OF REHEATER
PROBLEMS.
1/80
E
F
G
H
SYSTEM
92.0
100.0
.0
.0
96.0
63.0
.0
.0
.0
31.5
62.4
.0
.0
.0
31.2
744 737
232
** PROBLEMS/SOLUTIONS/COMMENTS
THE F-MODULE WAS AVAILABLE, HOWEVER, FGD SERVICE WAS NOT REQUIRED BECAUSE
A BOILER-RELATED POWER FAILURE FORCED THE BOILER TO OPERATE AT LOW LOAD.
2/80
E
F
G
H
SYSTEM
97.0
22.0
.0
.0
59.5
65.7
12.3
.0
.0
39.0
64.5
12.1
.0
.0
38.3
696 683
267
512
-------
EPA UTILITY FSD SURVEY: OCTOBER - DECEMBER 1980
PUBLIC SERVICE OF NEW MEXICO: SAN JUAN 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
3/80
5/80
6/80
7/80
E
F
G
H
SYSTEM
87.0
85.0
.0
.0
86.0
.0
93.6
.0
.0
46.8
.0
59.4
.0
.0
29.7
472
221 33.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE FIRST QUARTER ONLY ONE ABSORBER COULD BE OPERATED DUE TO AN
ELECTRICAL PROBLEM. CURRENTLY, OPERATIONS ARE LIMITED TO TWO ABSORBERS
UNTIL NEW REHEATERS ARE INSTALLED. REHEATER INSTALLATION IS EXPECTED TO
BE COMPLETED IN APRIL.
4/80 E
F
G
H
SYSTEM
99.3
99.9
.0
44.2
100.0
91.3
71.1
.0
58.5
90.8
68.5
53.3
.0
43.9
98.8 68.1
720 540
490 66.3
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE G IS DOWN FOR MAJOR REPAIRS WHICH WERE A RESULT OF AN INTERNAL FIRE
EARLIER IN THE YEAR.
A REGULATION CHANGE EFFECTIVE APRIl 18, NOW REQUIRES THAT THREE MODULES
OPERA'E TO MEET S02 REGULATIONS (SEE COMMENTS FOR 00/78).
MODULE H WAS UNAVAILABLE IN THE BEGINNING OF THE MONTH.
E
F
17
H
SYSTEM
99.1
98.9
.0
98.9
99.0
97.3
'>5.2
.0
91.9
94.8 100.0
86.7
84.8
.0
81.9
84.5
744 663
628 79.1
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER MAS DOWN FOR SEVERAL HOURS FOR MINOR MAINTENANCE AND BOILER TUBE
REPAIRS.
E
F
G
H
SYSTEM
89.2
89.6
.0
88.6
89.2
72.4
74.1
.0
83.8
76.7
56.0
57.4
.0
64.9
98.3 59.4
720 557
428 69.6
** PROBLEMS/SOLUTIONS/COMMENTS
AN ELECTRICAL CABLE FAILURE PREVENTED MODULES E AND F FROM OPERATING
SIMULTANEOUSLY. AUXILIARY POWER COULD ONLY BE PROVIDED TO ONE MODULE.
E
~
•3
H
.SYSTEM
97.6
96.9
.0
98.9
97.8
55.4
85.0
.0
91.0
77.1
49.1
75.3
.0
80.6
68.3
744 659 508 79.8
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS DOWN FOR SEVERAL DAYS IN JULY TO REPAIR STEAM TUBE LEAKS.
THE POWER CABLE WHICH FAILED IN JUNE WAS REPAIRED THIS MONTH. THIS CABLE
PERMITS SIMULTANEOUS OPERATION OF THE E AND F MODULES WITH THE H MODULE.
513
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
PUBLIC SERVICE OF NEW MEXICO: SAN JUAN 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOF
8/80
9/80
10/80
10/80
11/80
E
F
6
H
SYSTEM
97.8
.0
98.3
98.2
90.2
72.7
.0
92.6
85.2
100.0
85.8
69.1
.0
83.0
81.0
744 707
602 88.7
** PROBLEMS/SOLUTIONS/COMMENTS
TUBE LEAK REPAIRS IN THE BOILER CAUSED THE F6D SYSTEM NO TO OPERATE FOR
TWO DAYS.
E
F
G
H
SYSTEM
99.0
99.3
.0
97.6
98.6
56.1
56.1
.0
56.2
56.1
51.9
51.9
.0
52.1
62.5 51.9
720 667
374 85.5
** PROBLEMS/SOLUTIONS/COMMENTS
ESP PROBLEMS CAUSED ERRATIC OPERATION OF THE F6D SYSTEM FOR SEVERAL DAYS
IN SEPTEMBER.
THE FGD SYSTEM WAS NOT OPERATED DURING A SCHEDULED OUTAGE OF THE CHEMICAL
PLANT. THE SYSTEM WAS AVAILABLE DURING THIS TIME.
MODULE G WAS UNAVAILABLE IN SEPTEMBER BECAUSE OF ONGOING REPAIR OF FIRE
DAMAGE.
E
F
G
H
SYSTEM
14.7
15.7
.0
1.1
10.5
36.2
39.0
.0
.0
25.0
14.7
15.7
.0
.0
27.0 10.1
744 301
75 40.0
** PROBLEMS/SOLUTIONS/COMMENTS
UNIT 2 WAS OFF LINE FROM OCTOBER 4 TO OCTOBER 23 FOR A SCHEDULED FALL
OUTAGE.
THE "K" MODULE WAS UNAVAILABLE ESSENTIALLY THE ENTIRE MONTH AS A RESULT
OF MAI 1TENANCE BEING PERFORMED.
THE "G" MODULE REMAINED UNAVAILABLE DURING THE MONTH AS A RESULT OF THE
FIRE DjiMAGE INCURRED ON MARCH 24.
E
F
G
H
SYSTEM
14.7
15.7
.0
1.1
10.5
36.2
38.9
.0
.0
25.0
14.7
15.7
.0
.0
27.0 10.1
744 301
75 40.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS TAKEN OFF LINE ON OCTOBER 4 FOR A SCHEDULED OVERHAUL.
BOILER WAS RETURNED TO OPERATION ON OCTOBER 23.
THE
OPERABILITY AND AVAILABILITY OF THE FGD SYSTEM WERE LOW BECAUSE MODULE G
WAS STILL OFF LINE TO REPAIR FIRE DAMAGE INCURRED ON MARCH 24. MODULE H
WAS OFF LINE ESSENTIALLY THE ENTIRE PERIOD FOR MAINTENANCE.
97.6
90.0
85.8
73.3
55.3
47.2
514
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
PUBLIC SERVICE OF NEW MEXICO: SAN JUAN 2 (CONT.).
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
G
H
SYSTEM
.0
57.2
81.8
.0 .0
20.7 13.3
59.5 60.4 38.3
720
464
276
57.0
** PROBLEMS/SOLUTIONS/COMMENTS
UNIT 2 WAS DOWN FROM NOVEMBER 13 TO 18 TO REPAIR A WATERWALL TUBE LEAK AND
FROM NOVEMBER 19 TO 23 AS A RESULT OF THE FAILURE OF A START-UP
TRANSFORMER.
THE "H" MODULE WAS OUT OF SERVICE FROM NOVEMBER 1 TO 12 TO BALANCE THE
ROTOR IN THE BOOSTER BLOWER AND TO REPAIR THE ABSORBER RECIRCULATING
PUMP.
12/80
E
F
G
H
SYSTEM
95.3
95.6
.0
69.4
85.8
42.4
59.9
.0
51 ..7
51.6
100.0
34.3
48.4
.0
41.8
41.7
744 601
310 73.9
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS DOWN FROM DECEMBER 6 TO 7 TO REPAIR A TUBE LEAK, BUT THEN RE-
MAINED DOWN UNTIL DECEMBER 11 FOR A TRANSFORMER TIE-IN.
THE "H" MODULE WAS DOWN FROM DECEMBER 11 TO 19 TO REPAIR A LEAK THAT HAD
DEVELOPED AT THE SUCTION SIDE OF THE ABSORBER RECIRCULATING PUMP.
THE UNIT 2 FGD SYSTEM EXPERIENCED A LOSS OF POWER ON DECEMBER 24 AND DID
NOT RETURN TO SERVICE UNTIL DECEMBER 26 AS A RESULT OF COMPUTER
PROBLEMS THAT DEVELOPED.
THE "G" MODULE REMAINED OUT OF SERVICE THROUGH THE END OF THE FOURTH
QUARTER AS A RESULT OF THE FIRE DAMAGE INCURRED IN MARCH.
515
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICUUTE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - '/.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** PARTICLE SCRUBBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
LIQUID RECIRCULATION RATE - LITER/S
L/G RATIO - LITER/CU.M
PRESSURE DROP - KPA
SUPERFICIAL GAS VELOCITY - M/S
INLET GAS FLOW RATE - CU.M/S
INLET GAS TEMPERATURE - C
P4RTICLE REMOVAL EFFICIENCY - 7.
*** FGD SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
PUBLIC SERVICE OF NEW MEXICO
SAN JUAN
3
WATERFLOW
NEW MEXICO
C
9. ( .020 LB/MMBTU)
1*6. ( .340 LB/MMBTU)
****** (****** LB/MMBTU)
1560
534
468
487
534
BABCOCK & WILCOX
PULVERIZED COAL
BASE
(2040800 ACFM)
( 249 F)
t 400 FT)
( 28.0 FT)
( 9000 BTU/LB)
8000-11628
963.05
120.6
122.
CONCRETE
8.5
COAL
SUBBITUMINOUS
20934.
22.00
12.59-22.45
10.50
8.10-15.01
.80
.59-1.3
.03
0.0-0.09
VENTURI TOWER
VARIABLE-THROAT/BOTTOM-ENTRY PLUMB BOB
DAVY MCKEE
14'6" DIA X 32'8" HIGH
CARBON STEEL
AISI 1110
ACID BRICK
315.0
1.2
3.1
3.3
316.6
133.3
75.0
5000 GPM)
9.2 SAL/1000ACF)
12.5 IN-H20)
10.8 FT/S)
671000 ACFM)
272 F)
SALEABLE PRODUCT
WET SCRUBBING
WELLMAN LORD
NONE
DAVY MCKEE
DAVY MCKEE
FULL SCALE
516
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
PUBLIC SERVICE OF NEW MEXICO: SAN JUAN 3 (CONT.)
N^W/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
UNIT DESIGN S02 REMOVAL EFFICIENCY - 7.
CURRENT STATUS
INITIAL START-UP
CONTRACT AWARDED
** DECIGN AND OPERATING PARAMETERS
** ABSORBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SH'iLL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
GAS CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
LIQUID RECIRCULATION RATE - LITER/S
L/G RATIO - L/CU.M
GAS-SIDE PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/SEC
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
S02 REMOVAL EFFICIENCY - 7.
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
CONFIGURATION
WASH WATER SOURCE
WASH RATE - L/S
** REHEATER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
INLET FLUE GAS FLOW RATE - CU. M/S
INLET FLUE GAS TEMPERATURE - C
** FANS
NUMBER
NUMBER OF SPARES
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** TANKS
SERVICE
ABSORBER PRODUCT PUMP
** PUMPS
SERVICE
SCRUBBER RECIRCULATION
*** SALEABLE BYPRODUCTS
NATURE
FULL LOAD QUANTITY - M T/H
NEW
7. 99.50
90.00
1
12/79
8/78
TRAY TOWER
VALVE TRAY
BUBBLE CAP TRAY TOWER
DAVY MCKEE
30' X 33'6" X 78' HIGH
INORGANIC
REINFORCED CONCRETE
N/A
STAINLESS STEEL
TYPE 316L
5 LEVELS OF VALVE TRAYS
5
35.
.1
4.2
3.3
240.67
48.9
90.0
( 550 GPM)
( 1.0 GAL/1000 ACF)
(17.0 IN-H20)
( 10.8 FT/S)
( 510000 ACFM)
( 120 F)
MIST ELIMINATOR
2
HORIZONTAL
TREATED WATER
10.4 ( 165 GAL/MIN)
INDIRECT HOT AIR
EXTERNAL HEAT EXCHANGER
STEAM TUBE BUNDLES
866.41 (1836000 ACFM)
5E.8 ( 127 F)
4
1
BUFFALO FORGE
BOOSTER
FORCED DRAFT
DRY
328.25
120.6
CARBON STEEL
( 695600 ACFM)
( 249 F)
NUMBER
1
NUMBER
1
SULFURIC ACID
19.05 ( 21.00 TPH)
517
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
PUBLIC SERVICE OF NEW MEXICO: SAN JUAN 3 (CONT.)
DISPOSITION
** PROCESS CONTROL AND INSTRUMENTATION
C^EC'ICAL PARAMETERS
CONTROL LEVELS
MONITOR LOCATION
PHOCESS CONTROL MANNER
** WATER BALANCE
WVTER LOOP TYPE
** FG'J SPARE CAPACITY INDICES
A JSORBER - •/.
** FGD SPARE COMPONENT INDICES
A'iSORBER
MARKETED
PH & DENSITY
PH 5.5-6.5; SP.GR. 1.2-1.3
ABSORBER FEED AND PRODUCT SOLUTION
MANUAL
CLOSED
.0
.0
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
'/. REMOVAL
S02 PART.
PER BOILER FGD CAP.
HOURS HOURS HOURS FACTOR
12/79 M
SYSTEM
4/80
100.0
100.0
11.2
11.2
5.9
5.9
744 392
** PROBLEMS/SOLUTIONS/COMMENTS
THE SAN JUAN 3 BOILER AND FGD SYSTEM BEGAN OPERATIONS IN DECEMBER 1979.
CURRENTLY ONLY ONE MODULE IS OPERATING. THE OTHER THREE MODULES WILL
BECOME OPERATIONAL ONE BY ONE UNTIL ALL ARE ON LINE. THE SYSTEM IS NOT
EXPECTED TO BE FULLY OPERATIONAL (ALL FOUR MODULES) UNTIL 1982.
DURING DECEMBER THE BOILER EXPERIENCED ERRATIC OPERATIONS. NO FGD SYSTEM
PROBLEMS WERE REPORTED.
1/80 M
SYSTEM
86.0
86.0
54.4
54.4
41.5
41.5
744 568
309
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM FIGURES REFLECT THE OPERATION OF A SINGLE MODULE. ONLY ONE
MODULE WILL BE NEEDED UNTIL MAY 1982 TO MEET CURRENT S02 EMISSION
REGULATIONS.
2/80 M
SYSTEM
3/80 M
SYSTEM
98.0
98.0
85.5
85.5
13.6
13.6
78.3
78.3
79.6
79.6
1.0
1.0
56.7
56.7
696
44
744 539
422 53.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE ONE MODULE CURRENTLY OPERATIONAL AT SAN JUAN 3 OPERATED WITHOUT ANY
MAJOR PROBLEMS DURING THE FIRST QUARTER OF 1980. THE BOILER WAS OFF LINE
FOR APPROXIMATELY 24 DAYS IN FEBRUARY DUE TO AN ELECTRICAL PROBLEM.
M
SYSTEM
92.1
92.1
82.7
82.7
90.1
90.1
71.8
71.8
720 625
517 77.0
** PROBLEMS/SOLUTIONS/COMMENTS
MINOR REPAIR WORK WAS DONE TO THE BOILER THIS MONTH.
ITY WAS OVER 90X.
FGD SYSTEM AVAILABIL-
5/80 M
SYSTEM
100.0
100.0
78.1
78.1
100.0
100.0
32.7
32.7
744 311
243 35.0
518
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
PUBLIC SERVICE OF NEW MEXICO: SAN JUAN 3 CCONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE DOILER WAS OUT OF SERVICE FOR A SCHEDULED MAINTENANCE OUTAGE.
6/80 M 49.0 43.3 39.2 27.6
S'STEM 49.0 *3.3 39.2 27.•> 720 460 127 55.0
** PROBLEMS/SOLUTIONS/COMMENTS
MINOR REPAIR AND MAINTENANCE OF THE BOILER CAUSED SYSTEM OUTAGE TIME.
THE FGD SYSTEM DID NOT OPERATE AFTER JUNE 19 DUE TO FAILURE OF THE MIST
ELIMINATOR MESH PADS AND BOTTOM BALLAST TRAY.
7/80 M 75.5 89.8 89.8 74.5
SYSTEM 75.5 89.8 89.8 74.5 744 617 554 66.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS RETURNED TO SERVICE ON JULY 5 AFTER BOILER AND FGD
SYSTEM REPAIRS HERE MADE.
8/80 M 83.2 81.6 82.7 80.2
SYSTEM 83.2 81.6 82.7 80.2 744 732 597 81.9
** PROBLEMS/SOLUTIONS/COMMENTS
BEARINGS ON THE CIRCULATING PUMP MERE REPLACED DURING AUGUST.
A PUMP DISCHARGE VALVE HAS REPUCED DUE TO LEAKAGE.
9/80 M 96.7 59.4 59.1 45.7
SYSTEM 96.7 59.4 59.1 45.7 720 549 329 61.6
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS DOWN FOR SEVERAL DAYS IN SEPTEMBER BECAUSE OF BOILER
TUBE LEAKS.
THE FGD SYSTEM WAS NOT OPERATED DURING A SCHEDULED OUTAGE OF THE CHEMICAL
PLANT. THE SYSTEM WAS AVAILABLE DURING THIS TIME.
10/80 M 91.0 65.1 67.2 63.7
SYSTEM 91.0 65.1 67.2 63.7 744 728 474 84.2
** PROBLEMS/SOLUTIONS/COMMENTS
DURING OCTOBER THE BOILER WAS OUT OF SERVICE FOR APPROXIMATELY 24 HOURS
DUE TO A POWER TRIP CAUSED BY THE FORCED DRAFT FAN.
MODULE M WAS RETURNED TO SERVICE ON OCTOBER 8, 1980 FOLLOWING COMPLETION
OF THE CHEMICAL PLANT OUTAGE. HOWEVER, MODULE M WAS SHUT DOWN ON OCTOBER
29, 1980 TO REPLACE THE BADLY DAMAGED BOTTOM COLLECTOR TRAY.
11/80 M 59.0 73.0 86.0 38.0
SYSTEM 59.0 73.0 86.0 38.0 720 372 273 38.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING NOVEMBER THE BOILER WAS OUT OF SERVICE APPROXIMATELY 312 HOURS DUE
TO A SCHEDULED MAINTENANCE OVERHAUL. DURING THIS TIME REPAIRS WERE MADE
TO THE BOTTOM BALLAST TRAY AND SUPPORT BEAMS IN THE M MODULE.
519
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
PUBLIC SERVICE OF NEW MEXICO: SAN JUAN 3 CCONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP
SOZ PART. HOURS HOURS HOURS FACT
-—-— —-— — _ _ _ _ —____ ___—
MODULE M WAS NOT OPERATED FOR APPROXIMATELY 96 HOURS DUE TO A POWER
FAILURE THAT CAUSED AN UPSET IN THE CHEMICAL PLANT AND CONSEQUENT LACK
OF ABSORBER FEED SOLUTION.
12/80 M 90.0 86.0 87.0 65.0
SYSTEM 90.0 86.0 87.0 65.0 744 564 484 68.1
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS OUT OF SERVICE APPROXIMATELY 168 HOURS DUE TO TUBE LEAKS II
THE SUPERHEATER SECTION.
DURING DECEMBER MODULE M WAS OUT OF SERVICE APPROXIMATELY 50 HOURS DUE TO
AN INSPECTION FOLLOWING MAJOR REPAIRS COMPLETED IN NOVEMBER.
520
-------
EPA UTILITY FED SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
502 EMISSION LIMITATION - NS/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MM
GROSS UNIT GENERATING CAPACITY - MM
NET UNIT GENERATING CAPACITY M/FGD - MM
NET UNIT GENERATING CAPACITY HO/FGD - MM
EQUIVALENT SCRUBBED CAPACITY - MM
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
SALT RIVER PROJECT
CORONADO
1
ST. JOHNS
ARIZONA
D
43.
344.
******
700
350
350
365
280
RILEY STOKER
PULVERIZED COAL
BASE
( .100 LB/MMBTU)
( .800 LB/MMBTU)
(****** LB/MMBTU)
1226.94
404.4
152.
CONCRETE
5.8
(2600000 ACFM)
( 760 F)
( 500 FT)
t 19.0 FT)
** FL'EL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - '/.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RANG* SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANf;E CHLORIDE CONTENT - >.
*** PARTICLE CONTROL
** ESF
NUMBER
TYPE
SUPPLIER
I'^LET FLUE GAS CAPACITY - CU.M/S
ULET FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
PARTICLE REMOVAL EFFICENCY - 7.
** PARTICLE SCRUBBER
GENERIC TYPE
SPECIFIC TYPE
*** FG1 SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROHAMAY PRODUCT
St)2 REMOVAL MODE
PfOCESS TYPE
Pf-'OCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEH/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
UNIT DESIGN S02 REMOVAL EFFICIENCY - 7.
CURRENT STATUS
COMMERCIAL START-UP
COAL
SUBBITUMINOUS
19306.
25.00
19-35
16.00
12-20
1.
0.4-1.
( 8300 BTU/LB)
8,000-11,000
.00
.0
********
******
HOT SIDE
WESTERN PREC. DIVISION, JOY
1321.3 (2800000 ACFM)
404.4 ( 760 F)
.8 ( 3. IN-H20)
99.8
NONE
N/A
THROWAWAY PRODUCT
MET SCRUBBING
LIMESTONE
NONE
PULLMAN KELLOGG
BECHTEL
FULL SCALE
NEM
7. 99.87
66.00
1
12/79
521
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
SALT RIVER PROJECT: CORONADO 1 ICONT. )
INITIAL START-UP 11/79
CONTRACT AWARDED 6/76
** DESIGN AND OPERATING PARAMETERS
** ABSORBER
NUMBER
NUMBER OF SPARES
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
GAS CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
LIQUID RECIRCULATION RATE - LITER/S
GAS-SIDE PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/SEC
INLET GAS TEMPERATURE - C
S02 REMOVAL EFFICIENCY - X
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES PER STAGE
FREEBOARD DISTANCE - M
DISTANCE BETWEEN STAGES - CM
DISTANCE BETWEEN VANES - CM
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/S
CONSTRUCTION MATERIAL GENERIC TYPE
WASH WATER SOURCE
WASH RATE - L/S
** REHEATER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
PERCENT GAS BYPASSED - AVS
TEMPERATURE INCREASE - C
** FANS
NUMBER
NUMBER OF SPARES
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
** DUCTWORK
LOCATION
DIMENSIONS
SHELL GENERIC MATERIAL TYPE
UNER GENERIC MATERIAL TYPE
** DUCTWORK
LOCATION
D3MENSIONS
SPRAY TOWER
OPEN CROSSCURRENT SPRAY
WEIR HORIZONTAL SPRAY CHAMBER
PULLMAN KELLOGG
120 L X 28 W X 17 H
CARBON STEEL
AISI 1110
N/A
ORGANIC
GLASS FLAKE-FILLED POLYESTER
FLAKEGLASS
NONE
4
630.
6.6
121.1
82.0
(10000 GPM)
( 1.5 IN-H20)
( 21.6 FT/S)
( 250 F)
MIST ELIMINATOR
2
IMPINGEMENT
BAFFLE
CHEVRON VANE
VERTICAL
1
3
8.84
1.78
3.0
.1
4.6
(29.0 FT)
( .7 IN)
( 1.20 IN)
( .5 IN-H20)
( 15.0 FT/S)
HEIL NORYL E-265
COOLING TOWER SLOWDOWN
39.4 ( 625 GAL/MIN)
BYPASS
COLD SIDE
N/A
20.0
10.0
( 50 F)
2
0
GREEN FAN
BOOSTER
FORCED DRAFT
DRY
304.32
127.2
( 644880 ACFM)
( 261 F)
SCRUBBER INLET
15'7" W X 13' H
CARBON STEEL
NONE
SCRUBBER OUTLET
33 X 18
522
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
SALT RIVER PROJECT: C0RONADO 1 (CONT.)
SHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
MANUFACTURER
NUMBER
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
PRODUCT QUALITY - X SOLIDS
** TANKS
SERVICE
REACTION MIX
PROCESS WATER
MIST ELIMINATOR
SEAL WATER
LIMESTONE SLURRY STORAGE
SLUDGE STORAGE
** PUMPS
SERVICE
SLURRY RECIRCUUTION
SLUDGE DISPOSAL
SLURRY PURGE
ALKALI MAKEUP
PROCESS WATER
SEAL WATER
HIGH PRESSURE SEAL WATER
MIST ELIMINATOR WASH
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
DIMENSIONS - FT
SHELL GENERIC MATERIAL TYPE
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
*#* SLUDGE
** DISPOSAL
NATURE
TYPE
IOCATION
SITE TRANSPORTATION METHOD
SITE CAPACITY - CU.M
SITE SERVICE LIFE - YRS
** PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS
CONTROL LEVELS
MONITOR LOCATION
PROCESS CONTROL MANNER
PROCESS CHEMISTRY MODE
»* WATER BALANCE
WATER LOOP TYPE
EVAFORATION WATER LOSS - LiTER/S
PONt SEEPAGE/RUNOFF WATER cOSS - LITERS/S
MAKEUP WATER ADDITION - LITERS/S
** FGD SPARE CAPACITY INDICES
ABSORBER - 7.
CARBON STEEL
GLASS FLAKE POLYESTER-RESIN
LIMESTONE GRINDING
BALL MILL
MINE & SMELTER CORP.
2
11.8 ( 13 TPH)
20.0
NUMBER
NUMBER
11
THICKENER
1
0
105 (DIA) X 12 (DEPTH)
STEEL
102 SOLIDS
30Z SOLIDS
FINAL
LINED POND
ON SITE
PIPE (8 IN.
4525100
35
ABOVE GROUND, EPOXY LINED CEMENT ASB
( 3700.0 ACRE-FT)
S02 INLET CONCENTRATION GAS FLOW, PH
0-1000 PPM S02, 0-500,000 SCFM, 4-8 PH
INLET DUCT, FIRST AND FOURTH STAGES (PH)
AUTOMATIC ANO MANUAL
FEED FORWARD
OPEN
13.2
0
17.0
.0
( 210 GPM)
( 270 GPM)
523
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SALT RIVER PROJECT: CORONADO 1 (CONT. )
** FGD SPARE COMPONENT INDICES
ABSORBER .0
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP
500 PART. HOURS HOURS HOURS FACT!
11/79 SYSTEM 720
12/79 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE COROHADO UNIT 1 COMMENCED OPERATIONS IN NOVEMBER 1979. THE FGD
SYSTEM HAS PASSED EPA PERFORMANCE TESTS.
1/80 SYSTEM 744
2/80 SYSTEM 696
3/80 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE PERIOD STACK EMISSION TESTS WERE COMPLETED. NO OPERATIONAL
INFORMATION WAS AVAILABLE.
4/80 SYSTEM 720
5/80 SYSTEM 744
6/80 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
ALTHOUGH FGD SYSTEM PERFORMANCE DATA ARE BEING LOGGED, THE UTILITY REPORTE
THAT THE INFORMATION IS UNAVAILABLE FOR RELEASE AT THIS TIME.
7/80 SYSTEM 744
8/80 SYSTEM 744
9/80 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY MILL NOT AUTHORIZE THE RELEASE OF FGD PERFORMANCE DATA AT
THIS TIME, BUT NOTED THAT THE SYSTEM IS TO SHUT DOWN ON NOVEMBER 1, 1980
FOR A MAJOR OVERHAUL.
10/80 SYSTEM 744
11/80 SYSTEM 720
12/80 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
ON NOVEMBER 6, 1980 THE UNIT MAS TAKEN OFF LINE FOR A MAJOR OVERALL
THAT IS EXPECTED TO LAST FOR APPROXIMATELY 45 DAYS.
THE PERFORMANCE DATA ARE NOT YET AVAILABLE FOR RELEASE.
524
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANV NAME
PLANT NAME
UNIT NL'MBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MM
GROSS UUIT GENERATING CAPACITY - MM
NET UNI: GENERATING CAPACITY H/FGD - MM
NET UNI: GENERATING CAPACITY WO/FGD - MM
EQUIVALENT SCRUBBED CAPACITY - MM
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOH - CU.M/S
BOILER FLUE 6AS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - '/.
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
*« ESP
NUMBER
TYPE
SUPPLIER
INLET FLUE GAS CAPACITY - CU.M/S
INLET FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
PARTICLE REMOVAL EFFICENCY - 7.
** PARTICLE SCRUBBER
GENERIC TYPE
SPECIFIC TYPE
*** FGD SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROHAWAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
UNIT DESIGN S02 REMOVAL EFFICIENCY - 7.
CURRENT STATUS
COMMERCIAL START-UP
SALT RIVER PROJECT
CORONADO
2
ST. JOHNS
ARIZONA
D
43.
******
700
350
350
365
260
RILEY STOKER
PULVERIZED COAL
BASE
1226.94
404.4
152.
CONCRETE
5.6
( .100 LB/MMBTU)
( .800 LB/MMBTU)
(****** LB/MMBTUJ
(2600000 ACFM)
( 760 F)
( 500 FT)
( 19.0 FT)
( fl300 BTU/LB)
8,000-11,000
COAL
SUBBITUMINOUS
19306.
25.00
19-35
16.00
12-20
1.00
0.4-1.0
HOT SIDE
WESTERN PREC. DIVISION, JOY
1321.3 (2800000 ACFM)
404.4 ( 760 F)
.8 ( 3. IN-H20)
99.8
NONE
N/A
THROMAMAY PRODUCT
MET SCRUBBING
LIMESTONE
NONE
PULLMAN KELLOGG
BECHTEL
FULL SCALE
NEM
X 99.87
66.00
1
10/81
525
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
SALT RIVE1? PROJECT: CORONADO 2 ^CONT.)
lillTIAL START-UP
CONT3ACT AWARDED
** DESIGN AND OPERATING PARAMETERS
** ABSORBER
NUMBER
NUMBER OF SPARES
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
NUMBER OF CONTACTING ZONES
LIQUID RECIRCULATION RATE - LITER/S
GAS-SIDE PRESSURE DROP - KPA
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
SOi REMOVAL EFFICIENCY - 7.
** MIST ELIMINATOR
PRC-MIST ELIMINATOR/MIST ELIMINATOR
NUtiBER PER SYSTEM
GENERIC TYPE
SPKCIFIC TYPE
TR4DE NAME/COMMON TYPE
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES PER STAGE
FREEBOARD DISTANCE - M
DISTANCE BETWEEN STAGES - CM
DISTANCE BETWEEN VANES - CM
SUPERFICAL GAS VELOCITY - M/S
CONSTRUCTION MATERIAL GENERIC TYPE
WASH WATER SOURCE
WASH RATE - L/S
** REHEATER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
PERCENT GAS BYPASSED - AVG
TEMPERATURE INCREASE - C
** FANS
NUMBER
NUMBER OF SPARES
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
** DUCTWORK
LOCATION
DIMENSIONS
SHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
** DUCTWORK
LOCATION
DIMENSIONS
SHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
7/80
6/76
2
0
SPRAY TOWER
OPEN CROSSCURRENT SPRAY
WEIR HORIZONTAL SPRAY CHAMBER
PULLMAN KELLOGG
120 L X 28 W X 17 H
CARBON STEEL
AISI 1110
N/A
ORGANIC
GLASS FLAKE-FILLED POLYESTER
FLAKEGLASS
630.
.4
25.48
46.1
82.0
(10000 GPM)
(1.5 IN-H20)
( 54000 ACFM)
( 115 F)
MIST ELIMINATOR
2
IMPINGEMENT
BAFFLE
CHEVRON VANE
VERTICAL
1
3
8.84
1.78
3.0
4.6
HEIL NORYL E-265
COOLING TOWER SLOWDOWN
39.4 ( 625 GAL/MIN)
BYPASS
COLD SIDE
N/A
20.0
10.0
(29.0 FT)
( .7 IN)
( 1.20 IN)
( 15.0 FT/S)
( 50 F)
2
0
GREEN FAN
BOOSTER
FORCED DRAFT
DRY
304.32
127.2
( 644880 ACFM)
( 261 F)
SCRUBBER INLET
15'7" W X 13' H
CARBON STEEL
NONE
SCRUBBER OUTLET
33 X 18
CARBON STEEL
GLASS FLAKE POLYESTER-RESIN
526
-------
SALT RIVER PROJECT: CORONADO 2 (CONT.)
EPA UTILITY FGO SURVEY: OCTOBER - DECEMBER 1980
** REAGENT PREPARATION EQUIPMENT
F'JNCTION
D'lVICE
MANUFACTURER
NUMBER
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
PRODUCT QUALITY - X SOLIDS
** TANKS
SERVICE
REACTION MIX
PROCESS HATER
M'iST ELIMINATOR
SEAL MATER
LIMESTONE SLURRY STORAGE
SLUDGE STORAGE
*« RUMPS
SERVICE
SLURRY RECIRCUUTION
SLUDGE DISPOSAL
SLURRY PURGE
ALKALI MAKEUP
PPOCESS HATER
SEAL HATER
HIGH PRESSURE SEAL HATER
MIST ELIMINATOR HASH
«* SOLIDS CONCENTRATIN6/DEHATERING
DEVICE
NUMBER
NU1BER OF SPARES
DIMENSIONS - FT
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
*** SLU11GE
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE CAPACITY - CU.M
SITE SERVICE LIFE - YRS
** PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS
CONTROL LEVELS
MONITOR LOCATION
PROCESS CONTROL MANNER
PROCESS CHEMISTRY MODE
** HATER BALANCE
HATER LOOP TYPE
EVAPORATION HATER LOSS - LITER/S
POND SEEPAGE/RUNOFF HATER LOSS - LITERS/S
MAKEUP HATER ADDITION - LITERS/S
** FGD SPARE CAPACITY INDICES
ABSORBER - 7.
** FGD SPARE COMPONENT INDICES
ABSORBER
LIMESTONE GRINDING
BALL MILL
MINE & SMELTER CORP.
Z
11.S ( 13 TPH1
20.0
NUMBER
2
2
1
1
1
NUMBER
10
1
2
1
2
2
THICKENER
1
0
105 (DIA) X 12
10X SOLIDS
30X SOLIDS
FINAL
LINED POND
ON SITE
PIPE
4525100
35
(DEPTH)
( 3700.0 ACRE-FT)
S02 INLET CONCENTRATION GAS FLOH, PH
0-1000 PPM S02, 0-500,000 SCFM, 4-8 PH
INLET DUCT, FIRST AND FOURTH STAGES (PH)
AUTOMATIC AND MANUAL
FEED FORHARD
OPEN
13.2
0
17.0
.0
.0
( 210 GPM)
( 270 GPM)
527
-------
EPA. UTILITY FSD SURVEY: OCTOBER - DECEMBER 1980
SALT RIVER PROJECT: CORONADO 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CA1
S02 PART. HOURS HOURS HOURS FACT
7/80 SYSTEM 744
8/80 SYSTEM 744
9/80 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
INITIAL OPERATION OF THE FGD SYSTEM AT THE CORONADO 2 STATION COMMENCED
IN JULY, 1980.
DURING THE THIRD QUARTER 1980 A BEARING INSPECTION WAS CONDUCTED. THE UN
IS PRESENTLY IN THE PROCESS OF BEGINNING COMMERCIAL OPERATION.
10/80 SYSTEM 744
11/80 SYSTEM 720
12/80 SYSTEM 744
** PROBLEMS/SOLUTIONS/COI1MENTS
THE PERFORMANCE DATA ARE NOT YET AVAILABLE FOR RELEASE.
528
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
HOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RANGS SULFUR CONTENT - 7.
AVEFAGE CHLORIDE CONTENT - 7.
RAN(,E CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** ESP
NJMBER
TYPE
SUPPLIER
I'JLET FLUE GAS CAPACITY - CU.M/S
I:-ILET FLUE GAS TEMPERATURE - C
** PARTICLE SCRUBBER
NJMBER
GENERIC TYPE
SPECIFIC TYPE
SJPPLIER
SMELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LTNER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
G^S CONTACTING DEVICE TYPE
L/G RATIO - LITER/CU.M
PRESSURE DROP - KPA
SUPERFICIAL GAS VELOCITY - M/S
IKLET GAS FLOW RATE - CU.M/S
IKLET GAS TEMPERATURE - C
#** FGD SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
S02 REMOVAL MODE
SOUTH CAROLINA PUBLIC SERVICE
WINYAH
GEORGETOWN
SOUTH CAROLINA
B
43.
516.
519
280
258
261
( .100 LB/MMBTU)
( 1.200 LB/MMBTU)
(****** LB/MMBTU)
BABCOCK & WILCOX
PULVERIZED COAL
BASE
384.14 ( 814030 ACFM)
132.2 ( 270 F)
122. ( 400 FT)
CONCRETE
4.9 ( 16.0 FT)
( 11500 BTU/LB)
COAL
BITUMINOUS
26749.
13.50
******
6.5-7.0
1.70
1.0-1.2
********
******
COLD SIDE
RESEARCH-COTTRELL
384.1 ( 814030 ACFM)
13Z.3 ( 270 F)
VENTURI TOWER
VARIABLE-THROAT/SIDE-MOVABLE BLOCKS
BABCOCK t WILCOX
CARBON STEEL
AISI 1110
ORGANIC
RUBBER
SPRAY NOZZLES (316 SS)
1.9 (14.4 GAL/1000ACF)
.7 ( 3.0 IN-H20)
27.4 ( 90.0 FT/S)
192.1 ( 407015 ACFM)
132.2 ( 270 F)
THROWAWAY PRODUCT
WET SCRUBBING
529
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SOUTH CAROLINA PUBLIC SERVICE: WINYAH 2 (CONT.)
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
UNIT DESIGN S02 REMOVAL EFFICIENCY - X
CURRENT STATUS
INITIAL START-UP
** DESIGN AND OPERATING PARAMETERS
** ABSORBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
GAS CONTACTING DEVICE TYPE
L/G RATIO - L/CU.M
GAS-SIDE PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/SEC
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
S02 REMOVAL EFFICIENCY - X
** MIST ELIMINATOR
FRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
DUMBER OF STAGES
hUMBER OF PASSES PER STAGE
PRESSURE DROP - KPA
CONSTRUCTION MATERIAL GENERIC TYPE
Is ASH WATER SOURCE
** REHEATER
GENERIC TYPE
SPECIFIC TYPE
T<3ADE NAME/COMMON TYPE
PERCENT GAS BYPASSED - AVG
** FANS
NUMPER
SUPtLIER
FUNCTION
APPUCATION
FiUF GAS FLOW RATE - CU.M/S
FlUL GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
** DU:TWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LIMESTONE
NONE
BABCOCK & WILCOX
BURNS & ROE
FULL SCALE
NEW
7. 99.^0
45.00
1
7/77
TRAY TOMER
SIEVE TRAY
BABCOCK 8 WILCOX
CARBON STEEL
AISI 1110
N/A
ORGANIC
RUBBER
SIEVE TRAY
6.3 (
1.1 t
3.2 (
159.50 (
52.2 (
90.0
47.5 GAL/1000 ACF)
4.5 IN-H20)
10.5 FT/S)
338000 ACFM)
126 F)
MIST ELIMINATOR
1
IMPINGEMENT
BAFFLE
CHEVRON VANE
HORIZONTAL
1
3
.2
DURAKANE
SYSTEM RECYCLE WATER AND FRESH WATER
BYPASS
COLD SIDE
N/A
50.0
( 1.0 IN-H20)
STURTEVANT DIV.
BOOSTER
FORCED DRAFT
192.06
132.2
CARBON STEEL
SCRUBBER INLET
COR-TEN STEEL
NONE
OUTLET DAMPER
COR-TEN STEEL
CEILCOTE FLAKEGLASS
WESTINGHOUSE
( 407000 ACFM)
( 270 F)
530
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SOUTH CAROLINA PUBLIC SERVICE: WINYAH Z (CONT.)
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
NUMBER
** PUMPS
SERVICE
VENTURI RECIRCULATION
ABSORBER RECIRCULATION
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
DIMENSIONS - FT
OUTLET STREAM CHARACTERISTICS
*** SLUDGE
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
** WATER BALANCE
WATER LOOP TYPE
MAKEUP WATER ADDITION - LITERS/S
** FGD SPARE CAPACITY INDICES
ABSORBER - X
** FGD SPARE COMPONENT INDICES
ABSORBER
DAMPER TO STACK
CARBON STEEL
PLASITE (40-60 MILS) AND KAOCRETE
LIMESTONE GRINDING
BALL MILL
1
NUMBER
THICKENER
1
50 DIA
35X SOLIDS
FINAL
POND
ON SITE
PUMPED
OPEN
6.3
.0
.0
( 100 GPM)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
7/77 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
INITIAL OPERATION OF THE WINYAH 2 FGD SYSTEM TOOK PLACE IN JULY.
8/77 SYSTEM 90.0 7
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SOUTH CAROLINA PUBLIC SERVICE: WINYAH 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTO
"•"———•" ~'""" "~ — — —• ———— — —— ___——_ _ — __-, — ___„_ «»_»_ ______„.., «._«.-•«.«-.—. ___ ____« ___••. _____ ______ __ ___ •.__»._
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE OCTOBER-NOVEMBER PERIOD THE FGD SYSTEM WAS AVAILABLE 100X OF
THE TIME. FREQUENT PLUGGING OF SAMPLE LINES HAS BEEN CAUSING RECURRING
INSTRUMENTATION PROBLEMS.
12/77 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
AN ACCEPTANCE TEST WAS RUN IN DECEMBER; HOWEVER, THE RESULTS WERE REJECTED
DUE TO IMPROPER SAMPLE COLLECTION AND STORAGE TECHNIQUES.
1/78 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
IN EARLY JANUARY THE SYSTEM WENT DOWN TO FOR TWO DAYS TO CHECK THE INSTRU-
MENTATION.
THE S02 MONITORS HAVE AGAIN MALFUNCTIONED.
ALL THE SAMPLE LINES HAVE BEEN REPLACED AND NEW HEAT TRACINGS HAVE BEEN
INSTALLED AROUND THEM.
2/78 SYSTEM 672
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS BYPASSED FOR SERVERAL DAYS IN FEBRUARY TO ALLOW SYSTEM
CLEANING IN PREPARATION FOR TESTING BY BABCOCK AND WILCOX.
3/78 SYSTEM 744
4/78 SYSTEM 720
5/78 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
SOME MINOR SCALING WAS ENCOUNTERED DURING THE APRIL-MAY PERIOD BUT IT
DID NOT CAUSE AN OUTAGE.
6/78 SYSTEM 100.0 94.3 720 679 679
7/78 SYSTEM 100.0 97.0 744 722 722
** PROBLEMS/SOLUTIONS/COMMENTS
ONE SCHEDULED BOILER OUTAGE OCCURRED IN JUNE FOR THE INSTALLATION OF A
TEST PANEL. IN JULY, TWO BOILER OUTAGES OCCURRED. NO FORCED FGD
OUTAGES WERE REPORTED.
8/78 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED NO FORCED FGD OUTAGES DURING AUGUST.
9/78 SYSTEM 720
532
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
SOUTH CAROLINA PUBLIC SERVICE: WINYAH 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE SOZ ANALYZERS PERFORMED WELL DURING A TWO WEEK CERTIFICATION TEST
THAT TOOK PLACE IN SEPTEMBER.
10/78 SYSTEM .0 744 0 0 .0
11/78 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS DOWN FROM OCTOBER 1 TO NOVEMBER 15 FOR A TURBINE INSPECTION.
DURING THIS TIME THE FGD SYSTEM WAS CLEANED AND INSPECTED.
12/78 SYSTEM 84.8 82.6 82.6 62.1 744 740 611 89.3
** PROBLEMS/SOLUTIONS/COMMENTS
S02 MONITOR PROBLEMS CONTINUED THROUGH DECEMBER.
AN OUTAGE WAS NECESSARY FOR AN ABSORBER PUMP BELT RENEWAL.
FEED SLURRY FLOWMETER PROBLEMS WERE ENCOUNTERED DURING DECEMBER.
THE LIMESTONE MILL OIL PUMP PROBLEMS TRIPPED THE MILL OFF LINE A NUMBER
OF TIMES IN DECEMBER.
A MINOR OUTAGE WAS CAUSED BY PLUGGING OF THE SLURRY DELIVERY LINE.
QUENCHER PROBLEMS OCCURRED DURING DECEMBER.
744 744 742 89.3
672 647 623 75.4
744 716 690 75.3
** PROBLEMS/SOLUTIONS/COMMENTS
AN OUTAGE WAS REQUIRED TO RENEW QUENCHER PUMP BELTS AND FOR REPAIRS TO A
QUENCHER SUCTION VALVE.
OUTAGES WERE REQUIRED TO REPAIR A HOLE IN THE FEED SLURRY LINEt TO INSPECT
THE MODULE FOR PLUGGING, AND BECAUSE OF A BOOSTER FAN TRIP.
THE OPERATING VALUES SHOWN ARE THE FIGURES FOR FEBRUARY AND MARCH COMBINED.
4/79 SYSTEM 99.4 99.4 99.4 99.4 720 720 716 67.6
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE S02 MONITOR HAS PASSED THE STATE CERTIFICA-
TION TEST BUT REQUIRES CONTINUING MAINTENANCE TO KEEP IT OPERATING.
A MALFUNCTION OF THE RECIRCULATION TANK LEVEL INDICATOR RESULTED IN A LOW
LIQUID LEVEL WHICH FORCED THE SCRUBBER OUT OF SERVICE.
5/79 SYSTEM 98.4 98.7 100.0 95.6 744 721 711 75.1
1/79 SYSTEM
2/79 SYSTEM
3/79 SYSTEM
99.7
96.6
96.5
99.7
96.3
96.4
99.7
96.4
96.4
99.7
92.7
92.7
533
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SOUTH CAROLINA PUBLIC SERVICE: HINYAH Z CCONT. )
PERFORMANCE DATA
PERIOD MCIDULE AVAILABILITY OPER ABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOI
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE S02 MONITOR SAMPLE PUMP REQUIRES MAINTENANCE
ALMOST EVERY e4 HOURS.
A BOILER OUTAGE ALLOWED TIME FOR CLEANING ABSORBER TRAYS, UNPLUGGING FOUR
NOZZLES, CLEANING THE SUMP BOTTOM, AND REPAIRING A SPRAY WASH VALVE.
6/79 SYSTEM 92.4 92.3 92.1 91.6 80.00 720 716 660 79.8
** PROBLEMS/SOLUTIONS/COMMENTS
FOUR OUTAGES IN JUNE WERE DUE TO PLUGGED ABSORBER NOZZLES. THE PRIMARY
CAUSE APPEARED TO BE THAT A SCREEN IN THE ABSORBER SIDE OF THE SUMP BOTTOM
WAS LEFT OUT DURING THE PREVIOUS OUTAGE.
A HEAVY SCALE BUILD-UP IN THE SUMP BELOW THE VENTURI WAS NOTED.
THE UTILITY REPORTED THAT MGO TESTING HAS BEGUN.
7/79 SYSTEM 98.4 98.4 98.4 97.8 84.00 744 740 727 81.5
** PROBLEMS/SOLUTIONS/COMMENTS
THE ABSORBER MAS FORCED OFF-LINE ONCE DURING JULY DUE TO QUENCHER PUMP
PACKING PROBLEMS.
SOME PLUGGING WAS ENCOUNTERED WITH ONE OF THE ABSORBER NOZZLES.
SOME OUTAGE TIME WAS NEEDED TO INSTALL A QUENCHER WALL WASH NOZZLE.
TESTS WITH THE ADDITION OF MGO DURINS THE MONTH SHOWED IMPROVED S02
REMOVAL EFFICIENCIES OF APPROXIMATELY 10X, ALTHOUGH LOW S02 INLET READINGS
PREVENTED CONCLUSIVE TEST RESULTS.
8/79 SYSTEM 99.4 99.0 99.4 98.1 80.00 744 737 730 88.0
** PROBLEMS/SOLUTIONS/COMMENTS
A FOUR HOUR OUTAGE RESULTED FROM BOOSTER FAN CONTROL PROBLEMS.
A NEW PORT FOR THE SCRUBBER OUTLET GAS SAMPLE PROBE HAD TO BE INSTALLED.
THIS REQUIRED ONE HOUR OF SCHEDULED DOWN TIME.
9/79 SYSTEM 720
10/79 SYSTEM 744
11/79 SYSTEM 720
12/79 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
NO INFORMATION WAS AVAILABLE FOR THIS REPORT PERIOD.
1/80 SYSTEM 744
2/80 SYSTEM 696
3/80 SYSTEM 744
534
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
SOUTH CAROLINA PUBLIC SERVICE: WINYAH Z (CQNT,)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE FIRST QUARTER OF 1980 NO MAJOR FGD RELATED PROBLEMS WERE
REPORTED.
4/80 SYSTEM 100.0 100.0 100.0 85.3 720 614 614 60.2
5/80 SYSTEM 95.8 94.9 94.9 77.7 744 609 578 61.9
*»• PROBLEMS/SOLUTIONS/CO 1MENTS
THE FST SYSTEM WAS OFF LINE THROUGH PART OF MAY TO WASH DOWN THE ABSORBER
MODULFS.
6/80 SYSTEM 100.0 100.0 100.0 99.6 720 718 718 76.6
** PROBLEMS/SOLUTIONS/COMMENTS
NUMEROUS LEAKS IN THE FGD SYSTEM WERE REPAIRED THROUGHOUT THE PERIOD WHILE
THE BOILER AND SCRUBBER WERE IN SERVICE. NO MAJOR OPERATIONAL PROBLEMS
WERE REPORTED FOR APRIL, MAY, OR JUNE.
7/80 SYSTEM 100.0 100.0 100.0 100.0 744 744 744 75.3
** PROBLEMS/SOLUTIONS/COMMENTS
NO OPERATIONAL PROBLEMS WERE REPORTED DURING JULY.
8/80 SYSTEM 99.7 99.7 99.7 88.3 744 659 657 74.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE GRIT SEPARATOR PLUGGED CAUSING A TWO HOUR OUTAGE. THE FGD SYSTEM
WAS AVAILABLE THROUGH ALL OF AUGUST EXCEPT FOR THIS SHORT OUTAGE.
9/80 SYSTEM 96.5 100.0 100.0 87.2 720 629 629 73.4
** PROBLEHS/SOLUTIONS/COMMENTS
THE BOILER AND FGD SYSTEM WENT DOWN FOR A SCHEDULED MAINTENANCE OVERHAUL
ON SEPTEMBER 30, 1980. WORK SCHEDULED TO BE DONE INCLUDED INSTALLING A
SECOND TRAY IN THE ABSORBER MODULE, RENEWING DEMISTER WASH SYSTEM WITH
ALLOY 20 PIPING, AND CLEANING SCALE DEPOSITS FROM QUENCHER THROAT.
535
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MM
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
BJILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FU;L DATA
FUEL TYPE
FUEL GRADE
AVEFAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/L'.*
AVERAGE ASH CONTENT - 7.
RiMGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
R;,HGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PAFiTICLE CONTROL
** ES"
NUMBER
SUPPLIER
** PARTICLE SCRUBBER
GtNERIC TYPE
SPECIFIC TYPE
*** FGC SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
SY'STEM SUPPLIER
A-.; FIRM
DEVELOPMENT LEVEL
NEU/RETROFIT
UNiT DESIGN S02 REMOVAL EFFICIENCY - 7.
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
** DESIGN AND OPERATING PARAMETERS
** ABSORBER
NUMBER
GENERIC TYPE
SOUTH CAROLINA PUBLIC SERVICE
WINYAH
3
GEORGETOWN
SOUTH CAROLINA
B
****** (****** LB/MMBTU)
****** (****** LB/MMBTU)
****** (****** LB/MMBTU)
*****
280
252
258
280
RILEY STOKER
PULVERIZED COAL
BASE
********
*******
******
******
*******
COAL
******
26749.
********
******
********
******
1.70
******
********
******
RESEARCH-COTTRELL
NONE
N/A
THROHAWAY PRODUCT
WET SCRUBBING
LIMESTOh'E
BABCOCK & WILCOX
BURNS & ROE
FULL SCALE
NEW
90.00
1
6/80
5/80
SPRAY TOWER
(******* ACFM)
(**** F)
(**** FT)
(***** FT)
( 11500 BTU/LB)
******
536
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SOUTH CAROLINA PUBLIC SERVICE: WINYAH 3 (CONT.)
SPECIFIC TYPE OPEN COUNTERCURRENT SPRAY
SUPPLIER BABCOCK & WILCOX
SOZ REMOVAL EFFICIENCY - X .90.0
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR MIST ELIMINATOR
GENERIC TYPE IMPINGEMENT
SPECIFIC TYPE BAFFLE
TRADE NAME/COMMON TYPE CHEVRON VANE
** REHEATER
GENERIC TYPE INDIRECT HOT AIR
SPECIFIC TYPE EXTERNAL HEAT EXCHANGER
TRADE NAME/COMMON TYPE STEAM TUBE BUNDLES
** WATER BALANCE
WATER LOOP TYPE CLOSED
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
6/60 SYSTEM 60.0 60.0 60.0 46.6 720 559 336 59.5
** PROBLEMS/SOLUTIONS/COMMENTS
INITIAL FGD OPERATIONS BEGAN JUNE 3, 1980.
THE INLET DAMPER LOCKED UP FORCING THE FGD SYSTEM OUT OF SERVICE FOR PART
OF JUNE.
THERE HAVE BEEN CONTINUING PROBLEMS WITH THE THICKENER SUMP RESULTING FROM
IT'S LOCATION. THESE PROBLEMS FORCED THE FGD SYSTEM OUT OF SERVICE FOR
APPROXIMATELY 7 DAYS.
7/80 A 12.8 12.8 12.8 12.8
B 12.8 12.8 12.8 12.8
SYSTEM 12.8 12.8 12.8 12.8 744 744 95 79.8
** PROBLEMS/SOLUTIONS/COMMENTS
THE THJCKNER RAKE DRIVE MECHANISM WAS REPAIRED DURING JULY.
THE LA'JGE BELT DRIVEN PUMP HAS BEGUN TO SHOW SIGNS OF RAPID WEAR.
THE FGD SYSTEM WAS OUT OF SERVICE BECAUSE OF COMPUTER LOGIC PROBLEMS CAUSED
BY A SAD CABLE.
THE THICKNER SUMP PUMP AND MIXER MOTORS WERE FLOODED OUT CAUSING THE FGD
SYSTEM TO GO DOWN.
8/80 A 18.0 20.4 20.4 18.0
B 18.0 20.4 20.4 18.0
SYSTEM 18.0 20.4 20.4 18.0 744 658 134 79.4
** PROBLEMS/SOLUTIONS/COMMENTS
THE THICKNER SUMP PUMP AND MIXER MOTORS CONTINUED TO HAVE PROBLEMS BECAUSE
OF THE FLOODING LAST MONTH.
THE SCRUBBER OUTLET DAMPER WOULD NOT CLOSE PROPERLY WHICH REQUIRED WORK
DURING AUGUST.
THE ABSORBER TRAY STRAP WAS BROKEN IN SEVERAL AREAS AND REQUIRED REPAIR
WORK DURING THE MONTH.
9/80 A .0 .0 .0 .0
537
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SOUTH CAROLINA PUBLIC SERVICE: HINYAH 3 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACT(
B .0 .0 .0 .0
SYSTEM .0 .0 .0 .0 720 6*7 0 84.<
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM MAS OUT OF SERVICE THROUGH ALL OF SEPTEMBER BECAUSE OF
REPAIRS BEING MADE ON THE THICKNER.
10/80 SYSTEM 13.9 94.0 93.4 13.9 744 111 103 10.i
** PROBLEMS/SOLUTIONS/COMMENTS
DURING OCTOBER THE INSTALLATION OF THE ADDITIONAL ABSORBER TRAY AND THE
NEW MIST ELIMINATOR WASH SYSTEM WERE COMPLETED.
DURING THE SCHEDULED OVERHAUL THE MODULE WAS INSPECTED AND THE RUBBER
LINING WAS TESTED.
THE MODULE WAS REMOVED FROM SERVICE TO REPACK THE QUENCHER PUMP AND TO
INSPECT THE BELTS.
11/80 SYSTEM 100.0 100.0 100.0 100.0 720 720 720 86.!
12/80 SYSTEM 98.9 98.9 98.9 98.9 744 744 736 95.i
** PROBLEMS/SOLUTIONS/COMMENTS
DURING DECEMBER THE SYSTEM WAS REMOVED FROM SERVICE DUE TO A LIMESTONE
FEEDER FAILURE.
OUTAGE TIME DURING THE MONTH WAS ALSO CAUSED BY THE NECESSARY REPAIR
OF THE SEAL WATER LINE TO THE HOLDING TANK PUMPS.
538
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FED SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MM
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/F6D - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** ESP
NUMBER
TYPE
SUPPLIER
INLET FLUE GAS CAPACITY - CU.M/S
INLET FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
PARTICLE REMOVAL EFFICENCY - '/.
** PARTICLE SCRUBBER
GENERIC TYPE
SPECIFIC TYPE
*** FGD SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
S'32 REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
SfSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NHW/FETROFIT
UNIT DESIGN PARTICLE REMO/AL EFFICIENCY
UNIT DESIGN S02 REMOVAL EFFICIENCY - 7.
CURRENT STATUS
START-UP
SOUTH MISSISSIPPI ELEC PWR
R.D. MORROW. SR.
I
HATTISBURG
MISSISSIPPI
B
43. ( .100 LB/MMBTU)
516. ( 1.200 LB/MMBTU)
****** (****** LB/MMBTU)
400
200
160
191
124
RILEY STOKER
PULVERIZED COAL
BASE
303.29 ( 642700 ACFM)
132.2 ( 270 F)
124. ( 408 FT)
CONCRETE
3.3 ( 10.7 FT)
COAL
BITUMINOUS
27912.
15.00
14-17
6.50
7
( 12000 BTU/LB)
11000-11500
6 -
1 -
30
75
01
HOT SIDE
BUELL DIVISION, ENVIROTECH
579.5 (1228000 ACFM)
426.7 ( 800 F)
.1 (0. IN-H20)
99.6
NONE
N/A
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
NONE
ENVIRONEERING, RILEY STOKER
BURNS Si MCDONNELL
FULL SCALE
NEW
'/. 99.60
52.70
1
8/78
539
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SOUTH UISSISSIPPI ELEC PWR: R.D. MORROW, SR. 1 (CONT.)
INITIAL START-UP
CtlNTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
*» ABSORBER
NU1BER
GENERIC TYPE
SPECIFIC TYPE
TRS.OE NAME/COMMON TYPE
SUPPLIER
DIMENSIONS - FT
SH:LL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
GAS CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
LIQUID RECIRCULATION RATE - LITER/S
L/G RATIO - L/CU.M
GAS-SIDE PRESSURE DROP - KPA
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
SOS REMOVAL EFFICIENCY - X
PARTICLE REMOVAL EFFICENCY - 7.
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES PER STAGE
CONSTRUCTION MATERIAL GENERIC TYPE
WASH WATER SOURCE
** REHEATER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
PERCENT GAS BYPASSED - AVG
INLET FLUE GAS FLOH RATE - CU. M/S
INLET FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** FANS
NUMBER
NUMBER OF SPARES
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
** DUCTWORK
LOCATION
3HELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
8/78
5/75
PACKED TOWER
ROD DECK
VENTRI-SORBER
ENVIRCNEERING, RILEY STOKER
90 X 40 X 10
CARBON STEEL
AISI 1110
N/A
ORGANIC
SYNTHETIC RUBBER
CHLOROBUTYL
7 LAYERS OF SS RODS
7
1260.
6.6
2.0
192.03
132.2
85.0
.0
(20000 GPMJ
( 49.0 GAL/1000 ACF)
( 8.0 IN-H20)
406940 ACFM)
270 F)
MIST ELIMINATOR
1
IMPINGEMENT
BAFFLE
CHEVRON VANE
VERTICAL
3
1
FIBERGLASS REINFORCED PLASTIC
SUPERNATANT/FRESH MAKEUP
BYPASS
FLUE GAS
COLD SIDE
38.0
115.24 ( 244200 ACFM)
148.9 ( 300 F)
MILD STEEL/HASTELLOY G CLADDING
2
0
GREEN FAN
BALANCED DRAFT
BOILER I.D.
DRY
201.03
148.9
MILD STEEL
( 426000 ACFM)
t 300 F)
SCRUBBER INLET
CARBON STEEL
HASTELLOY G
SCRUBBER OUTLET TO STACK
CARBON STEEL
HASTELLOY G CLADDING
540
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SOUTH MISSISSIPPI EUC PWR: K.I. MORROW, SR. 1 (COHT.)
** RE\GENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
M \NUFACTURER
NUMBER
F'JLL LOAD DRY FEED CAPACITY - M.TONS/HR
PRODUCT QUALITY - X SOLIDS
** TA'4KS
SERVICE
LIMESTONE SLURRY
RECYCLE
** PUt:PS
SERVICE
ABSORBER RECIRCUUTION
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NU-ISER OF SPARES
FE;D STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
DIMENSIONS - FT
SHELL GENERIC MATERIAL TYPE
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
*** SLUDGE
** TREATMENT
METHOD
INLET QUALITY - 7.
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE DIMENSIONS
SITE CAPACITY - CU.M
»* PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS
CONTROL LEVELS
MONITOR LOCATION
PROCESS CONTROL MANNER
PROCESS CHEMISTRY MODE
** WATER BALANCE
WATER LOOP TYPE
** FGD SPARE CAPACITY INDICES
ABSORBER - X
** FGD SPARE COMPONENT INDICES
ABSORBER
LIMESTONE GRINDING
BALL MILL
KENNEDY VAN SAUN
1
.9 ( 1 TPH)
5.0
NUMBER
NUMBER
3
VACUUM FILTER
1
0
25X SOLIDS
60X SOLIDS
THICKENER
1
0
40 (DIA) X 11 (DEPTH)
MILD STEEL
10X SOLIDS
25X SOLIDS
FLYASH STABILIZATION
60.0
FINAL
LANDFILL
OFF SITE
TRUCK/CONVEYOR
600 X 850
403590
330.0 ACRE-FT)
PH, S02
5.7-5.9
RECYCLE TANK/INLET DUCT
AUTOMATIC
FEEDBACK/FEED FORWARD
CLOSED
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
SOUTH MISSISSIPPI ELEC PWR: R.D. MORROW, SR. 1 CCONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP
S02 PART. HOURS HOURS HOURS FACT
8/78 S STEM 744
9/78 S-> STEM 730
** PROBLEMS/SOLUTIONS/COMMENTS
A FORCED BOILER OUTAGE OCCURRED DURING THE PERIOD AS A RESULT OF BOILER
TUBE LEAKS. THE UNIT IS EXPECTED TO START UP AGAIN IN EARLY NOVEMBER.
10/78 SYSTEM .0 744 0 0 .1
11/78 SYSTEM .0 730 0 0 J
** PROBLEMS/SOLUTIONS/COMMENTS
OPERATION OF THE UNIT WAS INTERMITTENT DUE TO CONTINUING BOILER TUBE
PROBLEMS. THE BOILER WAS SHUT DOWN NOVEMBER 1 AS A RESULT OF BOILER TUBl
PROBLEMS. RESUMPTION OF OPERATION IS SCHEDULED FOR MARCH 1979.
THE FGD SYSTEM WAS BYPASSED ENTIRELY IN OCTOBER DUE TO SERIOUS CONTROL
VALVE PLUGGING.
12/78 SYSTEM .0 744 0 0 .C
1/79 SYSTEM .0 744 0 0 .C
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT HAS NOT YET BEEN RESTARTED SINCE THE NOVEMBER SHUTDOWN.
3/79 SYSTEM .0 673 0 0 .0
3/79 SYSTEM .0 744 0 0 .0
4/79 SYSTEM 730 631
*# PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER RETURNED TO SERVICE ON APRIL 1 AFTER COMPLETION OF REPAIRS
TO THE BOILER TUBES.
NO FGD SYSTEM RELATED PROBLEMS WERE REPORTED BY THE UTILITY FOR APRIL.
5/79 SYSTEM 744
6/79 SYSTEM 730
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE SYSTEM OPERATED MOST OF MAY AND JUNE WITH
NO MAJOR PROBLEMS.
7/79 SYSTEM 744
** PRQBLEMS/SOLUTIONS/COttMENTS
DURING THE FIRST WEEK OF JULY THE UNIT WAS REMOVED FROM SERVICE DUE TO
SEVERE PROBLEMS WITH THE FGD SYSTEM. THE UTILITY NOTED THAT ABOUT HALF
OF THE MODULE HEADERS WERE PLUGGED, HOLES WERE NOTED IN THE MODULE SHELL,
THE UPPER ROD BANK CORRODED AWAY FROM THE SHELL, AND EXTENSIVE PLUGGING
OF THE MIST ELIMINATOR OCCURRED. LINER FAILURE AT THE OUTLET DUCTKORK WAS
ALSO EXPERIENCED. THE UTILITY PUNS TO REPLACE THE DUCTWORK WITH
HASTALLOY. THE FGO SYSTEM IS EXPECTED TO BE OFF LINE FOR SEVERAL MONTHS
542
-------
10/79 SYbTEM
11/79 SVSTEM
12/79 SYSTEM
.0
.0
.0
.0
.0
.0
.0
.0
.0
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
SOUTH MISSISSIPPI ELEC PWR: R.D. MORROW, SR. 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
FOR REPAIRS TO BE COMPLETED.
8/79 SYSTEM .0 .0 744 0 0 .0
9/79 SYSTEM .0 .0 720 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT REMAINED OFF LINE DURING THE MONTHS OF AUGUST AND SEPTEMBER AS
MAINTENANCE AND REPAIR WORK CONTINUED.
.0 .00 91.00 744 282 0 23,0
.f 720 0
.0 744 0
*'•• PROBLEMS/SOLUTIONS/CrMMENTS
THE SCRUBBER HAS REMAINED OFF LINE THROUGH THE REPORT PERIOD DUE TO THE
LINING FAILURE. RELINING SHOULD BE COMPLETED AND THE UNIT ON LINE IN
MARCH.
1/80 SYSTEM .0 .0 .0 740 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT REMAINED OFF LINE DURING JANUARY AS RELINING OF THE SCRUBBERS
WAS COMING TO COMPLETION.
THE PRESATURATOR AREAS, BYPASS DUCTS, AND THE SECTIONS OF DUCT FROM
ABSORBER EXITS AT POINTS WHERE BYPASSED GAS MIXES WITH WET GAS ALL THE
WAY TO THE STACK ARE BEING LINED WITH HASTELLOY G (A 1/8 INCH LINING IS
BEING WELDED TO THE EXISTING CARBON STEEL).
THE MAIN BODY OF THE ABSORBER MODULES IMMEDIATELY ABOVE THE PRESATURATOR
SECTIONS ALL THE WAY TO THE ABSORBER EXIT IS BEING LINED WITH CHLOROBUTYL
RUBBER (ON THE EXISTING CARBON STEEL).
2/80 SYSTEM .0 .0 .0 696 0 0 .0
3/80 SYSTEM 41.5 95.1 100.0 39.5 744 309 294
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MARCH THE UNIT 1 FGD SYSTEM RETURNED TO SERVICE OPERATING 294 HOURS.
4/80 SYSTEM 100.0 99.0 100.0 99.0 80.00 720 720 713
** PROBLEMS/SOLUTIONS/COMMENTS
THERE WERE NO OPERATIONAL PROBLEMS RELATED TO THE FGO SYSTEM DURING APRIL.
FOUR INSPECTIONS WERE PERFORMED WHICH REQUIRED THE FGD SYSTEM TO BE OUT
OF SERVICE FOR SEVEN HOURS.
5/80 SYSTEM 99.7 99.8 100.0 88.7 80.00 744 660 658
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS SCHEDULED TO BE OUT OF SERVICE FOR 84 HOURS TO CLEAN THE
AIR PREHEATERS. THE BOILER OPERATED THE REMAINING HOURS IN MAY.
THE FGD SYSTEM WAS SCHEDULED TO BE OUT OF SERVICE FOR 1.5 HOURS FOR ROU-
TINE MODULE INSPECTION. THE FGD SYSTEM WAS AVAILABLE 99.7X DURING MAY.
6/80 SYSTEM 99.2 97.0 99.0 93.0 90.00 720 690 668 68.9
543
-------
EPA UTILITY FED SURVEY: OCTOBER - DECEMBER 1980
SOUTH MISSISSIPPI ELEC PWR: R.D. MORROW, SR. 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTC
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JUNE OPERATIONS CAME TO A HAULT FOR APPROXIMATELY SIX HOURS TO CLE4
THE MIST ELIMINATORS. OTHER OUTAGE TIME DURING THE MONTH HAS CAUSED
BY BOILER-RELATED PROBLEMS.
7/80 SYSTEM 94.1 99.3 99.3 94.1 90.00 744 705 700 67.3
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JULY THE SCRUBBER WAS INSPECTED FOR SCALE ACCUMULATION AND A TRIP
TEST WAS CONDUCTED ON THE SCRUBBER CONTROLS TO CHECK ON EARLIER MODIFICA-
TIONS.
THE MAJORITY OF OUTAGE TIME WAS CAUSED BY A MALFUNCTION OF THE BALL MILL.
THIS RESULTED IN A LOSS OF LIMESTONE SUPPLY IN THE STORAGE TANK.
A LEAK IN THE FEED WATER LINE CAUSED ADDITIONAL OUTAGE TIME DURING THE
MONTH.
8/80 SYSTEM 100.0 100.0 100.0 100,0 80.00 744 744 744 77.7
** PROBLEMS/SOLUTIONS/COMMENTS
NO PR3BLEMS WERE ENCOUNTERED DURIN3 THE MONTH OF AUGUST.
9/80 SYSTEM 99.2 ?9.6 99.6 99.2 720 717 714 70.3
** PROBLEMS/SOLUTIONS/CO1MENTS
DURIN« SEPTEMBER THE SCRUBBER WAS INSPECTED CAUSING TWO HOURS OF
OUTAGE TIME.
A BRIEF FGD OUTAGE OF 12 MINUTES WAS CAUSED BY AN ELECTRICAL SHORT.
THE UNIT AND FGD SYSTEM WERE OUT OF SERVICE FOR APPROXIMATELY 3 1/2 HOURS
DUE TO ESP PROBLEMS.
10/80 SYSTEM 62.6 94.4 94.4 25.1 744 198 187 18,0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING OCTOBER THE FSO SYSTEM WAS OFF LINE FOR 278 HOURS SO THAT GENERAL
SYSTEM REPAIRS COULD BE MADE.
BOILER TUBE LEAKS CAUSED A BOILER OUTAGE OF 38 HOURS DURING THE MONTH.
ESP PROBLEMS ENCOUNTERED IN OCTOBER CAUSED APPROXIMATELY 241 HOURS OF
OUTAGE TIME.
11/80 SYSTEM 24.9 41.9 41.9 10.8 720 185 78 20.6
** PROS LEMS/SO LUTIQNS/CQtlMENTS
DURING NOVEMBER THE FGD SYSTEM WAS SHUTDOWN FOR APPROXIMATELY 516 HOURS TO
MAKE REPAIRS TO THE HASTELLOY G MATERIAL IN THE SCRUBBER.
A BOILER TUBE LEAK CAUSED ADDITIONAL OUTAGE TIME DURING THE MONTH.
12/80 SYSTEM 99.9 99.4 99.4 64.0 744 479 476 49.8
544
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SOUTH MISSISSIPPI ELEC PWR-' R.D. MORROW, SR. 1 (CONT. )
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
DURING DECEMBER A FIRE IN THE BOILER CAUSED TWO BALL MILLS TO EXPLODE
RESULTING IN APPROXIMATELY 267 HOURS OF OUTAGE TIME.
A DUCT VOLTAGE TEST WAS CONDUCTED DURING DECEMBER.
545
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FSD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - N3/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
•RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
*** PARTICLE CONTROL
** ESP
NUMBER
TYPE
SUPPLIER
IMLET FLUE GAS CAPACITY - CU.M/S
INLET FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
PARTICLE REMOVAL EFFICENCY - X
** PARTICLE SCRUBBER .
GENERIC TYPE
SPECIFIC TYPE
*** FG!) SYSTEM
** GENER/L DATA
SALEABLE PRODUCT/THROWAWAK PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-1 fIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
UHIT DESIGN PARTICLE REMOVAL EFFICIENCY
UHIT DESIGN S02 REMOVAL EFFICIENCY - X
CURRENT STATUS
COMMERCIAL START-UP
SOUTH MISSISSIPPI ELEC PWR
R.D. MORROW, SR.
2
HATTISBURG
MISSISSIPPI
B
****** (****** LB/MMBTUJ
****** (****** LB/MMBTU)
****** (****** LB/MMBTU)
40
200
180
191
RILEY STOKER
PULVERIZED COAL
BASE
303.29 ( 642700 ACFM)
132.2 I 270 F)
124. ( 408 FT)
CONCRETE
3.3 ( 10.7 FT)
COAL
BITUMINOUS
27912.
15.00
14-17
6.50
( 12000 BTU/LB)
11000-11500
6 -
1 -
30
75
01
******
HOT SIDE
BUELL DIVISION, ENVIROTECH
579.5 (1228000 ACFM)
426.7 ( 800 F)
.1 ( 0. IN-H20)
99.6
NONE
N/A
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
NONE
ENVIRONEERING, RILEY STOKER
BURNS * MCDONNELL
FULL SCALE
NEW
X 99.60
52.70
1
6/79
546
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SOUTH MISSISSIPPI ELEC PUR: R.D. MORROW, SR. Z (CONT.)
IN :TIAL START-UP
COHTRACT AWARDED
** DES::GN AND OPERATING PARAMETERS
** ABSORBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
GAS CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
LIQUID RECIRCULATION RATE - LITER/S
L/G RATIO - L/CU.M
GAS-SIDE PRESSURE DROP - KPA
INLET GAS FLOW - CU. M/5
INLET GAS TEMPERATURE - C
S02 REMOVAL EFFICIENCY - X
PARTICLE REMOVAL EFFICENCY - X
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES PER STAGE
CONSTRUCTION MATERIAL GENERIC TYPE
WASH WATER SOURCE
** REHEATER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
PERCENT GAS BYPASSED - AVG
INLET FLUE GAS FLOW RATE - CU. M/S
INLET FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** FANS
NUMBER
NUMBER OF SPARES
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** DUCTWORK
LOCATION
oHELL GENERIC MATERIAL TYPE
MNER GENERIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
MANUFACTURER
N'JISER
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
PRODUCT QUALITY - X SOLIDS
6/79
5/75
PACKED TOWER
ROD DECK
VENTRI-SORBER
ENVIRONEERING, RILEY STOKER
10 X 40 X 10
CARBON STEEL
AISI 1110
N/A
ORGANIC
SYNTHETIC RUBBER
CHLOROBUTYL
7 LAYERS OF SS RODS
7
1260.
6.6
2.0
192.03
133.2
85.0
.0
(20000 GPM)
( 49.0 GAL/1000 ACF)
( 8.0 IN-H20)
( 406940 ACFM)
( 270 F)
MIST ELIMINATOR
IMPINGEMENT
BAFFLE
CHEVRON VANE
VERTICAL
3
1
FIBERGLASS REINFORCED PLASTIC
SUPERNATANT/FRESH MAKEUP
BYPASS
FLUE GAS
COLD SIDE
38.0
115.24 ( 244200 ACFM)
148.9 t 300 F)
MILD STEEL/HASTELLOY G CLADDING
Z
0
GREEN FAN
BALANCED DRAFT
BOILER I.D.
DRY
201.03
148.9
MILD STEEL
( 426000 ACFM)
( 300 F)
SCRUBBER INLET
MILD STEEL
HASTELLOY G
LIMESTONE GRINDING
BALL MILL
KENNEDY VAN SAUN
1
.9 t 1
5.0
TPH)
547
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
SOUTH MISSISSIPPI ELEC PWR: R.D. MORROW, SR. Z (CONT.)
** TANKS
Si RVICE
LIMESTONE SLURRY
RECYCLE
** PUMPS
SERVICE
AB50RBER RECIRCULATION
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUtSER
NUMBER OF SPARES
FEfO STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
DIMENSIONS - FT
SHELL GENERIC MATERIAL TYPE
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
*** SLUDGE
** TREATMENT
METHOD
INLET QUALITY - 7.
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE DIMENSIONS
SITE CAPACITY - CU.M
** PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS
CONTROL LEVELS
MONITOR LOCATION
PROCESS CONTROL MANNER
PROCESS CHEMISTRY MODE
** WATER BALANCE
WATER LOOP TYPE
** FGD SPARE CAPACITY INDICES
ABSORBER - X
** FSD SPARE COMPONENT INDICES
ABSORBER
NUMBER
1
1
NUMBER
3
VACUUM FILTER
1
0
Z57. SOLIDS
60X SOLIDS
THICKENER
1
0
40 DIA
MILD STEEL
10X SOLIDS
Z57. SOLIDS
FLYASH STABILIZATION
60.0
FINAL
LANDFILL
ON SITE
TRUCK/CONVEYOR
600 X 850
403590
( 330.0 ACRE-FTJ
PH, SOZ
5.7-5.9
RECYCLE TANK/INLET DUCT
AUTOMATIC
FEEDBACK/FEED FORWARD
CLOSED
.0
.0
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
SOZ PART. HOURS HOURS HOURS FACTOR
6/79 SYSTEM
720
548
-------
EPA UTILITY FRO SURVEY: OCTOBER - DECEMBER 1980
SOUTH MISSISSIPPI ELEC PWR: R.D MORROW, SR. 2 (CONT.>
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
»* PROBLEMS/SOLUTIONS/COMMENTS
R.D. MORROW 2 BEGAN SCRUBBER OPERATIONS IN THE LATTER PART OF JUNE. OPERA-
TIONAL DATA ARE NOT YET AVAILABLE.
7/79 SYSTEM 744
8/79 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
NO INFORMATION WAS AVAILABLE FOR THE JULY-AUGUST 1979 PERIOD.
9/79 SYSTEM 4.7 100.0 4.7 4.7 720 34 34 2.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING SEPTEMBER THE UNIT WAS TAKEN OFF LINE DUE TO FAILURE OF LINERS AND
PLUGGING IN THE MIST ELIMINATOR SECTIONS.
10/79 SYSTEM .0 .0 .0 .00 86.00 744 477 0 52.5
11/79 SYSTEM .0 .0 .0 720 0
12/79 SYSTEM .0 .0 .0 744 0
*# PROBLEMS/SOLUTIONS/COMMENTS
THE SCRUBBER HAS REMAINED OFF LINE THROUGH THE REPORT PERIOD DUE TO THE
LINING FAILURES. RELINING SHOULD BE COMPLETED AND THE UNIT ON SHOULD BE
BACK ON LINE IN MAY.
1/80 SYSTEM .0 .0 .0 744 743 0 75.4
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT REMAINED OFF LINE DURING JANUARY WHILE SCRUBBER LINER REPAIRS
CONTINUED.
THE PRESATURATOR AREAS, BYPASS DUCTS, AND THE SECTIONS OF DUCT FROM
ABSORBER EXITS AT POINTS WHERE BYPASSED GAS MIXES WITH WET GAS ALL THE
WAY TO THE STACK ARE BEING LINED WITH HASTELLOY G (A 1/8 INCH LINING IS
BEING WELDED TO THE EXISTING CARBON STEEL).
THE MAIN BODY OF THE ABSORBER MODULES IMMEDIATELY ABOVE THE PRESATURATOR
SECTIONS ALL THE WAY TO THE ABSORBER EXIT IS BEING LINED WITH CHLOROBUTYL
RUBBER (ON THE EXISTING CARBON STEEL).
2/80
3/80
4/80
SYSTEM
SYSTEM
SYSTEM
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.00
.00
696
744
720
698
486
0
0
0
0
75.0
.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM REMAINED OFF LINE THROUGH APRIL AS SCRUBBER LINER REPAIRS
CONTINUED. THE UNIT IS EXPECTED BACK ON LINE AT THE END OF MAY.
5/80 SYSTEM 2.4 14.2 14.2 2.4 85.00 744 127 18
549
-------
EPA UTILITY FGO SURVEY: OCTOBER - DECEMBER 1980
SOUTH MISSISSIPPI ELEC PWR: R.D. MORROW, SR. Z (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP,
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE UHIT REMAINED OFF LINE DURING HOST OF MAY TO COMPLETE SCRUBBER AND
STACK UNING MODIFICATIONS.
THE BOILER OPERATED 127 HOURS IN '1AY; HOWEVER, THE FGD SYSTEM OPERATED
ONLY 13 HOURS BECAUSE OF COMPUTER CONTROL PROBLEMS.
6/80 SYSTEM 99.3 90.0 99.1 78.0 90.00 720 625 561 68.9
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM COMPUTER LOST POWER DURING JUNE CAUSING THE UNIT TO
BE SHUT DOWN FOR 25 MINUTES.
DURING JUNE OPERATIONS CAME TO A HAULT FOR APPROXIMATELY FIVE HOURS TO
CLEAN THE MIST ELIMINATORS. OTHER OUTAGE TIME DURING THE MONTH WAS CAUSED
BY BOILER RELATED PROBLEMS.
7/80 SYSTEM 79.8 80.7 80.7 79.8 85.00 744 736 594 73.8
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JULY BALL MILL REPAIRS ACCOUNTED FOR THE MAJOR PORTION OF THE FGD-
RELATED OUTAGE TIME.
THE SCRUBBER WAS INSPECTED FOR SCALE ACCUMULATION AND A TRIP TEST WAS
CONDUCTED ON THE SCRUBBER CONTROLS TO CHECK ON EARLIER MODIFICATIONS.
THE SCRUBBING SYSTEM WENT OFF LINE DUE TO AN ALARM TRIGGERED BY HIGH
TEMPERATURE, WHICH WAS DETERMINED TO BE A FALSE ALARM.
A POSSIBLE TUBE LEAK SHUT THE BOILER DOWN ON JULY 27. THE UNIT WENT BACK
ON LINE WITHOUT FINDING THE LEAK. THE BOILER WAS THEN TAKEN OFF LINE ON
JULY 28 TO FIND THE LEAK AND MAKE THE NECESSARY REPAIRS.
PROBLEMS WITH THE BURNER MANAGEMENT CONTROL SYSTEM ALSO CAUSED A BOILER-
RELATED OUTAGE.
8/80 SYSTEM 98.8 99.5 99.5 98.8 80.00 744 739 735 74.3
** PROBLEMS/SOLUTIONS/COMMENTS
DURING AUGUST THE FGD SYSTEM WAS SHUT DOWN FOR FOUR HOURS FOR REPAIR OF A
TUBE LEAK.
8/80 SYSTEM 98.8 99.5 99.5 98.8 80.00 744 739 735 74.3
«* PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS OUT OF SERVICE APPROXIMATELY FIVE HOURS DURING AUGUST DUE
TO A BOILER TUBE LEAK.
AFTER THE REPAIRS TO THE BOILER TUBE AN ADDITIONAL FOUR HOURS OF OUTAGE
TIME WAS NECESSARY TO START UP THE FGD SYSTEM.
9/80 SYSTEM 99.8 99.5 99.5 88.3 720 639 636 62.4
** PROBLEMS/SOLUTIONS/COMMENTS
DURING SEPTEMBER THE BOILER HAS TAKEN OUT OF SERVICE FOR APPROXIMATELY
83 HOURS DUE TO A TUBE LEAK.
550
-------
EPA UTILITY FGO SURVEY: OCTOBER - DECEMBER 1980
SOUTH MISSISSIPPI ELEC PWR: R.D. MORROW, SR. 2 (CONT. )
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION '/. REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
„._____ ..*.*.., — — .___._«.___.. »..________-. MM — ______ — -, ____w_, _ — —— _ _ — -. — — ,- — _,_ — _____ -._____ .____ ___.,__
A BOILER INSPECTION.AND AN ELECTRICAL SHORT IN THE CONTROLS CAUSED THE
F6D SYSTEM TO SHUT DOWN WITH THE BOILER FOR APPROXIMATELY 1 1/2 HOURS.
10/80 SYSTEM 79.8 98.9 98.9 79.5 744 598 591 68.6
** PROBLEMS/SOLUTIONS/COMMENTS
PITTING OF THE HASTELLOY S MATERIAL IN THE SCRUBBER WAS DETECTED DURING A
SCRUBBER INSPECTION.
DURING OCTOBER FURNACE DRAFT PROBLEMS ACCOUNTED FOR APPROXIMATELY FOUR
HOURS OF DOWN TIME.
11/80 SYSTEM 80.2 95.3 95.3 74.8 720 565 538 67.7
** PROBLEMS/SOLUTIONSAOMHENTS
DURINt NOVEMBER THE FGD SYSTEM WAS OFF LINE APPROXIMATELY 131 HOURS TO
REPAIR DUCTWORK.
AN ADDITIONAL 8 HOURS OF OUTAGE TIME WAS REQUIRED FOR NOZZLE CLEANING.
12/80 SYSTEM 49.7 92.7 92.7 49.7 744 399 39.6
K* PROBLEMS/SOLUTIONS/COMMENTS
DURING DECEMBER REPAIRS TO THE SCRUBBER DUCT CAUSED APPROXIMATELY 348 HOURS
OF DOWN TIME.
THE RECYCLE NOZZLES PLUGGED CAUSING THE SYSTEM TO SHUTDOWN FOR APPROXIMATE-
LY 24 HOURS.
A ONE HOUR OUTAGE WAS CAUSED BY A MODULE HIGH TEMPERATURE ALARM.
551
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MM
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
5CTACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/S
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - '/.
AVERAGE MOISTURE CONTENT - 7,
RANG:: MOISTURE CONTENT - z
AVERAGE SULFUR CONTENT - V.
RANGE SULFUR CONTENT - 7.
AVE! AGE CHLORIDE CONTENT - X
KANUE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** ES'
NUMBER
SUPPLIER
INLET FLUE SAS CAPACITY - CU.M/S
I'>!LET FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
PARTICLE REMOVAL EFFICENCY - 7.
** PARTICLE SCRUBBER
GENERIC TYPE
SPECIFIC TYPE
*** FGJ SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
502 REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
SISTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
UNIT DESIGN S02 REMOVAL EFFICIENCY - 7.
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
SOUTHERN ILLINOIS POWER COOP
MARION
MARION
ILLINOIS
B
13. ( .030 LB/MMBTU)
516. ( 1.200 LB/MMBTU)
****** (****** LB/MMBTU)
272
173
161
165
173
BABCOCK & WILCOX
CYCLONE
BASE
285.50
143.3
122.
******
6.4
( 605000 ACFM)
( 290 F)
t 400 FT)
( 21.0 FT)
( 10250 BTU/LB)
8500-11400
COAL/REFUSE
BITUMINOUS
23841.
16.69
7.5-23.0
12.20
1.5-20.0
3.75
1.4-4.4
.10
0-0.12
1
BABCOCK & WILCOX
326.3 t 691500 ACFM)
143.3 ( 290 F)
.1 ( 1. IN-H20)
99.6
NONE
N/A
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
NONE
BABCOCK & WILCOX
BURNS & MCDONNELL
FULL SCALE
NEW
7. .00
89.40
1
6/79
5/79
552
-------
EPA UTILITY FGO SURVEY: OCTOBER - DECEMBER 1980
SOUTHERN ILLINOIS POWER COOP' MARION 4 (CONT.)
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
** ABSORBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
L/G RATIO - L/CU.M
GAS-SIDE PRESSURE DROP - KPA
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
S02 REMOVAL EFFICIENCY - X
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
** REHEATER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
** FANS
NUMBER
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
** TANKS
SERVICE
CIST ELIMINATOR WASH TANK
ABSORBER/QUENCHER RECYCLE
RECLAIMED WATER TANK
MLL PRODUCT TANK
IIMESTONE SLURRY STORAGE
** PUMPS
SERVICE
ABSORBER RECIRCULATION
QUENCHER RECIRCULATION
f.IST ELIMINATOR WASH
WASTE SLURRY
RECI-AIMED WATER
flU. PRODUCT
LIMESTONE SLURRY TRANSFER
SLULGE TRANSFER
** SOLIDS CONCENTRATING/DEWATERING
DIVICE
NUMBER
DIMENSIONS - FT
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
CAPACITY
*** SLUDGE
1/76
SPRAY TOWER
OPEN COUNTERCURRENT SPRAY
BABCOCK * WILCOX
9.9 ( 74.0 GAL/1000 ACF)
1.5
139.68
53.9
69.4
(6.0 IN-H20)
296000 ACFM)
129 FJ
MIST ELIMINATOR
IMPINGEMENT
BAFFLE
CHEVRON VANE
NONE
N/A
N/A
BUFFALO FORGE
BOOSTER
FORCED DRAFT
DRY
165.24
157.2
( 350150 ACFM)
( 315 F)
NUMBER
I
Z
1
1
1
NUMBER
5
2
2
2
2
2
2
3
THICKENER
1
125 (DIA) X 9
CENTRIFUGE
2
0
125 GPM
(DEPTH)
553
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SOUTHERN ILLINOIS POWER COOP: MARION 4 (CONT.)
** TREATMENT
METHOD FLYASH STABILIZATION
** DISPOSAL
NATURE FINAL
TYPE LANDFILL
LOCATION ON SITE
** PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS PH
CONTROL LEVELS 5-6
** WATER BALANCE
MATER LOOP TYPE CLOSED
** FGD SPARE CAPACITY INDICES
SCRUBBER - 7. 2.0
ABSORBER - X 38.0
** FGD SPARE COMPONENT INDICES
SCRUBBER .3
ABSORBER .6
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
5/79 SYSTEM 744
6/79 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE UNIT BEGAN OPERATION IN MAY. HOWEVER, THE
UNIT IS NOW DOWN AND HAS SUFFERED TWO PREVIOUS OUTAGES. THE PREVIOUS OUT-
AGES WERE DUE TO CENTRIFUGE AND THICKENER PROBLEMS. THE PRESENT OUTAGE
IS DUE TO BEARING FAILURES ON THE PUG MILL AND IMPROPER FIT OF THE SLUDGE
CONVEYING BELT.
7/79 SYSTEM 744
8/79 SYSTEM 7*4
9/79 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE THIRD QUARTER A ROUTINE INSPECTION OF THE SCRUBBER INTERNALS
SHOWED NO SCALE FORMATION.
THE UTILITY REPORTED THAT THE FGD SYSTEM HAS ACHIEVED A 0.7 LB/MMBTU OF
SOZ EMISSION LEVEL. THE UNIT IS SUBJECT TO THE 1.2 LB/MMBTU 503 EMISSION
STANDARD.
THE CONTINUOUS MONITORS HAVE NOT BEEN OPERATING ACCEPTABLY.
A TURBINE OVERHAUL/INSPECTION IS SCHEDULED FOR OCTOBER 1, 1979.
10/79 SYSTEM .0 744 0 0 .0
11/79 SYSTEM 110.0 26.7 720 192 192
12/79 SKSTEM 100.0 71.0 744 528 528
554
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
SOUTHERN ILLINOIS POWER COOP: MARION 4 (CONT.)
PERFORMANCE DATA
PERIOD .10DULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION '/. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS DOWN FROM OCTOBER 1 THROUGH NOVEMBER 17 FOR A BOILER/TURBINE
INSPECTION. NO MAJOR FGD RELATED PROBLEMS WERE ENCOUNTERED DURING THE
FOURTH QUARTER OF 1979 OTHER THAN SOME FREEZE-UPS CAUSED BY THE WINTER
WEATHER.
1/80 SYSTEM 100.0 10.0 74* 72 72
2/80 SYSTEM 100.0 31.0 696 216 216
3/80 SYSTEM 100.0 48.4 744 360 360
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JANUARY THE LOW BOILER AND SCRUBBER HOURS WERE A RESULT OF AN
18 DAY BOILER OUTAGE NEEDED FOR CORRECTION OF TUBE PROBLEMS. BOILER
OUTAGES DUE TO TUBE PROBLEMS WERE ALSO EXPERIENCED IN FEBRUARY AND MARCH.
THE ONLY REPORTED FGD-RELATED PROBLEM DURING THE FIRST QUARTER OF 1980 WAS
MAINTAINING THE BELT ALIGNMENT IN THE SLUDGE DISPOSAL SYSTEM.
4/60 SYSTEM 66.7 66.7 66.7 66.7 720 720 480 81.3
** PROBLEMS/SOLUTIONS/COMMENTS
SHAFT BREAKAGE WITHIN THE RECLAIM WATER PUMP CAUSED FGD SYSTEM OUTAGE TIME
DURING APRIL.
5/80 SYSTEM 77.4 58.8 58.8 32.3 744 408 240 49.6
** PHOBLEMS/SOLUTIONS/COMMENTS
A BOILER OUTAGE CAUSED THE FGD SYSTEM NOT TO OPERATE FOR TWO WEEKS.
SHAFT BREAKAGE WITHIN THE WATER RECLAIM PUMP CONTINUED THROUGH MAY.
6/80 SYSTEM 50.0 50.0 50.0 50.0 720 720 360 82.3
** PROBLEMS/SOLUTIONS/COMMENTS
SHAFT BREAKAGE WITHIN THE WATER RECLAIM PUMP CONTINUED TO CAUSE FGD
OUTAGE TIME. A SOLUTION HAS BEEN PROPOSED TO SIPCO BY THEIR ENGINEERING
CONSULTANT FOR CONSIDERATION.
7/80 SYSTEM 96.7 100.0 100.0 95.9 744 714 714 82.0
** PROBLEMS/SOLUTIONS/COMMENTS
AFTER REVIEW OF THE PROPOSED SOLUTION OF THE SHAFT BREAKAGE PROBLEM WITHIN
THE RECLAIM WATER PUMP, SIPCO AUTHORIZED THEIR CONSULTANT TO PROCEED
WITH THE WORK TO CORRECT THE PROBLEM.
8/80 SYSTEM 100.0 100.0 100.0 90.5 744 673 673 89.6
** PROBLEMS/SOLUTIONS/COMMENTS
PROBLEMS WITH THE SHAFT BREAKAGE IN THE RECLAIM WATER PUMPS CONTINUED
THROUGH AUGUST. A REPLACEMENT PUMP HAS BEEN PURCHASED TO SOLVE THE
PROBLEM.
9/80 A 100.0 100.0 100.0 100.0
555
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SOUTHErN ILLINOIS POWER COOP: MARION 4 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
B 100.0 100.0 100.0 100.0
SYSTEM 100.0 100.0 100.0 100.0 720 720 720 100.0
** PROBLEMS/SOLUTIONS/COMMENTS
SUMMARY OF GENERAL PROBLEMS TO DATE
THE MAJOR CAUSES OF SCRUBBER OUTAGES HAVE CENTERED AROUND COLD WEATHER-RE-
LATED CONVEYOR BELT AND PIPING PROBLEMS, PUG MILL BEARING FAILURES, AND
RECLAIM WATER PUMP SHAFT FAILURES. OTHER PROBLEMS HAVE BEEN RELATED TO
PROCESS CHEMISTRY CONTROL. THE UTILITY REPORTED THAT NUMEROUS SMALL PRO-
BLEMS ALSO HAVE OCCURRED BUT HAVE GENERALLY BEEN CORRECTED SOON AFTER THEIR
DISCOVERY. DETAILS OF THE PRIMARY SCRUBBER PROBLEMS ARE OUTLINED BELOW:
COLD WEATHER PROBLEMS
THE MOST SEVERE FREEZING PROBLEM CONCERNS THE SLUDGE CONVEYOR SYSTEM.
WHEN THE AMBIENT TEMPERATURE DROPS BELOW 30 F THE CONVEYOR SYSTEM BE-
COMES INOPERABLE. THE UTILITY HAS ATTEMPTED TO REMOVE THE FROZEN SLUDGE
USING VARIOUS COMMERCIAL AND COMPANY-BUILT SCRAPERS WITH LITTLE SUCCESS.
THE UTILITY ALSO INSTALLED HEATERS AT THE VARIOUS TRANSFER POINTS TO
THAW THE SLUDGE. THIS PROVED UNSUCCESSFUL AS WELL. THE PROBLEM HAS NOT
YET BEEN SOLVED.
AN ADDITIONAL PROBLEM WITH THE CONVEYOR SYSTEM HAS BEEN THE FAILURE OF
THE BELT TO TRACK CORRECTLY. ON SEVERAL OCCASIONS THE BELT HAS TOUCHED
THE STRUCTURAL STEEL SUPPORTS RESULTING IN BELT DAMAGE. HOWEVER, BY RE-
DUCING THE CONVEYOR SPEED THE UTILITY HAS INCREASED THE ESTIMATED BELT
LIFE FROM FIVE TO 10 YEARS.
THE OTHER COLO WEATHER PROBLEM IS RELATED TO THE SCRUBBER VESSEL PIPING
SYSTEM. ON SEVERAL OCCASIONS WATER LINE FREEZE UPS HAVE RESULTED IN
SCRUBBER OUTAGES. WHEN THE PROBLEM WAS DISCOVERED, THE UTILITY IN-
STALLED EXTENSIVE HEAT TRACING ON EXPOSED WATER LINES. ALTHOUGH THERE
HAS BEEN NO COLD WEATHER SINCE THE HEAT TRACING INSTALLATION, THE
UTILITY BELIEVES THAT THE PROBLEM IS SOLVED.
PUG MILL PROBLEM
SEVERAL BEARING FAILURES HAVE OCCURRED ON THE PUG MILL. THE UTILITY
HAS INCREASED THE MAINTENANCE ON THE MILL SYSTEM TO LESSEN THE LIKELI-
HOOD OF ANOTHER FAILURE. THE UTILITY REPORTED THAT IF THIS PROCEDURE
MODIFICATION DOES NOT INCREASE THE PUG MILL RELIABILITY TO AN ACCEPTABLE
LEVEL OTHER ACTION WILL BE TAKEN.
RECLAIM WATER PUMP SHAFT FAILURE
THE RECLAIM WATER PUMPS PRODUCE A VERY FLAT OUTPUT PRESSURE CURVE BUT
THEY FEED A SYSTEM COMPOSED OF MANY AUTOMATICALLY CONTROLLED DIAPHRAGM
VALVES. THE OPENING AND CLOSING OF THESE VALVES EXPOSES THE PUMPS TO
A WIDE VARIABILITY IN WATER REQUIREMENTS. MOTOR SHAFT FATIGUE RESULTS
WHEN THE PUMPS ATTEMPT TO RESPOND TO THE VARIABLE DEMAND. THE SYSTEM
SUPPLIER IS CURRENTLY SUPPLYING THE UTILITY WITH INFORMATION ON THE
OPERATION OF THE DIAPHRAGM VALVES. THE UTILITY'S CONSULTANT ENGINEERING
FIRM WILL REVIEW THE MATERIAL AND SUGGEST POSSIBLE CONTROL VALVE
CHANGES. THE UTILITY REPORTED THAT IF THIS IS NOT POSSIBLE OR DOES NOT
WORK, A DESIGN CHANGE TO A DIFFERENT PUMP TYPE WILL BE CONSIDERED.
WHILE THE PROBLEM CONTINUES, THE UTILITY IS KEEPING A COMPLETE SHAFT AND
IMPELLER ON SITE.
PROCESS CHEMISTRY
THE UTILITY HAS LOST CONTROL OF THE PROCESS CHEMISTRY SEVERAL TIMES.
THE SLURRY SOLIDS LEVEL HAS CONSEQUENTLY INCREASED TO THE POINT THAT
556
-------
EPA. UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
SOUTHERN ILLINOIS POWER COOP: MARION 4 (CONT.)
„ PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPER^-BILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
MWWWMW — —,». — »•• W«W«,,.—,•» — — '—-.— V —•>-* vw IB »•»•»« •» «P WV W ••I » M M •• .«.•.-••-»--»—•«••-•••- -.»—.»— » » H M. w _ M _ -. ..».—.».— — ».«.—. «. —' H M> W W W •
THE THICKENER RAKE HAS BECOHE INOPERABLE. TO SOLVE THE PROBLEM THE
UTILITY HAS BEEN IMPROVING THE CHEMISTRY MOHITCRINS SYSTEM. IN THE
INTERIM, WHERE EXISTING MONITORS ARE OUT OF SERVICE, LAB PERSONNEL
PERFORM MANUAL TESTS TO MAINTAIN PROCESS CHEMISTRY CONTROL.
THE BOILER AND THE F60 SYSTEM OPERATED THE ENTIRE MONTH OF SEPTEMBER WITH
NO PROBLEMS.
10/80 SYSTEM 100.0 100.0 100.0 57.7 744 429 429 42.3
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS TAKEN OFF LINE ON OCTOBER 18 FOR A SCHEDULED ANNUAL
OVERHAUL, DURING WHICH TIME THE FGD SYSTEM REMAINED AVAILABLE.
11/80 A 90.2 .0 .0 .0
B 90. Z .0 .0 .0
SYSTEM 90.Z .0 .0 .0 720 71 0 11.2
** PROBLEMS/SOLUTIONS/COMMENTS
DUE TO PROBLEMS ENCOUNTERED WITH THE BOILER, THE SCHEDULED MAINTENANCE
OUTAGE WAS CONTINUED THROUGH NOVEMBER 26,
WHEN THE UTILITY ATTEMPTED TO START THE FGD SYSTEM, A LEAK WAS DETECTED IN
THE HIGH PRESSURE LUBRICATION LINE ON THE BALL MILL CAUSING THE SYSTEM TO
REMAIN OUT OF SERVICE THROUGH NOVEMBER.
12/80 A 79.7 78.1 78.1 72.2
B 79.4 77.8 77.8 71.9
SYSTEM 79.6 77.9 77.9 72.0 744 688 536 88.3
** PROBLEMS/SOLUTIONS/COMMENTS
THE BALL MILL LUBRICATION PROBLEM CONTINUED INTO DECEMBER CAUSING APPROX-
IMATELY 150 HOURS OF OUTAGE TIME.
ON DECEMBER 30 THE B MODULE WAS TAKEN OFF LINE FOR APPROXIMATELY THREE
HOURS TO REPAIR A WALL LEAK IN THE QUENCHER SECTION. MODULE A WAS TAKEN
OFF LINE LATER THAT DAY DUE TO THE SAME PROBLEM.
557
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PUNT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTIC'JLATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS 'JNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY fc/FGD - MW
NET UNIT GENERATING CAPACITY WtVFGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
BOILtR SUPPLIER
BOTlcR TYPE
BOILER SERVICE LOAD
DCSIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPER ATUSE - C
STACK HEIGHT - M
S'.ACK SHELL
SVACK. TOP DIAMETER - M
** FUF.L DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - X
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE HQISTUSE CONTENT - X
AVERAGE SULFUR CONTENT - X
R*\'GE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
*** PARTICLE CONTROL
** MECHANICAL COLLECTOR
** FABfllC FILTER
TY;JE
** ESP
NUMBER
TYPE
SUPPLIER
INLET FLUE GAS CAPACITY - CU.M/S
INLET FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
PARTICLE REMOVAL EFFICENCY - X
** PARTICLE SCRUBBER
GENERIC TYPE
SPECIFIC TYPE
*** FGD SYSTEM
** GENERAL DATA
SALEABLE PR ODUCT/THROWAWA Y PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
.100 LB/MMBTU)
1.200 LB/MMBTU)
(****** LB/MMBTU)
SOUTHERN INDIANA GAS 4 ELEC
A.B. BROKN
1
WEST FRANKLIN
INDIANA
B
43. (
516. (
******
250
265
250
252
265
BABCOCK fc WILCOX
PULVERIZED COAL
BASE
429. 43 (
910000 ACFM)
310 F)
498 FT)
( 14.5 FT)
( 11100 BTU/LB)
10100-11600
152.
CONCRETE
4.4
COAL
BITUMINOUS
£5819.
9.40
8.45-11.4
13.30
10.10-21.10
3.35
2.8-3.9
.05
.01-.08
NONE
NONE
COLD SIDE
BUELL DIVISION, ENVIROTECH
372.8 ( 790036 ACFM)
145.0 ( 293 F)
.6 ( 3. IN-H20)
99.5
NONE
N/A
THROWAWAY PRODUCT
WET SCRUBBING
DUAL ALKALI
NONE
FMC
MID-VALLEY
558
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SOUTHERN INDIANA 6AS & ELEC: A.B. BROWN 1 CCONT.)
DEVELOPMENT LEVEL FULL SCALE
NEW/RETROFIT NEW
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY - X 99.50
UNIT DESIGN S02 REMOVAL EFFICIENCY - X 85.00
CURRENT STATUS 1
COMMERCIAL START-UP 4/79
INITIAL START-UP 3/79
CONTRACT AWARDED X2/76
** DESIGN AND OPERATING PARAMETERS
** ABSORBER
NUMBER
NUMBER OF SPARES
GcNERIC TYPE
SPECIFIC TYPE
T^AOE NAME/COMMON TYPE
SJPPLIER
DIMENSIONS - FT
S1ELL GENERIC MATERIAL
S/IELL SPECIFIC MATERIAL
SMELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
G^S CONTACTING DEVICE TYPE
NJMBCR OF CONTACTING ZONtS
LIQUID RECIRCULATION RATE - LITER/S
L/G SATIO - L/CU.M
GAS-SIDE PRESSURE DROP - K'A
I.JLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
S02 REMOVAL EFFICIENCY - X
** MI3T ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
GuNERIC TYPE
SPECIFIC TYPE
TUADE NAME/COMMON TYPE
CONFIGURATION
N.JMBER OF STAGES
NUMBER OF PASSES PER STAGE
DISTANCE BETWEEN STAGES - CM
PRESSURE DROP - KPA
CONSTRUCTION MATERIAL GENERIC TYPE
WASH WATER SOURCE
** REHEATER
GFNERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
*» FANS
NUMBER
NUM3ER OF SPARES
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FL'JE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** DUCTWORK
LOCATION
DIMENSIONS
SHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
2
0
VENTURI TOWER
VARIABLE-THROAT/BOTTOM ENTRY PLUMB BOB
DUAL-THROAT VARIABLE SCRUBBER
FMC
62 HIGH X 32 DIA.
CARBON STEEL
AISI 1110
N/A
ORGANIC
GLASS FLAKE-FILLED POLYESTER
FLAKEGLASS
DISC CONTACTORS
3
315. ( 5000 GPM)
1.3 (10.0 GAL/1000 ACF)
1.0 ( 4.0 IN-H20)
237.84 ( 504000 ACFM)
145.0 ( 293 F)
85.0
MIST ELIMINATOR
2
IMPINGEMENT
BAFFLE
CHEVRON VANE
HORIZONTAL
1
1
1.78 (
.5 (
NORYL PLASTIC
FRESH WATER
.7 IN)
2.0 IN-H20)
NONE
N/A
N/A
2
0
WESTINGHOUSE
BOOSTER
FORCED DRAFT
DRY
237.84
145.0
CARBON STEEL
( 504000 ACFM)
( 293 F)
SCRUBBER INLET
10'6" X 14'
CARBON STEEL
NONE
559
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SOUTHERN INDIANA SAS & ELEC: A.B. BROWN 1 (CONT.)
** DUCTWORK
LOCATION
DIMENSIONS
SHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
MANUFACTURER
NUM3ER
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
PRODUCT QUALITY - 7. SOLIDS
** TANKS
SERVICE
REACTION
SURGE TANK
SCRUBBER LIQUOR HOLDING
** PUMPS
SERVICE
ABSORBER RECIRCUUTION
THICKENER UNDERFLOW
REGENERATION RETURN
»* SCLIDS CONCENTRATINS/DEWATERING
DEVICE
NJtISER
NUMBER OF SPARES
CAPACITY
SHELL GENERIC MATERIAL TYPE
CUTLET STREAM CHARACTERISTICS
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
KUMBCR
NUK5LR OF SPARES
DIMENSIONS - FT
SHE! L GENERIC MATERIAL TYP:
*** SLJDCE
** TRcA^MENT
MiTHOD
** DISPOSAL
NATURE
TCPE
LOCATION
SITE TRANSPORTATION METHOD
SCTE DIMENSIONS
SITE CAPACITY - CU.M
SITE SERVICE LIFE - YRS
** PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS
CONTROL LEVELS
MONITOR LOCATION
PROCESS CONTROL MANNER
PROCESS CHEMISTRY MODE
** WATER BALANCE
WATER LOOP TYPE
SCRUBBER OUTLET
18 X S
CARBON STEEL
FLAKEGLASS
LIME SLAKING
SLAKER
WALLACE & TIERNAN
3
3.6 (
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SOUTHERN INDIANA GAS & ELEC: A.B. BROWN 1 (CONT.)
** CHEMICALS AND CONSUMPTION
NAME
CONSUMPTION
** FGD SPARE CAPACITY INDICES
ABSORBER - X
*« FGD SPARE COMPONENT INDICES
ABSORBER
LIME
6.3 TPH
£0.0
.3
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
3/79 SYSTEM
4/79 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
744
720
29.6
THE FGD SYSTEM BEGAN OPERATIONS ON MARCH 18, 1979. NO OPERATIONAL DATA
ARE YET AVAILABLE.
5/79 SYSTEM
6/79 SYSTEM
744
720
54.7
65.4
** PROBLEMS/SOLUTIONS/COMMENTS
OPERATING HOURS ARE NOT YET AVAILABLE. HOWEVER, THE UNIT HAS BEEN RUNNING
INTERMITTENTLY AS A RESULT OF PUMP LINER AND FRP PIPING DESIGN PROBLEMS.
7/79 SYSTEM 62.8
6/79 SYSTEM 94.3
** PROBLEMS/SOLUTIONS/COMMENTS
54.8
94.2
744 650 408 48.1
744 743 701 51.7
IN AUGUST THE FGD SYSTEM WAS FORCED OFF LINE FOR 43 HOURS DUE TO PROBLEMS
WITH THE RECYCLE PUMP IMPELLERS.
9/79 SYSTEM
74.6
74.2
720 716 534 62.5
** PROBLEMS/SOLUTIONS/COMMENTS
IN SEPTEMBER 52 HOURS OF SCHEDULED OUTAGE WERE USED TO INSTALL A WATER
FILTER. THE SCRUBBER WAS ALSO TAKEN OFF LINE FOR 72 HOURS FOR PRECIPITATOR
TESTING. THE ONLY FORCED OUTAGE DIRINS THE MONTH BEGAN ON SEPTEMBER 28 AND
LASTED THROU3H THE END OF THE MONTH AS A RESULT OF POOR FILTER CAKE
QUALITY. THIS HAS RESULTED FROM PROBLEMS WITH THE VACUUM FILTERS AS WELL
AS CHEMICAL PROBLEMS.
10/79
11/79
12/79
A
B
SYSTEM
A
B
SYSTEM
A
B
SYSTEM
88.6
87.3
88.0
91.0
91.0
91.0
80.9
81.2
81.1
96.8
98.5
97.7
97.1
94.4
95.8
80.9
81.3
81.1
100.0
98.5
99.3
98.2
95.5
96.9
80.9
81.2
81.1
84.5
86.0
85.3
89.4
86.9
88.2
80.8
81.2
81.0
744 649
720 663
744 743
634 49.6
635 62.1
603 53.5
561
-------
EPA UTILITY FGO SURVEY: OCTOBER - DECEMBER 1980
SOUTHERN INDIANA GAS & ELEC: A.B. BROWN 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
1/80
3/80
5/80
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE FOURTH QUARTER PROBLEMS WERE ENCOUNTERED WITH THE LIME SLAKER
FEED.
THE THICKENER RAKE FROZE CAUSING 9 DAYS OUTAGE TIME.
THE ISOLATION DAMPER HAS CAUSED SOME PROBLEMS THIS QUARTER. THE UTILITY
HAS NOT YET SOLVED THIS PROBLEM.
A
B
SYSTEM
99.0
99.0
99.0
96.5
99.0
98.0
99.1
99.1
99.1
96.4
99.0
97.7
744
7Z7 65.8
** PROBLEMS/SOLUTIONS/COMMENTS
SEVEN HOURS OF FGD SYSTEM FORCED OUTAGE TIME DURING JANUARY WERE CAUSED
BY A THICKENER RAKE STALL.
2/80 A
B
SYSTEM
99.1
98.4
98.8
70.3
70.0
70.2
98.8
97.8
93.3
69.4
68.7
69.1
696 687
481 75.5
** PROBLEMS/SOLUTIONS/COMMENTS
SOHE OUTAGE TIME IN FEBRUARY RESULTED FROM A WET SLUDGE PRODUCT. A
CHEMICAL IMBALANCE CAUSED THE SLUDGE PROBLEM.
A
B
SYSTEM
98.7
99.2
99.0
64.8
51.6
58.2
95.2
96.3
95.8
26.5
21.1
23.8
744 304
177 23.8
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MARCH, BOILER DOWN TIME WAS DUE TO A SCHEDULED UNIT OUTAGE, DURING
WHICH TIME MAINTENANCE WAS PERFORMED ON THE SCRUBBER.
4/80 A
B
SYSTEM
100.0
100.0
100.0
96.8
99.7
98.3
100.0
100.0
100.0
92.9
95.7
94.3
720 691
679 58.6
** PROBLEMS/SOLUTIONS/COMMENTS
DURING APRIL, THERE WERE NO OPERATIONAL PROBLEMS WITH THE FGD SYSTEM. THE
SYSTEM WAS AVAILABLE 100X OF THE TIME.
A
B
SYSTEM
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
82.8
82.8
82.8
744 604
616 53.7
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MAY NO FORCED OUTAGES WERE EXPERIENCED WITH THE FGD SYSTEM. THE
BOILER WAS OFF LINE FOR 140 HOURS DURING THE MONTH FOR GENERAL MAINTENANCE,
DURING WHICH TIME SOME GENERAL FGD SYSTEM MAINTENANCE WAS ALSO PERFORMED.
6/80 A
B
SYSTEM
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
98.2
98.2
98.2
720 706
707 55.4
562
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
SOUTHERN INDIANA GAS & ELEC: A.B. BROWN 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL
S02 PART.
PER BOILER FGD CAP.
HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
NO FGD RELATED PROBLEMS WERE REPORTED FOR THE MONTH OF JUNE.
SYSTEM OPERATED 100X OF THE TIME THE BOILER WAS ON LINE.
THE FGD
7/80
A
B
SYSTEM
98.1
86.8
92.4
97.9
87.7
92.8
97.9
87.7
92.8
92.5
82.9
87.7
744 703
653 62.6
** PROBLEMS/SOLUTIONS/COMMENTS
THE B MODULE RECIRCULATION PUMPS WERE THE MAJOR CAUSE OF DOWNTIME. TWO
PIECES OF THE CHEVRON MIST ELIMINATOR FELL CAUSING THE SUCTION LINES TO
PLUS.
ADDITIONAL PROBLEMS WITH THE PUMP WERE CAUSED BY THE THRUST BEARING.
WAS CORRECTED BY THE MANUFACTURER.
THIS
THE UNAVAILABILITY OF THE VACUUM FILTERS AND ASSOCIATED EQUIPMENT REQUIRED
THE SCRUBBER TO SHUTDOWN TO AVOID A STOPPAGE OF THE THICKENER RAKE. THIS
SITUATION ACCOUNTED FOR APPROXIMATELY 15 HOURS OF SYSTEM OUTAGE TIME
DURING JULY.
8/80
A
B
SYSTEM
94.5
94.8
94.6
94.5
94.8
94.6
94.5
94.8
94.6
94.5
94.8
94.6
744 744
704 61.4
** PROBLEMS/SOLUTIONS/COMMENTS
THE MAJOR CAUSE OF UNAVAILABLITY FOR AUGUST WAS PROBLEMS WITH SOLIDS
DISPOSAL, INCLUDING PROBLEMS WITH PRIMARY LIQUID-SOLID SEPARATION UP TO
ANO INCLUDING FINAL LANDFILLING.
9/80
A
B
SYSTEM
100.0
100.0
100.0
99.6
99.6
99.6
99.6
99.6
99.6
99.6
99.6
99.6
720 720
717 59.8
** PROBLEMS/SOLUTIONS/COMMENTS
SLUDGE DISPOSAL REMAINS THE MOST PREVALENT PROBLEM DUE TO MECHANICAL
BREAKDOWN OF THE DISPOSAL TRUCKS AND UNDERFLOW PUMPS, IN ADDITION TO THE
HIGH MAINTENANCE REQUIREMENTS OF THE ROTARY VACUUM FILTERS.
THE MONTH OF SEPTEMBER ALSO SAW AN EXTREMELY HIGH RATE OF FAILURE OF
RECIRCULATION PUMPS, WITH DAMAGE TO THE RUBBER LINED CASINGS AND IMPELLERS.
THE CAUSE OF THIS PROBLEM IS UNKNOWN TO THE UTILITY AT THIS POINT.
10/80
A
B
SYSTEM
98.4
100.0
99.2
98.2
93.8
96.0
98.2
93.8
96.0
98.2
93.8
96.0
744 744
714 59.8
** PROBLEMS/SOLUTIONS/COMMENTS
THE SYSTEM UNAVAILABILITY DURING THE MONTH WAS CAUSED BY TWO SEPARATE
INSTANCES OF REGULATOR VALVE FAILURE.
NO MAJOR FGD RELATED PROBLEMS WERE REPORTED FOR OCTOBER? HOWEVER, SEVERAL
PROCESS LINES HAD LOW FLOWS AT TIMES DUE TO BLOCKAGES CAUSED BY PIECES OF
BROKEN MIST ELIMINATOR.
11/80 A
B
SYSTEM
97.5
97.5
97.5
83.8
83.8
83.8
85.2
85.2
85.2
54.6
54.6
54.6
720 469
393 38.2
563
-------
EPA UTILITY F6D SURVEY'• OCTOBER - DECEMBER 1980
SOUTHERN INDIANA GAS & ELEC= A.B. BROWN 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER MAS DOWN FROM NOVEMBER 7 TO NOVEMBER 17.
THE FGD SYSTEM WAS SHUTDOWN ON NOVEMBER 6 DUE TO DEPLETION OF THE SODA
ASH INVENTORY WHICH RESULTED IN A LOW CHEMICAL CONCENTRATION.
THE TRANSITION DUCTWORK FROM ONE MODULE TO THE STACK WAS REPLACED WITH
317L S3 WHILE THE OTHER SIDE RECEIVED A FLOUROELASTOMER
COATING.
THE CHEVRONS WERE CAKED WITH AN EXTREMELY HARD AND HEAVY MATERIAL CONSIST-
INS PRIMARILY OF SODIUM CARBONATES AND SULFATES.
THE MIST ELIMINATORS WERE RE-TIED DURING NOVEMBER TO PREVENT FURTHER
SECTIONS FROM FALLING.
12/80
A
B
SYSTEM
100.0
93.2
99.2
97.4
95.0
96.2
97.4
95.0
96.2
94.3
92.1
93.2
744 721
694 52.4
** PROBLEMS/SOLUTIONS/COMMENTS
A MAJOR EQUIPMENT PROBLEM WITH THE LIME SLAKERS WAS ENCOUNTERED DURING
DECEMBER. THE PH AND LEVEL CONTROLS CAUSED ERRATIC OPERATION SEVERAL
TIMES DURING THE MONTH, ADDING TO THE CONTINUAL WATER BALANCE PROBLEMS.
564
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC F6D SYSTEMS
COMPANf NAME
PLANT MAME
UNIT NJMBLR
CITY
STATE
REGULATOF Y CLASSIFICATION
P ARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UN.:T GENERATING CAPACITY WO/FGD - MM
EQUIVAi-ENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUFL DATA
FtEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - X
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7.
RA^GE MOISTURE CONTENT - 7.
AVtRAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AV'iRAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
*# ESP
NUMBER
TYPE
SUPPLIER
INLET FLUE GAS TEMPERATURE - C
PARTICLE REMOVAL EFFICENCY - 7.
** PARTICLE SCRUBBER
GENERIC TYPE
SPECIFIC TYPE
*** FGD SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
UNIT DESIGN S02 REMOVAL EFFICIENCY - 7.
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
SPRINGFIELD CITY UTILITIES
SOUTHWEST
( .100 LB/MMBTU)
( 1.200 LB/MMBTU)
(****** LB/MMBTU)
SPRINGFIELD
MISSOURI
B
43.
516.
******
173
194
173
182
RILEY STOKER
PULVERIZED COAL
BASE
375.16 ( 795000 ACFM)
148.9 ( 300 F)
117. ( 384 FT)
CONCRETE
3.4 ( 11.0 FT)
( 11500 BTU/LB)
10500-12500
COAL
BITUMINOUS
26749.
13.00
10-22
9.00
6-12
3.50
2.5 - 4.5
.30
COLD SIDE
AIR CORRECTION DIVISION, UOP
148.9 ( 300 F)
99.7
NONE
N/A
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
AIR CORRECTION DIVISION, UOP
BURNS & MCDONNELL
FULL SCALE
NEW
- 7. 99.70
80.00
1
9/77
4/77
8/73
565
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SPRINGFIELD CITY UTILITIES: SOUTHWEST 1 (CONT.)
** DESIGN AND OPERATING PARAMETERS
** ABSORBER
NUMBER
GliHERIC TYPE
SPECIFIC TYPE
T.?ADE NAME/COMMON TYPE
SUPPLIER
DIMENSIONS - FT
S1ELL GENERIC MATERIAL
S'iELL SPECIFIC MATERIAL
SMELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LCNER SPECIFIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
G4S CONTACTING DEVICE TYPE
WJMBE3 OF CONTACTING ZONES
LIQUID RECIRCULATION RATE - LITER/S
L/S r?ATIO - L/CU.M
GAS-SIDE PRESSURE DROP - Ki'A
IMLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
S02 REMOVAL EFFICIENCY - X
** MlfTT ELIMINATOR
PKE-MIST ELIMINATOR/MIST ELIMINATOR
NUtBER PER SYSTEM
GENERIC TYPE
StECIFIC TYPE
TF:ADE NAME/COMMON TYPE
NUMBER OF STAGES
NUMBER OF PASSES PER STAGE
DISTANCE BETWEEN STAGES - CM
DISTANCE BETWEEN VANES - CM
CONSTRUCTION MATERIAL GENERIC TYPE
** REhEATER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
** FANS
NU1BER
SUPPLIER
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
MANUFACTURER
NUMBER
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
PRODUCT QUALITY - 7. SOLIDS
PACKED TOWER
MOBILE BED PACKING
TURBULENT CONTACT ABSORBER
AIR CORRECTION DIVISION, UOP
16 X 30 X 54.5 HIGH
CARBON STEEL
ASTM A-36
N/A
ORGANIC
SYNTHETIC RUBBER
NEOPRENE
I 7/8" NITRILE FOAM SPHERES
3
819. (13000 GPM)
5.5 ( 41.0 GAL/1000 ACF)
1.5 ( 6.0 IN-H20)
156.91 ( 332500 ACFM)
65.6 ( 150 F)
87.0
MIST ELIMINATOR
2
IMPINGEMENT
BAFFLE
CHEVRON VANE
2
3
1.52 ( .6 IN)
2.5 ( 1.00 IN)
FIBERGLASS REINFORCED PLASTIC
NONE
N/A
N/A
GREEN FAN
BOILER I.D.
DRY
192.06
168.3
CARBON STEEL
( 407000 ACFM)
( 335 F)
SCRUBBER INLET
CARBON STEEL
NONE
SCRUBBER OUTLET TO STACK
CARBON STEEL
PLASITE 4005
LIMESTONE GRINDING
BALL MILL
KENNEDY VAN SAUN
2
7.3 ( 8 TPH)
40.0
566
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SPRINGFIELD CITY UTILITIES: SOUTHWEST 1 (CONT.)
** TANKS
SERVICE
LIMESTONE SLURRY
SLURRY HOLD TANK
OEMISTER WASH TANK
PRESATURATOR SUPPLY TANK
** PUMPS
SERVICE
ABSORBER RECIRCULATION
MIST ELIMINATOR WASH
THICKENER FEED
SLURRY FEED
SLURRY TRANSFER
PRESATURATOR WATER-TRAP OUT TRAY WAS
** SOLIDS CONCENTRATING/DEWATERING
D iVICE
NUMBER
NUMBER OF SPARES
F'-ED STREAM CHARACTERISTICS
O'JTLET STREAM CHARACTERISTICS
** SOUDS CONCENTRATING/DEWATERING
DHVICE
NUMBER
N'JMBER OF SPARES
D.:t1Eh'3IONS - FT
SHELL GENERIC MATERIAL TYi'E
*** SLUDGi
** TREATMENT
** DISPOSAL
N/.TURE
LOCATION
SITE TRANSPORTATION METHOD
** PROCESS CONTROL AND INSTRUMENTATION
CKEMICAL PARAMETERS
CONTROL LEVELS
MONITOR LOCATION
PF'OCESS CONTROL MANNER
** WATER BALANCE
WATER LOOP TYPE
** FGD SPARE CAPACITY INDICES
ABSORBER - X
** FGD SPARE COMPONENT INDICES
ABSORBER
NUMBER
1
2
1
1
NUMBER
VACUUM FILTER
1
0
30X SOLIDS
60X SOLIDS
THICKENER
1
0
112 DIA
CARBON STEEL
FINAL
LANDFILL
ON SITE
TRUCK
PH, SLURRY DENSITY
PH 5.4-5.5
RECYCLE SLURRY LINE
MANUAL
CLOSED
20.0
.3
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL PER BOILER FGO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
0/77 SYSTEM
567
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SPRINGFIELD CITY UTILITIES: SOUTHWEST 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
INSTALLATION OF THE LIMESTONE FGD SYSTEM WAS COMPLETED DURING THE FIRST
QUARTER OF 1977 (BEHIND SCHEDULE, PRIMARILY BECAUSE OF DELAYS IN ELECTRIC-
AL WORK). FOLLOWING AIR/U'ATER TESTS AND CHECKOUT OF LIMESTONE PREPARATION
FACILITIES, THE FGD PLANT W4S STARTED UP IN EARLY APRIL 1977 FOR MECHANIC-
AL SHAKEDOSiN/DEBUGGING OPERATIONS WHICH CONTINUED THROUGHOUT THE SUMMER.
COMPLIANCE TESTING AND CERTIFICATION OF COMMERCIAL AVAILABILITY WERE SUC-
CESSFULLY COMPLETED IN SEPTEMBER, JUST BEFORE A SCHEDULED 3-MONTH FALL
SHUTDOWN. OPERATION OF THE SYSTEM HAS BEEN HAMPERED BY A NUMBER OF PROB-
LEMS: MIST ELIMINATOR PLUGGING (PIPIKS TO M.E. SFRAY SYSTEM HAS BEEN MOD-
IFIED), CORROSION IN THE FRESATURATOR (WAS RELINED WITH PRECRETE),
CORROSION OF THE INLET/OUTLET GAS DAMPERS (REPLACED WITH 316 SS DAMPERS),
AND FAILURE OF PRECRETE LINING IN THE SCRUBBER AHD CEILCOTE IN THE STACK
(BOTH FAILURES IDENTIFIED AS APPLICATION PROBLEMS). THE UTILITY ALSO
FOUND IT NECESSARY TO CHANGE THE SYSTEM PH CONTROL FRCM 5.9 TO 5.6 TO
INCREASE LIMESTONE UTILIZATION AND DECREASE PLUGGING WITHIN THE SYSTEM.
4/77 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
FGD OPERATIONS BEGAN IN EARLY APRIL. THE SYSTEM IS CURRENTLY EXPER-
IENCING MIST ELIMINATOR PLUGGING AND INSTRUMENTATION PROBLEMS.
5/77 SYSTEM 744
6/77 SYSTEM 7£0
** PROBLEMS/SOLUTIOHS/COMMENTS
THE SCRUBBER EXPERIENCED CORROSION IN THE PRESATURATOR AREAS THAT WILL
WILL REQUIRE RELINING.
7/77 SYSTEM 744
8/77 SYJTEM 744
9/77 S>3TEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS OPERATED ROUGHLY 60X OF THE AUGUST-SEPTEMBER
PERIOD. A NEW SOURCE PERFORMANCE TEST WAS RUN DURING THE SECOND WEEK OF
SEPTEMBER. LATER, THE UNIT WAS SHUT DOWN FOR THE FIRST TURBINE IN-
SPECTION.
10/77 SYSTEM 744
** PROBLEMS/SOLUTIONS/COI1MENTS
A SCHEDULED OCTOBER-NOVEMBER OUTAGE WAS INITIATED. THE UNIT IS SCHEDULED
TO START UP AGAIN IN JANUARY.
DURING OCTOBER THE OUTLET DAMPERS WERE MODIFIED. THE 316 SS DAMPERS WERE.
REPLACED WITH 316L SS DAMPERS.
THE PRESATURATOR WAS RELINED WITH HIGH MOLYBDENUM STEEL AS A RESULT
OF THE PRECRETE FAILURE NOTED EARLIER (JUNE).
OUTLET DUCTWORK WAS RELINED WITH CEILCOTE DURING THE OUTAGE.
HOLLOW PACKING BALLS WERE REPLACED WITH HEAVIER WALLED PLASTIC BALLS.
568
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SPRINGFIELD CITY UTILITIES: SOUTHWEST 1 (CONT. )
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
THE BALLS WERE RUPTURING AND FILLING WITH SLURRY MAKING THEM INEFFECTIVE.
LEAKING AROUND OUTLET DAMPERS WAS MINIMIZED BY SEAL-AIR FANS.
11/77 SYSTEM 720
12/77 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE PUNT SHUTDOWN CONTINUED UNTIL JANUARY 28 WHEN THE BOILER RESTARTED.
THE FGD SYSTEM WAS EXPECTED TO BE PUT BACK ON LINE IN FEBRUARY 1978.
DURING THE OUTAGE ALL REMAINING MODIFICATIONS TO THE FGD SYSTEM WERE COM-
PLETED.
1/78 SYSTEM 744
2/78 SYSTEM 672
** PROBLEMS/SOLUTIONS/COMMENTS
THE ABSORBERS DID NOT OPERATE DUE TO AN EXPANSION JOINT FAILURE BETWEEN
THE ID FAN AND THE ABSORBERS.
THE ABSORBERS ARE CURRENTLY BEING BY-PASSED. THE FGD SYSTEM IS EXPECTED
TO BE BACK ON LINE BY THE END OF APRIL.
3/78 SYSTEM 744
4/78 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
ONLY ONE ABSORBER MODULE IS CURRENTLY OPERATING. THE EXPANSION
JOINT FAILURE MENTIONED PREVIOUSLY WAS DIRECTLY RELATED TO THE DAMPER
FAILURE WHICH DIRECTED THE BOILER FLUE GAS TO THE SEALED OFF FGD
SYSTEM.
THE DAMPER LOUVERS HAVE BEEN STICKING. THERE ARE NO MANUAL CONTROLS FOR
THE DOUBLE LOUVER DAMPERS SO THAT WHEN INSTRUMENTATION FAILURES OCCUR THE
UNIT MUST BE SHUT DOWN. OF THE 12 DAMPERS 16 PAIRS) ON THIS SYSTEM 6
HAVE BEEN REBUILT.
AN FRP LINER FAILURE OCCURRED DURING THIS PERIOD.
A PUMP FAILURE OCCURRED DURING THE PERIOD. THE PROBLEM DOES NOT
APPEAR TO BE SEVERE.
5/78 SYSTEM 744
6/78 SYSTEM 720
**• PROBLEMS/SOLUTIONS/CO 1MENTS
THE S-I MODULE RAN STEADILY FOR OVER 11 DAYS. THE S-2 MODULE WAS STILL
DOWN «TH EXPANSION JOINT PROBLEMS.
DURING THE MONTH THE MIST ELIMINATOR WASH SYSTEM WAS ALTERED FROM A SEPAR-
ATE CLOSED LOOP FOR EACH MODULE TO A COMMON SYSTEM FOR BOTH MODULES. THE
NEW SYSTEM TAKES SUPERNATANT FROM THE TOP OF THE THICKENER FOR MIST ELIM-
INATOR SPRAY.
INSTRUMENTATION PROBLEMS WERE ENCOUNTERED DURING THE MONTH. PH PROBES
WERE LOST, THE MAG-FLOW METER FOR LIMESTONE SLURRY FAILED, AND THE AUTO-
569
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
SPRINGFIELD CITY UTILITIES: SOUTHWEST 1 (CONT. )
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
MATIC GAS ANALYZERS DID NOT OPERATE PROPERLY.
SOME PIPES EXPERIENCED PLUGGING DUE TO NEOPRENE PEELINS FROM VALVES. IT
IS EXPECTED THAT VALVE REPAIR OR REPLACEMENT SHOULD STOP THE PLUGGING.
THE SLUDGE SYSTEM EXPERIENCED SOME FILTER BELT PROBLEMS DURING THE MONTH.
REPAIRS WERE MADE BUT INSUFFICIENT SLUDGE HAS BEEN GENERATED TO DETERMINE
IF THE PROBLEMS HAVE BEEN SOLVED.
7/78 S-l
S-2
SYSTEM
16.7
.0
8.3
16.7
.0
8.3
16.7
.0
8.3
16.7
.0
8.3
744
62 70.1
** PROBLEMS/SOLUTIONS/COMMENTS
PROBLEMS WERE ENCOUNTERED WITH THE S-l MODULE TRANSFER PUMPS. NINE DAYS
WERE REQUIRED TO TRACE THE ELECTRICAL-RELATED PROBLEM.
A 17-DAY OUTAGE WAS CAUSED BY PROBLEMS WITH THE BALL MILL AIR SUPPLY WHICH
RESULTED IN THE UNAVAILABILITY OF SLURRY.
THE S-2 MODULE WAS STILL DOWN IN JULY WHILE THE UTILITY WAITED FOR THE
REPLACEMENT EXPANSION JOINT.
WORK WAS DONE DURING THE MONTH TO IMPROVE THE INSTRUMENTATION. IT WAS
DISCOVERED THAT MANY OF THE PROBLEMS WERE DUE TO SCALE ACCUMULATION ON THE
PROBES.
8/78 S-l
S-2
SYSTEM
59.0
.0
29.5
59.0
.0
29.5
59.0
.0
29.5
59.0
.0
29.5
744
220 56.6
** PROBLEMS/SOLUTIONS/COMMENTS
THE S-2 MODULE REMAINED DOWN THROUGHOUT AUGUST BECAUSE THE REPLACEMENT
EXPANSION JOINT HAD NOT YET ARRIVED.
EXPANSION JOINT REPAIRS ON THE S-l MODULE SCRUBBER FORCED THE MODULE OUT
OF SERVICE FOR 84 HOURS.
PROBLEMS WITH THE THICKENER AND PLUGGED LINES FORCED THE S-l MODULE OUT
OF SERVICE FOR 211 HOURS.
9/78 S-l
S-2
SYSTEM
22.1
.0
11.1
28.6
.0
14.3
28.6
.0
14.3
22.1
.0
11.1
720 557
80 49.1
** PROBLEMS/SOLUTIONS/COMMENTS
CONTINUATION OF THE EXPANSION JOINT PROBLEM RESULTED IN THE S-2 MODULE
REMAINING DOWN THROUGHOUT THE MONTH.
S-2 MODULE DOWN TIME WAS DUE TO PLUGGING Of THE THICKENER SLURRY MAKEUP
LINES AND FAILURE OF THE BALLS WITHIN THE MODULE.
THE HEAVIER-WALLED PING PONG BALLS THAT WERE INSTALLED DURING THE
DECEMBER 1977-JANUARY 1978 PERIOD WERE REPLACED WITH 1.25 INCH DIAMETER
SOLID RUBBER BALLS DURING SEPTEMBER 1978.
10/78 SYSTEM
.0
.0
.0
.0
744
26
570
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SPRINGFIELD CITY UTILITIES: SOUTHWEST 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS DOWN FOR A SCHEDULED OUTAGE DURING THE MONTH
CONSIDERABLE CLEANING OF THE S-l MODULE WAS DONE AS THE LOWER TWO LEVELS
OF THE MODULE HAD BEGUN TO PLUG WHEN THE BALLS FAILED (SEE SEPTEMBER
1978),
A THOROUGH CLEANING OF THE ENTIRE FGD SYSTEM OCCURRED DURING THIS PERIOD.
A BEARING WAS REPLACED ON THE SLURRY DRAW OFF PUMP. WORK MAS ALSO
REQUIRED ON A WASTE DRAW OFF PUMP.
THE OUTLET DUCT WAS CLEANED AND A PLASITE LINER WAS INSTALLED. REPAIR
WAS MADE TO THE BYPASS DUCT TOGGLE (A PAIR OF EXPANSION JOINTS WITH TWO
TO THREE FT. OF DUCT BETWEEN THEM) DUE TO METAL DETERIORATION.
THE RUBBER COATING ON HOLD TANK AGITATORS AND SLURRY STORAGE TANK
AGITATORS WERE REPAIRED.
MAINTENANCE WAS PERFORMED ON FANS, DAMPERS AND VALVES.
MAINTENANCE AND MODIFICATIONS TO THE INSTRUMENTATION HAVE YIELDED SOME
IMPROVEMENT IN OPERATIONS. SOME INSTRUMENTATION PROBLEMS RESULTED
FROM SCALE ACCUMULATION ON PROBES. MODIFICATIONS TO THE PRESATURATOR
TEMPERATURE PROBES WHICH WERE COMPLETELY COATED WITH MATERIAL ARE
EXPECTED TO PERMANENTLY RECTIFY THE PROBLEM IN THIS AREA.
THE FILTER BELTS HAVE STILL BEEN TEARING AS MENTIONED EARLIER
(JUNE, 1978). THERE HAVE BEEN PROBLEMS BOTH UPSTREAM AND DOWNSTREAM
OF THE FILTER BELTS IN THE SLUDGE DISPOSAL SYSTEM.
THE UTILITY REPORTED THAT THERE HAS BEEN NO SIGN OF SCALE ACCUMULATION
ON THE MIST ELIMINATORS SINCE THE WASH SYSTEM WAS MODIFIED AS REPORTED
IN JUNE, 1978.
11/78 S-l
S-2
SYSTEM
68.1
3*.9
51.5
64.7
22.4
43.6
64.7
22.4
43.6
64.3
22.3
43.3
720 716
312 52.1
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER OUTAGE LASTED INTO THE FIRST PART OF NOVEMBER DURING WHICH
TIME SCRUBBER REPAIR WORK CONTINUED.
AN FGD OUTAGE WAS CAUSED BY A FAN BEARING FAILURE ON THE S-2 MODULE
DURING NOVEMBER.
ALL DAMPERS WERE SERVICED, REPAIRED AND EXERCISED.
12/78 S-l
S-2
SYSTEM
45.2
81.7
63.4
32.9
76.2
54.6
32.9
76.2
54.6
29.7
68.7
49.2
744 671
366 5Q.9
** PROBLEMS/SOLUTIONS/COMMENTS
PRESATURATOR NOZZLE PLUGGING OCCURRED IN THE S-l MODULE DURING DECEMBER.
AFTER THE SPRAY NOZZLES WERE REPLACED FROZEN LINES PREVENTED MODULE
STARTUP.
SEVERAL LINES BROKE OR DEVELOPED LEAKS AS A RESULT OF FREEZE UPS.
ALL THE MAJOR OUTAGES CAN BE ATTRIBUTED TO THE COLD WEATHER. THE SYSTEM
571
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SPRINGFII.LD CITY UTILITIES: SOUIHWEST 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
1/79 S-l
s-2
SYSTEM
.0
42.6
21.3
WAS NOT DESIGNED WITH DUE REGARD TO WEATHER CONDITIONS.
ONE OR TWO MINOR SCRUBBER SHUTDOWNS RESULTED FROM FROZEN
.0 .0 .0
47.3 47.3 £9.0
24.9 24.9 14.5 744
INSTRUMENTATION.
457 108 43.9
** PROBLEMS/SOLUTIONS/COMMEHTS
THE S-2 MODULE WAS UNAVAILABLE FOR 117 HOURS BECAUSE OF VALVE FREEZE-UPS.
FROZEN VALVES AND EQUIPMENT CONTRIBUTED TO THE OUTAGES OF THE S-l MODULE.
DURING THE FIRST 15 DAYS OF JANUARY THE SECOND BALL MILL WAS UHUSEABLE
BECAUSE OF A COMPRESSED AIR SYSTEM FAILURE. THIS RESULTED IN AM
INSUFFICIENT LIMESTONE SLURRY SUPPLY TO THE S-l MODULE.
2/79 5-1 28.7 .0 .0 .0
3-2 24.2 32.0 32.0 24.2
SYSTEM 26.5 16.0 16.0 12.1 672 508 81 48.2
** PROBLEMS/SOLUTIONS/COMMENTS
THE S-l MODULE EXPERIENCED PLUGGING PROBLEMS IN THE FIRST AND SECCNO
STAGES DURING FEBRUARY AND DID NOT OPERATE. DUE TO FLUE GAS LEAKING INTO
THE MODULE, ACCESS COULD NOT BE OBTAINED TO CLEAU THE MODULE.
EXPANSION JOINT PROBLEMS AND BROKEN LINES THROUGHOUT THE SYSTEM WERE
REPORTED.
SCRUBBING OPERATIONS WERE HAMPERED DURING THE LATTER PART OF FEBRUARY
BECAUSE OF IHSUFFICIENT LIMESTONE SLURRY.
THE S-£ MODULE PROBLEMS INCLUDED FROZEN VALVES AND LINES.
3/79 S-l 62.0 39.5 39.5 38.8
S-2 55.1 14.0 14.0 13.7
SYSTEM 58.6 26.8 26.8 26.3 744 730 195 46.2
** PROBLEMS/SOLUTIONS/COMMENTS
THE MAJORITY OF MODULE S-l DOWNTIME WAS DUE TO A BROKEN SUPERNATE LINE AND
MAKEUP CROSS TIE.
THE UTILITY REPORTED THAT THE MODULE WAS UNABLE TO RUN FOR A TIME DUE TO
A DESIGN PROBLEM WITH THE WESTINGHOUSE 500 HP MOTORS.
4/79 S-l 42.6 30.9 30.9 18.5
S-2 51.6 45.0 45.0 87.0
SYSTEM 47.1 38.0 38.0 22.8 720 432 164 28.4
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE S-l EXPERIENCED AN EXPANSION JOINT FAILURE ON THE ID FAN DIS-
CHARGE.
LOW DENSITY AT THE SLURRY HOLD TANK WAS A MAJOR PROBLEM.
SOME PLUGGING OF THE FIRST STAGE OF THE S-2 MODULE WAS REPORTED BY THE
UTILITY.
5/79 S-l 84.1 77.5 77.5 67.0
572
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
SPRINGFIELD CITY UTILITIES: SOUTHWEST 1 (CONT.)
_ PERFORMANCE DATA •
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
S-2
SYCTEM
.0
42.1
.0
38.8
.0
38.8
.0
33.5
644
249 37.0
** PROBLEMS/SOLUTIONS/CC*1MENTS
THE S-.> MODULE HAS NOT OPERATED D'JRING MAY DUE TO A BROKEN RECYCLE TANK
AGITATOR SHAFT. A NEW ONE HAS BEEN ORDERED. RUBBER LINING OF THE SHAFT
AND REPAIR OF DAMAGED LINING ON THE IMPELLER WILL BE DONE ON SITE.
6/79
S-l
S-2
SYSTEM
55.0
.0
27.5
53.0
.0
26.5
53.0
.0
26.5
52.9
.0
26.5
720 719
191 53.8
** PROBLEMS/SOLUTIONS/COMMENTS
THE BROKEN AGITATOR SHAFT ON THE S-2 MODULE WAS REPLACED AND LINED DURING
JUNE.
THE S-l MODULE WAS OUT OF SERVICE ON THREE OCCASIONS DUE TO PLUGGING OF
THE FIRST AffD SECOND STAGES. THE UTILITY REPORTED THAT WITH THE EXCEPTION
OF THE PLUGGING PROBLEM ONLY A FEW MINOR SHORT DURATION TRIPS WERE NOTED.
7/79
S-l
S-2
SYSTEM
59.2
55.3
57.3
34.1
47.4
40.8
34.1
47.4
40.8
34.1
47.3
40.7
744 743
303 52.7
** PROBLEMS/SOLUTIONS/COMMENTS
THE S-l MODULE WAS NOT OPERATED DURING THE FIRST PART OF THE PERIOD DUE TO
PLUGGING IN THE FIRST AND SECOND STAGES. TWO OTHER OUTAGES OCCURRED.
ONE RESULTED FROM A BROKEN SLURRY LINE AND THE OTHER FROM PROCESS CONTROL
TROUBLE ATTRIBUTED TO A MINI COMPUTER MALFUNCTION.
THE S-2 MODULE WAS NOT OPERATED FOR TWO PERIODS. ONCE WHEN THE TANK WAS
BEING REFILLED AFTER AN AGITATOR WAS INSTALLED AND ONCE TO CLEAN THE FIRST
AND SECOND STAGES.
8/79
S-l
S-2
SYSTEM
74,6
94.8
84.7
53.8
70.9
62.4
53.8
70.9
62.4
50.7
66.8
58.8
744 701
437 58.6
** PROBLEMS/SOLUTIONS/COMMENTS
THE S-l MODULE WAS DOWN FOR TWO PERIODS DUE TO PLUGGING IN THE ABSORBER
SECTION. THE MODULE ALSO TRIPPED OFF AS A RESULT OF SUPERNATE PUMP
FAILURES.
9/79
S-l
S-2
SYSTEM
48.6
68.8
71.3
58.3
60.2
59.3
58.3
78.8
65.7
45.8
47.4
46.6
720 566
336 45.6
** PROBLEMS/SOLUTIONS/COMMENTS
THE S-l MODULE WAS OFF LINE DUE TO PLUGGING IN THE ABSORBER SECTION FOR
TWO PERIODS AND IT ALSO TRIPPED AS A RESULT OF SUPERNATE PUMP
FAILURES.
THE S-2 MODULE WAS OFF LINE ONCE DUE TO BROKEN SUPERNATE LINE, AND ONCE
DUE TO FAULTY PH PROBES IN SEPTEMBER. THE SCRUBBING SYSTEM HAS OFF LINE
FOR SEVERAL SHORT PERIODS DUE TO MINOR PROBLEMS.
10/79 SYSTEM
.0
744
.0
573
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SPRINGFIELD CITY UTILITIES: SOUTHWEST 1 (CONT.)
. PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
A SCHEDULED BOILER/SCRUBBER OVERHAUL BEGAN ON SEPTEMBER 29 AND CONTINUED
THROUGH OCTOBER 31.
BOTH SCRUBBER TOWERS WERE COMPLETELY CLEANED DURING THE OUTAGE.
THE SLURRY TANKS AND RELATED PIPING WERE CLEANED DURING OCTOBER.
THE SCRUBBER OUTLET DUCTWORK WAS RELINED WITH PLASITE.
ON AREAS OF THE SCRUBBING SYSTEM WHERE FIBERGLASS PIPING WAS BEING USED,
REPLACEMENTS WERE MADE WITH LINED CARBON STEEL PIPING.
THE Pil PROBES WERE REPAIRED.
REPAIR;1. WERE MADE TO THE LIMESTONE FEED BELT ON THE CONVEYOR SYSTEM.
REPAIRS WERE MADE TO THE S-2 MODULE HOLD TANK AGITATOR SHAFT DURING THE
OUTAGE
A PRESATURATOR SPRAY NOZZLE WAS REPLACED.
THE SCRUBBER DAMPERS WERE REPAIRED AND ADJUSTED.
THE SLUDGE DISPOSAL CONVEYOR SYSTEM WAS REPAIRED AND MODIFIED.
PUMP REPAIRS WERE MADE ON THE SUPERNATE PUMPS AND NEW STANDBY PUMPS
WERE INSTALLED AT THE SCRUBBING SYSTEM FACILITY.
11/79 S-l .0 .0 .0 .0
S-2 41.9 41.3 41.3 40.6
SYSTEM 20.9 20.6 20.6 20.3 720 708 146 58.1
** PROBLEMS/SOLUTIONS/COMMENTS
FOR THE FIRST WEEK OF NOVEMBER NEITHER MODULE WAS AVAILABLE DUE TO AN
OVERRUN ON SCHEDULED OUTAGE CAUSED BY A LACK OF MANPOWER,
THE S-l MODULE WAS UNAVAILABLE FOR THE LAST THREE WEEKS OF THE MONTH
BECAUSE OF THE LACK OF MANPOWER TO FINISH THE ABSORBER SECTION AND
HOLD TANK CLEANOUT.
PROBLEMS WITH THE S-2 MODULE RECYCLE PUMPS WERE ENCOUNTERED. THE MODULE
WAS REMOVED FROM SERVICE SO THAT THE REPAIRS COULD BE MADE.
SEVERAL ATTEMPTS TO RETURN THE S-l MODULE TO SERVICE WERE ABORTED DUE TO
VARIOUS PIPING PROBLEMS.
12/79 S-l 53.7 23.7 23.7 21.2
S-2 64.8 40.6 40.6 36.2
SYSTEM 59.3 32.2 32.2 28.7 744 664 213 53.2
** PROBLEMS/SOLUTIONS/COMMENTS
THE S-l ABSORBER SECTION AND HOLD TANK CLEANOUT WAS COMPLETED DURING
DECEMBER. THE MODULE WAS RETURNED TO SERVICE.
THE PRESATURATION NOZZLES CAUSED SOME PROBLEMS AND HAD TO BE REMOVED
AND CLEANED.
AT THE END OF THE MONTH THE ID FAN EXPANSION JOINT BROKE AND HAD TO BE
REPLACED.
574
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SPRINGFIELD CITY UTILITIES: SOUTHWEST 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL PER BOILER FGD CAP.
S02 PART, HOURS HOURS HOURS FACTOR
THE DENSITY METER ON THE RECYCLE LINE WAS REMOVED AND REPAIRED.
THE DRAINS ON THE MIST ELIMINATOR PUMPS HAD TO BE REPLACED.
THE WEIGH FEEDER WEIGH BELT AND CALIBRATED FEEDER WERE REPLACED AND
THE CALIBRATION FEEDER WAS CHECKED DURING DECEMBER.
1/80
S-l
S-2
SYSTEM
54.5
68.7
61.6
38.7
72.6
55.7
47.9
73.1
60.5
36.3
68.1
52.2
698
388 65.4
** PROBLEMS/SOLUTIONS/COMMENTS
AT THE BEGINNING OF JANUARY AN S-l ID FAN EXPANSION JOINT FAILED.
BOILER WAS SHUTDOWN SOON AFTER FOR BOILER-RELATED PROBLEMS.
THE
DURING THE LATTER PART OF THIS PERIOD THE S-l MIST ELIMINATOR AND TRAP OUT
TRAY HEADER FROZE. AFTER REPAIRS HERE MADE BOTH MODULES WERE PUT ON LINE.
BOTH WERE KEPT RUNNING UNTIL JANUARY 20 WHEN A FLANGE BROKE LOOSE ON THE
MIST ELIMINATOR HEADER.
AFTER MIST ELIMINATOR REPAIRS WERE COMPLETED THE S-l MODULE OPERATED UNTIL
JANUARY 27 WHEN FREEZING AIR LINES TO THE BALL MILLS PREVENTED THE USE OF
BOTH MODULES DUE TO THE LACK OF SLURRY.
THE S-2 MODULE WAS ON LINE AT THE BEGINNING OF THE MONTH BUT DEVELOPED
PRESATURATOR SPRAY NOZZLE PROBLEMS. WHILE THIS WAS BEING REPAIRED THE
UNIT WAS TAKEN OFF LINE. APART FROM THIS TIME THE MODULE WAS ON LINE.
2/80 S-l
S-2
SYSTEM
36.7
73.8
55.3
*9.1
.'1.7
31.5
73.2
52.4
29.1
71.6
50.'v
696 695
350 59.9
** PROBLEMS/SOLUTIONS/COr IMENTS
THE S--1 MODULE WAS OUT OF SERVICE IN THE FIRST PART OF FEBRUARY DUE TO
FROZEN AND BROKEN LINES. THE SUPERNATE LINE BROKE IN SEVERAL PLACES TAKING
BOTH MODULES OUT OF SERVICE FOR SEVERAL DAYS. OUCE THIS WAS REPAIRED BOTH
MODULES WERE IN SERVICE AS REQUIRED BY LOAD EXCEPT FOR A FEW MINOR TRIPS.
THE S-2 MODULE WAS EITHER IN SERVICE OR AVAILABLE FOR MOST OF THE MONTH.
3/80
S-l
S-2
SYSTEM
64.5
22.0
43.3
64.1
5.8
35.0
64.4
6.9
35.7
64.1
5.8
35.0
744 744
260 57.7
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MARCH THE S-l MODULE WAS OUT FOR 11 DAYS TO CLEAN THE ABSORBER
SECTION.
THE S-2 MODULE WAS OUT OF SERVICE FOR CLEANING THE ABSORBER SECTIONS AND
MIST ELIMINATORS FOR NEARLY ALL THE PERIOD BUT WAS AVAILABLE ON MARCH
25. IT WAS NOT OPERATED, HOWEVER, BECAUSE OF LOW UNIT LOAD DEMANDS.
4/80 :>-!
3-2
SYSTEM
78.2
15.1
46.7
69.1
6.9
37.9
37.9
59.6
6.0
32.8
720 621
236 42.4
PROBLEMS/SOLUTIONS/COMMENTS
THE S-l MODULE EXPERIENCED SHORT OUTAGES DURING APRIL CAUSED BY SLURRY
DRAW-OFF PUMP FAILURES AND MIST ELIMINATOR AND PRESATURATOR SPRAY SYSTEM
PROBLEMS.
575
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SPRINGFIELD CITY UTILITIES: SOUTHWEST 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
THE S-2 MODULE EXPERIENCED RECURRING HIGH FLUE GAS TEMPERATURE-RELATED
PROBLEMS DURING THE MONTH. THIS WAS CORRECTED BY REPAIRING THE SCRUBBER
INLET SCREEN.
5/80 S-l 72.9 60.7 69.1 60.6
S-2 43.6 30.7 35.2 30.7
SYSTEM 58.3 45.7 52.2 45.7 744 744 340 56.7
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MAY THE S-l SCRUBBER REQUIRED CLEANING.
PUMP AND PUMP CONTROL PROBLEMS ON THE S-l SCRUBBING TRAIN OCCURRED
DURING THE PERIOD.
THE S-2 MODULE WAS OFF LINE SEVERAL DAYS BECAUSE OF RECYCLE PUMP AND
RECYCLE SYSTEM REPAIRS.
FLUE GAS OUTLET DUCT REPAIRS WERE REQUIRED ON THE S-2 MODULE IN MAY.
6/80 S-l 85.6 85.6 85.5 84.9
S-2 12.8 6.8 7.2 6.8
SYSTEM 49.2 45.8 47.4 45.8 720 720 330 66.6
** PROBLEMS/SOLUTIONS/COMMENTS
THE S-l MODULE WAS IN CONTINUOUS SERVICE DURING JUNE WITH SHORT DURATION
OUTAGES FOR CLEANING, CONTROL SYSTEM DAMAGE CAUSED BY LIGHTNING, AND OTHER
MINOR MISCELLANEOUS PROBLEMS.
THE S-2 MODULE WAS CUT OF SERVICE FOR APPROXIMATELY 23 DAYS IN JUNE BECAUSE
OF A BROKEN SLURRY HOLD TANK AGITATOR SHAFT.
IN ADDITION TO THE OUTAGE CAUSED BY THE BROKEN SHAFT, THE S-2 MODULE HAD
SHORT DURATION OUTAGES CAUSED BY RECYCLE PUMP AGITATOR PROBLEMS, CONTROL
SYSTEM PROGRAMMING, AND OTHER MINOR MISCELLANEOUS PROBLEMS.
7/80 S-l 80.5 69.6 69.5
S-2 57.0 39.0 39.0
SYSTEM 68.7 54.3 72.4 54.3 744 743 404 80.6
** PROBLEMS/SOLUTIONS/C W1ENTS
DURING JULY THE S-l MODULE WAS CLEANED AND THE SPHERES WERE REPLACED.
THE S-l MODULE DUCTWORK NEEDED REPAIR DURING JULY CAUSING SOME OUTAGE TIME.
THE S10DGE DEWATERIK'G FILTER BELT AND THE HOLD TANK BEARING FAILED
ACCOUNTING FOR SOME OF THE S-l MODULE DOWNTIME.
THE S-l MODULE SPRAY CONTROL VALVE FAILED ADDING TO THE OUTAGE TIME.
HIGH FLUE GAS TEMPERATURE CONDITIONS RESULTED IN A SHUTDOWN OF BOTH THE
FGD MODULES.
THE S-2 MODULE AGITATOR SHAFT IN THE HOLD TANK FAILED CAUSING THE MODULE
TO COME OFF LINE.
PROBLEMS WERE ENCOUNTERED WITH THE SLURRY DRAW OFF PUMP, SUPERNATANT PUMP
AND THE RECYCLE PUMP CAUSING THE S-2 MODULE TO SHUTDOWN.
A POWER SUPPLY EQUIPMENT FAILURE RESULTED IN A S-2 MODULE OUTAGE.
AN EXPANSION JOINT FAILURE OCCURRED ON THE S-2 MODULE SEAL AIR FAN.
576
-------
EPA UTILITY FGD SURVEY-' OCTOBER - DECEMBER I960
SPRINGFIELD CITY UTILITIES: SOUTHWEST 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
A HIGH LEVEL CONDITION IN THE DRAW OFF SUMP WAS ALSO A CAUSE OF THE
S-2 MODULE LOW AVAILABILITY. THE PROBLEMS EXPERIENCED WITH THE CONTROL
SYSTEM CONTRIBUTED ALSO.
8/80 S-l
S-2
SYSTEM
73.7
71.9
72.8
67.*
55.*
61.*
62.4
67.*
55.*
61.4
7** 7**
*57 86.2
** PROBLEMS/SOLUTIONS/COMMENTS
THICKENER PROBLEMS ENCOUNTERED DURING AUGUST CAUSED BOTH MODULES TO
SHUT DOWN FOR PART OF THE MONTH.
THE OUTLET DUCT EXPERIENCED LEAKAGE CAUSING SOME SYSTEM DOWN TIME.
THE S-l MODULE DAMPER DRIVE FAILED CAUSED ADDITIONAL OUTAGE TIME.
THE LIMESTONE FEEDER FOR MODULE S-2 FAILED CAUSING THE S-2 MODULE TO
SHUT DOWN FOR PART OF THE MONTH.
THE FGD SYSTEM WAS SHUT DOWN DURING PART OF THE MONTH SO THAT VALVE REPAIRS
COULD BE MADE.
PROBLEMS WERE ENCOUNTERED WITH THE S-2 MODULE RECYCLE PUMP.
9/80 S-l
S-2
SYSTEM
78.5
57.5
68.0
85.8
.6
*3.2
87.*
.2
43.8
78.5
.2
39.4
720 658
283 80.3
** PROBLEMS/SOLUTIONS/COMMENTS
DURING SEPTEMBER, THE SCRUBBER OUTLET DUCTS EXPERIENCED LEAKING CAUSING
THE SYSTEM TO SHUTDOWN FOR PART OF THE MONTH.
THE S-l MODULE EXPERIENCED INLET DAMPER PROBLEMS.
THE RECYCLE SPRAY NOZZLES ON THE S-2 MODULE PLUGGED CAUSING ADDITIONAL
OUTAGE TIME.
THE RADIAN CORP. BEGAN PREPARING THE SYSTEM FOR TESTING IN THE FORCED
OXIDATION MODE. THIS IS IN CONJUNCTION WITH THE ADIPIC ACID TEST PROGRAM.
10/80 S-l
S-2
SYSTEM
.0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
.0
.0
7** 572
0 67.3
BOTH SCRUBBER MODULES WERE OUT OF SERVICE FOR THE ENTIRE PERIOD DUE TO
MAINTENANCE REQUIREMENTS THAT COULD NO LONGER BE DEFERRED.
THE 301LER WAS BROUGHT OFF LINE ON OCTOBER 2* FOR AN ANNUAL MAINTENANCE
OUTAGE. THIS OUTAGE HAD BEEN DELAYED FOR APPROXIMATELY ONE MONTH BECAUSE
OF SYSTEM ELECTRICAL DEMAND AND THE UNAVAILABILITY OF ALTERNATE POWER
PRODUCTION FACILITIES.
11/80 S-l
S-2
SYSTEM
.0
.0
.0
.0
720 1*7
0 11.9
577
-------
EPA UVILITY FGD SURVEY-' OCTOBER - DECEMBER 1980
SPRINGFIELD CITY UTILITIES: SOUTHWEST 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
K* PROBLEMS/SOLUTIONS/COMMENTS
THE SCRUBBER MODULES MERE NOT RETURNED TO SERVICE AT THE CONCLUSION OF THE
ANNUAL MAINTENANCE OUTAGE DURING NOVEMBER. WORK WAS IN PROGRESS TO
PREPARE THE MODULES FOR TESTING IN THE FORCED OXIDATION MODE OF OPERATION
IN CONJUNCTION WITH THE EPA ADIPIC ACID TEST PROGRAM.
12/80 S-l 37. ft .0 .0 .0
S-2 48.4 12.5 16.9 8.7
SYSTEM 42.9 6.3 7.7 4.4 744 520 65 49.3
** PROBLEMS/SOLUTIONS/COMMENTS
DURING DECEMBER, DOWN TIME RESULTED DUE TO PIPING SYSTEM MODIFICATIONS,
AN INLET DAMPER DRIVE FAILURE, FROZEN AND BROKEN PIPING, AND PROGRAMMABLE
CONTROLLER PROBLEMS.
578
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PUNT ^AME
UNIT NJMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICIPATE EMISSION LIMITATION - NG/J
SOS EM7SSION LIMITATION - NG/J
NOX EM;SSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MM
GROSS UNIT GENERATING CAPACITY - MW
MET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
Df.SIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
( .100 LB/MMBTU)
( 1.200 LB/MMBTU)
I .700 LB/MMBTU)
SPRINGFIELD WATER, LIGHT & PWR
DALLMAN
3
SPRINGFIELD
ILLINOIS
B
43.
516.
301.
350
205
190
202
205
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
401.11 ( 850000 ACFM)
137.8 ( 280 F)
152. ( 500 FT)
******
(***** FT)
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - '/.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - '/.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
COAL
******
24423.
8.30
10-12
17.50
10-20
3.30
2.5-3.5
.11
******
( 10500 BTU/LB)
10000-11000
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTEKT - 7.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** MECHANICAL COLLECTOR
SUPPLIER
** ESP
NUMBER
TYPE
SUPPLIER
INLET FLUE GAS TEMPERATURE - C
** PARTICLE SCRUBBER
GENERIC TYPE
SPECIFIC TYPE
COAL
BITUMINOUS
25353. ( 10900 BTU/LB)
10500-11500
11.50
10-14
13.50
10-15
2.90
2.7-3.1
********
******
JOY MANUFACTURING CO.
HOT SIDE
AIR CORRECTION DIVISION, UOP
137.8 ( 280 F)
NONE
N/A
579
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
SPRINGFIELD WATER, LIGHT & PWR: DALLMAN 3 (CONT.)
*** FSD FYSTEM
** GE4EKAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
S?£ REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
SfSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
N-W/RETROFIT
U;UT DESIGN PARTICLE REMOVAL EFFICIENCY
UMIT DESIGN S02 REMOVAL EFFICIENCY - X
CJRRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
OPER. & MAINT. REQUIREMENT - MANHR/DAY
** ABSORBER
NUMBER
NLM3ER OF SPARES
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
DIMENSIONS - FT
GAS CONTACTING DEVICE TYPE
NU-'BER OF CONTACTING ZONES
DISTANCE BETWEEN GAS CONTACTING ZONES - CM
GA'3-SIDE PRESSURE DROP - KPA
SUi'ERFICAL GAS VELOCITY - M/SEC
IKLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
S02 REMOVAL EFFICIENCY - 7.
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
CONFIGURATION
DISTANCE BETWEEN STAGES - CM
VANE ANSLES - DEGREES
CONSTRUCTION MATERIAL GENERIC TYPE
** REHEATER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
** FANS
NUMBER
NUMBER OF SPARES
SUPPLIER
FUNCTION
SERVICE
FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
MANUFACTURER
NUMBER
** TANKS
SERVICE
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
NONE
RESEARCH-COTTRELL
BURNS & MCDONNELL
FULL SCALE
NEW
X 99.50
95.00
1
1/81
10/60
12/77
2
0
COMBINATION
SPRAY/PACKED
RESEARCH-COTTRELL
30 DIA X 92.5 HIGH
CORRUGATED POLYPROPYLENE
5
61.0 (
.2 (
2.8 (
182.86 (
137.8 {
24.0IN)
.7 IN-H20)
9.1 FT/S)
387500 ACFM)
280 F)
95.0
MIST ELIMINATOR
2
HORIZONTAL
2.54 ( 1.0 IN)
30
904-L
NONE
N/A
N/A
2
0
AMERICAN STANDARD
BOOSTER
DRY
137.8 ( 280 F)
CARBON STEEL
LIMESTONE GRINDING
BALL MILL
KENNEDY VAN SAUN
2
NUMBER
S02 REMOVAL
ABSORBER FEED
580
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
SPRINGFIELD WATERt LIGHT & PWR: DALLMAN 3 (CONT.)
RtAGENT FEED
CEMISTER WASH
RETURN WATER
W£T-WELL
** PU1PS
SERVICE
ABSORBER FEED
Q'JEHCHER
DrMISTER WASH
S'JMP
MILL SLURRY
VACU1;M
FILTRATE
** SOLIDS CONCENTRATIN6/DEWATE!!ING
DEVICE
KMKEER
NUMBER OF SPARES
*** SLUDGE
MOISTURE CONTENT - X TOTAL FREE WATER
** DISPOSAL
NATURE
TVPE
S CTE TRANSPORTATION METHOD
** PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS
PROCESS CONTROL MANNER
PROCESS CHEMISTRY MODE
** WATER BALANCE
W*TER LOOP TYPE
MAKEUP HATER ADDITION - LITERS/S
** FGD SPARE CAPACITY INDICES
ABSORBER - X
** FGD SPARE COMPONENT INDICES
AB'JORBER
NUMBER
3
Z
Z
Z
$
Z
2
VACUUM FILTER
2
I
85.0
FINAL
LANDFILL
TRUCK
PH
AUTOMATIC
FEEDBACK
CLOSED
15.1
.0
.0
( 239 GPM)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
SOZ PART. HOURS HOURS HOURS FACTOR
10/80 SYSTEM 744
** PRCBLEMS/SOLUTIONS/COMMENTS
FGD SYSTEM OPERATION AT DALLMAN 3 COMMENCED IN OCTOBER 1980.
11/80 SYSTEM 720
12/80 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
SINCE STARTUP NO MAJOR FGD-RELATED PROBLEMS HAVE BEEN ENCOUNTERED. THE
UTILITY HAS REPORTED SOME CONDENSER TUBE PROBLEMS HAVE BEEN EXPERIENCED
WITH THE BOILER.
581
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC F6D SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MW
NET UNiT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** UN-T DATA - BOILER AND STACK
BJILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LFJ
AVERAGE ASH CONTENT - 7.
R;NGE ASH CONTENT - x
AVERAGE MOISTURE CONTENT - 7.
R/NGE MOISTURE CONTENT - '/.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7,
AVERAGE CHLORIDE CONTENT - 7.
R^NGE CHLORIDE CONTENT - X
*** PARTICLE CONTROL
** ESP
NUMBER
T\PE
INLET FLUE GAS TEMPERATURE - C
PARTICLE REMOVAL EFFICENCY - 7.
** PARTICLE SCRUBBER
GENERIC TYPE
SPECIFIC TYPE
*** FGD SYSTEM
** GENl'RAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
SOL REMOVAL MODE
PRCCESS TYPE
SYSTEM SUPPLIER
A-'£ FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
UNIT DESIGN S02 REMOVAL EFFICIENCY - '/.
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
ST. JOE ZINC
G.F. WEATON
1
MONACA
PENNSYLVANIA
B
43.
516.
******
120
60
60
*****
60
COMBUSTION ENGINEERING
PULVERIZED COAL
******
75.03
148.9
23.
******
3.2
.100 LB/MMBTU)
.200 LB/MMBTU)
(****** LB/MMBTU)
( 159000 ACFM)
( 300 F)
( 75 FT)
( 10.5 FT)
( 12500 BTU/LB)
******
( 300 F)
COAL
BITUMINOUS
29075.
11.50
******
********
******
2.00
2.0-4.5
.20
******
COLD SIDE
148.9
99.6
NONE
N/A
SALEABLE PRODUCT
WET SCRUBBING
CITRATE
MORRISON & KNUDSENAJ.S.B.M.
MORRISON & KNUDSEN
PROTOTYPE
RETROFIT
7. 99.60
90.00
1
1/80
11/79
582
-------
ST. JOE ZINC: 6.F. WEATON 1 (CONT.)
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
** DESIGN AND OPERATING PARAMETERS
** ABSORBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
GAS CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
LIQUID RECIRCULATION RATE - LITER/S
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
S02 REMOVAL EFFICIENCY - 7.
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
TfiADE NAME/COMMON TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
** REHEATER
NUMBER
GENERIC TYPE
S»ECIFIC TYPE
TRADE NAME/COMMON TYPE
** FAHS
NUMBER
APPLICATION
CONSTRUCTION MATERIAL GENERIC TYPE
** TANKS
SERVICE
SULFUR FLOTATION
SULF JR SLURRY
CITRATE SOLUTION STORAGE TANK
MAKE-UP WATER
SULFUR STORAGE
** PUT PS
StRVICE
SULFUR SLURRY
LFAN SOLUTION
SULFUR TRANSFER
SCRUBBER RECIRCULATION
SULFUR LOADING
RICH CITRATE SOLUTION
*** SALEABLE BYPRODUCTS
NATURE
QUALITY - X
** WATER BALANCE
WATER LOOP TYPE
PACKED TOWER
GRID PACKING
26 DIA. X 85 HIGH (20 PACKED SECTION)
CARBON STEEL
AISI 1110
N/A
ORGANIC
VINLY ESTER
FLAKE6LASS
SIZE 2 POLYPROPYLENE INTALOX SADDLES
1
283. t 4500 GPM)
73.62 ( 156000 ACFM)
48.9 ( 120 F)
90.0
MIST ELIMINATOR
2
IMPINGEMENT
BAFFLE
CHEVRON VANE
CHLORINATE PVC
INDIRECT HOT AIR
EXTERNAL HEAT EXCHANGER
STEAM TUBE BUNDLES
FLUE GAS, DO'JBLE INLET MECHANICAL DRAFT TYPE
CARBON STEEL
NUMBER
NUMBER
2
2
1
1
4
1
2
ELEMENTAL SULFUR
99.5
CLOSED
583
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
ST. JOE ZINC: S.F. WEATON 1 CCONT.)
** FGO SPARE CAPACITY INDICES
ABSORBER - X ,0
** FGD SPARE COMPONENT INDICES
ABSORBER .0
_ ____. PERFORMANCE DATA • —_— .
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FSD CAP,
S02 PART. HOURS HOURS HOURS FACTOR
11/79 SYSTEM 720
12/79 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
SINCE START-UP IN NOVEMBER THE UNIT HAS BEEN DOWN DUE TO MECHANICAL
PROBLEMS.
THE ELECTRIC MOTOR IN THE SCRUBBER LIQUOR RECYCLE UNIT HAS BEEN A PROBLEM
SINCE START-UP.
LEAKS HAVE BEEN ENCOUNTERED IN THE PIPING OF THE PRESCRUBBER SOLUTION.
SOME OF THE PIPING FAILURES WERE A RESULT OF FREEZING WEATHER CONDITIONS.
BECAUSE OF THE SMELTER SHUT DOWN AT ST. JOE ZINC, THE UNIT HAS BEEN
OPERATING AT A LOAD OF NO MORE THAN 20 TO 30 MW.
1/80 SYSTEM 744
2/80 SYSTEM 696
3/80 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE SYSTEM IS STILL GOING THROUGH THE DEBUGGING PHASE OF OPERATION. SOME
EQUIPMENT PROBLEMS HAVE OCCURRED, ESPECIALLY WITH THE HYDROGEN SULFIDE
GENERATOR AND HEAT EXCHANGERS> ONE OF WHICH HAD TO BE REMOVED AND RETURNED
TO THE MANUFACTURER. NO OPERATING HOURS WERE LOGGED DURING THE FIRST
QUARTER OF 1980 BRINGING THE TOTAL SYSTEM OPERATING HOURS TO DATE TO 42.
4/60 SYSTEM 720
5/80 SYSTEM 744
6/80 SYSTEM 720
** PROBLEMS/SOLUTIONS/CTMMENTS
THE GE)RGE F. WHEATON STATION HAS BEEN OPERATING AT A REDUCED LOAD OF 28
TO 30 !!W SINCE DECEMBER, 1979 DUE TO THE SHUTDOWN OF THE ST. JOE ZINC CO.
SMELTER. ALTHOUGH A NUMBER OF TRIAL RUNS OF THE CITRATE DEMONSTRATION
PUNT HAVE BEEN MADE DURING THE PAST SIX MONTHS, MECHANICAL BREAKDOWNS OF
EQUm'ENT AND PROBLEMS RELATED TO LOW TEMPERATURE OPERATION HAVE PREVENTED
CONTINUOUS OPERATION TO OBTAIN MEANINGFUL DATA. ST. JOE IS ATTEMPTING TO
NEGOTIATE A POWER SALES AGREEMENT THAT WILL PERMIT FULL UTILIZATION OF THE
STATION CAPACITY AND ALSO PROVIDE DESIGN FLUE GAS QUANTITIES TO THE DEMON-
STRATION PLANT. OPERATION OF THE POWER PLANT AT THE DESIGN RATES IS RE-
QUIRED FOR ACCEPTANCE AND DEMONSTRATION TESTING.
7/80 SYSTEM 744
8/80 SYSTEM 744
584
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
ST. JOE ZINC: 6.F. HEATON 1 (CONT.)
. __ , . PERFORMANCE DATA- •
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
SOS PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE CITRATE PROCESS DID NOT OPERATE DURING THE MONTHS OF JULY AND AUGUST
1980.
NEGOTIATIONS TO PERMIT THE POWER PLANT TO OPERATE AT HIGHER RATES AND
ALLOW THE DEMONSTRATION PUNT TEST PROGRAM TO PROCEED AS PLANNED ARE
CONTINUING.
9/80 SYSTEM 11.9 720 86
** PRQBLEMS/SOLUTIONS/COMMENTS
NEGOTIATIONS MENTIONED EARLIER CONTINUED THROUGH SEPTEMBER. MINIMAL
FGD OPERATIONS WERE REPORTED FOR THE MONTH.
10/80 SYSTEM 37.5 744 279
11/80 SYSTEM 13.9 720 100
12/80 SYSTEM 24.9 744 185
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM OPERATED 279 HRS DURING OCTOBER BUT RETURNED TO A MINIMAL
LEVEL OF OPERATION DURING NOVEMBER AND DECEMBER. LIMITED OPERATIONS HAVE
RESUMED AT THE ST. JOE ZINC SMELTER AW THE BOILER IS NOW OPERATING AT
40 MW. CURRENTLY, NEGOTIATIONS ARE UNDERWAY TO GAIN APPROVAL TO RUN
THE FGD SYSTEM PERFORMANCE TEST AT 40 MW INSTEAD OF THE PUNNED 55 MM.
585
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AMD PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT KAME
UNIT NUMBER
CITY
STATE
REGULAT3RY CLASSIFICATION
PARTICUUTE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MM
GROSS UNIT GENERATING CAPACITY - MM
NET UNIT GENERATING CAPACITY W/FGD - MM
NET UNIT GENERATING CAPACITY WO/FGD - MM
EQUIVALENT SCRUBBED CAPACITY - MM
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOM - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** PARTICLE SCRUBBER
GENERIC TYPE
SPECIFIC TYPE
*** FGD SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
UNIT DESIGN S02 REMOVAL EFFICIENCY - 7.
CURRENT STATUS
INITIAL START-UP
** DESIGN AND OPERATING PARAMETERS
** ABSORBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
SUPPLIER
GAS CONTACTING DEVICE TYPE
TENNESSEE VALLEY AUTHORITY
SHAWNEE
10A
PADUCAH
KENTUCKY
( .100 LB/MMBTU)
( 1.200 LB/MMBTU)
(****** LB/MMBTU)
(******* ACFM)
(**** F)
(**** FT)
516.
******
1750
10
10
*****
10
******
******
******
********
*******
******
******
******* (***** FT)
COAL
BITUMINOUS
******
********
******
********
******
2.90
******
********
******
(****** BTU/LB)
******
PACKED TOWER
MOBILE BED PACKING
THROWAWAY PRODUCT
WET SCRUBBING
LIME/LIMESTONE
VARIABLE - TEST FACILITY
AIR CORRECTION DIVISION. UOP
BECHTEL
PROTOTYPE
RETROFIT
90.00
1
4/72
PACKED TOWER
MOBILE BED PACKING
TURBULENT CONTACT ABSORBER
AIR CORRECTION DIVISION, UOP
1 7/8 IN DIA 11.5 GRAM NITRILE FOAM SPHERES
586
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
TENNESSEE VALLEY AUTHORITY: SHAWNEE IDA (CONT.)
3
NtJMBER OF CONTACTING ZONES
DISTANCE BETWEEN GAS CONTACTING ZONES - CM
ItfLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
** MI3T ELIMINATOR
P3E-MIST ELIMINATOR/MIST ELIMINATOR
N'JMBER PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
** REHEATER
GCNERIC TYPE
TCADE NAME/COMMON TYPE
** TANKS
SERVICE
EFFLUENT HOLD TANK
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
** WATER BALANCE
WATER LOOP TYPE
** FGD SPARE CAPACITY INDICES
ABSORBER - 7.
** FGD SPARE COMPONENT INDICES
ABSORBER
12.7 I
16.52 (
148.9 I
MIST ELIMINATOR
1
IMPINGEMENT
BAFFLE
CHEVRON VANE
DIRECT COMBUSTION
OIL
5.0IN)
35000 ACFM)
300 F)
NUMBER
#*#*
CENTRIFUGE
1
THICKENER
1
CLOSED
.0
.0
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
0/80 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
REFER TO THE PERFORMANCE UPDATE INFORMATION FOR SHAWNEE 10B.
587
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PUNT NAMc
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S03 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MM
GROSS UNIT GENERATING CAPACITY - MW
NET UWT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGD - MM
EQUIVALENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
B5ILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DcSIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FLEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RA>«3E ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
A\ERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** PARTICLE SCRUBBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
INLET GAS FLOW RATE - CU.M/S
INLET GAS TEMPERATURE - C
*** FGD SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
SOZ REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
UNIT DESIGN S02 REMOVAL EFFICIENCY - 7,
CURRENT STATUS
INITIAL START-UP
** DESIGN AND OPERATING PARAMETERS
** ABSORBER
NUMBER
GENERIC TYPE
TENNESSEE W.LLEY AUTHORITY
SHAKNEE
10B
PADUCAH
KENTUCKY
E
43.
516.
******
( .100 LB/MMBTU)
( 1.200 LB/MMBTU)
(****** LB/MMBTU)
1750
10
10
(******* ACFM)
(**** F)
(**** FT)
(***** FT)
(****** BTU/LB)
******
10
******
******
********
*******
******
******
COAL
BITUMINOUS
******
********
******
********
******
2.90
******
********
******
VENTURI TOWER
VARIABLE-THROAT/TOP-ENTRY PLUMB BOB
CHEMICO
1.7 ( 3500 ACFM)
148.9 ( 300 F)
THROWAWAY PRODUCT
WET SCRUBBING
LIME/LIMESTONE
VARIABLE - TEST FACILITY
CHEMICO DIVISION, ENVIROTECH
BECHTEL
PROTOTYPE
RETROFIT
90.00
1
4/7E
SPRAY TOWER
588
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
TENNESSEE VALLEY AUTHORITY: SHAWNEE 10B (CONT.)
SPECIFIC TYPE OPEN COUNTERCURRENT SPRAY
SUPPLIER CHEMICO DIVISION, ENVIROTECH
INLET GAS FLOW - CU. M/S 16.52 ( 35000 ACFM)
INLET GAS TEMPERATURE - C 148.9 ( 300 FJ
** MIST ELIMINATOR
FSE-MIST ELIMINATOR/MIST ELIMINATOR MIST ELIMINATOR
NJtIBER PER SYSTEM 1
G£NERIC TYPE IMPINGEMENT
SPECIFIC TYPE BAFFLE
T3ADE NAME/COMMON TYPE CHEVRON VANE
** REHEATER
GENERIC TYPE DIRECT COMBUSTION
T3ADE NAME/COMMON TYPE OIL
** TASKS
SERVICE NUMBER
SPR/.Y TOWER EFFLUENT HOLD TANK ****
OXIDATION TANK ****
D€SLPERSATURATION TANK ****
** WATER BALANCE
WATER LOOP TYPE CLOSED
** FG!I SPARE CAPACITY INDICES
AUSORBER - •/. .0
** FGU SPARE COMPONENT INDICES .
ABSORBER .0
, PERFORMANCE DATA •
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION '/. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
0/72 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
IN JUNE 1968, THE EPA INITIATED A PROGRAM TO TEST PROTOTYPE LIME AND
LIMESTONE SYSTEMS FOR REMOVAL OF SULFUR DIOXIDE AND PARTICULATE MATTER
FROM COAL FIRED BOILER FLUE GASES. THE PROGRAM WAS CARRIED OUT IN A TEST
FACILITY INCORPORATED INTO THE FLUE GAS DUCTWORK OF UNIT 10, A COAL-FIRED-
BOILER AT THE TVA SHAWNEE POWER STATION, PADUCAH, KENTUCKY. TVA IS THE
CONSTRUCTION AND FACILITY OPERATOR, AND BECHTEL CORP. IS CONTRACTOR, TEST
DIRECTOR AND REPORT WRITER.
THE TEST FACILITY CONSISTS OF THREE PARALLEL SCRUBBING SYSTEMS OF
PROTOTYPE SIZE, TREATING PART OF THE FLUE GAS FROM THE BOILER. EACH
SCRUBBER TRAIN IS CAPABLE OF TREATING APPROXIMATELY 30,000 ACFM OR THE
EQUIVALENT OF APPROXIMATELY 10 MM OF POWER PLANT GENERATING CAPACITY.
THREE PARALLEL WET SCRUBBINS SYSTEMS WERE SELECTED FOR THE TEST PRO-
JECT: 1) A VENTURI WITH A SPRAY TOWER AFTER ABSORBER, 2) A TURBULENT CON-
TACT ABSORBER (TCA), AND 3) A MARBLE-BED ABSORBER. THE VENTURI SYSTEM,
MANUFACTURED BY CHEMICAL CONSTRUCTION CO., CONTAINS AN ADJUSTABLE THROAT
THAT PERMITS CONTROL AND VARIATION OF PRESSURE DROP OVER A WIDE RANGE OF
FLOW CONDITIONS. THE TCA UNIT, MANUFACTURED BY UNIVERSAL OIL PRODUCTS,
INCORPORATES A FLUIDIZED BED OF LOW DENSITY PLASTIC SPHERES THAT ARE FREE
TO MOVE BETWEEN RETAINING GRIDS. THE MARBLE BED ABSORBER, SUPPLIED BY
COMBUSTION ENGINEERING CO., USES A PACKING OF 3 TO 4 INCH GLASS MARBLE
SPHERES AND A TURBULENT LAYER OF LIQUID AND GAS ABOVE THE MARBLE LAYER TO
ENHANCE MASS TRANSFER.
IN JUNE 1974, THE EPA BEGAN A 3-YEAR ADVANCED TEST PROGRAM AT THE
SHAKNEE FACILITY WITH THESE MAJOR GOALS: (1) CONTINUATION OF LONG-TERM
TESTING, WITH EMPHASIS PLACED UPON THE RELIABLE OPERATION OF MIST ELIMINA-
TION SYSTEMS AT INCREASED GAS VELOCITY, (2) INVESTIGATION OF ADVANCED PRO-
CESS AND EQUIPMENT DESIGN VARIATIONS FOR IMPROVING EQUIPMENT RELIABILITY
AND PROCESS ECONOMICS, AND (3) LONG-TERM RELIABILITY TESTING ON PROMISING
589
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
TENNESSEE VALLEY AUTHORITY: SHAWNEE 10B (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
PROCESS AND EQUIPMENT DESIGN VARIATIONS.
THE TWO PARALLEL SCRUBBING SYSTEMS OPERATING DURING THE ADVANCED PRO-
GRAM ARE THE VENTURI/SPRAY TOWER SYSTEM AND THE TCA UNIT. OPERATION OF
THE MARBLE-BED ABSORBER UNIT HAS BEEN PERMANENTLY DISCONTINUED.
EACH OF THE SCRUBBING SYSTEMS CONTAINS ITS OWN SLURRY HANDLING FACIL-
ITIES AND CAN TREAT APPROXIMATELY 30,000 ACFM OF GAS AT 300 F CONTAINING
1800 TO 4000 PPM OF SULFUR DIOXIDE AND 2 TO 4 GRAINS/SCF OF PARTICULATE
MATTER BOILER 10 NORMALLY BURNS A HIGH-SULFUR BITUMINOUS COAL.
FROM JUNE 197* TO JANUARY 1976, MIST ELIMINATION AND LIMESTONE UTILI-
ZATION TESTS WERE CONDUCTED AT THE SHAWNEE FACILITY. DURING THIS TEST
PERIOD THE VENTURI/SPRAY TOWER SYSTEM WAS OPERATED ON BOTH LIME AND LIME-E
STONE AND THE TCA SYSTEM WITH LIMESTONE. TESTING WAS PERFORMED UNDER A
CLOSED WATER OPERATION MODE. DURING THIS PERIOD THE SLURRY SOLIDS
CONTAINED APPROXIMATELY 40 TO BOX CBY WEIGHT) FLY ASH BECAUSE OF
RELATIVELY HIGH GAS INLET PARTICULATE LOADING. THIS TESTING PROGRAM IS
SCHEDULED TO RUN THROUGH TO FEBRUARY 1978.
ADDITIONAL INFORMATION AND DATA CONCERNING THE DETAILS OF THE ADVANCED
TEST PROGRAM ARE PRESENTED IN THE PERFORMANCE HISTORY THAT FOLLOWS.
9/75 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THIS EXPERIMENTAL EPA-FUNDED OPERATION IS PROCEEDING WITH THE TEST
PROGRAM. TWO ABSORBER MODULES APE CURRENTLY OPERATIONAL (10 MW EACH).
THE MARBLE-BED ABSORBER is STILL INOPERATIVE (SINCE JULY 1973).
CURRENT EXPERIMENTS ARE RELATED TO THE MIST ELIMINATOR SECTION.
10/75 SYSTEM 744
11/75 SYSTEM 720
12/75 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
RECENT TESTING AT SHAWNEE HAS SHOWN THAT THE CHEVRON MIST ELIMINATORS IN
BOTH THE SPRAY TOWER AND THE TCA CAN BE KEPT FREE OF SOLIDS BUILDUP AT
HIGH ALKALI UTILIZATION (GREATER THAN 90X), USING ONLY INTERMITTANT
WASHING WITH AVAILABLE RAW HATER. THIS HIGH UTILIZATION IS NORMALLY
ACHIEVED WITH LIME. IT HAS BEEN ACHIEVED WITH LIMESTONE AT REDUCED
SCRUBBER INLET SLURRY PH (ABOUT 5.2) AND WITH THREE EFFLUENT TANKS IN
SERIES TO SIMULATE A PLUG-FLOW REACTOR. TESTING IS CONTINUING TO DETER-
MINE THE EFFECTS OF PROCESS VARIABLES ON MIST ELIMINATOR PERFORMANCE AND
LIMESTONE UTILIZATION. FUTURE PLANS INCLUDE: (1) FACTORIAL TESTING WITH
LIME AND LIMESTONE TO DETERMINE THE EFFECTS OF PROCESS VARIABLES ON S02
REMOVAL AND (2) TESTING THE OXIDATION OF SLUDGE TO GYPSUM IN THE VENTURI/
SPRAY TOWER SYSTEM USING AIR SPARGING OF AN ACIDIFIED SLURRY BLEED
STREAM.
1/76 3YSTEM 744
2/76 !>YSTEM 696
*:* PROBLEMS/SOLUTIONS/COMMENTS
THE ADVANCED TEST PROGRAM IS CONTINUING. HIGHLIGHTS OF THE PROGRAM ARE
AS FOLLOWS:
EVALUATE SCRUBBER OPERABILITY DURING VARIABLE LOAD OPERATION.
CONTINUE LONG-TERM RELIABILITY TESTING.
INVESTIGATE METHODS FOR IMPROVING WASTE SOLIDS SEPARATION.
CONTINUE SLUDGE OXIDATION AND SLUDGE FIXATION STUDY PROGRAMS.
EVALUATE SYSTEM PERFORMANCE AT REDUCED FLY ASH LOADING.
590
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
TENNESSEE VALLEY AUTHORITY: SHAWNEE 10B (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP,
S02 PART. HOURS HOURS HOURS FACTOR
DETERMINE THE PRACTICAL UPPER LIMITS OF S02 REMOVAL EFFICIENCY.
EVALUATE ADDITION OF MAGNESIUM ION TO THE SCRUBBING SLURRY.
CHARACTERIZE ALL STACK GAS EMISSION COMPONENTS.
EVALUATE MATERIALS OF CONSTRUCTION OF ALL SCRUBBER AND PLANT-RELATED
COMPONENTS.
DEVELOPS A COMPUTER PROGRAM FOR DESIGN AND COST ANALYSIS OF FULL-SCALE
LIME/LIMESTONE SYSTEM.
3/76 SYSTEM 744
4/76 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
BECHTEL REPORTED THAT THE FACTORIAL TEST PROGRAM, EVALUATING THE PERFOR-
MANCE OF THE LIME/LIMESTONE SCRUBBING SYSTEMS WITH AND WITHOUT MAGNESIUM
ADDITION, HAS BEEN COMPLETED. CURRENTLY TESTING IS PROCEEDING ON THE
EVALUATION OF SYSTEM PERFORMANCE AS A FUNCTION OF LOW RESIDENCE TIMES
(1.5 TO 5.0 MINUTES) IN THE RECYCLE TANKS. IN ADDITION, A FLY ASH-FREE
DUCT IS BEING INSTALLED AT THE TEST FACILITY, TO ENABLE EVALUATION OF THE-
SYSTEM PERFORMANCE IN THE ABSENCE OF FLY ASH.
5/76 SYSTEM 744
6/76 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE TEST DIRECTOR, BECHTEL, PROVIDED THE FOLLOWING INPUT CONCERNING THE
OPERATION OF THE EXPERIMENTAL SCRUBBING SYSTEMS DURING MAY AND JUNE.
THE EFFECT OF MGO ADDITION WAS EXPLORED IN BOTH SCRUBBER SYSTEMS.
RESULTS INDICATE MAGNESIUM ION IN THE SCRUBBER SLURRY LIQUOR ENHANCES S02
REMOVAL AND CAN DEPRESS SULFATE SUPERSATURATION. IT WAS FOUND THAT THE
MAGNESIUM ION CONCENTRATION HAD TO EXCEED THE EQUIVALENT CHLORIDE ION
CONCENTRATION TO HAVE AN EFFECT ON 502 REMOVAL.
IN TJE TCA UNIT, WITH LIMESTONE SLURRY, S02 REMOVAL WAS INCREASED FROM 75
TO 95X BY INCREASING THE MAGNESIUM ION CONCENTRATION TO 9,000 PPM
IN EXCESS OF EQUIVALENT CHLORIDE ION. TO ACHIEVE THIS CONCENTRATION
MAGNESIUM WAS ADDED AT A RATE EQUAL TO 6X BY WEIGHT OF LIMESTONE ADDITION
RATE. IN THE VEHTURI/SPRAY TOWER SYSTEM, WITH LIME SLURRY, S02 RE-
MOVAL WAS INCREASED FROM 75 TO 90X BY INCREASING THE MAGNESIUM ION
CONCENTRATION TO 2,000 PPM IN EXCESS OF EQUIVALENT CHLORIDE ION. THE
MAGNESIUM OXIDE ADDITION RATE WAS 2X BY HEIGHT OF THE LIME ADDITION
RATE. BOTH SCRUBBING SYSTEMS OPERATED IN THE SUBSATURATED SULFATE MODE
WHEN MAGNESIUM OXIDE WAS ADDED. INLET S02 CONCENTRATIONS DURING THE
TESTS AVERAGE APPROXIMATELY 3,000 PFM DURING THESE TESTS.
FOLLOWING THE TEST BLOCKS MENTIONED ABOVE, BOTH SCRUBBERS BEGAN OPERATING
WITH LIME SLURRY SCRUBBING SOLUTIONS, THE TCA SYSTEM ON FLUE GAS CONTAIN-
ING FLY ASH AND THE VENTURI/SPRAY TOWER SYSTEM ON FLY ASH-FREE FLUE GAS.
7/76 SYSTEM 744
8/76 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
EXPERIMENTAL OPERATION OF THE EPA/TVA ALKALI SCRUBBING TEST FACILITY CON-
TINUED DURING THE JULY AMD AUGUST. BECHTEL, THE TEST DIRECTOR PROVIDED
THE FOLLOWING INPUT CONCERNING THE OPERATION OF THE PROTOTYPE TEST UNITS.
VENTURI/SFRAY TOWER SYSTEM: THIS SYSTEM RAN OFF FLY ASH-FREE FLUE GAS
USING A LIME SLURRY SCRUBBING SOLUTION. NO SIGNIFICANT DIFFERENCES IN
S02 REMOVAL, GYPSUM SATURATION AND SULFITE OXIDATION WERE DETECTED (VS
FLY ASH-LADEN FLUE GAS). ONE DIFFERENCE NOTED WAS THE FILTER CAKE SOLIDS
591
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER
TENNESSEE VALLEY AUTHORITY'- SHAWNEE 10B (COHT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
CONTENT WHICH WAS APPROXIMATELY 107. LOWER FOR THE FLY ASH-FREE SLUDGE (40
TO 50X SOLIDS) VERSUS THE FLY ASH-LADEN SLUDGE 50 TO 60X SOLIDS
IN ADDITION, OPERATION IN A LOW RESIDENCE TIME MODE (3 MINUTES) WAS
EXPLORED. SCALE-FREE OPERATION WAS ACHIEVED IN THIS MODE UNDER THE FOL
LOWING CONDITIONS: &•/. SOLIDS (NO FLY ASH) IN THE RECIRCULATED SLURRY,
PH OF THE SCRUBBER LIQUID INLET WAS 8.0, SUPERFICIAL GAS VELOCITY OF 9.4
FT/SEC, AND A TOTAL LIQUID-TO-GAS RATIO (L-G) OF 7.1 GAL/MCF. SOME SCALE
FORMATION OCCURRED WHEN THE SOLIDS CONTENT OF THE RECIRCULATED SLURRY
DROPPED BELOW THE 4X LEVEL.
TCA SYSTEM: THIS SYSTEM OPERATED ON FLY ASH-LADEN FLUE GAS USING A LIME
SLURRY SCRUBBING SOLUTION INNOCULATED WITH MAGNESIUM OXIDE. GYPSUM SUB- -
SATURATION OPERATION WAS ACHIEVED UNDER THE FOLLOWING CONDITIONS: MAGNES-
IUM ION CONCENTRATION EXCEEDED THE CHLORIDE ION CONCENTRATION BY 2000
PPM, SUPERFICIAL GAS VELOCITY WAS 12.5 FT/SEC., L/G WAS 50. THE SCRUB-
BING SOLUTION INLET PH WAS 7.0, AND RESIDENCE TIME WAS 4 MINUTES. THE
S02 REMOVAL EFFICIENCY WAS APPROXIMATELY 90X. WHEN L/6 WAS REDUCED TO
37, WHILE ALL OTHER CONDITIONS REMAINED CONSTANT, SEVERE GYPSUM SCALE
FORMATION RESULTED. INCREASING THE EFFECTIVE MAGNESIUM CONCENTRATION TO
4000 PPM AND THE SCRUBBER LIQUID INLET PH TO 8.0 DID NOT AMELIORATE THE
SCALE PROBLEM. PRESENTLY THE VENTURI/SPRAY TOWER SYSTEM IS OPERATING ON E
FLY ASH-FREE FLUE GAS WITH MAGNESIUM OXIDE-INNOCULATED LIME SCRUBBING
SLURRY.
9/76 SYSTEM 720
10/76 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
IN SEPTEMBER AND OCTOBER 1976 THE VENTURI/SPRAY SYSTEM WAS OPERATED WITH
FLY ASH-FREE FLUE GAS USING LIME SLURRY WITH MGO ADDITION. TYPICAL TEST
CONDITIONS WERE 9.4 FT/SEC SPRAY TOWER GAS VELOCITY, 21 GAL/MCF VENTURI
L/G, 50 GAL/MCF SPRAY TOWER L/G, 8X SLURRY SOLIDS (FLY ASH FREE),
3 MINUTES RESIDENCE TIME, 7.0 SCRUBBER INLET PH, AND 2000 PPM EFFECTIVE
MAGNESIUM ION CONCENTRATION (I.E., EXCESS OVER EQUIVALENT CHLORIDE ION).
RESULTS WERE NOT CONSISTENT AT THESE CONDITIONS. DURING ONE PERIOD, SCRUB-
BING INLET LIQUOR GYPSUM SATURATION AVERAGED 85X WITH SOX S02 REMOVAL EF-
FICIENCY AND SOME GYPSUM SCALE FORMATION. IN A LATER PERIOD, AT SEEMINGLY
IDENTICAL TEST CONDITIONS GYPSUM SATURATIONS DROPPED TO 10X WITH 98X
S02 REMOVAL AND THE SCRUBBER DESCALED. A SEVEN-WEEK PROGRAM OF IN-
TENSIVE FLUE GAS CHARACTERIZATION TESTING WAS STARTED IN MID-OCTOBER ON
THE VENTURI/SPRAY TOWER SYSTEM. THESE TESTS ARE BEING MADE TO MEASURE
SIMULATANEOUS INLET AND OUTLET FLUE GAS PARTICULATE MASS LOADING, PARTI-
CULATE SIZE DISTRIBUTION AND GASEOUS 503 CONCENTRATION. THE TCA SYSTEM
CONTINUED TO OPERATE DURING THIS PERIOD ON FLY ASH-LADEN FLUE GAS USING
LIME SLURRY WITH ADDED HGO. THE TEST RESULTS SO FAR INDICATED THAT THE
DEGREE OF SULFATE (GYPSUM) SATURATION IS A SENSITIVE FUNCTION OF THE
EFF'_UENT RESIDENCE TIME CONDITIONS: GAS VELOCITY 12.5 FT/SEC, L/G OF 50,
PH OF 7.0, 2000 PPM OF MG ION, AND 8X SOLIDS. AT THESE CONDITIONS
GYPS JM SATURATIONS WERE 95, 50, AND 92X, AT RESIDENCE TIMES OF 3, 4, AND
12 MiNUTES, RESPECTIVELY. FURTHER TESTS WERE RUN AT 37 GAL/MCF L/G, AND
8.0 I 1LET PH WITH OTHER CONDITIOKS THE SAME. DURING THESE TESTS GYPSUM SA-
TIONS WERE 95, 95, 50, AND 90X A". 3, 4, 5.4, AND 16 MINUTES RESI-
DENCE TIMES, RESPECTIVELY.
11/76 3V3TEM 720
12/76 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
FROM MID-OCTOBER THROUGH EARLY DECEMBER AN INTENSIVE FLUE GAS CHARACTERI-
ZATION TESTING PROGRAM WAS CONDUCTED ON THE VENTURI/SFRAY TOUER SYSTEM
WITH LIME SLURRY. OVER THE RANGE TESTED, OUTLET PARTICULATE MASS LOADING
592
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
TENNESSIE VALLEY AUTHORITY: SHAWNEE 10B (CONT.)
____ PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
______ „,.._.»__ _________*.«_ _______»_.._ .»_________» ___•..._*._...._ _____ _____ _ — ,...— ______ _ — -. — _. ______
WAS FOUND TO BE INDEPENDENT OF SLURRY COMPOSITION (8 TO 15X
SUSPENDED SOLIDS, 3,000 TO 16,000 PPM DISSOLVED SOLIDS), GAS FLOW RATE
(20,000 TO 35,000, ACFM), SPRAY TOWER LIQUID RATE (0 TO 1,400 6PM) AND
VENTURI PRESSURE DROP (3 TO 9 INCHES H20). WITH 4 TO 6 6R/DSCF PARTICULATE
MATTER IN THE INLET, TYPICAL OUTLET LOADINGS WERE 0.02 TO 0.04 GR/DSCF. -
WHEN OPERATING WITH FLUE GAS FROM THE ELECTROSTATIC PRECIPITATOR (.1 TO
.4 GR/DSCF TO THE SCRUBBER), THE SCRUBBER OUTLET LOADING AVERAGED 0.005
GR/DSCF. THUS, ENTRAINED SLURRY FROM THE MIST ELIMINATOR MUST HAVE BEEN
LESS THAN 0.005 GR/DSCF. SIZE DISTRIBUTION DATA ARE STILL BEING ANALYZED.
SULFURIC ACID MIST VALUES WERE APPROXIMATELY 2 TO 25 PPM AT THE SCRUBBER
INLET AND REMOVALS HAVE BEEN ABOUT 50 TO 757..
DURING THE REMAINDER OF DECEMBER THE VENTURI/SPRAY TOWER SYSTEM WAS DOWN -
FOR MODIFICATIONS FOR TWO-STAGE OXIDATION TESTING.
DURING NOVEMBER THE TCA WAS OPERATING WITH FLY ASH-CONTAINING FLUE GAS US-
ING LIME SLURRY WITHOUT ADDED MAGNESIUM OXIDE. OPERATING CONDITIONS WERE
12.5 FT/SEC GAS VELOCITY, 50 GAL/MCF L/G, 8.0 SCRUBBER INLET PH, AND 8 TO
15X SLURRY SOLIDS. AT THESE CONDITIONS THE S02 REMOVAL WAS ABOUT
SOX.
FLY ASH-FREE LIMESTONE TESTS WITHOUT MAGNESIUM OXIDE ADDITION BEGAN ON
THE TCA SYSTEM IN LATE NOVEMBER. TYPICAL OPERATING CONDITIONS WERE 12.5
FT/SEC GAS VELOCITY, 50 GAL/MCF L/G, AND 1.1 TO 1.2 STOICHIOMETRIC RATIO.
AT THE SAME STOICHIOMETRY, THE PH OF THE FLY ASH-FREE SLURRY WAS 0.2 TO
0.3 UNITS HIGHER THAN OBSERVED IN PREVIOUS RUNS WITH FLY ASH.
1/77 SYSTEM 744
2/77 SYSTEM 672
** PROBLEMS/SOLUTIONS/COMMENTS
THE VENTURI/SPRAY TOWER SYSTEM HAS BEEN OPERATED IN A TWO-SERIES-SCRUBBER
MODE WITH FORCED OXIDATION SINCE EARLY JANUARY 1977 AFTER SYSTEM MODIFICA-
TIONS TO ALLOW OPERATION OF THE VENTURI AND SPRAY TOWER WITH INDEPENDENT
SLURRY RECIRCULATION LOOPS. SULFITE OXIDATION WAS CARRIED OUT IN AN 8 FT
DIAMETER VENTURI (PRE-SCRUBBER) EFFLUENT HOLD TANK WHICH HAD AN AIR
SPARGER WITH 130-1/8 INCH HOLES IMMERSED IN 18 FT OF SLURRY. THE SPRAY
TOWER (AFTER SCRUBBER) FUNCTIONED AS A PRIMARY S02 ABSORBER.
TYPICAL OPERATION CONDITIONS, USING LIMESTONE SLURRY, WERE 6.7 FT/SEC
SPRAY TOWER GAS VELOCITY, 20-30 GAL/MCF VENTURI L/G, 70 GAL/MCF SPRAY
TOWER L/G 15X SOLIDS (WITH FLY ASH) IN VENTURI RECIRCULATED SLURRY, 4.5-5
VENTURI INLET (OXIDATION TANK) PH, AND 11.3 MINUTES OXIDATION TANK RESI-
DENCE TIME (BASED ON 600 GPM SLURRY FLOW TO VENTURI). DURING THESE
TESTS, AVERAGE OVERALL SULFITE OXIDATION RANGED FROM 93 TO 99X AT AIR
STOICHIOMETRIC RATIO OF 1.0 TO 4.7 LB-ATOMS OXYGEN/LB-MOLE S02 ABSORBED.
CORRESPONDING AVERAGE OXIDATION IN THE SPRAY TOWER RANGED FROM 10 TO 16X
AVERAGE OVERALL LIMESTONE UTILIZATION RANGED FROM 83 TO 96X. NO
SCALING WAS EXPERIENCED IN EITHER SCRUBBER. AVERAGE FILTER CAKE SOLIDS
WERE 79 TO 86X BY-WEIGHT COMPARED WITH 55 TO 65X WITHOUT FORCED OXIDA-
TION. SLURRY SOLIDS SETTLING RATE RANGED 0.5 TO 1.4 CM/MIN, 5 TO 10 TIMES
FASTER THAN THAT FOR UNOXIDIZED SLURRY. FINAL SETTLED DENSITY RANGED
65 TO SOX SOLIDS COMPARED WITH 45 TO 60X FOR SLURRY WITHOUT FORCED OXI-
DATION.
FLY ASH-FREE LIMESTONE TESTING ON THE TCA SYSTEM WAS COMPLETED IN EARLY
FEBRUARY. THE PH OF THE FLY ASH-FREE SLURRY WAS 0.2 TO 0.3 UNITS HIGHER
THAN OBSERVED IN PREVIOUS RUNS WITH FLY ASH. IN ADDITION THE FLY ASH-FREE
SLURRY APPEARED TO HAVE INFERIOR SOLIDS DEWATERIN6 CHARACTERISTICS. FOR
EXAMPLE THE CENTRIFUGE CAKE SOLIDS AVERAGED ABOUT SOX COMPARED WITH
ABOUT 60X FOR SLUDGE CONTAINING FLY ASH.
INTENSIVE FLUE GAS CHARACTERIZATION TESTING WITH LIMESTONE SLURRY ON THE
TCA SYSTEM BEGAN IN EARLY FEBRUARY AND ENDED IN EARLY MARCH 1977. PRELIM-
INARY ANALYSIS OF THE DATA SHOWED AN OUTLET MASS LOADING OF 0.4-0.8
GR/DSCF FLY ASH AND 0.02-0.03 GR/tSCF FOR FLUE GAS WITHDRAWN DOWNSTREAM OF
THE ESP. IT WAS ESTIMATED THAT THESE OUTLET MASS LOADINGS CONTAINED ABOUT
0.03 GR/DSCF FLY ASH, 0.02 GR/DSCF REENTRAINED SLURRY SOLIDS AND 0.015
593
-------
EPA UflLITY F6D SURVEY: OCTOBER - DECEMBER 1980
TENNESSEE VALLEY AUTHORITY: SHAWNEE 10B (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
ENTRAINED DISSOLVED SOLIDS (WHEN A CONTINUOUS MIST ELIMINATOR UNDER WASH
WAS USED). THESE VALUES VARY DEPENDING ON THE MIST ELIMINATOR WASH SCHEME
AND GAS FLOW RATE.
3/77 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MARCH THE VENTURI/SPRAY TOWER WAS TESTED WITH LIME SLURRY AND FLY
ASH LADEN FLUE GAS IN A TWO-STAGE SCRUBBER MODE WITH FORCED OXIDATION.
OPERATION WITH LIME WAS SIMILAR TO THE PREVIOUSLY REPORTED LIMESTONE
OPERATION WITH GREATER THAN 95X OXIDATION AT AN AIR STOICHIOMETRIC RATIO
OF 1.5 LB-ATOMS OXYGEN/LB-MOLE S02 ABSORBED WITH A SIMPLE AIR SPARGER IN
VENTURI HOLD TANK. SLURRY SOLIDS SETTLING RATE VARIED FROM 0.6 TO 1.9 CM/
MIN (A 5 TO 10-FOLD ENHANCEMENT OVER UNOXIDIZED SLURRY) AND FILTER CAKE
SOLIDS RANGED FROM 74 TO 88X (COMPARED TO 45 TO 60X WITH UN-
OXIDIZED SLURRY).
TWO MAJOR DIFFERENCES BETWEEN LIME AND LIMESTONE WERE OBSERVED IN A TWO-
STAGE FORCED OXIDATION SYSTEM. TO MAINTAIN PH CONTROL IT WAS NECESSARY TO
FEED LIME TO BOTH STAGES. WITH LIMESTONE, FEED TO THE SECOND STAGE ONLY
WAS ADEQUATE. TO MAINTAIN SOX S02 REMOVAL, IT WAS NECESSARY TO OPERATE
WITH A HIGHER SLURRY SOLIDS CONCENTRATION IN THE SPRAY TOWER LOOP WITH
LIMESTONE (15X) THAN WITH LIME (6X), RESULTING IN A TIGHTER WATER
BALANCE WITH LIMESTONE AND INADEQUATE WATER TO FLUSH THE MIST ELIMINATOR.
PRELIMINARY LIMESTONE TYPE AND GRIND TESTS MADE ON THE TCA SYSTEM DURING
MARCH INDICATED THAT S02 REMOVAL IS IMPROVED BY THE USE OF FINER GROUND
LIMESTONE. SOS REMOVAL WITH EQUIVALENTLY GROUND FREDONIA WHITE AND LONG-
VIEW, ALABAMA LIMSTONES WAS THE SAME. BLEEDSTREAM FORCED OXIDATION TESTS
ARE BEING CONDUCTED WITH A PENBERTHY ELL-3 INJECTOR IN A CLOSED LOOP
AROUND A BLEED STREAM HOLD TANK. INITIAL TESTS WERE UNSUCESSFUL DUE TO
HIGH PH OF 7 TO 8 IN THE HOLD TANK. BY LOWERING THE HOLD TANK PH TO 5 OR
6, SULFITE OXIDATIONS OF UP TO 98X WERE ACHIEVED,
4/77 SYSTEM 720
5/77 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT 10 BOILER WAS SHUT DOWN FOR A SCHEDULED TWO-MONTH MAINTENANCE
OUTAGE. BECAUSE OF THE BOILER OUTAGE, THE SHAWNEE SCRUBBERS DID NOT
OPERATE DURING APRIL OR MAY.
6/77 SYSTEM 720
7/77 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
SCRUBBER OPERATION RESUMED ON JUNE 15 AFTER A 10-WEEK SCHEDULED MAINTEN-
ANCE OUTAGE ON THE BOILER.
THE VENTUR/SPRAY TOWER SYSTEM CONTINUED TO OPERATED WITH TWO SCRUBBER
STAGES AND FORCED OXIDATION BY MEANS OF AN AIR SPARGIN3 RING IN THE VEN-
TURI HOLD TANK. IN JUNE AND JULY, OPERATION WAS WITH LIME SLURRY AND FLY
ASH-FREE FLUE GAS. THE SYSTEM PERFORMED WELL WITH LITTLE DIFFERENCE FROM
THE PREVIOUS LIME SLURRY TEST BLOCK WHEN THERE WAS FLY ASH IN THE FLUE
GAS. TYPICAL RESULTS WERE ABOUT 97X SULFITE OXIDATION AT AN AIR STOICHO-
METRY OF 1.6 LB-ATOMS OXYGEN/LB-MOLE S02 ABSORBED AN OXIDATION TANK PH
OF 5.5. TYPICAL SOLIDS SETTLING RATE WAS ABOUT 2 CM/MIN (AN ORDER OF MAG-
NITUDE BETTER THAN WITH UNOXIDIZED SLURRY) AND FILTER CAKE SOLIDS AVER-
AGED ABOUT 80X (COMPARED WITH 45 TO 60X WITH UNOXIDIDED SLURRY).
THE TCA SYSTEM OPERATED WITH FORCED OXIDATION IN THE HOLD TANK ACHIEVED BY
CIRCULATING SLURRY THROUGH AN AIR EDUCTOR. IN JUNE AND JULY, OPERATION WAS
WITH LIMESTONE SLURRY AND FLY ASH IN THE FLUE GAS. SULFITE OXIDATION WAS
594
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
TENNESSEE VALLEY AUTHORITY: SHAWEE 10B CCONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
POOR IN THE INITIAL TEST (LESS THAN 90X) MAINLY BECAUSE OF INADE-
QUATE AIR/SLURRY CONTACT IN THE HOLD TANK. BY INCREASING AGITATOR SPEED(TO
68 RPM), HOLD TANK SLURRY LEVEL (TO 12 FT) AND DECREASING PH (TO LESS THAN
5.5) IN THE SLURRY TO THE EDUCTOR, SULFITE OXIDATION OF 90X WAS
CONSISTANTLY ACHIEVED AT AN AIR STOICHIOMETRY OF ABOUT 4.5 LB-ATOMS
OXYGEN/LB-MOLE S02 ABSORBED. WASTE SOLIDS PROPERTIES WERE ENHANCED WITH
OXIDATION TO ABOUT THE SAME EXTENT AS OBSERVED IN THE VENTURI/SPRAY TOWER
SYSTEM. ADDITIONAL TESTING WILL BE DIRECTED TOWARD ACHIEVING 90X OR BETTER
SULFITE OXIDATION AT A REDUCED AIR STOICHIOMETRY.
8/77 SYSTEM 744
9/77 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE VENTURI/SPRAY TOVIER SYSTEM CONTINUED TO OPERATE WITH TWO SCRUBBING
STAGES AND FORCED OXIDATION USING AN AIR SPARGER IN THE VENTURI HOLD TANK.
OPERATION DURING AUGUST AND SEPTEMBER WAS WITH LIMESTONE SLURRY AND FLUE
GAS WITH LOW FLY ASH LOADING (FLUE GAS FROM DOWNSTREAM OF THE ESP). THE
SYSTEM PERFORMED WELL AT 4.5 TO 5.0 OXIDATION PH, WITH LITTLE DIFFERENCE
FROM THE PREVIOUS LIMESTONE TESTS WHEN THE FLUE GAS HAD FLY ASH LOADING.
(THE PREVIOUS TESTS HAD BEEN MADE ONLY AT OXIDATION PH OF 4.5 AND 5.0).
FOR THE AUGUST AND SEPTEMBER TESTS, THE OXIDATION PH WAS FURTHER INCREASED
TO 5.5, APPROACHING THE PH IN THE SPRAY TOWER. THIS CAUSED SOME DIFFICUL-
TIES IN THE OXIDATION PH CONTROL AND WIDER FLUCTUATIONS IN VENTURI AND
SPRAY TOWER LIMSTO"E STOICHIOMETRIC RATIOS. HOWEVER NEAR COMPLETE OXIDA-
TION WAS STILL ACHIEVED AT THE HIGHER PH. TYPICAL RESULTS WERE BETTER THAN
97X SULFITE OXIDATION AT AN AIR STOICHIOMETRY OF 1.7 ATOMS OXYGEN/
MOLE S02 ABSORBED AND AN OXIDATION PH OF 5.5. THE FILTER CAKE SOLIDS CON-
TENT AVERAGED BETTER THAN 85X. TESTS WERE ALSO CONDUCTED WITHOUT
THE DESUPERSATURATION TANK IN THE VENTURI SLURRY LOOP AND WITH THE OXIDA-
TION TANK LEVEL DROPPED FROM 18 TO 14 FT WITHOUT ADVERSE EFFECTS.
DURING AUGUST AND SEPTEMBER THE TCA SYSTEM WAS OPERATED MOSTLY IN A TWO-
TANK FORCE OXIDATION MODE USING AN AIR EDUCTOR. THE TCA EFFLUENT (LIME-
STONE SLURRY WITH A HIGH FLY ASH LOADING) WAS COLLECTED IN A SMALL LOW-PH
SLURRY HOLD TANK WHERE LIMESTONE WAS ADDED THUS TAKING ADVANTAGE OF THE
LOW PH SLURRY THROUGH THE AIR EDUCTOR FOR IMPROVED SULFITE OXIDATION AND
HIGH PH SLURRY TO TCA FOR BETTER S02 REMOVAL.
TESTS WERE MADE BOTH WITH THE AIR EDUCTOR MOUNTED ON TOP OF THE EFFLUENT
HOLD TANK WITH DOWNWARD SLURRY DfTC'IARGE TO THE BOTTOM OF THE TANK. AVER-
AGE SULFITE OXIDATION RANGE FROM 93 TO 98X AT ABOUT 2.5 AIR STOICHIOMETRYY
AND 5.2 EDUCTOR INLET PH. DURING TWO OF THE RUNS MADE IN AUGUST WHEN
THE ROTARY DRUM FILTER WAS USED THE FILTER CAKE SOLIDS CONTENT AVERAGED
85 AND 88X.
A TEN-DAY RUN WAS MADE IN SEPTEMBER ON THE TCA SYSTEM WITH AUTOMATIC LIME-
STONE FEED CONTROL BASED ON STOICHIOMETRY. THE LIMESTONE SLURRY FEED RATE
WAS CONTROLLED BY THE FLUE GAS FLOW RATE AND THE INLET S02 CONCENTRATION.
THE CONTROL SYSTEM WORKED WELL ACCORDING TO THE SPECIFICATIONS.
10/77 SYSTEM 744
11/77 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE VENTURI/SPRAY TOWER SYSTEM CONTINUED TO OPERATE WITH TWO SCRUBBING
STAGES AND FORCED OXIDATION IN THE VENTURI HOLD TANK. IN OCTOBER, THE FOL-
LOWING IMPROVEMENTS WERE MADE WITH NO SIGNIFICANT DROP IN OXIDATION EF-
FICIENCY WITH SATISFACTORY S02 REMOVAL EFFICIENCY:
THE SPRAY TOWER GAS VELOCITY WAS INCREASED FROM 6.7 TO 9.4 FT/SEC.
THE OXIDATION TANK LEVEL WAS DROPPED FROM 18 TO 14 FT.
THE AIR SPARGER RING CONTAINING 40 14-INCH DIAMETER HOLES, WAS RE-
PLACED WITH A SINGLE 3-INCH DIAMETER PIPE DISCHARGING DOWNWARD AT THE
595
-------
EPA ITILITY FGD SURVEY: OCTOBER - DECEMBER 1980
TENNESSEE VALLEY AUTHORITY: SHAWNEE 10B (CONT.)
_ PERFORMANCE DATA •
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
SOS PART. HOURS HOURS HOURS FACTOR
CENTER OF THE OXIDATION TANK 3 IN'JHES FROM THE BOTTOM.
WITH AIR DISCHARGED FROM AN OPEN-ENDED PIPE IT WAS APPARENT THAT THE AIR
DISPIRSIGN IN THE OXIDATION TANK WAS ACCOMPLISHED MAINLY BY THE TURBINE
AGITATOR RATHER THAN THE SPARGER. IN NOVEMBER, A ONE-MONTH RELIABILITY
TEST WAS STARTED ON THE VENTURI/SPRAY TOWER SYSTEM USING FORCED OXIDATION
WITH TWO SCRUBBER STAGES AND LIMESTONE SLURRY WITH HIGH FLY ASH LOADING.
THE FLUE GAS RATE TO THE SCRUBBER SYSTEM WAS VARIED ACCORDING TO THE BOIL-
ER LOAD WHICH RANGED BETWEEN 100 AND 155 MW. TEST CONDITIONS WERE SELECTED
TO MEET THE EPA NEW SOURCE PERFORMANCE STANDARDS OF 1.2 LBS SOS AND 0.1
LB F-ARTICULATE PER MILLION BTU. THIS RUN WAS STILL IN PROGRESS AT THE END
OF NOVEMBER. ON THE TCA SYSTEM, FORCED OXIDATION WITH A SINGLE SCRUBBER
STAGE USING AN AIR EDUCTOR WAS DISCONTINUED IN EARLY OCTOBER AFTER A HOLE
ERODED THROUGH THE EDUCTOR BODY. FORCED OXIDATION TESTING WILL BE RESUtlED
IN EARLY DECEMBER AFTER AN AIR SPARGER IS INSTALLED. DURING THE OCTOBER-
NOVEMBER PERIOD, A ONE-MONTH RELIABILITY TEST WITHOUT FORCED OXIDATION
WAS CONDUCTED ON THE TCA SYSTEM WITH LIMESTONE SLURRY, FLUE GAS WITH HIGH
FLY ASH LOADING, THREE HOLD TANKS IN SERIES, AND 7.5 INCHES STATIC HEIGHT
OF NITRILE FOAM SPHERES IN EACH OF 3 BEDS IN THE TCA. GAS RATE TO THE
SCRUBBER WAS VARIED WITH BOILER LOAD AND STOICHIOMETRIC RATIO WAS CON-
TROLLED BY AN AUTOMATIC LIMESTONE FEED SYSTEM. CONDITIONS WERE SELECTED TO
MEET THE EPA NEW SOURCE PERFORMANCE STANDARDS AT A LOW STOICHIOMTRIC RATIO
OF 1.2 MOLES CA/MOLE S02 ABSORBED. THE AVERAGE S02 REMOVAL FOR THE ENTIRE
RUN WAS 86X AT 2800 PPM WHICH WAS BETTER THAN THE 83X RE-
QUIRED TO MEET THE EMISSIONS STANDARD. HOWEVER, THE STANDARD WAS FREQUENT-
LY EXCEEDED FOR PERIODS GREATER THAN THE 3 HOURS ALLOWED BY THE EPA REGU-
LATIONS. AVERAGE OUTLET PARTICULATE MASS LOADING HAS 0.043 GRAIN/SCF DRY
WHICH WAS BETTER THAN THE 0.052 GRAIN/SCF DRY (AT 30X EXCESS AIR) RE-
QUIRED TO MEET THE STANDARD. THE RANGE OF THE OUTLET MASS LOADING WAS
0.026 TO 0.069 GRAIN/SCF DRY.
12/77 SYSTEM 744
1/78 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
A LIMESTONE RELIABILITY TEST ON THE VENTURI/SPRAY TOWER SYSTEM WAS
COMPLETED IN MID-DECEMBER, 1977 AFTER 965 OPERATING HOURS. THE TEST WAS
CONDUCTED WITH TWO SCRUBBER LOOPS WITH FORCED OXIDATION IN THE FIRST
(VENTURI) LOOP. THE FLUE GAS FLOW RATE WAS VARIED ACCORDING TO THE
BOILER LOAD WHICH RANGED BETWEEN 100 AND 155 MW.
TEST CONDITIONS WERE SELECTED TO MEET THE EPA NEW SOURCE PERFORMANCE STAN-
DARDS OF 1.2 LB S02 AND 0.1 LB PARTICULATE PER MILLION BTU. THE OPERATING
RELIABILITY OF THE SYSTEM WAS DEMONSTRATED. HOWEVER, DUE TO WIDE VARIATION
IN THE INLET S02 CONCENTRATION (2500-3400 PPM) AND THE SLOW SYSTEM RE-
SPONSE TIME THE S02 EMISSION STANDARD WAS FREQUENTLY EXCEEDED FOR PERIODS
GREATER THAN THE THREE HOURS ALLOWED BY EPA REGULATIONS. AVERAGE S02 RE-
MOVAL FOR THE ENTIRE RUN WAS 86X AT 2950 PPM AVERAGE INLET S02 WHICH WAS
HIGHER THAN THE 84X REQUIRED TO MEET THE STANDARD FOR 2800 PPM INLET
S02. THE OUTLET PARTICULATE LOADING RANGED FROM 0.021 TO 0.063 GRAIN/DRY
SCF, WITH A RUN AVERAGE OF 0.042 GRAIN/DRY SCF. THESE VALUES COMPARE WITH
LOADING OF 0.052 GR/DRY SCF OR LESS REQUIRED TO MEET THE EPA PARTICULATE
STANDARD, ASSUMING 30X TOTAL BOILER EXCESS AIR.
ANOTHER RELIABILITY RUN ON THE VENTURI/SPRAY TOWER SYSTEM WAS STARTED IN
MID DECEMBER USING LIME SCRUBBING. THE RUN WAS COMPLETED IN JANUARY 1978.
WITH THE EXCEPTION OF HIGHER SPRAY TOWER INLET PH AND HIGHER ALKALI UTILI-
ZATION INHERENT WITH THE LIME SYSTEM, THE OPERATING CONDITIONS AND THE
TEST RESULTS WERE SIMILAR TO THOSE OF THE LIMESTONE RELIABILITY RUN.
ON THE TCA SYSTEM, TWO RUNS WERE MADE WITH THE NITRILE FOAM SPHERES RE-
PLACED BY A 46 INCH HEIGHT (23 LAYERS) OF CEILCOTE PACKING SUPPORT PLATES.
AT FULL GAS FLOW RATE OF 30,000 ACFM, THE S02 REMOVAL FOR THE CEILCOTE
PLATES WAS SLIGHTLY LESS THAN THAT OF A 3-BED, 4-GRID TCA WITH FIVE INCHES
596
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
TENNESSEE VALLEY AUTHORITY: SHAWNEE 10B (CONT.)
,____ PERFORMANCE DATA—— — —
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
OF STATIC SPHERE HEIGHT PER BED. HOWEVER, AT 18,000 ACFM THE S02 REMOVAL
FOR THE CEILCOTE PLATES WAS A FEW PERCENTAGE POINTS HIGHER THAN THAT EX-
PERIENCED WITH THE TCA BEDS.
FORCED OXIDATION TESTS WERE CONDUCTED ON THE TCA SYSTEM WITH AN AIR SPARG-
ER USING LIMESTONE SLURRY WITH HIGH FLY ASH LOADING. BOTH ONE-TANK (AIR
SPARGING AND LIMESTONE ADDITION IN THE SAME TANK) AND TWO-TANK (AIR SPARG-
ING IN THE FIRST TANK AND LIMESTONE ADDITION IN THE SECOND) CONFIGURATIONS
WERE USED. NEAR COMPLETE SULFITE OXIDATION WAS ACHIEVED IN BOTH CONFIGURA-
TIONS AT AN AIR STOICHIOMETRY OF 1.8 ATOMS OXYGEN/MOLE S02 ABSORBED AND
OXIDATION PH OF 5.4-5.7.,THE OXIDATION TANK LEVEL WAS 18 FT.
2/78 SYSTEM 672
3/78 SYSTEM 744
*; PROBLEMS/SOLUTIONS/CC 1MENTS
MAJOR SYSTEM DOWNTIMES DURING THE PERIOD INCLUDEDD JANUARY 26 THROUGH FEB-
RUARY 4 FOR THE VENTURI/SFRAY TOWER AND JANUARY 26 THROUGH FEBRUARY 2 FOR
THE VCA SYSTEM DUE TO FREEZING WEATHER, AND MARCH 6 THROUGH MARCH 17 FOR
BOTH SYSTEMS DUE TO BOILER OUTAGE.
THE EFFECT OF THE SLURRY LEVEL IN THE AIR SPARGED OXIDATION TANK WAS IN-
VESTIGATED IN THE TWO SCRUBBER LOOP VENTURI/SFRAY TOWER SYSTEM WHICH IS
OPERATING ON LIME SLURRY WITH HIGH FLY ASH LOADING. NEAR COMPLETE SULFITE
OXIDATION (98X) WAS ACHIEVED WITH 1* FT AND 18 FT OXIDATION TANK
LEVELS AT AN AIR STOICHIOMETRIC RATIO OF 1.8 ATOMS OXYGEN/MOLE S02 AB-
SORBED. AN AIR STOICHIOMETRIC RATIO UP TO ABOUT 3.8 WAS NEEDED TO YIELD
NEAR COMPLETE OXIDATION WHEN THE TAW LEVEL WAS DROPPED TO 10 FEET.
A NEW TEST BLOCK WAS STARTED ON MARCH 1 ON THE VENTURI/SPRAY TOWER SYSTEM.
MAGNESIUM OXIDE WAS ADDED TO THE SPRAY TOUER SLURRY LOOP IN A TWO SCRUBBER
LOOP OPERATION WITH FORCED OXIDATION IN THE VENTURI LOOP. THE SYSTEM WAS
OPERATED IN A LIMESTONE SLURRY MODE WITH HIGH FLY ASH LOADING. THE PRIMARY
OBJECTIVE OF MAGNESIUM ADDITION IS TO IMPROVE THE S02 REMOVAL EFFICIENCY.
BECAUSE OF THE SHORTAGE OF COAL CAUSED BY THE LOCAL MINERS' STRIKE, COALS
FROM DIFFERENT SOURCES WERE BURNED IN THE BOILER. AS A RESULT, INLET S02
CONCENTRATION FLUCTUATED AS MUCH AS TENFOLD (350-3500 PPM) CAUSING PRO-
BLEMS IN SYSTEM CONTROL.
TCA WAS OPERATED WITH BOTH LIME AND LIMESTONE AND WITH MEGNESIUM OXIDE AD-
DITION. FLUE GAS WITH HIGH FLY ASH LOADING WAS USED. THESE TESTS WERE CON-
DUCTED PRIMARILY TO RESOLVE SOME OF THE INCONSISTENT RESULTS OBTAINED
DURING EARLIER LIME/MGO AND LIMESTONE/MGO TEST MADE IN APRIL THROUGH
NOVEMBER 1976. AIR LEAKAGE THROUGH THE SCRUBBER DOWNCOMER WAS SUSPECTED
IN SOME OF THOSE EARLIER RUNS, RESULTING IN HIGHER-THAN-NORMAL SULFITE
OXIDATION AND GYPSUM SATURATION. TEST RESULTS SO FAR WERE INCONCLUSIVE
DUE TO THE FLUTUATION IN INLET S02 AND CONTROL PROBLEMS MENTIONED ABOVE.
4/78 SYSTEM 720
5/78 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE VENTURI/SPRAY TOWER SYSTEM CONTINUED TO OPERATE THROUGH EARLY MAY WITH
MGO ADDITION AND WITH TWO SCRUBBER LOOPS. THE SYSTEM WAS OPERATED WITH
LIMESTONE SLURRY AND WITH HIGH FLY ASH LOADING. MGO WAS ADDED TO THE SPRAY
TOWER SLURRY LOOP TO MAINTAIN AN EFFECTIVE M6++ ION CONCENTRATION OF 5000
PPM (ABOUT 8000 PPM IN THE VENTURI SLURRY LOOP) TO IMPROVE THE S02 REMOVAL
EFFICIENCY IN THE SPRAY TOWER. OXIDATION WAS FORCED IN THE VENTURI SLURRY
HOLD TANK. UNDER TYPICAL OPERATING CONDITONS, THE OVERALL SOE REMOVAL WAS
96X AT 2300 PPM INLET S02 CONCETRATION, COMPARED TO 862
REMOVAL AT 1600 PPM INLET S02 WITHOUT MGO ADDITION. S02 REMOVAL BY VENTURI
ALONE WAS 30Z, ABOUT THE SAME AS THE CASE WITHOUT MGO ADDITION.
NEAR COMPLETE SULFITE OXIDATION COULD BE ACHIEVED AT AN
597
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
TENNESSEE VALLEY AUTHORITY: SHAWNEE 10B (CONT.>
_ „ PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
AIR STOICHIOMETRIC RATIO AS LOW AS 1.3 ATOMS OXYGEN/MOLE OF 502 ABSORBED,
IN THE SAME ORDER AS THE CASE WITHOUT M60 ADDITION.
FORCED OXDATION WAS ALSO CONDUCTED ON THE LIMESTONE SLURRY BLEED STREAM
FROM THE VENTURI/SPRAY TOWER SYSTEM. A SINGLE EFFLUENT HOLD TANK WAS USED
FOR BOTH VENTURI AND SPRAY TOWER. MGO WAS ADDED TO THE EFFLUENT HOLD TANK
TO MAINTAIN AN EFFECTIVE MG-n- ION CONCENTRATION OF 5000 PPM. A SLURRY
STREAM WAS TAKEN FROM THE SCRUBBER DOWNCOMER AND SENT TO AN OXIDATION TANK
INTO WHICH AIR WAS SPARGED. A RECYCLE STREAM OF ABOUT 30 GPM WAS SENT BACK
FROM THE OXIDATION TANK TO THE EFFLUENT HOLD TANK TO CONTROL PH IN THE
OXIDATION TANK AND TO PROVIDE GYPSUM SEEDS IN THE SCRUBBER SLURRY. FINAL
SYSTEM BLEED WAS WITHDRAWN FROM THE OXIDATION TANK. AT AVERAGE OXIDATION
TANK PH OF 6, SULFITE OXIDATION AVERAGED 98X. FILTER CAKE SOLIDS
CONTENT WAS 85X, SIMILAR TO THAT OBTAINED WITH TWO SCRUBBER LOOP
OPERATIONS. HOWEVER, THE SLURRY SOLIDS SETTLING RATE WAS ONLY ABOUT 0.*
CM/MIN, COMPARED TO ABOUT 0.8 CM/MIN F03 THE TWO LOOP OPERATION. SETTLING
RATE FOR UNOXIDIZED SLURRY CONTAINING MAGNESIUM ION NORMALLY DID NOT EX-
CEED 0.1 CM/MIN WITH 50 TO 60X FILTER CAKE SOLIDS.
TCA CONTINUED TO OPERATE WITH MGO ADDITION WITH BOTH LIME AND LIMESTONE
SCRUBBING. FLUE GAS WITH HIGH FLY ASH LOADING WAS USED. THE INTENT OF THE
TESTS WAS TO CLARIFY SOME OF THE INCONSISTANT RESULTS OBTAINED DURING
EARLIER RUNS MADE IN APRIL-NOVEMBER 1976, DURING WHICH SCRUBBER DOWNCOMER
AIR LEAKAGE WAS SUSPECTED IN SOME OF THE TESTS. IN GENERAL, TEST RUNS MADE
IN 1976 HAD HIGHER S02 CONCENTRATION, MOSTLY GREATER THAN 3000 PPM, WHILE
THE RECENT RUNS HAD ONLY ABOUT 2500 PPM. AT THE HIGHER INLET S02 AND THE
HIGHER RESULTANT S02 MAKE-PER-PASS, THE 1976 TESTS OPERATED EITHER UNSATU-
RATED OR SUPERSATURATED WITH RESPECT TO GYPSUM, DEPENDING ON THE SULFITE
OXIDATION LEVEL. SEVERE GYPSUM SCALING OCCURRED WHEN THE OPERATION WAS
UNDE* GYPSUM-SATURATED MODE. IN THE RECENT RUNS, OPERATION WAS MOSTLY
UNDEh GYPSUM-SATURATED MODE. HOWEVER, BECAUSE OF THE LOWER INLET S02 AND
LOWER S02 MAKE-PER-PASS, THE GYPJAJM SATURATION LEVELS WERE NOT HIGH ENOUGH
TO CAJSE ANY SIGNIFICANT SCALING.
6/78 SYSTEM 720
7/78 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
FORCED OXIDATION FEED STREAM FROM THE VENTURI/SPRAY TOWER SYSTEM
CONTINUED THROUGH MID-JUNE. TWO TEST RUNS WERE MADE IN WHICH MGO WAS
ADDED TO MAINTAIN AN EFFECTIVE MG++ CONCENTRATION OF 5000 PPM IN THE
SCRUBBER SLURRY AND NO RECYCLE STREAM WAS SENT BACK FROM THE OXIDATION
TANK (8 FT DIAMTER AND 18 FT TANK LEVEL) TO THE EFFLUENT HOLD TANK. AV-
ERAGE SULFITE OXIDATION WAS 96X OR HIGHER AT AN AIR STOICHIOMETRIC RATIO
OF 1.6 ATOMS OXYGEN/MOLE S02 ABSORBED. THE OXIDATION TANK PH WAS 5.4 TO
5.6 ONLY 0.2 UNITS HIGHER THAN THE EFFLUENT HOLD TANK PH. THE FILTER CAKE
SOLIDS WAS 85X AND THE SOLIDS SETTLING RATE WAS 0.4 TO 0.5 CM/MIN.
BOTH SCRUBBER SYSTEMS WERE SHUT DOWN FOR TWO WEEKS FROM JUNE 19 DUE TO A
BOILER OUTAGE SCHEDULED FOR RE-ROUTING THE FLUF GAS DUCT FROM THE 800 FT
STACK TO THE NO. 11 SMALL STACK.
FOLLOWING THE BOILER OUTAGE BOTH SCRUBBER SYSTEMS STARTED ON NEW LIME AND
LIMESTONE TEST BLOCKS IN WHICH ADIPIC ACID, AN ORGANIC PH BUFFER, WAS AD-
DED TO THE SCRUBBER SLURRY TO IMPROVE S02 REMOVAL EFFICIENCY.
INITIAL TEST RUNS WERE CONDUCTED WITHOUT ADIPIC ACID ADDITION TO ESTABLISH
THE BASE CASE S02 REMOVAL IN BOTH LIME AND LIMESTONE SCRUBBING FOR BOTH
SCRUBBING SYSTEMS. THE VENTURI/SPRAY TOWER SYSTEM WAS OPERATED WITH TWO-
SCRUBBER-LOOP CONFIGURATIONS WITH FORCED OXIDATION IN THE FIRST LOOP
WHILE THE TCA WAS OPERATED IN A ONE-SCRUBBER-LOOP SCHEME WITHOUT FORCED
OXIDATION.
PRELIMINARY RESULTS SHOWED THAT 96 TO 99X S02 REMOVAL WAS CONSIS-
TANTLY ACHIEVED IN THE VENTUR/SPRAY TOWER SYSTEM OPERATING WITH ABOUT 1600
PPM AND 1400 PPM ADIPIC ACID IN THE VENTURI AND SPRAY TOWER RESPECTIVELY.
THESE S02 REMOVALS COMPARE VERY FAVORABLY WITH THE 66X REMOVAL FOR
THE BASE CASE LIME RUN WITHOUT ADIPIC ACID. ON THE TCA SYSTEM, A LIME RUN
598
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
TENNESSEE VALLEY AUTHORITY: SHAWNEE 10B CCONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
WITH ABOUT 400 PPM ADIPIC ACID GAVE ABOUT SOX S02 REMOVAL, COMPARED
TO 67X FOR THE BASE CASE RUN.
8/78 SYSTEM 744
9/78 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
TESTING WITH ADIPIC ACID AS ADDITIVE FOR IMPROVING S02 REMOVAL EFFICIENCY
CONTINUED THROUGH AUGUST AND SEPTEMBER. BOTH VENTURI/SPRAY TOWER AND TCA
SYSTEMS WERE OPERATED ON LIMESTONE SLURRY WITH HIGH FLY ASH LOADING DURING
THIS PERIOD. THE TCA WAS OPERATED WITHOUT FORCED OXIDATION AND THE VENTURI
SPRAY TOWER WITH TWO-SCRUBBER-LOOP FORCED OXIDATION. AS IN THE LIME TESTS
WITH ADIPIC ACID ADDITION CONDUCTED IN JULY SIGNIFICANT IMPROVEMENT IN S02
REMOVAL EFFICIENCY WAS ALSO OBSERVED IN THE LIMSTONE TESTS. UNDER TYPICAL
OPERATION, S02 REMOVAL HIGHER THAN 90X COULD BE ACHIEVED BY THE
VENTURI/SPRAY TOWER WITH ABOUT 2100 PPM AND 1500 PPM ADIPIC ACID IN THE
VENTURI AND SPRAY TOWER RESPECTIVELY. UNDER THE SAME OPERATING CONDITONS
BUT WITHOUT ADIPIC ACID, THE S02 REMOVAL WAS ONLY 57X. THE SULFITE
OXIDATION EFFICIENCY AND WASTE SLUDGE DEWATERING PROPERTIES DID NOT APPEAR
TO BE AFFECTED BY THE PRESENCE OF ADIPIC ACID.
IN THE TCA, HIGHER THAN 90X S02 REMOVALS WERE OBTAINED WITH 750 TO
1500 PPM ADIPIC ACID COMPARED TO 71X REMOVAL FOR A BASE CASE RUN
WITHOUT ADIPIC ACID.
IN BOTH SCRUBBING SYSTEMS THE PH IN THE SCRUBBER SLURRY NEEDS TO BE HIGHER
THAN ABOUT 5.0, THE UPPER PH BUFFER POINT OF ADIPIC ACID, FOR THIS
ADDITIVE TO BE FULLY EFFECTIVE.
DETERIORATION OR DECOMPOSITION OF ADIPIC ACID APPARENTLY TAKES PLACE IN
THE SCRUBBER. ACTUAL FEED RATES OF ADIPIC ACID WERE 2 TO 3 TIMES HIGHER
THAN COULD BE ACCOUNTED FOR IN THE SYSTEM DISCHARGE SLUDGE.
10/78 SYSTEM 744
11/78 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
A ONE MONTH LONG-TERM RELIABILITY SUN WAS CONDUCTED ON BOTH THE VENTURI/
SPRAY TOWER AND TCA SYSTEMS USING LIMESTONE SLURRY WITH ADIPIC ACID AS AN
ADDITIVE FOR ENHANCING S02 REMOVAL EFFICIENCY. STEADY-STATE S02 REMOVAL
IN BLTH RUNS WAS CONSISTANTLY HIGH IN THE RANGE OF 96 TO 99X UNDER
TYPIC\L OPERATING CONDITIONS. THE VENTURI/SPRAY TOWER SYSTEM WAS OPERATED
WITH 'i-WO-SCRUBBER-LOOP FORCED OXIDATION. ADIPIC ACID CONCENTRATIONS WERE
1500 PPM IN THE TCA AND THE SPRAC TOWER, AND £400 PPM IN THE VENTURI. BOTH
SCRUBHER SYSTEMS OPERATED FREE OF SCALING AND PLUGGING.
LONG-TERM TESTS BEGAN IN MID-NOVEMBER TO COMPARE CONVENTIONAL LIME SCRUB-
BING WITH ADVANCED LIMSTONE SCRUBBING USING CHEMICAL ADDITIVES AND FORCED
OXIDATION. EACH TEST WILL LAST ONE MONTH OR LONGER. THE VENTURI/SPRAY TOW-
ER SYSTEM IS BEING OPERATED WITH TWO-SCRUBBER-LOOP FORCED OXIDATION AND
LIMESTONE SLURRY AND ADIPIC ACID ADDITION. THE TCA SYSTEM IS BEING OPERAT-
ED WITH LIME SLURRY (NO ADDITIVES) AND WITHOUT FORCED OXIDATION. DURING
THESE TESTS CONTINUOUS S02 EMISSIONS MONITORING PROCEDURES WILL BE
ASSESSED.
12/78 SYSTEM 744
1/79 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
LONG-TERM TESTS ON BOTH SCRUBBER SYSTEMS. WHICH BEGAN IN MID-NOVEMBER 1978
WERE COMPLETED NEAR THE END OF JANUARY 1979. THESE TESTS WERE CONDUCTED
TO COMPARE CONVENTIONAL LIME SCRUBBING WITH ADVANCED LIMESTONE SCRUBBING
599
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
TENNESSEE VALLEY AUTHORITY: SHAWNEE 10B (CONT.l
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
USING CHEMICAL ADDITIVES AND FORCED OXIDATION. THE VENTURI/SPRAY TOWER
WAS OPERATED WITH TWO-SCRUBBER-LOOP FORCED OXIDATION AND WITH LIMESTONE
SLURRY AND ADIPIC ACID ADDITION. THE TCA SYSTEM WAS OPERATED WITH LIME
SLURRY (NO ADDITIVE) AND WITHOUT FORCED OXIDATION. DURING THESE TESTS
CONTINUOUS S02 EMISSIONS MONITORING PROCEDURES WERE ASSESSED.
2/79 SYSTEM 672
3/79 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
ONE TEST RUN WAS CONDUCTED ON EACH OF THE TWO SCRUBBER SYSTEMS IN
EARLY FEBRUARY TO PROVIDE SAMPLES FOR LEVEL 1 BIOASSY TESTING BY LITTON
BIONETICS CORPORATION UNDER CONTRACT WITH EPA. ACTUAL SAMPLING OF SLUR-
RIES AND COHDENSATES FROM THE SCRUBBER AND OXIDATION TANK OFF-GASES WAS
PERFORMED BY BATTELLE COLUMBUS LABORATORY. FOR THIS PURPOSE, THE TCA WAS
OPERATED WITH LIMESTONE/FLYASH SLURRY AS A BASE CASE, AND THE VENTURI/
SPRAY TOWER WAS OPERATED WITH LIMESTONE/FLYASH SLURRY AND WITH ADIPIC
ACID ADDITIVE AND TWO-SCRUBBER-LOOP FORCED OXIDATION.
A SERIES OF TESTS WAS CONDUCTED ON THE VENTURI/SPRAY TOWER SYSTEM FROM
MID-FEBRUARY THROUGH THE END OF MARCH TO SIMULATE THE PLANNED TVA WIDOWS
CREEK UNIT 8 FULL-SCALE, TKO-SCRUBBER-LOOP FORCED-OXIDATION SCHEME.
SPECIAL WIDOWS CREEK LIMESTONE (STONEMAN) AND COAL (PITTSBURGH MIDWAY)
WERE USED AT SHAWNEE DURING THESE TESTS. NEAR COMPLETE SULFITE OXIDATION
WAS ACHIEVED AT OXIDATION TANK PH UP TO 6.0 AND AN AIR STOICHIOMETRY AS
LOW AS 1.5 ATOMS OXYGEN/ MOLE S02 ABSORBED. EXPECTED SLURRY CARRY-OVER
FROM THE FIRST TO THE SECOND SCRUBBER LOOP AT WIDOWS CREEK WAS SIMULATED
BY AN ARTIFICIAL BACKMIX STREAM OF UP TO 65 GPM.
A NEW LIME/ADIPIC ACID TEST BLOCK WITH AND WITHOUT FORCED OXIDATION
BEGAN IN EARLY FEBRUARY ON THE SINGLE-LOOP TCA SYSTEM USING FLUE GAS WITH
HIGH FLYASH LOADINGS. AT TCA INLET PH OF 7.0, 2400 TO 2900 PPM INLET S02,
L/G OF 50 GAL/ MCF, AND 15 INCHES TOTAL STATIC BED HEIGHT OF 1-7/8 INCH
NITRILE FOAM SPHERES, S02 REMOVALS WERE 83, 93, AND 977. WITH ZERO,
600, AND 1200 PPM ADIPIC ACID, RESPECTIVELY, WITHOUT FORCED OXIDATION.
S02 REMOVAL REMAINED HIGH AT 91X WITH 1200 PPM ADIPIC ACID WHEN L/6
WAS REDUCED FROM 50 TO 37 GAL/MCF. WHEN OXIDATION WAS FORCED WITH ABOUT
1.8 AIR STOICHIOMETRY, NEAR COMPLETE SULFITE OXIDATION WAS ACHIEVED AT
OXIDATION TANK PH (TCA INLET PH) UP TO ABOUT 5.5, AND 1200 PPM ADIPIC
ACID. S02 REMOVAL ABOVE 907. WAS OBTAINED AT TCA INLET FH AS LOW
AS 5.0 WITH FORCED OXIDATION.
4/79 SYSTEM 720
5/79 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
A SERIES OF BLEED STREAM OXIDATION TESTS USING LIMESTONE AND ADIPIC
ACID WAS CONDUCTED ON THE VENTURI/SPRAY TOWER DURING THE MONTH OF APRIL.
NEAR COMPLETE SULFITE OXIDATION WAS ACHIEVED UNDER CONDITIONS OF EITHER
LOW ^LUE GAS THROUGHPUT, WHICH RESU'.TED IN LOW BLEED RATES AND SUBSEQUENT-
LY HIGHER RESIDENCE TIMES IN THE OXIDATION TANK, OR RECIRCULATION AT
LIQUOT BACK TO THE EFFLUENT HOLD TANK WHICH ARTIFICIALLY MAINTAINED A LOW
PH IN THE OXIDATION TANK.
DURING THE MONTH OF APRIL, THE TCA WAS OPERATED WITH LIMESTONE, ADIPIC
ACID AliD FORCED OXIDATION USING A SINGLE TANK. AT AIR STOICHIOMETRIC
RATIOS OF 1.7-2.0 ATOMS OXYGEN/MOLE S02 ABSORBED, AN UNUSUAL SET OF CON-
DITIONS WAS ENCOUNTERED DURING WHICH THE LIQUID SULFITE ION LEVEL 1N-
CREASFJ TO A RANGE OF 800 TO 1700 PPM AND THE DEMAND FOR LIMESTONE TO
MAINTAIN THE SCRUBBER INLET PH AT 5.1 INCREASED TO A RANGE OF 1.8 TO 4.0
MOLES LIMESTONE/MOLE S02 ABSORBED. THE CAUSE HAS NOT YET BEEN DETERMINED
ALTHOUGH IT WAS FOUND THAT THE SITUATION COULD BE ALLEVIATED BY EITHER
INCREASING THE AIR STOICHIOMETRY TO GREATER THAN 2.2, OR BY MOVING THE
600
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
TENNESSEE VALLEY AUTHORITY: SHAWNEE 108 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
LIMESTONE FEED TO A SECOND TANK DOWNSTREAM OF THE OXIDATION TANK.
BOILER NO. 10 WENT DOWN ON MAY 5TH FOR A SCHEDULED 6 WEEK BOILER OUT-
AGE. DURING THIS PERIOD, THE VENTURI/SPRAY TOHER WILL BE DOWN BUT THE
TCA IS BEING OPERATED ON FLUE GAS FROM BOILER NO. 9 THROUGH THE NEWLY IN-
STALLED DUCT. DURING THIS PERIOD, THE TCA WILL COMPLETE A SERIES OF
LIMESTONE/ADIPIC ACID FACTORIAL TESTS WITH AND WITHOUT FORCED OXIDATION.
6/79 SYSTEM 720
7/79 SYSTEM 744
8/79 IDA 96.7 78.6
10B 93.6 73.0
SYSTEM 744
9/79 SYSTEM 720
-** PROBLEMS/SOLUTIONS/COMMENTS
BOILER NO. 10 WAS RESTARTED ON JULY 6, 1979 AFTER NINE WEEKS OF SCHEDULED
MAINTENANCE OUTAGE.
LIMESTONE FACTORIAL TESTING WITH ADIPIC ACID ADDITION ON THE VENTURI/SPRAY
TOWER SYSTEM CONTINUED THROUGHOUT THE THIRD QUARTER. THESE TESTS WERE
MADE WITH TWO-LOOP OPERATION WITH FORCED OXIDATION AND SPRAY TOWER ONLY
OPERATION WITHOUT FORCED OXIDATION, BOTH UNDER CLOSED-LOOP CONDITIONS.
OPEN-LIQUOR-LOOP TESTS WITH TWO-LOOP OPERATION AND WITHOUT FORCED OXIDATION
WERE ALSO CONDUCTED TO COMPARE THE RESULTS WITH "FRESH" ADIPIC ACID
AGAINST THOSE WITH "AGED" ACID OBTAINED UNDER CLOSED-LIQUOR-LOOP
CONDITIONS.
DURING THE THIRD QUARTER, ADDITIONAL LIMESTONE FACTORIAL TESTS WITH
ADIPIC ACID WERE CONDUCTED ON THE TCA SYSTEM TO SUPPLEMENT THOSE MADE IN
MAY AND JUNE. IN ADDITION, A SERIES OF LIMESTONE TESTS WITHOUT ADIPIC
ACID WERE PERFORMED USING A SINGLE TANK TO INVESTIGATE THE EFFECT OF AIR
STOICHIOMETRY AND OXIDATION TANK AGITATOR SPEED ON SULFITE OXIDATION. IN
A SIMILAR SERIES OF TESTS CONDUCTED IN APRIL BUT WITH ADIPIC ACID, AN
UNUSUAL SET OF CONDITIONS HAS ENCOUNTERED WHICH GAVE HIGH LIQUOR SULFITE
CONCENTRATION (800-1700 PPM) AND DEMANDED HIGH LIMESTONE STOICHIOMETRY
(1.8-4.0 MOLES CA/MOLE S02 ABSORBED) TO MAINTAIN A SCRUBBER INLET PH OF
5.1. THESE PHENOMENA WERE ALSO OBSERVED DURING TESTS WITHOUT ADIPIC ACID.
INSUFFICIENT SULFITE OXIDATION RATE (CAUSED BY REDUCED AIR STOICHIOMETRY
AND/OR REDUCED AGITATION IN THE OXIDATION TANK) AND DECREASED AMOUNT OF
SOLID CAS03 SEEDS WERE BELIEVED TO CAUSE HIGH SULFITE SUPERSATURATION
(HIGH SULFITE CONCENTRATIONS) AND THE RESULTANT BLINDING OF LIMESTONE BY
SULFITE (HIGH LIMESTONE STOICHIOMETRY).
10/79 IDA 99.8 58.7
10B 96.5 55.6
SYSTEM 744
11/79 10A .0
10B 99.7 94.7
SYSTEM 720
12/79 10A .0
10B 98.4 74.9
SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE TRAP-OUT FUNNEL, WHICH HAD BEEN INSTALLED EARLIER IN THE SPRAY TOWER
TO SEPARATE VENTURI AND SPRAY TOWER SLURRIES FOR TWO-SCRUBBER-LOOP OPERA-
TION, WAS REMOVED IN EARLY OCTOBER.
601
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
TENNESSEE VALLEY AUTHORITY: SHAWNEE 10B (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
THE SYSTEM WAS OPERATED THROUGHOUT THE FOURTH QUARTER IN A CONVENTIONAL
MODE IN WHICH THE VENTURI AND SPRAY TOWER USED A COMMON HOLD TANK. ADDI-
TIONAL FACTORIAL TESTS WERE CONDUCTED IN THIS MODE OF OPERATION THROUGH
MID-DECEMSER USING LIMESTONE/ADIPIC ACID SLURRY WITHOUT FORCED OXIDATION.
A NEW TEST BLOCK WAS INITIATED IN MID-DECEMBER TO OPTIMIZE THE LEVELS OF
PH AND ADIPIC ACID CONCENTRATION AT A DESIRED DEGREE OF S02 REMOVAL WITH
LIMESTONE SCRUBBING AND WITHOUT FORCED OXIDATION. IT HAS BEEN OBSERVED
THAT THE DECOMPOSITION RATE OF ADIPIC ACID IS DECREASED WITH REDUCING PH.
THE TESTING ON THE EFFECTS OF AIR STOICHIOMETRY AND OXIDATION TANK AGITATOR
SPEED ON SULFITE OXIDATION WAS CONCLUDED ON THE TCA SYSTEM IN MID-OCTOBER.
THE TCA SYSTEM WAS TEMPORARILY TRANSFERRED TO TVA/UOP EPRI IN MID-OCTOBER
FOR THE DEMONSTRATION OF THE DOWA BASIC ALUMINUM SULFATE SCRUBBING PROCESS.
1/80 SYSTEM
2/80 IDA
10B
SYSTEM
3/80 10A
10B
SYSTEM
100.0
99.0
.0
81.5
.0
54.7
744
696
744
** PROBLEMS/SOLUTIONS/COMMENTS
4/80 SYSTEM
5/80 10A
10B
SYSTEM
6/80 10A
10B
SYSTEM
DURING THE FIRST O"«
-------
EPA UTILITY FGO SURVEY: OCTOBER - DECEMBER X980
TENNESSEE VALLEY AUTHORITY: SH\WNEE 10B (CONT.)
PERFORMANCE DATA
PERIOD MO")ULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE VENTURI/SPRAY TOWER SYSTEM (TRAIN 100) WAS SHUT DOWN FROM MAY 28
THROUGH JUNE 17 FOR CONVERSION TO A SPRAY TOWER-ONLY SYSTEM BY THE PHYSICAL
REMOVAL OF THE VENTURI SECTION. THE SPRAY TOWER-ONLY TESTING BEGAN
JUNE 17 ON A SERIES OF LIMESTONE FACTORIAL TESTS, BOTH WITH AND WITHOUT
FORCED OXIDATION, TO CHARACTERIZE THE EFFECTS OF LIQUID-TO-GAS RATIO AND
SLURRY PH ON S02 REMOVAL IN THE SPRAY TOWER (THE FIRST SPRAY TOWER-ONLY
TESTING AT SHAWNEE).
7/80 10A 96.4 51.1
10B 97.2 88.3
SYSTEM 744
8/80 IDA 94.2 94.2 94.2
10B 99.1 42.2
SYSTEM 744 744
9/80 10A 89.9 88.8
IOB 94.0 93.1
SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
TRAIN 100 WAS AGAIN SHUT DOWN FROM AUGUST 11-28 FOR MODIFICATION OF THE
SLURRY PIPING AND INTERNAL HEADERS TO INCREASE THE SLURRY FLOW CAPACITY
FROM 1600 TO 2400 GPM. TESTING RESUMED ON AUGUST 28 ON ANOTHER
LIMESTONE FACTORIAL TEST SERIES WITH AND WITHOUT FORCED OXIDATION, BUT AT
HIGHER LIQUID-TO-GAS RATIOS (UP TO 150 GAL/MCF AT 20,000 ACFM AT 300 F GAS
RATE AND 2400 GPM MAXIMUM SLURRY FLOW RATE). THIS TEST SERIES IS EXPECTED
TO BE COMPLETED BY MID OCTOBER.
TESTING OF THE TCA SYSTEM (TRAIN 200) RESUMED ON JULY 15 AFTER THE SYSTEM
HAD BEEN RESTORED FROM THE DOWA PROCESS OPERATING MODE. AS PART OF THE
EPA FULL-SCALE 4DIPIC ACID DEMONSTRATION PROGRAM, THE SYSTEM HAD BEEN USED
THROUGHOUT THE THIRD QUARTER TO SIMULATE THE OPERATION OF THE FULL-SCALE
TCA UNITS OPERATING WITH LIMESTONE/ADIPTIC ACID SLURRY AT THE SOUTHWEST
STATION OF THE SPRINGFIELD CITY UTILITIES, AT SPRINGFIELD MISSOURI. TESTS
HAVE BEEN CONDUCTED BOTH WITH AND WITHOUT FORCED OXIDATION TO GENERATE
INFORMATION USEFUL FOR THE FULL-SCALE DEMONSTRATION.
10/80 10A 96.5 85.9
IOB 99.4 88.0
SYSTEM 744
11/80 10A 98.1 86.9
IOB 99.6 64.3
SYSTEM 720
12/80 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE LIMESTONE FACTORIAL TEST SERIES WITH AND WITHOUT FORCED OXIDATION ON
THE SPRAY TOWER SYSTEM (TRAIN 100) WAS COMPLETED ON OCTOBER 11, 1980.
THIS WAS FOLLOWED BY A LIMESTONE FACTORIAL SERIES WITH ADIPIC ACID
ADDITION, WITH AND WITHOUT FORCED OXIDATION, TO INVESTIGATE THE EFFECTS
OF ADIPIC ACID CONCENTRATION, PH, AND L/G ON S02 REMOVAL. A LONG-TERM
(UP TO 2000 HOURS) SFRAY TOWER DEMONSTRATION TEST BEGAN ON DECEMBER 26.
THE LON3-TERM RUN IS BEING OPERATED WITH LIMESTONE ENHANCED WITH 1300 PPM
ADIPIC ACID AT A PH OF 5.0 AND WITH FORCED OXIDATION TO DEMONSTRATE LONG-
TERM RELIABILITY AND BETTER THAN 90X S02 REMOVAL AND LIMESTONE UTILIZATION.
SIMULATION OF THE SPRINGFIELD CITY UTILITIES' FULL-SCALE TCA ON TRAIN 200
603
-------
EPA UTILITY FED SURVEY: OCTOBER - DECEMBER 1980
TENNESSEE VALLEY AUTHORITY: SHAWNEE 10B (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER F6D CAP.
SOZ PART. HOURS HOURS HOURS FACTOR
— —— —— —— —— —— ——— _«___« _ _____ —___ _____ ______ _—__ _ __
WAS COMPLETED ON NOVEMBER 16. ADIPIC ACID-ENHANCED LIMESTONE SCRUBBING
TESTS WITH AND WITHOUT FORCED OXIDATION WERE CONDUCTED TO GENERATE INFOR-
MATION USEFUL FOR THE EPA FULL-SCALE ADIPIC ACID DEMONSTRATION PROJECT NOW
UNDER WAY.
TRAIN 200 WAS SHUT DOWN DURING THE WEEK OF NOVEMBER 17 TO INSTALL "GLITSCH
GRID" BACKING IN PLACE OF THE MOBILE SPHERES. SHORT TESTS WERE CONDUCTED
THROUG'I THE END OF THE FOURTH QUAPTER TO CHARACTERIZE THE PACKING PRESSURE
DROP, SCALING AND PLUGGING POTENTIAL, AND S02 REMOVAL PERFORMANCE.
DOE IS ASSUMING SHAWNEE PROGRAM RESPONSIBILITY IN JANUARY 1981. TRAIN 200
IS TO BE SHUT DOWN IN JANUARY 1981 DUE TO LACK OF FUNDS. TRAIN 300 (COCUR-
RENT SCRUBBER) HAD BEEN IDLE SINCE JULY 7, 1980. CONTINUED OPERATION OF
TRAIN 100 INTO 1981 IS PLANNED.
604
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - N6/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MM
GROSS UNIT GENERATING CAPACITY - MM
NET UMT GENERATING CAPACITY W/FGD - MM
NET UNIT GENERATING CAPACITY WO/FGD - MM
EQUIVALENT SCRUBBED CAPACITY - MM
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
EOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOH - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACU TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEl GRADE
AVERAGE HEAT CONTENT - J/G
RANOE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - X
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - '/.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** ESP
NUMBER
SUPPLIER
PARTICLE REMOVAL EFFICENCY - y.
** PARTICLE SCRUBBER
NLHBER
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SH£LL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
L/6 RATIO - LITER/CU.M
PRESSURE DROP - KPA
INLET GAS FLOH RATE - CU.M/S
INLET GAS TEMPERATURE - C
SOS REMOVAL EFFICENCY - 7.
PARTICLE REMOVAL EFFICIENCY - 7.
**» FGD SYSTEM
TENNESSEE VALLEY AUTHORITY
HIDOWS CREEK
8
BRIDGEPORT
ALABAMA
E
52.
516.
******
( .120 LB/MMBTU)
( 1.200 LB/MMBTU)
(****** LB/MMBTU)
550
516
542
550
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
755.04 (1600000 ACFM)
137.8 ( 280 F)
****** (**** FT)
******
******* (***** FT)
COAL
******
23260.
25.00
10.00
3.70
******
( 10000 BTU/LB)
******
i
KOPPERS
50.0
4
VENTURI TOMER
VARIABLE-THROAT/SIDE-MOVABLE BLADES
TVA/POLYCON
23 MIDE X 28 DEEP (THROAT)
STAINLESS STEEL
AUSTENITIC
NONE
N/A
NONE
1
1.3
1.2
188.8
137.8
10.0
99.5
(10.0 GAL/1000ACF)
(5.0 IN-H20)
( 400000 ACFM)
( 280 F)
605
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
TENNESSEE VALLEY AUTHORITY: WIDOWS CREEK 8 (CONT.)
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
UNIT DESIGN S02 REMOVAL EFFICIENCY - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
** ABSORBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
r,HELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
IINER MATERIAL TRADE NAME/COMMON TYPE
GAS CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
L/C RATIO - L/CU.M
GAS-SIDE PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/SEC
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
£02 REMOVAL EFFICIENCY - 7.
** ABSOr BER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
SjPI LIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SMELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
G\S CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
L/G RATIO - L/CU.M
G4S-SIDE PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/SEC
WLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
502 REMOVAL EFFICIENCY - X
** MI'T ELIMINATOR
PFE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
NU1BER OF STAGES
NU.1BER OF PASSES PER STAGE
FR3EBOARD DISTANCE - M
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
NONE
TENNESSEE VALLEY AUTHORITY
NONE
FULL SCALE
RETROFIT
X 99.50
70.00
1
1/78
5/77
2/73
PACKED TOWER
MOBILE BED PACKING
POLYGON
30 WIDE X 16 DEEP X 34 HIGH
CARBON STEEL,STAINLESS STEEL
AISI 1110.AUSTENITIC
N/A.316L
ORGANIC
SYNTHETIC RUBBER
NEOPRENE
GRIDS
5
8.0
.5
3.7
188.76
137.8
70.0
( 60.0 GAL/1000 ACF)
(2.0 IN-H20)
( 12.0 FT/S)
( 400000 ACFM)
( 280 F)
PACKED TOWER
GRID PACKING
POLYGON
30 WIDE X 16 DEEP X 34 HIGH
CARBON STEEL,STAINLESS STEEL
AISI 1110.AUSTENITIC
N/A.316L
ORGANIC
SYNTHETIC RUBBER
NEOPRENE
GRIDS
5
8.0 (
.5 (
3.7 (
188.76 (
137.8 (
70.0
MIST ELIMINATOR
4
IMPINGEMENT
BAFFLE
CHEVRON VANE
VERTICAL
2
3
4.27
60.0 GAL/1000 ACF)
2.0 IN-H20)
12.0 FT/S)
400000 ACFM)
280 F)
(14.0 FT)
606
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
TENNESSEE VALLEY AUTHORITY: WIDOWS CREEK 8 (CONT.)
DISTANCE BETWEEN STAGES - CM
DISTANCE BETWEEN VANES - CM
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/S
CONSTRUCTION MATERIAL GENERIC TYPE
WASH WATER SOURCE
** REHEATER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
TEMPERATURE INCREASE - C
INLET FLUE GAS TEMPERATURE - C
NUMBER OF TUBES PER BUNDLE
CONSTRUCTION MATERIAL GENERIC TYPE
** FANS
NUMBER
SUPPLIER
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
NUMBER
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
PRODUCT QUALITY - X SOLIDS
** TANKS
SERVICE
ABSORBER RECYCLE
VENTURI RECYCLE
LIMESTONE SLURRY
PECIRC TNK UNDRFLW SURGE TANK
** PL'MPS
SERVICE
VENTURI RECIRCULATION
POND RETURN
RIVER WATER TRANSFER
ABSORBER RECIRCULATION
**« SL'JDSE
** DISPOSAL
NATURE
TYPf
SITE: DIMENSIONS
SITE CAPACITY - CU.M
** PROCESS CONTROL AND INSTRUt.ENTATION
CHEMICAL PARAMETERS
MONITOR LOCATION
** FG') SPARE CAPACITY INDICES
ABSORBER - 7.
** FGD SPARE COMPONENT INDICES
ABSORBER
2.54
3.8
.2
3.8
316L S3
FRESH WATER
C 1.0 IN)
C 1.50 IN)
C 1.0 IN-H20)
I 12.5 FT/S)
INDIRECT HOT AIR
EXTERNAL HEAT EXCHANGER
STEAM TUBE BUNDLES
10.0 ( 50 F)
51.7 t 125 F)
80
CARBON STEEL
PHILADELPHIA
BOILER I.D.
DRY
188.76
137.8
CARBON STEEL
( 400000 ACFM)
( 280 F)
LIMESTONE GRINDING
BALL MILL
1
36.3 ( 40 TPH)
40.0
NUMBER
4
4
1
1
NUMBER
10
**#*
****
12
FINAL
POND
110 ACRES'X 30 FT DEEP
4035900 I 3300.0 ACRE-FT)
PH, PRESSURE CHANGE, OUTLET S02
PH-ABSORBER RECYCLE LINE
.0
.0
607
-------
EPA UTILITY FSD SURVEY: OCTOBER - DECEMBER 1980
TENNESSEE VALLEY AUTHORITY: WIDOWS CREEK 8 (CONT.)
_ PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
5/77 SYSTEM 1.5 2.6
** PROBLEMS/SOLUTIONS/COMMENTS
1.5
744
11 40.9
STARTUP AND SHAKEDOWN PROCEDURES OFFICIALLY BEGAN ON APRIL 30, 1977.
SCRUBBING OPERATIONS BEGAN ON MAY 16 WHEN FLUE GAS WAS PASSED THROUGH A
AND B TRAINS.
6/77 SYSTEM 10.9 18.0
** PROBLEMS/SOLUTIONS/COMMENTS
10.9
720 438
79 36.3
C AND D TRAINS WERE STILL UNDERGOING PRESCRIBING PREPARATIONS THROUGH
JUNE. BECAUSE OF BOILER RELATED PROBLEMS SUFFICIENT STEAM WAS NOT AVAIL-
ABLE TO OPERATE THE FLUE GAS REHEATERS.
7/77 SYSTEM
8/77
A
B
C
D
SYSTEM
24.7
20.0
40.0
36.7
8.3
26.3
28.1
22.8
45.7
42.0
9.5
30.0
24.7
20.0
40.0
36.7
8.3
26.3
744 654
744 651
184 49.6
195 47.5
** PRODLEMS/SOLUTIONS/COMMENTS
27 SEPARATE INSTRUMENTATION FAILURES OCCURRED DURING THE PERIOD. THE
PROBLEMS WERE ASSOCIATED WITH FLOW METERS, VARIABLE-SPEED CONTROLS, S02
MONITORS, PH MONITORS, AND SOLIDS MONITORS. AUTOMATIC SCRUBBER CONTROLS
WERE INOPERATIVE. SCRUBBING OPERATIONS HAVE BEEN CONDUCTED MANUALLY BASED
ON PERIODIC SAMPLING.
MAJOR PROBLEMS HAVE BEEN ASSOCIATED WITH THE GUILLOTINE BYPASS AND DOUBLE
LOUVER SEAL-OFF GAS DAMPERS. S02 REACTS WITH RUBBER SEALS. DETERIORATION
RESULTS IN S02 AND FLYASH LEAKING. SUBSEQUENT FAILURE OF THE AUTOMATIC
GEAR BOXES NECESSITATES MANUAL DAMPER OPERATIONS. IT HAS NOT BEEN POSSIBLE
TO ENTIRELY ISOLATE MODULES FOR REPAIR WORK BECAUSE OF THIS LEAKAGE.
LOW ESP PARTICULATE REMOVAL EFFICIENCY HAS RESULTED IN HIGH FAN ROTOR
EROSION, MOTOR BURNOUTS AND LUBRICATION PROBLEMS.
THERE WAS EVIDENCE OF SCALE ACCUMULATION IN THE SCRUBBING SYSTEM, HOWEVER,
THIS WAS NOT SEVERE.
EROSION HAS OCCURRED IN THE CERAMIC VENTURI THROAT LININGS.
A RESULT OF THE POOR ESP EFFICIENCY.
THIS IS ALSO
9/77 A
33.3
RUBBER LINING FAILURES HAVE OCCURRED IN THE VENTURIS, ABSORBERS AND TANKS.
IT IS BELIEVED THAT THESE KERE APPLICATION-RELATED FAILURES. THE RUBBER
IN THE ABSORBER SECTION OF ALL FOUR TRAINS HAS DETACHED IN VARIOUS PLACES.
THE SUPPLIER HAS REPAIRED THE DEFECTIVE SECTIONS.
SOFT SCALE FORMATION MAY RESULT FROM IMPROPER STOICHIOMETRIC RATIOS.
STOICHIOMETRIC RATIOS OF 2.0, 3.0 AND 6.0 HAVE OCCURRED PERIODICALLY
BECAUSE OF MANUAL CONTROL AND OPERATOR JUDGEMENTS. IDEALLY THE RATIO
SHOULD FALL IN THE 1.4 TO 1.6 RANGF.
THE B*LL MILL HAS NOT BEEN ABLE TO OPERATE AT DESIGN CAPACITY. THE BALL
MILL H\S A DESIGN CAPACITY OF GRINDING 50 TPH BUT HAS ONLY BEEN ABLE TO
PRODUC: 35 TPH OF LIMESTONE SLURRY.
.U.I
17.8
608
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
TENNESSEE VALLEY AUTHORITY: WIDOWS CREEK 8 (COW.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
»
c
ri
'SYSTEM
72
97
98
75
.7
.4
.4
.5
68.2
97.0
98
71
.2
.1
57
82
83
60
.8
.1
.1
.2
720
609
433
45
.5
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THIS MONTH THE BOILER WAS OPERATED AT A REDUCED LOAD OF ABOUT
300 MH. AT THIS REDUCED LOAD, ONLY 3 TRAINS WERE REQUIRED TO HANDLE
ALL OF THE BOILER FLUE GAS.
SOME SCALING WAS DISCOVERED IN THE ABSORBER COLUMN AND ENTRAINMENT
SEPARATOR OUTLET OF ONE TRAIN.
SERIOUS EROSION PROBLEMS CONTINUE WITH THE ID FAN ROTORS.
THE UNIT WENT OFF LINE SEPTEMBER 30 FOR A SCHEDULED OUTAGE TO REPAIR BOIL-
ER TUBES. DURING THE OUTAGE, AN ATTEMPT WILL BE MADE TO CORRECT MANY OF
THE MECHANICAL PROBLEMS.
10/77 SYSTEM
100.0
.0
.0
** PROBLEMS/SOLUTIONS/COMMENTS
UNIT 8 WAS OFF-LINE FOR THE ENTIRE MONTH DURING A SCHEDULED OUTAGE FOR
REPAIR OF BOILER TUBES. DURING THIS PERIOD, MANY MECHANICAL AND INSTRU- -
MENTAL SCRUBBER r BLEMS WERE CORRECTED.
11/77 A
B
C
D
SYSTEM
57.0
85.5
89.8
99.8
75.8
87.7
49.0
51.5
57.2
43.5
50.3
720 413
362 38.8
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS BROUGHT BACK IN SERVICE ON NOVEMBER 11 FOLLOWING THE SCHED-
ULED BOILER OUTAGE (AVAILABILITY WAS CALCUATED FROM NOVEMBER 11 THROUGH
NOVEMBER 30).
ALL ID FANS HAVE BEEN REBUILT IN AM ATTEMPT TO CORRECT THE CORROSION AND
DRIVE MOTOR PROBLEMS.
GAS LEAKAGE FROM THE DAMPERS WAS CORRECTED BY WELDING A COVER PLATE OVER
THE SEAL DOORS. THE SUPPLIER IS CURRENTLY WORKING ON A NEW DESIGN FOR
DAMPERS.
INSTRUMENTATION PROBLEMS CONTINUE TO HAMPER PROPER SCRUBBER OPERATION.
12/77
A
B
C
D
SYSTEM
59.3
55.9
58.7
57.7
57.9
98.1
97.9
97.2
95.4
97.2
56.1
56.0
55.6
54.6
56.0
744 426
414 42.9
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS OFF-LINE FROM DECEMBER 20 TO DECEMBER 31 FOR REPAIRS OF A
BOILER TUBE LEAK.
DURING THE BOILER OUTAGE, AN INSPECTION WAS MADE OF THE SCRUBBER MODULES.
THE RUBBER LINER WAS FOUND TO BE MISSING IN SEVERAL AREAS OF ALL FOUR
MODULES AND WAS REPAIRED DURING THE OUTAGE.
609
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
TENNESSEE VALLEY AUTHORITY: WIDOWS CREEK 8 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
1/78 A
B
C
D
SYSTEM
90.2
86.7
84.6
88.8
87.6
98.5
94.5
91.9
97.0
95.5
81.9
78.5
76.4
80.6
79.4
744 618 590 60.1
** PROBLEMS/SOLUTIONS/COmENTS
2/78 A
B
C
D
SYSTEM
25.5
69.4
67.8
56.5
54.8
29.3
68.4
63.1
53.6
53.6
ALL FOUR SCRUBBER MODULES RETURNED TO SERVICE THIS MONTH FOLLOWING REPAIR
WORK ON THE RUBBER LINER DURING THE RECENT BOILER OUTAGE.
MINOR PROBLEMS WERE ENCOUNTERED WITH FREEZING AND BURSTING OF PIPING.
FEED HOPPERS AT THE LIMESTONE STORAGE AREA HAVE BEEN PLUGGING DUE TO FROZ-
EN GRAVEL.
THE BALL MILL SUMP PUMP LINERS HAVE BEEN WEARING OUT.
SOME PLUGGING OF THE VENTURI SPRAY NOZZLES WAS ENCOUNTERED DURING
JANUARY.
INSTRUMENTATION CONTINUES TO BE A MAJOR PROBLEM WITH OPERATION OF THE
SCRUBBER.
25.5
59.7
55.1
46.8
46.8 672 586 314 49.7
** PROBLEMS/SOLUTIONS/COMMENTS
THE OUTAGE TIME FOR TRAINS A AND B WAS REQUIRED TO REPLACE THE RUBBER
LINERS IN THE DOKNCOHER AREA WITH STAINLESS STEEL. C AND D TRAINS WILL
WILL RECEIVE THE SAME MODIFICATION.
3/78 A 81.9 90.8 78.6
B 48.4 53.4 46.2
C 26.8 30.9 26.8
D 81.6 90.5 78.3
SYSTEM 59.7 66.4 57.5 744 644 428 43.7
** PROBLEMS/SOLUTIONS/COMMENTS
TRAIN B WAS OUT OF SERVICE MARCH 1 THROUGH MARCH 13 TO INSTALL STAINLESS
STEEL IN THE ABSORBER AND VENTURI DOWNCOMER AREAS.
STAINLESS STEEL COVERS WERE INSTALLED AROUND TWO EXPANSION JOINTS ON TRAIN
C IN ORDER TO PREVENT FLUE GAS LEAKAGE.
A STAINLESS STEEL PLATE WAS WELDED OVER THE ENTRY DOOR OPENINGS TO TRAIN C
OUTLET AND BYPASS GUILLOTINE DAMPERS FOR THE PURPOSE OF ELIMINATING GAS
LEAKAGE.
TRAIN C WAS OUT OF SERVICE MARCH 14 THROUGH MARCH 29 TO INSTALL STAINLESS
STEEL ABSORBER AND VENTURI DOWNCOMER AREAS.
SEVERAL LIFTER BARS ON THE FEED AND DISCHARGE ENDS OF THE BALL MILL WERE
FOUND TO BE BADLY WORN.
THE UTILITY HAS HAD WEAR PROBLEMS WITH THE SLURRY SUMP PUMP LINERS AT THE
BALL MILL.
610
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
TENNESSEE VALLEY AUTHORITY: WIDOWS CREEK 8 (CONT.)
PERFORMANCE DATA
PERIOD MO'JULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
4/78 \
B
C
D
SYSTEM
80.0
67.7
90.0
38.1
69.0
38.8
85.8
100.0
50.8
81.4
66.6
64.4
80.0
38.1
62.3
720 540 448 44.4
** PROBLEMS/SOLUTIONS/COMMENTS
DURING A BRIEF INSPECTION OF THE SCRUBBING SYSTEM IN EARLY APRIL, SOLIDS
DEPOSITION WAS NOTICED IN THE MIST ELIMINATOR SECTION OF ALL TRAINS DUE TO
PLUGGING THAT HAD OCCURRED IN SEVERAL OF THE MIST ELIMINATOR SPRAY NOZZLES
TRAIN D WAS OUT OF SERVICE FOR 17 DAYS WHILE THE MIST ELIMINATOR WAS
DISASSEMBLED AND CLEANED.
A STAINLESS STEEL LINER WAS INSTALLED ON THE SLOPING SECTIONS OF THE
ABSORBER AND VENTURI OF TRAIN D.
STAINLESS STEEL PLATES WERE INSTALLED OVER THE ENTRY DOOR OPENINGS TO
TRAIN D INLET, OUTLET AND BYPASS GUILLOTINE DAMPERS TO REDUCE GAS LEAKAGE
STAINLESS STEEL COVERS WERE INSTALLED AROUND THE FIVE EXPANSION JOINTS ON
TRAIN D, TWO EXPANSION JOINTS ON TRAIN A, AND ONE EXPANSION JOINT ON TRAIN
B TO REDUCE GAS LEAKAGE.
THERE CONTINUES TO BE A WEAR PROBLEM WITH PUMP LINERS AT THE BALL MILL.
NO CAUSE OR SOLUTION OF THE PROBLEM HAS BEEN ASCERTAINED AS YET.
5/78
A
U
C
D
SYSTEM
97.2
52.0
100.0
100.0
100.0
88.0
34.0
68.7
69.9
66.1
59.7
744 486
444 44.4
** PROBLEMS/SOLUTIONS/COMMENTS
BEGINNING MAY 1978 AVAILABILITY CALCULATIONS EXCLUDED UNAVAILABLE HOURS
RESULTING FROM THE ID FAN SINCE THE ID FAN IS INTENDED PRIMARILY FOR
MAINTAINING BOILER FURNACE DRAFT. FGD SYSTEM AVAILABILITY CALCULATORS DO
INCLUDE UNAVAILABLE HOURS RESULTING FROM THE LIMESTONE PREPARATION
FACILITY.
ON MAY 29 A SMALL PERFORATION IN THE RIVERSIDE VERTICAL HALL OF THE ABSOR-
BER VESSEL WAS DISCOVERED (LEAKING SLURRY). FURTHER EXAMINATION SHOWED THAT
A STRIP OF LOOSE NEOPRENE HAD ALLOWED SLURRY TO CORRODE AUD/OR ERODE THE
BARE CARBON STEEL VESSEL. BECAUSE OF THE SMALL SIZE OF THE LEAK, NO ATTEMPT
WILL BE MADE TO PROVIDE A PERMANENT PATCH UNTIL THE NEXT EXTENDED OUTAGE ON
TRAIN A. THERE WAS NO EVIDENCE OF AHY CORROSIVE OR EROSIVE ATTACK ON THE
NEWLY-APPLIED STAINLESS STEEL ON THE SLOPING PORTIONS OF THE VESSEL.
6/78
A
B
C
D
SYSTEM
91.7
100.0
100.0
100.0
100.0
100.0
70.1
73.8
71.7
70.7
71.6
720 472
518 39.8
** PROBLEMS/SOLUTIONS/COMMENTS
SEVERE FAILURE OF THE BALL MILL OUTBOARD FLANGED FOURNAL BOLTS RESULTED
IN A LOSS OF SLURRY PRODUCTION SEVERAL TIMES DURING JUNE.
7/78
96.9
98.8
75.3
76.7
611
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER I960
TENNESSEE VALLEY AUTHORITY: WIDOWS CREEK 8 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
C
D
SYSTEM
91.7
90.7
100.0
96.6
70.4
88.8
77.8
744 578
579 53.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE BUCKET ELEVATOR SUPPLYING LIMESTONE TO THE BALL MILL FAILED ON JULY 21.
APPARENTLY, THE CHAIN CARRYING THE BUCKETS GOT OFF TRACK DAMAGING SEVERAL
BUCKETS BEFORE THE CONDITION WAS DISCOVERED. REPAIRS HERE NOT COMPLETED
UNTIL JULY 24.
BECAUSE OF THE NECESSITY FOR KEEPING UNIT 8 ON-LINE, THE SCRUBBER WAS RUN
WITHOU," LIMESTONE ADDITIONCTHERE IS AN APPROXIMATE 8-HOUR RESERVE OF GROUND
LIMESTONE WHEN THE SLURRY STORAGE TANK IS FULL).
SINCE THERE IS HO RESERVE BUCKET ELEVATOR, AN OPENING WAS CUT IN THE TOP
OF THE BALL MILL FEED HOPPER AND A CHUTE WAS INSTALLED EXTENDING OUTWARD
FROM THE OPENING TO ALLOW LOADING A LIMESTONE INTO THE BALL MILL FEED
HOPPER USING A CRANE UITH A CLAMSHELL LOADER. THIS WILL ALLOW CONTINUED
OPERATION OF THE BALL MILL IN THE EVENT OF FUTURE BUCKET ELEVATOR FAILURES.
8/78 A
B
C
D
SYSTEM
91.4
100.0
56.9
58.6
95.6
77.8
87.8
49.2
50.7
82.7
67.6
744 643
503 44.6
** PROBLEMS/SOLUTIONS/COMMENTS
ABSORBER SPRAY NOZZLE CONES CONTINUE TO DROP TO THE TOP GRID, DISTORTING
SPRAY PATTERNS. INSPECTIONS ON AUGUST 18 SHOWED CONSIDERABLE TOP GRID
HEAR OF THE 316 STAINLESS STEEL GRIDS, PROBABLY AGGRAVATED BY LOSS OF
NOZZLE CONES. FOUR SPRAYCO 1969F 5-INCH ORIFICE NOZZLES WERE BORROWED FROM
THE SHAkTIEE STEAM PLANT TEST FACILITY AND INSTALLED IN ABSC3BER B CM AUGUST
18 FOR EVALUATION AS POSSIBLE CANDIDATES FOR REPLACING NOZZLES IN CURRENT
USE. THESE SPRAYCO NOZZLES HAVE SUBSTANTIAL INTERNAL DEFLECTORS AND ARE
EXPECTED TO DEMONSTRATE IMPROVED PERFORMANCE.
SPRAYING SYSTEMS COMPANY WILL ALSO LEND FOUR OF THEIR 5-INCH SCRUBBER NOZ-
ZLES FOR TESTING. THESE ARE EXPECTED TO ARRIVE IN SEPTEMBER.
9/78 ft
D
SYSTEM
98.7
100.0
100.0
29.0
83.9
78.2
76.1
82.9
20.6
59.4
59.8
720 510
430 39.5
** PROBLEMS/SOLUTIONS/CQMHENTS
REPAIRS ON THE BUCKET ELEVATOR WERE COMPLETED ON SEPTEMBER 24.
10/78 A
B
C
D
SYSTEM
22.4
100.0
100.0
100.0
.0
75.0
23.0
19.9
22.2
.0
16.3
744 146
121 10.1
** PROBLEMS/SOLUTIONS/COMMENTS
THE LIMESTONE BUCKET ELEVATOR FAILED ON OCTOBER 4. THE ELEVATOR HAD BEEN
LAST REPAIRED ON SEPTEMBER 24. THE BUCKET ELEVATOR FAILURES ARE CAUSED
BY THE DRIVE SPROCKETS BECOMING LOOSE ALLOWING THE CHAINS TO WORK OFF OF
THE SPROCKET AND THE HOUSING NOT BEING PLUMB.
612
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
TENNESSEE VALLEY AUTHORITY: WIDOWS CREEK 8 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL
S02 PART.
PER BOILER FGD CAP.
HOURS HOURS HOURS FACTOR
SHORT-TERM PLANS ARE TO REBUILD THE BUCKET ELEVATOR DURING THE SCHEDULED
BOILER OUTAGE. THE LONG-TERM SOLUTION IS TO REPLACE THE BUCKET ELEVATOR
WITH CONVEYORS.
11/78 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
.0
720
.0
THE UNIT WAS DOWN FOR A SCHEDULED SCRUBBER/BOILER OUTAGE IN NOVEMBER.
A FIRE ON NOVEMBER 28 IN TRAIN A ABSORBER CAUSED BY WELDING DESTROYED THE
TURBULENT CONTACT ABSORBER (TCA) SPHERES INSTALLED DURING THE PRESENT
OUTAGE.
12/78
A
B
C
D
SYSTEM
67.7
.0
100.0
100.0
100.0
75.0
.0
15.2
11.8
15.3
10.6
37
79 2.4
** PROBLEMS/SOLUTIONS/COMMENTS
CLEANJP OF THE FIRE-DAMAGED TRAIN A ABSORBER WAS COMPLETED ON DECEMBER 5.
THE BU:KET ELEVATOR REPAIRS CONTINUED IN DECEMBER. A PORTABLE CONVEYOR
IS BEI.-1G USED TO SUPPLY LIMESTONE UNTIL THE BUCKET ELEVATOR REPAIRS ARE
COMPLETE.
1/79 SYSTEM 75.0
** PROBLEMS/SOLUTIONS/COMMENTS
.0
744
THE UNIT REMAINED OUT OF SERVICE BECAUSE OF TURBINE ROTOR PROBLEMS.
FOLLOWING THE NOVEMBER 28 FIRE, THE DECISION WAS MADE NOT TO RESTORE THE
DAMAGED NEOPRENE ABSORBER VESSEL LINING, BUT TO REPLACE IT WITH 316L STAIN-
LESS STEEL. TWO PRINCIPAL REASONS FOR NOT RESTORING THE RUBBER WERE HIGH
COST AND A STATEMENT BY THE RUBBER APPLICATOR THAT HE COULD NOT GUARANTEE
ANY RUBBER APPLIED TO THE VESSELS WITH THE AMBIENT TEMPERATURE BELOW ABOUT
55 F. STAINLESS STEEL (TYPE 316L) IS CHEAPER (APPLIED COST) THAN RUBBER
QUICKER TO APPLY, AND HAS BEEN DEMONSTRATED AT WIDOWS CREEK STEAM PLANT TO
BE VERY DURABLE FOP APPLICATION WITHIN THE ABSORBER VESSEL.
AN ESTIMATED 4,200 SQUARE FEET OF DAMAGED RUBBER WAS REMOVED AND 3/16-INCH-
THICK 316L STAINLESS STEEL WAS PURCHASED FOR REPLACEMENT. THIS ARRIVED AT
THE PLANT ON JANUARY 16. PREPARATION OF THE ABSORBER VESSEL INTERIOR FOR
INSTALLATION OF THE STAINLESS STEEL CONTIfJUED DURING JANUARY. SINCE TRAIN
A ABSORBER STAINLESS STEEL GRID (DIRECTLY BELOW THE SPRAY NOZZLES) WAS
DESTROYED BY THE FIRE, THE LOWER STAINLESS STEEL GRID FROM TRAIN B WAS
REMOVED AND INSTALLED AS THE TOP GRID IN TRAIN A. A NEW COMPLEMENT OF
FIBERGLASS-REINFORCED PLASTIC (FRP) ABSORBER VESSEL GRIDS WAS ORDERED AND
WAS SCHEDULED TO ARRIVE ONSITE DURING FEBRUARY.
2/79
A
13
D
SYSTEM
66.4
.0
100.0
100.0
100.0
75.0
.0
70.5
68.6
52.4
47.9
672 314
323 25.6
** PROBLEMS/SOLUTIONS/COMMENTS
TRAIN D BECAME AVAILABLE FEBRUARY 10 FOR THE INSTALLATION OF FORCED-
OXIDATION TEST EQUIPMENT. BY FEBRUARY 10, INSTALLATION WAS COMPLETED ON
PUMPS, TANKS, VACUUM FILTERS, AND MODIFICATION OF THE ABSORBER AND VENTURI
613
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
TENNESSEE VALLEY AUTHORITY: WIDOWS CREEK 8 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
AGITATOR CONTROL CIRCUITS. BY LATE FEBRUARY, ERECTION OF THE ELECTRICAL/
CONTROL BUILDING AND INSTALLATION OF FLOCCULENT PIPING WAS BEGUN. CON-
STRUCTION OF THE FACILITY IS EXPECTED TO BE COMPLETED IN MARCH.
NEW AGITATORS WERE INSTALLED ON THE TRAIN D ABSORBER AND VENTURI CIRCULA-
TION TANKS. THE NEW, MORE POWERFUL AGITATORS ARE NEEDED FOR THE FORCED-
OXIDATION TESTS.
3/79
A
B
C
D
SYSTEM
99.6
78.6
100.0
100.0
100.0
94.7
69.6
93.0
92.7
91.7
86.8
659
646 62.1
** PROBLEMS/SOLUTIONS/COMMENTS
REPAIRS OF DAMAGE RESULTING FROM THE FIRE IN TRAIN A LAST NOVEMBER WERE
COMPLETED BY MARCH 1, 1979. TRAIN A REMAINED OUT OF SERVICE UNTIL MARCH 8
TO REBUILD THE INDUCED-DRAFT FAN-A FLUID DRIVE.
BECAUSE THE REPLACEMENT FIBERGLASS-REINFORCED PLASTIC (FRP) GRATING DID
NOT ARRIVE AT THE PLANT BY MARCH 1, 1979, ORDINARY CARBON STEEL FLOOR
GRATING WAS INSTALLED FOR THE MARCH 8 STARTUP. INSPECTIONS LATE IN MARCH
REVEALED THAT CORROSION AND EROSION HAD DESTROYED APPROXIMATELY 70-80X
OF THE CARBON STEEL GRATING.
4/79 A
B
C
D
SYSTEM
96.4
100.0
100.0
100.0
100.0
100.0
85.0
77.9
75.8
81.5
80.1
720 519
577 46.8
** PROBLEMS/SOLUTIONS/COMMENTS
FOLLOWING THE BALLMILL TEST ON MARCH 21, 1979, WHERE SLURRY BEGAN TO OVER-
FLOW 3UT THE FEED END OF THE MILL, THE CLASSIFIERS WERE EXAMINED FOR POS-
SIBLE PLUGGING. ONE CLASSIFIER LINER WAS WORN, AND THE CYCLONE INLET PIPE
WAS PARTIALLY PLUGGED WITH SLURRY. REPAIRS WERE MADE, AND THE BALL MILL
RESUME! OPERATION WITH NO OVERFLOW PROBLEMS. WHEN THE CYCLONE LINERS ARE
WORN 0? THE CYCLONES ARE PARTIALLY PLUGGED, TOO MUCH MATERIAL IS RETURNED
TO THE MILL CAUSING OVERFLOW OF SLURRY OUT THE FED END OF THE MILL.
5/79 A
B
C
D
SYSTEM
100.0
100.0
100.0
100.0
100.0
97.5
59.3
100.0
100.0
89.2
83.6
50.8
89.7
87.9
78.0
80.20
744 638
580 54.9
** PROBLEMS/SOLUTIONS/COMMENTS
THE VENTURI HEADERS AND NOZZLES HAVE PLUGGED WITH SCALE AND SOLIDS. A NEW
VENTURI HEADER HAS BEEN INSTALLED AND IS BEING TESTED ON TRAIN B. THE
NEW HEADER CONSISTS OF SIX 5-INCH FULL-CONE NOZZLES WITH A 3-INCH DISCHARGE
ORIFICE. THE HEADER IS INSTALLED OVER THE VENTURI THROAT TO PROVIDE GOOD
THROAT COVERAGE. IF THE NEW HEADER PROVES SUCCESSFUL, NEW HEADERS WILL BE
INSTALLED IN ALL VENTURIS.
6/79 A
B
C
D
SYSTEM
100.0
100.0
100.0
99.6
99.9
93.6
89.9
91.1
93.8
92.1
75.7
72.6
73.6
75.8
74.4
84.20 99.50 720 582
536 51.4
614
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
TENNESSEE VALLEY AUTHORITY: WIDOWS CREEK 8 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE NEW HEADER IN TRAIN B PROVED SATISFACTORY SO NEW HEADERS WILL BE
INSTALLED ON ALL FOUR VENTURIS.
OPTIMIZATION TESTS ON THE UNIT 8 SCRUBBER HAVE BEGUN AND WILL BE COMPLETED
BY THE END OF OCTOBER. THE TESTS WILL INCLUDE TESTING THE ADDITIONAL FI-
BERGLASS REINFORCED PLASTIC GRIDS, NEW ABSORBER FULL-CONE SPRAY NOZZLES,
POLYPROPYLENE GRID-TYPE PACKING, AND TURBULENT CONTACT ABSORBER SPHERES.
THE 99.5X PARTICLE REMOVAL EFFICIENCY REPORTED FOR JUNE WAS THE AVERAGE
OF TWO EFFICIENCY TESTS RUN AS PART OF THE SCRUBBER OPTIMIZATION TESTS.
7/79 A
B
C
D
SYSTEM
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
89.4
100.0
44.6
41.8
42.5
35.0
41.0
86.40 99.01 744 291
305 23.7
** PROBLEMS/SOLUTIONS/COKMENTS
CORROSION WAS FOUND IN THE REHEAT TUBES IN TRAIN A. MATERIAL COLLECTED ON
THE TUBES CONSISTED OF FLY ASH AND FERROUS CORROSION PRODUCTS. CHLORIDE
AN'D SLURRY SOLIDS WERE ALSO DETECTED. THE CHLORIDE COULD HAVE BEEN DEPOS-
ITED DURING THE FIRE IN TRAIN A IN NOVEMBER 1978. THE NEOPRENE SCRUBBER
LINING CONTAINS CHLORIDE WHICH IS LIBERATED WHEN BURNED. A DETAILED
ANALYSIS OF THE TUBE CORROSION IS BEING PERFORMED.
THE 99.01X PARTICLE REMOVAL EFFICIENCY REPORTED FOR JULY WAS AN AVERAGE OF
THE EFFICIENCY TESTS RUN AS A PART OF THE SCRUBBER OPTIMIZATION TESTS.
8/79 A
B
C
D
SYSTEM
99.2
100.0
96.2
96.1
97.9
100.0
100.0
94.9
100.0
99.0
74.3
80.6
70.2
74.9
75.0
87.90 99.00 744 550
558 48.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE BALL MILL WAS OUT OF SERVICE BECAUSE OF BROKEN BOLTS WHICH SECURE THE
INBOARD BEARING JOURNAL TO THE BALL MILL. THE BOLTS WERE REPLACED AND THE
DISCHARGE ENO OF THE MILL WAS CLEANED. BOLT HOLES WERE REAMED TO AC-
COMODATE THE LARGER DIAMETER BOLTS AND LOCK NUTS WERE USED.
THE SCRUBBER OPTIMIZATION TEST CONTINUED DURING AUGUST.
9/79
A
B
C
D
SYSTEM
100.0
100.0
95.0
94.4
97.4
100.0
100.0
96.7
no.o
99.2
71.7
75.0
65.6
72.«
71.3
83.00 99.10 720 488
513 43.8
*»• PROBLEMS/SOLUTIONS/CCMMENTS
THE LIMESTONE BUCKET ELEVATOR, WHICH FEEDS LIMESTONE INTO THE BALL MILL
SURGE HOPPER, FAILED ON SEPTEMBER 28. THE FAILURE, WHICH HAS OCCURRED
BEFORE, WAS CAUSED BY LIMESTONE PARTICLE BUILDUP ON THE BUCKETS AND IN THE
BOTTOM OF THE HOUSING, RESULTING IN THE ELEVATOR JAMMING AND BREAKING OF
THE BUCKET GUIDE CHAINS. THE ELEVATOR WILL BE REPLACED WITH BELT CONVEYORS
IN THE SUMMER OF 1930.
10/79 A
58.3
72.7
51.1
615
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
TENNESSEE VALLEY AUTHORITY: WIDOWS CREEK 8 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
B
C
D
SYSTEM
100.0
100.0
93.4
87.9
95.8
95.2
100.0
90.9
67.3
66.9
70.3
63.9
744 523
476
3.8
** PROBLEMS/SOLUTIONS/COMMENTS
A PORTABLE CONVEYOR WAS USED TO SUPPLY LIMESTONE TO THE BALL MILL WHILE
THE BUCKET WAS BEING REPAIRED.
THE REPAIR OF THE BUCKET ELEVATOR CONSISTED OF THE REPLACEMENT OF ZS
BUCKETS, REPLACEMENT OF 50 FEET OF DRIVE CHAIN ON EACH SIDE OF THE BUCKETS,
AND REMOVAL OF LIMESTONE ACCUMULATIONS ON ALL SURFACES WITH HIGH-PRESSURE
WATER. THE BUCKET ELEVATOR WAS RETURNED TO SERVICE ON OCTOBER 6, 1979.
11/79 A
B
C
D
SYSTEM
96.9
100.0
90.0
80.3
91.8
87.5
100.0
83.3
92.2
90.8
63.9
78.6
60.8
67.4
67.7
87.60
720 526
487 36.3
»* PROBLEMS/SOLUTIONS/COMMENTS
12/79 A
B
C
D
SYSTEM
87.6
100.0
100.0
95.8
95.9
83.6
100.0
64.0
65.7
78.3
CONSTRUCTION OF AN ON-SITE AREA IN WHICH TO STACK GYPSUM WAS COMPLETED
DURING EARLY NOVEMBER AND STACKING (LANDFILL) OPERATIONS BEGAN ON NOVEMBER
15. THE TRAIN D SCPUSBER SLUDGE IS OXIDIZED BY AIR SPARGING, DEUATERED,
AND TRANSPORTED Tf !!E SITE IN TRUCKS. THE GYPSUM PILE IS FORMED WITH A
BULLDOZER, ANQ RUKOFF AND LEACHATE ARE MONITORED FROM LEACHATE UELLS, A
LEACHATE POND, AND A RUNOFF FOND. THE SYPSUM IS TO BE STACKED AS
HIGH AS 10 FEET.
67.7
85.6
51.9
53.2
64.6 744 603 481 37.5
** PROBLEMS/SOLUTIONS/COMMENTS
ON DECEMBER 29, 1979 OPTIMIZATION TESTS WERE COMPLETED. THE DATA OBTAINED
WILL BE ANALYZED TO DETERMINE THE - T MODIFICATIONS THAT CAN BE INSTALLED
TO INCREASE THE S02 REMOVAL ON THE SCRUBBER.
1/80 A
B
C
D
SYSTEM
70.4
83.5
100.0
28.3
70.6
79.8
100.0
100.0
54.7
83.6
39.2
56.3
55.5
26.9
44.5
83.60
744 366
331 23.9
** PROBLEMS/SOLUTIONS/COMMENTS
2/80 A
B
C
D
SYSTEM
80.0
86.5
91.1
87.6
86.3
83.6
90.2
97.6
93.2
93.7
DURING JANUARY THE UNIT 8 BOILER EXPERIENCED LOW AVAILABILITY, CAUSING THE
FORCED OXIDATION TESTS TO BE DISCONTINUED UNTIL AFTER THE SCHEDULED
MAINTENANCE OUTAGE WHICH WILL BEGIN IN SEPTEt^SER 1980. THE FORCED
OXIDATION TESTS ARE EXPECTED TO RESUME IN JANUARY 1931.
72.7
74.0
80.0
80.6
76.8 84.00 696 571 535 43.6
616
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
TENNESSEE VALLEY AUTHORITY: UIDOWS CREEK 8 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
3/80
5/80
A
B
C
D
SYSTEM
93.6
93.0
71.9
93.3
86.0
83.0
90.6
73.3
63.9
79.0
BY FEBRUARY 27, 1980, THE DIFFERENTIAL PRESSURE ACROSS THE TRAIN C ABSORB-
ER HAD REACHED 19 INCHES WATER GAGE. THE HIGH ABSORBER DIFFERENTIAL
PRESSURE WAS CAUSED BY PLUGGING OF TURBULENT CONTACT ABSORBER (TCA)
SPHERES WHICH WERE INSTALLED DURING SCRUBBER OPTIMIZATION TESTS. THE TCA
SPHERES WILL BE REMOVED IN MARCH.
85. 4
87.9
71.1
62.0
76.6 82.60 744 722 570 50.4
** PROBLEMS/SOLUTIONS/COMMENTS
4/80 A
B
C
D
SYSTEM
96.8
97.2
96.3
95.0
96.3
82.7
79.5
90.4
70.9
80.9
ON MARCH 3 THE TCA SPHERES INSTALLED IN TRAIN C AS PART OF THE OPTIMIZA-
TION TESTS WERE REMOVED. THE SPHERES HAD BECOME PLUGGED, RESULTING IN AN
ABSORBER DIFFERENTIAL PRESSURE OF 20 INCHES WATER GAGE. THE SPHERES HAD
BEEN IN USE SINCE NOVEMBER 17, 1979.
46.5
44.7
50.8
39.9
45.5 86.00 720 405 328 30.3
** PROBLEMS/SOLUTIONS/COMMENTS
A
B
C
D
SYSTEM
99.2
96.1
96.1
96.1
96.9
74.5
80.9
87.7
75.2
79.6
THE SCRUBBER SLURRY SPRAY NOZZLES WERE CLEANED AS PART OF A
SCHEDULED MAINTENANCE OUTAGE.
BALL MILL LINENS AND LIFTER BARS WERE REPLACED IN APRIL DURING A SCHEDULED
MAINTENANCE OUTAGE.
56.2
61.0
66.1
56.7
60.0 83.00 744 561 447 38.3
** PROBLEMS/SOLUTIONS/COMMENTS
ON MAY 16 THE LIMESTONE BUCKET ELEVATOR FAILED CAUSING UNIT 8 TO BE
REMOVED FROM SERVICE FOR SIX HOURS.
THE SCRUBBER SLURRY SPRAY NOZZLES ON THE B, C AND D MODULES WERE CLEANED
DURING MAY. THE CLEANING KEPT THE SYSTEM OFF LINE FOR 23 HOURS.
THE UNIT 8 BALL MILL MALFUNCTIONED ON MAY 28, DUE TO FAILURE OF INLET
BEARING BOLTS.
6/80 A
B
C
D
SYSTEM
100.0
100.0
99.6
100.0
99.9
5.3
100.0
93.9
98.6
74.5
100.0
100.0
99.5
100.0
99.8
4.9
91.8
86.3
90.6
68.3
82.20
720 661
492 44.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JUNE THE BALL MILL REMAINED OUT OF SERVICE FOR MAJOR REPAIRS THAT
INCLUDED REPAIR OF THE BALL MILL SHELL (CRACKS PRESENT). THE UNIT 7
SCRUBBER BALL MILL HAS USED IN PLACE OF THE UNIT 8 BALL MILL.
617
-------
EPA UTILITY FGD SURVEY: OCTOBE? - DECEMBER 1980
TENNESSEE VALLEY AUTHORITY: WIDOWS CREEK 8 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
7/80
A
B
C
D
SYSTEM
100.0
96.9
96.9
100.0
98.5
79.9
75.1
88.3
48.7
73.0
100.0
95.6
96.2
100.0
98.0
71.6
67.3
79.2
43.7
65.5 87.40
744 667 487 43.7
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT 8 BALL MILL SHELL WAS SHIPPED TO THE FACTORY FOR REPAIRS ON
JULY 24.
CLEANING OF THE SLURRY SPRAY NOZZLES REMAINS A SIGNIFICANT SCRUBBER
MAINTENANCE ITEM.
8/80 SYSTEM 744
9/80 SYSTEM 720
•'«* PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION FOR THE MONTHS OF AUGUST AND SEPTEMBER IS NOT AVAILABLE AT
THIS TIME.
10/80 SYSTEM 744
11/80 SYSTEM 720
12/80 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION FOR THE FOURTH QUARTER 1980 IS NOT AVAILABLE AT THIS TIME.
618
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT N'JMBER
CITY
STATE
REGULATOR CLASSIFICATION
PARTICULAR EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLWT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MW
NET UN:CT GENERATING CAPACITY W/FGO - MW
NET UNxT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** UN::T DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DuSIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
SVACK TOP DIAMETER - M
** FUl-L DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - X
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RA.>'GE MOISTURE CONTENT - X
AV'IRAGE SULFUR CONTENT - X
RAUGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
*** PARTICLE CONTROL
** ESP
TYPE
SUPPLIER
** PARTICLE SCRUBBER
GENERIC TYPE
SPECIFIC TYPE
*** FGD SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
SOS REMOVAL MODE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
UNIT DESIGN S02 REMOVAL EFFICIENCY - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
** DESIGN AND OPERATING PARAMETERS
SPACE REQUIREMENTS - SQ M
TEXAS POWER * LIGHT
SANDOW
4
ROCKDALE
TEXAS
B
43.
516.
( .100 LB/MMBTU)
( 1.200 LB/MMBTU)
(****** LB/MMBTU)
*****
545
545
*****
382
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
******** (******* ACFM)
******* (**** F)
****** (**** FT)
******
******* (****« FT)
(****** BTU/LB)
COAL
LIGNITE
******
13.00
******
35.00
******
1.60
******
********
******
COLD SIDE
C.E. WALTHER
NONE
N/A
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
COHBUSTION ENGINEERING
BROWN & ROOT
FULL SCALE
NEW
X 99.70
75.00
1
1/81
12/80
4046.7
( 43560 SQ FT)
619
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
TEXAS POWER & LIGHT: SANDOW 4 (CONT.)
** ABSORBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
** REHEATER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
PERCENT GAS BYPASSED - AVG
*** SLUDGE
** DISPOSAL
NATURE
TfPE
** WATER BALANCE
WATER LOOP TYPE
** F6U SPARE CAPACITY INDICES
A3SCRBER - 7.
** FGI) SPARE COMPONENT INDICES
A6SCSBER
SPRAY TOWER
OPEN COUNTERCURRENT SPRAY
COMBUSTION ENGINEERING
BYPASS
COLD SIDE
N/A
30.0
FINAL
POND
CLOSED
.0
.0
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
IE/80 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
744
OPERATIONS AT SANDOW 4 COMMENCED IN DECEMBER 1980. THE SYSTEM IS PRESENTLY
IN THE SHAKEOOVWDEBUGGING PHASE OF OPERATION.
620
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MM
NET UNIT GENERATING CAPACITY M/FGD - MM
NET UNIT GENERATING CAPACITY WO/FGD - MM
EQUIVALENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOM - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FU=L DATA
F JEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/6
RANGE HEAT CONTENT - BTU/LB
A7ERA3E ASH CONTENT - 7.
RANGE. ASH CONTENT - '/.
AVERiGE MOISTURE CONTENT - 7.
RANC£ MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERiGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** ESP
NUMBER
T1PE
SUPPLIER
IIILET FLUE GAS CAPACITY - CU.M/S
INLET FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
P/.RTICLE REMOVAL EFFICENCY - x
** PARTICLE SCRUBBER
GENERIC TYPE
SPECIFIC TYPE
*** FGD SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROMAMAY PRODUCT
SO2 REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
SY.5TEM SUPPLIER
A-t FIRM
DEVELOPMENT LEVEL
NEN/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
UNIT DESIGN S02 REMOVAL EFFICIENCY - 7.
CURRENT STATUS
COMMERCIAL START-UP
( .100 LB/MMBTU)
( 1.200 LB/MMBTU)
(****** LB/MMBTU)
TEXAS UTILITIES
MARTIN LAKE
1
TATUM
TEXAS
B
43.
516.
******
3000
793
750
760
595
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
1494.51 (3167000 ACFM)
168.3 ( 335 F)
******
******* (***** FT)
( 7380 BTU/LB)
6972-789*
COAL
LIGNITE
17166.
8.00
5.6-13.2
33.00
29.0-37.9
.90
0.5-1.5
********
COLD SIDE
RESEARCH-COTTRELL
1494.5 (3167000 ACFM)
168.3 t 335 F)
.5 ( 2. IN-H20)
99.4
NONE
N/A
THROMAMAY PRODUCT
WET SCRUBBING
LIMESTONE
NONE
RESEARCH-COTTRELL
C.T. MAIN
FULL SCALE
NEM
7. 99.40
71.00
1
10/78
621
-------
EPA UTILITY F60 SURVEY: OCTOBER - DECEMBER 1980
TEXAS UTILITIES: MARTIN LAKE i (CONT.)
INITIAL START-UP 4/77
** DESIGN AND OPERATING PARAMETERS
** ABSORBER
NUIIBER
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
GAS CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
DISTANCE BETWEEN GAS CONTACTING ZONES - CM
GAS-SIDE PRESSURE DROP - KPA
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
S02 REMOVAL EFFICIENCY - 7.
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES PER STAGE
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/S
CONSTRUCTION MATERIAL GENERIC TYPE
WASH WATER SOURCE
WASH RATE - L/S
** REHEATER
GcHERIC TYPE
SPECIFIC TYPE
TJADE NAME/COMMON TYPE
PERCENT GAS BYPASSED - AVG
TEMPERATURE INCREASE - C
INLET FLUE GAS FLOW RATE - CU. M/S
Is^LET FLUE GAS TEMPERATURE - C
** FANS
NUMBER
FUNCTION
APPlICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/3
** TAKKS
SFRVICE
AE.SORBER FEED
QUENCHER SUMP
** PUT IPS
SFRVICE
QUENCHER FEED PUMP
SLURRY FEED
ADSORBER RECIRCULATION
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
COMBINATION
SPRAY/PACKED
RESEARCH-COTTRELL
28 DIA. X 100 TALL
CARBON STEEL
AISI 1110
N/A
2 FT WETTED FILM CONTACTOR (HUNTERS PACKING)
4
91.4 t 36.0IN)
1.1 < 4.5 IN-H20)
177.13 ( 375350 ACFM)
162.8 ( 325 F)
95.0
MIST ELIMINATOR
12
IMPINGEMENT
BAFFLE
CHEVRON VANE
HORIZONTAL
2
3
.2 ( 1.0 IN-H20)
2.4 ( 8.0 FT/S)
POLYPROPYLENE
ASH POND RETURN WATER
7.9 t 126 GAL/MIN)
BYPASS
COLD SIDE
N/A
25.0
22.2 ( 72 F)
144.17 ( 305500 ACFM)
57.2 ( 135 F)
BALANCED DRAFT
BOILER I.D.
DRY
375.48 ( 795680 ACFM)
NUMBER
3
6
NUMBER
****
****
54
CENTRIFUGE
3
35X SOLIDS
69X SOLIDS
622
-------
TEXAS UTILITIES: MARTIN LAKE i CCONT.)
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
DIMENSIONS - FT
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
*** SLUDGE
** TREATMENT
METHOD
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
** PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS
** WATER BALANCE
WATER LOOP TYPE
MAKEUP WATER ADDITION - LITERS/S
** FGD SPARE CAPACITY INDICES
ABSORBER - 7.
** FGD SPARE COMPONENT INDICES
ABSORBER
THICKENER
1
140 (DIA) X 1Z (DEPTH)
157. SOLIDS
357. SOLIDS
FLYASH STABILIZATION
FINAL
LANDFILL
ON SITE
RAIL
PH, LIQUID LEVEL, LIQUID & GAS FLOW
CLOSED
34.6
.0
.0
( 550 GPM)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
8/77 SYSTEM
9/77 SYSTEM
10/77 SYSTEM
730
744
** PROBLEMS/SOLUTIONS/COMMENTS
11/77 SYSTEM
1Z/77 SI STEM
1/78 SYSTEM
INSTALLATION OF THE LIMESTONE StP'F ING SYSTEM AND THE ESP WAS COMPLETED
BY OCTOBER 1977. THE INITIAL OPERAUNG PHASE IS EXPECTED TO CONTINUE
THROUGH THE FIRST QUARTER OF 1978. COMPLIANCE TESTING WAS CONDUCTED IN
AUGUST 1977 AND CERTIFICATION OF COMMERCIAL AVAILABILITY IS AWAITED.
THE FGD SYSTEM IS CURRENTLY EXPERIENCING GENERAL MECHANICAL PROBLEMS AND
INSTRUMENTATION PROBLEMS.
THE UTILITY EXPERIENCED SOME DIFFICULTIES IN THE SLUDGE HANDLING SYSTEM.
AS A RESULT OF EQUIPMENT UNAVAILABILITY THE WASTE SLURRY IS CURRENTLY
BEI.4G DIRECTED TO THE ASH DISPOSAL AREA.
720
744
744
623
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
TEXAS UriLITIESJ MARTIN LAKE 1 (CONT.)
_ PERFORMANCE DATA •
PERIOD 10DULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE SLUDGE HANDLING SYSTEM DOES NOT OPERATE UNIFORMLY OVER EXTENDED
PERIODS.
2/78 SYSTEM 672
3/78 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
CERTIFICATION WAS RECEIVED FROM THE EPA DURING THE PERIOD. THE BOILER AND
FGD SYSTEM OPERATED THROUGHOUT THE PERIOD.
THE UTILITY IS STILL HAVING SOME PROBLEMS WITH THE SLUOSE HANDLING SYSTEM.
SOME FORCED OUTAGE TIME OCCURRED.
4/78 SYSTEM 720
5/78 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS TAKEN OFF LINE IN APRIL FOR AN ANNUAL TWO WEEK OUTAGE.
GENERATOR PROBLEMS WERE ENCOUNTERED IN MAY CAUSING THE UNIT TO BE TAKEN
OFF LINE THROUGH THE END OF THE MONTH.
6/78 SYSTEM 720
7/78 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE DAMPERS FOR EACH ABSORBER MODULE WERE NOT FUNCTIONING PROPERLY. IT
HAS BEEN IMPOSSIBLE TO ISOLATE INDIVIDUAL MODULES FOR REPAIRS (THE ENTIRE
SYSTEM WOULD HAVE TO BE SHUT DOWN IF REPAIRS WERE REQUIRED ON ONLY ONE
MODULE).
THE UNIT IS NOW CONSIDERED TO BE OPERATING COMMERCIALLY. OPERATIONS HAVE
BEEN SATISFACTORY. DEPENDING ON THE LIGNITE BURNED THE SCRUBBER CAN BE
OPERATED WITH ONLY FOUR OR SIX TOWERS ON LINE AND STILL BE IN COMPLIANCE.
THERE HAVE BEEN PROBLEMS WITH THE PH METERS. THE METERS HAVE NOT OPERATED
PROPERLY FOR SOME TIME NOW.
THE UTILITY HAS GENERALLY ONLY HAD TO PERFORM GENERAL MAINTENANCE ON THE
SCRUBBER TOWERS.
8/78 SYSTEM 744
9/78 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
ISOLATION DAMPER PROBLEMS CONTINUED.
THE UNIT CONTINUES TO REQUIRE EXCESSIVE MAINTENANCE. FGD SYSTEM ACCEPT-
ANCE TEST WERE PERFORMED BY THE UTILITY DURING AUGUST. RESULTS ARE NOT
YET AVAILABLE.
FLOt-l MEASUREMENT INSTRUMENTATION H^S BEEN FAILING.
624
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
TEXAS 'JTILITIES: MARTIN LAKE 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
OPACITY HAS OCCASIONALLY BEEN HIGHER THAN EXPECTED (20-25X) RESULTING FROM
ESP PROBLEMS.
10/78 SYSTEM 744
11/78 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
NO FGD SYSTEM PROBLEMS WERE REPORTED FOR THE OCTOBER-NOVEMBER PERIOD.
OUTAGES ARE PRIMARILY A RESULT OF ESP PROBLEMS. THE UTILITY IS RELUCTANT
TO OPERATE SCRUBBERS WHEN THE ESP SHOWS HIGH OPACTIY FOR FEAR OF PLUGGING
PROBLEMS.
12/78 SYSTEM 744
1/79 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM MAS SHUT DOWN WHILE THE BOTTOM ASH POND WAS CLEANED OUT.
THE UTILITY HAS BEEN DUMPING SLUDGE INTO THE BOTTOM ASH POND WHICH WAS
DESIGNED FOR BOTTOM ASH ONLY. ALSO SLUDGE IS PRODUCED FASTER THAN IT CAN
BE REMOVED BY RAIL CAR. THE ACTUAL PROBLEM IS REPORTEDLY IN THE DEWATER-
INS SYSTEM. HEAVY RAIN FALL HAS AGGREVATED THE SLUDGE DISPOSAL PROBLEM
BY FOULING THE THICKENER OPERATIONS AND BY THREATENING POND OVERFLOW.
SOME MIST ELIMINATOR WASH PROBLEMS WERE ENCOUNTERED.
THE FGD SYSTEM REPORTEDLY FUNCTIONED ACCEPTABLY WHEN OPERATED DURING
DECEMBER AND JANUARY.
COAL HANDLING WAS A SERIOUS PROBLEM DUE TO FREEZING OF THE COAL IN THE
HOPPERS. THIS PROBLEM EFFECTED ALL UNITS AT MARTIN LAKE FORCING THE
UTILITY'S GAS AND OIL UNITS TO CARRY THE POWER LOAD. ALL OF THE MARTIN
LAKE UNITS WERE DOWN FOR AN EXTENDED PERIOD IN LATE JANUARY.
THERE IS EVIDENCE THAT THE SULFUR CONTENT IN THE COAL IS INCREASING AS THE
MATERIAL IS MINED DEEPER. IF THE SULFUR CONTENT CONTINUES TO INCREASE
ADDITIONAL SCRUBBER TOWERS MAY HAVE TO BE INSTALLED.
2/79 SYSTEM 672
3/79 SYSTEM 744
4/79 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
UNIT 1 IS NOW IN FULL OPERATION ALTHOUGH A SLUDGE DISPOSAL PROBLEM STILL
EXISTS.
THE UTILITY HAS REPLACED THE LOUVER DAMPERS WITH GUILLOTINE DAMPERS WHICH
SEEM TO WORK BETTER. HOWEVER, THEY STILL HAVE PROBLEMS WITH THE GUIL-
LOTINE DAMPERS FAILING TO SEAL WHEN THEY BECOME SCALED.
THERE HAVE BEEN REPORTS OF TOWER LEAKS RESULTING FROM LINER FAILURE BUT
THE PROBLEM IS NOT SERIOUS.
5/79 SYSTEM 744
6/79 SYSTEM 720
625
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
TEXAS UTILITIES: MARTIN LAKE i (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
502 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE SLUDGE DISPOSAL SYSTEM IS STILL CAUSING SOME OPERATING PROBLEMS. THE
PROBLEMS REPORTED LAST QUARTER WERE CAUSED BY HEAVY RAINS WHICH FORCED
THE THICKENERS OUT OF SERVICE.
THE FGD SYSTEM OPERATED THROUGHOUT MOST OF THE REPORT PERIOD.
7/79 SYSTEM 744
8/79 SYSTEM 744
9/79 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
ENGINEERING WORK IS IN PROGRESS TO ADD TWO NEW SCRUBBING TOWERS TO EACH
MARTIN LAKE UNIT. THIS IS BEING DONE FOR THREE REASONS:
1) THE LIGNITE CURRENTLY DELIVERED HAS A GREATER SULFUR CONTENT THAN
THAT FOR WHICH THE FGD SYSTEM WAS ORIGINALLY DESIGNED.
2) THE BOILER FLUE GAS FLOW IS GREATER THAN THAT FOR WHICH THE FGD
SYSTEM WAS ORIGINALLY DESIGNED.
3) AS A RESULT OF CURRENT FGD SYSTEM MAINTENANCE REQUIREMENTS THE
UTILITY FEELS IT IS BEST THAT ONE SPARE MODULE BE AVAILABLE SO THAT
AT LEAST ONE CAN BE DOWN FOR CLEANING AT ALL TIMES.
THE TWO NEW TOWERS FOR EACH UNIT WILL BE DESIGNED FOR A LARGER CAPACITY
THAN THE ORIGINAL TOWERS.
DURING THE THIRD QUARTER THE UTILITY REPORTED THE SYSTEM OPERATED WELL.
HOWEVER EXCESSIVE MAINTENANCE WAS REQUIRED. THE SLUDGE DISPOSAL SYSTEM
PROBLEMS PLAGUING THE UNIT HAVE BEEN SOLVED.
10/79 SYSTEM 744
11/79 SYSTEM 720
12/79 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
PLUGGING PROBLEMS HAVE BEEN ENCOUNTERED DURING THE FOURTH QUARTER REQUIRING
HEAVY MAINTENANCE.
1/80 SYSTEM 744
2/80 SYSTEM 696
3/80 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
PLUGGING PROBLEMS CONTINUED IN THE FIRST QUARTER OF 1980, PARTICULARLY IN
THE WETTED FILM CONTACT AREA AND THE MIST ELIMINATOR SECTION. THE
MIST ELIMINATOR PLUGGING WAS RECENTLY SOLVED BY SWITCHING BACK TO LAKE
WATER FOR MIST ELIMINATOR WASH FROM AN ASH POND WATER WASH THE UTILITY
HAD BEEN TESTING.
THE FRP STRUCTURAL WORK IS BECOMING A PROBLEM. MUCH OF THE FRP SUPPORT
WORK HAS HAD TO BE REPLACED WITH STAINLESS STEEL.
THE UTILITY HAS PLANS TO INSTALL TWO NEW SCRUBBING TOWERS IN EARLY 1982.
THE NEW TOWERS HAVE BECOME NECESSARY DUE TO THE INCREASING LIGNITE
SULFUR CONTENT AND THE NEED FOR SPARE SCRUBBER CAPACITY.
626
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
TEXAS UTILITIES: MARTIN LAKE i (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
4/80 SYSTEM 720
5/80 SYSTEM 744
6/80 SYSTEM 720
*» PROBLEMS/SOLUTIONS/CCflMENTS
HIGH hAINTENANCE PROBLEMS REPORTED IN PREVIOUS MONTHS CONTINUED THROUGHOUT
THE SECOND QUARTER OF 1980. THE ABSORBERS ARE STILL EXPERIENCING PLUGGING
PROBLEMS.
7/80 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
CORROSION IN THE SCRUBBER MODULES MAS A PROBLEM DURING JULY.
THE FOUNDATION FOR THE TWO NEW SCRUBBING TOWERS WAS COMPLETED DURING THE
MONTH.
8/80 SYSTEM 744
9/80 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE FGD SYSTEM OPERATED WITHOUT ANY MAJOR
PROBLEMS DURING AUGUST AND SEPTEMBER.
10/80 SYSTEM 744
11/80 SYSTEM 720
12/80 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
NO OPERATIONAL PROBLEMS WERE REPORTED FOR THE MARTIN LAKE 1 FGD SYSTEM
DURING THE FOURTH QUARTER 1980.
627
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC F6D SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NS/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
EOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
EOILER FLUE GAS TEMPERATURE - C
STACk HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUcL DATA
FUEL TYPE
FJEl GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - •/.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RiNGE SULFUR CONTENT - 7.
A/ERAGE CHLORIDE CONTENT - 7.
R\NGE CHLORIDE CONTENT - 7.
*** PA'JTICLE CONTROL
** ESP
NUMBER
TYPE
SUPPLIER
Ih LET FLUE 6AS CAPACITY - CU.M/S
IKLET FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
PARTICLE REMOVAL EFFICENCY - 7.
** PARTICLE SCRUBBER
GENERIC TYPE
SPECIFIC TYPE
*** FGD SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
UNIT DESIGN S02 REMOVAL EFFICIENCY - 7.
CURRENT STATUS
INITIAL START-UP
TEXAS UTILITIES
MARTIN LAKE
Z
TATUM
TEXAS
B
43.
516.
******
3000
793
750
760
595
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
( .100 LB/MMBTU)
( 1.200 LB/MMBTU)
<****** LB/MMBTU)
(3167000 ACFM)
( 335 F)
(**** FT)
(***** FT)
( 7380 BTU/LB)
6972-7894
168.3
******
******
*******
COAL
LIGNITE
17166.
8.00
5.6-13.2
33.00
29.0-37.9
.90
0.5-1.5
********
******
COLD SIDE
RESEARCH-COTTRELL
1494.5 (3167000 ACFM)
168.3 ( 335 F)
.5 ( 2. IN-H20)
99.4
NONE
N/A
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
NONE
RESEARCH-COTTRELL
C.T. MAIN
FULL SCALE
NEW
7. 99.40
71.00
1
5/78
628
-------
TEXAS UTILITIES: MARTIN LAKE 2 (CONT.)
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
** DESIGN AND OPERATING PARAMETERS
** ABSORBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
GAS CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
GAS-SIDE PRESSURE DROP - KPA
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
S02 REMOVAL EFFICIENCY - X
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
TWADE NAME/COMMON TYPE
CONFIGURATION
NJMBER OF STAGES
NJM3ER OF PASSES PER STAGE
PRESSURE DROP - KPA
SJPERFICAL GAS VELOCITY - M/S
CONSTRUCTION MATERIAL GENERIC TYPE
W4SH WATER SOURCE
WASH RATE - L/S
** REHEATER
GENERIC TYPE
SPECIFIC TYPE
TSADL NAME/COMMON TYPE
PERCcNT GAS BYPASSED - AVG
TOlf ERATURE INCREASE - C
I.1LET FLUE GAS FLOW RATE - CU. M/S
INLET FLUE GAS TEMPERATURE - C
** FANS
NUMBER
FUNCTION
APPLICATION
SIRVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
#* TAUKS
SF.RVICE
AKSORBER FEED
qiJENCHER SUMP
** PUMPS
SERVICE
QUENCHER FEED PUMP
SLJRRY FEED
ABSORBER RECIRCULATIOH
** SOLIDS CONCENTRATING/DEWATERIN6
DE/ICE
NUilBER
FEl:D STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
COMBINATION
SPRAY/PACKED
RESEARCH-COTTRELL
28 DIA. X ZOO TALL
CARBON STEEL
AISI 1110
N/A
2 FT WETTED FILM CONTACTOR (MUNTERS PACKING)
4
1.1 C 4.5 IN-HaO)
177.13 ( 375350 ACFM)
162.8 ( 325 F)
95.0
MIST ELIMINATOR
12
IMPINGEMENT
BAFFLE
CHEVRON VANE
HORIZONTAL
2
3
.2 ( 1.0 IN-H20)
2.4 ( 8.0 FT/S)
POLYPROPYLENE
ASH POND RETURN WATER
7.9 ( 126 GAL/MIN)
BYPASS
COLD SIDE
N/A
25.0
22.2 ( 72 F)
144.17 ( 305500 ACFM)
57.2 ( 135 F)
BALANCED DRAFT
BOILER I.D.
DRY
375.48
168.3
C 795680 ACFM)
( 335 F)
NUMBER
3
6
NUMBER
***«
****
54
CENTRIFUGE
3
35X SOLIDS
69X SOLIDS
629
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
TEXAS UTILITIES: MARTIN LAKE z (CONT.)
** SOLIDS CONCENTRATING/DEWATERING
DEVICE THICKENER
NUMBER 1
DIMENSIONS - FT 140 (DIA) X 1Z (DEPTH)
FEED STREAM CHARACTERISTICS 15X SOLIDS
OUTLET STREAM CHARACTERISTICS 35X SOLIDS
*** SLUDGE
** TREATMENT
METHOD FLYASH STABILIZATION
** DISPOSAL
NATURE FINAL
TYPE LANDFILL
LOCATION ON SITE
SITE TRANSPORTATION METHOD RAIL
** PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS PH, LIQUID LEVEL, LIQUID & GAS FLOW
** WATER BALANCE
WATER LOOP TYPE CLOSED
MAKEUP WATER ADDITION - LITERS/S 34.6 ( 550 6PM)
** FGD SPARE CAPACITY INDICES
ABSORBER - X .0
** FGD SPARE COMPONENT INDICES
ABSORBER .0
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
5/78 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT BEGAN OPERATIONS IN MAY 1978. THE COMPLIANCE TESTING IS SCHEDUL-
ED FOR AUGUST.
6/78 SYSTEM 730
7/78 SYSTEM 744
8/78 SYSTEM 744
9/78 SY STEM 720
#* PROBLEMS/SOLUTIONS/COtlMENTS
THE FGD SYSTEM WAS TESTED FOR COMPLIANCE WITH ALL SIX MODULES IN THE GAS
STREAM DURING THE FIRST PART OF AUGUST. TEST RESULTS HAVE NOT YET BEEN
PUBLISHED. NO NAJOR FGD-RELATED PROBLEMS WERE REPORTED.
THE ESP PROBLEMS AT UNIT 1 HAVE NOT BEEN EXPERIENCED AT THIS UNIT.
10/78 SYSTEM 744
11/78 SYSTEM 720
630
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
TEXAS UTILITIES: MARTIN LAKE 2 tconr.>
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
COMPLIANCE TEST RESULTS ARE STILL BEING REVIEWED AND RESULTS ARE NOT YET
AVAILABLE.
12/78 SYSTEM 744
1/79 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
COAL HANDLING WAS A SERIOUS PROBLEM DUE TO FREEZING OF THE COAL IN THE
HOPPERS. THIS PROBLEM EFFECTED ALL UNITS AT MARTIN LAKE FORCING THE
UTILITY'S GAS AND OIL UNITS TO CARRY THE LOAD. ALL OF THE MARTIN LAKE
UNITS WERE DOWN FOR AN EXTENDED PERIOD IN LATE JANUARY.
THE FGD UNIT REPORTEDLY FUNCTIONED ACCEPTABLY WHEN OPERATED DURING
DECEMBER AND JANUARY.
THE FGD SYSTEM WAS SHUT DOWN WHILE THE BOTTOM ASH POND WAS CLEANED OUT.
THE UTILITY HAS BEEN DUMPING SLUDGE INTO THE BOTTOM ASH POND WHICH WAS
DESIGNED FOR BOTTOM ASH ONLY. ALSO SLUDGE IS PRODUCED FASTER THAN IT CAN
BE REMOVED BY RAIL CAR. THE ACTUAL PROBLEM IS REPORTEDLY IN THE DEWATER-
ING SYSTEM. HEAVY RAIN FALL HAS AGGREVATED THE SLUDGE DISPOSAL PROBLEM
BY FOULING THE THICKENER OPERATIONS AND BY THREATENING POND OVERFLOW.
SOME MIST ELIMINATOR PROBLEMS WERE ENCOUNTERED DURING DECEMBER AND
JANUARY.
THERE IS EVIDENCE THAT THE SULFUR CONTENT IN THE COAL IS INCREASING AS
THE MATERIAL IS MINED DEEPER. IF THE SULFUR CONTENT CONTINUES TO INCREASE
ADDITIONAL SCRUBBER TOWERS MAY HAVE TO BE INSTALLED.
2/79 SYSTEM 672
3/79 SYSTEM 744
4/79 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTS THAT OPERATIONAL PROBLEMS HAVE INCLUDED ABSORBER
LINER FAILURES AND TOWER LEAKS.
UNIT 2 IS NOW IN FULL OPERATION ALTHOUGH A SLUDGE DISPOSAL PROBLEM STILL
EXISTS.
THE UTILITY HAS REPLACED THE LOUVER DAMPERS WITH GUILLOTINE DAMPERS WHICH
SEEM TO WORK BETTER. HOWEVER, THEY STILL HAVE PROBLEMS WITH THE GUIL-
LOTINE DAMPERS FAILING TO SEAL WHEN THEY BECOME SCALED.
5/79 SYSTEM 744
6/79 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE SLUDGE DISPOSAL SYSTEM IS STILL CAUSING SOME OPERATING PROBLEMS. THE
PROBLEMS REPORTED LAST QUARTER WEfiE CAUSED BY HEAVY RAINS WHICH FORCED
THE THICKENERS OUT OF SERVICE.
THE FGD SYSTEM OPERATED THROUGHOUT MOST OF THE PERIOD.
7/79 SYSTEM 744
631
-------
EPA U1ILITY FSD SURVEY: OCTOBER - DECEMBER 1980
TEXAS UTILITIES: MARTIN LAKE z (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
8/79 KYSTEM 744
9/79 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
ENGINEERING WORK IS IN PROGRESS TO ADD TWO NEW SCRUBBING TOWERS TO EACH
MARTIN LAKE UNIT. THIS IS BEING DONE FOR THREE REASONS:
1) THE LIGNITE CURRENTLY DELIVERED HAS A GREATER SULFUR CONTENT THAN
THAT FOR WHICH THE FGD SYSTEM WAS ORIGINALLY DESIGNED.
2) THE BOILER FLUE GAS FLOW IS GREATER THAN THAT FOR WHICH THE FGD
SYSTEM WAS ORIGINALLY DESIGNED.
3) AS A RESULT OF CURRENT FGD SYSTEM MAINTENANCE REQUIREMENTS THE
UTILITY FEELS IT IS BEST THAT ONE SPARE MODULE BE AVAILABLE SO THAT
AT LEAST ONE CAN BE DOWN FOR CLEANING AT ALL TIMES.
THE TWO NEW TOWERS FOR EACH UNIT WILL BE DESIGNED FOR A LARGER CAPACITY
THAN THE ORIGINAL TOWERS.
DURING THE THIRD QUARTER THE UTILITY REPORTED THE SYSTEM OPERATED WELL.
HOWEVER EXCESSIVE MAINTENANCE WAS REPORTED. THE SLUDGE DISPOSAL SYSTEM
PROBLEMS PLAGUING THE UNIT WERE SOLVED.
10/79 SYSTEM 744
11/79 SYSTEM 720
12/79 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
PLUGGING PROBLEMS HAVE BEEN ENCOUNTERED DURING THE FOURTH QUARTER REQUIRING
HEAVY MAINTENANCE.
1/80 SYSTEM 744
2/80 SYSTEM 696
3/80 SYSTEM 744
*» PROBLEMS/SOLUTIONS/COMMENTS
PLUGGING PROBLEMS CONTINUED IN THE FIRST QUARTER OF 1980, PARTICULARLY IN
THE WETTED FILM CONTACT AREA AND THE MIST ELIMINATOR SECTION. THE
MIST ELIMINATOR PLUGGING WAS RECENTLY SOLVED BY SWITCHING BACK TO LAKE
WATER FOR MIST ELIMINATOR WASH FROM AN ASH POND WATER WASH THE UTILITY
HAD BEEN TESTING.
THE FRP STRUCTURAL WORK IS BECOMING A PROBLEM. MUCH OF THE FRP SUPPORT
WORK HAS HAD TO BE REPLACED WITH STAINLESS STEEL.
THE UTILITY HAS PLANS TO INSTALL TWO NEW SCRUBBING TOWERS IN EARLY 1983.
THE NEW TOWERS HAVE BECOME NECESSARY DUE TO THE INCREASING LIGNITE SULFUR
CONTENT AND THE NEED FOR SPARE SCRUBBER CAPACITY.
4/80 SYSTEM 720
5/80 SYSTEM 744
6/80 SYSTEM 720
632
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
TEXAS imCITIES: MARTIN LAKE z CCONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
HIGH MAINTENANCE PROBLEMS REPORTED IN PREVIOUS MONTHS CONTINUED THROUGHOUT
THE SECOND QUARTER OF 1980. THE ABSORBERS ARE STILL EXPERIENCING PLUGGING
PROBLEMS.
7/80 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
CORROSION IN THE SCRUBBER MODULES MAS A PROBLEM DURING JULY.
THE FOUNDATION FOR THE TWO NEW SCRUBBING TOWERS WAS COMPLETED DURING THE
MONTH.
8/80 SYSTEM 744
9/80 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE FGD SYSTEM OPERATED WITHOUT ANY MAJOR
PROBLEMS DURING AUGUST AND SEPTEMBER.
10/80 SYSTEM 744
11/80 SYSTEM 720
12/80 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
NO OPERATIONAL PROBLEMS WERE REPORTED FOR THE MARTIN LAKE 2 FGD SYSTEM
DURING THE FOURTH QUARTER 1980.
633
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NATE
UNIT NUMflER
CITY
STATE
REGULATOFY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PUNT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MM
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
SVACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FLEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RA^GE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - V.
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** ESP
NUMBER
TYPE
SUPPLIER
INLET FLUE GAS CAPACITY - CU.M/S
INLET FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
PARTICLE REMOVAL EFFICENCY - 7.
** PARTICLE SCRUBBER
GENERIC TYPE
SPECIFIC TYPE
( .
( 1.
100 LB/MMBTU)
200 LB/MMBTU)
(****** LB/MMBTU)
TEXAS UTILITIES
MARTIN LAKE
3
TATUM
TEXAS
B
516.
******
3000
793
750
760
595
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
149*.51 (3167000 ACFM)
168.3 ( 335 F)
****** (**** FT)
******* (***** FT)
COAL
LIGNITE
17166.
8.00
5.6-13.2
33.00
29.0-37.9
.90
0.5-1.5
( 7380 BTU/LB)
6972-7894
COLO SIDE
RESEARCH-COTTRELL
1494.5 (3167000 ACFM)
168.3 ( 335 F)
.5 (2. IN-H20)
99.4
NONE
N/A
*** FGD SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
UNIT DESIGN S02 REMOVAL EFFICIENCY - 7.
CURRENT STATUS
INITIAL START-UP
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
NONE
RESEARCH-COTTRELL
C.T. MAIN
FULL SCALE
NEW
7. 99.40
71.00
1
2/79
634
-------
TEXAS UTILITIES: MARTIN LAKE 3 CCONT.)
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
*» DESIGN AND OPERATING PARAMETERS
** ALSORBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
<=AS CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
DISTANCE BETWEEN GAS CONTACTING ZONES
GAS-SIDE PRESSURE DROP - KPA
INLET GAS FLOW - CU. M/S
INLFT GAS TEMPERATURE - C
S02 REMOVAL EFFICIENCY - 7.
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST fLIMINATOR
NUMBER PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
NJMBER OF STAGES
NUMBER OF PASSES PER STAGE
PRESSURE DROP - KPA
SJPERFICAL GAS VELOCITY - M/S
CDNSTRUCTION MATERIAL GENERIC TYPE
WASH WATER SOURCE
WASH RATE - L/S
** REHEATER
GENERIC TYPE
SPECIFIC TYPE
TCADE NAME/COMMON TYPE
PfRCENT GAS BYPASSED - AVG
** FANS
NU1BER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
** TANKS
Sf-.RVICE
ABSORBER FEED
QUENCHER SUMP
** PUMPS
SERVICE
PUMP
QUENCHER FEED
SLURRY FEED
ABSORBER RECIRCULATION
»* SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
DIMENSIONS - FT
COMBINATION
SPRAY/PACKED
RESEARCH-COTTRELL
CARBON STEEL
AISI 1110
N/A
2 FT WETTED FILM CONTACTOR (MUNTERS PACKING)
4
- CM 91.4 ( 36.0IN)
1.1 ( 4.5 IN-H20)
177.13 ( 375350 ACFM)
162.8 ( 325 F)
95.0
MIST ELIMINATOR
12
IMPINGEMENT
BAFFLE
CHEVRON VANE
HORIZONTAL
2
3
.2 ( 1.0 IN-H20)
2.4 ( 8.0 FT/S)
POLYPROPYLENE
ASH POND RETURN HATER
7.9 (126 GAL/MIN)
BYPASS
COLD SIDE
N/A
25.0
BALANCED DRAFT
BOILER I.D.
DRY
375.48
168.3
( 795680 ACFM)
( 335 F)
NUMBER
3
6
NUMBER
***»
54
CENTRIFUGE
3
35X SOLIDS
69X SOLIDS
THICKENER
1
140 (DIA) X 12 (DEPTH)
635
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
TEXAS UTILITIES: HARTIN LAKE 3 ICONT.)
FEED STREAM CHARACTERISTICS 15X SOLIDS
OUTLET STREAM CHARACTERISTICS 35X SOLIDS
*** SLUDGE
** TREATMENT
METHOD FLYASH STABILIZATION
** DISPOSAL
NATURE FINAL
TYPE LANDFILL
LOCATION ON SITE
SITE TRANSPORTATION METHOD RAIL
** PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS PH, LIQUID LEVEL, LIQUID * 6AS FLOW
** FGD SPARE CAPACITY INDICES
ABSORBER - 7. .0
** FGD SPARE COMPONENT INDICES
ABSORBER .0
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
______ __ _„_«. VVAV________ _ — .. -.«,«_____ _ — ____..-. — .-,-> ____«._-,.. — — — _____ —_ — -.-. ___»«. ______ «. — — — — ______
3/79 S' STEM 744
4/79 SI STEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
MARTIN LAKE UNIT 3 BECAME OPERATIONAL DURING MARCH. NO OPERATIONAL DE-
TAILS WERE AVAILABLE.
5/79 SYSTEM 744
6/79 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS IN OPERATION DURING THIS PERIOD ALTHOUGH OPERATIONAL DATA
WERE NOT AVAILABLE.
THE SLUDGE DISPOSAL SYSTEM IS EXPERIENCING SOME OPERATIONAL PROBLEMS.
7/79 SYSTEM 744
8/79 SYSTEM 744
9/79 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
ENGINEERING WORK IS IN PROGRESS TO ADD TWO NEW SCRUBBING TOWERS TO EACH
MARTIN LAKE UNIT. THIS IS BEING DONE FOR THREE REASONS:
1) THE LIGNITE CURRENTLY DELIVERED HAS A GREATER SULFUR CONTENT THAN
THAT FOR WHICH THE FGD SYSTEM WAS ORIGINALLY DESIGNED.
2) THE BOILER FLUE GAS FLOW IS GREATER THAN THAT FOR WHICH THE FGD
SYSTEM WAS ORIGINALLY DESIGNED.
3) AS A RESULT OF CURRENT FGD SYSTEM MAINTENANCE REQUIREMENTS THE
UTILITY FEELS IT IS BEST THAT ONE SPARE MODULE BE AVAILABLE SO THAT
AT LEAST ONE CAN BE DOWN FOR CLEANING AT ALL TIMES.
THE TWO NEW TOWERS FOR EACH UNIT WILL BE DESIGNED FOR A LARGER CAPACITY
THAN THE ORIGINAL TOWERS.
636
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
TEXAS UTILITIES: MARTIN LAKE 3 CCONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION '/. REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
DURING THE THIRD QUARTER THE UTILITY REPORTED THAT THE FGO SYSTEM OPERATED
WITHOUT ANY MAJOR OPERATIONAL PROBLEMS, HOWEVER, EXCESSIVE MAINTENANCE WAS
REQUIRED. THE SLUDGE DISPOSAL PROBLEMS PLAGUING THE UNIT HAVE BEEN SOLVED.
10/79 SYSTEM 744
11/79 SYSTEM 720
12/79 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
PLUGGING PROBLEMS HAVE BEEN ENCOUNTERED DURING THE FOURTH QUARTER REQUIRING
HEAVY MAINTENANCE.
1/80 SYSTEM 744
2/80 SYSTEM 696
3/80 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
PLUGGING PROBLEMS CONTINUED IN THE FIRST QUARTER OF 1980, PARTICULARLY IN
THE WETTED FILM CONTACT AREA AND THE MIST ELIMINATOR SECTION. THE
MIST ELIMINATOR PLUGGING WAS RECENTLY SOLVED BY SWITCHING BACK TO LAKE
WATER FOR MIST ELIf'NATOR WASH FROM AN ASH POND WATER WASH THE UTILITY
HAD BEEN TESTING.
THE FRP STRUCTURAL WORK IS BECOMING A PROBLEM. MUCH OF THE FRP SUPPORT
WORK HAS HAD TO BE REPLACED WITH STAINLESS STEEL.
THE UTILITY HAS PLANS TO INSTALL TVO NEW SCRUBBING TOWERS IN EARLY 1983.
THE NEW TOWERS HAVE BECOME NECESSARY DUE TO THE INCREASING LIGNITE SULFUR
CONTEMT AND THE NEED FOR SPARE SCRUBBER CAPACITY.
4/80 S", STEM 720
5/80 SKSTEM 744
6/80 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
HIGH MAINTENANCE PROBLEMS REPORTED IN PREVIOUS MONTHS CONTINUED THROUGHOUT
THE SECOND QUARTER OF 1980. THE ABSORBERS ARE STILL EXPERIENCING PLUGGING
PROBLEMS.
7/80 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
CORROSION IN THE SCRUBBER MODULES WAS A PROBLEM DURING JULY.
THE FOUNDATION FOR THE TWO NEW SCRUBBING TOWERS WAS COMPLETED DURING THE
MONTH.
8/80 SYSTEM 744
9/80 SYSTEM 720
637
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
TEXAS UTILITIES: MARTIN LAKE 3 ICONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION '/. REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE F6D SYSTEM OPERATED WITHOUT ANY MAJOR
PROBLEMS DURING AUGUST AND SEPTEMBER.
10/80 SYSTEM 744
11/80 SYSTEM 720
12/80 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
NO OPERATIONAL PROBLEMS WERE REPORTED FOR THE MARTIN LAKE 3 FGD SYSTEM
DURING THE FOURTH QUARTER 1980.
638
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MM
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGD - MM
EQUIVALENT SCRUBBED CAPACITY - MM
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - X
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
*** PARTICLE CONTROL
** ESP
NUMBER
TYPE
SUPPLIER
INLET FLUE GAS CAPACITY - CU.M/S
INLET FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
PARTICLE REMOVAL EFFICENCY - X
** PARTICLE SCRUBBER
GENERIC TYPE
SPECIFIC TYPE
*** FGD SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAMAY PRODUCT
S92 REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
SCSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NTW/PETROFIT
U.«T DESIGN PARTICLE REMO/AL EFFICIENCY
UNIT DESIGN S02 REMOVAL EFFICIENCY - X
CURKHNT STATUS
COMf.ERCIAL START-UP
TEXAS UTILITIES
MONTICELLO
3
MT. PLEASANT
TEXAS
B
43.
516.
( .100 LB/MMBTU)
( 1.200 LB/MMBTU)
(****** LB/MMBTU)
1900
800
750
*****
800
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
1650.71 (3498000 ACFM)
( 335 F)
(**** FT)
168.3
******
******
(***** FT)
(****** BTU/LB)
6500-7500
COAL
LIGNITE
******
18.90
******
31.90
******
1.50
******
.04
COLD SIDE
C.E. WALTHER
1650.7
168.3
.4
99.5
NONE
N/A
THROWAHAY PRODUCT
WET SCRUBBING
LIMESTONE
NONE
CHEMICO DIVISION, ENVIROTECH
C.T. MAIN
FULL SCALE
NEW
X 99.50
74.00
1
10/78
(3498000 ACFM)
( 335 F)
( 2. IN-H20)
639
-------
EPA ITILITY FGD SURVEY: OCTOBER - DECEMBER 1980
TEXAS UTILITIES: MONTICELLO 3 (CONT.)
INITIAL START-UP
** DESIGN AND OPERATING PARAMETERS
** ABSORBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
SH'ILL GENERIC MATERIAL
SHLLL SPECIFIC MATERIAL
SHE'LL MATERIAL TRADE NAME/COMMON TYPE
LIIIER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
NUMBER OF CONTACTING ZONES
LIQUID RECIRCULATION RATE - LITER/S
L/G RATIO - L/CU.M
GAS-SIDE PRESSURE DROP - KPA
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
S02 REMOVAL EFFICIENCY - 7.
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES PER STAGE
SUPERFICAL GAS VELOCITY - M/S
CONSTRUCTION MATERIAL GENERIC TYPE
WASH WATER SOURCE
WASH RATE - L/S
** REHEATER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
TEMPERATURE INCREASE - C
INLET FLUE GAS FLOW RATE - CU. M/S
INLET FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** FANS
NUMBER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
** TANKS
SERVICE
LIMESTONE SLURRY
RECYCLE
** PUMPS
SERVICE
ABSORBER RECIRCULATION
SLURRY FEED
5/78
SPRAY TOWER
OPEN COUNTERCURRENT SPRAY
CHEMICO DIVISION, ENVIROTECH
CARBON STEEL
AISI 1110
N/A
INORGANIC , ORGANIC
HYDRAULICALLY BOND ED -CEMENT, GLASS-FLAKE FILLED
PRE-KRETE 6-8.CEILOTE 103.CEILCRETE 2500AR
4
4000. (63*90 GPM)
9.4 ( 70.0 GAL/1000 ACF)
( 5.0 IN-H20)
( 907000 ACFM)
( 141 F)
1.2
428.01
60.6
74.0
( 10.0 FT/S)
MIST ELIMINATOR
3
IMPINGEMENT
BAFFLE
CHEVRON VANE
HORIZONTAL
1
4
3.0
POLYPROPYLENE
FRESH WATER BLENDED WITH FLY ASH POND RETURN
7.9 (126 GAL/MIN)
INDIRECT HOT AIR
EXTERNAL HEAT EXCHANGER
STEAM TUBE BUNDLES
-7.8 ( 18 F)
856.03 (1814000 ACFM)
60.6 ( 141 F)
CARBON STEEL
BALANCED DRAFT
BOILER I.D.
DRY
539.38
168.3
(1143000 ACFM)
( 335 F)
NUMBER
****
****
NUMBER
3
****
*** SLUDGE
640
-------
TEXAS UTILITIES: MONTICELLO 3 (CONT.)
EPA UTILITY KGD SURVEY: OCTOBER - DECEMBER 1980
** TREATMENT
MFTHOD
** DISPOSAL
NATURE
TVPE
LOCATION
** WATER BALANCE
WMTER LOOP TYPE
MAKEUP WATER ADDITION - LITERS/S
** FGD SPARE CAPACITY INDICES
ABSORBER - 7.
** F6D SPARE COMPONENT INDICES
ABSORBER
FLYASH STABILIZATION
FINAL
LANDFILL
ON SITE
CLOSED
34.4
.0
.0
( 546 6PM)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
4/78 SYSTEM
5/78 SYSTEM
720
744
** PROBLEMS/SOLUTIONS/COMMENTS
THE TEXAS AIR CONTROL BOARD REPORTED THAT THE TEXAS UTILITIES 750 MW
MONTICELLO UNIT 3 BEGAN FGD OPERATIONS DURING EARLY MAY. AS OF YET THE
UNIT HAS NOT RUN AT FULL LOAD BUT IS EXPECTED TO DO SO BY THE END OF
AUGUST.
6/78 SYSTEM
7/78 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
720
744
THE UNIT IS NOT AT FULL LOAD YET. THE UNIT IS OPERATING AT NO MORE THAN
A 300 MW LOAD (OF THE 750 MW TOTAL). ONE OF THE THREE FGD MODULES IS
FULLY OPERATIONAL. ANOTHER ONE IS PARTIALLY OPERATIONAL, WHILE THE THIRD
IS NOT OPERATING AT ALL.
8/78 SYSTEM
9/78 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
744
720
THE COMPLIANCE TEST HAS NOT YET TAKEN PLACE. THE FGD SYSTEM IS OPERATION-
AL. INSTRUMENTATION INDICATES THAT THE UNIT IS IN COMPLIANCE.
10/78 SYSTEM
11/78 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
744
720
12/78 SYSTEM
CONTINUOUS NOX, 02, AND S02 MONITORS ARE A PROBLEM AREA.
THE SLUDGE IS CURRENTLY NOT FIXATED. IT IS BEING PUMPED DIRECTLY TO THE
POND.
THE FGD SYSTEM IS FULLY OPERATIONAL. A PRELIMINARY TEST WAS PERFORMED ON
DECEMBER 14. RESULTS OF THE TEST ARE NOT YET AVAILABLE.
744
641
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
TEXAS UTILITIES: MONTICELLO 3 CCONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPFRABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
1/79 SYSTEM 744
** PROBLEMS/SOLUTIONS/C01IMENTS
THE FGO SYSTEM REPORTEDLY HAS BEEN PERFORMING WELL.
THE ESP IS NOT OPERATING WELL. COLLECTION EFFICIENCY IS UNEXPECTEDLY
LOW. AMMONIA INJECTION HAS BEEN TRIED TO IMPROVE REMOVAL EFFICIENCY.
THE PROBLEM REPORTEDLY IS THE RESULT OF STRUCTURAL DAMAGE. THE UNIT DID
NOT PASS THE EPA OPACITY TEST.
2/79 SYSTEM 672
3/79 SYSTEM 744
4/79 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT IS CURRENTLY DOWN FOR A SCHEDULED OVERHAUL. THE TOWERS HAVE
BEEN INSPECTED AND NO SCALING WAS FOUND.
SOME MINOR RECYCLE PUMP LINER PROBLEMS HAVE BEEN REPORTED.
DUE TO HIGH ASH LEVELS SOME PLATES IN THE ESP WERE FORCED OUT OF
ALIGNMENT CAUSING AN OPACITY PROBLEM.
THE NEXT COMPLIANCE TEST IS SCHEDULED FOR THE MEEK OF JUNE 18.
5/79 SYSTEM 744
6/79 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS IN OPERATION DURING THIS PERIOD ALTHOUGH OPERATIONAL DATA
MERE NOT AVAILABLE.
7/79 SYSTEM 744
8/79 SYSTEM 744
9/79 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE ESP WAS REBUILT AND SINCE THE INITIATION OF GAS CONDITIONING WITH
AMMONIA THE OPACITY PROBLEM HAS BEEN MINIMIZED.
DURING THE THIRD QUARTER THE UNIT OPERATED WITHOUT ANY MAJOR PROBLEMS.
SOME MINOR ABSORBER RECYCLE PUMP LINER FAILURES HAVE BEEN ENCOUNTERED.
10/79 SYSTEM 744
11/79 SYSTEM 720
12/79 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
NO PROBLEMS HAVE BEEN ENCOUNTERED DURING THE FOURTH QUARTER. SINCE GAS
CONDITIONING WITH AMMONIA BEGAN, THE OPACITY HAS BEEN ACCEPTABLE.
1/80 SYSTEM 744
642
-------
EPA UTILITY FGO SURVEY: OCTOBER - DECEMBER 1980
TEXAS UTILITIES: MONTICELLO 3 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
2/80 SYSTEM 696
3/80 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
NO PROBLEMS WERE ENCOUNTERED DURING THE FIRST QUARTER OF 1980.
4/80 SYSTEM 720
5/80 SYFTEM 744
6/80 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE MfNTICELLO 3 SCRUBBING SYSTEM PERFORMED WELL THROUGHOUT THE SECOND
QUARTER OF 1980. THE TEXAS AIR CONTROL BOARD REPORTED THAT IT HAD RECEIVED
VERY FEW EXCESS EMISSIONS REPORTS FROM THE STATION DURING THE APRIL-JUNE
PERIOD.
7/80 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED DURING JULY.
8/80 SYSTEM 744
9/80 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE RECYCLE PUMP LININGS HAVE BEEN A CONTINUAL
PROBLEM DURING AUGUST AND SEPTEMBER. AT ONE TIME DURING THE TWO MONTH
PERIOD THREE RECYCLE PUMP LINERS FAILED.
THE FGD SYSTEM HAS REPORTEDLY PERFORMED WELL AND IS IN COMPLIANCE MORE
THAN 95X OF THE TIME.
10/80 SYSTEM 744
11/80 SYSTEM 720
12/80 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE MONTICELLO 3 FGD SYSTEM CONTINUED TO OPERATE DURING THE FOURTH
QUARTER 1980 WITH NO MAJOR OPERATIONAL PROBLEMS REPORTED FOR THE THREE
MONTH PERIOD.
643
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
SOS EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/F6D - MW
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
EOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FLEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGF HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANFE ASH CONTENT - 7.
AVEf'AGE MOISTURE CONTENT - X
R4.NCJE MOISTURE CONTENT - 7.
AVEPAGE SULFUR CONTENT - 7.
RANCE SULFUR CONTENT - Y.
AVERAGE CHLORIDE CONTENT - '/.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** ES!>
NUMBER
SUPPLIER
T4LET FLUE GAS CAPACITY - CU.M/S
INLET FLUE GAS TEMPERATURE - C
** PARTICLE SCRUBBER
G'NERIC TYPE
SPECIFIC TYPE
*** FGn SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAKAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-5 FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
UNIT DESIGN S02 REMOVAL EFFICIENCY - 7.
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
( .100 LB/MMBTU)
( 1.200 LB/MMBTU)
(****** LB/MMBTU)
UTAH POWER & LIGHT
HUNTER
1
CASTLE DALE
UTAH
B
43.
516.
******
*****
400
400
*****
360
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
822.05 (1742000 ACFM)
130.0 « 266 F)
183. ( 600 FT)
CONCRETE
7.3 ( 24.0 FT)
( 12500 BTU/LB)
12,200 - 12,700
COAL
BITUMINOUS
29075.
10.00
9-12
6.50
.55
.00
******
BUELL DIVISION, ENVIROTECH
886.2 (1878000 ACFM)
127.6 ( 262 F)
NONE
N/A
THROWAWAY PRODUCT
WET SCRUBBING
LIME
NONE
CHEMICO DIVISION, ENVIROTECH
STEARNS-ROGER
FULL SCALE
NEW
7. 99.50
80.00
1
5/79
5/79
4/76
644
-------
UTAH POWER i LIGHT: HUNTER 1 (CONT.)
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
** DESIGN AND OPERATING PARAMETERS
** ABSORBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
NUMBER OF CONTACTING ZONES
L/G RATIO - L/CU.M
GAS-SIDE PRESSURE DROP - KPA
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
S02 REMOVAL EFFICIENCY - X
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES PER STAGE
FREEBOARD DISTANCE - M
SUPERFICAL GAS VELOCITY - M/S
CONSTRUCTION MATERIAL GENERIC TYPE
** REHEATER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
TEMPERATURE INCREASE - C
INLET FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** FANS
NUMBER
SJPP..IER
FUNCiION
APPLICATION
SER< ICE
FLUE: GAS FLOW RATE - CU.M/,3
FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENFRIC TYPE
** PU.1PS
SERVICE
ABSORBER RECIRCULATION
*** SLUDGE
** TREATMENT
METHOD
** DISPOSAL
NVTUBE
TVPE
LOCATION
SPRAY TOWER
OPEN COUNTERCURRENT SPRAY
CHEMICO DIVISION, ENVIROTECH
CARBON STEEL
AISI 1110
N/A
ORGANIC
GLASS FLAKE-FILLED POLYESTER
FLAKEGLASS
5.7
.6
205.51
130.0
80.0
( 43.0 GAL/1000 ACF)
( 2.5 IN-H20)
( 435500 ACFM)
( 266 F)
MIST ELIMINATOR
4
IMPINGEMENT
BAFFLE
CHEVRON VANE
HORIZONTAL
1
4
3.66
.3
POLYPROPYLENE
(12.0 FT)
( 1.0 FT/S)
INDIRECT HOT AIR
EXTERNAL HEAT EXCHANGER
STEAM TUBE BUNDLES
8.9 ( 48 F)
43.3 ( 110 F)
CARBON STEEL
STURTEVANT TJIV.
BALANCED DRAFT
FORCED DRAFT
DRY
411.02 (
130.0 (
CARBON STEEL
WESTINGHOUSE
671000 ACFM)
266 F)
NUMBER
16
FLYASH STABILIZATION
FINAL
POND
ON SITE
645
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
UTAH POWER * LIGHT: HUNTER 1 (CONT.)
** WATER BALANCE
WATER LOOP TYPE OPEN
«* FGD SPARE CAPACITY INDICES
ABSORBER - X .0
** FGD SPARE COMPONENT INDICES
ABSORBER .0
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
SOS PART. HOURS HOURS HOURS FACTOR
5/79 SYSTEM 78.6 32.8 744 311 244
** PROBLEMS/SOLUTIONS/COMMENTS
INITIAL FGD OPERATIONS BEGAN IN MAY 1979.
THE FIGURES REPORTED BY UTAH POWER AND LIGHT ARE NOT CONSISTENT WITH THE
FIGURES AS DEFINED BY PEDCO FOR THIS REPORT. IN THIS SURVEY "FGD SYSTEM
HOURS" IS THE AVERAGE OF THE MODULAR HOURS ACCUMULATED BY EACH ABSORBER
DURING A GIVEN MONTH. UPSL DEFINES "FGD SYSTEM HOURS" AS ACCUMULATED HOURS
WHEN ANY OR ALL OF THE ABSORBERS IS IN OPERATION DURING A GIVEN MONTH. THE
OPERABILITY AND UTILIZATION FIGURES REPORTED ARE BASED UPON "FGD SYSTEM
HOURS" AS DEFINED BY UPSL AND THEREFORE MAY YIELD DEPENDABILITY FACTORS
THAT ARE NOT COMPARABLE WITH OTHER DEPENABILITY FACTORS INCLUDED IN THIS
SURVEY.
6/79
7/79
8/79
9/79
SYSTEM
SYSTEM
SYSTEM
SYSTEM
98
100
100
100
.0
.0
.0
.0
96.
99.
100.
100.
9
1
0
0
720
744
744
720
713
738
744
720
698
738
744
720
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR OPERATIONAL PROBLEMS WERE REPORTED
DURING THE THIRD QUARTER OF 1979.
10/79
11/79
IS/79
1/80
2/80
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
100
100
100
100
100
.0
.0
.0
.0
.0
95.
91.
98.
95.
86.
6
1
2
9
8
BY THE UTILITY FOR
744
720
744
744
696
711
656
731
713
604
THIS UNIT
711
656
731
713
604
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THERE WERE NO MAJOR FGD PROBLEMS ENCOUNTERED
FROM t'CTOBER 1979 THROUGH FEBRUARY 1980.
3/80 SYSTEM 57.8 56.9 744 732 423
** PROBLEMS/SOLUTIONS/CO1MENTS
THE FGD SYSTEM WAS FORCED OUT OF SERVICE IN MARCH BECAUSE THE THICKENER
RAKE SHAFT FAILED AND THE TANK HAD TO BE DRAINED. THIS OUTAGE KEPT THE
SYSTEM DOWN FOR APPROXIMATELY 309 HOURS.
4/80 SYSTEM 100.0 60.1 720 433 433
5/80 SYSTEM 100.0 64.0 744 476 476
646
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
UTAH POWER i LIGHT: HUNTER 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE LOW FGD HOURS DURING APRIL AND MAY RESULTED FROM THE ANNUAL OUTAGE
FOR GENERAL FGD SYSTEM MAINTENANCE.
6/80 SYSTEM 100.0 97.9 720 705 705
** PROBLEMS/SOLUTIONS/COMMENTS
NO FGD SYSTEM PROBLEMS WERE REPORTED FOR JUNE.
7/80 SYSTEM 100.0 100.0 744 744 744
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR FGD-RELATED PROBLEMS MERE REPORTED DURING JULY.
8/80 SYSTEM 100.0 744 744
9/80 SYSTEM 100.0 720 713
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD PROBLEMS WERE ENCOUNTERED DURING
THE MONTHS OF AUGUST AND SEPTEMBER.
647
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT HAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NS/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MM
GROSS USIT GENERATING CAPACITY - MM
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/F6D - MM
EQUIVALENT SCRUBBED CAPACITY - MM
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOM - CU.M/S
BOILER FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK SHELL
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** ESP
NUMBER
SUPPLIER
INLET FLUE GAS CAPACITY - CU.M/S
INLET FLUE GAS TEMPERATURE - C
** PARTICLE SCRUBBER
GENERIC TYPE
SPECIFIC TYPE
*** FGD SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROMAWAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
UNIT DESIGN 502 REMOVAL EFFICIENCY - 7.
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
UTAH POMER & LIGHT
HUNTER
2
CASTLE DALE
UTAH
B
43.
516.
( .100 LB/MMBTU)
( 1.200 LB/MMBTU)
(****** LB/MMBTU)
*****
400
400
*****
360
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
******** (******* ACFM)
(**** p)
<**** FT)
*******
******
******
*******
COAL
******
29075.
10.00
9-12
6.50
.55
******
(***** FT)
( 12500 BTU/LB)
12,200 - 12,700
******
BUELL DIVISION, ENVIROTECH
886.2 (1878000 ACFM)
127.8 ( 262 F)
NONE
N/A
THROHAMAY PRODUCT
WET SCRUBBING
LIME
CHEMICO DIVISION, ENVIROTECH
STEARNS-ROGER
FULL SCALE
NEM
7. 99.50
80.00
1
6/80
6/80
648
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
UTAH pours s LIGHT: HUNTER z
** DE3IGN AND OPERATING PARAMETERS
** ABSORBER
GHNERIC TYPE
SPECIFIC TYPE
SUPPLIER
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
L:NER GENERIC MATERIAL
LI'NER SPECIFIC MATERIAL
LCNER MATERIAL TRADE NAME/COMMON TYPE
** MIST ELIMINATOR
PUE-MIST ELIMINATOR/MIST ELIMINATOR
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
** REHEATER
GENERIC TYPE
SPECIFIC TYPE
TR4DE NAME/COMMON TYPE
*** SLUICE
** TREATMENT
ME'-HOD
** DISPOSAL
NATURE
TYPE
LOCATION
** MATER BALANCE
WATER LOOP TYPE
SPRAY TOWER
OPEN COUNTERCURRENT SPRAY
CHEMICO DIVISION, ENVIROTECH
CARBON STEEL
AISI 1110
N/A
ORGANIC
GLASS FLAKE-FILLED POLYESTER
FLAKE6LASS
MIST ELIMINATOR
IMPINGEMENT
BAFFLE
CHEVRON VANE
INDIRECT HOT AIR
EXTERNAL HEAT EXCHANGER
N/A
FLYASH STABILIZATION
FINAL
POND
ON SITE
OPEN
, PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
0/80 SYSTEM
»* PROBLEMS/SOLUTIONS/COMMENTS
THE FIGURES REPORTED BY UTAH POWER AND LIGHT ARE NOT CONSISTENT WITH THE
FIGURES AS DEFINED BY PEDCO FOR THIS REPORT. IN THIS SURVEY "FGD SYSTEM
HOURS" IS THE AVERAGE OF THE MODULAR HOURS ACCUMULATED BY EACH ABSORBER
DURING A GIVEN MONTH. UP&L DEFINES "FGD SYSTEM HOURS" AS ACCUMULATED HOURS
WHEN ANY OR ALL OF THE ABSORBERS.IS IN OPERATION DURING A GIVEN MONTH. THE
OPERABILITY AND UTILIZATION FIGURES REPORTED ARE BASED UPON "FGD SYSTEM
HOURS" AS DEFINED BY UP&L AND THEREFORE MAY YIELD DEPENDABILITY FACTORS
THAT ARE NOT COMPARABLE WITH OTHER DEPENDABILITY FACTORS INCLUDED IN THIS
SURVEY.
6/80 SYSTEM 100.0
*# PROBLEMS/SOLUTIONS/COMMENTS
99.5
720 717
717
INITIAL OPERATIONS AT HUNTER Z. BEGAN IN JUNE AND THE FGD SYSTEM WAS DECLAR-
ED COMMERICAL. NO MAJOR STARTUP PROBLEMS WITH THE FGD SYSTEM WERE
ENCOUNTERED.
7/80 SYSTEM
100.0
98.9
744 736
736
649
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
UTAH POWER & LIGHT: HUNTER 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
NO MA-DR FGD-RELATED PROBLEMS WERE REPORTED DURING JULY.
8/80 SYSTEM 99.7 744 743
9/80 SYSTEM 100.0 720 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD PROBLEMS WERE ENCOUNTERED DURING
AUGUST AND SEPTEMBER.
650
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGO SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLWT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MW
NET UNT.T GENERATING CAPACITY W/F6D - MW
NET UN:T GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** UNiT DATA - BOILER AND STACK
BOILER SUPPLIER
B')ILER TYPE
BOILER SERVICE LOAD
D:-:SIGN BOILER FLUE GAS FLOW - CU.M/S
BOILF9 FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STAC< SHELL
STACK TOP DIAMETER - M
** FU1-L 3 AT A
FUJL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
R/NGE HEAT CONTENT - BTU/LB
A\ERAGE ASH CONTENT - V.
R/NGE ASH CONTENT - '/.
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RMNGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - 7.
*** PAkTICLE CONTROL
** ESF
NUMBER
TYPE
SUPPLIER
INLET FLUE GAS CAPACITY - CU.M/S
INLET FLUE GAS TEMPERATURE - C
** PARTICLE SCRUBBER
GENERIC TYPE
SPECIFIC TYPE
*** FGD SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
302 REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
UNIT DESIGN 502 REMOVAL EFFICIENCY - 7.
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
( .100 LB/MMBTU)
( 1.200 LB/MMBTU)
(****** LB/MMBTU)
UTAH POWER & LIGHT
HUNTINGTON
1
PRICE
UTAH
B
43.
516.
******
810
430
400
407
366
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
822.05 (1742000 ACFM)
130.0 ( 266 F)
183. ' ( 600 FT)
CONCRETE
7.3 ( 24.0 FT)
COAL
BITUMINOUS
29075.
10.00
9-12
6.50
******
.55
( 12500 BTU/LB)
12200-12700
********
COLD SIDE
BUELL DIVISION, ENVIROTECH
822.0 (1742000 ACFM)
127.8 ( 262 F)
NONE
N/A
THROWAWAY PRODUCT
WET SCRUBBING
LIME
NONE
CHEMICO DIVISION, ENVIROTECH
STEARNS-ROGER
FULL SCALE
NEW
X 99.50
80.00
1
5/78
5/78
1/75
651
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
UTAH POWER & LIGHT: HUKTINGTON 1 (CONT.)
** DESIGN AND OPERATING PARAMETERS
** ABSORBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
SUPPLIER
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
NUMBER OF CONTACTING ZONES
L/G RATIO - L/CU.M
GAS-SIDE PRESSURE DROP - KPA
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
S02 REMOVAL EFFICIENCY - X
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
C1NFIGURATION
NJMBER OF STAGES
NUMBER OF PASSES PER STAGE
FREEBOARD DISTANCE - M
S'JPERFICAL GAS VELOCITY - M/S
CONSTRUCTION MATERIAL GENERIC TYPE
** REPEATER
G£NEfcIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
TEMPERATURE INCREASE - C
INLET FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** FANS
NUMBER
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
Fi.UE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** TANKS
SERVICE
RECYCLE
** PUMPS
SERVICE
ABSORBER RECIRCULATION
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
OUTLET STREAM CHARACTERISTICS
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
CONFIGURATION
DIMENSIONS - FT
SPRAY TOWER
OPEN COUNTERCURRENT SPRAY
CHEMICO DIVISION, ENVIROTECH
CARBON STEEL
AISI 1110
N/A
ORGANIC
GLASS FLAKE-FILLED POLYESTER
FLAKEGLASS
5.7
.6
205.51
130.0
80.0
( 43.0 GAL/1000 ACF)
( 2.5 IN-H20)
( 435500 ACFM)
( 266 F)
MIST ELIMINATOR
4
IMPINGEMENT
BAFFLE
CHEVRON VANE
HORIZONTAL
1
4
3.66
.3
POLYPROPYLENE
C12.0 FT)
( 1.0 FT/S)
INDIRECT HOI AIR
EXTERNAL HEAT EXCHANGER
STEAM TUBE BUNDLES
8.9 { 48 F)
43.3 ( 110 F)
CARBON STEEL
STURTEVANT DIV., WESTINGHOUSE
BALANCED DRAFT
FORCED DRAFT
DRY
411.02 ( 871000 ACFM)
130.0 ( 266 F)
CARBON STEEL
NUMBER
4
NUMBER
16
VACUUM FILTER
60X SOLIDS
THICKENER
1
CYLINDRICAL
60 DIA
652
-------
EPA UTILITY FGO SURVEY: OCTOBER - DECEMBER 1980
UTAH POWER & LIGHT: HUNTINGTON 1 (CONT.J
SHELL GENERIC MATERIAL TYPE CARBON STEEL
LINER SPECIFIC MATERIAL TYPE GLASS FLAKE-FILLED POLYESTER
OUTLET STREAM CHARACTERISTICS 27.5X SOLIDS
*** SLUDGE
** TREATMENT
METHOD FLYASH STABILIZATION
** DISPOSAL
NATURE FINAL
TYPE LANDFILL
LOCATION ON SITE
SITE TRANSPORTATION METHOD TRUCK
** WATER BALANCE
WATER LOOP TYPE CLOSED
MAKEUP WATER ADDITION - LITERS/S 18.9 ( 300 GPM)
** FGD SPARE CAPACITY INDICES
ABSORBER - 7. .0
** FGD SPARE COMPONENT INDICES
ABSORBER .0
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION '/. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
0/78 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
THE FIGURES REPORTED BY UTAH POWER AND LIGHT ARE NOT CONSISTENT WITH THE
FIGURES AS DEFINED BY PEDCO FOR THIS REPORT. IN THIS SURVEY "FGD SYSTEM
HOURS" IS THE AVERAGE OF THE MODULAR HOURS ACCUMULATED BY EACH ABSORBER
DURING A GIVEN MONTH. UP&L DEFINES "FGD SYSTEM HOURS" AS ACCUMULATED HOURS
WHEN ANY OR ALL OF THE ABSORBERS IS IN OPERATION DURING A GIVEN MONTH. THE
OPERABILITY AND UTILIZATION FIGURES REPORTED ARE BASED UPON "FGD SYSTEM
HOURS" AS DEFINED BY UP&L AND THEREFORE MAY YIELD DEPENDABILITY FACTORS
THAT ARE NOT COMPARABLE WITH OTHER DEPENABILITY FACTORS INCLUDED IN THIS
SURVEY.
5/78 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
INITIAL OPERATIONS BEGAN ON MAY 10, 1978. COMMERCIAL FGD SYSTEM OPERATIONS
ARE EXPECTED TO BEGIN IN JUNE.
6/78 SYSTEM i5.3 65.3 720 720 470
7/78 S'tSTEM 97.7 95.9 744 731 714
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT BECAUSE 10-20X OF THE FLUE GAS BYPASSED THE FGD
SYSTEM AS DAMPERS ARE VARRIED BY THE OPERATOR, IT IS DIFFICULT TO DETERMINE
OVERALL S02 REMOVAL EFFICIENCY.
8/78 SYSTEM 100.0 73.1 744 544 544
9/7S SYSTEM 100.0 68.9 720 496 496
653
-------
EPA UTILITY F6D SURVEY: OCTOBER - DECEMBER 1980
UTAH POWER & LIGHT: HUNTINGTON 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
502 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
AN EXPLOSION CAUSED A THREE WEEK BOILER OUTAGE DURING THE AUGUST-SEPTEMBER
PERIOD.
THE UTILITY REPORTED THAT THERE WERE NO FORCED FGD OUTAGES DURING AUGUST
AND SEPTEMBER.
10/78 SYSTEM 100.0 100.0 744 744 744
11/78 SYSTEM 62.4 62.4 720 720 449
** PROBLEMS/SOLUTIONS/COMMENTS
THE THICKENER HAD SOLIDS BUILDUP THE LAST OF NOVEMBER AND THE FIRST PART
OF DECEMBER RENDERING THE RAKE INOPERATIVE. THE FGD SYSTEM WAS TAKEN OUT
OF SERVICE TO ALLOW MANUAL REMOVAL OF THE SOLIDS.
TO PREVENT FUTURE SOLIDS BUILDUP IN THE THICKENER THE UTILITY IS CONSIDER-
ING LOWERING THE PH AND POSSIBLY ADDING A FORCED OXIDATION SYSTEM. FOR NOW
THE UTILITY IS ATTEMPTING TO BE MORE CONSCIENTIOUS IN MAINTAINING PROPER
SOLIDS CONTENT IN THE THICKENERS.
12/78 SYSTEM 34.0 32.7 744 715 243
1/79 SYSTEM 76.2 65.7 744 642 489
** PROBLEMS/SOLUTIONS/COMMENTS
FREEZE-UP PROBLEMS CAUSED OUTAGES TOTALLING A FEW WEEKS DURATION DURING
DECEMBER AND JANUARY.
2/79 SYSTEM 90.1 58.2 672 434 391
3/79 SYSTEM 100.0 86.6 744 644 644
4/79 SYSTEM 100.0 76.8 720 553 553
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE PROBLEMS ENCOUNTERED DURING FEBRUARY-APRIL
INCLUDED LINING FAILURES (BOTH DESIGN-RELATED AND APPLICATION-RELATED),
PUMP PROBLEMS AND DAMPER PROBLEMS.
PROBLEMS HAVE BEEN EXPERIENCED WITH DAMPER MECHANISMS CLOGGING. THE CLOG-
GING CAN RESULT IN DAMPER LEAKING AS MUCH AS SOX.
THE UTILITY HAS BEEN OPERATING THE FGD SYSTEM AT A PH OF 5 RATHER THAN THE
DESIGN 6.5 TO YIELD A BETTER QUALITY SLUDGE PRODUCT.
5/79 SYSTEM 100.0 92.6 744 689 689
6/79 SYSTEM 62.5 54.9 720 632 395
7/79 SYJTEM 79.7 79.5 744 742 591
8/79 SYSTEM 30.1 27.0 744 669 201
9/79 SYSTEM 54.9 54.2 720 712 391
654
-------
EPA UTILITY FGO SURVEYS OCTOBER - DECEMBER 1980
UTAH P(WEH & LIGHT-' HUNTINGTON 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE PROBLEMS ENCOUNTERED DURING THE THIRD QUARTER 1979 INCLUDED FAILURE
OF CONTROL VALVES AND SOME AGITATOR PROBLEMS.
10/79 SYSTEM 74* 497
** PROBLEMS/SOLUTIONS/COMMENTS
ON OCTOBER 15 FGD OPERATIONS WITH LIMESTONE WERE INITIATED FOR TESTING
PURPOSES. IF THE FGD SYSTEM OPERATIONS ARE ADEQUATE WITH LIMESTONE THE
UTILITY WILL STUDY THE ECONOMIC TRADEOFFS OF LIME VS LIMESTONE SUCH AS
PUMP WEAR ETC. IF THE RESULTS FAVOR LIMESTONE THE HUNTINGTON 1 FGD SYSTEM
PROCESS MAY BE SHIFTED FROM LIME TO LIMESTONE.
11/79 SYSTEM 720 28
12/79 SYSTEM 744 642
1/80 SYSTEM 744 668
»* PROBLEMS/SOLUTIONS/COMMENTS
DUE TO A LACK OF RECORDS, DATA CONCERNING THE FGD SYSTEM OPERATIONS WAS
UNAVAILABLE FOR THE MONTHS OF OCTOBER 1979 THROUGH JANUARY 1980. IN
NOVEMBER THE BOILER WAS DOWN MOST OF THE MONTH FOR A SCHEDULED UNIT
OVERHAUL.
2/80 SYSTEM 100.0 86.9 696 605 605
3/80 SYSTEM 100.0 89.2 744 664 664
4/80 SYSTEM 98.1 92.1 720 676 663
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM OPERATED ALONG WITH THE BOILER DURING FEBRUARY AND MARCH
WITH NO MAJOR PROBLEMS.
5/80 SYSTEM 100.0 99.7 744 742 742
6/80 SYSTEM 100.0 99.2 720 714 714
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM OPERATED ALONG WITH THE BOILER DURING THE APRIL THROUGH
JUNE PERIOD EXCEPT FOR A FEW HOURS IN APRIL. THE UTILITY REPORTED THAT
NO MAJOR PROBLEMS OCCURRED DURING THIS TIME.
7/80 SYSTEM 100.0 87.2 744 649 649
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR FGD-RELATED PROBLEMS WERE REPORTED DURING JULY.
8/80 SYSTEM 100.0 744 695
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR OPERATIONAL PROBLEMS WERE REPORTED IN AUGUST.
9/80 SYSTEM .0 .0 720 0 0
655
-------
EPA UTILITY FGD SURVEY: OCTOBER - DECEMBER 1980
UTAH POWER & LIGHT: HUNTINGTON 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM AND BOILER MERE DOWN THROUGHOUT SEPTEMBER FOR A SCHEDULED
MAINTENANCE OVERHAUL.
10/80 SYSTEM 100.0 97.5 7
-------
APPENDIX B
DEFINITIONS
B-l
-------
DEFINITIONS
Boiler Commercial Service Date
Byproduct Nature
Commercial Service Date
(FGD System)
Company Name
Disposal
Efficiency:
Total Unit Design Particle
Removal Efficiency
Total Unit S02 Design
Removal Efficiency
B-2
Date when boiler and auxiliary
equipment (including FGD sys-
tem for new boilers) has met
initial supplier guarantees
and begins to contribute elec-
trical power to the power
grid.
The nature (e.g. elemental
sulfur, sulfuric acid) and
disposition (e.g. stockpile on
site, marketed) of the end
product by systems that gen-
erate a saleable product.
Date when the FGD system suc-
cessfully completes compliance
testing and the utility is
satisfied that the system
meets supplier contractual
guarantees.
Name of corporation as it ap-
pears in Electrical World -
Directory of Electrical Util-
ities, McGraw-Hill - Current
Edition - as space permits.
Disposal method for throwaway
product systems producing
sludge including: interim and
final disposal sites and
disposal type (minefill,
landfill, etc.) as well as
disposal location and site
capacity.
The actual percentage of par-
ticulate matter removed by the
emission control system (me-
chanical collectors, ESP, or
fabric filter and FGD) from
the untreated flue gas.
The actual percentage of SO2
removed from the flue gas by
the FGD system.
-------
FGD Viability Indexes
Availability Index
Reliability Index
Several parameters have been
developed to quantify the vi-
ability of FGD system technol-
ogy. Various terms such as
"availability," "reliability,"
"operability," and "utiliza-
tion" are used to accurately
represent the operation of any
FGD system during a given per-
iod. The above-mentioned pa-
rameters are defined below and
discussed briefly. The objec-
tives of this discussion are
to make the reader aware that
several different definitions
are being used and to select
appropriate parameters that
can be used for reporting pur-
poses so that reasonably con-
sistent comparisons can be
made.
Hours the FGD system is avail-
able for operation (whether
operated or not) divided by
hours in period, expressed as
a percentage. This parameter
tends to overestimate the vi-
ability of the FGD system be-
cause it does not penalize for
election not to operate the
system when it could have been
operated. Boiler downtime may
tend to increase the magnitude
of the parameter because FGD
failures generally cannot oc-
cur during such periods.
Hours the FGD system was oper-
ated divided by the hours the
FGD system was called upon to
operate, expressed as a per-
centage. This parameter has
been developed in order not to
penalize the FGD system for
elected outages, e.g., periods
when the FGD system could have
been run but was not run be-
cause of chemical shortages,
lack of manpower, short dura-
tion boiler operations, etc.
The main problem in using this
B-3
-------
FGD Operability Index
FGD Utilization Index
End Product
Sludge
formula is the concise determi-
nation whether or not the sys-
tem was "called upon to oper-
ate" during a given time per-
iod. In addition, an undefined
value can result when the FGD
system is not called upon to
operate for a given period
(e.g., turbine or boiler out-
age when FGD system is avail-
able) .
Hours the FGD system was oper-
ated divided by boiler operat-
ing hours in period, expressed
as a percentage. This param-
eter indicates the degree to
which the FGD system is actu-
ally used, relative to boiler
operating time. The parameter
is penalized when options are
exercised not to use the FGD
system in periods when the
system is operable. In addi-
tion, an undefined value can
result when the FGD system is
not called upon to operate for
a given period (e.g., turbine
or boiler outage when FGD sys-
tem is available).
Hours that the FGD system op-
erated divided by total hours
in period. This parameter is
a relative stress factor for
the FGD system. It is not a
complete measure of FGD system
viability because the parameter
can be strongly influenced by
conditions that are external
to the FGD system (e.g., in-
frequent boiler operation will
lower the value of the parame-
ter although the FGD system
may be highly dependable in
its particular application).
The SO2 removed from the flue
gas is not recovered in a us-
able or marketable form and
resulting sulfur-bearing waste
B-4
-------
Recoverable Byproduct
Energy Consumption, %
Equivalent Scrubbed Capacity
(ESC)
FGD Status:
Category 1
Category 2
Category 3
Cateogry 4
products must be disposed in
an environmentally acceptable
fashion.
The S02 removed from the flue
gas is recovered in a usable
or marketable form (e.g., sul-
fur, sulfuric acid, gypsum,
ammonium sulfate, sodium sul-
fate).
The percentage of gross unit
electrical generating capacity
consumed by the FGD system, as
defined by the following equa-
tion:
[Net MW w/o FGD - Net MW w/FGD]/
[Gross unit rating]
The effective scrubbed flue
gas in equivalent MW based on
the percent of flue gas scrubbed
by the FGD system.
Operational - FGD system is in
service removing SC>2 •
Under construction - ground
has been broken for installa-
tion of FGD system, but FGD
system has not become opera-
tional.
Planned, Contract Awarded -
contract has been signed for
purchase of FGD system but
ground has not been broken for
installation.
Planned, Letter of Intent
Signed - letter of intent has
been signed, but legal con-
tract for purchase has not
been awarded.
Category 5
Planned, Requesting/Evaluating
Bids - bid requests have been
released but no letter of in-
tent or contract has been is-
sued.
B-5
-------
Category 6
Category 7
Category 8
Fuel Firing Rate - TPH
Initial Start-Up (FGD System)
New
Plant Name
Process Additives
Process Type
Considering only FGD Systems -
an FGD system is proposed as a
means to meet an SO2 regulation,
Considering an FGD system as
well as alternative methods.
Nonoperational - FGD system
has been operated in the past
but has been shut down perma-
nently or for an extended in-
definite period of time.
Boiler fuel firing rate in
terms of tons per hour at max-
imum continuous load.
Date when flue gas first
passes through any component
of the FGD system (or is
scheduled to do so).
FGD unit and boiler were de-
signed at the same time or
space for addition of an FGD
unit was reserved when boiler
was constructed.
Unit identification as it ap-
pears in Electrical World -
Directory of Electrical Util-
ities, McGraw-Hill - Current
Edition - or as indicated by
utility representative for in-
stallations in planning stages.
A chemical compound or element
which is added to the process
or normally found with the
main process reagent in small
quantities (e.g., Mg, adipic
acid) to promote improved
process operation (e.g., scale
reduction, increased SO2
removal efficiency).
Company name if process is
patented. Generic name if
several companies have similar
processes (e.g., Lime, Lime-
stone, Wellman Lord, Thorough-
bred 121) .
B-6
-------
Regulatory Class
Retrofit
SO2 Removal Mode
Spare Capacity Index - %
Spare Component Index
System Supplier
Total Controlled Capacity
(TCC)
A. Unit(s) subject to Federal
New Source Performance
Standards (NSPS) promul-
gated in June 1979.
B. Unit(s) subject to Federal
New Source Performance
Standards (NSPS) promul-
gated in December 1971.
C. Unit(s) subject to stan-
dard (s) more stringent
than NSPS (6/79) .
D. Unit(s) subject to stan-
dard (s) more stringent
than NSPS (12/71), but
not more stringent than
NSPS (6/79)
E. Unit(s) subject to stan-
dard (s) equal to or less
stringent than NSPS
(12/71).
FGD unit will be/was added to
an existing boiler not specif-
ically designed to accommodate
FGD unit.
The manner in which the SC-2
from the flue gas is collected,
e.g., wet scrubbing, spray
drying, dry adsorption.
The summation of the individ-
ual component capacities (%)
minus 100%.
The equipment spare capacity
index (%) divided by the indi-
vidual component capacity (%).
A firm that fabricates and
supplies flue gas desulfuriza-
tion systems.
The gross rating (MW) of a
unit brought into compliance
with FGD, regardless of the
B-7
-------
Unit Rating
Gross
Net w/FGD
Net w/o FGD
percent of flue gas treated at
the facility. In the case of
prototype and demonstration
FGD systems, this figure will
be identical to the Equivalent
Scrubbed Capacity rather than
the gross unit rating if the
system is not meant to bring
the facility into compliance
with SC>2 emission standards.
Operational - Maximum contin-
uous gross generation capacity
in MW; Preoperational - maxi-
mum continuous design genera-
tion capacity in MW.
Gross unit rating less the en-
ergy required to operate
ancillary station equipment,
inclusive of emission control
systems.
Gross unit rating less the en-
ergy required to operate
ancillary station equipment,
exclusive of emission control
systems.
B-8
-------
APPENDIX C
TABLE OF UNIT NOTATION
C-l
-------
TABLE OF UNIT NOTATION
Classification
Area
Concentration
Flow
Heat Content
Length
L/G Ratio
Mass/Weight
Pressure
Temperature
Volume
English Unit
Acre
Square foot
Grains per standard
cubic foot
Parts per million
Pounds per million
Btu
Actual cubic feet
per minute
Gallons per minute
Pounds per minute
Ton per day
Ton per hour
Btu per pound
Foot
Inch
Mile
Gallons per
thousand actual
cubic feet
Pound
Ton
Inches of water
Degree Fahrenheit
Cubic feet
Acre-feet
Symbol
acre
ft2
gr/scf
ppra ,
lb/10 Btu
ft /min
(actual)
gal/rain
Ib/min
t/day
t/h
Btu/lb
ft
in
mi
gal/1000
ft3
(actual)
Ib
t
in. H20
op
ft3
Acre-ft
Survey Report
Notation
ACRE
SQ.FT
GR/SCF
PPM
LB/MMBTU
ACFM
GPM
LB/MIN
TPD
TPH
BTU/LB
FT
IN
MI
GAL/1000ACF
LB
T
IN. H20
F
CU.F
ACRE-FT
ASTM/SI Unit
Square meter
Square meter
Grams per cubic meter
Parts per million
Nanograms per joule
Cubic meters per
second
Liters per second
Kilogram per second
Metric ton per day
Metric ton per hour
Joules per
gram
Meter
Centimeter
Kilometer
Liters per cubic
meter
Kilogram
Megagram
Kilopascal
Degree Celsius
Cubic meter
Cubic meter
Symbol
«2
M
g/m3
PPm
ng/J
m3/s
liter/s
kg/s
M t/d
M t/h
J/g
m
cm
km
liter/nt3
kg
Mg
kPa
°C
:'
Survey Report
Notation
SQ.M
SQ.M
G/CU.M
PPM
NG/J
CU.M/S
LITER/S
KG/S
M T/D
M T/H
J/G
M
CM
KM
LITER/CU.M
KG
MG
KPA
C
CU.M
CU.M
I
S3
-------
APPENDIX D
FGD PROCESS FLOW DIAGRAMS
D-l
-------
LIMESTOHE SLURRT
TO UNIT 3
LIMESTONE SLURRY PUMPS
(TWO TOTAL)
WASTE -1
SLURRY
SUHP
WASTE SLURRY
PUMPS
(TWO 101*1)
RETURN
PUMP
SCRUBBER WASTE
STORAGE POXO
Alabama Electric,
Simplified Process Flow Diagram for Tombigbee 2 and 3
-------
D
I
• SINGLE LOUVER
DAMPER
LIMESTONE
STORAGE BIN
DOUBLE-BLADED
~ GUILLOTINE
DAMPER
WET LIMESTONE
GRINDING SYSTEM
L MILL
(SERVICE WATER)
TOTAL PROCESS
MAKE-UP WATER
(COOLING TOWER
SLOWDOWN)
-»• TO UNIT NO. 3
FROM UNIT NO. 3
-»• TO UNIT NO. 3
ABSORBER REAGENT^
FEED PUMPS
Arizona Electric Power Coop, Apache 2 and 3
Process Flow Diagram
-------
GO -S
-H -I.
3 N
•O O
—' 3
-i. Ql
fl> c
a, CT
-s o
o
O CO
~S
l/l <
-n o'
—' O>
o -
o
O 3"
O) —•
tO —•
^^ P*
3 —•
-------
D
ui
HILL I T rt
SLURRY I /*7>|
TANKS ' I tjj
SLURRY /~\ RECIRCULATION
TRANSFER STORAGE TRANSFER TAHt:S RECIRCULATION
PUMPS TA«K PUMPS PUMPS
Central Illinois Light,
Simplified Process Flow Diagram of Duck Creek 1
Power Plant and Emission Control System
-------
BOOSTER FAN
CHLORIDE/FLYASH PRECOOLER
FLYASH THICKENER
ABSORBER
NEUTRALIZE
REACTOR-CLARIFIER
CAUSTICIZERS
8 THICKENER
9 HORIZONTAL BELT FILTER
10 REHEAT FACILITY (EXPERIMENTAL)
STACK
4\
G
I
en
(MAKEUP)
iT—1
IJ
SOLIDS
/
Central Illinois Public Service, Newton 1:
Simplified Process Flow Diagram Showing One of Four Absorbers
-------
D
I
MAKEUP HATER
(POND MATER)
FROM ESP -
FLUE GASES
LIME FROM
STORAGE
SERVICE
WATER
TO STACK - FLUE GASES
MIST ELIMINATOR
— 1
£*•
I
I TO OTHER
~^_) RECYCLE TANK
1
j
THICK
\
\
^.
- OVERFLOW
TO ASH POND
FROM OTHER
~ RECYCLE TANK
TO IUCS
Columbus and Southern Ohio Electric, Conesville 5 and 6:
Simplified Process Flow Diagram for a Given Module
-------
To Stock
o
I
oo
Mist Eliminator
Make Up
From
Precipitator
Reaction Tank
.In-Tank
Strainer
_ Bleed
n Pump
Flyash Silo
Lime Silo
Flyash Wet'G
Tank
Flyash Feeder
Make Up
Lime
Feed Pumps
Disposal
Lime
Feeder
Lime
Slaker
Lime
Feed Tank
Cooperative Power Association, Coal Creek 1 and 2:
Simplified Process Flow Diagram
-------
D
v.o
BOILER
1ST STAGE
ADJUSTABLE VENTURI
FOR FLY ASH/S02
CaS03/S04
FLY ASH SLURRY
SCL ABSORBER SCRUBBER
RECYCLE RETURN SYSTEM
TO
STABILIZATION
FACILITIES
Duquesne Light, F. R. Phillips F6D System:
General Diagram.
-------
FROM DISPOSAL PONO
FLUE GAS
FROM PLANT
ISOLATION
DAMPER
O
I
REHEATER
NO. 2 FUEL OIL
SURGE
TANK
(EXISTING
V-103 * ¥-103
EPRI SYST.
EPRI SYSTEM
SYSTEM
COMBUSTION
AIR FAN
EPA SYSTEM
HAKE-UP
UATER
FLANGED
CONNECTION TO
CLIENT'S DUCT
I THICKENER
HOLD PUMP
>-r
'ti ABSORPTION
VACUUM FILTER
SYSTEM
TOWER RECYCLE
PUMP—tr:
. THICKENER
'--.HOLD TANK
VENTUR1 SCRUBBER
~~RECYCLE PUMP
THICKENER
UNDERFLOW
PUMP
SODA ASH,
DUST
COLLEC-
HPNEUMATIC
TRUCK COUPLING
PNEUMATIC
TRUCK
COUPLING
SODA ASH
VIBRATING
HOPPER
SODA ASH
HEIGH
FEEDER
REACTOR NO. 1
AND AGITATOR REACTOR NO. Z
AND AGITATOR REACTOR NO. 3
AND AGITATOR
FILTER CAKE
UASH UATER
ADDITIONAL S02 INJECTION
SODA ASH
TANK I
AGITATOR
REACTOR NO. 4
AND AGITATOR
REACTOR NO. 5
AND AGITATOR
Gulf Power, Scholz 1:
Simplified Process Flow Diagram of the Demonstration
Soda Ash/Limestone Dual Alkali Process
-------
AIR
HEATER
AMBIENT
AIR
MIST
ELIMINATOR
CLEAN GAS OUT TO STACK
MIST ELIMINATOR
WASH
MOBILE PACKING-
V"C 7^ 'V
PRE-SATURATION
4
I
in
APFA
WASTE
SLURRY TANK
o
UJ
UJ
>-
OL
0£
PUMP
Indianapolis Power and Light, Petersburg 3:
Simplified Process Flow Diagram for One of Four Absorbers
D-ll
-------
STACK
D. FAN
D
I
V-*
to
COAL
SUPPLY
FEEDER
PULVERIZER
STACK GAS
REHEATER
STACK GAS
SCRUBBER
RECYCLE
PUMP
Kansas City Power and Liqht, Hawthorn Units 3 and 4:
Simplified Process Flow Diagram of the Lime Scrubbing Process
LIME
PREPARATION
TANK
CLARIFIER
MAKE UP
WATER
TO ASH DISPOSAL
POND
-------
0
I
M
U)
STEAM COIL
REHEATER
ABSORBER
RE£IRCULATION
PUMPS
HEATERS TO
RECIRCULATIOrT SCRUBBER
TANKS
VENTURI
RECIRCULATION
PUMPS
HYDROCLONE
CLASSIFIER
LIMESTONE
BUNKER
LIMESTONE
SLURRY
STORAGE
BOILER
SETTLING POND
WET BALL
MILL
Kansas City Power and Light,
LaCygne 1 FGD System: General Diagram
-------
FURNACE
DAMPERS
w
i
TWO PRECIPITATORS
FOUR I.D. FANS
ONE
STACK
WATER RETURN TO
REACTION TANKS
BLEED PUMP
SPRAY PUMP |TRANSFER TANK
FOUR,
REACTION
TANKS
SLUDGE DISPOSAL
POND
Kansas Power and Light,
Schematic of Jeffrey Steam Generator and Emission Control Equipment
-------
WATER FOR
LIMESTONE SLWWYING
DILUTION HATER
(FROM RECIRCULATION TANK)
SLURRY PUMPS
TO OTHER
SCRUBBER MODULE
a
I
H
at
POND RETURN
(MAKE-UP)
1 WATER
WASH
PUMP
REClf
TANK
RECIRQ
PUMPS
-O"
MAKE-UP WATER
EFFLUENT
BLEED
SPRAV
PUMPS
EFFLUENT
BLEED PUMP
1
ON
i
T
1
BLEED
- oo—
n
REACTION
TANK
1 STRAINtR
c
PUN
p '
i
I *
M
i ^^
THICKENER
_WEIR
OVERFLOW
I
THICKENER
UNDERFLOW PUMPS
TO
•SETTLING
POND
Kansas Power and Light,
Lawrence 4 Operational FGD System:
Simplified Process Flow Diagram
-------
LlKSTWf tfATER FOB
HOPPER siuBRrip»G
\y
SCALPING
SCREEN
CtUSHEO
IWESTOKE
IUCKET
a
i
ADDITIVE
TRANSFER
PWtPS
•ALL
HIU
b
KILl*
""• wu
SLumrr
HIIER
DILUTION HATER (FROH
AOOITIVE STORAGE HECIRCULATIOI. TANH
TANK 60 SOLIDS
L
Kansas Power and Light,
Lawrence 5 Operational FGD System:
Simplified Process Flow Diagram
-------
D
I
r--v MIX/HOLD TANK
S.;
SPARE
SPARE
SPARE
Kentucky Utilities,
Green River FGD System: General Process Diagram
-------
QUENCHER
MIST
ELIMINATOR
(CHEVRON)
CONTACTOR
SCRUBBER
~- MODULE
ELECTROSTATIC
PRECIPITATOR
REACTION
TANK
BOILER
FLUE
GAS
D
I
M
C»
CONTACTOR
SCRUBBER
MODULE
MIST
ELIMINATOR
(CHEVRON)
Louisville Gas and Electric, Cane Run 4
FGQ System: Simplified Process Flow Diagram
-------
D
I
IN LINE REHEATER (STEAM)
1.0. BOOSTER FANS'
TO STACK
FROM-
ESP'S
'BYPASS
•MIST ELIMINATOR
MIST ELIMINATOR WASH
— BULK ENTRAINMENT
ccp»oATnp
SEPARATOR
-SPRAY TOWER ABSORBERS
CRUSHER-
DISINTEGRATOR
n
SPRAY PUMPS
IN-TANK STRAINER-
REACTION TANK
FEED PUMPS
f
FROM LIME
STORAGE TANK
LIME FEEDTANK
-ft
u
c
z>
TO DISPOSAL*
PUMPS
)UNDERFLOW PUMPS
MAKEUP
WATER
M.E.WASH
RECYCLE PUMP
TANK
Louisville Gas and Electric, Cane Run 5
FGD System: Simplified Process Flow Diagram
-------
COMBUSTION AIR
EXISTING
(RIVER WATER)
EMERGENCY WATER
SUPPLY
FROM ABSORBER A-201 PRIMARY REACTOR
OF TRAIN 2
REACTANT
(LIME SLURRY)
FEED TANK
TO ABSORBER
A-201
Louisville Gas and Electric, Cane Run 6
Dual Alkali FGD System: Simplified Process Flow Diagram
D-20
-------
GAS TO STACK
O
I
GAS REHEATERS
MIST ELIMINATOR
HASHERS
DRY CA(OH)2
ADDITIVE SYSTEM
GAS INLET
PH ELECTRODE STRAINERS
ASSEMBLY
FT I TPD V ^« riLItK
FIAPPFB I CONNECTION J FLAPPER
AFGL,ATPAPTEoiXAIR^LC l^.TATOR
Louisville Gas and Electric,
Paddys Run 6 FGD System:
Simplified Process Flow Diagram
-------
TREATED-GAS
DUCT
SPRAY TOWER
ABSORBER
"WET" VENTURI
SCRUBBER
Minnesota Power and Light, Clay Boswell 4:
General Diagram
D-22
-------
REHEAT BY-PASS
D
I
FILTER CAKE
Minnkota Power Cooperative, Milton R. Young 2:
Simplified Process Flow Diagram for One of Two Absorbers
-------
D
I
NJ
S02 BOOSTER FANS
MIST
ELIMINATORS
nuumu
LIME FEED
SYSTEM
^d
tfCLONE
If
—
u
c
" 0
:
e-
RECYCLE TANK
TO STACK
WASH TRAY
-ABSORBER TRAY
RECYCLE
LIQUOR
*- TO EMERGENCY
DUMP POND
TO DISPOSAL SITE
Monongahela Power, Pleasants 1 and 2:
Simplified Process Flow Diagram for One of Four Modules for Either Unit
-------
O
I
NJ
U1
FLUE
GAS
EMERGENCY WATER
MIST
ELIMINATORS
_ -*-CLEAN FLUE GAS
HXKSEAL WATER SUPPLY
UNDERSPRAY
MAKEUP
WATER
POND
RETURN
WASH TRAY POND
FLY ASH POND
Montana Power, Col strip 1 and 2:
Process diagram of a given FGD module
-------
TO CHIMNEY
COAL
PULVERIZER
D
I
to
CTi
FURNACE
MECHANICAL
OUST
COLLECTOR
(NULTICLONES)
J
BYPASS ^
*^HREH"
EVAPORATION PONDS
ON MESA
TEAM
REHEATER AIR FAN
Nevada Power, Reid Gardner 1,2 and 3:
Process diagram of a given FGD system.
-------
DISCHARGE
TO STACK
CONDENSER
PRESCRUBBER
(VARIABLE-
VENTURI)
a
i
KJ
FLUE GAS FROM
UNIT #11
FLY ASH PURGE TO POND
TRAY TOWER
ABSORBER
Na2C03
MAKE-UP
PURGE
STREAM
TREATED
PURGE STREAM
CENTRIFUGE
STORAGE
BIN
CRYSTALLIZER
STEAM
SODIUM SULFATE
CAKE
EVAPORATOR/
^CRYSTALLIZER
Qj COMPRESSOR
DRIED
SULFATE
PRODUCT
Northern Indiana Public Service,
D. H. Mitchell 11 Weilman_ Lord/Allied System:
General Process Diagram.
-------
FLUE GAS FROM BOILER
Northern States Power, Riverside 6 and 7:
General Diagram
D-28
-------
0
I
to
VD
FLUE GAS
TO
SCRUBBER
FIRST
STAGE
OOO
OXIOIZER
REHEATER
MIST
ELIMINATOR
OVERFLOW POTS
AND MARBLE BED
REACTION
TANK
A
SPRAY
PUMP
FLUE GAS
TO STACK
RIVER
MAKEUP
WATER
WEIR
THICKENER
RECIRC
TANK
THICKENER
UNDERFLOW
PUMP
ASH POND
LIMESTONE —i
SLURRY
TANK
SLURRY
PUMP
ASH POND
RETURN PUMP
Northern States Power, Sherburne 1 and 2 FGD System:
Simplified Process Flow Diagram
-------
oe-a
-a
CD
3
3
O <
o a>
ft) 3
1/1 -i.
— > o
o s:
S n>
-s
o >•
O) CO
CO -5
-J c
Q> O
3 ro
-h 3
O O>
-5 3
O
-s
oo
-------
FLUE GAS FROM
UPPER ESP
u
i
U)
A
HOT REHEAT GAS
EXHAUST PLENUM
EXHAUST
ISOLATION
DAMPERS
(4 PER UNIT)
FLUE GAS FROM
LOWER ESP
X
STACK INLET
DAMPERS (2)
(1 EACH SIDE)
DI CMIIM
PLENUM
INLET ISOLATION
DAMPERS (4 PER UNIT)
BOOSTER FAN FLOW
CONTROL DAMPERS
(4 PER UNIT)
STACK
ABSORBERS
(4 PER UNIT)
VENTURIS
(4 PER UNIT)
BOOSTER FANS
(4 PER UNIT)
Public Service of New Mexico, San Juan 1, 2, and 3*
FGD System Flue Gas Flow Path
*San Juan 3 is identical except that only one scrubbing
train is operational.
-------
O
I
LO
to
Mist-eliminator
wash tank A
From
scrubber B
Scrubber-
booster tan
I Makeup water
o scrubber B
^f^To scrubber B
First Second
stage stage
Third-stage
spray ouma
To
scrubber-B
booster fan
Limestone-slurry
makeup
Fourth-stage
'.spray pump
Reaction mi*
tank A
Flocculent
addition
Process-water tank
To seal-water system
To flush connections
•Mclriutclic
prtciptttlort
To alkali-preparation
system
To sludge
storage tanks
fnttlunlor
BooMtrtans
Salt River Project, Coronado 1 and 2:
Simplified Process Flow Diagram
-------
VENTURI SORBER
SCRUBBER™
(ONE IN USE)
ELEC.PRECIP. A1R
HEATER
STACK
(EXISTING)
. MIST
ELIMINATOR
TANK (ONE
IN USE)
MIST ELIMINATOR
PUMP
(ONE IN USE
ONE SPARE)
LIMESTONE
FEED BIN
(ONE IN USE
FOR TWO
l.D. FAN
(TWO IN USE)
WET CYCLONE
CLASSIFIER
FROM THICKENER
HUE
(ONE IN USE)
WEIGH FEEDER
(ONE IN USE)
MIXER
(ONE IN USE)
WET BALL HILL
(ONE IN USE)
MILL SLURRY
TANK
(ONE IN USE)
",N USE
SPARE)
SLURRY STORAGE
TANK
(ONE IN USE)
SLURRY
PUMP
(ONE IN USE
ONE SPARE)
RECYCLE TANK
(ONE IN USE)
RECYCLE
PUMP
(TWO IN USE
ONE SPARE)
THICKENER
SUPPLY
TANK
(ONE IN USE)
PUMP
(ONE IN USE
ONE SPARE)
South Mississippi Electric, R.D. Morrow 1 and 2:
Simplified Process Flow Diagram
-------
D
I
OJ
STACK
SODA ASH
STORAGE
LIME
STORAGE
LIME REACTOR —Hf
SULFUR DIOXIDE ABSORPTION
Na?S03 + S02 + H?0
USE 7SLAKER Ca(OH)2
WATER
CaS03/Na2S03 THICKENER
NaHSOi SURGE
JJITANK
CaS03/CaS04
2 NaHS0 + Ca(OH)
FILTER
SODIUM REGENERATION CAKE
2 - * CaS03 ' 1/2 H20 + Na2S03 + 1-1/2 H20
Southern Indiana Gas and Electric, A.B. Brown 1:
Dual Alkali FGD System Simplified Process Flow Diagram
-------
SCRUBBER INLET
TEST PORT LOCATION
TOP OF STACK
ELEVATION 1645'
TEST PORT
ELEVATION 1516'
a
i
U!
Ul
B" ABSORBER
MODULE
L—TOP OF OUTLET BREECHING
ELEVATION 1372'-2 3/8"
L_TOP OF BYPASS BREECHING
ELEVATION 1307'- 8 1/2"
-GRADE ELEVATION 1261'
BYPASS OUCT \
PRECIPITATOR
INLET TEST
PORT LOCATION
A" ABSORBER
MODULE
FHTEI CMX
(KlIEO KITH
FLTUH
UWflU
DISPOSM.)
SCRUBBER INLET
TEST PORT LOCATION
Springfield City Utilities, Southwest 1:
Simplified Process Diagram
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H2S GENERATION
METHANE/
CARBON MONOXIDE.
BOILER
PREHEATER
LIME
NEUTRALIZER
PRECONDITIONING AND
S02 ABSORPTION
H2o<->
CRYSTALLIZER
SULFUR
SLURRY
SULFUR
FLOTATION
SULFUR
PRODUCT
SULFUR PRECIPITATION
AND RECOVERY
St. Joe Zinc, G.F. Weaton 1:
Citrate FGD System Simplified Process Flow Diagram
D-36
-------
o
I
co
-j
I AIR
IFUEL OIL>— *>]REHEATER
1
' i
t
FIRST
HOLD
TANK
SECOND
HOLD
TANK
THIRD
HOLD
TANK
SAMPLE POINTS
OGAS COMPOSITION
®PARTICIPATE COMPOSITION & LOADING
®SLURRY OR SOLIDS COMPOSITION
GAS STREAM
LIQUOR STREAM
f
i
PROCESS
WATER
HOLD
TANK
STACK
-<>IAKEUP WATER|
DISCHARGE
SETTLING POND
Tennessee Valley Authority,
Shawnee IDA Prototype Test Unit:
General Process Diagram.
-------
a
i
u>
00
MAKE-UP WATER _
FLUE GAS
i r
^At
w
VENTURl) (
/ \
LIMESTONE
FLUE GAS
A
/N ^
^ w *
^ -
kx1
SPRAY TOWER
SPRAY TOWER EFFLUENT
HOLD TANK
VENT AIR
A
OXIDATION
TANK
n
CLARIFIED LIQUOR
WATER
D
C3
=3
N *
1
Y
_Mtl-
f
c
— >
— i ftf
1 t
I
DESUPERSATURATION
TANK
BLEED TO
DEWATERING
-, SYSTEM
Tennessee Valley Authority, Shawnee 10B Prototype Test Unit:
Modified Venturi/Spray Tower System for 2-Stage Oxidation Testing.
-------
o
i
u>
VD
MAKEUP WATER>—
PROCESS
WATER I
HOLD TANK
SAMPLE POINTS
OGAS COMPOSITION
®PARTICIPATE COMPOSITION & LOADING
0 SLURRY OR SOLIDS COMPOSITION
GAS STREAM
LIQUOR STREAM
SETTLING POND
Tennessee Valley Authority, ShawneelOB Prototype Unit:
General Process Diagram.
-------
D
I
4*
O
REHEATER
} FROM
\TRAINS STEAM .
[B,C, AND D ^f
~ TO ASH f
DISPOSAL POND
TO STACKJ>LENUM
FROM ESP
TO TRAINS l*""j
B,C, AND DS7"j SLURRY PUMP
L SEAL WATER
, HEADER
JUVER WATER
** PUMPS '
FROM POND WATER n
RECYCLE PUMPS
FROM LIMESTONE SLURRY n
TRANSFER PUMPS
FAN
, FROM B, C. AND D TRAIN
VENTURI CIRCULATION TANKS| '
. TO SETTLING POND
VENTURI
CIRCULATION
TANK AND
PUMPS
ABSORBER
CIRCULATION
TANK AND
PUMPS
EFFLUENT SLURRY
SURGE TANK AND PUMPS
LIMESTONE SLURRY
STORAGE TANK
LIMESTONE SLURRY
FEED PUMPS
\
Tennessee Valley Authority, Widows Creek 8 FGD System:
Process Flow Diagram for One of the Four Scrubber Trains
-------
FAN OUTLET DAMPER^
-TOWER INLET DAMPER
FROM BOILER
AIR PREHEATERS
FL¥ ASH
PUMP SEAL WATER,
BALL MILL COOLING
AND HOSE STATIONS
MAKEUP WATER TO
LIMESTONE AREA
SERVICE HATER ASH POND
(LAKE WATER) RETURN WATER
(RECYCLE WATER)
Texas Utilities,
Simplified Process Flow Diagram for One of the Three Identical
Martin Lake FGD Systems
-------
TO ASH AREA
BYPASS
TO SPRAY TOWER 301
FROM SPRAY TOWER 301 t
BOILER n
AIR U
HEATER
TO SPRAY TOWER 201
FROM SPRAY TOWER 201
TO SPRAY TOWER 301
TO SPRAY TOWER 201
MIST ELIMINATOR
WASH WATER
TO SPRAY TOWER 201
FROM SPRAY TOWER 301
FROM SPRAY TOWER 201*
TO SPRAY TOWER 301 -^
TO SPRAY TOWER 301
TO SPRAY TOWER 201 -«
TO SPRAY TOWER 301
TO SPRAY TOWER 201
TOWER DRAIN TO
DISPOSAL
LIMESTONE
STORAGE
BIN
TO SPRAY TOWER 301
TO SPRAY TOWER 201
SPRAY TOWER
RECYCLE PUMP
TOTAL PUMP SEALS AND
INSTRUMENT PURGE WATER
LIMESTONE GRINDING
SYSTEM
LIMESTONE SLURRY
TANK AGITATOR
FROM
LIMESTONE STORAGE
FROM ASH WATER
RHENTION POND
S0? REMOVAL AREA
SUMP PUMPS
S02 REMOVAL AREA SUMP
Texas Utilities,
Simplified Process Flow Diagram for Monticello 3
-------
TECHNICAL REPORT DATA
(Please reatl Instructions on (hrrcicric bcjon
1. REPORT NO.
EPA-600/7-81-012b
2.
3 RECIPltNT'S ACCESSION NO
4. TITLE AND SUBTITLE
EPA Utility FGD Survey: October - December 1980
Volume II. Design and Performance Data for
Operational FGD Systems
5 REPORT DATE
January 1981
6 PERFORMING ORGANIZATION CODE
7 AUTHOR(S)
M. Smith, M. Melia, N. Gregory, K. Scalf
8 PERFORMING ORGANIZATION REPORT NO
PN 3560-2-6
9. PERFORMING ORGANIZATION NAME AND ADDRESS
PEDCo Environmental, Inc.
11499 Chester Road
Cincinnati, Ohio 45246
10. PROGRAM ELEMENT NO.
1NE828
11 CONTRACT/GRANT NO
68-02-3173, Task 17
12. SPONSORING AGENCY NAME AND ADDRESS
13. TYPE OF REPORT AND PERIOD COVERED
EPA, Office of Research and Development
Industrial Environmental Research Laboratory
Research Triangle Park, N.C. 27711
Quarterly; 10-12/80
14. SPONSORING AGENCY CODE
EPA/600/13
15. SUPPLEMENTARY NOTES
IERL-RTP Project Officer is Norman Kaplan, Mail Drop 61, 919/541-2556.
reports are in the EPA-600/7-80-029 and EPA-600/7-79-022 series.
Related
16. ABSTRACT
This report is the first full compilation (not a supplement) since the October-
December 1979 report (EPA-600/7-80-029a). Because the next three reports are to
be supplements, this issue should be retained for reference throughout the year.
The report, which is generated by a computerized data base system, presents a
survey of operational and planned domestic utility flue gas desulfurization (FGD)
systems, terminated domestic utility FGD systems, operational domestic particle
scrubbers, and Japanese coal-fired utility boiler FGD installations. It sum-
marizes information contributed by the utility industry, process suppliers,
regulatory agencies, and consulting engineering firms. Domestic FGD systems are
tabulated alphabetically by development status (operational, under construction,
or in planning stages), utility company, process supplier, process, and waste
disposal practice. It presents data on boiler design, FGD system design, fuel
characteristics, and actual performance. It includes unit by unit dependability
parameters and discusses problems and solutions associated with the boilers and
FGD systems. Process flow diagrams and FGD system economic data are appended.
Because of its length, Section 3 of this report is published as a separate volume;
the remainder of the report is in Volume I (EPA-600/7-81-02la). The report
Front Matter and Appendices B, C, and D are repeated here to assist the reader.
17.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.IDENTIFIERS/OPEN ENDED TERMS C. COSATI Field/Group
Pollution
Flue Gases
Desulfurization
Electric Utilities
Waste Disposal
Boilers
Maintenance
Pollution Control
Stationary Sources
Utility Boilers
13B
21B
07A, 07D
15E
ISA
18. DISTRIBUTION STATEMENT
Release to public
19. SECURITY CLASS (ThisReport)
Unclassified
21. NO. OF PAGES
690
20. SECURITY CLASS (Thitpoge)
Unclassified
22. PRICE
EPA Form 2220-1 (9-73)
D-43
-------
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Office of Research and Development
Center for Environmental Research Information
Cincinnati, Ohio 45268
OFFICIAL BUSINESS
PENALTY FOR PRIVATE USE. S3OO
AN EQUAL OPPORTUNITY EMPLOYER
POSTAGE AND FEES PAID
US ENVIRONMENTAL PROTECTION AGENCY
EPA-335
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tear off; and return to the above address.
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Publication No. EPA-600/7-81-012b
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