United States Office of Air Quality EPA-340/1 -85-014b
Environmental Protection Planning and Standards October 1984
Agency Washington, D.C. 20460
Stationary Source Compliance Series
&ERA Utility FGD Survey
October 1983-
September 1984
Volume 2: Design
Performance Data
For Operating
FGD Systems (Parti)
-------
EPA-340/1-f5-014b
Utility FGD Survey
October 1983 - September 1984
Volume 2: Design Performance Data for
Operating FGD Systems (Part 1)
Alabama Electric, Tombigbee 2 through
Montana Power, Colstrip 2
M. T. Melia, R. S. McKibben,
and B. W. Pelsor
PEDCo Environmental, Inc.
11499 Chester Road
Cincinnati, Ohio 45246
EPA Contract No. 68-02-3963
Work Assignment No. 46
EPA Project Manager: John Busik
EPA Work Assignment Manager: Sonya M. Stelmack
U.S. ENVIRONMENTAL PROTECTION AGENCY
Stationary Source Compliance Division
Office of Air Quality Planning and Standards
Washington, D.C 20460
October 1984
-------
ACKNOWLEDGMENT
The EPA-SSCD Project Officer and authors of this report_
appreciate the assistance provided by Norman Kaplan, the Pro3ect
Officer for the U.S. Environmental Protection Agency (Industrial
Environmental Research Laboratory, Research Triangle Park, North
Carolina) for the Flue Gas Desulfurization Information System
(FGDIS), in updating and maintaining the data base and his sug-
gestions on the content and format of the survey report (and
project summary) and on other project activities.
DISCLAIMER
This report was prepared for the U.S. Environmental Protec-
tion Agency by PEI Associates, Inc., Cincinnati, Ohio, under Con-
tract No. 68-02-3963, Work Assignment No. 46. The contents of
this report are reproduced herein as received from PEI Associates,
Inc. The opinions, findings, and conclusions expressed are those
of the authors and not necessarily those of the U.S. Environmental
Protection Agency. Mention of trade names or commercial products
is not intended to constitute endorsement or recommendation for
use. Copies of this report are available from the National
Technical Information Services, 5285 Port Royal Road, Springfield,
Virginia 22161.
11
-------
NOTICE
The data in this information transfer document are supplied
voluntarily by utility representatives, flue gas desulfurization
(FGD) system suppliers and designers, regulatory agencies, and
others. The accuracy or completeness of the information con-
tained herein is not warranted by the Stationary Source Control
Division of EPA or the designated contractor. Portions of the
work upon which this publication is based were performed pursuant
to Contract Nos. RP982-32 (Electric Power Research Institute) and
68-02-3173 (Environmental Protection Agency).
A project summary will be distributed to organizations and
individuals indicating a specific interest in the field of FGD
technology. Interested parties can be added to the Project
Summary mailing list by contacting Carolyn Fowler at the Indus-
trial Environmental Research Laboratory (919/541-2915) or the
secretary of the Emission and Effluent Technology Branch of the
EPA (919/541-2578). Copies of preceding issues of this report
through December 1981 can be purchased from the National Tech-
nical Information Service, Springfield, Virginia 22161, (703)
487-4650. Succeeding issues of this report can be purchased from
the Electric Power Research Institute Research Reports Center,
P.O. Box 50490, Palo Alto, California 94303, (415) 965-4081.
This report summarizes the FGD system design and performance
data contained in a computerized data base known as the Flue Gas
Desulfurization Information System (FGDIS). Access to the FGDIS
is available through the National Technical Information Service
(NTIS) for a nonprofit user's fee. Users also have access to
additional design and performance data stored within the data
base that cannot conveniently be printed in this report. Direct
access to the data base affords analyses of the data (e.g.,
averages, maxima, minima, and standard deviations of various
parameters), the use of simple mathematical functions, the capa-
bility of virtually unlimited data cross-referencing, and data
tabulation to fit the user's individual information needs. An
FGDIS users manual is available from NTIS (NTIS No. PB 83 146
209) .
Requests for further information concerning the FGDIS and
periodic FGDIS training seminars should be directed to Michael
Melia or Skip Jones, PEI Associates, Inc. (513/782-4700). In-
formation concerning access to the FGDIS can be obtained from
Walter Finch, NTIS, 5285 Port Royal Road, Springfield, Virginia
22161 (703/487-4808) .
iii
-------
USE OF THIS REPORT
This report is the first fully compiled edition since the
July 1982-March 1983 issue released in April 1984, which contains
more complete design and performance data since the FGS system
startup dates. This report supersedes all previous issues.
Volume 1 includes several categorical summaries of key data and
the appendix sections. Volume 2, Parts 1 and 2 contain all
available design and performance data for operational FGD systems
(Section 13).
The Executive Summary contains the number and capacity of
FGD systems as of the end of December 1984, future (December 1993)
projections of controlled and uncontrolled generating capacity,
and unit-by-unit summaries of status changes (e.g., contract
awarded, under construction, or operational) and performance and
status highlights for the period.
Appendix sections include definitions, a table of unit
notation and simplified process flow diagrams, as well as data
on terminated FGD systems, particle scrubbers and Japanese FGD
systems.
IV
-------
ABSTRACT
The Utility FGD Survey report, which is generated by a
computerized data base system, represents a survey of operational
and planned domestic utility flue gas desulfurization (FGD)
systems. The three volume set summarizes information contributed
by the utility industry, system and equipment suppliers, system
designers, research organizations, and regulatory agencies. The
data cover system design, fuel characteristics, operating
history, and actual system performance. Also included is a
unit-by-unit discussion of problems and solutions associated with
the boilers, scrubbers, and FGD systems.
The development status (operational, under construction, or
in the planning stages), system supplier, process, waste disposal
practice, and regulatory class are tabulated alphabetically by
utility company. Simplified process flow diagrams of FGD systems,
definitions, and a glossary of terms are attached to the report.
Current data for domestic FGD systems show 124 systems in opera-
tion, 25 systems under construction, and 68 systems planned. The
current FGD-controlled capacity in the United States is 47,255 MW.
-------
CONTENTS
Acknowledgment
Notice
Use of This Report
Abstract
Section 13
(continued)
Design and Performance Data for Opera-
tional Domestic FGD Systems
Alabama Electric
Tombigbee 2
Tombigbee 3
Arizona Electric Power
Apache 2
Apache 3
Arizona Public Service
Cholla 1
Cholla 2
Cholla 4
Four Corners 1
Four Corners 2
Four Corners 3
Associated Electric
Thomas Hill 3
Basin Electric Power
Antelope Valley 1
Laramie River 1
Laramie River 2
Laramie River 3
Big Rivers Electric
D.B. Wilson 1
Green 1
Green 2
Central Illinois Light
Duck Creek 1
Central Illinois Public Service
Newton 1
Cincinnati Gas & Electric
East Bend 2
Colorado Ute Electric
Craig 1
Craig 2
Craig 3
VI
13-1
13-14
13-27
13-42
13-56
13-76
13-84
13-89
13-96
13-103
13-110
13-118
13-122
13-137
13-148
13-153
13-156
13-168
13-179
13-202
13-216
13-225
13-240
13-257
-------
CONTENTS (continued)
Columbus & Southern Ohio Electric
Conesville 5 13-260
Conesville 6 13-278
Cooperative Power Association
Coal Creek 1 13-293
Coal Creek 2 13-304
Delmarva Power & Light
Delaware City 1 13-313
Delaware City 2 13-323
Delaware City 3 13-333
Deseret Gen & Trans
Bonanza 1 13-343
Duquesne Light
Elrama 1-4 13-346
Phillips 1-6 13-366
East Kentucky Power
Spurlock 2 13-392
Grand Haven Board of Light and Power
J.B. Sims 3 13-397
Hoosier Energy
Merom 1 13-402
Merom 2 13-410
Houston Lighting and Power
W. A. Parish 8 13-420
Indianapolis Power & Light
Petersburg 3 13-427
Kansas City Power & Light
La Cygne 1 13-440
Kansas Power & Light
Jeffrey 1 13-470
Jeffrey 2 13-479
Jeffrey 3 13-487
Lawrence 4 13-492
Lawrence 5 13-506
Kentucky Utilities
Green River 1-3 13-520
Lakeland Utilities
Mclntosh 3 13-533
Louisville Gas & Electric
Cane Run 4 13-540
Cane Run 5 13-554
Cane Run 6 13-565
Mill Creek 1 13-574
Mill Creek 2 13-582
Mill Creek 3 13-589
Mill Creek 4 13-600
Paddy's Run 6 13-606
(continued)
vii
-------
CONTENTS (continued)
Marquette Board of Light and Power
Shiras 3 13-621
Michigan South Central Power Agency
Project I 13-625
Minnesota Power & Light
Clay Boswell 4 13-630
Minnkota Power
Milton R. Young 2 13-641
Monongahela Power
Pleasants 1 13-662
Pleasants 2 13-672
Montana Power
Colstrip 1 13-680
Colstrip 2 13-691
Colstrip 3 13-702
Montana-Dakota Utilities
Coyote 1 13-706
Muscatine Power & Water
Muscatine 9 13-712
Nevada Power
Reid Gardner 1 13-717
Reid Gardner 2 13-739
Reid Gardner 3 13-764
Reid Gardner 4 13-784
New York State Electric & Gas
Somerset 1 13-789
Niagara Mohawk Power
Charles R. Huntley 66 13-792
Northern Indiana Public Service
Schahfer 17 13-797
Northern States Power
Riverside 6-7 13-801
Sherburne 1 13-808
Sherburne 2 13-828
Pacific Power & Light
Jim Bridger 4 13-844
Pennsylvania Power
Bruce Mansfield 1 13-852
Bruce Mansfield 2 13-873
Bruce Mansfield 3 13-888
Philadelphia Electric
Cromby 1 13-899
Eddystone 1 13-904
Eddystone 2 13-908
Platte River Power Authority
Rawhide 1 13-912
(continued)
viii
-------
CONTENTS (continued)
Public Service of Indiana
Gibson 5
Public Service of New Mexico
San Juan 1
San Juan 2
San Juan 3
San Juan 4
Salt River Project
Coronado 1
Coronado 2
San Miguel Electric
San Miguel 1
Seminole Electric
Seminole 1
Seminole 2
Sikeston Board of Municipal Utilities
Sikeston 1
South Carolina Public Service
Cross 2
Winyah 2
Winyah 3
Winyah 4
South Mississippi Electric Power
R. D. Morrow, Sr. 1
R. D. Morrow, Sr. 2
Southern Illinois Power
Marion 4
Southern Indiana Gas & Electric
A. B. Brown 1
Springfield City Utilities
Southwest 1
Springfield Water, Light & Power
Dallman 3
Sunflower Electric
Holcomb 1
Tennessee Valley Authority
Paradise 1
Paradise 2
Widows Creek 7
Widows Creek 8
Texas Municipal Power Agency
Gibbons Creek 1
Texas Power & Light
Sandow 4
Texas Utilities
Martin Lake 1
Martin Lake 2
13-916
13-926
13-944
13-962
13-976
13-985
13-993
13-1000
13-1007
13-1012
13-1016
13-1023
13-1027
13-1042
13-1055
13-1065
13-1079
13-1093
13-1106
13-1121
13-1145
13-1159
13-1164
13-1169
13-1174
13-1180
13-1198
13-1204
13-1210
13-1222
(continued)
IX
-------
CONTENTS (continued)
Martin Lake 3
Monticello 3
United Power Association
Stanton 1A
Utah Power & Light
Hunter 1
Hunter 2
Hunter 3
Huntington 1
Naughton 3
West Penn Power
Mitchell 33
13-1233
13-1243
13-1253
13-1258
13-1269
13-1279
13-1283
13-1296
13-1301
x
-------
SECTION 13
DESIGN AND PERFORMANCE
FOR OPERATIONAL DOMESTIC FGD SYSTEMS
ALABAMA ELECTRIC, TOMBIGBEE 2
THROUGH
MONTANA POWER, COLSTRIP 2
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
SECTION 13
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 7.
AVERAGE SULFUR CONTENT - 7.
RAN3E SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** MECHANICAL COLLECTOR
NUMBER
TYPE
** ESP
NUMBER
NUMBER OF SPARES
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
TRADE NAME/COMMON NAME
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
*** FGD SYSTEM
ALABAMA ELECTRIC
TOMBIGBEE
2
LEROY
ALABAMA
D
516.
301.
525
255
235
243
179
RILEY STOKER
PULVERIZED COAL
BASE
449.72 (
143.9 (
122. (
CONCRETE
5.0 (
( .100 LB/MMBTU)
( 1.200 LB/MMBTU)
( .700 LB/MMBTU)
953000 ACFM)
291 F)
400 FT)
16.5 FT)
( 11424 BTU/LB)
10000-11000
COAL
BITUMINOUS
26572.
14.73
15-18
6.64
3.0-20.0
1.61
1.5-1.75
.04
******
0
NONE
1
0
HOT SIDE
RESEARCH-COTTRELL
449.7 ( 953000 ACFM)
143.9 ( 291 F)
.1 ( 1. IN-H20)
99.5
0
NONE
N/A
N/A
N/A
N/A
N/A
N/A
N/A
13-1
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ALABAMA ELECTRIC: TOMBIGBEE 2 (CONT.)
** GENERAL DATA
SALEABLE FRODUCT/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
ENERGY CONSUMPTION - 7.
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
DESIGN COAL SULFER CONTENT X
DESIGN COAL HEAT CONTENT - J/G
DESIGN COAL ASH CONTENT - X
DESIGN MOISTURE CONTENT - X
DESIGN CHLORIDE CONTENT - X
SPACE REQUIREMENTS SQ M
OPER. 4 MAINT. REQUIREMENT - MANHR/DAY
** QUENCHER/PRESATURATOR
NUMBER
TYPE
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
LIQUID RECIRCULATION RATE - LITERS/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
NONE
PEABODY PROCESS SYSTEMS
BURNS 8 MCDONNELL
FULL SCALE
NEW
7. 99.50
59.50
3.1
1
9/78
9/78
8/75
1.48
29075.0
10.00
8.00
.04
4645.0
72.0
( 12500 BTU/LB)
( 50000 SQ FT)
2
SPRAY
127.41 ( 270000 ACFM)
143.9 ( 291 F)
35. ( 550 GPM)
HIGH ALLOY
NICKEL BASE/CHROMIUM-IRON-COPPER-MOLYBDENUM
** ABSORBER
NUM5ER
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
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
NUMBER OF SPARES PER SYSTEM
NUMBER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
MANUFACTUPER
CONFIGURATION
2
0
SPRAY TOWER
OPEN COUNTERCURRENT SPRAY
N/A
PEABODY PROCESS SYSTEMS
24.0 DIA X 90.0
CARBON STEEL
AISI 1110
N/A
ORGANIC
GLASS FLAKE-FILLED POLYESTER
RESISTA-FLAKE 1151
NONE
6
1259.
9.9
1.0
3.0
127.41
54.4
85.0
99.5
(19980 GPM)
( 74.0 GAL/1000 ACF)
( 4.0 IN-H20)
( 10.0 FT/S)
( 270000 ACFM)
( 130 F)
PRIMARY COLLECTOR
2
0
1
IMPINGEMENT
BAFFLE
CLOSED VANE
SHAH-HEIL
HORIZONTAL
13-2
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ALABAMA ELECTRIC: TOMBIGBEE 2 (CONT.)
NUMBER OF STAGES
NUMBER OF PASSES PER STAGE
FREEBOARD DISTANCE - M
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
WASH WATER SOURCE
WASH FREQUENCY
** REHEATER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
LOCATION
PERCENT GAS BYPASSED - AVG
TEMPERATURE INCREASE - C
INLET FLUE GAS FLOW RATE - CU. M/S
INLET FLUE GAS TEMPERATURE - C
OUTLET FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC 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
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
MANUFACTURER
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
MANUFACTURER
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
1
1
1.22 (
.1 (
3.0 (
ORGANIC
POLYPHENYLENE
MAKEUP
INTERMITTENTLY
4.0 FT)
.5 IN-H20)
10.0 FT/S)
1
BYPASS
COLD SIDE
N/A
ABSORBER OUTLET DUCT
30.0
26.7 ( 48 F)
134.92 ( 285900 ACFM)
143.9 ( 291 F)
81.1 ( 178 F)
HIGH ALLOY
NICKEL BASE/CHROMIUM-IRON-MOLYBDENUM
2
0
CENTRIFUGAL
PEABODY PROCESS SYSTEMS
UNIT
FORCED DRAFT
DRY
225.10 ( 477000 ACFM)
143.9 ( 291 F)
CARBON STEEL
SHUT-OFF
GUILLOTINE
MOSSER
CARBON STEEL
NR
HIGH ALLOY
NICKEL BASE/CHROMIUM-IRON-COPPER-MOLYBDENUM
SHUT-OFF
GUILLOTINE
MOSSER
CARBON STEEL
NR
HIGH ALLOY
NICKEL BASE/CHROMIUM-IRON-COPPER-MOLYBDENUM
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
MANUFACTURER
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
2
CONTROL
LOUVER
MOSSER
CARBON STEEL
NR
NONE
N/A
** DUCTWORK
LOCATION
CONFIGURATION
DIMENSIONS
SHELL GENERIC MATERIAL TYPE
SCRUBBER INLET
RECTANGULAR
7 FT X 12 FT
CARBON STEEL
13-3
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
ALABAMA ELECTRIC: TOMBIGBEE 2 (CONT.)
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
»* DUCTWORK
LOCATION
CONFIGURATION
DIMENSIONS
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
MANUFACTURER
NUMBER
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
PRODUCT QUALITY - X SOLIDS
** TANKS
SERVICE
ABSORBER RECYCLE
MIST ELIMINATOR WASH
LIMESTONE SLURRY STORAGE
HYDROCLONE UNDERFLOW
MILL RECYCLE SUMP
WASTE SLURRY SUMP
** PUMPS
SERVICE
AISI 1110
NONE
N/A
SCRUBBER OUTLET TO STACK
RECTANGULAR
5.5 FT X 12 FT AND 13 FT X 16 FT
CARBON STEEL
AISI 1110
ORGANIC
FLUOROELASTOMER
WET BALL MILL
COMPARTMENTED
NR
KENNEDY VAN SAUN
9.1
35.0
NUMBER
1
1
1
****
1
1
( 10 TPH)
NUMBER
6
2
2
3
2
1
ABSORBER RECIRCULATION
LIMESTONE MILL SLURRY RECIRCULATION
LIMESTONE SLURRY FEED
MIST ELIMINATOR WA'SH
WASTE SLURRY
SUPERNATE RETURN
** SOLIDS CONCENTRATING/DEWATERING
DEVICE NONE
*** SLUDGE
FULL LOAD SLUDGE QUANTITY - M.TONS/HR (DRY)
V. CAS03 - DRY
7. CAS04 DRY
7. CACH2 DRY
7. CAC03 - DRY
7. ASH DRY
7. OTHER COMPOUNDS - DRY
** TREATMENT
METHOD BLEED
DEVICE N/A
PROPRIETARY PROCESS N/A
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE TREATMENT
SITE DIMENSIONS
SITE SERVICE LIFE - YRS
5.6
17.0
70.0
.0
5.0
1.0
7.0
6.2 TPH)
FINAL
POND
OH-SITE
PIPELINE
CLAY LINING
34.8 ACRE X 25 FT
20
13-4
-------
ALABAMA ELECTRIC: TOMBIGBEE 2 (CONT.)
UTILITY FED SURVEY: OCTOBER 1983 - SEPTEMBER 1984
** PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS
PHYSICAL VARIABLES
CONTROL LEVELS
MONITOR TYPE
MONITOR LOCATION
PROCESS CONTROL MANNER
PROCESS CHEMISTRY MODE
** WATER BALANCE
WATER LOOP TYPE
EVAPORATION WATER LOSS - LITER/S
SLUDGE HYDRATION WATER LOSS - LITER/S
POND SEEPAGE/RUNOFF WATER LOSS - LITERS/S
RECEIVING WATER STREAM
MAKEUP WATER ADDITION - LITERS/S
SOURCE OF MAKEUP WATER
** CHEMICALS AND CONSUMPTION
FUNCTION
NAME
PRINCIPAL CONSTITUENT
SOURCE/SUPPLIER
CONSUMPTION
UTILIZATION - X
POINT OF ADDITION
** FGD SPARE CAPACITY INDICES
ABSORBER - X
** FGD SPARE COMPONENT INDICES
ABSORBER
PH
PERCENT SOLIDS
PH 5.8-6.0
TBI
RECYCLE TANK
AUTOMATIC
FEEDBACK
CLOSED
10.5
.3
0
TOMBIGBEE RIVER
9.9
166 GP(1)
4 SPM)
( 157 GPM)
COOLING TOWER SLOWDOWN
ABSORBENT
LIMESTONE
95X CAC03
ALLIED PRODUCTS CO.
3.5 TPH [1.1 MOL/MOL S02]
90.0
BALL MILL
.0
.0
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL
S02 PART.
PER BOILER
HOURS HOURS
FGD CAP.
HOURS FACTOR
9/78 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.
10/78
A
B
SYSTEM
66.3
57.0
57.7
57.4
45.7
46.2
46.0
744 596
342
** PROBLEMS/SOLUTIONS/COMMENTS
BOILER SHUTDOWN.
ON OCTOBER 18 THE SUPERNATE LINE STARTED LEAKING. REPAIRS WERE MADE TO
THE FIBERGLASS PIPING.
11/78 A
B
SYSTEM
82.4
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.
13-5
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ALABAMA ELECTRIC: TOMBIGBEE 2 (CONT.)
PERIOD
PERFORMANCE DATA
MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
THE WASTE SLURRY AND SUPERNATE PIPING FAILURES WERE CORRECTED BY THE
ARCHITECT-ENGINEER.
12/78
A
B
SYSTEM
97.6
93.2
97.8 95. 4
91.8
87.6
89.7
744 700 668
** PROBLEMS/SOLUTIONS/COMMENTS
DOWNTIME DURING DECEMBER WAS NOT ATTRIBUTABLE TO THE FGD SYSTEM.
1/79
A
B
SYSTEM
75.3
65.8
89.2 70.6
75.1
65.6
70.4
744 742 524
«* PROBLEMS/SOLUTIONS/COMMENTS
SOME PLUGGING WAS ENCOUNTERED IN THE MIST
THE SYSTEM WAS DOWN FOR 75 HOURS SO THAT
CLEANED.
2/79
3/79
4/79
A
B
SYSTEM
A
B
SYSTEM
A
B
SYSTEM
95.0
96.3
98.4 95.7
93.1
94.4
94.5 93.8
100.0
100.0
100.0 100.0
42.0
42.6
42.3
92.2
93.6
92.9
40.6
40.6
40.6
ELIMINATOR DUE TO AN ESP OUTAGE.
THE MIST ELIMINATORS COULD BE
672 297 284
744 737 691
720 292 292
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY HAS REPORTED THAT NO UNUSUAL
5/79
6/79
A
B
SYSTEM
A
B
SYSTEM
48.8
58.9
92.7 53.9
1.8
95.4
98.3 48.6
47.6
57.4
52.5
1.0
51.8
26.4
PROBLEMS HAVE OCCURRED.
744 725 391
720 391 190
** PROBLEMS/SOLUTIONS/COMMENTS
7/79
8/79
A
B
SYSTEM
A
B
SYSTEM
THE UTILITY REPORTED THAT
WITH THE EXCEPTION OF DOWN
THE MIST ELIMINATORS WERE
21.0
70.9
93.0 46.0
88.9
24.9
99.2 56.9
THE FGD SYSTEM OPERATED WELL DURING MAY AND JUNE
TIME REQUIRED TO REPLACE THE MIST ELIMINATORS.
DEFORMED DURING A TEMPERATURE EXCURSION.
16.5
55.9
36.2
67.6
19.0
43.3
744 587 270
744 566 322
** PROBLEMS/SOLUTIONS/COMMENTS
THE SCRUBBER WAS NOT OPERATED FOR ABOUT 6 HOURS DUE TO A NECESSARY
ADJUSTMENT TO THE MODICON CONTROLLER.
13-6
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ALABAMA ELECTRIC: TOMBIGBEE 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
THE SCRUBBER WAS BYPASSED FOR ABOUT 37 HOURS DUE TO AN ESP OUTAGE.
9/79
A
B
SYSTEM
83.3
21.8
52.6
100.0
** PROBLEMS/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. Z 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
1/80
2/80
3/80
4/80
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
SLURRY LINE.
A
B
SYSTEM
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 100X OF THE TIME.
A
B
SYSTEM
100.0
61.3
86.6
74.0
61.3
86.5
73.9
720 719
532
13-7
-------
UTILITY FGO SURVEY: OCTOBER 1983 - SEPTEMBER
ALABAMA ELECTRIC: TOMBIGBEE 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROB.LEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT FOR THE MONTH OF APRIL THE SYSTEM WAS
AVAILABLE 100X OF THE TIME.
5/80
6/80
A
B
SYSTEM
34.9
92.8
63.9
34.7
92.2
63.5
100.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS AVAILABLE 100X OF THE MONTH OF MAY.
744 739
472
A
B
SYSTEM
100.0
.0
50.0
88.0
.0
44.0
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.
7/80
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
8/80
9/80
10/80
** 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.
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.
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.
A
B
SYSTEM
100.0
.0
50.0
.0
.0
.0
.0
.0
.0
744
.0
*# PROBLEMS/SOLUTIONS/COMMENTS
DURING OCTOBER THE UNIT WAS OUT OF SERVICE FOR A TURBINE/GENERATOR
INSPECTION.
13-8
-------
UTILITY FSD SURVEY: OCTOBER 1983 - SEPTEMBER
ALABAMA ELECTRIC: TOMBIGBEE Z (CONT.)
PERIOD
MODULE AVAILABILITY
OPERABILITY
KCKrUKHAN
RELIABILITY
REPAIR ON MODULE B DAMPER
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
OC UA 1 A
UTILIZATION /. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
MOTOR DRIVE CONTINUED THROUGHOUT THE MONTH.
15.5
.0
7.8
86.4
60.1
73.2
720 150 56 10.0
744 710 545 45.9
1/61
2/81
3/81
4/81
5/81
6/81
7/81
8/81
9/81
** 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.
SYSTEM 744
SYSTEM 672
SYSTEM 744
** PROBLEMS/SOLUTIOHS/COMMENTS
INFORMATION FOR THE FIRST QUARTER 1981 WAS NOT AVAILABLE AT THIS TIME.
SYSTEM 720
SYSTEM 744
SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION FOR THE SECOND QUARTER 1981 WAS NOT AVAILABLE.
SYSTEM 744
»* PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION FOR THE MONTH OF JULY WAS NOT AVAILABLE AT THIS TIME.
A
B
SYSTEM
A
B
SYSTEM
100.0
96.5
98.2
100.0
95.1
97.6
51.6
87.7
69.7
99.9
95.2
70.9
100.0
100.0
100.0
100.0
100.0
100.0
51.6
87.7
69.7
49.9
92.0
70.9
744 744
720 720
518 51.8
511 6.2
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE MONTHS OF AUGUST AND SEPTEMBER.
10/81
A
B
SYSTEM
16.9
16.9
16.9
3.5
99.6
51.5
3.5
99.6
51.5
.6
16.8
8.7
744 125
65 4.0
#* PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT AND THE FGD SYSTEM WERE OUT OF SERVICE FOR MOST OF OCTOBER FOR
SCHEDULED MAINTENANCE.
13-9
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ALABAMA ELECTRIC: TOMBIGBEE Z (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
11/81
12/81
1/82
2/82
3/82
4/82
5/82
A
B
SYSTEM
41.2
41.2
41.2
89.4
68.9
79.1
89.6
86.9
88.2
41.1
31.7
36.4
720 331 262 22.9
** PROBLEMS/SOLUTIONS/COMMENTS
DURING NOVEMBER THE SCHEDULED MAINTENANCE STARTED IN OCTOBER WAS COMPLETED.
A
B
SYSTEM
100.0
100.0
100.0
97.1
10.7
53.9
100.0
100.0
100.0
96.8
10.7
53.8
744 742
400 42.8
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING DECEMBER.
A
B
SYSTEM
93.3
93.3
93.3
93.4
.6
45.5
93.4
.8
47.1
93.4
.6
45.5
744 744
350 46.8
«* PROBLEMS/SOLUTIONS/COMMENTS
DURING JANUARY THE LIMESTONE FEED SYSTEM FROZE CAUSING AN UNAVAILABILITY
OF LIMESTONE SLURRY TO THE FGD SYSTEM.
A
B
SYSTEM
100.0
100.0
100.0
98.3
.0
49.1
81.5
.0
40.7
100.0
100.0 40.7 672 ' 557 274 38.2
** PROBLEMS/SOLUTIONS/COMMENTS
DURING FEBRUARY NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED.
A
B
SYSTEM
78.2
98.6
88.4
48.5
52.7
50.6
66.9
97.3
82.1
44.0
47.8
45.9
744 675
342 38.4
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MARCH THE MODULE A HYDROCLONE MALFUNCTIONED CAUSING SOME OUTAGE
TIME.
A
B
SYSTEM
A
B
SYSTEM
84.3
66.0
65.1
100.0
100.0
100.0
74.2
43.8
59.0
84.2
93.7
88.9
82.5
99.7
91.1
100.0
100.0
100.0
74.0
43.8
58.9
20.7
23.0
21.9
720 718
744 183
424 54.0
163 14.2
#* PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR FGD-RELATED PROBLEMS WERE REPORTED DURING THE MONTHS OF APRIL AND
MAY.
6/82 SYSTEM 99.2 99.5
** PROBLEMS/SOLUTIONS/COMMENTS
99.5
99.5
720 720
716 52.8
THE UTILITY REPORTED EXPERIENCING PROBLEMS WITH THE 2A OUTLET DAMPER DURING
JUNE.
7/82 SYSTEM
100.0
100.0
100.0
100.0
744
744
744 58.0
13-10
-------
UTILITY F6D SURVEY: OCTOBER 1933 - SEPTEMBER 1984
ALABAMA ELECTRIC: TOMBIGBEE 2 (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 MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING JULY.
8/82 SYSTEM 90.2 88.8 88.8 88.8 744 744 661 57.9
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED EXPERIENCING PROBLEMS WITH THE 2A AND 2B DAMPERS
DURING AUGUST.
9/82 SYSTEM 97.8 97.1 97.1 97.8 720 664 704 48.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE 2A DAMPERS WERE OUT OF SERVICE DURING PART OF SEPTEMBER FOR REPAIRS.
THE SCRUBBER WAS TAKEN OUT OF SERVICE DURING PART OF SEPTEMBER WHILE THE
PRECIPITATOR WAS TURNED OFF.
10/82 SYSTEM .0 .0 744 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE BOILER WAS SHUT DOWN DURING OCTOBER.
11/82 SYSTEM 74.7 98.4 98.4 73.9 720 540 532 49.1
** PROBLEMS/SOLUTIONS/COMMENTS
A BROKEN DAMPER CHAIN RESULTED IN DOWN TIME DURING NOVEMBER.
12/82 SYSTEM 95.2 95.0 95.0 90.8 744 711 676 48.2
»* PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING DECEMBER.
1/83 SYSTEM 100.0 100.0 100.0 100.0 744 744 744 59.2
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED BY THE UTILITY
DURING JANUARY.
2/83 SYSTEM 100.0 99.4 99.4 93.2 672 630 626 66.5
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE UNIT WAS SHUT DOWN DURING PART OF FEBRUARY.
3/83 SYSTEM 100.0 100.0 100.0 100.0 744 744 744 74.6
*» PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED BY THE UTILITY
DURING MARCH.
4/83 SYSTEM 89.7 98.1 98.1 82.0 720 602 591 60.6
5/83 SYSTEM .0 744 0 0
13-11
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
ALABAMA ELECTRIC: TOMBIGBEE 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
6/83
SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
720
THE UTILITY REPORTED THAT THE BOILER WAS SHUT DOWN DURING MAY AND JUNE FOR
A SCHEDULED MAINTENANCE OUTAGE.
7/83
A
B
SYSTEM
83.9
83.9
83.9
73.6
22.6
62.9
19.4
41.1
744 637
306 51.3
#* PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING JULY.
8/83
A
B
SYSTEM
96.9
100.0
98.5
78.3
21.7
50.0
78.2
21.7
49.9
744 743
372 65.8
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE A WAS OUT OF SERVICE DURING PART OF AUGUST FOR PRESATURATOR MAINTEN-
ANCE.
9/83
A
B
SYSTEM
100.0
100.0
100.0
25.7
73.8
49.8
25.4
73.1
49.3
720
712
355 51.9
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING SEPTEMBER.
10/83
A
B
SYSTEM
81.5
81.5
81.5
13.1
97.4
55.2
10.8
80.5
45.6
55.2 45.6 744 615
** PROBLEMS/SOLUTICNS/COMMENTS
NO MAJOR FGD-RELATED PROBLEMS WERE REPORTED DURING OCTOBER.
11/83 SYSTEM .0 720 0
»* PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS OFF LINE DURING NOVEMBER FOR A SCHEDULED FALL OUTAGE.
340 53.3
.0
12/83
A
B
SYSTEM
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
744 149
9.9
** PROBLEMS/SOLUTIONS/COMMENTS
SUB-FREEZING WEATHER CONDITIONS FORCED THE FGD SYSTEM OUT OF SERVICE DURING
DECEMBER. PIPING ASSOCIATED WITH LIMESTONE SLURRY FEED AND REAGENT PREPA-
RATION HAD FROZEN, PLUGGED, AND/OR BURSTED.
1/84
A
B
SYSTEM
45.4
80.0
62.7
18.8
62.5
40.6
40.6
18.8
62.5
40.6
744 744
302 55.2
13-12
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ALABAMA ELECTRIC: TOMBIGBEE 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
3/84
4/84
5/84
6/84
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE ABSORBER WAS INOPERABLE DUE TO FROZEN PIPES.
THE UTILITY REPORTED LIMESTONE FEED AND BALL MILL PROBLEMS DURING JANUARY.
A
B
SYSTEM
100.0
100.0
100.0
81.4
90.5
85.9
85.9
81.4
90.5
85.9
696 696
598 62.4
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING FEBRUARY.
A
B
SYSTEM
31.9
31.9
31.9
85.5
84.7
85.1
30.1
30.2
29.9
30.1
744 263
224 25.1
** PROBLEMS/SOLUTIONS/COMMENTS
THE ABSORBER WAS REMOVED FROM SERVICE DURING MARCH TO HELP DRY OUT THE
STACK.
THE UTILITY REPORTED THAT A UNIT TURBINE OUTAGE INSPECTION OCCURRED.
A
B
SYSTEM
.0
.0
.0
720 0
** PRC3LEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED A UNIT SHUT DOWN DUE TO A TURBINE OUTAGE.
.0
A
B
SYSTEM
12.9
12.9
12.9
3.4
54.3
28.8
6.5
.8
12.2
6.5
744 167
48 10.4
** PROBLEMS/SOLUTIONS/COMMENTS
THE ABSORBER WAS DOWN SEVERAL DAYS DURING MAY TO ALLOW HOT FLUE GAS TO DRY
THE STACK.
A
B
SYSTEM
100.0
100.0
100.0
77.0
53.7
65.3
65.3
77.0
53.7
65.3
720 720
470 61.2
** PROBLEMS/SOLUTIONS/COMMENTS
7/84
8/84
9/84
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING JUNE.
SYSTEM 744
SYSTEM 744
SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE THIRD QUARTER OF 1984.
13-13
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
SECTION 13
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION
S02 EMISSION LIMITATION - NG/J
NOX EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY -
GROSS UNIT GENERATING CAPACITY
NG/J
MW
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
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT 7.
RANGE CHLORIDE CONTENT 7.
*** PARTICLE CONTROL
»* MECHANICAL COLLECTOR
NUMBER
TYPE
*» ESP
NUMBER
NUMBER OF SPARES
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
TRADE NAME/COMMON NAME
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINEP SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
*** FGD SYSTEM
ALABAMA ELECTRIC
TOMBIGBEE
3
LEROY
ALABAMA
D
( .100 LB/MMBTU)
( 1.200 LB/MMBTU)
( .700 LB/MMBTU)
516.
301.
525
255
235
243
179
RILEY STOKER
PULVERIZED COAL
BASE
449.72 ( 953000 ACFM)
143.9 ( 291 F)
122. ( 400 FT)
CONCRETE
5.0 ( 16.5 FT)
( 11424 BTU/LB)
10000-11000
COAL
BITUMINOUS
26572.
14.73
15-18
6.64
3.0-20.0
1.61
1.5-1.75
.04
**»«#*
0
NONE
1
0
HOT SIDE
RESEARCH-COTTRELL
449.7 ( 953000 ACFM)
143.9 ( 291 F)
.1 (1. IN-H20)
99.5
0
NONE
N/A
N/A
N/A
N/A
N/A
N/A
N/A
13-14
-------
ALABAMA ELECTRIC: TOMBIGBEE 3 (CONT.)
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
** 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 302 REMOVAL EFFICIENCY - X
ENERGY CONSUMPTION - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
DESIGN COAL SULFER CONTENT - X
DESIGN COAL HEAT CONTENT - J/G
DESIGN COAL ASH CONTENT - X
DESIGN MOISTURE CONTENT - X
DESIGN CHLORIDE CONTENT - X
SPACE REQUIREMENTS - SQ M
OPER. i MAINT. REQUIREMENT - MANHR/DAY
»* QUENCHER/PRESATURATOR
NUMBER
TYPE
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
LIQUID RECIRCULATION RATE - LITERS/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** 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
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
NUMBER OF SPARES PER SYSTEM
NUMSER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
MANUFACTURER
CONFIGURATION
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
NONE
PEABODY PROCESS SYSTEMS
BURNS & MCDONNELL
FULL SCALE
NEW
X 99.50
59.50
3.1
1
6/79
6/79
8/75
29075.0
10.00
8.00
.04
4645.0
72.0
( 12500 BTU/LB)
( 50000 SQ FT)
2
SPRAY
127.41 ( 270000 ACFM)
143.9 ( 291 F)
35. ( 550 GPM)
HIGH ALLOY
NICKEL BASE/CHROMIUM-IRON-COPPER-MOLYBDENUM
2
0
SPRAY TOWER
OPEN COUNTERCURRENT SPRAY
N/A
PEABODY PROCESS SYSTEMS
24.0 DIA X 90.0
CARBON STEEL
AISI 1110
N/A
ORGANIC
GLASS FLAKE-FILLED POLYESTER
RESISTA-FLAKE 1151
NONE
6
1259. (19980 GPM)
9.9 (
1.0 (
3.0 (
127.41 (
54.4 (
85.0
99.5
74.0 GAL/1000 ACF)
4.0 IN-H20)
10.0 FT/S)
270000 ACFM)
130 F)
PRIMARY COLLECTOR
2
0
1
IMPINGEMENT
BAFFLE
CLOSED VANE
SHAH-HEIL
HORIZONTAL
13-15
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ALABAMA ELECTRIC: TOMBIGBEE 3 (CONT.)
NUMBER OF STAGES
NUMBER OF PASSES PER STAGE
FREEBOARD DISTANCE M
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
WASH WATER SOURCE
WASH FREQUENCY
** REHEATER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
LOCATION
PERCENT GAS BYPASSED - AVG
TEMPERATURE INCREASE - C
INLET FLUE GAS FLOW RATE - CU. M/S
INLET FLUE GAS TEMPERATURE - C
OUTLET FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC 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
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
MANUFACTURER
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
#* DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
MANUFACTURER
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
MANUFACTURER
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
CONFIGURATION
DIMENSIONS
SHELL GENERIC MATERIAL TYPE
1
1
1.22 (
.1 (
3.0 (
ORGANIC
POLYPHENYLENE
MAKEUP
INTERMITTENTLY
4.0 FT)
.5 IN-H20)
10.0 FT/S)
1
BYPASS
COLO SIDE
N/A
ABSORBER OUTLET DUCT
30.0
26.7
134.92
143.9
81.1
48 F)
285900 ACFM)
291 F)
178 F)
HIGH ALLOY
NICKEL BASE/CHROmUM-IRON-MOLYBDENUM
2
0
CENTRIFUGAL
PEABODY PROCESS SYSTEMS
UNIT
FORCED DRAFT
DRY
225.10 ( 477000 ACFM)
143.9 ( 291 F)
CARBON STEEL
SHUT-OFF
GUILLOTINE
MOSSER
CARBON STEEL
NR
HIGH ALLOY
NICKEL BASE/CHROMIUM-IRON-COPPER-MOLYBDENUM
SHUT-OFF
GUILLOTINE
MOSSER
CARBON STEEL
NR
HIGH ALLOY
NICKEL BASE/CHROMIUM-IRON-COPPER-MOLYBDENUM
CONTROL
LOUVER
MOSSER
CARBON STEEL
NR
NONE
N/A
SCRUBBER INLET
RECTANGULAR
7 FT X 12 FT
CARBON STEEL
13-16
-------
UTILITY F6D SURVEY: OCTOBER 1983 - SEPTEMBER
ALABAMA ELECTRIC: TOMBIGBEE 3 (CONT.)
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
»* DUCTWORK
LOCATION
CONFIGURATION
DIMENSIONS
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
MANUFACTURER
NUMBER
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
PRODUCT QUALITY - X SOLIDS
** TANKS
SERVICE
ABSORBER RECYCLE
MIST ELIMINATOR WASH
LIMESTONE SLURRY STORAGE
HYDROCLONE UNDERFLOW
MILL RECYCLE SUMP
WASTE SLURRY SUMP
*» PUMPS
SERVICE
AISI 1110
NONE
N/A
SCRUBBER OUTLET TO STACK
RECTANGULAR
5.5 FT X 12 FT AND 13 FT X 16 FT
CARBON STEEL
AISI 1110
ORGANIC
FLUOROELASTOMER
WET BALL MILL
COMPARTMENTED
NR
KENNEDY VAN SAUN
9.1
35.0
NUMBER
1
1
1
#***
1
1
ABSORBER RECIRCULATION
LIMESTONE MILL SLURRY RECIRCULATION
LIMESTONE SLURRY FEED
MIST ELIMINATOR WASH
WASTE SLURRY
SUPERNATE RETURN
»* SOLIDS CONCENTRATING/DEWATERING
DEVICE
*** SLUDGE
FULL LOAD SLUDGE QUANTITY - M.TONS/HR (DRY)
/. CAS03 - DRY
V. CAS04 - DRY
7. CAOH2 - DRY
V. CAC03 - DRY
/. ASH - DRY
7. OTHER COMPOUNDS - DRY
#* TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
*» DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE TREATMENT
SITE DIMENSIONS
SITE SERVICE LIFE - YRS
NUMBER
6
Z
Z
3
2
1
NONE
5.6
17.0
70.0
.0
5.0
1.0
7.0
( 10 TPH)
6.2 TPH)
BLEED
N/A
N/A
FINAL
PON'D
ON-SITE
PIPELINE
CLAY LINING
34.8 ACRE X 25 FT
20
13-17
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
ALABAMA ELECTRIC: TOMBIGBEE 3 (CONT.)
** PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS
PHYSICAL VARIABLES
CONTROL LEVELS
MONITOR TYPE
MONITOR LOCATION
PROCESS CONTROL MANNER
PROCESS CHEMISTRY MODE
** WATER BALANCE
WATER LOOP TYPE
EVAPORATION WATER LOSS - LITER/S
SLUDGE HYDRATION WATER LOSS - LITER/S
RECEIVING WATER STREAM
MAKEUP WATER ADDITION - LITERS/S
SOURCE OF MAKEUP WATER
CHEMICALS AND CONSUMPTION
FUNCTION
NAME
PRINCIPAL CONSTITUENT
SOURCE/SUPPLIER
CONSUMPTION
UTILIZATION - X
POINT OF ADDITION
PH
PERCENT SOLIDS
PH 5.8-6.0
TBI
RECYCLE TANK
AUTOMATIC
FEEDBACK
CLOSED
10.5 (
.3 (
166 GPM)
4 GPM)
POND SEEPAGE/RUNOFF WATER LOSS - LITERS/S 0
TOMBIGBEE RIVER
9.9 ( 157 GPM)
COOLING TOWER SLOWDOWN
ABSORBENT
LIMESTONE
95X CAC03
ALLIED PRODUCTS CO.
3.5 TPH [1.1 MOL/MOL S02I
90.0
BALL MILL
** FGD SPARE CAPACITY INDICES
ABSORBER - 7.
** FGD SPARE COMPONENT INDICES
ABSORBER
.0
.0
_ PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
502 PART. HOURS HOURS HOURS FACTOR
7/79
8/79
9/79
A
B
SYSTEM
23.7
27.8
25.8
11.0
10.2
744 295
76
72.7
*» PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM IS CURRENTLY UNDERGOING SHAKEDOWN/DEBUGGING OPERATIONS.
A
B
SYSTEM
59.4
44.5
52.0
99.7
** PROBLEMS/SOLUTIONS/COMMENTS
39.1
29.3
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
82.7
82.7
13-18
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ALABAMA ELECTRIC: TOMBIGBEE 3 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
502 PART. HOURS HOURS HOURS FACTOR
11/79
12/79
1/80
2/80
B
SYSTEM
90.9
86.8
99.5
** PROBLEMS/SOLUTIONS/COMMENTS
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 SYSTEM, WHICH CAUSED
A SHORTAGE OF REAGENT SLURRY, KEPT THE FGD SYSTEM OFF LINE FOR 4 HOURS.
A
B
SYSTEM
78.6
89.3
84.0
96.7
** PROBLEMS/SOLUTIONS/COMMENTS
78.6
89.3
84.0
720 720
605
DURIHG 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.
A
B
SYSTEM
69.2
45.4
57.3
30.5
20.0
25.3
100.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JANUARY UNIT 3 WAS AVAILABLE THE ENTIRE MONTH.
744 328
188
A
B
SYSTEM
33.3
100.0
66.7
100.0
** PROBLEMS/SOLUTIONS/COMMENTS
1.2
3.5
2.4
696
24
16
DURING 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
DURING MARCH THE UNIT 3 GENERATOR WAS KEPT OUT OF SERVICE. THE FGD SYSTEM
WAS AVAILABLE THE ENTIRE MONTH.
.0
720
4/80 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT DURING APRIL THE BOILER DID NOT OPERATE.
5/80 A 8.3 .7
.0
13-19
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
ALABAMA ELECTRIC: TOM3IGBEE 3 (CONT. )
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
6/80
B
SYSTEM
.0
4.2
95.8
** PROBLEMS/SOLUTIONS/COMMENTS
.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.
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
** PROBLEMS/SOLUTIONS/COMMENTS
NO FGD SYSTEM-RELATED PROBLEMS WERE ENCOUNTERED DURING JUNE.
379 52.0
7/80
A
B
SYSTEM
100.0
100.0
100.0
45.5
90.0
67.8
** PROBLEMS/SOLUTIONS/COMMENTS
100.0
100.0
100.0
39.7
78.6
59.2
744 650
440 47.8
8/80
9/80
10/80
11/80
THE FGD SYSTEM WAS AVAILABLE FOR OPERATION THE ENTIRE MONTH OF JULY.
MODULES ARE UTILIZED ON AN AS NEEDED BASIS.
THE
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
** PROBLEMS/SOLUTIONS/COMMENTS
NO FGD-RELATED PROBLEMS WERE ENCOUNTERED DURING THE MONTH OF AUGUST.
720 369 304 32.4
744 744 472 69.4
720 720 617 55.4
A
B
SYSTEM
A
B
SYSTEM
A
B
SYSTEM
90
90
90
97
97
97
99
99
99
.6
.6
.6
.4
.4
.4
.3
.3
.3
91.
73.
82.
68.
60.
63.
83.
87.
85.
4
7
4
4
9
4
6
9
7
91
73
82
68
60
63
83
87
85
.4
.7
,4
.4
.9
.4
.6
.9
.7
46
37
42
68
60
63
83
87
85
.8
.8
.2
.4
.9
.4
.6
.9
.7
** PROBLEMS/SOLUTIONS/COMMENTS
DURING SEPTEMBER THROUGH NOVEMBER PROBLEMS WERE ENCOUNTERED WITH THE
FROGRAMABLE 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
13-20
-------
UTILITY F60 SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ALABAMA ELECTRIC: TOMBIGBEE 3 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
SOS PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
NO PROBLEMS WERE ENCOUNTERED WITH THE UNIT OR THE FGD SYSTEM DURING DEC-
EMBER.
1/81
2/81
3/81
4/81
5/31
6/81
7/81
8/81
9/81
SYSTEM 744
SYSTEM 672
SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION FOR THE FIRST QUARTER 1981 WAS NOT AVAILABLE AT THIS TIME.
SYSTEM 720
SYSTEM 744
SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION FOR THE SECOND QUARTER 1981 WAS NOT AVAILABLE.
SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION FOR THE MONTH OF JULY WAS NOT AVAILABLE AT THIS TIME.
A
B
SYSTEM
A
B
SYSTEM
87.6
99.6
93.6
30.1
30.1
30.1
56.4
50.6
53.5
99.7
99.7
99.7
100.0
100.0
100.0
100.0
100.0
100.0
56.0
50.3
53.1
24.1
26.8
25.4
744
739
720 217
395 45.0
183 18.5
** PROBLEMS/SOLUTIONS/COMMENTS
DURING SEPTEMBER LOW SYSTEM UTILIZATION WAS DUE TO THE FACT THAT THE WIT
AND THE FGD SYSTEM WERE SHUTDOWN FOR SCHEDULED REPAIRS.
10/81
11/81
13/81
A
B
SYSTEM
A
B
SYSTEM
A
B
SYSTEM
96
96
96
99
99
99
95
95
95
.8
.8
.8
.2
.2
.2
.6
.6
.6
40
76
58
95
56
75
87
15
51
.2
.0
.1
.3
.5
.9
.8
.4
.6
92.
95
94.
98.
98
98
95,
77,
86,
.4
.9
.1
.9
.1
.5
.2
.6
.4
39.
74.
57.
74.
44.
59.
87.
15.
51.
5
8
2
5
2
3
7
4
5
744 732
720 563
744
743
425 62.8
427 43.4
383 48.1
*» PROBLEMS/SOLUTIONS/COMMENTS
DURING THE FOURTH QUARTER THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED
PROBLEMS WERE ENCOUNTERED.
1/82 A
93.3
78.6
91.9
76.2
13-21
-------
2/82
3/82
A
B
SYSTEM
A
B
SYSTEM
98.7
98.7
98.7
100.0
100.0
100.0
61.8
45.9
53.8
86.6
13.4
50.0
97.9
97.2
97.5
100.0
100.0
100.0
61.8
45.9
53.8
86.6
13.4
50.0
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ALABAMA ELECTRIC: TOMBIGBEE 3 (CONT.)
. PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
SOZ PART. HOURS HOURS HOURS FACTOR
B 93.3 14.7 67.9 14.2
SYSTEM 93.3 46.6 79.9 45.2 744 721 336 45.7
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JANUARY THE LIMESTONE FEED SYSTEM FROZE CAUSING AN UNAVAILABILITY
OF LIMESTONE SLURRY TO THE FGD SYSTEM.
672 672 362 51.7
744 744 372 45.1
»* PROBLEMS/SOLUTIONS/COmENTS
NO MAJOR FGD-RELATED PROBLEMS WER.E REPORTED FOR THE MONTHS OF FEBRUARY AND
MARCH.
>3.5 97.1 41.3
»0.8 96.0 26.5
720 468 244 26.9
744 744 661 78.9
** PROBLEMS/SOLUTIONS/COMMENTS
DURING APRIL AND MAY NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED.
6/82 SYSTEM 100.0 100.0 100.0 100.0 720 720 720 68.4
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING JUNE.
7/82 SYSTEM 100.0 99.4 99.4 99.4 744 744 740 64.7
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE A WAS OUT OF SERVICE DURING PART OF JULY DUE TO DAMPER PROBLEMS.
8/82 SYSTEM 100.0 95.3 95.3 95.3 744 744 709 67.4
*» PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING AUGUST.
9/82 SYSTEM 100.0 99.7 99.7 99.7 720 720 718 57.3
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED BY THE UTILITY
DURING SEPTEMBER.
10/82 SYSTEM 100.0 100.0 100.0 100.0 744 744 744 76.3
4/82
5/82
A
B
SYSTEM
A
B
SYSTEM
98.7
98.9
98.8
98.8
99.2
99.0
63.5
40.8
52.2
98.8
99.2
99.0
97.1
96.0
96.5
98.8
99.0
98.9
41.3
26.5
33.9
98.3
79.3
88.8
13-22
-------
UTILITY FGD SURVEY: OCTOBER 1933 - SEPTEMBER 1984
ALABAMA ELECTRIC: 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
NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED BY THE UTILITY
DURING OCTOBER.
11/82 SYSTEM 100.0 98.5 98.5 36.2 720 265 261 24.6
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE SCRUBBER WAS TAKEN OUT OF SERVICE DURING
NOVEMBER WHILE THE PRECIPITATOR WAS OUT OF SERVICE.
12/82 SYSTEM 100.0 91.5 91.5 49.0 744 398 365 24.1
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE A WAS OUT OF SERVICE DURING PART OF DECEMBER DUE TO PLUGGED INLET
NOZZLES.
1/83 SYSTEM 100.0 99.6 99.6 66.6 744 498 496 30.9
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS SHUT DOWN DURING PART OF JANUARY FOR A SCHEDULED OUTAGE.
THE 3A QUENCHER EXPERIENCED LOW FLOW PROBLEMS DURING JANUARY.
2/83 SYSTEM .0 .0 672 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS SHUT DOWN DURING FEBRUARY FOR A SCHEDULED OUTAGE.
3/83 SYSTEM .0 .0 744 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
THE SCHEDULED SHUTDOWN CONTINUED THROUGH MARCH.
4/83 SYSTEM 16.1 66.5 66.5 16.3 720 177 118 14.6
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT MAKE-UP WATER LINES WERE REPAIRED DURING APRIL.
5/83 SYSTEM 100.0 100.0 100.0 100.0 744 744 744 81.3
6/83 SYSTEM 99.9 99.4 99.4 99.4 720 720 716 78.8
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE A WAS OUT OF SERVICE DURING PART OF JUNE FOR MAINTENANCE.
7/83 A 100.0 85.0 84.7
B 100.0 99.9 99.6
SYSTEM 100.0 92.4 92.2 744 742 686 71.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING JULY.
8/83 A 97.7 40.6 40.6
13-23
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ALABAMA ELECTRIC: TOMBI6BEE 3 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
502 PART. HOURS HOURS HOURS FACTOR
10/83
B
SYSTEM
12/83
1/84
100.0
98.9
59.5
50.1
59.5
50.1
744
744
373 63.0
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE A WAS OUT OF SERVICE DURING PART OF AUGUST FOR PRESATURATOR MAINTEN-
ANCE.
9/83 A
B
SYSTEM
70.1
70.1
70.1
32.4
66.6
49.5
22.7
46.7
34.7
720 505 250
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS SHUT DOWN DURING SEPTEMBER FOR A SCHEDULED FALL OUTAGE.
34.4
A
B
SYSTEM
18.0
18.0
18.0
57.7
64.8
61.3
11.7
13.2
12.5
61.3 12.5 744 151 93 11.7
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS DOWN DURING MOST OF OCTOBER FOR A SCHEDULED FALL OUTAGE.
11/83 A
B
SYSTEM
77.9
82.4
80.1
69.4
61.0
65.2
69.4
61.0
65.2
470 66.0
65.2 65.2 720 720
** PROBLEMS/SOLUTIONS/COMMENTS
BROKEN LIMESTONE FEED LINES WERE REPORTED DURING NOVEMBER.
A FOUR-HOUR OUTAGE OCCURRED DURING NOVEMBER FOR MAINTENANCE ON THE LIME-
STONE PREPARATION EQUIPMENT.
THE UTILITY REPORTED PROBLEMS PLACING MODULE A IN SERVICE DURING NOVEMBER
DUE TO COMPUTER-RELATED PROBLEMS.
THE FGD SYSTEM WAS OUT OF SERVICE FOR FIVE DAYS DURING NOVEMBER TO DRY OUT
THE STACK.
A
B
SYSTEM
85.2
91.5
88.4
63.7
72.9
68.3
68.3
63.7
72.9
68.3
744
744
508 68.1
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED PROBLEMS WITH AN INLET DAMPER AT MODULE A DURING
DECEMBER.
SUB-FREEZING WEATHER CONDITIONS FORCED THE FGD SYSTEM OUT OF SERVICE DURING
DECEMBER CAUSING FROZEN, PLUGGED, AND/OR BURSTED PIPE LINES.
INCLEMENT WEATHER FORCED THE LIMESTONE PREPARATION EQUIPMENT OUT OF
SERVICE DURING DECEMBER.
A
B
SYSTEM
74.2
25.3
49.7
74.2
.0
37.1
37.1
74.2
.0
37.1
744
744
276 51.3
13-24
-------
UTILITY F6D SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ALABAMA ELECTRIC: 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
THE UTILITY REPORTED THAT THE ABSORBER WAS INOPERABLE DURING JANUARY DUE
TO FROZEN PIPES.
MECHANICAL PROBLEMS WITH MODULE B DISCHARGE DAMPER OCCURRED IN JANUARY.
LIMESTONE FEED AND BALL MILL PROBLEMS WERE REPORTED DURING THE MONTH.
2/84
3/64
4/84
5/84
6/84
A
B
SYSTEM
47.0
.0
23.5
95.9
.0
47.9
23.2
46.5
.0
23.2
696
337
162 22.8
*» PROBLEMS/SOLUTIONS/COMMENTS
MECHANICL PROBLEMS CONTINUED ON THE MODULE B DISCHARGE DAMPER DURING
FEBRUARY.
A
B
SYSTEM
55.2
59.7
57.5
58.4
48.5
53.4
36.8
40.3
33.4
36.8
744 513
274 40.9
** PROBLEMS/SOLUTIONS/COMMENTS
THE 3B DISCHARGE DAMPER WAS INOPERABLE IN MARCH DUE TO MECHANICAL
PROBLEMS.
MODULE A WAS INOPERABLE DUE TO A PLUGGED HYDROCLONE.
A
B
SYSTEM
73.8
73.8
73.8
72.6
48.8
60.7
60.6
72.5
48.7
60.6
720
719
436 73.8
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS OUT OF SERVICE DURING PART OF APRIL TO ALLOW HOT FLUE
GAS TO DRY THE STACK. WATER CARRYOVER HAD COLLECTED IN THE BASE OF THE
STACK MAKING IT DIFFICULT TO MAINTAIN ADEQUATE TEMPERATURES ABOVE DEW
POINT.
A
B
SYSTEM
98.5
98.5
98.5
94.0
74.1
84.1
82.8
92.6
73.0
82.8
744 733
616 73.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE ABSORBER WAS UNAVAILABLE IN MAY DUE TO THE REPLACEMENT OF MAKE-UP
WATER VALVES AND THE ROTATION OF MAKE-UP WATER NOZZLES.
A
B
SYSTEM
100.0
99.4
99.7
82.4
77.1
79.7
79.7
82.4
77.1
79.7
720 720
574 67.9
** PROBLEMS/SOLUTIONS/COMMENTS
7/84
8/84
9/84
SYSTEM
SYSTEM
SYSTEM
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING JUNE.
744
744
720
13-25
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1964
ALABAMA ELECTRIC: TOMBIGBEE 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
INFORMATION WAS UNAVAILABLE FOR THE THIRD QUARTER OF 198*.
13-26
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
SECTION 13
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
UP,
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 WIT 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
ARIZONA ELECTRIC POWER
APACHE
Z
COCHISE
ARIZONA
C
301.
530
195
175
183
98
RILEY STOKER
PULVERIZED COAL
BASE
520.98
376.7
122.
CONCRETE
4.9
.100 LB/MMBTU)
.800 LB/MMBTU)
.700 LB/MMBTU)
(1104000 ACFM)
( 710 F)
( 400 FT)
( 16.2 FT)
COAL
SUBBITUMINOUS
23260.
15.00
15-20
13.00
9.0-15.0
.70
0.4-0.6
.01
0.00-0.03
0
NONE
( 10000 BTU/LB)
9500-10800
** ESP
NUMBER
NUM3ER OF SPARES
TYPE
SUPPLIER
INLET FLUE GAS CAPACITY - CU.M/S
INLET FLUE GAS TEMPERATURE C
PRESSURE DROP KPA
PARTICLE REMOVAL EFFICENCY V.
** PARTICLE SCRUBBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON NAME
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
1
0
HOT SIDE
AIR CORRECTION DIVISION, UOP
521.0 (1104000 ACFM)
376.7 ( 710 F)
.1 (1. IN-H20)
99.6
0
NONE
N/A
N/A
N/A
N/A
N/A
N/A
N/A
*** FGD SYSTEM
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ARIZONA ELECTRIC POWER: APACHE Z (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 502 REMOVAL EFFICIENCY - X
ENERGY CONSUMPTION X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
DESIGN COAL SULFER CONTENT - X
DESIGN COAL HEAT CONTENT - J/G
DESIGN COAL ASH CONTENT - X
DESIGN MOISTURE CONTENT - X
DESIGN CHLORIDE CONTENT - X
SPACE REQUIREMENTS - SQ M
OPER. a MAINT. REQUIREMENT - MANHR/DAY
** QUENCHER/PRESATURATOR
NUMBER
TYPE
SUPPLIER
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
PRESSURE DROP - KPA
LIQUID RECIRCULATION RATE LITERS/S
L/G RATIO L/CU. M
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
NONE
RESEARCH-COTTRELL
BURNS 4 MCDONNELL
FULL SCALE
NEW
7. 99.60
85.00
4.1
1
1/79
8/78
7/74
1.00
23260.0
17.00
18.00
.00
4046.7
72.0
( 10000 BTU/LB)
( 43560 SQ FT)
CYCLONIC SPRAY QUENCHER
RESEARCH-COTTRELL
188.76
132.2
.2
567.
2.7
CARBON STEEL
AISI 1110
400000 ACFM)
270 F)
1.0 IN-H20)
9000 GPM)
20.0 GAL/1000 ACFM)
** 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 CONTACTIK'3 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 - X
PARTICLE REMOVAL EFFICENCY X
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
NUMBER OF SPARES PER SYSTEM
NUMBER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
2
1
COMBINATION TOWER
SPRAY/PACKED
N/A
RESEARCH-COTTRELL
30.0 DIA X 110.0
CARBON STEEL
AISI 1110
N/A
ORGANIC
GLASS FLAKE-FILLED POLYESTER
FLAKELINE 103
SPRAY ZONE i VERTICAL CROSS CHANNEL FIXED GRID P
567.
5.3
.6
3.0
94.38
68.3
97.0
99.6
( 9000 GPM)
( 40.0 GAL/1000 ACF)
( 2.5 IN-H20)
( 10.0 FT/S)
( 200000 ACFM)
( 155 F)
PRIMARY COLLECTOR
2
1
1
IMPINGEMENT
BAFFLE
13-28
-------
UTILITY FED SURVEY: OCTOBER 1983 - SEPTEMBER
ARIZONA ELECTRIC POWER: APACHE 2 (CONT.)
TRADE NAME/COMMON TYPE
MANUFACTURER
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
CONSTRUCTION MATERIAL SPECIFIC TYPE
WASH WATER SOURCE
WASH FREQUENCY
WASH RATE - L/S
** REHEATER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
PERCENT GAS BYPASSED - AVS
TEMPERATURE INCREASE C
INLET FLUE GAS TEMPERATURE - C
OUTLET FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** FANS
NUMBER
NUMBER OF SPARES
DESIC-N
SUPPLIER
FUNCTION
APPLICATION
.SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
CONSTRUCTION MATERIAL GENERIC TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MODULATION
SEAL AIR FLOU - CU. M/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MODULATION
SEAL AIR FLOW - CU. M/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
CLOSED VANE
HUNTERS
HORIZONTAL
2
3
.61
30.48
10.2
( 2.0 FT)
(12.0 IN)
( 4.00 IN)
1.0 IN-H20)
10.0 FT/S)
.2
3.0
ORGANIC
POLYVINYL CHLORIDE
FRESH
INTERMITTENT [LOWER STAGE]; ONCE EVERY HOUR [UPP
12.6 ( 200 GAL/MIN)
0
NONE
K/A
N/A
50.
43.
46.
89.
NONE
N/A
( 78 F)
( 115 F)
( 193 F)
2
0
CENTRIFUGAL
WESTINGHOUSE
UNIT
FORCED DRAFT
DRY
188.76
132.2
6.2
CARBON STEEL
( 400000 ACFM)
( 270 F)
(20.5 IN-H20)
SHUT-OFF
LOUVER
PARALLEL BLADE MULTILOUVER
OPEN/CLOSED
.24 ( 500 ACFM)
CARBON STEEL
NR
NONE
N/A
SHUT-OFF
GUILLOTINE
TOP-ENTRY GUILLOTINE
OPEN/CLOSED
.24 ( 500 ACFM)
CARBON STEEL
NR
HIGH ALLOY
NICKEL BASE/CHROMIUM-IRON-COPPER-MOLYBDENUM
SHUT-OFF
LOUVER
PARALLEL BLADE MULTILOUVER
13-29
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ARIZONA ELECTRIC POWER: APACHE 2 (CONT.)
MODULATION
SEAL AIR FLOW - CU. M/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
CONFIGURATION
DIMENSIONS
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
OPEN/CLOSED
.2"+ ( 500 ACFM)
CARBON STEEL
NR
HIGH ALLOY
NICKEL BASE/CHROMIUM-IRON-COPPER-MOLYBDENUM
ABSORBER INLET
RECTANGULAR
12.0 X 14.0
CARBON STEEL
AISI 1110
NONE
N/A
** DUCTWORK
LOCATION
CONFIGURATION
DIMENSIONS
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
MANUFACTURER
NUMBER
NUMBER OF SPARES
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
PRODUCT QUALITY - 7. SOLIDS
** TANKS
SERVICE
ABSORBER FEED
REAGENT FEED
MILL SLURRY SUMP
WASTE SLURRY SUMP
** PUMPS
SERVICE
AESOPBER
QUENCHER
MILL SLURRY RECYCLE
ADDITIVE FEED
WASTE SLURRY TRANSFER
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
*»* SLUDGE
MOISTURE CONTENT - 7. TOTAL FREE WATER
7. CAS04 DRY
** TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
ABSORBER OUTLET
RECTANGULAR
12.0 X 14.0
CARBON STEEL
AISI 1110
ORGANIC
FLUOROELASTOMER
WET BALL MILL
COMPARTMENTED
NR
KENNEDY VAN SAUN
1
0
4.5 (
45.0
NUMBER
NUMBER
3
4
2
2
1
NONE
70.0
80.0
NONE
N/A
N/A
FINAL
POND
OFF-SITE
PIPELINE
S TPH)
13-30
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ARIZONA ELECTRIC POWER: APACHE 2 (CONT.)
SITE TREATMENT
SITE DIMENSIONS
SITE CAPACITY - CU.M
SITE SERVICE LIFE - YRS
** PROCESS CONTROL AND INSTRUMENTATION
PROCESS STREAM
CHEMICAL PARAMETERS
PHYSICAL VARIABLES
CONTROL LEVELS
PROCESS CONTROL MANNER
PROCESS CHEMISTRY MODE
»* WATER BALANCE
WATER LOOP TYPE
MAKEUP WATER ADDITION - LITERS/S
SOURCE OF MAKEUP WATER
** CHEMICALS AND CONSUMPTION
FUNCTION
NAME
PRINCIPAL CONSTITUENT
SOURCE/SUPPLIER
UTILIZATION - X
POINT OF ADDITION
** FGD SPARE CAPACITY INDICES
ABSORBER X
MIST ELIMINATOR - X
FAN - X
BALL MILL - V.
EFFLUENT HOLD TANK - X
RECIRCULATION PUMP - X
NONE
25 TO 30 ACRES BY 18 FT DEEP
611500 ( 500.0 ACRE-FT)
30
QUENCHER RECYCLE LINE
PH
PERCENT SOLIDS
5.0 PH
MANUAL
FEEDBACK
OPEN
115.9
WELL WATER
ABSORBENT
LIMESTONE
>93X CAC03
PAUL LIME
99.0
BALL MILL
100.0
.0
.0
.0
.0
50.0
( 1840 GPM)
** FGO SPARE COMPONENT INDICES
ABSORBER
MIST ELIMINATOR
FAN
BALL MILL
EFFLUENT HOLD TANK
RECIRCULATION PUMP
1.0
.0
.0
.0
.0
1.0
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
INITIAL OPERATIONS BEGAN IN AUGUST WITH THE BOILER AND SCRUBBER SYSTEM
FOR TESTING PURPOSES.
720
** PROBLEMS/SOLUTIONS/COMMENTS
SCRUBBER AND BOILER TESTING CONTINUED THROUGH SEPTEMBER.
CONSTRUCTION SHOULD BE COMPLETE BY OCTOBER.
FINAL FACILITY
10/78 SYSTEM
*» PROBLEMS/SOLUTIONS/COMMENTS
744 303
59.5
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
13-31
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ARIZONA ELECTRIC POWER: APACHE 2 (CONT.)
. PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
STEEL TO STAINLESS STEEL.
11/78 A 2^.8 16.8
B 43.7 29.6
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-
INS 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
** PROBLEMS/SOLUTIONS/COMMENTS
COMPLIANCE TESTS WERE RUN ON THIS UNIT LAST NOVEMBER AND THE UNIT WAS
DECLARED COMMERCIAL IN FEBRUARY. THE FGD SYSTEM OPERATES ONLY ABOUT 50
7. 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
13-32
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ARIZONA ELECTRIC POWER: APACHE 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
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
8/79 SYSTEM 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
** 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 1007. OF THE TIME.
THE BOILER ENCOUNTERED DAMPER PROBLEMS THAT ACCOUNTED FOR MOST OF THE
DECEMBER DOUN TIME.
1/80 SYSTEM 91.0 58.3 88.8 57.3 744 731 426 56.1
13-33
-------
UTILITY FGD SURVEY: OCTOBER 1983 SEPTEMBER 1984
ARIZONA ELECTRIC POWER: APACHE 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
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 92.8 96.7 92.8 92.8 696 668 646 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 99.1 744 744 738 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/COMMENTS
.-J
DURING 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
** 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
13-34
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ARIZONA ELECTRIC POWER: APACHE 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
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
203 92.6 87.7 98.6 82.4
SYSTEM 92.7 87.7 98.6 82.4 744 699 613 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 FIRST 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
203 .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.
1/81 202 100.0 62.9 100.0 62.9
203 .0 .0 .0
SYSTEM 100.0 62.9 100.0 62.9 744 744 468 86.6
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE 202 WAS NOT OPERATED DURING THE LAST 276 HOURS OF THE MONTH AS A
RESULT OF THE LOW SULFUR CONTENT OF THE COAL BEING FIRED.
MODULE 203 WAS NOT AVAILABLE FOR OPERATION DURING JANUARY.
2/81 202 100.0 10.7 100.0 10.7
203 .0 .0 .0
SYSTEM 100.0 10.7 100.0 10.7 672 672 72 77.4
13-35
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ARIZONA ELECTRIC POWER: APACHE 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
DURING FEBRUARY THE OPERATION OF THE FGD SYSTEM WAS REDUCED DUE TO THE LOW
SULFUR CONTENT OF THE COAL.
REPAIRS WERE MADE ON TOWER 203 DURING FEBRUARY.
3/81 202 .0 .0 .0
203 100.0 53.7 100.0 43.7
SYSTEM 100.0 53.6 100.0 43.7 744 605 325 70.2
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MARCH MODULE 202 WAS NOT AVAILABLE DUE TO EROSION PROBLEMS.
THE SYSTEM WAS BY-PASSED DURING PART OF THE MONTH BECAUSE THE UNIT WAS
FIRING LOW SULFUR COAL.
4/81 202 .0 .0 .0
203 100.0 100.0 100.0 100.0
SYSTEM 100.0 100.0 100.0 100.0 720 720 720 98.2
** PROBLEMS/SOLUTIONS/COMMENTS
DURING APRIL MODULE 202 WAS NOT AVAILABLE FOR OPERATION DUE TO ERROSION
OF THE BOWL AREA OF THE MODULE. THIS HAS BEEN A CONTINUAL PROBLEM AND
THE UTILITY IS PRESENTLY CONDUCTING STUDIES TO ALLEVIATE THE PROBLEM.
5/81 202 100.0 .0 .0
203 100.0 100.0 100.0 100.0
SYSTEM 100.0 100.0 100.0 100.0 744 744 744 87.4
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MAY THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE
ENCOUNTERED.
MODULE 202 WAS AVAILABLE THE ENTIRE MONTH, BUT WAS NOT OPERATED.
6/81 202 100.0 .0 .0
203 100.0 100.0 100.0 100.0
SYSTEM 100.0 100.0 100.0 100.0 720 716 720 91.9
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR PROBLEMS WERE EXPERIENCED DURING THE
MONTH OF JUNE.
7/81 202 100.0 45.2 100.0 45.2
203 46.2 46.2 100.0 46.2
SYSTEM 100.0 91.4 100.0 91.4 744 744 680 91.0
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE 203 WAS TAKEN OUT OF SERVICE ON JULY 15 FOR PREVENTIVE MAINTENANCE
AND REPAIRS, AT WHICH TIME MODULE 202 WAS PUT INTO SERVICE.
8/81 202 100.0 39.9 100.0 35.5
203 .0 .0 ]o
SYSTEM 100.0 39.9 100.0 35.°5 744 661 264 75.2
13-36
-------
UTILITY F6D SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ARIZONA ELECTRIC POWER: APACHE 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 202 WAS REMOVED FROM SERVICE ON AUGUST 8 AS A RESULT OF PROBLEMS
ENCOUNTERED WITH THE ELECTROSTATIC PRECIPITATOR. THE MODULE WAS PLACED
BACK IN SERVICE ON AUGUST 21.
9/81 202 100.0 99.3 100.0 99.0
203 .0 .0 .0
SYSTEM 100.0 99.3 100.0 99.0 720 718 713 85.4
** PROBLEMS/SOLUTIONS/COMMENTS
THE ONLY PROBLEMS ENCOUNTERED DURING THE MONTH WERE BOILER RELATED.
10/81 202 100.0 100.0 100.0 41.5
203 .0 .0 .0
SYSTEM 100.0 100.0 100.0 41.5 744 303 309 29.2
** PROBLEMS/SOLUTIONS/COMMENTS
UNIT 2 WAS DOWN FROM OCTOBER 3 UNTIL OCTOBER 20 FOR ANNUAL MAINTENANCE AND
REPAIRS.
11/81 202 65.4 63.6 64.8 63.6
203 .0 .0 .0
SYSTEM 65.4 63.6 64.8 63.6 720 720 458 74.2
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE 202 WAS TAKEN OUT OF SERVICE TWICE DURING NOVEMBER BECAUSE OF LOW
SLURRY DENSITY.
ON NOVEMBER 22 THE SYSTEM WAS TAKEN OUT OF SERVICE FOR THE REMAINDER OF
THE MONTH FOR REPAIRS ON THE DAMPER SEALS.
ADDITIONAL OUTAGE TIME DURING THE MONTH WAS DUE TO BOILER-RELATED PROBLEMS.
12/81 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE ORIGINAL COPY OF THE DECEMBER UPDATE INFORMATION WAS LOST IN THE MAIL.
1/82 202 80.5 90.5 80.5 80.5
203 .0 .0
SYSTEM 80.5 90.5 80.5 80.5 744 662 599 70.9
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JANUARY MODULE 202 WAS DOWN APPROXIMATELY 145 DUE TO RESTRICTIONS
IN A FEED LINE.
2/82 202 .0 .0
203 98.6 96.2 99.0 96.2
SYSTEM 98.6 96.2 99.0 96.2 672 672 646 81.3
** PROBLEMS/SOLUTIONS/COMMENTS
DURING FEBRUARY MODULE 202 WAS DOWN FOR REPAIRS AND MAINTENANCE.
MODULE 203 WAS OUT OF SERVICE FOR APPROXIMATELY SIX HOURS DUE TO A
QUENCHER PUMP FAILURE.
13-37
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
ARIZONA ELECTRIC POUER: APACHE 2 (CONT.)
___, , PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
3/82 202
203
SYSTEM
100.0
100.0
.0
99.0
99.0
100.0
100.0
.0
87.3
87.3
744 656 649 50.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MARCH MODULE 203 WAS OUT OF SERVICE PART OF THE TIME DUE TO A UNIT
2 WATER WALL RUPTURE.
4/82 202 100.0 .0 .0
203 87.2 87.2 87.2 87.2
SYSTEM 87.2 87.2 87.2 87.2 720 720 627 70.1
** PROBLEMS/SOLUTIONS/COMMENTS
DURING APRIL OUTAGE TIME FOR MODULE 203 WAS DUE TO PUMP PROBLEMS.
5/82 202 3.9 5.3 100.0 3.9
203 .0 .0 .0
SYSTEM 3.9 5.3 100.0 3.9 744 541 29 48.6
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE 203 WAS UNAVAILABLE DURING MAY DUE TO SOME MAJOR REPAIRS AND RECON-
STRUCTION.
6/82 202 100.0 97.0 100.0 97.0
203 .., 100.0 .0 .0
SYSTEM 100.0 97.0 100.0 97.0 720 720 698 82.3
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING JUNE.
7/82 202 100.0 99.9 100.0 99.9
203 100.0 .0 .0
SYSTEM 100.0 99.9 100.0 99.9 744 744 743 85.1
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED BY THE UTILITY
DURING JULY.
8/82 202 100.0 98.4 100.0 87.3
203 100.0 .0 .0
SYSTEM 100.0 98.4 100.0 87.3 744 660 650 79.3
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING AUGUST.
9/82 202 100.0 87.7 100.0 87.7
203 100.0 .0 'o
SYSTEM 100.0 87.7 100.0 87^7 720 720 631 73.2
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING SEPTEMBER.
10/82 202 100.0 100.0 100.0 2.9
13-38
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ARIZONA ELECTRIC POWER: APACHE Z (COKT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
203 100.0 .0 .0
SYSTEM 100.0 100.0 100.0 2.9 744 22 22 2.0
** PROBLEMS/SOLUTIONS/COMMENTS
ON OCTOBER 1 THE UNIT MAS DOWN FOR ANNUAL MAINTENANCE AND REPAIR OUTAGES.
11/82 202 100.0 .0 .0
203 19.4 31.1 94.4 9.4
SYSTEM 19.4 31.1 94.4 9.4 720 217 68 15.1
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS PUT ON LINE NOVEMBER 21 AFTER THE COMPLETION OF ANNUAL
MAINTENANCE AND REPAIR OUTAGE.
MODULE 203 WAS PLACED BACK IN SERVICE ON NOVEMBER 24.
12/82 202 100.0 .0 .0
203 90.2 68.8 87.6 68.8
SYSTEM 90.2 68.8 87.6 68.8 744 744 512 65.1
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING DECEMBER.
1/83 202 100.0 .0 .0
203 100.0 68.7 100.0 64.2 .>
SYSTEM 100.0 68.7 100.0 64.2 744 696 478 57.2
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING JANUARY.
2/83 202 100.0 .0 .0
203 99.9 61.8 99.8 61.8
SYSTEM 99.9 61.8 99.8 61.8 672 672 415 62.4
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR FGD-RELATED PROBLEMS WERE REPORTED BY THE UTILITY
DURING FEBRUARY.
3/83 202 100.0 .0 .0
203 98.8 56.1 95.1 23.4
SYSTEM 98.8 56.1 95.1 23.4 744 311 174 25.2
*» PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS OFF LINE FROM MARCH 1 TO MARCH 17 DUE TO LOW DEMAND.
4/83 202 100.0 .0 .0
203 99.2 54.4 98.5 54.4
SYSTEM 99.2 54.4 98.5 54.4 720 720 392 54.1
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING APRIL.
5/83 202 100.0 .0 .0
13-39
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ARIZONA ELECTRIC POWER: APACHE 2 (CONT.)
7/83
8/83
9/83
202
203
SYSTEM
202
203
SYSTEM
202
203
SYSTEM
90
100
100
100
100
100
100
99
100
.3
.0
.0
.0
.0
.0
.0
.9
.0
2
49
51
75
75
7
42
50
.4
.2
.5
.0
.6
.6
.9
.2
.1
100
100
100
100
100
100
99
100
.0
.0
.0
.0
.0
.0
.7
.0
1
29
30
13
.4
.4
.8
.0
.6
13.6
7
42
49
.9
.0
.9
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
203 99.7 42.3 99.4 42.3
SYSTEM 99.7 42.3 99.4 42.3 744 744 315 50.3
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING MAY.
6/83 £02 100.0 .0 .0
203 100.0 26.9 100.0 8.5
SYSTEM 100.0 26.9 100.0 8.5 720 229 62 13.7
** PROBLEMS/SOLUTIONS/COMMENTS
UNIT 2 WAS TAKEN OFF LINE ON JUNE 10 AS A RESULT OF LOW DEMAND.
744 445 229 35.9
744 134 101 12.3
720 718 360 59.1
** PROBLEMS/SOLUTIONS/COMMENTS .>
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
FOR THE PERIOD OF JULY THROUGH SEPTEMBER, 1983.
10/83 202 100.0 .0 .0
203 100.0 .0 .0
SYSTEM 100.0 .0 .0 744 47 0 1.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT UNIT 2 WAS DOWN THE ENTIRE MONTH OF OCTOBER
EXCEPT FOR OCTOBER 1 TO OCTOBER 3. ANNUAL MAINTENANCE AND REPAIR BEGAN ON
OCTOBER 15.
11/83 202 100.0 .0
203 100.0 .0
SYSTEM 100.0 .0 720 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
UNIT 2 WAS DOWN THE ENTIRE MONTH OF NOVEMBER FOR ANNUAL MAINTENANCE AND
REPAIR.
12/83 202 100.0 .0
203 100.0 'o
SYSTEM 100.0 ID 7^ 0 0 >0
»* PROBLEMS/SOLUTIONS/COMMENTS
ANNUAL MAINTENANCE AND REPAIRS WERE COMPLETED ON DECEMBER 14. THE UNIT WAS
DOWN FOR THE REMAINDER OF THE MONTH DUE TO LOW POWER DEMAND.
1/84 202 100.0 .0
203 100.0 'o
SYSTEM 100.0 it) 744 0 0 0
13-40
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ARIZONA ELECTRIC POWER: APACHE 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILEP FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIOHS/COMMENTS
ANNUAL MAINTENANCE AND REPAIRS WERE COMPLETED ON DECEMBER 14. THE UNIT WAS
2/84 202 100.0 .0
203 100.0 .0
SYSTEM 100.0 .0 696 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
UNIT 2 WAS OFF LINE DURING JANUARY AND FEBRUARY DUE TO LOW POWER DEMAND.
744 158 43 8.3
720 587 496 40.4
744 744 744 73.0
720 548 573 46.5
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE PERIOD OF MARCH THROUGH JUNE 1984.
7/84 202 88.2 87.3 87.6 79.9
203 .0 .0 .0
SYSTEM 44.1 43.6 87.6 40.0 744 682 297 60.2
** PROBLEMS/SOLUTIONS/COMMENTS
MAINTENANCE WAS COMPLETED ON MODULE 202 AND IT WAS PLACED BACK INTO SERVICE
ON JULY 4, 1984.
MODULE 203 WAS OUT OF SERVICE DURING THE ENTIRE MONTH OF JULY.
8/84 SYSTEM 744
9/84 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR AUGUST AND SEPTEMBER 1984.
3/84
4/84
5/84
6/84
202
203
SYSTEM
202
203
SYSTEM
202
203
SYSTEM
202
203
SYSTEM
100.0
99.3
100.0
100.0
35.5
100.0
100.0
98.8
100.0
99.6
98.8
100.0
.0
27.1
27.1
40.9
43.6
84.5
39.9
60.1
100.0
6.5
98.1
100.0
89.5
89.5
100.0
100.0
100.0
100.0
98.0
100.0
100.0
100.0
100.0
.0
5.8
5.8
33.3
35.5
68.8
39.9
60.1
100.0
5.0
74.6
79.6
13-41
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
SECTION 13
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 - 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
** MECHANICAL COLLECTOR
NUMBER
TYPE
«* ESP
NUMBER
NUMBER OF SPARES
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
TRADE NAME/COMMON NAME
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
*** FGD SYSTEM
ARIZONA ELECTRIC POWER
APACHE
3
COCHISE
ARIZONA
43.
344.
301.
530
195
175
183
98
RILEY STOKER
PULVERIZED COAL
BASE
520.98
376.7
122.
CONCRETE
4.9
.100 LB/MMBTU)
.800 LB/MMBTU)
.700 LB/MMBTU)
(1104000 ACFM)
( 710 F)
( 400 FT)
( 16.Z FT)
( 10000 BTU/LB)
9500-10800
COAL
SUBBITUMINOUS
23260.
15.00
15-20
13.00
9.0-15.0
.70
0.4-0.6
.01
0.00-0.03
0
NONE
1
0
HOT SIDE
AIR CORRECTION DIVISION, UOP
521.0 (1104000 ACFM)
376.7 ( 710 F)
1 (1. IN-H20)
99.6
0
NONE
N/A
N/A
N/A
N/A
N/A
N/A
N/A
13-42
-------
ARIZONA ELECTRIC POWER: APACHE 3 (CONT.)
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
** 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
ENERGY CONSUMPTION - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
#* DESIGN AND OPERATING PARAMETERS
DESIGN COAL SULFER CONTENT - X
DESIGN COAL HEAT CONTENT - J/G
DESIGN COAL ASH CONTENT - X
DESIGN MOISTURE CONTENT - X
DESIGN CHLORIDE CONTENT X
SPACE REQUIREMENTS - SQ M
OPER. & MAINT. REQUIREMENT - MANHR/DAY
** QUENCHER/PRESATURATOR
NUMBER
TYPE
SUPPLIER
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
PRESSURE DROP - KPA
LIQUID RECIRCULATION RATE - LITERS/S
L/G RATIO L/CU. M
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** ABSORBER
NUMBER
NUM3ER 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
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
NUMBER OF SPARES PER SYSTEM
NUMBER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
NONE
RESEARCH-COTTRELL
BURNS 4 MCDONNELL
FULL SCALE
NEW
X 99.60
65.00
4.1
1
6/79
6/79
8/74
1.00
23260.0
17.00
18.00
.00
4046.7
72.0
( 10000 BTU/LB)
( 43560 SQ FT)
CYCLONIC SPRAY QUENCHER
RESEARCH-COTTRELL
188.76 (
132.2 (
.2 (
567. (
2.7 (
CARBON STEEL
AISI 1110
400000 ACFM)
270 F)
1.0 IN-H20)
9000 GPM)
20.0 GAL/1000 ACFM)
2
1
COMBINATION TOWER
SPRAY/PACKED
N/A
RESEARCH-COTTRELL
30.0 DIA X 110.0
CARBON STEEL
AISI 1110
N/A
ORGANIC
GLASS FLAKE-FILLED POLYESTER
FLAKELINE 103
SPRAY ZONE 4 VERTICAL CROSS CHANNEL FIXED GRID P
2
( 9000 GPM)
( 40.0 GAL/1000 ACF)
( 2.5 IN-H20)
( 10.0 FT/S)
( 200000 ACFM)
( 155 F)
567.
5.3
.6
3.0
94.38
68.3
97.0
99.6
PRIMARY COLLECTOR
2
1
1
IMPINGEMENT
BAFFLE
13-43
-------
UTILITY FGD SURVEY" OCTOBER 1983 - SEPTEMBER 1984
ARIZONA ELECTRIC POWER: APACHE 3 (CONT.)
TRADE NAME/COMMON TYPE
MANUFACTURER
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
CONSTRUCTION MATERIAL SPECIFIC TYPE
WASH WATER SOURCE
WASH FREQUENCY
WASH RATE - L/S
CLOSED VANE
MUNTERS
HORIZONTAL
2
3
.61 ( 2.0 FT)
30.48 (12.0 IN)
10.2 ( 4.00 IN)
45
.2 ( 1.0 IN-H20)
3.0 ( 10.0 FT/S)
ORGANIC
POLYVINYL CHLORIDE
FRESH
INTERMITTENT [LOWER STAGE]; ONCE EVERY HOUR [UPP
12.6 ( 200 GAL/MIN)
*« REHEATER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
PERCENT GAS BYPASSED - AVG
TEMPERATURE INCREASE - C
INLET FLUE GAS TEMPERATURE - C
OUTLET FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** FANS
NUMBER
NUM3ER OF SPARES
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE CU.M/S
FLUE GAS TEMPERATURE C
PRESSURE DROP - KPA
CONSTRUCTION MATERIAL GENERIC TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MODULATION
SEAL AIR FLOW - CU. M/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MODULATION
SEAL AIR FLOW CU. M/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUM3EP
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
0
NONE
N/A
N/A
50.0
43.3
46.1
89.4
NONE
N/A
2
0
CENTRIFUGAL
WESTINGHOUSE
UNIT
FORCED DRAFT
DRY
188.76
132.2
6.2
CARBON STEEL
78
115
193
F)
F)
F)
( 400000 ACFM)
( 270 F)
(20.5 IN-H20)
SHUT-OFF
LOUVER
PARALLEL BLADE MULTILOUVER
OPEN/CLOSED
.24 ( 500 ACFM)
CARBON STEEL
NR
NONE
N/A
SHUT-OFF
GUILLOTINE
TOP-ENTRY GUILLOTINE
OPEN/CLOSED
-24 ( 500 ACFM)
CARBON STEEL
NR
HIGH ALLOY
NICKEL BASE/CHROMIUM-IRON-COPPER-MOLYBDENUM
SHUT-OFF
LOUVER
PARALLEL BLADE MULTILOUVER
13-44
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ARIZONA ELECTRIC POWER: APACHE 3 (CONT.)
MODULATION
SEAL AIR FLOW - CU. M/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
»* DUCTWORK
LOCATION
CONFIGURATION
DIMENSIONS
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
CONFIGURATION
DIMENSIONS
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
MANUFACTURER
NUMBER
NUMBER OF SPARES
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
PRODUCT QUALITY - X. SOLIDS
OPEN/CLOSED
.24 ( 500 ACFM)
CARBON STEEL
NR
HIGH ALLOY
NICKEL BASE/CHROMIUW-IRON-COPPER-MOLYBDENUM
ABSORBER INLET
RECTANGULAR
12.0 X 14.0
CARBON STEEL
AISI 1110
NONE
N/A
ABSORBER OUTLET
RECTANGULAR
12.0 X 14.0
CARBON STEEL
AISI 1110
ORGANIC
FLUOROELASTOMER
WET BALL MILL
COMPARTMENTED
NR
KENNEDY VAN SAUN
1
0
4.5 ( 5 TPH)
45.0
** TANKS
SERVICE
ABSORBER FEED
REAGENT FEED
MILL SLURRY SUMP
WASTE SLURRY SUMP
NUMBER
1
1
1
1
** PUMPS
SERVICE
ABSORBER
QUENCHER
MILL SLURRY RECYCLE
ADDITIVE FEED
WASTE SLURRY TRANSFER
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
*** SLUDGE
MOISTURE CONTENT - 7. TOTAL FREE WATER
'/. CAS04 DRY
** TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
NUMBER
3
4
2
2
1
NONE
70.0
80.0
NONE
N/A
N/A
FINAL
POND
OFF-SITE
PIPELINE
13-45
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ARIZONA ELECTRIC POWER: APACHE 3 (CONT.)
SITE TREATMENT
SITE DIMENSIONS
SITE CAPACITY CU.M
SITE SERVICE LIFE - YRS
»* PROCESS CONTROL AND INSTRUMENTATION
PROCESS STREAM
CHEMICAL PARAMETERS
PHYSICAL VARIABLES
CONTROL LEVELS
PROCESS CONTROL MANNER
PROCESS CHEMISTRY MODE
*» WATER BALANCE
WATER LOOP TYPE
MAKEUP WATER ADDITION - LITERS/S
SOURCE OF MAKEUP WATER
** CHEMICALS AND CONSUMPTION
FUNCTION
NAME
PRINCIPAL CONSTITUENT
SOURCE/SUPPLIER
UTILIZATION X
POINT OF ADDITION
** FGD SPARE CAPACITY INDICES
ABSORBER 7.
MIST ELIMINATOR - '/.
FAN X
BALL MILL X
EFFLUENT HOLD TANK - X
RECIRCULATION PUMP X
** FGD SPARE COMPONENT INDICES
ABSORBER
MIST ELIMINATOR
FAN
BALL MILL
EFFLUENT HOLD TAW
RECIRCULATION PUMP
NONE
ZS TO 30 ACRES BY 18 FT DEEP
611500 ( 500.0 ACRE-FT)
30
QUENCHER RECYCLE LINE
PH
PERCENT SOLIDS
5.0 PH
MANUAL
FEEDBACK
OPEN
115.9
WELL WATER
ABSORBENT
LIMESTONE
>93X CAC03
PAUL LIME
99.0
BALL MILL
100.0
.0
.0
.0
.0
50.0
1.0
.0
.0
.0
.0
1.0
( 1840 6PM)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
7. REMOVAL
S02 PART.
PER BOILER FGD CAP.
HOURS HOURS HOURS FACTOR
6/79 SYSTEM
*# PROBLEMS/SOLUTIONS/COMMENTS
50.00 99.50 720
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.
7/79 SYSTEM
8/79 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
744
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
13-46
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1964
ARIZONA ELECTRIC POWER: 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 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.
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.
11/79 302 89.4 39.8 39.4 39.4
303 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 91.7 744 744 682 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 71.4 696 671 497 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
13-47
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ARIZONA ELECTRIC POWER: APACHE 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 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 29.0 744 721 216 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 96.0 100.0 95.6 744 717 688 99.6
13-48
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ARIZONA ELECTRIC POWER: 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 NOVEMBER THE FGD SYSTEM WAS FORCED OUT OF SERVICE DUE TO FAILURE
OF THE QUENCHER PUMPS, SAMPLE LINE AND TRANSFORMER.
THE BOILER UNIT TRIPPED CAUSING APPROXIMATELY FIVE HOURS OF OUTAGE TIME
DURING THE MONTH.
12/80 302 .0 .0 .0
303 100.0 98.6 100.0 96.6
SYSTEM 100.0 98.6 100.0 96.6 744 729 719 86.2
»* PROBLEMS/SOLUTIONS/COMMENTS
NO FGD-RELATED PROBLEMS WERE ENCOUNTERED DURING THE MONTH OF DECEMBER.
1/81 302 .0 .0 .0
303 100.0 52.9 100.0 46.1
SYSTEM 100.0 52.9 100.0 46.1 744 649 343 80.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS OUT OF SERVICE APPROXIMATELY 123 HOURS DURING JANUARY.
MODULE 303 WAS TAKEN OUT OF SERVICE FOR APPROXIMATELY 272 HOURS DUE TO THE
LOW SULFUR CONTENT OF THE COAL. MODULE 302 WAS NOT AVAILABLE FOR OPERATION
DURING JANUARY.
2/81 302 .0 .0 .0
303 100.0 27.4 100.0 27.4
SYSTEM 100.0 27.4 100.0 27.4 672 672 184 95.6
** PROBLEMS/SOLUTIONS/COMMENTS
DURING FEBRUARY THE OPERATION OF THE FGD SYSTEM WAS REDUCED DUE TO THE LOW
SULFUR CONTENT OF THE COAL.
REPAIRS WERE MADE ON TOWER 302 DURING THE MONTH.
3/81 302 78.5 23.7 52.5 23.7
303 .0 .0 .0
SYSTEM 78.5 23.7 52.5 23.7 744 744 177 87.5
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MARCH LOW OPERABILITY OF MODULE 302 WAS DUE TO THE FIRING OF LOW
SULFUR COAL.
MODULE 303 WAS UNAVAILABLE DUE TO A MALFUNCTION OF THE LIMESTONE GRINDING
CIRCUIT.
4/81 302 100.0 75.3 100.0 35.8
303 .0 .0 .0
SYSTEM 100.0 75.3 100.0 35.8 720 342 258 44.5
** PROBLEMS/SOLUTIONS/COMMENTS
DURING APRIL THE BOILER WAS UNAVAILABLE DUE TO A 2 WEEK SCHEDULED MAIN-
TENANCE OUTAGE.
MODULE 303 WAS NOT AVAILABLE FOR OPERATION DUE TO ERROSION PROBLEMS DIS-
COVERED IN THE MODULE BOWL AREA. THIS HAS BEEN A CONTINUAL PROBLEM AND
THE UTILITY IS PRESENTLY CONDUCTING STUDIES TO ALLEVIATE THE PROBLEM.
13-49
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ARIZONA ELECTRIC POWER: APACHE 3 (CONT.)
. . PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
5/81
302
303
SYSTEM
100.0
100.0
100.0
87.1
.0
87.1
100.0
100.0
87.1
.0
87.1
744 648 648 90.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MAY THE BOILER WAS TAKEN OUT OF SERVICE APPROXIMATELY 96 HOURS DUE
TO MAINTENANCE.
6/81 302 100.0 86.7 100.0 86.7
303 100.0 .0 .0
SYSTEM 100.0 86.7 100.0 86.7 720 720 624 87.1
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JUNE MODULE 303 WAS OUT OF SERVICE DUE TO REPAIRS ON THE ESP.
7/81 302 45.2 11.9 100.0 10.8
303 100.0 57.3 100.0 51.6
SYSTEM 100.0 69.2 100.0 69.2 744 670 464 77.6
#* PROBLEMS/SOLUTIONS/COMMENTS
MODULE 302 WAS REMOVED FROM SERVICE ON JULY 1 AS A RESULT OF PROBLEMS
WITH THE ELECTROSTATIC FRECIPITATOR. 'MODULE 303 WAS PLACED IN SERVICE
ON JULY 17 SO THAT PREVENTIVE MAINTENANCE COULD BE PERFORMED ON MODULE 302.
744 744 744 89.1
720 718 449 80.8
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE 303 WAS OFF LINE FOR APPROXIMATELY ELEVEN DAYS DUPING SEPTEMBER
AS A RESULT OF A MALFUNCTION THAT CAUSED THE INLET AND OUTLET DAMPERS TO
CLOSE.
10/81 302 .0 .0 .0
303 96.2 98.2 96.2 96.2
SYSTEM 96.2 98.2 96.2 96.2 744 729 716 78.6
** PROBLEMS/SOLUTIONS/COMMENTS
DURING OCTOBER TOWER 303 WAS OUT OF SERVICE FOR THREE HOURS TO CHANGE THE
QUENCHER PUMPS.
ADDITIONAL FGD SYSTEM OUTAGE TIME RESULTED FROM UNIT TRIPS.
11/81 302 .0 .0 88.1
303 100.0 100.0 68.1 88.1
SYSTEM 100.0 100.0 88.1 88.1 720 634 634 63.6
«* PROBLEMS/SOLUTIONS/COMMENTS
MODULE 303 WAS OUT OF SERVICE FROM NOVEMBER 3 THROUGH NOVEMBER 11 DUE TO
ESP PROBLEMS.
12/81 SYSTEM
8/81
9/81
302
303
SYSTEM
302
303
SYSTEM
100
100
62
62
.0
.0
.0
.0
.4
.4
100
100
62
62
.0
.0
.0
.0
.5
.5
100
100
62
62
.0
.0
.4
.4
100
100
62
62
.0
.0
.0
.0
.4
.4
13-50
-------
UTILITY F6D SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ARIZONA ELECTRIC POWER: APACHE 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 ORIGINAL COPY OF THE DECEMBER UPDATE INFORMATION WAS LOST IN THE MAIL.
1/82 302 95.1 84.0 93.7 73.2
303 .0 .0
SYSTEM 95.1 84.0 93.7 73.2 744 648 544 62.2
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JANUARY MODULE 302 WAS OUT OF SERVICE PART OF THE TIME DUE TO A
LEAK IN THE COLLECTION BOWL BELOW THE ABSORBER PACKING.
2/82 302 95.5 93.9 95.5 93.6
303 .0 .0
SYSTEM 95.5 93.9 95.5 93.6 672 670 635 84.4
** PROBLEMS/SOLUTIONS/COMMENTS
DURING FEBRUARY APPROXIMATELY 25 HOURS OF OUTAGE TIME WAS REQUIRED FOR
MAINTENANCE ON THE COLLECTION BOWL.
3/82 302 21.9 24.6 20.6 20.3
303 .0 .0 .0
SYSTEM 21.9 24.6 20.6 20.3 744 615 151 47.2
** PROBLEMS/SOLUTIONS/COMMENTS
ON MARCH 6, BOTH MODULES WERE TAKEN OUT OF SERVICE FOR MAJOR REPAIR AND
RECONSTRUCTION. THIS RESULTED IN SUSPENSION OF SCRUBBING OPERATIONS
FOR THE REMAINDER OF THE MONTH.
4/82 302 .0 .0 .0
303 .0 .0 .0
SYSTEM .0 .0 .0 720 53 0 3.8
** PROBLEMS/SOLUTIONS/COMMENTS
ON APRIL 1 AND APRIL 2, BOTH MODULES WERE OUT OF SERVICE FOR MAJOR REPAIR
AND RECONSTRUCTION.
AS OF APRIL 3, THE UNIT WAS DOWN FOR ANNUAL MAINTENANCE AND REPAIR.
5/82 302 .0 .0 .0
303 .0 .0 .0
SYSTEM .0 .0 .0 744 510 0 49.6
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS OUT OF SERVICE FOR THE MONTH OF MAY FOR MAJOR REPAIR
AND RECONSTRUCTION.
6/82 302 .0 .0
303 52.4 49.2 45.0 38.9
SYSTEM 52.4 49.2 45.0 38.9 720 569 280 66.9
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE 303 WAS PLACED BACK IN SERVICE ON JUNE 11 AFTER COMPLETION OF MAJOR
REPAIRS AND RECONSTRUCTION.
MODULE 303 WAS TAKEN OFF-LINE FOR APPROXIMATELY THREE DAYS DUE TO HIGH
OPACITY AND A QUENCHER PUMP MALFUNCTION.
13-51
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ARIZONA ELECTRIC POWER: APACHE 3 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
ESP REPAIRS SHUT THE SYSTEM DOWN FOR APPROXIMATELY THREE DAYS.
7/82 302 59.0 56.6 100.0 56.1
303 40.9 41.3 100.0 40.9
SYSTEM 99.9 97.9 100.0 97.0 744 738 722 87.8
** PROBLEMS/SOLUTIONS/COttMENTS
MODULE 303 WAS TAKEN OUT OF SERVICE ON JULY 13 TO REPAIR A LEAK IN THE
PACKING RETURN LINE TO THE ABSORBER FEED TANK.
MODULE 302 WAS PLACED IN SERVICE ON JULY 13 AFTER COMPLETION OF MAJOR
REPAIRS AND RECONSTRUCTION.
MODULE 302 WAS OUT OF SERVICE APPROXIMATELY 11 HOURS ON JULY 21 FOR TESTING
PURPOSES.
MODULE 302 WAS OUT OF SERVICE 11 HOURS ON JULY 26 DUE TO A TRIP OF UNIT 3.
8/82 302 96.8 95.3 96.4 87.6
303 100.0 .0 .0
SYSTEM 96.8 95.3 96.4 87.6 744 685 652 85.9
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING AUGUST.
9/82 302 100.0 85.3 100.0 72.8
303 100.0 .0 .0
SYSTEM 100.0 85.3 100.0 72.8 720 615 524 60.8
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING SEPTEMBER.
10/82 302 100.0 91.0 100.0 90.9
303 100.0 .0 .0
SYSTEM 100.0 91.0 100.0 90.9 744 743 676 74.6
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING OCTOBER.
11/82 302 98.4 65.4 97.1 53.8
303 100.0 .0 .0
SYSTEM 98.4 65.4 97.1 53^8 720 592 387 55.3
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DUPING NOVEMBER.
12/82 302 100.0 69.2 100.0 61.6
303 100.0 .0 '.Q
SYSTEM 100.0 69.2 100.0 61.6 744 662 458 46.2
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR FGD-RELATED PROBLEMS WERE REPORTED BY THE UTILITY
DURING DECEMBER.
13-52
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ARIZONA ELECTRIC POWER: APACHE 3 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION '/. REMOVAL PER BOILER FGD CAP.
502 PART. HOURS HOURS HOURS FACTOR
1/83 302 8.1 5.8 100.0 4.8
303 78.6 34.8 68.1 28.5
SYSTEM 86.7 40.6 100.0 33.2 744 609 247 40.2
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE 302 WAS TAKEN OUT OF SERVICE ON JANUARY 3 DUE TO AN INDUCED DRAFT
FAN MALFUNCTION.
MODULE 303 WAS PLACED BACK IN SERVICE ON JANUARY 6.
2/83 302 100.0 .0 .0
303 100.0 74.3 100.0 20.7
SYSTEM 100.0 74.3 100.0 20.7 672 187 139 17.5
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS TAKEN OFF LINE FEBRUARY 8 DUE TO LOW DEMAND.
3/83 302 100.0 17.6 100.0 10.7
303 100.0 50.9 100.0 31.0
SYSTEM 100.0 68.5 100.0 41.8 744 454 311 43.4
#* PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS OFF LINE FROM MARCH 18 TO MARCH 28 DUE TO LOW DEMAND.
4/83 302 .0
303 .0
SYSTEM .0 720 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
UNIT 3 WAS DOWN DURING THE MONTH OF APRIL FOR ANNUAL MAINTENANCE AND
REPAIR.
5/83 302 .0
303 .0
SYSTEM .0 744 0 0 .0
#* PROBLEMS/SOLUTIONS/COMMENTS
UNIT 3 WAS DOWN DURING MAY FOR ANNUAL MAINTENANCE AND REPAIR.
6/83 302 91.7 42.2 81.5 36.6
303 100.0 .0 .0
SYSTEM 91.7 42.2 81.5 36.6 720 624 263 50.8
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING JUNE.
744 336 188 28.7
744 641 361 56.8
7/83 302
303
SYSTEM
8/83 302
303
SYSTEM
99.4
100.0
99.4
97.6
100.0
97.6
56.0
.0
56.0
56.4
.0
56.4
97.7
97.7
95.4
95.4
25.3
.0
25.3
48.5
.0
48.5
13-53
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ARIZONA ELECTRIC POWER: APACHE 3 (CONT.)
10/83
11/83
12/83
302
303
SYSTEM
302
303
SYSTEM
302
303
SYSTEM
100
98
100
100
96
100
100
99
100
.0
.5
.0
.0
.7
.0
.0
.8
.0
38
38
44
44
21
21
.0
.8
.8
.0
.4
.4
.0
.6
.6
95
95
91
91
98
98
.9
.9
.9
.9
.9
.9
35.
35.
38.
38.
18.
18.
,0
2
,2
.0
,0
,0
.0
0
,0
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 FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING JULY AND AUGUST.
9/83 302 100.0 .0 .0
303 100.0 .0 .0
SYSTEM 100.0 .0 .0 720 7 0 .1
** PROBLEMS/SOLUTIONS/COMMENTS
BOTH MODULES WERE OUT OF SERVICE DURING SEPTEMBER DUE TO THE UNIT OPERATING
AT REDUCED LOAD.
744 675 262 40.8
720 616 274 41.0
744 618 134 29.2
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR FGD-RELATED PROBLEMS WERE REPORTED DURING THE FOURTH QUARTER OF
1983.
744 690 201 35.7
696 696 320 50.0
744 659 342 45.6
720 143 131 10.7
744 473 459 44.4
** PROBLEMS/SOLUTIONS/COHMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE PERIOD OF JANUARY THROUGH MAY 1984.
6/84 302 77.6 78.1 78.2 77.6
303 -0 .0 .0 .0
SYSTEM 77.6 78.1 78.2 77.6 720 716 559 68.6
1/84
2/84
3/84
4/84
5/84
302
303
SYSTEM
302
303
SYSTEM
302
303
SYSTEM
302
303
SYSTEM
302
303
SYSTEM
100
100
100
100
99
100
100
100
100
100
100
100
100
77
100
.0
.0
.0
.0
.9
.0
.0
.0
.0
.0
.0
.0
.0
.4
.0
29
29
46
46
51
51
91
91
69
27
97
.0
.1
.1
.0
.0
.0
.5
.4
.9
.0
.6
.6
.3
.7
.0
100.
100.
99.
99.
100.
100.
100.
100.
100.
100.
100.
100.
0
0
7
7
0
0
0
0
0
0
0
0
26
26
46
46
45
45
18
18
44
17
61
.0
.9
.9
.0
.0
.0
.5
.5
.9
.0
.1
.1
.1
.6
.7
13-54
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ARIZONA ELECTRIC POWER: APACHE 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
ON JUNE 24, MODULE 302 WAS TAKEN OUT OF SERVICE FOR PACKING REPAIRS AND
REMAINED OUT OF SERVICE FOR THE REST OF THE MONTH.
7/84 302 .0 .0 .0
303 88.0 87.9 88.0 87.9
SYSTEM 44.0 44.0 88.0 44.0 744 744 327 82.0
»* PROBLEMS/SOLUTIONS/COMMENTS
MAINTENANCE WAS COMPLETED ON MODULE 303 AND IT WAS PLACED BACK INTO SERVICE
ON JULY 4, 1984.
MODULE 302 WAS UNAVAILABLE FOR SERVICE DURING THE MONTH DUE TO ABSORBER
PACKING REPAIRS.
8/84 SYSTEM 744
9/84 SYSTEM 720
*» PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR AUGUST AND SEPTEMBER 1984.
13-55
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
SECTION 13
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
SOZ EMISSION LIMITATION - NG/J
NOX EMISSICN 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.
RAN3E SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** MECHANICAL COLLECTOR
NUMBER
NUMBER OF SPARES
TYPE
SUPPLIER
INLET FLUE GAS CAPACITY - CU.M/S
INLET FLUE GAS TEMPERATURE - C
PARTICLE REMOVAL EFFICENCY -7.
** ESP
NUMBER
TYPE
** PARTICLE SCRUBBER
NUMBER
INITIAL START-UP DATE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON NAME
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
ARIZONA PUBLIC SERVICE
CHOLLA
1
JOSEPH CITY
ARIZONA
84. (
430. (
344. (
615
119
115
119
119
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
226.51
135.6
76.
CONCRETE
3.7
.196 LB/MMBTU)
.000 LB/MMBTU)
.800 LB/MMBTU)
( 480000 ACFM)
( 276 F)
( 250 FT)
( 12.0 FT)
( 10150 BTU/LB)
9650-10600
COAL
BITUMINOUS
23609.
13.50
9.7-22.5
15.00
******
.50
0.4-1.0
.02
0.01-0.04
1
0
CYCLONE
RESEARCH-COTTRELL
226.5 ( 460000 ACFM)
135.6 ( 276 F)
75.0
0
NONE
2
10/73
VENTURI TOWER
VARIABLE-THROAT/BOTTOM-ENTRY LIQUID DISTRIBUTION
FLOODED DISC SCRUBBER
RESEARCH-COTTRELL
6.0 DIA X 45.0
STAINLESS STEEL
AUSTENITIC
ORGANIC
MAT-REINFORCED EPOXY
NONE
1
336.4 ( 5340 GPM)
13-56
-------
UTILITY FGO SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ARIZONA PUBLIC SERVICE: CHOLLA 1 (CONT.)
L/G RATIO - LITER/CU.M
PH CONTROL ADDITIVE
PRESSURE DROP - KPA
INLET GAS FLOW RATE - CU.M/S
INLET GAS TEMPERATURE - C
PARTICLE REMOVAL EFFICIENCY - X
*** 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 - X
ENERGY CONSUMPTION - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
*» DESIGN AND OPERATING PARAMETERS
OPER. & MAINT. REQUIREMENT - MANHR/DAY
** QUENCHER/PRESATURATOR
NUMBER
** 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
502 REMOVAL EFFICIENCY - X
PARTICLE REMOVAL EFFICENCY - X
** 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
2.9 (22.0 GAL/1000ACF)
ABSORBER SLURRY [TRAIN A ONLY]
3.7 (15.0 IN-H20)
113.3 ( 240000 ACFM)
136.7 ( 278 F)
99.2
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
NONE
RESEARCH-COTTRELL
EBASCO
FULL SCALE
RETROFIT
55.00
3.4
1
12/73
10/73
7/71
40.0
COMBINATION TOWER
SPRAY/PACKED
N/A
RESEARCH-COTTRELL
22.0 DIA X 70.0
STAINLESS STEEL
AUSTENITIC
TYPE 316L
NONE
N/A
N/A
VERTICAL CROSS CHANNEL FIXED GRID PACKING
1
( 24.0IN)
( 9300 GPM)
( 45.0 GAL/1000 ACF)
( .5 IN-H20)
( 6.9 FT/S)
( 205000 ACFM)
( 122 F)
61.0
586.
6.0
.1
2.1
96.74
50.0
92.0
99.7
SPRAY TOWER
OPEN COUNTERCURRENT SPRAY
N/A
RESEARCH-COTTRELL
22.0 DIA X 70.0
STAINLESS STEEL
AUSTENITIC
TYPE 316L
NONE
N/A
N/A
NONE
1
13-57
-------
UTILITY F6D SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ARIZONA PUBLIC SERVICE: CHOLLA 1 (CONT.)
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
NUM3ER PER SYSTEM
NUMBER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
NUMEER OF STAGES
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
WASH WATER SOURCE
WASH FREQUENCY
** REHEATER
NUMEER
NUMBER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
LOCATION
TEMPERATURE INCREASE C
INLET FLUE GAS FLOW RATE - CU. M/S
INLET FLUE GAS TEMPERATURE - C
OUTLET FLUE GAS TEMPERATURE - C
NUMBER OF BUNDLES PER BANK
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC 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
»» 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
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
586. ( 9300 GPM)
6.0 ( 45.0 GAL/1000 ACF)
.1 ( .5 IN-H20)
2.1 ( 6.9 FT/S)
96.74 ( 205000 ACFM)
50.0 ( 122 F)
25.0
PRIMARY COLLECTOR
Z
1
CYCLONIC
CYCLONIC SEPARATOR
CYCLONIC TOWER
VERTICAL
1
STAINLESS STEEL
AUSTENITIC
NONE
N/A
Z
1
IN-LINE
STEAM
BARE TUBE
SEPARATE VESSEL AFTER ABSORBER
22.2 t
115.62 (
48.9 (
71.1 (
3
STAINLESS STEEL
AUSTENITIC
2
0
CENTRIFUGAL
WESTINGHOUSE
UNIT
FORCED DRAFT
DRY
113.26
135.6
CARBON STEEL
40 F)
245000 ACFM)
120 F)
160 F)
( 240000 ACFM)
( 276 F)
2
0
CENTRIFUGAL
WESTINGHOUSE
BOOSTER
FORCED DRAFT
DRY
113.26
135.6
CARBON STEEL
( 240000 ACFM)
( 276 F)
SHUT-OFF
GUILLOTINE
NR
STAINLESS STEEL
AUSTENITIC
NONE
N/A
13-58
-------
ARIZONA PUBLIC SERVICE: CHOLLA 1 (CONT.)
UTILITY FED SURVEY: OCTOBER 1983 - SEPTEMBER 1984
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
«* DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
*» DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUM3ER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
»* DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
*» DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
NUMBER
SHUT-OFF
GUILLOTINE
NR
STAINLESS STEEL
AUSTENITIC
NONE
N/A
SHUT-OFF
GUILLOTINE
NR
STAINLESS STEEL
AUSTENITIC
NONE
N/A
CONTROL
LOUVER
NR
STAINLESS STEEL
AUSTENITIC
NONE
N/A
CONTROL
LOUVER
NR
STAINLESS STEEL
AUSTENITIC
NONE
N/A
SCRUBBER INLET
CARBON STEEL
AISI 1110
NONE
N/A
SCRUBBER OUTLET TO REHEATER
CARBON STEEL
AISI 1110
ORGANIC
MICA FLAKE-FILLED POLYESTER
BYPASS
CARBON STEEL
AISI 1110
NONE
N/A
NONE
N/A
N/A
0
13-59
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ARIZONA PUBLIC SERVICE: CHOLLA 1 (CONT.)
** TANKS
SERVICE
SCRUESER RECYCLE
WASTE SLURRY BLEED
ABSORBER RECYCLE
REAGENT PREP PRODUCT
»* PUMPS
SERVICE
SCRUBBER RECIRCULATION
ABSORBER RECIRCULATION
MIST ELIMINATOR WASH
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
**# SLUDGE
MOISTURE CONTENT - 7. TOTAL FREE WATER
** TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE TREATMENT
SITE DIMENSIONS
SITE CAPACITY - CU.M
** PROCESS CONTROL AND INSTRUMENTATION
PROCESS STREAM
CHEMICAL PARAMETERS
CONTROL LEVELS
PROCESS CONTROL MANNER
** WATER BALANCE
WATER LOOP TYPE
MAKEUP WATER ADDITION - LITERS/S
** CHEMICALS AND CONSUMPTION
FUNCTION
NAME
SOURCE/SUPPLIER
POINT OF ADDITION
** FGD SPARE CAPACITY INDICES
ABSORBER - 7.
** FGD SPARE COMPONENT INDICES
ABSORBER
NUMBER
1
2
1
2
NUMBER
3
2
«***
NONE
87.0
BLEED
N/A
N/A
FINAL
POND
ON-SITE
PIPELINE
NONE
70-100 ACRES X 6 FT DEEP
623730 ( 510.0 ACRE-FT)
SCRUBBER AND ABSORBER HOLD TANK
PH
PH 5.2 IN SCRUBBER HOLD TANK, 6.5 IN ABSORBER HO
MANUAL
OPEN
7.6
( 120 6PM)
ABSORBENT
LIMESTONE
SUPERIOR CO.
ABSORBER RECYCLE TANK
.0
.0
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
10/73 SYSTEM 744
13-60
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ARIZONA PUBLIC SERVICE: CHOLLA 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
302 PART. HOURS HOURS HOURS FACTOR
*# PROBLEMS/SOLUTIONS/COMMENTS
INITIAL TESTING OF THE FGD SYSTEM BEGAN ON OCTOBER 2, 1973. THE SYSTEM
OPERATED UNTIL 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.
11/73 SYSTEM 720
12/73 SYSTEM 744
** PROB-LEMS/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 AST)
CONSEQUENTLY HAS A LOWER DEGREE OF SULFUR DIOXIDE REMOVAL (25X).
SOME LINES PLUGGED, PARTICULARLY WHEN THE SYSTEM OPERATED AT LOW FLOW
RATES.
SOLIDS SETTLED OUT IN STANDBY PUMPS, AND EXCESSIVE FAN VIBRATIONS OCCURRED
BECAUSE OF ACCUMULATION OF SCALE BUILDUP WHEN THE UNIT WAS IDLE. TO
SOLVE THESE PROBLEMS THE PACKING GLAND POSITION WAS REVERSED (INSTALLED
UPSIDE DOWH). 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.
1/74 A 97.0
B 90.0
SYSTEM 93.5 744
2/74 A 100.0
13-61
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ARIZONA PUBLIC SERVICE: CHOLLA 1 (CONT.)
. PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL
S02 PART.
PER BOILER
HOURS HOURS
FGD CAP.
HOURS FACTOR
B
SYSTEM
3/74 A
B
SYSTEM
4/74 A
B
SYSTEM
5/74
94.0
97.0
100.0
66.0
83.0
66.0
57.0
61.5
672
744
720
** PRCBLEMS/SOLUTIONS/COMMENTS
A
B
SYSTEM
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.
98.0
99.0
98.5
744 744
6/74
7/74
8/74
A
B
SYSTEM
A
B
SYSTEM
A
B
SYSTEM
100.0
97.5
98.5
98.0
94.5
100.0
97.3
*« PROBLEMS/SOLUTIONS/COMMENTS
100.0
100.0
100.0
97.0
92.0
94.5
97.0
100.0
98.5
97,
98.
98.
94.
100,
97.3
720
744 744 729
744 744 724
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.
99.
97.0
83.0
68.0
75.5
720
744
** PROBLEMS/SOLUTIONS/COMMENTS
11/74 A
THE SYSTEM WAS SHUT DOWN IN LATE OCTOBER FOR AN ANNUAL BOILER AND FGD
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.
100.0
13-62
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UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ARIZONA PUBLIC SERVICE: CHOLLA 1 (CONT.)
PERIOD
12/74
1/75
PtKrUKn«ML.C UA 1 A
MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
B
SYSTEM
A
B
SYSTEM
A
B
SYSTEM
96
99
100
100
100
97.7 97
98.7 98
98.2 98
.0
.0 720
.0
.0
.0 744
.7 97.7
.7 98.7
.2 98.2 744 744 730
** PROBLEMS/SOLUTIONS/COMMENTS
OPERATION OF THE SYSTEM THROUGHOUT 1975 AND 1976 WAS ACCOMPANIED BY A NUM-
BER OF MINCR PROBLEM AREAS INCLUDING: SIGNIFICANT CORROSION ATTACK IN THE
VESSEL WALLS OF THE VENTURI FLOOOED-DISC PARTICULATE SCRUBBER MODULE; ACID
CORROSION IN THE B-SIDE REHEATER HOUSING; SCALE BUILDUP IN THE PIPE OUTLET
AT THE SLUOGE/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
** PRCBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT PROBLEMS WITH VESSEL 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
** PRCBLEMS/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 BUSHED. THE "WETTED FILM
CONTACTOR" PACKING LIFE HAS BEEN REDUCED.
4/75 A 88.5 88.5 82.4
13-6?
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
ARIZONA PUBLIC SERVICE: CHOLLA 1 (CONT.)
__ PERFORMANCE DATA
PERIOD NODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
502 PART. HOURS HOURS HOURS FACTOR
B 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 93.0 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
B 100.0 100.0 100.0 100.0
SYSTEM 97.3 97.3 97.3 744 744 724
** PROBLEMS/SOLUTIONS/COMMENTS
THE A-SIDE WAS SHUT DOWN FOR INSPECTION.
9/75 A 64.5 97.6 64.5
B 93.0 97.4 93.0
SYSTEM 78.8 97.5 78.8 720 720 567
»» PROBLEMS/SOLUTIONS/COMMENTS
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
13-64
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
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
** PROBLEMS/SOLUTIONS/COMMENTS
OUTAGES RESULTED FROM SCHEDULED EQUIPMENT OVERHAULS AND RECOATING OF VES-
SELS.
11/75 A 100.0 100.0 100.0
B 71.4 80.0 71.4
SYSTEM 85.7 90.0 85.7 720 720 617
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR OUTAGES OR PROBLEMS OCCURRED DURING THE REPORT PERIOD.
12/75 A 100.0 100.0 100.0
B 100.0 100.0 100.0
SYSTEM 100.0 100.0 100.0 744 744 744
«* 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
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
13-65
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 198*
ARIZONA PUBLIC SERVICE: CHOLLA 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION V. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
6/76
7/76
8/76
9/76
10/76
11/76
CORROSION AND PLUGGING PROBLEMS OCCURRED ON THE A-SIDE REHEATER
TUBES.
THE UTILITY REPORTED THAT PLUGGING OCCURRED IN THE FLOODED DISC SCRUBBER
RECIRCULATION LINES.
PLUGGING OCCURRED IN THE FLOODED DISC SCRUBBER PACKING.
PLUGGING OCCURRED IN THE MIST ELIMINATORS.
HEAVY PUMP MAINTENANCE WAS REQUIRED IN MAY. THE UTILITY NOW CONSIDERS
HEAVY PUMP MAINTENANCE NORMAL FOR THE CHOLLA 1 SCRUBBER.
A 64.1
B 39.4
SYSTEM 51.8
** PROBLEMS/SOLUTIONS/COMMENTS
7ZO
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 SCPUBBING SYSTEM
RECYCLE TANKS.
A 100.0
B 97.5
SYSTEM 98.8
A 100.0
B 100.0
SYSTEM 100.0
** PROBLEMS/SOLUTIONS/COMMENTS
744
744
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.
A
B
SYSTEM
100.0
100.0
93.9
97.0
100.0
100.0
100.0
100.0
93.9
97.0
720 720
698
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS IN SERVICE THE ENTIRE MONTH. NO SIGNIFICANT SCRUBBER
PROBLEMS WERE REPORTED.
A
B
SYSTEM
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
720 720
346
619
13-66
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ARIZONA PUBLIC SERVICE: CHOLLA 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
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
SYSTEM
71.6
91.9
81.8
72.3
93.4
82.9
71.6
91.9
81.8
744 744
608
** PROBLEMS/SOLUTIONS/COMMENTS
BAD C3471 ****
THE PERFORMANCE INDEX VALUES CONTAINED IN THESE TABLES ARE BASED UPON THE
MODULE 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
620
672 672
** PROBLEMS/SOLUTIONS/COMMENTS
THERE WERE MECHANICAL DIFFICULTIES WITH THE BY-PASS DAMPERS.
AVERAGE S02 INLET AND OUTLET VALUES DURING FEBRUARY WERE 350 PPM AND 175
PPM RESPECTIVELY.
3/77 A
B
SYSTEM
71.6
91.9
81.8
72.3
93.4
82.9
71.6
91.9
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.
13-67
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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
4/77
A
B
SYSTEM
99
98
99
.6
.6
.1
100
100
100
.0
,0
.0
88
87
87
.2
.3
.8
720 638 632
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED NO MAJOR PROBLEMS OCCURRED DURING APRIL.
5/77 A
B
SYSTEM
100.0
100.0
100.0
87.0
87.0
87.0
86.7
86.7
86.7
744 645
645
6/77
8/77
9/77
«* 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.
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
720 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED NO MAJOR PROBLEMS FOR THE MONTH OF JUNE.
720
7/77 A
B
SYSTEM
97.0
99.0
98.0
744 744
** PROBLEMS/SOLUTIONS/COMMENTS
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.
A
B
SYSTEM
97.2
98.6
97.9
97.2
98.6
97.9
97.2
98.6
97.9
744
729
** 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.
A
B
SYSTEM
100.0
100.0
100.0
99.7
99.7
99.7
100.0
100.0
100.0
99.7
99.7
99.7
720 720
718
** PROBLEMS/SOLUTIONS/COMMENTS
ONLY ROUTINE MAINTENANCE WAS REQUIRED FOR THE SCRUBBING SYSTEM DURING
SEPTEMBER.
13-68
-------
UTILITY FSD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ARIZONA PUBLIC SERVICE: CHOLLA 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
502 PART. HOURS HOURS HOURS FACTOR
10/77
A
B
SYSTEM
100
100
100
.0
.0
.0
99
99
92
.9
.9
.1
100.
100.
98.
0
0
7
99.
99.
99.
9
9
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 98.7 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 SHLL 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 97.0 97.0 17.6
B 90.9 96.9 16.5
SYSTEM 94.0 97.0 17.1 744 135 127
** PROBLEMS/SOLUTIONS/COMMENTS
THE FLOODED DISC SCRUBBER TANK HEADER FOR THE LIMESTONE SLURRY WAS REPAIR-
ED AFTER BEING DAMAGED DURING THE OVERHAUL.
THE BOILER AND SCRUBBER WERE OUT OF SERVICE MOST OF JANUARY AS THE
SCHEDULED OVERHAUL CONTINUED.
2/78 A 99.1 100.0 94.7
B 87.9 100.0 84.0
SYSTEM 93.5 100.0 89.4 672 642 600
13-69
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ARIZONA PUBLIC SERVICE: CHOLLA 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION V. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
4/78
6/78
7/78
8/78
9/78
** PROBLEMS/SOLUTIONS/COMMENTS
SOME MINOR LEAK REPAIRS WERE REQUIRED DURING FEBRUARY AFTER THE TWO MONTH
OVERHAUL/CLEANING WAS COMPLETED IN JANUARY.
3/78 A
B
SYSTEM
100.0
98.8
99.4
74.4
74.4
74.4
100.0
98.8
99.4
744
739
** PROBLEMS/SOLUTIONS/COMMENTS
ONE FORCED SHUTDOWN OCCURRED ON THE A-SIDE SCRUBBING TRAIN.
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.
5/78 A
B
SYSTEM
86.7
96.2
91.5
86.7
98.1
92.4
86.7
96.2
91.5
744 744
680
** PROBLEMS/SOLUTIONS/COMMENTS
THERE WERE NO SIGNIFICANT PROBLEMS REPORTED.
PERFORMED ON THE SYSTEM DURING MAY.
ONLY GENERAL MAINTENANCE WAS
A
B
SYSTEM
100.0
99.2
99.6
100.0
100.0
100.0
100.0
99.2 100.0 99.2
99.6 720 720
** 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.
100.0 100.0 100.0 100.0
95.1 95.1 95.1
97.6 97.6 97.6 744 744 726
** PROBLEMS/SOLUTIONS/COMMENTS
A
B
SYSTEM
REPAIRS WERE NECESSARY TO PLUGGED B-SIDE REHEAT COILS. THE COILS WERE
REPLACED.
A
B
SYSTEM
100.0
100.0
97.8
98.9
100.0
100.0
100.0
100.0
97.8
98.9
720 720
712
13-70
-------
UTILITY FSD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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
10/78
11/78
12/78
1/79
2/79
3/79
4/79
5/79
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED NO MAJOR PROBLEMS FOR THE MONTH OF SEPTEMBER.
A
B
SYSTEM
100.0
95.9
98.0
100.0
100.0
100.0
58.4
56.0
57.2
744 434 425
** PROBLEMS/SOLUTIONS/COMMENTS
ONLY ROUTINE MAINTENANCE WAS REQUIRED ON THE SCRUBBER IN OCTOBER.
100.0 100.0 100.0 100.0
91.3 100.0 91.3
95.7 100.0 95.7 720 720 688
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED NO MAJOR PROBLEMS FOR THE MONTH OF NOVEMBER.
A
B
SYSTEM
A
B
SYSTEM
88.1
85.6
86.9
88.1
68.3
88.2
88.1
85.6
86.9
744 744
646
*» PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY HAS REPORTED THAT THE FGD SYSTEM EXPERIENCED CONTROL PROB-
LEMS DURING DECEMBER.
A
B
SYSTEM
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
744 744
741
672 672 672
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED NO MAJOR PROBLEMS FOR THE MONTH OF FEBRUARY.
A
B
SYSTEM
100.0
95.2
100.0
97.6
95.0
100.0
97.5
95.2
100.0
97.6
744 744
726
** PROBLEMS/SOLUTIONS/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.
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
720 720
720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED NO PROBLEMS FOR THE MONTH OF APRIL.
A 99.1 99.4 99.1
13-71
-------
UTILITY FGD SURVEY: OCTOBER 1983 SEPTEMBER 1984
ARIZONA PUBLIC SERVICE: CHOLLA 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OFERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
SOZ PART. HOURS HOURS HOURS FACTOR
B 44.1 44.1 44.1
SYSTEM 71.6 71.8 71.6 744 744 533
** PROBLEMS/SOLUTIONS/COMMENTS
CORRODED DUCTWORK ON MODULE B FROM THE TOWER TO THE STACK WAS REPLACED
DURING MAY.
REPAIRS WERE MADE TO THE MODULE B SCRUBBER LINING.
6/79 A 78.2 78.0 78.2
B 100.0 100.0 100.0 100.0
SYSTEM 89.1 89.0 89.1 720 720 642
** PROBLEMS/SOLUTIONS/COMMENTS
THE MODULE A ABSORBER TOWER MUNTERS PACKING WAS REPLACED DURING JUNE.
EMERGENCY MAINTENANCE WAS PERFORMED JUNE 23 ON THE MODULE A COMMON DIS-
CHARGE HEADER.
7/79 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
NO INFORMATION WAS AVAILABLE FOR THE MONTH OF JULY.
8/79 A 95.7 95.6 95.7
B 95.7 95.7 95.7
SYSTEM 95.7 95.7 95.7 744 744 712
** PPOBLEMS/SOLUTION'S/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 97.8 100.0 45.0
B 94.3 98.0 43.3
SYSTEM 96.1 99.0 44.2 744 342 323
** PROBLEMS/SOLUTIONS/COMMENTS
DURING OCTOBER ROUTINE MAINTENANCE WAS PERFORMED ON THE FGD SYSTEM.
U/79 A 77.0 77.0
B 98.5 96.5
SYSTEM 87.8 87.8 720 720 632
12/79 A 94.0 94.0
B S6.7 86.7
SYSTEM 90.4 90.4 744 744 672
1/80 A 95.5 95.5
B 99.1 99.1
SYSTEM 97.3 97.3 744 744 724 91.7
2/80 A 100.0 100.0 100.0 100.0
13-72
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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
3/80
4/80
5/80
6/80
7/80
B
SYSTEM
A
B
SYSTEM
99.4
99.7
99.1
93.1
96.1
99.4
99.7
99.1
93.1
96.1
696 696
744 744
694 92.1
715 88.6
#* PROBLEMS/SOLUTIONS/COmENTS
NO FORCED OUTAGES WERE REPORTED BY THE UTILITY FOR THE FIVE MONTH PERIOD
OF NOVEMBER 1979 THROUGH MARCH 19SO. SOME SCHEDULED OUTAGE TIME WAS
REQUIRED FOR REPAIR OF THE REHEATER DUCTWORK.
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
720 720
** PROBLEMS/SOLUTIONS/COMMENTS
NO FGD-RELATED PROBLEMS WERE REPORTED FOR THE MONTH OF APRIL.
720 82.8
A
B
SYSTEM
100.0
99.2
99.6
100.0
99.2
99.6
100.0
99.2
99.6
100.0
99.2
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.
A
B
SYSTEM
100.0
99.3
99.7
80.7
87.7
84.2
100.0
99.1
99.6
68.7
74.6
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.
A
B
SYSTEM
100.0
100.0
100.0
100.0
98.6
99.3
100.0
100.0
100.0
100.0
98.6
99.3
744
744
739 95.8
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS AVAILABLE 100X OF THE TIME IN JULY.
UTILIZED FOR PART OF THE MONTH DUE TO LOW BOILER LOAD.
MODULE B WAS NOT
8/80
9/80
SYSTEM
SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
744
720
10/80
11/80
12/80
SYSTEM
SYSTEM
SYSTEM
DATA FOR THE AUGUST AND SEPTEMBER MONTHS WERE NOT AVAILABLE DUE TO
PERSONNEL CHANGES.
744
720
744
13-73
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ARIZONA PUBLIC SERVICE: CHOLLA 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
1/81 SYSTEM
2/81 SYSTEM
3/81 SYSTEM
4/81 SYSTEM
5/81 SYSTEM
6/81 SYSTEM
7/81 SYSTEM
8/81 SYSTEM
9/81 SYSTEM
10/81 SYSTEM
11/81 SYSTEM
12/81 SYSTEM
1/82 SYSTEM
2/82 SYSTEM
3/82 SYSTEM
4/82 SYSTEM
5/82 SYSTEM
6/82 SYSTEM
7/82 SYSTEM
8/82 SYSTEM
9/82 SYSTEM
10/82 SYSTEM
11/82 SYSTEM
12/82 SYSTEM
1/83 SYSTEM
2/83 SYSTEM
3/83 SYSTEM
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.
744
672
744
720
744
720
744
744
720
744
720
744
744
672
744
720
744
720
744
744
720
744
720
744
744
672
744
13-74
-------
UTILITY F6D SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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
INFORMATION WAS UNAVAILABLE FOR THE PERIOD OF JANUARY 1981 TO MARCH 1983.
4/83 SYSTEM 720
5/83 SYSTEM 744
6/83 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE PERIOD OF JANUARY 1981 TO JUNE 1983.
7/83 SYSTEM 744
8/83 SYSTEM 744
9/83 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE THIRD QUARTER OF 1983.
10/83 SYSTEM 744
11/83 SYSTEM 720
12/83 SYSTEM 744
»* PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE FOURTH QUARTER OF 1983.
1/84 SYSTEM 744
2/84 SYSTEM 696
3/84 SYSTEM 744
4/84 SYSTEM 720
5/84 SYSTEM 744
6/84 SYSTEM 720
7/84 SYSTEM 744
8/84 SYSTEM 744
9/84 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS NOT AVAILABLE FOR THE FIRST THREE QUARTERS OF 1984.
13-75
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
SECTION 13
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 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 - 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
** MECHANICAL COLLECTOR
NUMBER
NUMBER OF SPARES
TYPE
SUPPLIER
INLET FLUE GAS CAPACITY CU.M/S
INLET FLUE GAS TEMPERATURE - C
PARTICLE REMOVAL EFFICENCY -7.
** ESP
NUMBER
TYPE
** PARTICLE SCRUBBER
NUMBER
NUMBER OF SPARES
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON NAME
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
ARIZONA PUBLIC SERVICE
CHOLLA
Z
JOSEPH CITY
ARIZONA
72. (
430. (
344. (
615
285
235
250
285
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
519.09
142.2
168.
CONCRETE
4.5
.167 LB/MWBTU)
.000 LB/MMBTU)
.800 LB/MMBTU)
(1100000 ACFM)
( 288 F)
( 550 FT)
( 14.7 FT)
( 10150 BTU/LB)
9650-10600
COAL
BITUMINOUS
23609.
13.50
9.7-22.5
15.00
******
.50
0.4-1.0
.02
0.01-0.04
2
0
CYCLONE
RESEARCH-COTTRELL
259.5 ( 550000 ACFtl)
137.8 ( 280 F)
70.0
0
NONE
4
1
VENTURI TOWER
VARIABLE-THROAT/BOTTOM-ENTRY LIQUID DISTRIBUTION
FLOODED DISC SCRUBBER
RESEARCH-COTTRELL
6.0 DIA X 45.0
CARBON STEEL
AISI 1110
ORGANIC
MAT-REINFORCED EPOXY
NONE
1
617.4 ( 9800 GPM)
13-76
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ARIZONA PUBLIC SERVICE: CHOLLA Z (CONT.)
L/G RATIO LITER/CU.M
PH CONTROL ADDITIVE
PRESSURE DROP - KPA
INLET GAS FLOW RATE - CU.M/S
INLET GAS TEMPERATURE - C
PARTICLE REMOVAL EFFICIENCY - X
*** 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 - X
ENERGY CONSUMPTION - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
OPER. i MAINT. REQUIREMENT - MANHR/DAY
** QUENCHER/PRESATURATOR
NUMBER
** 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
L/G RATIO - L/CU.M
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
NUMBER OF SPARES PER SYSTEM
NUMBER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
NUMBER OF STAGES
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
WASH WATER SOURCE
WASH FREQUENCY
3.3
ABSORBER SLURRY
5.7
185.0
137.8
99.0
(25.0 GAL/1000ACF)
r
(23.0 IN-H20)
( 392000 ACFM)
( 280 F)
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
NONE
RESEARCH-COTTRELL
EBASCO
FULL SCALE
NEW
'/. 99.70
75.00
5.3
1
6/78
4/78
12/74
40.0
4
1
COMBINATION TOWER
SPRAY/PACKED
N/A
RESEARCH-COTTRELL
22.0 DIA X 70.0
CARBON STEEL
AISI 1110
N/A
ORGANIC
MAT-REINFORCED EPOXY; GLASS FLAKE-FILLED POLYEST
COROLINE 505AR; FLAKELINE 103
VERTICAL CROSS CHANNEL FIXED GRID PACKING
2
(19200 GPM)
( 48.9 GAL/1000 ACF)
( 10.0 FT/S)
( 392000 ACFM)
( 122 F)
1210.
6.5
3.0
184.98
50.0
98.0
99.0
PRIMARY COLLECTOR
4
1
1
CYCLONIC
CYCLONIC SEPARATOR
CYCLONIC TOWER
VERTICAL
1
STAINLESS STEEL
AUSTENITIC
NONE
N/A
13-77
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ARIZONA PUBLIC SERVICE: CHOLLA 2 (CONT.)
«* REHEATER
NUMBER
NUMBER OF SPARES
NUMBER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
LOCATION
TEMPERATURE INCREASE - C
INLET FLUE GAS TEMPERATURE - C
OUTLET FLUE GAS TEMPERATURE - C
NUMBER OF HEAT EXCHANGER BANKS
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
»* FANS
NUMBER
DESIGN
FUNCTION
APPLICATION
SERVICE
FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
4
1
1
IN-LINE
STEAM
BARE TUBE
TOP OF THE ABSORBER
22.2 ( 40 F)
49.4 ( 121 F)
71.1 ( 160 F)
3
HIGH ALLOY
NICKEL BASE/CHROMIUM-IRON-ttOLYBDENUM
CENTRIFUGAL
UNIT
FORCED DRAFT
DRY
137.8 ( 280 F)
NR
«* FANS
NUMBER
DESIGN
FUNCTION
APPLICATION
SERVICE
FLUE GAS TEMPERATURE C
CONSTRUCTION MATERIAL GENERIC TYPE
*# DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
CONSTRUCTION MATERIAL GENERIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
»* DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
MANUFACTURER
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
MANUFACTURER
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
CENTRIFUGAL
BOOSTER
INDUCED DRAFT
DRY
71.1 ( 160 F)
ORGANIC; CARBON STEEL IHOUSINGI; STAINLESS STEEL
4
SHUT-OFF
GUILLOTINE
NR
MOSSER
CARBON STEEL
STAINLESS STEEL
AUSTENITIC
4
CONTROL
LOUVER
NR
MOSSER
STAINLESS STEEL
AUSTENITIC
NONE
N/A
2
CONTROL
LOUVER
MOSSER
4
CONTROL
LOUVER
MOSSER
4
SHUT-OFF
LOUVER
13-78
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ARIZONA PUBLIC SERVICE: CHOLLA 2 (CONT.)
MANUFACTURER
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
MANUFACTURER
NUMBER
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
PRODUCT QUALITY - X SOLIDS
** TANKS
SERVICE
ABSORBER FEED
REAGENT FEED
MILL SLURRY SUMP
SCRUBBER RECYCLE
SLUDGE STORAGE
** PUMPS
SERVICE
SCRUEBER RECIRCULATION
ABSORBER RECIRCULATION
MILL SLURRY SUMP
REAGENT FEED
MIST ELIMINATOR WASH
*** SLUDGE
MOISTURE CONTENT - X TOTAL FREE WATER
** TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
INLET QUALITY - X
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE TREATMENT
** PROCESS CONTROL AND INSTRUMENTATION
PROCESS STREAM
CHEMICAL PARAMETERS
MOSSER
INLET
CARBON STEEL
AISI 1110
NONE
N/A
OUTLET
CARBON STEEL
AISI 1110
ORGANIC; ORGANIC
GLASS FLAKE-FILLED POLYESTER;
BYPASS
CARBON STEEL
AISI 1110
NONE
N/A
WET BALL MILL
COMPARTMENTED
NR
KENNEDY VAN SAUN
Z
6.4 (7 TPH)
25.0
NUMBER
2
****
****
NUMBER
12
8
****
**«*
#***
35.0
STABILIZATION
NR
NONE
15.0
FINAL
POND
ON-SITE
PIPELINE
NONE
SCRUBBER AND ABSORBER HOLD TANK
PH
INERT FLAKE-FILLED
13-79
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ARIZONA PUBLIC SERVICE: CHOLLA 2 (CONT.)
CONTROL LEVELS PH 4.8-5.2 IN SCRUBBER HOLD TANK; 5.9-6.2 IN ABS
** WATER BALANCE
WATER LOOP TYPE OPEN
MAKEUP WATER ADDITION - LITERS/S 7.6 ( 120 GPtt)
** CHEMICALS AND CONSUMPTION
FUNCTION ABSORBENT
NAME LIMESTONE
POINT OF ADDITION BALL MILL
** FGD SPARE CAPACITY INDICES
SCRUBBER - X 33.3
ABSORBER - X 33.3
** FGD SPARE COMPONENT INDICES
SCRUBBER 1.0
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 SHAKEDOKN PROBLEMS CLEARED UP BY THEN.
6/78 SYSTEM 720
7/78 SYSTEM 744
** PROBLEMS/SOLUTION'S/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.
13-80
-------
UTILITY FGO SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ARIZONA PUBLIC SERVICE: CHOLLA 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
SOS PART. HOURS HOURS HOURS FACTOR
10/78 SYSTEM 744
11/78 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
SHAKEDOUN 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
** PROBLEMS/SOLUTIONS/COMMENTS
DECEMBER-JANUARY INFORMATION IS UNAVAILABLE AT THIS TIME FOR CHOLLA 2.
THE UTILITY REPORTED THAT IT WOULD SOON BE KEEPING PERFORMANCE RECORDS.
1/79 SYSTEM 744
2/79 SYSTEM 672
3/79 SYSTEM 744
4/79 SYSTEM 720
5/79 SYSTEM 744
6/79 SYSTEM 720
7/79 SYSTEM 744
8/79 SYSTEM 744
9/79 SYSTEM 720
10/79 SYSTEM 744
11/79 SYSTEM 720
12/79 SYSTEM 744
1/80 SYSTEM 744
2/80 SYSTEM 696
3/80 SYSTEM 744
4/80 SYSTEM 720
5/80 SYSTEM 744
6/80 SYSTEM 720
7/80 SYSTEM 744
8/80 SYSTEM 744
9/80 SYSTEM 720
10/80 SYSTEM 744
11/80 SYSTEM 720
12/80 SYSTEM 744
13-81
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
ARIZONA PUBLIC SERVICE'- CHOLLA 2 (CONT.)
PERFORMANCE DATA-
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
1/81 SYSTEM 744
2/81 SYSTEM 672
3/81 SYSTEM 744
4/81 SYSTEM 720
5/81 SYSTEM 744
6/81 SYSTEM 720
7/81 SYSTEM 744
8/81 SYSTEM 744
9/81 SYSTEM 720
10/81 SYSTEM 744
11/81 SYSTEM 720
12/81 SYSTEM 744
1/82 SYSTEM 744
2/82 SYSTEM 672
3/82 SYSTEM 744
4/82 SYSTEM 720
5/82 SYSTEM 720
6/82 SYSTEM 720
7/82 SYSTEM 744
8/82 SYSTEM 744
9/82 SYSTEM 720
10/82 SYSTEM 744
11/82 SYSTEM 720
12/82 SYSTEM 744
1/83 SYSTEM 744
2/83 SYSTEM 672
3/83 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE PERIOD OF JANUARY 1979 TO MARCH 1983.
4/83 SYSTEM 720
5/83 SYSTEM 744
6/83 SYSTEM 720
13-82
-------
UTILITY F6D SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ARIZONA PUBLIC SERVICE: CHOLLA 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
INFORMATION WAS UNAVAILABLE FOR THE PERIOD OF JANUARY 1979 TO JUNE 1983.
7/83 SYSTEM 744
8/83 SYSTEM 744
9/83 SYSTEM 720
#* PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE THIRD QUARTER OF 1983.
10/83 SYSTEM 744
11/83 SYSTEM 720
12/83 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE FOURTH QUARTER OF 1983.
1/84 SYSTEM 744
2/84 SYSTEM 696
3/84 SYSTEM 744
4/84 SYSTEM 720
5/84 SYSTEM 744
6/84 SYSTEM 720
7/84 SYSTEM 744
8/84 SYSTEM 744
9/84 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS NOT AVAILABLE FOR THE FIRST THREE QUARTERS OF 1984.
13-83
-------
UTILITY FGO SURVEY: OCTOBER 1983 - SEPTEMBER 1984
SECTION 13
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 - 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
ARIZONA PUBLIC SERVICE
CHOLLA
4
JOSEPH CITY
ARIZONA
A
****** (****** LB/MMBTU)
****** (****** LB/MMBTU)
****** (**#*** LB/MMBTU)
965
375
350
495
126
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
********
*******
******
CONCRETE
(******* ACFM)
(**** F)
(**** 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 7.
AVERAGE MOISTURE CONTENT - >.
RANGE MOISTURE CONTENT 7.
AVERAGE SULFUR CONTENT - V.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT '/.
RANGE CHLORIDE CONTENT 7.
»** PARTICLE CONTROL
** ESP
NUMBER
COAL
******
23609.
13.50
******
15.00
******
.50
0.4-1.0
.02
0.01-0.04
( 10150 BTU/LB)
******
** PARTICLE SCRUBBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON NAME
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
*** FGD SYSTEM
** GENERAL DATA
SALEABLE FRODUCT/THROWAWAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
UNIT DESIGN S02 REMOVAL EFFICIENCY - 7.
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
0
NONE
N/A
N/A
N/A
N/A
N/A
N/A
NONE
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
RESEARCH-COTTRELL
EBASCO
FULL SCALE
NEW
95.00
1
6/81
3/81
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ARIZONA PUBLIC SERVICE: CHOLLA 4 (CONT.)
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
** QUENCHER/PRESATURATOR
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** ABSORBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
SOZ REMOVAL EFFICIENCY - X
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** REHEATER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** FANS
DESIGN
FUNCTION
APPLICATION
SERVICE
CONSTRUCTION MATERIAL GENERIC TYPE
** DAMPERS
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
*» DUCTWORK
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
** TANKS
SERVICE
NR
10/77
NR
NR
COMBINATION TOWER
SPRAY/PACKED
N/A
NR
NR
NR
NR
NR
NR
95.0
PRIMARY COLLECTOR
IMPINGEMENT
BAFFLE
CLOSED VANE
NR
NR
NR
NR
NR
NR
NR
CENTRIFUGAL
NR
FORCED DRAFT
DRY
CARBON STEEL
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
WET BALL MILL
COMPARTMENTED
NR
NUMBER
»***
13-85
-------
UTILITY FGD SURVEY: OCTOBER 1983 SEPTEMBER 1984
ARIZONA PUBLIC SERVICE: CHOLLA 4 (CONT.)
** PUMPS
SERVICE NUMBER
NR ****
*» SOLIDS CONCENTRATING/DEWATERING
DEVICE NA
*** SLUDGE
** TREATMENT
METHOD NA
DEVICE NA
PROPRIETARY PROCESS NA
** DISPOSAL
NATURE FINAL
TYPE POfJD
LOCATION ON-SITE
SITE TREATMENT NONE
** 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
3/81 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
IN MARCH 1981 THE FGD SYSTEM COMMENCED OPERATIONS. THE SYSTEM OPERATED
FOR APPROXIMATELY ONE WEEK BEFORE BEING TAKEN OFF LINE FOR A BEARING IN-
SPECTION.
4/81 SYSTEM 720
5/81 SYSTEM 744
6/81 SYSTEM 720
7/81 SYSTEM 744
8/81 SYSTEM 744
9/81 SYSTEM 720
10/81 SYSTEM 744
11/81 SYSTEM 720
12/81 SYSTEM 744
1/82 SYSTEM 744
2/82 SYSTEM 672
V62 SYSTEM 744
4/82 SYSTEM 720
5/82 SYSTEM 720
13-86
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ARIZONA PUBLIC SERVICE: CHOLLA 4 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
6/82 SYSTEM 720
7/82 SYSTEM 744
8/82 SYSTEM 744
9/82 SYSTEM 720
10/82 SYSTEM 744
11/82 SYSTEM 720
12/82 SYSTEM 744
1/83 SYSTEM 744
2/83 SYSTEM 672
3/83 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE PERIOD OF APRIL 1981 TO MARCH 1983.
4/83 SYSTEM 720
5/83 SYSTEM 744
6/83 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE PERIOD OF APRIL 1981 TO JUNE 1983.
7/83 SYSTEM 744
8/83 SYSTEM 744
9/83 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE THIRD QUARTER OF 1983.
10/83 SYSTEM 744
11/83 SYSTEM 720
12/83 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE FOURTH QUARTER OF 1983.
1/84 SYSTEM 744
2/84 SYSTEM 696
3/84 SYSTEM 744
4/84 SYSTEM 720
5/84 SYSTEM 744
13-87
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ARIZONA PUBLIC SERVICE: CHOLLA 4 (CONT.)
-_ . . PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
SOZ PART. HOURS HOURS HOURS FACTOR
6/84 SYSTEM 720
7/84 SYSTEM 744
8/84 SYSTEM 744
9/84 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS NOT AVAILABLE FOR THE FIRST THREE QUARTERS OF 1984.
13-88
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
SECTION 13
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
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 - V.
AVERAGE MOISTURE CONTENT V.
RANGE- MOISTURE CONTENT - '/.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** MECHANICAL COLLECTOR
NUMBER
TYPE
** ESP
NUMBER
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 502 REMOVAL EFFICIENCY 7.
ENERGY CONSUMPTION - 7.
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
ARIZONA PUBLIC SERVICE
FOUR CORNERS
1
FRUITLAND
NEW MEXICO
C
21. (
365. (
301. (
2085
195
170
175
195
RILEY STOKER
PULVERIZED COAL
BASE
384.13 (
171.1 (
76. (
CONCRETE
5.3 (
.050 LB/MMBTU)
.850 LB/MMBTU)
.700 LB/MMBTU)
814000 ACFM)
340 F)
250 FT)
17.5 FT)
( 8600 BTU/LB)
8500-9100
COAL
SUBBITUMINOUS
20004.
22.00
19-25
10.80
8.5-13.4
.75
.5-1.3
.03
.01-.06
0
NONE
0
NONE
THROWAWAY PRODUCT
WET SCRUBBING
LIME/ALKALINE FLYASH
NONE
GE ENVIRONMENTAL SERVICES
IN-HOUSE
FULL SCALE
RETROFIT
7. 99.50
50.00
2.6
1
11/79
11/79
0/78
13-89
-------
UTILITY FGO SURVEY: OCTOBER 1983 - SEPTEMBER
ARIZONA PUBLIC SERVICE: FOUR CORNERS 1 (CONT.)
** DESIGN AND OPERATING PARAMETERS
DESIGN COAL SULFER CONTENT - X 1.30
DESIGN COAL HEAT CONTENT - J/G 19771.0
DESIGN COAL ASH CONTENT - X 25.00
DESIGN MOISTURE CONTENT - X 13.40
DESIGN CHLORIDE CONTENT - X .06
SPACE REQUIREMENTS - SO M 520.2
OPER. & MAINT. REQUIREMENT - MANHR/DAY 200.0
»* QUENCHER/PRESATURATOR
CONSTRUCTION MATERIAL GENERIC TYPE MR
CONSTRUCTION MATERIAL SPECIFIC TYPE NR
( 8500 BTU/LB)
( 5600 SO FT)
** ABSORBER
NUMBER
NUMBER OF SPARES
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON 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 RECIRCUUTION RATE LITER/S
L/G RATIO L/CU.M
GAS-SIDE PRESSURE DROP - KPA
INLET GAS FLO'rJ - 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
NUMBER OF SPARES PER SYSTEM
NUMBER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
NUM5ER OF STAGES
NUMBER OF PASSES PER STAGE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
WASH WATER SOURCE
WASH FREQUENCY
** REHEATER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** FANS
NUMBER
NUMBER OF SPARES
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE CU.M/S
FLUE GAS TEMPERATURE - C
2
0
VENTURI TOWER
VARIABLE-THROAT/TOP-ENTRY PLUMB BOB
N/A
25 DIA
CARBON STEEL
AISI 1110
N/A
ORGANIC
GLASS FLAKE-FILLED POLYESTER
FLAKELINE 103
VENTURI THROAT [TANGENTIAL NOZZLES AT TOP t AT S
630.
3.2
2.5
192.06
171.1
67.5
99.5
(10000 GPM)
( 24.0 GAL/1000 ACF)
(10.0 IN-H20)
( 407000 ACFM)
( 340 F)
PRIMARY COLLECTOR
2
0
1
IMPINGEMENT
BAFFLE
CLOSED VANE
HORIZONTAL
1
6
ORGANIC
FIBER-REINFORCED POLYESTER
FRESH [FROM LAKE]
ONCE PER SHIFT
0
NONE
N/A
N/A
NONE
N/A
2
0
CENTRIFUGAL
AMERICAN STANDARD
UNIT
INDUCED DRAFT
WET
259.54 ( 550000 ACFM)
51.7 ( 125 F)
13-90
-------
UTILITY F6D SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ARIZONA PUBLIC SERVICE: FOUR CORNERS 1 (CONT.)
CONSTRUCTION MATERIAL GENERIC TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
SERVICE CONDITIONS
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
SERVICE CONDITIONS
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
CONFIGURATION
DIMENSIONS
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
CONFIGURATION
DIMENSIONS
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
MANUFACTURER
NUMBER
NUMBER OF SPARES
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
PRODUCT QUALITY - X SOLIDS
#* REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
MANUFACTURER
NUMBER
NUMBER OF SPARES
** TANKS
SERVICE
HIGH ALLOY
2
CONTROL
LOUVER
PARALLEL BLADE MULTILOUVER
AMERICAN STANDARD
120-130 F
STAINLESS STEEL
AUSTENITIC
NONE
N/A
SHUT-OFF
GUILLOTINE
NR
NR
NR
CARBON STEEL
AISI 1110
NONE
N/A
INLET
CIRCULAR
14 DIA X 90 FT
CARBON STEEL
ASTM A-283
NONE
N/A
OUTLET [ME TO STACK]
RECTANGULAR
12 X 12 X 50 FT
CARBON STEEL
ASTM A-283
STAINLESS STEEL
AUSTENITIC
SLAKER
NR
NR
JOY
1
0
13.6 ( 15 TPH)
30.0
WET BALL MILL
NR
NR
KENNEDY VAN SAUN
1
0
NUMBER
BLEED STREAM
RECYCLE
MAKEUP WATER
RETURN TRANSFER
LIME SLURRY
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ARIZONA PUBLIC SERVICE: FOUR CORNERS 1 (CONT.)
** PUMPS
SERVICE
NUMBER
2
4
****
4
2
2
****
****
RECYCLE
RECYCLE [STANDBY]
BLEED STREAM TANK
THICKENER UNDERFLOW
LIME SLURRY TRANSFER
RETURN WATER
SERVICE WATER
ME WATER
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
CONFIGURATION
DIMENSIONS FT
CAPACITY
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
FEED STREAM SOURCE
OUTLET STREAM CHARACTERISTICS
*** SLUDGE
FULL LOAD SLUDGE QUANTITY - M.TONS/HR (DRY)
MOISTURE CONTENT X TOTAL FREE WATER
X CAS03 DRY
X CAS04 - DRY
X CAOH2 - DRY
X CAC03 - DRY
X ASH - DRY
X OTHER COMPOUNDS - DRY
»« TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE TREATMENT
SITE DIMENSIONS
SITE CAPACITY - CU.M
SITE SERVICE LIFE - YRS
** PROCESS CONTROL AND INSTRUMENTATION
PROCESS STREAM
CHEMICAL PARAMETERS
PHYSICAL VARIABLES
CONTROL LEVELS
MONITOR TYPE
MONITOR LOCATION
PROCESS CONTROL MANNER
PROCESS CHEMISTRY MODE
** WATER BALANCE
WATER LOOP TYPE OPEN
EVAPORATION WATER LOSS - LITER/S 6.3
SOURCE CF MAKEUP WATER LAKE WATER
THICKENER
1
0
CIRCULAR
100
1000000
CARBON STEEL
AISI 1110
ORGANIC
GLASS FLAKE-FILLED POLYESTER
ABSORBER BLEED
40. OX
25.4
60.0
18.0
5.0
1.0
1.0
75.0
1.0
28.0 TPH)
NONE
NR
NR
FINAL
POND
ON-SITE
PIPELINE
NONE
70 ACRES/55 FT
4708550
10
( 3850.0 ACRE-FT)
SLURRY STREAM
PH
X SOLIDS, FLOW, TEMPERATURE
PH 6.2-7.2, 12X SOLIDS
PH- APS FLOW THROUGH; DENSITY--TEXAS NUCLEAR
RECYCLE LOOP ON TANGENTIAL NOZZLE HEADER
AUTOMATIC
FEEDBACK
(100 GPM )
13-92
-------
ARIZONA PUBLIC SERVICE: FOUR CORNERS 1 (CONT.)
UTILITY F6D SURVEY: OCTOBER 1983 - SEPTEMBER 1984
»* CHEMICALS AND CONSUMPTION
FUNCTION
NAME
PRINCIPAL CONSTITUENT
SOURCE/SUPPLIER
CONSUMPTION
UTILIZATION - X
POINT OF ADDITION
*» FGD SPARE CAPACITY INDICES
ABSORBER - 7.
** FGD SPARE COMPONENT INDICES
ABSORBER
ABSORBENT
LIME
CAO
CAN AM, PAUL LIME CO.
20 TPD
83.0
SLAKER, ABSORBER BOTTOM
.0
.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.
744
744
720
744
720
744
744
672
744
720
7/80 SYSTEM
8/80 SYSTEM
9/80 SYSTEM
10/80 SYSTEM
11/80 SYSTEM
12/80 SYSTEM
1/81 SYSTEM
2/81 SYSTEM
3/81 SYSTEM
4/81 SYSTEM
13-93
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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
5/81 SYSTEM 744
6/81 SYSTEM 720
7/81 SYSTEM 744
8/81 SYSTEM 744
9/81 SYSTEM 720
10/81 SYSTEM 744
11/81 SYSTEM 720
12/81 SYSTEM 744
1/82 SYSTEM 744
2/82 SYSTEM 672
3/82 SYSTEM 744
4/82 SYSTEM 720
5/82 SYSTEM 744
6/82 SYSTEM 720
7/82 SYSTEM 744
8/82 SYSTEM 744
9/82 SYSTEM 720
10/82 SYSTEM 744
11/82 SYSTF.M 720
12/82 SYSTEM 744
1/83 SYSTEM 744
2/83 SYSTEM 672
3/83 SYSTEM 744
#* PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE PERIOD OF JULY 1980 THROUGH MARCH 1983.
4/83 SYSTEM 720
5/83 SYSTEM 7^4
6/83 SYSTEM 7£0
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE PERIOD OF JULY 19SO THROUGH JUNE 1983.
7/83 SYSTEM 7^
8/83 SYSTEM -7
13-94
-------
UTILITY FGD SURVEYS OCTOBER 1983 - SEPTEMBER 1984
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
9/83 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE THIRD QUARTER OF 1983.
10/83 SYSTEM 744
11/83 SYSTEM 720
12/83 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE FOURTH QUARTER OF 1983.
1/84 SYSTEM 744
2/84 SYSTEM 696
3/84 SYSTEM 744
4/84 SYSTEM 720
5/84 SYSTEM 744
6/84 SYSTEM 720
7/84 SYSTEM 744
8/84 SYSTEM 744
9/84 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS NOT AVAILABLE FOR THE FIRST THREE QUARTERS OF 1984.
13-95
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
SECTION 13
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 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 - 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
ARIZONA PUBLIC SERVICE
FOUR CORNERS
2
FRUITLAND
NEW MEXICO
C
21. (
365. (
301. (
2085
195
170
175
195
RILEY STOKER
PULVERIZED COAL
BASE
384.13 (
171.1 (
76. (
CONCRETE
5.3 (
.050 LB/MMBTU)
.850 LB/MMBTU)
.700 LB/MMBTU)
814000 ACFM)
340 F)
250 FT)
17.5 FT)
COAL
SUBBITUMINOUS
20004.
22.00
19-25
10.80
8.5-13.4
.75
.5-1.3
.03
.01-.06
( 8600 BTU/LB)
8500-9100
** MECHANICAL COLLECTOR
NUMBER
TYPE
** ESP
NUMBER
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.
ENERGY CONSUMPTION - 7.
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
0
NONE
0
NONE
THROWAWAY PRODUCT
WET SCRUBBING
LIME/ALKALINE FLYASH
NONE
GE ENVIRONMENTAL SERVICES
IN-HOUSE
FULL SCALE
RETROFIT
7. 99.50
50.00
2.6
1
11/79
11/79
0/78
13-96
-------
UTILITY F6D SURVEY: OCTOBER 1983 - SEPTEMBER
ARIZONA PUBLIC SERVICE: FOUR CORNERS Z (CONT.)
** DESIGN AND OPERATING PARAMETERS
DESIGN COAL SULFER CONTENT X
DESIGN COAL HEAT CONTENT - J/G
DESIGN COAL ASH CONTENT - X
DESIGN MOISTURE CONTENT - V.
DESIGN CHLORIDE CONTENT - X
SPACE REQUIREMENTS - SQ M
OPER. J MAINT. REQUIREMENT - MANHR/DAY
** QUENCHER/PRESATURATOR
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** ABSORBER
NUMBER
NUMBER OF SPARES
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON 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
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
NUMBER OF SPARES PER SYSTEM
NUMBER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES PER STAGE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
WASH WATER SOURCE
WASH FREQUENCY
** REHEATER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** FANS
NUMBER
NUMBER OF SPARES
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE CU.M/S
FLUE GAS TEMPERATURE C
( 8500 BTU/LB)
( 5600 SQ FT)
1.30
19771.0
25.00
13.40
.06
520.3
200.0
NR
NR
2
0
VENTURI TOWER
VARIABLE-THROAT/TOP-ENTRY PLUMB BOB
N/A
25 DIA
CARBON STEEL
AISI 1110
N/A
ORGANIC
GLASS FLAKE-FILLED POLYESTER
FLAKELINE 103
VENTURI THROAT [TANGENTIAL NOZZLES AT TOP 4 AT S
630.
3.2
2.5
192.06
171.1
67.5
99.5
(10000 GPM)
( 24.0 GAL/1000 ACF)
(10.0 IN-H20)
( 407000 ACFM)
( 340 F)
PRIMARY COLLECTOR
2
0
1
IMPINGEMENT
BAFFLE
CLOSED VANE
HORIZONTAL
1
6
ORGANIC
FIBER-REINFORCED POLYESTER
FRESH [FROM LAKE]
ONCE PER SHIFT
0
NONE
N/A
N/A
NONE
N/A
2
0
CENTRIFUGAL
AMERICAN STANDARD
UNIT
INDUCED DRAFT
WET
259.54 ( 550000 ACFM)
51.7 ( 125 F)
13-97
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ARIZONA PUBLIC SERVICE: FOUR CORNERS 2 (CONT.)
CONSTRUCTION MATERIAL GENERIC TYPE HIGH ALLOY
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
SERVICE CONDITIONS
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
SERVICE CONDITIONS
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
»* DUCTWORK
LOCATION
CONFIGURATION
DIMENSIONS
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
CONFIGURATION
DIMENSIONS
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
MANUFACTURER
NUM3ER
NUMBER OF SPARES
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
PRODUCT QUALITY - X SOLIDS
«* REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
MANUFACTURER
NUMBER
NUMBER OF SPARES
»» TANKS
SERVICE
BLEED STREAM
RECYCLE
MAKEUP WATER
RETURN TRANSFER
LIME SLURRY
2
CONTROL
LOUVER
PARALLEL BLADE MULTILOUVER
AMERICAN STANDARD
120-130 F
STAINLESS STEEL
AUSTENITIC
NONE
N/A
SHUT-OFF
GUILLOTINE
NR
NR
NR
CARBON STEEL
AISI 1110
NONE
N/A
INLET
CIRCULAR
14 DIA X 90 FT
CARBON STEEL
ASTM A-283
NONE
N/A
OUTLET IME TO STACK!
RECTANGULAR
12 X 12 X 50 FT
CARBON STEEL
ASTM A-283
STAINLESS STEEL
AUSTENITIC
SLAKER
NR
NR
JOY
1
0
13.6 ( 15 TPH)
30.0
WET BALL MILL
NR
NR
KENNEDY VAN SAUN
1
0
NUMBER
1
2
1
1
13-98
-------
ARIZONA PUBLIC SERVICE: FOUR CORNERS 2 (CONT.)
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
** PUMPS
SERVICE
RECYCLE
RECYCLE [STANDBY]
BLEED STREAM TANK
THICKENER UNDERFLOW
LIME SLURRY TRANSFER
RETURN WATER
SERVICE WATER
ME WATER
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
CONFIGURATION
DIMENSIONS - FT
CAPACITY
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
FEED STREAM SOURCE
OUTLET STREAM CHARACTERISTICS
NUMBER
Z
4
****
4
2
Z
****
«***
THICKENER
1
0
CIRCULAR
100
1000000
CARBON STEEL
AISI 1110
ORGANIC
GLASS FLAKE-FILLED POLYESTER
ABSORBER BLEED
40.OX
»** SLUDGE
FULL LOAD SLUDGE QUANTITY - M.TONS/HR (DRY)
MOISTURE CONTENT - X TOTAL FREE WATER
X CAS03 - DRY
X CAS04 - DRY
X CAOH2 - DRY
X CAC03 - DRY
X ASH - DRY
X OTHER COMPOUNDS - DRY
** TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE TREATMENT
SITE DIMENSIONS
SITE CAPACITY - CU.M
SITE SERVICE LIFE - YRS
** PROCESS CONTROL AND INSTRUMENTATION
PROCESS STREAM
CHEMICAL PARAMETERS
PHYSICAL VARIABLES
CONTROL LEVELS
MONITOR TYPE
MONITOR LOCATION
PROCESS CONTROL MANNER
PROCESS CHEMISTRY MODE
** WATER BALANCE
WATER LOOP TYPE
EVAPORATION WATER LOSS -
SOURCE OF MAKEUP WATER
25.4
60.0
18.0
5.0
1.0
1.0
28.0 TPH)
75.0
1.0
NONE
NR
NR
FINAL
POND
ON-SITE
PIPELINE
NONE
70 ACRES/55 FT
4708550
10
( 3850.0 ACRE-FT)
SLURRY STREAM
PH
X SOLIDS, FLOW, TEMPERATURE
PH 6.2-7.2, 12X SOLIDS
PH- APS FLOW THROUGH; DENSITY- TEXAS NUCLEAR
RECYCLE LOOP ON TANGENTIAL NOZZLE HEADER
AUTOMATIC
FEEDBACK
LITER/S
OPEN
6.3
LAKE WATER
C 100 GPM)
13-99
-------
UTILITY FGO SURVEY: OCTOBER 1983 SEPTEMBER 1984
ARIZONA PUBLIC SERVICE: FOUR CORNERS 2 (CONT.)
** CHEMICALS AND CONSUMPTION
FUNCTION
NAME
PRINCIPAL CONSTITUENT
SOURCE/SUPPLIER
CONSUMPTION
UTILIZATION 7.
POINT OF ADDITION
** FGD SPARE CAPACITY INDICES
ABSORBER - X
** FGD SPARE COMPONENT INDICES
ABSORBER
ABSORBENT
LIME
CAO
CAN AM, PAUL LIME CO.
20 TPD
83.0
SLAKER, ABSORBER BOTTOM
.0
.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.
744
744
720
744
720
744
744
672
744
720
7/80 SYSTEM
8/80 SYSTEM
9/80 SYSTEM
10/80 SYSTEM
11/80 SYSTEM
12/80 SYSTEM
1/81 SYSTEM
2/81 SYSTEM
3/81 SYSTEM
4/81 SYSTEM
13-100
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ARIZONA PUBLIC SERVICE: FOUR CORNERS 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
5/81 SYSTEM 744
6/81 SYSTEM 720
7/81 SYSTEM 744
8/81 SYSTEM 744
9/81 SYSTEM 720
10/81 SYSTEM 744
11/81 SYSTEM 720
12/81 SYSTEM 744
1/82 SYSTEM 744
2/82 SYSTEM 672
3/82 SYSTEM 744
4/82 SYSTEM 720
5/82 SYSTEM 744
6/82 SYSTEM 720
7/82 SYSTEM 744
8/82 SYSTEM 744
9/82 SYSTEM 720
10/82 SYSTEM 744
11/82 SYSTEM 720
12/82 SYSTEM 744
1/83 SYSTEM 744
2/83 SYSTEM 672
3/83 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE PERIOD OF JULY 1980 THROUGH MARCH 1983.
4/83 SYSTEM 720
5/83 SYSTEM 744
6/83 SYSTEM 720
«* PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE PERIOD OF JULY 1980 THROUGH JUNE 1983.
7/83 SYSTEM 744
8/83 SYSTEM 744
13-101
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ARIZONA PUBLIC SERVICE: FOUR CORNERS 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
9/83 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE THIRD QUARTER OF 1983.
10/83 SYSTEM 744
11/83 SYSTEM 720
12/83 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE FOURTH QUARTER OF 1983.
1/84 SYSTEM 744
2/84 SYSTEM 696
3/84 SYSTEM 744
4/84 SYSTEM 720
5/84 SYSTEM 744
6/84 SYSTEM 720
7/84 SYSTEM 744
8/84 SYSTEM 744
9/84 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS NOT AVAILABLE FOR THE FIRST THREE QUARTERS OF 1984.
13-102
-------
UTILITY FGD SURVEY" OCTOBER 1983 - SEPTEMBER 1984
SECTION 13
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 - 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 - '/.
AVERAGE MOISTURE CONTENT - '/.
RANGE MOISTURE CONTENT
AVERAGE SULFUR CONTENT
RANGE SULFUR CONTENT - '/.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** MECHANICAL COLLECTOR
NUMBER
TYPE
** ESP
NUMBER
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
ARIZONA PUBLIC SERVICE
FOUR CORNERS
3
FRUITLAND
NEW MEXICO
C
21. (
365. (
301. (
2085
225
196
495
225
RILEY STOKER
PULVERIZED COAL
BASE
486.06
171.1
76.
CONCRETE
*******
.050 LB/MMBTU)
.850 LB/MMBTU)
.700 LB/MMBTU)
(1030000 ACFM)
( 340 F)
( 250 FT)
(***** FT)
( 8600 BTU/LB)
8500-9100
COAL
SUBBITUMINOUS
20004.
22.00
19-25
10.80
8.5-13.4
.75
.5-1.3
.03
.01-.06
0
NONE
0
NONE
THROWAWAY PRODUCT
WET SCRUBBING
LIME/ALKALINE FLYASH
NONE
GE ENVIRONMENTAL SERVICES
IN-HOUSE
FULL SCALE
RETROFIT
/. 99.50
50.00
1
11/79
11/79
0/78
13-103
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ARIZONA PUBLIC SERVICE: FOUR CORNERS 3 (CONT.)
«* DESIGN AND OPERATING PARAMETERS
DESIGN COAL SULFER CONTENT - X
DESIGN COAL HEAT CONTENT - J/6
DESIGN COAL ASH CONTENT - X
DESIGN MOISTURE CONTENT - X
DESIGN CHLORIDE CONTENT - X
SPACE REQUIREMENTS SQ M
OPER. & MAINT. REQUIREMENT - MANHR/DAY
** QUENCHER/PRESATURATOR
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** ABSORBER
NUMBER
NUMBER OF SPARES
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON 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
L/G RATIO - L/CU.M
GAS-SIDE PRESSURE DROP - KPA
INLET GAS TEMPERATURE - C
S02 REMOVAL EFFICIENCY - X
PARTICLE REMOVAL EFFICENCY - X
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
NUMBER OF SPARES PER SYSTEM
NUMBER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES PER STAGE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
WASH WATER SOURCE
WASH FREQUENCY
** REHEATER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** FANS
NUMBER
NUMBER OF SPARES
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
( 8500 BTU/LB)
( 5600 SQ FT)
1.30
19771.0
35.00
13.40
.06
520.2
200.0
NR
NR
2
0
VENTURI TOWER
VARIABLE-THROAT/TOP-ENTRY PLUMB BOB
N/A
25 DIA
CARBON STEEL
AISI 1110
N/A
ORGANIC
GLASS FLAKE-FILLED POLYESTER
FLAKELINE 103
VENTURI THROAT [TANGENTIAL NOZZLES AT TOP 4 AT S
3.2
2.5
171.1
67.5
99.5
( 24.0 GAL/1000 ACF)
(10.0 IN-H20)
( 340 F)
PRIMARY COLLECTOR
2
0
1
IMPINGEMENT
BAFFLE
CLOSED VANE
HORIZONTAL
1
6
ORGANIC
FIBER-REINFORCED POLYESTER
FRESH [FROM LAKE!
ONCE PER SHIFT
0
NONE
N/A
N/A
NONE
N/A
2
0
CENTRIFUGAL
AMERICAN STANDARD
NR
INDUCED DRAFT
WET
51.7 ( 125 F)
HIGH ALLOY
13-104
-------
ARIZONA PUBLIC SERVICE: FOUR CORNERS 3 (CONT.)
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
SERVICE CONDITIONS
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
SERVICE CONDITIONS
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
»* DUCTWORK
LOCATION
CONFIGURATION
DIMENSIONS
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
CONFIGURATION
DIMENSIONS
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
«* REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
MANUFACTURER
NUMBER
NUMBER OF SPARES
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
PRODUCT QUALITY 7. SOLIDS
»* REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
MANUFACTURER
NUMBER
NUMBER OF SPARES
** TANKS
SERVICE
2
CONTROL
LOUVER
PARALLEL BLADE MULTILOUVER
AMERICAN STANDARD
120-130 F
STAINLESS STEEL
AUSTENITIC
NONE
N/A
SHUT-OFF
GUILLOTINE
NR
NR
NR
CARBON STEEL
AISI 1110
NONE
N/A
INLET
CIRCULAR
NR
CARBON STEEL
ASTM A-283
NONE
N/A
OUTLET [ME TO STACK]
RECTANGULAR
NR "
CARBON STEEL
ASTM A-283
STAINLESS STEEL
AUSTENITIC
SLAKER
NR
NR
JOY
1
0
13.6 t 15 TPH)
30.0
WET BALL MILL
NR
NR
KENNEDY VAN SAUN
1
0
NUMBER
BLEED STREAM
RECYCLE
MAKEUP WATER
RETURN TRANSFER
LIME SLURRY
13-105
-------
UTILITY F6D SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ARIZONA PUBLIC SERVICE: FOUR CORNERS 3 (CONT.)
** PUMPS
SERVICE
NUMBER
RECYCLE 2
RECYCLE [STANDBY] 4
BLEED STREAM TANK ****
THICKENER UNDERFLOW 4
LIME SLURRY TRANSFER 2
RETURN WATER 2
SERVICE WATER ****
ME WATER ****
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
CONFIGURATION
DIMENSIONS - FT
CAPACITY
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
FEED STREAM SOURCE
OUTLET STREAM CHARACTERISTICS '
*** SLUDGE
FULL LOAD SLUDGE QUANTITY - M.TONS/HR (DRY)
MOISTURE CONTENT X TOTAL FREE WATER
DRY
DRY
DRY
DRY
THICKENER
1
0
CIRCULAR
100
1000000
CARBON STEEL
AISI 1110
ORGANIC
GLASS FLAKE-FILLED POLYESTER
ABSORBER BLEED
40.OX
X CAS03 -
'/. CAS04 -
X CAOH2 -
X CAC03 -
X ASH - DRY
X OTHER COMPOUNDS -
DRY
** TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE TREATMENT
SITE DIMENSIONS
SITE CAPACITY - CU.M
SITE SERVICE LIFE - YRS
*» PROCESS CONTROL AND INSTRUMENTATION
PROCESS STREAM
CHEMICAL PARAMETERS
PHYSICAL VARIABLES
CONTROL LEVELS
MONITOR TYPE
MONITOR LOCATION
PROCESS CONTROL MANNER
PROCESS CHEMISTRY MODE
** WATER BALANCE
WATER LOOP TYPE
EVAPORATION WATER LOSS - LITER/S
SOURCE OF MAKEUP WATER
25.4
60.0
18.0
5.0
1.0
1.0
75.0
1.0
( 28.0 TPH)
NONE
NR
NR
FINAL
POND
ON-SITE
PIPELINE
NONE
70 ACRES/55 FT
4708550
10
( 3850.0 ACRE-FT)
SLURRY STREAM
PH
X SOLIDS, FLOW, TEMPERATURE
PH 6.2-7.2, 12X SOLIDS
PH- APS FLOW THROUGH; DENSITY- TEXAS NUCLEAR
RECYCLE LOOP ON TANGENTIAL NOZZLE HEADER
AUTOMATIC
FEEDBACK
OPEN
6.3
LAKE WATER
( 100 GPM)
13-106
-------
ARIZONA PUBLIC SERVICE: FOUR CORNERS 3 (CONT.)
UTILITY FED SURVEY: OCTOBER 1983 - SEPTEMBER 1984
** CHEMICALS AND CONSUMPTION
FUNCTION
NAME
PRINCIPAL CONSTITUENT
SOURCE/SUPPLIER
CONSUMPTION
UTILIZATION - /.
POINT OF ADDITION
»» FGD SPARE CAPACITY INDICES
ABSORBER - X
** FGD SPARE COMPONENT INDICES
ABSORBER
ABSORBENT
LIME
CAO
CAN AM, PAUL LIME CO.
20 TPD
83.0
SLAKER, ABSORBER BOTTOM
.0
.0
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. 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.
744
744
720
744
720
744
744
672
744
720
7/80 SYSTEM
8/80 SYSTEM
9/80 SYSTEM
10/80 SYSTEM
11/80 SYSTEM
12/80 SYSTEM
1/81 SYSTEM
2/81 SYSTEM
3/81 SYSTEM
4/81 SYSTEM
13-107
-------
UTILITY FED SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ARIZONA PUBLIC SERVICE: FOUR CORNERS 3 (CONT.)
_ PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
5/81 SYSTEM 744
6/81 SYSTEM 720
7/81 SYSTEM 744
8/81 SYSTEM 744
9/81 SYSTEM 720
10/81 SYSTEM 744
11/81 SYSTEM 720
12/81 SYSTEM 744
1/82 SYSTEM 744
2/82 SYSTEM 672
3/82 SYSTEM 744
4/82 SYSTEM 720
5/82 SYSTEM 744
6/82 SYSTEM 720
7/62 SYSTEM 744
8/82 SYSTEM 744
9/82 SYSTEM 720
10/82 SYSTEM 744
11/82 SYSTEM 720
12/82 SYSTEM 744
1/83 SYSTEM 744
2/83 SYSTEM 672
3/83 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE PERIOD OF JULY 1980 THROUGH MARCH 1983.
4/83 SYSTEM 720
5/83 SYSTEM 744
6/83 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE PERIOD OF JULY 1980 THROUGH JUNE 1983.
7/83 SYSTEM 744
8/83 SYSTEM 744
13-108
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1964
ARIZONA PUBLIC SERVICE: FOUR CORNERS 3 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
9/83 SYSTEM 720
»* PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE THIRD QUARTER OF 1983.
10/83 SYSTEM 744
11/83 SYSTEM 720
12/83 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE FOURTH QUARTER OF 1983.
1/84 SYSTEM 744
2/84 SYSTEM 696
3/84 SYSTEM 744
4/84 SYSTEM 720
5/84 SYSTEM 744
6/84 SYSTEM 720
7/84 SYSTEM 744
8/84 SYSTEM 744
9/84 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS NOT AVAILABLE FOR THE FIRST THREE QUARTERS OF 1984.
13-109
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
SECTION 13
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 - V.
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
NUMSER
NUMBER OF SPARES
TYPE
SUPPLIER
INLET FLUE GAS CAPACITY - CU.M/S
INLET FLUE GAS TEMPERATURE - C
PARTICLE REMOVAL EFFICENCY - 7.
** PARTICLE SCRUBBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON NAME
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
*** FGD SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
502 REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
ASSOCIATED ELECTRIC
THOMAS HILL
3
MOBERLY
MISSOURI
B
******
516.
******
1150
730
667
495
670
BABCOCK & WILCOX
PULVERIZED COAL
BASE
(****** LB/MMBTU)
( 1.200 LB/MMBTU)
<****** LB/MMBTU)
(******* ACFM)
(**** F)
( 650 FT)
(***** FT)
( 10500 BTU/LB)
9600-9800
********
*******
198.
CONCRETE
*******
COAL
******
24423.
11.20
******
14.00
******
4.80
3.8-4.5
********
******
2
0
COLD SIDE
PEABODY INTERNATIONAL
1349.6 (2860000 ACFM)
148.9 ( 300 F)
99.7
0
NONE
N/A
N/A
N/A
N/A
N/A
N/A
N/A
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
MAG
M.W. KELLOGG
13-110
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ASSOCIATED ELECTRIC: THOMAS HILL 3 (CONT.)
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
** QUENCHER/PRESATURATOR
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** 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
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
PPE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
WASH FREQUENCY
** REHEATER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** FANS
NUMBER
NUM3ER OF SPARES
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
BURNS 4 MCDONNELL
FULL SCALE
NEW
7. 99.00
91.50
1
12/82
10/82
2/78
( 20000 SQ FT)
1858.0
MR
NR
4
1
SPRAY TOWER
OPEN CROSSCURRENT SPRAY
HORIZONTAL SPRAY CHAMBER
PULLMAN KELLOGG
26.0 X 18.0 X 80.0
CARBON STEEL
AISI 1110
N/A
INORGANIC
PREFIRED BRICK/SHAPES
ACID-RESISTANT BRICK I LOW H20 ABSORPTION]
NONE
4
2646,
2,
6
1142
137.3
92.0
(42000 GPM)
3 ( 17.4 GAL/1000 ACF)
4 ( 1.5 IN-H20)
7 (22.0 FT/S)
00 (2420000 ACFM)
( 280 F)
PRIMARY COLLECTOR
4
IMPINGEMENT
BAFFLE
CLOSED VANE
VERTICAL
NR
NR
INTERMITTENT
BYPASS
COLD SIDE
N/A
NR
NR
2
0
AXIAL
TLT-BABCOCK
UNIT
FORCED DRAFT
DRY
1349.63
148.9
CARBON STEEL
(2860000 ACFM)
( 300 F)
13-111
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ASSOCIATED ELECTRIC: THOMAS HILL 3 (CONT.)
»* FANS
NUMBER
NUMBER OF SPARES
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
CONSTRUCTION MATERIAL GENERIC TYPE
*» DAMPERS
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
*» REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
MANUFACTURER
NUMBER
NUMBER OF SPARES
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
** REAGENT,PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
MANUFACTURER
** TANKS
SERVICE
LIMESTONE-SLURRY STORAGE
MIST ELIMINATOR WASH
FLOCCULANT
THICKENER OVERFLOW
ABSORBER RECYCLE
FORCED OXIDATION
MILL-PRODUCT
** PUMPS
SERVICE
ABSORBER RECIRCULATION
WASH WATER
FLOCCULANT FEED
THICKENER UNDERFLOW
THICKENER OVERFLOW
LIMESTONE SLURRY TRANSFER
MILL-PRODUCT
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
DIMENSIONS FT
2
0
AXIAL
WESTINGHOUSE
UNIT
FORCED DRAFT
DRY
CARBON STEEL
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
WET BALL MILL
COMPARTMENTED
NR
KENNEDY VAN SAUN
2
0
74.4 ( 82 TPH)
SLAKER
NR
NR
NR
NUMBER
2
****
****
***#
****
2
2
NUMBER
16
****
****
*-***
****
CENTRIFUGE
7
THICKENER
1
180.0 DIA
13-112
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ASSOCIATED ELECTRIC: THOMAS HILL 3 (CONT.)
OUTLET STREAM CHARACTERISTICS
*»* SLUDGE
** TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
** DISPOSAL
NATURE
TYPE
SITE TRANSPORTATION METHOD
SITE TREATMENT
*» PROCESS CONTROL AND INSTRUMENTATION
MONITOR TYPE
** WATER BALANCE
WATER LOOP TYPE
MAKEUP WATER ADDITION - LITERS/S
** CHEMICALS AND CONSUMPTION
FUNCTION
NAME
PRINCIPAL CONSTITUENT
POINT OF ADDITION
** FGD SPARE CAPACITY INDICES
ABSORBER - X
** FGD SPARE COMPONENT INDICES
ABSORBER
30X SOLIDS
FORCED OXIDATION
N/A
N/A
FINAL
LANDFILL
TRUCK
NR
KVB
CLOSED
48.6
( 772 6PM)
ABSORBENT
DOLOMITIC LIME
60X CAO, 40X MGO
SLAKER
33.3
1.0
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
502 PART. HOURS HOURS HOUPS FACTOR
10/82 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
744
THE UTILITY REPORTED THAT INITIAL START-UP OF THE FGD SYSTEM OCCURRED
DURING OCTOBER, 1982.
11/82 SYSTEM
12/82 SYSTEM
1/83 SYSTEM
2/83 SYSTEM
3/83 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
7ZO
744
744
672
744
4/83 SYSTEM
5/83 SYSTEM
6/83 SYSTEM
THE UTILITY REPORTED PROBLEMS WITH A CENTRIFUGE IN THE SLUDGE DEWATERIUG
PROCESS SECTION. THE INABILITY TO REDUCE THE SLUDGE SOLIDS CONTENT HAS
FORCED THE UTILITY TO OPERATE BELOW THE FULL LOAD DEMAND.
720
744
720
13-113
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
ASSOCIATED ELECTRIC: THOMAS HILL 3 (CONT.)
__________________________________________ PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILXTY RELIABILITY UTILIZATION
XREHOVJL^
BOILER
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE PERIOD OF APRIL THROUGH JUNE 1983.
7/83 3A1
3A2
3B1
3B2
SYSTEM
8/83 3A1
3A2
3B1
362
SYSTEM
9/83 3A1
3A2
3B1
3S2
SYSTEM
35.6
63.8
13.8
80.8
64.7
36.7
51.3
59.3
50.0
65.7
23.9
60.1
40.0
72.6
65.5
35.2
61.5
14.9
79.9
63.8
36.8
51.4
59.4
50.1
65.9
24.0
60.4
39.5
68.9
64.2
63.8
65.9
64.2
32,5
56.9
13.8
73.9
59.0
36.7
51.3
59.3
50.0
65.7
23.9
60.1
39.3
68.5
63.9
744 688 439 80.6
744 742 489 93.5
720 717 460 91.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY ENCOUNTERED MAJOR PROBLEMS IN ATTEMPTING TO OPERAYE THE DE-
WATERING PLANT AT REQUIRED CAPACITY FOR FULL FLUE GAS SCRUBBING. THESE
PROBLEMS CENTERED AROUND THE CENTRIFUGE AND OXIDATION SYSTEM.
THE UTILITY EXPERIENCED CENTRIFUGE FAILURE WHILE DEWATERING UNDERFLOW TO
THE REQUIRED SOLIDS CONCENTRATION. IN ATTEMPTS TO DUPLICATE CONDITIONS
PRESENTED AT A TEST CENTRIFUGE, IT WAS DISCOVERED THAT OXIDIZED SLUDGE BE-
LOW THE DESIGN SOLIDS CONCENTRATION TRIPS THE MACHINE ON TORQUE AND UNOXI-
DIZED SLUDGE BELOW THE DESIGN SOLIDS CONCENTRATION TRIPS THE MACHINE ON
VIBRATION. THE UTILITY IS CONTINUING TO ADDRESS THE PROBLEM.
THE OXIDATION SYSTEM IS NOT UP TO REQUIRED CAPACITY. DURING THIS PERIOD
KORK ON 2 OF 3 COMPRESSORS HAS BROUGHT UP THEIR CAPACITY, BUT PLUGGING OF
THE SPARGER RINGS AND BUILD UP OF SOLIDS IN THE OXIDATION TANK CONTINUE TO
ADVERSELY EFFECT THE OXIDATION CAPABILITIES. DESIGN FAILURE OF THE MIXINS
PADDLES HAS ALSO OCCURRED AND A TEMPORARY FIX WAS MADE. VENTING OF SOLIDS
AT FULL OXIDATION RATES WITH SLURRY FLOW NEAR CAPACITY HAS ALSO BECOME A
PROBLEM. VARIOUS DESIGN CHANGES ARE PROJECTED FOR THE SYSTEM DURING THE
UNIT 3 FALL OUTAGE IN OCTOBER.
THE CONTINUOUS EMISSIONS MONITOR SAMPLE LINE REPLACEMENT IS HEARING COMPLE-
TION AND SHOULD BE READY FOR TESTING IN MID-OCTOBER.
DURING THIS REPORTING PERIOD, TESTS WERE RUN ON ONE ISOLATED SCRUBBER
MODULE RUNNING AT DESIGN FLOW TO DETERMINE OPERATING EFFICIENCY. RESULTS
OF THESE TESTS SHOWED SOX REMOVAL RATES WITHIN DESIGN BUT ONLY WHEN LIME-
STONE WAS ADDED AT A LEVEL OF OVER TWICE THE THEORETICAL STOICHIOMETRY.
10/83 3A1
3A2
3B1
3B2
SYSTEM
22.3
25.9
53.9
13.4
38.5
39.8
47.5
97.8
24.6
69.9
69.9
21.6
25.9
53.2
13.4
38.0
744 405
283 45.3
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS OFF-LINE FROM OCTOBER 17 THROUGH THE END OF THE MONTH. PROB-
LEMS WITH THE DEWATERING PLANT DURING THE THIRD QUARTER WERE STILL PRESENT
INTO THE FOURTH QUARTER.
-114
-------
UTILITY FSD SURVEY: OCTOBER 1983 - SEPTEMBER
ASSOCIATED ELECTRIC: THOMAS HILL 3 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
CARRYOVER OF SOLIDS THROUGH THE MIST ELIMINATORS CONTINUED TO BE A PROBLEM
DURING OCTOBER. SLUDGE WAS BUILDING UP IN THE DUCTS AND ON THE BOTTOM OF
THE STACK.
VELOCITY TESTS CONDUCTED DURING THE MONTH INDICATED ABOVE DESIGN VELOCI-
TIES THROUGH THE MODULES. OPERATIONAL PARAMETERS WERE SET TO REDUCE
VELOCITY.
DURING THE OCTOBER OUTAGE, WATER NOZZLES AND DRAINS WERE INSTALLED IN THE
BREECHING DOWNSTREAM OF THE MIST ELIMINATORS AND IN THE STACK TO REDUCE
SOLIDS BUILD UP.
STACK LINER DAMAGE WAS DISCOVERED TO BE THE RESULT OF CARRYOVER FROM THE
FGO SYSTEM DURING THIS PERIOD. THE EXTENT OF DAMAGE IS BEING EVALUATED.
11/83
3A1
3A2
3B1
3B2
SYSTEM
61.7
48.5
44.8
47.8
67.6
85.7
66.6
61.8
65.3
93.1
93.1
58.'+
45.4
42.2
44.5
63.5
720 491
457 56.3
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT OUTAGE CONTINUED THROUGH NOVEMBER 10, 1983.
FGD SYSTEM OUTAGE TIME DURING NOVEMBER WAS DUE PRIMARILY TO MIST ELIMINATOR
CLEANING.
12/83
3A1
3A2
3B1
3B2
SYSTEM
14.3
95.7
91.9
84.4
95.4
11.1
85.8
75.0
67.6
79.8
79.8
11.1
85.4
74.6
67.3
79.5
744 741
591 81.4
** PROBLEMS/SOLUTIONS/COMMENTS
FGD SYSTEM OUTAGE TIME DURING DECEMBER WAS DUE IN PART TO MIST ELIMINATOR
CLEANING.
SEVERE COLD WEATHER CONTRIBUTED TO FGD SYSTEM DOWN TIME DURING DECEMBER.
CENTRIFUGE FAILURE TO DEWATER THE SLUDGE UNDERFLOW AT THE REQUIRED SOLIDS
CONCENTRATION IS STILL A PROBLEM. NEGOTIATIONS ARE UNDERWAY WITH THE CEN-
TRIFUGE MANUFACTURER TO PLAN PERFORMANCE GUARANTEE TESTS.
MODIFICATIONS TO THE FORCED OXIDATION SYSTEM WERE MADE DURING THE FOURTH
QUARTER AND HAVE IMPROVED THE ABILITY OF THE SYSTEM TO OXIDIZE SCRUBBER
SLUDGE. A NUMBER OF DESIGN AND OPERATIONAL PROBLEMS ARE CONTINUOUSLY BEING
ADDRESSED.
1/84 3A1
3A2
3B1
332
SYSTEM
99.9
97.2
77.4
74.2
100.0
57.0
73.9
37.6
21.2
63.3
63.3
47.4
61.5
31.3
17.7
52.6
744 619
392 53.8
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE EXTREME COLD WEATHER ADVERSELY EFFECTED
BOTH BOILER AND SCRUBBER OPERATIONS.
2/84 3A1
3A2
95.1
66.5
48.0
53.5
25.5
28.4
13-115
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ASSOCIATED ELECTRIC: THOMAS HILL 3 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
3B1
3B2
SYSTEM
67.7
65.0
98.1
60.6
62.3
74.8
88.4
32.2
33.1
39.7
696 370
276 35.3
*« PROBLEMS/SOLUTIONS/COMMENTS
3/84
4/84
3A1
3A2
3B1
3B2
SYSTEM
3A1
3A2
3B1
3B2
SYSTEM
73.5
69.2
81.0
53.4
92.3
23.9
16.8
29.2
23.4
31.1
68.1
67.8
50.5
50.3
78.9
64.7
36.9
77.7
65.0
81.4
THE UTILITY REPORTED THAT THE UNIT WAS OFF LINE FOR 13 DAYS DURING
FEBRUARY.
65.7
65.4
48.7
48.6
76.2 744 718 567 76.5
78.9
81.4
23.3
13.3
28.0
23.4
29.4
720 260
212 28.1
*» PP.OBLEMS/SOLUTIONS/COMMENTS
5/84 3A1
3A2
3B1
332
SYSTEM
.0
.0
.0
.0
.0
THE UTILITY REPORTED THAT THE UNIT WAS OFF LINE 19 DAYS DURING APRIL.
THE ABSORBER AND DEWATERING FACILITIES UNDERWENT REPAIRS DURING THE
MONTH.
THE UTILITY IS CONTINUING TO HAVE PROBLEMS IN THEIR ATTEMPT TO OPERATE
THE DEWATERING PLANT AT REQUIRED CAPACITY FOR FULL FLUE GAS SCRUBBING.
THESE PROBLEMS ARE PRIMARILY DUE TO CENTRIFUGE FAILURE AHD OXIDATION
SYSTEM PROBLEMS.
DURING MARCH OF THIS PERIOD, M.W. KELLOGG, THE SYSTEM SUPPLIER, CONDUCTED
EXTENSIVE TESTING ON THE FGD SYSTEM. THIS TESTING WAS AN ATTEMPT TO
GET THE SYSTEM OPERATING AT DESIGN S02 REMOVAL EFFICIENCIES. AT THE END OF
THE QUARTER, TESTING WAS NOT COMPLETE, BUT IT WAS FOUND THAT OVER FEEDING
LIMESTONE BY 2 TO 3 TIMES WOULD RAISE THE SYSTEM PH TO LEVELS THAT WOULD
GIVE REMOVAL EFFICIENCIES ABOVE 90X. OPERATION AT THIS LEVEL OF UNREACTED
LIMESTONE IN THE WASTE SLURRY ONLY ADDS TO DEWATERING PROBLEMS. THROUGH
THE MIDDLE OF APRIL, M.W. KELLOGG CONTINUED ITS TESTING AND WILL ASSIST
THE UTILITY IN A SOLUTION TO ITS PROBLEMS WITH REACTOR CHEMISTRY.
.0
.0
.0
.0
.0 744 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE UNIT WAS OFF LINE ALL MONTH FOR A SCHEDULED
OUTAGE.
THE MODULES WERE UNAVAILABLE DUE TO REPAIR WORK IN THE ABSORBER
AND DEWATERING FACILITIES.
6/84
3A1
3A2
3B1
3B2
SYSTEM
40.0
40.0
26.3
20.3
42.2
88.0
83.8
49.5
42.3
89.5
89.5
36.9
37.3
20
17.8
37.6
8
720 302
271 33.2
13-116
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ASSOCIATED ELECTRIC: THOMAS HILL 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 THE UNIT WAS OFF LINE UNTIL JUNE 19 FOR A
SCHEDULED OUTAGE.
THE ABSORBER AND DEWATERING FACILITIES WERE BEING REPAIRED DURING JUNE.
7/84 3A1
3A2
3B1
3B2
SYSTEM
66.3
73.4
70.4
67.2
92.4
67.1
74.3
71.2
68.1
93.6
66.3
73.4
70.4
67.2
92.4
744 735
688 89.6
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY IS CONTINUING TO EXPERIENCE PROBLEMS IN THEIR ATTEMPT TO
OPERATE THE DEWATERING PLANT AT REQUIRED CAPACITY FOR FULL FLUE GAS
SCRUBBING. THOSE PROBLEMS ARE PRIMARILY DUE TO CENTRIFUGE FAILURE AND
OXIDATION SYSTEM PROBLEMS.
WITH THE COMPLETION OF TESTS IN APRIL THE FGD SYSTEM SUPPLIER,
M.W. KELLOGG, HAS RECOMMENDED AND WILL MAKE THE FOLLOWING MODIFICATIONS IN
ATTEMPTS TO BRING THE SYSTEM UP TO DESIGN PERFORMANCE
(1) REPLACEMENT OF REACTOR BAFFLER.
(2) REPLACEMENT OF ALL NOZZLES WITH BETE DESIGN.
(3) MODIFICATION OF THE RECYCLE PUMPS FOR HIGHER FLOW RATES.
(4) INSTALL A ROUGHING DEMISTER.
THE DESCRIBED WORK IS SCHEDULED TO BEGIN AUGUST 6TH.
8/84 3A1
3A2
3B1
3B2
SYSTEM
83.4
67.4
11.0
82.2
81.3
82.4
61.1
6.6
83.0
77.7
79.3
58.8
6.3
79.9
74.8
744 716 556 86.3
** PROBLEMS/SOLUTIONS/COMMENTS
FGD SYSTEM OUTAGE TIME DURING AUGUST WAS DUE IN PART TO MODULE CLEANING.
MODULE 3B1 UNDERWENT MAJOR DESIGN MODIFICATIONS DURING AUGUST.
THE UNIT WAS DOWN DURING PART OF AUGUST DUE TO BOILER LEAKS.
FGD SYSTEM OUTAGE TIME DURING AUGUST WAS DUE IN PART TO MODULE CLEANING.
MODULE 3B1 UNDERWENT MAJOR DESIGN MODIFICATIONS DURING AUGUST.
THE UNIT WAS DOWN DURING PART OF AUGUST DUE TO BOILER TUBE LEAKS.
9/84 SYSTEM 720
*« PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR SEPTEMBER 1984.
13-117
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
SECTION 13
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 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
** FABRIC FILTER
NUMBER
SUPPLIER
INLET FLUE GAS CAPACITY CU.M/S
INLET FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
PARTICLE REMOVAL EFFICENCY - 7.
TYPICAL GAS/CLOTH RATIO - M/MIN
** PARTICLE SCRUBBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON NAME
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
#** FGD SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
BASIN ELECTRIC POWER
ANTELOPE VALLEY
1
BEULAH
NORTH DAKOTA
C
43. ( .100 LB/MMBTU)
335. ( .780 LB/MMBTU)
****** (*#*#** LB/MMBTU)
770
440
385
495
440
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
969.75 (3055000 ACFM)
154.4 ( 310 F)
183. ( 600 FT)
CONCRETE
7.0 ( 23.0 FT)
COAL
LIGNITE
15352.
7.76
5.2-13.8
37.00
30.0-42.4
.68
0.4-1.2
.01
0.00-0.02
WESTERN PREC.
969.8
85.0
1.0
99.8
.7
0
NONE
N/A
N/A
N/A
N/A
N/A
N/A
N/A
THROWAWAY PRODUCT
SPRAY DRYING
LIME/SPRAY DRYING
JOY MFG/NIRO ATOMIZER
STEARNS-ROGER
( 6600 BTU/LB)
6093-7350
DIVISION, JOY
(2055000 ACFM)
( 185 F)
( 4.0 IN-H20)
( 2.2 FT/MIN)
13-118
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
BASIN ELECTRIC POWER: ANTELOPE VALLEY 1 (CONT.)
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
«* DESIGN AND OPERATING PARAMETERS
«* QUENCHER/PRESATURATOR
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** 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
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
FRE-MIST ELIMINATOR/MIST ELIMINATOR
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
»* 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
CONSTRUCTION MATERIAL SPECIFIC TYPE
FULL SCALE
NEW
X 99.SO
60.00
1
7/84
5/83
8/78
NR
NR
5
1
SPRAY DRYER
CROSSFLOW
ROTARY ATOMIZER
JOY MFG/NIRO ATOMIZER
46.0 X 36.0
CARBON STEEL
ASTM A-283
N/A
NONE
N/A
N/A
NONE
2
6.
.0
3.3
20.4
242.56
152.8
62.0
99.8
NONE
N/A
N/A
N/A
NR
NR
BYPASS
COLD SIDE
N/A
3.2
31.62
446.1
NR
NR
( 100 GPM)
( .2 GAL/1000 ACF)
(13.3 IN-H20)
( 67.0 FT/S)
( 514000 ACFM)
( 307 F)
( 67000 ACFM)
( 835 F)
«* FANS
NUMBER
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** DAMPERS
FUNCTION
GENERIC TYPE
CENTRIFUGAL
COMBUSTION ENGINEERING; CEMAX
UNIT
INDUCED DRAFT
DRY
85.0 ( 185 F)
CARBON STEEL
NR
NR
13-119
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
BASIN ELECTRIC POWER: ANTELOPE VALLEY 1 (CONT.)
SPECIFIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
*« DUCTWORK
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
»* REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
NUMBER
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
PRODUCT QUALITY - X SOLIDS
»* REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
NUMBER
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
»* TANKS
SERVICE
NR
** PUMPS
SERVICE
NR
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
*** SLUDGE
** TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE TREATMENT
** WATER BALANCE
WATER LOOP TYPE
EVAPORATION WATER LOSS - LITER/S
MAKEUP WATER ADDITION - LITERS/S
NR
NR
NR
NR
NR
NR
NR
NR
NR
SLAKER
BALL MILL
N/A
1
22.7
38.0
SLAKER
NR
NR
1
22.7
NUMBER
NUMBER
NONE
N/A
N/A
N/A
FINAL
LANDFILL
OFF-SITE
TRUCKED
NONE
OPEN
23.1
1.4
( 25 TPH)
( 25 TPH)
366 GPM)
22 GPM)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL
S02 PART.
PER BOILER FGD CAP.
HOURS HOURS HOURS FACTOR
5/83 SYSTEM
6/83 SYSTEM
744
720
13-120
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
BASIN ELECTRIC POWER: ANTELOPE VALLEY 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 UTILITY REPORTED THAT INITIAL OPERATIONS COMMENCED IN MAY 1983. THE
UNIT OPERATED IN A STARTUP PHASE DURING THE MONTHS OF MAY AND JUNE.
7/83 SYSTEM 744
8/83 SYSTEM 744
9/83 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY CONTINUED PERFORMANCE TESTING ON THE FGD SYSTEM DURING THE
THIRD QUARTER OF 1983.
10/83 SYSTEM 744
11/83 SYSTEM 720
12/83 SYSTEM 744
»* PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT ANTELOPE VALLEY 1 WAS STILL IN THE START-UP
PHASE OF OPERATION DURING THE FOURTH QUARTER OF 1983.
1/84 SYSTEM 744
2/84 SYSTEM 696
3/84 SYSTEM 744
4/84 SYSTEM 720
5/84 SYSTEM 744
6/84 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED TYPICAL PROBLEMS ASSOCIATED WITH START UP DURING THE
PERIOD OF JANUARY THROUGH JUNE 1984.
7/84 SYSTEM 744
«* PROBLEMS/SOLUTIONS/COMMENTS
COMMERCIAL OPERATION OF THE ANTELOPE VALLEY 1 FGD SYSTEM COMMENCED ON
JULY 1, 1984.
8/84 SYSTEM 744
9/84 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR FGD-RELATED PROBLEMS WERE REPORTED FOR AUGUST AND SEPTEMBER.
13-121
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 198'+
SECTION 13
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 - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** MECHANICAL COLLECTOR
NUMBER
TYPE
** ESP
NUMBER
NUMBER OF SPARES
TYPE
SUPPLIER
INLET FLUE GAS CAPACITY - CU.M/S
INLET FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
PARTICLE REMOVAL EFFICENCY - '/.
** PARTICLE SCRUBBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON NAME
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
*** FGD SYSTEM
BASIN ELECTRIC POWER
LARAMIE RIVER
1
WHEATLAND
WYOMING
A
43. (
86. (
301. (
1500
570
545
550
570
BABCOCK & WILCOX
PULVERIZED COAL
BASE
.100 LB/MMBTU)
.200 LB/MMBTU)
.700 LB/MMBTU)
10S5.37
141.1
183.
CONCRETE
8.7
COAL
SUBBITUMINOUS
19538.
7.89
5.5-6.5
28.92
27.0-30.0
.54
0.30-0.38
.04
0.01-0.02
0
NONE
1
0
COLD SIDE
BABCOCK I WILCOX
(2300000 ACFM)
( 286 F)
( 600 FT)
( 28.5 FT)
( 8400 BTU/LB)
8200-8400
1085.4
141.1
.8
99.6
0
NONE
N/A
N/A
N/A
N/A
N/A
N/A
N/A
(2300000 ACFM)
( 286 F)
( 3. IN-H20)
13-122
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
BASIN ELECTRIC POWER: LARAMIE RIVER 1 (CONT.)
*# 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 502 REMOVAL EFFICIENCY - X
ENERGY CONSUMPTION - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
#* DESIGN AND OPERATING PARAMETERS
DESIGN COAL SULFER CONTENT - X
DESIGN COAL HEAT CONTENT - J/G
DESIGN COAL ASH CONTENT - X
DESIGN MOISTURE CONTENT - X
DESIGN CHLORIDE CONTENT - X
SPACE REQUIREMENTS - SQ M
OPER. & MAINT. REQUIREMENT - MANHR/DAY
** QUENCHER/PRESATURATOR
NUMBER
TYPE
SUPPLIER
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
LIQUID RECIRCULATION RATE - LITERS/S
L/G RATIO - L/CU. M
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** 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
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
NUMBER OF SPARES PER SYSTEM
NUMBER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
RESEARCH-COTTRELL
BURNS & MCDONNELL
FULL SCALE
NEW
X 99.60
90.00
.9
1
7/80
7/80
1/77
.81
18931.3
7.89
28.92
.04
2322.5
80.0
( 8139 BTU/LB)
( 25000 SQ FT)
SPRAY ZONE
RESEARCH-COTTRELL
271.34 ( 575000 ACFM)
141.1 (
616. (
2.3 (
HIGH ALLOY
IRON BASE/NICKEL-CHROMIUM-COPPER-MOLYBDENUM
286 F)
9770 GPM)
17.0 GAL/1000 ACFM)
5
1
COMBINATION TOWER
SPRAY/PACKED
N/A
RESEARCH-COTTRELL
30.0 X 30.0 X 88.0
STAINLESS STEEL; HIGH ALLOY
AUSTENITIC; IRON BASE/NICKEL-CHROMIUM-COPPER-MOL
TYPE 316L; ALLOY 904L
NONE
N/A
N/A
VERTICAL CROSS CHANNEL FIXED GRID PACKING
1
1472.
5.3
1.5
3.0
271.34
141.1
95.0
60.0
(23372 GPM)
( 40.0 GAL/1000 ACF)
( 6.0 IN-H20)
( 10.0 FT/S)
( 575000 ACFM)
( 286 F)
PRIMARY COLLECTOR
5
1
1
IMPINGEMENT
BAFFLE
CLOSED VANE
HORIZONTAL
13-123
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
BASIN ELECTRIC POWER: LARAMIE RIVER 1 (COST.)
NUMBER OF STAGES
NUMBER OF PASSES PER STAGE
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
WASH WATER SOURCE
WASH FREQUENCY
WASH RATE - L/S
*» REHEATER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
PERCENT GAS BYPASSED - AVG
TEMPERATURE INCREASE - C
INLET FLUE GAS TEMPERATURE - C
OUTLET FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
»* FANS
NUMBER
NUMBER OF SPARES
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
PRESSURE DROP KPA
CONSTRUCTION MATERIAL GENERIC TYPE
** FANS
NUMBER
NUMBER OF SPARES
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
CONSTRUCTION MATERIAL GENERIC TYPE
»* DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
»* DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
»* DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
2
3
.6 ( 2-6 IN-H20)
3.0 (10.0 FT/S)
ORGANIC
POLYPROPYLENE
COOLING TOWER SLOWDOWN
UNDER-ONCE/15 MIN; TOP-ONCE/8 HRS
18.4 ( 292 GAL/MIN)
BYPASS
N/A
N/A
15.0
12.8 ( 23 F)
52.8 ( 127 F)
65.6 ( 150 F)
STAINLESS STEEL
AUSTENITIC
2
0
AXIAL
BABCOCK * WILCOX
UNIT
FORCED DRAFT
DRY
542.68
141.1
7.6
CARBON STEEL
(1150000 ACFM)
( 286 F)
(25.0 IN-H20)
2
0
AXIAL
BABCOCK t WILCOX
UNIT
FORCED DRAFT
DRY
CARBON STEEL
4
CONTROL
LOUVER; LOUVER
PARALLEL BLADE MULTILOUVRE; OPPOSED BLADE MULTIL
FORNEY ENGINEERING
DRY SIDE-CARBON STEEL; WET SIDE-STAINLESS STEEL
AISI 1110; AUSTENITIC
NONE
N/A
CONTROL
LOUVER; LOUVER
PARALLEL BLADE MULTILOUVRE; OPPOSED BLADE MULTIL
FORNEY ENGINEERING
DRY SIDE-CARBON STEEL; WET SIDE-STAINLESS STEEL
AISI 1110; AUSTENITIC
NONE
N/A
CONTROL
LOUVER; LOUVER
PARALLEL BLADE MULTILOUVRE; OPPOSED BLADE MULTIL
13-124
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
BASIN ELECTRIC POWER: LARAMIE RIVER 1 (CONT.)
MANUFACTURER
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
#* DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
CONFIGURATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPEC.IFIC MATERIAL TYPE
»* DUCTWORK
LOCATION
CONFIGURATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
CONFIGURATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
MANUFACTURER
NUMBER
NUMBER OF SPARES
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
PRODUCT QUALITY - 7. SOLIDS
** TANKS
SERVICE
FORNEY ENGINEERING
DRY SIDE-CARBON STEEL; WET SIDE-STAINLESS STEEL
AISI 1110; AUSTENITIC
NONE
N/A
10
5 CONTROL * 5 SHUT-OFF
LOUVER; LOUVER
PARALLEL BLADE MULTILOUVRE; OPPOSED BLADE MULTIL
FORNEY [LOUVER]; ANDCO [GUILLOTINE I
DRY SIDE-CARBON STEEL; WET SIDE-STAINLESS STEEL
AISI 1110; AUSTENITIC
NONE
N/A
SHUT-OFF
LOUVER; LOUVER
PARALLEL BLADE MULTILOUVRE; OPPOSED BLADE MULTIL
FORNEY [LOUVER3; ANDCO [GUILLOTINE]
DRY SIDE-CARBON STEEL; WET SIDE-STAINLESS STEEL
AISI 1110; AUSTENITIC
NONE
N/A
INLET
RECTANGULAR
CARBON STEEL
AISI 1110
NONE
N/A
OUTLET
RECTANGULAR
STAINLESS STEEL
AUSTENITIC
NONE
N/A
BYPASS
RECTANGULAR
CARBON STEEL
AISI 1110
NONE
N/A
WET BALL MILL
COMPARTMENTED
NR
KENNEDY VAN SAUN
ABSORBER FEED
QUENCHER FEED
LIMESTONE SLURRY
RECLAIM WATER
CENTPATE
SEAL WATER
13.6
35.0
NUMBER
5
5
1
1
1
1
( 15 TPH)
13-125
-------
UTILITY FGO SURVEY: OCTOBER 1983 - SEPTEMBER 1984
BASIN ELECTRIC POWER: LARAMIE RIVER 1 (CONT.)
** PUMPS
SERVICE
ABSORBER FEED
QUENCHER FEED
MILL PRODUCT
LIMESTONE SLURRY TRANSFER
MAKEUP WATER SUPPLY
RECLAIMED WATER
SEAL WATER
ABSORBER SLOWDOWN
THICKENER UNDERFLOW
CENTRATE
DEWATERING BUILDING SUMP PUMPS
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
CONFIGURATION
DIMENSIONS - FT
CAPACITY
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
FEED STREAM SOURCE
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
OVERFLOW STREAM CHARACTERISTICS
OUTLET STREAM DISPOSITION
OVERFLOW STREAM DISPOSITION
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUM3ER OF SPARES
DIMENSIONS - FT
CAPACITY
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
BELT GENERIC MATERIAL TYPE
BELT SPECIFIC MATERIAL TYPE
FEED STREAM SOURCE
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
OUTLET STREAM DISPOSITION
OVERFLOW STREAM DISPOSITION
NUMBER
10
5
2
2
1
2
2
2
9
2
THICKENER
3
0
CIRCULAR
110.0 DIA X 10.0
1000000
INORGANIC
HYDRAULICALLY-BONDED CONCRETE
QUENCHER BLEED
650 GPM; 10X SOLIDS
100 GPM; 3ox SOLIDS
550 GPM; 0.5X SOLIDS
TO CENTRIFUGE
TO RECLAIMED WATER & THEN TO QUENCHER
CENTRIFUGE
4
0
8
110 GPM
STAINLESS STEEL
AUSTENITIC
NONE
N/A
N/A
N/A
THICKENER UNDERFLOW
35X SOLIDS
70X SOLIDS
TO PUG MILL
TO CENTRATE TANK ft THEN THICKENER
*** SLUDGE
FULL LOAD SLUDGE QUANTITY - M.TONS/HR (DRY)
MOISTURE CONTENT - 7. TOTAL FREE WATER
X CAS03 - DRY
/. CASO<+ - DRY
7. CAOHZ - DRY
X CAC03 - DRY
** TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
INLET QUALITY X
** DISPOSAL
NATUP.E FINAL
TYPE LANDFILL
LOCATION ON-SITE
SITE TRANSPORTATION METHOD CONVEYED
TPH)
30.0
8.0
90.0
.0
2.0
FORCED OXIDATION
SPARGER IN QUENCHER
NONE
10.0
13-126
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
BASIN ELECTRIC POWER: LARAMIE RIVER 1 (CONT.)
SITE TREATMENT
SITE DIMENSIONS
SITE SERVICE LIFE - YRS
»* PROCESS CONTROL AND INSTRUMENTATION
PROCESS STREAM
CHEMICAL PARAMETERS
PHYSICAL VARIABLES
CONTROL LEVELS
MONITOR TYPE
MONITOR LOCATION
PROCESS CONTROL MANNER
PROCESS CHEMISTRY MODE
** WATER BALANCE
WATER LOOP TYPE
EVAPORATION WATER LOSS - LITER/S
POND SEEPAGE/RUNOFF WATER LOSS - LITERS/S
EFFLUENT WATER LOSS - LITERS/S
RECEIVING WATER STREAM
MAKEUP WATER ADDITION - LITERS/S
SOURCE OF MAKEUP WATER
»* CHEMICALS AND CONSUMPTION
FUNCTION
NAME
PRINCIPAL CONSTITUENT
SOURCE/SUPPLIER
CONSUMPTION
UTILIZATION - X
POINT OF ADDITION
** FGD SPARE CAPACITY INDICES
ABSORBER - X
MIST ELIMINATOR - X
FAN X
BALL MILL - X
EFFLUENT HOLD TANK - X
RECIRCULATION PUMP - X
THICKENER - X
CENTRIFUGE - X
*» FGD SPARE COMPONENT INDICES
ABSORBER
PVC LINING
60-90 FT DEEP [160 ACRES TOTAL FOR DISPOSAL]
35
ABSORBER FEED 4 QUENCHER FEED
PH, SOLIDS, S02 INLET, ACFM, S02 OUTLET
PERCENT SOLIDS; GAS FLOW
PH 5.8-6.2 IN ABSORBER; PH A.5-5.0 IN QUENCHER;
GREAT LAKES IPHi; DYNASCIENCE FOR CONTROL tS02;
ABSORBER FEED TANK & QUENCHER; DENSITY ON PUMP
AUTOMATIC
FEED BACK IPH 4 DENSITY]
CLOSED
23.3 ( 370 GPM)
0
.0 (0 GPM)
N/A
25.2 ( 400 GPM)
COOLING TOWER SLOWDOWN, WELLS & GRAYROCKS RESERV
ABSORBENT
LIMESTONE
95X CAC03
HOLLY SUGAR COMPANY
2000 TONS/MONTH
90.0
BALL MILL
25.0
25.0
.0
.0
25.0
25.0
33.3
.0
1.0
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
7/80 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
744
THE UNIT BEGAN INITIAL AND COMMERCIAL OPERATIONS ON JULY 1, 1980. NO MAJOR
PROBLEMS WERE REPORTED DURING STARTUP.
8/80 SYSTEM
9/80 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
744
720
THE UNIT IS STILL IN THE STARTUP PHASE OF OPERATIONS. NO PERFORMANCE DATA
ARE CURRENTLY AVAILABLE.
10/80 A
B
100.0
100.0
99.7
99.6
100.0
100.0
95.0
94.9
13-127
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
BASIN ELECTRIC POWER: LARAMIE RIVER 1 (CONT.)
_ PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
c
D
E
SYSTEM
100.0
21.5
100.0
100.0
99.7
22.6
81.4
100.0
100.0
100.0
100.0
100.0
95.0
21.5
77.5
96.0
744 709 715 85.8
12/80
1/81
2/81
3/81
** PROBLEMS/SOLUTIONS/COMMENTS
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
81.7
100.0
100.0
100.0
100.0
100.0
100.0
46.4
77.2
58.2
1.9
78.9
65.6
720 578
568 67.1
** PROBLEMS/SOLUTIONS/COMMENTS
DURING NOVEMBER THE BOILER WAS OUT OF SERVICE APPROXIMATELY 120 HOURS DUE
TO REPAIRS.
DURING THE MONTH MODULE D WAS OFF LINE 30 DAYS FOR REPAIRS.
A
B
C
D
E
SYSTEM
19.6
100.0
100.0
75.7
100.0
98.8
21.1
94.4
96.7
81.2
100.0
98.4
100.0
100.0
100.0
100.0
100.0
100.0
19.6
87.9
90.0
75.7
93.0
91.5
744 693
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.
A
B
C
D
E
SYSTEM
.0
100.0
100.0
100.0
100.0
100.0
.0
91.3
97.4
95.8
95.7
95.0
100.0
100.0
100.0
100.0
100.0
.0
88.6
94.5
93.0
92.8
92.2
744 722
686 97.1
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JANUARY MODULE A WAS UNAVAILABLE DUE TO MAINTENANCE ON WELDS IN THE
QUENCHER SECTION THAT FAILED DUE TO CORROSION OF THE UDDEHOLM 904L.
A
B
C
D
E
SYSTEM
.0
100.0
100.0
100.0
100.0
100.0
.0
94.0
97.7
97.8
90.7
95.1
100.0
100.0
100.0
100.0
100.0
.0
84.2
87.5
87.6
81.3
85.1
672 602
572 81.2
** PROBLEMS/SOLUTIONS/COMMENTS
DURING FEBRUARY MODULE A REMAINED OUT OF SERVICE DUE TO THE NECESSARY
MAINTENANCE OF THE WELDS IN THE QUENCHER SECTION.
80.6
100.0
25.8
81.4
100.0
18.2
100.0
100.0
100.0
79.3
97.4
17.7
13-128
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
BASIN ELECTRIC POWER: LARAMIE RIVER 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
D 100.0
E 100.0
SYSTEM 100.0
99.7 100.0 97.2
94.5 100.0 96.0
99.4 100.0 96.9
.744
725
721 96.6
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MARCH MODULES A AND C EXPERIENCED OUTAGE TIME DUE TO MAINTENANCE ON
THE WELDS IN THE QUENCHER SECTION RESULTING FROM CORROSION OF THE UDDEHOLM
904L.
4/81 A
B
C
D
SYSTEM
100.0
100.0
.0
100.0
100.0
100.0
91.6
98.5
.0
99.9
99.4
97.4
100.0
100.0
100.0
100.0
100.0
91.1
97.9
.0
99.3
98.9
96.8
720 716
697 96.1
** PROBLEMS/SOLUTIONS/COMMENTS
DURING APRIL MODULE C WAS OUT OF SERVICE FOR MAINTENANCE ON THE WELDS IN
THE QUENCHER SECTION DUE TO CORROSION OF THE UDDEHOLM 904L.
5/81
A
B
C
D
E
SYSTEM
106.0
100.0
.0
100.0
100.0
100.0
86.7
98.0
.0
98.3
99.3
95.6
100.0
100.0
100.0
100.0
100.0
78.2
88.4
.0
88.7
89.6
86.3
744 671
642 85.5
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MAY MODULE C WAS DOWN FOR MAINTENANCE ON WELDS ON THE QUENCHER
SECTION DUE TO CORROSION OF THE UDDEHOLM 904L.
6/81
A
B
C
D
E
SYSTEM
100.0
100.0
100.0
70.0
30.0
100.0
51.5
98.8
89.8
67.8
27.3
83.8
100.0
100.0
100.0
100.0
100.0
100.0
50.6
97.1
88.3
66.7
26.8
82.4
720 708
593 63.5
** PROBLEMS/SOLUTIONS/COMMENTS
D AND E MODULES WERE TAKEN OUT OF SERVICE FOR MAINTENANCE ON THE WELDS IN
THE QUENCHER SECTION. THE UDDEHOLM 904L IS CORRODING.
7/81 A
100.0
95.5
100.0
95.5
B
C
D
E
SYSTEM
100.0
100.0
100.0
.0
100.0
99.0
90.6
96.6
.0
95.4
100.0
100.0
100.0
100.0
99.0
90.6
96.6
.0
95.4
744 744
710 86.9
** PROBLEMS/SOLUTIONS/COMMENTS
E MODULE WAS TAKEN OUT OF SERVICE FOR MAINTENANCE ON WELDS IN THE QUENCHER
SECTION. THE UDDEHOLM 904L IS CORRODING.
8/81
A
B
C
D
E
SYSTEM
100.0
28.6
100.0
100.0
58.3
96.7
96.8
29.9
96.7
98.9
61.0
95.8
100.0
100.0
100.0
100.0
100.0
100.0
92.6
28.6
92.5
94.6
91.7
91.7
744 711
682 83.7
13-129
-------
UTILITY FED SURVEY: OCTOBER 1983 - SEPTEMBER 1984
BASIN ELECTRIC POWER: URAMIE RIVER 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
B AND E MODULES WERE TAKEN OUT OF SERVICE FOR MAINTENANCE ON WELDS IN THE
QUENCHER SECTION. THE UDOEHOLM 904L IS CORRODING.
9/81
A
B
C
D
E
SYSTEM
100
100
100
100
100
.0
.0
.0
.0
.0
.0
96.
.
91.
92.
94.
94.
2
0
3
4
0
0
100
100
100
100
100
.0
.0
.0
.0
.0
25
24
24
25
25
.7
.0
.4
.7
.1
.1
10/81
11/81
12/81
720 192
181 25.6
** PROBLEMS/SOLUTIONS/COMMENTS
THE B MODULE WAS TAKEN OUT OF SERVICE FOR MAINTENANCE ON WELDS IN THE
QUENCHER SECTION. THE UDDEHOLM 904L IS CORRODING.
THE UNIT WAS TAKEN OUT OF SERVICE FOR AN ANNUAL OVERHAUL.
A 100.0 .0
B .0 .0
C 100.0 .0
0 100.0 .0
E 100.0 .0
SYSTEM 100.0 .0 744 0 0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING OCTOBER THE UNIT WAS SHUTDOWN FOR SCHEDULED MAINTENANCE.
.0
A
B
C
D
E
SYSTEM
100.0
.0
100.0
100.0
100.0
100.0
37.8
.0
75.7
59.2
73.1
63.2
100.0
100.0
100.0
100.0
100.0
36.2
.0
72.4
56.6
69.9
59.0
720 689
423 40.3
** PROBLEMS/SOLUTIONS/COMMENTS
DURING OCTOBER AND NOVEMBER MODULE B WAS DOWN FOR MAINTENANCE IN THE
QUENCHER SECTION DUE TO CORROSION OF THE UDDEHOLM 904L.
A
B
C
D
E
SYSTEM
46.8
100.0
69.1
100.0
100.0
100.0
47.1
46.0
69.5
89.7
61.1
78.3
100.0
100.0
100.0
100.0
100.0
100.0
46.8
45.7
69.1
89.1
60.7
77.8
744 739
579 70.4
** PROBLEMS/SOLUTIONS/COMMENTS
DURING DECEMBER, MODULES A AND C WERE DOWN PART OF THE TIME FOR GENERAL
MAINTENANCE.
PROBLEMS WERE ENCOUNTERED WITH THE SEAL COATING IN THE ABSORBER FEED TANK.
1/82
A
B
C
D
E
SYSTEM
100
100
100
74
25
100
.0
.0
.0
.2
.8
.0
82.
99.
92.
82.
9.
91.
1
0
0
5
9
4
100
100
100
100
100
100
.0
.0
.0
.0
.0
.0
82
99
92
82
9
91
.1
.0
.0
.5
.9
.4
744 744
680 85.2
13-130
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
BASIN ELECTRIC POWER: LARAMIE RIVER 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 JANUARY THE D AND E ABSORBER FEED TANK WAS DOWN FOR SEAL COATING.
z/82 A
B
c
D
E
SYSTEM
100.0
100.0
100.0
100.0
53.6
100.0
51. Z
89.0
95.0
92.8
22.9
82.8
100.0
100.0
100.0
100.0
100.0
100.0
40.4
70.1
74.6
73.1
18.1
69.1
4/82
672 529
465 76.2
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE E WAS OFF-LINE PART OF FEBRUARY TO MAKE REPAIRS TO THE POTENTIAL
PROTECTION.
3/82 A
A
B
C
D
E
SYSTEM
74.2
100.0
100.0
100.0
100.0
100.0
55.6
61.7
60.4
98.0
99.9
93.9
100.0
100.0
100.0
100.0
100.0
100.0
55.6
61.7
60.4
98.0
99.9
93.9
744 744
699 76.1
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MARCH MODULE A WAS DOWN TO REPAIR A LEAK IN THE QUENCHER SECTION
RESULTING FROM CORROSION OF THE UDDEHOLM 904L.
A
B
C
D
E
SYSTEM
50.0
76.7
76.7
50.0
80.0
83.3
65.4
100.0
100.0
65.4
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
25.8
71.8
74.9
47.0
76.1
73.9
720 550
532 59.3
** PROBLEMS/SOLUTIONS/COMMENTS
DURING APRIL MODULES B, C, D, AND E WERE DOWN PART OF THE TIME TO PERFORM
MAINTENANCE ON THE MIXERS AND TO INSPECT THE MODULES.
5/82 A
B
C
D
E
SYSTEM
100.0
96.8
96.8
.0
100.0
98.4
70.9
90.3
93.3
.0
72.5
81.7
100.0
100.0
100.0
100.0
100.0
49.6
63.2
65.3
.0
50.8
57.2 744 521
** PROBLEMS/SOLUTIONS/COMMENTS
6/82 A
B
C
D
E
SYSTEM
100.0
100.0
100.0
.0
100.0
100.0
MODULE D WAS
56.6
92.3
84.2
.0
76.3
77.3
DOWN DURING MAY
100.0
100.0
100.0
100.0
100.0
FOR GENERAL MAINTENANCE AND REPAIR.
39.1
63.8
58.2
.0
52.8
53.5 720 498
426 75.7
385 56.8
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JUNE MODULE D WAS OUT OF SERVICE FOR NOZZLE REPAIR IN THE QUENCHER
SECTION.
13-131
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
BASIN ELECTRIC POWER: LARAMIE RIVER 1 (CONT.)
PERIOD
7/62
MODULE
A
B
C
D
E
SYSTEM
AVAILABILITY
64
71
93
67
100
99
.5
.0
.5
.7
.0
.2
OPERABILITY
30.
58.
86.
61.
95.
83.
0
4
7
6
9
2
PERFORMANCE DATA
RELIABILITY UTILIZATION
100
100
100
100
100
100
.0
.0
.0
.0
.0
.0
27
52
78
55
86
75
.1
.8
.3
.7
.6
.1
X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
744 672 559 62.6
9/82
10/82
11/82
»* PROBLEMS/SOLUTIONS/COMMENTS
DURING JULY MODULES A, B AND D WERE DOWN TO REPAIR NOZZLES IN THE QUENCHER
SECTION.
8/82
A
B
C
D
E
SYSTEM
100
100
77
100
12
97
.0
.0
.4
.0
.9
.6
90
96
80
84
10
90
.2
.3
.5
.1
.3
.4
100.
100.
100.
100.
100.
100.
0
0
0
0
0
0
67
71
60
62
7
67
.3
.8
.0
.8
.7
.4
744
555
501 68.4
** PROBLEMS/SOLUTIONS/COMMENTS
DURING AUGUST MODULES C AND E WERE DOWN FOR MAINTENANCE IN THE QUENCHER
SECTION RESULTING FROM CORROSION OF THE UDDEHOLM 904L.
A
B
C
D
E
SYSTEM
100.0
100.0
16.7
100.0
86.7
100.0
92.6
98.0
16.6
86.0
60.0
88.3
100.0
100.0
100.0
100.0
100.0
100.0
92.6
98.0
16.6
3 86 . 0
60.0
88.3
720 720
636 66.0
»* PROBLEMS/SOLUTIONS/COMMENTS
DURING SEPTEMBER MODULE C WAS DOWN FOR MAINTENANCE IN THE QUENCHER SECTION
RESULTING FROM CORROSION OF THE UDDEHOLM 904L.
A
B
C
D
E
SYSTEM
100.0
16.1
87.1
71.0
100.0
93.5
86.1
10.2
70.5
94.2
76.3
84.3
100.0
100.0
100.0
100.0
100.0
100.0
49.9
5.9
40.8
54.6
44.2
48.8
744 431
363 52.2
** PROBLEMS/SOLUTIONS/COMMENTS
DURING OCTOBER MODULES B, C AND D WERE DOWN FOR MAINTENANCE IN THE
QUENCHER SECTION RESULTING FROM CORROSION OF THE UDDEHOLM 904L.
A
B
C
D
E
SYSTEM
63.3
92.9
100.0
46.7
100.0
100.0
44.3
73.3
90.8
23.8
82.7
78.7
100.0
100.0
100.0
100.0
100.0
100.0
44.3
73.3
90.8
23.8
82.7
78.7
720 720
567 56.0
«* PROBLEMS/SOLUTIONS/COMMENTS
DURING NOVEMBER MODULES A, B AND D WERE DOWN FOR MAINTENANCE ON WELDS IN
THE QUENCHER SECTION RESULTING FROM CORROSION OF THE UDDEHOLM 904L.
12/82 A
B
93.5
100.0
70.0
79.5
100.0
100.0
57.4
65.2
13-132
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
BASIN ELECTRIC POWER: LARAMIE RIVER 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
502 PART. HOURS HOURS HOURS FACTOR
c
D
E
SYSTEM
100.0
100.0
96.8
100.0
32
43
57
70
.7
.9
.2
.8
100.
100.
100.
100.
0
0
0
0
26
36
46
58
.8
.0
.9
.1
744
610
432
43.4
1/83
2/83
** PROBLEMS/SOLUTIONS/COMMENTS
DURING DECEMBER MODULE A WAS DOWN FOR MAINTENANCE ON THE QUENCHER TOWER
MIXERS.
A
B
C
D
E
SYSTEM
100.0
100.0
74.2
100.0
100.0
100.0
46.1
57.5
.0
99.4
100.1
75.8
100.0
100.0
100.0
100.0
100.0
41.7
52.0
.0
89.9
90.6
68.5
744 673
510 46.2
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JANUARY MODULE C WAS DOWN FOR MAINTENANCE ON THE ICI ABSORBER FEED
PUMP SUCTION VALVE.
A
B
C
D
E
SYSTEM
100.0
100.0
71.4
39.3
100.0
100.0
79.2
83.6
47.1
38.5
83.5
84.2
100.0
100.0
100.0
100.0
100.0
100.0
72.9
81.5
43.3
35.4
76.8
77.5
672 618
521 56.9
** PROBLEMS/SOLUTIONS/COMMENTS
DURING FEBRUARY MODULE D WAS DOWN DUE TO A LEAK IN THE QUENCHER FLOOR.
3/83 A
B
C
D
E
SYSTEM
61.3
71.0
100.0
74.2
100.0
100.0
55.3
67.0
100.0
69.0
69.7
90.2
100.0
100.0
100.0
100.0
100.0
100.0
55.3
67.0
100.0
69.0
69.7
90.2
744
744
671 66.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING MARCH.
4/83 A
B
C
D
E
SYSTEM
99.9
69.9
99.9
99.9
33.3
100.0
78.3
53.0
92.5
81.7
8.3
79.7
100.0
100.0
100.0
100.0
100.0
100.0
60.1
44.5
71.0
62.7
6.4
61.2
720 553
441 57.0
** PROBLEMS/SOLUTIONS/COMMENTS
5/83 A
B
C
D
E
SYSTEM
41.9
41.9
41.9
41.9
.0
41.9
97.3
94.6
92.8
98.9
.0
95.9
100.0
100.0
100.0
100.0
100.0
MODULE E WAS DOWN DURING APRIL FOR MAINTENANCE, CLEANING AND PACKING OF THE
QUENCHER TOWER MIXERS.
40.6
39.4
38.7
41.2
.0
40.0 744 310 297 80.2
13-173
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 198*
BASIN ELECTRIC POWER: LARAMIE RIVER 1 (CONT.)
PERIOD
MODULE
AVAILABILITY OPERABILITY
PERFORMA
RELIABILITY
NCE UA 1 A '
UTILIZATION /. REMOVAL PER BOILER
S02 PART. HOURS HOURS
FGD CAP.
HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
6/83
A
B
C
E
D
SYSTEM
m
.
t
0
0
0
0
0
0
THE UNIT
WAS
DOWN DURING
PART OF
.
.
.
.
.
MAY FOR AN ANNUAL OUTAGE.
0
0
0
0
0
0 720 0
0 .0
** PROBLEMS/SOLUTIONS/COmENTS
ALL MODULES WERE DOWN DURING JUNE
7/83
A
B
C
D
E
SYSTEM
22.
58.
61.
83.
47.
68.
6
1
3
9
8
4
18.
2.
96.
93.
93.
77.
5
a
4
4
6
4
100
100
100
100
100
100
.0
.0
.0
.0
.0
.0
9.
1.
51.
52.
49.
41.
FOR MAINTENANCE AND AN ANNUAL
8
5
2
3
7
1 744 395
OVERHAUL.
306 55.5
#* PROBLEMS/SOLUTIONS/COMMENTS
8/83
A
B
C
D
E
SYSTEM
100.
83.
100.
87.
100.
100.
0
9
0
1
0
0
MODULES A
55.
50.
76.
59.
84.
81.
, B,
1
1
8
8
3
5
C, D,
100
100
100
100
100
100
AND E
.0
.0
.0
.0
.0
.0
WERE DOWN FOR MAINTENANCE DURING PART
50.
46.
70.
54.
77.
74.
5
0
5
9
4
8 744 683
OF JULY.
557 56.6
** PROBLEMS/SOLUTIONS/COMMENTS
9/83
A
B
C
C
D
E
SYSTEM
100.
100.
86.
86.
10.
100.
96.
0
0
7
7
0
0
7
MODULES B
88.
59.
81.
81.
91.
63.
92.
AND
1
5
0
0
0
7
9
D WERE
100
100
100
100
100
100
100
DOWN
.0
.0
.0
.0
.0
.0
.0
DURING
88.
59.
81.
81.
91.
63.
92.
PART OF AUGUST FOR MAINTENANCE
1
5
0
0
0
7
9 720 720
.
669 80.7
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE C WAS DOWN DURING PART OF SEPTEMBER FOR MAINTENANCE REQUIRED ON THE
QUENCHER SECTION RESULTING FROM TOWER MIXER PROBLEMS.
10/83
A
B
C
D
E
SYSTEM
67
100
55
100
100
100
.7
.0
.0
.0
.0
.0
45
80
54
66
91
84
.8
.6
.0
.9
.9
.8
100.
100.
100.
100.
100.
100.
0
0
0
0
0
0
39.
69.
46.
57.
79.
73.
5
5
6
7
3
Z
744 642
544 70.9
#* PROBLEMS/SOLUTIONS/COMMENTS
MODULES A AND C WERE DOWN DURING PART OF OCTOBER FOR MAINTENANCE ON THE
ABSORBER RECYCLE TANK MIXERS.
11/83 A
80.0
60.8
100.0
60.8
13-134
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
BASIN ELECTRIC POWER: LARAMIE RIVER 1 (CONT.)
PERIOD
12/83
MODULE
B
C
D
E
SYSTEM
A
B
C
D
E
SYSTEM
AVAILABILITY
100.0
100.0
43.3
100.0
100.0
100.0
100.0
100.0
64.5
100.0
100.0
OPERABILITY
69.6
97.4
34.9
83.9
86.7
89.0
85.3
44.7
51.6
55.4
81.5
FtKi-UKriAr
RELIABILITY
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
sue UAIA
UTILIZATION
69.6
97.4
34.9
83.9
86.7
82.4
79.0
41.4
47.8
51.3
75.5
X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
720 720 624 70.8
744 689 561 69.3
#* PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-REUTED PROBLEMS WERE ENCOUNTERED
DURING NOVEMBER AND DECEMBER 1983.
1/84
A
B
C
D
E
SYSTEM
80
100
100
100
100
100
.6
.0
.0
.0
.0
.0
54.
82.
42.
57.
77.
78.
0
7
4
2
7
5
100
100
100
100
100
100
.0
.0
.0
.0
.0
.0
49
76
39
52
71
72
.6
.0
.0
.6
.4
.2
744 684
537 62.0
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE A WAS DOWN FOR MAINTENANCE OF TANK MIXERS AND REPAIR OF A FEED
PUMP.
2/84
A
B
C
D
E
SYSTEM
89
100
13
100
100
100
.7
.0
.8
.0
.0
.0
71
51
13
80
36
75
.7
.1
.6
.5
.5
.9
100
100
100
100
100
100
.0
.0
.0
.0
.0
.0
66.
47.
12.
74.
79.
70.
1
1
6
3
8
0
696 642
487 59.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT MODULE C WAS DOWN FOR MAINTENANCE DURING
FEBRUARY.
3/84
A
B
C
D
E
SYSTEM
100.
100.
93.
9.
100.
100.
0
0
5
7
0
0
89
95
45
3
83
79
.8
.4
.2
.4
.1
.2
100
100
100
100
100
100
.0
.0
.0
.0
.0
.0
87
93
44
3
81
77
.7
.1
.1
.3
.1
.3
744 726 575 60.5
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY
4/84
A
B
C
D
E
SYSTEM
99.
20.
99.
79.
99.
99.
9
0
9
9
9
9
97
7
88
74
86
88
.2
.2
.6
.6
.4
.5
REPORTED
100
100
100
100
100
100
THAT
.0
.0
.0
.0
.0
.0
MODULE
93
6
84
71
82
84
D WAS
.1
.9
.9
.5
.8
.8
DOWN FOR MAINTENACE DURING MARCH.
720 690 611 76.3
13-135
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
BASIN ELECTRIC POWER: LARAMIE RIVER 1 (CONT.)
.. PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
7. REMOVAL
S02 PART.
PER BOILER FGD CAP.
HOURS HOURS HOURS FACTOR
6/84
7/84
8/84
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE B MAS DOWN FOR MECHANICAL MAINTENANCE DURING APRIL.
MODULE D WAS DOWN FOR MECHANICAL REVISIONS OF ABSORBER TANK MIXERS.
5/84 A
B
C
D
E
SYSTEM
100.0
71.0
100.0
100.0
33.3
100.0
97.0
65.2
84.2
79.7
27.0
88.3
100.0
100.0
100.0
100.0
100.0
100.0
97.0
65.2
84.2
79.7
27.0
88.3
744 744
657 67.4
** PROBLEMS/SOLUTIONS/COMHENTS
MODULES B AND E WERE DOWN DURING MAY FOR MAINTENANCE.
A
B
C
D
E
SYSTEM
53.3
53.3
46.7
100.0
46.7
75.0
62.2
.0
83.5
79.0
92.6
79.3
100.0
100.0
100.0
100.0
100.0
9.9
.0
13.3
12.6
14.8
12.7
720
115
91 50.2
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT MODULES A, C,
REPAIRS.
D AND E WERE OUT FOR TANK MIXER
A
B
C
D
E
SYSTEM
.0
100.0
100.0
100.0
100.0
100.0
.0
94.8
51.9
86.9
84.6
79.6
100.0
100.0
100.0
100.0
100.0
.0
90.7
49.7
83.2
81.0
76.1
744 712
566 58.6
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS AROSE DURING JULY.
A
B
C
D
E
SYSTEM
71.0
74.2
71.0
100.0
100.0
100.0
45.5
71.7
69.1
79.4
75.0
85.1
100.0
100.0
100.0
100.0
100.0
100.0
45.3
71.4
68.8
79.0
74.7
84.8
744 741
631 61.3
PROBLEMS/SOLUTIONS/COMMENTS
MODULES A,B AND C WERE DOWN DURING PART OF AUGUST FOR TANK MIXER
REPAIRS.
9/84 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR SEPTEMBER 1984.
720
13-136
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
SECTION 13
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 - 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
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON NAME
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
*** FGD SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
BASIN ELECTRIC POWER
LARAMIE RIVER
2
WHEATLAND
WYOMING
A
43.
86.
******
1500
570
500
495
570
BABCOCK t WILCOX
PULVERIZED COAL
BASE
( .100 LB/MMBTU)
( .200 LB/MMBTU)
(****** LB/MMBTU)
1321.32
56.1
183.
CONCRETE
8.7
COAL
SUBBITUMINOUS
19538.
7.89
******
28.92
******
.54
0.2-0.8
.04
******
(2800000 ACFM)
( 133 F)
( 600 FT)
( 28.6 FT)
( 8400 BTU/LB)
******
COLD SIDE
BABCOCK & WILCOX
1085.4 (2300000 ACFM)
141.1 ( 286 F)
.8 ( 3. IN-H20)
99.6
0
NONE
N/A
N/A
N/A
N/A
N/A
N/A
N/A
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
RESEARCH-COTTRELL
BURNS & MCDONNELL
13-137
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
BASIN ELECTRIC POWER: LARAMIE RIVER Z (CONT.)
DEVELOPMENT LEVEL PULL SCALE
NEW/RETROFIT NEW
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY - X 99.60
UNIT DESIGN SOZ REMOVAL EFFICIENCY - 7. 90.00
CURRENT STATUS 1
COMMERCIAL START-UP 7/86
INITIAL START-UP 7/81
CONTRACT AWARDED 1/77
** DESIGN AND OPERATING PARAMETERS
** QUENCHER/PRESATURATOR
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** 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
L/G RATIO L/CU.M
SUPERFICAL GAS VELOCITY M/SEC
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
S02 REMOVAL EFFICIENCY 7.
PARTICLE REMOVAL EFFICENCY - X
»* MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
NUM3ER OF STAGES
NUMBER OF PASSES PER STAGE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** REHEATER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
»* FANS
NUMBER
DESIGN
FUNCTION
APPLICATION
SERVICE
CONSTRUCTION MATERIAL GENERIC TYPE
** FANS
NUMBER
NUMBER OF SPARES
DESIGN
SUPPLIER
FUNCTION
APPLICATION
NR
NR
COMBINATION TOWER
SPRAY/PACKED
N/A
RESEARCH-COTTRELL
30.0 X 30.0 X 88.0
STAINLESS STEEL; HIGH ALLOY
AUSTENITIC; IRON BASE/NICKEL-CHROMIUM-COPPER-MOL
TYPE 316L; ALLOY 90<*L
NONE
N/A
N/A
VERTICAL CROSS CHANNEL FIXED GRID PACKING
2
- CM 61.0 ( 2*.OIN)
8.0 ( 60.0 GAL/1000 ACF)
3.0 (10.0 FT/S)
1085.37 (2300000 ACFM)
1*1.1 ( 286 F)
90.0
.0
PRIMARY COLLECTOR
IMPINGEMENT
BAFFLE
CLOSED VANE
VERTICAL
1
1
NR
NR
NONE
N/A
N/A
NONE
N/A
CENTRIFUGAL
UNIT
FORCED DRAFT
DRY
CARBON STEEL
2
0
AXIAL
BABCOCK i, WILCOX
UNIT
FORCED DRAFT
13-138
-------
UTILITY FGD SURVEYS OCTOBER 1983 - SEPTEMBER 1984
BASIN ELECTRIC POWER: LARAMIE RIVER 2 (CONT.)
SERVICE
CONSTRUCTION MATERIAL GENERIC TYPE
** DAMPERS
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
NUMBER
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
PRODUCT QUALITY - 7. SOLIDS
DRY
CARBON STEEL
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
WET BALL MILL
COMPARTMENTED
NR
2
13.6 (
30.0
15 TPH)
** TANKS
SERVICE
NR
NUMBER
** PUMPS
SERVICE
NR
»* SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
DIMENSIONS FT
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUK3ER
NUMBER OF SPARES
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
*** SLUDGE
*» TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE TREATMENT
SITE SERVICE LIFE - YRS
** PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS
PROCESS CONTROL MANNER
NUMBER
****
THICKENER
3
0
110.0 DIA X 10.0
INORGANIC
HYDRAULICALLY-BONDED CONCRETE
CENTRIFUGE
1
0
35X SOLIDS
60X SOLIDS
FORCED OXIDATION
OXIDATION TANK
N/A
FINAL
LANDFILL
ON-SITE
CONVEYED
NONE
35
PH, SOLIDS, S02 INLET, ACFM, S02 OUTLET
AUTOMATIC
13-139
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
BASIN ELECTRIC POWER: UVRAMIE RIVER Z (CONT.)
*» WATER BALANCE
WATER LOOP TYPE
MAKEUP WATER ADDITION - LITERS/S
CLOSED
16.9
( 269 GPM)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
7/81 SYSTEM
9/81
10/81
12/81
744
»» PROBLEMS/SOLUTIONS/COMMENTS
INITIAL OPERATION OF THE FGD SYSTEM BEGAN DURING JULY 1981.
8/81
A
B
C
D
E
SYSTEM
100
52
100
31
100
96
.0
.4
.0
.9
.0
.1
78
52
82
32
28
68
.2
.8
.3
.2
.8
.6
100
100
100
100
100
100
.0
.0
.0
.0
.0
.0
77
52
81
31
28
68
.6
.4
.7
.9
.6
.1
738
506 46.7
** PROBLEMS/SOLUTIONS/COMMENTS
B AND D MODULES WERE OUT OF SERVICE SO THAT BRACING WORK ON ROUND-OFF
CORNERS COULD BE PERFORMED.
A
B
C
D
E
SYSTEM
100.0
100.0
37.7
100.0
100.0
100.0
94.0
99.0
31.2
41.7
60.4
81.6
100.0
100.0
100.0
100.0
100.0
100.0
77.4
81.5
25.7
34.3
49.7
67.2
720 593
483 55.7
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED NO PROBLEMS WITH THE FGD SYSTEM WERE ENCOUNTERED IN
THE MONTH OF SEPTEMBER.
A
B
C
D
E
SYSTEM
83.9
100.0
100.0
100.0
38.7
100.0
78.9
99.1
99.2
96.0
11.7
96.2
100.0
100.0
100.0
100.0
100.0
100.0
78.1
98.1
98.2
94.9
11.6
95.0
744 736
708 88.0
** PROBLEMS/SOLUTIONS/COMWENTS
DURING OCTOBER MODULES E AND A WERE OFF-LINE PART OF THE TIME FOR
THE INSTALLATION OF BRACING.
11/81 A
100.0
99.9
B
C
D
E
SYSTEM
100.0
100.0
100.0
.0
100.0
99.9
99.9
94.0
.0
98.4
100.0
100.0
100.0
100.0
100.0
99.9
99.9
99.9
94.0
.0
98.0
720 720
708 95.3
** PROBLEMS/SOLUTIONS/COMMENTS
DURING NOVEMBER MODULE E WAS DOWN FOR MAINTENANCE ON THE WELDS IN THE
QUENCHER SECTION DUE TO CORROSION OF THE UDDEHOLM 904L.
100.0
100.0
100.0
20.5
90.9
94.1
94.4
25.4
100.0
100.0
100.0
100.0
73.4
76.0
76.2
20.5
13-140
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
BASIN ELECTRIC POKER: LARAMIE RIVER 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
E
SYSTEM
100.
100.
0
0
65.6
92.6
100.
100.
0
0
52
74
.9
.8
744
601
556
69.4
2/82
3/82
** PROBLEMS/SOLUTIONS/COMMENTS
OUTAGE TIME DURING DECEMBER RESULTED FROM PROBLEMS WITH THE SEAL COATING IN
THE ABSORBER FEED TANK. GENERAL MAINTENANCE WAS PERFORMED ON MODULE D,
WHICH ALSO ACCOUNTED FOR PART OF THE OUTAGE TIME.
1/82
A
B
C
D
E
SYSTEM
100.0
100.0
100.0
.0
100.0
100.0
99.3
99.5
99.1
.0
94.7
98.1
100.0
100.0
100.0
100.0
100.0
96.3
96.5
96.1
.0
91.8
95.0
744 722
#* PROBLEMS/SOLUTIONS/COMMENTS
DURING JANUARY THE MODULE D ABSORBER FEED TANK WAS RESEALED.
708 93.3
A
B
C
D
E
SYSTEM
100.0
100.0
100.0
42.9
100.0
100.0
99.8
87.6
75.7
29.6
89.2
96.0
100.0
100.0
100.0
100.0
100.0
100.0
94.7
83.1
71.8
28.1
84.6
91.0
672 638
609 83.9
** PROBLEMS/SOLUTIONS/COMMENTS
THE SEAL COATING OF THE D ABSORBER FEED TANK CONTINUED INTO FEBRUARY.
THE D MODULE WAS DOWN PART OF THE TIME TO MAKE REPAIRS TO THE POTENTIAL
PROTECTION.
A
B
C
D
E
SYSTEM
48.4
100.0
100.0
100.0
100.0
100.0
33.8
69.4
84.2
93.0
74.4
69.0
100.0
100.0
100.0
100.0
100.0
100.0
31.5
64.8
78.6
86.8
69.4
83.0
744 694
616 70.2
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MARCH MODULE A WAS OFF-LINE APPROXIMATELY 384 HOURS TO RESEAL THE
ABSORBER FEED TANK.
4/82
A
B
C
D
E
SYSTEM
6.7
26.7
3.3
23.3
26.7
21.7
.0
33.3
48.1
100.0
77.8
64.8
100.0
100.0
100.0
100.0
100.0
.0
1.2
1.8
3.8
2.9
2.4
720
18
1.3
** PROBLEMS/SOLUTIONS/COMMENTS
THE MODULES WERE DOWN PART OF APRIL TO SEAL COAT THE ABSORBER FEED TANKS.
MAINTENANCE WAS PERFORMED ON THE SPRAY NOZZLES IN THE QUENCHER SECTION OF
EACH MODULE.
5/82 A
B
C
93.5
100.0
.0
53.6
78.6
.0
100.0
100.0
50.2
73.7
.0
13-141
-------
UTILITY FGO SURVEY: OCTOBER 1983 - SEPTEMBER 1984
BASIN ELECTRIC POWER: L4RAMIE RIVER 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
D 100.0 80.2 100.0 75.2
E 100.0 92.6 100.0 86.8
SYSTEM 98.4 76.2 100.0 71.5
744 697 532 75.6
9/82
10/82
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MAY MODULE C WAS TAKEN OFF-LINE FOR MAINTENANCE AND REPAIRS.
6/82 A
100.0
89.3
100.0
89.3
B
C
D
E
SYSTEM
86.7
16.7
100.0
100.0
100.0
69.3
11.7
76.1
96.9
85.8
100.0
100.0
100.0
100.0
100.0
69.3
11.7
76.1
96.9
85.8
720 720
618 66.4
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JUNE MODULE C WAS OUT OF SERVICE PART OF THE TIME FOR NOZZLE REPAIR
IN THE QUENCHER SECTION.
7/82 A
67.7
54.7
100.0
43.6
B
C
D
E
SYSTEM
61.3
100.0
100.0
74.2
100.0
55.2
77.8
91.0
45.9
81.2
100.0
100.0
100.0
100.0
100.0
44.1
62.1
72.7
36.7
64.8
744 594
482 60.4
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JULY MODULES A, B AND E WERE DOWN TO REPAIR NOZZLES IN THE QUENCHER
SECTION.
8/82 A
80.6
67.0
100.0
63.9
B
C
D
E
SYSTEM
100.0
100.0
22.6
83.9
96.8
93.9
97.4
21.7
58.0
84.5
100.0
100.0
100.0
100.0
100.0
89.5
92.8
20.6
55.2
80.5
744 709
599 65.4
** PROBLEMS/SOLUTIONS/COMMENTS
DURING AUGUST MODULES A AND D WERE DOWN FOR MAINTENANCE IN THE QUENCHER
SECTION RESULTING FROM CORROSION OF THE UDDEHOLM 904L.
100.0
98.7
100.0
94.3
B
C
D
E
SYSTEM
100.0
36.7
63.3
.0
75.0
99.9
38.0
61.3
.0
74.5
100.0
100.0
100.0
100.0
95.4
36.4
58.6
.0
71.2
720 688
513 46.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING SEPTEMBER MODULES C, D AND E WERE DOWN FOR MAINTENANCE IN THE
QUENCHER SECTION RESULTING FROM THE CORROSION OF UDDEHOLM 904L.
A
B
C
D
E
SYSTEM
25.8
33.7
77.4
74.2
100.0
24.5
34.2
72.5
72.7
98.9
100.0
100.0
100.0
100.0
100.0
24.4
34.0
72.2
72.4
98.5
79.0
75.7
100.0
75.4
744 741
561 41.8
13-142
-------
UTILITY FGD SURVEY? OCTOBER 1983 - SEPTEMBER 1984
BASIN ELECTRIC POWER: LARAMIE RIVER 2 (CONT.)
: PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
1/83
2/83
#* PROBLEMS/SOLUTIONS/COMMENTS
DURING OCTOBER MODULE A WAS DOWN FOR MAINTENANCE ON WELDS IN THE QUENCHER
SECTION RESULTING FROM CORROSION OF THE UDDEHOLM 904L.
DURING OCTOBER MODULE D WAS DOWN FOR REPAIRS OF BRACING.
11/82
A
B
C
D
E
SYSTEM
.0
63.3
100.0
100.0
100.0
90.8
.0
33.1
97.9
63.4
93.6
72.0
100.0
100.0
100.0
100.0
100.0
.0
22.8
67.3
43.6
64.3
49.5
720 495
356 41.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING NOVEMBER MODULES A AND B WERE DOWN FOR MAINTENANCE ON WELDS IN THE
QUENCHER SECTION RESULTING FROM CORROSION OF THE UDDEHOLM 904L.
12/82
A
B
C
D
E
SYSTEM
32
100
100
100
100
100
.3
.0
.0
.0
.0
.0
27.
90.
97.
50.
100.
91.
1
4
2
2
0
2
100
100
100
100
100
100
.0
.0
.0
.0
.0
.0
26
87
93
48
96
88
.2
.3
.9
.6
.6
.2
744 719
656 68.8
** PROBLEMS/SOLUTIONS/COMMENTS
DURING DECEMBER MODULE A WAS DOWN FOR MAINTENANCE ON THE TOWER MIXERS AND
WETTED FILM CONTACT PACKING.
A
B
C
D
E
SYSTEM
100.0
22.6
100.0
83.9
100.0
100.0
92.2
9.4
88.1
74.2
81.2
86.3
100.0
100.0
100.0
100.0
100.0
100.0
71.6
7.3
68.4
57.7
63.1
67.0
744 578
498 61.1
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JANUARY MODULE B WAS DOWN TO ROUND OFF WELDS IN THE SCRUBBER.
A
B
C
D
E
SYSTEM
25.0
89.3
100.0
100.0
85.7
100.0
16.5
72.9
96.6
57.8
72.3
79.0
100.0
100.0
100.0
100.0
100.0
100.0
15.1
66.7
88.4
52.9
66.2
72.3
672 615
486 53.1
** PROBLEMS/SOLUTIONS/COMMENTS
DURING FEBRUARY MODULE A WAS DOWN DUE TO PROBLEMS WITH THE INLET ISOLATION
GUILLOTINE DAMPER.
DURING FEBRUARY MODULE E WAS DOWN TO CLEAN THE TOWER PACKING.
3/83 A
B
C
D
E
SYSTEM
100.0
100.0
100.0
100.0
51.6
100.0
95.4
83.7
93.9
46.6
28.8
87.1
100.0
100.0
100.0
100.0
100.0
100.0
90.3
79.2
88.8
44.1
27.2
82.4
744 704
613 62.4
13-143
-------
UTILITY FGD SURVEY'. OCTOBER 1983 - SEPTEMBER 1984
BASIN ELECTRIC POWER: LARAMIE RIVER 2 (CONT.)
_ PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
5/83
6/83
7/83
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MARCH MODULE E WAS DOWN FOR MAINTENANCE IN THE QUENCHER SECTION AND
TO CLEAN THE WETTED CONTACT PACKING.
4/83 A
B
C
D
E
SYSTEM
99.9
99.9
46.7
99.9
99.9
100.0
98.9
74.1
45.1
31.5
96.4
86.5
100.0
100.0
100.0
100.0
100.0
100.0
98.6
73.9
45.0
31.5
96.1
86.3
720 718
621 64.0
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE C WAS DOWN DURING APRIL FOR A CLEANING OF THE ABSORBER PACKING
AND GENERAL TOWER MAINTENANCE.
A
B
C
D
E
SYSTEM
100.0
100.0
.0
100.0
100.0
100.0
95.4
92.1
.0
92.3
75.4
88.8
100.0
100.0
100.0
100.0
100.0
56.5
54.6
.0
54.7
44.7
52.6 744 441 392
** PROBLEMS/SOLUTIONS/COMMENTS
A
B
C
D
E
SYSTEM
100.0
100.0
13.3
100.0
100.0
100.0
MODULE C WAS
100.0
76.5
8.0
85.6
81.3
87.9
DOWN DURING
100.0
100.0
100.0
100.0
100.0
100.0
MAY FOR MAINTENANCE IN THE QUENCHER SECTION.
100.0
76.5
8.0
85.6
81.3
87.9 720 720 633
** PROBLEMS/SOLUTIONS/COMMENTS
A
B
C
D
E
SYSTEM
48.1
100.0
100.0
100.0
64.5
100.0
MODULE C WAS
44.0
84.0
98.1
83.2
33.8
85.8
DOWN DURING
100.0
100.0
100.0
100.0
100.0
100.0
JUNE FOR MAINTENANCE.
41.4
79.1
92.4
78.4
31.8
80.8 744 701 601
65.0
** PROBLEMS/SOLUTIONS/COMMENTS
MODULES A AND E WERE DOWN DURING PART OF JULY FOR REPAIRS IN THE QUENCHER
SECTION.
8/83 A
A
B
C
D
E
SYSTEM
35.5
71.0
100.0
100.0
100.0
100.0
31.4
66.6
95.0
99.1
60.4
88.1
100.0
100.0
100.0
100.0
100.0
100.0
30.9
65.7
93.6
97.6
59.5
86.8
744 733
646 62.7
** PROBLEMS/SOLUTIONS/COMMENTS
9/83 A
MODULES A AND D WERE DOWN DURING PART OF AUGUST FOR MAINTENANCE.
100.0 64.0 100.0 3.8
13-144
-------
UTILITY F6D SURVEY: OCTOBER 1983 - SEPTEMBER 1984
BASIN ELECTRIC POWER: URAMIE RIVER 2 (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
SYSTEM
26.7
100.0
73.3
100.0
100.0
.0
93.8
100.0
99.4
90.6
100.0
100.0
100.0
100.0
.0
5.9
6.0
5.9
5.4
720 43 39 59.7
1/84
** PROBLEMS/SOLUTIONS/COMMENTS
MODULES B AND D WERE DOWN DURING PART OF SEPTEMBER FOR MAINTENANCE ON THE
QUENCHER TOWER MIXERS.
10/83 A
B
C
D
E
SYSTEM
100.1
100.1
100.1
.0
100.1
100.0
92.7
93.9
100.0
.0
80.5
91.8
100.0
100.0
100.0
100.0
100.0
16.3
16.5
17.8
.0
14.2
16.2
744 131
121 72.2
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE D WAS DOWN DURING PART OF OCTOBER FOR MAINTENANCE ON WELDS IN THE
QUENCHER SECTION.
ABSORBER RECYCLE TANK MIXERS WERE REPAIRED AT MODULE D DURING THE MONTH.
11/83 A
B
C
D
E
SYSTEM
12/83 A
B
C
D
E
SYSTEM
100.
100,
100,
43,
46,
97.
100.
100,
100,
100,
41.
100,
.0
.0
.0
.3
.7
.5
.0
.0
.0
.0
.9
.0
93.
98.
91.
70.
3
,7
.0
.0
,0
.7
100
100
100
100
.0
.0
.0
.0
28
29
27
21
.0
.0
.0
.0
.0
.0
.0
.6
.3
.0
.0
.2
720
.0
744 223
158 42.4
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS DOWN THE ENTIRE MONTH OF NOVEMBER AND MOST OF DECEMBER DUE TO
LOW POWER DEMAND.
A
B
C
D
E
SYSTEM
100.0
100.0
100.0
100.0
100.0
100.0
99.3
95.5
97.7
.0
.0
73.1
100.0
100.0
100.0
100.0
55.2
53.1
54.4
.0
.0
40.7
744 414
303 42.9
2/84 A
B
C
D
E
SYSTEM
3/84 A
B
C
D
E
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
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
696
744
.0
13-145
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
BASIN ELECTRIC POWER: LARAMIE RIVER 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
SOS PART. HOURS HOURS HOURS FACTOR
4/84
6/84
7/84
8/84
** PROBLEMS/SOLUTIONS/COMMENTS
A
B
C
D
E
SYSTEM
THE UTILITY REPORTED THAT NO MAJOR FGD-REUTED PROBLEMS WERE ENCOUNTERED
DURING THE FIRST QUARTER OF 1984.
.0 .0
.0 .0
.0 .0
.0 .0
.0 .0
.0 .0 720 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
A UNIT OUTAGE OCCURRED DURING THE MONTH OF APRIL.
5/84 A 6.5 .0
B 9.7 .0
C .0 .0
D 3.2 .0
E 9.7 .0
SYSTEM 7.3 .0
** PROBLEMS/SOLUTIONS/COMMENTS
744
.0
THE UTILITY REPORTED THAT THE UNIT WAS DOWN FOR MAINTENANCE ON ALL
ABSORBER FEED TANKS.
A
B
C
D
E
SYSTEM
100.0
100.0
33.3
93.3
100.0
100.0
84.6
91.6-
35.2
63.2
95.4
92.5
100.0
100.0
100.0
100.0
100.0
100.0
72.6
78.7
30.2
54.2
81.9
79.4
720 618
572 77.0
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE C WAS DOWN FOR MECHANICAL REPAIRS DURING JUNE.
A
B
C
D
E
SYSTEM
100.0
100.0
67.7
90.3
100.0
100.0
44.2
85.7
64.4
72.8
94.2
90.3
100.0
100.0
100.0
100.0
100.0
100.0
44.2
85.7
64.4
72.8
94.2
90.3
744
744
672 75.4
#* PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS AROSE DURING JULY.
A
B
C
D
E
SYSTEM
100.0
100.0
29.0
100.0
100.0
100.0
76.8
89.3
8.4
92.0
93.7
91.3
100.0
100.0
100.0
100.0
100.0
100.0
76.5
89.0
8.3
91.6
98.3
90.9
744 741
677 70.8
** PROBLEMS/SOLUTIONS/COMMENTS
9/84 SYSTEM
MODULE C WAS DOWN DURING PART OF AUGUST FOR ABSORBER MIXER REPAIRS.
WELDING WAS DONE IN THE QUENCHER SECTION DURING AUGUST.
720
13-146
-------
UTILITY FED SURVEY: OCTOBER 1983 - SEPTEMBER 1984
BASIN ELECTRIC POWER: LARAMIE RIVER 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
INFORMATION WAS UNAVAILABLE FOR SEPTEMBER 1984.
13-147
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
SECTION 13
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 - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** FABRIC FILTER
NUMBER
TYPE
** 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
TRADE NAME/COMMON NAME
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
*** FGD SYSTEM
BASIN ELECTRIC POWER
LARAMIE RIVER
3
WHEATLAND
WYOMING
A
43.
86.
******
1500
570
500
495
570
BABCOCK i WILCOX
PULVERIZED COAL
BASE
( .100 LB/MMBTU)
( .200 LB/MMBTU)
(****** LB/MMBTU)
1321.32
69.4
183.
CONCRETE
8.7
COAL
SUBBITUMINOUS
19538.
7.89
4.0-13.0
28.92
22.2-34.7
.54
0.2-0.5
.04
0.00-0.04
0
NONE
COLD SIDE
BABCOCK 4 WILCOX
1085.4
69.4
.2
99.6
0
NONE
N/A
N/A
N/A
N/A
N/A
N/A
N/A
(2800000 ACFM)
( 157 F)
( 600 FT)
( 28.6 FT)
( 8400 BTU/LB)
7906-8244
(2300000 ACFM)
( 157 F)
( 1. IN-H20)
13-148
-------
BASIN ELECTRIC POWER: LARAMIE RIVER 3 (CONT.)
UTILITY FGD SURVEY? OCTOBER 1983 - SEPTEMBER 1984
*» 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
** QUENCHER/PRESATURATOR
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** 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
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
502 REMOVAL EFFICIENCY. X
PARTICLE REMOVAL EFFICENCY - X
** MIST ELIMINATOR
FRE-MIST ELIMINATOR/MIST ELIMINATOR
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** 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
CONSTRUCTION MATERIAL SPECIFIC TYPE
«* FANS
DESIGN
FUNCTION
APPLICATION
SERVICE
CONSTRUCTION MATERIAL GENERIC TYPE
THROWAWAY PRODUCT
SPRAY DRYING
LIME/SPRAY DRYING
BABCOCK & WILCOX
BURNS & MCDONNELL
FULL SCALE
NEW
X 99.60
82.50
1
11/82
11/82
10/78
NR
NR
SPRAY DRYER
NR
HYDRAULIC PRESSURE NOZZLE
BABCOCK & WILCOX
54'8"W X 46'10"H
CARBON STEEL
AISI 1110
N/A
NONE
N/A
N/A
NONE
2
0. (
.0 (
1.6 (
1.5 (
377.52 (
137.2 (
85.0
99.6
0 GPM)
.3 GAL/1000 ACF)
6.5 IN-H20)
5.0 FT/S)
800000 ACFM)
279 F)
NONE
N/A
N/A
N/A
NR
NR
BYPASS
COLD SIDE
N/A
3.0
49.93
371.1
NR
NR
NR
NA
NR
DRY
NA
( 105800 ACFM)
( 700 F)
13-149
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
BASIN ELECTRIC POWER: LARAMIE RIVER 3 (CONT.)
*» DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
** DUCTWORK
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
NUMBER
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
PRODUCT QUALITY - X SOLIDS
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
NUMBER
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
** TANKS
SERVICE
SHUT-OFF
LOUVER
PARALLEL BLADE MULTILOUVER
NR
NR
NR
NR
CONTROL
LOUVER
PARALLEL BLADE MULTILOUVER
CARBON STEEL
AISI 1110
NR
NR
WET BALL MILL
COMPARTMENTED
NR
Z
6 TPH)
ABSORBER RECYCLE
NR
REAGENT PREP PRODUCT
30.0
SLAKER
NR
NR
Z
5.4
NUMBER
****
«**«
****
6 TPH)
** PUMPS
SERVICE
NR
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
**» SLUDGE
»* TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
»* DISPOSAL
NATURE
TYPE
LOCATION
SITE TREATMENT
** PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS
PROCESS CONTROL MANNER
NUMBER
NONE
N/A
N/A
N/A
FINAL
LANDFILL
ON-SITE
NONE
SOZ, ACFM, SOLIDS
AUTOMATIC
13-150
-------
BASIN ELECTRIC POWER: LARAMIE RIVER 3 (CONT.)
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
*# WATER BALANCE
WATER LOOP TYPE
EVAPORATION WATER LOSS - LITER/S
MAKEUP WATER ADDITION - LITERS/S
** CHEMICALS AND CONSUMPTION
FUNCTION
NAME
CONSUMPTION
OPEN
22.9
4.6
ABSORBENT
LIME
3 TPH
( 363 GPM)
( 73 GPM)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
11/82 SYSTEM 720
#* PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT INITIAL START-UP OCCURRED DURING NOVEMBER 1982.
12/82 SYSTEM 744
1/83 SYSTEM 744
2/83 SYSTEM 672
3/83 SYSTEM 744
4/83 SYSTEM 720
5/83 SYSTEM 744
6/83 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE FGD SYSTEM IS CURRENTLY BEING TESTED AND
IS STILL IN THE SHAKEDOWN/DEBUGGING PHASE OF OPERATION.
7/83 SYSTEM
8/83 SYSTEM
9/83 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
744
744
720
THE UTILITY CONTINUED PERFORMANCE TESTING ON THE FGD SYSTEM DURING THE
THIRD QUARTER OF 1983.
10/83 SYSTEM
11/83 SYSTEM
12/83 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
744
720
744
1/84 SYSTEM
2/84 SYSTEM
3/84 SYSTEM
THE UTILITY REPORTED THAT LARAMIE RIVER 3 DID NOT OPERATE DURING THE FOURTH
QUARTER DUE TO MAJOR DESIGN MODIFICATIONS OF THE SPRAY DRYER AND SLURRY
PREPARATION SECTIONS.
744
696
744
13-151
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
BASIN ELECTRIC POWER: LARAMIE RIVER 3 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
4/84 SYSTEM 720
5/84 SYSTEM 744
6/84 SYSTEM 720
7/84 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE FGD SYSTEM WAS DOWN DURING THE PERIOD
OF JANUARY THROUGH JULY, 1984 DUE TO A CONTINUATION OF MAJOR DESIGN
MODIFICATIONS IN THE SPRAY DRYER AND THE SLURRY PREPARATION SYSTEM.
8/84 SYSTEM 744
9/84 SYSTEM 7ZQ
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR AUGUST AND SEPTEMBER 1984.
13-152
-------
UTILITY F6D SURVEY: OCTOBER 1983 - SEPTEMBER 1984
SECTION 13
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 - V.
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - '/.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RAN3E 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 SCRUBBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON NAME
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
*** FGD SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
BIG RIVERS ELECTRIC
D.B. WILSON
1
CENTERTOWN
KENTUCKY
A
****** ( ****** LB/MMBTU )
****** (****** LB/MMBTU)
****** (****** LB/MMBTU)
680
WO
495
495
440
FOSTER WHEELER
PULVERIZED COAL
BASE
(******* ACFM)
(**** F)
(**** FT)
(***** FT)
(****** BTU/LB)
9600-11600
********
*******
******
NR
*******
COAL
BITUMINOUS
******
********
15.0-25.0
********
8.0-14.0
3.75
2.5-5.0
********
******
COLD SIDE
BUELL DIVISION, ENVIROTECH
412.9 ( 875000 ACFM)
162.8 ( 325 F)
0
NONE
N/A
N/A
N/A
N/A
N/A
N/A
N/A
THROWAWAY PRODUCT
WET SCRUBBING
LIME
M.W. KELLOGG
BURNS & ROE
FULL SCALE
NEW
13-153
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
BIG RIVERS ELECTRIC; D.B. WILSON i (CONT.)
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
«* DESIGN AND OPERATING PARAMETERS
** QUENCHER/PRESATURATOR
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
»* ABSORBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
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
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** REHEATER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
1
9/84
9/84
8/80
NR
NR
SPRAY TOWER
OPEN CROSSCURRENT SPRAY
HORIZONTAL SPRAY CHAMBER
NR
NR
NR
NR
NR
NR
NONE
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
** FANS
DESIGN
FUNCTION
APPLICATION
SERVICE
CONSTRUCTION MATERIAL GENERIC TYPE
#* DAMPERS
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
** TANKS
SERVICE
NR
NR
NA
NR
NA
NA
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
WET BALL MILL
NA
NA
NUMBER
13-154
-------
BIG RIVERS ELECTRIC: D.B. WILSON i (CONT.J
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
** PUMPS
SERVICE
NR
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
*** SLUDGE
** TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
*» DISPOSAL
NATURE
TYPE
SITE TREATMENT
NUMBER
NA
FORCED OXIDATION
NA
NA
NA
NA
NA
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
9/84 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
720
THE UTILITY REPORTED THAT INITIAL START-UP OF THE FGD SYSTEM COMMENCED IN
SEPTEMBER 1984.
13-155
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
SECTION 13
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/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
BIG RIVERS ELECTRIC
GREEN
1
SEBREE
KENTUCKY
D
43. ( -100
516. < 1.200
301. ( .700
444
242
222
495
242
LB/mBTU)
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
** MECHANICAL COLLECTOR
NUMBER
TYPE
** ESP
NUMBER
NUMBER OF SPARES
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
TRADE NAME/COMMON NAME
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
*** FGD SYSTEM
BABCOCK i WILCOX
PULVERIZED COAL
BASE
471.90
148.9
107.
CONCRETE
4.6
COAL
BITUMINOUS
22795.
15.38
9.6-27.5
11.40
5.3-20.1
3.91
2.0-6.0
.05
UNKNOWN
0
NONE
2
0
COLD SIDE
AMERICAN AIR FILTER
235.9
148.9
.3
99.6
0
NONE
N/A
N/A
N/A
N/A
N/A
N/A
N/A
(1000000 ACFM)
( 300 F)
( 350 FT)
( 15.0 FT)
( 9800 BTU/LB)
8200-11600
( 500000 ACFM)
( 300 F)
( 1. IN-H20)
13-156
-------
BIG RIVERS ELECTRIC: GREEN i CCONT.)
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
** 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 S02 REMOVAL EFFICIENCY - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
»* DESIGN AND OPERATING PARAMETERS
DESIGN COAL SULFER CONTENT - X
DESIGN COAL HEAT CONTENT - J/G
DESIGN COAL ASH CONTENT - X
DESIGN MOISTURE CONTENT - X
DESIGN CHLORIDE CONTENT - X
SPACE REQUIREMENTS - SQ M
OPER. & MAIHT. REQUIREMENT - MANHR/DAY
** QUENCHER/PRESATURATOR
NUMBER
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** 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
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
** REHEATER
NUMBER
NUMBER OF SPARES
NUMBER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
LOCATION
PERCENT GAS BYPASSED - AVG
TEMPERATURE INCREASE - C
INLET FLUE GAS FLOW RATE - CU. tVS
INLET FLUE GAS TEMPERATURE - C
OUTLET FLUE GAS FLOW RATE - CU. M/S
OUTLET FLUE GAS TEMPERATURE C
NUMBER OF HEAT EXCHANGER BANKS
NUMBER OF BUNDLES PER BANK
THROWAWAY PRODUCT
WET SCRUBBING
LIME
MAG
AMERICAN AIR FILTER
BURNS 4 ROE
FULL SCALE
NEW
7. 99.00
90.00
1
13/79
12/79
10/76
( 10000 BTU/LB)
( 117000 SQ FT)
4.00
23260.0
20.00
11.25
.05
10869.3
272.0
0
NR
NR
2
0
SPRAY TOWER
OPEN COUNTERCUPRENT SPRAY
N/A
AMERICAN AIR FILTER
34 X 71.5
CARBON STEEL
AISI 1110
N/A
ORGANIC
MASTIC
PENNGUARD ADHESIVE
NONE
1
1008
4
(16000 CPU)
3 (32.0 GAL/1000 ACF)
.4 ( 1.5 IN-H20)
2.8 ( 9.2 FT/S)
235.95 ( 500000 ACFM)
148.9 ( 300 F)
90.0
1
0
1
INDIRECT HOT AIR
EXTERNAL STEAM HEAT EXCHANGER
FIN TUBE BUNDLE
HEATED AIR INJECTED INTO BYPASS DUCT
.0
( 25 F)
( 160000 ACFM)
( 15 F)
( 256000 ACFM)
( 300 F)
13.9
75.50
-9.4
120.81
148.9
3
6
13-157
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
BIG RIVERS ELECTRIC: GREEN i
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
BIG RIVERS ELECTRIC: GREEN i
-------
UTILITY FGD SURVEY: OCTOBER 1983 SEPTEMBER 1984
BIG RIVERS ELECTRIC; GREEN i ICONT.)
CONFIGURATION
DIMENSIONS FT
CAPACITY
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
FEED STREAM SOURCE
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
OVERFLOW STREAM CHARACTERISTICS
OUTLET STREAM DISPOSITION
OVERFLOW STREAM DISPOSITION
*** SALEABLE BYPRODUCTS
NATURE
QUALITY - X
*** SLUDGE
FULL LOAD SLUDGE QUANTITY - M.TONS/HR (DRY)
MOISTURE CONTENT - X TOTAL FREE WATER
X CAS03 - DRY
X CAS04 - DRY
X ASH - DRY
** TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
INLET FLOW RATE - LITER/S
INLET QUALITY - X
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE TREATMENT
SITE DIMENSIONS
** PROCESS CONTROL AND INSTRUMENTATION
PROCESS STREAM
CHEMICAL PARAMETERS
PHYSICAL VARIABLES
CONTROL LEVELS
MONITOR TYPE
MONITOR LOCATION
PROCESS CONTROL MANNER
PROCESS CHEMISTRY MODE
** WATER BALANCE
WATER LOOP TYPE
EVAPORATION WATER LOSS LITER/S
SLUDGE HYDRATICN WATER LOSS - LITER/S
SLUDGE INTERSTITIAL WATER LOSS - LITERS/S
POND SEEPAGE/RUNOFF WATER LOSS - LITERS/S
RECEIVING WATER STREAM
MAKEUP WATER ADDITION - LITERS/S
SOURCE OF MAKEUP WATER
*» CHEMICALS AND CONSUMPTION
FUNCTION
NAME
PRINCIPAL CONSTITUENT
SOURCE/SUPPLIER
CONSUMPTION
UTILIZATION - X
CIRCULAR
125 DIA X 15.5 DEPTH
900000 GAL
INORGANIC
HYDRAULICALLY-BONDED CONCRETE
CARBON STEEL
ASTM A-36 ll/V'1
BLEED PUMP DISCHARGE
774 GPM, 6X SOLIDS
136 GPM, 257. SOLIDS
638 GPM, IX SOLIDS
TO VACUUM FILTERS
THICKENER RETURN WATER TANK
NONE
25.0
( 20.0 TPH)
18.2
75.0
82.<+
11.8
5.8
STABILIZATION
PUG MILL
CONVERSION SYSTEMS [POZ-0-TEC3
17.1 ( 272 GPM)
25.0
FINAL
LANDFILL
ON-SITE
TRUCK
NONE
200 ACRES
ABSORBER RECYCLE
PH
X SOLIDS
PH 9, 6X SOLIDS
LEEDS 8 NORTHRUP/TEXAS NUCLEAR
SCREEN TANKS
AUTOMATIC
FEEDBACK
CLOSED
.8 ( 12 GPM)
.3 (4 GPM)
.3 < <+ GPM)
0
N/A
23.1 ( 366 GPM)
COOLING TOWER SLOWDOWN [290 GPMJ/RIVER WATER [76
ABSORBENT
LIME [THIOSORBIC3
92X CAO, 2-6X INERTS, 2-6X MGO
ORAVO LIME
230 TPD
93.2
13-160
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
BIG RIVERS ELECTRIC; GREEN i
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
BIG RIVERS ELECTRIC: GREEN i (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
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 40.7 720 293
** PROBLEMS/SOLUTIONS/COMMENTS
DURING SEPTEMBER THE VENDOR INSTALLED NEW SWITCHES ON BOTH MODULES'
TRAVELING SCREENS.
10/80 SYSTEM 80.4 40.9 744 304
«* PROBLEMS/SOLUTIONS/COMMENTS
ON SEPTEMBER 12 THE FGD SYSTEM WAS TAKEN OFF-LINE FOR A SCHEDULED OUTAGE.
THE SYSTEM WAS PLACED BACK IN SERVICE ON OCTOBER 13.
DURING OCTOBER A CONTROL SYSTEM MALFUNCTION CAUSED APPROXIMATELY 2 1/2
DAYS OF OUTAGE TIME.
DUE TO LOST LEVEL IN ADDITIVE HOLD TANK THE SCREW CONVEYOR TRIPPED OUT.
THE THICKENER WAS CLEANED OUT AND THE LEAKS REPAIRED DURING THE MONTH.
LEAKS WERE ENCOUNTERED ON THE EXPANSION JOINTS LOCATED ON THE ABSORBER
OUTLET DUCT. THESE EXPANSION JOINTS WERE REPLACED DURING THE MONTH.
11/80 SYSTEM 97.5 96.0 720 691
** PROBLEMS/SOLUTIONS/COMMENTS
A LEAK IN MODULE A BLEED LINE DURING NOVEMBER CAUSED APPROXIMATELY 10
HOURS OF OUTAGE TIME.
12/80 SYSTEM 97.9 93.5 744 695
»* PROBLEMS/SOLUTIOHS/COMMENTS
DURING DECEMBER SEVEN HOURS OF DOWN TIME WAS DUE TO PROBLEMS AT THE SOLID
WASTE FACILITY.
LEAKS WERE ENCOUNTERED WITH THE MIST ELIMINATOR WASH LINES.
PROBLEMS WERE ENCOUNTERED WITH THE CLARIFIERS AT THE COOLING TOWER CAUSING
THE FGD SYSTEM TO BE TAKEN OUT OF SERVICE FOR APPROXIMATELY 23 HOURS.
1/81 SYSTEM 88.4 82.9 744 617
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE FIRST PART OF JANUARY THE UTILITY EXPERIENCED PROBLEMS WITH
HAULING THE WASTE PRODUCT. THIS CAUSED THE SYSTEM TO BE TAKEN OFF LINE
APPROXIMATELY THREE DAYS.
DURING THE MONTH IT WAS NECESSARY TO WASH THE ID FAN.
13-162
-------
UTILITY FGD SURVEY? OCTOBER 1983 - SEPTEMBER
BIG RIVERS ELECTRIC: GREEN i (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
SOS PART. HOURS HOURS HOURS FACTOR
PROBLEMS WERE ENCOUNTERED WITH THE RECYCLE PUMP PACKING.
2/81 SYSTEM 90.9 84.9 696 591
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY HAS EXPERIENCED BYPASS DAMPER PROBLEMS AND IN FEBRUARY INSTALL-
ED A SOLENOID ON THE DAMPER TO RESOLVE THE PROBLEM.
REPAIR WORK ON THE MIST ELIMINATOR LEAKS WAS PERFORMED DURING THE MONTH.
THICKENER MAINTENANCE CAUSED AN OUTAGE WHICH LASTED 22 HOURS.
THE ADDITIVE FEED LINE TO MODULE A REACTION TANK PLUGGED.
3/81 SYSTEM 100.0 51.4 744 382
** PROBLEMS/SOLUTIONS/COMMENTS
THE SYSTEM WAS SHUT DOWN DURING THE FIRST TWO WEEKS OF MARCH FOR SCHEDULED
MAINTENANCE.
4/81 SYSTEM 100.0 60.7 720 437
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED DURING APRIL.
5/81 SYSTEM 84.7 79.3 744 590
**' PROBLEMS/SOLUTIONS/COMMENTS
AT THE FIRST OF MAY GENERAL MAINTENANCE WAS PERFORMED ON THE SYSTEM.
PLUGGING WAS EXPERIENCED IN THE LINES ASSOCIATED WITH THE SLAKER.
THICKENER MAINTENANCE CAUSED THE SYSTEM TO BE OFF-LINE APPROXIMATELY
15 HOURS.
TWO OUTAGES WERE CAUSED BY THE THICKENER RAKE.
A LINE LEAK IN THE MIST ELIMINATOR WASH TANK WAS ENCOUNTERED. FIVE HOURS
OF OUTAGE TIME WAS NEEDED TO MAKE THE NECESSARY REPAIRS.
PLUGGED ADDITIVE LINES CAUSED TWO OUTAGES DURING THE MONTH.
6/81 SYSTEM 95.1 95.1 720 684
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JUNE THE ADDITIVE LINES TO BOTH MODULES PLUGGED CAUSING THE SYSTEM
TO SHUT DOWN THREE SEPARATE TIMES.
THE BYPASS DAMPER SOLENOID MALFUNCTIONED AND HAD TO BE REPLACED.
PROBLEMS HAVE BEEN ENCOUNTERED WITH THE MODULE B INLET DAMPER.
7/81 A 98.3 96.2 96.2 96.2
B 98.3 96.2 96.2 96.2
SYSTEM 98.3 96.2 96.2 96.2 744 744 716 93.9
13-163
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
BIG RIVERS ELECTRIC; GREEN i (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 MAJORITY OF THE OUTAGE TIME DURING THE MONTH RESULTED FROM PLUGGING OF
THE ADDITIVE FEED LINES AND CONTROL VALVES, AS WELL AS MECHANICAL PROBLEMS
WITH THE LIMIT SWITCHES ON THE DAMPERS.
8/81
9/81
A
B
SYSTEM
A
B
SYSTEM
95.2
95.2
95.2
84.5
84.5
84.5
92.6
92.6
92.6
96.4
96.4
96.4
92.6
92.6
92.6
96.4
96.4
96.4
85.3
85.3
85.3
79.9
79.9
79.9
744 686
720 597
635 88.9
575 71.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING SEPTEMBER, THE FGD SYSTEM AVAILABILITY WAS SLIGHTLY LIMITED DUE TO
THE REPLACEMENT OF THE CHEVRON MIST ELIMINATORS ON BOTH MODULES. THE MIST
ELIMINATORS WERE REPLACED DUE TO THEIR NORYL MATERIAL OF CONSTRUCTION
KHICH MELTED AT TEMPERATURES GREATER THAN 180 F. THE REPLACEMENT MIST
ELIMINATORS ARE CONSTRUCTED OF FIBERGLASS [FIRST STAGE] AND RYTON [SECOND
STAGE] RATED FOR TEMPERATURES GREATER THAN 300 F.
10/81 A
B
SYSTEM
75.3
75.3
75.3
98.3
98.3
96.3
98.3
98.3
98.3
74.8
74.8
74.8
744 566
557 69.7
** PROBLEMS/SOLUTIONS/COMMENTS
11/81 A
B
SYSTEM
96.2
94.9
95.6
DURING OCTOBER A PROBLEM WAS ENCOUNTERED WITH THE BY-PASS SOLENOID CAUSING
DOWN TIME.
OUTAGE TIME WAS NECESSARY TO REPAIR LEAKS ON THE INLET DAMPERS AND TO
INSPECT THE CHEVRONS.
A LOW PH CAUSED THE ADDITIVE LINE TO MODULE A TO PLUG RESULTING IN AN
OUTAGE.
THE BLEED LINE TO MODULE A RUPTURED ACCOUNTING FOR ADDITIONAL DOWN TIME.
94.9
94.9
94.9
94.9
94.9
94.9
94.9
94.9
94.9
720 720
683 97.1
** PROBLEMS/SOLUTIONS/COMMENTS
DURING NOVEMBER THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS
OCCURRED.
12/81
1/82
A
B
SYSTEM
98.9
98.9
98.9
97.6
97.6
97.6
97.6
97.6
97.4
97.6
97.6
97.6
744 744
726 91.2
PROBLEMS/SOLUTIONS/COMMENTS
A
B
SYSTEM
DURING DECEMBER NO MAJOR FGD-RELATED PROBLEMS WERE EXPERIENCED.
92.9
94.8
93.8
90.6
91.3
91.0
90.6
91.3
91.0
90.6
91.3
91.0
744 744 677 88.2
13-164
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
BIG RIVERS ELECTRIC; GREEN i 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 UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING JANUARY.
2/82
3/82
A
B
SYSTEM
A
B
SYSTEM
95
97
96
.4
.0
.2
98.4
98.4
98.4
93.
93.
93.
94.
94.
94.
1
1
1
4
4
4
93
93
93
.1
.1
.1
94.4
94.4
94.4
93
93
93
93
93
93
.1
.1
.1
.8
.8
.8
672 672 626 87.6
744 739 698 89.6
** PROBLEMS/SOLUTIONS/COMMENTS
DURING FEBRUARY
4/82
5/82
A
B
SYSTEM
A
B
SYSTEM
86
86
86
99
98
98
.9
.9
.9
.1
.1
.6-
96.
96.
96.
98.
98.
98.
4
4
4
1
1
1
AND
96
96
96
98
98
98
MARCH
.4
.4
.4
.1
.1
.1
NO MAJOR FGD-RELATED
58
58
58
98
98
98
.8
.8
.8
.1
.1
.1
PROBLEMS WERE REPORTED.
720 439 423 56.4
744 744 730 88.8
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING APRIL AND MAY.
6/82 Gl-A 98.5 98.5 98.5 98.5
Gl-B 98.5 98.5 98.5 98.5
SYSTEM 98.5 98.5 98.5 98.5 720 720 709 79.8
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING JUNE.
7/82 Gl-A 98.2 96.2 96.2 96.2
Gl-B 98.2 96.2 96.2 96.2
SYSTEM 98.2 96.2 96.2 96.2 744 744 716 93.9
** PROBLEMS/SOLUTIONS/COMMENTS
PLUGGING OF ADDITIVE FEED LINES AND CONTROL VALVES CONTRIBUTED TO THE
OUTAGE TIME DURING JULY.
MECHANICAL PROBLEMS WITH LIMIT SWITCHES ON THE DAMPERS ALSO CONTRIBUTED TO
OUTAGE TIME DURING THE MONTH.
8/82 Gl-A 100.0 99.2 99.2 91.8
Gl-B 100.0 99.2 99.2 91.8
SYSTEM 100.0 99.2 99.2 91.8 744 689 683 70.8
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING AUGUST.
9/82 SYSTEM 720
10/82 SYSTEM 744
13-165
-------
UTILITY FSD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
BIG RIVERS ELECTRIC; GREEN i (CONT.)
._ PERFORMANCE DATA '
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
11/82 SYSTEM 72°
12/82 SYSTEM 744
1/83 SYSTEM 744
2/83 SYSTEM 672
3/83 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE PERIOD OF SEPTEMBER 1982 THROUGH MARCH
1983.
4/83 SYSTEM 720
5/83 SYSTEM 744
6/83 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE MONTHS OF APRIL AND MAY THE FOLLOWING REPAIRS WERE MADE:
BOTH DOUBLE-LOUVRE SEAL AIR DAMPERS LOCATED AT THE INLET OF THE ABSORBER
VESSELS WERE REPLACED WITH BOTTOM-ENTRY GUILLOTINE SEAL AIR DAMPERS. THE
DOUBLE-LOUVRE DAMPERS DID NOT PROVIDE ADEQUATE ISOLATION TO ALLOW MAIN-
TENANCE DURING BOILER OPERATION. THE UTILITY ALSO REPORTED THAT THE
DOUBLE-LOUVRE DAMPERS CLOSED TOO SLOWLY DURING BYPASS (REASON WHY ORIGINAL
NORYL MIST ELIMINATORS WERE MELTED). THE FAULTY PRE-KRETE G-3 LINER MATE-
RIAL IN THE ABSORBER VESSELS WAS REPLACED WITH PENNGUARD MASTIC. THE PEMN-
GUARD MASTIC WAS APPLIED TO THE ABSORBER AND DUCTWORK FROM THE MIST ELIM-
INATORS TO THE OUTLET ABSORBER GUILLOTINE DAMPERS. PENNGUARD MASTIC AND
PENNGUARD BLOCK WERE BOTH APPLIED TO THE DUCTWORK LOCATED BETWEEN THE OUT-
LET ABSORBER GUILLOTINE DAMPERS AND THE STACK INLET.
THE UTILITY ALSO REPORTED REDUCING THE L/G RATIO ON BOTH ABSORBER VESSELS
(PUMP SPEEDS WERE REDUCED). THE UTILITY REPORTS STILL MEETING COMPLIANCE
LIMITS BUT HAVING A 14 PERCENT DECREASE IN LIME USAGE OVER LAST YEAR.
7/83 SYSTEM 744
8/83 SYSTEM 744
9/83 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE THIRD QUARTER. THE NEXT SCHEDULED UNIT OUTAGE IS SET TO BEGIN
THE FIRST WEEK OF NOVEMBER AND WILL LAST TWO WEEKS.
ABSORBER LIQUID RECIRCUUTION WAS DECREASED IN CONJUNCTION WITH CHANGES TO
NOZZLE HEADER DESIGN IN ORDER TO SAVE ON LIME CONSUMPTION. THE UTILITY
REPORTED THAT THE FGD SYSTEM WAS REMOVING MORE S02 THAN REQUIRED BY
LAW, THE LIQUID RECIRCULATION RATE FOR EACH OF THE TWO ABSORBERS
WAS DECREASED FROM A DESIGN FLOW RATE OF 20,280 GPM (L/G OF 40.6) TO 16,000
GPM (L/G OF 32.0). THREE OF THE SIX SPRAY HEADERS ON HALF OF THE PIG
TAIL NOZZLES WERE CHANGED TO FULL-FLOW TYPE (BASICALLY A 1-7/8 INCH OPEN
HOLE) NOZZLES. DURING NORMAL OPERATIONS 1 PIG TAIL HEADER IS USED IN CON-
JUNCTION WITH 2 COMBINATION HEADERS. WHEN THESE BECOME PLUGGED, AN ADDI-
TIONAL COMBINATION HEADER IS VALVED IN. WHEN ALL SIX HEADERS ARE USED THE
13-166
-------
UTILITY F6D SURVEY: OCTOBER 1983 - SEPTEMBER 1984
BIG RIVERS ELECTRIC; GREEN i (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
LIQUID RECIRCULATION RATE IS 16,000 GPM. HOWEVER, ONLY THREE OF THE FOUR
HEADERS ARE USED FOR NORMAL OPERATING CONDITIONS HAVING A LIQUID RECIRCU-
LATION RATE OF APPROXIMATELY 11,000 TO 13,000 GPM. BECAUSE OF THIS CHANGE
THE UTILITY REPORTED SAVING 11,200 TONS OF LIMESTONE AT A SAVINGS OF
$392,000 (COMPARED TO 1982 BASED ON A 9-MONTH PERIOD) WHILE STILL MEETING
ITS S02 LIMITATIONS.
10/83 SYSTEM 744
11/83 SYSTEM 720
12/83 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED OUTAGES WERE ENCOUNTERED
DURING THE PERIOD. THE UNIT WAS DOWN FOR THE FIRST AND SECOND WEEKS OF
NOVEMBER FOR SCHEDULED MAINTENANCE.
DURING 1983, THE UNIT AND FGD SYSTEM OPERATED A TOTAL OF 7854 5
AND 7592.7 HOURS, RESPECTIVELY. TOTAL FGD SYSTEM AVAILABILITY FOR THE YEAR
WAS 96.7 PERCENT.
THE AVERAGE COAL SULFUR CONTENT FOR THE YEAR WAS 3.58 PERCENT AND THE LIME
TO COAL USAGE RATIO FOR THE YEAR WAS 16:1.
1/84 SYSTEM 744
2/84 SYSTEM ' 696
3/84 SYSTEM 744
4/84 SYSTEM 720
5/84 SYSTEM 744
6/84 SYSTEM 720
7/84 SYSTEM 744
8/84 SYSTEM 744
9/84 SYSTEM 720
** FROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE PENNGUARD BLOCKS INSTALLED IN THE OUTLET DUCT
DURING THE SPRING OF 1983 HAVE WORKED FAVORABLY TO DATE.
THE UTILITY REPORTED THAT THE NEW DAMPERS, WHICH HAVE BEEN IN USE 18 MONTHS
TO DATE, HAVE OPERATED FAVORABLY.
MIST ELIMINATOR WASH PIPE PLUGGAGE WAS REPORTED. A HIGH PRESSURE WASH
(5000 PSD WAS REQUIRED TO CLEAR THE PLUGGED LINES.
OVERALL FGD SYSTEM AVAILABILITY DURING THE FIRST THREE QUARTERS OF 1984 WAS
ESTIMATED AT 90X. NO MAJOR OUTAGES OCCURRED DURING THIS TIME.
13-167
-------
UTILITY FGO SURVEYt OCTOBER 1983 - SEPTEMBER
SECTION 13
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 - 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 - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
**« PARTICLE CONTROL
** MECHANICAL COLLECTOR
NUMBER
TYPE
** ESP
NUMBER
NUMBER OF SPARES
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
TRADE NAME/COMMON NAME
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
*** FGD SYSTEM
BIG RIVERS ELECTRIC
GREEN
2
SEBREE
KENTUCKY
516.
301.
444
242
222
495
242
BABCOCK & WILCOX
PULVERIZED COAL
BASE
.100 LB/MMBTU)
1.200 LB/MMBTU)
.700 LB/MMBTU)
471.90
148.9
107.
CONCRETE
4.6
COAL
BITUMINOUS
22795.
15.38
9.6-27.5
11.40
5.3-20.1
3.91
2.0-6.0
.05
UNKNOWN
0
NONE
2
0
COLD SIDE
AMERICAN AIR FILTER
(1000000 ACFM)
( 300 F)
( 350 FT)
( 15.0 FT)
( 9800 BTU/LB)
8200-11800
235.9
148.9
.3
99.6
( 500000 ACFM)
( 300 F)
( 1. IN-H20)
0
NONE
N/A
N/A
N/A
N/A
N/A
N/A
N/A
13-1*8
-------
BIG RIVERS ELECTRIC; GREEN 2 (CONT.)
UTILITY FGD SURVEY? OCTOBER 1983 - SEPTEMBER 1984
*# 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 SOS REMOVAL EFFICIENCY - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
DESIGN COAL SULFER CONTENT - X
DESIGN COAL HEAT CONTENT - J/G
DESIGN COAL ASH CONTENT - X
DESIGN MOISTURE CONTENT - 7.
DESIGN CHLORIDE CONTENT - X
SPACE REQUIREMENTS - SQ M
OPER. & MAINT. REQUIREMENT - MANHR/DAY
** QUENCHER/PRESATURATOR
NUMBER
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** 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
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
*» REHEATER
NUMBER
NUMBER OF SPARES
NUMBER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
LOCATION
PERCENT GAS BYPASSED - AVG
TEMPERATURE INCREASE - C
INLET FLUE GAS FLOW RATE - CU. M/S
INLET FLUE GAS TEMPERATURE C
OUTLET FLUE GAS FLOW RATE - CU. M/S
OUTLET FLUE GAS TEMPERATURE - C
NUMBER OF HEAT EXCHANGER BANKS
NUMBER OF BUNDLES PER BANK
THROWAWAY PRODUCT
WET SCRUBBING
LIME
MAG
AMERICAN AIR FILTER
BURNS & ROE
FULL SCALE
NEW
7. 99.00
90.00
1
12/80
11/80
5/77
( 10000 BTU/LB)
( 117000 SQ FT)
4.00
23260.0
20.00
11.25
.05
10869.3
272.0
0
NR
NR
2
0
SPRAY TOWER
OPEN COUNTERCURRENT SPRAY
N/A
AMERICAN AIR FILTER
34 X 71.5
CARBON STEEL
AISI 1110
N/A
ORGANIC
MASTIC
PENNGUARD ADHESIVE
NONE
1
1008. (16000 GPM)
4.3 ( 32.0 GAL/1000 ACF)
.4 ( 1.5 IN-H20)
2.8 ( 9.2 FT/S)
235.95 ( 500000 ACFM)
148.9 ( 300 F)
90.0
1
0
1
INDIRECT HOT AIR
EXTERNAL STEAM HEAT EXCHANGER
FIN TUBE BUNDLE
HEATED AIR INJECTED INTO BYPASS DUCT
.0
13.9 ( 25 F)
75.50 ( 160000 ACFM)
-9.4 ( 15 F)
120.81 ( 256000 ACFM)
148.9 ( 300 F)
3
6
13-169
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
BIG RIVERS ELECTRIC; GREEN 2 (CONT.)
NUMBER OF TUBES PER BUNDLE 20
CONSTRUCTION MATERIAL GENERIC TYPE NR
CONSTRUCTION MATERIAL SPECIFIC TYPE NR
** 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
** 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
»* DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
SERVICE CONDITIONS
2
0
CENTRIFUGAL
WESTINGHOUSE
UNIT
FORCED DRAFT
DRY
274.80
148.9
CARBON STEEL
2
0
CENTRIFUGAL
WESTINGHOUSE
UNIT
INDUCED DRAFT
DRY
274.80
148.9
CARBON STEEL
( 582330 ACFM)
( 300 F)
582330 ACFM)
300 F)
SHUT-OFF
GUILLOTINE
TOP-ENTRY GUILLOTINE/SEAL AIR
AMERICAN AIR FILTER
350 F/INDEFINITE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
SERVICE CONDITIONS
SHUT-OFF
GUILLOTINE
TOP-ENTRY GUILLOTINE/SEAL AIR
AMERICAN AIR FILTER
350 F/INDEFINITE
»* DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
SERVICE CONDITIONS
** DAMPERS
NUM3ER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
MODULATION
SERVICE CONDITIONS
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** DUCTWORK
LOCATION
CONFIGURATION
DIMENSIONS
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
SHUT-OFF
LOUVER
PARALLEL BLADE MULTILOUVER
AMERICAN AIR FILTER
350 F/INDEFINITE
SHUT-OFF
GUILLOTINE
BOTTOM ENTRY GUILLOTINE/SEAL AIR
AMERICAN AIR FILTER
OPEN
350 F/INDEFINITE
CARBON STEEL
NR
ABSORBER INLET
RECTANGULAR
11 X 11 X 43.5 LENGTH
CARBON STEEL
AISI 1110
ORGANIC
MASTIC
13-170
-------
BIG RIVERS ELECTRIC: GREEN 2
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
BIG RIVERS ELECTRIC; GREEN 2 ICONT.)
DIMENSIONS - FT
CAPACITY
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
FEED STREAM SOURCE
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
OVERFLOW STREAM CHARACTERISTICS
OUTLET STREAM DISPOSITION
OVERFLOW STREAM DISPOSITION
*** SALEABLE BYPRODUCTS
NATURE
QUALITY - X
125 DIA X 15.5 DEPTH
900000 GAL
INORGANIC
HYDRAULICALLY-BONDED CONCRETE
CARBON STEEL
ASTM A-36 11/4"]
BLEED PUMP DISCHARGE
774 GPM, 67. SOLIDS
136 GPM, 25X SOLIDS
638 GPM, IX SOLIDS
TO VACUUM FILTERS
THICKENER RETURN WATER TANK
NONE
25.0
*** SLUDGE
FULL LOAD SLUDGE QUANTITY - M.TONS/HR (DRY)
MOISTUSE CONTENT - X TOTAL FREE WATER
X CAS03 - DRY
X CAS04 DRY
X ASH - DRY
** TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
INLET FLOW RATE - LITER/S
INLET QUALITY - X
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE TREATMENT
SITE DIMENSIONS
*» PROCESS CONTROL AND INSTRUMENTATION
PROCESS STREAM
CHEMICAL PARAMETERS
PHYSICAL VARIABLES
CONTROL LEVELS
MONITOR TYPE
MONITOR LOCATION
PROCESS CONTROL MANNER
PROCESS CHEMISTRY MODE
»* WATER BALANCE
WATER LOOP TYPE
EVAPORATION WATER LOSS - LITER/S
SLUDGE HYDRATION WATER LOSS - LITER/S
SLUOGE INTERSTITIAL WATER LOSS - LITERS/S
POND SEEPAGE/RUNOFF WATER LOSS - LITERS/S
RECEIVING WATER STREAM
MAKEUP WATER ADDITION - LITERS/S
SOURCE OF MAKEUP WATER
** CHEMICALS AND CONSUMPTION
FUNCTION
NAME
PRINCIPAL CONSTITUENT
SOURCE/SUPPLIER
CONSUMPTION
UTILIZATION X
POINT OF ADDITION
( 20.0 TPH)
18.2
75.0
82.4
11.8
5.8
STABILIZATION
PUG MILL
CONVERSION SYSTEMS IPOZ-0-TEC1
17.1 ( 272 GPM)
25.0
FINAL
LANDFILL
ON-SITE
TRUCK
NONE
200 ACRES
ABSORBER RECYCLE
PH
X SOLIDS
PH 9, 6X SOLIDS
LEEDS 4 NORTHRUP/TEXAS NUCLEAR
SCREEN TANKS
AUTOMATIC
FEEDBACK
CLOSED
.8 (12 GPM)
.3 (4 GPM)
.3 (4 GPM)
0
N/A
23.1 ( 366 GPM)
COOLING TOWER SLOWDOWN [290 GPM]/RIVER WATER
176
ABSORBENT
LIME tTHIOSORBIC)
92X CAO, 2-6X INERTS, 2-6X MGO
DRAVO LIME
230 TFD
93.2
SLAKER
13-172
-------
BIG RIVERS ELECTRIC; SREEN 2 (CONT.)
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
** FGD SPARE CAPACITY INDICES
ABSORBER - 7.
MIST ELIMINATOR - X
REHEATER - X
FAN - X
THICKENER - X
VACUUM FILTER - X
»* FGD SPARE COMPONENT INDICES
ABSORBER
MIST ELIMINATOR
REHEATER
FAN
THICKENER
VACUUM FILTER
30.0
.0
.0
.0
.0
33.0
.4
.0
.0
.0
.0
.1
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
11/80 SYSTEM 94.2 91.8 720 661
»* PROBLEMS/SOLUTIONS/COMMENTS
ON NOVEMBER 14, 1980 OPERATION OF UNIT 2 COMMENCED.
DURING THE MONTH TWO OUTAGES WERE CAUSED BY THICKENER RAKE PROBLEMS.
THE ADDITIVE FEED LINE PLUGGED CAUSING ABOUT EIGHT HOURS OF DOWN TIME.
DURING OPERATION ON LOW RECYCLE FLOW, A WELD ON THE BYPASS DAMPER
ADJUSTMENT ARM ROD FAILED.
26.1
744
194
12/80 SYSTEM 96.2
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS DOWN FOR 18 DAYS AT THE BEGINNING OF DECEMBER.
PROBLEMS WITH THE BYPASS DAMPER WAS ENCOUNTERED DURING THE MONTH.
1/81 SYSTEM 94.3 68.1 744 506
** PROBLEMS/SOLUTIONS/COMMENTS
THE DAMPERS MALFUNCTIONED ON MODULE B, WHEN THE RECYCLE PUMP TRIPPED,
CAUSING ABOUT SEVEN HOURS OF OUTAGE TIME.
THE UTILITY IS EXPERIENCING PROBLEMS WITH HAULING THE WASTE PRODUCT.
THE MODULE B REACTION TANK HAS EXPERIENCED PLUGGING DUE TO THE INABILITY
TO MAINTAIN THE PH.
94.0
696
2/81 SYSTEM 94.5
** PROBLEMS/SOLUTIONS/COMMENTS
DURING FEBRUARY THICKENER MAINTENANCE WAS PERFORMED.
3/81 SYSTEM 97.9 97.9 744
4/81 SYSTEM 99.9 99.5 720
654
728
716
13-173
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
BIG RIVERS ELECTRIC; GREEN z CCONT.)
_. 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 ENCOUNTERED DURING MARCH AND APRIL.
5/81 SYSTEM 92.7 92.0 744 684
** PROBLEMS/SOLUTIONS/COMMENTS
THE ADDITIVE LINE TO THE REACTION TANK PLUGGED CAUSING OUTAGE TIME
DURING MAY.
6/81 SYSTEM 96.2
** PROBLEMS/SOLUTIONS/COMMENTS
95.6
720
688
7/81
8/81
9/81
10/81
11/81
THE MODULE A DISCHARGE LINE SEPARATED DURING THE MONTH CAUSING A 10 HOUR
OUTAGE.
PROBLEMS WERE ENCOUNTERED WITH THE INLET PRESSURE SWITCH ON BOTH MODULES.
THE SWITCHES FOULED APPROXIMATELY SIX TIMES DURING JUNE CAUSING A TOTAL OF
14 HOURS OF OUTAGE TIME.
A
B
SYSTEM
94.0
94.0
94.0
89.1
89.1
89.1
89.1
89.1
89.1
77.2
77.2
77.2
744 645
574 77.5
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JULY, PLUGGING OF THE ADDITIVE FEED LINES AND CONTROL VALVES, AS
WELL AS MECHANICAL PROBLEMS WITH THE LIMIT SWITCHES ON THE DAMPERS
CONTRIBUTED TO THE MAJORITY OF THE OUTAGE TIME.
A
B
SYSTEM
A
B
SYSTEM
96.4
97.8
97.1
99.7
99.7
99.7
94.0
94.0
94.0
98.5
98.5
98.5
94.0
94.0
94.0
98.5
98.5
98.5
86.0
86.0
86.0
98.4
98.4
98.4
744
681
720 719
640 85.1
708 84.7
** PROBLEMS/SOLUTIONS/COMMENTS
NO FGD-RELATED PROBLEMS WERE REPORTED FOR THE MONTHS OF AUGUST AND SEPT-
EMBER.
A
B
SYSTEM
76.3
76.1
76.2
96.2
96.2
96.2
96.2
96.2
96.2
72.9
72.9
72.9
744 564
542 66.4
** PROBLEMS/SOLUTIONS/COMMENTS
DURING OCTOBER THE UTILITY REPORTED THAT PROBLEMS WERE ENCOUNTERED WITH A
RECYCLE PUMP VALVE.
THE BELT ON THE C MODULE RECYCLE PUMP WAS ADJUSTED ACCOUNTING FOR SOME
DOWN TIME.
DURING THE MONTH THE FALL SCHEDULED MAINTENANCE OUTAGE COMMENCED.
A
B
SYSTEM
62.6
62.6
62.6
87.4
87.4
87.4
87.4
87.4
87.4
44.5
44.5
44.5
720 367
320 45.5
13-174
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
BIG RIVERS ELECTRIC; GREEN 2 CCONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
1/82
2/82
** PROBLEMS/SOLUTIONS/COMMENTS
3/82
5/82
THE FALL SCHEDULED MAINTENANCE OUTAGE CONTINUED THROUGH THE BEGINNING OF
NOVEMBER.
THE ADDITIVE MASS VALVE ON THE A MODULE REACTION TANK WAS REPAIRED.
ADDITIONAL OUTAGE TIME WAS CAUSED BY A BROKEN REHEAT ISOLATION DAMPER
DRIVE AND A LEAK IN THE MIST ELIMINATOR MAKE UP.
THE B MODULE ADDITIVE MASS LINE PLUGGED CAUSING A PH DROP.
THE MIST ELIMINATORS WERE REPLACED DUE TO THEIR NORYL MATERIAL OF CONSTRUC-
TION WHICH MELTED AT TEMPERATURES GREATER THAN 180 F. THE REPLACEMENT
MIST ELIMINATORS ARE CONSTRUCTED OF FIBERGLASS [FIRST STAGE] AND RYTON
[SECOND STAGE] RATED FOR TEMPERATURES GREATER THAN 300 F.
12/81 A
B
SYSTEM
99.9
99.9
99.9
98.1
98.1
98.1
98.1
98.1
98.1
87.0
87.0
87.0
660
647 78.5
#* PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE TNCOUNTERED
DURING DECEMBER.
A
B
SYSTEM
96.5
96.8
96.6
95.1
94.4
94.8
95.1
94.4
94.8
95.1
94.4
94.8
744 744
705 86.9
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING JANUARY.
A
B
SYSTEM
99.7
99.7
99.7
97.8
97.8
97.8
97.8
97.8
97.8
97.8
97.8
97.8
672 672
657 88.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED EXPERIENCING NO MAJOR FGD-RELATED PROBLEMS DURING
FEBRUARY.
A
B
SYSTEM
39.9
39.9
39.9
91.9
91.9
91.9
91.9
91.9
91.9
39.9
39.9
39.9
744 323
297 40.5
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MARCH THE SYSTEM WAS TAKEN OFF-LINE PART OF THE TIME FOR A
SCHEDULED OUTAGE.
4/82 A
B
SYSTEM
61.8
61.8
61.8
92.6
92.6
92.6
92.6
92.6
92.6
55.6
55.6
55.6
720 432 401 50.1
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT AND SYSTEM WERE DOWN PART OF APRIL FOR A SPRING OUTAGE.
A 99.6 97.8 97.8 90.1
13-175
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 198*
BIG RIVERS ELECTRIC; GREEN 2 (CONT.)
___ PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION Y. REMOVAL PER BOILER FGD CAP.
502 PART. HOURS HOURS HOURS FACTOR
B 99.6 97.8 97.8 90.1
SYSTEM 99.6 97.8 97.8 90.1 744 685 671 77.8
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR FGD-RELATED PROBLEMS WERE REPORTED FOR THE MONTH OF MAY.
6/82 G2-A 99.3 97.7 97.7 95.9
G2-B 99.3 97.7 97.7 95.9
SYSTEM 99.3 97.7 97.7 95.9 720 707 690 80.4
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-REUTED PROBLEMS WERE ENCOUNTERED
DURING JUNE.
7/82 G2-A 94.0 89.1 89.1 77.2
G2-B 94.0 89.1 89.1 77.2
SYSTEM 94.0 89.1 89.1 77.2 744 645 574 77.5
** PROBLEMS/SOLUTIONS/COMMENTS
PLUGGING OF ADDITIVE FEED LINES AND CONTROL VALVES CONTRIBUTED TO THE
OUTAGE TIME DURING JULY.
MECHANICAL PROBLEMS WITH LIMIT SWITCHES ON THE DAMPERS ALSO CONTRIBUTED TO
OUTAGE TIME DURING THE MONTH.
8/82 G2-A 98.5 98.5 98.5 98.5
G2-B 98.5 98.5 98.5
SYSTEM 98.5 98.5 98.5 98.5 744 744 733 78.4
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-REUTED PROBLEMS WERE ENCOUNTERED
DURING AUGUST.
9/82 SYSTEM 720
10/82 SYSTEM 744
11/82 SYSTEM 720
12/82 SYSTEM 744
1/83 SYSTEM
2/83 SYSTEM 672
3/83 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE PERIOD OF SEPTEMBER 1982 THROUGH MARCH
1983.
4/83 SYSTEM 720
5/83 SYSTEM 744
6/83 SYSTEM 720
13-176
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
BIG RIVERS ELECTRIC: GREEN 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
DURING THE MONTHS OF APRIL AND MAY THE FOLLOWING REPAIRS WERE MADE:
BOTH DOUBLE-LOUVRE SEAL AIR DAMPERS LOCATED AT THE INLET OF THE ABSORBER
VESSELS WERE REPLACED WITH BOTTOM-ENTRY GUILLOTINE SEAL AIR DAMPERS. THE
DOUBLE-LOUVRE DAMPERS DID NOT PROVIDE ADEQUATE ISOLATION TO ALLOW MAIN-
TENANCE DURING BOILER OPERATION. THE UTILITY ALSO REPORTED THAT THE
DOUBLE-LOUVRE DAMPERS CLOSED TOO SLOWLY DURING BYPASS (REASON WHY ORIGINAL
NORYL MIST ELIMINATORS WERE MELTED). THE FAULTY PRE-KRETE G-8 LINER MATE-
RIAL IN THE ABSORBER VESSELS WAS REPLACED WITH PENNGUARD MASTIC. THE PENN-
GUARD MASTIC WAS APPLIED TO THE ABSORBER AND DUCTWORK FROM THE MIST ELIM-
INATORS TO THE ABSORBER OUTLET GUILLOTINE DAMPERS. PENNGUARD MASTIC AND
PENK3UARD BLOCK WILL BE APPLIED DURING THE NEXT MAJOR OUTAGE PERIOD TO THE
DUCTWORK LOCATED BETWEEN THE ABSORBER OUTLET GUILLOTINE DAMPERS AND THE
STACK INLET.
THE UTILITY ALSO REPORTED REDUCING THE L/G RATIO ON BOTH ABSORBER VESSELS
(PUMP SPEEDS WERE REDUCED). THE UTILITY REPORTS STILL MEETING COMPLIANCE
LIMITS BUT HAVING A 14 PERCENT DECREASE IN LIME USAGE OVER LAST YEAR.
7/83 SYSTEM 744
8/83 SYSTEM 744
9/83 SYSTEM 730
*« PROBLEMS/SOLUTIONS/COMMENTS
ABSORBER LIQUID RECIRCULATION WAS DECREASED IN CONJUNCTION WITH CHANGES TO
NOZZLE HEADER DESIGN IN ORDER TO SAVE ON LIME CONSUMPTION. THE UTILITY
REPORTED THAT THE FGD SYSTEM WAS REMOVING MORE SOZ THAN REQUIRED BY LAW.
THE LIQUID RECIRCULATION RATE FOR EACH OF THE TWO ABSORBERS
WAS DECREASED FROM A DESIGN FLOW RATE OF 20,280 GPM (L/G OF 40.6) TO 16,000
GPM (L/G OF 32.0). THREE OF THE SIX SPRAY HEADERS ON HALF OF THE PIG
TAIL NOZZLES WERE CHANGED TO A FULL-FLOU TYPE (BASICALLY A 1-7/8 INCH OPEN
HOLE) NOZZLES. DURING NORMAL OPERATIONS 1 PIG TAIL HEADER IS USED IN CON-
JUNCTION WITH 2 COMBINATION HEADERS. WHEN THESE BECOME PLUGGED, AN ADDI-
TIONAL COMBINATION HEADER IS VALVED IN. WHEN ALL SIX HEADERS ARE USED THE
LIQUID RECIRCULATION RATE IS 16,000 GPM. HOWEVER, ONLY THREE OF THE FOUR
HEADERS ARE USED FOR NORMAL OPERATING CONDITIONS HAVING A LIQUID RECIRCU-
LATION RATE OF APPROXIMATELY 11,000 TO 13,000 GPM. BECAUSE OF THIS CHANGE
THE UTILITY REPORTED SAVING 11,200 TONS OF LIMESTONE AT A SAVINGS OF
$392,000 (COMPARED TO 1982 BASED ON A 9-MONTH PERIOD) WHILE STILL MEETING
ITS S02 LIMITATIONS.
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE THIRD QUARTER. THE NEXT SCHEDULED UNIT OUTAGE IS SET TO BEGIN
THE FIRST WEEK OF NOVEMBER AND WILL LAST TWO WEEKS.
10/83 SYSTEM 744
11/83 SYSTEM 720
12/83 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED OUTAGES WERE ENCOUNTERED
DURING THE PERIOD. THE UNIT WAS DOWN FORTHE THIRD AND FOURTH WEEKS OF
NOVEMBER FOR SCHEDULED MAINTENANCE.
DURING 1983, THE UNIT AND FGD SYSTEM OPERATED A TOTAL OF 7966.7
13-177
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
BIS RIVERS ELECTRIC: GREEN 2 ICONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
AND 7742.7 HOURS, RESPECTIVELY. TOTAL FGD SYSTEM AVAILABILITY FOR THE YEAR
WAS 97.2 PERCENT.
THE AVERAGE COAL SULFUR CONTENT FOR THE YEAR WAS 3.58 PERCENT AND THE LIME
TO COAL RATIO FOR THE YEAR WAS 16:1.
1/84 SYSTEM 744
2/84 SYSTEM 696
3/84 SYSTEM 744
4/84 SYSTEM 720
5/84 SYSTEM 744
6/84 SYSTEM 720
7/84 SYSTEM 744
8/84 SYSTEM 744
9/84 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT A NEW OUTLET DUCT LINING (STEBBINS TILE) WAS
INSTALLED AT THE OUTLET DUCT MIXING ZONE DURING THE FIRST THREE QUARTERS OF
19S4.
THE UTILITY REPORTED THAT THE NEW DAMPERS, WHICH HAVE BEEN IN USE 18 MONTHS
TO DATE, HAVE OPERATED FAVORABLY.
MIST ELIMINATOR WASH PIPE PLUGGAGE WAS REPORTED. A HIGH PRESSURE WASH
(5000 PSI) WAS REQUIRED TO CLEAR THE PLUGGED LINES.
OVERALL FGD SYSTEM AVAILABILITY DURING THE FIRST THREE QUARTERS OF 1984 WAS
ESTIMATED AT 90X. NO MAJOR OUTAGES OCCORRED DURING THIS TIME.
13-178
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
SECTION 13
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
SOZ 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
NUMBER
TYPE
** ESP
NUMBER
NUMBER OF SPARES
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
TRADE NAME/COMMON NAME
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
*** FGD SYSTEM
CENTRAL ILLINOIS LIGHT
DUCK CREEK
1
CANTON
ILLINOIS
D
516.
301.
373
416
378
390
416
RILEY STOKER
PULVERIZED COAL
BASE
717.29
135.0
152.
CONCRETE
5.8
( .100 LB/MMBTU)
( 1.200 LB/MMBTU)
( .700 LB/MMBTU)
(1520000 ACFM)
( 275 F)
( 500 FT)
( 19.0 FT)
( 10396 BTU/LB)
9800-11000
COAL
BITUMINOUS
24181.
9.12
6-18
15.43
13-23
3.40
2.4-4.0
.06
******
0
NONE
2
0
COLD SIDE
POLLUTION CONTROL-WALTHER
358.6 ( 760000 ACFM)
135.0 ( 275 F1
.1 ( 1. IN-H20)
99.8
0
NONE
N/A
N/A
N/A
N/A
N/A
N/A
N/A
13-179
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
CENTRAL ILLINOIS LIGHT: DUCK CREEK 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 S02 REMOVAL EFFICIENCY - 7.
ENERGY CONSUMPTION - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
DESIGN COAL SULFER CONTENT - X
DESIGN COAL HEAT CONTENT - J/G
DESIGN COAL ASH CONTENT - '/.
DESIGN MOISTURE CONTENT - X
DESIGN CHLORIDE CONTENT - X
OPER. t MAINT. REQUIREMENT - MANHR/DAY
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
NONE
ENVIRONEERING, RILEY STOKER
GILBERT/COMMONWEALTH ASSOCIATES
FULL SCALE
NEW
85.30
2.9
1
8/78
7/76
8/73
4.00
22794.8
18.00
23.00
.05
144.0
( 9800 BTU/LB)
** QUENCHER/PRESATURATOR
NUMBER
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** 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
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
PPE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
NUMBER OF SPARES PER SYSTEM
NUMBER PER MODULE
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
0
NR
NR
4
0
PACKED TOWER
ROD DECK
VENTRI-SORBER
ENVIRONEERING, RILEY STOKER
40.0 X 5.0 X 40.0
STAINLESS STEEL; HIGH ALLOY [ATOP ABSORBER]
AUSTENITIC; NICKEL BASE/CHROMIUM-IRON-COPPER-MOL
TYPE 316L; HASTELLOY G
NONE
N/A
N/A
ROD DECKS
8
992.
5.9
3.0
3.7
167.05
135.0
85.3
(15750 6PM)
( 44.5 GAL/1000 ACF)
(12.0 IN-H20)
( 12.0 FT/S)
( 354000 ACFM)
( 275 F)
PRIMARY COLLECTOR
4
0
1
IMPINGEMENT
BAFFLE
CLOSED VANE
VERTICAL
2
3
3.66
121.92
6.3
90
.2
4.0
(12.0
(48.0
( 2.50
( 1.0
( 13.0
FT)
IN)
IN)
IN-H20)
FT/S)
13-180
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
CENTRAL ILLINOIS LIGHT: DUCK CREEK 1 (CONT.)
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
WASH WATER SOURCE
WASH FREQUENCY
WASH RATE - L/S
** REHEATER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
»* FANS
NUMBER
NUMBER OF SPARES
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
CONSTRUCTION MATERIAL GENERIC TYPE
#* DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
SEAL AIR FLOW - CU. M/S
SERVICE CONDITIONS
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUM5ER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
SEAL AIR FLOW - CU. M/S
SERVICE CONDITIONS
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
SEAL AIR FLOW - CU. M/S
SERVICE CONDITIONS
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
HIGH ALLOY
NICKEL BASE/CHROMIUM-IRON-COPPER-MOLYBDENUM
SUPERNATANT
EVERY 20 MINUTES
102.8 ( 1630 GAL/MIN)
0
NONE
N/A
N/A
NONE
N/A
4
0
CENTRIFUGAL
BUFFALO FORGE
UNIT
FORCED DRAFT
DRY
167.05 ( 354000 ACFM)
135.0 ( 275 F)
11.6 (38.0 IN-H20)
CARBON STEEL
SHUT-OFF
LOUVER
PARALLEL BLADE MULTILOUVER
AMERICAN STANDARD
1.96 ( 4150 ACFM)
450
CARBON STEEL
AISI 1110
NONE
N/A
8
SHUT-OFF
GUILLOTINE
NR
ENVIRONMENTAL ELEMENTS
.57 ( 1200 ACFM)
450
HIGH ALLOY
NICKEL BASE/CHROMIUM-IRON-COPPER-MOLYBDENUM
NONE
N/A
SHUT-OFF
LOUVER
PARALLEL BLADE MULTILOUVER
AMERICAN STANDARD
.00 ( 0 ACFM)
450
HIGH ALLOY
NICKEL BASE/CHROMIUM-IRON-COPPER-MOLYBDENUM
NONE
N/A
1
CONTROL
LOUVER
PARALLEL BLADE MULTILOUVER
13-181
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
CENTRAL ILLINOIS LIGHT: DUCK CREEK 1 (CONT.)
MANUFACTURER
SEAL AIR FLOW - CU. M/S
SERVICE CONDITIONS
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
KTJMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
SERVICE CONDITIONS
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
SEAL AIR FLOW - CU. M/S
SERVICE CONDITIONS
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
CONFIGURATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
CONFIGURATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
CONFIGURATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
MANUFACTURER
NUMBER
NUMBER OF SPARES
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
PRODUCT QUALITY - X SOLIDS
AMERICAN STANDARD
.00 ( 0 ACFM)
NR
HIGH ALLOY
NICKEL BASE/CHROMIUM-IRON-COPPER-MOLYBDENUM
NONE
N/A
8
CONTROL
NR
NR
BUFFALO FORGE
NR
NR
NR
NONE
N/A
SHUT-OFF
LOUVER
PARALLEL BLADE MULTILOUVER
AMERICAN STANDARD
1.96 ( 4150 ACFM)
700
NR
. NR
NONE
N/A
INLET
RECTANGULAR
CARBON STEEL
AISI 1110
NONE
N/A
OUTLET t BYPASS
CIRCULAR
HIGH ALLOY
NICKEL BASE/CHROMIUM-IRON-COPPER-MOLYBDENUM
NONE
N/A
TRANSITION DUCT AT BASE OF STACK
CIRCULAR TO SQUARE
HIGH ALLOY
NICKEL BASE/CHROMIUM-IRON-COPPER-MOLYBDENUM
NONE
N/A
WET BALL MILL
COMPARTMENTED
NR
KENNEDY VAN SAUN
36.3
35.0
( 40 TPH)
13-]!
-------
CENTRAL ILLINOIS LIGHT: DUCK CREEK 1 (CONT.)
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
** TANKS
SERVICE
ABSORBER RECYCLE
WASTE SLURRY BLEED
REAGENT PREP PRODUCT
MIST ELIMINATOR WASH
MILL SLURRY
** PUMPS
SERVICE
POND RETURN
MIST ELIMINATOR WASH
ABSORBER RECIRCULATION
SLURRY TRANSFER
MILL SLURRY
*» SOLIDS CONCENTRATING/DEWATERING
DEVICE
*** SLUDGE
** TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE TREATMENT
SITE DIMENSIONS
SITE CAPACITY - CU.M
SITE SERVICE LIFE - YRS
** PROCESS CONTROL AND INSTRUMENTATION
PROCESS STREAM
CHEMICAL PARAMETERS
PHYSICAL VARIABLES
CONTROL LEVELS
MONITOR LOCATION
PROCESS CONTROL MANNER
PROCESS CHEMISTRY MODE
** WATER BALANCE
WATER LOOP TYPE
RECEIVING WATER STREAM
MAKEUP WATER ADDITION - LITERS/S
** CHEMICALS AND CONSUMPTION
FUNCTION
NAME
PRINCIPAL CONSTITUENT
CONSUMPTION
UTILIZATION - 7.
POINT OF ADDITION
»* FGD SPARE CAPACITY INDICES
ABSORBER 7.
MIST ELIMINATOR - 7.
FAN X
BALL MILL - 7.
EFFLUENT HOLD TANK 7.
RECIRCULATION PUMP X
NUMBER
NUMBER
Z
8
12
2
2
NONE
BLEED
N/A
N/A
FINAL
POND
ON-SITE
PIPELINE
CLAY LINING
57 ACRES
125969
5
103.0 ACRE-FT)
ABSORBER RECYCLE
PH
PERCENT SOLIDS, LIQUID LEVEL
PH 6.0 AT INLET, 5.5 AT OUTLET
RECYCLE TANK
AUTOMATIC
FEEDBACK
CLOSED
NONE
37.8
ABSORBENT
LIMESTONE
95X CAC03
40 TPH
67.0
RECYCLE TANK
.0
.0
.0
.0
.0
33.0
( 600 GPM)
13-183
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
CENTRAL ILLINOIS LIGHT: DUCK CREEK 1 (CONT.)
** FGD SPARE COMPONENT INDICES
ABSORBER -°
MIST ELIMINATOR -0
FAN -0
BALL MILL -0
EFFLUENT HOLD TANK -0
RECIRCULATION PUMP 4-0
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 91.60 744 8
** 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 PATH. THE FIRST MODULE OF THE 4-MODULE
SCRUBBING SYSTEM WAS INSTALLED BY JUNE 1976 AND START-UP FOR SHAKEDOWN/DE-
BUGGINS 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
** PROBLEMS/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 WAS 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-
13-184
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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
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 (0.6X) KENTUCKY COAL.
1/77 SYSTEM .0 744 0 0 .0
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 WAS 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 0
1/78 SYSTEM .0 744 0
13-185
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
CENTRAL ILLINOIS LIGHT: DUCK CREEK 1 (CONT.)
.. PERFORMANCE DATA-
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION V. REMOVAL PER BOILER FGD CAP.
502 PART. HOURS HOURS HOURS FACTOR
2/78
3/78
4/78
5/78
6/78
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
.0
.0
.0
.0
.0
672
744
720
744
720 0
0
0
0
0
0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
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 45.0 46.0 46.0 42.0 744 691 315 62.5
9/78 SYSTEM 46.0 46.0 46.0 44.0 720 691 317 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
DESIGN. 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
BEING INVESTIGATED.
10/78
A
B
C
D
SYSTEM
19.1
22.5
.8
20.5
15.7
31.6
37.2
1.3
33.9
26.0
31.6
37.2
1.3
33.9
26.0
19.1
22.5
.8
20.5
15.7
744 449 H7 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.
13-186
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
CENTRAL ILLINOIS LIGHT: DUCK CREEK 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL
sea PART.
PER BOILER FGD CAP.
HOURS HOURS HOURS FACTOR
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.
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 WERE ADDED TO THE LOWER SEVEN ROD DECKS TO MAINTAIN
PRESSURE DROP REQUIREMENTS. THIS HAS BEEN FOUND TO BE AN ACCEPTABLE
SOLUTION AT OTHER ENVIRONEERING FGO 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 WAS 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
OCCURRED DURING DECEMBER.
LIMESTONE MILL PROBLEMS AND A PLUGGED LIMESTONE FEEDER HAMPERED SCRUBBER
OPERATIONS DURING DECEMBER.
THE SYSTEM EXPERIENCED FROZEN INSTRUMENT CONTROL LINES IN DECEMBER.
WAS THE MAJOR CAUSE OF THE DECEMBER SCRUBBER UNAVAILABILITY.
1/79 SYSTEM
.0
.0
.0
.0
744 738
THIS
77.0
13-187
-------
UTILITY FGD SURVEY'- OCTOBER 1983 - SEPTEMBER 1984
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/COMMENTS
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.
2/79 SYSTEM .0 .0 .0 .0 672 533 0 63.8
** 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 DURING 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 0 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.
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
4/79
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 95.7 37.4 69.7 9.9
B 95.7 44.2 73.2 11.7
C 94.7 41.8 71.1 11.1
13-188
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
CENTRAL ILLINOIS LIGHT: DUCK CREEK 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
D
SYSTEM
1.3
71.9
5.0
32.1
1.3
53.8
1.3
8.5
744
197
63
14.8
** PROBLEMS/SOLUTIONS/COMMENTS
MIST ELIMINATOR PUMP MALFUNCTIONS WERE REPORTED DURING MAY.
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.
MODULE D
STACK LINER BLISTERING WAS DISCOVERED DURING A SPRING INSPECTION.
PAIRS WERE MADE. THE STACK WILL BE INSPECTED AGAIN IN MARCH 1980.
RE-
6/79 A
B
C
D
SYSTEM
81.9
89.2
86.6
92.0
87.4
76.9
86.9
83.0
90.0
84.2
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 MILL SHAKER BASKET FAILURES.
7/79 A
B
C
0
SYSTEM
93.
94.
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 ELIMINATOR 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 SLURRY 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
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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/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 SEPTEMBER.
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.
SCRUBBER UNAVAILABILITY WAS PRIMARILY A RESULT OF CARRY-OVER PLUGGING
PROBLEMS FROM AUGUST AND SUBSEQUENT CLEAN-UP.
10/79
11/79
A
B
C
D
SYSTEM
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/COMHENTS
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.
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.
13-190
-------
UTILITY FED SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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
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
2/80
3/80
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
** 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.
A
B
C
D
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.
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
13-191
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
CENTRAL ILLINOIS LIGHT: DUCK CREEK 1 (CONT.)
. PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
302 PART. HOURS HOURS HOURS FACTOR
4/80
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
5/80
6/80
** PROBLEMS/SOLUTIONS/COMMENTS
THE MAJOR PROBLEM HINDERING SYSTEM OPERATIONS DURING APRIL WAS THE REBUILD
OF THE RECYCLE TANK MIXER.
MINOR PROBLEMS DURING THE MONTH WERE CAUSED BY THE INOPERABILITY OF THE
LIMESTONE HANDLING SYSTEM.
A
B
C
0
SYSTEM
44.6
45.7
34.7
43.6
42.1
68.6
70.3
53.3
67.0
64.8
72.0
73.5
59.1
73.9
69.7
44.6
45.7
34.7
43.6
42.1
744 484
314 49.4
** PROBLEMS/SOLUTIONS/COMMENTS
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
67.1
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
7/80
8/80
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.
A
B
C
D
SYSTEM
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.
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
68.9
90.1
90.7
81.9
82.7
81.0
81.6
81.9
744 713
609 76.5
13-192
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
CEKTRAL ILLINOIS LIGHT: DUCK CREEK 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION '/. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** 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
B
C
D
SYSTEM
43.1
47.8
45.6
46.3
45.6
39.2
47.2
43.2
46.0
43.9
41.5
48.2
45.9
47.6
45.9
39.2
47.2
43.2
46.0
43.9
720 720
316 81.3
** PROBLEMS/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.
10/80
A
B
C
0
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
744 744
532 64.6
PROBLEM.S/SOLUTIONS/COMMENTS
DURING OCTOBER THE FGD SYSTEM WAS 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.
11/80
A
B
C
D
SYSTEM
98.9
96.2
99.2
95.4
97.4
92.3
88.1
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
C
0
SYSTEM
93.
94.
87.
94.
92.
5
9
2
0
4
92
93
66
93
91
.6
.9
.0
.0
.4
94.
95.
90.
96.
94.
1
9
7
0
2
92.
93.
85.
92.
91.
2
5
6
6
0
744 741
677 79.7
13-193
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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/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.
1/81
A
B
C
D
SYSTEM
92.2
94.9
94.2
88.6
92.5
92.1
94.9
94.1
88.6
92.4
94.9
97.8
98.0
94.4
96.3
92.1
94.8
94.1
88.6
92.4
2/81
3/81
4/81
744 744
687 77.9
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JANUARY SOME OUTAGE TIME WAS DUE TO THE PLUGGING OF THE RECYCLE
TANK PUMP SUCTION SCREENS.
REPAIRS WERE MADE TO THE INLET DAMPER OF MODULE C AND THE RECYCLE TANK
PUMP OF MODULE D DURING THE MONTH.
A
B
C
D
SYSTEM
95.2
80.2
95.1
94.0
91.1
95.8
81.5
95.6
94.6
91.8
100.0
96.9
100.0
99.8
99.2
94.2
80.2
94.0
93.0
90.3
672 661
607 59.3
** PROBLEMS/SOLUTIONS/COMMENTS
DURING FEBRUARY PROBLEMS WERE ENCOUNTERED THAT NECESSITATED REPAIRS TO THE
LIMESTONE CONVEYOR BELT AND THE SLURRY SUPPLY TANK AND LINES.
A
B
C
D
SYSTEM
93.8
82.5
84.7
86.8
86.9
88.5
79.9
81.5
84.1
83.5
91.6
84.7
85.5
90.8
88.2
85.1
76.9
78.4
80.8
80.2
744 715
597 68.4
»» PROBLEMS/SOLUTIONS/COMMENTS
DURING MARCH OUTAGE TIME WAS DUE TO THE REPLACEMENT OF THE LIMESTONE MILL
HIGH LIFT PUMP AND THE SLURRY STORAGE TANK PUMP, BOTH LIMITING THE LIME-
STONE SLURRY SUPPLY. THE RECYCLE TANK PUMP ON MODULE C WAS ALSO REPLACED.
ADDITIONAL OUTAGE TIME WAS CAUSED BY PLUGGING IN THE MIST ELIMINATOR SEC-
TION OF ALL THE MODULES.
A
B
C
D
SYSTEM
26.2
27.1
44.8
52.1
37.5
27.1
28.1
29.1
28.4
28.1
28.1
29.5
30.2
29.5
29.2
23.3
24.2
25.0
24.4
24.2
720 619
174 58.6
** PROBLEMS/SOLUTIONS/COMMENTS
EXTENSIVE PLUGGING THROUGHOUT EACH MODULE WAS OBSERVED AT THE BEGINNING
OF APRIL, RESULTING IN THE NEED FOR EXTENSIVE MAINTENANCE CLEANING,
REPAIRS, AND UPGRADING OF EACH MODULE. THE MODULES WERE TAKEN OUT OF
SERVICE TWO AT A TIME SO THAT THE WORK COULD BE PERFORMED.
THE ISOLATION DAMPERS ON ALL FOUR MODULES HAVE BEEN A CONTINUAL PROBLEM.
THE DAMPERS STICK AND FAIL TO SEAL TIGHTLY RESULTING IN GASEOUS CONDITIONS
FOR MAINTENANCE CREWS. THE UTILITY IS PRESENTLY INVESTIGATING THE
SITUATION.
13-194
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
CENTRAL ILLINOIS LIGHT: DUCK CREEK 1 (CONT.)
PERIOD MODULE AVAILABILITY
5/81 A
B
C
D
SYSTEM
68.7
68.1
76.4
71.4
69.9
OPERABILITY
67.0
66.4
69.9
69.8
68.3
rCKTUKHAM
RELIABILITY
69.1
69.2
71.4
73.4
70.8
UC U« 1 A
UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
65.9
65.3
68.7
68.5
67.1
744 731 499 64.0
6/81
7/81
8/81
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MAY MAJOR REPAIR TO THE MODULE C FAN RESULTED IN LOW SYSTEM AVAILA-
BILITY DUE TO THE NEED FOR BYPASSING AROUND THE MODULE. PROBLEMS WITH
OPERATION OF THE MODULE C ISOLATION DAMPER AS WELL AS EXPANSION JOINT LEAK-
AGE, RESULTED IN GASEOUS WORKING CONDITIONS SUCH THAT REPAIR WORK COULD NOT
BE PERFORMED WITH THE SCRUBBER IN SERVICE.
PROBLEMS PERSIST WITH ALL THE ISOLATION DAMPERS.
1
B
C
D
SYSTEM
69.9
71.3
72.4
70.3
71.0
60.0
63.9
65.2
61.6
62.7
67.4
71.2
70.5
69.5
69.6
51.5
54.8
55.9
52.9
53.8
720 618
387 52.8
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JUNE WORK ON THE MODULE C ID FAN CONTINUED. DUE TO THE CONTINUAL
DAMPER PROBLEMS THE MODULE WAS TAKEN OUT OF SERVICE SO THAT THE REPAIRS
COULD BE COMPLETED.
A
B
C
D
SYSTEM
78.2
75.8
80.5
53.6
72.0
62.4
62.3
64.2
62.7
62.9
73.0
75.7
75.1
75.1
74.7
53.4
53.2
54.8
53.6
53.8
744 636
400 56.4
** PROBLEMS/SOLUTIONS/COMMENTS
PROBLEMS WITH OPERATION OF THE ISOLATION DAMPERS AND EXPANSION JOINT LEAK-
AGE DURING THE MONTH RESULTED IN LOW SYSTEM AVAILABILITY DUE TO THE NEED
FOR BYPASSING FLUE GAS TO ELIMINATE GASEOUS WORKING CONDITIONS DURING MAIN-
TENANCE OPERATIONS.
SIGNIFICANT REPAIR WORK WAS REQUIRED DURING THE MONTH ON THE MODULE A,B,
AND D RECYCLE PUMPS.
A
B
C
D
SYSTEM
79.4
79.7
79.6
60.3
74.8
78.6
78.9
78.9
60.3
74.2
80.0
79.6
80.3
62.6
75.6
78.6
78.9
78.9
60.3
74.2
744
744
552 75.0
** PROBLEMS/SOLUTIONS/COMMENTS
ISOLATION DAMPER AND EXPANSION JOINT PROBLEMS CONTINUED TO LOWER THE OVER-
ALL FGD SYSTEM AVAILABILITY.
MIXER REPAIR ON THE MODULE D RECYCLE TANK RESULTED IN LOW MODULE AVAIL-
ABILITY.
10/81 SYSTEM
11/81 A
B
.0
32.9
32.9
82.6
82.6
93.7
93.7
.0
26.9
26.9
744
.0
13-195
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
CENTRAL ILLINOIS LIGHT: DUCK CREEK 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
C 32.6 82.1 93.4 26.8
D 24.5 67.9 81.9 22.2
SYSTEM 30.7 78.8 90.8 25.7
720 235 185 20.7
1/82
2/82
3/82
** PROBLEMS/SOLUTIONS/COMMENTS
A MAJOR UNIT OUTAGE STARTED ON SEPTEMBER 18 AND CONTINUED THROUGH OCTOBER
AND ENDED ON NOVEMBER 21. DURING THIS TIME THE SCRUBBER WAS DRAINED OF
SLURRY AND CLEANED. ISOLATION DAMPER SEAL AIR PROBLEMS RESULTED IN LOW
AVAILABILITY DURING OPERATING PERIODS. IT WAS NECESSARY TO BYPASS THE
SYSTEM TO ELIMINATE HAZARDOUS WORKING CONDITIONS DURING MAINTENANCE
OPERATIONS.
12/81
A
B
C
D
SYSTEM
80.3
81.0
76.9
82.1
80.1
81.2
81.6
81.0
83.8
81.9
81.5
83.6
82.5
84.1
82.9
68.1
68.4
67.9
70.3
68.7
744 624
511 63.1
** PROBLEMS/SOLUTIONS/COMMENTS
DURING DECEMBER ISOLATION DAMPER SEAL AIR PROBLEMS RESULTED IN LOW
AVAILABILITY DURING OPERATING PERIODS. IT WAS NECESSARY TO BYPASS THE
SYSTEM TO ELIMINATE HAZARDOUS WORKING CONDITIONS DURING MAINTENANCE
OPERATIONS.
A
B
C
D
SYSTEM
79.1
73.4
73.8
67.3
73.4
74.4
68.6
69.0
69.1
70.3
76.7
71.5
71.0
71.9
72.8
72.4
66.7
67.1
67.3
68.4
744 724
509 70.5
** PROBLEMS/SOLUTIONS/COMMENTS
THE SCHEDULED BOILER OUTAGE THAT STARTED AT THE END OF DECEMBER ENDED ON
JANUARY 4.
THE LOW SYSTEM AVAILABILITY DURING JANUARY WAS PARTIALLY DUE TO THE LIME-
STONE IN THE STORAGE PILE BEING FROZEN LIMITING ITS DELIVERY TO THE FGD
SYSTEM.
LOW AVAILABILITY WAS ALSO DUE TO ISOLATION DAMPER SEAL AIR PROBLEMS RE-
QUIRING THE NEED FOR BY-PASSING FLUE GAS TO ELIMINATE HAZARDOUS WORKING
CONDITIONS DURING MAINTENANCE OPERATIONS.
A
B
C
D
SYSTEM
53.6
54.5
49.3
55.5
53.2
53.6
54.5
49.3
55.5
53.2
53.6
54.5
49.3
55.5
53.2
53.6
54.5
49.3
55.5
53.2
672 672
358 76.7
** PROBLEMS/SOLUTIONS/COMMENTS
THE LOW AVAILABILITY DURING THE MONTH OF FEBRUARY WAS PRIMARILY DUE TO
SEVERE PLUGGING OF THE MODULES.
THE ISOLATION DAMPER SEAL AIR PROBLEMS CONTINUED THROUGHOUT FEBRUARY.
A
B
C
D
SYSTEM
32.9
35.5
35.7
34.4
34.6
46.6
50.2
50.5
48.7
49.0
46.8
50.4
50.7
48.8
49.2
32.9
35.5
35.7
34.4
34.6
744 526
258 53.9
13-1=6
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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
4/82
6/82
8/82
»* PROBLEMS/SOLUTIONS/COMMENTS
THE LOW AVAILABILITY IN MARCH WAS DUE TO SEVERE PLUGGING OF THE ABSORBER
MODULES.
MODULE ISOLATION DAMPER SEAL AIR PROBLEMS CONTINUED THROUGH MARCH.
ON MARCH 23 THE UNIT WAS TAKEN OUT OF SERVICE FOR A SCHEDULED OUTAGE.
UNIT REMAINED OFF-LINE THROUGH THE END OF THE MONTH.
THE
A
B
C
D
SYSTEM
12.2
19.0
21.3
21.3
18.4
37.7
58.9
66.0
66.2
57.2
46.1
65.3
65.6
65.8
60.7
11.0
15.6
15.7
15.8
14.5
720 232
105 17.8
** PROBLEMS/SOLUTIONS/COMMENTS
THE SCHEDULED OUTAGE STARTED IN MARCH CONTINUED THROUGH TO APRIL 26.
DURING THE OUTAGE THE MODULES WERE CLEANED EXTENSIVELY. THIS HAS SHOWN
MUCH IMPROVEMENT IN THE SYSTEM'S RELIABILITY.
5/82 A
A
B
C
D
SYSTEM
91.1
92.2
91.9
91.7
91.7
91.1
92.2
91.9
91.7
91.7
91.1
92.2
91.9
91.7
91.7
91.1
92.2
91.9
91.7
91.7
744 744
682 66.9
*« PROBLEMS/SOLUTIONS/COMMENTS
MODULE ISOLATION DAMPER SEAL AIR PROBLEMS CONTINUE TO REDUCE THE AVAILABIL-
ITY DUE TO THE NEED FOR BY-PASSING FLUE GAS TO ELIMINATE GASEOUS WORKING
CONDITIONS DURING MAINTENANCE OPERATIONS.
A
B
C
D
SYSTEM
83.6
91.6
91.7
92.5
89.9
83.6
91.6
91.7
92.5
89.9
83.6
91.6
91.7
92.5
89.9
83.6
91.6
91.7
92.5
89.9
720 720
647 68.2
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE DOWN TIME DURING JUNE WAS TO REMOVE ANY SCALE ACCUMULATION AND TO
CLEAN THE MODULES.
7/82
A
B
C
D
SYSTEM
85.
88.
98.
87.
89.
5
8
0
3
9
87
90
79
78
84
.3
.6
.8
.4
.0
89
93,
89
89.
90.
.9
.2
.6
.4
.5
78
81
71
70
75
.3
.2
.6
.3
.3
744 667
560 57.1
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-REUTED PROBLEMS WERE ENCOUNTERED
DURING JULY.
A
B
C
D
SYSTEM
95.0
97.4
91.6
96.5
95.1
95.0
97.4
91.1
93.5
94.3
98.5
98.3
96.9
97.6
97.8
95.0
97.4
91.1
93.5
94.3
744 744
702 69.4
13-197
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
CENTRAL ILLINOIS LIGHT: DUCK CREEK 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
502 PART. HOURS HOURS HOURS FACTOR
9/82
10/82
11/82
12/82
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING AUGUST.
A
B
C
D
SYSTEM
83.3
88.3
87.5
84.7
85.9
81.5
86.5
86.5
82.4
84.2
95.3
96.0
95.9
99.4
96.6
76.6
81.3
81.3
77.5
79.2
720 677
570 65.5
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING SEPTEMBER. SYSTEM AVAILABILITY WAS REDUCED ONLY BY BOILER OUTAGE
TIME. RELIABILITY MORE ACCURATELY REFLECTS THE OPERATION OF THE SCRUBBER
DURING SEPTEMBER.
A
B
C
D
SYSTEM
93.6
95.9
95.5
92.7
94.4
93.4
95.9
91.5
92.7
93.4
96.0
96.3
96.0
94.6
95.7
93.4
95.9
91.5
92.7
93.4
744 744
695 72.2
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMSS WERE ENCOUNTERED
DURING OCTOBER.
A
B
C
D
SYSTEM
64.7
65.5
65.6
66.7
65.6
85.0
90.1
89.5
90.8
63.9
97.4
97.7
97.6
97.8
97.6
56.7
60.1
59.7
60.5
59.2
720 460
426 43.8
** PROBLEMS/SOLUTIONS/COMMENTS
DURING NOVEMBER THE UNIT WAS DOWN FOR CLEANING AND INSPECTION OF THE
MODULES.
A
B
C
D
SYSTEM
83.0
87.0
87.1
83.8
85.2
76.3
85.7
87.1
83.2
83.1
88.4
89.3
89.3
89.2
89.2
76.3
85.7
87.1
83.2
83.1
744 744
618 63.0
** PROBLEMS/SOLUTIONS/COMMENTS
A MAJOR PROBLEM OCCURRED WITH THE LIMESTONE PREPARATION EQUIPMENT FROM
DECEMBER 16 TO 23, 1982. THE LIMESTONE BALL MILL MOTOR FAILED AND HAD TO
BE EXTENSIVELY REPAIRED. DURING THIS TIME AN EMERGENCY SYSTEM WAS SET UP
SO THAT LIMESTONE IN A POWDERED FORM COULD BE CONVEYED TO THE SCRUBBER.
1/83
A
B
C
D
SYSTEM
93.
91.
93.
83.
91.
1
9
3
8
7
96,
95,
96,
92.
95,
.9
.6
.1
.2
.2
99.
99.
99.
99.
99.
.9
,9
9
,9
,9
89.
87.
88.
84.
87.
0
9
3
8
5
744 684
651 63.8
13-198
-------
UTILITY FGD SURVEY'- OCTOBER 1983 - SEPTEMBER 1984
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/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-REUTED PROBLEMS WERE ENCOUNTERED
DURING JANUARY.
2/83
A
B
C
D
SYSTEM
61.9
61.4
62.3
57. 4
60.7
97.2
96.3
97.8
90.1
95.3
100.0
100.0
100.0
100.0
100.0
61.9
61.4
62.3
57.4
60.7
672 428
408 45.7
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS OFF LINE FROM FEBRUARY 18 TO 28,
STACK.
3/63 SYSTEM
.0
.0
1983 TO REPAIR THE EXHAUST
744 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
4/83 A
B
C
D
SYSTEM
THE UNIT WAS OFF LINE FOR THE ENTIRE MONTH OF MARCH TO CONTINUE REPAIRING
THE EXHAUST STACK.
.0 .0
.0 .0
.0 .0
.0 .0
.0 .0 720
.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS OFF LINE DURING APRIL TO CONTINUE STACK LINER REPAIRS.
5/33
A
B
C
D
SYSTEM
60
60
60
59
60
.8
.1
.2
.7
.2
85
94
87
92
89
.2
.0
.1
.0
.6
99
99
99
96
98
.1
.2
.1
.9
.6
53
59
54
57
56
.5
.0
.7
.8
.2
744 467
418 40.1
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS OUT OF SERVICE UNTIL MAY 13,
NANCE ON THE STACK LINER.
1983 DUE TO CONTINUED MAINTE-
6/83
A
B
C
D
SYSTEM
97
99
98
98
98
.3
.3
.5
.1
.3
95
96
95
96
95
.1
.3
.2
.6
.8
99.
99.
99.
98.
99.
3
4
3
6
1
95
96
95
96
95
.1
.3
.2
.6
.8
720 720
690 71.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING JUNE.
7/83
8/83 A
A
B
C
D
SYSTEM
100.0
100.0
100.0
100.0
100.0
98.7
97.7
98.0
97.8
98.1
100.0
100.0
100.0
100.0
100.0
98.7
97.7
98.0
97.8
98.1
744 744
730 71.7
100.0
96.4
100.0
96.4
13-199
-------
UTILITY FGD SURVEY: OCTOBER 1933 - SEPTEMBER 1984
CENTRAL ILLINOIS LIGHT: DUCK CREEK 1 (CONT.)
PERIOD
9/83
MODULE
B
C
D
SYSTEM
A
B
C
D
SYSTEM
AVAILABILITY
100.
97.
100.
99.
93.
100.
97.
99.
97.
0
8
0
5
3
0
2
7
6
OPERABILITY
9*
94
95
95
89
95
92
95
93
.4
.7
.3
.2
.4
.0
.5
.3
.0
PERPOKHAF
RELIABILITY
100
100
100
100
100
100
100
100
100
.0
.0
.0
.0
.0
.0
.0
.0
.0
^H-t UAIA
UTILIZATION
94
94
95
95
89
94
92
95
92
.4
.7
.3
.2
.1
.7
.3
.0
.8
/. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
744 744 70S 70.3
720 718 668 62.2
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE PERIOD OF JULY THROUGH SEPTEMBER, 1983.
10/83
11/83
A
B
C
D
SYSTEM
A
B
C
C
D
SYSTEM
99.9
100.0
100.0
100.0
100.0
97.5
100.0
100.0
100.0
98.6
99.2
95.7
98.3
98.2
97.5
97.4
91.0
91.9
94.0
94.0
91.6
92.5
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
76.8
78.9
78.8
78.3
78.2
81.9
82.7
84.6
84.6
82.5
83.3
744 597
582 54.6
720 648
600 55.2
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE UNIT WAS OFF LINE FROM OCTOBER 25 TO NOVEMBER
4, 1983.
12/83 A
A
B
C
D
SYSTEM
88.5
88.5
88.5
88.5
88.5
85.2
85.2
85.6
86.7
85.7
88.2
88.2
68.2
88.3
88.2
85.2
85.2
85.6
86.7
85.7
744 744
638 69.6
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT SEVERE COLD WEATHER BETWEEN DECEMBER 24 AND 23
DISABLED THE COAL AND LIMESTONE HANDLING EQUIPMENT. LIMESTONE COULD NOT BE
LOADED INTO THE FACILITY RESULTING IN THE LOSS OF THE LIMESTONE SLURRY
SUPPLY. ALL FOUR MODULES WERE CONSIDERED UNAVAILABLE DURING THIS PERIOD.
744 684 602 60.2
696 696 673 70.3
744 707 670 69.1
1/84
2/84
3/84
A
B
C
D
SYSTEM
A
B
C
D
SYSTEM
A
B
C
D
SYSTEM
94.
94.
94.
93.
94.
100.
100.
100.
100.
100.
100.
100.
97.
100.
99.
1
3
0
7
0
0
0
0
0
0
0
0
8
0
5
89
86
89
87
88
96
96
98
95
96
96
95
94
93
94
.0
.4
.2
.6
.0
.0
.9
.2
.8
.7
.1
.1
.2
.7
.8
93.
93.
93.
92.
93.
100.
100.
100.
100.
100.
100.
100.
99.
100.
99.
5
6
2
7
2
0
0
0
0
0
0
0
5
0
9
81.
79.
82.
80.
80.
96.
96.
98.
95.
96.
91.
90.
89.
89.
90.
9
4
0
S
9
0
9
2
8
7
3
4
5
1
1
13-200
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE EXPERIENCED
DURING THE FIRST QUARTER OF 1984.
4/84 A
B
C
D
SYSTEM
88.9
88.9
88.9
86.9
83.4
97.4
90.6
96.4
89.2
93.4
100.0
100.0
100.0
100.0
100.0
86.6
80.5
85.7
79.3
83.0
5/84
6/84
720 640
598 58.1
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS TAKEN OFF LINE ON APRIL 27 FOR INSPECTIONS AND MAINTENANCE.
A
B
C
D
SYSTEM
35.1
32.1
35.1
34.1
34.1
84.6
80.2
84.8
81.7
82.8
100.0
100.0
100.0
100.0
100.0
27.8
26.3
27.8
26.8
27.2
744 244
202 14.5
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS OFF LINE UNTIL MAY 20 DUE TO INSPECTION AND MAINTENANCE.
A
B
C
D
SYSTEM
99.6
99.4
99.6
99.1
99.4
95.4
95.3
94.1
94.6
94.8
99.5
99.4
99.5
99.5
99.5
89.5
89.4
88.3
88.8
89.0
720 676
641 64.4
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE UNIT WAS OFF LINE FROM JUNE 15 UNTIL JUNE 18
FOR UNSPECIFIED REASONS.
717 67.2
7/84 A
B
C
D
SYSTEM
99.5
99.5
99.5
99.5
99.5
98.2
97.9
98.4
92.7
96.8
99.9
99.9
99.9
99.9
99.9
97.8
97.5
98.0
92.3
96.4
744 741
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR FGD-RELATED PROBLEMS WERE REPORTED DURING JULY.
8/84 SYSTEM 744
9/84 SYSTEM 720
»* PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR AUGUST AND SEPTEMBER 1984.
13-201
-------
UTILITY FGO SURVEY: OCTOBER 1983 - SEPTEMBER 1984
SECTION 13
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 - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT 7.
AVERAGE CHLORIDE CONTENT 7.
RANGE CHLORIDE CONTENT 7.
*** PARTICLE CONTROL
.100 LB/MMBTU)
1.200 LB/MMBTU)
<****** LB/MMBTU)
CENTRAL ILLINOIS PUBLIC SERV
NEWTON
1
NEWTON
ILLINOIS
D
43.
516.
******
575
617
575
590
617
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
(2163480 ACFM)
( 327 F)
1020.95
163.9
162.
CONCRETE
*******
COAL
BITUMINOUS
25353.
12.70
******
9.50
******
3.00
2.8-3.2
.20
******
( 530 FT)
(***** FT)
( 10900 BTU/LB)
******
** MECHANICAL COLLECTOR
NUM3ER
TYPE
** FABRIC FILTER
NUMBER
TYPE
** 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
TRADE NAME/COMMON NAME
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
0
NONE
0
NONE
COLD SIDE
RESEARCH-COTTRELL
1080.7 (2290000 ACFM)
162.8 ( 325 F)
.0 (0. IN-H20)
99.5
0
NONE
N/A
N/A
N/A
N/A
N/A
N/A
13-202
-------
CENTRAL ILLINOIS PUBLIC SERV: NEWTON 1 (CONT.)
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
*«* 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 - '/.
ENERGY CONSUMPTION - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
DESIGN COAL SULFER CONTENT - X
** QUENCHER/PRESATURATOR
NUMBER
TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
** 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
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** REHEATER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE N4ME/COMMON TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
THROWAWAY PRODUCT
WET SCRUBBING
DUAL ALKALI
GE ENVIRONMENTAL SERVICES
BUELL DIVISION, ENVIROTECH
FULL SCALE
NEW
/. 99.50
90.00
2.4
1
12/79
9/79
8/75
4.00
PRECOOLER
NR
4
0
PACKED TOWER
MOBILE BED PACKING
POLYSPHERE SCRUBBER
BUELL DIVISION, ENVIROTECH
18.0 X 48.0 X 72.0
CARBON STEEL
AISI 1110
N/A
ORGANIC
GLASS FLAKE-FILLED POLYESTER
NR
PLASTIC/RUBBER MOBILE BALLS
1
7
45.
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)
PRIMARY COLLECTOR
8
IMPINGEMENT
BAFFLE
CLOSED VANE
VERTICAL
NR
NR
1
BYPASS
COLD SIDE
N/A
NR
NR
** FANS
NUMBER
DESIGN
CENTRIFUGAL
13-20-
-------
UTILITY FGD SURVEY'- OCTOBER 1983 - SEPTEMBER
CENTRAL ILLINOIS PUBLIC SERV: NEWTON 1 (CONT.)
FUNCTION
APPLICATION
SERVICE
CONSTRUCTION MATERIAL GENERIC TYPE
** DAMPERS
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
»* TANKS
SERVICE
NR
** PUMPS
SERVICE
NR
BOOSTER
FORCED DRAFT
DRY
CARBON STEEL
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
SLAKER
NR
NR
MIX TANK
N/A
AGITATED TANK
NUMBER
****
NUMBER
*»**
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
DIMENSIONS - FT
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
DIMENSIONS FT
SHELL GENERIC MATERIAL TYPE
*** SLUDGE
»* TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
*» DISPOSAL
NATURE
TYPE
SITE TREATMENT
VACUUM FILTER
1
THICKENER
£
100.0 DIA
INORGANIC
HYDRAULICALLY-BONDED CONCRETE
THICKENER
1
100.0 DIA
CARBON STEEL
FIXATION
PUG MILL
CONVERSION SYSTEMS IPOZ-0-TEC1
FINAL
LANDFILL
NR
13-204
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
CENTRAL ILLINOIS PUBLIC SERV: NEWTON 1 (CONT.)
** WATER BALANCE
WATER LOOP TYPE CLOSED
** FGD SPARE CAPACITY INDICES
ABSORBER - X 33.0
*» FGD 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
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 720
«* 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 INCLUDED 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
2/80
744 723 336
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JANUARY TESTS WERE CONDUCTED TO CERTIFY THE GAS EMISSIONS MONITOR
AT NEWTON.
PRESATURATOR CORROSION AND EXPANSION JOINT REPAIRS AND A DEPLETION OF THE
FLYASH USED FOR SLUDGE STABILIZATION ACCOUNTED FOR THE LOW JANUARY
DEPENDABILITY FIGURES.
696 696 273
A
B
C
D
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
13-205
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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
** 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
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/SOLUTIOHS/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
BLOWS 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
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
.0
.0
.0
.0
13-206
-------
UTILITY FGD SURVEY: OCTOBER 1933 - SEPTEMBER 1984
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
B
C
D
SYSTEM
40.3
40.4
.0
20.2
40
40
20
.3
.4
.0
.2
40
40
20
.3
.4
.0
.2
40.
40.
20.
3
4
0
2
720
720
145
63.0
7/80
8/80
9/80
10/80
** 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.
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.
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
80.8
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.
A
B
C
D
SYSTEM
75.9
83.7
81.0
62.4
81.5
38.5
47.9
51.6
7.0
48.4
46.3
56.5
54.5
13.7
46.3
16.9
21.1
22.7
3.1
21.3
744 328
119 30.4
13-207
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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
** PROBLEMS/SOLUTIONS/COMMENTS
1/81
2/81
3/81
4/81
DURING 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
84.9
98. 3
100.0
97.2
99.0
100.0
69.9
59.9
58.8
70.0
84.3
720 719
465 69.6
** PROBLEMS/SOLUTIONS/COMMENTS
12/80 A
THE UTILITY REPORTED THAT NO MAJOR OUTAGES OCCURRED DURING NOVEMBER.
744 741
A
B
C
D
SYSTEM
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
70.7
** PROBLEMS/SOLUTIONS/COMMENTS
FGD SYSTEM AVAILABILITY WAS LOWERED DURING DECEMBER AS A RESULT OF
THICKENER PLUGGING PROBLEMS.
A
B
C
D
SYSTEM
A
B
C
D
SYSTEM
A
B
C
D
SYSTEM
90
73
96
88
99
93
96
92
100
100
94
87
86
94
90
.5
.9
.2
.3
.1
.2
.0
.3
.0
.0
.1
.1
.4
.1
.4
75
58
79
57
89
49
81
72
82
95
56
80
65
65
67
.0
.1
.8
.1
.5
.8
.1
.3
.4
.1
.9
.6
.9
.5
.2
99.
99.
100.
100.
100.
100.
100.
100.
100.
100.
100.
100.
100.
100.
100.
1
5
0
0
0
0
0
0
0
0
0
0
0
0
0
75
53
79
57
89
49
81
72
82
94
52
75
61
60
62
.0
.1
.8
.1
.5
.7
.0
.2
.3
.9
.7
.0
.0
.6
.2
744 744 425 71.4
672 671 639 66.6
744 689 463 63.3
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE FIRST QUARTER 1981.
A
B
C
D
SYSTEM
96.1
98.2
96.1
93.6
99.9
73.3
82.8
60.6
85.1
94.5
100.0
100.0
100.0
100.0
100.0
73.3
82.8
60.6
85.1
94.5
720 720
680 73.2
»* PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING APRIL.
5/81 A
93.3
66.9
98.3
61.4
13-208
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 198*
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
B
C
D
SYSTEM
85
91
93
100
.3
.9
.4
.0
78.
76.
43.
88.
0
6
2
3
98.5
98.5
97.4
98.4
71
70
39
81
.6
.3
.7
.0
744
683
603
60.5
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGO-RELATED PROBLEMS WERE ENCOUNTERED
DURING MAY.
6/81 A
B
C
D
SYSTEM
96.5
92.
88.
96.
100,
64.9
72.1
46.4
92.2
91.9
100.0
100.0
100.0
100.0
100.0
64.6
71.
46.
91.
91.
720 716
658 64.3
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JUNE NO MAJOR FGO-RELATED PROBLEMS WERE ENCOUNTERED.
7/81
8/81
9/81
A
B
C
D
SYSTEM
A
B
C
D
SYSTEM
A
B
C
D
SYSTEM
79.6
85.3
84.5
82.5
89.2
92.7
90.5
100.0
81.3
100.0
88.8
99.0
100.0
97.9
100.0
44.5
64.6
35.0
68.2
70.2
55.6
64.5
67.1
57.0
81.6
45.3
78.4
79.5
38.8
80.7
79.2
84.8
74.3
84.9
98.9
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
42.9
62.2
33.7
65.7
67.6
55.6
64.5
67.1
57.0
81.6
38.9
67.4
68.3
33.3
69.3
744 717
744 744
720 619
503 55.4
607 57.9
499 47.2
*# PROBLEMS/SOLUTIONS/COMMENTS
A SCHEDULED MAINTENANCE OUTAGE (BOTH BOILER AND FGD SYSTEM) BEGAN ON
SEPTEMBER 26.
10/81 SYSTEM 100.0
.0
.0
.0
744
.1
** PROBLEMS/SOLUTIONS/COMMENTS
DURING OCTOBER A SCHEDULED MAINTENANCE OUTAGE OF THE GENERATING UNIT
OCCURRED.
11/81
12/81
A
B
C
D
SYSTEM
A
B
C
D
SYSTEM
98.6
85.8
97.5
85.7
100.0
94.8
84.8
100.0
100.0
100.0
63.9
27.8
55.5
61.3
69.5
55.8
42.2
82.0
73.5
84.5
76.2
63.0
73.0
73.1
95.1
99.8
100.0
100.0
100.0
100.0
63.5
27.6
55.1
60.8
68.7
53.8
40.7
79.0
70.8
81.4
720
715
744 717
497 61.1
612 52.6
13-209
-------
UTILITY FGO SURVEY: OCTOBER 1983 - SEPTEMBER 198*
CENTRAL ILLINOIS PUBLIC SERV: NEWTON 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
1/82
3/82
3/82
DURING NOVEMBER AND DECEMBER THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED
PROBLEMS WERE ENCOUNTERED.
A
B
C
D
SYSTEM
A
B
C
D
SYSTEM
A
B
C
D
SYSTEM
100.
100.
50.
93.
100.
90.
93.
100.
91.
100.
90.
93.
80.
90.
100.
0
0
5
4
0
0
8
0
1
0
9
1
8
5
0
58
97
42
79
92
37
79
92
82
97
40
91
61
61
85
.5
,9
.3
.6
.7
.2
.6
.1
.0
.0
.1
.4
.7
.7
.2
100
100
100
100
100
100
100
100
100
100
84
92
90
89
100
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.2
.4
.0
.1
.0
58
97
42
79
92
37
79
92
82
97
40
91
61
61
85
.2
.4
.1
.3
.3
.2
.6
.1
.0
.0
.1
.4
.7
.7
.2
744 740
672 672
744 744
687 63.5
652 70.1
634 66.4
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE FIRST QUARTER 1982.
720 550 467 43.3
744 209 161 13.1
720 719 510 38.2
4/82
5/82
6/82
A
B
C
D
SYSTEM
A
B
C
D
SYSTEM
A
B
C
D
SYSTEM
100
98
94
95
100
71
100
100
99
100
99
100
98
99
.0
.2
.9
.0
.0
.0
.0
.0
.3
.0
.0
.7
.0
.3
.4
60
78
91
23
85
94
40
95
76
97
62
52
71
.9
.9
.7
.5
.0
.0
.3
.7
.7
.9
.0
.7
.7
.6
.0
100.
100.
100.
100.
100.
100.
100.
100.
100.
100.
100.
100.
100.
0
0
0
0
0
0
0
0
0
0
0
0
0
46.
60.
70.
17.
64.
26.
11.
26.
21.
97.
62.
52.
70.
5
3
0
9
9
0
5
4
9
6
0
5
6
5
9
»* PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE SECOND QUARTER.
7/82
8/82
A
B
C
D
SYSTEM
A
B
C
D
SYSTEM
22.
86.
94.
98.
97.
98.
93.
100.
99.
3
6
1
9
8
5
0
9
0
1
14.
79.
50.
81.
75.
97.
76.
48.
74.
0
8
0
1
2
8
0
2
4
2
92
98
97
98
100
99
100
100
99
.8
.8
.4
.7
.0
.5
.0
.0
.8
13
79
49
80
74
97
76
48
74
.&
.0
.S
.2
.4
.8
.0
.2
.4
.2
744 737
744 744
553 45.5
522 43.7
13-210
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
CENTRAL ILLINOIS PUBLIC SERV: NEWTON 1 (CONT. )
PERIOD
9/82
MODULE
A
B
C
0
SYSTEM
AVAILABILITY
100
100
100
100
.0
.0
.0
.0
.0
OPER ABILITY
78.7
.0
70.8
71.2
73.6
rcKruxnAr
RELIABILITY
100
100
100
100
.0
.0
.0
.0
^<-e UAIA
UTILIZATION
76.4
.0
68.8
69.2
71.4
'/. REMOVAL PER
S02 PART. HOURS
720
BOILER
HOURS
699
FGD
HOURS
514
CAP.
FACTOR
41.6
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE THIRD QUARTER OF 1982.
744 736 559 50.6
720 624 458 38.9
744 504 370 30.5
10/82
11/82
12/82
A
B
C
D
SYSTEM
A
B
C
D
SYSTEM
A
B
C
D
SYSTEM
48.3
48.4
96.5
93.3
95.5
.0
92.4
95.4
97.1
96.8
51.1
94.6
91.1
74.6
93.3
45.7
35.5
58.8
87.8
75.9
.0
88.0
42.1
89.9
73.3
35.1
70.8
45.4
63.1
73.4
90.8
96.0
94.3
96.1
100.0
97.9
95.3
97.7
97.4
91.7
96.0
94.2
96.4
100.0
45.2
35.1
58.2
86.8
75.1
.0
76.3
36.5
77.9
63.6
23.8
48.0
30.8
42.7
49.7
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE FOURTH QUARTER OF 1982.
744 504 544 48.0
672 672 500 54.4
744 744 606 64.4
1/83
2/83
3/83
A
B
C
D
SYSTEM
A
B
C
D
SYSTEM
A
B
C
D
SYSTEM
77
100
99
88
100
99
41
100
100
99
81
94
19
94
97
.3
.0
.3
.3
.0
.6
.8
.0
.0
.9
.7
.4
.4
.1
.6
28
134
39
121
77
70
36
18
100
74
56
94
3
94
81
.0
.7
.3
.6
.5
.5
.0
.2
.0
.3
.9
.1
.0
.1
.5
100.
100.
88.
100.
100.
100.
99.
100.
100.
100.
100.
99.
100.
100.
99.
0
0
8
0
0
0
2
0
0
0
0
7
0
0
7
19
91
26
82
73
70
36
18
100
74
56
94
3
94
81
.0
.3
.6
.4
.1
.5
.0
.2
.0
.3
.9
.1
.0
.1
.5
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE FIRST QUARTER OF 1983.
4/83 A
B
C
D
SYSTEM
99.4
97.8
.0
93.3
96.8
95.6
89.3
.0
88.9
91.3
100.0
100.0
100.0
100.0
95.6
89.3
.0
88.9
100.0
720 720
720 76.8
13-211
-------
UTILITY FGO SURVEY: OCTOBER 1983 - SEPTEMBER 1984
CENTRAL ILLINOIS PUBLIC SERV: NEWTON 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
7/83
9/83
MODULE C WAS OUT OF SERVICE DURING THE ENTIRE MONTH OF APRIL FOR LINING
REPAIRS.
5/83
A
B
C
D
SYSTEM
100.0
100.0
.0
100.0
100.0
100.0
50.0
.0
100.0
83.5
100.0
100.0
100-.0
100.0
1.3
.7
.0
1.3
1.1
744
10
.6
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS REMOVED FROM SERVICE ON MAY 1 FOR AN ANNUAL MAINTENANCE
OUTAGE.
MODULE C REMAINED OUT OF SERVICE DURING MAY FOR REPAIR OF THE FLAKEGLASS
LINING.
6/83 A
B
C
D
SYSTEM
99.9
100.0
100.0
.0
99.9
77.9
71.2
73.6
.0
76.2
99.7
100.0
100.0
100.0
45.0
42.5
.0
44.0
720 416
317 43.1
»* PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT REMAINED OUT OF SERVICE UNTIL JUNE 15 FOR THE ANNUAL MAINTENANCE
OUTAGE.
MODULE D WAS OUT OF SERVICE ALL MONTH FOR REPAIR OF THE FLAKEGLASS LINING.
A
B
C
D
SYSTEM
100.0
98.9
100.0
.0
99.6
93.3
98.9
100.0
.0
97.4
100.0
100.0
100.0
100.0
93.3
93.9
100.0
.0
97.4
744 744
725
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE D WAS OUT OF SERVICE DURING THE ENTIRE MONTH OF JULY FOR ABSORBER
LINING REPAIRS.
8/83 A
B
C
D
SYSTEM
100.0
94.6
100.0
16.8
100.0
87.0
82.9
99.6
15.1
94.8
100.0
100.0
100.0
100.0
100.0
87.0
82.9
99.6
15.1
94.8
744 744
706
** PROBLEMS/SOLUTIONS/COMMENTS
ABSORBER LINER REPAIRS AT MODULE D CONTINUED IN AUGUST.
A
B
C
D
SYSTEM
65.9
71.3
100.0
100.0
100.0
56.7
32.8
94.9
96.7
93.7
99.3
100.0
100.0
100.0
100.0
56.7
32.8
94.9
96.7
93.7
720 720
674 85.2
13-212
-------
UTILITY FGO SURVEY: OCTOBER 1983 - SEPTEMBER 1984
CEKTRAL 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
** PROBLEMS/SOLUTIONS/COMMENTS
10/83
1/84
MODULE A WAS UNAVAILABLE DURING PART OF SEPTEMBER DUE TO REPAIR OF THE
ABSORBER'S FLAKEGLASS LINING.
MODULE B WAS UNAVAILABLE DURING PART OF SEPTEMBER DUE TO SCALE AND TRASH
BUILD UP IN THE RECIRCULATION PUMP SUCTION STRAINERS CAUSING PLUGGING PROB-
LEMS.
A
B
C
D
SYSTEM
82.3
61.3
100.0
84.7
100.0
57.8
31.9
68.8
57.8
72.1
100.0
100.0
100.0
100.0
100.0
57.8
31.9
68.8
57.8
72.1
744 744
536
.0
** PROBLEMS/SOLUTIONS/COMMENTS
MODULES A AND D WERE DOWN DURING PART OF OCTOBER DUE TO DUCTWORK LINING
REPAIRS.
MODULE B WAS OUT OF SERVICE DURING PART OF THE MONTH DUE TO PUMP PACKING
SLEEVE FAILURE.
11/83 A
B
C
D
SYSTEM
100.0
10.6
98.9
100.0
100.0
99.8
.0
98.4
96.7
98.3
100.0
100.0
100.0
100.0
85.0
.0
83.8
82.4
63.7
720 613
603
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE B WAS DOWN DURING NOVEMBER DUE TO RECIRCULATING PUMP FAILURE.
12/83 A
B
C
D
SYSTEM
80.6
93.5
91.9
98.1
100.0
67.3
88.4
57.3
89.5
100.0
100.0
99.1
95.1
99.5
100.0
57.9
76.1
49.3
77.0
86.8
744 640
646
** PROBLEMS/SOLUTIONS/COMMENTS
A UNIT OUTAGE OCCURRED FROM DECEMBER 1 TO DECEMBER 5, 1983.
744 744
A
B
C
D
SYSTEM
98.1
61.3
93.1
99.9
100.0
93.1
41.0
49.7
89.9
91.3
99.9
99.7
99.7
99.9
100.0
93.1
41.0
49.7
89.9
91.3
679
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING JANUARY.
2/84 A
B
C
D
SYSTEM
59.5
92.8
92.7
88.8
100.0
12.0
97.6
64.5
52.4
82.2
100.0
100.0
100.0
100.0
100.0
10.2
83.2
72.0
44.7
70.0
696 593
487
13-213
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
CENTRAL ILLINOIS PUBLIC SERV: NEWTON 1 (CONT.)
____ PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERA8ILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
SOS PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE A WAS UNAVAILABLE DURING PART OF FEBRUARY DUE TO A PLUGGED SPRAY
NOZZLE.
3/84
A
B
C
D
SYSTEM
89.0
100.0
100.0
89.7
100.0
9.9
98.5
99.2
51.6
86.4
100.0
100.0
100.0
100.0
100.0
9.5
95.0
95.7
49.7
83.3
744 718
620
*» PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING MARCH.
4/84
A
B
C
0
SYSTEM
81.1
94.7
100.0
38.5
100.0
55.6
88.2
90.5
28.0
87.5
100.0
100.0
105.4
100.0
100.0
50.1
79.6
81.7
25.3
78.9
720 650
568
5/84
*« PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE UNIT WAS REMOVED FROM SERVICE APRIL 28 FOR
MAINTENANCE.
A 100.0 .0
B 100.0 .0
B 100.0 .0
C 100.0 .0
D 100.0 .0
SYSTEM 100.0 .0 744 0 0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT REMAINED OUT OF SERVICE THROUGHOUT MAY DUE TO THE ANNUAL
MAINTENANCE OUTAGE.
6/84
A
B
C
D
SYSTEM
.0
57.2
56.9
56.1
56.8
.0
96.8
61.2
74.4
77.5
99.7
98.7
98.6
99.0
.0
51.0
32.2
39.2
40.8
** PROBLEMS/SOLUTIONS/COMMENTS
720 379
294
7/84
8/84
THE UTILITY REPORTED THAT MODULE A WAS BEING RELINED DURING JUNE.
A
B
C
D
SYSTEM
62.5
100.0
100.0
100.0
100.0
53.5
50.3
34.4
82.1
73.4
100.0
100.0
100.0
100.0
100.0
53.5
50.3
34.4
82.1
73.4
744 744
546
*# PROBLEMS/SOLUTIONS/COMMENTS
94.0
100.0
85.6
RE LINING CONTINUED AT MODULE A DURING JULY.
40.5
65.2
21.7
100.0
100.0
100.0
40.1
64.5
21.5
13-214
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
CEKTRAL ILLINOIS PUBLIC SERV: NEWTON 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
D 88.3 72.6 100.0 71.9
SYSTEM 100.0 66.7 100.0 66.0 744 737 491
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD RELATED PROBLEMS AROSE IN AUGUST.
9/84 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR SEPTEMBER 1984.
13-215
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
SECTION 13
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/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
CINCINNATI 6A
EAST BEND
Z
RABBIT HASH
KENTUCKY
C
43.
516.
301.
650
650
600
619
650
S t ELECTRIC
( .100 LB/MMBTU)
( 1.200 LB/MMBTU)
( .700 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 - '/.
AVERAGE MOISTURE CONTENT-3- 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
NUMBER OF SPARES
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
TRADE NAME/COMMON NAME
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
BABCOCK & WILCOX
PULVERIZED COAL
BASE
1763.96
357.2
198.
CONCRETE
7.2
COAL
BITUMINOUS
25586.
11.90
9.0-14.0
10.00
9.0-11.0
2.60
1.0-4.0
*»#*»»**
******
0
NONE
0
NONE
1
0
HOT SIDE
WESTERN PREC.
1764.0
357.2
.1
99.6
0
NONE
N/A
N/A
N/A
N/A
N/A
N/A
(3738000 ACFM)
( 675 F)
( 650 FT)
( 23.5 FT)
( 11000 BTU/LB)
10800-13000
DIVISION, JOY
(3738000 ACFM)
( 675 F)
( 1. IN-H20)
13-216
-------
CINCINNATI GAS & ELECTRIC: EAST BEND Z (CONT.)
UTILITY FGO SURVEY: OCTOBER 1983 - SEPTEMBER 1984
**« 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 - X
ENERGY CONSUMPTION - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
DESIGN COAL SULFER CONTENT - X
DESIGN COAL HEAT CONTENT - J/G
DESIGN COAL ASH CONTENT - X
DESIGN MOISTURE CONTENT - X
SPACE REQUIREMENTS - SQ M
OPER. & MAINT. REQUIREMENT - MANHR/DAY
** QUEHCHER/PRESATURATOR
NUMBER
TYPE
SUPPLIER
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
PRESSURE DROP - KPA
LIQUID RECIRCULATION RATE - LITERS/S
L/G RATIO - L/CU. M
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** 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
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
NUMBER OF SPARES PER SYSTEM
NUMBER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
THROWAWAY PRODUCT
WET SCRUBBING
LIME
NONE
BABCOCK t WILCOX
SARGENT * LUNDY
FULL SCALE
NEW
/. 99.00
87.00
2.9
1
3/81
3/81
3/78
5.10
25586.0
11.90
10.00
13461.2
3
VENTURI
BABCOCK S
398.49
136.7
.2
552.
1.3
CARBON STEEL
AISI 1110
( 11000 BTU/LB)
( 144900 SQ FT)
WILCOX
844433 ACFM)
278 F)
1.0 IN-H20)
8760 GPM)
10.0 GAL/1000 ACFM)
3
0
COUNTER CURRENT TRAY TOWER
SIEVE TRAY
N/A
BABCOCK t WILCOX
43.0 DIA X 95.0
STAINLESS STEEL
AUSTENITIC
TYPE 316
NA
NA
NA
PERFORATED TRAYS
1
2205.
6.7
.6
2.4
329.66
50.6
87.0
(35000 GPM)
( 50.0 GAL/1000 ACF)
( 2.5 IN-H20)
( 8.0 FT/S)
( 698585 ACFM)
( 123 F)
PRIMARY COLLECTOR
6
0
2
IMPINGEMENT
BAFFLE
13-217
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
CINCINNATI GAS 4 ELECTRIC: EAST BEND 2 (CONT.)
TRADE NAME/COMMON TYPE
MANUFACTURER
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
CONSTRUCTION MATERIAL SPECIFIC TYPE
WASH WATER SOURCE
WASH FREQUENCY
WASH RATE - L/S
** REHEATER
NUMBER
NUMBER OF SPARES
NUMBER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
LOCATION
TEMPERATURE INCREASE - C
INLET FLUE GAS TEMPERATURE - C
NUMBER OF HEAT EXCHANGER BANKS
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
CLOSED VANE
BABCOCK & WILCOX
HORIZONTAL
2
1
2.13 C 7.0 FT)
182.88 C72.0 IN)
7.6 ( 3.00 IN)
90
.1 ( .5 IN-H20)
2.4 ( 8.0 FT/S)
ORGANIC
FIBER-REINFORCED POLYESTER
BLENDED
INTERMITTENT
58.4 ( 926 GAL/MIN)
1
0
0
INDIRECT HOT AIR
STEAM
STEAM TUBE BUNDLE
PLENUM COMBINING GAS FLOW FROM INDIVIDUAL ABSORB
13.9 ( 25 F)
51.7 ( 125 F)
2
NA
NA
»* FANS
NUMBER
NUMBER OF SPARES
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE C
PRESSURE DROP - KPA
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
PRESSURE DROP KPA
CONSTRUCTION MATERIAL GENERIC TYPE
»* FANS
NUMBER
NUMBER OF SPARES
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
CONSTRUCTION MATERIAL GENERIC TYPE
»* DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
4
0
CENTRIFUGAL
WESTINGHOUSE
UNIT
INDUCED DRAFT
DRY
1175.12
136.7
7.3
CARBON STEEL
2
0
CENTRIFUGAL
WESTINGHOUSE
UNIT
FORCED DRAFT
DRY
639.25
37.8
5.3
CARBON STEEL
3
0
CENTRIFUGAL
WESTINGHOUSE
BOOSTER
INDUCED DRAFT
DRY
CARBON STEEL
3
SHUT-OFF
LOUVER
(2490185 ACFM)
( 278 F)
(23.8 IN-H20)
(1354635 ACFM)
( 100 F)
(17.5 IN-H20)
13-218
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
CINCINNATI GAS 4 ELECTRIC: EAST BEND 2 (CONT.)
SPECIFIC TYPE
MANUFACTURER
MODULATION
SERVICE CONDITIONS
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
FUNCTION
MODULATION
** DUCTWORK
LOCATION
CONFIGURATION
DIMENSIONS
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
»* REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
MANUFACTURER
NUMBER
NUMBER OF SPARES
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
PRODUCT QUALITY - X SOLIDS
** TANKS
SERVICE
ABSORBER RECYCLE
REAGENT PREP PRODUCT
THICKENER OVERFLOW
THICKENER UNDERFLOW
** PUMPS
SERVICE
FEED SLURRY
ABSORBER RECIRCULATION
QUENCHER RECIRCULATION
THICKENER UNDERFLOW
CLARIFIED RECYCLE
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
CONFIGURATION
DIMENSIONS FT
CAPACITY
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
BELT GENERIC MATERIAL TYPE
BELT SPECIFIC MATERIAL TYPE
FEED STREAM SOURCE
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
OVERFLOW STREAM CHARACTERISTICS
OUTLET STREAM DISPOSITION
OVERFLOW STREAM DISPOSITION
OPPOSED BLADE
BABCOCK 4 WILCOX
OPEN
278
CARBON STEEL
NR
NR
NR
CONTROL
OPEN
AFTER SCRUBBER
CIRCULAR
17 FT. DIAMETER
CARBON STEEL
NR
NR
40 MILS PLASITE 4005/2 INCHES KAOCRETE HS
SLAKER
COMPARTMENTED
PASTE
WALLACE & TIERNAN
8
2
3.6 ( 4 TPH)
15.8
NUMBER
3
1
1
1
NUMBER
2
12
6
4
2
VACUUM FILTER
4
0
HORIZONTAL-PARALLEL
12 FT. DIAMETER X 20 FT.
22 TONS/HR
CARBON STEEL
AISI 1110
ORGANIC
POLYPROPYLENE
RUBBER
USBM 28
THICKENER UNDERFLOW
668 GPM, 30X SOLIDS
47.5X SOLIDS
200 GPM, 30X SOLIDS
MIXED WITH FLYASH & LIME
THICKENERS
13-219
-------
UTILITY F6D SURVEY: OCTOBER 1983 - SEPTEMBER 1984
CINCINNATI GAS t ELECTRIC: EAST BEND 2 (CONT.)
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
CONFIGURATION
DIMENSIONS - FT
CAPACITY
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
BELT GENERIC MATERIAL TYPE
BELT SPECIFIC MATERIAL TYPE
FEED STREAM SOURCE
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
OVERFLOW STREAM CHARACTERISTICS
OUTLET STREAM DISPOSITION
OVERFLOW STREAM DISPOSITION
*** SLUDGE
FULL LOAD SLUDGE QUANTITY - M.TONS/HR (DRY)
MOISTURE CONTENT - 7. TOTAL FREE WATER
X CAS03 - DRY
X CAS04 - DRY
X CAOH2 - DRY
X CAC03 - DRY
X ASH DRY
X SODIUM COMPOUNDS - DRY
X OTHER COMPOUNDS - DRY
«* TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
INLET FLOW RATE - LITER/S
INLET QUALITY - X
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE TREATMENT
SITE DIMENSIONS
SITE CAPACITY - CU.M
SITE SERVICE LIFE - YRS
»* WATER BALANCE
WATER LOOP TYPE
EVAPORATION WATER LOSS - LITER/S
SLUDGE HYDRATION WATER LOSS - LITER/S
SLUDGE INTERSTITIAL WATER LOSS - LITERS/S
POND SEEPAGE/RUNOFF WATER LOSS - LITERS/S
EFFLUENT WATER LOSS - LITERS/S
RECEIVING WATER STREAM
MAKEUP WATER ADDITION - LITERS/S
SOURCE OF MAKEUP WATER
** CHEMICALS AND CONSUMPTION
FUNCTION
NAME
PRINCIPAL CONSTITUENT
SOURCE/SUPPLIER
CONSUMPTION
UTILIZATION - X
POINT OF ADDITION
THICKENER
Z
0
CYLINDRICAL
190.0 DIA X 25.0
5000000 GALLONS
CARBON STEEL
N/A
POLYESTER RESIN
FLAKE GLASS
N/A
N/A
ABSORBER BLEED
1458 GPM, 7X SOLIDS
655 GPM, 30X SOLIDS
1129 GPM, OX SOLIDS
PUMPED TO WASTE STABILIZATION SYSTEM
RECYCLED
16.6 ( IS.3 TPH)
75.0
77.0
17.0
3.0
1.0
.0
.0
2.0
FIXATION
PUG MILL
CONVERSION SYSTEMS IPOZ-0-TEC]
42.1 ( 668 GPM)
30.0
FINAL
LANDFILL
ON-SITE
TRUCK
UNLINED
160 ACRES/120 FEET
23481600 ( 19200.0 ACRE-FT)
35
CLOSED
21.9
.4
6.9
0
.0
NONE
29.2
OHIO RIVER
( 348 GPM)
( 7 GPM)
( 109 GPM)
( 0 GPM)
( 464 GPM)
ABSORBENT
THIOSORBIC LIME
90X CAO, 5X MGO, 5X INERT
DRAVO LIME
250 TONS/DAY
96.6
RECIRCULATION TANK
13-220
-------
CINCINNATI GAS 4 ELECTRIC: EAST BEND 2 (CONT.)
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
** FGD SPARE CAPACITY INDICES
SCRUBBER - X
ABSORBER - X
MIST ELIMINATOR - X
REHEATER - X
FAN - X
SLAKER - X
EFFLUENT HOLD TANK
RECIRCULATION PUMP
THICKENER - X
VACUUM FILTER - X
*# FGD SPARE COMPONENT INDICES
SCRUBBER
ABSORBER
MIST ELIMINATOR
REHEATER
FAN
SLAKER
EFFLUENT HOLD TANK
RECIRCULATION PUMP
THICKENER
VACUUM FILTER
.0
.0
.0
.0
.0
2S.o
.0
25.0
.0
.0
.0
.0
.0
.0
.0
2.0
.0
3.0
.0
.0
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
3/81
A
B
C
SYSTEM
98.
97.
74.
100.
3
6
4
0
55
48
.j
51
.3
.4
.0
.8
100
100
100
.0
.0
.0
14.
12.
.
13.
1
4
0
2 47.70
744 190 99 12.6
** PROBLEMS/SOLUTIONS/COMMENTS
S/81
THE FGD SYSTEM BEGAN INITIAL AND COMMERCIAL OPERATIONS IN MARCH 1981. NO
MAJOR PROBLEMS WERE ENCOUNTERED DURING THIS TIME.
4/81 A
B
C
SYSTEM
5/81 A
B
C
SYSTEM
6/81 A
B
C
SYSTEM
96.
89.
86.
100.0
69.2
50.6
47.9
83.8
84.5
71.5
41.2
98.6
76.6
35.9
10.
61.
.3
.5
100.0
67.8
94.9
100.0
82.4
44.8
72.0
99.6
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
59.0
43.2
40.8
71.5
60.
28.
8.
48.
70.
38.
61.
85.2
78.70
96.10
84.60
720 614 515 60.4
744 586 360 41.4
720 616 614 62.6
»* PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE FGD SYSTEM HAS OPERATED SINCE MID-MARCH WITH
NO MAJOR PROBLEMS.
7/81 A
B
C
SYSTEM
A
B
C
SYSTEM
89.3
91.7
97.4
100.0
45.9
96.0
97.5
100.0
56.4
72.0
57.2
92.7
15.8
92.5
81.8
95.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
56.3
71.9
57.1
92.6
15.3
89.7
79.3
92.1
92.40
82.30
744 743
744 721
689 79.6
685 76.2
13-221
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
CINCINNATI GAS & ELECTRIC: EAST BEND Z (CONT.)
. PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
9/81
A
B
C
SYSTEM
85.
96.
33.
100.
7
6
5
0
67.
84.
10.
81.
5
6
4
3
100
100
100
100
.0
.0
.0
.0
62
78
9
75
.9
.8
.7
.7 77.40
720 671 545 65.3
1/82
2/82
3/82
4/82
5/82
6/82
7/82
8/82
** PROBLEMS/SOLUTIONS/COMMENTS
THE ONLY PROBLEM ENCOUNTERED DURING THE THIRD QUARTER INVOLVED ONE OF
THE TWO THICKENERS. THE PROBLEM NECESSITATED USE OF THE EMERGENCY ASH
POND FOR A SHORT PERIOD OF TIME TO HANDLE THE SLUDGE BEING GENERATED.
THE UTILITY REPORTED THAT TESTING WITH STRAIGHT LIME WILL TAKE PLACE FOR
A TWO TO THREE MONTH PERIOD BEGINNING IN NOVEMBER. CURRENTLY, THIOSORBIC
LIME IS BEING USED. THE FGD SYSTEM WAS DESIGNED TO OPERATE WITH STRAIGHT
LIME AS THE REAGENT AND, AS SUCH, THE TESTING WILL BE PERFORMED TO SEE IF
THE SYSTEM CAN MEET DESIGN GUARANTEES.
10/81
11/81
12/81
A
B
C
SYSTEM
A
B
C
SYSTEM
A
B
C
SYSTEM
92.4
97.6
91.7
100.0
96.4
96.4
96.4
100.0
93.4
93.4
81.0
100.0
31.4
89.3
75.0
97.8
61.2
75.8
12.6
74.5
53.7
56.4
63.1
86.6
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
29.3
83.3
85.1
91.3
22.6
28.0
4.6
27.6
49.7
52.2
58.4
80.1
81.60
86.70
85.70
744 695 679 68.2
720 266 198 30.0
744 689 596 68.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE FOURTH QUARTER THE BOILER AND THE FGD SYSTEM WERE TAKEN OFF-LINE
FOR AN INSPECTION. THE UTILITY REPORTED THAT THERE WERE NO SIGNS OF ANY
CORROSION OR EROSION. THE SYSTEM HAS PERFORMED WELL WITH NO PROBLEMS.
A
B
C
SYSTEM
64.1
97.0
48.7
100.0
57.6
94.5
34.4
93.2
100.0
100.0
100.0
100.0
50.5
82.8
30.1
81.8
80.60 744 653 608 75.9
#* PROBLEMS/SOLUTIONS/COMMENTS
DURING JANUARY PROBLEMS WERE ENCOUNTERED WITH ICE BUILDUP ON THE FANS.
SYSTEM 672
SYSTEM 744
SYSTEM 720
SYSTEM 744
SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE PERIOD OF MARCH 1982 TO JUNE 1982.
SYSTEM 100.0 99.0 100.0 98.1 744 733 730 68.7
SYSTEM 100.0 100.0 100.0 100.0 744 744 744 77.9
13-222
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
CINCINNATI GAS & ELECTRIC: EAST BEND Z (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
9/82 SYSTEM 100.0 99.7 100.0 98.9 720 714 712 61.5
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE PERIOD OF JULY THROUGH SEPTEMBER, 1982.
10/82 SYSTEM 100.0 100.0 100.0 2.5 744 19 19 1.6
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS REMOVED FROM SERVICE DURING OCTOBER FOR A MAINTENANCE OUTAGE.
11/82 SYSTEM 100.0 100.0 720 0
** PROBLEMS/SOLUTIONS/COMMENTS
OUTAGE TIME DURING NOVEMBER WAS DUE TO THE RETURN OF SERVICE ON UNIT 2 FROM
THE MAINTENANCE OUTAGE IN OCTOBER. BOILER OUTLET TEMPERATURE WAS INSUFFI-
CIENT FOR OPERATION OF THE PRECIPITATORS OR FGD SYSTEM.
744 715 711 52.2
744 734 732 67.1
672 672 672 74.5
744 677 669 69.2
720 547 541 71.2
744 741 733 91.8
720 655 651 81.7
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE PERIOD OF DECEMBER 1982 THROUGH JUNE 1983.
7/83 SYSTEM 100.0 99.5 100.0 92.9 744 694 691 80.1
8/83 SYSTEM 100.0 99.7 100.0 99.5 744 742 740 85.5
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING JULY AND AUGUST.
9/83 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE MONTH OF SEPTEMBER.
10/83 SYSTEM 744
11/83 SYSTEM 720
12/83 SYSTEM 744
12/82
1/83
2/83
3/83
4/83
5/83
6/83
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
100
100
100
100
100
100
100
.0
.0
.0
.0
.0
.0
.0
99
99
100
98
98
99
99
.4
.7
.0
.9
.6
.2
.4
100
100
100
100
100
100
100
.0
.0
.0
.0
.0
.0
.0
95
98
100
89
75
99
90
.6
.4
.0
.9
.1
.2
.4
13-223
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
CINCINNATI GAS & ELECTRIC: EAST BEND 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
NO MAJOR FGD-RELATED PROBLEMS WERE REPORTED DURING THE FOURTH QUARTER
OF 1983. AVAILABILITY WAS REPORTED AS 100X.
1/84 SYSTEM 744
2/84 SYSTEM 696
3/84 SYSTEM 744
4/84 SYSTEM 720
5/84 SYSTEM 744
6/84 SYSTEM 720
7/84 SYSTEM 744
8/84 SYSTEM 744
9/84 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE FGD SYSTEM WAS 100X AVAILABLE DURING THE
FIRST THREE QUARTERS OF 1984.
13-224
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
SECTION 13
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 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 - V.
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT
AVERAGE SULFUR CONTENT -
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** MECHANICAL COLLECTOR
NUMBER
TYPE
** ESP
NUMBER
NUMBER OF SPARES
TYPE
SUPPLIER
INLET FLUE GAS CAPACITY - CU.M/S
INLET FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
PARTICLE REMOVAL EFFICENCY - '/.
** PARTICLE SCRUBBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON NAME
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
*»* FGD SYSTEM
COLORADO UTE ELECTRIC
CRAIG
1
CRAIG
COLORADO
43. (
172. (
301. (
900
455
400
406
455
BABCOCK & WILCOX
PULVERIZED COAL
BASE
.100 LB/MMBTU)
.400 LB/MMBTU)
.700 LB/MMBTU)
722.29
121.1
183.
CONCRETE
10.9
COAL
SUBBITUMINOUS
23260.
8.00
******
16.00
******
.45
0.4-0.5
********
0.00-0.02
0
NONE
1
0
HOT SIDE
BELCO
1392.1
398.9
.7
99.9
0
NONE
N/A
N/A
N/A
N/A
N/A
N/A
N/A
(1530600 ACFM)
( 250 F)
( 600 FT)
( 35.8 FT)
( 10000 BTU/LB)
9100-10300
(2950000 ACFM)
( 750 F)
( 3. IN-H20)
13-225
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COLORADO UTE ELECTRIC: CRAIG 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
ENERGY CONSUMPTION - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
DESIGN COAL SULFER CONTENT - X
DESIGN COAL HEAT CONTENT - J/G
DESIGN COAL ASH CONTENT - X
DESIGN MOISTURE CONTENT - X
DESIGN CHLORIDE CONTENT - X
SPACE REQUIREMENTS - SQ M
OPER. & MAINT. REQUIREMENT - MANHR/DAY
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
NONE
PEABODY PROCESS SYSTEMS
STEARNS-ROGER
FULL SCALE
NEW
f. 99.80
85.00
1.3
1
12/80
10/80
5/77
.96
22329.6
11.60
15.30
.10
12140.2
264.0
( 9600 BTU/LB)
( 130680 SQ FT)
*» QUENCHER/PRESATURATOR
NUMBER
TYPE
SUPPLIER
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
PRESSURE DROP - KPA
LIQUID RECIRCULATION RATE - LITERS/S
L/G RATIO L/CU. M
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** 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
L/G RATIO - L/CU.M
GAS-SIDE PRESSURE DROP - KPA
SUFERFICAL 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
NUMBER OF SPARES PER SYSTEM
NUMBER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
QUENCH DUCT
PEABODY PROCESS SYSTEMS
217.07
121.1
.2
31.
.1
HIGH ALLOY
NICKEL BASE/CHROMIUM-IRON-MOLYBDENUM
( 460000 ACFM)
( 250 F)
( 1.0 IN-H20)
( 500 GPM)
( 1.1 GAL/1000 ACFM)
4
1
SPRAY TOWER
OPEN COUNTERCURRENT SPRAY
N/A
PEABODY PROCESS SYSTEMS
32.0 DIA X 52.5
CARBON STEEL
AISI 1110
N/A
ORGANIC [SPRAY ZONE 1; GLASS FLAKE-FILLED POLYEST
NATURAL RUBBER
BLACK NATURAL RUBBER
NONE
4
1512.
7.0
.4
3.0
217.07
121.1
85.0
50.0
(24000 GPM)
( 52.2 GAL/1000 ACF)
( 1.5 IN-H20)
( 10.0 FT/S)
( 460000 ACFM)
( 250 F)
PRIMARY COLLECTOR
4
1
1
IMPINGEMENT
BAFFLE
13-226
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COLORADO UTE ELECTRIC: CRAIG 1 (CONT.)
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
SUPERFICAL GAS VELOCITY - M/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
HASH WATER SOURCE
WASH FREQUENCY
WASH RATE - L/S
** REHEATER
NUMBER
NUMBER OF SPARES
NUMBER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
TRADE"NAME/COMMON TYPE
LOCATION
PERCENT GAS BYPASSED - AVG
TEMPERATURE INCREASE C
INLET FLUE GAS FLOW RATE - CU. M/S
INLET FLUE GAS TEMPERATURE - C
OUTLET FLUE GAS FLOW RATE - CU. M/S
OUTLET FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** FANS
NUMBER
NUMBER OF SPARES
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
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
PRESSURE DROP - KPA
CONSTRUCTION MATERIAL GENERIC TYPE
»* DAMPERS
NUMBER
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
MODULATION
SEAL AIR FLOW - CU. M/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
GENERIC TYPE
CLOSED VANE
HORIZONTAL
1
4
1.52
3.0
45
.2
3.0
ORGANIC
POLYPHENYLENE
RAW WATER
CONTINUOUS
6.3
5.0 FT)
1.20 IN)
( 1.0 IN-H20)
( 10.0 FT/S)
( 100 GAL/MIN)
4
1
1
BYPASS
COLD SIDE
N/A
OUTLET DUCT BETWEEN ME
23.0
& OUTLET DAMPER
27.8 (
194.89 (
43.3 (
302.02 (
73.9 (
STAINLESS STEEL
AUSTENITIC
4
0
AXIAL
BUFFALO FORGE
INDIRECT REHEAT
N/A
DRY
46.03 (
CARBON STEEL
4
1
AXIAL
BUFFALO FORGE
BOOSTER
FORCED DRAFT
DRY
372.80
121.1
3.4
CARBON STEEL
50 F)
413000 ACFM)
110 F)
640000 ACFM)
165 F)
97545 ACFM)
( 790000 ACFM)
( 250 F)
(11.0 IN-H20)
4
LOUVER
PARALLEL BLADE MULTILOUVER
FORNEY ENGINEERING
OPEN
3.07 ( 6500 ACFM)
CARBON STEEL/STAINLESS STEEL
ASTM A-285
NONE
N/A
4
LOUVER
13-227
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COLORADO UTE ELECTRIC: CRAIG 1 (CONT.)
SPECIFIC TYPE
MANUFACTURER
MODULATION
SEAL AIR FLOW - CU. M/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
MODULATION
SEAL AIR FLOW - CU. M/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
MODULATION
SEAL AIR FLOW - CU. M/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
MODULATION
SEAL AIR FLOW CU. M/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
MODULATION
SEAL AIR FLOW - CU. M/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
MODULATION
SEAL AIR FLOW - CU. M/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
PARALLEL BLADE MULTILOUVER
FORNEY ENGINEERING
OPEN
3.07 ( 6500 ACFM)
CARBON STEEL/STAINLESS STEEL
ASTM A-285
NONE
N/A
LOUVER
PARALLEL BLADE MULTILOUVER
FORNEY ENGINEERING
OPEN
3.07 ( 6500 ACFM)
CARBON STEEL/STAINLESS STEEL
ASTM A-285
NONE
N/A
GUILLOTINE
NR
FORNEY ENGINEERING
OPEN
.00 ( 0 ACFM)
CARBON STEEL/HIGH ALLOY
AISI 1110; NR
NONE
N/A
Z
LOUVER
PARALLEL BLADE MULTILOUVER
FORNEY ENGINEERING
OPEN
.00 ( 0 ACFM)
CARBON STEEL/STAINLESS STEEL
ASTM A-285
NONE
N/A
1
LOUVER
PARALLEL BLADE MULTILOUVER
FORNEY ENGINEERING
OPEN
.00 ( 0 ACFM)
CARBON STEEL/STAINLESS STEEL
ASTM A-285
NONE
N/A
2
LOUVER
PARALLEL BLADE MULTILOUVER
FORNEY ENGINEERING
CLOSED
.00 ( 0 ACFM)
CARBON STEEL/STAINLESS STEEL
ASTM A-285
NONE
N/A
13-228
-------
COLORADO UTE ELECTRIC: CRAIG 1 (CONT.)
UTILITY F6D SURVEY: OCTOBER 1983 - SEPTEMBER 1984
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
MANUFACTURER
NUMBER
NUMBER OF SPARES
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
PRODUCT QUALITY - 7. SOLIDS
** TANKS
SERVICE
ABSORBER RECYCLE
REAGENT PREP PRODUCT
THICKENER OVERFLOW
CLASSIFIER OVERFLOW
FLOCCULAHT
WASTE SLURRY BLEED
** PUMPS
SERVICE
RAW WATER
RECLAIM SUMP
POND
COOLING TOWER SLOWDOWN BOOSTER
ABSORBER RECIRCULATION
WASH SLURRY
SUPERNATANT
THICKENER UNDERFLOW
POLYELECTROLYTE
WASTE SLURRY
MILL RECIRCULATION
LIMESTONE SLURRY FEED
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
DIMENSIONS - FT
CAPACITY
INLET TO QUENCH
CARBON STEEL
AISI 1110
NONE
N/A
OUTLET TO DAMPER
CARBON STEEL
AISI 1110
ORGANIC
GLASS FLAKE-FILLED POLYESTER
DAMPER TO STACK
CARBON STEEL
AISI 1110
NONE
N/A
BYPASS
CARBON STEEL
AISI 1110
NONE
N/A
WET BALL MILL
COMPARTMENTED
NR
KENNEDY VAN SAUN
1
0
9.1 (10 TPH)
35.0
NUMBER
NUMBER
2
7
1
2
8
8
2
2
1
2
2
2
CENTRIFUGE
1
1
3.0 DIA X 6.0
126 GPM
13-229
-------
UTILITY FGO SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COLORADO UTE ELECTRIC: CRAIG 1 CCOKT.)
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
BELT GENERIC MATERIAL TYPE
BELT SPECIFIC MATERIAL TYPE
FEED STREAM SOURCE
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
OVERFLOW STREAM CHARACTERISTICS
OUTLET STREAM DISPOSITION
OVERFLOW STREAM DISPOSITION
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
CONFIGURATION
DIMENSIONS - FT
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
FEED STREAM SOURCE
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
OVERFLOW STREAM CHARACTERISTICS
OUTLET STREAM DISPOSITION
OVERFLOW STREAM DISPOSITION
«** SALEABLE BYPRODUCTS
HIGH ALLOY
NICKEL BASE/CHROMIUM-IRON-MOLYBDENUM
NONE
N/A
N/A
N/A
THICKENER UNDERFLOW
35X SOLIDS
60X SOLIDS
60 GFM
LANDFILL
TO WASTE SUMP i THEN TO THICKENER
THICKENER
1
0
CENTER DRAW
75.0 DIA X 15.0
CARBON STEEL
AISI 1110
ORGANIC
GLASS FLAKE-FILLED POLYESTER [WALLS]; MAT-REINFO
ABSORBER BLEED
5X SOLIDS
35X SOLIDS
100 GPM, <1X SUSPENDED SOLIDS
TO CENTRIFUGES
RECYCLED TO PROCESS
**# SLUDGE
FULL LOAD SLUDGE QUANTITY - M.TONS/HR (DRY)
MOISTURE CONTENT - X TOTAL FREE WATER
X CAS03 - DRY
X CAS04 - DRY
X CAOH2 - DRY
X CAC03 - DRY
X ASH DRY
X OTHER COMPOUNDS - DRY
** TREATMENT
METHOD
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
** PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS
PHYSICAL VARIABLES
CONTROL LEVELS
MONITOR TYPE
MONITOR LOCATION
PROCESS CONTROL MANNER
PROCESS CHEMISTRY MODE
10.5
40.0
22.6
70.2
.0
2.9
.3
3.9
( 11.6 TPH)
NONE
FINAL
LANDFILL
ON-SITE
TRUCK
PH, 502 CONCENTRATION
DENSITY, GAS FLOW, LIQUID FLOW
PH 5.4, SOLIDS 12-15X
UNILOK-PH, OHMART-DENSITY, BROOKS-FLOW, DYNASCIE
AT MODULE RECYCLE TANK
AUTOMATIC
FEEDBACK
** WATER BALANCE
WATER LOOP TYPE CLOSED
EVAPORATION WATER LOSS LITER/S 17.8
SLUDGE HYDRATICN WATER LOSS LITER/S .6
SLUDGE INTERSTITIAL WATER LOSS - LITERS/S 2.1
POND SEEPAGE/RUNOFF WATER LOSS - LITERS/S 0
EFFLUENT WATER LOSS - LITERS/S .0
282 GPM)
9 GPM)
33 GPM)
0 GPM)
13-230
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COLORADO UTE ELECTRIC: CRAIG 1 (CONT.)
RECEIVING WATER STREAM
MAKEUP WATER ADDITION - LITERS/S
SOURCE OF MAKEUP WATER
*# CHEMICALS AND CONSUMPTION
FUNCTION
NAME
PRINCIPAL CONSTITUENT
CONSUMPTION
UTILIZATION - X
POINT OF ADDITION
** FGD SPARE CAPACITY INDICES
ABSORBER - X
MIST ELIMINATOR - X
REHEATER - X
BALL MILL - X
EFFLUENT HOLD TANK - X
THICKENER - X
CENTRIFUGE - X
** FGD SPARE COMPONENT INDICES
ABSORBER
N/A
20.2 ( 321 GPM)
COOLING TOWER SLOWDOWN
ABSORBENT
LIMESTONE
CAC03
7000 LB/HR
75.0
BALL MILL
33.3
33.3
33.3
.0
33.3
.0
50.0
1.0
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
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
46.2
38.5
720 619
47.3
*# PROELEMS/SOLUTIONS/COMMENTS
12/80
A
B
C
D
SYSTEM
.0
53.8
73.9
60.5
62.7
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.
.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
744 716
407 63.0
1/81
** PROBLEMS/SOLUTIONS/COMMENTS
A
B
C
D
SYSTEM
.0
59.7
48.9
11.3
39.9
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.
.0
70.2
59.8
12.6
47.5
.0
71.0
60.5
12.7
48.1
.0
55.4
47.2
9.9
37.5
744 587
279 62.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JANUARY THE FGD SYSTEM EQUIPMENT CHECKOUT CONTINUED. MODULE A RE-
MAINED OUT OF SERVICE BECAUSE THE MECHANICAL PARTS NEEDED FOR REPAIR WORK
WERE NOT AVAILABLE.
13-231
-------
UTILITY FGO SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COLORADO UTE ELECTRIC: CRAIG 1 (CONT.)
___- PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
2/81
A
B
C
0
SYSTEM
.0
12.2
13.6
.0
8.6
.0
12.4
12.4
.0
8.3
.0
12.9
12.9
.0
8.6
.0
10.7
10.7
.0
7.1
672 580 36 64.2
** PROBLEMS/SOLUTIONS/COMMENTS
THE CHECKOUT OF THE FGD SYSTEM EQUIPMENT CONTINUED DURING FEBRUARY. MODULE
A NEEDED MECHANICAL PARTS FOR REPAIR. THREE OF THE FOUR MODULES WERE TO
BE OPERATING BY THE END OF THE MONTH.
MODULES B AND C ENCOUNTERED PROBLEMS WITH THE INLET AND OUTLET DAMPERS
DURING FEBRUARY.
3/81
A
B
C
D
SYSTEM
.0
.0
.0
35.5
11.8
.0
.0
.0
35.5
11.8
.0
.0
.0
35.7
11.9
.0
.0
.0
35.5
11.8
744 744 88 88.6
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MARCH MODULES A, B, AND C EXPERIENCED OPERATING PROBLEMS WITH THE
DAMPERS.
ADDITIONAL OUTAGE TIME WAS DUE TO THE READJUSTMENT OF THE FAN BLADE PITCH-
ES.
4/81
A
B
C
D
SYSTEM
.0
36.1
2.8
25.0
21.3
.0
59.9
4.2
40.5
34.9
.0
60.9
4.3
41.2
26.6
.0
35.6
2.5
23.9
20.7
720 427 149 52.9
«* PROBLEMS/SOLUTIONS/COMMENTS
DURING THE FIRST HALF OF APRIL THE SYSTEM EXPERIENCED PROBLEMS WITH THE
DAMPERS AND CONTROLS MALFUNCTIONING. MODULE A NEEDED PARTS AND THE OTHER
MODULES WERE REPAIRED.
ON APRIL 18 THE UNIT WAS SHUT DOWN FOR A SCHEDULED FIVE WEEK MAINTENANCE
OUTAGE.
5/81 SYSTEM .0 .0 .0 .0 744 101 0
6/81 SYSTEM .0 .0 .0 .0 720 699 0 97.1
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MAY AND JUNE THE SYSTEM WAS OUT OF SERVICE DUE TO DAMAGED MIST
ELIMINATOR PADS AND PLUGGING OF THE MIST ELIMINATOR.
THICKENER REPAIRS WERE PERFORMED DURING JUNE.
7/81 SYSTEM .0 .0 .0 .0 744 724 0 58.9
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM REMAINED OFF LINE THROUGH JULY AS A RESULT OF THE BROKEN
MIST ELIMINATOR TRAYS.
8/81 SYSTEM .0 .0 .0 .0 744 709 0 90.0
13-232
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COLORADO UTE ELECTRIC: CRAIG 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
AS OF THE END OF AUGUST, MODULES A AND C WERE READY FOR OPERATION; HOWEVER,
MODULE B NEEDED MORE MIST ELIMINATOR TRAYS.
DURING THE MONTH, THE THICKENER WAS DRAINED FOR REPAIRS THAT WERE EXPECTED
TO BE COMPLETED BY THE MIDDLE OF SEPTEMBER.
9/81 SYSTEM .0 .0 .0 .0 720 677 0 85.4
** PROBLEMS/SOLUTIONS/COMMENTS
MIST ELIMINATOR INSTALLATION WAS COMPLETED ON MODULES A,C, AND D BUT
WAS CONTINUING ON MODULE B.
THE THICKENER WAS REFILLED AFTER WORK WAS COMPLETED TO REPAIR LEAKS IN THE
BASE. AFTER REFILLING, MORE LEAKS WERE FOUND SO THE THICKENER WAS
DRAINED AGAIN.
10/81
1/82
A
B
C
D
SYSTEM
15.4
.0
14.1
12.8
14.1
15.4
.0
13.8
12.2
13.8
15.5
.0
13.9
12.2
13.9
15.3
.0
13.7
12.1
13.7
744 739 102 81.9
** PROBLEMS/SOLUTIONS/COMMENTS
DURING OCTOBER INSTRUMENTATION PROBLEMS WITH MODULES A, C AND D WERE
ENCOUNTERED.
720 720 573 90.8
744 744 626 68.5
** PROBLEMS/SOLUTIONS/COMMENTS
REPLACEMENT PARTS NEEDED FOR MODULE B KEPT THE MODULE OFF-LINE THROUGH THE
FOURTH QUARTER.
DURING NOVEMBER AND DECEMBER PLUGGING IN THE LIMESTONE BALL MILL WAS A
MINOR PROBLEM.
11/81
12/81
A
B
C
D
SYSTEM
A
B
C
D
SYSTEM
91.9
.0
68.5
78.8
79.6
79.5
.0
89.6
83.6
84.2
91.9
.0
68.4
78.6
79.5
79.4
.0
89.4
83.5
84.1
91.9
.0
68.4
78.6
79.6
79.4
.0
89.4
83.5
64.1
91.9
.0
68.4
78.6
79.6
79.4
.0
89.4
83.5
64.1
A
B
C
D
SYSTEM
82.0
.0
87.4
89.8
86.4
82.5
.0
87.5
90.3
86.8
82.8
.0
87.8
90.6
65.3
81.8
.0
86.7
89.5
86.0
744 737 640 84.2
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JANUARY THE MIST ELIMINATORS WERE CLEANED WEEKLY.
ROCKS IN THE LIMESTONE HAS CAUSED PLUGGING OF THE BALL MILL. THE SUPPLIER
IS WORKING ON THE PROBLEM.
13-233
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COLORADO UTE ELECTRIC: CRAIG 1 (CONT.)
_ . PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
THE UTILITY IS WAITING FOR PARTS TO MAKE THE NECESSARY REPAIRS TO MODULE B.
2/82
3/82
4/82
5/82
6/82
A
B
C
0
SYSTEM
72.9
2.2
88.8
65.3
76.5
73.1
2.1
89.1
65.5
76.6
73.9
2.1
90.0
66.2
76.3
72.8
2.1
88.7
65.2
76.3
672 669
513 83.6
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE B WAS REPAIRED DURING THE MONTH AND IS IN THE PROCESS OF BEING
STARTED UP.
DURING FEBRUARY PROBLEMS WERE ENCOUNTERED WITH THE LIMESTONE BALL MILL
LUBRICATION SYSTEM.
A
B
C
D
SYSTEM
40.9
85.4
85.1
79.7
96.9
40.9
85.4
85.1
79.7
97.1
41.5
86.5
86.2
80.7
98.3
40.9
85.2
84.9
79.5
96.3
744 742
720 80.2
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MARCH MODULE A WAS DOWN 428 HOURS FOR. CLEANING.
A
B
C
D
SYSTEM
46.9
70.7
76.1
20.8
71.5
47.1
71.0
76.3
20.8
71.7
49.2
74.2
79.7
21.8
75.0
46.8
70.6
75.8
20.7
71.3
720 715
513 82.7
** PROBLEMS/SOLUTIONS/COMMENTS
DURING APRIL PROBLEMS WERE ENCOUNTERED WITH THE SUPERNATE PUMPS.
A
B
C
D
SYSTEM
22.7
29.2
29.2
.0
27.0
56.4
72.6
72.5
.0
67.2
64.9
83.6
83.4
.0
77.3
22.6
29.1
29.0
.0
26.9
744 298
200 25.6
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MAY THE UNIT WAS OFF-LINE FOR THREE WEEKS FOR A SCHEDULED OUTAGE.
THE FGD SYSTEM WAS IN COMPLIANCE PRIOR TO THE SHUT DOWN.
A
B
C
D
SYSTEM
.0
58.2
58.5
.0
38.9
.0
58.1
58.2
.0
38.8
.0
58.1
58.2
.0
38.8
.0
58.1
58.2
.0
38.8
720 720
279 77.3
** PROBLEMS/SOLUTIONS/COMMENTS
AT THE BEGINNING OF JUNE, ALL MODULES WERE DOWN DUE TO FAULTY PIPING ON
THE SUPERNATE SYSTEM, WHICH WAS REPAIRED BY THE 10TH.
MODULES A AND D WERE OFF-LINE THE REST OF THE MONTH DUE TO LINER PROBLEMS.
7/82 A
B
C
.0
7.9
41.1
.0
8.2
42.4
.0
9.4
48.5
.0
7.9
41.0
13-234
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 198*
COLORADO UTE ELECTRIC: CRAIG 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
502 PART. HOURS HOURS HOURS FACTOR
D .0 .0 .0 .0
SYSTEM 16.4 16.9 19.3 16.3 744 720 IZl 62.8
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JULY ABSORBER LINER REPAIRS CONTRIBUTED TO MODULAR OUTAGES.
MAJOR DEMISTER REPAIRS ALSO RESULTED IN DOWN TIME DURING JULY.
8/82 A
B
C
D
SYSTEM
68.1
5.1
.0
.0
24.4
69.7
5.2
.0
.0
25.0
77.1
5.7
.0
.0
27.6
68.0
5.0
.0
.0
24.3
744 725 181 64.0
** PROBLEMS/SOLUTIONS/COMMENTS
MODULES C AND D WERE DOWN DURING AUGUST FOR LINING REPAIRS. A BOILERMAKER
STRIKE PREVENTED COMPLETION OF THESE REPAIRS DURING THE MONTH, AND THUS
ALSO CONTRIBUTED TO DOWN TIME.
MODULE B EXPERIENCED BOOSTER FAN PROBLEMS DURING AUGUST. THEY WERE
CORRECTED, HOWEVER BY THE END OF THE MONTH.
A
B
C
D
SYSTEM
3.5
84.2
.0
.0
29.2
3.7
89.2
.0
.0
31.0
3.6
88.2
.0
.0
30.6
3.5
84.0
.0
.0
29.2
9/82
720 678 210 68.5
** PROBLEMS/SOLUTIONS/COMMENTS
DURING SEPTEMBER MODULES C AND D WERE DOWN AWAITING COMPLETION OF THE
ABSORBER LINER REPAIRS.
MODULE A WAS DOWN DURING THE MONTH FOR DEMISTER WASH MODIFICATIONS.
10/82
A
B
C
D
SYSTEM
61.8
61.8
.0
.0
41.2
61.7
61.6
.0
.0
41.1
61.7
61.6
.0
.0
41.1
61.7
61.6
.0
.0
41.1
744 744 306 78.1
** PROBLEMS/SOLUTIONS/COMMENTS
MODULES A AND B WERE DOWN DURING OCTOBER FOR DEMISTER REPAIRS AND CLEANING.
MODULES C AND D REMAINED OUT OF SERVICE DURING OCTOBER AWAITING REPAIRS ON
THE ABSORBER LINER.
11/82
A
B
C
D
SYSTEM
63.2
55.4
.0
.0
39.5
77.1
67.6
.0
.0
48.2
90.1
79.0
.0
.0
56.3
63.1
55.3
.0
.0
39.4
720 589 284 41.8
** PROBLEMS/SOLUTIONS/COMMENTS
MODULES C AND D REMAINED OUT OF SERVICE DURING NOVEMBER AWAITING ABSORBER
LINER REPAIRS.
THE UNIT WAS DOWN FOR PART OF THE MONTH DUE TO A SCHEDULED OUTAGE.
12/82 A 100.0 100.0 100.0 100.0
13-235
-------
UTILITY FGO SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COLORADO UTE ELECTRIC: CRAIG 1 (CONT.)
_ . .- PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
4/83
B
C
D
SYSTEM
7.7
.0
.0
35.9
7.5
.0
.0
35.8
7.5
.0
.0
35.8
7.5
.0
.0
35.8
744 744
266 71.3
** PROBLEMS/SOLUTIONS/COMMENTS
MODULES C AND D WERE DOWN THE ENTIRE MONTH FOR ABSORBER LINER REPAIRS.
MODULE B WAS DOWN SHORTLY AFTER THE FIRST OF THE MONTH, ALSO FOR LINER
REPAIRS.
1/83
A
B
C
D
SYSTEM
95.8
.0
.0
.0
31.9
95.8
.0
.0
.0
31.9
98.1
.0
.0
.0
32.7
95.7
.0
.0
.0
31.9
** PROBLEMS/SOLUTIONS/COMMENTS
2/83
A
B
C
D
SYSTEM
57.2
.0
.0
88.1
48.4
MODULES B, C AND
57.5
.0
.0
45.5
34.3
D WERE DOWN
59.1
.0
.0
46.7
35.3
DURINI
57.2
.0
.0
45.2
34.2
237 68.5
672 668 230 63.0
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE A WAS DOWN DURING FEBRUARY FOR PREVENTIVE MAINTENANCE.
MODULE B WAS DOWN DURING FEBRUARY FOR ABSORBER LINER REPAIRS.
MODULE C WAS DOWN DURING THE MONTH FOR REPAIRS ON THE BOOSTER FAN LUBE SET.
MODULE D WAS AVAILABLE DURING FEBRUARY BUT NOT IN SERVICE. THE UTILITY WAS
ONLY OPERATING ONE MODULE.
3/83
A
B
C
D
SYSTEM
.
67.
71.
46.
0
1
0
0
1
76
81
52
.0
.7
.0
.1
.6
79
84
54
.0
.5
.0
.2
.6
67.
.
71.
46.
0
1
0
0
1
744 652
343 61.7
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE A WAS DOWN DURING MARCH DUE TO PROBLEMS WITH SCALE BUILD-UP ON THE
INLET DUCTWORK.
RECYCLE PUMP PROBLEMS ALSO CONTRIBUTED TO DOWN TIME FOR MODULE A DURING THE
MONTH.
MODULE C AWAITED COMPLETION OF WORK ON THE INTERFACE WASH SPRAY HEADER
DURING MARCH.
A
B
C
D
SYSTEM
.0
10.3
.0
92.4
33.8
.0
9.3
.0
89.4
32.9
.0
9.7
.0
93.4
34.3
.0
9.3
.0
89.2
32.8
720
718
£36 73.6
13-276
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COLORADO UTE ELECTRIC: CRAIG 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
5/83
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE A WAS DOWN DURING THE MONTH TO ALLOW FOR WORK ON A RECYCLE PUMP.
A CLEANING OF THE INLET DUCTWORK ALSO CAUSED DOWN TIME FOR MODULE A DURING
APRIL.
MODULE B WAS OUT OF SERVICE FOR MIST ELIMINATOR CLEANING.
MODULE C WAS DOWN SO THAT REPAIRS COULD BE MADE TO A SECTION OF A
WASH SPRAY HEADER.
242 70.7
A
B
C
D
SYSTEM
.0
64.8
.0
32.8
32.5
.0
66.9
.0
33.7
33.5
.0
79.8
.0
40.2
40.0
.0
64.8
.0
32.7
32.5
744 721
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE A WAS DOWN DURING THE MONTH FOR RECYCLE PUMP REPAIRS.
MODULE C WAS OUT OF SERVICE SO THAT REPAIRS COULD BE MADE ON A
WASH- SPRAY HEADER.
720 701
6/83 A
B
C
D
SYSTEM
31.1
57.0
.0
66.7
51.6
4.6
31.1
.0
68.4
34.7
5.1
34.5
.0
75.8
38.5
4.4
30.3
.0
66.7
33.8
243 68.4
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE A WAS DOWN DURING THE FIRST PART OF JUNE DUE TO PROBLEMS WITH
RECYCLE PUMP BEARINGS.
MODULE C WAS DOWN FOR THE ENTIRE MONTH OF JUNE DUE TO PROBLEMS WITH THE
BOOSTER FAN BLADE PITCH CONTROL.
7/83 A
B
C
D
SYSTEM
82.9
85.3
50.5
.0
72.9
82.9
56.3
34.4
.0
57.9
100.0
71.5
43.7
73.5
82.9
56.3
34.4
.0
57.8
744 743
430 74.7
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE C WAS OUT OF SERVICE DURING THE FIRST 12 DAYS OF JULY DUE TO MIST
ELIMINATOR HEADER PROBLEMS.
MODULE D WAS OUT OF SERVICE UNTIL JULY 25 DUE TO RECYCLE PUMP PROBLEMS.
8/83
9/83
A
B
C
D
SYSTEM
A
B
C
D
SYSTEM
96.0
.0
100.0
91.0
95.7
94.5
48.4
56.5
.0
66.5
96.1
.0
100.0
8.5
68.2
94.8
51.7
43.6
.0
63.4
96.5
100.0
8.5
68.5
96.3
52.6
44.3
64.4
96.0
.0
100.0
8.5
68.1
94.5
51.6
43.5
.0
63.2
744 743
720 718
507
455 75.6
13-237
-------
UTILITY FGO SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COLORADO UTE ELECTRIC: CRAIG 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
12/83
NO MAJOR FGD-RELATED OUTAGES WERE ENCOUNTERED DURING AUGUST AND
SEPTEMBER.
744 503
10/83
A
B
C
D
SYSTEM
67.7
22.3
.0
53.0
47.7
100.0
65.2
.0
21.9
62.4
100.0
65.1
21.8
62.3
67.7
44.1
.0
14.8
42.2
314 82.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS OUT OF SERVICE FROM OCTOBER 21 THROUGH THE END OF THE MONTH
FOR AN ANNUAL MAINTENANCE OUTAGE.
11/83 A
B
C
D
SYSTEM
.0
46.7
39.3
.0
28.7
.0
96.0
80.9
59.0
.0
46.7
39.3
.0
28.7
720
206
** PROBLEMS/SOLUTIONS/COMMENTS
THE ANNUAL MAINTENANCE OUTAGE WHICH BEGAN IN OCTOBER CONTINUED THROUGH
NOVEMBER 12.
THE UTILITY REPORTED PROBLEMS WITH A CIRCULATING WATER PUMP FROM NOVEMBER
13 TO NOVEMBER 15, 1983. THE UNIT WAS BROUGHT DOWN DURING THIS PERIOD.
MODULES A AND C WERE DOWN DURING PART OF NOVEMBER DUE TO ABSORBER GAS AND
LIQUID SIDE EQUIPMENT PROBLEMS.
THE UNIT WAS PLACED BACK IN SERVICE ON NOVEMBER 16.
A
B
C
D
SYSTEM
.0
99.2
99.2
15.7
71.4
.0
100.0
100.0
15.9
72.0
100.0
100.0
100.0
100.0
.0
99.2
99.2
15.7
71.4
744 736
531 98.9
** PROBLEMS/SOLUTIONS/COMMENTS
MODULES A AND D EXPERIENCED PROBLEMS WITH ABSORBER LIQUID SIDE EQUIPMENT
DURING DECEMBER.
A
B
C
D
SYSTEM
.0
100.0
32.5
96.2
76.3
.0
100.0
32.5
96.2
76.3
100.0
32.5
96.2
76.3
.0
100.0
32.5
96.2
76.3
1/84
744 744 567
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE A WAS DOWN FOR LIQUID SIDE EQUIPMENT PROBLEMS DURING JANUARY.
MODULE C WAS DOWN FOR LIQUID AND GAS SIDE EQUIPMENT PROBLEMS.
2/84 SYSTEM 696
3/84 SYSTEM 744
4/84 SYSTEM 72Q
13-238
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COLORADO UTE ELECTRIC: CRAIG 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
502 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE PERIOD OF FEBRUARY THROUGH APRIL
1984.
5/84
6/84
7/84
8/84
A
B
C
D
SYSTEM
A
B
C
D
SYSTEM
A
B
C
D
SYSTEM
A
B
C
D
SYSTEM
99.2
.0
99.3
98.6
99.0
100.0
28.3
100.0
100.0
100.0
100.0
41.9
91.5
99.9
100.0
84.3
68.4
100.0
29.0
93.9
83.7
.0
100.0
99.2
94.3
100.0
.0
76.5
89.0
88.5
78.8
21.3
53.7
78.7
77.5
80.1
67.5
95.6
19.4
87.5
99.9
100.0
99.2
99.7
100.0
.0
103.4
100.0
100.0
100.0
93.1
100.0
100.0
100.0
100.0
147.8
95.6
100.0
83.1
.0
99.3
98.6
93.7
100.0
.0
76.5
89.0
88.5
100.0
27.0
68.1
99.9
98.3
80.1
67.5
95.6
19.4
87.5
** PROBLEMS/SOLUTIONS/COMMENTS
744 739
720 720
744 744
744 744
697
637
732
651
NO MAJOR FGD-RELATED PROBLEMS WERE REPORTED DURING THE PERIOD OF MAY
THROUGH AUGUST 1984.
9/84 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR SEPTEMBER 1984.
720
13-239
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
SECTION 13
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.
RANSE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - '/.
AVERAGE SULFUR CONTENT '/.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT 7.
*»* PARTICLE CONTROL
** MECHANICAL COLLECTOR
NUMBER
TYPE
*« ESP
NUMBER
NUMBER OF SPARES
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
TRADE NAME/COMMON NAME
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
*** FGD SYSTEM
COLORADO UTE ELECTRIC
CRAIG
2
CRAIG
COLORADO
43. (
172. (
301. (
900
455
400
406
455
BABCOCK i WILCOX
PULVERIZED COAL
BASE
.100 LB/MMBTU)
.400 LB/MMBTU)
.700 LB/MMBTU)
722.29
121.1
183.
CONCRETE
10.9
COAL
SUBBITUMINOUS
23260.
8.00
«»****
16.00
******
.45
0.4-0.5
********
0.00-0.02
0
NONE
1
0
HOT SIDE
BELCO
1392.1
398.9
.7
99.9
0
NONE
N/A
N/A
N/A
N/A
N/A
N/A
N/A
(1530600 ACFM)
( 250 F)
( 600 FT)
( 35.8 FT)
( 10000 BTU/LB)
9100-10300
(2950000 ACFM)
( 750 F)
( 3. IN-H20)
13-240
-------
COLORADO UTE ELECTRIC: CRAIG 2 (CONT.)
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
** 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 - X
ENERGY CONSUMPTION - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
#* DESIGN AND OPERATING PARAMETERS
DESIGN COAL SULFER CONTENT - X
DESIGN COAL HEAT CONTENT - J/G
DESIGN COAL ASH CONTENT - X
DESIGN MOISTURE CONTENT - X
DESIGN CHLORIDE CONTENT - X
SPACE REQUIREMENTS - SQ M
OPER. & MAINT. REQUIREMENT - MANHR/DAY
*» QUENCHER/PRESATURATOR
NUMBER
TYPE
SUPPLIER
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
PRESSURE DROP - KPA
LIQUID RECIRCULATION RATE - LITERS/S
L/G RATIO - L/CU. M
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** 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
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
NUMBER OF SPARES PER SYSTEM
NUMBER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
NONE
PEABODY PROCESS SYSTEMS
STEARNS-ROGER
FULL SCALE
NEW
X 99.80
85.00
1.3
1
5/80
12/79
5/77
.96
22329.6
11.60
15.30
.10
12140.2
264.0
( 9600 BTU/LB)
( 130680 SQ FT)
QUENCH DUCT
PEABODY PROCESS SYSTEMS
217.07
121.1
.2
31.
.1
HIGH ALLOY
NICKEL BASE/CHROMIUM-IRON-MOLYBDENUM
460000 ACFM)
250 F)
1.0 IN-H20)
500 GPM).
1.1 GAL/1000 ACFM)
4
1
SPRAY TOWER
OPEN COUNTERCURRENT SPRAY
N/A
PEABODY PROCESS SYSTEMS
32.0 DIA X 52.5
CARBON STEEL
AISI 1110
N/A
ORGANIC (SPRAY ZONE]; GLASS FLAKE-FILLED POLYEST
NATURAL RUBBER
BLACK NATURAL RUBBER
NONE
4
1512.
7.0
.4
3.0
217.07
121.1
85.0
50.0
(24000 GPM)
( 52.2 GAL/1000 ACF)
( 1.5 IN-H20)
( 10.0 FT/S)
( 460000 ACFM)
( 250 F)
PRIMARY COLLECTOR
4
1
1
IMPINGEMENT
BAFFLE
13-241
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COLORADO UTE ELECTRIC: CRAIG 2 (CONT.)
TRADE NAME/COMMON TYPE
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES PER STAGE
FREEBOARD DISTANCE - H
DISTANCE BETWEEN VANES - CM
VANE ANGLES - DEGREES
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
WASH WATER SOURCE
WASH FREQUENCY
WASH RATE - L/S
»» REHEATER
NUMBER
NUMBER OF SPARES
NUMBER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
LOCATION
PERCENT GAS BYPASSED - AVG
TEMPERATURE INCREASE - C
INLET FLUE GAS FLOW RATE - CU. M/S
INLET FLUE GAS TEMPERATURE C
OUTLET FLUE GAS FLOW RATE - CU. M/S
OUTLET FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** FANS
NUMBER
NUMBER OF SPARES
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
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
PRESSURE DROP - KPA
CONSTRUCTION MATERIAL GENERIC TYPE
** DAMPERS
NUMBER
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
MODULATION
SEAL AIR FLOW - CU. M/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
GENERIC TYPE
CLOSED VANE
HORIZONTAL
1
1.
3.
45
5Z
0
3.0
ORGANIC
POLYPHENYLENE
RAW WATER
CONTINUOUS
6,3
0 FT)
20 IN)
1.0 IN-H20)
10.0 FT/S)
( 100 GAL/MIN)
1
1
BYPASS
COLD SIDE
N/A
OUTLET DUCT BETWEEN ME 4 OUTLET DAMPER
23.0
27.8 ( 50 F)
194.89 ( 413000 ACFM)
43.3 ( 110 F)
302.02 ( 640000 ACFM)
73.9 ( 165 F)
STAINLESS STEEL
AUSTENITIC
4
0
AXIAL
BUFFALO FORGE
INDIRECT REHEAT
N/A
DRY
46.03 t 97545 ACFM)
CARBON STEEL
4
1
AXIAL
BUFFALO FORGE
BOOSTER
FORCED DRAFT
DRY
372.80
121.1
3.4
CARBON STEEL
( 790000 ACFM)
( 250 F)
(11.0 IN-H20)
4
LOUVER
PARALLEL BLADE MULTILOUVER
FORNEY ENGINEERING
OPEN
3.07 ( 6500 ACFM)
CARBON STEEL/STAINLESS STEEL
ASTM A-285
NONE
N/A
4
LOUVER
13-242
-------
UTILITY F6D SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COLORADO UTE ELECTRIC: CRAIG Z (CONT.)
SPECIFIC TYPE
MANUFACTURER
MODULATION
SEAL AIR FLOW - CU. M/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
*« DAMPERS
NUMBER
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
MODULATION
SEAL AIR FLOW - CU. M/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
MODULATION
SEAL AIR FLOW - CU. M/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
«* DAMPERS
NUMBER
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
MODULATION
SEAL AIR FLOW - CU. M/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
MODULATION
SEAL AIR FLOW - CU. M/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
MODULATION
SEAL AIR FLOU - CU. M/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
PARALLEL BLADE MULTILOUVER
FORNEY ENGINEERING
OPEN
3.07 ( 6500 ACFM)
CARBON STEEL/STAINLESS STEEL
ASTM A-285
NONE
N/A
LOUVER
PARALLEL BLADE MULTILOUVER
FORNEY ENGINEERING
OPEN
3.07 ( 6500 ACFM)
CARBON STEEL/STAINLESS STEEL
ASTM A-285
NONE
N/A
GUILLOTINE
NR
FORNEY ENGINEERING
OPEN
.00 ( 0 ACFM)
CARBON STEEL/HIGH ALLOY
AISI mo; NR
NONE
N/A
2
LOUVER
PARALLEL BLADE MULTILOUVER
FORNEY ENGINEERING
OPEN
.00 ( 0 ACFM)
CARBON STEEL/STAINLESS STEEL
ASTM A-285
NONE
N/A
1
LOUVER
PARALLEL BLADE MULTILOUVER
FORNEY ENGINEERING
OPEN
.00 ( 0 ACFM)
CARBON STEEL/STAINLESS STEEL
ASTM A-285
NONE
N/A
2
LOUVER
PARALLEL BLADE MULTILOUVER
FORNEY ENGINEERING
CLOSED
.00 ( 0 ACFM)
CARBON STEEL/STAINLESS STEEL
ASTM A-285
NONE
N/A
13-243
-------
UTILITY F6D SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COLORADO UTE ELECTRIC: CRAIG 2 (CONT.)
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
INLET TO QUENCH
CARBON STEEL
AISI 1110
NONE
N/A
OUTLET TO DAMPER
CARBON STEEL
AISI 1110
ORGANIC
GLASS FLAKE-FILLED POLYESTER
*» DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
»* DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
MANUFACTURER
NUMBER
NUMBER OF SPARES
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
PRODUCT QUALITY - X SOLIDS
** TANKS
SERVICE
ABSORBER RECYCLE
REAGENT PREP PRODUCT
THICKENER OVERFLOW
CLASSIFIER OVERFLOW
FLOCCULANT
WASTE SLURRY BLEED
DAMPER TO STACK
CARBON STEEL
AISI 1110
NONE
N/A
BYPASS
CARBON STEEL
AISI 1110
NONE
N/A
WET BALL MILL
COMPARTMENTED
NR
KENNEDY VAN SAUN
9.1
35.0
NUMBER
4
1
1
4
1
1
( 10 TPH)
** PUMPS
SERVICE
RAW WATER
RECLAIM SUMP
POND
COOLING TOU'ER SLOWDOWN BOOSTER
ABSORBER RECIRCULATION
WASH SLURRY
SUPERNATANT
THICKENER UNDERFLOW
FOLYELECTROLYTE
WASTE SLURRY
MILL RECIRCULATION
LIMESTONE SLURRY FEED
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
DIMENSIONS FT
CAPACITY
NUMBER
2
7
1
2
8
8
2
2
1
2
2
2
CENTRIFUGE
1
1
3.0 DIA X 6.0
126 GPM
13-244
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1964
COLORADO UTE ELECTRIC: CRAIG 2 (CONT.)
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
BELT GENERIC MATERIAL TYPE
BELT SPECIFIC MATERIAL TYPE
FEED STREAM SOURCE
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
OVERFLOW STREAM CHARACTERISTICS
OUTLET STREAM DISPOSITION
OVERFLOW STREAM DISPOSITION
»# SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
CONFIGURATION
DIMENSIONS - FT
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
FEED STREAM SOURCE
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
OVERFLOW STREAM CHARACTERISTICS
OUTLET STREAM DISPOSITION
OVERFLOW STREAM DISPOSITION
HIGH ALLOY
NICKEL BASE/CHROMIUM-IRON-MOLYBDENUM
NONE
N/A
N/A
N/A
THICKENER UNDERFLOW
35X SOLIDS
60X SOLIDS
60 GPM
LANDFILL
TO WASTE SUMP ft THEN TO THICKENER
THICKENER
1
0
CENTER DRAW
75.0 DIA X 15.0
CARBON STEEL
AISI 1110
ORGANIC
GLASS FLAKE-FILLED POLYESTER tWALLSJ; MAT-REINFO
ABSORBER BLEED
57. SOLIDS
35X SOLIDS
100 GPM, <1X SUSPENDED SOLIDS
TO CENTRIFUGES
RECYCLED TO PROCESS
*** SLUDGE
FULL LOAD SLUDGE QUANTITY - M.TONS/HR (DRY)
MOISTURE CONTENT - X TOTAL FREE WATER
X CAS03 - DRY
X CAS04 - DRY
7. CAOH2 DRY
X CAC03 - DRY
X ASH - DRY.
X OTHER COMPOUNDS - DRY
** TREATMENT
METHOD
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
** PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS
PHYSICAL VARIABLES
CONTROL LEVELS
MONITOR TYPE
MONITOR LOCATION
PROCESS CONTROL MANNER
PROCESS CHEMISTRY MODE
10.5
40.0
22.6
70.2
.0
2.9
.3
3.9
11.6 TPH)
NONE
FINAL
LANDFILL
ON-SITE
TRUCK
PH, S02 CONCENTRATION
DENSITY, GAS FLOW, LIQUID FLOW
PH 5.4, SOLIDS 12-15X
UNILOK-PH, OHMART-DENSITY, BROOKS-FLOW, DYNASCIE
AT MODULE RECYCLE TANK
AUTOMATIC
FEEDBACK
** WATER BALANCE
WATER LOOP TYPE CLOSED
EVAPORATION WATER LOSS - LITER/S 17.8
SLUDGE HYDRATION WATER LOSS - LITER/S .6
SLUDGE INTERSTITIAL WATER LOSS - LITERS/S 2.1
POKD SEEPAGE/RUNOFF WATER LOSS - LITERS/S 0
EFFLUENT WATER LOSS - LITERS/S .0
RECEIVING WATER STREAM N/A
MAKEUP WATER ADDITION LITERS/S 20.2
( 282 GPM)
( 9 GPM)
( 33 GPM)
( 0 GPM)
( 321 GPM)
SOURCE OF MAKEUP WATER
COOLING TOWER BLOWDOUN
13-245
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COLORADO UTE ELECTRIC: CRAIG Z (CONT.)
** CHEMICALS AND CONSUMPTION
FUNCTION ABSORBENT
NAME LIMESTONE
PRINCIPAL CONSTITUENT CAC03
CONSUMPTION 7000 LB/HR
UTILIZATION - 7. 75.0
POINT OF ADDITION BALL MILL
** FGD SPARE CAPACITY INDICES
ABSORBER '/. 33.3
MIST ELIMINATOR - X 33.3
REHEATER - X 33.3
BALL MILL - X .0
EFFLUENT HOLD TANK - 7. 33.3
THICKENER - X .0
CENTRIFUGE - X 50.0
** FGD 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
7/79 SYSTEM 744
8/79 SYSTEM 744
9/79 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM AT CRAIG 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 FGO SYSTEM WAS PUT BACK ON LINE ON DECEMBER 19. SHAKEDOWN
OPERATIONS ARE CONTINUING.
1/80 SYSTEM 74^
2/80 SYSTEM 696
3/80 SYSTEM 744
** PR03LEMS/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.
13-246
-------
UTILITY F6D SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COLORADO UTE ELECTRIC: CRAIG 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
5/60
X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
PROBLEMS WITH OPENING/CLOSING THE BYPASS DAMPER HAVE BEEN ENCOUNTERED.
LARGER OPERATORS ARE BEING TESTED THAT MAY SOLVE THE PROBLEM.
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.
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
640 661
253 76.8
** PROBLEMS/SOLUTIONS/COMMENTS
THE CRAIG 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 COAL 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
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 A
B
C
D
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
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
744 672
327 75.6
13-247
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COLORADO UTE ELECTRIC: CRAIG 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
'/. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
9/80
10/80
11/80
12/80
1/81
** 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.
A
B
C
D
SYSTEM
48.6
58.2
61.1
67.4
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
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
99.5
99.5
99.5
99.5
99.5
89.4
91.5
88.4
92.5
90.5
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 BOILER WAS TAKEN OFF LINE ON OCTOBER 5 FOR A FIVE WEEK SCHEDULED
OUTAGE.
AN IN-LINE 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 5.7X.
A
B
C
D
SYSTEM
69.4
.0
70.8
72.2
70.8
61.7
.0
71.0
89.7
74.1
66.0
.0
76.0
96.0
79.3
27.5
.0
31.6
40.0
33.0
720 321
38.8
** PROBLEMS/SOLUTIONS/COMMENTS
A
B
C
D
SYSTEM
43.0
.0
53.8
60.5
52.4
57.5
.0
69.3
78.4
68.4
THE FGO 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 42.6
.0
70.7 51.3
80.0 58.1
69.8 50.7 744 551 377 54.6
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE B REMAINED OFF LINE DURING DECEMBER DUE TO BOOSTER FAN BLADE
PITCH PROBLEMS.
A
B
C
D
SYSTEM
67.2
.0
79.8
89.2
78.7
66.0
.0
78.2
88.9
77.7
66.2
.0
78.4
89.2
77.9
65.9
.0
77.9
88.7
77.5
744 742
414 85.5
13-248
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COLORADO UTE ELECTRIC: CRAIG 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
DURING JANUARY MODULE B REMAINED OUT OF SERVICE DUE TO BOOSTER FAN BLADE
PITCH PROBLEMS AND PROBLEMS WITH THE SYSTEM INTERLOCKS.
2/81 A
B
C
D
SYSTEM
32.7
65.5
.0
100.0
66.1
32.1
64.3
.0
100.0
65.5
32.2
64.5
.0
99.8
65.7
32.1
64.3
.0
100.0
65.5
672 672 90.1
** PROBLEMS/SOLUTIONS/COMMENTS
PROBLEMS WERE ENCOUNTERED DURING THE MONTH WITH OPENING THE MODULE A, B,
AND C DAMPERS.
DURING FEBRUARY MODULE A ALSO ENCOUNTERED PLUGGAGE IN THE MOISTURE SEPARA-
TOR.
3/81
A
B
C
D
SYSTEM
68.5
80.6
.0
52.4
52.4
69.8
82.3
.0
53.2
53.2
70.1
62.8
.0
53.5
53.5
67.9
80.1
.0
51.7
51.7
744 724 385 85.6
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MARCH MODULES C AND D EXPERIENCED PROBLEMS WITH THE MIST ELIMINATOR
PLUGGING.
ADDITIONAL OUTAGE TIME OF MODULE C WAS DUE TO OPERATIONAL PROBLEMS OF THE
DAMPERS.
4/81 SYSTEM .0 .0 .0 .0 720 596 0 59.3
** PROBLEMS/SOLUTIONS/COMMENTS
THE SYSTEM DID NOT OPERATE DURING APRIL BECAUSE OF PLUGGED MIST
ELIMINATORS. THE MIST ELIMINATORS ARE BEING CLEANED.
5/81 SYSTEM .0 .0 .0 .0 744 744 0
6/81 SYSTEM .0 .0 .0 .0 720 717 0 78.7
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MAY AND JUNE THE SYSTEM WAS OUT OF SERVICE DUE TO DAMAGED MIST
ELIMINATOR PADS AND PLUGGING OF THE MIST ELIMINATOR.
7/81 SYSTEM .0 .0 .0 .0 744 686 0 61.6
** PROBLEMS/SOLUTIONS/COMMENTS
ALL MODULES REMAINED OUT OF SERVICE DURING JULY AS A RESULT OF THE BROKEN
MIST ELIMINATOR TRAYS.
744 724 297 73.2
8/81 A
B
C
D
SYSTEM
.0
.0
59.7
39.5
33.1
.0
.0
61.0
40.5
33.8
.0
.0
61.8
41.0
34.3
.0
.0
59.4
39.4
32.9
13-249
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COLORADO UTE ELECTRIC: CRAIG Z (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
10/81
11/81
12/81
** PROBLEMS/SOLUTIONS/COMMENTS
MODULES A AND B REMAINED DOWN DURING AUGUST AS THE UTILITY WAS WAITING FOR
NEW MIST ELIMINATOR TRAYS.
MODULE D WAS UNAVAILABLE FOR PART OF THE MONTH AS A RESULT OF PROBLEMS WITH
DAMPERS.
9/81
A
B
C
D
SYSTEM
18.1
40.3
81.9
13.9
51.4
18.4
40.9
83.6
13.4
52.1
18.6
41.4
84.5
13.5
52.7
17.8
39.6
80.8
12.9
50.4
720 696
538 81.5
** PROBLEMS/SOLUTIONS/COMMENTS
ALL FOUR MODULES BECAME OPERABLE TOWARD THE END OF THE MONTH. MODULE D HAD
BEEN OUT OF SERVICE AS A RESULT OF OUTLET DAMPER PROBLEMS. MODULE A
WAS PUT IN SERVICE THE THIRD WEEK OF THE MONTH AFTER HAVING THE
MIST ELIMINATORS REPLACED. THE MODULES ARE NOW BEING SHUT DOWN
ON A REGULAR BASIS TO CLEAN THE MIST ELIMINATORS.
A
B
C
D
SYSTEM
83.9
44.6
85.2
65.3
99.7
83.7
44.3
84.9
84.9
99.3
83.8
44.4
85.1
85.1
99.5
83.7
44.3
84.9
84.9
99.3
744 744
739 85.7
** PROBLEMS/SOLUTIONS/COMMENTS
DURING OCTOBER MODULE B EXPERIENCED BOOSTER FAN BEARING PROBLEMS.
PROBLEMS WITH INSTRUMENTATION HINDERED ALL FOUR MODULES DURING THE MONTH.
A
B
C
D
SYSTEM
19.3
1.9
11.8
29.6
20.8
43.8
4.1
26.7
67.3
47.3
48.4
4.6
29.5
74.4
52.3
19.2
1.8
11.7
29.4
20.7
720 315
149 32.9
»» PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS SHUT DOWN FROM NOVEMBER 8 THRU NOVEMBER 23 FOR SCHEDULED
MAINTENANCE.
A PROBLEM WITH MANY OF THE VALVES STICKING AT STARTUP WAS RESOLVED BY
FLUSHING.
LIMESTONE BALL MILL PLUGGING PROBLEMS WERE ENCOUNTERED DURING
DECEMBER.
A
B
C
D
SYSTEM
33.2
32.9
88.0
51.6
68.5
33.3
33.1
88.7
51.9
69.0
33.8
33.6
89.9
52.6
70.0
32.9
32.7
87.6
51.3
68.1
744 735 507 82.1
»* PROBLEMS/SOLUTIONS/COMMENTS
DURING DECEMBER PROBLEMS WERE ENCOUNTERED WITH THE BOOSTER FAN BEARING.
MODULE D EXPERIENCED PROBLEMS WITH A BINDING OUTLET DAMPER.
13-250
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1964
COLORADO UTE ELECTRIC: CRAIG 2 (CONT.)
PERIOD
1/82
MODULE AVAILABILITY
A
B
C
D
SYSTEM
81.
75.
77.
83.
100.
3
0
1
3
0
OPERABILITY
83
77
79
86
100
.9
.5
.8
.1
.0
--rtKruKriAr
RELIABILITY
84
78
80
87
100
.9
.4
.7
.1
.0
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COLORADO UTE ELECTRIC: CRAIG 2 (CONT.)
PERPORHANLt UAIA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE B WAS OFF-LINE DURING JUNE DUE TO DAMAGED TURNING VANES.
MODULES A, C, AND D WERE TAKEN DOWN FOR CLEANING AND REPAIR OF THE MIST
ELIMINATOR DURING PART OF THE MONTH.
7/82 A 67.9 67.7 69.4 67.7
B 47.2 47.2 48.3 47.2
C 74.1 74.0 75.8 74.0
D 43.8 43.7 44.8 43.7
SYSTEM 77.6 77.5 79.4 77.5 744 744 577 79.
** PROBLEMS/SOLUTIONS/COMMENTS
8/82 A
B
C
D
SYSTEM
56.3
.0
85.5
29.5
57.1
DURING JULY
OF EXCESSIVE
57.3
.0
87.1
29.9
58.1
THE UNIT EXPERIENCED NUMEROUS INSTRUMENT FAILURES AS A RESULT
MOISTURE IN THE INSTRUMENT AIR SUPPLY.
63.2 56.2
.0 .0
96.1 85.4
33.0 29.4
64.1 57.0 744 730 424 68.
6
8
** PROBLEMS/SOLUTIONS/COMMENTS
DURING AUGUST MODULES B AND D WERE DOWN DUE TO INOPERABLE OUTLET DAMPERS.
MODULE D WAS REPAIRED BY THE END OF THE MONTH, HOWEVER REPAIRS CONTINUED
MODULE B.
9/82 A
B
C
D
SYSTEM
.0
.0
36.7
27.6
21.4
.0
.0
65.3
49.1
38.1
.0 .0
.0 .0
79.5 36.5
59.8 27.5
46.4 21.3 720 403 153 36.
ON
9
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE A WAS
MODULE B WAS
OUT OF SERVICE DURING SEPTEMBER DUE TO ABSORBER LINER DAMAGE
DOWN DURING SEPTEMBER DUE TO OUTLET DAMPER PROBLEMS.
DUCTWORK PROBLEMS WERE ALSO EXPERIENCED BY MODULE B DURING THE MONTH.
10/82 A
B
C
D
SYSTEM
.0
.0
50.9
25.0
25.3
THE UNIT WAS
LASTING THE
.0
.0
57.3
28.1
28.5
TAKEN OUT OF SERVICE ON SEPTEMBER 18 FOR AN ANNUAL OUTAGE
REMAINDER OF THE MONTH.
.0 .0
.0 .0
94.0 50.8
46.1 24.9
46.7 25.2 744 659 187 65.
1
** PROBLEMS/SOLUTIONS/COMMENTS
MODULES A AND B WERE DOWN DURING OCTOBER AWAITING ABSORBER LINER REPAIRS.
MODULE D DEVELOPED A BOOSTER FAN OIL LEAK DURING THE MONTH. THE PROBLEM
OCCURRED FOLLOWING THE UNIT OUTAGE AND FORCED THE MODULE OUT OF SERVICE FOR
REPAIRS.
11/82 A
.0
.0
.0
.0
13-252
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COLORADO UTE ELECTRIC: CRAIG 2 (CONT.)
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
SOS PART. HOURS HOURS HOURS FACTOR
B .0 .0 .0 .0
C 63.6 63.5 63.7 63.5
D 93.8 93.6 94.0 93.6
SYSTEM 52.5 52.4 52.6 52.4 720 720 377 71.
** PROBLEMS/SOLUTIONS/COMMENTS
12/82 A
B
C
D
SYSTEM
MODULES A AND B REMAINED OUT OF SERVICE DURING NOVEMBER AWAITING ABSORBER
LINER REPAIRS.
.0 .0 .0 .0
.0 .0 .0 .0
93.8 93.7 93.7 93.7
18.5 18.5 18.5 18.5
37.5 37.4 37.4 37.4 744 744 278 69.
3
6
«* PROBLEMS/SOLUTIONS/COMMENTS
1/83 A
B
C
D
SYSTEM .
MODULES A AND B REMAINED OUT OF SERVICE DURING DECEMBER AWAITING ABSORBER
LINER REPAIRS.
MODULE D DEVELOPED A BOOSTER FAN LUBE OIL LEAK DURING DECEMBER.
.0 .0 .0 .0
45.8 46.0 46.6 45.7
62.2 62.5 63.4 62.1
.0 .0 .0 .0
36.0 36.1 36.7 35.9 744 740 267 64.
1
*« PROBLEMS/SOLUTIONS/COMMENTS
2/83 A
B
C
D
SYSTEM
MODULE A WAS DOWN THE ENTIRE MONTH FOR ABSORBER LINER REPAIRS.
MODULE D WAS DOUN DURING JANUARY DUE TO A BOOSTER FAN OVERHAUL. MODULES
B AND C ALSO EXPERIENCED FAN PROBLEMS DURING THE MONTH.
MODULES B AND C EXPERIENCED DAMPER PROBLEMS IN JANUARY.
.0 .0 .0 .0
40.7 40.9 41.3 40.7
57.5 57.8 58.3 57.5
.0 .0 .0 .0
32.7 32.9 33.2 32.7 672 668 220 67.
5
*# PROBLEMS/SOLUTIONS/COMMENTS
3/83 A
B
C
D
SYSTEM
MODULES A AND C WERE DOWN DURING FEBRUARY FOR ABSORBER LINER REPAIRS.
MODULE B WAS DOWN DURING THE MONTH FOR REPAIRS ON THE INLET DAMPER.
MODULES B AND D WERE DOWN DURING FEBRUARY FOR BOOSTER FAN REPAIRS.
34.8 36.2 37.8 34.8
49.4 51.4 53.6 49.4
.0 .0 .0 .0
.0 .0 .0 .0
28.1 29.2 30.5 28.1 744 715 209 68.
0
4/83
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE C WAS DOWN DURING MARCH FOR ABSORBER LINER REPAIRS.
A 42.2 85.0 97.4 42.2
13-253
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COLORADO UTE ELECTRIC: CRAIG 2 (CONT.)
____, . PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
B .0 .0 .0 .0
C .0 .0 .0 .0
D .0 .0 .0 .0
SYSTEM 14.0 28.3 24.3 14.0 720 357 102 34.3
«* PROBLEMS/SOLUTIONS/COMMENTS
ON APRIL 15, THE UNIT WAS TAKEN DOWN FOR AN ANNUAL OUTAGE.
MODULES B AND C WERE UNDERGOING LINER REPAIR WORK DURING THE MONTH.
MODULE D WAS DOWN IN APRIL AWAITING THE RETURN OF A BOOSTER FAN FROM THE
MANUFACTURER.
544 87 49.5
5/83
A
B
C
D
SYSTEM
35.1
.0
.0
.0
11.7
48.0
.0
.0
.0
16.0
54.4
.0
.0
.0
18.1
35.1
.0
.0
.0
11.7
744
** PROBLEMS/SOLUTIONS/COMMENTS
6/83
A
B
C
D
SYSTEM
70.1
9.0
65.8
.0
48.3
THE UNIT WAS
70.6
7.9
66.3
.0
48.3
DOWN MOST OF
72.7
8.2
68.3
.0
49.7
MAY FOR AN ANNUAL OUTAGE.
70.1
7.9
65.8
.0
47.9
720
7/83
715 345 69.6
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE B WAS DOWN DURING MOST OF JUNE DUE TO PROBLEMS WITH A BOOSTER FAN
BLADE PITCH CONTROL.
DAMPER PROBLEMS ALSO ACCOUNTED FOR THE MODULE B OUTAGE IN JUNE.
MODULE D WAS DOWN DURING JUNE AWAITING THE RETURN OF A BOOSTER FAN FROM THE
MANUFACTURER.
A
B
C
0
SYSTEM
72.6
92.2
49.9
.0
71.6
72.7
37.4
52.7
.0
54.3
73.2
37.7
53.1
54.7
72.6
37.4
52.6
.0
54.2
744 742 403 73.7
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE A WAS DOWN DURING PART OF JULY FOR MIST ELIMINATOR CLEANING.
MODULE C WAS DOWN DURING PART OF THE MONTH FOR RECYCLE PUMP REPAIRS.
MODULE D WAS OUT OF SERVICE DURING JULY AWAITING DELIVERY OF A BOOSTER FAN.
744 744 470
8/83
A
B
C
D
SYSTEM
75.8
12.0
74.2
.0
54.0
75.8
83. 1
25.8
.0
63.3
75.8
88.0
25.8
63.2
75.8
88.0
25.8
.0
63.2
13-254
-------
UTILITY F6D SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COLORADO UTE ELECTRIC: CRAIG 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE D WAS DOWN DURING AUGUST DUE TO BOOSTER FAN REPAIRS.
9/83
A
B
C
D
SYSTEM
95.3
43.1
32.8
.0
57.1
95.6
57.1
67.4
.0
73,4
100.0
59.9
70.7
76.9
95.3
56.9
67.2
.0
73.2 720 718 527 75.8
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR FGD-RELATED OUTAGES
10/83
11/83
A
B
C
D
SYSTEM
A
B
C
D
SYSTEM
96.8
94.4
.0
.0
63.7
99.9
89.9
.0
.0
63.3
100.0
.8
.0
.0
33.6
100.0
.8
50.4
99.9
89.9
.0
63.3
WERE ENCOUNTERED DURING SEPTEMBER.
96.8
.8
.0
.0
32.5 744 718 242 81.3
99.9
89.9
.0
.0
63.3 720 456
12/83
1/84
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED DURING OCTOBER AND NOVEMBER
1983.
A
B
C
D
SYSTEM
64.0
72.2
78.2
.0
71.4
68.5
77.3
83.7
.0
76.5
67.1
75.7
82.0
75.0
64.0
72.2
78.2
.0
71.4
744 695 532 98.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED A UNIT TRIP ON DECEMBER 14 AND 15, 1983.
744 714 519
A
B
C
D
SYSTEM
86.0
72.8
50.3
.0
69.7
89.6
75.9
52.4
.0
72.6
94.8
80.3
55.4
76.8
86.0
72.8
50.3
.0
69.7
** PROBLEMS/SOLUTIONS/COMMENTS
2/84
3/84
4/84
SYSTEM
SYSTEM
SYSTEM
THE UTILITY REPORTED THAT THE UNIT SUFFERED A UNIT-TRIP AND SPENT 10 HOURS
OUT OF SERVICE.
THE UNIT LOST HOURS ON JUNE 27-29 DUE TO REPAIRS TO THE THICKENER.
696
744
720
13-255
-------
UTILITY FGD SURVEY: OCTOBER 1933 - SEPTEMBER 1984
COLORADO UTE ELECTRIC: CRAIG 2 (COST.)
. PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
5/84
INFORMATION WAS UNAVAILABLE FOR THE PERIOD OF FEBRUARY THROUGH APRIL
1984.
A
B
C
D
SYSTEM
50.7
51.8
.0
,0
34. Z
77.6
98.1
.0
.0
58.6
77.6
98.1
.0
58.6
41.0
51.8
.0
.0
30.9
744 393 230
** PROBLEMS/SOLUTIONS/COMMENTS
THE RECYCLE TANK AGITATOR WAS OUT OF SERVICE DURING MAY.
THE MIST ELIMINATOR PAD ON MODULE C WAS CLEANED DURING MAY.
6/84
7/84
8/84
A
B
C
D
SYSTEM
A
B
C
D
SYSTEM
A
B
C
D
SYSTEM
86.2
87.1
.0
75.6
83.0
91.7
86.7
.0
91.3
90.1
100.0
100.0
.0
100.0
100.0
87.0
62.3
.0
74.4
74.6
98.4
94.3
.0
99.9
97.5
86.3
100.0
.0
86.0
90.8
96.3
69.0
82.3
82.5
100.0
100.0
.0
100.0
100.0
100.0
100.0
146.1
100.0
86.2
61.7
.0
73.7
73.8
90.5
86.7
.0
91.8
89.7
86.3
100.0
.0
86.0
90.8
720
713
684
744 744
532
667
675
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR FGD-RELATED PROBLEMS WERE REPORTED DURING THE PERIOD OF JUNE
THROUGH AUGUST.
9/84 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR SEPTMBER 1984.
720
13-256
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
SECTION 13
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
SOZ 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 - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RAN3E SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
*** PARTICLE CONTROL
** FABRIC FILTER
NUMBER
PRESSURE DROP - KPA
TYPICAL GAS/CLOTH RATIO - M/MIN
** PARTICLE SCRUBBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON NAME
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
GAS CONTACTING DEVICE 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
COLORADO UTE ELECTRIC
CRAIG
3
CRAIG
COLORADO
C
13.
86.
******
900
447
424
495
447
BABCOCK * WILCOX
PULVERIZED COAL
BASE
722.29
*******
183.
CONCRETE
*******
( .030 LB/MMBTU)
( .ZOO LB/MMBTU)
(****** LB/MMBTU)
(1530600 ACFM)
(**** F)
( 600 FT)
COAL
SUBBITUMINOUS
23260.
(***** FT)
( 10000 BTU/LB)
9100-10300
10.
10.
8.00
.0-12.0
14.00
.0-12.0
.45
0.4-0.5
.10
0.05-0.10
1.5
.7
( 6.0 IN-H20)
( 2.3 FT/MIN)
0
NONE
N/A
N/A
N/A
N/A
N/A
N/A
N/A
THROWAWAY PRODUCT
SPRAY DRYING
LIME/SPRAY DRYING
BABCOCK & WILCOX
STANLEY CONSULTANTS
FULL SCALE
NEW
X 99.80
85.00
13-257
-------
UTILITY FGD SURVEY: OCTOBER 1933 - SEPTEMBER 1984
COLORADO UTE ELECTRIC: CRAIG 3 (CONT.)
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
** QUENCHER/PRESATURATOR
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** ABSORBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
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
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
S02 REMOVAL EFFICIENCY - X
PARTICLE REMOVAL EFFICENCY - '/.
*« MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
»» REHEATER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** FANS
DESIGN
FUNCTION
APPLICATION
SERVICE
CONSTRUCTION MATERIAL GENERIC TYPE
** DAMPERS
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
1
2/85
6/84
4/80
NR
NR
SPRAY DRYER
NR
HYDRAULIC PRESSURE NOZZLE
NR
MR
NR
NR
NR
NR
NONE
2
528.29
83.3
90.0
99.8
(1119490 ACFM)
( 182 F)
NONE
N/A
N/A
N/A
NR
NR
NR
NR
NR
NR
NR
NR
NR
INDUCED DRAFT
DRY
CARBON STEEL
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
SLAKER
NR
NR
13-258
-------
COLORADO UTE ELECTRIC: CRAIG 3 (CONT.)
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
** TANKS
SERVICE
NR
«* punps
SERVICE
NR
»* SOLIDS CONCENTRATING/DEWATERING
DEVICE
*** SLUDGE
** TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
** DISPOSAL
NATURE
TYPE
SITE TREATMENT
** MATER BALANCE
NUMBER
***»
NUMBER
****
N/A
N/A
N/A
N/A
FINAL
POND
NONE
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
6/84 SYSTEM
7/84 SYSTEM
8/84 SYSTEM
9/84 SYSTEM
*» PROBLEMS/SOLUTIONS/COMMENTS
720
744
744
720
THE UTILITY REPORTED THAT INITIAL START UP COMMENCED IN JUNE 1984.
COMMERCIAL START UP IS SCHEDULED FOR FEBRUARY 1985.
THE SPRAY DRYER SYSTEM AT CRAIG 3 IS THE SECOND BABCOCK AND WILCOX
LIME/SPRAY DRYING PROCESS IN OPERATION TO DATE. THE UTILITY REPORTED
THAT MODIFICATIONS ARE BEING MADE BASED ON PROBLEMS EXPERIENCED AT THE
FIRST BABCOCK AND WILCOX INSTALLATION (LARAMIE RIVER 3).
13-259
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
SECTION 13
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 - MW
** UNIT DATA - BOILER AMD 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
COLUMBUS & SOUTHERN OHIO ELEC
CONESVILLE
CONESVILLE
OHIO
D
43. (
516. (
301. (
1890
405
373
380
350
.100 LB/MMBTU)
.200 LB/MMBTU)
.700 LB/MMBTU)
COMBUSTION ENGINEERING
PULVERIZED COAL
CYCLING
596.95 (1265000 ACFM)
146.7 ( 296 F)
244. ( 800 FT)
CONCRETE
7.9 ( 26.0 FT)
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 7.
RANGE ASH CONTENT - V.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RAN3E CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** MECHANICAL COLLECTOR
NUMBER
TYPE
** ESP
NUMBER
NUMBER OF SPARES
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
TRADE NAME/COMMON NAME
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
*** FGD SYSTEM
COAL
BITUMINOUS
25237. ( 10850 BTU/LB)
10000-12000
14.90
10.0-24.0
7.50
5.0-18.0
4.50
4.2-5.1
.01
0.01-0.11
0
NONE
1
0
COLD SIDE
RESEARCH-COTTRELL
657.8 (1393893 ACFM)
146.7 ( 296 F)
.5 (2. IN-H20)
99.6
0
NONE
N/A
N/A
N/A
N/A
N/A
N/A
N/A
13-260
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COLUMBUS £ SOUTHERN OHIO ELEC: CONESVILLE 5 (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 SOS REMOVAL EFFICIENCY - X
ENERGY CONSUMPTION - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
OPER. 4 MAINT. REQUIREMENT - MANHR/DAY
## QUENCHER/PRESATURATOR
NUMBER
TYPE
SUPPLIER
INLET GAS TEMPERATURE - C
L/G RATIO - L/CU. M
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** 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
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
NUMBER OF SPARES PER SYSTEM
NUMBER PER MODULE
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
THROWAWAY PRODUCT
WET SCRUBBING
LIME
MAG
AIR CORRECTION DIVISION, UOP
BLACK & VEATCH
FULL SCALE
NEW
X 99.65
89.50
1.7
1
2/77
1/77
10/74
280.0
SPRAY CHAMBER
AIR CORRECTION DIVISION, UOP
141.1 ( 286 F)
.1 ( .6 GAL/1000 ACFM)
HIGH ALLOY
IRON BASE/NICKEL-CHROMIUM-COPPER-MOLYBDENUM
2
0
PACKED TOWER
MOBILE BED PACKING
TURBULENT CONTACT ABSORBER
AIR CORRECTION DIVISION, UOP
45.0 X 17.5 X 79.5
CARBON STEEL
AISI 1110
N/A
ORGANIC
SYNTHETIC RUBBER
NEOPRENE LS-576
GRID CAGES
1
1988.
6.6
2.0
4.0
301.81
51.7
92.0
99.6
(31560 GPM)
( 49.3 GAL/1000 ACF)
( 8.1 IN-H20)
( 13.1 FT/S)
( 639568 ACFM)
t 125 F)
PRIMARY COLLECTOR
2
0
1
IMPINGEMENT
BAFFLE
CLOSED VANE
HORIZONTAL
2
05
11.43
5.1
90
.5
(10.0 FT)
( 4.5 IN)
( 2.00 IN)
( 1.9 IN-H20)
13-261
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
COLUMBUS & SOUTHERN OHIO ELEC: CONESVILLE 5 (COST.)
SUPERFICAL GAS VELOCITY - M/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
WASH WATER SOURCE
WASH FREQUENCY
WASH RATE - L/S
** REHEATER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** FANS
NUMBER
NUMBER OF SPARES
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
CONSTRUCTION MATERIAL GENERIC TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
#* DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
#* DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
( 10.0 FT/S)
3.0
ORGANIC
FIBER-REINFORCED POLYESTER
RECLAIMED
CONTINUOUS
63.1 ( 1000 SAL/MIN)
NONE
N/A
N/A
NONE
N/A
Z
0
CENTRIFUGAL
GREEN FAN
UNIT
FORCED DRAFT
DRY
401.11 ( 850000 ACFM)
146.7 ( 296 F)
.6 ( 2.0 IN-H20)
CARBON STEEL
SHUT-OFF
GUILLOTINE
HIGH ALLOY
NICKEL BASE/CHROMIUM-IRON-MOLYBOENUM
.NONE
'JN/A
SHUT-OFF
GUILLOTINE
HIGH ALLOY
NICKEL BASE/CHROMIUM-IRON-MOLYBDENUM
NONE
N/A
2
CONTROL
GUILLOTINE & LOUVER
HIGH ALLOY
NICKEL BASE/CHROMIUM-IRON-MOLYBDENUM
NONE
N/A
INLET
CARBON STEEL
HIGH STRENGTH LOW ALLOY tHSLA]
NONE
N/A
OUTLET TO DAMPER
CARBON STEEL
HIGH STRENGTH LOW ALLOY IHSLA]
ORGANIC
GLASS FLAKE-FILLED POLYESTER
OUTLET BEYOND DAMPER
CARBON STEEL
13-262
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COLUMBUS & SOUTHERN OHIO ELEC: CONESVILLE 5 (CONT.)
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
#* DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
MANUFACTURER
NUMBER
#* TANKS
SERVICE
ABSORBER RECYCLE
RECLAIMED WATER
REAGENT PREP PRODUCT
MIST ELIMINATOR WASH
»* PUMPS
SERVICE
ABSORBER RECIRCULATION
LIME SLURRY TRANSFER
SLURRY MAKEUP
RECYCLE TANK DRAWOFF
MIST ELIMINATOR WASH
RECLAIM WATER
THICKENER UNDERFLOW
«* SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
BELT GENERIC MATERIAL TYPE
BELT SPECIFIC MATERIAL TYPE
FEED STREAM SOURCE
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
OUTLET STREAM DISPOSITION
OVERFLOW STREAM DISPOSITION
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
DIMENSIONS - FT
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
FEED STREAM SOURCE
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
OUTLET STREAM DISPOSITION
OVERFLOW STREAM DISPOSITION
*** SLUDGE
HIGH STRENGTH LOW ALLOY [HSLA]
INORGANIC
CHEMICALLY-BONDED CONCRETE
BYPASS
CARBON STEEL
HIGH STRENGTH
NONE
N/A
SLAKER
PASTE
N/A
WALLACE t
5
LOW ALLOY IHSLAI
TIERNAN
NUMBER
2
1
2
2
NUMBER
10
2
3
4
4
2
**«*
VACUUM FILTER
3
1
CARBON STEEL
AISI 1110
ORGANIC
POLYPROPYLENE
THICKENER UNDERFLOW
30X SOLIDS
BOX SOLIDS
TO IUCS PROCESS
TO RECLAIMED WATER TANK
THICKENER
2
0
145.0 DIA X 16.0
CARBON STEEL
AISI 1110
ORGANIC
EFOXY
ABSORBER BLEED
7-12X SOLIDS
30X SOLIDS
TO IUCS THICKENER
S THEN TO VACUUM FILTER
TO RECLAIMED WATER TANK
13-263
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COLUMBUS t SOUTHERN OHIO ELEC: CONESVILLE 5 (CONT.)
»* TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
INLET QUALITY - X
*» DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE TREATMENT
SITE DIMENSIONS
** PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS
PHYSICAL VARIABLES
CONTROL LEVELS
MONITOR LOCATION
PROCESS CONTROL MANNER
PROCESS CHEMISTRY MODE
** WATER BALANCE
HATER LOOP TYPE
MAKEUP WATER ADDITION - LITERS/S
** CHEMICALS AND CONSUMPTION
FUNCTION
NAME
PRINCIPAL CONSTITUENT
SOURCE/SUPPLIER
CONSUMPTION
UTILIZATION 7.
POINT OF ADDITION
** FGD SPARE CAPACITY INDICES
ABSORBER 7.
** FGD SPARE COMPONENT INDICES
ABSORBER
FIXATION
PUG MILL
CONVERSION SYSTEMS IPOZ-O-TECJ
50.0
FINAL
LANDFILL
ON-SITE
PIPELINE/CONVEYED
NONE
80 ACRES/50 FT
PH
RECYCLE TANK LEVEL
OUTLET PH 5.5-6.35 RECYCLE PH 7.0-7.5
SLURRY DISCHARGE FROM MODULE
AUTOMATIC
FEEDBACK
CLOSED
31.5
( 500 GPM)
ABSORBENT
LIME
90-95X CAO, 3-8X MGO
DRAVO
16 TPH
90.0
SLAKER
.0
.0
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
502 PART. HOURS HOURS HOURS FACTOR
12/76 SYSTEM 744
»* PROBLEMS/SOLUTIONS/COMMENTS
A MAJOR FIRE IN MODULE A DELAYED THE UNIT START-UP. THE FIRE CAUSED $2.1
MILLION DAMAGE. THE UTILITY'S INSURANCE COVERED THE DAMAGE AND A NEW
SCRUBBER MODULE WILL BE PURCHASED FROM AND INSTALLED BY UOP.
THE UTILITY IS CURRENTLY CONDUCTING AIR AND WATER TESTS ON MODULE B.
1/77 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
INITIAL START-UP FOR DEBUGGING AND COMMISSIONING PURPOSES OCCURRED IN
EARLY JANUARY. COMMERCIAL AVAILABILITY FOR SERVICE OCURRED ON JANUARY
27.
EARLY OPERATIONS WERE MARKED BY COLD WEATHER RELATED PROBLEMS SUCH AS
FROZEN LINES AND GEARS, CRACKED FLANGES, A FROZEN LIME BELT CONVEYOR, AND
A FROZEN PIPELINE FROM THE THICKENER TO THE IUCS FACILITY.
13-264
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UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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
2/77 B
SYSTEM
43.0
43.0
672 668
** PROBLEMS/SOLUTIONS/COMMENTS
3/77 B
SYSTEM
4/77 B
SYSTEM
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
41.8
40.0
40.5
37.4
744 520
720 685
** 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 S3 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
** 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
13-265
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UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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
SCHEDULED FOR SEPTEMBER 1977.
THE REPLACEMENT A-SIDE TCA MODULE REPLACING THE ORIGINAL MODULE DESTROYED
BY FIRE IN DECEMBER 1976 IS EXPECTED TO BE AVAILABLE FOR COMMERCIAL
SERVICE IN JANUARY 1978.
8/77 B
SYSTEM
9/77 B
SYSTEM
.0
52.9
.0
39.9
.0
46.9
.0
26.0
744 613
720 469
** PROBLEMS/SOLUTIONS/COMMENTS
THE PARTICULATE DROP TEST SCHEDULED FOR SEPTEMBER 1977 WAS PUSHED BACK TO
THE WEEK OF OCTOBER 24 1977.
THE SCRUBBER WAS NOT OPERATED THE ENTIRE MONTH OF AUGUST. REPAIRS MID
MODIFICATIONS CONTINUED UNTIL SEPTEMBER 13. THERE WERE SOME WEATHER-
RELATED DELAYS.
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
744 559
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
A
B
SYSTEM
93.0
97.0
95.0
64.0
79.0
71.5
62.0
76.0
69.0
22.0
27.0
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. DURIK3 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.
1/78 SYSTEM
2/78 SYSTEM
3/78 A
B
SYSTEM
744
672
20.0
20.0
20.0
19.0
15.8
17.4
64.0
54.0
59.0
10.0
8.0
9.0
744 379
0
0
66
.0
.0
13-266
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UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
COLUMBUS 4 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
THE UNIT STARTED UP AGAIN ON MARCH 16.
PH CONTROLS AND S02 ANALYZERS HAVE EXPERIENCED OPERATIONAL PROBLEMS.
IMPURITIES IN THE LIME HAVE CAUSED PLUGGING PROBLEMS.
4/78 A 67.0 58.0 61.0 58.0
B 65.0 59.0 63.0 59.0
SYSTEM 66.0 58.5 62.0 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.
5/78 A 52.0 45.0 45.0 44.0
B 54.0 50.0 51.0 69.0
SYSTEM 53.0 47.5 48.0 56.5 744 720 420
*# PROBLEMS/SOLUTIONS/COMMENTS
THE SYSTEM WAS TAKEN OUT OF SERVICE BECAUSE OF CONTINUED PROBLEMS WITH THE
FLOCCULANT FEED SYSTEM. THE THICKENER WAS EMPTIED TO RESTORE PROPE-R FLOC-
CULANT BALANCE.
6/78
A
B
SYSTEM
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 24
#* PROBLEMS/SOLUTIONS/COMMENTS
7/78
A
B
SYSTEM
66.0
43.0
54.5
AN FRP PIPING
66.0
33.0
49.5
FAILURE
66.0
33.0
49.5
IN THE MIST ELIMINATOR WASH SYSTEM OCCURRED.
64.0
32.0
49.0 744 727 35
** PROBLEMS/SOLUTIONS/COMMENTS
OUTAGE TIME WAS DUE TO PLUGGING IN THE MIST ELIMINATOR AND SCRUBBER BALL
REGIONS.
8/78 A 18.0 20.0 20.0 18.0
B 18.0 21.0 21.0 18.0
SYSTEM 18.0 20.5 20.5 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.
13-267
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 198*
COLUMBUS & SOUTHERN OHIO ELEC: CONESVILLE 5 (CONT.)
PERIOD
9/78
10/78
PtKrUKriANUC UAI A
MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
A
B
SYSTEM
A
B
SYSTEM
61.0 46.0 55.0 45. 0
54.0 44.0 53.0 43.0
57.5 45.0 54.0 44.0 720 707 316
72.0 37.0 38.0 36.0
82.0 46.0 47.0 45.0
77.0 41.5 42.5 40.5 744 713 301
** PROBLEMS/SOLUTIONS/COMMENTS
11/78
12/78
A
B
SYSTEM
A
B
SYSTEM
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.
43.0 29.0 29.0 25.0
84.0 74.0 75.0 66.0
63.5 51.5 52.0 45.5 720 642 331
6.6 .3 .3 .3
33.1 36.3 36.6 30.0
19.8 18.3 18.4 15.1 744 609 112
** PROBLEMS/SOLUTIONS/COMMENTS
1/79
2/79
SYSTEM
SYSTEM
THE LOW HOUPS FOR THIS PERIOD ARE ATTRIBUTED TO FREEZE UPS.
.0 .0 .0 .0 744 602 0
.0 .0 .0 .0 672 629 0
** PROBLEMS/SOLUTIONS/COMMENTS
3/79
4/79
A
B
SYSTEM
A
B
SYSTEM
THE SYSTEM WAS UNAVAILABLE DURING JANUARY AND FEBRUARY BECAUSE OF SEVERE
WINTER WEATHER.
50.0 49.0 50.0 43.0
.0 .0 .0 .0
25.0 24.5 25.0 21.5 744 652 160
17.0 58.0 73.0 12.0
.0 .0 .0 .0
8-5 29.0 36.5 6.0 720 149 43
** PROBLEMS/SOLUTIONS/COMMENTS
5/79
SYSTEM
MODULE B DID NOT OPERATE DURING MARCH AND APRIL BECAUSE OF SEVERE CORRO-
SION AT THE PRESATURATOR INLET DUCT WHICH IS BEING REPAIRED BY UOP.
.0 .0 .0 .0 744 744 0
** PROBLEMS/SOLUTIONS/COMMENTS
6/79
A
B
SYSTEM
REPAIRS WERE MADE TO THE SEAL BETWEEN THE THICKENER BASE AND SIDEWALL.
THE FGD SYSTEM WAS DOWN DURING MAY FOR AN ANNUAL OUTAGE.
69.0 35.0 36.0 33.0
50.0 21.0 22.0 20.0
59.5 28.0 29.0 26.5 720 670 191
13-268
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UTILITY F6D SURVEY? OCTOBER 1983 - SEPTEMBER 1984
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
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.
7/79
8/79
9/79
10/79
11/79
12/79 SYSTEM
A
B
SYSTEM
A
B
SYSTEM
A
B
SYSTEM
A
B
SYSTEM
A
B
SYSTEM
75.3
93.4
84.4
86.6
65.6
86.1
89.3
95.9
92.6
53.2
47.8
50.5
74.0
70.0
72.0
76.3
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
77.6
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
69.0
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
744 672
744 305
720 383
744 443
.0
.0
720
744
414
0
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.
I/SO
A
B
SYSTEM
89.0
93.0
91.0
38.0
50.0
44.0
45.0
59.0
52.0
13.0
17.0
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
B
SYSTEM
90.0
93.0
92.0
63.0
69.0
66.0
77.0
84.0
81.0
31.0
34.0
33.0
696 343
226 31.4
** PROBLEMS/SOLUTIONS/COMMENTS
A BOILER OUTAGE LASTING APPROXIMATELY 17 DAYS ALSO OCCURRED DURING
FEBRUARY.
13-269
-------
UTILITY FGO SURVEY: OCTOBER 1983 - SEPTEMBER
COLUMBUS t SOUTHERN OHIO ELEC= CONESVILLE 5 (CONT.)
PERIOD
- ------------ptKrUKnANue DAI A
MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION V. REMOVAL PER
S02 PART. HOURS
BOILER FGD CAP.
HOURS HOURS FACTOR
IN FEBRUARY, MIST ELIMINATOR NOZZLE PLUGGING OCCURRED CAUSING SOME FGD
SYSTEM OUTAGE TIME.
3/80
A
B
SYSTEM
88.0 82.0 82.0 82.0
88.0 81.0 82.0 81.0
88.0 82.0 82.0 82.0 744
744 606 75.4
** PROBLEMS/SOLUTIONS/COMMENTS
DURINS 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.
4/80
A
B
SYSTEM
THE MAJORITY OF THE MARCH FGD SYSTEM OUTAGE TIME WAS DUE
PROBLEMS WITH THE MIST ELIMINATOR NOZZLES.
94.6 84.4 87.7 78.9
74.9 65.8 68.4 61.5
84.7 75.2 78.0 70.3 720
TO CONTINUING
673 506 63.1
*» PROBLEMS/SOLUTIONS/COMMENTS
5/80
A
B
SYSTEM
CONTINUAL PROBLEMS WITH THE DAMPERS, PRESATURATOR HOSES,
THE CAUSES OF FGD SYSTEM OUTAGE TIME IN APRIL.
92.1 86.2 86.2 86.2
90.3 84.3 84.3 84.3
91.3 85.2 85.2 65.2 744
AND NOZZLES WERE
744 634 69.5
** PROBLEMS/SOLUTIONS/COMMENTS
6/80
A
B
SYSTEM
IN MAY, CONTROLS AND INSTRUMENTATION DEVELOPED PROBLEMS
OUTAGE TIME.
89.6 71.0 71.0 70.7
94.3 74.8 74.8 74.4
91.9 72.9 72.9 72.6 720
THAT CAUSED SOME
717 523 65.1
** PROBLEMS/SOLUTIONS/COMMENTS
7/80
A
B
SYSTEM
EXTERNAL CAUSES (IUCS DISPOSAL FACILITY, LOW UNIT DEMAND
PROBLEMS, ETC.) WERE RESPONSIBLE FOR THE MAJORITY OF THE
90.6 70.7 72.4 43.8
88.8 82.0 84.0 50.8
89.7 76.4 78.2 47.3 744
, SERVICE WATER
JUNE OUTAGES.
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
B
SYSTEM
98.0 83.5 84.9 48.5
95.4 88.8 90.4 51.6
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
B
SYSTEM
87.6 73.4 74.4 73.1
88.8 65.1 86.3 82.0
£8.2 79.2 80.3 78.9 720
717 568 71.5
13-270
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COLUMBUS 4 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 THE JULY-SEPTEMBER PERIOD INLET DAMPER SEAL LEAKING WAS A MAJOR
PROBLEM.
THE PRESATURATOR PROBLEMS CONTINUED IN SEPTEMBER CAUSING ADDITIONAL OUTAGE
TIME FOR THE FGD SYSTEM.
10/80 A 92.7 77.8 80.8 75.7
B 89.2 80.0 82.9 77.7
SYSTEM 91.0 78.9 81.9 76.7 744 723 571 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 43.9 720 630 316 35.9
** PROBLEMS/SOLUTIONS/COMHENTS
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 81.2 744 689 604 72.6
** PROBLEMS/SOLUTIONS/COMMENTS
DURING DECEMBER THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS
WERE ENCOUNTERED.
1/81 A 90.6 85.7 87.4 77.4
B 90.5 86.0 84.9 77.2
SYSTEM 90.5 86.0 84.9 77.2 744 672 575 71.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JANUARY THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS
WERE ENCOUNTERED.
2/81 A 93.2 89.9 91.2 83.4
B 95.4 94.9 93.6 88.1
SYSTEM 94.2 92.3 92.4 85.7 672 624 576 100.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING FEBRUARY THE UTILITY REPORTED THAT NO MAJOR FGO-RELATED PROBLEMS
WERE ENCOUNTERED.
3/81 A 3.7 15.7 21.0 .5
B 4.0 23.5 31.0 .9
SYSTEM 3.9 19.6 26.0 .7 744 26 5 1.6
13-271
-------
UTILITY FED SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COLUMBUS i SOUTHERN OHIO ELEC: CONESVILLE 5 (CONT.)
_______ PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION V. REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
»* PROBLEMS/SOLUTIONS/COMMENTS
8/81
9/81
10/81
11/81
DURING MOST OF MARCH THE BOILER AND FSD SYSTEM WERE OFF LINE FOR SCHEDULED
MAINTENANCE.
720 555 450
744 707 707
720 698 698
4/81
5/81
6/81
A
B
SYSTEM
A
B
SYSTEM
A
B
SYSTEM
98.9
94.3
96.6
99.7
99.7
99.7
99.4
98.5
99.0
83.7
78.6
81.1
100.0
100.0
100.0
100.0
100.0
100.0
90.1
84.5
87.3
100.0
100.0
100.0
100.0
100.0
100.0
64.5
60.6
63.3
95.0
95.0
95.0
96.4
96.9
96.9
#* PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR OPERATIONAL PROBLEMS WERE ENCOUNTERED
DURING THE SECOND QUARTER 1981.
7/81 A
B
SYSTEM
99.8
100.0
99.9
100.0
100.0
100.0
100.0
100.0
100.0
55.4
55.4
55.4
744 412
412
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JULY, THE BOILER ONLY OPERATED 412 HOURS AS A RESULT OF FAILURE OF A
BOILER FEED PUMP.
A
B
SYSTEM
A
B
SYSTEM
99.0
99.0
99.0
100.0
87.0
93.5
76.0
30.0
53.0
59.0
43.0
53.5
95.0
88.0
91.5
100.0
81.0
90.5
43.0
39.0
41.0
6.0
5.0
5.5
744 422
720
69
305
41
** PROBLEMS/SOLUTIONS/COMMENTS
SEVERE OUTLET DUCT CORROSION HAS OCCURRED ON UNIT 5. THE GUNITE LINER HAS
FAILED DUE TO INADEQUATE STRENGTH OF THE SUPPORTING MESH. THE UTILITY
IS LOOKING INTO INCONEL OR FRP AS A REPLACEMENT LINER.
UNIT 5 WAS REMOVED FROM SERVICE ON SEPTEMBER 19 AS A RESULT OF LOW DEMAND.
THE UNIT IS NOT EXPECTED TO BE BROUGHT BACK ON LINE UNTIL DECEMBER.
THIS OUTAGE PERIOD WILL BE UTILIZED FOR OUTLET DUCTWORK REPAIRS.
A
B
SYSTEM
100.0
100.0
100.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
744
#* PROBLEMS/SOLUTIONS/COMMENTS
DURING OCTOBER MAJOR MODIFICATIONS WERE BEING PERFORMED ON THE BOILER
DUCTWORK. THIS INCLUDED REPAIRING THE CORRODED INNER SUPPORTS AND REPLAC-
ING THE GUNITE.
A
B
SYSTEM
27.0
27.0
27.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
720
13-272
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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
*# PROBLEMS/SOLUTIONS/COMMENTS
1/82
2/82
3/82
4/82
5/82
6/82
DURING NOVEMBER MAJOR MODIFICATION TO THE FGD SYSTEM DUCTWORK WAS PERFORM-
ED. THIS WORK INCLUDED REPAIRING THE CORRODED SUPPORTS AND RECOATING
WITH GUNITE.
ADDITIONAL OUTAGE TIME DURING THE MONTH WAS DUE TO GENERAL FGD MAINTENANCE.
A
B
SYSTEM
84.0
84.0
84.0
82.0
82.0
82.0
86.0
86.0
86.0
77.0
77.0
77.0
744 699
573
#* PROBLEMS/SOLUTIONS/COMMENTS
DURING DECEMBER TEST WERE CONDUCTED ON THE ESP.
ADDITIONAL OUTAGE TIME DURING THE MONTH WAS DUE TO HIGH THICKENER SOLIDS
AND PROBLEMS WITH THE FLYASH HANDLING SYSTEM.
A
B
SYSTEM
A
B
SYSTEM
A
B
SYSTEM
97.0
88.0
92.5
99.0
98.0
98.5
100.0
93.0
96.5
83.0
81.0
82.0
80.0
76.0
78.0
89.0
90.0
89.5
87.0
85.0
86.0
89.0
84.0
86.5
95.0
96.0
95.5
69.0
67.0
68.0
64.0
60.0
62.0
76.0
77.0
76.5
744 617
672 535
744 636
506
417
569
** PROBLEMS/SOLUTIONS/COMHENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE FIRST QUARTER OF 1982.
720 443 317
744 434 350
720 158 112
A
B
SYSTEM
A
B
SYSTEM
A
B
SYSTEM
98.0
67.0
82.5
100.0
100.0
100.0
100.0
98.0
99.0
81.0
62.0
71.5
83.0
78.0
80.5
77.0
64.0
70.5
89.0
67.0
78.0
98.0
92.0
95.0
93.0
77.0
85.0
50.0
38.0
44.0
48.0
46.0
47.0
17.0
14.0
15.5
#* PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE SECOND QUARTER 1982.
7/82
8/82
9/82 5A
5A
53
SYSTEM
5A
5B
SYSTEM
94.6
94.3
94.4
99.2
99.5
99.4
93.7
85.6
89.6
89.4
99.1
94.2
96.5
88.2
92.3
87.5
97.0
92.3
58.1
53.1
55.6
66.9
74.1
70.5
744 461
744 557
414 43.9
524 56.2
96.4
89.7
92.3
55.5
13-273
-------
UTILITY FED SURVEY: OCTOBER 1963 - SEPTEMBER 1984
COLUMBUS 4 SOUTHERN OHIO ELEC-' CONESVILLE 5 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FSD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
10/82
56
SYSTEM
5A
SB
SYSTEM
97.0
96.7
86.4
86.3
86.3
83.5
86.6
88.0
86.5
87.3
85
89
89
87
88
.9
.1
.1
,6
.4
51
53
64
63
63
.6
.5
.2
.1
.7
720
744
445
543
386
474
47.5
55.1
3/83
** PROBLEMS/SOLUTIONS/COMMENTS
11/82 5A
SB
SYSTEM
.0
.0
.0
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE PERIOD OF JULY THROUGH OCTOBER, 1982.
.0
.0
.0
720 0
*» PROBLEMS/SOLUTIONS/COMMENTS
UNIT 5 WAS OUT OF SERVICE DURING NOVEMBER FOR AN ANNUAL OUTAGE.
.0
12/82 5A
SB
SYSTEM
23.7
23.7
23.7
.0
.0
.0
744
.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE ANNUAL OUTAGE CONTINUED FOR UNIT 5 THROUGHOUT THE MONTH OF DECEMBER.
1/83 5A
5B
SYSTEM
88.5
92.4
90.5
58.7
70.7
64.7
62.9
75.8
69.4
19.5
23.5
21.5
744 248
160 24.0
** PROBLEMS/SOLUTIONS/COMMENTS
UNIT 5 WAS PLACED BACK IN SERVICE DURING JANUARY FOLLOWING THE ANNUAL
OUTAGE.
2/83 5A
53
SYSTEM
91.8
88.3
90.0
89.3
86.6
88.0
89.7
87.0
88.3
87.2
84.5
85.8
672 656
577 60.7
** PROBLEMS/SOLUTIONS/COMMENTS
PRIOR TO FEBRUARY 16, 1983, THE UTILITY WAS CONSIDERING FGD SYSTEM
AVAILABLE TIME TO INCLUDE PERIODS WHEN SCRUBBER MAINTENANCE WAS PERFORMED
DURING A UNIT OUTAGE. THE UTILITY.NOW CONFORMS TO THE CORRECT DEFINITION
OF AVAILABILITY AND CONSIDERS THE SCRUBBER UNAVAILABLE DURING THESE
PERIODS.
5A
SB
SYSTEM
92.3
90.5
91.4
93.5
87.6
90.5
94.5
88.5
91.5
78.8
73.8
76.3
744 627
568 55.4
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING MARCH.
4/83 5A
SB
SYSTEM
92.6
95.3
94.0
90.2
93.0
91.6
92.4
95.3
93.9
89.9
92.6
91.3
720 717
657 66.0
13-274
-------
UTILITY FGD SURVEY: OCTOBER 1963 - SEPTEMBER 1984
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
** PROBLEMS/SOLUTIONS/COMMENTS
5/83
6/83
10/83
11/83
THE UTILITY ATTRIBUTED THE VERY GOOD PERFORMANCE OF MODULES A AND B DUR-
RING APRIL TO PROPER MAINTENANCE PERFORMED AND THE COMPLETION OF ESSENTIAL
CHANGES IN THE SCRUBBING SYSTEM DESIGN.
5A
SB
SYSTEM
82.3
74.6
78.4
78.1
77.6
77.8
78.7
78.2
78.4
60.6
60.2
60.4
744 578
450 49.3
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT OUTAGE TIME WAS ATTRIBUTED TO THE CLEANING
OF MIST ELIMINATORS DURING MAY.
MAINTENANCE WORK ON MIST ELIMINATOR PUMPS ALSO CAUSED OUTAGE TIME IN MAY.
A 72 HOUR OUTAGE OCCURRED DUE TO A CHEMICAL IMBALANCE OF THE MAKEUP WATER
POND. AIR HEATER DRAINAGE DURING A CLEANING OPERATION PRODUCED ACIDIC
CONDITIONS IN THE POND.
5A
SB
SYSTEM
88.2
96.5
92.4
75.5
90.9
83.2
77.6
93.4
85.5
39.0
46.9
43.0
720 372
310 37.1
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING JUNE.
7/83
8/83
9/83
5A
SB
SYSTEM
SA
SB
SYSTEM
SA
SB
SYSTEM
87.9
90.2
89.0
94.1
91.3
92.7
99.0
93.8
96.4
83.3
81.9
82.6
83.8
84.1
83.9
97.2
86.7
91.9
84.2
82.7
83.5
88.0
83.4
88.2
98.0
87.5
92.7
63.6
62.5
63.0
67.3
67.6
67.5
47.8
42.6
45.2
744 568
744 598
720 354
469 54.0
502 46.0
326 34.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE PERIOD OF JULY THROUGH SEPTEMBER 1983.
SA
SB
SYSTEM
99.1
98.1
98.6
98.0
94.7
96.3
98.0
94.7
96.3
46.9
45.3
46.1
744 356
343 33.5
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR FGD-RELATED OUTAGES WERE ENCOUNTERED DURING OCTOBER.
SA
SB
SYSTEM
58.6
57.1
57.8
98.2
94.7
96.5
98.2
94.7
96.5
54.4
52.5
53.5
720 399
385 38.7
13-;
-------
UTILITY FGO SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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
THE UTILITY REPORTED THAT ANNUAL OUTAGES OCCURRED DURING NOVEMBER FOR UNITS
5 AND 6.
12/83 A 30.2 59.2 67.1 19.5
B 31.3 60.8 69.0 20.0
SYSTEM 30.8 60.0 68.1 19.8 744 245 147 17.9
** PR03LEMS/SOLUTIONS/COMMENTS
FGD SYSTEM OUTAGE TIME DURING DECEMBER WAS DUE IN PART TO THE LOSS OF A
LIME FEED LINE AND FROZEN WATER LINES ON THE SLAKERS.
THE UNAVAILABILITY OF THE SLUDGE TREATMENT FACILITY CONTRIBUTED TO FGD
SYSTEM DOWN TIME DURING THE MONTH.
A LOCALIZED ABSORBER RUBBER LINER FAILURE ALSO CONTRIBUTED TO FGD SYSTEM
OUTAGE TIME DURING DECEMBER.
1/84 A 94.1 87.8 89.7 46.6
B 98.1 95.4 97.4 50.7
SYSTEM 96.1 91.6 93.5 48.7 744 395 362 35.0
** PROBLEMS/SOLUTIONS/COMMENTS
ABSORBER RUBBER LININGS WERE REPAIRED DURING THE MONTH.
MIST ELIMINATOR AND RECYCLE SPRAY NOZZLES WERE CLEANED DURING JANUARY.
A POWER SUPPLY FAILURE AND COMPUTER-RELATED PROBLEMS ACCOUNTED FOR OUTAGE
TIME IN JANUARY.
2/84 5A 98.9 70.4 81.3 20.5
5B 96.0 68.5 79.0 20.0
SYSTEM 97.4 69.5 80.1 20.3 696 203 141 17.5
«* PROBLEMS/SOLUTIONS/COMMENTS
POOR LIME QUALITY ACCOUNTED FOR OUTAGE TIME DURING FEBRUARY.
A POWER FAILURE AT THE SLUDGE TREATMENT PLANT CONTRIBUTED TO DOWN TIME.
ABSORBER LINER FAILURE ACCOUNTED FOR ADDITIONAL OUTAGE TIME IN FEBRUARY.
3/84 A 98.3 96.4 98.0 85.8
B 99.6 97.9 99.5 87.1
SYSTEM 98.9 97.1 98.8 86.4 744 662 643 64.4
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE UNIT WAS OUT OF SERVICE 14 HOURS DUE TO
FAULTY DAMPERS.
RECYCLE TANK AGITATOR PROBLEMS WERE REPORTED DURING MARCH.
720 526 516 51.0
744 594 592 58.0
4/84 5A
5B
SYSTEM
5/84 5A
53
SYSTEM
100.0
98.5
99.2
99.9
99.6
99.7
99.0
97.0
98.0
99.7
99.5
99.6
100.0
97.9
98.9
99.7
99.5
99.6
72.4
70.8
71.6
79.6
79.4
79.5
13-276
-------
UTILITY FGO SURVEY: OCTOBER 1983 - SEPTEMBER
COLUMBUS 4 SOUTHERN OHIO ELEC: CONESVILLE 5 (CONT.)
PERIOD
6/84
7/8*
MODULE AVAILABILITY
5A
SB
SYSTEM
5A
SB
SYSTEM
98
99
98
93
93
93
.3
.3
.8
.5
.5
.5
OPERABILITY
96
97
97
96
96
96
.6
.9
.3
.7
.7
.7
---KCKruxnAN
RELIABILITY
97
99
98
99
99
99
.9
.3
.6
.3
.3
.3
ue UAI «-- ______ _ _____ -- _____
UTILIZATION y. REMOVAL PER BOILER FGD CAP.
SOS PART. HOURS HOURS HOURS FACTOR
81
82
82
36
36
36
.8
.9
.3
.4
.4
.4
720 609 593 55.5
744 280 271 24.5
«# PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD RELATED PROBLEMS WERE ENCOUNTERED
DURING THE PERIOD OF APRIL THROUGH JULY, 1984.
8/84 SYSTEM 744
9/84 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR AUGUST AND SEPTEMBER 1984.
13-277
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
SECTION 13
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
COLUMBUS t SOUTHERN OHIO ELEC
CONESVILLE
CONESVILLE
OHIO
D
43. (
516. (
301. C
1890
405
373
380
350
.100 LB/MMBTU)
1.200 LB/MMBTU)
.700 LB/MMBTU)
COMBUSTION ENGINEERING
PULVERIZED COAL
CYCLING
596.95 (1265000 ACFM)
( 296 F)
( 800 FT)
146.7
244.
CONCRETE
7.9
( 26.0 FT)
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - V.
RANGE ASH CONTENT - V.
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
#* ESP
NUMBER
NUMBER OF SPARES
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
TRADE NAME/COMMON NAME
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
*** FGD SYSTEM
COAL
BITUMINOUS
25237. ( 10850 BTU/LB)
10000-12000
14.90
10.0-24.0
7.50
5.0-18.0
4.50
4.2-5.1
.01
0.01-0.11
0
NONE
1
0
COLD SIDE
RESEARCH-COTTRELL
657.8 ' (1393893 ACFM)
146.7 ( 296 F)
.5 ( 2. IN-H20)
99.6
0
NONE
N/A
N/A
N/A
N/A
N/A
N/A
N/A
13-278
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COLUMBUS « SOUTHERN OHIO ELEC: CONESVILLE 6 (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
ENERGY CONSUMPTION - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
OPER. & MAINT. REQUIREMENT - MANHR/DAY
»* QUENCHER/PRESATURATOR
NUMBER
TYPE
SUPPLIER
INLET GAS TEMPERATURE - C
L/G RATIO - L/CU. M
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** 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
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
PARTICLE REMOVAL EFFICENCY - X
»* MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NUKSER PER SYSTEM
NUMBER OF SPARES PER SYSTEM
NUMBER PER MODULE
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
THROWAWAY PRODUCT
WET SCRUBBING
LIME
MAG
AIR CORRECTION DIVISION, UOP
BLACK & VEATCH
FULL SCALE
NEW
Y. 99.65
89.50
1.7
1
7/78
6/78
10/74
280.0
SPRAY CHAMBER
AIR CORRECTION DIVISION, UOP
141.1 ( 286 F)
.1 ( .6 GAL/1000 ACFM)
HIGH ALLOY
IRON BASE/NICKEL-CHROMIUM-COPPER-MOLYBOENUM
2
0
PACKED TOWER
MOBILE BED PACKING
TURBULENT CONTACT ABSORBER
AIR CORRECTION DIVISION, UOP
45.0 X 17.5 X 79.5
CARBON STEEL
AISI 1110
N/A
ORGANIC
SYNTHETIC RUBBER
NEOPRENE LS-576
GRID CAGES
1
1988.
6.6
2.0
4.0
301.81
51.7
92.0
99.6
(31560 GPM)
( 49.3 GAL/1000 ACF)
8.1 IN-H20)
13.1 FT/S)
639568 ACFM)
125 F)
PRIMARY COLLECTOR
2
0
1
IMPINGEMENT
BAFFLE
CLOSED VANE
HORIZONTAL
2
4
3.05
11.43
5.1
90
.5
(10.0 FT)
( 4.5 IN)
( 2.00 IN)
( 1.9 IN-H20)
13-279
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COLUMBUS t SOUTHERN OHIO ELEC: CONESVILLE 6 (CONT.)
SUPERFICAL GAS VELOCITY - M/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
WASH WATER SOURCE
WASH FREQUENCY
WASH RATE L/S
» REHEATER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** FANS
NUMBER
NUMBER OF SPARES
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GiS TEMPERATURE C
PRESSURE DROP - KPA
CONSTRUCTION MATERIAL GENERIC TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
*# DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
»» DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
*» DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
( 10.0 FT/S)
3.0
ORGANIC
FIBER-REINFORCED POLYESTER
RECLAIMED
CONTINUOUS
63.1 ( 1000 GAL/WIN)
NONE
N/A
N/A
NONE
N/A
2
0
CENTRIFUGAL
GREEN FAN
UNIT
FORCED DRAFT
DRY
401.11
146.7
.6
CARBON STEEL
( 850000 ACFM)
( 296 F)
( 2.0 IN-H20)
SHUT-OFF
GUILLOTINE
HIGH ALLOY
NICKEL BASE/CHROMIUM-IRON-MOLYBOENUM
NONE
SHUT-OFF
GUILLOTINE
HIGH ALLOY
NICKEL BASE/CHROMIUM-IRON-MOLYBDENUM
NONE
N/A
CONTROL
GUILLOTINE & LOUVER
HIGH ALLOY
NICKEL BASE/CHROMIUM-IRON-MOLYBDENUM
NONE
N/A
INLET
CARBON STEEL
HIGH STRENGTH LOW ALLOY IHSLA]
NONE
N/A
OUTLET TO DAMPER
CARBON STEEL
HIGH STRENGTH LOW ALLOY tHSLA]
ORGANIC
GLASS FLAKE-FILLED POLYESTER
OUTLET BEYOND DAMPER
CARBON STEEL
13-280
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COLUMBUS & SOUTHERN OHIO ELEC: CONESVILLE 6 (CONT.)
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
»* DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
*» REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
MANUFACTURER
NUMBER
»» TANKS
SERVICE
ABSORBER RECYCLE
RECLAIMED WATER
REAGENT PREP PRODUCT
MIST ELIMINATOR WASH
** PUMPS
SERVICE
ABSORBER RECIRCULATION
LIME SLURRY TRANSFER
SLURRY MAKEUP
RECYCLE TANK DRAWOFF
MIST ELIMINATOR WASH
RECLAIM WATER
THICKENER -UNDERFLOW
»* SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
BELT GENERIC MATERIAL TYPE
BELT SPECIFIC MATERIAL TYPE
FEED STREAM SOURCE
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
OUTLET STREAM DISPOSITION
OVERFLOW STREAM DISPOSITION
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
DIMENSIONS FT
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
FEED STREAM SOURCE
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
OUTLET STREAM DISPOSITION
OVERFLOW STREAM DISPOSITION
*** SLUDGE
HIGH STRENGTH LOW ALLOY IHSLAJ
INORGANIC
CHEMICALLY-BONDED CONCRETE
BYPASS
CARBON STEEL
HIGH STRENGTH LOW ALLOY [HSLA]
NONE
N/A
SLAKER
PASTE
N/A
WALLACE & TIERNAN
5
NUMBER
2
1
2
2
NUMBER
10
2
3
2
»***
VACUUM FILTER
3
1
CARBON STEEL
AISI 1110
ORGANIC
POLYPROPYLENE
THICKENER UNDERFLOW
30X SOLIDS
BOX SOLIDS
TO IUCS PROCESS
TO RECLAIMED WATER TANK
THICKENER
2
0
145.0 DIA X 16.0
CARBON STEEL
AISI 1110
ORGANIC
EPOXY
ABSORBER BLEED
7-12X SOLIDS
30X SOLIDS
TO IUCS THICKENER 4 THEN TO VACUUM FILTER
TO RECLAIMED WATER TANK
13-281
-------
UTILITY FGO SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COLUMBUS * SOUTHERN OHIO ELEC: CONESVILLE 6 (CONT.)
»* TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
INLET QUALITY - 7.
*# DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE TREATMENT
SITE DIMENSIONS
** PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS
PHYSICAL VARIABLES
CONTROL LEVELS
MONITOR LOCATION
PROCESS CONTROL MANNER
PROCESS CHEMISTRY MODE
»* WATER BALANCE
MATER LOOP TYPE
MAKEUP WATER ADDITION - LITERS/S
** CHEMICALS AND CONSUMPTION
FUNCTION
NAME
PRINCIPAL CONSTITUENT
SOURCE/SUPPLIER
CONSUMPTION
UTILIZATION - X
POINT OF ADDITION
** FGD SPARE CAPACITY INDICES
ABSORBER - X
»* FGD SPARE COMPONENT INDICES
ABSORBER
FIXATION
PUG MILL
CONVERSION SYSTEMS tPOZ-0-TECJ
50.0
FINAL
LANDFILL
ON-SITE
PIPELINE/CONVEYED
NONE
80 ACRES/50 FT
PH
RECYCLE TANK LEVEL
OUTLET PH 5.5-6.3; RECYCLE PH 7.0-7.5
SLURRY DISCHARGE FROM MODULE
AUTOMATIC
FEEDBACK
CLOSED
31.5
( 500 GPM)
ABSORBENT
LIME
90-95X CAO, 3-8X MGO
ORAVO
16 TPH
90.0
SLAKER
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
6/78 A 56.0 49.0 51.0 42.0
B 44.0 33.0 34.0 30.0
SYSTEM 50.0 41.0 42.5 36.0
720 524 174
7/78
** PROBLEMS/SOLUTIONS/COMMENTS
INITIAL OPERATIONS OF THE CONESVILLE 6 FGD SYSTEM BEGAN IN JUNE.
CONTROL OF THE LOUVERED DAMPER OF THE BYPASS SYSTEM WAS LOST. THE
RESULT WAS BACK PRESSURE BUILDUP THAT AUTOMATICALLY SHUT DOWN THE BOILER.
SCRUBBER CONTROLS WERE NOT OPERATING PROPERLY AND NEEDED ADJUSTMENT.
A
B
SYSTEM
83.0
70.0
76.5
37.0
19.0
28.0
63.0
33.0
48.0
25.0
13.0
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
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COLUMBUS & 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
RESULT OF WATER HAMMER IN THE LINE 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
B 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.
10/78 A 93.0 29.0 30.0 24.0
B 37.0 35.0 36.0 29.0
SYSTEM 67.5 32.0 33.0 26.5 744 603 199
** PROBLEMS/SOLUTIONS/COMMENTS
PROBLEMS WITH DAMPER SEALS AND GUIDEBARS WERE ENCOUNTERED. THE UTILITY
PLANS TO REPLACE THEM DURING THE NEXT BOILER OUTAGE.
11/78 A 26.0 3.0 3.0 2.0
B 26.0 9.0 9.0 8.0
SYSTEM 26.0 6.0 6.0 5.0 720 600 36
«* PROBLEMS/SOLUTIONS/COMMENTS
LIME TRANSFER BAGHOUSE SHAKER PROBLEMS WERE EXPERIENCED.
THE THICKENER RAKE MOTOR BURNED OUT AND HAD TO BE REWOUND.
744 672 155
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 FGD SYSTEM DID NOT OPERATE DURING FEBRUARY DUE TO SEVERE WINTER WEATHER
CAUSING SYSTEM FREEZE UPS.
3/79 A 43.0 37.0 39.0 33.0
13-283
2/78 A
B
SYSTEM
1/79 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
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COLUKEUS 4 SOUTHERN OHIO ELEC: CONESVILLE 6 (CONT.)
PERIOD
4/79
5/79
MODULE
B
SYSTEM
A
B
SYSTEM
SYSTEM
PtKrUKHMM
AVAILABILITY OPERABILITY RELIABILITY
32.0
37.5
82.0
72.0
77.0
100.0
£8.0
32.5
79.0
59.0
69.0
29.0
34,0
79.0
59.0
69.0
UE UA 1 A---
UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
25.0
29.0 744 664 216
78,0
58.0
68.0 720 711 489
.0 744 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
REPAIRS WERE MADE
TO THE SEAL BETWEEN THE THICKENER BASE AND SIDEWALL.
THE BOILER DID NOT OPERATE
OUTAGE.
6/79
A
B
SYSTEM
43.0
49.0
46.0
37.0
49.0
43.0
39.0
52.0
45.5
DURING MAY DUE TO A SCHEDULED ANNUAL
27.0
31.0
29.0 720 433 209
** PROBLEMS/SOLUTIONS/COMMENTS
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
6.6.3
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
FLY ASH CONVEYING
PLUGGED PH LINES
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
PROBLEMS
RESULTED IN ABOUT A TWO DAY OUTAGE.
WERE A PROBLEM DURING THIS PERIOD.
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
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 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.
13-284
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UTILITY FGO SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COLUMBUS t SOUTHERN OHIO ELEC: CONESVILLE 6 (CONT.)
PERIOD
i/eo
rtKruKnANUc UAI A - ---
MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
A
B
SYSTEM
88.0 74.0 74.0 74.0
89.0 78.0 78.0 78.0
89.0 76.0 76.0 76.0 744 744 566 73.
9
** PROBLEMS/SOLUTIONS/COMMENTS
2/80
A
B
SYSTEM
NO MAJOR FGD SYSTEM RELATED PROBLEMS WERE REPORTED FOR JANUARY.
87.0 75.0 78.0 69.0
92.0 81.0 85.0 75.0
90.0 78.0 82.0 72.0 696 648 503 70.
8
** PROBLEMS/SOLUTIONS/COMMENTS
3/80
A
B
SYSTEM
IN FEBRUARY, MIST ELIMINATOR NOZZLE PLUGGING OCCURRED CAUSING SOME OUTAGE
TIME.
93.0 69.0 69.0 15.0
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 58.3 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
6/80
A
B
SYSTEM
CONTROL AMD INSTRUMENTATION PROBLEMS THAT DEVELOPED IN MAY WERE RESPONSI-
BLE FOR SOME FGD SYSTEM OUTAGE TIME.
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
THE FGD SYSTEM EXPERIENCED PROCESS CONTROL PROBLEMS DURING JULY.
PROBLEMS WITH LEAKING INLET DAMPER SEALS ALSO OCCURRED DURING JULY.
13-285
-------
UTILITY FGO SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COLUMBUS & SOUTHERN OHIO ELEC: CONESVILLE 6 (CONT.)
__-___..-__.--- HEKrUKnANL.C UA 1 A " __
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
8/80 A
B
SYSTEM
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
AMD 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
10/80 A
B
SYSTEM
11/80 A
B
SYSTEM
THE INLET DAMPER SEAL PROBLEM CONTINUED
EXTERNAL PROBLEMS WERE EXPERIENCED WITH
89.2 72.0 72.6 64.9
94.1 87.6 88.3 78.9
91.7 79.8 80.5 71.9
99.6 92.9 91.1 55.4
98.2 81.5 79.9 48.6
98.9 87.3 85.5 51.9
THROUGH AUGUST AND SEPTEMBER.
THE IUCS SYSTEM.
744 670 535 57.2
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
B
SYSTEM
86.0 84.0 84.0 84.0
87.6 76.7 76.7 76.7
86.8 80.3 80.3 80.3
744 744 744 79.1
** PROBLEMS/SOLUTIONS/COMMENTS
1/81 A
B
SYSTEM
2/81 A
B
SYSTEM
DURING DECEMBER SYSTEM AVAILABILITY WAS
TO THE RECLAIM WATER TANK.
97.6 92.7 92.7 92.7
98.4 90.5 90.4 90.4
97.9 92.0 91.5 91.5
89.7 81.0 81.3 74.7
95.2 89.2 89.6 82.3
92.4 85.0 85.4 78.4
LOW DUE TO NECESSARY REPAIRS
744 744 681 79.0
672 620 528 75.4
** PROBLEMS/SOLUTIONS/COMMENTS
3/81 A
B
SYSTEM
DURING JANUARY AND FEBRUARY THE UTILITY
PROBLEMS WERE ENCOUNTERED.
74.7 96.6 98.0 58.9
75.0 97.5 99.0 59.4
74.9 97.0 98.5 59.1
REPORTED THAT NO MAJOR FGD-RELATED
744 453 440 57.7
PROBLEMS/SOLUTIONS/COMMENTS
THE MAJORITY OF OUTAGE TIME DURING MARCH WAS THE RESULT OF LOW BOILER LOAD
OR A LACK OF POWER DEMAND.
13-286
-------
ITTILITY FGD SURVEY: OCTOBER 1933 - SEPTEMBER 1984
COLUMBUS t, SOUTHERN OHIO ELEC: CONESVILLE 6 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
SOS PART. HOURS HOURS HOURS FACTOR
DURING THE MONTH SOME MINOR PROBLEMS WERE ENCOUNTERED WITH VARIOUS PIECES
OF AUXILIARY EQUIPMENT. NO PROBLEMS WERE EXPERIENCED WITH EITHER MODULE.
5/81
6/81
11/81
53.3
51.4
*» PROBLEMS/SOLUTIONS/COMMENTS
4/81 A
B
SYSTEM
95.0
100.0
97.5
99.1
100.0
99.5
31.9
33.6
32.S
720 242
ON MAY 1, THE UNIT WAS OUT OF SERVICE FOR A SCHEDULED OUTAGE.
REMAINED OFF LINE THROUGH MAY 14.
744 620
720 648
A
B
SYSTEM
A
B
SYSTEM
99.6
99.6
99.6
99.2
99.2
99.2
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
83.3
83.3
83.3
90.0
90.0
90.0
236
THE UNIT
620
648
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR OPERATIONAL PROBLEMS WERE ENCOUNTERED
DURING MAY AND JUNE.
7/81
8/81
9/81
A
B
SYSTEM
A
B
SYSTEM
A
B
SYSTEM
99.6
99.2
99.4
99.0
98.0
98.5
100.0
89.0
94.5
100.0
100.0
100.0
90.0
89.0
89.5
85.0
87.0
86.0
100.0
100.0
100.0
94.0
92.0
93.0
94.0
97.0
95.5
73.9
73.9
73.9
74.0
73.0
73.5
35.0
36.0
35.5
744 550
744 607
720 297
550
547
256
** PROBLEMS/SOLUTIONS/COMMENTS
SEVERE OUTLET DUCT CORROSION HAS OCCURRED ON UNIT 6. THE GUNITE LINER HAS
FAILED DUE TO INADEQUATE STRENGTH OF THE SUPPORTING MESH. THE UTILITY
IS LOOKING INTO INCONEL OR FRP AS A REPLACEMENT LINER.
UNIT 6 WAS REMOVED FROM SERVICE ON SEPTEMBER 19 AS A RESULT 0* LOW DEMAND.
THE UNIT IS NOT EXPECTED TO BE BROUGHT BACK ON LINE UNTIL DECEMBER.
THIS OUTAGE PERIOD WILL BE UTILIZED'FOR OUTLET DUCTWORK REPAIRS.
10/81 A
B
SYSTEM
100.0
100.0
100.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
744
#* PROBLEMS/SOLUTIONS/COMMENTS
DURING OCTOBER MAJOR MODIFICATIONS WERE BEING PERFORMED ON THE BOILER
DUCTWORK. THIS INCLUDED REPAIRING THE CORRODED INNER SUPPORTS AND REPLAC-
ING THE GUNITE.
A
B
SYSTEM
27.0
27.0
27.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
720
13-287
-------
UTILITY FGO SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COLUMBUS & SOUTHERN OHIO ELEC: CONESVILLE 6 (CONT.)
_. PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMEKTS
12/81
1/82
2/82
3/82
DURING NOVEMBER MAJOR MODIFICATION TO THE FGD SYSTEM DUCTWORK WAS PERFORM-
ED. THIS WORK INCLUDED REPAIRING THE CORRODED SUPPORTS AND RECOATING
WITH GUNITE.
DURING THE MONTH ADDITIONAL OUTAGE TIME WAS DUE TO GENERAL FGD MAINTENANCE.
A
B
SYSTEM
88.0
88.0
88.0
83.0
83.0
83.0
93.0
93.0
93.0
66.0
66.0
66.0
744 592
491
** PROBLEMS/SOLUTIONS/COMMENTS
DURING DECEMBER MISCELLANEOUS EQUIPMENT PROBLEMS WERE ENCOUNTERED.
ALSO DURING THE MONTH OPACITY MONITORS WERE INSTALLED AND TESTED.
744 592 521
672 463 410
744 673 606
A
B
SYSTEM
A
B
SYSTEM
A
B
SYSTEM
100.0
100.0
100.0
98.0
99.0
98.5
99.0-
99.0
99.0
88.0
88.0
88.0
87.0
90.0
68.5
88.0
92.0
90.0
95.0
95.0
95.0
92.0
90.0
94.0
91.0
95.0
93.0
70.0
70.0
70.0
60.0
62.0
61.0
80.0
83.0
81.5
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE FIRST QUARTER OF 1982.
720 509 450
744 259 171
720 383 335
4/82
5/82
6/82
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
89.0
88.0
83.5
66.0
66.0
66.0
86.0
89.0
87.5
96.0
94.0
95.0
97.0
97.0
97.0
96.0
99.0
97.5
63.0
62.0
62.5
23.0
23.0
23.0
46.0.
47.0
46.5
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE SECOND QUARTER 1982.
744 502 474 50.2
744 571 530 56.7
720 600 544 64.9
7/82
8/82
9/82
6A
6B
SYSTEM
6A
65
SYSTEM
6A
6B
SYSTEM
99.7
99.9
99.8
99.8
100.0
99.9
97.2
96.5
96.8
92.9
95.9
94.4
93.9
91.9
92.9
90.4
91.0
90.7
93.7
96.8
95.2
97.7
95.5
96.6
91.3
91.9
91.6
62.6
64.7
63.7
72.1
70.5
71.3
75.3
75.8
75.6
13-288
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COLUMBUS 4 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
10/82
12/82
1/83
2/83
3/83
4/83
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE PERIOD OF JULY THROUGH SEPTEMBER, 1982.
6A
6B
SYSTEM
33.3
33.0
33.2
98.4
93.2
95.8
100.0
94.6
97.3
24.7
23.4
24.1
744 187
179 17.8
** PROBLEMS/SOLUTIONS/COMMENTS
UNIT 6 WAS OUT OF SERVICE DURING PART OF OCTOBER FOR AN ANNUAL OUTAGE.
6A
6B
SYSTEM
46.3
46.5
46.4
81.5
76.1
78.8
78.3
73.0
75.6
35.7
33.3
34.5
720 315
248 31.9
** PROBLEMS/SOLUTIONS/COMMENTS
UNIT 6 WAS OUT OF SERVICE DURING PART OF NOVEMBER FOR THE ANNUAL OUTAGE.
6A
6B
SYSTEM
6A
6B
SYSTEM
98.0
96.9
97.5
96.7
96.8
96.7
87.9
87.1
87.5
88.5
88.4
88.4
88.0
87.2
87.6
90.6
90.5
90.5
64.5
63.9
64.2
55.6
55.6
55.6
744 546
744 468
478 58.3
414 45.1
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING DECEMBER, 1982 THROUGH JANUARY, 1983.
6A
6B
SYSTEM
90.9
91.4
91.2
82.4
84.1
83.3
85.2
87.0
86.1
61.5
62.8
62.1
672 501
418 45.0
** PROBLEMS/SOLUTIONS/COMMENTS
PRIOR TO FEBRUARY 16, 1983, THE UTILITY WAS CONSIDERING FGD SYSTEM
AVAILABLE TIKE TO INCLUDE PERIODS WHEN SCRUBBER MAINTENANCE WAS PERFORMED
DURING A UNIT OUTAGE. THE UTILITY NOW CONFORMS TO THE CORRECT DEFINITION
OF AVAILABILITY AND CONSIDERS THE SCRUBBER UNAVAILABLE DURING THESE
PERIODS.
6A
6B
SYSTEM
88.8
90.2
89.5
86.6
89.6
88.1
87.5
90.5
89.0
80.2
82.9
81.6
744 689
607 61.7
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING MARCH.
6A
6B
SYSTEM
80.4
96.3
88.3
79.6
95.4
87.5
80.3
96.2
88.2
79.6
95.4
87.5
720 720
630 67.1
13-289
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
COLUMBUS & 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
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY ATTRIBUTED THE VERY GOOD PERFORMANCE OF MODULE 6B DURING APRIL
TO PROPER MAINTENANCE PERFORMED AND THE COMPLETION OF ESSENTIAL CHANGES IN
THE SCRUBBING SYSTEM DESIGN.
5/83 6A
6B
SYSTEM
94.5
96.0
95. Z
80.0
65.2
82.6
82.4
87.7
85.0
22.6
23.3
744 210
174 17.7
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT OUTAGE TIME WAS ATTRIBUTED TO THE CLEANING
OF MIST ELIMINATORS DURING MAY.
MAINTENANCE WORK ON MIST ELIMINATOR PUMPS ALSO CAUSED OUTAGE TIME IN MAY.
A 72 HOUR OUTAGE OCCURRED DUE TO A CHEMICAL IMBALANCE OF THE MAKEUP WATER
POND. DRAINAGE FROM THE CLEANING OF AN AIR HEATER PRODUCED ACIDIC
CONDITIONS IN THE POND.
6/83
6A
6B
SYSTEM
95.0
96.8
95.9
84.0
86.9
85.4
89.2
92.2
90.7
28.8
29.7
29.2
720 246
211 24.1
** PROBLEMS/SOLUTIONS/COMMENTS
7/83
8/83
9/83
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURIN5 JUNE.
744 341 299 32.0
744 593 556 47.0
720 391 356 33.3
6A
6B
SYSTEM
6A
6B
SYSTEM
6A
6B
SYSTEM
94
95
95
87
91
89
93
93
93
.9
.6
.2
.0
.1
.0
.3
.2
.3
86
88
87
92
95
93
91
90
91
.8
.3
.5
.4
.1
.8
.3
.8
.0
88
90
89
93
96
94
92
91
91
.9
.4
.6
.5
.2
.9
.0
.5
.8
39
40
40
73
75
74
49
49
49
.8
.5
.1
.7
.8
,7
.6
.3
.4
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR "FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE PERIOD OF JULY THROUGH SEPTEMBER, 1983.
10/83
6A
6B
SYSTEM
98.9
99.6
99.3
98.9
99.8
99.4
98.9
99.8
99.4
61.7
62.2
62.0
744 464
461 44.4
PROBLEMS/SOLUTIONS/COMMEHTS
NO MAJOR FGD-RELATED OUTAGES WERE ENCOUNTERED DURING OCTOBER.
11/83 6A
6B
SYSTEM
76.7
76.1
76.4
96.1
95.1
95.6
96.1
95.1
95.6
51.4
50.8
51.1
720 385
368 33.7
13-290
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COLUMBUS S 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
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT ANNUAL OUTAGES OCCURRED DURING NOVEMBER FOR UNITS
5 AND 6.
12/83 A 38.6 69.8 75.4 31.3
B 41.3 75.7 81.9 34.0
SYSTEM 39.9 72.8 78.6 32.7 744 334 243 26.1
** PROBLEMS/SOLUTIONS/COMMENTS
LOSS OF LINE FEED DUE TO FROZEN WATER LINES ON THE SLAKERS CONTRIBUTED TO
FGD SYSTEM DOWN TIME DURING DECEMBER.
A MODULE OUTAGE WAS REQUIRED TO CLEAN PLUGGED ABSORBER S. MIST ELIMINATOR
SFRAY NOZZLES.
THE UNAVAILABILITY OF THE SLUDGE TREATMENT FACILITY DURING DECEMBER
CONTRIBUTED TO FGD SYSTEM DOWN TIME.
1/84 A 96.2 93.9 95.2 73.9
B 96.8 94.5 95.8 74.5
SYSTEM 96.5 94.2 95.5 74.2 744 586 552 54.0
** PROBLEMS/SOLUTIONS/COMMENTS
PLUGGED RECYCLE, MIST ELIMINATOR AND PRESATURATOR SPRAY NOZZLES CONTRIBUTED
TO DOWN TIME IN JANUARY.
DAMPER OPERATION FAILURE OCCURRED DURING THE MONTH.
COMPUTER-RELATED PROBLEMS WERE ENCOUNTERED DURING JANUARY.
2/84 6A 95.8 73.8 84.9 23.4
6B 79.3 81.0 93.2 25.7
SYSTEM 87.6 77.4 89.1 24.6 696 221 171 18.6
** PROBLEMS/SOLUTIONS/COMMENTS
PROBLEMS WITH PLUGGED SPRAY NOZZLES WERE REPORTED IN THE MIST ELIMINATOR,
RECYCLE SYSTEM AND PRESATURATOR.
A POWER FAILURE AT THE SLUDGE TREATMENT PLANT OCCURRED DURING THE MONTH.
ABSORBER LINER FAILURE WAS REPORTED-DURING FEBRUARY.
3/84 A 99.9 98.1 100.0 57.0
B 75.4 93.1 94.8 54.0
SYSTEM 87.6 95.6 97.4 55.5 744 432 413 40.7
** PROBLEMS/SOLUTIONS/COMMENTS
PRESATURATOR PLUGGAGE ACCOUNTED FOR 8 HOURS OF OUTAGE TIME IN MARCH.
COMPUTER-RELATED PROBLEMS WERE REPORTED DURING MARCH.
ABSORBER LINER FAILURE RESULTED IN 5 HRS. OF DOWN TIME IN MARCH.
THE UTILITY REPORTED THAT MODULE B WAS UNAVAILABLE 160 HOURS DUE TO DAMPER
FAILURE.
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1964
COLUMBUS & SOUTHERN OHIO ELEC: CONESVILLE 6 (COKT.)
PERIOD
5/8*
6/84
7/84
MODULE AVAILABILITY
6B
SYSTEM
6A
6B
SYSTEM
6A
6B
SYSTEM
6A
6B
SYSTEM
100
100
100
99
99
100
100
100
99
99
99
.0
.0
.0
.9
.9
.0
.0
.0
.7
.7
.7
OPERABILITY
99
99
99
99
99
97
97
97
97
97
97
.8
.8
.0
.0
.0
.6
.6
.6
.1
.1
.1
FtKrUKnArl
RELIABILITY
100
100
100
100
100
100
100
100
99
99
99
.0
.0
.0
.0
.0
.0
.0
.0
.4
.4
.4
i_-e UAIA-- _______ ___ _______ _
UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
S9.
59.
41,
41.
41.
60.
60.
60.
57.
57.
57.
0
0
9
9
9
6
6
6
2
2
2
720 426 425 40.5
744 315 312 32.0
720 447 436 44.5
744 438 426
»* PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD RELATED PROBLEMS WERE ENCOUNTERED
DURING THE PERIOD OF APRIL THROUGH JULY, 1984.
8/84 SYSTEM 744
9/84 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMEKTS
INFORMATION WAS UNAVAILABLE FOR AUGUST AND SEPTEMBER 1984.
13-292
-------
UTILITY F6D SURVEY: OCTOBER 1983 - SEPTEMBER 1984
SECTION 13
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
** 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
** ESP
NUMBER
NUM3ER OF SPARES
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
TRADE NAME/COMMON NAME
GAS CONTACTING DEVICE TYPE
*** FGD SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
COOPERATIVE POWER ASSOCIATION
COAL CREEK
1
UNDERWOOD
NORTH DAKOTA
D
( .100 LB/MMBTU)
( 1.200 LB/MMBTU)
(*#**** LB/MMBTU)
516.
******
1100
550
500
501
327
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
1038.18 (2200000 ACFM)
160.0 ( 320 F)
201. ( 658 FT)
CONCRETE
6.7 ( 22.0 FT)
( 6258 BTU/LB)
3068-7660
COAL
LIGNITE
14556.
7.14
3.9-16.0
39.83
27.8-52.6
.63
0.2-1.4
.02
0.00-0.08
0
NONE
1
0
COLD SIDE
WHEELABRATOR-FRYE
1090.1 (2310000 ACFM)
160.6 ( 321 F)
.6 ( 3. IN-H20)
99.5
0
NONE
N/A
N/A
N/A
THROWAWAY PRODUCT
WET SCRUBBING
LIME/ALKALINE FLYASH
NONE
13-293
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COOPERATIVE POWER ASSOCIATION: COAL CREEK 1 (CONT.)
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEU/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY - 7.
UNIT DESIGN S02 REMOVAL EFFICIENCY - X
ENERGY CONSUMPTION - 7.
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
SPACE REQUIREMENTS - SQ M 8091.6
OPER. & MAINT. REQUIREMENT - MANHR/DAY 72.0
** QUENCHER/PRESATURATOR
NUMBER 0
** 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
L/G RATIO - L/CU.M
GAS-SIDE PRESSURE DROP - KPA
SUFERFICAL GAS VELOCITY - M/SEC
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
SOS REMOVAL EFFICIENCY - X
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
NUMBER OF SPARES PER SYSTEM
NUMBER PER MODULE
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
CONSTRUCTION MATERIAL SPECIFIC TYPE
WASH WATER SOURCE
WASH FREQUENCY
WASH RATE - L/S
** REHEATER
NUMBER 1
NUMBER OF SPARES 0
GENERIC TYPE BYPASS
SPECIFIC TYPE COLD SIDE
TRADE NAME/COMMON TYPE N/A
COMBUSTION ENGINEERING
BLACK & VEATCH
FULL SCALE
NEW
99.50
54.00
.2
1
8/79
7/79
5/76
( 87100 SQ FT)
4
0
SPRAY TOWER
OPEN COUNTERCURRENT SPRAY
N/A
COMBUSTION ENGINEERING
21.5 WIDE X 20 DEEP X 55 HIGH
STAINLESS STEEL
AUSTENITIC
TYPE 316L
NONE
N/A
N/A
NONE
1
1310.
8.0
.7
3.2
163.51
160.6
90.0
(20790 GP-M)
( 60.0 GAL/1000 ACF)
( 3.0 IN-H20)
( 10.6 FT/S)
( 346500 ACFM)
( 321 F)
PRIMARY COLLECTOR
4
0
1
IMPINGEMENT
BAFFLE
CLOSED VANE
HORIZONTAL
2
( 8.0 FT)
(30.0 IN)
( 3.00 IN)
( .5 IN-H20)
( 8.9 FT/S)
76.20
7.6
.1
2.7
ORGANIC
FIBER-REINFORCED POLYESTER
COOLING TOWER SLOWDOWN.
INTERMITTENT
37.6 ( 600 GAL/WIN)
13-294
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COOPERATIVE POWER ASSOCIATION: COAL CREEK 1 (CONT.)
PERCENT GAS BYPASSED - AVS 40.0
TEMPERATURE INCREASE - C 47.2
INLET FLUE GAS TEMPERATURE - C 57.2
OUTLET FLUE GAS TEMPERATURE - C 98.9
CONSTRUCTION MATERIAL GENERIC TYPE NR
CONSTRUCTION MATERIAL SPECIFIC TYPE NR
( 85 F)
( 135 F)
( 210 F)
** FANS
NUMBER
NUMBER OF SPARES
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
CONSTRUCTION MATERIAL GENERIC TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
*# DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
4
0
CENTRIFUGAL
GREEN FAN
BALANCED DRAFT
FORCED DRAFT
DRY
163.51
160.6
12.8
CARBON STEEL
( 346500 ACFM)
( 321 F)
(42.0 IN-H20)
8
ISOLATION
LOUVER
NR
CARBON STEEL
HIGH STRENGTH LOW ALLOY [HSLAJ
NONE
N/A
8
ISOLATION
LOUVER
NR
STAINLESS STEEL
AUSTENITIC
NONE
N/A
4
CONTROL
LOUVER
NR
CARBON STEEL
HIGH STRENGTH LOW ALLOY [HSLA1
NONE
N/A
8
ISOLATION
LOUVER
NR
CARBON STEEL
HIGH STRENGTH LOW ALLOY [HSLA]
NONE
N/A
OUTLET
STAINLESS STEEL
AUSTENITIC
NONE
N/A
INLET
CARBON STEEL
AISI 1110
13-295
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COOPERATIVE POWER ASSOCIATION: COAL CREEK 1 (CONT.)
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
*» DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
MANUFACTURER
NUMBER
PRODUCT QUALITY - X SOLIDS
** TANKS
SERVICE
ABSORBER RECYCLE
FLY ASH
REAGENT PREP PRODUCT
** PUMPS
SERVICE
BLEED STREAM
SLURRY FEED
REACTION TANK TRANSFER
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
*** SLUDGE
** TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE TREATMENT
SITE DIMENSIONS
SITE SERVICE LIFE - YRS
** PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS
PHYSICAL VARIABLES
MONITOR TYPE
MONITOR LOCATION
»* WATER BALANCE
WATER LOOP TYPE
NONE
N/A
BYPASS
CARBON STEEL
AISI 1110
NONE
N/A
PLENUM TO STACK
CARBON STEEL
AISI 1110
INORGANIC
HYDRAULICALLY-BONDED MORTAR
SLAKER
NR
NR
WALLACE 4 TIERMAN
2
10.0
NUMBER
2
#***
**«*
NUMBER
3
2
6
NONE
NONE
NR
N/A
FINAL
POND
ON-SITE
PIPELINE
CLAY LINING
400 ACRES
35
PH, S02
SOLIDS, LIQUID LEVEL
UNILOC FOR PH, LEAR-SIEGLER FOR S02, MOORE FOR S
REACTION TANK FOR PH
OPEN
13-296
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COOPERATIVE POWER ASSOCIATION: COAL CREEK 1 (CONT.)
** CHEMICALS AND CONSUMPTION
FUNCTION
NAME
PRINCIPAL CONSTITUENT
SOURCE/SUPPLIER
CONSUMPTION
POINT OF ADDITION
** FGD SPARE CAPACITY INDICES
ABSORBER - 7.
»* FGD SPARE COMPONENT INDICES
ABSORBER
ABSORBENT
LIME
CAO
PETE LIEN & SONS, INC.
RAPID CITY, SOUTH DAKOTA
SLAKER
.0
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
/. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
7/79 SYSTEM
** 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 (34-HOUR MINIUM PERIOD) ON
JULY 19.
8/79 SYSTEM
9/79 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
744
720
10/79 SYSTEM
11/79 SYSTEM
12/79 SYSTEM
THIS UNIT STARTED COMMERCIAL OPERATIONS ON AUGUST 1, 1979. SOME MINOR
SHAKEDOWN PROBLEMS WERE REPORTED FOR THE AUGUST-SEPTEMBER PERIOD.
744 711
720 703
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,
UNIT HAD TO OPERATE AT A REDUCED LOAD. NO FGD SYSTEM PROBLEMS WERE
REPORTED.
THE
1/80 SYSTEM
100.0
96.1
744 715
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
13-297
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
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
16.
A THREE TO FOUR HOUR OUTAGE WAS SCHEDULED ON JANUARY 27 TO MAKE REPAIRS ON
FGD SYSTEM EQUIPMENT.
2/80 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
99.9
696 695
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
** PROBLEMS/SOLUTIONS/COMMENTS
96.1
744 715
715
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.
WITH ONE MODULE DOWN DURING TESTING.
THE SYSTEM OPERATED
4/60
5/80
6/80
11
12
13
14
SYSTEM
96.7
100.0
100.0
'100.0
99.2
58
81
96
96
83
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.
11
12
13
14
SYSTEM
88.
79,
91.
91.
87.
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.
11
12
13
14
SYSTEM
92
98.
74.
93
89.
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
381 58.5
** PROBLEMS/SOLUTIONS/COMMENTS
THERE WERE NO MAJOR PROBLEMS REPORTED DURING JUNE.
AND REPAIRS WERE DONE THROUGHOUT THE MONTH.
ROUTINE MAINTENANCE
7/80 SYSTEM
100.0
100.0
100.0
87.1
744 648
648 47.1
13-298
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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
8/80
IN JULY, NO PROBLEMS WERE ENCOUNTERED WITH THE FGD SYSTEM.
11
12
13
14
SYSTEM
24.8
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 11
12
13
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
12/80 11
12
13
14
SYSTEM
46.
48.
33.
45.
43.4
60.6
45.8
47.2
33.1
44.2
42.6
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
1/81
2/81
11
12
13
14
SYSTEM
11
12
13
14
SYSTEM
100.0
100.0
100.0
100.0
100.0
82.5
82.5
82.5
82.5
82.5
45.2
46.8
38.7
44.6
43.8
57.4
79.1
71.8
1.8
52.5
NO MAJOR PROBLEMS WERE ENCOUNTERED DURING NOVEMBER AND DECEMBER.
45.2
46.8
38.7
44.6
43.8
3/81 11
47.4
50.4
47.5
65.2
59.2
1.5
43.3
23.9
744 744
672 554
326 58.3
291 45.6
13-299
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COOPERATIVE POWER ASSOCIATION: COAL CREEK 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
12
13
14
SYSTEM
47.
47,
47.
47,
,4
,4
,4
.4
73.
57.
58.
60.
7
8
4
9
34
27
29
28
.9
.4
.0
.8
744
353
215
30
.7
** PROBLEMS/SOLUTIONS/COMMENTS
4/81
5/81
6/81 11
12
13
14
SYSTEM
100.0
100.0
100.0
100.0
100.0
DURING THE FIRST QUARTER 1981 VIBRATION PROBLEMS WERE EXPERIENCED CAUSING
FAILURE OF THE REACTION TANK BLADES.
720 720 510 68.6
744 744 370 68.3
720 663 256 57.0
11
12
13
14
SYSTEM
11
12
13
14
SYSTEM
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
64.7
94.7
36.7
67.2
70.8
62.9
65.6
31.5
39.0
49.7
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
64.7
94.7
36.7
87.2
70.8
62.9
65.6
31.5
39.0
49.7
51.3
76.9
15.7
10.6
38.6
100.0
100.0
100.0
100.0
100.0
47.2
70.8
14.4
9.7
35.6
** PROBLEMS/SOLUTIONS/COmENTS
DURING THE SECOND QUARTER 1981 THE UTILITY REPORTED THAT NO MAJOR FGD-
RELATED PROBLEMS WERE ENCOUNTERED.
7/81 11
12
13
14
SYSTEM
8/81 11
12
13
14
SYSTEM
9/81 SYSTEM
34.3
49.9
8.9
54.8
37.0
41.5
46.6
8.0
84.4
45.2
34.1
49.7
8.9
54.6
36.8
33.3
37.4
6.
67.
36.
.5
.7
.3
.0
744 741
744 597
720 0
274 55.3
270 62.9
0 .0
PROBLEMS/SOLUTIONS/COMMENTS
10/81 11
12
13
14
SYSTEM
11/81 11
12
13
14
SYSTEM
NO MAJOR OPERATIONAL PROBLEMS WERE REPORTED FOR THE MONTHS OF JULY AND
AUGUST. THE UNIT WAS TAKEN OFF LINE IN SEPTEMBER FOR AN ANNUAL OUTAGE.
64.7
20.9
79.6
49.8
53.7
42.0
59.4
52.2
76.2
57.4
17.5
5.6
21.5
13.4
14.5
34.2
46
42
61
46.7
744 201
720 586
108 18.4
336 52.6
13-300
-------
UTILITY FGD SURVEY' OCTOBER 1983 - SEPTEMBER 1984
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
1/82
2/82
3/82
4/82
5/82
6/82
DURING OCTOBER THE UNIT WAS SHUTDOWN UNTIL THE 24TH FOR AN ANNUAL INSPEC-
TION.
12/81 11
12
13
SYSTEM
72.4
67.4
49.1
49.4
59.5
54.3
50.5
36.8
37.1
44.7
744 558
332 48.8
** PROBLEMS/SOLUTIONS/COMMENTS
GENERAL MAINTENANCE WAS PERFORMED ON THE FGD SYSTEM DURING THE FOURTH
QUARTER. NO FGD FORCED OUTAGES WERE ENCOUNTERED.
11
12
13
14
SYSTEM
11
12
13
14
SYSTEM
11
12
13
14
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
66.1
58.3
73.1
92.2
72.4
65.8
71.3
82.9
58.9
69.7
37.9
50.0
39.9
30.6
39.6
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
65.9
58.1
72.8
91.9
72.2
65.8
71.3
82.9
58.9
69.7
37.9
50.0
39.9
30.6
39.6
744 741
672 672
744 744
537 81.8
469 76.7
295 71.5
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR PROBLEMS OR FORCED OUTAGES WERE ENCOUNTERED DURING THE FIRST
QUARTER OF 1982.
720 718 308 75.1
744 653 203 55.9
720 663 289 92.1
11
12
13
14
SYSTEM
11
12
13
14
SYSTEM
11
12
13
14
SYSTEM
100.0
100.0
88.0
72.4
90.1
100.0
100.0
100.0
100.0
100.0
74.2
69.6
73.3
76.4
73.4
17.0
15.6
88.3
64.7
46.4
3.7
13.6
52.7
54.4
31.1
40.6
22.0
.0
52.8
43.6
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
16.9
15.5
74.0
64.5
42.7
3.2
11.9
46.2
47.7
27.2
37.4
20.3
54.3
48.6
40.1
** PROBLEMS/SOLUTIONS/COMMENTS
7/82 SYSTEM
DURING THE SECOND QUARTER 1982 GENERAL MAINTENANCE AND CLEANING OF THE
FGD SYSTEM ACCOUNTED FOR ANY UNAVAILABLE TIME.
744
13-301
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COOPERATIVE POWER ASSOCIATION: COAL CREEK 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
8/82 SYSTEM 744
9/82 SYSTEM 720
10/82 SYSTEM 744
11/82 SYSTEM 720
12/82 SYSTEM 744
1/83 SYSTEM 744
2/83 SYSTEM 672
3/83 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE PERIOD OF JULY 1982 THROUGH MARCH 1983.
4/83 SYSTEM 720
5/83 SYSTEM 744
6/33 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE PERIOD OF JULY 1982 THROUGH JUNE 1983.
7/83 SYSTEM 744
8/83 SYSTEM 744
9/83 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-REUTED PROBLEMS WERE ENCOUNTERED
DURING THE THIRD QUARTER OF 1983.
10/83 SYSTEM 744
11/83 SYSTEM 720
12/83 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE FGD SYSTEM AT COAL CREEK 1 WAS 100 PERCENT
AVAILABLE THROUGHOUT THE FOURTH QUARTER OF 1983.
1/84 SYSTEM 744
2/84 SYSTEM 696
3/84 SYSTEM 744
4/84 SYSTEM 720
5/84 SYSTEM 744
6/84 SYSTEM 720
13-302
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COOPERATIVE POWER ASSOCIATION: COAL CREEK 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
SOZ PART. HOURS HOURS HOURS FACTOR
7/84 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
FGD SYSTEM AVAILABILITY FOR THE PERIOD OF JANUARY THROUGH JULY 1984 MAS
REPORTED AS 100X.
8/84 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE SCHEDULED OUTAGE IN AUGUST, CORRODING REHEAT DUCTWORK WAS
REPLACED WITH 316L STAINLESS STEEL.
9/84 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED REPLACING DETERIORATING MIST ELIMINATOR
FIBERGLASS LININGS DURING THE FIRST THREE QUARTERS OF 1984.
13-303
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
SECTION 13
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
SOa 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
** MECHANICAL COLLECTOR
NUMBER
TYPE
** ESP
NUMBER
NUMBER OF SPARES
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
TRADE NAME/COMMON NAME
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
*** FGD SYSTEM
COOPERATIVE POWER ASSOCIATION
COAL CREEK
UNDERWOOD
NORTH DAKOTA
D
43.
516.
******
1100
550
500
501
327
( .100 LB/MMBTU)
( 1.200 LB/MMBTU)
(****»* LB/MMBTU)
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
1038.18 (2200000 ACFM)
160.0 ( 320 F)
201. ( 658 FT)
CONCRETE
6.7 ( 22.0 FT)
( 6258 BTU/LB)
3068-7660
COAL
LIGNITE
14556.
7.14
3.9-16.0
39.83
27.8-52.6
.63
0.2-1.4
.02
0.00-0.08
0
NONE
1
0
COLD SIDE
WHEELABRATOR-FRYE
1090.1 (2310000 ACFM)
160.6 ( 321 F)
.6 { 3. IN-H20)
99.5
0
NONE
N/A
N/A
N/A
N/A
N/A
N/A
N/A
13-304
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COOPERATIVE POWER ASSOCIATION: COAL CREEK 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.
ENERGY CONSUMPTION - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
SPACE REQUIREMENTS - SQ M
OPER. & MAINT. REQUIREMENT - MANHR/DAY
»* QUENCHER/PRESATURATOR
NUMBER
** 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
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
302 REMOVAL EFFICIENCY - '/.
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
NUMBER OF SPARES PER SYSTEM
NUMBER PER MODULE
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
CONSTRUCTION MATERIAL SPECIFIC TYPE
WASH WATER SOURCE
WASH FREQUENCY
WASH RATE L/S
THROWAWAY PRODUCT
WET SCRUBBING
LIME/ALKALINE FLYASH
NONE
COMBUSTION ENGINEERING
BLACK & VEATCH
FULL SCALE
NEW
X 99.50
54.00
.2
1
9/80
7/80
5/76
8091.6
72.0
( 87100 SQ FT)
4
0
SPRAY TOWER
OPEN COUNTERCURRENT SPRAY
N/A
COMBUSTION ENGINEERING
21.5 WIDE X 20 DEEP X 55 HIGH
STAINLESS STEEL
AUSTENITIC
TYPE 316L
NONE
N/A
N/A
NONE
1
1310
e
o
.7
3.2
163.51
160.6
90.0
(20790 GPM)
( 60.0 GAL/1000 ACF)
( 3.0 IN-H20)
( 10.6 FT/S)
( 346500 ACFM)
( 321 F)
PRIMARY COLLECTOR
4
0
1
IMPINGEMENT
BAFFLE
CLOSED VANE
HORIZONTAL
2
2
2.44
76.20
7.6
.1
2.7
ORGANIC
FIBER-REINFORCED POLYESTER
COOLING TOWER SLOWDOWN
INTERMITTENT
37.8 ( 600 GAL/MIN)
( 8.0 FT)
(30.0 IN)
( 3.00 IN)
( .5 IN-H20)
( 8.9 FT/S)
13-305
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COOPERATIVE POWER ASSOCIATION: COAL CREEK 2 (CONT.)
** REHEATER
NUMBER
NUMBER OF SPARES
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
PERCENT GAS BYPASSED - AVG
TEMPERATURE INCREASE - C
INLET FLUE GAS TEMPERATURE - C
OUTLET FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
»» FANS
NUMBER
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
CONSTRUCTION MATERIAL GENERIC TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
«* DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
»* DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
1
0
BYPASS
COLD SIDE
N/A
40.0
47.2
57.2
98.9
NR
NR
( 85 F)
( 135 F)
( 210 F)
CENTRIFUGAL
GREEN FAN
BALANCED DRAFT
FORCED DRAFT
DRY
163.51
160.6
12.8
CARBON STEEL
346500 ACFM)
321 F)
(42.0 IN-H20)
8
ISOLATION
LOUVER
NR
CARBON STEEL
HIGH STRENGTH LOW ALLOY tHSUU
NONE
N/A
8
ISOLATION
LOUVER
NR
STAINLESS STEEL
AUSTENITIC
NONE
N/A
4
CONTROL
LOUVER
NR
CARBON STEEL
HIGH STRENGTH LOW ALLOY [HSLAJ
NONE
N/A
8
ISOLATION
LOUVER
CARBON STEEL
HIGH STRENGTH LOW ALLOY [HSUU
NONE
N/A
OUTLET
STAINLESS STEEL
AUSTENITIC
NONE
N/A
13-306
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COOPERATIVE POWER ASSOCIATION: COAL CREEK 2 (CONT.)
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
»* DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
MANUFACTURER
NUMBER
PRODUCT QUALITY - X SOLIDS
** TANKS
SERVICE
ABSORBER RECYCLE
FLYASH
REAGENT PREP PRODUCT
** PUMPS
SERVICE
BLEED STREAM
SLURRY FEED
REACTION TANK TRANSFER
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
*** SLUDGE
** TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE TREATMENT
SITE DIMENSIONS
SITE SERVICE LIFE - YRS
*» PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS
PHYSICAL VARIABLES
MONITOR TYPE
MONITOR LOCATION
INLET
CARBON STEEL
AISI 1110
NONE
N/A
BYPASS
CARBON STEEL
AISI 1110
NONE
N/A
PLENUM TO STACK
CARBON STEEL
AISI 1110
INORGANIC
HYDRAULICALLY-BONDED MORTAR
SLAKER
NR
NR
WALLACE & TIERMAN
2
10.0
NUMBER
2
****
#***
NUMBER
3
2
6
NONE
NONE
NR
N/A
FINAL
POMD
ON-SITE
PIPELINE
CLAY LINING
400 ACRES
35
PH, S02
SOLIDS, LIQUID LEVEL
UNILOC FOR PH, LEAR-SIEGLER FOR S02, MOORE FOR S
REACTION TANK FOR PH
13-307
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COOPERATIVE POWER ASSOCIATION: COAL CREEK 2 (CONT.)
** WATER BALANCE
WATER LOOP TYPE
** CHEMICALS AND CONSUMPTION
FUNCTION
NAME
PRINCIPAL CONSTITUENT
SOURCE/SUPPLIER
CONSUMPTION
POINT OF ADDITION
** FGD SPARE CAPACITY INDICES
ABSORBER - X
»* FGD SPARE COMPONENT INDICES
ABSORBER
OPEN
ABSORBENT
LIME
CAO
PETE LIEN * SONS, INC.
RAPID CITY, SOUTH DAKOTA
SLAKER
.0
.0
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
7. REMOVAL PER BOILER FGD CAP.
502 PART. HOURS HOURS HOURS FACTOR
7/80
21
22
23
24
SYSTEM
61.8
18,
25.
52.
39.6
** PROBLEMS/SOLUTIONS/COMMENTS
52.4
15.9
21.2
44.9
33.6
744 631
250 34.5
INITIAL OPERATION OF THE FGD SYSTEM BEGAN IN JULY 1980.
PROBLEMS WERE REPORTED.
NO MAJOR START UP
8/80
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
** PROBLEMS/SOLUTIONS/COMMENTS
744 566
331 36.1
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
SYSTEM
10/80 21
22
23
24
SYSTEM
11/80 21
22
23
24
SYSTEM
12/80 21
22
23
24
SYSTEM
80.2
56.8
49.0
76.9
65.7
92,
86.
22.
70.4
63.1
77.0
25.0
77.8
58.7
51.3
22.2
89.4
55.4
80.0
56.7
48.9
76.7
65.6
91.7
86.0
22.0
70.2
44.2
53.9
17.5
54.4
57.5
50.3
21.8
87.6
54.3
720 718
744 742
720 504
744 730
472 59.1
70.0
41.0
404 65.2
13-308
-------
UTILITY F6D SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COOPERATIVE POWER ASSOCIATION: COAL CREEK Z (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR PROBLEMS HAVE BEEN ENCOUNTERED FOR THE MONTHS OF SEPTEMBER
THROUGH DECEMBER.
1/81 21
22
23
24
SYSTEM
2/81 21
22
23
24
SYSTEM
3/81 21
22
23
24
SYSTEM
99.8
99.8
99.8
99.8
99.8
99.7
99.7
99.7
99.7
99.7
55.4
55.4
55.4
55.4
55.4
75.7
37.6
46.3
68.9
57.1
72.5
37.9
32.8
82.6
56.5
56.3
44.7
27.7
91.3
55.1
75.5
37.5
46.2
68.8
57.0
72.5
37.8
32.7
82.4
56.4
31.2
24.7
15.3
50.5
30.5
744 743 42<+ 57.2
672 670 379 57.6
744 412 227 39.2
»* PROBLEMS/SOLUTIONS/COMMENTS
DURING THE FIRST QUARTER 1981 THE UTILITY REPORTED THAT NO MAJOR FGD-RELAT-
ED PROBLEMS WERE ENCOUNTERED.
ON MARCH 17 THE BOILER WAS TAKEN OUT OF SERVICE FOR A BOILER/TURBINE
OVERHAUL, MAINTENANCE AND MODIFICATIONS. THE UNIT WILL BE OUT OF SERVICE
FOR APPROXIMATELY TEN WEEKS.
4/81
5/81
6/81
21
22
£3
24
SYSTEM
21
22
23
24
SYSTEM
21
22
23
24
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
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
26.5 100.0 10.3
10.0 100.0 3.9
56.6 100.0 21.9
18.6 100.0 7.2
27.9 100.0 10.8
720
744
720 279
.0
.0
78 50.3
** PROBLEMS/SOLUTIONS/COMMENTS
UNIT WAS OFF-LINE DUE TO BOILER/TURBINE WARRANTY INSPECTION DURING THE
MONTHS OF APRIL, MAY, AND PART OF JUNE.
DURING THE SECOND QUARTER 1981 THE UTILITY REPORTED THAT NO MAJOR FGD-
RELATED PROBLEMS WERE ENCOUNTERED.
7/81 21
22
23
24
SYSTEM
72.5
9.5
60.6
23.9
41.6
63.7
8.3
53.2
21.0
36.6
744 654
272 53.3
13-309
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COOPERATIVE POWER ASSOCIATION: COAL CREEK 2 (CONT.)
PERIOD
8/81
9/81
10/81
11/81
12/81
MODULE
21
22
23
24
SYSTEM
21
22
23
24
SYSTEM
** PROE
21
22
23
24
SYSTEM
21
22
23
24
SYSTEM
21
22
23
24
SYSTEM
AVAILABILITY OPERABILITY
44.9
34.7
55.8
38.4
43.5
16.6
91.8
50.1
82.8
60.4
5 LEMS/SO LUTIONS/COMMENTS
NO FGD-RELATED
54.6
86.8
76.6
85.7
75.9
26.4
91.9
68.1
80.3
66.7
77.2
56.2
70.8
63.3
66.9
f CKFUKnAINUC U«l « _--..
RELIABILITY UTILIZATION '/. REMOVAL PER BOILER FGD
S02 PART. HOURS HOURS HOURS
35.5
27.4
44.1
30.4
34.4 744 588 256
16.4
90.6
49.4
61.7
59.6 720 710 429
PROBLEMS WERE REPORTED FOR THE THREE MONTH PERIOD.
54.6
86.8
76.6
85.7
75.9 744 744 565
26.4
91.9
68.1
80.3
66.7 ' 720 720 480
77.1
56.1
70.7
63.2
66.8 744 743 497
CAP.
FACTOR
51.0
69.8
83.6
67.4
68.8
»* PROBLEMS/SOLUTIONS/COMMENTS
GENERAL MAINTENANCE WAS PERFORMED ON THE FGD SYSTEM DURING THE FOURTH
QUARTER. NO FGD FORCED OUTAGES WERE ENCOUNTERED.
744 743 545 79.4
672 670 555 73.8
744 702 448 65.3
1/82
2/82
3/82
21
22
23
24
SYSTEM
21
22
23
24
SYSTEM
21
22
23
24
SYSTEM
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
82
54
92
63
73
85
65
93
86
82
93
61
46
54
63
.4
.9
.9
.0
.3
.9
.9
.5
.2
.9
.6
.5
.0
.3
.9
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
82
54
92
62
73
85
65
93
85
82
88
58
43
51
60
.3
.8
.7
.9
.2
.6
.6
.2
.9
.6
.3
.1
.4
.2
.3
PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR PROBLEMS OR FORCED OUTAGES WERE ENCOUNTERED DURING THE FIRST
QUARTER OF 1982.
4/82 21
60.3
60.3
100.0
60.3
13-310
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
COOPERATIVE POWER ASSOCIATION: COAL CREEK 2 (CONT.)
PERIOD MODULE AVAILABILITY OPERABILITY
22
23
24
SYSTEM
5/82 21
22
23
24
SYSTEM
6/82 21
22
23
24
SYSTEM
43.5
95.6
99.7
74.8
98.6
87.2
64.5
36.3
71.6
87.8
90.3
100.0
96.4
93.6
42.6
83.2
86.7
68.2
72.0
32.7
28.0
7.0
34.9
39.4
47.5
87.3
53.9
57.0
--rCKrUKRAN
RELIABILITY
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
UC UA 1 A--------- ______________
UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
42.6
83.2
86.7
68.2
71.9
32.7
27.9
7.0
34.9
39.3
47.4
87.1
53.7
56.9
720 720 491 73.1
744 743 260 64.9
720 718 409 64.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE SECOND QUARTER 1982 GENERAL MAINTENANCE AND CLEANING OF THE
FGD SYSTEM ACCOUNTED FOR ANY UNAVAILABLE TIME.
7/82 SYSTEM 744
8/82 SYSTEM 744
9/82 SYSTEM 720
10/82 SYSTEM 744
11/82 SYSTEM 720
12/82 SYSTEM 744
1/83 SYSTEM 744
2/83 SYSTEM 672
3/83 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE PERIOD OF JULY 1982 THROUGH MARCH 1983.
4/83 SYSTEM 720
5/83 SYSTEM 744
6/83 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE PERIOD OF JULY 1982 THROUGH JUNE 1983.
7/83 SYSTEM 744
8/83 SYSTEM 744
9/83 SYSTEM 720
13-311
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
COOPERATIVE POWER ASSOCIATION: COAL CREEK 2 (COST.)
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 FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE THIRD QUARTER OF 1983.
10/83 SYSTEM 744
11/83 SYSTEM 720
12/83 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE FGD SYSTEM AT COAL CREEK 2 WAS 100 PERCENT
AVAILABLE THROUGHOUT THE FOURTH QUARTER OF 1983.
1/84 SYSTEM 744
2/84 SYSTEM 696
3/84 SYSTEM 744
4/84 SYSTEM 7ZO
5/84 SYSTEM 744.
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE SCHEDULED OUTAGE IN MAY, CORRODING REHEAT DUCTWORK WAS
REPLACED WITH STAINLESS STEEL.
6/84 SYSTEM 720
7/84 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
FGD SYSTEM AVAILABILITY DURING THE PERIOD OF JANUARY THROUGH JULY WAS
REPORTED AS 100X.
8/84 SYSTEM 744
9/84 SYSTEM 720
«* PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED REPLACING DETERIORATING MIST ELIMINATOR
FIBERGLASS LININGS DURING THE FIRST THREE QUARTERS OF 1984.
13-312
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
SECTION 13
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
DELMARVA POWER
DELAWARE CITY
1
DELAWARE CITY
DELAWARE
E
129.
******
******
180
60
495
495
60
4 LIGHT
( .300 LB/MMBTU)
(****** 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
** MECHANICAL COLLECTOR
NUMBER
TYPE
SUPPLIER
PARTICLE REMOVAL EFFICENCY -7.
** FABRIC FILTER
NUMBER
TYPE
TYPICAL GAS/CLOTH RATIO - M/MIN
** 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
INITIAL START-UP DATE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON NAME
SUPPLIER
DIMENSIONS - FT
RILEY STOKER
PULVERIZED COAL
BASE
139.21 (
215.6 (
152. (
CONCRETE
6.1 (
295000 ACFM)
420 F)
500 FT)
20.0 FT)
COKE
BITUMINOUS
32564.
.50
0.3-0.7
.70
0.5-1.2
7.00
5.0-8.0
********
******
3
TUBULAR
PRAT-DANIEL
92.0
( 14000 BTU/LB)
13500-14500
0
NONE
.6
( 2.0 FT/MIN)
COLD SIDE
WESTERN PREC. DIVISION, JOY
34.8 ( 73700 ACFM)
54.4 ( 130 F)
.2 (1. IN-H20)
95.0
3
4/80
VENTURI TOWER
VARIABLE-THROAT/BOTTOM-ENTRY PLUMB BOB
N/A
AIRPOL
20 DIA X 70.0
13-313
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 198*
DELMARVA POWER t LIGHT: DELAWARE CITY 1 (CONT.)
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 - 7.
PARTICLE REMOVAL EFFICIENCY - X
»** 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 502 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
»* QUENCHER/FRESATURATOR
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** 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 PECIRCULATION RATE - LITER/S
L/G RATIO L/CU.M
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
CARBON STEEL
AISI 1110
ORGANIC; INORGANIC
GLASS FLAKE-FILLED POLYESTER; PREFIRED BRICK/SHA
NONE
315.0
6.8
.5
46.4
221.1
.0
81.5
( 5000 GPM)
(50.9 SAL/1000ACF)
( £.0 IN-H20)
( 98300 ACFM)
( 430 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
( 261360 SQ FT)
24280.3
144.0
NR
NR
3
0
TRAY TOWER
VALVE TRAY
BUBBLE CAP TRAY TOWER
DAVY MCKEE
20.0 X 20.0
INORGANIC
HYDRAULICALLY-BONDED CONCRETE
PORTLAND CEMENT
INORGANIC
PREFIRED BRICK/SHAPES
NR
VALVE TRAY
4
25. (
.7 (
34.59 (
54.4 (
.0
400 GPM)
5.5 GAL/1000 ACF)
73300 ACFM)
130 F)
PRIMARY COLLECTOR
3
IMPINGEMENT
BAFFLE
CLOSED VANE
HORIZONTAL
1
1
1.83 ( 6.0 FT)
13-314
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
DELMARVA POWER * LIGHT: DELAWARE CITY 1 (CONT.)
DISTANCE BETWEEN STAGES - CM
PRESSURE DROP - KPA
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
WASH WATER SOURCE
'WASH FREQUENCY
WASH RATE - L/S
»# REHEATER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
TEMPERATURE INCREASE - C
INLET FLUE GAS FLOW RATE - CD. M/S
INLET FLUE GAS TEMPERATURE - C
OUTLET FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE NR
CONSTRUCTION MATERIAL SPECIFIC TYPE NR
** 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
** DAMPERS
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
DIMENSIONS
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
** TANKS
SERVICE
NR
** PUMPS
SERVICE
ABSORBER RECIRCULATION
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
*** SALEABLE BYPRODUCTS
NATURE
FULL LOAD QUANTITY - M T/H
19.05 (
.1 (
ORGANIC
POLYPHENYLENE
COOLED CONDENSATE
INTERMITTENT
3.2 (
7.5 IN)
.3 IN-H20)
50 GAL/MIN)
DIRECT COMBUSTION
EXTERNAL COMBUSTION CHAMBER
NATURAL GAS
27.8
108.54
85.0
50 F)
230000 ACFM)
130 F)
185 F)
3
0
CENTRIFUGAL
ROBINSON
BOOSTER
INDUCED DRAFT
DRY
139.21 (
215.6 (
CARBON STEEL
NR
NR
NR
NR
NR
NR
NR
8.0 X 8.0
CARBON STEEL
AISI 1110
ORGANIC
FIBER-REINFORCED
MIX TANK
N/A
AGITATED TANK
NUMBER
295000 ACFM)
420 F)
POLYESTER
NUMBER
#***
NONE
SULFURIC ACID
11.34 ( 12.50 TPH)
13-315
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
DELMARVA POKER & LIGHT: DELAWARE CITY 1 (CONT.)
QUALITY X 93-°
DISPOSITION MARKETED
*** SLUDGE
** TREATMENT
METHOD N/A
DEVICE N/A
PROPRIETARY PROCESS N/A
** DISPOSAL
NATURE FINAL
TYPE POND
SITE TREATMENT CLAY LINING
*# PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS PH, SOLIDS, SP.G., CONC.
MONITOR LOCATION GAS OUTLET, SOLUTION OUTLET
PROCESS CONTROL MANNER AUTOMATIC
PROCESS CHEMISTRY MODE FEEDBACK
** WATER BALANCE
WATER LOOP TYPE CLOSED
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
SOS PART. HOURS HOURS HOURS FACTOR
5/80 SYSTEM 100.0 100.0 100.0 32.3 744 240 240
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM BEGAN INITIAL AND COMMERCIAL OPERATIONS ON MAY 22, 198Q.
NO MAJOR PROBLEMS WERE ENCOUNTERED FROM STARTUP THROUGH THE END OF
THE MONTH.
6/80 SYSTEM 98.9 98.9 98.9 98.9 720 720 712
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR PROBLEMS WERE ENCOUNTERED DURING JUNE.
7/80 SYSTEM 97.2 97.0 97.0 90.7 744 696 675
** 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 99.9 744 744 743
** PROBLEMS/SOLUTIONS/COMMENTS
NO FGD-RELATED PROBLEMS WERE REPORTED DURING AUGUST.
9/80 SYSTEM 78.3 78.3 78.3 78.3 720, 720 564
** 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 66.1 744 744 492
13-316
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
DELMARVA POWER t LIGHT: DELAWARE CITY 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
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.
1/81 SYSTEM 90.0 90.0 90.0 90.0 744 744 670
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JANUARY THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS
WERE ENCOUNTERED.
2/81 SYSTEM 86.0 84.0 84.0 76.0 672 607 512
** PROBLEMS/SOLUTIONS/COMMENTS
DURING FEBRUARY OUTAGE TIME WAS DUE TO LEAKS IN THE MIST ELIMINATOR AND
FAILURE OF THE PRESCRUBBER SPRAY NOZZLES.
3/81 SYSTEM 95.6 95.6 95.6 95.4 744 743 710
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MARCH THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE
ENCOUNTERED.
4/81 SYSTEM 74.0 83.0 83.0 74.0" 720 643 531
** PROBLEMS/SOLUTIONS/COMMENTS
DURING APRIL SOME OUTAGE TIME WAS CAUSED BY THE REPAIRS TO THE MIST ELIMI-
NATOR SHELL AND INTERNALS.
ADDITIONAL OUTAGE TIME WAS DUE TO THE REPLACEMENT OF THE BOOSTER BLOWER
DISCHARGE DUCT EXPANSION JOINT.
5/81 SYSTEM 98.1 98.1 98.1 98.1 744 744 730
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MAY REPAIRS WERE PERFORMED ON THE MIST ELIMINATOR SHELL.
6/81 SYSTEM 100.0 100.0 100.0 100.0 720 720 720
13-317
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1964
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 UTILITY REPORTED THAT NO PROBLEMS WERE ENCOUNTERED DURING JUNE.
7/81 SYSTEM 99.2 99.2 99.2 99.2 744 744 738
8/81 SYSTEM 77.4 77.4 77.4 46.9 744 451 349
** PROBLEMS/SOLUTIONS/COMMENTS
EXTENSIVE REPAIRS WERE MADE TO THE VENTURI PRESCRUBBER BRICK WORK DURING
A SCHEDULED AUGUST BOILER OUTAGE.
9/81 SYSTEM 95.1 95.1 95.1 95.0 720 719 684
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS DOWN FOR PART OF SEPTEMBER FOR REPAIRS TO THE PRESCRUB-
BER MIST ELIMINATOR.
10/81 SYSTEM 29.9 57.4 71.1 22.8 744 296 170
** PROBLEMS/SOLUTIONS/COMMENTS
ON OCTOBER 1 THE UNIT WAS SHUTDOWN FOR AN OVERHAUL.
11/81 SYSTEM 70.1 70.1 70.1 70.1 720 720 505
** PROBLEMS/SOLUTIONS/COMMENTS
DURING OCTOBER AND NOVEMBER CONTINUAL PROBLEMS WERE ENCOUNTERED WITH THE
PRESCRUBBER CIRCULATING PUMPS. THIS PROBLEM RESULTED FROM PUMP PLUGGING
RELATED TO INADEQUATE SCRUBBING OF THE GAS. THIS ULTIMATELY WAS THE
RESULT OF AN INSUFFICIENT NUMBER OF PUMPS.
12/81 SYSTEM 72.6 67.6 68.4 59.4 744 654 442
** PROBLEMS/SOLUTIONS/COMMENTS
OUTAGE TIME FOR THE BOILER DURING DECEMBER WAS DUE TO SUPERHEATER TUBE
LEAKS.
CONTINUED PROBLEMS WITH THE PRESATURATOR CIRCULATING PUMPS AND PLUGGING OF
THE PRESATURATOR AND ESP'S CAUSED THE SYSTEM UNAVAILABLE TIME.
1/82 SYSTEM 68.5 69.4 69.5 68.5 744 735 510
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JANUARY THE SYSTEM WAS OFF-LINE PART OF THE MONTH DUE TO NECESSARY
CLEANING OF THE MODULES AND TO REPLACE THE PRESATURATOR NOZZLE.
2/82 SYSTEM 91.5 91.5 91.5 91.5 672 672 615
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JANUARY AND FEBRUARY LEAKS IN THE PRESATURATOR PIPING ACCOUNTED FOR
SOME OF THE DOWN TIME.
PURGE LINE PLUGGING CAUSED ADDITIONAL OUTAGE TIME IN FEBRUARY.
3/82 SYSTEM 64.9 64.9 64.9 64.9 744 744 483
13-318
-------
UTILITY F6D SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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
PROBLEMS WERE ENCOUNTERED WITH THE REGENERATING SECTION OF THE SYSTEM
DURING MARCH.
4/82 SYSTEM 100.0 100.0 100.0 100.0 720 720 720
5/82 SYSTEM 92.2 92.2 92.2 92.2 744 744 686
** PROBLEMS/SOLUTIONS/COMMENTS
DURING APRIL AND MAY NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED.
6/82 SYSTEM 82.5 82.5 82.5 82.5 720 720 594
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JUNE THE SYSTEM WAS SHUT DOWN PART OF THE TIME TO REPAIR THE BRICK
LINING IN THE PRESATURATOR.
7/82 SYSTEM 63.8 63.8 63.8 63.8 744 744 475
** PROBLEMS/SOLUTIONS/COMMENTS
OUTAGE TIME OCCURRED DURING JULY DUE TO A HIGH PRESSURE DROP IN THE
PRESATURATOR. THE DROP WAS CAUSED BY COKE CARRYOVER TO THE ESP SEAL POTS.
EVAPORATOR PROBLEMS ACCOUNTED FOR AN OUTAGE DURING THE MONTH.
8/82 SYSTEM 90.2 90.2 90.2 90.2 744 744 671
** PROBLEMS/SOLUTIONS/COMMENTS
PART OF THE OUTAGE TIME DURING AUGUST WAS DUE TO LEAKS IN THE PRESATURATOR
CIRCULATION PIPING.
FAILURE OF THE PRESATURATOR SPRAY NOZZLE TIP ALSO RESULTED IN DOWN TIME
DURING THE MONTH.
9/82 SYSTEM 28.3 77.3 77.3 28.3 720 264 204
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS DOWN DURING PART OF SEPTEMBER FOR AN ANNUAL INSPECTION.
LEAKS IN THE PRESATURATOR RECIRCULATION PIPING CREATED DOWN TIME FOR THE
FGD SYSTEM IN SEPTEMBER.
ADDITIONAL OUTAGE TIME RESULTED FROM LEAKS IN THE DUCTWORK EXPANSION
JOINTS.
AN OUTAGE OCCURRED DURING SEPTEMBER FOR COKE SLAG BURN OUT.
10/82 SYSTEM 98.9 98.9 98.9 98.9 744 744 736
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING OCTOBER.
11/82 SYSTEM 97.9 97.9 97.9 97.9 720 720 705
13-319
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
DELMARVA POWER & LIGHT: DELAWARE CITY 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
NO MAJOR FGD-RELATED PROBLEMS WERE REPORTED BY THE UTILITY
DURING NOVEMBER.
12/82 SYSTEM 81.6 81.6 81.6 81.6 744 744 607
** PROBLEMS/SOLUTIONS/COMMENTS
DURING DECEMBER THE UNIT WAS DOWN FOR 45 HOURS TO CLEAN PLUGGED SCREENS
ON THE PRESATURATOR CIRCULATION PUMPS.
THE REMAINDER OF DOWN TIME DURING THE MONTH WAS DUE TO PROBLEMS WITH THE
ACID PLANTS.
1/83 SYSTEM 89.9 74.7 74.7 74.7 744 744 556
** PROBLEMS/SOLUTIONS/COMMENTS
OUTAGE TIME OCCURRED DURING JANUARY DUE TO THE BALANCING OF A BOOSTER FAN.
THE CLEANING OF A SUCTION SCREEN ON THE PRESATURATOR PRODUCED ADDITIONAL
OUTAGE TIME IN JANUARY.
THE UNIT WAS DOWN DURING JANUARY TO PERMIT REPAIR WORK ON THE ACID PLANT.
2/83 SYSTEM 97.3 69.3 69.3 69.3 672 672 466
** PROBLEMS/SOLUTIONS/COMMENTS
REPAIR WORK ON THE ESP CAUSED AN OUTAGE DURING FEBRUARY.
THE UNIT WAS DOWN DURING FEBRUARY TO PERMIT REPAIR WORK ON THE ACID PLANT
TAIL GAS LINE.
3/83 SYSTEM 95.6 95.6 95.6 95.6 744 744 711
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING MARCH.
4/83 SYSTEM 94.7 94.7 94.7 94.7 720 720 682
5/83 SYSTEM 98.9 98.9 98.9 98.9' 744 744 736
*» PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING APRIL AND MAY.
6/63 SYSTEM 84.7 84.7 84.7 84.7 720 720 610
** PROBLEMS/SOLUTIONS/COMMENTS
REPAIRS ON THE BRICK LINING IN THE PRESATURATOR CAUSED A FORCED OUTAGE
DURING JUNE.
7/83 SYSTEM 100.0 100.0 100.0 100.0 744 744 744
8/83 SYSTEM 96.0 96.0 100.0 96.0 744 744 714
13-320
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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 UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING JULY AND AUGUST.
9/83 SYSTEM 71.3 92.8 92.8 71.3 720 553 513
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS SHUT DOWN ON SEPTEMBER 24 FOR AN ANNUAL INSPECTION AND MAIN-
TENANCE.
10/83 SYSTEM 50.7 86.9 86.9 50.7 744 434 377
»* PROBLEMS/SOLUTIONS/COMMENTS
UNIT 1 WAS OUT OF SERVICE FROM SEPTEMBER 24 TO OCTOBER 14, 1983 FOR A
SCHEDULED OUTAGE. DURING THIS PERIOD AN ANNUAL BOILER INSPECTION AND FGD
SYSTEM MAINTENANCE WAS CONDUCTED.
THE FGD SYSTEM WAS DOWN DURING PART OF OCTOBER DUE TO A LACK OF SODIUM SUL-
FITE ABSORBING SOLUTION.
11/83 SYSTEM 94.2 94.2 94.2 94.2 720 720 678
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR FGD-RELATED OUTAGES WERE ENCOUNTERED DURING NOVEMBER.
12/83 SYSTEM 82.8 82.8 82.8 82.8 744 744 616
** PROBLEMS/SOLUTIONS/COMMENTS
FGD SYSTEM OUTAGE TIME DURING DECEMBER WAS DUE IN PART TO EXTREME COLD
WEATHER CONDITIONS.
BRIEF OUTAGES OCCURRED DURING THE MONTH DUE TO MIST ELIMINATOR LEAKS.
1/84 SYSTEM 98.9 93.9 98.9 98.9 744 744 736
** PROBLEMS/SOLUTIONS/COMMENTS
A LACK OF ABSORBING SOLUTION DUE TO EVAPORATOR CIRCULATING PUMP PROBLEMS
AND PLUGGED EVAPORATOR SOLUTION HEADERS LIMITED THE BURNING OF HIGH SULFUR
COKE DURING JANUARY.
2/84 SYSTEM 84.5 84.5 84.5 84.5 696 696 588
** PROBLEMS/SOLUTIONS/COMMENTS
PRESATURATOR CLEANING CONTRIBUTED TO OUTAGE TIME DURING FEBRUARY.
THE UTILITY REPORTED REPLACING FALLEN ACID BRICK DURING FEBRUARY.
MIST ELIMINATOR REPAIRS ACCOUNTED FOR ADDITIONAL DOWN TIME DURING
THE MONTH.
PRESATURATOR RECIRCULATING PROBLEMS WERE REPORTED DURING FEBRUARY.
3/84 SYSTEM 98.4 98.4 98.4 98.4 744 744 732
4/84 SYSTEM 99.6 99.6 99.6 99.6 720 720 717
5/84 SYSTEM 97.2 97.2 97.2 97.2 744 744 7C3
13-321
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
DELMARVA POWER & LIGHT: DELAWARE CITY 1 (CONT.)
.PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S03 PART. HOURS HOURS HOURS FACTOR
»* PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR FGD-RELATED PROBLEMS WERE REPORTED DURING MARCH THROUGH MAY.
6/84 SYSTEM 720
7/84 SYSTEM 744
8/84 SYSTEM 744
9/84 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE PERIOD OF JUNE THROUGH SEPTEMBER 1984.
13-322
-------
UTILITY F6D SURVEY: OCTOBER 1983 - SEPTEMBER 1984
SECTION 13
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 - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** MECHANICAL COLLECTOR
NUMBER
TYPE
SUPPLIER
PARTICLE REMOVAL EFFICENCY -7.
** FABRIC FILTER
NUMBER
TYPE
TYPICAL GAS/CLOTH RATIO - M/MIN
** 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
INITIAL START-UP DATE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON NAME
SUPPLIER
DIMENSIONS - FT
DELMARVA POWER & LIGHT
DELAWARE CITY
Z
DELAWARE CITY
DELAWARE
E
129. ( .300 LB/MMBTU)
»*«**# (****** LB/MMBTU)
****** (****** LB/MMBTU)
180
60
495
495
60
RILEY STOKER
PULVERIZED COAL
BASE
139.21 ( 295000 ACFM)
215.6 ( 420 F)
152. ( 500 FT)
CONCRETE
6.1 ( 20.0 FT)
COKE
BITUMINOUS
32564.
.50
0.3-0.7
.70
0.5-1.2
7.00
5.0-8.0
********
******
3
TUBULAR
PRAT-DANIEL
92.0
( 14000 BTU/LB)
13500-14500
0
NONE
.6
( 2.0 FT/MIN)
COLD SIDE
WESTERN PREC. DIVISION, JOY
34.8 ( 73700 ACFM)
54.4 ( 130 F)
.2 ( 1. IN-H20)
95.0
3
4/80
VENTURI TOWER
VARIABLE-THROAT/BOTTOM-ENTRY PLUMB BOB
N/A
AIRPOL
20 DIA X 70.0
13-323
-------
UTILITY FGO SURVEY'- OCTOBER 1983 - SEPTEMBER 1984
DEU1ARVA POWER 4 LIGHT: DELAWARE CITY 2 (CONT.)
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
*** FGD SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
SQZ REMOVAL MODE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
HEW/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
UNIT DESIGN 502 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
»* QUENCHER/PRESATURATOR
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** 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
L/G RATIO - L/CU.M
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
NUM3ER OF STAGES
NUMSER OF PASSES PER STAGE
FREEBOARD DISTANCE - M
CARBON STEEL
AISI 1110
ORGANIC; INORGANIC
GLASS FLAKE-FILLED POLYESTER; PREFIRED BRICK/SHA
NONE
315.0
6.8
.5
46.4
221.1
.0
81.5
( 5000 GPM)
(50.9 GAL/1000ACF)
( 2.0 IN-H20)
( 98300 ACFM)
( 430 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
( 261360 SQ FT)
24280.3
144.0
NR
NR
3
0
TRAY TOWER
VALVE TRAY
BUBBLE CAP TRAY TOWER
DAVY MCKEE
20.0 X 20.0
INORGANIC
HYDRAULICALLY-BONDED CONCRETE
PORTLAND CEMENT
INORGANIC
PREFIRED BRICK/SHAPES
NR
VALVE TRAY
4
25. (
.7 (
34.59 (
54.4 (
.0
400 GPM)
5.5 GAL/1000 ACF)
73300 ACFM)
130 F)
PRIMARY COLLECTOR
3
IMPINGEMENT
BAFFLE
CLOSED VANE
HORIZONTAL
1
1
1.83 ( 6.0 FT)
-------
UTILITY FGO SURVEY: OCTOBER 1983 - SEPTEMBER 1984
DELMARVA POWER & LIGHT: DELAWARE CITY Z (CONT.)
DISTANCE BETWEEN STAGES - CM
PRESSURE DROP - KPA
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
WASH WATER SOURCE
WASH FREQUENCY
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
OUTLET FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC 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
*» DAMPERS
FUNCTION
GENERIC .TYPE
SPECIFIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
#* DUCTWORK
DIMENSIONS
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
** TANKS
SERVICE
NR
** PUMPS
SERVICE
ABSORBER RECIRCULATION
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
*** SALEABLE BYPRODUCTS
NATURE
FULL LOAD QUANTITY - M T/H
19.05 (
.1 (
ORGANIC
POLYPHENYLENE
COOLED CONDENSATE
INTERMITTENT
3.2 (
7.5 IN)
.3 IN-H20)
50 GAL/MIN)
DIRECT COMBUSTION
EXTERNAL COMBUSTION CHAMBER
NATURAL GAS
27.8
108.54
54.4
85.0
50 F)
230000 ACFM)
130 F)
185 F)
NR
NR
295000 ACFM)
420 F)
3
0
CENTRIFUGAL
ROBINSON
BOOSTER
INDUCED DRAFT
DRY
139.21 (
215.6 (
CARBON STEEL
NR
NR
NR
NR
NR
NR
NR
8.0 X 8.0
CARBON STEEL
AISI 1110
ORGANIC
FIBER-REINFORCED POLYESTER
MIX TANK
N/A
AGITATED TANK
NUMBER
****
NUMBER
**«*
NONE
SULFURIC ACID
11.34 ( 12.50 TPH)
13-325
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
DEU1ARVA POWER & LIGHT: DELAWARE CITY 2 CCONT.)
QUALITY - X 93-°
DISPOSITION MARKETED
*** SLUDGE
** TREATMENT
METHOD N/A
DEVICE N/A
PROPRIETARY PROCESS N/A
** DISPOSAL
NATURE FINAL
TYPE POND
SITE TREATMENT CLAY LINING
** PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS PH, SOLIDSi SP.G., CONC.
MONITOR LOCATION GAS OUTLET, SOLUTION OUTLET
PROCESS CONTROL MANNER AUTOMATIC
PROCESS CHEMISTRY MODE FEEDBACK
** 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
5/80 SYSTEM 100.0 100.0 100.0 32.3 744 240 240
** PROBLEMS/SOLUTIONS/COMMENTS
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 80.4 80.4 80.4 80.4 720 720 579
** PROBLEMS/SOLUTIONS/COMMENTS
THE CHEVRON PACKING IN THE MIST ELIMINATOR FAILED CAUSING SOME FGD SYSTEM
OUTAGE TIME DURING JUNE.
FAILURE OF THE CIRCULATION PUMPS ALSO CAUSED OUTAGE TIME DURING THE MONTH.
7/80 SYSTEM 50.1 50.1 50.1 50.1 744 744 373
** 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.
13-326
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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
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 WELU1AN 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 WAS REQUIRED TO REPAIR LEAKS IN THE PRE-
SCRUBBER.
12/80 SYSTEM 100.0 100.0 100.0 100.0 744 744 744
»* PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED NO FGD-RELATED PROBLEMS DURING THE MONTH OF DECEMBER.
1/81 SYSTEM 93.0 93.0 93.0 93.0 744 744 692
2/81 SYSTEM 96.0 96.0 96.0 96.0 672 672 648
#* PROBLEMS/SOLUTIONS/COMMENTS
'j
DURING JANUARY AND FEBRUARY THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED
PROBLEMS WERE ENCOUNTERED.
3/81 SYSTEM 57.5 89.0 89.0 57.5 744 481 428
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MARCH THE BOILER WAS OUT OF SERVICE FOR PART OF THE MONTH DUE TO AN
OVERHAUL.
REPAIRS TO A LEAK IN THE MIST ELIMINATOR CAUSED SOME OUTAGE TIME.
4/81 SYSTEM 64.0 84.0 84.0 64.0 720 553 464
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS OUT OF SERVICE APPROXIMATELY 167 HOURS DURING APRIL DUE TO
A SCHEDULED MAINTENANCE OUTAGE.
THE FGD SYSTEM WAS UNAVAILABLE APPROXIMATELY 256 HOURS DUE TO THE REPLACE-
MENT OF THE PRESATURATOR MIST ELIMINATOR INTERNALS AND THE BRICK LINING.
5/81 SYSTEM 97.5 97.5 97.5 97.5 744 744 726
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MAY REPAIRS WERE PERFORMED ON THE BOOSTER BLOWER INSPECTION DOOR.
6/81 SYSTEM 75.8 75.8 75.8 75.8 720 720 546
** PROBLEMS/SOLUTIONS/COMMENTS
ON JUNE 23 THE SYSTEM WAS SHUT DOWN DUE TO A HIGH PRESSURE DROP. ON INSPEC-
TION, IT WAS DESCOVERED THAT THE PRESATURATOR NOZZLE HAD FAILED, THERE WAS
A CONSIDERABLE COKE BUILDUP IN THE PRESATURATOR MIST ELIMINATOR BOX, THE
MIST ELIMINATOR CHEVRONS HAD FAILED, THERE WAS A LARGE COKE BUILDUP IN THE
13-327
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
DELMARVA POWER 4 LIGHT: DELAWARE CITY 2 (CONT.)
.... . PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
SOS PART. HOURS HOURS HOURS FACTOR
ESP INLET SEAL POT AND A HIGH SOLIDS BUILDUP IN THE BOTTOM OF THE S02
ABSORBER. REPAIRS CONSISTED OF REPLACING THE PRESATURATOR NOZZLE TIP AND
CLEANING THE BUILDUP.
7/81 SYSTEM 76.9 76.9 76.9 76.9 744 744 572
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JULY, THE ACID BRICK LINING ON THE INLET TO THE PRESCRUBBER FAILED.
IN ADDITION, PROBLEMS WERE ENCOUNTERED WITH THE PRESCRUBBER NOZZLE TIP.
8/81 SYSTEM 97.8 97.8 97.8 97.8 744 744 728
9/81 SYSTEM 99.2 96.3 96.3 86.7 720 648 624
** PROBLEMS/SOLUTIONS/COMMENTS
DURING SEPTEMBER, THE BOILER WAS OFF LINE FOR 72 HOURS TO REPAIR A SUPER-
HEATER TUBE LEAK.
10/81 SYSTEM 100.0 100.0 100.0 100.0 744 744 744
11/81 SYSTEM 89.2 39.2 89.2 89.2 720 720 642
** PROBLEMS/SOLUTIONS/COMMENTS
DURING NOVEMBER THE FGD SYSTEM WAS DOWN 62 HOURS TO CLEAN THE ESP SEAL POT
AND TO REPLACE THE TIP OF A PRESATURATOR SPRAY NOZZLE.
12/81 SYSTEM 98.9 98.9 98.9 98.9 744 744 736
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING DECEMBER.
1/82 SYSTEM 78.5 78.5 78.5 78.5 744 744 584
** PROBLEMS/SOLUTIONS/COMMENTS
SOME OF THE OUTAGE TIME IN JANUARY WAS DUE TO A STEAM SHORTAGE.
2/82 SYSTEM 79.7 79.7 79.7 79.7 672 672 536
*» PROBLEMS/SOLUTIONS/COMMENTS
SOME OF THE OUTAGE TIME IN JANUARY AND FEBRUARY WAS DUE TO THE REPLACEMENT
OF A BOOSTER BLOWER BEARING.
THE SYSTEM WAS OFF-LINE PART OF THE MONTH TO REPAIR A PRESATURATOR
CIRCULATING PUMP.
OUTAGE TIME WAS NECESSARY TO UNPLUG THE PURGE LINE IN FEBRUARY.
3/82 SYSTEM 46.4 75.3 75.3 46.4 744 458 345
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MARCH THE BOILER WAS OFF-LINE PART OF THE TIME FOR THE ANNUAL OVER-
HAUL.
THE SYSTEM WAS UNAVAILABLE PART OF THE MONTH DUE TO PROBLEMS WITH THE
SCRUBBING SOLUTION SECTION.
4/82 SYSTEM 69.7 97.8 97.8 69.7 720 513 502
13-328
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
DELMARVA POWER & LIGHT: DELAWARE CITY Z (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 BOILER WAS OFF-LINE DURING APRIL DUE TO THE ANNUAL OVERHAUL WHICH
STARTED IN MARCH.
5/82 SYSTEM 96.0 96.0 96.0 96.0 744 744 714
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING MAY.
6/82 SYSTEM 96.6 96.6 96.6 96.6 720 720 696
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE EXPERIENCED
DURING JUNE.
7/82 SYSTEM 89.9 89.9 89.9 89.9 744 744 669
** PROBLEMS/SOLUTIONS/COMMENTS
A LACK OF SOLUTION DUE TO EVAPORATOR PROBLEMS ACCOUNTED FOR OUTAGE TIME
DURING JULY.
8/82 SYSTEM 94.2 95.0 95.0 94.2 744 738 701
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED BY THE UTILITY
DURING AUGUST.
9/82 SYSTEM 93.9 93.9 93.9 93.9 720 720 676
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING SEPTEMBER.
10/82
11/82
12/82
SYSTEM
SYSTEM
SYSTEM
98.
97.
97.
4
2
7
98
97
97
.4
.2
.7
98.4
97.2
97.7
98
97
97
.4
.2
.7 .
744
720
744
744
720
744
732
700
727
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE OCTOBER - DECEMBER PERIOD.
1/83 SYSTEM 98.7 98.7 98.7 98.7 744 744 734
** PR03LEMS/SOLLTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING JANUARY.
2/83 SYSTEM 97.5 97.5 97.5 97.5 672 672 655
13-329
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
DELMARVA POWER 4 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
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR FGD-REUTED PROBLEMS WERE REPORTED BY THE UTILITY
DURING FEBRUARY.
3/83 SYSTEM 32.0 88.8 88.8 32.0 74* 268 238
«* PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS DOWN FROM MARCH 12 TO MARCH 31 FOR AN ANNUAL OUTAGE.
4/83 SYSTEM 96.8 96.8 96.8 96.8 720 720 697
*# PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING APRIL.
5/83 SYSTEM 91.7 91.7 91.7 91.7 744 744 682
** PROBLEMS/SOLUTIONS/COMMENTS
REPAIRS TO THE ESP CAUSED A FORCED OUTAGE DURING MAY.
BOOSTER FAN REPAIRS ALSO CAUSED DOWN TIME DURING THE MONTH.
6/83 SYSTEM 81.0 81.0 81.0 81.0 720 720 583
** PROBLEMS/SOLUTIONS/COMMENTS
DOWN TIME OCCURRED DURING JUNE DUE TO REPAIRS ON A BOOSTER FAN.
REPAIRS ON A PRESATURATOR SPRAY NOZZLE ALSO FORCED THE SYSTEM OUT OF SER-
VICE DURING PART OF JUNE.
7/83 SYSTEM 86.6 86.6 86.6 86.6 744 744 644
** PROBLEMS/SOLUTIONS/COMMENTS
UNIT 2 WAS DOWN DURING PART OF JULY TO REMOVE A SOLIDS BUILD UP IN THE PRE-
SCRUBBER AND PRESCRUBBER INLET DUCT. SOME PRESCRUBBER SPRAY NOZZLES WERE
REPLACED DURING THIS PERIOD.
BOOSTER FAN REPAIRS WERE MADE AT UNIT 2 DURING JULY.
8/83 SYSTEM 98.0 98.0 100.0 98.0 " 744 744 729
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING AUGUST.
9/83 SYSTEM 61.8 81.8 81.8 81.8 720 720 589
** PROBLEMS/SOLUTIONS/COMMENTS
UNIT 2 WAS DOWN DURING PART OF SEPTEMBER TO REPAIR BRICKWORK AT THE INLET
TO THE PRESCRUBBER AND TO CLEAN THE PRESCRUBBER.
THE UNIT WAS DOWN DURING PART OF THE MONTH TO CLEAN THE ESP INLET SEAL
POTS.
10/83 SYSTEM 98.7 98.7 98.7 98.7 744 744 734
13-330
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 198*
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
#* PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR FGO-RELATED OUTAGES WERE ENCOUNTERED DURING OCTOBER.
11/83 SYSTEM 82.2 82.2 82.2 82.2 720 720 592
** PROBLEMS/SOLUTIONS/COMMENTS
PRESCRUBBER SPRAY NOZZLES WERE REPLACED DURING NOVEMBER.
MIST ELIMINATOR LEAKS WERE REPAIRED DURING NOVEMBER.
THE PRESCRUBBER WAS CLEANED DURING THE MONTH CONTRIBUTING TO FGD SYSTEM
DOWN TIME.
12/83 SYSTEM 92.2 92.2 92.2 92.2 744 744 686
** PROBLEMS/SOLUTIONS/COMMENTS
MIST ELIMINATOR LEAKS RESULTED IN FGD SYSTEM OUTAGES DURING THE MONTH.
LEAKS IN THE PRESCRUBBER CIRCULATION PIPING ALSO CONTRIBUTED TO DOWN TIME
DURING DECEMBER.
1/84 SYSTEM 81.7 81.7 81.7 81.7 744 744 608
** PROBLEMS/SdLUTIONS/COMMENTS
A LACK OF ABSORBING SOLUTION DUE TO EVAPORATOR CIRCULATING PUMP PROBLEMS
AND PLUGGED EVAPORATOR SOLUTION HEADERS LIMITED THE BURNING OF HIGH SULFUR
COKE DURING JANUARY.
THE UTILITY REPORTED THAT BOOSTER FAN REPAIRS WERE MADE DURING JANUARY.
THE REPAIR OF BROKEN WIRES IN THE ESP'S RESULTED IN OUTAGE TIME DURING THE
MONTH.
THE FAILURE OF PRESATURATOR CIRCULATING PUMPS ACCOUNTED FOR ADDITIONAL
DOWN TIME DURING JANUARY.
THE REMOVAL OF COKE BUILD UP IN THE ESP'S CONTRIBUTED TO FGD SYSTEM DOWN
TIME DURING THE MONTH.
696 696 653
744 744 717
720 720 707
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR FGD-RELATED PROBLEMS WERE REPORTED DURING FEBRUARY THROUGH APRIL.
5/84 SYSTEM 23.1 53.1 56.1 21.0 744 294 156
** PROBLEMS/SOLUTIONS/COMMENTS
THE ABSORBER WAS DOWN FOR MAINTENANCE DURING THE ANNUAL BOILER
OUTAGE IN MAY.
PROBLEMS WITH PLUGGING OF THE PRESATURATOR WERE REPORTED DURING MAY.
6/84 SYSTEM 720
13-331
2/84 SYSTEM
3/84 SYSTEM
4/84 SYSTEM
93.8
96.4
98.2
93.8
96.4
98.2
93.8
96.4
98.2
93.8
96.4
98.2
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
DELMARVA POWER 4 LIGHT: DELAWARE CITY 2 (CONT.)
. _________ PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION V. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
7/84 SYSTEM 744
8/84 SYSTEM 744
9/84 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE PERIOD OF JUNE THROUGH SEPTEMBER 1984.
13-332
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
SECTION 13
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 - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** MECHANICAL COLLECTOR
NUMBER
TYPE
SUPPLIER
PARTICLE REMOVAL EFFICENCY -7.
*# FABRIC FILTER
NUMBER
TYPE
TYPICAL GAS/CLOTH RATIO - M/MIN
»» 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
INITIAL START-UP DATE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON NAME
SUPPLIER
DIMENSIONS FT
DELMARVA POWER & LIGHT
DELAWARE CITY
3
DELAWARE CITY
DELAWARE
E
129.
******
******
180
60
495
495
60
RILEY STOKER
PULVERIZED COAL
BASE
139.21
215.6
152.
CONCRETE
6.1 t
( .300 LB/MMBTU)
(****** LB/MMBTU)
(****** LB/MMBTU)
( 295000 ACFM)
( 420 F)
( 500 FT)
20.0 FT)
COKE
BITUMINOUS
32564.
.50
0.3-0.7
.70
0.5-1.2
7.00
5.0-8.0
********
******
3
TUBULAR
PRAT-DANIEL
92.0
( 14000 BTU/LB)
13500-14500
0
NONE
.6
COLD SIDE
WESTERN PREC.
34.8
54.4
.2
95.0
( 2.0 FT/MIN)
DIVISION, JOY
( 73700 ACFM)
( 130 F)
( 1. IN-H20)
3
4/80
VENTURI TOWER
VARIABLE-THROAT/BOTTOM-ENTRY PLUMB BOB
N/A
AIRPOL
20 DIA X 70.0
13-333
-------
UTILITY FGD SURVEY'- OCTOBER 1983 - SEPTEMBER 1984
DELMARVA POWER 4 LIGHT: DELAWARE CITY 3 (CONT.)
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 - 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 - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
SPACE REQUIREMENTS - SQ M
OPER. & MAINT. REQUIREMENT - MANHR/DAY
** QUENCHER/PRESATURATOR
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** 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 RECIPCULATION RATE - LITER/S
L/G RATIO L/CU.M
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
CONFIGL'PATICN
NUMBER OF STAGES
NUMBER OF PASSES PER STAGE
FREEBOARD DISTANCE - M
CARBON STEEL
AISI 1110
ORGANIC; INORGANIC
GLASS FLAKE-FILLED POLYESTER; PREFIRED BRICK/SHA
NONE
315.0
6.8
.5
46.4
221.1
.0
81.5
( 5000 6PM)
(50.9 GAL/1000ACF)
( 2.0 IN-H20)
( 98300 ACFM)
( 430 F)
SALEABLE PRODUCT
WET SCRUBBING
WELLMAN LORD
DAVY MCKEE
DAVY MCKEE
FULL SCALE
RETROFIT
/. 90.00
90.00
1
5/80
5/80
9/77
24280.3
144.0
NR
NR
( 261360 SQ FT)
3
0
TRAY TOWER
VALVE TRAY
BUBBLE CAP TRAY TOWER
DAVY MCKEE
20.0 X 20.0
INORGANIC
HYDRAULICALLY-BONDED CONCRETE
PORTLAND CEMENT
INORGANIC
PREFIRED BRICK/SHAPES
NR
VALVE TRAY
4
25. (
.7 (
34.59 (
54.4 (
.0
400 GPM)
5.5 GAL/1000 ACF)
73300 ACFM)
130 F)
PRIMARY COLLECTOR
3
IMPINGEMENT
BAFFLE
CLOSED VANE
HORIZONTAL
1
1
1.83 ( 6.0 FT)
13-334
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
DELMARVA POWER & LIGHT: DELAWARE CITY 3 (CONT.)
DISTANCE BETWEEN STAGES - CM
PRESSURE DROP - KPA
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
WASH WATER SOURCE
WASH FREQUENCY
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
OUTLET FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC 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
** DAMPERS
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
DIMENSIONS
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
*# REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
** TANKS
SERVICE
NR
** PUMPS
SERVICE
ABSORBER RECIRCULATION
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
*** SALEABLE BYPRODUCTS
NATURE
FULL LOAD QUANTITY - M T/H
19.05 ( "
.1 (
ORGANIC
POLYPHENYLENE
COOLED CONDENSATE
INTERMITTENT
3.2 (
.5 IN)
.3 IN-H20)
50 GAL/MIN)
DIRECT COMBUSTION
EXTERNAL COMBUSTION CHAMBER
NATURAL GAS
27.8 ( 50 F)
108.54 ( 230000 ACFM)
54.4 ( 130 F)
85.0 ( 185 F)
NR
NR
( 295000 ACFM)
( 420 F)
3
0
CENTRIFUGAL
ROBINSON
BOOSTER
INDUCED DRAFT
DRY
139.21
215.6
CARBON STEEL
NR
NR
NR
NR
NR
NR
NR
8.0 X 8.0
CARBON STEEL
AISI 1110
ORGANIC
FIBER-REINFORCED POLYESTER
MIX TANK
N/A
AGITATED TANK
NUMBER
NUMBER
****
NONE
SULFURIC ACID
11.34 ( 12.50 TPH)
13-335
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
DEU1ARVA POWER & LIGHT: DELAWARE CITY 3 (CONT.)
QUALITY - X 93-°
DISPOSITION MARKETED
*** SLUDGE
** TREATMENT
METHOD N/A
DEVICE N/A
PROPRIETARY PROCESS N/A
** DISPOSAL
NATURE FINAL
TYPE POND
SITE TREATMENT CLAY LINING
** PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS PH, SOLIDS, SP.G., CONC.
MONITOR LOCATION GAS OUTLET, SOLUTION OUTLET
PROCESS CONTROL MANNER AUTOMATIC
PROCESS CHEMISTRY MODE FEEDBACK
** 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
5/80 SYSTEM 100.0 100.0 100.0 32.3 744 240 240
** PROBLEMS/SOLUTIONS/COMMENTS
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 66.4 86.4 86.4 720 720 622
** PROBLEMS/SOLUTIONS/COMMENTS
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
** 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
13-336
-------
UTILITY FGO SURVEY: OCTOBER 1983 - SEPTEMBER
DELMARVA POWER 4 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
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.
1/81 SYSTEM 64.0 64.0 64.0 64.0 744 744 479
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JANUARY PROBLEMS WERE ENCOUNTERED WITH LEAKS IN THE RECIRCULATION
PIPES AND THE MIST ELIMINATOR CAUSING OUTAGE TIME.
2/81 SYSTEM 88.0 88.0 88.0 88.0 672 672 590
** PROBLEMS/SOLUTIONS/COMMENTS
FAILURE OF THE RECIRCULATION PUMPS CAUSED SOME OUTAGE TIME DURING FEBRUARY.
LEAKS IN THE RECIRCULATION PIPES CAUSED ADDITIONAL OUTAGE TIME DURING THE
MONTH.
3/81 SYSTEM 83.3 63.3 83.3 83.3 744 744 620
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MARCH DOWNTIME WAS EXPERIENCED DUE TO CONTINUING REPAIRS TO THE
RECIRCULATION PIPES.
ADDITIONAL OUTAGE TIME WAS DUE TO THE REPAIRS TO THE MIST ELIMINATOR.
13-337
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
DELMARVA POWER & LIGHT: DELAWARE CITY 3 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
^ .____ _ __«. _«<_ » > »«0__«l OB»« ».«- _«_.» «»_«_,,_
4/81 SYSTEM 93.0 93.0 93.0 93.0 720 720 669
** PROBLEMS/SOLUTIONS/COMMENTS
DURING APRIL SOME OUTAGE TIME WAS DUE TO REPAIRS ON A HOLE IN THE ESP CELL.
ADDITIONAL OUTAGE TIME WAS DUE TO THE REPLACEMENT OF A PRESATURATOR
SPRAY NOZZLE.
5/81 SYSTEM 76.1 76.1 76.1 76.1 744 744 566
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MAY THE PRESATURATOR SHELL MATERIAL FAILED AND AN OUTAGE WAS NECES-
SARY TO REPAIR THE HOLE.
THE PRESATURATOR SPRAY NOZZLE FAILED ACCOUNTING FOR ADDITIONAL OUTAGE
TIME.
6/81 SYSTEM 100.0 100.0 100.0 100.0 720 720 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO PROBLEMS WERE ENCOUNTERED DURING JUNE.
744 744 736
744 744 744
720 719 647
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS OFF LINE FOR PART OF SEPTEMBER TO REPAIR THE ABSORBER
MIST ELIMINATOR.
10/81 SYSTEM 78.2 86.3 86.4 78.2 744 674 582
** PROBLEMS/SOLUTIONS/COMMENTS
DURING OCTOBER SOME OUTAGE TIME WAS REQUIRED FOR MIST ELIMINATOR REPAIR.
THE MIST ELIMINATOR WAS DAMAGED BY HEAT FROM THE REHEATER DURING AN
ELECTRICAL SHUTDOWN IN SEPTEMBER.
CARRYOVER INTO THE OVERHEAD DUCT CAUSED A SYSTEM SHUTDOWN FOR CLEANING.
THE UNIT WAS SHUTDOWN ON OCTOBER 27 FOR AN OVERHAUL.
11/81 SYSTEM 42.2 88.9 88.9 42.2 720 342 304
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT OVERHAUL CONTINUED INTO NOVEMBER. FOLLOWING STARTUP IT WAS
NECESSARY TO TAKE TWO SHORT SHUTDOWNS TO UNPLUG A WATER LINE.
12/81 SYSTEM 95.3 95.3 95.3 95.3 744 744 709
** PROBLEMS/SOLUTIONS/COMMENTS
DURING DECEMBER NO MAJOR PROBLEMS WERE ENCOUNTERED WITH EITHER THE BOILER
OR THE FGD SYSTEM.
7/81 SYSTEM
8/81 SYSTEM
9/81 SYSTEM
98.9
100.0
89.9
98.9
100.0
90.0
98.9
100.0
90.0
98.9
100.0
89.9
1/82 SYSTEM 84.8 84.8 84.8 84.8 744
13-338
631
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
DEU1ARVA POWER t LIGHT: DELAWARE CITY 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 JANUARY SOME OUTAGE TIME WAS DUE TO A STEAM SHORTAGE.
THE ESP DRAIN LINES WERE CLEANED DURING THE MONTH.
2/82 SYSTEM 97.2 97.2 97.2 97.2 672 672 653
»* PROBLEMS/SOLUTIONS/COMMENTS
DURING FEBRUARY THE PURGE LINE WAS REPAIRED.
3/82 SYSTEM 56.8 56.8 56.8 56.8 744 744 423
*# PROBLEMS/SOLUTIONS/COMMENTS
DURING MARCH PROBLEMS WITH THE SOLUTION REGENERATION SECTION HINDERED THE
FGD SYSTEM OPERATION PART OF THE TIME.
4/82 SYSTEM 78.9 78.9 78.9 78.9 720 720 568
** PROBLEMS/SOLUTIONS/COMMENTS
DURING APRIL THE SYSTEM WAS SHUT DOWN FOR 152 HOURS TO BALANCE THE
BOOSTER BLOWER.
5/82 SYSTEM 96.4 96.4 96.4 96.4 744 744 717
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MAY THE FGD SYSTEM OPERATED WITH NO MAJOR PROBLEMS BEING ENCOUNTER-
ED.
6/82 SYSTEM 99.4 99.4 99.4 99.4 720 720 716
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE EXPERIENCED
DURING JUNE.
7/82 SYSTEM 90.7 90.7 90.7 90.7 744 744 675
#* PROBLEMS/SOLUTIONS/COMMENTS
A LACK OF SOLUTION DUE TO EVAPORATOR PROBLEMS ACCOUNTED FOR OUTAGE TIME
DURING JULY.
8/82 SYSTEM 100.0 100.0 100.0 100.0 744 744 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING AUGUST.
9/82 SYSTEM 65.7 65.7 65.7 65.7 720 720 473
*« PROBLEMS/SOLUTIONS/COMMENTS
PROBLEMS WITH BOOSTER FAN VIBRATIONS RESULTED IN OUTAGE TIME DURING
SEPTEMBER.
A PLUGGAGE PROBLEM IN THE ESP SEAL POTS ALSO CONTRIBUTED TO OUTAGE TIME
DURING THE MONTH.
13-339
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1934
DELMARVA POWER 4 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
ADDITIONAL OUTAGE TIME WAS ATTRIBUTED TO LEAKS IN THE PRESATURATOR
CIRCULATION PIPING.
10/82 SYSTEM 44.6 92.0 92.0 44.6 744 361 332
*» PROBLEMS/SOLUTIONS/COMMENTS
DURING OCTOBER THE UNIT WAS DOWN FOR AN ANNUAL INSPECTION.
11/82 SYSTEM 78.9 97.9 97.9 78.9 720 580 568
** PROBLEMS/SOLUTIONS/COMMENTS
DURING NOVEMBER THE UNIT MAS DOWN FOR AN ANNUAL INSPECTION.
12/82 SYSTEM 98.7 98.7 98.7 98.7 744 744 734
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING DECEMBER.
1/83 SYSTEM 93.4 93.0 93.0 88.0 744 704 655
** PROBLEMS/SOLUTIONS/COMMENTS
AN OUTAGE OCCURRED DURING THE MONTH DUE TO THE CLEANING-OF THE PRESATURATOR
SUCTION SCREENS.
THE REPAIR OF A CRACKED NOZZLE ON THE PRESATURATOR CAUSED ADDITIONAL DOWN
TIME DURING JANUARY.
2/83 SYSTEM 100.0 100.0 100.0 100.0 672 672 672
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING FEBRUARY.
3/83 SYSTEM 94.8 94.8 94.8 94.8 744 744 705
** PROBLEMS/SOLUTIONS/COMMENTS
AN OUTAGE OCCURRED DURING MARCH DUE TO THE CLEANING OF A PRESATURATOR
CIRCULATION PUMP SUCTION SCREEN.
THE REPAIR OF BROKEN WIRE IN AN ESP ALSO RESULTED IN DOWN TIME DURING
MARCH.
4/83 SYSTEM 99.3 99.3 99.3 99.3 720 720 715
5/83 SYSTEM 99.3 99.3 99.3 99.3 744 744 739
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING APRIL AND MAY.
6/83 SYSTEM 100.0 100.0 100.0 100.0 720 720 720
13-340
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING JUNE.
7/83 SYSTEM 92.5 92.5 92.5 92.5 744 744 688
** PROBLEMS/SOLUTIONS/COMMENTS
UNIT 3 WAS DOWN DURING PART OF JULY FOR ESP REPAIRS.
THE UNIT WAS DOWN DURING THE MONTH FOR REMOVAL OF SOLIDS BUILD UP IN THE
PRESCRUBBER.
8/83 SYSTEM 93.0 93.0 100.0 93.0 744 744 692
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING AUGUST.
9/83 SYSTEM 86.3 86.3 86.3 86.3 720 720 621
** PROBLEMS/SOLUTIONS/COMMENTS
UNIT 3 WAS DOWN DURING PART OF SEPTEMBER TO REPAIR LEAKS ON THE PRESCRUB-
BER SPRAY NOZZLE FLANGE. IN ADDITION, A CERAMIC SPRAY NOZZLE TIP FAILED
TWICE DURING THIS PERIOD.
10/83 SYSTEM 100.0 97.4 97.4 84.1 744 643 626
** PROBLEMS/SOLUTIONS/COffllENTS
NO MAJOR FGD-RELATED OUTAGES WERE ENCOUNTERED DURING OCTOBER.
11/83 SYSTEM 58.6 89.4 89.4 53.8 720 433 387
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT AN ANNUAL BOILER OUTAGE TOOK PLACE DURING NOVEM-
BER.
12/83 SYSTEM 58.7 78.7 78.7 58.7 744 555 437
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS DOWN DURING PART OF DECEMBER FOR AN ANNUAL OUTAGE.
FGD SYSTEM OUTAGE TIME DURING DECEMBER WAS DUE IN PART TO A LACK OF SODIUM
SULFITE ABSORBING SOLUTION RESULTING FROM EVAPORATOR PROBLEMS.
1/84 SYSTEM 95.6 95.6 95.6 95.6 744 744 711
** PROBLEMS/SOLUTIONS/COMMENTS
A LACK OF ABSORBING SOLUTION DUE TO EVAPORATOR CIRCULATING PUMP PROBLEMS
AND PLUGGED EVAPORATOR SOLUTION HEADERS LIMITED THE BURNING OF HIGH SULFUR
COKE DURING JANUARY.
2/84 SYSTEM 97.6 97.6 97.6 97.6 696 696 679
13-341
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
DELMARVA POWER * LIGHT: DELAWARE CITY 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
NO MAJOR FGD-RELATED PROBLEMS WERE REPORTED DURING FEBRUARY.
3/84 SYSTEM 84.5 84.5 84.5 84.5 744 744 629
** PROBLEMS/SOLUTIONS/COMMENTS
PRESATURATOR CLEANING ACCOUNTED FOR OUTAGE TIME DURING THE MONTH.
PRESATURATOR CIRCULATION PUMP REPAIRS WERE MADE DURING MARCH.
FGD SYSTEM OUTAGE TIME DURING MARCH WAS DUE IN PART TO THE REPAIR OF A
BROKEN INSULATOR ON THE ESP.
4/84 SYSTEM 89.0 79.9 87.1 74.0 720 667 533
** PROBLEMS/SOLUTIONS/COMMENTS
LEAKS IN THE MIST ELIMINATOR SHELL WERE REPAIRED DURING APRIL.
LEAKS IN THE BOOSTER FAN DISCHARGE DUCTWORK WERE REPAIRED DURING APRIL.
THE FGD SYSTEM WAS DOWN DURING PART OF THE MONTH TO CLEAN THE PRESATURATOR.
A BOILER TUBE LEAK ACCOUNTED FOR 108 HOURS OF DOWN TIME DURING APRIL.
5/84 SYSTEM 86.8 86.8 86.8 86.8 744 744 646
** PROBLEMS/SOLUTIONS/COMMENTS
THE FAILURE OF A PRESATURATOR CIRCULATING PUMP MOTOR OCCURRED DURING MAY.
FAILURE OF A RUBBER LINED PIPE IN THE PRESATURATOR CIRCUIT RESULTED IN
DOWN TIME DURING MARCH.
PRESATURATOR PLUGGING PROBLEMS WERE REPORTED DURING MAY.
6/84 SYSTEM 720
7/84 SYSTEM 744.
8/84 SYSTEM 744
9/84 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE PERIOD OF JUNE THROUGH SEPTEMBER 1984.
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
SECTION 13
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
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
** FABRIC FILTER
NUMBER
SUPPLIER
** PARTICLE SCRUBBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON NAME
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
GAS CONTACTING DEVICE 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.
ENERGY CONSUMPTION 7.
DESERET GEN 4 TRANS
BONANZA
1
VERNAL
UTAH
A
****** (****** LB/MMBTU)
****** (****** LB/MMBTU)
****** ( ****** LB/MtlBTU )
800
410
388
400
410
******
PULVERIZED COAL
BASE
(******# ACFM)
(**** F)
(**** FT)
(***** FT)
( 10500 BTU/LB)
******
********
*******
******
NR
*******
COAL
BITUMINOUS
24423.
10.00
******
8.50
******
.50
******
********
******
ECOLAIRE
0
NONE
N/A
N/A
N/A
N/A
N/A
N/A
N/A
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
COMBUSTION ENGINEERING
BURNS & MCDONNELL
FULL SCALE
NEW
/. 99.60
95.00
2.9
13-343
-------
UTILITY FGO SURVEY: OCTOBER 1983 - SEPTEMBER 1964
DESERET GEN & TRANS: BONANZA 1 (CONT.)
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP .
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
** QUENCHER/PRESATURATOR
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** ABSORBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
SHELL MATERIAL TRADE NAME/COMMON TYPE
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
LINER MATERIAL TRADE NAME/COMMON TYPE
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** REHEATER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONSTRUCTION MATERIAL- GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** FANS
DESIGN
FUNCTION
APPLICATION
SERVICE
CONSTRUCTION MATERIAL GENERIC TYPE
** DAMPERS
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
»* REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
** TANKS
SERVICE
NR
9/8<+
7/80
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NA
NR
NA
NA
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
WET BALL MILL
COMPARTMENTED
NA
NUMBER
****
13-344
-------
DESERET GEN & TRANS: BONANZA 1 (CONT.)
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
** PUMPS
SERVICE
NR
*» SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
*** SLUDGE
** TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TREATMENT
** WATER BALANCE
WATER LOOP TYPE
SOURCE OF MAKEUP WATER
NUMBER
****
THICKENER
1
VACUUM FILTER
1
DEWATERED
NR
N/A
FINAL
LANDFILL
ON-SITE
NONE
CLOSED
COOLING TOWER SLOWDOWN
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
SOZ PART. HOURS HOURS HOURS FACTOR
SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
720
THE UTILITY REPORTED THAT INITIAL START-UP OF THE FGD SYSTEM COMMENCED IN
SEPTEMBER 1984.
13-345
-------
UTILITY FSD SURVEY: OCTOBER 1983 - SEPTEMBER
SECTION 13
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 - 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 V.
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
NUMBER OF SPARES
TYPE
SUPPLIER
INLET FLUE GAS CAPACITY CU.M/S
INLET FLUE GAS TEMPERATURE - C
PRESSUPE DROP - KPA
PARTICLE REMOVAL EFFICENCY -7.
** ESP
NUMBER
NUMBER OF SPARES
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
*** FGD SYSTEM
DUQUESNE LIGHT
ELRAMA
1-4
ELRAMA
PENNSYLVANIA
C
34.
258.
**#»**
487
510
487
494
510
BABCOCK t WILCOX
PULVERIZED COAL
BASE
( .080 LB/MMBTU)
( .600 LB/MMBTU)
(****** LB/MMBTU)
(2060000 ACFM)
( 300 F)
( 398 FT)
( 26.0 FT)
( 11568 BTU/LB)
11500-12500
972.11
148.9
121.
CONCRETE
7.9
COAL
BITUMINOUS
26907.
16.80
14.0-18.3
5.93
4.30-7.06
2.05
1.49-2.91
.04
0.03-0.05
4
0
MULTICLONE
RESEARCH-COTTRELL tl, 2, & 31; JOY WESTERN [41
972.1 (2060000 ACFM)
148.9 ( 300 F)
.7 (3. IN-H20)
95.0
10
0
COLD SIDE
RESEARCH COTTRELL [1, 2, & 31; JOY WESTERN [41
. 972.1 (2060000 ACFM)
148.9 ( 300 F)
.2 (1. IN-H20)
95.0
0
N/A
N/A
13-346
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
DUQUESNE LIGHT: ELRAMA 1-4 (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.
ENERGY CONSUMPTION - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AMD OPERATING PARAMETERS
DESIGN COAL SULFER CONTENT - X
DESIGN COAL HEAT CONTENT - J/G
DESIGN COAL ASH CONTENT - X
DESIGN MOISTURE CONTENT - X
DESIGN CHLORIDE CONTENT X
OPER. & MAINT. REQUIREMENT - MANHR/DAY
** QUENCHER/PRESATURATOR
NUMBER
«* 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
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
PP.E-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
NUMBER OF SPARES PER SYSTEM
NUMBER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
MANUFACTURER
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
CONSTRUCTION MATERIAL SPECIFIC TYPE
THROWAWAY PRODUCT
WET SCRUBBING
LIME
MAGNESIUM OXIDE, SODIUM
GE ENVIRONMENTAL SERVICES
GIBBS t HILL
FULL SCALE
RETROFIT
X 99.30
63.00
1.4
1
10/75
10/75
12/70
( 11500 BTU/LB)
2.20
26749.0
17.00
6.00
.03
296.0
5
1
VENTURI TOWER
VARIABLE-THROAT/TOP-ENTRY PLUMB BOB
N/A
GE ENVIRONMENTAL SERVICES
31.3 X 66.4
CARBON STEEL; STAINLESS STEEL [ABSORBER INTERNAL
AISI 1110; AUSTENITIC
N/A; TYPE 316L
ORGANIC; INORGANIC
MAT-REINFORCED POLYESTER; GLASS FLAKE-FILLED POL
CEILCRETE 2500AR; FLAKELINE 103; ACID RESISTANT
NONE
1
1071.
4.4
2.0
45.7
243.03
146.9
63.0
94.0
(17000 GPM)
( 33.0 GAL/1000 ACF)
( 8.0 IN-H20)
(150.0 FT/S)
( 515000 ACFM)
( 300 F)
PRIMARY COLLECTOR [EXTERNAL]
5
1
1
IMPINGEMENT
BAFFLE
OPEN VANE [SLAT]
HEIL
HORIZONTAL
1
4
7.6
( 3.
.00 IN)
90
.0
3.4
ORGANIC
FIBER-REINFORCED POLYESTER
.2 IN-H20)
11.0 FT/S)
13-347
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
DUQUESNE LIGHT: ELRAMA 1-4 (CONT.)
WASH WATER SOURCE
WASH FREQUENCY
** REHEATER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
TEMPERATURE INCREASE - C
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** FANS
NUMBER
NUMBER OF SPARES
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
CONSTRUCTION MATERIAL GENERIC TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
MODULATION
SEAL AIR FLOW - CU. M/S
SERVICE CONDITIONS
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
FRESH MAKEUP MATER OR THICKENER OVERFLOW
TOP-MANUAL ONCE/WEEK
DIRECT COMBUSTION
IN-LINE BURNER
OIL
16.7 ( 30 F)
NR
NR
5
1
CENTRIFUGAL
GREEN FUEL ECONOMIZER
BOOSTER
INDUCED DRAFT
WET
259.54 ( 550000 ACFM)
54.4 ( 130 F)
7.0 (23.0 IN-H20)
CARBON STEEL; HIGH ALLOY; HIGH ALLOY; STAINLESS
SHUT-OFF
BUTTERFLY
NR
NR
OPEN/CLOSED
.00 ( 0 ACFM)
300
STAINLESS STEEL/CARBON STEEL
AUSTENITIC; AISI 1110
NONE
N/A
»* DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
MODULATION
SEAL AIR FLOW - CU. M/S
SERVICE CONDITIONS
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
«* DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
MODULATION
SEAL AIR FLOW - CU. M/S
SERVICE CONDITIONS
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
CONFIGURATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
5
SHUT-OFF
LOUVER
PARALLEL BLADE MULTILOUVER
ALLIS-CHALMERS
OPEN/CLOSED
.00 ( 0 ACFM)
NR
STAINLESS STEEL/CARBON STEEL
AUSTENITIC; AISI 1110
ORGANIC
GLASS FLAKE-FILLED POLYESTER
5
SHUT-OFF
LOUVER
PARALLEL BLADE MULTILOUVER
ALLIS-CHALMERS
OPEN/CLOSED
.00 ( 0 ACFM)
NR
STAINLESS STEEL/CARBON STEEL
AUSTENITIC; AISI 1110
ORGANIC
GLASS FLAKE-FILLED POLYESTER
ABSORBER INLET
CIRCULAR
CARBON STEEL
AISI 1110
13-348
-------
UTILITY FGO SURVEY: OCTOBER 1983 - SEPTEMBER 1984
DUQUESNE LIGHT: ELRAMA 1-4 (CONT.)
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
CONFIGURATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
*# DUCTWORK
LOCATION
CONFIGURATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
MANUFACTURER
NUMBER
NUMBER OF SPARES
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
PRODUCT QUALITY - X SOLIDS
** TANKS
SERVICE
THICKENER OVERFLOW
LIME SLURRY DILUTION
ABSORBER EFFLUENT HOLD
THICKENER FOLMER MIX
THICKENER DISTRIBUTION BOX
WATER STORAGE
** PUMPS
SERVICE
ABSORBER RECIRCULATION
LIME SLUPRY FEED
THICKENER OVERFLOW
THICKENER UNDERFLOW
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
DIMENSIONS - FT
CAPACITY
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
BELT GENERIC MATERIAL TYPE
FEED STREAM SOURCE
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
OVERFLOW STREAM CHARACTERISTICS
OUTLET STREAM DISPOSITION
OVERFLOW STREAM DISPOSITION
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUM3ER OF SPARES
DIMENSIONS - FT
CAPACITY
NONE
N/A
ABSORBER OUTLET
RECTANGULAR
CARBON STEEL
AISI 1110
ORGANIC
GLASS FLAKE-FILLED POLYESTER
PRECOLLECTOR OUTLET
CIRCULAR
CARBON STEEL
AISI 1110
ORGANIC
GLASS FLAKE-FILLED POLYESTER
SLAKER
PASTE
N/A
WALLACE * TIERNAN
5
2
3.6 (4 TPH)
22.5
NUMBER
1
1
5
1
1
2
NUMBER
10
5
3
3
THICKENER
2
0
120 DIA X 8.5 HIGH
229500
CARBON STEEL [WALLS!J INORGANIC [BOTTOM!
AISI 1110; HYDRAULICALLY-BONDED CONCRETE
ORGANIC
BITUMINOUS BASE MODIFIED ASPHALT [FLOOR]; MICA F
RUEEER-CLAD CARBON STEEL
ABSORBER BLEED STREAM
57. SOLIDS
35-40X SOLIDS
0.1X
TO VACUUM FILTER
THICKENER OVERFLOW TANK
VACUUM FILTER
2
1
650 SQ FT t 750 SQ FT
60 TONS/HR
13-349
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
DUQUESNE LIGHT: ELRAMA 1-4 (CONT.)
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
BELT GENERIC MATERIAL TYPE
BELT SPECIFIC MATERIAL TYPE
FEED STREAM SOURCE
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
OVERFLOW STREAM CHARACTERISTICS
OUTLET STREAM DISPOSITION
OVERFLOW STREAM DISPOSITION
*** SLUDGE
7. ASH - DRY
/. OTHER COMPOUNDS - DRY
** TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
INLET QUALITY - X
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE TREATMENT
SITE SERVICE LIFE - YRS
** PROCESS CONTROL AND INSTRUMENTATION
PROCESS STREAM
CHEMICAL PARAMETERS
PHYSICAL VARIABLES
CONTROL LEVELS
MONITOR TYPE
MONITOR LOCATION
PROCESS CONTROL MANNER
PROCESS CHEMISTRY MODE
** WATER BALANCE
WATER LOOP TYPE
EFFLUENT WATER LOSS - LITERS/S
RECEIVING WATER STREAM
SOURCE OF MAKEUP WATER
** CHEMICALS AND CONSUMPTION
FUNCTION
NAME
PRINCIPAL CONSTITUENT
SOURCE/SUPPLIER
CONSUMPTION
UTILIZATION - X
POINT OF ADDITION
** FGD SPARE CAPACITY INDICES
ABSORBER 7.
MIST ELIMINATOR - X
FAN - X
SLAKER - X
EFFLUENT HOLD TANK - X
RECIRCULATION PUMP - X
THICKENER - X
VACUUM FILTER - X
»* FGD SPARE COMPONENT INDICES
ASSORBER
MIST ELIMINATOR
FAN
SLAKER
CARBON STEEL
AISI 1110
ORGANIC
NYLON
THICKENER UNDERFLOW
35-40X SOLIDS
507. SOLIDS
0.1
TO SLUDGE TREATMENT
COLLECTED IN A DISTRIBUTION BOX & THEN TRANSFERR
50.0
50.0
FIXATION
PUG MILL
CONVERSION SYSTEMS CPOZ-0-TEC]
37.5
FINAL
LANDFILL
OFF-SITE
TRUCK
NONE
10
RECIRCULATING SLURRY
PH
FLOW
PH 7.7
UNIVERSAL UNILOC
INLET TANGENTIAL NOZZLE TO ABSORBER
AUTOMATIC
FEEDBACK
OPEN
18.9 ( 300 GPM)
MONONGAHELA RIVER
RIVER WATER
ABSORBENT
MAGNESIUM-MODIFIED LIME
CAO, MGO
DRAVO
175-200 TPD
90.0
SLAKER
25.0
25.0
25.0
67.0
25.0
25.0
.0
100.0
1.0
1.0
1.0
.8
13-350
-------
DUQUESNE LIGHT: ELRAMA 1-4 (CONT.)
EFFLUENT HOLD TANK
RECIRCULATION PUMP
THICKENER
VACUUM FILTER
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
1.0
1.0
.0
1.0
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
0/75 SYSTEM
*» PROBLEMS/SOLUTIONS/COMMENTS
THE FIRST ELRAMA SCRUBBER WAS PLACED IN SERVICE ON OCTOBER 26, 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 MW 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
744 744
** PROBLEMS/SOLUTIONS/COMMENTS
11/75 SYSTEM
12/75 SYSTEM
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.
720 720
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
2/76 SYSTEM
3/76 SYSTEM
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.
696 696
744 744
13-351
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
DUQUESNE LIGHT: ELRAMA 1-4 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY CPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S03 PART. HOURS HOURS HOURS FACTOR
4/76 SYSTEM 72° 72°
** PROBLEMS/SOLUTIONS/COMMENTS
THE SYSTEM OPERATED DURING MARCH AND APRIL WITH TWO BOILERS COUPLED INTO
THE SCRUBBING SYSTEM. REVISIONS TO THE FIFTH SCRUBBING VESSEL HAVE BEEN
COMPLETED 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 THE SCRUBBING
SYSTEM IN THE TWO BOILER OPERATION MODE.
7/76 SYSTEM 744 744
8/76 SYSTEM 744 744
** 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 720 720
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 BTU). THESE RESULTS WERE BASED ON TWO BOILERS
COUPLED INTO THE FIVE SCRUBBING MODULES WHILE BURNING MEDIUM-SULFUR (1.0
TO z.ay.i COAL. THE MECHANICAL COLLECTORS AND ESP'S WERE IN SERVICE
DURING THE TESTS.
11/76 SYSTEM 720 720
13-352
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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
___ ^ ___ ___________ _«._BW«B»« »W «»H ««»«» ____. .»___ ___ _ V _____* *»>. V ______
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/COMMENTS
TESTING WITH THIOSORBIC LIME WAS CONDUCTED DURING THE PERIOD.
THE SCRUBBER 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
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
RUBBER-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) WERE 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 PLANT COMPLIANCE IS PROJECTED FOR FEBRUARY 1978.
-S02 REMOVAL EFFICIENCY IS APPROXIMATELY SOX.
-ELRAMA IS OPERATING IN A BASE/INTERMEDIATE LOAD MODE (FULL LOAD DAYTIME/
13-353
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
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
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 WORMEN RECYCLE PUMPS WERE INSTALLED. THE LIME HANDLING
SYSTEM INSTALLATION WORK CONTINUED. THE LAST TWO BOILERS ARE EXPECTED TO
BE TIED INTO THE FGD SYSTEM BY JANUARY 1978.
11/77 101 .0 .0
201 11.7 11.7
301 93.3 93.3
401 22.5 22.5
501 59.2 59.2
SYSTEM 46.7 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 SYSTEM 744 744
1/78 101 94.1 94.1
201 90.5 90.5
301 5.1 5.1
401 24.3 24.3
5°1 3.5 3.5
SYSTEM 54.4 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, ADDING AN ADDITIONAL 176 MW OF FLUE GAS LOAD
TO THE FGD SYSTEM.
13-354
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
OUQUESNE 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
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 70.8 30.*
201 96.2 41.2
301 .0 .0
401 37.2 15.9
501 40.0 18.0
SYSTEM 61.1 26.4 672 288 177
3/78 SYSTEM .0 .0 744 216 141
** 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 SS ON AREAS OF HIGH EROSION CAUSED
BY FLYASH IMPINGEMENT DURING THE OUTAGE.
EXPANSION JOINTS IN THE UPSTREAM DUCTWORK WERE SHIELDED BY METAL PLATES
WHICH WERE WELDED AT ONE END DURING THE FEBRUARY-MARCH PERIOD. EXPANSION
JOINTS IN THE DOWNSTREAM DUCTWORK WERE COMPLETELY REPLACED. THE DOWN-
STREAM DUCTWORK WAS RELINED WITH CEILCOTE.
ALSO DURING THE OUTAGE THE MODULE 401 INTERNALS WERE CLEANED AND"SOME
HOLES IN THE UPPER CONICAL REGION WERE REPAIRED.
THE SYSTEM CAME BACK ON LINE IN LATE MARCH, HOWEVER, BOILER NUMBER 3 WAS
NOT IN SERVICE.
4/78 SYSTEM 720 720
5/78 SYSTEM 744 744
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE APRIL-MAY PERIOD BOILER NUMBER 3 WAS STILL BEING OVERHAULED.
FGD SYSTEM CONSTRUCTION WAS COMPLETED AND PRELIMINARY TESTING WITH
THIOSORBIC LIME VERIFIED A SYSTEM S02 REMOVAL EFFICIENCY OF 83X.
6/78 SYSTEM 720 720
7/78 101 59.9 59.9 59.9 59.9
201 100.0 100.0 100.0 100.0
301 66.5 66.5 66.5 66.5
401 100.0 93.9 100.0 98.9
501 77.1 77.1 77.1 77.1
SYSTEM 100.0 100.0 100.0 100.0 744 744 744
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE 301 WAS PULLED OFF FOR A MAJOR CLEANING DURING THE JUNE-JULY
PERIOD.
MIST ELIMINATOR PLUGGING WAS EXPERIENCED AS A RESULT OF LOW m.
THE CHRONIC INABILITY TO CONTROL CHEMISTRY (PH) IS DIRECTLY RELATED TO
GRIT BUILD-UP IN THE LIME HANDLING AND SLURRY PREPARATION SYSTEM.
THE UTILITY IS CURRENTLY STUDYING WAYS TO TIGHTEN THE WATER BALANCE BY US-
13-355
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
DUQUESNE LIGHT: ELRAMA 1-4 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
ING THICKENER SUPERNATANT INTERMITTENTLY WITH CLEAR SERVICE WATER FOR THE
MIST ELIMINATORS.
8/78
9/78
101
201
301
401
501
SYSTEM
101
201
301
401
501
SYSTEM
76.9
100.0
50.7
100.0
70.9
99.6
72.1
59.6
93.3
78.1
93.6
99.2
76.9
100.0
50.7
100,0
70.9
100.0
72.1
56.3
89.0
78.1
93.6
100.0
76.9
100.0
50.7
100.0
70.9
99.6
72.1
58.2
92.9
78.1
93.6
98.7
76.9
100.0
50.7
100.0
70.9
99.6
72.1
56.3
89.0
78.1
93.6
97.3
744 744
741
720 720
700
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE AUGUST-SEPTEMBER PERIOD THE UTILITY REPORTED THAT MODULES 301
AND 501 WERE TAKEN OFF LINE FOR CLEANING.
THE RUBBER LINING ON THREE FAN HOUSINGS REQUIRED REPAIR DURING AUGUST AND
SEPTEMBER.
IT WAS NECESSARY TO SHUT DOWN THE LIME MIXING BASIN IN ORDER TO CLEAN OUT
EXCESSIVE GRIT AND SOLIDS BUILD UP.
A PARTICLE EMISSION COMPLIANCE TEST WAS RUN IN DECEMBER WHICH SHOWED THE
UNIT TO BE IN COMPLIANCE.
10/78
11/78
101
201
301
401
501
SYSTEM
101
201
301
401
501
SYSTEM
100.0
98.9
100.0
80.5
78.6
100.0
100.0
100.0
100.0
100.0
81.1
100.0
76.6
98.9
100.0
80.5
78.6
100.0
100.0
78.4
84.2
86.8
62.5
100.0
100.0
98.9
100.0
80.5
78.6
100.0
100.0
100.0
100.0
100.0
76.8
100.0
76.6
98.9
100.0
80.5
78.6
100.0
100.0
78.4
84.2
86.8
62.5
100.0
744 744
744
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
SYSTEM
100.0
76.3
93.0
68.0
97.9
100.0
94.7
72.7
85.6
64.8
69.5
100.0
100.0
75.4
92.5
66.9
97.0
100.0
94.7
72.7
85.6
64.8
69.5
96.8
744 744
720
13-356
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
DUQUESNE LIGHT: ELRAMA 1-4 (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 A 502 EMISSION COMPLIANCE TEST WAS RUN AND THE UNIT WAS
FOUND TO BE WITHIN THE ALLOWABLE STANDARD OF 0.6 LB/MM BTU.
1/79
101
201
301
401
501
SYSTEM
44.7
100.0
67.8
100.0
100.0
100.0
39.8
95.2
60.2
100.0
100.0
100.0
41.9
100.0
65.3
100.0
100.0
100.0
39.8
95.2
60.2
100.0
100.0
98.8
744 744
735
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY HAS STARTED HAULING SLUDGE OFF-SITE TO AN AREA ABOUT 10 MILES
AWAY.
2/79
3/79
4/79
5/79
6/79
7/79
8/79
101
201
301
401
501
SYSTEM
101
201
301
401
501
SYSTEM
101
201
301
401
501
SYSTEM
101
201
301
401
501
SYSTEM
101
201
301
401
501
SYSTEM
101
201
301
401
501
SYSTEM
101
201
301
100.0
90.2
14.1
97.8
100.0
100.0
98.9
100.0
77.7
54.5
70.4
100.0
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
98.5
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
100.0
90.2
14.1
97.3
100.0
100.0
95.4
91.0
73.8
39.2
65.9
100.0
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
100.0
81.0
94.8
86.0
99.3
40.7
100.0
98.7
100.0
96.5
100.0
90.2
14.1
97.8
100.0
100.0
98.8
100.0
76.8 .
46.3
69.0
97.7
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
100.0
90.2
14.1
97.3
100.0
100.0
95.4
91.0
73.8
39.2
65.9
91.4
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
99.6
81.0
94.8
86.0
99.3
40.7
100.0
98.7
100.0
96.5
672 672
672
744 744
680
720 720
688
744 744
744
720 720
717
744 744
744
13-357
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
DUQUESNE LIGHT: ELRAMA 1-4 (CONT.)
. , PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
'/. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
401
501
SYSTEM
9/79 101
201
301
401
501
SYSTEM
10/79 101
201
301
401
501
SYSTEM
11/79 101
201
301
401
501
SYSTEM
12/79 101
201
301
401
501
SYSTEM
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
88.1
100.0
100.0
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
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
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
744 744
744
720 720
675
744 744
744
100.0
15.2
92.5
98.3
93.9
100.0
51.6
90.9
100.0
68.6
100.0
100.0
100.0
15.3
92.4
100.0
94.9
100.0
100.
15.
92.
98.
93.9
100.0
720 720
720
100.0
100.0
96.1
84.4
100.0
48,
85.
100,
64,
100,
100.0
98.7
744 700
734
** PROBLEMS/SOLUTIONS/COMMENTS
THERE WERE 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
100.0
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
744 613
528
92.0
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 SPAPE.
AS OF FEBRUARY 1980 AND ARE STILL OPERATING WITHOUT ANY MAJOR PROBLEMS.
THE TWO RUBBER LINED WORMEN RECYCLE PUMPS HAVE NOW LOGGED 14,000 HOURS
13-358
-------
UTILITY FGD SURVEY? OCTOBER 1983 - SEPTEMBER
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
3/80
101
201
301
401
501
SYSTEM
100.
100.
73.
100.
78.
100.
0
0
7
0
1
0
100
100
73
48
78
100
.0
.0
.7
.4
.1
.0
100.
100.
73.
100.
78.
100.
0
0
7
0
1
0
100
100
73
48
78
100
.0
.0
.7
.4
.1
.0
744 744 595
*# PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS AVAILABLE FOR OPERATION THE ENTIRE MONTH Or MARCH.
4/80
101
201
301
401
501
SYSTEM
40.
72,
87.
100.
100.
38,
72.
87.
100.
100.
99.4
99.4
40.0
72.3
87.
100.
100.
100.
40.0
72.
87.
100.
100.
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
401
501
SYSTEM
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
83.0
96.8
100.0
100.0
37.1
89.0
71.2
96.8
98.5
744 744
586
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MAY THE FGD SYSTEM WAS AVAILABLE FOR OPERATION THE ENTIRE MONTH.
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
.0
100
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 FGD-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 30.9 21.2 23.5 21.2
13-359
-------
UTILITY FGO SURVEY? OCTOBER 1983 - SEPTEMBER 1984
DUQUESNE LIGHT: ELRAMA 1-4 (CONT.)
PERIOD MODULE
201
301
401
501
SYSTEM
AVAILABILITY
100.0
100.0
99.1
83.9
100.0
OPERABILITY
94.8
93.3
99.1
82.5
97.7
RELIABILITY UTILIZATION
100.0
100.0
99.1
83.7
100.0
94.6
93.3
99.1
82.5
97.7
7. REMOVAL PER
S02 PART. HOURS
744
BOILER
HOURS
744
FGD
HOURS
727
CAP.
FACTOR
65.0
** PROBLEMS/SOLUTIONS/COMHENTS
THE RELINING WITH CEILCOTE ON MODULE 501 COMMENCED IN JULY AND CONTINUED
FOR APPROXIMATELY 120 HOURS IN AUGUST.
THE RELINING OF MODULE 101 WITH CEILCOTE STARTED IN AUGUST ACCOUNTING
FOR THE LOW AVAILABILITY DURING THE MONTH.
9/80
10/80
11/30
101
201
301
401
501
SYSTEM
101
201
301
401
501
SYSTEM
101
201
301
401
501
SYSTEM
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
62.6
93.8
77. 2
99.8
59.7
22.8
100.0
100.0
99.2
95.4
95.8
23.3
98.5
72.7
96.5
96.8
68.8
96.4
59.3
93.8
77.2
98.9
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
61.4
93.8
77. 2
99.4
59.7
22.8
96.0
100.0
99.2
94.4
95.8
23.3
98.5
72.7
96.5
96.8
68.8
96.4
59.3
93.8
77. 2
98.9
720 720
680 64.5
744 744
720 75.1
720 720
711 79.3
*» PROBLEMS/SOLUTIONS/COMMENTS
DURING SEPTEMBER-NOVEMBER THE LINERS IN MODULES 101, 201 AND 301 WERE
REPLACED.
DURING NOVEMBER THE RUBBER LINER IN THE FAN HOUSING OF MODULE 101 WAS
COATED WITH URETHANE.
THE UTILITY REPORTED THAT THE WORMAN RECYCLE PUMPS HAVE NOW ATTAINED
20,000 HOURS OF OPERATION WITHOUT REPAIRS.
12/80
1/81
101
201
301
401
501
SYSTEM
101
201
301
401
501
SYSTEM
73
100
93
48
94
100
100
92
100
32
83
100
.0
.0
.9
.4
.9
.0
.0
.5
.0
.2
.2
.0
55
81
94
48
93
93
100
51
96
51
74
.1
.3
.6
.4
.4
.3
.0
.1
.6
.0
.1
.7
67
100
98
48
94
100
100
87
100
81
92
.1
.0
.9
.4
.8
.0
.0
.1
.0
.0
.2
.1
55.
81.
94.
48.
93.
93.
100.
51.
96.
51.
74.
1
3
6
4
4
3
0
1
6
0
1
7
744 744
694 54.8
744 744
556 41.0
13-360
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
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
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING DECEMBER AND JANUARY.
2/81 101
92.1
51.6
73.5
51.6
201
301
401
501
SYSTEM
99.1
98.9
3.6
95.2
97.2
86.5
93.2
3.6
93.6
82.1
88.2
98.9
3.6
95.2
89.9
86.5
93.2
3.6
93.6
82.1
672 672
552 33.6
** PROBLEMS/SOLUTIONS/COMMENTS
DURING FEBRUARY THE RUBBER LININGS ON THE FAN HOUSINGS OF MODULES 201 AND
301 WERE REPLACED WITH INCONEL 825.
3/81 101
59.8
38.7
49.1
38.7
201
301
401
501
SYSTEM
59.1
53.6
21.1
59.9
63.4
59.1
53.6
21.1
58.9
57.9
59.1
53.6
21.1
59.5
60.6
59.1
53.6
21.1
58.9
57.9
744 744
431 41.4
** PROBLEMS/SOLUTIONS/COMMENTS
UTILITY REPORTED THAT THE LOW BOILER CAPACITY FACTOR. FOR THE MONTH OF MARCH
WAS DUE TO THE COAL STRIKE (BOILERS WERE RUN AT REDUCED LOAD TO CONSERVE
FUEL). GENERAL CLEANING WAS PERFORMED ON BOTH BOILERS AND FGD SYSTEM
DURING THE MONTH.
THE FGD SYSTEM WAS DOWN FOR 10 DAYS TO REPAIR THE DUCTWORK AND EXPANSION
JOINT LOCATED AT THE STACK. DURING THE OUTAGE, THE STACK, DAMPERS, AUD
REMAINING EXPANSION JOINTS WERE INSPECTED. THE STACK INSPECTION SHOWED
MINOR DETERIORATION OF THE STACK FLUE.
4/81 101
88.1
76.9
86.6
76.9
201
301
401
501
SYSTEM
72.3
90.0
86.7
94.2
100.0
46.2
82.6
85.6
82.3
93.4
62.5
89.2
86.6
93.4
100.0
46.2
82.6
85.6
82.3
93.4
720 719
672 68.6
#* PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED DURING THE MONTH OF APRIL.
THE RUBBER COATED FAN HOUSING ON NUMBER 401 ID FAN WAS SPRAYED WITH A
POLYURETHANE COATING TO PROTECT AGAINST CORROSION/EROSION EFFECTS.
SODIUM THIOSULFATE ADDITION WAS INITIATED IN APRIL TO AID AGAINST
SCALING (HIGH EXCESS AIR PROBLEMS WHEN BOILERS RUN AT REDUCED LOADS).
5/81
101
201
301
401
501
100.0
.0
100.0
100.0
88.7
96.7
.0
100.0
67.0
50.2
100.0
.0
100.0
100.0
81.7
96.7
.0
100.0
67.0
50.2
SYSTEM
97.2
78.5
95.4
78.5
744 744
584 46.7
13-361
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 198*
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
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE MONTH OF MAY THE INGERSOLL RAND RECYCLE PUMPS ON MODULE 201
WERE REPLACED WITH RUBBER LINED WORMAN PUMPS.
101
201
301
401
501
SYSTEM
95.4
61.7
93.3
88.3
63.9
100.0
92.6
61.7
86.0
76.7
41.5
89.6
97.1
61.7
92. 8
86.8
53.5
98.0
92.6
61.7
86.0
76.7
41.5
89.6
720 720
645 58.0
7/81 101
98.9
86.0
98.8
86.0
201
301
401
501
SYSTEM
100.0
.0
98.4
100.0
99.3
98.9
.0
93.3
100.0
94.6
100.0
.0
98.2
100.0
99.3
98.9
.0
93.3
100.0
94.6
744 744
704 67.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JULY, MODULE 301 WAS OUT OF SERVICE FOR GENERAL CLEANING AND FOR THE
INSTALLATION OF POLYURETHANE IN THE FAN HOUSING.
8/81
101
201
301
401
501
SYSTEM
97.3
98.9
.0
97.7
97.4
97.8
90.5
58.5
.0
95.6
80.9
81.4
97.3
98.2
.0
97.5
96.9
97.5
90.5
58.5
.0
95.6
80.9
81.4
744 744
606 43.0
«* PEOBLEMS/SOLUTIONS/COMMENTS
MODULE 301 REMAINED DOWN DURING AUGUST FOR MAINTENANCE AND CLEANING.
9/81
101
201
301
401
501
SYSTEM
100.0
100.0
.0
100.0
100.0
100.0
68.2
98.3
.0
87.2
51.0
76.2
100.0
100.0
100.0
100.0
100.0
68.2
98.3
.0
87.2
51.0
76.2
720 720
549 39.8
** PROBLEMS/SOLUTIONS/COMMENTS
DURING SEPTEMBER MODULE 301 WAS OUT -OF SERVICE FOR CLEANING AND TO REPLACE
THE RECYCLE PUMP.
10/81
101
201
301
401
501
SYSTEM
85.6
100.0
.0
96.0
100.0
95.4
62.1
95.3
.0
94.0
57.6
77.2
81.2
100.0
.0
95.8
100.0
94.2
62.1
95.3
.0
94.0
57.6
77. 2
744 744
574 45.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING OCTOBER THE S02 MONITORS WERE CERTIFIED. TO DATE, THE MONITORS
HAVE AN EXCELLENT PERFORMANCE RECORD.
THE UTILITY CONTINUES TO ADD SODIUM THIOSULFATE TO CONTROL SCALE
BELIEVED TO BE CAUSED BY LOAD FLUCTUATIONS.
11/81 101
100.0
69.0
100.0
69.0
13-362
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
OLK3UESNE 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
201
301
401
501
SYSTEM
100.0
.0
100.0
100.0
100.0
100.0
.0
84.8
55.0
77.2
100.0
.0
100.0
100.0
100.0
100.0
.0
84.8
55.0
77.2
720 720 556 48.0
*» PROBLEMS/SOLUTIONS/COMMENTS
DURING NOVEMBER, THE MODULE 301 RECYCLE PUMPS WERE REPLACED WITH RUBBER
LINED PUMPS.
12/81
101
201
301
401
501
SYSTEM
100.0
94.5
91.9
13.5
100.0
99.9
30.3
80.2
90.7
13.5
26.2
60.2
100.0
93.5
91.7
13.5
100.0
99.7,
30.3
80.2
90.7
13.5
26.2
60.2
744 744
448 46.0
*» PROBLEMS/SOLUTIONS/COMMENTS
DURING DECEMBER, THE UTILITY REPORTED EXPERIENCING PROBLEMS WITH THE
PROCESS CHEMISTRY DUE TO LOAD FLUCTUATIONS.
1/82
2/82
3/82
101
201
301
401
501
SYSTEM
101
201
301
401
501
SYSTEM
101
201
301
401
501
SYSTEM
60.0
96.6
100.0
90.8
53.7
100.0
.0
79.6
96.3
100.0
91.4
91.8
.0
98.2
95.8
91.6
100.0
96.4
43.2
94.0
94.4
90.8
49.6
94.4
.0
78.5
93.9
82.6
81.3
84.1
.0
97.1
85.2
90.8
98.3
92.8
51.9
96.5
79.3
90.8
51.7
79.3
.0
79.4
96.2
100.0
90.4
71.7
.0
98.2
95.4
91.5
100.0
76.5
43.2
94.0
94.4
90.8
49.6
94.4
.0
78.5
93.9
82.6
81.3
84.1
.0
97.1
85.2
90.8
98.3
92.8
744 744
702 73.0
672 672
565 59.0
744 744
691 67.0
** PROBLEMS/SOLUTIONS/COMMENTS
4/82 SYSTEM
5/82 SYSTEM
6/82 SYSTEM
DURING THE FIRST QUARTER OF 1982, THE MODULE 101 RECYCLE PUMPS WERE
REPLACED WITH RUBBER LINED PUMPS.
720
744
720
*# FROBLEMS/SOLUTIONS/COMMENTS
7/82 SYSTEM
8/82 SYSTEM
9/82 SYSTEM
DURING THE SECOND QUARTER THE CONVERSION OF THE RECYCLE PUMPS TO RUBBER
LINED PUMPS WAS COMPLETED.
744
744
720
13-363
-------
UTILITY FGD SURVEY-' OCTOBER 1983 - SEPTEMBER 1984
DUQUESNE LIGHT: ELRAMA 1-4 (CONT.)
._ __-. . PERFORMANCE DATA-
PERIOD MODULE AVAILABILITY OPERABIUTY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
10/82 SYSTEM 744
11/82 SYSTEM 720
12/82 SYSTEM 744
1/83 SYSTEM 744
2/83 SYSTEM 672
3/83 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE PERIOD OF JULY 1982 THROUGH MARCH 1983.
4/83 SYSTEM 720
5/83 SYSTEM 744
6/83 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE PERIOD OF JULY 1982 THROUGH JUNE 1983.
7/83 SYSTEM 744
8/83 SYSTEM 744
9/83 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED COMPLIANCE WITH STACK EMISSION TESTS CONDUCTED IN JULY
AND AUGUST 1983.
10/83 SYSTEM 744
11/83 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMKENTS
THE UTILITY REPORTED A TWO WEEK ANNUAL OUTAGE IN NOVEMBER, DURING WHICH
TIME DAMPER AND DUCTWORK SECTIONS WERE REPAIRED.
12/83 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED INSTALLING A PILOT SCRUBBER MODULE AT THE ELRAMA STA-
TION DURING THE FOURTH QUARTER. THE 750 ACFM MODULE WILL BE USED TO TEST
THE USE OF ADDITIVES IN CONJUNCTION WITH THEIR LIME PROCESS.
1/84 SYSTEM 744
2/84 SYSTEM 696
3/84 SYSTEM 744
4/84 SYSTEM 720
5/84 SYSTEM 4
13-364
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
DUQUESNE LIGHT: ELRAMA 1-4 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
6/84 SYSTEM 720
7/84 SYSTEM 744
8/84 SYSTEM 744
9/84 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
OVERALL FGD SYSTEM AVAILABILITY FOR THE FIRST THREE QUARTERS OF 1984 WAS
ESTIMATED AT 90X.
THE UTILITY REPORTED THAT DUE TO A TIGHTENING OF THE WATER LOOP, IT IS
NO LONGER NECESSARY TO SPIKE THE THIOSORBIC LIME WITH DOLOMITIC LIME.
THE MAGNESIUM OXIDE CONTENT OF THE THISORBIC LIME IS SUFFICENT FOR
OPERATIONS.
THE UTILITY IS NOW DIVERTING INDUCED DRAFT FAN SPRAY WATER TO AN ASH POND
INSTEAD OF RECYCLING TO THE ABSORBERS. LIME CONSMPTION HAS IMPROVED SINCE
THE HIGHLY ACIDIC SPRAY WATER IS NO LONGER INTRODUCED IN THE SYSTEM.
THE UTILITY REPORTED A THREE WEEK SCHEDULED ANNUAL OUTAGE IN THE FIRST
THREE QUARTERS OF 1984. DURING THIS TIME REPAIRS WERE MADE TO DUCTWORK
AND DAMPERS. MIST ELIMINATOR TURN VANES WERE ALSO REPLACED.
THE 1000 CFM PILOT SCRUBBER LOANED TO THE UTILITY BY DRAVO IS NOW IN
OPERATION. THIS PILOT SCRUBBER IS USED TO TEST VARIOUS ADDITIVES TO THE
LIME PROCESS SUCH AS SODIUM THIOSULFATE AND OTHER ORGANIC ADDITIVES.
13-365
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
SECTION 13
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.
AVERA_GE 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
NUMBER OF SPARES
TYPE
SUPPLIER
INLET FLUE GAS CAPACITY - CU.M/S
INLET FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
** ESP
NUMBER
NUMBER OF SPARES
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
TRADE NAME/COMMON NAME
LINER GENERIC MATERIAL
DUQUESNE LIGHT
PHILLIPS
1-6
SOUTH HEIGHTS
PENNSYLVANIA
C
34. (
258. (
******
387
408
373
387
408
FOSTER WHEELER
PULVERIZED COAL
CYCLING
1047.62
183.3
104.
CONCRETE
7.9
.080 LB/MMBTU)
.600 LB/MMBTU)
(****** LB/MMBTU)
(2220000 ACFM)
( 362 F)
( 340 FT)
( 26.0 FT)
( 11568 BTU/LB)
11500-12500
COAL
BITUMINOUS
26907.
16.80
14.0-18.3
5.93
4.3-7.1
2.05
1.5-2.9
.04
.03-.05
6
0
MULTICLONE
RESEARCH-COTTRELL
174.6 ( 370000 ACFM)
183.3 ( 362 F)
.1 ( 1. IN-H20)
6
0
COLD SIDE
RESEARCH-COTTRELL
174.6 ( 370000 ACFM)
183.3 ( 362 F)
.1 (1. IN-H20)
70.0
0
NONE
N/A
N/A
ORGANIC
13-366
-------
DUQUESNE LIGHT: PHILLIPS 1-6 (CONT.)
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
#*# F6D 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 SOS REMOVAL EFFICIENCY - X
ENERGY CONSUMPTION - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
DESIGN COAL SULFER CONTENT - X
DESIGN COAL HEAT CONTENT - J/G
DESIGN COAL ASH CONTENT - X
DESIGN MOISTURE CONTENT - X
DESIGN CHLORIDE CONTENT - X
SPACE REQUIREMENTS - SQ M
OPER. & MAINT. REQUIREMENT - MANHR/DAY
** QUENCHER/PRESATURATOR
TYPE
»* 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
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
NUMBER OF SPARES PER SYSTEM
NUMBER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
MANUFACTURER
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES PER STAGE
FREEBOARD DISTANCE - M
DISTANCE BETWEEN VANES - CM
THROWAWAY PRODUCT
WET SCRUBBING
LIME
MAGNESIUM OXIDE, SODIUM
GE ENVIRONMENTAL SERVICES
GIBBS & HILL
FULL SCALE
RETROFIT
X 99.00
83.00
1.4
1
6/74
7/73
7/71
2.30
25586 . 0
21.00
7.00
.10
( 11000 BTU/LB)
( 261000 SQ FT)
140.0
NONE
4
0
VENTURI TOWER
VARIABLE-THROAT/SIDE-MOVABLE BLADES
N/A
GE ENVIRONMENTAL SERVICES
40.0 X 66.0
CARBON STEEL
AISI 1110
N/A
ORGANIC
MAT-REINFORCED EPOXY; GLASS FLAKE-FILLED POLYEST
COROLINE 505AR; FLAKELINE 103
VARIABLE THROAT VENTURI
1
(16000 GPM)
( 29.1 GAL/1000 ACF)
( 8.0 IN-H20)
(150.0 FT/S)
( 550000 ACFM)
( 362 F)
1008.
3.9
2.0
45.7
259.54
183.3
84.0
99.0
PRIMARY COLLECTOR
3
0
1
IMPINGEMENT
BAFFLE
CLOSED VANE
HEIL
HORIZONTAL
1
4
5.79
5.1
[EXTERNAL]
(19.0 FT)
( 2.00 IN)
13-367
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
DUQUESNE LIGHT: PHILLIPS 1-6 (CONT.)
VANE ANGLES - DEGREES
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
WASH WATER SOURCE
WASH FREQUENCY
** REHEATER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
TEMPERATURE INCREASE - C
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** FANS
NUMBER
NUMBER OF SPARES
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
CONSTRUCTION MATERIAL GENERIC TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MODULATION
SEAL AIR FLOW - CU. M/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MODULATION
SEAL AIR FLOW - CU. M/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MODULATION
SEAL AIR FLOW - CU. M/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
»* DUCTWORK
LOCATION
CONFIGURATION
DIMENSIONS
SHELL GENERIC MATERIAL TYPE
90
1.0 ( 4.0 IN-H20)
3.0 (10.0 FT/S)
ORGANIC
FIBER-REINFORCED POLYESTER
THICKENER OVERFLOW
CONTINUOUS
DIRECT COMBUSTION
IN-LINE BURNER
OIL
16.7 ( 30 F)
NR
NR
4
0
CENTRIFUGAL
GREEN FUEL ECONOMIZER
BOOSTER
INDUCED DRAFT
WET
183.76 ( 400000 ACFM)
51.7 ( 125 F)
5.2 (17.0 IN-H20)
CARBON STEEL; HIGH ALLOY; HIGH ALLOY; STAINLESS
SHUT-OFF
BUTTERFLY
N/A
OPEN/CLOSED
.00 ( 0 ACFM)
LINED CARBON STEEL
AISI 1110
STAINLESS STEEL
AUSTENITIC
SHUT-OFF
LOUVER
PARALLEL BLADE MULTILOUVER
OPEN/CLOSED
.00 ( 0 ACFM)
STAINLESS STEEL
AUSTENITIC
STAINLESS STEEL
AUSTENITIC -
SHUT-OFF
LOUVER
PARALLEL BLADE MULTILOUVER
OPEN/CLOSED
.00 ( 0 ACFM)
STAINLESS STEEL
AUSTENITIC
MR
NR
SCRUBBER INLET
RECTANGULAR
HA
CARBON STEEL
13-363
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
DUQUESNE LIGHT: PHILLIPS 1-6 (CONT.)
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
*» DUCTWORK
LOCATION
CONFIGURATION
DIMENSIONS
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
*# REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
MANUFACTURER
NUMBER
NUMBER OF SPARES
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
PRODUCT QUALITY - X SOLIDS
*# TANKS
SERVICE
ABSORBER RECYCLE
REAGENT PREP PRODUCT
THICKENER OVERFLOW
SLUDGE STABILIZATION
*» PUMPS
SERVICE
SCRUBBER/ABSORBER RECIRCULATION
THICKENER OVERFLOW
THICKENER UNDERFLOW
SLURRY FEED
MAKEUP WATER
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
CONFIGURATION
DIMENSIONS - FT
CAPACITY
FEED STREAM SOURCE
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
OVERFLOW STREAM CHARACTERISTICS
OUTLET STREAM DISPOSITION
OVERFLOW STREAM DISPOSITION
*» SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
CONFIGURATION
DIMENSIONS FT
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
FEED STREAM SOURCE
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
OUTLET STREAM DISPOSITION
OVERFLOW STREAM DISPOSITION
AISI 1110
NONE
N/A
SCRUBBER OUTLET
RECTANGULAR
NA
CARBON STEEL
AISI 1110
ORGANIC
GLASS FLAKE-FILLED POLYESTER
SLAKER
SLAKER
PASTE
WALLACE 4 TIERNAN
4
0
3.6 ( 4 TPH)
22.5
NUMBER
4
1
1
1
NUMBER
8
6
1
5
1
VACUUM FILTER
2
1
CIRCULAR
12(DIA)X16
150 LB/HR/SQ FT OF CLOTH
THICKENER UNDERFLOW
30-35X SOLIDS
SOX SOLIDS
<0.1X SOLIDS
SLUDGE TREATMENT
THICKENER UNDERFLOW TANK
THICKENER
3
1
CIRCULAR
75.0 DIA
CARBON STEEL
AISI 1110
ORGANIC
GLASS FLAKE-FILLED POLYESTER
ABSORBER BLEED
5X SOLIDS
30-35X SOLIDS
VACUUM FILTER
ME WASH
13-369
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
DUQUESNE LIGHT: PHILLIPS 1-6 (CONT.)
»*» SLUDGE
MOISTURE CONTENT - X TOTAL FREE WATER
7. CAS03 - DRY
/. CAS04 - DRY
/. ASH - DRY
** TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
INLET FLOW RATE - LITER/S
INLET QUALITY - V.
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE TREATMENT
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE TREATMENT
SITE SERVICE LIFE - YRS
** PROCESS CONTROL AND INSTRUMENTATION
PROCESS STREAM
CHEMICAL PARAMETERS
PHYSICAL VARIABLES
CONTROL LEVELS
MONITOR TYPE
MONITOR LOCATION
PROCESS CONTROL MANNER
PROCESS CHEMISTRY MODE
** WATER BALANCE
WATER LOOP TYPE
EVAPORATION WATER LOSS - LITER/S
SLUDGE HYDRATION WATER LOSS - LITER/S
SLUD3E INTERSTITIAL WATER LOSS - LITERS/S
POND SEEPAGE/RUNOFF WATER LOSS - LITERS/S
RECEIVING WATER STREAM
MAKEUP WATER ADDITION - LITERS/S
SOURCE OF MAKEUP WATER
** CHEMICALS AND CONSUMPTION
FUNCTION
NAME
PRINCIPAL CONSTITUENT
SOURCE/SUPPLIER
CONSUMPTION
UTILIZATION 7.
POINT OF ADDITION
** FGD SPARE CAPACITY INDICES
ABSORBER - X
MIST ELIMINATOR X
FAN - X
SLAKER - X
EFFLUENT HOLD TANK - X
RECIRCULATION PUMP - X
THICKENER - X
VACUUM FILTER - X
Z7.5
4.0
10.0
50.0
FIXATION
PUG MILL
CONVERSION SYSTEMS IPOZ-0-TEC1
34.6 ( 550 GPM)
50.0
INTERIM
CONCRETE PAD FOR ON-SITE CURING
CN-SITE
PIPELINE
N/A
FINAL
LANDFILL
OFF-SITE
TRUCK
CLAY LINING
10
SLURRY RECIRCULATION STREAM
PH
FLOW
PH SET 7.7
UNIVERSAL UNILOG
TANGENTIAL NOZZLE AT INLET TO ABSORBER
AUTOMATIC
FEEDBACK
OPEN
13.9
1.9
3.1
300
OHIO RIVER
22.0
RIVER
( 220 GPM)
( 30 GPM)
( 50 GPM)
( 350 GPM)
ABSORBENT
MAGNESIUM-MODIFIED LIME
CAO, MGO
DRAVO
120 TPD
85.0
SLAKER
.0
.0
.0
.0
.0
.0
50.0
100.0
13-370
-------
DUQUESNE LIGHT: PHILLIPS 1-6 (CONT.)
UTILITY FGO SURVEY: OCTOBER 1983 - SEPTEMBER 1984
«# FED SPARE COMPONENT INDICES
ABSORBER
MIST ELIMINATOR
FAN
SLAKER
EFFLUENT HOLD TANK
RECIRCULATION PUMP
THICKENER
VACUUM FILTER
.0
.0
.0
.0
.0
.0
.5
1.0
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL
SOS PART.
PER BOILER FGD CAP.
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
1/74 SYSTEM
2/74 SYSTEM
3/74 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
744
744
720
744
720
744
744
672
744
232
4/74 SYSTEM
5/74 SYSTEM
6/74 SYSTEM
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 1974.
THE SYSTEM HAS BEEN OPERATING CONTINUOUSLY SINCE IT RETURNED TO SERVICE
WITH VARIOUS NUMBERS OF BOILERS CONNECTED TO THE SCRUBBER SYSTEM AND
SCRUBBER TRAINS IN SERVICE.
720
744
720
13-371
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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
7/74 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGO SYSTEM CONSISTS OF 1 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 PLUGGING 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 SYSTEM 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 S02 REMOVAL EFFICIENCY IS 60X. THE
TWO-STAGE TRAIN ITSELF REMOVES SOX 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 WERE 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 100X FGD SYSTEM AVAILABILITY. OVERALL
SOZ REMOVAL EFFICIENCY WAS APPROXIMATELY 60X.
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
13-372
-------
UTILITY F6D SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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 FACTOR
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 WAS 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 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE PRESSURE DROP INSTRUMENTATION AT THE VENTURIS HAS BEEN A PROBLEM AREA.
THE DAMPERS HAVE STILL BEEN SEIZING 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
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM OPERATED ON FLUE GAS FROM ALL SIX BOILERS DURING JUNE. THE
TWO-STAGE SCRUBBING TRAIN HAS BEEN OUT OF SERVICE FOR GENERAL MAINTENANCE
AND A LINER LEAK REPAIR IN THE FIRST-STAGE SCRUBBER SINCE JUNE 19.
SOME RECYCLE PUMP REPLACEMENTS WERE REQUIRED DURING JUNE.
13-373
-------
UTILITY FGO SURVEY' OCTOBER 1983 - SEPTEMBER 198*
DUQUESNE LIGHT-' PHILLIPS 1-6 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERA8ILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
502 PART. HOURS HOURS HOURS FACTOR
THE SLUDGE STABILIZATION FACILITY HAS BEEN EXPERIENCING PROBLEMS.
UNBURNED CARBON FINES ARE CAUSING PLUGGING IN THE SCRUBBING SYSTEMS. THE
UTILITY HAS BEEN TRYING A WETTING AGENT TO MINIMIZE THE PROBLEM.
PROBLEMS WERE EXPERIENCED WITH THE LIME HANDLING SYSTEM DURING JUNE.
7/75 101
201
301
79.1
35.5
100.0
100.0
90.5
53.8
24.2
71.4
97.2
61.6
SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
GENERAL MECHANICAL PROBLEMS WERE EXPERIENCED IN JULY.
744 506
458
8/75 101
201
301
97.7
100.0
66.0
65.3
82.3
SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
64.2
91.7
43.4
42.9
60.5
744 489
453
SCRUBBER UNAVAILABILITY FORCED BOILER NO.6 TO BE RETURNED TO THE SCRUBBER
BYPASS PATH IN ORDER TO PREVENT LOSS OF BOILER CAPACITY.
PLUGGING AND MAINTENANCE PROBLEMS HAVE BEEN ENCOUNTERED.
EVALUATION OF VARIOUS RECYCLE PUMPS CONTINUED IN AUGUST.
9/75 101
201
301
401
SYSTEM
8.5
83.5
100.0
79.8
68.0
10/75
101
201
301
401
SYSTEM
88.
30,
73,
70,
65,
7.9
77.9
95.1
74.4
63.8
81.6
27.8
67.9
65.5
60.7
720 672
744 687
460
451
** PROBLEMS/SOLUTIONS/COMMENTS
IN OCTOBER 1975, 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
201
301
401
SYSTEM
12/75 101
201
301
401
SYSTEM
86.9
100.0
.0
10.4
49.3
50.8
93.2
25.7
54.4
56.0
86
100
10,
49.3
48.4
83.8
24.5
51.9
53.4
720 720
744 709
355
397
13-374
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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 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 38.4 37.2
201 74.2 72.0
301 14.0 13.6
401 97.9 95.0
SYSTEM 56.1 54.4 744 722 405
** PRCBLEMS/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.
2/76 101 97.8 94.4
201 98.5 95.1
301 24.7 23.9
401 60.4 58.3
SYSTEM 70.4 67.9 696 672 472
3/76 101 93.4
201 47.5
301 88.6
401 62.0
SYSTEM 72.9 744 542
4/76 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
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
PERIOD. THE GENERAL OPERATION MODE AT THIS FACILITY HAS ONE OF THE FOUR
SCRUBBING TRAINS OUT CONTINUALLY FOR REPAIRS, CLEANING, AND PREVENTIVE
MAINTENANCE. THE FGD SYSTEM AVAILABILITY FOR THE FIRST QUARTER OF 1976
WAS 72X.
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.
13-375
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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
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 SLUOGE IS CURRENTLY BEING STABILIZED WITH A CALCILOX ADDITION AT A
RATE OF APPROXIMATELY 10X BY WEIGHT OF SLUDGE. THE UTILITY IS PUNNING 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 SCROBBER MIST ELIMINATORS.
THE CEILCOTE COATING ON MODULE 401 FAILED (ORIGINAL COAT ERODDED AWAY AMD
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 POHD IS DEPLETED OF SLUDGE AND THE PERMANENT FACILITY HAS
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 SCRUEBER 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.
13-376
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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
HOURS: 23,274 THE TOTAL SCRUBBER HOURS VALUE IN-
AVERAGE MW 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: 81X 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 DEWATERIN6,
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
** PROBLEMS/SOLUTIONS/COMMENTS
1977 FULL COMPLIANCE OPERATIONS WILL INCLUDE 83X S02 REMOVAL FOR 2X 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 AMD LANDFILL. IUCS HAS BEEN AWARDED A TEN YEAR CON-
TRACT FOR THE USE OF THIS METHOD.
3/77 SYSTEM 744
4/77 SYSTEM 720
13-377
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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
ALL SIX BOILERS ARE COUPLED INTO THE FGD SYSTEM.
THE RECYCLE PUMP EVALUATION IS CONTINUING. THE CARBORUNDUM IMPELLERS
AND WEAR RINGS ARE PERFORMING WELL AFTER 4000 OPERATING HOURS.
CONSTRUCTION OF THE THICKENERS AND LIME FEEDERS IS STILL CONTINUING.
FULL PLANT COMPLIANCE SHOULD OCCUR BY DECEMBER 1977 WHEN THE NEW
THICKENERS AND SLAKERS COME ON LINE.
THE IUCS FACILITY IS JUST FILTERING OUT WATER. NO FIXATIVE IS BEING
ADDED. THE WASTE ARE BEING HAULED AWAY TO AN OFF-SITE LANDFILL ONE MILE
FROM THE STATION.
S02 AND PARTICULATE MATTER REMOVAL EFFICIENCIES ARE 50 AND 99+X
RESPECTIVELY.
1975 THIOSORBIC LIME TESTS SHOWS THAT 8X MGO IN THE LIME WAS OPTIMUM
FOR S02 REMOVAL BUT IT IS POSSIBLE TO GO AS HIGH AS 12X MGO. LIME
ARRIVING AT PHILLIPS WILL HAVE A 6X MGO CONCENTRATION. IT WILL BE
POSSIBLE TO BLEND THE LIME TO ACHIEVE HIGHER MGO AT THE STATION IF
NECESSARY.
5/77 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
DAMPER AND MIST ELIMINATOR REPAIRS WILL BE CORRECTED DURING THE NEXT
SCHEDULED OUTAGE. OVERALL SCRUBBER OPERABILITY IS ABOUT 75X.
THIOSORBIC LIME TESTS BEGAN IN LATE MAY BUT LASTED ONLY ABOUT ONE WEEK.
THE SCRUBBER SYSTEM WAS SHUT DOWN FOR THREE TO FOUR DAYS IN MAY DUE TO
LEAKING IN THE WET DUCT HEADER THAT LEADS TO THE STACK. WHEN THE LEAK WAS
REPAIRED SCRUBBING OPERATIONS BEGAN AGAIN ON FLUE GAS FROM FOUR BOILERS.
WHILE FIXING A DUCT LEAK INSPECTION OF OTHER COMPONENTS REVEALED THAT THE
BOILER EXIT DAMPERS WERE ERODING.
ONE OF THE MODULE 201 EXTERNAL MIST ELIMINATORS WAS SEVERLY ERODED AND
PLUGGED.
THE INTERIM SLUDGE DISPOSAL SYSTEM IS STILL OPERATIONAL. THE PERMANENT
SLUDGE DISPOSAL FACILITY IS ON SCHEDULE FOR THE DECEMBER 1977 COMPLETION
DATE.
THE CARBORUNDUM WEAR RINGS AND IMPELLERS WERE CONTINUING TO PERFORM WELL
AFTER 5000 OPERATING HOURS.
6/77 SYSTEM 720
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 CLEANOUT. S02 REMOVAL EFFICIENCY IS
APPROXIMATELY 50X.
13-378
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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 FACTOR
BOILER 6 HAS BEEN OUT OF SERVICE WHILE 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 RINGS AND STELLITE TIPPED IMPELLERS.
A THIOSORBIC LIME TEST WAS PREMATURELY TERMINATED BECAUSE OF SOME MINOR
SLAKER/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 BEING 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 S02 REMOVAL EFFICIENCY
OF 83X.
10/77 101 92.6 92.6
201 4.0 4.0
301 88.3 88.3
401 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.
11/77 101 92.1 92.1
201 91.6 91.6
301 28.1 28.1
401 56.3 56.3
SYSTEM 67.0 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.
13-379
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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 FACTOR
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
1/78 101
201
301
84.3
77.2
.0
65.1
56.6
SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
84.3
77.2
.0
65.1
56.7
744
744 744
421
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 DEWATERING 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 5X MGO HAS SHOWN THAT THE MGO 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 BAN-OS IN THE STACK WITH STAINLESS STEEL BANDS.
2/78
101
201
301
401
SYSTEM
43.5
58.5
3.8
31.7
34.4
3/78 SYSTEM .0
»* PROBLEMS/SOLUTIONS/COMMENTS
31.1
41.8
2.7
22.6
24.6
.0
672 480
744 0
167
0
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 BAN-OS.
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
13-380
-------
UTILITY F6D SURVEYS OCTOBER 1983 - SEPTEMBER
OUQUESNE 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
APRIL 15. DURING THE OUTAGE A NUMBER OF REPAIRS AND MODIFICATIONS WERE
MADE.
THE BOILER EXIT DAMPERS WERE LINED WITH 316 SS 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.
4/78 SYSTEM
5/78 SYSTEM
720 528
744
*» PROBLEMS/SOLUTIONS/COMMENTS
THE FGD 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
83X S02 REMOVAL REQUIREMENT FOR 2X SULFUR COAL. THERE WERE NO HOU3S 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
744 744
459
** PROBLEMS/SOLUTIONS/COMMENTS
THE INTERNAL MIST ELIMINATOR ON 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.
WATER 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 WAYS TO TIGHTEN THE WATER BALANCE BY
USING THICKENER SUPERNATANT INTERMITTENTLY WITH CLEAR SERVICE WATER FOR
13-381
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
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
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 WATER BALANCE AND LIME HANDLING EQUIPMENT.
WHEN WATER BALANCE IS ACHIEVED THE FGD SYSTEM EXPERIENCES A BUILD UP OF
SALTS.
8/78
101
201
301
+01
SYSTEM
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
638
** PROBLEMS/SOLUTIONS/COMMENTS
9/78
101
201
301
401
SYSTEM
63.7
82.7
83.9
65.6
74.0
62.4
75.6
67.5
55.7
65.3
THE RUBBER LINING IN MODULE 101 WAS REPAIRED.
HIGH PRESSURE WATER CLEANING WAS PERFORMED ON MODULES 101 AND 401.
62.4
75.6
67.5
55.7
65.3 ' 720 720 470
** PROBLEMS/SOLUTIONS/COMMENTS
10/78
11/78
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
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 LIME MIXING BASIN HAD TO BE SHUT DOWN OVER A WEEKEND SO THAT EXCESSIVE
GRIT AND SOLID PARTICLES THAT HAD BUILT UP COULD BE CLEANED OUT.
HIGH PRESSURE WATER CLEANING WAS PERFORMED ON MODULES 101 AND 401.
THE RUBBER LINING IN MODULE 101 WAS REPAIRED.
A MAJOR PROBLEM AREA DURING THE PERIOD WAS CAUSED BY INSUFFICIENT SUPPLIES
OF DRY FLYASH 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
SYSTEM.
96.1
87.5
87.9
2.2
68.4
41.1
100.0
88.9
69.0
74.8
744 744
720 720
509
538
13-382
-------
UTILITY FGO SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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
S02 AND PARTICULATE MATTER REMOVAL EFFICIENCY TESTS INDICATE THAT THE
STATION NOW MEETS STATE STANDARDS.
THE FGD SYSTEM IS EXPERIENCING A LARGE 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
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/COMMENTS
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.
1/79 101
201
301
401
SYSTEM
2/79 101
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
68.3
100.0
74.8
86.8
69.2
50.0
83.7
72.4
38.9
72.1
88.3
100.0
74.8
744 744
672 672
539
503
** PROBLEMS/SOLUTIONS/COMMENTS
EXCESSIVE SCALING IN THE MODULE 101 EXIT DUCT CAUSED SUPPORT COLUMNS TO
COLLAPSE. THE SCALE WAS REMOVED AND THE SUPPORT COLUMNS WERE SHORED UP.
3/79
4/79
5/79
6/79
101
201
301
401
SYSTEM
101
201
301
401
SYSTEM
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
100.0
.0
99.3
99.4
74.7
70.8
28.8
85.6
85.5
67.7
.0
96.3
88.0
100.0
71.1
86.8
5.9
85.0
84.9
65.7
100.0
.0
96.6
99.2
74.0
70.5
22.2
83.7
77.2
63.4
96
88
100
71.1
86.8
5.9
85.0
84.9
65.7
100.0
.0
96.6
99.2
74.0
70,
22,
83,
77,
7/79 101
100.0
98.6
63.4
98.6
744 744
720 720
744 744
720 720
529
473
550
457
13-3C3
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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
98.5
72.7
29.9
75.3
95.8
71.4
25.5
72.8
95.8
71.4
25.5
72.8
744 744 542
8/79 101
201
301
401
SYSTEM
9/79
10/79
101
201
301
401
SYSTEM
101
201
301
401
SYSTEM
11/79 101
201
301
401
SYSTEM
12/79
101
201
301
401
SYSTEM
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
89
89
0
5
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
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
100.0
89.5
89.3
.0
69.7
61.8
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
744 744
720 720
519
446
100
90
76
66.8
.0
98.6
89.6
72.9
65.3
744 696 515
720 720 441
744 744 486
** PROBLEMS/SOLUTIONS/COMMENTS
PRESENTLY THE UTILITY HAS BEEN ADDING SODIUM THIOSULFATE TO THE LIME TO
PREVENT SCALE FORMATION. THIS PROCESS HAS IMPROVED S02 COLLECTION AS
WELL.
THE SCRUBBER FAN HOUSING LINERS ARE BEING REPLACED.
THE MECHANICAL COLLECTORS ARE BEING UPGRADED TO IMPROVE THE QUALITY OF
THE WET SLUDGE.
1/80 101
201
301
401
SYSTEM
2/80 101
201
301
401
SYSTEM
.0
98.1
100.0
97.6
73.9
13.7
91.6
86.2
94.2
71.4
.0
93.3
99.0
95.8
72.0
13.7
91.6
84.6
90.5
70.1
.0
98.0
100.0
97.5
73.9
13.7
91.7
86.0
94.0
71.4
.0
93.3
99.0
95.8
72.0
13.7
91.6
84.6
90.5
70.1
744 744
696 696
536
488
«* PROBLEMS/SOLUTIONS/COMMENTS
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
13-384
-------
UTILITY F6D SURVEY: OCTOBER 1983 - SEPTEMBER 1984
DUQUESNE LIGHT: PHILLIPS 1-6 (CONT.)
: PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAR.
S02 PART. HOURS HOURS HOURS FACTOR
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 94.7 84.0 94.0 84.0
201 59.0 53.9 56.8 53.9
301 48.4 40.3 43.8 40.3
401 95.4 95.3 99.8 95.3
SYSTEM 60.3 54.7 73.6 54.7 744 744 407
** PROBLEMS/SOLUTIONS/COMMENTS
PROBLEMS WERE ENCOUNTERED WITH THE MODULE 101 ID FAN. THE MODULE WAS
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 92.6 89.4 92.4 89.4
201 14.2 10.0 10.5 10.0
301 99.2 99.0 99.8 99.0
401 95.8 94.6 98.6 94.6
SYSTEM 96.9 -73.3 75.6 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.
5/80 101 67.5 53.9 62.3 53.9
201 81.6 69.0 78.9 69.0
301 91.7 73.1 89.8 73.1
401 92.2 75.9 90.6 75.9
SYSTEM 83.2 68.0 80.2 68.0 744 744 506
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE 101 CAME OFF LINE IN MAY SO REPAIRS COULD BE MADE ON THE CONTROL
DAMPER AND TO INSTRUMENTATION.
DURING 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.
13-385
-------
UTILITY FGO SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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 FACTOR
MODULE 301 EXPERIENCED ID FAN PROBLEMS AND WAS 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
201
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.
101
201
301
401
SYSTEM
55.8
46.1
54.9
60.6
54.4
55.8
41.7
46.2
32.9
47.3
60.9
43.6
50.6
45.5
47.0
55.8
41.7
46.2
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
94.2
93.9
4.0
94.2
90.1
4.0
94.2
93.5
4.0
94.2
90.1
4.0
13-386
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
DUWESNE LIGHT: PHILLIPS 1-6 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
SYSTEM
93.8
71.5
92.6
70.2
93.6
71.3
92.6
70.2
720
523 58.2
*# PROBLEMS/SOLUTIONS/COMMENTS
DURING OCTOBER SCRUBBER MODULES 301 AND 401 WERE RELINED WITH CEILCOTE
CORALINE 505 AR LINERS.
11/80
101
201
301
401
SYSTEM
51.5
100.0
95.3
92.3
84.8
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
720 720
604 72.1
** PROBLEMS/SOLUTIONS/COMMENTS
DURING NOVEMBER MODULE 101 WAS RELINED WITH CEILCOTE CORALINE 505 AR LINER.
12/80
1/81
101
201
301
401
SYSTEM
101
201
301
401
SYSTEM
100.0
1.3
100.0
100.0
75.3
100.0
.0
87.8
98.8
71.7
99.9
.0
98.8
68.1
71.7
100.0
.0
85.5
91.2
69.2
100.0
.0
100.0
100.0
75.0
100.0
.0
87.5
98.7
71.6
99.9
.0
98.8
88.1
71.7
100.0
.0
85.5
91.2
69.2
744 744
744 744
534 62.2
533 56.1
#* PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING DECEMBER AND JANUARY.
2/81 101
201
301
401
SYSTEM
95.3
74.9
28.4
100.0
74.7
86.6
73.6
23.8
93.1
69.3
94.8
74.6
24.9
100.0
73.6
86.6
73.6
23.8
93.1
69.3
672 672
466 47.9
** PROBLEMS/SOLUTIONS/COMMENTS
DURING FEBRUARY A ROUTINE INSPECTION OF THE STACK REVEALED DETERIORATION
OF THE ACID-RESISTANT BRICK AND MORTAR, WHICH WILL NECESSITATE REPLACEMENT
IN THE NEAR FUTURE.
744 744 545 72.8
720 720 502 59.7
744 744 493 60.0
3/81
4/81
5/81
101
201
301
401
SYSTEM
101
201
301
401
SYSTEM
101
201
301
401
SYSTEM
97.2
99.1
.0
96.7
73.3
93.9
98.5
18.5
82.3
73.3
92.7
100.0
92.3
.0
71.3
97.2
99.1
.0
96.7
73.3
81.0
97.2
18.5
82.3
69.8
80.3
93.4
91.1
.0
66.2
97.2
99.1
.0
96.7
73.3
92.9
98.5
18.5
82.3
73.1
91.7
100.0
92.2
.0
71.0
97.2
99.1
.0
96.7
73.3
81.0
97.2
18.5
82.3
69.8
80.3
93.4
91.1
.0
66.2
13-387
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
DUQUESNE LIGHT: PHILLIPS 1-6 (CONT.)
. , PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITT RELIABILITY UTILIZATION
X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COmENTS
THE UTILITY REPORTED THAT MO MAJOR FGD-REUTED PROBLEMS WERE ENCOUNTERED
DURING MARCH, APRIL, AND MAY.
DURING THE MONTH OF MAY, REPLACEMENT OF THE RUBBER-LINED CARBON STEEL
HOUSING WITH INCOLEY 825 ON NUMBER 401 ID FAN WAS INITIATED. HOUSING
REPLACEMENTS ON FANS 201 AND 301 HAVE BEEN COMPLETED.
SODIUM THIOSULFATE ADDITION WAS UTILIZED THROUGHOUT THE MONTHS OF MARCH,
APRIL, AND MAY TO REDUCE SCALING ENHANCED BY HIGH EXCESS AIR REQUIREMENTS
OF THE BOILERS.
6/81 101
201
301
SYSTEM
100.0
100.0
100.0
.0
75.0
97.9
95.7
98.1
.0
72.9
100.0
100.0
100.0
.0
75.0
97.9
95.7
98.1
.0
72.9
720 720
525 68.0
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE 401 WAS OUT OF SERVICE DURING JUNE SO THAT THE FAN HOUSING COULD BE
REPLACED WITH INCONEL.
7/81
101
201
301
401
SYSTEM
97.7
98.3
97.8
.0
73.5
97.
93.
96.
.0
.1
.4
.0
71.6
97.7
98.0
97.8
.0
73.4
97.0
93.1
96.4
.0
71.6
744 744
533 69.8
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE 401 REMAINED OUT OF SERVICE DUE TO FAN REPAIRS AND GENERAL CLEANING.
8/81
101
201
301
401
SYSTEM
87.0
90.2
87.0
35.5
74.9
75.0
74.1
87.9
18.9
64.0
83.9
87.1
85.
20.
69.
.9
.9
.5
67.7
66.9
79.4
17.1
57.8
744 672
430 35.0
** PROBLEMS/SOLUTIONS/COMMENTS
PHILLIPS WAS SHUT DOWN FOR THREE DAYS IN AUGUST FOR A STACK AND FGD SYSTEM
INSPECTION. THE PRELIMINARY REPORT INDICATED STACK DETERIORATION TO THE
POINT OF DAMAGING THE STACK INTEGRITY. AS A RESULT, THE UTILITY PLANS TO
PRESSURIZE THE ANNULUS.
9/81
101
201
301
401
SYSTEM
71.
94.
98.
9.
68.2
58.6
75.9
82.4
2.1
54.7
67.0
93.0
97.7
2.3
65.0
58.6
75.9
82.4
2.1
54.7
720 720
394 30.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING SEPTEMBER MODULE 101 UNAVAILABLE TIME WAS DUE TO THE START OF AN
OVERHAUL.
MODULE 401 WAS OUT OF SERVICE FOR MOST OF SEPTEMBER TO INSTALL A NEW
EXTERNAL MIST ELIMINATOR (MUNTERS).
10/81 101
51.6
51.6
51.6
51.6
13-388
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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
96
95
97
85
.0
.4
.7
.2
52.
34.
97.
58.
0
0
7
8
92.8
88.1
97.7
82.6
52
34
97
58
.0
.0
.7
.8
744
744
440
26.0
*# PROBLEMS/SOLUTIONS/COMMENTS
THE CEILCOTE LINERS IN MODULES 101 AND 201 WERE REPLACED WITH COROLINE 505
DURING OCTOBER.
DURING OCTOBER THE UTILITY INSTALLED S02 MONITORS.
MONITORS HAVE AN EXCELLENT PERFORMANCE RECORD.
TO DATE, THE
11/81
101
201
301
401
SYSTEM
98.3
97.7
100.0
74.0
.0
27.8
25.4
100.0
40.8
.0
95.7
91.8
100.0
71.9
.0
37.8
25.4
100.0
40.8
720 720
294 25.8
#* PROBLEMS/SOLUTIONS/COMMENTS
DUE TO LOAD FLUCTUATIONS, MODULES 201 AND 301 WERE DOWN APPROXIMATELY
12 HOURS TO UNPLUG THE TANGENTIAL NOZZLES.
12/81
101
201
301
401
SYSTEM
.0
100.0
100.0
93.6
73.4
.0
64.6
37.7
93.6
49.0
.0
100.0
100.0
93.6
73.4
.0
64.6
37.7
93.6
49.0
744 744
365 33.0
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE 101 WAS OFF-LINE FOR THE ENTIRE PERIOD TO REPLACE THE RUBBER
LINED FAN HOUSING WITH INCONEL 825 AND TO INSTALL NEW STUDS IN THE
FAN ROTOR.
DURING NOVEMBER AND DECEMBER MODULE 101 WAS OFF-LINE FOR CLEANING.
THE MODULE OPERATED 6,487 HOURS BEFORE BEING SHUT DOWN.
1/82 101
201
301
401
SYSTEM
2/82 101
201
301
401
SYSTEM
3/82 101
201
301
401
SYSTEM
.0
100.0
90.2
95.6
71.5
.0
99.2
100.0
100.0
74.8
.0
99.1
100.0
100.0
74.8
.0
80.9
88.9
95.6
66.3
.0
64.0
80.4
100.0
61.1
.0
57.3
79.7
99.6
59.1
.0
100.0
90.1
95.6
69.9
.0
98.8
100.0
100.0
70.8
.0
98.4
100.0
100.0
70.1
.0
80.9
88.9
95.6
66.3
.0
64.0
60.4
100.0
61.1
.0
57.3
79.7
99.6
59.1
744 744
672 672
744 744
494 64.0
411 60.0
440 46.0
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE 101 WAS OFF-LINE THE ENTIRE FIRST QUARTER OF 1982 FOR REPAIRS.
NEW S02 MONITORS, INSTALLED IN JANUARY, WERE REPORTED TO HAVE WORKED WELL
THROUGHOUT THE FIRST QUARTER. THE UTILITY IS ALSO PRESENTLY REQUESTING/
EVALUATING BIDS TO PRESSURIZE THE STACK ANNULUS.
13-389
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
DUQUESNE LIGHT: PHILLIPS 1-6 CCONT.)
. PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
4/82 SYSTEM 730
5/82 SYSTEM 744
6/82 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE SECOND QUARTER THE S02 MONITORS WERE CERTIFIED.
THE MODULE 301 MIST ELIMINATOR WAS REPLACED DUE TO DETERIORATION.
THE MODULE 401 FAN HAD TO BE BALANCED DURING THE PERIOD CAUSING ADDITIONAL
OUTAGE TIME.
DURING THE PERIOD THE UTILITY INITIATED ADDING THIOSULFATE WHtN THE EXCESS
AIR RECORDED GREATER THAN 11. THIS HAS SOLVED SOME OF THERE
PREVIOUS PROBLEMS.
7/82 SYSTEM 744
8/82 SYSTEM 744
9/82 SYSTEM 720
10/82 SYSTEM 744
11/82 SYSTEM 720
12/82 SYSTEM 744
1/83 SYSTEM 744
2/83 SYSTEM 672
3/83 SYSTEM 744
»* PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE PERIOD OF JULY 1982 THROUGH MARCH 1983.
4/83 SYSTEM 720
5/83 SYSTEM 744
6/83 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY INITIATED STACK PRESSURIZATION AT PHILLIPS DURING THE MONTH TO
CONTROL SEEPAGE AND SUBSEQUENT CORROSION.
7/83 SYSTEM 744
8/83 SYSTEM 744
9/83 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE THIRD QUARTER OF 1983.
10/83 SYSTEM 744
13-390
-------
UTILITY F6D SURVEY? OCTOBER 1983 - SEPTEMBER 198*
DUQUESNE LIGHT: PHILLIPS 1-6 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
502 PART. HOURS HOURS HOURS FACTOR
11/83 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED INCREASING STACK PRESSURE BY TWO INCHES DURING THE
MONTH FOR CONTROL OF SEEPAGE.
12/83 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT ALTHOUGH THE UNIT HAS BEEN DOWN MONTHS AT A TIME
DURING MOST OF 1983, THE FGD SYSTEM HAS BEEN AVAILABLE.
STAINLESS STEEL BANDS AROUND THE ABSORBER LINER WERE REPLACED WITH
NARCOLITE DURING THE FOURTH QUARTER.
INSPECTIONS INDICATE THAT THE CEILCOTE LINING IN THE WET DUCT WILL HAVE TO
BE REPLACED OVER THE NEXT THREE YEARS.
1/84 SYSTEM 744
2/84 SYSTEM 696
3/84 SYSTEM 744
4/84 SYSTEM 720
5/84 SYSTEM 744
6/84 SYSTEM 720
7/84 SYSTEM 744
8/84 SYSTEM 744
9/84 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT OVERALL FGD SYSTEM AVAILABILITY FOR THE FIRST
THREE QUARTERS OF 1984 WAS ABOVE 90X.
IT WAS REPORTED THAT LESS DETERIORATION HAS OCCURRED IN THE STACK
NOW THAT IT IS PRESSURIZED.
AFTER 11 YEARS OF USAGE, THE CEILCOTE LINER IN THE WET DUCT TO THE STACK
DETERIORATED. THE LINER WILL BE REPLACED OVER THE NEXT THREE YEARS DUR-
ING ANNUAL OUTAGES.
THE UTILITY IS NOW DIVERTING INDUCED DRAFT FAN SPRAY WATER TO AN ASH POND
INSTEAD OF RECYCLING TO THE ABSORBERS. LIME CONSUMPTION HAS IMPROVED SINCE
THE HIGHLY ACIDIC SPRAY WATER IS NO LONGER INTRODUCED IN THE SYSTEM.
THE UTILITY REPORTED A THREE WEEK SCHEDULED ANNUAL OUTAGE IN THE FIRST
THREE QUARTERS OF 1984. DURING THIS TIME REPAIRS WERE MADE TO DUCTWORK
AND DAMPERS. MIST ELIMINATOR TURN VANES WERE ALSO REPLACED.
DUE TO LOW POWER DEMAND IN THE FIRST THREE QUARTERS OF 1984, PHILLIPS DID
NOT OPERATE STEADILY. AS A RESULT, BRIEF EPISODES OF HIGH EMISSIONS WERE
REPORTED. HOWEVER, THE SYSTEM OPERATED EFFICIENTLY OVER 24 HOUR PERIODS.
13-391
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
SECTION 13
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 U'O/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 - 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
EAST KENTUCKY POWER
SPURLOCK
MAYSVILLE
KENTUCKY
C
43.
516.
******
800
500
500
495
500
( .100 LB/MMBTU)
( 1.200 LB/MMBTU)
(****** LB/MMBTU)
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
******** (******* ACFM)
148.9 ( 300 F)
244. ( 802 FT)
CONCRETE
9.1 ( 30.0 FT)
COAL
******
25586.
16.00
******
8.00
******
3.50
******
********
0.02-0.11
( 11000 BTU/LB)
** ESP
TYPE
SUPPLIER
PARTICLE REMOVAL EFFICENCY - 7.
** PARTICLE SCRUBBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRACE NAME/COMMON NAME
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
GAS CONTACTING DEVICE 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.
HOT SIDE
AMERICAN AIR FILTER
99.5
0
NONE
N/A
N/A
N/A
N/A
N/A
N/A
N/A
THROWAWAY PRODUCT
WET SCRUBBING
LIME
THYSSEN/CEA
BLACK 4 VEATCH
FULL SCALE
NEW
7. 99.50
79.40
13-392
-------
UTILITY FGO SURVEY: OCTOBER 1983 - SEPTEMBER
EAST KENTUCKY POWER: SPURLOCK 2 (CONT.)
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
«* DESIGN AND OPERATING PARAMETERS
OPER. * MAINT. REQUIREMENT - MANHR/DAY
** QUENCHER/PRESATURATOR
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
»» ABSORBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
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
L/G RATIO - L/CU.M
GAS-SIDE PRESSURE DROP - KPA
S02 REMOVAL EFFICIENCY - X
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
NUMBER OF PASSES PER STAGE
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
WASH FREQUENCY
** REHEATER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** FANS
NUMBER
DESIGN
FUNCTION
APPLICATION
SERVICE
CONSTRUCTION MATERIAL GENERIC TYPE
** FANS
NUMBER
DESIGN
FUNCTION
APPLICATION
SERVICE
CONSTRUCTION MATERIAL GENERIC TYPE
*» DAMPERS
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
1
4/83
12/82
0/79
120.0
NR
NR
SPRAY TOWER
OPEN COUNTERCURRENT SPRAY
N/A
NR
NR
NR
NR
NR
NR
NONE
1.3
1.4
90.0
10.0 GAL/1000 ACF)
5.8 IN-H20)
PRIMARY COLLECTOR
4
IMPINGEMENT
BAFFLE
CLOSED VANE
4
.0 (
.3 (
ORGANIC
POLYPHENYLENE
CONTINUOUS
INDIRECT HOT AIR
COLO SIDE
N/A
NR
NR
CENTRIFUGAL
NR
FORCED DRAFT
DRY
HIGH ALLOY
CENTRIFUGAL
NR
FORCED DRAFT
DRY
HIGH ALLOY
NR
NR
NR
NR
.1 IN-H20)
1.0 FT/S)
13-393
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
EAST KENTUCKY POWER: SPURLOCK 2 (CONT.)
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
»* REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
«* TANKS
SERVICE
ABSORBER RECYCLE
REAGENT PREP PRODUCT
*» PUMPS
SERVICE
SLURRY TRANSFER
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
DIMENSIONS - FT
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
OUTLET STREAM CHARACTERISTICS
*** SLUDGE
** TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
»* DISPOSAL
NATURE
TYPE
SITE TRANSPORTATION METHOD
SITE TREATMENT
*» WATER BALANCE
WATER LOOP TYPE
NR
NR
NR
NR
NR
NR
NR
SLAKER
NR
NR
NUMBER
****
****
NUMBER
2
THICKENER
2
115.0 DIA
CARBON STEEL
AISI 1110
30X SOLIDS
FIXATION
PUG MILL
CONVERSION SYSTEMS [POZ-0-TEC1
FINAL
NR
RAIL
NR
CLOSED
PERFORMANCE DATA .
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
12/82 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT INITIAL START-UP OCCURRED IN DECEMBER, 1982.
1/83 SYSTEM 744
2/83 SYSTEM 672
3/83 SYSTEM
13-394
-------
UTILITY FGD SURVEYS OCTOBER 1983 - SEPTEMBER 1984
EAST KENTUCKY POWER: SPURLOCK 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
*# PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT SO FAR THE FGD SYSTEM IS OPERATING AT ABOUT 90X
EFFICIENCY WITH NO MAJOR PROBLEMS.
4/83 SYSTEM 720
5/83 SYSTEM 744
6/83 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY ANNOUNCED THAT THE SFURLOCK 2 FGD SYSTEM INITIATED COMMERICAL
OPERATION IN APRIL. PEFORMANCE DATA FOR THE PERIOD OF APRIL THROUGH JUNE
1983, ARE NOT AVAILABLE AT THIS TIME.
7/83 SYSTEM .0 .0 744 0
8/83 SYSTEM .0 .0 744 0
9/83 SYSTEM .0 .0 720 0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE FGD SYSTEM WAS OUT OF SERVICE DURING THE
THIRD QUARTER DUE TO DUCTWORK PROBLEMS.
STACK-RELATED PROBLEMS WERE ALSO REPORTED DURING THE PERIOD.
THE UTILITY HOPES TO RESUME OPERATION OF THE SPURLOCK 2 FGD SYSTEM DURING
THE FIRST QUARTER OF 1984.
10/83 SYSTEM 744
11/83 SYSTEM 720
13/83 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS REPORTED APPROXIMATELY 90 PERCENT AVAILABLE THROUGHOUT
THE FOURTH QUARTER OF 1983.
THE UTILITY REPORTED THAT THE UNIT WAS DOWN FROM MID-NOVEMBER TO LATE
DECEMBER DUE TO STACK AND DUCTWORK-RELATED PROBLEMS.
1/84 SYSTEM 744
2/84 SYSTEM 696
3/84 SYSTEM 744
<»/84 SYSTEM 720
5/84 SYSTEM 744
6/84 SYSTEM 720
7/84 SYSTEM 744
8/84 SYSTEM 744
9/84 SYSTEM 720
13-395
-------
UTILITY FGD SURVEY: OCTOBER 19Q3 - SEPTEMBER 1984
EAST KENTUCKY POWER: SPURLOCK 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 UTILITY REPORTED THAT THE FGD SYSTEM WAS OUT OF SERVICE DURING THE
FIRST THREE QUARTERS OF 1984 AND IS SCHEDULED TO GO BACK ON LINE BY LATE
DECEMBER 1984. THE SYSTEM WAS DOWN DUE TO STACK LINER REPLACEMENT AND
ABSORBER DUCTWORK REPAIRS.
13-396
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
SECTION 13
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
** ESP
NUMBER
TYPE
SUPPLIER
INLET FLUE GAS CAPACITY - CU.M/S
INLET FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
*# PARTICLE SCRUBBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON NAME
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
*»* FGD SYSTEM
»# GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
SOa REMOVAL MODE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
( .030 LB/MMBTU)
( 1.200 LB/MMBTU)
(#***** LB/MMBTU)
GRAND HAVEN BRD OF LIGHT & PWR
J.B. SIMS
3
GRAND HAVEN
MICHIGAN
B
13.
516.
******
78
65
58
495
65
BABCOCK « WILCOX
PULVERIZED COAL
BASE
122.69 ( 260000 ACFM)
142.8 ( 289 F)
110. ( 360 FT)
CONCRETE
2.6 ( 8.5 FT)
( 11000 BTU/LB)
10700-12265
COAL
BITUMINOUS
25586.
11.20
9.5-15.8
9.60
3.3-15.5
2.75
1.2-4.5
********
******
COLD SIDE
BABCOCK & WILCOX
127.4 ( 270000 ACFM)
140.6 ( 285 F)
.1 (0. IN-H20)
0
NONE
N/A
N/A
N/A
N/A
N/A
N/A
THROWAWAY PRODUCT
WET SCRUBBING
LIME
BAECOCK t WILCOX
BLACK 4 VEATCH
FULL SCALE
NEW
13-397
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
GRAND HAVEN BRD OF LIGHT & PWR: J.B. SIMS 3 (CONT.)
UNIT DESIGN S02 REMOVAL EFFICIENCY - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
** QUENCHER/PRESATURATOR
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** 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
L/G RATIO L/CU.M
GAS-SIDE PRESSURE DROP - KPA
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE C
SOe 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
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC 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
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** FANS
NUMBER
NUMBER OF SPARES
DESIGN
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE C
CONSTRUCTION MATERIAL GENERIC TYPE
90.00
1
8/83
5/83
12/79
NR
NR
2
1
SPRAY TOWER
OPEN COUNTERCURRENT SPRAY
N/A
BABCOCK & WILCOX
25.0 DIA X 95.0
STAINLESS STEEL
AUSTENITIC
TYPE 316L
NONE
N/A
N/A
4
1180.
11.8
1.4
122.69
140.6
90.0
(18737 GPM)
( 88.0 GAL/1000 ACF)
( 5.4 IN-H20)
( 260000 ACFM)
( 285 F)
PRIMARY COLLECTOR
1
IMPINGEMENT
BAFFLE
CLOSED VANE
VERTICAL
2
3
ORGANIC
FIBER-REINFORCED POLYESTER
BLENDED
6.6 ( 104 GAL/MIN)
1
IN-LINE
HOT WATER
NR
.0
27.8
122.69
50.6
NR
NR
( 50 F)
( 260000 ACFM)
( 123 F)
Z
0
NR
BALANCED DRAFT
INDUCED DRAFT
DRY
69.37
140.6
NR
147000 ACFM)
285 F)
13-398
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
GRAND HAVEN BRD OF LIGHT 4 PWR: J.B. SIMS 3 (CONT. )
»# FANS
NUMBER
NUMBER OF SPARES
DESIGN
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
CONSTRUCTION MATERIAL GENERIC TYPE
** DAMPERS
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
NUMBER
»* TANKS
SERVICE
ABSORBER RECYCLE
REAGENT PREP PRODUCT
SPARGER/OXIDIZER
** RUMPS
SERVICE
LIME SLURRY TRANSFER
SCRUBBER RECIRCULATION
RECYCLE WATER
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
CONFIGURATION
DIMENSIONS - FT
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
**« SLUDGE
** TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
INLET FLOW RATE - LITER/5
2
0
NR
BALANCED DRAFT
FORCED DRAFT
DRY
49.08
CARBON STEEL
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
NR
SLAKER
NR
NR
2
NUMBER
( 104000 ACFM)
NUMBER
2
6
2
THICKENER
1
0
CIRCULAR
70.0 DIA X 14.0
lay. SOLIDS
35X SOLIDS
VACUUM FILTER
2
1
35X SOLIDS
63X SOLIDS
FIXATION
PUG MILL
N/A
1.0
( 16 GPM)
13-399
-------
UTILITY FGD SURVEY'- OCTOBER 1983 - SEPTEMBER
GRAND HAVEN BRD OF LIGHT & PWR- J.B. SIMS 3 (CONT.)
** DISPOSAL
NATURE FINAL
TYPE LANDFILL
LOCATION OFF-SITE
»« PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS PH, SLURRY DENSITY
PROCESS CHEMISTRY MODE FEED FORWARD
** MATER BALANCE
WATER LOOP TYPE CLOSED
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
502 PART. HOURS HOURS HOURS FACTOR
5/83 SYSTEM 744
6/83 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
INITIAL START-UP AND SHAKEDOWN PROCEDURES OF THE FGD SYSTEM COMMENCED IN
MAY. THE UNIT IS SCHEDULED TO BEGIN COMMERCIAL OPERATIONS BY JULY, 1983.
THE UTILITY REPORTED THAT NO MAJOR PROBLEMS WERE ENCOUNTERED DURING STARTUP
WITH EITHER THE TURBINE OR FGD SYSTEM. INITIAL FGD PERFORMANCE TESTING
SHOWED A 98 PERCENT S02 REMOVAL EFFICIENCY.
SINCE STARTUP. THE UTILITY REPORTED THAT IT HAS ENCOUNTERD PROBLEMS WITH
PROPER BOILER COMBUSTION. .1
7/83 SYSTEM 744
8/83 SYSTEM 744
9/83 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE FGO SYSTEM BEGAN COMMERCIAL OPERATIONS ON
AUGUST 8, 1983. THE FGD SYSTEM HAS CONTINUED TO ACHIEVE HIGH S02 REMOVAL
EFFICIENCIES IN THE RANGE OF 90 TO 95X.
ALTHOUGH GAS SIDE OPERATION HAS BEEN EXCELLENT, THE UTILITY REPORTED THAT
IT EXPERIENCED MINOR PROBLEMS WITH SYSTEM CHEMISTRY AND WASTE HANDLING.
THE FORCED OXIDATION SYSTEM HAS NOT OPERATED TO ITS DESIGNED CAPACITY. AL-
THOUGH DESIGNED TO ACHIEVE BETWEEN 80 TO 90X OXIDATION, ACTUAL RATES
HAVE BEEN IN THE RANGE OF 10 TO 35X.- PLUGGED SPARGERS AND LOOSE
DCWNCOMERS IN THE OXIDATION TANK ARE REPORTED TO BE THE CAUSE.
THE UTILITY REPORTED THAT THE SLUDGE HANDLING CONVEYORS WERE UNDERDESIGHED.
THE UTILITY SOLVED THE PROBLEM BY INCREASING THE SPEED OF THE CONVEYORS.
MODULE A EXPERIENCED PLUGGED SPRAY NOZZLES DURING THE THIRD QUARTER. THE
UTILITY REPORTED THAT MAINTENANCE WORKERS REMOVED HARD SCALE FROM THE INLET
OF THE ABSORBER, AND CHUNKS OF SCALE DROPPED INTO THE
ABSORBER SUMP. SUBSEQUENTLY, THE PUMPS PICKED UP THE SCALE AND FED IT TO
THE NOZZLES CAUSING THEM TO PLUG.
PUMP ALIGNMENT PROBLEMS HAVE CAUSED SEVERAL BEARING FAILURES ON THE MODULE
B ABSORBER.
MINOR PLUGGING PROBLEMS WERE ENCOUNTERED WITH THE PUG MILL DURING THE
THIRD QUARTER.
10/83 SYSTEM 744
13-400
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
GRAND HAVEN BRD OF LIGHT t PWR: J.B. SIMS 3 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FSD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE FGD SYSTEM WAS FORCED OFF-LINE FOR 1.5 WEEKS
IN OCTOBER TO MAKE REPAIRS TO THE FORCED OXIDATION TANK. A LOOSE DOWN-
COMER IN THE TANK CAUSED DAMAGE TO THE STIR PADDLE AND RUBBER LINING.
11/83 SYSTEM 720
12/83 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR FGD-RELATED OUTAGES WERE ENCOUNTERED DURING THE MONTHS OF NOVEMBER
AND DECEMBER. FGD SYSTEM AVAILABILITY DURING THESE TWO MONTHS WAS APPROXI-
MATELY 99 PERCENT. THE SYSTEM WAS REPORTED TO BE ACHIEVING S02 REMOVAL
EFFICIENCIES IN THE RANGE OF 95 TO 98 PERCENT.
1/84 SYSTEM 744
2/84 SYSTEM 696
3/84 SYSTEM 744
4/84 SYSTEM 720
5/84 SYSTEM 744
6/84 SYSTEM 720
7/84 SYSTEM 744
8/84 SYSTEM 744
9/84 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT A SECTION OF MIST ELIMINATOR CHEVRON BAFFLES
FELL DURING THE THIRD QUARTER 1984.
THIOSORBIC LIME TESTING WAS CONDUCTED DURING THE FIRST THREE QUARTERS OF
1984.
FGD SYSTEM AVAILABILITY DURING THE FIRST THREE QUARTERS OF 1984 WAS
ESTIMATED AT 99X.
THE UTILITY REPORTED THAT S02 REMOVAL EFFICIENCIES DURING THE FIRST THREE
QUARTERS OF 1984 WERE APPROXIMATELY 92 TO 97 PERCENT.
BABCOCK AND WILCOX IS INSTALLING A DUST COLLECTION SYSTEM AT THE SLUDGE-
FLYASH MIXING AREA. EXCESSIVE DUST LEVELS FROM THE PUG MILLS WARRANTED
THE DECISION TO INSTALL THIS EQUIPMENT.
13-401
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
SECTION 13
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 PLANT GENERATING CAPACITY - MM
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/F6D - 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
** FABRIC FILTER
NUMBER
TYPE
** ESP
NUMBER
NUMBER OF SPARES
TYPE
SUPPLIER
INLET FLUE GAS CAPACITY - CU.M/S
INLET FLUE GAS TEMPERATURE - C
PARTICLE REMOVAL EFFICENCY - 7.
** PARTICLE SCRUBBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON NAME
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
HOOSIER ENERGY
MEROM
1
MEROM
INDIANA
D
43. C
516. (
******
*****
490
460
466
441
RILEY STOKER
PULVERIZED COAL
BASE
817.33
*******
214.
CONCRETE
5.8
.100 LB/MMBTU)
1.200 LB/MMBTU)
(*»**** LB/MMBTU>
(1732000 ACFM)
(**** F)
( 702 FT)
( 19.0 FT)
COAL
BITUMINOUS
****** (****** BTU/LB)
******
********
******
********
******
3.50
******
.20
******
0
NONE
0
NONE
1
0
COLD SIDE
BUELL DIVISION, ENVIROTECH
873.0 (1850000 ACFM)
137.8 ( 280 F)
99.4
0
NONE
N/A
N/A
N/A
N/A
N/A
N/A
N/A
13-402
-------
HOOSIER ENERGY: MEROM i (CONT.)
UTILITY FGD SURVEYS OCTOBER 1983 - SEPTEMBER 1984
»** 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 - X
ENERGY CONSUMPTION - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
DESIGN COAL SULFER CONTENT - 7.
DESIGN COAL HEAT CONTENT - J/G
DESIGN COAL ASH CONTENT - X
»* QUENCHER/PRESATURATOR
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** ABSORBER
NUMBER
NUMBER OF SPARES
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
LIQUID RECIRCULATION RATE - LITER/S
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
NUMBER OF SPARES PER SYSTEM
NUMBER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** REHEATER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
TEMPERATURE INCREASE - C
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
THROMAWAY PRODUCT
WET SCRUBBING
LIMESTONE
MITSUBISHI HEAVY INDUSTRIES
UNITED ENGINEERS & CONSTRUCTORS
FULL SCALE
NEW
X 99.40
90.00
1.2
1
8/82
8/82
3/78
4.20
24423.0
16.00
NT?
NR
4
0
PACKED TOWER
GRID PACKING
COCURRENT
MITSUBISHI
CARBON STEEL
NR
NR
NR
NR
NR
FIXED GRIDS
1333.
5.7
235.95
137.8
90.0
( 10500 BTU/LB)
(21160 GPM)
( 42.3 GAL/1000 ACF)
( 500000 ACFM)
( 280 F)
MIST ELIMINATOR
4
0
1
NR
NR
NR
HORIZONTAL
NR
NR
INDIRECT HOT AIR
MR
NR
27.8 ( 50 F)
NR
NR
13-403
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
HOOSIER ENERGY: MEROM i (CONT.J
** FANS
NUMBER
NUMBER OF SPARES
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
CONSTRUCTION MATERIAL GENERIC TYPE
** FANS
NUMBER
NUMBER OF SPARES
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
CONSTRUCTION MATERIAL GENERIC TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
MODULATION
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
MODULATION
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
MODULATION
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
MODULATION
»* DUCTU'ORK
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
»* REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
MANUFACTURER
NUMBER
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
2
0
CENTRIFUGAL
WESTINGHOUSE
BOOSTER
FORCED DRAFT
DRY
CARBON STEEL
Z
0
AXIAL
NOVENCO
UNIT
FORCED DRAFT
DRY
CARBON STEEL
SHUT-OFF
GUILLOTINE
NR; SEAL AIR
MOSSER
OPEN
SHUT-OFF
GUILLOTINE
NR; SEAL AIR
MOSSER
OPEN
SHUT-OFF
NR
NR
MOSSER
CLOSED
SHUT-OFF
NR
NR
MOSSER
OPEN
NR
NR
NR
NR
TOWER MILL
N/A
N/A
JAPAN TOWER MILL CO.
2
25.4 ( 28 TPH)
LIMESTONE PRECRUSHER
N/A
N/A
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
HOOSIER ENERGY: MEROM i
35X SOLIDS
VACUUM FILTERS
FGD SYSTEM
VACUUM FILTER
2
0
12.0 DIA X 24
THICKENER
35 /. SOLIDS
55 /. SOLIDS
IUCS
FORCED OXIDAT-ION
PUG MILL
CONVERSION SYSTEMS
15.0
FINAL
LANDFILL
ON-SITE
TRUCK
NONE
250 ACRES X
15360880
30
tPOZ-0-TEC]
50 FT
( 12560.0 ACRE-FT)
13-405
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
HOOSIER ENERGY: MEROM i ICONT.)
** WATER BALANCE
WATER LOOP TYPE
** CHEMICALS AND CONSUMPTION
FUNCTION
NAME
PRINCIPAL CONSTITUENT
POINT OF ADDITION
CLOSED
ABSORBENT
LIMESTONE
CAC03
PRECRUSHER
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
SQZ PART. HOURS HOURS HOURS FACTOR
8/82 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
744
9/82 SYSTEM
THE FGD SYSTEM COMMENCED OPERATION IN AUGUST AND IS CURRENTLY IN THE
STARTUP PHASE OF OPERATION. TESTING FOR NSPS COMPLIANCE IS SCHEDULED
FOR MARCH.
720
744
720
744
744
672
10/82
11/82
12/82
1/83
2/83
3/83
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
A
B
C
D
SYSTEM
,
53.
53.
53.
53.
53.
1
1
1
1
1
54
56
54
43
52
.1
.0
.2
.6
.0
54
56
54
43
52
.1
.0
.2
.6
.0
51
53
51
41
49
.3
.1
.4
.4
.3
744 706
367 58.6
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM COMPLETED COMPLIANCE TESTING DURING THE MONTH OF MARCH.
4/83 A
B
C
D
SYSTEM
100.0
100.0
100.0
100.0
100.0
74.4
74.4
.0
74.4
55.8
100.0
100.0
100.0
75.0
3.1
3.1
.0
3.1
2.3
720
30
23 35.0
PROBLEMS/SOLUTIONS/COMMENTS
5/83
6/83
A
B
C
D
SYSTEM
A
B
C
D
SYSTEM
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
THE UNIT WAS TAKEN OUT OF SERVICE ON APRIL 2 FOR STACK REPAIRS.
744
720
13-406
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
HOOSIER ENERGY: MEROM i
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
HOOSIER ENERGY; MEROM i (CONT.)
__________ , --------------- ----- - --------- PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
1/84
EXTREME COLD WEATHER CONDITIONS DURING DECEMBER RESULTED IN TORN EXPANSION
JOINTS.
A MALFUNCTION ON THE SLUDGE STABILIZATION SYSTEM OCCURRED DURING DECEMBER
RESULTING FROM EXTREME COLD WEATHER CONDITIONS.
493 74.0
A
B
C
D
SYSTEM
75.3
100.0
100.0
100.0
93.8
63.0
68.8
66.6
66.6
66.2
63.0
68.8
66.6
66.6
66.2
63.0
68.8
66.6
66.6
66.2
** PROBLEMS/SOLUTIONS/COMMENTS
A MALFUNCTION IN THE SLUDGE HANDLING SYSTEM ACCOUNTED FOR A SYSTEM OUTAGE
DURING JANUARY.
COMPUTER-RELATED PROBLEMS WERE ENCOUNTERED DURING THE MONTH.
FROZEN LIMESTONE ACCOUNTED FOR ADDITIONAL DOWN TIME IN JANUARY.
ADDITIONAL PROBLEMS DUE TO FREEZING WERE ENCOUNTERED DURING THE MONTH.
2/84
3/84
A
B
C
D
SYSTEM
A
B
C
D
SYSTEM
90.2
89.9
90.6
90.1
90.2
96.7
94.3
96.7
96.7
96.1
88.4
88.0
88.8
88.3
88.4
66.6
85.8
89.3
87.3
87.3
91.9
91.5
92.4
91.8
91.9
92.8
91.7
95.5
93.3
93.3
85.6
85.3
86.0
85.5
85.6
85.0
84.0
87.5
85.5
85.5
696 674
744 729
596 70.3
636 80.0
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR FGD-RELATED PROBLEMS WERE REPORTED DURING FEBRUARY AND MARCH.
A
B
C
D
SYSTEM
68.2
66.9
67.6
69.6
68.1
49.3
48.0
48.7
50.7
49.2
49.9
48.6
49.3
51.3
49.8
48.8
47.5
48.2
50.2
48.7
720
712
350 69.4
** PROBLEMS/SOLUTIONS/COMMENTS
5/84 SYSTEM
6/84 SYSTEM
7/84 SYSTEM
8/84 SYSTEM
9/84 SYSTEM
THE UTILITY REPORTED THAT A PUMP FAILURE AND BUCKET ELEVATOR FAILURES LED
TO PROBLEMS IN THE LIMESTONE PREPARATION SYSTEM.
744
720
744
744
720
13-403
-------
UTILITY FSO SURVEY: OCTOBER 1983 - SEPTEMBER 1964
HOOSIER ENERGY: MEROM i (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE PERIOD OF MAY THROUGH SEPTEMBER 1984.
13-409
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
SECTION 13
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 - 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
** MECHANICAL COLLECTOR
NUMBER
TYPE
** FABRIC FILTER
NUMBER
TYPE
** ESP
NUMBER
NUM5ER OF SPARES
TYPE
SUPPLIER
INLET FLUE GAS CAPACITY - CU.M/S
INLET FLUE GAS TEMPERATURE - C
PARTICLE REMOVAL EFFICENCY - 7.
** PARTICLE SCRUBBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON NAME
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
HOOSIER ENERGY
MEROM
2
MEROM
INDIANA
D
43.
516.
( .100 LB/MMBTU)
( 1.200 LB/MMBTU)
(*****« LB/MMBTU)
*****
490
460
466
441
RILEY STOKER
PULVERIZED COAL
BASE
S17.33
*******
214.
CONCRETE
5.8
(1732000 ACFM)
(**** F)
( 702 FT)
( 19.0 FT)
(****** BTU/LB)
******
COAL
BITUMINOUS
******
********
******
********
******
3.50
******
.20
******
0
NONE
0
NONE
1
0
COLD SIDE
BUELL DIVISION, ENVIROTECH
873.0 (1850000 ACFM)
137.8 ( 280 F)
99.4
0
NONE
N/A
N/A
N/A
N/A
N/A
N/A
N/A
13-410
-------
HOOSIER ENERGY; MEROM 2 CCONT.)
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
»** FGO 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 SQZ REMOVAL EFFICIENCY - X
ENERGY CONSUMPTION - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
DESIGN COAL SULFER CONTENT - 7.
DESIGN COAL HEAT CONTENT - J/G
DESIGN COAL ASH CONTENT - X
** QUENCHER/PRESATURATOR
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** ABSORBER
NUMBER
NUMBER OF SPARES
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
LIQUID RECIRCULATION RATE - LITER/S
L/G RATIO - L/CU.M
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
SOS REMOVAL EFFICIENCY - X
*« MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
NUMBER OF SPARES PER SYSTEM
NUMBER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** REHEATER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
TEMPERATURE INCREASE - C
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
MITSUBISHI HEAVY INDUSTRIES
UNITED ENGINEERS t CONSTRUCTORS
FULL SCALE
NEW
X 99.40
90.00
1.2
1
2/82
12/81
3/78
4.20
24423.0
16.00
NR
NR
4
0
PACKED TOWER
GRID PACKING
COCURRENT
MITSUBISHI
CARBON STEEL
NR
NR
NR
NR
NR
FIXED GRIDS
1333.
5.7
235.95
137.8
90.0
( 10500 BTU/LB)
(21160 GPM)
( 42.3 GAL/1000 ACF)
( 500000 ACFM)
( 280 F)
MIST ELININATOR
4
0
1
NR
NR
tlP.
HORIZONTAL
NR
NR
INDIRECT HOT AIR
NR
NR
27.8 ( 50 F)
NR
NR
13-411
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
HOOSIER ENERGY; MEROM 2 (CONT.)
*« FANS
NUMBER
NUMBER OF SPARES
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
CONSTRUCTION MATERIAL GENERIC TYPE
** FANS
NUMBER
NUMBER OF SPARES
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
CONSTRUCTION MATERIAL GENERIC TYPE
«* DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
MODULATION
«* DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
MODULATION
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
MODULATION
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
MODULATION
** DUCTU'CRK
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
»* REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
MANUFACTURER
NUMBER
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
*» REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
2
0
CENTRIFUGAL
WESTINGHOUSE
BOOSTER
FORCED DRAFT
DRY
CARBON STEEL
2
0
AXIAL
NOVENCO
UNIT
FORCED DRAFT
DRY
CARBON STEEL
SHUT-OFF
GUILLOTINE
NR; SEAL AIR
MOSSER
OPEN
SHUT-OFF
GUILLOTINE
NR; SEAL AIR
MOSSER
OPEN
SHUT-OFF
NR
NR
MCSSER
CLOSED
SHUT-OFF
NR
NR
MOSSER
OPEN
NR
NR
NR
NR
TOWER MILL
N/A
N/A
JAPAN TOWER MILL CO.
2
25.4 ( 28 TPH)
LIMESTONE PRECRUSHER
N/A
N/A
13-412
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
HOOSIER ENERGY: MEROM z CCONT.)
MANUFACTURER
NUMBER
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
** TANKS
SERVICE
PROCESS SURGE
INTERMEDIATE
** PUMPS
SERVICE
ABSORBER
ABSORBER COOLING
OXIDIZER FEED
THICKENER OVERFLOW
THICKENER UNDERFLOW
SURGE-TANK
SEED SLURRY
LIMESTONE SLURRY FEED tLOW HEAD3
LIMESTONE SLURRY FEED [HIGH HEAD]
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
DIMENSIONS FT
CAPACITY
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
FEED STREAM SOURCE
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
OUTLET STREAM DISPOSITION
OVERFLOW STREAM DISPOSITION
«* SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
DIMENSIONS - FT
FEED STREAM SOURCE
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
OUTLET STREAM DISPOSITION
*** SLUDGE
** TREATMENT
METHOD
' DEVICE
PROPRIETARY PROCESS
INLET QUALITY - V.
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE TREATMENT
SITE DIMENSIONS
SITE CAPACITY - CU.M
SITE SERVICE LIFE - YRS
PENNSYLVANIA CRUSHER CORP.
1
25.4 ( 28 TPH)
NUMBER
NUMBER
12
8
2
2
2
3
2
2
2
THICKENER
1
0
140 DIA
1116000 GAL
CARBON STEEL
AISI 1110
ORGANIC
NR
ABSORBER BLOWDOWN & SEED CYCLONE OVERFLOW
18 /. SOLIDS
35X SOLIDS
VACUUM FILTERS
FGD SYSTEM
VACUUM FILTER
2
0
12.0 DIA X 24
THICKENER
35 7. SOLIDS
55 7. SOLIDS
IUCS
FORCED OXIDATION
PUG MILL
CONVERSION SYSTEMS
15.0
FINAL
LANDFILL
ON-SITE
TRUCK
NONE
250 ACRES X 50 FT
15360880
30
IPOZ-O-TECl
( 12560.0 ACRE-FT)
13-413
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
HOOSIER ENERGY: MEROM 2 CCONT.)
#* WATER BALANCE
WATER LOOP TYPE
** CHEMICALS AND CONSUMPTION
FUNCTION
NAME
PRINCIPAL CONSTITUENT
POINT OF ADDITION
CLOSED
ABSORBENT
LIMESTONE
CAC03
PRECRUSHER
... PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL PER BOILER FGD CAP.
SOS PART. HOURS HOURS HOURS FACTOR
12/81 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
744
ON DECEMBER 30, 1981 OPERATION OF THE FGD SYSTEM INSTALLED ON MEROH 2
COMMENCED. THE SYSTEM IS PRESENTLY IN THE START UP PHASE WITH COMMERCIAL
OPERATION SCHEDULED FOR FEBRUARY.
1/82 SYSTEM
2/82 SYSTEM
3/82 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
744
672
744
THE UTILITY REPORTED THAT COMMERCIAL OPERATION WAS INITIATED ON THE FIRST
OF FEBRUARY. EXCEPT FOR SOME MINOR FREEZING PROBLEMS, NO MAJOR FGD-RELATED
PROBLEMS WERE ENCOUNTERED DURING THE FIRST QUARTER PERIOD.
HOWEVER, THE UTILITY DID REPORT THAT HIGH FLYASH LOADINGS TO THE ABSORBER
WERE ENCOUNTERED DUE TO ESP INABILITY TO REMOVE FLYASH FROM ITS HOPPERS.
THE PROBLEM WAS PARTIALLY DUE TO THE HIGH MOISTURE CONTENT OF THE COAL (FLY
ASH STICKS IN THE HOPPERS AND EVENTUALLY TRIPS ESP) IN ADDITION TO FIRING
WITH OIL DURING STARTUP (FLYASH STICKS TO OIL RESIDUE LEFT ON PLATES).
4/82 SYSTEM
5/82 SYSTEM
6/82 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
19.8
48.3
30.0
720
744
720
THE UTILITY REPORTED EXPERIENCING PROBLEMS WITH THE LINER CRACKING IN THE
THICKENERS AND SETTLING IN THE SUR&E TANKS DOWNSTREAM OF THE THICKENERS.
FGD AVAILABILITY FOR THE FIRST SIX MONTHS OF OPERATION WAS APPROXIMATELY
25 PERCENT.
7/82 A
80.5
B
C
D
SYSTEM
80.
80.
80.
80.
77.3
77.3
77.3
77.3
77.3
77.3
77.3
77.3
77.3
77.3
66.4
66.4
66.4
66.4
66.4
744 640
494 48.7
PROBLEMS/SOLUTIONS/COMHENTS
THE FGD SYSTEM EXPERIENCED A TOTAL OUTAGE TIME OF 145.2 HOURS DURING JULY.
104.5 HOURS OF THAT PERIOD WAS DUE TO A UNIT OUTAGE.
PART OF THE FGD SYSTEM OUTAGE WAS DUE TO AN INSPECTION OF THE PROCESS
TANKS.
A THICKENER LINER FAILURE ALSO CONTRIBUTED TO THE OUTAGE DURING JULY.
13-414
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
HOOSIER ENERGY: MEROM 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL PER BOILER FGD CAP.
502 PART. HOURS HOURS HOURS FACTOR
A 13 HOUR OUTAGE DURING JULY WAS THE RESULT OF AN EFFORT TO UNPLUG THE
THICKENER UNDERFLOW LINES.
PROBLEMS WITH A PRECIPITATOR LED TO A 13.5 HOUR OUTAGE DURING THE MONTH.
A 74 HOUR OUTAGE OCCURRED DURING THE MONTH DUE TO EXTENDED FGD MAINTENANCE
FOLLOWING THE UNIT OUTAGE.
8/82
A
B
C
D
SYSTEM
55.0
55.0
55.0
55.0
55.0
54.1
54.1
54.1
54.1
54.1
54.1
54.1
54.1
54.1
54.1
53.0
53.0
53.0
53.0
53.0
744 729
394 46.0
** PROBLEMS/SOLUTIONS/COMMENTS
A BREAKDOWN OF THE LIMESTONE PREPARATION SYSTEM LED TO A 334 HOUR OUTAGE
DURING AUGUST. THE BUCKET ELEVATOR CHAINS HAD TO BE REPLACED DUE TO
CRACKED LINKS IN THE CHAINS. THE UTILITY REPORTED THAT DUE TO THE NATURE
OF THE FAILURE, IT APPEARED THAT THE LINKS WERE DEFECTIVE.
9/82 A
A
B
C
D
SYSTEM
76.4
76.4
76.4
76.4
76.4
22.9
22.9
22.9
22.9
22.9
22.9
22.9
22.9
22.9
22.9
7.0
7.0
7.0
7.0
7.0
720 221
51 46.0
** PROBLEMS/SOLUTIONS/COMMENTS
A FAILURE OF THE LIMESTONE PREPARATION SYSTEM RESULTED FROM A PLUGGING
PROBLEM AND CAUSED A 6.5 HOUR OUTAGE DURING SEPTEMBER.
A 163.5 HOUR OUTAGE DURING THE MONTH WAS DUE TO PLUGGED WALL WASH LINES IN
THE QUENCHER SECTION. ALL LINES IN ALL FOUR MODULES WERE PLUGGED AND THE
CAUSE WAS SUSPECTED OF BEING A DESIGN DEFICIENCY IN THE SYSTEM. THE LINES
WERE UNPLUGGED WITHIN A MATTER OF DAYS AND THE SYSTEM WAS ALLOWED TO
CONTINUE OPERATING WITHOUT THE WALL WASH.
10/82 A
B
C
D
SYSTEM
87.3
87.3
87.3
87.3
87.3
49.7
57.3
65.7
76.4
62.3
52.4
60.5
69.4
80.7
65.8
49.3
56.9
65.2
75.8
61.8
744 738
460 47.7
** PROBLEMS/SOLUTIONS/COMMENTS
DURING OCTOBER PROBLEMS WITH A PRECIPITATOR LED TO A 39 HOUR OUTAGE.
A 21 HOUR OUTAGE OCCURRED DURING THE MONTH AS A RESULT OF A COMPUTER
MALFUNCTION.
A FAILURE IN THE LIMESTONE SLURRY PREPARATION SYSTEM PRODUCED A 19.5 HOUR
OUTAGE DURING OCTOBER.
DURING THE MONTH THE UNIT OPERATED TYPICALLY WITH THREE MODULES ONLY DUE TO
LOW BOILER LOADS.
11/82 A
B
C
D
SYSTEM
47.4
47.4
47.4
47.4
47.4
46.2
46.2
37.3
13.6
35.8
46.3
46.3
37.3
13.6
35.9
45.6
45.6
36.8
13.4
35.3
720 711
254 48.4
13-415
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
HOOSIER ENERGY: MEROM 2 (CONT.)
. . PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
Y. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
1/83
3/83
4/83
** PROBLEMS/SOLUTIONS/COMMENTS
DURING NOVEMBER PROBLEMS WITH A PRECIPITATOR LED TO A 13 HOUR OUTAGE.
A FAILURE IN THE LIMESTONE SLURRY PREPARATION SYSTEM PRODUCED A 51.5 HOUR
OUTAGE DURING NOVEMBER.
BYPASS DAMPER PROBLEMS CREATED A BRIEF 1 HOUR OUTAGE DURING THE MONTH.
A TOTAL FAILURE OF THE EXPANSION JOINTS THROUGHOUT THE FGD SYSTEM RESULTED
IN A 326.5 HOUR OUTAGE DURING NOVEMBER.
THE UNIT CONTINUED OPERATING WITH THREE MODULES ONLY DURING THE MONTH DUE
TO LOW LOADS.
12/82 A
B
C
D
SYSTEM
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
744 269
0 44.6
** PROBLEMS/SOLUTIONS/COMMENTS
THE EXPANSION JOINT FAILURE PROBLEM WITHIN THE FGD SYSTEM CONTINUED DURING
DECEMBER. REPLACEMENT OF THE JOINTS WAS IN PROGRESS.
A
B
C
D
SYSTEM
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
744 744
0 47.0
*» PROBLEMS/SOLUTIONS/COMMENTS
THE EXPANSION JOINT FAILURE PROBLEM CONTINUED DURING JANUARY AND
REPLACEMENT OF THE JOINTS WAS STILL IN PROGRESS.
2/83 A
B
C
D
SYSTEM
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
672 667
50.2
*» PROBLEMS/SOLUTIONS/COMMENTS
THE EXPANSION JOINT FAILURE PROBLEM CONTINUED DURING FEBRUARY AND
REPLACEMENT OF THE JOINTS WAS STILL IN PROGRESS.
A
B
C
D
SYSTEM
64,
64
64,
64,
64,
.0
.0
.0
.0
.0
744
40
0 44.3
** PROBLEMS/SOLUTIONS/COMMENTS
THE CONTINUATION OF EXPANSION JOINT REPAIRS OCCURRED DURING MARCH.
29.4
70.3
A
B
C
D
SYSTEM
59.0
75.7
75.7
67.8
69.5
35.4
84.7
74.7
45.9
60.2
37.9
90.7
79.9
49.2
64.4
62.0
38.1
49.9
720 597
360 57.8
13-416
-------
UTILITY FGO SURVEY: OCTOBER 1983 - SEPTEMBER 1984
HOOSIER ENERGY: MEROM 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL
S02 PART.
PER BOILER FGD CAP.
HOURS HOURS HOURS FACTOR
5/83
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT MODIFICATIONS WERE MADE TO MODULES A AND D DURING
APRIL.
COMPUTER MALFUNCTIONS WERE ATTRIBUTED TO PART OF THE 175 HOUR OUTAGES
DURING THE MONTH.
PLUGGED SPRAY HEADER LINES ALSO CONTRIBUTED TO THE 175 HOUR OUTAGES IN APRI
ESP MALFUNCTIONS CONTRIBUTED TO 39 HOURS OF FGD OUTAGE IN APRIL.
A
B
C
D
SYSTEM
95.8
95.8
76.4
95.8
90.9
88.6
85.0
61.2
95.5
82.6
88.6
85.0
61.2
95.5
82.6
88.6
85.0
61.2
95.5
82.6
744 744
614 60.3
** PROBLEMS/SOLUTIONS/COHMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING MAY.
6/83 A
B
C
D
SYSTEM
21.9
1.3
21.9
21.9
16.8
86.9
5.2
82.0
86.2
65.1
86.9
5.2
62.0
86.2
65.1
21.9
1.3
20.7
21.7
16.4
720 182
118 53.6
** PROBLEMS/SOLUTIONS/COMMENTS
EXTENSIVE SCHEDULED MAINTENANCE WAS PERFORMED ON THE FGD SYSTEM DURING A
BOILER OUTAGE IN JUNE.
7/83 A
B
C
D
SYSTEM
100.0
100.0
100.0
100.0
100.0
73.2
99.9
100.0
61.0
83.5
72.9
99.5
100.0
60.7
83.3
72.6
99.1
99.6
60.5
82.9
744 738
617 71.5
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS PARTIALLY BYPASSED DURING JULY TO MINIMIZE STACK LINER
CRACKING BY MAINTAINING A SPECIFIC TEMPERATURE RANGE WITHIN THE STACK. THE
UTILITY ATTRIBUTED LOWER S02 REMOVAL EFFICIENCIES TO THE BYPASS INCIDENT.
LINER REPAIRS ARE SCHEDULED FOR THE FALL OF 1983.
THE UNIT EXPERIENCED AN AIR HEATER FAILURE DURING JULY AND THE FGD SYSTEM
WAS CONSEQUENTLY USED TO COOL GAS, PROTECTING THE STACK LINER.
8/83 A
B
C
D
SYSTEM
99.7
99.7
99.7
99.7
99.7
98.8
98.9
99.2
97.9
98.7
99.5
99.6
100.0
98.6
99.4
85.8
85.9
86.2
85.0
85.7
744 646
638 65.4
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS AGAIN PARTIALLY BYPASSED DURING AUGUST TO MINIMIZE STACK
LINER CRACKING BY MAINTAINING A SPECIFIC TEMPERATURE WITHIN THE STACK.
9/83 A
97.2
88.3
90.4
38.1
13-417
-------
UTILITY FGO SURVEY: OCTOBER 1983 - SEPTEMBER 1984
HOOSIER ENERGY: MEROM 2 ICONT.)
_ hCKruKnAr
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY
B
C
D
SYSTEM
97.9 90.0 92.2
97.9 90.0 92.2
98.6 90.0 92.2
97.9 89.6 91.7
11.C UA 1 M ___-_, ____ _.
UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
38.9
38.9
38.9
38.7 720 311 278 28.6
*» PROBLEMS/SOLUTIONS/COMMENTS
10/83 A
B
C
D
SYSTEM
11/83 A
B
C
D
SYSTEM
13/83 A
B
C
D
SYSTEM
THE FALL SCHEDULED OUTAGE
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
FOR STACK LINER REPAIRS COMMENCED IN SEPTEMBER.
.0
.0
.0
.0
.0 744 0 0
.0
.0
.0
.0
.0 720 0 0 .0
744 0
2/84
3/84
«* PROBLEMS/SOLUTIONS/COMMENTS
1/84 A
B
C
D
SYSTEM
THE UTILITY REPORTED THAT THE UNIT WAS OUT OF SERVICE DURING THE FOURTH
QUARTER OF 1983.
.0 .0
.0 .0
.0 .0
.0 .0
.0 .0
744
.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS OUT OF SERVICE THROUGHOUT JANUARY.
A
B
C
D
SYSTEM
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
696
54
2.6
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT STACKLINER REPAIR WAS COMPLETED AND THE UNIT
WAS IN INITIAL START UP AT THE END OF THE MONTH.
A
B
C
D
SYSTEM
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
744
66
PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS SHUT DOWN ON MARCH 3 FOR TURBINE REPAIRS.
COMPLETED ON MARCH 31.
THE REPAIRS WERE
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
HOOSIER ENERGY: MEROM 2
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
SECTION 13
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 MW
«» UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN EOILER 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
** FABRIC FILTER
NUMBER
TYPE
SUPPLIER
NUMBER OF COMPARTMENTS
NUMBER OF SPARE COMPARTMENTS
INLET FLUE GAS CAPACITY - CU.M/S
INLET FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
PARTICLE REMOVAL EFFICENCY - 7.
TYPICAL GAS/CLOTH RATIO - M/MIN
** PARTICLE SCRUBBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON NAME
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
*** FGD SYSTEM
** GENERAL DATA
SALEABLE FRODUCT/THROWAWAY PRODUCT
SOS REMOVAL MODE
030 LB/MMBTU)
360 LB/MMBTU)
500 LB/MMBTU)
HOUSTON LIGHTING & POWER
W.A. PARISH
8
THOMPSONS
TEXAS
B
13. (
155. (
215. (
3670
600
545
551
492
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
1038.18 (2200000 ACFM)
148.9 ( 300 F)
152. ( 500 FT)
CONCRETE
6.7 ( 22.0 FT)
COAL
SUEBITUMINOUS
20799. ( 8942 BTU/LB)
8000-8785/8800-9636
4.75
4.77-10.00/2.26-6.00
26.69
25.98-31.30/21.17-27.67
.41
.34-.79/.08-.60
.01
.01
REVERSE FLOW
RESEARCH-COTTRELL
40
4
259.5 ( 550000 ACFM)
148.9 ( 300 F)
1.9 ( 7.5 IN-H20)
99.8
.6 ( 1.9 FT/MIN)
0
NONE
N/A
N/A
N/A
N/A
N/A
N/A
N/A
THROWAWAY PRODUCT
WET SCRUBBING
13-420
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
HOUSTON LIGHTING & POWER: W.A. PARISH 8 (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
ENERGY CONSUMPTION - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN Mm OPERATING PARAMETERS
DESIGN COAL SULFER CONTENT - X
DESIGN COAL HEAT CONTENT - J/G
DESIGN COAL ASH CONTENT - X
DESIGN MOISTURE CONTENT - X
DESIGN CHLORIDE CONTENT - X
SPACE REQUIREMENTS - SQ M
** QUENCHER/PRESATURATOR
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** 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
LIQUID RECIRCULATION RATE - LITER/S
L/G RATIO - L/CU.M
GAS-SIDE PRESSURE DROP - KPA
SUFERFICAL GAS VELOCITY - M/SEC
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
302 REMOVAL EFFICIENCY - X
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
NUMBER OF SPARES PER SYSTEM
NUMBER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
MANUFACTURER
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
CONSTRUCTION MATERIAL SPECIFIC TYPE
LIMESTONE
NONE
GE ENVIRONMENTAL SERVICES
BECHTEL
FULL SCALE
NEW
99.80
70.00
1.0
1
12/82
10/82
8/79
.44
20510.7
6.13
26.24
.02
9673.2
( 8818 BTU/LB)
( 104125 SQ FT)
CARBON STEEL; INORGANIC
AISI 1110; HYDRAULICALLY-BONDED MORTAR
- CM
3
1
SPRAY TOWER
OPEN COUNTERCURRENT SPRAY
N/A
GE ENVIRONMENTAL SERVICES
40.0 DIA X 90.3
STAINLESS STEEL
AUSTENITIC
TYPE 316L
ORGANIC
FIBERGLASS REINFORCED
CEILCOTE 2500AR
NONE
3
152.4
2142.
5.6
.7
3.0
422.03
146.9
85.0
60.0IN)
34000 GPM)
42.0 GAL/1000 ACF)
2.7 IN-H20)
9.9 FT/S)
894328 ACFM)
300 F)
PRIMARY COLLECTOR
3
0
1
IMPINGEMENT
BAFFLE
CLOSED VANE
GE ENVIRONMENTAL SERVICES
HORIZONTAL
3.66
.51
7.6
(12.0 FT)
( .2 IN)
.00 IN)
56
.1
3.0
ORGANIC
POLYPROPYLENE
( 3.
(
(
.3 IN-H20)
9.9 FT/S)
13-421
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
HOUSTON LIGHTING S POWER: W.A. PARISH 8 (CONT.)
WASH WATER SOURCE
WASH RATE - L/S
*« REHEATER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
PERCENT SAS BYPASSED - AVG
TEMPERATURE INCREASE - C
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** FANS
NUMBER
NUMBER OF SPARES
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
CONSTRUCTION MATERIAL GENERIC TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
MODULATION
SEAL AIR FLOW - CU. M/S
SERVICE CONDITIONS
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
»» DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
MODULATION
SEAL AIR FLOW - CU. M/S
SERVICE CONDITIONS
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
#* DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
MODULATION
SEAL AIR FLOW - CU. M/S
SERVICE CONDITIONS
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
CONFIGURATION
FRESH
12.6
0
BYPASS
COLD SIDE
N/A
18.0
17.8
NR
NR
4
0
CENTRIFUGAL
GREEN FAN
UNIT
FORCED DRAFT
DRY
259.54
148.9
13.4
CARBON STEEL
( 200 GAL/MIN)
32 F)
( 550000 ACFM)
( 300 F)
(44.0 IN-H20)
1
CONTROL
LOUVER
OPPOSED BLADE
ANDCO
NR
1.51 (
300
CARBON STEEL
CORTEN
NR
NR
SHUT-OFF
GUILLOTINE
SINGLE BLADE
ANDCO
NR
1.51
300
CARBON STEEL
CORTEN
NR
NR
SHUT-OFF
GUILLOTINE
SINGLE BLADE
ANDCO
NR
1.51 (
300
STAINLESS STEEL
317L
NR
NR
UPSTREAM
RECTANGULAR
3200 ACFM)
3200 ACFM)
3200 ACFM)
13-422
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
HOUSTON LIGHTING & POWER: W.A. PARISH 8 (CONT.)
DIMENSIONS
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
CONFIGURATION
DIMENSIONS
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
»* REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
MANUFACTURER
NUMBER
NUMBER OF SPARES
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
PRODUCT QUALITY - 7. SOLIDS
** TANKS
SERVICE
REAGENT PREP PRODUCT
THICKENER OVERFLOW
THICKENER UNDERFLOW
THICKENER
** PUMPS
SERVICE
LIMESTONE SLURRY
OVERFLOW
THICKENER UNDERFLOW
ABSORBER BLEED
THICKENER TUNNEL SUMP
LIMESTONE AREA SUMP
ABSORBER RECIRCULATION
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
CONFIGURATION
DIMENSIONS - FT
CAPACITY
SHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
BELT GENERIC MATERIAL TYPE
FEED STREAM SOURCE
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
OVERFLOW STREAM CHARACTERISTICS
OVERFLOW STREAM DISPOSITION
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
CONFIGURATION
DIMENSIONS - FT
CAPACITY
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
22X15.6
CARBON STEEL
ASTM A-36
NONE
NONE
DOWNSTREAM
RECTANGULAR
16.1X16.1
CARBON STEEL
ASTM A-36
INORGANIC
HYDRAULICALLY-BONDED MORTAR
WET BALL MILL
COMPARTMENTED
NR
K.V.S.
3.6 ( 4 TPH)
40.0
NUMBER
1
1
1
1
NUMBER
1
2
2
2
2
Z
9
VACUUM FILTER
2
0
PARALLEL
12XZO
63 TON/HOUR
CARBON STEEL
ORGANIC
NATURAL RUBBER
CLOTH
THICKENER UNDERFLOW
600 GPM, 25X SOLIDS
60X SOLIDS
400 GPM, OX SOLIDS
MAKEUP
THICKENER
1
0
ROUND
60.0 DIA X 15.0
416300
CARBON STEEL
ASTM A-283
ASPHALTIC MEMBRANE
13-423
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
HOUSTON LIGHTING 4 POWER: W.A. PARISH 8 (CONT.)
LINER SPECIFIC MATERIAL TYPE
FEED STREAM SOURCE
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
OVERFLOW STREAM CHARACTERISTICS
OUTLET STREAM DISPOSITION
OVERFLOW STREAM DISPOSITION
*** SLUDGE
FULL LOAD SLUDGE QUANTITY - M.TONS/HR (DRY)
MOISTURE CONTENT - X TOTAL FREE WATER
** TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
INLET QUALITY - X
»* DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE TREATMENT
SITE DIMENSIONS
SITE SERVICE LIFE - YRS
** PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS
PHYSICAL VARIABLES
PROCESS CONTROL MANNER
PROCESS CHEMISTRY MODE
** WATER BALANCE
WATER LOOP TYPE
»* CHEMICALS AND CONSUMPTION
FUNCTION
NAME
PRINCIPAL CONSTITUENT
CONSUMPTION
POINT OF ADDITION
** FGD SPARE CAPACITY INDICES
ABSORBER - X
MIST ELIMINATOR - X
FAN 7.
BALL MILL - X
RECIRCULATION PUMP - X
THICKENER - 7.
VACUUM FILTER - X
»* FGD SPARE COMPONENT INDICES
ABSORBER
MIST ELIMINATOR
FAN
BALL MILL
RECIRCULATION PUMP
THICKENER
VACUUM FILTER
FABRIC REINFORCED
ABSORBER BLEED
328 GPM, 7X SOLIDS
66 GPM, 30X SOLIDS
298 GPM, 2.5X SOLIDS
FILTRATION
MAKEUP
39.9
70.0
( 44.0 TPH)
STABILIZATION
PUG MILL
RESEARCH-COTTRELL
60.0
FINAL
LANDFILL
ON-SITE
TRUCK
CLAY LINING
ZS ACRES
3
PH
FLOW, DENSITY
AUTOMATIC
FEED FORWARD
CLOSED
ABSORBENT
LIMESTONE
CALCIUM
130 TON/DAY
BALL MILL
50.0
.0
50.0
100.0
50.0
.0
.0
1.0
.0
.0
1.0
1.0
.0
.0
13-424
-------
UTILITY FGD SURVEY; OCTOBER 1983 - SEPTEMBER
HOUSTON LIGHTING & POWER: w.A. PARISH 8 (CONT.)
PERFORMANCE DATA-
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
10/82 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT INITIAL START-UP OF THE FGD SYSTEM OCCURRED
DURING OCTOBER, 1982.
11/82 SYSTEM 720
12/82 SYSTEM 744
1/83 SYSTEM 744
2/83 SYSTEM 672
3/83 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT IS PRESENTLY IN THE SHAKEDOWN/DEBUGGING PHASE OF OPERATION.
4/83 SYSTEM 720
5/83 SYSTEM 744
6/83 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE SECOND QUARTER OF 1983.
7/83 SYSTEM 744
8/83 SYSTEM 744
9/83 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE THIRD QUARTER OF 1983.
10/83 SYSTEM 744
11/83 SYSTEM 720
12/83 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE FOURTH QUARTER OF 1983.
1/84 SYSTEM 744
2/84 SYSTEM 696
3/84 SYSTEM 744
4/84 SYSTEM 720
5/84 SYSTEM 744
13-425
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
HOUSTON LIGHTING & POWER: w.A. PARISH 8 (CONT.)
_____ -PERFORMANCE DATA _
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
SQZ PART. HOURS HOURS HOURS FACTOR
6/84 SYSTEM 720
7/84 SYSTEM 744
8/84 SYSTEM 744
9/84 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT DURING THE PERIOD OF JANUARY THROUGH SEPTEMBER
1984, EIGHT MIST ELIMINATORS WERE REPLACED. A UNIT TRIP OCCURRED CAUSING A
LOSS OF AUXILIARY POWER AND A SUBSEQUENT INABILITY TO BYPASS THE FGD
SYSTEM. AS A RESULT, THE EXTREME HIGH TEMPERATURE FLUE GAS ENTERED THE
MIST ELIMINATORS AND BURNED THEM OUT. NO DAMAGE WAS REPORTED TO OTHER
EQUIPMENT DOWSTREAM.
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
SECTION 13
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
INDIANAPOLIS POWER fc LIGHT
PETERSBURG
3
PETERSBURG
INDIANA
.100 LB/MMBTU)
.200 LB/MMBTU)
.700 LB/MMBTU)
516.
301.
1180
533
515
528
532
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
1061.77 (2250000 ACFM)
137.2 ( 279 F)
188. ( 616 FT)
CONCRETE
6.1 ( 20.0 FT)
*# 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
** MECHANICAL COLLECTOR
NUMBER
TYPE
*# ESP
NUMBER
NUMBER OF SPARES
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
TRADE NAME/COMMON NAME
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
*** FGD SYSTEM
COAL
BITUMINOUS
25004. ( 10750 BTU/LB)
10200-11000
10.50
S-12
10.75
10.5-16.5
3.25
2.8-4.5
»*»*****
******
0
NONE
Z
0
COLD SIDE
RESEARCH-COTTRELL
464.1 ( 983500 ACFM)
137.2 ( 279 F)
.4 ( 2. IN-H20)
99.3
0
NONE
N/A
N/A
N/A
N/A
N/A
N/A
N/A
13-427
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
INDIANAPOLIS POWER & LIGHTS PETERSBURG 3 (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.
ENERGY CONSUMPTION - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
DESIGN COAL SULFER CONTENT - X
DESIGN COAL HEAT CONTENT - J/G
DESIGN COAL ASH CONTENT - X
DESIGN MOISTURE CONTENT - X
DESIGN CHLORIDE CONTENT - X
OPER. « MAINT. REQUIREMENT - MANHR/DAY
** QUENCHER/PRESATURATOR
NUMBER
TYPE
SUPPLIER
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
LIQUID RECIRCULATION RATE - LITERS/S
L/G RATIO - L/CU. M
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
NONE
AIR CORRECTION DIVISION, UOP
GIBBS & HILL
FULL SCALE
NEW
7. 99.30
85.00
Z. 4
1
12/77
12/77
1/75
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
NUMBER OF SPARES PER SYSTEM
NUMBER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
( 10750 BTU/LB)
4.50
25004.5
15.00
12.00
.06
120.0
HORIZONTAL SPRAY CHAMBER
AIR CORRECTION DIVISION, UOP
265.44
137.8
16.
.1
CARBON STEEL
AISI 1110
( 562500 ACFM)
( 280 F)
( 250 GPM)
( .4 GAL/1000 ACFM)
** ABSORBER
NUMBER
N'JKSER 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
SUFERFICAL GAS VELOCITY - M/SEC
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE C
302 REMOVAL EFFICIENCY - X
PARTICLE REMOVAL EFFICENCY - X
4
0
PACKED TOWER
MOBILE BED PACKING
TURBULENT CONTACT ABSORBER
AIR CORRECTION DIVISION, UOP
30.0 X 30.0 X 100.0
CARBON STEEL
AISI 1110
N/A
ORGANIC
SYNTHETIC RUBBER
NEOPRENE LS-576
GRIDS
3
30.5
1386.
7.8
2.1
4.4
176.96
47.8
80.0
99.0
( 12.0IN)
(22000 GPM)
( 58.7 GAL/1000 ACF)
( 8.5 IN-H20)
( 14.5 FT/S)
( 375000 ACFM)
( 118 F)
PRIMARY COLLECTOR
8
0
2
IMPINGEMENT
BAFFLE
CLOSED VANE
13-428
-------
UTILITY FGD SURVEY? OCTOBER 1983 - SEPTEMBER 1984
INDIANAPOLIS POWER 4 LIGHT: PETERSBURG 3 (CONT. )
MANUFACTURER
CONFIGURATION
NUMBER OF PASSES PER STAGE
FREEBOARD DISTANCE - M
VAHE ANGLES - DEGREES
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
WASH WATER SOURCE
WASH FREQUENCY
«* REHEATER
NUMBER
NUMBER OF SPARES
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
LOCATION
PERCENT GAS BYPASSED - AVG
TEMPERATURE INCREASE - C
INLET FLUE GAS FLOW RATE - CU. M/S
INLET FLUE GAS TEMPERATURE - C
OUTLET FLUE GAS FLOW RATE - CU. M/S
OUTLET FLUE GAS TEMPERATURE - C
NUMBER OF HEAT EXCHANGER BANKS
NUMBER OF BUNDLES PER BANK
NUMBER OF TUBES PER BUNDLE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC 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
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
MODULATION
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
»* DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
MODULATION
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
STRUCTURE-LITE [UOP HAS PATENT]
HORIZONTAL
3
.91 ( 3.0 FT)
90
ORGANIC
FIBER-REINFORCED POLYESTER
THICKENER OVERFLOW, MAKEUP, TRAP-OUT TRAY RETURN
CONTINUOUS
2
0
INDIRECT HOT AIR
EXTERNAL HEAT EXCHANGER
STEAM TUBE BUNDLE
EXTERNAL
.0
16.7 ( 30 F)
149.59 ( 317000 ACFM)
47.8 ( 118 F)
74.80 ( 158500 ACFM)
64.4 ( 148 F)
1
1
565
CARBON STEEL
AISI 1110
2
0
CENTRIFUGAL
WESTINGHOUSE
BOOSTER
FORCED DRAFT
DRY
224.15
137.2
CARBON STEEL
( 475000 ACFM)
( 279 F)
2
CONTROL
GUILLOTINE
SIDE-ENTRY GUILLOTINE
ANDCO
OPEN/CLOSED
CARBON STEEL; HIGH ALLOY CSEALSI
AISI 1110; IRON BASE/NICKEL-CHROMIUn-COPPER-MOLY
NONE
N/A
SHUT-OFF
GUILLOTINE
NR
ANDCO
OPEN/CLOSED
CARBON STEEL; HIGH ALLOY CSEALSI
AISI 1110; IRON BASE/NICKEL-CHROMIUM-COPPER-MOLY
NONE
N/A
SHUT-OFF
GUILLOTINE
NR
ANDCO
13-429
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
INDIANAPOLIS POWER 4 LIGHT: PETERSBURG 3 (CONT.)
MODULATION
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
MODULATION
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
MODULATION
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
MODULATION
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
CONFIGURATION
DIMENSIONS
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
CONFIGURATION
DIMENSIONS
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
CONFIGURATION
DIMENSIONS
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
OPEN/CLOSED
CARBON STEEL; HIGH ALLOY ISEALSI
AISI 1110; IRON BASE/NICKEL-CHROMIUM-COPPER-MOLY
NONE
N/A
SHUT-OFF
GUILLOTINE
NR
MOSSER
OPEN/CLOSED
CARBON STEEL; HIGH ALLOY [SEALS:
AISI 1110; IRON BASE/NICKEL-CHROMIUM-COPPER-MOLY
NONE
N/A
SHUT-OFF
GUILLOTINE
NR
ANDCO
OPEN/CLOSED
CARBON STEEL; HIGH ALLOY CSEALSI
AISI 1110; IRON BASE/NICKEL-CHROMIUW-COPPER-MOLY
NONE
N/A
SHUT-OFF
GUILLOTINE
NR
ANDCO
OPEN/CLOSED
CARBON STEEL; HIGH ALLOY ISEALSJ
AISI 1110; IRON BASE/NICKEL-CHROMIUM-COPPER-MOLY
NONE
N/A
SCRUBBER INLET
CIRCULAR
16 FT DIA
CARBON STEEL
AISI 1110
NONE
N/A
SCRUBBER OUTLET
CIRCULAR
18 FT DIA
CARBON STEEL
AISI 1110
ORGANIC
GLASS FLAKE-FILLED POLYESTER
BYPASS
RECTANGULAR
16 FT X 20 FT
CARBON STEEL
AISI 1110
ORGANIC
GLASS FUKE-FILLED POLYESTER
13-430
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
INDIANAPOLIS POWER i LIGHT: PETERSBURG 3 (CONT.)
»* REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
MANUFACTURER
NUMBER
NUMBER OF SPARES
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
PRODUCT QUALITY - X SOLIDS
** TANKS
SERVICE
REAGENT PREP PRODUCT
WASTE SLURRY BLEED
ABSORBER RECYCLE
THICKENER OVERFLOW
SLURRY TRANSFER
ME WASH
** PUMPS
SERVICE
WET BALL MILL
COMPARTMENTED
NR
KENNEDY VAN SAUN
1
0
38.1
35.0
NUMBER
2
1
4
1
1
1
( 42 TPH)
NUMBER
ABSORBER RECIRCULATION 12
SLURRY TRANSFER 2
WASTE SLURRY 4
WASTE SLURRY BOOSTER 2
THICKENER UNDERFLOW 2
RECLAIMED WATER [THICKENER OVERFLOW] 2
ME WASH 2
SEAL WATER 3
REHEATER CONDENSATE RETURN 2
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
CONFIGURATION
DIMENSIONS - FT
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
BELT GENERIC MATERIAL TYPE
BELT SPECIFIC MATERIAL TYPE
FEED STREAM SOURCE
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
OUTLET STREAM DISPOSITION
OVERFLOW STREAM DISPOSITION
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
DIMENSIONS - FT
CAPACITY
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
OUTLET STREAM DISPOSITION
OVERFLOW STREAM DISPOSITION
*** SLUDGE
FULL LOAD SLUDGE QUANTITY - M.TONS/HR (DRY) 38.1
VACUUM FILTER
2
0
HORIZONTAL
10 DIA X 20.5
CARBON STEEL
AISI 1110
ORGANIC
COAL TAR EPOXY
ORGANIC
POLYPROPYLENE
THICKENER UNDERFLOW
28X SOLIDS
55X SOLIDS
SLUDGE STABILIZATION
RETURNED TO SYSTEM
THICKENER
1
0
165 DIA X 12
2000000
CARBON STEEL [WALLS]; INORGANIC [BOTTOM]
AISI 1110; HYDRAULICALLY-BONDED CONCRETE
ORGANIC
COAL TAR EPOXY
7-15X SOLIDS
28X SOLIDS
TO VACUUM FILTER
TO QUENCHER, ME WASH TANK, BALL MILL, RECYCLE TA
42.0 TPH)
13-431
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 198*
INDIANAPOLIS POWER 4 LIGHT: PETERSBURG 3 (CONT.)
** TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
INLET QUALITY - X
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE TREATMENT
SITE SERVICE LIFE - YRS
»* PROCESS CONTROL AND INSTRUMENTATION
PROCESS STREAM
CHEMICAL PARAMETERS
PHYSICAL VARIABLES
CONTROL LEVELS
MONITOR TYPE
MONITOR LOCATION
PROCESS CONTROL MANNER
PROCESS CHEMISTRY MODE
** WATER BALANCE
WATER LOOP TYPE
RECEIVING WATER STREAM
MAKEUP WATER ADDITION - LITERS/S
SOURCE OF MAKEUP WATER
** CHEMICALS AND CONSUMPTION
FUNCTION
NAME
PRINCIPAL CONSTITUENT
SOURCE/SUPPLIER
CONSUMPTION
UTILIZATION - X
POINT OF ADDITION
*» FGD SPARE CAPACITY INDICES
ABSORBER - X
MIST ELIMINATOR - X
REHEATER X
FAN - X
BALL MILL X
VACUUM FILTER - X
«* FGD SPARE COMPONENT INDICES
ABSOPBER
MIST ELIMINATOR
REHEATER
FAN
BALL MILL
EFFLUENT HOLD TANK
RECIRCULATION PUMP
THICKENER
VACUUM FILTER
FIXATION
PUG MILL
CONVERSION SYSTEMS CPOZ-0-TEC!
60.0
FINAL
LANDFILL
ON-SITE
TRUCK
NONE
8
ABSORBER RECYCLE
PH, INLET S02, OUTLET SO AT STACK
FLUE GAS OUTLET FLOW
PH 5.5-5.9
LEEDS & NORTHRUP
RECYCLE SLURRY LINE
MANUAL
FEEDBACK
CLOSED
NONE
55.6
RIVER WATER
( 882 GPM)
ABSORBENT
LIMESTONE
96X CAC03, 3X MGC03
SOUTHERN INDIANA QUARRY
500 TPD
83.0
BALL MILL
.0
.0
.0
.0
.0
50.0
.0
.0
.0
.0
.0
.0
.5
.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 744
13-432
-------
UTILITY FGO SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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
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 WERE
CONSTRUCTED AROUND SOME FGD COMPONENTS. THESE ENCLOSURES WILL BE
REMOVED WHEN INSTALLATION OF HEAT TRACING CAN BE COMPLETED.
1/78 SYSTEM 744 0
** PROBLEMS/SOLUTIONS/COMMENTS
INSTALLATION OF HEAT TRACING ON FGD SYSTEM COMPONENTS WAS COMPLETED
DURING THE PERIOD.
2/78 SYSTEM 672 0
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS TAKEN OFF LINE ON FEBRUARY 24 TO ALLOW CORRECTION OF
THE PROBLEMS ASSOCIATED WITH THE FLYASH REMOVAL SYSTEM.
PIPE AND VALVE FREEZE-UP DAMAGE WAS ENCOUNTERED AND REPAIRED.
REPAIRS WERE MADE ON THE ISOLATION DAMPERS.
3/78 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
INSULATION WAS INSTALLED ON FGD SYSTEM COMPONENTS DURING A SCHDEULED
SYSTEM OUTAGE.
A BROKEN PINION GEAR IN THE THICKENER WAS REPAIRED DURING THE SYSTEM
OUTAGE.
INSTRUMENTATION MAINTENANCE WAS PERFORMED DURING THE SYSTEM OUTAGE.
PROBLEMS WITH THE FLYASH HANDLING SYSTEM HAVE NOT YET BEEN SOLVED.
4/78 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS PUT BACK ON LINE IN MID-APRIL.
ALL CONTROL VALVES WERE RETURNED TO THE FACTORY FOR MODIFICATIONS. BOTH
CONTROL VALVES AND PIPING HAVE BEEN PROBLEM AREAS FOR THIS SYSTEM.
5/78 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE MAIN POWER TRANSFORMER FAULTED CAUSING THE SYSTEM TO SHUTDOWN.
6/78 SYSTEM 720
13-433
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
INDIANAPOLIS POWER 4 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 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 WERE EXPERIENCED.
AN S02 COMPLIANCE TEST WAS INVALID DUE TO BYPASS DAMPER PROBLEMS.
11/78 SYSTEM 7ZO
** 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
** 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. T/.
C MODULE 34.67.
D MODULE 34.IX
SYSTEM 28.IX
REPORTED FGD SYSTEM HOURS FOR THIS PERIOD WERE 562, 551, 880 AND 868 FOR
MODULES A, B, C AND D RESPECTIVELY.
1/79 SYSTEM 744
13-434
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
INDIANAPOLIS POWER 4 LIGHT: PETERSBURG 3 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGO SYSTEM WAS SHUTDOWN ON JANUARY 1, 1979 AS A RESULT OF SEVERE
WINTER 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
8/79 SYSTEM 744
9/79 SYSTEM .0 720 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS SHUTDOWN FOR A SCHEDULED BOILER AND SCRUBBER OVERHAUL IN
SEPTEMBER.
10/79 SYSTEM .0 744 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS DOWN FOR A SCHEDULED BOILER/TUPBINE/FGD SYSTEM OUTAGE FOR FOUR
WEEKS. THE UNIT STARTED UP AGAIN AFTER THE OUTAGE BUT HAD TO SHUTDOWN
AFTER ONLY A FEW DAYS BECAUSE OF BOILER PROBLEMS.
13-435
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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
INSTRUMENTATION IS A CONTINUING PROBLEM. THE MODULE PRESSURE MONITORS,
AND SOS AND PH MONITORS ARE ALL INOPERATIVE. THE UTILITY HAS BEEN UNABLE
TO KEEP THE FGD SYSTEM ON LINE FOR MORE THAN 10 DAYS WITHOUT HAVING AT
LEAST ONE MODULE FORCED OUT OF SERVICE.
11/79 SYSTEM 720 360
*# PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT CAME BACK ON LINE AGAIN IN MID-NOVEMBER AFTER RESOLUTION OF
BOILER PROBLEMS.
12/79 SYSTEM 744
»* PROBLEMS/SOLUTIONS/COMHENTS
DURING THE FOURTH QUARTER THE UTILITY REPORTED THAT THERE WERE NO NEW
MAJOR PROBLEMS.
1/80 SYSTEM 744
3/80 SYSTEM 696
3/80 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE FIRST QUARTER OF 1980, THE ENTIRE SCRUBBER PACKING BED WAS LOST
DUE TO EXCESSIVE WEAR OF THE NEOPRENE FOAM PACKING BALLS. THE UNIT
WILL BE TAKEN OFF LINE IN APRIL TO ACCOMODATE NECESSARY REPAIRS AND
REPLACEMENT OF THE BALLS.
BYPASS DAMPER FAILURES ALSO OCCURRED AND ARE REPORTED TO BE A CONTINUAL
PROBLEM. MODIFICATIONS WERE MADE TO THE SULLOTINE TYPE DAMPERS DURING
THE PERIOD.
4/80 SYSTEM 720
5/80 SYSTEM 744
6/80 SYSTEM 720
»* 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 720
12/80 SYSTEM 744
13-436
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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 UTILITY REPORTED THAT OPERATIONAL DATA FOR FGD OPERATIONS AT PETERS-
BURG 3 ARE STILL UNAVAILABLE FOR RELEASE.
1/81 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JANUARY, ALL OF THE PACKING SPHERES WERE REMOVED FROM THE FOUR
ABSORBER MODULES. THE SUPPORTING GRIDS WERE LEFT INTACT AND THE MODULES
ARE BEING UTILIZED AS GRID TOWERS.
ALSO DURING JANUARY, REPAIRS TO FREEZE DAMAGED PIPING WERE COMPLETED. THE
FRP RECLAIM WATER PIPING WAS RESET IN PLACES WHERE IT HAD PULLED APART AND
THE WASTE SLURRY AND SLUDGE TREATMENT WATER LINES WERE THAWED. SOME PIPING
GASKETS AND HEAT TRACING CIRCUITS WERE REPAIRED AND UPGRADED. IN ADDITION,
SOME DRAIN VALVES WERE ADDED TO IMPROVE THE CAPABILITY TO DRAIN PIPING AND
AVOID FUTURE FREEZE DAMAGE.
2/81 SYSTEM 672
3/81 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE FIRST QUARTER, PUMP REPAIRS INCLUDED REBUILDING THE CASING OF A
MIST ELIMINATOR WASH PUMP, OVERHAULING A RECYCLE PUMP, AND REPAIRING ONE
RECLAIM WATER PUMP AND MOTOR.
4/81 SYSTEM 720
5/81 SYSTEM 744
6/81 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE SECOND QUARTER, REMAINING PORTIONS OF THE FRP RECLAIM WATER
PIPING WERE RESET AND ALIGNED.
SCALE FORMATION WAS REMOVED FROM ALL MIST ELIMINATOR ASSEMBLIES DURING THE
SECOND QUARTER.
THE GUNNITE LINING IN THE PRESATURATOR DUCT SECTIONS OF THE FOUR ABSORBER
MODULES WERE REPLACED DURING THE THREE MONTH PERIOD.
7/81 SYSTEM 744
8/81 SYSTEM 744
9/81 SYSTEM 720
10/81 SYSTEM 744
11/81 SYSTEM 720
12/81 SYSTEM 744
1/82 SYSTEM 744
2/82 SYSTEM 672
3/82 SYSTEM 744
13-437
-------
UTILITY F6D SURVEYS OCTOBER 1983 - SEPTEMBER 198*
INDIANAPOLIS POWER & LIGHT: PETERSBURG 3 (CONT.J
... _ .._. ,.___... .PERFORMANCE DATA- .
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
n~^.en~«> = => = = O. n. _==».!>=>=,<»=> = =. »> >=c <__0=, =>__.= «=. 0= «» OE> CK en, K> OB CD = <= a. _ of «. « ______ _ _ ^ _ _ on
-------
UTILITY FGD SURVEY? OCTOBER 1983 - SEPTEMBER 1984
INDIANAPOLIS POWER S LIGHT: PETERSBURG 3 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
4/84 SYSTEM 7ZO
5/84 SYSTEM 744
6/84 SYSTEM 720
7/84 SYSTEM 744
8/84 SYSTEM 744
9/84 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS NOT AVAILABLE FOR THE PERIOD OF JANUARY THROUGH
SEPTEMBER OF 1984.
13-439
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
SECTION 13
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 - HW
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGO - 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
NUMBER
TYPE
** ESP
NUMBER
TYPE
*» PARTICLE SCRUBBER
NUMBER
NUMBER OF SPARES
INITIAL START-UP DATE
GENERIC TYPE
SPECIFIC TYPE
TR^DE NAME/COMMON NAME
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
PH CONTROL ADDITIVE
PRESSURE DROP - KPA
SUPERFICIAL GAS VELOCITY M/S
KANSAS CITY POWER & LIGHT
LA CYGNE
LA CYGNE
KANSAS
I
55.
1290.
( .128 LB/MMBTU)
( 3.000 LB/MMBTU)
(»***** LB/MMBTUJ
1450
874
820
848
874
BABCOCK & MILCOX
CYCLONE
BASE
1302.44
140.6
213.
CONCRETE
7.0
(2760000 ACFM)
( 285 F)
C 700 FT)
( 23.0 FT)
( 9400 BTU/LB)
9000-9700
COAL
SUBBITUMINOUS
21864.
25.00
25.0-35.0
8.60
9.0-10.0
5.39
5.0-6.0
.03
0.02-0.03
0
NONE
0
NONE
8
0
2/73
VENTURI TOWER
VARIABLE-THROAT/SIDE-MOVABLE BLOCKS
N/A
BABCOCK & WILCOX
18.0 X 22.0
STAINLESS STEEL
AUSTENITIC
INORGANIC
HYDRAULICALLY-BONDED MORTAR
NONE
315.0
1.9
LIMESTONE
2.5
48.8
( 5000 GPM)
(14.5 GAL/1000ACF)
(10.0 IN-H20)
( 160.0 FT/S)
13-440
-------
UTILITY FSO SURVEY: OCTOBER 1983 - SEPTEMBER 1984
ICANSAS CITY POWER t LIGHT: LA CYGNE 1 CCONT.)
INLET GAS FLOW RATE - CU.tt/S
INLET GAS TEMPERATURE - C
S02 REMOVAL EFFICENCY - 7.
PARTICLE REMOVAL EFFICIENCY - X
»*« FGD SYSTEM
M 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
ENERGY CONSUMPTION - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
SPACE REQUIREMENTS - SQ M
OPER. 4 MAINT. REQUIREMENT - MANHR/DAY
« WENCH ER/PRESATURATOR
NUMBER
** ABSORBER
NUMBER
NUMBER OF SPARES
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
SUPPLIER
DIMENSION'S - 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 CF CONTACTING ZONES
DISTANCE BETWEEN GAS CONTACTING ZONES - CM
LIQUID RECIRCULATICN 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
502 REMOVAL EFFICIENCY - X
PARTICLE REMOVAL EFFICENCY - 7.
162.8
140.6
22,0
95.0
( 345000 ACFM)
t £85 F)
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
NONE
BABCOCK & WILCOX
BLACK 4 VEATCH
FULL SCALE
NEW
7. 99.00
80.00
3.2
1
6/73
12/72
3/71
18765.8
300.0
( 202000
FT)
8
0
TRAY TOWER
SIEVE TRAY
N/A
BABCOCK 4 WILCOX
32.0 X 16.0 X 65
STAINLESS STEEL
AUSTENITIC
TYPE 316L
NONE
N/A
N/A
PERFORATED TRAYS
2
121.9
630.
5.6
.7
2.6
112.55
50.0
80.0
95.0
( 48.0IN)
(10000 GFM)
( 41.9 GAL/1000 ACF)
( 3.0 IN-H20)
( 8.5 FT/S)
( 238500 ACFM)
( 122 F)
** HIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
NUMBER OF SPARES PER SYSTEM
NUMBER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
mf."JFACTU=ER
CONFIGURATION
NVMBEP OF STAGES
NUMBER OF PASSES PER STAGE
FPEEEOAC3 DISTANCE - M
SUPERFICAL GAS VELOCITY - M/S
PRECOLLECTOR
8
0
1
BULK SEPARATION
PERFORATED TRAYS
SIEVE TRAY
BAECOCK 4 WILCOX
HCRIZCNTAL
1
1
1.68 (
2.6 (
5.5 FT)
8.5 FT/S)
13-441
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
KANSAS CITY POWER & LIGHT: LA CYGNE 1 (CONT.)
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
WASH WATER SOURCE
WASH FREQUENCY
** REHEATER
NUMBER
NUMBER OF SPARES
NUMBER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
LOCATION
PERCENT GAS BYPASSED - AVG
TEMPERATURE INCREASE - C
INLET FLUE GAS FLOW RATE - CU. M/S
INLET FLUE GAS TEMPERATURE - C
OUTLET FLUE GAS TEMPERATURE - C
NUMBER OF HEAT EXCHANGER BANKS
NUMBER OF BUNDLES PER BANK
NUMBER OF TUBES PER BUNDLE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** FANS
NUMBER
NUMBER OF SPARES
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
CONSTRUCTION MATERIAL GENERIC TYPE
** FANS
NUMBER
NUMBER OF SPARES
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
PRESSURE DROP - KPA
CONSTRUCTION MATERIAL GENERIC TYPE
»* DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
MODULATION
SEAL AIR FLOW - CU. M/S
SERVICE CONDITIONS
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
#* DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
MODULATION
SEAL AIR FLOW - CU. M/S
SERVICE CONDITIONS
STAINLESS STEEL
AUSTENITIC
NONE
N/A
0
1
IN-LINE
STEAM
BARE TUBE
TOP OF ABSORBER VESSEL
.0
( 30 F)
( 238500 ACFM)
( 122 F)
16.7 i
112.55
50.0
66.7
4
4
32
STAINLESS STEEL
AUSTENITIC
6
0
CENTRIFUGAL
WESTINGHOUSE
UNIT
INDUCED DRAFT
DRY
207.64
66.7
7.0
CARBON STEEL
152 F)
( 440000 ACFM)
( 152 F)
(23.0 IN-H20)
3
0
CENTRIFUGAL
WESTINGHOUSE
UNIT
FORCED DRAFT
DRY
6.1
CARBON STEEL
(20.0 IN-H20)
6
CONTROL
LOUVER
PARALLEL BLADE MULTILOUVER
NR
OPEN/CLOSED
.00 ( 0 ACFM)
285
CARBON STEEL
AISI 1110
NONE
N/A
8
CONTROL
LOUVER
PARALLEL BLADE MULTILOUVER
AIR CLEAN
NR
.00 ( 0 ACFM)
122
13-442
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
KANSAS CITY POWER & LIGHT: LA CYGNE 1 (CONT.)
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
»» DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
MODULATION
SEAL AIR FLOW - CU. M/S
SERVICE CONDITIONS
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
*» DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
MODULATION
SEAL AIR FLOW - CU. M/S
SERVICE CONDITIONS
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
MODULATION
SEAL AIR FLOW - CU. M/S
SERVICE CONDITIONS
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
CONFIGURATION
DIMENSIONS
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
CONFIGURATION
DIMENSIONS
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
»* DUCTWORK
LOCATION
CONFIGURATION
DIMENSIONS
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
STAINLESS STEEL
AUSTENITIC
NONE
N/A
8
SHUT-OFF
BUTTERFLY
N/A
NR
OPEN/CLOSED
.00 ( 0 ACFM)
NR
CARBON STEEL
AISI 1110
NONE
N/A
SHUT-OFF
LOUVER
PARALLEL BLADE MULTILOUVER
NR
OPEN/CLOSED
.00 ( 0 ACFM)
175
STAINLESS STEEL
AUSTENITIC
NONE
N/A
SHUT-OFF
LOUVER
PARALLEL BLADE MULTILOUVER
NR
OPEN/CLOSED
.00 ( 0 ACFM)
NR
CARBON STEEL
AISI 1110
NONE
N/A
INLET
CIRCULAR, RECTANGULAR
20 FT DIA, 10.5 FT X 10.5 FT
CARBON STEEL
AISI 1110
NONE
N/A
BREECHING TO STACK
CIRCULAR
20 FT DIA
CARBON STEEL
AISI 1110
ORGANIC
INERT FLAKE-FILLED VINYL ESTER
OUTLET
CIRCULAR, RECTANGULAR
12 FT DIA, 13 FT X 13 FT
CARBON STEEL
AISI 1110
-------
UTILITY F6D SURVEY: OCTOBER 1983 - SEPTEMBER 1984
KANSAS CITY POHER & LIGHT: LA CYGNE 1 (CONT.)
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
MANUFACTURER
NUMBER
NUKSER OF SPARES
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
PRODUCT QUALITY - X SOLIDS
#* TANKS
SERVICE
REAGENT PREP PRODUCT 1
ABSORBER RECYCLE
REAGENT PREP PRODUCT Z
SLURRY BOOSTER HOLD
** PUMPS
SERVICE
POND RETURN
SLURRY FEED
ABSORBER RECIRCULATION
SCRUE3ER RECIRCULATION
CLASSIFIER FEED
SPENT SLURRY BOOSTER
RECIRCULATION TANK DRAIN
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
*** SLUDGE
MOISTURE CONTENT - X TOTAL FREE WATER
** TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE TREATMENT
SITE DIMENSIONS
SITE CAPACITY - CU.M
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE TREATMENT
SITE DIMENSIONS
SITE CAPACITY - CU.M
SITE SERVICE LIFE - YRS
** PROCESS CONTROL AND INSTRUMENTATION
PROCESS STREAM
CHEMICAL PARAMETERS
CONTROL LEVELS
MONITOR TYPE
MONITOR LOCATION
PROCESS CONTROL MANNER
ORGANIC
INERT FLAKE-FILLED VINYL ESTER
WET BALL MILL
COMPARTMENTED
NR
KOPPERS HARDINGE
2
1
99.9 ( 110 TPH)
20.0
NUMBER
Z
&
Z
1
NUMBER
Z
Z
8
8
4
Z
1
NONE
76.0
BLEED
N/A
N/A
FINAL
POUD
OH-SITE
PIPELINE
NONE
160 ACRES Y.
2152480
FINAL
POND
ON-SITE
PIPELINE
NONE
500 ACRES X
6726500
10
11 FT DEEP
( 1760.0 ACRE-FT)
11 FT DEEP
( 5500.0 ACRE-FT)
VENTURI
PH
PH 5.6-5.8
UNILOC
VENTURI INLET
AUTOMATIC
-------
UTILITY F6D SURVEY: OCTOBER 1983 - SEPTEMBER 1984
KANSAS CITY POWER & LIGHT: LA CYGNE 1 (CONT.)
PROCESS CHEMISTRY MODE FEEDBACK
»* MATER BALANCE
MATER LOOP TYPE
MAKEUP WATER ADDITION - LITERS/S
** CHEMICALS AND CONSUMPTION
FUNCTION
NAME
PRINCIPAL CONSTITUENT
SOURCE/SUPPLIER
CONSUMPTION
POINT OF ADDITION
»* FGD SPARE CAPACITY INDICES
SCRUBBER - X
ABSORBER - X
MIST ELIMINATOR - X
REHEATER - X
FAN - X
BALL MILL - X
EFFLUENT HOLD TANK -
RECIRCULATION PUMP -
** FGD SPARE COMPONENT INDICES
SCRUBBER
ABSORBER
MIST ELIMINATOR
REHEATER
FAN
BALL MILL
EFFLUENT HOLD TANK
RECIRCULATION PUMP
OPEN
72.3
( 1148 GPM)
ABSORBENT
LIMESTONE
91X CAC03, IX MGC03
BATES COUNTY ROCK [SUPPLIER]
81 TPH MAX., 70 TPH TYPICAL
BALL MILL
.0
.0
.0
.0
17.0
100.0
.0
.0
.0
.0
.0
.0
1.0
1.0
.0
.0
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL
S02 PART.
PER BOILER FGD CAP.
HOURS HOURS HOURS FACTOR
12/72 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
6/73 A
B
C
D
E
F
G
SYSTEM
7/73 A
B
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
AND 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.
20.0
21.0
40.0
21.0
27.0
30.0
23.0
64.0 26.0 720 294 187 15.2
7.0
24.0
13-445
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
KANSAS CITY POWER & LIGHT: LA CYGNE 1 (CONT.)
PERIOD
8/73
9/73
10/73
11/73
12/73
MODULE AVAILABILITY
C
D
E
F
6
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
A
B
C
E
D
F
G
SYSTEM
--^tKI-UKnANUE DAI A
OPERABILITY RELIABILITY UTILIZATION
25.0
41. 0
27.0
25.0
31.0
64.0 26.0
79.0
64.0
65.0
74.0
47.0
48.0
70.0
68.0 64.0
13.0
.0
13.0
13.0
13.0
.0
.0
53.0 7.0
28.0
41.0
34.0
54.0
33.0
3.0
46.0
56.0 34.0
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
744 303 195 15.2
744 699 476 42.1
720 95 50 3.5
744 452 253 19.7
720 463 266 18.1
744 339 179 10.3
0/74 SYSTEM
1/74
** PROBLEMS/SOLUTIONS/COMMENTS
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
13-446
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
KANSAS CITY POWER & LIGHT: LA CYGNE 1 (CONT.)
PERIOD
2/74
3/74
MODULE AVAILABILITY
E
F
G
SYSTEM
A
B
C
0
E
F
G
SYSTEM
SYSTEM
OPERABILITY RELIABILITY UTILIZATION
23.0
37.0
81.0
50.0 24.0
66.0
68.0
59.0
76.0
52.0
100.0
65.0
69.0 37.0
.0
X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
744 364 182 6.0
672 364 251 16.0
744 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
E
F'
G
SYSTEM
6/74 A
B
C
D
E
F
G
SYSTEM
7/74 A
B
C
D
E
F
G
SYSTEM
8/74 A
B
C
D
E
F
G
SYSTEM
67.0
70.0
75.0
88.0
74.0
100.0
88.0
80.0
69.0
83.0
78.0
85.0
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
37.0
720 332
266 15.0
54.0
744 500
400 27.0
57.0
720 480
413 32.0
34.0
744 313
250 19.0
65.0
744 571
485 39.0
13-447
-------
UTILITY F6D SURVEY' OCTOBER 1983 - SEPTEMBER 1984
KANSAS CITY POWER & LIGHT: LA CYSNE 1 (CONT.)
PERIOD
9/74
10/74
11/74
MODULE AVAILABILITY
A
B
C
D
E
F
G
SYSTEM
A
B
C
0
E
F
G
SYSTEM
A
B
C
D
E
F
G
SYSTEM
._ __._____ = __ (-'CKI-UKnAnuC UM l«-
OPERABILITY RELIABILITY UTILIZATION
69.0
88.0
73.0
76.0
83.0
89.0
86.0
81.0 63.0
71.0
61.0
59.0
81.0
79.0
93.0
89.0
76.0 68.0
90.0
71.0
60.0
61.0
84.0
85.0
84.0
76.0 41.0
X REMOVAL PER BOILER FGD CAP.
SOS PART. HOURS HOURS HOURS FACTOR
730 606 491 36.0
744 662 503 39.0
720 386 293 23.0
12/74 SYSTEM
0/75 SYSTEM
1/75
.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE 1975 FIGURES ARE BASED UPON SYSTEM AVAILABLE HOURS AS A FUNCTION OF
HOURS IN THE PERIOD.
SYSTEM 100.0
** PROBLEMS/SOLUTIONS/COMMENTS
.0
744
.0
THE BOILER HAS SHUTDOWN DURING JANUARY AND FEBRUARY FOR TURBINE/GENERATOR
REPAIR.
2/75 SYSTEM
100.0
672
.0
3/75
A
B
C
D
E
F
G
SYSTEM
82.0
96.0
90.0
77.0
93.0
92.0
96.0
89.0
744 694
41.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING REDUCED LOAD CONDITIONS SOME OF THE MODULES WERE NOT REQUIRED AND
THEREFORE SHUT DOWN ALTHOUGH THEY WERE AVAILABLE. AVAILABILITY WAS THERE-
FOR HIGHER THAN SOME OF THE POSTED FIGURES INDICATE.
4/75 SYSTEM
100.0
720
3.4
13-448
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
KANSAS CITY POWER & LIGHT: LA CYGNE 1 (CONT.
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL
S02 PART.
PER BOILER FGO CAP.
HOURS HOURS HOURS FACTOR
»* PROBLEMS/SOLUTIONS/COMMENTS
DURING APRIL THE BOILER WAS OFF LINE FOR 25 DAYS DUE TO NECESSARY GENERATOR
REPAIRS.
5/75
6/75
7/75
8/75
9/75
10/75
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
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
75.0
83.0
87.0
78.0
92.0
85.0
83.0
84.0
744 683
56.0
720 667
56.0
744 590
50.0
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
A
B
C
D
E
F
G
SYSTEM
A
B
C
D
E
F
G
SYSTEM
78.0
84.0
84.0
85.0
79.0
78.0
74.0
80.0
720 610
42.0
66.0
77.0
46.0
74.0
72.0
73.0
65.0
68.0
744 231
13.0
13-449
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
KANSAS CITY POWER * LIGHT: LA CYGNE 1 (CONTo)
_____ . ,__-____- PERFORMANCE DATA- .-__. ,
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION /? REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
11/75
A
B
C
D.
E
F
G
SYSTEM
93.0
91.0
80.0
93.0
96.0
89.0
94.0
91.0
720 346
29.0
** 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.
12/75 A
B
C
D
E
F
G
SYSTEM
91.0
87.0
81.0
85.0
87.0
89.0
64.0
86.0
744 597
47.0
** PROBLEMS/SOLUTIONS/COMMENTS
THREE BOILER OUTAGES OCCURRED DURING DECEMBER.
1/76
2/76
3/76
4/76
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
86.
85.
91.
72.
84.
82.
84.
83.
94.
90.
86.
91.
92.
93.
95.
92.
92.
90.
88.
93.
94.
91.
91.
91.
92.
91.
89.
97.
96.
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
744 621
51.0
696 595
55.0
744 643
57.0
13-450
-------
UTILITY FGD SURVEYi OCTOBER 1983 - SEPTEMBER 1984
KANSAS CITY POWER fc LIGHT: LA CYGNE 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
F
G
SYSTEM
5/76
6/76
7/76
8/76
98.0
95.0
94.0
720
13.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE SYSTEM WAS SHUT DOWN ON APRIL 6 FOR A SCHEDULED BOILER AIR PREHEATER,
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.
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.
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
** PROBLEMS/SOLUTIONS/COMMENTS
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
13-451
-------
UTILITY F6D SURVEY: OCTOBER 1983 - SEPTEMBER 198*
KANSAS CITY POWER S LIGHT: LA CYGNE 1 (CONT.)
._ PERFORMANCE DATA--
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL PER BOILER FGD CAP.
SOS PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COmEKTS
THE UNIT WAS TAKEN OUT OF SERVICE AUGUST 24 FOR REPAIR OF A TURBINE BLADE.
THE UNIT WAS RETURNED TO SERVICE ON OCTOBER 20. OPERATION WAS INTERMIT-
TENT PENDING TURBINE BLADE REBALANCING AND REESTABLISHMENT OF NORMAL
OPERATING CONDITIONS.
DURING 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 SYSTEM 100.0
** PROBLEMS/SOLUTIONS/COMMENTS
.0
720
.0
THE SYSTEM WAS DOWN DUE TO TURBINE REPAIR.
10/76
11/76
12/76
A
B
C
D
E
F
G
SYSTEM
A
B
C
D
E
F
G
SYSTEM
A
B
C
D
E
F
G
SYSTEM
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
94.0
94.0
87.0
89.0
81.0
94.0
94.0
95.0
91.0
90.0
256
15.0
720 627
59.0
744 706
60.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE A-MOOULE 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
D
E
F
G
SYSTEM
2/77 A
94.0
90.0
95.0
95.0
95.0
92.0
90.0
93.0
93.0
744 539
43.0
13-452
-------
UTILITY FGD SURVEYS OCTOBER 1983 - SEPTEMBER 1984
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 93.0
C 93.0
D 94.0
E 93.0
F 94.0
G 88.0
SYSTEM 93.0 672 590 58.0
3/77 A 94.0
B 92.0
C 66.0
D 94.0
E 91.0
F 94.0
G 90.0
SYSTEM 92.0 744 558 50.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE EIGHTH MODULE HAS BEEN INSTALLED.
THE MIST 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
MODULES. 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 PLANT.
THE PLANT IS STILL GENERATING 700-720 MW DURING THE DAY AND 500-570 MW
AT NIGHT.
4/77 A 96.0
B 94.0
C 97.0
D 94.0
E 95.0
F 96.0
G 95.0
SYSTEM 95.0 720 384 31.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE EIGHTH MODULE HAS BEEN RUN FOR TWO DAYS.
5/77 SYSTEM 100.0 .0 744 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
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
13-453
-------
UTILITY FGO SURVEY: OCTOBER 1983 - SEPTEMBER 1984
KANSAS CITY POWER & LIGHT- U 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
7/77
8/77
MINOR CLEANOUT AND REPAIR WORK WAS DONE ON THE SCRUBBING SYSTEM DURING
THE TURBINE OUTAGE.
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.
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
** PR03LEMS/SOLUTIONS/COMMENTS
PARTICLE REMOVA1 TESTS WERE CONDUCTED IN LATE AUGUST AND UNIT NO.l HAS
PASSED THE COMPLIANCE REQUIREMENTS (0.13 LB/MM BTU).
MODULE B HAD LOW AVAILABILITY DUE TO THE BURNING OF THE MOTOR ON
THE RECIRCUUTIHG PUMP. IT WAS REMOVED FROM SERVICE AND STARTED AGAIN
AFTER 12 DAYS.
9/77
10/77
A
B
C
D
E
F
G
H
SYSTEM
A
B
C
D
E
F
G
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
720 524
50.0
744 457
13-454
-------
UTILITY F6D SURVEY: OCTOBER 1983 - SEPTEMBER
KANSAS CITY POWER & LIGHT: LA CY6NE 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
12/77
1/78
2/78
3/78
A 12 DAY OUTAGE IN OCTOBER WAS REQUIRED TO DESLAG THE BOILER.
11/77 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.
A
B
C
D
E
F
G
H
SYSTEM
90.0
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.
A
B
C
D
E
f
G
H
SYSTEM
A
B
92.0
93.0
95.0
94.0
91.0
97.0
96.0
93.0
94.0
95.0
95.0
672 578
58.0
13-455
-------
UTILITY F6D SURVEY: OCTOBER 1983 - SEPTEMBER 1984
KANSAS CITY POWER & LIGHT: LA CYGNE 1 (CONT.)
-. .-PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL PER BOILER FED CAP.
S02 PART. HOURS HOURS HOURS FACTOR
4/78
C
D
E
F
G
H
SYSTEM
A
B
C
D
E
F
G
H
SYSTEM
90,0
95.0
94.0
95.0
89.0
93.0
93.0
744 741
62.0
91.0
92.0
93.0
91.0
90.0
92.0
91.0
91.0
91.0
720 620
** PROBLEMS/SOLUTIONS/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
** PROBLEMS/SOLUTIONS/COMMENTS
IN MAY THE BOILER WAS DOWN TWICE FOR A TOTAL OF 151 HOURS. OUTAGES WERE
AGAIN CAUSED BY BOILER LEAKS.
GENERAL MAINTENANCE AND REPAIRS ON THE FGD SYSTEM CONTINUED.
6/78 SYSTEM 720 15
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS UP FOR ONLY 15 HOURS IN JUNE. IN THE FIRST PART OF JUNE
THERE WERE BOILER TU5E LEAKS. FROM JUNE 8 TO JUNE 17 A BOILER OUTAGE WAS
NECESSARY FOR GENERATOR REPAIR.
7/78
8/78
A
B
C
D
E
F
G
H
SYSTEM
A
B
88.0
97.0
92.0
94.0
68.0
93.0
93.0
95.0
93.0
92.0
93.0
744 341
13-456
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
KANSAS CITY POWER t LIGHT: LA CYGNE 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
C 95.0
D 96.0
E 93.0
F 94.0
6 95.0
H 95.0
SYSTEM 94.0 744 577
** PROBLEMS/SOLOTIONS/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
G
H
SYSTEM
96.
96.
96.
96.
96.
96.
95.
97.
96.
0
0
0
0
0
0
0
0
0
720 720
*» PROBLEMS/SOLUTIONS/COMMENTS
DURING THE JULY-SEPTEMBER PERIOD TWO ID FAN ROTERS WERE REPLACED.
10/78 A 96.0
B 96.0
C 93.0
0 97.0
E 97.0
F 93.0
G 97.0
H 96.0
SYSTEM 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
D
E
F
G
H
SYSTEM
92
95
94
93
"4
93
94
96
94
.0
.0
.0
.0
.0
.0
.0
.0
.0
720 720
** FROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO UNUSUAL OPERATING PROBLEMS WERE ENCOUNTERED
DURING OCTOBER AND NOVEMBER.
U/78 A 93.9
B Oc.9
C 94.0
13-457
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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
1/79
D
E
F
G
H
SYSTEM
A
B
C
D
E
F
G
H
SYSTEM
95.0
94
98
94 4
94.7
93.8
95.6
96.5
97.2
96.3
90.7
97.2
97.2
95.4
95.8
744 239
744 205
** 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
D
E
F
G
H
SYSTEM
95.0
94.6
92.6
93.5
95.1
94.3
94.1
93.8
94.1
96.1
96.0
93.2
95.6
96.5
94.8
95.7
93.4
95.2
672 342
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 A
B
C
D
E
F
G
H
SYSTEM
5/79 A
B
C
95.5
95.7
94.4
91.4
95.5
96.2
95.9
95.7
95.0
96.5
96.3
96.7
720 638
13-458
-------
UTILITY F6D SURVEYS OCTOBER 1983 - SEPTEMBER 1984
KANSAS CITY POWER 4 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
95.3
95.4
95.7
96.3
95.5
96.0
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.
8/79
9/79
10/79
.0
7/79 SYSTEM 100.0
** PROBLEMS/SOLUTIONS/COMMENTS
.0
THE TURBINE WAS OVERHAULED DURING JULY. DURING THE OUTAGE SOME MINOR
MAINTENANCE WAS PERFORMED ON THE SCRUBBING SYSTEM.
A
B
C
D
E
F
G
H
SYSTEM
A
B
C
D
E
F
G
H
SYSTEM
86.8
95.9
96.
96.
95.
96.
88.
96.9
94.1
744 231
96.0
96.1
95.6
94.3
96.7
96.1
96.0
96.9
96.0
720 618
»* PROBLEMS/SOLUTIONS/COMMENTS
THE FGD UNITS OPERATED WITH NO MAJOR PROBLEMS AND ONLY REGULAR MAINTENANCE
WAS PERFORMED DURING AUGUST AND SEPTEMBER.
A
B
C
D
E
F
G
H
SYSTEM
95.3
95.8
94.7
92.7
94.4
94.9
94.7
94.5
94.6
H/79 SYSTEM
12/79 SYSTEM
.0
.0
.0
.0
744 436
720 0
744 0
.0
.0
13-459
-------
UTILITY FGD SURVEY'. OCTOBER 1983 - SEPTEMBER 1984
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
2/80
4/80
«« PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WENT DOWN FOR AN OVERHAUL ON OCTOBER 19 AND WAS 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 MODULES, RE-
PLACEMENT OF THE ABSORBER SIDEWALLS, REPLACEMENT OF THE MODULE OUTLET
DUCTS AND DAMPERS, AND VARIOUS DUCTWORK PATCHING.
1/80 SYSTEM
.0
.0
744
.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER AND FGD SYSTEM REMAINED UNAVAILABLE DURING JANUARY DUE TO THE
ON-GOING 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.
3/80 A
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
100.0
100.0
100.0
100.0
93.3
53.1
31.3
.0
72.3
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 HOUP.S IN MARCH AS A RESULT OF
GENERATOR/TURBINE PROBLEMS. SOME ROUTINE CLEANING AND INSPECTIONS OF THE
FGD SYSTEM WERE PERFORMED DURING THE OUTAGE TIME.
A
B
C
D
E
F
G
H
SYSTEM
96.3
95.1
95.0
96.7
95.3
92.5
97.0
97.0
95.6
94.1
78.4
97. S
93.6
86.0
76.3
68.4
62.9
82.2
94.5
91.4
92.9
94.8
92.3
87.2
93.9
93.4
92.6
61.7
51.4
63.9
61.4
56.4
50.0
44.9
41.3
53.9
720 472
388 37.6
5/80 A
96.4
89.4
96.0
84.1
13-460
-------
UTILITY F60 SURVEY: OCTOBER 1983 - SEPTEMBER
KANSAS CITY POWER & LIGHT: LA CYGNE 1 CCONT.)
----rcnruKn«r
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
KANSAS CITY POWER & LIGHT: LA CYGNE 1 (CONT.)
__ , -PERFORMANCE DATA-
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
7. REMOVAL PER BOILER FGD CAP.
303 PART. HOURS HOURS HOURS FACTOR
11/80
2/81
** 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.
A
B
C
D
E
F
G
H
SYSTEM
99.9
100.0
100.0
90.0
100.0
100.0
99.7
100.0
87.5
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
10.0
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 98.77.
DURING THIS TIME.
MODULE D WAS OUT OF SERVICE DUE TO REPAIRS CAUSED BY FIRE DAMAGE RECEIVED
ON OCTOBER 13, 1980.
12/80 A
A
B
C
D
E
F
G
H
SYSTEM
97.8
98.0
99.1
.0
98.5
98.2
95.2
98.9
85.6
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-RELATED PROBLEMS OCCURRED DURING THE
MONTH OF DECEMBER.
1/81
A
B
C
D
E
F
G
H
SYSTEM
96.
94.
94.
18.
95.
97.
96.
97.
86.
9
1
4
3
8
0
8
2
6
100
100
100
1
100
100
100
100
100
.0
.0
.0
.5
.0
.0
.0
.0
.0
96
92
93
1
94
96
96
96
83
.1
.9
.2
.1
.9
.4
.1
.6
.3
76
76
77
1
76
78
79
79
68
.5
.7
.0
.0
.9
.6
.4
.8
.3
744 465
508 62.5
99.6
100.0
99.4
72.0
13-462
-------
UTILITY F60 SURVEY: OCTOBER 1983 - SEPTEMBER 1984
KANSAS CITY POWER t LIGHT: LA CYGNE 1 (CONT.)
PERIOD MODULE
B
C
0
E
F
G
H
SYSTEM
AVAILABILITY
99.3
99. ^
99.3
99.1
99.1
99.7
99.6
99.*
OPERABILITY
100.0
99.7
100.0
93.1
92.9
95.2
100.0
100.0
RELIABILITY
98.8
99.1
99.0
98.5
93.6
99.4
99.2
99.1
UTILIZATION
68.0
65.2
72.9
60.9
60.7
62.2
66.2
66.1
/. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
672 439 444 47.3
** PROBLEMS/SOLUTIONS/COMMENTS
DURING PART OF JANUARY AND FEBRUARY MODULE D WAS OUT OF SERVICE FOR REPAIRS
DUE TO FIRE DAMAGE.
3/81 A
B
C
0
E
F
6
H
SYSTEM
97.2
97.7
95.6
96.8
97.2
97.8
97.3
97.7
100.0
96.5
100.0
96.1
98.4
89.8
93.3
87.3
96.9
97.3
95.1
96.2
96.7
97.3
96.7
97.0
86.9
82.1
85.8
81.2
83.7
76.5
79.4
74.3
97.2
95.5
96.6
81.3
744 633
605 68.7
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO OTHER MAJOR FGD-RELATED PROBLEMS WERE EN-
COUNTERED DURING THE FIRST QUARTER 1981.
4/81 A
B
C
D
E
F
G
H
5/81
SYSTEM
A
B
C
D
E
F
G
H
SYSTEM
6/81 A
B
C
D
E
F
G
H
SYSTEM
97.4
97.5
97.1
97.2
97.4
97.4
97.4
97.1
97.3
98.2
97.3
97.6
97.3
97.6
97.6
96.7
94.5
94.9
94.0
94.0
94.5
94.3
94.6
94.0
45.7
46.1
45.7
45.8
45.7
45.8
45.8
45.4
97.3
99.9
99.7
97.5
42.0
100.0
94.4
98.2
98.6
45.8
99
99
100
100
100
100
100
100
.7
.7
.0
.0
.0
.0
.0
.0
53.
81.
84.
84.
33.
.
.
.
3
3
0
0
3
0
0
0
94
96
100
100
100
.1
.8
.0
.0
.0
5
8
8
8
3
.4
.2
.5
.5
.4
.0
.0
.0
4.3
19.6
99.3
99.0
99.2
79.4
99.6
99.9
100.0
100.0
100.0
100.0
20.2
100.0
20.6
.0
96.5
94.3
95.8
12.9
97.9
95.8
19.2
16.0
19.0
3.1
19.3
3.2
.0
720 338
330 36.1
744
75
32 12.6
97.0
67.6
84.5
12.4
720 109
89 4.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JUNE, MODULE E WAS UNAVAILABLE FOR 572 HOURS AS A RESULT OF PROBLEMS
ENCOUNTERED WITH THE VENTURI PUMP MOTOR.
13-463
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
KANSAS CITY POWER & LIGHT: LA CYGNE 1 (CONT.)
PERIOD MODULE
7/81 A
B
C
D
E
F
G
H
SYSTEM
8/81 A
B
C
D
E
F
G
H
SYSTEM
9/81 A
B
C
D
E
F
G
H
SYSTEM
AVAILABILITY
96.9
97.2
97.4
96.0
96.1
98.0
97.2
97.8
97.1
94.4
95.9
93.1
94.9
94.3
96.2
95.9
96.4
95.1
30.6
29.5
31.6
30.4
32.3
32.3
32.4
32.9
31.5
OPERABILITY
95.8
93.0
73.9
89.4
82.2
69.1
75.8
60.5
80.0
100.0
100.0
100.0
100.0
97.5
100.0
99.4
93.4
100.0
100.0
100.0
100.0
100.0
97.8
100.0
95.6
83.7
100.0
-PCKTUKriAr
RELIABILITY
95.4
95.7
95.1
93.7
93.4
95.8
95.0
95.0
94.9
93.3
95,4
91.3
94.0
92.5
95.0
94.7
94.9
95.1
91.2
88.5
94.8
91.3
96.1
96.6
96.6
98.4
93.9
(I.C UAI«-
UTILIZATION
64,2
62.4
49.6
59.9
55.1
46.4
50.8
40.6
53.6
77.8
86.0
72.5
79.9
70.4
73.2
71.8
67.4
74.9
27.9
29.5
31.6
30.2
26.9
30.5
26.3
23.0
28.4
X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
744 499 399 37.0
744 537 557 57.7
720 198 203 13.8
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGO-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE MONTHS OF JULY AND AUGUST.
DURING SEPTEMBER THE FGO SYSTEM WAS OFF-LINE 504 HOURS FOR A SCHEDULED
OVERHAUL.
10/81 A
A
B
C
D
E
F
G
H
SYSTEM
50.8
48.3
51.4
51.6
48.3
47.3
51.5
51.5
50.6
100.0
100.0
100.0
100.0
83.8
90.0
74.3
72.9
97.9
97.9
92.6
99.4
100.0
98.8
99.3
99.8
99.7
98.2
40.3
41.7
40.9
42.0
30.0
32.2
26.6
26.1
35.0
744 266
260 19.3
** PROBLEMS/SOLUTIONS/COMMENTS
DURING OCTOBER THE SYSTEM WAS OFF-LINE 345 HOURS TO COMPLETE A SCHEDULED
OVERHAUL.
11/81 A
B
C
D
E
F
G
H
SYSTEM
97.4
95.9
92.3
93.9
96.0
90.1
94.1
91.8
93.8
100.0
100.0
100.0
100.0
100.0
97.3
93.4
100.0
100.0
97.0
95.1
90.3
91.8
94.6
86.4
91.6
89.1
92.1
85.6
79.6
71.8
79.8
69.6
62.7
63.4
66.9
72.4
720 464
521 41.6
13-464
-------
UTILITY FGD SURVEY? OCTOBER 1983 - SEPTEMBER 1984
KANSAS CITY POWER i LIGHT: LA CYGNE 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL PER BOILER FGD CAP.
502 PART. HOURS HOURS HOURS FACTOR
*» PROBLEMS/SOLUTIONS/COMMENTS
DURING NOVEMBER THE UTILITY REPORTED THAT NO MAJOR FGD-REUTED PROBLEMS
WERE ENCOUNTERED.
12/81
A
B
C
D
E
F
6
H
SYSTEM
96.4
93.4
98.7
98.2
99.3
98.7
99.1
99.4
97.9
100.0
100.0
100.0
100.0
100.0
94.2
83.0
73.3
93.8
95.6
91.0
98.0
97.2
98.6
97.4
98.0
98.4
96.8
78.7
66.6
64.9
62.5
51.5
46.4
41.1
36.2
56.0
744 386
417 25.9
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD PROBLEMS WERE ENCOUNTERED DURING
DECEMBER.
1/82 A
B
C
D
E
F
G
H
SYSTEM
2/82 A
B
C
D
E
F
G
H
SYSTEM
3/82 A
B
C
D
E
F
G
H
SYSTEM
88.0
93.2
95.9
91.3
92.3
85.0
97.0
97.3
92.5
94.7
96.9
96.8
98.1
95.7
95.5
96.5
97.1
96.4
97.3
95.1
96.4
91.5
95.2
93.0
95.4
97.7
95.8
78.5
98.7
100.0
100.0
83.1
94.7
75.6
100.0
91.3
100.0
100.0
100.0
100.0
100.0
83.2
73.8
67.4
90.6
100.0
100.0
100.0
100.0
95.8
100.0
59.0
95.3
93.8
81.8
90.9
95.2
89.2
88.2
81.2
94.5
96.5
89.7
92.1
95.7
95.3
97.0
93.7
90.6
91.6
92.2
93.5
96.6
93.2
95.0
87.8
92.1
100.0
88.4
96.1
93.2
53.9
67.8
80.1
70.3
57.1
65.0
52.0
73.2
64.9
60.9
68.1
64.8
64.0
62.8
43.1
38.2
34.9
58.3
77.5
67.7
69.2
61.0
56.8
96.8
35.0
56.5
60.4
744 511
483 33.4
672 348
367 24.0
744 441
449 33.3
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE FIRST QUARTER 1982 THE UTILITY REPORTED EXPERIENCING NO MAJOR
FGD-RELATED PROBLEMS.
4/82 A
B
C
D
E
F
G
97.7
98.5
99.2
98.9
99.0
99.7
99.4
100.0
100.0
100.0
100.0
100.0
96.9
68.1
94.9
96.4
98.2
97.4
97.6
99.2
97.9
42.4
41.3
42.4
41.2
40.3
38.0
26.7
13-465
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
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
H
SYSTEM
98.7
98.9
92.4
94.7
96.7
97.3
36.2
38.6
720
282
278
20.5
** PROBLEMS/SOLUTIONS/COMMENTS
ON APRIL 16 THRU APRIL 30 THE UNIT WAS OUT OF SERVICE FOR AN OVERHAUL.
5/82 SYSTEM 100.0 .0 744 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MAY THE UNIT WAS SHUT DOWN FOR A SCHEDULED MAINTENANCE OUTAGE.
DURING THIS TIME GENERAL MAINTENANCE WAS PERFORMED ON THE FGD SYSTEM;
HOWEVER, THE SYSTEM WAS AVAILABLE FOR OPERATION IF NEEDED.
6/82
7/82
8/82
9/82
A
B
C
D
E
F
G
H
SYSTEM
99.2
98.7
95.0
99.5
99.5
89.9
99.2
98.9
97.5
94.3
100.0
98.2
100.0
90.0
68.6
100.0
100.0
93.9
97.1
95.8
84.3
98.7
98.1
64.9
97.7
96.7
91.7
25.8
30.2
26.9
36.3
24.6
18.8
34.8
31.9
28.7
720 197
206 13.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING JUNE.
A
B
C
D
E
F
G
H
SYSTEM
A
B
C
D
E
F
G
H
SYSTEM
A
B
C
D
E
F
G
H
SYSTEM
97.5
95.4
95.8
97.1
98.1
95.1
97.3
97.3
96.7
98.0
96.9
97.6
97.3
98.7
98.1
96.7
98.5
97.7
92.1
97.2
96.2
91.7
98.0
97.2
96.2
96.9
95.7
100.0
100.0
100.0
100.0
98.5
92.2
97.7
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
99.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
91.2
100.0
97.4
94.9
95.3
96.7
97.7
93.8
96.7
96.9
96.2
97.6
96.6
97.4
96.9
98.5
97.8
96.2
98.1
97.4
90.7
96.3
95.3
89.7
97.2
96.1
94.9
95.4
94.5
90.9
85.8
86.3
85.4
79.4
74.3
78.8
83.2
83.0
82.6
86.7
86.9
83.1
86.3
85.4
83.0
76.4
83.8
77.2
72.0
77.3
72.5
71.0
70.1
71.9
63.6
71.9
744 600
618 53.8
744 574
623 46.2
720 502
518 43.7
13-466
-------
UTILITY FGD SURVEYS OCTOBER 1983 - SEPTEMBER 1984
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
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE JULY - SEPTEMBER PERIOD.
10/82
A
B
C
D
E
F
G
H
SYSTEM
97.0
96.8
97.0
97.8
98.4
98.5
98.1
97.2
97.6
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
96.2
95.6
96.1
97.2
97.6
97.7
96.9
95.7
96.6
76.0
70.4
74.1
74.3
68.0
64.4
59.8
63.0
68.8
744 440
512 35.2
** PROBLEMS/SOLUTIONS/COMHENTS
NO MAJOR FGD-RELATED PROBLEMS WERE REPORTED BY THE UTILITY
DURING OCTOBER.
11/82 A
B
C
D
E
F
G
H
SYSTEM
13.2
13.2
13.1
12.8
12.8
12.8
12.8
13.3
13.0
79.2
79.2
78.3
76.7
77.1
77.1
76.7
79.6
78.0
99.0
99.5
98.5
96.5
95.9
96.7
95.8
99.5
97.7
13.2
13.2
13.1
12.8
12.8
12.8
12.8
13.3
13.0
720 120 94 11.6
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED TURBINE GENERATOR PROBLEMS DURING NOVEMBER.
12/82 SYSTEM .0 .0 744 0 0
1/83 SYSTEM .0 .0 744 0 0
2/83 SYSTEM .0 .0 672 0 0
3/83 SYSTEM .0 .0 744 0 0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS TAKEN OUT OF SERVICE ON NOVEMBER 7, 1982 FOR AN EXTENDED
OVERHAUL. THE OUTAGE CONTINUED THROUGH MARCH 1983.
.0
.0
.0
.0
4/83 SYSTEM .0
** PROBLEMS/SOLUTIONS/COMMENTS
.0
720
.0
THE UNIT WAS DOWN MOST OF APRIL DUE TO EXTENSIVE BOILER REPAIRS. REPAIRS
INCLUDED THE REPLACEMENT OF BOILER FLOORING, SIDE WALLS, AND SEVERAL
CYCLONES.
5/83 SYSTEM
6/83 SYSTEM
.0
.0
.0
.0
744
720
.0
.0
13-467
-------
UTILITY FGO SURVEY: OCTOBER 1983 - SEPTEMBER 198*
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
7/83
8/83
THE SCHEDULED OUTAGE CONTINUED THROUGH THE SECOND QUARTER OF 1983 WITH
TURBINE AND GENERATOR WORK BEING COMPLETED.
A
B
C
D
E
F
G
H
SYSTEM
60.1
61.2
61.7
62.9
63.3
62.8
63.3
63.7
62.*
91.1
88.6
95.*
9*. 3
93.5
82.*
99.2
92.7
92.2
96.1
92.8
9*. 5
96.9
97.7
96.2
97.6
98.*
96.3
*5.3
**.!
*7.*
*6.9
*6.5
*1.0
*9.3
*6.1
*5.8
7** 370
3*1
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY ATTRIBUTED LOW BOILER HOURS DURING JULY TO START-UP TIME AND
TESTS REQUIRED FOLLOWING THE EXTENDED OUTAGE.
A
B
C
D
E
F
G
H
SYSTEM
76.1
76.2
75.7
75.9
75.*
75.9
75.*
76.6
75.9
100.0
100.0
100.0
100.0
98.1
9*. 7
9*. 9
9*. 5
97.8
98.1
93.3
97.6
97.8
97.0
97.6
96.8
98.6
97.7
68.0
68.1
67.6
65.9
62.5
60.3
60.5
60.2
6*.l
744 474
*77 17.0
*» PROBLEMS/SOLUTIONS/COMMENTS
9/83 A
B
C
D
E
F
G
H
SYSTEM
THE UTILITY ATTRIBUTED LOW FGD SYSTEM AVAILABILITY DURING AUGUST TO CONTIN-
UED TESTING ON THE BOILER AND SCRUBBER.
.0
.0
.0
.0
.0
.0
.0
.0
.0 720 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
A FORCED OUTAGE OCCURRED DURING SEPTEMBER DUE TO TURBINE GENERATOR PROB-
LEMS. THE UTILITY HOPED TO BE BACK IN SERVICE BY NOVEMBER, 1983.
10/83 SYSTEM
11/83 SYSTEM
12/83 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
7**
720
7**
1/8* SYSTEM
THE UNIT WAS DOWN THE ENTIRE FOURTH QUARTER OF 1983 DUE TO CONTINUED BOILER
AND TURBINE REPAIRS. THE UTILITY HOPES TO BE BACK IN SERVICE BY THE
END OF JANUARY, 198*.
7**
13-*68
-------
UTILITY FGO SURVEYS OCTOBER 1983 - SEPTEMBER 1984
KANSAS CITY POWER & LIGHT: LA CYGNE 1 (CONT. )
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
50Z PART. HOURS HOURS HOURS FACTOR
3/84 SYSTEM 696
3/84 SYSTEM 744
4/84 SYSTEM 7EO
5/84 SYSTEM 744
6/84 SYSTEM 720
7/84 SYSTEM 744
8/84 SYSTEM 744
9/84 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED NO MAJOR FGD-RELATED OUTAGES DURING THE FIRST THREE
QUARTERS OF 1984. FGD SYSTEM AVAILABILITY WAS ESTIMATED AT 95X.
13-469
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 198*
SECTION 13
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
KANSAS POWER
JEFFREY
1
WAME60
KANSAS
C
& LIGHT
PARTICULATE EMISSION LIMITATION - NG/J
SOS 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 KO/FGD - MU
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
** 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
TRADE NAME/COMMON NAME
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
*** FGD SYSTEM
( .100 LB/MMBTU)
( .750 LB/MMBTU)
(****** LB/MMBTU)
322.
******
2720
720
680
495
540
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
1313.35 (2781000 ACFM)
135.6 ( 276 F)
183. ( 600 FT)
CONCRETE
7.9 ( 26.0 FT)
COAL
SUBBITUMINOUS
18899.
5.80
******
30.00
******
.32
******
.01
******
0
NONE
COLD SIDE
C.E. WALTHER
664.0
160.0
.3
98.6
0
NONE
N/A
N/A
N/A
N/A
N/A
N/A
N/A
( 8125 BTU/LB)
******
(1407000 ACFM)
( 320 F)
( 1. IN-H20)
13-470
-------
KANSAS POWER 4 LIGHT: JEFFREY 1 (CONT.)
UTILITY FGD SURVEY? OCTOBER 1983 - SEPTEMBER 1984
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
UMIT DESIGN PARTICLE REMOVAL EFFICIENCY
UNIT DESIGN S02 REMOVAL EFFICIENCY - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
** QUENCHER/PRESATURATOR
NUMBER
»* ABSORBER
NUMBER
NUMBER OF SPARES
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
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
502 REMOVAL EFFICIENCY - X
»* MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
NUMBER OF SPARES PER SYSTEM
NUMSER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES PER STAGE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
WASH WATER SOURCE
** REHEATER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
PERCENT GAS BYPASSED - AVG
TEMPERATURE INCREASE - C
INLET FLUE GAS TEMPERATURE - C
OUTLET FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
NONE
COMBUSTION ENGINEERING
BUCK & VEATCH
FULL SCALE
NEW
7. 99.00
60.00
1
8/78
8/78
7/73
6
1
SPRAY TOWER
OPEN COUNTERCURRENT SPRAY
N/A
COMBUSTION ENGINEERING
STAINLESS STEEL
AUSTENITIC
TYPE 316L
NONE
N/A
N/A
NONE
2
907. (14400 GPM)
5.3 ( 39.7 GAL/1000 ACF)
1.0 ( 4.0 IN-H20)
171.30 ( 363000 ACFM)
135.6 ( 276 F)
60.0
PRECOLLECTOR
6
1
1
BULK SEPARATION
BAFFLE SLATS
BULK ENTRAINMENT SEPARATOR
HORIZONTAL
1
1
ORGANIC
FIBER-REINFORCED POLYESTER
NR
1
BYPASS
COLD SIDE
N/A
25.0
27.8 ( 50 F)
48.9 ( 120 F)
76.7 ( 170 F)
NR
NR
13-471
-------
UTILITY FGD SURVEY'- OCTOBER 1983 - SEPTEMBER 1984
KANSAS POWER & LIGHT: JEFFREY 1 (CONT.)
** FANS
NUMBER
NUMBER OF SPARES
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** DAMPERS
FUNCTION
GENERIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
FUNCTION
GENERIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
»* DAMPERS
FUNCTION
GENERIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
CONFIGURATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
CONFIGURATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
CONFIGURATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
CONFIGURATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
CENTRIFUGAL
GREEN FAN
UNIT
FORCED DRAFT
DRY
135.6 ( Z76 F)
CARBON STEEL
SHUT-OFF
LOUVER
CARBON STEEL
AISI 1110
NONE
N/A
SHUT-OFF
LOUVER
CARBON STEEL
AISI 1110
NONE
N/A
NR
LOUVER
CARBON STEEL
AISI 1110
NONE
N/A
ABSORBER INLET
RECTANGULAR
CARBON STEEL
AISI 1110
NONE
N/A
ABSORBER OUTLET TO REHEAT ZONE
RECTANGULAR
CARBON STEEL
AISI 1110
ORGANIC
COAL TAR EPOXY
REHEAT ZONE TO STACK
RECTANGULAR
CARBON STEEL
AISI 1110
INORGANIC
CHEMICALLY-BONDED CONCRETE
BYPASS
RECTANGULAR
CARBON STEEL
AISI 1110
NONE
N/A
WET BALL MILL
COMPARTMENTED
13-472
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
KANSAS POWER & LIGHT: JEFFREY 1 (CONT.)
DEVICE TYPE
NUMBER
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
PRODUCT QUALITY - X SOLIDS
** TANKS
SERVICE
NR
3
ABSORBER RECYCLE
SLUDGE STORAGE
SLUDGE TRANSFER
MIST ELIMINATOR WASH
»* PUMPS
SERVICE
ABSORBER RECIRCULATION
ABSORBER BLEED
SLUDGE
POND RETURN
ADDITIVE FEED
ADDITIVE TRANSFER
*# SOLIDS CONCENTRATING/DEWATERING
DEVICE
*** SLUDGE
«* TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE TREATMENT
SITE DIMENSIONS
SITE SERVICE LIFE - YRS
** PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS
MONITOR TYPE
*» WATER BALANCE
WATER LOOP TYPE
MAKEUP WATER ADDITION - LITERS/S
** CHEMICALS AND CONSUMPTION
FUNCTION
NAME
CONSUMPTION
POINT OF ADDITION
** FGD SPARE CAPACITY INDICES
ABSORBER - 7.
** FGD SPARE COMPONENT INDICES
ABSORBER
10.9 (12 TPH)
60.0
NUMBER
4
****
****
****
NUMBER
6
****
****
«***
4
3
NONE
FORCED OXIDATION
AIR SPARGERS IN REACTION TANK
N/A
FINAL
POND
ON-SITE
PIPELINE
CLAY LINING
230 ACRES/80 FT
30
S02
DUPONT & LEAR SIEGLER
CLOSED
36.4
ABSORBENT
LIMESTONE
12130 LB/HR
BALL MILL
20.0
1.0
( 577 GPM)
13-473
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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
8/78 SYSTEM 7^4
** PROBLEMS/SOLUTIONS/COMMENTS
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 REPORTED.
INTEGRATED OPERATION OF THE SYSTEM IS EXPECTED DURING THE FIRST HALF OF
OCTOBER.
9/78 SYSTEM 720
10/78 SYSTEM 744
11/78 SYSTEM 720
12/78 SYSTEM 744
*» PROBLEMS/SOLUTIONS/COMMENTS
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 POSTPONMENT OF THE TEST
INDEFINITELY. INTERMITTENT FGD OPERATIONS ARE CONTINUING.
1/79 SYSTEM 744
2/79 SYSTEM 672
3/79 SYSTEM 744
»* 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 744
8/79 SYSTEM 744
9/79 SYSTEM 720
13-474
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
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
»* 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 UNIT WILL SHUT DOWN IN MID-SEPTEMBER FOR THE NORMAL TWO WEEK INSPECTION
AND MAINTENANCE OUTAGE. THE UNIT IS EXPECTED BACK ON LINE ON OCTOBER 1.
10/79 SYSTEM 744
11/79 SYSTEM 720
12/79 SYSTEM 744
*» PROBLEMS/SOLUTICNS/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.
720 720 720
744 744 744
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 AN AIR PREHEATER 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 BOILER AIR PREHEATER TUBES.
9/80 SYSTEM 100.0 100.0 100.0 100.0 720 720 720 67.7
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
100.0
100.0
13-475
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
KANSAS POWER & LIGHT: JEFFREY 1 (CONT.)
_ PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
KO PROBLEMS WITH THE BOILER OR THE FGD SYSTEM WERE ENCOUNTERED DURING
SEPTEMBER.
10/50 SYSTEM 100.0 100.0 100.0 37.* 74* 273 276
** PROBLEMS/SOLUTIONS/COMMENTS
DURING OCTOBER THE BOILER DID NOT OPERATE FOR APPROXIMATELY *66 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 9* 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 100.0 100.0 100.0 98.5 7** 733 733
** PROBLEMS/SOLUTIONS/COMMENTS
DURING DECEMBER THE FGD SYSTEM WAS AVAILABLE 100X.
A BOILER OUTAGE DURING THE MONTH WAS DUE TO A AIR PREHEATER PROBLEM.
1/81 SYSTEM 7*4
2/81 SYSTEM 672
3/81 SYSTEM 74*
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS OPERATED VERY LITTLE DURING THE FIRST QUARTER OF 1981.
THE UTILITY FIRED LOW SULFUR COAL DURING THE PERIOD.
DURING THE MONTH OF MARCH THE SYSTEM WAS DOWN FOR A PERIOD OF TWO WEEKS
DUE TO A SCHEDULED MAINTENANCE OUTAGE.
4/81 SYSTEM 720
5/81 SYSTEM 744
6/81 SYSTEM 720
7/81 SYSTEM 744
8/81 SYSTEM 744
9/81 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE JEFFREY 1 FGD SYSTEM OPERATED INTERMITTENTLY DURING THE SECOND AND
THIRD QUARTERS OF 1981. FLUE GAS GENERATED FROM THE LOW SULFUR CONTENT
COAL BURNED THROUGHOUT MUCH OF THE PERIOD DID NOT REQUIRE SCRUBBING.
10/81 SYSTEM 720
13-476
-------
UTILITY FGD SURVEY? OCTOBER 1983 - SEPTEMBER 1984
KANSAS POWER 4 LIGHT: JEFFREY 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
11/81 SYSTEM 720
12/81 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO FGD-RELATED PROBLEMS WERE ENCOUNTERED DURING
THE FOURTH QUARTER.
1/82 SYSTEM 744
2/82 SYSTEM 672
3/82 SYSTEM 744
*# PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO FGD-RELATED PROBLEMS WERE ENCOUNTERED DURING
THE FIRST QUARTER 1982. SOMETIME DURING THE FIRST AND/OR SECOND QUARTER
1982, THE UNIT WILL BE SHUTDOWN FOR A SCHEDULED Z WEEK SPRING OUTAGE.
4/82 SYSTEM 720
5/82 SYSTEM 744
6/82 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE SECOND QUARTER 1982.
7/82 SYSTEM 744
8/82 SYSTEM 744
9/82 SYSTEM 720
10/82 SYSTEM 744
11/82 SYSTEM 720
12/82 SYSTEM 744
1/83 SYSTEM 744
2/83 SYSTEM 672
3/83 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE JEFFREY 1 AND 2 FGD SYSTEMS HAVE NOT BEEN OPERATED SINCE THE FALL OF
1982 WHILE THE FINAL INSTALLATION WORK WAS COMPLETED ON THE JEFFREY 3 FGD
SYSTEM.
THE REACTION TANKS HAVE EXPERIENCED CORROSION RELATED TO FLEXING OF THE
STEEL TANK BASES. THIS HAS BEEN EVIDENCED PARTICULARLY AROUND THE MIXERS.
KPSL IS NOW PUTTING IN CONCRETE TANK FLOORS TO ELIMINATE THE PROBLEM.
THE JEFFREY 1 AND 2 FGD SYSTEMS HAVE BEEN SHOWING CORROSION IN THE
DOWNSTREAM DUCTWORK PARTICULARLY IN THE REHEAT MIXING ZONE. THE PROBLEM
HAS NOT YET BECOME SERIOUS.
13-477
-------
UTILITY FED SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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
4/83 SYSTEM 100.0 .0 720 0
** PROBLEMS/SOLUTIONS/COMMENTS
THE JEFFREY 1 FGD SYSTEM REMAINED DOWN WHILE FINAL INSTALLATION WORK ON
JEFFREY 3 WAS COMPLETED.
5/83 SYSTEM 100.0 .0 744 0
6/83 SYSTEM 100.0 .0 720 0
7/83 SYSTEM 100.0 .0 744 0
8/83 SYSTEM 100.0 .0 744 0
9/83 SYSTEM 100.0 .0 720 0
** FROSLEMS/SOLUTIONS/COMMENTS
THE JEFFREY 1 FGD SYSTEM WAS REPORTED TO HAVE BEEN AVAILABLE DURING THE
PERIOD OF MAY THROUGH SEPTEMBER. HOWEVER, DURING THIS TIME> THE FGD SYSTEM
WAS ONLY OPERATED FOR 1 MONTH DUE TO A SUMMER PEAK LOAD PERIOD.
THE NEXT UNIT OUTAGE IS SCHEDULED FOR THE FIRST OF DECEMBER. DURING THIS
OUTAGE, THE UTILITY PLANS TO DO SOME PATCH WORK ON THE ABSORBER OUTLET
DUCTING.
10/83 SYSTEM 744
11/83 SYSTEM 720
12/83 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
JEFFREY 1 WAS OUT OF SERVICE DURING THE FOURTH QUARTER OF 1983 DUE TO EX-
TENSIVE DUCTWORK REPAIRS.
1/84 SYSTEM 744
2/84 SYSTEM 696
3/84 SYSTEM 744
4/84 SYSTEM 720
5/84 SYSTEM 744
6/84 SYSTEM 720
7/84 SYSTEM 744
8/84 SYSTEM 744
9/84 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
JEFFREY 1 WAS OFF LINE DURING 1984. THE UTILITY REPORTED THAT THE
REPLACEMENT OF CORRODING OUTLET DUCTWORK IS PLANNED FOR THE NEXT SIX
MONTHS.
13-478
-------
UTILITY FSD SURVEY? OCTOBER 1983 - SEPTEMBER
SECTION 13
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FSD SYSTEMS
COMPANY NAME
PUNT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
SOZ 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
KANSAS POWER
JEFFREY
2
WAMEGO
KANSAS
C
43.
322.
******
2710
720
660
495
540
& LIGHT
( .100 LB/MMBTU)
( .750 LB/MMBTU)
(****** LB/MMBTU)
** UNIT DATA - BOILER AND STACK
BOILER SUPPLIER
BOILER TYPE
BOILER SERVICE LOAD
DESIGN BOILER FLUE GAS FLOW
BOILER FLUE GAS TEMPERATURE
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 - X
AVERAGE MOISTURE CONTENT - 7
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - 7
RANGE CHLORIDE CONTENT - X
»** PARTICLE CONTROL
** MECHANICAL COLLECTOR
NUMBER
TYPE
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
CU.M/S 1312.35 (2781000 ACFM)
C 135.6 ( 276 F)
183. ( 600 FT)
CONCRETE
7.9 ( 26.0 FT)
COAL
SUBBITUMINOUS
18899.
5.80
******
30.00
******
.32
******
.01
******
0
NONE
( 8125 BTU/LB)
******
** 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
TRADE NAME/COMMON NAME
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
*** FGD SYSTEM
COLD SIDE
C.E. WALTHER
664.0
160.0
.3
98.6
0
NONE
N/A
N/A
N/A
N/A
N/A
N/A
N/A
(1407000 ACFM)
( 320 F)
( 1. IN-H20)
13-479
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 198*
KANSAS POWER & LIGHT- JEFFREY 2 CCONT.)
** 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 - Y.
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
** QUENCHER/PRESATURATOR
NUMBER
** ABSORBER
NUMBER
NUMBER OF SPARES
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
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
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
NUMBER OF SPARES PER SYSTEM
NUMBER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES PER STAGE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
WASH WATER SOURCE
** REHEATER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
PERCENT GAS BYPASSED - AVG
TEMPERATURE INCREASE - C
INLET FLUE GAS TEMPERATURE - C
OUTLET FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
COMBUSTION ENGINEERING
BLACK & VEATCH
FULL SCALE
NEW
7. 99.00
60.00
1
5/80
1/80
7/73
6
1
SPRAY TOWER
OPEN COUNTERCURRENT SPRAY
N/A
COMBUSTION ENGINEERING
STAINLESS STEEL
AUSTENITIC
TYPE 316L
NONE
N/A
N/A
NONE
907.
5.3
1.0
171.30
135.6
60.0
( 39
GPM)
7 GAL/1000 ACF )
4.0 IN-H20)
363000 ACFM)
376 F)
PRECOLLECTOR
6
1
1
BULK SEPARATION
BAFFLE SLATS
BULK ENTRAINMENT SEPARATOR
HORIZONTAL
1
1
ORGANIC
FIBER-REINFORCED POLYESTER
NR
1
BYPASS
COLD SIDE
N/A
25.0
27.8 ( 50 F)
48.9 ( 120 F)
76.7 ( 170 F)
NR
NR
13-480
-------
KANSAS POWER S LIGHT: JEFFREY 2 (CONT.)
UTILITY FSD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
*# FANS
NUMBER
NUMBER OF SPARES
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** DAMPERS
FUNCTION
GENERIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
FUNCTION
GENERIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
FUNCTION
GENERIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
CONFIGURATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
CONFIGURATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
CONFIGURATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
CONFIGURATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
*» REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
CENTRIFUGAL
GREEN FAN
UNIT
FORCED DRAFT
DRY
135.6 ( 276 F)
CARBON STEEL
SHUT-OFF
LOUVER
CARBON STEEL
AISI 1110
NONE
N/A
SHUT-OFF
LOUVER
CARBON STEEL
AISI 1110
NONE
N/A
NR
LOUVER
CARBON STEEL
AISI 1110
NONE
N/A
ABSORBER INLET
RECTANGULAR
CARBON STEEL
AISI 1110
NONE
N/A
ABSORBER OUTLET TO REHEAT ZONE
RECTANGULAR
CARBON STEEL
AISI 1110
ORGANIC
COAL TAR EPOXY
REHEAT ZONE TO STACK
RECTANGULAR
CARBON STEEL
AISI 1110
INORGANIC
CHEMICALLY-BONDED CONCRETE
BYPASS
RECTANGULAR
CARBON STEEL
AISI 1110
NONE
N/A
U'ET BALL MILL
COMPARTMENTED
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
KANSAS POWER 4 LIGHT: JEFFREY Z (CONT.)
DEVICE TYPE
NUMBER
FULL LOAD DRY FEED CAPACITY - tt.TONS/HR
PRODUCT QUALITY - 7. SOLIDS
** TANKS
SERVICE
ABSORBER RECYCLE
SLUDGE STORAGE
SLUDGE TRANSFER
MIST ELIMINATOR WASH
** PUMPS
SERVICE
ABSORBER RECIRCULATION
ABSORBER BLEED
SLUDGE
POND RETURN
ADDITIVE FEED
ADDITIVE TRANSFER
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
*** SLUDGE
** TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE TREATMENT
SITE DIMENSIONS
SITE SERVICE LIFE - YRS
** PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS
MONITOR TYPE
** WATER BALANCE
WATER LOOP TYPE
MAKEUP WATER ADDITION - LITERS/S
** CHEMICALS AND CONSUMPTION
FUNCTION
NAME
CONSUMPTION
POINT OF ADDITION
** FGD SPARE CAPACITY INDICES
ABSORBER - X
** FGD SPARE COMPONENT INDICES
ABSCREER
NR
3
10.9 t 12 TPH)
60.0
NUMBER
4
«*»«
****
****
NUMBER
6
****
****
****
4
3
NONE
FORCED OXIDATION
AIR SPARGERS IN REACTION TANK
N/A
FINAL
POND
ON-S1TE
PIPELINE
CLAY LINING
230 ACRES/80 FT
30
502
DUPONT t LEAR SIEGLER
CLOSED
36.4
ABSORBENT
LIMESTONE
12130 LB/HR
BALL MILL
20.0
1.0
( 577 GPM)
13-482
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
KANSAS POWER i LIGHT: JEFFREY 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
1/80 SYSTEM 744
2/80 SYSTEM 696
3/80 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
INITIAL OPERATIONS AT JEFFREY 2 BEGAN IN JANUARY 1980. NO MAJOR PROBLEMS
HAVE BEEN ENCOUNTERED SINCE STARTUP.
4/80 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMHENTS
DURING APRIL THE SYSTEM WAS STILL IN THE SHAKEDOWN/DEBUGGING PHASE OF
OPERATION.
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
COMMERCIAL OPERATIONS BEGAN ON MAY 1> 1980. SINCE THEN THERE HAVE BEEN
NO PROBLEMS ENCOUNTERED WITH THE FGD SYSTEM. THE UNIT HAS OPERATED 100X
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 AN AIR PREHEATER TUBE LEAK
IN THE BOILER. NO FGD-RELATED OUTAGES OCCURRED DURING THE MOUTH.
8/80 SYSTEM 100.0 100.0 100.0 100.0 744 744 744 80.1
9/80 SYSTEM 100.0 100.0 100.0 100.0 720 720 720 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
13-483
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
KANSAS POWER & LIGHT: JEFFREY 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
DURING DECEMBER THE BOILER WAS OUT OF SERVICE DUE TO SUPERHEATER TUBE PROB-
LEMS. DURING THIS TIME THE F6D SYSTEM WAS 100X AVAILABLE.
1/81 SYSTEM 744
2/81 SYSTEM 672
3/81 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS NOT OPERATED MUCH DURING THE FIRST QUARTER OF 19S1
BECAUSE THE UTILITY WAS ABLE TO MEET COMPLIANCE USING ONLY LOW SULFUR
COAL.
THE UNIT WAS SHUT DOWN ALL OF MARCH AND PART OF FEBRUARY (SIX WEEKS) FOR
AN EQUIPMENT WARRANTY INSPECTION.
4/81 SYSTEM 720
5/81 SYSTEM 744
6/81 SYSTEM 720
7/81 SYSTEM 744
8/81 SYSTEM 744
9/81 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE JEFFREY 2 FGD SYSTEM OPERATED INTERMITTENTLY DURING THE SECOND AND
THIRD QUARTERS OF 1981. FLUE GAS GENERATED FROM THE LOW SULFUR CONTENT
COAL BURNED THROUGHOUT MUCH OF THE PERIOD DID NOT REQUIRE SCRUBBING.
10/81 SYSTEM 744
11/81 SYSTEM 720
12/81 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO FGD-RELATED PROBLEMS WERE ENCOUNTERED DURING
THE FOURTH QUARTER.
1/82 SYSTEM 744
2/82 SYSTEM 672
3/82 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO FGD-RELATED PROBLEMS WERE ENCOUNTERED DURING
THE FIRST QUARTER 1982. SOMETIME DURING THE FIRST AND/OR SECOND QUARTER
1982, THE UNIT WILL BE SHUTDOWN FOR A SCHEDULED 2 WEEK SPRING OUTAGE.
4/82 SYSTEM 720
5/82 SYSTEM 744
13-484
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
KANSAS POWER & LIGHT: JEFFREY 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
6/82 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE SECOND QUARTER 1982.
7/82 SYSTEM 7**
8/82 SYSTEM 744
9/82 SYSTEM 720
10/82 SYSTEM 744
11/82 SYSTEM 720
12/82 SYSTEM 744
1/83 SYSTEM 744
2/83 SYSTEM 672
3/83 SYSTEM 744
#« PROBLEMS/SOLUTIONS/COMMENTS
THE JEFFREY 1 AND 2 FGD SYSTEMS HAVE NOT BEEN OPERATED SINCE THE FALL OF
1982 WHILE THE FINAL INSTALLATION WORK WAS COMPLETED ON THE JEFFREY 3 FGD
SYSTEM.
THE REACTION TANKS HAVE EXPERIENCED CORROSION RELATED TO FLEXING OF THE
STEEL TANK BASES. THIS HAS BEEN EVIDENCED PARTICULARLY AROUND THE MIXERS.
KP&L IS NOW PUTTING IN CONCRETE TANK FLOORS TO ELIMINATE THE PROBLEM.
THE JEFFREY 1 AND 2 FGD SYSTEMS HAVE BEEN SHOWING CORROSION IN THE
DOWNSTREAM DUCTWORK PARTICULARLY IN THE REHEAT MIXING ZONE. THE PROBLEM
HAS NOT YET BECOME SERIOUS.
4/83 SYSTEM 100.0 .0 720 0
** PROBLEMS/SOLUTIONS/COMMENTS
THE JEFFREY 2 FGD SYSTEM REMAINED DOWN WHILE FINAL INSTALLATION WORK ON
JEFFREY 3 WAS COMPLETED.
5/83 SYSTEM 100.0 .0 744 0
6/83 SYSTEM 100.0 .0 720 0
7/83 SYSTEM 100.0 .0 744 0
6/83 SYSTEM 100.0 .0 744 0
9/83 SYSTEM 100.0 .0 720 0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT ALTHOUGH THE FGD SYSTEM WAS AVAILABLE THROUGHOUT
THE PERIOD BETWEEN MAY AND SEPTEMBER, THE SYSTEM WAS NOT REQUIRED TO OPER-
ATE.
THE NEXT UNIT OUTAGE IS SCHEDULED FOR NOVEMBER. DURING THIS OUTAGE, THE
13-485
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
KANSAS POWER & LIGHT: JEFFREY 2 (CONT.)
________. ,_______.-_.,. .._._._PERFORMANCE DATA - .
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
UTILITY PUNS TO DO SOME PATCH WORK ON THE ABSORBER OUTLET DUCTING.
10/83 SYSTEM 744
11/83 SYSTEM 720
12/83 SYSTEM 744
»« PROBLEMS/SOLUTIONS/COMMENTS
JEFFREY 2 WAS OUT OF SERVICE DURING THE FOURTH QUARTER OF 1983, HOWEVER THE
FGD SYSTEM WAS CONSIDERED 100X AVAILABLE.
1/84 SYSTEM 744
2/84 SYSTEM 696
3/84 SYSTEM 744
4/84 SYSTEM 720
5/84 SYSTEM 744
6/84 SYSTEM 720
7/84 SYSTEM 744
8/84 SYSTEM 744
9/84 SYSTEM 720
»* PROBLEMS/SOLUTIONS/COMMENTS
OVERALL FGD SYSTEM AVAILABILITY FOR THE FIRST THREE QUARTERS OF 1984 WAS
ESTIMATED AT OVER 85X. NO MAOR FGD-RELATED PROBLEMS WERE REPORTED.
13-486
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
SECTION 13
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 - 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
& LIGHT
( .100 LB/MMBTU)
<****** LB/MMBTU)
(****** LB/MMBTU)
KANSAS POWER
JEFFREY
3
WAMEGO
KANSAS
C
43.
******
******
2720
730
680
495
540
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
1312.35 (2781000 ACFM)
'135.6 ( 276 F)
133. ( 600 FT)
CONCRETE
7.9 ( 26.0 FT)
** 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 - '/.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** MECHANICAL COLLECTOR
NUMBER
TYPE
** 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
**» FGD SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROHAWAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
( 8125 BTU/LB)
******
COAL
SUESITUMINOUS
18899.
5.80
******
30.00
******
.32
******
.01
******
0
NONE
COLD SIDE
C.E. WALTHER
664.0
160.0
.3
98.6
0
NONE
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
COMBUSTION ENGINEERING
BLACK i VEATCH
FULL SCALE
NEW
7. 99.00
(1407000 ACFM)
( 320 F)
( 1. IN-H20)
13-487
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
KANSAS POWER & LIGHT: JEFFREY 3 (CONT.)
UNIT DESIGN S02 REMOVAL EFFICIENCY - V. 60.00
CURRENT STATUS 1
COMMERCIAL START-UP 5/83
INITIAL START-UP 5/83
** 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
LIQUID RECIRCULATICN RATE - LITER/S
L/G RATIO - L/CU.M
GAS-SIDE PRESSURE DROP - KPA
INLET GAS FLOU - CU. M/S
INLET GAS TEMPERATURE - C
SOS REMOVAL EFFICIENCY - 7.
»« MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
NUMBER OF SPARES PER SYSTEM
NUMBER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES PER STAGE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
WASH WATER SOURCE
** REHEATER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
PERCENT GAS BYPASSED - AVG
TEMPERATURE INCREASE - C
INLET FLUE GAS TEMPERATURE - C
OUTLET FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** FANS
NUMBER
NUMEER OF SPARES
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** DAMPERS
FUNCTION
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
SPRAY TOHER
OPEN COUNTERCURRENT SPRAY
N/A
COMBUSTION ENGINEERING
STAINLESS STEEL
AUSTENITIC
TYPE 316L
NONE
N/A
N/A
NONE
2
907. (14400 GPM)
5.3 ( 39.7 GAL/1000 ACF)
1.0 ( 4.0 IN-H20)
171.30 ( 363000 ACFM)
135.6 ( 276 F)
60.0
PRECOLLECTOR
6
1
1
BULK SEPARATION
BAFFLE SLATS
BULK ENTRAINMENT SEPARATOR
HORIZONTAL
1
1
ORGANIC
FIBER-REINFORCED POLYESTER
NR
1
BYPASS
COLO SIDE
N/A
25.0
27.8
48.9
76.7
NR
NR
( 50 F)
( 120 F)
( 170 F)
4
1
CENTRIFUGAL
GREEN FAN
UNIT
FORCED DRAFT
DRY
135.6
CARBON STEEL
SHUT-OFF
CARBON STEEL
AISI 1110
NONE
( 276 F)
-------
UTILITY FGD SURVEY? OCTOBER 1983 - SEPTEMBER 1984
KANSAS POWER & LIGHT: JEFFREY 3 (CONT.)
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
FUNCTION
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
«# DAMPERS
FUNCTION
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
CONFIGURATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
»* DUCTWORK
LOCATION
CONFIGURATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
CONFIGURATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
«* DUCTWORK
LOCATION
CONFIGURATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
NUMBER
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
PRODUCT QUALITY - X SOLIDS
** TANKS
SERVICE
SLUDGE STORAGE
SLUDGE TRANSFER
MIST ELIMINATOR WASH
ABSORBER RECYCLE
»* PUMPS
SERVICE
ABSORBER RECIRCULATION
ABSORDER BLEED
SLUDGE
POND RETURN
N/A
SHUT-OFF
CARBON STEEL
AISI 1110
NONE
N/A
NR
CARBON STEEL
AISI 1110
NONE
N/A
ABSORBER INLET
RECTANGULAR
CARBON STEEL
AISI 1110
NOME
N/A
ABSORBER OUTLET TO REHEAT ZONE
RECTANGULAR
CARBON STEEL
AISI 1110
ORGANIC
COAL TAR EPOXY
REHEAT ZONE TO STACK
RECTANGULAR
CARBON STEEL
AISI 1110
INORGANIC
CHEMICALLY-BONDED MORTAR
BYPASS
RECTANGULAR
CARBON STEEL
AISI 1110
NONE
N/A
WET BALL MILL
COMPARTMENTED
NR
3
10.9 (12 TPH)
60.0
NUMBER
****
****
«***
NUMBER
6
**»*
****
***«
13-489
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
KANSAS POWER & LIGHT: JEFFREY 3 (CONT.)
ADDITIVE FEED *
ADDITIVE TRANSFER 3
** SOLIDS CONCENTRATING/DEWATERING
DEVICE NONE
*»* SLUDGE
** TREATMENT
METHOD FORCED OXIDATION
DEVICE AIR SPARGERS IN REACTION TANK
PROPRIETARY PROCESS N/A
** DISPOSAL
NATURE FINAL
TYPE POND
LOCATION ON-SITE
SITE TRANSPORTATION METHOD PIPELINE
SITE TREATMENT CLAY LINING
SITE DIMENSIONS 230 ACRES/80 FT
SITE SERVICE LIFE - YRS 30
** WATER BALANCE
WATER LOOP TYPE CLOSED
** CHEMICALS AND CONSUMPTION
FUNCTION ABSORBENT
NAME LIMESTONE
CONSUMPTION 12130LB/HR
POINT OF ADDITION BALL MILL
_ PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
5/83 SYSTEM 744
6/83 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE JEFFREY 3 FGD SYSTEM COMMENCED OPERATION IN MAY AND IS CURRENTLY IN THE
STARTUP PHASE OF OPERATION.
THE JEFFREY 3 FGD SYSTEM IS SIMILIAR TO UNITS 1 AND Z EXCEPT THAT THE
OUTLET FROM THE ABSORBERS FEED INTO A COMMON BYPASS DUCT (FOR CONTINUOUS
REHEAT) WHICH THEN EXITS INTO THE STACK. UNITS 1 AND 2 HAVE MIXING
CHAMBER SECTIONS WHICH IN THE PAST HAVE CAUSED CORROSION PROBLEMS.
7/83 SYSTEM 744
8/83 SYSTEM 744
9/83 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT SINCE START UP, AT LEAST THREE OF THE FOUR AB-
SORBER SPRAY TOUERS HAVE OPERATED FULL TIME.
A UNIT OUTAGE FOR UNIT 3 BEGAN ON SEPTEMBER 17 AND WAS SCHEDULED TO LAST
TWO WEEKS. HOWEVER, DUE TO SOME UNEXPECTED TURBINE PROBLEMS, THE UNIT
OUTAGE MAY NOW LAST THREE WEEKS.
10/83 SYSTEM 744
11/83 SYSTEM 720
13-490
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
KANSAS POWER 4 LIGHT: JEFFREY 3 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
502 PART. HOURS HOURS HOURS FACTOR
12/83 SYSTEM 7**
** PROBLEMS/SOLUTIONS/COMMENTS
JEFFREY 3 WAS DOWN DURING PART OF DECEMBER DUE TO PROBLEMS BROUGHT ABOUT
BY THE EXTREME COLD WEATHER CONDITIONS.
1/84 SYSTEM 744
2/84 SYSTEM 696
3/84 SYSTEM 744
4/84 SYSTEM 720
5/84 SYSTEM 744
6/84
SYSTEM 720
7/84 SYSTEM 744
8/84 SYSTEM 744
9/84 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
OVERALL FGD SYSTEM AVAILABILITY FOR THE FIRST THREE QUARTERS OF 1984 WAS
ESTIMATED AT OVER 657.. NO MAJOR FGD-RELATED PROBLEMS WERE REPORTED.
13-491
-------
UTILITY FSD SURVEY: OCTOBER 1983 - SEPTEMBER 198*
SECTION 13
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
KANSAS POWER
LAWRENCE
4
LAWRENCE
KANSAS
C
43.
129.
******
576
125
115
495
125
4 LIGHT
( .100 LB/MMBTU)
( .300 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 - V.
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
** ESP
NUMBER
TYPE
** PARTICLE SCRUBBER
NUMBER
INITIAL START-UP DATE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON NAME
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
COMBUSTION ENGINEERING
PULVERIZED COAL
CYCLING
190.18
137.8
61.
CARBON STEEL
( 403000 ACFM)
( 280 F)
( 200 FT)
( 8.0 FT)
COAL
******
23260. ( 10000 BTU/LB)
******
9.80
9.8-16
11.80
******
.55
0.55-0.90
.03
******
0
NONE
0
NONE
2
1/76
VENTURI TOWER
VARIABLE-THROAT/VERTICALLY-ADJUSTABLE ROD DECKS
ROD SCRUBBER
COMBUSTION ENGINEERING
3.0 X 23.0
STAINLESS STEEL
AUSTENITIC
NONE
N/A
NORYL-CLAD FRP RODS
1
226.8 ( 3600 GPM)
2.4 (17.9 GAL/1000ACF)
2.2 (9.0 IN-H20)
15.2 ( 50.0 FT/S)
95.1 ( 201500 ACFM)
137.8
( 280 F)
13-492
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
KANSAS POWER 4 LIGHT: LAWRENCE 4 (CONT.)
PARTICLE REMOVAL EFFICIENCY - X
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
KANSAS POWER 4 LIGHT: LAWRENCE 4 (CONT.)
** REHEATER
NUMSER
NUMBER PER MODULE
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
OUTLET FLUE GAS TEMPERATURE - C
NUMBER OF HEAT EXCHANGER BANKS
NUMBER OF TUBES PER BUNDLE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
»* FANS
NUMBER
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE C
CONSTRUCTION MATERIAL GENERIC TYPE
** DAMPERS
GENERIC TYPE
SPECIFIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
GENERIC TYPE
SPECIFIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
GENERIC TYPE
SPECIFIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
»« DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
( 25 F)
( 363000 ACFM)
( 125 F)
( 150 F)
2
1
IN-LINE
HOT WATER
FIN TUBE
.0
13,9
171.30
51.7
65.6
2
66
CARBON STEEL
AISI 1110
CENTRIFUGAL
BUFFALO FORGE
BOOSTER
INDUCED DRAFT
DRY
80.22 f 170000 ACFM)
62.8 ( 145 F)
CARBON STEEL
LOUVER
NR
CARBON STEEL
HIGH STRENGTH LOW ALLOY tHSLAJ
NONE
N/A
LOUVER
NR
CARBON STEEL
HIGH STRENGTH LOW ALLOY [HSLAJ
NONE
N/A
LOUVER
NR
CARBON STEEL
HIGH STRENGTH LOW ALLOY IHSLA]
NONE
N/A
SCRUBBER INLET
CARBON STEEL
HIGH STRENGTH LOW ALLOY [HSLA]
NONE
N/A
SCRUBBER OUTLET
CARBON STEEL
HIGH STRENGTH LOW ALLOY [HSLA]
NONE
N/A
BYPASS
CARBON STEEL
HIGH STRENGTH LOW ALLOY tHSLA]
NONE
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
KANSAS POWER * LIGHT: LAURENCE 4 (CONT.)
LINER SPECIFIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
NUMBER
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
PRODUCT QUALITY X SOLIDS
*# TANKS
SERVICE
ABSORBER RECYCLE
SCRUBBER RECYCLE
WASTE SLURRY BLEED
REAGENT PREP PRODUCT
MILL SUMP/PRODUCT
RECLAIMED WATER
PUMPS
SERVICE
ADDITIVE FEED
MIST ELIMINATOR WASH
VENTURI RECIRCULATION
ASSCPBER RECIRCULATION
MILL SLURRY
ADDITIVE TRANSFER
ADDITIVE STORAGE
EFFLUENT BLEED
THICKENER UNDERFLOW
MAKEUP WATER RECIRCULATION
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUM5ER OF SPARES
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
FEED STREAM SOURCE
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
OUTLET STREAM DISPOSITION
OVERFLOW STREAM DISPOSITION
«** SLUDGE
** TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
INLET QUALITY - 7.
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE TREATMENT
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE TREATMENT
N/A
WET BALL MILL
COMPARTMENTED
NR
2
5.4 (
60.0
NUMBER
6 TPH)
2
2
2
1
****
****
NUMBER
6
****
2
2
****
****
****
****
2
«***
THICKENER
1
0
CARBON STEEL
HIGH STRENGTH LOW ALLOY CHSLAI
NONE
N/A
COLLECTION TANK
8-10X SOLIDS
30-35X SOLIDS
TO POND
RECLAIMED WATER TANK
FORCED OXIDATION
REACTION TANK
N/A
10.0
INTERIM
POND
CN-SITE
PIPELINE
NONE
FINAL
POND
ON-SITE
OVERFLOW FROM INTERIM SLUDGE POND
NONE
13-495
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
KANSAS POWER & LIGHT: LAWRENCE 4 (CONT.)
*» PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS
PHYSICAL VARIABLES
CONTROL LEVELS
MONITOR LOCATION
PROCESS CONTROL MANNER
PROCESS CHEMISTRY MODE
** WATER BALANCE
WATER LOOP TYPE
«* CHEMICALS AND CONSUMPTION
FUNCTION
NAME
PRINCIPAL CONSTITUENT
CONSUMPTION
POINT OF ADDITION
** FGD SPARE CAPACITY INDICES
ABSORBER - X
»* FGD SPARE COMPONENT INDICES
ABSORBER
PH, S02 CONCENTRATION
PERCENT SOLIDS, SLURRY FLOW
PH 6.5
PH PROBES IN REACTION TANKS
AUTOMATIC
FEEDBACK
CLOSED
ABSORBENT
LIMESTONE
93X CAC03, 7X (1GC03
1.5 TPH
BALL MILL
.0
.0
PERFORMANCE DATA-
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
/. REMOVAL
SOS PART.
PER BOILER
HOURS HOURS
FGD CAP.
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 SCRUESER
WALLS, CORROSION OF SCRUBBERS INTERNALS, BUILDUP ON ID FAN ROTORS, AND
PLUGGING OF DRAIN LINES, MARBLE BEDS, MID MIST ELIMINATORS. LOW S02
REMOVAL WAS CAUSED BY OVERBURNING OF THE LIMESTONE AND DROPOUT OF THE LIME
WITH THE ASH IN THE BOTTOM OF THE SCRUBBER.
THE SCRUBBERS WERE MODIFIED IN 1969 BY RAISING THE MIST ELIMINATOR AND
ADDING 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 SUH1ER 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
IN THE TAKK. 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
13-496
-------
UTILITY FED SURVEY: OCTOBER 1983 - SEPTEMBER 1984
KANSAS POWER S LIGHT: LAWRENCE 4 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FED CAP.
S02 PART. HOURS HOURS HOURS FACTOR
»* 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. SOX 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 BOU) 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 720
** 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 (O.SX 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 ONCE PER WEEK FOR INSPECTION AND CLEAN-
UP.
8/75 SYSTEM 744
9/75 SYSTEM 720
10/75 SYSTEM 744
11/75 SYSTEM 720
12/75 SYSTEM 744
1/76 SYSTEM 744
** 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 744
13-497
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
KANSAS POWER 4 LIGHT: LAWRENCE 4 (CONT.)
. « -PERFORMANCE DATA- .
PERIOD MODULE AVAILABILITY CPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
-c =,== = =» = = ,= =.= = ==,0== = = o.=>.=> =,<»=> =.«> <=> = -=«= = = ««j Ha ~ , «- = =. OB»W><->~c= Bn __,_, CK Mr _ . _ m _ _ <» _ w «_,__.,»_ _ _ _._._,
4/76 SYSTEM 720
5/76 SYSTEM 744
6/76 SYSTEM 720
7/76 SYSTEM 744
8/76 SYSTEM 744
9/76 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
A SCHEDULED UNIT OUTAGE BEGAN IN MID-SEPTEMBER FOR A TURBINE OVERHAUL.
THE UNIT IS SCHEDULED TO COME BACK ON LINE IN EARLY JANUARY.
10/76 SYSTEM 744
11/76 SYSTEM 720
12/76 SYSTEM 744
1/77 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
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.
2/77 SYSTEM 672
3/77 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
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 35Z
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.
4/77 SYSTEM 720
** 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
13-498
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
KANSAS POWER t LIGHT: LAWRENCE 4 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILED FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
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 ALLEH-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 AND 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/COMMEHTS
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 BOX 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 DOWN FOR INSPECTION AND THE NEW COOLING TOWER WAS BEING CONNECTED.
12/77 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT CAME BACK ON LINE DECEMBER 20 AT FULL CAPACITY. THE TURBINES
HERE BALANCED DURING DECEMBER.
1/76 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM OPERATED WITHOUT ANY PROBLEMS OTHER THAN SOME FREEZING OF
THE PIPELINES.
THICKENER DISCHARGE LINE FREEZING CAUSED CLARIFIER PLUGGING.
2/78 SYSTEM 672
13-499
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
KANSAS POWER 4 LIGHT: LAWRENCE 4 (CONT.)
_ . PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** 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 POHD.
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
8/78
9/78
100.0
100.0
100.0
100.0
100.0
100.0
100,
100,
100.
100.
100.
100.0
744
720 720
744 744
720 720
744 744
720
744
720
744
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER AND FGD SYSTEM BOTH OPERATED THROUGHOUT JUNE AND JULY WITHOUT
ANY FORCED OUTAGES.
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
63.0
63.0
63.0
744 744
720 456
744
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 Am A HALF IN SEPTEMBER FOR A SCHEDULED
FALL TURBINE/BOILER OUTAGE. ROUTINE MAINTENANCE INCLUDED BOILER AND
TURBINE CLEANING AND REPAIR.
10/78 SYSTEM
11/78 SYSTEM
12/78 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
744
720
744
576
720
744
1/79 SYSTEM
AN EPA SPONSORED CONTINUOUS MONITORING TEST BEGAN AT THIS UNIT AT THE
BEGINNING OF DECEMBER AND WILL CONTINUE THROUGH THE END OF JANUARY. THE
TEST INVOLVES 24 HOUR MONITORING OF S02, OPACITY AND NOX.
744
13-500
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
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
AN ID FAN WAS FORCED OUT OF SERVICE ON JANUARY 5 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 TO A 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
** 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
13-501
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
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 UNIT WAS DOWN FOR APPROXIMATELY 10 DAYS OF SCHEDULED OUTAGE FOR FALL
MAINTENANCE.
SOME AGITATOR SHAFT FAILURES OCCURRED IN THE REACTION TANK CAUSING
MAINTENANCE ATTENTION.
1/80 SYSTEM 100.0 100.0 100.0 744 744 744
a/60 SYSTEM 100.0 100.0 100.0 696 696 696
3/80 SYSTEM 100.0 100.0 100.0 744 744 744
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR PROBLEMS WERE REPORTED FOR THE LAWRENCE 4 SCRUBBER DURING
THE FIRST QUARTER L980.
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/COMMENTS
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
** 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
13-502
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1964
KANSAS POWER t 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/SOLUTIOHS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FSD-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/CCMMENTS
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 FGD SYSTEM WAS AVAILABLE THE ENTIRE MONTH.
1/81 SYSTEM 744
2/81 SYSTEM 672
3/81 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
LAWRENCE 4 WAS ON COLD STANDBY MUCH OF THE JANUARY-MARCH PERIOD AND
THEREFORE DID NOT SEE MUCH OPERATION. UTILITY REPORTED THERE WERE NO
FGD SYSTEM RELATED OUTAGES DURING THE QUARTER.
4/81 SYSTEM 720
5/81 SYSTEM 744
6/81 SYSTEM 720
7/81 SYSTEM 744
8/81 SYSTEM 744
9/61 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE MONTH OF SEPTEMBER, LAWRENCE 4 WAS ON COLD STANDBY FROM THE
THIRD TO THE TWENTY FIRST. NO FGD SYSTEM-RELATED PROBLEMS WERE REPORTED
FOR THIS UNIT DURING THE SECOND AND THIRD QUARTERS OF 1981.
10/81 SYSTEM 744
11/81 SYSTEM 720
12/81 SYSTEM 744
** PRCBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT BOILER OPERATIONS WERE NOT CURTAILED OR REDUCED
AS A RESULT OF THE FGD SYSTEM DURING THE ENTIRE FOURTH QUARTER 1981.
1/82 SYSTEM 744
2/82 SYSTEM 672
13-503
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 198*
KANSAS POWER It LIGHT: LAWRENCE 4 (CONT.)
.._ _____ PERFORMANCE DATA .
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
___.._ <° ____.»_ __.= _<.=.<=,O.__.=.=D ___. ~_ ___ -> _.= __ «>_____..««_._ _____ _____ =._=.__ ______ »___ _ _,_._
3/82 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO FGD-RELATED PROBLEMS WERE ENCOUNTERED DURING
THE FIRST QUARTER 1982. SOMETIME DURING THE FIRST AND/OR SECOND QUARTER
1982, THE UNIT WILL BE SHUTDOWN FOR A SCHEDULED 2 WEEK SPRING OUTAGE.
4/82 SYSTEM 720
5/82 SYSTEM 744
6/82 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE SECOND QUARTER 1982.
7/82 SYSTEM 744
8/82 SYSTEM 744
9/82 SYSTEM 720
10/82 SYSTEM 744
11/82 SYSTEM 720
12/82 SYSTEM 744
1/83 SYSTEM 744
2/83 SYSTEM 672
3/83 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
OVER THE PAST YEAR THE LAWRENCE 4 AND 5 F5D SYSTEMS HAVE OPERATED WITH NO
MAJOR PROBLEMS. THERE HAVE BEEN SOME CHRONIC MINOR PROBLEMS WITH SPRAY
HEADER PLUGGING. THERE MAY BE SOME MODIFICATIONS PERFORMED AT SOME POINT
IN THE FUTURE TO MINIMIZE THE PROBLEM.
THE DOWNSTREAM DUCTWORK IN BOTH THE LAWRENCE 4 AND 5 FGD SYSTEMS HAS BEEN
EXPERIENCING CORROSION THAT WILL REQUIRE SOME DEGREE OF REPLACEMENT.
THE CORROSION IS NOT RELATED TO CHLORIDES. A TIME TABLE FOR THE REPAIR
WORK WAS NOT REPORTED BY THE UTILITY.
4/83 SYSTEM 720
5/83 SYSTEM 744
6/83 SYSTEM 720
7/83 SYSTEM 744
8/83 SYSTEM 744
9/83 SYSTEM 720
13-504
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
KANSAS POWER 4 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 UTILITY REPORTED THAT NO MAJOR FGD-RELATED FORCED OUTAGES WERE ENCOUN-
TERED DURING THE PERIOD OF APRIL THROUGH SEPTEMBER.
THE NEXT UNIT OUTAGE IS SCHEDULED TO BEGIN ON OCTOBER 23 AND LAST FROM TWO
TO THREE WEEKS. DURING THE OUTAGE, THE UTILITY PLANS TO DO SOME TEMPORARY
PATCH WORK ON THE ABSORBER OUTLET DUCTING. THE UTILITY STATED THAT THIS
DUCTWORK WILL EVENTUALLY NEED SOME MAJOR REPLACEMENT WORK (PLANNED FOR
SOMETIME IN 198"+).
10/83 SYSTEM 744
11/83 SYSTEM 720
12/83 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
LAWRENCE 4 WAS ON LINE LESS THAN 600 HOURS DURING THE FOURTH QUARTER OF
1983 DUE TO LOW POWER DEMAND.
1/84 SYSTEM 744
2/84 SYSTEM 696
3/84 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR FGD-RELATED PROBLEMS WERE REPORTED DURING THE FIRST QUARTER
OF 1984.
4/84 SYSTEM 720
5/84 SYSTEM 744
6/84 SYSTEM 720
** FROBLEMS/SOLUTIONS/COMMENTS
A MAJOR OUTAGE OCCURRED DURING MAY AND JUNE TO REPLACE CORRODING OUTLET
DUCTWORK IN THE REHEAT SECTION. CARBON STEEL DUCTS WERE REPLACED WITH
FIBERGLASS.
7/84 SYSTEM 744
8/84 SYSTEM 744
9/84 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT OVERALL FGD SYSTEM AVAILABILITY FOR THE FIRST
THREE QUARTERS OF 1984 WAS ABOVE 90X.
13-505
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
SECTION 13
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGO SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
SQ2 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
KANSAS POWER
LAWRENCE
5
LAWRENCE
KANSAS
C
43.
815.
*#»#**
576
420
400
495
420
& LIGHT
( .100 LB/WMBTU)
( .500 LB/MMBTU)
(****** LB/MKBTU)
** 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 - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** MECHANICAL COLLECTOR
NUMBER
TYPE
** ESP
NUMBER
TYPE
*# PARTICLE SCRUBBER
NUMBER
NUMBER OF SPARES
INITIAL START-UP DATE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON NAME
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
PH CONTROL ADDITIVE
PRESSURE DROP - KPA
SUPERFICIAL GAS VELOCITY - M/S
COMBUSTION ENGINEERING
PULVERIZED COAL
CYCLING
599.78
148.9
107.
CARBON STEEL
4.9
(1271000 ACFM)
( 300 F)
( 350 FT)
( 16.0 FT)
( 10000 BTU/LB)
******
COAL
SUBBITUMINOUS
23260.
9.80
9.8-16.0
11.80
******
.55
0.55-0.90
.03
******
0
NONE
0
NONE
2
0
4/78
VENTURI TOWER
VARIABLE-THROAT/VERTICALLY-ADJUSTABLE ROD DECKS
ROD SCRUBBER
COMBUSTION ENGINEERING
5.0 X 37.0
STAINLESS STEEL
AUSTENITIC
NONE
N/A
TYPE 316L STAINLESS STEEL RODS
1
655.2 (10400 GPM)
2.2 (16.4 GAL/1000ACF)
LIMESTONE SLURRY
2.2 ( 9.0 IN-H20)
15.2 ( 50.0 FT/S)
13-506
-------
UTILITY F6D SURVEY: OCTOBER 1983 - SEPTEMBER 1984
KANSAS POWER & LIGHT: LAWRENCE 5 (CONT. )
INLET GAS FLOW RATE - CU.M/S
INLET GAS TEMPERATURE - C
PARTICLE REMOVAL EFFICIENCY - X
«** 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 - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
** qUEHCHER/PRESATURATOR
NUMBER
»* ABSORBER
NUMBER
NUMBER OF SPARES
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
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
NUMBER OF SPARES PER SYSTEM
NUMBER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
NUMBER OF STAGES
NUM3ER OF PASSES PER STAGE
FREEBOARD DISTANCE - M
DISTANCE BETWEEN STAGES - CM
DISTANCE BETWEEN VANES - CM
VANE ANGLES - DEGREES
PRESSURE DROP - KPA
SUFERFICAL GAS VELOCITY - M/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
WASH WATER SOURCE
WASH FREQUENCY
299.7
148.9
99.0
( 635000 ACFM)
( 300 F)
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
NONE
COMBUSTION ENGINEERING
BLACK * VEATCH
FULL SCALE
RETROFIT
X 98.90
52.00
1
4/78
4/78
9/69
2
0
SPRAY TOWER
OPEN COUHTERCURRENT SPRAY
N/A
COMBUSTION ENGINEERING
STAINLESS STEEL
AUSTENITIC
TYPE 316L
NONE
N/A
N/A
N/A
655.
2.6
.2
1.8
256.71
52.2
70.0
(10400 GPM)
19.1 GAL/1000 ACF)
.8 IN-H20)
6.0 FT/S)
544000 ACFM)
126 F)
PRIMARY COLLECTOR
2
0
1
IMPINGEMENT
BAFFLE
CLOSED VANE
HORIZONTAL
2
2
.09
30.48
8.9
90
.2
1.8
ORGANIC
( .3 FT)
(12.0 IN)
( 3.50 IN)
( 1.0 IN-H20)
( 6.0 FT/S)
FIBER-REINFORCED POLYESTER
POfJD RECYCLE
ONCE/DAY
13-507
-------
UTILITY F6D SURVEY: OCTOBER 1983 - SEPTEMBER 1984
KANSAS POWER & LIGHT: LAWRENCE 5 (CONT.)
WASH RATE - L/S 12.6
( 200 6AL/MIN)
*» REHEATER
NUMBER
NUMBER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
TEMPERATURE INCREASE - C
INLET FLUE GAS FLOW RATE - CU. M/S
INLET FLUE GAS TEMPERATURE - C
OUTLET FLUE GAS TEMPERATURE - C
NUMBER OF BUNDLES PER BANK
NUMBER OF TUBES PER BUNDLE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
*» FANS
NUMBER
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** DAMPERS
GENERIC TYPE
SPECIFIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
GENERIC TYPE
SPECIFIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
*« DAMPERS
GENERIC TYPE
SPECIFIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
( 25 F)
(1168000 ACFM)
( 125 F)
( 150 F)
2
1
IN-LINE
HOT WATER
FIN TUBE
13.9
551.18
51.7
65.6
2
66
CARBON STEEL
AISI 1110
CENTRIFUGAL
AMERICAN STANDARD
BOOSTER
INDUCED DRAFT
DRY
283.14 ( 600000 ACFM)
65.6 ( 150 F)
CARBON STEEL
LOUVER
NR
CARBON STEEL
HIGH STRENGTH LOW ALLOY IHSLA]
NONE
N/A
LOUVER
NR
CARBON STEEL
HIGH STRENGTH LOW ALLOY IHSLA]
NONE
N/A
LOUVER
NR
CARBON STEEL
HIGH STRENGTH LOW ALLOY IHSLA]
NONE
N/A
SCRUBBER INLET
CARBON STEEL
HIGH STRENGTH LOW ALLOY IHSLA1
NONE
N/A
SCRUBBER OUTLET
CARBON STEEL
HIGH STRENGTH LOW ALLOY IHSLA]
NONE
N/A
BYPASS
CARBON STEEL
HIGH STRENGTH LOW ALLOY [HSLAI
NONE
13-508
-------
UTILITY FGD SURVEY'- OCTOBER 1983 - SEPTEMBER 1984
KANSAS POWER t LIGHT: LAWRENCE 5 (CONT.)
LINER SPECIFIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
NUMBER
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
PRODUCT QUALITY - X SOLIDS
** TANKS
SERVICE
VENTURI i ABSORBER RECYCLE
ADDITIVE STORAGE
ADDITIVE DILUTION
MILL SUMP
MILL PRODUCT
RECLAIMED WATER
»* PUMPS
SERVICE
REACTION/RECYCLE TAHX BLEED
VENTURI RECIRCULATION
MIST ELIMINATOR WASH
MILL SLURRY
ADDITIVE DILUTION
ABSORBER RECIRCULATION
ADDITIVE TRANSFER
ADDITIVE STORAGE
ADDITIVE FEED
RECLAIMED WATER
»* SOLIDS CONCENTRATING/DEWATERINS
DEVICE
*** SLUDGE
** TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
INLET QUALITY - 7.
** DISPOSAL
NATUPE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE TREATMENT
*» DISPOSAL
NATU3 E
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE TREATMENT
** PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS
PHYSICAL VARIABLES
CONTROL LEVELS
MONITOR LOCATION
PROCESS CONTROL MANNER
PROCESS CHEMISTRY MODE
N/A
WET BALL MILL
COMPARTMENTED
HR
2
21.8 (
60.0
NUMBER
24 TPH)
1
1
****
****
****
****
NUMBER
*»**
2
****
2
2
2
#*»*
*-***
6
***»
NONE
FORCED OXIDATION
REACTION TANK
N/A
10.0
INTERIM
POND
Obl-SITE
PIPELINE
NONE
FINAL
POND
ON-SITE
OVERFLOW FROM INTERIM SLUDGE POND
NONE
PH, S02 CONCENTRATION
PERCENT SOLIDS, SLURRY FLOW, PRESSURE CHANGE ACR
PH 6.5
PH PROBES IN REACTION TANKS
AUTOMATIC
FEEDBACK
13-509
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 198*
KANSAS POWER & LIGHT: LAWRENCE 5 (CONT.)
** WATER BALANCE
WATER LOOP TYPE CLOSED
»* CHEMICALS AND CONSUMPTION
FUNCTION ABSORBENT
NAME LIMESTONE
PRINCIPAL CONSTITUENT 937 CAC03, 7X MGC03
SOURCE/SUPPLIER LAWRENCE, KANSAS
CONSUMPTION 4 TPH
POINT OF ADDITION BALL MILL
** 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
0/7* SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
THE LAWRENCE 5 BOILER WAS ORIGINALLY EQUIPPED WITH A LIMESTONE INJEC-
TION FGD SYSTEM MODELED AFTER THE FGD SYSTEM RETROFITED ONTO THE LAWRENCE
* BOILER. CONSTRUCTION OF THE LAWRENCE 5 BOILER AND SCRUBBING SYSTEM BE-
GAN IN MARCH 1968 AND PROCEEDED SIMULTANEOUSLY WITH THE RETROFIT WOPK ON
LAWRENCE *. 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/LIMESTOME 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 AMD
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.
8/7* SYSTEM 744
** FROBLEMS/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.
9/7* SYSTEM 720
10/7* SYSTEM 744
13-510
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
KANSAS POWER 4 LIGHT: LAWRENCE 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
THE UNIT OPERATED ON GAS AND OIL UNTIL OCTOBER 12 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
** 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
** PRCBLEMS/SOLUTIONS/COMMENTS
THE UNIT BURNED A MIXTURE OF 70X WYOMING AND 30X KANSAS COAL DURING JAN-
UARY.
Z/7S 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 AMD THE FGD
SYSTEM WAS BYPASSED.
7/75 SYSTEM .0 744 744 0
8/75 SYSTEM .0 744 744 0
13-511
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
KANSAS POWER 4 LIGHT' LAWRENCE 5 (CONT.)
. PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
<__*>«> »= == =C «- = «<»'*> => =!«««> <=__>_ t»CT=<=> C_<_____aD»«>«>C«, «_C_C__> _«_<__ W<»_ «_<*,.»__ _____ __«,
** PROBLEMS/SOLUTIONS/COMMENTS
OIL AND SAS 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.
SLURRY RECYCLE TANK SCREENS WERE REPLACED DURING THE SEPTEMBER-OCTOBER
PERIOD.
11/75 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
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 SYSTEM 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 507. 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.
13-512
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
KANSAS POWER t LIGHT: LAWRENCE 5 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
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 AND 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
** FROBLEMS/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
** PROBLEMS/SOLUTIONS/COMMENTS
OPERATION OF THE EXISTING MARBLE BED SCRUBBERS HAS BEEN QUITE SATISFACTORY
AND NEARLY 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 MW 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
U/77 SYSTEM 720
13-513
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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
D-lK__^,_ ____. ,= _«===,=«>>J «= = =, <*>o= ==><=. oo n= => = = = vc_w« <»_»« »«___ w~_ HE »____ «.»_,.
** PROBLEMS/SOLUTIONS/COMMENTS
THE SYSTEM OPERATED ACCEPTABLY THROUGHOUT OCTOBER AND NOVEMBER.
12/77 SYSTEM 744
1/78 SYSTEM 744
** PROBLEMS/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
At!D 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 APRIL 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/COMMENTS
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
13-514
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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
11/78 SYSTEM 720
** PROBLEMS/SOLUTIOHS/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 74* 642
1/79 SYSTEM 744
2/79 SYSTEM 672
*# 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 AST)
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 SYSTEM 744
11/79 SYSTEM 720
12/79 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS DCMN 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
13-515
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
KANSAS POWER 4 LIGHT: LAWRENCE 5 (CONT.)
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
_.____ -PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
MAINTENANCE ATTENTION DURING THE PERIOD.
1/80 SYSTEM 100.0 100.0 100.0 744 744 744
2/80 SYSTEM 100.0 51.7 696 360 360
3/80 SYSTEM 100.0 54.8 744 408 408
** 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 96.1 744 715 715 54.0
** FROBLEMS/SOLUTIONS/COMMENTS
A 29 HOUR OUTAGE OCCURRED 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 AIR
PREHEATER 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
12/80 SYSTEM 100.0 100.0 100.0 100.0 744 744 744
13-5:6
-------
UTILITY F6D SURVEY: OCTOBER 1983 - SEPTEMBER 198
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
KANSAS POWER 4 LIGHT- LAWRENCE 5 (CONT.)
_____ ____.__. . . PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
6/82 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE SECOND QUARTER 1982.
7/82 SYSTEM 744
8/82 SYSTEM 744
9/82 SYSTEM 720
10/82 SYSTEM 744
11/82 SYSTEM 720
12/82 SYSTEM 744
1/83 SYSTEM 744
2/83 SYSTEM 672
3/83 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
OVER THE PAST YEAR THE LAWRENCE 4 AND 5 FGD SYSTEMS HAVE OPERATED WITH NO
MAJOR PROBLEMS. THERE HAVE BEEN SOME CHRONIC MINOR PROBLEMS WITH SFRAY
HEADER PLUGGING. THERE MAY BE SOME MODIFICATIONS PERFORMED AT SOME POINT
IN THE FUTURE TO MINIMIZE THE PROBLEM.
THE DOWNSTREAM DUCTWORK IN BOTH THE LAWRENCE 4 AND 5 FGD SYSTEMS HAS BEEN
EXPERIENCING CORROSION THAT KILL REQUIRE SOME DEGREE OF REPLACEMENT.
THE CORROSION IS NOT RELATED TO CHLORIDES. A TIME TABLE FOR THE REPAIR
WORK WAS NOT REPORTED BY THE UTILITY.
4/83 SYSTEM 720
5/83 SYSTEM 744
6/83 SYSTEM 720
7/83 SYSTEM 744
8/83 SYSTEM 744
9/83 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED FORCED OUTAGES WERE ENCOUN-
TERED DURING THE PERIOD OF APRIL THROUGH SEPTEMBER.
THE NEXT UNIT OUTAGE IS SCHEDULED TO BEGIN THE FIRST WEEK OF OCTOBER AND
LAST FROM TWO TO THREE WEEKS. DURING THE OUTAGE, THE UTILITY PLANS TO DO
SOME TEMPORARY PATCH WORK ON THE ABSORBER OUTLET DUCTING. THIS TEMPORARY
PATCH WORK IS HOPED BY THE UTILITY TO LAST THROUGH 1984.
10/83 SYSTEM 744
11/83 SYSTEM 720
12/83 SYSTEM 744
13-518
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
KANSAS POWER I LIGHT: LAWRENCE 5 (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 FGD-RELATED OUTAGES WERE ENCOUNTERED
DURING THE FOURTH QUARTER OF 1983. FGD SYSTEM AVAILABILITY WAS 100X.
1/84 SYSTEM 744
2/84 SYSTEM 696
3/84 SYSTEM 744
4/84 SYSTEM 720
5/84 SYSTEM 744
6/84 SYSTEM 720
7/84 SYSTEM 744
8/84 SYSTEM 744
9/84 SYSTEM 720
#* PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT OVERALL FGD SYSTEM AVAILABILITY FOR THE FIRST
THREE QUARTERS OF 1984 WAS ABOVE 90X. NO MAJOR FGD-RELATED PROBLEMS WERE
REPORTED.
13-519
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
SECTION 13
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 - N6/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 - 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
** MECHANICAL COLLECTOR
NUMBER
NUMBER OF SPARES
TYPE
SUPPLIER
INLET FLUE GAS CAPACITY - CU.M/S
INLET FLUE GAS TEMPERATURE C
PRESSURE DROP - KPA
PARTICLE REMOVAL EFFICENCY -7.
** ESP
NUMBER
TYPE
** PARTICLE SCRUBBER
NUMBER
NUM3ER OF SPARES
INITIAL START-UP DATE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON NAME
SUPPLIER
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
KENTUCKY UTILITIES
GREEN RIVER
1-3
CENTRAL CITY
KENTUCKY
62.
387.
( .145 LB/MMBTU)
( .900 LB/MMBTU)
(****** LB/MMBTU)
264
65
59
62
65
BABCOCK t WILCOX
PULVERIZED COAL
PEAK
169.88
( 360000 ACFM)
( 760 F)
( 165 FT)
( 16.0 FT)
( 11250 BTU/LB)
10900-11600
50.
CARBON STEEL
4.9
COAL
BITUMINOUS
26167.
9.85
8.85-10.85
11.00
10.0-12.0
2.23
2.0-2.7
********
******
3
0
CYCLONE [MULTIPLE! 280/COLLECTOR
WESTERN PREC. DIVISION, JOY
( 105000 ACFM)
( 350 F)
( 2. IN-H20)
49.5
176.7
.5
80.0
0
NONE
1
0
9/75
VENTURI
VARIABLE-THROAT/TOP-ENTRY PLUMB BOB
N/A
AMERICAN AIR FILTER
CARBON STEEL; STAINLESS STEEL
AISI 1110; AUSTENITIC
INORGANIC
HYDRAULICALLY-BONDED MORTAR
NONE
1
13-520
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
KENTUCKY UTILITIES: GREEN RIVER 1-3 (CONT.)
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 - X
»** FGD SYSTEM
** GENERAL DATA
SALEABLE FRODUCT/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 SOS REMOVAL EFFICIENCY - X
ENERGY CONSUMPTION - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
»* DESIGN AND OPERATING PARAMETERS
DESIGN COAL SULFER CONTENT - X
DESIGN COAL HEAT CONTENT - J/6
DESIGN COAL ASH CONTENT - X
OPER. J MAINT. REQUIREMENT - MANHR/DAY
** QUENCHER/PRESATURATOR
NUMBER
** 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
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
NUMBER OF SPARES PER SYSTEM
NUMBER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
TRADE NiME/COMMON TYPE
MANUFACTURER
CONFIGURATION
NUMBER OF STAGES
129.1
.8
1.7
169.9
148.9
98.0
( 2050 GPM)
( 5.7 SAL/1000ACF)
( 7.0 IN-H20)
( 360000 ACFM)
( 300 F)
THROWAWAY PRODUCT
WET SCRUBBING
LIME
NONE
AMERICAN AIR FILTER
SARGENT i LUNDY
FULL SCALE
RETROFIT
X 99.50
98.00
4.6
1
6/76
9/75
6/73
3.80
25818.6
14.00
48.0
( 11100 BTU/LB)
1
0
PACKED TOWER
ENTRAINED PACKING
MOBILE BED CONTACTOR
AMERICAN AIR FILTER
20.0 X 20.0 X 3.0
CARBON STEEL; STAINLESS STEEL
AISI 1110; AUSTENITIC
N/A; TYPE 316
INORGANIC
HYDRAULICALLY-BONDED MORTAR
NR
PLASTIC/RUBBER MOBILE BALLS
1
614.
3.6
.7
3.7
142.99
46.7
80.0
98.0
9750 GPM)
27.0 GAL/1000 ACF)
3.0 IN-H20)
12.0 FT/S)
303000 ACFM)
116 F)
PRIMARY COLLECTOR
1
0
1
CENTRIFUGAL
RADIAL VANE
RADIAL BAFFLE
AMERICAN AIR FILTER
HORIZONTAL
1
13-521
-------
UTILITY FGD SURVEY: OCTOBER 1933 - SEPTEMBER 1984
KENTUCKY UTILITIES: GREEN RIVER 1-3 (CONT.)
NUMBER OF PASSES PER STAGE
FREEBOARD DISTANCE - M
DISTANCE BETWEEN VANES - CM
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
WASH WATER SOURCE
WASH FREQUENCY
WASH RATE - L/S
** REHEATER
NUMBER
NUMBER OF SPARES
NUMBER PER MODULE
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
OUTLET FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC 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
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MODULATION
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MODULATION
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
CONFIGURATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
»* DUCTWORK
LOCATION
CONFIGURATION
(13.5 FT)
7.6 (
.6 (
8.4 (
STAINLESS STEEL
AUSTENITIC
FRESH
CONTINUOUS
2.8 (
3.00 IN)
2.3 IN-H20)
27.5 FT/S)
45 GAL/MIN)
0
1
INDIRECT HOT AIR
EXTERNAL HEAT EXCHANGER
STEAM TUBE BUNDLE
.0
22.2
142.99
46.7
68.9
CARBON STEEL
AISI 1110
( 40 F)
( 303000 ACFM)
( 116 F)
( 156 F)
( 360000 ACFM)
( 300 F)
1
0
CENTRIFUGAL
BUFFALO FORGE
BOOSTER
FORCED DRAFT
DRY
169.88
148.9
CARBON STEEL
10
CONTROL
LOUVER
NR
NR
NR
NR
NR
NR
SHUT-OFF
GUILLOTINE
TCP-ENTRY GUILLOTINE/SEAL AIR
OPEN/CLOSED
CARBON STEEL
AISI 1110
NONE
N/A
INLET
RECTANGULAR
CARBON STEEL
AISI 1110
NONE
N/A
OUTLET
CIRCULAR
13-522
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
KEKTUCKY UTILITIES: GREEN RIVER 1-3 (CONT.)
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
«* DUCTWORK
LOCATION
CONFIGURATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
«* REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
NUMBER
NUMBER OF SPARES
PRODUCT QUALITY - X SOLIDS
»* TANKS
SERVICE
ABSORBER RECYCLE
REAGENT PREP PRODUCT
** PUMPS
SERVICE
SCRUBBER/ABSORBER RECIRCULATION
SLURRY TRANSFER
POND RETURN
BLEED STREAM
*» SOLIDS CONCENTRATING/DEWATERING
DEVICE
*** SLUDGE
** TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE TREATMENT
SITE DIMENSIONS
SITE CAPACITY - CU.M
SITE SERVICE LIFE - YRS
** PROCESS CONTROL AND INSTRUMENTATION
PROCESS STREAM
CHEMICAL PARAMETERS
PHYSICAL VARIABLES
CONTROL LEVELS
MONITOR TYPE
MONITOR LOCATION
PROCESS CHEMISTRY MODE
** WATER BALANCE
WATER LOOP TYPE
MAKEUP WATER ADDITION - LITERS/S
SOURCE OF MAKEUP WATER
CARBON STEEL
AISI 1110
INORGANIC
HYDRAULICALLY-BONDED MORTAR
RETROFIT DUCT TO FGD BOOSTER
CIRCULAR
CARBON STEEL
AISI 1110
NONE
N/A
SLAKER
BATCH
AGITATED TANK
1
0
20.0
NUMBER
FAN
NUMBER
3
2
z
z
NONE
BLEED
N/A
N/A
FINAL
POND
ON-SITE
PIPELINE
CLAY LINING [NATURALLY OCCURRING]
9 ACRES/35 FT
203629 ( 166.5 ACRE-FT)
12
REACTION TANK [PHI
S02, PH
GAS FLOW, PRESSURE DROP, PERCENT SOLIDS
PH 5.5-6.0; SOLIDS 10X
UNI FLO
PH-REACTANT TANK; DENSITY METERS-RECYCLE LINE
FEEDBACK
CLOSED
4.7
RIVER WATER
75 GPM)
13-523
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
KENTUCKY UTILITIES: GREEN RIVER 1-3 (CONT.)
** CHEMICALS AND CONSUMPTION
FUNCTION ABSORBENT
NAME LIME
CONSUMPTION 2 TPH
POINT OF ADDITION SLAKER
** FGD SPARE CAPACITY INDICES
SCRUBBER - 7. -0
ABSORBER - 7. »0
MIST ELIMINATOR - 7. .0
REHEATER - 7. .0
FAN - 7. .0
SLAKER - X .0
EFFLUENT HOLD TANK - 7. .0
RECIRCUUTION PUMP - X 33.0
** FGD SPARE COMPONENT INDICES
SCRUBBER .0
ABSORBER .0
MIST ELIMINATOR .0
REHEATER .0
FAN .0
SLAKER .0
EFFLUENT HOLD TANK .0
RECIRCULATICN PUMP 1.0
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
SOS PART. HOURS HOURS HOURS FACTOR
9/75 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE SYSTEM BECAME OPERATIONAL SEPTEMBER 13, 1975 ON A HALF-LOAD BASIS
BECAUSE OF A TURBINE OVERHAUL. LOGGING OF OPERATING DATA BEGAN DECEMBER
1975.
744
720
744 398 257
744 572 64
** 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 42.0 42.0 30.0 696 499 211
** PROBLEMS/SOLUTIONS/COMMENTS
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
13-524
10/75 SYSTEM
11/75 SYSTEM
12/75 SYSTEM 74.0 65.0 78.0
1/76 SYSTEM 42.0 11.0 14.0
35.0
9.0
-------
4/76
5/76
6/76
7/76
8/76
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
90
81
100
90
97
.0
.0
.0
.0
.0
100
100
99
98
97
.0
.0
.0
.0
.0
100
100
99
99
97
.0
.0
.0
.0
.0
77.
61.
82.
77.
97.
0
0
0
0
0
UTILITY FGD SURVEY: OCTOBER 1933 - SEPTEMBER 1984
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
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 THE 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.
HALF-LOAD OPERATIONS WERE CON-DUCTED THROUGHOUT THE PERIOD BECAUSE OF
BEARING PROBLEMS WITH ONE OF THE TWO TURBINE GENERATING UNITS.
11/76 SYSTEM 100.0 100.0 98.0 98.0 720 704 704
12/76 SYSTEM 73.0 97.0 87.0 70.0 744 536 517
** 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
** PRCBLEMS/SOLUTIONS/COMMENTS
DURING THE MONTH OF FEBRUARY IT WAS FOUND THAT THE CAP.BOLINE STACK LINER
WAS BADLY DETERIORATED. SCRUBBER AND BOILER OPERATIONS WERE TERMINATED
UNTIL THE STACK LINING WAS REPAIRED. THE STACK WAS REPAIRED FIRST BY
WELDING A BACKUP METAL PLATE TO THE PORTIONS OF THE STACK WHERE PITTING
13-525
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 198*
KENTUCKY UTILITIES: GREEN RIVER 1-3 (CONT.)
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
. PERFORMANCE DATA ,.
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
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 PARTICULATE 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
** PROBLEMS/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.
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 23.0 744 537 170
** PROBLEMS/SOLUTION'S/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
13-526
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
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 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 SYSTEM 64.0 100.0 98.0 64.0 744 474 474
** PROBLEMS/SOLUTIONS/COMMENTS
THE SCREENS ON THE SUCTION SIDE OF THE PUMPS THAT PUMP THE SLURRY FROM THE
PREP ROOM TO THE NOZZLES EXPERIENCED PLUGGING PROBLEMS. THE SCREENS GET
PLUGGED 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
** 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
13-527
-------
UTILITY FGD SURVEYS OCTOBER 1983 - SEPTEMBER 1984
KENTUCKY UTILITIES' GREEN RIVER 1-3 (COST.)
... . . . PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
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 11.2 100.0 100.0 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 THE 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/COMMENTS
THE UNIT 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
** 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 19SO. THE FGD SYSTEM WAS AVAILABLE THROUGHOUT THE
PERIOD BUT WAS NOT OPERATED.
1/80 SYSTEM 100.0 .0 744 0 0 .0
2/SO SYSTEM 100.0 .0 696 0 0 .0
13-528
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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
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 .0 730 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 SYSTEM 100.0 .0 720 0 0 .0
12/80 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.
1/81 SYSTEM 100.0 .0 744 0 0 .0
2/81 SYSTEM 100.0 .0 672 0 0 .0
3/81 SYSTEM 100.0 .0 744 0 0 .0
** PROBLEMS/SOLUTIONS/CCMMENTS
DURING MARCH AN ATTEMPT TO RUN A FULL LOAD COMPLIANCE TEST FAILED DUE TO
BLOWN INSULATORS. THE UTILITY IS PRESENTLY WAITING ON NEW INSULATORS.
THE FGD SYSTEM WAS AVAILABLE 100X OF THE TIME DURING THE FIRST QUARTER.
13-529
-------
UTILITY FGO SURVEY: OCTOBER 1983 - SEPTEMBER 1984
KENTUCKY UTILITIES: GREEN RIVER 1-3 (COST.)
_. -PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
502 PART. HOURS HOURS HOURS FACTOR
4/81 SYSTEM
5/81 SYSTEM
6/81 SYSTEM
100.0
100.0
100.0
.0
.0
.0
720
744
720
0
0
0
0
0
0
.0
.0
.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM DID NOT OPERATE DURING THE SECOND QUARTER 1981. THE UTILITY
IS WAITING FOR NEW GENERATOR TERMINAL LEADS. THE FGD SYSTEM WAS
AVAILABLE, HOWEVER, FOR OPERATION.
7/81 SYSTEM 100.0 .0 744 0 0 .0
8/81 SYSTEM 100.0 .0 744 0 0 .0
9/81 SYSTEM 100.0 .0 720 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
THE GREEN RIVER UNITS 1-3 REMAINED OFF LINE DURING THE SECOND QUARTER 1981.
THE FGD SYSTEM WAS AVAILABLE FOR OPERATION BUT WAS NOT NEEDED.
10/81 SYSTEM 100.0 .0 744 0 0
11/81 SYSTEM 100.0 .0 720 0 0
12/81 SYSTEM 100.0 .0 744 0 0
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS DOWN THROUGHOUT THE FOURTH QUARTER. THE UTILITY HAS IN-
TENDED TO OPERATE THE BOILER FOR A SHORT TIME HOWEVER, THE FGD SYSTEM
LIQUID CIRCUITS FROZE DUE TO THE WEATHER. BY THE TIME THE SYSTEM WAS
THAWED THE UTILITY NO LONGER REQUIRED THE POWER.
1/82 SYSTEM 100.0 .0 744 0 0 .0
2/82 SYSTEM 100.0 .0 672 0 0 .0
3/82 SYSTEM 100.0 .0 744 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE FIRST QUARTER THE SYSTEM WAS AVAILABLE FOR OPERATION; HOWEVER,
DUE TO A LACK OF POWER DEMAND THE SYSTEM DID NOT OPERATE.
4/82 SYSTEM 100.0 .0 720 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
THE SYSTEM DID NOT OPERATE DURING APRIL DUE TO A LACK OF POWER DEMAND.
5/82 SYSTEM 100.0 5.0 744 39 39
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MAY THE SYSTEM OPERATED APPROXIMATELY 39 HOURS IN PREPARATION FOR
TESTS SCHEDULED FOR JUNE.
6/82 SYSTEM 100.0 14.7 720 106 106
13-530
-------
UTILITY FGD SURVEY? OCTOBER 1983 - SEPTEMBER 1984
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 JUNE THE SYSTEM OPERATED APPROXIMATELY 106 HOURS IN WHICH TIME
COMPLIANCE TESTS WERE PERFORMED.
7/82 SYSTEM 100.0 100.0 100.0 8.5 744 63 63 6.9
** PROBLEMS/SOLUTIONS/COMMENTS
THE SYSTEM OPERATED ONLY 63 HOURS DURING JULY DUE TO LOW POWER DEMAND.
8/82 SYSTEM 100.0 .0 744 0 0 .0
9/82 SYSTEM 100.0 .0 720 0 0 .0
10/82 SYSTEM 100.0 .0 744 0 0 .0
*» PROBLEMS/SOLUTIONS/COMMENTS
THE SYSTEM DID NOT OPERATE DURING AUGUST, SEPTEMBER, OR OCTOBER DUE TO LOW
POWER DEMAND.
11/82 SYSTEM 100.0 100.0 100.0 1.5 720 11 11 .5
** PROBLEMS/SOLUTIONS/COMMENTS
THE SYSTEM OPERATED ONLY 11 HOURS DURING NOVEMBER DUE TO LOW POWER DEMAND.
12/82
1/83
2/83
3/83
SYSTEM
SYSTEM
SYSTEM
SYSTEM
100.0
100.0
100.0
100.0
0
0
0
0
744
744
672
744
0
0
0
0
0
0
0
0
.0
.0
.0
.0
** PROBLEMS/SOLUTIONS/COMMENTS
4/83
5/83
6/83
SYSTEM
SYSTEM
SYSTEM
THE SYSTEM DID NOT OPERATE DURING
1983 DUE TO LOW POWER DEMAND.
100.0
100.0
100.0
THE
0
0
0
PERIOD OF DECEMBER
720
744
720
1982
0
0
0
THROUGH
0
0
0
MARCH
.0
.0
.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE SYSTEM DID NOT OPERATE DURING THE SECOND
QUARTER DUE TO LOW POWER DEMAND.
7/83 SYSTEM 100.0 100.0 100.0 34.4 744 256 256 11.1
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING JULY.
8/83 SYSTEM 97.8 100.0 100.0 87.2 744 649 649 29.9
13-531
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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 UNIT WAS BROUGHT DOWN DURING AUGUST DUE TO LACK OF POWER DEMAND AND
REPAIRS WERE MADE ON A LEAKING FLOODED ELBOW PRECEDING THE MOBILE BED
CONTACTOR.
9/83 SYSTEM 98.6 100.0 97.1 46.0 720 331 331 12.9
** PROBLEMS/SOLUTIONS/COMMENTS
THE FGD SYSTEM WAS DOWN DURING PART OF SEPTEMBER DUE TO THE CONTINUED PROB-
LEM WITH THE LEAKING FLOODED ELBOW.
10/83 SYSTEM 100.0 .0 744 0 0 .0
11/83 SYSTEM 100.0 100.0 100.0 7.4 720 53 53 2.1
12/83 SYSTEM 100.0 .0 744 0 0 .0
#* PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE UNIT WAS DOWN DURING MOST OF THE FOURTH
QUARTER DUE TO LOW POWER DEMAND.
1/84 SYSTEM .0 .0 744 0 0 .0
2/84 SYSTEM .0 .0 696 0 0 .0
3/84 SYSTEM 100.0 .0 744 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE UNITS WERE OFF LINE DURING THE FIRST QUARTER
OF 19S4 DUE TO LOW POWER DEMAND. IN ADDITION, BECAUSE OF SEVERE WEATHER
CONDITIONS AND THE INTERMITTENT MODE OF OPERATION OF THE UNITS, THE FGD
SYSTEM WAS NOT AVAILABLE UNTIL MARCH.
4/84 SYSTEM 720
5/84 SYSTEM 74
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
SECTION 13
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 - K'G/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.
RAN3E 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
NUMBER
TYPE
** FABRIC FILTER
NUMBER
TYPE
** ESP
NUMBER
NUMBER OF SPARES
TYPE
SUPPLIER
INLET FLUE GAS CAPACITY - CU.M/S
INLET FLUE GAS TEMPERATURE - C
PARTICLE REMOVAL EFFICENCY - 7.
»* PARTICLE SCRUBBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON NAME
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LItJER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
LAKELAND UTILITIES
MCINTOSH
3
LAKELAND
FLORIDA
C
19.
516.
******
570
350
495
364
BABCOCK t WILCOX
PULVERIZED COAL
BASE
( .044 LB/MMBTU)
( 1.200 LB/MMBTU)
(****** LB/MMBTU)
********
143.3
76.
CONCRETE
*******
COAL
BITUMINOUS
26749.
10.00
7.0-17.0
6.00
4.2-9.5
2.56
1.3-3.6
.01
0.01-0.14
0
NONE
0
NONE
2
0
COLD SIDE
BABCOCK 4 WILCOX
251.9
138.9
99.6
0
NONE
N/A
N/A
N/A
N/A
N/A
N/A
N/A
(******* ACFM)
( 290 F)
C 250 FT)
(***** FT)
( 11500 BTU/LB)
11200-13500
( 533800 ACFM)
( 282 F)
13-533
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
LAKELAND UTILITIES: MCINTOSH 3 (CONT.)
*** 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 - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
SPACE REQUIREMENTS - SQ M
OPER. I MAINT. REQUIREMENT - MANHR/DAY
** QUEUCHER/PRESATURATOR
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** ABSORBER
NUMBER
NUM5ER OF SPARES
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
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 - '/.
«* MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
NUMBER OF STAGES
DISTANCE BETWEEN VANES - CM
PRESSURE DROP - KPA
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
WASH FREQUENCY
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
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
NONE
BABCOCK & WILCOX
C.T. MAIN
FULL SCALE
NEW
'/. 99.60
85.00
1
9/82
7/82
3/78
( 20000 SQ FT)
1858.0
24.0
NR
NR
2
0
SPRAY TOWER
OPEN COUNTERCURRENT SPRAY
N/A
BABCOCK & WILCOX
STAINLESS STEEL
AUSTENITIC
NR
NONE
N/A
N/A
NONE
2
2520.
10.7
1.9
584.64
54.4
85.0
(40000 GPM)
( 80.0 GAL/1000 ACF)
( 7.5 IN-H20)
(1238898 ACFM)
( 130 F)
PRIMARY COLLECTOR
2
IMPINGEMENT
BAFFLE
CLOSED VANE
HORIZONTAL
2
114.3
.1
ORGANIC
VINYL ESTER
CONTINUOUS
14.4
(45.00 IN)
( .5 IN-H20)
( 229 GAL/MIN)
INDIRECT HOT AIR
EXTERNAL HEAT EXCHANGER
STEAM TUBE BUNDLE
22.2 ( 40 F)
73.55 ( 155858 ACFM)
13-534
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
LAKELAND UTILITIES: MCINTOSH 3 (CONT.)
INLET FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** FANS
NUMBER
NUMBER OF SPARES
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
PRESSURE DROP - KPA
CONSTRUCTION MATERIAL GENERIC TYPE
»» FANS
NUMBER
SUPPLIER
** FANS
NUMBER
NUMBER OF SPARES
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
PRESSURE DROP - KPA
CONSTRUCTION MATERIAL GENERIC TYPE
«* DAMPERS
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
»* DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
NUMBER
FULL LOAD DRY FEED CAPACITY - M.TONS/HR
** TANKS
SERVICE
193.9 (
STAINLESS STEEL
AUSTENITIC
2
0
CENTRIFUGAL
TLT-BABCOCK
UNIT
FORCED DRAFT
DRY
6.4
CARBON STEEL
381 F)
(20.9 IN-H20)
(33.1 IN-H20)
TLT-BABCOCK
2
0
CENTRIFUGAL
GREEN FAN
BOOSTER
FORCED DRAFT
DRY
10.1
CARBON STEEL
NR
NR
NR
NR
NR
NR
NR
ID FAN DISCHARGE TO STACK
CARBON STEEL
AISI 1110
ORGANIC
INERT FLAKE-FILLED VINYL ESTER
2 BYPASS STREAMS
CARBON STEEL
AISI 1110
INORGANIC
HYDRAULICALLY-BONDED MORTAR
WET BALL MILL
COMPARTMENTED
NR
1
13.6 ( 15 TPH)
NUMBER
ABSORBER RECYCLE
QUENCHER
THICKENER OVERFLOW
13-535
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
LAKELAND UTILITIES: MCINTOSH 3 CCONT.)
*« PUMPS
SERVICE
NUMBER
8
4
Z
VACUUM FILTER
3
0
1080 TON/DAY
30X SOLIDS
55X SOLIDS
THICKENER
1
0
CIRCULAR
140.0 DIA
CARBON STEEL
157. SOLIDS
30X SOLIDS
28.8
ABSORBER RECIRCULATION
QUENCHER RECIRCULATION
CLARIFIED RECIRCULATION WATER
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
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
FULL LOAD SLUDGE QUANTITY - M.TONS/HR (DRY)
** TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
INLET QUALITY - X
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE TREATMENT
SITE DIMENSIONS
SITE CAPACITY CU.M
SITE SERVICE LIFE - YRS
** PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS
CONTROL LEVELS
PROCESS CONTROL MANNER
PROCESS CHEMISTRY MODE
** WATER BALANCE
WATER LOOP TYPE CLOSED
EVAPORATION WATEP LOSS - LITER/S 20.3
31.7 TPH)
FIXATION
PUG MILL
CONVERSION SYSTEMS IPOZ-0-TEC1
55.0
FINAL
LANDFILL
ON-SITE
TRUCK
NONE
125 ACRES X 40 FT
6115000 ( 5000.0 ACRE-FT)
30
PH, DENSITY, GAS FLOW, S02
PH 5.5-6.0
AUTOMATIC
FEED FORWARD
POND SEEPAGE/RUNOFF WATER LOSS - LITERS/S 303
MAKEUP WATER ADDITION - LITERS/S
** CHEMICALS AND CONSUMPTION
FUNCTION
NAME
PRINCIPAL CONSTITUENT
CONSUMPTION
** FGD SPARE CAPACITY INDICES
ABSORBER - X
** FGD SPARE COMPONENT INDICES
ABSORBER
14.4
ABSORBENT
LIMESTONE
CAC03
96000 TONS/YR
.0
.0
322 GPM)
228 GPM)
13-536
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
LAKELAND UTILITIES: MCINTOSH 3 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
SOS PART. HOURS HOURS HOURS FACTOR
7/82 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
INITIAL FGD OPERATIONS BEGAN AT THIS FACILITY DURING JULY. THE SYSTEM IS
CURRENTLY UNDERGOING SHAKEDOWN/DEBUGGING OPERATIONS.
8/82 SYSTEM 744
9/82 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE MCINTOSH 3 UNIT (BOILER AND FGD SYSTEM) COMMENCED COMMERICAL OPERATION
ON SEPTEMBER 1, 1982.
10/82 SYSTEM 744
11/82 SYSTEM 720
12/82 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE FOURTH QUARTER 1982.
1/83 SYSTEM 744
2/83 SYSTEM 672
3/83 SYSTEM 744
** PROSLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT IT WAS PLEASED WITH THE OPERATION OF THE UNIT
AND FGD SYSTEM. THE FGD SYSTEM AVAILABILITY IS REPORTED TO BE GREATER
THAN 95X.
NOTE: IN ADDITION TO HAVING THE CAPABILITY OF BURNING APPROXIMATELY 140
TONS/HR OF BITUMINOUS COAL WITH ASH CONTENTS RANGING FROM 7 TO 17
/., THE BOILER IS ALSO DESIGNED TO BURN REFUSE DERIVED FUEL (RDF).
THE UNIT IS CURRENTLY BURNING 300 TONS/DAY OF RDF COLLECTED FROM
THE NEARBY CITY OF LAKELAND, FLORIDA. THE RDF IS CONSUMED NORMALLY
WITHIN ONE 8 HOUR SHIFT. THE REPORTED HEAT CONTENT OF THE RDF IS
APPROXIMATELY 5000 BTU/LB COMPARED TO THE AVERAGE 11500 BTU/LB FOR
THE COAL. THE RDF PLANT AND BOILER HAVE THE CAPACITY OF BURNING
AN ADDITIONAL 8 TO 12 HOURS OF RDF (300 TO 450 TONS). THE UTILITY
CURRENTLY RECEIVES S6/TON FOR RDF DISPOSAL.
4/83 SYSTEM 720
5/83 SYSTEM 744
6/83 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE PERIOD OF APRIL THROUGH JUNE, 1983.
7/83 NORTH 100.0 100.0 100.0 97.3
SOUTH 77.3 79.3 100.0 78.9
SYSTEM 100.0 89.7 100.0 87.3 744 724 655 83.0
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
LAKELAKD UTILITIES: MCINTOSH 3 (CONT.)
. PERFORMANCE DATA-
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
502 PART. HOURS HOURS HOURS FACTOR
8/83
9/83
NORTH
SOUTH
SYSTEM
NORTH
SOUTH
SYSTEM
100.0
77.3
100.0
100.0
77.3
100.0
100.0
79.3
89.7
100.0
79.3
89.7
100,0
100.0
100.0
100.0
100.0
100.0
97.3
78.9
87.3
97.3
78.9
87.3
744 724 65S 83.0
720 701 634 83.0
** PROBLEMS/SOLUTIONS/COMMENTS
10/83
11/83
12/83
NORTH
SOUTH
SYSTEM
NORTH
SOUTH
SYSTEM
NOPTH
SOUTH
SYSTEM
56.5
46.4
51.5
56.5
46.4
51.4
56.5
46.4
51.5
100.0
82.0
91.0
100.0
82.1
91.0
100.0
82.0
91.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
56.5
46.4
51.5
56.5
46.4
51.4
56.5
46.4
51.5
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE PERIOD OF JULY THROUGH SEPTEMBER 1983.
744 421 333 69.4
720 407 370 69.4
744 421 383 69.4
#* PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE FOURTH QUARTER OF 1983.
744 744 744 87.3
696 264 312 25.8
744 144 144 8.5
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR FGD RELATED PROBLEMS WERE REPORTED DURING THE FIRST THREE
QUARTERS OF 1984.
4/84 SOUTH 100.0 100.0 101.8 98.4
NORTH
SYSTEM 720 696 78.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS AROSE DURING APRIL.
5/84 SOUTH 96.8 100.0 102.4 95.8
NORTH
SYSTEM 96.8 100.0 100.0 95.8 744 696 713 75.6
1/84
2/84
3/84
SOUTH
NORTH
SYSTEM
SOUTH
NORTH
SYSTEM
SOUTH
NORTH
SYSTEM
100.0
100.0
100.0
100.0
19.4
19.4
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
44.8
44.8
19.4
19.4
13-538
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
LAKELAND UTILITIES: MCINTOSH 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 MAJOR FGD-RELATED PROBLEMS AROSE DURING MAY.
6/84 SOUTH 100.0 100.0 103.6 99.2
NORTH
SYSTEM 100.0 100.0 100.0 99.2 720 672 714 74.5
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS AROSE DURING JUNE.
NORTH MODULE DATA WAS NOT REPORTED DURING THE FIRST TWO QUARTERS OF 1984
DUE TO SUSPECTED PROBLEMS WITH AN ELAPSED TIME METER.
7/84 SYSTEM 744
8/84 SYSTEM 744
9/84 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE THIRD QUARTER OF 1984.
13-539
-------
UTILITY FGD SURVEY : OCTOBER 1983 - SEPTEMBER
SECTION 13
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGO SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
SOS EMISSION LIMITATION NG/J
UOX 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 - '/.
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - '/.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RAN3E CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** MECHANICAL COLLECTOR
NUMBER
TYPE
** ESP
NUMBER
NUMBER OF SPARES
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
TRADE NAME/COMMON NAME
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
*** FGD SYSTEM
LOUISVILLE GAS & ELECTRIC
CANE RUN
LOUISVILLE
KENTUCKY
E
50.
516.
C .116 LB/MMBTU)
( 1.200 LB/MMBTU)
(****** LB/MMBTU)
992
188
175
178
188
COMBUSTION ENGINEERING
PULVERIZED COAL
CYCLING
346.37 (
160.0 (
76. (
CONCRETE
5.8
734000 ACFM)
320 F)
250 FT)
( 19.0 FT)
( 11300 BTU/LB)
10400-11900
COAL
BITUMINOUS
26284.
15.00
10.0-20.0
9.00
8.0-10.8
3.87
3.5-4.0
.04
0.03-0.06
0
NONE
2
0
COLD SIDE
RESEARCH-COTTRELL
172.2 ( 365000 ACFM)
160.0 ( 320 Ft
.0 (0. IN-H20)
99.0
0
NONE
N/A
N/A
N/A
N/A
N/A
N/A
N/A
13-540
-------
LOUISVILLE GAS « ELECTRIC: CANE RUN 4 (CONT.)
UTILITY F6D SURVEY: OCTOBER 1983 - SEPTEMBER 1984
** 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
ENERGY CONSUMPTION - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
*# DESIGN AND OPERATING PARAMETERS
DESIGN COAL SULFER CONTENT - X
DESIGN COAL HEAT CONTENT - J/G
DESIGN COAL ASH CONTENT - X
DESIGN MOISTURE CONTENT - X
DESIGN CHLORIDE CONTENT - X
OPER. & MAINT. REQUIREMENT - MANHR/DAY
#» QUENCHER/PRESATURATOR
NUMBER
TYPE
SUPPLIER
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
PRESSURE DROP - KPA
LIQUID RECIRCULATION RATE - LITERS/S
L/G RATIO - L/CU. M
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** ABSORBER
NUM3ER
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
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
NUMBER OF SPARES PER SYSTEM
NUMBER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
THROWAWAY PRODUCT
WET SCRUBBING
LIME
NONE
AMERICAN AIR FILTER
FLUOR - PIONEER
FULL SCALE
RETROFIT
X 99.00
85.00
1.6
1
8/77
8/76
4.00
25586.0 ( 11000 BTU/LB)
15.00
12.00
.07
304.0
WETTED WALL CONICAL FRUSTUM
AMERICAN AIR FILTER
172.24 (
160.0 (
.5 (
111. (
.6 (
CARBON STEEL
AISI 1110
365000 ACFM)
320 F)
2.0 IN-H20)
1760 GPM)
4.8 GAL/1000 ACFM)
2
0
PACKED TOWER
ENTRAINED PACKING
MOBILE BED CONTACTOR
AMERICAN AIR FILTER
20.0 X 20.0 X 27.5
CARBON STEEL
AISI 1110
N/A
INORGANIC; ORGANIC
HYDRAULICALLY-BONDED MORTAR;
PRE-KRETE G-8; PLASITE
PLASTIC/RUBBER MOBILE BALLS
1
1110. (17625 GPM)
8.1 ( 60.5 GAL/1000 ACF)
1.5 ( 6.0 IN-H20)
3.7 (12.0 FT/S)
137.56 ( 291500 ACFM)
54.4 ( 130 F)
87.0
PRIMARY COLLECTOR
2
0
1
IMPINGEMENT
BAFFLE
CLOSED VANE
HORIZONTAL
INERT FLAKE-FILLED
13-541
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 198*
LOUISVILLE SAS * ELECTPIC: CANE RUN
-------
UTILITY FGD SURVEY' OCTOBER 1983 - SEPTEMBER
LOUISVILLE GAS & ELECTRIC: CANE RUN <* (CONT.)
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
MODULATION
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
»# DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
MODULATION
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
«* DUCTKORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
NUMBER
NUMBER OF SPARES
PRODUCT QUALITY - X SOLIDS
** TANKS
SERVICE
AISI 1110
NR
NR
SHUT-OFF
GUILLOTINE
TOP-ENTRY GUILLOTINE/SEAL AIR
AMERICAN AIR FILTER
OPEN/CLOSED
CARBON STEEL
AISI 1110
NONE
N/A
SHUT-OFF
GUILLOTINE
TOP-ENTRY GUILLOTINE/SEAL AIR
AMERICAN AIR FILTER
OPEN/CLOSED
CARBON STEEL
AISI 1110
NR
NR
SCRUBBER INLET
CARBON STEEL
AISI 1110
NONE
N/A
SCRUBBER OUTLET TO REHEATER
CARBON STEEL
AISI 1110
ORGANIC
INERT FLAKE-FILLED VINYL ESTER
OUTLET FROM REHEATER TO STACK
CARBON STEEL
AISI 1110
INORGANIC
HYDRAULICALLY-BONDED MORTAR
BYPASS
CARBON STEEL
AISI 1110
NONE
N/A
GRINDING OF SOLIDS FOUND IN BARGE DELIVERED CARB
BALL MILL
TUBE MILL
1
0
35.0
NUMBER
ABSORBER RECYCLE
LIME SLURRY HOLD TANK
RECYCLE
13-543
-------
UTILITY FGO SURVEY: OCTOBER 1983 - SEPTEMBER 1984
LOUISVILLE GAS & ELECTRIC: CANE RUN 4 (CONT.)
** PUMPS
SERVICE
ABSORBER RECIRCULATION
THICKENER UNDERFLOW
THICKENER OVERFLOW
LIME SLURRY FEED
BLEED
»* SOLIDS CONCENTRATING/DEHATERING
DEVICE
NUMBER
NUMBER OF SPARES
CONFIGURATION
DIMENSIONS - FT
SHELL GENERIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
FEED STREAM SOURCE
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
OVERFLOW STREAM CHARACTERISTICS
CUTLET STREAM DISPOSITION
OVERFLOW STREAM DISPOSITION
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
CONFIGURATION
CAPACITY
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
BELT GENERIC MATERIAL TYPE
BELT SPECIFIC MATERIAL TYPE
FEED STREAM SOURCE
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
NUMBER
6
2
Z
z
4
THICKENER
1
0
CIRCULAR
85.0 DIA X 14.0
CARBON STEEL
NONE
N/A
ABSORBER BLEED
10X SOLIDS
245 GPM, 25X SOLIDS
185 GPM
VACUUM FILTER
LIME HOLD TANK 4 REACTION TANKS
VACUUM FILTER
2
1
CIRCULAR
500 GPM
NR
NR
NR
NR
N/A
N/A
THICKENER UNDERFLOW
25X SOLIDS
60X SOLIDS
*** SLUDGE
FULL LOAD SLUDGE QUANTITY - M.TONS/HR (DRY)
** TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
INLET QUALITY - 7.
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE TREATMENT
SITE SERVICE LIFE - YRS
** PROCESS CONTROL AND INSTRUMENTATION
PROCESS STREAM
CHEMICAL PARAMETERS
CONTROL LEVELS
MONITOR LOCATION
PROCESS CONTROL MANNER
PROCESS CHEMISTRY MODE
5.7
6.3 TPH)
FIXATION
PUG MILL
CONVERSION SYSTEMS IPOZ-0-TEC]
60.0
FINAL
LANDFILL
ON-SITE
TRUCK
CLAY LINING
10
RECYCLE LIQUOR
PH
PH 6.1-6.2 AT OUTLET 4 8.5 AT INLET TO ABSORBER
REACTION TANK
AUTOMATIC
FEEDBACK
-------
LOUISVILLE GAS t ELECTRIC: CANE RUN 4 (CONT.)
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
** WATER BALANCE
WATER LOOP TYPE
RECEIVING WATER STREAM
MAKEUP WATER ADDITION - LITERS/S
*# CHEMICALS AND CONSUMPTION
FUNCTION
NAME
PRINCIPAL CONSTITUENT
SOURCE/SUPPLIER
CONSUMPTION
UTILIZATION - X
POINT OF ADDITION
*» FGD SPARE CAPACITY INDICES
ABSORBER - 7.
MIST ELIMINATOR - X
REHEATER - X
FAN - 7.
EFFLUENT HOLD TANK - X
RECIRCULATION PUMP - X
THICKENER - X
VACUUM FILTER
«* FGD SPARE COMPONENT INDICES
ABSORBER
MIST ELIMINATOR
REHEATER
FAN
BALL MILL
EFFLUENT HOLD TANK
RECIRCULATION PUMP
THICKENER
VACUUM FILTER
OPEN/CLOSED
OHIO RIVER
6.3
( 100 GPM)
ABSORBENT
BETZ POLYFLOC 1100
CAOH2
AIRCO
15000 LB/HR DRY CAIOH12 AT FULL LOAD
100.0
RECYCLE TANK
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
8/76 SYSTEM 92.3 90.0
** PROBLEMS/SOLUTIONS/COMMENTS
91.0
89.5
87.00 99.00 744 740
666 65.0
9/76 SYSTEM
10/76 SYSTEM
91.5
92.6
INITIAL OPERATIONS OF THE CANE RUN 4 FGD SYSTEM BEGAN IN AUGUST WITH
THE SYSTEM OPERATING 90X 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
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.
90.0
90.0
90.5
90.7
90.0
72.6
88.00
90.00
720
744
720
600
648
540
62.0
51.0
13-545
-------
UTILITY FGD SURVEY: OCTOBER 1933 - SEPTEMBER 1984
LOUISVILLE GAS & ELECTRIC: CANE RUN 4 (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 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 96.0 95.0 94.0 79.2 89.00 720 600 570 52.0
12/76 SYSTEM 92.0 90.0 93.0 72.3 85.00 744 598 538 53.0
»* PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT OPERATED ON CARBIDE LIME DURING THE NOVEMBER-DECEMBER PERIOD.
1/77 SYSTEM 42.0 37.7 40.0 33.7 86.00 744 666 251 32.0
** PROBLEMS/SOLUTIONS/COMMENTS
DUE TO OHIO RIVER FREEZE UP BARGE DELIVERIES OF LIME CEASED CAUSING
THE FGD SYSTEM TO BE TAKEN OFF LINE ON JANUARY 12.
2/77 SYSTEM 100.0 1.2 672 0 8 .0
*» PR03LEMS/SOLUTIONS/COMMENTS
DURING FEBRUARY, THE SCRUBBER WAS ONLY OPERATED FOR TWO 4-HOUR PERIODS
TO PREVENT TOTAL FREEZE-UP.
3/77 SYSTEM 91.0 82.9 76.0 48.1 744 432 358 51.0
** 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 95.0 92.7 92.0 60.0 720 466 432 49.0
5/77 SYSTEM .0 744 0
6/77 SYSTEM .0 720 0
** PR03LEMS/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 HOT
YET FAILED, FAILURE SEEMED IMMINENT WITHIN 4-5 MONTHS). THE NEW LINING
WAS INSTALLED BY GENERAL COATINGS.
7/77 SYSTEM 95.0 90.0 90.0 43.5 744 360 324 36.0
13-546
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
LOUISVILLE GAS i 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 SYSTEM WAS PLACED BACK IN SERVICE ON JULY 17, 1977 AFTER SYSTEM
MODIFICATIONS WERE COMPLETED.
8/77
9/77
SYSTEM 79.0 89.5 90.0
SYSTEM 98.9 99.1 99.0
#* PROBLEMS/SOLUTIONS/COMMENTS
79.0
72.8
720
657
529
588 60.0
524 59.0
COMPLIANCE TESTING OCCURED DURING AUGUST AND SEPTEMBER 1977 BY EPA
PERSONNEL AND WAS OFFICIALLY APPROVED TO HAVE ACHIEVED COMPLIANCE.
10/77 SYSTEM
11/77 SYSTEM
12/77 SYSTEM
98.1
69.9
85.0
97.8
94.0
85.0
99.0
94.0
100.0
89.0
62.9
81.7
744
720
744
677
483
715
662 51.0
453 53.0
608 48.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING DECEMBER, "AIRCO", THE LIME SUPPLIER, HAD 1200 FT OF THEIR FEED
LINE FREEZE UP CAUSING LIME TO BECOME UNAVAILABLE FOR A SHORT TIME.
1/78
2/78
3/78
SYSTEM
SYSTEM
SYSTEM
66.4
100.0
100.0
66.6
33.5
87.0
35.0
66.4
.0
33.5
744
672
744
742
0
744
494 50.0
0 .0
249 52.0
** PROBLEMS/SOLUTIONS/COMMENTS
4/78
5/78
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.
SYSTEM 100.0 100.0 100.0 42.1 720 303 303 51.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS DOWN PART OF APRIL FOR REPAIRS.
SYSTEM 31.0 32.7 35.0 15.5 744 352 115 42.0
** 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.
6/78 SYSTEM
7/78 SYSTEM
8/78 SYSTEM
9/78 SYSTEM
99.3
98.8
100.0
100.0
99.3
98.7
94.2
100.0
99.3
98.7
96.0
100.0
99.3
91.1
94.2
19.2
720
744
744
720
720
687
744
138
715 50.0
678 44.0
701 53.0
138 31.0
13-547
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 198"+
LOUISVILLE GAS 4 ELECTRIC: CANE RUN 4 (CONT.)
____-- ___PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION Y. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
«* 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 100.0 97.2 98.0 58.3 720 432 420 36.0
** 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 FGO 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/SOLOTIONS/COMMENTS
THE UNIT DID NOT OPERATE DURING THESE 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 100.0 46.2 46.2 17.1 720 266 123 34.0
** 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.
744 701 692 62.0
744 744 664 61.0
720 168 0 36.0
** FROBLEMS/SOLUTIONS/COHMENTS
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 72.0 30.1 70.0 12.0 744 296 89 39.0
13-548
7/79 SYSTEM
8/79 SYSTEM
9/79 SYSTEM
93.0
92.0
98.7
89.2
.0
97.0
89.0
93.0
89.2
.0
-------
1/80 SYSTEM
2/80 SYSTEM
3/80 SYSTEM
100.0
100.0
82.0
100.0
99.8
80.5
99.0
99.0
80.0
95.6
66.7
74.3
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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
11/79 SYSTEM 96.0 93.9 94.0 58.1 720 445 418 42.0
12/79 SYSTEM 91.0 38.5 38.0 20.2 744 390 150 40.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE FOURTH QUARTER 1979 THERE WERE NO MAJOR PROBLEMS. THE LOW
SCRUBBER HOURS WERE A RESULT OF NECESSARY MAINTENANCE.
744 711 711 53.0
696 465 464 41.0
744 687 553 55.0
** 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 48.0
** 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 10.0
** 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.
6/30 SYSTEM .0 .0 .0 720 350 0 32.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING PART OF JUNE THE BOILER WAS ON RESERVE, IN WHICH TIME THE SCRUBBER
DUCTKORK AND LININGS WERE REPAIRED.
REPAIRS WERE MADE TO MODULE LININGS AND DUCTWORK. DUCTWORK REPAIRS/
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 85.7 744 687 638 58.0
** 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 76.9 744 576 572 50.0
9/80 SYSTEM 100.0 100.0 100.0 35.7 720 257 257 50.0
13-549
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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 UTILITY REPORTED THAT NO MAJOR OUTAGES OCCURRED DURING AUGUST AND
SEPTEMBER.
10/80 SYSTEM 100.0 100.0 100.0 83.1 744 611 611 50.0
*» PROBLEMS/SOLUTIONS/COtlMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE MONTH OF OCTOBER.
11/80 SYSTEM 71.8 52.6 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.
1/81 SYSTEM 81.0 81.0 81.0 81.0 744 744 604 35.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JANUARY THE FGD SYSTEM WAS OUT OF SERVICE APPROXIMATELY 140 HOURS
DUE TO A LACK OF AVAILABLE LIME.
2/81 SYSTEM .0 .0 .0 .0 672 268 0 35.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING FEBRUARY THE FGD SYSTEM WAS NOT AVAILABLE DUE TO MIST ELIMINATOR
AND DUCTK'OPK PROBLEMS.
3/81 SYSTEM 100.0 100.0 100.0 39.0 744 290 290 35.0
** PRCBLEMS/SOLUTIONS/COMMENTS
DURING MARCH THE UTILITY REPORTED THAT NO MAJOR FGD-REUTED PROBLEMS WERE
ENCOUNTERED.
4/81 SYSTEM 100.0 .0 720 0 0 .0
5/81 SYSTEM 100.0 .0 744 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE MONTHS OF APRIL AND MAY THE UNIT DID NOT OPERATE. HOWEVER,
THE FGD SYSTEM WAS AVAILABLE 100X.
6/81 SYSTEM 84.2 80.4 80.4 63.6 720 570 458 50.0
13-550
-------
UTILITY FGO SURVEY? OCTOBER 1983 - SEPTEMBER 1984
LOUISVILLE GAS 4 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
DURING THE MONTH OF JUNE THE PUMP PIT WAS SUBMERGED IN SLURRY.
7/81 SYSTEM 72.6 100.0 100.0 72.6 744 540 540 50.0
S/81 SYSTEM 39.9 65.9 65.9 39.9 744 451 297 50.0
9/81 SYSTEM 60.8 100.0 100.0 60.8 720 438 438 50.0
** PROBLEMS/SOLUTIONS/COMMENTS
ABSORBER MODULE PLUGGING ACCOUNTED FOR THE MAJORITY OF THE FGD SYSTEM
OUTAGE TIME DURING THE THREE MONTH PERIOD.
744 522 487 40.0
720 718 715 40.0
744 487 487 40.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE FOURTH QUARTER 1981.
1/82 SYSTEM 11.0 4.0 4.0 3.0 744 557 22 54.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JANUARY, LOW SYSTEM DEPENDABILITY PARAMETERS WERE DUE TO COLD
WEATHER FREEZING THE MOBILE BALLS AND PLUGGING THE MOBILE BED CONTACTOR.
2/82 SYSTEM .0 .0 .0 .0 672 0 0 50.0
3/82 SYSTEM 100.0 100.0 100.0 52.8 744 393 393 46.0
** PROBLEMS/SOLUTIONS/COMMENTS
FROM JANUARY 24 TO MARCH 8 THE UNIT AND MODULES WERE DOWN FOR GENERAL
REPAIRS.
10/81 SYSTEM
11/81
SYSTEM
12/81 SYSTEM
65.4
99.3
65.4
93.3
99.6
100.0
93.3
99.6
100.0
65.4
99.3
65.4
4/82
5/82
6/82
SYSTEM
SYSTEM
SYSTEM
97.1
92.3
94.6
96.4
91.2
93.8
96.4
91.2
93.8
70
79
81
.6
.2
.7
720
744
720
527
649
627
506
592
588
50
50
50
.0
.0
.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT
DURING THE SECOND QUARTER
7/82
8/82
9/82
SYSTEM
SYSTEM
SYSTEM
74.7
57.4
71.0
81.5
83.6
94.6
81.5
83.6
94.6
NO MAJOR FGD-RELATED
1982.
74
57
71
.7
.4
.0
PROBLEMS
744
744
720
WERE
682
511
540
ENCOUNTERED
556
427
511
50
50
50
.0
.0
.0
13-551
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1934
LOUISVILLE GAS S ELECTRIC: CANE RUN 4 (CONT.)
10/82
11/82
12/82
1/83
2/83
3/83
4/83
5/83
6/83
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
61
75
84
72
48
57
19
16
74
.6
.6
.9
.3
.1
.5
.7
.1
.0
93
99
100
99
99
95
100
97
100
.7
.8
.0
.1
.4
.5
.0
.6
.0
98
99
100
99
99
95
100
97
100
.7
.8
.0
.1
.4
.5
.0
.6
.0
61
75
84
72
48
57
19
16
74
.6
.6
.9
.3
.1
.5
.7
.1
.0
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
SOS PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
REPAIRS ON THE ABSORBER MOBILE BED CONTACTORS RESULTED IN OUTAGE TIME
DURING THE PERIOD OF JULY, AUGUST AND SEPTEMBER, 1982.
DUCTWORK REPAIRS ALSO ACCOUNTED FOR OUTAGE TIME DURING THE MONTHS OF JULY,
AUGUST AND SEPTEMBER 1982.
744 464 458 50.0
720 545 544 50.0
744 632 632 50.0
744 543 538 50.0
672 325 323 50.0
744 448 428 50.0
720 142 142 50.0
744 123 120 50.0
720 533 533 50.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGO-REUTED PROBLEMS WERE ENCOUNTERED
DURING THE PERIOD OF APRIL THROUGH JUNE 1983.
7/83 SYSTEM 100.0 .0 744 0 0
8/83 SYSTEM 100.0 .0 744 0 0
9/83 SYSTEM 100.0 91.7 91.7 3.1 720 24 22
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE THIRD QUARTER OF 1983.
744 413 410
720 363 361
744 364 133
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR FGD-RELATED PROBLEMS WERE REPORTED FOR THE FOURTH QUARTER OF 1933.
1/84 SYSTEM 744
2/S4 SYSTEM 696
3/84 SYSTEM 744
4/84 SYSTEM 720
5/84 SYSTEM 744
6/84 SYSTEM 720
13-552
10/83 SYSTEM
11/83 SYSTEM
12/83 SYSTEM
100.0
100.0
39.9
99.3
99.4
36.5
99.3
99.4
36.5
55.1
50.1
18.5
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
LOUISVILLE GAS & ELECTRIC'- CANE RUN 4 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
7/84 SYSTEM 744
8/84 SYSTEM 744
9/84 SYSTEM 720
*» PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE FIRST THREE QUARTERS OF 1984.
13-553
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
SECTION 13
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
LOUISVILLE GAS &
CANE RUN
LOUISVILLE
KENTUCKY
E
50.
516.
ELECTRIC
( ,116 LB/MMBTU)
( 1.200 LB/MMBTU)
(***»** LB/MMBTU)
992
200
192
195
200
RILEY STOKER
PULVERIZED COAL
CYCLING
349.21 t
1*8.9 (
76. (
CONCRETE
5.8 (
7*0000 ACFM)
300 F)
250 FT)
19.0 FT)
»* FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT J/G
RAN3E HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - V.
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - '/.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - '/.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
»** PARTICLE CONTROL
** MECHANICAL COLLECTOR
NUMBER
TYPE
** ESP
NUMBER
NUMBER OF SPARES
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
TRADE NAME/COMMON NAME
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
*** FGD SYSTEM
COAL
BITUMINOUS
25586. ( 11000 BTU/LB)
10*00-11900
13.90
10.0-20.0
9.00
8.0-10.8
3.80
3.5-*.0
.0*
0.03-0.06
0
NONE
2
0
COLD SIDE
RESEARCH-COTTRELL
17*.6 ( 370000 ACFM)
1*8.9 ( 300 F)
.0 (0. IN-H20)
99.0
0
NONE
N/A
N/A
N/A
N/A
N/A
N/A
N/A
13-55*
-------
LOUISVILLE GAS & ELECTRIC: CANE RUN 5 (CONT.)
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
** GENERAL DATA
SALEABLE PRODUCT/TIHROWAWAY 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.
ENERGY CONSUMPTION - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
DESIGN COAL SULFER CONTENT - 7.
DESIGN COAL HEAT CONTENT - J/G
DESIGN COAL ASH CONTENT - X
DESIGN MOISTURE CONTENT - X
DESIGN CHLORIDE CONTENT - X
OPER. & MAINT. REQUIREMENT - MANHR/DAY
** QUENCHER/PRESATURATOR
NUMBER
** 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
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
PARTICLE REMOVAL EFFICENCY - X
»» MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
NUMBER OF SPARES PER SYSTEM
NUMBER PER MODULE
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
CONSTRUCTION MATERIAL SPECIFIC TYPE
WASH WATER SOURCE
WASH FREQUENCY
THROWAWAY PRODUCT
WET SCRUBBING
LIME
NONE
COMBUSTION ENGINEERING
FLUOR - PIONEER
FULL SCALE
RETROFIT
X 99.00
85.00
1.5
1
7/78
12/77
4/75
( 11000 BTU/LB)
4.00
25586.0
15.00
12.00
.07
304.0
2
0
SFRAY TOUER
OPEN COUNTERCURRENT SPRAY
N/A
COMBUSTION ENGINEERING
32.0 X 22.5
CARBON STEEL
AISI 1110
N/A
STAINLESS STEEL
AUSTENITIC
TYPE 316L
NONE
3
1102.
9.0
.5
3.7
123.17
52.2
85.0
76.0
(17500 GPM)
( 67.0 GAL/1000 ACF)
2.0 IN-H20)
12.0 FT/S)
261000 ACFM)
126 F)
PRIMARY COLLECTOR
2
0
1
IMPINGEMENT
BAFFLE
CLOSED VANE
HORIZONTAL
2
3
.1 t .5 IN-H20)
2.1 (7.0 FT/S)
ORGANIC
FIBER-REINFORCED POLYESTER
RIVER
ONCE PER SHIFT
13-555
-------
UTILITY FGO SURVEY: OCTOBER 1983 - SEPTEMBER 198*
LOUISVILLE GAS 4 ELECTRIC: CANE RUN 5 (CONT.)
WASH RATE - L/S
5.0
( 80 GAL/MIN)
«* REHEATER
NUMBER
NUMBER OF SPARES
NUMBER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
COMBUSTION FUEL SULFER CONTENT - 7.
LOCATION
PERCENT GAS BYPASSED - AVG
TEMPERATURE INCREASE - C
INLET FLUE GAS FLOW RATE - CU. M/S
INLET FLUE GAS TEMPERATURE - C
OUTLET FLUE GAS TEMPERATURE - C
NUMBER OF TUBES PER BUNDLE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** FANS
NUMBER
NUMBER OF SPARES
DESIGN
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** FANS
NUMBER
NUMBER OF SPARES
DESIGN
FUNCTION
APPLICATION
SERVICE
FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
MANUFACTURER
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
MANUFACTURER
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
MANUFACTURER
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
2
0
1
IN-LINE
STEAM
FIN TUBE
.0
10 FT BEYOND THE ABSORBER OUTLET
.0
13.9 ( 25 F)
365.21 ( 562000 ACFM)
54.4 ( 130 F)
68.3 ( 155 F)
34
CARBON STEEL
AISI 1110
2
0
CENTRIFUGAL
UNIT
FORCED DRAFT
DRY
165.16
148.9
CARBON STEEL
( 350000 ACFM)
( 300 F)
2
0
CENTRIFUGAL
BOOSTER
INDUCED DRAFT
DRY
68.3 ( 155 F)
CARBON STEEL
SHUT-OFF
LOUVER
COMBUSTION ENGINEERING
CARBON STEEL/STAINLESS STEEL [BLADES]
AISI 1110; AUSTENITIC
NONE
N/A
SHUT-OFF
LOUVER
COMBUSTION ENGINEERING
CARBON STEEL/STAINLESS STEEL [BLADES!
AISI 1110; AUSTENITIC
NONE
N/A
SHUT-OFF
LOUVER
COMBUSTION ENGINEERING
CARBON STEEL/STAINLESS STEEL [BLADES]
AISI 1110; AUSTENITIC
NONE
N/A
13-556
-------
LOUISVILLE GAS & ELECTRIC: CANE RUN 5 (CONT. )
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
»» DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
»« REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE TYPE
NUMBER
NUMBER OF SPARES
PRODUCT QUALITY - X SOLIDS
** TANKS
SERVICE
4 OUTLET FROM REHEATER
ABSORBER RECYCLE
REAGENT PREP PRODUCT
** PUMPS
SERVICE
ABSORBER RECIRCULATION
LIME FEED
THICKENER UNDERFLOW
WATER RECYCLE
MIST ELIMINATOR WASH
»* SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
CONFIGURATION
DIMENSIONS - FT
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
FEED STREAM SOURCE
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
OVERFLOW STREAM CHARACTERISTICS
OUTLET STREAM DISPOSITION
OVERFLOW STREAM DISPOSITION
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
CONFIGURATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
BELT GENERIC MATERIAL TYPE
BELT SPECIFIC MATERIAL TYPE
FEED STREAM SOURCE
FEED STREAM CHARACTERISTICS
*** SLUDGE
INLET TO ABSORBER
CARBON STEEL
AISI 1110
NONE
N/A
OUTLET FROM ABSORBER TO REHEATER
CARBON STEEL
AISI 1110
ORGANIC
MICA FLAKE-FILLED POLYESTER
WET BALL MILL
TUBE MILL
1
0
Z5.0
NUMBER
NUMBER
2
2
2
Z
***#
THICKENER
1
0
CIRCULAR
110.0 DIA
CARBON STEEL
AISI 1110
NONE
N/A
ABSORBER BLEED
7X SOLIDS
250 GPM, 25X SOLIDS
250 GFM
VACUUM FILTER
RECYCLE TANK AND THEN REACTION TANK
VACUUM FILTER
2
1
CIRCULAR
NR
NR
NR
NR
NR
NR
THICKENER UNDERFLOW
25X SOLIDS
13-557
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
LOUISVILLE GAS & ELECTRIC: CANE RUN 5 (CONT.)
FULL LOAD SLUDGE QUANTITY - M.TONS/HR (DRY) 14.3
15.7 TPH)
** TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE TREATMENT
SITE SERVICE LIFE - YRS
** PROCESS CONTROL AND INSTRUMENTATION
PROCESS STREAM
CHEMICAL PARAMETERS
CONTROL LEVELS
MONITOR LOCATION
PROCESS CONTROL MANNER
PROCESS CHEMISTRY MODE
** WATER BALANCE
WATER LOOP TYPE
RECEIVING WATER STREAM
** CHEMICALS AND CONSUMPTION
FUNCTION
NAME
PRINCIPAL CONSTITUENT
SOURCE/SUPPLIER
CONSUMPTION
UTILIZATION - X
POINT OF ADDITION
** FGD SPARE CAPACITY INDICES
ABSORBER X
MIST ELIMINATOR - X
REHEATER - X
FAN X
BALL MILL - X
EFFLUENT HOLD TANK
RECIRCULATION PUMP
THICKENER X
VACUUM FILTER - X
** FGD SPARE COMPONENT INDICES
ABSORBER
MIST ELIMINATOR
REHEATER
FAN
BALL MILL
EFFLUENT HOLD TANK
RECIRCULATION PUMP
THICKENER
VACUUM FILTER
FIXATION
PUG MILL
CONVERSION SYSTEMS IPOZ-O-TEC]
FINAL
LANDFILL
ON-SITE
TRUCK
CLAY LINING
10
ABSORBER RECYCLE LINE
PH
PH 9 AT OUTLET t PH 5.4-5.6 AT INLET TO RECYCLE
REACTION TANK
AUTOMATIC
FEEDBACK
OPEN/CLOSED
OHIO RIVER
ABSORBENT
CARBIDE LIME
CAOH3
AIRCO
137,000 TPY
95.0
SLURRY FEED TANK
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
12/77 SYSTEM
744
13-558
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
LOUISVILLE GAS 4 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
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 60.0 50.0 50.0 12.2 744 182 91 27.0
** 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 100.0 96.9 96.0 90.0 720 669 648 52.0
5/78 SYSTEM 91.0 84.3 84.0 48.9 744 432 364 36.0
** PROBLEMS/SOLUTIONS/COMMENTS
FGD SYSTEM MODIFICATIONS WERE MADE DURING THE APRIL-MAY PERIOD IN PREP-
ARATION FOR PERFORMANCE TESTS. THE TESTS WERE PERFORMED; HOWEVER, THE
TEST METHODS WERE NOT FOLLOWED ACCURATELY AND THE DATA WAS INCONCLUSIVE.
6/78 SYSTEM 86.8 86.1 36.0 81.9 720 685 590 51.0
7/78 SYSTEM 83.1 80.1 80.0 68.0 744 632 506 48.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE STEAM REHEAT COIL INSTALLATION HAS BEEN A CHRONIC PROBLEM AREA. WELDS
HAVE BEEN FAILING EVER SINCE INITIAL OPERATIONS.
8/78 SYSTEM 76.0 85.9 85.0 62.4 744 540 464 42.0
9/78 SYSTEM 96.0 79.6 79.0 67.4 720 609 485 44.0
** PROBLEMS/SOLUTIONS/COMMENTS
PROBLEMS CONTINUED WITH THE REHEAT COILS.
10/78 SYSTEM 96.0 96.2 95.0 68.5 744 530 510 41.0
11/78 SYSTEM 95.0 93.7 94.0 32.9 720 253 237 40.0
** 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 46.0 40.6 744 654 302 47.0
1/79 SYSTEM 69.6 67.2 67.0 62.8 744 693 467 42.0
13-559
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
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
2/79 SYSTEM 77.0 70.6 70.0 50.1 672 477 337 42.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING FEBRUARY FREEZING CAUSED PROBLEMS WITH LIME DELIVERY.
3/79 SYSTEM 77.0 71.8 71.0 57.5 744 596 428 41.0
4/79 SYSTEM 99.0 99.2 99.0 49.6 720 360 357 45.0
** PROBLEMS/SOLUTIONS/COMMENTS
SOME PROBLEMS WERE EXPERIENCED WITH DAMPERS AND THERE WERE PUMP FAILURES.
5/79 SYSTEM 89.0 84.3 84.0 49.1 744 433 365 38.0
»* PROBLEMS/SOLUTIONS/COMMENTS
COMPLIANCE TESTING WAS AGAIN PERFORMED AT THIS UNIT ON MAY 15 AMD 19
AND A S02 REMOVAL EFFICIENCY OF 93X WAS DEMONSTRATED. THE UNIT WAS
DECLARED COMMERCIAL UPON COMPLETION OF THE TESTS.
6/79 SYSTEM 81.0 77.0 77.0 58.2 720 544 419 40.0
** 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.
744 583 420 38.0
744 613 540 46.0
720 469 392 45.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE WELDING PROBLEMS WITH THE REHEATER WERE ENCOUNTERED IN JULY AND
SEPTEMBER. THE FAILURES ARE CONTINUING AND ARE EXPECTED TO BE RESOLVED
BY THIS WINTER.
744 583 488 42.0
720 351 334 41.0
744 574 472 44.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE FOURTH QUARTER OF 1979 THE UTILITY REPORTED THAT NO MAJOR
PROBLEMS OCCURRED. THE UNIT REQUIRED ONLY NORMAL MAINTENANCE.
1/80 SYSTEM 94.0 92.1 92.0 72.2 744 583 537 43.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JANUARY NO OPERATIONAL PROBLEMS WERE ENCOUNTERED.
2/80 SYSTEM 81.0 71.9 71.0 49.7 696 481 346 50.0
7/79 SYSTEM
8/79 SYSTEM
9/79 SYSTEM
78.0
90.0
90.0
72.0
88.1
83.6
72.0
88.0
82.0
56.5
72.6
54.4
10/79 SYSTEM
11/79 SYSTEM
12/79 SYSTEM
87.0
97.0
86.0
83.7
95.2
82.2
85.0
95.0
82.0
65.6
46.4
63.4
13-560
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
LOUISVILLE GAS 4 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
** 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 66.0 44.5 44.0 27.2 744 454 202 29.0
** 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 43.0
** 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 46.0
** 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 78.7 744 669 586 50.0
** 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 49.6 744 632 369 50.0
9/80 SYSTEM 87.2 97.5 97.5 87.2 720 644 628 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
13-561
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
10.0
25.0
99.8
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 198*
LOUISVILLE GAS 4 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
** FROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO FGD-REUTED PROBLEMS WERE ENCOUNTERED DURING
THE FOURTH QUARTER 1980.
1/81 SYSTEM 100.0 99.7 99.7 69.4 744 667 665 50.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JANUARY THE UTILITY REPORTED THAT NO MAJOR FGD-REUTED PROBLEMS WERE
ENCOUNTERED.
Z/81 SYSTEM 82.0 77.0 77.0 59.0 672 512 394 50.0
*» PROBLEMS/SOLUTIONS/COMMENTS
DURING FEBRUARY SOME OUTAGE TIME WAS DUE TO FAN PROBLEMS.
ADDITIONAL PROBLEMS WERE ENCOUNTERED DUE TO REHEATER LEAKS.
3/81 SYSTEM 100.0 46.0 46.0 43.0 744 698 319 50.0
** PROBLEMS/SOLUTIONS/COMMENTS
OUTAGE TIME DURING MARCH WAS DUE TO STRIKING WORKERS AT THE PLANT.
4/81 SYSTEM 100.0 100.0 100.0 51.0 720 367 367 40.0
5/81 SYSTEM 100.0 95.9 95.9 92.3 744 716 687 45.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-REUTED PROBLEMS WERE ENCOUNTERED
DURING THE MONTHS OF APRIL AND MAY.
6/81 SYSTEM 100.0 .0 720 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE MONTH OF JUNE THE BOILER DID NOT OPERATE; HOWEVER, THE FGD
SYSTEM WAS AVAIUBLE 100X.
744 339 339 50.0
744 368 368 45.0
720 540 540 45.0
** PROBLEMS/SOLUTIONS/COMMENTS
THERE WERE NO MAJOR FGD REUTED PROBLEMS REPORTED FOR THE THIRD QUARTER
1981.
744 429 429 40.0
720 415 413 40.0
744 738 734 40.0
7/81 SYSTEM
8/81 SYSTEM
9/81 SYSTEM
45.6
49.5
75.0
100.0
100.0
100.0
100.0
100.0
100.0
45.6
49.5
75.0
10/81 SYSTEM
11/81 SYSTEM
12/81 SYSTEM
93.4
88.9
98.6
100.0
99.5
99.4
100.0
99.5
99.4
57.7
57.4
98.6
13-562
-------
1/82 SYSTEM
2/82 SYSTEM
3/82 SYSTEM
100.0
100.0
100.0
70.4
91.0
83.3
70.4
91.0
83.3
59.1
49.6
57.5
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
LOUISVILLE GAS t 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
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE FOURTH QUARTER 1981.
744 625 440 39.0
672 366 333 50.0
744 514 428 35.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE FIRST QUARTER 1982.
720 112 112 50.0
744 598 598 50.0
720 668 641 50.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE SECOND QUARTER 1982.
744 679 653 50.0
744 642 642 50.0
720 248 241 50.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE PERIOD OF JULY 1982 THROUGH SEPTEMBER 1982.
V82 SYSTEM
5/82 SYSTEM
6/82 SYSTEM
100.0
100.0
96.2
100.0
100.0
96.0
100.0
100.0
96.0
15.6
80.4
89.0
7/82 SYSTEM
8/82 SYSTEM
9/82 SYSTEM
87.8
86.3
33.5
96.2
100.0
97.2
96.2
100.0
100.0
87.8
86.3
33.5
10/82
11/82
12/82
SYSTEM .0
SYSTEM .0
SYSTEM .0
** PROBLEMS/SOLUTIONS/COMMENTS
A UNIT OVERHAUL WAS
1982 FORCING AN FGD
1/83
2/83
3/83
4/83
5/83
6/83
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
61.3
65.6
59.5
43.6
89.4
73.2
100.0
99.3
98.7
100.0
, 99.4
100.0
100
99
98
100
99
100
.0
.0
.0
744
720
744
0
0
0
0
0
0
50.0
50.0
50.0
PERFORMED DURING THE PERIOD OF OCTOBER THROUGH DECEMBER
SYSTEM OUTAGE.
.0
.3
.7
.0
.4
.0
61
65
59
43
89
73
.3
.6
.5
.6
.4
.2
744
672
744
720
744
720
456
444
449
314
669
527
456
441
443
314
665
527
50.0
50.0
50.0
50.0
50.0
50.0
13-563
-------
7/83 SYSTEM
8/83 SYSTEM
9/83 SYSTEM
69.1
29.0
83.6
100.0
39.3
97.6
100.0
39.3
97.6
69.1
29.0
55.4
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
LOUISVILLE GAS 4 ELECTRIC: CANE RUN 5 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
SOS PART. HOURS HOURS HOURS FACTOR
= _« = - -*. = = -" =- » «-.---. - . . ,« -. 0> -< _
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE PERIOD OF JANUARY THROUGH JUNE 1983.
744 514 514 50.0
744 549 216 50.0
720 409 399 50.0
** PROBLEMS/SOLUTIONS/COMMENTS
LOW AVAILABILITY DURING THE THIRD QUARTER WAS DUE IN PART TO GENERAL REP-
AIRS RESULTING FROM CORROSION PROBLEMS.
744 15 15
720 42-0 383
744 421 190
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR FGD-RELATED PROBLEMS WERE REPORTED FOR THE FOURTH QUARTER OF 1983.
1/84 SYSTEM 744
2/84 SYSTEM 696
3/84 SYSTEM 744
4/84 SYSTEM 720
5/84 SYSTEM 744
6/84 SYSTEM 720
7/84 SYSTEM 744
8/84 SYSTEM 744
9/84 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE FIRST THREE QUARTERS OF 1984.
10/83 SYSTEM
11/83 SYSTEM
12/83 SYSTEM
10.9
67.6
44.0
100.0
91.2
45.1
100.0
91.0
45.1
2.0
53.2
25.5
13-564
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
SECTION 13
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 - '/.
RANGE MOISTURE CONTENT - '/.
AVERAGE SULFUR CONTENT - V.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - /.
*** 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
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON NAME
SHELL GEKERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
& ELECTRIC
( .116 LB/MMBTU)
( 1.200 LB/MMBTU)
(****** LB/MMBTU)
LOUISVILLE GAS
CANE RUN
6
LOUISVILLE
KENTUCKY
E
50.
516.
******
992
299
277
280
299
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
502.57 (1065000 ACFM)
1*8.9 ( 300 F)
158. ( 518 FT)
CONCRETE
4.9 ( 16.0 FT)
COAL
BITUMINOUS
25586.
17.06
15.5-24.5
8.95
8.0-10.8
4.80
3.5-6.3
.04
0.03-0.06
0
NONE
0
NONE
COLD SIDE
251.8
148.9
99.4
0
NONE
N/A
N/A
N/A
N/A
N/A
N/A
N/A
( 11000 BTU/LB)
10400-11900
( 533500 ACFM)
( 300 F)
13-565
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
LOUISVILLE GAS & ELECTRIC: CANE RUN 6 (CONT.)
»** 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 302 REMOVAL EFFICIENCY - X
ENERGY CONSUMPTION - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
»* DESIGN AND OPERATING PARAMETERS
** QUENCHER/PRESATURATOR
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** 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
SUFERFICAL GAS VELOCITY - M/SEC
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
502 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
FREEBOARD DISTANCE - M
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY M/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
»* REHEATER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
PERCENT GAS BYPASSED - AVS
TEMPERATUPE INCREASE C
INLET FLUE GAS FLOW RATE - CU. M/S
THROWAWAY PRODUCT
WET SCRUBBING
DUAL ALKALI
THYSSEN/CEA
FLUOR - PIONEER
DEMONSTRATION
RETROFIT
X 99.00
95.00
1.0
1
4/79
10/76
NR
NR
TRAY TOWER
SIEVE TRAY
N/A
THYSSEN/CEA
32.0 DIA X 45.0
CARBON STEEL
ASTM A-283
N/A
ORGANIC
MICA FLAKE-FILLED POLYESTER
NR
PERFORATED TRAYS
2
( 4318 GPM)
( 10.0 GAL/1000 ACF)
( 9.9 IN-H20)
( 9.0 FT/S)
( 533000 ACFM)
( 300 F)
272.
1.3
2.5
2.7
251.52
148.9
94.2
PRIMARY COLLECTOR
2
IMPINGEMENT
BAFFLE
CLOSED VANE
HORIZONTAL
1
4
1.52 (
.2 (
2.7 (
ORGANIC
POLYPROPYLENE
5.0 FT)
1.0 IN-H20)
9.0 FT/S)
DIRECT COMBUSTION
EXTERNAL COMBUSTION CHAMBER
OIL
.0
27.8 ( 50 F)
205.98 ( 436500 ACFM)
13-566
-------
UTILITY FGO SURVEY: OCTOBER 1983 - SEPTEMBER 1984
LOUISVILLE GAS 4 ELECTRIC: CANE RUN 6 (CONT.)
INLET FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** FANS
NUMBER
DESIGN
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** DAMPERS
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
*» REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
*# TANKS
SERVICE
51.7
( 125 F)
ABSORBER RECYCLE
SECONDARY REACTION
NR
VACUUM FILTER FILTRATE
THICKENER OVERFLOW
REAGENT PREP PRODUCT
** PUMPS
SERVICE
( 533000 ACFM)
( 300 F)
NR
NR
CENTRIFUGAL
BOOSTER
FORCED DRAFT
DRY
251.SZ
148.9
CARBON STEEL
NR
NR
NR
NR
NR
NR
NR
SCRUBBER INLET
CARBON STEEL
AISI 1110
NONE
N/A
SCRUBBER TO REHEATER
CARBON STEEL
AISI 1110
ORGANIC
FIBER-REINFORCED POLYESTER
REHEATER TO STACK
STAINLESS STEEL
AUSTENITIC
NONE
N/A
BYPASS/TRANSITION DUCT
CARBON STEEL
AISI 1110
NONE
N/A
NR
NR
NR
NUMBER
REACTOR TRANSFER
ABSORBER RECIRCULATION
Z
Z
****
3
1
2
NUMBER
2
13-567
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
LOUISVILLE GAS t ELECTRIC: CANE RUN 6 (CONT.)
THICKENER HOLD TANK TRANSFER
LIME SLURRY
SODA ASH SOLUTION PUMP
THICKENER UNDERFLOW
VACUUM
LIME SLURRY FEED
VACUUM FPUMP
FILTRATE SUMP
SODA ASH
SILENCER OVERFLOW SUMP
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
CAPACITY
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
BELT SPECIFIC MATERIAL TYPE
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
*» SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
CONFIGURATION
DIMENSIONS - FT
SHELL GENERIC MATERIAL TYPE
OUTLET STREAM CHARACTERISTICS
*** SLUDGE
»» TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
«» DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE TREATMENT
** 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 - 7.
FAN - 7.
RECIRCULATION PUMP - X
** FGD SPARE COMPONENT INDICES
ABSORBER
FAN
RECIRCULATION PUMP
2
Z
Z
4
3
2
*#*#
2
2
2
VACUUM FILTER
3
1
3 TON/DAY
STAINLESS STEEL
AUSTENITIC
FIBER-REINFORCED POLYESTER
25X SOLIDS
63X SOLIDS
THICKENER
1
CYLINDRICAL
125.0 DIA X 23.0
CARBON STEEL
25X SOLIDS
FIXATION
PUG MILL
CONVERSION SYSTEMS
FINAL
LANDFILL
ON-SITE
TRUCK
NONE
PH
ABSORBER BLEED LIQUOR
AUTOMATIC
FEED FORWARD
tPOZ-0-TEC]
CLOSED
17.5
20.0
.0
100.0
.3
.0
1.0
( 278 6PM)
13-568
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
LOUISVILLE GAS * ELECTRIC: CANE RUN 6 (CONT. )
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
tt/79 SYSTEM 67.0 49.9 49.0 32.9 92.00 720 475 237 37.0
»* PROBLEMS/SOLUTIONS/COMMENTS
THIS UNIT STARTED OPERATING ON APRIL 4, 1979. COMPLIANCE TESTING IS
SCHEDULED FOR THE WEEK OF JUNE 3.
5/79 SYSTEM 46.0 21.5 21.0 14.7 91.00 744 506 109 42.0
6/79 SYSTEM 27.0 12.3 12.0 10.3 93.00 720 601 74 47.0
** 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 45.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT DID NOT OPERATE IN JULY AS PROCEDURES CONTINUED TO REPLACE THE
MIST ELIMINATORS.
8/79 SYSTEM 10.0 7.0 7.0 7.0 744 683 51 51.0
9/79 SYSTEM 70.0 60.0 60.0 44.0 720 531 317 46.0
** 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.
744 246 215 37.0
720 468 457 41.0
744 703 667 60.0
** 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 86.0 49.0 49.0 13.8 744 210 103 32.0
** 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 91.0 84.7 84.0 47.0 696 386 327 37.0
3/80 SYSTEM 72.0 70.0 70.0 64.5 744 686 480 51.0
** 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 73.9 720 581 531 37.0
13-569
10/79 SYSTEM
11/79 SYSTEM
12/79 SYSTEM
96.0
96.0
98.0
81.4
97.7
94.9
81.0
97.0
95.0
28.9
63.5
89.7
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 198*
LOUISVILLE GAS t 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 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 52.0
** 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 50.0
** 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 THE CLINKER GRINDER AND TO REPAIR A
BOILER TUBE LEAK.
IMPROVEMENTS TO THE PH CONTROL CIRCUITRY HAVE LEAD TO IMPROVED CARBIDE
LIME UTILIZATION.
EXPERIMENTATION 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 52.0
** 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 93.9X.
DURING NORMAL OPERATION IN JULY NO MAJOR FGD RELATED PROBLEMS WERE
ENCOUNTERED.
8/80 SYSTEM 99.3 94.6 94.6 84.5 744 665 628 50.0
9/80 SYSTEM 94.0 98.6 98.7 86.9 720 635 626 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
** 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
13-570
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
LOUISVILLE GAS & ELECTRIC: CANE 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 OCTOBER AND NOVEMBER THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED
PROBLEMS WERE ENCOUNTERED.
1Z/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.
1/81 SYSTEM 85.7 83.3 83.3 80.2 744 716 597 50.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JANUARY PROBLEMS WITH THE THICKENER RACK SHAFT CONTINUED TO CAUSE
OUTAGE TIME.
2/81 SYSTEM 99.6 99.5 99.5 71.6 672 483 4S1 45.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING FEBRUARY THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS
WERE ENCOUNTERED.
3/81 SYSTEM 99.6 34.2 34.2 28.0 744 607 208 50.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MARCH OUTAGE TIME WAS DUE TO STRIKING WORKERS AT THE PLANT.
4/81 SYSTEM 95.0 98.5 100.0 82.6 720 604 595 45.0
5/81 SYSTEM 96.8 96.9 100.0 96.8 744 243 720 55.0
6/81 SYSTEM 88.9 100.0 100.0 26.5 720 191 191 45.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE SECOND QUARTER 1981.
744 615 424 50.0
744 693 506 50.0
720 162 158 50.0
*» PROBLEMS/SOLUTIONS/COMMENTS
RUPTURE OF THE FRP THICKENER AND ABSORBER BLEED PIPE CAUSED PROBLEMS DURING
THE THIRD QUARTER 1981. THE UNIT IS EXPECTED TO BE REMOVED FROM SERVICE
IN OCTOBER FOR A THREE MONTH TURBINE OVERHAUL.
10/81 SYSTEM 100.0 -0 720 0 0 .0
U/81 SYSTEM 100.0 .0 720 0 0 .0
12/81 SYSTEM 100.0 .0 744 0 0 .0
7/81 SYSTEM
8/81 SYSTEM
9/81 SYSTEM
74.0
80.0
100.0
69.0
73.0
98.0
69.0
77.0
98.0
57.0
68.0
22.0
13-571
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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
DURING THE FOURTH QUARTER THE BOILER WAS DOWN FOR A TURBINE OVERHAUL.
1/82 SYSTEM 100.0 83.5 83.5 21.9 744 195 163 17.0
2/82 SYSTEM 100.0 76.5 76.5 70.4 672 618 473 54.0
3/82 SYSTEM 100.0 93.8 93.8 68.7 744 545 511 44.0
»* PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE FIRST QUARTER 1982.
4/82
5/82
6/82
SYSTEM 100.0 99.6
SYSTEM 100.0 99.7
SYSTEM 98.6 98.3
** PROBLEMS/SOLUTIONS/COMMENTS
100.0
100.0
100.0
68
96
82
.2
.4
.6
720
744
720
493
719
605
491
717
595
50.0
50.0
50.0
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE SECOND QUARTER 1982.
7/82
8/82
9/82
10/82
11/82
12/82
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
15.2
42.6
60.6
87.0
68.6
62.9
17.
50.
86.
94.
99.
95.
1
6
5
9
8
1
17.1
50.6
86.5
94.9
99.8
95.1
15
42
60
87
68
62
.2
.6
.6
.0
.6
.9
744
744
720
744
720
744
661
626
504
682
495
492
113
317
436
647
494
468
50.0
50.0
50.0
50.0
50.0
50.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT A MIST
PERIOD OF JULY THROUGH DECEMBER
1/83
2/83
3/83
4/83
5/83
6/83
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
52.8
.0
.0
3.3
32.1
38.3
99.
12.
51.
52.
7
0
6
6
99.7
12.0
51.6
52.6
52
3
32
38
ELIMINATOR
1982.
.8
.0
.0
.3
.1
.3
COLLAPSED DURING THE
744
672
744
720
744
720
394
0
0
200
463
525
393
0
0
24
239
276
50.0
50.0
50.0
50.0
50.0
50.0
** PROBLEMS/SOLUTIONS/COMMENTS
A TURBINE OVERHAUL WAS PERFORMED DURING THE PERIOD OF JANUARY THROUGH JUNE
1983 ACCOUNTING FOR SOME OF THE OUTAGE TIME DURING THAT PERIOD.
THE FAILURE OF A BOOSTER FAN ACCOUNTED FOR OUTAGE TIME DURING THE PERIOD OF
JANUARY THROUGH JUNE 1983.
7/83 SYSTEM 80.2 95.1 95.1 80.4 744 629 598 50.0
13-572
-------
UTILITY F6D SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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
8/83 SYSTEM 39.5 43.6 43.6 39.5 744 675 294 50.0
9/83 SYSTEM 89.9 84.5 84.5 40.3 720 343 290 50.0
** PROBLEMS/SOLUTIONS/COMMENTS
SLURRY PIPING REPAIRS WERE MADE DURING THE THIRD QUARTER OF 1983.
10/83 SYSTEM 60.8 93.2 93.2 40.3 744 322 300
11/83 SYSTEM 92.4 100.0 100.0 7.1 720 51 51
12/83 SYSTEM 64.5 50.2 50.2 16.5 744 245 123
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR FGD-RELATED PROBLEMS WERE REPORTED FOR THE FOURTH QUARTER OF 1983.
1/84 SYSTEM 744
2/84 SYSTEM 696
3/84 SYSTEM 744
4/84 SYSTEM 720
5/84 SYSTEM 744
6/84 SYSTEM 720
7/84 SYSTEM 744
8/84 SYSTEM 744
9/84 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE FIRST THREE QUARTERS OF 1984.
13-573
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
SECTION 13
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
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 - 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 - '/.
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - '/.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RAN3E SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT 7.
*** PARTICLE CONTROL
** MECHANICAL COLLECTOR
NUMBER
TYPE
** FABRIC FILTER
NUMBER
TYPE
** ESP
NUMBER
NUMBER OF SPARES
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
TRAOE NAME/COMMON NAME
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
LOUISVILLE GAS » ELECTRIC
MILL CREEK
1
LOUISVILLE
KENTUCKY
E
(
516.
******
100 LB/WMBTU)
( 1.200 LB/WMBTU)
(****** LB/MMBTU)
356
334
339
358
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
660.66
151.7
183.
CONCRETE
(1400000 ACFM)
( 305 F)
( 600 FT)
( 19.0 FT)
( 11500 BTU/LB)
10800-12100
5.8
COAL
BITUMINOUS
26749.
14.50
10.0-18.0
9.00
8.0-10.0
3.75
3.5-4.5
.04
.03-.06
0
NONE
0
NONE
2
0
HOT SIDE
WESTERN PRECIPITATOR
330.3 ( 700000 ACFM)
151.7 ( 305 F)
.1 (1. IN-H20)
99.4
0
NONE
N/A
N/A
N/A
N/A
N/A
N/A
13-574
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
LOUISVILLE GAS t ELECTRIC: MILL CREEK 1 (CONT.)
»** 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 - X
ENERGY CONSUMPTION - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
DESIGN COAL SULFER CONTENT X
DESIGN COAL HEAT CONTENT - J/G
DESIGN COAL ASH CONTENT - X
DESIGN MOISTURE CONTENT - X
DESIGN CHLORIDE CONTENT - X
OPER. t, MAINT. REQUIREMENT - MANHR/DAY
** QUENCHER/PRESATURATOR
NUMSER
TYPE
#* 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
L/G RATIO - L/CU.M
SUPERFICAL GAS VELOCITY - M/SEC
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE C
S02 REMOVAL EFFICIENCY - X
** REHEATER
NUMBER
NUMBER OF SPARES
NUMBER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
LOCATION
TEMPERATURE INCREASE - C
INLET FLUE GAS TEMPERATURE C
OUTLET FLUE GAS TEMPERATURE - C
NUMBER OF HEAT EXCHANGER BANKS
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
THROWAWAY PRODUCT
WET SCRUBBING
LIME
NONE
COMBUSTION ENGINEERING
FLUOR - PIONEER
FULL SCALE
RETROFIT
X 99.50
85.00
1.4
1
4/81
12/80
11/77
( 10000 BTU/LB)
4.50
23260.0
18.00
10.00
.06
120.0
0
NONE
2
0
SPRAY TOWER
OPEN COUNTERCURRENT SPRAY
N/A
COMBUSTION ENGINEERING
26.0 X 31.0
STAINLESS STEEL
AUSTENITIC
TYPE 316L
NONE
N/A
N/A
4
3755.
11.9
3.7
316.17
148.9
86.6
(59600 GPM)
( 88.9 GAL/1000 ACF)
( 12.0 FT/S)
t 670000 ACFM)
t 300 F)
2
0
1
IN-LINE
STEAM
FIN TUBE
DOWNSTREAM OF ABSORBER
27.8 ( 50 F)
54.4 ( 130 F)
82.2 ( 180 F)
2
CARBON STEEL
AISI 1110
13-575
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
LOUISVILLE GAS & ELECTRIC: MILL CREEK 1 (CONT.)
** FANS
NUMBER
NUMBER OF SPARES
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
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
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
MODULATION
SEAL AIR FLOW - CU. M/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
MODULATION
SEAL AIR FLOW CU. M/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
MODULATION
SEAL AIR FLOW - CU. M/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
CONFIGURATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
2
0
CENTRIFUGAL
AMERICAN STANDARD
BOOSTER
INDUCED DRAFT
DRY
82.2 ( 180 F)
NR
2
0
CENTRIFUGAL
AMERICAN STANDARD
UNIT
FORCED DRAFT
DRY
316.17 ( 670000 ACFM)
148.9 t 300 F)
NR
SHUT-OFF
LOUVER
PARALLEL BLADE MULTILOUVER
COMBUSTION ENGINEERING
OPEN/ CLOSED
.71 ( 1500 ACFM)
CARBON STEEL [BLADES 4 FRAMES]; STAINLESS STEEL
AISI 1110; AUSTENITIC
NONE
N/A
SHUT-OFF
LOUVER
PARALLEL BLADE MULTILOUVER
COMBUSTION ENGINEERING
OPEN/ CLOSED
.71 ( 1500 ACFM)
CARBON STEEL [BLADES & FRAMES]; STAINLESS STEEL
AISI 1110; AUSTENITIC
NONE
N/A
SHUT-OFF
LOUVER
PARALLEL BLADE MULTILOUVER
COMBUSTION ENGINEERING
OPEN/ CLOSED
.71 ( 1500 ACFM)
CARBON STEEL [BLADES & FRAMES]; STAINLESS STEEL
AISI 1110; AUSTENITIC
NONE
N/A
ABSORBER INLET
RECTANGULAR
CARBON STEEL
AISI 1110
NR
NR
13-576
-------
UTILITY FGD SURVEYS OCTOBER 1983 - SEPTEMBER
LOUISVILLE GAS & ELECTRIC: MILL CREEK 1 (CONT.)
** DUCTWORK
LOCATION
CONFIGURATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
*» DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
NUMBER
NUMBER OF SPARES
PRODUCT QUALITY - X SOLIDS
** TANKS
SERVICE
ABSORBER RECYCLE
REAGENT FEED
*# PUMPS
SERVICE
ABSORBER RECIRCULATION
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
CONFIGURATION
DIMENSIONS - FT
CAPACITY
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
BELT GENERIC MATERIAL TYPE
BELT SPECIFIC MATERIAL TYPE
FEED STREAM SOURCE
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
OVERFLOW STREAM CHARACTERISTICS
OUTLET STREAM DISPOSITION
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
CONFIGURATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
BELT GENERIC MATERIAL TYPE
BELT SPECIFIC MATERIAL TYPE
FEED STREAM SOURCE
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
OUTLET STREAM DISPOSITION
ABSORBER OUTLET
RECTANGULAR
CARBON STEEL
AISI 1110
NR
NR
BYPASS
CARBON STEEL
AISI 1110
NONE
N/A
WET BALL MILL
COMPARTMENTED
TUBE MILL
1
0
25.0
NUMBER
NUMBER
8
THICKENER
1
0
CIRCULAR
140 DIA X 15.0
1050000 GAL
NR
NR
NR
NR .
N/A
N/A
ABSORBER BLEED
1120 GPM/10X SOLIDS
280 GPM/30X SOLIDS
840 GPM
VACUUM FILTER
VACUUM FILTER
5
1
CIRCULAR
NR
NR
NR
NR
NR
NR
THICKENER UNDERFLOW
25X SOLIDS
45X SOLIDS
PUG MILL
13-577
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
LOUISVILLE GAS & ELECTRIC: MILL CREEK 1 (CONT.)
*** SALEABLE BYPRODUCTS
NATURE
*»* SLUDGE
** TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
INLET QUALITY - 7.
»» DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE TREATMENT
SITE SERVICE LIFE - YRS
*» WATER BALANCE
WATER LOOP TYPE
MAKEUP WATER ADDITION - LITERS/S
** CHEMICALS AND CONSUMPTION
FUNCTION
NAME
PRINCIPAL CONSTITUENT
SOURCE/SUPPLIER
POINT OF ADDITION
** FGD SPARE CAPACITY INDICES
ABSORBER - X
MIST ELIMINATOR - 7.
REHEATER - 7.
FAN - 7.
BALL MILL - 7.
EFFLUENT HOLD TANK - X
THICKENER - X
VACUUM FILTER - X
»* FGD SPARE COMPONENT INDICES
ABSORBER
MIST ELIMINATOR
REHEATER
FAN
BALL MILL
EFFLUENT HOLD TANK
THICKENER
VACUUM FILTER
NONE
FIXATION
PUG MILL
CONVERSION SYSTEMS IPOZ-O-TECJ
45.0
FINAL
LANDFILL
ON-SITE
TRUCK
CLAY LINING
10
OPEN/CLOSED
125.0
ABSORBENT
CARBIDE LIME
90X CAOH2
AIRCO
RECYCLE TANK
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
t 1984 GPM)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
12/80 SYSTEM 45.2 98.5
** PROBLEMS/SOLUTIONS/COMMENTS
98.5
44.5
90.00
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.
1/81 SYSTEM
51.0
46.0
46.0
42.0
94.80
744 675
312 45.0
13-578
-------
UTILITY FGD SURVEYS OCTOBER 1983 - SEPTEMBER 1984
LOUISVILLE GAS 4 ELECTRIC: MILL 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
DURING JANUARY A BROKEN BLEED PUMP DISCHARGE LINES CAUSE APPROXIMATELY 363
HOURS OF OUTAGE TIME.
2/81 SYSTEM 51.5 51.5 51.5 51.5 672 346 346 50.0
3/81 SYSTEM 39.0 36.0 36.0 35.0 744 712 258 50.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING FEBRUARY AND MARCH PROBLEMS WERE ENCOUNTERED DUE TO THE THICKENER
PLUGGING.
ADDITIONAL OUTAGE TIME DURING MARCH WAS DUE TO STRIKING WORKERS AT THE
PLANT.
720 226 57 25.0
744 267 162 35.0
720 563 191 50.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE SECOND QUARTER 1981 THE UTILITY REPORTED HAVING PROBLEMS
WITH THE GLYCOL HEAT EXCHANGER.
744 713 537 65.0
744 740 734 65.0
720 600 573 60.0
** PROBLEMS/SOLUTIONS/COMMENTS
ALL FGD SYSTEM DOWNTIME DURING THE THIRD QUARTER 1981 WAS ATTRIBUTED TO
PROBLEMS WITH THE GLYCOL HEAT EXCHANGER ON THE REHEAT SYSTEM.
4/81 SYSTEM
5/81 SYSTEM
6/81 SYSTEM
39.9
46.9
56.1
25.2
60.7
33.9
25.2
60.7
33.9
7.9
21.8
26.5
7/81 SYSTEM
8/81 SYSTEM
9/81 SYSTEM
76.3
99.2
85.7
75.3
99.2
95.5
75.3
99.2
95.5
72.2
98.7
79.6
10/81
11/81
12/81
SYSTEM
SYSTEM
SYSTEM
39.6
37.4
26.1
41.
39.
29.
0
8
1
41.0
39.8
29.1
39
37
26
.6
.4
.1
720
720
744
719
675
666
295
269
194
50.0
50.0
50.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE FOURTH
EXCHANGER.
1/82
2/82
3/82
SYSTEM
SYSTEM
SYSTEM
4.7
25.4
41.3
6.
25.
54.
2
6
9
QUARTER
6.2
25.6
54.9
PROBLEMS WERE
4
25
41
.7
.4
.3
ENCOUNTERED WITH
744
672
744
THE
570
GLYCOL HEAT
36
669 171
560
307
50.0
50.0
50.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT FROZEN LINES DURING THE FIRST QUARTER 1982
HINDERED THE FGD SYSTEM OPERATION.
AN ADDITIONAL PROBLEM EXPERIENCED DURING THE PERIOD WAS HEAT EXCHANGER
FAILURE.
13-579
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
LOUISVILLE GAS & ELECTRIC: MILL CREEK 1 (CONT.)
_ -PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
502 PART. HOURS HOURS HOURS FACTOR
4/82
5/82
6/82
SYSTEM
SYSTEM
SYSTEM
96.4
43.1
77.9
63
35
42
.9
.2
.2
63.9
35.2
42.2
6
30
16
.4
.9
.2
720
744
720
72
653
277
46
230
117
50.0
50.0
50.0
7/82 SYSTEM
8/82 SYSTEM
9/82 SYSTEM
33.5
64.5
75.3
61.5
69.7
75.3
61.5
69.7
75.3
23.4
64.5
75.3
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE SECOND QUARTER MAJOR PROBLEMS WERE EXPERIENCED WITH THE GLYCOL
HEAT EXCHANGE.
744 283 174 50.0
744 689 460 50.0
720 720 542 50.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT PROBLEMS WITH THE GYCOL REHEAT SYSTEM OCCURRED
DURING THE MONTHS OF JULY, AUGUST AND SEPTEMBER, 1982.
744 712 352 50.0
720 720 603 50.0
744 409 158 50.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT REHEATER TUBE FAILURES CAUSED SOME OUTAGE TIME
DURING THE PERIOD OF JULY THROUGH DECEMBER 1982.
SPRAY PUMP PROBLEMS WERE ALSO REPORTED FOR THE PERIOD OF JULY THROUGH
DECEMBER 1982.
10/82 SYSTEM
11/82 SYSTEM
12/82 SYSTEM
47.3
83.8
21.2
49.4
83.8
38.6
49.4
83.8
38.6
47.3
83.8
21.2
1/83
2/83
3/83
4/83
5/83
6/83
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
40.9
47.2
77.2
43.9
9.7
55.0
43.7
47.1
85.6
82.1
19.3
62.8
43.7
47.1
85.6
82.1
19.3
62.8
40.9
47.0
76.5
43.9
9.7
55.0
744
672
744
720
744
720
695
671
665
385
374
631
304
316
569
316
72
396
50.0
50.0
50.0
50.0
50.0
50.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT MIST ELIMINATOR
DURING THE PERIOD OF JANUARY THROUGH JUNE
7/83
8/83
9/83
SYSTEM
SYSTEM
SYSTEM
56.2
48.0
44.7
57.4
48.4
35.0
57.4
48.4
35.0
55.5
48.0
24.6
REPAIRS ACCOUNTED FOR
1983.
744
744
720
719
737
505
OUTAGE
413
357
177
TIME
50.0
50.0
50.0
13-580
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
LOUISVILLE GAS & ELECTRIC: MILL CREEK 1 (COHT. )
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
*» PROBLEMS/SOLUTIONS/COMMENTS
STACK REHEAT FAILURES DURING THE PERIOD RESULTED IN A STACK PLUME REHEAT
SYSTEM DESIGN.
10/83 SYSTEM 82.4 79.3 79.3 66.4 744 623 494
11/83 SYSTEM 73.3 68.4 68.4 56.8 720 598 409
12/83 SYSTEM 58.2 46.3 46.3 39.2 744 630 292
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR FGD-RELATED PROBLEMS WERE REPORTED FOR THE FOURTH QUARTER OF 1983.
1/84 SYSTEM 744
2/84 SYSTEM 696
3/84 SYSTEM 744
4/84 SYSTEM 720
5/84 SYSTEM 744
6/84 SYSTEM 720
7/84 SYSTEM 744
8/84 SYSTEM 744
9/84 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE FIRST THREE QUARTERS OF 1984.
13-581
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
SECTION 13
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 - 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
EOILER 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 - V.
RANGE ASH CONTENT - 7.
AVERAGE MOISTURE CONTENT - 7.
RANGE MOISTURE CONTENT - 7.
AVERAGE SULFUR CONTENT - 7.
RAN3E SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RAN3E CHLORIDE CONTENT 7.
»*» PARTICLE CONTROL
** MECHANICAL COLLECTOR
NUMBER
TYPE
** FABRIC FILTER
NUMBER
TYPE
** ESP
NUMBER
N'JMBER OF SPARES
TYPE
SUPPLIER
PRESSURE DROP - KPA
PARTICLE REMOVAL EFFICENCY - 7.
** PARTICLE SCRUBBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON NAME
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
LOUISVILLE GAS t ELECTRIC
MILL CREEK
LOUISVILLE
KENTUCKY
E
43.
516.
»»****
***##
350
325
330
350
.100 LB/MMBTU)
.200 LB/MMBTU)
(****»* LB/MMBTU)
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
660.66
151.7
183.
CONCRETE
(1400000 ACFM)
( 305 F)
( 600 FT)
( 19.0 FT)
( 11500 BTU/LB)
10800-12100
5.8
COAL
BITUMINOUS
26749.
14.50
10.0-18.0
9.00
8.0-10.0
3.75
3.5-4.5
.04
.03-.06
0
NONE
0
NONE
2
0
HOT SIDE
WESTERN PRECIPITATOR
.1 (1. IN-H20)
99.4
0
NONE
N/A
N/A
N/A
N/A
N/A
N/A
13-582
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
LOUISVILLE GAS & ELECTRIC: MILL CREEK 2 (CONT.)
»»* 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 - X
ENERGY CONSUMPTION - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
DESIGN COAL SULFER CONTENT - X
DESIGN COAL HEAT CONTENT - J/G
DESIGN COAL ASH CONTENT - X
DESIGN MOISTURE CONTENT - X
DESIGN CHLORIDE CONTENT - X
** QUENCHER/PRESATURATOR
TYPE
** ABSORBER
NUMBER
NUM3ER 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
L/G RATIO L/CU.M
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
NUMBER OF SPARES PER SYSTEM
NUMBER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
MANUFACTURER
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES PER STAGE
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
WASH WATER SOURCE
WASH FREQUENCY
WASH RATE - L/S
THROWAWAY PRODUCT
WET SCRUBBING
LIME
NONE
COMBUSTION ENGINEERING
FLUOR - PIONEER
FULL SCALE
RETROFIT
'/. 99.50
85.00
1.4
1
4/82
12/81
11/77
( 10000 BTU/LB)
4.50
23260.0
18.00
10.00
.06
NONE
2
0
SPRAY TOWER
OPEN COUNTERCURRENT SPRAY
N/A
COMBUSTION ENGINEERING
26.0 X 31.0
STAINLESS STEEL
AUSTENITIC
TYPE 316L
NONE
N/A
N/A
4
3755.
11.9
3.7
316.17
148.9
86.6
(59600 GPM)
( 88.9 GAL/1000 ACF)
( 12.0 FT/S)
( 670000 ACFM)
( 300 F)
PRIMARY COLLECTOR
4
0
2
IMPINGEMENT
BAFFLE
CLOSED VANE
ATLANTIC BRIDGE
HORIZONTAL
1
3.0
NR
NR
FRESH
INTERMITTENT
18.9
.5 IN-H20)
10.0 FT/S)
( 300 GAL/MIN)
13-583
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
LOUISVILLE GAS 4 ELECTRIC: MILL CREEK 2 (CONT.)
*» REHEATER
NUMBER
NUMBER OF SPARES
NUMBER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
TEMPERATURE INCREASE - C
OUTLET FLUE GAS TEMPERATURE - C
NUMBER OF HEAT EXCHANGER BANKS
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** FANS
NUMBER
NUMBER OF SPARES
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
»* FANS
NUMBER
NUMBER OF SPARES
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
CONSTRUCTION MATERIAL GENERIC TYPE
»* DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
MODULATION
SEAL AIR FLOW - CU. M/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
MODULATION
SEAL AIR FLOW - CU. M/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
MODULATION
SEAL AIR FLOW - CU. M/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
Z
0
1
IN-LINE
STEAM
FIN TUBE
27.8 ( 50 F)
82.2 ( 180 F)
2
CARBON STEEL
AISI 1110
2
0
CENTRIFUGAL
AMERICAN STANDARD
BOOSTER
INDUCED DRAFT
DRY
82.2 ( 180 F)
NR
2
0
CENTRIFUGAL
AMERICAN STANDARD
UNIT
FORCED DRAFT
DRY
NR
SHUT-OFF
LOUVER
PARALLEL BLADE MULTILOUVER
COMBUSTION ENGINEERING
OPEN/CLOSED
.71 ( 1500 ACFM)
CARBON STEEL [BLADES & FRAMES]; STAINLESS STEEL
AISI 1110; AUSTENITIC
NONE
N/A
SHUT-OFF
LOUVER
PARALLEL BLADE MULTILOUVER
COMBUSTION ENGINEERING
OPEN/CLOSED
.71 ( 1500 ACFM)
CARBON STEEL [BLADES 4 FRAMES]; STAINLESS STEEL
AISI 1110; AUSTENITIC
NONE
N/A
SHUT-OFF
LOUVER
PARALLEL BLADE MULTILOUVER
COMBUSTION ENGINEERING
OPEN/CLOSED
.71 ( 1500 ACFM)
CARBON STEEL [BLADES 4 FRAMES]; STAINLESS STEEL
AISI 1110; AUSTENITIC
13-584
-------
UTILITY FED SURVEY? OCTOBER 1983 - SEPTEMBER 1984
LOUISVILLE GAS 4 ELECTRIC: MILL CREEK 2 (CONT.)
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
CONFIGURATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
CONFIGURATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
** TANKS
SERVICE
ABSORBER RECYCLE
REAGENT FEED
** PUMPS
SERVICE
NONE
N/A
ABSORBER INLET
RECTANGULAR
CARBON STEEL
AISI 1110
NR
NR
ABSORBER OUTLET
RECTANGULAR
NR
NR
NR
NR
BYPASS
CARBON STEEL
AISI 1110
NONE
N/A
WET BALL MILL
COMPARTMENTED
NR
NUMBER
NR
NUMBER
**«*
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
CONFIGURATION
DIMENSIONS - FT
CAPACITY
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
BELT GENERIC MATERIAL TYPE
BELT SPECIFIC MATERIAL TYPE
FEED STREAM SOURCE
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
OVERFLOW STREAM CHARACTERISTICS
OUTLET STREAM DISPOSITION
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
BELT GENERIC MATERIAL TYPE
BELT SPECIFIC MATERIAL TYPE
THICKENER
1
0
CIRCULAR
140 DIA X 15.0
1050000 GAL
NR
NR
NR
NR
N/A
N/A
ABSORBER BLEED
1120 GPM/10X SOLIDS
280 GPM/30X SOLIDS
840 GPM
VACUUM FILTER
VACUUM FILTER
1
0
NR
NR
NR
NR
NR
NR
13-585
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
LOUISVILLE GAS & ELECTRIC: MILL CREEK Z (CONT.)
OUTLET STREAM CHARACTERISTICS
*** SALEABLE BYPRODUCTS
NATURE
*** SLUDGE
** TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
INLET QUALITY - X
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE TREATMENT
SITE SERVICE LIFE - YRS
** WATER BALANCE
WATER LOOP TYPE
MAKEUP WATER ADDITION - LITERS/S
»» FGD SPARE CAPACITY INDICES
ABS03EER - X
MIST ELIMINATOR - X
REHEATER - X
FAN - X
THICKENER - X
VACUUM FILTER - X
*» FGD SPARE COMPONENT INDICES
ABSORBER
MIST ELIMINATOR
REHEATER
FAN
THICKENER
VACUUM FILTER
45X SOLIDS
NONE
FIXATION
PUG MILL
CONVERSION SYSTEMS CPOZ-0-TEC1
45.0
FINAL
LANDFILL
ON-SITE
TRUCK
CLAY LINING
10
CLOSED
125.0
( 1984 GPM)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
12/81 SYSTEM 100.0 57.3
** PROBLEMS/SOLUTIONS/COMMENTS
75.0
100.0
95.00 99.00 744
262
150 50.0
MILL CREEK 2 COMMENCED OPERATIONS ON DECEMBER 18, 1981. THE FGD SYSTEM
WAS AVAILABLE 100X OF THE TIME SINCE START-UP.
1/82 SYSTEM
2/82 SYSTEM
3/82 SYSTEM
24.1
88.5
73.8
25.3
88.5
73.8
25.3
88.5
73.8
24.1
88.5
73.8
744
672
744
707
672
744
179 50.0
595 50.0
549 50.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE FIRST QUARTER 1982 THE UTILITY EXPERIENCED START-UP PROBLEMS
WITH THE UNIT 2 FGD SYSTEM.
4/82 SYSTEM
85.6
84.1
100.0
75.7
720 648
545 50.0
13-586
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
LOUISVILLE GAS t ELECTRIC: MILL CREEK 2 (CONT.)
PERIOD
5/82
6/82
KtKI-UKnAr-U.t UAI A
MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER
S02 PART. HOURS HOURS
SYSTEM
SYSTEM
100.0
81.7
100.0 100
81.1 81
.0
.1
22.4
78.7
744
720
167
699
FGD
HOURS
167
567
CAP.
FACTOR
50
50
.0
.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE SECOND QUARTER
OUTAGE TIME.
7/82
8/82
9/82
10/82
11/82
12/82
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
.0
.0
.0
.0
.0
55.8
.0
.0
.0
.0
.0
70.1 70
.0
.0
.0
.0
.0
.1
FAILURE OF THE RECIRCULATION PUMP CAUSED SOME
.0
.0
.0
.0
.0
50.4
744
744
720
744
720
744
714
713
558
739
691
535
0
0
0
0
0
375
50
50
50
50
50
50
.0
.0
.0
.0
.0
.0
** PROBLEMS/SOLUTIONS/COMMENTS
1/83
2/83
3/83
4/83
5/83
6/83
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
36.8
56.3
93.5
86.8
.0
.0
THE UTILITY REPORTED
OCCURRED DURING THE
38.6 38
59.3 59
92.7 92
87.2 87
.0
.0
THAT
PERIOD
.6
.3
.7
.2
.0
A MAJOR BEARING
OF JULY THROUGH
36.8
52.4
81.5
67.2
.0
.0
FAILURE ON THE
DECEMBER 1982
744
672
744
720
744
720
2B BOOSTER FAN
710
594
654
555
184
151
274
352
606
484
0
0
50
50
50
50
50
50
.0
.0
.0
.0
.0
.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THICKENER PROBLEMS DURING THE PERIOD OF JANUARY
THROUGH JUNE 1983.
BLEED LINE PROBLEMS WERE ALSO EXPERIENCED DURING THE FIRST SIX MONTHS OF
1933.
PUMP FAILURES WERE REPORTED CAUSING OUTAGE TIME DURING THE PERIOD OF
JANUARY THROUGH JUNE 1983.
744 743 473 50.0
744 646 577 50.0
720 554 411 50.0
*» PROBLEMS/SOLUTIONS/COMMENTS
REPAIRS ON THE ABSORBER VENT SYSTEM WERE MADE DURING THE THIRD QUARTER
OF 1983.
THE NEED TO ISOLATE THE SERVICE WATER SYSTEM RESULTED IN DOWN TIME DURING
THE THIRD QUARTER.
10/83 SYSTEM 77.6 72.9 72.9 48.4 744 494 360
13-587
7/83 SYSTEM
8/83 SYSTEM
9/83 SYSTEM
63.6
81.0
71.8
63.7
89.3
74.2
63.7
89.3
74.2
63.6
77.6
57.1
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
LOUISVILLE GAS « ELECTRIC: MILL CREEK Z (CONT.)
, PERFORMANCE DATA _
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION '/. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
11/83 SYSTEM 70.4 58.9 58.9 45.1 720 552 325
12/83 SYSTEM 58.3 47.7 47.7 39.1 744 610 291
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR FGD-RELATED PROBLEMS WERE REPORTED FOR THE FOURTH QUARTER OF 1983.
1/84 SYSTEM 744
2/84 SYSTEM 696
3/84 SYSTEM 744
4/84 SYSTEM 720
5/84 SYSTEM 744
6/84 SYSTEM 720
7/84 SYSTEM 744
8/84 SYSTEM 744
9/84 SYSTEM 720
«* PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE FIRST THREE QUARTERS OF 1984.
13-588
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
SECTION 13
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
LOUISVILLE GAS 4 ELECTRIC
MILL CREEK
LOUISVILLE
KENTUCKY
D
43. (
516. (
301. (
1084
427
420
495
427
.100 LB/MMBTU)
1.200 LB/MMBTU)
.700 LB/MMBTU)
BABCOCK t WILCOX
PULVERIZED COAL
BASE
755.04
148.9
183.
CONCRETE
6.4
(1600000 ACFM)
( 300 F)
( 600 FT)
( 21.0 FT)
** 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
NUMBER OF SPARES
TYPE
SUPPLIER
INLET FLUE GAS CAPACITY - CU.M/S
INLET FLUE GAS TEMPERATURE - C
PARTICLE REMOVAL EFFICENCY - 7.
** PARTICLE SCRUBBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON NAME
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
COAL
BITUMINOUS
26284. ( 11300 BTU/LB)
11000-12000
15.00
13.0-16.0
10.00
9.0-15.0
3.87
3.5-4.0
.04
.03-.06
0
NONE
0
NONE
2
0
COLD SIDE
AMERICAN AIR FILTER
377.5 ( 800000 ACFM)
148.9 ( 300 F)
99.5
0
NONE
N/A
N/A
N/A
N/A
N/A
N/A
13-589
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
LOUISVILLE GAS S ELECTRIC: MILL CREEK 3 (CONT.)
*** FGD SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
502 REMOVAL MODE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY
UNIT DESIGN SOZ REMOVAL EFFICIENCY - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
DESIGN COAL SULFER CONTENT - 7.
DESIGN COAL HEAT CONTENT - J/G
DESIGN COAL ASH CONTENT - X
DESIGN MOISTURE CONTENT - 7.
DESIGN CHLORIDE CONTENT - X
OPER. t MAINT. REQUIREMENT - MANHR/DAY
** QUENCHER/PRESATURATOR
NUMBER
TYPE
SUPPLIER
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
PRESSURE DROP - KPA
LIQUID RECIRCULATION RATE - LITERS/S
L/G RATIO - L/CU. M
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
*» 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
L/G RATIO - L/CU.M
GAS-SIDE PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/SEC
INLET GAS FLOU - CU. M/S
INLET GAS TEMPERATURE - C
S02 REMOVAL EFFICIENCY X
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
NUMBER OF SPARES PER SYSTEM
NUMBER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
MANUFACTURER
THROWAWAY PRODUCT
WET SCRUBBING
LIME
AMERICAN AIR FILTER
FLUOR POWER SERVICES
FULL SCALE
NEW
'/. 99.00
85.00
1
3/79
8/78
11/75
4.00
27912.0
16.00
15.00
.06
120.0
4
VENTURI
AMERICAN AIR FILTER
188.76 (
148.9 (
.5 (
126. (
.7 (
CARBON STEEL
AISI 1110
( 12000 BTU/LB)
400000 ACFM)
300 F)
2.0 IN-H20)
2000 GPM)
5.0 GAL/1000 ACFM)
4
0
PACKED TOWER
ENTRAINED PACKING
MOBILE BED CONTACTOR
AMERICAN AIR FILTER
16.0 X 20.0
CARBON STEEL
AISI 1110
N/A
INORGANIC
HYDRAULICALLY-BONDED MORTAR
PRE-KRETE G-8
POLYURETHANE BALLS
1
1285. (20400 GPM)
7.4 ( 55.0 GAL/1000 ACF )
1.5 ( 6.0 IN-H20)
3.0 (10.0 FT/S)
175.03 ( 370900 ACFM)
148.9 ( 300 F)
85.7
PRIMARY COLLECTOR
8
0
2
IMPINGEMENT
BAFFLE
CLOSED VANE
ATLANTIC BRIDGE
13-590
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
LOUISVILLE GAS i ELECTRIC: MILL CREEK 3 (CONT.)
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
CONSTRUCTION MATERIAL SPECIFIC TYPE
WASH WATER SOURCE
WASH FREQUENCY
WASH RATE - 1/5
** REHEATER
NUMBER
NUMBER OF SPARES
NUMBER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
LOCATION
TEMPERATURE INCREASE - C
INLET FLUE GAS TEMPERATURE - C
OUTLET FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** FANS
NUMBER
NUMBER OF SPARES
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CD.M/S
FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
CONSTRUCTION MATERIAL GENERIC TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
»* DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
HORIZONTAL
1
3
2.13
7.62
2
7.0
3.0
1.
FT)
IN)
00 IN)
1.0 IN-H20)
15.0 FT/S)
5
.2
4.6
STAINLESS STEEL
AUSTENITIC
FRESH
10X OF THE AREA WASHED EACH 1/2 MINUTE
2.5 (40 GAL/MIN)
0
1
IN-LINE
STEAM
BARE TUBE
TOP OF ABSORBER
27.8 ( 50 F)
54.4 ( 130 F)
82.2 ( 180 F)
CARBON STEEL
AISI 1110
2
0
CENTRIFUGAL
AMERICAN STANDARD
UNIT
FORCED DRAFT
DRY
377.52 ( 800000 ACFM)
148.9 ( 300 F)
12.9 (42.3 IN-H20)
CARBON STEEL
SHUT-OFF
GUILLOTINE
TOP-ENTRY GUILLOTINE
STAINLESS STEEL
AUSTENITIC
NONE
N/A
SHUT-OFF
GUILLOTINE
TOP-ENTRY GUILLOTINE
STAINLESS STEEL
AUSTENITIC
NONE
N/A
SHUT-OFF
GUILLOTINE
TOP-ENTRY GUILLOTINE
STAINLESS STEEL
AUSTENITIC
NONE
N/A
13-591
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
LOUISVILLE GAS J ELECTRIC: MILL CREEK 3 (CONT.)
*» DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
#* DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
»* REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
NUMBER
NUM3ER OF SPARES
PRODUCT QUALITY - X SOLIDS
»* TANKS
SERVICE
CARBIDE LIME SLURRY
ADDITIVE SLURRY DAY
REACTION
THICKENER
** PUMPS
SERVICE
ADDITIVE SLURRY TRANSFER
RECYCLE
ABSORBER BLEED
THICKENER UNDERFLOW
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
DIMENSIONS - FT
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
FEED STREAM SOURCE
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
OUTLET STREAM DISPOSITION
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUM3ER
NUMBER OF SPARES
ABSORBER INLET
CARBON STEEL
AISI 1110
NONE
N/A
ABSORBER OUTLET
CARBON STEEL
AISI 1110
INORGANIC
HYDRAULICALLY-BONDED MORTAR
DOWNSTREAM OF REHEATER
CARBON STEEL
AISI 1110
ORGANIC
HYDRAULICALLY-BONDED MORTAR
BYPASS
CARBON STEEL
AISI 1110
INORGANIC
FOAM GLASS BLOCKS
WET BALL MILL
COMPARTMENTED
TUBE MILL
1
0
25.0
NUMBER
NUMBER
7
10
6
2
THICKENER
1
0
125.0 X 10.0
CARBON STEEL
AISI 1110
NONE
N/A
ABSORBER BLEED
10X SOLIDS
20X SOLIDS
VACUUM FILTER
VACUUM FILTER
5
1
13-592
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
LOUISVILLE GAS * ELECTRIC: MILL CREEK 3 (CONT.)
FEED STREAM SOURCE
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
OUTLET STREAM DISPOSITION
*** SALEABLE BYPRODUCTS
NATURE
«** SLUDGE
** TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
INLET QUALITY - X
*# DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE TREATMENT
SITE SERVICE LIFE - YRS
»* PROCESS CONTROL AND INSTRUMENTATION
PROCESS STREAM
CHEMICAL PARAMETERS
MONITOR TYPE
MONITOR LOCATION
PROCESS CHEMISTRY MODE
*» WATER BALANCE
WATER LOOP TYPE
MAKEUP WATER ADDITION - LITERS/S
** CHEMICALS AND CONSUMPTION
FUNCTION
NAME
PRINCIPAL CONSTITUENT
SOURCE/SUPPLIER
POINT OF ADDITION
** FGD SPAPE CAPACITY INDICES
ABSORBER X
MIST ELIMINATOR - X
REHEATER - 7.
FAN X
BALL MILL - '/.
EFFLUENT HOLD TANK
RECIRCULATION PUMP
THICKENER X
VACUUM FILTER - X
** FGD SPARE COMPONENT INDICES
ABSORBER
MIST ELIMINATOR
REHEATER
FAN
BALL MILL
EFFLUENT HOLD TANK
RECIRCULATION PUMP
THICKENER
VACUUM FILTER
THICKENER UNDERFLOW
SOX SOLIDS
45X SOLIDS
PUG MILL
NONE
FIXATION
PUG MILL
CONVERSION SYSTEMS
45.0
FINAL
LANDFILL
ON-SITE
TRUCK
CLAY LINING
10
SLURRY RECYCLE
PH
UNILOC
IN REACTION TANK
FEEDBACK
tPOZ-0-TECl
OPEN/CLOSED
ABSORBENT
CARBIDE LIME
90X CAOH2
AIRCO
RECYCLE TANK
.0
.0
.0
.0
.0
.0
.0
.0
.0
( 150 GPM)
25
.0
.0
.0
.0
.0
.0
1.0
.0
.0
13-593
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
LOUISVILLE GAS 4 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
8/78
SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
INITIAL FGD OPERATIONS BEGAN ON AUGUST 13, 1978. OPERATIONAL HOURS WERE
NOT AVAILABLE FOR AUGUST.
9/78 SYSTEM 81.0 80.7 80.0 80.0 720 714 576 52.0
** PROBLEMS/SOLUTIONS/COMMENTS
FRP PIPING PROBLEMS WERE ENCOUNTERED.
SOME BEARING AND SHAFT RELATED PUMP PROBLEMS WERE ALSO ENCOUNTERED
DURING SEPTEMBER.
10/78 SYSTEM 86.0 85.5 85.0 81.6 744 710 607 54.0
11/78 SYSTEM 93.0 85.2 85.0 41.5 720 351 299 40.0
** PROBLEMS/SOLUTIONS/COMMENTS
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 .0
1/79 SYSTEM .0 744 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT DID NOT OPERATE DURING DECEMBER OR JANUARY.
2/79 SYSTEM 26.0 18.0 18.0 17.4 672 651 117 52.0
3/79 SYSTEM 62.0 53.1 53.0 52.4 744 735 390 51.0
** PROBLEMS/SOLUTIONS/COMMENTS
COMPLIANCE TESTING WAS PERFORMED DURING MARCH AND THE UNIT WAT DECLARED
COMMERCIAL.
4/79 SYSTEM 75.0 63.6 63.0 44.4 720 503 320 40.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE ONLY PROBLEMS REPORTED WERE WITH DAMPERS AND PUMP FAILURES.
5/79 SYSTEM 100.0 97.8 97.0 64.7 744 492 481 38.0
6/79 SYSTEM 56.0 51.9 51.0 47.9 720 665 345 48.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO UNUSUAL OPERATING PROBLEMS WERE ENCOUNTERED
DURING MAY OR JUNE.
7/79 SYSTEM 63.0 59.9 59.0 55.2 744 686 411 53.0
8/79 SYSTEM 76.0 68.0 68.0 50.3 744 550 374 47.0
13-594
-------
UTILITY FED SURVEY: OCTOBER 1983 - SEPTEMBER 1984
LOUISVILLE GAS & 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
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 91.0 90.6 91.0 83.9 720 667 604 50.0
10/79 SYSTEM 83.0 82.0 82.0 76.1 744 690 566 44.0
** 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
12/79 SYSTEM .0 744 0 0 .0
1/80 SYSTEM .0 744 0 0 . 0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE OVERHAUL GENERAL SCRUBBER MAINTENANCE WAS DONE BUT NO MAJOR
MODIFICATIONS WERE MADE.
2/80 SYSTEM 37.0 36.1 36.0 26.6 696 512 185 39.0
»* PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT CAME BACK ON LINE ON FEBRUARY 10 AFTER THE TURBINE OVERHAUL
WORK WAS COMPLETED.
3/80 SYSTEM 37.0 36.9 37.0 30.6 744 618 228 46.0
»* 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 42.2 720 715 304 53.0
** 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 CONOENSATE PUMP.
5/80 SYSTEM 67.5 51.4 51.4 34.4 744 498 256 47.0
*# 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 14.0
13-595
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
LOUISVILLE GAS 4 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
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 52.0
»» 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 58.7 744 535 437 60.0
9/80 SYSTEM 57.2 60.4 60.4 57.2 720 682 412 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
DURING THE MONTH OF OCTOBER.
11/80 SYSTEM 57.1 49.4 49.4 41.9 720 611 302 60.0
** PROBLEMS/SOLUTIONS/COMMENTS
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.
1/81 SYSTEM .0 .0 .0 .0 744 521 0 40.0
2/81 SYSTEM .0 .0 .0 .0 672 593 0 50.0
3/81 SYSTEM 1.0 1.0 1.0 1.0 744 675 8 50.0
** FROBLEMS/SOLUTIONS/COmENTS
DURING THE FIRST QUARTER 1981 MAJOR CORROSION DAMAGE CAUSED FAILURE OF
THE PRECRETE-G.
FROZEN LINES ENCOUNTERED DURING THE PERIOD ACCOUNTED FOR SOME OUTAGE TIME.
REPAIRS TO THE MIST ELIMINATOR SHELL CAUSED ADDITIONAL OUTAGE TIME.
DURING MARCH STRIKING WORKERS ADDED TO THE OUTAGE TIME OF THE SYSTEM.
4/81 SYSTEM 32.9 33.2 33.2 32.9 720 714 237 45.0
13-596
-------
ITTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
LOUISVILLE GAS 4 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 THE MONTH OF APRIL THE UTILITY REPORTED HAVING PROBLEMS WITH FROZEN
PIPELINE FAILURES.
5/81 SYSTEM 33.7 37.9 37.9 33.7 744 662 251 55.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE MONTH OF MAY THE UTILITY REPORTED HAVING PROBLEMS WITH
THE THICKENER.
6/81 SYSTEM 34.6 34.6 34.6 34.6 720 719 249
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE MONTH OF JUNE THE UTILITY REPORTED HAVING MODULE CORROSION
PROBLEMS.
744 641 472 60.0
744 716 657 65.0
720 720 582 65.0
** PROBLEMS/SOLUTIONS/COMMENTS
MIST ELIMINATOR MODULE FAILURES WERE ENCOUNTERED DURING THE THIRD QUARTER
1981.
744 332 298 50.0
720 623 233 50.0
744 721 308 50.0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE FOURTH QUARTER PUMP FAILURES WERE ENCOUNTERED.
PROBLEMS DURING THE PERIOD WERE ALSO EXPERIENCED WITH THE THICKENER AND
CORROSION.
7/81 SYSTEM
8/81 SYSTEM
9/81 SYSTEM
63.4
89.2
80.8
73.6
91.8
80.8
73.6
91.8
80.8
63.4
88.3
80.8
10/81 SYSTEM
11/81 SYSTEM
12/81 SYSTEM
41.4
32.4
41.4
89.7
37.4
42.7
89.7
37.4
42.7
41.4
32.4
41.4
1/82
2/82
3/82
SYSTEM
SYSTEM
SYSTEM
.0
.0
.0
.0
.0
.0
.0
.0
.0
744
672
744
743
612
202
0
0
0
50.
50.
50.
0
0
0
** PROBLEMS/SOLUTIONS/COMMENTS
4/82
5/82
6/82
SYSTEM
SYSTEM
SYSTEM
.0
.0
8.9
DURING THE FIRST
THE MODULES AND
.0
.0
12.7
QUARTER
THE MIST
.0
.0
12.7
1982 THE FGD
ELIMINATORS.
.0
.0
8.9
SYSTEM WAS OFF-LINE
720
744
720
TO REBUILD
704
665
502
0
0
64
50.
50.
50.
0
0
0
13-597
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
LOUISVILLE GAS 4 ELECTRIC: MILL CREEK 3 (CONT.)
7/82 SYSTEM
8/82 SYSTEM
9/82 SYSTEM
36.4
60.5
15.3
36.5
59.8
43.7
36.5
59.8
43.7
36.4
58.3
15.3
10/82 SYSTEM
11/82 SYSTEM
12/82 SYSTEM
71.5
74.0
.0
73.4
60.6
.0
73.4
60.6
.0
59.7
30.1
.0
... . 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 SECOND QUARTER, THE MIST ELIMINATOR SHELL ON ALL MODULES WAS
RELINED.
744 742 271 50.0
744 726 434 50.0
720 252 110 50.0
»* PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THICKENER PROBLEMS WERE EXPERIENCED DURING THE
MONTHS OF JULY, AUGUST AND SEPTEMBER, 1982.
744 605 444 50.0
720 358 217 50.0
744 550 0 50.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT MIST ELIMINATORS WERE BEING REBUILT DURING THE
PERIOD OF JULY THROUGH DECEMBER 1982.
REHEAT TUBES WERE ALSO REBUILT/REPLACED DURING THIS PERIOD.
42 0 50.0
672 88 63 50.0
744 454 186 50.0
720 416 0 50.0
744 579 420 50.0
720 501 216 50.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED PROBLEMS WITH PLUGGING IN THE REHEATER DURING THE
PERIOD OF JANUARY THROUGH JUNE 1983.
FAILURE OF THE REHEAT TUBES OCCURRED DURING THE FIRST SIX MONTHS OF 1983
CAUSING FGD SYSTEM OUTAGE TIME.
744 742 209 50.0
744 737 20 50.0
720 659 0 50.0
** PROBLEMS/SOLUTIONS/COMMENTS
LEAKS IN THE STACK REHEAT SYSTEM WERE REPAIRED DURING THE THIRD QUARTER OF
1983.
10/83 SYSTEM 13.8 14.7 14.7 13.6 744 685 101
11/63 SYSTEM 56.7 .0 720 0 0
13-598
1/83
2/83
3/83
4/83
5/83
6/83
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
9
25
57
30
.0
.4
.0
.0
.0
.0
71
41
72
43
.0
.6
.0
.0
.5
.1
.0
71.6
41.0
.0
43.1
9
25
56
30
.0
.4
.0
.0
.5
.0
7/83 SYSTEM
8/83 SYSTEM
9/83 SYSTEM
28.1
2.7
.0
28.2
2.7
.0
28.2
2.7
.0
28.1
2.7
.0
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
LOUISVILLE GAS t ELECTRIC: MILL CREEK 3 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
SOS PART. HOURS HOURS HOURS FACTOR
12/83 SYSTEM 25.9 8.6 8.6 6.7 744 583 25
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR FGD-RELATED PROBLEMS WERE REPORTED FOR THE FOURTH QUARTER OF 1983.
1/84 SYSTEM 744
2/84 SYSTEM 696
3/84 SYSTEM 744
4/84 SYSTEM 720
5/84 SYSTEM 744
6/84 SYSTEM 720
7/84 SYSTEM 744
8/84 SYSTEM 744
9/84 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE FIRST THREE QUARTERS OF 1984.
13-599
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
SECTION 13
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 - MW
LOUISVILLE Gt
MILL CREEK
4
LOUISVILLE
KENTUCKY
D
43.
516.
301.
495
495
495
495
495
IS & ELECTRIC
( .100 LB/MMBTU)
« 1.200 LB/MMBTU)
( .700 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 CCTTENT - 7.
RANGE ASH CONTENT - V.
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
NUMBER OF SPARES
TYPE
SUPPLIER
INLET FLUE GAS CAPACITY - CU.M/S
INLET FLUE GAS TEMPERATURE - C
PARTICLE REMOVAL EFFICENCY - 7.
** PARTICLE SCRUBBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON NAME
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
BABCOCK t WILCOX
PULVERIZED COAL
BASE
(1600000 ACFM)
( 300 F)
( 600 FT)
(***** FT)
( 11500 BTU/LB)
11000-12000
755.04
148.9
183.
CONCRETE
*******
COAL
BITUMINOUS
26749.
15.00
13.0-16.0
10.00
3.5-4.0
3.75
******
.08
.03-.06
0
NONE
0
NONE
2
0
COLD SIDE
AMERICAN AIR FILTER
377.5 ( 800000 ACFM)
148.9 ( 300 F)
99.5
0
NONE
N/A
N/A
N/A
N/A
N/A
N/A
13-600
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
LOUISVILLE GAS S ELECTRIC: MILL CREEK 4 (CONT.)
«»* FGD SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
UNIT DESIGN S02 REMOVAL EFFICIENCY - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
DESIGN COAL SULFER CONTENT - X
DESIGN COAL HEAT CONTENT - J/G
DESIGN COAL ASH CONTENT - X
DESIGN MOISTURE CONTENT - X
DESIGN CHLORIDE CONTENT - X
** QUENCHER/PRESATURATOR
NUMBER
TYPE
SUPPLIER
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
L/G RATIO - L/CU. M
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** 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
LIQUID RECIRCULATION RATE - LITER/S
SUPERFICAL GAS VELOCITY - M/SEC
S02 REMOVAL EFFICIENCY - X
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
NUMBER OF SPARES PER SYSTEM
NUMBER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
MANUFACTURER
CONFIGURATION
NUMBER OF PASSES PER STAGE
FREEBOARD DISTANCE M
DISTANCE BETWEEN STAGES - CM
DISTANCE BETWEEN VANES - CM
PRESSURE DPOP KPA
SUPERFICAL GAS VELOCITY - M/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
THROWAWAY PRODUCT
WET SCRUBBING
LIME
AMERICAN AIR FILTER
FLUOR POWER SERVICES
FULL SCALE
NEW
85.00
1
10/82
7/82
2/76
4.00
27912.0
16.00
15.00
.06
4
VENTURI
AMERICAN AIR FILTER
( 12000 BTU/LB)
188.76 (
148.9 (
.7 (
CARBON STEEL
AISI 1110
400000 ACFM)
300 F)
5.0 GAL/1000 ACFM)
4
0
PACKED TOWER
ENTRAINED PACKING
MOBILE BED CONTACTOR
AMERICAN AIR FILTER
16.0 X 20.0
CARBON STEEL
AISI 1110
N/A
INORGANIC
HYDRAULICALLY-BONDED MORTAR
PRE-KRETE G-8
POLYURETHANE BALLS
1285. (20400 GPM)
3.0 (10.0 FT/S)
85.0
PRIMARY COLLECTOR
8
0
2
IMPINGEMENT
BAFFLE
CLOSED VANE
ATLANTIC BRIDGE
HORIZONTAL
3
2.13 (
7.62 (
2.5 (
.2 (
4.6 (
STAINLESS STEEL
AUSTENITIC
7.0 FT)
3.0 IN)
1.00 IN)
1.0 IN-H20)
15.0 FT/S)
13-601
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
LOUISVILLE GAS & ELECTRIC: MILL CREEK 4 (CONT.)
WASH WATER SOURCE
WASH RATE - L/S
*» REHEATER
NUMBER
NUMBER OF SPARES
NUMBER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** FANS
NUMBER
NUMBER OF SPARES
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
CONSTRUCTION MATERIAL GENERIC TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
*» DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
NUMBER
FRESH
2.5 ( 40 GAL/MIN)
4
0
1
IN-LINE
STEAM
BARE TUBE
CARBON STEEL
AISI 1110
2
0
CENTRIFUGAL
AMERICAN STANDARD
UNIT
FORCED DRAFT
DRY
377.52 ( 800000 ACFM)
148.9 ( 300 F)
12.9 (42.3 IN-H20)
CARBON STEEL
4
SHUT-OFF
GUILLOTINE
TOP-ENTRY GUILLOTINE
STAINLESS STEEL
AUSTENITIC
NONE
N/A
ABSORBER INLET
CARBON STEEL
AISI 1110
INORGANIC
HYDRAULICALLY-BONDED MORTAR
ABSORBER OUTLET
CARBON STEEL
AISI 1110
INORGANIC
HYDRAULICALLY-BONDED MORTAR
DOWNSTREAM OF REHEATER
CARBON STEEL
AISI 1110
ORGANIC
HYDRAULICALLY-BONDED MORTAR
BYPASS
CARBON STEEL
AISI 1110
NONE
N/A
WET BALL MILL
COMPARTMENTED
NR
1
13-602
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
LOUISVILLE GAS t ELECTRIC: MILL CREEK <» (CONT.)
»* TANKS
SERVICE
CARBIDE LIME SLURRY
ADDITIVE SLURRY DAY
REACTION
THICKENER
»» PUMPS
SERVICE
ADDITIVE SLURRY TRANSFER
RECYCLE
SCRUBBER BLEED
THICKENER
NR
»* SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
DIMENSIONS - FT
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
*** SALEABLE BYPRODUCTS
NATURE
*** SLUDGE
** TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE TREATMENT
SITE DIMENSIONS
*» PROCESS CONTROL AND INSTRUMENTATION
PROCESS STREAM
CHEMICAL PARAMETERS
MONITOR TYPE
MONITOR LOCATION
** WATER BALANCE
WATER LOOP TYPE
*# CHEMICALS AND CONSUMPTION
FUNCTION
NAME
PRINCIPAL CONSTITUENT
SOURCE/SUPPLIER
NUMBER
2
1
NUMBER
7
10
6
2
****
THICKENER
1
0
125.0 X 10.0
CARBON STEEL
AISI 1110
NR
NR
10X SOLIDS
20X SOLIDS
NONE
FIXATION
PUG MILL
CONVERSION SYSTEMS tPOZ-0-TEC]
FINAL
POND
ON-SITE
PIPELINE
CLAY LINING
100 ACRES
SLURRY RECYCLE
PH
UNILOC
IN REACTION TANK
CLOSED
ABSORBENT
CARBIDE LIME
90X CAOH2
AIRCO
13-603
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
LOUISVILLE GAS 4 ELECTRIC: MILL CREEK 4 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
502 PART. HOURS HOURS HOURS FACTOR
7/82 SYSTEM 5.4 21=8 21.8 4.6 744 156 34 50.0
** PROBLEMS/SOLUTIONS/COHMEKTS
THE UTILITY REPORTED THAT START-UP FOR THE NEW BOILER WAS ON JULY 15, 1982.
8/82
9/82
10/82
11/82
12/82
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
41.4
39.4
.0
.0
35.1
78.5
52.4
.0
56.6
78.
52.
56.
5
9
0
6
41.
38.
35.
1
5
0
0
1
744
720
744
720
744
390
529
0
347
461
306
277
0
0
261
50.0
50.0
50.0
50.0
50.0
** PROBLEMS/SOLUTIONS/COMMENTS
1/83
2/83
3/83
4/83
5/83
6/83
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
18.1
.0
25.3
44.7
65.2
6.4
THE UTILITY
BOILER WERE
24.2
.0
64.4
48.5
95.3
7.4
REPORTED THAT PROBLEMS
ENCOUNTERED DURING THE
24.
64.
48.
95.
2
0
4
5
3
7. -4
18.
24.
41.
59.
6.
1
0
1
3
4
4
ASSOCIATED WITH START-UP OF THE NEW
PERIOD OF JULY THROUGH DECEMBER, 1982.
744
672
744
720
744
720
558
600
278
612
464
619
135
0
179
297
442
46
50.0
50.0
50.0
50.0
50.0
50.0
** PROBLEMS/SOLUTIONS/COMMENTS
BYPASS DAMPER REPAIRS WERE MADE DURING THE PERIOD OF JANUARY THROUGH JUNE,
1983.
THE UTILITY REPORTED A THICKENER RAKE FAILURE DURING THE PERIOD OF JANUARY
THROUGH JUNE, 1983.
THE UTILITY REPORTED REHEAT PROBLEMS DURING THE PERIOD OF JANUARY THROUGH
JUNE, 1983.
7/83
8/83
9/83
SYSTEM
SYSTEM
SYSTEM
37.5
36.6
15.7
40.
39.
15.
7
1
7
40.7
39.1
15.7
36
36
15
.8
.6
.7
744
744
720
673
695
720
274
272
113
50.0
50.0
50.0
** PROBLEMS/SOLUTIONS/COMMENTS
A THICKENER RAKE STOPPED UP IN ACCUMULATED THICKENER SOLIDS DURING THE
THIRD QUARTER RESULTING IN OUTAGE TIME.
THICKENER UNDERFLOW PUMP PROBLEMS CONTRIBUTED TO LOW AVAILABILITY DURING
THE PERIOD.
THE UTILITY REPORTED PLUGGING IN THE ABSORBER MOBILE BALL BEDS DURING THE
THIRD QUARTER.
10/83 SYSTEM 4.8 12.4 12.4 4.8 744 290 36
11/83 SYSTEM 43.6 32.5 32.5 31.7 720 701 228
13-604
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
LOUISVILLE GAS & ELECTRIC: MILL CREEK 4 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
12/83 SYSTEM 57.4 45.8 45.8 39.4 744 640 293
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR FGD-RELATED PROBLEMS WERE REPORTED FOR THE FOURTH QUARTER OF 1983.
1/84 SYSTEM 744
2/84 SYSTEM 696
3/84 SYSTEM 744
4/84 SYSTEM 720
5/84 SYSTEM 744
6/84 SYSTEM 720
7/84 SYSTEM 744
8/84 SYSTEM 744
9/84 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE FIRST THREE QUARTERS OF 1984.
13-605
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
SECTION 13
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
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/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** WIT 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
& ELECTRIC
( .100 LB/MMBTU)
( 1.200 LB/MMBTU)
(**»**# LB/MMBTU)
LOUISVILLE GAS
PADDY'S RUN
6
LOUISVILLE
KENTUCKY
E
43.
516.
*»*#»*
302
72
67
69
72
FOSTER WHEELER
PULVERIZED COAL
PEAK
174.60 ( 370000 ACFM)
168.3 ( 335 F)
76. ( 250 FT)
CONCRETE
4.3 ( 14.0 FT)
»* FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE 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
** MECHANICAL COLLECTOR
NUMBER
TYPE
** ESP
NUMBER
NUMBER OF SPARES
TYPE
SUPPLIER
INLET FLUE GAS CAPACITY - CU.M/S
INLET FLUE GAS TEMPERATURE - C
PARTICLE REMOVAL EFFICENCY - 7.
** PARTICLE SCRUBBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON NAME
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
»** FGD SYSTEM
COAL
BITUMINOUS
26284. ( 11300 BTU/LB)
10400-11900
14.00
10.0-20.0
9.00
8.0-10.8
3.70
3.5-4.0
.04
.03-.06
0
NONE
1
0
COLD SIDE
RESEARCH-COTTRELL
174.6 ( 370000 ACFM)
168.3 ( 335 F)
99.1
0
NONE
N/A
N/A
N/A
N/A
N/A
N/A
N/A
13-606
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
LOUISVILLE GAS & ELECTRIC: PADDY'S RUN 6 (CONT.)
»* 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
ENERGY CONSUMPTION - 7.
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
DESIGN COAL SULFER CONTENT - X
DESIGN COAL HEAT CONTENT - J/G
OPER. & MAINT. REQUIREMENT - MANHR/DAY
»* QUENCHER/PRESATURATOR
NUMBER
»* 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 X
PARTICLE REMOVAL EFFICENCY - X
THROWAWAY PRODUCT
WET SCRUBBING
LIME
COMBUSTION ENGINEERING
FLUOR - PIONEER
FULL SCALE
RETROFIT
X 99.10
90.00
2.8
1
4/73
4/73
7/71
4.00
24190.4
192.0
»» MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
NUMBER OF SPARES PER SYSTEM
NUMBER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
MANUFACTURER
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
CONSTRUCTION MATERIAL SPECIFIC TYPE
( 10400 BTU/LB)
2
0
PACKED TOWER
STATIC BED PACKING
MARBLE-BED SCRUBBER
COMBUSTION ENGINEERING
17.0 X 18.0 X 50.0
CARBON STEEL
AISI 1110
N/A
ORGANIC
GLASS FLAKE-FILLED POLYESTER;
FLAKELINE 103; FLAKELINE 151
MICA FLAKE-FILLED
GLASS
2
7.
510.
5.
2.
3.
87.
168.
85.
99.
MARBLES
6
9
7
0
30
3
0
0
3.0IN)
8100 GPM)
43.8 GAL/1000 ACF)
11.0 IN-H20)
10.0 FT/S)
185000 ACFM)
335 F)
PRIMARY COLLECTOR
4
0
2
IMPINGEMENT
BAFFLE
CLOSED VANE
COMBUSTION ENGINEERING
HORIZONTAL
2
3
1,
121.
52
92
45
4.3
.4
.0
( 5.0 FT)
(48.0 IN)
( 1.70 IN)
1.5 IN-H20)
10.0 FT/S)
ORGANIC
POLYPROPYLENE
13-607
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
LOUISVILLE GAS 4 ELECTRIC: PADDY'S RUN 6 (CONT.)
WASH WATER SOURCE
WASH FREQUENCY
WASH RATE - L/S
** REHEATER
NUMBER
NUMBER OF SPARES
NUMBER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
COMBUSTION FUEL SULFER CONTENT - X
LOCATION
PERCENT GAS BYPASSED - AVG
TEMPERATURE INCREASE - C
INLET FLUE GAS TEMPERATURE - C
OUTLET FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** FANS
NUMBER
NUMBER OF SPARES
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE CU.MYS
FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
SEAL AIR FLOW - CU. M/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
CONFIGURATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
CONFIGURATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
CONFIGURATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
PRODUCT QUALITY - X SOLIDS
FRESH
EVERY 8 HOURS
8.8 ( 140 6AL/MIN)
0
2
DIRECT COMBUSTION
IN-LINE BURNER
NATURAL GAS
.0
IN OUTLET DUCT
.0
27.8 ( 50 F)
52.2 ( 126 F)
80.0 ( 176 F)
CAST IRON
NR
1
0
CENTRIFUGAL
WESTIHGHOUSE
BOOSTER
INDUCED DRAFT
DRY
82.58
80.0
CARBON STEEL
175000 ACFM)
176 F)
CONTROL/SHUT-OFF
LOUVER
NR
COMBUSTION ENGINEERING
.00 ( 0 ACFM)
CARBON STEEL
AISI 1110
NONE
N/A
INLET
RECTANGULAR
CARBON STEEL
AISI 1110
NONE
N/A
OUTLET
RECTANGULAR
CARBON STEEL
AISI 1110
NONE
N/A
BYPASS
RECTANGULAR
CARBON STEEL
AISI 1110
NONE
N/A
GRINDING OF SOLIDS FOUND IN BARGE DELIVERED CARB
25.0
13-608
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
LOUISVILLE GAS 4 ELECTRIC: PADDY'S RUN 6 (CONT.)
»* TANKS
SERVICE
ABSORBER RECYCLE
REAGENT PREP PRODUCT
THICKENER OVERFLOW
## PUMPS
SERVICE
RECYCLE
ABSORBER BLEED
THICKENER UNDERFLOW
CARBIDE LIME SLURRY
THICKENER OVERFLOW
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
CAPACITY
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
BELT GENERIC MATERIAL TYPE
BELT SPECIFIC MATERIAL TYPE
FEED STREAM SOURCE
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
OUTLET STREAM DISPOSITION
OVERFLOW STREAM DISPOSITION
*« SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
DIMENSIONS - FT
CAPACITY
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
FEED STREAM SOURCE
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
OUTLET STREAM DISPOSITION
OVERFLOW STREAM DISPOSITION
*** SLUDGE
X CAS03 - DRY
X CASC4 - DRY
X ASH - DRY
»* TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
INLET QUALITY - X
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE TREATMENT
NUMBER
****
****
***»
NUMBER
3
****
2
***«
****
VACUUM FILTER
2
1
240 TONS/DAY
CARBON STEEL
AISI 1110
NR
NR
ORGANIC
POLYPROPYLENE
THICKENER UNDERFLOW
23X SOLIDS
45-50X SOLIDS
LANDFILL
TO THICKENER
THICKENER
1
0
50 DIA X 17.0
250000
CARBON STEEL
AISI 1110
NONE
N/A
ABSORBER BLEED
10X SOLIDS
23X SOLIDS
VACUUM FILTER
TO REACTION TANK
96.0
4.0
3.5
FIXATION
LANDFILL
NONE
40.0
FINAL
LANDFILL
OFF-SITE
TRUCK
NONE
13-609
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
LOUISVILLE 6AS & ELECTRIC'- PADDY'S RUN 6 (CONT.)
** PROCESS CONTROL AND INSTRUMENTATION
PROCESS STREAM
CHEMICAL PARAMETERS
CONTROL LEVELS
»* WATER BALANCE
WATER LOOP TYPE
MAKEUP WATER ADDITION - LITERS/S
** CHEMICALS AND CONSUMPTION
FUNCTION
NAME
PRINCIPAL CONSTITUENT
SOURCE/SUPPLIER
CONSUMPTION
POINT OF ADDITION
»* FGD SPARE CAPACITY INDICES
ABSORBER - X
MIST ELIMINATOR - X
REHEATER - X
FAN - X
EFFLUENT HOLD TANK -
RECIRCULATION PUMP -
THICKENER - X
VACUUM FILTER - X
«* FGD SPARE COMPONENT INDICES
ABSORBER
MIST ELIMINATOR
REHEATER
FAN
EFFLUENT HOLD TANK
RECIRCULATION PUMP
THICKENER
VACUUM FILTER
INLET, OVERFLOW POT DRAINS, SUMP
PH
PH <6 UPPER BED, PH >4 LOWER BED, PH 8-10 AT INL
CLOSED
3.1
( 50 6PM)
ABSORBENT
CARBIDE LIME
CAIOH12
AIRCO
4800 LB/HR DRY CAIOH32
ADDITIVE SLURRY TANK
20.0
.0
.0
.0
.0
33.0
.0
.0
.0
.3
.0
.0
.0
1.0
.0
.0
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
/. 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
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.
6/73 6A
6B
SYSTEM
.1
6.0
3.1
.0
2.1
1.1
720 255
13-610
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
LOUISVILLE GAS 4 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
7/73 6A 21.0 6.7
6B 21.0 6.7
SYSTEM 21.0 6.7 744 240 50
** 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 6A 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 7<^ ° ° -°
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS SHUT DOWN DUE TO A LACK OF DEMAND.
2/74 SYSTEM -° 672 0 0 .0
3/74 SYSTEM -° 744 0 0 .0
13-611
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 198*
LOUISVILLE GAS 4 ELECTRIC: PADDY'S RUN 6 (CONT.)
PERIOD
4/74
5/74
6/74
7/74
8/74
MODULE AVAILABILITY OPERABILITY RELIABILITY
SYSTEM
SYSTEM
SYSTEM
6A
6B
SYSTEM
6A
6B
SYSTEM
51.0
81.0
66.0
50.0
77.0
63.5
UTILIZATION Y. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
.0
.0
.0
21.0
33.3
27.2
2.1
3.2
2.7
720
744
720
744
744
0 0
0 0
0 0
306 202
31 20
.0
.0
.0
** PROBLEMS/SOLUTIONS/COMMENTS
9/74
SYSTEM
THE UNIT HAS BEEN ON AND
DEMAND.
.0
OFF FREQUENTLY DUE
.0
TO FLUCTUATION IN POWER
720
43 0
** PROBLEMS/SOLUTIONS/COMMENTS
10/74
6A
6B
SYSTEM
THE BOILER WAS SHUT DOWN
100.0
100.0
100.0
BECAUSE OF A LACK
32.9
32.9
32.9
OF DEMAND.
744
245 245
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER WAS OPERATED TO PERFORM LIMESTONE TESTS ON THE
11/74
SYSTEM
.0
.0
720
FGD SYSTEM.
122 0
** PROBLEMS/SOLUTIONS/COMMENTS
12/74
1/75
2/75
3/75
4/75
5/75
6/75
7/75
8/75
9/75
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
6A
6B
SYSTEM
THE BOILER WAS SHUT DOWN
100.0
100.0
100.0 100.0
BECAUSE OF A LACK
.0
.0
.0
.0
.0
.0
.0
.0
.0
100.0
100.0
100.0
OF DEMAND.
744
744
672
744
720
744
720
744
744
720
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
0 0
720 720
.0
.0
.0
.0
.0
.0
.0
.0
.0
6A 100.0 100.0
13-612
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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
6B
SYSTEM
100.0
100.0
100.0
** PROBLEMS/SOLUTIONS/COMMENTS
100.0
100.0
744 744
744
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 LG&E'S PEAK LOAD DETERMINATION). 502 REMOVAL
WAS REPORTED TO BE OVER 98X.
SYSTEM OUTAGE IN THE LAST TWO WEEKS OF OCTOBER WAS DUE PRIMARILY TO
PROBLEMS WITH THE BREECHING IN THE BOILER SECTION.
11/75
6A
6B
SYSTEM
100.0
100.0
100.0
100.0
100.0
100.0
100.0
720 720
720
** PROBLEMS/SOLUTIONS/COMMENTS
THE BOILER AND SCRUBBER SYSTEM OPERATED MOST OF THE REPORT PERIOD ON A
MONDAY-FRIDAY BASIS.
12/75
6A
6B
SYSTEM
90.1
90.1
90.1
90.1
90.1
90.1
744 744
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
** PROBLEMS/SOLUTIONS/COMMENTS
S02 REMOVAL EFFICIENCY WAS REPORTED TO BE 99X DURING JANUARY.
2/76 SYSTEM 66.7 9.8 696 102
** PROBLEMS/SOLUTIONS/COMMENTS
139
68
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
** 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
5/76 SYSTEM
6/76 SYSTEM
.0
85.0
95.0
.0
2.3
21.3
720
744
720
2
20
161
0
17
153
13-613
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
LOUISVILLE GAS & ELECTRIC: PADDY'S RUN 6 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
Z 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 SOS REMOVAL EFFICIENCY
WAS 98 TO 99X DURING THIS OPERATING SEGMENT.
7/76 SYSTEM 87.7
8/76 SYSTEM 92.8
** PROBLEMS/SOLUTIONS/COMMENTS
30.8
8.6
744 261
744 69
229
64
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
10/76 SYSTEM 94.6
** PROBLEMS/SOLUTIONS/COMMENTS
.0
21.2
720 0
744 167
0
158
.0
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 CARBIDE LIME SCRUBBING ABSORBENT. FOLLOWING
COMPLETION OF THIS RUN, THE UNIT WILL BE SHUT DOWN AND MODIFICATIONS WILL
BE INCORPORATED INTO THE SYSTEM FOR OPERATION WITH COMMERCIAL GRADE (HIGH
CALCIUM) LIME.
11/76 SYSTEM 99.3
** PROBLEMS/SOLUTIONS/COMMENTS
99.3
720 720
715
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
** PROBLEMS/SOLUTIONS/COMMENTS
71.4
744 539
531
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.
1/77 SYSTEM
2/77 SYSTEM
3/77 SYSTEM
.0
.0
79.2
.0
.0
41.4
744 103
672 62
744 389
0
0
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
13-614
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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
5/77 SYSTEM 42.5 16.0 744 280 119
** PROBLEMS/SOLUTIONS/COMMENTS
IN MID MARCH LGiE 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 SYSTEM 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 SYSTEM -0 744 0 0 .0
2/78 SYSTEM -° 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.
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
LOUISVILLE GAS 4 ELECTRIC: PADDY'S RUN 6 (CONT.)
PERFORMANCE DATA-
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S03 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. 4 744 190 189
** 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 LG4E 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
8/79 SYSTEM 45.0 13.0 744 218 99
9/79 SYSTEM .0 .0 720 36 0
13-616
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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
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.
4/60 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 .0 744 0 0 .0
9/80 SYSTEM 100.0 .0 720 0 0 .0
13-617
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
LOUISVILLE GAS 4 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
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS NOT OPERATED DURING THE FOURTH QUARTER 1980 DUE TO THE LACK
OF DEMAND.
1/81 SYSTEM 100.0 .0 744 0 0 .0
3/81 SYSTEM 100.0 .0 672 0 0 .0
3/81 SYSTEM 100.0 .0 744 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE FIRST QUARTER 1981 THE UNIT WAS NOT OPERATED DUE TO THE LACK OF
DEMAND.
4/81 SYSTEM 100.0 .0 720 0 0 .0
5/81 SYSTEM 100.0 .0 744 0 0 .0
6/81 SYSTEM 100.0 .0 720 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
THROUGHOUT THE SECOND QUARTER 1981 THE BOILER DID NOT OPERATE; HOWEVER,
THE FGD SYSTEM WAS AVAILABLE 100X.
7/81 SYSTEM 100.0 .0 744 0 0 .0
8/81 SYSTEM 100.0 .0 744 0 0 .0
9/81 SYSTEM 100.0 .0 720 0 0 .0
*» PROBLEMS/SOLUTIONS/COMMENTS
PADDY'S RUN UNIT 6 REMAINED OFF LINE DURING THE THIRD QUARTER 1981.
10/81 SYSTEM 100.0 .0 744 0 0
11/81 SYSTEM 100.0 .0 720 0 0
12/81 SYSTEM 100.0 .0 744 0 0
** PROBLEMS/SOLUTIONS/COMMENTS
THROUGHOUT THE FOURTH QUARTER THE FGD SYSTEM WAS AVAILABLE FOR OPERATION;
HOUEVER, THE BOILER WAS NOT NEEDED.
1/82 SYSTEM 100.0 .0 744 744 0
Z/BZ SYSTEM 100.0 .0 672 0 0 .0
3/82 SYSTEM 100.0 .0 744 0 0 .0
13-618
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1964
LOUISVILLE GAS & ELECTRIC: PADDY'S RUN 6 (CONT.)
PERIOD
rc«ruKnAMi.c UAI A------------- ---_.
MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER
S02 PART. HOURS
BOILER FGD CAP.
HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE FIRST QUARTER 1982 THE FGD SYSTEM WAS AVAILABLE FOR OPERATION;
HOWEVER, THE SYSTEM WAS NOT NEEDED DUE TO A LACK OF POWER DEMAND.
4/82
5/82
6/82
SYSTEM
SYSTEM
SYSTEM
100.0
100.0
100.0
.0
.0
.0
720
744
720
0
0
0
0
0
0
0
0
*# PROBLEMS/SOLUTIONS/COMMENTS
7/82
8/82
9/82
10/82
11/82
12/82
1/83
2/83
3/83
4/83
5/83
6/83
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
DUE TO A LACK OF POWER DEMAND,
QUARTER 1982.
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
THE
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
.0
UNIT DID NOT OPERATE
744
744
720
744
720
744
744
672
744
720
744
720
DURING THE
0
0
0
0
0
0
0
0
0
0
0
0
SECOND
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT THE UNIT AND FGD SYSTEM DID NOT OPERATE DURING
THE PERIOD OF JULY 1, 1982 THROUGH JUNE 30, 1983. THE FGD SYSTEM WAS
REPORTED AVAILABLE 100X OF THE TIME.
7/83 SYSTEM
8/83 SYSTEM
9/83 SYSTEM
100.0
100.0
100.0
.0
.0
.0
744
744
720
0
0
0
0
0
0
.0
.0
.0
** PROBLEMS/SOLUTIONS/COMMENTS
10/83 SYSTEM
11/83 SYSTEM
12/83 SYSTEM
THE UNIT AND FGD
HOWEVER, THE FGD
100.0
100.0
100.0
SYSTEM DID NOT OPERATE
SYSTEM WAS REPORTED TO
.0
.0
.0
DURING THE THIRD
BE 100X AVAILABLE
744
720
744
QUARTER
0
0
0
OF 1983
0
0
0
t
.0
.0
.0
13-619
-------
UTILITY F6D SURVEY: OCTOBER 1983 - SEPTEMBER 198*
LOUISVILLE GAS S 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
THE UTILITY REPORTED THAT THE UNIT AND SCRUBBER DID NOT OPERATE DURING THE
FOURTH QUARTER OF 1983.
1/84 SYSTEM 744
2/84 SYSTEM 696
3/84 SYSTEM 744
4/84 SYSTEM 720
5/84 SYSTEM 744
6/84 SYSTEM 720
7/84 SYSTEM 744
8/84 SYSTEM 744
9/84 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE FIRST THREE QUARTERS OF 1984.
13-620
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
SECTION 13
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
MARQUETTE BOARD OF LIGHT 4 PWR
SHIRAS
MARQUETTE
MICHIGAN
B
13. (
172. (
215. (
40
44
495
495
44
.030 LB/MMBTU)
.400 LB/MMBTU)
.500 LB/MMBTU)
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
92.63 t 196292 ACFM)
68.3 ( 155 F)
107. ( 350 FT)
CONCRETE
2.7 ( 9.0 FT)
** 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
*# FABRIC FILTER
NUMBER
SUPPLIER
PRESSURE DROP - KPA
PARTICLE REMOVAL EFFICENCY - 7.
TYPICAL GAS/CLOTH RATIO - M/MIN
** PARTICLE SCRUBBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON NAME
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
*** FGD SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
COAL
SUEBITUMINOUS
20129. ( 8654 BTU/LB)
******
10.25
«****«
23.42
******
.30
******
********
******
GE ENVIRONMENTAL SERVICES
1.7 ( 6.8 IN-H20)
99.8
.6 ( 2.0 FT/MIN)
0
NONE
N/A
N/A
N/A
N/A
N/A
N/A
N/A
THROWAWAY PRODUCT
SPRAY DRYING
LIME/SPRAY DRYING
GE ENVIRONMENTAL SERVICES
LUTZ.DALY, t BRAIN
FULL SCALE
NEW
13-621
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
MARQUETTE BOARD OF LIGHT & PWR: SHIRAS 3 (CONT.)
UNIT DESIGN PARTICLE REMOVAL EFFICIENCY - 7. 99.80
UNIT DESIGN S02 REMOVAL EFFICIENCY - '/. 80.00
CURRENT STATUS 1
COMMERCIAL START-UP 4/83
INITIAL START-UP 3/83
CONTRACT AWARDED 10/80
** DESIGN AND OPERATING PARAMETERS
DESIGN COAL SULFER CONTENT - '/.
** QUEHCHER/PRESATURATOR
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** ABSORBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON 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
INLET GAS TEMPERATURE - C
S02 REMOVAL EFFICIENCY - X
PARTICLE REMOVAL EFFICENCY - X
.60
NR
NR
SPRAY DRYER
NR
ROTARY ATOMIZER
35'6" DIAMETER
NR
NR
NR
NONE
N/A
N/A
129.4
80.0
99.9
( 265 F)
** MIST ELIMINATOR
PRE-MIST ELIMINATOR/MIST ELIMINATOR NONE
GENERIC TYPE N/A
SPECIFIC TYPE N/A
TRADE NAME/COMMON TYPE N/A
CONSTRUCTION MATERIAL GENERIC TYPE NR
CONSTRUCTION MATERIAL SPECIFIC TYPE NR
** REHEATER
GENERIC TYPE BYPASS
SPECIFIC TYPE COLD SIDE
TRADE NAME/COMMON TYPE N/A
PERCENT GAS BYPASSED - AVG 3.0
CONSTRUCTION MATERIAL GENERIC TYPE NR
CONSTRUCTION MATERIAL SPECIFIC TYPE NR
#* FANS
DESIGN NR
FUNCTION MR
APPLICATION MR
SERVICE NR
CONSTRUCTION MATERIAL GENERIC TYPE NR
** DAMPERS
FUNCTION NR
GENERIC TYPE NR
SPECIFIC TYPE NR
CONSTRUCTION MATERIAL GENERIC TYPE NR
CONSTRUCTION MATERIAL SPECIFIC TYPE NR
LINER GENERIC MATERIAL TYPE NR
LINER SPECIFIC MATERIAL TYPE NR
** DUCTWORK
SHELL GENERIC MATERIAL TYPE NR
SHELL SPECIFIC MATERIAL TYPE NR
LINER GENERIC MATERIAL TYPE NR
LINER SPECIFIC MATERIAL TYPE NR
*» REAGENT PREPARATION EQUIPMENT
FUNCTION SLAKER
DEVICE NR
DEVICE TYPE MR
13-622
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
MARQUETTE BOARD OF LIGHT & PWR: SHIRAS 3 (CONT.)
** PUMPS
SERVICE NUMBER
KR ****
»* SOLIDS CONCENTRATING/DEWATERING
DEVICE NONE
*** SLUDGE
** TREATMENT
METHOD N/A
DEVICE N/A
PROPRIETARY PROCESS N/A
## DISPOSAL
NATURE FINAL
TYPE LANDFILL
LOCATION OFF-SITE
SITE TREATMENT NR
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
3/83 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
INITIAL START-UP FOR THE FGD SYSTEM OCCURRED DURING MARCH, 1983.
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
MARQUETTE BOARD OF LIGHT & PWR: SHIRAS 3 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
MATERIALS TO COMPLETE THE JOB. ISOLATION OF THE DRYER HAS ENABLED THE
UTILITY TO KEEP THE UNIT ON LINE DURING THE ENTIRE INSTALLATION PERIOD.
PROBLEMS WITH SCRUBBER MATERIAL BUILDUP ON THE SPRAY DRYER WALLS AND ATOM-
IZER SWIRL VANES WAS DETERMINED TO BE A RESULT OF OPERATING THE SYSTEM NEAR
OR BELOW THE DEW POINT TEMPERATURE. THE PROBLEM HAS BEEN RESOLVED BY ADDING
INSTRUMENTATION WHICH ALLOWS THE OPERATORS TO MONITOR MORE CLOSELY THE IN-
LET AND OUTLET TEMPERATURE OF THE SPRAY DRYER.
10/83 SYSTEM 744
11/83 SYSTEM 720
12/83 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED OUTAGES WERE ENCOUNTERED
DURING THE FOURTH QUARTER OF 1983.
FINAL INSTALLATION AND TESTING OF THE NEW GRANULATOR WASTE REMOVAL SYSTEM
IS SCHEDULED FOR FEBRUARY 1984.
GE ENVIRONMENTAL SERVICES, IN COOPERATION WITH THE UTILITY, WILL DESIGN AND
TEST A NEW VARIABLE SPEED TYPE ATOMIZER AT THE SHIRAS 3 FACILITY. ATOMIZER
SPEEDS WILL BE CONTROLLED VIA A DC MOTOR IN COMPARISON TO CONVENTIONAL
DRIVE SYSTEMS, WHICH REQUIRE MANUALLY CHANGING THE DRIVE SHAFT PULLEY.
PRESENTLY, A FULL DAY IS REQUIRED TO CHANGE A DRIVE SHAFT PULLEY.
1/84 SYSTEM 744
2/84 SYSTEM 696
3/84 SYSTEM 744
4/84 SYSTEM 720
5/84 SYSTEM 744
6/84 SYSTEM 720
7/84 SYSTEM 744
8/84 SYSTEM 744
9/84 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE FIRST THREE QUARTERS OF 1984.
13-624
-------
UTILITY F6D SURVEY: OCTOBER 1983 - SEPTEMBER
SECTION 13
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 - '/.
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
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON NAME
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
*** FGD SYSTEM
** GENERAL DATA
SALEABLE PRODUCT/THROUAWAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
MICHIGAN SO CENTRAL PWR AGENCY
PROJECT
1
LITCHFIELD
MICHIGAN
B
13. ( .030 LB/MMBTU)
365. ( .850 LB/MMBTU)
<****** LB/MMBTU)
55
55
50
51
55
BABCOCK t WILCOX
PULVERIZED COAL
BASE
103.83
156.7
76.
CARBON STEEL
2.9
( 220015 ACFM)
( 314 F)
( 250 FT)
( 9.5 FT)
COAL
BITUMINOUS
28377.
10.00
6.0-15.0
6.00
4.0-8.0
2.25
0.0-4.3
********
******
HOT SIDE
BE LCD
126.2
156.7
.1
99.8
0
NONE
N/A
N/A
N/A
N/A
N/A
N/A
N/A
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
MAG
BABCOCK t WILCOX
( 12200 BTU/LB)
11000-13000
( 267510 ACFM)
( 314 F)
( 1. IN-H20)
13-625
-------
UTILITY F6D SURVEY: OCTOBER 1983 - SEPTEMBER 1984
MICHIGAN SO CENTRAL PWR AGENCY: PROJECT 1 (CONT.)
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
UNIT DESIGN S02 REMOVAL EFFICIENCY - 7.
ENERGY CONSUMPTION - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
** QUENCHER/PRESATURATOR
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** 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
L/G RATIO - L/CU.M
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 STAGES - CM
DISTANCE BETWEEN VANES - CM
VANE ANGLES - DEGREES
PRESSURE DROP KPA
SUPERFICAL GAS VELOCITY - M/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC 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
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** FANS
DESIGN
FUNCTION
APPLICATION
SERVICE
CAMPBELL DEBOE & ASSOCIATES
FULL SCALE
NEW
90.00
1.8
1
5/83
5/83
6/79
NR
KR
1
0
SPRAY TOWER
OPEN COUNTERCURRENT SPRAY
N/A
BABCOCK & WILCOX
32.5 X 92.5
STAINLESS STEEL
AUSTENITIC
TYPE 316L
NONE
N/A
N/A
NONE
1.3
2.4
87.84
160.0
90.0
( 10.0 GAL/1000 ACF)
( 7.9 FT/S)
( 186147 ACFM)
( 320 F)
PRIMARY COLLECTOR
1
NR
NR
NR
VERTICAL
2
1
25.91 (10.2 IN)
6.9 ( 2.70 IN)
107
.1 ( .3 IN-H20)
2.7 ( 8.8 FT/S)
ORGANIC
FIBER-REINFORCED POLYESTER
BLENDED
5.4 (85 GAL/MIN)
1
IN-LINE
STEAM
NR
27.8 ( 50 F)
88.35 ( 187219 ACFM)
STAINLESS STEEL
AUSTENITIC
NR
NR
NR
NR
13-626
-------
UTILITY FGD SURVEY' OCTOBER 1983 - SEPTEMBER 1984
MICHIGAN SO CENTRAL PWR AGENCY: PROJECT 1 (CONT. )
CONSTRUCTION MATERIAL GENERIC TYPE
** DAMPERS
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
*# REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
#* TANKS
SERVICE
ABSORBER RECYCLE
THICKENER OVERFLOW
SPARGER/OXIDIZER
REAGENT PREP PRODUCT
THICKENER UNDERFLOW
«* PUMPS
SERVICE
LIME PRODUCT
SLURRY TRANSFER
THICKENER UNDERFLOW
ABSORBER RECIRCULATION
SAND
CYCLONE
VACUUM FILTER FEED
FILTRATE
VACUUM
CLARIFIED RECYCLE
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
CONFIGURATION
DIMENSIONS - FT
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
SHELL SPECIFIC MATERIAL TYPE
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
**# SLUDGE
** TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
NR
NR
NR
NR
NR
NR
NR
NR
HORIZONTAL IN-VERTICAL OUT
STAINLESS STEEL
AUSTENITIC
NR
NR
WET BALL MILL
NR
NR
NUMBER
NUMBER
Z
2
2
3
2
2
2
2
2
2
THICKENER
1
0
CYLINDRICAL
70.0 DIA
17X SOLIDS
29X SOLIDS
VACUUM FILTER
2
1
FIBER-REINFORCED POLYESTER
29X SOLIDS
60X SOLIDS
FORCED OXIDATION
NR
NR
13-627
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
MICHIGAN SO CENTRAL PWR AGENCY: PROJECT 1 (CONT.)
** DISPOSAL
NATURE FINAL
TYPE LANDFILL
LOCATION OFF-SITE
SITE TRANSPORTATION METHOD TRUCK/RAIL
SITE TREATMENT NONE
** PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS PH-SOLIDS-ADDITIVES
MONITOR LOCATION RECYCLE SLURRY LINE
PROCESS CONTROL MANNER AUTOMATIC
PROCESS CHEMISTRY MODE FEEDBACK/FEED FORWARD
** WATER BALANCE
WATER LOOP TYPE CLOSED
EVAPORATION WATER LOSS - LITER/S 4.0 (64 GPM)
SLUDGE HYDRATION WATER LOSS - LITER/S 1.1 C 17 GPM)
POND SEEPAGE/RUNOFF WATER LOSS - LITERS/S 0
RECEIVING WATER STREAM 105
MAKEUP WATER ADDITION - LITERS/S 5.4 ( 85 GPM)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
5/83 SYSTEM 744
6/83 SYSTEM 730
** PROBLEMS/SOLUTIONS/COMMENTS
INITIAL FGD OPERATIONS COMMENCED IN MAY 1983.
THE UTILITY REPORTED EXPERIENCING SOME MINOR PUMP BEARING AND VACUUM
FILTER PROBLEMS DURING STARTUP.
7/83 SYSTEM 744
8/83 SYSTEM 744
9/83 SYSTEM 7ZO
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED MINOR PROBLEMS ASSOCIATED WITH START-UP DURING THE
THIRD QUARTER, HOWEVER, NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED.
10/83 SYSTEM 744
11/83 SYSTEM 720
12/83 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE FOURTH QUARTER OF 1983.
1/84 SYSTEM 744
2/84 SYSTEM 696
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD RELATED OUTAGES WERE ENCOUNTERED
DURING THE PERIOD OF OCTOBER 1983 THROUGH FEBRUARY 1984. S02 REMOVAL DUR-
ING THIS PERIOD WAS ESTIMATED AT 95X.
13-628
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
MICHIGAN SO CENTRAL PWR AGENCY: PROJECT 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
THE LIMESTONE CRUSHER WAS REPLACED DURING THE PERIOD OF OCTOBER 1983 TO
FEBRUARY 1984 DUE TO INADEQUATE SIZING.
THE UTILITY REPORTED PROBLEMS WITH THE VACUUM FILTRATION SYSTEM DURING THE
PERIOD OF OCTOBER 1983 TO FEBRUARY 1984. THE PROBLEMS WERE SUBSEQUENTLY
WORKED OUT AND REPAIRS WERE MADE.
3/84 SYSTEM 744
4/84 SYSTEM 720
5/84 SYSTEM 744
6/84 SYSTEM 720
7/84 SYSTEM 744
8/84 SYSTEM 744
9/84 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
A GENERATOR FAILURE OCCURRED IN LATE FEBRUARY 1984, FORCING A SHUT DOWN OF
THE TOTAL FACILITY FOR THE REMAINDER OF THE FIRST THREE QUARTERS OF 1984.
THE UTILITY IS CURRENTLY DISCUSSING MODIFICATIONS OF THE DEWATERING SYSTEM
TO PROVIDE EASIER AND MORE ECONOMICAL DEWATERING. A SIX MONTH TEST PROGRAM
BEGINNING IN JANUARY 1985 WILL DETERMINE WHETHER OR NOT THE MODIFICATIONS
SHOULD BE MADE PERMANENT.
13-629
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
SECTION 13
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
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 - MW
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
MINNESOTA POWER
CLAY BOSWELL
4
COHASSET
MINNESOTA
D
43.
516.
301.
1000
554
504
511
475
t LIGHT
( .100 LB/MMBTU)
( 1.200 LB/MMBTU)
( .700 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 - 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
** MECHANICAL COLLECTOR
NUMBER
TYPE
** ESP
NUMBER
NUMBER OF SPARES
TYPE
SUPPLIER
INLET FLUE GAS CAPACITY - CU.M/S
INLET FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
PARTICLE REMOVAL EFFICENCY - 7.
** PARTICLE SCRUBBER
NUMBER
NUMBER OF SPARES
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON NAME
SUPPLIER
DIMENSIONS - FT
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
NUMBER OF CONTACTING ZONES
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
1086.40 (2302161 ACFM)
148.9 ( 300 F)
183. ( 600 FT)
CONCRETE
11.3 ( 37.0 FT)
COAL
SUBBITUMINOUS
19276. ( 8287 BTU/LB)
7509-9923
9.40
******
24.50
20.3-28.3
.94
0.4-2.8 IPACKMAKERSl
.01
******
0
NONE
1
0
HOT SIDE
WESTERN PREC.
94.4
398.9
.6
99.7
DIVISION, JOY
( 200000 ACFM)
( 750 F)
( 3. IN-H20)
4
1
VENTURI TOWER
VARIABLE-THROAT/ADJUSTABLE DRUM
RADIAL FLOW VENTURI
PEABODY PROCESS SYSTEMS
30.0 DIA X 40.0
STAINLESS STEEL
AUSTENITIC
ORGANIC
NATURAL RUBBER
NONE
1
13-630
-------
UTILITY F6D SURVEY: OCTOBER 1983 - SEPTEMBER 1984
MINNESOTA POWER 4 LIGHT: CLAY BOSWELL 4 (CONT.)
LIQUID RECIRCULATION RATE - LITER/S
L/G RATIO - LITER/CU.M
PH CONTROL ADDITIVE
PRESSURE DROP KPA
INLET GAS FLOW RATE - CU.M/S
INLET GAS TEMPERATURE - C
PARTICLE REMOVAL EFFICIENCY - X
*»* 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 502 REMOVAL EFFICIENCY - X
ENERGY CONSUMPTION - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
** DESIGN AND OPERATING PARAMETERS
DESIGN COAL SULFER CONTENT - 7.
DESIGN COAL HEAT CONTENT J/G
DESIGN COAL ASH CONTENT -
DESIGN MOISTURE CONTENT -
DESIGN CHLORIDE CONTENT -
SPACE REQUIREMENTS - SQ M
OPER. & MAINT. REQUIREMENT - MANHR/DAY
** QUENCHER/PRESATURATOR
NUMBER
** 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
L/G RATIO - L/CU.M
GAS-SIDE PRESSURE DROP - KPA
SUFERFICAL 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
NUMBER OF SPARES PER SYSTEM
NUMBER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
841.7
2.1
ABSORBER SLURRY
3.0
148.9
99.7
(13360 GPM)
(16.0 GAL/1000ACF)
f
(12.0 IN-H20)
( 835840 ACFM)
( 300 F)
THROWAWAY PRODUCT
WET SCRUBBING
LIME/ALKALINE FLYASH
NONE
PEABODY PROCESS SYSTEMS
EBASCO
FULL SCALE
NEW
/. 99.73
89.00
1.3
1
4/80
2/80
2.80
19980.3
9.40
25.00
.01
14864.0
100.0
( 8590 BTU/LB)
( 160000 SQ FT)
4
1
SPRAY TOWER
OPEN COUNTERCURRENT SPRAY
N/A
PEABODY PROCESS SYSTEMS
35.0 DIA X 60.0
CARBON STEEL
AISI 1110
N/A
ORGANIC
NATURAL RUBBER
BLACK NATURAL RUBBER
NONE
1
2104.
7.0
5.0
3.7
302.08
53.3
89.0
33400 GPM)
52.2 GAL/1000 ACF)
20.0 IN-H20)
12.0 FT/S)
640130 ACFM)
128 F)
PRECOLLECTOR
4
1
1
BULK SEPARATION
PERFORATED TRAYS
SIEVE TRAY
HORIZONTAL
13-631
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
MINNESOTA POWER & LIGHT: CLAY BOSWELL 4 (CONT.)
NUMBER OF STAGES
NUMBER OF PASSES PER STAGE
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC 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
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
1
1
.Z ( 1.0 IN-H20)
3.4 ( 11.0 FT/S)
STAINLESS STEEL
AUSTENITIC
MAKEUP OVERSPRAY AND MAKEUP/SUPERNATANT MIXTURE
29.9 ( 474 GAL/MIN)
1
BYPASS
HOT SIDE
N/A
5.0
14.4 ( 26 F)
HIGH ALLOY
NICKEL BASE/CHROMIUM-IRON-MOLYBDENUM
»* 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
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
DIMENSIONS
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
678800 ACFM)
144 F)
4
1
CENTRIFUGAL
GREEN FAN
UNIT
INDUCED DRAFT
WET
320.33 (
62.2 (
HIGH ALLOY
4
NR
-GUILLOTINE
NR
CARBON STEEL
AISI 1110
HR
NR
4
NR
GUILLOTINE
NR
HIGH ALLOY
NICKEL BASE/CHROMIUM-IRON-COPPER-MOLYBDENUM
NR
NR
4
NR
LOUVER
NR
CARBON STEEL
AISI 1110
NR
NR
ABSORBER TO REHEATER
12.0 DIA
CARBON STEEL
AISI 1110
ORGANIC
GLASS FLAKE-FILLED POLYESTER
13-632
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
MINNESOTA POWER 4 LIGHT: CLAY BOSkELL 4 (CONT.)
*« DUCTWORK
LOCATION
DIMENSIONS
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
MANUFACTURER
NUMBER
FULL LOAD DRY FEED CAPACITY - (1.TONS/HR
PRODUCT QUALITY - 7. SOLIDS
** TANKS
SERVICE
REHEAT SECTION
NR
STAINLESS STEEL
AUSTENITIC
NONE
N/A
S LAKER
NR
NR
PEABODY PROCESS SYSTEMS
ABSORBER RECYCLE
REAGENT PREP PRODUCT
MIST ELIMINATOR WASH
FLYASH
»* PUMPS
SERVICE
18.2
20.0
NUMBER
4
1
1
1
( 20 TPH)
ALKALI FEED
FLY ASH SLURRY FEED
SCRUBBER RECIRCULATION
ABSORBER RECIRCULATION
WASH WATER
** SOLIDS CONCENTRATING/DEWATERING-
DEVICE
«** SLUDGE
FULL LOAD SLUDGE QUANTITY - M.TONS/HR (DRY)
MOISTURE CONTENT - 7. TOTAL FREE WATER
X CAS03 - DRY
X CAS04 DRY
X CAOH2 DRY
'/. CAC03 - DRY
X ASH - DRY
** TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE TREATMENT
SITE DIMENSIONS
SITE CAPACITY - CU.M
SITE SERVICE LIFE - YRS
*# PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS
PHYSICAL VARIABLES
CONTROL LEVELS
MONITOR TYPE
MONITOR LOCATION
PROCESS CONTROL MANNER
NUMBER
2
2
8
12
2
NONE
19.7
45.0
5.0
3.0
.0
1.0
91.0
21.7 TPH)
BLEED
N/A
N/A
FINAL
POND
OFF-SITE
PIPELINE
CLAY LINING
276 ACRES
9556522
35
( 7814.0 ACRE-FT)
PH AND S02
DENSITY IN RECYCLE TANK
PH 3-6; 7-9X SOLIDS
DUPONT AND LEAR SIEGLER FOR S02
RECYCLE TANK
AUTOMATIC
13-633
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 198*
MINNESOTA POWER 4 LIGHT: CLAY BOSWELL 4 (CONT.)
PROCESS CHEMISTRY MODE FEEDBACK
** WATER BALANCE
WATER LOOP TYPE
EVAPORATION WATER LOSS - LITER/S
SLUDGE HYDRATION WATER LOSS - LITER/S
SLUDGE INTERSTITIAL WATER LOSS - LITERS/S
MAKEUP WATER ADDITION - LITERS/S
SOURCE OF MAKEUP WATER
** CHEMICALS AND CONSUMPTION
FUNCTION
NAME
PRINCIPAL CONSTITUENT
CONSUMPTION
POINT OF ADDITION
** FGD SPARE CAPACITY INDICES
SCRUBBER - X
ABSORBER - V.
** FGD SPARE COMPONENT INDICES
SCRUBBER
ABSORBER
CLOSED
27.6
.1
4.3
32.0
RIVER WATER
( 438 6PM)
( 1 GPM)
( 69 GPM)
( 508 GPM)
ABSORBENT
LIME
CAO
NONE tALKALINITY PROVIDED BY FLY ASH]
SLAKER
33.0
33.0
1.0
1.0
_ PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL
S02 PART.
PER BOILER FGD CAP.
HOURS HOURS HOURS FACTOR
4/80 SYSTEM
720
** PROBLEMS/SOLUTIONS/COMMENTS
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
7/80 1
2
3
<4
SYSTEM
8/80 1
2
3
9/80
SHAKEDOWN 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 SEPTEMBER.
SYSTEM
1
2
3
87.8
97.8
100.0
.0
96.1
71.8
75.5
29.4
49.7
75.5
71.6
89.6
14.7
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
14.5
720 712
744 652
684 79.0
492 61.7
13-634
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
MINNESOTA POWER & LIGHT: CLAY BOSWELL 4 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
4
SYSTEM
10/80
11/80
12/80
1/81
2/81
3/81
65.1
80.3
100.0
100.0
64.5
79.6
744 737
592 73.7
** PROBLEMS/SOLUTIONS/COMMENTS
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.
1
2
3
4
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
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE 4 OUTAGE TIME DURING NOVEMBER WAS DUE TO NECESSARY CLEANING AND
GENERAL REPAIRS.
1
2
3
4
SYSTEM
100.0
93.4
19.4
96.5
100.0
100.0
62.0
2.4
87.6
87.6
100.0
100.0
100.0
100.0
100.0
100.0
61.3
2.4
86.6
83.5
744 735
621 89.7
** PROBLEMS/SOLUTIONS/COMMENTS
DURING DECEMBER MODULE 3 OUTAGE TIME WAS DUE TO GENERAL MAINTENANCE AND
REPAIRS TO THE VENTURI LINER.
744 744 707 93.0
672 667 545 86.0
744 712 654 88.9
1
2
3
4
SYSTEM
1
2
3
4
SYSTEM
1
2
3
4
SYSTEM
100.0
69.4
100.0
73.1
100.0
100.0
82.1
75.7
100.0
100.0
79.8
40.2
100.0
100.0
100.0
100.0
48.1
98.4
38.7
95.0
92.2
36.4
48.9
67.8
81.7
55.6
29.5
94.8
95.8
91.8
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
48.1
98.4
38.7
95.0
91.5
36.2
48.5
67.3
81.1
53.2
28.2
90.7
91.7
87.9
13-635
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
MINNESOTA POWER & LIGHT: CLAY BOSWELL 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
6/81
7/81
8/81
9/81
DURING THE FIRST QUARTER 1981 THE UTILITY REPORTED THAT NO MAJOR FGD-RELAT-
ED PROBLEMS WERE ENCOUNTERED.
4/81
5/81
1
2
3
4
SYSTEM
1
2
3
4
SYSTEM
54.3
88.1
94.0
100.0
100.0
95.2
95.3
93.0
.0
96.1
28.2
70.5
56.7
88.1
81.1
51.2
75.2
66.0
.0
64.3
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
26.3
65.7
52.8
82.1
75.6
46. 8
67.7
59.5
.0
58.0
720 671
744 671
545 83.5
432 63.4
** PROBLEMS/SOLUTIONS/COMMENTS
DURIMG MAY MODULE 4 WAS DOWN FOR AN INSPECTION, MAINTENANCE AND VENTURI
MODIFICATIONS.
1
2
3
4
SYSTEM
100.0
96.1
94.0
33.5
100.0
71.6
74.9
78.3
31.7
85.5
100.0
100.0
100.0
100.0
100.0
71.6
74.9
78.3
31.7
85.5
720 720
616 89.5
«* PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR PROBLEMS WERE ENCOUNTERED DURING THE
MONTH OF JUNE.
744 651 561 78.0
744 665 544 73.8
720 682 608 87.8
1
2
3
4
SYSTEM
1
2
3
4
SYSTEM
1
2
3
4
SYSTEM
66.
100.
100.
79.
100.
27.
100.
78.
100.
100.
100.
100.
58.
66.
100.
5
0
0
0
0
3
0
5
0
0
0
0
2
7
0
56
93
78
29
86
9
100
31
100
60
60
100
41
65
88
.2
.9
.8
.5
.1
.3
.0
.3
.0
.2
.0
.0
.8
.0
.9
100.
100.
100.
100.
100.
100.
100.
100.
100.
100.
100.
100.
100.
100.
100.
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
49
82
69
25
75
8
91
28
91
73
56
95
39
61
84
.2
.1
.0
.8
.4
.3
.5
.0
.5
.1
.8
.4
.6
.5
.4
** PROBLEMS/SOLUTIONS/COMMENTS
THERE WERE NO MAJOR FGD-RELATED PROBLEMS REPORTED FOR THE THIRD QUARTER
1981.
10/61
11/81 1
1
2
3
4
SYSTEM
100.0
56.4
87.6
60.7
100.0
90.8
56.4
78.5
58.7
94.8
100.0
100.0
100.0
100.0
100.0
90.8
56.4
78.5
58.7
94.8
744 744
705 88.0
87.5
67.6
100.0
51.2
13-636
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
MINNESOTA POWER 4 LIGHT: CLAY BOSWELL 4 (CONT.)
PERIOD
12/81
MODULE
2
3
4
SYSTEM
1
2
3
4
SYSTEM
AVAILABILITY
35.0
100.0
64.4
93.8
100.0
100.0
25.0
75.8
100.0
OPERABILITY
38.8
100.0
80.6
95.9
77.4
98.0
20.2
75.1
90.2
HtKI-UKHAr
RELIABILITY
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
UTILIZATION
29.4
76.4
61.1
72.8
77.4
98.0
20.2
75.1
90.2
X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
720 546 524 66.5
744 744 671 79.6
1/82
2/82
3/82
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE FOURTH QUARTER.
1
2
3
4
SYSTEM
1
2
3
4
SYSTEM
1
2
3
4
SYSTEM
78.0
100.0
75.1
90.4
100.0
.0
100.0
100.0
100.0
100.0
68.4
100.0
100.0
47.8
100.0
48.0
100.0
75.1
82.5
100.0
.0
100.0
89.6
100.0
99.8
59.5
92.3
94.6
43.8
96.7
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
48.0
100.0
75.1
82.5
100.0
.0
97.8
81.8
94.0
91.2
59.0
91.5
53.5
43.4
96.0
744 744
672 614
744 738
744 98.0
613 86.0
714 92.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR PROBLEMS WERE ENCOUNTERED DURING THE
FIRST QUARTER 1982.
720
744
4/82
5/82
6/82
SYSTEM
SYSTEM
1
2
3
4
SYSTEM
64
100
83
82
100
.9
.0
.9
.4
.0
65
86
62
82
98
.4
.7
.2
.2
.8
100
100
100
100
100
.0
.0
.0
.0
.0
50
66
47
63
76
.4
.8
.9
.3
.2
720 555
549 62.9
** PROBLEMS/SOLUTIONS/COMMENTS
7/82 SYSTEM
8/82 SYSTEM
9/82 SYSTEM
10/82 SYSTEM
11/82 SYSTEM
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING JUNE.
744
744
720
744
720
13-637
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 198*
MINNESOTA POWER 4 LIGHT: CLAY BOSWELL * (CONT.)
. PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
12/82 SYSTEM
1/83 SYSTEM
2/83 SYSTEM
3/83 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
*/83
5/83
6/83
7/83
8/83
9/83
10/83
74*
74*
672
7**
INFORMATION WAS UNAVAILABLE FOR THE PERIOD OF JULY 1982 THROUGH MARCH 1983.
1
2
3
4
SYSTEM
1
2
3
4
SYSTEM
1
2
3
4
SYSTEM
96.9
76.0
65.3
34.9
91.0
78.2
88.6
79.2
96.6
100.0
89.7
71.0
99.6
86.8
80.3
50.6
66.1
33.5
76.8
59.4
65.2
15.2
93.5
77.8
56.8
1.8
53.9
37.5
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
80.2
50.6
66.0
33.5
76.7
59.*
65.2
15.2
93.5
77.8
35.3
1.1
33.5
23.3
720 719
744 744
720 *48
553 82.0
579 68.9
168 34.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE PERIOD OF APRIL THROUGH JUNE 1983.
74* 663 562 78.0
744 7*4 664 78.5
720 577 496 61.0
1
2
3
4
SYSTEM
1
2
3
4
SYSTEM
1
2
3
4
SYSTEM
96.8
100.0
100.0
100.0
100.0
100.0
98.3
100.0
86.0
100.0
100.0
100.0
100.0
92.2
100.0
78.1
19.8
72.5
83.7
84.7
33.5
85.9
80.4
67.9
89.2
55.9
79.0
72.5
50.5
86.0
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
69.6
17.6
64.7
74.6
75.5
33.5
85.9
80.4
67.9
89.2
44.8
63.3
58.1
40.4
68.8
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE PERIOD OF JULY THROUGH SEPTEMBER 1983.
1
2
3
4
SYSTEM
98.1
100.1
100.1
100.1
100.0
9.0
100.0
59.6
96.2
88.3
100.0
100.0
100.0
100.0
100.0
4.5
53.1
29.7
47.9
45.1
74* 371
335 34.2
13-635
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
MINNESOTA POWER & LIGHT: CLAY BOSWELL 4 (CONT.)
PERIOD
11/83
12/83
MODULE
1
2
3
4
SYSTEM
1
2
3
4
SYSTEM
AVAILABILITY
60.0
100.0
100.0
100.0
100.0
89.8
100.0
100.0
100.0
100.0
OPER ABILITY
.0
51.0
63.8
79.9
64.9
9.9
30.4
52.4
45.6
46.1
----KtKrUKnAr
RELIABILITY
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
SUe UAIA
UTILIZATION
.0
51.0
63.8
79.9
64.9
9.9
30.4
52.4
45.6
46.1
X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
720 720 467 62.8
744 744 343 88.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE FOURTH QUARTER OF 1983.
1/84
2/84
3/84
4/84
5/84
6/84
1
2
3
4
SYSTEM
1
2
3
4
SYSTEM
1
2
3
4
SYSTEM
1
2
3
4
SYSTEM
1
2
3
4
SYSTEM
1
2
3
4
SYSTEM
40.2
100.0
68.8
100.0
100.0
100.0
54.0
83.0
100.0
100.0
61.0
99.6
100.0
77.2
100.0
100.0
100.0
100.0
95.8
100.0
43.1
100.0
90.3
100.0
100.0
100.0
34.5
100.0
76.7
100.0
25.9
100.0
71.0
100.0
99.0
86.5
46.6
66.8
97.1
99.0
48.2
98.0
99.4
47.1
97.5
80.9
84.2
38.2
85.5
96.3
36.4
100.0
69.8
98.4
100.0
92.3
30.5
92.1
56.9
90.6
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
100.0
100.0
100.0
22.2
93.8
61.0
89.4
88.8
86.4
46.6
66.7
96.9
98.9
47.8
97.3
98.7
46.8
96.9
80.7
84.0
38.1
85.3
96.0
36.1
99.4
69.2
97.6
100.0
92.3
30.5
92.1
56.9
90.6
744 639
696 695
744 739
720 718
744 738
720 720
661 80.0
688 85.0
721 97.0
691 94.4
744 97.0
652 90.2
«* PROBLEMS/SOLUTIONS/COMMENTS
7/84 SYSTEM
8/84 SYSTEM
9/84 SYSTEM
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS AROSE DURING THE
FIRST TWO QUARTERS OF 1984.
744
744
720
13-639
-------
UTILITY FED SURVEY: OCTOBER 1983 - SEPTEMBER 1984
MINNESOTA POWER & LIGHT: CLAY BOSWELL 4 (COKT.)
. . PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
503 PART. HOURS HOURS HOURS FACTOR
«* PROBLEMS/SOLUTXONS/COKMENTS
INFORMATION WAS UNAVAILABLE FOR THE THIRD QUARTER OF
13-640
-------
UTILITY F6D SURVEY: OCTOBER 1983 - SEPTEMBER 1984
SECTION 13
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 - 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
** ESP
NUMBER
NUM3ER OF SPARES
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
TRADE NAME/COMMON NAME
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
GAS CONTACTING DEVICE TYPE
MINNKOTA POWER
MILTON R. YOUNG
2
CENTER
NORTH DAKOTA
D
43. (
516. (
******
690
440
402
409
374
BABCOCK 4 WILCOX
CYCLONE
BASE
958.33
176.7
168.
CONCRETE
7.6
.100 LB/MMBTU)
1.200 LB/MMBTU)
(****** LB/MMBTU)
(2030800 ACFM)
( 350 F)
( 550 FT)
( 25.0 FT)
( 6500 BTU/LB)
6000-6800
COAL
LIGNITE
15119.
8.90
7.2-14.3
38.00
30-45
.60
.4-.8
********
******
0
NONE
2
0
COLD SIDE
WHEELABRATOR-FRYE
479.2 (1015400 ACFM)
176.7 ( 350 F)
.3 ( 1. IN-H20)
99.8
0
NONE
N/A
N/A
N/A
N/A
N/A
N/A
N/A
13-641
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
MINNKOTA POWER: MILTON R. YOUNG 2 (CONT.)
»*» 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 - X
ENERGY CONSUMPTION - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
OPER. 4 MAINT. REQUIREMENT - MANHR/DAY
** QUENCHER/PRESATURATOR
NUMBER
** 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
NUM3ER 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
NUMBER OF SPARES PER SYSTEM
NUM2ER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES PER STAGE
FREEEOARD DISTANCE - M
VAS'E ANGLES - DEGREES
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
WASH WATER SOURCE
WASH FREQUENCY
WASH RATE - L/S
THROWAWAY PRODUCT
WET SCRUBBING
LIME/ALKALINE FLYASH
NONE
THYSSEN/CEA
SANDERSON & PORTER
FULL SCALE
NEW
X 99.60
78.00
1.6
1
6/78
9/77
ft/75
92.0
2
1
SPRAY TOUER
OPEN COUNTERCURRENT SPRAY
N/A
THYSSEN/CEA
40.0 DIA X 120.0
CARBON STEEL
AISI 1110
N/A
ORGANIC
GLASS FLAKE-FILLED POLYESTER
FLAKELINE 500
NONE
1
3456.
8.7
.2
2.8
399.70
168.3
85.0
70.0
(54850 6PM)
( 64.8 GAL/1000 ACF)
( 1.0 IN-H20)
( 9.1 FT/S)
( 847000 ACFM)
( 335 F)
PRIMARY COLLECTOR
Z
1
1
IMPINGEMENT
BAFFLE
CLOSED VANE
HORIZONTAL
1
5
2.44
120
.2
2.8
ORGANIC
POLYPHENYLENE
BLENDED
CONTINUOUS
50.5
( 8.0 FT)
( 1.0 IN-H20)
( 9.1 FT/S)
( 800 GAL/MIN)
13-642
-------
MINNKOTA POWER: MILTON R. YOUNG 2 (CONT.)
UTILITY F6D SURVEY: OCTOBER 1983 - SEPTEMBER 1984
** REHEATER
NUMBER
NUMBER OF SPARES
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
LOCATION
PERCENT GAS BYPASSED - AVG
TEMPERATURE INCREASE - C
INLET FLUE GAS TEMPERATURE - C
OUTLET FLUE GAS TEMPERATURE - C
NUMBER OF TUBES PER BUNDLE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** FANS
NUMBER
NUMBER OF SPARES
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
CONSTRUCTION MATERIAL GENERIC TYPE
** FANS
NUMBER
NUMBER OF SPARES
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
PRESSURE DROP - KPA
CONSTRUCTION MATERIAL GENERIC TYPE
** DAMPERS
GENERIC TYPE
SPECIFIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
»» DAMPERS
GENERIC TYPE
SPECIFIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
»» DAMPERS
GENERIC TYPE
SPECIFIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
GENERIC TYPE
SPECIFIC TYPE
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
1
0
BYPASS
COLD SIDE
N/A
OUTLET DUCT
12.0
22.2
54.4
76.7
0
CARBON STEEL
AISI 1110
2
1
AXIAL
BUFFALO FORGE
UNIT
FORCED DRAFT
DRY
519.09
176.7
3.2
CARBON STEEL
2
1
AXIAL
TLT-BABCOCK
BOOSTER
FORCED DRAFT
DRY
8.8
CARBON STEEL
GUILLOTINE
NR
CARBON STEEL
AISI 1110
NONE
N/A
GUILLOTINE
NR
STAINLESS STEEL
AUSTENITIC
NONE
N/A
LOUVER
NR
CARBON STEEL
AISI 1110
NONE
N/A
BUTTERFLY
NR
STAINLESS STEEL
AUSTENITIC
NONE
N/A
40 F)
130 F)
170 F)
(1100000 ACFM)
( 350 F)
(10.6 IN-H20)
(28.8 IN-H20)
13-643
-------
UTILITY FGD SURVEY'- OCTOBER 1983 - SEPTEMBER 1984
MINNKOTA POWER: MILTON R. YOUNG 2 (CONT.)
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
«* DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
*« DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
MANUFACTURER
NUMBER
NUMBER OF SPARES
FULL LOAD DF5Y FEED CAPACITY - M.TONS/HR
PRODUCT QUALITY - X SOLIDS
»* TAWS
SERVICE
ABSORBER RECYCLE
THICKENER UNDERFLOW
FLY ASH SLURRY FEED
LIME SLAKER TRANSFER
THICKENER OVERFLOW
CLARIFIER OVERFLOW/ME WASH
TRAY RECYCLE
LIME SLURRY FEED
** PUMPS
SERVICE
ABSORBER RECIRCULATION
TRAY RECIRCULATION
TRAY SPRAY/CLARIFIER OVERFLOW
THICKENER UNDERFLOW
THICKENER OVERFLOW
LIME SLAKER TRANSFER
LIME SLURRY FEED
FLYASH SLURRY FEED
MIST ELIMINATOR SFRAY
CLARIFIER UNDERFLOW
FILTER BELT WASH
BLOW DOWN SUMP
FILTRATE
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
DIMENSIONS - FT
CAPACITY
SHELL GENERIC MATERIAL TYPE
INLET
CARBON STEEL
AISI 1110
NONE
N/A
OUTLET
CARBON STEEL
AISI 1110
ORGANIC
GLASS FLAKE-FILLED POLYESTER
BYPASS
CARBON STEEL
AISI 1110
NONE
N/A
SLAKER
NR
NR
WALLACE » TIERNAN
1
0
3.6 ( 4 TPH)
13.0
NUMBER
2
1
1
1
1
1
2
1
NUMBER
3
4
2
2
2
2
2
2
2
2
2
2
2
CENTRIFUGE
2
THICKENER
2
130 DIA X
3000000
INORGANIC
15 HIGH
13-644
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
MINNKOTA POWER: MILTON R. YOUNG 2 (CONT.)
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
FEED STREAM SOURCE
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
OUTLET STREAM DISPOSITION
OVERFLOW STREAM DISPOSITION
#* SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
CAPACITY
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
BELT GENERIC MATERIAL TYPE
BELT SPECIFIC MATERIAL TYPE
FEED STREAM SOURCE
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
OUTLET STREAM DISPOSITION
OVERFLOW STREAM DISPOSITION
CONCRETE
ORGANIC
FIBER-REINFORCED POLYESTER
ABSORBER BLEED
12X SOLIDS
40X SOLIDS
TO VACUUM FILTER
TO FLYASH SLURRY, VACUUM FILTER WASH, & ME WASH
VACUUM FILTER
2
0
750 TON/DAY
CARBON STEEL
AISI 1110
ORGANIC
NATURAL RUBBER
ORGANIC
POLYPROPYLENE
THICKENER 4 CLARIFIER UNDERFLOW
30X SOLIDS
60X SOLIDS
TO LANDFILL
TO THICKENER
**» SLUDGE
FULL LOAD SLUDGE QUANTITY - M.TONS/HR (DRY)
MOISTURE CONTENT - 7. TOTAL FREE WATER
X CAS03 - DRY
*# TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE TREATMENT
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE TREATMENT
SITE SERVICE LIFE - YRS
** DISPOSAL
NATURE
TYPE
LOCATION
SITE DIMENSIONS
SITE CAPACITY - CU.M
»« DISPOSAL
NATURE
TYPE
LOCATION
SITE DIMENSIONS
SITE CAPACITY - CU.M
** PROCESS CONTROL AND INSTRUMENTATION
CHEMICAL PARAMETERS
PHYSICAL VARIABLES
CONTROL LEVELS
19.1
.0
DEWATERED
N/A
N/A
FINAL
LANDFILL
OFF-SITE
TRUCK
CLAY LINING
INTERIM
POND
ON-SITE
PIPELINE
CLAY LINING
1
INTERIM
POND
ON-SITE
11.92 ACRES
218672
INTERIM
POND
ON-SITE
11.92 ACRES
218672
( 21.0 TPH)
X 15 FT DEEP [SEMI-CIRCLE]
( 178.8 ACRE-FT)
X 15 FT DEEP [SEMI-CIRCLE]
( 178.8 ACRE-FT)
PH
PERCENT SOLIDS
SOLIDS 5.5-12X; PH 4.0-5.5
13-645
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
MINNKOTA POWER: MILTON R. YOUNG 2 (CONT.J
PROCESS CONTROL MANNER MANUAL
** WATER BALANCE
WATER LOOP TYPE CLOSED
EVAPORATION WATER LOSS - LITER/S 34.6 ( 550 GPM)
MAKEUP WATER ADDITION - LITERS/S 44.1 ( 700 GPM)
»* CHEMICALS AND CONSUMPTION
FUNCTION ABSORBENT
NAME FLY ASH
PRINCIPAL CONSTITUENT 20-25X CAO, 5-9X M60
CONSUMPTION 16 TPH
UTILIZATION - 7. 83.0
POINT OF ADDITION SLURRY FEED TANK
** FGD SPARE CAPACITY INDICES
ABSORBER - '/. 100.0
** FGD SPARE COMPONENT INDICES
ABSORBER 1.0
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 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 2 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 15X OF THE FLUE GAS BYPASSED FOR REHEAT). 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 Z 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
13-646
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
MINNKOTA POWER: 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
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
»* 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 THE BOILER AND FGD SYSTEM CAME BACK ON LINE FEBRUARY 21 AFTER COM-
PLETION OF THE TURBINE REPAIRS. THE COMPLIANCE TEST HAS AGAIN BEEN RE-
SCHEDULED 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
** PPOBLEMS/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 UNDEPDESIGNED
AND PRONE TO FAILURE. THE CHAINS ARE CURRENTLY BEING REPLACED.
7/78 SYSTEM 744
13-647
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
MINNKOTA POWER: MILTON R. YOUNG Z (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL PER BOILER FGD CAP.
SOS PART. HOURS HOURS HOURS FACTOR
8/78 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
744
9/78 SYSTEM
10/78 SYSTEM
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.
720
744
** 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
B
SYSTEM
4.6
37.7
42.3
5.1
28.4
33.5
33.8
4.6
25.7
30.3
744 673
225 54.0
** PROSLEMS/SOLUTIONS/COMMENTS
MINNKOTA POWER COOP REPORTED THE FOLLOWING STATISTICS FOR THE YEAR OF 1978:
TOTAL PERIOD HOURS: 8760
TOTAL BOILER HOURS: 6926
HOURS: 1790
HOURS:
66.7X
FGD
SYSTEM
46.1
52.7
53.9
41.7
TOTAL A-MCDULE
TOTAL B-MODULE HOURS: 2110
ANNUAL BOILER CAPACITY FACTOR:
SYSTEM PERFORMANCE:
A-MODULE
AVAILABILITY 92.3
OPERABILITY 28.0
RELIABILITY
UTILIZATION 22.2
B-MODULE
28.5
25.9
20.4
THE B-TOHER 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
B
SYSTEM
4.6
37.7
42.3
5.1
23.4
33.5
33.8
4.6
25.7
30.3
744 673
225 54.0
13-648
-------
UTILITY FGD SURVEY^ OCTOBER 1983 - SEPTEMBER 1984
MINNKOTA POWER: 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
** 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
SEVERE ENOUGH THAT HOLES HAVE BEEN DISCOVERED IN TOWER WALLS.
2/79 A
B
SYSTEM
3/79 A
B
SYSTEM
19. 4
32.1
51.5
19.4
32.1
51.5
26.5
44.0
70.5
26.5
44.0
70.5
70.5
70.5
19.4
32.1
51.5
19.4
32.1
51.5
672 491
744 543
346 58.1
383 58.1
** PROBLEMS/SOLUTIONS/COMMENTS
TWO DAYS OF DOWN TIME WERE 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 TOWER WERE REPAIRED DURING THE PERIOD.
COLD WEATHER INHIBITED SCRUBBER STARTUPS AFTER REPAIRS WERE MADE DURING
THE PERIOD.
4/79 A
B
SYSTEM
5/79 A
B
SYSTEM
3.0
57.1
60.1
3.0
57.1
60.1
3.2
61.6
64.8
3.2
61.6
64.8
65.4
65.4
3.0
57.1
60.1
3.0
57.1
60.1
720 668
744 690
432 69.4
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 WERE MADE, AND REPAIRS WERE MADE ON A THICKENER DRIVE GEAR.
6/79 A
B
SYSTEM
17.2
36.3
52.8
17.2
36.3
52.8
17.2
36.3
52.8
720
380 88.7
52.8 52.8 720
** PROBLEMS/SOLUTIONS/COMMENTS
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 CLARIFIER.
13-649
-------
UTILITY F6D SURVEY: OCTOBER 1983 - SEPTEMBER 1984
MXNNKOTA POWER: 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
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 (SLAS 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 (AS 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.
7/79 A
B
SYSTEM
44.5
.0
44.0
44.5
.0
44.0
44.0
44.5
.0
44.0
744 744
331 86.7
*» PROBLEMS/SOLUTIONS/COMMENTS
8/79 A
B
SYSTEM
28.7
10.6
39.0
THE UTILITY HAS REPORTED THAT A TRAY RECYCLE CONTROL VALVE AND AH 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 DURING JULY.
28.7
10.6
39.0
39.0
28.7
10.6
39.0
744 744
293 92.3
** PROBLEMS/SOLUTIONS/COMMENTS
9/79
A
B
SYSTEM
21.4
1.2
23.0
DURING 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.
SLUDGE HAD TO BE REMOVED BY MINING IT FROM THE TOP.
THE
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.
21.5
1.2
23.0
23.0
21.4
1.2
23.0
720
717
163 96.6
13-650
-------
UTILITY FGO SURVEY: OCTOBER 1983 - SEPTEMBER 1984
MINNKOTA POWER: MILTON R. YOUNG 2 (CONT.)
-PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
SOS PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
DURING SEPTEMBER THE A-SIDE WAS DOWN DUE TO HEAVY SOLIDS IN THE THICKENER
AND CLARIFIER. HIGH VIBRATIONS WERE EXPERIENCED WITH THE BOOSTER FAN.
THE B-SIDE REMAINED OUT OF SERVICE DUE TO PROBLEMS WITH THE THICKENER AND
CLARIFIER.
10/79 A
B
SYSTEM
11/79
.0
31.3
31.3
.0
31.4
31.4
.0
31.3
31.3
743
233 89.7
31.4 31.3 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY IS IN THE PROCESS OF CLEANING THE CLARIFIER.
THE CLARIFIER AGITATOR DRIVE GEAR FAILED CAUSING DOWN TIME FOR REPAIR IN
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.
A
B
SYSTEM
.6
15.4
16.0
.7
16.7
17.4
17.4
.6
15.4
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
B
SYSTEM
26.6
9.7
36.3
31.5
11.5
43.0
43.0
26.6
9.7
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
B
SYSTEM
7.1
.0
7.1
10.5
.0
10.5
10.5
7.1
.0
7.1
744 504
53 58.5
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JANUARY, COLD WEATHER CAUSED SOME PIPE LINES AND A BOOSTER
FAN TO 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 AMD REPAIR OF THE THICKENER WAS COMPLICATED BY SUB-ZERO AMBIENT
TEMPERATURES.
13-651
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
MINNKOTA POWER: MILTON R. YOUNG Z (CONT.)
_. . PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
502 PART. HOURS HOURS HOURS FACTOR
2/80 SYSTEM .0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
696 696
0 97.1
3/80
4/80
5/80
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.
A
B
SYSTEM
22.6
6.2
28.9
22.6
6.2
28.8
22.6
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 FOR 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 WHILE 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
13-652
-------
UTILITY F6D SURVEY: OCTOBER 1983 - SEPTEMBER 1964
MINNKOTA POWER: 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
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.
6/80 A .0 .0 .0
B 41.8 40.4 41.4 39.3
SYSTEM 41.8 40.4 41.4 39.3 720 701 283
** 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 .0 .0 .0
B 65.3 64.5 65.8 52.0
SYSTEM 65.3 64.5 65.8 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 90.7 54.3 98.8 53.9
B 56.9 44.2 99.4 44.0
SYSTEM 99.2 98.6 99.2 98.0 744 739 729 92.8
** PROBLEMS/SOLUTIONS/COMMENTS
BOTH MODULES WERE OPERATED DURING AUGUST.
DURING THE MONTH, MAINTENANCE WORK WAS DONE ON THE SPRAY RECYCLE PUMPS
(TEFLON PACKING), THE VACUUM FILTER DRUM, SPRAY NOZZLES, THE ABSORBER
AGITATOR, THE CLARIFIER CONE, AND THE THICKNER RAKE MECHANISM.
9/80 A 70.1 72.6 100.0 66.9
B 66.7 25.1 100.0 23.2
SYSTEM 100.0 97.9 100.0 90.3 720 664 650 78.5
13-653
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 198*
MINNKOTA POWER: 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 FGD SYSTEM WAS AVAILABLE DURING ALL OF SEPTEMBER.
BOTH MODULES WERE OPERATED DURING THE MONTH.
10/80 A 90.4 85.4 87.1 76.2
B 17.7 .0 .0
SYSTEM 100.0 85.4 87.1 76.2 744 664 744 75.7
** PROBLEMS/SOLUTIONS/COMMENTS
DURING OCTOBER AVAILABILITY FOR MODULE B WAS LOW DUE TO LEAKS IN THE TOWER.
1/81
2/81
3/81
11/80 A
B
SYSTEM
42.2
98.6
100.0
40.4
54.0
94.5
100.0
96.4
99.1
38.7
50.1
90.6
720 690
720 88.6
** PROBLEMS/SOLUTIONS/COMMENTS
AVAILABILITY WAS LOW FOR MODULE A DUE TO LEAKS IN THE TOWER DURING THE
MONTH OF NOVEMBER.
12/80 A
B
SYSTEM
41.5
30.0
71.5
33.2
29.5
62.8
54.5
88.6
66.7
40.0
28.4
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.
A
B
SYSTEM
83.8
.0
63.9
94.4
.0
94.4
100.0
100.0
83.9
.0
83.9
744 661
624 83.8
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JANUARY THE SYSTEM WAS SHUT DOWN FOR PART OF THE MONTH TO REPACK
THE ABSORBER TOWER AGITATOR.
ADDITIONAL OUTAGE TIME WAS DUE TO ISOLATION DAMPER PROBLEMS.
A
B
SYSTEM
33.9
83.3
95.0
11.8
87.4
99.8
100.0
100.0
100.0
11.8
83.3
95.0
672 641
** PROBLEMS/SOLUTIONS/COMMENTS
DURING FEBRUARY NO MAJOR FGD-REUTED PROBLEMS WERE ENCOUNTERED.
639 88.5
A
B
SYSTEM
58.3
29.6
87.8
66.3
28.4
94.6
100.0
100.0
100.0
58.3
25.0
83.8
744 655
620 78.7
13-654
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
MINNKOTA POWER: MILTON R. YOUNG 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
DURING MARCH SOME OUTAGE TIME WAS DUE TO ISOLATION DAMPER PROBLEMS.
BOOSTER FAN PROBLEMS CAUSED ADDITIONAL DOWN TIME.
4/81 A .0 .0 .0 .0
B 2.7 5.4 5.6 2.7
SYSTEM 2.7 5.4 5.6 2.7 720 360 20 78.8
** PROBLEMS/SOLUTIONS/COMMENTS
DURING APRIL THE MIST ELIMINATOR PLUGGED CAUSING SYSTEM DOWN TIME.
PROBLEMS WERE ENCOUNTERED WITH THE BOOSTER FAN.
5/81 A 65.4 73.3 75.0 65.4
B .0 .0 .0 .0
SYSTEM 65.4 73.3 75.0 65.4 744 661 487 80.9
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MAY MODULE A EXPERIENCED BOOSTER FAN PROBLEMS.
6/81 A 72.3 66.3 68.2 52.6
B .0 .0 .0 .0
SYSTEM 72.3 66.3 68.2 52.6 720 571 379 77.9
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JUNE MODULE B WAS OUT OF SERVICE FOR MAINTENANCE. MAINTENANCE WAS
PERFORMED ON THE SPRAY NOZZLES, MIST ELIMINATOR, TRAY UNDERSPRAY STRAINER,
ISOLATION DAMPER, AND THE FLAKE LINING.
MODULE B SPRAY RECYCLE NOZZLES WERE CLEANED AND THE WASH TRAY HEADER WAS
CHECKED FOR PLUGGING.
THE RECYCLE TANK TRAY ON MODULE A WAS CLEANED DURING JUNE.
7/81 A 28.8 32.1 33.3 28.8
B .0 .0 .0 .0
SYSTEM 28.8 32.1 33.3 28.8 744 666 214 82.9
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE A WAS REMOVED FROM SERVICE ON JULY 10 WHEN THE THICKENER RAKE DRIVE
BROKE. THIS CAUSED THE MODULE TO REMAIN OUT OF SERVICE THE REST OF THE
MONTH.
DURING THE MONTH, THE FLAKE LINING WAS BEING REPAIRED ON MODUi-E B.
NEW MIST ELIMINATORS WERE INSTALLED IN MODULE B DURING JULY.
8/81 A .0 .0 .0 .0
B 58.1 48.6 49.5 44.2
SYSTEM 58.1 48.6 49.5 44.2 744 677 329 79.9
*» PROBLEMS/SOLUTIONS/COMMENTS
DURING AUGUST, MODULE A WAS OFF LINE AWAITING FAN BLADES AND REPAIRS TO
THE ABSORBER TOWER.
MODULE B WAS DOWN FOR PART OF THE MONTH AS REPAIRS CONTINUED TO THE
13-655
-------
UTILITY FGD SURVEY: OCTOBER 1933 - SEPTEMBER
MINNKOTA POWER: MILTON R. YOUNS 2 (CONT.)
PERIOD
9/81
MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
A
B
SYSTEM
THICKENER RAKE DRIVE.
.0 .0 .0 .0
100.0 97.2 100.0 85.8
100.0 97.2 100.0 85.3 720 636 618 83.
1
** PROBLEMS/SOLUTIONS/COMMENTS
10/81
11/81
12/81
A
B
SYSTEM
A
B
SYSTEM
A
B
SYSTEM
THE UNIT WAS DOWN TWICE DURING THE MONTH AS A RESULT OF BOILER TUBE LEAKS
THE A MODULE REMAINED DOWN DURING THE MONTH FOR REPAIRS.
78.7 49.7 53.2 30.8
35.5 56.9 60.9 35.3
100.0 100.0 100.0 66.1 744 461 492 83.
100.0 98.0 98.9 88.9
.0 .0 .0
100.0 98.0 98.9 88.9 720 653 640 87.
22.6 21.7 21.5 21.5
78.6 78.6 79.2 78.6
100.0 100.0 100.0 100.0 744 744 744 90.
.
0
4
1
** PROBLEMS/SOLUTIONS/COMMENTS
1/82
A
B
SYSTEM
THE MAJOR PROBLEM ENCOUNTERED DURING THE FOURTH QUARTER WAS FAILURE OF
THE FLAKEGLASS LINERS.
SPRAY NOZZLE PLUGGING WAS ALSO ENCOUNTERED DURING THE THREE MONTH PERIOD.
17.0 19.1 19.2 17.0
68.5 77.0 77.7 68.5
85.5 85.5 97.0 85.5 744 662 636 81.
7
»» PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS DOWN PART OF JANUARY TO DESLAG THE BOILER.
DURING THE MONTH THE FLAKE LINING IN MODULE A WAS REPAIRED.
MODULE B WAS TAKEN OUT OF SERVICE WHEN THE REAR BEARING TEMPERATURE ON THE
BOOSTER FAN BEGAN TRENDING UP.
2/82
3/82
A
B
SYSTEM
A
B
SYSTEM
THE ISOLATION DAMPERS WOULD NOT OPERATE DURING THE FRIGID WEATHER.
65.9 65.9 65.9 65.9
31.1 31.1 31.1 31.1
96.9 96.9 96.9 96.9 672 672 651 81.
0 .0 .0
55.9 96.2 100.0 55.9
55.9 96.2 100.0 55.9 744 432 415 72.
1
1
** PROBLEMS/SOLUTIONS/COMMENTS
4/82
A
B
SYSTEM
DURING MARCH THE UNIT WENT DOWN FOR A SCHEDULED ANNUAL OUTAGE.
.0 .0
0 .0
.0 .0 720 0 0 .0
13-656
-------
UTILITY FSD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
MINNKOTA POWER: 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/COMMENTS
THE UNIT WAS OFF-LINE DURING APRIL FOR AN ANNUAL OUTAGE. THE FGO SYSTEM
WAS ALSO DOWN FOR THE ENTIRE MONTH.
5/82 A 78.0 88.9 94.9 72.5
B .0 .0 .0
SYSTEM 78.0 88.9 94.9 72.5 744 607 539 76.6
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE B WAS DOWN THE MONTH OF MAY BECAUSE OF REPAIRS BEING PERFORMED ON
THE FLAKE LINING AND THE SPRAY RECYCLE NOZZLES.
MODULE A WAS DOWN AT THE BEGINNING OF MAY BECAUSE OF THE ANNUAL OUTAGE.
LATER IN THE MONTH THE MODULE WAS TAKEN OFF-LINE DUE TO ID FAN PROBLEMS.
6/82 A 86.2 91.9 93.8 76.4
B .0 .0 .0
SYSTEM 86.2 91.9 93.8 76.5 720 599 550 73.5
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE B WAS OUT OF SERVICE DURING JUNE BECAUSE WORK WAS BEING
PERFORMED ON THE FLAKE LINING AND THE SPRAY RECYCLE NOZZLES.
MODULE A WAS OFF-LINE AT THE BEGINNING OF JUNE DUE TO SCHEDULED MAINTENANCE
ON THE TURBINE. THE MODULE WAS ALSO DOWN DURING MID-MONTH WHEN THE BOILER
WAS OFF-LINE DUE TO A TUBE LEAK AND TO SET THE LIMIT SWITCHES.
744 744 726 80.2
744 744 740 80.2
720 720 712 81.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE PERIOD OF JULY THROUGH SEPTEMBER 1982.
10/82 A-ll 50.5 62.6 63.2 50.5
A-21 49.5 35.0 35.3 28.3
SYSTEM 100.0 97.5 98.5 78.8 744 601 586 75.9
** FROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED BY THE UTILITY.
DURING OCTOBER.
11/82 A-ll 79.5 77.1 77.8 71.9
A-21 .0 .0 .0
SYSTEM 79.5 77.1 77.8 71.9 720 672 518 62.3
7/82
8/82
9/82
A-ll
A-21
SYSTEM
A-ll
A-21
SYSTEM
A-ll
A-21
SYSTEM
97.6
.0
97.6
7.4
96.8
100.0
.0
98.9
98.9
97.6
.0
97.6
7.4
92.0
99.4
.0
98.9
98.9
100.0
100.0
7.4
92.0
99.4
.0
98.9
98.9
97.6
.0
97.6
7.4
92.0
99.4
.0
98.9
98.9
13-657
-------
UTILITY FGD SURVEY: OCTOBER 19Q3 - SEPTEMBER 1984
MINNKOTA POWER: 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/COMMENTS
MODULE A-ll WAS DOWN FROM NOVEMBER 16 TO NOVEMBER 22 FOR REPAIR OF LEAKS.
MODULE A-21 WAS OUT OF SERVICE FOR THE ENTIRE MONTH TO ALLOW FOR THE PER-
FORMANCE OF MAINTENENCE WORK.
12/82 A-ll 42.1 48.0 48.9 42.1
A-21 .0 .0 .0 .0
SYSTEM 42.1 48.0 48.9 42.1 744 653 313 65.7
** PROBLEMS/SOLUTIONS/COMMENTS
HIGH VIBRATIONS FROM AN ID FAN FORCED THE REMOVAL OF A SET OF FANS ON
THE UNIT AND CONSEQUENTLY, AN FGD SYSTEM OUTAGE.
REPAIRS CONTINUED DURING DECEMBER ON THE LEAKS THAT DEVELOPED IN MODULE
A-ll.
MAINTENANCE WORK CONTINUED DURING THE MONTH ON MODULE A-21.
A DAMAGED COLD REHEAT LINE PRODUCING A LOW VACUUM RESULTED IN A UNIT TRIP
ON DECEMBER 10. THE UNIT WAS BROUGHT DOWN ON DECEMBER 13 TO REPAIR THE
COLD REHEAT LINE.
1/83 A-ll 100.0 97.7 92.3 90.8
A-21 3.0 1.2 1.1 1.1
SYSTEM 100.0 98.9 93.4 91.9 744 692 684 82.6
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING JANUARY.
2/83 A-ll 100.0 94.8 86.0 83.7
A-21 .0 .0 .0 .0
SYSTEM 100.0 94.8 86.0 63.7 672 594 562 82.4
*» PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING FEBRUARY.
3/83 A-ll 80.6 95.6 94.8 75.7
A-21 .0 .0 .0 .0
SYSTEM . 80.6 95.6 94.8 75.7 744 589 563 77.0
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE A-21 HAD BEEN OUT OF SERVICE SINCE OCTOBER AND REMAINED OUT OF
SERVICE DURING MARCH FOR REPAIRS TO THE ABSORBER LINING.
THE UNIT WAS TAKEN OUT OF SERVICE ON MARCH 25 FOR A SCHEDULED OUTAGE.
4/83 A-ll 33.3 88.1 87.6 29.7
A-21 .0 .0 .0 .0
SYSTEM 33.3 88.1 86.0 29.7 720 243 214 69.5
»* PROBLEMS/SOLUTIONS/COMMENTS
THE ANNUAL OUTAGE WHICH BEGAN ON MARCH 25 ENDED ON APRIL 20.
WHEN ATTEMPTING TO START A BOOSTER FAN, THE FAN HOUSING FLOODED AND CAUSED
13-656
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
HINNKOTA POWER: MILTON R. YOUNG Z (CONT.)
PERIOD
5/83
6/83
MODULE
A-ll
A-21
SYSTEM
A-ll
A-21
SYSTEM
AVAILABILITY
98.
98.
99.
99.
A
Z
0
2
3
0
3
OPERABILITY
FAN HOUSING
95.4
.0
95.4
98.4
.0
98.4
PtHt-ORHAr
RELIABILITY
JUt DAIA
UTILIZATION 7. REMOVAL
SQZ PART.
EXPANSION JOINT TO
86.9
.0
86.9
98.4
.0
98.4
84.
84.
94.
94.
RUPTURE.
8
0
8
9
0
9
PER
HOURS
744
720
BOILER
HOURS
661
695
FGD
HOURS
631
683
CAP.
FACTOR
83.8
83.5
»* PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING MAY AND JUNE.
7/83
A-ll
A-21
SYSTEM
99.6
.0
99.6
98.2
.0
98.2
95.3
95.3
76.6
.0
76.6
744 580
570 81.5
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING JULY.
8/83
A-ll
A-21
SYSTEM
89.4
.0
89.4
97.3
.0
97.3
97.3
.0
97.3
89.4
.0
89.4
744 684 665 89.5
** PROBLEMS/SOLUTIONS/COMMENTS
WORK CONTINUED DURING AUGUST ON RELINING THE A-21 MODULE ABSORBER TOWER.
MODULE A-ll EXPERIENCED EXPANSION JOINT PROBLEMS DURING AUGUST.
MODULE A-ll ALSO EXPERIENCED FLYASH SLURRY LINE PROBLEMS DURING THE MONTH.
9/83
A-ll
A-21
SYSTEM
76.3
.0
76.3
89.3
.0
89.3
91.2
.0
91.2
70.1
.0
70.1
720 566 505 80.2
** PROBLEMS/SOLUTIONS/COMMENTS
WORK CONTINUED DURING SEPTEMBER ON RELINING THE A-21 MODULE ABSORBER TOWER.
FLYASH SLURRY LINE PROBLEMS CONTINUED DURING SEPTEMBER AT THE A-ll MODULE.
MODULE A-ll ALSO EXPERIENCED PROBLEMS WITH THE SPRAY RECYCLE PUMP STRAINERS
DURING THE MONTH.
10/83
11/83
A-ll
A-21
SYSTEM
A-ll
A-21
SYSTEM
16.1
90.3
100.0
.0
100.0
100.0
14.4
83.9
98.3
.0
100.0
100.0
100.0
87.3
100.0
100.0
100.0
13.0
75.9
88.9
.0
100.0
100.0
744
673
720 720
662 89.8
720 87.4
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR FGD-RELATED OUTAGES WERE ENCOUNTERED DURING OCTOBER AND NOVEMBER
1983.
12/83 A-ll
.0
.0
.0
.0
13-659
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
MINNKOTA POWER: 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
A-21 70.1 78.1 54.3 54.3
SYSTEM 70.1 78.1 54.3 54.3 744 5X8 404 75.6
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE A-ll WAS BEING RELINED DURING DECEMBER.
MAINTENANCE WORK WAS PERFORMED ON THE MODULE A-21 ABSORBER SLURRY RECYCLE
SYSTEM DURING DECEMBER ACCOUNTING FOR LOW FGD SYSTEM AVAILABILITY.
THREE UNIT OUTAGES OCCURRED DURING DECEMBER DUE TO BOILER TUBE LEAK AND HY-
DROGEN LEAK REPAIRS.
1/84 A-ll .0 .0 .0 .0
A-21 84.5 84.5 100.0 84.5
SYSTEM 84.5 84.5 100.0 84.5 744 744 629 87.8
** PROBLEMS/SOLUTIONS/COMMENTS
MODULE A-ll WAS NOT AVAILABLE FOR SERVICE DUE TO MODULE RELINING.
THE UTILITY REPORTED THAT THE ABSORBER WAS SHUT DOWN TO MAKE REPAIRS ON
MODULE A21 SPRAY RECYCLE SYSTEM.
696 696 696 78.4
744 744 76.8
720 641 636 74.7
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS AROSE DURING THE
PERIOD OF FEBRUARY THROUGH APRIL 1984.
5/84 A-ll 100.0 .0
A-21 100.0 .0
SYSTEM 100.0 .0 744 0 0 .0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT WAS SHUT DOWN THROUGHOUT MAY FOR ITS ANNUAL OUTAGE.
6/84 A-ll .0 .0 .0
A-21 100.0 89.8 105.5 45.6
SYSTEM 100.0 89.8 100.0 45.6 720 366 328 79.4
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS AROSE DURING JUNE.
7/84 SYSTEM 744
8/84 SYSTEM 744
9/84 SYSTEM 72Q
2/84
3/84
4/84
A-ll
A-21
SYSTEM
A-ll
A-21
SYSTEM
A-ll
A-21
SYSTEM
3.4
100.0
100.0
100.0
100.0
100.0
100.0
100.0
100.0
.0
100.0
100.0
.0
100.0
100.0
.0
99.1
99.1
100.0
100.0
100.0
100.0
99.8
99.8
.0
100.0
100.0
.0
100.0
100.0
.0
88.3
88.3
13-660
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
MINNKOTA POWER: MILTON R. YOUNG 2 (CONT.)
PERFORMANCE DATA -
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
SOZ PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE THIRD QUARTER OF 1984.
13-661
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
SECTION 13
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 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 - 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
*» MECHANICAL COLLECTOR
NUMBER
TYPE
** FABRIC FILTER
NUMBER
TYPE
** ESP
NUMBER
NUMBER OF SPARES
TYPE
SUPPLIER
INLET FLUE GAS CAPACITY - CU.M/S
INLET FLUE GAS TEMPERATURE - C
PARTICLE REMOVAL EFFICENCY - 7.
** PARTICLE SCRUBBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON NAME
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
MONONGAHLA POWER
PLEASANTS
1
WILLOW ISLAND
WEST VIRGINIA
D
21. (
516. (
301. (
1160
626
560
595
626
FOSTER WHEELER
PULVERIZED COAL
BASE
1132.56
132.2
305.
CONCRETE
6.1
.050 LB/MMBTU)
1.200 LB/MMBTU)
.700 LB/MMBTU)
(2400000 ACFM)
( 270 F)
(1000 FT)
( 20.0 FT)
( 12500 BTU/LB)
11000-13300
COAL
BITUMINOUS
29075.
********
14.7-16.0
4.50
3.0-5.0
3.00
2.5-3.5
.05
******
0
NONE
0
NONE
2
0
COLD SIDE
AIR CORRECTION DIVISION, UOP
566.3 (1200000 ACFM)
132.2 ( 270 F)
99.5
0
NONE
N/A
N/A
N/A
N/A
N/A
N/A
13-662
-------
MONONGAHELA POWER: PLEASANTS 1 (CONT.)
UTILITY FGD SURVEY' OCTOBER 1983 - SEPTEMBER 1984
*#» FGD SYSTEM
*« GENERAL DATA
SALEABLE PRODUCT/THROWAWAY PRODUCT
S02 REMOVAL MODE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
WIT DESIGN PARTICLE REMOVAL EFFICIENCY
UNIT DESIGN SOS REMOVAL EFFICIENCY - X
ENERGY CONSUMPTION - 7.
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
»* DESIGN AND OPERATING PARAMETERS
DESIGN COAL SULFER CONTENT - X
DESIGN COAL HEAT CONTENT - J/G
DESIGN COAL ASH CONTENT - X
DESIGN MOISTURE CONTENT - X
DESIGN CHLORIDE CONTENT - X
SPACE REQUIREMENTS - SQ M
OPER. & MAINT. REQUIREMENT - MANHR/DAY
** QUENCHER/PRESATURATOR
NUMBER
TYPE
SUPPLIER
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
PRESSURE DROP - KPA
LIQUID RECIRCULATION RATE - LITERS/S
L/G RATIO - L/CU. M
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** ABSORBER
NUMBER
NUMBER OF SPARES
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
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
NUMBER OF SPAPES PER SYSTEM
KUM5ER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
THROWAWAY PRODUCT
WET SCRUBBING
LIME
NONE
BABCOCK & WILCOX
UNITED ENGINEERS & CONSTRUCTORS
FULL SCALE
NEW
'/. 99.55
90.00
1
12/80
12/78
9/75
4.50
28842.4
16.00
5.00
.05
20252.2
208.0
( 12400 BTU/LB)
( 218000 SQ FT)
4
VENTURI
BABCOCK 4 WILCOX
283.14
148.9
1.0
504.
1.8
CARBON STEEL
AISI 1110
600000 ACFM)
300 F)
4.0 IN-H20)
8000 GPM)
13.3 GAL/1000 ACFM)
4
1
TRAY TOWER
SIEVE TRAY
N/A
BABCOCK J WILCOX
CARBON STEEL
AISI 1110
N/A
ORGANIC
SYNTHETIC RUBBER
CHLOROBUTYL
PERFORATED TRAYS
1
1008. (16000 GPM)
4.0 ( 30.2 GAL/1000 ACF)
1.2 ( 5.0 IN-H20)
3.0 (10.0 FT/S)
250.11 ( 530000 ACFM)
51.7 ( 125 F)
90.0
PRIMARY COLLECTOR
4
1
1
IMPINGEMENT
BAFFLE
13-663
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
MONONGAHEU POWER: PLEASANTS 1 (CONT.)
TRADE NAME/COMMON TYPE
MANUFACTURER
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES PER STAGE
DISTANCE BETWEEN STAGES - CM
SUPERFICAL GAS VELOCITY - M/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
WASH WATER SOURCE
WASH FREQUENCY
WASH RATE - L/S
** REHEATER
NUMBER
NUMBER OF SPARES
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
LOCATION
PERCENT GAS BYPASSED - AVG
TEMPERATURE INCREASE - C
INLET FLUE GAS TEMPERATURE - C
OUTLET FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** FANS
NUMBER
NUM3ER OF SPARES
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
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
PRESSURE DROP - KPA
CONSTRUCTION MATERIAL GENERIC TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
SERVICE CONDITIONS
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
(84.0 IN)
( 10.0 FT/S)
CLOSED VANE
BABCOCK i WILCOX
HORIZONTAL
Z
3
313.36
3.0
ORGANIC
FIBER-REINFORCED POLYESTER
THICKENER OVERFLOW/MAKEUP
CONTINUOUSLY; ONCE EVERY 2 HOURS
15.1 ( 240 GAL/MIN)
1
0
BYPASS
COLD SIDE
N/A
AHEAD OF STACK
15.0
13.9 ( 25 F)
51.7 ( 125 F)
65.6 ( 150 F)
NR
NR
4
0
CENTRIFUGAL
AMERICAN STANDARD
BOOSTER
FORCED DRAFT
DRY
267.10
132.2
7.9
CARBON STEEL
( 566000 ACFM)
( 270 F)
(26.0 IN-H20)
2
0
NR
AMERICAN STANDARD
UNIT
FORCED DRAFT
DRY
493.14 (1045000 ACFM)
132.2 ( 270 F)
7.6 (25.0 IN-H20)
CARBON STEEL
4
SHUT-OFF
LOUVER
PARALLEL/OPPOSED BLADE MULTILOUVER
FORNEY ENGINEERING
270
CARBON STEEL
HIGH STRENGTH LOW ALLOY IHSU1
NONE
N/A
SHUT-OFF
LOUVER
PARALLEL/OPPOSED BLADE MULTILOUVER
FORNEY ENGINEERING
13-664
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
MONONGAHEU POWER: PLEASANTS 1 (CONT.)
SERVICE CONDITIONS
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
»# DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
MANUFACTURER
NUMBER
NUMBER OF SPARES
PRODUCT QUALITY - X SOLIDS
** TANKS
SERVICE
RECIRCULATION
ME WASH
SLURRY TRANSFER
SLURRY FEED
THICKENER OVERFLOW
SLUDGE STABILIZATION
** PUMPS
SERVICE
QUENCHER RECIRCULATION
ABSORBER RECIRCULATION
THICKENER UNDERFLOW
LIME SLURRY TRANSFER
LIME SLURRY FEED
SLUDGE TRANSFER
RETURN WATER
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUM3ER OF SPARES
CONFIGURATION
DIMENSIONS FT
CAPACITY
125
STAINLESS STEEL
AUSTENITIC
NONE
N/A
INLET
CARBON STEEL
AISI 1110
NONE
N/A
OUTLET
CARBON STEEL
AISI 1110
ORGANIC; INORGANIC
ASPHALT-URETHANE; BOROSILICATE GLASS
OUTLET AFTER BYPASS JUNCTION
CARBON STEEL
AISI 1110
INORGANIC
NR
BYPASS
CARBON STEEL
AISI 1110
NONE
N/A
SLAKER
DETENTION
N/A
DORR-OLIVER
3
1
15.0
NUMBER
****
1
1
2
2
NUMBER
8
16
****
2
*«**
THICKENER
2
0
CIRCULAR
175.0 DIA X 10.0
2190000
13-665
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
MONONGAHELA POWER: PLEASANTS I (CONT.)
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
FEED STREAM SOURCE
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
OUTLET STREAM DISPOSITION
OVERFLOW STREAM DISPOSITION
*** SALEABLE BYPRODUCTS
NATURE
*«* SLUDGE
** TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
INLET QUALITY - 7.
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE TREATMENT
SITE DIMENSIONS
SITE SERVICE LIFE - YRS
»* PROCESS CONTROL AND INSTRUMENTATION
PROCESS STREAM
CHEMICAL PARAMETERS
PHYSICAL VARIABLES
CONTROL LEVELS
MONITOR TYPE
MONITOR LOCATION
** WATER BALANCE
WATER LOOP TYPE
RECEIVING WATER STREAM
SOURCE OF MAKEUP WATER
»* CHEMICALS AND CONSUMPTION
FUNCTION
NAME
PRINCIPAL CONSTITUENT
SOURCE/SUPPLIER
CONSUMPTION
UTILIZATION - 7.
POINT OF ADDITION
** FGD SPARE CAPACITY INDICES
ABSORBER X
FAN - 7.
SLAKER X
THICKENER - X
** FGD SPARE COMPONENT INDICES
ABSOPBER
FAN
SLAKER
THICKENER
CARBON STEEL
AISI 1110
ORGANIC
COAL TAR EPOXY
ABSORBER BLEED
6X SOLIDS
307. SOLIDS 127-327.1, PH 8.0
TO SLUDGE TREATMENT
RECIRCULATION TANK
NONE
FIXATION
MIX TANK
DRAVO [CALCILOXJ
30.0
FINAL
POND
OFF-SITE [1.5 MILES]
PIPELINE
NONE
ZOO ACRES X 200 FT
31
OUTLET FROM ABSORBER
PH, SOZ
DENSITY, FLOW
PH 5.9-6.0, 6X SOLIDS IN SLURRY
UNILOC [PH], LEAR SIEGLER [S02],
ABSORBER DOWNCOMER FOR PH
TEXAS NUCLEAR [
CLOSED
OHIO RIVER
RIVER WATER AND COOLING TOWER SLOWDOWN
ABSORBENT
THIOSORBIC LIME
>90X CAO,
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
MONONGAHELA POWER: PLEASANTS 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
3/79 SYSTEM 744
4/79 SYSTEM 720
** PROBLEMS/SOLUTIONS/COttMENTS
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 WELD 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
RE LINING.
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 690
3/80 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
NO INFORMATION WAS 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
13-667
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
MONQNGAHELA POWER: PLEASANTS 1 (CONT.)
. PERFORMANCE DATA--
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION / REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE SECOND QUARTER 1980 REPORT PERIOD.
7/80 SYSTEM 744
8/80 A 96.3 27.9
B 93.1 28.5
C .0 .0
D 98.1 28.5
SYSTEM 73.1 21.2 744 216 158 23.2
9/80 SYSTEM .0 .0 720 0 0 .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. DURING THE OUTAGE THE FOLLOWING REPAIRS WERE TO BE PEPFORMED:
1. REPLACE FABRIC EXPANSION JOINTS WITH ELASTOMER JOINTS
2. REPLACE GUNITE LININGS ON OUTLET DUCTWORK
3. BEGIN RE-LINING S02 MODULES RUBBER LINING DUE TO SEVERE BLISTERING
4. COAT THICKENER OVERFLOW TANK WITH COAL TAR EPOXY
5. MISCELLANEOUS PUMP AND VALVE MAINTENANCE
6. UPGRADE THE ISOLATION DAMPERS
10/80 SYSTEM .0 .0 744 0 0 .0
»» PROBLEMS/SOLUTIONS/COMMENTS
THE PLEASANTS 1 FGD SYSTEM REMAINED OFF LINE THROUGH THE MONTH OF OCTOBER.
11/80 SYSTEM 720
12/80 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION FOR THE MONTHS OF NOVEMBER AND DECEMBER WAS NOT AVAILABLE.
1/81 SYSTEM 744 86.2
2/81 SYSTEM 672 81.0
3/81 SYSTEM 744 33.3
** PROBLEMS/SOLUTIONS/COMMENTS
DURING AN FGD SYSTEM OUTAGE IN MARCH IT WAS DISCOVERED THAT THE PLASITE
LINING IN THE OUTLET DUCTWORK FOR MODULES B AND D WAS FAILING. THE B MOD-
ULE DUCTWORK WAS PATCHED AND THE MODULE RETURNED TO SERVICE. THE D MODULE
WAS KEPT OFF LINE AND THE OUTLET DUCTWORK FOR THIS MODULE WILL BE RELINED
WITH CHLOROBUTYL RUBBER.
4/81 SYSTEM 720
5/81 SYSTEM 744
6/81 SYSTEM 720
10/81 SYSTEM 7^4
11/81 SYSTEM 720
13-668
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
MONONGAHELA POWER: PLEASAKTS 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
12/81 SYSTEM 744
1/82 SYSTEM 74<+
2/82 SYSTEM 672
3/82 SYSTEM 744
4/82 SYSTEM 720
5/82 SYSTEM 744
6/82 SYSTEM 720
7/82 SYSTEM 744
8/82 SYSTEM 744
9/82 SYSTEM 720'
10/82 SYSTEM 744
11/82 SYSTEM 720
12/82 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE PERIOD OF APRIL 1981 TO DECEMBER 1982.
1/83 1A 38.7 38.4
IB 90.8 90.2
1C 68.2 67.7
ID 46.8 46.5
SYSTEM 81.5 81.0 744 739 602 74.0
2/83 1A .0 .0
IB 99.1 99.1
1C 100.0 100.0
ID 70.7 70.7
SYSTEM 89.9 89.9 672 672 604 67.0
3/83 1A 39.5 29.4
IB 64.0 47.7
1C 90.8 67.7
ID 53.3 39.8
SYSTEM 82.5 61.6 744 555 458 51.0
** PROBLEMS/SOLUTIONS/COMMENTS
EXPANSION JOINTS WERE REPLACED ON MODULES 1A AND IB DURING MARCH.
4/83 1A 42.8 33.3
IB 76.8 59.9
1C 39.0 30.4
ID 92.7 72.2
SYSTEM 83.8 65.3 720 561 470 48.0
5/83 1A 83.7 67.7
IB 57.1 46.2
1C 57.6 46.6
ID 82.4 66.7
SYSTEM 93.6 75.8 744 602 564 54.0
13-669
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
MONONGAHELA POWER: PLEASANTS 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 UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING APRIL AND MAY, 1983.
6/83 1A 99.6 33.3
IB 99.2 33.2
1C 100.0 34.4
ID .0 .0
SYSTEM 99.6 33.7 720 241 242 24.0
** PROBLEMS/SOLUTIONS/COMMENTS
UNIT 1 WAS OUT OF SERVICE DURING PART OF JUNE FOR AN ANNUAL OUTAGE.
LIME SLURRY TANKS WERE LINED WITH EPOXY COATING DURING THE ANNUAL OUTAGE IN
JUNE.
OUTLET DUCTS WERE RELINED DURING THE OUTAGE IN JUNE.
THE MODULE ID MIST ELIMINATOR SECTION WAS RELINED WITH CHLOROBUTYL RUBBER
DURING THE ANNUAL OUTAGE IN JUNE.
7/83 SYSTEM 744
8/83 SYSTEM 744
9/83 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE THIRD QUARTER OF 1983.
10/83 SYSTEM 744
11/83 SYSTEM 720
12/83 SYSTEM 744
»* PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE FOURTH QUARTER OF 1983.
1/84 SYSTEM 744
2/84 SYSTEM 696
3/84 SYSTEM 744
4/84 SYSTEM 72o
5/84 SYSTEM 744
6/84 SYSTEM 720
7/84 SYSTEM 744
8/84 SYSTEM 744
9/84 SYSTEM 720
13-670
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
MONONGAHELA POWER: PLEASANTS 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
INFORMATION WAS UNAVAILABLE FOR THE FIRST THREE QUARTERS OF 1984.
13-671
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
SECTION 13
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 - MW
MONONGAHELA POWER
PLEASANTS
2
WILLOW ISLAND
WEST VIRGINIA
D
21. C .050
516. ( 1.200
301. ( .700
1160
626
580
595
626
LB/MMBTU)
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
»* MECHANICAL COLLECTOR
NUMBER
TYPE
** FABRIC FILTER
NUMBER
TYPE
** ESP
NUMBER
NUMBER OF SPARES
TYPE
SUPPLIER
INLET FLUE GAS CAPACITY - CU.M/S
INLET FLUE GAS TEMPERATURE - C
PARTICLE REMOVAL EFFICENCY - 7.
** PARTICLE SCRUBBER
NUMBER
GENERIC TYPE
SPECIFIC TYPE
TR4DE NAME/COMMON NAME
SHELL GENERIC MATERIAL
SHELL SPECIFIC MATERIAL
LINER GENERIC MATERIAL
LINER SPECIFIC MATERIAL
FOSTER WHEELER
PULVERIZED COAL
BASE
1132.56
132.2
305.
CONCRETE
6.1
(2400000 ACFM)
( 270 F)
(1000 FT)
( 20.0 FT)
( 12500 BTU/LB)
11000-13300
COAL
BITUMINOUS
29075.
********
14.7-16.0
4.50
3.0-5.0
3.00
2.5-3.5
.05
******
0
NONE
0
NONE
2
0
COLD SIDE
AIR CORRECTION DIVISION, UOP
566.3 (1200000 ACFM)
132.2 ( 270 F)
99.5
0
NONE
N/A
N/A
N/A
N/A
N/A
N/A
13-672
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
MONONGAHELA POWER: PLEASANTS 2 (CONT.)
»** 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 - X
ENERGY CONSUMPTION - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
DESIGN COAL SULFER CONTENT - X
DESIGN COAL HEAT CONTENT - J/G
DESIGN COAL ASH CONTENT - X
DESIGN MOISTURE CONTENT - X
DESIGN CHLORIDE CONTENT - X
SPACE REQUIREMENTS - SQ M
OPER. & MAINT. REQUIREMENT - MANHR/DAY
** QUENCHER/PRESATURATOR
NUMBER
TYPE
SUPPLIER
INLET GAS FLOW - CU. M/S
INLET GAS TEMPERATURE - C
PRESSURE DROP KPA
LIQUID RECIRCULATION RATE - LITERS/S
L/G RATIO L/CU. M
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** ABSORBER
NUMBER
NUMBER OF SPARES
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
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
NUMBER OF SPARES PER SYSTEM
NUMBER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
THROWAWAY PRODUCT
WET SCRUBBING
LIME
NONE
BABCOCK & WILCOX
UNITED ENGINEERS &
FULL SCALE
NEW
X 99.55
90.00
2.4
1
12/80
10/80
9/75
CONSTRUCTORS
4.50
28842.4
16.00
5.00
.05
20252.2
208.0
( 12400 BTU/LB)
( 218000 SQ FT)
4
VENTURI
BABCOCK S WILCOX
283.14 (
148.9 (
1.0 (
504. (
1.8 (
CARBON STEEL
AISI 1110
600000 ACFM)
300 F)
4.0 IN-H20)
8000 GPM)
13.3 GAL/1000 ACFM)
4
1
TRAY TOWER
SIEVE TRAY
N/A
BABCOCK S WILCOX
CARBON STEEL
AISI 1110
N/A
ORGANIC
NATURAL RUBBER
BLACK NATURAL RUBBER
PERFORATED TRAYS
1
1008.
4.0
1.2
3.0
250.11
51.7
90.0
(16000 GPM)
( 30.2 GAL/1000 ACF)
( 5.0 IN-H20)
( 10.0 FT/S)
( 530000 ACFM)
( 125 F)
PRIMARY COLLECTOR
4
1
1
IMPINGEMENT
BAFFLE
13-673
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
MONONGAHELA POWER: PLEASANTS 2 (CONT.)
TRADE NAME/COMMON TYPE
MANUFACTURER
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES PER STAGE
DISTANCE BETWEEN STAGES - CM
SUPERFICAL GAS VELOCITY - M/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
WASH WATER SOURCE
WASH FREQUENCY
WASH RATE - L/S
** REHEATER
NUMBER
NUMBER OF SPARES
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
LOCATION
PERCENT GAS BYPASSED - AVG
TEMPERATURE INCREASE - C
INLET FLUE GAS TEMPERATURE - C
OUTLET FLUE GAS TEMPERATURE - C
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** FANS
NUMBER
NUMBER OF SPARES
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
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
PRESSURE DROP KPA
CONSTRUCTION MATERIAL GENERIC TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
SERVICE CON'DITIONS
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
*« DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
(84.0 IN)
( 10.0 FT/S)
CLOSED VANE
BABCOCK & WILCOX
HORIZONTAL
2
3
313.36
3.0
ORGANIC
FIBER-REINFORCED POLYESTER
THICKENER OVERFLOW/MAKEUP
CONTINUOUSLY; ONCE EVERY 2 HOURS
15.1 ( 240 GAL/MIN)
1
0
BYPASS
COLD SIDE
N/A
AHEAD OF STACK
15.0
13.9 ( 25 F)
51.7 ( 125 F)
65.6 ( 150 F)
NR
NR
4
0
CENTRIFUGAL
AMERICAN STANDARD
BOOSTER
FORCED DRAFT
DRY
267.10 ( 566000 ACFM)
132.2 ( 270 F)
7.9 (26.0 IN-H20)
CARBON STEEL
2
0
NR
AMERICAN STANDARD
UNIT
FORCED DRAFT
DRY
493.14 (1045000 ACFM)
132.2 ( 270 F)
7.6 (25.0 IN-H20)
CARBON STEEL
4
SHUT-OFF
LOUVER
PARALLEL/OPPOSED BLADE MULTILOUVER
FORNEY ENGINEERING
270
CARBON STEEL
HIGH STRENGTH LOW ALLOY [HSLAJ
NONE
N/A
4
SHUT-OFF
LOUVER
PARALLEL/OPPOSED BLADE MULTILOUVER
FORNEY ENGINEERING
13-674
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
MONONGAHELA POWER: PLEASANTS 2 (CONT.)
SERVICE CONDITIONS
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
»* DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
DEVICE TYPE
MANUFACTURER
NUMBER
NUMBER OF SPARES
PRODUCT QUALITY - X SOLIDS
*# TANKS
SERVICE
RECIRCULATION
ME WASH
SLURRY TRANSFER
SLURRY FEED
THICKENER OVERFLOW
SLUDGE STABILIZATION
*# PUMPS
SERVICE
QUENCHER RECIRCULATION
ABSORBER RECIRCULATION
THICKENER UNDERFLOW
LIME SLURRY TRANSFER
LIME SLUPRY FEED
SLUDGE TRANSFER
RETURN WATER
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
NUMBER OF SPARES
CONFIGURATION
DIMENSIONS - FT
CAPACITY
125
STAINLESS STEEL
AUSTENITIC
NONE
N/A
INLET
CARBON STEEL
AISI 1110
NONE
N/A
OUTLET
CARBON STEEL
AISI 1110
ORGANIC; INORGANIC
ASPHALT-URETHANE; BOROSILICATE GLASS
OUTLET AFTER BYPASS JUNCTION
CARBON STEEL
AISI 1110
INORGANIC
NR
BYPASS
CARBON STEEL
AISI 1110
NONE
N/A
SLAKER
DETENTION
N/A
DORR-OLIVER
3
1
15.0
NUMBER
***#
*»**
1
1
2
2
NUMBER
8
16
#**»
2
****
THICKENER
2
0
CIRCULAR
175.0 DIA X 10.0
2190000
13-675
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
MONONGAHELA POWER: PLEASANTS Z (CONT.)
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
FEED STREAM SOURCE
FEED STREAM CHARACTERISTICS
OUTLET STREAM CHARACTERISTICS
OUTLET STREAM DISPOSITION
OVERFLOW STREAM DISPOSITION
*** SALEABLE BYPRODUCTS
NATURE
*** SLUDGE
** TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
INLET QUALITY - X
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE TREATMENT
SITE DIMENSIONS
SITE SERVICE LIFE - YRS
** PROCESS CONTROL AND INSTRUMENTATION
PROCESS STREAM
CHEMICAL PARAMETERS
PHYSICAL VARIABLES
CONTROL LEVELS
MONITOR TYPE
MONITOR LOCATION
** WATER BALANCE
WATER LOOP TYPE
RECEIVING WATER STREAM
SOURCE OF MAKEUP WATER
«* CHEMICALS AND CONSUMPTION
FUNCTION
NAME
PRINCIPAL CONSTITUENT
SOURCE/SUPPLIER
CONSUMPTION
UTILIZATION - 7.
POINT OF ADDITION
** FGD SPARE CAPACITY INDICES
ABSORBER - X
FAN - 7.
SLAKER - X
THICKENER - X
** FGD SPARE COMPONENT INDICES
ABSORBER
FAN
SLAKER
THICKENER
CARBON STEEL
AISI 1110
ORGANIC
COAL TAR EPOXY
ABSORBER BLEED
67. SOLIDS
307. SOLIDS 127-32X15 PH 8.0
TO SLUDGE TREATMENT
RECIRCULATION TANK
NONE
FIXATION
MIX TANK
DRAVO ICALCILOX1
30.0
FINAL
POND
OFF-SITE tl.5 MILES]
PIPELINE
NONE
200 ACRES X 200 FT
31
OUTLET FROM ABSORBER
PH, S02
DENSITY, FLOW
PH 5.9-6.0; 6X SOLIDS IN SLURRY
UNILOC IPHJ, LEAR SIEGLER IS02J,
ABSORBER DOWNCOMER FOR PH
TEXAS NUCLEAR [
CLOSED
OHIO RIVER
RIVER WATER AND COOLING TOWER SLOWDOWN
ABSORBENT
THIOSORBIC LIME
>90X CAO, 4-7X MGO
DRAVO
11.1 TPH
94.0
SLAKER
33.3
.0
1.0
.0
1.0
.0
1.0
.0
13-676
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 19S4
MONONGAHELA POWER: PLEASANTS 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION '/. 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.
1/81 SYSTEM 744 60.4
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JANUARY IT WAS NECESSARY TO CLEAN THE SOLIDS OUT OF THE THICKENER
OVERFLOW TANK AS A RESULT OF PROBLEMS WITH THE DENSITY CONTROL.
2/81 SYSTEM 672 50.0
#* PROBLEMS/SOLUTIONS/COMMENTS
A NINE-FOOT SECTION OF PIPE HAD TO BE RELINED DURING THE MONTH
ON MODULE B AS A RESULT OF FAILURE OF THE RUBBER LINER.
3/81 SYSTEM 744 72.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING MARCH.
4/81 SYSTEM 720
5/81 SYSTEM 744
6/81 SYSTEM 720
7/81 SYSTEM 744
8/81 SYSTEM 744
9/81 SYSTEM 720
10/81 SYSTEM 744
11/81 SYSTEM 720
12/81 SYSTEM 744
1/82 SYSTEM 744
2/82 SYSTEM 672
3/82 SYSTEM 744
4/82 SYSTEM 744
5/82 SYSTEM 744
6/82 SYSTEM 744
13-677
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
MONONGAHELA POWER: PLEASANTS 2 (CONT.)
_. .PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
7/82 SYSTEM 744
8/82 SYSTEM 744
9/82 SYSTEM 720
10/82 SYSTEM 744
11/82 SYSTEM 720
12/82 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE PERIOD OF APRIL 1981 TO DECEMBER 1982.
1/83 2A 76.2 62.0
2B 94.9 77.2
2C 16.4 13.3
2D 100.0 81.7
SYSTEM 95.8 78.0 744 605 581 58.0
2/83 2A .0 .0
2B 72.3 72.3
2C 99.3 99.3
20 99.6 99.6
SYSTEM 90.4 90.4 672 '672 607 70.0
3/83 2A 27.7 27.7
2B 90.3 90.3
2C 30.6 30.6
2D 72.6 72.6
SYSTEM 73.7 73.7 744 744 549 70.0
4/83 2A 98.1 63.5
2B 100.0 68.1
2C .0 .0
20 .0 .0
SYSTEM 67.7 43.8 720 466 474 35.0
** PROBLEMS/SOLUTIONS/COMMENTS
THE UNIT 2 STACK BRICK LINING WAS REPAIRED DURING APRIL. A CROSS-OVER DUCT
TO UNIT 1 WAS USED DURING THE REPAIR WORK TO KEEP UNIT 2 IN SERVICE.
5/83 2A 100.0 99.7
2B 65.0 64.7
£C .0 .0
2D 99.2 98.7
SYSTEM 88.1 87.7 744 740 652 69.0
6/83 2A 97.9 97.9
2B 100.0 100.0
2C 63.2 63.2
2D 37.2 37.2
SYSTEM 99.4 99.4 720 720 716 70.0
** PR03LEMS/SOLUTIONS/COMMEMTS
THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED
DURING MAY AND JUNE, 1983.
7/83 SYSTEM 744
13-678
-------
UTILITY F6D SURVEY: OCTOBER 1983 - SEPTEMBER 1984
MONONGAHELA POWER: PLEASANTS 2 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
SOS PART. HOURS HOURS HOURS FACTOR
8/83 SYSTEM 744
9/83 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE THIRD QUARTER OF 1983.
10/83 SYSTEM 744
11/83 SYSTEM 720
12/83 SYSTEM 744
#* PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE FOURTH QUARTER OF 1983.
1/84 SYSTEM 744
2/84 SYSTEM 696
3/84 SYSTEM 744
4/84 SYSTEM 720
5/84 SYSTEM 744
6/84 SYSTEM 720
7/84 SYSTEM 744
8/84 SYSTEM 744
9/84 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE FIRST THREE QUARTERS OF 1984.
13-679
-------
UTILITY F6D SURVEY: OCTOBER 1983 - SEPTEMBER 1984
SECTION 13
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL DOMESTIC FGD SYSTEMS
COMPANY NAME
PLANT NAME
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 - 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
( .100 LB/MMBTU)
( 1.200 LB/MMBTU)
( .700 LB/MMBTU)
MONTANA POWER
COLSTRIP
1
COLSTRIP
MONTANA
D
43.
516.
301.
664
360
332
344
360
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
674.82 (1430000 ACFM)
143.9 ( 291 F)
153. ( 503 FT)
CONCRETE
5.0 ( 16.5 FT)
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - J/G
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - '/.
RANGE ASH CONTENT - V.
AVERAGE MOISTURE CONTENT - V.
RANGE MOISTUP.E CONTENT 7.
AVERAGE SULFUR CONTENT - 7.
RAM3E SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RAN3E CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** MECHANICAL COLLECTOR
NUMBER
TYPE
** ESP
NUMBER
TYPE
»* PARTICLE SCRUBBER
NUMBER
NUMBER OF SPARES
INITIAL START-UP DATE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON NAME
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
PH CONTROL ADDITIVE
PRESSURE DROP KPA
SUPERFICIAL GAS VELOCITY - M/S
COAL
SUEBITUMINOUS
20569. ( 8843 BTU/LB)
8162-8897
8.60
6.1-12.6
23.90
21.0-25.0
.78
0.4-1.0
.01
******"
0
NONE
0
NONE
3
0
9/75
VENTURI TOWER
VARIABLE-THROAT/TOP-ENTRY PLUMB BOB
N/A
THYSSEN/CEA
15.0 DIA
CARBON STEEL
AISI 1110
INORGANIC
PREFIRED BRICK/SHAPES
NONE
1
415.8 ( 6600 GPM)
1.8 (13.8 GAL/1000ACF)
LIME/ALKALINE FLY ASH
4.2 (17.0 IN-H20)
61.0 ( 200.0 FT/S)
13-620
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
MONTANA POWER: COLSTRIP 1 (CONT.)
INLET GAS FLOW RATE - CU.M/S
INLET GAS TEMPERATURE - C
PARTICLE REMOVAL EFFICIENCY - X
*** 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 - V.
ENERGY CONSUMPTION - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AWARDED
** DESIGN AND OPERATING PARAMETERS
DESIGN COAL SULFER CONTENT X
DESIGN COAL HEAT CONTENT - J/G
DESIGN COAL ASH CONTENT - X
DESIGN MOISTURE CONTENT - X
DESIGN CHLORIDE CONTENT - X
OPER. & MAINT. REQUIREMENT - MANHR/DAY
** QUENCHER/PRESATURATOR
NUMBER
*# 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
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
NUMBER OF SPARES PER SYSTEM
NUMBER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
MANUFACTURER
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES PER STAGE
225.1
143.9
99.5
( 477000 ACFM)
( 291 F)
THROWAWAY PRODUCT
WET SCRUBBING
LIME/ALKALINE FLYASH
NONE
THYSSEN/CEA
BECHTEL
FULL SCALE
NEW
'/. 99.50
60.00
3.3
1
11/75
9/75
10/72
( 8162 BTU/LB)
1.00
18984.8
12.60
25.00
.01
152.0
3
0
COMBINATION TOWER
VENTURI/SPRAY
N/A
THYSSEN/CEA
35 DIA X 70.5
CARBON STEEL
AISI 1110
N/A
ORGANIC
GLASS FLAKE-FILLED POLYESTER; INERT FLAKE-FILLED
RIGIFLAKE 4850; PLASITE 4020 t 4030
VENTURI THROAT AND SPRAY ZONE
479.
2.4
4.4
2.7
201.31
48.9
80.0
99.5
( 7600 GPM)
( 17.8 GAL/1000 ACF)
(17.5 IN-H20)
( 9.0 FT/S)
( 426600 ACFM)
( 120 F)
PRIMARY COLLECTOR
3
0
1
IMPINGEMENT
BAFFLE
CLOSED VANE
HEIL
HORIZONTAL
1
4
13-681
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 198*
MONTANA POWER: COLSTRIP 1 (CONT.)
FREEBOARD DISTANCE - M
DISTANCE BETWEEN VANES - CM
VANE ANGLES - DEGREES
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
WASH WATER SOURCE
WASH FREQUENCY
WASH RATE - L/S
** REHEATER
NUMBER
NUMBER OF SPARES
NUMBER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
LOCATION
PERCENT GAS BYPASSED - AVG
TEMPERATURE INCREASE - C
INLET FLUE GAS FLOW RATE - CU. M/S
INLET FLUE GAS TEMPERATURE - C
OUTLET FLUE GAS TEMPERATURE - C
NUMEER OF HEAT EXCHANGER BANKS
NUMBER OF BUNDLES PER BANK
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** FANS
NUMBER
NUM3ER OF SPARES
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
CONSTRUCTION MATERIAL GENERIC TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
MODULATION
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
MODULATION
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
3.96 (13.0 FT)
2.5 ( 1.00 IN)
120
.1 ( .3 IN-H20)
2.7 ( 8.7 FT/S)
ORGANIC
POLYPHENYLENE
BLENDED
CONTINUOUS UNDERSPRAY AND ONCE/DAY OVERSPRAY
51.1 ( 810 GAL/MIN)
3
0
1
IN-LINE
STEAM
PLATECOIL
IN DUCT AFTER ABSORBER
.0
30.6
201.31
( 55 F)
( 426600 ACFM)
( 120 F)
175 F)
79.4 (
12
11
HIGH ALLOY
NICKEL BASE/CHROMIUM-IRON-COPPER-MOLYBDENUM; NIC
3
0
CENTRIFUGAL
BUFFALO FORGE
UNIT
INDUCED DRAFT
DRY
223.21
79.4
11.0
473000 ACFM)
175 F)
(36.0 IN-H20)
CARBON STEEL; ORGANIC
SHUT-OFF
BUTTERFLY
N/A
ALLIS-CHALMERS
OPEN/CLOSED
CARBON STEEL
AISI 1110
NONE
N/A
SHUT-OFF
GUILLOTINE
SIDE-ENTRY GUILLOTINE
MOSSER
OPEN/CLOSED
STAINLESS STEEL
AUSTENITIC
NONE
N/A
6
CONTROL
LOUVER
PARALLEL BLADE MULTILOUVER
13-682
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
MONTANA POWER: COLSTRIP 1 (CONT.)
MANUFACTURER
MODULATION
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
CONFIGURATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
#* DUCTWORK
LOCATION
CONFIGURATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
CONFIGURATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
MANUFACTURER
NUMBER
NUMBER OF SPARES
PRODUCT QUALITY - X SOLIDS
** TANKS
SERVICE
BUFFALO FORGE
VARIOUS
CARBON STEEL
AISI 1110
NONE
N/A
INLET
CIRCULAR
CARBON STEEL
AISI 1110
NONE
N/A
OUTLET
RECTANGULAR
CARBON STEEL
AISI 1110
ORGANIC
GLASS FLAKE-FILLED POLYESTER
REHEATER
RECTANGULAR
STAINLESS STEEL
AUSTENITIC
NONE
N/A
SLAKER
PASTE
BIF
2
1
10.0
NUMBER
VENTURI & ABSORBER RECYCLE
SLURRY TRANSFER
SLUPPY STORAGE
EFFLUENT BLEED
TRAY WASH WATER RECYCLE
** PUMPS
SERVICE
VENTURI RECIRCULATION
ABSORBER RECIRCULATION
POND RETUPN
LIME SYSTEM
EFFLUENT BLEED
TRAY WASH WATER RECYCLE
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
NUMBER
6
6
3
****
Z
2
NONE
*** SLUDGE
** TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
BLEED
N/A
N/A
13-683
-------
UTILITY FGD SURVEY^ OCTOBER 1983 - SEPTEMBER 1984
MONTANA POWER'- COLSTRIP 1 (CONT.)
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE TREATMENT
SITE DIMENSIONS
SITE CAPACITY - CU.M
SITE SERVICE LIFE - YRS
*» DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE TREATMENT
SITE DIMENSIONS
SITE CAPACITY CU.M
SITE SERVICE LIFE YRS
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE TREATMENT
SITE DIMENSIONS
SITE CAPACITY - CU.M
SITE SERVICE LIFE - YRS
»* PROCESS CONTROL AND INSTRUMENTATION
PROCESS STREAM
CHEMICAL PARAMETERS
PHYSICAL VARIABLES
CONTROL LEVELS
MONITOR LOCATION
PROCESS CONTROL MANNER
PROCESS CHEMISTRY MODE
»* WATER BALANCE
WATER LOOP TYPE
EVAPORATION WATER LOSS - LITER/S
POKD SEEPAGE/RUNOFF WATER LOSS LITERS/S
MAKEUP WATER ADDITION - LITERS/S
SOURCE OF MAKEUP HATER
** CHEMICALS AND CONSUMPTION
FUNCTION
NAME
PRINCIPAL CONSTITUENT
SOURCE/SUPPLIER
CONSUMPTION
POINT OF ADDITION
** FGD SPARE CAPACITY INDICES
SCPUE5ER - X
ABSORBER 7.
MIST ELIMINATOR - 7.
REHEATER - X
FAN X
SLAKER - X
EFFLUENT HOLD TANK
RECIRCULATION PUMP
** FGD SPARE COMPONENT INDICES
SCRUBBER
ABSORBER
MIST ELIMINATOR
REHEATER
FAN
INTERIM
POND
ON-SITE
PIPELINE
CLAY LINING IBENTONITEJ
15 ACRE/20-30 FEET DEEP
550350 ( 450.0 ACRE-FT)
3
INTERIM
POND
ON-SITE
PIPELINE
CLAY LINING IBENTONITE]
15 ACRE/20-30 FEET DEEP
550350 ( 450.0 ACRE-FT)
3
FINAL
POND
ON-SITE
PIPELINE
CLAY" LINING tBENTONITE]
150 ACRE/20-30 FEET DEEP
5503500 ( 4500.0 ACRE-FT)
10
RECIRCULATING SLURRY
PH
X SOLIDS, FLOW, PRESSURE
PH 4.5 TO 5.5
RECIRCULATION TANK
MANUAL
FEEDBACK
CLOSED
1.9
0
18.3
ME WASH,
( 30 SPM)
( 290 GPM)
LIME SLAKER, AND SEAL WATER
ABSORBENT
LIME/FLY ASH
90X CAO/16-21X CAO AND 5X MGO
PETE LIENE
5 TPD tLIMEJ
SLAKER
20.0
20.0
.0
50.0
20.0
100.0
20.0
50.0
.5
.5
.0
.0
.5
13-684
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
MONTANA POWER: COLSTRIP 1 (CONT.)
SLAKER
EFFLUENT HOLD TANK
RECIRCULATION PUMP
1.0
.5-
1.0
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
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
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
90
98
97
74
96
93
94
88
79
.0
.0
.0
.0
.0
.0
.6
.2
.8
.0
.2
.7
.6
.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
f
19.
42.
59.
63.
65.
57.
49.
26.
0
28.
37.
64.
73.
5
4
2
9
8
4
0
9
0
0
0
8
5
1
** PROBLEMS/SOLUTIONS/COMMENTS
A TEMPERATURE EXCURSION RESULTED IN DAMAGE TO SYSTEM COMPONENTS CAUSING
SYSTEM DOWNTIME.
THE EMERGENCY SCRUBBER QUENCH WATER SUPPLY SYSTEM FAILED TO OPERATE
DURING A TEMPERATURE EXCURSION RESULTING IN INTERNAL DAMAGE.
THE LININGS 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
92.5 744 744 72.9
95.4. 672 48 3.0
.0 -0 744 0 0 .0
83.0 720 600 49.9
85.4 744 624 64.1
87.4 720 672 68.6
1/77 SYSTEM
2/77 SYSTEM
3/77 SYSTEM
4/77 SYSTEM
5/77 SYSTEM
6/77 SYSTEM
13-685
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
MONTANA POWER: COLSTRIP 1 (CONT.)
PERIOD
7/77
B/77
9/77
10/77
11/77
12/77
1/78
2/78
3/78
4/78
5/78
MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
85. 1
93.3
92.5
95.6
96.3
98.3
95.7
99.5
92.0
99.8
66.0
744 696 71.8
744
720
744
720
744
744
672
744
720
1.3 744 10
** PROBLEMS/SOLUTIONS/COMMENTS
6/78
ins,
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
89.7
95.2
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.
720
744
744
720
744
720
744
744
672
744
80.Z 720 597
744
720
88.4
** PROBLEMS/SOLUTIONS/COMMENTS
7/79 SYSTEM
98.0
DURING MAY AND JUNE THE UNIT WAS BEING OVERHAULED. THE AVAILABILITY FOR
THESE PERIODS IS BASED UPON OPERATIONS BEFORE AND AFTER OVERHAUL.
744
13-686
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
MONTANA POWER: COLSTRIP 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
502 PART. HOURS HOURS HOURS FACTOR
8/79 SYSTEM 97.3 744
9/79 SYSTEM 95.2 720
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
FCR THE MONTHS OF AUGUST AND SEPTEMBER.
10/80 96.2
13-6M7
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
MONTANA POWER: COLSTRIP 1 (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 7. REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
SYSTEM
11/80
SYSTEM
12/80
98.2
99.0
744
720
SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED NO MAJOR FGD PROBLEMS DURING THE FOURTH QUARTER 1980.
1/81 SYSTEM 96.0 744
2/81 SYSTEM 97.4 672
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JANUARY-FEBRUARY THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED
PROBLEMS WERE ENCOUNTERED.
3/81 SYSTEM 99.8 744
4/81 SYSTEM 96.6 720
5/81 SYSTEM 97.1 744
6/81 SYSTEM .0 720 0
** PROBLEMS/SOLUTICNS/COMMENTS
DURING JUNE THE BOILER WAS OUT OF SERVICE FOR A SCHEDULED OVERHAUL. DURING
THIS TIME ROUTINE PATCHING WAS PERFORMED ON THE FGD SYSTEM.
7/81 SYSTEM 99.3 744
8/61 SYSTEM 99.2 744
9/81 SYSTEM 96.9 720
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE THIRD QUARTER NO FGD-RELATED PROBLEMS WERE ENCOUNTERED.
10/81 SYSTEM 98.4 744
11/81 SYSTEM 92.8 720
12/81 SYSTEM 96.9 744
** PROBLEMS/SOLUTIONS/COMMENTS
DURING THE FOURTH QUARTER THE UTILITY REPORTED THAT NO PROBLEMS WERE
ENCOUNTERED WITH THE FGD SYSTEM.
1/82 SYSTEM 92.8 744
2/82 SYSTEM .0 672
3/82 SYSTEM .0 744
13-688
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
MONTANA POWER: COLSTRIP 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
DURING FEBRUARY AND MARCH THE UNIT AND THE FGD SYSTEM WERE TAKEN OFF-LINE
FOR AN ANNUAL OVERHAUL.
4/82 SYSTEM 720
5/82 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
DURING APRIL AND MAY THE UNIT AND FGD SYSTEM WERE OFF-LINE FOR SCHEDULED
MAINTENANCE.
6/82 SYSTEM 98.5 720
7/82 SYSTEM 94.2 744
8/82 SYSTEM 91.0 744
9/82 SYSTEM 97.3 720
10/82 SYSTEM 93.8 744
11/82 SYSTEM 89.5 720
12/82 SYSTEM 94.7 744
1/83 SYSTEM 97.5 744
2/83 SYSTEM 96.7 672
3/83 SYSTEM 97.8 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO FGD-RELATED PROBLEMS WERE ENCOUNTERED DURING
THE LAST TEN MONTHS OF OPERATION. DURING THIS PERIOD OF TIME THE AVERAGE
FGD SYSTEM AVAILABILITY WAS 95.1 PERCENT.
4/83 SYSTEM 87.0 720
5/83 SYSTEM .0 744
6/83 SYSTEM .0 720
#* PROBLEMS/SOLUTIONS/COMMENTS
DURING MAY AND JUNE THE UNIT AND THE FGD SYSTEM WERE TAKEN OFF-LINE FOR
A SCHEDULED SPRING OVERHAUL.
7/83 SYSTEM 744
«* PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE MONTH OF JULY.
8/83 SYSTEM 95.6 744
9/83 SYSTEM 90.0 720
13-689
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER
MONTANA POWER: COLSTRIP 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
NO MAJOR F6D-RELATED PROBLEMS WERE ENCOUNTERED DURING AUGUST AND
SEPTEMBER.
10/83 SYSTEM 744
11/83 SYSTEM 720
12/83 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE FOURTH QUARTER OF 1983.
1/84 SYSTEM 92.9 744
2/84 SYSTEM 90.6 696
3/84 SYSTEM 93.9 744
»* FROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR FGD-RELATED OUTAGES WERE REPORTED DURING THE FIRST QUARTER OF 1984
4/84 SYSTEM 98.4 720
5/84 SYSTEM 96.9 744
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR FGD-RELATED OUTAGES WERE REPORTED DURING APRIL AND MAY 1984.
6/84 SYSTEM 720
7/84 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
A SCHEDULED OVERHAUL WAS MADE DURING JUNE AND JULY 1984.
8/84 SYSTEM 744
9/84 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR AUGUST AND SEPTEMBER 1984.
13-690
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
SECTION 13
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 - V.
RANGE MOISTURE CONTENT - V.
AVERAGE SULFUR CONTENT - 7.
RANGE SULFUR CONTENT - 7.
AVERAGE CHLORIDE CONTENT - 7.
RANGE CHLORIDE CONTENT - 7.
*** PARTICLE CONTROL
** MECHANICAL COLLECTOR
NUMBER
TYPE
*# ESP
NUMBER
TYPE
** PARTICLE SCRUBBER
NUMBER
NUMBER OF SPARES
INITIAL START-UP DATE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON NAME
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
PH CONTROL ADDITIVE
PRESSURE DROP - KPA
SUPERFICIAL GAS VELOCITY - M/S
.100 LB/MMBTU)
1.200 LB/MMBTU)
.700 LB/MMBTU)
MONTANA POWER
COLSTRIP
2
COLSTRIP
MONTANA
D
43. (
516. (
301. (
664
360
332
344
360
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
674.82 (1430000 ACFM)
143.9 ( 291 F)
153. ( 503 FT)
CONCRETE
5.0 ( 16.5 FT)
COAL
SUBBITUMINOUS
20569.
8.60
6.1-12.6
23.90
21.0-25.0
.78
0.4-1.0
.01
( 8843 BTU/LB)
8162-8897
0
NONE
0
NONE
3
0
5/76
VENTURI TOWER
VARIABLE-THROAT/TOP-ENTRY PLUMB BOB
N/A
THYSSEN/CEA
15.0 DIA
CARBON STEEL
AISI 1110
INORGANIC
PREFIRED BRICK/SHAPES
NONE
1
415.8 ( 6600 GPM)
1.8 (13.8 GAL/1000ACF)
LIME/ALKALINE FLY ASH
4.2 (17.0 IN-H20)
61.0 ( 200.0 FT/S)
13-691
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
MONTANA POWER: COLSTRIP 2 (CONT.)
INLET GAS FLOW RATE - CU.M/S 225.1
INLET GAS TEMPERATURE - C 143.9
PARTICLE REMOVAL EFFICIENCY - 7. 99.5
*** FGD SYSTEM
( 477000 ACFM)
( 291 F)
** 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
ENERGY CONSUMPTION - X
CURRENT STATUS
COMMERCIAL START-UP
INITIAL START-UP
CONTRACT AKARDED
** DESIGN AND OPERATING PARAMETERS
DESIGN COAL SULFER CONTENT - X
DESIGN COAL HEAT CONTENT - J/G
DESIGN COAL ASH CONTENT - X
DESIGN MOISTURE CONTENT - X
DESIGN CHLORIDE CONTENT - X
OPER. & MAINT. REQUIREMENT - MANHR/DAY
** QUENCHER/PRESATURATOR
NUMBER
** 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
L/G RATIO - L/CU.M
GAS-SIDE PRESSURE DROP - KPA
SUFERFICAL GAS VELOCITY - M/SEC
INLET GAS FLOW - CU. ft/5
INLET GAS TEMPERATURE - C
S02 REMOVAL EFFICIENCY - X
PARTICLE REMOVAL EFFICENCY - X
*« MIST ELIMINATOR
PP.E-MIST ELIMINATOR/MIST ELIMINATOR
NUMBER PER SYSTEM
NUMBER OF SPARES PER SYSTEM
NUMBER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
MANUFACTURER
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES PER STAGE
THROWAWAY PRODUCT
WET SCRUBBING
LIME/ALKALINE FLYASH
NONE
THYSSEN/CEA
BECHTEL
FULL SCALE
NEW
X 99.50
60.00
3.3
1
10/76
5/76
10/72
( 8162 BTU/LB)
1.00
18984.8
12.60
25.00
.01
152.0
3
0
COMBINATION TOWER
VENTURI/SPRAY
N/A
THYSSEN/CEA
35 DIA X 70.5
CARBON STEEL
AISI 1110
N/A
ORGANIC
GLASS FLAKE-FILLED POLYESTER; INERT FLAKE-FILLED
RIGIFLAKE 4850; PLASITE 4020 J 4030
VENTURI THROAT AND SPRAY ZONE
2
( 7600 GPM)
( 17.8 GAL/1000 ACF)
(17.5 IN-H20)
( 9.0 FT/S)
( 426600 ACFM)
( 120 F)
479.
2.4
4.4
2.7
201.31
48.9
80.0
99.5
PRIMARY COLLECTOR
3
0
1
IMPINGEMENT
BAFFLE
CLOSED VANE
HEIL
HORIZONTAL
1
4
13-692
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
MONTANA POWER: COLSTRIP 2 (CONT.)
FREEBOARD DISTANCE - M
DISTANCE BETWEEN VANES - CM
VANE ANGLES - DEGREES
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/S
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
WASH WATER SOURCE
WASH FREQUENCY
WASH RATE - L/S
** REHEATER
NUMBER
NUMBER OF SPARES
NUMBER PER MODULE
GENERIC TYPE
SPECIFIC TYPE
TRADE NAME/COMMON TYPE
LOCATION
PERCENT GAS BYPASSED - AVG
TEMPERATURE INCREASE - C
INLET FLUE GAS FLOW RATE - CU. M/S
INLET FLUE GAS TEMPERATURE - C
OUTLET FLUE GAS TEMPERATURE - C
NUMBER OF HEAT EXCHANGER BANKS
NUMBER OF BUNDLES PER BANK
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
** FANS
NUMBER
NUMBER OF SPARES
DESIGN
SUPPLIER
FUNCTION
APPLICATION
SERVICE
FLUE GAS FLOW RATE - CU.M/S
FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
CONSTRUCTION MATERIAL GENERIC TYPE
«* DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
MODULATION
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
MANUFACTURER
MODULATION
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DAMPERS
NUMBER
FUNCTION
GENERIC TYPE
SPECIFIC TYPE
3.96 (13.0 FT)
2.5 ( 1.00 IN)
120
.1 ( .3 XN-H20)
2.7 ( 8.7 FT/S)
ORGANIC
POLYPHENYLENE
BLENDED
CONTINUOUS UNDERSPRAY AND ONCE/DAY OVERSPRAY
51.1 ( 810 6AL/MIN)
3
0
1
IN-LINE
STEAM
PLATECOIL
IN DUCT AFTER ABSORBER
.0
30.6
201.31
48
55 F)
426600 ACFM)
120 F)
175 F)
.9
79.4
12
11
HIGH ALLOY
NICKEL BASE/CHROMIUM-IRON-COPPER-MOLYBDENUM;
3
0
CENTRIFUGAL
BUFFALO FORGE
UNIT
INDUCED DRAFT
DRY
223.21
79.4
11.0
NIC
473000 ACFM)
175 F)
(36.0 IN-H20)
CARBON STEEL; ORGANIC
SHUT-OFF
BUTTERFLY
N/A
ALLIS-CHALMERS
OPEN/CLOSED
CARBON STEEL
AISI 1110
NONE
N/A
SHUT-OFF
GUILLOTINE
SIDE-ENTRY GUILLOTINE
MOSSER
OPEN/CLOSED
STAINLESS STEEL
AUSTENITIC
NONE
N/A
6
CONTROL
LOUVER
PARALLEL BLADE MULflLOUVER
13-693
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
MONTANA POWER: COLSTRIP Z (CONT.)
MANUFACTURER
MODULATION
CONSTRUCTION MATERIAL GENERIC TYPE
CONSTRUCTION MATERIAL SPECIFIC TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
CONFIGURATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
BUFFALO FORGE
VARIOUS
CARBON STEEL
AISI 1110
NONE
N/A
INLET
CIRCULAR
CARBON STEEL
AISI 1110
NONE
N/A
*« DUCTWORK
LOCATION
CONFIGURATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** DUCTWORK
LOCATION
CONFIGURATION
SHELL GENERIC MATERIAL TYPE
SHELL SPECIFIC MATERIAL TYPE
LINER GENERIC MATERIAL TYPE
LINER SPECIFIC MATERIAL TYPE
** REAGENT PREPARATION EQUIPMENT
FUNCTION
DEVICE
MANUFACTURER
NUMBER
NUMBER OF SPARES
PRODUCT QUALITY - 7. SOLIDS
** TANKS
SERVICE
VENTURI S. ABSORBER RECYCLE
SLUSHY TRANSFER
SLURRY STORAGE
EFFLUENT BLEED
TRAY WASH WATER RECYCLE
** PUMPS
SERVICE
VENTURI RECIRCULATION
ABSORBER RECIRCULATION
POND RETURN
LIME SYSTEM
EFFLUENT BLEED
TRAY WASH WATER RECYCLE
** SOLIDS CONCENTRATING/DEWATERING
DEVICE
*** SLUDGE
OUTLET
RECTANGULAR
CARBON STEEL
AISI 1110
ORGANIC
GLASS FLAKE-FILLED POLYESTER
REHEATER
RECTANGULAR
STAINLESS STEEL
AUSTENITIC
NONE
N/A
SLAKER
PASTE
BIF
Z
1
10.0
NUMBER
NUMBER
6
6
3
**«#
2
2
NONE
** TREATMENT
METHOD
DEVICE
PROPRIETARY PROCESS
BLEED
N/A
N/A
13-694
-------
MONTANA POWER: COLSTRIP 2 (CONT.)
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 198*
#* DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE TREATMENT
SITE DIMENSIONS
SITE CAPACITY - CU.M
SITE SERVICE LIFE - YRS
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE TREATMENT
SITE DIMENSIONS
SITE CAPACITY - CU.M
SITE SERVICE LIFE - YRS
** DISPOSAL
NATURE
TYPE
LOCATION
SITE TRANSPORTATION METHOD
SITE TREATMENT
SITE DIMENSIONS
SITE CAPACITY - CU.M
SITE SERVICE LIFE - YRS
** PROCESS CONTROL AND INSTRUMENTATION
PROCESS STREAM
CHEMICAL PARAMETERS
PHYSICAL VARIABLES
CONTROL LEVELS
MONITOR LOCATION
PROCESS CONTROL MANNER
PROCESS CHEMISTRY MODE
** WATER BALANCE
WATER LOOP TYPE
EVAPORATION WATER LOSS - LITER/S
POND SEEPAGE/RUNOFF WATER LOSS - LITERS/S
MAKEUP WATER ADDITION - LITERS/S
SOURCE OF MAKEUP WATER
** CHEMICALS AND CONSUMPTION
FUNCTION
NAME
PRINCIPAL CONSTITUENT
SOURCE/SUPPLIER
CONSUMPTION
POINT OF ADDITION
** FGD SPARE CAPACITY INDICES
SCRUBBER - 7.
ABSORBER - X
MIST ELIMINATOR - X
REHEATER - X
FAN X
SLAKER - X
EFFLUENT HOLD TANK - X
RECIRCULATION PUMP - X
** FGD SPARE COMPONENT INDICES
SCRUBBER
AESC-PEER
MIST ELIMINATOR
REHEATER
FAN
INTERIM
POND
ON-SITE
PIPELINE
CLAY LINING EBENTONITE3
15 ACRE/20-30 FEET DEEP
5503SO ( 450.0 ACRE-FT)
3
INTERIM
POND
ON-SITE
PIPELINE
CLAY LINING [BENTONITE1
15 ACRE/20-30 FEET DEEP
550350 ( 450.0 ACRE-FT)
3
FINAL
POIID
ON-SITE
PIPELINE
CLAY LINING [BENTONITE]
150 ACRE/20-30 FEET DEEP
5503500 ( 4500.0 ACRE-FT)
10
RECIRCULATING SLURRY
PH
X SOLIDS, FLOW, PRESSURE
PH 4.5 TO 5.5
RECIRCULATION TANK
MANUAL
FEEDBACK
CLOSED
1.9
0
18.3
{ 30 GPM)
( 290 GPM)
ME WASH, LIME SLAKER, AND SEAL WATER
ABSORBENT
LIME/FLY ASH
90X CAO/16-21X CAO AND 5X MGO
PETE LIENE
5 TPD [LIME]
SLAKER
20.0
20.0
50.0
20.0
100.0
20.0
50.0
.5
.5
.0
.0
.5
13-695
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
MONTANA POWER: COLSTRIP 2 (CONT.)
SLAKER 1-0
EFFLUENT HOLD TANK .5
RECIRCULATION PUMP 1.0
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
SYSTEM
SYSTEM
SYSTEM
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 7, 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
364
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.IX 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
13-696
-------
UTILITY FGO SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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
REPAIRS DURING THE BOILER OVERHAUL, THE AVAILABILITY COMES TO 93.8X.
SYSTEM 86.9 720
** 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 96.57..
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 WAS 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
THE ROUTINE MAINTENANCE CAN BE PERFORMED
SO THE AVAILABILITY REMAINS HIGH.
95.8
92.7
98.1
WHILE THE MODULES ARE ON
744
744
696
LINE
13-697
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 198*
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
3/80 SYSTEM 98.2 744
** 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/SOLUTIONS/COMMENTS
NO AVAILABILITY DATA WERE 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 WERE 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-RELATED PROBLEMS WERE ENCOUNTERED
DURING THE MONTHS OF AUGUST AND SEPTEMBER.
10/80 96.0
SYSTEM 744
11/80 96.1
SYSTEM 720
12/80 92.4
SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED NO MAJOR FGD PROBLEMS DURING THE FOURTH QUARTER 1980.
1/81 SYSTEM 97.5 744
2/81 SYSTEM 97.4 672
** PROBLEMS/SOLUTIONS/COMMENTS
DURING JANUARY AND FEBRUARY NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED.
3/81 SYSTEM 98.0 744
4/81 SYSTEM 94.5 720
5/81 SYSTEM .0 744
13-698
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
MONTANA POWER: COLSTRIP Z (CONT.)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
502 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MAY THE BOILER WAS OUT OF SERVICE FOR A SCHEDULED OVERHAUL. DURING
THIS TIME ROUTINE PATCHING WAS PERFORMED ON THE FGD SYSTEM.
6/81 SYSTEM 99.3 720
7/81 SYSTEM 98.4 744
8/81 SYSTEM 96.7 744
9/81 SYSTEM 94.2 720
** PROBLEMS/SOLUTIONS/COMMENTS
DURING MAY THE BOILER WAS OUT OF SERVICE FOR A SCHEDULED OVERHAUL. DURING
DURING THE THIRD QUARTER NO FGD-RELATED PROBLEMS WERE ENCOUNTERED.
10/81 SYSTEM 98.0 744
11/81 SYSTEM 92.6 720
12/81 SYSTEM 96.1 744
#* PROBLEMS/SOLUTIONS/COMMENTS
DURING THE FOURTH QUARTER THE UTILITY REPORTED THAT NO PROBLEMS WERE
ENCOUNTERED WITH THE FGD SYSTEM.
1/82 SYSTEM 92.5 744
2/82 SYSTEM 93.1 672
3/82 SYSTEM 744
»* PROBLEMS/SOLUTIONS/COMMENTS
DURING MARCH THE UNIT AND THE FGD SYSTEM WERE TAKEN OUT OF SERVICE FOR AN
ANNUAL OVERHAUL.
4/82 SYSTEM 96.7 720
5/82 SYSTEM 94.9 744
** PROBLEMS/SOLUTIONS/COMMENTS
DURING APRIL AND MAY THE UTILITY REPORTED THAT NO MAJOR FGD-RELATED
PROBLEMS WERE EXPERIENCED.
6/82 SYSTEM 90.0 720
7/82 SYSTEM 95.0 744
8/82 SYSTEM 97.8 744
9/82 SYSTEM 96.0 720
10/82 SYSTEM 96.2 744
11/82 SYSTEM 93.4 720
12/82 SYSTEM 97.0 744
13-699
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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
1/83 SYSTEM 94.8 744
2/83 SYSTEM 99.9 672
3/83 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
THE UTILITY REPORTED THAT NO FGD-REUTED PROBLEMS WERE ENCOUNTERED DURING
THE LAST SEVEN MONTHS OF OPERATION. DURING THIS PERIOD OF TIME THE AVERAGE
FGD SYSTEM AVAILABILITY WAS 95.1 PERCENT.
THE UTILITY REPORTED THAT NO FGD-RELATED PROBLEMS WERE ENCOUNTERED DURING
THE FIRST QUARTER 1983. THE UNIT WAS SHUTDOWN IN MARCH FOR A SCHEDULED
YEARLY SPRING OVERHAUL.
4/83 SYSTEM .0 720
5/83 SYSTEM 98.4 744
6/83 SYSTEM 99.1 720
** PROBLEMS/SOLUTIONS/COMMENTS
THE SPRING OVERHAUL ENDED IN APRIL AND THE UNIT AND FGD SYSTEM WERE
PLACED BACK INTO SERVICE. THE UTILITY REPORTED THAT HO MAJOS FGD-RELATED
PROBLEMS WERE ENCOUNTERED DURING THE REMAINDER OF THE SECOND QUARTER.
7/83 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE MONTH OF JULY.
8/83 SYSTEM 97.1 744
9/83 SYSTEM 97.0 720
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR FGD-RELATED PROBLEMS WERE ENCOUNTERED DURING AUGUST AND
SEPTEMBER.
10/83 SYSTEM 744
11/83 SYSTEM 720
12/83 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR THE FOURTH QUARTER OF 1983.
1/84 SYSTEM 90.4 744
2/84 SYSTEM 97.0 696
3/84 SYSTEM 95.1 744
13-700
-------
UTILITY FGD SURVEY: OCTOBER 1983 - SEPTEMBER 1984
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
NO MAJOR FGD-RELATED OUTAGES WERE REPORTED DURING THE FIRST QUARTER OF 1984
4/84 SYSTEM 720
5/84 SYSTEM 744
6/84 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
A SCHEDULED OVERHAUL WAS MADE DURING THE ENTIRE SECOND QUARTER OF 1984.
7/84 SYSTEM 100.0 744
** PROBLEMS/SOLUTIONS/COMMENTS
NO MAJOR FGD-RELATED PROBLEMS WERE REPORTED DURING JULY.
8/84 SYSTEM 744
9/84 SYSTEM 720
*» PROBLEMS/SOLUTIONS/COMMENTS
INFORMATION WAS UNAVAILABLE FOR AUGUST AND SEPTEMBER 1984.
13-7C1
-------
TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing)
1. REPORT NO,
EPA 340/1-85-014b
3. RECIPIENT'S ACCESSION NO.
4. TITLE AND SUBTITLE
Utility FGD Survey
October 1983 - September
Volume 2, Part 1
3. REPORT DATE
October 1984
1984
6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
8. PERFORMING ORGANIZATION REPORT NO,
M.T. Melia, R.S. McKibben, B.W. Pelsor
9. PERFORMING ORGANIZATION NAME AND ADDRESS
PEDCo Environmental, Inc.
11499 Chester Poad
Cincinnati, OH 45246-0100
10. PROGRAM ELEMENT NO.
11. CONTRACT/GRANT NO.
68-02-3963, Task No. 46
12. SPONSORING AGENCY NAME AND ADDRESS
U.S. Environmental Protection Agency
Stationary Source Compliance Division (EN-341)
401 M Street, S.W.
Washington, D.C. "20460
13. TYPE OF REPORT AND PERIOD COVERED
Final, Oct. 1983-Sept. 1984
14. SPONSORING AGENCY CODE
15. SUPPLEMENTARY NOTES
Summarized in EPA 340/1-85-014 - Utility FGD Survey Summary
EPA Task Manager - Sonva Stelmack (202) 382-2851
16. ABSTRACT
This report, which is generated by a computerized data base system,
represents a survey of operational and planned domestic utility flue gas
desulfurization (FGD) system. The three volume set summarizes information
contributed by the utility industry, system and equipment suppliers, system
designers, research organizations, and regulatory agencies. The data cover system
design, fuel characteristics, operating history, and actual system performance.
Also included is a unit-by-unit discussion of problems and solutions associated
with the boilers, scrubbers, and FGD systems.
The development status (operational, under construction, or in the planning
stages), system supplier, process, waste disposal practice, and regulatory class
are tabulated alphabetically by utility company. Simplified process flow diagrams
of FGD systems, definitions, and a glossary of terms are attached to the report.
Current data for domestic FGD systems show 124 systems in operation, 25 systems
under construction, and 68 systems planned. The current FGD-controlled capacity
in the United States is 47,255 JXW.
17.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b-IOENTIFIERS/OPEN ENDED TERMS C. COSATI Field/Group
18. DISTRIBUTION STATEMENT
Release unlimited
19. SECURITY CLASS (This Report)
unclassified
21. NO. OF PAGES
20. SECURITY CLASS /This page/
unclassified
22. PRICE
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