&EPA
United States
Environmental Protection
Agency
Industrial Environmental Research EPA-600/7-79-022c
Laboratory May 1979
Research Triangle Park NC 2771 1
EPA Utility FGD Survey:
December 1978 -
January 1979
Interagency
Energy/Environment
R&D Program Report
-------
RESEARCH REPORTING SERIES
Research reports of the Office of Research and Development, U.S. Environmental
Protection Agency, have been grouped into nine series. These nine broad cate-
gories were established to facilitate further development and application of en-
vironmental technology. Elimination of traditional grouping was consciously
planned to foster technology transfer and a maximum interface in related fields.
The nine series are:
1. Environmental Health Effects Research
2. Environmental Protection Technology
3. Ecological Research
4. Environmental Monitoring
5. Socioeconomic Environmental Studies
6. Scientific and Technical Assessment Reports (STAR)
7. Interagency Energy-Environment Research and Development
8. "Special" Reports
9. Miscellaneous Reports
This report has been assigned to the INTERAGENCY ENERGY-ENVIRONMENT
RESEARCH AND DEVELOPMENT series. Reports in this series result from the
effort funded under the 17-agency Federal Energy/Environment Research and
Development Program. These studies relate to EPA's mission to protect the public
health and welfare from adverse effects of pollutants associated with energy sys-
tems. The goal of the Program is to assure the rapid development of domestic
energy supplies in an environmentally-compatible manner by providing the nec-
essary environmental data and control technology. Investigations include analy-
ses of the transport of energy-related pollutants and their health and ecological
effects; assessments of, and development of, control technologies for energy
systems; and integrated assessments of a wide range of energy-related environ-
mental issues.
EPA REVIEW NOTICE
This report has been reviewed by the participating Federal Agencies, and approved
for publication. Approval does not signify that the contents necessarily reflect
the views and policies of the Government, nor does mention of trade names or
commercial products constitute endorsement or recommendation for use.
This document is available to the public through the National Technical Informa-
tion Service, Springfield, Virginia 22161.
-------
EPA-600/7-79-022C
May 1979
EPA Utility FGD Survey:
December 1978 - January 1979
by
M. Smith, M. Melia, T. Koger,
R, McKibben, and J. Uihlein
PEDCo. Environmental, Inc.
11499 Chester Road
Cincinnati, Ohio 45246
Contract No. 68-02-2603
Task No, 48
Program Element No. EHE624
EPA Project Officers:
N. Kaplan J.C. Herlihy
Industrial Environmental Research Laboratory Division of Stationary Source Enforcement
Office of Energy, Minerals, and Industry Office of Enforcement
Research Triangle Park, NC 27711 Washington, DC 20460
Prepared for
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Research and Development
Washington, DC 20460
-------
NOTICE
This report, (prepared by PEDCo Environmental, Inc., Cincin-
nati, Ohio, under EPA Contract No. 68-02-2603, Task No. 48) is
provided as an information transfer document. Data in this
report are supplied voluntarily by utility representatives; flue
gas desulfurization (FGD) system designers, and suppliers; regu-
latory personnel; and others. Neither EPA nor the designated
contractor warrants the accuracy or completeness of information
contained in this report.
This report is the first in a series of four issues. The
succeeding three issues will be supplemental in nature. It is
suggested that the, user retain this issue for reference
throughout the year, because much of the information contained in
this report~will not be published again until around March 1980.
Supplemental issues wTTi be cumulative, so that it will be neces-
sary only to retain the latest issue and this report to have all
available information.
Initial distribution of the report (generally, one copy per
company) is limited to organizations and individuals indicating a
specific interest in the field of FGD technology. Additional
copies of this report and succeeding issues can be purchased from
National Technical Information Service, Springfield, Virginia
22151.
ii
-------
CONTENTS
Notice
Tables
Executive Summary and Highlights
Section I Summary List of FGD Systems
Section 2 Status of FGD Systems
Section 3 Design and Performance Data for Operational
FGD Systems
Alabama Electric
Tombigbee 2
Arizona .Electric Power
Apache 2
Arizona Public Service
Cholla 1
Choila 2
Central Illinois Light
Duck Creek 1
Columbus and Southern Ohio Electric
Conesville 5
Conesville 6
Duquesne Light
Elrama 1™4
Phillips 1-6
Gulf Power
Scholz 1,2
Indianapolis Power and Light
Petersburg 3
Kansas City Power and Light
Hawthorn 3
Hawthorn 4
La Cygne 1
Kansas Power and Light
Jeffrey 1
Lawrence 4
Lawrence 5
Kentucky Utilities
Green River 1-3
Page
ii
vi
vii
1
6
33
33
35
38
51
54
59
67
71
80
95
97
101
109
117
132
135
143
149
iii
-------
CONTENTS (continued)
Page
Louisville Gas and Electric
Cane Run 4 156
Cane Run 5 161
Mill Creek 3 164
Paddy's Run 6 166
Minnkota Power Cooperative
Milton R. Young 2 175
Montana Power
Colstrip 1 180
Colstrip 2 184
Nevada Power
Reid Gardner 1 187
Reid Gardner 2 198
Reid Gardner 3 214
Northern Indiana Public Service
Dean H. Mitchell 11 225
Northern States Power
Sherburne 1 234
Sherburne 2 248
Pennsylvania Power
Bruce Mansfield 1 259
Bruce Mansfield 2 273
Philadelphia Electric
Eddystone 1A 279
Public Service Company of New Mexico
San Juan 1 286
San Juan 2 290
Southern Carolina Public Service Authority
Winyah 2 293
Southern Mississippi Electric
R. D. Morrow 1 296
Springfield City Utilities
Southwest 1 298
Tennessee Valley Authority
Shawnee 10A 306
Shawnee 10B 308
Widows Creek 8 320
Texas Utilities
Martin Lake 1 328
Martin Lake 2 332
Monticello 3 335
Utah Power and Light
Huntington 1 338
Section 4 Summary of FGD Systems by Company 341
Section 5 Summary of FGD Systems by System Supplier 342
IV
-------
CONTENTS (continued)
Page
Section 6 Summary of FGD Systems by Process 344
Section 7 Summary of Operating FGD Systems by Process 345
and Unit
Section 8 Summary of End-Product Disposal Practices 347
for Operational FGD Systems
Section 9 Summary of FGD Systems in Operation 349
Section 10 Summary of FGD Systems Under Construction 351
Section 11 Summary of Contract Awarded FGD Systems 353
Section 12 Summary of Planned FGD Systems 354
Section 13 Total FGD Units and Capacity (MW) Installed 356
by Year
Section 14 Design and Performance Data for Operational 357
Particulate Scrubbers
Appendix A FGD System Cost Data: Operational and
Nonoperational Systems A-l
A-l Major FGD System Equipment Summary A-7
A-2 Cost Element Factors A-12
A-3 Description of Cost A-15
A-4 Categorical Results of Reported and
Adjusted Capital and Annual Costs for
Operational FGD Systems A-18
A-5 Costs for Operational FGD Systems A-19
A-6 Costs for Non-Operational FGD Systems A-23
Appendix B FGD Process Flow Diagrams B-l
Appendix C Definitions C-l
Appendix D Glossary of Units D-l
v
-------
TABLES
No. gage
I Number and Total Capacity of FGD Systems vii
II Summary of Changes, December 1978-January 1979 ix
III Performance of Operational Units, December 1978-
January 1979 , x
VI
-------
EXECUTIVE SUMMARY
This report has been prepared every other month by PEDCo
Environmental, Inc., under contract to the Industrial Environmental
Research Laboratory/Research Triangle Park and the Division of
Stationary Source Enforcement of the U.S. Environmental Protection
Agency. After the February-March 1979 issue, reports will be
issued quarterly (every three months). This is the first issue
generated by a new computerized data base system, the structure
of which is illustrated in Figure 1. This issue differs from the
previous ones in that the scope of design data for operating FGD
systems is vastly expanded, section formats are revised somewhat
and a new section includes operational particulate scrubbers.
Table I summarizes the status of FGD systems in the United States
during December 1978 and January 1979. Table II lists the units
that changed status in this period, and Table III shows the
performance of operating units.
TABLE I. NUMBER AND TOTAL CAPACITY OF FGD SYSTEMS
Status
Operational
Under construction
Planned:
Contract awarded
Letter of intent
Requesting/evaluating bids
Considering only FGD
systems
TOTAL
No. of
Units
46
45
21
2
11
33
158
Total
Controlled
Capacity, MW*
16,842
18,927
11,647
1,100
9,156
17,784
75,456
Equivalent
Scrubbed ...
Capacity, MWT
15,773
16,924
11,071
960
8,268
17,014
70,010
* Total Controlled Capacity (TCC) is the summation of the gross
unit capacities (MW) brought into compliance with FGD systems
regardless of the percent of the flue gas scrubbed by the FGD
system(s).
Equivalent Scrubbed Capacity (ESC) is the summation of the ef-
fective scrubbed flue gas in equivalent MW based on the percent
of the flue gas, scrubbed by the FGD system(s).
vii
-------
Figure 1. Computerized data base structure diagram.
-------
TABLE II. SUMMARY OF CHANGES: FGP SUMMARY REPORT,
DECEMBER 1978 - JANUARY 1979
FOB status report
11/30/78
Allegheny rower
Hitahell 3
Cincinnati Sas & Electric
East Bend 2
Houston Light & rower
rarish 8
Louisville (Us & lleetrio
Srimble county l
Louisville Sas & Xleetrie
Trimble County 2
Middle south Utilities
Arkansas Coal 5
Middle south utilities
Arkansas Coal 6
Middle South Utilities
Louisiana Goal 1
Middle South utilities
Louisiana Coal 2
Middle South utilities
Miieissippi Coal 1
Middle South utilities
Miseiaeippl Coal 2
Northern States power
Sherburne 4
rower Authority of New York
Arthur Kill Plant
Southern California Zdison
Alanltoi 6
Tennessee Valley Authority
Cumberland
Tennessee Valley Authority
Johnsonville
Tennessee Valley Authority
Paradise 1
Tennessee Valley Authority
Paradise 2
Texas Power & Light
Sandow 4
Texas Utilities'
• Mill Creek 1
Texas Utilities
Mill Creek 2
TOTAL*
Operational
No.
46
46
MW*
18,773
15,773
Under
construction
NO,
43
*1
+1
45
MW»
15,892
610
382
16,924
Contract
awarded
No.
20
-1
+1
+1
+1
-1
21
MW*
10,820
6BO
178
704
704
382
11,071
Letter of
Intent
No.
3
• 1
2
MW*
1,820
860
960
Requesting/
evaluating bids
No,
I
+1
•H
+1
+1
.1
+1
+1
+1
-1
-1
11
MW*
3,224
512
810
890
890
890
890
890
600
704
704
8, 268
Considering
only FGD
NO.
27
+1
+1
il
+1
+ 1
-1
tl
+1
33
MW*
13,364
300
S7S
S7S
700
600
600
750
750
17,014
Total
No.
144
+1
+1
+1
+1
•H
+1
+1
tl
+1
+1
-1
+1
+1
+1
+1
+1
158
MW"
60,593
300
112
175
§7S
840
890
890
690
890
890
860
700
175
600
750
750
70,010
Equivalent Scrubbed Capacity (ai a remit of the converaion to equivalent scrubbed capacity valuee, the totals as of
11/30/78 shown above have been modified accordingly and will therefore differ from the totals reported in the
October-November 1978 Summary Report).
3LX
-------
TABLE HI. PERFORMANCE OF OPERATIONAL UNITS
DECEMBER 1978 - JANUARY 1979
Plant
Tomblgbee 2
Apache 2
Choi la 1
Choi la 2
Duck Creek 1
Coneivllle 5
Conesvllle 6
Elrama
Phillips
Scholz 1-2
Petersburg 3
Hawthorn 3
Hawthorn 4
LaCygne
Jeffrey 1
Lawrence 4
Lawrence 6
Green Rivera 1-3
Cane Run 4
Cane Run 8
Mill Creek 3
Paddy 'i Run 6
Milton 8. Young 2
ColstMp 1
Colstrlp 2
Reid Qerdner 1
Reid Gerdner 2
Raid Gardner 3
Dean H. Mitchell 11
Sherburno 1
Sherburna 2
Bruce Manaflald 1
Bruce Mansfield 2
Eddyetone 1A
San Juan 1
San Juan 2
Wlnyah 2
A.O, Morrow 1
Southwest 1
Shiwnte 10A
Shawnet 108
Widows Creek 8
Martin Lake 1
Martin Lake 2
Montlcello 3
Hunting ton 1
TOTAL
FGD system
capacity,
179
180
119
350
416
411
411
510
410
23
532
110
110
874
540
125
420
64
190
200
426
70
405
358
358
125
125
126
116
720
720
917
917
120
361
•350
140
124
194
10
10
650
898
696
800
86(
16,269
Flue gas,
% scrubbed
70
100
100
100
100
100
100
100
100
N/Ad
100
100
100
100
76
100
100
100
100
100
100
100
86
100
100
100
100
100
100
100
100
100
100
N/Ad
100
100
60
62
100
N/A"
N/A"
100
78
76
100
86
FGO capacity
on line
during
'•Jlflj-
179
119
360
416
411
411
610
410
23
532
110
110
874
540
125
420
200
405
358
368
125
125
126
115
720
720
917
917
120
361
360
140
124
194
10
10
595
598
800
866
14,790
No Information
for this
period,
MW
Shut down
through-
out
period,
MW
180
64
190
425
70
550
1,479
FGD system
availability,
Dec.
95
20
20
31
94
53
96
96
100
64
94
97
86
63
Jan.
95
0
0
0
96
70
64
83
66
28
94
93
99
21
FGD system
operabjllty,
Dec.
88
21
18
23
100
46
93
100
100
63
66
34
Jan.
99
0
0
0
100
67
74
61
67
99
25
76
FGD system
reliability,
Dec.
88
21
19
23
46
93
100
100
72
83
86
Jan.
99
0
0
0
67
74
81
6?
28
99
25
FGD system
utilisation,
Dec.
aa
20
15
21
79
74
41
92
13
100
64
82
49
33
Jan.
99
0
0
0
78
72
63
67
74
66
28
99
IB
66
' Equivalent tcrubbed capacity.
' Th1i category Includes tht flue gat capacity being handled by the FGD eyitem at least part of the tint during the report period,
c Tht percent figures listed art ivtrage values for all lyttem scrubbing trtlni during the period.
d Flu* gai % scrubbed for prototype and demonstration unit* 1s not applicable unless the lyitem 1i dulgned to bring a unit Into compliance with
So, emission standards.
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The total power generating capacity of the electric utility
industry in the United States is now approximately 564 GW.
Coal-fired units account for approximately 265 GVr or 47% of this
total. As indicated in Table I, 46 power generating units (all
coal-fired) are now equipped with operating FGD systems. These
units represent a total controlled capacity of 16,842 MW, which
is 3% of the total utility power generating capacity and just
over 6% of the utility coal-fired capacity. Projections indicate
that the total power generating capacity of the U.S. electric
utility industry will be approximately 878 GW by 1988, an in-
crease of 56% over the present total. (This value reflects the
annual loss resulting from the retirement of older units, which
is considered to be 0.4% of the average generating capacity at
the end of each year.) Approximately 395 GW ' ' or 45% of the
1988 total will come from coal-fired units. Of the 158 FGD-
equipped units (75,456 MW) shown in Table I, 156 (74,891 MW) are
scheduled for operation by 1988. Therefore, approximately 8.5%
of the projected total generating capacity and nearly 19% of the
projected coal-fired capacity will be controlled by FGD by the
end of 1988.
HIGHLIGHTS: DECEMBER 1978-JANUARY 1979
The following paragraphs highlight FGD system developments during
December 1978 and January 1979.
Allegheny Power System (APS) plans to install an FGD system on
Mitchell 3, a 300-MW (gross) coal-fired unit located in Courtney,
Pennsylvania. The FGD system is currently scheduled to start up
in August 1982. Design S02 removal efficiency is 95%. APS has
not yet selected a process or system supplier. Bid request and
evaluation will probably commence in September 1979.
Arizona Public Service reported that the Cholla 1 FGD system
remained in service during the report period. The FGD system's
average reliability for December and January was 88 and 99%,
respectively. The boiler was in service 744 hours during each
month.
Cincinnati Gas and Electric reported that construction began on
the utility's 650 MW (Gross) East Bend 2 FGD installation. The
B&W lime slurry system is designed to remove SO, with an 87%
efficiency. A contract was awarded to IUCS for the sludge dis-
posal system.
The Thoroughbred 121 prototype FGD system retrofitted on Gulf
Power's Scholz 1 and 2 units achieved 100% operability during
December and January. The Thoroughbred 121 facility removes S02
and flyash from an effective 23 MW capacity slip stream drawn
from the two 47 MW (gross) Scholz units, chiyoda International,
the system supplier, reported that removal efficiencies for S02
have ranged from 93 to 95%.
XI
-------
Houston Lighting and Power reported that bids are now being
requested for an FGD system planned for W.A. Parish 8, a new
550-MW coal-fired unit scheduled for start up in late 1982. The
utility plans to equip the unit with a fabric filter for partic-
ulate matter control and a wet limestone FGD system for S0~
control.
Kansas City Power and Light reported that the LaCygne 1 FGD
system was in service during the report period, achieving average
system availabilities of 94 and 96% for the months of December
and January, respectively. Unit power production was limited by
a number of boiler-related outages during the period, resulting
in unit service times of 239 and 205 hours for December and
January, respectively.
Louisville Gas and Electric (LG&E) reported that they are plan-
ning a new coal-fired power-generating station for installation
in Bedford, Kentucky. The first two units of this new station,
known as Trimble County, are each 575-MW (gross) pulverized
coal-fired boilers supplied by Combustion Engineering. Each unit
will be equipped with an electrostatic precipitator for the
particulate matter control and an FGD system for SO, control.
LG&E has not yet selected a process or supplier. Trimble County
1 is scheduled to start up in July 1984 and Trimble County 2
sometime in 1986.
Middle South Utilities reported that bid request and evaluation
is now proceeding for six new 890-MW (gross) coal-fired boilers
planned for installation at three separate stations in the util-
ity's power-generating network. These new units are identified
as Arkansas Coal 5 and 6, Louisiana Coal 1 and 2, and Mississippi
Coal 1 and 2. The steam generators are pulverized coal-fired
units supplied by Babcock and Wilcox. Either a low sulfur west-
ern grade of coal or lignite, with an average sulfur content of
0.5%, will be burned in the units. Currently, Middle South
Utilities plans to start up Arkansas Coal 5 and 6 in January 1986
and January 1988, respectively; Louisiana Coal 1 and 2 in January
1986 and January 1988, respectively; and Mississippi Coal 1 and 2
in January 1985 and January 1987.
Nevada Power reported that the FGD systems for Reid Gardner 1, 2,
and 3 were in service during December. FGD system availabilities
for the month were 96, 96, and 100%, respectively.
Northern States Power reported that the FGD system availability
for Sherburne 1 was 94% in both December and January and that the
FGD system availability for Sherburne 2 was 97% in December and
93% in January.
xii
-------
A contract was awarded by SOHIO to Southern California Edison and
Stearns-Roger for the installation of a lime FGD system on
Southern California Edison's Alamitos 6 unit. This contractural
agreement occurred as a result of an "emission offset" program
that may enable SOHIO to build an oil terminal and storage facil-
ity at Long Beach, California. The contract requires Sohio to
supply 100% of the FGD system capital cost and projected operat-
ing costs for a period of 15 years. The FGD system will scrub
approximately one-third of the flue gas generated by the 480-MW
Alamitos 6 unit. Alamitos 6 burns natural gas and oil (0.25%
maximum sulfur content). The utility will use a horizontal spray
tower to remove 95% of the SO, from the inlet gas stream to the
scrubber. Sludge will be dried and trucked to a landfill. The
FGD system is expected to be operating commercially by January
1982.
The Tennessee Valley Authority reported the following information
for their FGD activities at the Cumberland, Johnsonville, and
Paradise stations:
0 TVA is planning to install a 600-MW equivalent FGD system at
their existing 1300-MW (gross) coal-fired Cumberland Sta-
tion. The system will be designed to remove 90% of the
inlet SO-. A process or system supplier has not been an-
nounced. If a lime or limestone system is selected, start
up could occur as early as July 1982.
0 TVA is requesting and evaluating bids for a 600-MW equiva-
lent FGD system at their existing 1450-MW (gross) coal-fired
Johnsonville Station. The system will use regenerable
magnesium oxide scrubbing to remove 90% of the inlet SO,.
The system is scheduled to start up in December 1982.
0 TVA has awarded a contract to Chemico for two limestone FGD
systems for Paradise 1 and 2, two existing coal-fired units
each rated at 704 MW (gross). Each system will include six
scrubber modules, five of which are required for full load.
Design SO. removal efficiency is 84.2%. The systems are
scheduled to start up in 1982.
Texas Air Control Board reported that Texas utilities plans to
install an FGD system on their Mill Creek 1 and 2 lignite-fired
units, located southwest of their Martin Lake station. An FGD
process has not yet been selected for the new 750 MW (gross)
units, but the utility has decided to control particulate matter
with electrostatic precipitators. Currently start-up dates are
scheduled for 1985 and 1986 for units 1 and 3, respectively.
Virginia Electric and Power reported that state SO- emission
requirement revisions will now allow the utility to operate Mt.
Storm station without retrofitting the facility with an FGD
system. The station has been deleted from the Utility FGD Survey
Report.
xiii
-------
Winyah 2 of South Carolina Public Service Authority achieved an
FGD system availability of better than 99% in January. The
boiler operated 744 hours and the FGD system operated 742 hours.
xiv
-------
REFERENCES FOR EXECUTIVE SUMMARY
a. Sixth Biennial Survey of Power Equipment Requirements of the
U.S. Electric Utility Industry: 1977-1986. Sponsored by
the Power Equipment Division, National Electrical Manu-
facturers Association.
b. Temple, Barker, and Sloane, Inc. Policy Testing Model for
Electric Utilities, Exhibit I1-3.
c. Twelth Annual Power Engineering Survey, Power Engineering,
April 1978.
XV
-------
EPA UTILITY F6D SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 1
SUKfARY LIST OF F6D SYSTEMS
COMPANY NAME/
UNIT NAME
ALABAMA ELECTRIC COOP
TOMBIGBEE
TOMBIGpfE
ALLEGHENY POWER SYSTEM
MITCHELL
PLEASANTS
PLEASANTS
ARIZONA ELECTRIC POWER COCP
APACHE
APACHE
ARIZONA PUfeLIC SfHVlCt
CHOLLA
CHOLLA
CHOLLA
FOUR CORNERS
FOUR CORNERS
FOUR CORNERS
FOUR CORNERS
FOUR CORNERS
ASSOCIATED ELECTRIC COOP
THOMAS HILL
BASIN ELECTRIC POWER COOP
ANTELOPE VALLEY
ANTELOPE VALLEY
LARAMIi RIVER
LARAftlE RIVER
LARAMIE RIVER
616 RIVERS ELECTRIC
GREEN
GREEN
CENTRAL ILLINOIS LIGHT
eUCK CREEK
DUCK CREEK
CENTRAL ILLINOIS PUBLIC SEftV
NEWTON
CENTRAL MAINE POWER
SEARS ISLAND
CINCINNATI GAS t ELECTRIC
EAST BEND
COLORADO UTE ELECTRIC ASSK.
CRAIG
CRAIG
COLUMBUS t SOUTHERN OHIO ELECc
CONESVILLE
CONESVILLE
POSTON
POSTON
UNIT Nf.
2
3
3
1
2
2
3
1
2
4
1
2
3
4
S
3
1
2
1
2
3
1
2
1
2
1
1
2
1
2
»
5
6
5
6
UNIT LOCATION
LERCt
LEROY
COURTNEY
BELKONT
BELMONT
COCHISE
COCHISE
JOSEPH CITY
JOSEPH CITY
JOSEPH CITY
FARMINETON
FARMIN6TON
FASMINGTON
FAROINGTON
FARMINGf ON
MOBF.RLY
BEULAH
BEULAH
WHEATLAND
WHEATLAND
WHEATLAND
SEBREE
SEBREE
CANTON
CANTON
NEWTON
PENOBSCOT BAY
RABBITHASH
CRAIG
CRAIG
CONESVILLE
CONESVILLE
ATHENS
ATHENS
ALABAMA
ALAPAMA
PENNSYLVANIA
WEST VIRGINIA
WEST VIRGINIA
A" nONA
ARIZONA
ARIZONA
ARIZONA
ARIZONA
NEW MEXICO
NEW MEXICO
NEW MEXICO
NPW MEXICO
NEW MEXICO
MISSOURI
NORTH DAKOTA
NORTH DAKOTA
WYOMING
WYGWING
WYOMING
KENTUCKY
KENTUCKY
ILLINOIS
ILLINOIS
ILLINOIS
MAINE
KENTUCKY
COLORADO
COLORADO
OHIO
OHIO
OHIO
OHIO
START-UP
DATE
9/78
6/79
8/82
3/79
3/80
e/78
4/79
10/73
4/78
6/80
0/79
0/79
C/79
Q/S2
0/82
1/82
11/81
11/83
4/80
10/80
4/82
12/79
12/80
7/76
1/84
11/79
11/87
10/81
3/79
3/79
1/77
6/78
0/83
0/85
STATUS
1
2
6
2
2
1
2
1
1
2
Z
2
2
3
3
3
3
6
2
2
3
2
2
1
5
2
6
2
2
2
1
1
6
6
REG
CLASS
A
A
B
A
A
B
B
B
(1
t>
e
e
e
e
e
A
e
e
A
A
A
•A
A
A
A
A
A
A
B
B
e
e
B
e
1. OPERATIONAL UNITS
2. UNITS UNDER CONSTRUCTION
3. PLANNED - CONTRACT AWARDED
4. PLANNED - LETTER OF INTENT SI6NFD
5. PLANNED - REQUESTING/EVALUATING BIDS
6. PLANNED - CONSIDERING ONLY F60 SYSTEMS
7. PLANNED - CONSIDERING F6D SYSTEMS; ALSO ALTERNATIVE METHODS
A. BOILER CONSTRUCTED SUBJECT TO FEDERAL NSPS
E" BOILER SUBJECT TO STATE STANDARD THAT IS MORE STRINGENT THAN THE FEDERAL NSPS
C. BOILER SUBJECT TO STATE STANDARD THAT IS E8UAL TO OR LESS STRINGENT THAN NSPS
0. OTHER
E. REGULATORY CLASS UNKNOWN
-------
EPA UTILITY F6D SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 1
SUWARY LIST OF FGD SYSTEMS
COMPANY NAME/
UNIT NAPE
COMMONWEALTH EDISON
POWERTON
COOPERATIVE poWER ASSOCIATION
COAL CREEK
COAL CREEK
DELMARVA POWER & LIGHT
DELAWARE CITY
DU8UESNE LI6HT
ELRANA
PHILLIPS
EAST KENTUCKY POWER COOP
SPURLOCK
GENERAt PUBLIC UTILITIES
COHO
SEWARD
GULF POWER
SCHOL7.
HCOSUR ENERGY
MEBOW
MEROIH
HOUSTON LIGHTING ft POWER CO.
W.A. PARISH
INDIANAPOLIS POWER * LIGHT
PETERSBURG
PETERSBURG
KANSAS CITY POWER 8 LIGHT
HAWTHORN
HAWTHORN
LA CY6NE
KANSAS POWER & LIGHT
JEFFREY
JEFFREY
LAWRENCE
KENTUCKY UTILITIES
GREEN RIVER
LAKELAND UTILITIES
HC IK TOSH
LOUISVILLE CAS t ELECTRIC
CANE RUN
CANE RUN
CANE PUN
MILL CRfcEK
MILL CREEK
MILL CREEK
MILL CREEK
. PADDY'S RUN
1. OPERATIONAL UNiTS
?. UNITS UNDER CONSTRUCTION
i. PLANNED - CONTRACT AWARDED
UNIT NC. UNIT LOCATION
51
1
2
1-2
1-t
2
1
7
1.2
1
2
e
3
4
3
t
1
1
2
4
5
1-3
3
4
5
1
2
3
6
si
6.
7.
PERKIN
UNDERWOOD
UNDERWOOD
DELAWARE ClT^
' ELRAMA
SOUTH HEIGHT
WAYSV1LLI-
ERIE
SEWARD
CHATTAHOOCHEE
SULLIVAN
SULLIVAN
BOOTH
PETERSBURG
PETERSBURG
KANSAS CITY
KANSAS CITY
LA CY6NE
NAME: 60
LAWRENCE
LAWRENCE
CENTRAL CITY
LAKELAND
LOUISVILLE
LOUISVILLE
LOUISVILLE
LOUISVILLE
LOUISVILLE
LOUISVILLE
LOUISVILLE
LOUISVILLE
ILLINOIS
NORTH DAKOTA
NORTH DAKOTA
DELAWARE
PENNSYLVANIA
PENNSYLVANIA
KENTUCKY
PENNSYLVANIA
PENNSYLVANIA
FLORIDA
INDIANA
INDIANA
TEXAS
INDIANA
INDIANA
MISSOURI
MISSOURI
KANSAS
KANSAS
KANSAS
KASTSAS
KANSAS
KENTUCKY
FLCRIDA
KENTUCKY
KENTUCKY
KENTUCKY
KENTUCKY
KENTUCKY
KENTUCKY
KENTUCKY
KENTUCKY
START-UP R|!-6
DATE STATUS CLASS
7/79
5/79
10/80
4/80
10/75
7/73
3/80
5/88
5/85
8/78
4/81
1/82
10/82
12/77
10/83
11/72
8/72
2/73
6/78
6/80
1/76
11/71
9/75
10/81
12/77
3/79
A/81
4/82
8/78
7/81
4/73
2
2
2
2
1
1
3
6
6
1
2
2
5
1
2
1
1
1
1
2
1
1
1
3
1
1
2
2
3
1
2
1
PLANNED - LETTER OF INTENT SIGNED
PLANNED - REQUESTING/EVALUATING BIDS
PUNNED - CONSIDERING ONLY FGD SYSTEMS
PLANNED - CONSIDERING FSD SYSTEMS* ALSO ALTERNATIVE
C
A
A
C
B
e
A
A
A
C
A
A
A
A
A
B
B
C
B
B
B
C
A
A
A
A
B
B
B
B
C
METHODS
A. BOILER CONSTRUCTED SUBJECT TO flBIRAl NSPS
B BOILER SUBJECT TO STATE STANDARD THAT IS MORI STRINGENT THAN THI FEDERAL NSP!
tl llllll SUBJICT TO STATE STANDARD THAT IS EQUAL TO OR LISS STRINSBNT THAN NSPS
D. OTHER
t. REGULATORY CLASS UNKNCWN
-------
EPA UTILITY F6D SURVEY; DECEMBER 1978 - JANUARY 1979
SECTION 1
SUMMARY LIST OF FGD SYSTEMS
COMPANY KANE/
UNIT NA«£
LOUISVILLE GAS I ELECTRIC
TRIABLE COUNTY
TRIMBLE COUNTY
MIDDLE SOUTH UTILITIES
ARKANSAS COAL
ARKANSAS COAL
LOUISIANA COAL
LOUISIANA COAL
MISSISSIPPI COAL
MISSISSIPPI COAL
UNIT Nt. UNIT LOCATION
1 BEDFORD
2 BEDFORD
5
6
1
2
1
2
KENTUCKY
KENTUCKY
ARKANSAS
ARKANSAS
LOUSIANA
LOUSIANA
MISSISSIPPI
MISSISSIPPI
START-UP
DATE
7/84
0/8*
1/86
1/88
0/86
0/88
0/85
0/87
STATUS
6
6
5
5
5
5
5
5
REG
CLASS
D
D
0
D
D
D
D
D
MINNESOTA POWER R LIGHT
CLAY BOSWELL 4
KINNKOTA POWER COOPERATIVE
MILTON R. YOUN6 2
MONTANA POWER
COLSTR1P 1
COLSTPIP 2
COLSTRIP 3
COLSTRIP 4
NEVADA POWER
HARRY ALLEN 1
HARRY ALLEN 2
HARRY ALLEN 3
HARRY ALLEN *
REID GARDNER 1
REID GARDNER 2
REID GARDNER 3
REID 6ARDNER 4
WARNER VALLEY 1
WARNER VALLEY 2
HEW ENGLAND ELECTRIC SYSTEM
BRAYTON POINT 3
NIAGARA MOHAWK POWER COOP
CHARLES R. HUNTLEY 66
NORTHERN INDIANA PUS SERVICE
EAILLY 7
BAILLY 8
DEAN H. MITCHELL 11
NORTHERN STATES POWER
SHERBURNE 1
SHERBURNE 2
SHERBURNt 3
OTTER TAIL POWER
COYOTE 1
PACIFIC CAS g ELECTRIC
FOSSIL 1
FOSSIL 2
COHASSET
CENTER
COLSTRIP
COLSTRIP
COLSTRIP
COLSTRIP
MINNESOTA
NORTH DAKOTA
MONTANA
MONTANA
MONTANA
MONTANA
N.E. LAS VEGAS NEVADA
N.E » LAS VE6AS NEVADA
N.E. LAS VEGAS NEVADA
N.E. LAS VEGAS NEVADA
MOAPA
MOAPA
MOAPA
MOAPA
ST. GEORGE
ST. GEORGE
SOMERSET
BUFFALO
CHESTERTON
CHESTERTON
GARY
BECKER
BECKER
BECKER
BEULAH
NEVADA
NEVADA
NEVADA
NEVADA
UTAH
UTAH
MASSACHUSETTS
NEW YORK
INDIANA
INDIANA
INDIANA
MINNESOTA
MINNESOTA
MINNESOTA
NORTH DOKOTA
CALIFORNIA
CALIFORNIA
5/80
9/77
9/75
5/76
7/80
7/81
O/ 0
0/82
O/ 0
01 0
7/76
3/76
*/77
5/84
5/81
0/85
0/86
6/85
6/86
6/87
6/88
4/7*
*/74
6/76
0/83
6/84
6/85
6
t
6
6
1
1
1
6
6
6
A
8
B
e
1. OPERATIONAL UNITS
2. UNITS UNDER CONSTRUCTION
?. PLANNED - CONTRACT AWARDED
*. PLANNED - LETTER OF INTENT SIGNED
5. PLANNED - RE8UESTIN6/EVALUATIN6 BIDS
6. PLANNED - CONSIDERING ONLY FGD SYSTEMS
?. PLANNED - CONSIDERING FGD SYSTEMS; ALSO ALTERNATIVE METHODS
A. BOILER CONSTRUCTED SUEJECT TO FEDERAL NSPS
B. BOILER SUBJECT TO STATE STANDARD WAT IS WORE STRINGENT THAN THE FEDERAL NSPS
C. BOILER SUBJECT TO STATE STANDARD THAT IS EQUAL TO OR LESS STRINGENT T«AN NSPS
D. OTHER
F. REGULATORY CLASS UNKNOWN
-------
EPA UTILITY FED SURVEY: DECEMBER 197S - JANUARY 1979
SECTION 1
SUMMARY LIST Of FGD SYSTEMS
COMPANY NAXIL/
UNIT NAME
PACIFIC POWER 8 LIGHT
JIM BR1DGER
PENNSYLVANIA POWER
BRUCE MANSFIELD
BRUCE MANSFIELD
BRUCE MANSFIELD
PHILADELPHIA ELECTRIC
CROMBY
EDDYSTONE
EDOYSTONfc
EDDYSTONE
POTOMAC ELECTRIC POWER
DICKERSON
POWER AUTHORITY OF NEW TO MS
ARTHUR KILL
PUBLIC SERVICE OF INDIANA
eiesoN
PUpLIC SERVICE OF NEW MEXICO
SAN JUAN
SAN JUAN
SAN JUAN
SAN JUAN
SALT RIVER PROJECT
CORONA 60
CO RON A 60
CORONADO
SAN MIGUEL ELECTRIC COOP
SAN MIGUEL
SEMJNOLE ELECTRIC
SEMINOLE
S IKES TON BOARD OF MUNIC. LTIL.
SIKESTON
SOUTH CAROLINA PUBLIC SERVICE
WINYAH
kllNYAH
SOUTHERN CALIFORNIA IBISOU
ALAMITCS
SOUTHERN ILLINOIS POVSR CCOP
MARION
MARION
SOUTHERN INDIANA 6AS & ELEC
A.B. BROWN
SOUTHERN MISSISSIPPI ELECTRIC
R.D. MORROW
ii.e. MORROW
UNIT I
4
1
2
3
1*
IB
2
4
3
1
2
3
4
1
2
3
1
1
1
2
3
t>
4
5
t
1
2
IC. UNIT LOCATION
ROCK SPRINGS
SHIPPINGPORT
SHIPPIN6PORT
SHIPPINGPORT
PHOFNIXVILLE
EDDYSTONE
tDDYSTONE
EDDYSTONE
DICKERSON
STATEN ISLAND
PRINCETON
WAT|RFLOW
UATFRFLOU
UATKRFLOW
WATER FLOW
ST. JOHNS
ST. JOHNS
ST. JOHNS
SAN MIGUEL
PALATKA
SIKESTON
GEORGETOWN
GEORGETOWN
SEAL BEACH
MARION
MARION
HIST FRANKLIN
HATTlSBUSe
HATTISBUR6
WYOMING
PENNSYLVANIA
PENNSYLVANIA
PENNSYLVANIA
PENNSYLVANIA
PENNSYLVANIA
PENNSYLVANIA
PENNSYLVANIA
MARYLAND
NEy YORK
INDIANA
NEW MEXICO
NFW MEXICO
NEW MEXICO
NEW MEXICO
APJ70NA
ARIZONA
ARIZONA
TEXAS
FLORIDA
MISSOURI
SOUTH CAROLINA
SOUTH CAROLINA
CALIFORNIA
ILLINOIS
ILLINOIS
INDIANA
MISSISSIPPI
MISSISSIPPI
START-UP
DATE
9/79
12/75
7/77
4/80
6/80
9/75
6/80
6/80
s/es
11/88
0/82
4/78
8/78
6/79
1/82
8/79
1/80
0/87
g/ao
6/83
6/81
7/77
5/80
1/82
5/79
0/84
5/79
8/78
5/79
STATUS
2
1
1
2
«
1
4
6
6
6
S
1
1
3
3
2
2
6
2
6
2
1
3
3
2
6
2
1
2
REG
CLASS
B
K<
B
B
B
B
S
B
0
R
A
S
B
B
B
a
B
B
A
A
A
A
A
D
A
A
A
A
A
1, OPERATIONAL UNITS 4. PLANNED - LETTER OF INTENT SIGNED
?. UNITS UNDER CONSTRUCTION 1. PLANNED - RESUESTIN6/IVALUATIN6 BIDS
J. PLANNED - CONTRACT AUARPEO 6. PMNNED - CONSIDERING ONLY F60 SYSTEMS
7. PLANNED - CONSIDERING F60 SYSTEMS; ALSO ALTERNATIVE METHODS
A. BOILIR CONSTRUCTED SUBJECT TO FEMRAL NSPS
i. BOILER SUBJECT TO STATE STANDARD THAT IS MORE STPIN6INT THAN THE FEDERAL NSPS
C* BOILER SUBJECT TO STATE STANDARD THAT IS EQUAL TO OR LESS STRINSENT THAN NSPS
P. OTHIR
E. RfeUMTORV CLASS UNKNOWN
-------
EPA UTILITY FGD SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 1
SUMPARY LIST OF FGD SYSTEMS
COMPANY NAME/
UNIT NAKE
SOUTHWESTERN ELECTRIC POWER
HENRY W. PERKEY
SPRIN6FIELO ClTY UTILITIES
SOUTHWEST
SPRINGFIELD WATER, LIGHT s PUR
DALLMAN
ST. JOE ZINC
6.F. VEATON
TAMPA ELECTRIC
616 BEND
TENNESSEE VALLEY AUTHORITY
CUMBERLAND
JOHNSOMVILLE
PARADISE
PARADISE
SHAWNEE
SHAVNEE
WIDOWS CREEK
WIDOWS CREEK
TEXAS MUNICIPAL POWER AGENCY
GIBBONS CREEK
TEXAS POVER i LIGHT
SANDOW
TWIN OAKS
TWIN OAKS
TEXAS UTILITIES
FOREST GROVE
MARTIN LAKE
MARTIN LAKE
MARTIN LAKE
MARTIN LAKE
MILL CREEK
MILL CREEK
MONTICELLO
UTAH POWER 8 LIGHT
EMERY
EMERY
HUNTINSTON
UNIT NO. UNIT LOCATION
1
1
3
1
4
HALLSVILLE
SPRINGFIELD
SPRINGFIELD
MONACA
TAMPA
TFXAS
MISSOURI
ILLINOIS
PENNSYLVANIA
FLORIDA
CUMBERLAND C 1 TYTE NNESSEE
1-10
1
Z
10A
10B
7
8
1
6
1
2
1
1
2
3
4
1
2
3
1
I
1
NEW JOHNSONVILLTFNNESSEE
PARADISE
PARADISE
PADUCAH
PADUCAH
BRIDGEPORT
BRIDGEPORT
CARLOS
ROCKDALE
ATHENS
TATUM
TATUM
TATUM
TATUM
HENDERSON
HENDERSON
MT. PLEASANT
CASTLE DALE
CASTLE DALE
PRICE
KENTUCKY
KENTUCKY
KFNTUCKY
KENTUCKY
At APAMA
ALABAMA
TEXAS
TFXAS
TEXAS
TEXAS
TEXAS
TEXAS
TEXAS
TEXAS
TEXAS
TFXAS
TEXAS
TEXAS
UTAH
UTAH
UTAH
START-UP
DATE
2/84
4/77
8/80
4/79
0/85
7/82
0/82
0/82
4/82
4/72
4/72
ID/SO
5/77
1/82
7/BO
8/83
9/84
0/81
4/77
5/78
2/79
0/85
0/85
0/86
5/78
4/79
6/80
5/78
STATUS
3
1
2
2
6
6
5
3
3
1
1
2
1
3
2
6
6
5
1
1
2
3
«
6
1
2
2
1
RE6
CLASS
A
A
A
B
A
C
c
C
c
c
c
c
c
A
A
A
A
A
A
A
A
A
D
0
A
A
A
A
WISCONSIN POWER I LIGHT
COLUMBIA
PORTAGE
WISCONSIN
1/80
1. OPERATIONAL UNITS
?. UNIT! UNDiR CONSTRUCTION
3. PLANNED - CONTRACT AWARDfO
«. PUNNID - LETTIR OF iNTINT SI6NIR
S. PUNNED • REeUESTXNe/iVALUAtlNG BIDS
6. PLANNED - CONSIDiRJNG ONLY FSD SYSTEMS
7. PLANNiD - CONSIDERING F6P 5YSTIMS; ALSO ALTERNATIVE METHODS
4. BOILER CONSTRUCTED SUBJECT TO FEDERAL NSPS
S. BOILER SUWICT TO STA1I STANDARD THAT IS MORI ITRINSiNT THAN THl FlftlRAL NSPS
1. BOILIR SUWICT TO STATI STANDARD 1HAT IS E6UAL TO OR (.HI STRIN6INT THAN NSPS
D. OTHER
ft RESULATOIY CLASS UNKNOWN
-------
FP» UTILITY FGD 5URVEY: DECEMBER 19?f - JANUARY 1979
SECTION 2
STATUS OF f6D SYSTEMS
UNIT IDENTIFICATION
ABSTRACT
•LABAMA ELECTRIC COOP
TOMBIGBEf
2
NEW 255.0 MH (GROSS)
179.0 "W (ESC)
COAL
1.15 XS BITUMINOUS
LIMESTONE
PEA80DY PROCESS SYSTEMS
F.NFRGY CONSUMPTION: ****X
STATUS 1 STARTUP 9/72
REFER TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION.
PFABGDY ENGINEERING WAS AWARDED A CONTRACT FOR THE INSTALLATION OF A
LIMESTONE FGD SYSTEM ON THIS UNIT. A HIGH-EFFICIENCY ESP INSTALLED
UPSTREAM OF THF F6D SYSTEM PROVIDES PRIMARY PARTICULATE CONTROL. THE FGD
SYSTCC? CCNTAINS TWO SCRUBBING TRAINS, TREATING APPROXIMATELY 70* OF THE
FLUE GAS FOR REKOVAL OF SOZ. STACK GAS REHEAT Is NOT REQUIRED. THE UNIT
IS CtRREi'TLY IN THE SH AK EDQWN-D EBUGGIN6 PHASE OF OPERATIONS.
ALABAMA ELECTRIC COOP
TOMBI6BEE
7
NEW ?55.Q WW (GROSS)
179.0 KW (ESC )
COAL
1.15 IS BITUMINOUS
LIMESTONE
PEA600Y PROCESS SYSTEMS
FNFRGY CONSUMPTION: *****
STATUS 2 STARTUP 6/79
REFER TO SECTION 3 OF THIS RtPORT FOR ADDITIONAL INFORMATION.
PEADODY tNGlNEERING WAS AWARDED A CONTRACT FOR THE INSTALLATION OF A
LIMESTONl FGD SYSTEM ON THIS UNIT. A HIGH-EFFICIENCY ESP INSTALLED
UPSTREAM OF THE FGD SYSTEM PROVIDES PRIMARY PARTICULATE CONTROL. THE FGD
SYSTEM CCNTAINS TWO SCRUBBING TRAINS, TREATING APPROXIMATELY 7o« OF THE
FLUE GAS FOR REMOVAL OF S02. STACK GAS REHEAT IS NOT REQUIRED. THE UNIT
IS CUKREfTLY IN THE SHAKEDOWN-DEBUGGING PHASE OF OPERATIONS.
ALLEGHENY POWER SYSTEM
MITCHELL
RETROFIT
COAL
***** xs
300-0 MU
300.0 MH
(GROSS )
(fSC)
ALLEGHENY POWER SYSTEM WILL INSTALL FLUE GAS DESULFURIZATlQN EQUIPMENT
ON UNIT :< AT THE MITCHELL PCfcER STATION. THE UTILITY IS CURRENTLY
IN THE PROCESS OF EVALUATING VARIOUS FGD TECHNOLOGIES. THE FGD IN-
STALLATUN IS SCHEDULED TO BEGIN OPERATIONS IN AUGUST 1982.
ENER6Y CONSUMPTION: *****
STATUS 6 STARTUP 8/K2
ALLEGHENY POWER SYSTEM
PLEASANTS
1
NEW 625.0 MW (GROSS)
519.0 My (ESC)
COAL
4.50 XS BITUMINOUS
I 1ME
PABCOCK 8 WIICOX
ENERGY CONSUMPTION: *****
STATUS 2. STARTUP 3/79
THE THREE PRINCIPAL OPERATING UTILITY COMPANIES OF THE ALLEGHENY POWER
SYSTEM ARE INSTALLING AN EMISSION CONTROL SYSTEM FOR THIS NEW COAL-FIRED
UNIT WHICH INCLUDES A HI6H-EFFICIENCY ESP UPSTREAM OF FOUR THAT TOWERS
FOR THE CONTROL OF PARTICULARS AND SULFUR DIOXIDE. DESIGN REMOVAL
EFFICIENCIES FOR THIS EKJSS1CN CONTROL SYSTEM ARE 90 AND 99.5 PERCENT,
RESPECTIVELY. THE 9RAVQ CO. IS SUPPLYING THIOSQRBIC LINE. THE CONSULTING
ENGINEERING FIRM IS UNITED ENGINEERS AND CONSTRUCTORS. CURRENTLY,
ERECTION OF THE SCRUBBING EQUIPMENT IS IN PROGRESS.
ALLEGHENY POWER SYSTEM
PLEASANTS
?
NEW 625.0 MW (GROSS)
519.0 NW (fSC>
COAL
4.50 XS BITUMINOUS
LIME
BABCOCK I UILCOX
FNERGY CONSUMPTION: *****
STATUS 2 STARTUP 3/PO
THE THREE PRINCIPAL OPfcRATiNG UTILITY COMPANIES OF THE ALLEGHENY POKER
SYSTtK f(f.f. INSTALLING AN EMISSION CONTROL SYSTEM FOR THIS NEW COAL-FIRED
UNIT WHICH INCLUDES A HIGH-EFFICIENCY ESP UPSTREAM OF FOUR TRAY TOWERS
FOR THE CONTROL OF PARTICULATES AND SULFUR DIOXIDE. DESIGN REMOVAL
EFFICIENCIES FOR THIS EMISSION CONTROL SYSTEM ARE 90 AND 99.5 PERCENT,
RESPECTIVELY. THE D^AVO CO. IS SUPPLYING THIOSORBIC LIME. THE CONSULTING
ENGINEERING FIRM IS UNITEO ENGINEERS AND CONSTRUCTORS.
FOUNDATION WORK ON THE SCRUBBER PLANT IS IN PROGRESS.
ARIZONA ELECTRIC POWER COOP
APACHE
Z
NEW 245.0 MW (GROSS)
180.0 MW (ESC)
COAL
.70 XS BITUMINOUS
LIMESTONE
RESEARCH COTTRELL
ENERGY CONSUMPTION: *****
STATUS 1 STARTUP 8/78
REFER TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION- THE FGD
SYSTtK FCR THIS NEW 200 MW UNIT WAS SUPPLIED BY RESEARCH COTTRELL. THE
DESIGN INCLUDES A 22 ACRE SLUDGE POND AND A 6t ACRE ASH POND, BOTH OF
WHICH ARE UNL1NED AND TEN FEET DEEP. A REHEAT SYSTEM IS NOT INCLUDED. THE
LINERS UTFD IN THE STACK AND THE DUCTS THAT LEAD TO THE STACK ARE A NEW
COLE BRAMI CXL2000 WHICH HAS A VERY HIGH HgAT RESISTANCE. THIS UNIT BURNS
EITUMNOIS COAL WITH ASH CONTENTS OF . 7t AND 10X RESPECTIVELY.
INITIAL OPERATION OF THIS UNIT BEGAN IN AUGUST, 1978.
-------
EPA UTILITY FGG SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION z
STATUS or FGD SYSTEMS
UNIT 16ENTI.fl CATION
ABSTRACT
ARIZONA ELECTRIC POWtR COOP
APACHE
3
NEW 24J.O MW (GROSS)
no.o KW (rsc)
COAL
.70 XS BITUMINOUS
LIMESTONE
RESEARCH COTTRELL
ENERGY CONSUMPTION: *****
STATUS 2 STARTUP 4/79
CONSTRUCUON Or UN IT J IS NO* ESSENTIALLY COMPLETE. STRUCTURE
fRECTION or THE SCRUBPER-ABSORBER TOWERS IS COMPLETE. EACH SCRUBBER CAN
HANDLE 41.0,000 ACFM AT ?70F AND RECIRCULATE 20,000 6PM OF SLURRY.
THERE ART CURRENTLY TUO PONDS WITH A TOTAL OF 2Q-
VRS CAPACITY FOR DISPOSAL OF UNF1XATED SLUD6E. TWO ADDITIONAL PONDS
ARE FLANktD PROVIDING AN ADDITIONAL 20 YRS OF DISPOSAL CAPABILITY. THERE
WILL BE K> REHEAT. BECAUSE Or THE HUGH COST OF THE UNIT 2 STACK LINER,
UNIT 3 WILL USE A CE1LCOTE LINING INSTEAD OF THE CXL2000 USED IN UNIT 2.
ARIZONA PUBLIC SERVICE
CHOLLA
1
RETROFIT 119.0 MW (6RO&S)
11V.0 MW (ESC)
COAL
.50 XS SUB&ITUMINOUS
LIMESTONE
RESEARCH COTTRELL
ENERGY CONSUMPTION: 4.£*
STATUS 1 STARTUP 10/73
REFER TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION
THIS LIMtSTONt SCRUBBING SYSTEM WAS PLACED IN SERVICE IN OCTOBER 1973.
THIS SCRIEBER PLANT CONSISTS OF TWO PARALLEL SCRUBBING TRAINS.
PARTHULATE CONTROL IS PROVIDED BY TUO FLOODED DISC SCRUBBERS. S02
CONTROL is PROVIDED ev ONE PACKED (HUNTERS PACKING) TOWER (A-SIDE).
FLUE GAS CLEANING WASTES ARF DISCHARGED TO AN EXISTING FLY ASH POND.
NO WATER IS RECYCLED PACK FROM THE DISPOSAL PONo- IN-LlNE STEAM
REHEATER: RAISE THE GAS TEMPERATURE 40 F.
ARIZONA PUPL1C SERVICE
CHOLLA
I
NEW 350.0 MW (GROSS)
150.0 MW crso
COAL
.50 XS SUB BITUMINOUS
LIMESTONE
RESEARCH COTTRELL
ENERGY CONSUMPTION: ****x
STATUS 1 STARTUP */76
REFER TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION.
THE CONTACT FOR THIS WET LIMESTONE SCRUBBING SYSTEM WAS AWARDED BY THE
UTILITY 10 RESEARCH-COTTRELL. THE DESIGN INCLUDES MECHANICAL COLLECTORS
FOR PRIMARY PAHT1CULATE REMOVAL. THE FGD SYSTEM CONSISTS OF FOUR PARALLEL
FLOODED CISC AND PACKED TOWER ABSORBER TRAINS. THREE ARE REQUIRED FOR
FULL LOAl, CAPACITY. INITIAL OPERATIONS B^AN IN APRIL 1978. COMPLIANCE
TESTING fcAS COMPLETED DURING THE SECOND WEEK OF AUGUST 1978. THE UNIT IS
CURRENTLY UNDERGOING SHAKEDOWN AND DEBUGGING OPERATIONS.
ARIZONA PUFLK SERVICE
CHOLLA
4
NEW 750.0 MW (GROSS)
126.0 MW (ESC>
COAL
.50 XS
LIMESTONE
RESEARCH COTTRELL
ENERGY CONSUMPTION: ****X
STATUS 2 STARTUP 6/*0
UNIT NO. 4 IS CURRENTLY UNDER CONSTRUCTION. APS HAS AWARDED THE FGO
CONTRACT TO RESEARCH COTTRELL. THE STATE REGULATORY AGENCY HAS NOT Y£T
DECIDED 1HE EMISSION PECULATIONS WHICH WILL APPLY TO THE PLANT. THE C-E
BOILER WILL FIRE THE SAME CO«L AS CHOLLA N0.1, WITH SULFUR CONTENT OF
0.44-1.0 PERCENT* THE A-E FIRM IS E6ASCO. THE FGD SYSTEM IS A DOUBLE LOOP
LIMESTONt ABSORPTION PROCESS AND REVENUES OF THE CONTRACT TO R-C ARE
REPORTED TO 6E SS MM. FOR CONTROL OF PARTICULAR, AN ESP WILL HANDLE
100X OF 1HE FLUE GAS.
ARIZONA PUBLIC SERVICE
FOUR CORNERS
1
RETROFIT 175.0 MW (6ROSS)
175.0 MW (ESC>
COAL
.75 XS
LIME/ALKALINE FLYASH
CHEMICO
ENERGY CONSUMPTION: *****
STATUS I STARTUP 0/79
APS IS UF6RADING THg OPERATIONAL PARTICULATE SCRUBBERS AT THE FOUR
CORNERS 1,2, AND 3 FOR ADDITIONAL S02 REMOVAL. CURRENTLY, EACH UNIT HAS 2
CHEMICO VSNTUR1 SCRUBBER MODULES FOR PARTICULATE CONTROL. ROUGHLY 3CX OF
THE FLUE CAS S02 CONTENT IS REMOVED AT THI PRESENT TIME IN THE VENTURIS
WITH THE H16H AKALINE FLYASH. NEW MEXICO APC OFFICIALS INDICATED THAT
THE b FOIR CORNERS UNITS WILL BE REQUIRED TO REMOVE AT LEAST 67.5X OF THE
STATION 502 (AIL 5 UNITS CONSIDERED TOGETHER). ADDITIONAL ALKALINITY WILL
BE IMPARTED TO THE SCRUBBING SOLUTION BY ADD1N6 LIME.
ARIZONA PUPLIC SERVICE
FOUR CORNERS
2
RETROFIT 175.0 MW (GROSS)
175,0 MW (ESC)
COAL
.75 XS
LIME/ALKALINE FLYASH
CHEMICO
ENERGY CONSUMPTION! •***»
STATUS 2 STARTUP 0/79
APS IS UFGRADING THE OPERATIONAL PARTICULATE SCRUBBERS AT THE FOUR
CORNERS 1,2. AND 3 FOR ADDITIONAL S02 REMOVAL. CURRENTLY, E*CH UNIT HAS 2
CHEMICO tF.NTURI SCRUBBER MODULES FOR PARTICULATE CONTROL. ROUGHLY 3CX OF
THE FLUE GAS S02 CONTENT IS REMOVED AT THE PRESENT TIME IN THE VENTURIS
WITH THE HIGH ALKALINE FLYASK. NEW MEXICO APC OFFICIALS INDICATED THAT
THE 5 FOIR CORNERS UNITS WILL BE REBUIREO TO REMOVE AT LEAST 67.SX OF THE
STATION SO2(ALL 5 UNITS CONSIDERED TOGETHER). ADDITIONAL ALKALINITY WILL
BE IMPARTED TO THE SCRUBBING SOLUTION BY ADDING LIME.
-------
EPA UTILITY F6D SURVEY: DECEMBtR 197t - JANUARY 1979
SECTION 2
STATUS OF FGD SYSTEMS
UNIT IDENTIFICATION
ABSTRACT
ARIZONA PUBLIC SERVICE
FOUR CORKERS
?
RETROFIT 229.0 MW (GROSS)
?2«.0 Mt. (ESC)
COAL
.75 XS
LIME/ALKALINF FLYASH
CHF.MICO
ENERGY CONSUMPTION: *****
STATUS 2 STARTUP 0/7«
APS IS UICRADING THE OPERATIONAL PARTICULATF SCRUBBERS AT THE FOUR
CORNERS 1,2, AND 3 FOR ADDITIONAL $02 REMOVAL. CURRENTLYt EACH UNIT HAS 2
CHtCKC VENTUR1 SCRUBBER MODULES FOR PARTICULUTE CONTROL. ROUGHLY 3CX OF
THE FLUE 6AS S02 CONTENT IS REMOVED AT THE PRESENT TIME IN THE VENTURIS
VlTH THE HIGH AKAL1NE FLYASH. NEW MEXICO APC OFFICIALS INDICATES THAT
THE 5 FCIP CORNERS UNITS WILL 6E REflUlRED TO REMOVE AT LEAST 67.SX OF THE
STATION J02ULL 5 UNITS CONSIDERED TOGETHER), ADDITIONAL ALKALINITY WILL
BE IhFARKD TO THE SCRUBBING SOLUTION BY ADDING L1MF..
ARIZONA PUP L1C SERVICE
FOUR CORNERS
4
RETROFIT 755. o MW (SROSS)
755.0 MW (ESC>
COAL
.75 XS
THE UTILITY IS CURRENTLY EVALUATING THE DATA AND INFORMATION ACCUMULATED
DUR1N6 Tft HORIZONTAL PROTOTYPE SCRUBBING PROGRAM IN ORDER TO ASCERTAIN
VARIOUS FOSSIBLF. SmmifS TO CONTROL THF EMISSIONS FROM THIS COAL FIRED
755-Mb UMT. ADS WILL BE REOUIRED TO REDUCE THI CURRENT LEVEL OF $02
EMISSIONS FROM THE FNTIRE PLANT BY INCREASING THE REMOVAL EFFICIENCY
TO AT LF.m 67.SX. A CONTRACT HAS tiCEfj AWARDED TO UNITED ENGINEERS FOR
THE IKGUMRING AND CONSTRUCTION OF AN F6D SYSTEM.
UNITED ENGINEERS
ENERGY CONSUMPTION: »***X
STATUS 3 STARTUP 0/F2
ARIZONA PUBLIC SERVICE
FOUR CORNERS
5
RETROFIT 755.0 MW (GROSS)
755.0 MW (ESC)
COAL
.75 XS
LIME
UNITED ENGlNEfcRS
ENERGY CONSUMPTION: «***x
STATUS 3 STARTUP 0/82
THE UTILITY IS CURRENTLY EVALUATING THfe DATA AND INFORMATION ACCUMULATED
DURING THF HORIZONTAL PROTOTYPE SCRUBBING PROGRAM IN ORDER TO ASCERTAIN
VARIOUS IOSS1BLE STRATEGICS TO CONTROL THF EMISSIONS FROM THIS COAL FIRED
7SS-KH UMT. APS WILL BE RIOOlftED TO REDUCE THi CURRENT LEVU OF SO?
EMISSION:: FROM THE ENTIRE PLANT BY INCREASING THE REMOVAL EFFICIENCY
TO AT LEfST 67.SX. A CONTRACT HAS Bt AWARDED TO UNITED ENGINEERS FOR
THE CKCI OfER1NG AND CONSTRUCTION OF AN FGD SYSTEM.
ASSOCIATED ELECTRIC COOP
THOMAS HILL
j
NEW 720.0 MW (GROSS)
£70.0 MU (ESC)
COAL
*.EO XS
LIMESTONE
PULLMAN ITELLOGG
ENERGY CONSUMPTION: «*«•»
STATUS 3 STARTUP 1/C.2
ASSOCIATED ELECTRIC COOP AWARDED A CONTRACT TO PULLMAN KEL LOSS FOR THE
ENGINEERING^ PROCUREMENT AND CONSTRUCTION OF AN FGD SYSTEM ON THE UTILI-
TY'S THOPAS HILL UNIT NO. 3 POWER PLANT. $02 REMOVAL FGUIPMENT UILL OPER-
ATE IN CONJUNCTION WITH A HIGH EFFICIENCY ESP. THE SYSTEM, SCHEDULED FOR
START-UP IN 1982, WILL UTILIZE MAGNESIUM-PROMOTED LIMESTONE AS A REAGENT
IN THE FtUR MODULE WEIR FGD SYSTEM. REHEAT WILL PROBABLY NOT BE INCLUDED.
THE STACK WILL BE BRICK LINfO. THE DRY FIXATED SLUDGE WILL RE
HAULED TC AN ACTIVE STRIP MIME. CONSTRUCTION OF THE BOILER HAS PEGUN.
BASIN ELECTRIC POWFR COOP
ANTELOPE VALLEY
1
NEW 440.0 MW (GROSS)
440.0 MW (ESC)
COAL
.68 XS LIGNITE
LIME (DRY COLLECTION)
JOY MF6* CO. WESTERN PRECIPITA
ENERGY CONSUMPTION: ****x
STATUS 3 STARTUP 11/31
THE UTILHY HAS SELECTED A LIME SCRUBBING PROCESS FOR THEIR PLANNED
FGD SVSTtM. THE UNIT WILL FIRE LIGNITE COAL WITH A SULFUR CONTENT
OF O.ft PERCENT AND AN ASH CONTENT OF B.O PERCENT (6600 BTU/LB). THE
WATFR LOCP WILL BE OPEN WITH MAKE-UP COMING FROM COOLING TOWER PLOWDOWN,
THE SLID IE WILL BE DISPOSED IN A MINE LANDFILL. A CONTRACT HAS BEEN
AWARDED 10 WESTERN PRECIPITATION DlViSON. JQY MFG. C0> FOR A DRV FGD
SYSTEM. 1HE SPRAY DRYER HAS BEEN SUBCONTRACTED TO NlRO ATOMITER.
BASIN ELECTRIC POWER COOP
ANTELOPE VALLEY
^
440.0 MU (GROSS)
440.0 ffW (ESC)
COAL
.68 XS LIGNITE
PROCESS NOT SELECTED
VENDOR NOT SELECTED
ENERGY CONSUMPTION: *****
STATUS 6 STARTUP 11/?3
THE UTILITY IS TENTATIVELY INVESTIGATING VARIOUS FGD PROCESSES FOR THIS
SECOND LIGNITE-FIRED UNIT SCHEDULED AT THE NEW STATION LOCATED IN MERCER
COUNTY, KAR BEULAH, NORTH DAKOTA. THIS NEW FACILITY WILL BE KNOWN AS
THE ANTELOPE VALLEY STATION AND WILL BE RE8UIRED TO COMPLY WITH STATE
AIR EMISSIONS STANDARDS VIA THE BEST AVAILABLE TECHNOLOGY. START-UP IS
NOW SCHEDULED FOR NOVEMBER 1963.
-------
EPA UTIim F6D SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 2
STATUS OF FGD SYSTEMS
UNIT IDENTIFICATION
ABSTRACT
BASIN ELECTRIC POWER COOP
LARA*IE RIVER
1
NEW 600.0 MW (GROSS)
600.0 MW (ESC)
COAL
.80 XS
LIMESTONE
RESEARCH COTTRELL
ENERGY CONSUMPTION: *****
STATUS 2 STARTUP 4/?0
RESEARCH-COTTRELL IS CURRENTLY F AftRl;CA TIN* THE DUAL-LOOP LIMESTONE WET
SCRUBBERS. ON-SITE CONSTRUCTION COMMENCED IN JANUARY 1978. SLUDGE WILL BE
DEUATERE6 TO 83X SOLIDS BEFORE LANDFILL. THE SCRUBBERS WILL BE I»ADE OF
STAIMLESS STEEL AND WILL HANBLE 2.3 «W ACFM AT g86 F. L/6 RATIO WILL BE
60. fifcW frAS 6EEN AWARDED A CONTRACT FOR TWO ESP'S. THE DESIGN DOES NOT
INCLUDE STACK CAS RFHEAT. COOHN6 TOWER SLOWDOWN WILL BE USFD FOR MAKE-UP
WATER IN THIS CLOSED LOOP SYSTEM. CONSTRUCTION IS NOW 20X COMPLETE.
BASIN ELECTRIC POWFR COOP
LARAM1E RIVER
2
NED 600.0 WW (CROSS)
600.0 MW (ESc>
COAL
.60 XS
LIMESTONE
RESEARCH COTTRELL
ENERGY CONSUMPTION: *****
STATUS 2 STARTUP 10/80
RESEAFCH-COTTRELL IS CURRENTLY FABRICATING THE DUAL-LOOP LIMESTONE WET
SCRUBBERS. ON-SITE CONSTRUCTION COMMENCED IN JANUARY 1978. SLUD6E WILL BE
DEWATEREC TO 83* SOLIDS BEFORE, LANDFILL. THE SCRUBBERS WILL BE MADE OF
STAINLESS STEEL AND WILL HANDLE 2.3 MM ACFM AT 386 F. L/6 RATIO WILL BE
60. ItV MS BEEN AWARDED A CONTRACT FOR TWO ESP'S. THE DESISN DOES NOT
INCLUDE STACK 6AS RFHE*T. cOCLjNC TOWER SLOWDOWN WILL BE US1D FOR MAKE-UP
WATER IN THIS CLOSED LOOP SYSTEM. CONSTRUCTION IS NOW 20X COMPLETE.
BASIN ELECTRIC POWER COOP
LASAMIE RIVER
5
NEW 600.0 MW (GROSS)
600.0 MU (FSC)
COAL
.80 XS
LIME (DRY COLLECTION)
BABCOCK K VILCOX
INIR6Y CONSUMPTION: ***«X
STATUS 3 STARTUP t/?2
LARAMIE RIVER STATION WILL FIRE SUBBITUMjNOUS COAL WITH THE FOLLOWING
CHARACTERISTICS: g100 BTU/L8, 0.8 PERCENT SULFUR AND 7.0 PERCENT ASH A
CONTRACT FOR A DRY TYPE FGD SYSTEM HAS BIFN AWARDED TO BABCOCK f WILCOX.
BIG RIVERS ELECTRIC
6RIEN
1
NEK 242.0 HU (6ROSS)
242.0 MU (esc)
COAL
3.75 XS BITUMINOUS
LI Me
AMERICAN AIR FILTER
ENfRGY CONSUMPTION: ****X
STATUS 2 STARTUP 12/79
THI EMISSION CONTROL SYSTiM FOR THIS N|H COAL-FIRED UNIT IS BEING
SUPPLIED FY AMERICAN AIR FILTER. THE SYSTEM WILL CONSIST OF A COLD-SIDE
ESP AND WO SPRAY TOWEKS CONTROLLING PARTICULATE AND S02 TO 99.6 PERCENT
AND $0 PiRCENT, RESPECTIVELY. THf §&W iOILER WILL FIRE HIGH SULFUR (3.5
TO «.S PiT/CENT) WESTERN KENTUCKY COAL, CONSTRUCTION IS NOW 66X COMPLETE
ON THE BCILER AND SOX COMPLETE ON THE FGD SYSTEM. THf DESIGN INCLUDES AN
INDIRECT HOT AIR REHEAT SYSTEM. IUCS WILL CONSTRUCT A SLUDGE DISPOSAL
SYSTiP TC SERVICE BOTH 6RIEN 1 AMP 2.
PIS RIVERS ELECTRIC
6REEN
2
NEW 242.0 MW (GROSS)
242.0 MW (ESC>
COAL
3.75 XS BITUMINOUS
LIME
AMERICAN AIR FILTER
ENERGY CONSUMPTION: ****X
STATUS 2 STARTUP 12/80
THE (MISSION CONTROL SYSTEM FOR THIS NEN COAL-FIRED UNIT IS BEIN6
SUPPLIED BY AMERICAN AIR FILTER. THE SYSTEM WILL CONSIST OF A COLD SIDE
ESP AND 1WO SPRAY TOWERS CONTROLLING PARTTCULATE AND S02 TO 99.6 PERCENT
AND (0 PERCENT, RESPECTIVELY. THE ggW BOILER WILL FIRE HI6H SULFUR (3.5
4.S PERCENT) WESTERN KENTUCKY COAL. THE FED SYSTEM WILL INCLUDE AN
INDIRECT HOT AIR REHEAT SYSTEM. IUCS WILL CONSTRUCT A SLUDGE DISPOSAL
SYSTEM Td SERVICE BOTH GREEN 1 AND 2. THE BOILER IS CURRENTLY 81 COMPLETE
AND CONSIRUCTION HAS JUST BEGUN ON THE FGD SYSTEM.
CENTRAL ILLINOIS LIGHT
DUCK CREEK
1
NEW 416.0 MU (GROSS)
416.0 MU (E$C>
COAL
3.30 XS BITUMINOUS
LIMESTONE
RILEV STOKER/ENVIRONEERING
ENERGY CONSUMPTION: ****«
STATUS 1 STARTUP 7/76
REFER TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION. RILEY
STOKER W»S THE SUPPLIER OF THE FOUR VENTUR1-ABSORBER MODULES AT THIS
UNIT. SCNUBBER TANKS AND PUMPS ARE NEOPRENE LINED. A HIGH EFFICIENCY ESP
IS UPSTREAM OF THE FOUR VENTLR1-ABSORBER SCRUBBER MODULES FOR PARTICULATE
CONTROL- THE CONCRETE STACK IS LINED WITH CEILCOTE FLAKELINE 151. NO RE-
HEAT SYS1EM IS INCLUDED. TH? FIRST LIMESTONE SLURRY SCRUBBER MODULE WAS
PLACED It, SERVICE ON SEPTEMBER 9,1976, AND OPERATED INTERMITTENTLY UNTIL
APRIL 1, 1977. ALL FOUR MODULES BECOME OPERATIONAL ON JULY 24, 1978.
-------
EPA UTILITY FGD SURVEY: DECEMBER f>1t - JANUARY 1979
SECTION 2
liTATUS OF Fee SYSTEMS
UNIT IDENTIFICATION
ABSTRACT
CENTRAL ILLINOIS LIGHT
DUCK CREFK
2
NEW 416.0 »w (GROSS)
(16.0 MW
COAL
3.20 XS BITUMINOUS
LIMESTONE
VENDOR NOT SELECTED
ENERGY CONSUMPTION: ****X
STATUS 5 STARTUP 1/F4
THE UTILITY HAS NOT YET SELECTED A SYSTEM SUPPLIER. THE UTILITY WILL
USE ESP'! FOR PARTICULAR CONTROL AND EITHgR LIMESTONE OR DOUBLE ALKALI
FOR SC2 OFiSORPTION. THE UTILITY IS NOW IN THE PROCESS OF EVALUATING
BIDS AND A STUDY IS UNDERWAY TO DETERMINE THE SLUDGE DISPOSAL STRATEGY
THAT WILL BE EMPLOYED.
CENTRAL ILLINOIS PUBLIC SERV
NEWTON
1
NEW 617.Q MW (GROSS)
617.0 WW (ESC)
COAL
4.00 XS BITUMINOUS
DUAL ALKALI
BUF.LL/ENVIRCTECH
FNERSr CONSUMPTION: *****
STATUS 2 STARTUP 11/79
A CONTRACT HAS BEEN AWARDED BY c»PSO TO BUELL/ENVIRoTFCH FOR THE
INSTALLATION OF AN EMISSION CONTROL SYSTEM ON UNIT 1. THE KEY COM-
PONENTS CF THE EMISSION CONTROL SYSTEM INCLUDE: A HIGH-EFFICIENCY ESP;
FOUR PRFCOOLERS, FOUR POLYSPHERE ABSORBERS, THREE THICKENERS, TWO EX-
PERIMENT*! REHFAT SYSTEMS, AND THREE HORIZONTAL EXTRACTION FILTERS FOR
SLUDtE DCATERING. MORE THAN 5U PERCENT OF THE CONSTRUCTION WORK
AT THE PLANT HAS BEEN COMPLETED. THE F6D SYSTEM WILL HAVE CEILCOTE-
LINEC ABSORBER MODULES.
CENTRAL MAINE POWER
SEARS ISLAND
1
NEW 600.0 MW (GROSS)
6CD.O MW (ESC>
COAL
***** XS
LIME OR LIMESTONE
VENDOR NOT SELECTED
ENERGY CONSUMPTION: ****X
STATUS 6 STARTUP 11/«7
BECAUSE (F THE DISCOVERY OF A GEOLOGICAL FAuLT ON SEARS ISLAND, THE
UTILITY HAS CANCELLED PLANS FOR A 11SO-MN NUCLEAR POWER PLANT. A 60C-MW
COAL FIRtD UNIT IS NOW BEING PLANNED IN ITS PLACE. COMMERCIAL OPERATION
IS PROJECTED FOR NOVEMBER 1986. COMPLIANCE WITH $02 NSPS WILL BE
ACHIEVED BY INSTALLING AN FED SYSTEM. LIME AND LIMESTONE SCRUBBING
PROCESSED ARE EEING GIVfN PPiMARY CONSIDERATION. CURRENTLY, CMPCO HAS
FILED AN APPLICATION WITH THE STATE PUBLIC UTILITIES COMMISSION. A DE-
LAY IN RECEIVING A PERMIT FROM THE MAINE PUBLIC UTILITIES COMMISSION
HAS RESULTED IN A REVISED START-UP DATE OF NOVEMBER 19B7.
CINCINNATI GAS & ELECTRIC
EAST BEND
?
NEW 650.0 MM (GROSS)
650.0 MW (ESC)
COAL
5.00 XS
LIME
BABCOCK K WILCOX
FNEftGY CONSUMPTION: *****
STATUS 2 STARTUP 10/P.1
A CONTRACT HAS BEEN CONDITIONALLY AWARDED TO BABCQCK AND WILCOX FOR A
COMMERCIAL LIME SCRUBBING SYSTEM. THE COAL SOURCE IS EXPECTED TO BE *
WESTERN KENTUCKY COAL WITH A HIGH SULFUR CONTENT. THE THREE LIME SLURRY
FED MODULES WILL BE PRECEDED BY AN ESP FOR PARTICULATE CONTROL. A
CONTRACT HAS BEEN CONDITIONALLY AWARDED TO IUCS FOR THE SLUDGE FIXATION.
THE A-t FIRM iS SARGENT AND LUNDV. UNIT FOUNDATION HAS BEGUN AND
FGD SYSTEM CONSTRUCTION WILL BEGIN IN EARLY 1979.
COLORADO UTE
CRAIG
1
NEW
ELECTRIC ASSN.
450.0 FW (GROSS)
450.0 MW (ESC)
COAL
.45 XS SUBBITUNINOUS
LIMESTONE
PEABODY PROCESS SYSTEMS
ENERGY CONSUMPTION: ***«X
STATUS 2 STARTUP 3/79
PFABODY PROCESS SYSTEMS HAS BEEN AWARDED A CONTRACT TO DESIGN AND
SUPPLY A LIMESTONE SLURRY SPRAY TOWER ABSORBER SYSTEM FOR S02 REMOVAL
FROM LOW-SULFUR COAL-FIRED BOILER FLUE GAS FROM UNITS 1 AND 2.
PARTICULATE CONTROL WILL BE PROVIDED BY HOT-SIDE ESP'S UPSTREAM OF THE
ABSORBER SYSTEM. SLUDGE UILL BE STABILIZED AND HAULED TO A MINEFILL
THERE kllL BE A STE«M cOIL TYPE STACK GAS REHEATER INCLUDED. RF6UIRED
PARTICUL«TE AND S02 REMOVAL EFFICIENCIES ARE 99.8 A*D 85 PERCENT
RESPECTIVELY. FGD CONSTRUCTION IS NOW 80% COMPLETE.
COLORADO UTE ELECTRIC ASSN.
CRAIG
J
NEW 450.0 MW (GROSS)
450.0 MU (ESC)
COAL
.45 XS SUBBITUMINOUS
LIMESTONE
PEABODY PROCESS SYSTEMS
ENERGY CONSUMPTION: ****X
STATUS 2 STARTUP 3/79
PEAECDY PROCESS SYSTEMS HAS BEEN AWARDED A CONTRACT TO DESIGN AND
SUPPLY A LIMESTONE SPRAY TOWER ABSORBER SYSTEM FOR SO? REMOVAL
FROM LOU-SULFUR COAL-FIRED BOILER FLUE GAS FROM UNITS 1 AND 2.
PARTICULATE CONTROL WILL BE PROVIDED BY HOT-SIDE ESP'S UPSTREAM OF THE
ABSORBER SYSTEM. SLUDGE WILL BE STABILIZED AND HAULED TO A RINEFILL.
THERE WILL BE A STEAM COIL TYPE STACK GAS REHEAT£R INCLUDED. RE8UIRED
PARTICULATE AND S02 REMOVAL EFFICIENCIES ARE 99.6 AND 85 PERCENT
RESPECTIVELY. FGD CONSTRUCTION IS NOW BOX COMPLETE.
10
-------
fPA UTILITY FSO SURVEY: DECFHBER 1978 - JANUARK 1979
SECTjON 2
STATUS OF FGD SYSTEMS
OMIT 10ENTIFICAT10N
ABSTRACT
COLUMBUS * SOUTHERN OHIO ELEC.
CONESVILLE
5
NEW 411 .0 MW (GROSS)
411.0 MW (ESC)
COAL
4.67 XS BITUMINOUS
LIME
AIR CORRECTION DIVISION, UOP
ENERGY CONSUMPTION: 3.9*
STATUS 1 STARTUP 1/77
REFER TO SECTION 3 Of THIS REPORT FOR ADDITIONAL INFORMATION. THE
BOILER AM) ESP WERE COMPLETED AND PLACED IN SERVICE IN SEPTEMBER 1976.
THE B-SltE MODULE BECAME AVAILABLE FOR SERVICE IN JANUARY 1977.
COMMERCIAL OPERATIONS MERE ACHIEVED ON FEBRUARY 13, 1977. THE EMISSION
CONTROL SYSTEM FOR THIS UNIT CONSISTS OF A COLD-SIDE ESP FOLLOWED BY
TWO LIME TCA MODULES SUPPLIED BY uOP. DRAVO IS SUPPLING THE THIOSORB1C
LIME REAGENT. IUCS IS SUPPLYING A POZ-O-TgC SLUDGE STABILIZATION FAtUITy
COLUMBUS K SOUTHERN OHIO ELEC.
CONESVILLE
6
NEW 411.0 Py (GROSS)
411.0 MW (ESC)
COAL
4.67 XS BITUMINOUS
I 1ME
AI& CORRECTION DIVISION, UOF
ENERGY CONSUMPTION: 3.95:
STATUS 1 STARTUP 6/78
REFEF TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION. CRSOE
SI6UID L(NG TERM CONTRACTS WITH DRAVO FOR THE PURCHACE OF THIOSORBIC LIME
AND HTH IUCS FOR A SLUDGE FIXATION SYSTEM. CONSTRUCTION COMMENCED IN
1977 AND WAS COMPLETED IN JANUARY 1978. SIMILAR TO UNIT 5, THIS MINE
MOUTH pLWT BURNS COAL WITH 17% ASH AND 4.5 TO 4.9X SULFUR CONTENTS. THE
DESIGN IKLUOES A* ESP UPSTREAM OF THE FGD SYSTEM FOR PARTICIPATE
CONTROL. THE F60 SYSTEM INCLUDES TWO UWE TCA MODULES FOR THE REMOVAL OF
S02.
COLUMBUS 8 SOUTHERN OHIO El£C. THIS UM1 WILL BURN HIGH SULFUR OHIO COAL (APPROXIMATELY 2.5 PERCENT
PCS TON
5
NEW 375.0 MM (GROSS)
375.0 MW (ESC)
COAL
2.50 XS
PROCESS NOT SELECTED
VENDOR NOT SELECTED
ENERGY CONSUMPTION: *****
STATUS 6 STARTUP 0/83
SULFUR CONTENT). THE DESIGN CF THE EMISSION CONTROL STRATEGY HAS NOT
YET BEEN FINALIZED. THE PROCESS WILL EITHER BE LIME, LIMESTONE, OR
DOUBLE ALKALI.
COLUMBUS &
POSTON
e
NEW
SOUTHERN OHIO ELEC.
THIS UM'I WILL BURN HIGH SULFUR COAL (APPROXIMATELY 2.5 PERCENT SULFUR
CONTENT). THE DESIGN OF THE EMISSION CONTROL STRATEGY FOR THIS UNIT
HAS NOT ITT BEfN FINALIZED.
375.0 MW (GROSS)
375.0 NW (ESC)
COAL
2.50 IS
PROCESS NOT SELECTED
VENDOR NOT SELECTED
fNERGY CONSUMPTIONS *****
STATUS 6 STARTUP 0/85
COMMONWEALTH EDISON
POWfcRTOM
51
RETROFIT 450.0 MW (GROSS)
425.0 MW
COAL
3.60 XS
LIMESTONE
Klf CORRECTION DIVISION, UO?
PNE»GV CONSUMPTION; ****%
STATUS 2 STARTUP 7/79
TH'E AIR CORRECTION DIVISION OF UOP MAS AWARDED THE CONTRACT FOR A WET
LIMESTONE SYSTEM THAT WILL P£ BACKFITTtb ON TO sOUEfi NO. 51, ONE QF TWO
I6ENUCAI BOILERS SUPPLING STEAM TO AN 850-HK TURBINE-SENEdATOR. THE
SLUDGE WILL BE STABILIZED AND HAULED TO A LANDFILL. REHEAT WILL BE
PROVIDED HY A STEAK COIL WHICH WILL HEAT THE AMBIENT AIR THAT IS PUMPED
INTO THE SCRUsaiR OUTLET EEfORt THE FLUE GAS ENTERS THE STACK. THE S02
EMISSION STANDARD IS 1.S LB. S02/MM 6TO. CONSTRUCTION jS
ABOUT C.Oi COMPLETE.
COOPERATIVE POWER ASSOCIATION
COAL CREEK
1
NEW 545.0 MU (GROSS)
327.0 MW (ESC)
COAL
.63 XS LIGNITE
LIME
COMBUSTION ENGINEERING
ENERGY CONSUMPTION: *****
STATUS 2 STARTUP 5/79
THIS UNIT IS UNDER THF COMBINED OWNERSHIP OF COOP POWER AND UNITED POWER.
A CONTRACT HAS BEEN AWARDED TO COMBUSTION ENGINEERING FOR THE INSTALLA-
TION OF LIME FGD SYSTEMS ON UNITS 1 AND £ AT THIS STATION. THE F60 SYSTEM
FOR EACH BOILER WILL CONSIST Of FOUR SPRAY TOWER ABSORBER MODULES FOR S02
REMOVAL. CLECTRCSTATIC PRE CI PlTATORS WILL BE INSTALLED UPSTREAM OF EACH
ABSORBER TRAIN. CONSTRUCTION BEGAN EARLY IN AUGUST 1977. THE UNIT IS NOW
85-90% CCMPLETE. BAD WINTER WEATHER SLOWED CONSTRUCTION SLIGHTLY.
11
-------
EPA UTILITY F6B SUPVFY: DECEMBER 197f - JANUARY 1979
SECTION 2
fTATUS Of FGD SYSTEMS
UNIT IDENTIFICATION ABSTRACT
COOPERATIVE POWER ASSOCIATION
COAL CREEK
2
NEW 5*5.0 fy (CROSS)
JZ7.0 *y (ESc>
COAL
.63 XS LIGMTF
LIME
COMBUSTION EKblNEERlNE
ENERGY CONSUMPTION: ****!£
STATUS 2 STARTUP 10/t'O
THIS UM1 IS UNDER THE COMBlfFD OWNERSHIP OF COOP POWER AND UN 1 TED POW ER.
A CONTRACT HAS BEEN AWARDED TO COMBUST ION ENGINE£R1*6 FOR T" ""*"?"
TION OF LINE F6D SYSTFMS ON IN1TS 1 AND 2 AT THIS STATION. THE F6D STSTEM
FOR tACH EOILER WILL CONSIST OF FOUR SPRAY TOWER ABSORBER MOCULES FOR SO2
REMOVAL. ELECTROSTATIC PRECI PITATORS WILL BE INST*LL »«"""" OF EACH
ABSORBER TRAIN. CONSTRUCTION BEGAN EARLY IN AUGUST 1 "7 *N » ™E UNIT IS
NOW 45X COMPLETE, THERE HAVE BEEN MINOR DELAYS BUT START-UP IS STILL
SCHEDULE!. FOR NOVEMBER 1979.
DELMARVA POWtR & LIGHT
DELAWARE CITY
1 -3
RETROFIT 1«0.0 »y (GROSS)
180.0 MW
COKE
7.50 XS COKt
WELLMAN LORD
BftVV POWFRCAS
ENERGY CONSUMPTION: ****S!
STATUS 2 STARTUP 4/EG
DFLMAPVA'S DELAWARE CITY PLANT HAS 4 BOILFRS, 3 OF WHICH HAVE STEAM
CAPACITlfcS Of 500K LBS/HR EACH. THE BOILERS GENERATE STEAM AS HELL AS
ELECTRICAL POWER FOR GETTY REFINING & MARKETING. ?-8* S COKE WILL BE
BURNED IK THE BOILERS (INSTEAD OF THE LOW-S CRUDE OIL NOW BURNED) WHEN
THE CONTfrL S^STEK ROES INTO OPERATION IN APRIL 1980. DELMARVA WILL USE
VENTUR1 SCRUBBERS FOR PARTICIPATE REMOVAL AND WELLMAN-LORD F GO SYSTEMS AT
EACH BOItER GAS EXIT FOR SO? CONTROL. DESIGN PARTICULATE AND SO? REMOVAL
EFFICIENCIES ARE 90 AND 85-9C PERCENT RESPECTIVELY. CONSTRUCTION IS 3f?X
COMPLETE .
fOOUfSNt LIGHT
ELRAHA
RETROFIT
XS
510.0 MW (GROSS)
51C.O My (ESC)
«*••*
LIME
CHEMICO
ENERGY CONSUfPTlONr 3.SX
STATUS 1 STARTUP 10/75
REFER TO SECTION 3 Of THIS REPORT FOR ADDITIONAL INFORMATION.
THE F6D JYSTEM ON THIS 4-BOILER UNIT CONSISTS OF FIVE COMI«ON -HE *DER EO
SINGLE S1A6E VENTURT SCRUBBER-ABSORBERS DOWNSTREAM FROM A MECHANICAL
COLLECTOf-ESP PARTICULATE REMOVAL SYSTEM. T«E PLANT BURNS COAL WITH A
HEATING \ALVE OF 11,000 BTU/LB AND SULFUR AND ASH CONTENTS Of 1.8 TO 2.2X
AND 21X ifSPECTIVELY. DEWATERFD SLUDGE FROM THE IUCS PLANT IS HAULED TO
AN OfF-SJTE LANDFILL. THE SYSTEM INCLUDES A DIRECT OIL-FIRED STACK GAS
REHEAT SYSTEM. DESIGNED REMOVAL EFFICIENCIES ARE 99% (PART) AND 83%
(S02).
DUaUFSNE LIGHT
PHILLIPS
1-6
RETROFIT tIC.0 My (GROSS)
410.0 MW (ESC)
COAL
2.00 XS
LIME
CHEMICO
ENERGY CONSUMPTION: 2.4'
STATUS 1 STARTUP 7/73
REFER TO SECTION 3 OF THIS RtPORT FOR ADDITIONAL INFORMATION.
THE FED AND B3JUS02).
EAST KENTUCKY POWER COOP
SPURLOCK
?
NEK 500.0 My (GROSS)
500.0 HW (EsC)
COAL
3.SO XS
LIME
AOL/COMBUSTION E8UIP ASSOCIATE
ENERGY CONSUMPTION: ****X
STATUS 3 STARTUP 3/FO
A CONTRACT HAS BEEN AyAROEO TO ADL/COMBUSTION ECUIPMENT ASSOCIATES FOR
A HHf SLURRY FGD SYSTEM ON THE NEW 500-MW UNIT SPURLOCK ?. PARTICULATES
WILL BE CONTROLLED BY A 99.5i EFFICIENT ESP. COOLIN6 TOWER BLOWDOWN WILL
BE USED /S THE MAKE-UP WATER SOURCE FOR THE FGD SYSTEM. THE DESIGN S02
REMOVAL tFFICIENCY IS 90Z. THE SYSTEM IS NOW IN THE DESIGN PHASE.
GENERAL PUBLIC UTILITIES
COHO
1
NEW 900.Q MW (GROSS)
8CO.O My (ESC)
COAL
3.50 XS
PROCESS NOT SELECTED
VENDOR NOT SELECTED
FHFR6Y CONSUMPTION: ****X
STATUS 6 STARTUP 5/88
STARTUP BATE WAS CHANGED TO 5/88 FOR BOTH BOILER A«D DESULFURIZATI ON
SYSTEM. IIME AND LIMESTONE SCRUBBING ARE THE PRIMARY STRATEGIES BEING
CONSIDERFD FOR COMPLIANCE WITH NEW SOURCE PERFORMANCE STANDARDS. NO
DECISION HAS BEEN MAOF YET, ALTHOUGH A SLURRY TYPE SYSTEM IS NOT
CONTEMPLATED.
12
-------
EPA UTILITY F6D SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION z
JTATUS OF FCD SYSTtMS
UNIT IDENTIFICATION
ABSTRACT
GENERAL PUBLIC UTILITIES
SEWARD
7
NEW £00.0 PIU (GROSS)
800.0 MW (ESC>
COAL
***** XS
PROCESS NOT SELECTED
VENDOR NOT SELECTED
ENERGY CONSUMPTION: *****
STATUS 6 STARTUP 5/85
STARTUP BATE WAS CHANCED TO 5/85 FOR BOTH BOILER AND DESULFURIZATION
SYSTEM. LIME AND LIMESTONE SCRUBBING ARE THE PRIMARY STRATEGIES BEING
CONSIDERED FOR COMPLIANCE WITH THE NEW SOURCE PERFORMANCE STANDARDS.
NO DECISION HAS BEEN MADE YET, ALTHOUGH A SLURRY TYPE WILL NOT PE USED.
GULF POWER REFER TO
SCHOLZ INTERNAT
1,2 ON AUEliS
RETROFIT 23.0 MW (GROSS) BUBBLING
23.0 «W (ESC) PROVIDES
COAL BY A DOU
2.50 XS BITUMINOUS EXISTING
LIMESTONE (CHIVODA 121) ALONG hi
CHIYODA INTERNATIONAL
ENERGY CONSUMPTION: *****
STATUS 1 STARTUP 8/78
SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION. CHIVQDA
IONAL SUPPLIED THIS 23 MW PROTOTYPE UNIT WHICH BEGAN OPERATION
1 30, 1978. THE CT-121 SYSTEM INCLUDES A NEWLY DEVELOPED JET
REACTOR WHICH FEATURES A LARGE GAS-LIQUID INTERFACIAL AREA AND
PARTICULATE AS WELL AS 502 REMOVAL. MIST ELIMINATION is PROVIDED
FIE PASS VERTICAL CHEVRON. GYPSUM IS PRODUCED AND STACKED IN THE
POND. THE STACKING CAPABILITIES OF THE GYPSUM ARE BEING TESTED,
1H THE GROUND WATER NEAR THE STACK SITE TO CHECK FOR LEACHING.
HOOSIER ENERGY
MEROM
1
NEW 490.0 MU (GROSS)
441.0 MU (ESC)
COAL
3.50 XS
LIMESTONE
MITSUBISHI INTERNATIONAL
ENERGY CONSUMPTION: ****X
STATUS 2 STARTUP 4/81
HOOSIER ENERGY AWARDED A CONTRACT TO MITSUBISHI INTERNATIONAL CORP. FOR
TWO LIMESTONE FGD SYSTEMS FDR HESOM 1 AND 2. THE NEW 490 MW COAL-FIRED
UNITS ARE PLANNED FOR LOCATION IN SULLIVAN, INDIANA. THE FLUE GAS STREAMS
WILL BE CLEANED OF PARTICULATE WITH ESP'S (99.4X) AND OF SULFUR DIOXIDE
WITH GRIP-TOWER ABSORRERS OCX). SLUDGE WILL BE STABILIZED AND
STOCKPILED. THE GROUND WAS BROKEN FOR CONSTRUCTION IN NOVEMBER 1977.
BOILER S1RUCTURAL STEEL IS NOW BEING ERECTED AND FGD FOOTINGS ARE IN PLACE
HOOSIER ENERGY
MEROM
?
NEW 490.0 MU (GROSS)
441.0 MW (ESC)
COAL
3.50 XS
LIMESTONE
MITSUBISHI INTERNATIONAL
ENERGY CONSUMPTION: *****
STATUS 2 STARTUP 1/J2
HOOSIER ENERGY AWARDED A CONTRACT TO MITSUBISHI INTERNATIONAL CORP. FOR
TWO LIMESTONE FGD SYSTEMS FOR HEROK 1 AND 2. THE NEU 490 MW COAL-FIRED
UNITS ARE PLANNED FOR LOCATION IN SULLIVAN, INDIANA. THE FLUE GAS STREAMS
WILL BE CLEANED OF PARTICULATE WITH ESP'S (99.4Z) AND OF SULFUR DIOXIDE
WITH GRIC-TOUER ABSORBERS (9o%>. SLUDGE WILL BE STABILIZED AND
STOCKPILED. THE GROUND WAS BROKEN FOR CONSTRUCTION IN NOVEMBER 1977, BUT
DUE TO TKt BAD WINTER WEATHER, CONSTRUCTION WAS DELAYED. THE BOILER IS
ESSENTIALLY COMPLETE. STARTUP IS EXPECTED SHORTLY.
HOUSTON LIGHTING ft POWER CO,
U.A. PARISH
8
NEV 550.0 MU (GROSS)
512.0 MH (fSC)
COAL
.60 XS
LIMESTONE
VENDOR NOT SELECTED
ENERGY CONSUMPTION: ****X
STATUS 5 STARTUP 10/82
HLSP WILL BE INSTALLING AN FGD SYSTEM ON THE UTILITY'S 600 MW W. A.-
PARISH g UNIT. PARTICUALTE MATTER WILL BE CONTROLLED BY BAGHOUSE UP-
STREAM OF THE LIMESTONE SLURRY FGD SYSTEM. THE FGD SYSTEM WILL BE
DESIGfcEO TO REMOVE SO? WITH AN EFFICIENCY OF GREATER THAN B3X. REHEAT
WILL BE PROVIDED BY BY-PASSING 71 OF THE PARTICULATE CLEANED
GAS. SLUDGE WILL BE DFWATERFD, BLENDED WITH FLYASH AND DISPOSED IN AN
ON SITE LANDFILL. INITIAL STARTUP IS SCHEDULED FOR FALL, 1982.
INDIANAPOLIS POWER & LIGHT
PETERSBURG
3
NEW 532.0 MW (GROSS)
532.0 MW (ESC)
COAL
3.25 XS BITUMINOUS
LIMESTONE
AIR CORRECTION DIVISION, UOf
ENERGY CONSUMPTION: 2.4X
STATUS 1 STARTUP 12/77
REFER TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION. THE WET
LIMESTONE FGD SYSTEM INSTALLED ON THIS UNIT WAS SUPPLIED BY THE AIR
CORRECTIIN DIVISION OF UOP. UNIT 3 FIRES BITUMINOUS COAL HAVING A SULFUR
CONTENT CF 1.5-4.5Z» AN ASH CONTENT OF 9-10X AND A 11,000 BTU/LB
VALUE. TkO ESPS PROVIDE PRIMARY PARTICULATE CONTROL UPSTREAM OF A FOUR-
MODULE TCA FGD SYSTEM. STABILIZED SLUDGE IS DISPOSED ON AN ON~SlTE POND.
THE OESIEN INCLUDES AN INDIRECT STEAM TUBE REHEAT SYSTEM. SHAKE DOWN
AND DEBUGGING OPERATIONS ARE STILL PROCEEDING.
13
-------
EPA UTILITY F&D SURVEY: DECEMBER 197P - JANUARY 1979
SECTION 2
STATUS OF FGD SYSTEMS
UNIT IDENTIFICATION ABSTRACT
INDIANAPOLIS POWER t. LIGHT
PETERSBURG
4
NEW 53C-0 MU (CROSS)
530.0 MW (ESC)
COAL
3.50 XS BITUMINOUS
LIMESTONE
RESEARCH COTTRELL
ENERGY CONSUMPTION: *****
STATUS 2 STARTUP 10/FJ
KANSAS CITY POWER E LIGHT
HAWTHORN
POWER * LIGHT AWARDED A CONTRACT TO RESEARCH COTTRFLL
FOR A LIKE STONE FGD SYSTEM. S02 REMOVAL EFFICIENCY WILL BE
APPROXIMATELY BO PERCENT. THIS NEW UNIT WILL FIRE HIGH-SULFUR
BITUKINOU COAL WITH A HEATING VALUE OF 11,000 STU/LB AND ASH AND
SULFUR CONTENTS OF 10 PERCENT AND 3.5 PERCENT, RESPECTIVELY, SLUDGE KILL
BE DtVAT.RED AND MlXEt) WITH FLYASH TO PRODUCE A DRV STABILIZED PRODUCT.
EXCAVATICN, FOUNDATION WORK AND SOME STEEL WORK IS NOW IN
PROGRESS ON THE UNIT.
RETROFIT 110.0 f!W (CROSS)
110.0 MM (ESC)
COAL
.60 IS BITUMINOUS
LIME
COMBUSTION ENGINEERING
ENERGY CONSUMPTION: 1 . 6X
STATUS 1 STARTUP 11/72
REFER TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION.
THE SCRUfPER-ASSORBFR SYSTEM ON THIS UNIT WAS CONVERTED FROM A LIMESTONE
FURNACE INJECTION AND TAIL-ENO SYSTEM TO A TAIL-END LIME SLURRY SYSTEM.
OPERATIC!* IN THE LIME SCRUBBING MODE COMMENCED ON JANUARY 1, 1977. COM-
PLIAKCi 1EST INDICATED THE DMT MEETS THE KANSAS CITY 0.1? LB/HM
BTU PARTICULATE REG. F60 SYSTEM DESIGN INCLUDES A FINNED-TUBE STEAH
REHE*T£R, AN ON-SITE UNLINED SLUDGE DISPOSAL POND, AND A CHEVRON MIST
ELIMINATOR SYSTEM. THE 2 FGD MODULES CAN BE BY-PASSED IN EMERGENCIES.
KANSAS CITY POWER 8 LIGHT
HAWTHORN
4
RETROFIT 110.0 MU (GROSS)
110.0 MU (ESC)
COAL
.60 XS BITUMINOUS
LIME
COMBUSTjON ENGINEERING
ENERGY CONSUMPTION: 1.8X
STATUS 1 STARTUP 8/72
REFER TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION.
THE SCRUDPER-ABSORBER SYSTE" ON THIS UNIT WAS CONVERTED FROM A
FURNACE INJECTION AND TAIL-END SYSTEM TO A TAIL-END LIME SLURRY SYSTEM.
OPERATION IN THE LIME SCRUBBING MODE COMMENCED ON JANUARY 1, 1977- COM-
PLIANCE TEST INDICATED THE UNIT MEETS THE KANSAS CITY 0.17 LB/MM
BTU PARTICULATE REG. FGD SYSTEM DESIGN INCLUDES A FINNED-TUBE STEAM
REHEATER, AN ON-SITE UNLINED SLUDGE DISPOSAL POND, AND A CHEVRON
ELIMINATE SYSTEM. THE 2 FGD MODULES CAN BE BY-PASSED IN EMERGENCIES.
KANSAS CITY POWER R LIGHT
LA CV6NE
1
NEW
874.0 MW (GROSS)
874.0 MU (ESC)
COAL
5.39 XS SUPBITUMINOUS
LIMESTONE
PABCOCK R WILCOX
ENERGY CONSUMPTION: 2.7X
STATUS 1 STARTUP 2/73
REFER TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION.
THE EMISSION CONTROL SYSTEM FOR THIS NEW COAL-FIRED POWER-GENERATING UNIT
CONSISTS OF EIGHT SCRUBBER MODULES FOR FLY ASH AND 502 REMOVAL. EACH
MODULE ItvCLUDES A VENTURI SCRUBBER IN SERIES WITH A 2-STAGE IMP IN CEMENT
PLATE ABSORBER. THE SCRUBBER PLANT is AN INTEGRAL PART OF THE POWER-
6ENFRATIKG COMPLEX, ALLOWING NO FLUE 6AS PYPASS. INITIAL OPERATIONS
COMMEKCED IN FEB. 1973. COMMERCIAL SERVICE HAS ATTAlNgfi 6V JUNE 1973.
KANSAS POWER K LIGHT
JEFFREY
1
NEW 720.0 MU (GROSS)
540.0 MU (£SC>
COAL
.32 XS
LIMESTONE
COMBUSTION ENGINEERING
ENERGY CONSUMPTION: *****
STATUS 1 STARTUP 8/78
REFER TO SECTION 3 Op THIS REPORT FOR ADDITIONAL INFORMATION. COMBUSTION
ENGINEERING SUPPLIED THE LIMESTONE EMISSION CONTROL SYSTEM FOR THIS NEW
COAL FIRID UNIT. THE UNIT CONSISTS OF A COLD-SIDE ESP AND SPRAY TOWERS
FOR THE CONTROL OF SOJ AND PARTICULATE EMISSIONS. 30X Of THE FLUE 6AS IS
BYPASSED FOR REHEAT. NOx EMISSIONS ARE CONTROLLED BY AN AIR OVtRFIRE
SYSTEM AT THE TAN6ENTIALLY HRED PULVERIZED BUNKERS. THE CLFANEB 6ASES
ARE VENTfD TO A 600 FT STACK. SLUD6E IS MIXED WITH BOTTOM ASH AND
DISPOSED OF IN THE EXISTING ON-SITE BOTTOM ASH POND.
KANSAS POWER k LI6HT
JEFFREY
2
MEW 700.0 MW (GROSS)
490.0 MW (ESC)
COAL
.30 XS
LIMESTONE
COMBUSTION ENGINEERING
ENERGY CONSUMPTION: **«*X
STATUS 2 STARTUP 6/80
COMBUSTICN ENGINEERING IS SUPPLYING THE EMISSION CONTROL SYSTEM FOR THIS
NEW COAL FIRED UNIT. THE SYSTEM WILL CONSIST OF A COLD-SIDE ESP ANb SPRAY
TOWERS FCR THE CONTROL OF PARTICIPATE AND 502 EMISSIONS. 30X OF THE FLUE
6AS WILL EE BYPASSED FOR REHEAT. AN OVERFIRE AIR SYSTEM AT THE TAN6ENT1AL
FIRED PULVERIZED BURNERS WILL CONTROL NOX EMISSIONS. THE CLEANED GASES
WILL BE VENTED TO A 600 FT STACK. SLUD6E WILL BE MIXED WITH BOTTOM ASH
AND DISPOSED ON-SITE IN THE BOTTOM ASH POND. THE SYSTEM STEEL WORK IS UP
AND CONSTRUCTION IS APPROXIMATELY 40X COMPLETE.
14
-------
EPA UTI11TY FCit SURVEY! 6ECF.MBER 1978 - JANUARY 1979
SECTION 2
STATUS OF FGD SYSTEMS
UNIT IDENTIFICATION
ABSTRACT
KANSAS POWER B, LIGHT
LAWRENCE
4
RETROFIT 125.0 MW (GROSS)
1JS.O MW (FSc>
COAL
.55 XS
LIMESTONE
COMBUSTION ENGINFER1NG
ENERGY CONSUMPTION! *«**«
STATUS 1 STARTUP 1/76
RF.FF.K TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION.
THE NEH LIMESTONE FGD SYSTEM COMMENCED OPERATIONS JN EARLY JANUARY 1977.
THE KEk SYSTEM REPLACED MARBLE-BED TOWERS WITH SPRAY TOWERS. THERE HAVE
BEEN NO FORCED SCRUBBfR OUTAGES REPORTED SINCE START-UP. CONTINUOUS S02
MONITORS HAVE RECORDED SO? REMOVAL EFFICIENCIES OF BETTER THAN P5*.
THE UTILITY REPORTED PARTICIPATE REMOVAL IS SUCH THAT NO VISIBLE PLUME
EXITS THl STACK. THE PLANT IS FIRING COAL RATED AT 10,000 BTU/LB WITH A
SULFUF1 CONTENT OF 0.5X
KANSAS POWER & LIGHT
LAWRENCE
5
RETROFIT 4?0.0 DIM (GROSS)
420.0 MW (ESC)
COAL
.55 XS
LIMESTONE
COMBUSTION ENGINEERING
ENERGY CONSUMPTION: *****
STATUS 1 STARTUP 11/71
REFER 10 SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION. THE
ORIGINAL LIMESTONE INJECTION AND TAIL-END SCRUBBING SYSTEM W«S SHUT
DOWN ON PARCH 20 SO THAT THE NEW ROD-SCRUBBER AND SPRAY TOWER ABSORBER
SYSTEM CHILD BE TIED INTO THE UNIT. THE NFW SYSTEM, WHICH INCLUDES TWO
MODULES, EACH CAPABLE OF HANDLING APPROXIMATELY SO PERCENT OF THE TOTAL
BOILER FIDE GAS FLOW, CAME ON LlNE APRIL 1«. 1978. THE SYSTEM DESIGNER
AND SUPPLIER WAS COMBUSTION ENGINEERING. THE UNIT FIRES LOW SULFUR
WYOMING COAL WITH A HFAT CONTENT OF 10,000 BTU/LB.
KENTUCKY UTILITIES
GREEN RIVER
1-3
RETROFIT 64.0 MW (GROSS)
64.0 MW (ESC)
COAL
4.00 XS BITUMINOUS
LIME
AMERICAN AIR FILTER
ENERGY CONSUMPTION: 3.u
STATUS 1 STARTUP 9/7S
REFER TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION.
THE SCRIMPER PLANT INSTALLED AT THIS STATION CONSISTS OF ONE MODULE
DESIGNED TO REMOVE PARTICULATE (VARIABLE-THROAT VENTURI) AND SO? (MOBILE
-BED CONTACTOR) FROM COAL-FIRED BOILER FLUE GAS. THE SCRUBBER WAS
DESIGNED AND SUPPLIED BY AAF. SLUDGE IS DISPOSED IN AN ON-SITE UNLINED
POND. THE COAL BURNED HAS SULFUR AND ASH CONTENTS OF 4.0 AND 11*
RESPECTIVELY AND A MOISTURE CONTENT OF 6-10 PERCENT. INITIAL STARTUP
OCCURRED IN SEPTEMBER 1975. COMMERCIAL OPFRATION BEGAN IN JANUARY 1976.
LAKELAND UTILITIES
MCINTOSH
1
NEW 364.0 PW (GROSS)
364.0 MU (ESC)
COAL
Z.56 XS BITUMINOUS
LIMESTONE
BABCOCK g WILCOX
ENERGY CONSUMPTION: ****X
STATUS 3 STARTUP 10/K1
THE CITY OF LAKELAND DEPARTMENT OF ELECT RlC AND WATER UTILITIES AWARDED
A CONTRACT TO BSW FOR AN EMISSION CONTROL SYSTEM ON THE UTILITY'S NEW
350-MW PCWER GENERA6IN6 UNIT, MCINTOSH 3. THE UNIT WILL UTILIZE COLD
SIDE FSP'S FOR PARTICULATE REMOVAL AND TWO LIMESTONE SCRUBBER ABSORBER
MODULES. START-UP IS SCHEDULED FOR OCTOBER 1981. THE COAL WILL CONTAIN
ABOUT E.5* SULFUR. THE UNIT DESIGN INCLUDES A REHEAT AND AN IUCS SLUDGE
DISPOSAL SYSTEM. SITE EXCAVATION HAS BEGUN.
LOUISVILLE GAS g ELECTRIC
CANE RUN
4
RETROFIT 190.0 My (GROSS)
190.0 BW (ESC>
COAL
3.75 XS
LIKE
AMERICAN AIR FILTER
ENERGY CONSUMPTION: 1.6%
STATUS 1 STARTUP 8/76
REFER TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION.
THE FCC SYSTEM RETROFITTED ON THIS BOILER WAS DESIGNED AND SUPPLIED BY
AMERICAN AIR FILTER AND WAS FIRST PLACED IN THE GAS PATH ON AUGUST 7,
1976. THE SYSTEM CONSISTS OF TWO PARALLEL MODULES WHICH INCLUDE MOBILE
BED CONTACTORS AND OPERATE WITH A CARBIDE LIME ADDITIVE. FOLLOWING A
NUMBER OF MAJOR SYSTEM MODIFICATIONS (CHEVRON-TYPE MIST ELIMINATOR. OIL
FIRED RFIFAT, PLASITE DUCT LINER, HIGHER L/6), THE SYSTEM SUCCESSFULLY
PASSED COMPLIANCE TESTING (85X SO? REMOVAL) ON AUGUST 3 AND 4, 1977.
LOUISVILLE GAS & ELECTRIC
CANE RUN
•5
RETROFIT ?00.0 KM (GROSS)
2CO.O MU (ESC)
COAL
3.75 XS BITUMINOUS
LIME
COMBUSTION ENGINEERING
ENERGY CONSUMPTION: 1.5*
STATUS 1 STARTUP 12/77
REFER TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION.
THE FED SYSTEM FOR THIS UNIT WAS DESIGNED AND SUPPLIED BY COMBUSTION
ENGINEERING. IT CONSISTS OF TWO SPRAY TOWER ABSORBERS FOR FULL-LOAD SO2
REMOVAL tUt UTILIZES CARBIDE LIME AS THE ABSORBING REAGENT. IN-LINE STEAM
REHEAT, A COMMON REACTION TANK, AND A THICKENER FOR SOLIDS DEWATERING
ARE INCLIOED. AN EXISTING UPSTREAM ESP PROVIDES PRIMARY PARTICIPATE
CONTROL. THE FGD SYSTEM BEGAN INITIAL OPERATION IN DEC. 1977 BUT A COAL
STRIKE FlffCED A PLANT SHUTDOWN. THE SYSTEM WAS RE-STARTED HARCH 2«, 1978.
15
-------
FPA UTILITY ffeD SURVEY: DECEMBER 197F - JANUARY 1979
SECTION 2
CTATUS OF FSD SYSTEMS
UNIT IDENTIFICATION
ABSTRACT
LOUISVILLE GAS t ELECTRIC
CANE RUN
6
RETRpflT 278.0 My (GROSS)
27f.O MW (ESC)
COAL
3.75 XS
DUAL ALKALI
AOL/COMBUSTION EQUIP ASSOCIATE
FNFRGY CONSUMPTION: *****
STATUS Z STARTUP 3/79
THE CONTACT FOR THIS FULL-SCALE DEMONSTRATION flat SYSTEM HAS BFEN
AWARDED 1C A.D. LITTLE/COMBUSTION EflUlPMENT ASSOC. FOR THE INSTALLATION
OF A DOUILE ALKALI SYSTEM. THE FEDERAL EPA HILL SUBSIDIZE A MAXIMUM
$4.5 MM IOR OPERATION, RESEARCH AND DEVELOPMENT, AND REPORT WRITING FOR
A ON£-YE«F PERIOD FOLLOWING THE FIRST THREE MONTHS OF OPERATIONS
COAL
3.75 XS
LIME/LIMFSTONE
COMElUSTION ENGINEERING
fNERGY CONSUMPTION: *****
STATUS 2 STARTUP */M
A COMPLIANCE SCHEDULE WAS SUBMITTED TO TH£ JEFFERSON COUNT* Alfc POLLUTION
CONTROL USTRICT WITH 4/81 ESTABLISHED AS THE STARTUP DATE FOR AN F6D
SYSTEM. CPERATIN6 DATA AND UFORMAT10N FROM THE FULL-SCALE SCRUP0EK PLANT
NOW IN STRVKE ON THE NO. 4 UNIT AT CANE RUN WILL BE OBTAINED BEFORE THE
UTILITY FROCtEDS WITH ADDITIONAL SYSTEM DESI6N WORK. * CONTRACT HAS
AWAR&fD 10 COMBUSTION ENGINSlRlNG FOR A LI M E /I IM ESTOIHE F6D SYSTEM.
LOUISVILLE IAS t ELECTRIC
MIIL CREEK
2
RETROFIT 350.0 MW (GROSS)
350.0 MW (FSC)
COAL
3.75 XS
LIME/LIMESTONE
COMBUSTION EN61NFEPING
FNER&Y CONSUMPTION: *****
STATUS 3 STARTUP 4/?2
A COMPLIANCE SCHEDULE WAS SUBMITTED TO THE JEFFERSON COUNTY AIR POLLUTION
CONTROL CISTRICT WITH 4/82 ESTABLISHED AS THE STARTUP DATI FOR AN f6p
SYSTEM. CPERAT1NG DATA AND IKFORMATION FROM THE FULL-SCALE SCRUEBiR PLANT
NOW IN SERVICE ON THE NO. 4 UNIT AT CANF RUN WILL BE OBTAINED BEFORE THE
UTILITY M?OCEIDS WITH ADDITIONAL SYSTEM DESIGN WORK. A CONTRACT WAS
AWAPDID 10 COMbUSTION ENGINEERING FOR A LIWE'lIMESTONf F$B SYSTEM.
LOUISVILLE GAS K ELECTRIC
MILL CREEK
J
NEW 425.0 KM (GROSS)
425.0 MW (ESC)
COAL
3.75 XS BITUMINOUS
LIME
AMERICAN AIR FILTE"
ENERGY CONSUMPTION: *****
STATUS 1 STARTUP 8/7$
REFER TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION. THI SYSTEM
WAS DESICNED AND SUPPHID BY AAF AND UTILIZES CARBIDi LIME
AS THE ABSORBENT. FOUR MOBILE-BEG ABSORBERS TREAT THfc FLUE GAS RESULTING
FROM THE COMBUSTION OF HIGH-SULFUR COAL. THE SYSTEM OPERATES IN AN OPEN
WATER LOCF. THE SCRUBPW WASTE is STABILIZED WITH FLYASH AND LIME.
THE UNIT RECAME OPERATIONAL ON AUGUST 13i 1978.
LOUISVILLE GAS I ELECTRIC EECAlSt
MILL CREEK UNIT STA
t NEW 495-
IV EW 495.0 MW (GROSS) IS IN PR
495.0 MW (ESC) TREATING
COAL CLOSED.
3.75 *S REHEAT W
LIME PRIOR TO
AMERICAN AIR FILTER
ENERGY CONSUMPTION: ****%
STATUS Z STARTUP 7/E1
IOWEH DEMAND HAS NOT COME Up AS RAPIDLY AS HAD BEEN EXPECTED,
KT-UP HAS BEEN MOVED PACK TO JULY 1961. CONSTRUCTION OF THIS
I73. THE FGD SYSTEM CONSISTS OF TWO 2-STA6F MARBLE
BED ABSOKBERS WHICH ARE DESIGNED TO USE CARBIDE LIME ADDITIVE AS THE
scRUtciNc REAGENT. PADDYS RUN NO. 6 is A PEAK-LOAD UNIT THAT OPERATES
ONLY DURING DEMAND PERIODS. AN EXTENSIVE EPA SCRUBBER/SLUDGE EVALUATION
STUDY WAI COMPLETED IN AUGUST 1977. THIS UNIT HILL BE RETIRED WHEN MILL
CREEK 3 ITCOMES FULLY OPERATIONAL.
16
-------
EPA UTILITY FGt SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 2
STATUS OF FGD SYSTEMS
UNIT IDENTIFICATION
ABSTRACT
LOUISVILLE 6AS I ELECTRIC
TRIMBLE COUNTY
1
NEW 575.0 «W (GROSS)
575.0 MW (ESC)
COAL
4.00 XS BITUMINOUS
PROCESS NOT SELECTED
VENDOR NOT SELECTED
ENERGY CONSUMPTION: *****
STATUS 6 STARTUP 7/84
L6&E WILL BE INSTALLING F6D SYSTEMS ON TWO OF THE UTILITY'S TRIABLE
COUNTY UMTS. THE 575-MW UNITS WILL BURN COAL WITH AN AVERAGE 4* SULF(jR
CONTENT (IF NO COAL WASH IS INCLUDED). PARTICULATE MATTER WILL BE
CONTROLLED BY ESP'S AND SOZ KILL BE CONTROLLED BY WET SCRUBBING (90X
REMOVAL EFFICIENCY). SLUDGE DISPOSAL STRATEGY IS AS YET, UNDECIDED.
START-UP IS SCHEDULED FOR JULY 1984 A«D 1986 RESPECTIVELY.
LOUISVILLE CAS t ELECTRIC
TRIMBLE COUNTY
?
NEW 575.0 My (GROSS)
575.0 MW (ESC)
COAL
4.00 XS BITUMINOUS
PROCESS NOT SELECTED
VENDOR NOT SELECTED
ENER6Y CONSUMPTION: *****
STATUS 6 STARTUP 0/84
LG&E W1LI BE INSTALLING FED SYSTtMS ON TWO OF THE UTILITY'S TRIABLE
COUNTY UMTS. THE 575-MW UNITS WILL BURN COAL WITH AN AVERAGE 4X SUlfUR
CONTENT (IF NO COAL WASH IS INCLUDED). PARTICULATE MATTER WILL BE
CONTROLLtD BY ESP'S AND SO2 WILL BE CONTROLLED BY WET SCRUBBING (9QX
REMOVAL EFFICIENCY). SLUDGE DISPOSAL STRATEGY IS AS YET* UNDECIDED.
START-UP IS SCHEDULED FOR JULY 1984 A(gO 19B6 RESPECTIVELY-
MIDDLE SOUTH UTILITIES
ARKANSAS COAL
5
NEW 890.0 MW (CROSS)
890.0 MW (ESC)
COAL
.50 ZS
PROCESS NOT SELECTED
VENDOR NOT SELECTED
ENERGY CONSUMPTION: *****
STATUS 5 STARTUP 1/R6
A CONTRACT HAS BEEN AWARDED FOR BOILERS AMD TURBINES ON S*X NEW MIDDLE
SOUTH UTILITIES UNITS. THE UTILITY IS CURRENTLY RE«UESTING/EVALUATING
BIDS FOR THE FGD INSTALLATIONS ALTHOUGH THE TYPE OF FGO SYSTEM HAS NOT
YET EEEN DETERMINED.
MIDDLE SOUTH UTILITIES
ARKANSAS COAL
6
NEW 890.0 MW (GROSS)
890.0 MW (ESC>
COAL
.50 ZS
PROCESS NOT SELECTED
VENDOR NOT SELECTED
ENERGY CONSUMPTION: *****
STATUS 5 STARTUP 1/88
A CONTRACT HAS BEEN AWARDED FOR BOILERS AND TURBINES ON SIX NEW MIDDLE
SOUTH UTILITIES UNITS. THE UTILITY IS CURRENTLY REQUESTING/EVALUATIN6
BIOS FOR THE FGD INSTALLATIONS ALTHOUGH THE TYPE OF FGD SYSTEM HAS NOT
YET BEEN DETERMINED.
MIDDLE SOUTH UTILITIES
LOUISIANA COAL
1
NEW 890.0 MW (GROSS)
890.0 MU (ESC>
COAL
.50 XS
PROCESS NOT SELECTED
VENDOR NOT SELECTED
ENERGY CONSUMPTION: ****z
STATUS 5 STARTUP 0/86
A CONTRACT HAS BEEN AWARDED FOR BOILERS AND TURBINES ON SIX NEW MIDDLE
SOUTH UTILITIES UNITS. THE UTILITY IS CURRENTLY REQUEST/EVALVAT1N&
BIDS FOR THE FGD INSTALLATIONS ALTHOUGH THE TYPE OF FGO SYSTEM HAS NOT
YET BEEN DETERMINED.
MIDDLE SOUTH UTILITIES
LOUISIANA COAL
2
NEW 890.0 MW (GROSS)
890.0 MU (ESC)
COAL
.50 XS
PROCESS NOT SELECTED
VENDOR NOT SELECTED
ENERGY CONSUMPTION: ****X
STATUS 5 STARTUP 0/88
A CONTRACT HAS BEEN AWARDED FOR BOILERS AND TURBINES ON SIX NEu MIDDLE
SOUTH UTILITIES UNITS. THE UTILITY IS CURRENTLY REQUESTING/EVALUATING
BIDS FOR THE FGD INSTALLATIONS ALTHOUGH THE TYPE OF FGD SYSTEM HAS NOT
YET BEEN DETERMINED.
17
-------
F PA UTILITY FGD SURVEY: DECEMBER 1"7t - JANUARY 1979
SECTION 2
bTATUS Of F6D SYSTEMS
UNIT IDENTIFICATION
ABSTRACT
"IDDLE SOUTH UTILITIES
MISSISSIPPI COAL
1
NEW 89C.O l»» (GROSS)
P90.0 MW (fSc >
COAL
.50 IS
PROCESS NOT StLECTC|>
VENDOR NOT SELECTED
ENERGY CONSUMPTION: *****
STATUS 5 STARTUP 0/?5
A CONTRACT HAS BEEN AWARDED FOR BOILERS AND TURBINES ON SIX NEU MIDDLE
SOUTH UTILITIES UNITS. THE UTILITY IS CURRENTLY RfOUESTIN6/EVALUATINS
tIDS FOR THE F6D INSTALLATIONS ALTHOU6H THE TYPE OF FGD SYSTEM HAS NOT
YET eerw BETERWINEO.
MIDDLE SOUTH UTILITIES
MISSISSIPPI COAL
7
NEW 850.0 Mb (GROSS)
890.0 KW (ESC)
COAL
.50 XS
PROCESS NOT SELECTED
VENDOR NOT SELECTED
ENERGY CONSUMPTION: *****
STATUS 5 STARTUP 0/K7
A CONTRACT HAS BEEN AWARDED FOR BOILERS AND TURBINES ON Si* NEW MIDDLE
SOUTH UTILITIES UNITS. THE UTILITY IS CURRENTLY REQUESTING/EVALUATING
BIDS fOR THE FGD INSTALL ATI OIvS ALTHOUGH THE TYPE OF FGD SYSTEM HAS NOT
YbT fcEEN DETERMINED.
MINNESOTA POWER & LIGHT
CLAY BOSWELL
t
NEW 5GQ.Q MW (GROSS)
475.0 MW (ESC)
COAL
.80 XS SUBBITUMINOUS
LIME/ALKALINE FLYASH
PEABOOY PROCESS SYSTEMS
ENERGY CONSUMPTION: *****
STATUS 2 STARTUP 5/80
KINNfSOT/i PRL HAS AWARDED A CONTRACT TO PEABODT PRoCESS sVSTEMS FOR A
LIltE/ALKlLINE FLYASH SCRUBBING SYSTEM. THE CONFIGURATION WILL BE VENTURI
SCRUbPER" FOLLOWED BY SPRAY TOWERS. HOT SIDE ESP'S WILL BE USED FOR
PARTICDL0TE CONTROL. STACK GAS REHEAT WILL BE ACCOMPLISHED BY BYPASSING
Sr. OF FliF GAS AROUND THE SCRUBBER. THE UNIT WILL FIRE S UBBI TOM INOUS
COLSTR1P COAL UlTH A SULFUR CONTENT OF 0-S*« AND AN ASH CONTENT OF 9.OX
(HEATING VALUE-8300 BTU/LP). MAKE-UP WATER SOURCE WILL BE THE RIVER AND
THE CLAY LINED POND. CONSTRUCTION OF THE FGD SYSTEM IS ABOUT 9QX
COMPLETE .
KINNKOTA POWER COOPERATIVE
HILTON R. YOUNG
2
N£W 477.0 MW (GROSS)
4C5.0 MW (ESC)
COAL
.70 XS LIGNITE
LIME/ALKALINE FLYASH
ADL/COMBUSTlON EQUIP ASSOCIATE
ENERGY CONSUMPTION: 1.9X
STATUS 1 STARTUP 9/77
REFER TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION.
THIS LIME/ALKALINE FLYASH SCRUBBING WAS DESIGNED AND SUPPLIED BY
ADL/CCMB ISTION EQUIPMENT ASSOCIATES. IT CONSISTS OF A COLD-SIDE ESP
FOLLOWED BY TWO SPRAY TOWERS. THE DESIGN INCLUDES A WASH TRAY AND A
CHEVRCKl P1ST ELIMINATOR. 15X FLUE «AS BYPASS PROVIBFS STACK 6AS REHEAT.
THE UNIT FIRES A LOW-SULFUR &ORTH OOKOTA LIGNITE WITH AN AVERAGE ASH
CONTENT CF 8 PERCENT, SULFUR CONTENT OF 0.7 PERCENT, AND H£A1 CONTENT OF
6500 (IV/IB. THE FLYASH ALKALINITY IS USED AS THE PRIMARY S02 REA6ENT.
MONTANA POWER
COLSTRIP
1
NEW ?tC.O I'M (GROSS)
36C.O MW (ESC)
COAL
.77 XS SU6BITUMINOUS
LIME
ADI/COMBUSTION E9U1P ASSOCIATE
ENERGY CONSUMPTION: J.JT
STATUS 1 STARTUP 9/75
REFER TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION.
THIS rtC EflUlPPED UNIT WAS DECLARED COMMERCIAL IN NOVEMBER 1975. THE
SCROEBINt SYSTEM PROVIDES PARTICIPATE AND S02 CONTROL WITH THREE SCRUBBER
MODULES. FACH MODULE CONSISTS OF A DOWNFLOW VENTURI SCRUBBER CENTERED
WITHIN Ah UPFLOW SPRAY TOWER ABSORBER. EACH MODULE CAN TREAT 40% OF
THE TOTAL BOILER FLUE GAJ AND THE MODULES CANNOT BE BYPASSED. TtfE UN-
STA6UI7£» SLUDGE IS DISPOSED IN AN ON-SITE LINED DISPOSAL POND. IN-LINE
STEAM KE^EAT AND CLOSED WATER LOOP CAPABILITY ARE INCLUDED IN THE SYSTEM.
MONTANA POWER
COLSTRIP
2
NEW 360.0 MM (GROSS)
360.0 MW (ESC)
COAL
.77 XS SUtBlTUMINOUS
LIME
ADL/COMBUSTlON E8UIP ASSOCIATE
ENERGY CONSUMPTION: 3.3X
STATUS 1 STARTUP 5/76
REFER TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION.
THIS FGD EQUIPPED UNIT WAS DECLARED COMMERCIAL IN AUGUST 1976. THE
SCRUtBINS SYSTEM PROVIDES PARTICULATE AND S02 CONTROL WITH THREE SCRUBBER
MODULES. EACH MODULE CONSISTS OF A DOWNFLOW VENTURI SCRUBBER CENTERED
WITHIN Ah UPFLOW SPRAY TOWER ABSORBER. EACH MODULE CAN TREAT 40* OF
THE TOTAL BOILER FLUE GAS AND THE MODULES CANNOT BE BYPASSED. THE UN-
STABHI7tl> SLUDGE IS DISPOSED IN AN ON-SITE LINED DISPOSAL POND. IN-LINE
STEAM REhEAT AND CLOSED WATER LOOP CAPABILITY ARE INCLUDED IN THE SYSTEM.
18
-------
EPA UTILITY FKC SURVEYS OECEMBEff 1976 - JANUARY
SECTION 2
STATUS OF F6D SYSTEMS
UNIT IDENTIFICATION
ABSTRACT
MONTANA POWER
COLSTRIP
3
NEV 700
700
tOAL
.70 XS
LIME/ALKALINE
• 0
.0
ttu
MU
(6ROSS)
CESO
A CONTRACT FOR THE INSTALLATION OF TWO ADBITIOWAL LI ME /ALKALINE FLYASH
SCRU6BINI SYSTEMS HAS BEEN AWARDED TO A.D. LITTLE/CO«fi«JS Tl ON EQUIPMENT '
ASSOCIATES. THESE SYSTEMS WILL BE INSTALLED ON UNITS "5 AND 4 OF THE
COLS1R1P POWER STATION. COLSTRIP UNITS 1 AND 2 ARE BOTH EQUIPPED KITH
OPERATIONAL LIME/ALKALINE FLYASH SCRUBBING SYSTEMS FOR THE REMOVAL OF
PARTICIPATES AND SULfUR DlOXjDE.
FLYASH
ADI/COMBUSTION EQUIP ASSOCIATE
ENERGY CONSUMPTION: ***«*
STATUS 3 STARTUP 7780
MONTANA POWER
COLSTRIP
«
NEW roo.o MM (GROSS)
7CO.O MW
COAL
.70 XS
LIME/ALKALINE FLYASH
ADL/COM6USTION EQUIP ASSOCIATE
ENERGY CONSUMPTION: *****
STATUS 3 STARTUP 7/S1
A CONTRACT FOR THE INSTALLATION OF TWO ADDITIONAL LIME/AIKAL1NE FLYASH
SCRUfcfJNf SYSTEMS HAS BEEN AWARDED TO A.D. UTTLE/cOflfiUS TjON EfitllPMENT
ASSOC1ATIS. THESE SYSTEMS WILL BE INSTALLED ON UNITS 3 AND 4 OF THE
COLSTRIP POWER STATION. COLSTRIP UNITS 1 AND ? ARE BOTH EQUIPPED WITH
OPERATlonAL LIME/ALKALINE Ft YASH SCRUBBING SYSTEMS FOR THE REMOVAL OF
PARTICULmS AND SULFUR DIOXIDE.
NEVADA POWER
HARRY ALLEN
1
NEW 500.0 MM (GROSS)
500.0 MW (FSO
COAL
***** Xs
PROCESS NOT SELECTED
VENDOR NOT SELECTED
ENERGY CONSUMPTION: ****X
STATUS 6 STARTUP 6/F5
CONS1DE.R1K6 HOT SIpE ESP IN CONJUNCTION WIT" **> f6D SrSTEM. SPECIFICA-
TIONS HAVE NOT YET BEEN PREPARED.
NEVADA POWER
HARRY ALLEN
Z
NEW 500.0 MW (GROSS)
500.0 MM (FSC)
COAL
***** XS
PROCESS NOT SELECTED
VENDOR NOT SELECTED
FNERGT CONSUMPTION: ****X
STATUS 6 STARTUP 6/?<>
CONS1DER1N6 HOT SIDE ESP IN CONJUNCTION UlTH AN F6D SYSTEM. SPECIFICA-
TIONS HAV- NOT YET BEEN PREPARED.
NEVADA POWER
HARRY ALLEN
CONSIDERING HOT SIDE ESP IN CONJUNCTION WITH AN FGD SYSTEM. SPECIFICA-
TIONS HA« NOT YET BEEN PREPARED.
NEW 5CO.O »W (GROSS)
5CO.O MW (ESC)
COAL
***** XS
PROCESS NOT SEtECTED
VENDOR NOT SELECTED
ENFR6Y CONSUMPTION: ****Z
STATUS 6 STARTUP 6/P7
NEVADA POWER
HARRY ALLEN
4
NEW 500.0 MU (CROSS)
500.0 MW (ESC)
COAL
***** XS
PROCESS NOT SELECTED,
VENDOR NOT SELECTED
ENFR6T CONSUMPTIONS ****«
STATUS 6 STARTUP 6/F8
CONSIDERING HOT SIDE ESP IN CONJUNCTION UjTH AN FGD SYSTEM. SPECIFICA-
TIONS HAVE NOT YET BEEN PREPARED.
19
-------
EPA UTILITY FGD SURVEY: DECEMPfR 1«7f - JANUARY 1979
SECTION Z
HATUS OF F6D SYSTEMS
UNIT IDENTIFICATION
ABSTRACT
NEVADA POWER
REID GARDNER
1
RETROFIT 125.0 MW (GROSS)
125.0 MW (ESe)
COAL
.50 XS
SODIUM CARBONATE
ADL'COMBUSTION EQUIP ASSOCIATE
ENERGY CONSUMPTION: *****
STATUS 1 STARTUP 4/74
REFER TO SECTION J OF THIS REPORT FOR ADDITIONAL INFORMATION. THIS SODIUM
CARBONATt-BASED (TRONA) SCRU6BINS SYSTEM CONSISTS OF ONE MO&ULt CONTAIN-
ING A TWIN VARIABLE THROAT VtNTURI SCRUBBER FOLLOWED BY A SEPARATOR
IN SERIES WITH A SINGLE-STAGE PERFORATtD-PLATF WASH TOWER. PRIMARY
PARTlCULAlE CONTROL 1$ PROVIDED BY UPSTREAM MECHANICAL COLLECTORS.
AN INDIRtCT STEAM HOT AIR REHEAT SYSTEM RAISE? THE GAS TEMPERATURE IOF
PRIOR TO DISCHARGE TO THE MAIN STACK. THE fLUE 6AS CLEANING WASTES ARE
ULTICATEIY DISPOSED IN AN ON-SITfe CLAY-LINED SOLAR EVAPORATION POND.
NEVADA POWER
REID GARDNER
?
RETROFIT 125.0 MW
125.0 MW (FSC>
COAL
.50 XS
SODIUM CARBONATE
ADL/COMBUSTION EQUIP ASSOCIATE
ENERGY CONSUMPTION: ****X
STATUS 1 STARTUP
NEVADA POWER
REID GARDNER
J
NF> 125.0 »w (GROSS)
125.0 I*W
COAL
.$0 tS
SODIUM CARBONATE
ADL/COMBUSTION E6UIP ASSOCIATE
ENERGY CONSUMPTION: ****%
STATUS 1 STARTUP 6/76
REFEK TO SECTION 3 OF THIS RtPORT FOR ADDITIONAL INFORMATION. THIS SODIUM
CARBOKATf-BASED (TRONA) SCRUBBING SYSTEM CONSISTS OF ONE MODULE CONTAIN-
ING A TWIN VARIABLE THROAT VENTUR1 SCRUBBFR FOLLOWED PY A SEPARATOR
IN SERIES WITH A SINGLE-STAGE PERFORATED-PLATE WASH TOWER. PRIMARY
PARTKULfU CONTROL IS PROVIDED BY UPSTREAM MECHANICAL COLLECTORS.
AN INDIRECT STEAM HOT AIR REHEAT SYSTEM RAISES THE GAS TEMPERATURE 3CF
PRIOR TO DISCHARGE TO THE MAIN STACK. THE FLUE GAS CLEANING WASTES ARE
ULTIKATEIY DISPOSED IN AN ON-SITE CLAY-LINED SOLAR EVAPORATION POND.
REFER TO SECTION J Of THIS REPORT FOR ADDITIONAL INFORMATION.
THIS UM 1 IS A NEW COAL-FIRED BOILER THAT IS ESHIPPED WITH SODIUM
CARBONATt-BASED (TRONA) SCRUBBING SYSTEM WHICH INCORPORATES A TWIN
VARIABLE-THROAT VtNTURI SCRUBBER FOLLOWED BY A SEPARATOR IN SERIES WITH
A SINGLE-STAGE PERFORATED-PLATE WASH TOWER. MECHANICAL COLLECTORS PROVIDE
PRIMARY FARTICULATE CONTOL. REHEAT IS PROVIDED BY A INDIRECT STEAM HOT
AIR REHI/iT SYSTEM. WASTE IS DISPOSED IN AN ON-SITE CLAY-LINED POND.
NEVADA POWER
PEID GARDNER
4
NEW ?50.0 MW (GROSS)
250.0 MW (fEC>
COAL
.75 XS
PROCESS NOT SfcLECTED
VENDOR NOT SELECTED
FNER6Y CONSUMPTION: ****X
STATUS 6 STARTUP
NEVADA PCVER COMPANY HAS SCRAPPED THjIR ORIGINAL PLANS TO MAKE UNIT 4 A
COPY OF IMIT 3. THE NEW PLANS CALL FOR A ?50-MU UNIT TO BE IN OPERATION
BY U§3. THE UTILITY IS PRIPARJN6 SPEC 1 fitATIONS AT THIS TIME.
CONSTRUCTION IS SCHEDULED TO START IN 1980.
NEVADA POWER
WARNER VALLEY
1
NEW ?5C.O MW (GROSS)
250.0 MW (ESC)
COAL
***** XS
PROCESS NOT SELECTED
VENDOR NOT SELECTED
ENERGY CONSUMPTION: *****
STATUS 6 STARTUP 6/64
SPECIFICATIONS ARE BEING PREPARED FQft A SCRUBBING SYSTEM. NEVADA POWER
HAS NOT UT ANNOUNCED PLANS FOR THIS UNIT'S EMISSION CONTROL STRATEGY.
NEVADA POWER
WARNER VALLEY
?
NEW 250.0 MW (GROSS)
250.0 MW (ESC)
COAL
***** xs
PROCESS NOT SELECTED
VENDOR NOT SELECTED
ENERGY CONSUMPTION: ****x
STATUS 6 STARTUP 6/85
SPECIFICATIONS ARE BEING PREPARED FOR A SCRUBBING SYSTEM. NEVADA POWER
HAS NOT IfT ANNOUNCED PLANS FOR THIS UNIT'S EMISSION CONTROL STRATEGY.
20
-------
tPA UTILITY F6D SURVEY: DICIMBER 1978 - JANUARY 1979
SECTION 2
STATUS OF FGD SYSTEMS
UNIT IDENTIFICATION
ABSTRACT
NEW ENGLAND ELECTRIC SYSTEM
BRAYTON POINT
3
RETROFIT 650.0 MW (GROSS)
650.0 MW (ESc)
OIL
1.00 XS LOW SULFUR
PROCESS NOT SELECTED
VENDOR NOT SELECTED
ENERGY CONSUMPTION: *****
STATUS 7 STARTUP O/ 0
NEW IMGLjNO ELECTRIC SYSTEM HAS REQUESTED PERMISSION TO BURN 1.5X SULFUR
COAL AT THIS UNIT. THIS IS ALLOWABLE UNDER STATE STANDARDS BUT $03
EMISSIONS WOULD BE ABOVE ALLOWABLE FEDERAL LEVELS. A DECISION BY THE EPA
IS STILL PENDING. MEANWHILE, THE UTILITY IS INVESTIGATING VARIOUS ADVANCE
REGENEKAILE F60 SYSTEMS WHICH OFFER A BREAKTHROUGH IN OPERATING COSTS
AND PRODICE ELEMENTAL SULFUR AS AN END PRODUCT. THE UTILITY IS CURRENTLY
INVOLVED IN BENCH AND LABORATORY SCALF INVESTI6ATIONS OF SULfUR RECOVERY.
THIS UNIT IS CURRENTLY OPERATIONAL FIRING LOW SULFUR FUEL OIL.
NIAGARA MOHAWK POWER COOP
CHARLES R. HUNTLEV
66
RETROFIT 1CO.O MW (GROSS)
100.0 MW (ESC)
COAL
1.60 XS
AQUEOUS CARBONATE
ROCKWELL INTERNATIONAL
ENERGY CONSUMPTION: *****
STATUS 3 STARTUP 0/82
A CONTRACT WAS AWARDED TO ATOMICS INTERNATIONAL F()R THE DESIGN AND
INSTALLATION OF AN AOUEOUS CARBONATE FGD SYSTEM. THIS DEMONSTRATION
SYSTEM WILL PRODUCE END-PRODUCT SULFUR. FUNDS ARE BEING PROVIDED BY THE
U.S. EPA AND THE EMPIRE STATE ELECTRIC ENERGY RESEARCH CORP. THE DESIGN
502 REMOVAL EFFICIENCY HILL cE 90 PERCENT. ROCKWELL INTERNATIONAL IS
PRESENTLY IN THE DESIGN PHASE.
NORTHERN INDIANA PUB SERVICE
BAIILY
r
RETROFIT 190.0 MW (GROSS)
190.0 MW (F$C>
COAL
3.00 XS
PROCESS NOT SELECTED
VENDOR NOT SELECTED
ENERGY CONSUMPTION! *****
STATUS 6 STARTUP O/ 0
NORTHERN INDIANA PUBLIC SERVICE IS CURRENTLY CONSIDERING A LIME OR LIME-
STONE SCRUBBING UNIT FOR BAULY 7 AND 8. THEY ARE ALSO WAITING FOR
PERFORM ME RESULTS OF THE WELLMAN LORD/ALLIED CHEMICAL UNIT IN SERVICE
AT DEAN h. MITCHELL 11. LOW SULFUR COAL MAY BE EMPLOYED TO COMPLY WITH
$02 EHSJION REGUALTIONS. APPLICABLE INDIANA 502 REGULATIONS ARE STILL
NOT FIRMIY ESTABLISHED*
NORTHERN INDIANA PUB SERVICE
BAILLY
a
RETROFIT too.o MW (GROSS)
400.0 MW (ESC)
COAL
3.00 XS
PROCESS NOT SELECTED
VENDOR NOT SELECTED
INER6Y CONSUMPTION: *****
STATUS 6 STARTUP O/ 0
NORTHERN INDIANA PUBLIC SERVICE IS CURRENTLY CONSIDERING A LIME OR LIME-
STONE SC TUBBING UNIT FOR BAULY 7 AND 8. THEY ARE ALSO WAITlNfi FOR
PERFORMANCE RESULTS OF THE WELLMAN LORD/ALLIED CHEMICAL UNIT IN SERVICE
AT DEAN *. MITCHELL 11. LOW SULFUR COAL MAY 81 EMPLOYED TO COMPLY WITH
$02 IMISSION REGULATIONS. APPLICABLE INDIANA $02 REGULATIONS ARE STILL
NOT FIRMLY ESTABLISHED.
NORTHERN INDIANA PUB SERVICE
DEAN H. MITCHELL
11
RETROFIT 115.0 MW (GROSS)
115.0 MW (ESC)
COAL
3.SO XS
WELLMAN LORD
DAVY poufRGAs
ENERGY CONSUMPTION: *****
REFER TO SECTION 3 OF THIS REPORT f(}R ADDITIONAL INFORMATION
THIS FGt> SYSTEM IS AN INTEGRATION OF THE WilLMAN-LOR D $02 RECOVERY
PROCESS CFFERED BY DAVY POWERGAS AND THE $02 TO SULFUR REDUCTION PROCESS
DEVELOPED BY ALLIED CHEMICAL. DAVY POWERGAS 1$ THE DESIGN AND
CONSTRUCTION FIRM AND ALLIED CHEMICAL IS SYSTEM OPERATOR AND PRODUCT
MARKETER! PERFORMANCE TESTS kERE SUCCESSFULLY COMPLETED ON SEPTEMBER 14.
1977. A DEMONSTRATION YEAR COMMENCED ON SEPTEMBER 16* 1977.
STATUS 1
STARTUP 7/76
NORTHERN STATES POWER
SHERBURNE
1
NEW 720.0 MW (GROSS)
720.0 MW (ESC)
COAL
.80 XS SUBBITUMI NOUS
LIMESTONE/ALKALINE FLYASH
COMBUSTION ENGINEERING
ENERGY CONSUMPTION: Z.82
STATUS 1 STARTUP 3/76
REFER TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION.
FULL COMMERCIAL OPERATION OF THE SVSTEH BEGAN ON MAY 1, 1976. THE SCRUB-
BING SYSTEM FOR THIS UNIT CONSISTS OF 12 MODULES. EACH SCRUBBING MODULE
INCORPORATES A VENTRI-ROD SECTION AND A MARBLE BED ABSORBER FOR PAR-
TICULATE AND SULFUR DlOXjDE REflOVAL* A FORCED OXIDATION SYSTEM CONVERTS
ALL THE CALCIUM SULFITE TO SULFATE PRIOR TO DISCHARGE TO A CLAY-LINED
SETTLING POND. STACK GAS REHEAT IS PROVIDED BY IN-LINE HOT WATER TUBES.
THE COAL BURNED AT THIS UNIT CONTAINS 0.8X SULFUR AND 9-10X ASH.
21
-------
EPA IU1L1TY FbD SU'-VEY: D E t I pf f R 1971' - JANUARY 1979
SECTION 2
STATUS OF FGD SYSTEMS
UNIT 1DENTIflCATION
ABSTRACT
NORTHERN STATES POWER
SHE Rf'URNE
2
NEW 720.0 KW (GROSS)
730.0 fU (ESc)
COAt
.80 %S SUEBITUMINOUS
LIMESTONF/ALKALINE FLYASH
COMBUSTION ENCIPHERING
ENERGY CONSUMPTION: 2.ax
STATUS 1 STARTUP 4/77
REFER TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION.
THE SHER-URNE NO. 2 AIR SUAL1TY CONTROL SYSTEM jS IDENTICAL IN DESIGN TO
THE SYSTf* IN OPERATION ON THE NO. 1 UNIT AT THIS STATION. TWELVE 2-STA6E
PARTICIPATE SCRUBBER (VENTRI-ROD SCRUBBER) AND SULFUR DIOXIDE ABSORBER
(MAR6LE-:''ED ABSORBER) MODULES ARE PROVIDED FOR FLYASH AND S02 CONTROL.
ELEVEN MCDULES ARE EQUIPPED FOR fU|.L C-ENERATIN6 CAPACITY OPERATIONS.
THE CALCIUM SULFITE IS FORCIBLY OXIDIZED TO SULFATE PRIOR TO DISCHARGE TO
THE DISPfSAL POND. IN-LINE NOT WATER TUBES PROVIDE STACK GAS REHEAT.
NORTHERN STATES POWER
SHERRURNF
N£U
COAL
.PO iS
L 1KESTONE
860.0 KW (GROSS)
720.0 My
TWO ADDITIONAL COAL-FIRED PC WER-GE N ERATIN6 UMTS ARE SCHEDULED TO BE IN-
STALLED H NSP'S SHERBURNE COUNTY 6ENERATIN6 STATION IN BECKER MINNESOTA.
A LETTER OF INTENT HAS BEEN S16NEO WITH C-E FOR A LIMESTONE SLURRY SPRAY
TOWER SYHEM FOR THIS NEW 860-MU UNIT. THE 2-STAGE SCRUBBING SYSTEM WILL
REMOVE PARTICULATES (?9.sx> & soz (8ox>. THE BOILER CONTRACT HAS SEEN
AWARDFD 10 BAB COCK S WILcOX AND THE TURBINE WILL BE SUPPLIED BY GENERAL
ELECTRIC, START-UP HAS BEEN DELAYED TO WAY 1984 AND CONSTRUCTION START-Up
HAS ertN BELAYED UNTIL APRIL 1980 DUE TO ENVIRONMENTAL PROBLEMS.
ENERGY CONSUMPTION: *****
STATUS I STARTUP 5/84
OTTER TAIL POWER
COYOTE
1
NEW 440.0 MW (GROSS)
44P.O WW (ESC)
COAL
.87 X5 LIGNITE
AflUEOUS CARBONATE (OR* COLLECT
WHEELABRATOR-FRYE/R.I.
CNFR6V CONSUMPTION: ****%
STATUS 2 STARTUP 5/51
THIS NEW COAL-URED STATION IS JOINTLY OWNED BY FIVE UTILITIES. OTTER
TAIL POWER IS THE MAJOR OWNER AND CONSTRUCTOR. MONTANA-DAKOTft UTItIT£S
IS THE FACILITY OPERATOR. THIS PLANNED UNIT WILL FIRE LOW SULFUR LI6NITE
FROM THE KERCER COUNTY AREA IN A BgW CYCLONE BOILER. THE CONTRACT FOR
THIS AQUSOUS CARBONATE/FABRIC FILTER S02 SCRUBBER-ABSORBER WAS AWARDED TO
WHEELARRJTOR-FRYE AND ATOMICS INTERNATIONAL. THE DRY REMOVAL SYSTEM
COMBINES AI'S AQUEOUS CARBONATE PROCESS IN A W-f FABRIC FILTER. UNIT
CONSTRUCTION IS NOW JOX COMPLETE AND FGD SYSTEM CONSTRUCTION HAS JUST
tEGUK,.
PACIFIC GAS ft ELECTRIC
FOSSIL
1
NEW sec.D MM <€ROSS>
(5CO.O MW (ESC)
COAL
.80 ZS
LIMESTONE
VENDOR NOT SELECTED
ENERGY CONSUMPTION: *****
STATUS 6 STARTUP 0/35
PGRE AMNCUNCED PLANS TO BUILD TWO 600-MW COAL-FIRED POWER GENERATING
UNITS IN NORTHERN CALIFORNIA. THE FIRST UNIT WILL BURN COAL WITH A
HEATING VALUE OF 12000 BTU/LB, 0.8X SULFUR AND 101 ASM CONTENTS. THE
SECOND UNIT WILL BURN COAL OF AN EOUAL OR BETTER QUALITY. THE EMISSION
CONTROL
-------
EPA UTILITY FGB SURVEY: DECEMBER 1978 - JANUARY 1579
SECTION 2
STATUS Of FGO SYSTEMS
UNIT IDENTIFICATION
ABSTRACT
PENNSYLVANIA POWER
PRUCE MANSFIELD
1
NEW 917.0 MW (GROSS)
917.0 MW (ESC)
COAL
3.00 XS PITUM1NOUS
I IME
CHEMICO
FNERGY CONSUMPTION: 6.OX
STATUS 1 STARTUP 12/75
REFER TO SECTION I OF THIS REPORT fOfi ADDITIONAL INFORMATION.
THIS EMISSION CONTROL SYSTEM WAS DESI6NED TO REMOVE FLYASH AND S02 FROM
3.35 KM ftCFM OF FLUEGAS USING THIOSOJteiC LIME AS A SCRUBBING ABSORBENT.
THE INITIAL SHAKEDOWN AND DEBUGGING PHASE OF OPERATION BEGAN FOR PART OF
THE SYSTFtf IN DECEMBER 1975. PARTIAL COMMERCIAL OPERATION COMMENCED IN
APRIL 1976. THE UNIT VAS CERTIFIED FULL-LOAD COMMERCIAL IN JUNE 1976.
THE FC.D SYSTEM HAS EXPERIENCED OPERATIONAL PROBLEMS SjNCE IT HAS BEEN IN
SERVICE ft QUIRING A NUMBER OF SYSTEM REPAIRS AND DESIGN MODIFICATIONS.
PENNSYLVANIA POWER
PRUCE MANSFIELD
?
NEW 917.0 MW (GROSS)
917.0 MW (ESC)
COAL
3.00 XS BITUMINOUS
LIME
CHEMlCO
FNERGY CONSUMPTION: 6.05!
STATUS 1 STARTUP 7/77
REFER TO SECTION 3 OF THIS RfcPORT FOR ADDITIONAL INFORMATION.
THIS EMISSION CONTROL SYSTEM WAS DESIGNED TO REMOVE FLYASH AND S02 FROM
3.35 *M flCFM OF FLUE 6AS USING THIOSORBIC LIME AS A SCRUBBING ABSORBENT.
SIX SCRUtBING TRAINS, EACH INCLUDING TWO VENTURI SCRUBBERS IN SERIES
ARRANGEMENT, ARE PROVIDED FOR FULL-LOAD OPERATION. THE INITIAL SHAKEDOWN
AND 6EBUC-GING PHASE OF OPERATION BEGAN FQR THREE TRAINS IN JULY, 1977.
FULL COMMERCIAL OPERATION FOR THE ENTIRE SYSTEM COMMENCED ON OCTOBER 1,
1977.
PENNSYLVANIA POWER
BRUCE MANSFIELD
3
NEV 917.0 MW (GROSS)
917.0 MW (ESC)
COAL
3.00 XS
LIME
PULLMAN KELLOGG
ENERGY CONSUMPTION: *****
STATUS 2 STARTUP 4/80
A CONTRACT WAS AWARDED TO PULLMAN KELLOGG FOR THE FGD SYSTEM AT THIS
UNIT. THC EMISSION CONTROL SYSTEM FOR THIS UNIT WILL CONSIST OF ESP'S
UP-STREAf OF FIVE WEIR HORIZONTAL CROSSFLOW WET SCRUBBING MODULES.
EACH KODILE CONSISTS OF SIX STAGES, ONE BEING A SPARE. SLUDGE WILL BE
DISPOSED OF BY THE EXISTING SYSTEM AT THE BRUCE MANSFIELD PLANT. L1KER
IN THE SUCK WILL BE AN INCONEL 625 MATERIAL. THE UNIT IS CURRENTLY
UNDER COKSTRUCTION WITH ESP'S 70-80 PERCENT COMPLETE AND THE FGf
SYSTEM 3C PERCENT COMPLETE. UNIT START-UP WILL BE IN APRIL 1980.
PHILADELPHIA ELECTRIC
CROMOY
RETROFIT 150.0 My (GROSS)
150.0 MW (ESC)
COAL
3.00 XS
MAGNESIUM OXIDE
UNITED ENGINEERS
ENERGY CONSUMPTION:
STATUS 6
THE UTILITY PLANS TO RETROFIT ONE OF THE TWO BOILERS AT CROMBY VlTH AN
FGD SYSTtK. HOWEVER, A FINAL DECISION HAS NOT BEEN MADE. THE SYSTEM
BEING GIVEN PRIMARY CONSIDERATION IS MAGNESIUM OXIDE. CURRENTLY, THE
UTILITY IS RE-NEGOTIATING CONSENT ORDERS AND THE START-UP DATE OF JUNE
1980 IS TENTATIVE.
* ** *%
STARTUP 6/SO
PHILADELPHIA ELECTRIC
EDDYSTONE
1 A
RETROFIT 12Q.O My (GROSS)
120.0 WW (ESC)
COAL
2.60 XS
MAGNESIUM OXIDE
UNITED ENGINEERS
ENERGY CONSUMPTION: *****
REFER TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION.
THE EMULSION CONTROL SYSTEM FOR THIS UNIT CONSISTS OF THREE PARALLEL
SCRUtiBINE TRAINS FOR THE CONTROL OF PARTICULATE AND SULFUR DIOXIDE.
THE C-SICE SCRUBBING TRAIN INCLUDES -AN SO? ABSORBER MODULE IN SERIES
WITH A P*RTICULATE SCRUBBER. APPROXIMATELY ONE-THIRD OF THE BOILER FLUE
6AS IS SCRUBBED WITH MAGNESIUM OXIDE SLURRY FOR SO 2 REMOVAL. THE SPENT
SLURRY IS REGENERATED AT THE ESSEX SULFURIC ACID PLANT IN NFWARIT, N.J.
THE REGENERATED MASOX IS RETURNED TO THE PLANT FOR S02 SCRUBBING SERVICE.
STATUS 1
STARTUP 9/75
PHILADELPHIA ELECTRIC
EDDYSTONE
IB
RETROFIT 240.0 MW (GROSS)
240.0 MW (ESC)
COAL
2.60 XS
MAGNESIUM OXIDE
UNITED ENGINEERS
ENERGY CONSUMPTION! *****
STATUS A STARTUP 6/PO
THE INSTPILATION OF AN FGD SYSTEM ON THE BALANCE OF THE FLOE GAS FROM
THIS UNIT WILL FOLLOW PENDING THE OUTCOME OF THE PERFORMANCE OF THE
EXPERIME HAL SCRUBBING UNIT WHICH HAS BEEN INSTALLED AND CURRENTLY
OPERATIONAL ON THIS UNIT. CURRENTLY, 3 PARTICULATE SCRUBBERS ARE TREATING
THE FULL GAS LOAD FROM THIS UNIT. CONSENT ORDERS ARE PRESENTLY BEING
RE-NEGOTlftTED AND THE START-IP DATE OF JuNE, 1980 IS TENTATIVE.
-------
EPA UTILITY FtO SURVEY: DECEMBER
- JANUARY 1979
SECTION 2
1TATUS OF FED SYSTEMS
UNI T 1DENTJ FI CAT1 ON
ABSTRACT
PHILADELPHIA ELECTRIC
EOOYSTONF
?
RETROFIT 334.0 f,y (CROSS)
334.0 MW lESC)
COAL
2.50 XS
l-APNE SIUM OXIDE
UNITED ENGINEERS
FNERGY CONSUMPTION: *****
STATUS 6 STARTUP 6/FO
THE UTILITY IS AWAITING PERFORMANCE RESULTS FRO* THE EXPERIMENTAL F60
SYSTEM INSTALLED ON UNIT 1 AT THIS STATION BEFORE PRECEEDING WITH THE
DESIGN Of AN FDD SYSTEM FOR THIS COAL-FIRED BOILER. THE SYSTEM PEIN6
6IVEK PRIMARY CONSIDERATION IS MAGNESIUM OXIDE, DESIGNED JOINTLY Bt
UNITES E!>filNtERS AND PHILADELPHIA ELECTRIC. CURRENTLY, THE UTILITY IS
RE-NEGOT IATING CONSENT ORDERS AND THE START UP DATE OF JUNE 1980 is
TENTATIVE.
POTOMAC ELECTRIC POWER
01CKERSON
4
NEW scc.o MW (F.ROSS)
PCO.O MW (FSC)
COAL
2.00 IS
PROCESS NOT StLECTED
VENDOR NOT SELECTED
ENERGY CONSUMPTION: *****
STATUS 6 STARTUP 5/85
THERt ARL NO FIRM PLANS FOR INSTALLATION OF AN FGD SYSTEM. STARTUP DATE
OF THE BULER IS PLANNED FOR 1985. THIS UNIT WILL BURN 2i SULFUR COAL
V.ITH A HATING VALUE OF 11000 BTU/L6.
POWER AUTHORITY OF NEW YORK
ARTHUR KILL
NEW 700.0 MW (GROSS)
700.0 KW (FSC)
COAL
3.00 *S
PROCESS NOT SELECTED
VENDOR NOT SELECTED
ENERGY CONSUMPTION: *****
STATUS 6 STARTUP 11/P8
THE UTILITY IS CONSIDERING ROTH REGeNfRABLE AND LIMESTONE FGD PROCESSES.
FGD TECHNOLOGY IS BEING CONSIDERED FOR A FOSSIL FUEL BURNING UNIT WHICH
KILL EMPLOY COAL AS THE PRIMARY FUEL AND OIL AS BACKUP. REFUSE WILL ElE
PROVIDED SS A SUPPLEMENTAL FUEL SUPPLY. THE PREFERRED PLANT SITE IS THE
ARTHUR KILL FACILITY LOCATED ON STATEN ISLAND. THE PROJECT DESIGN
ENGINEERING FIRM IS SARGENT AND LUNDY. pUBLK SERVICE COMMISSION HEARINGS
ARE IN PROGRESS.
PUBLIC SERVICE OF INDIANA
GIBSON
5
NEW 650.0 WW (GROSS)
650.0 «W (FSC)
COAL
3.30 XS
PROCESS NOT SELECTED
VENDOR NOT SELECTED
ENERGY CONSUMPTION: *****
STATUS 5 STARTUP 0/82
PUBLIC SERVICE CO OF INDIANA ANNOUNCED PLANS FOR THE CONSTRUCTION OF THIS
NEW iSC-*V COAL FIRED POWER GENERATING UNIT AT GIBSON STATION. FjIDS HAVE
BEEN RECiEVED AND ARE BEING EVALUATED. INITIAL START-UP IS SCHEDULED FOR
1982.
PUBLIC SERVICE OF NEW MEXICO
SAN JUAN
1
RETROFIT 361.0 MW (GROSS)
361.0 MW (ESC)
COAL
.80 IS
UELLMAN LORD
DAVY POWERGAS
ENERGY CONSUMPTION: *****
REFER TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION. THIS FGD
SYSTEM IS AN INTEGRATION OF THE WELL*AN LORD SO? RECOVERY PROCESS OF
DAVY POWERGAS AND ALLIED CHEMICAL'S S02 REDUCTION TO SULFUR PROCESS. A
HOT SIDE ELECTROSTATIC PREC1PITATOR P&ECEfDS THE F6D SYSTEM. OF THE FOUR
ABSORBER ToUERS INSTALLED, THREE ARE NEEDED TO CARV THE FULL LOAD. THE
COAL PURUD AT THIS UNIT HAS SULFUR AN!) ASH CONTENTS OF .8* AND 20X
RESPECTIVELY. THE SYSTEM OPERATES ON A CLOSED WATER LOOP WITH
RIVER WATER BEING USED AS MAKE-UP FOR LOSSES DUE TO EVAPORATION.
STATUS 1
STARTUP «/78
PUBLIC SERVICE OF NEW MEXICC
SAN JUAN
2
RETROFIT 350.0 MW (GROSS)
350.0 MW (ESC)
COAL
.80 tS
WELLMAN LORD
DAVY POWERGAS
FNERGY CONSUMPTION: *****
STATUS 1 STARTUP 8/78
REFER TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION. THIS fGD
SYSTEM IS AN INTEGRATION OF THE WELLMAN LORD S02 RECOVERY PROCESS OF DAWY
POWERGASRALLIED CHEMICAL'S S02 REDUCTION TO SULFUR PROCESS. A NOT SIDE
ELECTROSTATIC PRECIPITATOR PHECEEDS THE FGD SYSTEM. THE SYSTEM INCLUDES
FOUR ABSCRBER TOWERS, THREE OF WHICH ARE NECESSARY TO CARRY THE FULL
LOAD. THE WATER LOOP IS CLOSED WITH RIVER WATER BEING USED TO MAKE UP FOR
LOSSES DIE TO EVAPORATION. THE COAL BURNED AT THIS UNIT HAS SULFUR AND
ASH COHTENTS OF 0.8* AND 20* RESPECTIVELY.
-------
EPA UTU1TY FGD SURVEY! DECFM8E.R 197$ - JANUARY 1979
SECTION 2
STATUS OF FGD SYSTEMS
UNIT IDENTIFICATION
ABSTRACT
PUBLIC SERVICE OF NEW MEXICO
SAN JUAN
3
NEW 534.0 MW (GROSS)
534.0 MW (ESc>
COAL
.BO IS
WELLMAN LORD
DAVY POKE"eAS
ENERGY CONSUMPTION: *****
A CONTRACT HAS BEEN AWARDED TO DAVY POWERGAS TO SUPPLY FOUR ABSORBER
TOWERS FCR REMOVAL OF S02 AT THIS NEW UNIT. ON| MODULE IS EXpFCTED fO
BE OPERATIONAL BY JUNE 19y9 WHICH WILL PRIN6 THE UNIT INTO COMPLIANCE
KITH FEftkPAL NSPS. THE REMAINING THREE MODULES SHOULD BE OPERATIONAL
BY JAflUAfY 1982 AT WHICH T1MI THE UNIT WILL Bf IN COMPLIANCE OF STATE
STANDARDS. POWF.R PLANT CONSTRUCTION IS BEHIND SCHEDULE BUT ABSORBER
CONSTRUCTION IS PROCEEDING AS PLANNED. IT IS POSSIBLE THAT Tul FINAL
THREE ABSORBERS HAY BE IN AS EARLY AS JANUARY 1981.
STATUS 3
STARTUP 6/79
PUBLIC SERVICE OF NEW MEXICO
SAN JUAN
4
NEV 534.0 MW (GROSS)
534.0 MN (ESC>
COAL
.BO *S
MELLMAN LORD
DAVY POWFRGAS
ENERGY CONSUMPTION: *****
STATUS 3 STARTUP 1/5Z
DAVY POWCR6AS HAS BEEN AWARDED A CONTRACT TO SUPPLY THf $02 REMOVAL
SVSTtP FCR THIS UNIT. THE PLANS INCLUDE A WILLflAN. LORD SO? RECOVERY
PROCESS AS WELL AS AN UPSTREAM ELECTROSTATIC PRE Ci PI TA TOR FOR PRIMARY
PARTKUMT6 REMOVAL F66 OPERATIONS ARE EXPECTfB TO BB6IN AT THIS PLANT
IN JANUARY 1982.
SALT RIVER PROJECT
CORONADO
1
NEW 350.0 MW (GRQSS)
780.0 MW (ESC)
COAL
1.00 XS SUBBITUMINOUS
LIMESTONE
PULLMAN KELLOGG
ENERGY CONSUMPTION: *****
STATUS 2 STARTUP 8/79
THIS NEW UNIT WILL BURN LOW SULFUR WESTERN COAf A MAXIMUM OF «0* OF THE
FLUE CAS WILL BE SCRUBBED TO MEET SULFUR DIOXIDE EMISSION REGULATIONS.
PULLMANmLLQ6& Witt PROVIDE 2 W6IR HORIZONTAL SPRAY TOWERS UTILIZING
LIMESTONE SLURRY FOR SO? CONTROL. THE SYSTEM WILL UTILIZE RUBBER-LINED
SLURRY RECYCLE PUMPSt EACH RATED AT 'SQO EPM. RIGIFLAKE-LINED SCRUBBER
HODULIS, VERTICAL HER MIST ELIMINATORS AND A MlNINUM OF 20 PERCENT OF
THE FLUE CAS WILL BE PYPASSFD FOR REHEAT. THE SLUDGE WILL BE PONDED-
STRUCTURAL WORK IS 90* COMPLETE.
SALT RIVER PROJECT
CORONADO
2
NEW
3SO.O RW (GROSS)
280.0 MW (ESC)
COAL
1.00 ZS SUBBITUMINOUS
LIMESTONE
PULLMAN KELL066
ENEftGV CONSUMPTION: *****
STATUS 2 STARTUP 1/PO
THIS NEW UNIT WILL BURN LOW SULFUR WESTERN COAL' A MAXIMUM OF 80* OF THE
FLUE CAS WILL BE SCRUBBED TO MEET SULFUR DIOXIDE EMISSION REGULATIONS.
PULLKAN/KFLLOGG WILL PROVIDE ? WEIR HORIZONTAL SPRAY TOWERS UTILIZING
LIMESTONE SLURRY FOR SO? CONTROL. THE SYSTEM WILL UTILIZE RUBBER-LINED
SLURRY RECYCLE PUMPS, EACH RATED^AT 98oo GPM, RIGIFLAKE-LINED SCRUBBER
MODULES, VERTICAL HFIl MIST ELIMINATORS AND A MINIMUM OF 20 PERCENT OF
THE FLUE GAS WILL BE BYPASSED FOR REHEAT. THE SLUDGE WILL BE PONDED.
STRUCTURAL WORK IS 60* COMPLETE.
SALT RIVER PROJECT
CORONADO
3
NEW 350.0 MW (GROSS)
280.0 MU (ESC)
COAL
1.00 ZS
LIMESTONE
VENDOR NOT SELECTED
ENERGY CONSUMPTION: *****
STATUS 6 STARTUP 0/87
THIS NEW UNIT WILL BURN SULDUR WESTERN COAL. EIGHTY PERCENT OF THE
GAS WILL '.'I SCRUBBED TO MEET SULFUR DIOXIDE EMISSION REGULATIONS.
UTILITY IS CURRENTLY CONSIDERING THE INSTALLATION OF TWO HORIZONTAL
SPRAY T04.ERS EMPLOYING A LIMESTONE SCRUBBING SOLUTION TO REMOVE S02.
FROM THE FLUE GA$. SCHEDULED COMMERCIAL OPERATION DATE IS 1987. PLANS
FOR AN EMISSION CONTROL SYSTEM HAVE NOT BEEN FINALIZED. SLUDGE WILL
PROBABLY BE PONDED.
SAN MIGUEL ELECTRIC COOP
SAN MIGUEL
1
NEW 400.0 MW (GROSS)
400.0 MU (ESC>
COAL
1.70 ZS LIGNITE
LIMESTONE
BABCOCK K WlLCOX
ENERGY CONSUMPTION: *****
STATUS 2 STARTUP 8/80
THE EMISSION CONTROL FOU1PMEM FOR THE COAL-FIRED RADIANT BOILER WILL
CONSIST ff AN ESP UPSTREAM OF FOUR LIMESTONE SCRUBBING MODULES. THE
SCRUEEER FLUE GAS CAPACITY IS NOMINALLY DESIGNED AT 1.579 MILLION ACFM .
(302 F>. DESIGN S02 REMOVAL EFFICIENCY IS 86 PERCENT FOR 4400 PPM S02
INLET. L/P RATIOS ARE 10 AND 45 FOR BUENCHER AND ABSORBER, RESPECTIVELY.
RESEARCH COTTRELL HAS BEEN AWARDED THE SLUDGE DISPOSAL CONTRACT. FGD
SYSTEM FCUNOATION AND STRUCTURAL STEEL WORK IS COMPLETE. INITIAL START-
UP IS SCHDULED FOR LATE SUMMER 19EO.
25
-------
FPA UTILITY FED SURVEY: t>fcCEI»BFR 197F - JANUARY 1979
SECTION 2
STATUS OF FGO SYSTEMS
UNIT IDENTIFICATION
ABSTRACT
SEMINOLE
SEM1NOLE
1
NEW
ELECTRIC
fc2o»0 MW (GROSS)
620.0 MW (ESC)
COAL
2.75 XS
LIMESTONE
VENDOR NOT SELECTED
FNER6Y CONSUMPTION: *****
STATUS 6 STARTUP 6/F-3
SEMINCLE FLtCTRIC HAS ANNOUNCED PLANS TO CONSTRUCT ONE AND POSSIBLY TWO
NEW 600 Hi COAL-FIRED UNITS. THE UTILITY INTENDS TO UTILIZE ESPs FOR PAR-
TICULATE REMOVAL AND A LIMESTONE F«D SYSTEM FOR S02 CONTROL OF EMISSIONS
FROM THE HURMN6 OF 2.75X SULFUR, 8.5* ASH COAL (11000 BTU/LB HEATING
VALUE). 7HE UTILITY EXPECTS TO INITIATE REOUESTS FOR BIDS FOR THE F6D
SVSTtl" IN NAY 1979.
SIKESTON
SIKESTON
1
NEW
COAL
2.80 XS
LIMESTONE
PAPCCICK R
FNERGY
STATUS
BOAPD OF PUNIC. UTIl.
23T .0
235.0
*W
(CROSS )
(F.SC)
e&W MS /WARDED A CONTRACT FOR THE BOILER AIR 8UALITY CONTROL SYSTEM.
THE AGCS WILL CONSIST OF 2 ESP'S FOLLOWED BY 1 F6D MODULES, EACH CAPABLE
OF HANDLING 50% OF THE BOILER LOAD; ONE WILL BE ON STAND-BY AT ALL TIMES.
THE UNIT KILL BURN A ?.fit SULFUR COAL. THE SIKESTON STATION UILL FEATURE
AN FRP-LJNED STACK, 2 PONDS (ONE FOR FLY ASH, ONE FOR SCRUBBER SLUDGE-
FjOTTCf A fH DISPOSAL). AND * AXlAL FLOW FANS. NO STACK 6AS REHEAT IS
PLANf.ED. MAXIMUM FLUF CAS CAPACITY IS 74B,390 ACFM AT 288 F.
STRUCTURAL STEEL ERECTION IS NOW ABOUT 33* COMPLETE
W1LCOX
CONSUMPTION! *****
2 STARTUP 6/«1
SOUTH CAROLINA PUBLIC SEPVICt
WINYAH
?
NEW 280.0 MW (GROSS)
140.0 MM (ESC)
COAL
1.00 XS BITUMINOUS
LIMESTONE
PABCOCK R WILCOX
ENERGY CONSUMPTION: .7*
STATUS 1 STARTUP 7/77
RF.FF.R TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION.
THI EMISSION CONTROL 5YSTIH FOR THIS UNIT CONSISTS OF A 100* CA^ACHY ESP
FOLLOWED HY A 5CX CAPACITY LIMESTONE 'GD SYSTEM. ONE FgD MODULE, CONSIST-
ING OF A VENTURI SCRUBBER AND TRAY TOWER ABSORBER, REMOVES 7OX OF THE
INLFT SQ:> REHEAT IS SUPPLIED BY FLUE 6AS BYPASS. THE SCRUBBING WASTES
ARE DTSCMNGED TO AN ON-SITg, UNLINED DIKED POND. THE NO. 2 UNIT
COMMENCED INITIAL OPERATION IN JULY 1977.
SOUTH CAROLINA PUBLIC SERVICE
WINYAH
3
300.0 MW (GROSS)
300.0 PW (ESC)
NEW
COAL
1.70 XS
LIMESTONE
RABCOCK 8 WILCOX
ENERGY CONSUMPTION: *****
STATUS 3 STARTUP 5/HO
A CONTRACT HAS BEEN AWARDED TO BABCOC* R WlUOX FOR THE INSTALLATION
OF THE Ffti SYSTEM ON THIS UNIT. PARTICULATt REMOVAL WILL BE PROVIDED
BY RfSEAKH COTTRELL FSP'S. THE BOILER IS A COAL-FIRED DRY-BOTTOM UNIT
WHICH WILL BURN COAL WITH A 1.7X SULFUR CONTENT AND A, HEAT VALUE OF
11,SCO B1U/LB. THE GENERATING EQUIPMENT IS BEING SUPPLIED BY R1LEY
STOKER. 100X OF THE FLUE GAS WILL BE SCRUBBED. ALL FGD FOOTINGS
HAVE BEEF. POURED AND BOILER STRUCTURAL STEEL WORK IS NEARLY COMPLETE.
SOUTHERN CALIFORNIA EDISON
ALAMITOS
6
RETROFIT 480.0 MW (GROSS)
175.0 MW (ESC)
OIL
.25 »S
LIME
SO. CALIFRON1A EDISON/STEARNS
ENERGY CONSUMPTION: *****
STATUS 3 STARTUP 1/F2
AS A RESILT OF AN "EMISSION OFFSET" AGREEMENT, STANDARD OIL OF OHIO
HAS CONTRACTED SCE AND STEARNS AND ROD6ERS TO INSTALL A LIKE SCRUBBING
SYSTEM OK ITS EXISTING ALAMITOS 6 UNIT. THE FGD SYSTEM WILL TREAT ONE
THIRD OF THE FLUE GAS WITH HORIZONTAL WEIR MODULES. REHEAT WILL BE
P»OVI|)ED bV THE BALANCE Qf THE FLUE GAS. THE SLUDGE WILL BE DEUATERED BY
CENTRIFUGES OR DISC DRYERS AND HAULED TO AN OFFSjTE LANDFILL.
SOUTHERN ILLINOIS POWER C00f
MARION
4
NEW 164.0 MU (GROSS)
184.0 MW (ESC)
COAL
3.00 XS
LIMESTONE
BABCOCK R WILCOX
ENERGY CONSUMPTION: ****X
STATUS 2 STARTUP 5/79
THE EMISSION CONTROL SYSTEM fOR THIS NfcW COAL-FIRED BOILER CONSISTS OF AN
ESP FOR FARTICULATE CONTROL FOLLOWED BY 2 SPRAY TOWERS FOR S02 CONTROL.
LIMESTONt SLURRY WILL BE USED AS THE SCRUBBING REAGENT. SIPC IS NOT
PLANNING TO UTILIZE FLUE GAS REHEAT AND IS CURRENTLY PLANNING ON A BRICK
LINING FCR THE STACK. SIPC INTENDS TO USE A LANDFILL WITH ASH
STABILIZATION FOR SLUDGE DISPOSAL. CONSTRUCTION IS NEARLY 100X COMPLETE
AND THE SYSTEM HAS BEEN AIR TESTED. THE BOILER IS NOW OPERATING. THE
FGD SYSTFK WILL START IN HAY.
26
-------
FPA UTILITY F6D SURVEY! DECEMBER 1971! - .IANUABY 1979
SECTION 2
STATUS Of FGO SYSTEMS
UNIT l&ENTIFI CATION
ABSTRACT
SOUTHERN ILLINOIS POWER COOP
MARION
s
NEW 300.0 MW (6ROSS*
300.0 MW
COAL
3.75 XS
Du*L ALKALI
FMC CORPORATION
FNER6Y CONSUMPTION: ****X
STATUS 2 STARTUP 3/79
THE UTILITY HAS AWARDED A CONTRACT TO fWC FOR TMI INSTALLATION OF A
DOUBLE ALKALI SCRUBBING SYSTEM U1U1ZIN6 SODA ASM AND LIMI. THIS UNIT
IS A PAR1 OF A NEW POWER STATION LOCATED IN WEST FRANKLIN, INDIANA.
THE SYSTl<- HILL PRODUCE A FILTIR CAKE WASTI PRODUCT WHICH WILL PE
DISPOSED OF IN AN ON-SITE LANDFILL. THE PARTICULAR EMISSIONS WILL
GE COMTRULED BY A BUELL-E.NV IROT ECU COLD-SIDE £$P. THE CONSTRUCTION
WORK AND ENGINEERING IS APPROXIMATELY 78X COMPLETE. THE F6D SYSTEM
IS ESSENTIALLY COMPLETE.
SOUTHERN MISSISSIPPI ELECTRIC
R.D. MORROW
1
NEW 200.0 MW (CROSS)
124.0 MW .6(, RESPiCTIVILY. A WATER SPRAY HAS SEEN ADDED IN THE
AY-PASS cue? TO PROTECT THE, LINER FROM TEPPIRATUBE EXCURSION. SLUDGE MILL
RE STAUIUZiD WITH FLYASH ANC DISPOSED OF ON-SITE* INITIAL STARTUP HAS
BEGUN. HtUEVER RUE TO BOILER PHOEiLENS NO OPERATING TldE HAS BEEN ACCUMU-
LATES. ACCEPTANCE TESTIN6 IS IXPICTED IN NOVSMSIR.
SOUTHERN MISSISSIPPI ELECTRIC
R.6. HORROW
2
NIW 70C.O MW (gROSS)
124.0 MW (ESC)
COAL
1.00 XS
LlMESTONr
RILEY STOKE8/tNVlRON6tRJN6
fNERSY CONSUMPTION: ****»
STATUS 2 STARTUP S/79
A CONTRACT WAS AWARDED BY SME TO RILEY STOKIR/INVIRONllRlNS FOR THIS
F6D SYSTEM. PARTICULATES WILL BE CONTROLLFD BY A HIGH-EFFICIENCY ESP
UPSTREAM OF THE FSD SYSTEM. Of SIGN SULFUR DIOXIDE AND PARTICIPATE
EFFICIENCIES ARE B 5 AND W ,(• PERCENT^ RISPiCTIVILY. A WATER SPRAY HAS
HEN ADDID IN THE IY-PASS DUCT TO PROTECT THi LINfB FRON TIMPIRATUR1
EXCURSION. SLUDGE WHI BE STAPHUEA WITH FLYASH AND DISPOSED ON THE
PLANT Silt. CONSTRUCTION OF THE WET LIMESTONE SCRUBBING SYSTEM IS NOW
IN ITS FINAL STAGES, THF, BOHtfi IS NOW IN OPERATION.
SOUTHWESTERN ELECTRIC POWER
HENRY W. PCftKIY
1
NEW 720.0 MU (GROSS)
720.0 MU (ISC)
COAL
.80 XS LISNlTf
LIMESTONE
AIR CORRECTION DIVISION, UOF
ENERGY CONSUMPTION: ***«X
STATUS 3 STARTUP 2/M
A CONTRACT FOR THE EMISSION CONTROL SYSTEM HAS 8ffN AVAR BED 10 THE AIR
COmCTICN DIVISION Of UQP. THE SYSTEM 6ISI6N INCLU»|S TWO COLD-SIDE
ISP'S fOt PARTICULATE REMOVAL UP-STREAM FROM 4 SPRAY TOWERS WHICH
UTIH?l IIHESTONE SLURRY FOR S02 CONTROL. SLUP6E DISPOSAL WILL BE HANDLED
iY AN JUCS SYSTIM. START-UP IS IXPICTIB iY FEBRUARY 198*.
SPR1NSFIEL6 CITY UTILIT1IS
SOUTHWEST
1
NEW 194.0 MW
-------
EPA UTILITY FGD SURVEY: DECEMBER 197f - JANUARY 1979
SECTION 2
STATUS OF FGD SYSTEMS
UNIT IDENTIFICATION
ABSTRACT
SPRIN6F1ELD WATER, LIGHT K
DALLMAN
T
205.0 *w (GROSS)
2C5.0 MW f£Sc>
COAL
3.70 XS
L1MESTONF
RESEARCH COTTRELL
ENERGY CONSUMPTION: *«**X
STATUS Z STARTUP 8/SO
FUR * CONTRACT WAS AWARDED TO RESEARCH COTTRELL FOR THE INSTALLATION Of A
LIHESTONi F6D SYSTEM. REQUIRED SULFUR DIOXIDE REMOVAL EFFICIENCY IS 90
PERCENT. A SLUDGE DISPOSAL STRATEGY HAS NOT BEEN FINALIZED, GUT THE
UTILITY IS CONSIDERING EITHER PONDING OR LANDFILL. CONSTRUCTION OF THE
FCD SYSTEM FOUNDATIONS HAVE BEGUN* ALL SYSTEMS ARE OKI SCHEDULE. THE
BOILER OHFRATION WA$ SCHEDULED TO COMMENCE IN JuNE 1978.
ST. JOE ZINC
E.F. WEATON
1
RETROFIT 60.0 nW (CROSS)
60.0 MW (ESC >
COAL
3.00 IS
CITRATE
BUREAU OF MINES
ENERGY CONSUMPTION: ****X
STATUS 2 STARTUP 4/79
CONSTRUCTION CONTINUES ON THE CITRATE PROCESS SCRUBBING SYSTEM WHICH WILL
CONTROL UJ EMISSIONS FROM A 6Q-HV COAL-FIRED POWER GENERATING UNIT AT
ST. JOE .INC. THIS UNIT PROVIDES POWER FOR THE LOCAL UTILITY GRID.
FGD SYST'I" START-UP IS SCHEDULED FOR DECEMBER 1978. THF, REGENERABLE FED
SYSTEM WILL PRODUCE ELEMENTAL SULFUR AS A BY-PRODUCT. ALL MAJOR CONSTRUC-
TION IS COMPLETE. WIRING AND PIPING WORK IS NOW BEING COMPLETED.
TAMPA ELECTRIC
BIG BEND
(
NEW 450.0 MW (GROSS)
450.0 MW (ESC)
COAL
2.50 XS
PROCESS NOT SELECTED
VENDOR NOT SELECTED
SNER6Y CONSUMPTION! *****
STATUS 6 STARTUP 0/65
TAMPA ELECTRIC HAS ANNOUNCED PLANS TO INSTALL AN FGD SYSTEM AT BIG SEND
4 WHICH IS SCHEDULED TO BEGIN OPERATIONS EARLY IN 1985. THE F60 PROCESS
HAS NOT If T BEEN SELECTED. PRIM ART PARTICULATE CONTROL WILL BE PROVIDED
BY AN ELECTROSTATIC PRICIPITATOR UPSTREAM OF THE FGD SYSTEM. AN INPIRECT
(STEAM COL) HOT AIR INJECTION REHEAT SYSTEM WILL BE INCLUDED AT THE
SCRUtiPtR OUTLET. DESIGN SULFUR DIOXIDE REMOVAL EFFICIENCY WILL BE
90 PERCEIT
TENNESSEE VALLEY AUTHORITY
CUMBERLAND
RETROFIT 1700.0 MW (GROSS)
600.0 MW (ESC)
COAL
***** XS BITUMINOUS
PROCESS NOT SELECTED
VENDOR NOT SELECTED
ENERGY CONSUMPTION: «**•%
STATUS 6 STARTUP 7/82
TVA INSTALLING A HEAVY-MEDIA COAL-CLEANING SYSTEM AND HAS AGREED TO
INSTALL I* 6QO-MW F6D SYSTEM AT THE CUMBERLAND PLANT TO BRING IT INTO
COMPLIANCE WITH STATE AND FEDERAL S02 EMISSION LIMITS. THE TYPE OF
FGD SVSTII* CHOSEN WILL BE DETERMINED BY PROTOTYPE LEVEL EVALUATION OF
SEVERAL ADVANCED SCRUBBER CONCEPTS.
TENNESSEE VALLEY AUTHORITY
JOHNSONVILLE
1-10
RETROFIT 1*50.0 MW (GROSS)
600.0 MW (ESC)
COAL
***** XS
MAGNESIUM OXIDE
TVA/UNITFO ENGINEERS
FNERGY CONSUMPTION: *****
STATUS 5 STARTUP 0/82
TVA IS PLANNING TO RETROFIT A 600-MU MGNESlU* OXIDE FGD SYSTEM AT THE
JOHNSOMV1LLE STEAM PLANT, A 1500-MU COAL-FIRED STATION. ENGINEERING
ASSISTANCE: WILL BE PROVIDFD BY UNITES ENGINEERS. THIS PROJECT is
BUDGETTED AT $185 MILLION, INCLUDING THE COST OF A NEW 60D-FT. STAC*.
TENNESSEE VALLEY AUTHORITY
PARADISE
1
RETROFIT 704.0 MU (GROSS)
704.0 WW (ESC)
COAL
***** XS
LIMESTONE
VENDOR NOT SELECTED
FNFR6Y CONSUMPTION: *****
STATUS 3 STARTUP 0/82
TVA IS RtOUESTING/EVALUATINP BID SPECIFICATIONS FOR TWO LIMESTONE SLURRY
FGD SYSTEMS WHICH WILL BE RETROFITTED ONTO TWO 6SO-MW HIGH SULFUR c«AL-
FIRED BOILERS AT THIS STATION. THE FGD SYSTEMS HILL TREAT 10OX OF THE
FLUE GASES FROM BOTH UNITS. TVA HAS PROJECTED THE TOTAL COST OF THE
PARADISE FGD SYSTEMS TO BE APPROXIMATELY S220 MILLION (»170/KW). BID
REQUEST MS COMPLETED BY MID-NOVEMBER AND EVALUATION IS NOW IN PROCESS.
BIB EVALIATION IS EXPECTED TO BE COMPLETED BY JANUARY 1 AND A CONTRACT
SHOULD EH AWARDED SHORTLY THEREAFTER.
-------
EPA UTILITY f6t SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 2
STATUS OF FGD SYSTEMS
UNIT IDENTIFICATION
ABSTRACT
TENNESSEE VALLEY AUTHORITY
PARADISE
2
RETROFIT 704.0 Hy (GROSS)
704.0 MW (ESC)
COAL
4.20 XS
LIMESTONE
VENDOR NOT SELECTED
ENERGY CONSUMPTION: *****
STATUS 3 STARTUP 4/82
TVA IS REQUESTING/EVALUATING BID SPECIFICATIONS FOR TWO LIMESTONE SLURRY
FGD SYSTF*S WHICH WILL BE RETROFITTED ONTO TWO 650-WW HIGH SULFUR COAL-
FIRED BOILERS AT THIS STATION. THE FGD SYSTEMS WILL TREAT 10GX OF THE
FLUE EAStS FROM BOTH UNITS. TVA HAS PROJECTED THE TOTAL COST OF THE
PARADISE F60 SYSTEMS TO Bt APPROXIMATELY *220 MILLION (S170/KW). BIO
REflUtST MS COMPLETED BY WiD-NOVEMBER AND EVALUATION IS NOW IN PROCESS.
BID EVALIATION IS EXPECTED TO BE COMPLETED BY JANUARY 1 AND A CONTRACT
SHOULD B I; AWARDED SHORTLY THEREAFTER.
TENNESSEE VALLEY AUTHORITY
SHAWNEE
10A
RETROFIT 10.0 p-W (GROSS)
10.0 MW (ESC)
COAL
2.90 XS BITUMINOUS
LIME/LIMESTONE
AIR CORRECTION DIVISION, UOF
ENERGY CONSUMPTION: **••*
STATUS 1 STARTUP 4/72
REFER TO THE BACKGROUND INFORMATION IN SECTION 3 of TH1$ REPORT. THIS
TURBULEN1 CONTACT ABSORBER (TCA) L1ME/LIMSSTONE SCRUBBING SYSTEM HAS BCEN
OPERATIONAL SINCE APRIL 197?. THIS TEST PROGRAM IS FUNDED BY THE EPA WITH
TVA AS TI-F CONSTRUCTOR AND FACILITY OPERATOR. THE BFCHTEL CORP. OF SAN
FRAN(i$c( is THE MAJOR CONTRACTOR* TEST DIRECTOR! AND REPORT WRITER.
TESTING CHEMICAL ADDITIVES FOR IMPROVING S02 REMOVAL EFFICIENCY
CONTINUED THROUGH OCTOBER AND NOVEMBER. BOTH VENTURI /SPRAY TOWER AND TCA
SYSTEMS K:flE OPERATED ON LIMESTONE SLURRY WITH FLY ASH LOADING.
TENNESSEE VALLEY AUTHORITY
SHAWNEE
100
RETROFIT 10.0 MW (GROSS)
10.0 MW (ESC>
COAL
2.90 XS BITUMINOUS
LIME/LIMESTONE
CHEMICO
ENERGY CONSUMPTION: *****
STATUS 1 STARTUP 4/72
REFER TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION. THIS
VENTURI/SPRAY TOWER LIME/LIMESTONE SCRUBBING SYSTEM HAS BEEN OPERATIONAL
SINCI APfTL 1972. THIS TEST PROGRAM IS FUNDED BY THE EPA WITH TVA AS THE
CONSTRUCTOR AND FACILITY OPERATOR. THE BECHTEL CORP. OF SAN FRANCISCO IS
THE MAJOt CONTRACTOR! TEST DIRECTOR, AND REPORT WRITER. TESTING WITH
CHEMICAL ADDITIVES FOR IMPROVING S02 REMOVAL EFFICIENCY CONTINUED
THROUGH OCTOBER AND NOVEMBER. BOTH VENTURI/SPRAY TOWER AND TCA SYSTFMS
WERE OPERATED ON LIMESTONE SLURRY WITH HIGH FLYASH LOADING.
TENNESSEE VALLEY AUTHORITY
WIDOWS CREEK
7
RETROFIT 575.0 MW (GROSS)
575.0 MW (ESC)
COAL
3.70 XS BITUMINOUS
LIMESTONE
COMBUSTION ENGINEERING
ENERGY CONSUMPTION: *****
STATUS 2 STARTUP 10/80
TENNESSEE! VALLEY AUTHORITY ANNOUNCED THAT A CONTRACT HAS SEEN A«ARDED TO
COMBUSTI (N ENGINEERING FOR A LIMESTONE SLURRY SPRAY TOWER FGD SYSTEM. THE
FGD SYSTI.H WILL TREAT HIGH SILF'.IH COAl FLUE GAS. THE SPRAY TOMER ABSORBERS
WILL BE CONSTRUCTED OF 317L STAINLESS STEEL. THE NUMBER 7 UNIT FIRES COAL
WITH THE SAME CHARACTERISTICS AS THE COAL FIRED IN UNIT 8. INITIAL
OPERATION'S ARE SCHEDULED FOR OCTOBER 19SO. THE FGD SYSTEM IS CURRENTLY
UNDER CONSTRUCTION.
TENNESSEE VALLEY AUTHORITY
WIDOWS CREEK
8
RETROFIT 550.0 MM (GROSS)
550.0 MW (ESC)
COAL
4.30 XS
LIMESTONE
TENNESSEE VALLEY AUTHORITY
ENERGY CONSUMPTION: *****
STATUS 1 STARTUP 5/77
REFER TO SECTION 3 OF THIS REPORT FQR ADDITIONAL INFORMATION.
THE EMISSION CONTROL SYSTEM FOR THIS 516 MW COAL-FIRED POWER GENERATING
UNIT CONSISTS OF EXISTING ELECTROSTATIC PRECIPITATORS FOLLOWED BY FOUR
PARALLEL SCRUBBING TRAINS, EACH CAPABLE OF HANDLING 25 PERCENT OF THE
BOILER FLUE GAS FROM UNIT 8. EACH TRAIN INCLUDES A RECTANGULAR THROAT
VENTURI SCRUBBER AND A 6»IO-TOWER ABSORBER SUPPLIED By POLYCOM. THE GRID
TOWER CA* BE CONVERTED TO A MOBILE-BED TOWER IF GREATER S02 REMOVAL IS
REQUIRED .
TEXAS MUNICIPAL POWER AGENCY
GIBBONS CREEK
1
NEW 400.0 MW (GROSS)
400.0 «W (ESC)
COAL
1.06 XS LIGNITE
LIMESTONE
COMBUSTION ENGINEERING
ENERGY CONSUMPTION: *****
STATUS 3 STARTUP 1/82
COMBUSTICN ENGINEERING WAS AWARDED A CONTRACT TO DESIGN AND SUPPLY A
400-MW LIGNITE-FIRED BOILER, ESP, AND FGD SYSTEM AT GIBBONS CREEK STEAM
ELECTRIC STATION UNIT NO. 1. THE BOILER UILL BURN 1.06* SULFUR LIGNITE.
FLUE GAS WILL BE CLEANED OF PARTICULATES BY A COLD-SIDE ESP (99.73X
EFFICIENCY). SOZ WILL BE REMOVED BY 3 SPRAY TOWER MODULES UTILIMNG A
LIMESTONF SLURRY (72.5 TO S7.5X EFFICIENCY). A CONTRACT HAS BEEN AWARDED
TO IUCS FOR SLUDGE DISPOSAL. CONSTRUCTION IS TO BEGIN IN THE SPRING OF
1979. COCMIRICAL START-UP IS SCHEDULED FOR JANUARY, 1982*
29
-------
fPA UTILITY »60 SUPVrVs DECtMBFk 197P - JANUARY 1979
SECTION ?
STATUS OF F60 SYSTEMS
»MT IDENTIFICATION
ABSTRACT
TtXAS POWER R LIGHT
SANDOW
N EW 545.0 MW (GROSS )
38?.0 MW (FSC>
COAL
1.60 XS LI6NITF
LIMESTONF
COMBUSTION EN6INEERIN6
FNERGY CONSUMPTION : *****
STATUS 2 STARTUP 7/PO
COMBUSTIIN ENGINEERING HAS BEEN CHOSEN AS THE BOILER AND FGD VENDOR FOR
THIS UNIT. BOILER CONSTRUCTION BEGAN ON SFPTjMBER 9, 1977. PARTICULATE
REMOVAL (OU1PMENT WILL PE LOCATED ON THE COLD-SIDE OF THE AIR HEATER.
SOME PORTION OF THE FLUE GAS WILL BYPASS THE SCRUBBER FOR RFHEAT. THE
SPENT SH.RRY WILL BE PONDED AND WATER RECYCLED.
-NULL — NIL L--NULL—NUL I.--N ULL--NUL|.--NULL-~NULl--NuL L—NULL--NULL--NULL--N
TEXAS POWER
TWIN OAKS
1
NEW
* L16HT
750,0 My (GROSS)
75P.O f«K
COAL
***** XS LIGNITE
L IMESTONE
VENDOR NOT SELECTED
ENERGY CONSUMPTION: *****
STATUS 6 STARTUP 8/83
THIS UNIT WILL BE JOINTLY OWNED |V TPftL AND ALCOA. A FIRM DECISION HAS
NOT TEEN MADE WHETHER TO INSTALL FfiD FACILITIES. THIS IS PRIMARILY [U&
TO THE F-iCT THAT SUCH A DECISION IS NOT YET REfiUIRED IN THE UTILITIES
PLANNING TIMETABLE
TEXAS POWER S LIGHT
TWIN OAKS
?
NEW 750.0 KU (GROSS)
750.0 «M «ESe>
COAL
***** XS tIENITE
LIMESTONE
VENDOR NOT SELECTED
FNERGV CONSUMPTION: *****
STATUS 6 STARTUP 9/84
THIS UNIT WILL BE JOINTLY OWNED fiY TPM. AND ALCOA. A FIRM DECISION HAS
NOT EIEEN F*ADE WHETHER TO INSTALL FGD FACILITIES. THIS IS PRIMARILY »U£
TO THE F*CT THAT SUCH A DECISION IS NOT YIT RE8UIRID IN THI UTILITIES
PLANNING TIMETABLE
TEXAS UTILITIES
FOREST 6ROVE
1
NEW 750.0 "U <6ROSS>
750,0 MH (ISC)
COAL
***** XS L1GNITI
PROCESS NOT SELECTED
VENDOR NOT SELECTED
ENERGY CONSUMPTION: ****X
STATUS 5 STARTUP 0/M
TEXAS UTILITIES IS PLANNING A NEW 750~MU UN]T AT THE FOREST iROVE SITE.
TWO tSP'S WILL BE INSTALLED FOA PARTICULAR CONTROL. THE UTILITY IS
CURRENTL1 RE8UIST1N6 KIDS FOR AN FED SYSTEM. START-UP IS SCHEDULED FOR
LATi 1981. THI BOILER WILL PE SUPPLIED BY IABCCCK 8 WHCOX COMPANY.
THE DESIGN DOES NOT INCLUDE A STACK BAS REHEAT SYSTEM,
TEXAS UTILITIES
MARTIN MKF
t
NEW 793.0 MW (GROSS)
595.0 MW (ESC)
COAL
.90 XS LIGNITE
LIMESTONE
RESEARCH CQTTRELL
ENIR6Y CONSUMPTION! *****
STATUS 1 STARTUP 4/77
REFER TO SECTION 3 Of THIS REPORT F,OR ADDITIONAL INFORMATION. THIS NEW
793 MW UMT FIRES TEXAS LIGNITE CONTAINING Q.9X SULfUR (AVG> AN» 8X ASH
(AVE). Tlif UNIT IS E6UIPPED MITH AN EMISSION CONTROL SYSTEM MHICN
INCLUDES COLD-SIDE FSP'S AND A LIMESTONE F6D SYSTEM BOTH SUPPLIED BY
RiSiARCH-COTTRiLL* THE F6D SySTEH CONSISTS OF 6 PACKED/SPRAY TOWER
ABSORBERS WHICH TREAT 7SX OF TH{ TOTAL BOILER FLUE f>A$. THE REMAINING
FLUE CAS IS BYPASSED FOR RtHgAT. TOTAL S02 REMOVAL EFFICIENCY IS 70.SX.
THE FLUE MS CLEANING WASTES ARE STABILIZED AND DISPOSED IN AN ON-SITE,
LANDFILL .
TEXAS UTILITIES
MARTIN LAKE
I
NEW 793.0 MW (GROSS)
595.0 MW (5SC)
COAL
.90 XS LIGNITE
LIMESTONE
RESEARCH COTTRELL
ENERGY CONSUMPTION: *****
REFER TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION. THIS NEW
793 MW UMT FIRES TEXAS LIGNITE CONTAINING G.9X SULFUR (AV6) AND SX ASH
(AVG). Tit UNIT IS EQUIPPED WITH AN EMISSION CONTROL SYSTEM CONSISTING
OF COLD-TIDE ESP'S AND A LIMESTONE FGD SYSTEM, BOTH SUPPLIED BY
RESEARCH -COTTRELL. THE FGD SYSTEM CONSIST; OF 6 PACKED/SPRAY TOWER
APSOKBtRJ WHICH TREAT 75X OF THE TOTAL BOILER FLUE GAS. THE REMAINING
FLUE GAS IS BY-PASSED FOR REHEAT. TOTAL DESIGN SO? REMOVAL EFFICIENCY IS
70.51, TK FLUE GAS CLEANING WASTES ARE STABILIZED AND DISPOSED IN AN
CN-SITE LANDFILL.
STATUS 1
STARTUP 5/78
30
-------
EPA UTILITY FGO SURVEY: DECEMBER 1978 - JANUARY 1979
SECTjON 2
STATUS OF FED SYSTEMS
UNIT IDENTIFICATION
ABSTRACT
TEXAS UTILITItS
MARTIN LAKE
7
793.0 MW (GROSS)
595.0 KW t£SC>
COAL
.90 XS LIGNITE
LIMESTONE
RESEARCH COTTKELL
ENERGY CONSUMPTION: *****
STATUS 2 STARTUP J/79
THIS K'tU 793-MW POWER GENERATING UMT HILL FIRE TEXAS LIGNITE CONTAINING
0.9X SULFUR (AVG.) AND BX ASH CAVG.). TO MEET FEDERAL NSPSt THE
BE EtUlPFtD WITH AN EMISSION CONTROL SYSTEM CONSISTING OF COLD-SIDE ESP'S
AND A LIU STONE FGD SYSTEM, BOTH SUPPLIED BY RESEARCH-COTTRELL. THE F6D
SYSTEM CcNsISTS OF 6 PACKED/SPRAY TOWER ABSORBERS WHICH WILL TREAT 75* OF
THE TOTAL BOILER FLUE GAS. THE REMAINING GAS WILL BE BYPASSED FOR REHEAT.
TOTAL DE!I6N SO? REMOVAL EFFICIENCY IS 70.5X THE FLU* GAS CLEANING
WASTES WILL BE STABILIZED AND DISPOSED IN AN ON-SITE LANDFILL.
TtXAS UTILITIES
MARTIN LAKE
t
NEW 7SO.O ?,* (GROSS)
750.0 MW (FSC)
COAL
.90 XS LIGNITE
LIWESTONF
RESEARCH COTTHELL
ENERGY CONSUMPTION: *****
THE CONTRACT FOR THIS FGD SYSTEM HAS BEEN AWARDED TO REsEARCH-COTTRELL.
THE bOlLiR IS NOW BEING ERECTED. START-UP HAS BEEN DELAYED TO EITHER
1985 OR 1986.
STATUS 3
STARTUP Q/R5
TEXAS UTUITIiS
MILL CREEK
1
NEW 750.0 MW (ftiOSS)
750.0 MK (ESc)
COAL
***** XS LIGNITE
PROCESS NOT SELECTED
VENDOR NOT SELECTED
ENERGY CONSUMPTION: *****
STATUS 6 STARTUP 0/85
TEXAS UTILITIES IS PLANNING TWO NEW 75Q-MW UNITS F 0" THE UTHITY'S
MILL CRIFir SITE. THI UTILITY KILL INCORPORATE F6C SYSTEMS ON EACH UNIT
SO THAT 502 EMISSIONS WILL BE CONTROLLED TO APPROXIMATELY H6/MM PTl).
PARTICULm MATTER WILL B6 CONTROLLED BY ESP'S. START-UP FOR UNITS
1 AND2 A fF PROJECTID TO Bl 1985 AND 19g« »ESPE CT1VH Y.
TEXAS UTILITIES
MILL CREEK
I
NEW 750.0 MM (GROSS)
750.0 MW (ESc)
COAL
***** X$ LIGNITE
PROCESS NOT SELECTED
VENDOR NOT SELECTED
ENERGY CONSUMPTION: ****%
STATUS 6 STARTUP 0/P6
TEXAS UTILITIES IS PLANNING TWO NEW 750-MW UNITS F 0" THE UTILITY'S
MILL CREEK SITE. THE UTILITY WILL INCORPORATE FGD SYSTEMS ON t* C« UNIT
SO THAT 502 EMISSIONS WILL BE CONTROLLED TO APPROXIMATELY 1 IB/MM BTU.
PART1CLIOTE MATTER WILL BE CONTROLLED BY ESP'S. START-UP FOR UNITS
1 AND 2 tKt PROJECTED TO BE 1985 AND 1986 RESPECTIVELY.
TEXAS UTILITIES
MONTICELLO
5
NEW 8CC.O MW (GROSS)
800.0 MW (ESC>
COAL
1.50 XS LIGNITE
LIMESTONE
CHEMICO
ENERGY CONSUMPTION: ****%
STATUS 1 STARTUP 5/78
REFER TO SECTION 3 OF THIS REPORT FQR ADDITIONAL INFORMATION. THE
EMISSION CONTROL SYSTEM FOR THIS UNIT CONSISTS OF A HIGH EFFICIENCY ESp
AND A LIMESTONE FGD SYSTEM. THE ESP (POLLUTION CONTROL-WALTHER) PROVIDES
PRIMARY FARTKULATE CONTROL 199.56X). THE F60 SYSTEM CONSISTS OF 3
LIMESToNt SCRUBBING SPRAY TOkFRS THAT PROVIDE PRIMARY S02 CONTROL (742).
THE FED IVSTEM IS DESIGNED TO TREAT 3 MM ACFM OF FLUE GAS RESULTING FROM
COAL WIT^ 1.SX SULFUR, 18.9X ASH AND C.04X CL. THE FLUE GAS CLEANING
WASTIS AfE DISPOSED IN AN ON-SITE LINED POND.
UTAH POWER g LIGHT
EMERY
1
NEW 400.0 KU (GROSS)
360.0 MW (ESC)
COAL
.50 XS
LIME
CHFftICO
ENERGY CONSUMPTION: *****
STATUS 2 STARTUP «/79
A CONTRACT HAS BEEN AWARDED TO THE CHFMICO AIR POLLUTION DIVISION FOR A
PEBBLE LIKE WET SCRUBBING SYSTEM FOR THIS NEW UNIT. THE SCRUBBING SYSTEM
IS DESlGfcED TO OPERATE IN AN OPEN WATER LOOP MODE WITH AN S02 REMOVAL
EFFICIENCY OF 80 PERCENT FOR LOW SULFUR UTAH COAL. PRIMARY PARTICULATE
CONTROL MLL BE PROVIDED BY AN ESP UPSTREAM OF THE SCRUBBERS. THE SLUDGE
WILL BE STABILIZED WITH FLY«$H AND DISPOSED OF ON THE PLANT SITE. THE
A-E DESIGN FIRM FOR THIS PROJECT IS STEARNS-R06ER. CONSTRUCTION {S NOW
IN ITS FINAL STAGES.
31
-------
UTILITY F6D SURVEY: DECtPBF.S 197F - JANUARY 1979
SECTION 2
STATUS OF F6D SYSTEMS
UNIT IDENTIFICATION
ABSTRACT
UTAH POWFR t LIGHT
FMERY
NEW 400.0 MW (GROSS)
360.0 M* (F,Sc >
COAL
.50 XS
I 1ME
CHEMICO
FNF.RGY CONSUMPTION: ***«X
STATUS 2 STARTUP 6/PO
UTAH F'H AWARDED CHIMICO A CONTRACT TO SUPPLY A LIME FGO SYSTEM FOR ENERY
? OESlGNtD TO OPERATE IN AN OPEN WATER LOOP MODE VjTH AN SO? REMOVAL EF-
FICIENCY OF 60 PERCENT (FIRING LOW SULFUR UTAH COAL). PRIMARY PARTlCUtATE
CONTROL ULL 8E PROVIDED BY AN ESP UP-STREAM OF THE SCRUBBERS. THE SLUDGE
WILL 6f STABILI7ED WITH FLY*SH AND DISPOSED OF ON TH£ PLANT SITE. INITIAL
TOILER AtD F6D SYSTFM START-UP iS SCHEDULED FOR JuN* 1WO» THIS UNIT WILL
?F IDENTICAL TO UNIT 1, CONSTRUCTION ON THIS UNIT IS ABOUT 3 5X COMPLETE.
UTAH POWCR «. LIGHT
MUNTIN6TON
1
NEW 430.0 PW (GROSS)
166.0 ru (rse>
COAL
.50 XS
IIWE
FfFfR TO SECTION 3 OF THIS REPORT FOR ADDITIONAL INFORMATION. CHEffICO WAS
THE SUfPHER OF A LIME SCRUPE1N6 SVSTFM FOR THIS NEW UNIT. PRIMARY
PARTUULm RIWOVAL IS PROWIOFD BY AN ISP INSTALLED UPSTREAM OF THE WET
SCRUBBING SYSTEM. A DAMPER IS USED DURING OPERATION TO ALLOW BETWEEN 10
AND t'C PERCENT OF THE FLUE «AS TO PY-PASS THE FGD SYSTEM. DESIGN REMOVAL
EFFICIENCIES FOR SO? AND PARTiCULATI ARE 10 AND 99.5 PERCENT
RFSPtCTIVKLY. SLUftS! IS DEWATEREB <60!f SOLIDS) AND TRUCKED TO AN ON-SJTE
IAN6FILI. INITIAL OPERATIONS AT THIS UNIT SiGAN ON MAY 10* 197S.
ENERGY CONSUMPTION: *****
STATUS 1 STARTUP 5/7£
WISCONSIN POWER & LIGHT
COLUMBIA
2
NEV $27.0 MW (GROSS)
311.0 MW (FSC>
COAL
.80 XS
LIME/ALKALINE FLYASH
CHEMICO
PNER6Y CONSUMPTION: *****
STATUS 3 STARTUP 1/fiO
A CONTRACT HAS SEEN AWARDED TO CHEMICO FOR A LlMi/FLVASH ffifi SYSTEM. IT
WILL CONSIST OF TWO SPRAY MOCULES WITH A HOT-SIDE ESP FOR PARTICULAR
REMOVAL. A CLOSED LOOP WATER SYSTEM IS ANTICIPATED WITH FLYASH STABILI-
ZATION Of THE SLUDGE. A SLUDGE DISPOSAL POND LOCATED OFF-SITE IS BEING
CONSIDERF.0. THE FGD SYSTEM IS faFING DESIGNED TO TP-EAT 60% OF THE FLUE
GAS ffESUlTING FROM THE COMBUSTjON OF LOW SULFUR COLSTR1P COAL. THE
RFMAIKINf 40% WILL BE BYPASSED FOR REHEAT.
-------
EPA UTILITY FGO SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FCD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
cm
STATE
REGULATORY CLASSIFICATION
PARTICIPATE EMISSION LIMITATION - NG/J
502 EMISSION LIMITATION - IHG/J
NET PLANT GENERATING CAPACITY - MM
GROSS UNIT GENERATING CAPACITY - MU
NET UNIT GENERATING CAPACITY U/FGD - Mb
NET UNIT GENERATING CAPACITY WO/FGD - »W
EQUIVALENT SCRUBBED CAPACITY - MW
** BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM GO HER FLUE GAS FLOW - CD.MS
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPi
FUEL GRADE
AVERAGE HEAT CONTENT - KJ/KG
8ANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - X
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTEkT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - 8
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - %
RANGE CHLORIDE CONTENT - X
FUEL FIRING RATE - M T/H
FUEL FIRING RATE - PIH
** ESP
NUMBER
TYPE
SUPPLIER
PARTICIPATE DESIGN REMOVAL EFFK1EKY
** F6D SYSTEM
SALEABLE PRODUCT/THROW *UAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICULATE DESIGN REMOVAL EFFICIENCY
S02 DESlbK REMOVAL EFFICIENCY - X
INITIAL START-UP
CONTRACT AWARDED
** ABSORBER
NUMBER
TYPE
INITIAL START UP
SHELL MATERIAL
SHELL LINER MATERIAL
INTERNAL MATERIAL
BOILER LOAD/ABSORBER - X
LIQUID RECIRCtlLATION RATE - LITER/S
L/G RATIO - L/CU.M
S02 DESIGN REMOVAL EFFICIENCY - X
** FANS
NUMBER
TYPE
CONSTRUCTION MATERIALS
ALABAMA ELECTRIC COOP
TOWBIGBEE
2
LEROY
ALABAMA
A
***** *
516.
*******
?S5.0
225.0
*******
179.0
RILEV STOKER
PULVERIZED
BASE
6/79
4*9.72
HJ.9
12J.
*******
(****** LB/KMiTU>
( 1.200 LB/FMBTU)
COAL
BITUMINOUS
*******
********
10-1*
********
******
1.15
0.8-1.5
********
******
*******
*****
( 953000 »CFM>
( 291 F)
( 400 FT)
(*«*** FT)
(****** BTU/LB)
11000-12000
(*** TPH>
HOT SIDE
RESEARCH-COTTRELL
X 99.3
THROW AW AY PRODUCT
WET SCRUBBING
LIMESTONE
PEABODV PROCESS SYSTEMS
BURNS S MCDONALD
FULL SCALE
NEW
- X 99.3Q
59.50
9/78
8/75
SIEVE TRAY SPRAY TOWER
9/78
CARBON STEEL
316L SS
316 SS
35.0
1259. (19980
9.4 ( 70.0 GAL/1000ACF)
85.0
1
ID. DIRECT COUPLED
CARBON STEEL
33
-------
UTILITY F6D SURVEY: DECEMBER 1978 - JANUAPY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FED SYSTEMS
•* MIST ELIMINATOR
NUMBER
TYPF
** PUMPS
SERVICE
RECYCLE
MILL RECYCLE
LIMfSTONt SLURRY
WASH WATER
WASTE SLURRY
SUPERNATE RETURN
** TANKS
SERVICE
SLURRY FitcYCLE
LIMESTONE SLURRY STORAGE
WASHWATFR
** REHEATER
NUMBER
*• THICKENER
NUMBER
1
CHEVRON
NUMBFR
6
2
2
3
2
1
NUMBER
1
1
1
1
1
** WATER LOOP
TYpE OPEN
FRESH MAKEUP WATER ADDITION - Lims/s U.6
*• REA6ENT PREPARATION EQUIPMENT
NUMBER OF BALL MILLS 1
BALL MILL CAPACITY- M T/H 9.1
*• TREATMENT
** DISPOSAL
NATURE FINAL
TYPE LINED POND
LOCATION ON SITE
TRANSPORTATION PIPE
< 280 6PM)
< 10.0 TPH)
•-._... .........---pERf ORMANCE DATA ^- '•—*—-------— — --•- ;-----—..
PERIOD MODULE AWAIIAPILITY OPERASILITY FfLlABlLITV UTILIZATION X REMOVAL PER BOILER FGO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
8/7? SYSTEM
9/7R SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 9/78 tOUIffENT: r6D StSTEMt GfcNERAL
tND DATE 9/78 COMMENTS!
INITIAL OPERATION BEGAN DURING SEPTEMBER.
AFFECTED MODULES: SYSTEM
10/78 SYSTEM
11/76 SYSTEM
12/78 SYSTEM
744
720
744
720
744
PROBLEMS/SOLUTIONS/COMMENTS
START DATE 12/78 E6DIFWENT: FGO SYSTEM, GENERAL
tND DATE 1/79 CCMHtNTS:
THE UTILITY HA! REPORTED THAT THE UNIT HAS SUFFERED NO MAJOR PROBLEMS.
OPERATIONAL HCURS ARE NOW BEING ACCUMULATED.
AFFECTED MODULES: SYS*
1/79 SYSTEM
744
-------
SPA umm F«6 SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL F60 SYSTFMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATl
REGULATORY CLASSIFICATION
PART1CULATE EMISSION LIMITATION - hG/J
S02 EMISSION LIMITATION - MS/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MM
NET UNIT GENERATING CAPACITY W/FGD - Mfe
NET UNIT GENERATING CAPACITY NO/FGC * f>W
ECU1VALFNT SCRUBBED CAPACITY - I«IW
** BOILER DATA
SUPPLIER
TYPI
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU.*/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - KJ/KG
RANGE HEAT CONTENT - EtlU/Lt>
AVERAGE ASH CONTENT - 3
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT -
AVERAGE CHLORIDE CONTEKT
RANGE CHLORICr CONTENT - X
FUEL FIRING RATE - M T/H
FUEL FIRING RATE - MU
** ISP
- X
TYPE
SUPPLIER
PARTICULAR DESIGN REPCVAl, EFFICIENCY
*« F60 SYSTEM
SALEAILE PRODUCT/THROWmV PRODUCT
GENFRAL PROCESS TYPE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICULAR DESIGN REMCVAL EFFKIEKCY
S02 DESIGN REMOVAL EFFICIENCY - t
COMMERCIAL DATE
INITIAL START-UP
CONSTRUCTION COHPliTlOIH
*« ABSOPBIK
POWER COOP
< .100 LP/MMBTU)
< .BCD IB/MMBTU)
ARIZONA
APACHE
COCHISE
ARIZONA
6
43.
344.
• 590.0
245.0
?DO.O
*******
180.0
RUEV STOKER
PULVERIZED COAL.CRT BOTTOM
BASE
0/78
******** (*******
******* <»**» f)
12?. < 400 FT)
******* (****» FT)
TYPI
INITIAL START UP
NUHKER OF STAGES
SHELL MATERIAL
SHELL LINER MATERIAL
NOWLF TYPE
GAS FLOU - CU.H/S
GAS TEMPERATURE - C
LUulD RECIRCULATION RATE - LITfRAS
PRESSURE DROP " "PA
** MIST ELIMINATOR
NUMBER
TYPE
COAL
BITUMINOUS
*******
10.00
******
********
******
.70
0.5-0.8
********
******
*******
*****
(*«**** BTU/L8)
10000-11000
(*** TPH)
1
HOT SIDE
AIR CORRECTION DIVISION, UOP
99. t
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
RESEARCH COTTRELL
iURNS I MCDONALD
FULL-SCALE
NEH
99. 50
85.00
11/78
8/78
8/7B
PACKED TOMER
8/78
1
MILD STEEL
GLASS-FLEX
31« SS
188.76
132.2
1760.
.1
( 400000 ACFM)
( 270 F>
(20QOO 6P«>
( .6 IN-H20)
4
CHEVRON
35
-------
EPA UTILITY FdD SURVEY: DECEMBER 1?7f - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FtD SYSTEMS
CONFIGURATION
** VATER LOOP
TYPE
RECOVERED HATER RETURN - LITER/S
FRESH MAKEUP WATER ADDITION - L1TEKS/S
*• DISPOSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
DIMENSIONS
AREA - ACRES
CAPACITY - CU.M
*• DISPOSAL
NATURE
TYPF
LOCATION
TRANSPORTATION
DIMENSIONS
AREA - ACRES
CAPACITY - CU.M
( 540D GPU)
< 1840
HORIZONTAL
OPEN
340.2
115.9
FINAL
SLUDGE POND
OFF-SITE ON LEASED LAND
PUMPED
22 ACRES X 18 FT DEEP
22.0
4843QS < 396.0 ACRE-FT)
FINAL
ASH POND
OFF-SITE ON LEASED LAND
PUMPED
64 ACRES X 18 FT DEEP
64.0
1408696 ( 1152.0 ACRE-FT)
PERIOD NODULE AVAILABILITY OPERAE1L1TY
PERFORMANCE DATA
PLIABILITY UTILIZATION
x REMOVAL
502 PARTi
PER BOILER F6D CAP,
HOURS HOURS HOURS FAC10R
10/TR SYSTEM
744
3D z
58.1
11/78
12/7R
** PROBLEMS/SOLUTIONS/COWMENTS
START DATE 10/7? ECUKrtNT: REAGENT HANDLING
END DATE 11/78 PROBLEM: NOT DEFINED/SPECIFIED
THE LIMESTONE (RUSHER WAS UNABLE TO MEET ITS DESIGN CAPACITY.
AFFECTED MODULES: SYSTEM
** PROdLEMS/SOLUTIONS/CPMMENTS
START DATE 10/78 EBU1FMENT: f60 SYSTEM, GENERAL
END DATE 11 /78 COMWCNTS:
A COMPLIANCE TEST HAS COMPLETED BUT THE RESULTS ARE NOT YET AVAILABLE.
THE ACCEPTANCE IS SCHEDULED FOR THE BEGINNING OF 1979.
AFFECTED MODULES: SYSTEM
A 25.0 17.0
B 44.0 30.C
SYSTEM 720 488 80.7
SYSTEM 744 512
** PROBLEMS/SOLUTIONS/COHKENTS
START DATE 12/78 EOUII'WENT: RECYCLE PUMP
END DATE 1/79 PROBUMt NOT DEFINED/SPECIFIED
THE FGD SYSTEM WAS NOT IN SERVICE DURING DECEMBER OR JANUARY DUE TO
VARIOUS "DEBUGGING" PROBLEMS ESPECIALLY IN MAINTAINING RECYCLE PUMP OPER-
ATION.
AFFECTED MODULES: SYSTEM
•• PROBLEMS/SOLUTIONS/COMMEN1S
START DATE 12/78 EfiUIFMENT: F6D SYSTEM, GENERAL
END DATE 1/79 COMMITS:
RESULTS OF A KCENT COMPLIANCE TEST INDICATED THAT S02 EMISSIONS MERE
BETWEEN 1.2 LE/MM BTU, THE FEDERAL STANDARD, AND 0.8 LB/MM BTU, THE STATE
STANDARD. KIT*OUT THE F60 SYSTEM. THE UTILITY IS CURRENTLY BURNING LOU
SULFER COAL (t.6X S> AND THEY BELIEVE THAT THE STATE STANDARD COULD RE MET
WITHOUT F6D SYSTEM OPERATION WHEN THE FURNACE IS "FINE TUNED".
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 12/78 tCUIFPENT: PIPING
END DATE 1/79 PRCBIFfl! COMPONENT FAILURE* OTHER
36
-------
EPA UTILITY MB SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORM C.C E DATA FOR OPERATIONAL FGD SYSTEMS
............ . .... -PERFORMANCE DATA----- — - — -
PERIOD NODULE AVAILABILITY CPERABILITY PLIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
SO? PART. HOURS HOURS HOURS FACTOR
A 30 HOUR OUTftbE OCCURRED DUE TO A RUpTURED PIPF.
AFFECTED MODULES: SYSTEM
1/79
SYSTEW 7«* 662
37
-------
'PA UTILITY FGD SURVFY: DECtUBfrR 197f - JANUARY 1979
SECTION 3
OtSKN AND PERFORMAKE DATA FOR OPERATIONAL FGD SYSTEMS
COMPANY MAKE
PLANT NAMF,
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PART1CULATE EMISSION LIMITATION - N6/J
$02 EMISSION LIMITATION - SG/J
NFT PLANT 6FNERATING CAPACITY - MV
GROSS UNIT GtNERATING CAPACITY - Hb
NET UNIT GENERATING CAPACITY U/FGD - M V*
NET UNIT GENERATING CAPACITY WO/F61 - "V
EQUIVALENT SCRUBBED CAPACITY - MW
•* BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM UOIliR FLUE GAS FLOW - CU.f/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAMETER - M
»* FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - KJ/K6
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - X
RANFE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - *
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANfE SULFUR CONTENT - X
AVERAGE CHLORIDF. CONTENT » X
RANC-f CHLORIDE CONTENT - X
FUEL FIRING RATE - M T/H
FUEL FIRING RATE - MW
»* MECHANICAL COLLECTOR
TYpI
SUPPLIER
PARTICULATE DESIGN PEMCVAL EFFICIENCY
** PARTICULATE sCPuBRER
NUMBER
TYPI
NUMPER OF STASIS
SHELL MATERIAL
LINING MATERIAL
TYPE OF NOZJLfS
BOILER LOAD/SCRUSBER - X
FLUf SAS CAPACITY - CU.M/S
FLUE GAS TEMPERATURE - c
LlSUIfr RICIRCULATION RATE - LITEfi/S
L/S RATIO - LITIR/CU.M
PRESSURE OROP * KPA
PARTICULATE INLET LOAD • f'/CU.M
PARTICULATE DESI&N REnOVAl EFFJCIEdCY
** F60 StSTEH
SALFABLf PRO DUCT/THROW AWAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
DEVILOPMENT LEVEL
NEW/RETROFIT
PARTICULATE DESIGN REMOVAL EFFICIENCY
S02 DESIGN REMOVAL EFFICIENCY - X
COMMERCIAL DATE
INITIAL START-UP
CONSTRUCTION COMPLETION
CONTRACT AWARDED
STARTED REQUESTING BIDS
( .1'8 LP/MMBTU)
( 1.000 LR/MMBTU)
ARIZONA PUBLIC SERVICE
CHOLLA
1
JOSEPH CITY
ARIZONA
B
85.
430.
615.0
119.0
115.0
120.0
119,0
COMBUSTION ENGINEERING
PULVERIZED COAL. WET BOTTOM
BASE
0/62
74S.39 ( SZOOOO ACFIO
******* (**** F)
It. t 256 FT)
******* (**«** FT)
COAL
SUSmUMINObS
23609.
9.7-?2.5
15.00
******
.SO
O.U-1.0
.02
0.01-0.04
49.0
119
( 10150
9650-106DO
< 54 TPH)
CYCLONES
RESEARCH COTTRELL
X 7S.Q
FLOODED DISC
1
316L SS
CIILCOTE AND FLAKE6LJSS
156.7 271 F)
136.7 2170 GPM)
1.4 10.1 6AL/1000ACF)
3.7 1! IN-H20)
4.6 2.(!Q 6P/SCF)
99.2
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
RESEARCH COTTRELL
E9ASCO
FULL-SCALE
RETROFIT
99.70
58.50
12/73
10/73
12/73
7/71
*/71
38
-------
EPA UTILITY FGD SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DF.S16N AND PFRFCRKAKCE DATA FOR OPERATIONAL F6D SYSTEMS
STARTED PRELIMINAY DESIGN
** ABSORBER
NUMBER
TYPF
INITIAL START UP
SUPPLIED
NUMBER OF STAGES
DIMENSIONS
SHELL MATERIAL
INTERNAL MATERIAL
N01ZLF TYPE
BOILER LOAO/APSORBER . J
6AS FLOW - CU.M/S
GAS TEMPERATURE - C
LIOUID RECIRCULATION RATE - LITEfl/S
L/6 RATIO - L/CU.M
PRESSURE DROP - KPA
SUPfRFKAL CAS VELOCITY - K/SEC
PARTICULATE INLET LOAD - G/CU.K
PARTICULAR OUTLET LOAD- 6/CU.M
PARTICULATE REMOVAL EFFICIENCY - *
S02 INLET CONCENTRATION - PPM
S02 OUTLET CONTRAT10N - PPM
S02 DESIGN REMOVAL EFFICIENCY - X
** ABSORBER
MUMPER
TYPE
INITIAL START UP
SUPPLIER
NUMBER OF STAGES
DIMENSIONS
SHELL MATERIAL
INTERNAL MATERIAL
NOZZLE TYPE
BOILER LOAD/ABSORBER - K
6AS FLOW - CU.M/S
GAS TEMPERATURE - C
LIQUID RECIRCULATION RATE - LITER/!!
L/fi RATIO - L/CU.M
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - K/SEC
PARTItULATE 1NLFT LOAD - 6/CU.f,
PARTICULATE OUTLET LOAD- C/CU.H
$02 INLET CONCENTRAT10K - PPM
S02 OUTLET CONTRATlON - P.PK
soz OESI&N REMOVAL EFFICIENCY - %
1/71
PACKED TOWER
10/73
RESEARCH COTTRELL
1
22 DIA X 7(1 HIGH
3UL SS
316L SS
SPINNER VANE
50.0
113.26
135.6
( 240000 ACFM)
< 276 F)
(10000 SPI")
( 49.0 GAL/1000ACF)
< .5 IN-H20)
C 6.9 FT/S)
( 1.995 6R/SCF)
( .001 GR/SCF)
630.
6.6
.1
.0
99.7
42C
515
25.0
1
HOLLOW TOWFR
10/73
RESEARCH COTTRELL
1
22 DIA X 70 HIGH
31«L SS
316L SS
SPINNER VANE
sn.o
113.26 ( 24DOOO ACFM)
135.6 ( 276 F>
«30. (10000 GPM>
6.6 ( 49.0 6AL/1000ACF)
.1 ( .5 IN-H20)
2.1 ( 6.9 FT/S)
4.6
.0
(20
35
92.0
( 1.995 6P/SCF)
( .001 GR/SCF)
** FANS
NUMBER
TYPE
CONSTRUCTION MATERIALS
** FANS
NUMBER
TYPF
CONSTRUCTION MATERIALS
** MIST ELIMINATOR
NUMBER
TYPE
CONSTRUCTION MATERIAL
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES
FREEBOARD DISTANCE - M
DEPTH . M
VANE SPACING - CM
VANE ANGLES
WASH SYSTEM
PRESSURE DROP - KPA
2
I.D.
MILD STEEL
2
I.D.
MILD STEEL
CHEVRON
POLYPROPYLENE
HORIZONTAL
2
2
4.11 (13.5 FT)
.30 ( 1.0 FT)
3.8 ( 1.50 IN)
45 DEG.
INTERMITTENT OVERSPRAY
.1 ( .5 IN-H20)
39
-------
F.PA UTILITY FSB SUPVFY: DECEMBER 197F - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL F6D SYSTFHS
•* HIST El IM1NATOR
MUMPER
TYPF
CONSTRUCTION MATERIAL
CONfI6URATION
NUNF/ER OF STAGES
NUMPER Of PASSES
fSEEBOARD DISTANCE - f
DEPTH . M
VANE SPACING - CM
VANF AMSLES
WASH SYSTEM
PRESSURE DROP - KPA
** PROCfSS CONTROL CHEMISTRY
CONTROL MANNER
** PUMPS
SERVICE
RECIRCULATION
** TANKS
SERVICE
FLOODED DISC SCRUBBER TANK
SLUD6E HOLDUP TANK
ABSORBER TOWER HOLDUP TANK
LIMESTONE SLURRY MAKEUF TANK
** REHEAJER
NURE>ER
TYPE
HEATING KEDIUr
TEMPERATURE BOOST - C
ENERGY REQUIRED
** WATER LOOP
TYPE
FRESH MAKEUP WATER ADDITION - LITEKS/S
** REAGENT PREPARATION F.OU IP« E«T
NUMBER OF BALL MILLS
** DISPOSAL
NATURE
TYPE
TRANSPORTATION
DIMENSIONS
AREA - ACRES
CAPACITY - CO.M
SLAT IMPINGEMENT
POLYPROPYLENE
HORI70NTAL,
7
4
«.11 (13.5 FT)
.30 < 1.0 FT)
1S.O ( 7.in IN)
45 DEC.
INTERMITTENT OVERSPRAY
.1 ( .5 IN-N20)
MANUAL
NUMBER
1
IN-LINE
STEAM
22.?
8MM ETU/HR
40 F)
OPEN
7.6 < 120 6Pf)
1
FINA1
UNLINED PONG
PIPE
70-100 ACRES X 6 FT DEEP
85.0
6H3730 <
510.0 ACRF-FT)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY CPERABILITY PLIABILITY UTILIZATION
X REMOVAL PER BOiLER FGD CAP.
SQ2 PART. HOURS HOURS HOURS FACTOR
10/73 SYSTEM
11/73 SYSTEM
12/73 SYSTEM
744
7ZO
744
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 12/73 EOUIFKENT: REHEATER
END DATE 4/74 PROBLEM: DESIGN-RELATED VIBRATION
BECAUSE OF A DIFFERENCE IN THE SIZE OF THE MAIN DUCT AND REHEATED TRANS-
ITION DUCT, THE GAS FLOU PRODUCES HARMONIC VIBRATIONS IN THE REHEATER.
THE VIBRATIONS WERE PARTIALLY DAMPENED BY INSTALLATION OF BAFFLES.
AFFECTED MODULES: SYSTEM
40
-------
EPA UTILITY FGO SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FGD SYSTEMS
-. . . PERFORMANCE DATA
PERIOD HOOULE AVAILABILITY OPERAB1LITY IELIABILITY UTILIZATION
X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLU1IONS/COMMENTS
START DATE 12/73 EQUIPMENT: REHEATER
END DATE 4/74 PHOBIEM: CHEMICAL-RELATED CORROSION
ONE OF THE REl-EATER BUNDLES WAS BADLY CORRODED BY ACID THAT CONDENSED IN
THE UNINSULATED DUCT UPSTREAM OF THE REHEATERS. THE TUBE BUNDLE MAS RE-
PLACED AND A BAFFLE WAS INSTALLED TO DIVERT CONDENSED ACID FROM REHEATER
TLBES.
AFFECTED MODULES: B
** P80BLEMS/SOLUTIONS/COMMENTS
START DATE 12/73 EQUIPMENT: DUCTWORK
END DATE 4/74 COKMtNT: PREVENTIVE MAINTENANCE
THE DUCT UPSTREAM OF THE REHEATER kAS INSULATED. THE ACID CONDENSATION
OCCURRED ONLY IN THE B-NODULE WHICH CONTAINS NO INTERNAL PACKING AND THERE
FCRE HAS A LOfcER DEGREE OF SULFUR DIOXIDE REMOVAL (25 PERCENT).
AFFECTED MODULES: B
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 12/73 E6UIFWENT: PIPING
END DATE 4/74 PRCBlFM: CHEMICAL-RELATED PLUGGING
SCME LINES PUGGED, PARTICULARLY WHEN THE SYSTEM OPERATED AT LOU FLOW
RATES.
AFFECTED MODULES: SYSTEM
*« PROBLEMS/SOLUTIONS/COMMENTS
START DATE 12/73 tGUIWENT: RECYCLE PUMP
END DATE 4/74 PROBIFM: CHEMICAL-RELATED PLUGGING
SCLIDS SETTLES OUT IN STANDBY PUMPS, AND EXCESSIVE FAN VIBRATIONS OCCURRED
BECAUSE Of ACCUMULATION OF SCALE BUILDUP WHEN THE UNIT WAS IDLE. TO SOLVE
THESE PROBLEM: THE PACKING GLAND POSITION WAS REVERSED (INSTALLED UPSIDE
DCWN). THE FAH WAS SANDBLASTED. THE PIPING WAS HOD1FIED TO ELIMINATE STAG-
NANT POCKETS. AND PUMPS WERE FLUSHED IMMEDIATELY AFTER REMOVAL FROM
SERVICE.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 12/73 £6UIFWENT: RECYCLE PU«P
END DATE **/** PROBtER: CHEMICAL-RELATED PLUGGING
THE UTILITY £ X FFfilENC E« SOLIDS BUILDUP IN THE FDS STDF FINS GLAND" BO* AND
ON TOP OF THt SPRAY DOME.
AFFECTED MODULES: SYSTEM
1/7*
A
B
SYSTEM
2/74 A
B
SYSTEM
3/74 B
A
SYSTEM
4/74
5/74 A
B
SYSTEM
6/74 A
B
SYSTEM
58.0
97.0
90.0
94.0
100.0
94.0
97.0
66.0
100.0
63.0
46.0
57.0
62.0
99.0
99.0
100.0
100.0
100.0
744
672
744
720
744
720
744
41
-------
EPA UTILITY F6D SUPVEY: DECEMBER 197P - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FGO SYSTEMS
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY CPERARIHTY ^LIABILITY UTILIZATION t REMOVAL PER BOILER F60 CAP.
S02 PART. HOURS HOURS HOURS FACTOR
7/74
A
fi
SYSTEM
97.0
92 .0
95.0
744
8/74
9/74
10/74
11/74
12/74
1/75
Z/75
3/75
4/75
5/75
A
B
SYSTEM
B
A
SYSTEM
B
SYSTfcP
97.0
97.0
97.0
99.0
95.0
97.0
8;.o
68. 0
76.0
744
720
744
** PROBLEMS/SOLUTIONS/COMflENTS
START DATE 10/74 E6UIF«ENT: F6D SYSTEM, GENERAL
END DATE 10/74 COMMENTS:
ANNUAL BOILtP AND F6D SYSTEM OVERHAUL.
AFFECTED MODULES: SYSTEM
A 100.0
B 98.0
SYSTEM 99.0
A 100.0
B
SYSTEM 100.0
B 99.Q
A 98.0
SYSTEM
** PROdLEMS/SOLUTIONS/COMMENTS
720
744
744
START DATE 0/75 EQUIPMENT: FGD SYSTEM, GENERAL
EN6 DATE 0/76 COMMENTS:
OPERATION OF iHE SYSTEM THROUGHOUT 1975 AND 1976 WAS ACCOMPANIED BY A NUM-
BER fiF MINOR SR06LEI" AREAS INCLUDIN6: SI6NI FICANT C ORHOSI ON ATTACK IN THE
VESSEL WALLS f.f THE VENTURI FLOODED-DISC PARTICULATE SCRUBBER MODULE; ACID
CORROSION IN 1HE B-SIDE REHEATER HOUSING; SCALE BUILDUP IN THE PIPE OUTLET
AT THE SLUD6EJFLYASH EVAPORATION FOND; PLUGGING IN THE SCRUBBER TOWER PACK
IkG «ND MIST LtlMINATOR; EPflSlON IN THE PUMPS; CORROSION IN THE BOILER EX-
HAUST ELPOH Of THE DUCTUORK LEADING FROM THE SfRUBBERS TO THE STACK.
AFFECTED MODULES; SYSTEK
A
B
SYSTEM
SYSTEM
A
B
SYSTEM
A
B
SYSTEM
96.0
99.0
98.0
88.0
65.0
77.0
48.Q
40.0
44.0
67Z
744
720
744
** PROdLEMS/SOLUTIONS/COMMENTE
START DATE 5/75 E8UK«ENT: FGD SYSTEM, GENERAL
£ND DATE 5/75 COMMtNTS:
BOTH MODULES tERE OFF LINE FOR HOST OF THE MONTH FOR SCHEDULED REPAIRS AND
CLEANING.
AFFECTED MODULES: A
-------
EPA UTILITY FC6 SUfcVEY: DECEMBER 1978 - JANUARY 1979
SECTION J
DESIGN AND PERFORMANCE DATA FOR OPERATICNAL F6D SYSTEMS
PERFORMANCE DATA •
PERIOD MODULE AVA11ABIL1TY OPEPAPUnV «LIAB1 LIT Y UTILIZATION X REMOVAL PEP. BOILER F60 CAP.
S02 PART. HOURS HOURS HOURS FACTOR
*'75 A 100.0
& 100 .0
SYSTEM 100.0 720
** PROBLEMS/SOLUTIONS/COMMENTS
START OATE 6/75 EQUIPMENT: ABSORBER
END DATE 6/75 PROBtF:M: CHEMICAL-RELATED PLUGGING
PLUGGING IN TfF A-SIOE ABSORBER PACKING HAS OBSERVED.
AFFECTED MODULES: A
** PR06LEMS/SOLUTIONS/COMMENTS
START DATE 6/75 EQUIPMENT; HIST ELIMINATOR
END DATF 6/75 PROBlEH: CHEMICAL-RELATED PLUGGING
PLUGGING OCCURRED IN MIST ELIMINATORS.
AFFfCTEO MODULES: A
*• PROBLEMS/SOLUTIONS/COMMENTS
START DATE 6/75 tCUIFMENT: F6D SYSTEM, GENERAL
END DATE 6/75 COMHFNTSi
NC MAJOR PFOBUMS WERE ENCOUNTERED DURING THE PERIOD.
AFFECTED MODULES: SYSTEM
7/75 A 97.0
B 98.0
SYSTEM 98.0 744
** PR00LEWS/SOLUTIONS/COMMENTS
START DATE 7/75 ICUIFWENT: SCRUBBER
£No DATE 7/75 PfOPLFfl: DESIGN-RELATED FLOW DISTRIBUTION
MODULES UtRL 1HUT DOWN TO CLEAN FLOW RESTRICTIONS IN FLOODED-DISC REC1R-
CbLATION LINES.
AFFECTED MODULES: SYSTEM
8/75 A 95.0
B 100.0
SYSTEM 98.0 7*4
*+ PROBLEMS/SOLUTIOftlS/COMMENlS
START DATE 8/75 E6UI f«tNT: FGD SYSTEM, GENERAL
END OATE 6/75 CCHRtNT: PREVENTIVE MAINTENANCE
THE A-SIDE WA !. SHUT DOWN FOR INSPECTION.
AFFECTED MODULES: A
9/75 A 98.C
B 97.0
SYSTEM 98.0 720
** PROBLEMS/SOLUTIONS/COMKENTS
START DATE 9/75 ESUIM*ENT: SCRUBBER
END DATE 9/75 PROBIEM: CHEMICAL-RELATED PLUGGING
MINOR OUTAGE (.fSULTED FROM PLUGSED FDS RECIRCUL ATION LINES
AFFECTED MODULES: SYSTEM
10/75 A 84.0
B 55.0
SYSTEM 70.0 744
•* PROULEMS/SOLUTIONS/COMMENTS
START DATE 10/75 EfiUI^ENTs F6D SYSTEM, GENERAL
f«D DATf 10/75 COMMtNT: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTA6E
OUTAGES RESULTED FROM SCHEDULED ESljIPMENT OVERHAULS AND RECOATIN6 OF VES-
SELS.
AFFECTED MODULES: SYSTEM
11/75 A 100.0
-------
EPA UTILITY fGO SURVEY: DECEMBER 197f - JANUARY 1979
StCTION 3
DESIGN AND PERFORMANCE (ATA FOR OPERATIONAL FGD SYSTEMS
------ ._ -------------- ............... ----- PERFORMANCE 6 AT A-------- - - - .............. ---- .........
PE»IOO MODULE AVAILABILITY CPERAP1L1TY ftLIAPUITV UTILIZATION X REMOVAL PER BOILER F«D CAP.
$02. PART. HOURS HOURS HOURS FACTOR
B 80. 0
SYSTEM 90.0 720
** PROULEMS/SOLUTIONS/CCMMENTS
START DATE 11/75 tfilllFMENT: F6D SYSTEM, GENERAL
£N6 BATE 11/75 COMMENTS:
NC N^JOR OUTAGES OR PROBLEMS OCCURRED DURING THE REPORT PERIOD.
AFFECTED MODULES: SYSTEK
12/75 A 100.0
6 100.0
SYSTEM 100.0 744
*» PROBLEMS/SOLUTIONS/CCMMENTS
START DATE 12/75 EOUIIMENT: RECYCLE PUMP
END DATE 12/75 PUOBttM: MECHANICAL-RELATED COMPONENT INEFFICIENCY
MINOR PROBLEMS ENCOUNTERED INCLUDED RECYCLE PUMP REBUILDING.
AFFECTED MODULES: SYSTEM
** PROHLEMS/SOLUTIONS/CCMMENT8
START DATE 12/75 fcOUUCEMT: REAGENT HANDLING
END DATE 12/75 f-ftOBLFM: NOT DE FINED /SPECl FI ED
ThE P-SIDE REIFATER COIL MALFUNCTIONED.
AFFECTED MODULES! t
1/76 A 99.0
B 99.0
SYSTEM 99.0 7 A 4
** PROBLEMS/&OLUT10NS/CCMMENTS
START DATE 1/76 lOUIPMENTJ VALVES
6ND DATE 1/76 PROBLEM; CHEMICAL-RELATED PLUGGING
MINOR VALVE PLUGGING OCCURRED.
AFFECTED MODULES! SYSTCM
*« PR06LEMS/SOLUTION5/COrMENT5
START DATE 1/76 EQUIPMENT: PIPING
END DATE 1 lib
MINOR LINi PLIG6IN6 OCCURRED.
AFFItTIS
•* PROBLEMS/SOLUTIONSSCOMMENTS
START (ATE 1/76 [CUlfrENT: FGD SYSTEM,
END DATE 1 /76 COMMENTS:
MCDULE B OPERATING HOURS WERE LOVER BECAUSE OF REDUCED SYSTEM REOUIKFMENTS
AFFECTED MODULES: SYSTEM
2/76 SYSTEM 696
3/76 SYSTEM 7*4
4/76 B 98. 0
SYSTEM 99.0 720
«* PRUBLEMS/SOLUTIONS/CCMMENTS
START DATE 4/76 tGUIFMENT: DUCTWORK
END DATE 4/76 PROfUFM: DESIGN-RELATED INFERIOR CONSTRUCTION MATERIAL
THE FGD SYSTEf IS CURRENTLY E XPfcRIENCEINS COATING FAILURES IN THE ELGOU OF
THE SCRUBBER EXHAUST DUCT.
AFFECTED. MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 4/76 EQUIPMENT: REAGENT HANDLING
END DATE *'?6 PR061FM: NOT DEFINED/SPECIFIED
THE UTILITY PtRfORMED SQME MINOR REPAIRS TO THE HOUSING OF THE B-SIDF
REHEATER.
AFFECTED MODULES: B
44
-------
EPA UTILITY FGD SURVEY: DECEMBER 1976 - JANUARY 1«79
SECTION 3
DESIGN AND PERFORMS DATA FOR OPERATIONAL F6D SYSTEMS
......_...___..___—............._........PERjORHAN(f
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION x REMOVAL PER BOILER FGO CAP'.
SC2 PART. HOURS HOURS HOURS FACTOR
«••"•"•••" •"•" «™ • «•«•«••»••••• — •»•*••.*••»••.••»«* *•.«•. • <* W ••*.«• *l» • *•••«• V «••>•. »••*•• *»•>«•*.«• *>•.••••> • •*.<*..*„ «,»••>« • «•«•••••
5/76 A 76.0
B 100.0
SYSTEM 86.0 74*
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 5/76 E6UIFMINT: REHEATFR
END DATE 5/76 PROBITM: CHEMICAL-RELATED CORROSION
THE A-SlOE EXPERIENCED SOME CORROSION AND PLUGGING PROBLEMS IN THE REHEAT-
ER TUBES.
AFFECTED MODULES: A
•* PROBLEMS/SOLUTIONS/COMMENTS
START DATE 5/76 tGUlMENT: PUMP, OTHER
END DATE 5/76 PROBiM: NOT DEFINED/SPECIFIED
THE UTILITY RIPORTED PLUG61N6 IN foS LjNES.
AFFECTED MODULES: SYSTfKi SYSTEM
** PROBLins/SOLUTIONS/COMMENTS
START DATE 5/76 tQUlFfENT: SCRUBBER
END DATE 5/76 PPOBlEM: CHEHICAL-RiLATSV PUOS6IN6
PLUGGING OCCURRED IN THE FDS PACKING-
»f?ICTED HODULES: SYSTEM
•* PHObLEMS/SOUUTlONS/CCrWENTS
START DATE 5/76 fc«UirwENT: MIST ELIMINATOR
END DATE 5/76 PROBif*: CHEMICAL-RELATED PLUGGING
PLUG6IN6 OCCUhfiED IN THE HIST ELIMINATORS.
AFFECTED MODULES: SYSTiM
6/76 A 64.0
B 39.0
SVSTEK 52.0 720
** PR08LEMS/SOLUTIONS/COMMENTS
START DATE 6/76 iOUItPENT: F60 SYSTEHt GENERAL
END DATE 6/76 CCnlMNTi PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTAGE
LOW RELIABILITY FACTORS FOR THE MONTH OF JUNE RESULTED FROM A SCHEDULED
MID-YEAR SCRU^ER SHUTDOWN FOR MAINTENANCE, INSPECTION AND REPAIRS.
AFFECT-ED WODULESr SYSTEM
«* PROBLEMS/SOLUTIONS/CnHMENTS
START DATE 6/76 EQUIPMENT: RECYCLE TANK
END DATE 6/76 PROSUM: C HEMI CAL-RELATE C CORROSION
SOME SCALING /NO CORROSION PROBLEMS U ER E UNCOVERED IN THF SYSTEM'S RFCYCIE
TANKS.
AFFECTED MODULES: SYSTEM
7/76 A 100.0
B 98.0
SYSTEM W»0 7*4
** PROBLEHS/SOLUTIONS/COMMENTS
START DATE 7/76 EOUIfHENT: SCRUBBER
END DATE 8/76 COMMENTS:
REPAIRS TO THE COATING IN THE ELBOM OF THE SCRUBBER EXHAUST DUCT HERE COM-
PLETED.
AFFECTED MODULES: SYSTEM
•* PROBLEMS/SOLUTIONS/COMMENTS
START DATE 7/76 EBUIFKENT: MIST ELIMINATOR
END DATE 9/76 PROBLEM! MECHANICAL-RELATED COMPONENT FAILURE
A MALFUNCTIONING SOLENOID VAtVE IN THE MIST ELIMINATOR WASH SYSTEM OF THE
P-SIDE, PREVENTING ADEQUATE WASHING, RESULTED IN A MINOR SCRUBBER OUTAGE*
AFFECTED MODULES: SYSTEM
8/76 A 100.0
-------
EPA UTILITY FED SURVEY; DECIMBF.R 197f - JANUARY 1979
SECTION 2
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL F60 SYSTEMS
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY CPERAftlLlTY PLIABILITY UTH17AT10N X REMOVAL PER BOILER FGD CAP-
S02 PART. HOURS HOURS HOURS FACTOR
B 100.0
SYSTEM 100.0 744
9/76 A 100.0
B 100.0
SYSTEM 100.0 720 720
** PRO&LtMS/SOLUTIONS/COMMENTS
START DATE 9/76 £6tlII«ENT: FGD SYSTEM, GENERAL
END DATE 9/76 COfMFNTS:
T*E POILEK REGAINED OUT of SERVICE THE ENTIRE MONTH. NO SISNIFICANT PROB-
LEWS WERE PEPCRTFD.
AFFECTEO MODULfcS: SYSTEM
10/76 A 56.0
B 56.0
SYSTEM 56.0 744 417
11/76 A 96.0
B 98.0
SYSTEM 97.0 720 720
«* PROBLEMS/SOLUT10NS/COMMENTS
START DATE 11/7* l-GUIFMENT: FGO SYSTEM, GENERAL
tND DATF 11/76 COI»M?NTS:
ThO PINOR fORCFD SCRUBBER OUTAGES OCCURRED DURING THE PERIOD.
AFFECTED MODULES: SYSTEM
** PROBIEBS/SOLUTIONS/CCMMENTS
START DATE 11/76 EOUlfcPENT: REA6FNT HANDLING
END DATE 11/76 PFOB If « : ME CHA N 1C AL-RELA TE D COMPONENT FAILURE
A REHEATER STEAM LEAK CAUSED A MINOR FORCED OUTAGE.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 11/76 tCUlfHENT: GAS DAMPER
END DATE 11/76 PPOBitH: DESIGN-RELATED FLOW DISTRIBUTION
Ad INLET tAS DAMPER ADJUSTMENT PROBLEM IN BOTH THE A-SIDE AND B-SIBE SCRUB
BIN6 TRAINS C/USED A MINOR OUTA6F .
AFFECTED MODULES: SYSTEM
12/76 A 9B.O
B 1CO.O
S»STFK 99.0 744 744
•* PROBLtMS/SOLUTIONS/COMMENTS
START DATE 12/76 EQUIF*ENT: GAS DAMPER
END DATE 12/76 PROP I.EM: DESIGN-RELATED FLOU DISTRIBUTION
OKE OUTAGE WAS REPORTED. THE OUTAGE WAS THE RESULT OF AN ADDITIONAL AD-
JUSTMENT TO TUF A-SIDE GAS INLET DAMPER.
AFFECTED MODULbS: A
1/77 A 72.0
B 93.0
SYSTEM 83.0 744 744
** PROBLEHS/SOIUTIONS/COMMENTE
START DATE 0/77 ECUIFMENT:
END DATE 0/77 COMMENTS:
TtiE PERFORMANCE INDEX VALUFS CONTAINED IN THESE TABLES ARE BASED UPON THE
MODULES' ACTUAL SERVICE TIME fOR THE PERIOD VERSUS THE NUMBER OF HOURS THS
MODULES ARE CALLED UPON TO OPERATE FOR THE SAME PERIOD. THE MODULES OPER-
ATE ON A CEMA*D-QNLY BASIS. FLUE GAS IS BYPASSED AROUND THE MODULES WHEN
THEY ARE NOT NEOUIBED FOR SERVICE.
AFFECTED MODULES: SYSTt*
2/77 A '9'0
46
-------
EPA UTILITY FGD SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL F6D SYSTFMS
, PERFORMANCE DATA
PERIOD MODULE AVAILABILITY CPERAB1LITY (^LIABILITY OT1L17AT10N X REMOVAL PER BOILER F6D CAP-
S02 PART. HOURS HOURS HOURS FACTOR
6 99.0
SYSTEM 99.0 672 672
** PRObLEMS/SOLUTIONS/COMMENTS
START DATE 2/77 tOUlVHENT: ABSORBER
tNO DATE 2/77 CCMfiFNTS: RESEARCH AND DEVELOPMENT
ThE fUNTgKi PACKING IN THE A-SIDE TOWER VIAS REPLACED.
AFFECTED MODULES: A
** PR09LEMS/SOLUTIONS/COFMENTS
START DATE 2/77 EfiUI FMEN-T: SCRUBBER
END DATE 2/77 PROBIFM: CHEMICAL-RELATED PLUGGING
MIPiiOR SCRDBEEF VESSEL PLUGEIN6 OCCURRED-
AFFECTED MODULES: SYSTEM
** PR03LEMS/SOLUTIONS/COMHENTS
START DATE 2/77 EQUIPMENT: F6D SYSTEM, GENERAL
END DATE 2/77 PROPtfHT CHEM1CAL-RELATED CORROSION
MINOR CORROSKN OCCURRED IN THE SYSTEM.
AFFECTED MODULES: SYSTEM
*• PROSLEMS/SOLUTIONS/CCMMENTS
START DATE 2/77 ECUIfMENT: PIPING
END DATE 2/77 PROBLEM: NOT 0EFINED/SPECIfI ED
SOME PROBLEMS OCCURRED WITH THE LIQUID PIPING'
AFFECTED MODULES: SYSTEM
** PROSLEMS/SOLUTIONS/COMMENTS
START DATE 2/77 EQUIPMENT: GAS DAMPER
END DATE 2/77 PROfiim: MECHANICAL-RELATED COMPONENT FAILURE
TI-.ERE WERE MECHANICAL DIFFICULTIES KITH THF BY-PASS DAMPERS.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 2/77 E6UIFMENT: FGD SYSTEM, GENERAL
fcND DATE 2/77 COMMENTS:
AVERAGE SCE IMET/OUTLET VALUES DURING THE PERIOD WERE 350 PPM AND 175 PPM
AFFECTED MODULES: SYSTEM
3/77 A 72.0
B 93.0
SYSTEM 83.0 7*4 7*4
4/77 A 1dO«0
B 100 . 0
SYSTEM 100.0 720 638
5A77 A 87-0
B B7.0
SYSTfR £7.0 744 645
** PROBLEMS/SOLUTlONS/COMtfENTS
START DATE 5/77 E8UIPMENT: FGD SYSTEM, GENERAL
END DATE 5/77
OUTAGE TIME F(R THE BOILER AND FGO SYSTEM WAS A RESULT OF THE SCHEDULED
MID-YEAR SCRUtBER CLEANOUT.
AFFECTED MODULES: SYSTEM
** PROHLEMS/SOLUTIONS/CCMMENTS
START DATE 5/77 EBUIfMENT: FGD SYSTEM, GENERAL
END DATE 5/77 COMMfcNTS: RESEARCH AND DEVELOPMENT
DLRING BAY REEEARCH-COTTRELL PERSONNEL CONDUCTED FORCED OXIDATION TESTS BY
BLOWING AIR 1*TO THE FLOODED DISC SCRUBBER AND CONVERTING ALL CAS03 TO
CASO* FO SUPERIOR SLUDGE DEWATER1NG. HANDLING AND SCALE-FREE OPERATION.
AFFECTED MODULES: SYSTEM
6/77 A 100.0
-------
EPA UTILITY FGD SURVEY: DECEMBER 1976 - JANUARY 1979
SECTION 3
DESIGN AND FtRFOFiKAhCE DATA FOR OPERATIONAL FGC SYSTEMS
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY CPEPAB1L1TY IFLIAPILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
SOa PART. HOURS HOURS HOURS FACTOR
— —•——••• V«W» ««K«««B«MVB« • _««»»*» ._KW_~««»V •«.„••»•»••—•••• ••_ H » VB.WV —•».— • «•«•„•_ — • — ™ ™ VKHKK
B 100.0
SYSTEM 100.0 720 7?0
7/77 A 97.0
B 99.0
SYSTtM 98.0 744 744
•* PR06LEMS/SOLUT10NS/COMMEN1S
START DATE 7/77 tCUIFfENTs REAGENT HANDLING
fcND DATE 7/77 pROBlEM: MECHANICAL-RELATED COMPONENT FAILURE
A MINOR LEAK OCCURRED IN THE LIMESTONE SLURRY TANK.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUT10NS/COMMENTS
START DATE 7/77 EQUIPMENTS SCRUBBER
END DATE 7/77 PROetF.M: I»E CHA NIC A L-RE L A TE D COMPONENT FAILURE
A KINOR LEAK CCCURREO IN THE B-SIDE RETURN LINE FROM THE FDS TO THE FDS.
TANK.
AFFECTED MODULES: B
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 7/77 EeUIfNENTl FGD SYSTEM, GENERAL
END D»TE 7/77 CCKMFNTS: RESEARCH AND DEWELOPKENT
RESEARCH-COTTfcELL PERSONNEL ARE STILL ON THE PLANT SITE* CONTINUING FORCED
OJUDATION STUMES.
AFFECTED MODULES: SYSTtf"
8/77 A 97.0
6 99.0
SYSTEM 98.0 744 744
9/77 A 100.0
B 100.0
SYSTEM 100.0 7JO 7?0
** PROBLEMS/SOLUTIOMS/COCMENTE
START DATE 9/77 t«Ul(*ENT: FGD SYSTEM, GENERAL
END DATE 9/77 COMMENTS:
DOWN TIME WAS REQUIRED TO REPAIR LEAKS IN THE SLURRY DISPOSAL TANK AND THE
FtS RETURN LIf,f. .
AFFECTED MODULES: SYSTEM
*« PROBLEMS/SOLUTIONS/COMMENTS
START DATE 9/77 EQUIPMENT: SCRUBBER
END DATE 9/77 PROBi/m: MECHANICAL-RELATEO COMPONENT FAILURE
A LEAK OCCURRED AT THE SLURRY DISPOSAL TANK.
AFFECTED MODULES: SYSTEM SYSTEM
10/77 A 100.0
B 100.0
SYSTEM 100.0 744 744
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 9/77 EQUIPMENT: FGD SYSTEM, GENERAL
END DATE 10/77 COMMITS:
NO PROBLEMS W£"5E REPORTED FOR OCTOBER.
AFFECTED MODULES: SYSTEM
11/77 A 100.0
B 98.0
SYSTEM 99.0 720 169
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 11/77 E6UIIMENT: SCRUBBER
END DATE 11/77 PROBLEMS MECHANICAL-RELATED COMPONENT FAILURE
THE P-S1DE OlMAGE WAS DUE TO LEAKS IN THE VENTURI SECTION OF THE SCRUBBER
AISD AN EXPANSION JOINT FAILURE IN A RECYCLE PUMP-
48
-------
EP» UTILITY FGD SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFOPMAkCE DATA FOR OPERATIONAL FGD SYSTEMS
.... _. _.__ __.._ PERFORMANCE DATA
PERIOD NODULE AVAILABILITY OPERABIL1TY PLIABILITY UTILIZATION X REMOVAL PER BOILER FGO CAP.
SO? PART. HOURS HOURS HOURS FACTOR
AFFECTED MODULES: f
** PROBLEMS/SOLUTIONS/COMMENTS
START BAjE 11/77 EQUIPMENT: RECYCLE PU«P
END DATE 11/77 FROB(,Ew: MECHANICAL-RELATED COMPONENT FAILURE
THE B-SIDE OUTAGE WAS DUE TO LEAKS IN THE VENTURI SECTION OF THE SCRUPBER
AND AN EXPANSION JOINT FAILURE IN K RECYCLE PUMP.
AFFECTED MODULES: E
** PROBLEMS/SOLUTIONS/CCMMENTS
START DATE 11/77 E8U1FMENT: BOILER-RELATED
END DATE 11/77 COMM^NTSr
HIE BOILER OPfRATED ONLY IfB.S HOURS BECAUSE OF A SHUTDOWN FOR OVERHAUL IN
ThE LAST HALT OF NOVEMBER. THE UNIT IS SCHEDULED TO START UP IN MID-DEC-
EHBER.
AFFECTED MODULES: SYSTEM
1Z/77 SYSTEM 744
** PR06LEKS/SOLUTIONS/COMWENTS
START DATE 12/77 E6UIFMENT: FGD SYSTEM, GENERAL
END DATE 12/77 CCMMENTSi
THE eOILER AND SCRUBBING SYSTEM WERE DOWN AS THE OVERHAUL PERIOD CONTINUED
THIS MOJOR OVERHAUL CONTINUED INTO JANUARY 1978.
AFFECTED MODULES: SYSTEM
1/78 A 97.0
6 91 .0
SYSTEM 94.0 60.00 99.70 744 135
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 1/78 EQUIPMENT: FGD SYSTEM* GENERAL
END DATE 1/78 COMMENTS:
THE FLOODED DISC SCRUBBER TANK HEADER FOR THE LIMESTONE SLURRY WAS REPAIR-
ED AFTER BEING DAMAGED DURING THE OVERHAUL. THE BOILER WAS OPERATED ONLY
135 HOURS DURING JANUARY AS THE OVERHAUL HAD EXTENDED INTO THIS MONTH.
AFFECTED MODULES: SYSTEM
2/78 A 99.0
e - - 68 ve
SYSTEM 94.0 50.00 672 642
** PR08LEMS/SOLUTIONS/COWMENTS
START DATE 2/78 EBU1FMENT: F6D SYSTEM, GENERAL
END DATE 2/78 PROBLEM: NOT DEFINED/SPECIFIED
SOME MINOR LftK REPAIRS AFTER THE OVERHAUL/CLEANING TOOK PLACE DURING
FEBRUARY.
AFFECTED MODULES: SYSTEM
3/78 A 74.0
8 74.0
SYSTEM 74.0 744 744
** PR06LEMS/SOLUTIONS/COMHENTS
START DATE 3/78 E8UI RHENT: FGD SYSTEM, GENERAL
E«D DATE 3/78 PROBICM: NOT DEFINED/SPECIFIED
CUE FORCED SHlTDOUN OCCURRED ON THE A-SIDE.
AFFECTED MODULES: A
4/78 A 100.0
B 100.0
SYSTEM 100.0 720 720
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 4/78 EOUIPKENTr FGD SYSTEM, GENERAL
END DATE 4/78 PROBLEM: NOT DEFINED/SPECIFIED
A MINOR LEAK REPAIR WAS NECESSARY AFTER AN OVERHAUL/CLEANING.
49
-------
FP« UTILITY FGD SURVEY: DECEMBER 197E - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FCG SYSTEMS
PERFORMANCE DATA „.„_...- —
PERIOD MODULE AVAILABILITY CPERAPIL1TY ^LIABILITY UTILIZATION * REMOVAL PER BOILER F60 CAP.
S02 PART. HOURS HOURS HOURS FACTOR
S/78
AFFECTED MODULES: SYSTEM
A
ft
SYSTEM
87.0
98.0
93.0
744
6/78
7/78
9/78
10/78
•* PROBLEMS/SOIUHONS/CCMMENTS
START DATE 5/76 ECUKMENT: F6D SYSTEH, GENERAL
END DATE 5/78 COMMITS:
THERE WERE NO SIGNIFICANT PROBLEMS REPORTED. ONLY GENERAL MAINTENANCE WAS
PERFORMED ON THE SYSTEM.
AFFECTED MODULES: SYSTEM
A
B
SYSTEM
100.0
100.0
100.0
720
** PROBLEMS/SOLUTIONS/COMMENTS
START KATE 6/78 tOUIPMENT: F60 SYSTEH, GENERAL
END DATE 6/78 COMMfNTS:
NC PROBLEMS WLRE REPORTED.
AFFECTED MODULES: SYSTEM
B
SYSTEM
100.0
100.0
744
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 7/78 ECUIFMENT: FGD SYSTEH, GENERAL
END DATE 7/78 COMWCNTS:
OALY ROUTINE MAINTENANCE HAS
AFFECTED MODULES: SYSTEM
8/78 SYSTEM
98.0
744
«* PROBLEMS/SOLUT10NS/COMMENTS
START DATE S/78 ECUIfWENT: RECYCLE TANK
END DATE f/7S PROBIEM: NOT DEFINED/SPECIFIED
REPAIRS MERE NECESSARY TO PLU66ED B-SIDE REHEAT COILS.
AFFECTED MODULES: B
8
SYSTEM
100.0
100.0
720 720
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 9/78 EGUIFMENT: FGD SYSTEH, GENERAL
END DATE 9/78 COMMENTS:
NO PROBLEMS U(RE REPORTED.
AFFECTED MODULES: SYSTF-M
B
SYSTEM
100.0
100.0
744 434
** PR08LEMS/SOLUTIONS/COMMENTS
START DATE 10/78 EQUIPMENT: FGD SYSTEH, GENERAL
END DATE 10/78 COMMFNTS:
ONLY ROUTINE !>AiNTENANCE WAS REQUIRED.
AFFECTED MODULES: SYSTEM
11/78 SYSTEM
100.0
720 720
** PROBLEMS/SOLUTIONSSCOMMENTS
START DATE 11/78 E6UIFMENT: FGD SYSTEM, GENERAL
END DATE 11/78 COMMfNTSl
NO PROBLEMS WERE REPORTED.
AFFECTED MODULES: SYSTEM
50
-------
EPA UTILITY F66 SURVEYS DECEMBER 1978 - JANUARY 1979
SECTION 31
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL F66 SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - MG/J
S02 EMISSION LIMITATION - KG/J
NET PLANT GENERATING CAPACITY - »w
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY V/FGD - f
NET UNIT GENERATING CAPACITY WC/FGD -
EOU1VALFNT SCRUBBED CAPACITY - Mfc
i'W
** BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU.F/S
FLUE GAS TEMPERATURE - C
STACK HE IGHT - M
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEt GRADE
AVERAGE HEAT CONTENT - KJ/KG
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - *
RANCE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - *
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - *
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - %
FUEL FIRING RATE - M T/H
FUEL FIRING RATE - MW
•* MECHANICAL COLLECTOR
PARTICULATE DESIGN REMOVAL EFFICIENCY -
** FGD SYSTEM
SALEABLE. PRODUCT/THSOKAWAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMiNT LEVEL
NEW/RETROFIT
PARTICULATE DESIGN REMOVAL EFFICIENCY -
S02 DESIGN REMOVAL EFFICIENCY - X
INITIAL START-UP
CONSTRUCTION INITIATION
CONTRACT AWARDED
• • ABSORBER
NUMBER
TYPE
INITIAL START UP
BOILER LOAD/ABSORBER - X
6AS FLOW - CU.M/S
GAS TEMPERATURE - C
** REHEATER
TYPE
HEATING MEpIUI"
TEMPERATURE BOOST - C
** WATER LOOP
TYPE
FRESH MAKEUP WATER ADDITION - LITERS/S
ARIZONA PDPLIC SERVICE
CHQLLA
2
JOSEPH CITY
ARIZONA
t>
72.
344.
615.0
350.0
250.0
.167 LB/WMBTU)
.8(50 LB/MMBTU)
350.0
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
0/7P
******** <*******
******* <**** F)
****** (**** FT)
******* <***** FT)
COAL
SUBB1TUHINOUS
25609.
13.50
15.00
******
.50
0.44-1.0
.02
0.01-0.04
* ******
*****
< 101SO BTU/IR)
965-10,600
{*«•* TPM)
THROWAfciAV PRODUCT
UET scRueeme
LIMESTONE
RESEARCH COTTRELL
EBASCO
FULL-SCALE
NEW
99.70
75.00
4/7*
7/75
12/74
PACKED fOUEfi PBECEEDKO BY FLOODE0 DISC SCRUBBER
6/7?
25.0
184.98 ( 392000 ACFM>
SO.O < 122 F>
IN-LINE
STEAM
22.2
OPEN
7.6
40 F>
( 120 6PH)
51
-------
EPA UTILITY F60 SURVEY; DECtMBFfc 197E - JANUARY 1979
SECTION 3
DESIGN AND PF R F GRM f>C E DATA FOR OPERATIONAL F6D SVSTFMS
*• REAGENT PREPARATION EQUIPMENT
NUMPER OF BALL KILLS
ElALl MILL CAPACITY- M 1/H
*• DISPOSAL
NATURE
TVPF
6.3
FINAL
SLUDGE POMP
( 7.P TP«>
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY CPERAPIL1TY (PLIABILITY UTILIZATION X REMOVAL PER BOILER F60 CAP.
S02 PART. HOURS HOURS HOURS FACTOR
4/78 SYSTEM
7?0
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 4 /78 EeUIPfENT: F6D SYSTEM,
END DATF 5/78 PROBUM: NOT DEFINED/SPECIfI ED
SOME PROBLEMS HAVE OCCURRED V1TH VIBRATIONS THROUGH THF SYSTEM.
AFFECTED MODULES: SYSTEM
•* PR06LEMS/SOLUT10NS/COMMENTS
START DATE 4/78 CGUIfttENT: F6D SYSTEM, GENERAL
END DATE 5 <7B COMMENTS:
TK FPA HAS GRANTED THE UTILITY AH EXTENSION FOR COMPLIANCE.
AFFECTED MODULES: SYSTEM
5/78 SYSTEM
6/78 SYSTEM
744
7ZO
** PROBLfcMS/SOLUTlONS/COMMENn
START DATE 6/7f EQUIIMENT: F60 SYSTEM, GENERAL
END DATE 7/78 CCMM ENTS:
SHAKFCOWN/CfBlGGlKG OPERATIONS ARE CONTINUING.
AFFFCTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 6/78 EGUIFMENT: PIPING
END DATE 7/78 PPOBUM: DESIGN-RELATED VIBRATION
THE SLURRY RECYCLE PIPING HAS EXPERIENCED CONTINUAL VIBRATION. THE CON-
TRACTOR HAS PiTN INJECTING NITROGEN GAS INTO THE LINES TO DAMPEN THE
VIBRATION&fAIR WAS NOT USED BECAUSE THE SUtFITF. WOULD BE OXIDIZED TO SUL-
FATE *ND RfSUlT jfj SCALE FORMATION^.
AFFECTED MODULES: SYSTtM
** PROBLEMS/SOLUTIONS/COMMtNTS
START DATE 6/78 tQUIfMENT: ADSORBER
END OATF, 7/78 FPOBifM: INSTALLATION-RELATED MATERIALS FAILURE
TKC CORROSION RESISTANT COATING IN THE DOUNCOnER AREA IN ONE OF THE
AtSOREER MODULES HAS BEEN PEELING AWAY.
AFFECTED MODULES: SYSTEM
7/78 SYSTEM
8/78 SYSTEM
744
744
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 8/78 fCUIFMENT: PIPING
END DATE 9/7S PROBLEM: DESIGN-RELATED VIBRATION
THE SLURRY COCPONENTS ARE STILL EXPERIENCES RrSONANT VIBRATIONS.
AFFECTED MODULES: SYSTEM
** PR06LEMS/SOLUTIONS/CCMMENTS
START DATE 8/78 EGUIPMENT: FCC SYSTEM, GENERAL
END DATE 9/78 COMMENTS:
SMKfDOYN/DEEIG6JNG OPERATIONS ARE CONTINUING.
AFFECTED MODULES: SYSTEM
9/78 SYSTEM
10/78 SYSTEM
720
744
-------
EPA UTILITY FSD SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMKE DATA FOR OPERATIONAL F€D SYSTEMS
.... PERFORMANCE DATA
PERIOD MODULE AVAILABILITY CPERABIL1TY PLIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S03 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 10/78 teuiFNENT: FCD SYSTEM, GENERAL
END DATE 11/78 COMMENTS:
SMKEDOWN DE.BIGGING OPERATIONS ARE CONTINUING. SOME SCRUBBER COMPONENTS
ARE STILL MANKED BY BECHTEL STAFF, APS IS OPERATING WOST Qf THE SYSTEM AT
THIS TIME.
AFFECTED MODULES: SYSTEM
11/78 SYSTEM 720
53
-------
EP« UTILITY FGt> SUPVEV: DECEMBER 1976 - JANUARY 1979
SECTION 3
DESIGN AND PERFOSMrCE DATA FOR OPERATIONAL FGD SYSTFMS
COMPANY MAKE
PLANT NAME
UNIT NUMBER
CITY
STATE
RE6ULATORY CLASSIFICATION
PARTICIPATE EMISSION LIMITATION - NG/J
SOZ EMISSION LIMITATION - N6/J
NfT PLANT GENERATING CAPACITY - MW
GROSS UNIT 6ENERATIN6 CAPACITY - ««
NET UNIT GENERATING CAPACITY W/FGD - Ml.
NET UNIT GENERATING CAPACITY VO/FGD - fli
EQUIVALENT SCRUBBED CAPACITY - My
** EOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU.»/S
FLUE GAS TEMPERATURE . C
STACK HE IGHT - H
STACK TOP DIAMETER - M
•* FUEL DATA
FUEL TYPE
FUEL GRADF
AVERAGE HEAT CONTENT - KJ/KG
RANGE HEAT CONTENT - BTU/LB
AVERAGE A$H CONTENT - 1
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANEE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - *
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - *
RANGE CHLORIDE CONTENT - %
FUEL FIRING RATE - H T/H
FUEL FIRING RATE - HU
CENTRAL ILLINOIS LIGHT
DUCK CREEK
1
CANTON
ILLINOIS
A
43.
516.
400.0
416.0
400.0
( .ICO LB/MMBTU)
( 1.200 LP/MMBTU)
41ft.0
RILEY STOKER
BALANCED-DRAfTt FRONT FIRED DRYBOTTOM, PULV. CCA
BASE
0/76
667.7* <1415000 ACFM)
135.0 < 275 F)
152. < 500 FT)
******* (*•*** FT)
COAL
BITUMINOUS
24423.
18.Q
********
******
».30
8.0-9.0
.03
******
157.8
400
( 10500 BTU/LB)
***** *
(174 TPH)
** ESP
NUMBER
TYPE
SUPPLIER
PARTICULATE DESIGN REMOVAL EFFICIEf>CY
FLUf GAS TEMPERATURE - C
PRESSURE DROP - *PA
** FGD SYSTEM
SALEABLE PRODUCT/THROW AWAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICULATE DESIGN REMCVAl EFFICIENT
$02 DESIGN REMOVAL EFFICIENCY - t
COMMERCIAL DATE
INITIAL START-UP
CONTRACT AWARDED
• * ABSORBER
NUMBER
TYPE
INITIAL START UP
NUMBER OF STAGES
DIMENSIONS
SHELL MATERIAL
INTERNAL MATERIAL
NUMBER OF NOZZLES
NOZZLE TYPE
BOILER LOAD/ABSORBER - I
GAS FLOW - CU.M/S
GAS TEMPERATURE - C
LIQUID RECIRCULATXON RATE - LITER/S
COLD SIDE
POLLUTION CGNTROL-VALTHER
99.8
135.0
.2
275 F)
t IN-H20)
SALEABLE PRODUCT
UET SCRUBBING
LIMESTONE
RILEY STOKFfl/ENUIRONEERING
61LBFRT/COMMONWEALTH
FULL-SCALE
NEW
99.80
35.00
8/7R
7/76
8/74
ROD DECK SPRAY TOWER
7/76
t>
40 X 5 X 40
CARBON STEEL
HASTALLOV G
13
OPEN PIPE ARRANGEMENT
25.0
167.01 < 353900 ACFfO
135.0 i 275 F)
945. O5000
54
-------
EPA UTILITY FGD SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
OES1SN AND PERFORMANCE DATA FOR OPERATIONAL F60 SYSTEMS
PRtSSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/SEC
S02 INLtT CONCENTRATION - PPM
S02 OUTLET CONTRATION - PPM
*• FANS
NUMBER
TYPF
CONSTRUCTION MATERIALS
** HIST ELIMINATOR
NUMPER
TYPE
CONSTRUCTION MATERIAL
CONFIGURATION
NUMBER OF STAGES
MUMPER OF PASSES
VANE SPACING - CM
VANE ANGLES
WASH SYSTEM
SUPERFICIAL 6AS VELOCITY - HISS
PRESSURE DROP - KPA
** PROCESS CONTROL CHEMISTRY
CONTROL VARIABLES
CONTROL MANNER
MODE
•* PUMPS
SERVICE
POND RETURN
ROND RETURN (SPARE)
WASTE TRANSFER
WASTE TRANSFER (SPARE)
MIST ELIMINATOR SPRAY
MIST ELC1MATOR SPARY
RECIRCULATION
RECIRCULATION (SPARF)
SLURRY TRANSFER
SLURRY TRANSFER (SPARE)
** TANKS
SERVICE
RECIRCULATION
WASTE COLLECTION
LIMESTONE SLURRY STORAGE
LIMESTONE SLURRY STORAGE (SPARt)
MIST ELIMINATOR WASH
** WATER LOOP
TYPE
FRESH MAKEUP WATER ADDITION - L1TERS/S
** REAGENT PREPARATION EQUIPMENT
NUMBER OF BALL HILLS
BALL MILL CAPACITY- M T/H
*• DISPOSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
AREA - ACRES
CAPACITY - CU.M
?.o ( e.o I
4.0 ( 13.0 FT/S)
3000
252
4
BOILER I.D.
CARBON STEEL
4
CHEVRON
HASTALLOY 6
HORIZONTAL
2
3
6.3 ( 2.SO IN)
90 DFG.
CONTINUOUS, 6U PRESSURE, FRONT AND BACK OF FIRST
4.0 < 13.0 FT/S)
.2 ( 1.0 1N-H20)
SO?, PHt SOLIDS CONTENT OF SLURRY
AUTOMATIC
FEEDBACK AND FEED FORWARD
NUMElER
NUMBER
4
1
1
CLOSED
37.8
1
3.6
FINAL
LINED POND
ON SITE
PUMP
65.0
317980
( 600 6PM)
( 4.0 TPH)
( 260.0 ACRE-FT)
55
-------
FPA UTILITY FGD SURVEY: DECEfBFR 197f - JANUARY 1979
SECTION I
DESIGN AND PERFORfAKE DATA FOR OPERATIONAL F«D SYSTEMS
PERFORMANCE DATA "
PERIOD NODULE AVAILABILITY OPERAPIL1TY PLIABILITY UTILIZATION 8! REMOVAL PER BOILER F60 CAP-
S02 PART. HOURS HOURS HOURS FACTOR
6/7? SYSTEM
7/7B SYSTEM
91.60 99.PO 720 0
720 0
.(1
.0
** PROBLEKS/50LUT10NS/COKMENTS
START DATE 7/76 EQUIPMENT: FGD SYSTEM, GENERAL
END DATE 7/78 COMMtNTS:
ALL FOUR MODULfS BE C AplE OPERATIONAL ON JULY 24.
AFFECTED MODULES: SYS
** PRCBLEMS/SOLUTIONS/COWKENTS
START DATE 7/78 E8UIf«ENT: F6D SYSTEM, GENERAL
tNO DATE 7/78 PROBlFM! DESIGN-RELATED UNDERSIZED COMPONENT
MODIFICATIONS WERE MADE TO THE UNpFR DESIGNED SLURRY TRANSFER TANK.
AFFECTED MODULES: SYS
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 7/76 ESUIFWENT: F6D SYSTEM, GENERAL
END DATE 9/78 PROBLEM: NOT DEFINED/SPEClFI ED
A PLUGGING PRff'LEM CAUSED BY cOAL FINES IN THE SLURRY WAS EXPERIENCED.
THE FINES RESILTED FROM COMMON COAL AND LIMESTONE HANDLING SYSTEM.
AFFECTED MODULES: SYS
** PROBLEMS/SOLUTIONE/COMMENTS
START DATE 7/78 E6UIFWENT: REAGENT HANDLING
END DATE 9/78 FROEIFM: NOT DEFINED/SPECIFIED
ThE COMMON C0 a AND LIMESTONE HANDLING SYSTEM ALLOWED COAL FINES TO PLUG
TfcE FGD SYSTEM
AFFECTED MODULES: SYS
8/78 SYSTEM
9/78 SYSTEM
744
720 691
.0
.0
«« PROBLEMS/SOLUTlONS/COMMtNTS
START DATE 9/78 EGUIFPENT: FGD SYSTEM, GENERAL
fcND DATE 9/78 ppOBLFBs NOT DEFINED/SPECIFIED
SCREEN BASKcTT WERE USED TO KEEP COAL PARTICLES FROM THE LIMESTONE.
CCAL PARTICLES RfSULT FROM COMMON HANDLING SYSTEM.
AFFECTED MODULES: SYS
*» PROBLEMS/SOLUTIONS/COMMENTS
START DATE 9/78 tSUIH^ENT: REAGENT HANDLING
END DATE 9/78 FROBS.FM: DESIGN-RELATED UNDERSIZED COMPONENT
TtiE SLURRY TRANSFER SYSTEM PREVENTED PROPER SLURRY FLOW D t)E TO UNDER
DESIGN. THE CLD SYSTEM WAS REPLACED KITH A NEW PIPING SYSTEM.
AFFECTED MODULES: SYS
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 9/78 ISUIM-ENT: VALVES
END DATE 9/78 PROBLEM: CHEMICAL-RELATED PLUGGING
PLUGGING OF TFE RECYCLE PUMP SHUT-OFF VALVFS OCCURED.
BEING REPLACED KITH PINCH VALVES.
AFFECTED MODULES: SYS
THE
THE VALVES ARE
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 9/78 EGUIFMENT: PUMP, OTHER
END DATE 9/78 PPOBUM: C H E«l C AL-RELA T? D PLUGGING
TfcE SCRUEiEEB (.ASTE WATER SUMP PUMPS HAVE BEEN PLUGGING. NEW Pu«PS ARE
BEING INVESTIGATED.
AFFECTED MODULES: SYS
10/78 SYSTEM
744
449
.0
** PROBLEMS/SOLUTIONS/COMMENTS
START BATE 10/78 tCUIFMENT: VALVES
END DATE 10/78 PROBLEM; NOT 0EFINED/SPECIFI ED
-------
FPA UTILITY FGD SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORPIAHE DATA FOR OPERATIONAL FGD SYSTEMS
. PERFORMANCE DATA
PERIOD NODULE AVAILABILITY CPERABILITY FtLIABlLITY UTILIZATION X REMOVAL PER BOILER F60 CAP.
S02 PART. HOURS HOURS HOURS FACTOR
*"—•"*••• •*"»—•- — w*—WMHW—w VW«H«B«*.W _—•—*.____«... «vBa.MBHik«av_ ••_»•« • • — «-.— »_«•••. v. — m. ^ _ _«,«••> ••••• —
A LEAKING VALVE RESULTED IN CONTAMINATION OF THE RECYCLE PUMP 6LAND SEAL
WATER SYSTEM HTH POND RETURN WATER CAUSIN6 SCALING AND PLUGGING FOXING
SHUTDOWN OF Tli£ RECYCLE PUMPS. A NEW VALVE SYSTEM WAS INSTALLED AND THE
OPERATING PRESSURES WERE CHANGED.
AFFECTED MODULES: SYS
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 10/78 E8UIFMENT: RECYCLE PUMP
END DATE 10/7B PROBITM: NOT DEFINED/SPECIFIED
THE RECYCLE PU'PS WERE SHUT DOWN KHEN CONTAMINATION OF THE GLAND SEAL
WATER SYSTEM CAUSED BY A FAULTY VALVE CURRED.
AFFECTED MODULES: SYS
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 10/78 EOUIFRENT: VALVES
END DATE 10/7B PfOPifM: NOT DEFINEO/SPFCJFIED
A FLOW CONTROL VALVE WAS REMOVED BECAUSE IT CAUSED ABRASION AND FAILURE
OF THE RECYCLE HEADER. NONE OF THE MODULES NOW UTILIZE FLOW CONTROL
VALVES.
AFFECTED MODULES: 0
*+ PR08LEMS/SOLUT10NS/C00MENTS
START DATE 10/78 ECUIPPENT: MIST ELIMINATOR
END DATE 10/76 PROBLEM: NOT DEFINED/SPECIFI ED
T*E MIST ELIMINATOR SPRAY NOZZLES PLUGGED PY COAL PARTICLES WERE CLEANED
THE COAL PARTICLES RESULT FROM A COMMON COAL/LIMESTONE HANDLING SYSTFM.
A LlfiUlD/SOLIl SEPARATOR HAS BEEN INSTALLED IN THE SLURRY SYSTEM TO PRE-
VENT REOCCUSRIMCE.
AFFECTED MODULES: SYS
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 10/78 ECU1PKENT: F6D SYSTEM, GENERAL
END DATE 10/78 PROBLEM: NOT DEFINED/SPECIFIED
EXCESSIVE LIMiSTONE CARRYOVER TO THE BIST ELIMINATOR WAS NOTED. THE TOP
RCD DECK VAS REMOVED TO IMPROVE G/>S FLOW ANo ELIMINATE THE CARRYOVER
PROBLEM.
AFFECTED MODULES: SYS
** PROBLEMS/SOLUTIONS/COMMENTS
START-MT-E 10/78 ESUIfMENT: FGD SYSTEM GENERAL
END DATE 11/78 PROBLFM: DESIGN-RELATED FLOW DISTRIBUTION
BLANK OFF PL A IF S WERE ADDED TO THE LCI HER SEVEN ROD DECKS TO MAINTAIN
PRESSURE CROP REQUIREMENTS. THIS HAS BEEN FOUND TO BE AN ACCEPTABLE:
SOLUTION AT 01HER ENVIRONEERIN6 SYSTEM INSTALLATIONS.
AFFECTED MODULES: SYS
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 10/78 EQUIPMENT: REAGENT HANDLING
END DATE 10/78 PROBLEM: NOT DEFINED/SPECIFIED
THE COMMON CO />L /L1M E STONE HANDLING SYSTEM ALLOWED CflAL PARTICLES TO PLUG
MIST ELIMIHATCR SPRAY NOZZLES. A LIQUID/SOLID SEPARATOR HAS BEEN INSTAL-
LED TO PREVEN) FUTURE PLUGGING.
AFFECTED MODULES: SYS
11/78 SYSTEM 7ZO 661 .C
«* PROBLEMS/SOLUTIONS/COMMENTS
START DATE 11/78 EOUIFMENT: PUMP, OTHER
END DATE 11/78 PROBLEM: MECHANICAL-RELATED MATERIALS FAILURE
THE B-MODULE SLURRY TANK PUMP LINER EXPERIENCED A FAILURE RESULTING IN
SCRUBBER SYSTEM SHUTDOWN. THE SPARE PUMP WAS ALREADY OUT OF SERVICE TO
REPLACE ITS ORIGINAL 50-HP MOTOR WITH A 75-HP MOTOR.
AFFECTED MODULES: B
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 11/78 E6UIFMENT: PUMP, OTHER
END DATE 11/78 PROBlfN: DESIGN-RELATED UNDERSIZED COMPONENT
BAD C3471 0
57
-------
EPA UTILITY F&D SURVEY: DECEPGER 197F. - JANUARY 1979
SECTION 3
DESIGN AND PERFORMAtfE DATA FOR OPERATIONAL F6D SYSTFHS
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERA01L1TY PLIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
A SPARF SLURR1 TANK PUMP WAS OUT OF SERVICE TO REPLACE ITS ORIGINAL <0-HP
AFFECTED MODULES: B
•* PROBLEMS/SOLUTIONS/COKMENTS
START DATE 11/78 tOUIFKENT: REAGENT HANDLING
END DATE 11/78 PROBLEM: MECHANICAL-RELATED MATERIALS FAILURE
TfcE PINION SEARING ON THE BALL MILL DRIVE FAILED. THE FAILURE IS BEING
1&VESTIGATED. FGD SYSTE OPERATION WAS HALTED DUE TO THE FAILURE-
AFFECTED MODULES: SYS
** PROBLE«S/SOLUT10NS/COI»MENTS
START DATE 11/78 tCUIOENI: INSTRUMENTAL CN
END DATE 11y78 F'ROBlfM: NOT DEFINEO/SPF CIFI ED
THE LEVEL AND DENSITY INSTRUMENTS ON RECYCLE TANKS ARE BEING MODIFIED.
AFFECTED MODULES: SYS
i
*• PROBLEMS/SOLUT10NS/COKMENTS
START DATE 11/78 E6U1FMENT: INSTRUMENTATION
END DATE 11/78 PROBIFM: NOT DEFINED/SPECIFI ED
THE LEEDS I NCRTHRUP LEVEL AND DENSITY TRANSMITTERS ARE BEING REPLACED
WITH ROSEttOUNl TRANSMITTERS.
AFFECTED MODULES: SYS
-------
EPA UTILITY FED SUSVEY: DECEMBER 1978 - 4ANUARV 1979
SECTION 3
DESIGN AND PERFOKMA«E DATA FOB OPERATIONAL F6D SYSTEMS
COMPANY MAKE
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICIPATE EMISSION LIMITATION
S02 EMISSION LIMITATION - hG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - nk
NET UNIT 6ENERATING CAPACITY WC/FGD - fV
EOUIVALENT SCRUBBED CAPACITY - *W
** BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FICH - CU.f/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - KJ/KG
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - J
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURF CONTENT - I
AVERASE SULFUR CONTENT - *
RANGE SULFUR CONTENT - Z
AVERAGE CHLORIDE COUTE&T - %
RANGE .CHLORIDE CONTENT - *
FUEL FIRING RATE - M T/h
FUEL FIRING RATE - MW
** ESP
NUMPER
TYPE
SUPPLIER
** F66 SYSTEM
SALEABLE PRODKCT/THfiOWAWAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEU/RETROFIT
PARTICIPATE DESIGN REMOVAL EFF1C1EKCY
S02 DESIGN REMOVAL EFFICIENCY - 2
COMMERCIAL DATE
INITIAL START-UP
CONSTRUCTION INITIATION
CONTRACT AWARDED
** ABSORBER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
NUMBER OF STAGES
SHELL MATERIAL
SHELL LINER MATERIAL
BOILER LOAD/ABSORBER - X
GAS FLOW - CU.M/S
GAS TEMPERATURE - C
LIOUID RECIRCULATION RATE - L1TER/S
PRESSURE DROP - KPA
SUPERF1CAL GAS VELOCITY . M/SEC
COLUMBUS & SOUTHERN OHIO ELEC.
CONESVULE
S
CONESVTLLE
OHIO
B
(****** LB/MMBTU)
C 1.000 LP/MMBTU)
430.
2100.0
411.0
375.0
391.0
411.0
COMBUSTION ENGINEERING
PULVERIZED COAL, DRV BOTTOM
BASE
0/77
******** (******* ACF|O
146.7 < 296 F>
244. < 800 FT)
******* (***** FT)
COAL
BITUMINOUS
25237.
15.10
12-19
7.50
******
4.67
4.2-5.1
******
149.7
*****
( 10850 BTU/L9)
10300-11220
<165 TPH>
COLD SIDE
RESEARCH COTTRELL
THROWAUAY- PRODUCT
WET SCRUBBING
LIME
THIOSOR6IC
AIR CORRECTION DIVISION, UOP
BLACK R VEACH
FULL SCALE
NEW
- X 99.60
89.50
2/77
1/77
5/75
10/74
TURBULENT CONTACT ABSORBER
11/77
AIR CORRECTION DIVISION,UQP
4
CARBON STEEL
NEOPRENE
60.0
298.44
141.1
2394.
1.8
3.9
( 632416 »CFM>
( 206 F)
(38000 GPM>
< 7.3 IN-H20)
( 12.8 fits')
59
-------
EPA UTILITY F6D SURVEY: DECEMBER 197f - JANUARY 19?9
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FCo SYSTEMS
** ABSORBER
NUMPER
TYPE
INITIAL START UP
SUPPLIER
NUMBER OF STACES
SHELL MATERIAL
SHELL LINER MATERIAL
BOILER LOAD/ABSORBER - X
GAS FLOW - CU.M/S
6AS TEMPERATURE - C
LiauiD RECIRCULATION RATE - LITER/S
PRESSURE DROP - KPA
SUPERFICAL KAS VELOCITY - M/SEC
** FANS
NUMBER
** VACUUM FILTER
NUMBER
** MIST ELIMINATOR
NUMBER
TYPE
CONFISCATION
** MIST ELIMINATOR
NUMBER
TYPE
** PU|»|PS
SERVICE
RECYCLE
TRANSFER TANK PUMP
MAKE-UP SLURRY PUMP
RECYCLE TANK SLUDGE PUPP
M.E. WASH TANK PUMP
RECLAIMED WATER PUMP
** TANKS
SERVICE
RECYCLE
RECLAIMED WATER TANK
SLURRY TRANSFER TANK
SLURRY STORAGE
M.E. WASH TANK
( 632416 ACFM>
( 286 F>
(38000 6PM)
< 7.3 IN-H20)
( 12.? FT/S)
TURBULENT CONTACT ABSORBER
1/77
AIR CORRECTION OlVlSIONfUOP
4
CARBON STEEL
NEOPRENE
60.0
141.1
2394.
1.8
3.9
4
CHEVRON
HORIZONTAL
ENTRAPMENT SEPARATOR
NUMBER
1
1
1
1
1
THICKENER
CONSTRUCTION MATERIAL
DIAMETER - M
OUTLET SOLIDS - X
CARBON STEEL WITH CONCRETE FLOOR
44.2 (145 FT)
32.5
** WATER LOOP
TYPE
FRESH MAKEUP WATER ADDITION - LITEK5/S
** TREATMENT
TYPE
CONTRACTOR
PRODUCT CHARACTERISTICS
OPEN
31.5
( 500 6PM)
PROPRIETARY (POZ-0-TEC)
IUCS
73X SOLlCS
** DISPOSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
AREA - ACRES
FINAL
LANDFILL
ON-SITE
PIPE
50.0
-------
EPA UTILITY FGD SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FGD SYSTEMS
—. . _ _ PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION 55 REMOVAL PER BOILER FGD CAP.
502 PART. HOURS HOURS HOURS FACTOR
12/76 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMENTS
START DATE 12/76 EflUIFKENT: F6D SYSTEM. GENERAL
END DATE 12/76 PPOBIFM: NOT DEFINED/SPECIFIED
A MAJOR FIRb IN MODULE A DFLAYED THE UNIT START-UP. THE FIRE CAUSED 12.1
MILLION DAMAGf. THE UTILITY'S INSURANCE COVERED THE DAMAGE AND A NEW
SCRU6BFR MODULE WILL BE PURCHASED FROM AND INSTALLED BY UOP.
AFFECTED MODULES: A
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 12/76 EOUIFWENT: FGD SYSTEM, GENERAL
END DATE 12/76 COMMENTS:
THE UTILITY IS CURRENTLY CONDUCTING AIR AND WATER TESTS ON WODULF B.
AFFECTED MODULES: B
1/77 STSTEW 744
** PROBtEMS/SOLUTIONS/COMMiNTS
START DATE 1/77 EfiUlfMENTs FGD SYSTEM, GENERAL
END BATE 1/77 COMMENTS:
IMTIAt START-UP FOR DEBUGGING AND COMMISSIONING PURPOSES OCCURRED IN
EARLY JANUARY. COMMERCIAL AVAILABILITY FOR SERVICE OCURRED ON JANUARY
27.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/CCMWENTS
START DATE 1/77 EQUIPMENT: F6D SYSTEM, GENERAL
END DATE 1/77 PFOBIFM: WE ATHER-RELATE D COMPONENT FAILURE
EARLY OPERATIONS WERE MARKED BY COLD WEATHER RELATED PROBLEMS SUCH AS
FROZEN LINES AND GEARS, CRACKED FLANGES, A FR07EN LIME BELT CONVEYOR, AND
A FROZEN PIPELINE FROM THE THICKENER TO THE IUCS FACILITY.
AFFECTED MODULES: SYSTEM
2/77 B 43.0 43.0
A
SYSTEM 672 668
**P*OaLE*S/SOLUTIONS/COMMENTS
START DATE 2/77 tOUIFWENT: FGp SYSTEM, GENERAL
END DATE 2/77 COMMENTS:
COMMERCIAL ST'PT-UP OF MODULE 8 OCCURRED ON FEBRUARY 13, 1977. THE LONG-
EST PERIOD OF CONTINUOUS OPERATION WAS 132 HOURS.
AFFECTED MODULES: B
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 2/77 EfiUl FPENT: ESP
END DATE 2/77 COMMENTS:
TfcE UTILITY RtPORTED THAT THE ESP OPERATED SATISFACTORILY.
AFFECTED MODULES: SYSTEM
** PR08LEMS/SOLUTIONS/COMMENTS
START BATE ?/77 E6UIFHENT: PIPING
END DATE 2/77 F'F!OPLFM: DESIGN-RELATED PRESSURE SURGES
PRESSURE SURE IS OCCURRED IN THE PRfSATUDATOR PIPING*
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 2/77 EQUIPMENT: GAS ANALYZER
END DATE 2/77 PROBLEM: MECHANICAL-RELATED COMPONENT FAILURE
THE CONTINUOUS S02 ANALYZERS OPERATED UNSATISFACTORILY.
AFFECTED MODULES: SVSTEP
** PROBLERS/50LUTIONS/COMMENTS
START DATE 2/77 tOUIFPENT: ABSORBER
END DATE 2/77 PP06tFM: DESIGN-RELATED FLOW DISTRIBUTION
61
-------
EPA UTILITY FGD SURVEY: DECtMBFR 1978 - JANUARY 1979
SECTION 3
DESIGN JND PERFOPP.AfCE DATA FOR OPERATIONAL FC-0 SYSTFWS
PERFORMANCE BAT A
PERIOD MODULE AV«ILAPILITY OPERABIL1TY PLIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
— ————— — ———— — — — — — — .- — — —..»• — „ ••—•___ „ v_ -•»»*• — — — «.__.«, __ „••»•,^^«..— »»•• »««»•• — — • • — — •-——_• „,«. — «• •.•*••*•
MODULE B EXPEfIENCED POOR VELOCITY DISTRIBUTION THROUGH THE TCA BEDS.
AFFECTED MODULES: B
** PRObLEKS/SOLUTIONS/COMFENTS
STAPT DAjE 2H1 i Ctl tr ENT: MIST ELIMINATCR
END DATE 2/77 FFOBITM: NQT DEFINED/SPECIF1 ED
SCRUFEUNE LIGIOR WAS CARRYING OVER INTO THE MIST ELIMINATOR SECTION
AFFECTED MODULES: E
4/77
A
B
SYSTEM
40.0
39.0
36.0
744
720 685
** PROELEMS/SOLUTION&/COHHENTS
START DATE 4/77 eeilllPENT: F60 SYSTEM, GENERAL
END DATE 5/77 COMMfNTS:
A STACK OUTLET TEMPERATURE OF 20C F IS BEING MAINTAINED IN ORDER TO !»IN-
1FUE ACID RAINOUT AND STACK CORRCSION PROBLEMS.
AFFECTED MODULES: El
** PR06LEMS/SOLUTIONS/COMENTS
START DATE 4/77 ECUirwENT: ABSORBER
END DATE 5/77 PF.OBlFH: C HEMI C AL-RFLA T F fi CORROSION
TtE 716 SS PRfSATURATOR ARFA HAS EXPERIENCED CORROSION-
AFFECTED MODULES: B
** PROBLEMS/SOLUTIONS/COKWENTS
START DATE 4/77 EeUIFflENT: RECYCLE TANK
END DATE 5/77 I'ROEUEM,: INSTALLATION-RELATED MATERIALS FAILURE
TI-E RUBBER LI^ER IN THE RECYCLE TANK HAS BEEN PEELING AWAY. THE PROBLEM
APPEARED TO P* APPLICATION-RELATED.
AFFECTED MODULES: S
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE *'" fQUlFPENT: THICKENER
END DATE 5/77 PFOfUfM: C HEMI C AL-RELATE 11 PLUGGING
SCXE PLUGGING HAS OCCURRED IN THE TUBE THICKENERS.
AFFECTED MODULts: SYSTEM
*• PROBLEMS/SOLUTIONS/COCMENTS
START DATE 4/77 ECUJf^ENT: REA6ENT HANDLING
END DATE 5/77 PROBIEH: NOT DEFINED/SPECIFIED
TKE BUALITY Of THE LIKE SLURRY HAS BEEN A PROBLEM AREA. HOCKS UP TO FIVE
INCHES IN DIAf-FTER HAVE BEEN DETECTED* THIS HAS PROMPTED DRAVO TO INSTALL
MECHANICAL SEPARATORS AND »!ETAL DETECTORS AT THE LIME SHIPMENT FACILITY.
AFFECTED MODULES: SYSTEM
5/77
6/77
A
B
SYSTEM
A
B
SYSTEM
58.0
66.0
50.0
59.0
51.0
60.0
48.0
58.P
744
7ZO
71 2
713
** PROfaLEMS/SOLUTIONS/COMMENTS
START DATE 6/77 £6U1H«ENT: F6D SYSTEM, GENERAL
END DATE 6/77 CCKMkNTS:
T»E F-EIDE MODULE DID NOT OPERATE THE ENTIRE MONTH PENDING COMPLETION
Of A NUMBER Of NECESSARY MODIFICATIONS AND REPAIRS.
AFFFCTED MODULES: B
7/77
A
B
SYSTEM
744
744
62
-------
EPA UTILITY F6C SURVEY: DECEMBER 1978 - JANUARY 1AS NOT OPERATED THE ENTIRE NONTH. REPAIRS AND MODIFICATIONS
CONTINUED UNTIL SEPTEMBER 13. THERE WERE SOME WEATHER-RELATED DELAYS.
AFFECTED MODULtSs SYSTEM
9/77 A
B 52.9 39.9 46.9 26.0
SYSTEM 720 469
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 9/77 EQUIPMENT: FGD SYSTEM, GENERAL
END DATE 9/77 COMMiNTS: RESEARCH AND DEVELOPMENT
THE PARTICULAR DROP TEST SCHEDULED FOR SEPTEMBER 1977 HAS PUSHED BACK TO
THE VEEK OF OCTOBER 24 1977.
AFfECTED MODUtES: SYSTEM
10/77 A
e 32.0 24.0 25.0 18.0
SYSTEM ?** 559
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 10/77 ECUIFPENT: FGD SYSTEM, GENERAL
END DATE 11/77 CCMMfMTS:
63
-------
EPA UTILITY FGD SURVFY: DECEMBER 197! - JANUARY 1979
SECTION 3
DtSlCN AND PERFORhASCE DATA FOR OPERATIONAL FGD SYSTEMS
------------------------------------------ PERFORMANCE DATA
PERIOD MODULE AVAILABILITY CPERAE'ILJTY PLIABILITY UTILIZATION
X REMOVAL PER BOILER FGD CAP-
SO? PART. HOURS HOURS HOURS FACTOR
THE SCRUBIER MS DOWN FROM OCTOBER 10 TQ NOVEMBER 1Q.
AFFECTED MODULES: SYSTEP
** PROBLEMS/SOLUT1 ONS/COKWENTS
START DATE 10/77 EGUIfKENT: ABSORBFR
END DATF 10/77 PROPiEfl: I NSTA LI AT 1 ON- R ELATE D MATERIALS FAILURE
6-MOt>ULE HAC 10 BE REL1NFD IN SOME AREAS HlTH NtOfRENE RUBBER
AFFECTED MODULES: B
11/77
A
B
SYSTEM
10.0
33.0
4.0
33. C
4.0
33-0
4.0
33. C
720 715
** PROBLEMS/SOLUTIONS/COKNENTS
START DATE 11/77 EaUlFPtENT: ABSORBER
END DATE 11/77 COMMENTS:
MODULE A WENT HACK ON LINE NOVEMBER 21. DURING LOW LOAD PERIODS SOLIDS
BIRD UP THiDfD TO CAUSE PLUGGING BECAUSE Of LOW FLOW RATES. DURING THE
LOW LOAD PERILS ALL GAS WAS DUCTED THROUGH ONE MODULE WHILE THE OTHER WAS
ShUT DOWN.
AFFECTED MODULES: SYSTEM
12/77
A
6
SYSTEM
93.0
97.0
64.0
79.0
62.0
76.0
22.0
27. C
744
** PROBLEMS/SOLUTlONS/COMflENTS
START DATE 12/77 ECUITMENT: f6D SYSTEH, GENERAL
END DATE 3/78 COMMENTS:
TKE UNIT WENT DOWN DECEMBER 12 FOR A S-NONTH SCHEDULED OUTAGE. MODULE A
HE6AN COPKFKC3AL OPERATIONS DECEMEED 3 OPERATING AS MUCH AS POSSIBLE
THROUGH DECEMiER 12. MODULE B OPERATED DECEMBER 1 THROUGH 12. DURING THE
SHUTDOWN THE UIL1TY WILL DECIDE IF THE SYSTEM SUPPLIERS HAVE MET SPFCS
ON THE BOILER 'ND TURBINES. THE UNIT IS SCHEDULED TO BE BACK ON LINE IN
MID-MARCH FrUT THIS KAY BE PUSHED 6ACK TO APRIL 1.
AFFECTED MODULES:
** PROBLEMS/SOLUTIONS/COMMENTE
START DATE 12/77 F.OUIFMENT.: STACK
END DATE 3/78 PRtP IFM : -D E SIGN'-RFLATED INFERIOR CONSTRUCTION
DURING THE DEUMSER TO MARCH 197? SHUTDOWN THE CARBON STEEL FLUE WILL BE
REPLACED kITH AN ACID-BRICK LINING.
AFFECTED MODULES: SYSTKtf
1/7P
2/7«
3/7fi
A
B
SYSTEM
A
B
SYSTEM
A
B
SYSTEM
20.0
20.0
19.0
64.Q
54.0
10.0
8.0
744
672
744
379
** PROBLEMS/SOLUTIONS/COMMENTS
ST*RT DATE 3/78 EOUIIflENT: FGC SYSTEM, GENERAL
£ND DATE 3/78 COMMENTS*
TfcE UNIT STARTED UP AGAIN ON HAfiCH 16.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COKMENTS
START DATE 3/78 EGUIfPENT: GAS ANALYZER
END DATE 3/78 PROBLEM: NOT DEFINED/SPECIFIED
P* CONTROLS AM) S02 ANALYZERS HAVE EXPERIENCED OPERATIONAL PROBLEMS
AFFECTED MODULES: SYSTEM
64
-------
EPA UTILITY FGD SURVEY: DECEMBER 1978 - JANUARY 1«79
SECTION 3
DESIGN AND PERFORHA HC E DATA FOR OPERATIONAL FGD SYSTEMS
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY PLIABILITY UTILIZATION % REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PR06LEMS/SOLUTIONS/COMMENTS
START DATE 3/78 E6L)I FI"! ENT: FGD SYSTEM, GENERAL
END DATE 3/78 PROBLEM: CHEMICAL-RELATED PLUGGING
IMPURITIES IN THE LIME HAVE CAUSED PLUGGING PROBLEMS.
AFFECTED MODULES: SYSTEM
4/78 A 67.0 58.0 61.0 58.0
B 65.0 59.0 63.0 59.0
SYSTEM 720 716
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE */78 EflUIFfXENT: THICKENER
fcND DATE 4/78 PROBLEM: CHEMICAL-RELATED PLUGGING
TfcE SYSTEM WAS DOWN DUE TO AN EXCESS OF FLOCCULANT IN THE THICKENER.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 4/78 tGUIFWENT: ABSORBER
END DATE 4/78 PROBLEM: CHEMICAL-RELATED PLUGGING
EXCESS FLOCCUlANT IN THE THICKENER YIELDED A HIGH SOLIDS LEVEL IN THE
OVERFLOW AMD RESULTED IN PLUGGING PROBLEMS IN THE ABSORBER MODULES.
AFFECTED MODULES: SYSTEM
5/78 A 52.0 43.0 45.0 44.0
B 54.0 50.0 51.0 49.C
SYSTEM 744 7?0
** PROBLEMS/SOLUTIONS/COMKENTS
START DATE 5/78 £OL>I FKENT: THICKENER
END DATE 5/78 PROBLEM: CHEMICAL-RELATFD PLUGGING
THE SYSTEl" HAI TAKEN OUT OF SERVICE BECAUSE OF CONTINUED PROBLEMS WITH THE
FLOCCULANT FEfD SYSTEM. THE THICKENER WAS EMPTIED TO RESTORE PROPER FLOC-
CULANT BALANCfc.
AFFECTED MODULES: SYSTEM
6/78 A 48.0 37.0 37.0 37.0
8 30.0 30.0 30.0 30.0
SYSTEM 720 720
** PROBLEWS/SOLUTlONS/COHHENTS
START DATE 6/78 teUIMXENT: PIPING
END DATE 6/78 PROBLEM: NOT DEFINED/SPECIFIED
A* FRP PIPING FAILURE IN THE MIST ELIMINATOR WASH SYSTEM OCCURRED.
AFFECTED MODULES: SYSTEM
7/78 A 66.0 66.0 66.0 64.0
B 43.0 33.0 33.0 32.0
SYSTEM 744 727
** PROBLEMS/SOLUTIONS/COMHENTS
START DATE 7/78 E6UIFKENT: ABSORBER
END DATE 7/78 PPOBtFM: CHEMICAL-RELATED PLUGGING
OUTAGE TIME WOS DUE TO PLUGGING IN THE MIST ELIMINATOR AND SCRUBBER PALL
REGIONS.
AFFECTED MODULES: SYSTEM SYSTEM
8/78 A 1F.C 20.0 20.0 18.0
B 18.0 21.0 21.0 18.0
SYSTEM 744 667
** PROBLEMS/SOLUTIONS/COMMENTS
ST*RT DATE 8/78 EeUIF^ENT: MIST ELIMINATOR
END BATE */78 PROBLEM: CHEMICAL-RELATED PLUGGING
THE FORCED OU1AGE TlflE WAS DUE, IN PARTt TO TIME REQUIRED TO REMOVE SCALE
FfiOM THE MIST ELIMINATOR.
AFFECTED MODULES: SYSTEM
65
-------
EPA UTILITY f6D SURVEY: DECEMBER 197? - JANUARY 1979
SECTION 3
DESIGN AMD PERFORMANCE DATA FOR OPERATIONAL FED SYSTEMS
------------------- --- . ------------------- PERFORMANCE DATA ------------ -- ------ — - -------- - — - --- •"
PERIOD NODULE AVAILABILITY CPERA6IL1TY PLIABILITY UTILIZATION X REMOVAL PER BOILER FfiD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
9/78
10/78
A
B
SYSTE*
A
B
SYSTEM
61.0
54.0
72.0
82.0
46.0
44.0
37.0
47.0
55.0
53.0
38.0
47.0
45.0
43.0
36.0
45. 0
11/78
12/73
** PROBLEHS/SOLUTIONS/COMMENTS
START DATE f 116 tflUITfENT: ABSORBER
END DATE 8/78 PROBLEM: 0 E SIGN -RF LATE 0 INFERIOR CONSTRUCTION MATERIAL
TlfE FORCED OU1A6E TIME WAS DUE. IN PART. TO TIME REQUIRED TO REPLACE SOME
OF THE PING PCN6 BALLS IN THE MODULES.
AfFFCTED MODULES': SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 6/78 ECUIfwENT: 6AS DAMPER
END DATE 9/78 FROBlFM: NOT DEFINED/SPECIFIED
THE UTILITY EXPERIENCED BYPASS DAMPER PROBLEMS DURING THE PERIOD.
AFFECTED MODULES: SYSTEM
** PROSLEMS/SOLUTIONS/COMMENTS
START DATE 8/78 EOUIfENT: P1P1N6
tND DATE 9/78 PROBLEM: NOT DEFINED/SPECIFIED
PS08LEMS OCCU1'»ED RELATED TO BROKEN SLUDGE LINES AND PLUGGING IN THE LIME
SLURRY FEED LINES.
AFFECTED MODULES: SYSTEM
7?0 707
744 713
** PROaiEMS/SOLUTIONS/COMPENTS
START DATE 10/78 EOUIfENT: CAS DAMPER
END DATE 11/78 PROBIEM: NOT DEFINED/SPECIFIED
DAMPER DRIVE IPOBLEMS WERE REPORTED BY THE UTILITY.
AFFECTED MODULES: SYSTEM
** PKOBLE.MS/SOLUTIONS/COMMENTS
START DATE 10/78 tQUlfENT: ABSORBER
END DATE 11/78 PROBIEN: 1 MSTALLATION-RE LATE D MATERIALS FAILURE
MINIMAL RUPEE V LINER FAILURE MAS OBSERVED AT THE TOP OF ONE OF THE
SCRUflBER MODOLfS'AND JUST-AFTER-THE PRE S ATURATOR.
AFFECTED MODULESi SYSTEM
720 «4Z
744 609
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 12/78 EfiUIFHENT: FGD SYSTEM, GENERAL
END DATE 1/79 PROBIEMI HEATHER-RELATED COMPONENT FAILURE
THE LOW HOURS FOR THIS PERIOD ARF ATTRIBUTED TO FREEZE UPS.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE O/ 0 EQU1 f PENT:
END DATE O/ 0
THE LOU HOURS FOR THIS PERIOD ARE ATTRIBUTED TO FREEZE UPS.
AFFECTED MODULES: SYSTEM
A
B
SYSTEH
A
B
SYSTEM
43.0
84.0
6.6
33.1
29.0
74.0
.3
36.3
29.0
75.0
.3
36.6
26.0
66.0
.7
30.0
1/79
A
B
SYSTEM
744 602
66
-------
EPA UTILITY FCit SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION I
DESIGN AND PERFORNAKE DATA FOR OPERATIONAL FCC SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - N6/J
S02 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY ~ "«
GROSS UNIT GENERATING CAPACITY - Mb
NET UNIT GENERATING CAPACITY W/FGD - M«
NET UNIT GENERATING CAPACITY WC/FGC - PW
EQUIVALENT SCRUBBED CAPACITY - MW
** BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU.MS
FLUE 6AS TEMPERATURE - C
STACK HEIGHT - fl
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - KJ/KG
RANGE HEAT CONTENT - BTU/LB
AVERAGE Ajh CONTENT - I
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTEKT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - %
AVERAGE CHLORIDE CONTENT - *
RANGE CHLORIDE CONTENT - *
FUEL FIRING RATE - M T/H
FUEL FIRING RATE - MU
** ESP
NUMBER
TYPE
SUPPLIER
** F6D SYSTEM
SALEABLE FRO^UCT/THfifrK AWAY PRODittT
GENERAL PROCESS TYPE
PROCESS TYPF
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICULATE DESIGN REMCVAL EFFICIENCY
SO2 DESIGN REMOVAL EFFICIENCY - %
COMMERCIAL DATE
INITIAL START-UP
CONSTRUCTION INITIATION
CONTRACT AWARDED
** ABSORBER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
NUMBER OF STAGES
SHELL MATERIAL
SHELL LINER MATERIAL
BOILER LOAD/ABSORBER - X
GAS FLOW - CU.M/S
GAS TEMPERATURE - C
LIQUID RECIRCULATION RATE - LITERS!
PRESSURE DROP - KPA
SUPFRFICAL GAS VELOCITY - M/SEC
- X
COLUM&US 8 SOUTHERN OHIO ELEC.
CONESVILLE
6
CONESVILLE
OHIO
B
(****** LB/MMBTU)
< 1.000 LB/MMBTUJ
43P.
2100.0
411.0
375.0
391.0
411.0
COMBUSTION ENGINEERING
PULVERIZED COAL, DRY BOTTOM
BASE
0/77
******** (******* ACFM)
146.7 < 296 F)
?44. < 800 FT)
******* (***** fT>
COAL
BITUMINOUS
25237.
15.10
12-19
7.50
******
4.67
4.2-5.1
******
149.7
*****
( 10850 BTU/LP)
10300-11220
<1*5 TPH)
COLD SIDE
RESEARCH COTTRELL
THROKAMAIf 'PRODUCT
WET SCRUBBING
LIME
THIOSORBIC
AIR CORRECTION DIVISION, UOP
BLACK 8 VEACH
FULL SCALE
NEU
99.60
89.50
6/7P
6/78
5/75
10/74
TURBULENT CONTACT ABSORBER
AIR CORRECTION DIVISION,
CARBON STEEL
NEOPRENE
60.0
298.44
141.1
2394.
1.8
3.9
( £32416 ACFp>
C 286 r)
(38000 GPR)
< 7.3 IN-H20)
< 12.8 FT/S)
67
-------
EPA UTILITY fGO SURVEY: OECEKBfR 19?f - JANUARY 1979
SECTION 3
Of.SI6N AND PERFORMANCE DATA f Of OPERATIONAL fCO SYSTEMS
•* FANS
NUMBER
** VACUUM FILTER
** HIST ELIMINATOR
NUMBER
TYPE
CONFIGURATION
** MIST ELIMINATOR
NUMPER
TYPE
** PUMPS
SERVICE
RECYCLE
TRANSFER TANK PUMP
MAKf-UP SLURRY PUMP
RECYCLE TANK SLUDGE PUfP
M.E. WASH TANK PUMP
RECLAIMED WATER PUMP
TANKS
SERVICE
RECYCLE
RECLAIMED WATER TANK
SLURRY TRANSFER TANK
SLURRY STORAGE
M.E. WASH TANK
** THICKENER
CONSTRUCTION MATERIAL
DIAMETER - M
OUTLET SOLIDS - X
** WATER LOOP
TYpE
FRESH MAKEUP WATER ADDITION - LITERS/S
** TREATMENT
TYpE
CONTRACTOR
PRODUCT CHARACTERISTICS
*• DISPOSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
AREA - ACRES
CHEVRON
HORI70NTAL
ENTRAPMENT SEPARATOR
NUMBER
NUMBER
1
1
1
1
1
CARBON STEEL WITH CONCRETE FLOOR
44.? (145 FT)
32.5
OPEN
31.5
( 500 GPWj
PROPRIETARY (POZ-0-TEC)
ttKS
73!? SOLIDS
FINAL
DIKED LANDFILL
ON-SITE
PIPE
50.0
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY CPERABILITY ffllABlLlTY UTILIZATION
* REMOVAL
soz PORT,
PER BOILER F6D CAP.
HOURS HOURS HOURS FACTOR
6/78
A
B
SYSTEM
56.0
44.0
49.0
33.0
51.0
34.0
43.0
30. C
720 524
** PROULEMS/SOLUTIONS/COMMENTS
START DATE 6/78 EOUIFNENT: 6AS DAMPER
END DATE 6/78 pfrOBlFM: MECHANICAL-RELATED COMPONENT FAILURE
CONTROL Or THt LOUVF.RERED DAMPER OF THE BfPASS SYSTEM WAS LOST. THE
RESULT WAE 6ACK PRESSURE BUILDUP THAT AUTOMATICALLY SHUT DOWN THf BOILIR.
AFFECTED MODULES: SYSTEM
-------
EPA UTILITY F60 SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN UNO PERFORMANCE DATA FOR OPERATIONAL F6D SYSTEMS
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 6/78 EQUIFflENT: INSTRUMENTATION
END DATE 6/78 PROBLEM: NOT DEFINED/SPECIF I ED
SCRUFBER CONTROLS WERE NOT OPERATING PROPERLY AND NEEDED ADJUSTMENT.
AFFECTED MODULES: SYSTEM
7/78 A 83.0 37,0 63.0 25.0
8 70.0 19.0 13.0 13.0
SYSTEM 74* 502
** PROaieMS/SOLUTIONS/COMMENTS
START DATE 7/78 EQUIPMENT: 6AS DAMPER
END DAT? 7/78 PROBLEM: NOT DEFINED/SPECIFIED
THE LCUVefiED CAMPER PROBLEM CONTINUED*
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 7/78 E8UIFMENT! PIPING
END DATE 7/78 PROBLEM: MECHANICAL-RELATfD COMPONENT FAILURE
THE FRP TRANSFER LINE FROM THE THICKENER TO THE IUCS SYSTEM RUPTURED AS A
RESULT OF A W/>T£R HAMMER IN THE LINE AND HAD TO BE REPAIRED.
AFFECTED MODULES: SYSTEM
8/78 A 47.0 50.0 66.0 43,0
B 62.0 60.0 81.0 52.0
SYSTEM 744 642
** PBOBLEMS/SOLUTIONS/COMMENTS
START DATE 8/78 EGUIFMENT: PIPING
END DATE 8/78 PROBLEM: NOT DEFINED/SPECIFIED
PROBLEMS HERE ENCOUNTERED WITH THE SLUDGE LINE. THE UTILITY REPORTS
THAT THIS IS TYPICALLY A HIGH MAINTENANCE AREA.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 8/78 ECUUNENT: GAS DAMPER
END DATE 8/78 PROBtEM: NOT DEFINED/SPECIFIED
PROBLEMS WERE ENCOUNTERED WITH THE BYPASS CONTROL DAMPERS. THE UTILITY
RtPORTS -TtlfrT -THIS I fr TYPICALLY A HIGH MAINTENANCE AT1EA.
AFFECTED MODULES: SYSTEM
9/78 * 55.0 50.0 53.0 49.0
B 69.0 55.0 57.0 , 54.0
SYSTEM 720 706'
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 9/78 EBUIFPENT: REA6ENT HANDLING
END DATE 9/78 PROBLEM: NOT DEFINED/SPECIFIED
A PROBLEM ARE/i WAS THE PLUGGING OF THE LIME SLURRY FEED LINES.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUIIONS/COMMENTS
START DATE 9/78 EQUIPMENT: GAS DAMPER
END DATE 9/78 PROBtEM: NOT DEFINED/SPECIFIED
BY-PASS DAMPED CONTROt PROBLEMS CONTINUED THROUGH SEPTEMBER.
AFFECTED MODULES: SYSTEM
10/78 A 98.0 29.0 30.0 24.0
8 37.0 35.0 36.0 29.0
SYSTEM 744 603
** PR08LEMS/80LUTIONS/COMMENTS
START DATE 10/78 EQUIPMENT: GAS DAMPER
END DATE 10/78 pRQBltM: NOT DEFINED/SPECIFIED
PROBLEMS WITH DAMPER SEALS AND 61) IDE BARS WERE ENCOUNTERED. THE UTILITY
PLANS TO REPLACE THEM DURING THE NEXT BOILER OUTAGE.
69
-------
EPA UTILITY F6D SURVEY; DECEMBER 1
-------
EPA UTILITY FCI) SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NC/J
S02 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - Mh
NET UNIT GENERATING CAPACITY W/FGD - M k
NET UNIT GENERATING CAPACITY WO/FGt - f>W
EQUIVALENT SCRUBBED CAPACITY - MW
** BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU.MS
FLUE 6AS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAMETER - M
• * ESP
NUMBER
SUPPLIER
** MECHANICAL COLLECTOR
SUPPLIER
** PARTICULATE SCRUBBER
TYPE
** F6D SYSTEM
SALEABLE PRODUCT/THROWAWAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICIPATE DESIGN REMCVAl EFFICIENCY
S02 DESIGN REMOVAL EFFICIENCY - »
COMMERCIAL DATE
INITIAL START-UP
CONSTRUCTION INITIATION
CONTRACT AWARDED
** ABSORBER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
NUMBER OF STAGES
DIMENSIONS
SHELL MATERIAL
SHELL LINER MATERIAL
INTERNAL MATERIAL
GAS FLOW - CU.M/S
GAS TEMPERATURE - C
LIQUID RECIRCULATION RATE - LITER/:
PRESSURE DROP - KPA
PARTICULATE REMOVAL EFFICIENCY - X
** FANS
TYpE
CONSTRUCTION MATERIALS
SERVICE - WET/DRY
** PUMPS
SERVICE
.100 LP/MMBTU)
.600 LP/MMBTU>
DUOUESNg LlfcHT
ELRAMA
1-*
ELRAMA
PENNSYLVANIA
6
43. C
25ft. (
*9t.O
510.0
475.0
493.0
510.0
DABCOCK AND WILCOX
PULVERIZED COAL
BASE
0/52
******** (******* ACFM)
******* (**** F)
122. ( 400 FT)
******* (***** FT)
RECYCLE
1
RESEARCH COTTRELL
RESEARCH COTTRELL
S02 SCRUBBERS ACT AS PART. SCRUBBERS
THROWAWAY PRODUCT
WET SCRUBBING
LIME
CHENICO
GIBBS AND HILLi INC.
FULL-SCALE
RETROFIT
- * 99.00
83.00
10/75
10/75
12771
12/70
VARIABLE THROAT VENTURI
10/75
CHFMIcO
1
30 DlA. X 6C HIGH
MILD STEEL
CE1LCOTE
316L SS AND CEILCOTE
254.83 ( 540000 ACFM)
150.6 t 303 F)
100S. (16000 GPM)
7.5 (30.0 IN-H20>
99.0
SCRUBBER I.C.
RUBBER LINED AND 316L SS HUBS
WET
NUMBER
****
71
-------
EPA UTILITY F6D SURVEY: DECEKBF.fi 197f - JANUARY 1979
SECTION I
DESIGN AND PE R f ORR A r.( E DATA FOP OPERATIONAL FED SYSTEMS
•* REHEATED
TYpt DIRECT COMRUSTION
•• THICKENER
NUMBER 2
OUTLET SOLIDS - X 3?.C
** HATER LOOP
TYpF OPEN
•* TREATMENT
TYPE POr-0-TEC
CONTRACTOR 1UCS
PRODUCT CHAPACTfRISTICS 70? SOLIDS
** DISPOSAL
NATURE FINAL
TYPE LANDFILL
LOCATION OFF SITE
TRANSPORTATION TRUCK
PERFORMANCE DATA
PERIOD NODULE AVAILABILITY OPERABIL1TY PLIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
0/75 SYSTEM
*• PROtiLEKS/SOLUTIONS/COMPIENTS
START DATE 0/75 IfiUIFHENT: F6D SYSTEM, GENERAL
END DATE 0/75 COfiftNTS:
THE FIRST ELRJKA SCRUBBER WAS PLACED IN SERVICE ON OCTOBER 26, 1975. IT
HAD BEEN SCHEDULED FOR AN EARLIER STARTUP DATE BUT BECAUSE OF THE SEUERITY
AM) NUMBER OF PROBLEMS ENCOUNTERED AT PHILLIPS, STARTUP WAS DELAYED UNTIL
rAKIY OF THE PFOBLEMS AT PHILLIPS WERE RESOLVED AND THE MODIFICATIONS COULD
BE INCORPGRATEC AT BOTH STATIONS.
AFFECTED MODULES: SYSTEr
** PROBLtKS/SOLUTIONS/COKMENTS
START DAJE 0/75 EOUIfNENT: F6D SYSTEM, GENERAL
END DATE 0/75 CCP*W£NTS:
BOILER NO. i ;AS INITIALLY CONNECTED TO THE F6D SYSTEM ON OCTOBER 26, 1975
THIS BOILER H*S AN EOUIVALFNT CAPACITY OF APPROXIMATELY 100 MW ANo THE
EMISSIONS ARf HANDLED BY ONE '-SCRUBBER - TO tNSURE RELIABILITY IN THE CASF
OF A SCRUBBER MALFUNCTION, TWO SCRUBBERS ARE OPERATED AT PARTIAL LOAD TO
PROTECT THE BCILER AND TURBINE GENERATOR AGAINST A TRIP-OfF.
AFFECTED MODULES: SYSTEK
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 0/75 EGUlfNENT: F6D SYSTEM, GENERAL
END DATE 2/76 COKMiNTS:
T*E PC1LFR OPFRATED CONTINUOUSLY ON THE SCRUBBER SYSTEM THROU6H JANUARY
1976. TWO MINOR OUTAGES OCURRED. ON FEBRUARY 4, 1976 A SECOND POILFR WAS
CCUPLED INTO 1HE SCRUBBER COMPLEX. PRESENTLY, 2 UNITS ARE THE MAXIMUM THA
CAN BE TIED I MO THE SCRUBBER PLANT. TO DATE, THE UTILITY HAS ENCOUNTERED
TkE USUAL CIN
-------
EPA UTILITY FGO SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND FERFORMhCE DATA FOP OPERATIONAL FED SYSTEMS
........... _ PERFORMANCE DATA ---
PERIOD MODULE AVAILABILITY CPERAS1LITY t'f LIAE) I LIT Y UTHI7ATION X REMOVAL PER BOILER FGD CAP.
SOZ PART. HOURS HOURS HOURS FACTOR
CCND ElOILfcR «*S CONNECTED ON FEBRUARY 4. 1976. FOUR OF THE SCRUBBER VES-
SELS HAVE BEEh IN SERVICE IN VARIOUS COMBINATIONS. THE FIFTH VESSEL HAS
NCT BEEN IN SERVICE BECAUSE IT IS BEING REVISED FOR TRIAL INSTALLATION OF
RLBBER-LINED KtCVCLE PUMPS.
AFFECTED MODULES: SYSTEM
11/75 SYSTEM 720
12/75 SYSTEM 11,1,
0/76 SYSTEM 69.5
1/76 SYSTEM 744
** PROBLEMS/SOLUTIONS/COCMENTS
START DATE 1/76 EBUIFMENT: REA&ENT HANDLING
£ND DATE 1/76 PPOBUM: MECHANICAL-RELATED COMPONENT FAILURE
ONE OUTAGE WAT CAUSED BY A LIME FEEDER BELT FAILURE.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENT;:
START DATE 1/76 EeUKMENT: SCRUBBER
END DATE 1/76 PROBLEM: MECHANICAL-RELATED COMPONENT FAILURE
OkE OUTAGE WAf CAUSED BY INOPERATIVE THROAT DAPPERS.
AFFECTED MODULES: SYSTEM
Z/76 SYSTEM 696
3/76 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 3/76 EQUIPMENT: FED SYSTEM* 6ENERA|_
END DATE 4/76 COMMENTS:
T*E SYSTEM OPERATED DURIN6 THE REPORT PERIOD WITH TWO BOILERS COUPLED INTO
THE SCRUBEIIN6 SYSTEM. REVISIONS TO THE FIFTH SCRUBBING VESSEL HAVE BEEN
COMPLETED AND OPERATIONS ARE PROCEEDING WITH TWO RUBBER-LINED RECYCLE
PliMPS.
AFFECTED MODULES: SYSTEM
4/76 SYSTEM 720
5/76 SYSTEM 744
** PROBLEMS/SOLUTIONS/CCKMENTS
START DATE 5/76 EQUIPMENT: F6D SYSTEM, GENERAL
END DATE 6/76 COMMtNTS:
ThE SYSTEM IS STILL OPERATING WITH TWO BOILERS COUPLED INTO THE SCRUBBING
SYSTEM. THE 1UCS SLUDGE FIXATION SYSTEM IS CONTINUING TO OPERATE AT THIS
STATION.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 5/76 EOUIf'KENT: RECYCLE PUMP
END DATE 6/76 COMMfNTS:
THE FIFTH SCRUBBING VESSEL WAS TAKEN OUT OF SERVICE FOR REPAIRS AfcD MODIFI
CATIONS REOUIKEO FOR THE RUBBER-LINED RECYCLE PUMPS.
AFFECTED MODULES; SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 5/76 E6UI1MENT:
END DATE 6/76 COMMENTS!
THE UTILITY IJ CURRENTLY CONDUCTING A PERFORMANCE TEST ON THE SCRUBBING
SYSTEM IN THE TWO BOILER OPERATION MODE.
AFFECTED MODULES: SYSTEM
6/76 SYSTEM 720
7/76 SYSTEM 7A*
73
-------
UTILITY F6D SURVEY: DECEMBER 1970 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FGD SYSTEMS
. ...... ----PERFORMANCE DATA- ___....——------- ..--------
PERIOD MODULE AVAILABILITY OPERAB1LITY PLIABILITY UTILIIATION X REMOVAL PER BOILER FGD CAP.
SOZ PART. HOURS HOURS HOURS FACTOR
«• PROHLEMS/SOLUTIONS/COMMENTS
START DATE 7/76 EOUItMENT: F6D SYSTEM, GENERAL
END DAT? «/76 COMMENTS:
THE FIFTH SCRU3BIN6 VESSEL EMPLOYING TWO RUBBER-LINED RECYCLE PUMPS HAS
OPERATIONAL FCR A SHORT PERIOD OF TINE DURIN6 THE REPORTING MONTHS- TWO
BOILERS REMAU COUPLED INTO THE SCRUBBING SYSTEM. THE CONSTRUCTION OF AD-
DITIONAL LIMF STORAGE SILOS AND A THICKENER WILL BE REflUIRED FOR FULL SCAl
OPERATION. TfF UTILITY HAS SIGNED A LETTER OF INTENT WITH IUCS FOR A LONG
TERM SLUDSE FIXATION SYSTEM. HIGH CALCIUM LIME IS STILL BEING EMPLOYED IN
THE SCRUBBING SYSTEM.
AFFECTED MODULES: SYSTEM
8/76 SYSTEM 744
9/76 SYSTEM 720
•• PROBLEMS/SOLUTIONS/COMMENTS
START DATE 9/76 fcSUIFMENTl F6D SYSTEM, GENERAL
END DATE 10/76 COMMtNTS:
OPERATIONS AT THIS STATION DURING THE REPORT PERIOD PROCEEDED WITH TWO
BOILERS COUPLtD INTO THE 5-MODULF SCRUBBING SYSTEM. THE 5TH SCRUBBING VES
SEL WAS OPERATIONAL DURING THE REPORT PERIOD WITH THE RUBBER-LINED RECYCLE
PIMPS IN SERVICE. OPERATIONS ARE STILL PROCEEDING ON AN OFEN WATER-LOOP
BASIS. PART CF THE THICKENER OVERFLOW IS STILL BEING DIVERTED TO THE ASH
PCND AND NOT KCYCLED BACK TO THE PROCESS. BECAUSE BOTH THE BEAVER VALLEY
AlsD PRUCF MANSFIELD STATIONS ARE FULLY OPERATIONAL, THIS STATION HAS BEEN
RELEGATED TO FCAK LOAD OPERATIONS. GENERAL LOAD OPERATIONS ARE FULL LOAD
CAPACITY IN THE DAYTIME AND 50 TO 60 PERCENT LOAD REDUCTION AT NIGHT.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 9/76 E8UIFMENT: FGD SYSTEM, GENERAL
END DATE 10/76 COMMkNTSt RESEARCH AND DEVELOPMENT
TfcSTS WERE CONDUCTED DURING THE PERIOD TO DETERMINE pARTICuLATE AND SOZ
RbMOVAL EFFICIENCIES. SOZ REMOVAL EFFICIENCY WAS 50 PERCENT. PARTICULATE
EMISSIONS WE HE BEING REDUCED WELL BELOW 0.1 UP/MM BTU STANDARD (ACTUAL RE
SILTS: O.OA Li/MM BTU). THESE RESULTS WERE BASED ON TWO BOILERS COUPLED
1KTQ THE 5 SCRUBBING MODULFS WHILE BURNING MEDIUM-SULFUR (1.0 TO 2.8 PER-
CENT) COAt. TfE- MECHANICAL COLLECTORS AND ESP'S WF*E IN SEUVICE OlfRING TVlt
TtSTS.
AFFECTED MODULES: SYSTEM
10/76 SYSTEM 744
11/76 SYSTEM 720
*» PROSLEMS/SOLUTIONS/COMNENTS
START DATE 11/76 EOUU1ENT: FGD SYSTEM, GENERAL
END DATE 12/76 COMMENTS:
THE SCRUBBER PKMAINED IN SERVICE THROUGHOUT THE REPORT PERIOD WITH TWO
BOILERS COUPLfcD INTO THE SCRUBBING SYSTEM. A RECYCLE PUMP EVALUATION IS
BEING CONDUCTFD BY THE UTILITY AT BOTH PHILLIPS AND ELRAMA STATIONS.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 11/76 EOUIfMENT: RECYCLE PUMP
END DATE 13/76 PRCBtFM: MECHANICAL-RELATED MATERIALS FAILURE
OBSERVATIONS CF THE RUBBER-LINED RECYCLE RUMPS INDICATE SOME SEVERE ABRAS-
ICN AND GOUGING HAVE OCCURRED AFTER 1000 HOURS OF SERVICE TIME.
AFFECTED MODULES: SYSTEM
12/76 SYSTEM m
1/77 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 1/77 EQUIPMENT: FGD SYSTEM, GENERAL
END DATE 3/77 COKMtNTS: RESEARCH AND DEVELOPMENT
74
-------
FPA UTILITY FCC SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DAT A FOR OPERATIONAL F6D SYSTEMS
.—..... . _ . PERFORMANCE DATA •
PERIOD MODULE AVAILABILITY OPERARILITY PLIABILITY UTILIZATION x REMOVAL PER BOILER FGO CAP,
S02 PART. HOURS HOURS HOURS FACTOR
TESTING ON THJOSORBlC LIKE WAS CONDUCTED DURING THE PERIOD.
AFFECTED MODULES: SYSTEI*
** PROBLE«S/SOLUTIONS/COK«ENTS
START DATE 1/77 tOUITPENT: FGD SYSTEM, GENERAL
END DATE 3/77 COMMENTS:
THE SCRUBBER HANT CONTINUED OPERATIONS DURING THE REPORT PERIOD WITH TWO
BOILERS COIJPtLtl 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 1976. THE FULL COMPLIANCE STRATEGY
WILL CONSIST CF THE FOLLOWING} 83* S02 REMOVAL FOR 2X SULFUR COAL UTILIZIN
TMOSORBIC Lff C6-12X MG), FIXATING THE SCRUBBER SLUDGE WITH THE IUCS PCZ
0-TEC STABILIZATION METHOD AND HAULING THIS MATERIAL TO AN OFF-SITE HSPOS
Al/LANDFILl AHF.A. CURRENT $02 ANC PARTICULATE REMOVAL EFFICIENCIES AHE5C
AND 99 + lt, UfSIECTIVELY. THE INTERIM IUCS UNIT NOW IN SERVICE CONSISTS OF
THE OLD MOHAVf- PROTOTYPE PLUS A VACUUM FILTER. THE STABILIZATION MATERIAL
HAS BEEN UTILIZED IN A PARKING LOT CONSTRUCTION PROJECT. IUCS HAS BEEN A-
WARDFD A 10-YfAR CONTRACT FOR THE CONTINUED USE OF THIS SYSTEM FOR FUTURE
PLANT OPERATICNS.
AFFECTED MODULES: SYSTEM
2/77 s»STE» 672
3/77 SYSTEM 50.00 99.00 744
4/77 SYSTEM 720
** PROBLEMS/SOLUTION S/COMMENTS.
STAPT DATE 4/77 EOU1PKENT: FGD SYSTEM, GENERAL
END DATE 5/77 COMMENTS:
CONSTRUCTION CF TWO 120-FOOT DIAMETER THICKENERS IS CONTINUING. DUE TO TH
GOUGING OF THf RUBBER-LINED RECYCLE PUMPS DURING THEIR TESTING, THEY HAVE
BEEN REMOVED. THE UTILITY IS CONSIDERING TRYING ANOTHER SFT OF RUBBER*
LINED PUMPS. OUOUESNE LIGHT ALSO IS CONTINUING EFFORTS TO OBTAIN ALTERNAT
LANDFILL AREAi FOR SLUDGE DISPOSAL.
AFFECTED MODULES: SYSTEM
5/77 SYSTEM 744
6/77 SYSTEM 72t)
*+ PROBLEMS/SOLUTIONS/COMMENTS
START DATE 6/77 IOUIFMENT: FGD SYSTEM, GENERAL
END DATE 7/77 COMfHNTS:
DLfiUESNE 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 (HflHAVE PROTOTYPE) CONTINUED TO FIX-
ATE SCRUBbF-P 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/
HALF LOAD NIGHT-TIME). 1976 CAPACITY FACTOR WAS 69.5X.
AFFECTED MODULES: SYSTEM
7/77 SYSTEM 50.00 744
8/77 SYSTEM 744
*« PROBLEMS/SOLU1IONS/COMMENTS
START DATE 8/77 EOUIfMENT: FGD SYSTEM, GENERAL
C-ND DATE 9/77 COMMfNTS!
THE TWO ADDITIONAL THICKENERS WERE COMPLETELY INSTALLED. THE IUCS SYSTEM
WAS UPGRADED. END OF CONSTRUCTION IS PROJECTED FOR FEBRUARY 197*. F(lLL
PLANT COMPLIANCE IS PROJECTED FOR APRIL 1978*
75
-------
EPA UTILITY FtD SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
OFS1GN AND PERFORMANCE DATA FOR OPERATIONAL FGD SYSTFMS
PERFORMANCE; DATA
PERIOD MODULE AVAILABILITY OPERA9ILITY ffLIA6ILITY UTILIZATION
X REMOVAL PER BOILER FGB CAP.
S02 PART. HOURS HOURS HOtlliS FACTOR
AFFECTED MODULES: SYSTEM
9/77 SYSTEM
10/77 SYSTEC
11/77
720
744
START DATE 10/77 EOUKCENT: VALVES
tND DATE 10/77 PROBIEM: MECHANICAL-RELATfO MATERIALS FAILURE
MODULE 101 HAS UNAVAILABLE OCTOBER 4 DUE TO A PLEED VALVE LEAK AMD WAS TA-
KEN OUT OF SERVICE AT THE END OF THE MONTH FOR CLEANUP.
AFFECTED MODULES: 101
** PROBLEMS/SOLUT10NS/COMMENTS
START DATE 10/77 [OUIfMENT: FfiD SVSTENi GENERAL
END DATE 10/77 COMMNTS:
HCDULE ?01 WAJ AVAILABLE FOR THE ENTIRE MONTH.
AFFECTiD MODULES: 201
** PRO&LEMS/SOLUTIONS/COMWENTS
START DATE 10/77 f GUI I'HENT! FAN
END DATE 10/77 PROBLEM: MECHANICAL-RELATFD MATERIALS FAILURE
MCDULE 301 ANt 401 HAD OUTA6ES IN OCTOBER RESULTING FROM A RUBBER LIKING
FAILURE ON AN I.D. FAN.
AFfrCTED MODULES: 301 4(1
** PROBLEMS/SOLUTICNS/COMMENTS
START DATE 10/77 fOUIfHENT: RECYCLE PUMP
END DATS 11/77 ppCEUEMl MECHANICAL-RELATED COMPONENT FAILURE
MCDULE SOI EXPERIENCED RECYCLE PuKP OUTAGES IN LATE NOVEMBER.
AFFECTED MODULES: 501
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 10/77 EOUITMENT: F6D SYSTEM, GENERAL
END DATE 11/77 COKWlNTS:
UtV RUBBER LI FED WORMtN RECYCLE PUMPS WERE INSTALLED. THE LIME HANDLING
SYSTEM INSTALLATION WORK CONTINUED. THE LAST TUO TOILERS ARE EXPECTED TO
BE TIED INTO 1HE FGD SYSTEM BY JANUARY 1978.
AFFECTED MODULES: SYSTtM
** PROuLEMS/SOLUTlONS/COMMENTS
START DATE 10/77 EOUIPMENT: BOILER-RELATED
END OATE 11/77 COMMENTS:
TLBE LEAKS fOfCED A BOILER OUTAGE IN NOVEMpER.
AFFECTED MODULES; SYSTEM
101
2P1
301
401
501
SVSTtM 720
** PROULEMS/SOLUTIONS/COMMENTS
ST*RT DATE 11/77 ESUITMENT: FGD SYSTEM, 6ENERAL
END DATE 11/77 COMMENTS:
MODULE 101, 2C1 AND 401 HAVE LOW OPERATIONAL HOURS BECAUSE ONLY TkO BOILER
ARE TIED INTO THE FGD SYSTEM TO DATE.
AFFECTED MODULES: 101 2C1 401
** PROBLEMS/SOLUTIONS/COHMENTS
START DATE 11/77 EOUI^WENT: SLUDGE DISPOSAL
END DATE 11/77 COPiMtMTS:
TK SLUDGt HANDLING SYSTEM IS FUNCTIONING PROPERLY ANP IS NOW IN FULL SER-
VICE.
AFFECTED MODULES: SYSTEM
12/77 SYSTEM
744
76
-------
EPA UTILITY FCC SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FED SYSTEMS
........—— — -._.„_.._. . -----PERFORMANCE DATA-—- ........ ...
PERIOD NODULE AVAILABILITY OPERA01LITY H:LIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
SO? PART. HOURS HOURS HOURS FACTOR
t* PR06LEMS/SOLUTIONS/CCMMENTS
START DATE 12/77 EOUIfHENT: RECYCLE PUMP
END DATE 1/78 PROBLEM: MECHANICAL-RELATED COMPONENT FAILURE
DURING m PEMOD A NEW WORKER RECYCLE PUMP INSTALLED IN NOVEMBER EXPERI
EMCED JACK SHAFT BEARING PROBLEMS RESULTING IN REMOVAL 0F SCRUBBER TRAIN
SCI FROM SERVICE.
AFFECTED MODULES: 501
** PROHLEMS/SOLUTIONS/CONMENTS
START DATE 12/77 EQUIPMENT: FGD SYSTEM, GENERAL
END DATE 1/78 COMMITS:
BOILER NO. 4 l>AS CONNECTED* ADDING AN ADDITIONAL 176 MW OF FLUE GAS LOAD T
THE FGD SfStf.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 12/77 ECUIFHENT: SLUDGE DISPOSAL
END DATE 1/7B COMMENTS:
THE IUCS SLUDCE DISPOSAL FACILITY IS IN SERVICE PRODUCING GOOD PRODUCT.
LOW LOAD AND A COAL STRIKE HAVE HAMPERED GOOD SCRUBBER OPERATIONS. THERE
IS SOME OUTA6I TIME SCHEDULED FOR MARCH.
AFFECTED MODULES; SYSTEM
1/78 101
201
301
401
SOT
SYSTEM 744
2/78 101
201
301
401
sot
SYSTEM 672
** PROBLEMS/SOLUTIONS/CQMMENTS
START DATE- 2/7fl tOUI F»ENT: FSB' SYSTEM* GENER AL
END BATE 3/78 COMMENTS:
THE SYSTEM WAS SHUTDOWN ON FEBRUARY 11 AS A RESULT OF A COAL SHORTAGE.
BOILERS 1, 2 fND 4 ARE NOW COMPLETELY CONNECTED TO THE FGD SYSTEM. POILER
3 IS UNDEREOIfG AM EXTENSIVE OVERHAUL AND WILL BE CONNECTED TO THE SYSTEM
IK LATf APRIL.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 2/78 EOUIfMENT: GAS DAMPER
END DATE 3/78 PROBLEM: DESIGN-RELATED INFERIOR CONSTRUCTION MATERIAL
BOILER EXIT DAMPERS WERE LINED WITH 316 SS ON AREAS OF HIGH EROSION CAUSED
BY FLYASH IMPINGEMENT.
AFFECTED MODULES: SYSTEK
** PftOBLEMS/SOLUTIONSSCOMMENTS
START DATE 2/78 EOUI P!»ENT: EXPANSION JOINT
END DATE 3/78 PROBLEM: DESIGN-RELATED INFERIOR CONSTRUCTION MATERIAL
EXPANSION JOINTS IN THE UPSTREAM DUcTkORK WERE SHIELDED BY METAL PLATES
WHICH WERE WELDED AT ONE END. EXPANSION JOINTS IN THE DOWNSTREAM pUcTWORK
WERE COMPLETELY REPLACE. THE DOWNSTREAM DUCTWORK WAS RELINED WITH
CEILCOTE.
AFFECTED MODULES: SYSTEM
•* PROBLEMS/SOLUTIONS/COMMENTS
START DATE 2/78 EflUIfflENT: ABSORBF.R
END DATE 3/78 COMMENT: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTAGE
MODULE 401 INTERNALS WERE CLEANED AND SOME HOLES IN THE UPPER CONICAL RE-
77
-------
EPA UTILITY FGD SUSVFY: DECtM&ER 197f - JANUARY 1979
SECTION 3
DES16N AND PERFORMANCE DATA FOR OPERATIONAL FCD SYSTEMS
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY CPER.BILJTY ^LIABILITY UTILIZATION ««"OA •««j|«
GJON WERE REPAIRED-
AFFECTED MODULES: 401
3/73 101
301
401
501
SYSTEM 744
** PROBLEMS/SOLUT1ONS/COMMENTS
START DATE 4/78 ESU1KWENT: FGD SYSTEM, GENERAL
gNo DATE 5/78 COMMENTS:
OLRIMG THE APflL-MAY PERIOD BOILER NUMBER 3 WAS STILL BEING OVERHAULED.
FED SYSTEM COtSTRUCTION WAS COMPLETED AND PRELIMINARY TESTING VERIF1FD SYS
TEH S02 Rtl«OV*L EFFICIENCY.
AFFECTED MODULES: SYSTEM
4/7P SYSTEM 720
5/7S SYSTEM 7** 547
6/78 SYSTEM 720 492
** PROULEMS/SOLUTIONS/COHWENTS
START DATE 6/78 fc(5UIr"ENT: ABSORBER
END DATE 7/78 COKMtNT: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTAGE
NODULE 301 HA; PULLED OFF FOR A MAJOR CLEANING DURING THE PERIOD.
AFFECTED MODULES: 301
»* PROBLEMS/SOLUTIONS/COMMENTS
START DATE 6/78 EGU1FPENT: MIST ELIMINATOR
END DATE 7/78 pfOSUM: CHEMICAL-RELATED PLUGGING
MIST ELIMINATE PLUGGING WAS EXPERIENCED AS A RESULT OF LOW PH.
AFFECTED MODULES: SYSTEM
** PRObLEMS/SOLUTlONS/COMMENTS
START DATE 6/78 EOUIf-»ENT: REAGENT MAUDLINS
HMD DATE 6/78 FRGBUM: NOT DEFINED/SPECIFIED
T»,e CHKONIC INABILITY TO CONTROL CHEMISTRY is DiRrcrcY RELATEB TO em
PULD-UP IN TH LIME HANDLING AND SLURRY PREPARATION SYSTEM.
AFFECTED MODULES: SYSTEM
*« PR08LEMS/SOLUTIONS/COMMENTS
START DATE 6/78 fGUIFMENT: F6D SYSTEM, GENERAL
END DATE 7/7$ COMMITS:
THE UTILITY IS CURRENTLY STUDYING WAYS TO TIGHTEN THE WATER BALANCE BY US-
1*6 THICKENER SUPERNATANT INTERMITTENTLY WITH CLEAR SERVICE WATER fO* THE
MIST ELIMINATES. A COMPLIANCE TEST SHOULD TAKE PLACE DURING THE NEXT RE-
PORT PERIOD.
AFFECTED MODULES: SYSTEM
7/78 SYSTEM 744 662
8/78 SYSTEM 744 678
** PROiLEMS/SOLUTIONS/COMMENTS
START OATE 8/78 EQUItMENTt ABSORBER
tND DATE 9/78 COMMENT: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTAGE
DLRING AUGUST, MODULES 3D1 AND 501 WERE TAKEN OOWN FOR CLEANING.
AFFECTED MODULES: 301 SC1
** PRObLEMS/SOLUTlONS/COMMENTS
START OATE 8 /78 EflUIfENT: FAN
END DATE 9/78 PRORiEft: MECHANICAL-RELATED MATERIALS FAILURE
RUBBER LIKING ON THREE FAN HOUSINGS WAS REPAIRED.
AFFECTED MODULES: SYSTEM
78
-------
fPA UTILITY F6t SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AMD PERFORMANCE DATA FOX OPERATIONAL FGD SYSTEMS
. . .. .. PERFORMANCE DATA --
PERIOD MODULE AVAILABILITY GPERABIL1TY ^LIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
502 PART. HOURS HOURS HOURS FACTOR
• •*•••• «••••«•« «•••»••«•«»•••••• • •««•«!»••«••*» • V«**I«*«»IBM • »•««••••••• H • • » «•«• • «»«<*• <••••» B v V* • W •••tOTMW
** PR08LEMS/SOLUTIONS/COMMENTS
START DATE A/78 EQUIPMENT: REAGSNT HANDLING
END DATE 9/78 PROBLEM: PLUGGING. OTHER
IT U#S NECESS'KV TO SHUT DOWN THE tIME MIXING BASIN IN ORDER TO CLEAN OUT
EXCESSIVE CRI1 AND SOLIDS BUILD UP.
AFFECTED MODUltS: SYSTEM
9/78 SYSTEM 720 664
10/7S SYSTEM 744
11/71! SYSTEM 720
12/78 101 92.?
201 71.2
301 85.2
401 6f>.3
501 75.8
SYSTEM .00 744 707
«. PROBLEMS/SOLUT10NS/COMIHENTS
START DATE 12/78 Cdtll fHENTc FGD SYSTEM, GENERAL
END DATE 12/7R CCKM'NTS:
A COKPLIAkCE 1EST WAS RUN IN DECEMBER WHICH SHOWED THE UNITS TO PE IN
COMPLIANCE.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 12/7S EfiUHKENT: SLUDGE DISPOSAL
END DATE 1/79 COMMITS:
THf UTILITY HtS STARTED HAVING SLUDGE OFF SITE TO AM AREA ABOUT 10 MILES
A HAY.
AFFECTED MODULES: SYSTtM
1/79 101 40.1
201 91.9
301 59.9
401 100.0
5fl1 96 •*
SYSTEM 744 641
79
-------
FPA UTILITY FUD SURVEY: DECEMBER 197f - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FGD SYSTEMS
COMPANY NAME
PLANT NAMF
UNIT NUMBFH
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - N6/J
S02 EMISSION LIMITATION - hG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - Mb
NET UNIT GENERATING CAPACITY U/FGD - Mv
NET UNIT GENERATING CAPACITY WO/F6D - >V
EQUIVALENT SCRUPBFD CAPACITY - MW
*« 60ILFR DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - fU.*/S
FLUF GAS TEMPERATURE - C
STACK HE IGHT - M
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - K J /KG
RANGE HFAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - %
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - Z
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - T
RANtE SULFUR CONTENT - 5!
AVERAGE CHLORIDE CONTEKT - X
RAN6E CHLORIDE CONTENT - t.
FUEL FIRING RATE - « T/H
FUEL FIRING RATE - MH
«* ESP
NUME-ER
SUPPLIER
PARTICULATE DESIGN REMOVAL EFFJC1EKY
** MECHANICAL COLLECTOR
NUH8ER
SUPPLIER
** FGD SYSTEM
SALEABLE PRODU<;T/T HR OW AUA Y PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEy/RETROFIT
PARTICULATE DFSIGN REMOVAL EFFICIENCY
S02 DESl&N REMOVAL EFFICIENCY - i
INITIAL START-UP
CONSTRUCTION COMPLETION
CONSTRUCTION INITIATION
CONTRACT AWARDED
STARTED REQUESTING BIDS
STARTED PREL1MINAY DES16N
** ABSORBER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
NUHPER OF STAfES
DIMENSIONS
SHELL MATERIAL
SHELL LINER MATERIAL
INTERNAL MATERIAL
.080 LB/MMBTU)
.6CO LB/MMBTU)
DUQUESNE LHHT
PHILLIPS
1-4
SOUTH HEIGHT
PENNSYLVANIA
B
34.
25P-
587.0
410.0
?77.0
387.0
410.0
FOSTF R-WHEFLER
DRY POTTOM, PULVERIZED COAL
BASE
**/**
P73.01 (1850000 ACFM)
182.2 « 3" F)
104. « 340 FT)
******* (***** FT)
COAL
***** *
26400.
1ft.20
******
* **** ** *
( 11350 BTU/LB)
* *****
?.oo
1 .0-2.8
********
(*** TPH)
RESEARCH COTTRELL
80.0
RESEARCH-COTTRELL
THROwAwAY PRODUCT
WET SCRUBBING
LIME
CHEMICO
GIBBS AND HILL
FULL-SCALE
RETROFIT
99.00
83.00
7/73
7/73
12/71
7/71
10/70
1?/69
VARIABLE THROAT VENTURI
7/73
CHEMIcO
1
45 DIA- X 5C HUH
MHO STEEL
CEILCOTE
316L SS AND CEILCOTE
80
-------
EPA UTILITY FGD SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FED SYSTEMS
NOIILE TYPE
6AS FLOW - CU.R/S
GAS TEMPERATURE - C
StiPERFlCAL 6AS VELOCITY - M/SEC
PARTICIPATE OUTLET LOAD- G/CU.M
PARTICULATE REMOVAL EFFICIENCY -
S02 INLET CONCENTRATION - PPM
TANGENTIAL, BULL NOZ?LE
25S.13
171.1
12.2
.1
9D.O
1400
< 547000 ACFM)
< 340 F)
< 40.0 FT/S)
( .040 GR/SCF)
NUMBER
TYPE
INITIAL START UP
SUPPLIER
NUMBER OF STAGES
DIMENSIONS
SHELL MATERIAL
SHELL LINER MATERIAL
INTERNAL MATERIAL
NOZZLE TYPE
6*S FLOW - CU.H/S
6AS TEMPERATURE - C
SOPERFICAL GAS VELOCITY - M/SEC
PAHTICULATE OUTLET LOA6- G/CU.H
PARTICULATE REMOVAL EFFICIENCY - *
S02 INLET CONCENTRATION - PPM
VARIABLE THROAT VENTURI (IN SERIES WITH 101)
7/73
CHEMIcO
1
45 DIA. X 5C HIGH
MILD STEEL
CEILCOTE
316L SS AND CEILCOTE
TANGENTIAL, BULL NOZZLE
25S.13
171.1
12.2
.1
90.0
1400
( 547000 ACFK)
« 340 F)
< 40.0 FT/S)
( .040 GP/SCF)
** FANS
NUMBER
TYPE
CONSTRUCTION MATERIALS
SCRUBBER 1.0.
316L SS; NATURAL RUBBER LINED HOUSING
** MIST ELIMINATOR
NUMBER
TYPE
PRESSURE DROP - KPA
8
CHEVRON
.5
( 2.0 1N-H20)
** PUMPS
SERVICE
RECIRCULATION
THICKENER OVERFLOW
THICKENER UNDERFLOW
LIME SLURRY
LIME SLUKRY
-------
FPA UTILITY FbO SURVFY: DECEMBER 197t - JANUARY 1979
SECTION 3
DESIGN AND PF R FORM A fvC E DATA FOR OPERATIONAL FED SYSTEMS
** DISPOSAL
NATURE FINAL
TTPE LANDFILL
LOCATION OFF-SITE
TRANSPORTATION TRUCK
PERFORNANCF DATA " -----
PERIOD MODULE AVAILABILITY OFECAMLIIV (•FLiAt.iiiTY UTILIZATION x REMOVAL PER BOILER FGO CAP.
S02 PART. HOURS HOURS HOUfiS FACTOR
0/73 SYSTEM
•• PR06LE!«S/SOLUTIONS/COM!»ENTS
START DATE 0/73 £6UIH«ENT: F6D SYSTEM, GENERAL
END DATE 0/75 COHMfMTS:
DETERMINATION OF THE AVAILABILITY OF THE PHILLIPS SYSTEM HAS BEEN DIFF-
CILT. UNTIL flL BOILERS WfRE CONNECTED TO THE SCRUBBERS* THERE WAS AT
LEAST ONE SPA f-E TRAIN AND AS MUCH AS 100 PERCENT SPARE SCRUBBER CAPACITY.
TtEREFOREi HAVING A TRAIN OUT OF SERVICE FOR MAINTENANCE DID NOT REDUCE TH
CAPABILITY OF THE SCRUBBF.R SYSTEM. UNTIL ALL SIX BOILERS WERE CONNECTED,
MEANINGFUL AVAILABILITY FACTORS COULD NOT BE COMPUTED* ON MARCH 17, 1975,
ThE SIXTH POIIFR WAS CONNECTED, AND ALL FOUR SCRUBBER TRAINS WERE REOUIRED
TO BE IN SERVICE. OPERATION IN THAT MODE CONTINUED UNTIL AUGUST 4, 1975,
WHEN THE NO. >' BOILER MAS REMOVED FROM THE SCRUBBER SYSTEM BECAUSE THE PH
LEVEL COULD NCT BE MAINTAINED AND DEPOSITS BECAME UNMANAGEABLE TO THE POIN
THAT SCRUBBER OUTAGES UERE REDUCIN6 GENERATING CAPABILITY OF THE STATION.
AFFECTED MODULES: SYSTEM
•* PROULEMS/SOLUTIONS/COMMENTS
START DATE 0/73 teUHWENT: FGD SYSTEM, GENERAL
END DATE 0/75 COMM'.NTS:
STARTUP Of A IORTION OF THE PHILLIPS SCRUBPER SYSTEM BEGAN JULY 1973.
SEVERAL PROBLEMS THEN DEVELOPED IK THE FORM OF EROSION OF FANS AND THE LIM
Ft-ED SYSTEM C1USIN6 OUTAGES Of THE SCRUBBER SYSTEM. AFTER AN EXTENDED
OUTAGE, THE SCRUBBER SYSTEM WAS RETURNED TO SERVICE IN MARCH 1974. THE
SYSTEC HAS BE'K OPERATING CONTINUOUSLY SINCE THAT TIME WITH VARIOUS NUMBER
OF BOILERS CONNECTED TO THE SCRUBBER SYSTEM AND SCRUBBER TRAINS IN SERVICE
AFFECTED MODULES! SYSTEM
7/73 smii» 28.fl 81,0 744 232
8/73 SYSTEM 744
9/73 SYSTEM 7ZO
10/73 SYST£l"l 744
11/73 SYSTEM 7JO
12/73 SYSTEM 744
1/74 SYSTEM 744
2/74 SYSTEM 672
3/74 SYSTEM 744
4/74 SYSTEM 720
5/74 SYSTEM m
6/74 SYSTEM 7?Q
7/74 SYSTEM 744
8/74 SYSTEM 74<
9/74 SYSTEM 720
10/74 SYSTEM 744
82
-------
EPA UTILITY FGO SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FGD SYSTEMS
_ PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPEPABIHTY PLIABILITY UTILIZATION
X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
11/74
1 2/7*
1/75
2/75
3/75
A/75
5/75
6/75
7/75
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
101
201
301
401
SYSTEM
.00
720
744
744
672
744
720
744
720
744 506
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 7/75 EQUIPMENT: F6D SYSTEM, 6ENERAL
END DATE 7/75 CCKM ENTS:
THE FOURTH FGt TRAIN AND SIXTH BOILER HERE TIED IN ON MARCH 17, 1975.
TICULATE TESTS IN MAY SHOWED OUTLET LOADINGS OF 0.04 LB/MULION BTU«
AFFECTED MODULES: SYSTEM
PAR
«* PROULEMS/SOLUT10NS/COMMENTS
START DATE 7/75 tfiUI PMENT: SCRUBBER
END DATE 7/75 COMWfNT: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTA6E
THE J-STA6E TtAIN HAS BEEN OUT OF SERVICE FROM JUNE 19 FOR GENERAL CIEANXN
AhD REPAIR OF A LEAK IN THE FIRST-STAGE SCRUBBER.
AFFECTED MODULES: SYSTEM
6/75 301
401
101-
SYSTEM
744 ««9
** PROeLEMS/SOLUTJONS/COMMENTS
START DATE 8/7$ I.OUUKINT: SCRUBBER
END DATE ft/75 PROB if M : N OT D E FINED/SPIC1 FI EC
SCRURBIR UNAVAILABILITY FORCED RElUKNlNS BOILER TO THE SCRUBBER BY-
PASS PATH IN CPOER TO PRIVfNT LOSS Of iOILfR CAPACITY.
AFFECTED MODULES: SYSTEM
*» PROHEPS/SOLUTIONS/COMMENTS
START DATE S/75 tOUIt^ENT: F6D SYSTEM, GfcKERAL
END DATE S/75 PROBlfM: CHEMICAL-RELATED PLIJ66IN6
PLU6G1N6 AND MAINTENANCE PROBLEMS HAVE IEEN ENCOUNTERED.
AFFECTED MODULES: SYSTEM
** PROSLEMS/SOLUTIONS/COMMENTS
START DATE S/7S I6U3FHINT: RECYCLE PUMP
END DATE 1/75 PROPUMj NOT DEFINED/SPECIFIED
{VALUATION OF VARIOUS RECYCLE PUMPS IS CONTINUING.
AFFECTED MODULESi SYSTEM
9/75 101
201
301
401
201
SYJTtK
720 519
-------
FPA UTILITY FGD SURVEY: DECEMBER 197f - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FO* OPERATIONAL FED SYSTFMS
PEfif ORMANCF DATA
PERIOD MODULE AVAILABILITY CPEBAE1L1TY ^LIABILITY UTILIZATION * REMOVAL PER BOILER FGD CAP.
S02 PART. HOUPS HOURS HOURS FACTOR
10/75 101
201
301
401
SYSTEM 744 619
*« PRODLEMS/SOLUTICMS/COMMENTS
START DATE 10/75 EQUIfENT: FGD SYSTEM, GENERAL
fcNO D'TE 10/75 COMKINTS: RESEARCH AND DEVELOPMENT
IK OCTOBF& 19/5, PHILLIPS INITIATED THIOSORBIC LIME SCRUBBING IN THEIR
S1N6LI-STACE VCDULF.S ON AN EXPERIMENTAL BASIS. THE PURPOSE IS TO STUDY
COMPLIANCE FEASIBILITY, SO? REMOVAL EFFICIENCY, AND QUALITY OF THE SLUDGf
GENERATED BY 1HE SINGLE-STAGE MODULES.
AFFECTED MODULES: SY$TtM
11/75 101
201
301
401
SYSTEM 720 468
12/75 101
201
301
401
SYSTEM 744 463
** PROOLEMS/SOLUTIONS/COMMENTS
START DATE 12>75 fOUIfMENT: F6D SYSTEM, GENERAL
END DATE 12/75 CCMMtNTS;
THE UTILITY CONCLUDED THE THIOSOREIC LIME TESTING PR06RAM IN KID-DECEMBER.
FCUR BOILtRE 4ERE COUPLED TO THE SCRUBBING SYSTEM DURING THE RUN. THE
UTILITY IS NOU ANALYZING THE DATA GENERATED DURING THE TEST PROGRAM. THF
SCRUBBERS HAVL BEEN PUT BACK ON REGULAR LldE. NO UNUSUAL PROBLEMS UERE EN
COUNTERED DURJM6 THE TEST RUN.
AFFECTED MODULES: SYSTEM
1/76 101
201
301
401
SYSTEM 72.0 744 493
*« PROdLEMS/SOLUTIONS/COfWENTS
ST*RT DATE 1/76 EOUIFMENT: F6D SYSTEM, GENERAL
END DATE 1/76 COMMENTS:
THE 2.5-MONTH T£ST F'ROGR«M WITH THIOSORBIC L IMF INCLUDED 1612 HOURS ON ONE
TRAIN AND 130' HOURS ON ANOTHER TRAIN. RESULTS INDICATE THAT THE RE6UIRED
DEGREE OF SCi2 REMOVAL (83 PERCENT) CAN BE OBTAINED WITH AN M60 CONTENT OF
8-10 PERCENT IN THE L1«E WITH SINGLE-STAGE SCRUBBING.
AFFECTED MODULES: SYSTEM
2/76 101
201
301
401
SYSTEM 696 435
3/76 101
201
301
401
SYSTEM 744
4/76 SYSTEM 720
-------
EPA UTILITY FED SURVEY: DECEMBER 1976 - JANUARY 1979
SECTION 3
DtSIGN AND PERFORMANCE DATA FOR OPERATIONAL F6D SYSTEMS
..... _ PERFORMANCE DATA ...... -
PERIOD BOODLE AVAILABILITY OPERABIL1TY RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUT10NS/COMMENTS
START DATE 4*76 E«UIH
-------
FPA UTILITY F6D SUPVEY: DECEMBER 197£ - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL F£D SYSTEMS
PERFORMANCE DATA-- • •
PERIOD MODULE AVAILABILITY OPERABIL1TY PLIABILITY UTILIZATION * REMOVAL PER BOILER FGO CAP.
SC2 PABT. HOURS HOURS HOURS FACTOR
REPAIRS WERE CADE ON THE TURNING VANES TO THE SCRUBBER MIST ELIMINATOR.
AFFECTtD MODULES: SYSTEM
** PROBLEMS/SOLUTION S/CCI"*ENTS
START DATE g/76 £GUir«ENT: EXPANSION JOINT
END PATE fc/76 COMMENTr PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTAGE
REPAIR WORK W'S NECESSARY ON THE EXPANSION JOINT SEAL WHERE THE DUCTWORK
TIES INTO THE ?AIN STACK.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 8/76 ECUItMENT: STACK
END DATE 8/76 CCfiM'NT: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTAGE
THE STEEL PANCS AROUND THE INNER STACK STRUCTURE UfRE REPAIRED.
AFFECTED MODULES: SYSTEM
*» PROBLEMS/SOLUTIONS/COKMENTS
START DATE 8/76 E8UIFMENTS FAN
END DATE 8/76 CCMMfNT: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTA6E
THE I.D. FANS WERE OVERHAULED.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE S/76 E6UIHWENT: 6AS DAMPER
END DATE f. lib COMMtNT: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTAGE
TK P01LER EXIT DAMPERS WERE REPAIRED*
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 8/76 tOUIFKENT: STACK
END DATE 8/76 COMMENT: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTAGE
REPAIRS k/fcRE MDE TO STOP LEADM6E OF THE ACID-BRICK LINING IN THE MAIN
STACK.
AFFECTED MODULES: SYSTEM
9/76 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 9/76 E6UIFMENT: FGD SYSTEM, GENE ML
END 0«TE 10/76 COMMENTS!
BOILER NUMBtRt 2 THROUGH 6 WERE COUPLED INTO THE SCRUBBING SYSTEM. BOILER
NO. 1 IS DOWN FOR OVERHAUL AND REPAIRS. THE lUCS INTERIM SLUDGE PROCESS-
ING PLANT IS INDER CONSTRUCTION AND' WILL BE IN SERVICE BY DECEMBER 1976.
1H TEMPORARY FACILITIES WILL PROCESS THE THICKENER UNDERFLOW AND PONDED
SLUDGE UNTIL 1HE POND IS DEPLETED OF SLUDGE AND THE PERMANENT FACILITY HAS
BEEN INSTALLED. SCRUBBING OPERATIONS ARE STILl PROCEEDING IN AN OPEN UATE
LOOP MODE vm PART OF THE THICKENER OVERFLOW BEING DIVERTED TO THE ASH
PCND. BECAUSE BOTH THE BEAVER VALLEY AND BRUCI MANSFIELD STATIONS ARE
FULLY OPEfiATICNALt THIS STATION HAS BEEN RELEGATED TO PEAK LOAD OPERATIONS
6CNE*H LOAD CPEffAjIONS ARE FULL LOAD CAPACITY IN THE DAYTIME AND SO TO 67
PERCENT LOAD "EDUCTION AT NIGHT.
TOTAL SCRUBBtP HOURS: 23,27* THE FIGURES AT THE LEFT WcftE COMPILED
TOTAL BOILE* HOURS: 83,6*2 BY THE UTILITY FOR SYSTEM OPERATIONS
TOTAL SCRUEUFR OUTAGE TIME: 5,HO FOR THE PERIOD FOLLOWING START-UP IN
TOTAL SCRUPtCR AVAILABLE JULY 1973 INCLUSIVE TO OCTOBER 1976.
HOURS: 33,274 THE T0TAL SCRUBBER HOURS VALLI INCLUD
AVERAGE Pk LOAD/SCRUBBER OPERATION OPERATION TIME WHIN ONE OR "ORE OF
HOUR: <*J THE MODULES WERE IN SERVICE. TOTAL
TOTAL OPEfiAtlLITV INDEX: 2*X BOILER AND UNAVAILABILITY VALUES APPL
TOTAL RHIAIUITY INDEX: an FOR ALL THE CORRESPONDING UNITS. THE
TOTAL SCRUBBER AVAILABILITY INDEX IN-
CLIDBS THE TIMI WHEN ONE OR MORE
MODULES WfRE AVAILABLE POR SERVICE.
AFFECTED MODULES,) 8VSTEP
** PRObLEMS/SOLUTIONS/CCMMiNTS
START DATE 9/76 l«UIf«ENTl SLUD6I DISPOSAL
tND DATE 10/76 COMPtNTSl
86
-------
EPA UTILITY FGD SURVEY! DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMAKCE DATA FOR OPERATIONAL FGD SYSTEMS
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY CPERA&IL11Y PLIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
UKTIL THE IUCS INTERIM SLUD6E PROCESSING PLANT IS COMPLETE THE TEMPORARY
FACILITIES WILL PROCESS THE THICKENER UNDERFLOW AND PONDED SLUDGE UNTIL TH
POND IS DEPLE1EO OF SLUDGE.
AFFECTED MODULES: SYSTEM
10/76 SYSTEM 744
11/76 SYSTEM 7?o
** PROBLEMS/SOLiniONS/COMKENlS
START DATE 11/76 ESCULENT: RECYCLE PUMP
END DATE 12/76 COMMINTSl RESEARCH AND DEVELOPMENT
ThE RECYCLE PIMP EVALUATION IS CONTINUING.
AFFECTED MODULES: SYSTtK
** PROBLEMS/SOLUTIONS/CCMMENTS
START DATE 11/76 tBUIfENT: F6D SYSTEM, GENERAL
END DATE 17/76 COMMfNTSt
ThE UTILITY REPORTED THAT BOILERS TWO THROUGH SIX REMAINED COUPLED INTO TH
SCRUBBING SYS IfM DURING THE REPORT PERIOD. THF INTERIM IUCS FIXATION
FACILITY WAS INSTALLED AND COMMENCED OPERATIONS IN DECEMBER. THE UTILITY
REPORTED THAT THE VENTURI SCRUBBERS ARE STILL DEVELOPING LARGE AMOUNTS OF
SCALE ON THE INTERNALS, RESULTING IN TWICE NORMAL PRESSURE DROPS. THE RE-
CYCLE PUMP EVALUATION HAS BEEN IN PROGRESS. APPROXIMATELY 2500 TO 2POO
HOURS OF OPERATION TIME HAVE BEEN ACCUMULATED ON THE VARIOUS UNITS WITH NO
FAILURES OR APPRECIABLE WEAR OBSEfiVED. THE ADDITIONAL DEHATERIN6 AND RE-
AGENT PREPARA1ION EQUIPMENT IS NOU BEING INSTALLED. THE CONTRACT HAS BEEN
AkARDED TO DR'VO TO PROVIDE THIOSOR6IC LIME FOR THIS SCRUBS ING SYSTEM. AL
BOILERS HAVE kFEN HEADEREO INTO THE SCRUBBER PLANT., A NUMBER OF THE UNITS
WIRE DOWN FOR OVERHAUL AND REPAIR. THE INTERIM IUCS AOZ-0-TEC UNIT REMAIN
EC IN SERVICE, FILTERING OUT WATER ONLY. THE RECYCLE PUMP EVALUATION IS
CONTINUING. 'FTER 4000 HOURS OF OPERATION THE CARBORUNDUM IMPELLERS AND
WEAR RINGS STILL LOOK GOOD. S02 AND PARTICULATE REMOVAL EFFICIENCIES ARE
SC AND 99 + 5! RiSPECT JVEIY. INSTALLATION OF THE ADDITIONAL SILOS, THICKENER
AhD LIME frfO-.US IS STILL IN PROGRESS. FULL COMPLIANCE PLANT OPERATIONS
AfcE SCHEDULED FOR DECEMBER.
AFFECTED MODULES: SY$TtM
** PROBLEMS/SOLUTIONS/COMMEN1S
START DATE 11/76 E6UIFfENT: SCRUBBER
END DATf, 12/76 PKOfiiEM: CHEMICAL-RELATED SCALING
TKE VENTURI SCRUBBERS ARE STILL DEVELOPING LARGE AMOUNTS OF SCALE ON THE
INTERNIALS. TI ti PRESSURE DROPS HAVE DOUBLED AS A RESULT,
AFFECTED MODULES: SYSTEM
12/7* SYSTEM ; 50.00 99.00 7*4
1/77 301
401
101
2C1
SYSTEM 7**
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 1/77 EfiUIfMENT: FGD SYSTEM, GENERAL
END DATE 3/77 CCMMfNTS:
1S77 FULL COMFLlANCE OPERATIONS WILL INCLUDE 83X S02 REMOVAL FOR 2? SULFUR
CCAL UTILIZING THIOSORBIC LIME C6-12X M6) AND FI*ATIN6 THE SCRUBBER WASTES
WITH THE IUCS P02-0-TEC METHOD. THE FIXATED MATTER WHL BE HAULED A«A» TO
AN OFF-SITE DISPOSAL AND LANDFILL. IUCS HAS BEEN AWARDED A TEN YEAR CON-
TRACT FOR THE USE OF THIS METHOD. THE CARBORUNDUM IMPELLORS AND WEAR RING
CONTINUE TC LCOK GOOD AFTER MORE THAN 5000 HOURS OF OPERATION.
AFFECTED MODULES: SYSTEM
2/77 SYSTEM 672
3/77 SYSTEM 7**
87
-------
EPA UTILITY FbD SUPVFY: DECEMBER 197t - JANUARY
SECTION 3
DESIGN AND PERFGR0AKCE DATA FOR OPERATIONAL F€D SYSTFHS
--------------------------- ..... ---------- PERFORMANCE DATA ---------------------------------
PERIOD MODULE AVAILABILITY CPERABIL1TY PLIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP-
SO? PART. HOURS HOURS HOURS FACTOR
4/77 SYSTEM 720
** PR08LEMS/SOLUTIONS/COMMENTS
START DATE 4/77 E6UIFKENT: F6D SYSTfHt GENERAL
END DATE 5/77 COMMiNTS:
DAMPER AND CIST ELIMINATOR REPAIRS WILL BE CORRECTED DURING A SCHEDULED
OITAGE. OVERALL SCRUBBER AVAILABILITY IS ABOUT 75X. THE INTER1I" SLUD6E
DJSPCSAL SYSTb* Is STILL OPERATIONAL. THE PERMANENT SLUDGE DISPOSAL FACIL
I1Y IS OH SCHEDULE FOR THE DECEMBER 1977 COMPLETION DATE.
AFFECTED MODULES: SYSTEM
** P ROBL EM S /SOLUTI ON S/C CMPSENTS
START OAjE 4/77 EOUIFfENT: F6D SYSTEM, GENERAL
END DATE 5/77 COMMENTS: RESEARCH AND DEVELOPMENT
TKICSORBIC Lift TESTS BEGAM IN LATE NAY BUT LASTED ONLY ABOUT ONE WEFK.
AFFECTED MODULES: SYSTEM
** PROeLEMS/SOLUTIONS/CCMMENTS
START DATE 4/77 EGUIrfENT: DUCTWORK
END DATE 5/77
TfcE SCRUBBER SYSTEM WAS SHUT DOWN FOR THREE TO FOUR DAYS IN MAY DUE TO
LEAKING IN THf WET DUCT HEADER THAT LEADS TO THE STACK. WHEN TMf LEAK WAS
REPAIRED FLUE GAS FROM FOUR BOILERS BEGAN TO BE SCRUBBED.
AFFECTED MODULES: SYSTEM
** PR06LEMS/SOLUTIONS/COMMENTS
START DATE 4/77 ESUItWENT: GAS DAMPER
END DATE 5/77 PPOBtF.M: CHEMICAL-RELATED EROSION
WHILE F1X1*<6 f DUCT LEAK INSPECTION OF OTHER COMPONENTS REVEALED THAT THE
BOILER EXIT DAMPERS WERE ERODING.
MODULES: SYSTEM
«» PROBLEMS/SOLUTIONS/COMMENTS
START DATE 4/77 EQUIPMENT: MIST ELIMINATOR
END DATE 5/77 PfcOeLF-N: CHEMICAL-RELATED PLUGGING
ONE 201 EXTERML MIST ELIMINATOR WAS SEVERLY ERODED AND PLUGGED.
AFFECTED MODULES: Z01
5/77 SYSTEM 75^6 741
6/77 SYSTEM 7?0
** PROBLEMS/SOLUTIONS/CCMMENTS
START DATE 4/77 ESUIfMENT: FGD SYSTEM, GENERAL
END DATE 7/77 COMMtNTS:
ALL SIX BOILEfcS ARE COUPLED INTO THE SCRUBBER PLANT. FLUE GAS FROM FIVE 0
T*ESE UNITS IJ BEING TREATED BY THE SCRUBBERS. ONLY FOUR OF THE SIX BOIL-
ERS ARE ACTUALLY OPERATING BECAUSE OF THE CURRENT TURBINE REPAIR OUTAGE.
OPERATIONS AR£ PROCEEDING WITH ONE SCRUBBING TRAIN BEING SPARED AT ALL
TIMES (MA1NTEKANCE AND CLEANOUT). S02 REMOVAL EFFICIENCY IS APPROXIMATELY
5CX.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 6/77 E6UITMENT: BOILER-RELATED
END DATE 7/77 COMMENTS:
BOILER NO. 6 MS BEEK DOWN FOR ftN EXTENDED TURBINE REPAIR OUTAGE*
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 6/77 E6Uir«ENT: RECYCLE PUMP
END DATE 7/77 COMWfNTS: RESEARCH AND DEVELOPMENT
THE RECYCLE PIMP EVALUATION STUDY CONTINUED DURING THE PERIOD. COMPONENTS
BEING EVALUATED INCLUDE: C A RP OR UN CUM IMPELLERS, CARBORUNDUM WEAR RINGS, TI
TANIUM IMPELLERS, 317SS WEAR RINGS (STELLITE TIPPED).
AFFECTED MODULES: SYSTEM
88
-------
EPA UTILITY FGB SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMAKE DATA FOR OPERATIONAL F60 SYSTEMS
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY SRLlABIlITY UTILIZATION X REMOVAL PER BOILER FGO CAP.
_ S02 PART. HOURS HOURS HOURS FACTOR
" ™ ••'""••••^••"^ »MWW«W«H«« • <**«•««•>•«.•• VB « •»•» KND REPAIRS WILL BE CARRIED OUT. CURRENT S02 REMOVAL EFF-
ICIENCY IS 503. BY EARLY APRIL THE SYSTEM IS FXPECTEO TO REACH COMPLIANCE
WITH AN SC2 REMOVAL EFFICIENCY OF 83X.
AFFECTED MODULES! SYSTEM
9/77 SYSTEM 50.00 720
10/77 101
301
*01
SYSTEM 7*4
** PR03LIMS/SOLUTIONS/COMMENTS
S-TftR-T-DATf 10^77 ffitirfMINTt FGp SYSTfR, BKNtMl
fND DAT! 10/77 PRQBUM: NOT DEFINED/SPECIFIED
MODULI 161 WAS DOWN A TOTAL OF 113 HOURS IN OCTOBER.
AFWCTiD MODULES: 101
** PROBLEMS/SOLimONS/CnMMiNTS
START DATI 10/77 teUIFHENTj SCRUBSfft
1N» 6ATI 10/77 COHMlNTf PRfViNTIVI MAINTfNANCI SCHISULtD UNIT OUTA6I
MCPUtl 201 WAS PUT IN S6RVUI ON flCTOSSR |6 AFTIR IXTiNSIVi ttlAH UP AND
REPAIRS TO HU'Blft LINING AND l.D, FAN.
AFFECTED MODULESt 201
•* PROBLEMS/SOLUTIONS/COMMENTS
START DATI 10/77 teUIffENT: F6D SYSTEM, 6INSRAL
ENB DATE 10/77 COMMFNTSS
MODULI 501 WAS DOWN A TOTAL OF 57 HOURS jN OCTOBER.
AFFECTED MODULES: ?01
** PftOBlEMS/SOLUTIQNS/COMMEim
START DATS 10/77 IBUH'MENTs FAN
END DATI 10/77 PROBLrHs MlCHANICAL-RIUATED MATERIALS FAILURE
MCOULE *01 WAT DOWN A TOTAL OF 3« HOURS IN OCTOilR FOR REPAIR OF HOLFS IN
FAN LINJN6 ANB TYJN6 IN THICKENER BLEED LINE.
AFFECTED MODULES: 401
11/77 SYSTEM
720
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 11/77 ESUIFPIENT: DUCTWORK
END DATE 11/77
89
-------
EPA UTILITY F(,D SURVEY: DECEMBER 1«7F - JANUARY 1979
SECTION 3
DESIGN AND PERFOFKAKCE DATA FOR OPERATIONAL F«D SYSTEMS
PERFORMANCE DATA '" '
PERIOD MODULE AVAILABILITY OPERAEUITY IT LI Ad I LIT V UTILIZATION * REMOVAL PER BOILER FGD CAP.
SOZ PART. HOURS HOURS HOURS FAtTOR
DURIf'f, THE SHUDOUN OUTLET DUCT LEAKS WERE REPAIRED.
AFFECTED MOPULES: SYSTEM
•• PROBLEMS/SOLUTIONS/COMMEN1S
START DATE 11/77 EGUIffENT: DUCTWORK
END DATS 11/77
POILfR EXIT DAMPERS WERE REPLACED DUE TO EROSION BY FLYASH.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMEN15
START DATE 11/77 EBUHfiENT: STACK
END DATE 11/77
COHROSION OF STEEL BANDS IN STACK WAS DISCOVERED DURING THE PERIOD.
AFFECTED MODULES; SYSTEM
• * PROISLEWS/SOLUTIONS/CfiMMENTS
START DATE 11/77 tBUJl'ENT: SLUD6E DISPOSAL
END DATE 11/77 FROBtFM: NOT DEFINED/SPECIFIED
DEHATERIN6 OPiPATIONS ARE NOT WORKING PROPERLY* CAUSING PROBLEMS IN SLUDGE
HANDLING.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMINTS
START DATE 11/77 IOU1FMENT: FGD SYSTEM, GENERAL
fcND DATE 11/77 COMMENTS:
THt RESULTS FfiOM THIOSORI1C LIME LSt CAN NOT TIT fiF QUANTIFIED DUE TC LIKE
FEED SYSTfeM PfOBLIMS.
AFFECTED MODULES: SYSTSK
*• PROILEMS/SOLUTIONS/CCMMINTS
START DATE 11/77 EQUIPMENT: REAGENT NANDLINS
END DATE 11/77 PHCPfMt NOT DE F] NED/SPFCIF I ID
LIME FEED 5YSIPW PROBLEMS OCCURRF-D OVER THE PERIOD.
AFFf.CTEf) MODULES: SYSTEM
12/77 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 1Z/77 fcOUIF»»ENTs FGD SYSTEM, SENERAt
tND DA-TE 1/78" COWMtNTS:
CLHULAT1VE HOIRS FOR JANUARY 1977 THROU6H 1-?-76 MERE 22391 FOR MODULE 101
,2099* FOR MOtULE 201* 22229 FOR MODULE 301 AND 22259 F OR MODULE 4jj1.
AFFECTED MODULES; SYSTEM
** PROBLEMS/SOLUTIONS/COHMENTS
START OAjE 12>77 EOUIFKENT: SCRURBFR
END DATE 1/78 CCMttfNT: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTA6E
SCRUBBER TRAIh 301 WAS DOWN FOR AN OVERHAUL FROM NOVEMBER 17 TO MONDAY FE-
BRUARY 6, 197? WHEN IT MAS RETURNED TO SERVICE.
AFFECTED MODULES: 301
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 12/77 EfiUIFMENT: F6D SYSTEM, GENERAL
END DATE 1/78 COMMENTS:
SCRUBBER TRAIH 401 WAS REMOVED FROM SERVICE ON THE 6TH OF FEBRUARY.
AFFECTED MODULES: 401
** PR06LEMS/SOLUT10NS/COI»MENT$
START DATE 12/77 EQUIPMENT: SLUDGE DISPOSAL
END DATE 1/76 PROBUM: NOT DEFINED/SPECIFIED
THE IUCS INTEMM SLUDGE TREATMENT SYSTEM HAS SOME DEWATER1NS PROBLEMS
DURING DECEMBER PHILLIPS EXPERIENCED POOR SLUDGE REMOVAL. THE IUCS PLANT
IS WORKING ON A PART TIME BASIS. FULL OPERATIONS ARE EXPECTED LATE THIS
SFRIN6. THE tOOR QUALITY SLUDGE IS SENT TO AN EMERGENCY POND AND THEN HE-
CIRCUIATFD 6ACK TO THE THICKENER
AFFECTED MODULES: SYSTEM
90
-------
EPA UTILITY FGD SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN »ND PERFOfKAriCE DATA FOR OPERATIONAL FGD SYSTEMS
PERFORMANCE DATA -------------------- - ---------------------
PERIOD MODULE AVAILABILITY DURABILITY (PLIABILITY UTILIZATION Z REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
~ ™~ "*"" ™ """"*"•• »™»— »~«fc»— _ M. "•^•••.•.••^••.•^•.^ — «.•.«.•»««,_«_ AKK«.»M*» — 9BM» W V A_ A K«« « • «•__•• •• w V .•• IB •
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 12/77 EQUIfNENT: REAGENT HANDLING
END DATE 1/78 COKKfNTS: RESEARCH AND DEVELOPMENT
TESTING WITH IHJOSORBIC LIWE AT 5X M60 HAS SHOWN THAT THE W60 CONCENTRATI-
ON IS NOT GREfT ENOUGH TO EFFECT ADI8UATE SQ2 REMOVAL ON A SINGLE STA6E
SCRUPBER. THtY ARE 60IN6 TO TEST AT A GREATER M60 CONCENTRATION BY START-
ING *T 101 ANP THEN DROPPING BACK UNTIL THE CONCENTRATION IS SATISFACTORY.
THJS TESTING, AS WEIL AS SCRUBBER OPERATIONS, HAVE, HOWEVER, BEEN HAMPER-
ED BY LOW LfAtS AS A RESULT Of THE COAL STRIKE.
AFFECTED MODULES: SYSTEM
** PROEJLEMS/SOLUTIONS/COWMENTS
START DATE 12/77 EOUIfMENT: STACK
END DATE 1/78
THERE WILL BE AN BUTA6E AT PHILLIPS HO REPLACE THE CARBON STEEL BANDS IN
THE STACK U T ti STAINLESS STEEL BANDS,
AFFECTED MODULES: SYSTEM
1/78 301
401
101
201
SYSTtH 7*4 *?1
2/78 101
Z01
301
401
SYSTEM 672 167
** PROBLEMS/SOLUTIONS/COMWENTS
START DATE 2/78 EQUIPMENT: STACK
fcND DATE 5/78
AK OUTAGE OCCURRED BETW5EN JANUARY 6 AND JANUARY 8 WHEN THE STACK ORAIN
LEAKS WERE REPAIRED PT SANDBLASTING THE OUTER WALL AND REPLACING THE CAR-
PON STEEL BAN!S WITH STAINLESS STEEL BANDS.
AFFECTED MODULES; SYSTEI*
START DATE 2/78 EGUIPMENT: F6D SYSTEM, GENERAL
END DATE 3/78 COPIMtNTS:
THE SYSTEM WAS SHUTDOWN ON FEBRUARY 11 DUE TO THE COAL SHORTAGE. THE OUT-
ACE CONTINUED THROUGH MARCH AND THE SYSTER IS SCHEDULED TO BE ON LINE BY
APRIL 15. DUMNG THE OUTAGE A NDMPER OF REPAIRS AND MODIFICATIONS WERE
MADE.
AfFECTED WODULES: SYSTEM
** PfiO&LEMS/StnUTIONS/CCMMENTS
START DATE 2/78 t«UI FWENTs GAS DAMPER
tND DATE 3/78 COMPtNT: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTAGE
THE BOILEfl EXIT DAMPERS WERE LINED WITH 316SS ON AREAS Of HIGH EftOSION
CAUSED BY HY«*H INPINGEHENT.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/CCMMENTS
START DATE 2/78 ECUK'MENT: EXPANSION JOINT
END DATE 3/78 COKMfNTi PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTAGE
EXPANSION 40IMTS ON THE INLET DUCTWORK WERE SHIELED BY METAL PtATES WHICH
WERE WELDtD A 1 ONE END.
AFFECTED HODULESi SYSTEM
** PROBLEHS/SOLUTIONS/COftMENTS
START BATE 2/78 E«UIFHENTS DUCTWORK
END DATE 3/78 COMPHNT: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTAGE
NUMEROUS HOLES IN IKE WET GAS ftUcT WORK WERE REPAIRED AND THE DUCTS WERE
RELINED WITH CEILCOTE.
91
-------
F.PA UTILITY F6D SURVEY: DECEMBER 197fc - JANUARY 1979
SECTION 3
DESIGN AND PERFORMA^E DATA FOB OPERATIONAL FCO SYSTEMS
--------------------------- ...... --------- PERFORMANCE DATA ------- - ----------------------------------
PERIOD MODULF AVAILABILITY OPERAEILITY FELIABILITY UTILISATION * REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
AFFtCTED MODULES: SYSTEK
*• PROBLEMS/SOLUTION S/CO!»MEN1S
START DATE 2/78 Etllil f*ENTi GAS DAMPER
END BATE 3/78 CCMMfNT: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTAGE
THE THROAT CAPPERS WERE CLEANED ON ALL THE SCRUBBERS.
AFFECTED MODULES: SYSTEK
** PRObLEMS/SOLUTIONS/COMENTS
STA«T OAjE 2/78 teUIIMENT: MIST ELIMINATOR
END DATE 3/78 CDM-UKT: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTA6E
INTERNAL MIST ELIMINATORS WERE CLEANED' THE EXTERNAL MIST ELIMINATORS,
WHICH ARE ADIY DETERIORATE D t MAY RE. REPLACED.
AFFECTED MODULES- SYSTEM
*« PROElLEMS/SOLUTIONS/COMMENTS
START DATE 2/76 ffiUI('-£NT: STACK
END D*Tf 3/78 COMMiNT: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTAGE
THE STACK BB J CKLINI N6 WAS INSPECTED AND SO»E BRICKS WERE REPLACED AT THE
TOP OF THE STi>CK.
AFFECTED MODULES: SYSTEM
•• PR06LEWS/SOLUTIONS/COWMENTS
START DATE 2/78 EBUIf'»ENTs FGD SYSTEM, GENERAL
EK'D DATE 7/76 CGPMtNTS:
CONSTRUCTION kORK ON ADDITIONAL P6UIPMENT SUCH AS THE THICKENED AND SILOS
IS ALMOST COMPETE. IT WAS NOTED THAT THE CEHCOTE LINER COROLJNE 505AR
HAS HELD UP WILL OVER THREF YEARS ON THE CONICAL APEX OF MODULE *01.
AFFECTED MODULES: 5YSTEK 4C1
3/78 SYSTEM
4/7? SYSTEM
744
720
402
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE
END DATE
4/78 tOUIFfENT:
5/73 COMMENTS:
THE F6D SYSTEM CAME
IS NOT OPERATIN6 AT
FGD SYSTEM, GENERAL
BACK
FULL
ON LINE AFTER THE COAL
LOAD BECAUSE THE NO. *
STRIKE IN LATE MARCH. IT
ROjLER IS STILL OUT AND
COMPLIANCE TESTS WILL TAKE PLACE1K
LINE* TO SFE IF THE SYSTEM IS MEETING THE
?J SULFUR COAL. THERE WFRF NO HOURS RE
SHOUIK BE PACK ON L I NE IN M I D-J UL Yi
JULY, AFTER BCILER 6 IS BACK ON
831 502 REMOVAL REQUIREMENT FOR
PORTED FOR THIS PERIOD BECAUSE OF PRELIMINARY TESTING BETMG CONDUCTIK'G IN
PREPARATION FIR THE COMPLIANCE TESTS. SO FAR, TESTS INDICATE THAI THE SYS
TEM WILL COMPLY WITH THE REQUIRED STANDARDS. THE AVAILABILITY FOR ALL
FOUR TRAINS WIS BETWEEN 65 AND 75 PERCENT.
AFFECTED MODULES: SYSTEM
5/78 SYSTEM 70,0
6/78 SYSTEM
744
720
619
597
«* PROBLEMS/SOLUTIONS/COMMENTS
START DATE 6/76 EQUIt'PENT: MIST ELIMINATOR
tND DATE 7/78 CCMMCNT: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTAGE
THE INTERNAL TST ELIMINATOR ON MODULE 2Ql WAS REMOVED AM) CLEANED OVER
THE PERIOD.
AFFECTED MODULES: 201
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 6/76 ICUII-PENT: F6D SYSTEM, GENERAL
END DATE 7/78 COMMENTS:
THE FGD SYSTEf HAS ACCUMULATED APPROXIMATELY 24000 HOURS OF OPERATION ON
ALL FOUR MODULES SINCE START-UP.
AFFECTED MODULES: SYSTEM
«* PROSLEMS/SOLUTIONS/COMMENTS
START DATE 6/78 EfiUIfMENT: PROCESS CONTROL
END DATE 7/78 PROBlFn: NOT DEFINED/SPECIFIED
92
-------
FPA UTILITY FED SURVEY: DECEMBER 1978 - JANUARY 1°79
SECTION 3
DESIGN AND PERFORMAKE DATA FOR OPERATIONAL F6D SYSTEMS
..... .. _—„ PERFORMANCE DATA --
PERIOD MODULE AVAILABILITY CPERAB1LITY RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
WATER BALANCE PROBLiHS HAVK CONTRIBUTED TO THE OCCURRANJE OF~LOW PH, RE-
SULTING IN HlfT ELIMINATOR PLUGGING.
AFFECTED BODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 6/76 EQUIPMENT: REAGENT HANDLING
END DATE 7/78 PROBiEM! NOT DEFINEO/SPECIFIED
THE WIST ELIMINATOR PLUGGING IS ALSO RELATED TO LOW PH RESULTING FROM LIME
HANDLING AND SLURRY PREPARATION SYSTEM FAILURE.
AFFECTED MODULES; SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 6/78 EQUIPMENT: F6D SYSTEM, GENERAL
END DATE 7/78 COMWtNTSS
T« UTILITY It CURRENTLY STUDYING WAYS TO TIGHTEN THE WATER BALANCE BY
US IMP THICKENER SUPERNATANT INTERMITTENTLY WITH CLEAR SERVICE WATER FOR TH
MIST ELIMINATORS. THE COMPLIANCE TEST SHOULD TAKE PLACE DURING THE NEXT
REPORT PERIOD .
AFFECTED MODULES: SYSTEM
7/7S SYSTEM 74* 506
8/78 SYSTEM 744 708
** PROBLEHS/SOLUTIONS/CCMMENTS
START DATE 8/78 EQUIPMENTS MIST ELIMINATOR
END DATE 9/78 COMMENT: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTAGE
DURING TH| AUGUST-SEPTEMBER PERIOD MIST ELIMINATOR CLEANING TOOK PLACE IN
ORDER TO CORRFCT THfc PLUGGING PROBLEM.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COPI«ENTS
START DATE 8/78 EGUIFMENT: MIST ELIMINATOR
END DATE 9/78 PROBLEM: NOT DEFINED/SPECIFIED
Ih AUGUST THE INTERNAL MIST ELIMINATOR ON MODULE 201 WAS REPLACED.
AFFECTED MODULES; 201
•* PROBLEMS/SOLUTIONS/COMMENTS
START DATE 8/78 EQUIPMENT: REAGENT HANDLING
END BATE 9/76 COMMENTS PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTAGE
THE LIME HIXIC& BASIN HAD TO BE SHUT DOwN OVER A WEEKEND SO THAT EXCESSIVE
GRIT AND SOLID PARTICLES THAT HAD BUILT UP COULD BE CLEANED OUT.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 8/78 EQUIPMENT: ABSORBER
END DATE 9/78 CCMMlNTt PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTAGE
HIGH PRESSURE WATER CLEANING WAS PERFORMED ON MODULES 101 AND 4()1 •
AFFECTED MODULES: 101 4f1
** PROBLEMS/SOLUTIONS/CCMMENTS
START DATE E/78 EQUIPMENT: ABSORBER
END DATE 9/78
THE RUBBER LIMNG IN MODULE 101 WAS REPAIRED.
AFFECTED MODULES: 101
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 8/78 EQUIPMENT: SLUDGE DISPOSAL
END DATE 9/78 PROBLEM: NOT DEFINED/SPECIFIED
A MAJOR PftOBLIM 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.
AFFECTED MODULES: SYSTEM
9/78 STSTEM
7JO 572
93
-------
F.PA UTILITY F6D SURVEY: DECtneFR 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FED SVSTF.BS
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERAEILITY PLIABILITY UTILIZATION X REMOVAL PER BOILER FGD "P.
SO? PART. HOURS HOURS HOURS MCTOR
10/78 SYSTEM
11/7? SYSTEM
12/75
101
201
301
401
SYSTEM
91.9
88.0
27.?
87.5
744
720
744
540
** PROBIEMS/SOLUTJONS/COMMENTS
START DATE 12/78 ECUItHENT: SLUDGE DISPOSAL
END DATE 1/79 FOOBIEM: NOT DEFINED/SPECIFIED
DUR1N6 THE PERIOD THE LACK 0' FLYAsH FOR MIXING WITH SLUD6E WAS A PROBLEB
AFFECTED HODULES: SYSTtn
1/79
101
201
301
401
SYSTEM
86. 7
69.?
50.0
83.6
744 539
-------
EPA UTILITY FGt SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
OES16N AND PERFOKMAhCE DATA FOR OPERATIONAL F6D SYSTEMS
COMPANY MAKE
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICIPATE EMISSION LIMITATION - KG/J
S02 EMISSION LIMITATION - H6/J
NCI PLANT GENERATING CAPACITY - MU
GROSS UNIT GENERATING CAPACITY - «k
NET UNIT GENERATING CAPACITY H/FGD - Mt.
NET UNIT GENERATING CAPACITY VO/FGC - t>*»
EOUIVALFNT SCRUBBED CAPACITY - NU
** BOILER DATA
SUPPLIER
TYPf
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU."/S
FLUE GAS TEMPERATURE . C
STACK HE16HT - l"l
STACK TOP DIAMETER - H
«* FUEL DATA
FUEL TYPE
FUEL 6RADE
AVERAGE HEAT CONTENT - KJ/HO
RANEE HEAT CONTENT - BTU/IB
AVERAGE ASH CONTENT - X
RANtE A&H CONTENT - X
AVtRAGt MOISTURE CONTENT
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - «
RANGE SULFUR CONTENT - X
AVEKA6I CHLORIDE, CONTENT •
RAN6E CHLORIDE CONTENT - X
FUEL FIRING RATf, - M T/H
FUEL FlftlNg MT8 - MM
** SSP
- X
TYPI
SUPPLIER
PARTICIPATE, DESIGN REMOVAL EFFICIENCY
FLUE 6AS TEMPERATURE - C
** FSC SYSTEM
SALEABLE PRODUCT/THROW AWAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICULATE DESIGN REMOVAL EFFICIENT
S02 DESIGN REMOVAL EFFICIENCY - X
INITIAL START-UP
** ABSORBER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
DIMENSIONS
SHELL MATERIAL
BOILER LOAD/ABSORBER - X
GAS FLOW - CU.M/S
PARTICULATE INLET LOAD - G/CU>*
** MIST ELIMINATOR
NUMBER
TYPE
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASSES
• X
<****** LB/MMPTU)
(****** LP/MMBTU)
GULF POWfR
SCHOLZ
1,2
CHATTAHOOCHEE
FLORIDA
C
******
******
80.0
25.0
23.0
*******
23.0
SABCOCK AND WILCOX
PULVERIZED COAL, DRV BOTTOM
BASE
Q/53
******** (******* ACFM)
******* (**** F)
23. ( 76 FT)
******* (»**** FT)
COAL
BITUMINOUS
29075.
11.00
******
5.00
******
?.50
2.5-5.0
********
******
34.5
*****
COLD SIDE
BUEU
99.5
1S1.7
( 12500 6TU/LB)
******
( 36 TPH)
( 305 F)
SALEABLE PRODUCT
WET SCRUBBING
LIMESTONE (CHIYODA 121)
CHIYODA INTERNATIONAL
CATALYTIC INC.
PROTOTYPE
RETROFIT
99.50
90.00
8/78
JET BUBBLING REACTOR
am
CHIYODA INTERNATIONAL
24 FT D1A.
STAINLESS STEEL
50.0
25.01 ( SjOOO ACFIO
.1 ( .010 GR/SCF)
CHFVRON
VERTICAL
2
2
-------
FPA UTILITY F6D SURVEY: DECEMBER 19?P - JANUARY 1979
SECTION 3
DES16N AKD PERFORMANCE DATA FOR OPERATIONAL FtD SYSTEMS
SYSTEM
** WATER LOOP
TYPE
•* BYPRODUCTS
BYPRODUCT NATURE
DISPOSITION
MINUTE ..ASH OF FIRST STAGE EVERY TWO WEEKS
CLOSED
GYPSUM
STACKED IN POND
, PERFORMANCE DATA ----
PERIOD MODULE AVAILABILITY OPERABIL1TY PLIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
SOZ PART. HOURS HOURS HOURS FACTOR
8/78 SYSTEM
744
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 8/78 EQUIPMENT: F6D SYSTEM* GENERAL
END DATE 8/78 COMMENTS:
OPERATION BEGAN ON AUGUST 3Q,197E.
AFFECTED MODULES: SYSTEM
• * PROdLEMS/SOLUTIONS/COMMENTS
START DATE 8/78 EOUIPMENT: FGD SYSTEM, GENERAL
END DATE 9/78 COMMITS:
NC INITIAL OPfRATlONAL PROPLEMS VIKt REPORTED.
AFFECTED MODULES; SYSTEM
9/78 SYSTEM
10/78 SYSTEM
720
720
*« PR06LEMS/SOLUTIONS/CCMWENTS
START DATE 10/78 ECUlFMENTi F6D SYSTEM* GENERAL
6NO DATE 11/78 COMMENTS;
NC MAJOR OPERATIONAL PROBLEMS WIRE REPORTED*
AFFECTED MODULES: SYSTlf!
PROBLEMS/SOLUTIONS/COMMENTS
START DAjE 1(3/78 EQUIPMENTS
END DATE 10/78 COMMkNTSS
A 1JC HOUR SCKDULED
AFFECTED MODULES: SYSTEM
GD SYSTEM* GENERAL
OUTAGE OCCURRED IN OCTOBER,
t1/7« SYSTEM
SYSTEM
100.0
720
744
** PROULEMS/SOLUTIONS/CCMHENTS
START DATE 12/78 tOUIfENT: F60 SYSTEM. GENERAL
6NO DATE 1/79 COMMINTSs
TfcERE HAVE BEEN NO UNPLANNED SHUTDOWNS 6Ufi?N6 B$CEI"BER AND JANUARY,
AFFECTED MODULES* SYSTfM
** PROBUEMS/SOLUTION5/COMMENTS
START DATE 13/78 ECUIFKINT: f66 SYSTEM* BtNERftL
END DATE
1/79 COMMENTS;
THE SYSTEM IS NOW BFJN6 OPERATED IN WHAT 1$ CALLED PHASE II OF THE
THE SYSTEM IS DELIBERATELY BEING. UPSET FROM EflUILIERIUM (PH, OXIDIZING AIR
IKPUT, ETC.) TO SEE HOW THE SYSTEM RESPONDS.
MODULES: SYSTEM
1/79 SYSTEM
100.0
744
96
-------
EPA UTILITY FGO SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FGD SYSTfMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - f.6/J
S02 EMISSION LIMITATION - liG/J
NET PLANT GENERATING CAPACITY - MV
CROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - Ml*
NET UNIT GENERATING CAPACITY WO/F6B - fU
EQUIVALENT SCRUBBED CAPACITY - MW
• * BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU.K/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - KJ/KG
RANGE HEAT CONTENT - B1U/LB
AVERAGE ASH CONTENT - X
RANGE ASH CONTENT - X
AVERAGE MOISTURF, CONTEKT - X
RANGE MOISTURE CONTENT - »
AVERAGE SULFUR CONTENT - I
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTEM - %
RANGE CHLORIDE CONTENT - X
FUEL FIRINfi RATE - M T/h
FUEL FIRING RATE - MW
** ESP
NUMBER
T»Pf
SUPPLIER
PARTICULATE DESIGN REMCVAl EFFICIENCY
»« F66 SYSTEW
SALEABLE PRODUCT/THROW AWAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
SYSTEM SUPPLIER
A-l FIRM
DEVftOPniNT LIVIL
NIK/RETROFIT
MRTJfULATI D6SI6N RIMBVAt
SO2 OESISN REMOVAL EFFICIENCY - X
COMMERCIAL DAT!
INITIAL START-UP
CONSTRUCTION COMPLETION
CONSTRUCTION INITIATION
CONTRACT AMARDI6
•* ABSORBER
NUMBER
TYPt
INITIAL START UP
SUPPLIER
NUMBER OF STAGES
DIMENSIONS
SHELL MATERIAL
SHELL LINER MATERIAL
BOILER LOAD/ABSORBER - X
6AS FLOW - CU.M/S
GAS TEMPERATURE - C
L/6 RATIO - L/CU.M
PRESSURE DROP - KPA
(****** LB/MMBTU)
( 1.200 LB/MMBTU)
INDIANAPOLIS POWER
PETERSBURG
3
PETERSBURG
INDIANA
A
******
516.
1180.0
532.0
515.0
52S.O
532.0
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
o/rr
******** (******* ACFM)
T37.2 t 279 F)
188. ( £16 FT)
******* (***** FT)
COAL
BITUMINOUS
25Q04.
********
9-10
********
10. 3-16.5
3.2S
1.5-4.5
********
****** '
23<«0
515
f 10750 BTU/LB)
******
(258 TPH)
COLD SIDE
RESEARCH COTTRELL
X 99.3
THROUAWAY PRODUCT
WET SCRUBBING
LIMESTONE
AIR CORRECTION DIVISION* UOP
EIBBf. AND HILL
FULL-SCALE
NIW
99. SQ
B«.00
12/77
12/77
8/77
1Q/7S
1/75
TURBULENT CONTACT ABSORBER
12/77
AIR CORRECTION DIVISION* UOP
3
30 X
30 X 30 X 1CO
CARBON STEEL
RUBBER
25.0
176.96
47.8
6.7
1.7
( 375000 ACFM>
( 50.0 6AL/1000ACF)
< 7.0 JN-H20)
97
-------
fP» UTILITY FGO SURVFY; DECEMBER 19?P - JANUARY 1979
SECTION 3
DES1FN AND PERFORMANCE DATA FOR OPERATIONAL FCD SYSTEMS
SUPfRFKAL GAS VELOCITY -
PARTICULATE INLET LOAD - C/CU.K
S02 INLET CONCENTRAT I0h - PPM
S02 OUTLfcT CONTRATION - PFK
S02 DESIGN REMOVAL EFFICIENCY - X
«* FANS
NUMBER
TYPE
ELIMNATOR
NUMBER
CONFIGURATION
PUMPS
SERVICE
RECYCLE
** TANKS
SERVICE
LIMESTONE SLURRY
WASTE SLURRY
RECYCLE
THICKENER OVERFLOW
«* REHEATER
TYPf
HEATING MEDIUM
TEMPERATURE BOOST - C
ENERGY MEQU1RFO
THICKENER
NUMBER
CONSTRUCTION MATERIAL
DIAMETER - "
OUTLET SOLIDS - X
WATER LOOP
TYPF
FRESH MAKEUP WATER ADDITION - LHfRS/S
.1
3400
385
85.0
BOOSTER
a
HORIZONTAL
NUMBER
8
NUMBER
( U.5 FT/S)
t .025 GR/SCF)
tttt
tttt
***<
* ***
INDIRECT HOT AIR
STEAM
1(^.7 ( 30 F)
24« MM BTU/HR.
CARBON STEEL
(165 FT)
88? GPM>
SO.!
CLOSED
55.6
REAGENT PREPARATION EQUIPMENT
NUMBER OF BALL MILLS
BALL MILL CAPACITY- M T/H
TREATMENT
CONTRACTOR
IUCS
( «Z.O TPH)
DISPOSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
FINAL
UNLINED POND
ON-SITE
TRUCK
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITV ^LIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
SOZ PART. HOURS HOURS HOURS FACTOR
12/77 SYSTEM
7*4
** PR08LEMS/SOLUTIONS/COMMENTS
START DATE 12/77 ttUJf!"ENT: FGD SYSTEM,
END DATE 12/77 COMMCNTSs
OPERATION Of ALL FOUR MODULES COMMENCED DURING DECEMBER.
AFFECTED MODULES: SYSTEM
•* PROBLEMS/SOLUTIONS/COMMENTS
START DATE 12/77 E8UIFMENT: AGITATOR
END DATE 12/77 PROPLTM: NOT DEFINED/SPECIFIED
98
-------
EPA UTILITY FGD SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMAKCE DATA FOR OPERATIONAL F6D SYSTEMS
---------- - ------------------------------- PERFORMANCE- DATA -------- - ---------------------------------
PERIOD MODULE AVAILABILITY GPERABIL1TY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
REPAIRS TO TH£ RECYCLE TANK AGITATOR WERE REQUIRED.
AFFECTED MODULES: A
SYSTEM 7*4
** PROBLEMS/SQLUTJONS/COMMENTS
START DATE 1/78 E6UIFWENT: BOILER-RELATED
END BATE 4/78 PROBUM: NOT DEFINED/SPECIFIED
PROBLEMS WERE fNCOUNTERED WITH THE FLYASH HANDLING SYSTEM FORCING FGt>
SHUTDOWN. THfc UNIT WAS RESTATED IN THE RIDDLE OF APRIL.
AFFECTED MODULES:
2/78 SYSTEM 672
** PROBLEMS/SOLUTIONS/COMWENTS
START DATE 2/7» E^UKHENT! PIPING
END DATE. J/7B PR081FMS WEATHER-RELATED COMPONENT FAILURE
PIPE FREEZE~Uf DAMAGE WAS REPAIRED.
AFFECTED MODULES: 5YST6K
3/7P SYSTEM 74*
*« PROBLIMS/SOLUTIONS/COMWENTS
START DATE 3/78 IQUIF'MtNT: F6D SYSTEMi GENERAL
END DATE 3/78 CONMtN'TSs
IMSULATION UK! INSTALLED DURING THE SYSTEM OUTAGE.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COKMENT&
START DATE 3/78 EQUIPMENT: THICKENER
END DATE 2/78 PROBLEM: MECHANICAL-RELATED COMPONENT FAILURE
A PRCKEN FINICN GEAR WAS REPAIRED DURING THE SYSTEM OUTAGE.
AFFECTED MODULES: SYSTEM
** PROGLEMS/SOLUTIONS/COMHENTS
START DATE 3/78 EGUIFKENT: INSTRUMENTATION
END DATE 3/78 COKMtNT: PREVENTIVE MAINTENANCE
IHSTRUNENTATI (N MAINTENANCE PERFORMED DURIN6 THE SYSTEM OUTAGE.
AFFECTED MODULES: SYSTEM
«/78 SYSTEM 720
•« PROBIEKS/SOLUTIONS/COMMENTS
START DATE 4/76 teUIfMENT: VALVES
END DATE 5/78 PROBLEM: NOT DEFINED/SPECIFIED
All CONTROL VM.VES U£RE RETURNED TO THE FACTORY FOR MODIFICATIONS.
AFFECTED MODULES: SYSTEM
5/78 SWIM 7*4
** PROBlEMS/SOLUTIONS/COMMENTS
START DATE 5/76 EQUIPMENT: BOILER-RELATED
END DATE 611% PRCtUEM: NOT DEFINED/SPECIFIED
THE MAIN POWER TRANSFORMER FAULTED CAUSING THE SYSTEM TO SHUTDOWN.
AFFECTED MODULES: SYSTEM
6/78 SYSTIM nO
7/7B SYSTEM 7*4
8/78 SYSTEM 7**
** PROBIEMS/SOLUTIONS/COMMENTS
START BATE 8/78 E6UIFMENT: PROCESS CONTROL
END DATE 9/76
PROBLEMS HAVE BEEN EXPERIENCED WITH CONTROLS.
AFFECTED MODULSSs SYSTEM
-------
EPA UTILITY F6D SURVFY: DECEI»PER I97f - JANUARY 1979
SECTION 3
DESIGN AND PERFOR*A»CE DAT* FOR OPERATIONAL F6o SYSTEMS
PERFORMANCE DATA "
PERIOD MODULE AVAILABILITY OPERA8ILITY ^LIABILITY UT1LI7ATIOM * REMOVAL PI" BOILER F6D CAP.
SCI2 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
ST»RT DATE 8/7B EOUHMENT: PIPING
END DATE 10/7fc
PHOBlfMS HAVE SEEN EXPERIENCED WI]H CONTROLS.
CRACKING PROBLEMS HAVE BEEN EXPERIENCED WITH FIBERGLASS PIpING. THt PROB-
LEM WAS SOLVED BY REPLACING SECTIONS WITH RUBBER LINED STEEL PIPING, NEK
FMP PJPINt, A I'D PROVIDING ADDITIONAL PIPE SUPPORTS.
AFfECTED MODULES: SYSTEM
9/7E SYSTEM 720
10/78 SYSTEM 744
** PR06LEMS/SOLUTIONS/CCMMENTS
START DATE 10/76 EGUII-KENT: GAS DAMPER
END DATE 10/78 PROBIEM: NOT DE FINED/SPE CI FI ED
B»PASS DAMPER I'ROBLfMS WERE EXPEDIENCE.
AFFECTED MODULES: SYSTEM
•* PROBLEMS/SOLUTIONS/COMMENU
START DATE 10/7B EOUI^ENT: F6D SYSTEM, GENERAL
END DATE 10/78 COMMENTS:
AN 502 CONHIINCE TEST WAS INVALID DUE TO P.VPASS DAMPER PROBLEMS.
AFFECTED MODULES: SYSTEM
11/78 SYSTEM 7ZO
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 11/76 EQUIPMENT: REAGfNT HANDLING
END DATF 11/78 PRODIEM; WEATHER-RELATED COMPONENT FAILURE
FPEm-UPS IN THE LIME DELIVERY SYSTEM WERE EXPERIENCED
AFFECTED MODULES: SYSTtM
*« PROaLEMS/SOLUTIONS/COMMENTS
START DATE 11/76 E6UHMENT: INSTRUMENTATION
END DATE 11/76 PROBLEM: NOT DEFINED/SPECIFIED
AN INSTRUMENTATION POWER TRANSFORMER FAILURE CAUSED ABOUT 6 DAYS OUTAGE.
AFFECTED MODULES: SYSTEM
1Z/78 SYSTEM 744
•» PROBLEMS/SOLUTIONS/COMMENTS
START DATE 1Z/78 EOUlfHENT: FGD SYSTEM, GENERAL
END DATE 1/79 COMMf.NTS:
OPERATIONAL HCIIRS ARE NOT VET AVAILABLE. THE UTILITY REPORTED THAT THE
SYSTEM HAS NO 1 YET SEEN ACCEPTED.
AFFECTED MODULES: SYSTEM
t/79 SYSTEM 744
100
-------
EPA UTILITY FGD SURVEY: DECEMBER 1V78 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMA&CE DATA FOR OPERATIONAL F6D SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
SO? EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - HH
GROSS UNIT GENERATING CAPACITY - »t>
NET UNIT GENERATING CAPACITY W/F6D - Mk
NET UNIT GENERATING CAPACITY WO/F6D - I'V
EQUIVALENT SCRUBBED CAPACITY - MU
** BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE 6AS FLOW - CU."/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT • M
STACK TOP DIAMETER - M
•* FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE NEAT CONTENT - KJ/KG
RANGE HEAT CONTENT - BTU/L6
AVERAGE A$H CONTENT - X
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - %
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - I
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - (
FUEL FIRING RATE - M T/H
FUEL FIRING RATE - MU
«* FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - KJ/KG
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - X
RANGE ASH CONTENT - X
AVERAGE HOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTEXT'- X
RANGE CHLORIDE CONTENT - >
FUEL FIRING RATE - M T/H
FUEL FIRING RATE - MU
•* FGD SYSTEM
SALEABLE PROOUCT/THROUAWAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICULATE DESIGN REMOVAL EFFICIENCY
S02 DESIGN REMOVAL EFFICIENCY - X
INITIAL START.-UP
** ABSORBER
KANSAS CITY POWER R LIGHT
HAWTHORN
KANSAS CITY
MISSOURI
B
8?.
******
K36.0
110.0
98.0
100.0
110.0
TYPE
INITIAL START UP
SUPPLIER
DIMENSIONS
SHELL MATERIAL
SHELL LINER MATERIAL
( .190 LB/MMBTU)
(»***** LB/MMBTU)
COMBUSTION ENGINEERING
DRY POTTOM, PULVERIZF.D-COAL
CYCLIC
0/53
235.95 < 500000 ACFM)
148.9 ( 300 F>
61. < ZOO FT)
******* {***** FT)
CO»L
BITUMINOUS
22795.
11.00
******
********
******
.60
******
********
******
45.3
*****
COAL
BITUMINOUS
26516.
u.oo
******
********
******
3.00
******
********
« *****
45.3
*****
< 9800 BTU/LP)
******
( 50 TPH)
( 1UOO BTU/Lfi)
******
( 50 TPH)
THROVAUAY PRODUCT
WET SCRUBBING
LIME
COMBUSTION ENGINEERING
BLACK AND VEACH
FULL-SCALE
RETROFIT
. X 99.0Q
70.00
11/72
MARBLE BED
11/72
COMgUSTION ENGINEERING
18 X 26 X 56
CARBON STEEL
CEILCOTE
101
-------
FPA UTILITY FED SURVEY: DECtKBER 1«7f - JANUARY 1979
SECTION 3
DESIGN AND PERFORMAKE DATA FOR OPERATIONAL FED SYSTfMS
INTERNAL MATERIAL
NUMBER OF NOJ7LFS
PRESSURE DROP - KPA
SUPERFHAL GAS VELOCITY - K/SEC
** fANS
TYPE
•* MIST ELIMINATOR
NUMPER
TYPE
CONSTRUCTION MATERIAL
CONFIGURATION
NUMBER OF PASSES
FREFBOARD DISTANCE - M
DEPTH . M
VANF SPACING - CM
VANF ANGLES
WASH SYSTEM
PRESSURE DROP - KPA
** PROCESS CONTROL CHEMISTRY
CONTROL VARIABLES
CONTROL RANGE
** TANKS
SERVICE
S02 SCRUBBER TOWER HOLCUP
** REHEATER
TYpf
HEATING MEDIUM
** THICKENER
NUBPER
DIAMETER - M
** WATER LOOP
TYpE
** SEA6FNT PREPARATION EQUIPMENT
NUMBER OF SLAKERS
SLAKER CAPACITY - M T/D
•* TREATMENT
TYPE
SUPPLIER
«* DISPOSAL
NATURE
TYPE
LOCATION
AREA - ACRES
CAPACITY - CU.H
316L SS
6f
?.? (13.0 IN'HZO)
3.0 ( 10.0 FT/S)
SCRUBBER l.D.
2
CHEVRON
FIBERGLASS
HORIZONTAL
2
J.05 <10.0 FT)
.18 < .6 FT)
7.6 t 2-00 IN)
45 DEG.
EI6HT WASH LANCES; CLARIFIED AND HAKE-UP WATER
.4 ( 1.5 IN-H20)
PH
NUMBER
• ***
IN-LINE
HOT WATER
1
35.1
CLOSED
1
51.7
150 PSI6
(115 FT)
( 57.0 TPH)
SOME STABILIZATION FROM FLYASH
NONPROPRIETARY
FINAL
UNLINED POND
ON-SITE
160.0
31JOB80 ( 2SAO.O ACRE-FT)
....................—.... ...._—. .PERFORMANCE DATA-------—-———— — — — ......_..—._
PERIOD MODULE AVAILABILITY OPERABUITY PLIABILITY UTILIZATION X REMOVAL PER BOILER FGfi CAP.
S02 PART. HOURS HOURS HOURS FACTOR
7/75
3A
3B
SYSTEM
42.0
74* 58*
** PROBLEMS/SOtUTIONS/COKMENTS
START DATE 7/75 E8UI H^NT: F6D SYSTEM, 6ENERAL
tND DATE 7/75 COMMENTS:
A-PIOBULE EUCOINTERED A LEAK IN THE CITY WATER LINE.
AFFECTED MODULES: 3A
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 7/75 EBUinwENT: DUCTWORK
END DATE 7/75 PROPlEMr CHEMICAL-RELATED PLU66IN6
102
-------
EPA UTILITY F6D SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 2
DESIGN AND PERFORMAKCE DATA FOR OPERATIONAL FED SYSTEMS
_. . PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABUITY fFLIABILITY UTILIZATION X REMOVAL PER BOILER F6ft CAP.
SOZ PART. HOURS HOURS HOURS FACTOR
ThE 6UCT TO Tit I.(. FAN BECAME PLUGGED.
AFFECTED MODULES: JA
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 7/75 EOUir«ENT: GAS DAMPER
END SATE 7/75 Pf'OBiF.M: MECHANICAL-RELATED COMPONENT INEFFICIENCY
At OUTLET DAMIF.R IN MODULE A MALFUNCTIONED.
AFFECTED MODULES: 3A
** PROELEMS/SOLUTIONS/COMMENTS
START DATE 7/75 EGUIFWENTI ABSORBER
tND DATE 7/75 PROBLEM: NOT DEFINED/SPECIFIED
MARBLES kim LOST FROM THE BED IN MODULE B.
AFFFCTEt MOftULtS; JK
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 7/75 t6LI!WENT! PIPING
END DAir 7/75 PROBt.fMt MECHANICAL-RELATED COMPONENT FAILURE
A SPRAY HtADFF WAS BROKEN IN MODULE B.
AFFECTED MODULES: SB
8/75
9/75
10/75
11/75
3A
SP
SYSTEM 744
** PROILIMS/SOLUTIONS/CCMMENTS
START BATE P/75 E6UII^£NT: FAN
END DATE fi/75 mOBUM: NOT DEFINED/SPECIFIED
TH I.D. rAK (OR HALf THt iQlLlR hAS LOST.
AFFiCTED MODULES: SVSUM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 8/75 ECUIFPENT; F6D SYSTEM, GENERAL
END DATE B/75 COMMBMTS:
TK PROBLEMS FK'COUNTERED IN JULY CONTINUED INTO AUGUST.
AFFECTED MODULES: SYSTEM
3A
3f
SYSTEM
69.0
Z3.0
720 358
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 9/75 EGUDHENT: FGD SYSTEM, GENERAL
END DATE 9/75 COMMENTS:
OUTAGE DUE TO CLEANING AND MECHANICAL REPAIRS. POTS, COVERS,AND MARBLES IN
TtiE MARBLE BFD OF MODULE JP WERE REPLACED*
AFFECTED MODULES: SYSTEM
3A
3P
SYSTEM
65.0
81.0
744 180
** PROBLEMS/SOLUTIONS/CCMMENTS
START DATE 10/75 EOUU'MENT: RECYCLE PUMP
END DATE lQ/75 PFOPHM: NOT DEFINED/SPECIFIED
MODULE 3A OUTAf,E UA S DUE LARGELY TO REPLACEMENT OF A RECYCLE PUMP MOTOR.
AFFECTED MODULES: 3A
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 10/75 teUITMENTt BOILER-RELATED
END DATE 10/75 COKMENT: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTAGE
A SCHEDULED B1ILER OVERHAUL REDUCED BOILER OPERATION HOURS*
AFFECTED MODULES: SYSTEM
3B
SYSTEM
720
103
-------
EPA UTILITY FGD SURVfY: DECEMBER 197E - JANUARY 1979
SECTION 3
DESIGN AND PERFOKKAKE DATA FOR OPERATIONAL F6D SYSTEMS
PERFORMANCE DATA ... ,.p
PERIOD MODULE AVAILABILITY OPERABUITY PLIABILITY UTILIZATION X REMOVAL PER BOILER FbD *"^»
SO? PART. HOURS HOURS HOURS FACTOR
** PRObLEMS/SOLUTIONS/COMMENTS
ST»RT DATE 11/75 EOUH^ENT: R01LER-RELATE D
END DATE 1/76 CCMMENTSI „ -BU»i,i THE
BCILFRS AMD SCRUBBERS WERE SHUT DOWN FOR A SCHEDULED TURBINE OVERHAUL. THt
SYSTEM IS SCHt.DUCED TO 60 PACK ON-LINE IN JANUARY 1976. SYSTEM WAS DO«N
ALL MONTH PFCHISE OF FR07EN EBUIPCENT AND LINE AND A MANPOWER SHORTAGE
TC A EOILIF" AKO TURblNE OVERHAUL ON ANOTHER UNIT AT THIS STATION.
AFFECTED MODULES: SYSTEM
3*
36
SYSTEM 744
1/76 3A
3P
SYSTEM 744
2/76 3A 37.0
3fl 1.0
SYSTEM 4*6 503
** PROBLEMS/SOLUTJONS/COMMEN1S
START DATE 2/76 f'UI^'ENT: SCPUPBITR
END DATE 2/76 H>CfUM: CHEMICAL-RELATED PLUGGING
SCRUBBER OUTAtfS RESULTED FROM PLUGGING IN THE SCRUBBER PED. CAUSED PY
CONVfRSlON fRCW AN UNDER-BF.O TO OVER-BED S'PRAY SYSTEM.
AFFECTED MODULES: SYSTEM
3/76 3A
SYSTEM 744
** PROSLEMS/SOLUTIONS/COMMENTS
START DATE 3/76 EGUJFKENT: SCRUBBER
END DATE 4/76 COMMtNTSs
RECONVIRSICN (F MODULI 3B'S SPRAY SYSTEM TO AN UNDFR-ilD CONFIGURATION HAS
BtIN COMPLETE I.
AFFECTED MODULES: 3B
** PROBliMS/SOLUTIONS/COMMENTS
START DATE 3/76 tOUllf|NT: 6AS DAMPER
END DATE 4/76 CQKMCNTS:
TK PYPASS SYSTEM HAS BEEN MODI FJ10 AND CHANGED TO A SLIDE-€ATE PAMPER
ARRANGEMENT.
AFFECTED MODULES: 39
4/76 3*
3P
SYSTEM 710
5/76 3A
ip
SYSTEM 744
** pROBLENS/SOLUnONS/COMMENn
START DATE 5/76 E6UIMENT: F6D SYSTEM, GENERAL
|ND OATE S/76 COMMtNTSs
THE SYSTEM WAS SHUT DOWN DURINf. THE MONTH DUE TO THE CONTINUATION OF MAN-
POWER SHORTAGE PROBLEMS. THE UTILITY DID PMFORM SOME CLEANING AND REPAIRS
DURING THE MOhTH.
AFFECTED MODULES: SYSTEM
6/76 3A 39.0
3B **.0
SYSTEM '20 505
104
-------
EPA UTILITY F6D SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL F60 SYSTEMS
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABIL1TY PLIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 6/76 EQUIPMENT: HIST ELIMINATOR
END DATE 6/76 PROBLEM: NOT DEFINED/SPECIFIED
THE UTILITY IS IN THE PROCESS OF MODIFYING THE DEMISTER WASH SYSTEM ON
BOTH UNITS 3 fND 4. THE WATER LANCES ARE BEING CHANGED FROM FRP TO CARBON
STEEL TO ATTEMPT TO PREVENT THE LCSS OF THE NOZZLES AND THE SUBSEQUENT
SCATTERING OF THE LANCES.
AFFECTED MODULES! SYSTEM
7/76 SYSTEM 744
** PROfilEMS/SOLUTIONS/COKMENTS
START DATE 7/76 EQUIPMENT: F6D SYSTEM, GENERAL
END DATE 8/76 CCHMfNTS:
THE UTILITY IS PRESENTLY CONVERTING THIS SYSTEM FROM LIMESTONE INJECTION
AND TAIL END SCRUBBING TO A LIME SLURRY BASED SCRUBBING SYSTEM.
AFFECTED MODULES: SYSTEM
8/76 SYSTEM 744
9/76 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 9/76 E6UIfl«ENT: F6D SYSTEM, GENERAL
END DATE 10/76 COMMENTS:
THE SYSTEM WAS VIRTUALLY OUT OF SERVICE THE ENTIRE REPORT PERIOD. MANPOWER
COMMITMENTS WERE SERIOUSLY HAMPERED BY A MAJOR EXPLOSION WHICH OCCURRED IN
TtE COAL MILL PULVERIZING AREA OF HAWTHORN NO. 5.
AFFECTED MODULES: SYSTEM
10/76 SYSTEM 744
11/76 3A
3B
SYSTEM 720
** PR08LEMS/SOLUTIONS/COMKENTS
START DATE 11/76 EfiUI FMENT: F6D SYSTEM, GENERAL
EN6 DATE 12/76 COMMENTS:
THE UNIT DID NOT OPERATE BECAUSE OF THE ONGOING MAJOR MODIFICATIONS BEING
IMPLEMENTED 0 It THE SCRUBBING SYSTEM. THE SYSTEM SHOULD BE READY FOR OPERA-
TION FEB 1. TFE UNIT MUST UNDERGO A SERIES OF TESTS TO INSURE COMPLIANCE
WITH CITY AND FEDERAL REGULATIONS.
AFFECTED MODULES: SYSTEM
12/76 3A
3B
SYSTEM 744
1/77 3A
36
SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
ST*RT DATE 1/77 EQUIPMENT: FGD SYSTEM. GENERAL
£HD DATE 3/77 COMMENTS:
UNIT NO. 3 WAS DOWN FOR THE ENTIRE MONTH OF JANUARY FOR THE COMPLETION OF
MCNDIFICATIONi AND REPAIRS ON THE SCRUBBERS AND BOlLER. THE UNIT BECAME
AVAILABLE FOR SERVICE AND TESTING ON FEE 7.THE UNIT'S MEASURED PARTICULAT£
EMISSIONS AT 1HE SCRUBBER OUTLET WAS 0.12 LB/MM BTU (WELL BELOW THE
REQUIRED 0.17 LB/MM BTU) BURNING APPROXIMATELY 2.0 z SULFUR COAL. THE
CONVERSION FRCM LIMESTONE TO LI«F HAS GONE SMOOTHLY- SOME INITIAL PROBLEMS
WITH PROCESS CHEMISTRY CONTROL HAVE BEEN CORRECTED. OTH£R «INOR PROBLEMS
INCLUDED PUMP MALFUNCTIONS AND LOSS OF SLAKIN6 WATER PRESSURE. SYSTEM
OPERATIONS ARi CONTINUING AT OX SOLIDS AND 100* BLOWDOttN WITH A FRESH
WATER MAKE-UP CF APPROXIMATELY 7.0 6PM/MW.
105
-------
EPA UTILITY FGO SURVFY: OECCMBEf 197fr - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL F6D SYSTEMS
PERFORMANCE DATA "T«rw r»B
PERIOD MODULE AVAILABILITY flPERABlLITI PLIABILITY UTILISATION X REMOVAL PER BOILER F6D S*r-
302 PART. HOURS HOURS HOURS FACTOR
2/77 3A
36
SYSTEM
3/77
4/77
5/77
7/77
AFFECTED MODULES: SYSTLM
£8.0
t<>. 0
.00
672 383
3»
3B
SYSTEM
3A
3B
SYSTEM
99.0
85.0
57«0
57.0
744
482
72Q 7ZO
»* PR06LEMS/SOLUTIONS/COMMENTS
START DATE 4/77 ECUIfl»ENT: FED SYSTEM, GENERAL
END DATE 5/77 COMMITS:
ThE SYSTEM IS NOW OPERATING AT ABOUT 15-25 PERCENT SLOWDOWN.THE PH CONTROL
SYSTEM OPERATIONS HAVE BEEN EXCELLENT.DURING HAY THE BOILER BURNED GAS FOR
216 HOURS (NO I INCLUDED IN OPERAEILITY FIGURES). SQ2 REMOVAL EFFICIENCY IS
ESTIMATED AT ".(7-60 PERCENT FOR BOTH MODULES tALTHOU6H ACTUAL TESTS HAVE NOT
BEEN RUN FOR ABOUT A Y£AR AND A HALF. BOTH MODULES ARE CURRENTLY OPERATING
SIMULTANEOUSLY.
AFFECTED MODULES: SYSTEM
3A
3B
SYSTEM
5S.O
58.0
6/77 SYSTEM
744
720
736
720
** PROBLEMS/SOLUT10NS/COKMENTS
START DATE 6/77 16UIFMENT: B01LER-RELATFD
END DATE 6/77 COMPtNTS:
ThE UNIT FIRES NATURAL GAS THROUGHOUT THE MONTH WITH THE EXCEPTION OF A
72-HOUR PtflOl DURING WHICH COAL MS FIRED AND THE SCRUBBERS MERE OPERATED
FOR SCRU&BfR FfRSONNEL PURPOSES ONLY.
AFFECTED MOBULESj SYSTEM
PROBLEMS/-SOLUTIONS/COMMENTS
START DATE 7/77 tBUIf'MENT: BOILER-RELATED
END DATE 9/77 COWW tNTS:
TtiE UNIT FIREt NATURAL GAS FOR THE ENTIRE PERIOD, MAKING SCRUBBER OPERATION
UNNECESSARY.
AFFECTED MODULES: SYSTEM
3A
3d
SYSTEM
10.0
10.0
8/77 SYSTEM
9/77 SYSTEM
10/77 SYSTEM
744
744
720
7*4
744
744
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 10/77 ECU1FKENT: BOILER-RELATED
END DATE 1l/77 COMMENTS:
THE UNIT WAS SHUT DOWN BECAUSE OF A LACK OF NATURAL GAS UNTIL NOVEM8FR 3*
WHEN IT BEGAN FIRING COAL.
-------
EPA UTILITY FGO SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORKAKE DATA FOR OPERATIONAL FGD SYSTEMS
------------------------------------------ PERFORMANCE DATA ------------------------------------------
PERIOD MODULE AVAILABILITY OPERABILITY PLIABILITY UTILIZATION X REMOVAL PER BOILER F60 CAP.
S02 PART. HOURS HOURS HOURS FACTOR
™ *"•"* •"* *™ • •• »™ «- — «-«l_ _<•«_•» _•«,__ V ••»••. BK ••• »» -1 fc -i • «••••»•-
** PROBLEMS/SOLOT10NS/COMNENTS
START DATE 10/77 EGUIftfENT: ABSORBER
END DATE 11/77 PRCBIFB: NOT DEFINED/SPECIFIED
DURING eOILER DOWN TI|"E,THF REACTION TANKS AND SPRAY HEADERS WERE REPLACED
BY STAINLESS STEEL COMPONENTS; THE INTERCONNECTING PIPING Is RUBBER LINED.
AFFECTED MODULES: SYSTEM
11/77 SYSTEM 57.0 720 720 4110
12/77 SYSTEM 47.0 744 744 3460
** PROBLEWS/SOLUT10NS/CCMMENTS
START DATE 12/77 t CiUI f WENT: FGD SYSTEM, GENERAL
END DATE 1 /7« COKMFNT: PREVENTIVE MAINTENANCE
THE FG6 MODULES WERE CLEANED DURING BOILER OUTAGES (THERE WERE NO FGD-
RELATF.D OUTAGfS).
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/CflttHENTS
START DATf 12/77 tOUIfWENT: PIPING
END DATE 1/78 PROBLEM: MECHANICAL-RELATED COMPONENT INEFFICIENCY
SOME LEAKS IN THE FED PIPING WERE REPLACED.
AFFECTED MODULES: SYSTEM
1/7E SYSTEM 7«4 7*4
Z/78 SYSTEM 30.0 672 672 1V80
** PROBLEMS/SOLUTIONS/CnPMENTS
START DATE 2/76 ESUII'MENT: BOILER-RELATED
END DATE 3/78 PROBLFM: CHEMICAL-RELATED EROSION
DIKING FEKRUAKY THE UNIT WAS DOWN FOUR TIMES WITH ECONOMIZER AND WATER
WAIL LEAKS(5(H HOURS TOTAL). WATER WALL LEAK REPAIR AS WELL AS ACID
CLEANING or THE BOILER CAUSED ADDITIONAL OUTAGE TIME DURING THE LAST WEEK
OF MARCH.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE lilt 66UI ffiENT: BOI LER»R|!LATE D
END (ATE 3/78 COMMENT; PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTAGE
A TWO WEEK OUTAGE WAS SCHEDULED DURING MARCH FOR SEASONAL MAINTENANCE.
AFFECTED MOBULfcS: SYSUM
3/78 SYSTEM 6J.O 7*4 7**
4/78 SYSTEM 44.0 7?0 T20 3270
** PROBLEMS/SOLUT10N&/COMMENTS
START DATE 4/78 EOUI'MENT: DUCTWORK
END DATE 5/78 f'RCBlEMs NOT DE FINED/SPF CI FIEO
AN AlK PPt;H£A1FR FIRE DISCOVERED ON HAT 12 CAUSED DAMAGES THAT FORCED
MODULE A TO e» DOWN THE REST OF THE MONTH.
AFFECTED MODULES: !A
** PROIiLEMS/SOLUTIONS/COMMtNTS
START DATE 6/78 EQUIPMENT: FGD SYSTEM, GENERAL
END DATE 7/71 COMMtNTSt
NC INFOmilOh WAS AVAILABLE FOR THE JUNi-JULY REPORT PERIOD DUE TO A PLAN
STRIKE.
AFFECT6D MODULES: SYSTEM
S/7S SYSTEM 744 744
tin SYSTEM 720
7/78 SY8T1M 744
107
-------
EPA UTILITY F&D SURVEY: DECtMPER 197f - JANUARY 1979
SECTION 3
DESKN AND fERFORMAKCf DATA FOR OPERATIONAL F«D SYSTFBS
PERIOD HOODIE AVAILAP1L1TV OPERAPUITY KELIA&1LITY UTILIZATION * REMOVAL PER BOILER FGD CAP-
S02 PART. HOURS HOURS HOURS FACTOR
6/7R SYSTEM
744
•* PROBLEMS/SOLUTIONS/COMMENTS
START DATE 8/78 E6UKKENT: FGD SYSTfU. gtNtRAt
ENC DATE 9/78 COMMENTS:
THE SCRUBEIK6 SYSTEM IS OPERATING EVEN THOU6H THE UTILITY IS STILL IN THE
H1DST OF A STFIKE. FGD PERFORMANCE FIGURES ARE NOT AVAILABLE SINCE THE
UTILITY u *(n RECORDING FGD SYSTEM OPERATING HOURS DURING THE STRIKE.
AFFECTED MODULES: SYSTEM
9/78 s*STE» 720
10/78 SYSTEM 744
** PROBLEMS/SOLUTIONS/CCHMENTS
START DATE 10/78 EOUlfMENT: FGD SlfSTEH, eENERAl
END DATE 11/78 COMMtf.TS:
ALTHOUGH THE STRIKE IS OVER NO OPERATIONAL DATA IS AVAILABLE. THE FC-D
SYSTEM IS IN OPERATION.
AFFECTED MODULES: SY$*
11/78 SYSTEM 720
12/7B SYSTEM 744
** PRObLEMS/SOLUTIONS/COMMENTS
START DATE 12/78 ESUITPENTl FGD SYSTEM, GENERAL
£No DATE 1/79 COMMfNTS:
HOURS OF OFER-'TjON ARE STILL NOT AVAILABLE. THE FGD SVSTEM IS IN OPERATIC
BUT AT PRESENT PERSONNEL ARE BEING REASSIGNED PREVENTING ACCURATE DATA
RECORDING.
AFFECTED MODULES: SYS*
1/79 SYSTEM 744
108
-------
EPA UTILITY FG6 SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL F6D SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
C1T»
STATE
REGULATORY CLASSIFICATION
PARTKULATE EMISSION I IMITATION - K6/J
S02 EMISSION LIMITATION - MG/J
NET PLANT GENERATING CAPACITY - FtV
CROSS UNIT GENERATING CAPACITY - Mh
NET UNIT GENERATING CAPACITY W/FGD - M'.
NET UNIT GENERATING CAPACITY WC/FGD - f-W
EQUIVALENT SCRUBBED CAPACITY - MU
** BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU.P/S
FLUE GAS TEMPERATURE - C
STACK HEI6HT - M
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - KJ/KG
RANEE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - X
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - Z
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTEKT - X
RANGE CHLORIDE CONTENT - X
FUEL FIRING RATE - M T/H
FUEL FIRING RATE - HW
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - KJ/KG
RANGE HEAT CONTENT - B1U/LB
AVERAGE ASH CONTENT - 2
RANfE ASH CONTENT - *
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - Z
FUEL FIRING RATE - M T/H
FUEL FIRING RATE - »U
** FGD SYSTEM
SALEABLE PRODUCT/THROWAUAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIfm
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICULATE DESIGN REMOVAL EFFICIENCY
So2 DESIGN REMOVAL EFFICIENCY - X
INITIAL START-UP
** ABSORBER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
DIMENSIONS
SHELL MATERIAL
SHELL LINER MATERIAL
KANSAS cm POWER » LIGHT
HAWTHORN
( .190 LR/MMBTU1
(****** LB/MMBTU)
KANSAS CITY
MISSOURI
B
8?.
******
83A.O
110.0
98.0
10D.O
110.0
COMBUSTION ENGINEERING
DBY BOTTOM, PULVERIZFD-COAL
CYCLIC
0/55
235.95
148*9
61.
*******
COAL
BITUMINOUS
2J795.
11.00
******
********
******
.60
******
***** ***
******
45.3
*****
COAL
BITUMINOUS
26516.
14.00
******
********
******
3.00
******
***** ***
******
45.3
*****
( 500000 ACFFi)
( 300 F>
C ZOO FT>
(***** FT)
( 9800 BTU/Lfl)
******
( 50 TPH)
C 11400 BTU/LEO
******
f 50 TPH)
THROWAWAY PRODUCT
b£T SCRUBBING
LIMg
COMBUSTION ENGINEERING
BLACK AND VEACH
FULL-SCALE
RETROFIT
99.00
70.00
8/72
MARBLE BED
8/72
COMgUSTION ENGINEERING
18 X 26 X 5
-------
EPA UTILITY F6D SURVEY: DECEMBER 197? - JANUARY 1979
SECTION 3
DESIGN AND PERFOFMAKCE DATA FOR OPERATIONAL FGD SYSTEMS
INTERNAL MATERIAL
NUMPER OF NOZZLES
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/SFC
3UL SS
6^
7.2
3.0
(13.0 IN-H20)
C 10.0 FT/S)
** FANS
TYPt
*« KIST ELIMINATOR
NUMPER
TYPE
CONSTRUCTION MATERIAL
CONFIGURATION
NUMBER OF PASSES
FREEBOARD DISTANCE - *
DEPTH . M
VANE SPACING - CM
VANC ANGLES
MASH SYSTEM
PRESSURE CROP - KPA
** PROCESS CONTROL CHEMISTRY
CONTROL VARIABLES
CONTROL RANGE
*• TANKS
SERVICE
502 SCRUBBED TOWER HOLDUP
•* REHEATER
TYPE
HEATING
** THICKENER
NUMBER
DIAMETER - M
SCRUBBER I.D.
CHEVRON
FIBERGLASS
HORIZONTAL
2
3.05 (10.0 FT)
.18 t .6 FT)
7.6 < 3.00 IN)
45 DEG.
EIGHT WASH LANCES; CLARIFIED AND MAKE-UP WATER
.4 < 1.5 IN-H20)
PH
«.5-6.5
NUMBER
****
IN-LINE
HOT WATER 325f, 150 PSIG
35.1
(115 FT)
** WATER LOOP
TYPF
** REAGENT PREPARATION EQUIPMENT
NUMBER OF SLAKERS
SLAKER CAPACITY - M T/t
** TREATMENT
TYPE
SUPPLIER
** DISPOSAL
NATURE
TYPt
LOCATION
AREA - ACRES
CAPACITY - CU.M
CLOSFD
1
51.7
( 57.0 TPH)
SOME STABILIZATION FPOM FLYASH
NONPflOPRIETARV
UNL1NEO POND
ON-SITE
160. 0
213088Q
( 2560.0 ACRE-FT)
—.. ... PIRFORMANCF, DATA ..................................
PERIOD NODULf AVAILABILITY CAPABILITY FtLIAbJLITY UTILIZATION X REMOVAL PER BoILER FGO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
7/75 4A
SYSTEM
g.O
744 518
«* PROBLEMS/SOLUTIONi/COMMENTS
START BATE 7/75 ICUlFPENTi ABSORBiR
END DATE 7/75 PROBirHl CHEMlCAL-RELATfC PLU6GIMC
BOTH MODULES TNCOUNTERED MARBLE BED PLUG61N6 AND STRAINER PROBLEMS.
AFFECTED MOBULtS: SYSTEM
8/75 4«
110
-------
EPA UTILITY FCC SURVEY: DECEMBER 1978 - JANUARY
SECTION 3
DESIGN AND FERFOR«AI\CE DATA FOR OPERATIONAL FGD SYSTEMS
. PERFORMANCF DATA • —— .—.
PERIOD NODULE AVAILABILITY CPERABILITY (PLIABILITY UTILIZATION Z REMOVAL PER BOILER FED CAP.
S02 PART. HOURS HOURS HOURS FACTOR
*B
SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 8/75 Efltl WENT: F60 SYSTEM, GENERAL
END DATE 8/75 CCMMfNTS:
A NEW PROCESS CHEMISTRY is BEING TRIED- ATTEMPT INS TO RUN AT 1001 SLOWDOWN
AKD NEAR ZERO PERCENT SOLIDS WITH PH BEING MAINTAINED AT 5 WITHOUT LIME
STONE INJECTION. EMPHASIS IS BEING PLACED ON PARTICULATE CONTROL.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMNENTS
START DATE 8/75 EfiUIH*;ENT: FAN
END DATE fl/75 PSOBUM: NOT DEFINED/SPFCIFIED
LOST HALF OF TOILER TO I.D. FAN OUTAGE CAUSING BOTH FGD MODULES TO BE SHUT
DCUN TO PREVENT LOSS OF THE ENTIRE UNIT.
AFFECTED MODULES: SYSTEM
9/75 4* 52.0
4P 53.0
SYSTEM 720 3'5
** PROBLEMS/SOLUTIONS/CCMMENTS
START DATE 9/75 L«UIf*ENT: FGD SYSTEM, GENERAL
END DATE 9/75 COMMENTS:
SCRUPBER MODULES WERE RETURNED TO SERVICE ON SfPT. 21 AFTER REPLACEMENT OF
THE ORIGINAL I.D. FAN ON NODULE 48 SIDE.
AFFECTED MODULES: SYSTbM
** PROtiLEMS/SOLUTIONS/COMMENTS
START DATE 9/75 [GUITKENT: SCRUBBER
END DATE 9/75 COMMf-NTS:
THE HARBIE BED WAS REMOVED FROM MODULE A AND REPLACED WITH A STAINLESS
S7tEL PERFORATED BED. THf MARBLES WIRE REMOVED BECAUSE OF CONTINUING
OPERATIONAL DIFFICULTIES. NEVI DESIGN RESULTED IN INCREASED AVAILABILITY
AKD CONTINUED HIGH PARTICULATE EFFICIENCY (97 PERCENT).
AFFECTED MODULES: 4A
10/75 4A 60.0
4B 91. t
SYSTEM 7*4 721
*« PRO^LEMS/SOLUTIONS/COMMENTS.
START DATE 10/75 LCUIF-MENT: FGO SYSTEM, GENERAL
END DATE 10/75 COMMtNTS:
THE EXPERIMENT WjTH A PROCESS CHEMISTRY OF 100% BLOWDOWN AND ZERO PERCENT
SOLIDS IS STILL IN PROGRESS. S02 REMOVAL EFFICIENCY IS IN THE 50 TO 60
PERCENT RANGE. KCPfcL IS CONCENTRATING ON PARTICULATE CONTROL.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 10/75 EOUIFMENT:
END DATE 10/75 f-fOBIFM: NOT DEFINED/SPECIFIED
THERE WAS A MINOR BOILER RESTRICTION ON THE A-SIDE BETWEEN THE ECONOMIZER
AND THE INLET DRAFT DUCT.
AFFECTED MODULES: 4A
11/75 4A
4B 99.0
SYSTEM 72Q 720
** PROGLEMS/SOLUT10NS/COMMENTS
START DATE 11/75 E6UIFMENT: RECYCLE TANK
END DATE 11/75 PROBIEM: CHEMICAL-RELATED PLUGGING
MODULE 4A WAS SHUT DOWN DURING THE REPORT PERIOD DUE TO LOSS OF DRAFT
THROUGH THE DLCTWORK FROM THE ECONOMIZER TO THE AIR PREHEATER, RESULTING
IK FREQUENT PLUGGING OF THE REHEATER UNTIL THE SYSTEM WAS SHUT DOWN.
111
-------
EPA UTILITY F6D SURVEY: DECEMBER 197F - JANUARY 1979
SECTION 3
DESIGN AND PERFORMAhCE PAT* FOR OPERATIONAL FGD SrSTFMS
PERFORMANCE DATA " ~
PERIOD MODULE AVAILABILITY CPERABILITY KfLIABlLlTY UTILIZATION * REMOVAL PER BOILER FGO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
12/75
AFFECTED NODULES: AA
4A
4P
SYSTEM
16.C
744 640
1/76
PR00LEPS/SOLUTIONS/COMMENTS
START DATE 12/75 EeuiFKENT: BOILER-RELATED
END DATE 12/75 COMMtK'T: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTA6E
TtC ECILEfc OU1A6E OF 5 DAYS WAS DUE TO A SCHEDULED OVERHAUL.
AFFECTED MODULES: SYSTEM
4A
4E>
SYSTEM
744
2/76
«* PROBLEMS/SOLUTIONS/COKMENTS
START DATE 1/76 E6UIH»ENT: F6D SYSTEM, GENERAL
END DATE 1/76 PPCBtEM: NOT DEFINED/SPECIFIED
T*E SYSTEM VKi DOWN ALL KONTH DUE TO FROZEN EQUIPMENT AND LINES
WAS ASSIGNED 10 A BOILER AND TURBINE OVERHAUL ON ANOTHER UNIT.
AFFECTED MODULES: SYSTEH
MANPOWER
4A
46
SYSTEM
78.0
696
579
** PROeLEWS/SOLUTIONS/COMRENTS
START DATE 2/76 CCUIIKENT: DUCTWORK
END DATE 2/76 fROBird: NOT DEFINED/SPECIFIED
MODULE 4A WAS SHUT DOWN THE ENTIRE nONTH BECAUSE OF CONTINUING LOSS OF
DRAFT THROUGH THE DUCTWORK FROH THE ECONOMJSER TO THE AIR PREHEATER.
AFFECTED MODULES: 4A
** PROBLEWS/SOLUTIONS/COHMENTS
START DATE 2/76 ECUjrKENT: SCRUPBFR
tNO DATE 2/76 PFOeiEH: CHEMICAL-RELATED PLUG6INE
MODULE e EXPERIENCED PLUGGING IN THE NARBLE BED.
AFFECTED MODULES: 46
3/76
4/76
5/76
«* PROBLEMS/SOLUTIONS/COMMENTS
START DATE 2/76 E6UIFKENT: RECYCLE PUMP
END DATE 2/76 PROPlFM: NOT D E FINE D /SPE CI F I ED
A RECYCLE PUH F BROKE DOWN ON THE B-SIDE.
AFFECTED MODULES: 4D
4A
4E!
SYSTEM
3.0
744
706
•* PROBLEWS/SOLUTIONS/COKMENTS
ST*RT DATE 5/76 EfiUIFffENT: 6AS DAMPER
END BATE 4/76 COMMENTS!
THE UNIT'S 6YFASS SEALS WERE REPLACED WITH SLIDE-BATE DAMPERS.
AFFECTED MODULES: SYSTEM
4A
4e
SYSTEM
4A
4B
SYSTEM
42.0
40.0
27.0
27.0
720 550
744
** PR06LEMS/SOLUT10NS/COMMENTS
START DATE 5/76 EOUIFMENT: RECYCLE TANK
END DATE 6/76 PROBtFM: CHEMICAL-RELATED PLUGGING
112
-------
EPA UTILITY FGD SURVEY: DECFMBER 1978 - JANUARY 1°79
SECTION 3
DESIGN AND PERFOKMAfitE DATA FOR OPERATIONAL FGD SYSTEMS
_. PERFORMANCE DATA-'
PERIOD NODULE AVAILABILITY OPERAB1LITY RELIABILITY UTILIZATION
% REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
OhE OF THE REPEAT TUBE BUNDLES WAS REMOVED TO FACILITATE CLEANING AND
MAINTENANCE D I.E TO PLUGGING PROBLEMS.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUT10NS/COKMENTS
START DATE 5/76 EQUIPMENT: FGD SYSTEM, GENERAL
END DATE 6/76 COMMFNTS:
CtRRENTLY, THE UTILITY IS IN THE PROCESS OF MODIFYING THE SCRUBBING SYSTEM
FfcOM * LIKESTINE INJECTION AND TAIL-END SCRUBBING BASED SYSTEM TO A LIME
SLURRY BASED SYSTEM.
6/76
11/76
4A
48
SYSTEM
AFFECTED MODULES: SYSTEM
65.p
5.0
7/76 SYSTEM
8/76 SYSTEM
9/76 SYSTEM
720 460
744
744
720
** PPOBLEMS/SOLUTIONS/COMMENTS
START DATE 9/76 EGUI »I*ENT: FGD SYSTEM, GENERAL
END DATE 10/76 COMMfNTS:
THE SYSTEM WAS OUT OF SERVICE VIRTUALLY THE ENTIRE REPORT PERIOD DUE TO A
MAJOR EXPLOSICN WHICH OCCURRED IN THE COAL MILL PULVERIZING AREA OF UNIT 5
WHICH SERIOUSLY HAMPERED OPERATIONS AND MANPOWER COMMITMENTS.
AFFECTED MODULES: SYSTEM
10/76 SYSTEM
4A
4E>
SYSTEW
91.0
744
720 7fi6
1/77
** PROBLEMS/SOLUTIONS/COPWENTS
START DATE 11/76 EQUIPMENT: FGD SYSTEM, GENERAL
E«6 DATE 13/76 COMMtNTS:
TtiE UTILITY- rS-IN THE PROCESS" Of CCNVER TING THE SYSTEH TO A NET LIME
SCRUBBING SYS1FM, WHICH WILL COMMENCE OPERATIONS IN THE FIRST PART OF
JANUARY.
AFFECTED MODULES: SYSTEM
12/76 4A
4B
SYSTEM
4A
4E
SYSTEM
85.0
74.0
744
744
572
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 1/77 EBUIFMENT: FGD SYSTEM, GENERAL
END DATE 3/77 COMMCNTS:
THE UNIT BECAKE AVAILABLE FOR SERVICE IN THE LIME SCRUBBING MODE ON JAN. 1
1577. TESTING FOR COMPLIANCE WITH PARTICULATE CODES OCCURRED DURING THE
MONTH. THE UNIT WAS FOUND TO MEET THE EMISSION REGULATION OF 0.17 LB/MM BT
BIRNIN6 2.CX 5ULFUR COAL. SYSTEM OPERATIONS ARE STILL CONTINUING AT OX
SCLjDS AND 10CZ BLOUDOWN. THE FRESH WATER MAKE-UP RE8UIREMENT IS 7/0 6PMVM
AFFECTED MODULES: SYSTEM
2/77 4A
4B
SYSTEM
3/77 4A
80.0
50.0
82.0
672 591
113
-------
EPA UTILITY F&D SURVEY: DECEMBER 1<>7fr - JANUARY 1979
SECTION 3
DESIGN AND PERFORKAIiCE DATA FOR OPERATIONAL FGD SYSTEMS
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPEPABIL1TY PLIABILITY UTILIZATION * REMOVAL PER BOILER FGD <•**•
S02 PART. HOURS HOURS HOURS FACTOR
4B 97.0
SYSTEM 74* 539
*/77 4» 43.0
*B 43.0
SYSTEM 720 720
«* PROBLEMS/SOLUTIONS/COMMENTS
START DATE 4/77 EOUIH^ENT: F6D SYSTEM, GENERAL
END DATE 5/77 COMMITS:
THE SYSTEM IS NOW OPERATING WELL AT ABOUT 15-25X SLOWDOWN. THE PH CONTROL
SYSTEM OPERATIONS HAVE BEEN EXCELLENT. DURING MAY THE BOILER BORNEO 6AS FO
41* HOURS (NOT INCLUDED IN THE OPERAB1LITY VALUES). SOZ REMOVAL EFFICIENCY
IS ESTIMATED M 50-60* FOR BOTH MODULES. ALTHOUGH ACTUAL TESTS HAVE NOT
BEEN RUN FOR
-------
EPA UTILITY FGD SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL F60 SYSTEMS
PERIOD
10/77
11/77
12/77
1/78
2/7$
PERFORMANCE DATA
MODULE AVAILABILITY OFERASILITY IEL1ABIL1TY UTILIZATION X REMOVAL PER BOILER
S02 PART. HOURS HOURS
4P
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
73. C
74.0
69.0
70.0
68.0
720
744
720
744
744
25.0 672
589
550
496
520
508
672
FSD CAP.
HOURS FACTOR
550
496
520
508
167
3/78
4/78
5/78
6/78
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 2/78 fCUIFWENT: BOJLCR-RELATEO
END DATE 3/78 PROBLEM: NOT DEFINED/SPECIFIED
TttE UNIT kAS UOWN THREE TIKES DURING FEBRUARY FOR NON-SCRUBBER RELATED
PROBLEMS AND CNCE FOR A FUEL SAFETY TRIP. IN MARCH THERE WERE THREE
ECONOMI7tfi LEAK OUTAGES (APPRO*. 231 HOURS).
AFFECTED MODULES: SYSTEC
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 2/78 EQUIPMENT: SCRUBBER
END DATE 3/78 F-ROBlfM: NOT DEFINED/SPECIFIED
THE UNIT HAS tOWN ONCE IN FEBRUARY AND A6AIN FOR 32 HOURS IN MARCH FOR
GENERAL MAINTENANCE.
AFFECTED MODULES: SYSTEM
7/78
8/78
SYSTEM
SYSTEM
56.0
76.0
744
720
744
720
406
220
** PROBLEMS/SOLtiTIONS/COMMENTS
START DATE 4/78 E6UIFPENT: THICKENER
END DATE 5/7S PROBLEM: CHEMICAL-RELATED PLUGGING
F€D OUTAGE IN MAY WAS DUE TO CLAPIFIER PLUGGING.
AFFECTED MODULES: SYSTEM
** FRObLEMS/SOLUTIONS/COMMENTS
START-BATE 4/7« tOUI IMENT: F6D SYSTEM. GENERAL
END DATE 5/76 COMMENT: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTAGE
APRIL OUTAGE TIME WAS FOR SCHEDULED GENERAL MAINTENANCE AND CLEANING.
AFFECTED MODULES: SYSTEM
SYSTEM
SYSTEM
42. C
744
720
7(4
403
** PfiObLEMS/SOLUTIOKS/COMMENTS
START DATE 6/78 tOUIFttENT: FGD SYSTEM* GENERAL
END DATE 7/78 COMMENTS:
NO INFORMATION WAS AVAILABLE FOR THE JUNE-JULY PERIOD BECAUSE OF A PLANT
STRIKE.
AFFECTED MODULES: SYSTEM
SYSTEM
SYSTEM
744
744
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 8/78 £CUI FKENT: F6D SYSTEM. GENERAL
END DATE 9/78 COMMENTS:
THE SCRUBBING SYSTEM IS OPERATING ALTHOUGH THE UTILITY IS STILL IN THE
MIDST OF A STUKE. FGD PERFORMANCE FIGURES ARE NOT AVAILABLE BECAUSE THE
UTILITY IS N01 RECORDING FGD OPERATION HOURS DURING THE STRIKE.
AFFECTED MODULES: SYSTEM
9/78 SYSTEM
720
115
-------
UTILITY F6D SURVEY: OECIMBFR 197E - JANUARY 1979
SECTION 3
DESIGN AND PERFOPKAKCE DATA FOR OPERATIONAL FGD SYSTEMS
PERFORMANCE DATA - — —— ..-...»-- —— ....
PERIOD MODULE AVAILABILITY OPE RAP, I LIT Y PLIABILITY UTILIZATION * REMOVAL PER BOILER f60 CAP.
S02 PART. HOURS HOURS HOURS FACTOR
10/78 SYSTEM 7*4
•* PR06LEMS/SOLUTIONS/COMKENTS
START DATE 10/78 SOU I (^ENT: FGD SYSTEM, GENERAL
END DATE 11/78 COMMENTS:
ALTHOUGH THl STRIKE IS OVER NO OPERATIONAL DATA IS AVAILABLE. THE FGD
SYSTEM IS IN OPERATION.
AFFECTED MODULES: SYS*
11/78 SYSTEM 7?0
12/7? SYSTEM 7*4
»* PROBLEMS/SOLUTIONS/COMMENTS
START DATE 12/78 ESUIfWENT: F6D SYSTEM, GENERAL
END DATE 1/79 COMMENTS:
HCURS OF OPEPPTjON ARE STILL NOT AVAILABLE* THE FGD SYSTEM IS IN OPERATIC
BIT AT PRESEN1 FERSONEL ARE BEING REASSIGNED PREVENTING ACCURATE DATA
RtCORDING.
AFFECTED MODULES: SYSTLM
1/79 SYSTEM 74*
116
-------
EPA UTILITY FGO SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL F6D SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - (,6/J
NET PLANT GENERATING CAPACITY - nw
GROSS UNIT GENERATING CAPACITY - Ml.
NET UNIT GENERATING CAPACITY U/FGD - M I.
NET UNIT GENERATING CAPACITY Wfi/FGD - "V
EQUIVALENT SCRUBBED CAPACITY - nU
** BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU.F/S
FLUE 6AS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAMETER - I"
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - KJ/KG
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - *
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTEUT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
FUEL FIRING RATE - M T/H
FUEL FIRING RATE - MU
** PARTICULATE SCRUBBER
NUMBER
TYPE
SUPPLIER
NUMBER OF STAGES
SHELL MATERIAL
LINING PATCH *L
NUMBER OF NOZZLES
TYPE OF NOZZLES
BOILER LOAD/SCRUBBER - X
FLUE GAS CAPACITY - CU.M/S
fLUE GAS TEMPERATURE - C
LIQUID RECIRCULATION RATE - LITER/S
L/6 RATIO - LITER/CU.M
PRESSURE DROP - KPA
SUPERFICIAL GAS VELOCITY - W/S
PARTICULATE DESIGN REMOVAL EFFICIENCY
S02 INLET CONCENTRATION - PPM
** F6D SYSTEM
SALEABLE PRODUCT/THROWAWAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
SYSTEM SUPPLIER
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICULATE DESIGN REMOVAL EFFICIENCY
S02 DESIGN REMOVAL EFFICIENCY - X
COMMERCIAL DATE
INITIAL START-UP
CONSTRUCTION INITIATION
** ABSORBER
NUMBER
TYPE
INITIAL START UP
KANSAS CITY POWER £ LIGHT
LA CYGNE
1
LA CVSNE
KANSAS
- X
. X
.128 LP/MMBTU)
1.500 LB/KMBTUi
55. C
645. (
USO.O
B74.0
820.0
844.0
874.0
BABCOCK AND W1LCOX
PULV COAL, SUPERCRITICAL, CYCLONE FIRED
BASE
0/73
1502.44 £2760000 ACFM)
140.6 < 2R5 F>
213. < 700 FT)
******* <***** FT)
COAL
SUBBITUMINOtlS
21913.
24.36
24-25
8.60
9-10
5.39
5-6
.03
0.02-0.03
366.4
820
BTU/LB)
9000-9700
(404 TPH)
8
VARIABLE THROAT VENTURI
BABCOCK AND UILCOX
1
316L SS
KAOCRETE CERAMIC
80
SPINNER VANE, COORS CERAMIC
12.5
162.8
57.2
315.0
1.6
1.7
39.6
9S.2
4500.000
345000 ACFM)
135 F)
5000 GPM)
12.0 GAL/10CQACF)
7 IN-H20)
130.0 FT/S)
TKROWAUAV PRODUCT
WET SCRUBBING
LIMESTONE
BABCOCK g UILCOX
FULL-SCALE
NEW
99.50
80.00
6/73
2/73
4/69
TRAY TOWER
2/73
117
-------
UTILITY FbO SURVEY: DECEMEiER 197f - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE CATA FOR OPERATIONAL F60 SYSTEMS
SUPPLIER
NUMPER OF STAKES
DIMENSIONS
SHELL MATERIAL
SHELL LINER MATERIAL
INTERNAL MATERIAL
NUMBER OF N027LES
NOZILF TYPE
60ILER LOAD/ABSORBER - 7.
6AS FLOW - CU.M/S
GAS TEMPERATURE - C
LIOUID RtClRCULATlON RATE - LITfR/l
L/6 RATIO - L/CU.M
PRESSURE DROP - KPA
SUPERFIfAL CAS VELOCITY - M/SEC
S02 OUTLET CONTRATION - PPM
FANS
NUMBER
TYPF
CONSTRUCTION MATERIALS
BABCOCK 8 WILCOX
?
32 X 16 * 25
31AL SS
NONE
316L SS SIEVE TRAY
16
SPINNER-WAKE. CERAMIC
1J.5
112.55
50.0
567-
3.5
1.5
4.6
1000
( 238500 ACFM>
{ 122 F>
( 9000 GPW)
( 26.5 6AI/1000ACF)
( 6.0 IN-HZO)
< 15.0 FT/S)
F6D I.D.
SS CLIP ON EACH BLADE
•• FANS
NUMBER
TYPE
** MIST ELIMINATOR
MUMPER
TYPE
CONSTRUCTION MATERIAL
BOILER I.D.
SIEVE TRAY
SS
** MIST ELIMINATOR
TYPE
CONSTRUCTION MATERIAL
FREEBOARD DISTANCE - «
DEPTH - M
VANE SPACIN6 - CM
VANE ANCLES
WASH SYSTEM
SUPERFICIAL GAS VELOCITY - M/S
PRESSURE DROP - KPA
CHEVRON (2 CHEVRONS IN 3 MODULES)
FRP
3.66 (12.0 fT>
.24 ( .8 FT)
7.6 < 3.00 IN)
45 DEG.
CONT. 230 CPM OVERSPRAY
2.6 C 6.4 FT/S)
.3 < 1.4 IN-H2o>
** MIST ELIMINATOR
NUMfER
TYPE
CONSTRUCTION MATERIAL
FREEBOARD DISTANCE - M
DEPTH - M
VANE SPACING - CM
VANE ANGLES
WASH SYSTEM
SUPERFICIAL &AS VELOCITY - M/S
PRESSURE DROP - KPA
•* PROCESS CONTROL CHEMISTRY
CONTROL VARIABLES
CONTROL RANGE
CONTROL MANNER
SENSOR LOCATION
** PUMPS
SERVICE
POND UATER RETURN
LIMESTONE SLURRY MAKEUP
TRAT TOWER ABSORBER
VENTURI
CHEVRON
FRP '
7.66 (12.0 FT)
.24 < .8 FT)
7.6 ( 3.00 IN)
45 DEC.
CONT. 230 GFM OVERSPRAV
2.6 ( fl.4 FT/S)
.3 ( 1.4 1N-H20)
PH, SOLIDS X
PH(5.6-5.S)
AUTOMATIC
PH AT VENTURI, SOLIDS AT VENTURI RECIRC. LINE
NUMBER
** TANKS
SERVICE
LIMESTONE SLURRY MA|(EUF
RECYCLE TANK
NUMBER
2
8
118
-------
EPA UTILITY FGD SURVEY: DECEMBER 1978 - JANUARY 1979
SfcCTION 3
DESIGN AND PERFORMAKE DATA FOR OPERATIONAL F6D SYSTEMS
** REHEATER
NUMBER
TYPE
HEATING MEDIUM
TEMPERATURE BOOST - C
** REHEATER
NUMBER
TYPE
TEMPERATURE BOOST - C
** WATER LOOP
TYPE
FRESH MAKEUP WATER ADDITION - LITEivS/S
** REA6ENT PREPARATION EQUIPMENT
NUMBER OF BALL MILLS
REA6ENT PRODUCT - X SLURRY SOLIDS
** DISPOSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
AREA - ACRES
CAPACITY - CU.M
1
IN-LINE
STFAM
33.3
( 60 F)
INDIRECT HOT AIR
33.3 < 60 F)
OPEN
72.3 ( 1148 GPM)
Z
66.0
FINAL
UNLINtD POND
ON-SITE
RUPEER LINED PIPE
160.0
2152*80 ( 1760.0 ACRE-FT)
PERIOD MODULE AVAILABILITY GPERABIL1TY
PERFORMANCE DATA
(•{LIABILITY UTILISATION
x REMOVAL PER BOILER FED CAP.
SOZ PART. HOURS HOURS HOURS FACTOR
12/72 SYSTEM
744
PROBLEMS/SOLUTIONS/COMMENTS
START DATE 12/72 EGUI?«ENT: F60 SYSTEM, GENERAL
END BATE
12/72 COMMENTS:
THE FIRST TRIAL OPERATION BEGAN ON DECEMBER 26, 197? AND WAS PLAGUED WITH
NUMEROUS PROBLEMS. SOME OF THESE PROBLEMS, SUCH AS VIBRATIONS OF THE
IfcDUCED-DRAFT FANS AND THEIR SENSITIVITY TO INBALANCE, OCCURRED EVEN BE-
FORE THE BOILtiR AS FIRED. AS THESE FABRICATION PROBLEMS MERE CORRECTED
AfcD THE F£C StSTEM WENT INTO OPERATION TWO OTHER TYPES OF PROBLEMS AP-
PEARED THE FIRST TYPE ASSOCIATED KITH THE WET LIMESTONE PROCESS.INCLUDED
PLUGGING OF T ft DEMI STER AND STRAINED S. THE CORROSION AS SO CT ATE D HITH
CONDENSATION CF ACID VAPORS FROM THE CAS ONITHF REHEATER TUBE BUNDLES
WAS CONTROILEC BY INJECTION OF SLIP STREAMS OF HOT AIR FROM THE BOILER'S
COMBUSTION AIR HEATER INTO THE SCRUBBED FLUE 6ASES AT THE INLET TO THE
REPEATER UNITS. THIS PRACTICE WHICH REDUCED THE MAXIMUM GENERATING
CAPACITY OF THE BOILER BY LIMITING THE AIR AVAILABLE FOR COAL COMBUSTION,
IS NO LONGER N1CESSARV BECAUSE OF SYSTEM DESIGN MODIFICATIONS.
AFFECTED MODULES: SYSTEM
0/74 SYSTEM
** PRQBLEMS/SOLUTIONS/COMKENTS
START DATE 0/74 [GUIFMENT: '
END DATE 0/0 COMM[NTS:
THE 1974 FIGURES ARE BASED UPON ACTUAL SYSTEM OPERATION HOURS AS A
FUNCTION CF ACTUAL BOILER HOURS
AFFECTED MODULES: SYSTEM
1/74
A
B
C
D
E
F
e
SYSTEM
2/74
49.0
S2.0
44.0
87.0
23.0
37.0
81.0
50.0
66.0
74*
119
-------
EPA UTILITY fGD SURVEY: DECEKBFR 197f - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FGD SYSTEMS
PERIOD
3/74
4/74
5/74
6/74
7/74
8/74
9/74
10/74
MODULE
B
C
0
E
f
6
SYSTEM
SYSTEM
A
B
C
0
t
f
e
SYSTEM
A
6
C
0
E
F
E
SYSTEM
A
B
C
D
f
f
6
SYSTEM
A
B
C
D
£
F
G
SYSTEM
A
B
C
0
E
f
6
SYSTEM
A
B
C
D
e.
f
c
S'STEM
A
e
PERFORMANCE DATA
AVAILABILITY CPEMBILITY ^LIABILITY UTILIZATION
68.0
59.0
76.0
52.0
100.0
65.0
69.0
67.0
70.0
75.0
88.0
74.0
100.0
8*.0
80.0
69.0
83.0
78.0
85.0
7S.O
84.0
80.0
80.0
«z.o
84.0
83.0
90.0
8?.0
83.0
87.0
86.0
75.0
80.0
86.0
81 .0
85.0
79.0
77.0
80.0
90.0
90.0
73.0
81.0
81.0
7?.0
99.0
85.0
69.0
88.0
73.0
76.0
83.0
89.0
86.0
81.0
90.0
71.0
* REMOVAL PER BOJLER FGD CAP.
SOJ PART. HOURS HOURS HOURS FACTOR
672
744
720
744
720
744
744
720
120
-------
EPA UTILITY F6D SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFOftMAhC E DATA FOR OPERATIONAL FGD SYSTEMS
— PERFORMANCE DATA
PERIOD MODULE AVAILABILITY CPERABUITY PLIABILITY UTILIZATION
Z REMOVAL PER BOILER
SCZ PART. HOURS HOURS
FGD
HOURS
CAP.
FACTOR
C 60.0
D 61.0
E 84.0
F 85.0
6 {14.0
SYSTEM 76.0
11/7* A 90.0
B 71.0
C 60.0
D 61.0
E 84.0
f 85.0
6 84.0
SYSTEM 76.0
12/74 SYSTEM
0/75 SYSTEM
744
720
744
** PAOBLEMS/SOLUTIONS/COPmENTS
START DATE 0/75 ESUItnENT: F6D SYSTEM, GENERAL
END DATE 0/75 COMMENTS:
T*E 1975 FIIUH.S ARE BASED UPON SYSTEM AVAILABL HOURS AS A FUNCTION OF
HOURS IN THE PERIOD.
AFFECTED MODULES: SYSTEM
1/rs
2/75
3/75
SYSTEM
SYSTEM
744
67Z
SYSTEM
82.0
96.0
90.0
76.0
93.0
92.0
96.0
90.0
744 694
** MOeLEMS/SQLUTlONS/COMMNTS
START DATE 3/75 ESUIFHENTs F6D SYSTfH, GENERAL
END OATi 3/75 COMMINTSJ
DURING RSHJCEC LOAD CONDITIONS SCHf OF THi K80UUES WERE NOT RfegjRfO AND
T^UffORI SHU1 DOWN ALTHOUGH THiV HiRi AVAILABLE. AVAILABILITY HAS THIKE-
FOR HIiHIR THIN SQMi OF THI POSTED FIGURES INDICATE.
AFFECTED MODULES! SYSTEM
4/7S SYSTEM
5/75
720
6/75
YSTEB
95.0
B5.0
94. 0
90.0
90.0
89.0
63.0
89.0
8B.O
85.0
64.0
as.o
84.0
86.0
89.0
86.0
744 6*3
720 667
121
-------
EPA UTILITY f60 SUPVEV: DECEMBER 197f - JANUARY 1979
SECTION 3
DESIGN AND PE R F OPKA 1st E DATA FOR OPERATIONAL F66 SYSTFWS
PERFORMANCE DATA ~
PEPIOD HOODIE AVAILABILITY CPEPARIHTY ffLIAnillTY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
7/75
A
B
C
D
E
F
6
SYSTEM
78.0
90.0
90.0
E4.0
85.0
67.0
85.0
7*4 590
8/75
9/75
10/75
11/75
A
B
C
D
E
F
6
SYSTEM
75.0
8S.O
87.0
78.0
92.0
65.0
87.0
84.0
** PR08LEWS/SOLUTIONS/COMMENTS
START DATE 8/75 EAUlrMENT: F6D SYSTEMt GENERAL
END DATE K/75 COKMtNTSl
("OODLES A AND D ARE USED FOR RESEARCH TESTS.
EVENING FOR CLEANING.
AFFECTED MODULES: A D
A 78.0
B 81.0
C 84.0
D 65.0
E 79.0
F 7P.O
G 74.0
SYSTEM *0.0
A 66.0
B 77.0
C 46.0
D 74.0
E 72-rO
F 73.0
6 65.0
SYSTEM 6B.O
744 630
ONE MODULE IS SHUT DOVIN EAC.
720 610
744
231
** PKOBLEm/SOLUTIONS/COHKENTS
START KATE 10/75 ECUIPWENT: F6D SYSTEM, GENERAL
END DATF 11/75 PROBLEM: NOT 6EFINED/SPECIFI ED
T*E EYST£* UA£ DOWN OCTOBER 16 JO NOVEMBER 13 OWING TO PROBLEMS WITS
TXE GENERATOR AND I.D. AIR FAN.
AFFECTED MODULES: SYSTEf
«* PROBLEMS/SOLUTIONS/COIKMENTS
START DATE 10/75 ESUI^'ENT: F6D SYSTEM, GENERAL
END DATE 11/75 COhtftNTS:
AVAILABILITY fRCURES FOR OCTOBER AND NOVEMBER DO NOT INCLUDE THE OUTAGE
TIME FROM OCTOBER 16 TO NOVEMBER 13.
AFFECTED MODULES: SYSTEM
SYSTEM
93.0
90.0
80.0
93.0
96.0
89.0
94.0
91.0
7?0 346
122
-------
EPA UTILITY f6D SURVEY: DECEMBER 1976 - JANUARY 1979
SECTION 3
DESIGN AND PERFOKKAKCE DATA FOR OPERATIONAL F6D SYSTEMS
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY tELIABUITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
SC2 PART. HOURS HOURS HOURS FACTOR
12/75
A
B
C
0
E
F
6
SYSTEM
91.0
87.0
81.0
85.0
87.0
89.0
64.0
£6.0
7*4 597
** P80BLEMS/SOLUTIONS/COKWENTS
START DATE 12>75 EOUItWENT: BOILER-RELATED
END DATE 12/75 F-RCFUFM; NOT DEFINED/SPECIFIED
THREE BOILEK OUTAGES OCCURRED DURING DECEMBER.
AFFECTED MODULES- SYSTEM
1/76
2/76
3/76
A
B
C
D
E
F
e
SYSTEM
A
B
C
0
E
F
6
SYSTEM
A
B
C
0
E
f
6
SYSTEM
86.0
85.0
91.0
72.0
84.0
52,0
64.0
87.0
94.0
90.0
86.0
91.0
92.0
93.0
95.0
92.0
92.0
90.0
£8.0
93.0
94.0
91.0
91.0
91.0
744 618
696 594
4/76 SYSTEM
744
720
643
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 4/76 EMINENT: BOILER-RELATED
END DATE 5/76 COMMENT: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTAGE
THE SYSTEM WAS SHUT DOWN ON APRIL 6 FOR A SCHEDULED BOILER, AIR PREHEATER,
AltD STACK BREECHING OVERHAUL. THE UNIT WAS RESTARTED ON HAY 10.
AFftCTED MODULES: SYSTEM
*» PROBLEMS/SOLUTIONS/COMMENTS
START DATE 4/76 SSUlFMENTt DUCTWORK
£ND DATE 5/76 PROBLFB: CHEMICAL-RELATED CORROSION
DIRIN6 THE OU1A6E SOnE MAINTENANCE WAS PREFORHFD ON THE SCRUBBER BUCTHORK,
PRIMARILY BECAUSE OF CORROSION PROBLEMS.
AFFECTED MODULES: SYSTEM
5/76 A
B
C
D
E
F
6
SYSTEM
96.0
92.0
93.0
96.0
89.0
95.0
96.0
94.0
744 436
-------
EPA UTILITY FGD SURVEY: DECEMBER 197? - JANUARY 1979
SECTION 3
DES16N AND PERFORMAKCE DATA FOR OPERATIONAL FED SYSTFMS
PERFORMANCE DATA I'TII" i-.B
PERIOD MODULE AVAILABILITY CPERABIL1TY RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D "P.
SO? PART. HOURS HOURS HOURS FACTOR
** PROBLEKS/SOLUTIONS/COMMENTS
START DATE 5/76 IBUIfENTs F6D SYSTEM, GENERAL
END DATE 5/76 PROBLEM: NOT DEFINED/SPECIFIED
FROM KAY 10 TC TH£ END 0' THE MONTH FOUR UNIT OUTAGES WERE ENCOUMTERFD.
AFFECTED MODULES: SYSTEM
6/76 A 93.0
6 94.0
C 94.0
D 95.0
E 93.0
f 93.0
e 9i.o
SYSTEM 93.0 720
•* PROBLEMS/SOLUTIONS/COMMENTS
START DATE A/76 IOUI FMENTt FGD SYSTFMt GENERAL
END DATE 6/76 FCCBKM: NOT DEFINED/SPECIFIED
FOUR FORCED MINOR SCRUBBER OUTAGES OCCURRED DURIN6 JUNE.
AFFECTED MODULES: SYSTEM
7/76 96.0
95.0
92.0
93.0
93.0
95.0
94.0
SYSTEM 94.0 744
«* PROBLEMS/SOLUTIONS/COMMENTS
START DATE 7/76 £CUI THENT: F6D SYSTEM* GENERAL
END DATE 7/76 PPCBlfM: NOT DEFINED/SPECIFIED
TkO MINOR SCRLPBER OUTAGES OCCURRSD DURING JULY.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 7/76 EQUIPMENT: FGD SYSTEM, GENERAL
END DATE 7/76 tCMMINTS:
THE UNIT RF CO ft) ED ITS LARGEST MU-HOUR MONTH SINCE INITIATION OF COMMERCIAL
OPERATION
AFFECTED MODULES: SYSTEM
8/76 A 94.0
B 93.0
C 92.0
D 94.0
E 92.0
F 90.0
G 88.0
S»STEM 92.0 744
** PROBLENS/SOLUTIONS/COMMENTS
START DATE 8/76 EQUIPMENT: BOILER-RELATED
END DATF 10/76 PROBLEM: NOT DEFINED/SPECIFIED
ThE UNIT MAS TAKEN OUT OF SERVICE AUGUST H FOR REPAIR OF A TURBINE PLADE.
THE UNIT bAS RETURNED TO SERVICE ON OCTOBER 70. OPERATION WAS INTERMIT-
TENT PENDING TURBINE BLADE REBALANCING AND REESTABL1SHMENT OF NORMAL
OPERATING CONDITIONS.
AFFECTED MODULES: SYSTEM
*« PROBLEMS/SOLUTIONS/COMMENTS
START BATE 8/76 E6U!F«ENT: STACK
END DATE 10/76 PROBLCn: NOT OEF1NED/SPECIFIEO
DURING THE TUfPINE REPAIR PERIOD THE UTILITY CpATED THE STACK INNER
STRUCTURE WITH PLASTITE 400S.
124
-------
EPA UTILITY FGD SURVEY: DECEMBER 1978 - JANUARY 1479
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FGD SYSTEMS
--—-—•— — -----——------•— -PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERA6IL1TV PLIABILITY UTILIZATION
X REMOVAL PER BOILER FGD CAP.
SO? PART. HOURS HOURS HOURS FACTOR
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 1/76 ECUIFMENT: F6D SYSTEM, GENERAL
END DATE 8/76 COMMITS:
THE AUGUST AVAILABILITY FIGURES DO NOT INCLUDE THE OUTAGE TIME.
AFFECTED MODULES: SYSTEM
9/76 SYSTEM
10/76 SYSTEM
11/76
720
7*4
12/76
YSTIM
IVSTIM
95.0
9J.O
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
720 627
744 706
1/77
** PROBLENS/SOLUTIONS/COMMENTS
START DATE 12/76 HUJIMENT: RECYCLE PUMP
END DATE 12/76 FROBUM: NOT DEFINED/SPECIFIED
TfcE A-MODULE VENTURI RECYCLE PUMP EXPERIENCED SOME PROBLEMS AND WAS
REPAIRED.
AFFECTED MODULES* A
•* PROBLEMS/SOLUTIONS/COMMENTS
START DATE 12/76 EQUIPMENT: REAGENT HANDLING
EN* "BATE 12/76 PFOB'lEM: NOT DEFINED/SPECIFIED
THE C-MODULE'! REHEAT STEAM TUBE BUNDLES WERE INCREASED IN NUMBER FROM
FCUR TO EIGHT.
AFFECTED MODULES: C
94.0
90.0
95.0
95.0
95.0
92.0
90.0
93.0
YSTEM
2/77
3/77
744 714
93.0
93.0
93.0
94.0
93.0
94.0
88.0
93.0
94.0
92.0
86.0
94.0
672 634
12S
-------
EPA UTILITY F6D SURVEY: DECEMBER 197F - JANUARY 1979
SECTION 3
DESIPN AND PFRFORMAKf E DATA FOR OPERATIONAL FCC SYSTEMS
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY CPERABIL1TY PLIABILITY UTILIZATION t REMOVAL PER BOILER FGO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
E
F
S
SYSTEM
91 .0
94.0
90.0
92.0
744
*• PROBLEMS/SOLUTIONS/COMMENTS
START BATE 7177 ECUIfMENT: F6D SYSTEM, GENERAL
END DATE ?/77 COWM1NTS:
THE EIGTH MOBILE HAS BEEN INSTALLED.
AFFECTED MODULES: H
** PR08LEMS/SOLUTIONS/COMKENTS
START DATE 3/77 E»UJH"ENT: MIST ELIMINATOR
END DATE 3/77 PROBLEM: NOT DEFINED/SPECIFIED
THE MIST ELIMINATORS IN TWO MODULES HAVE BEEN MODIFIED TO THE POINT VHERE
THEY HAVE PIF*- OPERATING CONTINUOUSLY CLEAN.
AFFECTED MODULES; SYSTEM
** PR06LEMS/SOLUTIONS/CCMMENTS
START DAjE 3/77 EGUIFWENT: REHEATER
END DATE 3/77 FROPlEM: NOT D E FIN ED /S PE CI f I ED
ADDITIONAL BA MC S OF STEAM TUBE BUNDLES HAVE BEEN INSTALLED IN SOME MODULES
50 f CF REHEAT MAS BEEN DETERMINED AS THE NECESSARY AMOUNT FOR THE
LA CYN6E Kt>. 1 UNIT.
AFFECTED MODULES: SYSTEM
»* PRObLEMS/SOLUTIONS/COMMENTS
START DATE 3/77 IBUlfENT: PROCESS CONTROL
END DATE 7/77 COKMtNTS:
THE WATER Loof is NOW 95* CLOSED-
AFFECTED MODULES: SYSTEM
** PR08LEMS/SOLUTIONS/COWMENTS
START DATE 3/77 ECUMCENT: SLUDGE DISPOSAL
END DATE 3/77 IOMM tNTS:
A NEW SETTLINC POND IS BFIN6 INSTALLED AT THE PL*NJ.
AFFECTED MODULES: SYSTEM
•* PROBLEMS/SOLUTIONS/COMMENTS
STVIRT DATE 3/77 EOtll FMBWT: BOILER-RELATED
END DATE 3/77 CCMM [NTS:
THE PLANT IS iTILL 6ENERATIN6 7QO-7ZO »V DURIN6 THE DAY AND 500-570 MM
AT NIGHT-
AFFECTED MODULES: SYSTEM
4/77 A 96.0
B 94.0
C 97.0
fi 94.0
E 95.0
f 99.0
6 95.0
SYSTEM 95.0 7ZO
•• PROBIEMS/SOLUIIONS/COMMENTS
START DATE 4/77 E6UITMENT: ABSORBER
END DATE 4/77 COMMENTS:
THE EI6HT fcODUE HAS BEEN RUN FOR TWO DAYS.
AFFECTED MODULES; H
5/77 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
START BATE 5/77 EOUIH-IENT: B01LER-R£LATE 0
END DATE 7/77 PROBLEM: NOT DEFINED/SPECIFIED
TfcE UNIT WAS 5HUT DOWN IN MAY DUE TO TURBINE PROBLEMS. THE UNIT RESTARTED
JULY 5, 1977.
126
-------
EPA UTILITY FGO SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMAt.CE DATA FOR OPERATIONAL FED SYSTEMS
... . . . PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABIL1TY PLIABILITY UTILIZATION * REMOVAL PER BOILER FGD CAP.
SO? PART. HOURS HOURS HOURS FACTOR
AFFECTED MODULES: SYSTEM
•* PROBLEMS/SOLUTIONS/COKMENTS
START DATE 5/77 EQUIPMENT: MIST ELIMINATOR
END DATE 5/77 PROBLEM? NOT DEFINED/SPECIFIED
THE MIST ELIM0TOR WASHING CONFIGURATION IS BEING CHANGED TO WORK
CCUNTERCURRKN1 TO THE 6AS FLOW.
AFFECTED MODULES: SYSTEM
** PR06LEMS/SOLUTIONS/COMMENTS
START DATE 5/77 tQUIf-MINT: REHEATER
END DATE 5/77 PROBLEM: NOT DEFINED/SPEClf1 ED
ADDITIONAL TUf.E. BUNDLES ARE BEING ADDED TO INCREASE THE REHEAT AREA.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/CCMMENTS
START DATE 5/77 EQUIPMENT: SLUDGE DISPOSAL
END DATE 5/77 COMM tNTSJ
THE NEW SETTLING POND IS STILL BEING DRAWN UP. EXCAVATION HAS NOT BEGUN.
AFFECTED MODULES: SYSTEM
6/77 SYSTEM 720
•* PROBLEMS/SOLUTIONS/COMMENT!;
START DATE 6/77 EQUIPMENT: F6D SYSTEM, GENERAL
END DATE 6/77 COMM I:NTS:
MINOR CLEAMON1 AND REPAIR WORK WAS DONE ON THE SCRUBBING SYSTEM DURING
THE TURBINE OITA6E.
AFFECTED MODULES: SYSTEM
7/77 A 95.0
B 93.0
C 94.0
D 95.0
E 95.0
F 95.0
6 95.0
H 95.0
SYSTEM 95.0 744 52B
** PROBLEMS/SOLUTIONS/CCMMENTS
START DATE 7/77 EQUIPMENT: FGD SYSTEM, GENERAL
END DATE 7/77 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 CF 8CO-820 MW.
AFFECTED MODULES: SYSTEM
8/77 A 89.0
B 55.0
93.0
93.0
90.0
93.0
93.0
H 94.0
SYSTEM 87.0 744 507
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 8/77 EQUIPMENT: FGD SYSTEM* GENERAL
END DATE 8/77 COMMENTS:
PARTICULATE REMOVAL TESTS VERE CONDUCTED IN LATE AUGUST AND UNIT N0.1 MAS
PASSED THE COMPLIANCE REQUIREMENTS (0.13 LC?/MN BTU).
AFFECTED WOoULlS: SYSTEM
** PR06LEMS/SOLUTIONS/COMMENTS
START DATE 8/77 EQUIfMENT: RECYCLE PUMP
END DATE f/77 PROBLEMS COMPONENT FAILURE* OTHER
127
-------
EPA UTILITY F£D SURVEY: DECEMBER 197P - JANUARY 1979
SECTION I
DISI6N AND PERFORMANCE DATA fOR OPERATIONAL F6D 5YSTFMS
PERFORMANCE DATA "
PERIOD MODULE AVAILABILITY OPEPAPIL1TY ^LIABILITY UTILIZATION X REMOVAL. PER BOILER FGC CAP.
S02 PART. HOURS HOURS HOURS FACTOR
MODULE B HAD LOW AVAILABILITY DUE TO THE BURNING OF THE REC1RCUL*TINf
PIMP. IT HAS REMOVED AND STARTED AGAIN AFTER 12 CAYS.
AFFECTED MODULES: t
9/77
11/77
A
B
C
D
E
F
G
H
SYSTEM
10/77 A
6
C
E
f
6
H
SYSTEM
93.0
94.0
89.0
90.0
93.0
95.0
9?.0
9J.O
9?.0
91.0
96.0
89.0
94.0
93.0
94.0
89.0
95.0
92.0
720 524
744 456
** PROBLEMS/SOLUTIONS/COMMEN1S
START DATE 10/77 EOUUSENT: BOILER-RELATED
END OATS 10/77 PROBISM: NOT DEF1NED/SPFCIFI ED
A 12 DAY OITAU IN OCTOBER WAS REQUIRED TO DESLAC THE
AFFECTED MODULES: SYSTEM
A
B
C
D
E
F
6
H
SYSTIM
93.0
96,0
9!,0
94.0
92.0
93.0
V6.D
95.0
94.0
720 234
*» PROeLEMS/SOLUTIONS/CCMMENTS
START DATI 11/77 tSUIPMINTt IOHr»-RILATf 6
END D*TE 12/77 (CMMfNTi p»SVfNTlVE MAINTfNANCE SCHfDULED UNIT CUTASi
TM POILIK KM SHUT DOWN NPVeMfff 15 etCAUSE OF A NlCiSjARY TURBINE
OVERHAUL. THt SOItfR KENT PACK Rh LINi
AFFFCTI8 HO&ULiSS SYSTEM
iz/rr A
B
C
e
E
F
6
H
SYSTIM
VS.P
«B.O
96.0
96.0
96.0
9T.O
9R.O
99.0
97.0
744 300
•• PRObLEMS/SOLUTlONS/CPMMENTS
START DATE 12/77 EOUIIMENT: BOILFR-RELATfD
END DATE 12/77 PROBLEM: NOT DEFINiC/SPECIflit
TJ-ERF WERE A tf W SMALL SOILiF RELATED OUTAGES TN DICEPIRER.
AFFECTED MODULES: SYSTEM
1/78 A
e
c
90.0
95.0
95.0
126
-------
EPA UTILITY FED SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FED SYSTEMS
PERIOD MODULE
D
E
F
6
H
SYSTEM
. .. PERFORMANCE DATA
AVAILABILITY OPERABUITY ^LIABILITY UTILIZATION
95.0
93.0
94.0
94.0
94.0
94.0
X REMOVAL PER
SOZ PART. HOURS
744
BOILER FGD
HOURS HOURS
300
CAP.
FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 1/78 tOUIFHENT: BOILER-RELATED
END DATE 1778 ppOfHFM: NOT DEFINED/SPECIFIED
THERE WE"I SOIVr BOILER RELATED OUTAGES IN JANUARY, TOTALTN6 ABOUT 50
HOURS.
AFFECTED MODULES: SYSTEM
«* PROBLEMS/SOLUT10NS/COKHENTS
START DATE 1/78 EOUIFMENT: F60 SYSTEM, GENERAL
END DATE 1/78 COMMENTS:
THE FED SYSTFF CONTINUED TO OPERATE WITHOUT ANY PROBLEMS.
AFFECTED MODULES: SYSTEM
2/7R
3/78
4/78
C
D
E
F
6
H
SYSTEM
C
D
E
F
6
H
S*ST!«
C
D
i
F
i
«
SVSTIW
•*
92.0
93.0
9S.O
94.0
91.0
97.0
96.0
93.0
94.0
95.0
95.0
90.0
95.0
94.0
95,0
89.0
93.0
93.0
91.0
92.0
93.0
¥1.0
90.0
92.0
91.0
91.0
91.0
672 578
7*4 741
720
START DAT! 4/78 ISUIMENTs BOILiR-Rf LAT I B
END DAT! 4/78 PROB If H I NOT DEMNIB/SPS CIF lit
THE BOUIR VAS DOWN A TOTAL OF 10E HOURS IN APRIL. THIS TIME INCLUDED
TKREi OUT APIS HUE TO BOILER LEAKS AND LACK OF LOAD REttUIR EMENT.
AFFECTED MODULES: SYSTiM
** PftOBLEMS/SOLUUONS/COMMENTS
START DATE 4/78 EOUXfKENT: REHEATiR
END PATE 4/78 PROBLEM: NOT DEFINED/SPECIFIED
DURING THE POItER OUTAGES MODIFICATIONS TO THE F6D SYSTEM INCLUDED
CHANGING THE KHEAT TUBE BUNDLES.
AFFECTED MODUltS: SYSTEM
5/78 A
B
89.0
92.0
129
-------
EPA UTILITY f&D SURVEY: DECtf<6FR 197P - JANUARY 1979
SECTION 3
DESIGN AND PFRFORM AI>CE DATA FOR OPERATIONAL FGD SYSTEMS
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY CPERARILI T» ^LIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
c
D
E
F
e
H
SYSTEM
92.0
93.0
92.0
91.0
93.0
86.0
91. C
744 593
«* PROBLEMS/SOLUTIONS/COMMENTE
START HATE 5/78 EGUUCENT: BOI LfR-RELATF D
END DATE 5/78 PROBLFH: NOT DEFINED/SPECIFIED
IH WAY THE bOILER WAS DOWN TWjCt FOR A TOTAL OF 15 HOURS. OUTAGES HERE
AEAIN CAUSED tY BOILFR LEAKS.
AFFFCTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COKMENTS
START DATE 5/7? ICUIffENT: FGD SYSTEM, GENERAL
END DATE 5/7K PROP If H: NOT DEFINED/SPECIFIED
GENERAL MAINTENANCE AND REPAIRS ON THE FGD SYSTEM CONTINUED.
AFFECTED MODULES: SYSTEM
6/78 SYSTEM 720 150
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 6/78 tOUIfENT: BOILER-RELATED
END DATE fc/78 PROPlfM: NOT D E FIN E D/S PE CI F I ED
T^E UNIT fcAS IP FOR ONLY 15 HOURS IN JUNE. IN THE FIRST PKRT OF JUNE
THERE WERE V0 !LER TUBE LEAKS. FROM JUNE 8 TO JUNE 17 A BOILER OUTAGE WAS
NECESSARY FOP
-------
EPA UTILITY fGD SURVEY: DECFWBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FGD SYSTEMS
PERIOD MODULE A VAIt AEUL ITY ClPERABILITY
PERFORMANCE DATA
RELIABILITY UTIL17ATION
X REMOVAL PER BOILER FED CAP.
S02 PART. HOURS HOURS HOURS FACTOR
DOUBLE STAGE MST ELIMINATORS. BETTER MIST ELIMINATION AT THE SCRUBBER
tXIT WOULD REDUCE THE FREBUENCY OF REHEATER CLEANING.
AFFECTED MODULES: SYSTEM
9/78
A
e
c
D
f.
F
6
H
SYSTEM
10/78 A
U79
C
0
I
f
G
H
SYSTEM
96.0
96.0
96.0
V6.0
96.0
96.0
95.0
97.0
96.0
96.0
96.0
9S.O
97.0
97.0
98.n
97.0
96.0
97.0
7ZO
744 255
*» PROBLEMS/SOLUT10NS/COMMENTS
START DATE 10/78 teUIIMENT: FGD SYSTEM, GENERAL
END DATE 11/78 COMMENTS:
TtiE UTILITY REPORTED THAT NO UNUSUAL OPERATINS PROBLEMS WERE ENCOUNTERED)
AFFFCTtO MODULES; SYSTEM
11/78
12/78
A
B
C
D
E
F
G
H
SYSTEM
A
B
C
D
E
F
6
H
SYSTEM
92.0
95.0
94.0
93.0
94.0
93.0
94.0
96.0
94.0
97.9
9?. 9
94.0
95.0
94.7
90.5
94.4
94.7
720 7?0
744 239
** PROBLEMS/&OLUTIONS/COMMENTS
START DATE 1Z/78 ECUIFMENT: BOILER-RELATF.D
END DATE 1/79
DIKING THIS PtRIOD THE UNIT EXPERIENCED A MULTITUDE OF COILER OUTAGES.
AFFECTED MODULES: SYSTEM
A
B
C
D
E
F
6
H
SYSTEM
95.6
96.5
97. Z
96.3
90.7
97.2
97.2
95.4
744 205
151
-------
fP» UTILITY F6D SURVFYt DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMA^E DATA FOR OPERATIONAL FGO SYSTEMS
COMPANY NAMf
PLANT NAME
UNIT NUMPER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - l\iG/J
S02 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MW
NFT UNIT GENERATING CAPACITY V/FGD - Mk
HE! UNIT GENERATING CAPACITY WO/Ffit - !•«
EQUIVALENT SCRUBBED CAPACITY - MW
** BOILFR CATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATt
MAXIMUM bOUER FLUE GAS FLOW - CU.f/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAMETER - «
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - KJ/KG
RANGE HEAT CONTENT - BTU/LI
AVERAGE ASH CONTENT - *
RANCE ASH CONTENT - %
AVERAGE MOISTURE CONTENT - X
RANGE M01STURF CONTENT - X
AVERAGE SULFUR CONTENT - J
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - K
RANGE CHLORIDE CONTENT - X
FUEL FIRING RATE - M T /H
FUEL FIRING RATE - MW
** ESP
TYpE
SUPPLIER
FLUE GAS TEMPERATURE - C
PRESSURE DROP - KPA
•* F6D SYSTEM
SALEABLE PRODUCT/T HRCW AWAY PRODUCT
GENERAL PROCESS TYPC
PROCESS TYPE
SYSTEM SUPPLIER
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICULATE DESIGN REMCVAL EFFICIENT
502 DESIGN REMOVAL EFFICITNCY - X
COMMERCIAL DATE
INITIAL START-UP
** ABSORBER
TYPE
INITIAL START UP
INTERNAL MATERIAL
PRESSURE DROP - KPA
.100 LP/KMETU)
.300 LB/MMBTU)
KANSAS POWER i LIGHT
JEFFREY
1
WAME60
KANSAS
fl
43. (
129. <
2720.0
720.0
. 680.0
*******
540.0
COMBUSTION ENGINEERING
TANGFNTIALLY FIRED PULVERI7EO COAL
BASE
** /**
******** (A****** ACFM)
135.6 < 276 F>
18% < «00 FT)
******* {***** FT)
COAL
******
( 812S BTU/LP)
******
5. «0
******
30.00
******
.32
** ****
.01
******
?26.7
* ****
COLD SIDE
C-E WALTHER
11?.6
.2
(250 TPH)
276 F>
1 IN-H20)
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
COMBUSTION ENGINEERING
FULL-SCALE
NEW
99.0o
60.00
8/78
8/78
S
VERTICAL SPRAY TOWER (PRESSURIZED)
8/78
JKL SS
1.0 ( 4.0 IN-H20)
** ABSORBER
NUMBER
TYPE
INITIAL START UP
INTERNAL MATERIAL
PRESSURE DROP - KPA
1
VERTICAL SPRAY TOWER (PRESSURIZED) (SPARE)
8/7R
316L SS
1.0 ( 4.0 1N-H20)
** FANS
NUMBER
TYPF
00ILFR I.D.
132
-------
EPA UTILITY FRO SURVEY: DECEMBER 1476 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL F60 SVSTFMS
** HIST ELIMINATOR
TYpE
CONSTRUCTION MATERIAL
CONFIGURATION
NUMBER OF PASSES
FREEBOARD DISTANCE - M
VANE SPACING - CM
VANE ANGLES
WASH SYSTEM
** TANKS
SERVICE
REACTION TANKS
** REHEATER
TYPE
** WATER LOOP
TYPE
FRESH MAKEUP WATER ADDITION - L1TER5/S
** REAGENT PREPARATION EQUIPMENT
NUMBER OF BALL MILLS
BALL MILL CAPACITY- M 1/H
** TREATMENT
TYPE
PRODUCT CHARACTERISTICS
*• DISPOSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
CHEVRON
FIBERGLASS
HORIZONTAL
2
1.22 ( 4.0 FT)
5.1 ( 2.00 IN)
45 DE6
POND WATER, 150 PSI6
NUMBER
It
BYPASS
CLOSED
35.1
1
10.9
( 557 GPW)
( 12.0 TPH)
NON-PROPRIETARY
MIXED WITH BOTTOM ASH
FINAL
UNLINID POND
Oft SITE 1 MILE FROM PLANT
PUMPFD
.........._--.,.-----. ._ ......_._.-_pERFORMANCE DATA--—
PERIOD MODULE AVAILABILITY OPERABILITV HELIABILITY UTILIZATION
x REMOVAL
$02 PART.
PER BOILER FGD CAP.
HOURS HOURS HOURS FACTOR
6/78 SYSTEM
744
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 8/78 EfiiJI FMENTs FGD SYSTEM, GENERAL
END DATE 9y78 COMMENTS:
THE SYSTEM IS IN THE SHAKEDOWN PHASE OF OPERATION. EACH OF THE SIX
MODULES OPERATED DURING THIS PERIOD. NO MAJOR PROBLEMS WERE REPORTtD.
INTEGRATED OPERATION OF THE SYSTEM IS EXPECTED DURING THE FIRST HALF OF
OCTOBER.
AFFECTED MODULES: SYSTEM
9/78 SYSTEM
10/78 SYSTEM
720
744
•• PROBLEMS/SOLUTIONS/COMKENTS
START DATE 10/78 EQUIPMENT: FGD SYSTEM, GENERAL
END DATE 11/78 COMMENTS:
UTERRATft) OPERATION FOR THIS UNIT HAS NOT VET BEEN ACHIEVED. A CERTIF-
ICATION TEST MUCH HAD BEEN SCHEDULED HAD TO BE CANCELLED DUE TO A BOILER
OUTAGE. AT THIS TIME THE COLD WEATHER HAS FORCED POSTPONMENT OF THE TEST
^DEFINITELY. MEANWHILE INTERMITTENT F6D OPERATIONS CONTINUE.
AFFECTED MODULES: SYSTEM
11/78 SYSTEM
12/78 SYSTEM
720
744
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 12/78 ECUIIMENT: F6D SYSTEM, GENERAL
END DATE 1/79 COMMENTS:
133
-------
UTILITY F6D SURVEY: OECfcMBES 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMAKCE DATA FOR OPERATIONAL FGD SYSTEMS
PERFORMANCE DATA
PERIOD NODULE AVAILABILITY OPECABILITY PLIABILITY UTILIZATION X REMOVAL PER BOILER FGO "P.
S02 PART. HOURS HOURS HOURS FACTOR
NO PROBLEMS HAVE BEEN REPORTED FOR THIS PERIOD*
AFFECTED MODULES: SYSTEM
1/79 SYSTEM 744
1S4
-------
EPA UTILITY FED SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMAKE DATA FOR OPERATIONAL FED SYSTEMS
COMPANY NAME
PLANT NAMF
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICIPATE EMISSION LIMITATION - N6/J
S02 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MV
GROSS UNIT GENERATING CAPACITY - MU
NET UNIT GENERATING CAPACITY W/FGD - M*
NET UNIT GENERATING CAPACITY WO/FGD - PW
EQUIVALENT SCRUBBED CAPACITY - MW
** BOILER DATA
SUPPLIER
TYPF
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM bOlltR FLUE 6A S FLOW - CU.f/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEA1 CONTENT - KJ/KG
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - I
RANGE ASH CONTENT - g
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - *
AVERAGE SULFUR CONTENT - *
RANGE SULFUR CONTENT - *
AVERAGE CHLORIDE CONTEKT - 2
RANGE CHLORIDE CONTENT - X
FUEL FIRING RATE - M T/H
FUEL FIRING RATE - MM
** PARTICULATE SCRUBBER
NUMBER
TYPE
SUPPLIER
NUMBER OF STAGES
LINING MATERIAL
INTERNAL MATERIAL
TYPE OF NOZZLES
BOILER LOAD/SCRUBBER - X
FLUE 6AS CAPACITY - CU.M/S
FLUE GAS TEMPERATURE - C
Lieuie RECIRCULATION RATE - LITER/:
L/G RATIO - LITER/CU.M
PRESSURE DROP - KPA
PARTICULATE INLET LOAD - 6/CU.K
S02 INLET CONCENTRATION - PPM
** FGD SYSTEM
SALEABLE PRODUCT/THROWAWAV PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPF
SYSTEM SUPPLIER
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICULATE DF-SIGN REMOVAL EFFIC1EHCY
S<)2 DESIGN REMOVAL EFFICIENCY - X
INITIAL START-UP
** ABSORBER
KANSAS POWFK & LIGHT
LAWRENCE
TYPE
INITIAL START UP
SUPPLIER
NUMBER OF STAGES
SHELL MATERIAL
INTERNAL MATERIAL
.100 LB/MMBTU)
.300 LB/MMBTU)
LAWRENCE
KANSAS
B
43. (
129. (
*******
125.0
115.0
*******
125.0
COMBUSTION ENGINEERING
PULV. COAL, BALANCED DRAFT, TAN6ENTEALLY FIRED
CYCLIC
0/59
190.18
137.B
37.
2.4
COAL
******
23260.
9.(tO
******
********
******
.55
******
.03
******
45.3
115
( 403000 ACFH)
< 280 F)
< 120 FT>
< 8.0 FT)
< 10000 BTU/LB)
* **** *
( 50 TPH)
RECTANGULAR VARIABLE THROAT ROB DECK VENTURI
COMBUSTION ENGINEERING
1
316L SS APPROACH AND THROAT
RUBBfR COATED FIBERGLASS (NOREL) ROITS
NON-ATOMIZINGf FAN TYPE SPRAY
50.0
95.1
137.8
226.6
2.4
2.2
201500 ACFM)
280 F)
3600 GPM)
18.0 SAL/1COOACF)
9 IN-H20)
3.03 GK/SCF)
.748
THROVAWAY PRODUCT
WET SCRUBBING
LIMESTONE
COMBUSTION ENGINEERING
FULL-SCALE
RETROFIT
. * 98.9Q
73.00
1/.76
VERTICAL COUNTERCURRENT SPRAY TOWER
1/76
COMeUSTION ENGINEERING
2
316L SS
HEADERS OF FRP
135
-------
EPA UTILITY F6D SURVEY: DECtCfER 197f - JANUARY 1979
SECTION 3
DESIGN AND PE R f ORCi A kC E DATA FOR OPERATIONAL FGD SYSTEMS
MUMPER OF NOZZLES
BOILER LOAD/ABSORB EH - X
GAS flOk - CU.n/S
GAS TEMPERATURE - C
LIQUlt* RECIRCULAT10N RATE - LIlfK/S
L/6 RATIO - L/CU.K
PRESSURE DROP - KPA
PARTICIPATE OUTLET LOAD- G/CU.K
PARTICULATE REMOVAL EFFICIENCY - *
S02 OUTLET CONTPATJON - PPK
S02 DESIGN REMOVAL EFFICIENCY - X
** FANS
NUMPER
** WIST ELIMINATOR
NUMBER
TYPF
CONSTRUCTION MATERIAL
CONFIGURATION
WASH SYSTEM
*« MIST ELIMINATOR
NUMPER
TYPE
CONSTRUCTION MATERIAL
WASH SYSTEM
** PKOCtSS CONTROL CHEMISTRY
CONTROL VARIABLES
CONTROL RANGE
CONTROL MANNER
MODE
SENSOR LOCATION
** PUMPS
SERVICE
SLURRY FEED PUMPS (SCREW TYpE)
MIST ELIMINATOR MASH PUMPS
MILL SLURRY PUMPS
CLASSIFICATION TANK TRANSFCR
RECYCLE SPRAY PUMPS
** TANKS
SERVICE
TOHifi R6 CIRCULATION
VENTURI REC18CUIAT10N TANK
CLARIFICATION AND COLLECTION TANK
DILUTION AND STORAGE TANK
RCACTICN TANK BtiiD TAKK
** RIHIATIR
TVpi
HIATIH6 NfoIU*
TINPfRATURi BOOST - C
INfRSY
< 174500 ACFM)
< 12* F>
< 5300 6Pw)
( 30.0 6AL/1000ACF)
< 2.5 IN-H20)
( .032 SR/SCFJ
3?
5P.O
8?. 3 5
51.1
134.
4.0
.6
.1
9P.9
200
77.0
8
CHEVRON
FRP
INTERMITTENT, HIGH PRESSURE HATER WASH DIRECTED
BULK ENTRAIMMENT SEPARATOR
INTERMITTENT, HIGH PRESSURE WATER WASH DIRECTED
SO?, SLURRY FLOWS, PH, X SOLIBS» PRESSURE DROP
PH * 5.5-5.?
AUTOMATIC
FEEDBACK
PH PROBES IN REACTION TANKS
NURSCR
6
****
3
3
+ ***
IN-LINi
HOT WATIR
11,1 < 20 F)
1.15* OF BOILER OUTPUT
**
NUMBER
*« WATER LOOP
TYPE
** REACfNT PREPARATION EQUIPKINT
NUMPER OF BALL MILLS
*• TREATMENT
TYPI
INLFT- K6/S
INLET SOLIDS - X
CLOSF6
NONPfOPRIETARY; FORCED OXIDATION WITH AIR
1fl1.? (1339Z LB/HIN)
32. 5
136
-------
EPA UTILITY FGD SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FGD SYSTEMS
• * DISPOSAL
NATURE INTERIM
TVPE UNLINED POND
LOCATION ON-SITE
AREA - ACRES 16.0
«* DISPOSAL
NATURE FINAL
TYPE UNLINED POND
LOCATION ON-SITE
TRANSPORTATION OVERFLOW FROM INTERIM SLUDGE POND
AREA - ACRES 4.0
** DISPOSAL
NATURE FINAL
TYPE UNLINED POND
LOCATION ON-SJTE
TRANSPORTATION OVERFLOW FROM INTERIM SLUDGE POND
AREA - ACRES 2P.O
** DISPOSAL
NATURE FINAL
TYPE SLUDGE POND
LOCATION ON-SITE
AREA - ACRES 28.0
** DISPOSAL
NATURE FINAL
TYPE SLUDGE POND
LOCATION ON-SITE
AREA - ACRES 4.0
.. PERFORMANCE DATA
PERIOD NODULE AVAILABILITY CPERflBILITY ^LIABILITY UTILIZATION X REMOVAL PER BOILER FGO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
0/70 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 0/70 EOUIHHENT: FGD SYSTEM, GENERAL
END DATE 0/70 CCKM fNTS:
MAJOR MODIFICATIONS IN 1970 WERE SANDBLASTING AND COATING OF THE INTERIOR
0-l-TH-E-S-dHJBBfR-S-i R EPtACEMENT -Of ALL INTERNAL STEEL~ PIPES WITH PLASTIC AND
FIBERGLASSt AM) REPLACEMENT OF STAINLESS STEEL DEMISTERS WITH FIBERGLASS.
SINCE DEMISTEf PLUGGING WAS NOT COMPLETELY ELIMINATED, THE UNIT HAS WASHED
MANUALLY EVER\ NI&HT TO MAINTAIN THE REflUlRED OUTPUT.
AFFECTED MODULES: SYSTEM
0/72 SYSTEM
** PROBLEMS/SOLUTIONS/CCMMENTS
START DATE 0/72 EGUIPMENT: FGD SYSTEM, GENERAL
END DATE 0/72 COMMENTS:
TfcE MODIFICATIONS IN THE SUMMER OF 1972 ON THE TWO FGD MODULES INCLUDED
ENLARGEMENT OF THE CRYSTALLIZATION TANK, AND INSTALLATION OF NEW PLASTIC
SPRAY NOZZLES, NEW SLURRY PUMPS A(|D STR A1NERS ,A ND NEW MULTIPLE MIXERS
I* THE TANK. PROBLEMS THAT REMAINED INCLUDED CORROSION, INEFFICIENT
DAMPERS, EXPAhSlON JOINT FAILURE, DEMISTEft FOULING, RAPID EROSION OF THE
SLURRY PUMP, ?ND VALVE FAILURE.
AFFECTED MODULES: SYSTEM
0/73 SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 0/73 EOUIPMENT: F6D SYSTEM, GENERAL
END DATE 0/73 COKMtNTS:
OPERATION Of 1HE FGD SYSTEM SINCE THE FALL OF 1973 HAS BEEN THE MOST
SUCCESSFUL TO DATE.
AffECTED MODULES: SYSTEM
0/74 SYSTEM
137
-------
EPA UTILITY F60 SURVEY: DECEMBER 197f - JANUARY 1979
SECTION 3
DESIfiN AND PERFORMAWE DATA FOR OPERATIONAL FGD SYSTEMS
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY CPERAP1LITY SELIA6ILITY UTILIZATION X REMOVAL PER BOILER F60 CAP.
SOZ PART. HOURS HOURS HOURS FACTOR
6/75 SYSTEM
720
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 6775 EGimPENT: FGD SYSTEM, GENERAL
END DATE 6/75 COMMITS:
STATION LOAD IS REDUCED TO 50 PERCENT EVERYNI6HT. THEREFOREi ONE OF THE
MODULES CAN RE TAKEN OFF-LINE NIGHTLY OFR CLEANING OR REPAIR. WYOMING CCA
(1.5 PERCENT SULFUR) IS BEING BURNED IN THE BOILER. SOME NATURAL GAS HAS
BEEN PURNtp S]NCE JUNE 20.
AFFECTED MODULES: SYSTEM
7/75 SYSTEM
744
8/7;
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
11/76
12/76
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
** PRO
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
** PROl
SYSTEM
SYSTEM
SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 7/75 ECUIFKENT: FGD SYSTEM, GENERAL
END DATE 8/75 COMMENTS:
EACH MODULE IS HUT DOUN ONCE PER UF.EK FOR INSPECTION AND CLEAN-UP.
AFFECTED MODULES: SYSTEM
744
720
744
720
744
744
* PROULEMS/SOLUTIONS/CCMMENTS
START DATE 1/76 EQUIPMENTS F6D SYSTEM, GENERAL
END DATE 2/76 COMMITS:
TOE UTILITY IS REPLACING THE SCRUBBING SYSTEM WITH A VENTURI-ROD FOLLOWED
BY A SPRAY TOkfR.
AFFECTED MODULES: SYSTEM
696
744
720
744
720
744
744
720
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 9/76 EQUIPMENT: BOILER-RELATE 0
END DATE 12/76 COMMENT: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTAGE
A SCHECUlEt> UMT OURA6E COMMENCED IN MID-SEPTEMBER FOR A TURBINE OVERHAUL
AND RESTARTED IN EARLY JANUARY.
AFFECTED MODULES: SYSTEM
744
720
744
138
-------
EPA UTILITY F6C SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORWAUCE DATA FOR OPERATIONAL FGO SYSTEMS
.......... . .. PERFORMANCE DATA .......... — -—......
PERIOD MODULE AVAILABILITY CPERABIL1TY PLIABILITY UTILIZATION X REMOVAL PER BOILER F60 CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 12/76 EQUIPMENT: BOILER-RELATED
fcND DATE 12/76 COMMENTS:
ThE UNIT CONTINUES TO FIRE LOU StjLFllR WYOMING COAL.
AFFECTED MODULES: SYSTEM
1/77 SYSTEM 7*4
«* PROfcLEMS/SOLUTIONS/COHMENTS
START DATE 1/77 EBU11'MENTs F6D SYSTEM, GENERAL
END DATE 1/77 COMMENTS:
THE NEW LIMES10NE FGD SYSTEM BECAME COMMERCIALLY OPERABLE IN EARLY
JANUARY 1977. THE UTILITY REPORTS THAT BOTH PARTICIPATE AND $02 REMOVALS
ARE QUITE SATISFACTORY.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 1/77 EOUI I'MENT: TANK, OTHER
fcND DATE 3/77 PROBtfM: NOT DEFINED/SPECIFIED
MINOR PROBLEM; HAVE BEEN RELATED TO MAINTAINING DESIRED SOLIDS LEVEL IN TH
MAKE-UP TANK. MODIFICATIOON PLANS INCLUDE CESSATION OF SLURRY DILUTION,
WHICH CURRENTLY PRECEDES THE INTRODUCTION OF THE FRESH LIMESTONE SLURRY
IMO THE RECI KCULATION LOOP. THE UTILITY PLANS TO PUMP THE 35 PERCENT
SCLIDS SLURRY DIRECTLY FROM THE SLURRY TANK INTO THE RECIRCULATION LOOP.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 1/77 EQUIPMENT: PUMP, OTHER
END DATE 3/77 COMMENTS:
CURRENTLY SEVERAL DIFFERENT MAKES UF SLURRY PUMPS ARE BEING USED. ALL ARE
FUNCTIONING WELL SO FAR. THE PUMPS HAVE NOT BFEN TN SERVICE LON6 ENOUGH
FCR COMPARISONS TO BE DRAWN.
AFFECTED MODULES: SYSTEM
2/77 SYSTEM 672
3/77 SYSTEM 744
4/77 SYSTEM 720
*• PR06LEMS/SOLUT10NS/COMMENTS
START DATE 4/77 tCUIFKENT: FGD SYSTEM. GENERAL
END DATE 5/77 COMMENTS:
THE SCRUBBER t.AS NOT REQUIRED FOR SERVICE DURING THE REPORT PERIOD BECAUSE
NATURAL GAS UfS FIRED IN THE BOILER.
AFFECTED MODULES: SYSTEM
5/77 SYSTEM 744
6/77 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 6/77 EQUIPMENT: F6D SYSTEM, GENERAL
tNo DATE 7/77 COMMENTS:
THE NO. J BOIlfR HAS BEEN FIRING 10[)X NATURAL 6AS FOR ALL BUT 8-10 BAYS
SINCE THE PE6JNNING OF APRIL 1977.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 6/77 EQUIFMENT: MIST ELIMINATOR
END BATE 7/77 PROPtPM: NOT DEFINED/SPECIFIED
MIST ELIWINATCfi CRACKS HAVE BEEN A PROBLEM.
AFFECTED MODULES: SYSTEM
*• PROBLEMS/SOLUTIONS/COMMENTS
START DATE 6/77 EQUIPMENT: RECYCLE TANK
END BATE 7/77 PROBlCM: NOT DEFINED/SPECIFIED
139
-------
FPA UTILITY F6D SURVEY: DECEMBER 197f - JANUARY 1979
SECTION 3
OES16N AND PERFORMAI,Ct DATA FOR OPERATIONAL F6D SYSTEMS
PERFORMANCE DATA ~'
PERIOD MODULE AVAILABILITY OPERABILITY PLIABILITY UTILIZATION X REMOVAL PER BOILER F.6D "P.
S02 PART. HOURS HOURS HOURS FACTOR
A COMPRESSOR IREAKDOWN IN TH§ RECYCLE TANK AIR A61TATION SYSTEM AND THE
RECYCLE TAMt STRAINER SCREEN WASH HAVE BEEN PROBLEM AREAS.
AFFECTED MODULES: SYSTCI"
** PROBLEMS/SOLUT10NS/COKKENTS
START DATE 6/77 IGUirfENT: AUXILIARY EQUIPMENT
END DATE 7/77
SCOT BLOKER PFOBLEMS WERE ENCOUNTERED.
AFfCCTED MODULES: SYSTEM
•* PR06LEMS/SOLUTIONS/COMKENTS:
START DATE fc/77 E6UIFMENT: PUMP, OTHER
END DATE 6/77 PROBlFM: NOT DEFINED/SPFCIFI ED
THE DENVER SLIRRY PUMPS ARE EXPERIENCES SOME ON-60IN6 PRCBLEMSt WHILE
THE ALLEN-SHE M«AN-HOFF PUMPS ARE OPERATING SATISFACTORILY.
AFFECTED MODULES: SYSTEI"
7/77 SYSTEM
8/77 SYSTEK
7*4
744
** PROfiLEMS/SOLUTIONS/COMMENTS
START DATE 8/77 EOUIFtfENT: FSD SYSTEM, GENERAL
END DATE 8/77 COMMtNTS:
ThE BOILER BURKED NATURAL GAS THROUGHOUT All BUST.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE */77 EOUIfflENT: BIST ELIMINATOR
END DATE 8/77 COKMlNTS:
ThE MIST ELIMINATOR CRACKS H^VE pt!=N REPAIRED.
AFFECTED MODULES: SYSTEM
»* PROBLEMS/SOLUTIONS/COMMENTS
START DAjF- fi/77 EOl)III«ENT: RECYCLE TANK
END DATE 9/77 PROBtFM: NOT DEFINED/SPECIFIED
THE RECYCLE TMK STRAINER PROBLEMS PERSISTED
ccMpfiEssofv UA: MALFUNCTIONING.
AFFECTED MODULES: SYSTEM
THE AIR AGITATION SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 8/77 EGUIFftENT: PUMP, OTHER
END DATE 9/77 COHMENTSj
TltE DENVER SLIRRY PUMPS ARE FUNCTIONING ADEQUATELY AT PRFSENT.
GLAND PACKING ARE BEING REDESIGNED.
AFFECTED MODULES: SYSTEM
THE PUMP
9/77 SYSTEM
720
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 9/77 E6UIfHENT: BOILER-RELATED
END DATE 9/77 COMMFNTS:
AS OF SEPTEMEUR 15 THE UNIT BURNTD COAL.
AFFECTED MODULES: SYSTEM
10/77 SYSTEM
744
*« PROBLEMS/SOLUTIONS/CCMMENTS
START DATE 10/77 n«UlPNENT: FGD SYSTEM* GENERAL
END DATE 10/77 COMMfNTSj
THE SYSTEM CAPACITY WAS CUT BACK TO 50 PERCENT IN OCTOBER BECAUSE A NEU
COOLING TOUER IS BEING CONSTRUCTED.
AFFECTED MODULES: SYSTEM
11/77 SYSTEM
720
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 11/77 EGUir«ENT: FCD SYSTEM, GENERAL
END DATE 11/77 PROBLEM: NOT DEFINED/SPECIFI ED
140
-------
EPA UTILITY FGD SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORKAf,CE DATA FOR OPERATIONAL F6D SYSTEMS
... . .... PERFORMANCE DATA
PERIOD HOODIE AVAILABILITY CPERA6ILITY GFLIABILITY UTILIZATION * REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
Oh NOVEMBER 19 A MAJOR FGD SYSTEK OVERHAUL TOOK PLACE WHILE THE TURBINE
WAS DWON FOR INSPECTION AND THE NEW COOLING TOWER WAS BEING CONNECTED.
AFFECTED MODULES: SYSTEM
12/77 SYSTEM 744
** PROULEMS/SOLUTIONS/COMHENTS
START DATE 12/77 J8UIFMENT: FGD SYSTEM, GENERAL
END DATE 12/77 COFIMtNTS:
THE UNIT CAME BACK ON LINE DECEMBER 20 AT FULL CAPACITY.
AFFECTED MODULES; SYSTEM
1/78 SYSTEM 744
•* PROBLEMS/SOLUTIONS/COMMENTS
START DATE 1/78 EQUIPMENT: PIPING
END DATE 1/7B PSOEUEM: WEATHER-RELATED COMPONENT FAILURE
TfcE F60 SYSTEP* OPERATED WITHOUT ANY PROBLEMS OTHER THAN SOME FREEZIN6 OF
THE PIPELINES.
AFFECTED MODULES: SYSTEM
** PR08LEMS/SOLUTIONS/COHMENTS
START DATE 1/78 ESUIFMENT: THICKENER
END DATE 1/78 PROBLEM: PLUGGING. OTHER
DISCHARGE LINt FREEZING CAUSED CLARIFIES PLUGGING.
AFFECTED MODULES: SYSTEM
2/76 SYSTEM 672
** PROBLEMS/SOLUTIONS/COMHENTS
START DATE 2/78 tOUKMENT: PIPING
END DATE J/78
THE THICKENER UNDERFLOW LINE IS STILL FROZEN AND TWO 3 INCH DIAMETER FIRE
HCSES ARE BEIfiG USED TO PUMP THE UNDERFLOW SOLIDS TO THE POND.
AFFECTED MODULES: SYSTEM
3/78 SYSTEM 744
4/78 SYSTEM ??0
5/7$ SYSTEM 744
6/78 SYSTEM 720
•* PROBLENS/SOLUTIONS/CCMMENTS
START DATE 6/78 EQUIPMENT: F6D SYSTEM, GENERAL
END DATE 7/78 COMMENTS:
THE BOILER AND FGD SYSTEM BOTH OPERATED THROUGHOUT THE PERIOD WITHOUT
AkV FORCED OU1A6ES.
AFFECTED MODULES: SYSTEM
7/78 SfSTEM 744
8/78 SYSTEM 744
** PHOBLEMS/SOLUTIONS/COHMENTS
START DATE 6/78 EBUIFMENT: F6D SYSTEM, GENERAL
END DATE 9/78 COMMENTS:
THE UTILITY RfPORTED THAT THE SYSTEM R*N WITH NO FORCED OUTAGES DURING THE
PERIOD.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 8/78 EClUJFKENT: BOILER-RELATED
END DATE 8/78 COMMENT: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTAGE
THE SYSTEM RAt CONTINUOUSLY THROUGHOUT THE PERIOD WITH THE EXCEPTION OF A
ONE WEEK OUTACE FOR A BOILER-TURBINE INSPECTION.
HI
-------
EPA UTILITY F6D SURVEY: OECEWRFR 1P7f - JANUARY 1979
SECTION 3
OES1EN AND PFRFORMAKE DATA FOR OPERATIONAL FGD SYSTFMS
PERFORMANCE DATA "" "
PERIOD MODULE AVAILABILITY CPERA61LITY PLIABILITY UTILIZATION Ji REMOVAL PER BOILER F 6 D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
AFFECTED MODULES: SYSTEM
9/78 SYSTEM 720
•* PROBLtMS/SOLUTlONS/CCMMENTS
START DATE 9/78 tGUIFHENT: BOILER-RELATED
tND DATF 9/78 COMM[NT: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTAGE
THE UNIT kAS f.OUN THE LAST WEEK AhD A HALF IN SEPTEMBER FOR A SCHEDULED
FALL TURPINE/'fOILER CUTA6E. ROUTINE MAINTENANCE INCLUDES BOILER AND
TURBINE CLEANING AND REPAIR.
AFFFCTED MODULES: SYSTEM
10/78 SYSTEM 744
11/78 SYSTEM 720
12/78 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 12/78 EQUIPMENT: F6D SYSTEM, GENERAL
END DATE 12/78 COMMfNTS:
AN fPA SPONSORtD CONTINUOUS MONITORING TEST BEGAN AT THIS UNIT AT THE
BFEINNING OF OiCEWBER AND WILL CONTINUE THROUGH THE END Qf JANUARY. THE
TEST INtfOLVfS 24 HOUR MONITORING OF S02,OPACITY AND NOX.
AFFECTED MODULES: SYSTEM
1/79 SYSTEM 744
2/79 SYSTEM 672
** PR06LEMS/SOLUTIONS/CCMMENTS
START DATE 2/79 tCUIFKENT: A6ITATOR
END DATE 2/79 PPOBtrMr COMPONENT FAILURE, OTHER
ONE MODULE WAT FORCED OUT OF SERVICE FOR 2 DAyS WHEN ITS TANK AGITATOR
FAILED.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMCNTS
START DATE 2/79 EOUIfMENT: FAN
EN* DATE 2/79 fRCBtfMr NOT DEFINED/SPECIFIED
OKE MODULE WAI FORCED OUT OF SERVICE FOR AN 8 CAY PERIOD DUE TO A FAN
MOTOR MALFUNCTION*
AFFECTED MODULES: SYSTEM
142
-------
EPA UTILITY FGD SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FED SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATt
REGULATORY CLASSIFICATION
PART1CULATE EMISSION LIMITATION -
S02 EMISSION LIMITATION - NG/J
NpT PLANT 6ENERATJNG CAPACITY - MU
CROSS UNIT GENERATING CAPACITY - Mk
NET UNIT GENERATING CAPACITY W/F6D - « fc
NET UNIT GENERATING CAPACITY WCVFCt - PW
EQUIVALENT SCRUBBED CAPACITY - Wfcl
** BOILER DATA
SUPPLIER
TYPF
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU.c/S
FLUF 6AS TEMPERATURE - C
STACK HE I6HT - M
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - KJ/KG
RANGE HEAT CONTENT - bTl/Lf
AVERAGE ASH CONTENT - X
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT
RANGE CHLORIDF CONTENT - X
FUEL FIRING RATE - M T/H
FUEL FIRING RATE - MW
** PARTICULATE SCRUBBER
- X
TYPE
SUPPLIER
NUMFER OF STAGES
LINING MATERIAL
INTERNAL "MATERIAL
TYPE OF NOZZLES
BOILER LOAD/SCRUBBER - X
FLUE 6 AS CAPACITY - CU.M/S
FLUE 6AS TEMPERATURE - C
LlOUlti REC1RCULATION RATE - LITtK/J
L/6 RATIO - LITfR/CU.M
PRESSURE DROP - KPA
S02 INLFT CONCENTRATION - PPM
** FG6 SYSTEM
SALEABLE PRODUCT/THROWAWAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TVPf
SYSTEM SUPPLIER
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICULATE DESIGN REMOVAL EFFICIENCY
$02 DESIGN REMOVAL EFFICIENCY - *
INITIAL START-UP
** ABSORBER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
NUMBER OF STAGES
SHELL MATERIAL
INTERNAL MATERIAL
NUMBER OF NOZ7LES
KANSAS POWER 8 LIGHT
LAURENCE
5
LAWRENCE
KANSAS
B
43. < .100 LB/MMBTU)
?15 . ( .500 LB/MMBTU)
420.0
400.0
*******
420.0
COMBUSTION ENGINEERING
PULV COAL, BALANCED DRAFTt TANGENTIAL FIRED
CYCLIC
0/71
599.78 (1271000 ACFM)
14f».9 t 300 F>
11*. < 375 FT)
******* (***** FT)
COAL
* *****
21260.
******
***** ***
***** *
.55
****** •
.03
******
136.0
400
( 10000 BTU/LB)
* *****
(150 TPH)
RECTANGULAR VARIABLE THROAT
COMBUSTION ENGINEERING
1
316L SS APPROACH AND THROAT
316L SS RODS
NON-ATOMIZING,
50.0
299.7
148.9
655.2
2.1
2.2
.748
FAN TYPE SPRAY
t 635000 ACFM)
( 300 F)
(1C400 GPM)
(16.0 GAL/1000ACF)
( 9 IN-HJO)
THROUAUAY PRODUCT
WET SCRUBBING
LIMESTONE
COMBUSTION ENGINEERING
FULL-SCALE
RETROFIT
- X 98.90
52.00
11/71
VERTICAL COUNTERCURRENT SPRAY
4/78
COMgUSTION ENGINEERING
1
316L SS
HEADERS FRP, NOZZLES CERAMIC
1*
143
-------
FPA UTILITY FfcD SURVEY: DECEMBER 197£ - JANUARY 1979
SECTION 3
DtSIGN AND PERFORKAKCE DATA FOP OPERATIONAL FED SYSTEMS
BOILER LOAD/AFSORPER - X
6AS FLOW - CU.M/S
6AS TFMPfcRATURE - C
LIttUID RcClRCULATION RATE - LITfR/S
L/6 RATIO - L/CU.M
PRESSURE DROP - KPA
PARTICULATE REMOVAL EFFICIENCY - *
S02 OUTLET COK'TRATJON - PPf
S02 DESIGN REMOVAL EFFICIENCY - X
FANS
NUMBER
"1ST ELIMINATOR
MUMPER
TYPE
CONSTRUCTION MATERIAL
CONFIGURATION
WASH SYSTEM
5P.O
25ft. 71
52.2
655.
98.9
35?
52.0
< 5*4000 ACFM)
< 126 F>
(1C400 SP(n)
< 19.0 6AL/10DOACF)
( 2.5 IN-H20)
CHEVRON
FRP
HORIZONTAL
INTERMITTENT, HIGH PRESSURE WATER WASH DIRECTED
** WIST El ICIINATOR
NUHPER
TYPE
CONSTRUCTION MATERIAL
WASH SYSTEM
BULK ENTRAINMENT SEPARATOR
FRP
INTERMITTENT, HIGH PRESSURE WATER WASH DIRECTED
** PROCESS CONTROL CHEMISTRY
CONTROL VARIABLES
CONTROL RANGE
CONTROL MANNER
WODF
SENSOR LOCATION
SO?, SLURRY FLOWS, PH, X SOLIDS, PRESSURE CHANCE
PH=5.5-5.7
AUTOMATIC
FEEDBACK
PH PROBES IN REACTION TANKS
** PUMPS
SERVICE
REACTION-RECYCLE TANK BLEF.D
RECYCLE
SLURRY FEED PUMPS (SCREW TYPE)
SLURRY FEED PUMPS {SCREW TYPE) (SP/R
MIST ELIMINATOR WASH PUMPS
MILL SLURRY PUMP
MILL SLURRY PUMP (SPARE)
CLASSIFICATION TANK TRANSFER PUI»P
CLASSIFICATION TANK TRANSFER PUMP
-------
EPA UTILITY FGD SURVEY: DECFKBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FGD SYSTEMS
** DISPOSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
AREA - ACRES
** DISPOSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
AREA - ACRES
FINAL
UNLINEO POND
ON-SlTE
OVERFLOy FRO* INTERIM SLUDGE POND
4.0
FINAL
UNLINED POND
ON-SITE
OVERFLOW fPGK INTERIM SLUDGE POND
2R.O
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY CPERASILITV RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP-
S02 PART. HOURS HOURS HOURS FACTOR
7/75 SYSTEM
8/75
9/75
744
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 7/75 E6U1FKENT: BOILER-RELATED
END DATE 8/75 COMMENTS:
OIL AND GAS WrRE IN JULY AND AUGUST, RESULTING IN NO FED OPERATION-
AFFECTED MODULES; SYSTEM
SYSTEM
SYSTEM
744
7?0
** PR08LEMS/SOLUTIONS/COMMENTS
START DATE 9/75 ESUIFKENT: BOILER-RELATED
END DATE 10/75 COtfMtNTS:
GAS AND OIL WTPE BURNED ON A PART TIME BASIS DURING SEPTEMBER AND OCTOBER.
BOILER OUTAGE WAS DUE TO INSPECTION AND TURBINE REPAIR.
AFFECTED MODULES: SYSTEP
10/75
11/75
12/75
1/76
2/76
PROBLEMS/SOLUTIONS/COMMENTS
START DATE 9/75 E8UIH*ENT: RECYCLE TANK
END DATE 10/75 PROBlFHt CHEMICAL-RELATED PLUGGING
ADDITIONAL BOILER OUTAGE WAS DUE TO REPLACEMENT OF THE SLURRY TANK ECREENi
AFFECTED MODULES: SYSTEM
SYSTEM
SYSTEM
744
720
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 11/75 E6UIPWENT:
END DATE 1/76 COMMENTS:
PROJECTIONS Fit UTILITY FOR THIS llMT CALL FOR DAYS OF OPERATION IN
1976 WITH FUEt CONSUMPTION BEING 60 PERCENT COAL, 25 PERCENT FUEL OIL. AND
15 PERCENT GAS.
AFFECTED MODULES: SYSTEM
** PROeLEMS/SOLUTIONS/COMMENTS
START DATE 11/75 EOUIFt-ENT: FGD SYSTEM, GENERAL
END DATE 1/75 COMM ENTS:
LIKE UNIT 4 TUS UNIT MAY PE CONVERTED TO A VENTR1-ROD AND SPRAY TOWER
SCRUBBING SYSTEM.
AFFECTED MODULES: SYSTEM
SYSTEM
SYSTEM
SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 2/76 EGUItKENTj FGD SYSTf". GENERAL
END DATE 9/76 COMMENTS:
744
744
696
145
-------
FP» UTILITY FbD SURVEY: DECtWtFR 1«7fl - JANUARY 1979
SECTION 3
OESI6N AKD PERFORMANCE OAT* FOR OPERATIONAL F6D SVSTFMS
_ .......... _ -PERFORMANCE 6 AT A ------------------------ I 7^1
PERIOD MODULt AVAUABUITY CPEMBIim PLIABILITY UTILIZATION ""OV* .OltER
NO INFORMATION HAS IMPORTED BY THE UTILITY FOR THE PERIOD.
AFFECTED MODULES: SYSTEM
3/76 S*STEK 7**
4/76 SYSTEK 7?0
5/76 SYSTEM 7*4
6/76 SYSTEM 72°
7/76 SYSTEM 7**
8/76 SYSTEM 7**
9/76 SYSTEM 720
10/76 SYSTEM 744
** PROBLEMS/SOLUT10NS/COMNEN1S
START DATE 10/76 E OUI 1'^ENT: F6C SYSTfHt GENERAL
END DATE 12/76 CCKFTK'TS:
THE FCILER FlfFS NO. 2 FUEL OIL IN ADDITION TO LOW SULFUR WYOMING COAL
bHILF THE NEW SCRUBBING FACILITIES ARE BEING INSTALLED. THE ORIGINAL
INJECTION AND TAIL-END SCRUBBING SYSTEM IS STILL AVAILABLE FOR SERVICE
AftD OPERATED hHEN THE INIT FIRES COAL. THE SYSTEM WILL TREAT FLUE 6AS
RESULTING FROP THE BURNING OF LOU SULFUR (0.5 PERCENT) WYOMING COAL.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 10/76 EfiUIFMENT: F6D SYSTEM, GENERAL
END DATE U/76 CCMMfNTSS
THE UTILITY Rl-PORTS THAT THE INSTALLATION OF THE NEki ROD AND SPRAy TOUER
SCRUPtlNG SYS KM IS NOW IN PROGEESS. THE SYSTEM WILL CONSIST OF TWO SCRUB-
BING TRAINS EACH HANDLING SO PERCENT OF THE FLUE 6AS CAPACITY. FOUNDATION
AMD STRUCTURAL STEEL ERECTION HAS BEEN COMPLETED, AN6 SOME OF THE BRFECHIN
HAS BEEN INSTILLED. THE F6D WILL OPERATE IN A FULLY AUTOMATIC BASIS.
AFFECTED MODULES: SYSTEM
** PftOBLEMS/'SoLOTIONS/COHMENTS
START DATE 10/76 £OUII«ENT: PROCESS CONTROL
END DATE 12/76 PROBttM: NOT DEFINED/SPECIFIED
KPSL REPORTED THAT C-E HAS ENCOUNTERED SOME PROBLEMS WORKING OUT AND FINE
TUNING SOfF Of THE LOGIC CIRCUITS.
AFFECTED MODULES: SYSTEM
11/76 SYSTEM 720
12/76 SYSTEM m
** PROtiLEMS/SOLUTIONS/COMMENTS
START DATE 1/77 E8UIFMENTJ F60 SYSTEM, GENERAL
tND DATE 5/77 COMMENTS:
KPSL REPORTbD THAT CONSTRUCTION OF THE NEW SCRUBBING SYSTEM IS STILL IN
PS06RESS. ALL FOUNDATION WORK HAS BEEN COMPLETED AND THE ERECTION OF THE
STRUCTURAL STFEL AND BREECHING IS CONTINUING. THE MODULES ARE NOW BEING
ESECTED AT THE PLANT SITE, PARALLEL TO THE EXISTING MARBLE-BED SYSTEM.
AFFECTED MODULES: SYSTEM
1/77 SYSTEM 744
2/77 SYSTEM 672
3/77 SYSTEM 744
4/77 SYSTEM 720
5/77 SYSTEM 744
146
-------
EPA UTILITY FGD SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMAf-CE DATA FOR OPERATIONAL FED SYSTEMS
.............. , --PERFORMANCE DATA —
PERIOD MODULE AVAILABILITY OPERABILITY SELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
SC2 PART. HOURS HOURS HOURS FACTOR
6/77 SYSTEM 72Q
** PROfaLEMS/SOLUTlONS/CCMKENTS
START DATE 6/77 EQUIPMENT: F6D SYSTEM, GENERAL
END DATE 7/77 COhMCNTS:
OPERATION OF THE EXISTING MARBLE BED SCRUBBERS HAS BEEN 8UITE SATISFACTORY
AKD NEARLY PROBLEM FREE. THE CONNECTING DUCTWORK IS CURRENTLY BEING INSTAL
LED AS CONSTRICTION CONTINUES. THE TWO PARALLEL SCRUBBING MODULES, EACH
DESIGNED TO HANDLE ZOO MW OF GENERATING CAPACITY ARE INSTALLED, AS ARE
ThE REHEATER TUBE BUNDLES. THE EXISTING MARBLE BED SCRUBBERS WILL BE
REMOVED WHEN 1HE NEW SCRUBBING SYSTEM IS READY FOR S02 REMOVAL OPERATIONS.
AFFECTED MODULES: SYSTEM
7/77 SYSTEM 744
8/77 SYSTEM 744
9/77 SYSTEM 720
** PROBLEMS/SOLUT10NS/CCMMENTS
START DATE 9/77 E6UIHUNT: F6D SYSTEM, GENERAL
END DATE 9/77 CCMMlNTSl
TK CONSTRUCTION ON THE NEW SCRUPBER PLANT IS CONTINUING ACCORDING TO
SCHEDULE AMD IS EXPECTED TO BE SCMPLETF, BY APRIL 1978. KP&L INDICATED
THAT MORE DETAILED INFORMATION WOULD BE AVAILABLE FOR THE NEXT REPORT.
AFFECTED MODULES: SYSTEM
10/77 SYSTEM ?44
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 10/77 tOUHCENT: F66 SYSTEM, GENERAL
END DATE 11;77 COMMFNTS:
TfcE SYSTEM OPERATED UNDER NORMAL CONDITIONS THROUGHOUT OCTOBER AND NOVEMBE
WITH NO PROBLtWS.
AFFECTED HODULfcS: SYSTEM
11/77 SYSTEM 720
1?/77 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMHENTS
START DATE 12/77 EQUIPMENT: FGD SYSTEM, GENERAL
END DATE 1/78 COWMtNTS:
THE CONSTRUCTION OF TEO VENTRI-ROB SCRUBBERS IS NOW COMPLETE. THE INLET
DUCTWORK IS BUNS INSTALLED, AND THE OUTLET DECT WORK WILL BE INSTALLED
ALON6 WITH ADUT10NAL CONTROLS DURING THE SCHEDULED OUTA6E IN APRIL 1978,
HTE PRESENT Fit SYSTEM OPERATED WITHOUT AMY PROBLEMS.
AFFECTED MODULES: SYSTEM
1/78 SYSTEM 744
2/78 SYSTEM '72
** PR06LEMS/SOLUTIONS/COMMENTS
START DATE 2/76 EOUI^ENT: FGD SYSTEM, GENERAL
END DATS 3/78 CCMMtNTSs
THE CRI6IMAL FtD SYSTEM WAS PULLED OFF LINE ON MARCH 20 SO THAT THE NEW
5CRUBBER-A6SOUSIR SYSTEM COULD BE TUB INTO THE 6AS PATH. THES NEW SKSTEH
CONSISTS Of T*0 MODULES IACH WITH A ROB SCCTION FOR PARTICULAR REMOVAL
AMD A SPRAY TtWIER FOR SO? REMOVAL. THE CAPACITY IS 210 MW IACH KODULf.
IhlTAL OPERATION SHOULD BEGIN BY THE FIRST OF MAT.
AFFECTED MODULES: SYSTEM
5/78 SYSTEM 7«4
4/7B SYSTEM 720
147
-------
FP» UTILITY FGD SURVEY: DECIMPER 197f - JANUARY
SECTION 3
OlSltN AND PERFORMKE DATA FOR OPERATIONAL F6D SYSTEMS
------------------------------------------ p£K FORMANCf DATA
PERIOD MODULE AVAILABILITY CPERABILJTY ,rLJAHILITY UTILISATION
BOILER
5/7P
6/78
** PRO&LEMS/SOLUTIONS/COMMENTS
START DATE
-------
EPA UTILITY FGD SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DtSIGN AND PERFORMANCE DATA FOR OPERATIONAL FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
RE6ULATORY CLASSIFICATION
PARTKULATE EMISSION LIMITATION - MC/J
502 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MM
GROSS UNIT GENERATING CAPACITY - HW
NET UNIT GENERATING CAPACITY U/F6D - Mt
NET UNIT GENERATING CAPACITY UO/FGI) - fU
EQUIVALENT SCRUBBED CAPACITY - KU
** BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU.K/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAMETER - M
( .097 LP/MMRTU)
< 1.670 LP/MMBTU)
KENTUCKY
GREEN R1VEP
1-3
CENTRAL CITY
KENTUCKY
C
42.
718.
*******
64.0
60.0
62.0
64.0
BAPCOCK AND UILCOX
DRV BOTTOM, PULVERIZED COAL
PEAK
0/50
( 360000 ACFH)
( 300 F>
16^.88
HP.9
SO.
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - KJ/KG
RANGE HEAT CONTENT - RTU/LB
AVERAGE ASH CONTENT - I
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTfhT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
FUEL FIRING RATE - M T/H
FUEL FIRING RATE - MW
** MECHANICAL COLLECTOR
TYpE
SUPPLIER
PARTICIPATE DESIGN REMCVAL EFFICIEfCV - 1
FLUE GAS CAPACITY - CU .M/S
PRESSURE DROP - KPA
** PARTICULATE SCRUBBER
NUMBER
TYPE
SUPPLIER
NUMBER OF STAGES
SHELL MATERIAL
LINING MATERIAL
INTERNAL MATERIAL
TYPE OF NOZZLES
BOILER LOAD/SCRUBBER - X
FLUE GAS CAPACITY - CU.M/S
FLUE GAS TEMPERATURE - C
LIQUID RECIRCULATION RATE - LITER/S
L/C RATIO - LITER/CU.M
PRESSURE DROP - KPA
PARTlCUtATE INLET LOAD - G/CU.M
S02 INLET CONCENTRATION - PPM
** FGD SYSTEM
SALEABLE PRODUCT/THROW AWAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
SYSTEM SUPPLIER
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICULATE DESIGN REMCVAL EFFICIEKY - X
S02 DESIGN REMOVAL EFFICIENCY - X
COMMERCIAL DATE
INITIAL START-UP
COAL
BITUMINOUS
255S6.
13.40
******
12.10
******
4.00
******
********
******
*******
*****
( 165 FT)
( 16.0 FT)
( 11000 8TU/LB)
******
(*** TPH)
CYCLONES
WESTERN PRECIPITATION
85.0
49.5 < 105000 AC?M)
.5 ( 2 IN-H20)
1
VARIABLE THROAT VENTURl
AMERICAN AIR FILTER
1
MILD STEEL
ACID PROOF PRECRETE
STAINLESS STEEL THROAT
SPINNER VANE
100.0
136.0 ( 288200 ACFH)
52.2 t 12* f>
85.7 ( 1360 6P«>
4.6 (34.5 6AL/1000ACF)
1.7 t 7 IN-H20)
5.0 ( 2.?0 6R/SCF)
2200.000
THROWAWAY PRODUCT
WET SCRUBBING
LIM£
AMERICAN AIR FILTER
FULL-SCALE
RETROFIT
99.50
80.00
6/76
9/75
149
-------
FPA UTILITY FGD SURVEY: fEClPBER 197F - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FGD SYSTEMS
CONSTRUCTION INITIATION
CONTRACT AWARDED
• * ABSORBS R
NUMPER
TYPE
INITIAL START UP
SUPPLIER
NUMBER OF STAGES
DIMENS IONS
SHELL MATERIAL
SHELL LINER MATERIAL
eOILEP LOAD/APSORBER - X
GAS FLO* - CU.M/S
GAS TEMPfcRATUSE - C
LIQUID PiClRCULATIGM RATE - LITER/S
L/E RATIO - l/CU.M
PRESSURE DROP - KPA
SUPERFKAL 6AE VELOCITY - M/SEC
PARTICULATE OUTLET LOAD- 6/CU.f,
S02 OUTLET CONTRAT10N - PPM
•• FANS
CONSTRUCTION MATERIALS
** MIST ELIMINATOR
NUMPE*
TYPE
CONSTRUCTION MATERIAL
CONFIGURATION
NUMPER OF STAGES
NUMBER OF PASSES
FREEBOARD DISTANCE - M
DEPTH - M
WASH SYSTEM
SUPERFICIAL GAS VELOCITY - M/S
PRESSURE DROP - KPA
4/74
6/73
MOBILE BEO CONTACTOR
9/75
AMERICAN AIR FILTER
1
20X20X27.5
MILD STEfL
ACID PROOF REFRACTORY
10(1.0-
136.00
57.2
*14.
4.S
1.0
4.3
.1
400
( 288?00 ACFM)
( 126 F>
( 9750 GpW)
< 34.0 6AL/1000ACF)
( 4.0 IN-H20)
{ 14.0 FT/S)
( .044 6R/SCF)
bOILFR ID BOOSTER FAN
MILD STEEL
RADIAL VANE
STAINLESS STEEC VANES
HORIZONTAL
1
1
P.38
.91
(27.5 FT>
< 3.0 FT)
OUTWARD SPRAY AT 50 6PM, CONTINUOUS
7.6 t 25.0 FT/S)
.5 C 2.0 IN-H20)
PROCESS CONTROL CHEMISTRY
CONTROL VARIABLES
CONTROL RANGE
SENSOR LOCATION
S02, SAS FLOW PRESSURE DROP* P«» PERCENT SOLIDS
PH-5 TO 8.5; 10% SOLIDS IN RECYCLE
PH-RFACTANT TANK; DENSITY METERS-RECYCLE LINE
*« PUMPS
SERVICE
RECYCLE
REClRCUlATlfiN
RECIRCULATION (SPARE)
SLURRY TRANSFER
POND VATER RETURN
BLEED STREAM
TANKS
SERVICE
SLAKING TANK (SPARE)
SLAKED SLURRY DILUTION/HOLDING TANK
REACTION/RECYCLE
SLAKIN6 TANK
** REHEATER
TYpF
NEATIN6 HEoIUM
TEMPERATURE BOOST - C
** WATER LOOP
TYPE
FRESH MAKEUP WATER ADDITION - LITFRS/S
*• DISPOSAL
NATURE
TYPE
NUMBER
4
2
1
2
2
2
MUMBFR
1
****
1
1
IN-LINE
STEAM
27.S
CLOSED
4.7
FINAL
LINED POND
50 F)
( 75 6PM)
150
-------
EPA UTILITY FGO SURVEYS DECEMBER 1976 - JANUARY 1P79
SECTION 3
DESIGN AND PERFORM AKE DATA FOR OPERATIONAL F60 SYSTEMS
LOCATION
TRANSPORTATION
AREA - ACRES
CAPACITY - CU.H
ON-SITE
PIPE
7.4
203629
( 166.5 ACRE-FT)
PERFORMANCE DATA-- • — ....
PERIOD MO'OULE AVAILABILITY OPERABIL1TY IFL1ABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
9/75 'SYSTEM
720
** PROtlLtMS/SOLUTJONS/COMMENTS
START DATE 9/75 IGUIFKENT: F6D SYSTEM. GENERAL
END DATF 1/76 COfiMlNTS:
THE SYSTEM BECAME OPERATIONAL SEPTEMBER 13, 1975 ON A HALF-LOAD BASIS
BECAUSE OF TUttilNE OVERHAUL. LfcGtlNG OF OPERATING DATA BEGAN DECEMBER
1575.
AFFECTED MODULES: SYSTEM
10/75 SYSTEM
11/75 SYSTEM
1 2/75 SYSTEM
1/76 SYSTEM
74.0
42.0
65.0
11.0
76.0
14.0
35.0
9.0
744
720
744
744
398
257
£40
** PRQBLEMS/SOLUTIONS/COMMEN1S
START DATE 1/76 ESl/I fMENT: RECYCLE PUMP
END DATE 1/76 PROBIFM: NOT D E FINED /SPE Cl F 1 ED
A MAJOR PKCBLiM WAS FAILURE OF THE RECYCLE PUMPS.
AFFECTED MODULES: SYSTEM
•» PROBLEMS/SOLUTIONS/COMMENTS
START DATE 1/76 EQUITttENT: PIPING
END DATE 1/76 PROBLEM: WEATHER-RELATED COMPONENT FAILURE
THAWING AND RfcPAIH OF NUMEROUS FROZEN LINES WAS REQUIRED.
AFFECTED MODULES: SYSTEM
*• PROBLEMS/SOLUTIONS/COMMENTS
START DATE 1/76 EfiUIfMENT: PUMP, OTHER
END DATE 1/76 PFOPUM: NOT DEFINED/SPECIFIED
SHUTDOWN OF SIMP PUMPS WAS NECESSARY.
AfffcTfo MODULES: SYSTEM
** PRObLEMS/SOLUTIONS/COMMENTS
START DATE 1/76 16UIFMENT: TANK, OTHER
tND DATE 1/76 PFOeifM: NOT DEFINED/SPECIFIED
A MAJOR PROtiLtM AREA WAS THE FEED TANK AGITATOR.
AFFECTED MODULES: SYSTEM
2/76 SYSTEM
70.0
42.0
42.0
30.0
696
211
** PROtiLEMS/SOLUTIONS/COMMENTS
START DATE 2/76 EOUI FfENT: TANK, OTHER
END DATE 2/76 FROBIEM: NOT DEFINED/SPECIFI ED
REPAIRS WERE MDE TO THE TANK A6I1ATORS, SLAKE TANKS AND MIX-HOLD TANKS
CONTRIBUTING 10 OUTA6E TIMF.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTE
START DATE 2/76 tOUIfMENT: RECYCLE PUMP
END DATE 2/76 PPOBIFM: NOT DEFINED/SPECIFIED
REPAIRS AND CtEANOUT OF REACTANT PUHPS CONTRIBUTATED TO OUTAGE TIME.
AFFECTED MODULES: SYSTEM
3/76 SYSTEM
97.0
85.0
95.0
52.0
744
386
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 3/76 EOUIFMENT: PUMP, OTHER
END DATE 3/76 PROBLEM: NOT DEFINED/SPECIFIED
151
-------
EPA UTILITY fbO SURVEY: DECEMBER 1"57f. - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL F6D SYSTEMS
PERFORMANCE DATA .. -,_
PERIOD MODULE AVAILABILITY CAPABILITY ^UAtlLITY UTILISATION »o«"™|^ ^ B011ER ^FGD^ ^.^
ALL RUBBEfc-LIftD IMPELLERS WERE REPLACED IN THE PUMPS.
AFFECTED MODULES: SYSTfcM
4/76
5/76
6/76
7/76
8/76
SYSTEM-
SYSTEM
SYSTEC
SYSTEM
SYSTEM
90
81
10P
90
97
.0
.0
.0
.0
.0
100
1CO
99
98
97
.0
.0
.0
.0
.0
100
100
99
99
97
.0
.0
.0
.0
.0
77
61
82
7?
97
.0
.0
.0
.C
.0
10/76
11/76
12/76
1/77
2/77
720
744
720
744
744
744
4i>6
574
722
PROBLEMS/SO LOTION 5/COMMENTS
START DATE 8/76 EfiUjfKENT: FAN
END DATE 8/76 FROBLtM: DESIGN-RELATED VIBRATION
VIBRATION IN 1HE SCRUBBER BOOSTER I.D. FAN NECESSITATED SYSTEM SHUTDOWN'
AND REPAIR.
AFFECTED MODULES: SYSTEM
9/76 SYSTEM
86.0
100.0
100.0
79.0
720
571
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 9/76 EQUIPMENT: FAN
END DATE 9/76 PROP IFM r NOT D EFIN ED/S PE CI FI ED
MINOR FAN F>ROfLEMS OCCURRED BUT NO FORCED OUTAGE TIME WAS REQUIRED.
AFFECTED MODULES: SYSTEM
** PR06LEMS/SOLUT10NS/COMMENTS
START DATE 9/76 EOUIfWENT: BOIL ER-RELA TF D
END DATE 9/76 FROBIEM: NOT DEFINED/SPECIFIED
HALF-LOAD OPEhATIONS WERE CONDUCTED THROUGHOUT THE PERIOD BECAUSE OF
BEARING PRCBLfMS TO ONE OF THE TWO TURBINE GENERATING UNITS.
AFFECTED MODULES: SYSTEM
SYSTEM
SYSTEM
100.0
100.0
100.0
1CO.O
100.0
98.0
94. C
98.0
744
7?0
699
7Ci4
PROBLB»S/«OLUTION?/CeMMENrS
START DATE 11/76 £8UIF«ENT: ABSORBER
END DATE 12/76 COMMENTS:
DURING NOVEMBff? AND DECEMBER, 1974 SOME FLUE 6A S WAS BY-PASSED AROUND
THE SYSTEM WHILE THE UTILITY CONDUCTED A CHECKOUT OF THE SCRUBBER INTERNAL
ADD REPLACED fOME OF THE PACKING SPHERES IN THE MOBILE BED.
AFFECTED MODULES: SYSTEM
SYSTEM
SYSTEM
73.0
94.0
97.0
94.0
87.0
94.0
70.0
94.0
744
744
744
517
698
•* PROBLEMS/SOLUTIONS/COMMENTS
START DATE 1/77 E6UIFMENT: ABSORBER
END DATE 1/77 PROBLEM: MECHANICAL-RELATED COMPONENT FAILURE
T»,E SCRUBBER MS RELINED WITH PRFCRETE, REPLACINC THE ORIGINAL
"CARBOL1NE" WHCH SHOWED EXCESSIVE FLAKING
AFFECTED MODULES: SYSTEM
*• PROBLEMS/SOLUTIONS/COMNENTS
START DATE 1/77 ECUIFMENT: STACK
END DATE 1/77 PROBlE«: NOT DEFINED/SPECIFIED
THE STACK WAS REL1NED WITH
AFFECTED MODULES! SYSTEM
36.0
91.0
91.0
36.0
672 266
243
*• PROBLEMS/SOLUTIONS/COMMENTS
START DATE ?/77 EODIFMENT: STACK
END DATE 3/77 PROP LEU: DESIGN-RELATED INFERIOR CONSTRUCTION MATERIAL
152
-------
EPA UTILITY FGD SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FED SYSTEMS
---- ........ --- . ------------------- _ ------- PERFORMANCE DATA ------------------------------------------
PERIOD MOOULF AVAILABILITY CAPABILITY PLIABILITY UTILIZATION X REMOVAL PER 60ILER FGD CAP.
SC2 PART. HOURS HOURS HOURS FACTOR
DURllNG THt MO*TH OF FEBRUARY JT WAS FOUND THAT THE CARBOLINE STACK LINER
WAS BADLY CfcT tR 1 ORA T ED. SCRUBBER AND BOILER OPERATIONS WERE TERMINATED
UtiTIkVL THE STUCK LINING IS REPAIRED. THE STACK WAS REPAIRED FIRST BY
WELDING A BACKUP METAL PLATE TO THF PORTIONS OF THE STACK WHERE PITTING
OCCURRED. THE ENTIRE STACK WAS THEN LINED WITH REFRACTORY COATING CALLED
PRECRl-TE t-F hY AAF . THE REPAIRS WERE COMPLETED MARCH 7.
AFFECTED MODULES: SYSTEC
** PROBLEMS/SOLUTION S/COK1£N7S
START DATE 2/77 EQUIPMENT: F6D SYSTEM, GENERAL
END DATE 2/77 CCMNjNTS:
IK BOILER IS NOT OPERATED WITHOUT THE SCRUBBER BECAUSE THERE IS NO ESP
FOR PARTI'CULAIF CONTROL.
AFFECTED MODULES: SYSTEM
3/77 SYSTEM
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.C
6/77
9/77
10/77
11/77
7*4
720
7*4
720
167
527
3*0
164
513
3*0
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 6/77 EQUIPMENT: SCRUBBER
END DATE 6/77 PRCBllB.M: NOT DEFINED/SPECIFIED
WORK ON THE SCMUBBER MODULF CONCERNS REPAIRS TO THE UNDER6FD DAMPER SYSTEM
AND LEAKING IK THE VENTURI.
AFFECTED MODULES: SYSTEM
** PROetEMS/SOLUTIONS/COMMENTS
START DATE 6/77 (OUIFMEKtT: REAGENT HANDLING
END DATE 6/77 PPOBIFM: NOT DEFINED/SPECIFIED
LIME SLAKING OPERATIONS WAS REPAIRED.
AFFECTED MODULES: SYSTtd
7/77 SYSTEM
744
•* PROBLEMS/SOLUTIONS/COMMENTS
»TA*T DATE 7/77 teUI^MENT: F6D SYSTEM, GfcKTEHAL
END DATE 11/77 COMMENTS:
A STRIKE It PLANT OPERATING PERSONNEL RESULTED IN BOILER AND FGD SYSTEM
SHUTDOWN.
AFFECTED MODULES: SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
86.0
91.0
91.0
*1«0
7*4
720
74*
720
332
J01
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 11/77 EOUIfMENT: RECYCLE PUMP
END DATE 12/77 PROPLEM: NOT DEFINED/SPECIFIED
PROBLEMS WERE ENCOUNTERED HITH LEAKS IN RECYCLE PUMP IMPELLER COATINGS
AND PUMP FAILtWES. TWO PUMPS WERE DOWN AND BEING BYPASSED.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTI ONS/COHMENTS
START DATE 11/77 EQUIPMENT: PIPING
END DATE 2/78 PROBIEM: WE ATHER-REL ATED COMPONENT FAILURE
DUE TO THfc VEfY COLD HEATHER NUMEROUS FREEzE-UPS OCCURED INCLUDING THE
SLURRY LINE TC THE POND CAUSING FGD OUTAGE.
AFFECTED MODULES: SYSTEM
153
-------
FPA UTILITY f&O SURVEY: DECEMBER 197f - JANUARY 1979
SF.CTJON 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FSD SYSTEMS
PER FOR NANCE DATA
PERIOD MODULE AVAILABILITY OPERAP1L1TY PLIABILITY UTILI7AT10N * REMO>/AL PER BOJ^" FGD r.rrno
S02 PART. HOURS HOURS HOURS FACTOR
12/77
** PR08LEMS/SOLUTIONS/CCMMENTS
START DATE 11/77 E«UI>VENT: PUMP, OTHER
END DATE 11/77 PROBIfcM: NOT DEF1NED/SPFCIFI ED
SLNP PUMP FAILURES WERE NOTED.
AFFECTED MODULES: SYSTEM
•« PSOBLEMS/SOLUTIONS/COMMENTS
START DATE 11/77 EflUItMENT: ABSORBER
tND DATE 11/77 PROFJIC«: NOT DEFINED/SPECIFIED
LEAKS IN THE FACKING WERE NOTED.
AFFECTED MODULES: SYSTtW
50.0
63.0
91.0
50.0
744
596
175
PRObL EMS/SOLUTIONS/COMMENTS
START DATE 12/77 EGUIfKENT: FGD SYSTEM, GENEFfAl
END DATE 1 /7B COM* tNTS:
Th£ SYSTEM COILD HAVE BEEN CONSlDtRE.O AVAILABLE THROUGHOUT MOST OF THE
PERIOD BUT BECAUSE EMERGENCY CONDITIONS THF UTILITY CHOSE TO CONCENTRATE
THEIR MAINTENANCE CREWS ON POWER GENERATION RATHER- THAN F6D OPERATION.
UNDER NORMAL CONDITIONS THF RELATIVELY MNOR FT, D SYSTEM PROBLEMS fcOULD
HAVE BEEN SOLVED MORE QUICKLY.
AFFrCTED MODULES: SYSTEM
3?.0
32.0
ZJ-.'O
744
672
537
672
170
7/78
8/78
2/78 £CU1 f'!»ENT: F6D SYSTEdr GENERAL
4/78 PROBLEM: NOT DEFINED/SPFCIFIED ,
DLRJN6 THt FRLfZE UP NUMEROUS GASKETS WERE TORN THROU6HOUT THE SYSTEM.
THE SYSTEM fcAi SHUT DOWN COMPLETELY FOR REPAIR WORK.
3/78
4/7S
5/78
SYSTEM
SYSTEM
SYSTEM
100.0
41.0
64.0
99
100
.0
• 0
99
100
.0
.0
41
64
.0
.0
744
720
744
669
295
474
296
474
•* PROBLEMS/SOLUTIONS/COMMENTS
START DATE 5/78 EftUI^PENT: PUMP, OTHER
END DATE 5/78 PROBLEM: PLUGGING, OTHER
The SCREENS o^ THE SUCTION SIDE OF THE PUMPS THAT PUHP THE SLURRY FROM THE
PfitP ROOM TO THE NOZZLES EXPERIENCED PLUGGING PROBLEMS. THE SCREENS 6ET
PLUGGED WITH IARGE GRIT IN THE SLURRY AND ARE SUCKED OUT OF POSITION BY
ThE PUWPS. TKf UTILITY REPORTED THAT THIS TENDS TO BE A RE-OCCURRINS
PROBIEM.
AFFECTED MODULES: SYSTEM
6/78 SYSTEM
7J.O
100.0
100.0
77.0
720
525
524
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 6/76 EdUIFfHENT: f6D SYSTEM, GENERAL
END DATE 7/78 PROBLEM: NOT DEFINED/SPECIFIED
BOILER AND F66 SYSTEM OUTAGES DURING JUNE AND JULY WERE FOR ROUTINE
MAINTENANCE.
AFFECTED MODULES:
SYSTEM 13.0 96.0 10,0.0
SYSTEM 61.0 99.0 99.0
13.0
28.0
744
744
103
207
99
205
•* PROBLEMS/SOLUTIONS/COKMENTS
START DATE 8/78 tOUIfKENT: PUMP, OTHER
END DATE 8/78 PRCBICM: NOT DEFINED/SPECIFIED
154
-------
EPA UTILITY FRO SURVEY: DECfMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PFRF ORMA f.C E DATA FOR OPERATIONAL FED SYSTEMS
. PERFORMANCE DATA
PERIOD MODULE AVAILABILITY CPERARU1TY PLIABILITY UTILIZATION
9/78
X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
THE UNIT kAS 10UN FROM AUGUST 1 UNTHL AUGUST 12 AS A RESULT OF BLEED
PUMP PROBLEMS .
AFFECTED MODULES: SYSTEM
76.0
98.0
100.0
41.0
7?0 303
Z98
** PRObLEMS/SOLUTlONS/COMMENTS
START DATE 9/78 EQUIPMENT: FGO SYSTEM. GENERAL
END DATE 9/78 PROBLEM: PLUGGING, OTHER
BECAUSE OF PLUGGING PROBLEMS THE FG D SYSTEM WAS OPERATED AT APPROXIMATELY
ONE THIRD OF TOTAL CAPACITY THROUGHOUT SEPTEMBER.
AFFECTED MODULES: SYSTEM
10/78 SYSTEM
30.0
94.0
96.0
30.0
744
Z36
*• PROBLEMS/SOLUTIONS/COMMENTS
START DATE 10/78 E6UJFKENT: RECYCLE TANK
END DATE 10/78 PROBLEM: PLUGGING, OTHER
T»E FCD SYSTEM EXPERIENCED RECYCLE TANK SCREEN PLUGGING.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMWENTS
START DATE 10/78 ECUKflENT: FAN
END DATE 10/78 PROEUrM; NOT DEFINED/SPECIFIED
THE FCD SYSTEM EXPERIENCED VIBRATING FAN PROBLEMS.
AFFECTED MODULES: SYSTEM
11/7S SYSTEM
24.0
100.0
74.0
24. C
730 175
175
•* PROBtEMS/SOLUTIONS/COMMENTS
START DATE 11/76 EdUjfl'ENT: FGO SYSTEM, ftNERAL
END DATE 11/78 COMMENTS:
TkE UNIT HAS IOWN THE LAST T«0 WEEKS OF NOVEMBER DUE TO LOU I.OAD DEMAND.
AFFECTED MODULES: SYSTEM
12/78
1/79
SYSTEM
SYSTEM
744
672
155
-------
EPA UTILITY F&D SURVEY: DECEMBER 197f - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL F£D SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - Nt/J
S02 EMISSION LIMITATION - kG/J
NET PLANT GCNERATING CAPACITY - MW
CROSS UNIT GENERATING CAPACITY - MV
NET UNIT GENERATING CAPACITY W/FGD - M*
NET UNIT GENERATING CAPACITY WC/FGC - I»W
EQUIVALENT SCRUfBFD CAPACITY - CIW
•» BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATfe
MAXIMUM BOILER FLUE GAS FLOW - cu.c/s
FLUE CAS TEMPERATURf - C
STACK HEIGHT - M
STACK TOP DIAMETER - K
•* FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - KJ/KG
DANCE HEAT CONTENT - BTU/IB
AVERAGE ASH CONTENT - *
RANGE ASH CONTENT - *
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - *
AVERAGE SULFUR CONTENT - Jf
RANGE SULFUR CONTENT - %
AVERAGE CHLORIDE CONTENT - t
RANEE CHLORIDT CONTENT - I
FUEL FIRING RATE - M T/H
FUEL FIRING RATE - MW
GAS s ELECTRIC
(******
(****** LB/M.WBTU)
LOUISVILLE
CANE RUN
4
LOUISVILLE
KENTUCKY
******
99?. 0
190.0
18?. 0
185.0
19P.O
COMBUSTION ENGINEERING
PULVERIZED COAL
RASE
*» /**
346.37 ( 734000 ACFH)
160.0 ( 3?0 F)
76. < 250 FT>
******* (***** FT)
COAL
******
< 11500 BTU/L.B)
******
********
15-16
***** ***
******
3.7S
3.5-4.0
***** ***
******
* * **** *
* ****
C*** TPH)
• * ESP
PARTICULATE DESIGN REMOVAL EfFICIEKY - *
•* F6D SYSTEM
SALEABLE PRO DUCT/THROW AWAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICULATE DESIGN REMOVAL EFFICIENCY . Z
So2 DESIGN REMOVAL EFFICIENCY - it
COMMERCIAL DATE
INITIAL START-UP
CONSTRUCTION INITIATION
CONTRACT AWARDED
99.0
THROWAUAY PRODUCT
WET SCRUBBING
LIMB
CARBIDE
AMERICAN AIR FILTER
FULL-SCALE
RETROFIT
99.00
85.00
9/77
8/76
10/74
4/74
** ABSORBER
TYPE
INITIAL START UP
SUPPLIER
SHELL LINER MATERIAL
L/6 RATIO - L/CU.M
SO? DESIGN REMOVAL EFFICIENCY -
** FANS
TYPE
*• BIST ELIMINATOR
MUMPER
TYPE
CONSTRUCTION MATERIAL
MORUE BED (PARALLEL)
6/76
AMERICAN AIM FILTER
PRECRETE AND PLACITE 4005
P.O ( 60.0 6AL/1000ACF)
87.5
ID BOOSTER
4
CHEVRON
PLASITE 4005 LINING
156
-------
EPA UTILITY FGD SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMA&CE DATA FOR OPERATIONAL F6D SYSTEMS
** TANKS
SERVICE
REACTANT-RECYCLE
** REHEATED
TYPE
TEMPERATURE BOOST - C
** THICKENER
DIAMETER - M
•* WATER LOOP
TYPE
FRESH MAKEUP WATER ADDITION - LITERS/S
** DISPOSAL
NATURE
TYPE
LOCATION
NUMBER
****
DIRECT COMBUSTION
27.8 ( 50 F>
22.9
OPEN
FINAL
LINED POND
ON SITE
( 75 FT)
< 100 GPW)
......... PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERARILITV PLIABILITY UTILIZATION
X REMOVAL PER BOILER FGO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
8/76 SYSTEM
90.0
90.0
87.50
744 7*0
•* PROBLEMS/SOLUTIONS/COMMENTS
START DATE 8/76 E8U1IMENT: FGD SYSTEM. GENERAL
END DATE 8/76 PROBIFM: NOT DEFINED/SPECIFIED
OUTAGE TIME DIKING THE MONTH WAS DUE PRIMARILY TO EQUIPMENT INSPECTIONS,
RfcPAIR/REFLACEMENT OF AUXILIARY MOTOR PARTS, AND DEPLETION OF ABSORBENT
SUPPLY BECAUSE OF A LATE BARGE DELIVERY.
AFFECTED MODULES: SYSTtfl
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE R/76 EQUIPMENT: F6D SYSTEM, GENERAL
END DATE 8/76 COMMENTS:
THE SCRUBBING SYSTEM HAS BEEN GENERALLY OPERATING AT APPROXIMATELY 50 TO
ft PFRCENT FLIE GAS CAPACITY.
AFFECTED MODUlfcS: SYSTEM
**- PROBtEMS/SOLUTIONS/COWMENTS
START DATE 8/76 EQUIPMENT: AUXILIARY EQUIPMENT
END DATE E/76 PROBlEM: NOT DEFINED/SPECIFIED
SOME MINOR PRCBLEMS HAVE BEEN ENCOUNTERED WITH AUXILIARY EQUIPMENT MOTORS.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 8/76 EQUIPMENT: SPRAY NOZZLES
END DATE 8/76 PROBLEM: NOT DEFINED/SPECIFIED
SOME MINOR PRC8LEMS HAVE BEEN ENCOUNTERED WITH SpRAY NOZ7LES IN THE MOBILE
BED CONTACTOR. THE SPRAY NOZZLES ARE SF'INNER-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 NOZZLE
HAVE BEEN REPtACED WITH CERAMIC CONSTRUCTED COMPONENTS.
AFFECTED MODULES: SYSTEM
9/76 SYSTEM
10/76 SYSTEM
90.0
90.0
90.0
7J.O
720
744
7?0
•* PROBLEMS/SOLUTIONS/COMMENTS
START DATE 10/76 EQUIPMENT: FGD SYSTEM, GENERAL
END DATE 10/76 PROBLEM: NOT DEFINED/SPECIFIED
THE UNIT WAS 1AKEN OUT OF SERVICE ON OCTOBER 25, 1976 TO IMPLEMENT
ADDITIONAL MODIFICATIONS TO THE SCRUBBING SYSTEM. MAJOR SYSTEM MODIFICA-
T10NS INCLUDE INCREASING PUMP CAPACITY AND DECREASING PRESSURE DROP.
THESE TUO PROBLEMS HAVE HINDERED OPERATION OF THE UNIT AT FULL LOAD
157
-------
FPA UTILITY FGD SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PFRFORMAKE DATA FOR OPERATIONAL FGD SYSTEMS
----------------------- ...... ------------- PERFORMANCE DATA
PERIOD MODULE AVAUABIL1TY OPERAPU1TY SUABILITY UTILIZATION
BOZIER
CAPACITY.
AFFECTED MODULES: SYSTEM
PROBLEMS/SOLUTIONS/COMMENTS
START DAT? 10/76 tOUIFHENT: F6D SYSTEM, GENERAL
END DOTE 10/76 COtfMlNTS:
TC DATE, THt fECHANICAL RELIABILITY Of THE SYSTEM AS A FUNCTION OF
SfcRVICE TIKE IFRSUS OUTAGE TIME, HAS BEEN VERY 600D .
AFfECTEO MODULES: SYSTEM
12/76
1/77
SYSTEM
SYSTEM
SYSTEM
¥5.0
9Q.O
720
744
744
2/77
3/77
4/77
** PROELEMS/SOLUTIONS/COMWENTS
START DATE 1/77 EBUIf^ENT: F6D SYSTEM, GENERAL
END DATE 3/77 COMMINTS:
DIE TO OHIO RIVER FREEZE Up PAR6E DELIVERIES OF LIKE CEASED.
AFFECTED MODULES: SYSTEM
SYSTEM
672
** PR06LEMS/SOLUTIONS/COMMENTS
START DATE 2/77 EAUIMKENT: F6B SYSTEM, GENERAL
END DATE 2/77 COMMENTS:
DtRINfi FEEiRUATV, THE SCRUBBER UAS ONLY OPERATED FOR TWO 4-HOUR PERIODS
TO PREVENT TOTAL FREEZE-UP.
AFFECTED MODULES: SYSTEM
P3.0 83.0
** PROBLEMS/SOLUTIONS/CCMMENTS
START DATE 3/77 tOUIVMENT: FGD SYSTEM, GENERAL
END DATE 3/77 COMMfNTS:
THE SCRUBBER CAME BACK ON-LINE ON MARCH U, 1977.
AFFECTED MODULES:
744 43Z
** PROSLEMS/SOLUTIONS/COMMENTT
START DATE 3/77 EQUIPMENT: GAS DAMPER
END DATE 3/77 PROBLEM: NOT DEFINED/SPECIFIED
DC POWER SUPPtY TO THE BYpASS DAMPER FAILED. THE SCRUBBER SYSTEM WAS
BYPASSED hHILF REPAIRS WERE MADE.
AFFECTED MODULES! SYSTEM
SYSTEM
7X0
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 4/77 tOUllMENT: F60 SYSTFH, GtMRAL
END DATE 7/77 COMMENTS:
THE SCRUBBING SYSTEM WAS DOWN TOR MODIFICATIONS FROM APRIL 18 TO JOLT 17,
1977.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/CCMMENTS
START DATE 4/77 t6UIF»ENT: MIST ELIMINATOR
END DATE 7/77 FROBlf-M: NOT BE FINED/SPF CI F IEB
A CHFVRON TYPF MIST ELIMINATOR WAS INSTALLED DURIN6 THE OUTA6E
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 4/77 tSUIHWENT: PIPING
END DATE 7/77 PR061F:M: NOT DEFINED/SPECIFIED
158
-------
EPA UTILITY F60 SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION i
DESIGN AND PERFOFUAKCE DATA FOR OPERATIONAL FED SYSTEMS
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
A NEW SPRAY HINDER WAS ADDED TO INCREASE THE L/6 RATIO DURIN6 THE OUTAGE.
AFFECTED MODULES: SYSTEM
** PR06LEMS/SOLUTIONS/CCMHENTK
START DATE */77 fOUIFKENT: RECYCLE TANK
END DATE 7/77 PROBLEM: NOT DEFINED/SPECIFIED
DIRECT OIL-FIXED REHEAT WAS ADDED DURING THE OUTAGE;
AFFECTED MODULES: .SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 4/77 ESUIFKENT: DUCTWORK
END DATE 7/77 FROBI.EM: DESIGN-RELATED INFERIOR CONSTRUCTION MATERIAL
ThE LINING IN THE SYSTEM FROM THE MIST ELIMINATOR TO THE STACK WAS REPLACE
WITH PLASITl 40Q5 (THE ORIGINAL LINING MAS BUBPLINGt BUT HAD NOT YET
FAILED, FAUtHE SEEMED IMMINENT WITHIN 4-5 MONTHS). THE NEU LINING WAS
INSTALLED tY LENERAL COATINGS.
AFFECTED MODULES: SYSTlf
5/77
6/77
7/77
9/77
10/77
11/77
12/77
1/78
SYSTEM
SYSTEM
SYSTEM
90.0
43
74*
no
744 3«0
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 7/77 E.BUIPMENT: F60 SYSTEM. GENERAL
END DATE 7/77 COWMtNTS:
THE SYSTFH KAS PLACED BACK IN SERVICE ON JULY 17, 1977 AFTER SYSTEM
MODIFICATIONS MERE COMPLETED.
AFFECTED MODULES: SYSTEK
8/77 SYSTEM
94.0
93.0
744 657
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 8/77 EQUIPMENT: FGD SYSTEM, GENERAL
END DATE 9/77 COMMfNTS:
COMPLIANCE TESTING OCCURFD OURIN6 AUGUST AND SEPTEMBER 1977 BY EPA
PERSONNEL AND VAS OFFICIALLT APPROVFO TO HAVE ACHIEVED COMPLIANCEV
AFFECTED MODULES: SYSTEM
SYSTEM
SYSTEM
99.0
98.0
99.0
89.0
720 529
744 677
** PROBLEMS/SOLUT10NS/CCMMENTS
START DATE 10/77 E6UIFHF.NT: REAGENT HANDLING
DURING DECFMBER, "AIRCO", THE LIME SUPPLIER, HAD 1200 FT OF THEIR FEED
LINE FREEZE Ut.
AFFECTED MODULES: SYSTEM
SYSTEM
SYSTEM
SYSTEM
94.0
85.0
67.0
63.0
82.0
67.0
720 483
744 715
744
A* PROBLEMS/SOLUTIONS/COMMENTS
START DATE 1/78 EOUIFWENT: FGO SYSTEM, GENERAL
END DATE 1/78 ^^"5™^^ *0" * TIME BUT THERE HERE NO SCRUBBER BREAKDOWNS.
AFFECTED MODULES: SYSTEM
2/76
SYSTEM
672
159
-------
FPA UTILITY fGD SURVEY: DECtWE'ER 197f - JANUARY 1979
SECTION 3
DESIGN AND PERFOPMAKE DATA FOR OPERATIONAL FGD SYSTEMS
------------------------------------------ PERFORMANCF DATA
PERIOD MODULE AVAILABILITY CPErA.ILlTY .ELIAB1L1TT UTILIZATION *B«"«AL^
BO It EH
3/7P
4/7F,
6/78
7/78
8/78
10/78
11/78
13/78
1/79
*• PROBLEMS/SOLUTIONS/COMMENTS
START DATE ?/78 E 8U1 Fi-ENT: FGO SYSTEM, 6ENERAL
END DATE 3 111 COMMtNTS: ..„„,.,-
ThE UNIT WAS tOWN THE ENTIRE MONTH OF FEBRUARY DUE TO A COAL SHORTAGE
AKD A LACK OF AVAILABLE LIME RESULTING FROM THE SEVERE WINTER WEATHtR.
TfE UNIT CAME i ACK ON LINE MARCH 21, 1978.
AFFtCTED MODULES: SYSTtK
SYSTEM
1DQ.O
47.0
720 303
*• PRObLEMS/SOLUTIONS/CCMMENTS
START DATE 4/78 E6U!M»ENT: BOlLfR-RELATFD
END DATE 4/7fi (RCBUM: NOT DEFINED/SPECIFIED
DtRING APHL 1HE BOILER WAS DOWN FOR REPAIRS.
AFFECTED MODULES: SYSTEM
5/78 SYSTEM
31.0
35.0
35.0
12.f>
744 352
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 5 >78 EUUirPENT: BOI LER-RELATF D
END DATE 5/7f fFOPl'M: NOT DEFINED/SPECIFIED
TFE (3C1LFR UA! DOhN AGAIN IN MAY (OR REPAIRS.
AFFECTED MODULES; SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 5 /78 EGUIFfENT: 6AS DAMPER
END DATE 5/7B FfCPLfM: NOT DEFINED/SPECIFIED
DURINC THE MAt BOILER OUTAGE A NUMBER OF MODIFICATIONS VtRE MAKE TO THE
DAMPERS IN TMC FSD SYSTEM.
AfFECTEO MQDULES: SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
99.0
99.0
94.0
100.0
99.0
91 .0
94.0
19.0
7ZO
744
744
720
720
687
744
138
** PROBLEMS/SOLUTIONS/COMMENTS
START BATE 9/76 EOUIFRENT: BOlLFR-RELATFD
END DATE 11/78 PR061EM: NOT DEFINED/SPECIFIED
ThE BOILER WAS DOWN IN SEPTEMBER TO NOVEHBFR 1978 FOR TUBE REPAIRS.
AFFECTED MODULES: SYSTEM
SYSTEM
SYSTEM
SYSTEM
97.0
58.0
744
720
744
472
** PROdLEMS/SOLUTTONS/COMWENTS
START BATE 12/78 EOUI F1HENT: BOILER-RELATED
ENp DATE 1/79 PROBLEM: NOT DEFINED/SPECIFIED
DURING THIS PrRiOD A TURPINE BECAME UNOPERATIONAL. THE UNIT IS EXPECTED T
fit OFF LINE UkTIL APRIL.
AFFECTED MODULES: SYSTEM
SYSTEM
744
160
-------
EPA UTILITY F60 SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL F6D SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - KiG/J
S02 EMISSION LIMITATION - N6/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MM
NET UNIT GENERATING CAPACITY W/FGO - «».
NET UNIT GENERATING CAPACITY WO/FGC - CV
EOUIVALF.NT SCRUBBED CAPACITY - NW
** BOILER DATA
SUPPLIER
TYPF.
SERVICE LOAD
COMMERCIAL SERVICE DATfc.
MAXIMUM BOILER FLUfc GAS FLOW - CU.f'/S
FLUE GAS TEMPERATURF - C
STACK HEIGHT - M
STACK TOP DIAMETER - M
** FUEL DATA
FUEt TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - KJ/KG
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - *
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLOR1DF CONTEXT - X
RANGE CHLORIDE CONTENT - X
FUEL FIRING RATE - M T/H
FUEL FIRING RATE - MW
*• ESP
** F6D SYSTEM
SALEABLE PRODUCT/THROW AWAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICULATE DESIGN REMOVAL EFFICIENCY
S02 DESIGN REMOVAL EFFICIENCY - X
COMMERCIAL DATE
INITIAL START-UP
CONSTRUCTION INITIATION
CONTRACT AWARDED
** ABSORBER
NUMBER
TYPE
INITIAL START UP
** REHEATER
TYPF
HEATING MEDIUM
TEMPERATURE BOOST - C
** THICKENER
NUMBER
** HATER LOOP
TYPE
** TREATMENT
CONTRACTOR
LOUISVILLE £AS R ELECTRIC
CANE RUN
(***»** LB/MMBTU)
(****** UB/NMBTU)
LOUISVJLLE
KENTUCKY
A
******
******
-------
UTILITY fCD SUBVFY; DECE^PER 1?7f - JANUARY 1979
SECTION 3
DESIGN AND PERFOPMKfE DATA FOR OPERATIONAL FGO SYSTFMS
** DISPOSAL
NATURE
TYPE
LOCATION
F INAL
LINED POND
ON SITE
PERFORMANCE DATA
MODULE AVAILABILITY OPERABILITY PLIABILITY UTILIZATION
BOILER
12/77 SYSTEM
3/7f
4/78
5/78
6/78
7/7P
8/78
7*4
** PRObLEMS/SOLUTJONS/COMMENTS
START DATE 12/77 [OUJFf'ENT: F6D SYSTsMf
tND DATE 1?/77 COMMtNTS:
OPERATION OF THE F6D SYSTEM BEGAN ON DECEMBER 79. 1977-
TIONS WERE NOT CONTINUOUS.
AFFFCTED MODULES: SYSTEM
INITIAL OPERA
1/7S SYSTEM
7*4
•* PROBLEWS/SOLUTIONS/COMMENTS
START DATE 1/78 tOUUNENT: INSTRUMENTATION
tND DATE 1/76 PR06UM: NOT DEFINED/SPECIFIED
SCME OF THE CCNTROLS WERE NOT WORKING PROPERLY AND MODIFl3*71ONS HERE
NICETSARY.
AFFECTED MODULES: SYSTEM
2/7B SYSTEM
672
** PROBLEMS/SOLUTIONS/COMMENU
START DATE 2/7? fOUjFI'ENT: F6D SYSTEM* GENERAL
END DATE }/7fe FPOPliT: NOT D E F IME D/S PE CI F I £0
THE TLANT FEMP1NED OFF LINE THROUGHOUT FEBRUARY AND RESTARTED ON HA"CH 2*.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/CCMHENTS
START DATE 2/78 EGDIF-KENT: F60 SYSTEH, EENERAt
END DATE 3/78 PROBlFN: NOT DEFIM£D/SPECIFI ED
VARIOUS IMTI I STAR-UP PROBLEMS %ERE STILL GEIN6 ENCOUNTERED CAUSING
FCD SYSTEM OUTAGES.
AFFECTED MODULES: SYSTEM
SYSTEM
SYSTEM
50.0
97.0
12.?
90.C
744 182
7?0 669
** PROBLEMS/SOLUTIONS/CCMHENTS
START DATE 4/78 tCUI[*ENT: F6D SYSTEM, GENERAL
END DATE 5/78 CCHUCNTS:
F6D SYSTEM MODIFICATIONS WERE MADE DURING THIS TIME IN PREPAR1T90N FOR
PtRFORMANCE TFSTS. HOWEVER THE EPA TEST METHODS WERE NOT FOLLOWED
ACCURATELY'
AFFECTtD MODULES: SYSTEM
SYSTEM
SYSTEM
84.0
86.0
49.0
82.0
744 432
720 685
PROBLEMS/SOLUTIONS/COMMENTS
START DATE 6/78 teUIFWENT: REAGENT HANDL1N6
tND DATE 7/78 PROBLFM: DtSIGN-RFLATED INFERIOR CONSTRUCTION MATERIAL
TI-E STEAM REHEAT COIL INSTALLATION HAS BEEN A CHRONIC PROBL5H AREA.
HAVE PEEN FAILING EVER SINCE INITIAL OPERATIONS.
AFFECTED MODULES- SYSTEM
WELDS
SYSTEM
SYSTEM
?0.0
P6.0
68. 0
62.0
744
744
632
5*0
PROBLEMS/SOLUTIONS/COMMENTS
START DATE 8/78 £6UlFMENT: REAGENT HANDLING
END DATE 9/78 FP.OEHFM: DESIGN-RELATED INFERIOR CONSTRUCTION MATERIAL
162
-------
EPA UTILITY FGD SURVEY: DECEMBER 1978 - JANUARY 1979
StCTlON 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FGD SYSTEMS
._—_ . ........ ....... -PERFORMANCE DATA
PERIOD MODULE AVAILABILITY UPC ft API L 1TY f,f LI Ab ILITY UTILIZATION
X REMOVAL PER BOILER FED CAP.
S02 PART. HOURS HOURS HOURS FACTOR
9/78
10/7P
PROBLEMS CONTINUED WITH THF REHEAT COILS.
AFFECTED MODULES: A
SYSTEM
SYSTEM
BO.O
96.0
67.0
71.0
720
744
609
570
** PRDSLEMS/SOLllTIONS/COKMENTS
START DATE 10/7P tCLlJ fi*ENTt REAGENT HANDL1N6
tND DATE 11/76 FRObLFK: DESIGN-RELATED INFERIOR CONSTRUCTION MATERIAL
TKt SYSTEM WAS SHUTDOWN FOR REPAIRS TO THE STEAM REHEATE.R COILS.
OUTAGE LASTED ABOUT TWO WEEKS.
AFFECTED MODULES: SYSTt*
11/7? SYSTEM
12/7? SYSTEW
1/79 SYSTEM
54.7
69.6
94.0
46.2
67.4
46.2
67.4
33.0
40.6
62.?
7ZO
744
744
253
654
693
THE
302
467
163
-------
tP» UTILITY FCD SURVEY: DECEMbFP 197? - JANUARY 1979
SECTION ?
DESIGN AND FF R FORM K E DATA FOR OPERATIONAL FED SYSTEMS
COMPANY NAKE
PLANT NAMF
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PART1CULATE EMISSION LIMITATION - NG/J
SO? EMISSION LIMITATION - KC/J
NFT PLANT GFNER«TING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - Mk
NFT UNIT GEHIRATIKG CAPACITY k'/FGD - »w
NET UNIT GENERATING CAPACITY WO/FGl - !>h
EOUIVALFNT SCRUPBFD CAPACITY - MW
** noiLFR DATA
SUPPL1ER
TYPF
SERVICE LOAP
COMMERCIAL SERVICE DATt
MAXIMUM BOILER FLUE GAS FLOW - CU.f/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAMETER - M
*« FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - KJ/KG
RANGE HEAT CONTENT - BTU/Lt
AVERAGE ASH CONTENT - »
RANTE ASH CONTENT - X
AVERAGE MOISTURE CONTFI\T - Z
RANGE MOISTURE CONTFNT - X
AVERAGE SULFUR CONTENT - 2
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDF CONTEIsT - X
RANGE CHLORIDE CONTENT - X
FUEL FIRING RATE - f T/H
FUEL FIRING RATE - MW
LOUISVILLE £AS K ELECTRIC
KILL CREEK
LOUI5VILLE
KENTUCKY
B
***** *
******
*******
{*.**** LP/MMBTU)
(****** LF/NMfcTU)
425.0
<25.0
BABCOCK AND UlLCOX
puLvnoizro COAL
BASE
**/**
******** (******* «CFM)
******* (**** F>
****** (**** FT)
******* (***** FT)
COAL
BITUMINOUS
Z6749.
11.50
******
********
3.75
3.75
3.5-4.0
********
******
*******
*****
< 11500 BTU/LB)
******
{*** TPH)
** ESP
•* FGD SYSTEM
SALEABLE P RO DUCT /THROU AWAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE.
PROCESS ADDITIVES
SYSTEM SUPPLIER
DEVELOPMENT LFVEL
NEW/RETROFIT
PARTICULATE DESIGN REMOVAL FFF1CIEKY
SQ2 DESIGN REMOVAL EFFICIENCY - X
INITIAL START-UP
*« ABSORBER
NUMBER
TYPF
INITIAL START UP
SHELL MATERIAL
SHELL LINER MATERIAL
THROWAWAY PRODUCT
WET SCRUBBING
LIME
CARBIDE .
AMERICAN AIR FILTER
fULL-SCAlt
NEW
- 1 99.00
85.00
8/7P
MOBILE BED SPRAY TOWER
8/78
CARBON STEEL
PRECRETE
HEATING MEDIUM
«* WATER LOOP
T»PF
FRESH MAKEUP WATER ADDITION - LITE^/S
** TREATMENT
TYPE
** DISPOSAL
NATURE
TYPF
STEAM
OPEN
9.4
( 150 6PM)
FLYASH AMD LIME STABILIZED
FINAL
SLUDGE POND
164
-------
EPA UTILITY FI50 SURVEY: DECEMBER 1V7g - JANUAPY 1«79
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FGO SVSTFHS
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPEPABILITY PLIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP-
£02 PART. HOURS HOURS HOURS FACTOR
8/78
9/78
10/78
11/78
SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE B/78 teUIHfENT: FGD SYSTEM, GENERAL
END DATE B/78 COMMtNTS:
OPERATION BEG'M ON AUGUST 13, 1978.
AFFECTED MODULES: SYSTEM
744
81.0
80.0
720 7U
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 9/78 EQUIPMENT: PIPING
END DATE 9/78 PFOBlfcM: NOT DEFINED/SPECIFIED
FRP PIPING PPCBLEMS WERE ENCOUNTERED.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SQLUTIONS/COMMENTS
START DATE 9/78
END DATE 9/78
PUMP PROBLEMS WERE RELATED TO BEARING AND SHAFT FAILURES.
AFFECTED MODULES: SYSTEM
SYSTEM
SYSTEM
a«.o
85.0
81.0
42. 0
744
720
710
351
** PROBLEMS/SOLUTIONS/COMMENTS
START BATE 11/78 E6UIFHENT: BOILER-RELATE 0
END DATE 11/78 COMMtNT: PREVENTIVE MAINTENANCE
THE UNIT WAS SHUT DOWN NOVEMBER 18t 1978 FOR SCHDULED INSPECTION. RFSTA&T
IS PROJECTED FOR FEBRUARY 1, 1979.
AFFECTED MODULES: SYSTEM
12/78
SYSTEM
•*
744
START DATE 12/78 E8UIFWENT: F6D SYSTEM, GENERAL
END DATE 1/7? COMMINTS:
THE UNIT DID NOT OPERATE DURING DECEMBER OR JANUARY.
AFFECTED MODULES: SYSTEM
1/79
SYSTEM
744
16!
-------
UTILITY F6D SURVEY: DECEPbER 197f - JANUARY 1979
SECTION 3
DESIGN AND FERFORMAHE DATA FOR OPERATIONAL fCD SYSTEMS
COMPANY NAMF
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - KG/J
NfT PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - Mfc
NET UNIT GENERATING CAPACITY W/FGD - <"
N?T UNIT GENERATING CAPACITY WO/FGt> -
EOUIVALFNT SCRUBBED CAPACITY - MW
** F01LER OA1A
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATt
MAXIMUM BOILER FLUE GAS FLOW - fU.
FLUE GAS TEHPFRATURT - C
STACK HEIGHT - If
STACK TCP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - KJ/KG
RANfiE HEAT CONTENT - BTU/LE>
AVERAGE ASH CONTENT - X
RANEE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - *
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLOR1DF CONTENT - X
RANGE CHLORIDE CONTENT - *
FUEL F IRING RATE - "I T/H
FUEL FIR1N6 RATE - MU
** FSP
LOUISVILLE 6»S t ELECTRIC
PADDY'S RUN
6
LOUISVILLE
KENTUCKY
C
43. ( .100 L9/MMBTU)
516. f 1.200 LB/MMBTU)
»** ****
70.0
64.0
65.0
70.0
FOSTER WHEELER
DRY POTTOM, PULVERIZED COAL
SUMMER PEAKING LOAD
0/51
18?.76 < 400000 ACFM)
17-?.* ( 355 F)
76. < 250 FT)
******* (***** FT)
SUPPLIER
PARTICIPATE DESIGN REMOVAL EFFICIENCY
** FGD SYSTEM
SALEABLE PRO* UCT/THROW AWAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
CONSTRUCTION FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICULATE DESIGN REMOVAL EFF1C1EACV
502 DESIGN REMOVAL EFFICIENCY - X
INITIAL START-UP
CONSTRUCTION COMPLETION
CONSTRUCTION INITIATION
CONTRACT AWARDED
STARTED REfiUESTING BIDS
STARTED PRELIMINAV DESIGN
** ABSORBFR
NUMBER
TYPE
INITIAL START UP
SUPPLIER
NUMPER OF STAGES
DIMENSIONS
SHELL MATERIAL
SHELL LINER MATERIAL
6AS FLOW - CU.M/S
£AS TEMPERATURE - C
L/6 RATIO - L/CU.M
PRESSURE D»OP - KPA
COAL
* *****
26749.
11.50
******
********
******
2.50
2.0-3.5
********
******
***** **
*****
( 11500 BTU/L8)
******
(*** TPM)
RESEARCH COTTRELL
- X 99-1
THROVAWAY PRODUCT
WET SCRUBBING
LIME
CARBIDE
COMBUSTION ENGINEERING
PIONEER SERVICES
FULL-SCALE
RETROFIT
- X 99.10
9H.OO
4/7?
4/73
6/72
7/71
12/70
0/70
MARBLE BED
4/73
COMBUSTION
2
17X1&X50 HlgH
2 1/2 INCH THICK FRP
316 SS
82.58 ( 175000 ACFM)
176.7 ( 350 f)
2.2 ( 16.5 6AL/1000ACF)
2.9 (11.5 IN-H20)
166
-------
EPA UTILITY FGD SURVEY: DECEMBER 1978 - JANUARY 1*79
SECTION 3
DESIGN AND PERF CPU A KC E CAT* FOR OPERATIONAL F6D SYSTEMS
SUPERflCAL GAS VELOCITY - H/SEC
SO2 INLtT CONCENTRATION - PPM
** VACUUM FILTER
NUMBER
TYPE
CONSTRUCTION MATERIAL
CAPACITY - W T/D
INLET SOLIDS - *
OUTLET SOLltS - X
i* WIST ELIMINATOR
NUMBER
TYPE
CONSTRUCTION MATERIAL
FREFBOARO DISTANCE - H
DEPTH - N
VANE SPACING - CM
VANE ANGLES
WASH SYSTEM
PRESSURE DROP - KPA
** TANKS
SERVICE
REACTION TANK
SCRUBBER RECIRCULATION
REACTION SUR6E TANK
ADDITIVE SLURRY TANK
** REHEATER
TYPE
TEMPERATURE BOOST - C
** THICKENER
NUMBER
DIAMETER - M
OUTLET SOLIDS - X
** MATER LOOP
TYPE
FRESH MAKEUP WATER ADDITION
** TREATMENT
TYpE
SUPPLIER
2.7
2000
ROTARY OR UK
NYLON BELT
217.7
22.0
45,0
( 9.0 FT/S)
< 240 T/ft)
CHEVRON
FIBERGLASS
1.37 ( 4.5 FT)
1.52 ( 5.0 FT)
2.5 ( 1.00 IN)
45 DEG.
WATER HASH-RIVER, 60 PSI, 100-200 6PM, DURATION
.4 ( 1.5 JN-H205
NUMBFR
• ***
* **»
*«**
****
DIRECT COMBUSTION
21.7 ( 39 F)
15.Z
22.0
CLOSED
i 50 FT)
( 50 6PM)
FIXATION WITH LIME
NONPROPR1ETARY
** DISPOSAL
NATURE
TYPE
TRANSPORTATION
AREA - ACRES
CAPACITY - CU.H
FINAL
UNLINED POND
TRUCK
10.0
30575 <
Z5.0 ACRE-FT)
------------------------------------------ PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERAeitlTY PLIABILITY UTILIZATION
..ILEt
4/73
6A
6P
SYSTEM
1S.O
56.0
720
** PROHLEMS/SOLUTIONS/COMMENTS
START DATE 4/73 E8UIF«ENTr F6D SYSTEM. 6ENERAL
EN° D*TE MONIES w"l"cPMATED ONE AT A TI«E, «TH FREQUENT SNUTDONNS FOR INSPECTIO
OF E8UIPMENT AND MINOR REPAIRS.
AFFECTED MODULES: SYSTEM
5/73 6A
11.0
167
-------
EPA UTILITY F6D SURVEY: DECtKBFR 197f - JANUARY 1?79
SECTION 3
DESIGN AND PERFORKAUCE DATA FOP OPERATICNAL FfiP SYSTEMS
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERAB1LITY (PLIABILITY UTILIZATION * REMOVAL PER BOILER FPD CAP.
SO? PART. HOURS HOURS HOURS FACTOR
66 65.0
SYSTEM '**
** PROGLEMS/SOLUTIONS/COMWENTS
START DATE 5/73 tGllir-ENT: FGD SYSTEM, GENERAL
£N0 DATE 5/73 COMMENTS:
SINGLE-MODULE OPERATION CONTINUED THROUGH MAY 1«t WHEN THE UNIT WAS SHUT
DOWN FOR MODI FICATIONS.
AFFECTED MOOULfS: SYSTtM
»* PRCBLEMS/SOLUTIOMS/COMMENTS
START DATE 5/73 tCUIFMENT: THICKENER
END DATE 5/73 PKOBlfM: NOT DEFINED/SPECIFIED
EQUIPMENT WAS INSTALLED FOP INJECTION OF A FLOCCULATING AGENT INTO THE
CLARIFIER TAN*.
AFFECTED MODULES: SYSTEK
6/73 6A 1.0
6P 6.0
SYSTEM 720
•« PROBLEMS/SOLUTIONS/CCMMENTS
START DATE 6/73 EOtltKENT: RECYCLE PUMP
END DATF 6/73 Pf'OBlfM: MECHANICAL-RELATED COMPONENT INEFFICIENCY
OPERATION WAS INTEHMITTENT FROf JUNE 19 TO JULY 11 BECAUSE OF MECHANICAL
PROBLEMS klTH THE SLURRY PUMPS.
AFFECTED MODULES: SYSTff
7/73 6A ?1.0
6P 21.0
SYSTEM 7««
*« PROSLEMS/SOLUTIONS/COMMENTS
START DATE 7/73 EOUIPMENT: REAGENT HANDLING
END DATE 7/73 MOPUM: CHEMICAL-RELATED PLUGGING
DURING A SCHEDULED OUTAGE FROM JULY 12 TROUGH AUGUST 1, SEVERAL REPAIRS
WERE MADE TO 1HE LIME SLURRY MAKE-UP SYSTEM. A DISINTEGRATOR UNIT WAS
INSTALLED TO KfDUCE PLUGGING OF STRAINERS AND SLURRY CONTROL VALVES.
AFFECTED MODULES: SYSTEM
8/73 6A 53.0
6B 64.0
SYSTEM 744
»* PROBLEMS/SOLUTIONS/COMMENTS
START DATE 8/73 EGUTFMENT: B01LER-RELAT F, D
ENfi DATf 8/73 FSCBLfM: NOT DEFINED/SPECIFIED
TH OPERATION WAS CONTINUOUS fROM AUGUST 2 TO AUGUST 18 EXCEPT FOR A BRIEF
SHUTDOWN DUE 70 A BOILER-RELATED PROBLEM.
AFFECTED MODULES: SYSTEM
•* PROBLEMS/SOLUTIONS/COMMENTS
START DATE 8/73 tflUIFKENT: THICKENER
END DATE 8/73 PROBif>i: NOT DEFINED/SPECIFIED
FUCM AUGUST 1? TO SEPTEMBER 5, TH£ SYSTEM «AS SHUT DOWN TO REPLACE THE
CLARIFIER'S UhDERFLOW LINE WITH ONE OF LARGER DIAMETER AND TO INSTALL
ADDITIONAL PUfP CAPACITY IN THE CLARIFIERS'S OVERFLOW SYSTEM.
AFFECTED MODULES: SYSTEM
9/7? 6A 85.0
6B 72.0
SYSTEM 720
*» PROBLEMS/SOLUTIONS/COMMENTS
START DATE 9/73 ESUI^ENT: ABSOR6SR
END DATE 9/73 FROBIFM: NOT DEFINED/SPECIFIED
^~~ THE UNIT OPERATED CONTINUOUSLY BETWEEN SEPTEMBER 6 AND 20 EXCEPT FOR A
168
-------
EPA UTILITY FED SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMAMIE DATA FOR OPERATIONAL FfiO SYSTFMS
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERAB1LITY PLIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
7-HOUR SHUTDOWN TO REPAIR A WARBLE BED SUPPORT PLATE.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SQLUTIONS/COMMENTS
START DATE 9/73 EOUIfMENT: FED SYSTEM, GENERAL
END DATE 9/73 COMMtNTS:
THE UNIT UAS SHUT DOWN FROM SEPTEMBER 20 TO THE END OF THE MONTH.
AFFECTED MODULES; SYSTEM
10/73
6«
6fi
SYSTEM
11/73
12/73
2/74
J/74
4/7*
5/74
6/74
7/74
6/74
49.0
94.0
744
*» PROBLEMS/SOLUT10NS/COMMENTS
START DATE 10/73 tQUIFHENT: F6D SYSTEM, GENERAL
END DATE 12/73 COMMENTS:
THE F6D SYSTEM WAS OPERATED UNTIL DECEMBER C0 AFTER WHICH THE BOILER AND
THE SCRUBBER PODULES WERE SHUT DOfcN BECAUSE OF NO DEMAND (THIS IS A
PEAKING-LOAD FOILER).
AFFECTED MODULES: SYSTEM
6A
6e
SYSTEM
6A
66
SYSTEM
3S.o
1CO.C!
44.0
78.0
1/74 SYSTEM
720
744
744
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 1/74 E6UIFWENT: BOILER-BELATED
END DATE 7/74 COMMfNTS:
THE BOILER WAS SHUT DOWN BECAUSE OF NO DEMAND.
AFFECTED MODULES: SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
6A
6B
SYSTEM
50.0
77.0
672
744
720
744
720
744
744
** PROBLEMS/SOLUTIONS/CONMENTS „.,.,.„
ST'RT DATE 6/74 EQU1FKENT: BOILER-RELATED
END DATE 8/74
UNIT HA!
AFFECTED MODULES: SYSTEM
9/74 SYSTEM
OFf FRE8UENTIY DUE TO FLUCTUATION IN POWER DEMAND.
720
cun n»TF 9/74 COMMENTS:
T*E EOILER WAJ SHUT DOWN BECAUSE OF NO DEMAND.
AFFECTED MODULES: SYSTfcM
169
-------
UTILITY F6D SURVEY: DECEMBER 197f - JANUARY 1979
SteTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL F6D SYSTEMS
PERFORMANCE DATA
PERIOD MODULE AVAIlAPUITr OPERARIL1TY fELlABILITY UTUI7AT10N X REMOVAL PER BOILER F6D CAP.
$02 PART. HOURS HOURS HOURS FACTOR
10/7*
10/75
11/75
6«
66
SYSTEM
100.0
100.0
744
PRObLtMS/SOLUTlONS/COKMENTS
START DATE 10/74 I6UIfMENT: FGD SYSTEM, GENERAL
END DATE 10/74 CCMMCNTS: RESEARCH AND DEVELOPMENT
BOILER TURNED ON SPECIFICALLY TO PERFORM LIMESTONE TESTS ON F6D SYSTEM.
AFFECTED MODULES: SYSTEM
11/74 SYSTEM
720
** PR06LEKS/SOLUTIONS/COMMIENTS
START DATE 11/74 EOUIf-MENTS B01LFR-RELA TE 0
END DATE 6/75 COMMENTS:
Tlii BOILER. WAS SHUT DOWN BECAUSE: OF NO DEMAND.
AFFECTED MODULES: SYSTEM
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
6P
•SYSTEM
744
744
672
744
720
744
720
744
744
100.0
100.0
** PR06LEMS/SOLUTION5/COMMEN1S
START DATE 9/75 E8UIP«ENTs F6D SYSTEM, GENERAL
END DATE 10/75 COMMENTS:
THE pOILE* ANC F6D SYSTEM WERE OPERATIONAL ALL OF SEPTEMPER AND THE FIRST
TWO WEEKS IN OCTOBER. OPERAelLITY FOR BOTH MODULES DURING THE. OPERATIONAL
PERIOD WAS IOC PERCENT (RASED UPON LGKE'S PEAK LOAD DETERMINATION). 502
REMOVAL WAS REPORTED TO BE OVER 98 PERCENT.
AFFECTED MODULES: SYSTEM
** PROHLEMS/SOLUTIONS/COMMENTS
START DATE 9/75 ECUIfHENT: BOILER-RELATED
END DATE 10/75 PROBIEM: NOT DEFINED/SPECIFIED
SYSTEM OUTA6E IN THE LAST TWO WEEKS OF OCTOBER WAS DUE PRIMARILY TO BREECH
1*6 IN THE BOILER SECTION.
AFFECTED MODULES: SYSTEM
6A
68
SYSTEM
6A
6B
SYSTEM
100.0
100.0
100.0
100.0
744
720
«* PROBLEMS/SOLUT10NS/COMMENTE
START DATE 11/75 EQUIPMENT: FGD SYSTEM, GENERAL
END DATE 12/75 COMMENTS:
170
-------
EPA UTILITY FGO SURVEY: DECEMBER 1976 - JANUARY 1«?9
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FGD SYSTEMS
------------------------------------------ PERFORMANCf DATA ------------------------------------------
PERIOD MODULE AVAILABILITY CPERAEULITY PLIABILITY UTILIZATION X REMOVAL PER BOILER FED CAP.
_ _____ ___ __ __ , S02 PART. HOURS HOURS HOURS FACTOR
THE BOILEH ANH SCRUBBER SYSTEM R«N MOST OF THE REPORT PERIOO~ON~MONDAV-
FRIDAY EIASIS.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 11/75 E6Ulf*lENT: SCRUBBER
END BATE 12/75 Pfi06i.E«: NOT DEFINED/SPECIFIED
TVO MINOR OUT'KES IN DECEMBER WfRE DUE TO MALFUNCTION AND REPAIR OF THE
DUAL STRAINER SUITCH SHAFT IN THE BOTTOM OF THE SCRUBBER MODULE.
AFFECTED MODULES: SYSTEM
12/75 6» 90.0
68 90.0
SYSTEM 744
1/76 6A 100.0
66 100.0
SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 1/76 beUHMENT: F6D SYSTEM, GENERAL
END DATE 1/76 COMMENTS:
5C2 REMOVAL EFFICIENCY WAS REPORTED TO BE 99 PERCENT CURING JANUARY.
AFFECTED MO»ULE$: SYSTEM
Z/76 SYSTEM 696
** PR06LEMS/SOLUTIONS/COMMENTS
START DATE 2/76 t«UlfWENT: FGD SYSTeHt GENERAL
END DATE 2/76 COMMENTS:
EXTENS1VF SLUDGE STUDY; FIXATION, LEACHATES, SEASONAL VARIATIONS.
SCRUBBER/SLUD FE! STUDY SCHEDULED FOR JUNE OR JULY. THE SCRUBBER WILL NOT
BE OPERATED OMIL THE START OF THE STUDY PROGRAM UNLESS THE BOILER IS
REQUIRED FOR LEAKING POWER DEMANDS. HIGHLIGHTS OF THE SCRUBBER/SLUDGE
STUDY PROGRAM ARE AS FOLLOWS.
6 MONTHS DURATION.
ONE SCHEDULED SHUTDOWN FOR TEST MODIFICATIONS.
DELIBERA1E HIGH CHLORIDE CONCENTRATION OPERATION.
MGO INNOtULATION.
AFFFCTEB W6DULES: SYSTEM
3/76 SYSTEM 7**
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 3/76 E6UIIM£NT: FGD SYSTEM, GENERAL
END DATE 4/76 COMMIMTS:
T»E UNIT DID NOT OPERATE DURING THE REPORT PERIOD IN ANTICIPATION OF THE
EPA SCRUBBER/SLUDGE STUDY. THE UTILITY IS NOW COMPLETING SYSTEM MODIFICA-
TIONS FOR THE OPERATION OF THE TEST PROGRAM.
AFFECTED MODULES: SYSTEM
4/76 SYSTIM '
100.0
"*
5/76 6A 100.0
66 100.0
SYSTIM
** PROBLEMS/SOLUTIONS/COMMEN7S
ST*«T BATS 5/76 ieUIHIINT: F6D SYSTEM* 6ENERAL
END MTE THIS PFAKCLoIcNUN!T WAS OPERATED FART Of THI TIM BURIN6 THE REPORT PERIOD
(APPROXIMATEU 2 WEEKS IN MAY AND TWO WEEKS IN JUNE,). THE SCRUBBER WAS
AVAHABIE TO 1HI BOIUR 100 PERCINT Of THE TIM AND 50? RWOYAL EFFICIENCY
WAS 98 TO 99 S 6URINS THIS OPSRAT1N5 SEGMENT.
AFFECTED MODULES: SYSTEM
7ZO
6/7« SYSTEM
171
-------
EPA UTILITY F&D SURVEY: DEClMbER 197^ - JANUARY 1979
SECTION 3
DESIGN AND PERFOPHAfcCE DATA FOR OPERATIONAL FGD SYSTEMS
._. PERFORMANCE DATA —•--
PERIOD MODULE AVAILABILITY OPERABIL1TY PLIABILITY UTILIZATION % REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
lilt 6A 100.0
6e 100.0
SYSTEC. 7*4
•* PROBLEMS/SOLUTIONS/COMMENTS
START DATE 7/76 E6UIH«ENT: FGD SYSTEM, GENERAL
END DATE 8/76 COMMtNTS:
THIS UNIT WAS OPERATIONAL PART OF THE TIME DURING THE JUIY-AU6UST PERIOD.
THE SCRUBBING SYSTEM WAS AVAILABLE TO THE BOILFR ON A 100 PERCENT BASIS.
NO MAJOR SCRUtPER-RELATED PROBLEMS WERE ENCOUNTERED.
AFFECTfcD MODULES: SYSTtlt
6/76 6A 1CQ.O
66 100.0
SYSTEM 7*4
9/76 SYSTEM 720
** PSOBLEMS/SOLUTIONS/COMHENTf
START DATE 9/76 EGUItMENT: FGD SYSTEM* GENERAL
END DATE 10/76 COMMENTS: RESEARCH AND DEVELOPMENT
THE UNIT DID NOT OPERATE THROUGHOUT SEPTEMBER AND THE FIRST 3 WEEKS IN
OCTOBER. THE &PA-FUNDED SCRUBBER/SLUDGE STUDY PROGRAM COMMENCED OCTOBER 25
THE INITIAL PMSE OF THE PROGRAM CALLS FOR OPERATIONS TO PROCEED FOR A 20
TO 30-DAY PERIOD WITH CARBIDE LIME SCRUBBING APSORBENT. FOLLOWING COMPLE-
TION OF THIS KIN, THE UNIT WILL BE SHUT DOWN AND MODIFICATIONS WILL (SI
INCORPORATED INTO THE SYSTEM FOR OPERATION WITH COMMERCIAL 6RADE (HISH
CALCIUM) LIME .
AFFECTED MODULES! SYSTEM
10/76 S»STEM 7*4
11/76 6A 99.0
6P 99.Q
SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 11/76 EGUIPMENT: FGD SYSTEM, GENERAL
END -OA-TE 12/76 CfHMfNTS: RESEARCH AND DEVELOPMENT
TdE UNIT WAS IN SERVICE BURINS THE REPORT PERIOD. THE SCRUBBING SYSTfM
OPERATED 99.5 PERCENT OF THE TIME THE BOILER WAS IN SERVICE CARBIDE LIME
WAS EMPLOYED 'S THE 502 ABSORBENT. THE HIGH CA CIUM (VIRGIN) LIME RUN,
SCHEDULED AS FART OF THE SCRUBBER/SLUDGE STUDY, WILL COMMENCE ON MARCH 1,
1*77.
AFFECTED MODULES: SYSTEM
12/76 6A 99.0
6B 99.0
SYSTEM 7«4
1/77 SYSTEM 7«4
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 1/77 ECU1FMENT: FGD SYSTEM, GENERAL
END DATE 2/77 COHMfNTS:
BECAUSE OF SEVFRE WEATHEP CONDITIONS THERE WERF NO BOILER OPERATIONS AND
NC SCRUBBER OFERATIONS UNTIL MARCH 15, 1977.
AFFECTED MODULES: SYSTtM
2/77 SYSTEM 672
3/77 SYSTEM 744
4/77 SYSTEM 720
5/77 SYSTEM 744
172
-------
EPA UTILITY F6D SURVEY: DECEMBER 1976 - JANUARY 1"579
SECTION 3
DtSIGN AND PERFORMANCE DATA FOR OPERATIONAL FGD SYSTEMS
............. ------------------ ..__ ------ -PERFORMANCE BAT A ----------- - ---------- - -------------------
PERIOD MODULE AVAILABILITY OPERARILITY RELIABILITY UTILIZATION X REMOVAL PER BOILER FED CAP.
S02 PART. HOURS HOURS HOURS FACTOR
•* PROBLEMS/SOLimONS/COMMENTS
START DATE 5/77 EQUIPMENT: F6D SYSTEM, GENERAL
END DATE 5/77 COHM1NTS: RESEARCH AND DEVELOPMENT
IK MID MARCH Ifi&E BEGAN TESTS FOR EPA WITH REGULAR LIME SINCE ONE OF THE
OBJECTIVES OF THE TEST WAS TO DETERMINE WHpTHER THERE WERE APPRECIATE
DIFFERENCES BtTWEEN REGULAR LIME AND CARBIDE LIME AT THIS FACILITY. CURING
OPERATION U'lTh REGULAR LIME, SCALING PROBLEMS OCCURRED, INDICATING THAT TH
SCALING RESULlfD FROM INCREASED OXIDATION LEVELS. AVAHAFILF OPTIONS FOR
CONTROLLING SCALING WERE LIMITED BY THE FIXED DESIGN FEATURES OF THE SCRUB
PfcR HARDWARE. THE OPTION SELECTED WAS ADDITION OF MGO TO THE SCRUBBING
MEDIUM. WHEN CEO WAS ADDED, THE SCALING PROBLEM WAS ELIMINATED, ALLOWING
COMPLETION OF THE TEST PROGRAM.
AFFECTED MODULES: SYSTEM
6/77 s»STE« 720
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 6/77 E6UIFHENT: F60 SYSTEM, GENERAL
END DATE 8/77 COMMENTS: RESEARCH AND DEVELOPMENT
THE SCRUBBER/SIUDGE EVALUATION STUDY CONTINUED DURING THE PERIOD. THE
SCRUBBER FLAN1 (ONE MODULE IS BEING UTILIZED FOR THIS EXPERIMENTAL PROGRAM
WAS IN SERVICE ON A VIRTUALLY CONTINUOUS BASIS FROM JUNE 18 TO AUGUST 8
OPERATING CN fAGNESIUM INNOcULATFD COMMERCIAL LIME. SYSTEM OPERABIL1TY
DIRIN6 THIS PFRIOD WAS APPROXIMATELY 96X. 502 REMOVAL EFFICACY WAS
MEASURED IK EHESS OF 99. 5X, THfc SYSTEM WAS SHUT DOWN AT THIS POINT TO
PERFORM A NUMbfR OF SCHEDULED MODIFICATIONS TO THE SYSTEM FOR TEST PUR-
PCSES. SPECIFICALLY, MODIFICATIONS ARE BEING IMPLEMENTED TO THE SYSTEM IN
ORDER TO BYPASS THE REACTION TANK IN ORDER TO CONDUCT A SHORT TERM HFTFN-
T1CN TIME TEST. THE TESTING HAS COMPLETED IN AUGUST *77 AFTER THE MODIFI-
CATIONS WERE MODE.
AFFECTED MODULES: SYSTEM
7/77 SYSTEM 744
8/77 SYSTEM 744
9/77 SYSTEM 72°
** PROBLEMS ASOLUTI ON S/COMMENTS
START DATE 9/77 E8UIFMENT: BOILER-RELATF C
END DATE 3/78 COMMENTS;
THE UNIT IS CIRRENTLY NOT OPERATING DUE TO THE LACK OF POWER REQUIREMENT.
AFFECTED MODULES: SYSTEM
10/77 SYSTEM 74*
11/77 SYSTEM 7ZO
13/77 SYSTEM 7U
1/78 SYSTEM 7*4
Z/78 SYSTEM 672
744
3/78 SYSTEM
*/78 SYSTEM
**
PROBLEMS/SOLUTIONS/COMMENTS
START DATE 4/78 EOUIH*ENT: BOILE R-RE»-ATE 0
5/78 SYSTEM
F«»!v-S »SS"S«"M LINE ONLY A FEW HOURS DURING THIS PERIOD. NO OPERATION*
PROBLEMS WERE REPORTED BY THE UTILITY.
AFFECTED MODULES: SYSTEM
744
173
-------
FPA UTILITY fee SURVEY: DECEMBER 197f" - JANUARY 1979
SECTION 3
DESIGN AND PERFOPMAKE DATA FOR OPERATIONAL F6D SYSTEMS
PERfORMANCF D AT A * ~"
PERIOD MODULE AYAILAPIL1TY OPERABIL1TY MLLIABILITY UTILIZATION X REMOVAL PER BOILER FGO CAP.
SC2 PART. HOURS HOURS HOURS FACTOR
6/7E SYSTEM 720
** PR06LEMS/SQLUTIONS/COMMENTS
START DATE 6/78 t «UI F'MENT: 601LER-RfLATt0
END DATE 7/78 COKMtNTS:
THE UMT RAK INTERMITTENTLY FOR ABOUT EI6HT TO TEN DAYS OVER THIS PERIOD.
AFFECTED MODULES: SYSTEM
7/7B SYSTEM 744
8/78 SYSTEM 74*
** PR06LEHS/SOLU7IONS/COMMENTS
START DATE 8/78 EGLIlfENT: THICKENER
£N0 DATE 9/78 COMMI-NTS: RESEARCH AND DEVELOPMENT
THIS UNIT WAS OPERATED FflR TUO WEEKS IN SEPTEMRER SO THAT TESTING OF A NEW
FLOCCULANT COILD BE CARRIED OUT. THE RESULTS OF THESE TESTS WILL DETERMINE
THE TYPE OF FIOCCULANT THAT WILL £E USED IN THE FUTURE AT THE OTHER 16«£
UNITS.
AFFECTED MODULES: SYSTEM
9/78 SYSTEM 720
TO/7R SYSTEM 744
** PROBLEMS/SOLUTIONS/CCMMENTS
START DATE 10/78 E6UIFHENT: 601LFR-RELA TF D
END DATE 11/78 CdMMINTS:
THE BOILER WAt NOT OPERATED DURING OCTOBER OR NOVEMBER.
AFFECTED MODULES: SYSTEM
11/7* SYSTEM 720
12/78 SYSTEM 744 n
** PROHLEMS/SOLUTIONS/COMMENTS
START DATE 1?/7S E6UII'»ENT: F6D SYSTEM, GENERAL
END DATE 1/79 COKMlNTSi
THE UNIT UAS KOT OPERATED DURING DECEMBER OK JANUARY.
AFFECTED MODULES: SYSTEM
1/79 SYSTEM 744 „
174
-------
EPA UTILITY FGO SURVEY: DECEMBER 1*76 - JANUARY 1979
SECTION J
DESIGN AND PERFCPMAfvCE DA T A FOR OPERATIONAL FED SYSTFMS
COMPANY NAMt
PLANT NAMF
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION -
SO2 EMISSION LIMITATION - NG/J
NfT PLANT GENERATING CAPACITY - Mw
GROSS UNIT GENERATING C»PAClTV - Mfc
NET UNIT C-ENERATIMG CAPACITY WF6D - * V
NET UNIT GENERATING CAPACITY VO/FGC> - H;
E6UIVALFNT SCRUUBFD CAPACITY - MW
** BOILER DATA
SUPPLIER
TYPF
SERVICE LOAD
COMMERCIAL SERVICE DATt
MAXIMUM BOILER FLUE GAS FLOW - CU.»/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP 01AI"ETtR - M
*« FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - KJ/KG
RANGE HtAT CONTENT - BTU/Lt
AVERAGE ASM CONTENT - *
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTE.KT - *
RANGE MOISTURE CONTENT - *
AVERAGE SULFUR CONTENT - *
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTFNT - X
FUEL FIRING RATE - M T/H
FUEL FIRING RATF. - HW
** ESP
NUMPER
SUPPLIER
PARTICULATE DESIGN REHCVAl EFFKIEKY
*« FGD SYSTEM
SALEABLE PRODUCT/THROWAW AY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEb/RF.TROFlT
PARTICULATE DESIGN REMCVAl EFF]C1E^CY
S02 DESIGN REMOVAL EFFICIENCY - X
COMMERCIAL DATE
INITIAL START-UP
CONSTRUCTION INIT1ATIOK
CONTRACT AWARDED
** ABSORBER
NUMBER
TYPE
INITIAL START UP
L/G RATIO - L/CU.M
PARTICULATE 1NLFT LOAD - E/CU.f
S02 INLET CONCENTRATION - PPM
S02 OUTLET CONTRATION - PPK
S02 DESIGN REMOVAL EFFICIENCY - X
** CENTRIFUGE
NUMBER
M1NNKOTA POWER COOPERATIVE
MILTON R. YOUNG
2
CENTfR
NORTH DAKOTA
B
****** (****** LB/MMBTU)
516. ( 1.200 LB/MMBTU)
690.0
477.0
408.0
417.0
405.0
BA6COCK ANt H1LCOX
CYCLONE FIRED
BASE
0/77
955.90
179.4
168.
*******
- X
(2021400 ACFK)
t 355 F)
( 550 FT)
(*«*** FT)
COAL
LIGNITE
15119.
********
5-8
3S.OO
******
.70
******
********
******
*******
*****
< 6500 BTU/LB)
******
(*** TPH)
UHFELAGRATOR-FRYE
99.6
THROVAWAY PRODUCT
UET SCRUBBING
LIMEVALKALIKE FLYASH
ADI/COMBUSTION EQUIP ASSOCIATE
SANOFRSON It PORTER
FULL-SCALE
NEW
99.60
75.00
6/78
9/77
9/75
4/75
SPRAY TOWER
6/77
10.7
.0
1900
475
75.0
< 80.0 GAL/1000ACF)
C .005 GP/SCF)
** FANS
NlW
TYPE
BOILER l.D.
175
-------
FPA UTILITY FED SURVEY: DECtKbFR 197f - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FGD SYSTfMS
FANS
NUMBER
TYPF
VACUUM FILTER
NUHPER
TYPF
CAPACITY - M T/D
OUTLET SOLIDS - X
B01LFR l.D. (SPARE)
ROTARY DRUM
45.3 ( 50 T/D)
60.0
MIST ELIMINATOR
TYpE
TANKS
SERVICE
RECYCLE/Fit ACT ION
REHEATER
TYpE
TEMPERATURE BOOST - C
THICKENER
CONSTRUCTION MATERIAL
OUTLET SOLIPS - Z
CHEVRON
NUMBER
Z
BYPASS
13.9 « 25 F)
CONCRETE WITH POLYETHYLENE COATING
40.0
WATER LOOP
TYpF OPEN
FRESH MAKEUP WATER ADDITION - LITFRS/S **.l
DISPOSAL
NATURE FINAL
TYPE MINEFILL
LOCATION OFF-SITE
TRANSPORTATION TRUCK
( 700 6PM)
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABIL1TY FfLIABlLITY UTILIZATION Z REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
9/77 SYSTEM
720
** PROBLEM-S/SOLWTIONS/CCMMEN1S
START DATE 9/77 ECUirKENT: FED SYSTEM. GENERAL
END DATE 9/77 COBCUNTSs
THE UTILITY Rf.PORTED INTERMITTENT OPERATION SINCE INITIAL START-UP.
AFFECTED MODULES: SYSTEM
»• PROBLEMS/SOLUTIONS/COMMENTS
START DATE 9/77 EQUIFPENT: PIPING
END DATE 9/77 PROBIFM: WEATHER-RELATED COMPONENT FAILURE
MAJOR OPERATIONAL PROBLEMS HAVE OCCURRED AS A RESULT OF SEVERE WINTER
WEATHER CONDITIONS. PARTICULARLY NUMEROUS INSTANCES OF FROZEN AND RUPTURED
LINES. THE S^STEK WAS SHUT DOWN DURING THE FIRST PART OF THE MONTH OF
DECEMBER TO IfSTALL HEAT TRACING IN THE LIOUID CIRCUIT.
AFFECTED MODULES: SYSTtM
** PhOeLEMS/SOLUTIONS/COMMENTS
START DATE 9/77 EflUlfWENT: INSTRUMENTATION
END DATE 9/77 F-POBU H; MECHANICAL-RELATED COMPONENT FAILURE
SOME MINOR PRCHLF.HS HAVE OCCURRED WITH THE FLOW METERS (R OTAHET E R S) .
AFFECTED MODULES: SYSTEM
«* PROBLEMS/SOLUTIONS/COMMENTS
START DATE 9/77 ECUIFfENT: GAS DAMPER
END DATE 9/77 PROBLEM: MECHANICAL-RELATED COMPONENT FAILURE
SOME MINOR PRCPLEMS HAVE BFEN REPORTED WITH THE SYSTEM'S GUILLOTINE 6AS
DAMPtRS.
AFFFCTED MODULES: SYSTEM
10/77 SYSTEM
176
-------
EPA UTILITY FGD SURVEY: DECEMBER 1978 - JANUARY 1?79
SECTION 3
DESIGN AND PERFORHAI\CE DATA FOR OPERATIONAL FGO SYSTEMS
" PERFORMANCE DATA .
PERIOD MODULE AVAILABILITY OPERABILITY (^LIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COfmENTS
START DATE 10/77 EQUIPMENT: FGD SYSTEM, GENERAL
END DATE; 11/77 PROBLEM: WEATHER-PELATED COMPONENT FAILURE
WCSK CONTINUED ON INSTALLATION OF ELECTRICAL HFAT TRACING ON SLURRY LINES
AND WATER FIP1M6.
AFFECTED MODULES: SYSTEM
11/77
12/77 SYSTEM m
** PROaLEMS/SOLUTIONS/COMMENTS
START DATE 12/77 ECUIF^ENT: BOlLER-RELATED
END DATE 1/78 COMMENTS:
TfcERE WAS AN t.FERGENCY SHUTDOWN ON DECEMBER 5 AS A RESULT OF BEARING DAM-
AGE WITHIN THE TURBINES.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLU1IONS/COMMENTS
START DATE 12/77 EOUIFMENT: FGD SYSTEM, GENERAL
END DATE 1/78 COMMENTS:
A COMPLIANCE TEST ORIGINALLY SCHEDULED TO BE WITHIN THIS PERIOD HAS PEEN
TENTATIVELY RESCHEDULED WITH THE EPA fOR THE END OF MARCH. THE UNIT IS
TO HAVE THE SYSTEMS IN EQUILIBRIUM (WATER BALANCE).
AFFECTED MODULES: SYSTEM
0/78 A 92.3 28.0 22.2
B 28.5 25.9 20.*
SYSTEM 46.0 53.0 54.0 42.0 876 692 66.7
1/78 SYSTEM 744
2/78 SYSTEM 672
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 2/78 E6UIKPENT: FGO SYSTEM, GENERAL
END DATE 3/78 COMMENTS:
BCTH THE EOILtR AND FGD SYSTEM C A I»E BACK ON LINE FEBRUARY 21 AFTER COM-
PLETION Of TH£- TURBINE REPA IRS. THE COMPLIANCE TEST HAS AGAIN BEEN" RE-
SCHEDULED WITf EPA FOR THE END OF MAY.
AFFECTED MODULES: SYSTEM
*« PROBLEMS/SOLUTIONE/COMMENTS
START DATE 2/78 E6UIFMENT: FAN
END DATE 3/78 PPOBUM: MECHANICAL-RELATED COMPONENT FAILURE
ONE FORCED-DRAFT FAN CUPSTREAM OF THE FED SYSTEM) HAD AN OIL LEAK AND A
SHAFT ALI6NM.EM PROBLEM. THE FAN HAS TAKEN OFF LINE AND SHIPPED TO
BUFFALO FORGE FOR REPAIRS. THE AFFECTED MODULE WAS DOWN FROM FEBRUARY 2?
THROUGH APRIL 10, WHEN THE REPAIRED UNIT WAS RE-INSTALL ED.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COPIMENTS
START DATE 2/78 E6UIFMENT: VACUUM FILTER
END DATE 3/78 PROBiEn: MECHANICAL-RELATED COMPONENT FAILURE
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 A HI) HOPE TO INCORPORATE MODIFICATIONS TO IMPROVE THE PERFOR-
MANCE OF THE FILTERS.
AFFECTED MODULES: SYSTEM
3/78 SYSTEM 7**
4/78 SYSTEM 72°
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 4/78 ECUIf«ENT: F6D SYSTEM. GENERAL
END DATE 7/78 CCMHtNTS:
177
-------
FPA UTILITY FGD SURVEY: DECEMBER 197P - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FGD SYSTEMS
PERFORMANCE OAT A
PERIOD MODULE AVAUA8ILITY CPERAP1L1TY i-rLlAHILlTY UTILIZATION X REMOVAL PER BOILER F€D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
COMPLIANCE TEJT1N6 TOOK PLACE DURING THE WEEK OF JUNE !> . THE REPORT
SHOULD BE AVAILABLE TO THE UTILITY DY THE END OF JUNE.
AFFECTED MODULES: SYSTEM
** PROGLEMS/SOLUTIONS/COMMENTS
START DATE A/78 ECUIf^ENT: GAS DAMPER
END DATE 7/78 PROBLEM: DESItN-RELATED UNDERSIZED COMPONENT
T*E UNIT MS tOWN WITH DAMPER PROBLEMS
-------
EPA UTILITY fCl SURVEY: DECEMBER 1978 - JANUARY 1979
StCTION 3
DESIGN AMD PERFORMANCE DATA FOR OPERATIONAL F6D SYSTEMS
PERFORMANCE DATA . .
PiRIOD MODULE AVAILABILITY OPEPAB1L1TY FEHA6ILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
SC2 PART. HOURS HOURS HOURS FACTOR
F.D. FAN PROBLEMS HAVE CONTtNUED AND HAVE BEEN A MAJOR CONCERN.
AFFECTED MODULES: SYSTtK
11/7B SYSTEM 72Q
12/78 SYSTEM 744
1/79 SYSTJK 744
** PROQLEMS/SOLUTIONS/CCMMENTS
START DATE 1/79 ICUIf'KENT: FAN
£«D BATE 1/79 PPOBIEH: COMPONENT FAILURE, OTHER
DIE TO A FnILlRE Of A FORCED DRAF1 FAN MOTOR 3 MODULE UAS DOUN AND UNIT
WAS AT HALT I CAD.
AFFECTED MODULES: B
** PROBLEMS/SOLUTIONS/COMMENTS
START BATE 1/79 EBUIfMENT: ABSORBER
END DATE 1/79 COCMINTS:
WHILE THE FAN MOTOR UAS BEING REPAIRED THE HOLES IN THE P TOWER WERE
REPAIRED.
AFFECTED MODULES: b
** PROBLEKS/SOLUTIONS/COMWENTS
START DATE 1/79 E«UIFt*EWT: ABSORBER
END DATE 1/79 PROPlEM! WEATHER-RELATED COMPONENT FAILURE
FREEZING KEATfER PRESENTED START UP DIFICULTY.
AFFECTED MODULES: A
** PROBLEKS/SOLUTIONS/COMWENTS
START DATE 1/79 E6U1 tf
-------
•PA UTILITY F6D SURVEY: DECEMBER 197P - JANUARY 1979
SECTION 3
DESIPN AND PERFORMANCE &ATA FOP OPERATIONAL FGD SYSTEMS
COMPANY NAKE
PLANT NAME
UNIT NUMBER
CITY
STATE
RfSULATORY CLASSIFICATION
PART1CULATE EMISSION LIMITATION - NG/4
S02 EMISSION LIMITATION - H6/J
NFT PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MH
NET UNIT GENERATING CAPACITY W/FGD - Ml
NET UNIT GENERATING CAPACITY WO/F60 - W
EQUIVALENT SCRUBBED CAPACITY - MM
• * BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU.P/S
fLUE GAS TEMPFRATURE - C
STACK HEIGHT - M
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - KJ/K6
RANGE HEAT CONTENT - P1U/LE)
AVERAGE ASH CONTENT - J
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - *
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
FUEL FIRING RATF - M T/H
FUEL FIRING RATE - Nkl
•* PARTICULATE SCRUBBER
NUMPEfl
TYPE
SUPPLIER
SHELL MATERIAL
LINING MATERIAL
INTERNAL MATERIAL
BOILER LOAD/SCRU6BIR - X
FLUE GAS TEMPERATURE - C
L/6 RATIO - LITER/CUtM
PRESSURE DROP - KPA
S02 INLET CONCENTRATION - PPM
** F6D SYSTtfl
SALEABLE PRODUCT/THROW AWAY PRODUCT
GENERAL PROCESS TYPE
PROCESS 1YPE
PROCESS ADDITIVES
SYSTEM SUPPLIER
A-£ FIRM
DEVELOPMENT LfVFL
NEW/RETROFIT
COMMERCIAL DATE
INITIAL START-uP
*« ABSORBER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
NUMBER OF STAGES
SHELL MATERIAL
SHELL LINER MATERIAL
L/G RATIO - L/CU.M
SUPFRFICAL GAS VELOCITY - M/SEC
PARTICULATE REMOVAL EFFICIENCY - X
MONTANA POWER
COLSTRIP
1
COLSTRjP
MONTANA
A
***** *
516.
* ******
J60.0
730.0
343.0
36(1.0
******
* *****
BASE
* * /**
* *******
*******
152.
*******
COAL
SUBBITUMINCUS
20569.
P.60
6.1-12.6
23.90
******
.77
0.4-1.0
***** ***
******
*******
*****
(****** LR/MM8TU)
( 1.200 LB/MMBTU)
(*«*,**** ACFfl)
(*«** f)
< 500 FT)
(***** FT)
( 8843 BTU/LP)
8.162 KIN
(*** TPH)
VARIABLE THROAT VENTURI
COMBUSTION EQUIPMENT ASSOCIATES
CARBON STEFL
ABRASION RESISTANT BRICKS IN THROAT
216 SS OR AREAS OF PLUMB BOB
3J. 1
4P.9 < 120 F)
2.0 <1!.0 GALMOOCACF)
4.2 ( 17 lN-H2o>
BOO.000
THROWAWAY PRODUCT
WET SCRUBBING
LIME
ALKALINE FLVASH
ADL/COMBUSTION EOU3P ASSOCIATE
BECHTEL
FULL-SCALE
NEW
11/75
9/75
SPRAY TOWER
9/75
COMBUSTION EQUIPMENT ASSOC.
1
CARBON STEEL
GLASS FLAKE POLYESTER
?.4 ( 16.C GAL/1000ACF)
2.7 < 9.0 FT/S)
99.5
180
-------
SECTION 3
DESIGN AND PERFORMKCE OAT* FOR OPERATIONAL FGD SYSTEMS
SOZ INLET CONCENTRATION -N6/J
$02 INLET CONCENTRATIOk -NG/J
** FANS
NUMBER
TYPE
CONSTRUCTION MATERIALS
** HIST ELIMINATOR
TYPE
CONSTRUCTION MATERIAL
CONFIGURATION
NUMBER OF PASSES
WASH SYSTEM
SUPERFICIAL GAS VELOCITY - M/S
** PROCESS CONTROL CHEMISTRY
CONTROL VARIABLES
** -PUMPS' •- •
SERVICE
ABSORBER/VENTURI
ABSORPER/VENTURI fSPARE)
WASH TRAY
WASH TRAY (SPARE)
RECYCLE TANK TO THICKENER
SLUD6E TO POND
POND WATER RETURN
** TANKS
SERVICE
VENTURI/ABSORPER RECYCLE TANK
CLEAR WATER TRAY RECYCLE TANK
** REHEATER
TYpf
HEATIN6 MEf|IUI«
TEMPERATURE BOOST • C
** THICKENER
(•**** 18/MNBTU)
( 260 LB/MW6TU)
FGD 1.0.
CARBON STEELt RUBBER LINED CASING
CHEVRON
NOREL PLASTIC
HORIZONTAL
4
INTERMITTANT WASH BOTH TOP AND BOTTOM OF MIST fL
2.7 ( 8.7 FT/S)
SO?, PHi PERCENT SOLIDS
NUMBER
** WATER LOOP
TYPE
2
1
Z
1
****
****
****
NUMBER
3
1
IN-LINE
STEAK
37.8
CLCSFB
( 68 F>
** DISPOSAL
NATURE
TYPE
LOCATION
** DISPOSAL
NATURE
LOCATION
TRANSPORTATION
INTERIM
LINED POND
ON-SITE
FINAL
OFF-SITE
PIPE
PERIOD
9/75
10/75
11/75
12/75
1/76
2/76
___..._..........—.. ...... — PERFORMANCE DATA ..... — — — __ — -------
MO.DULE AVAILABILITY OPERABIL1TY LIABILITY UTILIZATION ^JWjm^ ^ 10 111. .Jj^ "^
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM 90.0
SYSTEM 98.0
720
744
720
744
744
696
720
456
576
720
672
624
1.0
19.0
42.0
60.0
64.0
65. C
181
-------
EP» UTILITY F60 SURVEY: DECEMBER 1 SYSTEM, C-ENERAL
END DATE 10/76 COKWII^TS;
A TEfPERATURE EXCURSION RESULTED l« DAMA6E TO SYSTEM COMPONENTS CAUSIM6
StSTFM DOWNTI >'E .
AFFECTED MODULES: SYSTEM
** PRObLEMS/SOLUTIONS/COMMENTS
START DATE 1Q/76 EOUIFMENT: F6D SYSTEM, GENERAL
END DATE 10/76 PPOBlEw: NOT OEFINED/SPFCIf]ED
THE EPERGtNCY SCRUBBER QIJENcH WATtR SUPPLY SYSTEM fAILED TO OPERATE
DURING A TEMPERATURE EXCURSION.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 10/76 tOUIFKEN1: ABSORBER
END DATE 12/76 PPOBlEH: NOT DEFINED/SPECIFIED
The LININGS WIPE DAMAGED DURING A TEMPERATURE EXCURSION.
AFFECTED MODULES: SYSTEM
•* PROBLEMS/SOLUTIONS/COMHENTS
START DATE 10/76 E«UIf*ENTs HIST ELIMINATOR
END DATE 12'?6 PROBLEM: NOT DEFINED/SPFCIFIED
HIST ELIMINATOR DAMAGE OCCURFO AS THE RESULT OF A TEMPERATURE EXCURSION
IK OCTOBER.
AFFECTED MODULES: SYSTEM
11/76 SYSTEM
63.0
720 720
56.0
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 11/76 EOUIICENT: FAN
END DATE 12/76 PROBLEM: NOT DEFINED/SPECIFIEB
A FAILURE OF AN ID fAN MOTOR
AFFECTED MODULES: SYSTEM
12/76
1/77
2/77
3/77
4/77
5/77
6/77
7/77
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
74.0
93.0
95.0
87.0
85.0
87.0
65.0
744
744
672
744
720
744
720
744
744
744
480
600
624
672
696
67. C
73.0
3-0
SO. (I
64.0
69.0
72.0
182
-------
EPA UTILITY FfiD SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DES16N AND PERFORMANCE DATA FOR OPERATIONAL F6D SYSTEMS
PERIOD
,<
8/77
9/77
10/77
11/77
12/77
1/78
2/78
3/78
4/7E
5/78
PERFORMANCE DAT*
MODULE AVAILABILITY OPERAniLITY RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
SYSTEW
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
93.0
93.0
96.0
96.0
98.0
96.0
100.0
9?,0
100.0
66.0
744
720
7**
720
744
744
672
744
7?0
744
•t PRO&LEMS/SOLUTIONS/COMNENTS
STAP-T BATE 5/7R EfiUI FKENT: BOILER-RELATED
£NO DATE 5/7E COMKfcNT: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTA6E
THE UNIT MAS HESTARTED AFTER ITS ANNUAL OVERHAUL DURING HAY.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 5/78 IGUIIMINT: FAN
END DATE 5/78 CCKW!WTS:
THE !.D. FAN fOTOR WAS NOT AVAILABLE DURING UNIT RESTART*
AFFECTED MODULES: 1A
6/78 SYSTEM 76.0 720
7/78 SYSTEM 96.0 7**
8/78 SYSTEM 97.0 7**
9/7? SYSTEM 96.0 7ZO
10/76 SYSTEM 95.0 744
11/78 SYSTEM 91.0 72°
183
-------
EP* UTILITY F&t SURVEY: DECEMBER 1
-------
EPA UTILITY FGD SURVEY! »EcEMeE» 1978 - JANUARY 1«79
SECTION 3
DSS16N AND PERFORMANCE DATA FOR OPERATIONAL F6D SYSTEMS
S02 INLET CONCENTRATION -N6/J
SOZ INLET CONCENTRATE -N6/J
*« FANS
NUMBER
TYPE
CONSTRUCTION MATERIALS
** MIST ELIMINATOR
TVPF.
CONSTRUCTION MATERIAL
CONFIGURATION
NUMBER OF PASSES
UASH SYSTEM
SUPERFICIAL GAS VELOCITY - W/S
*« PROCESS CONTROL CHEMISTRY
CONTROL VARlAPLfS
»'• pUMpS
SERVICE
ABSORBER/VENTURI
ABSORBER/VENTURI (SPARE)
UASH TRAY
UASH TRAY (SPIRE)
RECYCLE TANK TO THICKENER
SLUDGE TO POND
FOND WATER RETURN
** TANKS
SERVICE
VENTURI/ABSORBER RECYCLE TANK
CLEAR UATER TRAY RECYCLE TANK
** REHEArER
TTpE
HEATING MEoIUW
TEMPERATURE BOOST - C
** THICKENER
NUMBER
*• WATER LOOP
TYPE
** DISPOSAL
NATURE
TYPE
LOCATION
** DISPOSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
(*•*** IB/BCIBTU)
( 260 LB/MflBTU)
Fee I.D.
CARBON STEEL, RUBBER LINED CASIN6
CHfVRON
NOREL PLASTIC
HORIZONTAL
t
2.7
UASH BOTH TOP AND ^OTTOIH OF HIST FL
( 8.7 FT/S)
SO?, PH, PERCENT SOLIDS
NUMBfN
2
1
2
1
****
«***
****
IN-LINE
STEAM
37.8
CLOSED
INTERIM
LINED POND
ON-SITE
FINAL
POND
OFF-SITE
PIPE
68 F)
PERIOD
5/76
6/76
7/76
8/76
9/76
tO/76
MODULE
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
._„„ .. PERFORMANCE DATA
AVAHABIILITT OPERABILITY RELIABILITY UTILIZATION
100.0
100.0
99.0
96.0
98.0
90.0
Z REMOVAL PER
S02 PART. HOURS
744
720
744
744
7?0
744
BOILER FED
HOURS HOURS
536
384
312
240
7?0
744
CAP.
FACTOR
1.0
23.0
20.0
13.0
65. C
77.0
185
-------
EP* UTILITY FGD SURVEY: DECEMBER 1971? - JANUARY 1979
SECTION 3
DESIGN AND PERFORMhCE DATA FOR OPERATIONAL FG|> SYSTEMS
PERIOD
11/76
12/76
1/77
2/77
3/77
4/77
5/77
6/77
7/77
8/77
9/77
10/77
11/77
12/77
1/78
2/78
J/7B
MODULE
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
AVAILABILITY CPEPAB1LITY ^.LIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
94.0
93.0
8S.O
94.0
97.0
85.0
63.0
bR.O
91.0
81.0
90.0
98.0
98.0
9R.O
97.0
95.0
89.0
** PROBLEMS/SOLUTION S/CPWMENTS
START DATi 3/78 EeuiFMENT: BOILER-RELATED
END DATE 4/78 COMMIT: PREVENTIVE MAINTENANCE SCHEDULED
THE BOILER WAS SHUT DOWN FOR ANNUAL OVERHAUL.
AfFEcTfcD MODULES: SYSTEM
4/7?
5/7S
6/7S
7/78
8/78
9/7B
10/7?
11/7f
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
87.0
99.0
97.0
96.0
99.0
94.0
99.0
99.0
720 720
744 744
744 720
672 648
744 672
720 696
744 312
720 672
744 67?
744
720
744
720
744
744
672
744
UNIT OUTAGE
720
744
720
744
744
720
744
720
80.0
82.0
68.0
73.0
7/1.0
68. n
23.0
61.0
58.0
0
0
0
0
186
-------
fPA UTILITY FGt> SURVEY; DEC?M6ER 1978 - JANUARY 1979
SECTION 3
DESICiN AND PtRFORMAKE DATA FOR OPERATIONAL FGD SYSTEMS
COMPANY NAME
PLANT NAKf
UNIT NUMBSR
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULAR EMISSION LIMITATION - N6/4
S02 EMISSION LIMITATION - K6/J
NET PLANT GENERATING CAPACITY - f,v
GROSS UNIT GENERATING CAPACITY - Mfc
NFT UNIT GENERATING CAPACITY M/FGD - Ml.
NET UNIT GENERATING CAPACITY VO/FGO - l»fc
EQUIVALENT SCRUBBED CAPACITY - KIW
** BOILER DATA
SUPPLIER
TYPF
SERVICE LOAD
COMMERCIAL SERVICE DATtf
MAXIMUM BOILER FLUE GAS FLOW - CD.;»/S
FLUE 6AS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE MEAT CONTENT - KJ/K6
RANGE HFAT CONTENT - BTU/LE
AVERAGE ASH CONTENT - *
RANEE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X'
RANGE MOISTURE CONTFNT - X
AVERAGE SULFUR CONTENT - )!
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTEKT - I
RANGE CHLORIDE CONTENT - *
FUEL FIRING RATE - M T/H
FUEL FIRING RATE - MM
** MECHANICAL COLLECTOR
TYpf
SUPPLIER
** PARTICULATE SCRUBBER
TYPE
SUPPLIER
SHELL MATERIAL
TYPE OF NOZZLFS
BOILER LOAD/SCRUBBER - X
LlftUlO RfcCIRCULATION RATE - LITfR/S
L/G RATIO - LITER/CD. M
PRESSURE BROP - KPA
SUPERFICIAL GAS VELOCITY - M/S
PARTKULATE INLET LOAD - G/CU.H
PARTICULAR DESIGN REMOVAL EFF1C1EKY
SQZ INLET CONCENTRATOR - PPH
** F6D SYSTEM
SALEABLE PRODUCT/THROW AWAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LFVEL
NEW/RETROFIT
PARTICULATE DESIGN REMCVAL EFFU1EOCY
SoZ DESIGN REMOVAL EFFICIENCY - X
INITIAL START-UP
CONSTRUCTION INITIATION
CONTRACT AWARDED
** ABSORBER
MUMPER
TYPE
NEVADA POWER
REID GARDNER
1
MOAPA
NEVADA
A
47.
F1*.
*******
125.0
110.0
< .100 LP/MMPTU)
< 1.200 LP/MMFlTU)
125.0
FOSTER-WHEELER
WET BOTTOM
BASE
0/65
••225.--21'
176.7
61.
*******
COAL
******
2B959.
6.00
******
********
******
.SO
0.5-1.0
********
******
*******
*****
< 47SOOO »CFM->
( 350 F)
( 200 FT)
(***** fT>
( 12430 BTU/LI3)
******
<*** TPH)
MULTICLONES
RESEARCH COTTRELL
VARIABLt THROAT VENTURI
COMBUSTION ENGINEERING
1NCOLOY 825
TANGENTIAL
50.0
157.5
1.1
3.7
50.3
1.4
97.0
375.000
< 2500
(10.0 GAL/1000ACF)
< 15 IN-H20)
( 165.0 FT/S)
( .60 GR/SCF)
THROWAWAY PRODUCT
WET SCRUBBING
SODIUM CARBONATE
ADL/COMBUSTION EQUIP ASSOCIATE
BECHTEL
FULL-SCALE
RETROFIT
97.00
90.00
4/7*
12/72
7/71
PERFORATED PLATE WASHING TOWER
167
-------
fPA UTILITY ftO SURVEY: DECEMBER 19?f - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FED SYSTEMS
INITIAL START UP
NUMPER Of STAGES
DIHENSIONS
BOILER LOAD/ABSORBER - 3
LI8UIO REC1RCULATION RATE - LITER/1
PRESSURE DROP - KPA
SUPERFICAL 6AS VELOCITY . K/SEC
S02 OUTLET CONTRATION - PPM
** FANS
NUMGER
TYPE
CONSTRUCTION MATERIALS
*• HIST ELIMINATOR
NUMBER
TYPE
CONSTRUCTION MATERIAL
CONFIGURATION
WASH SYSTEM
PRESSURE DROP - KPA
** TANKS
SERVICE
VENTURI RECYCLE
** REHEATER
TYPE
HEATING MEDIUM
TEMPERATURE BOOST . C
ENERGY RE6UIRFD
** MTE» LOOP
TYPE
FRESH MAKEUP WATER ADDITION - LITFfS/S
•* DISPOSAL
N*TURE
TYPF
LOCATION
AREA - ACRES
** DISPOSAL
N»TURE
TYPE
LOCATION
TRANSPORTATION
AREA - ACRES
4/74
1
50 DIA.
100.0
38.
.7
3.4
17
< 600
< 3.0 IN-H20)
( 11.0 FT/S)
I .C. BOOSTER FAN
CARBON STEEL
RADIAL VANE
316L SS
HORIZONTAL
•NONE
.1
( .5 IN-H20)
NUMBFR
****
INDIRECT HOT AIR
STEAM
16.7 < 30 F>
15.2""« BTU/HR; 4MW
OPEN
1.6
( 25 6PM)
INTERIM
CLAy LINED POND
ON-SITE
FINAL
EVAP POND
ON SITE
GRAVITY FLOW fROM INTERIM SLUDGE POND
«f..O
........ -PERFORMANCE DATA- —•
PERIOD MODULE AVAILABILITY OPERARIL1TY (PLIABILITY UTILIZATION
X REMOVAL
SC2 PART.
PER BOILER FCD CAP.
HOURS HOURS HOURS FACTOR
*/7* SYSTEM
720
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 4/74 ECUIFKENT: FGD SYSTEM, GENERAL
1/75 SYSTEM
2/75 SYSTEM
END DATE 4/74 COMMENTS:
TKE SYSTEM WAS FIRST PLACED IN SERVICE IN APRIL 1974. THE SCRUBBING $*STE
DESIGN WAS &ASED ON INFORMATION Al«e DATA OBTAINED FROM AN 8000-ACFM PILOT
PLANT PROGRAM CONDUCTED AT REID GARDNER STATION IN 19?1 AND 1972.
AFFECTED MODULES: SYSTEM
744
672
«• PROBLEMS/SOLUTIONS/COMMENTS
START DATE 2/75 EQUIPMENT:
END DATE 2/75 PPOP.UM: WEATHER-RELATED COMPONENT FAILURE
168
-------
EPA UTILITY FGD SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PER FORM A f,C E DATA FOR OPERATIONAL F6D SYSTFMS
_ . PERFORMANCE DATA
PERIOD MODULE AVAILABILITY CPERA0IL1TY RELIABILITY UTILIZATION X REMOVAL PER BOILER F60 CAP-
S02 PART. HOURS HOURS HOURS FACTOR
FROZEN SODIUM CARBONATE FEED LINES ACCOUNTED FOR OUTAGE TIME.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 2/75 E«UIPHENT: F6D SYSTEM, GENERAL
END DATE 2/75 PROBLEM: NOT DEFINED/SPECIFIED
A 2-DAY LACK (F CHEMICALS RESULTED IN OUTAGE TIME.
AFFECTED MODULES: SYSTEM
3/75 SYSTEM 744
4/75 SYSTEM 720
** PROBLEMS/SoLUTlONs/COMMENTS
START DATE 4/75 f:Bl)IFMENT: BOILER-RELATED
END DATE 5/75 COMMENT: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTAGE
TfcE BOILER HAS SHUT DOUN APRIL II FOR ROUTINE MAINTENANCE AND PLACED BACK
C-M LINE MAY 1?.
AFFECTED MODULES: SYSTEM
5/75 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 5/75 teui FflENT: FGD SYSTfiMt GENERAL
END DATE 6/7; COMMtNTS:
A HIGH ASH COKTENT OF UP TO 20 PERCENT BY WEIGHT OF THE COAL BURNED
RECENTLY HAD l\0 EFFECT ON FMMISSICNS.
AFFECTED MODULES: SYSTEM
6/75 SYSTEM 7?0
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 6/75 EQUIPMENTS F6D SYSTEM, 6ENERAL
END DATE 6/75 PROBIEM: NOT DEFINED/SPECIFIED
ROUTINE MECHANICAL PROBLEMS WERE REPORTED.
AFFECTED MODULES; SYSTEM
** PROBLEMS/SOLUTIONS/COMBENTS
START DATE 6/75 ECUIfMENT: INSTRUMENTATION
END DATE 6/75 PROBIEM: NOT DEFINED/SPECIFIED
RCUTINE INSTRUMENTAL PROBLEMS UERE REPORTED.
AFFECTED MODULES; SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 6/75 EOUIFPENT: PIPING
END DATE 6/75 PROBLEM! CHEMICAL-RELATED EROSION
ABRASION CF RIPBER LINED PIPES HAS A PROBLEM.
AFFECTED MODULES; SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 6/75 EOUIFMENT: F6D SYSTEM, GENERAL
END DATE 6/75 COMBENTS:
THE UTILITY HAS REPORTED THAT A SECOND PERFORMANCE TE$T WAS RECENTLY
COMPLETED AND PASSED.
AFFECTED MODULES: SYSTEM
7/75 SYSTEM 74*
** PROBLEMS/SOLUTIONS/COMMENTS
START DATS 7/75 E6UUMENT: BOILER-RELATED
END DATE 9/75 PROBLEM: NOT DEFINED/SPECIFIED
OkE OUTAGE UNFFLATED TO THE FGD SYSTEM WAS REPORTED FROM JULY THROUGH
SEPTEMBER.
AFFECTED MODULES: SYSTEM
PROBLEMS/SOLUTIONS/COMMENTS
START DATE 7/75 EBUIfMENT: FGD SYSTEM, GENERAL
END DATE 9/75 I'KOBUM: NOT DEFINED/SPECIFIED
189
-------
EPA UTILITY FtD SURVEY; DECEMBER 197* - JANUARY 1979
SECTION 3
DESHN AND PERFORMANCE DATA FOR OPERATIONAL FGfc SYSTEMS
-—-PERFORMANCE BAT A - — .......— ......
PERIOD MODULE AVAILABILITY CPERAGIL1TY ^LIABILITY UTILIZATION * REMOVAL PER BOILER F60 CAP.
S02 PART. HOURS HOURS HOURS FACTOR
OUTAGFS DURING JULY THROUGH SEPTEMBER WERE CAUSED Br SCRUP6ER MALFUNCTIONS.
AFFECTED MODUltS! SYSTEM
a/75
9/75
10/75
SYSTEM
SYSTEM
SYST|I»
7P.O
60.0
.n
744
720
744
716
303
559
*» PROfiLEMS/SOLUTIONS/CPMNENTS
START DATE 1fl/7S EOUII-fENT: BOILER-RELATED
ENp OATF 10/75 COMMIT: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTAGE
LOW OPERATING TIME DURING OCTOBER WAS DUE TO SCHEDULED BOILER MAINTENANCE.
AFFECTED MODULES: SYSTEM
•* PROBLEMS/SOLUTIONS/COMMEN1S
START DATE 1C/75 EflUU^ENT: REAGENT HANDLING
END DATE 10/75 PROBl.tn: NOT DEFINED/SPECIFIED
-------
EPA UTILITY FtD SURVEY: DECEMBER 1978 - JANUARY 1«»79
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FGD SYSTEMS
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY CPERABUJTY HLIABIL.IT V UTILIZATION X REMOVAL PER BOILER FGD CAP-
S02 PART. HOURS HOURS HOURS FACTOR
** PROBtEMS/SOlUTIONS/COMHENTf:
START DATE 2/76 teUI WENT: F6D SYSTEM, GENERAL
END DATE 2/76 COMM iNTS:
FINE SCRUBBER INOPERATIVE PERIODS WERE REPORTED DURING FEBRUARY. THREE OF
THESE OUTAGES WERE NOT RELATED TO THE FGD SYSTEM.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 2/76 ECUIIHENT: PUMP, OTHER
END DATE 2/76 PROBlfM: NOT DEFINED/SPECIFIED
SEAL WATER PRCtfLFMS WERE REPORTED DURING FEBRUARY.
AFFECTED MODULES: SYSTEf
«* PR06LEMS/SOLUTIONS/COMMENTS
START DATE 2/76 EQUIPMENT: PIPING
IND DATE 2/76 PROSlFM! C HEM1 C AL-RELATF, D PLUGGING
CKEMICAL LINE PLUGGING PROBLEMS WERE NOTED DURING FEBRUARY.
AFFECTED MODULES: SYSTEM
3/76 SYSTEM 99.0 72.0 99.0 39.0 744 39b 287
• * PROULEMS/SOLUTIONS/COMNENTS
START DATE 2/76 fc&UI FMCNTi SCRUBBER
END DATE 3/7« PROBlfM: NOT DEFINED/SPFCJFIED
ONI FOPCIC SCKUBBER OUTAGE WAS CAUSED BY A VENTURI LEAK.
AFFECTED MODULES: SYSTEM
*/76 SYSTEM 15.0 91.0 100.0 13.0 720 106 970
** PROBLEMS/SOLUTlONS/COMMEim
START DATE 4/76 t6Ulf*ENT: SoUiR-RELATED
END DATE 4/76 COMMtMT: PREVENTIVE MAINTENANCE SCHEDULE1! UNIT OUTAGE
ThE POILER KA£ TAKEN OUT OF SERVICE IN APRIL FOR INSPECTION OF VftLVgS AND
CCAL CONDUITS.
AFFECTED MODULES: SYSTFK
5/76 SYSTEM 744 0
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 5/76 teUIMENT: EI01LFR-RELAT E D
END DATE 7/76 CCMMtNT: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTAGE
THE UNIT WAS SHUT DOWN FOR A SCHEDULED TURBINE OVERHAUL AND BURNER LINE
CONDUIT REPLACEMENT.
AFFECTED MODULE$: SYSTEM
6/76 SYSTEM 7ZO 0
7/76 SYSTEM 744 0
8/76 SYSTEM 97.0 75.0 94.0 49.0 744 479 360
*« PROBLEMS/SOLUTIONS/COMMENTS
START DATE 8/76 tSUI f-MINT: THICKENER
END DATE «/76 COMMENT: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTAGE
PLUGGING IN TH THICKENER CAUSED AN OUTAGE DURING AUGUST.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 8/76 EfiUIPMENT: TANK, OTHER
END DATE 6/76 COMMtNT: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTAGE
PLUGGING IN T«E TRAY RECYCLE TANK DURING AUGUST RESULTED IN A FGC OUTAGE.
AFFECTED MODULES: SYSTEM
9/76 SYSTEM 95.0 97.0 95.0 89.0 720 656 639
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 9/76 eeuiFMENT: SPRAY NOZZLES
END DATE 9/76 PROBLEM: CHI-MI CA L-RELATFO PLUGGING
191
-------
EPA UTILITY FCD SURVEY; DECtMBER 1«7F - JANUARY 1979
SEtTiON 3
DtSlGN AND PERFOfMAKfE DATA FOR OPFRATIONAL FED SYSTEMS
__ ..... - — -. .............PERFORMANCE DATA- »——. .... —— — "
PERIOD MODULE AVAILABILITY CPERAniLlT* PLIABILITY UTILISATION X REMOVAL PER BOILER FfiD CAPt
SO? PART. HOURS HOURS HOURS FACTOR
PLUGGING IN THE ViNTQRJ SPRAY HEADERS CAUsED A SCRUBBER OUTAGE.
AFFICTED MOPULfcS: SYSTEM
** PROHLEMS/SOLUTJONS/CCMMENTS
START DATl "76 ieuifHINT: FAN
END DATE 9/76 PPOEtfn: NOT DIFINID/SPICIFIID
A* l.C. FAN MALFUNCTION RESULTED IN SCRUBSSR OUTAGE &URIN6 SIPTE"6ER.
AFFECTED MODULfcS: SYSTEH
10/76
11/76
a/77
3/77
*/77
5/77
96,0
Vfe.O
87.
?*<• 676
«• PROBLEMS/SOLUTIONS/COHMENTS
START KATE 10/76 ESUI^ENT: Rf*6ENT HANOI, INt
tNC PATE 10/76 FFCiiEW: NOT DEFINED/SPI Elf I ID
SCRUBBER QUTAtF TIHr WAS RfSUIREB FOB INSTALLATION OF * NEW CARBONATf FEFO
LINE.
AFFECTED MODULES: SYSTSf
** PROBLEMS/SOLUTIONS/COfMINTS
START DATE 10/76 EOUItWENT: PIPING
END DATIf 10/76 PRCBUPI: C H1H1 C AL-RELAT F D PLUGGING
A MINOR SCRUeiFR TRIP WAS CAUSED BY PLUG6IN6 IN THI SCRUBBER EFFLUENT
SUCTION LIKE.
AFFECTED MODULES: SYSTEM
SYSTEM
87.0
84.0
71.r
720 631
** PROflLEMS/SOLUTIONS/COMFIENTS
START DATE 11/76 EOUIFPIENT: REAGENT HANDLING
fcND DATE 11/76 rpOBUH: NOT DEFINED/SPECIFIED
ONE FORCED SCRUBBER OUTAGE OCCURRED BECAUSE OF A SCREW CONVEYOR FAILURE,
RESULTING Ik t INABILITY TO MIX THE CHEMICAL APSORPENT.
AFFECTED MODULES; SYSTEM
12/76 SYSTEM
93.0
8R.O
92.0
80.0
677
599
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 1Z/76 F«tJr"ENT: FGD SYSTEM, GENERAL
END DATE 12/76 PKCBLEM: NOT DEFINED/SPECIFIED
A FORCED FED CUTAGE RESULTED FROM CHEMICAL DEPLETION.
AFFECTED MODULES: SYSTEM
** PROULEMS/SOLUT10NS/CCMHENTS
START DATE 12/76 ECUItMENT: PROCESS CONTROL
END DAT? 12/76 COMtNT: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTAGE
A PLUGGED SENSING LINE FORCED AN FGD OUTAGE DUPING DECEMBER.
AFFECTED MODULES: SYSTEM
1/77 SYSTEM
72.0
67.0
87.0
59.0
744 645
437
•* PROSLEMS/SOLUTIONS/CCMMENTS
START DATE 1/77 ECU! (WENT: ABSORBER
END DATE 1/77
RLBBFR LINING DEPAIRS WERE INITIATED IN THE SEPARATOR SECTION OF THE
SCRUBBING MOBILE ON JANUARY 22. THE LINING WAS DAMAGED BY A HIGH
TEMPERATURE EHURS10N RESULTING FROM A MALFUNCTION IN THE UNIT'S AIR
PREHEATER.
AFFECTED MODULES: SYSTEM
SYSTEM
SYSTE*
SYSTEM
SYSTEM
672
744
720
744
5P9
669
400
705
192
-------
EPA UTILITY FGL SURVEY: DECEMBER 1978 - JANUARY 1°79
SECTION 3
DESIGN AND PERFORMAKE DATA FOR OPERATIONAL F6D SYSTEMS
._..-...._...._._............ __.....---PERFORMANCE DATA------- -----
PERIOD MODULE AVAILABILITY CPERAB1LITY PLIABILITY UTILIZATION X REMOVAL PER BOHER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
6/77 SYSTEM
47.0
45.0
44 .Q
44. fl
720 701
315
** PROBLEMS/SOLUHONS/COMMINTS
START DATE 6/77 E6UIFMENT: ABSORBER
END DATE 6/77 COMMI-NTSt
REPAIRS OH THI DAMAGED RUBBER LINING WERE COMPLETED BY MID-JUNE AND THE
SYSTEM RfMlNIB IN SERVICE THROUGHOUT THE MAJORITY OF THE MONTH.
AFFECTED MODULES: SYSTfM
•* PR06LEMS/SOLUTIONS/CCMMEN1S
START DATE 6/77 |6Uir"ENT: PROCESS CONTROL
SN*-OATf ft/77 COMMfNTs PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTtfE
A I" I NCR FORCEG OUTAGE RESULTED FROM A HIGH-LON PRESSURE TRIP CAUSED PY
A PLUGGED StNi'lNG LINE.
AFFECTED MODULES! SYSTEM
7/77
SYSTEM
99.0
99.0
99.0
99.0
744 744
** PROBLEMS/SOLUTIONS/CCMMENTS
START DATE 7/77 E«UIF!«ENT: ABSORBER
END DATE 7/77 CCMMCNT: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTAGE
THE SYSTEM WA I TAKEN OUT OF THE CAS PATH ONLY ONCE DURING THE MONTH
BECAUSE OF A SCHEDULED INSPECTION OF THE NEWLY REPLACED RUBBER LINER IN
THE SEPARATOR SECTION.
AFFECTED MODULES: SYSTEM
8/77 SYSTEM
19.0
21.0
19.0
19.0
744 662
138
** PR06LEMS/SOLUTIONS/COMNENTS
START DATE 8/77 tOUIIMENT: FAN
END DATE 8/77 PROBLEM: DESIGN-RELATED VIBRATION
I.D. FAN RELAVS WERE INSTALLED BECAUSE OF HIGH FAN VIBRATIONS.
AFFECTED MODULES: SYSTEM
9/7? SYSTEM
84.0
73.0
69.0
35.0
720
343
252
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 9/77 EBUIFWENT: B01LER-RELATFB
END DATE 9/77 PROBLEM: NOT DEFINED/SPECIFIED
THE BOILFR WAS OUT OF SERVICE FOR MOST OF THE MONTH.
AFFECTED MODULESr SYSTEM
** PROBLEMS/SOLUTIONS/COMMEN1S
START DAjE O/ 0 EQUIPMENT: 6AS DAMPER
END DATE 9/77 PROBtEM: NOT DEFINED/SPECIFIED
THE SCRUBBER MO LIMIT SWITCH PROBLEMS WITH 14 A & B GUILLOTINE DAMPERS.
AFFECTED MODULES: SYSTEM
10/77 SYSTEM
99.0
99.0
99.0
84.7
744 635
630
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 10/77 tCUIFHENT: FAN
END DATE 10/77 PROBLEM: NOT DEFINED/SPECIFIED
TtE UNIT WAS DOWN FOR 5 HOURS DURING OCTOBER TO REPAIR AN I.D. FAN LEAK.
AFFECTED MODULES: SYSTEM
11/77 SYSTEM
78.7
81.5
78.6
78.1
720 690
562
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 11/77 t"U J TMENT: RECYCLE TANK
END DATE 11/77 PROBLEM: CHEMICAL-RELATED PLUGGING
SCREEN PL16GIM? IN THE RECYCLE TANK WAS A PROBLEM DURING NOVEMBER-
AFFECTED MODULES: SYSTEM
** PR08LEHS/SOLUTIONS/COMMENTS
START DATE 11/77 E6UIFKENT: INSTRUMENTATION
END DATE 11/77 FFCBIEM: NOT DEFINED/SPECIf1ED
193
-------
EPA UTILITY F6D SURYFY: DECEMBER 197C - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FCD SYSTEMS
PERFORMANCE DATA — "
PERIOD MODULE AVAILABILITY CPERAB1LITY fELIABlLITY UTILISATION « REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
SCRUBBER INSTRUMENTATION DIFFICULTY WAS EXPERIENCED DURIN6 NOVEMBER.
AFFECTED MODULES: SYSTEM
•* PROBLEKS/SOLUTIONS/COMMENTS
START DATE 11/77 EQUIPMENT: TANKi OTHER
END OATC 11/77 fRCPifM: NOT DEFINED/SPFCIFIED
TliE SYSTEM WAS DOWN FOR THE INSTALLATION OF AN OUTLET N0721E IN THE
BOOSTER TAKK.
AFFECTED MODULES: SYSTEM
12/77
SYSTEM
B5.0
83.0
71.0
744
631
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 12/77 EQUIPMENTS ABSORBER
END DATE 1?/77 PROBITM: NOT DEFINED/SPECIFIED
ThO OUTAGES WIRE CAUSED BY HIGH TRAY DIFFERENTIAL PRESSURE.
AFFECTED MODULES: SYSTEM
•• PROBLEMS/SOLUT10NS/CCMMENTS
STAPT DATE 12/77 E6UIF»ENTs FAN
END DATE 12/77 FPOBLfM: NOT DEFINED/SPECIFIED
ELECTRICAL PRCPLEMS IN THE 1A FORCED DRAFT FAN CAUSED AN FED SYSTEM
OUTAGE.
AFFECTED MODULES: SYSTEM
** PRQttLEKS/SOLUTIONS/COMMENTS
START BATE 12/77 tSUII-KENTj ABSORBER
tNO DATE 12/77 PROBtirHs NOT DE FINED/S PfCI F I ED
TfcE fCRUBbER MS OFF-L1NF FOR APPRO*IMATILT 109 HOURS PUF TO HI6H TRAY
DIFFERENTIAL FRESSURE AND SOME PLUGGING IN THE I.D. FAN SENSING LINE.
AFFECTED MODULES: SYSTEM
** PNObLEMS/SOLUTIONS/COMMENTS
START DATE 12/77 E6U1F*ENT; 6AS DAWPfR
END DATE 12/77 PROBiEB: NOT DEFINED/SPtCIFIED
TtE fOUEK WAS DOWN ABOUT 113 HOURS I IN DECEMBER.
AFFECTED MO&UIES: SYSTEM S1STEM
1/73
2/78
SYSTEM
SYSTEM
56.0
97.0
6P.O
75.0
69.0
94.0
56. n
43.0
744
672
616
4U
292
** PROBlEMS/SOLUTIONS/COMMENir
START DATE 2/7S ESUIFMENT: DUCTWORK
END DATE ;/7S PfiOeLEM: NOT DEFINED/SPECIFIED
A DUCT HI-LO fRESSURE TRIP CONTRIBUTED TO THE FEBRUARY OUTA6E TIME.
AFFECTED MODULES: SYSTEM
** PROfcLEMS/SOLUTIONS/COMKENTS
START DATE 2/78 EOUII-fENT: BOILER-RELATED
END DATE 3/78 FROEUFM: NOT DEFINED/SPECIFIED
TKE BOILER WE»T OUT OF SERVICE ON FEBRUARY 17 FOR A THREE WEEK OUTAGE.
AFFECTED MODULES: SYSTEM
•* PROHLEWS/SOLUTIONS/COMMENTS
START DATE 2/78 E6UIf*ENT: PROCESS CONTROL
END DATE 2/7B PRC81EM: CHEMICAL-RELATED PLUGGlNfi
PLUGGED StNSI>-« LINES CONTPIBUTED TO THE OUTAGE TIME DURING FEBRUARY.
AFFECTED MODULES: SYSTEM
3/78 SYSTEM
2S.O
58.0
58.0
28.0
744
355
207
PROBLEMS/SOLUTIONS/COMMENTS
START DATE 3/78 EfiUjFMENT: BQlLEp-RELATED
END DATE 3/78 PROBLEM: NOT DEFINED/SPECIFIED
TKE BOILER WAS OFF LINE UNTIL MARCH 16.
194
-------
EPA UTILITY FGD SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMAKE DATA FOR OPERATIONAL F6D SYSTEMS
............ .PERFORMANCE DATA-—— ,--.. ......
PERIOD NODULE AVAILABILITY OPERAB1L1TY PLIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
SO? PART. HOURS HOURS HOURS FACTOR
AFFECTED MODULES: SYSTEM
** PHOBLEMS/SOLUTIONS/COMMEN1S
START DATE 3/78 lOUIfWENT: RECYCLE TANK
END OATF. 3/76 PROBUM: NOT DEFINED/SPECIFIED
A PROBLEM WAS ENCOUNTERED WITH THE.REHEAT STEAM REGULATOR DURIN6 MARCH
AFFECTED MODULES: SYSTtf
** PROBLEWS/SOLUTIONS/COMMENTS
START DATE 3/78 ECVIIMENT: GAS DAMPER
tND DATE 3/7E PSCBlFM: NOT DEFINED/SPECIFIED
PROBLEMS WITH THE GUILLOTINE SWITCHES DELAYED START-UP OF THE FED SYSTEM
UMIL MARCH 2i.
AFFECTED MODULES: SYSTEM
4/78 SYSTEM 100.0 97.0 100.0 75.0 720 560 541
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 4/78 E6UIFMENT: FGD SYSTEM, GENERAL
END DATE 4/78 COMMtNTS:
THERE WERE NO FGD SYSTEM FORCED OUTAGES. ALL DOWNTIME WAS (SOILED
RELATED.
AFFECTED MODULES: SYSTEM
5/78 SYSTEM 97.0 9?.0 96.0 78.0 744 630 56?
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 5/76 £«UiIMENT: 6{)I LER-R ELMF D
END DATE 5/78 PROBIEM: NOT DEFINED/SPEcIFIED
REPAIRS TO THE CONDENSER AND PRODUCTION CONTROL CONTRIBUTED CONTRIBUTED
TO BOILER OUTAGES.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 5/78 EQUIPMENT: FAN
END DATE 5/78 FPCPIFM: NOT DEFINED/SPECIFIED
HIGH TEMPCRATIRE ON AN 1.0. FAN BEARING CAUSED AN OUTAGE.
AFFECTED MODULES: SYSTEM
6/78 SYSTEM 89.0 89.0 100.0 89.0 720 720 644
** PROBLEMS/SOLUTIONS/CCMMENTS
START DATE 6/78 ESUIFMENTs SCRUBBER
END DATE 6/7E PKOBIFM: NOT DEFINED/SPECIFIED
TfcERE WAS ONE SCHEDULED FGD OUTAGE TO REPAIR A LEAK ON THE VENTURI WATER
BOX.
AFFECTED MODULES: SYSTEM
7/78 SYSTEM 100.0 99.0 100.0 99.C 744 744 736
** PROBlEMS/SOLUilONS/COMMENTS
START DATE 7/76 EfiUiFWENT: ABSOftBFft
END DATE 7/76 PRCB1FM: NOT DEFINED/SPFclFlED
A SCHEDULED FCD OUTAGE WAS RE&UIRED TO RECTIFY A HIGH TRAY DIFFERENTIAL
PRESSURE PR061FM. THE TRAY WAS CLEANED OUT DURING THE OUTAGE.
AFFECTED MODULES: SySTEM
8/78 SYSTEM 94.0 94.0 93.0 89.0 744 706 661
** PROfiLEMS/SOLUTIONS/COMMENIS
START DATE 8/78 E6UIFMENT: ABSORBER
END DATE 8/78 PROSLCH : NOT DEFINED/SPECIFI ED
THE SCRUBBER IAS FORCED OFF LINE ON AUGUST 5 BECAUSE OF A LOSS OF THE
ASH PANEL CONTROL POWER. THIS LEFT THE UNIT WITHOUT EMERGENCY SPRAY TO
THE SCRUBBERS •
AFFECTED MODULES: SYSTEM
195
-------
EPA UTILITY F&D SURVEY; DECEMBER 197f - JANUARY 1979
SECTION 3
DESIGN AND PERFOPMAKCE DATA FOR OPERATIONAL FCD SYSTFMS
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY CPEPABILITY PLIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PR06LEMS/SOLUTIONS/COM>«IENTS
START DATE f /7£ IGU1WENT: SCRUBBER
END DATE f,/78 pKt'PlFM: NOT D E F IN ED/S Pf CI FI ED
A FORCCD OUTAfC OCCURRED ON AU&uST 20 WHEN THERE WAS A SCRUBBER VENTURI
HIGH TEWPEFATIRE ALARM. THE EXACT CAUSE WAS NOT KNOWH BUT A BOILER TUBE
LEAK WAS SUSP'CTED.
AfFECTtD MODULES: SYSTLI"
** PROeLEMS/SOLUTIONS/CCMMENTr
START DATE J/78 EOUIf^ENT: ABSORBfR
END DATf f/78 COMMENT: pREVENTlVC MAINTENANCE SCHEDULED UNIT OUTA6E
TKt-Rf WAS CfcF. SCHEDULED OUTA6E jURING THE MONTH TO CLEAN THE TRAy.
AFFECTED MOOUl tS: SYSTEM
9/78 SYSTEM
99.0
97.0
99.0
87.0
720 644
626
** PRObLEMS/SOLUTIONS/COMMENTS
START DATE 9/7? rfiUl FT ENTs BOI Lf R-RELATE D
END DATE 9/78 PROPIEM! NOT DEFINED/SPECIFIED
TtFRf WERE TH^fE BOILER RELATED OUTAGES DURING SEPTEMBER.
LEAK AND BOILER BURNER WERE REPACKED.
AFFECTED MODULES: SYSTEM
A BOILER TUBE
PROBLEMS/SOLUTIONS/COMMENTS
START DATE 9/78 tGUII^ENT: GAS DAWPER
END DATE 9/78 PROEUfM: DESI6N-RELATE0 PRESSURE SURSCS
DtRUt THE MOhTH A BOILER TRIP OCCURRED WHICH WAS CAU$ED BY SCRUPBER
HiGH DUCT PRE SfURE.
AFFECTED MODULES: SYSTEM
10/78 SYSTEM
100.0
1CO.O
100,0
90.C
7*4 667
667
** PROBLEMS/SOLUTIONS/CCMMENTS
START DATE 10/78 EOUHHENT: BOI LFR-RELAT E D
END DATE 10/76 PROMT*: NOT D E F INE D/S PE CI F I ED
TK POILER WAI OFF LINE FOR ABOUT 77 HOURS FOR REMOVAL OF AN ASH CLINKER.
AFFECTED MODULES: SYSTEM
11/78 SYSTEM
100.0
100.0
100.0
90.0
720
598
•* PRObLEMS/SOLUTJONS/COMMENTS
START DATE 11/78 CCUIMEN1: INSTRUMENTATION
END DATE 11/76 PRCBlfM: NOT DEFINED/SPECIFIED
THE FGD SYSTEM WAS DOWN FOR SCRUBPER OUTLET TEMPERATURE PROBE REPAIRS.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOtUTIONS/COMMENTS
START DATE 11/78 E6UI FMENT: BOILF.R-RELATE D
END DATE 11/76 FttOBLF.M: NOT DEFINED/SPECIFIED
OUTAGE TIMf RFiULTED WHEN BOILER PROBLEMS CAUSED THE VENTURI OUTLFT GAS
TECPERATURt TO HECOME TO HIGH (TEMPERATURE ALARM HIGH TRIP).
AFFECTED MODULES: SYSTEM
1Z/7B SYSTEM
95.6
92.8
92.9
92.0
744 737
684
** PROBLEMS/SOLUTIONS/COMMENTS
START BATE 12/78 fCUjf-MENT: SCRUBBER
END DATE 12/78 PROBUM: NOT DEFINED /SPF (.If I £0
THE SCRUBBJHfi SYSTEM WAS OUT OF SERVICE TO REPAIR A LEAK IN * VENTURI
LINE.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 17/78 EQUIPMENT: SCRUBBER
END DATE 12/78 PRCBUM: NOT DEFINED/SPF C! FIED
TfcE FED SYSTf WAS DOWN TO CLEAN THE VENTURI RACE TRACK AND CLEAN PRESSURE
196
-------
EPA UTILITY FGD SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMAKCE DATA FOR OPERATIONAL FED SYSTEMS
... . . PERFORMANCE DATA
PERIOD MODULE AVAILABILITY CPERAB1LITY PLIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
502 PART. HOURS HOURS HOURS FACTOR
SENSING LINES .
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 12/78 EOUItPIENT:
END DATE 12/78 PROBLEM: NOT DEFINED/SPECIFIED
THE BOILER WAS OFF LINE APPROXIMATELY 1 DAY FOR PULVERIZER REPAIRS.
AFFECTED MODULES: SYSTEM
1/79 SYSTEM 83.9 73.7 73.7 67.0 7*4 6R1 502
•* PROBLEMS/SOLUTIONS/COMNENTS
START-BATE 1/79 E6UIPMENT: BOILER-RELATED
END DATE 1/79 PROBLEM: NOT DEFINED/SPECIFIED
THE TOILER WAS DOWN ABOUT 5 BAYS TO REMOVE A CLINKER FROM THE BOTTON
HOPPER.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COKMENTS
START DATE 1/79 EOUIfttENT: PUMP, OTHER
END DATE 1/79 PROBUMi NOT DEFINED/SPECIFIED
A FORCED OUTACE HAS CAUSED WHEN THE 2C LOAD CENTER TRIPPED RESULTING IN
LOSS OF POWER TO TRAY SPRAY PUMP. REPAIRS WERF MADE ON THE TRAY AND SPRAY
SYSTEMS.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUT10NS/COMMENTS
START DATE 1/79 tdUIFPENT: FAN
END DATE 1/79 COMMSNT: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTAGE
TUF F6D SYSTEf WAS DOWN FOR A SHORT PERIOD TO INSPECT THE SEARING ON THE
I.D. FAN.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 1/79 tOUIIMENT: SCRUBBER
END DATE 1/79 PROBUM: NOT DEFINED/SPECIFIED
THE FGD SYSTEM UAS DOWN TO REPAIR A LEAK IN THE VENTURI LINE.
AFFECTED MODULES: SYSTEM
Z/79 STSTEM 85.6 85.9 85.9 85.6 672 670 575
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 2/79 EOUI FMENT: SCRUPBFR
END DATE 2/79 PROBLEM: NOT DEFINED/SPECIFIED
THE FED SYSTEM WAS DOWN TO CLEAN THE VENTURI RACE TRACK NOZZLES, CLEAN THE
EFFLUENT LINE AND REPAIR LEAK IN VENTURI LINE.
AFFECTED MODULES: SYSTEM
** PROSLEMS/SOLUTIONS/COMMENTS
START DATE 2/79 EBUIfMENT: PIPING
END DATE 2/79 FPOBifm: NOT DEFINED/SPECIFIED
A BREAK Ih THE ASH CIRCULATING WATER LjNE RESULTING IN LOSS OF EMERGENCY
COOLING WATER FORCED THE FGD SYSTEM OFF LINE.
AFFECTED MODULES; SYSTEM
197
-------
EPA UTILITY FCD SURVEY: DECEMBER 1?7E - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL F60 SYSTEMS
COMPANY NAM!:
I't.ANT NAME
UNIT NUMBER
CITY
s r AT t
Kf&ULATORY CLASSIFICATION
PAkTKULATE EMISSION LIMITATION - NC/J
S02 EMISSION LIMITATION - KG/J
NEI f'LMK'T GENERATING CAPACITY - MW
GWOr,5 UNIT GENERATING CAPACITY - M>
Nl 1 UNO f.tNERATlNG CAPACITY W/FGD - Ml.
«t I UM.T GLNtRATlNS CAPACITY WO/F6D - H»'
f nil] m.i -41 SCRUBBED CAPACITY - MW
** yOILFR DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE OATt
MAXIMUM BOILER FLUE GAS FLOW - CU.P/S"
FLUF 6AS TEMPERATURE - C
STACK HEIGHT - K
STACK TOP DIAMETER - If
( .100 LB/M«BTU»
I****** LP/MMBTU)
NEVADA POWEfc
REID GARDNER
2
MOAPA
NEVADA
A
4%
******
*******
12%0
110.0
***** **
125.0
FOSTfR WHEELER
PULVERIZED CQALt WET BOTTOM
BASE
0/69
Z23.21 ( 473000 ACF«J
176.7 < 350 f>
61. ( 200 FT)
4 ******
(***** FT)
** FUEL DATA
FUEL TYPE COAL
FUEL GRADE ******
AVERAGE HEAT CONTENT - KJ/K6 2*842.
RANGE HEAT CONTENT - BTU/LG
AVERAGE ASH CONTENT - X X.OO
RANGE ASH CONTENT - X 8.-10.
AVERAGE MOISTURE CONTENT - X ********
RANGE MOISTURF CONTENT - X S-6
AVERAGE SULFUR CONTENT - X .50
RANGE SULFUR CONTENT - X 0.5-1.0
AVSHAGE CHLORIDE CONTENT - X ********
RANGE CHLORIDE CONTENT - X ******
FUEL FIBIN6 RATE - M T/M *******
FUEL FIRING RATE - MW *****
** MECHANICAL COLLECTOR
TYpE
SUPPLIER
»» PARTICULATE SCRUBBER
NUMBER
TYPE
SUPPLIER
LINING MATERIAL
TYPE OF MoZZLES
BOILER LOAD/SCRUBBER - X
LIOUID RECIRCULATION RATE - LITER/S
L/6 RATIO . LITER/CU.M
PRESSURE DROP - KPA
so2 INLET CONCENTRATION - PPM
** F6D SYSTEM
SALEABLE PRODUCT/THROW AWAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICULATE DESIGN REMOVAL EFFICIENCY - X
SoZ DESIGN REMOVAL EFFICIENCY - X
INITIAL START-UP
• * ABSORBER
NUMPEp,
TYPE
INITIAL START UP
NUMBER OF STAGES
DIMENSIONS
BOILER LOAD/ABSORBER - X
L/G RATIO - L/CU.M
( 12400 BTU/LP)
* *****
(*** TPH)
MULTICLONES
RESEARCH COTTRELL
VARIABLE THROAT VENTURI
AOL/COMBUSTION EQUIP ASSOCIATES
1NCOLOY E25
TANGENTIAL
50.0
( 2SOO GPn>
(10.0 GALMOCOACf)
( 15 IN-H20)
157.5
1.3
3.7
375.000
THROWAUAY
WET SCRUBBING
SODIUM CARBONATE
ADL/COMBUST10N EQUIP ASSOCIATE
BECHTEL
FULL-SCALE
RETROFIT
97.QO
90.00
4/74
1
PEP.FERATF6 PLATE HASHING TOWER
4/74
1
30 DIA.
100.0
.2 ( 1.6 6AL/1000ACF)
198
-------
EPA UTILITY F6D SURVEY: DECEM8E* 1978 - JANUARY 1979
SECTION 3
DES16N AND PERFOKMAMCE DATA FOR OPERATIONAL F6D SYSTEMS
S02 OUTLfcT CONTRAT10N - PPM
** FANS
TYPF
CONSTRUCTION MATERIALS
17
1.0. BOOSTER FAN
CARBON STEEL
** BIST ELIMINATOR
NUMBER
TYPE
CONSTRUCTION MATERIAL
CONFIGURATION
WASH SYSTEM
PRESSURE: DROP - KPA
** TANKS
SERVICE
VENTURI RECYCLE
*» REHEATER
TYPE
HEATING MEDIUM
TEMPERATURE BOOST - C
ENERGY REQUIRED
** VATER LOOP
TYPE
FRESH MAKEUP WATER ADDITION • LITF.RS/S
** DISPOSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
AREA - ACR6S
** DISPOSAL
NATURE
TYP1
LOCATION
AREA - ACRES
VANE
3161 SS
HORIZONTAL
NONE
.1 ( .5 IN-H20)
NUMBF-R
****
INDIRECT MOT AIR
STirA"
16.7 ( 30 F)
15.2 MM BTU/H (RATING)t * MW
OPfN
1.6
25
FINAL
EVAP POND
ON-sm
GRAVITY FLOW FROM INTERIM SLUDGE POND
45.0
INTERIM
1 PONO (SHARED WIT
ON-SJTE
6.0
........._......._......— .......... PER FORMANCE DATA ..-.. — ...—_........ .............
PERIOD MODULE AVAILABILITY OPERAB1LITY PLIABILITY UTILIZATION X REMOVAL PER BOILER F6o CAP.
502 PART. HOURS HOURS HOURS FACTOR
4/74 SYSTEM
720
** PROULEMS'SOLUTIONS/COMPENTS
START DATE 4/74 EQUIPMENT: FGD SYSTfM. GENERAL
END DATE 4/74 COMMtNTS:
TttE FGO SYSTEM UAS PLACED IN SERVICE IN APRIL 1974. THE SCRUBBING SYSTEM
DESIGN UAS BA
-------
fPA UTILITY F6D SURVEY: DECEMBER 1«7f - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL F60 SYSTFMS
-------- ........ . ................. --- ..... PERFORMANCE DATA---- ..... --- - ------------------------ !!"""
PERIOD MODULf AVAILABILITY GPERAPILITY "LIABILITY UTILISATION X REMOVAL PER BOILER F6D CAP,
SO? PART. HOURS HOURS HOURS FACTOR
** PR06LEMS/SOLUTJONS/COWMENTS
START DATE 2/75 [OUl">eNT: PIPING
END DATE 6/75 PSOFJ I CM : CHEMICAL-RELATED EROSION
AtRASION Or » LfBER-LlNED plpis MfRf A PROBLEM.
AFFfCTED MODULES: SYSTIM
** PR06LEMS/SOLUTIONS/CCMMENTS
STA«T OATE 2775 I6UJI"ENT: F6D SYSTEM, EUNERAL
END DATE 6/75 CORHI-NTSl
A SECOND PFF.FOPHANCE TEST WAS PASSfS.
AFfiCTED HODULESs SYSTif
** PROBLEKS/SOLUTIONS/COMMENTS
START OATE 2/75 ECUl^ENT: B01LFR-RELAT! D
END DATF 6/75 PKOE>lFM: NOT DEFINED/SPECIFIED
TtiE UNIT I>AS HSTARTED AFTER SHUTDOWN FOR S-YEAR TURBINE OVERHAUL •
AFFECTED MODULES: SYSTtP
** PRODLEWS/SOLUTIONSyCCWMENTS
START SATE ?/75 EOUirfENT: PUWP, OTHER
tND DATE
AFFECTED MODULES: SYSTf*
** PROBLEMS/SOLUT10NS/COHKENTS
START DATE Z/75 E»UIffENT: BOILER-RELATED
ENC DATE 6/7S FfiOEUEMi NOT DE FINEO/SPF CIF IED
PC1LER CONTROLS WERE A PROBLEM.
AFFECTED MODULES: SYSTEM
** PROBLEWS/SOLUTIONS/COMflENTS
START DATE ?/75 CGUI H*ENT: RECYCLE TANK
END BATE 4^75 PFOPttW: NOT DEFINED/SPECIFIED
A PLUGGED REOCLE LINE STRAINER WAS A
AFFECTED MODULES: SYSTtr
3/75
*/75 SYSTEM 720
5/75 SYSTEM 744
6/75 SVSTJK 7?CI
7/75 SYSTEM 65.0 7*4
8/75 SYSTEM 744
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 8/75 L6UIPMENT: REA6ENT HANDLING
END DATE 9/75 PFOBIfM: NOT DEFINED/SPECIFIED
A oROKEN fcUCK!,T ELEVAT0R CONTRlBuTFD TO A FORCED F6D OUTA6E.
AFFECTED MODULES: SYSTtr
. ** PBOBLEMS/SOLUTIONS/COMMENTS
START DAyE 8/75 ESUII'HENT: PIPIN6
END DATE 9/75 PROB(tH: C HEMICAL-RFLATE fi EROSION
WORN RECIRCUIMION PIPING CONTRIBUTED TO FORCED F6D OUTAGE.
AFFECTED MODULES: SYSTEF
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 8/75 E6UIFWENT: ABSORBER
END DATE 9/75 PROBtEn: NOT DEFINED/SPECIFIED
RtBBFR LIMER LEAKAGE CONTRIBUTED TO FORCED F6D OUTAGE.
AFFECTED MODULES: SYSTEM
200
-------
EPA UTItITT FCC SURVEY: DECEMBER 1978 - JANUARY 1«79
SECTION 1
DESIGN AND PERFORMAhf.E DATA FOR OPERATIONAL FGD SYSTFMS
... . PERFORMANCE DATA
PERIOD MODULE AVAILABILITY GPEPA8ILITY PLIABILITY UTILIZATION X REMOVAL PER BOILER FED CAP-
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
St*RT DATE 8/75 EeUlf'NENT: FGD SYSTEM, GENERAL
END DATE 9/75 FRCBlfM: NOT DEFINED/SPECIFIED
STRAINER PLUGtlNG CONTRIBUTED TO FORCED F6D OUTAGE TIME.
AFFECTED NODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 8/75 E«l!IF«£NT: F6D SYSTEM, GENERAL
END DATE 9/75 PROBlFM: NOT DEFINED/SPECIFIED
THREE FORCED OUTAGES OCCURRED CURING AUGUST AN& SEPTEMBER.
AFFECTED MODULES: SYSTEM
9/75 SYSTEM 77.0 69.0 720 645 496
tO/75 SYSTEM 87.0 62.0 744 531 464
** PROBLEMS/SOLUTIONS/COMMENTf
START DATE 10/75 EOUIFMgNT: PUMP, OTHER
END DATE 10/75
PUMP REPAIR NKESSITATED A« FGD OUTAGE-
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COKKENTS
START DATE 10/75 EBUIFMENT: INSTRUMENTATION
END DATE 10/75 PROBt.rn; NOT DEFINED/SPECIFIED
INSTRUMENT PLIGGING CAUSED AN FGD OUTAGE.
AFFECTED MODULES: SYSTEM
** PHOBLEMS/SOLUTIONS/COMMENTS
START DATE 10/75 EOUIf«ENT: PIPING
END DATE 10/75 PRCE>lEn: NOT DE FINED /$ PE CI F IED
REPAIR OF PIPING LEAKAGE NECESSITATED AM FGD OUTAGE.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 10/75 EQUIPMENT: FGD SYSTEM, GENERAL
END DATE 10/75 PROBlFM: MQT DEFINtD/SPECIFIED
THREE FORCED SCRUBBER OUTAGES WgRg REPORTED FOR OCTOBER.
AFFECTED MODULES: SySTEM
11/75 SYSTEM 99.0 83.0 720 603 596
12/75 SYSTEM 744
** PROSLEMS/SOLUTIONS/CCMMENTS
START DATE 12/75 EQUIPMENT: PIPING
END DATE 1/76 FKOBlfM: HEATHER-RELATED COMPONENT FAILURE
FROZEN CARBONATE LINES CONTRIBUTED TO FGD OUTAGE TIME*
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 12/75 EfiUIFCENT: PROCESS CONTROL
END DATE 1/76 PROBtFM: N<)T DE FINED/S PF CI F I ED
PLUGGED PRFSSIRE-SENSING LINES CONTRIBUTED TO FGO OUTAGE TIME.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START D*TE 12/75 EQUIPMENT: DUCTWORK
END DATE 1/76 PROBltH: DEsIGN-RELATED PRESSURE SURGES
DUCT PRESSURE TRIPS CONTRIBUTED TO FGD OUTAGE TIME.
AFFECTED MODULES: SYSTEM
** PROSLEMS/SOLUTIONS/CCMMENTS
START DATE 12/75 EQUIPMENT: PUMP, OTHER
END DATE 1/76 PROBLEM: NOT DEFINED/SPECIFIED
OVERHAUL OF A TRAY RECYCLE PUMP CONTRIBUTED Tfl FGD OUTAGE TIME.
201
-------
EPA UTILITY f6D SURVEY; DECIDER 197f - JANUARY 1979
SFCTION 3
DESIGN AND PERFORMANCE DAT* FOR OPERATIONAL FG& SYSTEMS
PERIOD MODULE AVAILABILITY OHERAHILITY
AFFFCTED MODULES: SYSTEM
1/76 SYSTEM 72.0 66.0
2/76 SYSTEM 84. C 86.0
^LIABILITY UTILIZATION * REf
66.0 62.0
66.0 83. C
10VAL PER E
PART. HOURS t
744
696
(OILER FGO "CAP.
IOURS HOURS FACTOR
691 *58
675 578
** PROoLE'S/SOLUTlONS/CcMMENTs
START BATE 2/76 [GUIfPENT: PUNP, OTHER
END DATE 2/76 PFCBt^H: NOT D EFINE D /SPE Cl f I ED
PLUGGING 1H A VENTURI PUMP CONTRIBUTED TO F60 OUTAGE TIME.
AFFECTED MODULES: SYSTEM
** PfiO&LEf'S/SOLUTlONS/CeKMENTS
START DATE 2/76 ECU I I-K ENT: FGD SYSTEM, GENERAL
END DATE 2/76 PROBIFM: NOT DE FINED /S PF_ CI F I ED
CKFMICAL DEPLETION CONTRIBUTED TO FGO OUTAGE TIME.
AFFECTED MODULES; SYSTEM
*» PROGLEKS/SOLUTIONS/CCMMENTS
START DATE 2/76 tCDlfPENT: PUMP, OTHER
END DATE 2/76 PPOBLFM: NOT 0 E FINED /SPE CI F I ED
SEAL WATE* PRf.fiLEKS CONTRIBUTED TO FGD OUTAGE TIKE.
AFFECTED MODULES: SYSTE0
** PROBLEKS/SOLUTIONS/CCHWEN1S
START DATE ? /76 EGUIfPENT: FGD SYSTEM, GENERAL
END DAT? 2776 PROBiEIMS NOT DEFINED/SPECIFIED
THE UTILITY REPORTED FOUR ScRUBBF* INACTIVE PERIODS DURING FEBRUARY, THREE
OF WHICH fcERE SCRUBBER-RELATED OUTAGES.
AFFECTED MODULES: SYSTEM
3/76 SYSTEM
67.0
«n.o
62.0
53.0
744 660
395
** PROULEMS/SOLUTIONS/COMBENTS
START DATE 3/76 EOUIFHENT: FGD SYSTEM, GENERAL
END DATE 3/76 F'ROBtEM: NOT DEFINED/SPECIFIED
TkO FGD FCRCEC OUTAGES OCCURRED DURING MARCH.
AFFECTED MODULES- SYSTEM
** PROBLEMS/SOLUTIONS/COKWEN1S
START DATE 3/76 E«UIF«ENT: F6D SYSTEM. GENERAL
END DATE 3/76 PROBLEM: NOT DEFINED/SPECIFIED
AK ELECTRICAL FAILURE RESULTED IN AN FGD SYSTEM OUTA6E.
AFFFCTED MODULES: SYSTEM
** PR06LEHS/SOLUTIONS/COWMENTS
START DATE 3/76 EQUIFKENT: ABSORBFR
END DATE 3/76 PROBLEM: CHEMICAL-RELATFD PLUGGING
PLUGGING IN ThE TRAY SYSTEM RESULTED IN A SUBSEQUENT OVERHAUL OF THE TRAY
CYCLE PUWPS. THIS CAUSED FGD OUTAGE TINHE.
AFFECTEP MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COKMENTS
START DATE 3/76 EQUIPMENT: F6C SYSTEM, GENERAL
END DATE 3/76 PROBLEM: NOT DEFINED/SPECIFIED
TkO FORCED SCRUBBER OUTAGES WERE REPORTED FOR MARCH.
AFFECTED MODULES: SYSTEM
4/76 SYSTEM
85.0
77.0
83.0
68. C
7?0 629
488
** PROBLEMS/SOLUTlONS/COHMENTS
START DATE 4/76 E«UlFI"ENT: INSTRUMENTATION
END DATE 4/76 PROBLEM: CHEMICAL-RELATE0 PLUGGING
PLUGGED SENSING LINES RESULTED IN FGD OUTAGE TIME.
AFFECTED MODULES; SYSTEM
** PR08LEMS/SOLUTIONS/COMMENTS
START DATE 4/76 EfiUIfMENT: RECYCLE TANK
END DATE 4/76 PROBLEMS NOT DEFINED/SPECIFIED
202
-------
EPA UTILITY F6D SURVEY! DECEMBER 1978 - JANUARY 1079
SECTION 3
DESIGN AND PERFORMAKE DAT* FOR OPERATIONAL FGD SYSTEMS
—. _ PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY FEL1ABILITY UTILIZATION
% REMOVAL PER BOILER FGO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
6/76
7/76
8/76
A REHEATED I E «K RESULTED
AFFECTED MODULES: SYSTtM
FGD OUTAGE TIME.
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 4/76 ECUIfftENT: SCRUBBER
END DATE 4/76 PFOB|E«: NOT DEFINED/SPECIFIED
VENTURI SfOOL RECYCLE REPLACEMENT REQUIRED FGD OUTAGE TIKE.
AFFECTED MODULES: SYSTEM
** PR03LEMS/SOLUTIONS/COKMENTS
START DATE 4/76 ECUHKENT: TANK, OTHER
END DATE 4/76 PROBi^M: NOT DEFINED/SPECIFIED
T ANK- PATCHM1G REfiUIRED FGft OUTAGfc TIW€i
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COWMENTS
START DATE 4/76 E8UIH*ENT: F6D SYSTEM, GENERAL
END DATE 4/76 FRORUM: NOT DEFINED/SPECIFIED
FOUR FORCED SCRUBBER OUTAGES HERE REPORTED BY THE UTILITY FOB APRIL.
AFFECTED MODULES: SYSTEM
5/76 SYSTtl"
99.0
83.0
98.0
79.0
744
0
** PROBLE»S/SOLUT10NS/COMKENTS
START DATE 5/76 EOUIfBENT: SCRUBBER
END DATE 5/76
PLUGGED VENTUKI LINES UERE A PROBLEM.
AFFECTED MODULES: SYSTEM
** PROBLENS/SOLUTIONS/COMHENTS
START DATE 5/76 tCUIK«ENT: INSTRUMENTATION
END DATE 5/76 PROP(tM: CHEMICAL-KELATFD PLUGGING
A PLUGGED SENSING LINE WBS A PROBLEM.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMNENTS
START DATE 5/76 EGUirttENT: FGD SYSTEM, GENERAL
END DATE 5/76 COMMENTS:
TOTAL SCRUBBER OPERATION TIME TO DATE IS 9488 HOURS.
AFFECTED MODULES: SYSTEM
SYSTEM
SYSTEM
91.0
81.0
96.0
57.0
720
744
518
421
** PRO&LEMS/SOLUTIONS/COMMENTS
START DATE 7/76 EGUIIMENT: SCRUBBER
£ND DATE 7/76 PROBLEM: NOT DEFINED/SPECIFIED
A PROBLEM VIT| A HIGH SQLID$ CONCENTRATION IN THE VENTURI SCRUBBING CYCLE
CONTRIBUTED Tt F6D OUTAGE TIME.
AFFECTED MODULES: SYSTEM
** PROBLEKS/SOLUTIONS/COMMENTS
START DATE 7/76 teulrWENT: PIPING
END DATE 7/76 PROBLEM: NOT DEFINED/SPECIFIED
THE REPIACEMEI\T OF A RUBBER-LINED PIPE IN THE VENTUftl SCRUBBER CONTRIBUTED
10 FED OUTAGE TIME.
AFFECTED MODULES: SYSTEM
** PR06LEKS/SOLUTIONS/COMMENTS
START BATE 7/76 E6UIFWENT: FGD SYSTEM, GENERAL
END DATE 7/76 PROBLEM: NOT DEFINED/SPECIFIED
1UO SCRUBBER CUTA6ES WERE REPORTED DURING
AFFECTED MODULES: SYSTEM
95.0
75.0
94.0
7T.D
744 709
530
203
-------
EPA UTILITY FbD SURVEY: DECEMBER 197* - JANUARY 1979
SECTION 3
DESIGN AND F-E R F OKI" A KCE DATA FOR OPERATIONAL f6o SYSTFMS
------------------------------------------ PERFORMANCE DATA ---- .---- -------- -- ---------- - —
PERIOD MODULE AVAILABILITY CURABILITY PLIABILITY UTIL17ATION ' ««J»" „«$,
** PRObLEMS/SOLUTIONS/COMMENTS
START DATE B/76 ESUIFWENT: F6B SYSTEM, GENERAL
END DATF 6/76 PROEUfM: NOT DEFINED/SPECIFIED ...„.,.- -..,-
DEPLFTION Cf CHEMICAL ABSORBENT CONTRIPUTED TO F6 D OUTAGE TIME.
AFFECTED MODULES: SYSTLM
• * PROBLEMS/SOLUTION S/COWMENTS
START BATE 8/76 EBUIfWENT: BOILER-RFLATf D
END DATE B/76 PROeUM: NOT DEFINED/SPECIFIED
BOILER TRIPS CONTRIBUTED TO F6& OUTAGE TlHF*
AFFECTED MODULES: SYSTt"
*» PROBLEMS/SOLUTION S/CCMKENTS
START DATE B/76 EfiUIFKIENT: SCRUP8ER
END DATE 8/76 PROBlEMS NOT D£ FINED/SPF CI FI EO
IEAKA6E IN THF VENTtlRI RECYclE LINE CONTRIPUTED TO F6D OUTAGE TIWE.
AFFECTED MODULES: SYSTEM
«* PROBLEMS/SOLUTIONS/COMMENTS
START DATE 8/76 tOll^ENT: THICKEMER
END DATE 8/76 MCBLfM: PLUGGING, OTHER
PLU6«ING IN THE THICKENER CONTRIBUTED TO FGO OUTAGE
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 8/76 ECUIfENT: F6D SYSTEM, GENERAL
END DATE 8/76 fKOP LE H : N OT D E f 1NE D /S PE Cl U ED
FCRCED OUTAGE TIME TOTALED 34. 5 HOURS FOR THE FGD
AFFFCTED MODULES: SYSTEM
*Y$TtM 94.0 9«.0 94,0 91,0 JtO 6(!1 «53
•* PROULEMS/SOLUT10NS/COMMENTS
START DATE 9/76 f.6UIF«ENT: FAN
END DATE 9/76 PROBUMl NOT D E FINE D /S PE C7 F I ED
MINOR TRIPS WERE CAUSED PV PLUGGING IN THE 1,0, FAN REFERENCE LINES,
AFFECTED MODULES; SYSTEM
•* PCOBLERS/SQLUTIONS/COMMENTS
START DATE 9/76 EOUIPKENTt INSTRUMENTATION
END DATE 9/76 PROBiM: NOT D E f I ME D /S P E U F I ED
A KINOR SVSTEC TRIP MAS C«USEg BY A FALSE HIGH TEMPERATURE READING IN
TIE VENTUR] CAUSED BY WATER IN THE INSTRUMENT.
AFFECTED MODULES: SYSTtM
10/76 SYSTEM 95.0 95.0 9S.O 8S ,C 744 694 65*
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 10/76 EBUIfENT: GAS DAMPER
END DATE 10/76 PPOBtEM: NOT DEFINED/SPECIFIED
SCRUBBER TRIPE WERE CAUSED BY VENTURI 6AS DAMPER PROBLEMS.
AFFECTED MODULES: SYSTEM
** PR08LEMS/SOLUTIONS/COMMENTS
START DATE 10/76 E8U1HHENT: PIPING
END DATE 10/76 FPOBI.KM; NOT DE FINED/SPF CI FI ED
REPLACEFIENT Of THE CARBONATE FEED LINE CONTRIBUTED TO FGD OUTAGE TIME.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 10/76 ESUIfWENT: PIPING
END DATE 10/76 PROBlfM: CHEMICAL-RELATED PLUGGING
PLUGGING IN Tfcf SCRUBBER EFFLUENT LINE CONTRIBUTED TO FGD OUTAGE TIME.
AFFECTED MODULES: SYSTEM
•* PR00LEMS/SOLUTION5/CCMMENTS
START DATE 10/76 ESUIf^ENT: BOILER-RELATED
END DATE 10/76 PROBlfM: NOT DEFINED/SPECIFIED
204
-------
EPA UTHJTY FGO SURVEY: DECEMBER T978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL F6D SYSTEMS
....—...... ..... . .—. ----PERFORMANCE DATA —
PERIOD MODULE AVAILABILITY OPERABILJTY PLIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
SC2 PART. HOURS HOURS HOURS FACTOR
SCRUBBER OUTA« TI«| DUE TO BOILER TRIPS AMOUNTED TO APPROXIMATELY 65
HOURS.
AFFECTED MODULES: SYSTEM
11/76 SYSTEM 52.0 58.0 51.0 50.0 720 621 363
12/76 SYSTEM 744 275 D
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 12/76 [GUIFKENT: BOILER-RELATED
END DATE 12/76 PROBLEM: NOT DEFINED/SPECIFIED
TfcE BOILER UA< OOHN FOR REPAIR OF A CONDENSER TUBE LEAK AND BOTTOM ASH
AFffrCTED flODULtSs SYSTEM
** PRObLEMS/SOLUTIONS/COMMENTS
START DATE 12/76 t'SUll'NENT: GAS DAMPER
END DATE 12/76 PROBUM: NOT DEF INED/SPE CI F 1 fcD
OlRIfJf THt BOILER OUTAGE THE SCRUBBER'S GUILLOTINE DAMPERS WERF BADLY
DAMAGED. THE SCRUBBER REMAINED OUT OF SERVICE DURING THE MONTH OF
DECEMBER.
AFFfCTED MODULES: SYSTEM
1/77 SYSTEM 744 0
*« PROBLEMS/SOLUTION&/COMHENTS
START DATE 1/77 jOUIMENT: BOILER-RELATED
END DATE 1/77 FKOPIIM: NOT DEFINED/SPECIFIED
THE R01LF.fi tiAi OFF LINE DURING JANUARY FOR MAINTENANCE*
AFFECTfcO MODULES: SYSTfcM
Z/7r SYSTEM 95.0 75.0 88.0 5ft.0 672 516 387
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 2/77 f 6Ul FB6NTI SCRUPBEk
END DATE 2/77 PROBUM: NOT DEFINED/SPf(IFI ED
A MINOR SCRUB .ED OUTA6E RESULTED FROM A VENTUfU PIPING LEAK.
AFFECTED MODULES: SYSTtf
** PHOI9L«MS/SOLUTIONS/COMMEN1S
START DATE 2/77 fe«UUMENTs FGO SYSTEM, GtNERAL
END DATE 2/77 F'POEt'M: NOT DE FINED/S PF CI FI ED
AT THE END of FEBRUARY THERE WERE SOME ELECTRICAL PROBLEMS.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DAT? 2/77 LQUIFHENT: TANK, OTHER
END DATE 2/77 f-KOBt'M: NOT DE FINED/S PE CIF 1 ED
A PINCR SCRUE'ER OUTAGE UA$ REQUIRED TO ClF-Aty THE VA$H TRAY RECyCLF TANK.
AFFECTED MODULES: SYSTEM
3/77 SYSTEM 92.0 £6.0 97.0 76.0 744 659 567
** PROBLEMS/SOLUT10NS/COMMENTS
START DATE 7/77 EGUIFTENT: ABSORBER
END DATE 3/77 PPOPLfM: CHEMICAL-RELATED PLUGGING
A PLUGGED SPR/iY TRAY CONTRIBUTED TO FGD OUTAGE TIME.
AFFECTED MODULES: SYSTHM
** PRObLEMS/SOLUTIONS/CCMMENTS
START DATE 3/77 E6UIFMENT: FGD SYSTEM, GENERAL
END DAT? 3/77 PRGBLFM: NOT DEFINED/SPFCIFI ED
ELECTRICAL PRCPLEMS CONTRIf?UTED TO FGD OUTAGE TIME.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 3/77 [(lOH^ENT: CAS DAMPER
END DATE 3/77 FFOtUrM: 0ESIGN-RFLATED PRESSURE SURGFS
205
-------
FPA UTILITY F&D SURVEY: DECtKBFft 197? - JANUARY 1979
SECTION 3
DESIGN AND PE RF ORM A ».C E DATA FOR OPERATIONAL FGD SYSTEMS
------------------------------------------ PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPEMCILITT ^LIABILITY UTILIZATION
IJOUU
OLCT PRESSURE SWINGING CONTRIBUTED TO FGD OUTAGE TIKE.
AFFECTED MODULES: SYSTEM
** PROSLEMS/SOLiniONS/COKMENTS
START DATE 3/77 EBUI^ENT: FAN
END DATE 3/77 PROBlFM: NOT D I FINE 0 /S PF CI F I ED
AN I.D. FAN SUNG CONTRIBUTED TO FGD OUTAGE TIME.
AFFECTED MODULES: STSTEK
A/77 SYSTE>
95.0
95.0
95.0
95.0
720 720
685
*» PROBLEMS/SOLUTIONS/COMWENTS
START DATE 4/77 EBUIf'ENT: SCRUPBES
END DATE */77 PROBLEM? NOT D E FIN E D /S PE CI F I ED
FCRCFD FGD OU1A6E T1«E RESULTED FROM A LEAK IN THE VEMTUKJ DISCHARGE LINF.
AFFECTED NODULES: SYSTEM
5/77 SYSTEM
99.0
E5.0
98 .0
60.0
7*4
445
•» PROBLEHS/SOLUllONS/COfWENTS
START DATE 5/77 £«UjfNENT; Bfll L ER-RELA T E D
END DATE 5/77 PROBIFH: NOT DEFINED/SPFclfI ED
CltE BOILEK OUTAGE OCCURRED DURING PAY.
AFFECTED MODULES: SYSTtn
*« PROatEHS/SOLUTlONS/COKKENTS
STApT DATf 5/77 ECUIFKENT: PUMP, OTHER
END DATE 5/77 PROBttMr NOT DEFINED/SPECIFIED
THE ASH SERVICF PUMPS WERE OUT Of SERVICE FOR AppRoXIHATELY TO HOURS
RESULTING IN DO EMERGENCY SPRAY THUS FORCING THE FGD SYSTEM OUT OF SFRVjCE
AFFECTED MODULES: SYSTEM
6/77 SYSTEM
94.0
93.0
94 .0
83.0
: FGD SYSTEM, GENERAL
720 639
596
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 6/77
tND DATE 6/77 COMMENTS:
TtiREF FORCED SCRUBBER OUTAGES WERE REPORTED IN JUNE.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COKMENTS
START DATE 6/77 EBUlf-'WENT: INSTRUMENTATION
END DATF 6/77 PROBLEM: C HEMIC AL-RELATF D PLUGGING
OtiE FORCED OUTAGE WAS DUE TO PLUGGING OF THE I.D. FAN SENSING CINE.
AFFECTED HODUlESl SYSTEM
** PROBLEKS/SOLUTIONS/COMMENTS
START DATE 6/77 ECUIPMENT: FGD SYSTEM, GENERAt
END DATE 6/77 PPOBIEH: NOT D E F IN EO/S PE Cl f 1 ED
OkE FORCED OU1A6E WAS DUE TO A BREAKER TRIP RESULTING IN LOSS OF CONTROL
POWER.
AFFFCTED MODULES: SYSTEM
«« PROULEMS/SOLUTIONS/COMMENTS
START DATE 6/77 EBUIfMENT: SPRAY NOZZLES
END DATE 6/77 PROFUFM: CHEMICAL-RELATED PLU66ING
OfcE FORCED OUTAGE WAS DUE TO PLU6UN6 Of THE SPRAY NOZZLES IN THE VENTOR1.
AFFECTED MODULES: SYSTEM
7/77 SYSTEM
40.0
41.0
40.0
40.0
744 733
298
** PftOB|.Ef*$/50LUT10N$/COM!"!ENT$
START 6ATF 7/77 E6UUMEN7:
END BATE 7/77 PROBIEH: DESI6N-RELATEC PRESSURE SURGES
SEVEN FORCED (CD OUTAGES WRRE DUE TO A H16H/LOW TRIP IN THE SCRUBBER DUCT
DURIN6 JULY.
AFFECTED MODULES: SYSTEM
206
-------
EPA UTUITV FGt SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AMD PE RFOPMA IvC E DATA FOR OPERATIONAL FED SYSTEMS
__.._.._._ . .... PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY ((LIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
*» PROBLEMS/SOLUT10NS/COWWENTS
START DATE 7/77 EQUItKENT: SPRAY NOZZLES
END DATE 7/77 PRCBLiM: CHEMICAL-RELATED PLUGGING
ONE TWO HOUR CUTAGE WAS REQUIRED TO CORRECT A PLUGGING PROBLEM IN THE
VENTURI SPRAY NOZZLES DURING JULY.
AFFECTED MODULES: SYSTEM
8/77 SYSTEM B7.0 91.0 87.0 79.0 74* 6?9 590
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 8/77 EQUIPMENT: SCRUBBE.R
END DATE 8/77 PROBLEM: NOT D£ FINED/SPE CI FI ED
A LEAK IK! THE VENTURI RECYCLE HEADER RESULTED IN AN FGD OUTAGE.
AFFECTED MODULES: SYSTEM
** PR08LEMS/SOLUTIONS/COMWEN1S
START DATE S/77 ICUIfMENT: DUCTWORK
END DATE 8/77 PROBLEM: DESIGN-RELATED PRESSURE SURGES
A SCRUPBEfi DUCT HIGH/LOU BOILER TRIP PROBLEM RESULTED IN OUTAGE TIME*
AFFECTED MODULES: SYSTfcK
** PROBLEHS/SOLUTIONS/COMMENTS
START DATE 8/77 EGUlf-WENT: BOILER-RELATED
END DATE 8/77 PROBLEM: NOT DEFINED/SPECIFIED
TKRE WAS ONE BOILER RELATED OUTAGE DURING AUGUST.
AFFECTED MODULES: SYSTEF
9/77 STSTEK 74.0 67.0 71.0 64.C 720 716 46?
** PROQLEMS/SOLUTIONS/COMMENTS
START DATE 9/77 EGUlTMENT: SCRUBBER
END DATE 9/77 PPCBt-fM: NOT DEF1NED/SPE cIF I £D
A LEAK IN THE VENTURI RECYCLE LINES RESULTED IN FORCED FGD OUTAGE TIMf.
AFFECTED MODULES: SYSTEM
*« PROBLEMS/SOLUTIONS/COHKEN1S
START DATE 9/77 EQUIPMENT: PUMP, OTHER
END DATE 9/77 PROBLEM: NOT DEFINED/SPECIFI ED
TRAY RECYCLE (UKP REPAIR NECESSITATED F€D OUTAGE TIME.
AFFECTED MODULES: SrSTEl*
** PROBLEKS/SOLUTIONS/COMCENTS
START DATE 9/77 EfiUl^iENT: INSTRUMENTATION
END D»TE 9/77 PFOBlEH! CHEMICAL-RELATED PLUGGING
DUCT PRESSURE HIGH/LOU SENSING LINF PLUGGING RESULTED IN FORCED F6D OUTAGE
AFFECTED MODULES: SYSTEf
** PROBLEMS/SOLUTIONS/COMMENTS
START DAjE 9/77 E8UIFMENT: FGD SYSTEM, GENERAL
END DATE 9/77 PROBLE«: NOT DEFINED/SPECIFIED
Ak OUTAGE OCCtRRED WHEN THE. ASH SLUICE SYSTEff W E H|T OUT OF SERVICE
-------
EP» UTILITY FGD SURVEY: DECEPbER 1
-------
EPA UTILITY fCSt SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FGD SYSTEMS
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY CPERA6IL1TY PLIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
REPAIRS OK THE THICKENER OVERFLOW pUMP CONTRIBUTED TO FGD OUTAGE TIME.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMWENTS
START DATE 1/78 ESUIfHENT: SCRUBBER
END DATE 1/78 PROB^tM: NOT DEFINED/SPEClfI ED
SCME BUILD UP IN THF VENTURI CONTRIBUTED TO FGD OUTAGE Tl«F DURING
JANUARY.
AFFECTED MODULES: SYSTtP
2/78 SYSTEM 93.0 92.0 92.0 87.C 672 6?6 585
** PROBLEMS/SOLUT10NS/COKMENTS
START DATE 2/78 IfiUIfflENT: INSTRUMENTATION
END DATE 2/78 PROBLEM: CHEMICAL-RELATED PLUGGING
A DUCT HltH/LfW PRESSURE TRIP CONTRIBUTED TO OUTAGE TIME.
AFFECTED MODULES: SYSTEM SYSTEM
** PROatEMS/SOLUTlONS/COMMENTS
START DATE 2/78 EQU1W!ENT: BOILER-RELATE D
END DATE 2/7B PROBlfM: NOT DEFINED/SPECIFIED
ThE POILF.R WAi: OUT OF SERVICE FOR 34 HOURS DURING FEBRUARY.
AFFECTED MODULES: SYSTEM
3/76 SYSTEM 9B.O 89.0 97.0 80.0 74*. 672 595
** PRObLEMS/SOLUTlONS/CCMMENTS
START DATE 3/78 E«UJFtfENT: FGD SYr.TEM, GfcNtRAL
END DATE 3/78 FPOUIfM: NOT DEFINED/SPECIFIED
TfcERF WAS CULT ONE FORCED FGD OUTAGE DURING MARCH WHICH LASTED AF'PROX1MATE
LY 1P HOUfcS.
AFFECTED MODULES: SYSTEM
** PROELEMS/SOLUTIONS/CCMWENIS
START DATE 3/7fc EOUII^ENT: BOILSR-ftELATED
END DATE 1/78 COMMENTS:
A SCHDULED BOILER OUTAGE AT THF BEGINNING OF MARCH TO REMOVE ASH
W*S CANCELLED .
AFFECTED MODULES: SYSTtl*
4/78 SYSTEM 1CO.O 9E.O 100.0 4*.C 720 320 317
** PROBLEMS/SOLUTIONS/CCKMENTS
START DATE 4/78 tGliltWENT: P.OI L ER-RELATE 0
END DATE 4/7B COMMtMT: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTAGE
ThERE WAS 0*E SCHEDULED BOILER OUTAGE WHICH LASTED ABOUT 403 HOURS.
AFfECTED MODULES: SYSTEM
5/76 SYSTEM 100.0 100.0 100.0 V7.0 ?44 726 724
** PROBLEKS/SOLUTIOMS/COMKENTS
START DATE 5/78 tGUIlKENT: BOI LT R-RE LA T F tl
END DATE 5/78 PROBLFH: NOT 0 EF1 NED/S PF. CI F I ED
ThE FOILER WAS OFF FOR APPROXIMATELY 1g HOURS FOR REPAIRS ON THE MILL
SPOKES.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/CCfrtfENTS
START DATE 5/78 ECUI t-f-ENT: FGD SYSTEMt GENERAL
END DATE 5/78 PKOPUM: NOT D E FINED/SPE'CI F I ED
TfcE 2A SEC. FjSfAKER TRIPPEI5 AND CAUSED AN OUTAGE OF ABOUT ONE HOUR.
AFFECTED MODULES: SYSTEM
6/7B SYSTEM 100.0 92.0 100.0 92.0 7?Q 720 661
** PROBLEKS/SOLUTIONS/COKHENTS
START DATE 6/78 E8UIFMENT: F6D SYSTEM, GENERAL
END DATE 6/78 PROBUM: NOT D E F I H ED /S PE CI F I ED
209
-------
EPA UTILITY f&6 SURVEY: 0£Ctl»frFK 197f - JANUARY 1979
StCTICN 3
DESIGN AND FERf0*MA'CE DATA FOP OPERATIONAL FfD SYSTEMS
PERFORMANCE DATA -----------------------------
PERIOD MODULE AVAILABILITY OPEP.ABUm PLIABILITY UTILIZATION POV BOILER
TKRE'WERE TO* SCHEDULED FED OUTAGES TO UNPLUG THE TRAYS AND TO CHANSE
THE OIL ON TH* i .p. CAN •
AFFECUD MODULES: SYSTtK
** PROBLEMS/iOLUTIONS/COMMENTS
START DATE t/76 E<>UIFI«ENT: DUCTWORK
END DATE < /7fr PKOetKM: DESIGN-RELATED PRESSURE SUR6SS
A FORCED FCD UlTA&f OCCURRED WHEN HIGH DUCT PRESSURE CAUSED A BOILER TRIP.
AFFECTED MODULES: SYSTEM
7/76 STSTE* KO.O £2.0 79.0 7A.O 74* 676 551
*» PROKLEMS/SOLUT10NS/COMNENTS
START DATE 7 /78 tOUIIWENT: BOILF.R-RILATE D
END DATE 7/7£ f'PCFKh: NOT DE F INED/S PE CI F I ID
TK PCILFI. k»' OUT OF SERVICE DUE TO A BOILER TUBE LEAK.
AFFECTED KODULIS: SYSTEM
*«
START DATE 7/7? ICUI'flENI: 60CTWORK
END DATF 7/7B FfCE-l^: D E SIGN-RELATE D PRESSURE SURGES
HIGH OUCT P&ESSURt WAS THf; CAUSE OF A BOILER TRIP. THE HIGH DUCT PRESSURE
WAS CAUSED EiY A FAULTY POSITIONER ON THE 1.0. FAN CONTROLLER.
AFFECTED MODULES: SYSTEM
** PPOULEMS/SOLUTIONS/COHMENTS
START DATE 7/78 EOLIIPtNT: EXPANSION JOINT
END DATE 7/78 FFCBIEH; DE, S1GN-RF LATE D INFERIOR CONSTRUCTION MATERIAL
Tt-E I.D. FAIv rXPANSION JOINT ON THE SCRUPBFR WAS REPLACED.
AFFECTED MODULES: SYSTEM
•* PROCLEMS/SOLUTIONS/COWWENTS
START DATE 7/78 EGUirfENT: FAN
END DATE 7/78 FPOEITM: NOT DEFINED/SPECIFIED
Ah fft OUTAIE OCCURRED WHEN A EtOLT, WHICH FELL FROM THE FAN, CAUSED
VIBRATIONS.
AFFECTED MODULES: SYSTEM
** PRObLEMS/SOLUTlONS/COMMENTS
START DATE 7/78 LCUjr-PENT; BOILER-RELATED
END DATE 7/78 PROP UM JvNOT DEFINED/SPECIFIED
A SECOND E'CILfR TRIP DURING JULY MS CAUSED BY AN UNDETERMINED SOURCE.
AFFECTED MODULtS: SYSTEF1
** PROBLEMS/SOLUTIONS/COMMENTS
STApT DATE 7/78 EOUIfPENT: PIPING
END DATE 7/78 PFOFUEM: CHEMICAL-RELATED PLUGGING
THE SUCTION LINE FROM THF VENTURI DISCHARGE LINE TO THE EFFLUENT PUMPS
WAS CLEANED 0 IT DUE TO PLUGGING.
AFFECTED MODULES: SYSTEM
8/78 SYSTEM 81.0 82.0 93.0 81. P 744 7?3 601
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 8/78 fcCUIFMENT: ABSORBER
END DATE 8/78 COMMENT: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTAGE
ThO SCHEDULED OUTAGES DUPING AUGUST WERE NECESSARY TO CLEAN THE SCRUBBER
TRAY.
AFFECTED MODULES: SYSTEM
•* PROBLEMS/SOLUTIONS/COMMENTS
START DATE S /78 EQUIPMENT: SPRAY NOZZLES
END DATE £ /78 COMWfNT: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTA6E
A SCHEDULED OITAGE WAS NECESSARY TO CLEAN THE NOZZLES ON THE SCRUBBER SPRA
RACK. THE STMNLESS STEEL PIPE TO THE TRAY SPRAY NOZZLES WAS ALSO
REPLACED.
AFFECTED MODULES: SYSTEM
-------
EPA UTILITY FGD SURVEY: DECEMBER 1978 - JANUARY 1«79
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FED SYSTEMS
....... ._._..... .... ........ PERF OHM ANCE 6 AT A • • »-.—..-_._ — .._... — _.—..
PERIOD MODULE AVAILABILITY CPERAB1L1TY IELIA6ILITY UTILIZATION Z REMOVAL PER BOILER FPD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
•« PROBLEKS/SOLUTIONS/COMMENTS
START DAT; «/78 reuirnENT: DUCTWORK
END DATE K/78 PROBLEM: DESIGN-RELATED PRESSURE SUR6ES
Oh AUGUST 1 T»f SCRUBBER EXPERIENCED HIGH DUCT PRESSURE.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUT10NS/COWMENTS
START OATE 8/78 EQUIPMENT: PUMP, OTHER
END DATE 8/78 PROBtFM: NOT DEFINED/SPECIFIED
ON AU6UST I IT WAS NECESSARY TO TAKE THE SCRUBBER OFF LINE TO REPACK THE
VEKTURI PUMPS .
AfFECTEO MODULES: SYSTEM
** PRObtENS/SOLUTIONS/COMMENTS
START DATE S/78 LCUlffiENT; F6D SYSTEM, GENERAL
END DATE t /78 F FOB IE PI : MOT D EFINED /S PE CI F I ED
A THIRD OUTA6F IN AUGUST WAS CAUSED BY A LOSS OF THE ASH PANEL CONTROL
PCWER. THIS LEFT THE SCRUBBER WITHOUT EMERGENCY SPRAY.
AFFECTED MODULES: SYSTEM
9/78 SYSTEI" tOO.O «7.0 100.0 94 . P 720 693 675
** PRObLEHS/SOLUTlONS/CCKMENTS
STABT DATE 9/78 IttllfENT: F6D SYSTEM, GENERAL
END DATE 9/78 CCNMNT: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTAGE
A SCHEDULED SCRUBBER OUTA6E TOOK PLACE DURING SEPTEMBER IN ORDER TO CLEAN
THE TRAY RECYCLE TANK AS WELL AS THE TRAY AND SOME OF THE LINES.
AFFECTED MODULES: SYSTEK
** PAOBLEMS/SOLUTIONS/COPMEN1S
START DATE 9/78 ESUIIWENT: B01LFR-RELATE0
END DATE 9/7g PROEIEM: NOT DEFINEO/SPEC1FItD
THREE BOILER ELATED OUTAGES WERE CAUSED BY PROBLEMS WITH A 1C-KU
GENERATOR. CCNTROL POUER SURGES WERE BEING CAUSED BY OVERVOLTA6E MOTOR
TRIPS.
AFFECTED MODULES: SYSTEM
10/7S SYSTEM 96.0 95.0 99.0 92.0 744 7J1 6£S
** PRObLEMS/SOLUTIONS/COMMENTS
START DATE 10/78 EeUIFWINT: INSTRUMENTATION
END DATE 1C/76 COMMIT: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTAGE
OLRm OCTOBFl- THE SCRUBBER INSTRUMENTS WERE WORKED ON DURING A SCHEDULED
OUTAGE.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 10/78 t«VI f "
-------
SPA UTILITY F60 SURVEY: DECEMETR l97f - JANUARY 1979
StCTlON 3
DESIGN AM) PERFORMANCE DATA fOR OPERATIONAL F60 SYSTEMS
PERFORMANCE DATA "
PERIOD MODULE AVAILABILITY OPEPAf'lDTY PLIABILITY UTILIZATION X REMOVAL PER BOILER F68 CAP.
S02 PART. HOURS HOURS HOURS FACTOR
.. PROGLEMS/SOLUTIONS/COMMENTS
START DME 11/7f E6UIFKENT: BOILER-RELATED
END DATE 11/76 COMMINT: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTAGE
TfcE UNIT K*S !HUT DOWN NOVEMBER 12 FOR SCHEDULED BOILER MAINTENANCE. THE
UMT REMAINED OUT OF SERVICE THE RtMAJNDER OF THE MONTH.
AFFECTED MODULES: SYSTEM
12/78 SYSTEM 95.9 100.0 100.0 13.7 74* 990 990
** PR06LEMS/SOLUT10NS/COMMENTS
START DATE 12/78 [OUIfWENT: PIPING
END DATE t?/78 COtfMtNT: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTAGE
Tt-E SCRUBf-'ER VAS DOWN TO UNPLUG EFFLUENT LINE.
AFFECTED MODULES: SYSTEM
•* PRObLEMS/SOLUTIONS/CCKMENTS
START D«TE 12/7* EOUIFKENT: BOILER-RELATED
END DATE 12V78 PRCElFn: NOT DEFINED/SPECIFIED
WhILf THE SCRtfEER WAS DOWN THE FOILER WAS ALSO OOUN FOR PULVERIZER
REPAIRS.
AFFECTED MODULES: SYSTEM
** PROeLEMS/SOLUTIONS/COKIPIENTS
START DATE 12/7E ECLlhMENTr BOIL FR-RELATF D
END DATE 1Z/7E COMiMtf.T: pREVENTlV^ MAINTENANCE SCHEDULED UNIT OUTAGE
TtE PCJLER kA£ OFF UNTIL DECEMBER 76 FOR SCHEDULED MAINTENANCE.
AFFECTED MODULES: SYSTEM
1/79 SYSTEM 82.9 61.3 81.3 73.9 7«4 676 549
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 1/79 IQUIIfENT: ABSORBER
END DATE 1/79 PROBLEM: NOT DEFINED/SPECIFIED
TK F6D SYSTEK WAS DOWN TO CLEAN A TRAY SCREEN.
AFFECTED MODULES: SYSTEM
•* PROBLEMS/SOLOTIONS/CCMMENTS
START DATE 1/79 E6UII^ENT: PIPING
£ND DATE 1/79 PPOBttM: NOT DEFINED/SPECIFIED
THE F6D SYSTF!' WAS DOWN TO REPAIR A LEAK IN THE VENTUAI RECYCLE LINE.
AFFECTED MODULES: SYSTEM
** PROBLErS/SOLUTlONS/COMMENTS
START DATE 1/79 16UJFKENT: BOILER-RELATED
END DATE 1/79 PROBLFM: NOT D E FINED/S PF CI F I ED
TFE BCILEfc WA < DOWN TO REPAIR TUBE LEAKS.
AFFECTED MODULES: SYSTEM
** PROfcLEMS/SOLUTJONS/COMflENTS
STApT OAjE 1/79 EQUIfMENT: PUMP, OTHER
END D«TE 1/79 PROBLEM: NOT DEFINED/SPECIFIED
REPAIRS WERE MDE ON THE TRAV ANB SPRAY PUMP SYSTEMS.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 1/79 teuiffENT: RECYCLE PUMP
END DATE 1/79 PROBit«: NO* DEFINED/SPECIFIED
THE VENTURI RECYCLE PUMP LOST POWER.
AFFFCTED MODULES: SYSTEM
** PRObLEMS/SOLUTIONS/COMMENTS
START DATE 1/79 EOUIFMENT: PUMP, OTHER
END DATE 1/79 FRCE^En: NOT DEFINED/SPECIFIED
TlfE SCRUBfc'£R 1R*V PUWP HOTOR «tNT TO 6RCUND. THE ?C LOAD CENTER TRIPPED.
212
-------
EPA UTILITY F6D SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN UNO PERFORMANCE DATA FOR OPERATIONAL F6D SYSTEMS
......... PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABIL1TV RELIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP-
SO? PART. HOURS HOURS HOURS FACTOR
** PROBLEWS/SOLUTIONS/CCKMENTS
START DATE 1/79 EQUIPMENT: DUCTWORK
END DATE 1/79 PROBLEM: DESIGN-RELATED PRESSURE SURGES
THERE WAS SCRIBBER TRIP ON HIGH DUCT PRESSURE.
AFFECTED MODULES: SYSTEM
** PBOBLEMS/SOLUTIONS/COMMENTS
START DATE 1/79 E6UIFKENT: DUCTWORK
END DATE 1/79 PROB LEM I D E SIGN-RE LATE D PRESSURE SURGES
A HIGH DUCT PRESSURE TRIP WAS RESPONSIBLE FOR A SHORT OUTAGE. THE PRESSUR
SENSING LINES WERE CLEANED.
AffECTtD MODULES! SYSTE*
2/79 SYSTEM 96.5 93.1 93.2 87.9 672 634 591
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 2/79 E8UIPMENT: PIPING
END DATE 2/79 PROBLEM: NOT DEFINED/SPECIFIED
THE FGD SYSTEK WAS DOWN TO REPAIR LEAK IN THE VENTURI LINE.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COKMENTS
START DATE 2/79 E6UIIKENT: FGD SYSTEM, GENERAL
END DATE 2/79 fFOB LEW: NOT DEFINED/SPECIFIED
THE F6D SYSTE* WAS FORCED OUT OF SERVICE DUE TO A ?8 LOAD CENTER POWER
LOSS.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUT10NS/COMMENTS
START DATE 2/79 lOU!H»!ENTl PIPING
END DATE 2/79 PROPtEM: NOT DEFINED/SPECIFIED
THE SCRUBBER *A S FORCED DOWN DUE TO A BREAK IN THE ASH WATER CIRCULATING
WATER LINE RESULTING IN LOSS OF EMERGENCY COOLING WATER.
AFFECTED MODULES: SYSTEM
** PR06LEMS/SOLUT10NS/CCMMENTS
START DATE 2/79 tCUKCENT: SCRUBBER
END DATE 2/79 PROBLEM: NOT DEFINED/SPECIFIED
Tfcf F6D SYSTEf WAS DOWN BECAUSE OF A LEAK ON THE VENTURI RACE TRACK AND
TC CLEAN THE \ENTURI RACE TRACK NOZZLES.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMHENTS
START DATE 2/79 EQUIfKENT: BOILER-RELATED
END OjTE 2/79 PROBtfM: NOT DEFINED/SPECIFIED
THE BCILEK bAt DOWN TO REPftIR A TUBE LEAK-
AFFECTED MODULES: SYSTEf
213
-------
EPA UTILITY ffcD SURVEY: DECEMBER l97f - JANUARY 1979
SECTION 3
DESIGN AND PtRfOPMANCE DATA FOR OPERATIONAL f6D SYSTEMS
COMPANY NAPf
PLANT NAMF
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NC/J
S02 EMISSION LIMITATION - *t/J
NfT PLANT GENERATING CAPACITY - MW
CROSS UNIT GENERATING CAPACITY - Mb
NET UNIT GENERATING CAPACITY W/FGD - Ml
MET UNIT GENERATING CAPACITY WC/F6C - fW
EQUIVALENT SCRUBBED CAPACITY - KW
•* BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUl GAS FLOW - CU.l"/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAMETER - M
•* FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - KJ/KG
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - »
RANGE ASH CONTENT - Z
AVERAGE MOISTURE CONTEM - t
RANGE MOISTURF CONTENT - *
AVERAGE SULFUR CONTENT - %
RANGE SULFUR CONTENT - J
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - %
FUEL FIRING RATE - M T/H
FUEL FIRING RATE - MM
•* MECHANICAL COLLECTOR
TYpf
SUPPLIER
PARTICULATE DESIGN REMCVAl EFFICIENCY
** PARTICULATE SCRUBBER
NUHPER
TYPF
SUPPLIER
LINING MATERIAL
TYPE Of NOHLFS
BOILER LOAD/SCRUBBt* - X
LIQUID RfcClRCULATlON RATE - LITF.R/S
L/6 RATIO - L1TER/CU.I"!
PRESSURE DROP - KPA
SUPERFICIAL GAS VELOCITY - M/S
•* F6D SYSTEM
SALFABLE PRO DUCT/T HR OW AWAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETfiOFIT
PARTICULATE DESIGN REMOVAL EFFICIENCY
SO 2 DE$IKN REMOVAL EFFICIENCY - X
COMMERCIAL DAT£
INITIAL START-UP
CONSTRUCTION IMITIAT10*
CONTRACT AWARDED
«* ABSORBER
( .100
( 1.200 LP/MMPTU)
NEVADA POW5R
REID GARDNER
3
KOAPA
NEVADA
A
41!.
516.
*******
125.0
110.0
*******
12?.0
FOSTER WHEELER
PULVERIZED, BALANCED DRAFT
BASE
0/76
?E3.21 < 473000 ACFK>
176.7 ( 350 F)
61. < ZCO FT)
******* (***** FT)
COAL
******
2B959.
B.OO
* *****
********
******
.50
0.5-1.0
***** ***
***** *
*****
< 1245G BTU/LBJ
(***
MILTICLONES
RESEARCH COTTRELL
X 75.0
VARIABLE THRQAT
AOL/COMBUSTION EQUIP ASSOCIATES
1NCOLOY 82S
TANGENTIAL
157.5
1.3
5.0
50.3
( 2SOO
<10.0 GAL/1000ACF)
< 20 1N-N20)
( 165.0 FT/S)
TYPF
INITIAL START UP
THROWAUAY PRODUCT
WET SCRUBBING
SODIUM CARBONATE
ADI/COMBUSTION EQUIP ASSOCIATE
BECHTEL
FULL-SCALE
NEW
- X 99.00
85.00
7/76
6/76
0/7*
0/73
PERFORATED PLATE WASHING TOWER
6/76
214
-------
EPA UTILITY F6D SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOP OPERATIONAL FGD SYSTEMS
NUMBER OF STAGES
DIMENSIONS
BOILER LOAD/APSORBER - X
LIQUID RECIRCULATION RATE
PRESSURE DROP - KPA
PART1CULATE OUTLET LOAD -
- LITER/S
NG/J
$02 DESIGN REMOVAL EFFICIENCY - X
1
30 DlA.
100.0
38.
.7
41703.
91.2
( 600 GPM)
( 3.0 IN-H20)
(97.000 LB/MMBTU)
** FANS
NUMBER
TYPE
CONSTRUCTION MATERIALS
** WIST EljMlNATOR
MUMPER
TYPE
CONFIGURATION
MASH SYSTEM
PRESSURE DROP - KPA
** RIHEATER
TYPS
HEATING KEDIUM
TEMPERATURE BOOST - C
ENERGY REQUIRED
** MATER LOOP
TYPf
FRESH MAKEUP WATER ADDITION - LITERS/S
** DISPOSAL
NATURE
TYPE
LOCATION
AREA - ACRES
** DISPOSAL
NATURF
TYPE
LOCATION
TRANSPORTATION
AREA - ACRES
I.D. BOOSTER FAN
CARBON STEEL
1
RADIAL VANE
HORIZONTAL
NONE
.1
C .5 IN-H20)
INDIRECT HOT AIR
STEAM
16.7 ( 30 F>
4 Ml*
OPEN
1.6
( 25 GPP)
INTERIM
LINED ASH FOND
ON-SITE
6.0
FINAL
EV»P POND
ON-SITE
GRAVITY FLOW FROM 1NTERIW SLUDGE PON"
45.0
. PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABIL1TY PLIABILITY UTILIZATION
X REMOVAL PER BOILER FGD CAP-
S02 PART. HOURS HOURS HOURS FACTOR
7/76 SYSTEK 45.Q 4t«0
** PROoLEMS/SOLUTIONS/COMKENTS
70.0
42.C
744 692
316
7/76 tOUIFHENT: SCRUBBER
7/76 PROBLEM: NOT DEFINED/SPECIFIED
A HIGH SOLIDS CONCENTRATION IN THE VENTURI SCRUBBING SOLUTION CYCLE MAS
A PROBLEM DURING JULY.
J SYSTEM '
START DATE
END DATE
AFFECTED
** PROBLEWS/SOLUTTONS/CCI"IHEN75
START DATE 7/76 EQUIFftENT: FGD SYSTEM, GENERAL
END DftTF 7/76 PROPLFM: NOT DEFINED/SPECIFIED
FCUR OUTAGES >ERE REPORTED FOR THE MONTH, THREF OF WHICH MERE FORCED
SCRUPBER OUTAffS.
AFFECTED MODULES: SYSTEM
** PROaLEKS/SOLU1IONS/COK«!ENTS
START DATE 7/76 EGUIfKENT:
END DATE
SYSTEM, GENERAL
7/76 CCKMtMTSr
ThE UNIT 3 SYSTEM WAS PLACED IN OPERATION ON JULY 1Z, 1976. THE SCRUBBING
SYSTEM DESIGN HAS BASED ON INFORMATION AND DATA OBTAINED FROM AN SOOO-ACFM
PILOT PLANT PI-OGRAM CONDUCTED AT THIS STATION IN 1??1 AND 19?Z.
AFFECTED MODULES: SYSTtK
215
-------
FPA UTILITY F6D SURVEY: DECEMBER 197F - JANUARY 1979
SECTION 3
DESltN AND PERFCRMAt.CE BATA FOR OPERATIONAL FGD SYSTEMS
PERFORMANCE DATA
PERIOD MODULE AVAIIAPILITY OPEPA&ILITY FELIABILITY UTILIZATION * REMOVAL PER BOILER ™" ,?„«»
S02 PART. HOURS HOURS HOURS FACTOR
.* PFOBLEMS/SOLUTIOKS/COMMENTS
START DATE 7/76 EQUIPMENT: REAGENT HANDLING
END D/TE 7/76 PROBLEM: NOT DEFINED/SPECIFIED
A BUcKET EltVfTOR MALFUNCTION WAS A PROBLEM DURING JULY.
AFFECTED MODULES: SYSTEM
SYSTEM 56.0 «3.0 50.0 43.0 7*4 744 3i3
«* PROBLEMS/SOLUTIONS/COMKENTS
START DATE 6/76 E6UIH«ENT: REHEATER
END DOTE 8/76 PROBLFM: NOT DEFINED/SPEClFIED
SEMEATER KCTO-K BURNOUT RESULTED IN FGO OUTAGE TIME.
AFFECTED MODULES; SYSTEM
** PR06LEMS/SOLUTIONS/CCM1ENTS
START DATE SJ76 EOUIfMENT: SCRUBBER
END DATE E/76 PROPlEM: NOT DEFINED/SPECIFIED
DISTRUCTICN OF THE VENTURI FLOOR RESULTED IN FGO OUTAGE TIME.
AFFECTED MODULES: SYSTEM
•* PROBLEMS/SOLUTIONS/COMMENTS
START DATE 6/76 EQUIPMENT: FAN
END DATF 6/76 PROBLEM: NOT DEFINED/SPECIFIED
FORCED SCRUBBER OUTAGE WFRE CAUSED BY AN I.D. FAN ELECTRICAL MALFUNCTION
A*D I.D. FAN INSULATION PROBLEMS.
AFFECTED MODULtS: SYSTEM
•* PROBLEMS/SOLUTIONS/COMMENTS
START DATE 8/76 tOUIf«ENT: THICKENER
END DATE 6/76 PROBLEM: CHEMICAL-RELATED PLUGGING
TUtrtNER TANK PLUGGING RESULTED IN FGD OUTAGE TIME.
AFFECTED MODULES: SYSTEM
9/76 SYSTEM 49.0 46.0 46.0 44.0 7?0 679 3t*
»* PR06LEMS/SOLUTIONS/CCMMENTS
START DATE 9/76 EGUI »I"ENT: SCRUBBER
END DATE 9/76 PROBtfM: NOT DEFINED/SPEClFI ED
A VENTURI VIBMTION TRIP RESULTED IN FGD OUTAGE TIME.
AFFECTED MODULES: SYSTEM
** PROSLEKS/SOLUTIONS/COMMENTS
START DATE 9/76 E6UIFMENT: F6D SYSTEM, GENERAL
END DATE 9/76 CCKMfNTS:
THE SYSTEM KA S PLACED BACK IN SERVICE ON SEPTEMBER IN FOLLOWING Ej|TENSIV£
REPAIRS AND M(DIFICATJONS FROM THE PRECEEOING MONTH.
AFFECTED MODULES; SYSTEM
** PCOBLEMS/SOLUTIONS/COMMEN1S
START DATE 9/76 E6U1FMENT: REAGENT HANDLING
END DATE 9/76 PPOBiE«: NOT DEFINED/SPECIFIED
ThO REHEATER IAN TRIPS RESULTED I* FGD OUTA6E TIME.
AFFECTED MODULES: SYSTEM
10/76 SYSTEM 23.0 Z9.C Z1.0 21.0 744 5«g 159
** PROBLEMS/SOLUT10NS/CCMMENTS
START DATE 10/76 ECUIIMENT: PROCESS CONTROL
END DATE 10/76 FROBIFH: NOT DEFINED/SPECIFIED
HIGH SOLIDS CCNTENT IN THE VENTURI RECYCLE SOLUTION RESULTED IN OUTA6E
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 10/76 EOUlfMENT:
END DATE 10/76 PROBLEM: COMPONENT FAILURE, OTHER
216
-------
EPA UTILITY fGD SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMAME DATA FOR OPERATIONAL FGD SYSTEMS
—— PERFORMANCE DATA
PERIOD HODULE AVAILABILITY OPEPAEIL1TY "(LIABILITY UTILIZATION
X REMOVAL PER BOILER FGD CAP-
S02 PART. HOURS HOURS HOURS FACTOR
A SCRUBBER 6*? DAMPER MALFUNCTION RESULTED IN FGD OUTAGE TIME.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLU110NS/COMMENTS
START DATE 10/76 EQUIPMENT: SCRUBBER
END DATE 10/76 PROP if n : NOT DEF1NED/SPF.CIFIED
VENTIRI BOX PHOEiLEMS RESULTED N FGD OUTAGE TIME.
AFFECTED MODULES: SYSTEM
11/76 SYSTEM
28.0
80.0
29.0
29.0
720
264
** PRCBLEMS/SOLUT10NS/COHMENTS
START DATE 11/76 EOUIf^ENT: SfRUBBER
END DATE 11/76 PROB1EM: NCT DEFINED/SPECIFIED
THE SCRUBBER SYSTEM WAS NOT IN OPERATION THE FIRST HALF OF NOVEMBER DUE TO
REPAIRS ot L.E*KS IN THE VENTURI SCRUBBER BOX. THE SYSTEM WAS RESTARTED
NOVEMBER IV.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 11/76 EfiUI tPiENT: REAGENT HANDLING
END DATE 11/76 (-FCEUfM: NOT DEFINED/SPECIFIED
A SCREW COfVEYOR MALFUNCTION (PREVENTING CHEMICAL MIXING) RESULTED IN F6D
OUTAGE TIME.
AFFECTED MODULES: SYSTEM
12/74 SYSTEM
99.0
97.0
99 .0
97. 0
744
744
721
•* PROBLEMS/SQLUTlONS/COMMENTS
START DATE 12/76 fCUirf«ENT: EXpAN$ION JOINT
END DATE 12/76 F-fiOBlEMs NOT DE FINED/S PF cl F I £t>
ONE MINOR SCRU.BER OUTAGE OCCURRED BECAUSE OF REPAIRS TO THE J.D. FAN
EXPANSION JOI M .
AFFECTED MOOL'LES: SYSTEF
1/77 SYSTEM
9B.O
98. C
91.0
744
690
676
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 1/77 tBUirfitNT:
END &ATE 1/77 F-rofiirM: CHEMICAL-RELATED PLUBEINE
A PLU6SED 7RAV RESULTED IN F6D OlTAbE TIME..
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 1/77 E6UJIKENT; REHEATER
END DATE 1/77 FKG&lCM: NOT DEFINED/SPECIFIED
A REHEATER STFAM LEAK RESULTED IN A MINOR FORCED QUTA6E.
AFFECTED MODULES: SYSTEM
2/77 SYSTEM
81.0
74.0
72.0
63. n
672
575
422
** PROBLEMS/SOLUtlONS/COMFIENTS
START DATE 2/77 IBUIffENT: ABSORBER
END DATE 2/77 FPCR1.FM: NOT DEFINED/SPECIFIED
ThREE FORCED SCRUBBER OUTAGES WERE CAUSED t-1 PKOELFMS WITH THE UPPER TRAY.
AFFFCTED MODULES: SYSTEM
** PROfcLEMS/SOLUTIONS/COMMENTS
START DATE 2/77 ESUirfENT: PIPING
tND DATE 2/77 PPCEltM: NOT DEFINED/SPECIFIED
AK OUTAGE RESILTED FOR CLEANING OUT THE SOOIUM CARBONATE LINE.
AFFECTED MODULES: SYSTIC:
3/77 SYSTEM
44.0
51.0
52.0
44.0
744 679
324
»* PROBiEMS/SOLUTlONS/COKWENTS
START DATE 3/77 tCUlFP«ENT: F6D SYjlEM, GENERAL
END DATE 3/77 FPCBUM: I N STALLATION-RE LAT po MATERIALS FAILURE
217
-------
EPA UTILITY F6D SURVE*: DECtHBER 1971 - JANUAPY 1979
SECTION 3
DESlfN *ND PERFOPKAHE DATA fO" OPERATIONAL FED SYSTEMS
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY CPERABILITY «LI*BILIIV UTILIZATION ' BOILER
UE RUBBER LIMNG IN T«E SEPARATOR REQUIRED DOWNTIME FOR CUR1N6.
AFFECTED MODULES: SYSTEI"
** PRObLEKS/SOLUTIONS/COMWENTS
START DATE 3/77 I CUI f">ENT: EXPANSION JOINT
END DATE 3/77
ThE SCRURfcER IAN EXPANSION JOINT BLfcW OUT CAUSING OUTAGE TIKE.
AFFECTED MODULES; SYSTEM
** PROBLEMS/SOLUT10NS/COMMENTE
START DATE 3/77 I CHI I * ENT : ABSORBER
END DATE 3/77 PROPiM: CHEMICAL-RELATED PLUGGING
MINOR OUTAGES WERE CAUSED B* A PLUGGED TRAY.
AFFECTED MODULES: SYSTEM
•« PROBLEMS/SOLUTIONS/COMMENTS
STAeT DATE 7/77 Efil4lh>ENT: FGD SYSTEM, GENERAL
END DATC 3/77 FR(lP|E|t\; NOT 0 E F INgD /S ff CI F I ED
A MINOR OtTAS^ WAS CAUSED RY THE 6J5 LJMJT SWITCH TRIPPIN6.
AFFECTED BOPUIES: SYSTtf
4/77 SYSTEM C.6.0 f5.0 85.0 83. f! 720 709 600
•* PBOtlLEMS/SOLUTIONS/COMHENIS
START DATE 4/77 f PHI fKENT : ABSORBER
END DATE */77
A HIGH TRAY DIFFEHENTAL RESULTED IN F6D OUTA6E T IMF .
AFFECTED MODULES: SYSTEM
** PROOLEMS/SOlllTlONS/CnKMENTS
START DATE
-------
EPA UTILITY F6D SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL F60 SYSTEMS
.. .......—..-_,._..„_... PERFORMANCE DATA——
PERIOD MODULE AVAILABILITY OPERAPILITY RELIABILITY UTILIZATION
X REMOVAL PER BOILER FGD CAP*
S02 PART. HOURS HOURS HOURS FACTOR
A HIGH TRAY DIFFERENTIAL PRESSURE READING CONTRIBUTED TO FORCED SCRUBBER
OUTAGES.
AFFECTED MODULES: SYSTEM
7/77 SYSTEM
73.0
73,0
73.0
73.D
7*4 74*
5*2
** PROBLEMS/SOLUTIONS/CCMMENTS
START DATE 7/77 i«UI^ENT: F6D SYSTEM.
END DATE 7/77 COMMENTS:
FIVE FORCED SCRUBBER OUTAGES MERE ENCOUNTERED DURING JULY.
AFFECTED MODULES; SYSTEM
** PROBLEMS /-SOLUTI ON S/CCKMENTS
START DATE 7777 tOUIFKENT: VALVES
END DATE 7/77 PROBltM: NOT DEFINED/SPECIFIED
REPAIRS TC THE VENTURI DISCHARGE VALUE CONTRIBUTED TO FGD OUTAGE TIKF,
AFFECTED MODULES* SYSTEM
8/77 SYSTEM
70.0
63.0
63.0
sn.o
74* 629
375
** PROBLEMS/SOLimONS/COMMENIS
START DATE £/77 ECUUMENT: PIPING
END DATE 6/77 PROBLEM: NOT DEFINED/SPECIFIED
OLE TC A LEAK IN VENTURI RECYCLE LINE THE UNIT WAS OFF LINE PART OF THE
MONTH.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 7/77 EOUIFXENT: FAN
END DATE 7/77 PROBtFM: DESIGN-RELATED VIBRATION
SCRUBBER FAN VIBRATION PROBLEMS CONTRIBUTED TO FORCED SCRUBBER OUTAGES.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 8/77 EOUIfKENT: FGD SYSTEM. GENERAL
END DATE 8/77 PROBLEM: NOT DEF1NED/SPECIFI ED
A FALSE ALARM DUE TO SCRUBFtR OUTLET TEMPERATURE CAUSED SHUTDOWN FOR ABOUT
A DAY.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COKKENTS
START DATE E/77 tGDIf^ENT: BOILER-RELATED
END DATE B /77 FROBi.Fn: NOT DEFINED/SPECIFIED
T*E BClLEf WAI OUT OF SERVICE FOR ABOUT A WEEK DURING
AFFECTED MODULES: SYSTtf
9/77 SYSTEM
90.0
90.0
99.0
90.0
720 720
646
** PROBLEWS/SOLUTIONS/COMMENTS
START DATE 9/77 teillfKENT: PROCESS CONTROL
END DATE 9/77 PFCBUM: NOT DEFINED/SPE CI FIfcD
H16H SOLIDS If THE VENTURI RECYCLE SYSTEM CAUSED SOME OUTAGE TIME IN
SEPTFMBER.
AFFFCT&D MODULES: SYSTEM
«* PROBLEKS/SOLUTIONS/COMMENTS
START DATE 9/77 EGUIFPENT: PIPING
END D«TF 9/77 PROBLEM: NOT DEFINED/SPECIFIED
NEW EFFLULKT MD POST NEUTRALIZATION LINES WERE INSTALLED.
AFFECTED MODULES: SYSTEM
10/77 SYSTEM
99.0
90.0
99.0
61.0
744
506
A55
** PROBI.EKS/SOLUTIONS/COMMENTS
START DATE 10/77 E«UIIMENT: BOI LF.R-RELATE 0
END DATE 10/77 COKMtNT: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTAGE
THE SCRUBUFR MS DOWN 28*«*2 HOURS DURING OCTOBER FOR A SCHEDULED BOILER
219
-------
EPA UTILITY FED SU»VFY: OECt^BER 1<97f - JANUARY 1979
SECTION 3
DESIGN AKD PFRFORMKE DATA FOR OPERATIONAL FGD SYSTEMS
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY CPEPAt'ILITY KFLIARILITY UTILIZATION X REMOVAL PER BOILER fGD CAP,
S02 PART. HOURS HOURS HOURS FACTOR
OUTAGE.
AFFECTED MODULES: SYSTEM
*» PROBLE»"S/SOLUTIONS/COMMENTS
START DAlE 10/77 tCUIH«ENT: FAN
tND D*TT 10/77 FFCEiM: DESIGN-RELATED VIBRATION
4.45 HOURS OU1AGE TIME OCCURRED AS A RESULT OF HIGH VIBRATION PROBLEMS ON
A SCRUPBF.F MS.
AFFECTED MODULES: SYSTEM
11/77 SYSTEM 89.0 88.0 89.0 87.C 720 709 62*
• • PKOBLEMS/SOLUTIONS/COMMENTf " " . , .. .
START (AT? 11/77 EQUIPMENT: VALVFS
END DATE 11/77 PROEUKM: NOT D E FINED/S FT C) F I ED
THF SCRUBEF.K .AS DOWN ROUGHLY 6Q HOURS FOR THE INSTALLATION OF AN OUTLET
NOZZLE IN THF BOOSTER TANK.
AFFFCTED MODULES: SY$TEM
»* PRO&LEMS/SOLUTIONS/COMMEN1S
START DATE 11/77 EOU1WENT: BOILER-RELATED
END DATE 11/77 PROOUM: NOT DEFINEB/SPECIFIED
THE pOILfk ME OUT OF SERVICE APPROXIMATELY 15 HOURS IN NOVEMBER.
AFFECTED MODULES: SYSTEM
12/77 SYSTEM BR.O 92.0 96.0 93.0 7*4 692 633
** PR08LEMS/SOLUTIONS/COMMENTS
START DATE 12/77 tCUIMENT: INSTRUMENTATION
END DATE 12/77 PFOElEMr NOT DEFINED/SPECIFIED
A FAULTY THERMOCOUPLE CAUSED "SEPARATOR HI6H TEMPERATURE" WHICH IN TURN
CONTRIBUTED TC FGD OUTAGE TIME.
AFFF.CTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 12/77 E6UIFKENT: BOILFR-RELATED
END DATE 12/77 ffORiM: NOT DE FINED/SPF CI FI ED
BOILER OUTAGE TIME AMOUNTED TO 51 HOURS IN DECEMBER*
AFFECTED MODULES: SYSTEM
** PROeLEMS/SOLUTIONS/CCMMENTS
START DATE 1J/77 EGUII'IENT: SPRAY NOZZLES
END DATE 12/77 FPOPlfM; NOT DEFINED/SPECIFIED
TKE INSTALLATION OF TRAV SPRAY STRAINER CONTRIBUTED TO FGD OUTAGF TIME.
AFFECTED MODULES: SYSTEM
•* PROclLEMS/SOLUTIONS/COMMENTS
START DATE 12/77 EGUIF^ENT: INSTRUMENTATION
tND DATE 12/77 FRORl.FMi NOT DEFINED/SPECIFIED
INSTALLATION CF NEW SENSING LINES CONTRIBUTED TO F6D OUTAGE TIME.
AFFECTED MODULES: SYSTEM
1/7P SYSTEM 100.0 100.0 100.0 100.C 7*4 744 740
•* PftOfiLEMS/SOLuTlONS'COMMENTS
START DATE 1 /7f eQUjfENTf
END DATT 1/78 PROBHMt CHEMICAL-RELATED PLUefilNC
A PLUGGED VIN1URI N02ZLE CAUSED THE ONLY F60 OUTAGE DURING J*NUA«».
AFFFCTED MODULES; SYSTEM
** PROBUMI/80LUTIONS/COMMENTS
START DATE 1/7B ESUI^ENT: BOILER-RELATED
END DATE 1/71 COMMtNTSl
T>( POILFh OPffiATED THE INT1BE MONTH WITH NO OPERATIONAL PROBLEMS.
AFFFCTtD MODULES! SYSTEM
2/76 SYSTEM 96.0 95.0 95.0 88.P 672 619 S88
220
-------
EPA UTILITY FGO SURVEY: DECEMBER 1978 - JANUARY 1579
SECTION 3
DESIGN AND PERFORMAKCE DATA FOR OPERATIONAL FCD SYSTEMS
..._.....- ------- — --- - ------------------ PERFORMANCE DATA -------------------------------------------
PERIOD MODULE AVAILABILITY OPERABILITY PLIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 2/78 18UIIWENT: SCRUBBER
END DATF 2/78 PPOBICM: NOT DEFINED/SPECIFIED
AK FGo SYSTEM OUTAGE DUE TO A HIGH VENTURI TEMPERATURE (CAUSED BY FAULTY
WIRING) OCCUR t!:» DURING FEBRUARY.
AFFECTED MODULES: SYSTtM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 2/78 EBUIfWENT: INSTRUMENTATION
tNO DATE ?/78 PROBlEM: NOT DEFINED/SPECIFIED
A MINOR OUTAGt WAS NECESSARY TO CHECK THE VENTURI TEMPERATURE INDICATOR.
AfFfCTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 2/78 EQUIPMENT: TANK, OTHER
END DATE 2/78 PROBUM: CHEMICAL-RELATED PLUGGING
AK FGD OUTAGE WAS CAUSED BY PLUGGING OF THE MIX TANK WHICH MADE IT IMPOS-
SIBLE TO OIX CHEMICALS.
AFFECTED MODULES: SYSTEM
3/78 SYSTEM 97.0 97.0 97.0 >96.0 7** 7*1 718
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE J /78 E6UIFMENT: TANK, OTHER
END DATE 3/76 F-RGBUK: C HIM1 C AL-HFLA TE D PLUGGING
THE MIX TANK H'OBLEM CONTINUED INTO MARCH CAUSING THE ONtV FGD DOWNTIME
FOR THE MONTH.
AFFECTED MODULES! SYSTEM
»* PROSLEMS/SOLUtlONS/COMMENIS
START DATE 3/78 tCUIWENT: BOILER-RELATED
END DATE 3/7S PROBLEM: NOT DEFINED/SPECIFIED
A FURNACE HIGf/LOW PRESSURE TRIP CAUSED A BOILIR OUTAGE OF 6 HOURS.
AFFECTED MODULES: SVSTtP
4/78 SYSTEM 97.0 89.0 97.0 87. C 720 7()4 «29
**
START DATE 4/78 ECUUMENT: SPRAY NOZ2LIS
END DATE 4/7fc PKOB LEU : NOT DEFINED/SPE C] F IID
THE FGD SYSTfiK WAS DOWN 'OR REPAIRS ON THE W6NTURI IMIRSeNCY SPRAY SYSTEM.
AFFECTED MODULES: SYSTEM
** PROBLEKS/SOLUTIONS/COMMENTS
START DATE 4/78 [CLlll«ENT: BOILFR-RFLATE D
END DATE 4/76 PRCFfM: NOT HE FINED/S PE CI F I ID
TK POlLtK UA i DOWN APPROXIMATELY 70 HOURS DURING APRIL.
AFFtCUD MODULES! SYSTEM
3/7E SYSTEM 97.0 77.0 96. 0 66. C 744 6t& 494
**
START DATE S/78 IPUIffiENTi BOHF.R-RELATB D
IND D«TF J/7R COMMENT: PREVENTIVE MA1NTINANCE SCHEDULiD UNIT OUTAQF
THERE WAS A SCHEDULED OUTAGE OF nO HOURS FOR ROHIS MAINTENANCE DURING
MAY.
AFFCCTED MOBULiSl SYSTfM
** PROgLEMS/SOLUTIONS/COMMENTS
START DATE ! /7I TSUI fH'INT! IN8THUMENTAT10M
tND DATE 5/78 FFCgLFMt NOT DE riNED/SPf CI FI ED
All FfiD FCKtfct PUTA&E RiSULTED FROM A FAULTY TEMPiRATUNt "KOBE AT THI
, VENTUH, DlfilNf MAY.
AFFfCTED MODULES! SYSTEM
SYSTEM 100.0 9A.O 96.0 98. P 7ZO 715 «B6
221
-------
EPA UTILITY FGD SURVEY: DECEMBER 197f - JANUARY 1979
SECTION 3
DESIGN *KD PERFORMI.CE DATA FOR OPERATIONAL F6D SYSTEMS
PERFORMANCE DATA — ..-...-...
PERIOD MODULE AVAILABILITY OFEKAE-IL1TY (EL1ABILITY UTILIZATION * REMOVAL PER 60JLFR fGP CAP.
SO; PART. HOURS HOURS HOURS FACTOR
** PRObLEMS/SOLUTlONS/COMMENTS
START DATE 6/78 EeUIHENT: B01LFR-RELATFH
END DATE fc/78 PF6BKH: NOT D E F JNE D /S PE CIF I ED
A HIGH/LCI. FU'MACE PRESSURE TRIP RESULTED IN BOIIE DOWNTIME.
AFFECTED MQDUlES: SYSTEM
** PR06LEMS/SOLUT10NS/COM1ENTS
STAPT DATE t /78 tBUU'ENT: AUXILIARY EOUJPMENT
END DATE 6/78 PFOBUM: NOT DEFINED/SPEClFI ED
A SCHEDULED FID OUTAGE OCCURRED WHEN THE FIRE SPRAY SYSTEM WAS OUT OF
SERVICE.
AFFCCTED MODULES: SYSTEM
7/78 SYSTEM 100.0 60.0 100.0 7?.0 744 726 58J
•* PROBLEMS/SOLUTlONS/COMWENTS
START DATE 7/78 t6Ulf«ENT: SCRUBBER
END DATE 7/78 PFOFJlfM: NOT DEFINED/SPEc'*I ED
LOU VEK'TURl FlOU CAUSED AN FED OUTAGE. THIS WAS CORRECTED WHEN THf RACE
TRACK WERE CLEANED.
AFFECTED WOOULES: SYSTEM
** PROBLEWS/SOLUTIONS/COIKMENTE
START DATE 7/78 EOUJFPENT: BOILER-RELATED
END DATE 7/78 CCH*l,NT: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTAGE
A SCHEDULES OI.TA6E TO CLEAN THE TURBINE LUBE OIL COOLERS OCCURRED OURIN6
JULY.
AFFECTED HODULES: STSTEK
** PROBLEMS/SOLUTIONS/CrcnEMTS
START DATE 7/78 EGUI'K'ENT: TANK, OTHER
END DATE 7/78 PFOPIEM: NOT DEFIKED/SPECIFI ED
AK OUTAGE WAS RE8UIRE6 FOR INSPECTION OF THE VENTURI TANK AND RACE TRACK.
CURINC THE OUTAGE THE TAMK AND RACE TRACK NOZZLES WERE CLENED ANt> THE
RUBBER LIMNC ON THE VENTURI SPOOL WAS REPLACED.
AFFECTED MODULES; SYSTEM
** PROBLEKS/SOLUTIONS/COPMENTS
START DATE 7/78 EOUIFKENT: $£RUeBER
END DATE 7/78 PROBLEM: NOT DEFINED/SPECIFIED
AN OUTAGE WAS REQUIRED TO CLEAN THE VENTURIRACF TRACK;
AFFECTED MODULES: SYSTEM
8/78 SYSTEM 9R.O 93.0 98.0 97.0 744 736 721
** pROBLEMS/SOLUTIONS/COMMENTS
START DATE M78 EGUIfPENT: BOILER-RELATEfi
END DATE S/78 PROBtKM: NOT DEFINED/SPECIFIED
ONE FORCED BOILER OUTAGE OCCURRED DUE TO HIGH FURNACE PRESSURE*
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMHENTS
START DATE 8/78 tSUU'WENT: FAN
END DATE P/7E FFGBIEM; DESIGN-RELATED PRESSURE SURGES
THE SCRUBBER MS FORCED OFF LINE ON AUGUST 26 DUE TO HIGH SCRUBBER FAN
OUTLET PRESSURE. THE SCRUPBER PRESSURE SENSING LINE WAS CLEANED.
AFFECTED MODULES: SYSTEM
** PHOBLEMS/SOLUTJONS/COMMENTS
START DATE 8/78 (CUIFWENT: FGD SYSTEM, GENERAL
END DATE 5/78 PROBLEM: NOT DEFINED/SPECIFIED
OK AUGUST 2V 1HE SCRUBBER EFFLUENT SOLIDS LEVEL HAS HIGH CAUSING AN OUTAGE
OF APPROXIMATtLY FIVE HOURS. THE SYSTEM WAS FLUSHED TO CORRECT THE
PKoBlEM.
AFFECTED MODULES: SYSTEM
9/7P SYSTEM 100.0 97.0 100.0 32.0 720 236 22R
222
-------
EPA UTU1TY f6C SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FED SYSTEMS
PERFORMANCE DATA
PEPIOO MODULE AVAILABILITY CPERABILITY F-EL1A61L1TY UTILIZATION X REMOVAL PER BOILER F6|> CAP.
SO? PART. HOURS HOURS HOURS FACTOR
_...•___ ______ ____________ ___________ ____________ __•. — ___ — -—_ _____ _____ _____ ______ _____ _____•,
** PROblEMS/SOLUTlONS/COMWENTS
START DATE 9/78 ECUKMENT: BOILER-RELATED
END DATE 9/78 COHMIN'T: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTAGE
TtiE HMT UEKT HOUN ON SEPTEMBER 10 FOR A TURBINE OVERHAUL WHICH LASTED
THROUGH THE END OF THE MONTH.
AFFECTED MODULES: SYSTEM
10/78 SYSTEM
100.0
7*4
** PROBLEMS/SOLUTIONS/COMMENU
START DATE 10/78 E6UIIMENT: BOILER-RELATED
BN» DATE 10*7* COMM £NT : P Rf VE NT1VE MAINTENANCE SC-HEDULED UNIT OUTAfiE
T*E UNIT WAS ilO.N THE ENTIRE MONTH OF OCTOBER FOR TURBINE OVERHAUL.
AFFECTED MODULES: SYSTEM
11/78 SYSTEM
98.0
91.0
91.0
63.
720 489
447
»* PRObLEMS/SOLUiIONS/COMMENTS
START DATE 11/78 ESDI THEN1!: BOtLER-RELAT E I)
END DATE 11 /7B COMMINTS:
THE UNIT WAS iROUSHT SACK ON LINE THE 10TH OF NOVEMBER*
AFFECTED MODULES: SYSTEM
** PROeiEMS/SOLUTIONS/COMWENTS
START 0*TE 11/78 ESUIfMENT: INSTRUMENTATION
END DATE 11/76 PROF I'*: NOT DEFINED/SPECIFIED
THE FED SYSTEI" WAS DOWN AgOUT 3 HOURS FOR REPAIRING VENTURI TEMPERATURE
PhOBES.
AFFECTED MODULES: SVSTEPi
1Z/7S SVSTfM
100.0
100.0
100.0
100.0
744 744
744
*» PROBLIMS/SOLUTION5/COKMENTS
START DATE 1?/78 ISUIH'ENT: F6D SYSTEM, GENERAL
tND DATE U/7B COMMENTS:
NO FGD OUTAbES WERE REPORTED DURING DECEMBER.
AFFECTED MODULES: SYSTEM
1/79 SYSTEM
66.4
67. Z
67.2
66.4
744
735
494
** PRO&LEKS/SOLUTIONS/COMMENTS
START DATE 1/79 CGUIIHENT: SCRUBBER
END DMF 1/79 PFCBOM: NOT DE FINtD/SPE CI F HD
OUTAGE TIKE W/S MCPSSARY TO REpAIP A HOLE IN THE VENTURI BOX.
AFFECTED MODULES: SYSTEM
»* PROSLEMS/SOLUTIONS/COMMENIS
START DATE 1/79 EIGUItKENT: PROCESS CONTROL
END DATE 1/79 PCOBtFM: HOT DEFINED/SPECIFIED
TkO FORCFO OUTAtfS OCCURRED BECAUSE EFFLUENT SfiLI&S WERE HIGH.
V«S CLF.ANEO.
AFFECTED MOPUlfS: SYSTtK
THE SYSTEM
** PRObLEMS/SOLUTIONS/COMMENTE
START B*Ti ?/*9 EfiUIfMENT: FAN
END DATE 2/79 PPOBlFM: COMPONENT FAILURE, OTHER
A MAJOR OUTAF.I: OCCURED WHEN THf SCRUBBER RCHEATER FAN MOTOR BURNT OUT.
AFFECTED MOCULfS: SYSTEM
2/7* SYSTEM
40.6
45.7
45.7
40.6
672 660
** PROBLEMS/SQLUTIONS/CfWENTS
START CATS ?/79 ERUIIWENT: REMEATFR
END D»TE 2/79 FROBIP.M: NOT DEFINED/SPECIFIED
A STFAM LEAK 3K THE SCRUBBFR REHEATER COIL RESULTED IN OUTAGE TIMf.
AFFFCTiD MODULES: SYSTEf
223
-------
FPA UTILITY FtD SURVEY: DECt^BFR 197£ - JANUARY 19?9
SECTION 3
OES16N AND PE R F Of* A (*C E DATA FOR OPERATIONAL FGD SYSTEMS
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY (PLIABILITY UTILIZATION I REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
»* PROBLEMS/SOLUTIONS/COMNENTS
START DATE ?/79 EGUir*£NT; SCRUBBER
IND DATE ?/79 PPOP I m s NOT D E FI N ED /S PE CI F I ED
T*E FGD SYSTEC WAS OFF F0« A FEW HOURS TO REPAIR A LEAK IN THE VENTURI
L INt.
AFffCTfcD «ODULt5: SYSTEM
** PRObLEHS/SOLUTION5/COMMEN7S
START DATE ?/79 EOUIFPENT: PIPING
END DrTF. 3/79 FROB I.HH : NOT DEFINED/SPECIFIED
IK SCRUPfjER kAS DOWN TO REPAIR LEAKS IN EFFLUENT AND VENTURI LINES.
AFFECTED MODULES: SYSTtK
• • PROBLEMS/SOLUTIONS/COWt'ENTS
START DATE 2/79 FGUIff'ENT: B01 L ER-REUA T F D
END DATE Z/79 PPOBiKM: DESIGN-RELATED PRESSURE SURGES
THb SCRUBPtR W f>S OFF WITH HIGH FURNACE PRESSURE ON THE BOILER.
AFFC CTED MODUl EE: SYSTEM
** PROBLEKS/SOLUT10NS/COKMENTS
START DATE 2/79 tOOIffENT: SCRUPBFR
END DATE J/79 PKCBlEH: NOT 0EFIN ED/SPFCIFI ED
ThE RACE TFACt NOZZLES WERE CLEANED.
AFFECTED MODULES: SYSTEM
224
-------
EPA UTILITY F6D SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PAftTICULATE EMISSION LIMITATION - hG/J
S02 EMISSION LIMITATION - H6/J
NET PLANT GENERATING CAPACITY - nw
6ROSS UNIT GENERATING CAPACITY - flk
NET UNIT GENERATING CAPACITY W/FGD - Mi
NET UMIT GENERATING CAPACITY WO/FGt> - *H
EQUIVALENT SCRUBBED CAPACITY - NU
** BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MII-KUM 60HER FLUE GAS FLOW - CtJ.t/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL 6RADE
AVERAGE HEAT CONTENT - KJ/KG
RANGE HEAT CONTENT - BTU/lb
AVERAGE ASH CONTENT • t
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTEhT - *
RANGE MOISTURE CONTENT - X
AVERASE SULFUR CONTENT - X
RANGE SULFUR CONTENT - %
AVERAGE CHLORIDE CONTEKT - X
RANGE CHLORIDE CONTENT - V.
FUEL FIRING RATE - M T/H
FUEL FIRING RATE - WW
** ESP
NUMBER
** PARTICULAR SCRUBBER
NUMBER
TYPE
NUMBER OF STAGES
** FGD SYSTEM
SALEABLE PRODUCT/THR OW AWAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS ADDITIVES
SYSTEM SUPPLIFR
A-E FIRM
CONSTRUCTION FIRM
DEVELOPMENT LEVEL
NEW/RFTROFIT
PABTICULATE DESIGN REMOVAL EFFICIEfiCY
S02 DESIGN REMOVAL EFFICIENCY - X
COMMERCIAL DATE
INITIAL START-UP
CONSTRUCTION COMPLETION
CONSTRUCTION INITIATIOK
CONTRACT AWARDED
** ABSORBER
NUMBER
TYPE
INITIAL START UP
NUMBER OF STAGES
BOILER LOAD/APSORBER - X
GAS FLOW - CU.M/S
GAS TEMPERATURE - C
PARTKULATE REMOVAL EFFICIENCY - X
S02 DESIGN REMOVAL EFFICIENCY - x
NORTHERN INDIANA PU6 SERVICE
DEAN H. MITCHELL
11
GARY
INDIANA
C
115.0
115.0
115.0
***** **
115.0
******
BASE
5/7C1
217*07
14P.9
******
C<>AL
******
25JS6.
********
10.
11.00
(****** LB/MHDTU)
{******
< 4-60000 ACTM') '
( 300 F)
(**** FT)
{***** FT)
( 11000 BTU/LP)
******
3.50
3.2-?.5
********
******
45.3
*****
( 50 TPH)
VARIABLE THRoAT VtNTURl
1
SALEABLE PRODUCT
WET SCRUG&ING
UELLMAN LORD
SODIUM SULFITE-BISULFITE
DAVY POWERGAS
DAVY POtaERGAS
DAVY POWERGAS
DEMONSTRATION
RETROFIT
9ft.5o
9P.OO
6/77
7/76
12/75
8/74
6/72
VALVF TRAY-COLLECTOR TRAY
7/76
100.0
198.20
H2.2
9E.O
91.0
< 420000 ACF«)
( 288 F)
225
-------
EPA UTILITY F&D SURVEY: DECtKSER lQ7f - JANUARY 1979
SECTION J
DESIGN AND PERFCRMr.CE DATA FOR OPERATIONAL FGD SYSTEMS
CENTRIFUGt
NUMPER
TYPE
SODIUM SOLFITt CRYSTAL REMOVAL
FANS
NUMBER
TYPE
BOOSTER
FANS
NUMBER
TYPE
BOILER l.D.
PUMPS
SERVICE
DISSOLVING TANK TO ABSORBER FEED T
FLYASH PUR6F TO POND PIMP
RECYCLE
EVAPORATOR-CRYSTALLIZES FEE9
ABSORBER FEED
NUWBFR
****
tut
3
***»
* * **
TANKS
SERVICE
ABSORBER FEED TANK
ABSORBER SURGE TANK
NACC3 MAKEUP, NA2S03 DISSOLVING
REHEATER
TYpE
TEMPERATURE BOOST - C
NUMBER
****
****
****
DIRECT COMBUSTION
27,f ( 5r F)
WATER LOOP
TYpE
REAGENT PREPARATION EQUIPMENT
POINT OF ADDITION
BYPRODUCTS
BYPRODUCT NATURE
BYPRODUCT 8UALITY - X
CLOSED
PNEUMATIC CONVEYOR
ELEMENTAL SULFUR
99.9
PERIOD NODULE AVAILABILITY CPERABILITY
PERFORMANCE DATA
UTILITATION
T REMOVAL PEP BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
11/76 SYSTEM
• * PROBLEMS/SOLUTlONS/COC^ENTSi
START DATE 11/76 EOUIF^ENT:
F6D SYSTEM, GENERAL
fcND DATE 7/77
FOLLOWING COMFlETjON OF CONSTRUCTION IN MID-1976, START-UP OF THE VARIOUS
SUBSYSTEMS AN:: COMPONENT PARTS WAS IN1T1ATFD* DURING THE PERIOD JULY
THROUGH NOVEMBER, THREE SUSTAINED RUNS OF THE SO? A8SORBCR AND REGENERATE
SYSTEM UNDER M3RMAL OPERATING CONDITIONS WERE ACHIEVED. SO 2 REMOVAL EFFI-
CIENCY HAS EOl«L TO OR GREATER THAN THE 9QX PERFORMANCE CRITERIA. UNIT 11
BOILER OPL«AT:p 121 FULL DAYS AND 10 PARTIAL DAYS. THE VCLLMAN-LORD $02
RECOVERY UNIT OPERATED 71 FULL DAYS AND 23 PARTIAL DAYS. DURING THIS PER-
ICD, NUMEROUS MODIF I CATIONS AND CORRECTIONS TO THE SYSTEM HERE COMPLETED.
THESE INCLUDED MODIFYING THE ABSORBER KOcH VALVE TRAYS TO IMPROVE TURN-
DCWN, RUBBER LINING THE BOTTOM ABSORBER COLLECTOR TRAY, RELOCATING AND IM-
PROVING TEMPERATURE CONTROL OF THE LOW PRESSURE STEAM SUPPLY, INSTALLING
IMPROVED SO? .'AMPLF PROBES AND SEVERAL REPLACEMENTS AND MOD IF I CAT ION« TO
T*E PURGE SALT RECOVERY AREA. FULLY INTEGRATED OPERATIONS INCLUDING SOZ
REDUCTION AND SULFUR RECOVERY OCCURRED IN NOVEMBER, 1V76. JANUARY THROUGH
MAY 1977 - UNJT 11 BOILER WAS OUT-Of-$ERVICE FOR ABOUT FIVE BONTHS FOLLOH-
It.fi A BOILLR-i ELATED MISHAP WHICH OCCURRED ON JANUARY 15, 1977, DURING
START-UP AFTEF A SCHEDULED MAINTENANCE TURN AROUND.
OK JUNE 13, 1'77 FGD OPERATIONS RESUMED FOLLOWING RETURN TO FULL SERVICE 0
226
-------
EPA UTILITY FGt SURVEY: DECEMBER 1*78 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL F60 SYSTEMS
._.__.— — .- — ----- -— ------ ....—..-..PERFORMANCE 6 AT A --- -
PERIOD NOODLE AVAILABILITY OPERABILITY PLIABILITY UTILIZATION
t REMOVAL
502 PART.
PER BOILER FGD CAP'
HOURS HOURS HOURS FACTOR
UNIT 11 BOUEH. BY JUNE 15 FULLY INTEGRATED OPERATION OF THE ENTIRE FGP
PLANT WAS ACHIEVED. THROUGH JUNE AND JULY* SEVERAL HUNDRED HOURS OF TOTAL
S1STEM OPERATION AT BOTH PARTIAL AND FULL LOAD WERE ACCRUED*
AFFECTED MODULES: SYSTII"
12/76 SYSTEM
1/77 SYSTEM
Z/77 SYSTtM
3/77 SYSTEM
4/77 SYSTEM
5/77 SYSTEM
6/77 SYSTEM
7/77 SYSTEM
8/77 SYSTEM
74*
7*4
672
74*
720
74*
720
7*4
744
** PROBLEMS/SOLUTIONS/COMMEN1S
START DATE
END DATE
FGD SYSTEM* GENERAL
9/77 SYSTEM
10/77 SYSTEM
8/77 t GUI I CiLNT :
9/77 COMM [NTS:
PERFORMANCE TESTS COMMENCED ON AUGUST 29, 1977 AND WERE SUCCESSFULLY COM-
PLETED ON SEPTEMBER 14, 1977. THE TEST PERIOD INCLUDED 12 DAYS AT 92 MW
FLUE 6AS teuIvALENT AND 3.5 DAYS AT 110 MU FLUE GAS EQUIVALENT. DURING
TUS FERICt, MX OF THE SQ? WAS REMOVED WKILE BURNING COAL CONTAINING 31
SULFUR AND 20< TONS OF ELEMENTAL SULFUR W^RE RFCOVER. ALL PERFORMANCE CRI
TtRIA WERE CE1 INCLUDING S02 REMOVAL, PARTICULATE EMISSION, RAW MATERIAL
A*D UTILITY CCNSUMPTIONS AND RECOVERED SULFUR 8UAL1TY. THE FGD UNIT SHUT
DCUN SEPTEMBER 19 AND REMAINED IDLE THROUGH MONTH END DUE TO COAL FEED
PROBLEMS RESULTING FROM WET COAL ON THE UNIT 11 BOILER.
AFFECT£D MODULtS: SYSTEM
720
744
** PROisLEMS/SOLUTIONS/COKMENTS
START DATE 10/77 IOUIPMENT: F6D SYSTEM,
END DATE 10/77 COMMENTS:
A DEMONSTRATICN PERIOD OF ONE YEAR BEGAN SEPTEMBER 16. DUR1N6 OCTOBER, TH
F£D UNIT OPERATED 132 HOURS. OPERATIONS WERE INTERUPTED WHILE HEAT PAL-
ACE TESTS WERE CONDUCTED ON THE UNIT 11 BOILER BY NIPSCO AND TRU AND WERE
INTERRUPTED FLRTHfcR TO MARf; REPAIRS TO THE S02 REDUCTION SECTION, THE EVAP
ORATOR, AND T ht UNIT 11 POILER.
AFFECTED MODULES: SYSTEM
11/77 SYSTEM
74.0
72.0
90.0
730
428
** PR06LEKS/SOLUTIONS/COMMENTS
START DATE 11/77 E6UIIWENT: FGO SYSTEM, GENERAL
END DATE 11/77 COMMENTS!
T»iE FGD UNIT ITERATED FOR 18 CONSECUTIVE DAYS, AVERAGING 90* S02 REMOVAL
WITH ;?5 LONG TONS OF SULFUR RECOVERED. FGD OPERATION WAS INTERRUPTED BY
UKIT 11 BCjLEi TUBE LEAK AND RESUMPTION OF FGD OPERATION WAS FURHTER DELAY
EC BY MAINTENANCE IN THE EVAPORATOR SECTION.
AFFECTED MODULES: SYSTEM
** PROHLEMS/SOLUTIONS/COMWENTS
START OATE 11/77 ECUIffENT: 6AS DAMPER
END DATE 11/77 COMMIT: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTAGE
MAINTENANCE W />S PERFORMED ON THE FLUE GAS ISOLATION DAMPER.
AFFECTED MODULES; SYSTEM
2E7
-------
FP» UTILITY FtD SURVEY: DECEMBER 19/F - JANUARY
SECTION 3
DESIGN AND PERFOPKAhCE DATA FOR OPERATIONAL F60 SYSTEMS
...... - ................................... PERFORMANCE DATA ---- ...... --------------------- " ...
PERIOD MODULE AVAILABILITY OF-ERA8IL]TY PLIABILITY UTILIZATION I REMOVAL PER BOILER FGo CAP.
S02 PART. HOURS HOURS MOORS FACTOR
** PROciLEMS/SOLUTIONS/COWMENT S
START HATE 11/77 £»UI'«tNT: FAN
lHt> DATE 11/77 CCPNlNT: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTAGE
MAINTENANCE W« PERFORMED ON THE FLUE GAS BOOSTER BLOWER.
AFFFCTED MODUIES: SYSTEM
** PRObLEKS/SOLUTl ONS/COPMENTS,
START DATE 11/77 fc CiU I I » ENT : AUXILIARY ESU1PMENT
tND DATE 11/77 COMMNT: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTAGE
MAINTENANCE Vtf. PERFORMED ON THE S02 REDUCTION SECTION.
AFFFCTED MOMJLfs' S*STtM
12/77 SYSTEM 49.0 .0 .T 768 0
•* PR08LEMS/SOLUTIONS/COMMENTS
START DATE 12/77 ESUIIKENT: FAN
END DATE 12/77 COMM('NTs PREVENTIVE MAINTENANCE SCHEDULE; UNIT OUTAGE
MAINTENANCF W ,T PERFORMED ON THE FLUE GAS BOOSTER BLOWER
AFFECTED MODULES: SYSTEM
*• rROBLEMSSSOLUTlONS/COKPENTS
START DATE 12/77 COtirCENT: AUXILIARY E8UIPKENT
END DATE 12/77 COM IN T s P REVE NTI VE MAINTENANCE SCHEDULED UNIT OUTAGE
MAINTENANCE W)S PERFORMED ON THE ABSORBER SOLUTION REGENERATION SECTION.
AFFECTED MODULfS: SYSTEM
•* PROBLEMS/SOLUTIONS/COHMENTS
START DATE 12/77 teUJI'ENT: FGD SYSTEM, GENERAL
END DATE 1?/77 COMMCNTSs
Tht FCD SYSTSr WAS NOT OPERATED DURING THIS PERIOD DUE TO ABNORMAL BOILER
OPERATING CONDITIONS RELATED TO HIGH SILICA LEVELS IN THE FEED WATER. THE
HIGH SILICA LtVELS RESULTED FROM HIGH MAKE-UP WATER REQUIREMENTS DUE IN
PART TO A HIGHfR THAN NORMAL FGD PLANT USAGE, AS WELL AS UNIT 11 COAL FEED
PRCBLfM AND A PRECIPITATION MALFUNCTION,
AFFECTED MODULES: SYSTtK
1/78 SYSTEM 60.0 .0 ,n 720 0
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 1/78 EQUIPMENT: FGD SYSTEM, GENERAL
END DATE 1 /78 COMMITS:
TH£ FKD SYSTEM REMAINED DOWN THROUGHOUT JANUARY AS HIGH SILICA LEVELS IN
TKE UNIT 11 BULER FEED WATER PERSISTED.
AFFECTED KOOULtS: SYSTEM
** PROtiLEMS/SOLUTIONS/COMMENTS
START DATE 1 /7R t*UI'KENT: ESP
END OATF 1/78 PROS|.FM! NOT BE FINEO/S Pf CI Fl ED
MAINTENANCE w*s PERFORMED ON THE UNIT 11 PRECIPITATOR.
AFFFCTED MODULiS: SYSTif
** PNOULEMS/SOLUTIONS/COMMENTS
START DATE 1/78 EOUJIMfNT: FAN
END DATE 1/78 COMMIT! pREVENTlVi MAINTENANCE
MAINTENANCE UdS PERFORMED ON THE FLUE GAS ROOSTER IUOWER.
AFFECTED MODULESs SYSTIM
** PRCBLEMS/SOLUTIONS/COMMENTS
STA^T DATE 1/7g lOUIfttENT: AUXILIARY EQUIPMENT
£ND DATE 1 /78 COMM^Tt pREVENTtyE MAINTENANCE
MAINTENANCE W/S PERFORMED ON THE FGD SYSTEM SO?
AFFICTID MODULISl SVSTLP
2/76 SYSTfM 47.0 .0 .0 720
** PROiiLiMS/SOLUTlONS/CCMMENTS
START DATE 2/T« E6UIFMINTI
END DAT! ?/78 COMMTNTSj
228
-------
EPA UTILITY FGD SURVEY: DECEMBER 1V78 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FGD SYSTEMS
......—......—. PERFORMANCE DATA ...... ...
PERIOD MODULE AVAILABILITY OPERABIL1TY PLIABILITY UTILIZATION X REMOVAL PER 60HER FGD CAP.
502 PART. HOURS HOURS HOURS FACTOR
THE F6D SYSTEM WAS NOT OPERATED DUE TO ABNORMAL BOILER OPERATING CONDITION
RELATED TC HIGH SILICA LEVELS IN THE BOILER FEF0 WATER* COUPLED WITH UNIT
11 COAL FEED PROBLEMS, STOP VALVE PROBLEMS, PRECIP1TATOR MALFUNCTION AND A
LfcAKING BOILEK TUBE AND WORK ON THE FLUE GAS ISOLATION DAMPER.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 2/78 tGUIFMENT: FAN
END DATE 2/78 COMMENT: PREVENTIVE MAINTENANCE
MAINTENANCE IMS PERFORMED ON THE FLUE GAS BOOSTER BLOWER.
AFFECTED MODULES: SYSTEM
** PR08LEMS/SOLUTIONS/CGMMENTS
START DATE 2/78 t OU1""ENT: GAS DANPER
END DATE 2/78 COMMfNT: PREVENTIVE MAINTENANCE
MAIN.TENANCF WJ5 PERFORMED ON THE FLUE GAS ISOLATION DAMPER.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 2/78 EQUIPMENT: RECYCLE PUMP
END DATE 2/78 COMMENT: PREVENTIVE MAINTENANCE
MAINTENANCI W'S PERFORMED ON THE EVAPORATOR CIRCIRCULATIN6 PUMP.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 2/78 tOUI^ENT: PIPING
END DATE 2/76 COMMIT: PREVENTIVE MAINTENANCE
MAINTENANCE WAS PERFORMED ON THE S02 SUPERHEATER PIPING.
AFFECTED MODULES: SYSTEM
3/78 SYSTEM 90.0 77.0 30.C 720 215
• * PROBLEMS/SOLUTIONS/COMKENTS
START DATE J/76 IOUIme«T: FGD S*STEM» GENERAL
END DATE 3/76 COKMfNTS:
TKF FGD SYSTEM OPERATED FOR TEN DAYS. OPERATION WAS INTERRUPTED BY SHUT'
DCWN OF THE UMT 11 BOILER FOR AFFAIR OF COAL GRINDING MILLS AND PRECIPITA
TORS. PRCPl-R CONDITIONS COULD NOT BE R fc-ES TABl ISHED FOR RE-START OF THE
FGD OPERATION BECAUSE OF COAL FEED AND GRINDING PROBLEMS CAUSED FY EXTREME
LY POOR SU/lLI 1Y COAL.
AFFECTED MODULES: SYSTEM
*• PSOBLIMS/SOLUT10NS/COMMENTS
START DATE 3/78 tCIUllPlENT: FAN
END DATE 5/78 COMMfNT: PREVENTIVE MA1N1FNANCF
MAINTENANCE W«5 PERFORMED ON THE BOOSTER BLOWER*
AFFECTED WODULIS: SYSTtC!
** PROSLEMS/SOLUTIONS/COMMENTS
START DATE 3/78 IGUIiKENT: GAS OAMPER
END DATE I /7B FROFJ if: M ! NOT DE FINED/SPFCIF I ED
OPERATING PROBLEMS WERE INrOUNTgRED HjTH THE FLUE liAj ISOLATION PAMPER.
AFFECTED MODULES: SYSTEM
4m SYSTEM .0 .0 .0 720 C)
** MOBltMS/SOLUTlONS/COMMENTii
START DATE 4/78 [OUII'IHENTl FAN
END DATE 4/78 COPiMiNT: PRIVENT1VG MAINTENANCE SCHfDULED UNIT OUTA6|
TtlE fLIJE 6AC ICOSTEP RLOWtP WAS OUT OF SERVICi FOR THIS EMTIRi PIRIOD FOR
RIBLADIN6. TH FGD SYSTiM WAS 1NCPERABII.
AFFECTED MODIILtS: SYSTEM
** PfiCtafMS/KOLUTIONS/COMMENTS
(TART DATE 4/78 E Cl! JI fENTs CAS DAMPFR
tND B»TF. 4/7« FKPUMs Kf CHANIC At-MLATF D COMPONENT FA I LUCE
A FAILURE OF Wl FLUF 6A5 ISOLATION DAMPtR OCCURRED.
-------
UTILITY FfcD SURVEY: DECEMBER 1<»7f - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FGD SYSTEMS
----------------- . ------------------------ PERFORMANCF DATA ------------- "" --------
PERIOD MODULE AVAILABILITY CPERAdLITY KLIAE>ILITY UTILIZATION * REMOVAL PER BPHER "J
SOS PART* HOURS HOURS HOUR*
AFFECTED MODULES: SYSTEM
** PROBLEMS /SOLUTION 5/COI«KENTS
START DATE 4/78 EOUIFMENT: FGD SYSTEM, GENERAL
END DATE 4/78 COMMITS: . _ . „.
A NEW SUPPLY (f HI6H SULFUR COAL WAS OBTAINED »N& SUCCE SS F llLLY TESTED ON
UMT 11 Pt'ILEU THJS COAL IS EXPECTED TO ALLEVIATE PAST DIFFICULTIES
T>E COAL fEtD AND GRINDIN6 SYSTEM.
AFFECTED MODULIS: EYSTE*
»* PRObLEWS/SOLUTIONS/COK«ENTS
START DATE 4/78 EGlim'ENT: FAN
tND DATF */78 CCKp> (NT : ' pREVENTl V^ MAINTENANCE
MAINTENANCE WHS PEHFORMED ON THE BOILER I'f' FANS.
AFFECTED MODULES! SYSTEf
•* PROfllEMS/SOLUTIONS/COMHENTS
START DATE 4 /7B lOtl rfl [NT: AUXILIARY EQUIPMENT
END DATE 4 /7fc COKMtNTS:
MAINTENANCE WPS PERFORMED ON THE BOILER I'D. FA*|S.
AFFECTED MODULES: SVSTEK
** PROyLEMS/SOLUTIONS/COMMENTS
START DATE 4/76 CGUIFPENT: AOSORBER
END DATE 4/78 COKMiNT: PREVENTIVE MAINTENANCE
MAINTENANCE w/is PERFORMED ON THt FGD ABSORBER.
AFFECTED MODULES: SYSTtl*
5/78
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 5/78 E6UIPPENT: FGD SYSTEM, GENERAL
END DATE 5/78 COMMENTS:
TtE SO? RECOVIRY PORTION OF THE FSD SYSTEM OPERATED FOR 26 DAYS. THF COP-
PLFTED FGD SYSTEM OPERATED FOR 11 DAYS.
AFFECTED MODULES: SYSTEM
«* PRClBLEMS/EOLUTlON S/CCWWENTS
START DATE 5/78 E6UIFHENT: GAS DAMPER
END DATE 5/78 F'ROB IE M : KE CHANICAL-RE L ATED COMPONENT FAILURE
FSD OPERATION!: WERE INTERRUPTED PY FAILURE OF THE FLUE GAS ISOLATION DAMP-
ER.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 5/78 EGUI f KENT: POI LER-RELATE D
END DATE 5/78 COMMFNTS:
FCD OPERATIONS WERE INTERRUPTED BY PROBLEMS WITH WET COAL WHICH REQUIRED
T*E UNIT 11 BULER TO OPERATE ON LOW SULFUR COAL FOR A SHORT PERIOD.
AFFECTED MODULES: SYSTEF
** PR06LEMS/SOLUTIONS/COMMENTS
START DATE 5/78 efiUIIKENT: AUXILIARY EQUIPMENT
END DATE 5/78 PROBLEM: CHEMICAL-RELATED PLUGGING
FGD OPERATIONS WERE INTERRUPTED BY PLUGGING OF AN ENTRAINKENT SEPARATOR IN
THE S02 REDUC UON UNIT.
AFFECTED WODULfS: SYSTEM
6/78 SYSTEM 13.0 1.0 .0 7?0 ?00
•* PROBLEMS/SOLUTIONS/COMMENTS
START DATE 6/78 E6UIFMENT: FGD SYSTEM, GENERAL
END DATE 6/78 C00MtNTS:
THE FGD PROCESS FACILITIES, CONSISTING Of THE ABSORBER, EVAPORATOR, 302 RE
DICTION AND PIPGE TREATMENT UNITS, WERE AVAILABLE FOR OPERATION FOR ESSEN-
TIALLY THE ENURE PERIOD.
AFFECTED MODULES: SY$TEf
-------
EPA UTILITY F60 SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMA&CE OAT* FOR OPERATIONAL FCD SYSTEMS
------------------------------------------ PERFORMANCE DATA ------------------------------------------
PERIOD MODULE AVAILABILITY CPEFABIL1TY (PLIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/CCMMENTS
START DATE 6/78 E8UIFMENT: FAN
END DATE 6/78 FfOBtFM: MECHANICAL-RELATED COMPONENT FAILURE
OPERATION OF 1*6 FGD SYSTEM WAS LIMITED BY FAILURE OF THE ROOSTER BLOWER
CR1VF TUREINE .
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIQNE/CCMMENTS
START DATE tilt ECUIFNENT: GAS CAMPER
END DATE (jilt F'POBUM: MECHANICAL-RELATED COMPONENT FAILURE
OPERATION OF IHE F6D SYSTEM WAS LIMITED DUE , IN PART, TO THE INABILITY OF
TfE ISOLATION bAMPER TO OPERATE
AFFECTED MODULES: SYSTEM
7/78 SYSTEM 6.0 « .0 ?.0 720 170
** PR06LEMS/SOLUTIONS/COMMENTS
START DATE 7/76 SOUI FM6NT: FAN
END DATE 7/7* PSPEUIM: MECHANIC* L-HELATEB COMPONENT FAILURE
OPERATION OF THE FED SYSTEM WAS LIMITED iY IMBALANCE OF THE BOOSTER BLOWER
OLE TO INABILITY OF THE ISOLATION DAMPER TO OPERATE, THIS CONDITION COULD
NCT E>£ COmC If D UNTIL POWER DEMANDS PERMITTED A SHUT DOWN OF UNIT 11 BOIL
IK. FLUE tAf MOOSTER BLPWER PROBLEMS INCLUDED LOW OIL PRESSURE, LEAKIN6
BEARtNO OIL SMLS AND DRIVE TURBINE GOVERNOR MALFUNCTION.
AFFECTED MODULES:
** PR081EMS/SOLUTIONS/COMMENTS
START DATE 7/78 EOUIFMENT: 6AS DAMPER
END DATE 7/78 FROEUFM: MECHANICAL-RELATED COMPONENT FAILURE
1H ISOLATION DAMPED WAS INOPERABLE OVER THE PERIOD.
AFFECTED MODULES: SYSTEM
** PKOBLEWS/SOLUTIONS/COMMENTS
START DATE 7/78 EOUIfMENT: BOILER-RELATED
tNO DATE 7/78 .
RECURRING FLUCTUATIONS IN THE PRFSSURE OF THE MAIN STEAM SUPPLY TO THE FGD
SYSTEM LIMITED FGD OPERATIONS.
AFFECTED MODULES: SYSTEM
**
START DATE 7/78 EOUUfENT: p6D SYSTEM, GENERAL
END DATE 7/7p COMMINTS:
THE FGC PROCESS FACILITIES WERE AVAILABLE FOR OPERATION FOR THE INTIRE
PtRIOD.
AFFECTED MODULES: SYSTEM
8/78 SYSTEM 98.0 98 . 0 98.0 720 707
** PROfiLEKS/SOCUTlON J/COMMENTS
START DATE S/7fi t«UjWEKT! FGD SYSTEM' GENERAL
END DATE fi/78 CCMMINTS:
THE UMT 11 BULIR OPERATED CONTINUOUSLY ON HICH SULFUR CO»L THROUGHOUT TH
PiRIOD. THE F(;D SYSTEM ACHIEVED FULL OPERATION ON THE FIRST DAY OF THE
PIRIOD. AFTE* PROtiLEMS WITH THE BOOSTER BLOWER WE R E CORR ECTE D, IT RFMAINE
IN FULL OfERAlION FOR THE BALANCE OF THE PERIOD WITH THE EXCEPTION OF ONE
TkO-HOUR INTERRUPTION DUE TO AN ELECTRICAL MOTOR MALFUNCTION.
AFFECTED MODULES." SYSTEM
•« PROeLIMS/SOLUTJONS/COMMENTS
START BATE F./78 tCUirMENT: FAN
END DATE K/?£ PPOB IFM t MECHANIC AL-HF LATfC COMPONENT FAILURE
MINOR DOOSTIR i'LOWER PROBLEMS OCCURRED OVER THF PERIOD.
AFFECTED MODULES! SYSTEM
9/7* 8YSTSM 44.0 99.0 44. P 720 319
-------
EPA UTILITY FGD SURVEY; DECIMBFR 19?f - JANUARY 1979
SECTION 3
DESI6N AN'D PERFORMANCE OAT* FOR OPERATIONAL FGD SYSTEMS
---------- _ ..... ----------- ....... -------- PERFORMANCE DATA -------------------------------
Pi.ZOD MODULE AVAILABILITY OPE.MILITt PLIABILITY UTILIZATION I-WOV >« •««" HJ«,
** PROBLEKS/SOLUTIONS/COMMENT?
STAPT DATE 9/7R tOUIICENT: f6D SYSTEM. GENERAL
END DATf 9/78 CCMMINTS:
THE UMT 11 BULER OPERATED ON HT6H SULFUR COAL UNTIL SEPTEMBER 12 WHEN IT
WAS SHUT DOWN FOR AN ANNUAL OVERHAUL. THE BOILER REMAINED OOWN THROUGH TH
r*D OF THfc PEflOD. THE FGD SYSTEM CONTINUED IN FULL OPERATION UNTIL SfP-
TEMPER 1?. k!1H THE EXCEPTION Of ONE TWO-HOUR INTERRUPTION DUE TO A GOVER-
NCR PALFUNCTKN ON THE S02 COMPRESSOR DRIVF TURBINE, AND HAS THEN SHUT DCH
CONCURRENTLY '.! TH THE UNIT 11 BOILFR.
AFFFCTEO MOr>ULiS: SYSTEM
•* PRODLEMS/SOLUTJONS/CCMPIENTS
START DATE 9/7S E6UIFMENT: AUXILIARY EQUIPMENT
END DATE 0/78 PROB |.h M : M E CHA NI C A L-RE L ATED COMPONENT FAILURE
A GOVERNOR MALFUNCTION OCCURRED ON THE S02 COMPRESSOR BRIyE TURBINE CAUS-
IhG A TWO-HOUf. OUTA6E ON THE FCiD OPERATIONS.
AFFl CTED MODUl II: SYSTt«
10/7" SYSTEM 44.0 73.0 44.0 8*0 369
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 10/76 tCUl'fENT: F6D SYSTEM. GENER/ll.
END DATF 10/7t COMMFNTS:
THIS PERIOD CrVEFiS SEPTEMBFR 29 THROUGH NOVEMBER 2. FOLLOWING THE AMNUfl
TURNAROUND, TK UNIT 11 FrOILER RESTARTED ON OCTOBER 6. A NEW BASELINE TES
WAS RUN ON THl BOILER OCTOBER 1 THROUGH 12. BALANCING OF THE FLUE CAS
C-COST6R PLCUEO WAS THEN COMPLETED AFTER WHICH THE FGD SYSTEM WAS STARTED 0
OCTOPE8 1fe.
AFFECTED MODULES: SYSTt*
11 /7D SVSTEM 99.0 99.0 98.0 720 709
** PROBLEMS/SOLUTIONS/COMMENTS
STAPT DATE 11/78 ECUJtKENT: AUXILIARY FOU1PBENT
END DATE 11/78 PROB IE M : M f. CHAN 1C A L-RE L A TE D COMPONENT FAILURE
PCRBLFMS kERF ENCOUNTERED WITH THE SODIUM SULFATE PURGE DRYER WHICH NECES-
SITATED DISPOSING OF PART OF THE SULFATE PURGE TO THE BOTTOM ASH POND FOR
A PORTION Of 1ME PERIOD.
AFFECTED MODULES: SYSTEM
** PROBLEKS/SOLUT10NS/COMMEN1S
STAf!T OAfE 11/7R fSUIFWENT: FGD SYSTEM, EKNERAL
END DATE 11/7B COfiBtNTS:
TXE UNIT 11 BUIER OPERATEft CONTINUOUSLY ON HIGH sULFuff COAL ExCFPT FOR ON
THREE-HOUR OU1H6E FOR REPAIR OF A STEAK CONTROL VALVE. VARIATIONS IN THE
PRESSURE OF T*f STEAM SUPPLY TO F6D OCCURRED DUE TO HIGH SILICA IN THE
MAKE-UP WATER ON UNIT 11.
AFFECTED MODULES:
12/78 SYSTEM 64.0 7?.Q 6*.0 7ZQ ««
** PROBLEMS/SOLUTJONS/COMWENTS
START DATE 12/78 ICUUMENT: FJOI LER-RFLATE 0
END DATE 12/78 PROPIRM: NOT OE FINED/SPF CI F IED
THE BOILF-R KAT SHUT DOWN FROM DEC. «14 TO DEC. 17 TO CLEAN THE AIR
PREHEATERS.
AFffCTED MODULES: SYSTEM
** PRObLEMS/SOLUTIONS/COMMENTS
START DATE 12/78 EOUIFKENT: BOI LFft-RELATF D
END DATF 1?/78 COMMENTS:
TkE FOILER OPERATED ON HIGH SULFUR COAL.
AFFECTED MODULES: SYSTtM
«* PROBLEMS/SOLUTIONS/COMMENTS
START DATE 12/78 ECUIP"«ENT: AUXILIARY EOUIPMENT
END DATE 12/78 PROB^r,: WEATHER-RELATED COMPONENT FAILURE
232
-------
EPA UTILITY F6B SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE BAT* FOR OPERATIONAL FGD SYSTEMS
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABIL1TY PLIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
502 PART. HOURS HOURS HOURS FACTOR
Afc INSTRUMINT KALfUNCTjON DUE TO FREEZING RESULTED IN THF PLUGGING OF A
HEAT EXCHANGES IN THE S02 REGENERATION UNIT. TH£ FGD SYSTEM WAS DOWN FOR
ThREE DAYS WHILE THE EXCHANGER WAS CLEANED.
AFFECTED MODULES; SYSTEM
** PR08LEMS/SOLUTIONS/COMWEN1S
START DATE 12/78 tOUHMENT: FGD SYSTEM, GENERAL
END DATE 12/78 PROBLflir NOT DEFINED/SPECIFIED
THE FCD SYSTEh WAS SHUT DOWN FOR THREE DAYS FflR CLEANING A HEAT EXCHANGER
IN THE SO? REtFNERATION UNIT.
AFFECTED MODULES: SYSTEM
1/79 SYSTEM 36.0 2£ .0 2E .0 7<4 T«B
** PROBLEMSASOLUTIONS/CCKHENTS I
START DATE 1/79 E'QUII-KENTr BOILFR-RELATE D
END DATE 1/79 COMM ENTS:
THE FC3LEK OPtFATEC ON HIGH SULFUR COAL FROM JANUARY i-H AND LOU SULFUR
COAL JANUARY 15-11.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUT10NS/COMKENTS
START DATE 1/79 [euiH'ENT: FGD SYSTEM, GENERAL
END DATE 1/79 CO*M SNTS:
IKTKiRATED OPiRATlON OF THE FGD SYSTEM CONTINUFD TO JANUARY 10 WHEN THE
SO? REDUCTION UNIT kAS SHUT DOWN FOR REPAIR OF A SULFUR CONDENSER INCLUDIN
CCfiRFCTlVf MEASURES TO AVOID FUTURE PROBLEMS WITH THE CONDF.NSER. THE
AESORPTJOM ANt REGENERATION UNITS CONTINUED IN OPERATION TO JANUARY 29
WITH RECYCLE t.F EOZ TO THE ABSORBER INLET. THf FGD SYSTEM REMAINED DOWN
THROUGH JANUARY 31.
AFFECTED MODULES: SYSTEM
-------
FPA UTILITY F6D SURVEY; DECEP6ER 197f - JANUARY 1979
StCTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FGD SYSTEMS
COMPANY NAPE
PLANT NAHF
UNIT NUMEIEK
CITY
STAT E
REGULATORY CLASSIFICATION
P'RTICULATE EMISSION LIMITATION - Ki/J
SP2 EMISSION LIMITATION - SG/J
NfT PLANT ttNERATlNG CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - Mb
NfT UNIT GENERATING CAPACITY W/FGD - MV
NET UNIT CiEKtRATlN6 CAPACITY WO/FGt - fW
EOUIVALENT SCRUfBED CAPACITY - KW
** P.OILFR DATA
SUPPL1 tR
TYPF
SERVICE LOAD
COMMERCIAL SERVICE DATl
MAXIMUM tlOHER CLUE CA I FLOW - CU."/S'
FLUE GAS TIMPERATUKt - C
STACK HE I6HT - M
STACK TOP DIAFtTER - M
** FUEL DATA
FUEL TYPE
FUEL 6RAOE
AVEFACE HEAT CONTENT - KJ/KG
RANPE HfAT CONTENT - MU/lfc
AVERAGE A$H CONTENT - i
RANT,£ ASH CONTENT - X
AVERAGE MOISTURE CONTENT - %
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - 9!
RANCE SULFUR CONTENT - *
AVERAGE CHLORIDE COHTEM - %
RANGE CHLORIDE CONTENT - >
FUEL F IRIN6 RATE - fl T /H
FUEL F IRING RATF - HW
** PARTICULAR SCRUORER
TYPE
SUPPLIER
NUMPER OF STACEE
SHELL MATERIAL
INTERNAL MATERIAL
NUMBER OF NOZZLES
TYPE OF NOZZLES
BOILER LOAD/SCRUBBER - X
FLUf 6AS CAPACITY - CU.W/E
FLUE GAS TEMPERATURE - C
LIGUID fcEClRCULATION RATE - LITER/J
L/6 RATIO - LITER/CU.M
PRESSURE DROP - KPA
SUPERFICIAL 6As VELOCITY - M/S
** F60 SYSTEM
SALEABLt PRODUCT/THROWAWAY PROCUCT
GENERAL PROCESS TYPE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
OEVELOPNENT LEVEL
NEW/RETROFIT
PARTICIPATE DESIGN REKCVAL EFFIC1E^CY
So2 DESIGN REMOVAL EFFICIENCY - J
COMMERCIAL pATg
INITIAL START-UP
*• ABSORBER
.0?.7 LR/MMBTU)
.960 tn/MMBTU)
NORTHERN STATES POWER
SHERFUPNC
1
BECKER
MINNESOTA
B
37. <
417. <
3?00.0
720.C
68H.O
70n.O
7ZC.O
COMBUSTION ENGINEERING
PULVERIZED COAlf BALANCER DRAFT
BASE
0/7A
13*0.16
****** <»*** FT)
******* (****« FT)
COAL
SURBITUMINOUS
19771.
9.00
******
?5.00
******
.80
******
********
******
369.1
( £500
******
(407 TPM)
TYPF
INITIAL START UP
SUPPLI ER
NUMRER OF STAGES
12
RECTANGULAR VARIABLE THROAT ROD DECK VENTURI
COMBUSTION ENGINEERING
2
CARBON STEEL JNLET, SUL. ss SKIRT. 316L VENTURI
3UL SS RODS
26
CERAMIC
9.0
12E.6 ( 259900 ACFM)
154.4 ( 310 F)
J2T..O ( 3540 GPM)
1.9 414.0 6AL/1000ACF)
3.7 C 15 1N-H20)
24.4 ( 80.0 FT/S)
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE/ALKALINE FLYASH
COMBUSTION ENGINEERING
BLACK AND VEATCH
FULL-SCALE
NEW
99.00
50.00
3/76
3/76
12
MARBLE BED
3/76
COMBUSTION ENGINEERING
1
234
-------
EPA UTILITY FED SURVEY: DEcfHBE* 1978 - JANUARY
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL F6D SYSTEMS
DIMENSIONS
SHELL MATERIAL
SHELL LINER HATEftlAL
INTERNAL MATERIAL
NUMBER of NOZZLES
N02ZLE TYPE
BOILER LOAD/ABSORBER - X
6AS FLOW - CU.N/S
6AS TEMPERATURE - C
L16U1D RECIRCULATION RATE - LITEfi/S
L/6 RATIO . L/CU.H
PRESSURE DROP - KPA
SUPERFICAL 6As VELOCITY - M/SEC
PARTKULATE INLET LOAD - G/CU.H
PARTICULATE OUTLET LOAD- G/CU.f:
PARTICULATE REMOVAL EFFICIENCY - *
S02 INltT CONCENTRATION - PPM
S02 OUTLET CONTRAT10N - PPK
S02 DESIGN REMOVAL EFFICIENCY - X
18X26.5
CARBON STEFL <1'4 IN)
CEILCOTt FLAKE FIBERGLASS
316LSS PERFORATED PLATE, FRP SPRAY HEADERS
54
CERAMIC
9.0
200000 ACFft)
130 F>
1900 GPfiJ
9.5 GAL/1000ACF)
2.0 IN-H20)
31.0 FT/S)
( 3.000 6R/SCF)
( .0?6 Gft/SCF)
94.38
54.4
120.
1.3
.5
9.4
6.9
.1
99.0
TOO
325
55.0
** HIST ELIMINATOR
MUMPER
TYPE
CONSTRUCTION CATER UL
CONFI6URATION
NUMBER OF STAGES
NUMBER OF PASSES
FREEBOARD DISTANCE - »
VANE SPACING - CM
WASH SYSTEM
SUPERFICIAL GAS VELOCITY - PI/S
PRESSURf DROP - KPA
** PROCESS CONTROL CHEMISTRY
CONTROL VARIABLES
CONTROL RANGE
CONTROL MANNER
MODE
** PUMPS
SERVICE
POND RETURN
THICKENER UKDFKFLOU
MAKEUP WATER
******
RECYCLE
SPRAY
** TANKS
SERVICE
REACTION
MAKEUP WATER
SLURRY KAKEUP
** REHEATER
MUMPER
HEATING MEDIUM
TEMPERATURE BOOST
ENER6Y REQUIRED
** THICKENER
NUMPER
TYPE
DIAMETER - M
OUTLET SOLIDS - if
** WATER LOOP
TYPr
12
CHEVRON
FRP
HORIZONTAL
?
6
7.20 (10.5 FT)
10.2 < 4.00 IN)
INTERMITTENT UPWARD WASH ROTATABLE, 120-150 PSI6
9.4 < 31.0 FT/SJ
.0 ( .0 IN-H20)
SLURRY PH, SLURRY SOLIDS, TANK LEVELS, PRESSURE
PRESSURE DROP 12 IN H20, 10X SOLIDS, PH=5-5!5
AUTOMATIC
FEEDBACK
1
1
1
2
Z
12
NUMBER
1
1
1
11
IN-LINE
280 F HOT WATER
2?.2 <
132 «H BTU/H
4C F)
CENTER RAKF DRIVE
4*.B (160 FT)
OPEN
235
-------
F PA UTILITY fbD SURVEY: DECffFR ^t>7f - JANUARY 1979
SECTION 3
DlSldN AND Pf RFORMKCE DATA FOR OPERATIONAL F€D SKSTFflS
** REAGENT PREPARATION EQU1PPFNT
NUNF-ER OF bALL "ILLS
BALL MILL CAPACITY- M T/H
REAGENT PROPUCT - 1 SLLRRY SOLUi
** TREATMENT
TYPF
SUPPLI ER
•* DISPOSAL
NATURF
TYpr
LOCATI ON
TRANSPORTATION
AREA - ACRES
CAPACITY - CU.M
1
21.6
60.0
( 24.C TpH)
FORCIBLY OXIDIZED
NONPPOPR1ETARY
FINAL
LINED POND
ON-SITF
PIPE
500.0
30575000
( 25000.0 ACRE-FT)
PERFORMANCE. DATA
PERIOD MODULE AVAILABILITY CPERARILITY HLIAHILITY UTILIZATION 2 REMOVAL PER BOILER FSD CAP.
SO? PART. HOURS HOURS HOURS FACTOR
4/76 SYSTEM
720
** PROBLEMS/SOLUTIONS/COKMENTS
START DATE 4/76 IOU J 111'ENT: FGO S»STEM» 6ENERAL
END DATE 4/76 COKBfNTS:
A PRELIMINARY SYSTEM CHECKOUT WAS SUCCESFULLY COMPLETED BY PASS1N6 AIR AND
WATER THROUGH THE SYSTEM.
AFFECTtD MODULES: SYSTEM
5/76
102
10?
104
105
106
107
10?
109
110
111
112
SYSTEM
te.o
S J.C
81.0
59.0
7?.C
90.0
57.0
69.0
60.0
75. 0
72.0
67.0
7<« 657
60.0
** PROBIEMS/SOLUTIONE/COMMENTS
START BATE 5/76 EBUIfMENT: SPRAY NOZZLES
tND DATE 6/76 PfiOPlEM: NOT DEFINED/SPECIFIED
MCDIFICAT10NS ARF CONTINUING ON THE SPRAY SYSTEM. SPRAY NOZZLES AND
STRAINER SYSTf*.
AFFECTED MODOLIS: SYSTEM
*« PROBLEMS/SOLUTIONS/COKMENTE
START DATE 5/76 E6UI f'Pi ENT: FGD SYSTEM, GENERAL
END DATE 5/76 COMMENTS:
FIRST COMMERCIAL OPERATION COMMENCED MAY 1, 1976. THIS IS AN INTERMEDIATE
LCAD UNIT OPEK'TING NEAR FULL CAPACITY DURING THE DAY AND 35 PERCENT
CAPACITY AT N16HT.
AFFECTED MODULES: SYSTEM
6/76 SYSTEM
84.0
720 688
73.0
7/76
101
TO?
103
104
105
106
107
10?
80.0
6^.o
71.0
E1.0
£0.0
6P.O
81.0
75.0
236
-------
EPA UTILITY fGD SURVEY: DECEMBER 1978 - JANUARY 1079
SECTION 3
DESIGN AND PF. RFORMA hCE CATA FOR OPERATIONAL FCC SYSTEMS
... . ... ...—.— ......PER f ORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABIL1TY RELIABILITY UTILIZATION
X REMOVAL PER BOILER FGD CAP.
SOZ PART. HOURS HOURS HOURS FACTOR
109
110
111
11Z
SYSTEM 84.0
79.0
63.0
91.0
69. C
744 512 51.0
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 7/76 EGUIFfENT: SPRAY NOZZLES
END DATE 8/76 PROBIEM: CHEMICAL-RELATEC PLUGGING
THE SLURRY N07ZLKS ARE FREOUENTLY PLUGGED BY PARTICLES ABOVE QUARTER INCH
SIZE. STRAINER NOD IFICATIONS ARE PLANNED TO ALLEVIATE THIS PROBLEM.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 7/76 EQU1FMENT: ABSORBER
END DATE R/76 PPOPtrM: CHEMICAL-RELATED SCALING
HARD SCALE GYFSUM FORMATION ON THE VESSEL WALLS HAS LEVELED OFF- THE
CLEANING FPOCrSURE CALLS FOR 3-4 MODULES TO BE TAKEN OUT OF SERVICE EACH
NIGHT. THUS, EACH MODULE IS CLEANED ONCE EVERY 3 DAYS.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 7/76 EQUIPMENT: FGD SYSTEM, GENERAL
END DATE 8/76 COMM fNTS:
A CRFW OF 70 FFOPLE IS REQUIRED TC MAINTAIN SCRUBBER OPERATIONS.
AFFECTED MODULES: SYSTEM
** PR08LEMS/SOLUT10NS/COMMENTS
START DATE 7/76 EGUIfMENT: RECYCLE TANK
END DATE 8/76 PROPtEM: CHEMICAL-RELATED SCALING
THE DEPOSITION OF SOFT SOLIDS IS STILL CONTINUING IN THE REHEATERS.
AFFECTED MODULES: SYSTEM
** PRC6LEMS/SOLUT10NS/COKWENTS
START DAyE 7/76 ESUIfKENT: MIST ELIMINATOR
END DATE 8/76 PROBLEM: CHEMICAL-RELATED SCALING
TliE DEPOSITIOK OF SOFT SOLIOS IS STILL CONTINUING IN jU E MIST ELIMINATORS.
AFFECTED MODULES: SYSTtl*
«/76 101
102
103
104
105
106
107
108
109
110
111
112
SYSTEM
9/76 101
102
105
106
107
108
109
110
111
112
SYSTEM
94.0
46.0
93.0
51.0
84.0
83.0
76.0
71.0
84.0
81.0
76.0
67.0
91.0
90.0
93.0
76.0
76.0
79.0
65.0
79.0
65.0
80.0
92.0
96.0
744 705
80.0
95.0
720 566
68.0
237
-------
EPA UTILITY F6D SURVEY: DECICBFR 197f - JANUARY 1979
SECTION 3
DESIGN AND PERFCD*AKCI DATA FOP OPERATIONAL F6D SYSTfMS
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY CPEKABILITY FFLIABILITY UTILIZATION r REMOVAL PER BOHER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
• « PROHLEMS/SOLUTJONS/COCiMENIf
START DATE 9/76 l«UIf*ENT: SPRAY NOZZLES
END DATE 1C/76 PROPlFM: NOT D E F I N ED /S PF. CI F I ED
THF STRAINFR SYSTEM IS BEING MODIFIED. THF. DUPLEX UNITS ARE TO BE
REPLACED bY Ih-TANK SCREENS AND WASH LANCES. BOTH ARE LOCATES AT THE
SICTION Sltt tMEN7J
START DATE 9/76 E6Ull-^ENT: REHEATF.R
END DMF 1C/76 PROPUMr «I CHA NIC AL-REL ATE D COMPONENT FAILURE
CARBON STEEL (IN TUBF REHEAT BUNDLES ARE AN AREA OF CONCERN. KOLTIPLE
FAILURES IN FCUR UNITS HAVE REEN EXPERIENCED.
AFFECTED MODULES; SYSTEM
10/76
11/76
101
102
10?
104
105
106
107
108
109
110
111
112
SYSTEM
101
10J
10?
104
105
106
107
10?
10
-------
EPA UTILITY FGD SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMAKE DATA FOR OPERATIONAL F6D SYSTEMS
PERIOD
MODULE AVAILABILITY
108
109
110
111
112
SYSTEM 95.0
OPERABU1TY RELIABILITY UTILIZATION
95.0
94.0
88. D
7J.O
75.0
X REMOVAL PER
S02 PART. HOURS
744
BOILER F6D
HOURS HOURS
722
CAP.
FACTOR
91.0
** PROBLEMS/SOLUTIONS/COKMENTS
START CATE 12/76 EQUIPMENT: F6D SYSTEM. GENERAL
END DATt 12/76 COMHlNTSs
TtE UTILITY IS NOW CONDUCTING A FILL-LOAD EVALUATION STUDY. ANALYZING
SYSTEM OPERATION ON 10 NODULES VS. THE DES IGNF.D 11 MODULES.
AFFECTED MODULES: SYSTEM
1/77 101
102
103
104
105
106
107
108
109
110
111
112
SYSTEM
2/77 101
102
IDS
104
105
106
107
108
109
110
111
112
SYSTEM
91.0
3/77
101
102
103
104
105
106
107
108
109
110
111
112
SYSTEM
94.0
75.0
99.0
76.0
96.0
77.0
70.0
92.0
£1.0
40.0
75.0
95.0
89.0
99.0
64 '.0
96.0
£4.0
99.0
81.0
6Z. C
98.0
93.0
98.0
61.0
47.0
92. (l
95.0
93.0
93.0
95.0
88.0
93.0
95.0
83.C
78.0
72.0
744 607
73. C
672
609
£3.0
95.0
744 7*3
97.0
** PROBLEMS/SOLUTIONS/COMHENTS
START OATf 3/77 ESUlfMENT: SPRAY NOZZLES
END DATE 3/77 PROBLEM: NOT DEFINED/SPECIFIED
ALL CODULtS AFC NOy FITTED WITH IN-TANK STRAINERS.
AFFECTED MODULES- SYSTEM
4/77
101
102
103
104
V4.0
65.0
92.C
95.0
239
-------
EPA UTILITY F6D SUPVFY: DECtNBFR 1
-------
EPA UTILITY F60 SURVEY: DECEMBER 1978 - JANUARY 1979
DESIGN AND PERFORMAKI DATA FOR OPERATIONAL FGD SYSTEMS
PERFORMANCE 6 AT A
PERIOD MODULE AVAILABILITY OPERAPU1TY RELIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP-
SO? PART. HOURS HOURS HOURS FACTOR
WHILE THE UNIT WAS OUT jN JUNE THE FGD SYSTEM «AS CLEANED. THIS CLEANING
WAS CREDITED FOR ONE OF THE HIGHEST A VA ILApILIT IES EVER DEMONSTRATED ON
THIS UNIT,
AFFECTED MODULES: SYSTEf
8/77
101
10?
103
104
105
106
107
108
109
110
111
112
SYSTEM
85.0
89.C
66.0
55.0
81.0
90.0
83.0
79.0
72.0
85.0
90.0
66.0
95.0
744
640
68.0
** PROBLEMS/SOLUT10NS/COMMENTS
START DATE 8/77 E6U1FWENT: ABSORBER
END DATE 9/77 PROBIEM: NOT DEFINED/SPECIFI ED
SCNE ANGLES WS-RE INSTALLED ON THE PRIMARY CONTACTOR RODS TO RESIST EROS10M
AFFECTED MODULES: SYSTEM
9/77
101
102
10?
104
105
106
107
108
109
110
111
112
SYSTEM
86.0
85.0
88.0
92.0
£8.0
6?.0
63.0
90.0
86.0
77.0
77.0
£7.0
95.0
81.0
** PROBLEMS/SOLUTIONS/COKWENTS
START DATE 9/77 tGUIfENT: PUMP, OTHER
END DATE 10/77 PRCEIEM: NOT DEFINED/SPECIFIED
TWENTY-FOUR PI^PS ARE BEING COMPLETELY OVERHAULED.
AFFECTED MODULES: SYSTfK
** PROBLEKS/SOLUT10NS/CC««ENTS
STAftT DATE 9/77 ESUIfMENT: PUKP, OTHEfe
END DATE 9/77 PROBltM: MATERIALS FAILUKE,OTHER
KCDULE 10t SPRftY WATER PUMP WAS OVER HAULED IN SEPTEMBER.
AFFECTED MODULES: 106
10/77
101
102
103
104
105
106
107
108
109
110
111
112
SYSTEC.
68.0
70.0
81.0
55.0
97.0
63.9
35.0
P7.0
99.0
96.0
J9.0
5P.C
96.0
744
609
68. C
** PROBLEKS/SOLUTIONS/COCmENlS
START DATE 10/77 ECUHfENT: SPRAY NOZZLES
END DATE 11>77 FROBLFM: NOT DEFIMED/SPECIFI ED
241
-------
FP» UTILITY F6D SURWCY: DtttHBEP 197f - JANUARY 1 979
SECTION 3
DESIGN AND PF R f Of-fl A ht E DATA FOR OPERATIONAL FGo SYSTFMS
... . __ -PERFORMANCE DATA -•—------
PERIOD NODULE AVAILABILITY CAPABILITY SUABILITY UTILISATION X REMOVAL PER BOILER FGD CAP.
502 PART. HOURS HOURS HOURS FACTOR
STKAINfR/kA&Hif SCREEN EPOSION H*S BEEN A PROBLEM. REPAIR AND RFPLACEMENT
HAS fiEEN CONTINUALLY NECESSARY. 216 SS MATERIAL WILL BE USED IN THE
FLTURt.
AFFECTED MODULES: SYSTtf
11/7?
101
102
103
10*
105
106
107
10P
109
110
112
SYSTEM
92.0
77.0
S1.0
77. (1
*2.C
f7.0
91. C
89.0
69. C
V?.0
52.0
720 70S
61.C
** PHOBLEWS/SOLUTlONS/CO*PENTS
START D«TE 12/77 E6UI (•» ENT: SPRAY N07ZIES
END DATE 1/76 PSOBLfM: NOT DE FINE D/S PE CI F I ED
ThE REPLACEMENT PROGRAM HAS BEGUN ON DECEMBER ?1, 1977. IT TAKES 4.TO 6
DAYS FOR kORK ON EACH MODULE TO REPLACE THE STRAINER SYSTEM.
AFFECTED MODULES: SYSTfC
12/77
1/78
2/7?
101
102
103
10*
105
106
107
10R
109
110
111
112
SYSTEM
101
102
103
10<
105
10*
107
10?
109
110
111
112
SYSTEM
101
102
103
10*
105
106
107
10S
109
110
111
112
SYSTEM
91.o
92.0
92.0
97.0
90.0
95.0
94.p
71.0
92.0
26.P
67.0
96.0
9C.D
95.C
90.0
63.0
66.0
7T.O
S*.0
84.0
92.0
64.0
91.0
en.o
es.o
93.0
92.0
89.0
74.0
85.0
89.0
es.o
76.0
£6.0
88.0
87.0
744
55?
62.0
744
648
71.0
636
77.C
242
-------
EPA UTILITY 1(0 SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORM A KE DATA FOR OPERATIONAL F«D SYSTFHS
PERFORMANCf DATA
PERIOD MODULE AVAILABILITY OPERABILITY PLIABILITY UTILIZATION
X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTIONS/COMWENTS
START DATE 2/78 tOUllWENI; F6D SYSTEM, GENERAL
tNt> DATE 3/78 COMMLNTS:
MODULES WHICH ««E SHOWING AVAILABILITY OF LESS THAN 80 PERCENT, ARE
THOSE IN UHICh THE STRAINER MODIFICATIONS WERE PEfifOnED.
AFFtCTED MODULES: 101 Ul 10? 110
»* PROBL.EMS/SOLUTIONS/COMMENTS
START DATE 2/78 E6UIFWENT: ABSORBER
END DATE 2/78 FROeLrM: NOT DEFINED/SPECIF1 ED
A SULK ENTRAPMENT SEPARATOR MAS INSTALLED ALON6 WITH A KOC" WASH TRAY.
AFFECTED MODULES: SYSTEM
J/7S
«/78
101
10Z
103
104
105
106
107
10S
109
110
111
112
SYSTEM
101
10Z
103
104
105
106
107
10S
109
110
111
11?
SYSTEM
92.0
95.0
71.0
65.0
64.0
89.0
90.0
83.0
62.0
69.0
97.0
71.0
79.0
90.0
92.0
87.0
«7.0
44.0
B1.0
65.0
91.0
86.0
9J.O
91.0
67.0
52.0
744 676
80.0
720 713
91.0
** PROBLE1S/SOLUTIONS/CCNMENTS
STAST DATE 4/78 LGUIfENT: FGD SYSTEM, GENERAL
END DATE 4/7E CCKMlNTS:
STRAINER MODIFICATIONS WERE. PERFORMED OK MODULES 104 AND 112.
AFFECTED MODULES: 104 11?
5/78 101
102
103
104
105
106
107
108
109
110
111
112
SYSTEM
6/7*
102
103
104
61.0
£6.0
85.0
£.6.0
89.0
64.0
62.0
8J.O
82.0
71.0
67.0
79.0
50.r
F4.0
P5.0
J5.C
744 635
72. 0
243
-------
FPA UTILITY FGD SURVM: DECEMBER I97f - JANUARY 1979
SCCTION 3
CtSlth AND PERFOPKAhCE DATA FOR OPFRATJONAL FCD SYSTEMS
PERIOD
MODULE AVAILABILITY
105
106
107
108
109
110
111
11?
SYSTEl" 97.0
PERFORMANCE DATA III""
OPERABlllTY ItLIAEllITY UTILIZATION X REMOVAL PER BOILER ^FGj^ f^^*R
6?.0
7R.C
55.0
i8.0
62.0
72. P
'5 "° 7ZO 717 81. C
7/7? 101
103
10J
10*
105
106
107
10*
109
110
111
112
SYSTE*
76.0
71 ,P
74.0
75.0
52.C
75.0
63.0
62.C
72.0
66.0
73.0
5.p
7*4 6'4
75. 0
•* PROEILEWS/SOLUTIONS/COMWENTS
$TART DATE 7/78 IfiUIFKENT: HIST ELIMINATOR
END DATE 7/78 fKOBltM: CHEMICAL-RELATED PLUG6JN6
TKf CCCURftAMCr OF PI.U66IN6 PRORLfWS IN THE MIST ELIMINATOR HAS BEEN MORt
FREQUENT THAN NORMAL .
AffECTED MODULES: SYSTEM
*• PROBLEMS/SOLUTIONS/COMMENTS
START DATE 7/78 EQUIPMENT: SPRAY NOZZLES
E«B DATE 7/78 FSOBIfM: NOT DEFINED/SPECIFIED
STRATKFR KCDl fjCATjONS CoNT 1 Ml E .
AfFE-tTEO MODULES: SYSTtM
** PBOetlMS/SOLUTIONS/COKiMENTS
START OAJE 7/78 EQUIPMENT: PUMP, OTHER
tND DATE 7/78 PROEtlEMi NOT D E F 1NED /S PE CI f I ED
THE UTILITY IS EVALUATING NEW RUPBER LINED PUMPS (,///6PM) TO HELP CORRECT
THE REHEATER *'ND « 1ST ELIMINATOR PLU6GING PROBLEMS
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 7/78 EQUIPMENT: RECYCLE TANK
END DATE 7/78 PfCRSIM: CHEMICAL-RELATED PLUGGING
T*E OCCURAf'CE PF PLUGGING PROBLEMS IN THE REHEATER HAS BEEN MORE
FREQUENT THAN NORMAL
AFFECTED MODULES: SYSTEf
** PROBLEMS/SOLUT10NS/COMNENTS
START DATE 7/76 EQUIPMENT: F6D SYSTEM, GENERAL
END DATE
7/78
THE UTILITY IE PREPARING FOR TH £ STATE COMPLIANCE DEADLINE ON NOV. 1,1978.
CURRENTLY TES1IN6 HAS BEEN PROCEEDING ON D IFFERENT MODULES IN AN EFFORT
TO FINE TUKE THE SYSTEM.
AFFECTED MODULES: SYSTtM
** PROBLEMS/SOLUTIONS/COMMENT!
START DATE 7/78 EOU1IMENT: ABSORBFR
END DATE 7/76 PROEUEn: CHEMICAL-RELATED EROSION
TI-.E FfD SYSTEM HAS BEEN EXPERIENCING
VIEAR.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 7/78 EQUIPMENT: MIST ELIMINATOR
END DATE 7/78 PROBLEM: NOT DEFINED/SPECIFIED
CONTACTOR WALL AND BARBLE BED
244
-------
EPA UTILITY FGD SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORM AKCE DATA FOR OPERATIONAL FGD SYSTEMS
....—...... .. .. PERFORMANCE DATA-—•
PISJOD BODULt AVAILABILITY CPERABU1TY VEL1AP1L1TY UTILIZATION
X REMOVAL PER BOILER F60 CAP.
S02 PART. HOURS HOURS HOURS FACTOR
THE UTILITY IS EVALUATING NEK STAINLESS STEEL MIST ELIMINATOR WASH
LANCES (TO REFLACE THE ORIGINAL FIBERGLASS LANCEs> TO HELP CORRECT THE
REHEATER AMD MST ELIMINATOR PLUGUNG PROBLEMS.
AFFECTED MODULES; SYSTEM
8/78
9/78
102
103
10*
105
106
107
10*
109
110
111
112
SYSTEM
101
102
103
104
105
106
107
108
109
110
111
112
SVSTEH
91 .0
64.C
65.Q
73.0
63.0
65.0
80.0
81.0
73.0
63.0
73.0
64.0
63.0
62.0
77.0
77.0
58.0
82.0
6?.0
68.0
80.0
80.0
55.0
75.0
744
79.C
97.0
720 35?
36. C
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 9/78 teUIFMENTs MIST ELIMINATOR
END DATE 9/76 PROFjltM: CHEMICAL-RELATED PLUGGING
DIFFERENT MIST ELIMINATOR SPRAY PATTERNS ARE BEIN6 TESTED AS POSSII3LE
SOLUTION TO TH MIST FLIMINATOR PLUGGING PROBLEM REFERRED TO IN 4ULU
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 9/78 tSUU-FENT: BOILER-RELATED
END DATE 10/78 CCKMtNT: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTAGE
IK: BOILER kAl TAKEN OFF LINE ON SEPTEMBER IS, 1978 FOR A SCHEDULED
AUNUAL BOILER AND TURBINE INSPECTION. THE 60 ILER CAME PAC* ON LINE IN
TfcE MIDDLE OF OCTOBER.
AFFECTED MODULES: SYSTEM
** PRObLEMS/SOLUTIONS/COMHENTS
START DATE 9/78 EQUIPMENT: PUMP, OTHER
END DATE 9/76 PROSIFK: NOT DEFINED/SPECIFIED
ThE RUBBER LI I'C D PUMPS THAT THE UTIL]TY WAS INVESTIGATING IN JULYt 1978
HAVE BEEN ORDfFED. FOUR OF THE PUMPS HAVE BFEN RECEIVED AND ONE IS
INSTALLED. THE OTHERS WILL BE INSTALLED AS THEY COME IN
AFFECTED MODULES: SYSTEM
10/7B
101
102
103
104
105
106
107
108
109
110
95.0
65.0
88. C
81.0
71.0
78.0
77.0
fc3.0
&5.C
61.0
245
-------
EPA UTILITY F6D SURVEY! DECEK&fN 1<>7! - JANUARY 1979
SfCTlON 3
DISHN AND PlRfCFUAKCE DAT* tOt OPFRAT10NAL F6D StSTFMS
---------------------- _ ........... -------- PERFORMANCE DATA ---- >
PERIOD MODULE AVmABHITY OPERAHILITY PLIABILITY UTILZZAT10N
BOIt|«
111
SYSTEM
?*.n
70. n
9?.Q
744
37. C
11/7?
PROBLEMS/SOLUTIONS/COMMENTS
START DATE 10/78 IQUIfMENT: PUMP, OTHER
tND DATE 10/78 ffORLEM: NOT DE FXMED/S PECI Fl E» .,..„.,
ThE 2 IN. D1A. SS RODS IN THE PRIMARY CONTACTOP WERE RFPLACED WITH 6<518)
01A. CKRAMt COATED C.S. RODS. THt CERAKIC SLEEVES ARE 9/1« IN. THICK.
PKEPARIN& THE «
-------
EPA UTILITY fGD SURVEY: DECfMBER 1978 - JANUARY 1979
SECTION 3
DES16N AND PE«FOBMAUCE 6ATA FOR OPERATIONAL F6D SYSTEMS
PERIOD
MODULE AVAILABILITY
107
108
109
110
111
112
SYSTEW
OPERABILITV PLIABILITY UTILIZATION
61.0
69.0
96.0
92.0
*3.C
93.0
X REMOVAL PER
SO? PART. HOURS
744
BOILER FGD
HOURS HOURS
688
CAP.
FACTOR
65.8
Z47
-------
FP» UTILITY F6D SURVEY: DECtMBER 197J - JANUARY 1979
SECTION 3
DESIGN AND PE R FOFM A t
******
******
369.1
680
(407 TPH)
12
RECTANGULAR VARIABLE THROAT ROD DECK VENTURI
COMBUSTION ENGINEERING
CARBON STEFU INLFT, 316L SS SKlRTt 316L VENTURI
316L SS RODS
2ft
CERAMIC
9.0
122.6 ( 259900 ACFn>
154.4 ( 310 F)
223.0 ( 354P 6P«)
1.9 (14.0 6AL/1000ACF)
3.7 ( 15 IN-H20)
24.4 < 80.0 FT/S)
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE/ALKALINE FLYASH
COMBUSTION ENGINEERING
BLACK AND VEACH
FULL-SCALE
NEW
99.CQ
50.00
4/77
4/77
12
MARBLE BED
4/77
COMBUSTION
1
248
-------
EPA UTILITY F6D SURVEY: DECEMBER 1978 - JANUARY 1979
DESIGN AND
SECTION 3
DATA TOR OPERATIONAL FGD SYSTEMS
DIMENSIONS
SHELL MATERIAL
SHELL LINER MATERIAL
INTERNAL MATERIAL
NUMBER Of NOZ7LES
NOZZLE TYPE
BOILER LOAD/ABSORBER - %
GAS FLOW - CU.M/S
6AS TEMPERATURE - C
LIBUID RECIRCULATION RATE -
L/6 RATIO - L/CU.K
PRESSURE DROP - KPA
SUPFRF1CAL 6A$ VELOCITY - M/SEC
PARTICULATE INLET LOAD - f/CU.Ci
PARTICULATE OUTLET LOA D- G /CU.fi
PARTICULATE REMOVAL EFFICIENCY - X
S02 INLFT CONCENTRATION - PPM
S02 OUTLtT CONTRAT10N - PPC
S02 DESIGN REMOVAL EFFICIENCY - *
18X26.5
CARBON STEEL n/4 IN)
CEILCOTE FLAKE FIBERGLASS
316L SS PERFORATED PLATE. FRP SPRAY HEADERS
54
CEpACIC
94.38
5«.4
120.
1.3
.5
9.4
6.9
.1
99.0
700
I2C
55.0
( 200000 ACFfO
( 130 F)
( 1900 GP|n>
t 9.5 GAI/1000ACF)
( 2.0 1N-H20)
( 31. P FT/S)
( 3.000 GP/SCF)
( .036 6R/SCF)
** FANS
NUMBER
TYPE
CONSTRUCTION MATERIALS
SCRUBBER I.D.
CARBON STtFL
** MIST
NUMSER
TYPE
CONSTRUCTION MATERIAL
CONFIGURATION
NUMBER OF STAGES
NUMBER OF PASStS
FREEBOARD DISTANCE - K
VAN? SPACING - CM
WASH SYSTEM
SUPERFICIAL GAS VELOCITY - M/S
PRESSURE DROP - K.PA
** PROCFSS CONTROL CHEMISTRY
CONTROL VARIABLES
CONTROL RANGE
CONTROL MANNER
MODE
** PUMPS
SERVICE
POND RETURN WATER
THICKENER
KAKEUP WATER
******
RECYCLE
SPRAY
** TANKS
SERVICE
REACTION
MAKEUP WATER
SLURRY MAKEUP
** REHEATFR
NUMBER
TYPr
HEATIN6 KEDIL^
TEMPERATURE BOOST - C
ENERGY RE6UIRED
NUMBER
TYPE
DIAMETER - I*
OUTLET SOLIDS -
12
CHEVRON
FRP
HORIZONTAL
*
?.20 (10.5 FT)
10.2 ( 4.00 IN)
INTERMITTENT UPWARD WASH ROTATABLE, 120-150 PSI6
9.4 ( 31.C FT/SJ
.0 ( .0 IN-H20)
SLURRY PH, SLURRY SOLIDS, TANK LfVfLS, PRESSURE
PRESSURE DROP M IN H20. 10X SOLIDS, PH>5-5.5
AUTOMATIC
FEEDBACK
1
1
1
i
I
12
Nl/KBFH
1
1
1
11
IN-LINE
280 F HOT WATER
22.? < 40 F>
132 MM BTU/H
1
CENTFR
4?. 8
28.0
DRIVE
(160 FT)
249
-------
EPA UTILITY ftO SUPVEY: DECt«bFR 197f- - JANUARY 1979
SECTION 3 i
DES16N AND FERFOPMAf.CE DATA FOR OPERATIONAL FED SYSTEMS
•• WATER LOOP
TYPE
OPTN
«• REAGENT PREPARATION EflUIPHENT
NUMFEP. Of BALL MILLS
BALL MILL CAPACITY- M T/H
REA6ENT PRODUCT - X SLURRY SOLIDS
1
21. «
60.0
?4.0
•• TREATMENT
TYPf
SUPPL1 ER
•• DISPOSAL
NATURE
TYPt
LOCATION
TRANSPORTATION
AREA - ACRES
CAPACITY - CU.M
PERIOD
4/77
5/77
6/77
MODULE AVAILABILITY
201
20?
20!
20*
205
2P6
207
208
209
210
211
212
SYSTEM 92.Q
211
212
209
20F.
206
2C3
204
201
202
SYSTEM 91.0
201
202
203
204
205
206
207
20 e
209
210
211
212
SYSTrw 96.0
CPERAPHITY
95.0
93.0
87.0
f-3.0
84.0
94.0
74.0
91.0
67.0
85.0
86.0
91.0
9S.O
94.0
98.0
100.0
44.0
95,0
33.0
10D.O
92.0
76.0
78.0
79.0
«9.0
74.0
67.0
e-B.o
88.0
78.0
45.0
85.0
FORCIBLY OXIDIZED
NONPROPRIETAfiY
FINAL
LINED POND
ON-SITE
PIPE
500.0
SC575000 < 25000.0 ACRF-FT)
PLIABILITY UTILIZATION X REMOVAL PER BOILER FGB CAP.
$02 PART. HOURS HOURS HOURS FACTOR
57.50 99.00 720 6°7 78. C
744 6«4 75.0
720 7?0 83.0
** PROeLeWS/SOLUTIONS/CCMMENTS
START DATE 6/77 ECUIFPENT: RECYCLE TANK
END DATf 7/77 fSCBLfM: NOT D E FIIMEO/SPE CIF 110
CRACKING AND 'UBBLIN6 OF THE CE1LCOTE LINING HAS BEEN OBSERVED ABOVE THE
LIQUID LEVEL CF THE INTERNAL RECYCLE TANK.
AFFECTED MODULES: SVSTEP
250
-------
EPA UTILITY F6D SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL F6D SYSTEMS
PERIOD MODULE AVAILABILITY CPERABIIITT
• ---PERFORMANCE DATA-----
PLIABILITY UTILIZATION
X REMOVAL PER BOILER FED CAP.
S02 PART. HOURS HOURS HOURS FACTOR
7/77 201
202
203
2C4
205
206
2D7
2C8
209
210
211
212
SYSTEM 97.0
96. C
87.0
B6.0
97.0
96.0
68.0
ffl.O
95.0
57.0
93.0
94.0
67.0
744 602 72. C
8/77 201
202
203
204
205
206
207
20 £
209
210
211
212
SYSTEM
fifi.O
75.0
67.0
62.0
£4.0
35.0
81.0
eo.o
56.0
79.0
71.0
33.0
93.0
744
69.0
** PROBLEMS/SOLUTIONS/COMMENTS
START -DATE 8/77 EfiUlIMENT: PUMP, OTHER
END DATE 9/77 PROBLEM: NOT DEFINED/SPECIFIED
SFRAY PUMPS WiTE OVERHAULED.
AFFECTED MODULES: 20* 2 Co
** PRObLEMS/SOLUTIONS/cOKMfNTS
START DATE ?, 117 EOUII^ENT: SPR*Y NOJILtS
END DATE 9/77 PRGPLEM: NOT DE FINED/S PT CI F I ED
TfcC SPRAY NOZZLES REfiUIRED EXTENSIVE CLEANING.
AFF£.;cTEO MODULES: 206 2 C9
9/77
2P1
202
203
204
205
206
207
209
210
211
212
SYSTEM
94.0
89.0
61.0
£2.0
90.0
ei.o
82.0
52,P
56.0
87.0
73.0
£6.0
720 717
83.C
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 8/77 teilF'NENT: TANK» OTHER
END DATE 9/77 PROEUM! CHEMICAL-RELATED ER.OS10N
THE STRAINEHS IN THE REACTION -TA.NK HAVE STARTED ERODING.
REPLACING THEF< VERY SOON.
AFFCCTED MODULES: 207 2(9
NSP ANTICIPATES
10/77 201
202
203
204
2P5
98.0
89.0
*7.0
f.6.0
62.0
251
-------
EPA UTILITY f&D SURVEY: DtCECBfR 197£ - JANUARY 1979
SECTION 3
DESIGN AMP PERFORMANCE DATA fOR OPERATIONAL FGo SYSTFMS
PERFORMANCE DATA "
PtRIOD MODULE AVAILABILITY OPEPAB1LITY PLIABILITY UTILIZATION * REMOVAL PER BOILER F60 CAP.
S02 PART. HOURS HOURS HOURS FACTOR
207
206
2C8
209
210
21J
SYSTEM 9->.o
98.0
99.0
9J.O
96.0
96. 0
61. C
744 684 85. C
** PROEiLEMS/SOLUIIONS/CCMMENlS
START DATE 10/77 I Oil I (KENT: PUKP, OTHER
END DATE 11/77 PR061FM: NOT DCF1NED/SPEClfI ED
THE LOW OHRA' 1LITIES ARE PUE TO SPRAY WATER PUMP OVERHAULS. 24 PUMPS
ACE BEING OVERHAULED.
AFFFCTEI) MODULES: SYSTtK
•• PROttlEMS/SOLUTlONS/COHMENlS
START DATE 10/77 E6U1H»1INT: F6D SYSTEM, GENIftAL
END DATE 11/77 If-OELfM: C HIHI CAL-RELATE D EROSION
SIRAINtR/d'ASN K< SCREEN EPOS10N HAS BEEN A PROBLEM. 316 SS MATERIAL WILL
Et UPtD IN THf FUTURE. REPLACEMENT MATERIAL IS EXPECTED TO ARRIVE IN
DECEMBER AND kORK IS EXPECTED TO LAST FOR THREF MONTHS.
AFFECTED MODULES} SYSTIP
11/77
201
2C2
2P3
JO*
205
204
207
20«
209
210
211
212
SYSTEM
12/77 201
202
203
204
2C5
206
2P7
2P8
209
210
211
212
SYSTEM
91.0
93.0
1/7B
2P1
2P2
203
204
2C5
20«
207
208
209
210
211
212
SYSTEM
92.Q
65.0
fcO.O
93. C
73.0
75.0
66.0
94.0
77. P
91.0
65.0
53.0
93.0
94.0
P1.0
89.0
95.0
93.0
n.o
62.0
B2.0
90.0
92.0
91.0
7«..0
64.0
72.0
74.0
67.0
91.0
fe&.O
77.0
72.0
73.0
84.0
715
85.0
744 73S
84.0
MOBLiMS /SOLUTIONS /COMMENTS
START DATE 12/77 teUIICENT: ABSOBBfR
EKO DATE 1/78 CRORUNl NOT DEF1NEB/SPF CI MEO
744 602
73.0
252
-------
EPA UTILITY FGD SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FGD SYSTEMS
. .... ... PERFORMANCE DATA
PERIOD HODULE AVAILABILITY OPERAB1LITY PLIABILITY UTILIZATION
X REMOVAL PER BOILER FED CAP.
S03 PART. HOURS HOURS HOURS FACTOR
2/78
3/7*
THE REPLACEMENT OF STRAINER SCREENS WAS BEGyN ON DECEMBER ?t.
4-6 DAYS FOR fcORK ON EACH MODULE.
AFFECTED MODULES: SYSTEM
201 83.0
202 85.0
203 55.0
204 91.0
205 89.0
206 76.0
207 71.0
208 89.0
209 65.0
210 81.0
211 97.0
212 60.0
SYSTEM 92.0 672 620
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 2/76 (CU1FMENT: A8SOPBFR
END DATE 2/76 PROBLEM: NOT D I FINED/S PF Cl F UD
STRAINER ROD 1MCATIONS WfRF PERFORMED ON MODULES 203 AND 212.
AFFFCTED MODULES: 203 £1?
IT TAKES
77.C
201
202
203
204
20$
206
207
208
209
210
211
212
SYSTEM
97.0
92.0
90.0
H.O
7B.O
P5.0
91.0
62.0
83.0
78.0
te.o
£9.0
744 74<
*• PROULEMS/SOLUTIONS/COMMENTS
START DATE 3778 tOUll^ENT; F6D SYSTEM, GENERAL
END DATE 3/78 COMM HUTS:
Ttfc UNIT t-ENFKATED MAXIMUM MEGAWATT-HOURS AND THE F60 SYSTEM TIED THE
H16HEST RtcORttD AVAILABILITY 0F S? PERCENT.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUT10N!i/COMMENT$
START DATE 4/78 E6UI r-l*ENT: ABSOPBFR
tND DATE «/78 COMMt^TSr
MODULE 201 WAJ CONVERTED TO A SPRAY TOWER DURIN6 ApRIL.
AFFFCTE-D MODULES: 201
•* PROBLEMS/SOLUTIONS/COMMENTS
START DATE 3/76 EOUIf^ENT: ABSORBFH
ttttt DATE ?/7E FRGBLrM: NOT DE FINED/S PF. CI FI ED
STRAINTR FiCDIIJCATIONS WFRF PERFORMED ON MODULES 208 AND 210.
AFFECTED MODULES: ?0f. 2 1C1
4/7B 201
202
203
204
205
206
207
208
209
70.0
82.0
90.0
t>4.0
«1.0
fJ.O
64.0
£6.0
7K.O
253
-------
EPA UTILITY FGD SURVEY: DECIDER I97f - JANUARY 1979
StCTION i
DtSI6N AMD PERFORMANCE DATA ffl* OPERATIONAL F6D SYSTEMS
. . PERFORMANCE DATA-"--" " -
PERIOD MODULE AVAILABILITY CFERAPILITY PLIABILITY UTILIZATION * REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
210
211
212
SYSTEf
90.0
67.0
£5.0
92.0
720 719
85.0
** PROEiLCMS/SOLUTIONS/COMMENlS
START DATE 4/77 f OUI IF ENT: FED SYSTEMt GENERAL
5/7P
201
202
203
204
205
206
207
208
209
210
211
212
SYSTEP
END DATE 5/77
FROM FULL SCAU STARTUP ON APRIL 1. THE SYSTEM HAS BEEN OPERATING VERY
Will WITH NC 'JMOR PROBLEMS ENCOUNTERED. THE UTILITY IS MAINTAINING A
SCHEDULE OF Nlf.HTLY CLEANING ON THE. SCRl'EiBFRS. THE CURRENT SCHEME IE SUCH
TMT EACH POD LIE IS CLEANED AFTER 7.8 DAYS.
AFfFCTED MODUl tS: SYSTtl"
97.0
94.0
9o)o
90.0
69.0
90.0
9?.0
?P..O
91.0
78.0
14.0
91.0
744
13.C
** PRCBLEMS/SOLUTIONS/COMMENTf
START DATE 5/76 ICUIH1ENT: APSORBFR
END DATE 5/7R PROBUM: NOT DEFINED/SPECIFIED
ThERF WERE LIffR FAILURES (CflLCOTE) IN MOST OF THE MODULES DURING MAY.
THE LINERS KEfE REPAIRED BY THE CE1LCOTE COMPANY AT THEIR OWN EXPENSE.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMNENTS
START DATE 5/78 EGimfENT: BOILER-RELATED
END DATE 5/78 COBPUNT: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTAGE
TkE UNIT kEKT DOWN ON MAY * FOR THE FIRST YEAR BOILER AND TURBINE INSPEC-
TION AND k*s IOWN THE REMAINDER OF
AFFECTED MODULES: SYSTEM
6/78
7/78
2ni
202
203
204
205
2C6
208
209
210
211
212
STSTEM
201
202
203
204
205
206
207
208
209
210
211
95.0
77.0
46.0
41.0
67.0
62.0
62.0
78.0
60.0
62.0
76.0
75.0
89.0
62.0
93.0
90.0
64.0
ft.O
67.0
64.0
M.O
73.0
720 572
64.G
254
-------
EPA UTILITY FGD SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMAUCE DATA FOR OPERATIONAL FGD SYSTEMS
PERFORMANCE DAT A
PERIOD MODULE AVAILABILITY OPERAB1L1TY PLIABILITY UTILIZATION
X REMOVAL PER BOILER FGD CAP-
S02 PART. HOURS HOURS HOURS FACTOR
212
SYSTEM
95.Q
71.0
74* 697
75.0
*• PROBLEMS/SOLUTIONS/COMMENTS
START DATE 7/7B EOUIfCENT: PUMP, OTHER
END DATE 7/78 PROBLEM: NOT DEFINED/SPECIFIED
THE UTILITY If EVALUATING NEW RUBBER LINED PUMPS (8000 6PM) AS POSSIBLE
SOLUTIONS TO THE MIST ELIMINATOR AND REHEATER PLUGGING PROBLEMS.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 7/76 ESUIF'PENT: MIST ELIMINATOR
END DATE 7/78 P HOB If Hi NOT DEFINED/SPECIFIED
1H UTILITY IS EVALUATING NEW STAINLESS STEEL MIST ELIMINATOR HASH LANCES
(1C REPLACE OM61NAL FIBERGLASS LANCES).
AFFECTED MODULES: SYSTEM
** PROULEMS/SOLUTIONS/COMNENTS
START DATE 7/78 FOUItMENT: ABSORBER
END DATE 7/78 PROBUM; CHEMICAL-RELATED EROSION
The FGD SYSTEM HAS BEEN EXPERIENCING PRIMARY CONTACTOR WALL AND MARBLE
BED NEAR.
AFFECTED MODULES: SYSTEM
•* PROBUEMS/SOLUT10NS/COMMENU
START DATE 7/7B r«UIIKENT: F6D SYSTEM, GENERAL
END DATE 7/76 COMMiMTS:
TtiE UTILITY IS PREPARING FOR THE STATE COMPLIANCE DEADLINE ON NOVEMBER 1.
CORRENTLY TESTING HAS BEEN PROCEEDING ON DIFFERENT MODULES IN AN EFFORT
TO FINE TUNE THE SYSTEM.
AFFECTED MODULES: SYSTEM
»* PROULEMS/SOLUTIONS/COMMENTS
START DATE 7/78 EQUIPMENT: RECYCLE TANK
END DATE 7/78 ffiGBITM: C HEMI CAl-RELATE 0 PLUGGING
PLUGGING PROBLEMS IN .THE REHEArER HAVE BEEN MORE FREQUENT THAN NORMAL.
AFFECTED MODULES: SYSTtK
•* PftOBLEMS/SOLUTlONS/COMMENTS
START DATE 7/78 tCtlfENT: ABSORBER
END DATE 7/78 PROBlPMs NOT DEFINED/SPECIFIED
THE UTILITY IE IN THE PROCESS OF RfMINING THE ORIGINAL ZURN DUPLEX
STRAINERS AND REPLACING THFM WITH 516 SS STRAINERS.
AFFECTED MODULES' S^SUP
** PROBLEMS/SOLUTIONS/COMMENTS
START DATF 5/7t ICUIffiENT: ABSORBER
END DATF 5/7S PROBLFM: NOT DEFINED/SPECIFIED
TM: IKLET SEAL STRIPS UERE REPAIRED.
AFFECTED MODULES: SYSTtr
** PRObLEMSASOLUTIONS/COMMENTS
START DATE 7/7F. tOUI FlfENTs MIST ELIMINATOR
END DATE 7/76 F-fC!P|PM: C HEMI CAL-RELATE 8 PLUGGING
PLUGGING PROBirMS IN THE MIST ILIKINATOR H*VE SEEN MORE FREQUENT THAN
NCRMAL.
AFFECTED MODULtS:
8/78 Z01
Z02
203
20*
20S
206
2C7
208
es. n
100.0
4R.O
79.0
n.o
7?.0
64.0
F7.0
-------
FPA UTILITY ftD SURVEY: DtClCBEP I97f - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FED SYSTEMS
PERIOD
MODULE AVAILABILITY
209
210
211
212
SYSTEM 91. 0
PERFORMANCE DATA
OPERAPILITY RELIABILITY UTILIZATION * REMOVAL
S02 PART, t
54.0
7fc.O
EO.O
71.0
PER BOILER FG
•(OURS HOURS HOU
744 695
t> CAP*
RS FACTOR
73.0
*• PROPLEMS/SOLUT10NS/COMMEMTS
START DATE ?/78 EGUIH'IENT: F6D SYSTEM* GENERAL
eMD DATE 9/7? COMWtNTS:
MC FCD RELATE! OUTAGES KERF REPORTED BY THE UTILITY FOR THF AUGUST-SEP
TIMBER REPORT PERIOD .
AFFECTED MODULES: SYSTEM
9/78
201
202
21?
ZDA
205
206
207
208
209
210
211
212
SYSTlf
96.0
73.0
8Z.O
70.0
61.0
74.0
64.0
e?.o
72.0
75.P
7S.O
82.0
68.0
720 720
78.0
** PfiOtiLEnS/SOLUTTONS/COKNENTS
START DATE 9/78 IClIlfEKT: PUMP, OTHER
EMI) DATE 9/78 COM" *NTS:
Tt-E RUHBER LIKD PUMPS THAT THE UTILITY WAS INVESTIGATING HAVE BEEN
OKDERED. FOUf OF THE PUMPS HAVE bltU RECEIVED AND ONE IS INSTALLED.
OTHERS WILL BE INSTALLED AS THtT ARE RECEIVED.
AFFECTED MODULES: SYSTtf
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 9/78 iOLI FMENT: MIST ELIMINATOR
END DATE 9/78 H>CB|,f|i!: NOT D E FINED/SPTCI f I ED
DIFFERENT MSI ELIMINATOR SPRAY PATTERNS ARE BEING TESTED.
AFFECTED MODULES: SYSTtM
THE
10/78 201
203
204
205
206
207
208
209
210
211
212
SYSTEM
94.0
90.0
79.0
59.0
73.0
69.0
64.0
7e».0
76.C
7?.0
69.0
7?.0
£2.0
744 6S8
72*0
** PROfcLEMS/SOLUTlOKS/COMiiNU
START DATE 10/78 EeUHMENT: ABSORBER
END DATF 10/7U CPCPIEM: NOT DEFINEB/SPECIfI ED
DINING OCTC&ft MODUIE 202 EXPERIENCED STRAINER PLUS6A6E .
AFFECTED MODULES: 203
*« PROELIMS/SOLUTIONS/COKMENTS
START DATF 10/78 tCUIfHENTs RECYCLf TANK
END DATE 10/76 PROBLEM: NOT DEFINED/SPECIFIED
DURING OCTOBER fcODULE 203 EXPERIENCED REHEATER PROBLEMS WHICH TOfiETHFR
UJTH STRAINER PLUGGING CAUSED A « TO 5 DAT OUTAGE.
AFFECTED NODULES: 203
256
-------
EPA UTILITY FGC SURVEY: DECEMBER 1978 - JANUARY
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FED SYSTEMS
....... — PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERARUITY tt LIABILITY UTILIZATION
X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
11/78 201
202
203
204
205
206
207
208
209
210
211
212
SYSTEM 92.0
e4.o
45.0
E?.0
80.0
75.0
58.0
77.0
75.0
P3.0
83.0
7?.0
47.0
720 472 47.0
** PROBLEMS/SOLUTIONS/CCMMENTS
START DATE 11/78 E«>UIH*ENT: POILER-RELAT E 0
END DATE 11y78 COMMtNT: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTAGE
THE LOW NOVEMlER BOILER HOURS RESULTED FROM A TURBINE INSPECTION.
AFFECTED MODULES: SYSTtf
** PROBLEWS/SOLUTIONS/COMPIENTS
START DATE 11/76 tCtlIHENT: PUMP. OTHER
END DATE 11/78 COMMfNT: PREVENTIVE MAINTENANCE
NORMAL OVtRHAU MAINTENANCE WAS PERFORMED ON THE SPRAY PUMPS OF MODULES
2C2 AND 21?.
AFFECTED MODULES: 202 21?
12/76 2(51
202
203
204
205
206
207
20*
209
210
211
212
SYSTEM
f5.0
92.0
89.0
ft.O
f.4-,0
R4.0
96.0
68.C
7?.0
92.0
M.O
94.0
744
77.2
** PKOBLEMS/SOLUTIONS/COMMEMU
START DATE 12/7g [6UIK»INT! FSD1 SYSTEM, 6SNIRAL
INC DATt 1/79 H?CPiEMs VIATHIR-RELATI6 COMPONiNT FAUURi
TIL PROBLI'I'S !NCOUNTSRiD UfRf MAINLY WfATHIR RSUAT60.
AFFECTED MODULES: SYSTI.f
• * PUOf-LE^S/SCLUTlONS/CO.KENTf
START DATE 12/78 ieuIII*INT: DOILER-Rf LAT E b
tND DATI 1/79 PRCPL^M: NOT 6EF1NID/SPIClFICD
TKRF *IRi PRfF'LIMS WITH THE COAL FEEDER StlTS RESULTING IN MOVIN6 COAL
FhOM COAL STOCKPILES TO THE B01LFK.
AFFECTED MODULlS: SYSTlM
1/7? 201
202
203
204
205
206
2fl7
2C8
2C9
210
211
57.0
£9.0
91.0
*5.0
92.0
fcJ.O
75.0
97.9
74.0
f,H.O
100.0
257
-------
EPA UTILITY F6D SURVEY: DECtKBER 1?7f - JANUARY 1979
SECTION 3
DES1CN AND PFRFORKAhCE DATA FOR OPERATIONAL FSD SYSTEMS
PER FORMANCE DATA--- •-
PERIOD WODULE AVAILABILITY CPERAPILITY rf LI At! I LIT Y UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
$0.0
SYSTEK
744 tf&
69.f
258
-------
EPA UTILITY F6C SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMS DATA FOR OPERATIONAL FED SYSTEMS
COMPANY NAME
PLANT NAKF
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - *v
GROSS UNIT GENERATING CAPACITY - P!U
NET UNIT GENfcRATINC CAPACITY V/F6D - Ft
NET UNIT GENERATING CAPACITY VO/FG6 - !"V
EQUIVALENT SCRUBBED CAPACITY - MW
** BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MA-XinUM bfllLtfe FLUE GAS FLOW - Ct.MS
FLUF GAS TEKPFRATURr - C
STACK HE 16HT - *
STACK TOP DIAMETER - Pi
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - KJ/KG
RANEE HEAT CONTENT - BTU/LE
AVERAGE ASH CONTENT - *
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - *
AVERAGE SULFUR CONTENT - S
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE COMTEK! - X
RANGE CHLORJDF CONTENT - 5!
FUEL FIRING RATE - « T/H
FUEL FIRING RATE - MW
•« PARTICULATE SCRUBBER
NUHPER
TYPE
SUPPLIER
NUMPER OF STAGES
SHELL MATERIAL
LINING MATERIAL
INTERNAL MATERIAL
TYPE OF NOZZLES
BOILER LOAD/SCRUBBER - X
fLUE GAS CAPACITY - CU.tf/S
FLUE GAS TEMPERATURE - C
LIttUID RECIRCULATION RATE - LITER/::
L/G RATIO - LITFR/CU.M
PRESSURE DROP - KPA
SUPERFICIAL GAS VELOCITY - K/S
PARTICULATE DESIGN REMOVAL EFFICIENCY
S02 INIET CONCENTRATION - PPK
S02 OUTLET CONCENTRATION - PP*
SOj DESIGN KEPOVAL EFFICIENCY - £
** F6D SYSTEM
SALFAeLt PRODUCT/THROWAUAY PRPHlCT
GENERAL PROCESS TYPE
PROCESS TYPE
PROCESS A'DDITIVFS
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RFTROFIT
PARTICULATE DESIGN RECCVAL EFFICIENCY
So2 DESIGN REMOVAL EFFUIFNCY - J
COMMERCIAL DATE
INITIAL START-UP
PENNSYLVANIA POWER
BRUCE MANSFIELD
1
SH1PPIN6POR1
PENNSYLVANIA
B
15. < .035 LF!/MMiTU>
25?. ( .600 LR/MMBTU)
Z751.0
917.0
Jsbio
017.0
FOSTFR WHEELER
SUPERCRITICAL, PULVERIZED COAL, BALANCED DRAFT
BASE
0/76
1580.86 (335GOOO ACfftT
UO.* < 265 F)
?9P. ( 950 FT>
******* (***** FT)
COAL
ilTUf
267*9.
1Z.90
11.5-13.5
7.00
5.5-?.5
T.OO
1 .75-3.75
********
******
301.1
*****
< 11500 BTU/L8>
11000-11950
(132 TPH)
VARIABLE THROAT VENTUKI
CHEMlCO
CARBON STEfL
POLYSTER FLAKEGL.ASS
317 SS AND S5 WITH FLAKEGLASS LINING
TANGENTIAL FfED C1 SET AT THRoAT,1 AT BOTTOMS
17.0
?63.5 < 558333 ACFM)
1*0.6 ( 285 F)
1386.0 (22000 GPWJ
*.? («0.0 GAL/100QACF>
5.7 ( 27 IN-HPO)
61.0 < 200.0 FT/S)
- % 90.8
3C90.000
930.000
92.1
THROkAUAY PRODUCT
WET SCPUfblKG
LIME
TH10SORBIC
CHFMICO
GILBERT/COMKONWEALTH ASSOCIATES
FULL-SCALE
NEW
. X 99.»o
9?.10
6/7*
12/75
259
-------
EPA UTILITY FbD SUPVTY: DECtlETR 19?t - JANUARY 1979
SECTION 3
DF.S1GN AND PERFORMANCE DATA FOR OPERATIONAL tGD STSTF.HS
UP
. X
** AtSORE'ER
MUMEER
TYPt
INITIAL START
SUPPL1 ED
DIMENSIONS
SHELL. MATERIAL
SHELL LINER MATfKIAL
1NTFRNAL MATERIAL
N027LF. TYPE
BOILER LOAD/AE>SORBER
6AS FLOk, - CU.K/S
GAS TEKF'tRATURE - C
LI fill 1C REC1&CULATIOM RATE - LIlfR/S
L/t RATIO - L/CU.M
PRESSURC DROP - KPA
SUPFRFICAL GAS VELOCITY - l»/SFl
SOE 1NLFT CCNCENTRAT 10K - PPM
SOI OUTLET COHTRAT10N - fPf
S02 BESIbN REMOVAL EFFICIEfcCY - X
** FANS
TYPf
CONSTRUCTION MATERIALS
SERVICE - WET/DRY
FIXED THROAT VENTURl
1Z/75
CHFMHO
U DIA X ST.5 HIGH
CARBON STEfL
POLTFSTER FLAKEGLASS
CAPBON STEEL, FLAKE6LASS LINING
TANGENTIAL FF.ED
17.C
< 426600 AtF«)
( 127 F)
(19400 GPM)
( «s.o 6
< 8.0 IN-H20)
(100.0 FT/S)
201.31
6.0
30.5
6
I .D.
LINED C.S.; BLADES-INCONEL 625
WET
KUMPER
Trpr
CONSTRUCTION MATERIAL
CONFIGURATION
MUMPER OF STAGES
NUMER OF PASSES
VANE SPACING - CM
VANF ANGLES
UASH SYSTEM
SUPERFICIAL GAS VELOCITY - N/S
PRESSURF DROP - KPA
•• MIST CLIWINATOR
NUMPER
Trpr
CONSTRUCTION MATERIAL
CONFIGURATION
NUMBEF OF STAf[S
NUMBER OF PASSES
VANf SPACING - CM
VANE ANCLES
LASH SYSTEM
SUPERFICIAL GAS VELOCITY - K/S
PRESSURE DROP - KPA
** PUMPS
SERVICE
RECYCLE
SCRUBBER RECYCLE (SPARE)
LIMF SLURRY TRANSFER
******
ABSORBER RECYCLE
ABSORBER RECYCLE
THICKENER UNDERFLOW TO MIX TANK
THICKFNER TRANSFER
«• TANKS
SERVICE
THICKENER
*I»IN6 TANK fCALCILOX I THCKSR UNDR
SLUDGE TRANSFER
MIXlNf- TANK CSPFNT SlUSRT t FLVASH2
RECYCLE (SCRUPFiFR)
FRP
HOPI70NTAL (?-SHAPE)
1
t
7.6 ( 3.00 IN)
90 DFG.
OVERSPRAY/UNDERSPRAYt ONE/SHIFT FOR OVERSPRAY, C
30.5 (100.0 FT/S)
.1 < .3 IN-H20)
tHFVRON-SCRUttBCR
FRP
HORIZONTAL (?-SHAPE)
1
^
7.6 ( 3.00 IN>
90 DFG.
OVERSPRAY/UNDERSPRAY, ONCE/SHIFT FOR
30.5 (100.0 FT/S)
.1 ( .3 1N-H20)
NUMBER
NOMBFR
****
2
****
****
6
260
-------
EPA UTILITY FGB SURVEY: BECEMBER 1978 - JANUARY 1979
SECTION 3
DES16N AND PERFORMANCE 6ATA FOR OPERATIONAL FED SYSTEMS
RECYCLE (ABSORBER)
«• REHEATER
NUMBER
TYPE
TEMPERATURE BOOST - C
ENERGY REQUIRED
** THICKENER
NUMBER
TYPE
CONSTRUCTION MATERIAL
9IAMETER - M
OUTLET SOLIDS - %
»* WATER LOOP
TYPE
** REAGENT PREPARATION EQUIPMENT
NUMBER OF SIAKERS
SLAKER CAPACITY - M T/t
»* TREATMENT
TYPE
SUPPLIER
CONTRACTOR
PRODUCT CHARACTERISTICS
** DISPOSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
AREA - ACRES
CAPACITY - CU.M
DIRECT COMBUSTION
2?.2 (
28 BTU/H
F>
RAKE DRIVE
CARBON STEEL
61.0 (200 FT)
30.0
OPEN
< 2.2 TPM)
CALCILOX
PROPRIETARY
DRAVO
CONSISTENCY OF GRANULAR SOIL
FINAl
LANDFILL
OFF-SITE
PIPE
140D.C
59927QOO < 490(70.0 ACRE-FT)
... ...... ......PER fORMANCf DATA-----
PERIOD MODULE AVAILABILITY CF'ERABILIIY Kf LIABILIT Y UTILKATION
x REMOVAL PER BOUER FED CAP.
S02 PART. HOURS HOURS HOURS FACTOR
A
6
t
D
E
F
SYSTEM
744
** PROOlEfS/SOLUTIOMS/CCrriENTS
START DATE 12/75 EBUIFMENT: FGD SYSTEM, GENERAL
END DATE 17/75 CC*M(NTS:
INITIAL OPERAHON (SHAKEDOWN AND DEBUGGING) FOR PART OF THE SYSTEM COM-
MENCED IN DECEMBER
AFFECTED MODULES: SYSTEM
0/76 SYSTEM
** PRPnLtMS/SOLUTIONS/COMf.ENTS
FED SYSTEM, GENERAL
START BATE 0/76 fcGUIFPENT:
END DATE 0/76 COMMENTS;
S1NCF. THE UM1 COMMENCED COMMERCIAL OPERATIC IN APRIL 1976, A NUMBER OF
PROBLEM AREAS HAVE BEEN ENCOUNTERED. MAJOR AREAS OF CONCERN ARE SPECIFIED
BELOW:
1. EXCESSIVE MAINTENANCE PROBLEMS WITH THE WET I.D. FAN HOUSINGS.
2. EXCESSIVE WATER ENTRAPMENT AND CARRY OVER OUT OF THE STACK CAUSING A
STACK MU PROBLEM.
3. REHEAT BURNER PROBLEMS.
4. STACK FLUE LINEP FAILURES.
AFFECTED MODULES: SYSTEM
1/76 SYSTf* 744
261
-------
FPA UTILITY F6B SURVEY: DECEMBER I97f- - JANUARY 1979
SECTION 3
AND PERFOPMUE DATA FOR OPERATIONAL FCD SYSTEMS
-. ------- ... ---------------------- .... ---- PERFORMANCE 0 AT A ------------------------- ' ------ " --- — —
PERIOB MCBULE AVAILABILITY OPEMPHITY IFL1ABUITV UTILIZATION X REMOVAL PER BOILER F6D CAP,
S02 PART. HOURS HOURS HOURS FACTOR
** PRO&LEMS/SOLUTIOMS/COMWENTS
START BATE 1/76 EfiUIHENT: MIST ELIMINATOR
END BATE 1/76 PfiOBLfM: CHEMICAL-RELATED PLU661NG
THE UMT SHUT DOWN fOR ONE WEEK DtE, IN PART, TO PLU66ED MIST EL1MIN»TORS.
AFFECTED MODULES: SYSTEK
*« PROBLEMS/SOLUTION S/COMMEN1S
START PATE 1/76 EGUIFI'ENT: FAN
ENB DATE 1/76 PFJOBlfH: BE SIGN-RE LATtD VIBRATION
1H UNIT SHUT DOWN FOR ONE WEEK OUEi IN PAPTi TO I.». FAN HOUSING VIPRA-
TION PROBLfHS.
AFFECTED MODULES: SYSTIP
2/76 SYSTEC 6?6
** PROBLEMS/SOLUTIONS/COMMENTE
START CATE 2/76 E«UJ. IMENTj REHEATER
END BATE J/76 FFOBIFM: NOT DEFINED/SPECIFIED
FIRST ATTEMPT* AT STARTING UP THE REHEAT BURNERS WERE MADE THIS MONTH. SO
MANY PROBLEMS WERE (.NCOUNTFRED THAT THE VENDOR IS GOING TO REDESJtN NEW
RtHEIT BUKNtR^
AFFECTED MODULES: SYSTEM
3/76 SYSTEP 7«A
*/76 SYSTEM 7?0 506
** PROELEMS/SOLUTIONS/COMMENTS
START DA1E A /7fc E.GUII-KENT: FSB SYSTEM, 6ENEHAL
[MB B'TE 4/76 CCMM ?NTS:
TCT^L OPeRATIH, HOURS A CCU^Ul AT£ D TO DATE ARE AS FOLLOWS: 0, 210, 984,
2147, 2t.0f, AtD 2427 FOR MODULES A THROUGH F RESPECTIVELY. THE SCRllfBINE
SYSTFC IS CURffNTLY HANDLING FLUE GAS AT A TOTAL E8UIVALENT CAPACITY OF
APPROXIMATELY £40 MW (GROSS).
AFFtCTED KODUtES: SYSTEM
5/76 A
e
c
D
£
F
SYSTEM (JO.O 100.0 100. 0 80.0 7A4 595 0
«* PROBLEMS/SOLUTIONS/CORMENTS
START BATE 5/76 tGUIIHENT: F6B SYSTEM, GENERAL
ENB DATE 5/76 C
-------
EF>A UTILITY F6D SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FED SYSTEMS
.. ...... .—. ... ......pjRf ORMANCF DATA •
PERIOD MODULE AVAILABILITY CPEPABILITY ^LIABILITY UTILIZATION
X REMOVAL PER BOILER F«jO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
B25 MW CM JUNE 1* 1976. OVER THE PERIOD A REVISED SCRUBBER BAFFLE
SYSTEM WAS INSTALLED IN AN EFFORT TO CORRCCT THE SCRUBBER RECYCLE PUMP CA-
VITATION PROBlfcHS.
AFFECTED MODULES: SYSTEM
7/76
A
b
C
6
E
F
SYSTEM
e/76
10/76
90.0
100.0
100.0
90.0
744 673
** PROBLEMS/SOLUTIONS/COMMENIS
START DATE 7/76 EGUIFMENT: REHEATED
END DAT? 7/76 PROBLEM: NOT DEFINED/SPECIFIED
Tt-E SYSTEM SUIPLIER IS STILL TRYIN6 TO SOLVE THE REHEAT BURNER PROBLEMS.
AFFFCTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 7/74 ECUIFMENT: MIST ELIMINATOR
END DATE 7/76 PfiOBl&M: 6ESI6N-RFLATE0 UNDERSIZED COMPONENT
TESTS CONDUCTS THIS MONTH SHOWED THAT THE FGD SYSTEM MIST ELIMINATORS ARE
NOT PERFORMING TO DESI6N AND THAT THERE IS EXCESSIVE WATEH ENTRAINED ]N
1H CLEANED FU'E 6ASSES CAUSING A STACK RAIN PROBLEM. CHEMICO !S WORKIN6
Oh THE DFSItN OF ADDITIONAL MIST ELIMINATORS THAT WILL REMOVE THIS EXCESS
WATER.
AFFECTED MODULUS: SYSTEM
A
6
C
D
£
F
SYSTEM 95.0 100.0 100.0 95. P 7*4 70S 0
»* PRObLEMS/SOLUTIONS/COKMENTS
ST*RT »»TE P/76 tCUI^ENT: MIST ELIMINATOR
END DATE S /76 CCMMiNTS: RESEARCH AND ti EVELOPK |NT
SECONDARY VERTICAL MIST ELIMINATORS WERE INSTALLED IN THE ABSORBE» D""
CHAR6E DUCT U AN ATTEMPT TO REDUCE THE EXCESSIVE ENTRAINED WATER. THEY
DID NOT WORK 16CAUSE THE FLUE GAS BLEW THEM APART IN A FEW MINUTES OF OP-
ERATION.
AFFECTED MODULES: SYSTEM
C
0
E
F
SYSTEM
100.0
100,0
100.0
100.0
720 720
SYSTEM
99.0
100.0
100.0
99. P
744 720
11 / 76 A
B
C
263
-------
EPA UTILITY FGB SUPVFY: DEC£l»bER l97f - JANUARY 1979
SECTION 3
DES1CN AND PERFORMA^E DATA FOR OPERATIONAL F6D SYSTEMS
pERf ORMANCF DATA ""
PERIOD MODULE AV'ILABHITY OPERAPILITY ttLIABlLITV UTILISATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
D
I
f
SYSTEM
3P.O
10D.O
100.0
720 277
• * PRObLEPS/SOLUTlONS/COMMENIS
START DATE 11/76 tOUI H" ENT: BOI LFR-RELATF I)
END DATE 11 /76 COHM INTS:
A THPEE Wf.tK CIITA6E OCCURRFD CUE TO A FURNACE IMPLOSION.
AFFCCTED MODULES: SYSTFP
12/76
** PROBL£»"S/SOLUT10NS/COMI«IENTS
START DATE 11/76 tetlf^ENT: F6D SYSTEM, GENERAL
END DATE 11/76 COHMI-NT: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTAGE
DliRING THE OU1AGE SCALE THROUGHOUT THE FGD SYSTEM WAS REMOVED.
AFFECTE& ffCtUl ES: SYSTEC
•• P«OBLE»»S/SOLUT10HS/COI«IWENTS
START DATE 11/76 E6UIFMENT: STACK
END DATE 11/76 PDOE>tFn: DESIGN-RELATED INFERIOR CONSTRUCTION MATERIAL
DtRING THE THI^EE WEEK OUTAGE THE UNIT 1 CHIMNEY FLUEs WERE INSPECTED. THE
A-S1DE FLUF PCLYESTER LINING MATERIAL WAS FLAKING OFF AND ACID ATTACK WAS
STARTING TO CCRRODE THE CAPBON STfcfL FLUE. THE LINING SUPPLIER IS INVESTI-
GATING THE PR (CLEM.
AFFECTED MODULES! SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 11/76 tCUII-TENTl MIST ELIMINATOR
END DATE 11/76 F'ROeUM: CHEMI C AL-RELA TF D PLUGGING
DURING TH[; OUTAGE THE PLUGGED MIST ELIMINATORS WERE CLEANED.
AFFECTtD MODULES: SYSTEM
A
b
C
D
E
F
SYSTEM
1/77
C
D
I
f
SYSTEM
100.0
95.0
92.0
77.0
91.0
9?.G
VI. 0
100.0
100.0
51.0
74.0
98.0
9T.O
91. 0
97.0
£9.0
g?.0
68. D
89.0
64.0
61.0
744
744 675
** PROBLEMS/SOLUTION S/CCCMEM S
START OATi 1/77 SCUK*ENTs F6D SYSTFK, MINERAL
END DATf 1/77 PSOBIFH: WEATHIR-RiLATID COMPONINT FAILURE
StVERI W1NTI.R feEATHER MDi OPERATION OF THE OUTDOOR F6D SYSTEM WfRY 61FFI-
FICULT ANti AFfFOTfcD THE RELIA6ILITY OF THE UNIT.
AFFECTED MODULtS: SYSTEM
•* PROBLEMS/SOLUTIONS/COMMENTS
START 6ATE 1/77 t6U f;«ENT: THICKEMR
END DATE 1/77 PROBLEMS MECHANICAL-RELATED COMPONENT FAILURE
DLR1N6 THt FltST PART OF THE MONT* THE THICKENER RAKE MECHANISM JAMMED AND
CCULD NOT B[ IEPAISID. THE TH1CKFNER WAS OPERATED FOR APPROXIMATFLY THREE
WtEKJ WITH THC RAKE STOPPED UNTIL THE UNIT 2 THldCfNER COUUD BE PUT INTO
EftERCENCY EFFUCE.
AFFECTED MODULES: SYSTEM
2/77
77.0
69.0
70.0
65.0
56.0
264
-------
EPA UTILITY FfiO SURVEY: DECEMBER 1978 - JANUARY i
-------
EPA UTILITY FtD SURVEY: DECtHPFF 1ENT: F6D SYSTEM, GENERAL
END DATE 5/77 COMMENTS:
THE UNIT kAS STARTED UP ON MAY 21 USING D, E, AND F MODULES DUE TO REPAIRS
BEING MADE TO THE A-SIOE CHIMNEY FLUE.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
iTApT DATE 5/77 EQUIPMENT: REAGENT HANDLING
END DATE 5/77 F'F'OB | E M : NOT D E F IN ED/SPE Cl F I ED
THERE HERt PRC6LEMS SLAKING L1M£ AND GETTING MAGNESIUM LEuELS BUILT UP IN
THE SCRUBbEH RECYCLE LOOPS AFTER STARTUP.
AFFECTED MODULES: SYSTEM
266
-------
EPA UTILITY F6D SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFOfcMA«E DATA FOR OPERATIONAL FGD SYSTEMS
... ...... . PERFORMANCE DATA •
PERIOD MODULE AVAILABILITY OPERABIL1TY PLIABILITY UTILIZATION
X REMOVAL PER BOILER FED CAP.
S02 PART. HOURS HOURS HOURS FACTOR
6/77 A
B
C
D
E
f
SYSTEM
94.0
95.0
90.0
100.0
100.0
97.0
94. C
90.0
720 6*9
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE K/77 EGUIFMENT: STACK
END DATE 8/77 PKOfUfc'M: NOT DE FINED /SPECI F IE6
Oti AUGUST 1t 1HE 1A CHIMNEY FLUE LINER REPAIRS WERE COMPLETED AND THE A, B
AkO C TRAINS kfRE STARTED UP.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTION WCOMMENTS
START DATE 8/78 E.CUI f* ENT: FAN
END DATE */7£ PPCB(.fn: NOT DEFINED/SPECIFIED
SEVERAL REPAIfS WERE MADE TO TH £ ID FAN HOUSING THIS MONTH.
AFFECTED MODULES: SYSTEM
•« PROBLEMS/SOLUTIONS/COMMENTS
START HATE £/77 teUI(»»ENT: FCD SYSTEM, GENERAL
END DATE */77 COfllONTS:
THE AVFRAtf 512 REMOVAL EFFICIENCY FOR THE MONTH WA$ 86. 7 X BASED ON THREE
6KAB SAMPLES.
AFFECTED MODULES: SYSTEM
** PR06LEMS/SOLUTIONS/CCMMENTS
START DATE F/77 i GUI FWENT: FGD SYSTEM, GENERAL
END DATE
M77
YORK RESEAPCH BEGAN SETTING UP EQUIPMENT TO CONTINUOUSLY MONITOR THE 502
REMOVAL EFFICIENCIES AS PART OF AN EPA RESEARCH PROJECT TO DETERMINE FEA-
SIBLE NSPS FOh FGD.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE f/77 tCKJIIKENT: PROCESS CONTROL
END DATE l>/77 COMMENTS: RESEARCH AND DEVILOPMENT
EXTENSIVE MOD iriCATIONS ART PEINfi MADE IN THE PH CONTROL SYSTEMS IN AN EF-
FORT TO DtVlSl A WORKABLE PH CONTROL SYSTEM.
AFFECTED MODULES: SYSTEM
7/77 A
e
c
D
E
F
99.0
9
-------
EPA UTILITY FfcD SUSVEY: DECtMBER
- JANUARY 1979
SECTION 3
OESICN AND FERFOfKAKE DATA FOR OPERATICNAL FOD SYSTEMS
PERIOD MODULE AVAILABILITY OPEPARILJTY
PER FORM AN Cf DATA «...
I-EIIABILITY UTILIZATION X REMOVAL PER BOItER f6D CAP.
SOZ PART. HOURS HOURS HOURS fACTOS
D VJ.O 100.0
E 95.0 99.0
F 88. 0 95.0
SYSTEM
93.0
9?.f1
85.0
66.7Q
744
69Z
*« PROBLEMS/SOLUTIONS/COMMENTS
START DATE S/77 [CUIfENT: BOILFR-RELATED
END DATE t /77 COMM cNTSr
UMT 1 WAS DO* FR00 AUGUST 13 TO 15 BECAUSE OF BOILER TUBE LEAKS.
AFFrCTED MODULES: SYST11"
9/77
A
a
c
D
I
f
SYSTEW
£7.0
62 .0
81.0
57. .0
50.0
43.0
97.0
95.
AFFECTED MODULES: SYSTEM
11/77
95.0
99.0
91.0
95.c
99.0
91.0
95.0
99.0
91.0
268
-------
EPA UTILITY FGD SURVEY; DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERfORMAkCI DATA FOR OPERATIONAL FGD SYSTEMS
.„..—— — ———— PERFORMANCE 6 AT A
PERIOD MODULE AVAILABILITY OPERABILITY RELIABILITY UTILIZATION
X REMOVAL PER BOILER FFD CAP.
SO? PART. HOURS HOURS HOURS FACTOR
D
E
F
SYSTEM 720 720
** PRObLEMS/SOLUTlONS/COMMENTS
START DATE 11/77 tflUUMENT: STACK
END DATE 11/77 COMMENTS:
REMOVAL Of T«r OLD COATIN6 AND PRIMING OF THE FLUE LINING IN FLUF IB IS
PROCEEDING SLCWER THAN ANTICIPATED. IT IS EXPECTED THAT TOTAL WORK ON THE
FLUE WILL NOT PE COMPLETED UNTIL FEBRUARY OR MARCH 1978.
AFFECTED MODULES: SYSTEK
U/77 A
6
C
D
E
100.0
93.0
99.0
1CO.O
94.0
100.0
91 .C
79.C
91.0
SYSTEM
6?6
** PROBLEMS/SOLUTIONS/COMMEN1S
START DATE 12/77 tGUIFKENT: STACK
END DATE 12/77 COMMENT: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTA6E
SANOpLASTIhfi f.f UNIT IFi FLUfc IS NtARING COMPLETION. THE FLUE WILL HF RE-
LINED WITH CXt-2000.
AFFECTED HOCULES: SYSTFM
0/7B SYSTEM
** PROBLEMS/SOLUTIONS/COMHtNTS
START DATE 0/78 t&UIfMENT: F£D SYSTEM, GENERAL
END DATE 0/76 COM (NTS :
N(iTE: AN ATTFWf'T IS ALWAYS MACE TO 8 E 61 N OPERATION OF THF POILFR AND FGD
SYSTtM SIMULTANEOUSLY AT BRUCE MANSFIELD. OCCASIONALLY PROBLEMS DE-
LAY POllfR STARTUP MAKING 11 POSSIBLE FOR MONTHLY FGD MODULE HOURS
TO EXCEED ACTUAL BOILER HOURS.
AFFECTED MODULES: SYSTEM
1/78
A
B
C
D
E
F
SYSTEM
100.0
100.0
100.0
100.0
58.0
74 A
371
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 1/78 ECUIFfENT: BOILFR-RELATE0
END DATE 1/7& COM* (NTS:
THE UNIT TRlPfED SEVERAL TIMES »«E TO DIFFICULTIES IN BURNING WET STOCK-
PILE COAL.
AFFECTED MODULES: SYSTEf
** PROBLEMS/SOLUT10NS/COI«MENTS
START DATE 1/78
END DATE
FAN
1/78 Pf:CBit>,: CHEMICAL-RELATED EROSION
ThERF WERE PRCF-LEKS WITH THE IB T™ WHICH NECESSITATED EXTENSIVE REPAIRS.
L1NIN6 ABRASKh AND DISEsONDMENT IK FAN CAUSED CORROSION OF UNDERLYING SUP-
PORT KFTAL.
AFFECTED MODULES: SYSTEM
2/78 A
B
C
D
79.0
61.0
82.0
100.0
£0.0
100.0
79. C
61 .0
82.0
269
-------
EPA UTILITY FED SURVEY: DECEMBER l97f - JANUARY 1979
SECTION !
DtSlCN AND PfRFOPMAhCE DATA FOR OPERATIONAL FI5D SYSTEMS
PERIOD MODULE AVAHABILITY CPCMML1TY
PtRFORMANCF BAT A
UTILIZATION
„»», •»«» .J",
£
F
SYST6*
672 414
** PR06LEMS/SOLUT10NS/COHKENTS
START DATE ?/78 CGUIItENT; F6D SYSTEM. PENERAL
fND DATE ?/78 COMWINTS:
FMENSIVE CEPtjRS TO THE 1F< ID FAN AND THE EMERGENCY NEED FOR LOAD FROM
THE PLANT DURING TH F COAL STPJITE TEMPORARILY OVERLOADED THE 1A AND 1C
TRAINS.
AFFECTED "OrULFS: f( A C
START OATF 2/7S EcimrENT: FAN
tNO DATf 2/7f< FPOBird: NOT DE FIKED/S Pr CI F JED
EXTENSIVE RfP,«IRS TO THE 1p ID FAN WERE NECESSARY-
AFFECTED WODULtS: fc
** PKO&LEKS/&OLUTIONS/COMMENTS
START BATE 2/78 16UKCENTS MIST ELIMINATOR
END DATE lilt PPOPLfH: HE CHA NIC AL-Rf L ATP D COMPONENT FAILURE
T*E flST ILIBlNATOd WILL BE REPLACED ON THE 1C TRAIN AS A RESULT OF THE
TEMPORARY OVEROAD THAT OCCURRED CN THE 1A AND 1C TRAIN DURJN6 THE PFRIOt.
AFFECTED RODULES: c
START DATE Z/78 ECUIH«ENT: STACK
£ND DATE ?/7fc CCMUcK'T: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTAGE
m 1ft FLUf R[LlN]NC CONTINUED.
AFFECTED NODULES: SYSTEM
3/78
A
e
c
D
E
f
SYSTEM
**
43.0
91.C
90.0
65.0
50.0
60.0
47.0
9ft.0
97.0
70.0
54.0
65.(1
45.0
91.0
90.0
65.0
50.0
60.0
744 689
START DATE 3/78 IfibllTENT: STACK
END DATE 3/7? CCMKH.NT: PREVENTIVE MAINTENANCE SCHEoULfD UNjT OUTAGE
REPLACEMENT 01 THE LINING IN THE 1B CHIMNEY KITH CXL 2000 WAS COMPLETED.
AFFECTED MODULES: SYSTEM
** PROBLEHS/SOLUTIONS/COKMENT*
START DATE 3/76 tGUIFMENT: FAN
END DATF 3/78 F'RCBirM: NOT DE FINED /SPE CI F IED
REPAIRS WERE MDE ON THE A, B AND C FAN HOUSINGS.
AFFECTED MODULES: SYSTCH
4/7E
A
e
c
D
E
r
SYSTEM
74.0
88.0
49.0
67.0
97.0
94.0
74.0
es.o
49.0
67.0
97.0
94.0
74.0
Bfj.0
49.0
87.0
97.0
94.0
720 7ZO
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 4/78 EQUIPMENT: FAN
END DATE 4/76 PROBLEM: NOT DEFINED/SPECIFIED
MISCELLANEOUS LEAK REPAIRS HERE DONE ON FAN HOUSINGS.
AFFFCTED MODULES: SYSTtM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 4/78 COUIfHENT: GAS PAMPER
END DATE 4/78 PRCPLfM: NOT DEFINED/SPECIFIED
370
-------
EPA UTILITY FGO SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORM«E DATA FOR OPERATIONAL FGD SYSTEMS
........ . — PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABUITY PLIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
MISCELLANEOUS LEAK REPAIRS WERE MADE TO
AFFECTED MODULES: SYSTEM
5/7B
6/7?
A
e
c
6
E
F
96. 0
98.0
91.0
9?.0
9?.C
97.0
97.0
85.0
84.0
86.0
59.0
59.0
52.0
53.n
53.0
SYSTEM
744 457
** PRObLEMS/SOLUTlONS/COMMtNTS
START DATE 5/76 IGUIFKCNT: F6fr SYSTEM, {.ENtRAL
END DATE 5 lit- COMMENTS:
ThE ANNUAL EO}LER INSPECTION OUTA6E BEGAN ON MAY 20.
AFFECTED MODULES: SYSTtM
«* PROBLEMS/SOLUTIONS/COMMENTS
START DATE 5/78 EQUIPMENT: FAN
END DATE 5/76 F>PCBlEM: NOT DEFINED/SPECIFIED
EXTENSIVE REPAIRS WERE MADE ON THE 16 FAN.
AFFECTED MODULES: SYSTEM
7/78
6/78
9/7S
11/78
A
B
C
D
E
F
SYSTEM
1DO.O
100.0
100.0
100.0
720
** PRC8LEMS/SOLUTION&/COMMENTS
START DATE 6/78 tBUIPMENT: HOILER-RFLATED
END DATE */7f COMMENTS :
THE DNJT OOTAfF TjME WAS FOR BOILER INSPECTION AND 6ENERATOR STATOR COOLER
REPAIRS.
AFFECTED MGDULfcS: SYSTEM
** PROBLEMS/SOLUTJONE/COMMENTS
START DATE 6/77 fCUIfPENT: F6D SYSTEM. eENERAu
END DATE 6/77 CCMM LNTSs
ALL OUTAGES EXPERIENCED RY THE UNIT THIS MONTH WERE F60-RELATED.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONE/COMWEN15
START DATE fr/77 E6Uirf«ENT: MIST ELIMINATOR
END DATt 6/77 PPOELfM: CHEM1CAL-RELATFD PLU6GIN6
HORIZONTAL hiST ELIMINATOR PRESSURE DROPS INCREASED TO THE POINT THAT NEW
MIST ELIMINATE MODULES WERE INSTALLED ON Dt E AND F SCRUBBERS AND D AND E
ALSORBERS.
AFFECTED MODULES: D E F
SYSTEM
SYSTEK
SYSTEM
SYSTEM
SYSTEM
SYSTEM
** PR06LEMS/SOLUTIONS/COMMENTE
START DATE 12/76 EOUI f-rENT: FGD SYSTEM, GENERAL
END DATT 1 IT) COMM tNTS:
7*4
744
720
7*4
7HO
744
Z71
-------
FPA UTILITY ftD SURVEY: DCCtf&FR 197f - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FGD SYSTFMS
PERFORMANCE DATA
PERIOD HODULt AVAILABILITY CURABILITY t-eLIAE-ILITY UTILIZATION * REMOVAL PER BOILER FGD CAP.
502 PART. HOURS HOURS HOURS FACTOR
NC I^iFORI',AT10^ WAS AVAILABLE: FOR THIS REPORT PFRIOD.
AffECTED MODULES: SYS*
1/79 SYSTff 74*
272
-------
tPA UTILITY F66 SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PER FORM ItCE DATA FOR OPERATIONAL FGD SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICIPATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - ht/J
NET PLANT GENERATING CAPACITY - MW
6POSS UNIT GENERATING CAPACITY - fik
NET UNIT GENERATING CAPACITY V/FGD - Mt
NET UNIT GENERATING CAPACITY VC/FGD - '^
EQUIVALENT SCRUBBED CAPACMY - MU
** BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATt
MAXIMUM BO HER FLUE GAS FlOW - ft."/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAMETER - M
«* FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - KJ/K6
RANGE HEAT CONTENT - B1U/LB
AVERAGE ASH CONTENT - i
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - *
RANGE MOISTURF CONTENT - X
AVERAGE SULFUR CONTENT - *
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTEUT - X
RANGE CHLORIDE CONTENT - *
FUEl FIRING RATE - * T/H
FUEL FIRING RATf - M V
** PARTICIPATE SCRUPBER
NUMBER
TYPE
SUPPLIER
SHELL MATERIAL
LINING MATERIAL
INTERNAL MATERIAL
TYPE OF NOZZLFS
BOILER LOAD/SCRUPP If - 7,
FLUE GAS CAPACITY - CU.C./S
FLUF 6AS TEMPFRATURF - C
LI6UIB RECIRCl'LATIOK R*TE - LITER/J
L/6 RATIO - LITER/CU.I"!
PRESSURE DROP - KPA
SUPERFICIAL GAS VELOCITY - */S
PARTICULATE DESIGN REMOVAL EFFICIENT
S02 INLET CONCENTRATION - PPM
SOZ OUTLET CONCfNTRATICN - PPM
S02 DESIGN REMOVAL EFFICIENCY - I
** FGD SYSTEM
SAlFABLt PRODUCT/THROUAWAY PRODUCT
GENERAL PROCESS TYPF
PROCESS TYPE
PROCESS ADDITIVFS
SYSTEM SUPPLIER
A-E FIR«!
DEVELOPMENT LFVEL
NEW/RETROFIT
PARTICULATE DESIGN REMOVAL EFFICIENCY
Sfl2 DEjIfeN PEMOVAL EFFICIENCY - i
COMMERCIAL pATE
INITIAL START-UP
• OM LP/MMETU)
.600 LR/MMBTU)
PENNSYLVANIA POwER
BRUCE MANSFJELo
i.
SHIPPjNGPORT
PENNSYLVANIA
B
15. {
?5R. (
2751.0
017.0
825.0
880.0
917.0
FOSTER UHEELER
SUPERCRITICAL, PULVERIZED COAL, BALANCED DRAFT
BASE
0/77
1580.86 (3350000 ACFB)
( 285 F)
HC.6
J90.
BITUMINOUS
267*9.
12.90
11.5-13.5
7.00
5.5-P.5
7.00
1.75-3.75
******
•501 .1
*****
( 950 FT)
(***** FT)
{ 11500 BTU/LB)
11000-11050
TPH)
VARIABLE THROAT VENTURI
CHEMJCO
CARBON STEFL
POLYESTER FLAKEGLASS
317 <=S AND SS WITH FLAKE6LASS LINING
TANGENTIAL fEED CSET AT THROAT. SET AT BOTTOM]
17.0
267.5 < 558333 ACFp)
140.6 ( 285 F)
1386.0 (2200C 6PM)
F.3 (40.0 6AL/1000ACF)
5.7 < 2? 1N-H20)
61.0 ( 200.0 FT/S)
- X 99.8
3n9C.oon
-------
EPA UTILITY FGD SURVEY: DECtMPFR 19?f - JANUARY 1979
SECTION J
DESIGN AND PER1CPU A'C£ DATA fOR OPERATIONAL FED SYSTEMS
•• AbSORBFR
MUMPER
TYPE
INITIAL START UP
SUPPLI IR
DIMENSIONS
SHELL MATERIAL
SHELL LINER MATERIAL
1NTFRNAL MATERIAL
NOZ7LF TYPE
BOILER LOAD/ABSORBER . X
GAS FLOV - CU.M/S
CAS TEMPERATURE - c
LIQUID RECIRCULAT10N RATE - LITfR/!
L/G RATIO - L./CU.H
PRESSURE CROP - KPA
SUPrRFICAL 6AS VELOriTV - K'/SFC
S02 INLrl CPNCENTP A1 If r - FPI":
SO 2 OUTLET CONTRfTKt, - rpf
S02 DESlbN REMOVAL FfFiClFNCV - X
** FANS
TYPf
CONSTRUCTION MATERIALS
SERVICE - WET/DRY
FIXED THROAT VENTUR1
7/77
CHEMlcC
34 DIA X 51.' HIGH
CAPBON STEEL
POLYFSTER FLAKE6LASS
CARbON STEEL, FLAKEGLASS
TANGENTIAL FEED
17.0
201 .31
5?.8
f .0
?.D
3C.5
930
ACFM)
< 127 F)
(19*00 GP")
( 45.0 6AL/100DACF)
( £.0 IN-H20)
dfO.O FT/S)
6
I .0.
HOUSING-RUBBER LINED C.S.; BLADES INCONEl
WET
** MIST ELIMINATOR
KUMPER
TYPE
CONSTRUCTION MATERIAL
CQNF IGURATION
NUMFER Of STAGES
NUMPER OF PASSES
VANF SPACING - CM
VANE ANGLES
yASH SYSTEM
SUPERFICIAL 6AS VELOCITY - M/S
PRESSURE DROP - KPA
** MIST ELIMINATOR
NUMBER
TYPE
CONSTRUCTION MATERIAL
CONFIGURATION
NUMP.ER OF STAGES
NUMF:ER OF PASSES
VANE SPACING - CM
VANF ANGLES
WASH SYSTEM
SUPERFICIAL 6AS VELOCITY - M/S
PRESSURE DROP - KPA
** PROCESS CONTROL CHFNJETkY
CONTROL VARIAPLTl
CONTROL RANGE
CONTROL MANNER
MODE
SENSOR LOCATION
** PUMPS
SERVICE
SCRUBPER RECYCLE
SCRUBBER RECYCLE (SPARE)
LIME SLURRY TRANSFER
******
ABSORBER RECYCLE
ABSORBER RECYCLE (SPARt'
THICKENER UNDERFLOW TO MIX TANK
THICKENER TRANSFER
CHEVRON-ABSORBER
FRP
HORIZONTAL (2-SHAPE)
1
4
7.6 ( 3.00 IN>
90 DtG.
OVERSPRAY/UNDERSPRAY, ONE/SHIFT FOR OVtRSPRAY, C
3P.5 (100.C FT/S)
.1 C .3 1N-H20)
CHEVRON-SCRUBBER
FRP
HORI70NTAL C2-SHAPE)
1
4
7.6 < 3.00 JN)
90 DEG.
OVFRSPRAY/UNDERSPRAY, ONCE/SHIFT FOR OVfRSPRAY,
30.5 (100.P FT/S)
.1 ( .J IN-H20)
PH SLURRY SOLlDSt Ll«UJD LEVEL, LIOUIO FLOW
PH 6.8-7.2
AUTOMATIC
FEEDBACK
PH-RECIRCULAT1N6 LINES AND THICKENER
NUMBER
274
-------
EPA UmiTY C6fl SURVEY! BltfWBiR 1978 • JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FfiD SYSTEMS
** TANKS
SERVICE
THICKENER UNDERFLOW
MIXING TANK ICALCUOX & THCKNR UND
SLUDGE TRANSFER
HIKING TANK [SPENT SLUfcRY & FLYASH ,
RECYCLE (SCRUPBER)
RECYCLE (ABSORBER)
** RIHfcATER
TYPE
TEMPfRATURfc ROOST - C
ENER6Y
NUMBFR
*»**
2
****
****
6
6
BISECT COHIUSTION
2?,2 (
28 BTU/H
40 F>
** THICKINEP
NUMBER
TtPf
CONSTRUCTION MATERIAL
DIAMETER - 1
OUTLET SOLIDS - X
** WATER LOOP
TYPE
** REA6ENT PREPARATION EQUIPMENT
NUMPER OF SLAKgRS
SLAKER CAPACITY - M T/K
** TREATMENT
TYpF
SUPPLIER
CONTRACTOR
PRODUCT CHARACTERISTICS
•* DISPOSAL
NATURE
TYpr
LOCATION
TRANSPORTATION
AREA - ACRES
CAPACITY - CU.M
1
RAKE
CARSON STEFL
61.0
30.0
2
2.0
«200 FT)
Tf-H)
CALCILOX
PROPRIETARY
DRAVO
CONSISTENCY OF 6R«NULAR SOIL
FINAL
LAMDFILL
OFF-SITE
PIPE
1*00.0
599270QOO («
-------
UTILITY f6D SURVFY: DECEMBER 1°7f - JANUARY 1979
SECTION 3
DESIGN AND FERFORMAKCE DATA FOR OPERATIONAL F6D SYSTFMS
PtRFORMANCF: DATA ' " •
PERIOD MODULF AVA1LAPJLITY CFERABIUTY rf'LIABUITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
REPAIRS UtRE MOF TO THE ZP F|.UE STACK BECAUSE OF THE PREMATURE FAILURE OF
SEVERAL TtST MTCHES.
AFFECTED MOHUltS: 2y
11/77
*« PRObLEMS/SOLUTlONS/CONMENTS
START DATE 10777 LCUIFhENT: 60KER-RELATF D
END DATf 10/77 PPOBlEfll NOT DEFINED/SPECIFIED
TK UNIT TSlPfED DUE TO FAULTY 6FNERATOR CONTROL TRANS'ORHERSc
AFFECTED MODULES: SYSTEK
2B
2C
?D
PE
?F
SYSTEM
100.0
96.0
66.0
*7.0
55.0
47.0
100.0
100.0
92.0
57.0
53.0
6?. n
81. n
74.0
46.0
4?.P
J4.0
730 5«1
«* PROaLENS/SOLUTlONS/COMMENTS
START DATE 11/77 £CUI M1ENT: BOI Lf R-RELATE C
END DATE
11/77
f-RCPlfW: NOT DEFINED/SPECIFIED
ASSOCIATED WITH THE STATION POytR TRANSFORMERS CAUSED LIMITATION
IK LOAD Oh UNIT 2. THREE OF THE SIX STATION POWER TRANSFORMERS FOR UNIT ?
UtRE DESTROYED
AFFECTED MODULES: SYSTEM
12/77
76
?F
SYSTEM
74.0
99.0
98.0
100.0
89.0
99.0
77.0
100.0
100.0
100.0
65.0
93.0
86.0
83. P
£6.0
69.0
76.0
744 607
PROBLEMS/SOLUTIONS/COMMENTS
ST*RT KATE 1Z/77 tOUItMENTs PIPIN6
«ND DATE: 12/77 FPOPUM: NOT DEFINED/SPFCIFIED
CCLD UEATNfK CAUSED SOME PROBLEMS IN PROCESS PIPING.
AFFECTtD MODULES: SYSTtf
1/7E
?A
?D
?E
?F
SYSTEM
95.0
100.0
96.0
94.0
99.0
99.0
58.0
100.0
56.0
100.0
100.0
96.0
31.0
76.0
Z9.0
70.0
64.0
50.0
744 391
*« PR06LEMS/SOLUTIONS/CCMMENTS
START DATE 1/78 tOUIIWENT: BOILFR-RELATE D
END DATE 1/78 PKOBliM: NOT DEFINED/SPECIFIED
T*t UNIT TR1PI1D SEVERAL TIMES DOE TO DIFFICULTIES IN BURNING WET STOCK-
PILE COAL. WHTN THE UNIT WAS ON LINE DURING THIS MONTH, THE MET COAL ALSO
PREVENTED FULL LOAD OPERATION OF COAL MILLS.
AFFECTED MODULES:
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 1/76 ECUIfMENT: BOILER-RELATED
END DATE 1 /7£ PROPtE«: NOT DEFINED/SPECIFIED
BOILER CONTROL VALVE ("W" V*LVE> PROBLEMS COMPO^NtEO $T*R T~UP 61 FF1 CWLTIES
2/7P
2A
?C
?C
20
64.0
87.0
89.0
97.0
46.C
6R.O
88.0
71.0
48.0
66.0
88.0
71.0
276
-------
tPA UTILITY FGD SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFOPMAhCE DATA FOR OPERATIONAL FGD SYSTEMS
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY CPERABU1TY DELIABI LIT Y UTILIZATION
* REMOVAL PER BOILER FED CAP.
S02 PART. HOURS HOURS HOURS FACTOR
2E
2F
SYSTEM
99.0
78.0
99.0
78.0
99.0
78.0
672
672
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 2/78 E.6UI PMENT: FAN
END DATE 2/78 PfOBUM: NOT DE FINED/S PFC1F I ED
M/iNY PROBLEMS OCCURRED WITH I.D. FAN COOLERS DUE TO INCLEMENT WEATHER.
AFFECTED MODULES: SYSTIM
** PROBLEWS/SOLUTIONS/COKMEN1S
START DATE 3/78 t«UI IflENT: BOILER-RELATED
END *ATE 3/7E F-ROP (.<:*•« NOT D E FINtD/SPE CI F I fcrO
A BOILER TUBE LEAK CAUSED SEVERAL DAYS' OUTAGE.
AFFECTED MODULES: SYSTIM
3/78 ?A
2B
2C
?D
2E
?F
SYSTEM
100.0
97.0
1^.0
95.0
95.0
97.0
100.0
91.0
10.0
1CO.O
96.0
99.0
67. tl
60. 0
13.0
68.0
64.0
65.0
744 494
4/78
*« PROfaLEMS/SOLUTIONS/COMMENIS
START DATE 3/78 E6UIIMENT: FAN
tND DATE 3/78 PPOP.LrM: NOT DEFINED/SPECIFIED
[XTENS1VE I.D. FAN HOUSING REPAIRS WERE PERFORMED ON THE 2C FAN.
AFFECTED MODUltS: 2C
2A
2B
?C
?D
2E
2F
SYSTEM
100.0
100.0
59.0
15.0
H.O
17.0
82.0
82.0
59.0
15.0
14.0
13.0
£1 .0
81.0
59.0
15.0
14.0
13.C
720 713
t* PROBLEMS/SOLUTION S./CCKMENU
START DATE 4/7R tOUIt'MENT: STACK
LND DATE 4/7f F'ROPUM: CHEMICAL-RELATED EROSION
ChlMNFY FLUE L1NINING REPAIRS ON 2H APRIL 5.
AFFiCTED MODULES: 2R
** PROBLEMS/SOLUTIONS/COHMENTS
START DATE 4/78 F6DI t^ENT: FAN
END DATE 4/78 PFOPltR: NOT D E F IK' ED/SPS CI F I tD
EXTENSIVE REP*IRS WERE MADE ON THt 2C I.D. FAN, CAUSING IT TO BE DOWN FROM
MARCH A THPOIHH APRIL 13.
AFFECTED MODULES: 2C
** PRObLEMS/SOLUTIONS/COMMENTS
START DATE 5/78 tOUIIKENT: STACK
END DATE 5/7B PROBI.KM: CHEMICAL-RELATED EROSION
21 STACK LiNjw. REPAIRS CONTINUED.
AFFECTED MODULES: ?B
5/7P 2A
?B
?C
?D
2E
2F
SYSTEM
100.0
100.0
100.0
100.0
100.0
100.0
37. P
37.0
37. f!
744 270
** PRO&LEMS/SOLUTIONS/COMMENTS
START DATE 5/78 EClllI F'f ENT: FAN
END DATE 5/78 PRORIFM: NOT DEFINED/SPECIFI ED
277
-------
fP» UTILITY FbP SUFVfY: D£C£Mnif> ic?j . JANUARY 1?79
SECTION I
OfSlt-N AND PERF OfidAtvCE DATA FOR OPERATIONAL FGO SYSTEMS
.„ --PEftFORMANCf DATA- — - " '
PERIOD MODULf AUAILAHHITY CPERA&H11Y '(LIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAT.
SOJ PART. HOURS HOURS HOURS FACTOR
»"•«»«• *»•><•»* •>••*•••••!•••>• • •»»*«••«»«*• 4,»w«H.w»«<»a>« WM«WW»*>MM*>M i»»t m mm •• — •*" •.••••* •»•< •— •»• —*••« • ••»•••
Ur t'MT fcAS ifF-LINf FOR 7 WEEKS FOR REPAIRS TO THE 2C I.D. MN, 1NCLUD-
INC. COVERIN6 1HE HOUSING WITH jNCOtOY 825.
AFFECTED MODULES: 2C
2A 70.o 100.0 rc.o
2B 69.0 100.0 69.0
?C 66.0 100.0 66.0
n
SYSTEM 720 417
•• PROBlifS/SOLUTIONS/COMMENTS
START DATE H7f (SUHHiNTt STACK
END D»TE «/7!i FROfiUM: C HtMl C AL-RF,LATr D EROSION
2i: STACK LIMM: REPAIRS CONTINUED.
AfFFCTED MODULES: ?R
*» PROtatCS/SOLiniONS/COMMf Nl £
START DATE 6/7K EUUirrENT: F6D SYSTEM, GENERAL
END DATC 6/78 COHMlNTSs
*NOTf: AN ATTIMPT IS ALWAYS MADE 10 BEGIN OPERATION Of THE BOILER AND F6D
SYSTEM SIMULTANEOUSLY AT PKUCE MANSFIELD. OCCASIONALLY PROBLEMS
DELAY 1'OILtR START-UP, MAKING IT POSSIBLE FOR MONTHLY F6D MODULE
HOURS 10 F.XCFED ACTUAL BOILER HOURS.
AFFECTED MODULES: SYSTEM
744
720
744
7?U
744
• • PROPLEMS/SOLUTIONS/COMHENU
START DATE 12/7J! 16UI FHENT: FGD SYSTEM, 6ENERAL
END DATE 1 IT) CCKf (NTS:
NC INfORMATIO* WAS AVAILABLE FOR THIS PERIOD.
AFFECTED MOtlULkS; SYS*
1/79 SYSTEM 744
7/78
8/7F
9/7P
10/78
11/7f
12/78
SYSTEM
SYSTfK
SYSTEM
SYSTEM
SYSTEM
SYSTEM
278
-------
EPA UTILITY F6D SURVEY: DECFNBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMAKCE DATA FOR OPERATIONAL FGD SYSTEMS
COMPANY NAHf
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - KG/J
S<32 EMISSION LIMITATION - NG/J
NET PL*NT GENERATING CAPACITY - nw
6ROSS UNIT GENERATING CAPACITY - flk
NET UNIT GENERATING CAPACITY V/FGD - «V.
NFT UNIT GENERATING CAPACITY WC/FGC - i*H
E6UIVALFNT SCRUBBED CAPACITY - l»«
** BQILFR DATA
SUpPLItR
TYPF
SERVICE LOAD
COMMERCIAL SERVICE DATE
HA-XIfUM BOILER FLUE GAS FLOW - Ctl.*/5
FLUF. 6AS TEMPF.RATURF. - C
STACK HEIGHT - »
STACK TOP DIAMETER - K
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERA6F HEAT CONTENT - KJ/KG
RANGE HEAT CONTENT - &TU/LE
AVERAGE ASH CONTENT - %
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - K
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
FUEL FIRING RATE - H T/H
FUEL FIRING RATE - NW
** PARTICULATE SCRUBBER
NUMF-ER
TYPE
SUPPLIER
NUMF-ER OF STAGES
SHELL MATERIAL
BOILER LOAD/SCRIJCBER - X
•* F6D SVS1EK
SALEABLE PRO OUCT/T HR OK AWA Y PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
SYSTEM SUPPLIER
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICULATE DESIGN REMOVAL EFFICIENCY
S02 DESIGN REMOVAL EFFICIENCY - X
COMMERCIAL DATE
INITIAL STAPT-UP
** ABSORBER
MUMPER
TYPE
INITIAL START W
SUPPLIER
NUMPER OF STAGES
BOILER LOAD/APSORPEP - t
GAS FLOW - CU.M/S
LlflUID RECIRCIJLATION RATE - LITER/S
L/G RATIO - L/CU.M
PRESSURE DROP - KPA
** REHEATER
TYPF
PHILADELPHIA ELECTRIC
EDOYETONE
1A
EDDYSTONE
PENNSYLVANIA
G
******
******
1395.0
120.0
130.0
* ******
120.0
******
******
BASE
**/**
*********
157.2
(****** LB/MMBTU)
(****** LR/HMBTUJ
COAL
******
31634.
9.40
******
5.90
******
?.60
<-»****»*
< 315 F)
(**** FT)
(***** FT)
( 13600 BTU/LB)
******
***** ***
******
*******
*****
VENTRI-ROD
tNV]PONEfRING
1
316L SS
25.0
SALEABLE PRflDUCT
WET SCRUBBING
MAGNFSIUM OXIDE
UNITED ENGINEERS
DEMONSTRATION
RETROFIT
99.00
90.00
9/75
9/75
VENTPI-ROD
9/75
ENV1RONEE-RING
<*** TPH)
3T.3
126.47
F43.
ft. 5
2.5
< 268COO ACF«>
(13384 GP«O
( 48.5 GAL/1000ACF)
(1C.O 1.N-H20J
DIRECT COMPUSTlON
279
-------
EPA UTILITY FGD SURVEY: DECEPBEI- 1971 - JANUARY 1979
SECTION 3
DEJlfcN AND PER FORMATE DATA F00 OPERATIONAL F6D SYSTEMS
** WATER LOOP
TYpf
FRESH MAKEUP WATER
** BYPRODUCTS
BYPRODUCT N*TUF CIL.
THERE ARE TUO FURNACES ON THf NO. 1 BOILER. EACH FURNACE WAS INSTALLED
WITH PARTICIPATE CONTROLS CONSISTING OF MECHANICAL COLLECTORS AND AN
ELECTROSTATIC PRECIPITATOR.
THF MAGNESIUM OXIDE-BASED FLUE GAS DESULFURIZATION (FGD) SYSTEM ON
8CILEP NO. 1 fT THE EDDYSTONE STATION OF PHILADELPHIA ELECTRIC CO. (PECO)
WAS DESIGNED 'ND INSTALLED BY UNITED ENGINEERS AND CONSTRUCTORS, INC., IN
CC-OPERATION UTH PHILADELPHIA ELECTRIC. THE SYSTEM CONSISTS OF THREE
FIRST-STAGE SCRUBBER MODULES IN PARALLEL FOR PARTICULATE CONTROL (TWO
EKVIPONEEtiING VENTRI-ROD SYSTEMS AND ONE PF ABOD Y-LURG1 VENTURI UNIT) AND A
SECOND-STAGE INVI RONEERING AtSOKFtR MODULE WITH TWO VENTRI-ROD BEDS FOR
SLLFUR DIOlDr REMOVAL.
THE THREE FIRST-STAGE SCRUBBERS ARE SIZED TO HANDLE ALL THE EXHAUST
FROM UNIT 1 UHCH HAS A WET GENERATING CAPACITY OF 316 MW . THE SECOND-STAG
AtSORBER IS S12ED TO HANDLE ONE-THIRD OF THE GAS FLOW EQUIVALENT TO
APPROXIMATELY 105 MW (NET). THE SYSTEM IS DESIGNED TO REMOVE 90 PERCENT OF
The SULFUR D10IDE FROM BOILER STACK GAS. A GENERAL PROCESS FLOW DIAGRAM
OF THE WET SCABBING SYSTEM IS PRESENTED IN APPENDIX 6.
SCRUF6ER OPERATING HISTORY
THERE kAS A BRIEF OPERATING PERIOD ON THE PARTICULATE SCRUBBERS FROM
MlD-NOVEMbfR, 1974 TO MARCH, 1975, THAT UNCOVERED A NUMBER OF PROBLEM
A*EAS. DUE TO A NUMBER OF EXTENUATING CIRCUMSTANCES, PARTICULATE SCRUBBING
WAS NOT RESTATED UNTIL JULY 23, 1975, WITH ONE PARTICULATF SCRUBBING TRAI
FCLLOWED EY TH OTHER TWO TRAINS, on AUGUST 15 AND OCTOBER 2, RESPECTIVELY
THE SULFUR DlCXlDE ABSORBER WAS ST*RTED FOR THE FIRST TIME ON OCTOBER E,
1975. AND THE MAGNESIUM OXIDE REGENERATION fACILjTY FIRST pRQDUCED MAGNE-
SIUM SULFITE ft-OM THE EDDYSTONE SCRUBBER ON OCTOBER 28t 1975.
THE MAGNESIUM OXIDE REGNERATICN FACILITY HAS BEEN OPERATED TO PROCESS
ALL MAGNESIUM SULFITE DOWNS AT THE EDDYSTONE SCRUBBER.
THE SULFU* DIOXIDE SCRUBBING SYSTEM WAS TEMPORARILY SHOT DOWN DECEMBER
31, 1975, BECAUSE THE ACID PLANT REGENERATION FACILITY AT THE OLIN CHEMICA
SLLFURlC ACID PLANT IN PAULSEORO, NEW JERSEY PERMANENTLY CEASED OPERATIONS
TfcE ACID FLAN! REGENERATION FACILITY WAS RELOCATED TO THE ESSEX CHEMICAL
PLANT IN NfWAktr, NEW JERSEY.
THE PARTICULATE AND SULFURE DIOXIDE SCRUBBING SYSTEM INSTALLED ON THE
280
-------
EPA UTILITt FGD SURVEY: OECtHSItR 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL F6D SYSTEMS
... --- .......... — ...... — ................p£Rf ORMANCE DATA ----- • ------------------ • ---------- - --------
PERIOD MODULE AVAILABILITY OPERABU1TY t-fLlKB I L1TY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
E6DYSTONE NO . 1 UNIT IS THf FIRST pHAsE OF A TWO-PHASE PROJECT. FOLLOWIN6
SICCFSSFUL Of VRLOP6MTN OF THIS SYSTEM WITH MORE CONTINUOUS OPERATION, IT
KILL BE INCORPORATED INTO THE DESI&N FOR THE COMPLETE SULFUR DIOXIDE
REMOVAL OK tOl'YSTONC NO. 2 AND ONE OF THE TWO EXISTING UNITS AT THf CROMBY
STATION.
ADDITIONAL INFORMATION AND DAI* CONCERNING THE OPERATION OF THE PAR-
T1CULATE AND t-HLFUR D10XIDP SCRUfBERS INSTALLED AT THIS PLANT ARF PROVIDED
IK THE PERFORMANCE TABLE THAT FOLLOWS.
AFFECTED MODULES: SYSTEM
11/74 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 11/74 tOUI FWENT: F6D SYSTEM, GENERAL
END DATE 6/75 COMMENTS: RESEARCH AND DEVELOPMENT
THE SCRUBBING SYSTEM AT THIS PLANT CONSISTS OF THREE PARALLEL SCRUBBING
TRAINS INCORP (RATING 3 WET PARTICIPATE SCRUBBERS AND ONE S02 ABSORBER
MODULE. ThERF WAS A BRIEF OPERATING PERIOD ON THE PARTICULATE SCRUBBERS
FROM MID-KCVEftiER 1974 TO MARCH 1975. PROBLEMS ENCOUNTERED CENTERED AROUND
It,! SCRUBEiEfc iCOSTEfi FANS AND THE FLUE GAS AND LIQUID CONDITIONS. THE
B-SIDE BOOSTE S FAN DEVELOPED HlfiH SHAFT VIBRATION WHEN STARTED FOR THE
FIRST TIME. THIS PROBLEM WAS DESIGN RELATED. INVOLVING AN EXCESSIVE CLEAR-
ANCE AREA BlTv-fEN THE SHAFT AND WHEEL UB. ALSO, EXTENSIVE CORROSION
DEVELOPED IN 1H E C-S1DE PARTICULATE SCRUBBER INTERNALS. THIS WAS CAUSED BY
LCW SCRUBBING SOLUTION PH LEVELS AND CHLORIDE LEVELS AS HIGH AS 2000 PPM.
THESE CONtjlTICNE COUPLED WITH THE THERMAL SHOCK OF A HOT START PROCEDURE
CAUSED THt COHOOSION. THIS PROEfLFK WAS AMELIORATED BY CAUSTIC ADDITION,
HIGHER BtOHOOMJ AND EMPLOYING A COLD START PROCEDURE. AT APPROXIMATELY TH1
TIME, A ChECKCl'T Of SOJ SYSTEM WAS CONDUCTED, BLISTERING AND PEELING OF TH
pOLYyRETHAMt COATINGS WERE DETECTED AND CORRECTED PY RECOATING WITH FLAKE-
GLASS.
AFFECTED MODULbS: SYSTtK
12/74 SYSTEM 74*
1/75 SYSTEM 7*«
2/75 SYSTtM 672
3/7! SYSTFM ?**
4/75 SYSTEM 720
5/75 SYSTEM 74<-
6/75 SYSTEM 720
7/75 SYSTIH 744
** PROHLEMS/SOLUT10NS/COMMENTE
START DATE 7/75 tOUIFHENT: FGD SYSTEM, GENERAL
END DATE 1/76 COdftNTS: RESEARCH AND DEVELOPMENT
THE C-SIDE PA l-TjCULATE SCRUBOER RESTARTED ON JULY 23, 1975. THE 7VIO REMAIN
JMi TRINS, H-'.IDE AMD A-SIDE, WERE PUT INTO OPERATION ON AUGUST 1s AND
OCTOBER ?, RE M^ECTIVELY. THE SC2 ABSORBER MODULE IN THF; C-SIDE SCRUBBING
ThAIN WAS 1KI1IALLY PLACED IN SERVICE OCTOEER 2, 1975. THE OLIN CHEMICAL
MCO REGENERATION FACILITY FIRST PROCESSED MAGNESIUM SULFITE FROM THE EDOY-
STONF SCRUFPEI ON OCTOBER 2», 1975. THE C-SIDE PARTICULATE SCRUBBER OPERA-
TED A TOTAL 0* 2*31 HOURS THROUGH JANUARY ?1, 1976, FOR AN AVA1LABUTY OF
7t PERCENT. THJ Cf-SIDE TRAIN HAS OPERATED A TOTAL OF 19J3 HOURS THROUGH
JANUARY 71, 1 ,76 FOR AN AVAILABILITY OF 55 PERCENT. THE A-SIDE TRAjK OPERA
TtO A TOTAL Of 626 HOURS THROUGH JANUARY 31, 1976, FOR AN AVAILABILITY OF
24 PERCENT THC C-SIDE 502 ABSORBER WAS IN SERVICE A TOTAL PF 556 HOURS
THROUCH OECtfifR 31, 197 , WITH AN AVAILABILITY OF 33 PERCENT SINCE START
UF'. PROBLEMS ^'COUNTERED IN THE OPERATION OF THE THREE SCRUBBING TRAINS
INCLUDED: tlNDff-DESISNED RECI RcUL ATI ON PUMPS, MALFUNCTION OF THE FLUF 6AS
281
-------
fPA UTILITY FtD SURVFY: DECtMPER 197f - JANUARY 19?9
SE CTJON 3
DESIGN AND PFRFOFMKE DATA FOR OPERATIONAL FGD SYSTFMS
---- ______________________________________ PERFORMANCE DATA ------------------------------------------
PERIOD MODULE AVAILABILITY OPE«tAf>JLlTY i£LIAf>UITY UTILIZATION X REMOVAL PER BOILER F 6 D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
f Y-PAS! DAMPFl DRIVf UNjTS AM) FAILURE OF THE DOUBLE-BRICK REFRACTORY.
LINING IH THE PEHtAT COMBUSTION CHAMBER.
AFFECTED MODULES: SYSTfcM
B/73 SYSTEM 744
9/75 SYSTEM 720
10/7S SYSTEM 744
11/75 SYSTfM 7?0
12/7! SYSTEM 744
1/76 SYSTIM 744
2/76 SYSTEM 696
** PROBLEMS/SOLUTION S/COMHENTf
START DATE ? /76 rOUIITENT* F6D SYSTEM, GENERAL
END DATE 5/76 COMMITS! RESEARCH AND DEVELOPMENT
OPERATION or THE so? SCRUBBING SYSTEM AT EDDYSTONE WAS TFHPORARILY HALTED
FitCAUSF THE A(]D PLANT RFCK NF RA T I CN FACILITY AT THE OLlN CHEMICAL SULFURTC
ACID PLANT IN FAULSF'ORC, NEW JFRSEY PERMANENTLY CEASED OPERATIONS* THf
UTILITY IS NO l, INVESTIGATING ALTERNATIVE HF 6ENE R ATI ON SITES. A MINIMUM PER
ICD OF SIX MOKTHS WILL BE REQUIRED FOR RELOCATION ONCt A CHOICE IS MADE.
Tht UTILITY AKNOUNCEb PLANS FOR RELOCATION OF THE REGENERATION FACILITY AT
TKL ESSEX CHEMCAL PLANT IM NEWARK, N tW JERSEY.
AFFECTED MODULES:
3/76 SYSTEM 7*4
4/76 SYSTEM 7?0
5/76 SYSTEM 744
6/76 SYSTEM 7?G
** PROBLtMS/SOLUT! ONS/CCMMENTS
START DATE 6/76 EGUIf-MENT: FGD SYSTEM, GENERAL
END DATE £/76 COMMFMTS: RESEARCH AND DEVELOPMENT
RESUMPTION OF SO? SCRUBBING OPERATIONS IS PRESENTLY SCHEDULED FOR DECEMBER
1576. THE RtLCtATlON OF THF REGENERATION FACILITY IS NOW IN PROGRESS. THF.
PART1CULATF SIRUBBERS ARE OPERATlCNAL. THE C-SIDE eOOSTER FAN HAS DtVELOPE
A MATERIALS F'JLURE BETWEEN THE HUB AND SHAFT (IDENTICAL TO THE B-SIDE UNI
T MENTIONS,!) AfCVS).
AFFECTED MODULES! SYSTEM
7/76 SYSTEM ^^^
8/76 SYSTEM 744
9/76 SYSTEM 720
** PROBLEMS/SOLUTIONS/COBMENTS
START DATE 9/76 ECUIFfENT: FGD SYSTEM, GENERAL
END DATE 10/76 COMMENTS: RESEARCH AND DEVELOPMENT
ALL THREE BOOSTER FANS HAVE NOW DEVELOPED THE MATERIALS FAILURE FJETKFEN TH
HIS AND SHAFT (AS IDENTIFIED IN THE ABOVE FOR THE B-SIDE UNIT). THESE UNIT
HAVE E-EEN RETIRMED TO THF MANUFACTURER FOR MODIFICATIONS AND REPAIRS.
CURRENTLY, ONI OF THE PART1CULATE SCRUBBERS IS lit THE FLUE 6AS STREAM.
TC DATE, ALL 1HREE OF THE WET PARTUULATC SCRUBBERS HAVE NOT SEEN ANY
AFPRECIAEiLE SIMULTANEOUS SERVICE TIME.
AFFECTED MODULES: SYSTEM
10/76 SYSTEM 744
11/74 SYSTEM 720
282
-------
IPA UTILITY FGB SURVEY: DtCfMBiB 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FCD SYSTEMS
......................................-.-~PfNFORMANC6 6 AT A .......................................
PERIOD MODULE AVAIL ABILITY CPERABU1TY PLIABILITY UTILISATION X REMOVAL PER BOILER FSB CAP.
$02 PART. HOURS HOURS HOURS FACTOR
** PSOkiLEMS/SOLUUONS/COMMINTS
START BATE 11/74 leUlfWINT! F6D SYSTFM, GfNERAL
INC OATI 1?m COMMtNTSs SISIARCH AND DiVELQPMINT
MJO SeRUBIINe OPERATIONS ARi NOW SCHEDULED TO RESTART IN MAY 1977. RI6INIR
-ATION FACILITY RELOCATION IS PEIN6 COMPL|T|p, AND MODIFICATIONS TO THE ID
BOOSTER FANS CURRENTLY BFINd IFFfCTiD CONSIST OF CONVERSION FROM A SHRINK
FIT TO A 4LIP FIT. THIS! MODIFICATIONS ARE EXPECTiB TO ELIMINATE RECURRING
VIBRATION PROtLiMS,
AFFECTED MODULES! SYSTfcM
12/76 SYSTEM 74*
1/77 SYSTEM 744
** PROaLEMS/SOLUTIONi/COMMENTS
START DATE 1/77 IQUIIKENT: FGD SYSTEM, GENERAL
fcND BATE 1/77 COMMITS: NfSbARCH AND DEVELOPMENT
TK ^AGNESIUW OXlOf SCRURB1N6 SYSTEM AT EDDySTONE NO. IA IS STILL SCHEDULE
FCR RESTART lit MAY 1977. THE STftRT-UP OF THE NEW MGNESIUM jyLFITE RE6ENER
-ATIPN FACILItT AT THE ESSFX CHEMICAL PLANT AT NEWARKi N.J. IS ALSO SCHED-
ULED FOR MY 1°77. THE THREE PARALLEL VINTUfiJ SCRUBBERS CONTROLLING PARTIC
-ULATE EMISSIONS ON EDDYSTONE NO. 1 WENT BACK INTO SERVICE IN MARCH 1977-
AFFECTED MODULES: SYSU*
?/77 SYSTEM 672
3/77 SYSTEM 7«4
4/77 SYSTEM 720
** PROBLEMS/SOLUTIONS/COKMEfnTS
START DATE 4/77 ECUITMENT: FGO SYSTcMi GENERAL
END DATE 5/77 CCHMNTS: RESEARCH AND DEVELOPMENT
RESUMPTION OF MAGNESIUM OXIDE SCRUBBING OPERATIONS OCCURRED DURING THE
REPORT PEhlOD. THE UTILITY REPORTED THAT SflZ SCRUBBING OPERATIONS WERE
NOT CONTINUOUS THROUGHOUT THE PERIOD. THE ABSORBER WAS IN SERVICE APPROXI-
MATELY 20e HOI"S DURING MAY. REGENERATION OPERATIONS AT THE ESSEX FACILITY
WERt NOT CONDUTED DURIN6 THE PERIOD. PECO PLANS TO INITIATE S02 RECOVERY
A*D MAGOX REGf.NERATlON OPERATIONS DURING THE MONTH OF JUNE. THE S02 MODULE
CCNTAINS TWO AT'SORBER SECTIONS }N SERIES (EACH SECTION CONSISTING OF AN
ADJUSTABLE; ROC DECK WITH UNDERSPR AYS). ONLY ONE OF THE ABSORBER SECTIONS I
PE1NG USED FOf S02 REMOVAL. SQ2 REMOVAL EFFICIENCY HAS NOT BEEN MEASURED.
MAGNESIUM OX I fit LOSSES IN THE SYSTEM (ABSORBTION AND REGENERATION) ARE
ESTIMATED AT 10 PERCENT.
AFFECTED MODULES: SYSTEM
5/77 SYSTEM 7**
6/77 SYSTEM 7*D
** PROiaLtMS/SOLUTIONS/COMWtNTS
START DATE d/77 EOUIIMENT: F6D SYSTEM, GENERAL
fcND D/>Tf 7/77 COMMtNTSs RESEARCH AND DEVELOPMENT
FAILURE Of MIKOR ANCILLARY ESUIPMENT CAUSED SOME SHUTDOWNS. LATER, THE
eCILTF ITSELF WENT DOWN. OVER THIS PERIOD THE ROTARY VALVE ON THE MAG.
SULFTTE DRIER DISCHARGE PLUGGED REPEATEDLY. ALSO THE BELTS ON THE MAH-OX.
PRESLAKER FAILED.
AFFfCTED
7/77 SYSTEM
6/77 SYSTtM
** PSOBLEMS/SOLUTIONS/COMMENTS
START DATE P./77 tBUICKENT: FGD SYSTEM, GENERAL
END DATE 11/77 COMMINTS: RESEARCH AND DEVELOPMENT
-------
EPA UTILITY FOD SURVTY; DECfcf*6FR 197P - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FCD SYSTFMS
PERFORMANCE DATA • "
PERIOD MODULE AVAILABILITY CPERAFULITY PLIABILITY UTILIZATION x REMOVAL PER BOILER FBO CAP.
SO? PART. HOURS HOURS HOURS FACTOR
THE ROTARY V*LVE PROBLEM APPEARS TO BE SOLVED. CUMULATIVE AVAILABILITY
SINCE HAY IS fSTIMATED TO BE ROUGHLY 33*. PECO REPORTED 131 HOURS Of
CONTINUOUS OPLRATION FOR THE SCRUtBER AND THICKENER CENTRIFUGE DRYING
LOOP. DURH'b 1HE. REPORT PERIOD THERE HAVE BEEN CONTINUAL PROBLEMS WITH
THE GLAND PACKING ON THE FGD SYSTEM CIRCULATION PUMPS (STUFFING BOX).
PECO HAS SJNCt CHANGED THE 6LAND CONFIGURATION. THERE ALSO WAS A PROBLEM
WITH HI6H SCLK'S FORMATION IN THE THICKENER. DURING THF OCTOBER-NOVEMBER
PERIOD THESE kAS ONf RUN WHICH LASTED APPROXIMATELY FIVE DAYS.
ELAND PACKING PROBLEMS PERSISTED AND MECHANICAL SEALS ARE BEING CONSIDERED
AS PCSSIfat AITERNATIVES. EVEN WITH HEAT TRACING THE SEAL WATER FROZE-UP
CAUSING ROTAMiTERS TO DURST. HIGH SOLIDS PROBLEM IN THE THICKENER IS STIIL
A PROBLEM AREA.
AFFECTED MODULES: SYSTtf
9/77 SYSTEI* 720
10/77 SVSTEI" 744
11/77 SYSTff 720
12/77 SYSTEM 744
** PROBLEHS/SOLUTIONS/CCmMENTS
START BATE 1?/77 [BUIFMENT: FGD SYSTEM, GENERAL
END DATE 1/7P COMMINTS: RESEARCH AND DEVELOPMENT
1H UNIT WENT DOWN DECEMBER ?2 FOR A TURBINE OVERHAUL. DURING THE OUTAGE
MAINTENANCE AM MINOR MODIFICATIONS WILL BE MADE ON THE SCRUBBERS. THE UNI
IS EXPECTED Tl BE BACK ON LINE THE FIRST WEEK IN MARCH. THE AVAILABILITY
FACTOR FOR THL OCT, NOV, AND DEC QUARTER WAS 4?X. DURING THIS PERIOD SOME
OF THE HEM RACING FAILED AND OTHER PROBLEMS OCCURRED WHEN LINES FROZE AT
THE ACID PLAN' CAUSING THE FACIU1V TO BE RUN INTERMITTENTLY. THE GLAND
PACKING PROBLEMS HAVE NOT YET BEEN SOLVED AND MECHANICAL SEALS ARE STUL
BEING CONSIDE FED.
AFFECTED MODULES: SYSTEM
1/7F SYSTEK 744
2/7P SYSTEM 672
** PROBLEMS/SOLUTIONS/COHMENTS
START DATE 2/78 EOUIf^ENTi FGD SYSTEM, GENERAL
END DATE 3/78 COMMt-NTS: RESEARCH AND 0 tVELOPMENT
THE TURBINE OVERHAUL CONTINUED DURING THE REPORT PERIOD. DURING THE SHUT-
DOWN PERIOD IT WAS FOUND THAT SOME HIGH PRESSURE STEAM TUBES WERE CRACKED,
SO UNIT MAINTINANCE HAS TAKEN LONGER THAN EXPECTED. SOME MINOR FGD SYSTEM
MODIFICATIONS HAVE BEEN INCORPORATED IN THE COURSE OF THE SHUTDOWN PERIOD.
START UP IS EXPECTED IN MID-APRIL 78.
AFffCTED MODULES: SYSTtM
3/78 SYSTEM 744
4/7P SYSTEM 720
*» PROBLEMS/SOLUTIONS/CCMMENTS
START DATE 4/78 EOUIfMENT: FGD SYSTEM, GENERAL
END DATE 5/7£ COfifMNTS: RESEARCH AND DEVELOPMENT
TfcE UNIT CAME BACK 0N LINE JUNE 1 AFTER AN EXTENSIVE SYSTEM MODIFICATION
OITAGE WHICH IEGAN DECEMPER 22. THE UNIT WAS EXPECTED BACK ON LINE IN Ml»-
AFRll, BUT THtRE WAS A PROBLEM WITH A SUPER PRESSURE STEAM TURBINE.
AFFECTED MODULES: SYSTt*
5/7f SYSTEM 744
6/78 SYSTEM 720
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 6/78 ESUIFKENT: FGD SYSTEM, GENERAL
END DATE 7/78 COMMfNTS: RESEARCH AND DEVELOPMENT
284
-------
EPA UTILITY f€0 SURVEY: DECFMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORHAtvCE DATA FOR OPERATIONAL F6D SYSTEMS
PERFORMANCE 6 AT A
PERIOD NODULE AVAILABILITY CPERARIL1TY PLIABILITY UTILIZATION X REMOVAL PER SOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
DIKING JUNE TH FGo SYSTEM ACHIEVED A 49Z OPERABILlTy. OPERA8ILITY FOR
JULY WAS 51*. PROBLEMS OCCURRED THE LAST WEEK OF JUNE WITH THE MGS03 $LuRR
CIRCULATION PIMP WHEN THE UTILITY DISCOVERED THE RUBBER LINER HAS TORN
AfcAY. THERE HIVE BEEN SOME PROBLEMS WITH THE M60 SECTION WHERE THE M60
MIXES WITH THf. SYSTEM LIQUOR. FIRE BRICK WAS REMOVED FROM THE FLUID BED
REACTOR CHAMBCR TO REPLACE THE ACID BARRIER PLATES WHICH WERE FAILING.
THE FIRE fcRICK WAS THEN REPLACED. THE SLOW PIECE BY PIECE PROCEDURE HAS
TIME. CONSUMING AND ACCOUNTED FOR MOST OF THE RpGENERABLE FACILTY DOWN
TIME (MOST OF JUNE AND JULY). MAJOR PROBLEMS WERE SOLVED ON THE REGENER-
ATIVE FACILITY OVER THE PERIOD REVOLTING IN IMPROVED AVAILABILITY OF THE
FACILITY.
AFFECTED MODULES: SYSTEM
7/78 SYSTEM 7*4
B/7B 1A Zfi.O 32.C
SYSTEM 744 631
** PROHLEHS/SOLUT10NS/COMMENTS
START DATE 8/78 ttUlfEMT: FGD SYSTEM, GENERAL
tND DATE 8/7E COMMINTS: RESEARCH AND DEVELOPMENT
DURING THE NOMH OF AUGUST SCRUBBER CIRCULATING PIPING PROBLEMS WERE
tNCOUNTEREt. t BUTTERFLY CONTROL VALVE WAS NOT FULL* OpEN AND A SECTION
Of PIPE DOWNSTREAM AT A $0 DEGREE BEND ERODED AWAY. TO CORRECT THE PROBLEM
THE BUTTERFLY VALVE WAS TAKEN OUT AND REPLACED WITH A RESTRICTION ORIFACE.
THE CIRCULATICN PUMPING RATE WAS ALSO REDUCED.
AFFECTED MODULES; SYSTtK
9/78 1.A 78.0 56.0
SYSTEM 720 516
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 9/76 tCUIfWENT: FGD SYSTEM, GENERAL
END DfTF 9/78 COMMtNTSs RESEARCH AND DEVELOPMENT
THE UTILITY REPORTED THAT NO MAJOR PROBLEMS WERE ENCOUNTERED DURING THE
MONTH OF SEPTEMBER. CERTAIN MECHANICAL PROBLEMS WERE RESOLVED WHICH CAUSED
Ah IMPROVEMtNl IN THE OPERABILITY FIGURE.
AFFECTED MCpULtS: SYSTEM
10/7S A ' 23.0
SYSTEM "**
** PfiOfDLEMS/SOLUTIONS/COMMENT!-
START DATE 10/78 tOUIFPENT: REAGENT HANDLING
END DATE 1?/78 PROBLEM: NOT DEFINED/SPECIFI ED
THE F«D SYSTE* WAS SHUT OO^N FOR AN APPRECIABLE TIME DURING THE LAST
OUARTER OF 1978 DUE TO MODIFICATIONS TO THE »6
-------
!PA UTJUITT I6D SURVJYs D!CS*fiER 1«7f - JANUARY 1979
StCTION I
DiSl&N ANO NRFORMANfl DATA FOR rpl^ATICNAL FED SYSTEMS
COMPANY NAMf
PLANT NAMF
UNIT NU"PFR
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATF, MISSION LIMITATION - NUJ
$02 IMISSICN LIMITATION - K6/J
NET PLANT CfNERAtlNS CAPACITY - ««
6POSS UNIT CINIRATJNi CAPACITY - Mfc
NET UNIT 6F.NCRATIN6 CAPACITY W/F60 • Mv
NET UNIT 6eHRATlN6 CAPACITY VO/FCit > W
EQUIVALENT SCRUhfcFP CAPACITY - MW
** BOILER DATA
SUPPLIER
TYPE
SERVICi LOAD
COMMERCIAL SERVICI [>ATt
MAXIMUM 60ILtR FLUfc 6A5 FLOW - CU.C/S
fLUF GAS TE^PFRATURf - C
STACK HEIGHT - «
STACK TOP DIAMETER - M
** FUEL DATA
FUiL TYPE
FUEL GRADE
AVERACr HEAT CONTENT - KJ/KG
RANFE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - X
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - %
RANGE MOISTURE CONTENT - *
AVERAGE SULFUR CONTENT - X
RANGE SULfUR CONTENT - %
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - %
FUEL FIRING RATE - M T/H
FUEL FIRING RATE - f>U
** ESP
TYPE
PARTICUtATE DESIGN REMOVAL EFFICIENT - i
«* PARTICULAR SCRUBBER
NUflPER
TYPE
SUPPLIER
SHELL MATERIAL
LINING MATEPIAL
FLUE 6AS CAPACITY - CU.M/S
FLUF GAS TEMPERATURE - C
LI fill ID lit CIRCULATION RATE - LITfS/J
PRESSURE CROP - KPA
** F6D SYSTEM
SALFAPLE PROOUCT/THRONAWAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
SYSTEM SUPPLIER
DEVELOPMENT LEVEL
NEW/RETPOF1T
PARTKULATE DESIGN REMOVAL EFFICIFItCY - %
SO 2 DESIGN REMOVAL EFFKIFNCY - *
INITIAL START-UP
CONSTRUCTION INITIATIOK
** ABSORBER
TYPE
INITIAL START UP
SUPPLIER
NUMBER OF STAGES
SHELL MATERIAL
BOILER LOAD/AFSORBER - *
PUHL|C SIAVICE 6f NIW MEXICO
SAN JUAN
.050 LJ/MMPTU>
.3*0
NEW MIX1CO
e
*******
161.0
11*. 0
*******
361.0
******
******
BASE
0/76
6Z2.44
122.C
******
*******
COAL
« *****
1F841.
******
U.82
*******
.SO
******
********
******
181. A
*****
HOT SIDE
99.S
3
VENTURJ
DAVY POUERGAS
CARBON STEEL
ACID BRICK
257.2
136.1
224.9
3.0
(1319000 ACF«>
( 253 F>
(**** FT)
(***** FT)
( 8100 BTU/LB)
***** *
(200 TPH>
( 545000 ACFM)
t 277 F)
( 3570 6PM)
( 12 IN-H20)
SALEABLE PRODUCT
WET SCRUBBING
DAVY POWERGAS
FULL-SCALE
RETROFIT
99.50
85.00
4/7"
1/76
SPRAY TOWER
4/7ft
DAVY po«£RsAS
5
CONCRETE AN6 316 SS
33.0
286
-------
EPA UTILITY F6D SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FGD SYSTEMS
GAS FLOW - CU.M/S
6AS TiUPERATURE - t
LIQUID RECIRCULATION RATE - LI1ER/S
PRESSURE DROP - KPA
SUPERF1CAL GAS VELOCITY - M/SEC
PARTICULAR INLET LOAD - C-/CU.M
PARTICIPATE REMOVAL EFFICIENCY - X
S02 INLET CONCENTRAT10H - PPM
S02 OUTLET CONTRATION - PPM
SOZ DESIGN REMOVAL EFFICIENCY - X
207.16
46.9
47.
4.0
3.3
.1
75.0
700
70
90.0
439000 ACFM)
120 F>
750 GPn>
16.0 IN-H20)
10.8 FT/S)
.053 GR/SCF)
** ABSORBER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
NUMBER OF STAGES
SHELL MATERIAL
BOILER LOAD/ABSORBER - X
GAS FLO* - CU.M/S
6AS TfftPERATURE - C
LIQUID RECIRCULATION RATE • LITEP/!
PRESSURE DROP - KPA
SUPERFKAL CAS VELOCITY - M/SEC
PARTICULATE INLIT LOAD * G/CU.f
PARTICULATE REMOVAL EFflCIENCV - X
802 INLET CONCENTRATIOfc - PPM
SOZ OUTLET CONTRATION - PPM
SOa DESIbN REMOVAL EFFICIENCY - X
** FANS
TYpf
*« PUMPS
SERVICE
SLURRY PUMP
VENTURI RECIRCULATION
** ftEHEATFR
TYpf
HEATING MEDIUM
TEMPERATURE. BOOST - C
1
SPRAY TOWER (SPARE)
4/7R
DAVY
207.16
4B.9
47.
CONCRETE AND 316 SS
33.0
- (' 439000 ACFM>
( 120 F)
( 750
(16.0 IN-H20)
t 10.8 FT/S)
( .0!3 GR/SCF)
4.0
J.3
.1
75.0
700
70
90.0
DRV FAN
NUMBTR
****
****
INDIRECT HOT AIR
STfAM
27.8 ( 50 F>
** wATEP LOOP
TYpF
FRESH MAKEUP WATER ADDITION - LITERS/S
** BYPRODUCTS
BYPRODUCT NATURE
BYPRODUCT QUANTITY - B T/H
DISPOSITION
** DISPOSAL
NATURF
TYPE
TRANSPORTATION
- ACRES
CLOSED
30.2
( 480 GPW)
SULFUR
.85 ( .94 TPH)
MARKETED
FINAL
ASH POND
TRUCK
?BO.O
PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPEPAnlLlTY fFLlABlLXTY UTILIZATION
X REMOVAL
S02 PART.
PER BOILER
HOURS HOURS
FGD
HOURS
CAP.
FACTOR
4/78 SYSTEM
** PRO&LEMS/SOLUTIONS/COMMENT;
START DATE 4/78 IOUIFMINT: FGD SYSTEM, GENERAL
END DATF 4/78 COMMENTS:
SCZ AdSORBTIOb BEGAN ON *P"K 8, 1978 USING TWO
THIRD OF THE FLUE GAS IS BEING BYPASSED.
AFFECTED MODULES: SYSTEM
720
OF THE FOUR CELLS. ONE
287
-------
EPA UTILITY FGD SURYTY; DtCtX&ER 1 16U1H»ENT: FSB SYSTFM, GENERAL
bND DATF 5/78 F'ROBLFM: NOT 0 E F IN ED /S PE Cl f 1 ED
THE AtSORBfRS WERE DOWN FOR 26 HOURS*
AFFECTED MODULES: SYSTtf*
5/7! SYSTEM 74*
6/7?. SYSTEM 720
** PROBLEHS/SOLUTlONS/tOMMENTS
START DATE fc/78 t&UltKENT: SCRUBBER
END DATE 7/78 FROPIEM: NOT D E FIN ED /SPE Cl F I ED
A HIGH PRtfSUKE DROP ACROSS THE: VENTURIS PREVENTED FULL FLUE GAS THROUGH
ThE FGD SVSTEC.
AFFECTED MODULES: SYSTEM
7/78 SYSTEM 74*
8/7R SYSTtI* 744
** PROBLE«S/SOLU1IOMS/COII!WENTS
START UATE 8/78 eCUIIfiENT: SCRUBBFR
END DATF 9/78 PFOBLFM: NOT DE FINED /S PF Cl F I ED
THE HIGH PRESSURE DROP WAS LOWERED BY ADJUSTING INTERNAL PLUMB BOBS.
AFFECTED MODULES: SYSTEM
** PROBLfcMS/SOLUTlONS/COPKENTS
START DATf R/78 EOUIFKENT: MIST ELIMINATOR
END DATE 9/78 HFOBttM: (JOT DEFINED/SPECIFIED
REPAIRS Ulft F
-------
EPA UTILITY FfC SURVEY! DFCfKBlR 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FED SYSTEMS
— — PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERAB1LITY PLIABILITY UTILIZATION X REMOVAL PER BOILER FGO C«P>
$02 PART. HOURS HOURS HOURS FACTOR
AFFECTED MODULES: SYSTEP
1/79 SVSTtf 7U
-------
FPK UTILITY FGD SURVfY: DECENgFR 197F - JANUARY 1979
SECTION 3
OESIC.N AND PFRFORMISfE bATA FOR OPFRATIONAL F G [> SYSTEMS
COMPANY N'AMfc
PLANT N«ME
UNIT NUMBFR
CITY
STATE
RF6ULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NfT PLANT GENERATING CAPACITY - KW
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - »U
NFT UNIT GENERATING CAPACITY WO/FGD - l-W
EOUlVALfNT RCRUP6FD CAPACITY - fW
*• POILFR DA1A
SUppLItR
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM 60 HEP FLUE GAS FLOVI - CU.-/S
FLUF. GAS TEMPFRATURE - C
STACK HEIGHT - f
STACK TOP DIAMETFR - M
** FUEL OAT*
FUEL TYPE
FUEL FRADF
AVER Aft HEAT CONTENT - KJ/KG
RANFiE HtAT CONTENT - P TU/LP
AVERAGE ASH CONTENT - J
MANCE ASH CONTENT - %
AVERAGE MOISTURE CONTENT - X
RANGE W01STURF CONTENT - V
AVERAGE SULFUR CONTENT - t
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTEST - %
RANGE CHLORIDE CONTENT - *
FUEL FIRING RATF - f T/H
FUEL FIRING RATE - HW
PUPLlC SERVICE OF NEW MEXICO
SAN JUAN
WATER FLOW
NEW "tXICO
P
21.
146.
*******
TSP.O
30ft.0
*******
35P.O
******
******
BASE
**/**
6ZZ.44
12?.(t
******
*******
27. 45
******
14.82
******
.PO
* *****
*'******»
* *****
181.4
*****
.05G LP/RMRTU)
.3*0 LR/fHBTU)
<1319000 ACFM)
< 253 F)
<**** FT)
(***** FT)
< 9000 BTU/LP)
***** *
(200 TPH)
ESP
TYpr
SUPPLI tR
PARTICULATt OFSIGN REMOVAL EFFlCIEIif.Y - *
** PARTICULATE SCRURBER
NUMBER
TYPE
SUPPLIER
SHELL MATERIAL
LINING MATERIAL
FLUE 6AS CAPACITY - CU.M/S
FLUE GAS TEMPERATURE - C
LIQUID RECIRCULATIDN RATE - LITER/S
PRESSURE DROP - KPA
•« F6D SYSTEM
SALEABLE PROD UCT/THP OW AWAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
SYSTEM SUPPLIER
CONSTRUCTION FIRM
DEVELOPMENT LFVEL
NEW/RETROFIT
PARTICULATE DESIGN REMOVAL EFFICIENCY - %
302 DESIGN REMOVAL EFFICIENCY - X
INITIAL START-UP
CONSTRUCTION INITIATION
** ABSORBER
NUHPER
TYPF
SUPPLIER
SHELL MATERIAL
BOILER LOAD/APSORBER . Z
1
HOTSIDE
WESTFRN PRECIplTAflON
99.5
DAVY POWERGAS
CARBON STEEL
ACID BRICK
?5?.Z
136.1
224.9
3.0
( 545POO ACFK)
< 277 F)
( 3570 GPP)
t 1? IN-H20)
SALEABLE PRODUCT
WET SCRUBBING
DAVY POWER6AS
STEARNS AND ROGER
FULL-SCALE
RETROFIT
99.50
85.00
8/78
1/76
SPRAY TOWERS
DAVY POWER6AS
CONCRETE AND 316 SS
3T.O
290
-------
KPA UTIUTY fSft SUSV1Y8 DiCfMBiR 1978 • JANUARY
SECTION 3
DESIGN AMD PiRFOUtAKCI DATA FOR OPERATIONAL FiB SYSTFMS
SAS FLOW - CU.M/S
6AS TEMPERATURE - C
L/6 RATIO - L/CU.H
PRESSURE DROP - KPA
SUPfRflCAL 6AS VELOCITY - M/S5C
PARTICUIATE OUTLtT LOAD- 6/CU.fl
So2 INLCT CONCENTRATION - PPM
SO 2 OUTUIT CONTRATjCN • PPM
S02 DIS16N REMOVAL EFFICIENCY - X
** Al'SORBSl!
TYPf
SUPPLIIR
SHELL MATERIAL
BOILER LOAD/AF!SORBER - S
6AS FLOW - CU.M/S
CAS TEMPERATURE - c
L/C RATIO - L/CU.M
PRESSURE DROP - KPA
SUPfRFKAL KAS VELOCITY - P/SSt
PARTICULATE OUTLtT LOAC. 6/CU.H
502 INLET CONCENTRATION - PPM
S02 OUTLET CONTRAT10N • PPM
S02 OF El ON REMOVAL EFFICIENCY - X
107. 16
48. 9
.2
4.0
439000 ACFH)
120 F>
1.7 6AL/1000ACF)
U.Q IN-HZO)
10.P FT/S)
.079 6R/SeF>
85
65.0
1
SPRAY TOWER (SPARE)
DAVY POME8GAS
CONCRETE AND 3U SS
JJ.O
?Q7.U < 439000 ACFM)
4?,9 ( 12R F)
• 2 ( 1.7 6AL/1000ACF)
•4^0 <1«.0 IN-H2O
T.S ( 10.8 FT/S)
.2 ( .079 GR/SCF)
1200
85
85.0
** FANS
** PUMPS
SERVICE
SLURRY
VENTURI RECIRCULATION
** RtHEATER
TYPE
HEATIN6 MEDIUI"
TEMPERATURE BOOST - C
** WATER LOOP
TYPE
** BYPRODUCTS
JYPRODUCT NATURE
BYPRODUCT QUANTITY - PI T/H
DISPOSITION
** DISPOSAL
NATURF
TYPF
LOCATION
AREA - ACRES
INDIRECT HOT AIR
STEAK
27.8 C 50 F)
CLOSED
ELEMENTAL SULFUR
MARKETED
FINAL
ASH POND
OFF-SITE
2ROO.O
2.25 TPH)
PERIOD MODlILt AVAILABILITY OPE PAPlUTY
PERFORMANCE DATA ----- — ---- -- --- — ------------------ -----
UTILIZATION X REMOVAL PER BOILER F60 CAP.
S02 PART. HOURS HOURS HOURS FACTOR
6/7* SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE f /7fc E«UIf*iENT: F6D SYSTEM, 6ENERAL
9/7S CCMMCMTS:
INITIAL 0(f RATIONS hEGAN IN LAtE AUGUST.
FCR THE FIRST TIME IN EAPLY SfcPTF»TfER«
AFFECTED MODULES: SYSTfl"
DATE
7A4
ALL THREE MODULES RAN TOGETHER
** PRCbLfPS/SOLUTIONS/COMMENTS
START BATE !>./?& EWUIfMENT: 6AS DAMPER
END DATF 9/78 PPOFLFM: MOT DEFINED/SPFClFI ED
PKOBIEMS kERC (NCOUNTEBED WITH yOOSTER FAN CONTROL DAMPER.
291
-------
EPA UTILITY FGD SURVEY: DECE!«[
-------
EPA UTILITY FGD SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FGo SYSTEMS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - KG/J
S02 EMISSION LIMITATION - H.G/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACjTY - ftk
NET UNIT GENERATING CAPACITY W/FGD - Mt
NET UNIT GENERATING CAPACITY WO/FGD - I»W
EOUIVALENT SCRUBBED CAPACITY - MW
«* BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE t>ATk
KAXIMUM BOlLtR FLUE GAS FLOW - CU.i"/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - KJ /KG
RANGE HEAT CONTENT - B1U/LB
AVERAGE ASH CONTENT - I
RANGE ASH CONTENT - *
AVERAGE MOISTURf CONTEt,T - 1
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - It
RANGE SULFUR CONTENT - *
AVERAGE CHLORIDE CONTENT - %
RANGE CHLORIDF CONTENT - '/.
FUEL FIRING RATE - M T/H
FUEL. F IRING RATE - MW
** ESP
NUMBER
TYPE
SUPPLIER
SOUTH CAROLINA PUBLIC SERVICE
WINYAH
2
GEORGETOWN
SOUTH CAROLINA
A
****** (****** L8/MMPTU)
****** <»***** LR/MMBTU)
*******
26C.O
25P.O
260.0
1*0.0
BABCOCK AND WILCOX
PULVF.RUFD COAL
BASE
0/77
******** (*******
132.? < Z70 F)
****** <* *** FT)
******* (***** FT)
COAL
BITUMINOUS
26749.
13.50
******
********
6.5-7.0
1.00
1.0-1.2
********
******
* ******
*****
< 11500 BTU/LB)
******
(*** TPH)
COLD SIDE
RESEARCH COTTpELL
** pARjICuLATE SCRUBBER
NUMPER
TYPE
FLUE GAS CAPACITY - CU.K/S
FLUE GAS TEMPERATURE - C
L/G RATIO - LIUR/CU.M
pRESSURF DROP - KPA
SUPERFICIAL GAS VELOCITY - K/S
** FGD SYSTEM
SALEABLE PRODUCT/THPOW AWAY PROfL'CT
GENERAL PROCESS TYFF
PROCESS TYPE
SYSTEM SUPPLIFR
A-E FIRM
DEVELOPMENT LFVEL
NEW/RETROFIT
PARTICULATE DESIGN REKlVAl EFFICIENCY
S02 DESIGN REMOVAL EFFICIENCY - %
INITIAL START-UP
** ABSORBER
TYPF
INITIAL START UP
GAS FLOW - CU.M/S
GAS TEMPERATURE - C
t/G RATIO - L/CU.M
PRESSURE DROP - KPA
SUPERFICAL GAS VELOCITY - M/SEC
S02 INLET CONCENTRATION - PPM
VENTURI
19?.1
13?.2
1.9
.7
27.*
< 407015 ACFM)
( 270 F)
(14.* GAL/1000ACF)
( 7 IN-H20)
( 9n.O FT/S)
THPOVAWAY PRODUCT
WET SCRUBBING
LIMESTONE
BABCOCK R VILCOX
BURNS AND PCE
FULL-SCALE
NEW
99.4Q
6".DO
7/77
1
TRAY TOWER
7/77
159.50
5?.?
ft. 3
1.1
7.2
935
( 33BOOD ACFPi)
( 126 F)
{ 47.5 6AL./1DOOACF)
< 4.5 iN-H20)
< 10.5 FT/S)
293
-------
fPA UTILITY (dt SUPVtYs PECEI»Fif(i 1«7r • JANUARY 1979
SECTION 3
PIS1CN AM) F"(RFOfcMA%CI DATA FOR OPERATIONAL F(.0 SYSTFMS
S02 OUTLET CONTRATION • fff
SO? BfSI&N ftlMOVAL FFFICI1NCY - X
** FANS
TYpF
60.0
O. FAN
siRvirt
SLURRY
«« REHIATER
TYPE
*» THICKENER
DIAMtTEK - M
OUTLET SOLIDS - i
«* WATEP LOOP
TYpt
FRESH MAKEUP VATtR ADOlTICn - LITFL'/S
** REA&rNT f'REPARATION fQUIPMfNT
OF BALL MILLS
** DISPOSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
NU»Sf R
****
5«.
OPFN
( 50 FT)
fc.J
FINAL
UNL1N£D POND
ON SITE
PIPE
ion GPP))
.—. -PERFORHANCF DATA
PE"IOD MODULI AVAILABILITY OPERAPILITY «HIABIIIT» UTILIZATION % REMOVAL PER BOJLER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
2/78
J/7R
4/78
5/78
6/7f
7/78
8/7?
672
** PR06LEMS/SOLUTIONS/COKMENTS
START DATE 2/78 EOUJTMtNT: FGD SYSTEM, GENERAL
END DATE 3/7E COMMINTS:
THE FCD SYSTEI* WAS BYPASSED FOR SERVERAL BAYS TO ALLOW SYSTEM CLEANIN& IN
PREPARATION Fr,R TESTING PY UABCOCK AND WILCOX.
MODULtS: SYSTEM
SYSTEM
SYSTEM
744
720
** PftOULEMS/SOLUTIONS/CCMMENTS
START DATE 4/76 tOUH^ENT: FGD SYSTEM, GENERAL
END DATE 5/78 PfOPlEM! CHEMICAL-RELATE0 SCALING
SONE MINOR SCAtiNfi WAS ENCOUNTERED BUT IT DID NOT CAUSE AN OUTAGE.
AFFECTED MODULES: SYSTEM
SYSTEM
SYSTEM
SYSTEM
SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE S/78 EOUIFMENT: FGD SYSTEM, GENERAt
END DATE 9/78 COI-ilMNTS:
THE UTILITY RC^ORTED NO FORCED F6D OUTAGE.
AFFECTED MODULES; SYSTEM
74*
720
744
744
722
9/78 SYSTEM
720
294
-------
EPA UTILITY FGD SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMAKE DATA FOR OPERATIONAL FGD SYSTEMS
: ------------------------------------------ PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERABILITY ^LIABILITY UTILIZATION
X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
10/7?
11/76
12/78
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 9/76 E6UIFWENT: INSTRUMENTATION
fcND DATE 9/73 COMMENTS:
THE SO? ANALYJKRS PERFORMED WELL DURING A CERTIFICATION TEST.
AFFECTED MODULES: SYSTEM
SYSTEM
SYSTEM
SYSTEM
84.8
£2.6
62.6
82.1
744
720
744
740 611Q
*» PSOULEMS/SOLUT10NS/COMMENTS
START DATE 12/76 EOU1IMENT: INSTRUMENTATION
iND DATE 1/79 ppOBltM: NOT DEFINED/SPECIFIED
SC2 MONITOR PROBLEMS CONTINUE.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 12/76 fcOUl f^ENT: PU«P« OTHER
END DAT? 1/79 (SOPO*: NOT DEFINED/SPECIFIED
AN OUTAGE WAS NECESSARY FOR ABSORbER PUMP KELT RENEWAL.
AFFECTED MODULES: SYSUP
*« PROULEMS/SOLUTIONii/COMMENIS
START DATE 1?/7B EOUIffENT: INSTRUMENTATION
END DATE 1/79 HKOBit-M: NOT DEFINED/SPECIFIED
FEED SLURRY flOUMETER PROBLEMS WfBE ENCOUNTERED.
AFFECTED MODULES: SYSTtM
** PROBLtKS/SPLLnl ON S/CCKMENTS
START DAT? 12/7S1 tCUlC*£NTi REAGENT HANDLING
END DATE 1/79 FRORttMS NOT DEFINED/SPECIFIED
THE OIL PUMP fOR LIMESTONE MILL EXPERIENCED TRIpS.
AFFECTED MOBUIES: SYSTEM
** PRObLEMS/SOLUTIONS/COMKENTS
START DATE 1?/78 ECU! WENT: REAGENT HANDLlNb
END DATF: 1/79 PKOEI>M: PLUGGING, OTHER
A MINOR OUTAC, • WAS CAUSED RY PLUGGING Of THE SLURRY DELIVERY LINT.
AFFECTED MODULES: SYSTfcK
** PROBLtttS/SOLUTIOHS/COI"lK!£N1S
START DATE 12/7P, EOUl'KENT: SCRUBBFR
END DATE 1/79 PROBLEM: NOT 0 E FIN ED /S PE CI F I ED
QLENCHFR PROBLEMS WERE EXPERIENCED DURING DECEMBER.
AFFECTED MODULES: SYSTtM
1/79 SYSTtM
99.6
99.6
99.6
99.6
744
744 7*20
295
-------
rPA UTILITY F66 SURVEY: PtCt*t)FR 19?f - JANUARY 1979
StCTlON 3
OtSICN AND rtRFORMKE DATA FOR OPFRAT1CNAL F60 SYSTEMS
COMPANY NAMt
PLANT NAKE
UMT NUfBffi
CITY
STATE
REGULATORY C LA SS 1 F J C AT ION
PARTICULAR EMISSION LIMITATION - KC/J
S02 EMISSION LIMITATION - KG/J
NFT PLANT GENERATING CATAC1TY - MW
GROSS UNIT tlNSRATINL CAPACITY - MV
NET UNIT GENERATING CAPACITY V/FGD - W
NET UNIT GENERATING CAPACITY WC/FGt - f
EOUIVALINT SCRUP6FD CAPACITY - WW
SOUTHERN MISSISSIPPI ELECTRIC
R.P. MORROW
HATTiSEURG
MISSISSIPPI
A
AT.
S1*.
400.0
?00.0
1SP.O
* *•**» **
124.0
( .100 LP/HMSTU)
< 1.200 LP/F1MBTU)
*« B01LFR CATA
SUPPLIER
TYPf
SERVICt LOAD
COMMERCIAL SERVICE DATE
MAXIHU* t.OHER FLUE GAS FLOW - CU.f/S
FLUE 6A<- TIMPFRATUKT . C
STACK HEIGHT - f»
STACK TOP DIAfETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - KJ/KG
RANGE HEAT CONTENT - FTU/Llt
AVERAGE ASH CONTENT - 1
RANGE ASH CONTENT - X
AVEF-AGE MOlSTURf: CONTENT - X
RANGE KCJSTURE CONTENT - X
AVERAGE SULFUR CONTENT - 1
RANGE SULFUR CONTENT - X
AVEBAFE CHLORIDE CONTENT - X
KANGE CHLORIDE CONTENT - *
FUEL F Jf IN6 RATE - W 7 /H
fUEl FIFIN6 RATE - WW
** ESP
TYPF
SUPPLIER
PARTICIPATE DFS16N PEUCVAL EfFIClE(«CY
** FGO SYSTFM
SAUFABLF PRODUCT/TH»OWAWAY PRODUCT
GENERAL PROCESS TYPF
PROCESS TYPE
SYSTEM SUPPLIER
A-t FIR*
CONSTRUCTION FIRK
DEVELOPfiENT LEVEL
NEW/RETROFIT
PARTICIPATE DFSI6N PEHCVAL EFFICIEfCY
SOZ DESIGN REMOVAL EFFICIENCY - X
INITIAL START-UP
•* ABSORBFR
NUMBER
TYPE
INITIAL START UF>
SUPPLI f.R
NUMBER OF STAGES
DIMENSIONS
INTERNAL MATERIAL
GAS FLOW - CU.M/S
GAS TEMPERATURE - C
*« fANS
TYPF
** VACUUM FILTER
NUMPER
OUTLET SOLIDS - X
RHEY STOKER
PULVFRI2ED COAL
BASE
0/7P
13?. 2
12*.
COAL
******
27912.
fi'.OO
******
********
1.
1.00
******
* * ******
******
*******
*****
(******* ACFM)
C 270 F)
t 408 FT)
(***** FT)
< 12000 BTU/LEl)
***** *
<***
HOT SIDE.
BU.ELI/ENVIROTECH
2 99.6
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
RIUY STOKER/ENVIRONEEFtING
tUBNS AND MCDONALD
RILEY STOKER
fUIL-SCAIE
NEW
- X 99.6Q
85.00
VENTURI-ROD
8/7P
RILEY STOKFR/ENVIRONEERING
7
90 X 40 X 1C
7 LAYERS OF STAINLESS STFEL ROBS
192.03 ( 406940 ACFM)
1J?.2 < 270 M
I-D
60.0
296
-------
FPA UTILITY FGD SURVEY: OFCfMBER 1976 - JANUARY 1079
SECTION 3
DESIGN AND P£RFOfMA*CE DATA FOR OPERATIONAL FGO SYSTFHS
** HIST EL 1W1NATOR
NUMBER
CONFIGURATION
*« REHEATER
TYpE
** THICKENER
NUMBER
** WATER LOOP
TYpF
** TREATHfNT
TYPE
SUPPLIER
1
VERTICAL
BYPASS
1
CLOSED
fLYASH STARILIZtO
NONPRQPRI tTARY
«* DISPOSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
FINAL
LANDFILL
OFF-SITE
TRUCK
.. PERFORMANCE DATA
PERIOD MODULE AVAILABILITY OPERAPILITY KLIAPILITY UTILIZATION x REMOVAL PER BOILER FED CAP.
SC2 PART. HOURS HOURS HOURS FACTOR
8/78 SYSTEK
744
9/7P
10/7!?
11/7c.
1?/7F
** PRORLEWS/SOLUTIONS/COMKENTS
START DATE 5/78 E6UIIWENT: EIOI LFR-R E LATF D
tND OATF 9/78 COMMITS:
A FORCED bCIl'-R OUTAGE OCURRED OUH1N6 THE PERIOD AS A RESULT OF P01LER
TUBE LEAKS.
AFFFCjED MODULES: SYSTEM
SYSTE»
SYSTEM
720
744
** PROBLEWS/SOLUT10NS/COKMENTS
START DATE 10/78 EOUI FMENT: BOI LER-RFLA T F 0
END DATE 11/78 COMMENTS:
OPERATION OF IHE UNIT WAS INTERMITTENT DUE TO CONTINUING BOILER TUBT
PROBLEMS. TM! EOlLtR WAS SHUT D 0 yfi NOVEMBER 1 AS A RESULT OF BOILER TUBE
PKOPLEMS. RESUMPTION OF OPERATION IS SCHEDULED FOP MARCH 1979.
AFFECTED MODULES: SYSTEM
*« PROElLEWS/SOLUTIONS/COMKENTS
START DATE 10/78 ECUIfKENT: VALVES
END DATE 1C/7* PPOEltM: CHEMICAL-RELATED PLUGGING
ThE FGD SYSTEi- WAS FYPASSED ENTIRELY IN OCTOPER DUE. TO SERIOUS CONTROL
VALVE PLUGG1M.
AFFECTED WOOtlLES: SySTCf
SYSTEM
SYSTEM
720
744
** PROeLEtfS/SOLUTIONS/CCMMENTr
START DATE 12/78 EQUIf'ENT: FGD SYSTEM, GENERAL
END DATE 1/79 CCKCTMTS:
T»,E UNIT H*S f>OT YET BEEN RESTARTED SINCE ITS NOVEMBER SHUTDOWN,
AFFECTED MODULES: SYSTtF
1/79 SYSTEM
744
297
-------
EP» UTILITY FGO SURVEY: DECEMBER 197? - JANUARY 1979
SECTION 3
DESIGN AND PERFOPMKCE DATA FOR OPERATIONAL F6D SYSTEMS
COMPANY NAME
PLANT NAMF
UNIT NUMFER
CJTT
STATE
RECULATORY CLASSIFICATION
PART1CULATE EMISSION LIMITATION - Nt/J
502 EMISSION LIMITATION - &G/J
NFT PLANT 6E(,ERATING CAPACITY - MV
GROSS UNIT GENERATING CAPACITY - Mk
NET UNIT GENERATING CAPACITY W/FGD - Ml,
NFT UNIT GEKERATING CAPACITY WO/FED - <>W
EOU1VALFNT SCRICBED CAPACITY - MW
SPRINGFIELD CITY UTILITIES
SOUTHWEST
SPRINGFIELD
MISSOURI
A
41.
516.
173.D
194.0
177.0
18?.0
194 .0
( .100 LB/MMSTU)
( 1.2PO L6/MMBTU)
** riOILER DATA
SUPPLIER
TYPF
SERVICE LOAfi
COMMERCIAL SERVICE DATS
MAXIMUM [.OILER FLUE GAS -FLOW - CU.MS
FLUE GAS TEMPERATURE - C
STACK HE IGHT - M
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - KJ/KG
RANGE HEAT CONTENT - ETU/Lfc
AVERAGE ASH CONTENT - *
RANC-E ASH CONTENT - %
AVERAGE MOISTURE CONTENT
fiANFE MOISTURE CONTENT - *
AVERAGE SULTUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTEKT -
RANGE CHLORIDE CONTENT - X
FUEL F IR1NG RATF - M T /H
FUEL FIRING RATE - MW
«* ESP
- X
TYPF
SUPPLIER
PARTICULATE DESIliN KEfCVAt EFFKIEKY
FLUE GAS TEMPERATURE - C
*• FGD SYSTEM
SALFABLE PRCDUCT/THROW*WAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
SYSTEM SUPPLIER
A-t FIR*
DEVELOPMENT LEVEL
NEW/RF TROF1T
PARTICULATE DESIGN REMtVAL EFFICIEKY
SOZ DESIGN REMOV*L EFFICIENCY - X
INITIAL START-UP
•* ABSORBER
TYPE
INITIAL START UP
SUPPLI E"?
NUMPER OF STAGES
&OHER LOAD/APSORE tR - X
GAS FLOW - CU.K/S
GAS TEMPERATURE - C
L/6 RATIO - L/CU.M
SOj DESIGN REPOVAL EFFICIENCY
FANS
TYpF
RILEY STOKER
PULVERIZED COAL
BASE
0/76
117-
COAL
BITUMINOUS
Z9075.
17.00
******
********
6-12
3.50
******
.30
******
<******* ACF*)
( 300 F)
( 384 FT)
<***** FT)
< 12500 BTU/LB)
<*** TPH)
1
COLD SIDE
AjR CORRECTION DIVISION, UOP
99.7
UP.9 ( 300 F>
THROUAWAY
WET SCRUBBING
LIMESTONE
AIR CORRECTION DIVISION, UOP
BURNS t MCDONNELL
FULL-SCALE
NEW
- X 99.70
BO .00
4/77
2
TCA
4/77
AlR CORRECTION DIVISION, UOP
50.0
15*.91
14f.9
2.1
91.7
BOILER I.D.
< 332500 ACFH)
( 300 F)
( 16.0 GAL/1DOOACF)
298
-------
6PA UTUITV FfiD SURVFYi DECEIVE* 1978 - JANUARY 1979
SfCTlON 3
AND PtRrORKAKE DATA FOR OPERATIONAL F6D SYSTTMS
** VACUUM FILTER
TYPE
OUTLET SULKS - X
M MIST ELIKINATOR
TYPF
NUMBER OF STAftS
** PROCfSS CONTROL CHEMISTRY
CONTROL VARIAPUS
• » THICKENER
NUMPER
** WATER LOOP
TVpf
** TREATMENT
TTPF
PRODUCT CHARACTERISTICS
«* DISPOSAL
MATURE
TYPE
TRANSPORTATION
AREA - ACRES
ROTARY DRUM
6H.O
CHfVRON
PH, <5AS FLOk,
1
CLOSED
NONPROPR]ETARY
DRV FLYASH STABILISED
FINAL
LANDFILL
TRUCK
10.0
............... PERFORMANCE DATA-----
PERIOD MODULC AVAILABILITY OPEfAtllHTY IFLJABILITV UTILIZATION
X REMOVAL
SO? PART,
PER BOILER F(56 CAP.
HOURS HOURS HOURS FACTOR
0/77 SYSTtW
PROBLEMS/SOLUTIONS/COMMENTS
START DATE
END DATr
0/77
0/77
SYSTEM
S/77 SYSTEM
7/77 SYSTEH
8/77 SYSTEM
FGD SYSTEM, GENERAL
CCMM fK'TS:
0( THE LIMESTONE FSD SYSTEM fc>AS COMPLETED DURING THE FIRST
OUARTER OF 19 ?7 (BEHIND SCHEDULE, PRIMARILY BECAUSE OF DELAYS IN ELECTRIC-
AL WORK). FOLLOWING AIR/WATER TESTS AND CHECKOUT OF LIMESTON5 PREPARATION
FACILITIES, TI'E FGD PLANT WAS STARTED UP IN EARLY APRIL 1977 FOR MECHANIC-
AL SHAKEDOWN/IEgUCGING OPERATIONS WHICH CONTINUED THROUGHOUT THE SUMMER.
COMPLIANCE TESTING AND CERTIFICATION OF COMMERCIAL AVAILABILITY UEKt SUC-
CESSFULLY COMFLETED IN SEPTEMBER, JUST BEFORE A SCHEDULED T-NONTH FALL
StUTDOWN. OPERATION OF THC SYSTEM HAS BEEN HAMPERED BY A NUMBER OF PR08-
LCMS: MIST ELIMINATOR PLUGGING (PIPING TO M.E. SPRAY SYSTEM HAS PEEN MOD-
IFICATION), COfftOSIOM IN THF PRESATURATOR (WAS RELINEO WITH PRECRETE),
CORROSION OF TfE: INLET/OUTLET GAS CAMPERS (REPLACED WITH 7HSS DAMPERS),
AND FAILURi OF PRECRETE LINING IN THE SCRU6PER AND CEILCOTE IN THE STACK
(BOTH FAILURES IDENTIFIED AS APPLICATION PROBLEMS). THf UTILlTY ALSO
FOIND IT NECESSARY TO CHANGE THE SYSTEM'S PH CONTROL FROM 5.9 TO 5.* TO
INCREASE LIMES 10NE UTILIZATION AND DECREASE PLUGGING WITHIN THE SYSTEM
AFFECTED MODULES: SYSTt*
7?,0
744
744
744
*« PROBLEMS/SOLUTIONS/COHMENTS
START DATE 8/77 ECUIPKENT: F6D SYSTEM, GENtRAL
END DATE 9/77 COMMITS:
THE FGD SYSTEM WAS OPERATED ROUGHLY «0 PERCENT OF THE AUGUST-SEPTEMBER
PERIOD. A ME* JOURCE PERFORMANCE TEST WAS RUN DURING THF. SECOND WEEK OF
SEPTEMBER. L/lTERf THE UNIT WAS SHUT DOWN FOR THE FIRST TURBINE IN-
SPECTION.
299
-------
FPA UTILITY FtD SU*VrY; DECfMPCP. 197f - JANUARY 1979
SECTION 3
DESIC-N AND FERFOSHAliCE DATA FOR OPERATIONAL FGD SYSTFMS
PERFORMANCF DATA ------- -- ---- — -- --- - ------ —.- — — .. .....
MODUlf AVAILABILITY CPF. » Af! 1 1 1 T Y '(LIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
SC2 PART. HOURS HOURS HOURS FACTOR
AFFECTtfl MODtlLlS: SYSTtK
9/77 SYSTEM
ID/77 SYSTEM
.70 99.7$ 7?0
** PfcOeLEMS/SOLUTl ON S /C CMWENTS
START DATE 10/77 EQUIIMENT: gAS DA|»PER
IND DATE 11/77 PROFUEM: D E SIGN-RFLATf D INFERIOR CONSTRUCTION MATERIAL
OITIFT OAKFER*. WERE MODIFIED {REPLACED WITH 316L STAINLESS STEEL OANPERS).
AFfF.CTED WOOULtS:
START DATE 10/77 tOUIffi-NT: F6D SYSTEHt GfcNERAL
END D»TF 11/77 COMMfNTS:
A SCHEDULED 0 ITOBER -NOVEMBE R OUTAbE UAS INITIATED.
TO START UF> A
-------
EPA UTILITY FSB SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMAfvCE DATA FOR OPERATIONAL FGD SYSTEMS
.... --- ,- — ...... ----- .. --- - ------- ... ----- PERFORMANCE DATA ------ - ------------------------------- ....
PERIOD MODULE AVAILABILITY OPEPABILITY PLIABILITY UTILIZATION X REMOVAL. PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
*» PROBLEMS/SOLUTIONS/COHMENTS
START DATE 2/78 tCUIIMENT: F60 SYSTEM, GENERAL
END DATE 3/78 COMMENTS:
TJiE ABSORBERS ARE CURRENTLY BEING BY-PASSED* THE FGD SYSTEM IS EXPECTED
TO BE PACK ON LINE BY THE END OF APRIL.
AFFECTED MODULES: SYSUM
3/78 SYSTEM 744
4/78 SYSTEM 720
*« PROTEUS/ SOLUTIONS /COMMENTS
START DATE 4/78 EQUIPMENT: FGD SYSTEM, EtNERAL
tND PATE 5/78 CCRFUNTS:
ONLY ONE SCRU;i''ER-AbSORBfR MODULE IS CURRENTLY OPERATING. THE EXPANSION
JOINT FAILURF MENTIONED PREVIOUSLY WAS DIRECTLY RELATED TO TH5 DAMPER
FAILURE WHICH ALLOWED THE TOILER TO CONTINUE PUMPIN6 t* S TO THE SEALfD OFF
Ftft SYSTEM.
AFFECTED MODULES: SYSTEM
** PH06LEMS/SOLUTIONS/COMMENTS
START DATE 4/78 EOUirHENT: ABSORBfR
END D*TF 5/7E PROBLEM: DESIGN-RELATED INFERIOR CONSTRUCTION MATERIAL
THE UNIT EXPERIENCED AN FRP LINER FAILURE OVER THE PERIOD.
AFFECTED MODULES: SYSTtM
** PROBLEMS/SOLUTIONS/CCMMENTS
START DATE 4/78 EfiUI l^ENl: PIPING
END DATE 5 /7P PROBLEM: NOT BE FINED/S Pf CI F HD
A fUI»P FAHUfil OCCURRED PUP 1Mb THE PERIOD.
AFFECTED MODULES: SYSTEP
5/78 SYSTEM 744
4/7B SYSTEM 720
START DATE fc/78 E«UrirgNTt FGD SY$TEM» SfcNEfiAL
END DATE 6/78 CCMMJNTS;
THE A-MODUIE kAN STEADILY FOR OVFR 11 DAYS, 8-MODULF HAS STILL DOWN WITH
EXPANSION JOIM PROBLEMS
AFFECTED MODULES: SYSTEM
** PRObLEMS/SOLUTIONS/COMMENTS
START DATE 6/7? tOUJffENT; MIST ELIMINATOR
END DATE 6/7(1 CftMMiNTS: RESEARCH AND DEVELOPMENT
DURING THE MOMH THE MIST FLIM1NA10H kASH SYSTEM W«S AI.TFRED FROM A SEPAR-
ATE CLOSED LOCH FOR EACH MODULE TO A COMMON SYSTEM FOR BOTH MODULES. THE
NEW SYSTEM TAKF8 SUPERNATANT FRO* THE TOP OF THE THICKENER FOR MIST ELIM-
INATOR SPMY.
AFFECTED MODULES: A B
** PROBLEMS/SOLUTIONS/COMfENTS
START DATE 6/78 tSUKNENT: INSTRUMENTATION
END DATE 6/78 f-ROBlEM: NOT DE FINED/S PF CI F I ED
IhSTPUMENTATICN PROBLEMS WERE fiNCOUNTERED DURING THE MONTH. PH PROBES
WERE LOST, THf MA6-FLOW METER FOR LIMESTONE SLURRY FAILED, AND THE AUTO-
0ATIC GAS ANALYZERS DIB NOT OPERATE PROPERLY.
AFFECTED MODULES: SYSTLM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 6/78 E«Uir«ENT: PIPING
tND DATE 6/7S Pt'OBlFpl! PLUGGING, OlHEP
SOHE PIPTS PLUGED DUE TO UfcOPRfcNE. PEELING FRQ" VALVES"
AFFFCTED MODULES: SYSTEM
301
-------
EPA UTILITY KD SURVEY: DECtrBFR 1971 - JANUAHY 1979
SECTION 3
DES1CN AND PERFORM HCE DATA FOR OPERATIONAL FtD SYSTEMS
---- ............... ------ ........... ------ PERFORMANCE BAT A ----- ...... ------------- ....... ------ " ----
PERIOD MODULE AVAILABILITY CPERAfllim ((LIABILITY UTILIZATION * REMOVAL PER BOILER FED CAP.
S02 PART. HOURS HOURS HOURS FACTO*
«••»•• •<«•••» ««••••»»*»•• • ••••MBKMIWW •*••>••**«*<•« «MWV*1*W»«WM »•§•»» «•*••• »•*<••• ••• •* ^ B M •*•••!• •••»••
«* PROSJLEMS/SOLUT10NS/COMMENTS
iTART DATE 6/7C ICUIII'ENT: SLUDFE DISPOSAL
END frATf 6/78 PRCPttMs NOT DEFINED/SPECIFIED
TH6 SLUDGE SYSTEM EXPERIENCED SOMfc FILTER BELT PROPLEHS DURING THE MONTH
PbT ThfSI KtRi REPAIRED.
AFFECTED MODULES: SYSTEM
7/7' A 14. ? 16.7 16.7 1A.7
e
SYSTEM 7** ?<* «8. D
START DATE 7/78 fcSUI CMNT: TRANSFER PUMP
END DME r/78 f'Roei'-i«i! NOT DEFINED/SPICIF IEB
PROBLEMS kfRE FNCOUNTENER WITH THE MODULE-A TR»NSFfR PUMPS* MINT DAYS
WIRE REQUIRED TO TRACE THE ELEC TRKAL -R HATED PROBLEM.
AFFECTED MODULES: A
** PROBLEMS/SOLUTIONS/COMMINTS
START DATE 7/7E) tftUIlMENT: REAGENT HANDLING
END DATE 7/78 PRCCUtM: NOT DE FIKED/SPF CI F I ED
A 17-DAY OtITACf WAS CAUSED BY PROBLEMS UITH THF BALL MILL AIR SUPPLY WHICH
RESULTED IN Ti'f UNA VAIL ABU 1TY OF SLURRY.
AFFtCUD MODULES: SYSTEM
START DATE 7/78 t EU 1 if! EN1: ABSOPBFR
END DATE 7/78 PPOPtTM: NOT DEFINED/SPECIFIED
ft-MOOULE kAS (.TILL DOWN IN JULY WHILE THE UTILITY WAITED FOR THE REPLACE-
MENT EXPANFIOI JOINT.
AFFECTED MODULES: «
*« PROQLEMS/SOLUTIONS/COMMENU
START DATE 7/78 tOUIIMENT: INSTRUMENTATION
END DATE 7/78 PSOBlEHs NOT DE FINED/SPt CI F I ED
WORK WAS DONE DURING THE MONTH TO IMPROVE THE INSTRUMENTATION. IT WAS
D1SCOVFRED THfT MANY OF THE PROEiLbMS WERE DUE TO SCALE ACCUMULATION ON THE
PKOfiES.
AFFECTED MODULES: SYSTEM
8/78 A 59.0 59.0 59 . 0 59.0
SYSTEM 744 ^^^ S4.«
•* PROBLEMS/SOLU1IONS/COMMEN1S
START DATE 8/78 EeUICMENT: DUCTWORK
END DATE £ /78 PROBIFM: NOT DEFINED/SPECIFIED
Ttit FI-MODULE ftMAINEO DOWN THROU6HOUT AU6UST BFCAUSE THE REPLACEMENT EX-
PANSION JOINT HAD NOT YET ARRIVED. EXPANSION JOINT REPAIR WAS REQUIRED ON
THE A-MODULE.
AFFECTED MODULES: A 6
** PP06LEMS/SOLUTIONS/COMMENTS
START DATE R/7f E6UIK*ENT: F6D SYSTEM, GENERAL
END DATE B/78 CCMMINTS:
TKERF WERC NO SCHEDULED OUTA6ES.
AFFECTED MODULES: SYSTEM
** PROULENS/SOLUTIONS/CdMMENTS
START DAlE 8/78 EtUIFMENT: THICKENER
END DATE 8/78 PROBi/*: CHEMICAL-RELATED PLUGGING
PKOBLF.MS klTH THE THICKENER AND PLUGGED LINES CAUSED THE A-M08ULF OUTAGE
TOTALING £11 fOURS.
AFFECTED MODULES: A
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE R/7B ECUlr'ENT: PIPING
END DATE 8/78 FHOBlEH: C HEMI C AL-RELA TE L PLUGGING
302
-------
EPA UTILITY FGD SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND ff. RFORMA MCE DATA FOR OPERATIONAL F6D SYSTEMS
......... ......... --PERFORMANCE DATA —
PERIOD HODUU AVAILABILITY OPERAKILITY FELIAB1LITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
PROBLEMS VilTH THE THICKENER AND PLU66EO LINES CAUSED A-MODULE OUTAGES
TOTALING i11 »-OURS.
AFFECTED MODULES: A
9/76 A ZJ.1 ZB.6 28.6 22.1
B
SYSTEM 720 557 47.6
** PROBLEMS/SOLUTIONS/CCWMENTS
START DATE 9/78 EQU1IKENT: DUCTWORK
END DATE 9/78 PKCBiPH: NOT DEFIN ED/SPECIF1 ED
CONTINUATION (F THE EXPANSION JOINT PROBLEM RESULTED IN THE B-MODULE RE-
FA IN I*lG DOWN 1HROUGHOUT THE flONTH.
AFFECTED MODULES: 6
** PROaiEWS/SOLUTlONS/COMMENTS
START DATE 9/7E EQUIPMENT: THICKENER
END DAT? 9/78 FROBI.E-M: CHEMICAL-RELATED PLUGGING
A-KOOULE DOWN TIME HAS DUE TO PLUfc&jNG OF THE THICKENER SLURRY MAKEUP
LINE? AND FAILURE OF THE BALLS WITHIN THE MODULE.
AFFECTED MODULES; A
** PROBLEMS/SOLUTIONS/CCMMENTS
START DATE 9/78 tfllll f PENT: ABSORBFR
END DATE 9/78 PROBiEn: DESIGN-RELATED INFERIOR CONSTRUCTION MATERIAL
A-NODULE tALL5 FAILED OVER THE PERIOD- THE HEAV IEp-WALLED PING PONG BALLS
ThAT WfRE INSTALLED DURING THE DECEMBER 1977-JANUARY 197E PERIOD WERE: RE-
PLACED HITH 1 .?5 INCH DIAMFTER SOLID RUBBER BALLS DURING SEPTEMBER 1.
AFFECTED MODULES: A
*• PROBLEMS/SOLUTIONS/COMMEN1S
START DATE 10/78 tOUI»*ENT: FGD SYSTEM, GENERAL
END DATE 1C/78 CCWMtNTS:
A THOROUGH CLEANING OF THE ENTIRE F6D SYSTEM OCCURRED DURING THIS PERIOD.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMWENTS
STAPT DATE 10/78 EGUIf?
-------
fPA UTILITY FbD SURVfY: PEtfMEn- 19?fc - JANUARY 1979
SECTION I
DESIPN AND Ff RFORMf.CE DATA FOP OPERATIONAL FGD SYSTTKS
PERFORMANCF BAT A —
PERIOD MOOULF AVAILABILITY OPEPAfllLITY PLIABILITY UTILIZATION X REMOVAL PER BOILER FfiO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
THt RUtEER COATING ON HOLD TANK AGITATORS *Nt> SLURRY STORAGE TANK AGITATOR
WERE SEFAIKFD.
AFFECTED MODULES: SYSTEM
11/7?
A
B
SYSTEM
?5.7
26.3
64.7
22.5
64.7
22.5
64.7
22.4
720
716
SO.!
** PROBLEMS/SOLUTIONS/COMMENTS
ST*RT DATE 11/7E lOUI r* ENT: BOILER-RELATED
tND DATE 11 /78 CCPMfNTS:
Ttf pOlLfR OUlfGE LASTED 9NTO THE FIRST PART OF NOVEHBF.R.
AFFFCTED MODULES: SYSTEf
12/7P
1/79
START DATE 11/78 E GUI FfENt: FAN
tND DATF 11/78 PPOB i E M : WE CHANIC AL-REL ATF D COMPONENT FAILURE
AK ftt OUTAtE MS CAUSED 61 A FAN BEARING FAILURE ON MODULE B .
AFFECTED MODULES: Ei
** PROBLEI«S/SOLUT10NS/COKKENTS
START BATE 1C1/78 f GUI WENT: GAS DAPPER
tND DATF 10/7R COGENT: PREVENTIVE MAINTENANCE
ALL DAMPFKS WIRE SERVICED, REPAIRED AND EXERCISED.
AFFECTED MODULES: SYSTEM
A
6
SYSTEf
45.2
81.7
76.2
32.9
76.2
29,7
68. 7
7*4 671
*« PROBLEMS/SOLtJTIONS/CfllUMENTS
START DATE 12/7E EOUIFMENT: PIPING
END DATE 12/78 FKOPUM: WEATHER-RELATED COMPONENT FAILURE
OKCE THf SPRA> N02?LES UERE REPLACED FROZEN LINES PREVENTED MODULE STARTUP
AFFECTED MODULES: A
•* PROBLEHS/SOLUTIONS/COMMENTS
START DATE 12/78 teiiltWENT: PIPING
END DATE 12/78 PPOBLfM: WEATHER-RELATED COMPONENT FAILURE
SEVERAL LINES BROKE OR DEVELOPED LEAKS.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIOHS/COMMENTS
START »ATE 1?/7f ECUIffENT: F6D SYSTEK, GENERAL
END DftTE 1Z/7E PPOBlEM: WEATHER-RELATED COMPONENT FAILURE
ALL THE MAJOR OUTAGES C ftN p.L ATTRIBUTED TO THE COLD WEATHER. THE SYSTEM
WAS NOT DESJGf'fD WITH DUE REGARD TO WEATHER CONDITIONS.
AFFECTED MODULES; SYSTEM
« PROBLEMS/SOLUTIONS/COMMEN1S
START DATE 12/78 £ GUI ?<"!ENT:
tND DATE 1?/7£ PRCPiER: CHEMICAL-RELATED PLUGGING
NCZZIE PLUGGACF AT THE PRES^TURATOR CAUSED OUTAGE TIME ON ONE MODULE.
AFfECTEO MODULES: A
** PROBLEMS/SOLUTIONS/CCMMENTS
START DATE 12/78 fOUIIKENT: INSTRUMENTATION
tND OATF 12/78 PPOBi£«: WEATHER-RELATED COMPONENT FAILURE
OhE OR TWO NUISANCE TRIPS WERE DUE TO FROZEN 1NSTROMENTS-
AfFECTED MODULES: SYSTEM
A
B
SYSTEM
47.3
47.3
29.0
744 457
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 1/79 EBUIffENT: VALVES
END DATE ,>79 PROBIFM: WEATHER-RELATED COMPONENT FAILURE
304
-------
EPA UTILITY FfD SURVEY! DECEMBER 1978 - JANUARY 1«79
SECTION 5
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL F6D SYSTFflS
. PERFORMANCE DATA-— ----
PERIOD MODULE.AVA11APIL1TY OPERA9ILITY «FL I At 1L1TY UTILIZATION X REMOVAL PER BOILER FPD CAP-
S02 PART. HOURS HOURS HOURS FACTOR
ONE MODULE EXffRIjNCED HAjOR ODTA6E TIME DuE TO FROzFK VALVES.
AFFECTED MODULES: 6
** PROBLEMS/SOLUT10NS/CONMENTS
START DATE 1/79 EQUIPMENT: F6D SYSTEM, SENERAL
END DATE 1/79 PROP.ir«: WEATHER-RELATED COMPONENT FAILURE
FROZFN VALVES AND EQUIPMENT CONTRIBUTED TO THE oUT«6E$ OF A MODULE.
AFFECTED MODULES: A
** PROBLEMS/SOLUTIONS/COMMENTS
START 0*TE 1/79 E6UIFMENT: REAGENT HANDLING
END DATE 1/7,9 PKOBITM: NOT DEFINED/SPECIFIED
DURING T«l FlhST 15 DAYS OF JANUARY THE SECOND BALL MILL WAS UNUSEA6LE
DIE TO LACK Of AIR. THIS CAUSED PROBLEMS IN KFEPING LIMF.STONE SLURRY
SUPPLIED TO THE. A-MODULE.
AFFECTED MODULES: A
305
-------
FPA UTILITY FbD SUPVFY; CECE^FFP 1 SYSTEMS
COMPANY NACE
PLANT NAKF
UNIT NUMBER
CITY
STAT E
RF6ULATORY CLASSIFICATION
PARTICIPATE EMISSION LIMITATION - KC/J
SOZ EMISSION LIMITATION - NC/J
NfT PLANT GENERATING CAPACITY - MW
GROSS UNIT CENERATING CAPACITY - MV
NET UNIT GENERATING CAPACITY V/F6D - K !
NET UNIT GENERATING CAPACITY KO/FGD - I
E8UIVALFNT SCRUBBED CAPACITY - Py
TENNFSSEE V AL L E t AUTHORITY
SHAWNEE
PADUCAH
KENTUCKY
C
516.
1750.0
10.0
10.0
1D.O
( .100 LP/MMETU)
( 1.ZOO LP/MMBTU)
** tOILFR DATA
SUPPLIER ******
TYPE BASE
SERVICE LOAD •****«
COMMERCIAL SERVICE CiATE **/**
KAKIKUH BOILER FLUE 6AS FLOW - CU-^/S *****•«•
FLUF EAS TE1PERATURF - C *******
STACK Hf 1GHT - « ******
STACK TOP OIAFCTER - f *******
(**•*•** *CF«>
(**** F)
<**** FT)
(***** FT)
** FUEL DATA
FUEl TYFE
fUEl CRAOE
AVERAGE HEAT CONTENT - KJ/KG
SANGE HEAT CONTENT - PTU/LB
AVERAGE AsH CONTENT - X
RANGE ASH CONTENT - *
AVERAGE MOISTURE CONTENT - *
RANGE MOISTURE CONTENT - X
AVEFAGE SULFUR CONTENT - JT
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - *
FUEl f 1RIN6 RATE - f. T /H
FUEl FIRING RATf - MW
** FtD SYSTEM
SALEABLE PRO DUCT/T HR 0V AWAY PROOUCT
GENERAL PROCESS TYPf
PROCESS TYPF
SYSTEM SUPPLIER
A-£ FIRM
CONSTRUCTION FIRIH
DEVELOPMENT LEVEL
NEW/RETROFIT
INITIAL STAPT-UP
** ABSORBFR
TYpF
INITIAL START UP
SUPPLIER
NUMEER OF STAGES
6AS FLOW - CU.H/S
6AS TEMPERATURE - C
PARTICULATE INLET LOAD - 6/CU.I*
SOZ INLET CONCENTRATIOfc - PPM
•* MIST ELIMINATOR
NUMBER
TYPF
HASH SYSTEM
** REHEATFR
TYPE
COAL
BITUMINOUS
* *******
***** *
***** ***
* *****
2.90
(****** 8TU/LR)
******
***** ***
******
{*** TPH)
THROWAWAY PRODUCT
yET SCRUBBING
AIR CORRECTION DIVISION, UOP
BECHTEL
TVA
PROTOTYPE
RETROFIT
4/7?
TURBULENT CONTACT ABSORBF, F!
AIR CORRECTION DIVISION, UOP
U.16
UP.9
6.9
2900
C 30000 ACFH)
( 300 F>
( 3.000 GP/SCF)
CHEVRON
INTERMITTENT WASHING KITH AVAILABLE RAU WATER
DIRECT COMBUSTION
306
-------
EPA UTILITY F66 SURVEY! DECEMBER 1978 - JANUAR.Y 1979
SECTION 3
DIS16N AND PERFOSMKE DATA FOR OPERATIONAL FED SYSTtHS
.... ......... . . .PERFORMANCE DMA----- — — —--- ........ ....
PERIOD MODULE AVAILABILITY OPERA01L1TY fELIARILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
0/79 SVSTE.M
•* PRQBLEMS/SOLUTIONS/COKHIENTS
START DATE 0/72 CQUIfWENTl FGD SVSTfMt 6INE»«L
{NO DAT! 0/79 CCMMMTSj
REFER TO riKrCRMANCE UPDATE INFORMATION FOR IHAWNEE 108.
AFFECTED HODULtS: SYSTEf
307
-------
CPA UTILITY Fi,6 SUmY: 6ECLMBFR 197' - JANUARY 1979
SfcCTjON 3
DESIGN AND PfcRFOflMAKE DATA FOR OPERATIONAL FGD SYSTEMS
COMPANY NAME
PLANT NAMf
UMT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICIPATE EMISSION LIMITATION - KC-./J
SOi1 EMISSION LIMITATION - Kt/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT ttNERATING CAPACITY - Kk
NFT UNIT GEIvCRATIK'G CAPACITY W/FGD - Mt
NET UNIT GENERATING CAPACITY WO/F60 - "M
E6U1VALFNT SCRUPBED CAPACITY - MW
TENNFSSEE VM.IEY AUTHORITY
SHAUNEE
TOP
PADUCAH
KENTUCKY
1,7.
51*.
1750.0
10.0
10.0
*******
10.0
( .100 LP/MMBTU)
( 1.ZOO LFi/MHBTU>
** eOILFR DATA
SUPPLIER
TYPE
SERVICt LOAD
COMMERCIAL SERVICE DATE
MAXIMUf EiOlLER FLUt GAS FLOW - CU.f/S
FLUE GAS TEHPFRATURt - C
STACK HEIGHT . I*
STACK TOP DIAMETER - M
•* FUEL DATA
FUEL TYFC
FUEL GRADE
AVERAGE HEAT CONTENT - Kj/KG
RANCE HEAT CONTENT - iHU/LB
AVE»AEE ASH CONTENT - I
RANCE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - !
RANCE K01STIIRE CONTTNT - *
AVERAGE SULFUR CONTENT - it
RAN(sf SULFUR CONTENT - X
AVERAGE CHLORIDE CONTFhT - g
RANCf CHLORIDE CONTfNT - X
FUEl FIRING RATE - K T/H
FUEL F IR1NG RATE - MU
** PARTTCULATE SCRUBEtER
TYPI
SUPPLIER
FLU6 6AS CAPACITY - CU.P/S
FLUF SAS Ttl-PEKATURE . C
** F6D SYSTEM
SALEABLE PRODUCT/T HROW ANAY PRODUCT
CEhfRAL PROCESS TYPE
PROCESS TYPE
SYSTEM SUPPLIER
A-E FIRM
CONSTRUCTION FIRM
DEVELOPMENT LFVFL
kEM/RETftOFIT
INITIAL START-UP
NUMPER
TYPE
INITIAL START UP
SUPPLIER
GAS FLOW . CU.M/S
GAS TEMPERATURE - C
** MIST ELIMINATOR
NUMBER
** REHEATER
TYpF
***** *
BASE
******
**/**
***** **
******
***** **
COAL
BITUMINOUS
«******
********
******
********
******
7.90
******
********
******
*******
*****
1
VENTURI
CHFMICO
U.2
HP.9
(<******* ACFM)"
<«*** F)
(**** FT)
(***** FT)
(****** BTU/LB)
******
(*** TPH>
( 30000
( 300 F)
PRODUCT
WET stftueeiNG
LIME/LIMESTONE
CHFMICO
ElECHTEL
TVA
PROTOTYPE
RETROFIT
4/7?
1
SPRAY TOUEP
4/72
CHEMIcO
14.16
( 30000 ACFM)
< 300 F)
DIRECT COMPLETION
308
-------
EPA UTILITY FCC SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FED SYSTEMS
.. ------- . -------------------------------- PERFORBANCF DATA --------------------------------- . ________
PERIOD MODULE AVAILABILITY OPERAB1LITY ^LIABILITY UTILIZATION X REMOVAL PER BOILER FGO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
0/72 SYSTEM
** PR06LEMS/SOLUTIONS/COMMENTJ
START DATE 0/72 IBUlrMENT: F6D SYSTEM, GENERAL
END DATE 0/72 COMMENTS: RESEARCH AND DEVELOPMENT
IK JUhF 1>;68, THE EPA INITIATED A PROGRAM TO TEST PROTOTYPE LIME AND
LIMESTONE SYSTEMS FOR REMOVAL OF SULFUR DIOXIDE AND PARTICULATE FROM COAL-
FIRED POILEK HUE GASES. THE PROGRAM WAS CARRIED OUT IK A TEST FACILITY
INCORPORATED IK TO THE FLUE GAS DUCTWORK OF UNIT NO. 10, A COAL-FIRED BOIL-
ER AT THE TVA SHAWNEE POWER STATION, PADUCAH, KENTUCKY. TVA is THF CON-
STRUCTION AND FACILITY OPERATOR AND BECHTEL CORP- IS CONTRACTOR, TEST
0 1RECTOR AMD- f-EPORT WRITER.
THE TtST FACILITY CONSISTS OF THREE PARALLEL SCRUBBER SYSTEMS Of PRQ-
TCTYPE SIZE, 1REATING PART OF THE FLUE CAS FROM THE BOILER. EACH SCRUbPtP
TRAIN IS CAPAUE OF TREATING APPROXIMATELY 30,000 *CF« OR THE EQUIVALENT
OF AppRoXIMATILY 10 MW OF POWER PLANT GENERATING CAPACITY.
THREE PARALLEL W£T SCRUBBtR SYSTEMS WEPE SELECTED FOR THE TEfT PRO-
JECT: 1) A VENTURI WITH A SPRAY TOWER AFTER ABSORBER, ?> A TURBULENT CON-
TACT ABSORBER OCA), AND J) A MARBLE-BED APSORBER. THE VENTUR1 SYSTEM,
MANUFACTURED I.Y CHEMICAL CONSTRUCTION CO., CONTAINS AN ADJUSTABLE THROAT
TMT PFRMITS CONTROL AND VARIATION OF PRESSURE DROP OVER A WIDE RANGE OF
FLOW CONDITION. THfc TC A UNIT, M ANUF A CTURE5 PY UNIVERSAL OIL PRODUCTS,
INCORPORATES A FLUIDIZED BfD OF LOW DENSITY PLASTIC SPHERES THAT ARE FREE
TC MOVE PETWE'N RETAINING GRIDE. THE MAR6LF BED AiSORBfR, SUPPLIED BY
coHiUSTieh ENGINEERING co., USES A PACKING OF *-*-JNCH GLASS MARBLE
SPHERES AM, n TURBULfNT LAYER OF LIQUID AND GAS APOvT THE MARBLE LAYFR TO
IKHANCi MASS 1RANSFFR.
IN JUM 1<74, THE EPA PE6AN A 3-YEAR ADVANCED TiST PFOpRAM AT THF
SfrAWNEt FACILHY WITH THFSf MAJOR GOALS: (1) CONTINUATION OF LONG-TERM
TfSTING, WITH ERPHASIS PLACED UPON THE RiLIASLi OPERATION OF MIST ELIMINA-
TION &YsTt»«S H INCREASID 6AS VELOCITY, (2) INVESTIGATION OF ADVANCIO PHO-
CiSS AND teUIIftNT DESjGN VARIATIONS FOR IMPROVING EQUIPMENT RELIABILITY
AKD PROCFSS ECONOHICS, AND (3> LONG-TERM RELIABILITY TESTING ON pROMlsiNS
PKOCESS AM) ItUIPHINT DESIGN VARIATIONS.
THE TWO P*RALL!L SCRUIB1N6 SYSTEMS OPERATING DURING THE ADVANCfD PRO-
GRAM APE THE ViNTURl/SPRAY TOUER SYSTEM AND THE TCA UNIT. GENERAL PROCESS
FLOW DIAGRAMS OF THI TWO PROTOTYPE UNITS ARC PROVIDED IN APPENDIX P. OPEP-
A TION OF THE f' A R&L f -B6 D AFEORS-IB UNIT HAS IEIN PERMANENTLY DISCONTINUED.
EACH Of Tff SCRUBBING SYSTEMS CONTAINS ITS OWN SLURRY HANDLING FACIL-
ITIES AND CAN TREAT APPROXIMATELY SO, 000 ACFM OF GAS AT 300 F CONTAINING
1SPO TO 4(.'00 IPM OF SULFUR DIOXIDE AND ? TO t ERA1NS/SCF OF PARTICULATE.
ffllLFR NO. 1 FORMALLY HURNS A HIGH-SULFUR BITUMINOUS COAL.
FROM JUNE 1974 TO JANUARY 1976, MIST ELIMINATION AND LIMESTONE UTILI-
ZATION TFSTS hERE CONDUCTED AT THE SHAWNEE FACILITY. DURING THIS TEST PER-
IOD THE VENTUH1 /SPRAY TOWER. SYSTEM WAS OPERATED ON BOTH LIME AND LIMESTONE
AND THE TCA S1STEM WITH LIMiSTONF. TESTING WAS PERFOSMfD UNDER A CLOSED-
WATER OPERATICN MODE. DURIN6 THIS PERIOD THE SLURRY SOLIDS CONTAINED AP-
PROXIMATELY tC TO 50 P6RCENT-BY-VEI6HT FLY ASH BECAUSE OF RELATIVELY HIGH
GAS INLET PARIKULATI LOADING. THIS TESTING PR06PA* IS SCHEDULED TO RUN
THROUGH TC FE'liUARY 1978.
ADDITIONAL INFORMATION AND DATA CONCERNING THE! DETAILS OF THE ADVANCfD
TEST PROGRAM fPE PRfSENTFD IN THF PERFORMANCE TABLF. THAT FOLLOWS.
AFFECTED MODULES: SYSTEM
9/75 SYSTEM 7*°
** PROBLEMS/SOLUTIONS/COMWENTS
START DATE 9/75 fcCUilPENT: F6D SYSTEM, GENERAL
END DATE 10/75 COdWiNTS: RESEARCH AND PIViLOPfENT
TMS EXPFHHMTAL EPA-FUNDFD OPERATION IS PROCEEDING WITH THE TEST PROGRAM
TWO ABSORfifR fODULES ARE CURRENTLY OPERATIONAL (10 MW fACH). THE MARPLE-PE
AbSORBTR IS STILL INOPERATIVE (SINCE JULY 1973). CURRENT EXPERIMENTS ARE
RtLATF.D TC MlfT ELIMINATOR SECTION.
AFFFCTED MODULES: SYSTEM
'0/75
309
-------
EPA UTILITY r&D SUPVET; OEClClifR 197f - JANUARY 1979
SECTION I
*NO PFSF OfM M f. DATA FO*1 OPERATIONAL F 6 D SYSTFMS
. ----- .. ---------- ..... --------- - ----- ----PUFORi'lANCr DATA----- — -— —"—•---- --------- .. — . — .. — ...
PERIOD MODULE AVAILABILITY OPERAEHITY ^LIABILITY UTlLifATlCN X REMOVAL PER BOILER fCD CAP.
SO!; PART. HOURS HOURS HOURS 'ACTOR
11/7? SYSTEM 720
• • PRO tL(MS/SOLUTIONS/COM MtN'T£
START CAT! 11/75 IfililflNTi F66 SYS1|M, 6iN|RAL
tM) D*TC 1?/7* tfM»MNTSj SFSfARCH AND DIVILOPMINT
KtCJNT TI8TIN4 AT SHAWNtt HAS SHOhN THAT THt CHIVRON MIST ELIMINATOR! IN
E-CTH THE SPRA> TOUf.fi AND THE TC A CAN S( KEPT Mil OF SOLIDS BUILHIP IT HIG
ALKALI UTH1ZH10N (6REATER 1HAN 40 PtfiCtNT), USING ONLY INTERS I T TANT
WASHIMfi WITH TfST-
iKe THE OXIDATION of suu&si TO (JYPSUW IN THE VFNTURI/SPRAY TOWER SYSTEM
USING AIR SPAFCING OF AN ACKJflED SLURRY BLEED STREAM.
AFFtCTED MODUltE: SYSTrP"
12/75 SYSTEM 7*4
1/76 SYSTEM 744
START DATE 1/76 IOUI!«EMT: F60 SYSTEM, GENERAL
tNC OATT 2/76 COfM tNTSs RESEARCH AND DEVELOPMENT
THE ADVANCED If ST PR06RAM IS CONTINUING. HIGHLIGHTS OF THE PROeR'K ARE AS
FCLLObS:
EVALUATE scRUtnER OPERABILITY DURING VARIABLE LOAD OPERATION.
CONTINUE LCAG-TERM RELIABILITY TESTING.
IKyESTlGATF MHHODS FOR IMPROVING HASTE SOLIDS SEPARATION.
CONTINUE SLUDtf: OXIDATION AND SLUDGE FIXATION STUDY PROGRAMS.
EVALUATE SYSTtP PERFORMANCE AT RFDUCfD FLY ASH LOADIN6.
DETERMINE THl PRACTICAL UPPER LIMITS OF SO? REMOVAL EFFICIENCY.
EVALUATE ADD] II ON OF MAGNESIUM 10K TO THE SCRUBBING SLURRY.
CHARACTERIZE 'it STACK GAS EMISSION COMPONENTS.
EVALUATE MTfUALS OF CONSTRUCTION OF ALL SCRUBBER AND PLANT-RELATED
CCMPONENTS.
DtVELOPE A COPPUTiR PR06RAH FOR 6ISI6N AND COST ANALYSIS OF FULL-SCALE
LIME/LIMESTONt: SYSTEM.
AFFECTED MQDULEs: Sl'STtf
2/76 SYSTEM 696
3/76 SYSTEM 744
** PROULEMS/SOLUTIONS/COKMIN1S
START DATE 3/76 IQUIfMENT: FGD SYSTIM, StNiRAL
6ND DATF t/?6 COMH-NTSl RESEARCH AND DEVELOPMENT
PtCHTEL RtPORlFD THAT THF FACTORIAL TEST PR06RAM, IVALUATIN6 THE PERFOR-
MANCE OF THl UM1/L1MISTQNT SCRUBBING SYST|MS WjTH AND WITHOUT HA6NES1UK
ADDITION HAS tfEN COMPLETED. CURRENTLY TESMN6 IS PROCEED1N6 ON THE EVALUA
TION OF SYSTE" PERFORMANCE AS A FUNCTION OF LOW RESIDENCE TIMES (1.5 TO S.
MINUTES) IN T»ii RE-CYCLE TANKS, IN ADDITION, A FLY ASH-FRFI DUCT IS BEING
INSTALLED Al THE TEST FACILITY, THUS ENABLING EVALUATION OF SYSTFH PERFOR-
MANCF IN THE ^SfNCE OF FLY ASH.
AFFECTED MODULES: SYSTEM
*/76 SYSTEM ?20
5/76 SYSTEM 744
** PROBtEwS/SOLUTIONs/COMMENTS
START DATE 5/76 tOUIFMENT: F6D SYSTEM. SfNERAl
END OATE 6/76 COMWtNTS: RESEARCH AND DEVELOPMENT
THE TEST OlREtTOR, BECHTFL, PROVIDED THE FOLLOWING INPUT CONCERNING THE
310
-------
EPA UTILITY IFGD SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FGD SYSTEMS
.. . PERFORMANCF DATA •
PERIOD WODULF AVAILABILITY OPERAB1LITY PLIABILITY UTILIZATION X REMOVAL PER BOILER FE6 CAP.
SO? PART. HOURS HOURS HOURS FACTOR
OPERATION OF THE EXPERIMENTAL SCRUBBING SYSTEMS OURIN6 THE REPORT PERIOD.
THE EFFECT CF M60 ADDITION WAS EXPLORED IN BOTH SCRUBBER SYSTEMS. RESOLTS
INDICATE HAGNt'SIUH ION IN THE SCRUBBER SLURRY L1BUOR ENHANCES SO? REMOVAL
AI\D CAN DEPRESS SULFATE SUPE RSATURAT1 ON . IT WAS FOUND THAT THE MAGNESIUM
ICN CONCENTRATION HAD TO EXCEED THE EUUIVALENT CHLORIDE ION CONCENTRATION
TC HAVF, AN EFfFCT ON S02 REMOVAL.
i* THE TCA UNIT, WITH LIMESTONE SLURRY, soz REMOVAL WAS INCREASED FROM 75
TO 95 PERCENT PY INCREASING THF MAGNESIUM ION CONCENTRATION TO 9,000 PPM
It, EXCESS OF FOUIVALENT EQUAL TO 6 PERCENT BY WEIGHT Of THE LIMESTONE AD-
DITION RATE. IN THE VENTURI/S PR AY TOWER SYSTEM, WITH LIME SLURRY, SO? RE-
MOVAL WAS INCFFASED FROM 75 TO 90 PERCENT BY INCREASING THE MAGNESIUM ION
CONCENTRATION TO ?,'000 PPM.IN EXCfcSS OF EQUIVALENT CHLORIDE TON. THE'MAG-
NESlUM OXIDl ADDITION RATE uAS 2 PERCENT 6Y WEIGHT OF THE LIME ADDITION
RATE. BOTH SCRUBBING SYSTEMS OPfcRATED IN THE SUBS*TURATED SUlFATE MODE
wdEN MAGNESIUM OXIDE WAS ADDED* INLET soz CONCENTRATIONS DURING THE TESTS
AVERACF APPKOJIMATELY 3,000 PPM DURING THESE TESTS.
FOLLOWING THE TEST BLOCKS MENTIONED ABOVE, BOTH SCRUBBERS ARE OPERATING
WITH LIMf SLURRY SCRUBBING SOLUTIONS, THE TCA SYSTEM ON FLUE GAS CONTAIN-
IlvG FLY ASH A ftp THE VENTURI/S PR AY TOWER SYSTEM ON FLY ASH-FREE FLUE GAS.
AFFfCTED MOOUlES: SYSTEM
6/76 SYSTEM 7?0
7/76 SYSTEM 744
** PROBLEMS/SOLUTI ONS/COMMENTS
START DATE 7/76 EGblf'MENI: FGD SYSTEM, GENERAL
END DATE B/76 COMMENTS: RESEARCH AND DEVELOPMENT
EXPEPIMfNTAL CPERATION Or THE EPA/TV* ALKALI SCRUBBING TEST FACILITY CON-
TINUED DURING THE REPORT PERIOD. B^CHTEL, THE TEST DIRECTOR, PROVIDED THE
FCLLOWING 1NPIT CONCERNING THE OPERATION OF THE PROTOTYPE TEST UNITS.
VENTURI/SFSAY TOWER SYSTEM: THIS SYSTEM RAN OFF FLY ASH-FRFE FLUE 6AS USIN
A LIME SLUPKY SCRUBBING SOLUTION. NO SIGNIFICANT DIFFERENCES IN $02 REMOV-
AL, GYPSUM SATURATION AND SULflTE OXIDATION WERE DETECTED (VERSUS FLY ASH-
LADEN FLUE GAi). ONE DIFFERENCE NOTED WAS THE FILTER LAKE SOLIDS CONTENT
VhlCH WAS AFPIOXIMATELY 10 PERCENT LOKER FOR THE FLY ASH-f»EE SLUDGE 140
TC 50 PERCENT SOLIDS)VERSUS THE FLY ASH-LADEN SLUD6E 150 TO 60 PERCENT
SOLIDS. IN ADUTION OPERATION IN A LOW RESIDENCE TIME MOD E< 3MINUTES)WAS
EXPLORED. SCAIf-FREE OP£RAT]ON WAS ACHIEVED IN THIS MODE UNDER THk FOLLOW-
ING CONDITIONS: 8 PERCENT SOLIDS (NO FLY ASH) IN THE Rr Cl RCULATED SLtlRRY,
PK OF THF SCRIFBER LIOUID INLET WAS 8.0, SUPERFICIAL GAS VELOCITY OF 9.4
FT/SEC., AND H TOTAL LIQUID.TO-6AS RATIO (1-6) OF 7.1 GAL/MCF. SOME SCALE
FC"M«TION OCCIBRED WHEN THF SOLIDS CONTENT or THE RECJ.RCULATED SLURRY
DROPPED BtLOW THE * PERCENT LEVEL-
TCA SYSTEM: TWIS SYSTEM OPERATED ON FLY ASH-LADEN FLUE BAS USING A LIME
SLURRY SCRUtBJ!»6 SOLUTION INNOCULATEO WITH MAGNESIUM OXIDE. SYPSUfl StleS*''-
URATION OPERATION WAS ACHIEVED UNDER THE FOLLOWING CONDITIONS: MAGNESIUM
UN CONCENTRATION EXCEEDED THE CHLORIDE 10N CONCENTRATION BY 2000 PPM, SU-
PERFICIAL GAS VELOCITY W*S 12.5 FT/SEC., L/6 WAS 50. THf SCRUBBIN6 SOLU-
TION INLET PH WAS 7.0, AND RESIDENCE TIME WAS 4 MINUTES. THE S02 REMOVAL
EFFICIENCY M ! APPROXIMATELY 90 PERCENT. WHEN L/G WAS REDUCED TO 37, WHILE
ALL OTHER CONIITIONS REMAINED CONSTANT, SEVERE GYPSUM SCALE FORMATION RE-
SILTED INCHIA'ING THE EFFECTIVE MAGNESIUM CONCENTRATION TO 4000 PPM AND
TfcE SCRUPbFP LIQUID INLET PH TO f! .0 DID NOT AMELIORATE THE SCALE PROBLEM.
PkESFNTLY THE VENTURI/SPRAv TOWER SYSTEM IS OPERATING ON FLY ASH-FREE FLUE
GAS WITH KAtNiSIUH OX1DE-1NNOCULATED LIME SCRUBBING SLURRY-
AFFECTED MODULES: SYSTIM
6/7ft SYSTEM 744
9/76 SYSTEM 7?0
** PROtJLEMS/SOLUIIONS/COWENTS
START DATE 9/76 E«UIH«ENT: FGD SYSTEM, GENERAL
END DATE 10/76 CCMMLNTS: RESEARCH Aht> DEVELOPMENT
It, SEPTEMBER Mit OCTOBER 1o?6 THE VEN TU RI/SPRAY SYSTEM WAS OPERATED WITH
311
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EPA UTILITY FKD SURVEY: DtCtKPFFi 197f - JANUARY 19'9
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL F6D SYSTEMS
— --- -PERFORMANCE DATA .........
PERIOD MODULE AVAILABILITY OPERAIUL1TY iTLlAMLlTY UTILIZATION X REMOVAL PER BOILER F6D CAP.
SO? PART. HOURS HOURS HOURS FACTOR
FLY ASH-FPft HUE G»S USjNfi LlKlE SLURRY WITH ADDED MGO TYPICAL
TEST CONDITIONS WERE 9.4 FT/SEC SPRAY TOWER 6A$ V|LOC1TY, ?1 GAL/«Cf VENTU
HI L/6, 51 6AI/MCF SPRY TOUER L/E, g PERCENT SLURRY SOLIDS (FLY ASH FREE)*
3 MINUTES RESIDENCE TIME, 7.0 SCRUBBER INLET PH, AND 2000 PPM EFFECTIVE
MAGNESIUM ION CONCENTRATION d.F.f EXCESS OVER EQUIVALENT CHLORIDE ION).
RhSULTS WERE KOT CONSISTENT AT THESE CONDITIONS. DURING ONE PERIOD, SCRUB-
BINS INLET LIUJOR GYPSUM SATURATION AVERAGED 85 PERCENT WITH 80 pERCFNT 50
RtROVAl WITH !OME GYPSUM SCALS FORMATION. IN A LATFR PERIOD, AT SEEMINGLY
1DTNT1CAL TE.S1 CONDITIONS GYPSUM SATURATIONS DROPPED TO 10 PERCENT WITH 9
PERCENT Si'.2 R.'KOtfAL AND THF SCRUBBER DESCALED. A SEVEN-MEEK PROGRAM OF IN-
TENSIVE FLUE kAS CHARACTERIZATION TESTING VAS STARTED IN MID-OCTOBER ON
TKE VfNTURI/SHVAY TOWER SYSTEM. THESE TESTS ARF BEIN6 HADE TO MEASURE
SlMUtATANtOUS INLET AND OUTLET FLUE GAS PARTICIPATE MASS LOADINGt PARTT-
CULATE S17E DISTRIBUTION AND 6ASEOUS So3 CONCENTRATION. THF TCA SYSTEM
CONTINUED TO fPERATE DURING THIS PERIOD ON FLY ASH-LADEN FLUE 6AS USING
LIME SLURRY WITH ADDED MGO.THE TEST RESULTS SO FAR INDICATED THAT THE
DEGREE OF SUl IA TE (6 YFSUM )S ATURAT I ON IS A SENSITIVE FUNCTION OF THE
EFFLUENT RESIDENCE TIME CONDITIONSrGAS VELOCITY 12.5 FT/SEC, L/6 OF 50, PH
Of 7.0, JCDO IPM OF HG ION, AND R PERCENT SOLIDS. AT THESE CONDITIONS
GYPSl'f SATURATION WERE 95,50,AND 92 PERCENT,AT RESIDENCE TIMES OF 3,4,AND
12 MINUTES,RESPECTIVELY.FURTHER TESTS WERE RUN AT 17 GAL/MCF L/6,AND 8.0
INLET PH UTH OTHER CONDITIONS THE SAME. DURING THESE TESTS GYpSUM SATURA-
TIONS WERE 95, 95, 50, AND 90 PERCENT AT 3, 4, 5.4, AND 16 MINUTES RESI-
DENCE TIMES, lESPECTIVELY.
AFFECTED MODULES: SYSTtP
10/76 SYSTEM 744
11/76 SYSTEM 720
** PROfcLEMS/SOLUTIONS/CCMMENTS
START DATE 11/76 tGUIFWENT: FGD SYSTEM, GENERAL
END DATE 12/76 COHHS.NTS! RESEARCH ANt> DEVELOPMtNT
FROM MIo-CtTOffR THROUGH EARLY DECEMBER AN INTENSIVE FLUE GAS CHARACTERI-
ZATION TESTING PROGRAM WAS CONDUCTED ON THE VENTURl/SPRAY TOWEft SYSTEM
WITH LIME SLUUK'Y. OVER THE RANGE TESTED, OUTLET PARTICIPATE MASS LOADING
HAS FOUND TO !F INDEPENDFNT OF SLURRY COMPOSITION S, 3,000 TO 16,000 PPM DISSOLVED SOLIDS), GAS FLOW RATE
(20,CCO TO 35,000, ACFH>» SPRAY TOWER LlflUIO RATE Co TO 1,400 GPCO ANB
VtNTURI PRESStRE DROP (3 TO 9 INCHES HZO). WITH 4 TO 6 6R/OSCF PARTICULAT£
IK THE IMFT lYpicAi OUTLET LOADINGS WERE 0.02 TO 0.04 GR/DSCF. WHEN OPER-
ATING WITH FLIF GftS FROM THE ELECTROSTATIC PRECIPUATOR (0.1 TO 0.4
GR/OSCF TO THt SCRUBBER), THE SCRUBBER OUTLET LOADING AVERAGED 0.005
GR/DSCF. THUS. ENTRAINED SLURRY FROM THE M.E. PUST HAVE BEEN LESS THAN
0 .OOSGR/DSCf. SIZE DISTRIBUTION DATA ARE STILL BEING ANALYZED. SULFURIC
ACID MIST VALUS WERE APPROXIMATELY 2 TO 25 PPM AT THE SCRUBBER INLET AND
REMOVALS HAVE BEEN ABOUT so TO 75 PERCENT.
THE REMAINDER OF DECEMBER THE VENTURIJSPR AY TOWER SYSTEM WAS DOWN FOR MOD-
IFICATIONS fOR TWO-STAGE OXIDATION TESTING. SEE APPENDIX 6 FOR A PRflCESS
FLOW DIAGRAM.
HRIN6 NOVFMBtR THE TCA WAS OPERATING WITH FtY ASH-CONTAlNlNG FLOE GAS US-
IHG LIME SLURRY WITHOUT ADDED MAGNESIUM OXIDE. OPERATING CONDITIONS VERE
12.5 FT/StC G;j VELOCITY, 50 6AL/KCF L/G, 8.0 SCRUBBER INLET PH, AND 8 TO
15 PERCENT SLURRY SOLIDS. AT THESE CONDITIONS THF. SO? REMOVAL WAS ABOUT
PERCENT.
FLY ASH-FREE LIMESTONE T£STS WITHOUT MAGNESIUM OXIDE ADDITION BEGAN ON TH
TCA SYSTEC IN LATE NOVEMBEP. TYPICAL OPERATING CONDITIONS WERE 12.5 FT/SE
GAS VELOCITY, SO GAL/MCF L/6, AND 1.1 TO 1.3 STOICHIOHETR1C RATIO. AT THE
SAKE STOICHIO^FTRY, THE PH OF THE FLY ASH-FREE SLURRY WAS 0.2 TO C.3 UNITS
H1£HER THAN OB IERVED IN PREVIOUS RUNS WITH FLY ASH.
AFFECTED MODULES: SYSTEM
12/7t SYSTEM 7(U
1/77 SYSTEM ll>lt
»* PROoLEMS/SOLUTIONS/Cni»KENTf
START DATE 7/77 EQUIIPENT: FGD SYSTEM, GENERAL
END DATE 2/77 COMMITS: RESEARCH AND DEVELOPMENT
312
-------
EPA UTILITY FGH SURVEY: DECEMBER 1978 - JANUARY 1«79
SECTION 3
DESIGN AND PFRFOFt.AKE DATA FOR OPERATIONAL FGD SYSTrHS
. ----------------------------------------- PERFORMANCE DATA -------------- ...... ----------- .... .......
PERIOD MO&ULF AVAILABILITY OPERAHUITY PLIABILITY UTILIZATION X REMOVAL PER BOILER FED CAP.
$02 PART. HOURS HOURS HOURS FACTOR
THE VENTURI/SIKAV TOWfR SYSTEM HAS BEEN OPERATED IN A TVO-SER IE S-SCRUEBE R
MODE KITH FORtrO OXIDATION SINCE EARLY JANUARY 1977 AFTER SYSTEM MOfFICA-
TJONS TO ALLOV OPERATION OF THE VENTURI AND SPRAY TOWER WITH INDEPENDENT
SLUR RY RECIRCMLATION LOOPS. SULF1TE OXIDATION WAS CARRIED OUT IN AN 8 FT
DIAMETER VENTLPI (PRE-S C RUPBER) EFFLUENT HOLD TANK WHICH HAD AN AIR SPARG-
WITH 130-1/b INtH HOLES IMMERSED IN 18 FT OF SLURRY. THE SRAY TOWER (AFTER
SCRUBBER) FUNCTIONED AS A PRIMARY S02 ABSORBER.
TYPICAL OPERA IION CONDITIONS, USING LIMESTONE SLURRY, WERE 6.7 FT/SEC SPAY
TOWER GAS VELOCITY, 20-30 6AL/MCF VENTURI L/G, ?Q GAL/MCF SPRAY TOWER L/G
15 PERCENT SOLIDS IN VENTURI RECIRCULATED SLURRY, A. 5-5.0
VINTIIR1 IKLfT (OXIDATION TANK) PH, AND 11.3 MINUTES OXIDATION TANK RFSI-
DENCE TIME (EA'.tD ON 600 GPM SLURRY FLOW TO VENTURI). DURING THESE TESTS*
AVERAGE OVERALL SULF1TE OXIDATION RANGED FROM 93 TO 99 PERCENT AT AIR
ST01CHIOMETRI I RATIO OF 1.0 TO 4,7 LB-ATOMS OXYGEN/LB-M OL E S02 APSORBEO.
CORRESPONDING AVERAGE OXIDATION IN THE SPRAY TOWER RAN6ED FROM 1C TO 16 *
AVERAGE OVERAIL LIMESTONE UTILIZATION RANGED FROM »3 TO 96 X
SCALING WAS EXPERIENCED IN EITHER SCRUBBER. AVERAGE FILTER CA«E SOL1&S
WERE 79 TO 66 S BY WEIGHT COMPARED WITH 55-65 X WITHOUT FORCED OXIDATION.
SLURRY SOUDS SETTLING RATE RANGED 0.5 TO 1.4 CM/MZN, 5 TO 10 TIMES
FASTER THAN T^T FOR UNOXIDIZED SLURRY. FINAL SETTLED DENSITY RANGED 65-8C
PIRCF.NT SOLID; COMPARED WITH 45-&C PERCENT FOR SLURRY WITHOUT FORCED OXI-
DATION.
FLY ASH-FfcEE UMFSTONE TESTING ON THE TcA SYSTEM WAS COMPLETED IN EARLY
FEBRUARY. THE PH OF THE FLY ASH-FREE SLURRY WAS 0.? TO 0.3 UNITS Hit HER
TfcAN OBSERVED IN PREVIOUS RUNS WITH FLY ASH. IN ADDITION m FLY ASH-FREE
SLURRY APKARlD TO HAVE INFERIOR SOLIDS DEHATER1NG CHARACTERISTICS. FOR
EXAMPLE THF Ci-MTRIFUGE CAKE SOLIDS AVbRAGEC ABOUT 50 * COMPARED WITH
AtOUT 60 r-FFCf^T FOR SLUDGE CONTAINING FLY ASH.
1KTEUS1VE FLU:: GAS C HAR ACTC RI ZAT I ON TESTING WITH LIMESTONE SLURRY ON THE
TCA SYSTEM BEtAN IN EARLY FEBRUARY AND ENDED IN EARLY MARCH 1977. PRFLIM-
IMRY ANALYSIS OF THE DATA SHOWED AN OUTLET MASS LOADING OF 0.4-0. S
GK/DSCF FLY A £H AND 0.02-0.03 GR/CSCF FOR FLUE GAS WITHDRAWN DOWNSTREAM OF
THE ESP.11 WAS ESTIMATED TNAT THCSr OUTLET MASS LOADINGS CONTAINED ABOUT
0.03 GR/DSCt fLY ASH, 0.0? GR/DSCf REENTRA1NED SLURRY SOLIDS AND 0.015
ENTRAINED DISSOLVED $OLID$(wHEN A CONTINUOUS MIST ELIMINATOR UNDER WASH
WAS USED, THEU VALUES VA*T DEpENBlMG ON THE MlST ELIMINATOR WASH SCHEME
AKD GAS FLOW MTE.
AFFECTED MODULES: SYSTEM
2/77 SYSTEM 672
3/77 SYSTEM "*
** PROtiLEMS/SOLUTIONS/COMMENTS
START DATE 3/77 till^ENT! FGD SYSTEM, RENE HAL
END DATE -?/77 CCM"tNTS: RESEARCH AND DEVELOPKINT
DURING MARCH 1HE VI NTUR I /SPRA Y TOUEH HAS TESTED WITH L1MF SLURRY AND FLY
ASH LADEN FLUf GAS IN A TWO-STAGE SCRUBBER MODE WITH FORCED OXIDATION OP-
ERATION WITH LIME WAS SIMILAR TO THE PREVIOUSLY REPORTED LIMESTONE OPERA-
TION WITH f,fcFfTER THAN 95 PERCENT OXIDATION AT AN AIR S TO ICHI OWE T RIC RATIO
OF 1.5 Lfl-ATOfS OXYGEN/L^-WOLE S02 ADSORBED WITH A SIMPLE AIR SpARGfP IN
VENTURJ HCLl) 1ANK. SLURRY SOLIDS SETTLING RATE VARHD FROM 0.( TO 1.9 CM/
I" IN (A 5 TC 1f-FOLD ENHANCEMENT OVER UNOXIfimD SLURRY) AND FILTER CAKE
SOLIDS RANffD TROM 74 TO 8? PERCENT COMPARED TO 45 TO 60 PERCENT WITH UN-
OXIDmO Uir.
TkO MAJOR DIFFERENCES BETWEEN LIME AND LIM|STONE WERE OBSESVED IN A T«0-
S1AGE FORCED (XIDAT10N SYSTEM TO MAINTAIN PH CONTROL IT WAS NECESSAKT TO
FEED LIME TO I'OTH STAGES. WITH LIMESTONE, FEED ONLY TO THf SECOND STAGE WA
WAS ADEfiuATi. TO MAINTAIN ROX SOJ REMOVAL, IT WAS NECESSARY TO °""ATt
WITH A HIGH SLURRY SOLlOS CONCENTRATION IN THE SPRAY TOWER LOOP WITH LIME-
STONE (15 PERIFNT)THAN WITH LIME (A PERCENT), RESULT^? IN A TIGHTER WATER
IALANCE WITH LIMESTONE AND INADEQUATE WATER TO FLUSH THE MIST ELIMINATOR.
PRELIMINARY LIMESTONE TYPE AND GRIND TESTS MADE ON THE TCA SYSTEM DURING
MARCH INDICATE THAT 502 RFMOVAL IS IMPROVED 6Y THE' USF OF FINER GROUND
LIMESTONE. SO. REMOVAL WITH I? BUI V AL E NTL Y GROUND FREDONIA WHITE AKD LON6-
VUW ALABAMA UMSTONES WAS THE SAME. BLUDSTREAN fORCtD OXIDATION TSSTS
ARE BEIN« CONDUCTED WITH A PENSERTHY ELL-3 INJECTOR IN A CLOSED LOOP
313
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FPA UTILITY F&D SURVEY: DECfc"fctR \t>lf - JANUARY 1979
SECTION 3
DESK-M *ND PERFORMANCE DATA FOP OPERATIONAL FCD SYSTEMS
ftK FORMANCF OAT A '
PERIOD MODULE AVAILABILITY OPERAHILITY FLIArULITY UTILIZATION X REMOVAL PER BOILER FGD CAP-
SO? PART. HOURS HOURS HOURS FACTOR
AROUND A t-LEfi: STRfA* HOLD TANK. INITIAL TESTS WERE UNS UC ES S Fill CUE TO
HIGH PH Of 7 10 8 IN THF HOLD TANK- BY LOWERING THE HOLD TANK PH TO 5 OR
6, SULFITE OXIDATION UP TO 98 PERCENT WAS ACHIFVFD.
AFFECTEU MODULES: SYSTEM
4/77 SYSTEM
7EO
** PKOdLEfS/SOLUTTONS/COMKENTS
START DATE 4/77 t «U I f" ENT: FGD SYSTEfl, GENERAL
END DATE 5/77 COKMtwTS: RESEARCH AND DEVELOPMENT
UMT 10 BOILEf WAS SHUT DOWN FOR A SCHEDULED TWO-MONTH MAINTENANCE OUTAGE.
BECAUSE OF TH'. ROILER OUTAF-E, THF SHAfcNEE SCRUBBERS DID NOT OPERATE DURING
APRIL AND KAY .
AFFECTED MODULES: SYSTEM
5/77 SYSTEH T><>
6/77 SYSTEM ' 720
** PR06LEKS/SOLUTIONS/CCMENTS
START DATE 6/77 £OUI!ltENT: F60 SYSTEM, GENERAL
END DATE 7/77 COKMFNTSS RESEARCH AND DEVELOPMENT
SCRUfcBFR OPfcR,«TlON RESUMED ON JUNE 15 AFTER A 10-WEEK SCHEDULED MAINTEN-
AkCE OUTAGE Of\ THE BOILE.F).
TfcE VENTUR/SP i-/Y TOWER SYSTEM CONTINUED TO OPERATED WITH TW 0 SCRUEiBEP
STAGFS AND FOICEO OXIDATION BY NFANS OF AN AIR SPARGING PING IN THE VEN-
TIIRI HOLD TANK, IN JUNE AND JULY, OPERATION WAS WITH LIME SLURRY AND fLY
ASH-FREE fltE
-------
EPA UTILITY FED SURVEYS DECEMBER 1978 - JANUARY 1«79
SECTION 3
DESIGN AND PERFCRMAKE DATA FOR OPERATIONAL FGD SYSTEMS
........ .... .. -•-•-PERFORMANCF DATA-—- ..... —...... .....
PERIOD MODULE AVAILABILITY OPERABILITY PLIABILITY UTUIZATION * REMOVAL PER BOILER FGD CAP.
802 PART. HOURS HOURS HOURS FACTOR
»•»"•• * !•• »• ww »™«B^w»-»«B»»»t«fr«m »ww»w»ww™i»™w in««*iB,MiHM,a-i>»>«>*e «.BBw»«m»B«M,M«(Mihe« >• w* >* m «v « *aw >v m matwnm «» w «a •» „ — • ••••• ««•••«
97 PERCENT SULFITE OXlDA^ON AT «N AIR STOJCMIOMITRY OF 1.7 ATOMS OXTSEN/
HOLE SOZ ABSOI'&ID AN6 AN OXIDATION PH OF 5.5. THI F1LT|R CAKE SOLIDS CON-
TENT AVIRACit-D PETTIS THAN PI PERCENT. TISTS WERE ALSO CONDUCTED WITHOUT
TH DfSUPlRSA HIRATICN TANK IN THi VENTURl SLURRY LOOP AND WITH THE OXIDA-
TION TANK LEVU DROPPED FROM 1R TC U FT WITHOUT ADVERSE EFFECTS.
BURJN6 AUGUST AND SEPTEMBER THi TCA SYSTEM WAS OPERATED MOSTLY IN A TWO-
TANK FORCE OXIDATION ROD I USJN6 AN Alfl ED4ICTOR. TH! TEA EFFLUENT (LI*I-
STONF SLURRY HTH A HIOH FLU ASH LOADING) WAS COLLECTED IN A SMALL LOW-PH
ALURRY HOLD TANK WHiRI LIKISTQNi WAS ADBID THUS TAKING ADVANTA6E OF THE
LOW PH SLURRY THROUGH THE AIR IBUCTOR FOR IMPROVED SULFJT6 OXIDATION AND
HlgH PH SLUftRI TO TCA FOR PETTER 50? REMOVAL.
TrsT WERE MADi BOTH WITH THE AIR EOUCTOR MOUNTED ON TOP OF THE EFFLUFNT
HCtD TANK WIT) BOWNWARD SLURRY DISCHARGE TO THF BOTTOM OF THE TANK. AVER-
AGE SULFIlt OHDAT10N RANGE FROM 9! TO 98 X AT ABOUT 2.5 AIR STOICHIOMETRY
AAD 5.2 EDUCTCR INLET PH. DURING 1WO OF THE RUNS MADE IN AUGUST WHEN
ThE ROTARY DRl» FILTER WAS USED THE FILTER CAKE SOLIDS CONTENT AVERAGED
f. 5 AMD 8P PERCf NT.
A ttN-DAy RUN VAS WADE IN SEPTtMPER ON THE TCA SYSTEM WITH AUTOMATIC LIME-
STONE FEED CONTROL BASED ON STO1CH10METRY. THE LIMFSTONE SLURRY FEED RATE
WAS CONTROLLFl BY THE FLUE GAS FLOW RATE AND THE INLET 502 CONCENTRATION.
TfcE CONTROL S«TEM WORKED WELL ACCOROIN6 TO THF SPECIFICATIONS.
AFFECTED MODULES: SYSTEM
9/77 SYSTEM 720
10/77 SYSTEM 74*
** PROBLtMS/SOLUTlONS/COKMENTS
START DATE 10/77 fcOUI fMENT: FED SYSTEHt GENERAL
tND DATE 11/77 COMWFN1S: RESEARCH AND DEVELOPMENT
TI-E VENTURI/SFKAV TOWER SYSTEM CONTINUED TO OPFRATE WITH TWO SCRUBBER
STAGFS AND FORCED OXIDATION IN THE VENTURl HOLD TANK. IN OCTOBER, THE FOL-
LOWING IHPROVtKENTS WERE MADE WITH NO SIGNIFICANT DROP IN OXIDATION EF-
FlCIfNCY HTH SATISFACTORY S02 REMOVAL EFFICIENCY.
THE SPRAY TOWER GAS VELOCITY WAS INCREASED FROM 6.7 TO 9.4 FT/SEC.
ThE PXjDATlON TANK LEVEL WAS DRIPPED FROM 1, TO U FT.
THE AIR SFARGIO RING CONTAINING AC lU-jNCH DIA«f.TER HOLES* W*S RE~
FLACEO HIM A SINGLE S-INCH DIAMETER PIPE SIDCHARCING DOWNWARB AT THE
CENTEF. OF THE OXIDATION TANK I INCHES FROM THE BOTTOM.
WITH AIR UISOARGID FROM AN OPEN-ENDED PlP£ IT WAS APPARENT THAT THE AIR
DISPERSION IN THE OXIDATION TANK WAS ACCOMPLISHED MAINLY 6Y THE TURhlNE
AtMATOR MTHTK THAN THE STARGER. IN NOVEMBER, A ONE-MONTH RELIABILITY
TEST WAS STAR1ED ON THE VENTURl /SPR AY TOWER SYSTEM USING FORCED OXIDATION
WITH TWO SCRUU ER STAGES AN!) LIMESTONE SLURRY WITH HIGH FLY ASH LOADING.
THE FLUE CAS KATE TO THE SCRUBBER SYSTEM WAS VARIED ACCORDING TO THE BOIL-
ER LOAD WHICH f'ANGED BETWEFN 100 AND 155 MW. TEST CONDITIONS WERE SELECTED
TC MFET TfcE E FA NEW SOURCE PERFORMANCE STANDARDS OF 1.2 IBS 502 AND 0-1
Lt PARTiCLiUT- PER MILLION BTU. THIS RUN «AS STILL IN PROGRESS AT THF END
Of NOVEMBER. (M THE TCA SYSTEM, FORCED OXIDATION WlTH A SINGLE SCRUBBER
STAGE USIH.P ** AIR EDUCTOR WAS SIDCONTINUED IN EARLY OCTOBER AFTER A HOLE
ERODED THPOU6H THE OF.UCTOR BODY COFiCED OXIDATION TESTING WILL BE RESUMED
Id EARLY tECEnER AFTER AN AIR SPARGER IS INSTALLED.
Ik OCT0eeF:-NO«MEER, A ONE-MONTH RELIABILITY TEST WITHOUT FORCED OXIDATION
WAS CONDUCTED ON THE TCA SYSTEM WITH LIMESTONE SLURRY, FLUE 6AS WITH HIGH
FLY ASH LCADItC, THREE HOLD TANKS IN SERIES, AND 7.5 INCHES STATIC HEIGHT
Of NlTRILE F0« SPHERES IN EACH Of 3 BEOS IN THE TCA GAS RATE TO THE
SCRUPEIER VAS \ARIEp WITH BOlLER LOAD AND STOHHIOME TR 1C RATIO WAS CON-
TROLLED BY AM AUTOMATIC LIMESTONE FEED SYSTEM. CONDITIONS WERE SELECTED TO
MEET THE EPA I^FW SOURCE PERFORMANCE STANDARDS AT A LOW ST 01CH10MTRIC RATIO
OF 1.2 MOLES IA/MOLE 502 ABSORBED. THE AVERAGE 502 REMOVAL FOR THE ENTIRE
ftlN WAS 8t PERCENT *T 2600 PP« WHICH WAS 6FTTER THAN THE 83 PERCENT RE~
OU1PFD TO F»fET THE EMISSIONS STANDARD. HOWfVER, THF STANDARD WAS FRE6UENT-
LY EXCftDtD FIR PERIODS GREATER THAN THE 3 HOURS ALLOWED BY THE EPA REGU-
LATIONS. AVERAGE OUTLET PAPTICULATE MASS LOADING WAS 0.043 GRAIN/SCF DRY
k'HlCH WAS BETltR THAN THE 0.052 GRAIN/SCF DRY (30 PERCENT EXCESSAIR) RF-
GL'IRED TO ?EEl THt STANDARD. THE RANGE OF THE OUTLET MASS LOADING WAS
P.02C TO G.G6'- GRAIN/SCF DRY.
515
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?PA UTILITY Ft,D SURVEY: OECfKBfR 197F - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL F6o SYSTEMS
PERFORHANCF DATA «...
PERIOD MODULF AV«IIAPILITV OPEPABUHY PLIABILITY UTILIZATION * REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
AFFECTED MODULES: SYSTEM
11/77 SYSTE* 720
12/77 SYSTEf 7«4
«« PRO&LEMS/SOLUTI ON 5/COMK:EN1 f
START DATE 1?/77 fceim»EMT: FGD SYSTEM* E EN E R AL
END DATE 1/78 COKMFNTS: RESEARCH AND DEVELOPMENT
A LIMESTONE RELIABILITY TEST ON THE VENTURI/SPRAY TOWER SYSTEM WAS
COMPLETED IN MD-DECE«BER,1977 AFTER 965 OPERATING HOURS. THE TEST WAS
CONDUCTED HTH TWO SCRUBPER LOOPS WITH FORCED OXIDATION IN THE MRSTCVEN-
TLRI) LOOFi TI-E fLUE GAS FLOW RATE WAS VARIED ACCORDING TO THE BOILER LOOT)
WHICH RANGED ifTwEEN 100 AND 155 KU .
TfST CONOITlOrv? WERE SELECTED TO KF.ET THE FPA NEW SOURCE PERFORMANCE STAN-
DARDS OF 1.2 in 502 AND 0.1 LB PA«TICULATE PER MILLION BTU. THE OPERATING
RELIABILITY Of THE SYSTEM WAS DEMONSTKATEC. HOWEVER, DUE TO WIDE VARIATION
Ik THE INLET sn? CONCENTRATION AMD THE SLOW SYSTF.H RE-
SpONSE TIME THE SO? EMISSION STANDARD WAS FREQUENTLY EXCEEDED FOR PERIODS
GREATER THAN 1H£ THREE HOURS ALLOWED BY EPA REGULATIONS. AVERAGE S02 RE-
MOVAL FOR THE ENTIRE RUN WAS 86 I AT 2950 PPM AVERAGE INLET S02 WHICH WAS
H16HFR THAN T(£ 84 * REfllJIRED TO MEET THE STANDARD FOR 2800 PPM INLET
5C2. THE OUTLET PARTKULATE LOADING RANGED FROM 0.021 TO 0.063 6RAIN/DRY
SCF, WITH A RIM AVERAGE OF 0.012 GRAIN/DRY SCF. THESE VALUES COMPARE WITH
LCADING OF L'.l'SZ GR/DRY SCF Oft LESS REOUIRED TO MEET THE EPA PARTICIPATE
STANDARD ASSUHNG 30 PERCENT TOTAL BOILER EXCESS AIR.
ANOTHER RELIABILITY RUN ON THE VENTUR1/SPRA* TOWER SYSTEM WAS STARTED IN
HID DECEMBER (SING LIME SCRUBBING. THE RUN WAS COMPLETED IN JANUARY 1978.
HUH THE EXCflTION OF HIGHER SPRAY TWOER INLET PH AND HIGHER ALKALI UTILI-
ZATION INHEREhT WITH THE LIME SYSTEM, THE OPERATING CONDITIONS AND THE
TkST RESULTS vrRE SIMILAR TO THOSE OF THE LIMESTONE RELIABILITY RUN.
oh THF TCA SY;TE«» TWO RUNS WERE MADE yiTH THE NITRILE FOAM SPHERES RE-
PLACFD BY A tr INCH HEIGHT (23 LAYERS) OF CElLCOTE PACKING SUPPORT PIATES.
AT fULL GAS FLOW RATE OF 30,000 ACFM, THE 502 REMOVAL FOR THE CElLCOTE
PLATES WAS SLK.HTLY LESS THAN THAT OF A 3-FJED, 4-GRID TCA WITH FIVE INCHFS
OF STATIC SpHtrE HEIGHT PEP BED. HOWEVER, AT 1C,000 ACFM THE 502 REMOVAL
FOR THE CEILCfTE PLATES WAS A FEW PERCENTAGE POINTS HIGHER THAN THAT EX-
PERIENCED WITH THE TCA BEDS.
FORCED OXIDATION TESTS WERF CONDUCTED ON THE TCA SYSTEM WITH AN AlR SP»«6-
ER USING LIME1TONE SLURRY WITH HIGH FLY ASH LOADING. BOTH ONE-TANK tAIR
SPARGING AND LIMESTONE ADDITION IN THE SAMF.TANK) AND TWO-TANK (AIR SPAR6-
JkG IN THE FIfcST TANK AND LIMESTONE ADDITION IN THE SECOND) CONFIGURATIONS
WERE USED. NE« COMPLETE SULF1TE OXIDATION WAS ACHIEVED IN BOTH CONFIGURA-
TIONS AT AN AIR STOICHIOMETRY OF 1.8 ATOMS OXYGEN/HOLE SOZ ABSORPED AND
OXIDATION PH ff 5.4-S.7. THE OXIDATION TANK LEVEL WAS 18 FT.
AFFECTED MODULES: SYSTEM
1/7P SYSTEM 744
2/7? SYSTEM 672
** PROBLEMS/SOLUTIQNS/COMMENTS
STAPT DATE 2/7? E6UIFKENT: FGD SYSTEM, GENERAL
END DATE 3/78 CPMMtNTS: RESEARCH AND DEVELOPMENT
MAJOR SYSTEM iOWNTIMES DURING THE PERIOD INCLUDEDD JANUARY 26 THROUGH FEB-
RUARY < FCP TtE VENTURI/SPRAY TOWER AND JANUARY 36 THROUGH FEBRUARY 2 FOR
ThE TCA SYSTEM DUE TO FREEZING WEATHER. ANO MARCH 6 THROUGH MARCH 17 FOR
DCTH SYSTEMS CUE TO BOILER OUTAGE.
TKE EFFECT OF THE SLURRY LEVEL IN THE AIR SPARGED OXIDATjON TANK WAS IN-
VESTIGATED IK THE TWO SCRUBBER LOOP VENTURI/SPRAY TOWER SYSTEM WHICH IS
OPERATING OK UME SLURRY WITH HIGH FLY ASH LOADING. NEAR COMPUTE SUIMTE
OXIDATION (98 t) WAS ACHIEVED WITH 14 FT ANB 18 FT OXIDATION TANK
LEVELS AT AN HR STOICHIOMFTRIC RATIO OF I.B ATOMS OXYGEN/MOLE soz AB-
SORBFD. AK Alf STOICHIOHfTR1C RATIO UP TO ABOUT 3.R WAS NEEDED TO YIELD
316
-------
EPA UTILITY fGO SURVEY: DECEMBER 1V78 - JANUARY 1979
SECTION 3
DESIGN AND PFRFORKAfcCE DATA FOR OPERATIONAL FGD SYSTEMS
...... . --PERFORMANCE DATA .
PERIOD MODULE AVAILABILITY OPF.RAPILITY FHL1ABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
NEAR COMPLETE OXIDATION WHEN THE TANK LEVEL WAS DROPPED TO 10 FEFT.
A NEV TEST bL'-CK WAS STARTED CM PARCH 1 ON THE VENTURI/SPRAY TOWER SYSTEM.
MAGNFSIUM OX IDF WAS ADDED TO THE SPRAY TOWER SLURRY LOOP IN A TWO SCRUBBER
LOOP OPERATION WITH FORCED OXIDATION IN THF VENTUR1 LOOP. THE SYSTEM WAS
OPERATED U A LIMESTONE SLURRY MOGF WITH HIGH FLY ASH LOASING. THE PRIMARY
OBJECTIVE Cf F16NESIUM ADDITION IS TO IMPROVE THE 5(J2 REMOVAL EFFICIENCY.
BECAUSE Of THL SHORTAGE OF COAL CAUSED BY THE LOAK MINERS' STRIKE, COALS
FROM DIFFtRLNl SOURCES VfRf PURNF.D IN THE BOILFR. AS A RESULT, INLET 502
CONCENTRATION FLUCTUATED AS MUCH AS TENFOLD (3r-0-3500 PPM) CAUSING PRO-
BLEMS IN SYSTfctf CONTROL.
TCA WAS OPERAltD WITH BOTH LIME A M> LIMESTONE fsND WITH MEGNESjUtf OXIDE AD-
DITION. FLUE l,AS WITH HIGH FLY ASH LOADING WAS USED. THESE TESTS WERE CON-
OUCTtB PR1PARJLY TO RESOLVE SOME OF THE INCONSISTENT RESULTS OBTAINED
DURING EARLIEf L 1ME/MGO AND LIMESTONE/MGO TEST MADE IN APRIL NOVEMBER
1*76. AIR LEAKAGE THROUGH THE SCRUBBER DOWNCOMER WAS SUSPECTED IN SOME
OF THOSE tALICR RUNS, RESULT ING IN HIGHER-THAN-NORMAL SULFITE OXIDATION
AKD GYPSUM SATURATION. TEST RESULTS SO FAR WERE 1NCONSLUSIVE BECAUSE OF
THE FLUTUATIOC IN INLET 502 AND CONTROL PROBLEMS MENTIONED ABOVE.
AFFECTED MODULES: SYSTEM
3/78 SYSTEM 744
4/78 SYSTEK 720
** PROfltEMS/SQLUjlONS/COMMENTS
START DATE 4/78 tGUjfPENT: FGD SYsTEH, GENERAL
END DATF 5/78 COMMtNTS: RESEARCH AND DEVELOPMENT
TfE VENTUR1/SFRAV TOWER SYSTEM CONTINUED TO OPFRATE THROUGH EARLY MAY WITH
MtO AUDIT ION AND WITH TWO SCRUBBER LOOPS. THE SYSTEM WAS OPERATED WITH
LIMSTONi SLURRY AND WITH HIGH FLY ASH LOADING. rMGO WAS ADDED TO THE SPRAY
TbOER SLURRY 100P TO MAINTAIN AN EFFECTIVE MGTT ION CONCENTRATION OF SOOC
PFM (ABOUT tiOCO PPM IN THE VENTUR1 SLURRY LOOP) TO IMPROVE THE 5C2 REMOVAL
EFFIVIENCY IN THE SPRAY TOVER. OXIDATION WAS FORCED IN THE VENTURI SLURRY
HOLD TANK. UKUFR TYPICAL OPERATING CONDITONS, THE OVERALL 502 REMOVAL WAS
9t PrRCENT AT 2300 PPM INLFT 502 CONCETRATI ON, COMPARED TO 86 PERCENT
PL.''0Vt.L AT 16:.0 PPW INLET 50? WITHOUT M60 ADDITION. 502 REMOVAL BY VENTURI
ALt;NE. WAS 3D (KRCENT ABOUT THE SAME AS THE CASF WITHOUT MGO ADDITION. 50?
RtKOVAL PY VEI.TUR1 ALONE WAS 30 PERCENT, ABOUT THE SAME AS THE CASE WITH-
OUT fGO AUDITION. NEAR COMPLETE SULFITE OXIDATION COULD BE ACHIEVED AT AN
AIR STOICH10M[TRIO RATIO AS LOW AS 1.3 ATOnS OXYGEN/MOLE OF SO? ABSORBED,
Ifc THE SAKE 0«ER AS THE CASE WITHOUT M60 ADDITION.
FORCED OXDATIIN WAS ALSO CONDUCTED ON THE LIMESTONE SLURRY BLEED STREAM
FROM THE VENTIRI/SPRAY TOWER SYSTtM. A SINGLE EFFLUENT HOLD TANK WAS USED
FOR EiOTH VEKTlivI AND SPRAr TOWER. MGO WAS ADDED TO THE EFFLUENT HOLD TANK
TC MAINTAIN AC EFFECTIVE MC-.TT ION CONCENTRATION OF 5000 PPM. A SLURRY
STREAM WAS TAM-N FROM THE SCRUBBER DUONCOMER AKD SFTT TO AW OXIDATION TANK
UTO WHICH AIP WAS SPARGED. A RECYCLE STREAM OF ABOUT 50 £PM WAS SENT BACK
FKCM THE OXIDATION TANK TO THE EFFLUENT HOLD TANK TO CONTROL PH IN THE
OXIDATION TANr AND TO PROVIDE GYPSUM SEEDS IN THE SCRUBBER SLURRY FINAL
SYSTEM BLtFfc MS WITHDRAWN FROM THE OXIDATION TANK. AT AVERAGE OXIDATION
TANK PH OF 6, EULFITE OXIDATION AVERAGED 98 PERCENT. FILTER CAKE SOLIDS
CONTENT WAs Ei PERCENT, SIMILAR TO THAT OBTAINFD WITH TWO SCRUBBFR 1POP
OPERATIONS*. HfVEVEK, THE SLURRY SOLIDS SETTLING RATE WAS ONLY ABOUT T.4
Cf/MIN, COMPAftO TO ABOUT 0.8 CM/MIN FOR THE TWO LOOP OPERATION. SETTLING
RATE FOR UNOXIOIZED SLURRY CONTAINING MAGNESIUM ION NORMALLY DID NOT EX-
CEED 0.1 CM/BIN WITH 50 TO 60 PERCFNT FILTER CAKE SOLIDS.
TCA CONTINUED TO OPERATE WITH MGO ADDITION W 1TH BOTH LIME AND LIMSTCNt
SCRUBBING.FLUt GAS WITH HIGH FLY ASH LOADING WAS USED. THE INTENT OF THESE
TESTS WAS TO CLARIFY SOMF OF THE INCONSISTANT RESULTS OBTAINED DURING
EARLIER RUNS fADE IN APRIL-NOVEBPIR 1976t DURING WHICH SCRUBBER DOWNCOMER
AIR LEAKACF *?••* SUSPECTED IN SOWS OF THE TFSTS. IK GENERAL, TEST RUNS «ADE
Ih 1976 HAD HIGHER S02 CONCENTRATION, MOSTLY GREATER THAN TOOO PFM, WHILE
THE RECENT RUI*!; HAD ONLY APOUT 25CO PPM. AT THE HIGHER INLET So2 AND THE
H1GHEP RESULTS! SO 2 MAKE-PER-P AS S, THE 1976 TESTS OPERATED EITHFR UNSATU-
RATAFD OR SUPtK SATURATED WITH RESPECT TO GYPSUM, DEPENDING ON THE SULFITE
OXIDATION LEVtL. SEVERE GYPSUM SCALING OCCURRED WHEN THE OPERATION HAS
GYPSUM-SATURATED MODE. IN THE RECENT RUNS, OPERATION WAS MOSTLY
117
-------
EPA UTILITY F6D SURVEY: BECEH'FR 1"57? - JANUARY 1979
SECTION 3
DESI6N AND PERFORMANCE DATA FOR OPERATIONAL FCD SYSTFMS
PfcMOD MODULE AVAILABILITY OPERAF-HITY
PlftFORMANCf
PLIABILITY UTILISATION
X REMOVAL P£" BOILER FGD CAP.
SO? PART. HOURS HOURS HOURS FACTOR
GYPSUn-JMURAiED MODf. HOWEVifi t BECAUSE OF THE LOWfR INL6T SO? AND
L6WER S02 MKI-PH-PaSSf THE S1PSU« SATURATION LfVSLS V**t NOT HIGH ENOUGH
TO CAUSE ANY 'I6N1FICANT
AFFFCTfB MODULUS SYSTfcf
S/7R
6/7F SYSTF*
720
7/78 SYSTEM
8/78 SYSTEM
STA ERUjCENTs FGD SYSTEM*
END DATt 7/7F. COMMiNTS: RESEARCH AND DEVELOPMENT
KSCPt) OXIDATION FEES STREAM FROM THE V ENTUR?/SPRAY TOWI* SYSTEM CONTINUED
THOUGH HID- JIM. TWO TEST RUNS TWO TEST RUNS WERE HADE IN WH ICH MOO WAS
AtiOEl' 70 MIN1AIN AN EFFECTIVE M6*+ CONCENTRATION OF 5000 PPM IN THE
SCfcUEBER Sl,UR|,Y ANO NO RECyCLE STREAM WAS SENT BACK FROM THt OXIDATION
TANK (» FT DIUfTER A^f T p FT TANK LfV6L> TO THF EFFLUENT HOLB TANK. AV-
tBASF SULflTE OXIDATION WAS 96 X OR HIGHER AT AN AIR ST01 CH10HE7R jC RATlo
OF 1.6 ATOfS CXYGEN/MOLE S02 ABSORBED. THE OXIDATION TANK PH WAS 5.« TO
5.6 CNLy C.2 IMIT HIGHER THAN THE FFFLUENT HOLB TANK PH. THE FILTER CAKE
ECU PS WAS t 5 PERCENT AND THE SOLIDS SETTLING RATE WAS Q.4 TO 0.5 CM/MIN.
PCTH SCRUI.E'EP SYSTEMS WERE SHUT H OWN FOR TWO WEEKS FRO* JUNE 19 RUE TO A
BOILFR OUTAGE SCHEDULED FOR R£-ROLITlNG THE FLUF 6AS DuCT FROM THF
-------
FPA UTILITY F6D SURVEY: DECEMBER 1978 - JANUARY 1079
SECTION 3
DESIGN AND PERFOPKAKE DATA FOR OPERATIONAL FGD SYSTEMS
.. -PERFORMANCE DATA-—
PERIOD NODUU. AVAILABILITY OPERABU1TY PLIABILITY UTILIZATION * REMOVAL PER BOILER FED CAP.
S02 PART. HOURS HOURS HOURS FACTOR
TC BE FULLY E fFEclIVE-
DETERIORATION OR DECOMPOSITION OF AOIPIC Ad" APPARENTLY TAKES PLACE IN
THE SCRUBBER. ACTUAL FEED RATES OF AD1PIC ACID WERE 2 TO 3 TIMES HIGHER
THAN COULD BE ACCOUNTED FOR IN THE SYSTEM DISCHARGE SLUDGE.
AFFECTED MODULES: SYSTEM
9/78 SYSTEM 720
10/78 SYSTEM 744
** PROflLEMS/SOLUTIONS/COMMENTS
START DATE 10/78 EOUIIMENT: FGD SYSTEM, GENERAL
END DATE 11/78 COMMENTS: RESEARCH AND DEVELOPMENT
A ONE MONTH LCNG-TERM RELIABILITY RUN WAS CONDUCTED ON BOTH THE VENTURI/
SFRAY TOWER AKD TCA SYSTEMS USING LIMSTONE SLURRY WIT H AOIPIC ACID AS AN
ADDITIVE FOR ifiHANCING 502 REMOVAL EFFICIENCY. STEADY-STATE 50? REMOVAL IN
BOTH RUNS WAS CONS1STANTLY HIGH IN THE RANGE OF 96 TO ">9 PERCENT UNDER
TYPICAL OPERATING CONDITIONS. THE VENTURI/SPRAY TOWER SYSTEM WAS OPERATED
WITH TUO-SCRUH4ER-LOOP FORCED OXIDATION. ADIPIC AC ID CONCENTRATIONS WERF
1500 PPM IN TK TCA AND THE SPRAY TOWER, AND 2AQO PPM IN THE VENTIRJ, BOTH
SCRUBBER SYSTEMS OPERATED FREE OF SCALING AND PLUGGING
LCNG-TERM TtSlS BEGAN IN MID-NOVEMBER TO COMPARE CONVENTIONAL LIME SCRUB-
BING WITH ADVANCED L.IMSTONE SCRUBBING USING CHEMICAL ADDITIVES AND FORCED
OXIDATION. EACH TEST WILL LAST ONE MONTH OR LONGER. THE VENTURI/SPRAY TOW-
ER SYSTEM is rtm OPERATED WITH IWO-SCRUSPER-LOOP FORCED OXIDATION AND
LIMESTONE SLUF.RV AND AOIPIC ACID ADDITION. THE TCA SYSTEM IS BEIN6 OPERAT-
ED WITH LIME SLURRY (NO ADDITIVES) AND WITHOUT FORCED OXIDATION. DURING
THESE TESTS CONTINUOUS S02 EMISSIONS MONITORING PROCEDURES WILL BE
ASSESSED.
AFFECTED MODULES: SYSTEM
11/78 SYSTE* 720
12/78 SYSTEM 7*A
*« PR08LEMS/SOLUTIONS/COfWENTS
START DATE 12/78- EQU1FMENT: FGD SYSTEM, GENERAL
END DATt 1/79 COM!* ::NT S: RESEARCH AND DEVELOPMENT
LCNG-TERM TESTS ON BOTH SCRUBBER SYSTEMS. WHICH BEGAN IN MID-NOVEMBER 1976
WERE COMPLETE!, NEAR THE END OF JANUARY 1979- THESE TESTS WERE CONDUCTED
TC COMPARE CONVENTIONAL LIME SCRUBRING WITH ADVANCED LIMESTONE SCRUBBING
USING CHEMICA1 ADDITIVES AND FORCED OXIDATION. THE VENTURI/SPR AY TOWER
WAS OPERATED UTH TWO-SCRUPBER-LOOP FORCED OXIDATION AND WITH LIMESTONE
SLURRY AND ADJPIC ACID ADDITION. THE TCA SYSTEM WAS OPERATED WITH LIME
SLURRY (NO ADi'TIVE) AND WITHOUT FORCED OxlOATION. DURING THESE TESTS
CONTINUOUS S0<: EMISSIONS MONITORING PROCEDURES WERE ASSESSED.
AFFECTED MODULES: SYS*
1/79 SYSTEM
744
319
-------
FP» UTILITY FliD SURVM: BECtfPfR 1'7t - JANUARY 1979
St CTION 3
ItSlGN AND PFRFCRMAf
** FUEL DATA
FUEL TYPE
FUEL CF'ADE
AVERAGE HEAT TONTEMT - KJ/KG
RANGE HEAT CONTENT - B TU/lfc
AVERAGE ASH CONTENT - i
RANGE ASH CONTENT - X
AVtRAGE HOISTLIRF COMTEK! - %
RANGE MOISTURE CONTENT - *
AVERAGE SULFUR CONTENT - *
RANGE SULFUR CONTFNT - £
AVERAGE CHLORIDE CONTENT - 1!
RANGE CHLORIDE CONTENT - %
FUEL FIRING RAT? - M T /H
FUEL F IUNG RATE - Mil
COAL
* *****
25.00
******
10.00
* *****
4.30
******
***** ***
******
*******
*****
( 10000 BTU/LB)
******
(*** TPH)
• * ESP
SUPFLJ if
PARTICULATE DESIGN REMOVAL EFFIClE»>eY
- X
KOPPERS
50.0
•• PARTICULA7F
NUIUPEP
TYPF
NUMPEP OF STAGES
SHELL MATERIAL
BOILER L OAD/Sf RUB8ER - t
L/G RATIO - LmR/CU.M
PRESSURE DROP - KPA
PARTICULATE INLET LOAD - G/CU.K
PART1CUIATE OUTLET LOAD - 6/CU.K
PARTICULATE DFSIGN REMOVAL F.FF1CIE&CY
SOZ INLET CONCENTRATION - PPM
S02 DESIGN REMOVAL EFFKIFMCY - X
** FGD SYSTEM
SALEABLE pROtucT/ThRow*w*> PROIUCT
GENERAL PROCESS TYPE
PROCESS TYPE
SYSTEM SUPPLIER
DEVELOPMENT LEVFL
NEh/RETROFIT
PARTlCtlATE DESIGN REMCVAl EfFlClEUCY
SOZ DESIGN REMOVAL EFFICIENCY - X
COMMERCIAL DATE
INITIAL START-UP
CONSTRUCTION INITIATION
CONTRACT AWARDED
- X
VARIABLE THROAT VENTURI
i
316L SS
25.0
1.3 (10.0 GAL/1000ACF)
1.2 t 5 JN-H20)
12.6 ( 5.50 GR/SCF)
.1 < .020 GR/SCF)
99.5
34*0.000
10.0
THROWAWAY PRODUCT
WET SCRUBBING
LIMESTONE
TENNESSEE VALLEY AUTHORITY
FULL-SCALE
RETROFIT
99.5o
eo.oo
1/7H
5/77
2/73
2/73
TYPE
MULTIGP.ID TOWER
320
-------
EPA UTILITY F6D SURVEY: DECEMBER 1«?8 - JANUARY 1979
SECTION 3
DESIGN AND PERF0PMAKCE DATA FDR OPERATIONAL F6D SYSTEMS
INITIAL START UP
SUPPLIER
NUMBER OF STAGES
DIMENSIONS
SHELL MATERIAL
SHELL LINER MATERIAL
INTERNAL MATERIAL
BOILER LOAD/APsORBER - X
L/6 RATIO - L/CU.H
PRESSURE DROP - KPA
SUPFRFICAL 6AS VELOCITY - M/SEC
PARTICIPATE OUTLET LOAD- G/CU.K
S02 OUTLET CONTRAT10N - PPP
S02 DESIGN REMOVAL E.FF1C1FNCY - !!
** ABSORBER
NUMBER
TYPE
INITIAL START UP
SUPPLIER
NUMBER OF STAGES
DIMENSIONS
SHELL MATERIAL
SHELL LINER MATERIAL
INTERNAL MATERIAL
BOILER LOAD/APsORBtR - X
L/6 RATIO - L/CU.M
PRESSURE DROP - KPA
SUPERF1CAL GAS VELOCITY - M/SEC
PARTICULATE OUTLET LOAD - NG/J
SOZ OUTLtT CONTRAT10N - PPC
502 DESIGN REMOVAL EFFICIENCY - i
** FANS
NUMBER
TYPE
** WIST ELIMINATOR
NUMBER
TYPF
CONSTRUCTION MATERIAL
CONFIGURATION
NUMBER OF PASSES
DEPTH - M
VANE SPACING - CM
WASH SYSTEM
SUPERFICIAL 6AS VELOCITY - «/S
** PROCESS CONTROL CHEMISTRY
CONTROL VARIABLES
SENSOR LOCATION
5/77
POtYcON
5
JO WIDE X U DEEP X 34 HIGH
CARBON STEEL
RUPBFR, 3UL SS ON SLOPIN6 SECTIONS
314L SS GRIDS (BOTTOM, CENTER AND TOP);
25.0
?.0 t 60.0 GAL/1000ACF)
.5 ( ?.0 IN-H20>
3.7 ( 12.0 FT/S)
.0 ( .020 6P/SCF)
*5Q
7C.O
1
TOWER WITH PACKING
5/77
POLYCON
5
20 WIDE X 1t DEEP X 34 HIGH
CARBON STEEL
RUPBFR, 3VL SS ON SLOPING SECTIONS
31«L SS GRIDS (BOTTOM, CENTER AND TOP); FRf>
.0
P.O
.5
1.7
9.
650
70.0
BOILfR I.D.
CHEVRON
31*L SS
VERTICAL
4
.30
1.P
CONTINUOUS
2.7
t 60.0 6AL/TOOOACF)
t 2.0 IN-H20)
< 12.0 FT/S)
< .020 LB/IWTU)
< 1.0 FT)
< 1.50 IN)
FT/S)
PH» PRESSURE CHANGEi OUTLET
RECYCLE LINE
«* PUMPS
SERVICE
ABSOPpEP RECIRCULAT]ON
VENTURI RECIRCULATION RUMPS
VENTURI RECIRCULATION PUMPS (SPAKE)
LIMESTONL SLURRY FttD PUMPS
POND WATER RETURN PUMPS
«* TANKS
SERVICE
RECIRCULATION
VENTURI RECIRCULATION TANKS
LIMESTONE SLURRY STORAGE
RECIRC TNK UNPRFLW SUME TANK
«* REHEATER
TYPE
HEATING MEDIUM
TEMPERATURE BOOST - C
NUMBER
10
4
2
• ***
****
NUMBfK
INDIRECT HOT AIR
ETEAf
27. e e
50 F)
321
-------
FP» UTILITY FSO SURVEY: DtClf.f-Efc 1">7f - JANUAPY 1979
SECTION 3
DESIGN AMD PERFORMANCE DATA FOR OPERATIONAL FGD SYSTEMS
*• "EA6ENT PKEPAR»TION io
NUMPFR Of BALL MILLS
BALL MILL CAPACITY- M T/H
1
45.?
{ 50.0 TPH)
** DISPOSAL
NATURE
TYPE
DIMENSIONS
AREA - ACRES
CAPACITY - CU.fc
FINAL
POND
110 ACRES * -'0 FT DEEP
111.0
4035900 < 3300.0 ACRE-FT'
PERFORMANCE DATA
PERIOD MODULI AVAILA01LITY OPERAHILITY tfLIABILITY UTILISATION % REMOVAL PER BOILER FGD CAP.
SO? PART. HOURS HOURS HOURS FACTOR
6/77
6A
er
BC
80
SYSTEf Z*.0 70. 0 30.0 26.0
744 657 0
** PROeLE«S/SOLUTIONE/COCilNTS:
TVA HAS HAD EXTENSIVE PROBLEMS WITH START-UP OF ITS SCRUBBFR FACILITY.
AFFECTED MODULES: SYSTEM
«• PR06LEMS/SOLUTIONS/CCMMENTS
START DATE 8/77 t6UKwENT: FAN
END DATE t/77 PROPLhM; C H EMI C AL-RE LAT E 0 EROSION
THERE HAVE BttH EROSION PROBLEMS HTH THE l.D. FAN BLADES.
AfFECTED MODULES: SYSTEM
** PROBLEMS/SOLU1IONS/COMMENTE
START DATE 8/77 ESUli^ENT: FAN
bND DATF S/77 PPOBlfM: MECHANICAL-RELATED COMPONENT INEFFICIENT
TKE FAN DRIVE "OTORS HAVF ALSO BF.EN TROUBLfSOMt.
AFFECTED MODULES; SYSTEf
** PR06LEMS/SOLUTIONS/COM«1ENTS
START DATE t111 tCUIF^ENT: GAS DAMPER
END DATE £ /77 FROB iT ft • ME CHA N I C A L-RE L ATE D COMPONENT FAILURE
THE EU1LLOTINF DAMPERS ARE INOPERARLE DUE TO JAMMED GEAR BOXES.
AFFECTED MODULES: SYSTfM
*« PROULEMS/SOLUTIONS/COMMENTS
START DATE fi/77 ECUIh>.ENT: GAS DAMPER
E.ND DATE P/77 PROB15M: CHEMICAL-RELATED EROSION
THE SEALS AROlfJD THE: DAMPERS HAVE CORRODED, CAUSING LEAKA6F OF THE FLUE
GAS AND PARTI tULATE .
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE R/77 ECUIFfENT: ABSORBER
END DATE 8/77 PROBLEM: NOT DEFINED/SPECIFIED
T»iE RUBBER LIMNG IN THE ARSORBER SECTION OF All FOUR TRAINS HAS DETACHED
Ik VARIOUS PLACES. THE VENDOR HAS REPAIRED THE DEFECTIVE SECTIONS.
AFFECTED MODULES: SYSTEM
•• PROBLEMS/SOLUTIONS/COMi»ENTS
START DATE 8/77 EQUIPMENT: INSTRUMENTATION
END DATE ?/77 PROBLEM: NOT DEFINED/SPECIF1ED
1KSTRUKENTATICN HAS BEEN A SERIOUS PROBLEM AREA.
AFFECTED MODULES: SYSTEM
*• PRObLEMS/SOLUTIONS/COMMENTS
START DATE 8/77 t-etl FXENT: REAGENT HANDLING
tND DATE 8/77 F-PCBl?M: NOT D E F INE D /S PIT CI F I ED
THE EAL.L FILL IS ONLY ABLE TO PRODUCE 35 TPH OF LIMESTONE SLURRY OUT OF
IT'S 50 TPH CAPACITY.
122
-------
EPA UTILITY FGD SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PESFORKAKCE DATA FOR OPERATIONAL FGD SYSTEMS
... ---- ........... ---- ....... ------------ -PERFORMANCE DATA -------- ...... ------- ........ ____ .. ...... .
PERIOD MODULE AVAILABILITY OPERA0IL1TY IE LIAEI 1LITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
AFFECTED MODULES: SYSTIf
9/77 6A
SB
8C
60
SYSTEM 75.0 71.0 71.0 60.0 7?0 609 0
*« PRO&LiWS/SOLUTIONS/CCMMENTS
START DATE 9/77 EUL'I ffENTs B01 LPR-Rf LAT| D
END DATE 9/77 COMMtNTS:
DIR1N6 THIS MCNTH THE BOILER WAS OPERATED AT A REDUCED LOAD OF ABOUT
TCC PW. AT THJS REDUCED LOAD, ONLY 3 TRAINS WERE RE8UIRED TO HANDLE
ALL CF THE bOJLER FLUE GAS.
AFFECTED MODULES: SYSTEM
*« PK08LEMS/SOLUTIONS/CONMENTS
START DATE 9/77 IOU1FMEHT: FGD SYSTEM, GENERAL
END DATE 9/77 PROBLEM: CHEMICAL-RELATED SCALING
SOME SCALING k»S DISCOVERED IN THE ABSORBER COLUMN AND ENTRAINMENT
SEPARATOR OUTLET OF ONE; TRAIN.
AFFECTED MODULES: SYSTtC
** PRObLEMS/SOLUTIONS/COKMENTS
START DATE 9/77 tOUIlKENT: FAN
END DATE 9/77 PROBLEM: CHEMICAL-RELATED EROSION
SERITUS ERC&ICN PROBLEMS CONTINUE WITH THE I.D. FAN ROTORS*
AFFECTED MODULES: SYSTEM
** PROeLEMS/SOLUTIONS/CCMMENTS
STApT DATE 9/77 EOUI'FMENT: BOI LER-RELATf D
END DATf 9/77 f ROB lift : N OT D E F INED /SPF CI F I ED
TJiE UNIT WENT OFF LINE SEPTEMBER 3D FOR A SCHEDULED OUTAGE TO REPAIR BOIL-
ER TUBES. DUKIM; THE OUTAGE, AN ATTEMPT WILL BE MADF TO CORRECT MANY OF THE
MECHANICAL PRCFLEM&.
AFFECTED MODULES:
10/77 SYSTEM 7*4
** PROBLEMS/SCLUTIONS/COKiPiENTS
START DOTE 10/77 tGUIH-'ENT: BOILER-RELATED
END DATE 10/77 f'SOBLFM: NOT DEFINED/SPECIFIED ,
UMT 8 WAi OFFLINE FOR THE ENTIRE MONTH DUR1N6 SCHEDULED OUTAGE FOR \
REPAIR OF 60IIER TUBES. DURING THIS PERIOD, MANY MECHANICAL AND INSTRUMEN-
TAL sCRuPCffc IROBLEMS WERE
AFFFCTED MODULES: SYSTEF"
11/77 8A
8P
SC
>
SYSTEM 86.0 te.O 86. 0 50. P 7?0 41J 0
** PROfeLEMS/SOLUTlONS/cOMMtNTS
START DATE 11/77 fcOUI I KENT: FGD SYSTgM, CENERAu
END DATE 1^£7IN]7 "^'ROUiHT BACK IN SERVICE ON NOVEMBER 11 FOLLOWING THE SCHED-
ULED flOUt R 01TA6E (AVAILABILITY hAS CALCUATFD FROM NOVEMBFR 11 THROUGH
NOVEMBER 20>.
MODULES: SYSTEM
** PRObLEMS/SQLUTIONS/COftMENTr
START DATE 11/77 EC
END DATE 1 J (" 1 .D .. f ANS '"fA VE~ BEEN REFUILT IN AN ATTEMPT TO CORRECT THE CO**OSlON AND
DRIVE MOTOR PROBLEMS.
AFFFCTED MODULES: SYSTEK
323
-------
EPA UTILITY fGD SURVEY: CECEPFJER 197F - JANUARY 1979
SECTION 3
DESIGN AMD rFRFOfipAKF 6ATA FOR OPERATIONAL FCD SYSTEMS
------------------------------------------ PERFORMANCE DATA ------------ — ------ - ---------- - ---------
PERIOD MODULE AVAILABILITY CPERARIHTY IELIAB1L1TY UTILIZATION X REMOVAL PER BOILER FGO CAP.
SO? PART. HOURS HOURS HOURS FACTOR
** PROBLEMS/SOLUTION S/COKKENTE
ST*KT BATE 11/77 EBUIFF'ENT: 6AS DAMPER
END DATE 11/77 PFOBLFM: C HEMI C AL-RELA TE D EROSION
G,S LEAKAGE F''OM THt DAMpERS WA$ CORRECTED BY WELDING A COVER PLATE OVER
THE SEAL tOCRr. THE VENDOR IS CURRENTLY WORKING ON A NEW DFjIGN FOR THE
DANPFRS.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START D*TE 11/77 ECIJ1 I f E NT: INSTRUPENTAT 1 CM
£ND DATE 11/77 C OUR f NTS:
ALMOST ALL INSTRUMENTATION PROfcLFKS CONTINUE TO HAMPER PROPER SCRUBBER
OPERATION.
AFFECTED MODULES: SYSTEM
12/77 8A
EC
80
SYSTEM 5^.0 97.0 59.0 56.0 74* «26 0
** PROfcLEMS/SOLUTI ON S/C nWNENTS
START DATE "(Z 111 E«UI(KENT: B01 L ER-R E LAT f C
END DATE 1?/77 PS(;EilFH; NOT DEFINED/SPECIFIED
TH UNIT UAS CFF-LINE FROM DECEMHER 20 - DECEMBER 31 FOR REPAIRS OF A
.PCILEU TUBE IFAK.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COKi«ENT!:
START DATE 12/77 EGU1FKENT: SCRUBBER
CND DATE 12/77 COMMIT: PREVENTIVE MAINTENANCE
DLRINf THJS OITAGE, AN INSPECTION WAS MADE OF THE SCRUBBER MODULES.
AFFECTED MODULES: SYSTEM
** PROtiLEKS/SOLUTIONS/CCMWENTS
START DATE 12/77 EOUIH«ENT: SCRUPBEH
END DATE 1?/77 FPOBIEM: NOT DE FINE D /SPE CI F I ED
TKE RUPBFI- LIhER WAS FOUND TO BE KISSING IN SEVERAL AREAS OF ALL FOUR
MODULES *NC u t$ REPAIRED DURING THE OUTAGE.
AFFECTED MODULES: SYSTEM
8A
8B
8C
8D
SYSTEM £6.0 96.0 96.0 79. C 744 616 0
** PROBLEMS/SOLUTIONS/COMHENTE
START DATE 1/78 ESUlfKENT: SCRUpBER
END DATE 1 /7S PROBLEM: NOT D E FIN E D /S PF CI F I ED
ALL FOUR SCRUiPER MODULES RETURNED TO SERVICE THIS MONTH FOLLOWING REPAIR
UtRK ON THE RUBER LINER.
AFFECTED MODULES: sYSTll*
** PRO^LEMS/SOLUTI ONS/COMMENTS
START DATE 1/78 ECUIFPENT: PIPING
END DATE 1/76 PROBLEM: NOT DE F IN ED /S PE CI F 1 ED
THERE HAVE BEFN MINOR PROBLEMS WITH COOLIN6 LINES FREEZING AND EURST1N6.
AFFECTED MODULES: SYSTEM
** PR06LEMS/SOLUTIONS/COMMENTS
START DATE 1/78 E«UJF*ENT: REAGENT HANDLING
END DATE 1/78 PFOBiEM: pLUGGINS, OTHER
FEED HOPPERS *T THE LIMESTONE STORAGE AREA HAVE BEEN PLACING OUf TO FROI-
Eh 6 C A VE L •
AFFECTED MODULES: SYSTEM
324
-------
EPA UTILITY FED SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFOPWAUCE DATA FOR OPERATIONAL F6D SYSTEMS
...... PERFORMANCE DAT*
PERIOD MODULE AVAILABILITY OPERAB1L1TY PLIABILITY UTILIZATION t REMOVAL PER BOILER FED CAP.
S02 PART. HOURS HOURS HOURS FACTOR
•*•"""" "" "«•»" "" m*nm «.••• — — ••—•.— -«_•_______ .. _ _ «w *••«..• _ — «..._«*.«*i —•.••• «.•_«,,• *«..*.• —•*••—•• <**__.» — — - — - —
** PROBLEMS/SOLUTIONS/CCMMENTS
START BATE 1/78 EGU1FWENT: REAGENT HANDLING
END PATE 1/78 PPOBltM: CHEMICAL-RELATED EROSION
ThE BAIL MILL SUMP PUMP LINER HAVE BEEN WEARING OUT.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/CCMMENTS
START DATE 1/78 EBUIFMENT: SPRAY NOZZLES
END DATE 1/78 PROBLEMS C HE«1 CAL-RELAT F I) PLU6GING
SOME PLUGGING OF THE VENTURI SPRAY NOZZLES WAS ENCOUNTERFD.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUT10NS/CCMMENTS
START DATE 1/78 EBUIfMENT: INSTRUMENTATION
END DATE 1/7B FFfOBlFM: NOT DEFINED/SPECIFIED
IfcSTRUMENTATICN CONTINUES TO gE A MAJOR PROBLEM KITH OPERATION OF THF
SCRUBBER.
AFFECTED MODULES: SYSTEF
E/78 8P
8C
8D
8A
SYSTEM 55.0 54.0 61 «C 47.d 67? 5F6 0
** PROBLEMS/SOLUTIONS/CCKMENTS
START DATE 2 /78 tPUIl^'ENT: F6D SYSTFMt GENERAL
END DATE 2/76 CCKM(NTS;
THE UTUITK COMPANY REPODRTED THAT THEY COULD NOT ACCURATELY DETERMINE
RELIABILITY BFCAUSE OF THEIR INABILITY TO CALCULATE UNIT LOAD DEMAND ON A
DAILY BASIS, GENERALLY IT IS ASSUMED THAT SYSTEM FORCED OUTAGE HOURS PLUS
TK HOURS THE F6D SYSTEM WAS OPERATED WILL GIWF ROU6LY THE HOURS THt SYS-
TEM HAS CALLEC UPON TO OPERATEf IN THIS WAY, RELIABILITY CAN BE CALCULATED
IhDIRECTLY. BtfcEVER, IN THIS CASE,TWO TRAINS AT A TIME HAVE BEEN DOWN ON A
SCHEDUiED OUTAGE fQti NECESSARY MODIFICATIONS. PART OF THIS OUTAGE TIME
LIMITED EOILEi OPERATION SO THAT THE UNIT CoULD NOT R(jN AT FULL LOAD WHEW
THERE WAS DEMAND FOR A FULL LOAD. FOR THIS CALCULATION IT WAS ASSUMED THAT
THERE WAS A DEMAND f OR FULL LOAD DURING THE ENTIRE OUTAGE SO THAT ALL OF
THE TRAINS VOlLj) HAVE BEEN CALLED THE ENTIRE SCHEDULED OUTAGE. THE PESULT
WAS A VERY CO^SERVATIVE ESTIMATE OF RELIABILITY WHERE HOURS CALLED=SYSTEM
FORCED OUTAGE TIME 6. SYSTEM SCHEDULED OUTAGE TIME R HOURS THE FGP SYSTEM
OPERATED.
NOTE - THIS IS A PEDCO ESTIMATE.
»FFFcTjD MODULES: SYSTEM
** PR06LEMS/SOLUTIONS/COMMENTE
START DATE 2/78 ECUirMENT: DUCTWORK
END DATE 2/78 FFOEUfM: NOT DEFINED/SPECIFIED
THE OUTAGE Tiff FOR TRAINS A A*i 0 6 WAS RE8UIREP TO REPLACE THE RUBBED
LINERS IN THE DOWNCOMER AREA WITH STAINLESS STEEL. THE OTHFR TWO TRAINS
WILL RECIIVE SIMILAR TREATMENT.
AFFECTED MODULES: SYSTEM
3/78 £A
BF<
fcC
SYSTEM 60.0 i6.0 59.C 5F.C 7*4 °
*• PROBLEMS/SOLUTIONS/COMM£NT£
START DATE 3/78 tGUIFMENT: DUCTWORK
END DATE 3/76 PSOCtFM: NOT DEFIMED/SPECIFI ED
TRAIN E WAS CIT OF SERVICE MARCH 1-KARCH 13 TO INSTALL STAINLESS STtFL IN
THE: AesoREfER ^ND VENTURI DOWN COMER AREAS.
AFFECTED MODULES: W
325
-------
EPA UTILITY FbD SUPVF-Y; DICHT1FR 197t • JANUARY 1979
SECTION 3
DESIGN AND PfRFOPMKE DATA FOR OPERATIONAL F6D SYSTEMS
----- .. ..... --- ... .................. ------ PmORMANCF CAT A ..... - -------------------- - ------ " .......
PERIOD MODUlf AVAILABILITY CFERA^UITY • C L1AB I L1TY UTILIZATION X REMOVAL PER BOHER ff.C CAP,
S02 PART. HOURS HOURS HOURS FACTOR
»•»••• —»•••• • •••••*«»•••• •»•»•«••••• ••>•»•••>«••!•*• ••^•••••MMVVW •« • VOT »•!•••*«• * •• •• oi <• Ma M „, MB • •••*• •••««*
** PROULIMS/SOLUTlONS/CO^f NT?
START CATl :/7? tSUIH'INT! EXPANSION JOINT
tND DAT! J/78 Pf>OPl>,Kt NOT 0 E FINID/S PI CIFI ED
STAINLESS mU COVfRS WFRF INSTALLED AROUND TWO EXPANSION JOINTS ON TRAIN
C IN ORDEf TP PREVENT FLUE GAS IFAKA6E.
AFFICTED nODULES: 1C
«* PROUlEMS/SOLUTIONS/CCfWENT!
START DATE ?/?!', ECUI^ENT: GAS
END DUE 7/7f PROPLfW: NOT DE F IKE D/5 Pf CI M ED
A STAINLESS S1E6L PLATE WAS WELDED OVER THF INTRY BOOR OPENINGS TO TRAIN C
OtlTLIT ANE tYMSS GUILLOT1NI DAMPERS FOR THE PURPOSE OF ELIMINATING 6AS
LIAKAGE.
AFFECTED MODULES; EC
** PROBLtMS/SOLUTIONS/COHPENl f
START DATE 3/78 ECUHTENT: DUCTWORK
END DATE 3m I'POPlfM: NOT DE FINED /t PF CI F I ED
TRAIN C WAS OIT OF SERVICE MARCH U - Z9 TO INSTALL STAINLFSS STEEL IN THE
ArSOPRER AND VFNTUR1 DOWNCOMER AREAS.
AFFECTED MOpULtS: fC
** PROBLEMS/SOLUTIONS/COKWENTS
START DATE 3/7t tGUKfENT: REA6FNT HANDLING
END DATE 3/78 FF.OPifn: NOT DEFINED/SPECIFIED
SEVERAL Lirtf f BARS ON THE FEEn AM) DISCHARGE ENDS OF THE PALL KILL WERE
FCiUNC TO tt BAPLY WORN.
AFFECTtD MODULES: SYSTfC
** PROOLEMS/SOLUTIONS/COKiMENTS
START DATE 3/7t t'OUI fWENT: TRANSFER PUMP
END DATE J/7t fKOPfH: C HEMI C AL-RfLAT E S> EROSION
T»:E UTILITY HAS HAD WEAR PROBLEMS WITH THE SlUPRY SUMP Piil".P LINERS AT THE
BALL KILL.
AFFECTED MODULES: SYSTIW
4/78 8A
8E>
8C
SYSTEM 69.0 fJ.C 67.0 62. C 72C 540 T
** PROBLEKS/SOLUTIONS/COKMENTS
START DATE 4/78 E-CUI H"-ENT: MIST ELJM1NATCP
END DATE 4/78 FRCPUM: C HEMI CAL- RELATE C PLUGGING
DLRINC A E.flff INSPECTION OF THE SCRUEBIN6 SYSTEP IN EARLY APRIL, SOLIDS
IEPOSIT10N WAf NOTICED IN THE MIST ELIMINATOR SECTION OF ALL TRAINS DUE TO
PLUGGING THAT HAD OCCURRFD IN SEVERAL OF THE MIST ELIMINATOR SPRAY NOZZLES
TRAIN D WAS N CT IN OPERATION FOR 17 DAYS WHILE THE MIST ELIMINATOR HAS
DISASSEMBLED «D CLEANED.
AFFECTED MODULES:
«* PR06LEMS/SOLUTIONS/COMMENU
START DATE 4 /7B EGUIFKENT: FGD SYSTEM, GENERAL
END DATE 4/78 FKOPIFM: NOT D E FINED/SPF CI F IED
« STAlNLfjSS S1EEL LIN" WAS INSTALLED ON THE SLOPING SECTIONS OF THE
AtSOREIER AMD VFNTURI.
AFFECTED MODULES: SYSTEM
•* PR06LEMS/SOLUT10NS/COMMENTS
START DATE 4/78 tCUIFFENT: 6AS DAMPER
END DATE 4/78 fPOE< LF.M : NOT 0 E FINED/SPE CI F I ED
STAINLESS STEH PLATfS WFRE INSTALLED OVER THE ENTRY DOOR OPENINGS TO TRAI
D INLET, OUTLIT AND BYPASS GUILLOTINE DAMPERS TO REDUCE GAS LEAKAGE.
AFFECTED MODULES: 6D
326
-------
EPA UTILITY FGD SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL F60 SYSTEMS
. PERFORMANCE DATA
PERIOD NODULE AVAILABILITY CPERARIL1TY PLIABILITY UTILIZATION X REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
** PRObUEMS/SOLUTIONS/COKMENIT
START DATE 4/7B ESUIhWENT: EXPANSION JOINT
END DATE 4/78 FfOPlfM: NOT DEFINED/SPECIFIED
STAINLESS STElL COVERS WERF INSTALLED AROUND THE FIVE EXPANSION JOINTS ON
TRAIN Pi TfcO EXPANSION JOINTS ON TRAIN «, AND ONE EXPANSION JOINT ON TRAIN
B TO REDUCF 6 AS LEAKAGE.
AFFFCTED MODULES: 8A R f £D
** PROBLEMS/SOLUTIONS/COPMENTS
START DATE 4/78 EOUI^^'ENT: TRANSFER PUMP
END DATE 4/78. FFOEUtM: CHEMICAL-RELATED EROSION
TURF CONTIKUtS TO BE A WEAR PR OB LE« VI TH PUMP LINE RS AT THE BALL MltL. NT)
CAUST OR SOLUTION OF THE PROBLEM HAS BEEN ASCERTAINED AS YET.
AFFECTED WOPULtSt SYSTIK
5/7* SYSTEM 744
6/7« SYSTEW 730
7/7E SYSTEM 744
8/7? SYSTE« 744
9/7? SYSTt* 720
10/7S SYSTEI* 744
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 1P/7P tCUll«ENT: BOILER-RELATED
tND DATE 1/79 IPMCHNT: PREVENTIVE MAINTENANCE SCHEDULED UNIT OUTAGE
THE pCILE* ^•E^T OFF LINE IN EARLY OCTOBER FOR BOILER OVERHAUL. THE UNIT
RESTARTED FOR A FEW DAYS IN DtCEM&ER UNT1LL A TURBINE ROTOR PROBLEM
WAS DISCOVERED. THE PROBLEM FORCED THE UNIT OFF LINE THROUGH JANUARY.
AFFECTED MODULES: SYSTtf!
11/7F SYSTEM 72°
12/78 SYSTEM 74*
1/7"? SYSTEM 7**
-------
FPA UTILITY FtD SURVEY: DECtMBFR 197? - JANUARY 1979
SECTION 3
DESICN AND PE R FOSM A f,f f DATA FOR OPERATIONAL FGD SYSTrPiS
COMPANY NAPE
PLANT NAME
UNIT NUHPER
CITY
STATE
RF6ULAICRY CLASSIFICATION
PARTKUIATE EMISSION LIMITATION - NG/J
SO? EMISSION LIMITATION - KG/J
NfT PLANT GENERATING CAPACITY - *V
6ROSS UNIT GENERATING CftPAcUY - Mk
NET UNIT GENERATING CAPACITY W/FGD - Pi
NFT UNIT GENERATING CAPACITY WO/FGC - ffc>
EOUIVAL'NT SCRUFBED CAPACITY - P.«
** BOILFR tATA
SUPPLIER
TYPF.
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM bOlLER FLUE GAS FLOW - CU.f/S
FLUF GAS TEWPFRATURf - C
STACK HE IGHT - H
STACK TOP DIAMETER - P.
** FUEL DATA
fU£L TYPt
FUEL GRADE
AVERAGE HEAT CONTENT - KJ/KG
RANPE HEAT CONTENT - FID/lEt
AVERAGE ASH CONTENT - !
RANGE ASH CONTENT - %
AVEPA6E MOISTURE CONTEM - S
RANGE MOISTURE CONTFNT - *
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - I
AVERAGE CHLPRIOt CONTENT - I
RANGE CHLORIDE CONTENT - X
FUEL FIRING RATE - IX T/H
FUEL FIRING RATE - MK
• * ESP
TYpE
*• FGD SYSTEM
SALEAPLT PRODUCT/TKROWAWAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPf
SYSTEM SUPPLIER
DEVELOPMENT LEVEL
NEy/RETkOFIT
PARTICULATE DESIGN RERCVAl EFFICIENCY
S0£ DESIGN REPOVAL CFFK1FNCY - t
COMMERCIAL DATE
INITIAL START-UF>
** ABSORBER
TYPF
INITIAL START UP
SUPPLIER
NUMBER OF STAfES
DIMENSIONS
BOILER LOAD/APSORRER - X
GAS FLOW - CU.M/S
GAS TEMPERATURE - C
** CENTRIFUGt
OUTLET SOLloS - X
** FANS
TYPF
< .ICO LP/MMBTU)
( 1.200 L6/HWBTU)
TEXAS UTILITIES
MARTIN LAKH
1
TATUM
TEXAS
A
51A.'
3000.0
793,0
750.0
* ******
595.0
COMBUSTION ENGINEERING
PULVF.RIZED COAL
BASE
0/77
U9<.51 (SU7000 ACFK)
16?.3 ( 335 F)
****** (**** FT)
******* (***** FT)
COAL
LIGNITE
17166.
P.PO
******
33.00
******
.90
******
********
******
«53.5
* ****
COLD SIDE
THROUAWAY PRODUCT
WET SCRUBBING
LIMESTONE
RESEARCH COTTRELL
FULL-SCALE
NEW
99.40
71.00
8/77
4/77
PACKED SPRAY TOKFR
4/77
RESEARCH COTTRELL
28 DIA. X 1CO TALL
< 7380 BTU/LB)
***** *
(500 TPH)
177.13
162.f.
69.0
BOILER I.D.
C 375350 ACFH)
( 325 F)
328
-------
FPA umm rco SURVEYS DECEMBER me - JANUARY 1979
SECTION 3
OESICN AND PFRFORKAtyCE DATA FOR OPERATIONAL F6D SYSTEMS
** HIST ELIMINATOR
NUBPEp
TYPE
,* REHEATER
TYPE
TEMPERATURE BOOST - C
** THICKENER
TYPE
DIAMETER - »
OUTLET SOLIDS - X
** MATER LOOP
TYpf
FRESH fAKEUP WATER ADDITION - LITEKS/S
.** TREATMENT
TYpE
SUPPLIER
PRODUCT CHARACTERISTICS
** DISPOSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
12
CHEVRON
UY PASS
40.0
6RAV1TY
4?. 7
35.0
CLOSED
34.6
{ 7? F)
(140 FT)
( 550 GPM)
FLYASH STABILIZED
NONPROPRItTARY
CENTRIFUGE ScLIDs MIXED «ITH FLY ASH
FINAL
LANDFILL
ON-SlTE
RAIL
PERIOD MODULE AVAILABILITY OPERAttUlTV
-PERFORMANCE. DATA
KfcLlAB I LITY UTILIZATION
t REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
8/77 SYSTEM
9/77 SYSTEM
10/77 SYSTEM
744
7?0
744
** PRObLEHS/SOLUTIONS/COI^iENTS
START DATE 10/77 ICUI O'.ENT : F60 SYSTEM,
fcN6 D*TE 1/78 COBCfK'TS:
INSTALLATION IF THE LIMESTONF SCRUBBING SYSTEM AND THE ESP WAS COMPLETED
BY OCTOBER 1977. THF INITIAL OPFRAT1N6 Ph*SE IS EXpECTED TO CONTINUE
THROUGH Tht FIRST BUARTER OF 1978. COMPLIANCE TESTING fc'AS CONDL'CTetl jN
LATE 1977 AND CERTIFICATION OF COMMERCIAL AVAILABILITY IS AWAITED.
AFFECTED MODULES: SYSTEC
** PROBLEMS/SOLUTIONS/COf;l«ENTJ
START DATE 10/77 ECUIfKENT: REAGENT HANDLING
tND DATE 1/78 FRteUH: NOT DE FINE D/S PF C] F I ED
THE UTILITY E >PE R1E ti CE t> SQWE DIFFICULTIES
AFFECTED MODULES: SYSTt?
11/77
12/77
1/7E
2/78
SYSTEM
SYSTEM
SYSTEM
SYSTEM
IN THE SLURRY HANDLING SYSTEM.
720
74<
744
67Z
** PROBLEMS/SOLUTIONS/CCMWENTT
START DATE 217% ECUIfMENT: FGD SYSTEM, GENERAL
END DATE. 3/78 CCKMbNTS:
CEKTIFICATICN VAS RtCIEVEO FROP THE EPA DURING THE PERIOD.
FGD SYSTEM OPE FATED THROUGHOUT THE PERIOD.
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE ? /78 E6LIIS-ENT: REAGENT HANDLING
END DATE J/7B PPCBiFH: NOT D E F IN E D/ S P F CI F I ED
^ „ ...K
THF BOUFR AND
J29
-------
fPA UTILITY FGD SURVEY; DiftKBFR 197F - JANUARY 1979
SECTION 3
DESIGN AND PERFOFMAKE DATA FOR OPERATIONAL FED SYSTEMS
------------------------------- . ---------- PERFORMANCE DATA --------------------------- - --------------
PERIOD MODULfc AVAILABILITY OPERABUITY PLIABILITY UTUI7AT10N X REMOVAL PER BOILF.R FGO CAP.
S02 PART. HOURS HOURS HOURS FACTOR
THC UTILITY I* STILL HAVING SOME PROBLEMS WITH THE SLURRY HANDLIN6 SYSTEM.
SOME FORCED OITA6E TIME OCCURRED.
AFFFCTED MODULES: SYSTfH
3/73 SYSTEf 744
4/7* SYSTEM 7?G
** PRObLEKS/SOLUTIONS/COMMENTS
START DATE A /7£ tOUII-t»ENT: FGD SYSTEM, GENERAL
END DATE 5 /7? COKMktvTSl
THE UNIT WAS 1AKEK OFF L1NF IN APRIL FOR A^ ANNUAL TWO WEEK OUTAGE*
AFFECTED MODULES. SYSTEM
•* PRObLEMS/SOLUTlONS/COMMENTS
STAfT DATE 4/78 t6UIH*ENT: BOILER-RELATED
END DATE 5/78 COHHLNTS:
GENERATOR PROitEMS WERE ENCOUNTEPE0 IK WAY CAUSING THE UNIT TO BE TAKEN
OFF LINE 1HROICH TH f END OF THE I«CNTH.
AFFECTED MODULES: SYSTEM
5/78 s>STEI» 74«
6/7S SYSTEM 7?0
STAPT DATE 6/78 tBUjPENT: GAS BAMpER
END DATE 7/78 PROBlfcM: NOT Of FINE B/S PF tl FI ED
THt DAMPERS FIR EACH ABSORBER MODULE WERE NOT FUNCTIONING PROPERLY. IT
HAS BEEN IfiPO iSIBLE TO ISOLATE INDIVIDUAL MODULES FOR REPAIRS (THE E*'T1RF
SYSTFf WOUU t*VF TO ElE SHUT DOWN IF REPAIRS UFRf RtOUIRFC ON ONLY ONE
MODULE).
AFFECTED MODULES: SYSTtf:
** PRObLEMS/SOLUTIONS/COMMENTS
START DATE 6/7* EQUIPMENT: F6D SYSTEM, GENERAL
tND DATE 7>76 COKUFNTSl
TKE CNIT 1£ O'FRATING COMMERCIALLY.
AFFECTED MODULES: SYSTEM
*« PRO&LEMS/SOLUTIONS/COfiMENTS
START DATE 6/7B EOUI^ENT: PROCFSS CONTROL
END DATE 7/78 PROPIFK: NOT DE FINEB/S PF CIFI.EB
TKfRF HAVE B E f-N PROBLEMS WITH THE PH METERS. THE MITERS HAVE NOT OPERATED
PROPFRLY FOR JOME TIME NOW.
AFFECTED MODULES: SYSTEM
7/78 SYSTEM 744
S/7e SYSTEM 744
t* PROBLEMS/SOLUTIONS/COMMENTS
ST«RT »*TE 8/78 EeUIFt'ENT: CAS DAMPER
tND DATE 9/78 PROBLEM: NOT DEFINED/SPECIFIED
ISOLATION tjAMffR PROBLi«S CONTINUE"*
AFFECTED MODULES: SYSTEM
«* PROBLEMS/SOLUTIONS/COMMENTf
START DATf 8/76 tCUI^ENT: F6D SYSTEM, GENERAL
END DATE 9/78 CPKM'JuiTS:
THE DMT CONTINUES TO REOUIRE EXCESSIVE MAINTENANCE. FGD STSTEM ACCEPT-
ANCE TEST VERl PERFORMED BY THE UTILITY DUR1N6 AUGUST. RESULTS ARE NOT
YET AVAILABLE .
AFFECTED MODULES: SYSTEM
** PROfaLEMS/SOLUTIONS/COPMENTS
START DATE f /78 EOUI^ENT: INSTRUMENTATION
END DATE 9/78 FfiCELEM: NOT D E F INED /S Pt CI F I ED
330
-------
EPA UTILITY F6D SURVEY: DECEMBER 1?78 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL FGD SYSTEMS
..................................... ---- -PERFORMANCE BAT A- — - — -—-—- ------ ......... ___ ........
PERIOD MODULE AVAILABILITY CPERAPILITY PEL1ABIL1TY UTILIZATION * REMOVAL PER SOHER FGD CAP.
____ ............ ____ .............. SOZ PART. HOURS HOURS HOURS FACTOR
FLOW MJASUSIM1NT IN STRUMf NT AT JON HAS BEEN FAILINe!"""
AFFECTED MODULES: SYSTEM
** PROBLEMS/SOLUTIONS/CCMMINTS
START DATE 1/71 ICtlltMNTs ESP
END DATE 9/7B CO("«tf,TS;
OPACITY HAS BEiN HIGHER THAN IXPiClfD (20-25XJ RESULTING FROM ESP PROI-
LEMS,
AFFfCTEB MODULES: SYSTIf
»m iw«« no
10/78 SYSTEM 744
** PROBLEMS/SOlUTIONS/CCI*MENTS
START DATE 10/78 IfiUI FPENlt FGD SYSTEM, 6INERAL
END DATE 11/7? CMrMNTS:
NC PROBLEMS H»VE BlfN REPORTED.
AFFECTED MODULES: SYSTEM
11/78 SYSTEM 720
12/7B SYSTEM 744
** PR06LEMS/SOLUTIONS/CCKMENTS
START DATE 12/78 ttiUI'l£NT: StUDC-E DISPOSAL
tND DATE 1/79 PRCeil-M: NOT D E FINEO/SPF CI F IED
Tht FGD SYS1EI* MAS SHUT DOWN WHILE THE BOTTOM ASH PONIl WAS CLEANED OUT.
TK UTILITY H*J BEEN DUMPING SlUBtf INTO THE POND WHICH WAS DESIGNED FOR
BOTTOM ASH CNIY. ALSO SLUDGE IS PRODUCED FASTER THAN IT IS REMOVED 6V RAI
CAR. THE UTILITY IS NOT GETTING RAIL CARS FAST ENOUGH. THE ACTUAL
PROBUM IS RE SPORTEDLY IN THE. DENATURING SYSTEM.
AFFFCUD MODULES: SYSTEM
• * PDOEILEMS/SOLUTIONS/COMPENTS
STA^T D6Tt 12/7E tiGUI f fiENT: MIST ELIMINATOR
END DATf 1/79 PROB L« W : NOT D f FINED/SPf CI FI ED
SCMie MIST ELIMNATOR WASH PRO£jLt'"S WERE ENCOUNTERED.
AFFECTED MODULES: SYSTTM
** PROiJLEMS/SOLUTIONS/CCMI'INTE
START DATE 1J/7B EfiUI^'iENT: F6D SYSTEM, GENERAL
END DATE 1/79 COMWtNTSs
THf FED SYSTEf HAS REPORTEDLY RAN WELL DURING DECEMBER AND JANUARY.
AFFECTED MODULES: SYSTEM
** PROLiLEMS/SOLUTIONS/COMMENTS
START DATE 12/78 tfiUllHENT: BOI LFR-RELAT f 0
tND DAT! 1/79 PKCBIKM: Wi ATHER-R tLATE D COMPONENT FAILURE
CCAL HANDLING k'AS A SIRIOUS PROBLEM DUI TO FREEZING OF THE COAL IN THE
HOPPERS. THIS PROBLEM EFFECTED ALL UNITS AT MARTIN LAKE FORCING THE GAS
AND OIL UMTS TO CARRY THI LOAD.
MODULES: SYSTEM
*« PR06LEMS/SOLU1IONS/COMMENTS
START DATE 12/78 tOL'IMENT: FGD SYSTEM, GENERAL
* THE SCRUPB1NG SYSTEM WAS SHUT BOWN FOR A TI«E DURING THE REPORT PERIOD.
AFFECTED MODULES: SYSTEM
1/79 SYSTEM 744
331
-------
FPA UTILITY FtD SURVEY; DECEfbER I'm - JANUARY 1979
SECTION 3
DESKN AND PERFORMANCE DATA FOR OPERATIONAL FGD SYSTTHS
COMPANY
PLANT NAKF
UNIT NUMF'ER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICIPATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - IsG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UMT GENERATING CAPACITY - ^
NET UNIT GENERATING CAPACITY W/F6P - Mi
NET UNIT GENERATING CAPACITY HC/FGl - *V
EOUIVALFNT SCRUEBCO CAPACITY - MW
** BOILER DATA
SUPPLIER
TYPf
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM C01LER FLUE GAS FLOW - CU.r/S
FLUF FAS TtMPf RATURT - C
STACK Hf 16HT - I"
STACK TOP DIAKETtR - H
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGC HEAT CONTENT - KJ/K6
RANfE HbAT CONTENT - HTU/LF
AVERAGE A$H CONTENT - 1
RANfE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOlSTURf CONTENT - Jf
AVEM61 SULFUR CONTENT - t
RANGE SULFUR CONTENT - %
AVERAGE CHLORlDr CONTEM - K
RANBE CHLORIOF CONTENT - *
FUEL FIRING RATI, - ? T/H
FUEL FIRIN& RATE - MU
** F.SP
«* FGD SYSTEM
SALEABLE PRO OUCT/T HR OW AWAY PRODUCT
6ENFRAL PROCESS TYPE
PROCESS TYPE
SYSTEM SUPPLIfR
DEVELOPMENT LEVEL
NEW/RFTROF1T
PARTICULATt OES1UN REMOVAL EFFlCIEtitY
S02 DES1C.N RiWOV
INITIAL START-UP
•« AbSORBER
EFFICIENCY - it
lYPt
INITIAL START UP
SUPPLIER
NUMBER OF STAGES
DIMENSIONS
BOUER LOAD/APSORBER
GAS FLOW - fU.M/f
6AS TFMPCRATURE - C
** CENTRIFUGE
OUTLET SOLIDS - *
*• FANS
NUMBER
( .100 LP/MMPTU)
( 1.200 LP/MMBTU)
TEXAS UTILITIES
MARTIN LAKE
?
TATUf
TEXAS
A
41.
516.
3POO.O
79?.D
750.0
*******
595.0
COMBUSTION ENGINEERING
PULVEKI2FD COAL
BASE
0/7?
1494.51 C3167000 ACFM)
16P.J ( 335 fl
****** (**** FT)
******* (***** FT)
COAL
LIGNITE
17166.
P.00
******
33.00
******
.90
******
********
******
457.5
*****
COLD SIDE
( 7380 BTU/LR)
***** *
(SCO TPH)
PRODUCT
WET SCRUBBING
LIMESTONE
RESEARCH COTTRELL
FULL SCALE
NEW
99.40
M.OO
S/7C
PACKFD SPRAY TOWER
5/78
RESEARCH COTTRELL
3
28 DIA. X JCO TALL
•* MIST ELIMINATOR
NUMPER
177.13
162. *
69.0
BOILER 1.6.
12
CHEVRON
( 375350 ACF«)
( 325 F>
332
-------
EPA UTILITY FGD SURVEY: DECKER 1978 - JANUARY 1°79
SECTION 3
DESIGN AND PERFORMAUCE DATA FOR OPERATIONAL FGD SYSTEMS
*« RENEATEN
TYPE
TEMPERATURE BOOST - C
** THICKENER
NUMBER
TYPE
DIAMETER - M
OUTLET SOLIDS - X
** WATER LOOP
TYpF
FRESH N«K£UP WATER ADDITION -
** TREATMENT
TYpE
SUPPLIER
PRODUCT CHARACTERISTIC!!
«* DISPOSAL
MATURF
TVPI-
LOCATION
TRANSPORTATION
BY PASS
40.0 ( 7? f)
GRAVITY
42.7
35.0
CLOSED
34.6
(UO FT)
( 550 6PM)
FLYASH STAfillZATION
NONPROPRIETARY
CENTRIFUGE SollDs MIXED «1TH FLY ASH
FINAL
LANOFUL
ON-SITE
RAIL
... _ PERFORMANCE DATA------- „—..--.
PERIOD MODULE AVAILABILITY CPERAiILITY PLIABILITY UTILIZATION X REMOVAL PER BOILER FED CAP.
SOS PART. HOURS HOURS HOURS FACTOR
5/76 SYSTEM
6/78 SYSTEM
11/78
12/78
744
720
** PROaLtMS/SOLUTIONS/COMKENTf.
START DATE 6/78 LCUII"ENT: FED SYSTEM, GENERAL
END DATE 7/7fc CCMfUNfS:
TH UNIT hf6A^ OPERATION? IN MAY 197E. THE CO«»LIANCr TESTING IS SCHfDUL-
ED FOR AUGUST .
AFFECTED MODULES: SVSTtK
7/78 SYSTEM
sm
744
7**
** PROeLEI"S/SOLUTIONS/COK«INTS
START DATE £/7f
END DATE
FGD SYSTEM, GENERAL
9/78 COMMITS:
TH F6D SYSTf WAS TESTED FOR COMPLIANCE WITH ALL SIX MODULES IN THE 6AS
SWAM DURJN6 THE FIRST PART OF AUGUST. TEST RESULTS HAVE NOT Y6T BfEN
PbfaiSHED. tit, NAJOR F6D-RELATCD FROBLEMS WERE REPORTED.
AFFTCTFO MODULES: SYSTEM
9/7P SYSTEM
10/78 SYSTEM
10/78
11/78
START DATE
END DATE
AFFECTED MODULES: SYSTEM
EfiUirtt'ENT: f6D SYSTEM, SENERAL
S:
RESULTS ARS
SYSTEM
744
.
START DATE 12/78 ECUIIIItNT: eOuEH-HFLATF I)
END DATE 1/79 FROB IFH : Wf. ATHE R-R EL AT ED COMPONfNT FAILURE.
CCAL HANDLING WAS A SIR10US PROBLEM DUi TO FREF.MN6 OF THE COAL IN THE
353
-------
EPA UTILITY FbD SUPVCY: OECtNPFR 1*7f - JANUARY 1979
SECTION 3
DESIGN AND PERFOSMkCE DATA FOP OPERATIONAL FfiO SYSTF.MS
PERIOD MODULI AVAILABILITY OPERAflLlTy
... PER f ORNANCF 6 AT A ----
TLlAeiLlTY UTILISATION
X REMOVAL PER BOILER FED CAP.
SC2 PART. HOURS HOURS HOURS FACTOR
HOPPtfiS. 1H1' PBOBLfM EFFFCTED ALL UNITS 'T MARTIN LAKE FORCING THt CAS
AND OIL UNITS TO CARRY THE LOAD.
AFFECTED MODUL IS: SYSTEM
** PRC&LEMS/IOLUTIONS/CCMINTS
8TA|)T DATE 12/7g t till f» SNTJ F6t> SYSTEM, GtNERAL
END DATE 1 /79 CCO'kTSt
NC PROBLEMS H/'VE feftN REPORTED.
PIHKD.
AFFtCTED MODULES: SYSTEM SYSTEM
•* PROBLEMS/SOLUTIONS/COMMENTS
STA^T DATE 12/78 tGLT^ENT: F6D SYSTEM, OblVERAL
END DATE 1 /79 tCI-l" 'ATS:
TKf FCD H*f R!FORTEDLY RAN MELL DURING DECFMPiF AhD JANUARY.
AFFECTED MODULES: SYSTEM
** PROgLEMS/SOLUTIONS/CCMMENTS
STApT DATE 12/78 COUIifENT: SLUDGE DISPOSAL
END DATF 1/79 FRCBHK: NOT DE FINEtl/SPF CI F IID
TliE FRD 5VSU6 WAS SHUT DOWN WHILE THE BOTTOM ASH POND WAS CLEANFD OUT.
ThE UTILITY H
-------
EPA UTILITY FGB SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE OATA FOR OPERATIONAL F6D SYSTEMS
COMPANY NAPE
PLANT NAME
UNIT NUPBEfi
CITY
STATE
REGULATORY CLASSIFICATION
PARTKULATE fcMISSION LIMITATION - hC/J
50! EMISSION LIMITATION - KG/J
NET PLANT GENERATING CAPACITY - MY
6ROSS UNIT GENERATING CAPACITY - *W
NET UNIT GENERATING CAPACITY V/FGD - M k
NET UNIT GENERATING CAPACITY VO/FGD - PI.
EQUIVALENT SCRUBBED CAPACITY - fW
** BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM cOHER FLUE GAS FLOW --CU.»/S"
FLUE GAS TEMPFRATURF - C
STACK HE IGHT - N
STACK TOP DIAMETER - t»
*« FUEL DATA
IUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - KJ/KG
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - 5
RANfiE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - t
RANGE CHLORIDE CONTENT - *
FUEL FIRING RATt. - I* T/H
FUEL FIRING RATE - MH
(****** L8/MM8TU)
<****** LB/MMBTU)
TEXAS UTILITIES
MONTICELLO
3
MT. PLEASANT
TEXAS
******
* *****
1900.0
75olo
*******
800.0
COMBUSTION ENGINEERING
PULVERIZED COAL
BASE
om
******•»*• (******* «CF«)
16?.3 { 335 F)
****** (**** FT)
******* (***** FT)
COAL
LIGNITE
18.90
********
******
1.50
******
.04
******
(****** BTU/LB)
6500-7500
(*** TPH)
»* ESP
TYPf
SUPPLIER
PARTICIPATE DFS1GN REMOVAL EFFICIENCY
FLUE GAS TEMPERATURE - C
** F6D SYSTEM
SALEABLE PRODUCT/T HR OW AWAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPE
SYSTEM SUPPLIER
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICIPATE DESIGN REMOVAL EFFICIENCY
S02 DESIGN PEMOVAL FFFICIEfcCY - X
COMMERCIAL DATE
INITIAL START-UP
** ABSORBSR
TVPF
INITIAL START UP
SUPPLIER
NUMBER OF STAGES
BOILER LOAD/APSORBER - X
GAS FLOW - CU.M/S
GAS TEMPERATURE - C
LIOUID REC1RCULATION RATE - LITER/I
L/6 RATIO . L/CU.R
PRESSURE DROP - KPA
PARTjCULATE IK'LTT LOAD - G/CU>K
PARTKULATE OUTLET LOAD- G/cU«>
502 INLET CONCENTRATION - PPM
S02 OUTLET CONTRATION - PPK
S02 DFSI&N REMOVAL EFFICIENCY - X
COLD SIDE
C-E WALTHER
99.5
16?.3
( 335 F)
TH*OUAUAY PRODUCT
UET SCRUBBING
LIMESTONE
CHEMICO
FULL-SCALE
NEU
99.50
74.00
10/7F
5/7«
SPRAY TOUERS
5/7?
CHEMIcO
4
33.0
42?.01
60.6
4000.
( 907000 ACFM)
< 141 F)
<6349C GPK)
C 70.0 GAI/1000ACF)
( J.O IN-H20)
( .050 GR/SCF)
( .050 GR/SCF)
496
74.0
335
-------
EPA UTILITY HiD SUFVEY: OECE^EtER 197T - JANUARY 1979
SECTION 3
DESUN AND PERFOOFAKCE DATA FOR OPERATIONAL F60 SVSTFMS
*« FANS
NUMfER
TYPF
3
BOILER I.D.
*» HIST EL 1MINATOR
NUMPER
TYPf
CONFIGURAT10N
NUMPER OF STAGES
CHFVRON
HORIZONTAL
1
«* PUMPS
SERVICE
RECYCLE
LIHFSTONl SLURRY P II« P
NUMBF. R
3
****
** TANKS
SERVICE
LIMESTONE SLURRY
RECYCLE
NUMBER
****
* ***
** REHEATED
TYpF
HEATING NEplUI*
** VATER LOOP
TYpC
FRESH MAKEUF WATER ADDITION -
*« TREATMENT
TYpE
** DISPOSAL
NATURE
TYPE
LOCATION
INDIRECT HOT AIR
STEAt"
CLOSED
3*.*
FLYASH STABILIZED
FINAL
LANDFILL
ON-SITE
PERIOD
PERFORKANCf DATA ------------------------------------------
AVAHABH IT» OTERAPILITY PLIABILITY UTILIZATION x REMOVAL PER BOILER F6D CAP.
S02 PART. HOURS HOURS HOURS FACTOR
4/78 SYSTEM
** PROELEMS/SOLUTIOMS/COKMENTS
START DATE 4/78 £GUl!f«ENT: F6D SYSTEM, GEMERAL
£No DATE 5/78 COKMfNTS:
T^E TEXAS AIR CONTROL BQARP REPORTED THAT THE TEXAS UTILITIES 750 MK
HCNTICELLO UMT 3 BE6AN F6D OPERATIONS DURING THE REPQRT PERIOD. AS OF
YfcT THE UNIT H*S NOT RUN AT FULL LOAD BUT IS EXPECTED TO BY THE E NO Op
AUGUST.
AFFECTED MODULES: SYSTir
5/7? SYSTEM
«/7£ SYSTEM
744
720
tNc CATf 7/76
TtiE UNIT IS NU AT FULL LOAD YE T • ONE OF THE THREE F6D MODULES IS FULLY
OPERATIONAL. ANOTHER ONE IS PARTIALLY OPERATION A(. t WHILE THi THIRD IS NOT
OFERAT1N6 AT flL AS YET.
AFFECTED MODULES: SYSTEM
** F-RCBLEI"S/SOLUTIONS/COMMENTS
START DATE 6/7£ EBUIffENT: FGD SYSTEM, CENERAL
7/78
6/78 SYSTEM
744
744
PROfeLEnS/SOLUTION5/COMMENTS
START DATE */78 EOUjff'ENT: F6D SYsTEH, 6ENERAL
END DATE 9/78 COHN hNTS:
336
-------
EPA UTILITY FGD SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMAKE DATA FOR OPERATIONAL F6D SYSTEMS
............ ------------------ ...... — . — PERFORMANCE; BAT A ------ - — -- ---- ......... — . -------------
PERIOD MODULE AVAILABILITY CPERAP1LITY ^LIABILITY UTILIZATION X REMOVAL PEP BOILER FED CAP.
S02 PART. HOURS HOURS HOURS FACTOR
THE COMPLIANCE TEST HAS NOT YET TAKEN PLACE. THE FGD SYSTEM IS OPERATION-
AL. INSTRUMEfTATION INDICATES THAT THE UNIT IS IM COMPLIANCE.
AFFECTED MODULES: SYSTEI"
9/78
10/78
11/7*
12/7P
SYSTEM
SYSTEM
720
744
** PR06LENS/SOLUT10NS/COMMENTS
START DATE 10/78 E6U1F«ENT: INSTRUMENTATION
END DATE 11/78 PROBLEM: NOT DEFINED/SPECIFIED
CONTINUOUS N0«,0e» AND S02 MONITORS ARE A PROBLEM AREA.
AFFECTED MODULES: SYSTEM
•* PR06LEMS/SOLUTIONS/CCMMENTS
START DATE 10/76 E6U1!;NENT: SLUDGE DISPOSAL
END DATE 11/7S CCMMtNTS:
TfcE SLUDEE IS CURRENTLY NOT FIXATED.
PCND.
AFFECTED MODULES: SYSTEM
SYSTEM
SYSTEM
IT IS BEIN6 PUMPED DIRECTLY TO THE
720
7*4
•* PROHLEMS/SOLUT10NS/COMMENTS
START DATE 12/78 EGL'IfMENT: FGD SYSTEM. GENERAL
END DATE 1?/?8 CCHMINTS:
TH F6D SYSTEM IS FULLY OPFRATIONAL. A PRELIMINARY TEST WAS PERFORMED ON
DtCEME'ER 1*. RESULTS OF THE T6ST ARE NOT YET AVAILABLE.
AFFECTED MODULES: SYSTEM
** PROBLEWS/SOLUT10NS/COMMENTS
START DATE 1Z/78 E6UIt!*ENT: FGD SYSTEM, GENiERftL
END DATE 1/79 COKM I^TS:
Tft F€D SYSTEM REPORTEDLY HAS BEEN PERFORMING WELL.
AFFECTED MODULES; SYSTtP
** PROBLEMS/SOLUTI OK S/C CMCEN T S
START DATE 1Z/78 ESUHF.ENT: ESP
LND DATE 1/79 f-POPL'M: MATERIALS F AI LURF ,OTH ER
fl-t ESP IS KOI OPERATING WELL. COLLECTION EFFICIENCY IS NOT AS HIGH AS IT
ShOULO BE. AFNON1A INJECTION HAS BEEN TRIED TO IMPROVE ITS EFFICIENCY.
REPORTEDLf T H I. PROBLEM IS THE RESULT OF STRUCTURAL DAMAGE.
AFFF.CTED MODULES: SYSTEM
1/79 SYSTEM
744
357
-------
FPA UTILITY F6D SURVEY? DECtMBFF, 197£ - JANUARY 1979
SECTION 3
DESIGN AND PT R F OPf A hC E DATA F0» OPERATIONAL FGo
COMPANY NAKi
PLANT NAHF
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - 0.6/J
S02 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - *v
GROSS UNIT GENERATING CAPACITY - pV
NET UNIT GENERATIK'6 CAPACITY W/FGD - f
NET UNIT GENERATING CAPACITY WC/FGt, -
ESUIVALfNT SCRUBBED CAPACITY - fW
UTAH POWER K LI&HT
HUNTINGTON
1
PRICF
UTAH
A
******
******
B10.0
430.0
40H.O
(****** LP/MM8TU)
566.0
•* BOILER DATA
SUpPLI ER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATfc
MAXIMUM BOILER FLUE GAS FLOW - tli.i/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - I*
STACK TOP DIAMETER - l»
«« FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - KJ/KC
RANGE HfAT CONTENT - PTU/LE
AVERAGE ASH CONTENT - »
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTEia - X
RANGE HCISTURF CONTFNT - T
AVERAGE SULFUR CONTENT - *
RANC-E SULFUR CONTENT - t
AVERAGE CHLORIDF CONTENT - X
RANGE CHLORIDE CONTENT - 3!
FUEL FIRING RATE - M T/H
FUEL FIRING RATE - KW
COMBUSTION ENGINEERING
PULVERIZED COAL, TANGENTIAUY FIRED
BASE
0/7P
82?.05 <17«COD ACFM>
130.0 < 266 F)
1ST. ( 600 FT)
******* (***** FT)
COAL
******
10.00
******
.50
******
********
******
151.5
430
(****** BTU/LR)
4 **** *
(167 TPH)
** ESP
TYPE
SUPPLIER
** FG& SYSTEM
SALEABLE PRO DUCT/THROW AWAY PRODUCT
GENERAL PROCESS TYPE
PROCESS TYPt
SYSTEM SUPPLIER
A-E FIRM
DEVELOPMENT LEVEL
NEW/RETROFIT
PARTICULATE DESIGN REMCVAL FFFK1ECCY
$02 DESIGN REMOVAL EFFICIENCY - X
INITIAL START-UP
** A6SOP8FR
NUMPER
TYPt
INITIAL START UP
SUPPLIER
SHELL MATERIAL
SHELL LINER MATERIAL
6AS TEMPERATURE - C
L/fi R«T10 - L/CU.M
»* FANS
NUMBER
TYPF
*« FANS
NUMPER
TYPE
COLD SIDE
BUELL/ENVIRcTECh
THROWAWAY PRODUCT
WET SCRUBBING
LIME
CHEH1CO
STEARNS & ROGERS
FULL-SCALE
NE.V
9
-------
EPA UTILITY FG6 SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 3
DESIGN AND PERFORMMCE DATA fOR OPERATIONAL F60 SYSTEMS
** VACUUM FILTER
NUMBER
OUTLET SOLIDS - X
*« MIST ELIMINATOR
CONSTRUCTION l"ATERlAL
CONFIGURATION
MUMPER OF PASSES
FREEBOARD DISTANCE - M
«* PUMPS
SERVICE
RECYCLE
** TANKS
SERVICE
RECYCLE
** REHEATER
TYpE
HEAT1N6 MEDIUM
TEMPERATURE BOOST - C
«* REHEATER
TYpE
TEHPE«ATUR£ BOOST - C
** THICKENER
TYPf
CONSTRUCTION MATERIAL
DIAMETER - M
OUTLET SOLIDS - X
** HATER LOOP
TYPF
FRESH MAKEUP WATER ADDITION - LI1ERS/S
** TREATMENT
TYPE
** DISPOSAL
NATURE
TYPE
LOCATION
TRANSPORTATION
60.0
POLYPROPYLENE
HORIZONTAL
I
3.66
NUMBER
4
NUMBER
4
IN-LINE
STf AM
26.7
BYPASS
2«.7
(12.0 FT)
( 4? F)
48 F>
CYLINDRICAL WITH DORR OLIVER RAKF
CARBON STEEL WltH FLAKE6LASS LINING
1*.3 < 60 FT)
27-5
CLOSED
1P.9
NONPROPRlETARY
FINAL
LANDFILL
ON SITE
TRUCK
( 300 GPM)
STABILIZED
PER fORMAMCE DATA • • -
MODULE AVAILABILITY OPFRABILlTr PLIABILITY UTILIZATION X REMOVAL PER BOILER FGD CAP.
S02 PART. HOURS HOURS HOURS FACTOR
5/7P SrSTE*
** PROfcLEMS/SOLUTIONS/COMNtNTS
START DATE 5/78 EOUIfENT: FGD SYSTE«t GEN£RAL
END DATE 5/78 CCMMINTS:
IMT1AL OfERAIIONS BEGAN ON MAY 1C»
AFFECTED MODULES: SYSTEM
6/7E SYSTEM
720 720
** PROELEKS/SOLUTIONS/COM^ENTS
START DATE 6/7£ E GUI F*1' ENT: F6D SYSTEM.
END DATE 7/78 CCMMINTS:
THE UTILITY RtPORTCD THAT 1Q-ZO* OF THE FLUE GAS WAS BYPASSED.
AFFECTED MODULES: SYSTEM
7/78 SYSTE»
744 731
339
-------
EPA UTILITY FbP SURVEY: DECt*BER 197£ - JANUARY 1979
SECTION 3
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL F6D SVSTFHS
-----PERFORMANCE DATA---- ...... ._.--.-..........
PERIOD MODULE AVAILABILITY CPERABIL1TY tELIABUITY UTILIZATION X REMOVAL PER BOILER F60 CAP.
S02 PART. HOURS HOURS HOURS FACTOR
6/76 SYSTEK 744 544
«• PROBLEMS/SOLUT10NS/COMMENTS
START DATE 8/78 EOU1IMENT: BOILER-RELATED
END DATE 9/76 COKMfK'TS:
AK EXPLOSION (AUSED A THREE WEEK BOILER OUTAGE.
AFFECTED MODULES; SYSTEM
** PROaLEKS/SOLUTIOMS/COKMENTS
START DATE «/78 EOUIFKENT: FGD SYSTEM, GENERAL
END DATE 9/76 COMMITS:
Tf-E UTILITY RtPORTEB THUT THERE' WfRj NO FORCED F15D -QUTA6ES.
AFFECTED MODULES: SYSTEM
9/7R sTSTEM 720 496
10/78 SYSTEM 100.0 100.C 744 744 7440
11/78 SYSTEM 62.4 6Z.4 7?0 7?0 449Q
** PROBLEMS/SOLUTIONS/COMMENTS
START DATE 11/78 EOUlfWENT: THICKENER
END DATF 12/78 ^fOBlfM: NOT DEFINED/SPECIFIED
Tfcf THICKENER HAD SOLIDS BUILDUP THE LAST OF NOVEMBER AND THE FIRST PART
OF DECEMPl* FCRCING SYSTEM SHUTDOWN TO ALLOU MANUAL REMOVAL OF THE SOLIDS.
AFFECTED MODULES: SYSTEM
12/76 SYSTEM 14.0 32.7 744 715 2430
*« PROBLEMS/SoLUtlONS/COMMENTS
START DATE 1?/78 |QUi H^ENT: F6D SY^TEHt GENERAL
END DATF 1/79 fPOSlfM: WfATHER-RELATED COMPONENT FAILURE
MEE?r-UP PNO'JtEMS CAUSED OUTAGES OF A FEU WEEKS DURATION.
AFFECTED MODULES: SYSTEM
1/79 489 76.? 65.7
SYSTEM 7*4 642
S40
-------
EPA UTILITY F6D SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 4
SUMMARY Of FGD SYSTEMS BY COMPANY
TOTM.
COMPANY NAME
ALABAMA ELECTRIC COOP
ALLEGHENY POWER SYSTEM
ARIZONA ELECTRIC POWER CCOP
ARIZONA PUBLIC SERVICE
ASSOCIATED ELECTRIC COOP
PASIN ELECTRIC POWER COOP
BIG RIVERS ELECTRIC
CENTRAL ILLINOIS LIGHT
CENTRAL ILLINOIS PUBLIC SFRV
CENTRAL MAINE POWER
CINCINNATI GAS It ELECTRIC
COLORADO UTE ELECTRIC ASSN.
COLUMBUS t SOUTHERN OHIO fLEC.
COMMONWEALTH EDISON
COOPERATIVE POWER ASSOCIATION
DELFURVA POWER R LIGHT
DUBUESNE LIGHT
EAST KENTUCKY POWER CCOP
GENERAL PUBLIC UTILITIES
6ULF POWER
HOOSIER ENERGY
HOUSTON LIGHTING * POWER CO.
INDIANAPOLIS POWER 8 LIGHT
KANSAS CITY POWER K LIGHT
KANSAS POWER ft LIGHT
KENTUCKY UTILITIES
LAKELAND UTILITIES
LOUISVILLE GAS 1 ELECTRIC
MIDDLE SOUTH UTILITIES
MINNESOTA POWER & LIGHT
MINNKOTA POWER COOPERATIVE
MONTANA POWER
NEVADA POWER
NIAGARA MOHAWK POWER COOP
NORTHERN INDIANA PUR SERVICE
NORTHERN STATES POWER
OTTER TAIL POWER
PACIFIC GAS 1 ELECTRIC
PACIFIC POWER £ LIGHT
PENNSYLVANIA POWER
PHILADELPHIA ELECTRIC
POTOMAC EUCTRIC POWER
POWER AUTHORITY OF NEW YCRK
PUBLIC SERVICE OF INDIANA
PUbLIC SERVICE OF MEW MEXICO
SALT RIVER PROJECT
SAN MIGUEL ELECTRIC COOP
SEMINOLE ELECTRIC
SIKESTON BOARD OF HUNK. UTIL.
SOUTH CAROLINA PUfUIC SERVICE
SOUTHERN CALIFORNIA EDISCN
SOUTHERN ILLINOIS POWER COOP
SOUTHERN INDIANA GAS R ELEC
SOUTHERN MISSISSIPPI ELECTRIC
SOUTHWESTERN ELECTRIC POWER
SPRINGFIELD CITY UTILITIES
SPRINGFIELD WATER, LIGHT Si PV.K
ST. JOE ZINC
TAMPA ELECTRIC
TENNESSEE VALLEY AUTHORITY
TEXAS MUNICIPAL POWER AGENCY
TEXAS POWER ( LIGHT
TEXAS UTILITIES
UTAH POWER t LIGHT
WISCONSIN POWEK £ LIGHT
NC.
2
3
?
f
1
5
2
1
1
1
1
2
4
1
2
1
2
1
2
1
2
1
2
3
4
1
1
10
t
1
1
4
1C
1
3
5
1
2
1
3
4
1
1
1
4
3
1
1
1
?
1
1
1
7
1
1
1
1
1
*
1
3
C
3
1
*K
358.
1338.
760.
J&84.
670.
£680.
484.
* 32 .
617.
600.
'50.
900.
1572.
425*
*54.
180.
020.
r>00.
1*00.
23.
P82.
'12.
1062.
1094.
1575.
64.
364.
:508.
1340.
475.
<05.
4120.
3125.
100.
705.
tl 60.
440.
1600.
•=50.
i1 "* 5 1 .
t 44.
r'00.
7QO.
C50.
1779.
f 40.
400.
£20.
235.
440.
175.
484.
265.
748.
720.
194.
205.
60.
450.
;753.
400.
1*82.
',585.
1086.
716.
OPERATIONAL
NO.
1
0
1
2
0
0
0
1
0
0
0
0
2
0
0
0
2
0
0
1
0
0
1
3
3
1
0
4
0
0
1
2
3
0
1
2
0
0
0
2
1
0
0
0
2
0
0
0
0
1
0
0
0
1
0
1
0
0
0
3
0
0
3
1
0
MW
179.
0.
180.
469.
0.
0.
0.
416.
0.
0.
0.
0.
H22.
0.
0.
0.
920.
0.
0.
23.
0.
0.
532.
1094.
1085.
64.
0.
885.
0.
0.
405.
720.
375.
0.
115.
144C.
0.
0.
0.
1834.
120.
0.
0«
0.
711.
0.
0.
0.
c.
140.
0.
0.
0.
124.
C.
194.
0.
0.
0.
570.
0.
0.
1990.
366.
0.
CONSTRUCTION CONTRACT
AWARDED
NO.
1
2
1
4
0
2
2
0
1
0
1
2
0
1
2
1
0
0
0
0
2
0
1
0
1
0
0
3
0
1
0
0
0
0
0
0
1
0
1
1
0
0
0
0
0
2
1
0
1
0
0
1
1
1
0
0
1
1
0
1
0
1
1
2
0
MW
179.
1036.
180.
705.
0.
1200.
484.
0.
617.
0.
650.
900.
0.
425.
654.
180.
0.
0.
0.
0,
£82.
0.
530.
0.
490.
P.
0.
1123.
C.
475.
0.
0.
0.
0.
p.
0.
440.
0.
550.
917.
0.
0.
0.
0.
0.
560.
400.
0.
235.
0.
C.
164.
265.
124.
n.
0.
205.
60 .
Or
575.
0.
582.
595.
720 .
0.
NO'
0
0
0
2
1
2
0
0
0
0
0
0
0
0
0
0
0
1
0
0
0
0
0
0
0
0
1
1
0
0
0
2
0
1
0
0
0
0
0
0
0
c
0
0
2
0
0
0
0
1
1
0
0
0
1
0
0
2
1
1
MW
0.
0.
0.
1510.
670.
1040.
0.
0.
0*
0.
0*
0.
0.
"0.
0.
0.
0-
50Q.
0.
0.
o.
o!
0.
0.
0.
364.
350.
0.
0.
0.
1400.
0«
100.
0.
c.
0.
0*
0.
0-
0.
c.
0.
0.
1068.
0.
0.
0.
0.
300.
175.
0.
0.
0.
«K fk
720.
0.
.
0-
0"
1406.
.
75 Q»
.
» 4 j»
31 0.
PLANNED
NO.
0
1
0
o
o
1
o
0
1
0
0
2
0
0
0
0
0
2
0
0
1
0
0
0
0
0
2
6
0
0
0
7
0
2
1
0
2
0
0
3
1
1
1
0
1
0
1
0
0
1
0
0
0
I
0
3
MW
0.
300.
0.
0.
C.
440.
0.
4U.
0.
600.
0.
p.
7bC«
e-
0.
r.
n.
0.
1600.
P.
0.
512.
0.
0.
n.
0.
P.
115C.
5340.
0.
0.
C.
2750.
0.
5VC*.
72p.
0.
1600.
P.
P.
724.
^ t\f\
rOC.
6SC»
P«
28 p.
r.
62P«
P.
P.
"•
300.
"*
0»
•
*
•
1200.
0.
•
22SO*.
0*
<
TOTALS
7
-------
EPA UTILITY F6D SURVEY: DECtPbEft 197f - JANUARY 1979
SECTION *
SUKfiARY Of FGD SYSTEMS P Y SYSTEM SUPPLIER
TOTAL
SYST[M SUPPLIER/PROCFSS
ADL/COM6USTION EOU1P ASSOCIATE
DUAL ALKALI
LI IF
LIKE/ALKALINE fLYA$H
SODIUM CARBONATE
TOTAL -
AIR CORRECTION DIVISION, UOP
LIME
LIMESTONE
LIME/LIMESTONE
SODIUM CARBONATE
TOTAL -
AMERICAN AIR FILTER
LIME
TOTAL -
EABCOU g WILCOX
LIME
LIME {DRY COLLECTION)
LIMESTONE
TOTAL -
PUELL/ENVIROTECH
DUAL ALKALI
TOTAL -
BUREAU Of MINES
CITRATE
TOTAL -
CHEMICO
LIME
LIMt STONE
LIME/ALKALINE FLYASH
LII»C /LIMESTONE
TOTAL -
CHIYODA INTERNATIONAL
LIMESTONE (CHIYOOA 121)
TOTAL -
COMBUSTION ENGINEERING
LIME
LIMESTONE
LIMESTONE/ALKALINE FLYASH
LIME/LIMESTONE
TOTAL -
DAVY POVERGAS
HELLMAN LORD
TOTAL -
FMC CORPORATION
DUAL ALKALI
TOTAL -
JOY MF6. CO, HESTER* PRECIPITA
LIME (DRY COLLECTION)
TOTAL -
NO.
1
3
3
3
10
2
4
1
1
8
6
6
3
1
7
11
1
1
1
1
7
1
4
1
13
1
1
6
7
2
2
17
6
6
1
1
1
1
MW
278.
1220.
1805.
375.
3678.
822.
1871.
10.
550.
3253.
1658.
1658.
1686.
600.
2*97.
4765.
617.
617.
60.
60.
3840.
800.
895.
10.
5545.
23.
23.
1144.
2932.
1440.
700.
6216.
2074.
2074.
265.
265.
440.
440.
OPERATIONAL
NO.
0
2
1
3
6
2
2
1
0
5
3
7
0
0
2
2
0
0
0
0
5
1
0
1
7
1
1
4
3
2
0
9
3
3
0
0
0
0
MW
0.
720.
405.
375.
1500.
522.
726.
10.
0.
1558.
679.
679.
0.
0.
1014.
1014.
o.
0.
0.
0.
3120.
800.
0.
10.
3930.
23.
23.
490.
1085.
1440.
0.
3015.
S26.
P26.
0.
0.
o.
0.
CONSTRUCTION
MO.
1
0
0
0
1
0
1
0
1
2
3
3
3
0
3
6
1
1
1
1
2
0
3
0
5
0
0
2
3
0
1
6
1
1
1
1
0
0
BW
278.
0.
0.
0.
E76.
0.
425.
0.
550.
975.
979.
979.
1688.
0.
819.
?507.
617-
617.
60.
60.
720.
0'
579.
0.
1299.
0.
0.
654.
1447.
0.
350.
2451.
160.
180.
265.
265.
0.
0.
CONTRACT
AWARDED
NO.
0
1
2
0
3
0
1
c
0
1
0
0
0
1
2
3
0
0
0
0
0
0
1
0
1
0
0
0
1
0
1
2
2
2
0
0
1
1
MW
0.
500.
1400.
0.
1?00«
0.
720.
0.
0.
72o.
0.
0.
0.
600.
664.
1264.
0.
0.
0.
0.
0.
0.
316.
0.
316.
0.
0.
0«
400.
0.
350.
750.
106P.
1068.
0.
o.
440.
440.
342
-------
EPA UTILITY FGt SURVEYi DECEMBER 1978 - JANUARY 1979
SECTION 5
SUMMARY Of F6D SYSTEHS PY SYSTEM SUPPLIER
TOTAL
SYSTFM SUPPLIER/PROCESS
MITSUBISHI INTERNATIONAL
LIKESTONE
TOTAL -
PEABOOY PROCESS SYSTEMS
LIMESTONE
LIKE/ALKALINE FLYASH
TOTAL -
PULLMAN KELL06G
LIKE
LIMESTONE
TOTAL -
RESEARCH COTTRELL
LIMESTONE
TOTAL -
RILEY STOKER/ENVIROIiEERING
LIMESTONE
TOTAL -
ROCKWELL INTERNATIONAL
AQUEOUS CARBONATE
TOTAL -
SO. CAL1FRON1A ED I S CN/ STEA RNS
LIME
TOTAL -
TENNESSEE VALLEY AUTHORITY
LIMESTONE
TOTAL -
UNITED ENGINEERS
LIME
MAGNESIUM OXIDE
TOTAL -
VENDOR NOT SELECTED
LIMESTONE
TOTAL -
WHE ILABRATOR-fRYE/R .1.
AQUEOUS CARBONATE IDRY COLLECT
TOTAL -
NO.
2
Z
4
1
5
1
3
4
13
13
3
3
1
1
1
1
1
1
Z
1
3
Z
2
1
1
nw
882.
863.
1258.
475.
1733.
917.
1230.
2U7.
5425.
5425.
664.
664.
100.
100.
175.
175.
550.
550.
1510.
120.
1630.
1408.
1408.
440.
440.
OPERATIONAL
NO.
0
0
1
0
1
0
0
0
5
5
2
2
0
0
0
0
1
1
0
1
1
n
0
0
0
KU
0.
0.
179.
0.
179.
0.
0.
0.
1P39.
1839.
540.
540.
0.
0.
0.
0.
550.
550.
0.
120.
120.
0.
0.
0.
0.
CONSTRUCTION
NO.
2
2
3
1
4
1
2
3
7
7
1
1
0
0
0
0
0
0
0
0
0
0
0
1
1
Mfc
882.
882.
1079.
475.
1554.
917.
56o.
1477-
2836.
?836.
124.
124.
0.
0.
0-
0.
0.
0.
0.
c.
0.
0.
0.
440.
440.
CONTRACT
AWARDED
NO.
0
0
0
0
0
0
1
1
1
1
0
0
1
1
1
1
0
0
2
0
2
2
?
0
0
MW
0.
0.
0«
0.
0.
0.
670.
670.
750.
750.
0.
0.
100.
too.
175.
175.
0.
0.
1510.
0.
1510.
140*.
1408-
0.
0.
TOTAL -
112 43768.
46 15773.
45 1*924.
21 11071.
343
-------
EPA UTILITY FtiD SURVEY: DECIDER 197? - JANUARY 1979
SECTION 6
SUMMARY Of F6D SYSTEMS BY PROCESS
TOTAL
STATUS
OPERATIONAL CONSTRUCTION CONTRACT
AWARDED
PLANNED
PROCESS
AQUEOUS CAhBONATL
CITRATE
LIMESTONE/CH1YODA 121
MAGNESIUM OXIDE
BELLMAN LORD
SUbTOTAL - SALEABLE PRODUCT
AQUEOUS CARBOMATE/SPKA Y DRYING
DUAL ALKALI
LIKE
LI HESTONE
LI MESTONE/ALKALlNf FLYA5.H
LIHE/ALK ALINE FLYASH
LIME/LIMESTONE
LIME/SPRAY DRYING
PROCESS NOT SELECTED
SODIU"! CARbONATE
SUBTOTAL - THROWAyAY PKODUCT
TOTALS
SALEABLE. X DF TOTAL HW
NO.
1
1
1
e
f
14
1
?
51
56
2
F
R
2
3 2
t
14C
1 5P
*u
100.
60.
23.
1444.
2074.
3701.
440.
1170.
12941.
25734.
1480.
3175.
1328.
1040.
1S670.
925.
66503.
70204.
5
NO.
0
0
1
1
3
5
0
0
16
17
2
1
2
0
0
3
41
46
MU
0.
0.
23.
120.
826.
96*.
0.
0.
5798.
6746.
USD.
405.
20.
D.
0.
375.
14626.
15795.
6
NO.
0
1
0
0
1
2
1
3
11
£2
0
4
1
0
0
1
43
45
HW
0.
60.
0.
0.
no.
240.
44C.
1170.
4958.
8206.
0.
105.4.
358.
0.
0.
S5C.
16736.
16976.
1
NO.
1
0
0
0
2
3
0
0
4
E
0
3
1
2
0
0
16
21
m
100.
0.
0.
0.
1068.
11S8.
0.
0.
2185.
4592.
0.
1716.
350.
1040.
0.
0.
9683.
11051.
11
NO.
0
0
0
4
0
4
0
0
0
9
0
0
1
0
32
0
42
46
MM
C.
0.
c.
1324.
0.
1324.
0.
0.
0.
57SR.
0.
0.
60P.
0.
1
-------
tPA UTILITY FGD SURVEY: DECEMBER 1978 - JANUARY 1979
SfCT10N ?
SUWMAKY OF OPERATIONAL FGD SYSTEMS 61 PROCESS AND UNIT
PROCESS/
UNIT NAC.F UNIT NO.
LIKE
ERUCf MANSFIELD 1
BRUCE MANSF 1ELP ?.
CANE RUN i
CANfc RUN 5
COLSTRIP 1
COLSTRIP ?
CONESVILLE r
CONESVILLE 6
ELRAMA 1-4
GfiFEN RIVER 1-3
HAWTHORN J
HAWTHORN 4
HUNTIN6TCN 1
HILL CREEK
PADDY'S RUN t
PHILLIPS 1-6
LIMESTONE
APACHE ?
CHOLLA 1
CHOLLA ?
DUCK CREEK 1
JEFFREY 1
LA CYGNE 1
LAWRENCE '•
LAWRENCE 5
MARTIN LAKE i
MAPTIN LAKE i
MONTICELLO 3
PETERSBURG *
R.D. MORROW 1
SOUTHWEST 1
TOMBI6EEE '-
WIDOWS CREEK fc
W1NYAH ?
LIMESTONE (CHIYODA 1?1>
SCHOLZ 1*2
LIMESTONE/ALKALINE FLYASH
SHEREURNE 1
EHFRPURNF i'
LIME/ALKALINE fLYASH
MILTON R. YOUNG I
LIME/LIMESTONE
C U AUhl f f 1 0 A
9f1^HnCC •»**•*
SHAWNtl 10B
MACNfSlUM OXIDE
EDDVSTONE 1A
CAPACITY
nw
917.
917.
190.
200.
360.
360.
411.
411.
510.
64.
110.
110.
366.
425.
70.
410.
5831 .
1BO.
119.
350.
416.
540.
874.
125.
420.
5«5.
595.
BOO.
532.
124.
194.
179.
550.
140.
6733.
23.
23.
720.
720.
144(1.
405.
405.
10.
10.
2C.
120.
12C.
INITIAL
STARTUP
12/75
7/77
8/76
12/77
9/75
5/76
1/77
6/7P
10/75
9/75
11/72
8/72
5/7R
sm
4/73
7/73
8/7S
10/73
4/7P
7/76
8/7R
2/73
1/76
11/71
4/77
5/78
5/76
12/77
8/78
4/77
9/78
5/77
7/77
8/78
3/76
4/77
9/77
4/7?
4/7?
9/75
COMMERCIAL
STARTUP
6/76
10/77
9/77
6/78
11/75
10/76
2/77
6/78
10/75
6/76
O/ 0
O/ 0
O/ 0
O/ o
O/ 0
•o/ o
11/78
12/73
O/ 0
fl/78
8/78
6/73
O/ 0
O/ 0
P/77
O/ 0
10/78
12/77
O/ 0
O/ o
O/ 0
1/78
O/ 0
O/ 0
3/76
4/77
6/78
O/ 0
O/ 0
9/75
345
-------
FPA UTILITY F£0 SURVEY: rECEKBFF 197? - JANUARY 1979
SECTION 7
OF OPERATIONAL F6D SYSTKKS oY PROCESS AND UNIT
PROCESS/
UNIT NAME
SODILIF CARBONATE
KEID GARDKEB
REID EARDNEK
RE IB GARDNEK
WELL^AN LORD
DEAN H. MTCHELL
SAN JUAN
SAN JUAK
UNIT NO.
1
i
11
1
7
CAPACITY
nv
12s!
125.
375.
115.
361.
350.
INITIAL
STARTUP
4/74
6/76
7/76
4/7P
P./7B
CCKPERCI AL
STARTUP
O/ C
O/ 0
7/76
6/77
O/ 0
O/ 0
626.
TOTAL
15773.
346
-------
EPA UTILITY F6D SURVEY: DECEMBER 1978 - JANUARY
SECTION 8
SU*HARY OF END-PRODUCT DISPOSAL PRACTICES FOR OPERATIONAL F6D SYSTEMS
DpncF ss y
rnUVCvQf
UNIT NAME
LINE
BRUCE MANSFIELD
BRUCE MANSFIELD
CANE RUN
CANE RUN
COLSTR1P
COLSTRIP
CONESVILLE
CONESVILLE
ELD AM A
GREEN RIVER
HAWTHORN
HAWTHORN
HUNTIN6TON
HILL CREEK
PADDY'S RUN
PHILLIPS
UNIT NO
1
2
4
5
1
2
5
6
1-4
1-3
3
4
1
3
6
1-6
STABILIZED UNSTABlLIZED TYpE DISPOSITION
LANDFILL
LANDFILL
LINED POND
LINED POND
POND
LANDFILL
DIKED LANDFIL
LANDFILL
LINED POND
UNLINED POND
UNLINED PC N(>
LANDFILL
SLUDGE POND
UNLINED POND
LANDFILL
LIMESTONE
APACHE
CHOLLA
C HOLLA
DUCK CREEK
JEFFREY
LA CYGNE
LAWRENCE
LAWRENCE
KARTIN LAKE
*ART!N LAKE
PIONTICELLO
PETERSBURG
R.D. MORROW
SOUTHWEST
TOMB1GBEE
WIDOWS CREEK
U1NYAH
2
1
2
1
1
1
4
5
1
2
3
3
1
1
2
8
2
LIMESTONE (CHIYODA 121)
SCHOLZ 1.2
LIMESTONE/ALKALINE FLYASH
UNLIMED POND
UNLINED POND
UNLINED POND
LANDFILL
LANDFILL
LANDFILL
UNLINED POND
LANDFILL
LANDFILL
LINED POND
SLUD6E POND
UNLINED POND
SLUDGE POND
LINED POND
UNLINED POND
POND
UNLINED POND
GYPSUM
STACKED IN POND
SHERBURNE
SHERBURNE
LINED POND
LINED POND
HILTON R. YOUNG
LIME/LIMESTONE
SHAkNEE
SHAWNEE
OXIDE
EDDYSTONE
SODIUM CARBONATE
PEID GARDNER
REID GARDNER
PETD GARDNER
1C A
10 B
1A
HINEFILL
SULFURIC ACID
EVAP PONO
EVAP POND
EVAP POND
347
-------
FPA UTILITY F60 SURVEY: DECEH6ER 1978 - JANUARY 1979
SECTION 8
SUMMARY Of END-PRODUCT DISPOSAL PRACTICES FOR OPERATIONAL FGD SYSTEMS
PROCESS/
UNIT NAME
—. —THROWAWAY
UNIT NO STAbHl7FD UfcSTABIL 12 EO
-BYPROOUCT-
TYPI
DISPOSITION
LORD
BEAN H. miTCMELL 11
SAN JUAN 1
$AN JUAN 2
ASH POND
ASH POND
ELEMENTAL SULFUR
ELEMENTAL SULFUR
ELEMENTAL SULFUR
MARKETED
MARKETED
348
-------
EPA UTILITY fGO SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 9
SUMMARY OF F60 SYSTEMS IN OPERATION
Co«l»*N» NAME/
UNIT N»NE UNIT NO.
ALABAMA ELECTRIC COOP
TOMBI6BEE 2
ARIZONA ELECTRIC POWER COOP
APACHE 2
ARIZONA PUBLIC SERVICE
C HOLLA 1
ARIZONA PUBLIC SERVICE
C HOLLA 2
CENTRAL ILLINOIS LIGHT
DUCK CREEK 1
COLUMBUS 8 SOUTHERN OHIO ELEC.
CONESVILLE 5
COLUMBUS * SOUTHERN OHIO ELEC.
CONESVILLE 6
DUaUESNE LIGHT
ELRAMA 1-4
oUQUeSNE LIGHT
PHILLIPS 1-6
GULF POWER
SCHOLZ 1,2
INDIANAPOLIS POWER * LI 6HT
PETERSBURG 3
KANSAS CITY POWER s LIGHT
HAWTHORN 3
KANSAS ClfV POWER I LIGHT
HAWTHORN 4
KANSAS CITY POWER t LI6HT
LA CVGNE 1
KANSAS POWER t LIGHT
JEFFREY 1
KANSAS POWER & LIGHT
LAWRENCE 4
KANSAS POWER E LIGHT
LAWRENCE 5
KENTUCKY UTILITIES
GREEN RIVER 1-3
LOUISVILLE GAS t ELECTRIC
CANE RUN 4
LOUISVILLE GAS 8 ELECTRIC
CANE RUN 5
LOUISVILLE GAS & ELECTRIC
MILL CREEK 3
LOUISVILLE GAS * ELECTRIC
PADDY'S RUN 6
MINNKOTA POWER COOPERATIVE
MILTON R. YOUNG ^
MONTANA POWER
COLSTRIP 1
NEW OR C
RETROFIT
NEW
NEW
RETROFIT
NEW
NEW
NEW
NEW
RETROFIT
RETROFIT
RETROFIT
NEW
RETROFIT
RETROFIT
NEW
NEW
RETROFIT
RETROFIT
RETROFIT
RETROFIT
RETROFIT
NEW
RETROFIT
NEW
NEW
:APACITY
MW
179.0
180.0
119.0
350.0
416.0
411.0
411.0
510.0
410.0
2!.Q
532.0
110.0
110.0
874. 0
540.0
125.0
420.0
64.0
190.0
200.0
425.0
70.0
405.0
360.0
PROCESS/ J
SYSTEM SUPPLIER
LIMESTONE
PEABODV PROCESS SYSTEMS
LIMESTONE
RESEARCH COTTRELL
LIMESTONE
RESEARCH COTTRELL
LIMESTONE
RESEARCH COTTRELL
LIMESTONE
RILEY STOKER/ENVIRONEER1NG
LIME
AIR CORRECTION DIVISION, UOP
LIME
AIR CORRECTION DIVISION, UOP
LIME
CHEMIC0
LIME
CHEM1CO
LIMESTONE (CHIYODA 1?1)
CHIYODA INTERNATIONAL
LIMESTONE
AIR CORRECTION DIVISION, UOP
LIME
COMBU$TION ENGINEERING
LIME
COMBUSTION ENGINEERING
LIMESTONE
BABCOCK & WILCOX
LIMESTONE
COMBUSTION ENGINEERING
LIMESTONE
COMBUSTION ENGINEERING
LIMESTONE
COMBUSTION ENGINEERING
LIME
AMERICAN AIR FILTER
LIME
AMERICAN AIR FILTER
LIME
COMBUSTION ENGINEERING
LIME
AMERICAN AIR FILTER
LIME
COMBUSTION ENGINEERING
LIME/ALKALINE FLYASH
AOL/COMBUSTION EQUIP ASSOCIATE
LIME
AOL/COMBUSTION EOUIP ASSOCIATE
iTART-UP
DATE
9/78
8/78
10/73
4/7E
7/76
1/77
6/78
10/75
7/73
8/78
12/77
11/72
6/72
2/73
8/78
1/76
11/71
9/75
8/76
12/77
8/78
4/73
9/77
9/75
349
-------
FPA UTILITY F6D SURREY! DECEMBER 197? - JANUARY 1979
SECTION 9
SUMMARY OF F6D SYSTEMS IN OPERATION
COMPANY NAME/
UNIT N»*E UNIT NO*
MONTANA POWER
COLSTRlp 2
NEVADA POWER
REID GA'RDNER 1
NEVADA POWER
REIP GARDNER 2
NEVADA POWER
REID GARDNER 3
NORTHERN INDIANA Pub SERVICE
DEAN H. MITCHELL 11
NORTHERN STATES POWER
SHERBUftNE 1
NORTHERN STATES POWER
SHERBURNS 2
PENNSYLVANIA POWER
BRUCE MANSFIELD 1
PENNSYLVANIA POWER
BRUCE MANSFIELD 2
PHILADELPHIA ELECTRIC
EDDYSTONE 1A
PUBLIC SERVICE OF NEW MEXICO
SAN JUAN 1
PUBLIC SERVICE OF NEW MEXICO
SAN JUAN 2
SOUTH CAROLINA PUBLIC SERVICE
WINYAH 2
SOUTHERN MISSISSIPPI ELECTRIC
R.D. MORROW 1
SPRINGFIELD CITY UTILITIES
SOUTHWEST 1
TENNESSEE VALLEY AUTHORITY
SHAWNEE 10A
TENNESSEE VALLEY AUTHORITY
SHAMNEE 10B
TENNESSEE VALLEY AUTHORITY
WIDOWS CREEK s
TEXAS UTILITIES
MARTIN LAKE 1
TEXAS UTILITIES
MARTIN LAKE 2
TEXAS UTILITIES
HONTlCELLO 3
UTAH POWER g LIGHT
HUNTINGTON 1
NEW OR
RETROFIT
NEW
RETROFIT
RETROFIT
NEW
RETROFIT
NEW
NEW
NEW
NEW
RETROFIT
RETROFIT
RETROFIT
NEW
NEW
NEW
RETROFIT
RETROFIT
RETROFIT
NEW
NEW
NEW
NEW
CAPACITY
MW
360.0
125.0
125.0
125.0
115.0
720,0
720. 0
917.0
917.0
120.0
361.0
350.0
uo.o
124.0
194.0
10.0
10.0
550.0
595.0
595.0
800.0
366.0
PROCESS/
SYSTEM SUPPLIER
LIME
AOL/COMBUSTION EQUIP ASSOCIATE
SODIUM CARBONATE
ADt/COMBUSTION EQUIP ASSOCIATE
SODIUM CARBONATE
ADL/COMBUSTION' gflUIP ASSOCIATE
SODIUM CARBONATE
ADI/COMBUSTION EQUIP ASSOCIATE
WEILMAN LORD
DAVY POWEREAS
LIMESTONE/ALKALINE FLYASH
COMBUSTION ENGINEERING
LIMESTONE/ALKALINE FLYASH
COMBUSTION ENGINEERING
LIME
CHEMICO
LIME
CHEMICO
MAGNFSIUM OXIDE
UNITED ENGINEERS
WELLMAN LORD
DAVY POWERGAS
WELLMAN LORD
DAVY POWEREAS
LIMESTONE
EiABCOCK 8 WILCOX
LinESTONE
RILEY STOKER/ENVIRONEERING
LIMESTONE
AIR CORRECTION DIVISION! UOP
LICE/LIMESTONE
AIR CORRECTION DIVISION, UOP
LIME/LIMESTONE
CHEMICO
LIMESTONE
TENNESSEE VALLfY AUTHORITY
LIMESTONE
RESEARCH CQTTRELL
LIMESTONE
RESEARCH COTTRELL
LIMESTONE
CHEMICO
LIME
CHEMICO
START-UP
DATE
5/76
4/74
4/74
6/76
7/76
3/76
4/77
12/75
7/77
9/75
4/78
8/78
7/77
8/78
4/77
4/72
4/72
5/77
4/77
5/78
5/78
5/78
350
-------
EPA UTILITY F6D SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 10
SUMMARY OF FGD SYSTEMS UNDER CONSTRUCTION
CflMpAN* NAME/
UNIT NA«E UNIT NO-
ALABAMA ELECTRIC COOP
TONBI6BEE 3
ALLEGHENY POWER SYSTEM
PLEASANTS 1
ALLE6HENV POWER SYSTEM
PLEASANTS 2
ARIZONA ELECTRIC POWER COOP
APACHE 3
ARIZONA PUBLIC SERVICE
CHOLLA 4
ARIZONA PUBLIC SERVICE
FOUR CO«NERS 1
ARIZONA PUBLIC SERVICE
FOUR CORNERS 2
ARIZONA PUBLIC SERVICE
FOUR CORNERS 3
BASIN ELECTRIC POWER COOP
LARAMIE RIVER t
BASIN ELECTRIC POWER COOP
LARAMIE RIVER 2
BIS RIVERS ELECTRIC
6REEN 1
BI6 RIVERS ELECTRIC
GREEN 2
CENTRAL ILLINOIS PUBLIC SERV
NEWTON 1
CINCINNATI GAS I ELECTRIC
EAST BEND 2
COLORADO UTE ELECTRIC ASSN.
CRAIG t
COLORADO UTE ELECTRIC ASSN.
CRAIG 2
COMMONWEALTH EDISON
POWERTON 51
COOPERATIVE POWER ASSOCIATION
COAL CREEK 1
COOPERATIVE POWER ASSOCIATION
COAL CREEK 2
DELMARVA POWER I LIGHT
DELAWARE CITY 1-3
HOOSlER ENERGY
HER on 1
HQOSIER ENERGY
NEROI 2
INDIANAPOLIS POWER & LIGHT
PETERSBURG *
KANSAS POWER 8 LIGHT
NEW OR (
RETROFIT
NEW
NEW
NEW
NEW
NEW
RETROFIT
RETROFIT
RETROFIT
NEW
NEW
NEW
NEW
NEW
NEW
NEW
NEW
RETROFIT
NEW
NEW
RETROFIT
NEu
NEW
NEW
hEW
:APACITY
MW
179.Q
519.0
519.0
160.0
126.0
175.o
175.0
229.0
600.0
600.0
242.0
34?. 0
617.0
650.0
450.0
450.0
425.0
327.0
327.0
180.0
441.0
441.0
530.0
490.0
PROCESS/
SYSTEM SUPPLIER
LIMESTONE
PEABODY PROCESS SYSTEMS
LIME
BABCOCK E WILCOX
LIME
BABCOCK 6 WILCOX
LIMESTONE
RESEARCH COTTRELL
LIMESTONE
RESEARCH COTTRELL
LIME/ALKALINE FLVASH
CHEMICO
LIME/ALKALINE FLYASH
CHEMICO
LIME/ALKALINE FLYASH
CHFMICO
LIMESTONE
RESEARCH COTTRELL
LIMESTONE
RESEARCH COTTRELL
LIME
AMERICAN AIR FILTER
LIME
AMERICAN AIR FILTER
DUAL ALKALI
BUELL/ENVIROTECH
LIME
BABCOCK « WILCOX
LIMESTONE
PEABOOY PROCESS SYSTEMS
LIMESTONE
PEABODY PROCESS SYSTEMS
LIMESTONE
AIR CORRECTION DIVISION, UOP
LIME
COMBUSTION ENGINEERING
LIME
COMBUSTION ENGINEERING
WELLMAN LORD
DAVY POWERGAS
LIMESTONE
MITSUBISHI INTERNATIONAL
LIMESTONE
MITSUBISHI INTERNATIONAL
LIMESTONE
RESEARCH COTTRELL
LIMESTONE
START-UP
DATE
6/79
3/79
3/BO
4/79
6/80
0/79
0/79
0/79
4/80
10/80
12/79
12/80
11/79
10/81
3/79
3/79
7/79
5/79
10/80
4/80
4/81
1/82
10/83
6/80
JEFFREY
COMBUSTION ENGINEERING
351
-------
EPA UTILITY FGD SURVEY: DECEMBER 197B - JANUARY 1979
SECTION 10
SUMMARY OF FGO SYSTEMS UNDER CONSTRUCTION
COMPANY NAME/
UNIT NAME UMT NO*
LOUISVILLk GAS & ELECTRIC
CANE RUfc t
LOUISVILLE GAS t ELECTRIC
MILL CREEK 1
LOUISVILLE GAS t ELECTRIC
MILL CREEK I
MINNESOTA POW£P 8 LIGHT
CLAY BOSKELL 4
OTTER TAIL POWFR
COYOTE 1
PACIFIC POWER t LIGHT
JIN BRIDGER 4
PENNSYLVANIA POWER
BRUCE MANSFIELD 3
SALT RIVER PROJECT
CORONADO 1
SALT RIV^R PROJECT
CORONADO 2
SAN *I6uEL ELECTRIC COOP
SAN MIGUEL 1
SIKESTON BOARD OF MUNIC. UTIL.
SlKESToN 1
SOUTHERN ILLINOIS POWER COOP
MARION 4
SOUTHERN INDIANA GAS « ELEc
A.B. BROWN 1
SOUTHERN MISSISSIPPI ELECTRIC
R.D. MORROW 2
SPRINGFIELD WATER, LIGHT ft PWR
&ALLMN 3
ST. JOE ZINC
G.F. WEATON 1
TENNESSEE VALLEY AUTHORITY
WIDOWS CREEK 7
TEXAS POWER I LIGHT
SANDOW *
TEXAS UTILITIES
MARTIN LAKE 3
UTAH POWER ( LIGHT
EMERY 1
UTAH POWER & LIGHT
EMERY 2
NEW OR
RETROFIT
RETROFIT
RETROFIT
NEW
NEW
NEW
NtW
NEW
NEW
NEW
NEW
NEW
NEW
NEW
NEW
NEW
RETROFIT
RETROFIT
NEW
NEW
NEW
NEW
CAPACITY
MW
278.0
350.0
495.0
475.0
440.0
550.0
917.0
280.0
280.0
400.0
235.0
184.0
265.0
124.0
205.0
60.0
575.0
382.0
595.0
360.0
360.0
PROCESS/
SYSTEM SUPPLIER
DUAL ALKALI
AOL/COMBUSTION EOUIP ASSOCIATE
LIME/LIMESTONE
COMBUSTION ENGINEERING
LIME
AMERICAN AIR FILTER
LIME/ALKALINE FLVASH
PEABQDY PROCESS SYSTEMS
AQUEOUS CARBONATE (DRY COLLECT
WHEELABRATOR-FRYE/R.I.
SODIUM CARBONATE
AIR CORRECTION DIVISION, UOP
LIME
PULLMAN KELLOGG
LIMESTONE
PULLMAN KELLOGG
LIMESTONE
PULLMAN KELLOGG
LIMESTONE
fABCOCK 8 WILCOX
LIMESTONE
BABCOCK & WILCOX
LIMESTONE
BABCOCK g WILCOX
DUAL ALKALI
FMC CORPORATION
LIMESTONE
RILEY STQKER/ENVIRONEERING
LIMESTONE
RESEARCH COTTRELL
CITRATE
BUREAU OF MINES
LIMESTONE
COMBUSTION ENGINEERING
LIMESTONE
COMBUSTION ENGINEERING
LIMESTONE
RESEARCH COTTRELL
LIME
CHfHICO
LIME
CHEM1CO
START-UP
BATE
3/79
4/81
7/81
5/80
5/81
9/79
4/80
8/79
1/8o
6/80
11/80
5/79
3/79
5/79
8/80
4/79
10/80
7/80
?/79
4/79
6/80
352
-------
EPA UTILITY KB SURVEY: DECEMBER 1«7S - JANUARY 1979
SECTION 11
SUMMARY Of CONTRACT AWARDED FGD SYSTEMS
COMPANY NAME/
UNIT NAME UNIT NO*
ARIZONA PUBLIC SERVICE
FOUR CORNERS *
ARIZONA PUBLIC SERVICE
FOUR CORNERS 5
ASSOCIATED ELECTRIC COOP
THOMAS HILL 3
BASIN ELECTRIC POWER COOP
ANTELOPE VALLEY 1
BASIN ELECTRIC POWER COOP
LARAMIE RIVER 3
EAST KENTUCKY POWER COOP
SPURLOCK 2
LAKELAND UTILITIES
NCINTOSH 3
LOUISVILLE tAS K ELECTRIC
MILL CREEK I
MONTANA PO«E*
COLSTRIP 3
MONTANA POWER
COLSTRIP 4
NIAGARA MOHAWK POWER COOP
CHARLES R. HUNTLEY 66
PUBLIC SERVICE OF NEW MEXICO
SAN JUAN 3
PUBLIC SERVICE OF NEW MEXICO
SAN JUAN 4
SOUTH CAROLINA PUBLIC SERVICE
WINYAH 3
SOUTHERN CALIFORNIA EDISON
ALAMITOS 6
SOUTHWESTERN ELECTRIC POWER
HENRY W. PERKEY 1
TENNESSEE VALLEY AUTHORITY
PARADISE 1
TENNESSEE VALLEY AUTHORITY
PARADISE 2
TEXAS MUNICIPAL POWER AGENCY
GIBBONS CREEK i
TEXAS UTILITIES
MARTIN LAKE 4
WISCONSIN POWER t LIGHT
NEW OR (
RETROFIT
RETROFIT
RETROFIT
NEW
NEW
NEW
NEW
NEW
RETROFIT
NEW
NEW
RETROFIT
NEW
NEW
NEW
RETROFIT
NEW
RETROFIT
RETROFIT
NEW
NEW
NEW
:APACITV
MW
7S5.0
755.0
670.0
440.0
600.0
500.0
364.0
350.0
700.0
700.0
100.0
534.0
534.0
300.0
175.0
720.0
704.0
704.0
400.0
750.0
316.0
PROCESS/
SYSTEM SUPPLIER
LIME
UNITED ENGINEERS
LIME
UNITED ENGINEERS
LIMESTONE
PULLMAN KELLOGG
LIME (DRY COLLECTION)
JOY MFG. COt WESTERN PRECIPITA
LIME (DRY COLLECTION)
BABCOCK 8 WILCOX
LIME
AOL/COMBUSTION EQUIP ASSOCIATE
LIMESTONE
BABCOCK K WILCOX
LIME/LIMESTONE
COMBUSTION ENGINEERING
LIME/ALKALINE FLYASH
AOL/COMBUSTION EBUIP ASSOCIATE
LIME/ALKALINE FLYASH
AOL/COMBUSTION EQUIP ASSOCIATE
AQUEOUS CARBONATE
ROCKWELL INTERNATIONAL
WELLMAN LORD
DAVY POWERGAS
WELLMAN LORD
DAVY POWERGAS
LIMESTONE
BABCOCK 6 WILCOX
LIME
SO. CALIFRONIA EDISON/STEARNS
LIMESTONE
AIR CORRECTION DIVISION, UOP
LIMESTONE
VENDOR NOT SELECTED
LIMESTONE
VENDOR NOT SELECTED
LIMESTONE
COMBUSTION ENGINEERING
LIMESTONE
RESEARCH COTTRELL
LlWfc/ALKALIHE FLYASH
START-UP
DATE
0/82
0/82
1/8?
11/81
4/82
3/80
10/81
4/82
7/80
7/81
0/fiJ
6/79
1/82
5/«0
1/82
3/84
0/8?
4/82
1/82
0/85
1/80
353
-------
FPA UTILITY F6D SURVEY: DECEMBER 1976 - JANUARY 1979
SECTION 12
SUMMARY OF PLANNED F6D SYSTEMS
COMPANY NAME/ NEW OR CAPACITY PROCESS/
UNIT N*ME UMT NO. RETROFIT MV SYSTEB SUPPLIER
STAfiT-UP
DATE
LETTER OF INTENT SIGNED
NEW
NO"THERN STATES POKER
SHERBURNE 3
PHILADELPHIA ELECTRIC
EOOYSTONE
RETROFIT
IB
720.0
2*0-0
RE8UESTIN6/EVALUATIN6 BIDS
CENTRAL ILLINOIS LIGHT
DUCK CREEK 2
HOUSTON LIGHTING I POWER CO.
W.A. pARlsH 6
MIDDLE SOUTH UTILITIES
ARKANSAS COAL 5
MIDDLE SOUTH UTILITIES
ARKANSAS COAL 6
MIDDLE SOUTH UTILITIES
LOUISIANA COAL 1
MIDDLE SOUTH UTILITIES
LOUISIANA COAL 2
MIDDLE SOUTH UTILITIES
MISSISSIPPI COAL 1
MIDDLE SOUTH UTILITIES
MISSISSIPPI COAL 2
PUBLIC SERVICE OF INDIANA
GIBSON 5
TENNESSEE VALLEY AUTHORITY
40HNSONVILLE 1-10
TEXAS UTILITIES
FOREST GROVE 1
CONSIDERING F€D SYSTEMS
ALLEGHENY POWER SYSTEM
MITCHELL 3
BASIN ELECTRIC POWER COOP
ANTELOPE VALLEY 2
CENTRAL MAINE POWER
SEARS ISLAND 1
COLUMBUS & SOUTHERN OHIO ELEC .
POSTON 5
COLUMBUS £ SOUTHERN OHIO ELEC. NEW
POSTON 6
GENERAL pUBLIC UTILITIES
COHO 1
GENERAL PUBLIC UTILITIES
SEWARD 7
LOUISVILLE GAS t ELECTRIC
TRIMBLE COUNTY 1
LOUISVILLE GAS t ELECTRIC
TRIMBLE COUNTY 2
NEW
NEW
NEW
NEW
NEW
NEW
NEW
NEW
NEW
RETROFIT
NEW
-------
EPA UTILITY FGD SURVEY! DECEMBER 197S - JANUARY 1979
SECTION 12
SUMMARY OF PLANNED F6D SYSTEMS
COMPANY NAME/
UNIT N«Mt UNIT NO.
NEVADA POWER
HARRY ALLEN 1
NEVADA POWER
HARRY ALLEN 2
NEVADA POWER
HARRY ALLEN 3
NEVADA POWER
HARRY ALLEN 4
NEVADA POWER
REID GARDNER 4
NEVADA POWER
WARNER VALLEY 1
NEVADA POWER
WARNER VALLEY 2
NORTHED INDIANA pUb SERVICE
BAILLY 7
NORTHERN INDIANA PUB SERVICE
BAILLY 6
PACIFIC GAS & ELECTRIC
FOSSIL 1
PACIFIC 6AS & ELECTRIC
FOSSIL 2
PHILADELPHIA ELECTRIC
CROMBY
PHILADELPHIA ELECTRIC
EDDYS TONE 2
POTOMAC ELECTRIC POWER
DICKERS ON 4
POWER AUTHORITY OF NEW YORK
ARTHUR KILL
SALT RIVER PROJECT
CORONADO 3
SEMINOLE ELECTRIC
SEKINOLE 1
SOUTHERN ILLINOIS POWER COOP
MARION 5
TAMP* ELECTRIC
BIG BEND 4
TENNESSEE VALLEY AUTHORITY
CUMBERLAND
TEXAS POWER i LIEHT
TWIN OAKS 1
TEXAS POWER g LI6HT
TWIN OAKS 2
TEXAS UTILITIES
MILL CREEK 1
TEXAS UTILITIES
MILL CREEK 2
NEW OR I
RETROFIT
NEW
NEW
NEW
NEW
NEW
NIW
NEW
RETROFIT
RETROFIT
NEW
MEW
RETROFIT
RETROFIT
NEW
NEW
NEW
NEW
NEW
NEW
RETROFIT
NEW
NEW
NEW
NEW
:APACITY
NU
500.0
SOO.O
500.0
$00.0
250.0
250.0
2SO.D
190.0
400.0
800.0
800.0
150.0
334.0
800.0
700.0
280.0
620.0
300.0
450.0
600.0
750.0
750.0
750.0
750.0
PROCESS/
SYSTEM SUPPLIER
PROCESS NOT SELECTED
VENDOR NOT SELECTED
PROCESS NOT SELECTED
VENDOR NOT SELECTED
PROCESS NOT SELECTED
VENDOR NOT SELECTED
PROCESS NOT SELECTED
VENDOR NOT SELECTED
PROCESS NOT SELECTED
VENDOR NOT SELECTED
PROCFSS NOT SELECTED
VENDOR NOT SELECTED
PRQCFsS NOT SELECTED
VENDOR NOT SELECTED
PROCESS NOT SELECTED
VENDOR NOT SELECTED
PROCESS NOT SELECTED
VENDOR NOT SELECTED
LIMESTONE
VENDOR NOT SELECTED
LIMESTONE
VENDOR NOT SELECTED
MAGNESIUM OXIDE
UN1TEC ENGINEERS
MAGNESIUM OXIDE
UNITED ENGINEERS
PROCESS NOT SELECTED
VENDOR NOT SELECTED
PROCESS NOT SELECTED
VENDOR NOT SELECTED
LIMESTONE
VENDOR NOT SELECTED
LIMESTONE
VENDOR NOT SELECTED
PROCESS NOT SELECTED
VENDOR NOT SELECTED
PROCESS NOT SELECTED
VENDOR NOT SELECTED
PROCESS NOT SELECTED
VENDOR NOT SELECTED
LIMESTONE
VENDOR NOT SELECTED
LIMESTONE
VENDOR NOT SELECTED
PROCESS NOT SELECTED
VENDOR NOT SELECTED
PROCESS NOT SELECTED
VENDOR NOT SELECTED
START-UP
DATE
6/85
6/86
6/87
6/88
0/83
6/84
6/85
O/ 0
C/ 0
0/R5
0/86
6/80
6/80
5/fl5
11/88
0/87
6/83
0/84
0/85
7/82
8/63
9/84
0/85
0/86
355
-------
EPA UTILITY fGO SURVEY: OECtMBER 1978 - JANUARY 1979
SECTION 13
TOTAL fGO UMTS AND CAPACITY (HU) INSTALLED BY YEAR
YEAR
1968
1971
1972
1973
1974
1975
1976
1977
1978
1979
1980
1981
1982
1983
1984
1985
1986
1987
UNDEFINED
NEy
NO.
1
3
8
7
3
6
8
10
13
22
24
9
17
6
8
10
5
5
20
ON LINE
My
0.
420.
2*0.
1473.
250.
1971.
2051.
4664.
470*.
7198.
9453.
4630.
8650.
2965.
4306.
6365.
3830.
2270.
12*0.
TERMINATED
NO. MW
0
0
0
1
0
0
1
0
0
0
0
0
0
0
1
0
0
0
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
250.
0.
0.
0.
TOTAL ON LINE
NO. MU
1 0.
4
12
18
21
27
34
44
57
79
103
112
129
135
142
152
157
162
420.
660.
2133.
2363.
4354.
6405.
11069.
15773.
22971.
32124.
37054.
45904.
48869.
52925.
59?9Q.
63120.
65390.
356
-------
EPA UTILITY F6D SURVEY: DECEMBER 1978 - JANUAOY 1<>79
SECTION U
DESIGN AMD PERFORMANCE DATA FOR OPERATIONAL PARTICULAR SCRUBBERS
COHPANY NAME COMMONWEALTH
PLANT NAME WILL COUNTY
UNIT NUMBER 1
CITY ROMEOVjLLE
STATE ILLINOIS
REGULATORY CLASSIFICATION ******
PARTICULATE EMISSION LIMITATION - N6/J 0.
S02 EMISSION LIMITATION - NG/J 774.
NET PLANT GENERATING CAPACITY - MU
GROSS UNIT GENERATING CAPACITY - MH
NET UNIT GENERATING CAPACITY W/FGD - MU
NET UNIT GENERATING CAPACITY UO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MU
** BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE ******
AVERAGE HEAT CONTENT - KJ/K6 22260.
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - X 7.40
RANGE ASH CONTENT - X 3-16
AVERAGE MOISTURE CONTENT - X ********
RANGE MOISTURE CONTENT - X ******
AVERAGE SULFUR CONTENT - X 1.50
RANGE SULFUR CONTENT - X 0.3 - 4.5
AVERAGE CHLORIDE CONTENT - X ********
RANGE CHLORIDE CONTENT - X ******
FUEL FIRING RATE - M T /H 77.1
FUEL FIRING RATE - MU 167
( .000 (.B/MMBTU)
( 1.600 LB/MMBTU)
167.0
137.0
.0
.0
BABCOCK 8 WILCOX
UET BOTTOM, CYCLONE
CYCLIC
0/55
363.36 C 770000 ACFM)
179.4 ( 355 F>
107- ( 350 FT)
3.R < 12.4 FT)
( 9570 BTU/LB)
9,100 - 10,500
{ 65 TPH)
** ESP
NUMBER
TYPE
SUPPLIER
PARTICULATE DESIGN REMOVAL EFFICIENCY - X
FLUE GAS TEMPERATURE - C
** PARTICULATE SCRUBBER
NUMBER
TYPE
SUPPLIER
SHELL MATERIAL
LINING MATERIAL
TYPE OF NOZZLES
FLUE GAS CAPACITY - CU.M/S
FLUE GAS TEMPERATURE - C
LI«UID RECIRCULA-TION RATE - LITER/S
L/6 RATIO - LITER/CU.M
PRESSURE DROP - KPA
SUPERFICIAL GAS VELOCITY - M/S
PARTICULATE INLET LOAD - 6/CU.*
PARTICULATE DESIGN REMOVAL EFFICIENCY - X
1
COLD SIDE
WESTERN PRECIPITATION (JOY MANUFACTURING)
79.0
179.4 ( 355 F)
ADJUSTABLE THROAT VENTURI
BARCOCK S WILCOX
CARBON STEEL
PLASITE AND KAOCRtTE
STAINLESS STEEL
181-7
179.4
365.4
2.4
a. ?.
36.6
.4
9fl.O
( 385000 ACFM)
( 355 F)
{ 5600 GPf!)
(18.0 GAL/1000ACF)
< <3 1N-H20)
( 120.0 FT/S)
( .16 GR/SCF)
357
-------
EPA UTILITY FGD SURVEY: DECEMBER 1«7fl - JANUARY 1979
SECTION U
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL PARTICULATE SCRUBBERS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - KG/J
NET PLANT GENERATING CAPACITY - MVf
GROSS UNIT GENERATING CAPACITY - Mb
NET UNIT GENERATING CAPACITY V/FGD - HW
NET UNIT GENERATING CAPACITY WO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU.K/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP D1AMETFR - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - KJ/K6
RANGE HEAT CONTENT - BTU/LEl
AVERAGE ASH CONTENT - *
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
FUEL FIR1N6 RATE - M T/h
FUEL F IR1NG RATE - MU
** ESP
** MECHANICAL COLLECTOR
** PARTICULATE SCRUBBER
NUMBER
TYPE
(****** LB/MMBTU)
( 3.200 LB/MMFITU)
DETROIT EDISON
ST. CLAIR
6
BELLE RIVER
MICHIGAN
C
***** *
1376.
1775.0
325.0
*******
.0
.0
COMBUSTION ENGINEERING
COAL FIRED TWO-STAGE SUPERHEATER
BASE
0/61
******** (******* ACFM)
132.2 < 270 F>
****** (**** FT)
******* (***** FT)
COAL
SUBBITUMINOUS
*******
4.no
******
********
22 - 24
********
0.3 - 0.4
***** ***
******
120.6
*****
(****** BTU/LB)
9,500 - 9,600
(133 TPH)
VENTURI
356
-------
EPA UTItlTY F6D SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 14
DESIGN AND PERFORMANCE DATA FOB OPERATIONAL PARTICULATE SCRUBBERS
COMPANY NAME
PLANT NAME
UN IT NUMBER
CJITY
S TATE
P.E6ULATORY CLASSIFICATION
(•ARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY — Kfc
NET UNIT GENERATING CAPACITY V/F6o - MB
NET UNIT GENERATING CAPACITY WO/FGfc - MW
E«UIVALENT SCRUBBED CAPACITY - MU
MINNESOTA POWER t LIGHT
AURORA
1
AURORA
MINNESOTA
******
0. < .000 (.B/KMBTU)
****** <****** LP/HMBTU)
116.0
58.0
.0
.0
** BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - K
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - KJ/KG
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - *
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
FUEL FIRING RATE - M T/H
FUEL FIRING RATE - MU
** PARTICULATE SCRUBBER
NUMBER
TYPE
SUPPLIER
SHELL MATERIAL
LINING MATERIAL
BOILER LOADlSCRU-BfiER - X
FLUE GAS CAPACITY - CU .M/S
FLUE GAS TEMPERATURE - C
L/G RATIO - LITER/CU.M
PRESSURE DROP - KPA
SUPERFICIAL GAS VELOCITY - M/S
PARTICULATE INLET LOAD - S/CU.M
PARTICULATE OUTLET LOAD - G/CU.P
S02 INLET CONCENTRATION - PPM
SOZ OUTLET CONCENTRATION - PPM
502 DESIGN REMOVAL EFFICIENCY - X
COMBUSTION ENGINEERING
PULVERIZED COAL
******
0/53
******** (******
******* (**** F)
****** (**** FT)
******* {***** FT)
COAL
SUBBITUMINOUS
2CHC>9.
********
******
Z6.70
******
1.37
******
********
******
*******
*****
( 8800 BTU/LB)
******
(*** TPH)
1
ELBAIR SPRAY-IMPINGEMENT
KREBS ENGINEERING
316 ELC STAINLESS STEEL
FLAKE-POLYESTER
1-00 .0
( 291160 ACFM)
t 340 F>
( 8.3 GAL/1000ACF)
( 3 IN-H20)
I 7.0 FT/S)
( 2.06 6R/SCF)
( .040 GR/SCF)
137.4
171.1
1.1
.7
2.1
4.7
.1
800.000
500.000
37.0
359
-------
fPA UTILITY F6D SURVEY: DSUMBF.P 197F - JANUARY 1979
SECTION U
DESIGN AND PERFORMAKCE DATA FOR OPERATIONAL PARTICULATE SCRUBBERS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
RE6ULATORV CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - RU
GROSS UN]T GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY U/FGD - Mw
NET UNIT GENERATING CAPACITY UO/F6D - MW
EQUIVALENT SCRUBBED CAPACITY - «W
•* BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPERATURE . C
STACK HEIGHT - M
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - KJ/KG
RANGE HEAT CONTENT - BTU/L6
AVERAGE ASH CONTENT - *
RANfE ASH CONTENT - X
AVERAGE nOJSTURE CONTENT - %
RANGE MOISTURE CONTENT - 1
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
FUEL FIRING RATE - M T/H
FUEL FIRING RATE - MW
*• PARTICULATE SCRUBBER
NUMBER
TYPE
SUPPLIER
SHELL MATERIAL
LINING MATERIAL
BOILER LOAO/SCRUSBER - X
FLUE GAS CAPACITY - CU.M/S
FLUE GAS TEMPERATURE - C
L/G RATIO - LITER/CU.M
PRESSURE DROP - KPA
SUPERFICIAL GAS VELOCITY - MS
PARTICULATE INLET LOAD - G/CUtH
PARTICULATE OUTLET LOA6 - G/CU.K
SOJ INLET CONCENTRATION - PPW
S02 OUTLET CONCENTRATION - PPM
SO2 DESIGN REMOVAL EFFICIENCY - I
( .000
(****** LR/MMBTU)
MINNESOTA POWER ft LIGHT
AURORA
2
AURORA
MINNESOTA
******
0.
******
116.0
*** ****
58.0
.0
.0
COMBUSTION ENGINEERING
PULVERIZED COAL
******
0/55
******** (******* ACFH)
******* (•*** F)
****** <***"* FT)
******* (***** FT)
COAL
SUBB1TUMI NOUS
20469.
********
******
26.70
******
1.37
******
********
****** .,
( 6800 BTU/LB)
******
*****
(*** TPH)
EL6AIR SPRAY-IMPINGEMENT
KRESS ENGINEERING
316 ELC STAINLESS STEEL
FLAKE-POLYESTER
100.0
137.4
171.1
1.1
.1
800.000
$00.000
37.0
291UO ACFM)
340 f>
8.3 GAL/1000ACF)
3 IN-HZO)
7.0 FT/S)
2.06 6R/SCF)
.0*0 SR/SCF)
360
-------
EPA UTILITY FGD SURVEY: DECEMBER 1978 - JANUARY 1«7
-------
EpA UTILITT F6D SURVEY: DECEMBER 197E - JANUARY 1979
SECTION 14
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL PARTICIPATE SCRUBBERS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - KG/J
S02 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/F6D - !«>•'
NET UNIT GENERATING CAPACITY WO/FGt - KW
EOUIVALENT SCRUBBED CAPACITY - MW
** BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - K J/KG
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - *
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - JE
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
FUEL FIRING RATE - M T/H
FUEL FIRING RATE - KM
PACIFIC POWER K LIGHT
DAVE JOHNSTON
It
GLENROCK
WYOMING
******
0.
< .000 LB/WM8TU)
<****** LB/MHBTU)
*******
530.0
.0
.0
COMBUSTION ENGINEERING
PULVERIZED, COAL
******
* * /**
******** (******» ACFMJ
******* <**** f)
76. < 250 FT)
******* (***** FT)
COAL
SUBBITUMINOUS
172P2.
12.00
* *****
2«.00
***** *
.50
* *****
.04
******
*******
*****
( 74JO BTU/LB)
******
(*** TPH)
** ESP
** PARTICULATE SCRUBBER
NUMBER
TTPE
SUPPLIER
LINING MATERIAL
FLUE GAS CAPACITY - CU.M/S
FLUE GAS TEMPERATURE - C
LIOU1D RECIRCULATION RATE -LITFR/S
L/G RATIO - LITEH/CU.M
PRESSURE DROP - KPA
PARTICULATE INLET LOAD - G/CU.C
PARTICULATE DESIGN REMOVAL EFFICIENCY
$02 INLET CONCENTRATION - PPM
S02 DESIGN REMOVAL EFFICIENCY - i
VENTURl
CHEMICO
POLYESTER-LINED STEEL
327.5
135.0
409.5
1.3
2.5
9.2
99.7
459.000
40.0
< 694000 ACFCi)
( 275 F)
( 6500 GPM)
t 9.4 GAL/10OQACF)
( 10 IN-H2IO)
( 4.00 GR/!iCF>
362
-------
EPA UTILITY FGD SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION U
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL PARTICIPATE SCRUBBERS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
SOZ EMISSION LIMITATION - K6/J
NET PLANT GENERATING CAPACITY - MW
6ROSS UNIT GENERATING CAPACITY - «U
NET UNIT 6ENERATIN6 CAPACITY W/F&6 - Mil
NET UNIT GENERATING CAPACITY WO/FGti - MU
EQUIVALENT SCRUBBED CAPACITY - HU
** BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - KJ /KG
RANGE HEAT CONTENT - 6TU/LB
AVERAGE ASH CONTENT - X
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - t
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
FUEL FIRING RATE - M T /H
FUEL FIRING RATE - KW
POTOMAC ELECTRIC POWER
CHALK POINT
A
******
MAPVLNAD
******
o.
******
189Z.Q
630.0
630.0
.0
.0
******
******
BASE
«*/*«
********
*******
******
*******
OIL
******
*******
********
******
***** ***
******
********
< .000 LB/MMBTU)
(****** LB/MMBTU)
(******* ACFM)
(**** F)
(***'* FT)
(***** FT)
(****** BTU/LR)
******
**
***
(*** TPH)
363
-------
EPA UTILITY F6D SURVEY: DECEMBER 197? - JANUARY 1979
SECTION U
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL PARTICIPATE SCRUBeERS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
SOJ EMISSION LIMITATION • NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT ffcNERATING CAPACITY - Mfc
NET UNIT GENERATING CAPACITY V/F6D - MW
NET UNIT GENERATING CAPACITY WO/FGD - MU
ECIUIVALENT SCRUBBED CAPACITY - MW
POTOMAC ELECTRIC POWER
DICKERSON
DlCKERSON
MARYLAND
******
0.
688.
54*.0
190.0
181.0
.0
.0
( .000 UB/MMBTU)
( 1.600 LB/MMPTU)
** BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAMETER - M
•• FUEL DATA
FUEL TYPt
FUEL GRADE
AVERAGE HEAT CONTENT • KJ /KG
RANGE HEAT CONTENT - 8TU/LB
AVERAGE ASH CONTENT - X
RANGE ASH CONTENT - *
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - *
AVERAGE SULFUR CONHNT - X
RANGE SDLfUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONUNT - *
FUEL FIRING RATE - M T/H
FUEL FIRING RATE - MU
** ESP
COMBUSTION ENGINEERING
DRV BOTTOM i PULVERIZED COAL
BASE
0/6?
?78.«2 < 590000 ACFM)
126.1 < 259 F)
122. t 400 FT)
******* (****« FT)
COAL
******
272U.
14.00
******
********
******
?.oo
******
* *******
******
67.1
*****
I 11700 BTU/LB)
******
( 74 TPH)
SUPPLHR
PARTICULATE DESIGN REMOVAL EFFICIENCY
«* PARTICULATE SCRUBBER
NUMBER
TYPE
SUPPLIER
BOILER LOAD/SCRUBBER - X
FLUE GAS CAPACITY - CU.M/S
FLUE GAS TEMPERATURE - C
L/G RATIO - LITER/CU.M
PRESSURE DROP - KPA
RCSEARCH-COTTRELL
- X 94.0
1
ADJUSTABLE VENTURI
CHEMJCO
50.0
139.2
126.1
2.7
( 295CIOO ACFM>
( 259 F)
(20.0 6AL/1000ACf>
( 11 IN-H20)
364
-------
EPA UTILITY FGD SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 14
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL PARTKULATE SCRUBBERS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PHRTICULATE EMISSION LIMITATION -
SOZ EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - MM
NET UNIT GENERATING CAPACITY V/fGO - HU
NET UNIT GENERATING CAPACITY WO/FGS - KW
E8UIVALFNT SCRUBBED CAPACITY - MW
** BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU.K/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - H
STACK TOP DIAMETER - M
*« FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - KJ/KG
RANGE HEAT CONTENT - BTU/LB
AVERAGE AsH CONTENT - X
RANEE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - *
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANEE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
FUEL FIRING RATE - M T /H
FUEL FIRING RATE - MW
*« FUEL DATA
FUEL TYpi
FUEL GRADE
AVERAGE HEAT CONTENT - KJ /KG
RANGE HEAT CONTENT - BTU/li
AVERAGE ASH CONTENT - X
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT
RANGE CHLORIDE CONTENT - X
FUEl FIRING RATE - M T /H
FUEL FIRING RATE - MW
** ESP
NUMBER
«* MECHANICAL COLLECTOR
( .000
{****** LB/MMBTU)
- X
- X
PUBLIC SERVICE OF COLORADO
ARAPAHOE
4
DENVER
COLORADO
******
0.
******
*******
*******
112.0
.0
.0
******
PULVERIDED, COAL
******
0/55
******** (******* ACFM)
******* (**** f)
****** (**** FT)
******* (**«** FT)
COAL
SUBBITUMINOUS
Z3725.
9.30
******
13.70
***** *
.95
******
.01
******
*******
*****
COAL
******
Z34«3.
12.50
******
11.20
******
.65
******
.01
******
*******
*****
< 10200 BTU/LB)
******
<*** TPH)
( 10100 BTU/LB)
******
(*** TPH>
•* PARTICULATE SCRUBBED
NUMBER
TYPE
SUPPLIER
NUMBER OF STAGES
SHELL MATERIAL
LINING MATERIAL
INTERNAL MATERIAL
L/fi RATIO - LITER/CU.M
SUPERFICIAL 6AS VELOCITY - M/S
PARTICULATE INLET LOAD - G/CU.P
PARTICULATE OUTLET LOAD - G/CU.M
PARTICULATE DESIGN REMOVAL EFFICIENCY
S02 INLET CONCENTRATION - PPM
1
TCA
UOP
J
CARBON STEEL
RURBfR
STAINLESS STEEL
7.5
7.*
1.8
.0
93.0
SOO.OOO
(S6.0 tALMQOOACO
( 11.0 FT/S)
( .PO GR/SCF)
( .070 GR/SCF)
365
-------
FPA UTILITY FGD SURVEY! DECtMBER 197? - JANUARY 1979
SECTION 14
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL PARTICIPATE SCRUBBERS
— »«••• »••••.•« • •.«..» A AAV »•• ••• ••• •••^••^^•••••i •••"..»__••.•••—••••<••• •••« — •••— ••••.•»•.•••!• B B» •• K* I
SO2 OUTLET CONCENTRATION - PPM 350.000
SO; DESIGN REMOVAL EFFICIENCY - X 30.0
366
-------
EPA UTILITY F60 SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION U
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL PARTICIPATE SCRUBBERS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICIPATE EMISSION LIMITATION - N6/J
S02 EMISSION LIMITATION - N6/J
NET PLANT GENERATING CAPACITY - MU
GROSS UNtT GENERATING CAPACITY - Mk
NET UNIT GENERATING CAPACITY U/F60 - MW
NET UNIT GENERATING CAPACITY UO/FGD - MW
EQUIVALENT SCRUBBED CAPACITY - MW
«* BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATt
MAXIMUM BOILER FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - M
STACK TOP DIAMETER - t»
** FUEL DATA
FUEL TYPt
FUEL GRADE
AVERAGE HEAT CONTENT - KJ/KG
RANGE HEAT CONTENT - BtU/LB
AVERAGE ASH CONTENT - X
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RAN6E MOISTURE CONTENT - *
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
FUEL FIRING RATE - M T/H
FUEL FIRING RATE - KU
** ESP
NUMBER
** MECHANICAL COLLECTOR
NUMBER
** PARTICULATE SCRUBBER
NUMBER
TYPE
SUPPLIER
NUMBER OF STAGES
SHELL MATERIAL
LINING MATERIAL
INTERNAL MATERIAL
BOILER LOAD/SCRUBBER - X
FLUE GAS CAPACITY - CU.M/S
FLUE GAS TEMPfftATUR£ - C
L/G RATIO - LITER/CU.M
PRESSURE DROP - KPA
SUPERFICIAL GAS VELOCITY - M/S
PARTICULATE IKLET LOAD - 6/CU.r
PARTICULATE OUTLET LOAD - G/CU.W
PARTICIPATE DESIGN REMOVAL EFFICIENCY
S02 INLET CONCENTRATION - PPM
SOJ OUTLET CONCENTRATION - PPM
SO2 DESIGN REMOVAL EFFICIENCY - J£
PUBLIC SERVICE OF COLORADO
CHEROKEE
1
DENVER
COLORADO
******
0.
******
710.0
115.0
100.0
.0
.0
BABCOCK R UILCOX
PULVERIZED COAL
***** *
0/57
< .000 LB/MMBTU)
(****** LB/MMBTU)
********
*******
******
*******
COAL
BITUMINOUS
23493.
1J.50
******
11.30
******
.65
******
.01
******
(******* ACFM)
(**** F)
(**** FT)
(***** FT)
< 10100 BTU/LB)
(*** TPH)
1
TCA
UOP
3
CARBON
RUBBER
STAINLESS STEEL
67.0
164. 4
U6.1
7.5
3.2
3.4
1.8
.0
97.0
500.000
420.000
16.0
( 348400 ACFM)
( 295 F)
(56.0 GAL/IOOOACF)
( 13 jN-H20>
( 11.0 FT/S)
( .SO 6R/SCF)
( .020 GR/SCF)
367
-------
FPA UTILITY F6D SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION U
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL PARTICIPATE SCRUBBERS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTKULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - N6/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNJT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGC - MW
EQUIVALENT SCRUBBED CAPACITY - MW
** BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU .M/S
FLUE 6AS TEMPERATURE - C
STACK HE IGHT - M
STACK TOP DIAMETER - M
** FUEL tiATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - KJ/KG
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - *
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - Z
FUEL FIRING RATE - M T/H
FUEL FIRING RATE - MW
( .000
(****** L.B/MMBTU)
PUBLIC SERVICE OF COLORADO
CHEROKEE
3
DENVER
COLORADO
* *****
P.
******
710.0
170.0
150.0
.0
.0
BABCOCK 8 WILCOX
PULVERIZED? COAL
0/62
********
*******
******
* ******
COAL
BITUMINOUS
23493.
12.50
******
11.30
******
.65
******
.01
******
*******
*****
<******* ACFMJ
{**** I)
(**** FT)
<***** FT)
< 10100 BTU/LB)
******
(*** TPH)
** ESP
NUMBER
** MECHANICAL COLLECTOR
NUMBER
** PARTICIPATE SCRUBBER
NUMBER
TYPE
SUPPL1ER
NUMBER OF STAGES
SHELL MATERIAL
LINING MATERIAL
INTERNAL MATERIAL.
BOILER LOAD/SCRUBBER - Z
FLUE GAS CAPACITY - CU .M/S
FLUE GAS TEMPERATURE - c
L/C, RATIO - LITER/cU.M
PRESSURE DROP - KPA
SUPERFICIAL GAS VELOCITY - M/S
PARTICULATE INLET LOAD - G/CU.fl
PARTICULATE OUTLET LOAD - G/CU.M
PARTICULATE DESIGN REMOVAL EFFICIENCY
S02 INLET CONCENTRATION - PPM
S02 OUTLET CONCENTRATION - PPM
SO? DESIGN REMOVAL EFFICIENCY - X
- X
2
TCA
UOP
3
CARBON STgpt
RUBBER
STAINLESS STEEL
20.0
57.6
137.8
7.5
3.2
3.4
.9
.0
95.0
500-000
420.000
16.0
t 122000 ACFM)
< 280 F)
(56.0 GAL/1000ACF)
t 13 IN-H20)
C 11.0 fT/S)
( .40 GR/SCF)
< .020 6R/SCF>
368
-------
EPA UTILITY F6D SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION 14
DESIGN AND PERFORMANCE. DATA FOR OPERATIONAL PARTICIPATE SCRUBBERS
COMPANY NAME
PLANT NAME
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - Mtf
GROSS UNiT GENERATING CAPACITY - MW
NET UNIT GENERATING CAPACITY W/FGD - MW
NET UNIT GENERATING CAPACITY WO/FGU - MJ
EQUIVALENT SCRUBBED CAPACITY - MU
** BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU.M/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - K
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - KJ/KG
RANGE HEAT CONTENT - BTU/L6
AVERAGE ASH CONTENT - X
RANGE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - X
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - X
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - X
RANGE CHLORIDE CONTENT - X
FUEL FIRING RATE - M T/H
FUEL FIRING RATE - MW
** ESP
NUMBER
** MECHANICAL COLLECTOR
NUMBER
PUBLIC SERVICE Of COLORADO
CHEROKEE
4
DENVER
COLORADO
0. <
****** <«
710.0
175.0
350.0
.0
.0
COMBUSTION ENGINEERING
PULVERIZED COAL
•000 LB/MMBTU)
***** LB/MMBTU)
0/68
717.29
135.0
COAL
BITUMINOUS
23493.
12.50
******
11.30
******
.65
(1520000 ACFM)
{ 275 M
{**** ft)
(***** FT)
f 10100 BTU/LB)
.01
******
* ******
* * ***
(*** TPH)
** PARTICULATE SCRUBBER
NUMBER
TYPE
SUPPLIER
NUMBER OF STAGES
SHELL MATERIAL
LINING MATERIAL
INTERNAL MATERIAL
L/6 RATIO - LITER/CU.M
PRESSURE DROP - KPA
SUPERFICIAL GAS VELOCITY - M/S
PARTICULATE INLET LOA& - G/cU.0
PARTICULATE OUTLET LOAD - G/CU.K
PARTICULATE DESIGN REMOVAL EFFICIENCY
S02 INLET CONCENTRATION - PPM
SOZ OUTLET CONCENTRATION - PPM
S02 DESIGN REMOVAL EFFICIENCY - X
TCA
UOP
•J
CARBON ST£EI.
RUBBER
STAINLESS STEEL
7.5
3.2
3.4
1.6
.0
97.0
500.000
420.000
16.0
(56.0 GAL/1000ACF)
13 IN-H20)
11.0 FT/S)
.70 GR/SCF)
.020
369
-------
'PA UTILITY F6D SURVEY: DECEMBER 197f - JANUARY 1979
SECTION U
DESIGN AND PERFORMANCE DATA FOR OPERATIONAL PARTICIPATE SCRUBBERS
NAMl
PLANT NAKE
UNIT NUMBER
CITY
STATE
REGULATORY CLASSIFICATION
PARTICULATE EMISSION LIMITATION - NG/J
S02 EMISSION LIMITATION - NG/J
NET PLANT GENERATING CAPACITY - MW
GROSS UNIT GENERATING CAPACITY - WW
NET UNIT GENERATING CAPACITY U/FGD - "W
NET UNIT GENERATING CAPACITY HO/F6D - MW
EOUIVALENT SCRUBBED CAPACITY - WW
** BOILER DATA
SUPPLIER
TYPE
SERVICE LOAD
COMMERCIAL SERVICE DATE
MAXIMUM BOILER FLUE GAS FLOW - CU.ft/S
FLUE GAS TEMPERATURE - C
STACK HEIGHT - H
STACK TOP DIAMETER - M
** FUEL DATA
FUEL TYPE
FUEL GRADE
AVERAGE HEAT CONTENT - K J /KG
RANGE HEAT CONTENT - BTU/LB
AVERAGE ASH CONTENT - *
RANEE ASH CONTENT - X
AVERAGE MOISTURE CONTENT - t
RANGE MOISTURE CONTENT - X
AVERAGE SULFUR CONTENT - ?
RANGE SULFUR CONTENT - X
AVERAGE CHLORIDE CONTENT - t
RANGE CHLORIDE CONTENT - X
FUEL FIRING RATE - M T /H
FUEL FIRING RATE - MW
** ESP
TYpF
< .000
(****** LB/KKBTU)
PUBLIC SERVICE OF COLORADO
VALMONT
5
VALWONT
COLORADO
******
0.
******
273.8
166.0
166.0
.0
.0
******
PULVERIZED COAL
BASE
0/64
******** (*«***** ACFM)
******* (**** F)
****** f**** FT)
******* (***** FT)
COAL
SUREITUMINOUS
***** **
5 20
*****
* ** **
*****
*****
*****
(****** BTU/LB)
******
(*** TPH)
COLD SIDE
** MECHANICAL COLLECTOR
-------
APPENDIX A
FGD SYSTEM COST DATA: OPERATIONAL AND NONOPERATIONAL SYSTEMS
A-l
-------
INTRODUCTION
The cost of flue gas desulfurization (FGD) systems for the
control of sulfur dioxide emissions is an area of intense inter-
est and substantial controversy. As a result, many computer
models have recently been developed to estimate capital and
annual costs. As part of an effort by the U.S. Environmental
Protection Agency to provide meaningful economic data concerning
FGD systems, reported economic data have been incorporated into
the EPA Utility FGD Survey report. This information has appeared
as a separate appendix of the report since October 1976. Until
January 1978, this cost appendix consisted entirely of data
reported by the utilities with little or no interpretation pro-
vided by PEDCo Environmental, Inc. Beginning with the May 1978
report, the format and content of the cost appendix were revised
to include reported and adjusted costs for the operational FGD
systems.
The rationale for including adjusted as well as reported
costs stems primarily from the lack of comparability of the
reported costs. Many of the reported cost figures, both capital
and operating, are largely site-sensitive values that cannot be
accurately compared because they refer to different FGD battery
limits and different years in which the expenditures were made.
As a result, an analysis of the cost data was made for the opera-
tional units since these systems offer the potential of having
complete and accurate economic data. The adjustments were made
to provide comparable, accurate cost data for the sulfur dioxide
portion of the emission control system. This, in effect, will
eliminate much of the confusion that exists concerning the re-
ported data, and it will provide a common basis for the reported
costs.
A-2
-------
APPROACH
In March 1978, each utility having at least one operational
FGD system was given a cost form containing all available cost
information then in the PEDCo files. The utility was asked to
verify the data and fill in any missing information called for
on the form. A follow-up visit by the PEDCo Environmental staff
was arranged to assist in data acquisition and to insure com-
pleteness and reliability of information. Results of the cost
analysis were forwarded to each participating utility for final
review and comment.
The cost data were treated solely to establish the accurate
costs for FGD systems, on a common basis, not to critique the
design or reasonableness of the costs reported by any utility.
Adjustments focused primarily on the following items:
0 All capital costs were adjusted to July 1, 1977, dol-
lars using the Chemical Engineering Index. All capital
costs, represented in dollars/kilowatt ($/kW), were
expressed in terms of gross megawatts (MW). Actual
costs were reported by utilities in dollar values for
years 1970 to 1980. These values are represented in
terms of the year of greatest capital expenditures.
0 Gross unit capacity was used to express all FGD capital
expenditures because the capital requirement of an FGD
system is dependent on actual boiler size before de-
rating for auxiliary and air quality control power
requirements.
0 Particulate control costs were deducted. Since the
purpose of the study was to estimate the incremental
cost for sulfur dioxide control, particulate control
costs were deducted using either data contained in the
cost breakdowns or as a percentage of the total direct
cost (capital and annual). The percentage reduction
varied depending upon system design and operation.
A-3
-------
The capital costs associated with the modification or
installation of equipment not part of the FGD system
but needed for its proper functioning, were included
(e.g. - stack lining, modification to existing ductwork
or fans, etc.).
Indirect charges were adjusted to provide adequate
funds for engineering, field expenses, legal expenses,
insurance, interest during construction, allowance for
startup, taxes, and contingency.
All annual costs, represented in mills/kilowatt-hour
(mills/kWh), were expressed in terms of net megawatts
(MW) .
Net unit capacity was used to express all FGD annual
expenditures because the annual cost requirement of an
FGD system is dependent on the actual amount of kilo-
watt-hours (kWh) produced by the unit after derating
for auxiliary and air quality control power require-
ments.
All annual costs were adjusted to a common capacity
factor (65%).
Replacement power costs were not included since only a
few utilities reported such costs and these were pre-
sented using a variety of methods.
Sludge disposal costs were adjusted to reflect the
costs of sulfur dioxide waste disposal only (i.e.,
excluding fly ash disposal) and to provide for disposal
over the anticipated lifetime of the FGD system. This
latter correction was necessary since several utilities
reported costs for sludge disposal capacity that would
last only a fraction of the FGD system life. The
adjustments were based on a land cost of $2000/acre
with a sludge depth of 50 ft in a clay-lined pond (clay
is assumed to be available at the site).
A 30-year life was assumed for all process and economic
considerations for all new systems that were installed
for the life of the unit. A 20-year life was assumed
for all process and economic considerations for retro-
A-4
-------
fit systems that were installed for the remaining por-
tion of the life of the unit.*
0 Regeneration and by-product recovery facility costs
were added for those regenerable systems not reporting
such costs.
To the extent possible, all cost adjustments were made using
the previous assumptions developed by PEDCo Environmental. When
cost data were inadequate, adjustments were made using process
design data in conjunction with the previous cost assumptions.
In some cases, no adjustments were possible because of in-
sufficient data.
* The use of a 30-year service life for new units coincides with
the conclusion of the National Power Survey of the Federal
Power Commission which recognized this value as reasonable for
steam-electric plants. A 20-year service life was assumed for
all retrofit units even if the remaining life of the units is
less than this value. Thus, two different rates are used and
should be noted when making comparisons between new and retro-
fit systems.
A-5
-------
DESCRIPTION OF COST ELEMENTS
Capital costs consist of direct costs, indirect costs, con-
tingency costs, and other capital costs. Direct costs include
the "bought-out" cost of the equipment, the cost of installation,
and site development. Indirect costs include interest during
construction, contractor's fees and expenses, engineering, legal
expenses, taxes, insurance, allowance for start-up and shake-
down, and spares. Contingency costs include those costs result-
ing from malfunctions, equipment alterations, and similar un-
foreseen sources. Other capital costs include the nondepreciable
items of land and working capital.
Annual costs consist of direct costs, fixed costs, and over-
head costs. Direct costs include the cost of raw materials,
utilities, operating labor and supervision, and maintenance and
repairs. Fixed costs include those of depreciation, interim
replacement, insurance, taxes, and interest on borrowed capital.
Overhead costs include those of plant and payroll expenses. The
various capital and annual cost components are discussed and
defined in greater detail in the following paragraphs.
The direct capital costs include the following elements:
° Equipment required for the FGD system. Table A-l
provides a summary of the major process equipment used
in regenerable and nonregenerable systems.
° Installation of equipment, including foundations; steel
work for support, buildings, piping and ducting for
effluents, slurries, sludge, and make-up water, control
panels, instrumentation, insulation of ducting, buildings,
piping, and other equipment, painting and piling.
0 Site development may include clearing and grading,
construction of access roads and walkways, establish-
ment of rail, barge, and/or truck facilities, and
parking facilities.
A-6
-------
TABLE A-l. MAJOR FGD SYSTEM EQUIPMENT SUMMARY
Category
Description
Material handling-
raw materials
Peed preparation-
raw materials
Sulfur dioxide
absorption
Flue gas reheat
Gas handling
Sludge disposal
Utilities
By-product
handling
Equipment for the handling and transfer of
raw materials includes unloading facilities,
conveyors, storage areas and silos, vibrators,
atmospheric emission control associated with
these facilities, and related accessories.
Equipment for the preparation of raw material
to produce a feed slurry consists of feed
weighers, crushers, grinders, classifiers,
ball mills, mixing tanks, pumps, agitators,
and related accessories.
Equipment for treating the flue gas includes
absorbers, mist eliminators, hold tanks,
agitators, circulating pumps, pond water re-
turn pumps, and related accessories.
Equipment required includes air, steam, or
hot water heaters, condensate tanks, pumps,
soot blowers, fans, fuel storage facilities,
gas bypass equipment, and related accessories.
Equipment to handle the boiler flue gas in-
cludes booster fans, ductwork, flue gas by-
pass system, turning vanes, supports, plat-
forms, and related accessories,
Nonregenerable FGD systems require solids/
water separation equipment such as clarifiers,
vacuum filters, centrifuges, sludge fixation
equipment, and related accessories.
Equipment to supply power and water to the
FGD equipment consists of switch-gear, break-
ers, transformers, piping, and related
accessories.
Equipment for processing the by-product of
regenerable FGD systems may include a rotary
kiln, fluid bed dryer, conveyor, storage silo,
vibrator, combustion equipment and oil stor-
age tanks, waste heat boilers, hammer mills,
evaporators, crystallizers, strippers, tanks,
agitators, pumps, compressors, sulfuric acid
absorber and cSoling, mist eliminator, pumps,
acid coolers, tanks, etc.
(continued)
A-7
-------
TABLE A-l. (continued)
Category
Description
Regeneration
Purge treatment
Auxiliary
Equipment for regeneration of the absorbing
medium of an FGD system may consist of re-
actor vessels, material handling system,
storage, weigh feeder, conveyor, rotary kiln,
fluid bed calciner, dust collector, storage
silo, vibrator, combustion equipment and oil
storage tanks, waste heat boiler, hammer
mill, evaporators, crystallizers, strippers,
tanks, agitators, pumps, compressors, sul-
furic acid absorber and cooling, mist elimi-
nator, pumps, acid coolers, tanks, etc.
Equipment for the removal of purge material
(e.g. sodium sulfate) includes refrigeration,
pumps, tanks, crystallizer, centrifuge,
dryer, dust collector, conveyors, storage,
and related equipment.
Equipment not directly related to the
FGD system, but which may require design or
modification to accommodate an FGD system
may include such items as existing fans,
ducts, or stack. If new fans, ducts, or
stacks are added to improve boiler perfor-
mance and accommodate the FGD systen, the
costs are prorated to the boiler and FGD
system.
A-8
-------
Indirect capital costs include the following elements:
° Interest accrued on borrowed capital during construction,
° Contractor's fee and expenses, including costs for
field labor payroll; field office supervision; person-
nel; construction offices; temporary roadways; railroad
trackage; maintenance and welding shops; parking lot;
communications; temporary piping and electrical and
sanitary facilities; safety security (fire, material,
medical, etc.); construction tools and rental equip-
ment; unloading and storage of materials; travel ex-
penses; permits; licenses; taxes; insurance; overhead;
legal liabilities; field testing of equipment; start-
up; and labor relations.
0 Engineering costs, including administrative, process,
project, and general; design and related functions for
specifications; bid analysis; special studies; cost
analysis; accounting; reports; consultant fees; pur-
chasing; procurement; travel expenses; living expenses?
expediting; inspection; safety; communications; model-
ing; pilot plant studies (if required because of pro-
cess design or application novelty); royalty payments
during construction; training of plant personnel; field
engineering; safety engineering; and consultant ser-
vices.
0 Legal.expenses, including those for securing permits,
rights-of-way, etc.
° Taxes, including sales, arid excise taxes.
° Insurance covering liability for equipment in transit
and at site; fire, casualty, injury, and death; damage
to property; delay; and noncompliance.
° Allowance for start-up and shakedown includes the cost
associated with system start-up.
° Spare parts including pumps, valves, controls, special
piping and fittings, instruments, spray nozzles, and
similar items.
Other capital costs include the following elements:
° Land required for the FGD process, waste disposal, re-
generation facility, and storage.
* Working capital, including the total amount of money
invested in raw materials and supplies in stock,
finished products in stock, and unfinished products
A-9
-------
in the process of being manufactured; accounts re-
ceivable; cash kept on hand for payment of operating
expenses such as salaries, wages, and raw materials
purchases; accounts payable; and taxes payable.
Annual cost of an FGD system includes the following direct,
fixed and overhead charges:
° D i r e c t C ha r g e s
Raw materials, including those required by the FGD
process for sulfur dioxide control, absorbent regenera-
tion, sludge treatment, sludge fixation, flocculants,
etc.
Utilities, including water for slurries, cooling and
cleaning; electricity for pumps, fans, valves, lighting
controls, conveyors, and mixers; fuel for reheating of
flue gases; and stream for processing.
Operating labor, including supervisory, skilled, and
unskilled labor required to operate, monitor, and
control the FGD process.
Maintenance and repairs, consisting of both manpower
and materials to keep the unit operating efficiently.
The function of maintenance is both preventive and
corrective to keep outages to a minimum.
Byproduct Sales; credit from the sale of byproducts
regenerable FGD processes (e.g. sulfur, sulfuric acid)
is a negative charge deducted from the annual direct
cost to obtain the net annual direct cost of the FGD
system.
° Fixed Charges
Depreciation - the annual charge to recover direct and
indirect costs of physical assets over the life of the
asset.
Interim, replacement - costs expended for temporary or
provisional replacement of equipment that has failed or
malfunctioned prematurely.
Insurance, including the costs of protection from loss
by a specified contingency, peril, or unforeseen event.
Required coverage could include losses due to fire,
personal injury or death, property damage, explosion,
lightning, or other natural phenomena.
A-10
-------
• Taxes/ including franchise, excise, and property taxes
levied by a city, county, state, or Federal government.
Interest on borrowed funds.
° Overhead
Plant and administrative overhead is a business expense
that is not charged directly to a particular part of a
project, but is allocated to it. Overhead costs in-
clude administrative, safety, engineering, legal and
medical services; payroll; employee benefits; recrea-
tion; and public relations.
Table A-2 provides a summary of the means used to determine
the missing cost elements if th© costs were not reported or
insufficient information prevented their actual determination.
The assumptions and cost bases for determining the capital and
annual costs of FGD systems were developed by the PEDCo staff
based upon previous economic studies conducted for the U.S. EPA
(Flue Gas Desulfurization Process Cost Assessment, May 1975;
Simplified Procedures for Estimating Flue Gas Desulfurization
System Costs, June 1976, EPA-600/2-76-150; Particulate and Sulfur
Dioxide Emission Control Costs for Large Coal-Fired Boilers,
March 1978, EPA-600/7-78-032) .
A-ll
-------
TABLE A-2. COST ELEMENT FACTORS
Category
Value
Indirect capital costs:
Interest during
construction
Field overhead
Contractor's fee and
expenses
Engineering
Taxes
Spares
Shakedown allowance
Other capital costs:
Contingency
Direct annual costs:
Raw materials:
Fixation chemicals
Lime
Limestone
Magnesium oxide
Sodium carbonate
Salt cake (credit)
Sulfur (credit)
Sulfuric acid (credit)
Utilities:
Electricity
Water
Steam
Operating labor:
Direct labor
Supervision
10% of total direct capital costs
10% of total direct capital costs
5% of total direct capital costs
10% of total direct capital costs
2% of total direct capital costs
1% of total direct capital costs
5% of total direct capital costs
20% of total direct and indirect
capital costs
$2/ton
$40/ton
$10/ton
$150/ton
$80/ton
$50/ton
$65/ton
$25/ton
25 mills/kWh
$0.20/103 gal
$0.80/106 Btu
$8.50/man-hour
15% of direct labor costs
Contingency costs are used only when the cost data supplied are
incomplete (such as equipment costs or direct costs only) and a
contingency cost must be factored in to give an accurate estimate
of the total capital cost.
(continued)
A-12
-------
TABLE A-2. (continued)
Category
Value
Maintenance:
Labor and materials
Supplies
Overhead:
Plant
Payroll
Fixed annual costs:
Depreciation
Interim replacement
Taxes
Insurance
Capital costs
4% of total direct capital costs
15% of labor and materials costs
50% of operation and maintenance costs
20% of operating labor costs
3.33% or 5% (new or retrofit)
0.7% or 0.35%
4%
0.3%
9%
Some system components have life spans less than the expected
service life of the system. Interim replacement is an allow-
ance factor used in estimating annual revenue requirements to
provide for the replacement of these short-lived items. An
average allowance of 0.35% of the total investment is normally
provided and used for systems with an expected service life of
20 years or less. A higher allowance of 0.70% of the total
investment is provided and used for systems with an expected
service life of 30 years or more.
A-13
-------
DEFINITION OF COST ELEMENTS
The costs displayed in Appendix A are accompanied by a
series of alphabetic characters summarizing data presented for
each FGD system. These relate to the cost elements described
earlier in this section and identify what has been included and
excluded for reported and adjusted capital and annual costs. The
alphabetic characters, along with their titles, are briefly de-
scribed in Table A-3.
A-14
-------
TABLE A-3. DESCRIPTION OF COST
Code
Title
Description
L
M
N
0
articulate control (required for FGD pro-
ess) included in capital cost.
Particulate control (included in FGD
process) included in capital cost.
Total direct capital costs included.
Partial direct capital costs included.
Total indirect capital costs included.
Partial indirect costs included.
Chemical fixation of sludge included in
capital cost.
Dry sludge disposal included in capital
0081.
Off-site landfill area included in
capital coat.
Sludge pond included in capital cost.
Additional sludge disposal capacity
added for life of system.
Stack included in capital cost.
Modifications to stack, ducts, and/or
fans included in capital cost.
Total regeneration facility cost included
in capital cost.
Partial regeneration facility cost in-
cluded in capital cost.
R & D costs included in capital cost.
Particulate precollection device (ESP,
fabric filter, venturi) prior to FGD
system required for proper operation of
SO, control system.
Particulate collection equipment (venturi
scrubber) is included in the FGD system.
Complete cost of all FGD equipment, the
labor and materials required for equip-
ment installation, and interconnecting
the system is included in the total
capital cost.
One or a number of direct cost items, or
the cost associated with one or a number
of direct cost items, are excluded from
the total capital cost.
Complete cost of all the indirect cost
elements, including interest during con-
struction, contractor's fees, engineer-
ing, legal expenses, taxes, insurance,
allowance for start-up, and spares, is
included in total capital cost.
One or a number of indirect cost items,
or the cost associated with one or a
number of indirect cost items, are ex-
cluded from the total capital cost.
The cost of a chemical fixation process
which stabilizes the flue gas cleaning
wastes prior to disposal is included in
the total capital cost.
The cost of a secondary dewatering or
treatment method, such as filtration, cen-
trifugation, or forced oxidation, which
ultimately produces a dry sludge cake
for final disposal, is included in the
total capital cost.
The cost of an off-site area used as a
landfill for flue gas cleaning wastes is
included in the total capital cost.
The cost of an on-site disposal area for
ponding of treated or untreated flue gas
cleaning wastes is included in the total
capital cost.
The cost of additional SO. waste disposal
capacity required for FGD system operation
over the anticipated service life of the
unit is included in the total capital cost.
The cost of the stack is included in the
total capital cost.
Modifications to existing equipment (stack,
fans, ducts, etc.) which are required be-
cause of inclusion of an FGD system.
Complete cost of entire regeneration
facility included in total capital cost.
Part of the cost associated with the re-r
generation facility included in the total
capital cost.
Bench scale or pilot plant studies to de-
termine process and design characteristics.
(continued)
A-15
-------
TABLE A-3. (continued)
Code
Title
Description
W
X
Costs underwritten by system supplier in-
cluded in capital cost.
Excess reagent supply costs included in
capital cost.
Total direct annual costs included.
Partial direct annual costs included.
Total fixed annual costs included.
Partial fixed annual costs included.
Overhead cost included in total annual
cost.
Particulate control costs included in
direct annual cost.
Sludge disposal service costs (contract)
included in direct annual cost.
Replacement energy costs included in
total annual costs.
Capital expenditures underwritten by the
system supplier for system repairs or
modifications for optimization of perfor-
mance or R 6 D programs.
Capital expenditures for reagent supply
exceeds the amount required for the period
of initial operation.
Complete cost of all raw materials,
utilities, operating labor and maintenance
and repairs is included in the total
annual cost.
One or a number of direct annual cost items,
or the cost associated with one or a number
of direct annual cost items, are excluded
from the total annual cost.
Complete cost of all fixed cost elements,
including depreciation, interim replace-
ment, insurance, taxes, and interest, is
included in the total annual cost.
One or a number of fixed annual cost items,
or the cost associated with one or a
number of fixed annual cost items, are ex-
cluded from the total annual cost.
Plant and payroll overhead costs are in-
cluded in the total annual cost.
The cost of operating particulate collection
equipment included in the FGD system is in-
cluded in the total annual cost.
The treatment and disposal of flue gas
cleaning wastes that are handled by an
outside firm.
The cost of additional power-generating
capacity required to compensate for power
used by the FGD system.
A-16
-------
RESULTS OF COST ANALYSIS
The results of the operational FGD system survey are summarized
in Table A-4 and Section A-l. Table A-4 produces a summary of a
categorical analysis of the reported and adjusted .capital and
annual costs for the operational FGD systems addressed in the
survey. Included in this categorical analysis are the ranges,
means, and standard deviation for all the various types and
categories of FGD systems examined. Section A-l summarizes the
reported and adjusted capital and annual costs for all the oper-
ational FGD systems addressed in the survey (Section A-2 summarizes
available cost data for nonoperational FGD systems).
In an attempt to further clarify and allow additional compar-
ison of costs between different FGD units, the adjusted fixed
annual costs were standardized. This was done by taking the
adjusted Total Direct and Indirect Capital Costs for each unit
and applying the identical rate for costs of depreciation, interim
replacement, taxes, insurance and capital. These new sums were
totaled, then added to the adjusted Variable Cost to determine
the Total Standardized Annual Costs. In this manner costs can be
compared based upon the assumption that Utilities can incur Fixed
Annual Costs at the same rate.
A-17
-------
TABLE A-4, CATEGORICAL RESULTS OF THE REPORTED AND ADJUSTED
CAPITAL AND ANNUAL COSTS FOR OPERATIONAL PGD SYSTEMS
CATEGORY
REPORTED—
—CAPITAL, «/K«— -ANNUAL, MILLS/KttH
RANGE AVG DEV RANGE AV6 DEV
ADJUSTED
CAPITAL, */«! ANNUAL, NILLS/KUH—
RANEE AVG DEV RANGE AVG DEV
oa
ALL
NEU
RETROFIT
THROUAUAT PRODUCT
SALEABLE PRODUCT
LIMESTONE
LINE
LINE/ALKALINE FLYASH
SODIUN CARBONATE
UELLNAN LORD
LIMESTONE/ALKALINE FLYASH
MAGNESIUM OXIDE
.3- 14.9 6.3
.3- 14.3 4.4
2.1-14.9 8.3
.3- 14.3 5.9
5.3-156.9 77.0 34.9
5.3-120.6 71.4 30.0
29.2-156.9 83.7 42.7
5.3-120.6 67.1 29.2
93.3-156.9 132.5 23.5 3.3- 14.9 9.1
5.3- 99.5 61.4 27.6 1.6- 3.3 2.2
29.2-120.6 74.1 29.7 .3- 14.3 9.0
85.9- BS.9 85.9 .0 *****- .0 .0
42.9-113.6 66.5 33.3 2.1- 2.1 2.!
127.9-156.9 137.6 13.7 14.9- 14.9 14.7
47.9- 47.9 47.9 .0 2.0- 2.0 2.0
156.7-156.7 156.7 .0 »**«*- .0 .0
5.1
5.0
4.4
4.9
5.8
.8
4.S
.0
.0
.0
.0
.0
60.9-233.2 94.2 35.2 2.7- 12.4 5.5 2.4
66.4-117.6 85.5 16.9 2.8- 8.7 5.2 2.0
60.9-233.2 103.6 45.8 2.7- 12.4 5.8 2.6
60.9-140.6 87.0 21.2 2.7- 8.7 5.2 1.9
134.8-233.2 184.0 49.2 12.4- 12.4 12.4 .0
66.4-117.6 93.1 21.9 2.9- 6.6 5.0 1.4
47.5-140.4 88.9 21.1 2.7- 8.7 6.0 2.0
93.0- 93.« 93.0 .0 5.2- 5.2 5.2 .0
60.9-107.? 74.4 22.2 3.2- 4.4 3.6 .6
134.8-134.8 134.8 .0 12.4- 12.4 12.4 .0
71.5-71.5 71.5 .0 2.8- 2.8 2.8 .0
233.2-233.2 233.2
.0 *****- .0 .0 .0
-------
EPA UTILITY F60 SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION A-1
COSTS FOR OPERATIONAL F6D SYSTEMS
UNIT DESCRIPTION
ALABAMA ELECTRIC COOP
TOH6I6BEE
179.0 MW (NET)
ARIZONA ELECTRIC POWER COOP
APACHE
2
180.0 MW (NET)
CENTRAL ILLINOIS LIGHT
DUCK CREEK
1
416.0 MW (NET)
COST DESCRIPTION
CAPACITY FACTOR, X
TOTAL CAPITAL, $/KW(YE*R)
TOTAL ANNUAL, MILLS /KWH (YEAR )
COST ELEMENTS
CAPACITY FACTOR, X
TOTAL CAPITAL, S/KW(YEAR)
TOTAL ANNUAL, Mlu.S/KWH(tE AR)
COST ELEMENTS
CAPACITY FACTOR, X
TOTAL CAPITAL, $/KW(YfAR)
TOTAL ANNUAL, MILLS /KWH ( YiAR)
COST ELEMENTS
REPORTED ADJUSTED !
0 65
69.5(1978) .Q< 0>
.0( 0) «0( 0)
C,E,J
0 65
5.3(1978) ,0( 0)
,0< 0) .0( 0)
BfC
0 65
93.3C197B) ,0( 0)
3.3( 0) .0( 0)
C,E,J,M
STANDARDIZED
ADJUSTED
65
,0( 0)
.0( 0)
65
.0« 0)
.0( Q)
65
.OC 0)
.0< 0)
COLUMBUS 8 SOUTHERN OHIO ELEC. CAPACITY FACTOR, X
CONESVILLE
II
411.0 MW (NET)
TOTAL CAPITAL, S/KWtYFAR)
TOTAL ANNUAL, "ILLS/KWH(YEAR)
COST ELEMENTS
51 65 65
55.5(1975) 70,7(1975) ?Q,7(1975)
4,7( 0) 7.4< 0) 7,4( 0)
B,C,Ji«,T,K, C»E«J»M,S,U» C,F,J,»,S,U,
Y W,Y W,Y
COLUMBUS (t SOUTHERN OHIO ELEC. CAPACITY FACTOR, X
CONESVILLE
f
411.0 MW (NET)
TOTAL CAPITAL, »/KW(Y6AR)
TOTAL ANNUAL, WILLS/KWH(YEAR)
COST ELEMENTS
0 65
55.5(1978) 70.7(1978)
.0( 0) ,0( 0)
B,C,J,I%T,X, C,E,J,PI,S,U,
Y W,Y
65
,0(
0)
C)
OUQUESN6 LI6HT
FLRAMA
1-4
510.0 «W (NFT)
CAPACITY FACTOR, X
TOTAL CAPITAL, S/KW(YEAR>
TOTAL ANNUAL, PILLS/KWH(YEAR)
COST ELEMENTS
64 65 65
113.4(1976) 127.1C 0) 127.1(1976)
8.6( 0) 7.8< 0) 7.5( 0)
B,D,F,I,J,n, C,E,1,J,M,S, C,E,I,J,M,S,
T,V,X,Y U,Y U,V
DUBUESNE LI6HT
1-6
410.0 MU (NET)
CAPACITY FACTOR, x
TOTAL CAPITAL* »/KW(YEA*>
TOTAL ANNUAL, MILLS/KWH(YEAP)
COST ELEMENTS
70 65 65
106.9(197?) 140.6(1972) 140.6C197?)
7.8( 0) 8.6( 0) 6.21 0)
B,D,F,I,J,K, C,Eil,J,«,S, C,E,I,J,M,S,
T,V,X,Y U,Y U,Y
INDIANAPOLIS POWER k LI6HT
PETERSBURG
5
53Z.O MW (NET)
CAPACITY FACTOR, X 0 65 65
TOTAL CAPITAL, S/KW(YEAR) 99.5(1976) 100.6(1976) 100.6(1976)
TOTAL ANNUAL, MILLS/KWH(YEAR) .0( 0) 6.6( 0) 7.4( 0)
COST ELEMENTS C.F,G,J,M C,E,G,J,M,S, C,E,G,J,M,S,
U,W,Y U,W,Y
KANSAS CITY POWER K LIGHT
HAWTHORN
5
110.0 MW (NET)
CAPACITY FACTOR, X 14
TOTAL CAPITAL, S/KW(YEAR) 29.2(1972)
TOTAL ANNUAL, MILLS/KWH(YEAR) E.4( 0)
COST ELEMENTS B,D,F,T,X
65 65
87.Z(1972) 87.2(1972)
4.7( 0) 4.4( 0)
B,C,E,J,K,S, B,C,E,J,K,$,
U,W,X U.W.X
KANSAS CITY POWER & LIGHT
HAWTHORN
I
110.0 MW (NET)
CAPACITY FACTOR, x o
TOTAL CAPITAL, $/KW(YEAR> 29.2(1972)
TOTAL ANNUAL, KILLS/KWH(YEAR) £.4( 0)
COST ELEMENTS 8,D,F,T,X
65 65
87.2(1972) 87.2(197?)
4.7( 0) 4.4( 0)
6,C,E,J,K,S, B,C,E,J,K,S,
U.W.X U,W,X
****** INDICATES COST FIGURES NOT YET AVAILABLE
A- 19
-------
FPA UT1LITT
SURVEY: DECEHE-ER T>7F - JANUARY "79
SECTION A-1
COSTS FOR OPERATIONAL FGD SYSTEMS
UNIT DESCRIPTION
KANSAS CITY POWER * LIGHT
LA CYCNE
874.0 HW (NET)
rENTUCKY UTILITIES
GREEN RIVER
1-3
64.0 NW (NET)
LOUISVILLE «AS & £LECTRlC
fANE RUN
4
19Q.O HW (NET)
LOUISVILLE CAS & ELECTRIC
CANE RUN
5
200.0 MW (NET)
LOUISVILLE CAS g ELECTRIC
PADDY'S RUN
I-
70.0 HW (NET)
COST DESCRIPTION
CAPACITY FACTOR, X
TOTAL CAPITAL, J/KW(YEAR>
TOTAL ANNUAL, HILL S /KWH ( YE AR )
COST ELEMENTS
CAPACITY FACTOR, X
TOTAL CAPITAL, S/KW(YEAR)
TOTAL ANNUAL, HILLS /KWH ( YE AR)
COST ELEHENTS
CAPACITY FACTOR, X
TOTAL CAPITAL, $/KW(YfAR>
TOTAL ANNUAL, KILLS /KWH( YE AR)
COST ELEMENTS
CAPACITY FACTOR, X
TOTAL CAPITAL, */KU(YEAR)
TOTAL ANNUAL, MILLS /KWH( YEAR)
COST ELEMENTS
CAPACITY FACTOR, x
TOTAL CAPITAL, S/KW(YEAR)
TOTAL ANNUAL, HILLS /KVH(VEAR >
COST ELEMENTS
REPORTED
30
53.6(1972)
1.7( 0)
B.C.E.J.S
16
70.3(1975)
14. 3( 0)
B.C,E,J,S,U,
W
55
66.5(1975)
.0( 0)
C,E,H,J,8,T
0
63.4(1977)
,0( 0)
C,E,H,J
0
52.8(1973)
.o( n>
C,E
ADJUSTED
65
66.0(1972)
3.P( 0)
C,E,J,K,S,U
65
77.5(1975)
2.7( 0)
C,E,J,S,U,W
65
80.6(1975)
5.R( 0)
C,E,H,J,K,Q,
S.U.W
65
67.5(1977)
5.6C 0)
C,E,H,J,K,S,
65
76.4(1973)
6.5( 0)
C,E,S,U,W
STANDARDIZED
ADJUSTED
65
68.0(1972)
C,E,J,K,S,U
65
77.5(1975)
5.2( 0)
C,E,J,S,U,V
65
fO. 6(1975)
6.2( 0)
C,F,H,J,K,Q,
S.U.W
65
67.5*1977)
5.6< 0)
C,E,H,J,K,S,
u,w
65
76.4(1973)
6.4( 0)
C.E .S.U.W
•IWNKOTA POWER COOPERATIVE
HILTON 0. VOUN6
?
405.0 HW (NET)
CAPACITY FACTOR, *
TOTAL CAPITAL, S/KU(YEAR>
TOTAL ANNUAL, HILLS /KWH (YE AR)
COST ELEHENTS
0 65 65
85.9(1976) 93.0(1976) 93.0( 0)
.0( D> 5.2( Q) 5.2( 0)
C,E,H,P C,E,H,K,P,S, C.E.H.f.P.S.
U,W U.V
•ONTANA POWER
1
360.0 HW (NET)
CAPACITY FACTOR, x
TOTAL CAPITAL,- S/KW(YE*R)
TOTAL ANNUAL, HILLS/KWH(YEAR)
COST ELEMENTS
76 65 65
77-U1975) 77iZ(t975) 77.2'1?7S>
.0( 0) 4.1( 0) 4.0C 0)
8,C,E,j,P,T C,E,J,K*P,S, C,E,J,K,P,S,
u,w u,w
MONTANA POWER
COLSTRIP
a
360.0 MW (NET)
CAPACITY FACTOR, x
TOTAL CAPITAL, $/KW(VEAR)
TOTAL ANNUAL, KILLS /KUH (YE A R >
COST ELEHENTS
76 65 65
77.1(1975) 77.2(1975) 77.2<1975)
.3( 0) 4.K 0) 4.1( 0)
e,C,E,J,P,T C,E,J,K,P,S, C,E,J,K,P,S,
U,W U,W
NEVADA POWER
PEID 6ARDNER
1
125.0 MW (NET)
CAPACITY FACTOR, x
TOTAL CAPITAL, S/KW(YEAR>
TOTAL ANNUAL, HILLS/KWH(YEAR)
COST ELEMENTS
67 65 65
42.9(1973) 60.9(1973) 60.9(1973)
2.1( D> 3.2( 0> 3.4( 0)
B,D,E,P,S,U, B,D,E,P,S,U, B,D,E,P,S,U,
w,x u,x w,x
NEVADA POWER
REID 6ARDNER
c
125.0 HW (NET)
CAPACITY FACTOR, x
TOTAL CAPITAL, t/KW(YEAR)
TOTAL ANNUAL, HItLS/KWH(YEAR)
COST ELEMENTS
67 65 65
42.9(1973) 60.9C1973) 60.9(1973)
2.1( 0> 3.2( 0> 3.4f 0)
8,0,E,P,S,U, B,6,E,P,S,U, B,D,E,P,S,U,
w.x w,x u,x
****** INDICATES COST FIGURES NOT VET AVAILABLE
A- 20
-------
EPA UTILITY FED SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION A-1
COSTS FOR OPERATIONAL F6D SYSTEMS
UNIT DESCRIPTION
COST DESCRIPTION
COST
REPORTED ADJUSTED STANDARDIZED
ADJUSTED
NEVADA POWER
REID GARDNER
5
125.0 MW (NET)
CAPACITY FACTOR! X
TOTAL CAPITAL, $/KW(Y£AR)
TOTAL ANNUAL, HILLS/KVB
TOTAL ANNUAL, WILLS/KWH(YEAR)
COST ELEMENTS
77 65 65
156.9(1976) 134.8(1976) 134.8(1976)
14.9( 0) 12.4( 0) 11.01 0)
B,C,E,L,N,S, C,E,L,N,S,U» C,E,L.N,S,U,
u,w,x,z w,z w,z
NORTHERN STATES POWER
SHERBURNE
1
720.0 MW (NET)
CAPACITY FACTOR, x
TOTAL CAPITAL, $/KW(YEAP.)
TOTAL ANNUAL, MILLS/KWH(YEAR)
COST ELEMENTS
73 65 65
47.9(197?) 71.5(1972) 71.5*1972)
2.Of 0) 2.?( 0) 3.3( 0)
B,C,J,S,U,X, C,E,J,K,S,U, C,E,J,K,S,U,
NORTHERN STATES POWER
SHERBURNE
?
720.0 HW (NET)
CAPACITY FACTOR, x
TOTAL CAPITAL, $/KU(YEAR)
TOTAL ANNUAL, MILLS/KWH (YE AR >
COST ELEMENTS
73 65 65
47.9(1972) 71.5(1972) 71.5(1972)
2.0( 0) 2.P( 0) 3.3( 0)
B,C,J,S,U,X, C,E,J,K,S,U, C,E,J,K,S,U,
z u w
PENNSYLVANIA POWER
BRUCE MANSFIELD
1
917.0 MW (NET)
CAPACITY FACTOR, x
TOTAL CAPITAL, S/KUCYEAR)
TOTAL ANNUAL, MILLS/KVH (YE AR)
COST ELEMENTS
40 65 65
120.6(1975) 102.1(1975) 102.1(1975)
14.3( 0) 8.7( 0) 10. H 0)
B,C,E,S,I,Lt C,E,G,I,M,S, C ,E ,6 ,1 ,W , S ,
S,U,W,X U,W U,V
PENNSYLVANIA POWER
BRUCE MANSFIELD
2
917.0 HW (NET)
CAPACITY FACTOR, x
TOTAL CAPITAL, J/KVKYEAR)
TOTAL ANNUAL, HILLS/KWH(YEAR)
COST ELEMENTS
40 65 65
120.6(1975) 102.1(1975) 102.1(1975)
14.3( 0) 6.7( 0) 10.8( 0)
B,C,E,E,I,L, C,E,G,I,H,S, C,E,G,I,N,S,
S,U,W,X U,W U,V
PHILADELPHIA ELECTRIC
tft6 YS TQfl€
1 A
120.0 HW (NET)
PUBLIC SERVICE OF NEW MEXICO
SAN JUAN
1
361.0 HW (NET)
PUBLIC SERVICE OF NEW MEXICO
SAN JUAN
?
350.0 MW (NET)
SOUTH CAROLINA PUBLIC SERVICE
2
140.0 HW (NET)
CAPACITY FACTOR, x
TOTAL CAPITAL, S/KW(YEAH)
TOTAL ANNUAL, KILLS/KWH(YEAR)
COST ELEMENTS
CAPACITY FACTORi X
TOTAL CAPITAL, */KW(YEAR)
TOTAL ANNUAL, MILLS /KWH (YE AR )
COST ELEMENTS
CAPACITY FACTOR, 1
TOTAL CAPITAL, S/KWCYFAR)
TOTAL ANNUAL, WILLS /KWH (YE AR )
COST ELEMENTS
CAPACITY FACTOR, X
TOTAL CAPITAL, $/KW(YEAR)
TOTAL ANNUAL, MILLS /KWH (YE AR)
COST ELEMENTS
0
15*. 7(1972)
.0( 0)
D,F,N,P
0
127.9(1977)
.0( 0)
A,C,E,N
0
127.9(1977)
.0( 0)
A.,C,E,N
80
47.4(1976)
1.6( 0)
C,F,J,M,SiV
65
233. 3(1972)
.C( 0)
C,E,N,P
65
.OC 0)
.0( 0)
65
.OC 0)
.C( 0)
65
66,* (1976)
2.9( 0)
Ct£,J.K,MrS,
U,W
65
.oc -p>
.0( 0)
.OC 0)
,C( 0)
.OC 0)
.DC 0)
65
6.4(1976)
3.2C 0)
CfStJ,K,HpSi.
U,W
****** INDICATES COST FIGURES NOT YET AVAILABli
A- 21
-------
EPA UTILITY f6D SURVEY: DEClKBER 197S - JANUARY 1979
SECTION A-1
COSTS FOR OPERATIONAL F6D SYSTEMS
UNIT DESCRIPTION
SOUTHERN MISSISSIPPI EL£CTRjC
R.D. MORROW
1
124.0 NW (NtT)
SPR1N6FIELD CITY UTILITIES
SOUTHWEST
1
194.0 MU (KE I)
COST DESCRIPTION
CAPACITY FACTOR, X
TOTAL CAPITAL, S/KU(Y£AR)
TOTAL ANNUAL, MILLS /KWH (YE AR)
COST ELEMENTS
CAPACITY FACTOR, X
TOTAL CAPITAL, $/KW(YEAR)
TOTAL ANNUAL, MILLS /KWH (Y£ AR)
COST ELEMENTS
REPORTED ADJUSTED STANDARDIZED
0 65
3 7«4 (1975 )
.0( CO
C,E
.0( 0>
,0( 0)
0 65
77.3(1974) 117.6(1974)
.OC 0) 6
C,F,H,J,P C,E,
.Z( 0)
H,J,K,P,
s.u.u
TENNESSEE VALLEY AUTHORITY
WICOUS CREEK
8
550.0 MW (NET)
CAPACITY FACTOR, *
TOTAL CAPITAL, S/KUCYEAR)
TOTAL ANNUAL, MILL S/KWH(YE AR)
COST ELEMENTS
0 65
69.5(197?) 113
.0( 0> 5
C,E,J C,E,
.1(1976)
.3( 0)
J,S,U,k
ADJUSTED
ts
.0 C 0)
.OC 0)
65
117.6(1974)
6.9( 0)
C,E,H,J,K,P,
S.U.U
65
113.1(1976)
5.K 0)
C,F,J,S,U,W
****** INDICATES COST FIGURES NOT YET AVAILABLE
A- 22
-------
EPA UTILITY F60 SURVEY: DECEMBER 1978 - JANUARY 1979
SECTION A-2
COSTS FOR NON-OPERATIONAL FSO SYSTEMS
UNIT DESCRIPTION
ALABAMA ELECTRIC COOP
TOMBI6BEE
?
179.0 HW (NET)
ARIZONA ELECTRIC POWER COOP
APACHE
3
180.Q MW (NET)
BASIN ELECTRIC POWER COOP
LARAMIE RIVER
1
600.0 HW (NET)
BASIN ELECTRIC POWER COOP
LARAMIE RIVER
2
600.0 MW (NET)
BIG RIVERS ELECTRIC
GREEN
1
242.0 MW (NET)
BOSTON EDISON
MYSTIC
6
.0 MW (NET)
CENTRAL ILLINOIS PUBLIC SERV
1
617.0 MW (NET)
COLORADO UTE ELECTRIC ASSN.
CRAIG
1
450.0 MW (NET)
COLORADO UTE ELECTRIC ASSN.
CRAIG
2
450.0 nw (NET)
COMMONWEALTH EDISON
POWER TON
11
425.0 MW (NET)
COST DESCRIPTION
CAPACITY FACTOR, X
TOTAL CAPITAL. */KW(YEAR)
TOTAL ANNUAL, MILL S /KUM ( YE AR )
COST ELEMENTS
CAPACITY FACTOR, X
TOTAL CAPITAL, S/KW(YEAR)
TOTAL ANNUAL, KILLS /K«H < YE AR )
COST ELEMENTS
CAPACITY FACTOR, X
TOTAL CAPITAL, S/KWCYEAR)
TOTAL ANNUAL, MILLS /KWH ( YE AR)
COST ELEMENTS
CAPACITY FACTOR, X
TOTAL CAPITAL, $/KW(YEAR)
TOTAL ANNUAL, MILLS /KWH ( YE AR )
COST ELEMENTS
CAPACITY FACTOR, X
TOTAL CAPITAL, i/KW(YEAR)
TOTAL ANNUAL, MILLS /KWH (YE AP)
COST ELEMENTS
CAPACITY FACTOR, X
TOTAL CAPITAL, S/KW(YEAR)
TOTAL ANNUAL, MILLS /KWH ( YE AR )
COST ELEMENTS
CAPACITY FACTOR, X
TOTAL CAPITAL, S/KW(YEA*)
TOTAL ANNUAL, K1LLS/KWH(YE AR )
COST ELEMENTS
CAPACITY FACTOR, X
TOTAL CAPITAL, $/KW(YEAR)
TOTAL ANNUAL, MILLS /KWH (YE AR)
COST ELEMENTS
CAPACITY FACTOR, X
TOTAL CAPITAL, J/KW(YEAR)
TOTAL ANNUAL, «ILLS/KWH
-------
EPA UTILITY FGD SURVEY: DECEMBER 197E - JANUARY 1979
SECTION A-2
COSTS FOR NON-OPERATIONAL FSB SYSTEMS
UNIT DESCRIPTION
COMMONWEALTH EDISON
WILL COUNTY
1
.0 MW (NET)
DETROIT EOISON
ST. CLA1R
6
.0 MW (NET)
ILLINOIS POWER COMPANY
WOOD RIVER
1
.0 MW (NET)
LOUISVILLE 6AS 8 ELECTRIC
CANE RUN
6
378.0 MW (NET)
PACIFIC POWER & LI6HT
JIM 8RIDGER
t
550.0 MW (NET)
POTOHAC FLECTRIC POWER
DICKERSON
3
.0 MW (NET)
PUBLIC SERVICE OF COLORADO
V A L*0 NT
5
.0 MW (NET)
SALT RIVER PROJECT
CORONADO
2
2PO.O MW (NET)
SOUTHERN INDIANA GAS S ELEC
«.B. BRoWN
1
265.0 MW (NET)
SOUTHERN MISSISSIPPI ELECTRIC
R.O. MORROW
7
124.0 NW (NET)
COST DESCRIPTION
CAPACITY FACTOR. X
TOTAL CAPITAL. S/KW(YEAR>
TOTAL ANNUAL, MILLS /KWHf YE AR )
COST ELEMENTS
CAPACITY FACTOR, X
TOTAL CAPITAL, $/KW(YEAR)
TOTAL ANNUAL, « ILL S /KWH ( YE AR)
COST ELEMENTS
CAPACITY FACTOR, X
TOTAL CAPITAL, S/KW(YEAR)
TOTAL ANNUAL, MI LLS /KWH ( YE AR)
COST ELEMENTS
CAPACITY FACTOR, X
TOTAL CAPITAL, J/KW(YEAR)
TOTAL ANNUAL, MILLS/KWH(YEAR)
COST ELEMENTS
CAPACITY FACTOR, X
TOTAL CAPITAL, J/KWfYEAR)
TOTAL ANNUAL, MI LLS /KWH (YE AR)
COST ELEMENTS
CAPACITY FACTOR, X
TOTAL CAPITAL, */KW(YEAR)
TOTAL ANNUAL, MILLS /KWH (YE AR)
COST ELEMENTS
CAPACITY FACTOR, X
TOTAL CAPITAL. J/KH(YfAR>
TOTAL ANNUAL, KILLS /KWH (YE AR )
COST ELEMENTS
CAPACITY FACTOR, X
TOTAL CAPITAL, */KW(YEAR)
TOTAL ANNUAL, HILLS /KWH (YEAR)
COST ELEMENTS
CAPACITY FACTOR, X
TOTAL CAPITAL, J/KW(Y£AR)
TOTAL ANfUAL, HILLS/KWH( YE ARJ
COST ELEMENTS
CAPACITY FACTOR, X
TOTAL CAPITAL, $/KW(YEAR)
TOTAL ANNUAL, MILLS /KWH (YE AR)
COST ELEMENTS
REPORTED
49
113.0(1972)
13. 1C 0)
B,C,E,G,J,X
0
80.3f1976>
9.6( 0)
B,C ,E,J,I",X
0
82.5(1972)
.Of 0)
A,C,E,«,N
0
57.9(1977)
3.2( 0)
C,E ,H,M,S,V,
W
0
120.0(1979)
.CC 0)
C,E,J
0
68.0(1978)
.Of 0)
A.C.E.M
0
87»0(19?«)
.0( 0)
B,C,E,J
0
98.0<197R)
.0( 0>
C»E
0
43.2(1979)
.0( 0)
C,E,G
0
37.4(1975)
.0( 0)
C,E
COST
ADJUSTED STANDARDIZED
ADJUSTED
65 65
.Q< 0) -0( 0)
.0( 0) .0( 0)
65 65
.0( 0> .0( 0)
.0( 0) .0( 0)
65 65
.o( o> .or 0)
.0< 0) .0( 0)
65 65
.0< 0) .0( 0)
.01 0) .0( 0)
65 65
.0< 0) .0( 0)
.0( 0) .0( 0)
65 65
.0( 0) ,0( 0)
.DC 0) .Of 0>
65 65
,0( 0) .£>( 0)
.Of 0> .0( 0)
65 65
.Of 0) .Of 0)
.Of 0) .Of 0)
65 65
.Of 0) .Of 0)
.Of 0) .Of 0)
65 «5
.Of 0> .Of 0)
.Of 0) .Of 0)
**«.** INDICATES COST FIGURES NOT VET AVAILABLE
A- 24
-------
APPENDIX B
FGD PROCESS FLOW DIAGRAMS
THIS APPENDIX COMPRISES OPERATING FGD SYSTEMS
ARRANGED ALPHABETICALLY ACCORDING TO UTILITY
-------
CO
I
ro
DILI BCTCLE PIMPS-1
(TVD TO»L)
LIWSTIK StUtUr PVHPS
(THO TOTHl)
J
ABSORBED BICYCLE PUWS -
(SII PER UNIT)
MWTE-I
SLUPBt
SWW
WtSTE SLURRT
I \ \
US TO STUCJ
IT 3
(THO T01*L)
SWEMITE
IE Tim
>-SC«UBMI> WSTC
STOMGE KCID
Alabama Electric,
Simplified Process Flow Diagram for Tombigbee 2
-------
FLUE
t>S
NOSTU
f«M
i
co
Lorn*
SMLI no Tint
««' [ICHttCd
J —
—
U I loimt
JTEM
t
s
\ -s
r TX S
OME
MS
HOSIDI auuflti
LIHESTCMC Slum H*t£l»
WTEI PWUUC
~7
L
1 WHTIOIUVTf U\AXX)
SCRUOER
,
,-J ,, .„
Monu A |
ASH-LAOOll
MATES
1
,
U
7A
S
.
[Z
NK
|^
a.
(.S
TACK
rc
TAIC
s
IS
K
X*
__..-
^
t
i
1 SURSE TMI
L
PAKTICUIAT{|
soMcn I
• L
HDOULE •
LADW
nt
I i ^
r~
[
j
i ,
ET«
10
Arizona Public Service, Choila 1 :
Simplified Process Flow Diagram
-------
ro
b fi
l.D. FMS F.O. FJU6
Htcrecuunion
T*«B RECHOJUTIO*
WBPS
Central Illinois Light,
Simplified Process Flow Diagram of Duck Creek 1
Power Plant and Emission Control System
-------
MAKEUP HATER
(POND HATER)
FROM ESP -
FLUE GASES
LIME FROM
STORAGE
SERVICE
HATER
DO
01
L_
TO STACK - FLUE GASES
HIST ELIMINATOR
ZEQ223.A
>1IJ>JJJJJIT
SLURRY
STORAGE
TANK
s
TO OTHER
RECYCLE TANK
» OVERFLOW
TO ASH POND
FROM OTHER
RECYCLE TANK
••TO IOCS
Columbus and Southern Ohio Electric, Conesville 5 and
Simplified Process Flow Diagram for a Riven Module
6:
-------
DO
I
CTl
1ST STAGE
ADJUSTABLE VENTURI
FOR FLY ASH/S02
2ND STAGE
S02 ABSORBER SCRUBBER
CaS03/S04
FLY ASH SLURRY
RECYCLE RETURN SYSTEM
TO
STABILIZATION
FACILITIES
Duquesne Light, F. R. Phillips FGD System:
General Diagram.
-------
JET BUBBLING REACTOR
STACK
WATER
CX ~— ^vcm . ^.S£
jSy \i trt~* •»* ' v***^" """" «w«i^j >-— M t
- ^r^F^.'T^^. 41--
'.-^*-^ftv "•-"
-------
STACK
I.D. FAN
CO
I
oo
COAL
SUPPLY
FEEDER
PULVERIZER
STACK GAS
AIR HEATER
STACK GAS
REHEATER
STACK GAS
SCRUBBER
LIME
PREPARATION
TANK
CLARIFIER
RECYCLE
PUMP
Kansas City Power and Light, Hawthorn Units 3 and 4:
Simplified Process Flow Diagram of the Lime Scrubbing Process
MAKE UP
UATER
TO ASH DISPOSAL
POND
-------
CD
I
STEAM COAL
REHEATER
AIR
HEATERS TO
RECIRCULATIO
TANKS
ENTURI
SCRUBBER
VENTURI
RECIRCULATION
PUMPS
HYDROCLONE
CLASSIFIER
LIMESTONE
BUNKER
LIMESTONE
SLURRY
STORAGE
160 ACRE
SETTLING POND
BOILER
WET BALL
MILL
Kansas City Power and Light,
LaCygne 1 FGD System: General Diagram
-------
FURNACE
DAMPERS
CD
I
ONE
STACK
TWO PRECIPITATORS
FOUR I.D. FANS
WATER RETURN TO
REACTION TANKS
BLEED PUMP
RANSFER TANK
FOUR,
REACTION
TANKS
SLUDGE DISPOSAL
POND
Kansas Power and Light,
Schematic of Jeffrey Steam Generator and Emission Control Equipment
-------
LllCSTOXC IMTCR FOR
HOW5R SLUMYIHG
D1LUT1W KATER (FRO*
AOOIT|»C STORAGE BEC1RCULATIOH TANkj
TA« 60 SOLIDS
CO
I
I
ADDITIVE
DILUTION
AOOULVt
-CT
^TO 01HEB
SCRUSBES
NODULE
ONE OF TW NODULES
TO STACK
FLUE GAS FRflC
AIR PREHEATER
OUTLET DAMPER
REHEATER
REHEATER BLOWER
. MIST ELIMINATOR
ADDITIVE
(FROM MILL)
MAKEUP
HATER"
ROD SCRUBBER
SPRAr PUMP
ftl
ADDITIVE
FEED
^*
[I
<
1
1
^ /a
i T
1' lilj
REACTION I.
TANK :r
STRAINERS:
y
_
a
/
ABSI
Q_
ADDITIVE
STORAGE TANK
1
EFFLUENT
BLEED
COMMINUTOR
-TO POND
Kansas Power and Light,
Lawrence No. 4 Operational FGD System
Simplified Process Flow Diagram
-------
HATER fW
LIKSTONt SLUUH1N6
DILUTIM HATER
(FROM RECIRCULATION TANK)
SLUBJ
03
I
STACK I POND RETURN
(MAKE-UP)
I WATER
TO STRAINER I
WASHERS "*^
I
THICKENER
UNDERFLOW PUMPS
WEIR
OVERFLOW
TO
SETTLING
POND
Kansas Power and Light,
Lawrence No. 5 Operational FGD System
Simplified Process Flow Diagram
-------
DO
I
ELECTRICAL
GENERATING
UNIT NO. 1
ELECTRICAL
GENERATING
UNIT NO. 2
BOILER
NO. 1 I
BOILER NO. 2
BOILER
AIR
Hi MECHANICAL p]
V COLLECTORS M £X,STI|(6
I.D.P) '-"-O STACIC
FAN I,/ FAN I/' | H Q fl | FA"
NO. 3 I
RECYCLE r". MIX/HOLD TANK
^^
SPARE
MAKEUP HATER
MAKEUP HATER
SPARE
SPARE
Kentucky Utilities,
Green River FGD System: General Process Diagram
-------
QUENCHER
HIST
ELIMINATOR
(CHEVRON)
ELECTROSTATIC
PRECIPITATOR
BOILER
FLUE
GAS
CO
-P.
CONTACTOR
SCRUBBfR
MODULE
vv\/
DAMPERS V
CONTACTOR
SCRUBBER
MODULE
FAN
MIST
ELIMINATOR
(CHEVRON)
FLOCCULANT
ADDITION
Louisville Gas and Electric, Cane Run 4
FGD System: Simplified Process Flow Diagram
-------
REAGENT
ELECTROSTATIC
PRECIPITATOR
CO
I
BOILER
FLUE -
GAS
"TO STACK
-STEAM
REHEAT
SPRAY
TOMER
LIME SLURRY
FEED PUMP
REACTION
TANK
— 1
RECYCLE
PUMP 1
/~s
^
i
1 THK
/
Louisville Gas and Electric, Cane Run 5 FGD System:
Simplified Process Flow Diagram
-------
CO
cn
50GPM FRESH WATER l*VE I
ZSOGPM FRESH WATER (MAX. SHORT-TERM)
pH6 OR HIGHER
5 «OO wv - TOTAL:
.4 7.TOO
»H 9 J 4.O30 CPM/SCPuBBi"
FLOW HCTEA 8.IOO CPM ITOTAL)
NOTE
CPU FIGU«t5 «EPBf5tHT JO. I RATIO
0»«/IOOO
TO VACUUM FVEH HOUSE
GAS INLET STEAM 0LO»Cf»S
WATCH
FOT CHAIN WATER
ADDITIVE K.UIIIIT WATCH
1CRU88C* OI5CHAHOf MATE*
PI1CHAMC
Louisville Gas and Electric,
Paddys Run No. 6 FGD System:
Process Flow Diagram.
-------
FLUE
GAS
EMERGENCY WATER
PLENUM
DO
-J
BLEED
MIST
ELIMINATORS
3 "CLEAN FLUE GAS
HXH-SEAL WATER SUPPLY
.UNDERSPRAY ^ MAKEUP
'WATER
STEAM
REHEAT
WASH TRAY POND
FLY ASH POND
Montana Power, Col strip 1 and 2:
Process diagram of a given FGD module.
-------
TO CHIMNEY
FURNACE
COM.
PULVERIZER
DO
CO
MECHANICAL
OUST
COLLECTOR
(HULTICLONES)
BYPASS f
-Biirt^
HEATER
p—L_n
BOILER
1.0. FAN
BOILER
F.O. FAN
PURGE
TO ASH POND
ASH POND PUMP
ip
REHEATER AIR FAN
TRAY RECYCLE PUMP
SODA ASH
EVAPORATION PONDS
ON MESA
HATER FROM
ASH PONO
ASH POND
SH MAKEUP
TANK
ASH AND HATER
SODA ASH
SLURRY PUMP
Nevada Power, Reid Gardner 1,2 and 3:
Process diagram of a given FGD system.
-------
DISCHARGE
TO STACK
CONDENSER
PRESCRUBBER
{VARIABLE-THROAT
VENTURI)
CO
to
FLUE GAS FROM
UNIT #11^
• ~7~
FLY ASH PURGE TO POND
TRAY TOWER
ABSORBER
PURGE
STREAM
TREATED
PURGE STREAM
TO S02
REDUCTION
PLANT
CENTRIFUGE
STORAGE
BIN
CRYSTALLIZER
SODIUM SULFATE
CAKE
ws,|« STEAM
EVAPORATOR/
CRYSTALLIZER
QJ COMPRESSOR
DRIED
SULFATE
PRODUCT
Northern Indiana Public Service,
D. H. Mitchell No. 11 Wellman. Lord/Allied System:
General Process Diagram.
-------
FLUE GAS
TO
SCRUBBER
\ FIRST
* ^T H r* r*
co
i
r\>
o
ooo
OXIDIZER
REHEATER
GAS
TO STACK
RIVER
MAKEUP —
WATER
MIST
ELIMINATOR
OVERFLOW POTS
AND MARBLE BED
REACTION
TANK
WEIR
THICKENER
RECIRC
TANK
THICKENER
UNDERFLOW
PUMP
•A
SPRAY
PUMP
ASH POND
LIMESTONE —i
SLURRY
TANK
\A
SLURRY
PUMP
ASH POND
RETURN PUMP
Northern States Power, Sherburne 1 and 2 FGD System:
Simplified Process Flow Diagram
-------
CD
I
to
Pennsylvania Power, Bruce Mansfield FGD System:
Process Flow Diagram for Unit 1 or 2
-------
oo
i
IM
ro
FRESH
WATER >
INLET
BACKWASH
SPRAYS
STACK GAS
FROM I.D.
FANS
PARTICIPATE
SCRUBBER
HUMIDIFIED
GAS STREAM
Mg (OH)2 SLURRY
PARTICULATE
SCRUBBER
SURGE TANK
TO WASTE WATER
"TREATMENT SYSTEM
CLEAN GAS UUTLL1
MIST ELIMINATORS
MIST ENTRAPMENT SEPARATOR
S0_ SCRUBBER
SURGE TANK
Philadelphia Electric Co.,
Eddystone 1 FGD System:
General Process Diagram.
VENTURI ROD MODULES
SCRUBBING SLURRY INLET
TO Mg S03
RECOVERY
-------
BOILER
\7
EXISTING
ELEC.PRECIP. MR
HEATER
CO
LIMESTONE
FEED BIN
(ORE IN USE
FOR TUO
BOILERS)
MEIOJ FEEDER
(OK IN USE)
VENTURI SORBER
SCRUBBER™
(ONE IN USE)
UET BALL MILL
(ONE IN USE)
HILL SLURRY J2L SLURRY STORAGE
-—..„., rtinr TAHV
ORE SPARE)
SLURRY
PUMP
(ONE IN USE
ONE SPARE)
RECYCLE TANK
(ONE IN USE)
RECYCLE
PUMP
(TWO IN USE
ONE SPARE)
THICKENER
SUPPLY
TANK
(ONE IN USE)
PUMP
ONE IN USE
ONE SPARE)
Southern Mississippi Electric, R.D. Morrow 1:
Simplified Process Flow Diagram
-------
SCRUBBER INLET
TEST PORT LOCATION
DO
I
ro
TOP OF STACK
ELEVATION IMS'
TEST PORT
ELEVATION 1516*
-TOP OF OUTLET BREECHING
ELEVATION 1372'-2 3/8*
-TOP OF BYPASS BREECHING
ELEVATION 1307'- 8 1/2*
GRADE ELEVATION 1261*
PRECIPITATOR
INLET TEST
PORT LOCATION
SCRUBBER INLET'
TEST PORT LOCATION
Springfield City Utilities, Southwest 1:
Simplified Process Diagram
-------
ro
01
i AIR
IFUEL OIL >— *-| REHEATER {-- ,
TCA
SCRUBBERV-J&
-------
ro
REHEATER -
1.
— ^--
JFLUE GAS>~O—fr-
VENTURI
SCRUBBER
PROCESS
WATER
HOLD TANK
SCRUBBER
EFFLUENT
HOLD
TANK
SAMPLE POINTS
O6AS COMPOSITION
&PARTICULATE COMPOSITION & LOADING
©SLURRY OR SOLIDS COMPOSITION
GAS STREAM
LIQUOR STREAM
SETTLING POND
Tennessee Valley Authority, Shawnee 10 Prototype Unit:
General Process Diagram.
-------
FLUE GAS
MAKE-UP WATER
CD
I
ro
VENT AIR
I
OXIDATION
TANK
D
CLARIFIED LIQUOR
WATER
SPRAY TOWER EFFLUENT
HOLD TANK
:z>
Z3
». ,*
1
t
^•4
1
c
o
c
t vl
i
DESUPERSATURATION
TANK
BLEED TO
DEWATERING
_ SYSTEM
Tennessee Valley Authority, Shawnee 10 Prototype Test Unit:
Modified Venturi/Spray Tower System for 2-Stage Oxidation Testing.
-------
CD
FROM
ITRAINS
REHEATER
STEAM
ENTRAPMENT
SEPARATOR
B,C, AND D
~ TO ASH
DISPOSAL POND
TO STACK PLENUM
"I •*-
'
FHflM FSP
^N
•
cz
FAN
- FROM B. C, AND D TRAIN
VENTURI CIRCULATION TANKS]
TO SETTLING POND
SLURRY PUMP
SEAL WATER
. HEADER
/ -^ t ^~
RIVER WATER
TO TRAINS
B,C, AND D
^ PUMPS
FROM POND WATER
RECYCLE PUMPS
FROM LIMESTONE SLURRY
VENTURI
CIRCULATION
TANK AND
PUMPS
ABSORBER
CIRCULATION
TANK AND
PUMPS
EFFLUENT SLURRY
SURGE TANK AND PUMPS
BT°CTIAHDSrii Zl LIMESTONE SLURRY
B,C,ANDU|J_J STORAG£ TANK
LIMESTONE SLURRY
FEED PUMPS
Tennessee Valley Authority, Widows Creek 8 FGD System:
Process Flow Diagram for One of the Four Scrubber Trains
-------
FM WHET DJWERv.
- TWER INLET aura
FROM BOILER
AIR PREHEATERS-
•<]
DO
I
ro
vo
inuRE^ LOCATION OF
FUTURE
=1 REHEATER
PUf> SEN. HATER,
BALL HILL COOLING
AND HOSE STATIONS
MAKEUP HATER TO
LIMESTONE AREA
ASH POO)
RHURR HATER
(RECYCLE HATER)
tssj
Texas Utilities,
Simplified Process Flow Diagram for One of the Two Identical
Martin Lake FGD Systems
-------
FAN
CD
I
ۥ>
o
TQ A$H AR£A
BYPASS
TO SPRAY TOUER 301
FROM SPRAY TOUER 301
TO SPRAY TOUER 201
FROH SPRAY TOUER 201
BYPASS
TO SPRAY TOUER 301
HIST ELIMINATOR
WASH HATER
TO SPRAT TWER 201 -4
TO SPRAY TOUER 201
FROH SPRAY TOUER 301
TO SPRAT TOWER 301
TO SPRAY TOUER 301
FROM SPRAY TOUER
TO SPRAT TOUER 201 -»
TP SPRAT TOUER 301 -^
TO SPRAY TOUER 201
LIMESTONE
STORAGE
BIN
TO SPRAY TOUER 301
TO SPRAY TOUER 201
TOTAL PIMP SEALS AND
INSTRUMENT PURGE HATER
LIMESTONE GRINDING
SYSTEM
LIMESTONE SLURRY
TAMC AGITATOR
-LIMESTONE
_, r\SLURRY
PUMP
FROM
LIMESTONE STORAGE
FROM ASH HATER
RETENTION POND
SO, REMOVAL AREA
SUN? PUHPS
S02 REMOVAL AREA SUB>
Texas Utilities,
Simplified Process Flow Diagram for Monticello 3
-------
APPENDIX C
DEFINITIONS
C-l
-------
DEFINITIONS
Boiler Capacity Factor:
Boiler Utilization Parameters:
Byproduct
Disposal
Efficiency:
Particulate Matter
SO,
FGD Viability Indexes
(kwh generation in year)/maxi-
mum continuous generating
capacity in kW x 8760 hr/yr).
Hours boiler operated/hours in
period, expressed as a percen-
tage.
The nature (e.g. elemental
sulfur, sulfuric acid) and
disposition (e.g. stockpile on
site, marketed) of the end
product produced by systems
that generate a saleable
product.
Disposal method for throwaway
product systems producing
sludge including: stabilized
or unstabilized sludge, inter-
im and final disposal sites
and disposal type (minefill,
landfill, etc.) as well as
disposal location.
The actual percentage of
particulate matter removed by
the emission control system
(mechanical collectors, ESP,
or fabric filter and FGD) from
the untreated flue gas.
The actual percentage of SO,
removed from the flue gas by
the FGD system. Design
removal efficiency values are
presented for nonoperational
systems for which actual
removal data are not avail-
able.
Several parameters have been
developed to quantify the
viability of FGD system tech-
nology. Various terms such as
"availability," "reliability,"
"operability," and "utiliza-
tion" are used to accurately
02
-------
Availability Index
Reliability Index
represent the operation of any
FGD system during a given
period. The above-mentioned
parameters are defined below
and discussed briefly. The
objectives of this discussion
are to make the reader aware
that several different defini-
tions are being used and to
select appropriate parameters
that can be used for reporting
purposes so that reasonably
consistent comparisons can be
made.
Hours the FGD system is avail-
able for operation (whether
operated or not) divided by
hours in period, expressed as
a percentage. This parameter
tends to overestimate the
viability of the FGD system
because it does not penalize
for election not to operate
the system when it could have
been operated. Boiler down-
time may tend to increase the
magnitude of the parameter
because FGD failures generally
cannot occur during such
periods.
Hours the FGD system was
operated divided by the hours
the FGD system was called upon
to operate, expressed as a
percentage. This parameter
has been developed in order
not to penalize the FGD system
for elected outages, e.g.,
periods when the FGD system
could have been run but was
not run because of chemical
shortages, lack of manpower,
short duration boiler opera-
tions, etc. The main problem
in using this formula is the
concise determination whether
or not the system was "called
upon to operate" during a
given time period. In addi-
tion, an undefined value can
C-3
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FGD Operability Index
FGD Utilization Index
End Product
Saleable
result when the FGD system is
not called upon to operate for
a given period (e.g., turbine
or boiler outage when FGD
system is available).
Hours the FGD system was
operated divided by boiler
operating hours in period,
expressed as a percentage.
This parameter indicates the
degree to which the FGD system
is actually used, relative to
boiler operating time. The
parameter is penalized when
options are exercised not to
use the FGD system in periods
when the system is operable.
In addition, an undefined
value can result when the FGD
system is not called upon to
operate for a given period
(e.g., turbine or boiler
outage when FGD system is
available).
Hours that the FGD system
operated divided by total
hours in period. This para-
meter is a relative stress
factor for the FGD system. It
is not a complete measure of
FGD system viability because
the parameter can be strongly
influenced by conditions that
are external to the FGD system
(e.g., infrequent boiler
operation will lower the value
of the parameter although the
FGD system may be highly
dependable in its particular
application).
The S02 removed from the flue
gas is recovered in a usable
or marketable form (e.g.,
sulfur, sulfuric acid, gypsum,
ammonium sulfate, sodium
sulfate).
C-4
-------
Energy Consumption, %
rowaway The ^ removed from j.ne fiue
gas is not recovered in a
usable or marketable form and
resulting sulfur-bearing waste
products must be disposed in
an environmentally acceptable
fashion.
The percentage of gross unit
electrical generating capacity
consumed by the FGD system, as
defined by the following
equation:
[Net MW W/o FGD - Net MW w/FGD]/
Gross unit rating]
Equivalent Scrubbed Capacity (ESC) The effective scrubbed flue
gas in equivalent MW based on
the percent of flue gas scrubbed
by the FGD system.
FGD Status:
Category 1
Category 2
Category 3
Category 4
Category 5
Category 6
Operational - FGD system is in
service removing S02.
Under Construction - ground
has been broken for installation
of FGD system, but FGD system
has not become operational.
Planned, Contract Awarded -
contract has been signed for
purchase of FGD system but
ground has not been broken for
installation.
Planned, Letter of Intent
Signed - letter of intent has
been signed, but legal con-
tract for purchase has not
been awarded.
Planned, Requesting/Evaluating
Bids - bid requests have been
released but no letter of
intent or contract has been
issued.
Considering only FGD Systems -
an FGD system is proposed as a
means to meet an S02 regulation.
C-5
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Category 7
Category 8
FGD Vendor
Fuel Characteristics
General Process Type
New
Process Additives
Process Type
Considering an FGD system as
well as alternative methods.
Nonoperational - FGD system
has been operated in the past
but has been shut down perma-
nently or for an extended
indefinite period of time.
A firm that fabricates and
supplies flue gas desulfuriza-
tion systems.
Type of fuel, average gross
heating value in Btu/lb.
average percent ash and
average percent sulfur content
for fuel as fired.
The manner in which the S02
from the flue gas is collected,
e.g. wet scrubbing, spray
drying, dry adsorption.
FGD unit and boiler were
designed at the same time or
space for addition of an FGD
unit was reserved when boiler
was constructed.
A chemical compound or element
which is added to the process
or normally found with the
main process reagent in small
quantities (e.g. Mg, adipic
acid) to promote improved
process operation (e.g. scale
reduction, increased SO,
removal efficiency).
Company name if process is
patented. Generic name if
several companies have similar
processes (e.g., Lime, Limestone,
Wellman Lord, Thoroughbred
121).
C-6
-------
Regulatory Class
Retrofit
Start-up Date
Total Controlled Capacity [TCCl
Total FGD System Lost
Generation Factor
Unit Location
A. New boiler constructed
subject to Federal New
Source Performance Stan-
dards (NSPS), 8/17/71.
B. Existing boiler subject
to State Standard that is
more stringent than the
NSPS, 8/17/71.
C. Existing boiler subject
to State Standard that is
equal to or less stringent
than NSPS, 8/17/71.
D. Other (unknown, undeter-
mined) .
FGD unit will be/was added to
an existing boiler not specifi-
cally designed to accommodate
FGD unit.
Date when initial S02 removal
began or is scheduled to
begin.
The gross rating (MW) of a
unit brought into compliance
with FGD, regardless of the
percent of flue gas treated at
the facility. In the case of
prototype and demonstration
FGD systems, this figure will
be identical to the Equivalent
Scrubbed Capacity rather than
the gross unit rating if the
system is not meant to bring
the facility into compliance
with S02 emission standards.
The total monthly lost genera-
tion hours due to FGD train
outages divided by the total
monthly expected generation if
the FGD trains would have been
available for operation,
expressed as a percentage.
City and State listed in
mailing address.
C-7
-------
Unit Name
Unit Rating
Gross
Net w/FGD
Net w/o FGD
Utility Name
Water Make-Up
Unit identification as it
appears in Electrical World -
Directory of Electrical Util-
ities, McGraw-Hill - Current
Edition - or as indicated by
utility representative for
installations in planning
stages.
Operational - Maximum con-
tinuous gross generation
capacity in MW; Preoperational
- maximum continuous design
generation capacity in MW.
Gross unit rating less the
energy required to operate
ancillary station equipment,
inclusive of emission control
systems.
Gross unit rating less the
energy required to operate
ancillary station equipment,
exclusive of emission control
systems.
Name of corporation as it
appears in Electrical World -
Directory of Electrical Util-
ities, McGraw-Hill - Current
Edition - as space permits.
Gallons per minute of make-up
water required per MW of
capacity.
C-8
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APPENDIX D
TABLE OF UNIT NOTATION
D-l
-------
TABLE OF UNIT NOTATION
D
I
ro
Classification
Area
Concentration
Flow
Heat Content
Length
L/G Ratio
Mass/Weight
Pressure
Temperature
Volume
English Unit
Acre
Square foot
Grains per standard
cubic foot
Parts per million
Pounds per million
Btu
Actual cubic feet
per minute
Gallons per minute
Pounds per minute
Ton per day
Ton per hour
Btu per pound
Foot
Inch
Mile
Gallons per
thousand actual
cubic feet
Pound
Ton
Inches of water
Degree Fahrenheit
Cubic feet
Acre-feet
Symbol
acre
ft2
gr/scf
ppm ,
lb/10 Btu
ft3/min
(actual)
gal/min
Ib/min
t/day
t/h
Btu/lb
ft
in
mi
gal/1000
ft3
(actual)
Ib
t
in. H20
°F
ft3
Acre- ft
Survey Report
Notation
ACRE
SQ.FT
GR/SCF
PPM
LB/MMBTU
ACFM
GPM
LB/HIN
TPD
TPd
BTU/LB
FT
IN
MI
GAL/1000ACF
LB
T
IN. H20
F
CU.F
ACRE-FT
ASTM/SI Unit
Square meter
Square meter
Grams per cubic meter
Parts per million
Nanograms per joule
Cubic meters per
second
Liters per second
Kilogram per second
Metric ton per day
Metric ton per hour
Kilojoule per
kilogram
Meter
Centimeter
Kilometer
Liters per cubic
meter
Kilogram
Megagram
Kilopascal
Degree Celsius
Cubic meter
Cubic meter
Symbol
M2
M
g/m3
ppm
ng/J
m3/s
liter/s
kg/s
M t/d
M t/h
kJ/kg
m
cm
km
liter/in3
kg
Mg
kPa
°C
m3
m
Survey Report
Notation
SQ.M
SQ.M
G/CU.M
PPM
NG/J
CU.M/S
LITER/S
KG/S
M T/D
M T/H
KJ/KG
M
CM
KM
LITER/CU.M
KG
MG
KPA
C
CU.M
CU.M
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REPORT NO*
EPA-600/7-79-022c
k TITLE ANDSUBTITLE
EPA Utility FGD Survey: December 1978 -
January 1979
AUTHOR(S) ._
M Smith, M.Melia, T.Koger, R.McKibben, and
J.Uihlem
f~ TECHNICAL REPORT DATA
202/755-8137)- Related reports are also in the EPA-
CTThe report is the first in a series generated by a new computerized data
base system and the first full compilation (not a supplement) since the December 1977
-January 1978 report. Because the next three reports are to be supplements, this
issue should be retained for reference throughout the year. This report differs from
the previous series in that the scope of design data for operating flue gas desulfuri-
zation (FGD) systems is expanded, section formats are revised, and a new section
includes operational particulate scrubbers. The report surveys utility FGD systems
in the U.S. It summarizes information contributed by the utility industry, process
suppliers, regulatory agencies, and consulting engineering firms. Systems are tabu-
lated alphabetically by development status (operational, under construction, or in
planning stages), utility company, process supplier, process, waste disposal prac-
tice, and regulatory class. It presents data on system design, fuel sulfur content,
operating history, and actual performance. It includes unit by unit dependability
parameters and discusses problems and solutions associated with the boilers and
FGD systems. Process flow diagrams and FGD system economic data are appended
to the report. Current data show 46 operating FGD systems, 45 systems under con-
struction, and 67 planned units. Projected 1988 FGD capacity is about 70,000 MW.
17.
KEY WORDS AND DOCUMENT ANALYSIS
a.
DESCRIPTORS
b.lDENTIFIERS/OPiN ENDED TERMS
c. COSATI Field/Group
Pollution
Flue Gases
Desulfurization
Electric Utilities
Waste Disposal
Boilers
Maintenance
Pollution Control
Stationary Sources
Utility Boilers
13B
21B
07A,07D
15E
13A
18. DISTRIBUTION STATEMENT
Unlimited
19. SECURITY CLASS (ThisReport)
Unclassified
21. NO, OF PAGES
450
20. SECURITY CLASS {This page I
Unclassified
22. PRICE
EPA Form 2280-1 (»-73) D~3
AU.S.GOVERNMENTPRINTINGOFFICE:1979 -6^0 -013/3906 REGIONNO.4
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