vvEPA
United States Industrial Environmental Research EPA-600/7-79-183
Environmental Protection Laboratory August 1979
Agency Research Triangle Park NIC 27711
Fabric Filter
System Study:
First Annual Report
Interagency
Energy/Environment
R&D Program Report
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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.
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EPA-600/7-79-183
August 1979
Fabric Filter System Study:
First Annual Report
by
K.L. Ladd, G.R. Faulkner, and S.L Kunka
Southwestern Public Service Company
P.O. Box 1261
Amarillo, Texas 79105
Contract No. 68-02-2659
Program Element No. EHE624A
EPA Project Officer: Dale L. Harmon
Industrial Environmental Research Laboratory
Office of Energy, Minerals, and Industry
Research Triangle Park, NC 27711
Prepared for
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Research and Development
Washington, DC 20460
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FIRST ANNUAL REPORT
FABRIC FILTER SYSTEM STUDY
ABSTRACT
This research program was initiated with the overall ob-
jective of characterizing the performance of a fabric filter
system installed on a large utility boiler that utilizes low
sulfur Western coal.
First year activities included installation of support
systems, start-up of fabric filter system and planning for
special test programs. Air flow tests were conducted in Octo-
ber, 1978, and the air flow rate was determined to be approxi-
mately 1.6 million acfm. Special testing is scheduled to begin
in December, 1978, allowing time for the system to reach a more
normal operating level.
This report is submitted in fulfillment of Contract No.
68 02 2659 by Southwestern Public Service Company under the
sponsorship of the U. S. Environmental Protection Agency. This
report covers the period October 1, 1977 to October 15, 1978.
11
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TABLE OF CONTENTS
Page
I. Introduction & Background 1
II. Executive Summary 3
III. Description of the System 4
IV. Start-up of Fabric Filter System 30
V. Testing 39
APPENDICES
A. Fabric Filter System Dustube Log
B. Typical Bid Request
C. Status of IKOR Instrumentation
D. Corrosion Coupon Assembly Drawings
E. Evaluation of Filter Bag Performance
iii
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LIST OF FIGURES
Figure 1 Combustion Air Flue Gas Flow Diagram
Figure 2 Government Furnished Property - Van #043310
Figure 3 Government Furnished Property - Van #043310
Figure 4 Input-Output Computer Flow
Figure 5 Manual Sampling Probes - Joint Detail
Figure 6 Manual Sampling Probes - End View
Figure 7 Flue Gas Monitoring Station, Harrington #2
Figure 8 Strip Chart, Baghouse Start-up
Figure 9 Typical Timing Sequence of Fabric Cleaning
iv
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LIST OF TABLES
I. Average Characteristics of Harrington Station Coal
II. Fabric Filter System Design Parameters
III. Fabric Characteristics
IV. FSS Program Name, Sublevel Number, and Function
V. S09/N0 Specifications Standard
£~ X
VI. Oo Specifications
VII. Stack Flue Gas Monitoring Specification
VIII. Air Flow Test Results
IX. Summary of Field Collection/Analysis Procedures
X. Elemental Analyses by Atomic Absorption Spectrometry
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CONVERSION TABLE
To Convert From
Btu/lb
°F
ft
gr/scf
in.
in. W.G.
Ib
miles
oz.
ppm
Btu
cfm
ft/sec
sq.ft.
Ibs. of tension
stack pressure in Hg
wscf/106 Btu
lbs/106
Ibs/wscf
ft2
To
joules/kg
°C
m
gm/m3
cm
mm Hg
gm
km
grams
mg/ liter
joules
cubic meters/hr
centimeters/sec
sq. meters
newtons
kg/cm2
wscm/ joule
nanogram/.ioule
micrograms/m3
meters2
Multiply by
4186.8
(°F-32)/1.8
0.305
2.29
2.54
1.87
454
1.609
28.350
1.0
1055
1.699
30.48
0.093
4.448
0.035
2.6 x 10'11
433.3
16.018 x 108
0.093
vi
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FABRIC FILTER SYSTEM STUDY
First Annual Report
I. INTRODUCTION & BACKGROUND
Southwestern Public Service Company is an electric utility
headquartered in Amarillo, Texas. The Company has a generating
capacity of 2740 MW and serves customers in Texas, Oklahoma, New
Mexico and a small area of Kansas. Harrington Station, South-
western's first coal-fired plant, went into operation in July,
1976, with one unit on line.
The basic problem in designing Harrington's second coal-
fired unit was the selection of a flue gas treating and control
system which would satisfy the Environmental Protection Agency's
New Source Performance Standards. Southwestern studied the
existing alternatives for controlling coal-fired boiler emis-
sions and an effort was made to select a type of emission con-
trol device which would not require scrubbing for particulate
removal.
The primary systems initially considered for particulate con-
trol were electrostatic precipitators. However, it was determined
that numerous utilities were having problems with hot side precip-
itators being used in association with low sulfur Western coal,
so this type of precipitator was not considered.
While obtaining bids and information from suppliers of elec-
trostatic precipitators some mention was made of the use of fabric
filters for particulate control. The use of this type of filter
system in Southwestern's service area is very common (the carbon
black industry) and after observing how fabric filters were ap-
plied at Sunbury and NUCLA a decision was made to compare electro-
static precipitators with fabric filter systems. After comparing
all parameters (design, operating, maintenance, costs) Southwestern
wrote a set of specifications and then negotiated a contract for
a fabric filter system to be supplied by Wheelabrator-Frye, Inc.
Only a small amount of information on the performance of
fabric filters at other utility installations was available when
-1-
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Southwestern Public Service was making its evaluation. Because
of that, Southwestern and the Environmental Protection Agency
agreed to make a comprehensive study of a commercial operating
unit. The study will require two years to complete the collec-
tion and assessment of one full operating year's worth of data.
Following the testing phase of the program, operational
and maintenance data will continue to be recorded until 1982,
to determine the long term reliability of the system. Special
tests will be conducted through the use of an on-site pilot
baghouse.
The objective of the study is to implement an overall pro-
gram of testing and evaluation design to (1) fully characterize
the fabric filter system applied to Harrington Station, Unit #2;
(2) study the technical and economic feasibility of the system;
and (3) determine the system's optimum operating conditions.
This report describes the work that was done during the first
year of study and assesses the project's achievements in rela-
tion to the objectives previously set forth.
-2-
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II. EXECUTIVE SUMMARY
Southwestern Public Service Company installed a fabric fil-
ter system on Unit #2 of its first coal-fired facility for the
collection of particulate from low sulfur Western coal. The in-
stallation is a 28-compartment Wheelabrator-Frye, Inc. baghouse,
which has several support systems, including an EPA mobile labora-
tory, a datalogging system and selected instrumentation.
The fabric filter system was started up on June 21, 1978. A
start-up plan was implemented by Southwestern to help avoid prob-
lems such as dew point and acid point conditions. Two compart-
ments at a time were brought on line and when pressure drop across
the baghouse reached 4" wg the cleaning cycle was initiated, along
with the fly ash conveying system. Subsequent to the initial
start-up, adjustments were made to the cleaning sequence, defla-
tion, pressure and shaker operation to optimize fabric cleaning.
Air flow tests were performed at Harrington Station to deter-
mine air flow through the fabric filter system. Southwestern*s
results indicate that the air flow rate is approximately 1.6 mil-
lion acfm at full load. During the second year of the study
special tests will be conducted by Southwestern Public Service
and its subcontractor, GCA, to measure specific parameters simul-
taneously at five locations so that the effect of the baghouse
on these parameters can be determined.
Other areas that are being assessed by the fabric filter
study include the corrosiveness of flue gases passing through
the baghouse and the performance of different types of fabric
filters. Corrosion test coupons have been installed in each of
the 28 compartments and will be removed periodically for analysis.
Compartments 7 and 22 have been equipped with different types of
bags for testing purposes. The test bags will remain in the com-
partments for the duration of the study. A procedure for testing
experimental bags is being developed.
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III. DESCRIPTION OF THE SYSTEM
A. Harrington Station
Harrington Station is located approximately five miles north-
east of Amarillo, Texas. Unit #2, on which the fabric filter is
installed, has a 350 MW turbine with a tangentially-fired steam
generator. The Combustion Engineering boiler utilizes low sul-
fur Wyoming coal to produce 2,688,000 pounds of steam per hour.
The average characteristics of the coal are given in Table I.
TABLE I
Average Characteristics of Harrington Station Coal
Moisture 28.26%
Ash 4.74%
Volatile Matter 32.00%
Fixed Carbon 35.00%
Sulphur 0.33%
Calorific value, as rec'd 8,425 Btu/lb
The fly ash laden flue gas from the boiler flows through the
preheater directly through the fabric filter system and then out
the stack. A diagram of the system is shown in Figure 1.
B.' Fabric Filter System
The emission control device selected for Unit #2 is a Wheela-
brator Frye, Inc. fabric filter baghouse system. The baghouse
is designed to operate at a flue gas flow of 1,650,000 acfm at
313° F. Minimum design efficiency is 98.6%, which would permit
0.1 pounds of particulate/million Btu out the stack. The exterior
of the baghouse has 3.5 inches of fiberglaas insulation; there is
no insulation between plenums and compartments. Other design
parameters are summarized in Table II.
The filter bags are suspended from a shaker mechanism by a
hook and a J-bolt spring to maintain a design tension. The bags
are fastened at the bottom to a thimble with a clamp. Table III
gives the fabric characteristics.
-4-
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TABLE II
Fabric Filter System Design Parameters
Compartments 28
Bags/compartment 204
Bag manufacturer W. W. Criswell Divn.
Wheelabrator-Frye, Inc.
Model No. 366, Series 11.5 RS Dustube
Bag diameter 11.5 in.
Bag length 30.5 ft.
Bag spacing, center to center 14.0 in.
Air to cloth ratio, gross 3.16:1
w/1 compartment down 3.27:1
w/2 compartments down 3.40:1
Bag reach 2
TABLE III
Fabric Characteristics
Maximum operating temperature 550° F (288° C)
Thread count 66 x 30
Weight 10.5 ounces/sq. yd.
Permeability at 0.5 in WG 45-65 cfm/ft2
Cloth material Fiberglass
Finish Silicon/Graphite
The baghouse is provided with bypass dampers and start-up,
emergency operation and shut down. There are two baghouses on
Harrington Unit #2, one designated East and one designated West.
Each one has its own operating control system and all bypass
dampers are separated for each system. These are poppet type
dampers which are 68 inches in diameter; they can be operated
independently of each other. For each compartment there are
the following dampers.
Type Diameter Operated
1. Outlet Poppet70 in.motor
2. Reinflation Poppet 12 in. motor
3. Deflation Poppet 30 in. motor
4. Inlet Butterfly 60 in. manually
Bag cleaning is accomplished by a combination of reverse
air and gentle shaking. During normal filtering sequence, out-
let and reinflation dampers are open and the deflation damper is
closed. During cleaning cycles the reinflation and outlet dampers
-6-
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close, leaving only the inlet damper open. After an initial
settle period the deflation damper opens, which pressurizes the
clean side of the bag. This pressure breaks up the filter cake
collected on the dirty side of the bag.
After a settle period the shaker motors are energized
briefly to shake off the remaining filter cake. After a final
settle period the reinflation and outlet dampers open, putting
the compartment back in service.
The Unit #2 fabric filter system has four cleaning cycle
modes which were designed to provide maximum flexibility of
operation. Mode 1 will clean the West baghouse only and then
the control system will reset; Mode 2 will clean the East bag-
house and reset; Mode 3 will clean compartments 1 through 28
before the system is reset; Mode 4 will clean the East and
West baghouses simultaneously, one compartment at a time on
each baghouse.
Maintenance of the baghouse is accomplished periodically
by inspecting individual compartments for signs..of failure (such
as holes or slackness of bags). There have been five bag failures
to date and in September a decision was made to retension the bags
to maintain 60 pounds. A Fabric Filter System Dustube Failure
Log (See Appendix A) is utilized by inspection personnel to re-
cord where, when and why failures occur; these forms are kept
on file at Harrington Station.
Maintenance inspections also revealed minor problems with
the shaker mechanism. These maintenance items were primarily
lubrication and adjustment of the shaker mechanism (one or two
pins in the linkage were replaced).
It is anticipated that when a method for cooling compart-
ments prior to entry by inspection personnel has been worked out,
it will take 2 to 2% hours to cool down an individual compartment.
It is then estimated that 15 or 20 minutes would . be required
for single bag replacement.
-7-
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C. Support Systems
1. EPA Trailer: In order to accommodate the extra equip-
ment and personnel required for special testing, it was felt a
mobile facility should be made available for use during the
testing phase of the project. System Lab personnel surveyed
the local market, but were unable to find a trailer that met
the requirements for a test facility. In March, 1978, Kenneth
Ladd, Project Manager, was informed by EPA that a Government-
owned, 30-foot trailer was available for project work. Upon
approval by the Project Officer and completion of EPA paper
work, the trailer was sent to Amarillo and received by South-
western Public Service on May 12, 1978.
The trailer was delivered to the System Lab where it was
inspected and a list of necessary repairs and refurbishing
items was made. Some of the repairs that were made included
painting the outside of the trailer and securing paneling
on the inside that had come loose. Electrical, plumbing and
lighting installations were inspected and determined to be in
satisfactory condition.
Upon completion of needed repairs, the mobile lab was
moved to Harrington Station and parked underneath the baghouse,
north of the control room. This position offers natural pro-
tection from the elements and is also easily accessible from
the different sample locations. The trailer will remain at
this location for the duration of the project (see Figures 2
and 3 for layout of the EPA trailer).
2. Datalogging System: One of the objectives of the fab-
ric filter study is to correlate manual sampling results with
operating data to define the performance of the fabric filter
system. The parameters listed below are being continuously
monitored at five points in the flue gas stream:
S02 N0x 02 Particulate (grain/cu.ft.)
Flue gas flow (acfm) Temperature (except in stack)
Duct pressure (except in stack).
-8-
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DEMONSTRATION TEST ON
FABRIC FILTER SYSTEM
Contract No. 68-02-3659
Southwestern PUBLIC SERVICE Company
DRAWING NO.
-------
Additional operating parameters being measured or calcu-
lated on a continuous basis are pressure drop across the system,
power consumption, load on the unit, fuel flow, particulate re-
moval, cleaning mode and frequency, and flue gas flow. This
data will not be as specialized as the manual sampling infor-
mation, but rather will represent every day operation of the
fabric filter system.
The Fabric Filter System (FSS) programs are executed under
the sublevel processor of the Harrington Station, Unit #2,
computer. The plant computer is a Westinghouse Model W2500,
16 bit, real time computer with a one million word disc and
64 K words of core. All contact and analog inputs from the
five sampling stations are brought into the computer, which
also has access to other performance parameters concerning the
plant.
The FSS data collection package is modular in nature (i.e.,
each program is independent of the others, but accomplishes a
specific function necessary for the successful operation of
the package). Each program in the package is disc resident
and is assigned a unique sublevel number. Table IV lists
each program name, sublevel number and general function.
A general software overview is illustrated in Figure 4.
On the left of the figure are the inputs to the programs and
on the right are outputs. FSS1, the first program to run, moni-
tors the position of the baghouse outlet dampers and the bypass
dampers. If an outlet damper is closed for more than 10 minutes
out of the hour, a bit in the core resident out-of-service flag
(OSV) is set. If a bypass damper is opened once during the hour
a corresponding bit is also set in the same flag word. This pro-
gram also decides when it is time to print the daily baghouse
summary log and output to magnetic tape. (Note: The magnetic
tape is not operational; parts have been re-ordered and should
arrive in approximately four months).
FSS2 is the second program to run and monitors the status
of the instrumentation at the five sampling ports. Based on
-11-
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TABLE IV
PROGRAM
NAME
FSS \
FSS a
F5S3
PS54
FSS5
FSS4T SERVICE. TIME.
MONITORS IWSTRUMENTA-TJON PAULT
-------
IMPUTE
CLOCK. EVERY
MINUTE
OUTPUTS
CONTACT INPUTS
28 BAGHOUSE COMPARTMENT PAMPERS
£ BTPASS (TAMPERS
_L
T
COMTACT INPUTS
38 FAULT AMP CALIBRATION
INPICATOR'-s
AMALOOr IMPUTE
ANALOCr INPUTS
aS AMALO& SIGrN&LS PROM
SAMPLING
CORE FLAGS { OSV
CORE FLACrS
osv---
K
/PU
r
PUNT VALUES
._ AN
BV AVERA&E
iNTEQrRATE
c
COC?£
BIP PROM \
F5Si AT IZJOAM)
OR
A&1P PROM ~"
(OPERATOR
TAPE
FIGURE 4. INPUT-OUTPUT COMPUTER FLOW
-13-
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contact closures from the equipment three modes of operation
are detected: normal, fault, and calibrating. Some of the
devices undergo an automatic daily calibration which is recog-
nized by a contact closure. The program then checks that the
zero and span calibration readings are within allowable limits.
If a calibration check shows an instrument to be in error,
an alarm is generated on the alarm CRT and all data from the
instrument is flagged as questionable. When an instrument is
in either the calibration or fault mode the sampling program
is inhibited from collecting data from that instrument. The
program uses information from the FSS Common to determine what
each of the 32 contact inputs represent and stores information
in FSS Common regarding the status of the instrumentation. FSS
Common is a 100-word sector of disc that serves as a common
data pool for all FSS programs.
The third FSS program uses the FSS Common to determine which
inputs are to be sampled and which are to be ignored due to a
fault condition or a calibration check. FSS4 maintains a
running total of every input from the five sampling stations.
Since a point may be sampled a different number of times in any
hour a sample counter for each input is incremented every time
a sample is taken. An averaged value is then determined by
dividing the running total by the number of samples. This pro-
gram also calculates, every minute, a corrected mass flow rate,
the energy consumption for both baghouses, and keeps a running
total of these quantities.
Every hour, the fourth FSS program is run. FSS4 uses the
data collected by FSS3 and stored in FSS Common on disc to cal-
culate hourly averages of the s.ampled inputs by dividing the
running totals by the number of samples taken. This program
calculates performance parameters based on these hourly average
values. If coal is being fired, particulate loading, pounds of
particulate loading, pounds of particulate per million Btu and
pounds per million Btu of fuel input of S09 and NO are calculated.
Z. X
-14-
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Removal efficiencies for particulate, SO,,, NO , and 09 and
Z» X £,
the temperature drop across both baghouses are also calculated
by this program. The air-to-cloth ratio of each baghouse is
determined by counting the number of compartments out of ser-
vice for the hour as represented by the core resident out-of-
service flags and the uncorrected mass flow rates. The program
records various plant performance data that is to be put into
the log.
All of the hourly averages, calculated data, and recorded
plant parameters are then written to one of 24 hourly result
files. Data collected between midnight and 1:00 a.m. will go
to the first file (hour #1), data collected between 1:00 a.m.
and 2:00 a.m. will go to the second file (hour #2) and so on
until the data collected between 11:00 p.m. and midnight will
go to the 24th hour (hour #24). Since several other data logs
are printed at midnight the FSS ~ summary log is not printed
until 00:30 a.m.
The FSS summary log is implemented by use of two programs.
The first of these, FSS5, prints the page headers and column
titles on each of the six pages of the log. These headers and
titles are stored on disc and can be changed by using the
utility programs described later. Rather than outputting di-
rectly to the printer the FSS summary log programs output data
to the Westinghouse Message Writer Program. In this mode data
is stored in a disc file until the computer has time to output
it to the printer. Additionally, it allows the log to be out-
put to magnetic tape by doing one call.
The second of these log programs, FSS6, prints the actual
hourly data and flags values that are questionable because of
calibration check failures. After the first.page of data has
been printed, FSS6 does a time delay of one minute, and then
calls FSS5 which will output the page headers and column titles
for the second summary log page. FSS5 will then call FSS6 to
-15-
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output the second page of hourly data, and when finished will
delay another minute and call FSS5. This process continues
until all six pages of the FSS summary log have been printed by
the message writer. The one minute time delay allows the message
writer to empty its buffer, before the next page of print is
loaded into this buffer. After the sixth page is output the
program time delays for three minutes and then FSS5 is called
which resets the core resident control flags and determines if
the log should be output to magnetic tape. The log goes to
magnetic tape only if the log programs have been run automatic-
ally by FSS1.
The FSS software package provides two means of initiating
printing the FSS summary log. The first occurs automatically
every day and produces the 24-hour printed data that is also
stored on magnetic tape. The second means is a push-button
labeled "Baghouse Log" on the control room operator's console.
When this button is pushed the hourly results can be output by
setting one of the core resident control flags equal to the
previous hour. The demand button is inhibited from calling
the FSS summary log between 11:15 and 1:05 which avoids the
possibility of the log being demanded at a time that would
interfere with the automatic daily output of the log. A mes-
sage is returned to the operator telling him that he cannot
demand the log now.
To facilitate modification of the page headers and the
column titles, a program was written to allow these titles to
be read in from cards and arranged in the proper format and
placed in the page header and column title disc files. Com-
plete instructions for usi^g this program are found in the
program listing.
-16-
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3. Instrumentation (select, purchase, install): Speci-
fications for monitoring equipment needed to meet the study's
requirements were submitted to bidders in October, 1977 (see
Appendix B for typical Bid Request). A review and evaluation
of bids was completed in November, 1977. Lear Siegler and IKOR
were the vendors selected. The following equipment was purchased.
Four (4) Lear Siegler SM800 S02/M0 Monitors (see Table V)
for specifications). The Lear Siegler SM800 Stack Gas
Monitor is an "in situ" measurement system for sulfur
dioxide (SC^) and nitric oxide (NO) concentrations in
stack emissions. The SM800 is a second-derivative spec-
trometer that specifically measures the narrow band
absorption of ultraviolet energy in S02 and NO molecules.
The spectrometer consists of an optical transmitter/
receiver (transceiver) unit which is mounted on the side
of a stack plus an integral probe that projects into the
stack flue gas stream. The light source, monochromator
detector, and electronic circuitry are contained in the
transmitter unit, while a special retroreflector and gas
measurement cavity are housed in the end of the probe.
Outputs from the transceiver are transmitted to the bag-
house control room converter unit. In the baghpuse con-
trol room the signal is monitored and recorded on a back-
up analog recorder. A second 4-20 ma output is trans-
mitted to the plant computer located in Unit #2 control
room.
-17-
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TABLE V
S09/N0v SPECIFICATIONS STANDARD
^ J*
Requirements:
1. Monitoring - to meet specifications, continuous output
2. Analyzer Span - S02 0-1500 ppm
NO 0-1000 ppm
A.
3. Meet specifications of EPA, CFR Title 40, Part 60, Appen-
dix B, of October 6, 1975 as to accuracy, calibration and
operation
4. Recorded on strip chart in control room at plant
5. Zero and span calibration checked daily
6. Location of monitor
a. >^ 1.0 meters from sides of stack or duct wall
(6' long from outside wall)
b. Monitor representative concentration
c. In-leakage of air will not change the concentration
before emission to atmosphere
7. Required accuracy by EPA
Accuracy ±20% of Ref. X value
Cal. Error £ 5% of each cal. gas (50%, 90%)
Zero Drift { 2 hr) 2% of span
Zero Drift (24 hr) 2% of span
Cali. Drift ( 2 hr) 2% of span
Cali. Drift (24 hr) 2.5% of span
Response Time 15 minutes (max)
Operational Period 7 days (min)
8. Required Certification - on site operation
Conditioning Period 7 days
Operational Test 7 days
NO 27 measurements (3/hr) ±2070 correlation Method 7
A.
S02 9 measurements (1/hr) ±2070 correlation Method 6
Accuracy same as above (#7)
-18-
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Table V continued
S02/NOX Specification Standard
9. Data Collection - 4 or more readings/hr continuous output to
recorder
10. Data Recorded
a. Hourly averages of S00 and NO
£» X
b. Heat content of fuel
c. Percent of each fuel
d. Integrated MW coal
e. Any parameters used in calculations
11. Calculations
a. Conversion to correct units Ibs/million Btu
E = C • F (20.9)
(20.9(l-Bwa)-7«,02)
where
E = emissions (lbs/106 Btu)
F = ratio of dry flue gases to heat constant (wscf)
(106 Btu)
C = pollutant concentration (Ib/wscf)
Bwa = .027
The last factor will determine the mass flue gas flow attri-
buted to excess air
b. 1 hr averages
c. Excess Emissions (only at stack locations) - alarmed and
printed when exceeds equation
E. = (% Btu in Coal) (1:2)
S02 (70 Btu on Coal + % Btu on gas)
EA = \°L Btu on Coal) (7.0) + (%Btu on gas) (.2)
NOV (7oBtu on Coal + % Btu on Gas)
•A.
Using hourly average concentration convert to Ib/MBtu
-19-
-------
Four (4) Lear Siegler CM50 Oxygen Analyzer Control Moni-
tors (see Table VI for specifications). The Lear Siegler
CM50 in-stack oxygen analyzer is an in-situ system for
the measurement of excess oxygen in combustion process
flue gases which includes automatic, unattended cali-
bration checks. During each calibration cycle (once
every 24 hours) the calibration gas floods the measure-
ment side of the cell, providing a low-level calibration
point. The CM50 measures the excess oxygen in a flue gas
using a proprietary, yttria-stabilized, zirconium oxide
fuel cell type sensor. The probe is electrically and
pneumatically connected to the central unit located near
the probe. The partial pressure of oxygen in the flue
gas is compared to the reference gas providing an output.
The cell output is a function of oxygen content of the
flue gas. The control unit performs the signal processing
and transmits all information to a remote readout unit
located in the baghouse control room.
The excess oxygen percentage is recorded on the bag-
house control room's analog recorder. The primary re-
cording of the oxygen levels is done by the plant computer,
These oxygen percentages are used for normalizing the sul-
fur dioxide and nitric oxide emission levels on a wet
basis per EPA's alternative monitoring requirements.
-20-
-------
TABLE VI
02 SPECIFICATIONS
Requirements:
1. Monitoring - continuous output, used to determine the
effects of excess air on the flue gas mass flow
2. Analyzer span - 0-10% 02
3. Meet specifications of EPA CFR Title 40, Part 60, Appen-
dix B, as to accuracy, calibration and operation
4. Recorded on strip chart in control room
5. Zero and span calibration checked daily
6. Location of monitor
a. >. 1.0 meter from stack wall (6* long probe from outside
of wall)
b. On stack in location to monitor representative
concentration
7. Required Accuracy by EPA:
Zero drift (2 hour) <. 0.4% 02
Zero drift (24 hour) < 0.5% 02
Calibration drift (2 hour) <_ 0.4% 02
Calibration drift (24 hour) <_ 0.4% 02
Operational period 7 days (min)
8. Required Certification - on site operation
Conditioning Period 7 days
Operational Period 7 days
(2 hour) Field Test &
Span Drift <. 0.4% 02
(24 hour) 15 -.sets of Data
@ 2 hour intervals <_ 0.5% 02
9. Data Collection - 4 or more readings/hour, continuous
output to recorder
LO. Data Recorded - 1 hour averages
LI. Calculations - Oo is used in emission equation
The hourly average value will be used.
-21-
-------
One (1) Lear Siegler Opacity Monitor (see Table VII for
specifications): The Lear Siegler RM41 Visible Emission
Monitoring System is a transmissometer which measures light
transmittence through an optical medium such as smoke or
dust. An optical transceiver unit mounted on one side of
a stack and a reflector unit on the opposite side comprise
the transmissometer. A light source, a detector, and elec-
tronic circuitry are all contained in the transceiver and
only a special retroreflector is housed in the reflector
unit. The dual-beam measurement technique automatically
and continuously corrects the measurement for variations
in temperature, line voltage, lamp aging and component drift
or aging.
Output from the transceiver is transmitted to the baghouse
control room converter unit that simultaneously provides
an indication of optical density and opacity corrected to
stack-exit conditions. The opacity is recorded in the
baghouse control room on a back-up analog recorder. A
second 4-20 ma output is transmitted to the plant computer,
which is the primary recorder.
Four (4) IKOR Continuous Particulate Monitors: The IKOR
Model 2710 In-stack Continuous Particulate Monitor System
is designed to meet many requirements for in-situ measure-
ments of particulate concentration on a continuous, real-
time basis. The in-stack sensor probe, a bullet-shaped
sensor manufactured of highly corrosion resistant metals
and alloys, is electrically isolated from the wall of the
probe by an-insulator. The ceramic insulator is isolated
from the direct gas and particulate flow by a metal hood.
To optimize particle impaction the sensor is faced directly
in the air stream.
-22-
-------
TABLE VII
STACK FLUE GAS MONITORING SPECIFICATION
OPACITY
Requirements:
1.
2.
3.
4.
5.
6.
7.
8.
Monitoring - Transmissometer: continuous output
Meet Specifications of EPA CFR Title 40 Part 60 as to
measurement, accuracy, calibration, operation
Recorded on strip chart in control room
Zero and span calibrations checked daily
Monitor mounted on stack. It will transverse a diagonal path
Required Accuracy by EPA
a. Spectral Response
b. Angle of view
c. Angle of projection
d. Calibration error
e. Zero Drift (2 hr)
f. Calibration drift (24 hr)
g. Response time
h. Operational period
Data collection
Calculations
a. Average (10 sec)
b. Average (6 min)
Data Recorded
a. 6 min. averages
b. Hourly opacity
c.
Photopic
5
5°
<_ 3% opacity
<_ 27o opacity
<_ 27o opacity
10 sec. (max)
7 days (test)
10 sec. readings, continuous output
6 min
1 hr
10,
10 logged/hr
(average of 6 min averages)
Continuous output to recorder
Alarms
a. 6 min average >_ 20%
-23-
-------
The probe senses a charge transfer which occurs when
two dissimilar materials come in physical contact, either by
direct impact and/or sliding and rubbing (triboelectricity).
Upon collision between particles in the flowing gas stream
and the electrically isolated sensing probe, a charge trans-
fer results in the flow of a small electrical current. This
current or work function is the difference between the Fermi
energy level (maximum quantum energy level) of the particu-
lates and the zero energy level of the metal sensor.
During instantaneous contact, the equilibrium state
requires that the Fermi levels coincide with the surface
having the higher energy level equal to the lower energy level.
This gives rise to a contact potential difference. When con-
tact is suddenly broken (as in a continuous flow condition)
the body having the lower work function becomes negatively
charged. In this way, a metal sensor subject to collision
by a particulate cloud can give an electrical current as a
signal due to redistribution of charges from particle impact.
The current output from the sensor probe connects to an
electronics module attached to the external end of the probe
and is transmitted to the 2710 control unit located in the
baghouse control room. In this system a signal is produced
equal in magnitude to the current generated by charge transfer.
This signal is amplified and converted into an output related
to the particulate charge transfer. In the compliance moni-
toring mode the electronic signal is recorded on an analog
recorder in the baghouse control room and integrated over
a finite period of time. This integrated output is scanned
by the plant computer.
The specifications of the IKOR 2710 are:
a. Recommended particle size 1 ym to 10 ym
b. Gravimetric weight gain to
electronics signal One sigma standard
deviation: > ± 10%
-24-
-------
One (1) Ellison Instruments' Annubar: The annubar Type 86
Flow Sensor is an annubar averaging velocity head sensor for the
natural measurement of flow through a duct or stack. The sensor
is comprised of four computer-located, upstream ports to provide
an average upstream pressure and one downstream or static pressure
port. The annubar sensors do not clog in flows with normal amounts
of dirt and debris. The high pressure center created by the flow
forms a buffer, which keeps the pressure sensing ports clean.
The differential pressure between the upstream and down-
stream ports is proportional to the square of the fluid velocity.
The sensor is connected to a differential pressure device for
data transmission to the baghouse control roorrfs analog recorder
and to the plant computer.
The following specifications are for the annubar Type 86
Sensor:
a. Extra heavy duty insert-type sensor (2.375" o.d. probe)
b. Supported on both sides of duct
c. 5/8" diameter sensing ports
d. Designed for stack handling gases up to
1200 F for large size stack and ducts
e. 316 stainless steel construction material
f. Accuracy: ± 2. 370 of actual flow
g. Approved by U. S. Government GSA PBE-4-1590
Twenty (20) Leeds and Northrup recorders for recording
other operating parameters.
In addition, miscellaneous support equipment, thermocouples,
and flow transmitters were purchased and a software program was
developed. Delivery of the equipment began in February, 1978,
and continued through April. Mounting, piping and wiring of
the instruments took place in May and June and during July and
August of 1978 the Lear Siegler monitors were checked out,
started up and calibrated (Southwestern notified Lear Siegler
of bad components before equipment could be started up under
warranty). The Lear Siegler SM800 probes had to be sent back
-25-
-------
to the factory and were not returned to Southwestern until
July, 1978.
Start-up of IKOR instrumentation began in July, 1978. The
IKOR field man requested the IKOR probes be returned to the fac-
tory for modification and they were sent back to Southwestern
in August. The IKOR instruments still do not operate properly.
A summary of some of the problems remaining to be resolved can
be reviewed in Appendix C. Numerous efforts by Southwestern
and IKOR engineers have failed to produce recordable data. It
is anticipated that early in November Southwestern will advise
IKOR of a deadline for repairing the equipment. A report on
the IKOR situation is presently being prepared to determine what
steps to take to get the equipment to function properly.
By September, 1978, the Lear Siegler equipment was installed
and most of the initial installation problems had been resolved.
The equipment (with the exception of the IKOR monitors) seems to
be performing in an acceptable manner. The equipment calibrates
itself every 24 hours. These readings are fed into the computer
where they are verified within EPA limits. If one parameter is
out of the accepted range, the computer will sound an alarm and
the problem is identified and corrected. A record of each problem
is maintained at the plant that indicates the date, time, how it
was repaired and when the items went back into service. Strip
charts are also filed at the plant after they have been changed.
The maintenance record indicated the following problems have
been experienced since the start of the Lear Siegler equipment but
they have all been resolved by Southwestern personnel.
1. UV lamps on S02 monitors malfunctioned.
2. Problem encountered with probe alignment (photomultiplier
tube).
3. Problem encountered with transceiver card.
4. Replaced a power transformer and power supply card on the
Q analyzer.
-26-
-------
5. Had to make adjustments to the temperature control card.
6. Resolved the problem on percent (^ card for the C^ analyzer.
7. Encountered some difficulty in putting in scan gas and other
known gases to certify the equipment to be sure it was reading.
Manual sampling equipment was purchased from Lear Siegler
and Accurex. Four sampling.probes were designed by Olon Plunk
and Steve Jones (Southwestern employees) and were built at
Harrington Station by instrumentation personnel (the fifth probe
was already on hand)(see Figures 5 and 6, Manual Sampling Probe).
Probe liners were purchased from Accurex. Two PM100 Consoles
were purchased from Lear Siegler but because they did not meet
specifications were sent back. Two manual sampling control units
to be used on the outlet were then designed and built by South-
western's System Lab. In addition, four vacuum pumps for NO
X
testing were purchased from Fisher Scientific. The manual sam-
pling equipment remains to be certified but will be certified in
time for special testing.
The majority of the glassware required for the testing pro-
gram was purchased from Ace Glassware.
-27-
-------
-j.o "if£). - JJ" "O. £>.
75
-------
tit til I' "' I " "l">< I? "" ' ""»''''' 11' I
-------
IV. START-UP OF FABRIC FILTER SYSTEM
A. Start-up Plan
Before a start-up plan was formulated for Harrington Sta-
tion baghouse, an investigation was made of other fabric filter
system start-ups. Southwestern personnel visited with other
utilities which have baghouses in operation and sought the ad-
vice of start-up personnel at various locations (particularly
at Kramer and Sunbury Stations). Individuals known to have ex-
pertise in the start-up of these systems, such as Rowan Perkins,
Dupont, and Fred Cox, Menardi Southern, were consulted. Addi-
tionally, a literature survey was made and the recommendations
of various manufacturers were studied and discussed with the
Wheelabrator-Frye representatives.
The following considerations were used to plan the start-up
procedures so that minimum difficulties would be encountered.
1. Orient operators.
2. Check out equipment.
3. Avoid dew point and acid point conditions.
4. Preheat compartments.
5. Condition and precoat the fabric.
6. Start up with natural gas through the boiler.
7. Change from natural gas to coal with flue gas going through
the baghouse as quickly as possible.
8. Designate specific sequence for compartments to be brought
on-line.
9. Add additional compartments as load increases.
10. Monitor required operating parameters during start-up and
the first cleaning sequence, such as inlet, outlet tempera-
tures; baghouse AP and opacity.
B. Actual Start-up Procedures
Because Harrington Station, Unit #2, was capable of start-up
on natural gas, the baghouse was bypassed for several weeks be-
fore it was started. During this phase all dampers were closed
in order to completely isolate the baghouse and to prevent con-
cdensation of flue gas in the baghouse. Because no dampers are
-30-
-------
1007o leakproof, however, all compartment doors were left open
in order to pull fresh air into the baghouse and to prevent
any leakage of wet flue gas into the compartments.
With all baghouse compartments still isolated from the flue
gas, all hopper heaters were energized for two or three days
prior to start-up in order to help preheat the compartments.
Since the unit was on-line but not firing coal, all bypass
dampers were open and the unit had approximately 200 MW load
on the boiler.
The planned start-up consisted of maintaining a consistent
200 MW load, increasing coal flow and decreasing natural gas
flow to the boiler; a minimum condition of at least 507o gas
firing was desired. Once the air preheater gas-out temperature
was at least 300° F on the East and West sides, the baghouse was
ready for start-up.
It was planned to bring two compartments on line at a time
until half of them were in service, because the unit would be
at half load (see Figure 7). The following procedure was
selected:
Bring in Service: Close:
Compartments 1 and 3 1st bypass damper on West
Compartments 16 and 18 1st bypass damper on East
Compartments 5 and 7 2nd bypass damper on West
Compartments 20 and 22 2nd bypass damper on East
Begin closing bypass dampers slowly
Compartments 9 and 11 3rd bypass damper on West
Compartments 24 and 26 3rd bypass damper on East
Compartments 13 and 2 4th bypass damper on West
Compartments 28 and 15 4th bypass damper on East
Once these steps were completed the baghouse would be in service
with the ash laden flue gas passing through the fabric filter
system.
At this point it should be noted that, as with all start-
ups, not everything proceeded as planned. The following events
actually took place during the start-up.
-31-
-------
West Outlet Monitoring Station
(Id's 1,2,3,4,5) \
<
^»,
1 .-.
3 "^
5 -^
West Baghouse 7 —
"*" 9 ,_
•^H*
11 ^
13 _
^^
West Inlet Monitoring Station
(Id's 1,2,3, 5) '
.MONITOR LOCATION
OUAN. DESCRIPTION MON.I.O.NO.
5 0, MONITOR t
4 IXOR 2
3 SM 800 NO, SO, 3
, 2 ANNU8AR 4
3 THERMOCOUPLE PROBE* 3
i OPACITY MONITOR | 9
••Hl^iH
f
r^L ®
-'
\s
V
y
i
•
^
I
— • 2
cru
cr 5
<:a
— 10'
<^2
••—
15 r:
L7 =s
19 ^
2! -;.
23 ^
25 ^
27 _
i pM i
u
k
\ —
u
.^ \
A
— »<
^•••B
^
A
^1^^^
1
y\
^A,
^
A
V
^
A
^
A
i
HH
Stack Monitoring Station
(ld*'s ,3,6)
East Outlet Monitoring Station
d is
-± 13
^ZO
^22 East Saghouse
^ ^
^23
East Inlet Monitoring Station
-^(Id's 1,2,3,5)
NORTH
Sailer
FIGURE 7. HARRINGTON NO. 2 FLUE GAS MONITORING STATION
-32-
-------
Compartments 1 and 3 were initially brought into service
and the first bypass damper on the West side was closed. Com-
partments 16 and 18 (East) were brought into service and the
first bypass damper on the East side was closed. At this point
the Wheelabrator-Frye service engineer felt that the AP across
the bags was too high (approximately 0.9" WG). He felt that a
AP around 0.7" WG and 0.8" WG would be better; therefore, another
compartment was brought into service on each side. During this
time the initial compartments put in service were developing fly
ash cake and the AP was still slowly increasing. Because of the
sufficiently high inlet and outlet temperatures through the bag-
house and the bag AP it was decided to bring into service an
additional four compartments on each side before closing another
bypass damper. After a total of seven compartments were in ser-
vice on each baghouse the second bypass damper was closed. The
remaining compartments on both East and West baghouses were
brought into service with only two bypass dampers on each bag-
house in closed position. Thus, all 28 compartments were in
service. At this point the remaining two bypass dampers on
each baghouse were ready to be closed. These bypass dampers
were closed slowly and the effects on opacity can be seen in
Figure 8, which shows a marked decrease in opacity only after
the last bypass damper on each side was closed. At this point
the baghouse was completely in service with the fabric being
conditioned. The elapsed time, between first compartment being
brought into service and the last bypass damper closed was 3
hours and 50 minutes.
Boiler load was maintained at 200 MW with primary fuel sta-
bilized as coal and only the igniter natural gas in service.
The baghouse AP was approximately 1.2" WG. The bag coating
was expected to require approximately 20 hours before reaching
a pressure drop of A" WG. When pressure drop across the bag-
house approached 4" WG, which took approximately 32 hours at
200 MW, the timing circuit control power was turned on and the
-33-
-------
FIGURE 8. STRIP CHART, BAGHOUSE START-UP
-34-
-------
cleaning mode selector was placed in Mode 3, which allowed the
system to clean one compartment at a time.
The deflation fan was started for the Mode 3 operation. When
the pressure drop reached 4" WG the cleaning cycle was initiated,
along with the fly ash conveying system.
C. Problems Encountered/Resolved
Approximately three weeks after the fabric filter system was
initially started, Southwestern was able to operate Harrington
Station, Unit #2, at full load (362 MW) with only coal in service.
The unit has operated at loads consistently above 200 MW and during
the peak periods it has had 350 MW.
Adjustments have been made to the cleaning sequence, defla-
tion, pressure and shaker operation to optimize fabric cleaning.
At this point it is felt that bag life is a major factor in over-
all performance and in the coming months, Southwestern plans to
continue to evaluate very carefully the cost of operating expenses
due to fabric replacement and the AP power requirements.
The procedure for making adjustments in the cleaning sequence
is to change only one.of the settings at a time. Figure 9 shows
adjustments made in the initial timing sequences. The baghouse
is then allowed to operate several days in a cleaning sequence
and an evaluation of the effects is made. Efforts have been made
to shorten the interval times and settling times, and increase
the shake time. The variation for shake time has been changed
from 5 to 30 seconds; for one adjustment the deflation sequence
was set so that no deflation pressure occurred. Over a period
of several days the baghouse AP began to increase, at which time
the deflation pressure was readjusted to be maintained below
0.3" WG. The fabric began to clean again with a 2.0" WG improve-
ment within two hours after the readjustment.
Initially the deflation AP across the fabric was specified
to be 0.6" to 0.8" WG. As load was varied.with a manually con-
trolled damper on the deflation fans, the deflation AP was not
-35-
-------
INTERVAU
TIMER
OFF
ON
CLOSE
COMPT. OUTLET
« SETTLE
TIMER
ON
OFF
DEFLATION)
TIMER
ZEC.
IOSE(
«
6O SEC.
1 sec.
i
o.
xj
-------
consistent; therefore, some "pancaking" of the bags occurred due
to over-deflation. Manual control of the deflation AP is diffi-
cult to impossible to control with load change.
The bags were initially installed with 40 to 45 pounds of
tension. The daily inspections indicate that during the defla-
tion cycle of the cleaning sequence a double fold of the fabric
results just above the thimble. Lab tests performed by the ven-
dor indicate that a bag tension of 60 pounds removes the double
fold.
The baghouse was to have operated with a AP of 5" WG flange
to flange with a 3.4:1 air-to-cloth ratio. Higher AP readings
than 5" have been experienced; therefore, an investigation was
undertaken to determine the mass flow of flue gas. This test
was inconclusive, and later pitot transverses along with stochio-
metric calculations seemed to indicate the unit runs at design
gas flow af full load. More transverses, however, will be con-
ducted in the near future.
A pitot tube and air flow monitoring check was made at the
3.4:1 air-to-cloth ratio. The AP across the system is still
running in excess of the predicted 5" WG; therefore, additional
cleaning cycle schedules are being planned and made to optimize
the AP and the cleaning sequence relative to bag life versus
operating pressure differential.
Recent decisions have been made on additional changes which
would help the fabric filter operate more effectively. These
changes include:
1. Bags were retensioned to a setting of approximately 60
pounds on September 21.
2. Continue to work on cleaning sequence in order to have
optimum cleaning and bag life.
3. Install deflation automatic AP control system.
4. Install additional manometer reading ports across the
outlet valve of six compartments to investigate individual
compartment flow characteristics. Taps for manometer con-
nection were installed on September 19, 1978.
-37-
-------
5. Continue to visually inspect each compartment every day
(five bags have been found with pencil-size hole leaks
since start-up).
6. Addition of a ventilation system to aid in cooling the
top compartments for inspection and maintenance.
-38-
-------
V. TESTING
A. Description of Testing Done to Date
1. Method: In October air flow tests were conducted on the
Harrington Station fabric filter system to determine the exact
air flow. The primary reason for measuring the air flow was
to see if it was causing high AP readings. Tests were run at
two inlet locations and one point on the stack.
During previous tests a large amount of turbulence was
encountered at the inlet, causing the test results to disagree
with air flow measurements from stoichiometric combustion
calculations. This discrepancy between calculated and measured
values prompted a velocity traverse from the stack. The stack
was selected because it met criteria specified in EPA Reference
Method 2 ("eight stack diameters downstream from the disturbance")
2. Equipment: The following equipment was used to conduct the
air flow tests:
Two 20-foot pitot tubes.
One manometer.
One EPA Reference Method 4 Moisture Sampling Train.
One EPA Reference Method 3 Orsat Apparatus.
B. Test Results
The October air flow test results are summarized in Table VIII
-39-
-------
TABLE VIII
Air Flow Test Results
Ihlet
„ n T Mbl. wt Stack .. Velo- o^t Gas Gas Stack
07 C09 H2U ts Ib/lb Press. Avg' city A,-., Pi^ Flew Gas
Traverse %Z % Z % °F ncle in Hg /SP~ ft/sec sqfft. ACFM* ACFM** Flow ACFM
SPS
S Type
Pitot
Tube 4.8 14 9.5 335° 29.05 2647 1.123 77.99 339.8 1,618,212 1,615,813 1,575,999
WBF
Std
Pitot
Tube 4.8 14 9.5 335° 29.05 2647 0.895 77.79 339.8 1,628,372 -. 1,585,894
* Corrected to Baghouse inlet conditions at 25.66" Hg and 345° F and 4.55% 02.
** Stoichiometric calculation.
-------
C. Special Testing
1. Field Sampling and Analysis: The approach to the field
testing program shall encompass the determination of two sets
of parameters, each of which will be measured at separate times.
The stipulation of simultaneous sampling will be met within each
set of parameters, but not all parameters will be measured simul-
taneously. The intent is to measure specific parameters at all
five locations simultaneously so that the effect of the baghouse
on these parameters can be determined. In keeping with sound
engineering judgement and, equally important, reasonable man-
power and cost considerations, selected combinations of para-
meters shall be measured concurrently and simultaneously at
the five locations and other measurements can also be measured
simultaneously, but at different times.
Table IX lists the parameters to be tested, the test method
and the collection set to which each parameter is assigned (A or
B) . The gas phase compounds (NOX, S02, SO-j, SO^, Cy-C12 organics
plus opacity, total mass flow, ash samples and coal samples col-
lected on all days) will be collected simultaneously but on an
alternate day other than the particulate samples.
Specific procedures presented in Table IX are described
as follows:
Particulate Emissions - EPA Method 5 shall be utilized.
The five sample locations will be sampled simultaneously
using five trains. Southwestern Public Service Company
will provide the appropriate support systems to allow
transversing of the sampling trains.
Particle Size Distribution - The three particle size dis-
tribution measurement techniques to be utilized shall
include: (1) in-stack impactors (0.5 to 20 pm); (2) Con-
densation Nuclei Counters with (0.0025 to 0.3 ym) Diffu-
sion Denuders; (3) Electro-Optical Dust Counters (0.3
to 10 um).
Five in-stack impactors will be used to collect simul-
taneous samples at the five locations. The outlet samples
-41-
-------
TABLE IX
SUMMARY OF FIELD COLLECTION/ANALYSIS PROCEDURES
N)
I
Two Inlet
Sampling
Parameter - Procedure Points
Particulate emission
EPA Method 5 x
P-articulate Size Dis-
tribution in-stack
imp actor x
Particulate Size Dis-
tribution- CNA/DD x
Particulate Size Dis-
tribution - Electro-
optical DC x
Flue Gas Opacity -
Lear Siegler
NOV - EPA Method 7
X X
so2 so3 so4
EPA Methods 6 & 8 x
02 ^ CO C02 N2 G.C. x
Total Mass Flow in con-
junction with EPA
Method 5 x
Moisture Content in con-
junction with EPA
Method 5 x
Organics - C^-C^ Inte-
grated bag sample, on-
site G.C. Analysis x
Organics C7-C12 XAD Sor-
bent, Lab Analysis
Ash: Grab Samples/Cone
and Quarter
Coal: Ultimate Samples
by SW Public Serv. Co.
Two Outlet
Sampling
Points
x
x
X
X
X
X
X
X
X
X
X
Stack
Ports
x
X
X
X
X
X
X
X
X
X
X
Collec-
Coal Hopper tion
Sampler Samples Time
A
A
A
A
A&B
B
A&B
A&B
A&B
A
A
B
x A&B
x A&B
-------
should run several hours (6 to 12) in order to collect
enough particulate matter. The inlet samples should be
run only for a few minutes (5 to 15) to avoid overloading.
Several inlet samples should be taken during the outlet
sampling period to ensure representative inlet conditions.
Two complete small particle measurement systems shall be
used during the tests. The small particle measurement
systems consist of the condensation nuclei counter with
diffusion denuder, the electro-optical particle counter
and associated dilution systems, recorders, etc. One
system will be used to take measurements at the inlet,
alternating between two sample locations, and the other
system will be used at the three outlet locations.
Flue Gas Opacity - Opacity measurements must be adequate
to characterize baghouse efficiency. Opacity measure-
ments shall be taken at the outlet of each baghouse.
NO - To determine the concentration of NO before and
after the baghouse, EPA Method 7 will be performed
simultaneously at the five sample stations. Each test
shall consist of three runs, with each run consisting of
four samples, collected at fifteen minute intervals. The
average of the four samples will constitute a run.
SOo, SOV SO/ - Tests shall be performed using EPA Method
I _ _ 6 for SO- and EPA Method 8 for S03 and SO^.
John Nader, EPA, Research Triangle Park, North Carolina,
may be able to provide additional information for the SO-j
testing.
02, CO, C02, N2 - Fixed gas analysis will be accomplished
— with a gas chromotograph utilizing a
thermal conductivity detector. The bag sampler (Tedlar or
Teflon) used to collect the fixed gases (as well as vola-
tile hydrocarbons) shall represent five integrated samples
collected simultaneously in conjunction with the EPA Method
5 run. Orsat analyzers will be available in the field as
back-up equipment.
Total Mass Flow - Preliminary traverse will be conducted at
each sampling location to determine proper sampling conditions
The reported mass flow rates will be those determined from the
pitot tube readings obtained with the EPA Method 5 equipment.
The pitot tubes will be calibrated in the GCA wind tunnel,
prior to each test series.
Moisture Content - The moisture content will be determined
in conjunction with the EPA Method 5 runs.
Organics - The volatile organics (C-,-C/-) will be vapor phase
-43-
-------
components and will be analyzed on site with a gas chroma-
tograph column at 150 C. GCA shall use both AID and Carle
gas chromatographs with integrating recorders for this
purpose. The samples for C-.-C, analysis are to be collected
in the integrated bag samples aiscussed above for 02, CO,
C02 and N~ collection. The non-volatile organics (greater
than Cx-) must be captured by a sorbent material and re-
turned to the laboratory for subsequent solvent extraction
and G.C. analysis. To collect these organic species, the
Method 5 train will be modified by placing a gas adsorbent
column between the filter and the impinger.
Ash - Ash samples will be collected on all days that sampling
takes place. These samples shall be collected from the silo
or hoppers, as appropriate, with several samples taken each
day. At the end of a day's sampling, the collected ash will
be coned and quartered a sufficient number of times to re-
duce the representative sample to 1 kilogram.
Coal - Coal samples will be provided by Southwestern Public
Service Company.
2. Laboratory Analyses
(a) Elemental Analyses: The program will include selected
elemental analyses on coal feed, hopper ash and sampling train
particulate catches. Specifically, GCA will analyze 18 coal
samples, 18 ash samples, 45 sampling train particulate catches
and 9 quality control samples. Each of these samples will be
analyzed for the 19 elements specified in Table X. There will
be a total of 1620 determinations. The analytical procedures
to be followed are described below and are designed to encom-
pass the analysis of the raw fuel, the ash collected by the bag-
house and particulate from the sampling train cyclones (if used)
as well as sampling train particulate filters. The basic tech-
nique to be employed for all elemental analyses is Atomic Ab-
sorption Spectrometry (AAS). Three different spectrometer con-
figurations shall be employed, in order to achieve desired in-
strumental sensitivities. The preparation procedures utilized
shall depend on both the sample type and element of interest.
For analytical procedure for each of the elements see Table X.
Two preparative techniques must be used in order to analyze
the ash samples for the broad spectrum of parameters listed
-44-
-------
TABLE X
ELEMENTAL ANALYSES BY ATOMIC ABSORPTION SPECTROMETRY
Ele-
ment
Al
As
B
Ba
Be
Ca
Cd
Co
Cr
Fe
Hg
K
Mg
Mn
Pb
Se
Si
Ti
V
Zn
Sample
Prepara-
tiona
Fusion^
aqua regia/
hydride
generation0
aqua regia
aqua regia
aqua regia/
fusiond
aqua regia
aqua regia
aqua regia
aqua regia/
fusion**
aqua regia
aqua regia
aqua regia
aqua regia
aqua regia
aqua regia
aqua regia/
hydride gen-
eration0
fusion'3
aqua regia
aqua regia
aqua regia
Analytical
Wavelength
(nm)
309.3
193.7
249.7
553.6
234.9
422.7
228.8
240.7
357.9
248.3
25-3.7
166.5
285.2
279.5
283.3
196.0
251.6
365.3
318.3
213.9
Conditions
Flame
N20/C2H2
ArH9
e.
N20/C2H2
N20/C2H2
N20/C2H2
Air/C2H2
Air/C2H2
Air/C2H2
Air/C2H2
Air/C2H2
Flameless
Cold Vapor
Air/C2H2
N20/C2H2
Air/C2H2
Air/C2H2
Ar/H2
N20/C2H2
N20/C2H2
N20/C2H2
Air/C2H2
Solution
Sensitivity
(yg/mA)
1
0.001
15
0.4
0.025
0.08
0.025
0.15
0.1
0.12
0.001
0.04
0.025
0.055
0.5
0.001
1.8
1.9
1.7
0.018
Expected
Sample Con-
centration
major
trace
minor
minor
trace
major
trace
trace
trace
major
nitra- trace
minor-major
minor-major
trace
trace
trace
major
trace-minor
trace-minor
trace-minor
Preparation methods applicable only to ash samples.
Dry ashing of the sample followed by sodium carbonate fusion
cAqua regia digestion followed by hydride generation.
Analysis will be performed on samples prepared by both methods.
-45--
-------
(see Table X). The majority of these elements will be ex-
tracted from ash or particulate samples (regardless of com-
pound form) by an acid (aqua regia) reflux. The more refrac-
tive species shall be prepared by a basic fusion. In particu-
lar, silica (Si02) and the oxides alumina (A^O.,), chromium
sesquioxide (C^O^) and beryllium oxide (BeO) are not ade-
quately extracted by the acid reflux; therefore, for the
latter elements (Cr, Al, Be), an AAS analysis will be carried
out on solutions obtained from both preparative procedures.
All coal samples will be prepared for analysis by a Paar
Oxygen bomb combustion procedure.
The specific AAS instrumental configuration indicated in
Table X is geared toward achieving the desired sensitivity
for each element and is based on the expected concentration
(major, trace, etc.); therefore, the majority of the para-
meters shall be determined by standard aspiration techniques
using either an air/acetylene or an air/nitrous oxide flame.
Exceptions to the standard flame procedure are the arsenic,
selenium and mercury determinations. Because of the short
wavelengths of the characteristic absorption lines of As and
Se, the Hydride generation method shall be the preferred
configuration. The desired analytical sensitivity for the
Hg determination shall be obtained by a reduction of the Hg
in the prepared solution to its elemental form followed by a
measurement of the absorbance produced by the evolved Hg vapor.
(b) Specific Inorganic Compound Analysis: The program
shall also include some specific compound analyses for the
major constituents of the ash samples. This analysis will
include the crystalline phases of SiO^, AloOo, Fe20^, CaO,
MgO, Na20, I^O and TiC^, which are anticipated to be the major
constituents of the ash samples. The preferred method for the
identification of these specific crystalline phases present in
the samples is X-ray Diffraction Analysis (XRD); therefore, the
analysis of the crystalline phase (using XRD) shall be performed
-46-
-------
and the results shall provide an accurate determination of minera-
logical quantitative data.
For this analysis, GCA shall use a Phillips (Norelco) water-
cooled Xray generator with a 114.6 mm Debye-Scherrer camera
(Charles Supper Col). Powder patterns shall be measured with a
precision of about 0.03 mm. Following the conversion of the data
to "d-spacings" using the Bragg equation, tables (such as the
Powder Diffraction File published by the Joint Committee on Pow-
der Diffraction Standards and ASTM file) shall be used to identify
the phases present. GCA will also make use of its in-house data
file on airborne particulates and fly ash constituents.
(c) £-}~^-\2 Analysis: Organic emissions boiling in the Cj-
C,2 hydrocarbon range shall be collected on XAD-2 resin. Organic
material will be extracted from the 45 resin samples by methylene
chloride for 24 hours in a Soxhlet extractor. After extraction
the methylene chloride solution will be transferred to a Kuderna-
Danish evaporator where it will be concentrated to a volume of
5 ml.
To determine the individual C7~cio hydrocarbon equivalent
(by boiling point) emission rates, a 1 ml aliquot of concentrate
shall be analyzed by gas chromatography with flame ionization
detection. By using boiling point-retention time and response
amount calibration curves, the data (peak retention times and
peak areas) shall be interpreted by summing peak areas in ranges
obtained from the boiling point-retention time calibration. The
area sums shall also be converted, using the response-amount
calibration curve, to amounts of material in each boiling point
range as follows:
C? 90 to 110° C
Cg 110 to 140° C
C9 140 to 160° C
CIQ 160 to 180° C
Cn 180 to 200° C
C12 200 to 220° C
-47-
-------
This analysis shall be performed on Tracer gas chromato-
graph equipped with dual columns, dual flame ionization detec-
tors and a linear temperature program. Peak areas and reten-
tion times shall be recorded on Hewlett-Packard integrator.
Columns shall be 10% OV-101 on 100/120 mesh Supelcoport. The
GC shall be programmed for five minutes isothermal at 50 C/min
from 50° C to 220° C. Retention-time and per area calibrated
curves shall be derived using this program for a mixture of
n-heptane, n-octane, n-nonane, n-detane, n-undecane, and
n-dodocane.
(d) Coal and Ash Analysis: Coal and hopper ash samples
shall be submitted to Gilbert Associates. Coal samples shall
be tested for ultimate, proximate and Btu. Ash samples shall
be tested for loss on ignition and carbon.
D. Plans for Special Testing
1. Schedule for special testing calls for Southwestern to
begin its tests in December, 1978. The subcontractor (GCA Cor-
poration) will conduct its first series of tests in January,
1979. The original schedule called for testing to start in
October, 1978, but it was decided to postpone any special sam-
pling until the fabric filter system's performance reached a
more normal operating level.
A consultant contract was executed by Southwestern Public
Service Company on August 31, 1978 with GCA Corporation, Bed-
ford, Massachusetts. The other two consultant firms which sub-
mitted proposals for the special testing program were Southern
Research Institute and Meteorological Research Institute. Selec-
tion of the consultant was based on technical evaluations of the
proposal and costs for the proposed programs.
2. Corrosion testing: The interaction of a metal with its
environment is the corrosion process which is particularly pre-
valent in many pollution control installations. There are three
primary causes of corrosion in a fabric filter* and these are:
*Fabric Filter Manual
Chapter VII, Sec. 2.131, Pg 85.5
-48-
-------
1. Chemical attack on the base metal due to gas and for solid
particulate incompatability with the materials of construction.
2. Electrolytic corrosion caused by use of dissimilar materials
of construction.
3. Operating near or below the water or acid dew point which
allows condensation and subsequent corrosion.
Southwestern, in an effort to assess the corrosiveness of the
flue gases passing through the fabric filter system at Harrington
Station, has placed low carbon steel coupons in the baghouse
structure. Each of the 28 compartments have a coupon just inside
the entrance door on the clean air side seven feet from the floor.
Both inlet ducts and outlet ducts also have a coupon in each (see
Appendix D for related drawings).
All coupons are insulated from any baghouse structural metal.
The coupons are thoroughly cleaned and weighed before installation.
They will be cleaned and weighed again when removed in order to
determine weight loss, if any.
The present plan is to remove every other coupon after 120
days to check corrosion and then remove the remaining coupons
after one year exposure. No coupons will be removed from the
inlet or outlet ducts until the Unit #2's first year inspection.
Compartment coupons will be removed in the following order:
© 2 (15) 16
2 © 17 (18)
(5) 6 (T§) 20
(3> 10 (2p 24
11 (&) 25 (26)
14' (21) 28
-49-
-------
3. Test Bags: Two test compartments have been equipped
with different types of fabric filters for testing purposes.
In Compartment 22 there are 34 Acid Flex and 33 Tri-Temp bags
installed (supplied by Fabric Filters). In Compartment 7
there are three Nomex bags and twelve Cris-0-Flex bags installed.
These bags were given to Southwestern by W. W. Criswell for
evaluation purposes. The test bags will remain in the com-
partments for the duration of the study and periodically some
will be removed for testing (see Appendix E for first test
results). After initial evaluations have been completed, it
is anticipated that Nomex bags may be installed in one en-
tire compartment for a more definitive evaluation.
-50-
-------
APPENDIX A
FABRIC FILTER SYSTEM DUSTUBE LOG
-51-
-------
Unit No..
Compartment No..
Nd. r'aully Husluhrs
HARRINGTON STATION
FABRIC FILTER SYSTEM
DUSTUBE FAILURE LOG
Page.
Date of Inspection.
Inspector
.of.
I 2
9 10
11 12
16
14
13
12
II
10
i
r
JK
I
Walkway
Door
Walkway
-52-
-------
CODK K)R LOCATION OF DUSTUBE FAILURE
Compartment No.,
1. Lower cuff
2. Seam
3. Upper cuff
4. Lower 1/3 fabric
5. Middle 1/3 fabric
6. Upper 1/3 fabric
Shaded Red - bag has been tied off
ADDITIONAL INFORMATION
DATE
BAG NO.
REMARKS
-------
BAG INSPECTION - INSTRUCTIONS
December 14, 1977
1. One compartment will be inspected during every working
day to insure that every 28 working days the baghouse
compartments have all been inspected.
2. A copy of the baghouse inspection form will be turned in
to George Faulkner or Rick Traywick.
3. A bag is located by a number designating the row and then
the bag number. For example, bag 717 is located in the
7th row and is the 17th bag.
4. The upper left quadrant is used to record a code number
which represents a failure as designated on the back
page of the bag failure inspection sheet.
5. Remarks under additional information should be as detailed
as necessary to identify the failure.
6. Bags that are replaced should be noted on the Dustube Re-
placement Log by shading the bag location green and re-
cording the date.
7. Manhours required to inspect, tie-off, or replace bags
should be recorded on the appropriate forms.
-53-
-------
APPENDIX B
TYPICAL BID REQUEST
-54-
-------
Southwestern Public Service Company
f. O. BOX 1261 • AMARILLO. TEXAS 79170
July 7, 1977
KVB Equipment Corporation
17332 Irvine Blvd.
Tustin, California 92680
Subject: Stack Monitoring Equipment Harrington #2
Gentlemen:
In order to meet Federal and State Emission Monitoring Laws, the follow-
ing items will need to be installed on our Harrington Unit #2 electric
generating station. Please send itemized quote for the following:
I. Opacity Analyzer - visible emissions monitoring system using a
transmissometer Span 0-100%.
II. S02/NOX stack gas analyzer system.- Span S02 0 - 1500 ppm
NOX 0 - 1000 ppm
III. Oxygen Analyzer System. Span 02 0 - 10%
Each of these systems should include the following:
A. Factory certification to meet E.P.A.'s CFR Title 40 Part 60,
Appendix B as to measurement, accuracy, calibration and operation.
B. Output to drive strip chart and computer input
4-20 ma and/or 0-10 volts.
C. Strip chart recorder for continuous monitoring.
D. Stack mounting in outdoor environment.
.E. Three (3) additional sets of the following:
1. Instruction Manuals.
2. Wiring and interconnection diagrams
3. Installation drawings.
F. Calibration Contact - To disable analyzer output while in
self calibration.
G. Fault Indication/Contact - To indicate failure of unit.
H. Large field termination area in junction box capable of
handling #14 awg multi-conductor cable.
-55-
-------
Page -2- July 7, 1977
I. Any probe to be at least 61 long measured from outside
mounting on stack.
J. Span to be set at the factory.
Options:
• . 1. Protective weather enclosure for probe/analyzer
assemble.
2. Maintenance kit - bulbs, filters, etc.
3. 480 volt A.C. motors, relays, solenoids.
This generating station consists of the following:
350 mw turbine-generator.
C.E. tangentially fired boiler.
Copes-Vulcan soot blowers.
Wheelabrator-Frye baghouse.
Equipment delivery must be on or before January 1978. Please send
quotes within three weeks to:
Southwestern Public Service Company
P. 0. Box 1261
Amarillo, Texas 79170
Attention: Eddie Barron (806) 378-2443
Olon Plunk (806) 378-2194
Sincerely,
Eddie Barron
EB:vm
-56-
-------
APPENDIX C
STATUS OF IKOR INSTRUMENTATION
as of 10/5/78
-57-
-------
10/15/78
Pete,
IKOR Status:
Outlets
WEST - no modifications - currently reads about
4% x 100 scale; signal usually stable
until what appears to be welding in the
area - pegs the signal out on all scales.
EAST - No modifications - was reading about the
same as West until about 1 week ago. Sig-
nal is currently pegged out on all scales.
Technician's brief survey did not turn up
anything obvious - unit turned off while
working, same noise problem affected it.
Inlet
WEST/EAST - Modified with resistors provided by
IKOR (2 days for 1 engineer & 1 tech).
At times will get a 30-40%. Fairly stable
signal on lowest (x.l) scale. Other scales
still peg out. Most of the time signal is
pegged out or varying between 0-100% wildly.
Signal varies with time/megawatt loading
and sun position. No correlation has been
drawn between wild readings and what's
actually happening. Blowing preheater
soot blowers has no effect on readings.
Generally
No signals to recorders are usable as they vary
too much. Signals have not been compared to a
hand sample. Plant computer readout is likewise
useless.
James Lower, John Yost and Sol have tried to
stabilize the signal and/or noise unsuccessfully.
Problems/Answers beyond our current ability and
time schedules.
Suggestions
Have IKOR send in "expert" with field experience
to modify equipment/installation to suit our needs,
Thanks ETR
-58-
-------
APPENDIX D
CORROSION COUPON ASSEMBLY
DRAWINGS
-59-
-------
BOLT- I0x 24 * 1-1/2 , 316 STAINLESS
or CHROME PLATED
-« 2 x2 *6 ANGLE IRON BRACKET
316 HO WASHER
TEFLON TUBING- 1/4" O.D., 1/2" LONG
TEFLON WASHER -1/4 n 3/8
TEFLON WASHER - 1/4"x
CORROSION COUPON
316 10 WASHER
N°IO HEX NUT, 316
-------
CORROSION TEST COUPON
Q
Areo 36 Sq. Inches
Average Weight '. 74.5 Grams
Average Thickness 0.0315"
-61-
-------
LOCATION OF CORROSION COUPONS
One coupon per compartment , numbers on coupons to match numbering of
compartments. (No. 1 thru No. 28)
Inlet and Outlet Ducts:
West Side;
No. 32
No. 30
No. 31
Inlet
No. 36
East Side;
\
No. 34
No. 35
w. a
\
No. 33
-Inlet
Total: 36
-62-
-------
V-42e
SPECIAL TESTING PROCEDURES
CORROSION
CORROSION DESCRIPTION
0 ^
4
~o>~15"
O
0 <=>
20 MPY
...
Severe
even
general
(E 1)
Severe
uneven
general
(E 2)
Severe
even
localized
(E 3)
Severe
uneven
localized
(E 4)
...
—
...
1. 3efore cleaning strin testers will be photographed if they appear unusual in anv respect.
i.e. partly eaten away, heavy deposit, etc.
2. All strip testers will be photographed after cleaning.
If there is negligible (or no) corrosion any staining or other'unusual appearance will
be repeated.
4. Large pits u-ill be measured (depth) and reported.
-63-
-------
CORROSION COUPON WEIGHTS
for
HARRINGTON STATION BAGHOUSE UNIT #2
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20
72.1150
71.4471
72.4578
71.4497
71.3295
71.0409
71.4606
71.5762
71.1310
71.3176
71.3980
71.1820
71.5155
71.7493
71.7500
76.3133
74.1110
74.3495
73.1115
73.9455
Q Panel Type S, 3" x 6" x
SAE 1010 low carbon steel
ASTM D-609 Specks
Acid cleaned and dried as
before weighing
,.032'
February 28, 1978
(weight to nearest million)
21. 71.1887
22. 71.4255
23. 71.2358
24. 75.8967
25. 75.8130
26. 72.4751
27. 75.9499
28. 75.5271
29. 75.6703
30. 76.3859
31. 68.1900
32. 77.8147
33. 78.2758
34. 78.3320
35. 78.2010
36. 76.9453
37. 76.7273
38. 77.4247
39. 68.2680
40. 68.1907
41. 68.1615
in standard corrosion coupon procedure
Prepared by Mario Tinajero
-64-
-------
APPENDIX E
EVALUATION OF FILTER BAG PERFORMANCE
(10/13/78)
-65-
-------
AUG 2 9 1978
ENVIRONMENTAL CONSULTANT
COMPANY
August 27, 1978
Southwestern Public Service Company
P. 0. Box 1261
Amarillo, Texas 7917Q
Attn: dr. Kenneth L. Ladd, Dr.
Dear Ken:
In accordance to our recent telephone conversation and your letter of
August 21, 1978, Environmental Consultant Company is pleased to quote
for your testing requirements.
The cost per set of three (3) filter bags for tests one (1) through
six (6), is projected to be 5375.00 not to exceed a maximum cost of
$400.00 for the three (3) bags. The maximum charge is necessary as
very often in fabric testing, confirmation of data through re-testing
is necessary.
I would like to suggest further testing to ensure proper evaluation and
performance levels of the fabric as par the attached laboratory data
sheet. Recommended testing is indicated by an X.
Fabric count and yarn systems are important factors in fabric evalua-
tion as well as breaking strengths.
As you know Ken, glass yarns have singles versions as well as a variety
of yarn structures of texturized yarns in today's filter fabric. The
exact yarn designation and the construction (count) should be determined
in each evaluation.
Environmental Consultant Co. would be pleased to perform all the tests
as indicated on the data sheet to include any necessary photographs to
demonstrate a particular situation, for a maximum charge of S450.00- for
the three (3) filter bags (3150.00 per filter bag).
Plicrophotographs can be accomplished at a charge of 8500.00 per sample.
Thank you Ken for allowing Environmental Consultant Co. to quote on your
testing requirements. You may rsst assured the sincere interest in
meeting Southwestern Public Service's testing needs and if I may be of
any further service, please do not hesitate to contact me.
Very truly yours,
Winston F. Budrow
UFB:jb Consultant-Chemist
P. 0. Box 9936- Phoenix, Az. 85068 -Telephone 602-997-7795 - Laboratory: 1 1423 N. Cave Creek Rd. -Phoenix, Az. 85020
Filtration Fabric Consulting and Testing
-66-
-------
ENVIRONMENTAL CONSULTANT
COMPANY
P. 0. Bo»9936
Phoenix. Arizona 85068
PREPARED FOR SOUTHUCSTERN PUBLIC SERVICE COP1PAHY
P. 0. BOX 12S1
AHARILLO, TZXAS 79170
DATE
TLN _
PAGE.
Identification
Fiber Content
Weight As received
OZ/SQ. yd. Cleaned (Vacuum)
Cleaned (Washed)
Thickness (inches!
Count
Weave
Yarn Warp/L«nmh
System Filing/Width
Permeability A> received
CFM/tq ft 9 .5" H90 Cleaned (Vacuum)
Cleaned (Washed)
Breaking
Strength Warp/Length
Ibs/inch Filling/Width
Breaking
Strength Were/Length
S Loss Filling/Width
Mullen Burn (Ibs/sa inch)
Mullen Burr; % Loss
Flex Cycles IMIT Method)
Flex Cycles (% Loss)
% Exrractable Solvent
Mutter Water
Acid/Alkaline (PHI
% Ignition Loss (LOI)
Treatment Physical Tyo*
Treatment Chemical Type
% Elt..CMir. Ware/Length
Filling/Width
Seaminq
Fabrication Cuffing
Ring Cover
Hardware Tyoe
Length (inches) Tension
Diameter (inches) Tension
Fabrication Rating
Other Testing .f
jptUtlt t^-^U^^^^
tut,M*l> JJiatUrV/i'in V /&Jt<4
X
X
y
X
X
X
X
X
X
X
X
X
X
X
X
X
X
y
X
X
X
X
^tMJ~
Filtration Fabri^Consulting and Tasting
-67-
-------
ENVIRONMENTAL CONSULTANT - - O(>O
COMPANY /Xi. $7/-
October 13, 1978
TLN 1065
Page 1
REPORT
SOUTHWESTERN PUBLIC SERVICE CONPANY
ANARILLO, TEXAS
Six filter bags were submitted for evaluation on a continuing filter
bag performance program. Three filter bags u/ere new and identified as
Acid Flex FF, Tri Temp FF, and Criswell which represents the base origin-
al fabric data. These original fabric samples will remain in storage for
any future use deemed necessary.
The remaining three bags were received used, securely protected in
plastic bags. The bags were labeled Acid Flex FF, Tri Temp FF, and
Crisuell, all removed 20 September 1978. These bags were reported to be
in a dirty state after completion of the cleaning cycle.
Attached is the technical data received from the evaluation.
All bags were fully layed out for'general observations.
The fabrication on all bags is rated as good. All bag seams con-
tained from 1.8" to 2" of fabric in the feld lock seam configuration
referred to as a wide folded seam.
Seaming contained the triple row chain lock type stitch, sewing
with E glass 4 ply sewing yarn with a Teflon coating. The cuffing was a
lock type stitch utilizing the same yarn.
All filter bags were properly sewn with the texturized surface inside,
filament surface' to the outside.
Cuff ropes contained in Fabric Filters bags (acid flex and tri temp)
are 3 ply glass rope, whereas the Criswell bags contained 18 ply asbestos
rope. Both types are of comparable quality and will adequately serve the
purpose.
The Fabric Filter material was heat cleaned (coronized), whereas
the Criswell fabric is not heat cleaned (greige goods).
P.O. Box 9936-Phoenix, Az. 35068-Telephone 502-997-7795-L3boratory: 1226 c. Northern Ave., Suite 0,-Phoenix, Az. 85020
Filtration Fabric Consulting and Testing
-68-
-------
Page 2
The used and new bags ware weighed in the as received condition
prior to testing. In general, all three used bags weighed nearly the
same (© 24 Ibs). This normally would not be significant, however, when
the new.bag weight is compared, the two bags from Fabric Filters con-
tained about 145$ over the original weight (dust loading), whereas the
Crisu/ell bag was over 200$ the original weight (dust loading). The
difference in loading could be due to the cleaning cycle differences,
or the fact that the Crisuell bag is accepting a higher dust air flow
through the fabric.
Results of the weight and permeability readings strongly indicate
a severe plugged condition. It was noted that the Crisuell fabric has
a higher as received permeability, while carrying a higher dust loading.
Microscopic examination of the used fabric surfaces revealed the Criswell
fabric to have a more porus filter cake. This is no doubt due to the
higher level of texturized glass yarns in comparison to the Fabric Filters
surfaces. This would suggest that the Crisuell fabric is filtering at
a higher rate, causing a higher level of physical breakdown of the glass
filaments, accounting for the greater percent loss of strengths.
The low MIT flex values are common values received on used fabrics.
It is nearly impossible to remove all the abrassive embedded particulate
matter from used fabric, hence low values are usually received in the
HIT value. To interpret this data is near impossible with only the one
test for comparison. The next set of used bags tested will become sig-
nificant as any further decline in NIT flex values strongly indicates
that the glass filaments are becomming fatigued, and is a measure of
fabric life. Glass filter fabric failure usually occurs at NIT values
from 20 to 40 cycles with the .03 jaw and a load of 4 Ibs.
It was noted that the dust cake on the fabric was difficult to re-
move, however, when exposed to high humidity the cake did discharge at
an easier rate. This indicates that the dust is suceptable to electro-
static charge build-up. It may be that the low sulfur, high resistivity
of the dust may contain an electrostatic charge. The glass bags being
a non conducting media would not allow the electrostatic charge to
disipate and thereby making dust cake discharge difficult. As a possible
trial, the injection of higher humidity in the flue gases would reduce
the electrostatic charge build up, and may prove advantageous for cake
discharge.
-69-
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ENVIRONMENTAL CONSULTANT
COMPANY
P. 0.8ox9936
Phoenix, Arizona 85068
PREPARED FOR SOUTHWESTERN PUBLIC SERVICE COMPANY
AHARILLO, TDCAS
DATE October 13L 1978
TLN .
PAGE.
1065
identification NOJ BAGS
Fiber Content
Weight At received
OZ/SQ. yd. Cleinid (Vicuum)
Cleaned (Wnnedl
Thickness (inches)
Count
Weave
Yarn Waro/Lenath
Syrtem Filing/Width
Permeability As received
CFM/sQ h S> .5" H70 Cleaned (Vacuum)
Cleaned (Washed)
Breaking
Strength Warp/Length
Ibs/inch Filling/Width
Breaking
Strength Warp/Lengih
% Lou FillingAVidth
Mull*n Burst (Ibs/ia inch!
Mullen Burst % Loss
Flex Cycles (MIT Metnod) .03 Oaw / 4 Ib. load
Flex Cvclei 1% Loss)
% Eitraciable Solvent
Mjner Water
Acid/Alkaline IPM)
% Ignition Losi ILOI)
Acid Tlex Ffj TT
Class
_
_
13.65
.018
it. x 2&
~\ f 1TV
37 1/0 F
75 1/2 T
75. 1/0 F
57.5
643
307
_
_
710
10,745
4.36
Treatment physical Tyoe |
Treatment Chemical Tyoe
o, -, Waro/Lencth
Fillir.gAVidth
Seamino
Fabrication Cu'fing
Glass
..
_
13.08
.016
45 x 24
•< i 1Tlil
37 1/0 F
75 1/2 T
75 1/0 F
Crisuell
Glass
_
_
10.38
.017
65 x 32
^ i m.i
150 1/2 F
75 1/2 T
I
61.0
561
7H7
_
_
538
3785
58.6
389
146
_
—
498
4598
2.56 2.95
Hardware Type
Length (inches) Tension.
Diameter (inches) Tension
Fabrication Rating
Orner Tevting % Logs Qn ionition g soo°r (LOT}
less .13
Leas .13
1.37-2
Filtrstion Fabric Consulting snd Testing
-70-
-------
ENVIRONMENTAL CONSULTANT
COMPANY
P. 0.8ox9936
Phoenix, Arizona 35068
PREPARED FOR SOUTHUESTERM PUBLIC SERVICE COMPANY
DATE Octobar 13, 1978
PAGERS
Identification u5E:r) SACS
Fiber Content
Weight As received
OZ/SQ. yd. Cleaned (Vacuum)
Cleaned (Washed)
Thickness (inches)
Count
Weave
Yarn Warp/Length
System Filing/Width
Permeability As received
CFM/sq rt © .5" H,0 Cleaned (Vacuum)
Cleaned (Washed)
Breaking
Strength Warp/Length
Ibs/inch Filling/Width
Breaking
Strength Warp/Length
% Loss Filling/Width
Mullen Burs; (Ibi/sQ inch)
Mullen Burst % Lois
Flex Cycles (MIT Method) _n-, -,aiH f & ,ST 1n.,H
Flex Cycles (% Loss)
% Extractable Solvent
Maner Water
Acid/Alkaline (PH)
% Ignition Loss (LOI)
Treatment Physical Type
Treatment Chemical Tyce
«, c,,-,M!r. WarD/Lennh
Filling/Width
Seaming Tripla row
Fabrication Cuffing
Ring Co'i«r
Hardware Tyoe
Lenqth (inches) Tension
Diameter (inches) Tension
Fabrication Rating
Other Testing
NBM Rag Tot'gJ. Weight (ibg-l
Usad Bao Total Uaioht (ibs.)
ArHrt rinx FF
Glass
22.98
U.73
13.81
.019
AA v 9T
3 X 1TU)
37 1/OF
75^ r 73 '/of
1.30
39.0
56.2
518
262
19.43
U.63S
541
23.6 '/.
57T1
51.35S
4.12
Chain lock
lock
-
Good
9.5
23.7
TT
Glass
20.23
14.12
13.17
.018
AA y 74
3 x 1TU
37 1/0 F
75'/2r7S'bf
2.15
43.0
58.4
403
276
28*
21.3*
298
44.6 '/.
71 ?q
42.52
2.34
Chain lock
lock
Good
9.7
23.5
rrisueilL
Glass
19.22
11.38
10.93
.017
fi5 v T1
3 x 1TUI
150 1/2 F
7
-------
WATER DROP NIGRATION
TEXTURIZED SIDE TESTED
Sample (original)
Acid Flax FF
Tri Temp FF
Crisuell
Idet Out Time
Indefinate (10 min. +)
Indefinata (10 min. +)
7 Seconds
Sample (2hrs. (j 5QO°F)
Acid Flax FF
Tri Tamp FF
Crisuell
liJat Out Time
Indefinata (15 min. +)
Indefinate (15 min. +)
Indefinate (15 min. +)
-72-
-------
TECHNICAL REPORT DATA
(Please read Inxructions on the reverse before completing)
1. REPORT NO.
EPA-600/7-79-183
2.
3. RECIPIENT'S ACCESSION NO.
4. TITLE AND SUBTITLE
Fabric Filter System Study: First Annual Report
5. REPORT DATE
August 1979
6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
K.L.Ladd, G.R. Faulkner, and S.L.Kunka
8. PERFORMING ORGANIZATION REPORT NO.
9. PERFORMING ORGANIZATION NAME AND ADDRESS
Southwestern Public Service Company
P.O. Box 1261
Amarillo, Texas 79105
10. PROGRAM ELEMENT NO.
E HE 62 4 A
11. CONTRACT/GRANT NO.
68-02-2659
12. SPONSORING AGENCY NAME AND ADDRESS
EPA, Office of Research and Development
Industrial Environmental Research Laboratory
Research Triangle Park, NC 27711
13. TYPE OF REPORT AND PERIQ
Annual; 10/77 - 10/78
D COVERED
14. SPONSORING AGENCY CODE
EPA/600/13
15.SUPPLEMENTARY NOTES ERL-RTP project officer is Dale L. Harmon, Mail Drop 61,
919/541-2925.
16. ABSTRACT The report describes first-year activities of a comprehensive EPA-funded
study of a commercial fabric filter unit on a 350-MW low-sulfur-coal-fired unit at
Southwestern Public Service Company's Harrington Station at Amarillo, Texas. Two
years will be required to complete collection and assessment of 1 full operating
year's worth of data. Following the testing phase of the program, operational and
maintenance data will continue to be recorded until 1982 to determine the long-term
reliability of the system. Special tests will be conducted through the use of an on-
site pilot baghouse. First-year activities include installation of support systems,
startup of the full-scale fabric filter system, and planning for special test programs.
Special testing on the full-scale system began in February 1979. Results will be
included in the next annual report.
17.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.IDENTIFIERS/OPEN ENDED TERMS
c. COSATI Field/Croup
Pollution
Fabrics
Gas Filters
Coal
Combustion
Dust
Pollution Control
Stationary Sources
Fabric Filters
Particulate
13B
11E
13K
21D
21B
11G
18. DISTRIBUTION STATEMENT
Release to Public
19. SECURITY CLASS (ThisReport)
Unclassified
21. NO. OF PAGES
79
20. SECURITY CLASS (Thispage)
Unclassified
22. PRICE
EPA Form 2220-1 (9-73)
-73-
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