Clean Air Power Ammonia SCR Manual-R1 · PDF fileClean Air Power Ammonia SCR Manual CAP Confidential Page 1 of 29 Clean Air Power HISCR DeNOx SILENCER MANUAL ... the aqua spray should

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Ammonia SCR Manual

CAP Confidential Page 1 of 29

Clean Air Power

HISCR DeNOx SILENCER MANUAL For Ammonia Reductant

Clean Air Power Job # 3135

HISCR DeNOx Model # 130/165WR20L

PC# 3025A (8 New Units)

BP Florida River Compression Facility, Durango, CO – Peaking Power Project

BP America Production Co (Onshore)

501 Westlake Park Boulevard Houston, TX 77079

Purchase Order # 4540013831 12/24/03

Clean Air Power

Ammonia SCR Manual


Table of Contents 1. SCR Overview

1.1. SCR Basics 1.2. System Overview 1.3. Installation 1.4. Commissioning Overview

2. SCR Operation 2.1. Startup 2.2. Shutdown

3. Clean Air Power Scope of Supply 3.1. DeNOx Silencer Specifications 3.2. System Components

4. Maintenance 4.1. Scheduled Maintenance 4.2. Cleaning Instructions

5. Troubleshooting 6. Performance Specifications

6.1. Engine Data 6.2. DeNOx Silencer Guarantees 6.3. Oil and Fuel Specifications 6.4. DeNOx Silencer Warranty

7. Miscellaneous & Vendor Supplied Information 7.1. VFD Controller 7.2. Recommended Ammonia Tank Purchasing Specification and System Notes

8. Spare Parts Lists of Figures 1. SCR Schematic (Reactions) 2. Competing SCR Reactions 3. SCR Piping Schematic 4. DeNOx Silencer Dimensional Drawings

4.1. Elevation View 4.2. End View 4.3. Front View 4.4. Recommended Structural Stiffeners for Engine Enclosure 4.5. Bolt on Stack with Test Port(s)

5. Electrical Schematic 6. Ammonia Tank Drawing Lists of Tables 1. Maintenance Schedule 2. List of Spare Parts Provided with System

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Ammonia SCR Manual


1. SCR Overview

1.1. SCR Basics

SCR is the acronym for Selective Catalytic Reduction of NOx with Ammonia (NH3). When ammonia is utilized as the reductant, it is injected into directly into the duct prior to reaching the catalyst. Catalyst selectivity is defined by how the ammonia reacts in the exhaust stream. Refer to the equations in figure 1. For high reduction of NOx:

NH3 Selectively Reacts with NOx NH3 does not react with O2 to form NOx NH3 is distributed uniformly in the exhaust duct

SCR SCHEMATIC

Figure 1

4 NO + 4 NH3 + O2 4 N2 + 6 H2O2 NO2 + 4 NH3 + O2 3 N2 + 6 H2O

NHNH33

NONOxx OO22

Engine Engine ExhaustExhaust

SCR CatalystSCR Catalyst

NN22

HH22OO

OO22

Liquid NH3

Mixing Section(s)

To To Oxidation Oxidation CatalystCatalyst

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Ammonia SCR Manual


The main competing SCR reactions and there preference levels are shown below. These reactions curves and the net performance are shown in Figure 2. These performance curves are for illustration purposes only. SCR NOx: High Activity Preferred 4NH3 + 4NO + O2 → 4N2 + 6H2O 4NH3 + 2NO2 + O2 → 3N2 + 6H2O NH3 Oxidation: Low Activity Preferred 4NH3 + 5O2 → 4NO + 6H2O 4NH3 + 3O2 → 2N2 + 6H2O

Figure 2

Temperature

Temperature

Temperature

Net NOx Reduction

NH3 Oxidation and Decomposition

Selective NOx Removal

Competing SCR Reactions

NO

x Conversion %

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Ammonia SCR Manual


Other (secondary) SCR reaction and are shown below: 4NO + 4NH3 + 3O2 -------------> 4N2O + 6H2O 6NO + 4NH3 -------------> 5N2 + 6H2O 8NO + 2NH3 -------------> 5N2O + 3H2O 6NO2 + 8NH3 -------------> 7N2 + 12H2O 2NH3 + 2O2 -------------> N2O + 3H2O An oxidation catalyst is supplied downstream of the SCR catalyst to destroy Carbon Monoxide, NMNEHCs, aldehydes and regulated HAPs as per the requirements in Section 6.2. The oxidation catalyst also helps controls ammonia slip by oxidizing any excess ammonia exiting from the SCR catalyst. In a properly operating system, NOx formation across the oxidation catalyst is minimal. Typical oxidation reaction products are described below. 2CO + O2 ---------------> 2CO2 CXHY + (x+y/4)O2 ----------------> XCO2 + Y/2H2O 2H2 + O2 -----------------> 2H2O

1.2. SCR System Overview A piping schematic of the SCR system is shown in Figure 3. The aqueous ammonia shall be injected into the exhaust stream via one or more injection nozzles, as specified in the dimensional drawing (Figure 4). The injection nozzle(s) shall be located in the exhaust line to the SCR DeNOx Silencer or in the body of the unit which ever is determined by CLEAN AIR POWER. The temperature of the exhaust gas shall vaporize the injected ammonia/water solution, and passage through the reactive silencer section upstream of the

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Ammonia SCR Manual


catalyst array will provide proper mixing of the ammonia into the exhaust stream prior to reaching the catalyst. The rate of injection of the ammonia/water solution into the exhaust stream is regulated by a controller, which in turn governs a variable speed pump. The programming of the controller is determined during SCR commissioning by mapping the emissions profile of the engine and the required level of NOx reduction.

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Ammonia SCR Manual


SCR Piping Schematic

P

RV

Injection Pump w/ VFD

Fine Filter

Coarse Filter

(25 Micron)

Isolation valve

Flow Meter

Pressure Gage

Check Valve

Nozzle

DeNOx Silencer

CUSTOMER CAP

CUSTOMER

CAP

Support Steel

Relief Valves (Typical )

To Injection Pumps (Typical)

1” Ammoia Supply From Tank

1” Liquid Return to Tank

1” To Tank

½”

1/4”

CUSTOMER CAP

T

Figure 3

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Ammonia SCR Manual


DeNOx Silencer Dimensional Drawing(s)

SCALE: APPROVED BY: DRAWN BY: HLHDATE: 11/10/2003 REVISED:

DRAWING NO.:PC-3022-1

CAP-HIS Emissions Reduction Systems9837 Whithorn Drive, Houston, TX 77095

MODEL HISCR-130/165WR20L

HISCR SILENCERSCatalytic Converter/Silencer

31 "

Inlet & Outlet 12 " 150# FF ANSI Template Flange

1/2" CPL (TYP)

FLOW

Catalyst Portal and Array

FINISH: HI TEMPERATURE BLACKWEIGHT: 6500 Lbs

238 "

128 "

47 "20 "

Support Brackets each with 2 1/2" holes with 4" wide X 2 1/2" tall clearance in center plate (TYP)

NH3 Injection

39 "

79 1/2 "

13 11/16 "10 "

52 "

Elevation Dwg. Figure 4A

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Ammonia SCR Manual


Figure 4B

End View (Looking Upstream)






54 3/8 "84 1/2"

43 "

45 "


END VIEW

31 "

96 "

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Ammonia SCR Manual







54 3/8 "84 1/2"

43 "

45 "


FRONT VIEW

31 "

54 5/8 "

96 "

2 "18 " 18 "

4 " (to

be de

termin

ed)2 "

Figure 4C Front View (Looking Downstream)

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Ammonia SCR Manual


SCALE: APPROVED BY: DRAWN BY:WYDATE: 02/05/2004 REVISED:

DRAWING NO.:


HISCR Structual Support

Clean Air Power

A500-B Tubing on side extending to base and welding to crossbrace gussets to provide supportBolted to Enclosure Frame Tubing

A36 Structural Channel

154 5/8"

60"

10"121 " 15 5/8"

31 3/8"Engine Enclosure

Air Flow

Enclosure Sturctual Tubing

End View

Top View

Figure 4D Recommended Structure Stiffeners

for Engine Enclosure

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Ammonia SCR Manual


1.3 DeNOx SCR CATALYTIC CONVERTER INSTALLATION Installation of the HISCR DeNOx Silencer is simplified by having minimal customer connections to be made. Mechanical connections are made at the engine exhaust duct, injection nozzle(s) and pump skid. Electrical wiring is required for the engine signal (from the engine governor, or manifold), thermocouples, pressure gages and an alarm pressure switch for loss of compressed air. EXHAUST CONNECTIONS The CLEAN AIR POWER Selective Catalytic Reduction (SCR) DeNOx catalyst/silencer housing is installed in the same fashion as a standard exhaust silencer. The (SCR) DeNOx catalyst/silencer can be installed in either a vertical or horizontal position. If the unit is to be mounted vertically, a proper foundation is necessary for support of the DeNOx silencer. A footprint of the mounting base ring for the DeNOx silencer is described in the dimensional drawing. If the unit is to be mounted horizontally, the DeNOx silencer must be seated in the cradle designed to provide adequate support along the entire length of the silencer. If the catalyst housing is located above the engine, the aqua spray should not enter the engine turbocharger The exhaust piping shall be installed with a minimum number of elbows and sized using accepted piping design practices to minimize exhaust back pressure. AMMONIA TUBING The injection pump and motor are mounted on a base plate with ammonia/water line filters. An ammonia injection pressure gauge and rotometer (flow meter) are also included in the injection control system. The injection system panel must be located away from excessive vibration. All tubing shall be sized in accordance with accepted piping practices to minimize dynamic head loss No copper, brass,

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Ammonia SCR Manual


aluminum, zinc, galvanized, or Viton materials are to be used in the ammonia system. Keep the stainless steel ammonia tubing running from the pump to the nozzle as far as possible from any hot exhaust surfaces. Slope the tubing continuously upward from the pump to the nozzle to prevent vapor locks. RELIEF VALVE The user is to supply and pipe up a relief valve located down-stream of the check valve for the ammonia pump. This relief valve should be set at 100 to 125 psig to protect the filters. The relief valve should vent back to the upper section of the storage tank (turn down inside tank). In some cases, the relief valve can be vented to atmosphere since it will not normally operate. The materials of construction should be as described in “Materials” above AMMONIA STORAGE TANK The tank (by others) should be elevated at least 3 ft (1 Meter) above the pump to provide NPSH. The higher the tank height the better it is for good pump performance in hot ambient temperature and/or elevation above sea-level. A relief valve and vacuum breaker are required. A stainless tank, or synthetic material tank is preferred. An internally coated steel tank is acceptable See recommended tank purchasing specification and ammonia tubing / piping comments in Section 7. 19% AMMONIA BY WEIGHT AQUA SOLUTION

This strength aqua solution has a lower vapor pressure usually allowing a non-pressure vessel design to be used for storage. It also provides more Net Positive Suction Head to the pump. This strength aqua starts vapor flashing at about 120 deg F at sea level pressure. (A 29% aqua solution flashes at about 79 deg F.) If 29% aqua is the only strength available locally it can be diluted by your supplier to 19% strength by adding 52.6 gal. of softened/deionized/distilled water to each 100 gal. of 29% solution. Assure your supplier uses only

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Ammonia SCR Manual


“softened” water, that the usual magnesium, calcium, etc. have been removed so they will not scale up the catalyst ELECTRICAL CONNECTIONS There is a minimum of electrical components- motor, inverter, and 4-20 ma signal source. All electrical wiring required as specified for the SCR DeNOx silencer shall be installed in accordance with accepted wiring practices. Refer to Figure 6 for Wiring Schematic The controller is wired directly to the engine governor, and is designed to receive and interpret a 4 to 20 milli-amp signal from the governor. Or, the 4 to 20 MA signal can be produced by a transducer sensing boost pressure. The connection between the governor, or manifold, pressure point and pump will be made in conduit. Wire gauge shall be in accordance with local electrical requirements and not smaller than 16 gauge. Power to the pump is provided by a variable speed driver which is powered by 120 VAC 60 HZ. The fractional HP pump motor is 3 phase 230V 60 HZ Differential pressure reading and temperature monitor for the engine exhaust are provided. Two thermocouples and two (single input) transmitters will be provided for each unit. The Temperature transmitters use 24 VDC power input, 4-20 ma output, measuring range is 32 to 1050 F. Due to the high heat radiation, the transmitters should be located away from the thermocouple head. The transmitters are housed in an enclosure, which enables mounting anywhere inside the engine enclosure. The pressure transducer is a differential pressure transducer. The Pressure transducer uses 24 VDC power input, 4-20 ma output, measuring range 0 to 25 inches of water, operating temperature 32 to 122 F. A relay and timer for controlling ammonia flow on startup is also included. Timer/relay wiring details to follow.

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Ammonia SCR Manual


ELECTRICAL SCHEMATIC

Figure 5

SCALE: APPROVED BY: DRAW N BY:W YDATE: 101/29/2004 REVISED:

DRAW ING NO.:

CAP-HIS Emissions Reduction Systems9837 W hithorn Drive, Houston, TX 77095

Ammonia Injection Control Schematic

Clean Air PowerHISCR Silencer/Converter

L1 L2 L3

T1 T2 T3

R1R10

10V

A1

D11

D12D13

D14

CM

120 VAC IN

Vessel

Pressure Gage

Flowmeter

Motor

Urea Tank

ENgine KW signal (4 to 20 MA) go toA1 and CM

VFD

Note:Detailed urea nozzle configuration please see the nozzle installation schematicDetailed wiring of VFD please refer to VFD manual

Filter

Relief Valve

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Ammonia SCR Manual


1.4 SCR Commissioning Overview

Start-up and Training A Clean Air Power representative will be delegated to the Client’s site for the startup and commissioning of each SCR unit. The CAP representative will also provide onsite training for the Client's operators and technicians, to run concurrent to commissioning.

Note: Engine must be tuned and engine exhaust emissions must meet specified levels in Section 6.1 prior to SCR commissioning by Clean Air Power. After catalyst outlet emissions levels have been achieved, then the injection flow rate is recorded and the pump speed established. The driver can be set to operate automatically within the preferred load ranges. Permitting and Civil Work

CAP currently does not participate in permitting, civil work or consultations such as seismic planning.

2 SCR Operation 2.1 Startup SCR system start up is accomplished by engine start up and time interval for sufficient catalyst temperature. The recommended injection temperature is 750°F for best vaporization of ammonia solution. The minimum injection temperature is 500F. Based on engine exhaust temperature and engine operating data provided by the customer, the ammonia injection (at 500F) should occur within three minutes of startup. 2.2 Shutdown The ammonia flow is controlled by the engine signal. The pump will shutdown automatically when the engine is shut down.

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Ammonia SCR Manual


3.0 Clean Air Power Scope of Supply

3.1 Clean Air Power HISCR DeNOx Silencer Specifications

The DeNOx Silencer design shall be multi-chamber, reactive/absorptive type for the noise level specified, or the “generic” description “Commercial,” “Standard,” “Residential,” or “Hospital.” This generic description of noise quality can be misleading in the attempt to specify silencing quality. Compare silencer size when evaluating quotations. Silencing quality is to be determined in initial design. Refer to Section 6 for any Silencing guarantees or ratings A proper foundation is necessary for support of the DeNOx Silencer. A footprint describing the support pattern is in the dimensional drawing. Construction shall be of heavy gauge, carbon steel plate, minimum 11 gauge, rolled and continuously welded, incorporating standard flanged and dished heads for pressure vessel-like construction. Flanges shall be 150 lb. F.F. ANSI diameter and drilling template. Couplings shall be 3000 lb. rating and shall be sufficient in number to provide sample ports for: Catalyst upstream temperature, catalyst downstream temperature, high temperature alarm/shutdown, drain, and oxygen sensor or as optional equipment. The DeNOx Silencer shall be installed in a manner which best fits the piping configuration (with side inlet and/or side outlet) and in a location where inlet gas temperature is appropriate The DeNOx Silencer shall have external surfaces sandblasted and coated with a high temperature paint or construction of stainless steel is also optional construction or metallized by the flame spray method for carbon steel construction.

The DeNOx Silencer shall be equipped with a “catalyst portal” at near mid-section for easy access to the catalyst assembly, a seal ring shall provide the catalyst assembly a seal against exhaust gas bypass, and support to withstand

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Ammonia SCR Manual


vibration and thermal stress. The catalyst assembly shall be provided with structural support to guard against damaging effects of engine backfire. The ammonia solution system as employed, will have one or more injection nozzle(s). The location number and size of couplings will be specified on the dimensional drawing. The reagent injection pump will provide the proper volume of solution to the injection nozzles for the specified emissions reduction. Site specific requirements may call for installation of insulation on the exhaust pipe and shell sections of the DeNOx Silencer to maintain constant inlet temperature. The SCR catalyst composition shall be of a zeolite or equal high temperature formulation which will provide a high level of NOx reduction and applied to a substrate as described above over a proper wash coat. The application of the catalyst materials will provide adherence quality to the substrate and wash-coat, to prevent any flaking or separation of the formulation from the substrate during normal operation. The oxidation catalyst composition will be of platinum group metals applied to a substrate as described above, and incorporated in the catalyst formulation are to be materials which provide a wash-coat and adherence to the substrate to prevent any flaking or separation of the formulation from the substrate during normal operation. The catalyst formulation will be such that the light of temperature begins the reduction process at less than 220C. 3.2 System Components CHECK VALVE A ¼” stainless steel check valve having 1 psi crack pressure installed in ammonia feeding line protects the system’s components against an excessive pressure build up from “boiling” aqua at or near the nozzle. This may occur temporarily after startup when the pump is started, or when the ammonia flow is shut down on a hot exhaust system. Flashing of vapor from 19% aqua starts at 120 deg F at sea level pressure. NOTE- A check valve with a high crack pressure spring loses valuable pump pressure.

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Ammonia SCR Manual


FILTERS Cuno filters in plastic housings having extra large dirt storage capacity are furnished. Both filter housing are identical, except the suction filter element is 25 micron, and the discharge filter element is 1 micron. The max working pressure is 125 psig, ¾” with NPT connections.. The plastic housings provide a visual method of inspecting the filter element- the housings are to be shielded from sunlight. NOTE: The user is responsible for determining that the filter plastic housings are in accordance with all local codes governing ammonia solution. It is to be replaced by the user by a suitable metal housed filter if it is determined the plastic construction is not to local code specifications. A 100/125 psia relief valve should also be provided by user to prevent damage to the filter.

FLOW METER Mounted with the sight flow glass in a vertical position with inlet at the bottom and outlet at the top. Connections are ¼” on the back. The GPM scale on the meter has been matched to the glass internal bore and the float weight. Max WP is 200 psig. CONTROLLER, VARIABLE FREQUENCY The inverter uses 120V, 50/60 HZ power, and converts it to 230V, 3-phase power for the motor. The motor speed varies as the 4-20 ma signal varies which is a measure of the hp/kW load of the engine. The inverter is in a general purpose enclosure, has a LED display of the HZ output, and a keypad to set the motor speed parameters to match the 4-20 ma signal to the motor speed- Hz. NOZZLE SIZING Clean Air Power provides two identical of ammonia nozzles per system (one is a spare). The nozzles will produce the desired GPH with a pump pressure of at least 25-30 psig but not higher than 100 psig to protect the filter rating. A small nozzle size is desirable as it requires higher pump pressure which raises the flash temperature. (The flash temperature is raised to about 160-170F at 35 psig pump pressure).

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Ammonia SCR Manual


PRESSURE GAGE A liquid filled gage of non-brass/aluminum construction, scale of 150 psig or 200 psig is used. PUMP & MOTOR The pump is a positive displacement gear type pump, magnetically coupled to a 220 volt 3-phase motor. There is no internal relief valve built into the pump. Connections are ¼” threaded. The motor is a TEFC,1800 nominal rpm, close-coupled type. Motor speed is controlled by a variable frequency inverter using a 4-20 ma signal supplied by the user.

4.0 Maintenance 4.1 Scheduled Maintenance A Typical maintenance schedule is described below. Actual intervals will depend upon operating parameters. Due to low operating hours at this site, maintenance intervals should be longer.

Item Year 1 Year 2 Year 3 Year 4 Year 5 Year 6 SCR Catalyst

I I I, C, As Req’d

I, RL As Req’d

I, RL As Req’d

I, C, or RL As Req’d

Oxidation Catalyst

I I I, C, As Req’d

I, I, I, C, R As Req’d

Annual Maintenance And Replace Spare Part

I I I, R As Req’d

I, I I, R As Req’d

Ammonia Delivery System

I I I I,R As Req’d

I I

Symbol Description I Inspect Annually (4 to 8 hrs) C Clean Catalyst as per procedure RL Remove upstream layer, move remaining layers forward and install new

layer downstream R Replace

TABLE 2

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Ammonia SCR Manual


The catalyst in the DeNOx Silencer has an operational life expectancy of five (5) to seven (7) years. Operation and maintenance within good operating practices will provide a long and trouble-free life. 4.2 DeNOx SILENCER - CLEANING INSTRUCTIONS 4.2.1 DISASSEMBLY The DeNOx Silencer catalyst module is accessible through the catalyst portal. Remove the fasteners at the catalyst portal flange to allow working room and access to the catalyst monolith 4.2.2 CLEANING There are several methods suggested for cleaning the catalyst monolith depending on the degree of loading. Following are some suggestions: When the SCR catalyst inlet has an accumulation of residual ash and other products of combustion (not caked oil), surfaces can be cleaned with the application of low pressure dry air from the outlet side of the catalyst, blowing the dirt away from (instead of blowing into) the surface of the catalyst. After removing the accumulated ash, re-install the catalyst module with the original outlet side to the inlet. Another method is to soak the oxidation catalyst monolith in a solution of phosphorous free detergent in deionized water, rinse with deionized water, then blow dry when the particulate has soaked free. When the "oxidation" catalyst inlet is severely covered with oil carryover and other products of combustion, it is recommended that the module be cleaned with an ammonia hydroxide wash, free of lead and other heavy metals, and other contaminates which could poison the catalyst. For assurance of cleanliness and inspection including refurbishment and repair, return the catalyst module to CLEAN AIR POWER.

5.0 Troubleshooting

When conversion rate falls below compliance level, inspect catalyst for masking by particulate. Follow cleaning instructions, when necessary, to remove the accumulation of lube oil ash and coked oil.

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Ammonia SCR Manual


Pressure drop is a measure of catalyst cleanliness. Catalyst should be cleaned when pressure drop across the DeNOx Silencer increases by 3.0 inches of water column. Excessive pressure drop across the catalyst is the result of accumulation of particulates, oil carryover and other products of combustion. A log of progressively increased pressure drop to a predetermined level should be kept. This will assist to establish cleaning intervals. Periodic testing on semi-annual basis will provide a record of catalyst aging primarily by accumulation of ash and other products of combustion. This periodic testing and pressure drop readings are preferred methods of tracking catalyst activity. Aging of the ammonia/water or urea solution is a source of catalyst contamination and a cause of reduced catalyst activity. The source of ammonium hydroxide or urea should be from a reputable supplier and the mix should be certified. The solution should contain no minerals or heavy metals which could deactivate the catalyst. The transport and transfer of the solution should be clean and dirt free to the onsite storage tank.

6.0 Performance Specifications 6.1 Engine Data Engine Type: Twelve* Cummins QSK 60 series 2000 DQKC engine rated 2000 KW at 1800 rpm. * - 8 New SCR units and 4 Refurbished SCR units supplied under PO

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Ammonia SCR Manual


Cummins “Not to Exceed” Engine Emission Inlet Concentrations

#1 and/or #2 Diesel Fuel only Emissions 100% load

NOx 7 gm/Hp-hr 605 ppm

CO 0.9 gm/Hp-hr N/A

VOC N/A N/A

SO2 0.58 gm/Hp-hr N/A

Exhaust Temperature The operating exhaust temperature range for HISCR-130/165WR20L is between 650 °F to 950 °F. Exhaust temperature outside this range will void catalyst warrantee and emission guarantees.

6.3 HISCR DeNOx Silencer Guarantees Guaranteed Outlet Concentrations behind DeNOx Catalytic Silencers:

Emissions Concentration

NOx 90% reduction (0.7 gm/Hp-hr)

CO 90% reduction

VOC 60% reduction

NH3 slip <5 ppm

Note:The oxidation catalyst will convert SO2 into SO3. No SOx reduction can be made by catalytic converter/silencer. Noise reduction from the engine(s) only will be 35 DB. Approximate Consumption of Reducing Agent (per system) 19% Aqua. Ammonia

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Ammonia SCR Manual


Engine Aqua. Ammonia 19%

QSK 60, 2000 DQKC, 90% NOx reduction

12 GPH (gallon Per Hour)

Pressure Drop Across DeNOx Catalytic Silencer Flange to flange : Not Specified, approximately 8”

6.3 Oil and Fuel Specifications

.5% by wt Sulfur (5000 ppmw maximum) diesel fuel is recommended. Maximum ppmv of sulfur in the exhaust gas is defined in the warranty statement. Engine is to be properly vented to reduce oil carryover and not to be vented into the exhaust stream ahead of the catalyst. Combustibles content in the exhaust gas shall not produce catalyst outlet temperature higher than 1100oF. Contaminants in excess of these amounts shall void the warranty. Refer to Section 6.4 for warranty Operation and maintenance shall be in accordance with manufacturers' recommended procedures at minimum and within good operation practices

6.4 Warranty Terms

Warranty is a commitment against defective material and workmanship. Clean Air Power warrants that for a period of twenty four (24) months from date of sale that we will repair or replace, at our discretion, any part(s) or whole of the CAP HISCR system that may prove to be defective in material or workmanship. The term of the original warranty is not extended by any such action. This warranty is for a DeNOx SCR Silencer with ZNX™ Catalyst as per proposal R03 R03-1111-1/5B dated December, 17, 2003. In addition, for the same time period, Clean Air Power will guarantee the performance of our system will meet certain performance levels based on the engine and operational conditions specified at the time of sale.

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Ammonia SCR Manual


In order for this performance guarantee to be valid, the following items or condition will be the owner/operator's responsibilities. Warranty is a commitment against defective material and workmanship. Clean Air Power warrants that for a period of thirty (30) months from date of sale or twenty four (24) months of service, whichever shall first occur, that we will repair or replace, at our discretion, any part(s) or whole of the CAP HISCR system that may prove to be defective in material or workmanship. The term of the original warranty is not extended by any such action. This warranty is for a DeNOx SCR Silencer with ZNX™ Catalyst as per proposal R03-1111-1B5 dated December, 17, 2003. In addition, for the same time period, Clean Air Power will guarantee the performance of our system will meet certain performance levels based on the engine and operational conditions specified at the time of sale. In order for this performance guarantee to be valid, the following items or condition will be the owner/operator's responsibilities.

A. Maximum NOx from engine will not exceed published engine OEM emission data. B. Maximum CO from engine will not exceed published engine OEM emission data. C. Maximum NMHC from engine will not exceed published engine OEM emission data. D. Temperature of exhaust at the catalyst will be 650_°F minimum to _950 °F maximum

to prevent catalyst damage, but compliance will be based on the operating data provided.

E. Oxygen Concentration will be between 5% to 18%. F. There will be no unburnt fuel in the exhaust stream. G. The catalyst must be cleaned as per CAP instruction when the pressure drop

increases by 25% for typical operating conditions. Such periodic cleaning of particulates is not a warranty item.

H. Engine operation will be stable and reproducible. Engine will be operated and maintained in accordance within manufacturer's recommended practice.

I. Maximum lubrication oil consumption rate will be less than 0.0015 Lb./BHP-Hr. J. Lube oil sulfated ash content will not exceed 0.5% on a weight basis. K. A high temperature alarm/shutdown will be maintained in the catalyst outlet set at a

maximum of 1000°F. However, a lower shutdown temperature will provide a wider margin of protection. CAP recommends a setpoint no more than 100 °F above the visible operating temperature, provided the upper temperature limit is not exceeded

L. Fuel will not contain heavy metals such as lead, mercury, arsenic, antimony, zinc, copper, tin, iron, barium, nickel, chrome and phosphorous. Content of these elements at the catalytic system must not exceed 1 PPM singularly or collectively exceed 5 PPM.

M. Chlorinated and Silicon containing compounds in the exhaust gas will not exceed 1 PPMv

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Ammonia SCR Manual


N. Sulfur compounds in the exhaust gas stream will not exceed _400_ PPMv. O. Contaminants from urea or ammonia reductant must not accumulate to levels that

cause catalyst contamination Should the CLEAN AIR POWER system not perform as stated on the performance guarantee and the equipment has been maintained per the above terms and conditions, CLEAN AIR POWER will be obligated to either repair or replace any part(s) or whole of the system so that it will perform as stated. The term of the original performance guarantee is not extended by any such action.

UNDER NO CIRCUMSTANCES WILL CLEAN AIR POWER ASSUME ANY CONSEQUENTIAL LIABILITIES.

ZNX is a trademark of Engelhard Corporation

7.0 Miscellaneous and Vendor Supplied Information

7.1 VFD Controller

7.2 Recommended Purchasing Specifications…

For Aqueous Ammonia Storage Tank and Components For Use in Selective Catalytic Reduction NOx Abatement System

Reagent: 19% by weight Ammonium Hydroxide (Aqua Ammonia) Solution

7.2.1. STORAGE TANK (See Figure 6)

A. Size: 10000 gallons minimum recommended to accommodate full load bulk shipment by tanker.

B. Materials: stainless tank. All connections to be flanged nozzles.

C. Pressure rating: 25 psig design pressure, ASME coded pressure vessel.

D. Safety: Tank must be grounded

E. A manway is recommended.

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Ammonia SCR Manual


F. The tank should be elevated at least 3 ft (1 Meter) above the pump inlet to

provide NPSH. Higher tank height is better for good pump performance in hot ambient temperature and/or elevation above sea-level.

Tank Elevation: TBD by Customer

7.2.2. COMPONENTS AND TANK CONNECTIONS Materials: No copper, aluminum, zinc, or viton materials

A. Combination vacuum breaker / pressure relief valve with emergency rating (may be supplied as separate components)

B. Level Gauge (mechanical float type) in head of tank.

C. 1 inch OD pipe to ammonia injection pumps with isolation valve.

D. 1 inch OD pipe from relief valves on SCR ammonia tubing

E. 1 inch OD pipe liquid return (recirculation) from injection pump header with

isolation valve

F. 60 PSI Maximum Pressure Gage

G. 1” inch OD pipe ammonia vapor equalization line with isolation valve

H. Liquid Tank Fill Connection to Tanker Supply header specifications by ammonia supplier

I. Drain Connection and Valve

7.2.3 AMMONIA PIPE/TUBING (see Figure 3)

Recommend running 150# minimum SS pipe from tank to point(s) near the pump and then run tubing from the end of the pipe(s) to the pump. Materials: 304 Stainless Steel Tubing with Minimum pressure rating of 2000 psi.

Clean Air Power

Ammonia SCR Manual


Welding is the preferred joining method.

A. ½ inch OD tubing (minimum) from injection pump ammonia supply header to pump with individual isolation valves

B. ¼ inch OD tubing (minimum) connecting injection pump to nozzle and relief valve discharge to return header

C. 1 inch pipe (minimum) for injection pump supply header, injection pump return

header, and relief valve return header

Figure 6

Ground Liquid to Injection pumps

Vapor

Drain

NPSH

Vacuum Breaker/pressure relief valve

Manway

Liquid Fill

Pressure Gage

Liquid Return from Injection Pumps

Return from ammonia Tubing relief valves

LG

Clean Air Power

Ammonia SCR Manual


8.0 Spare Parts The following spare parts are included with the system. Spare parts should last well beyond the warranty period under normal operation Item Description Clean Air P/N Qty Included (per

unit) 1 Ammonia nozzle : 500061-1 1 2 1 micron filter: 500070-1 1 3 25 micron filter 500071-1 1

Table 2

Other components to be replaced as needed.

Contact Clean Air Power at 281-463-8883 for pricing on spare and replacement parts.

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