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Worldwide PollutionControl Association
IL Regional Technical SeminarIL Regional Technical SeminarAugust 3-4, 2010
Visit our website at www wpca infoVisit our website at www.wpca.info
Wet FGD Lessons Learned - DesignWet FGD Lessons Learned - Designby
Greg Bielawski
WPCA Regional SeminarSpringfield IllinoisSpringfield, Illinois
August 4, 2010
Yesterday: Multiple Absorbers per Boiler:este day u t p e bso be s pe o eMany dampers & many more pumps
Proprietary and Confidential .2
Today: Single Absorber per BoilerToday: Single Absorber per Boiler
Proprietary and Confidential .3
Importance of Gas Flow Distribution
4
©
Packed Towers No Longer Used
Excellent contactor, but big plugage problems
5
©
B&W Absorber Gas Inlet with Tray
6
©
Spiral Nozzle:Excellent Drop Size, but Not Suitablep ,
7
©
Hollow Cone Spray Nozzle
8
©
FRP Spray Headers
9
©
FRP Can be done right, but there must be a stringent spec….
Alloy Spray Headers
10
©
Rubber lining blockage:Common problem with Rubber-Lined Pipe p p
11
©© 2008 Babcock & Wilcox 11
Mist Eliminator Upgrade
Original Mist Eliminator Design New Modern Mist Eliminator Design
Mist Eliminator Upgrade
12
©
Typical Lower & Upper Mist Eliminator
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©
Source: Munters
Mist Eliminator Wash System
14
©© 2008 Babcock & Wilcox 14
ME Wash StrainerME Wash Strainer
15
©© 2008 Babcock & Wilcox 15
Top of Mist Eliminator with Wash Header
16
©
Wet FGD Absorber FireWet FGD Absorber Fire
17
©© 2008 Babcock & Wilcox 17
Absorber Pump with FRP Pipe (Note Supports)
18
©
Absorber Pump Gearbox Failures:Gearboxes likely need water coolingGearboxes likely need water cooling
19
©© 2008 Babcock & Wilcox 19
Absorber Mixer Design
Mixers must be distributed around the tank, not clustered
installation angle = f (d1, d2, n2, q, quantity of agitators)
ß = too largeß = 0deposits at g
deposits inthe centre
pthe vesselwall
ß = optimalno deposits
S
20
©
Source: Ekato
Mixer on Absorber Shell: Outboard Support Neededpp
21
©
Source: Alstom Unit at Centralia
Agitator Motor DriveAgitator Motor Drive
Coleson Cove 7/8/04
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©
Erosion of Alloy Mixer Blade(Two Year Outage Inspection)(Two-Year Outage Inspection)
23
©
Absorber Tank Access DoorNeed Big Doors; Must be to Codeg ;
24
©
Source: Alstom Unit at Centralia
Thank You!Thank You!
25
© 25© 2009 The Babcock & Wilcox
WFGD Operations & MaintenanceWFGD Operations & Maintenanceby
Greg Bielawski
WPCA Regional SeminarSpringfield IllinoisSpringfield, Illinois
August 4, 2010
Estimated Plant WFGD Operations per ShiftEstimated Plant WFGD Operations per Shift
Operator shift super 1x (shared)Operator shift super 1x (shared)
Control room operator 1x
Field operatorsField operatorsAQCS 2xElectrical 1x (shared)
Lab tech 1 per shift (for 2 shifts – shared)
Maintenance shared with boiler
Total Dedicated Personnel: 3Total Shared Personnel: 3+
Proprietary and Confidential © 2008 Babcock & Wilcox Power Generation Group, Inc. All rights reserved. .27
T i l Ab b M i t A ti itiTypical Absorber Maintenance Activities
Activity Description Frequency
Estimated Labor
ManhoursEquipment
On/OffAQCS On/Off
ABSORBERABSORBER
Inspect alloy parts 1 per year 24 off off
Inspect/repair internal piping 1 per year 24 off off
Inspect/clean nozzles 1 per year 24 off off
Inspect/clean mist eliminators 1 per year 24 off off
Inspect/clean flow distributors 1 per year 24 off off
Inspect/replace man way gaskets 1 per year 24 off off
Inspect fasteners 1 per year 24 off offInspect fasteners 1 per year 24 off off
List continues for many pages:
Proprietary and Confidential © 2008 Babcock & Wilcox Power Generation Group, Inc. All rights reserved. .28
Contact [email protected] for complete set
E ti t d M i t C tEstimated Maintenance Costs for the Wet FGD System
Estimated annual maintenance manhours for the Wet FGD: ~6,900 hours
Estimated annual spare parts/materials cost for the Wet FGD: ~$515,000
Notes:
The above maintenance activities, frequency, and estimated labor , q y,values are typical and may vary dependent on equipment suppliers.
Total maintenance costs may vary in the industry from plant to plant.
Proprietary and Confidential © 2008 Babcock & Wilcox Power Generation Group, Inc. All rights reserved. .29
Thank You!Thank You!
Proprietary and Confidential .30© 2009 The Babcock & Wilcox Company. All rights reserved.