coal gen 2011 wet fgd performance upgrade at b.l. england unit 2
DESCRIPTION
TRANSCRIPT
A Recent Case Study ofWet FGD Performance Improvements
At B.L. England Unit 2 using
ALRD® Technology
Presenters:Amy Evans, Marsulex Environmental Technologies
Dennis Del Vecchio, NAES Corporation
BL England Staff & Management– Eric Adolfsen | BL England Plant Engineer– Dennis Prichett | BL England Scrubber Supervisor
Authors– Mike Hammer | Marsulex Environment Technologies– Amy Evans | Marsulex Environment Technologies– Dennis Del Vecchio | NAES / RC Cape May Holdings– Gary Andes | WorleyParsons
Acknowledgments
Plant Background and Administrative Consent Order (ACO)Upgrade OptionsImplementation and ConstructabilityPerformance ResultsConclusions
Agenda
B.L. England
Cape May County, NJ on the Great Egg Harbor River450 MW plant3 generating units (2 coal, 1 oil)Unit 2– 155 MW, balanced draft– Equipped with FGD, ESP, LNB, SNCR– Eastern bituminous coal (3.2% S)
FGD LSFO Wallboard grade gyp, sold locally– Retrofitted in 1994 with open spray tower WFGD system– Designed for 93% SO2 removal
Administrative Consent Order
Issued date: 2006Issued by: New Jersey Department of Environmental ProtectionRequirement: Increase SO2 removal efficiency to 97% while firing 3.2% ( 5.11 lbs SO2/MM Btu) sulfur bituminous coal.
– Emission limit of 0.15 lbs SO2/MMBtu on a 30 day rolling avg– Emission limit of 0.25 on a 24 hour basis
Deadline: May 2010Project Requirements:
– Meet emission limits– Do not adversely impact particulate emissions– Do not adversely impact ME carryover from the absorber
Options Considered
Chemistry changes“Traditional” MethodsALRD® | Absorber Liquid Redistribution Device
ALRD Technology
Aspects:Commercially demonstrated technologyIncreases L/G contact
— Solves wall effect and re-entrains and re-activates wall slurry
— Solves flue gas “sneakage” along absorber wall
Minimal effect on flue gas pressure drop
ALRD Technology
Recommended technology for B.L. England Unit 2:Two ALRD levels determined to meet removal requirementsCould be incorporated into two scheduled outagesDetermined most cost and schedule effective method
ALRD ImplementationEngineering, procurement and fabrication in 12 weeks
Designed to enable installation within scheduled outages
Items were fabricated in shop– Shop Fab Details:
Carbon Steel mounting plate welded to Alloy support brackets. ALRD Plates laser cut in the shop
– Field Details: Carbon Steel mounting plates eliminated the need for certified alloy
welders in the field– Better fit-up and quality control
Design included two ALRD levels with support brackets & rubber lining
ALRD ImplementationLocation critical to meet design requirements― Level 1
2nd and 3rd absorber spray levels 30 brackets and 28 sections
― Level 2 3rd and 4th absorber spray levels 29 brackets and 27 sections
A phased approach was utilized for field installation– ALRD level 2 was installed during Fall 2009 outage, 12 days– ALRD level 1 was installed during Spring 2010 outage, 25 days– Criteria: Unit ready to produce electricity at end of each outage
Project Team
Owner: RCCMH
Engineer: WP
Constructor: Nooter
FGD OEM: MET
O&M Services: NAES
Project Organization Chart
Phased Approach Work Schedule
Developed execution plan during proposal– Reviewed contractor and owner safety plan, described construction
work plan, resource histogram, reporting and tracking requirements
All workers attended a Site safety orientation presentation Fire blankets and fire watch were critical for a rubber-lined vesselWorkers required to wear harnesses when in vessel for protection from falling Workers used the “Buddy System” to help insure a safe working environment Project risks reviewed and mitigation strategies implemented
Constructability
Components designed and fabricated to pass through access doors– Bottom absorber door - 30 inch X 54 inch– Hoisted to work level
ALRD Level 1 – 75’ ALRD Level 2 – 80’
Scaffolding installation critical– Structural integrity of spray headers as supports verified– Positioning precarious
Needed to protect rubber lining on pipe header, spray nozzles, and absorber vessel walls
Needed to be located to allow sections to be installed without interference
Constructability
ALRD Plates were delivered pre-drilled — Critical to be positioned correctly for holes to line upSection templates were provided to ensure proper fit– Constructed of stainless steel and weighed ~40 lbs– Used templates to make replicas of plywood that weighed ~4 lbsBrackets and plates designed to be modular for ease of handling and installationInnovative use of graphics to report progress daily
Constructability
Tower scaffolding was installed on top of the spray headers and the
attachment plate locations were laid out
Execution of Work
The rubber lining was removed
The shell was prepped for welding
Execution of Work
The bracket was made of CS base plate and shop welded to the alloy bracket for
easy field welding
All of the support brackets were installed and aligned
using the actual plates
Execution of Work
All welding was completed before any of the rubber lining
efforts were began
The ALRD support bracket shell and rubber lining was beveled to ensure proper lining profile
Execution of Work
All the lining efforts were completed before the plates
were installed
The plates were installed, bolting was selected as the preferred
method of attachment
Execution of Work
The plate was lined to seal it to the wall to ensure all the liquid running
down the wall could be re-entrained
The work area was cramped but all work
was performed without incident or
any lost time
Execution of Work
System operated to meet the 0.15 lbs SO2/MMBtu after May 1st
Performance Results
System operated to meet the 0.15 lbs SO2/MMBtu on 30 day rolling average
Performance Results
courtesy of EPA's Clean Air Markets Division
The upgrade, from proposal to installation, was accomplished in a 10 month period
2500+ man-hours of installation work without incident
Scheduled outages utilized for equipment installation
Capital Investment for upgrade was minimized
System was able to successfully achieve state-required emissions limit– Increased SO2 removal from 93% to 97% at 3.2% Sulfur coal
– Outlet Emission of 0.15 lbs SO2/MMBtu is achieved
– No noticeable increase in pressure drop– No change to any of the existing recycle pumps or spray headers
Conclusions
Contact Information:
Amy Evans | Marsulex Environmental [email protected]
717-274-7129
Dennis Del Vecchio | NACE [email protected]
609-390-5171