Coal gen 2011 wet fgd performance upgrade at b.l. england unit 2


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Dennis Del Vechhio, NAES Special Project Supervisor at B.L. England Generating Station, presented A Case Study of Wet FGD Performance Improvements at the Coal-Gen Conference on August 17.

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Coal gen 2011 wet fgd performance upgrade at b.l. england unit 2

  1. 1. A Recent Case Study of<br />Wet FGD Performance Improvements <br />At B.L. England Unit 2 <br />using <br />ALRD® Technology<br />Presenters:<br />Amy Evans, Marsulex Environmental Technologies<br />Dennis Del Vecchio, NAES Corporation<br />
  2. 2. Acknowledgments<br />BL England Staff & Management<br />Eric Adolfsen |   BL England Plant Engineer<br />Dennis Prichett | BL England Scrubber Supervisor<br />Authors<br />Mike Hammer | Marsulex Environment Technologies<br />Amy Evans | Marsulex Environment Technologies<br />Dennis Del Vecchio | NAES / RC Cape May Holdings<br />Gary Andes | WorleyParsons<br />
  3. 3. Agenda<br />Plant Background and Administrative Consent Order (ACO)<br />Upgrade Options<br />Implementation and Constructability<br />Performance Results<br />Conclusions<br />
  4. 4. B.L. England <br />Cape May County, NJ on the Great Egg Harbor River<br />450 MW plant<br />3 generating units (2 coal, 1 oil)<br />Unit 2<br />155 MW, balanced draft<br />Equipped with FGD, ESP, LNB, SNCR<br />Eastern bituminous coal (3.2% S)<br />FGD LSFO<br /> Wallboard grade gyp, sold locally<br />Retrofitted in 1994 with open spray tower WFGD system<br />Designed for 93% SO2 removal<br />
  5. 5. Administrative Consent Order<br />Issued date:2006<br />Issued by: New Jersey Department of Environmental Protection<br />Requirement: Increase SO2 removal efficiency to 97% while firing 3.2% ( 5.11 lbs SO2/MM Btu) sulfur bituminous coal. <br /><ul><li>Emission limit of 0.15 lbs SO2/MMBtu on a 30 day rolling avg
  6. 6. Emission limit of 0.25 on a 24 hour basis</li></ul>Deadline: May 2010<br />Project Requirements:<br /><ul><li>Meet emission limits
  7. 7. Do not adversely impact particulate emissions
  8. 8. Do not adversely impact ME carryover from the absorber</li></li></ul><li>Options Considered<br />Chemistry changes<br />“Traditional” Methods<br />ALRD® | Absorber Liquid Redistribution Device<br />
  9. 9. ALRD Technology<br />Aspects:<br />Commercially demonstrated technology<br />Increases L/G contact<br /><ul><li>Solves wall effect and re-entrains and re-activates wall slurry
  10. 10. Solves flue gas “sneakage” along absorber wall</li></ul>Minimal effect on flue gas pressure drop<br />
  11. 11. ALRD Technology<br />Recommended technology for B.L. England Unit 2:<br />Two ALRD levels determined to meet removal requirements<br />Could be incorporated into two scheduled outages<br />Determined most cost and schedule effective method<br />
  12. 12. ALRD Implementation<br />Engineering, procurement and fabrication in 12 weeks<br />Designed to enable installation within scheduled outages<br />Items were fabricated in shop<br /><ul><li>Shop Fab Details:
  13. 13. Carbon Steel mounting plate welded to Alloy support brackets.
  14. 14. ALRD Plates laser cut in the shop
  15. 15. Field Details:
  16. 16. Carbon Steel mounting plates eliminated the need for certified alloy welders in the field
  17. 17. Better fit-up and quality control</li></ul>Design included two ALRD levels with support brackets & rubber lining<br />
  18. 18. ALRD Implementation<br />Location critical to meet design requirements<br /><ul><li>Level 1
  19. 19. 2nd and 3rd absorber spray levels
  20. 20. 30 brackets and 28sections
  21. 21. Level 2
  22. 22. 3rd and 4th absorber spray levels
  23. 23. 29 brackets and 27 sections</li></ul>A phased approach was utilized for field installation<br /><ul><li>ALRD level 2 was installed during Fall 2009 outage, 12 days
  24. 24. ALRD level 1 was installed during Spring 2010 outage, 25 days
  25. 25. Criteria: Unit ready to produce electricity at end of each outage</li></li></ul><li>Project Team<br />Owner: RCCMH<br />Engineer: WP<br />Constructor: Nooter<br />FGD OEM: MET<br />O&M Services: NAES<br />
  26. 26. Project Organization Chart<br />
  27. 27. Phased Approach Work Schedule<br />
  28. 28. Constructability<br />Developed execution plan during proposal<br />Reviewed contractor and owner safety plan, described construction work plan, resource histogram, reporting and tracking requirements<br />All workers attended a Site safety orientation presentation <br />Fire blankets and fire watch were critical for a rubber-lined vessel<br />Workers required to wear harnesses when in vessel for protection from falling <br />Workers used the “Buddy System” to help insure a safe working environment <br />Project risks reviewed and mitigation strategies implemented<br />
  29. 29. Constructability<br />Components designed and fabricated to pass through access doors<br />Bottom absorber door - 30 inch X 54 inch<br />Hoisted to work level<br /><ul><li>ALRD Level 1 – 75’
  30. 30. ALRD Level 2 – 80’</li></ul>Scaffolding installation critical<br /><ul><li>Structural integrity of spray headers as supports verified
  31. 31. Positioning precarious
  32. 32. Needed to protect rubber lining on pipe header, spray nozzles, and absorber vessel walls
  33. 33. Needed to be located to allow sections to be installed without interference</li></li></ul><li>Constructability<br />ALRD Plates were delivered pre-drilled <br /><ul><li>Critical to be positioned correctly for holes to line up</li></ul>Section templates were provided to ensure proper fit<br />Constructed of stainless steel and weighed ~40 lbs<br />Used templates to make replicas of plywood that weighed ~4 lbs<br />Brackets and plates designed to be modular for ease of handling and installation<br />Innovative use of graphics to report progress daily<br />
  34. 34.
  35. 35.
  36. 36. Execution of Work<br />Tower scaffolding was installed on top of the spray headers and the attachment plate locations were laid out <br />The rubber lining was removed<br />
  37. 37. Execution of Work<br />The shell was prepped for welding<br />The bracket was made of CS base plate and shop welded to the alloy bracket for easy field welding<br />
  38. 38. Execution of Work<br />All of the support brackets were installed and aligned using the actual plates<br />All welding was completed before any of the rubber lining efforts were began<br />
  39. 39. Execution of Work<br />The ALRD support bracket shell and rubber lining was beveled to ensure proper lining profile<br />All the lining efforts were completed before the plates were installed<br />
  40. 40. Execution of Work<br />The plates were installed, bolting was selected as the preferred method of attachment<br />The plate was lined to seal it to the wall to ensure all the liquid running down the wall could be re-entrained <br />
  41. 41. Execution of Work<br />The work area was <br />cramped but all work <br />was performed <br />without incident or <br />any lost time<br />
  42. 42. Performance Results<br />System operated to meet the 0.15 lbs SO2/MMBtu after May 1st<br />
  43. 43. Performance Results<br />System operated to meet the 0.15 lbs SO2/MMBtu on 30 day rolling average <br />courtesy of EPA's Clean Air Markets Division<br />
  44. 44. Conclusions<br />The upgrade, from proposal to installation, was accomplished in a 10 month period<br />2500+ man-hours of installation work without incident<br />Scheduled outages utilized for equipment installation<br />Capital Investment for upgrade was minimized<br />System was able to successfully achieve state-required emissions limit<br /><ul><li>Increased SO2 removal from 93% to 97% at 3.2% Sulfur coal
  45. 45. Outlet Emission of 0.15 lbs SO2/MMBtu is achieved
  46. 46. No noticeable increase in pressure drop
  47. 47. No change to any of the existing recycle pumps or spray headers</li></li></ul><li>Contact Information:<br />Amy Evans | Marsulex Environmental Technologies<br /><br />717-274-7129<br />Dennis Del Vecchio | NACE Corporation<br /><br />609-390-5171<br />