FGD-Fluegas Desulphurication Plant O&M PDF

NO.: CDTE-FGD.
INDIA-TRAINING-01
China dating Technologies Engineering co ltd
PROJECT TITLE:
IL&FS Cuddalore Power Project-Flue Gas Desulphurisation Plant
CLIENT:
IL&FS TAMIL NADU POWER COMPANY LIMITED
LOCATION OF WORK:
CUDDALORE DISTRICT,TAMIL NADU,INDIA
Training Materials of Wet Flue Gas Desulfurization

(FGD) Unit System of China Datang Gorporation
Rev. Description Date Made by Checked Appd.
A First issue 02-FEB-2016

NO.: CDTE-FGD.INDIA-TRAINING-01
Training Materials of Wet Flue Gas Desulfurization

(FGD) Unit System of China Datang Gorporation

The Desulfurization Project Phase I in India

China Datang Technologies & Engineering Co., Ltd.

October 2015

Approved by:
Examined by:
Prepared by:

Table of Contents
FGD ................................................................................................ 4
Chapter 1 Limestone-gypsum Wet FGD Process System ................................................................................. 4
.............................................................................................................................. 4
Section I Flue gas system .................................................................................................................... 4
........................................................................................................................ 12
Section II Absorber system ................................................................................................................. 12
............................................................................................................................ 25
Section III Slurry preparation system ................................................................................................... 25
.................................................................................................................... 28
Section IV Gypsum dewatering system ................................................................................................ 28
............................................................................................................................ 37
Section V Discharge system ................................................................................................................ 37
........................................................................................................................ 40
Section VI Process water system .......................................................................................................... 40
............................................................................................................................ 46
Section VII Wastewater treatment ......................................................................................................... 46
FGD ...................................................................................... 51
Chapter II Impact on FGD Unit from Variation Range of Fuel Characteristics .............................................. 51
............................................................................................ 51
Section I Impact on system from flue gas flow rate change .............................................................. 51
SO2 .................................................................................... 55
Section II Impact on system from SO2 concentration change of flue gas ........................................... 55
.................................................................................... 58
Section III Impact on system from dust concentration change of flue gas ........................................... 58
FGD .............................................................................. 63
Section IV Effect of chlorine content in coal on FGD unit design ....................................................... 63
FGD .............................................................................................. 66
Chapter III Non-metal Corrosion Prevention Materials of Wet FGD System .................................................. 66
.................................................................................... 66
Section I Technical Construction Requirements for Non-Metal Corrosion Prevention Materials..... 66
........................................................................................ 74
Section II Reasons for Damage of Rubber and Reinforced Resin Lining........................................... 74
........................................................................................................................................ 78
Chapter III Electrical System ............................................................................................................................ 78
................................................................................................ 78
Section I Electrical ElementaryWiring Diagram for Desulfurization System ................................... 78
.................................................................................... 81
Section II Desulfurization Service Voltage and Neutral Point Grounding Mode................................ 81
UPS ......................................................... 82
Section III AC Emergency Power Supply, DC System and Uninterruptible Power Supply (UPS) ..... 82
............................................................................ 84
Section IV Desulfurization System Load Calculation and Desulfurization Transformer Selection ..... 84
.................................................................................... 89
Section V Protective Load Statistics and Diesel Generator Selection................................................. 89
................................................................................................ 92
Section VI Selection and Layout of Desulfurization Electrical Equipment ......................................... 92
............................................................................................................ 93
Section VII Control, Protection and Measurement ................................................................................ 94
...................................................................................................................... 100
Section VIII Anti-thunder and Grounding ............................................................................................ 100
.............................................................................................. 100
Section IX Lighting, Overhaul and Slide Wire System ...................................................................... 100
.............................................................................. 101
Section X Cable, Cable Building and Cable Fireproof Plugging ...................................................... 101
.......................................................................................................................... 102
Section XI Communication System.................................................................................................... 102
...................................................................................................................................... 104
Chapter IV Thermal System............................................................................................................................ 104
.................................................................................................................................. 104
Section I Overview .......................................................................................................................... 104
KKS ......................................................................... 107
Section II KKS Identification System (Thermal Expertise Part) ...................................................... 107
...................................................................................................................116
Section III Distributed Control System ...............................................................................................117
...................................................................................... 121
Section IV Principles of Interlock Protection Logic, Control and Regulation ................................... 122
.................................................................................................................. 144
Section V Desulfurization Thermotechnical Instruments ................................................................. 144
CEMS ...................................................................... 150
Section VI CEMS System (Continuous Flue Gas Emission Monitoring System) ............................. 150
FGD ......................................................... 156
Section VII Monitoring and Analysis of All Measured Data in Normal Operation of FGD System ... 156
FGD ......................................................................................... 162
Chapter V Debugging, Operation and Performance Experiments of FGD System ....................................... 162
FGD ............................................................................................................. 162
Section I Debugging of FGD system ............................................................................................... 162
FGD ............................................................................................................. 224
Section II Operation of FGD System ................................................................................................ 224
FGD ..................................................................................................... 244
Section III Performance Test of FGD System ....................................................................................... 244
FGD ..................................................................................................... 260
Chapter VI Common Operation Problem Analysis of FGD System ............................................................. 260
FGD ..................................................................................................... 260
Section I Low desulfurization efficiency of FGD system................................................................ 260
FGD ................................................................................................. 269
Section II FGD system and stack corrosion .......................................................................................... 269
FGD ............................................................................................................... 282
Chapter VII FGD System Operation Management ....................................................................................... 282
FGD ......................................................................................... 282
Section I Required capacity of FGD operators ................................................................................ 282
FGD ......................................................................................................... 284
Section II FGD system operation adjustment .................................................................................... 284

C hin a Da t an g Co rpor at ion D e sul fur i za tion Op er at ion a nd Equ ip men t M an a ge ment
S ta ff O c cup ation al Qu al i fic a tion Tr ain in g M at e ri al
FGD
Chapter 1 Limestone-gypsum Wet FGD Process System

Section I Flue gas system
1
1. Process procedure

FGD
GGHFGD
The design of the flue gas system shall consider the normal operation of the
system and the operation in emergencies, including the big changes of flue gas
temperature in short time caused by the sudden changes in the upstream boiler.
Normally, the flue gas system is of the unit system (as for the FGD system of two
boilers and one tower, the flue gas system is the main pipe system), and each system
includes the booster fan, GGH, flue damper (FGD inlet raw gas damper, clean gas
damper, the bypass gas damper) and the corresponding flue, expansion joints, etc.
GGH
100
The raw flue gas from the boiler induced draft fan, pressurized by the adjustable
moving blade booster fan and cooled down by the GGH, then enters the absorber
system. The flue gas can also be directly discharged to the stack by the bypass flue,
namely the flue gas can 100% pass through the bypass.
SO2
GGH
The raw flue gas entering the absorber system would get through cooling and
saturation of the absorber, and the SO2 among it will be absorbed. The clean flue gas,
after spray washing and removal of fogdrop and then heated by the GGH, will enter
the flue and be discharged from the stack.
FGD 3
(1 1 1 )
FGD FGD
FGD
In order to separate the FGD system and the boiler system, each flue gas system
is set with three flue gas dampers (one raw gas damper, one clean gas damper, one
bypass gas damper). When the desulfurization system is in normal operation, the
bypass damper is closed and the raw gas damper and clean gas damper are open. The
4

raw flue gas enters the FGD unit through the raw flue gas damper for desulfurization.
In emergency of requiring shutting down the FGD system, the bypass damper will
automatically and quickly open while the raw gas damper and the clean gas damper
will automatically shut down. The flue gas will be discharged directly into the stack
through the bypass flue and bypassing the FGD system.

All the dampers are equipped with seal air system, which will lead the seal air
into the blades of the dampers closed to block the flue gas flow on both sides of the
dampers.

2 100 FGD
5mbar
The damper seal air system consists of the seal fan and its seal air station. Each
set of flue gas system is set with a seal air station and two low pressure seal air fans
and the capacity of each is the maximum gas consumption of 100% single set of FGD
unit with one for operation and the other for standby. The seal gas pressure maintains
5mbar higher than the maximum pressure of the flue gas. The seal air station is
equipped with electric heater.
1
Figure 1 Typical flue gas system flow chart
Stack
Induced draft fan
Absorber
5

Seal fan
Booster fan
2
2. Main equipment
GGH
Main equipment of the flue gas system including: booster fan, GGH, flue gas
damper, expansion joints, damper sealing systems, etc.
2.1
2.1 Booster fan
FGD
DL50002000 1.2 1.1
10
The booster fan is used to pressurize the flue gas to overcome the side resistance
of the flue gas of the FGD system. According to Technical Code for Designing Fossil
Fuel Power Plants DL5000-2000, the air pressure margin of the selected fan should
be 1.2, the flow margin 1.1, and plus 10 of temperature margin.

Since the booster fan is set at the sides of the hot flue gas, it avoids the corrosion
of the flue gas with low temperature so as to reduce the difficulty of fan
manufacturing and material selection. The fan blade materials mainly consider
preventing blade abrasion in order to ensure long-life operation; As for the structure,
consider the convenience of overhaul and replacement of the impeller and blade.

In the desulfurization system, the booster fans are mostly the axial flow fans. The
project adopts the adjustable moving blade axial flow fan.

DCS
The adjustable moving blade means the impeller is equipped with a set of
hydraulic device, which can adjust the blade installation angle in operating state so as
to change the output power of the fan under the condition of the boiler load change. It
mainly consists of the blade, wheel hub, hubcap, support cover and hydraulic
regulating device, etc. When the fan operates, the hydraulic regulating system
responds to the control signal from the DCS and drive the blade shaft to rotate to
6

achieve the purpose of adjusting the blade installation angle. The wheel hubs are
usually of welded structure and the blade materials generally use the spheroidal
graphite cast iron or low alloy steel.
2.2
2.2 GGH
4560
80
The temperature of the clean flue gas from the desulfurization tower is 45-60
and the flue gas is in the wet saturation state. If directly discharged, it will cause two
adverse consequences: One is the low spread ability of the rising flue gas and the
water mist may be formed near the stack to pollute the environment, namely the
so-called the smoke plume downwash; The other is that since the flue gas temperature
is below the dew point, acid droplets will condense from the flue gas, namely the
so-called "raining", which not only pollutes the environment but also cause low
temperature corrosion to the equipment. Therefore, in the FGD system, the GGH is
usually set behind the desulfurization tower using the raw flue gas from the boiler to
heat the clean flue gas to at least above 80 and then discharged into the atmosphere
in order to increase the spread ability of the flue gas and avoid low temperature
corrosion.

gas-gas heater
GGH
The hot media of the GGH mainly include the raw flue gas, high-temperature
water, vapour or electricity. Usually, there are more methods of using the raw flue gas
to heat the clean flue gas, namely the gas-gas heater with the abbreviation of GGH.
7

Ash ejector
center drive unit
Seal fan
Rotor
Top Structure
Clean flue gas side
End post
Seal air pipeline
Bottom beam
Raw flue gas side
Side post
8

Rotor shell
Flue gas reheater layout drawing
FGD
The rotary type heat exchanger is the most commonly used type of heat
exchanger in the current FGD unit.
GGH
GGH GGH
80
Rotary GGH is with enamel piece as the heat exchanger element. The heat
exchanger element coated with enamel selects and uses the products with advanced
waveform and high heat transfer coefficient to reduce the total weight of GGH and
save expenses for the replacement of the heat exchanger unit. GGH uses the raw flue
gas from the boiler to heat the clean flue gas after desulfurization to make the lowest
temperature of the clean flue gas at the inlet of the stack above 80.
GGH
DCS
GGH GGH
() 30
50000
Each GGH is set with two electric drive units with one for main drive and the
other for standby, and all the motors adopt the form of air cooling. If the main drive is
out of work, the auxiliary drive will be automatically switched through the DCS to
prevent the rotor from stopping rotating. The GGH design can satisfy that the rotor
stops rotating without damage or deformation in the condition of power-losing of
auxiliary power. The overall service life of the GGH (shell, rotor and cell, drive unit)
is not less than 30 years while the service life of the heat exchanger element is more
than 50,000 hours.
GGH
GGH
,
10 FGD
GGH adopts the vertical layout of the main shaft, namely the airflow direction of
the raw flue gas is upward while the clean flue gas downward. Since the raw flue gas
contains the fly ash of a certain concentration, the fly ash may deposit on the inside of
the unit, and as time goes by, the efficiency of heat transfer may reduce. In order to
prevent the depositing and fouling between the GGH heat transfer surfaces which will
9

influence the heat transfer efficiency, increase the resistance and air leakage rate and
reduce the service life, it is needed to use the compressed air to sweep or the
high-pressure water to clean regularly with the ash ejector, which is equipped with
one or two retractable spray guns. The spray gun is of two layers of the inner pipe and
outer pipe and can use two kinds of cleaning medium at the same time. The inner pipe
is the high-pressure water nozzle while the outer pipe is the compressed air or
low-pressure water nozzle. The high-pressure water pump wash is the online wash
(about 10 times a year, according to the operation of the unit). When FGD unit stops
running, the heat exchanger can be washed with the low-pressure water.
GGH
GGH GGH
GGH
The ash ejector is of the fully retractable type, which only exposes to the flue gas
at work. After the GGH finishes soot blowing, it will be retracted outside the GGH
shell. The seal air system ( ash ejector self-prepared) provides the seal air in the joint
of the ash ejector and GGH shell, and the main corrosion prevention measures to
prevent the overflow of the raw flue gas from GGH are as follows: The static module
with exposure to the flue gas are protected with the glass flake resin coating. The
rotary parts such as the rotor and cell as well as box bar adopt the Corten steel. The
sealing strip adopts advanced stainless steel and the heat exchanger element adopts
the low carbon steel coated with enamel.
2.3
2.3 Flue gas damper
FGD 3
/
Each set of FGD flue system totally has three flue gas dampers. All flue gas
dampers adopt double blades louver damper with the open/close function driven by a
motor.

:
The corrosion prevention measures for the damper are mainly guaranteed by the
correct selection of metal materials. See the list below for details of the materials of
main module:

List of the Main Design Parameters and Materials of the Flue Gas Damper
(preliminary)

Item Raw gas damper Clean gas damper Bypass damper
DIN1.4529 DIN1.4529
Q235-A
Q235-A
Carbon steel is coated with
10

Blade DIN1.4529 or equivalent clean flue gas side carbon

steel is coated with
DIN1.4529 or equivalent, and
raw flue gas side adopts
Q235-A
35# DIN1.4529 35# DIN1.4529

35#
Shaft 35# steel is coated with 35# steel is coated with
DIN1.4529 or equivalent DIN1.4529 or equivalent
DIN1.4529
Q235-A DIN1.4529

Q235-A Clean flue gas side carbon
Framework Q235-A is coated with
steel is coated with
DIN1.4529 or equivalent
DIN1.4529 or equivalent
DIN 1.4529
Alloy C276 Alloy C276

Sealing
DIN 1.4529 or Alloy C276 or equivalent Alloy C276 or equivalent
material
equivalent
2
(1 1 ) 0.5kPa
The inlet and outlet flue gas damper and the bypass damper share a set of seal air
system including 2 seal fans (one for use and the other for backup) and an electric
heater. The seal air pressure is 0.5kPa higher than the flue gas pressure, and it is
considered in design that the fan should have sufficient capacity and pressure head.

The damper auxiliary equipments such as the seal fan and electric heater are all
supplied by the damper manufacturer with match.
11


Section II Absorber system
1
1) Spray tower
Mist eliminator
Raw flue gas inlet
Clean flue gas outlet
Spray pipe
Absorber reaction tank
12

1. The absorber system flow chart

pH

pH
Flue gas
Air vent to atmosphere
Process water
Flow meter
Mist eliminator and wash water
Gypsum hydrocyclone
pH PH meter
Densimeter
Limestone slurry
Emergency slurry tank
To the drainage pit of absorber
Absorber
Slurry circulation pump
Process water
13

Oxidation fan
Process water
Process water
pH Measurement of pH value and density
To gypsum dewatering
Gypsum slurry discharge pump
To emergency slurry tank
Process water
Absorber blender
1.1
1.1 Overview
/
Adopt the local forced oxidation process of wet limestone/gypsum to remove

the sulfur dioxide in the flue gas and generate the by-product gypsum.
SO2SO3
HFHCl SO2
In the absorber, the circulating slurry fogdrop contacts with the reverse flue
gas flow to clean SO2, SO3, HF, HCl, dust and other noxious substances in the flue
gas while the calcium carbonate in the slurry reacts with SO2 and generates calcium
sulfite. The clean flue gas, after desulfurization and dust removal, is discharged out of
the absorber after the fogdrop in the flue gas are removed by the mist eliminator.

Inject air to the slurry collected in the absorber slurry pool (in the lower half
of the absorber acting as the reaction area of the absorber) to oxidize the calcium
sulfite to calcium sulfate and generate the gypsum crystals. In order to keep the
suspension of solid particles in the slurry and strengthen the oxidation reaction, four
blenders are configured in the absorber slurry pool.

During normal operation, the gypsum slurry discharge pump will deliver the
gypsum slurry to the gypsum hydrocyclone for dewatering.
FGD
14

FGD
The exhaust gate is set at the top of the absorber and is closed during normal
operation. When FGD unit uses the bypass or is shutdown, the exhaust gate will open
to discharge the wet steam in the tower and the flue to maintain the pressure balance
inside and outside the flue gas system. When the bypass damper opens, the raw gas
damper and the clean gas damper will close, and then open the exhaust gate of the
absorber.
1.2
1.2 Reaction principle
SO2
The SO2 removal principle in the absorber is as follows:
SO2
SO2 in flue gas reacts with the calcium carbonate in the slurry to generate
calcium sulfite:
CaCO3 SO2 H 2 O CaSO3 H 2 O CO2 1
With the intermediate transition reaction of the oxygen in the flue gas and the
bisulfite, part of calcium sulfite changes into gypsum (dihydrate calcium sulfate) :
CaSO3 H 2 O SO2 H 2 O Ca(HSO3 ) 2 2
Ca( HSO3 )2 1 2O2 H 2 O CaSO4 2 H 2 O SO2 3
The remaining calcium sulfite in the absorber slurry pool oxidizes with the air
blown by the oxidation fan to generate calcium sulfate.
CaSO3 H 2 O 1 2O2 H 2 O CaSO4 2H 2 O 4
At the same time, some other chemical reactions also occur: The reaction of
sulphur trioxide, chlorine hydride and hydrofluoric acid with calcium carbonate
generates gypsum, calcium chloride and calcium fluoride:
CaCO3 SO3 2H 2 O CaSO4 2H 2 O CO2 5
CaCO3 2 HCl CaCl2 H 2 O CO2 6
15

CaCO3 2 HF CaF2 H 2 O CO2 7
1.3
1.3 Procedure description

/
SO2 SO3 HCl
HF
CaSO42H2O
The hot flue gas from the induced draft fan of the boiler after pressurized by the
booster fan enters the spray absorber for desulfurization. In the absorber, the flue gas
contacts with the reverse limestone/gypsum slurry flow and is cooled to the adiabatic
saturation temperature. SO2 and SO3 in the flue gas react with the limestone in the
slurry to generate calcium sulfite and calcium sulfate, and the HCl and HF in the flue
gas also react with the limestone in the slurry and is absorbed. The saturated flue gas,
after desulfurization, is discharged into stack after fogdrop in it is removed by mist
eliminator on top of the absorber. The oxidation air fan blows air into slurry pool of
absorber, to oxidize calcium sulfite to calcium sulfate, and supersaturated calcium
sulfate solution crystallizes into gypsum (CaSO42H2O). The gypsum slurry is
continuously pumped out by the gypsum slurry discharge pump and sent to gypsum
hydrocyclone for concentration, and send the concentrated gypsum slurry to two-stage
dewatering system which generally uses belt-type vacuum dewatering machine. When
solid content in slurry inside the absorber is relatively lower, do not sent slurry for
two-stage dewatering.
1.4
1.4 Main equipment
1.4.1
1.4.1 Absorber
SO2
The absorber integrates SO2 washing and absorption, oxidation and gypsum
crystallization into one. Such tower model has been adopted more widely. The tower
model has advantages in terms of operation and maintenance workload, operation cost,
operation flexibility, being easy to improve, etc.:

16

The absorber is generally designed in reverse flow mode, which can, to some
extent, hold liquid drops through rising flue gas to extend the time of liquid drop
staying in absorption area, thus intensifying complete contact between flue gas and
absorbent, improving the desulfurization efficiency.

Besides nozzle, there is no other equipment in the absorption area of the

absorber, which reduces probability of scaling, blocking and abrasion, increases the
availability ratio of the equipment and reduces overhaul workload.

Less equipment in the tower reduces resistance of desulfurization system and
saves energy.
SO2
The absorber can be equipped with standby spraying layer which can adapt to
changes of SO2 loaded by the unit, keep the operation flexible, and maintain stable
desulfurization efficiency.

The absorber for the project is characterized as follows:
192
80kPa
The absorber is set with five layers of spray systems, for each layer of spray system is
set with about 192 eccentric cone nozzles, nozzle inlet pressure head is about 80kPa,
and there is two-level mist eliminator set on spraying layer.

The absorber is of empty tower structure, which means low pressure drop
inside the tower.

No scaling or blocking problem on inner surface of the absorber.
FGD
pH //
FGD
The layout of spraying layer, nozzle, mist eliminator and flue gas inlet and
outlet in the absorber has referred to operation experience of FGD design, defining the
distance between spraying components according to effective spraying trace and
retention time of droplets. Meanwhile, it adopts appropriate pH value, liquid/gas ratio,
calcium/sulphur ratio, oxidation air quantity, slurry concentration, flue gas velocity
and other performance parameters, thus ensuring continuous, stable and economical
operation of FGD system.
17


(CaSO42H2O)
4
Oxidation and crystallization mainly occur in slurry pool of the absorber.

Dimension of slurry pool of absorber can provide enough slurry retention time to
complete calcium sulfite oxidation and gypsum (CaSO42H2O) crystallization. There
are 4 sets of side-entering blenders set on slurry pool of absorber to keep solid
particles in slurry pool in suspension state and intensify oxidation of calcium sulfite.
pH
SO2 pH
pH 5.25.8
The pH value of slurry in slurry pool of absorber is under control of

limestone amount, and the limestone slurry amount poured into absorber depends on
boiler load, SO2 content and actual pH value of slurry in absorber. PH value of slurry
in absorber is about 5.2-5.8. Add limestone slurry into slurry pool of absorber to mix
with gypsum slurry. Mixed slurry in slurry pool of absorber is sent to nozzle through
spray pipe set by slurry circulation pump, forming extremely fine droplets and
spraying into the tower.
FGD
FGD
The air release valve is set at the top of the absorber and the valve is closed
during normal operation. When FGD unit takes bypasses or it stops, open the air
release valve to discharge wet steam in tower so as to eliminate air differential
pressure due to cooling during operation or stopping of oxidation fan of absorber.
1.4.2
1.4.2 Absorber slurry circulation pump

Slurry recirculation system adopts unit system design, each spraying layer is
equipped with one set of slurry circulation pump, and each set of absorber is equipped
with five sets of slurry circulation pump. Quantity of operating slurry circulation
pump depends on change of boiler load and requirements for absorbed slurry flow, so
as to reach the required absorption efficiency. Since it can select the most economical
pump operation mode according to boiler load, the recirculation system can reduce
energy consumption under lower boiler load.
1.4.3
18

1.4.3 Slurry spraying system

/L/G 95%
The slurry spraying system consists of spraying components and nozzles. One
spraying layer consists of main pipe slurry distribution pipeline with connecting
branch pipes and nozzles; spraying components and nozzles are arranged in a cross
section evenly covering absorber and spraying slurry coverage rate reaching the
required value to make slurry contact with flue gas sufficiently, thus ensuring to
reliably realize 95% desulfurization efficiency under proper liquid/gas ratio (L/G) and
with no scaling on the inner surface of absorber.
FRP
Hollow cone nozzle and FRP spray pipeline made of silicon carbide can extend
operation time, with no corrosion, abrasion, gypsum scaling, blocking or other
problems.
1.4.4
1.4.4 Mist eliminator
FGD FGD
FGD
Mist eliminator is the key equipment in FGD system, for its performance can
directly influence continuous and reliable operation of the wet FGD system. Mist
eliminator fault will stop the desulfurization system. Therefore, scientific and rational
design and usage of mist eliminator have great significance to keep normal operation
of wet FGD system.

Main performance and design parameters of mist eliminator:

Demisting efficiency. It refers to the ratio between mass of droplets collected

in unit time by mist eliminator and the mass of droplets entering mist eliminator.
Demisting efficiency is a critical index to examine mist eliminator performance.
There are many factors influencing demisting efficiency, mainly including: Flue gas
velocity, evenness of distribution of air flow passing mist eliminator section, blade
structure, distance between blades, mist eliminator layout form, etc..

19

System pressure drop. It refers to pressure loss when flue gas passes through
mist eliminator channel, and the more system pressure drop is, the higher the energy
consumption is. Pressure drop of demisting system is mainly related to factors of flue
gas velocity, blade structure, distance between blades, water load in smoke, etc. When
the mist eliminator blade is seriously scaled, system pressure drop will obviously
increase. Therefore, it is conductive to master system operation state by monitoring
changes of pressure drop, and find out problems and dispose in time.

3.55.5m/s
Flue gas velocity. Neither too high nor too low flue gas velocity on mist
eliminator section is beneficial to normal operation of mist eliminator. Too high flue
gas velocity is easy to cause secondary water in flue gas, thus reducing demisting
efficiency, and meanwhile, high velocity will cause larger system resistance and
higher energy consumption. Too low velocity on mist eliminator section is not
beneficial to liquid-gas separation, nor beneficial to improve demisting efficiency.
Besides, the lower the design velocity is, the larger the design absorber section will be
and so will the investment. Design flue gas velocity shall be close to the critical
velocity. According to different mist eliminator blade structures and layout forms,
design velocity is generally 3.5-5.5m/s.

SO2
2095mm
3050mm
Distance between mist eliminator blades. Selection of distance between mist
eliminator blades is quite important to ensure demisting efficiency and maintain stable
operation of demisting system. Large blade distance will cause lower demisting
efficiency and higher water content in flue gas, which is easy to cause fan fault and
lead to abnormal stop of the entire system. Besides increasing energy consumption,
too small blade distance can also reduce washing efficiency, cause scaling and
blocking on blade, and finally lead to system stop. Blade distance shall be selected
according to system's flue gas characteristics (flow velocity, SO2 content, water load,
dust concentration, etc.), absorbent utilization rate, blade structure and other
comprehensive factors. Blade distance is generally designed 20-95mm. Currently, the
mostly common mist eliminator blade distance in desulfurization system is 30-50mm.
20


1m
Mist eliminator wash water pressure. Generally, the mist eliminator wash
water pressure is defined according to washing nozzle characteristics, distance
between nozzle and mist eliminator and other factors (distance between nozzle and
demister is generally less than or equal to 1m). Low wash water pressure will cause
bad washing effect while higher wash water pressure will be easier to increase the
water content in flue gas, and reduce blade service life at the same time.

14m3/m2h
Mist eliminator wash water volume. Besides the requirements for the mist
eliminator itself, selection of mist eliminator wash water amount also needs to
consider requirements for system water balance. It needs to use a large amount of
water to wash in short time under some conditions, while sometimes, it needs to use
small amount of water to wash in long time. The specific wash water amount shall be
defined according to working conditions, and generally, the transient wash water
consumption amount of demister section is about 1-4m3/m2h.

100300
Washing coverage rate. Washing coverage rate refers to the coverage degree
of wash water on mist eliminator section. According to different operation conditions,
the washing coverage rate is generally 100-300%.

35
2h
Mist eliminator washing cycle. Washing cycle refers to the time interval of
each washing of mist eliminator. Since mist eliminator washing will increase the
water content in flue gas (generally being 3-5 times of the content of non-washing),
washing should not be too frequent, but the interval shall not be too long, otherwise it
will be easy to cause scaling. Mist eliminator washing cycle is mainly defined
according to flue gas characteristics and absorbent, generally not exceeding 2h.

75mg/Nm3
The absorber is set with a two-level mist eliminator at the top of the last spraying
component on the absorber top. After passing the circulating slurry spraying layer, the
flue gas continuously flows through two-level mist eliminator to remove the
contained slurry fogdrop. In order to avoid mist eliminator blocking, it is equipped
21

with flushing system. After the flue gas passing through the two-level mist eliminator,
the water content in flue gas is lower than 75mg/Nm3 (dry basis). Mist eliminator
cleaning system adopts intermittent operation and automatic control.
1.4.5
1.4.5 Oxidation air system
/ FGD
SO2
Wet limestone/gypsum FGD process is divided into forced oxidation and natural
oxidation. Small amount of SO2 absorbed by slurry is oxidized by oxygen in flue gas
in absorption area, which is called natural oxidation. Forced oxidation refers to
spraying air into oxidation area of the tank to promote to oxidize soluble sulfite to
sulfate, control scaling and finally crystallize to gypsum.
FGD
(CaSO31/2H2O)(CaSO42H2O)
In the FGD system, oxygen content in flue gas itself is not enough for oxidation
reaction to produce calcium sulfite. Therefore, it needs to provide forced oxidation
system to provide oxidation air for slurry of absorber. Oxidation air oxidizes
semi-water calcium sulfite (CaSO31/2H2O) generated in desulfurization reaction to
calcium sulfate and crystallize to gypsum (CaSO42H2O).

FGD
Oxidation air system consists of oxidation fan and oxidation air distribution
piping net in centralized arrangement. Generally, each set of FGD unit is equipped
with two sets of oxidation fans, one for operation and the other for standby.

n
When oxidation air is evenly distributed to slurry pool of absorber through

oxidation air distribution piping net: Each absorber is set with several pieces of
oxidation air distribution branch pipes on each of which there are many small holes,
oxidation air is sprayed out from these holes, forming small air bubbles evenly
distributed on reacting slurry pool section of the absorber, and the bubbles rises up to
slurry pool surface under function of buoyancy force and fully mixes with slurry
during rising, and oxidation reaction is conducted, thus realizing high oxidation
efficiency.
22

1.4.6
1.4.6 Discharge pump of absorber
1 1
Discharge pump of absorber (one for operation and one for standby) is installed
nearby the absorber. The discharge pump of absorber pumps out gypsum slurry from
slurry pool of absorber through pipelines and sends to gypsum hydrocyclone station.

Slurry pool side wall of absorber is installed with a high-low liquid level meter,
which can measure the density of slurry.
DCS
Density instrument sends the density signal to DCS, when the absorber is
switched on and the density reaches or approaches to the set value, the discharge
pump starts, and gypsum slurry is pumped into the gypsum hydrocyclone for
separation from the slurry pool of the absorber. Gypsum slurry is continuously
discharged, so liquid level of the absorber will decline, and then flushing valve or
water inlet valve of the mist eliminator will be opened to convey filtrate water into the
absorber to maintain the liquid level; by this time, the density of slurry in the absorber
will decrease, when it reaches the set value, underflow and overflow of the
hydrocyclone will return to the absorber, gypsum slurry enters the belt-type vacuum
dewatering machine, and the pipeline closes until that the density of gypsum reaches
or approaches to the set value.

23

Discharge pump of the absorber may also empty the slurry pool of the absorber
into the emergency slurry tank so as to facilitate the overhaul for absorber, blender
rotary blades, nozzle, mist eliminator and wash water pipe of the mist eliminator.
1.4.7
1.4.7 Blender of absorber
34
(CaCO3 )
SO2
3-4 blenders are horizontally arranged in radial direction within the bottom slurry
pool of absorber; its function is to keep the slurry in the flow state, thereby also
maintain the desulfurization active substance (CaCO3 solid particle) in uniform
suspension state in the slurry, and ensure the absorption and reaction capacity of
slurry on SO2.
1.4.8 PH
1.4.8 PH meter
EDC 2
PH 2 pH pH DCS pH DCS pH
SO2
pH SO2 pH
pH
Slurry pipeline is extended respectively from E, D and C outlet pipeline of the

circulation pump, and the converged pipeline is set with 2 sets of pH meters; 2 sets of
pH meters will send pH signal to DCS, and when the pH value is lower than the set
value, DCS will consider the flue gas load and SO2 concentration at the inlet and
outlet of flue gas based on pH value to control the feeding regulating valve opening of
limestone slurry, increase the feeding of limestone slurry, restrain the decline of pH
value and ensure the removal efficiency of SO2; When the pH value is higher than or
close to the set value, turn down the feeding regulating valve opening of limestone
slurry to prevent that pH value is too high, thus causing scale formation in the system.
1
PH 2 PH
There is only 1 branch pipe to feed slurry in normal operation; when this section
of pipeline needs to exit or the circulation pump stops operation, open the pipeline
flushing valve of pH meter, after 2 minutes of flushing, open the electrically-operated
valve of pH meter direction, and close the electrically-operated valve at the branch
pipe inlet; inspectors need to close the manual valve of this branch pipe manually,
depositing the slurry for precipitation.
24


Section III Slurry preparation system

FRP
Medium adopted by slurry preparation of the wet mill generally contain process
water and filtrate water. With different media, materials used by tank and pipeline in
slurry preparation system are different; when process water is adopted, carbon steel is
generally adopted for slurry pipeline; If filtrate water is used to make slurry, corrosion
prevention shall be considered due to the chloride ion content in the filtrate, adopt
materials such as carbon steel lined with rubber or FRP material. Task of slurry
preparation system is to offer qualified limestone slurry for absorber system.
1
1. Limestone wet-milling slurry preparation system
1.1
1.1 System description
FGD 90325
44m
The FGD system adopts limestone blocks wet-milling slurry preparation scheme;
request on the limestone particle size in slurry: 90325 meshes (44m).
(20mm)
,
Limestone (particle size 20mm) is sent to the unloading hopper by truck, to the
limestone silo via the feeder and bucket elevator, and then conveyed to the wet ball
mill by weighing feeder and ground into slurry. Limestone slurry is pumped into the
hydrocyclone, after separation, materials of large size re-circulate, and qualified
overflow materials are stored in the limestone slurry tank, and then delivered into the
absorber via the limestone slurry pump.
2.2
2.2 Main equipment

The system mainly includes unloading hopper, limestone silo, bucket elevator,
limestone mill, weighing feeder, mill slurry circulation pump, mill re-circulation tank,
hydrocyclone, limestone slurry pump, limestone slurry tank, slurry tank blender and
other equipment.
25

2.2.1
2.2.1 Unloading hopper
FGD
Limestone blocks are sent to FGD by self-discharging truck or other methods,

and discharged into the unloading hopper. Upper part of hopper is equipped with a
steel grate to prevent the entering of limestone of large particle size.

20mm
To reduce the size and cost of wet mill, the plant won't conduct crushing
generally. Feeding limestone crushing size shall be usually not larger than 20mm.
Limestone transported by truck is discharged into the hopper, sent to the bucket
elevator passing the vibrator feeder with metal separator, and then sent to the
limestone silo through bucket elevator.
2.2.2
2.2.2 Limestone silo

The silo is designed with 2 discharge holes, separately feeding each set of mill;
the discharge hole is designed with air cannon anti-blocking measures.

On the top of limestone silo has been set with a sealed manhole door, which
should be quickly opened by hinge and handle, besides, there is exhaust gate on the
top.

50mg/Nm3
Ventilation & dust collector of the silo is bag-type dust collector, and the
maximum dust content in clean gas after dust removal is less than 50mg/Nm3.

Charge level indicator which is used to confirm the volume is equipped on the
silo, and also can be used for distant indication.

Necessary stair landing shall be designed for the convenience of overhaul and
maintenance of dust collector, charge level indicator, etc.

Each discharge hole of the silo should be installed with shut off valve.
32.2.4
26

32.2.4 Weighing feeder

Weighing feeder is used to measure and transport the limestone to the ball mill,
and capacity of each set of the limestone belt weighing feeder shall be confirmed
based on the limestone feeding amount required by the limestone slurry preparation
system.

Feeder operates in a complete sealing state to prevent dust. Sealing of the feeder
is made of demountable plates, each of which is equipped with sealing gasket and
quickly opening plug pin that is convenient for maintenance.

The feeder is designed to discharge belt spilt and entrainment into the feeding
trough.
2.2.5
2.2.5 Limestone mill
(
) 100
The limestone milling system adopts the wet ball mill slurry preparation system.
Slurry preparation mode is the re-circulation mode (each set of mill is equipped with 1
set of rotational flow station). When 2 sets of the mills are adopted, the output of each
set of mill is designed based on 100% of total design output.

FGD SO2
44m(325 90)
()
Model selection of wet limestone mill may ensure the continuous or

discontinuous operation. The mill can ensure to supply limestone slurry required by
the FGD process under all operational working conditions. Material fineness of mill
outlet can meet the requirement of SO2 absorption system, and the particle size
generally reaches 44m (325 meshes; 90% of the passing rate). The ball mill is
equipped with a full set of the driving system, including motor, reducer, air clutch, a
full set of bearing and lubricating system (oil cooling equipment included). The
lubricating oil system can ensure that bearings won't be damaged in the process of
mill stopping because of oil pump failure; it may ensure sufficient lubrication under
all operation conditions even during starting, and the high-pressure oil pump is
adopted.
2.2.6
27

2.2.6 Hydrocyclone
(
)()
2530wt
Hydrocyclone is used to separate the limestone slurry at the wet mill outlet,
separated overflow slurry (including fine particles) will directly enter the limestone
slurry tank, and underflow (including large particles) returns to the wet mill. Each
hydrocyclone is installed with a separate manual valve. Hydrocyclone is in annular
layout, and the whole system is self-support framework, which entirely adopts steel
members. Each rotational flow station is set with a cyclone for standby. Each set of
mill is equipped with a group of limestone slurry hydrocyclones, and can meet the
requirement of limestone slurry fineness. Overflow slurry of each group of limestone
slurry hydrocyclones shall be able to enter the limestone slurry tank. Concentration of
limestone slurry can be correctly controlled in any concentration 25-30wt.
2.2.7
2.2.7 Pump, tank and blender

2 sets of mill slurry re-circulation pumps are equipped for each set of the mill
with one for operation and one for standby;

100BMCR 1~1.5
The limestone slurry pump is used to send the limestone slurry into the
absorber, and is set with frequency converter. Its capacity is designed based on 1-1.5
times of limestone slurry consumption needed by desulfurization under the working
conditions of 100% of BMCR of one boiler, and this pump is also equipped with
standby pump.

1 mill re-circulation tank for each set of mill;
68
2 limestone slurry tanks; The total capacity is designed as per the
consumption of 6-8h.

Section IVGypsum dewatering system

28

Function of gypsum dewatering system is to remove the moisture in gypsum

slurry to facilitate the storage and transportation, and return the removed moisture to
the absorber or absorbent preparation system for reutilization to reduce water
consumption. The dewatering system contains 2 stages: One-stage dewatering system
(primary dewatering system) and two-stage dewatering system.
Limestone slurry
Absorber
Raw flue gas
Gypsum slurry
Wastewater treatment system
Hydrocyclone
Dewatering machine
To gypsum stockpile
To slurry preparation system
1
1. One-stage dewatering system
SO2
1,0701,150kg/m3
15wt 3
4 50wt
29

Gypsum crystals generated by reaction with SO2 in the absorber are continuously
sent to the gypsum hydrocyclone for primary separation by discharge pump of
gypsum slurry so as to ensure that the density in the absorber keeps 1,070-1,150kg/m3.
After primary separation of slurry with concentration about 15%wt from the absorber
in hydrocyclones, concentration of the top flow is generally 3-4%, and that of the
underflow is generally 50%wt. A part of the top slurry flow is sent to the wastewater
treatment system and another part returns to the absorber for cyclic utilization; the
underflow is sent to the two-stage dewatering system and dewatered into gypsum.
1.1
1.1 Gypsum slurry discharge pump

1015wt
FGD
Gypsum slurry discharge pump generally adopts centrifugal pump, and is set
with frequency converter. Its main function is to send the gypsum slurry with
concentration about 10-15%wt in the absorber into the hydrocyclone for primary
dewatering, and regulate the pump revolving speed via conversion of current
frequency to make the pressure at hydrocyclone inlet constant; Then regulate the sand
sinking nozzle of hydrocyclone to change the top flow slurry amount of hydrocyclone
so as to ensure the flow and concentration of hydrocyclone outlet. When an overhaul
is required for FGD system, the gypsum slurry discharge pump can be used to pump
the slurry in absorber into the emergency slurry tank.
1.2
1.2 Gypsum hydrocyclone
30

Feeding port
Overflow nozzle
Overflow port
Staving
Taper pipe
Sand sinking nozzle
Feeding port
Staving
Taper pipe
Sand sinking nozzle
31

Hydrocyclone mainly used to separate and classify particulate matters is

extensively applied in metallurgy and mining industry. In gypsum hydrocyclone,
gypsum slurry enters the distributor, and is shunted into the single cyclone. Cyclone
accelerates the sediment by using centrifugal force, and the slurry flow is separated on
the tangent direction of hydrocyclone inlet under the acting force to make slurry form
an annular operation. Large particles are thrown into the circular surface of
hydrocyclone, fine particles stay in the center, and clarified liquid is extracted from
the upper part via the immersed pipe; dense slurry flows away from the bottom,
however, the dilute part of gypsum slurry enters the overflow. Slurry is separated as
per light and heavy components through gravity, centrifugation and rotational flow in
hydrocyclones. The larger pressure at the cyclone inlet is, the smaller particle size in
the overflow slurry will be. Via sampling for gypsum slurry in the absorber of plenty
of gas desulfurization systems, the distribution of gypsum crystal size can be obtained,
thereby gypsum crystals suitable for dewatering can be separated, and unqualified
gypsum crystals will return to the absorber for further crystallization.
32

Reference Diagram of Gypsum Hydrocyclone

2
2. Two-stage dewatering system

10
Primary concentrated slurry flowing from the underflow of gypsum

hydrocyclone enters the two-stage dewatering system for further dewatering until that
water content of gypsum is not larger than 10%. The two-stage dewatering is
generally completed by adopting belt-type vacuum dewatering machine and
centrifugal hydroextractor and auxiliary equipment.
2.1
2.1 Gypsum quality:

Gypsum quality generally depends on the following conditions:

Limestone quality (inert substance/magnesium compound content and
particle size of limestone)

Concentration of fly ash entering the raw flue gas of the absorber
SO2HCl
Compositions of the raw flue gas (SO2, HCl, etc.)

Process water quality (chloride ion content)
2.2
2.2 Quality requirement of typical gypsum
2.2.1
2.2.1 Quality requirement of building gypsum:
10wt
Water content of gypsum 10%wt
95wt
Dry gypsum purity 95%wt
100mg/kg
Chloride ion content 100mg/kg dry gypsum
2.2.2
33

2.2.2 Quality requirement of cement gypsum:

15wt
Water content of gypsum 15%wt
90wt
Dry gypsum purity 90%wt
100mg/kg
Chloride ion content 100mg/kg dry gypsum
1. 1. Filter cloth washing

2. 2. Rubber dewatering belt washing
3. 3. Filter cake washing box
4. 4. Feeding box
5. 5. Rubber dewatering belt
6. 6. Filter cloth
7. 7. Filter cloth aligning mechanism
8. 8. Filter cloth tensioning
9. 9. Unloading roller
10. 10. Driving roller
11. 11. Driven roller
12. 12. Vacuum tray
13. 13. Framework
2.3
2.3 Belt-type vacuum dewatering system

Cl- 20000ppm 100ppm
34

50wt 90wt
Belt-type vacuum dewatering system is constituted by the main equipment like

belt-type vacuum dewatering machine, vacuum pump, gas-water separator, and
auxiliary equipment like filter cloth flushing unit and filter cake flushing unit. Its first
function is to transfer Cl- in gypsum crystal to the liquid phase and discharge it out of
the system via water scrubbing to reduce its content from 20000ppm to 100ppm; the
second is to further dewater the slurry with 50%wt of solid content to be bulk gypsum
with 90%wt of solid content. Belt-type vacuum dewatering machine is a
high-efficiency concentration equipment which makes the best of material self-weight
and vacuum draw to realize solid-liquid separation, and is featured by high
dewatering efficiency, low filter cake water content, large treatment capacity, low
operation and maintenance cost, etc. Its structure is shown in the diagram. The
dewatering machine consists of rubber belt, filter cloth, vacuum chamber, driving
roller, driven roller, feeding hopper, unloading unit, filter cloth aligning unit, filter
cloth/rubber belt washing device, frame, etc. Slurry is evenly distributed on the filter
cloth when entering the fishtail feeding hole, and forms material layer. Filter cloth is
supported by rubber belt; rubber belt carrying filter cloth and filter cloth carrying
gypsum moves in constant velocity. Rubber belt is opened with transverse groove, the
center of which is a drainage hole. When the rubber belt carries filter cloth and its
materials to pass through the vacuum chamber, free water in gypsum and filter cake
flushing water flow to rubber belt drainage hole through filter cloth under the action
of vacuum draw, and feed into the dewatering machine vacuum chamber. The vacuum
chamber bottom is connected with the filtrate confluence main pipe by a series of soft
vacuum sealing hoses, and the filtrate main pipe is tangentially connected into the
gas-water separator. At the dewatering machine head (drive motor side), unloading
roller changes its direction of rotation; filter cake separates with filter cloth under the
effect of gravity, enters the unloading hopper, and is sent to the gypsum silo via
belt-type conveyer. After removing filter cake, filter cloth passes through the drip
washing area during the returning, where the filter cloth is washed by using waste
water of vacuum pump. If filter cloth goes askew, the filter cloth aligning roller is
adopted to correct; the path of the filter cloth is controlled by the limit switch.
35

36

Water ring vacuum pump is a power equipment to conduct pumping of gypsum

filtrate. During operation of the vacuum pump, there will form a crescent cavity
between the pump body and impeller due to the rotation of eccentric impeller, which
generates negative pressure. Under the effect of negative pressure, free water of
gypsum slurry together with pumping air will enter the filtrate confluence main pipe
via the dewatering machine vacuum chamber, and then tangentially enter the
gas-water separator. Gas-water separator is the equipment realizing the gas-liquid
two-phase separation, gas phase and liquid phase are separated in gas-water separator
due to different centrifugal effects, gas phase is discharged into the atmosphere via
vacuum pump and liquid phase enters the filtered water tank under the effect of
gravity. Various process water and filtered water in the system will return to the
filtered water tank finally, and be sent to the limestone slurry preparation system or
absorber for reutilization.

Section V Discharge system
FGD
FGD /
In FGD system, the drainage pit is usually located near the absorber, and is used
to collect the draw-off during normal operation, washing and overhaul of absorber
area. The drainage pit collects the flushing water and/or blowoff water of FGD unit. If
the drainage pit reaches certain liquid level, the pump will transport the slurry in it to
the absorber or emergency slurry tank.

37

Emergency slurry tank is used to discharge and store the slurry in the absorber
slurry pool under the condition of overhaul, minor repair, stop or emergency of
absorber. Slurry in the absorber can be sent to the emergency slurry tank through the
absorber discharge pump; Slurry can be conveyed back to the absorber from the
emergency slurry tank via the emergency slurry pump.
1
Emergency slurry tank: 1
4
Emergency slurry tank blender: 4 sets (side-entry)
2
Emergency slurry pump: 2 sets
1
Drainage pit of absorber area: 1
1
Blender of drainage pit of absorber area, 1 set
2
Drainage pit pump of absorber area: 2 sets
1
Drainage pit of slurry preparation area: 1
1
Blender of drainage pit of slurry preparation area: 1 set
2
Drainage pit pump of slurry preparation area: 2 sets
1
Drainage pit at the dewatering area: 1
1
Blender of drainage pit at the dewatering area, 1 set
2
Drainage pit pump at the dewatering area: 2 sets
1
1. Emergency slurry tank

38

Emergency slurry tank is generally set within the desulfurization island, and used
to collect the absorber slurry in case of accidents and maintenance work of
desulfurization island.

Capacity of the emergency slurry tank is usually designed slightly larger than the
absorber slurry pool, and blender is equipped and vertically installed on the top or
side wall. Blender is to maintain the rotating suspension of slurry in the pool to
prevent the sediment of solid particles.
2
2. Emergency slurry pump

Emergency slurry pump is used to discharge the slurry of the emergency slurry
tank.

Uniflow single-stage centrifugal pump is generally selected for emergency slurry

pump, whose design flow is relatively large and which enables it to entirely pump the
slurry of the emergency slurry tank back to the absorber in a short time.
3
3. Drainage pit of absorber area

Drainage pit of absorber area is used to collect the pipeline effluent of absorber
area during normal operation, washing and overhaul.
33 3
Drainage pit of absorber area is generally designed into a rectangular pool of

33m and 3m deep, and there is corrosion prevention lining in it. The pit body and pit
top are made of strong concrete; besides, manhole is set for the convenience of
overhaul. The drainage pit also has inlets of many channels, and is equipped with
blender. Blender is vertically placed at the center of drainage pit top. Blender is used
to prevent sediment of solid particles of slurry in the pit.
4
4. Drainage pit pump of absorber area

39

Drainage pit pump installed on the drainage pit top is used to transport the slurry
from the drainage pit to the absorber or emergency slurry tank.

Drainage pit pump is generally designed as uniflow single-stage centrifugal

vertical pump, its design flow is relatively large to prevent that relatively large inflow
cannot be emptied timely, suction pipe and pump are installed in the pit, but motor
and coupling are installed on the pit top.
5
5. Drainage pit pump of slurry preparation area

Drainage pit pump installed on the drainage pit top is used to transport the slurry
from the drainage pit to the limestone slurry tank.


6
6. Drainage pit pump at the dewatering area

FILTRATE WATER TANK
Drainage pit pump is installed on the top of drainage pit, which is used to convey
the slurry from the drainage pit to filtrate water tank.



Section VI Process water system

Process water system is used to offer the water required by system water
replenishing and flushing in the desulfurization island.

40

FGD
Process water tank is installed in the desulfurization island. 2 sets of water

supply systems of process water and mist eliminator flushing water are set. There will
be water consumption within FGD unit area, which mainly contains the flue gas
saturation carrying, and crystal water of gypsum, surface water and wastewater
discharge. This consumption is mainly complemented by inputting fresh process
water.

Process water comes from the main plant.
FGD
100
Process water should be supplied to the process water tank set on FGD unit site.
Process water is supplied into all equipment needing process water from the process
water tank via the process water pump. Relevant process water pump is equipped with
100% of allowance.

Process water is mainly used to wash the absorber mist eliminator and prepare
limestone slurry, and also used as the flushing water for all conveying equipment and
slurry pipelines. Process water also can be used as the cooling water of partial
equipment of the desulfurization island.
1
1. Supply system of process water includes
1 FGD 1 FGD
1 FGD process water tank and 1 cooling water tank. Design volume of the water
tank shall ensure the safe operation of FGD unit.

Inlet control of process water tank includes the control signal and inlet valve.

All needed connecting pipe, supply, discharge, overflow and drainage, liquid
level control, inspection door, overflow pipe, drainage pipeline, and all other units
needed, flange, etc.
2 1001 1
2 sets of 100% process water pumps with one for operation and one for standby.
3 1002 1
41

3 sets of 100% mist eliminator flushing pumps with two for operation one for
standby.
2 1001 1
2 sets of 100% cooling water pumps with one for operation and one for standby.
2 FGD
2. There are equipment and systems below consuming process water in FGD
unit.

Mist eliminator flushing unit

Limestone slurry preparation system
-
Two-stage dewatering (belt-type vacuum dewatering machine-vacuum pump)
and seal water
GGH
Flushing of heat exchanger elements of GGH

Absorber blender flushing under the emergency state

Flushing of pumps and pipelines

Oxidation air cooling
3 FGD
3. There are equipment and systems below consuming cooling water in FGD
device.

Circulation pump and oxidation fan

Booster fan

Wet mill

Other small pumps (process water may be adopted)
42

4
4. Process water system diagram
43

C hin a Da t an g Co rpor at ion D e sul fur i za tion Op er at ion a nd Equ ip men t M an a ge ment St a ff O ccup a tion al Qu ali fi c at ion Tra inin g Ma te ri al
44

4
4. System water equilibrium diagram
Taken away by dewatering system.

(Gypsum surface water and water carried
by gypsum molecules)
Process water
Taken away by flue gas system. (Water

vapor and liquid water)
FGD FGD system
Taken away by wastewater system.
5
5. Typical water quality requirement

Contents Unit Data Remarks

Process water
quality

kPa 50
Pressure
- SO4 2- mg/l 1280
45


Contents Unit Data Remarks
- Cl - mg/l 250
1
-
mmol/l 1.005.00 Vacuum pump sealing is
- Hardness
required to be less than 1.
GGH
15
Suspended solid mg/l 2060 GGH washing and
particle oxidation air cooling are
required to be less than 15.

Average 20
temperature
- pH
67
- pH value

Quality of gypsum flushing water (the same as the process water quality)

Quality of equipment cooling water (the same as the process water quality)

Section VII Wastewater treatment
1
1. System determination

pH 46
CdHgCrAsPbNi
CuZn
FGD
Water quality of desulfurization wastewater is very special, and is featured by:

Instable water volume; Wastewater quality of different desulfurization units
46

usually has a very larger difference, and even if wastewater quality extracted by the
same set of desulfurization unit in the different phases will be also different;
Wastewater is faintly acid with pH value of 4-6, and has a high content of suspended
solids (gypsum, monox, metal hydroxide and fly ash), soluble chloride, calcium
sulfate, magnesium sulfate and other salts; Desulfurization wastewater contains
the first class pollutants of heavy metal ions (Cd, Hg, Cr, As, Pb, Ni and other heavy
metal ions) and the second class pollutants (Cu, Zn, fluoride, sulfide, etc.); these metal
ions come from coal, absorbent and supplementary water of different producing areas,
so the concentration of individual heavy metal ion may have a great difference. Due to
moisture vaporization of FGD system and cycle use of recycled water, the
concentration of these metal ions in wastewater may be higher compared with the
wastewater discharge standard. Based on the above characteristics of desulfurization
wastewater, some countries with developed desulfurization technology have
formulated relevant water quality discharge standard.

DL/T-997-2006
Water quality standard of desulfurization wastewater in the domestic power

industry is Discharge Standard of Wastewater from Limestone-Gypsum Flue Gas
Desulfurization System in Fossil Fuel Power Plants (DL/T-997-2006). Metal ion
precipitation process is a typical process of current desulfurization wastewater
treatment, and is also a very effective method to remove heavy metals and other
pollutants in wastewater. However, this method for wastewater treatment cannot
remove chloride, but is widely applied before value of chloride ion being limited by
discharge standard.
2
2. Setting of wastewater treatment system

The desulfurization wastewater system is designed as per continuous blow-down
and continuous treatment.
/
pH
Wastewater inlet/outlet flow and pollutant concentration shall be controlled; in
pollutants, the online real-time monitoring is conducted for flow, pH value, suspended
solids and other parameters can be regularly monitored based on the environmental
requirement.

Desulfurization wastewater treatment system is generally independently arranged

including the design and supply of the whole-set desulfurization wastewater treatment
system, and the specific system and equipment generally include:
47


HCl
Chemical dosing systems include: Lime powder storage and transportation,

slurry preparation and dosing system; Organic sulfur measuring & dosing system;
Polymeric iron measuring & dosing system; Polyelectrolyte preparation and
measuring & dosing system; HCl measuring & dosing system, etc. Various dosing
systems should include storage equipment, dissolving unit, measuring unit, pipeline
valve, etc.

A complete set of sludge dewatering unit includes dewatering machine, mud
bucket and other corollary equipment.

Complete hydrochloric acid discharge, storage, measuring and acid dosing
system equipment.

Process water system shall at least include water used by lime powder slurry
preparation system and dispensing of various dosing systems; Spray water; Flushing
water used when vessel, pump and pipeline of lime slurry preparation system stop
working; Flushing water of dewatering machine; Flushing water used when sludge
pump and pipeline stop working to wash pipelines, valves, etc..

Set necessary wastewater storage pool, wastewater pump, etc.
1 1
1 1
In order to make the system with high availability, various medical solution
storage tank shall be set with one for operation and one for standby; The measuring
box should be designed based on the capacity prepared by 1 time/day, and set with
one for operation and one for standby.

Materials selection of all equipment, pipelines and valves in the whole-set

system should be matched with the water quality characteristics of desulfurization
wastewater, dosed agentia and process effluent.
Ca(OH)2 pH
///
/
48

Alkali needed by wastewater neutralizing will select the lime milk Ca(OH)2
prepared by lime powder, the added alkali amount is controlled by pH measured value,
dosage of other chemical substances (organic sulfur/flocculant (polymeric
iron)/coagulating support agent (polyelectrolyte)/ hydrochloric acid/oxidizing agent)
should be automatically adjusted in proportion to desulfurization wastewater quantity
and water quality. Wastewater flow meter shall be set in the system.

Water used by desulfurization wastewater treatment system is taken from the

process water system and circulating cooling water system and the process water
should be adopted as far as possible.

All pumps shall be installed with check valve at the discharge side, isolating
valve at the discharge and suction side, and evacuation protection device. The pump
should be selected by matching with the conveying medium and installment
environment.
/
PVC PP PTFE
Metering pump is reciprocating/diaphragm pump type with the same

manufacturer and type, is equipped with variable frequency regulation and manual
adjustment for stroke, and is also equipped with safety valve, pressure buffer vessel
and pressure gauge. Flow passage material of metering pump should be erosion
resistance to chemical solution, and may adopt PVC or PP, and the membrane is PTFE.
Flow calibration meter is installed on each dosing line.
PLC
PLC
Various dosing systems may realize the complete automatic control via the local
control cabinet, accept the control signal of PLC, and send the system state signal to
PLC DCS. Various dosing processes should be equipped with flow and pressure
measuring instrument.

All automatic valves are equipped with manual switch. All storage tanks are
equipped with liquid level indicators and liquid level touch switch preventing
overfilling, and are interlocked with other facilities.
PLC
49

Filter cake discharge on the sludge dewatering equipment can be manually

operated on the switch board and also can be done through PLC.

1 1 1 1
Lime slurry required in wastewater neutralization is prepared by the outsourcing
bagged high purity lime powder. The whole system includes: Lime milk preparation
tank, circulation pump (one for operation and one for standby), lime milk storage tank
and lime milk slurry pump (one for operation and one for standby).

30min
Reaction chamber of triple tanks is used for neutralization, reaction and
flocculation, and provides the required blender equipment. The design hydraulic
retention time of three boxes is larger than 30min.

pH
6hr
Concentration and clarification tank has the combined action of coacervation,
clarification and sludge concentration, and is equipped with rotating sludge scraper.
Wastewater after flocculation enters the concentration and clarification tank for
further flocculation and sufficient precipitation, and the supernatant liquid overflows
into the neutralizing water pool; for bottom sludge generated, a part reflows to pH
adjusting box to enhance the effect of wastewater treatment and fully exert the
function of residual chemical agents, and the other part is periodically discharged and
treated with dewatering. The design retention time of the pool body shall be larger
than 6hr.

7
15
All chemicals required by desulfurization wastewater treatment process shall be
stored in storage and dosing unit that meets labor hygiene and drug safety standards; 7
days of storage amount should be considered for chemicals that can be purchased
from this locality, but 15 days of storage amount should be considered for chemicals
purchased from the different place.
50

FGD
Chapter II Impact on FGD Unit from Variation Range of Fuel
Characteristics

Section I Impact on system from flue gas flow rate change
SO2 Cl- FGD
FGD SO2 FGD
Apart from SO2 discharge and Cl- content, the physical property of untreated flue
gas is also a very crucial factor to design FGD system, and significant characteristics
of flue gas include flow, temperature and pressure, in which the flue gas flow has the
largest impact on FGD system design; just like determining the parameter of SO2
discharge, flue gas flow is one of the basic conditions to be determined in designing
FGD system, and is also a parameter difficult to determine. Because the smoke
exhaust rate of boiler not only changes along with coal properties, but is affected by
the factors below: Unit load, excess air quantity, outlet temperature of air pre-heater,
and air leakage of air pre-heater and other parts.
1
1. Impact on system related parameters from overload and underload.
125 75
100
To accurately describe the impact of load change on system, working conditions

under 125% load and 75% load are calculated and compared. In comparison, only the
change of flue gas amount is considered, other conditions are consistent with 100%
load, and this condition won't exist in practical project.
1.1 GGH
1.1 GGH project data setting
1.1.1
1.1.1 Relevant theoretical calculation results
25 50 75
3000000
Item Increase 25 Increase 50 75 load
51


Desulfurization 95 93.81 91.78 97.15
efficiency

Outlet concentration of 85.8mg/Nm 102.4mg/Nm 132.7mg/Nm 67.2mg/Nm
absorber
m/s
Flue gas velocity in 3.82 4.77 5.85 2.86
absorber m/s
t/h
Limestone consumption 8.58 10.73 13.68 6.44
t/h
t/h
68.8 85.82 103.76 50.68
Water consumption: t/h
t/h
15.3 19.1 242 11.5
Gypsum output t/h
Nm3/h
Oxidation air demand 18972 23715 29328 14229
quantity Nm3/h
t/h
8.1 10.1 12.3 6.1
Wastewater output t/h
1.1.2
1.1.2 Result analysis
25 50 75
3000000

Desulfurization 1 1.3 3.4 2.3
efficiency in absorber

Outlet concentration of 1 19.3 54.7 21.7
absorber

Flue gas velocity in the 1 24.9 53.1 25.1
absorber
52

t/h
Limestone consumption 1 25.1 59.4 25.0
t/h
t/h
1 24.7 50.8 26.3
t/h
1 24.8 58.2 24.8
Gypsum output t/h
Nm3/h
Oxidation air demand 1 251 54.5 25
quantity Nm3/h
t/h
1 24.7 51.9 24.7

Outlet temperature of 43 43 43 43
absorber
1.2 GGH
1.2 Cancellation of the GGH project data setting
25 50 75
3000000

Desulfurization 96.58 94.91 93.36 97.53
efficiency

Outlet concentration of 84.6mg/Nm 101.4mg/Nm 127.3mg/Nm 166.1mg/Nm
absorber

Flue gas velocity in the 3.99m/s 4.99m/s 5.99m/s 2.99m/s
absorber
t/h
Limestone consumption 8.6 10.76 13.68 6.46
t/h
t/h
108.5 136.1 154.3 81.0
53

t/h
15.35 19.2 24.2 11.53
Gypsum output t/h
Nm3/h
Oxidation air demand 18972 23715 29328 14229
quantity Nm3/h
t/h
8.1 10.1 12.3 6.1

Outlet temperature of 47 47 47 47
absorber
1.2.2
1.2.2 Data analysis
GGH GGH
60%
It can be seen from comparison of relevant parameters of setting GGH and
cancelling GGH that except that process water consumption increase is relatively
more (about 60%), other data are basically fair compared with that before
transformation.
1.3
1.3 Analysis of impact on system from flue gas amount change
1.3.1
1.3.1 Direct impact brought by the increase of the flue gas amount:
1)
1) Flue gas velocity in absorber increases
2)
2) Slurry amount carried by the flue gas increases, which increases the weight
of flotsam
3)
3) Consumption of limestone and process water increases
4)
4) Gypsum output increases
5)
5) Oxidation air demand amount increases.
54

1.3.2
1.3.2 Indirect impact brought by the increase of the flue gas amount:
1)
1) Flow resistance of the system increases
2)
2) Output demand of fan increases
3)
3) Flushing frequency demand of mist eliminator improves
4) GGH
4) GGH blocking probability increases and enlarges
5)
5) Scale formation and abrasion probability of the system increases
6)
6) Gypsum dewatering concentration increases
SO2
Section II Impact on system from SO2 concentration change of flue
gas
1SO2
1. Determination of SO2 concentration
1.1 DL/T5196-2004)
1.1 It is specified in Technical Code for Designing Flue Gas Desulfurization Plants of
Fossil Fuel Power Plants (DL/T5196-2004) that:

SO2
Since the sulfur content contained in design coal as received to be employed for
main project is generally at the average level, SO2 concentration (both design value
and check value) at the inlet of the FGD unit shall be fully investigated. Considering
the actual conditions of coal procurement and the change tendency of coal quality, the
higher value within the change limits shall be selected.
1.2 /HJ/T179-2005
55

1.2 It is specified in Flue Gas Limestone/lime-gypsum Desulfurization Project

Technical Specification of Thermal Power Plant (HJ/T179-2005) that:
BMCR
ECR
Design parameter of flue gas of newly built desulfurization unit should adopt the
flue gas parameter under the condition of BMCR and burning the design fuel, and the
proofread value should adopt the flue gas parameter under the condition of boiler
economic continuous rating (ECR) and burning the fuel with the largest sulphur
content.

When adding FGD unit to the built power plant, its design conditions and
proofread working condition should be confirmed based on the flue gas parameter
measured at the inlet of the desulfurization unit, besides, the variation trend of fuel
shall be fully considered.
3SO2
3. Impact on system from SO2 concentration change
3.1
3.1 Theoretical calculation condition
100SO2 2500mg/Nm3
GGH
100% load refers to the situations listed in aforesaid sample cases, SO2 content is
2500mg/Nm3, and system comparison in this section is considered as per GGH
system setting.
100% 125% 150% 200%
Item 100% load 125% load 150% load 200% load
%
Desulfurization efficiency 96.52% 95.30% 94.13% 91.95%
of the system %
mg/Nm3
Concentration at the 85.8 144.6 216.1 393.6
absorber outlet: mg/Nm3
kg/h
Limestone consumption 8,583 10,597 12,611 16,639
kg/h
% 23.4% 46.9% 93.9%
56

Capacity of the slurry Benchmark

preparation system %
kg/h
68,808 71,468 74,738 80,786
Water consumption kg/h
kg/h
15,305 18,837 22,377 29,580
Gypsum output kg/h
%

Capacity of gypsum 23% 46.2% -93.3%
Benchmark
dewatering system %
Nm3/h
Oxidation air demand 19,368 24,210 29,052 38,736
quantity Nm3/h

-25% -50% -100%
Oxidation air allowance % Benchmark
m3/h
Required circulating 10,886.8 12,245 13,453 15,596
slurry amount m3/h

Circulating slurry 4.07 -7.47 -15.78 -27.35
allowance %
t/h
8,097 8,065 8,065 8,065

Flue gas temperature at 42.81 43.03 43.24 43.69
absorber outlet
3.2
3.2 Effect analysis
SO2
7.4715.78
27.35 25
It can be seen from the above table that the increase of the SO2 results in a
proportionate increase of demand of slurry preparation system, dewatering system and
oxidation air system; Growth of demand of circulating slurry amount is relatively
smaller, respectively being: 7.47, 15.78 and 27.35, equal to 25% of sulphur
content increase; System water consumption also increases at different levels.
57

SO2
In actual projects, due to the basic completion of system configuration, especially the
limited capacity of slurry preparation system, the safety of the system equipment can
be guaranteed only through the decrease of desulfurization efficiency, reduction of the
flue gas amount and other measures in case of SO2 content increase. Sticking to
overall FGD, balance of the entire system will be damaged and will cause the
following problems:

Inadequate oxidation in the absorber, scaling and difficulty in gypsum
dewatering
SO2
SO2 concentration at absorber outlet cannot be ensured

Increase abrasion of system equipment

Gypsum quality cannot be ensured

Aggravate corrosion of system equipment, and service time is seriously
shortened

Section III Impact on system from dust concentration change of
flue gas
1
1. Dust influence on desulfurization system

Dust influences on the wet desulfurization system mainly include:

Reduce gypsum quality;

Aggravate slurry abrasion to equipment;

58

Increase the difficulty of desulfurization gypsum dewatering;

"Sealing" absorbent, and deprive of its activity.

Increase wastewater discharge amount

Increase inert substance content in absorber, and aggravate scaling of system
equipment
pH
pH
pH
Al3+ F-
The fourth influence is manifested during operation as that slurry pH value and
desulfurization efficiency decline, the pH value of slurry pool still cannot rise even
after injecting large flow of absorbent slurry into the absorber, and absorption
efficiency does not rise again obviously. It's mainly because of higher dust content in
absorber, lower pH value control during operation. The complex compound combined
with Al3+ in fly ash and F- in slurry reaches to certain concentration and is absorbed
on the absorbent solid particle surface, which "seals" absorbent activity and obviously
slows down absorbent dissolution rate.

N2CO2O2
SO2NOxHClHF NH3CH4CH3C1
Besides, other chemicals introduced to the system with fly ash, such as
magnesium and manganese, can work as oxidation catalyst, which is beneficial to
forced oxidation process, but harmful for inhibiting oxidation process. Besides
influencing chemical reaction of the process, some heavy metals brought in with fly
ash can also influence the quality of wastewater discharge. Therefore, it is generally
not expected to bring excessive fly ash into absorption system. Gas composition of the
inlet flue gas mainly includes N2, CO2, O2, water vapor, SO2, NOx, HCl, HF and
sulfuric acid vapor, and minor compound includes NH3, CH4, CH3Cl, etc. There are
some harmful microelements contained in flue gas or fly ash, such as the mercury and
mercury compound which are seriously treated at present.

Desulfurization gypsum with large amount of dust:
59

3
3. Relevant theoretical data
100SO2 100mg/Nm3
GGH
The 100% load mentioned in this section refers to the design conditions of the
specified flue gas amount, SO2 content and dust concentration of 100mg/Nm3; the
system has considered GGH system setting.
100% 200% 300% 400% 500% 600% 700% 800%
Item 100% load 200% load 300% load 400% load 500% load 600% load 700% load 800% load
mg/Nm3
System dust content 100 200 300 400 500 600 700 800
mg/Nm3
kg/h
15,305 15,454 15,545 15,649 15,766 15,985 16,122 16,258
Gypsum output kg/h
kg/h
Dust content in 110.24 220.07 329.80 438.93 547.58 655.33 762.56 870.03
gypsum kg/h
CaSO4
92.00% 91.10% 90.59% 89.98% 89.31% 88.08% 87.35% 86.62%
CaSO4 content in
60

gypsum

Dust content in 4.1% 4.9% 5.7% 6.5% 7.3% 8.1% 8.9% 9.6%
gypsum

Dust percentage in 0.72 1.42 2.12 2.80 3.47 4.10 4.73 5.35
gypsum %
/
Total quantity of dust 16.8% 19.6% 22.0% 25.2% 27.8% 29.9% 31.9% 34.0%
inert
substance/solid in the
slurry of absorber

3.50% 4.00% 4.50% 4.50% 4.80% 5.30% 5.50% 5.80%
Top solid content of
gypsum hydrocyclone
4.
4. Data analysis

It can be seen from the above table that with increase of dust content,
0.72%
5.35
The gypsum output of desulfurization system increases slightly, but dust ratio
in gypsum increases considerably from 0.72% to 5.35;
CaSO4 92 86.62
Gypsum quality gets worse obviously, in which CaSO4 content decreases
from 92 to 86.62
16.8 34
20
200mg/Nm3
The percentage of dust inert substance in the slurry of the absorber
increases from 16.8 to 34, namely increased by more than one time. For safe and
stable operation, percentage of dust inert substance in the slurry of the absorber
shall generally be less than 20%, and dust concentration at the inlet is basically
200mg/Nm3.
61

In order to ensure system operation, it needs to adjust solid content in top

current of gypsum hydrocyclone during the theoretical calculation to ensure
rationality of relevant data. But in the actual project, hydrocyclone has generally been
installed, and adjustment range and possibility are smaller.

The above data and analysis are somehow different from actual project:

Calculated value in theory cannot check dust influence on "sealing" degree
and sealing of limestone;

Dust discharge amount of theoretical calculation increases in proportion,

without considering the influence of dust size and its property effect on discharge
amount. Therefore, the discharge amount value can only be used for reference;

In theoretical calculation, since it has not considered the influence on other

factors after the ratio of inert substance and dust in the slurry increases, the gypsum
quality reflected in the calculation is not qualified. However, in the actual project,
excessive dust will seriously disrupt the system and greatly reduce desulfurization
efficiency;

Generally theoretical calculation is lack of direct corresponding relation
between the increase of dust content and wastewater discharge amount;

Generally, theoretical calculation cannot complete the evaluation of the
abrasion loss of the system due to increase of dust content;

Theoretical calculation generally does not consider the effect of the increase
of the dust content on the system oxidation result.
62

FGD
Section IVEffect of chlorine content in coal on FGD unit design
FGD
0.02 0.5 80 HCl 95

HCl FGD
L/G
The other characteristic of the significant effect of the fuel coal on FGD system
design is chlorine content in coal. Like coal sulphur content, coal chlorine content
varies with original coal district and coal forming time. Coal chlorine content has
quite broad changing range, ranging from lower than 0.02 to higher than 0.5.
During the burning process, over 80% chlorine in coal turns into HCl, and not lower
than 95% HCl will be removed by FGD unit, thus leaving soluble chloride of certain
concentration in circulating slurry. High-concentration chloride will reduce the
alkalinity of slurry and make slurry more corrosive, and alkalinity of slurry influences
L/G and absorbent use ratio required by the desulfurization rate, and the strength of
the slurry's corrosivity will affect the selection and maintenance expenses of the
structural materials.
FGD Cl-
Cl-
mg/kg Cl-
Cl- 500mg/L
Cl-
20g/L Cl- 15g/L
Since slurry volume in FGD system is larger, Cl- content in circulating slurry will
not change rapidly. Generally, it does not need to consider the normal daily change of
coal chlorine content influence on the Cl- concentration in circulating slurry.
Therefore, the average coal chlorine content (taking mg/kg coal as the unit) can be
used as design value. For desulfurization system relying on wastewater discharge to
control Cl- concentration, if waste discharge is interrupted, Cl- concentration will
increase rapidly, and its increasing speed exceeds 500mg/L per day. Therefore, when
confirming chloride ion concentration in slurry, it needs to consider to store certain
allowance, for example, if the Cl- concentration in the slurry is required not to exceed
20g/L, it can be designed according to 15g/L of Cl- concentration.
FGD
FGD
In special circumstances, other trace substances in fly ash and coal can also
influence FGD system performance. However, in normal circumstances, their
significance is much smaller than sulphur and chlorine content. The influence of these
compositions in coal on FGD system performance greatly depends on the efficiency
63

of dust collector in the upstream.

FGD
1.2150mg/L,0.05
0.050.15 0.47 FGD
Chloride in FGD process slurry originates from the fuel coal, industrial
supplementary water and absorbent. Generally, chlorine content in limestone is quite
small, chlorine content in industrial supplementary water is 1.2-150mg/L, the content
in most coals is not more than 0.05, the content in fewer coals is 0.05-0.15, and
the content in some high-ash coals can be up to 0.47. Therefore, most of the
chloride in FGD process slurry originates from fuel coal.
CI-
Cl- concentration in the slurry can be determined in process technology
specifications with the following methods.
FGD
Only provide chlorine content in the fuel and chloride content in industrial
water, and FGD suppliers determine design chloride concentration according to
results of material balance calculation results.

Power plant may specify the minimum and maximum values for the design
chloride concentration in process slurry.

If there are requirements for quality of gypsum byproducts, the maximum
chloride content in solid byproduct can be specified.
50g/L NTU
3040C1- L/G
FGD
FGD FGD
FGD C1-
C1-
C1-
According to test data, when slurry chloride concentration exceeds 50g/L, mass
transfer capacity (represented with NTU) of an absorber will reduce by 30-40.
Therefore, absorber with higher Cl- concentration needs higher L/G and more
limestone or needs to change other performance parameters of the FGD system to
neutralize chloride influence on desulfurization efficiency. If FGD system owners do
not allow discharging wastewater, FGD suppliers have to conduct FGD system design
according to the chloride content confirmed by material balance in the craft process,
no matter how high the obtained Cl- concentration is. If wastewater discharge is
64

allowed, it needs to consider the allowable Cl- concentration of gypsum, and it is

necessary to compare the cost required to enable wastewater treatment to comply with
standards with the design scheme for high Cl-concentration.
65

FGD
Chapter III Non-metal Corrosion Prevention Materials of Wet
FGD System

Section I Technical Construction Requirements for Non-Metal
Corrosion Prevention Materials

FGD
70
Investment cost, annual maintenance cost and system service life of wet flue gas
desulfurization system greatly depend on selection and construction of corrosion
prevention and anti-wearing materials of the system. Generally, people give more
attention to material selection, but little attention is given to construction influence on
corrosion prevention. According to the survey, 70% of corrosion prevention problems
of wet FGD are caused by construction quality or procedure. Therefore, technical
requirements for construction related to corrosion prevention and other aspects are
hereby briefly explained.
1
1. Site Corrosion Prevention for Rubber Liner
1.1
1.1 Construction Conditions

12
During the entire rubber liner process (sand blasting- mucilage coating- lining-
repair), ensure to record the construction environment temperature, temperature of
lining base surface, relative humidity and temperature of corresponding dew points
every 1-2 hours after each shift starts and during operation.
15oC
Minimum temperature for rubber plate is 15 oC.
10 oC 30 oC 3K
Base: When the optimum temperature range is between 10 oC and 30 oC,
the dew point distance shall not be less than 3K.
5 oC 10 oC 5K
66

If the temperature range is between 5oC and 10oC, the dew point
distance shall not be less than 5K.
70
Relative humidity shall not be higher than 70%.
1.2
1.2 Rubber Liner Procedures

Construction flow chart for tank rubber liner
1. 4.
2. 3. 6..
1. Iron piece 4. Binder painting
2. Sand blasting 3. Base coat 6. Paint adhesive
acceptance
painting
9. 8. 7. 5.
9. Dismantle scaffold 8. Acceptance of 7. Paste rubber plate 5. Rubber plate
division acceptance polishing
10. 2-8 11.2 12.

10. Bottom rubber liner (repeating 2-8) 11. Acceptance of division 12. Overall Project handover
(2) acceptance
1.3
1.3 Acceptance Standards for Lining Base
DIN 28053

10mm 10mm
3mm

Sa2
ISO8503-1
RZ50m.
After completing the steel base, Party A and Party B jointly conduct the
acceptance and deliver corrosion prevention work according to German standard DIN
28053 and drawing requirements. Equipment lining surface shall be locally flat,
corner point shall be smooth, fillet radius of the convex corner surface shall be more
than 10mm and that of the concave corner surface shall be more than 10mm. Local
(including welding seam) roughness shall be less than 3mm, and shell thickness, after
polishing, shall be larger than the designed minimum thickness of the equipment.
Pitting, crack, undercut, scratch, scale and other surface defects have to be polished
and removed, repair the parts needing to be polished through welding, and welding
67

seam has to be polished neatly and smoothly without air hole. The steel surface
treatment grade shall reach to Sa2 after sand blasting, i.e., conduct the sand blasting
until metal white, completely remove oxide scale, rust and other sundries, only leave
spots or striped shadow, and clean up grinding materials and dust. Roughness shall
comply with the required roughness in "Base Surface Roughness" of ISO8503-1 (see
Appendix), RZ50m.
1.4
1.4 Rubber Liner Acceptance Standards
1.4.1
DIN
1.4.1 The entire rubber liner process (sand blasting- mucilage coating- lining- repair)
shall strictly comply with the rubber plate construction specifications of DIN
standard.

No cross seam allowed.

Plate connection direction shall be ensured not to be opposite to medium flow

direction. Wherein the blender rotates clockwise, the wall shall rotate from left to
right, and ensure that the connection seam does not go against the flow direction
of the slurry; the connection seam of pipe orifice shall be arranged in the inner
side, and be polished to be flat to prevent flushing.

During the rubber liner process, all the construction equipment personnel shall
wear socks or soft-soled shoes, and cannot wear hard-soled shoes; when pasting
rubber, it is necessary to use chalk to draw net-shaped lines, roll from inside to
outside, discharge all the air in it, and rolling shall be compact without lack of
compaction. In order to ensure lining quality, represent each construction
personnel with one English letter, and register and file. It is required to mark the
rolled places with chalk during construction, and write down the letter
representing the construction personnel for quality tracking.

Rubber plate cannot be stretched or compressed at will, and ensure that the
lining between rubber plate and base surface is even and complete without air
68

bubbles.

30mm
Minimum width for connection seam shall not be less than 30mm. Pay
attention to the liquid flow direction and rubber plate joint cannot go against with
the liquid flow direction.

Flange surface shall be fully lined, and try not to leave connection seam.

It is necessary to roll the rubber plate after lining strictly in accordance with
requirements to discharge the air between rubber plate and base surface.
Kerabutyl BS
In case of repair, it shall be conducted strictly as per the procedures, and refer
to the construction specifications for our Kerabutyl BS rubber plate for details.
100
After completion of the rubber liner, 100% electric spark testing and thickness
check for the lining surface shall be conducted under the presence of Party A's
personnel, and tension test and hardness test on test plate shall be done to check
whether the quality conforms to the construction specifications.
1.4.2
200100mm 46mm 600
1.4.2 Produce the test plate while conducting rubber liner, and materials used shall be
the same as materials of corrosion prevention equipment, and each test plate is
200100mm and 4-6mm in thickness. Complete corrosion prevention construction in
one piece of test plate in every 600m2 of corrosion prevention area, evaluate the test
plate and ensure that all the inspection items for the entire set of equipment are the
same as those for test plate. Rubber adhesive strength of the test plate shall comply
with requirements regulated in construction specifications, and meanwhile ensure that
the adhesive strength of construction lining rubber plate meets the requirements for
test plate. Test adhesive strength of test plate to ensure it meets the requirements and
specifications for coating construction.
2
2. Site Corrosion Prevention for Glass Flake
69

2.1
2.1 Ambient Condition:
: :16C 22C10C30C
Material: The optimum temperature range is 16C to 22C. 10C in
minimum, 30C in maximum
: 10C 25C 10C30C
3
Base: The optimum is between 10C and 25C, the minimum is 10C,
the maximum is 30C, and 3C higher than air dew point at least.
2.2
2.2 Corrosion Prevention Construction Flow Chart for Site Flake
1. 2. 3.
1. Engine body acceptance 2. Machine surface treatment 3. Base coat painting
5. 6.
4. 6. Wear-resisting layer

5. Lining construction and check for construction and check
4. Lining construction and check treatment
for the first flake layer the second flake layer
7. FRP 8.
7. Intensified construction for FRP 8. Surface coating 9.
lining 9. Acceptance of division
10.
Project handover 10. Dismantle scaffold
12. 11.2
12. Overall 11. Acceptance of division
acceptance (2)
2.3
2.3 Key Points and Standards for Machine Acceptance
2.3.1
2.3.1 Key Points and Standards for Metal Shell Acceptance

It is necessary to ensure that hand or tools can operate smoothly during

construction, with no extremely narrow or dead-angle parts.
3mm
70

Surface of the lining of metal shell shall be flat, with no roughness more than
3mm.
2
For screw holes or lug holes of inner and outer liners, the hole diameter shall
be increased by 2 times of gross thickness of lining. And they shall be polished to
transit smoothly.

All the spare modules welded to shell shall be welded before lining, and
welding is strictly forbidden after lining.

The supporting ring and reinforcement bar and other internal modules in the
equipment shall be continuously and fully welded with cylinder and angular position
and welding seam shall be polished to be able to transit smoothly.

R 5mm 10mm
Metal shell of lining equipment is required to be flat and smooth; its edges
shall be in circular arc transition with convex and concave circular arc radius (R) not
less than 5mm and 10mm respectively.
R5 Above R5
R10 Above R10
g. DN25
DN25
g. The minimum caliber of pipe required for lining is DN25; the flange can
be designed as reduced flange if smaller connecting size is needed but the pipe caliber
shall be at least DN25.
h.
71

h. Quality requirements for welding seam

The surface of welding seam shall be smooth and even without crack,
pore, overlap, slag inclusion, crater or any other defects.
2mm

The convex base metal of butt welding seam shall be even and consistent
in height. Generally, they shall not exceed 2mm but not less than the
base metals.

The fillet welding seams are generally as high as thinner steel sheets.
0.5mm 100mm
10
The undercut depth of welding seam edges shall not exceed 0.5mm,
continuous length not exceed 100mm and total length of both undercut
edges not exceed 10% of weld length.

All welding seams required for lining should be fully welded without
solder skips.

After welding, it's necessary to polish and clear all the welding seams in
the way of polishing, remove the splashes, overlaps, rags and others of
welding seams and their periphery and polish welding seams required for
lining to be in the state of smooth transition.

Appearance requirements for lining sides

No paint, greasy dirt, grease or any other foreign substance shall be
allowed to stick to the lining sides.

No crater, temporary support or any other parts are allowed to exist in
the lining sides.
0.5mm
72

No mechanical damage deeper than 0.5mm is allowed to be in the lining

sides.
3
3. Acceptance Standards for Concrete Tank Base

The concrete tank should be poured by steel mold and the quality acceptance
standards of internal surface required for lining are as follows:

The base of concrete tank should be smooth and dense after the mold of
concrete tank is removed and lining surface should be free from greasy dirt, slurry,
cement powder, porosity, honeycomb, pitted surface and any other superficial defects.
6
Its moisture content is below 6%.

The surface should be smooth and free from local concave-convex after being
leveled in a mechanical way (defects are not allowed to be recovered by cement
mortar filling or plaster).
R10mm R5mm
Circular arc transition of internal corner R is 10mm and circular arc
transition of external corner R is 5mm.

No hole, falloff or any other great concrete defects are allowed to be on the
concrete surface. If base surface and lining surface fail to reach the above
requirements, construction unit shall repair.

The welding seam surface of embedded steel parts should be smooth and free
from undercut, overlap and slag inclusion or any other defects.
4
4. Finished Product Protection

It is not allowed to make welding, fire cutting or any other operations on the
73

equipment body which has undergone construction of inner corrosion

prevention (rubber liner) and it is necessary to keep away from any fire. If
technical transformation is necessary to the equipment, it shall be advised to
make good protection.

It is not allowed to collide or hit equipment in the installation or use.

No installer is allowed to wear shoes of hard bottom or spikes, carry match or

lighter, or smoke while entering the inside of corrosion prevention equipment.

All the construction tools and other personal belongings (spare modules
required for installation) are required to be handled with care and prevented from
collision on the surface of corrosion prevention in the installation and construction.

5mm 15mm
While placing heavier or edged equipment (or module) in the equipment, it is

necessary to place rubber sheet of or thicker than 5mm or flat wood sheet of or thicker
than 15mm on the bearing point in advance so as to offer effective protection for the
layer of corrosion prevention.

It is not allowed to stick grease, adhesive, solvent or any other organic matter
to the layer of corrosion prevention in the process of construction.

In the installation and construction, it is necessary to inform the construction

unit of corrosion prevention of surveillance so as to tackle accident in time.

Section II Reasons for Damage of Rubber and Reinforced Resin
Lining

There are many reasons for damage of rubber and reinforced resin lining in the
process of use and here are some key reasons for damage in discussion by time of
damage.
74

1
1. Reason for Premature Lining Damage

The most noteworthy reasons for premature damage of rubber and reinforced
resin lining include: incorrect technical specifications and product updates, resulting
in adoption of improper products and grave temperature and mechanical damage.

FGD
(EPRI FGD
FGD
FGD
In addition to incorrect selection of materials, product change is the most

important factor for damage of rubber lining. In the US history of FGD application,
quality problems resulting from product change due to too rough technical
specifications for film products used to be rather frequent; as a result, US Electric
Power Research Institute (EPRI) presided in formulating "Guidelines to Technical
Requirements for FGD Rubber". It was found in a survey in the US that three
different kinds of rubber applied in the same FGD module were claimed to be the
same kind of rubber. Besides, some manufacturers has altered their formulas for
rubber and resin products but failed to alter their marks or names of products. The
"improvement" of some products even resulted in performance degradation. As
eco-friendly regulations are increasingly harsher, formulas are being re-formulated for
many resin products so as to decrease or not use aromatic amine curing agent or
styrene cross-linking agent. However, the redesigned formulas have not been verified
so far concerning their long-term impact on product performance. The above
experiences suggest that, it is necessary to first of all, guarantee quality of raw
materials in order to guarantee lining quality. Synthetic rubber and resin are high
polymers and products in different batches are different in degree of polymerization
and other performances, so it is hard for some small plants with poorer manufacturing
technology to pledge stable quality. Thus, it is necessary to select the film and resin a
well-reputed manufacturer produces. It is necessary to store the raw materials as
required so as to prevent slab rubber, resin and all kinds of additives from expiring.
China power system should also formulate technical specifications for FGD rubber
and resin as instructions for engineering technicians in power plants to select such
75

type of materials and make quality check on the materials.

GF
As previously mentioned, in order to apply slab rubber and reinforce resin lining,
not only the raw materials are required to be up to standard but also their construction
quality counts. Any negligence in the construction may result in lining defects in early
scaling. For example, early local lining blister primarily results from: there are blisters,
pores and other defects on the base, which are not found or in improper treatment
before lining; local residual air is not removed when slab rubber is pressed, GF resin
daub is rolled or glass fiber cloth is lined; rust removal by sand blasting is not
complete or dust or any other dirt fall in the process of lining; equipment welding
seam or corner treatment fails to reach specified requirements. Blister or delaminating
in multiple locations or in large area may result from: slab rubber or resin expiration;
the mucilage for pasting rubber sheet is mixed with moisture or ineffective; improper
selection of resin curing agent; too high humidity, too low temperature, poor control
of interval between two procedures and other reasons in the lining construction.

2
4 FGD
180
FGD
Sharp temperature change in operation or accident, larger scaling block or
mechanical foreign substance in the slurry or mechanical collision in overhaul may
result in premature damage of rubber and resin lining. It is not allowed to hit the outer
walls of lining by iron hammer during overhaul and it is necessary to be particularly
careful and prevent damage of lining while clearing gypsum scaling on the lining
surface. During absorber overhaul, it is necessary to bind both ends of steel tubes of
scaffold with something soft, pad pipe fittings at the bottom of tank with wood sheet,
be particularly careful and prevent damage of lining while clearing sediment at the
bottom of slurry pool in the absorber. Once lining cracks, it will soon result in base
corrosion and perforating. In the spray tower, if the slurry sprayed out from the nozzle
directly faces the tower wall, the lining will be penetrated within a short time (2-4
months). The two kinds of lining applied in FGD unit have strict temperature limits,
and in case of abnormal working condition and abnormal high temperature, damage to
76

the lining will gradually show up. Therefore, when smoke discharge temperature of
the boiler exceeds certain limit value (generally being 180 ), there shall be
automatic protection measures, such as rapidly separating FGD system or putting
emergency cooling units into operation to prevent the two kinds of lining being
damaged by high temperature.

During lining construction, most of the used solvents are flammable with quite
high fire risk. So it is necessary to intensify ventilation; especially, the attention shall
be paid to prevent flammable gas gathering to a dangerous extent. Besides, most of
the solidified reinforced resins and vulcanized film lining are flammable, and there
has once been serious fire disaster caused by welding on the internal or external wall
of absorber with lining. Therefore, the absorber lined with organic corrosion
prevention materials shall be hung with warning plate of "No Welding" in
conspicuous place. When it is necessary to conduct electric welding, there shall be
elaborate fire prevention measures.
2
2. Reasons for Final Lining Damage

VE
Linings of rubber plate and reinforced resin are semi-permeable protective layers.
One reason for final failure of these linings lies in that moisture penetrating in the
middle of lining and steel plate base causes delamination; the other reason lies in
material aging. In this aspect, the aging of rubber flake is faster than that of VE resin
of glass flake. That part of the coating layer or lining layer bumps up and bubble is
filled with gas and liquid, which proves the existence of penetration. That rubber
lining layer loses its original elasticity, becoming hard and even friable or cracked,
which is the characteristic of aging. Main factors influencing the emergence of bubble
include resistance to moisture penetration of materials, lining thickness and
temperature gradient through the lining. The influence of temperature gradient is
usually called "cold wall" effect. Besides, resin content of resin layer and scaling of
resin to reinforced materials can also influence the emerging time of bubble.
77


Chapter III Electrical System
GGH
UPS
UPS
Working range of electrical system includes the electrical systems of flue gas
system, absorbent preparation system, absorber system, GGH system, gypsum
dewatering system, process water system, desulfurization wastewater discharge
system, compressed air system within dehydration scope, and emergency power
supply system, DC system and UPS system. Electrical system includes: power supply
and distribution system, electrical control and protection, DC system, AC emergency
power supply and AC uninterruptible power supply (UPS), lighting and overhaul
system, anti-thunder grounding system and safety sliding contact line, communication
system, cable and cable structures, electrical equipment layout, etc.

Design of electrical system for FGD project is conducted according to relevant
principles for coal-fired power plant design.

Section I Electrical Elementary Wiring Diagram for Desulfurization
System
1 11kV
1. Elementary Wiring of 11kV Desulfurization System

Elementary wiring of electrical system is the main and core part of electrical part
of desulfurization island. It is closely related to the reliability, economic efficiency
and other factors in the operation of desulfurization system, and has great influence on
the electrical equipment layout, equipment selection, relaying protection and control
method and so on. So it is necessary to combine with the specific situation of power
plant to make comprehensive analysis and comparison for the rational selection of
wiring scheme.

78

Elementary wiring of electrical system shall comply with requirements for power
supply reliability and power quality of desulfurization equipment, requirements for
simple and clear wiring and simple operation and maintenance, requirements for the
initial operation and operation in the final scale of desulfurization island, requirements
for staging operation, and requirements for advanced technology and being
economically reasonable.

2x100%
According to the Technical Code for Designing Flue Gas Desulfurization Plants
of Fossil Fuel Power Plants, auxiliary power capacity for main plant of the new
power plant shall be considered to include desulfurization capacity and each set of
machine on desulfurization island is set with two sections of high-pressure
desulfurization busbars, with connection between the two sections which can be
mutually replaced by each other. The plant busbar of main plant supplies power for
two lines with 2x100% capacity.

Elementary Wiring for Electrical System (the Figure below)
79

C hin a Da t an g Co rpor at ion D e sul fur i za tion Op er at ion a nd Equ ip men t M an a ge ment St a ff O ccup a tion al Qu ali fi c at ion Tra inin g Ma te ri a l
80

2 415V/240V
2. Elementary Wiring for 415V/240V Desulfurization System
415/240V PCPower CenterMCCMotor Control
Center()380V 75kW
100kW MCC PC
MCC
415/240V system adopts power supply modes of two levels: PC - Power Center
and MCC - Motor Control Center. 380V system is neutral point solid grounding
system. Power for 75kW and above motor circuit, 100kW and above static load circuit
and all MCC power circuits is supplied by PC, and power for other loads is supplied
by nearby MCC.
415/240V
AB 415/240V
()415/240V AB
/ 11kV
Desulfurization island is set with three 415/240V desulfurization power centers,
one for each unit and one for public area, and all of them are wired sectionally with
single busbars. Each desulfurization power center is set with A and B sections of
415/240V desulfurization busbars, electrified by two mutually-standby (dark standby)
low-voltage dry-type transformers. A and B 415/240V desulfurization sections are
respectively set with interconnection switches which turn on under normal situation
and trip off the incoming line of certain section in case of its power fault, and the
interconnection switches can switch manually/automatically. Power supplies for the
six sets of low-voltage dry-type transformers are respectively accessed from 11kV
desulfurization section.
MCC
90kW PC 90kW
MCC
The power of all MCCs shall be supplied with unconnected single busbar, and
coupled loads are respectively connected to the two sections. 90kW and above motor
circuit and feeder circuit connected to PC are adopted with air circuit-breaker, and
90kW and below motor circuit and feeder circuit on MCC are adopted with moulded
case circuit breaker.

Section II Desulfurization Service Voltage and Neutral Point
Grounding Mode

81

11kV 415V
The high-pressure service voltage of desulfurization shall be determined
according to the auxiliary power supply voltage of main plant and the high pressure
and low pressure of service voltage for desulfurization island are 11kV and 415V
respectively.
11kV
300A
Neutral point grounding mode of desulfurization power distribution system is
consistent with that of the main plant: 11kV system is adopted with low-resistance
grounding with grounding current limited to be 300A, and low-voltage distribution
system is adopted with three-phase four-line neutral point solid grounding mode.
UPS
Section III AC Emergency Power Supply, DC System and
Uninterruptible Power Supply (UPS)

400kVA/320kW
PC A B
Emergency power supply system is for public use of desulfurization island to
ensure safe stopping and equipment safety after power failure on the desulfurization
island. The project is equipped with a specialized diesel generator set
(400kVA/320kW). Desulfurization emergency section is electrified by Section A or B
of desulfurization PC in normal situation, and is electrified by diesel generator set
after the power-lossing of the entire plant.
11kV
415V
220V
Desulfurization island is set with DC system to supply power for loads of

electrical control, signal, relaying protection, 11kV and 415V circuit-breakers closing,
etc. DC system is wired with single busbar, combining power and control loads, and
the two sets of DC system capacities can be mutually replaced by each other with
busbar connection. Voltage grade is 220V. DC system includes storage battery free of
maintenance with nickel-cadmium valve, charging unit and DC feeder panel (as
shown in the following figure).
82

230V UPS PLC

PC
UPS UPS
60
Desulfurization island is set with 230V UPS system. UPS is generally for public
use on the desulfurization island, for PLC and other important loads on the island. AC
power supply of the UPS originates from desulfurization PC section and emergency
section, and DC power supply originates from UPS storage battery free of
maintenance with nickel-cadmium valve. UPS shall maintain, after the entire plant is
out of power, all its loads to continue to operate for at least 60 minutes under the rated
voltage (as shown in the following figure).
83


Section IVDesulfurization System Load Calculation and
Desulfurization Transformer Selection
1
1. Desulfurization Load Classification
1.1
1.1 Classification by use
GGH
Desulfurization unit load: It refers to the load of desulfurization tower unit,

including booster fan, slurry circulation pump, GGH, oxidation fan, etc.;

Desulfurization public load: It refers to the load of public power of the entire
desulfurization island, generally including gypsum dewatering system, slurry
preparation system, wastewater system and thermal control system, etc.
1.2
1.2 Classification according to significance degree
I
84

Class I load: It refers to the load which may influence equipment safety
during short-term (required time to recover power supply through manual switching)
power failure, such as booster fan, slurry circulation pump, etc.;
II
Class II load: It refers to the loads that tolerate short-time power failure but
may cause damage to the equipment or affect the normal operation in case of far
long-term power failure, such as oxidation fan, wet mill, absorber blender, air
compressor, lighting, etc.;
III
Class III load: It refers to the load which will not directly influence operation
during long-term power failure, such as overhaul load, various submerged pumps of
drainage pit, etc.;
OI
DCS
Class OI load: It refers to the load which needs continuous power supply
during the operation of desulfurization equipment and in the process of stopping
(including emergency stopping) and during a time period even after stopping, such as
thermal control DCS cabinet, instrument power cabinet, fire alarm load, etc.;
OIII
Class OIII load: It refers to the load which provides power supply when the
entire desulfurization island is out of power to ensure that the desulfurization
equipment can be stopped safely and be re-started soon after that, such as various
motor lubrication pumps, cooling fan, wash pump, bypass gas damper, etc.
1.3
1.3 Classification according to operation mode

Loads with frequent continuous operation Loads with frequent
intermittent or short time operation

Loads with not frequent continuous operation Load with not frequent
intermittent or short time operation
2
Continuous - those continuously operating with loads for over 2 hours for each
85

time;
2 10
Short time - those continuously operating with loads for more than 10 minutes
and less than 2 hours for each time;

10
Intermittent - those repeating periodic work from loading to stopping for each
time with each work period not exceeding 10 min;

Frequent - motors related to normal operation and generally used every day;

Not frequent - motors which are not used under normal situation and are only
used during overhaul, emergency or equipment starting and stopping
1.4
1.4 Classification according to layout location
MCC MCC MCC
Absorber unit MCC Gypsum dewatering MCC Slurry preparation
MCC
MCC MCC
Wastewater treatment MCC Electric control building MCC
1.5
1.5 Classification according to whether desulfurization load needs to be started
automatically

Those needed to be started automatically after fault elimination and operation

of emergency power supply; Those without needing to be started automatically
after fault elimination and operation of emergency power supply;
2
2. Load calculation

Specific calculating principles are as follows:

86

Loads which continue to operate shall be calculated;

During operation of desulfurization equipment, equipments of continuous
operation infrequently shall be calculated;

Equipments which operates infrequently but in short-term and infrequently
but continuously shall not be calculated;

For devices that back up each other and are powered by the same auxiliary
power supply, only the part that is put into service shall be calculated;

DL/T51532014
Refer to regulations in the Technical Rule for Designing Auxiliary Power
System of Fossil Fuel Power Plants (DL/T5153-2014) for calculating modes for
loads of other equipment models.

DL/T51532014
The "conversion factor" method should be applied for load calculation. Refer
to regulations in the Technical Rule for Designing Auxiliary Power System of
Fossil Fuel Power Plants (DL/T5153-2014) for relevant calculating modes.
3
3. Selection of Desulfurization Transformer

Selection of desulfurization transformer capacity shall satisfy power supply to

loads of the entire desulfurization island under normal operation, and will not shorten
service life due to overload and overheat in short time.
6 1#2#
10 50
The project is equipped with 6 sets of low-voltage dry desulfurization
transformers, among which two sets for 1#machine, two sets for 2#machine and two
sets for public area, and each two sets are for standby mutually. Capacity for each set
shall be selected according to sum of all the low-voltage calculating loads of the two
low-voltage desulfurization transformers, and it shall reserve 10% margin and ensure
that it can operate for short time in 50% overload situations.

87

Impedance of low-voltage desulfurization transformer shall be confirmed

according to bearing capacity of low-voltage appliance to short-circuit current.

DL/T 51532014
The capacity of low-voltage desulfurization transformer is calculated according

to regulations in the Technical Rule for Designing Auxiliary Power System of Fossil
Fuel Power Plants (DL/T5153-2014).

Calculation of unit low-voltage desulfurization transformer capacity in the
project is shown in the following figure:
No. of units
Total
Sum
(kVA Low plant transformer capacity selection

(kVA)
Calculation of public low-voltage desulfurization transformer capacity in the project

is shown in the following figure:
88

No. of units
Total
(kVA Low plant transformer capacity selection

(kVA)

Section V Protective Load Statistics and Diesel Generator Selection
1
1. Protective Load Classification

Protective load can be divided into two categories according to its properties:
A
( A1 )( A2 )
Class A protective load: It refers to the protective load which needs to be
promptly put into operation after power failure, the load which operates for
about half an hour (called Class A1) and the load which operates in uncertain
time (called Class A2).
B

89

Class B protective load: It refers to the protective load which does not need
to be promptly put into operation after power failure and can operate half an hour to
one hour after power failure and operates in uncertain time.

Protective loads can be put into operation successively according to their
properties during emergency:
1-- A
1 - Put class A protective load into operation immediately after power
failure;
2-- A1 B A2

2 - Stop the operation of Class A1 load after half an hour of power failure,
put class B protective load into operation and keep the operation of Class A2 load.
2
2. Protective Load Statistics

Commissioning law of desulfurization security shall be considered for the

protective load statistics. Loads which can be staggered for operation time shall not be
completely calculated, and protective loads which operate at the same time could be
calculated in phases with the larger one being taken as calculation power.

DL/T51532014
Protective load statistics shall be conducted according to "conversion factor"
method, and calculation shall comply with regulations in the Technical Rule for
Designing Auxiliary Power System of Fossil Fuel Power Plants (DL/T5153-2014).
3
3. Selection of Diesel Generator
DL/T51532014
Selection of diesel generator shall be based on regulations in the Technical Rule

for Designing Auxiliary Power System of Fossil Fuel Power Plants (DL/T5153-2014),
including model selection, capacity selection, voltage calibration on busbar during
starting of maximum motor, etc.

Calculation sheet of protective load is as follows:
90

Engaged time Instant-Start

Instant Delayed
Nos. Total
Load name Rated
Nos. of standby capacity(KW) Short Short
NO. capacity(KW)
time and time and Rotary load Static load
Continuous Continuous
intermittent intermittent
1 Low pressure lubricant pump of the mill 4 4 2 8 8
2 Blender motor of absober 30 4 0 120 120
3 Booster fan oil pump motor 22 2 0 44 44
4 Booster fan circulating oil pump motor 4 2 0 8 8
5 Cooling water pump motor 37 2 1 37 37 37
6 UPS UPS-DP 40 2 1 40 40
7 DC charger 16 2 1 16 16
8 415V FGD Unit 415VAC power supply cabinet 15 2 0 30 30
9 415V FGD common 415VAC power supply cabinet 10 1 0 10 10
10 Diesel-engine generator self-power 3 1 0 3 3 3
11 Electrical control building emergency AC lighting loads 2 3 0 6 6 6
12 Gypsum dewater building emergency AC lighting loads 4 2 0 8 8 8
13 CEMS CEMS room emergency AC lighting loads 1 4 0 4 4 4
MCC L.V unit MCC distribution room emergency AC
14 1 4 0 4 4 4
lighting loads
15 GGH GGH room emergency AC lighting loads 1 4 0 4 4 4
16 Fire alarm 5 1 0 5 5 5
17 Ansorber elevator 22 2 0 44 44
The instantaneous operation load(continuous) in
71
totalP1(kW)
The instantaneous operation load(short time
0
and intermittent)P2(kW)
The time delay operation load(continuous) in total
196
P3(kW)
The time delay operation load(short time and
124
intermittent) in totalP4(kW)
The sum of emergent load rated power
37
which is initially input(rotating) P1ed(kW)
The sum of emergent load rated power
34
which is initially input(static) P2ed(kW)
Sum of rated power of the emergent load
329
P=P1+P3+0.5(P2+P4)
Calculation load Sc=KP (K=0.8) 263.2
Pc=ScCosc(Cosc=0.86) 226.35
SenSc(n=1) 263.20

150Se15S Verification of short time over load
capability when the generator with load starts one motor with the 356.15
largest capacity. The generator can bear 150% Se in the hot status,
time is 15 s.Se[nSc+(1.25
Diesel generator continuous
output capacity should be greater than the maximum load calculation
SenSc=263.2kVA
Pe=304kW
Diesel generator capacity to choose:
Se=380kVA
Recheck of the diesel generator output capacity
1 Output power verification for 1 hour

246.5
operation without stopping PxaPc/(1.1g), (a=1.15,g=0.96)
The first loading capability verification of the

253
diesel generator:Px2.5KQP1eDCOSQ2P2eD (KQ=5,COSQ=0.4)
Voltage level rectification of the

bus during the starting of the maximum motor : 0.881
Um=Se/(Se+1.25KqPdmX'd), (Kq=6.5,Pdm=37kW,X'd=0.17)
91


Section VI Selection and Layout of Desulfurization Electrical
Equipment
1
1. Selection of Desulfurization Electrical Equipment

Switch cabinet shall have five-prevention (prevent electric misoperation)
function, namely:
1
(1) Prevent loaded pulling (closing) isolating switch
2
(2) Prevent mis-pulling (closing) circuit-breaker
3
(3) Prevent laying ground wire with electricity
4
(4) Prevent closing the switch with ground wire
5
(5) Prevent entering electrified gap by mistake
2
2. Layout of Electrical Equipment
11kV PC PC/MCC
UPS
MCC MCC MCC MCC
MCC
DL/T51532014
This project is characterized by single electric control building in which is set
with 11kV section, PC section, security PC/MCC section, diesel generator room,
storage battery room and relaying protection room (UPS, DC and fast switching).
Besides electric control building, it is also equipped with local MCC distribution
room, such as unit MCC distribution room, wastewater MCC distribution room, slurry
preparation MCC distribution room and dewatering MCC distribution room. Room
layout of electric control building and equipment layout of distribution room shall
comply with regulations in the Technical Rule for Designing Auxiliary Power System
of Fossil Fuel Power Plants (DL/T5153-2014).

92

General requirements are as follows:

7 60
There shall be two exits for switchgear room which is more than 7 meters
long, and one more when the length of the room exceeds 60m.

The door of auxiliary switchgear room shall be fireproof and open outwards,
with locks which can be unlocked from inside without keys, such as spring locks. The
door between the adjacent switchgear rooms shall be able to open from two
directions.

Pipelines or cables irrelevant to the switchgears shall not penetrate through
the auxiliary switchgear room.
2m 3m
Net height of cable interlayer shall not be less than 2m, but not more than 3m.
1.2m
Low voltage switchboard cabinet is arranged in single row and the min-width
of the operating walkway behind the switchboard shall be 1.2m.
2.3m
It shall add shield when the height of bare conductor of the walkway behind
screen is less than 2.3m.
1
If handcart high-pressure switch cabinet is used for auxiliary switchgear, each

section of working busbar should be equipped with one standby handcart or one
standby cabinet together with a handcart.

12 D0201D0202D0203D0204D0501
As to low pressure auxiliary switchgear, besides the reservation of standby

circuit, position of 1-2 standby screens shall be reserved for each busbar section if the
space allows. Refer to D0201, D0202, D0203, D0204 and D0501 for equipment
layout drawings
93

Section VII Control, Protection and Measurement

1
1. Control
/ PLC
11kV
11kV 415V
220V 230V
UPS DCS /
Inside desulfurization electric control building is set with desulfurization control

room in which there is no regular electrical control screen / set, and all the important
electrical equipments on the island are under centralized monitor of desulfurization
PLC. Monitoring objects include: 11kV section of power supply incoming line for
desulfurization, subsection of 11kV section for desulfurization, low-voltage
desulfurization transformer, 415V low-voltage auxiliary power supply incoming line
and subsection, emergency power supply incoming line, diesel generator, all motors
under centralized control of desulfurization unit, 220V DC system and 230V UPS
(only for monitoring). The "valve closing/opening" commands issued by
desulfurization DCS shall be two mutually independent dry contacts and be sent to
electrical switch cabinet with hardwiring.
11kV 11kV
Feeder of 11kV section at the power supply outlet of 11kV desulfurization

section of the main power house shall be brought into the unit control system of the
main project, with control mode keeping consistent with that of the main project.
2
2. Dual Supply Switching
11kV
Operation of 11kV desulfurization section and dual-power switching mode are
adopted with fast switch unit.
2.1
2.1 Starting conditions
2.2.1
2.1.1 Normal starting

PLC/
Remote
94

The fast switch device can be activated manually in startup and shutdown status
or during operational load change under normal situation for the purpose of operating
without power failure. The starting command can come from the remote control
center (PLC) and/or the local controller. The unit can be deployed by means of
hardwire or communication. Only when the key is turned to "Remote" position, the
fast switch device can be activated in remote by means of communication.
2.2.2
2.1.2 Emergency starting

The relaying protection device can detect and eliminate faults when they occur
on the incoming lines. Meanwhile, the relaying protection device can send out fast
switch activation command for the activation of fast switch in case of incoming line
faults.
A B
Since there is difference between electrical and non-electrical faults, emergency

starting are also classified into type A and type B, which can activate fast switch
device respectively with different switchover time sequence.
2.2.3
2.1.3 Abnormal starting

Upper switch trip or switch of incoming line trip caused by system fault shall
lead to power-lossing of the motor busbar. The busbar power switchover must be
activated by the fast switch unit with internal integrated abnormal detection criterion.
Keep in mind that latch the fast switch device to avoid mis-switch when manually
disconnect the power switch of incoming line.

The abnormal starting contains: LV starting, low frequency starting, slip starting,
reverse power starting and switch tripping starting.
2.2
2.2 Basic requirements on fast switch unit

The fast switch must be activated when one power supply loses voltage while
another is normal.
95


The fast switch must be ensured to have minimum power interruption to enable
the easy starting for the motor automatically.

The fast switch shall be activated only for once to avoid severer incidents in case
that normal power is brought onto the faulty element more than once when continuous
faults occur to the busbar or the outgoing wire.

No matter the circuit-breaker is disconnected or not when the working power

looses pressure, the unit should automatically activate for delay till the circuit-breaker
of work power trips off and make sure the circuit-breaker is disconnected before fast
switch unit being activated. In such case, activation of fast switch due to faults or
inverse power transmission of emergency power supply can be avoided when the
work power is disconnected in other places.

BZT
The fast switch should not be activated in the following cases: Potential
transformer (PT) fuse burnout, secondary circuit-breaker trip, PT switch pull-apart or
PT handcart pullout. By detecting the current of incoming line circuit-breaker, the
BZT only acts when there is no voltage and current on the side of incoming line.

The fast switch shall not be activated when the two-way power supply are out of
voltage.

The fast switch action must be away from the duration when the busbar voltage
is decreasing out of any cause. It means to recover the bus voltage in a short time, so
the delay time of fast switch must be longer than the maximum elimination time of
external fault.
3
3. Protection
3.1 11kV
3.1 Desulfurization 11kV section power supply
96

11kV
11kV
Power supply line of the desulfurization 11kV section is adopted with
microcomputer line longitudinal differential protection (non-fiber). The protection
device is installed in the high-pressure cabinet at the beginning of desulfurization
11KV section power supply line, and is in the charge of main power house.
3.2
3.2 Low voltage desulfurization transformer

Low voltage desulfurization transformer (normally dry type) is adopted with
microcomputer protection device and the following protection measures shall be
deployed:
2MVA
Longitudinal differential protection (2MVA or above transformers)

Current quick-break protection

Overcurrent protection

Single-phase grounding protection

Temperature protection

The protection device is installed on the high-pressure cabinet of the low voltage
desulfurization transformer.
3.3
3.3 Protection of high-pressure auxiliary motors

The high-pressure auxiliary motor is adopted with microcomputer protection
device, and the following protection measures must be deployed:
1500kW
Longitudinal differential protection (for motors over or equal to 1500 kW)

97

Current quick-break protection

Overcurrent protection


Overload protection

Low voltage protection

The protection device is installed on the high-pressure cabinet of high-pressure
auxiliary motor.
3.4
3.4 Protection of low voltage auxiliary motors

The low voltage auxiliary motor is adopted with motor controller and the
following protection measures must be deployed:

Phase-to-phase short-circuit protection

Grounding protection

Overload protection

Low voltage protection

The motor controller is installed on the panel of circuit booth of low voltage
distribution board.
3.5
3.5 Diesel generator protection

The following protection measures must be deployed for diesel generator:
98

1 2 3
1) Overcurrent protection 2) Longitudinal differential protection 3)
4
4. Measurement

PLC
PLC
420mA PLC
PLC
The control room of desulfurization island shall not be equipped with regular
stereo or optical character plate. All the switch state signal, electrical emergency
signal and warning signal are sent to the desulfurization island PLC. The control room
of desulfurization island shall not be equipped with regular measuring meters. As
prescribed by all the procedures, the electrical continuous measuring signals (current,
voltage, power, etc.) which need to be displayed on PLC should be transformed into
4-20mA by transmitter in the switch cabinet to send to the desulfurization island PLC.
It can also be transformed into digital signals by intelligent control module to send to
the desulfurization island PLC through communication interface in the form of bus
line. The measuring point shall be assigned by Technical Code for Designing
Electrical Measurement and Energy Metering Device:
4.1 DI
4.1 DI quantity
/
The signals such as circuit-breaker disconnection and connection, circuit-breaker

remote/local switchover, circuit-breaker control circuit break, protective action and
protection device fault.
4.2 DO
4.2 DO quantity

Circuit-breaker connection and disconnection command.
4.3 SOE
4.3 SOE quantity

Signal of circuit-breaker fault trip
99

4.4 AI
4.4 AI quantity
420mA
Signal of circuit 4-20mA analogue quantity
4.5 PI
4.5 PI quantity

Signal of circuit pulsed quantity

Section VIII Anti-thunder and Grounding
1
1. Anti-thunder Protection

2000mm PVC
The desulfurization unit is deployed within the protection scope of stack
lightning rod and does not need additional anti-thunder protection. However, it must
be checked in the project. Lightning protection zone must be set for units out of the
anti-thunder protection scope of the stack lightning rod. The downlead is wrapped
with reliable PVC protective tube at the 2000mm or less distance to the ground.
2
2. Grounding

The grounding of desulfurization area shall be deployed according to the
requirements of Grounding of AC Electrical Device.

The isolated closed grounding grid shall be built in the desulfurization area.
There must be at least four points in that closed grounding grid which are connected
electrically to the main grounding grid of power plant. The grounding resistance must
be up to the required value of the specification after the grounding grid in the
desulfurization island area and the main grounding grid are reliably connected.

Section IXLighting, Overhaul and Slide Wire System
100

MCC MCC
The independent lighting and overhaul MCC section shall be set, which supplies
the lighting and overhaul power for all places.

The lighting system is made up of three subsystems: AC normal lighting system,

AC emergency lighting system and DC emergency lighting system. All the building
lighting, area lighting, walkway lighting and equipment lighting within the area of
desulfurization unit belong to the scope of the electrical engineering.
12V 12V
The overhaul voltage of the absorber is 12V. The low-voltage 12V overhaul
lighting socket box shall be deployed along the platform of the absorber and near the
manhole. The multi-polar tube energy-saving slide wire shall be installed to the
electric hoist and electric lifting equipment.

Section X Cable, Cable Building and Cable Fireproof Plugging
1
1. Cable

ZRC-YJV22-11/110.4kV
ZRC-YJLV22-0.6/1.1
0.4kV
ZRC-YJV22-0.6/1.1
High-pressure cable is adopted with low-smoke fire-retardant steel-tape armored
copper conductor XLPE insulated PVC sheathed power cable (ZRC-YJV22-11/11)
with cross section greater than the minimum heat-stable cross section; 0.4kV power
cable is adopted with low-smoke fire-retardant steel-tape armored aluminum
conductor XLPE insulated PVC sheathed power cable (ZRC-YJLV22-0.6/1.1); 0.4KV
fire-proof power cable is adopted with fire-proof steel-tape armored copper conductor
XLPE insulated PVC sheathed power cable (ZRC-YJV22-0.6/1.1).

[ZRC-KVVP22-0.6/1.1]
[NH-KVVP22-0.6/1.1]
[ZRC- DJVPVP22-0.6/1.1]
Control cable is adopted with low-smoke fire-retardant steel-tape armored

copper conductor XLPE insulated PVC sheathed and total-shielded power cable
[ZRC-KVVP22-0.6/1.1]; fire alarm cable is adopted with low-smoke fire-proof
101

steel-tape armored copper conductor XLPE insulated PVC sheathed and total-shielded
power cable [NH-KVVP22-0.6/1.1]; low-smoke fire-retardant steel-tape armored
copper conductor XLPE insulated PVC sheathed and total-shielded copper wires are
used to weave individually screened power cable [ZRC- DJVPVP22-0.6/1.1].
PLC
220V24V
The cable to PLC thermal control cabinet shall be deployed one-for-one, and
different cables must be used for different purposes. 220V and 24V cables must be
separated and cores of control cable must be centralized.
2
2. Cable Building
11kV
0.4kV
The cable is mainly deployed by means of bridging. Partial area is deployed by
cable duct and pipe burying. 11kV power cable, 0.4kV power cable, control cable,
signal cable and so on shall be deployed layer by layer (or separately).
3
3. Cable Fireproof Plugging

The fireproof plugging to cable and cable building must be in compliance with
the requirements of procedure. Such plugging measures as arranging fireproof
partition board, plugging material in necessary places, cable tank and fire-resistant
partition board and brushing fire retardant coating to the cable must be taken.

Section XICommunication System

The production administration communication and dispatching communication

system should be set in the desulfurization island, whose switch uses power plant
program control exchange. A marshalling box should be set in the desulfurization
island (that of production administration communication and dispatching
communication should be set apart). Wirings between phone branch boxes use
telephone cable. All cables should be concealed laid in pipe indoors, while the part
outdoors should be laid underground in pipe, and the other part laid along the cable
tray.

102

Set up fixed speaker-phone in every local regional alarm panel and other
important places.
103


Chapter IV Thermal System

Section I Overview
1
1. The Constitution of Thermal System in Desulfurization Island

The thermal automation system is an important part of desulfurization island and

the basic condition of desulfurization system to work normally. The desulfurization
island thermal automation system mainly includes the following parts:
(1) (2)DCS (3)
(1) Local instrument testing system (2) Distributed control system (DCS)
(3) Other supporting systems
2
2. Local Instrument Testing System

DCS
Local instrument testing system is the base of thermal automation system, which
is mainly about monitoring, measuring and gathering the operating parameters of the
desulfurization island site and equipments and sends the signal to the DCS, providing
reliable data for desulfurization island to operate normally.
3DCS
3. Distributed Control System (DCS)
DCS DCS
DCS
DCS is the pivot of thermal automation system in the desulfurization island. The
operator collects the site data provided by site instrument by DCS and sends
command to each local equipment through DCS to adjust state and maintain the
normal operation of desulfurization island.
4
4. Other Supporting Systems
CEMS
104

Other supporting systems include CEMS, industrial television, fire alarm, power
and air sources, etc.
5
5. The Control Mode and Level of Desulfurization Control System
5.1
5.1 Control mode and level
DL/T 5196-2004
DCS
The requirements of desulfurization control design in the current Technical Code

for Designing Flue Gas Desulfurization Plants of Fossil Fuel Power Plants DL/T
5196-2004: The level of thermal automation of desulfurization system should be
consistent with the automatic control level of the unit. Desulfurization system should
adopt DCS to finish the monitoring and control of the unit's desulfurization equipment
and its supporting system including electrical equipment.

It can be done in the desulfurization control room:

SOX
Under the normal operation condition of the unit, the operating parameters
and conditions of desulfurization equipment can be monitored and controlled
effectively. And the total emission and emission concentration of pollutants like SOX
can be automatically maintained in normal limits to achieve environmental
requirements in the operational state of the boiler;

If there is any irregularity of the unit or abnormal working condition of the

desulfurization process system, it can be disposed according to predetermined
sequence, to adapt desulfurization system to corresponding emergency state;

If there occurs working condition endangering the operation of the unit and
desulfurization process system, it can automatically start the interlock protection of
the system and shut off corresponding equipment or even the whole-set
desulfurization unit.
105


CRT
It can complete the start and stop of the whole-set desulfurization system
with the cooperation of a few local inspectors. CRT and keyboard are the
monitoring means of normal operation of desulfurization system. There is no
regular control dial in the control room, only with a few emergency operating
buttons (to open the bypass damper).
23
Two to three operators on duty is to be allocated for the whole-set
desulfurization control (including inspectors).
5.2
5.2 The reliable measures of desulfurization thermal control system.
5.2.1
5.2.1 Signal detection
FGD FGD pH
Adopt redundant configuration to important process detecting parameters like

FGD inlet flue gas temperature, FGD inlet flue gas pressure, absorber liquid level and
pH meter, etc. Use imported equipment for actuator and important instrument of the
important controlled object of process system.
5.2.2 DCS
5.2.2 DCS system configuration
100
Adopt redundant (100%) configuration to operator station, controller,

communication bus and interface. If a fault occurs, the system can proceed in an
undisturbed switch automatically and give operator station a fault alarm. Meanwhile,
operators are able to replace and overhaul the fault equipment online to remove partial
fault quickly.
5.2.3
5.2.3 Interlock protection
FGD
FGD system has a necessary interlock protection to ensure the system can
operate safely and reliably.
106

5.2.4 FGD
5.2.4 The system has a manual operation button for bypass dampers in FGD control
room where operators can open bypass dampers in case of accidents.
5.2.5 FGD
5.2.5 The exchange of major signals for protection between the FGD system and the
boiler is in the mode of hardwiring.
KKS
Section II KKS Identification System (Thermal Expertise Part)
1
1. Overview
KKS Krartwerk-Kennzeichen System
KKS
KKS is the abbreviation of the German term Kraftwerk-Kennzeichen System,
which means the power plant identification system. The KKS has three different types
of identifications, i.e., process-related identification, installation point identification
and location identification.

Every part and equipment component of a power plant usually has three kinds of
codes:
1.1
1.1 Process-related code

The process-related identification of systems and equipment components are

identified according to their functions in mechanical, civil engineering, electrical as
well as control and instrument engineering.
1.2
1.2 Installation point code

The identification of installation points of electrical, instrument and control

devices installed on installation units (such as switch cabinet, panel and console). It is
only specific to the installation locations of electrical, instrument and control devices
on the switch cabinet, panel and console, and does not involve the identification of
107

macro structures.
1.3
1.3 Location code

The location identification in building structure, on the floors and in space, as

well as in fire protection district and designated terrains (surface area network) is
intended for macro buildings or areas.
2KKS
2. Composition of KKS Code
KKS 4
KKS code is composed of 4 classifications. With different forms for each

classification, they are composed of code element of classifications and numbers. The
latter is composed of data characters consisted of letter and digit symbols.

0 1 2 3
Classification
Class 0 Class 1 Class 2 Class 3
number

Classification The whole
System code Equipment unit code Module code
title power plant
Data character G F0 F1F2F3 FN A1A2 AN A3 B1B2 BN

mark
AN
Data character N AAA NN AA NNN A AA NN
A or N
type
108

Prefix symbol
Process-related code
Prefix symbol of system code

0
Numbers of similar systems and units of

individual part of power plant identified by
Class 0
System classification
KKS
Dividing system and units by KKS identification letters
System No.
Subdividing the system and units into subsystems and unit

parts and numbering them
Equipment unit classification

KKS
Dividing mechanical, electrical and instrument control
equipments by KKS identification letters
Equipment unit No.
109

Number of mechanical equipment, electric and instrument control equipment
Additional codes
Additional code of equipment unit
Module classification
KKS
Dividing modules, signals or signal application (applying as
needed) according to KKS identification letters
Module No.
Codes of modules, signals and signal application
If the code is unique, then data characters in the bracket can be omitted. This point
above should be appointed by both parties of the project.
3 KKS
3. Main KKS Codes of Desulfurization System
3.1
3.1 Process system code
HT
Main function HT: Desulfurization (flue gas chemical processing system
includes residue removal and absorption)
HTA
HTA Flue gas pipeline system
HTB
HTB Flue gas side heat exchanger and flue gas heater
HTC
HTC Flue gas fan system
HTD
110

HTD The absorber and flue gas cleaning system

HTF
HTF Absorption circuit
HTG
HTG Oxidation system includes supply system
HTJ
HTJ Absorbent supply system includes storage system.
HTK
HTK The absorbent preparation system and distribution system
HTL
HTL The solid unloading includes the pipeline system of dewatering and
backwater, not including concentration and solid dewatering system.
HTM
HTM The concentration and solid dewatering system
HTN
HTN The solid drying and compression system
HTP
HTP The gypsum transfer, storage and delivery system
HTQ FGD
HTQ The FGD water supplying and processing system
HTT
HTT Drainage system
HTW
HTW Sealing liquid supply system
HTY
HTY Control and protective instrument
3.2
3.2 Classification codes of the equipment (thermal control expertise part)
AA
AA Valves, dampers, etc., including the actuator and the manual
operation
111

AB
AB The isolating module and air interlocks
AC
AC The thermal exchanger, heat transfer surface
AE
AE Rotating, driving, lifting, and rotational transmission units
(including manipulators)
AF
AF Continuous belt conveyor and feeder (including elevators)
AG
AG Generators
AH
AH Heating, cooling and air-condition
AJ
AJ Size segmentation equipment
AK
AK Compression and packing equipment
AM
AM Mixer and blender
AN
AN Compressor and fan
AP
AP Pump
AT
AT Cleaning, drying, filtering and separating equipment
AX
AX The checkout and monitoring equipment for the maintenance of
power plant
3.3
3.3 Classifications and codes of instrument control equipment
112

AA

Classification AA of
Description
measuring equipment

CE
Electric variable

CF
Flow

CG
Position

CL
Liquid level

CM
Moisture or humidity

CP
Pressure

CQ
Analyzing variable

CS
Revolving speed

CT
Temperature

CY
Displacement, like vibration, etc.
3.4
3.4 Instrument control equipment No.
NNN

Equipment No.
Description
NNN

001-099
Analogue quantity remote transmission measurement (ANAL OG SIGNAL)

101199
Digit remote transmission measurement ( DIGIT SIGNAL)
113

NNN

Equipment No.
Description
NNN

201299
Undefined (FREE)

301399
Undefined (FREE)

401499
Measuring point for inspection and evaluation

501599
Local indicator

601699
Undefined (FREE)

701799
Undefined (FREE)

801899
Undefined (FREE)
Combined
901999 operation measurement circuit (such as two out of three operating results
and multichannel recorder) ( COMBINED SIGNAL)
3.5
3.5 Cutline identification
114

1 The explanation of controlling cutline

identification (Figure 1)
1 Explanation 1
2 Explanation 2
3 Explanation 3
3.6
3.6 Examples
1
Example 1:
2 2
The equipment name of No.2 slurry circulation pump of No.2 unit flue gas
desulfurization system:
2 2 12
115

2 The coding of No.2 unit is 12;

3 HTF
3 With the system code of HTF, the slurry circulation pump belongs to the slurry
absorption system in desulfurization;
4 2 02
4 The pump is No.2 pump, which can be 02 subsystem of the system;
5 AP
5 The pump's equipment code is AP;
6 001
6 The initial number of the pump in the branch system is 001.
KKS 10HTF20 AP001
As a result, the KKS code of the equipment is: 10HTF20 AP001
2
Example 2:
1
The coding of pressure measuring instrument at the inlet of the desulfurization
booster fan of No.1 unit.
7 1 11
7 The coding of No.1 unit is 11;
8 HTA
8 With the system code of HTA, the pressure measuring instrument belongs to the
flue gas system of desulfurization;
9 10
9 The number of the measuring point in system is 10;
10 CP
10 The code of pressure measuring instrument is CP;
11 001
11 The signal is an analogue quantity signal, with the number of 001.
10HTA10 CP001
As a result, the number of the measuring point in the instrument is:
10HTA10 CP001
116

Section III Distributed Control System

1
1. Definitions
1.1
1.1 Distributed control system
DCS
Distributed control system (DCS) refers to a distributed computer control system

for centralized surveillance, operation, management and distributed control of
manufacturing process.
DCS
Common DCS manufacturers include:
DCS ABB SYMPHONY
Import DCS manufacturers: Swiss ABB - SYMPHONY system
SIEMENS TXPTXP3000 PCS7
German Siemens - T - XP, T - XP3000 and PCS7 systems
WESTINGHOUSE OVATION
US Westinghouse (Westinghouse) - OVATION system
FOXBORO I/A
US Foxboro - I/A system
MAX maxDNA
Shanghai Instrument Max - maxDNA system (US)
HITACHI HIACS5000
HITACHI - HIACS5000 system
HONEYWELL
US Honeywell Corporation
DCS GE XDPS400
Domestic DCS manufacturers: Shanghai Xinhua (GE) - XDPS-400 system
MACS 3
HollySys - system MACS 3
EDPF2000
117

Guodian Zhishen - EDPF-2000

Zhejiang Supcon Information Co., Ltd.
1.2 DCSMCSDASSCS
1.2 Meanings of DCS, MCS, DAS and SCS referred to concerning control system
DCS
DCS: Distributed control system
DAS
DAS: Data acquisition system
MCS
MCS: Modulating control system
SCS
SCS: Sequence control system
2
2. Network structure of DCS
2.1 DCS
2.1 Desulfurization DCS as an independent control system
SIS

21"LCD

SIS

1# 2# 3#
21"LCD 21"LCD 21"LCD

DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU
#1 #2
SIS Plant information management system

SIS
SIS SIS gateway
118

Desulfurization engineer station
Colored laser printer
1# Desulfurization 1# operator station
Laser printer
Laser printer
Laser printer
Power cabinet
Terminal cabinet
#1 #1 boiler desulfurization unit system
#2 #2 boiler desulfurization unit system
Electrical, process water, etc.
Slurry preparation and dewatering
Desulfurization engineer room
Desulfurization control room
DCS DCS electronics room
2.2. DCS DCS

2.2. Networking of desulfurization DCS and unit plant DCS
119

SIS
#1 #1 #2 #2

21"LCD 21"LCD 21"LCD 21"LCD

SIS SIS
#1 #2
#1 #1 #2 #2
1# N# 1# N#
21"LCD 21"LCD 21"LCD 21"LCD

#1DCS300MW DCS #2DCS300MW

DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU DPU

21"LCD 21"LCD 21"LCD
#1DCS DCS #2DCS

SIS Plant information management system SIS
SIS SIS gateway
Control network
#1 #1 host unit historical site
#1 #1 host unit engineer station
Colored laser printer
Host unit engineer room
#1 1# #1 host unit 1# operator station
#1 N# #1 host unit N# operator station
#1 #1 unit screen
Laser printer
Laser printer
#1 DCS #1 unit DCS switch unit (redundancy)
#1 DCS300MW #1 unit DCS (300MW)
Host unit control room
DCS Plant utility system DCS switch (redundancy)
#2 DCS #2 unit DCS switch unit (redundancy)
DCS Utility system DCS
Redundant fiber
120

DCS DCS core switch (redundancy)
#2 #2 unit screen
Host unit engineer room
#2 #2 unit screen
#2 1# #2 host unit 1# operator station
#2 N# #2 host unit N# operator station
#2 #2 host unit historical site
#2 #2 host unit engineer station
DCS DCS switch unit (redundancy)
#2 DCS(300MW) #2 unit DCS (300MW)
SIS SIS gateway
Desulfurization system local operator station
Desulfurization system local operator station
Desulfurization system local engineer station
Desulfurization control room
Laser printer
Power cabinet
Terminal cabinet
#1 DCS #1 unit desulfurization DCS cabinet
Terminal cabinet
Terminal cabinet
Terminal cabinet
DCS Desulfurization utility system DCS cabinet
Terminal cabinet
#2 DCS #2 unit desulfurization DCS cabinet
Desulfurization system local electronics room
FOXBORO,NOATION Take systems of FOXBORO, NOATION and

HollySys for example
Host unit
Desulfurization system

121

Section IVPrinciples of Interlock Protection Logic, Control and

Regulation
1
1. Open loop and closed loop control system
1.1
1.1 Open loop control system:

A control system will be called open loop control system so long as it is granted
with constant impact output (controlled variable) in which controlled variable is
controlled by controlling variable only and controlled variable, on the contrary, is
unable to influence the controlling variables.

Open loop control system is shown in the schematic diagram of the structure in
the figure.

Controller Controlled object

Disturbing quantity

Input quantity Output quantity
ur ua n
1.2
1.2 Closed loop control system:
,
Output is in direct or indirect feedback to the input terminal, forming a closed

loop, and the system engaged in control is called closed loop control system. Since the
system is controlled by the deviation in the principle of negative feedback, it is called
feedback control system or deviation control system.

Functions of all elements and signal flows in the closed loop control system are
shown in the structural figure as follows.
122

ur ue ua n

Controller Controlled object

Input quantity Feedback

Test unit Output quantity
ucf
2
2. Key control parameters in limestone-gypsum wet-process FGD
,,,,
:
Flue gas desulfurization system is influenced by multiple factors as a system.
However, in system design and operation, the following factors shall be highlighted:

Ash content in the flue gas at the inlet. Too high ash content in the flue gas
may result in deteriorating system operation, reflecting the low efficiency of
absorption (it is called limestone absorbent poisoning since the increase of limestone
addition works little), difficulty in dewatering of belt conveyor, aggravating abrasion
of equipment, etc. What is noteworthy is that deteriorating system operation on that
account may take long time to be corrected.
pH 5.56.0
pH
pH value of slurry in the absorber is required to be controlled within a specific

range, generally 5.5-6.0; otherwise, a too low pH value may result in loss of
absorption capacity of slurry; and too high pH value may result in grave consequences
of scaling and blocking of the system. The pH value undergoes online dynamic
regulation via the feeding quantity of limestone to adapt to boiler operation
fluctuations and changes in working conditions.

Density of slurry in the absorber. It is required to be controlled within the

specified range; too low density may result in difficulty of gypsum crystallization in
the slurry and difficulty of dewatering in the dewatering machine; and too high
density may result in graver system abrasion.
Cl- 20000ppm
123

The Cl ion concentration of in the slurry of absorber is advised to be kept

20,000ppm; too high concentration may offer harsher demand for materials and too
low density may result in too high discharge of wastewater.
GGH 80
GGH
Temperature of flue gas at the outlet. Concerning GGH flue gas heating
system, flue gas at the outlet is required to be higher than 80 in
temperature to guarantee discharge of flue gas. Concerning no GGH flue gas
heating system, there is no special demand for flue gas at the outlet, but
corrosion prevention in the flue of outlet and stack is required.
S02
S02 pH
S02 content in flue gas at the outlet. It is necessary to keep an eye on the
parameter; in deviation, it is necessary to make a comprehensive analysis of boiler
load, S02 content of the flue gas at the inlet, number of working circulation pumps, pH
value of slurry and other influential factors.
3
3. Key regulation control system in desulfurization system

Mainly includes:

Automatic control of pressure at the inlet of booster fan

Automatic control of slurry feeding system in the absorber

Automatic control of liquid level in the absorber (control of mist eliminator)

Pressure regulation at the inlet of gypsum hydrocyclone

Regulation of water supply at the inlet of the mill

Regulation of water supply at the inlet of circulation tank of the mill

Automatic control of gypsum filter cake thickness in the gypsum dewatering
124

system
3.1
3.1 Automatic control of pressure at the inlet of booster fan;

Based on the pressure of flue gas at the inlet of desulfurization system, regulate
the electric actuating mechanism of damper (or guide blade) of booster fan to regulate
the pressure rise in the booster fan to guarantee that the pressure of the flue gas is
capable of overcoming resistance in the desulfurization system. Introduce the location
of the moving blade of an induced draft fan of the boiler (or signal of negative
pressure of the boiler hearth) as a feed forward signal for modulating circuit. Location
of the actuator of booster fan is in feedback for feedback signal of modulating circuit.
3.2.
3.2. Automatic control of slurry feeding system in the absorber;
FGD SO2 FGD SO2 FGD
pH
Input signals: SO2 concentration at the inlet of FGD, SO2 concentration at the
outlet of FGD, oxygen content at the outlet of FGD, raw flue gas flow, pH value of
slurry in the absorber, flow of limestone slurry into the absorber and density of
125

limestone slurry.
Output signal: Opening of regulating valve for supply of limestone slurry.

SO2
SO2 SO2
SO2 Ca/S
pH pH PID
PID
Control Principles: Measure SO2 concentration in the raw flue gas and clean flue
gas, correct corresponding temperature, pressure, humidity and flue gas amount,
calculate desulfurization efficiency, multiple it by SO2 concentration in raw flue gas to
get SO2 load and multiple SO2 load by limestone purity and Ca/S coefficient to get the
required quantity of limestone slurry. Meanwhile, compare the pH value of slurry in
the absorber and the pH set value, output by PID regulator, set upper limit and lower
limit, correct regulated quantity of slurry supplied, output corrected demand for
limestone slurry and feedback to quantity of limestone slurry in the absorber for
comparison, and regulate the opening of regulating valve for supply of limestone
slurry by control of PID regulator to realize control of chemical reactions of
desulfurization system.
SO2 15
6% FGDSO2 C1
21FGD
If oxygen content is 6%, SO2 concentration at the inlet of FGD C1 = SO2
concentration at the inlet15/ (21-oxygen content at the outlet of FGD)
SO2 15
6% FGDSO2 C2
21FGD
If oxygen content is 6%, SO2 concentration at the outlet of FGD C2 = SO2
concentration at the outlet15/ (21-oxygen content at the outlet of FGD)
1C2 / C1 ) 100%
Desulfurization rate = (1-C2/C1) 100%
FGD K
K=0.93K
Blast capacity in the dry state at the inlet of FGD = K blast capacity at the inlet
of booster fan; (In design, K=0.93; actual K value may be adjusted depending on
measured moisture at the site)
SO2 FGD FGDSO2
126

SO2 load = the blast capacity at the inlet of FGD (actual oxygen content in dry
state) SO2 concentration at the inlet of FGD (actual oxygen content in dry state)
3.3
3.3 Automatic control of liquid level in the absorber (control of mist eliminator)

Based on waiting time for change in liquid level in the absorber and flushing in
the mist eliminator layer, complete washing in the mist eliminator and realize control
of liquid level in the absorber.
3.4
3.4 Control of slurry discharge pump in the absorber

Regulate the revolving speed of the variable frequency regulation pump in the
slurry discharge pump in the absorber based on pressure at the inlet of gypsum
hydrocyclone and make the revolving speed of the variable frequency regulation
pump as a feedback signal for circuit regulation. Guarantee density of gypsum at the
outlet of hydrocyclone.
3.5
3.5 Regulation of water supply at the inlet of wet mill

127

Based on the proportion of limestone quantity at the inlet of wet mill and water
supply, multiple feeding quantity of belt weigh feeder by proportion to get the
required quantity of water supply, compare it with the flow of water supply in the wet
mill, and regulate the opening of regulating valve for water supply at the inlet of the
wet mill by proportion in its output.
3.6
3.6 Regulation of water supply at the inlet of circulating slurry tank in the wet mill

Compare the actually measured density value at the outlet of the wet mill with
the set value of density, and calculate out the feedwater quantity that is needed to add
to the slurry circulation tank according to the deviation. Then, compare the needed
feedwater quantity with the feedwater flow being added to the slurry circulation tank
and control the output by regulating the opening of feedwater regulating valve at the
inlet of slurry circulation tank proportionally.
3.7
3.7 Automatic control of gypsum filter cake thickness in the gypsum dewatering
system

10
The belt speed is regulated by the variable frequency controller through the
thickness measure of gypsum filter cake, in order to achieve that the gypsum moisture
remains at 10% after dewatering.
4
4. Sequential control logic of desulfurization control system
4.1
4.1 Main functional groups of desulfurization control system

Functional group of flue gas system

Functional group of the absorber

Functional group of absorber mist eliminator
128


Functional group of absorber slurry circulation pump

Functional group of pits in the absorber area

Functional group of absorber discharge system

Functional group of mist eliminator wash water system

Functional group of slurry feeding system of limestone slurry

Functional group of density measure of the limestone slurry system

Functional group of limestone slurry preparation system

Functional group of process water system

Functional group of belt-type vacuum dewatering system

Functional group of mill slurry preparation system, etc.

Generally speaking, functional groups are the combination of functions on a

certain scale that are completed by means of logical relations by several equipments
held together in the control system logic. For example:

GGH
Equipments included in the functional group of flue gas system is as follows:

bypass damper, raw gas damper, booster fan, GGH (if any), seal fan of the flue gas
damper, seal air heater, absorber discharge valve, clean gas damper, etc.
4.4.1
4.4.1 Start-stop sequence of desulfurization system
129

FGD
Step sequence of FGD starting operation

Name of
1 functional group Process water system

-- 12
Module name of
functional group Preselected module - process water pump 1, 2

Give manual command: start manually (give manual
Command command: start automatically)

Name of
2 functional group Absorber pit

--
Module name of
functional group Sub-functional group - pump of the absorber pit

Command Give manual command: start automatically

Name of
3 functional group Slurry system of gypsum overflows

--
Module name of
functional group Preselected module - slurry pump of gypsum overflows

Command Give manual command: start manually

Name of
4 functional group Filtrate water system

-- 12
Module name of
functional group Preselected module - filtrate water pump 1, 2
130



Name of
5 functional group Limestone slurry system

--
Module name of
functional group Preselected module - limestone slurry pump


Name of
functional group Density measure of the limestone slurry system

(Limestone slurry system sets automatic start)

Name of
6 functional group Limestone
--
Module name of Sub-functional group module - feeding of limestone slurry
functional group tank


Name of
7 functional group Wastewater rotational flow system

-- 12
Module name of
functional group Preselected module - waste water hydroclone feed pump 1, 2

131


Name of
8 functional group Wastewater system

-- 12
Module name of
functional group Preselected module - wastewater pump 1, 2


Name of
9 functional group Process water system of mist eliminator

-- 12
Module name of
functional group Preselected module - wash pump of mist eliminator 1, 2


12

Name of Absorber system (oxidation fan 1, 2, blender, mist eliminator,
10 functional group limestone slurry supply)

--
Module name of
functional group Sub-functional group - absorber system


Name of
11 functional group Absorber gypsum slurry system

-- 12
Module name of
functional group Preselected module - discharge pump of gypsum slurry 1, 2


132


1
Name of
12 functional group Absorber circulation pump 1

-- 1
Module name of
functional group Module of sub-functional group - absorber circulation pump 1


2
Name of

-- 2
Module name of


3
Name of

-- 3
Module name of


Name of
15 functional group Absorber flue gas system
--
GGH

Module of functional group - absorber flue gas system
Module name of (including: automatic start of booster fan, automatic start of
functional group GGH)
133



Name of
16 functional group Gypsum dewatering system

Module name of
functional group

Command

Independent Name of
Emergency slurry tank system
system functional group

--
Module name of
functional group Module of functional group - emergency slurry tank system


If some of the above systems have started, continue the
execution by skipping them.
FGD
Step sequence of FGD stopping operation

Name of
1 functional group Absorber flue gas system
--
GGH
Module name of Module of functional group - absorber flue gas
functional group system (including: automatic start of booster
fan, automatic start of GGH)

134

Command Give manual command: stop manually

1
Name of
-- 1
Module name of Module of sub-functional group - absorber
functional group circulation pump 1


2
Name of
-- 2


3
Name of
-- 3


Name of
5 functional group Absorber gypsum slurry system
-- 12
135

Module name of Preselected module - discharge pump of

functional group gypsum slurry 1, 2


12

Name of Absorber system (oxidation fan 1, 2, blender,
6 functional group mist eliminator, limestone slurry supply)

--
Module name of
functional group Sub-functional group - absorber system


Name of
7 functional group Process water system of mist eliminator
-- 12
Module name of Preselected module - wash pump of mist
functional group eliminator 1, 2


Name of
8 functional group Limestone slurry system

--
Module name of
functional group Preselected module - limestone slurry pump


136


Name of
9 functional group Limestone slurry preparation system
--
Module name of Sub-functional group module - feeding of
functional group limestone slurry tank

Command Give manual command: stop automatically

Name of
10 functional group Slurry system of gypsum overflows
-- 334
Module name of Preselected module - slurry pump of gypsum
functional group overflows 3, 34


Name of
11 functional group Wastewater rotational flow system
-- 12
Module name of Preselected module - waste water hydroclone
functional group feed pump 1, 2


Name of
12 functional group Filtrate water system

-- 12
Module name of
functional group Preselected module - filtrate water pump 1, 2
137



Name of
13 functional group Wastewater system

-- 12
Module name of
functional group Preselected module - wastewater pump 1, 2


Name of
14 functional group Gypsum dewatering system

Module name of
functional group

Command

Independent Name of
system functional group Process water system

-- 12
Module name of
functional group Preselected module - process water pump 1, 2


Independent Name of
system functional group Absorber pit
--

Sub-functional group - pump of the absorber pit
Module name of
138

functional group


Independent Name of
system functional group Emergency slurry tank system
--
Module name of Module of functional group - emergency slurry
functional group tank system

4.1.2
4.1.2 Start-stop sequence of functional groups of the flue gas system
:
Start the sequential control:
:
Allowable conditions of the sequential control: (with)

The operation of at least two slurry circulation pumps

The operation of any one oxidation fan
MFT
No MFT signal

The full operation of boiler electric precipitator
STEP1: 0
STEP1: Set the position of guide blade of the booster fan to the 0 place and turn it
into manual control;
STEP2:
STEP2: Open the clean gas damper; after opening the clean gas damper, close the
absorber discharge valve;
139

STEP3: GGH GGH

STEP3: Start GGH functional group (start the sequential control of GGH);
STEP4: GGH
STEP4: After the operation of GGH main or auxiliary motor;
STEP5:
STEP5: Start booster fan functional group (start the sequential control of booster
fan);
STEP6:
STEP6: After starting the booster fan, open raw gas damper;
STEP7:
STEP7: Slowly close the bypass damper; turn the guide blade of booster fan into
manual control
STEP8:
STEP8: Sequential control ends
:
Stop the sequential control:
STEP51:
STEP51: Turn the guide blade control of the booster fan into manual control;
STEP52:
STEP52: Slowly open the bypass damper;
STEP53: 5
STEP53: Turn off the guide blade of booster fan, and when the closing of guide blade
reaches below 5%, start the shutoff of booster fan functional group (shut off the sequential
control of booster fan);
STEP54:
STEP54: Close raw gas damper; after closing the raw gas damper, open the absorber
discharge valve;
STEP55:
STEP55: Close the clean gas damper;
STEP56: GGH GGH
STEP56: Stop GGH functional group (stop the sequential control of GGH);
STEP57:
140

STEP57: Sequential control ends

4.2
4.2 Protection and trip of the desulfurization system

Interlocking control of the desulfurization trip

FGD
As one of the supporting systems of the whole unit, the desulfurization system
isn't generally set with a compulsory boiler trip signal. The protection of the boiler is
realized through its own protection (When there is no bypass flue, the compulsory
boiler trip signal shall be considered to set), and the protection of desulfurization unit
is realized through FGD trip and bypass operation mode.
FGD

FGD trip generally means the separation of flue gas system of the
desulfurization system from the host, with the flue gas going through the
bypass and the booster fan stopping.

Bypass operation generally means opening the bypass damper of the
desulfurization system, with other systems operating as usual and no
operation happening.
4.2.1 FGD
4.2.1 FGD trip conditions
FGD
FGD will trip with any of the following conditions
III
Inlet temperature of the raw flue gas is higher than the value of III;
III 3s >400Pa)
After the pressure of flue gas before raw gas damper is higher than the value
of III and delays for 3s; (>normal value+400Pa)
III 3s <1000Pa)
After the pressure of flue gas before raw gas damper is lower than the value
of III and delays for 3s; (<normal value-1000Pa);
141

GGH GGH II
50s
No operation occurs to GGH main and auxiliary motors, or the revolving
speed of sensor in the GGH test box is lower that the value of II with raw gas
damper not closed and delaying for 50s;
30min
Any two of the three circulation pumps trip and delay for 30min, or the three
circulation pumps trip at the same time;
()
Booster fan trips (adopting the falling edge of the operation signal pulse);
MFT
Boiler MFT
4.2.2 FGD
4.2.2 Operation conditions of FGD bypass
FGD
FGD bypass operates with any of the following conditions.
II 3s
>400Pa)
After the pressure of flue gas before raw gas damper is higher than the value
of II and delay for 3s; (>normal value +400Pa);
II 3s <800Pa
After the pressure of flue gas before raw gas damper is lower than the value
of II and delay for 3s; (<normal value -800Pa);
FGD II (>200mg/Nm3 1 FGD
III (>230mg/Nm3)
FGD inlet flue dust is higher than the value of II (>200mg/Nm3 and delaying
for 1h) or higher than the value of III (>230mg/Nm3)
II>155
Temperature of raw flue gas is higher than the value of II (>155)

Boiler is in operation with oil
4.2.3 FGD
4.2.3 FGD and boiler exchanging signals

142

Signals to the boiler:

Bypass damper closed;
2/3
Bypass damper open (2/3);

Booster fan trips;
FGD
FGD trip signal;

Signals from the boiler:
MFT
Boiler trip signal (MFT);

Input of boiler oil gun (the large oil gun being in operation);
A
Induced draft fan A trips;
B
Induced draft fan B trips;

Boiler load (steam flow)

Negative pressure of hearth

Input of dust collector
4.2.4
4.2.4 Interlock protection problems of bypass damper

Design and model selection of the damper and actuator shall be ensured
safety
143


Perfection of the DCS interlock protection logic

Management of the construction site

Section V Desulfurization Thermotechnical Instruments
1
1 Main instruments in the desulfurization system are as follows:
1.1
1.1 Local pressure gauge

According to interface patterns, the local pressure gauge in the desulfurization

system can be divided into two kinds: bourdon tube pressure gauge and
diaphragm-type pressure gauge. The bourdon tube pressure gauge is used for
measuring the non-corrosive medium without suspended solids, while the
diaphragm-type pressure gauge is used for measuring the corrosive medium with
suspended solids. The bourdon tube pressure gauge gets pressure through pulse tubes,
while the diaphragm-type pressure gauge is directly installed in the process pipeline
through flange.

Bourdon tube pressure gauge Diaphragm-type pressure gauge
1.2
1.2 Remote instrument

144

420mA DC Pt100
Remote instrument refers to the instrument that can transmit measured

parameters to control system in the form of standard signals. Signal patterns of remote
instrument include analogue quantity 4-20mA DC, thermocouple, thermal resistance
Pt100, and passive dry contact switch.

Remote instruments in the desulfurization system are as follows:
1.2.1
1.2.1 Thermal resistance

Pt100
Thermal resistance is a temperature measurement component whose resistance
value varies with the temperature and increases as the temperature rises. Industrial
thermal resistance includes two categories: platinum thermal resistance and copper
thermal resistance. And generally, the Pt100 platinum thermal resistance is adopted
within the industry.
1.2.2 /
1.2.2 Pressure/differential pressure transmitter
// 420mA
Pressure/differential pressure transmitter is a measuring instrument that receives

tested pressure/differential pressure signals and transforms them into 4-20mA
electrical signals to output according to certain rules. There are mainly two kinds of
interface patterns as to the pressure transmitter in the desulfurization system:
screw-thread interface and flange interface. Pressure transmitter with a screw-thread
interface is used for measuring flue gas, air, process water and other mediums, while
diaphragm-type pressure transmitter is used for measuring corrosive mediums with
suspended solids. Pressure transmitter with a screw-thread interface gets pressure
through pulse tubes, while diaphragm-type pressure transmitter is directly installed on
the process pipeline through the flange. The diaphragm of diaphragm-type pressure
transmitter shall be adopted with Hastelloy.
145


Thread-interface pressure transmitter Flange-interface diaphragm pressure transmitter
1.2.3
1.2.3 Mass flow meter and electromagnetic flow meter
1.2.3.1
1.2.3.1 Mass flow meter

Mass flow meter, ultrasonic densimeter, etc. are generally

adopted in density measurement in desulfurization and mass flow
meter is more popular. The law of Coriolis force is adopted in the
mass flow meter, which attains density value and quality flow of
fluid by measuring resonant frequency of flowing liquid.

Measuring points set in the densimeter in the desulfurization system include:

Density of absorber (bypass pipeline at the outlet of gypsum slurry discharge pump),
density of limestone slurry tank (bypass pipeline at the outlet of limestone slurry
pump) and outlet of slurry circulation pump for limestone slurry (bypass pipeline).
1.2.3.2
1.2.3.2 Electromagnetic flow meter

Electromagnetic flow meter measures induced electromotive force of fluid in the

magnetic field according to Faraday's law of electromagnetic induction in which
induced electromotive force is in direct proportion to flow rate and calculates volume
flow of fluid based on area of cross section of pipeline.
146

1.2.4 /
1.2.4 Ultrasonic material/radar liquid level meter
//
/
Ultrasonic material/radar liquid level meter runs in a way in which it radiates
ultrasonic wave/microwave pulse to the surface of measured substance and measures
interval between pulse wave transmission and reception to calculate feeding/liquid
level.
1.2.5
1.2.5 Guide wave radar material level meter

()
Guide wave radar material level meter adopts the law of microwave pulse
radiation but microwave pulse is transmitted by one (or two) guide wave substance(s)
extruded from top of tank to the bottom of tank instead of space. The guide wave
substance can be metal stiff stick or soft metal cable. Guide wave radar material level
meter possesses the following characteristics:

It is immune from impact of dust and steam;

It is immune from impact of change in medium characteristics, such as
density, particle size, humidity and angle of repose of materials;

The medium adhering to the guide wave stick has no impact on
measurement;

Therefore, the guide wave radar material level meter is the first choice in
measurement of material level in limestone powder silo.
1.2.6
1.2.6 Level switch

Level switches are more frequently used in desulfurization system including
147

radio frequency admittance (capacitance) material level switch and tuning fork
material level switch. Level switches are applicable to system alarm and protection
since they are simple, cheap and reliable. The radio frequency admittance material
level is generally applicable to high and low material level alarm in the limestone
(block) storage silo while tuning fork material level switch is primarily applicable to
high and low material level alarm in limestone powder silo, water level, etc.
1.2.7 pH
1.2.7 pH meter
pH
pH
PPPTFE
The pH meter is composed of electrodes, supports, and secondary instruments. It
makes measurement by bypass flow cell and its measuring points are generally
located on the measurement pipeline of bypass at the outlet of gypsum slurry
discharge pump. The pH supports are made from non-metal materials (PP, PTFE).
2
2. Installation of thermal instruments
2.1
2.1 Installation of pressure gauge and pressure transmitter in the slurry pipeline

Diaphragm pressure gauge and pressure transmitter are adopted in pressure

measurement in the slurry pipeline. Piping diagrams for diaphragm pressure gauge
and pressure transmitter on the slurry pipeline are as
follows:
Instrument pipeline
2.2.
2.2. Installation of pressure transmitter in flue
148


Diagrams for flue gas pressure sampling and
piping are as follows:
>7.5% Gradient > 7.5%
Flow direction
Instrument pipeline
Instrument pipeline
2.3
2.3 Installation of differential pressure transmitter of mist eliminator

Flue gas where differential pressure of mist eliminator is sampled contains

substantial moisture so reserved interface at side of absorber should be slant
downwards in some angle so that moisture is able to flow back to the absorber. There
is no point of moisture in layout of pulse pipelines either. Differential pressure
measuring and piping diagram for mist eliminator is as shown in the right figure.
2.4 pH
2.4 Installation of pH meter
pH
pH
pH pH
pH
Due to difference in mode of installation, pH sensors generally include: Three

categories including immersion, flow (branch pipe) and insertion (direct). The pH
149

meter adopts mode of measurement of flow cell in common in which gypsum slurry
flows in and out of side from bottom of flow cell and pH meter is inserted from top of
flow cell. Generally, pH meter and densimeter are placed on the same platform for
overhaul. The pH secondary meter is placed on the nearby railing supports in the
mode of wall-hung installation and secondary meter sets weather enclosure.
pH
The pH meter should be regularly marked and calibrated by standard liquid while
it is used.
Pipeline instrument
Instrument pipeline
2.5
2.5 Installation of flow measuring instrument

Flow measuring instruments have requirements for pipeline direction and length
of direct pipelines. Mass flow meter and electromagnetic flow meter are required to
be installed on vertical pipes and medium flows in a bottom-up way. Such a mode of
installation makes suspended solids in slurry sink to the pipelines and prevents
measuring pipelines from not filling.
CEMS
Section VI CEMS System (Continuous Flue Gas Emission Monitoring
System)
1 CEMS
1. CEMS system in desulfurization island measures the following flue gas
compositions:
150

FGD SO2O2
FGD inlet: SO2, O2, dust;
FGD SO2O2NOXCO
FGD outlet: Flue gas flow, SO2, O2, NOX, dust, humidity, CO, temperature,
pressure.

Composition of flue gas on-line measurement unit

Sampling and pretreatment system

Analysis system

The subsystem for system control and data collection and treatment

Compressed air system

Instrument chamber and power supply
2CEMS
2. Introduction to CEMS extractive method
CEMS
CEMS extractive method mainly includes: Direct extractive and diluting
extractive.
2.1
2.1 Direct extractive

The method is the most traditional method of continuous flue gas analysis in
which it continuously extracts measured flue gas that flows into the gas analyzer after
undergoing probe filtration, heating and thermal insulation, condensation and
dewatering, and fine filtration.
120
15 11
151

Direct extractive: Make rough filtration, heat, make thermal insulation (120)
dehumidify, make fine filtration, measure original concentration of pollutants in flue
gas (temperature of measured gas falls to 15 or is 11 lower than ambient
temperature), mark and make point measurement by zero gas and standard gas.
2.2
2.2 Extracting dilution
100

EPA

Extracting dilution refers to dilution of flue gas extracted in some multiple by
clean air (100 times for instance). In this way, it may prevent sophisticated sample
pretreatment system among ways of extractive without dewatering. Therefore, it is a
wet measurement, which is preferred by US Environmental Protection Agency (EPA)
and popular in the US. However, such a way is demanding for high-precision diluting
header that is required of regularly replacing filtration unit.
1:100

Diluting extractive: Internal and external (heating) dilution, typical dilution ratio
of 1:100, long distance of flue gas transmission, low dew point, measured
concentration of diluted flue gas pollutants, marking and point measurement by zero
gas and standard gas.
2.3 CEMS
2.3 Comparison with ways of monitoring gas pollutants in CEMS system

Sampling methods Advantages Disadvantages
Full1. 1.
extractive
1. Dry state measurement;
- dry base 1. Heating and sampling pipelines are
2. adopted in measurement of soluble gas;
NDIRNDUV
2. High reliability and measurement
GFCFTIR 2.
precision;
(NDIR, NDUV, 2. Sample gas should undergo
GFC, FTIR, etc.) 3. pretreatment in higher sample flow;

3.
3. Cost reduction by adoption of
multi-component analyzer;
3. The whole sampling and pretreatment
4. system requires measures of corrosion
prevention;
4. Fidelity in flue gas transmission
and consistency between displayed
152


Sampling methods Advantages Disadvantages
measured component concentration
and output data;
5.
5. Convenient replacement of probe
filter;
6.

6. Simple system calibration and
auto calibration of analyzer and
system;
1.; 1.
Dilution Extractive
- wet base 1. Wet base measurement, the US
specifications and requirements; 1. It is necessary to equip diluting air
purification unit due to higher demand
2. quantity for diluting gas;
(,
) 2.
2. In most cases, tracing heat is not

(Ultraviolet required in gas transmission
fluorescence andpipelines; 2. Incomplete purification may result in
chemiluminescence) serious analysis error (local error);
3.
3.

3. Low sampling flow, less probe
blocking and no reverse purging
unit equipped for most; 3. It is necessary to monitor or correct
change in pressure of diluting air and
4.
temperature of sampling probe and often
mark diluting probe;
4. Longer distance of transmission
4.
between sampling probe and
analysis system;
4. It is necessary to configure multiple
5.
analyzers in multi-component gas
5. No need for condensation or analysis;
dehumidification.
3 CEMS
3. Principles of direct extractive in CEMS
CEMS

Flue gas CEMS is composed of flue gas sampling and pretreatment system, flue
gas auxiliary parameter measurement system (flue gas pressure, flow, temperature,
turbidity, etc.) and data collection and treatment subsystem.
153

Flue
Probe case
Sampling probe
ZV1 ZV1 magnetic valve
SM200 Smokemeter SM200
Standard gas
Tracing heat pipeline
Blowoff
Clean flue gas analysis cabinet
Filter
Sampling pump
MP1 MP1 peristaltic pump
MP2 MP2 peristaltic pump
Drainage
Condensate dewatering unit
154

Flow meter
Magnetic valve
Filter
Instrument
ZV12 ZV12magnetic valve
N2 N2 zero gas
SO2 SO2 standard gas
NOx NOx standard gas
O2 O2 standard gas
CO CO standard gas
SM200 Smokemeter SM200
Humidity meter
Filter reducing valve
Compressed air storage tank
Flow measuring case
Instrument air system
4CEMS
4. Simple daily maintenance of CEMS system

First of all, observe signal of flow alarm: If flow signal alarm, it will indicate
unsmooth gas circuit, blocking filtering gas, sintering sampling pipe, or gas leakage in
extracting pump, thus it will be advised to check one by one;

Check whether displayed values of analysis instruments and displayed values
of glass rotor flow meter are normal;

Check standard barometer and prevent leakage;
155


Check whether there is paper jam or shortage of paper in the printer;

Check whether pressure of zero gas is up to standard;
O2
Check whether measured result of O2 concentration is too high, which
indicates leakage in the sampling pipeline;

Check whether all functions of graphic display and sheet printing are normal;

Check whether ambient temperature is normal;
FGD
Section VII Monitoring and Analysis of All Measured Data in
Normal Operation of FGD System
1
1. CO2 measurement

CO2 measurement should be calibrated every week. If value seems not reliable, it
shall be necessary to shorten interval of calibration.
2pH
2. pH measurement

The measuring equipment should be checked in the lab every week and
calibrated at least every four weeks.
3
3. Pressure measurement in flue

Flue pressure measurement and pipe connection should be checked and cleaned
every month.
4
156

4. Density of slurry in the absorber

It shall be checked every week.
5
5. Chemical measurement and analysis

The projects analyzed:

Limestone slurry: Density.
pH CaSO42H2OCl-CaSO31/2H2O
CaCO3
Absorber slurry: pH value, density, CaSO42H2O, Cl ion concentration, solid
content, CaSO31/2H2O, CaCO3.
pH CaSO42H2OCl CaSO31/2H2O
Gypsum slurry: pH value, density, CaSO42H2O, Cl ion concentration, solid
content, CaSO31/2H2O.

Methods of analysis:
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157

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158

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159

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.

Requirements for parameter control:

Limestone quality has direct impact on desulfurization efficiency, thus it is

necessary to sample and analyze limestone from each vehicle. Analyze slurry
composition to conduct inspection on chemical reaction degree in the absorber and
rate of utilization of limestone. Generally, test slurry in absorber and slurry in gypsum
tank and analyze once per day.
pH pH
4
160

pH value and density are key indicators of slurry in absorber, thus it is necessary
to analyze pH value and density per shift and analyze slurry at 4 sampling ports per
time, including outlet of gypsum slurry discharge pump, underflow of gypsum
hydrocyclone, limestone slurry tank and filtrate case.
161

FGD
Chapter VDebugging, Operation and Performance Experiments of
FGD System
FGD
Section I Debugging of FGD system
1
1. Debugging purpose and task
FGD FGD
The debugging of FGD System is the trial operation of various equipment of

FGD System after installment to check whether every indicator of all the equipment
meets the requirements or not, whether every pre-set function can be realized or not,
and whether each equipment and system can operate coordinately or not, so as to
ensure that the performance and indicators of the whole-set unit satisfy the design
requirement.

FGD
So far, there are no official standards, procedures, or specifications for the

desulfurization system debugging, but the relatively perfect debugging procedures and
standards for major unit debugging can be the reference. Generally speaking, the
debugging phases of FGD System can be divided into: Monomer debugging,
subsystem debugging, whole-set start-up and test run.
1.1
1.1. Monomer debugging

4
8
It refers to the test run of a single set of equipment. Such as, for the slurry
circulation pump, monomer test run refers to the process to conduct the no-load test
run of the motor for 4 hours after the installment of the slurry circulation pump, then
to connect the motor to the pump and conduct the test run of the pump for 8 hours
when the liquid level in the absorber satisfies the circulation pump start-up allowable
conditions. During the test run, check whether the operation of the pump is steady and
whether the vibration, bearing temperature and motor coil temperature conform to
related acceptance specifications. After conforming to the specifications, handle the
162

test run certificate and deliver it for subsystem test run. The monomer test run is
generally led by the construction unit with the cooperation of the debugging unit.
1.2
1.2 Test run of subsystem

GGH
It refers to the adjusting operation of each system based on water or air as the
medium after the completion of monomer equipment debugging. For example, in the
subsystem test run of the flue gas system, besides the booster fan, damper and GGH,
it also includes the operation of the slurry circulation pump located in the absorber
system. In the debugging of the flue gas system, it is necessary to test the regulating
characteristics of the booster fan, the resistance characteristics of the flue gas system,
the leakproofness of the damper and the resistance characteristics of the absorber, etc.
Sometimes, due to the time requirement, monomer debugging and subsystem
debugging can be carried out simultaneously, for example, the debugging of the flue
gas system and the monomer debugging of the slurry circulation pump, oxidation fan,
gypsum slurry discharge pump, the damper seal fan can be conducted simultaneously.
The subsystem test run is generally led by the debugging unit with the cooperation of
the construction unit.
1.3 FGD
1.3 Whole-set start-up debugging phase of FGD System
FGD 168h
It refers to the thermal-state debugging phase. It refers to the process from the
first flue gas discharge to 168h full-load operation, and to hand-over of FGD for trial
production. The whole-set start-up is generally led by the debugging unit with the
cooperation of the construction unit.
2
2. Submission of debugging materials

After entering the site, the debugging personnel shall first compile the
Debugging Outline which generally is compiled by the chief debugging engineer. The
Debugging Outline reflects the general arrangement and steps of the debugging and
guides the entire startup debugging. The Debugging Outline generally includes the
163

following contents:
2.1
2.1 Project profile and equipment configuration.
FGD
It briefly introduces the composition of project construction, design, civil

engineering, installation and debugging units of the FGD System being debugged, and
also the project characteristics if necessary, so that the personnel concerned can learn
about the project and the debugging requirements.
FGD
It introduces the main design parameters of the FGD System, including the flue
gas parameter, limestone characteristics, and water quality characteristics. The
system's desulfurization efficiency, pressure loss, power consumption, water
consumption, limestone consumption, gypsum quality and other performance
guaranty parameters. It introduces the equipment composition and main
characteristics of each system.
2.2
2.2 Basis for debugging

It is necessary to list the regulations and procedures which shall be followed in

debugging, relevant documents, design materials and equipment technology
instructions of the competent department of the project.
2.3
2.3 Organization and responsibilities of debugging

In accordance with the requirements of Rules for Start-up and Final Acceptance
on Capital Construction Projects of Thermal Power Plant, establish the debugging
organization and define the tasks and responsibilities to the test run command team
which includes the installation, debugging and production personnel in the test run of
individual equipment and subsystem of FGD and whole-set start-up.
2.4
2.4 Scope of debugging

164

It refers to the equipment and systems required in the startup of FGD system. It
defines the adjustment test items which should be completed in startup process
according to the requirements of debugging.
2.5
2.5 Debugging plan, principle and executing procedures. It contains debugging
management procedures in all phases of debugging.
2.6
2.6 Quality control of debugging.
/
It mainly contains the debugging quality and safety control policies, safeguard
measures, quality objectives, etc.

FGD
Generally, the Debugging Outline should be submitted within a week after the
arrival of debugging unit. Monomer debugging scheme is usually submitted by the
construction unit. The debugging unit should submit it one week before the subsystem
test run. The FGD system debugging scheme generally includes the following parts:
FGD
Power on debugging scheme for FGD
DCS
DCS debugging scheme

Flue gas system debugging scheme

Absorber system debugging scheme

Limestone slurry preparation system debugging scheme

Gypsum dewatering system debugging scheme

Wastewater treatment system debugging scheme
165


Chemical analysis debugging scheme
FGD
FGD cold state debugging scheme
FGD
FGD whole-set start-up debugging scheme

Debugging scheme generally includes the following contents:

System introduction;

Debugging purpose;

Compiling basis;

Debugging conditions and environmental requirements;

Debugging contents, methods and procedures;

Debugging organizations, personnel requirements and division of labor;

Safety precautions;

Debugging quality control points;

Records and reports required.

It is supposed to summarize the debugging techniques after the debugging, which

is also an important part of the handover document when the system is transferred for
166

production. All kinds of parameters should be adjusted in debugging and related

records should be made, and problems occurred in the test run shall be analyzed with
treatment measures and conclusions.
FGD
The FGD system debugging report generally includes the following parts:
FGD
Power on debugging report for FGD
DCS
DCS debugging report

Flue gas system debugging report

Absorber system debugging report

Limestone slurry preparation system debugging report

Gypsum dewatering system debugging report

Wastewater treatment system debugging report

Chemical analysis debugging report
FGD
FGD cold state debugging report
FGD
FGD whole-set start-up debugging report

Debugging report generally includes the following contents:

System overview;

167

Compiling basis;

Debugging content and process;

Problems occurred in debugging and corresponding solutions;

Debugging conclusions and suggestions;
3
3. Test run of subsystem
FGD FGD
FGD
GGH
The test run of individual equipment and subsystem of the FGD system includes
monomer debugging and subsystem debugging. Monomer debugging is the test run of
single auxiliary equipment in the FGD system, including electric and thermal control
protection device. The work in this phase is finished by combining in the subsystem
debugging. Subsystem debugging refers to the debugging of a single system such as
process system and function system. It includes the debugging test run with flue gas
of all the equipments and systems such as power, measurement and control; i.e., the
cold state simulation test run of main components of the FGD system. Those systems
contain utility system (process water system and compressed air system), absorber
system, flue gas system (including booster fan, GGH and its auxiliary system),
limestone preparation system (including the limestone delivery system, limestone
slurry preparation system, limestone slurry feeding system), gypsum dewatering
system (including belt-type vacuum dewatering system), empty system (emergency
slurry tank and drainage pit system) and sampling system. Cold state debugging of the
flue gas system is the core of subsystem debugging, it is also an important part for the
overall check of the equipment condition and for system interlock and protection test.
3.1
3.1 Commissioning of electrical system
FGD
UPS
168

The power-on of system should be completed before test run of individual

equipment and subsystem of FGD. All systems under desulfurization electrical system
such as power supply system, DC system, AC emergency power supply, AC
uninterruptible power supply (UPS) and secondary line, should be put into operation.
11kV415V
6kV FGD
Electrification conditions for the auxiliary power: The monomer debugging for
electric switches of the 11kV or 415V systems have been finished, and it is qualified
and with the conditions for putting into operation; the DC system equipment
debugging has been finished, and it is qualified and with the conditions for putting
into operation; the grounding system debugging has been finished, and it is qualified
and with the conditions for putting into operation; the lighting and communication
debugging have been finished, and they are qualified and with the conditions for
putting into operation; the debugging for the affiliated firefighting system and
facilities of electrical system have been finished; the static debugging for the interlock
protection system of electrical system has been finished; the 6kV system of the power
plant side has been ready for the power supply of FGD system and can be put into
operation at any time.
11kV415V UPS DCS
11kV and 415V system is electrified; DC system and UPS system are put into
operation; and DCS system supplies power.
3.2
3.2 Commissioning of the thermal control system
FGD DCS SCS
,
MCS
Before the test run of individual equipment and subsystem and the whole-set
start-up of FGD, the SCS control range realized by DCS includes the monitoring and
control of all pumps, fans, valves and dampers in the unit control room and the
normal operation of the interlock protection of equipment. All MCS control circuits
are put into normal operation.
3.3
3.3 Test run of damper seal system
3.3.1
3.3.1 Check before debugging

The individual test run of motor of each fan is qualified.
169


The installation of fan and all relevant air flues and instruments is completed.

The foundation of fan is firm, and all bolts have been tightened.

Check the air door of seal air system and the switch shall be flexible and
indication be correct.

The lubricating oil level of fan is normal and cooling water unblocked.
3.3.2
3.3.2 Test run of fan
DCS
Connect the coupling and start the fan with DCS for the first time. Stop with
the emergency button when the full speed is reached and observe whether there is
abnormal phenomenon or frication sound about each module. And the formal test run
can only be conducted after the confirmation of no problem.

Check the temperature and vibration of bearing periodically during test run.
Stop the test run at once if abnormal situation is founded, and continue the test run
after the abnormal situation is eliminated.
3.4
3.4 Test run of process water system
FGD
GGH
The process water provided for the FGD system has many purposes, and the
main purpose is to supplement the moisture which is taken away by the wastewater
system, evaporated in the absorber and taken away due to generation of the final
product "gypsum". Meanwhile, the process water is also used for cooling the
oxidation air and flushing GGH, discharge pipelines, gypsum filter cloth and filter
cake. The system generally comprises the process water pump and the mist eliminator
flushing pump.
3.4.1.
170

3.4.1. Liquid injection of process water tank

The conditions which shall be provided before the liquid injection:

Installation of related pipelines and valves are completed;

The interior of process water tank is cleaned without anything left, and all
manhole doors are closed after checking;

Check all valves of the system, place them in suitable positions and put into
relevant meters;

The interlock protection test of process water tank is completed;

Liquid injection:

Water is filled into the process water tank, and the water supply pipeline and
the process water tank are flushed;

The water source of process water tank comes from the outlet water of
circulating water, and a flow meter is arranged on the water inlet main pipeline. The
water enters the process water tank through the flow meter, filter screen and electric
door, and the supply of water and the shut-off operation are controlled by the electric
door. When water is injected into the process water tank for the first time, water
supplement shall be conducted through the filter screen which shall be cleaned in time.
The liquid level of the process water tank should be controlled automatically so as to
keep the normal water level of process water tank.
3.4.2
3.4.2 Check before test run of water pump

Individual test run of water pump motor is qualified;

171

Installation of related pipelines, valves and pump are completed;

The flushing of pipeline with water is completed;

The pump foundation is firm and the bolt is tight;

Switches of corresponding valves are flexible and position feedback is
correct;

The lubricating oil level of pump is normal and cooling water unblocked;

The pump is rotated manually, and the rotation is smooth;
3.4.3
3.4.3 Interlocking, protection and sequential control test of pump

Interlocking and protection of process water pump;

Interlocking and protection of the flushing pump of mist eliminator;

Sequential control operation of water pump;
3.4.4
3.4.4 Test run of water pump

No-load test run and protection test of pump motor are completed;

Water level of process water tank is enough;
DCS
Connect the coupling, start the water pump with DCS for the first time and
then stop the water pump with the emergency button when reaching the full speed,
observe whether abnormal phenomenon and friction sound occur on each module and
172

conduct the test run after confirming there is no problem;

Monitor the revolving speed, current, inlet and outlet pressure of the pump
during test run;

Check the temperature, vibration and sealing of the bearing periodically. Stop
the test run at once if abnormal situation is founded, and continue the test run after the
abnormal situation is eliminated.
3.4.5
3.4.5 Startup of process water system

Firstly, conduct local check on the equipment system, connect the mechanical
seal water of equipment and start the equipment after the inspection is completed.
Select a pump as the operation pump, and the other as the standby pump;

Start the sequential control start procedure of the process flushing pump;

Start the sequential control start procedure of the mist eliminator flushing
pump;

After the equipment is started, open the user valves for auto on, and confirm
whether the process water pump and the flushing pump of mist eliminator are within
the normal range.
3.4.6.
3.4.6. Stop of the process water system

All the other slurry pumps and pipelines shall be shut down, while the process
water system can only be stopped after all flushing is completed;

After all flushing is completed, set the equipment according to the
173

requirements of the sequential control procedures, execute the sequential control

"stop", and confirm that the following operations are completed in sequence:
a
a Close the seal water and cooling water of the mechanical seal of all slurry
pumps;
b
b Cut the liquid level control of process water tank, stop the process water pump
and the flushing pump of mist eliminator, and empty the process water tank
completely if the system is shut down for a long time.
3.5
3.5 Test run of compressed air system

GGH
The air source of compressed air system is generally connected by the power
plant air compressor room, and the system is equipped with the instrument
compressed air tank and service compressed air tank according to the requirements.
The compressed air source comes from the main engine, and is mainly used for
equipment such as the pneumatic door, GGH soot blowing and bag-type dust
collector.

Check whether the pipelines, valves and instruments of the compressed air
system are installed completely;

Put into related instruments;

Blow and sweep the compressed air pipelines and tanks;

Inflate the compressed air pipes after blowing and sweeping, and dredge the
water at the bottom periodically;

Blow and sweep all gas pipelines;

Put into all gas pipelines.
174

3.6
3.6 Test run of limestone delivery and slurry preparation system
3.6.1
3.6.1 Limestone delivery system

A set of limestone delivery system comprises: A vibratory feeder, a metal

separator and a bucket elevator.

Installation of each set of equipment of system is completed;

The limestone unloading silo and the limestone storage silo shall be cleaned
without leaving anything, and all manhole doors shall be closed after checking;

Put into relevant meters;

Interlock protection test of each set of equipment is completed;

Test run of the individual equipment is completed;
DCS
Conduct the no-load test run of limestone delivery system, and start the dust
collector, auxiliary equipment, metal separator and vibratory feeder of the limestone
storage silo with DCS in sequence. Check whether the limestone delivery system can
operate continuously and normally.

Conduct the on-load test run of limestone delivery system. Unload the limestone
to the limestone unloading hopper with a truck, and put into the dust collector and
auxiliary equipment of limestone unloading hopper before unloading. Then, the
procedure starts the limestone delivery system so as to feed for the limestone storage
silo.
3.6.2
175

3.6.2 Test run of limestone wet-milling slurry preparation system

1 1 1
2 1 1 1
A set of limestone milling system adopts the wet ball mill slurry preparation
system. The handling capacity of each set of system is determined according to the
system design. The system generally comprises a limestone weighing feeder, a wet
ball mill, a slurry re-circulation tank matched for the ball mill, two slurry
re-circulation pumps of ball mill, a limestone hydrocyclones station and system
pipeline valves.
3.6.2.1
3.6.2.1 Test run of limestone weighing feeder
3.6.2.1.1
3.6.2.1.1 No-load test run

Preparations:

All bearings, transmission modules and reducers shall be filled with enough
oil;

Check whether other sundries exist in the feeder;

Completely check whether each part of the feeder is intact;

The electrical part installation and wiring of feeder are completed.

After the above preparation work is completed, plug in the power, jog the button
"test run", and conduct the no-load running if the running direction is correct.

During the no-load running, specially-assigned persons shall observe the running
176

situation of the rubber belt, drive unit and bottom sweeping. Stop the machine
immediately if problems occur. The tightness degree of the rubber belt and sweeping
chain can be adjusted through corresponding tensioning screw rods. The above
situation is generally debugged before leaving the factory, and adjustment conducted
shall not be too much if no special situation occurs. Conduct the readjustment after
the machine runs for a period.
3.6.2.1.2
3.6.2.1.2 On-load running

After the no-load running is normal, on-load test shall be conducted on the feeder.
Firstly, start the feeder in a no-load mode, and runs with load after the operation is
normal.
3.6.2.1.3
3.6.2.1.3 Make the original record during test run, which comprises the voltage,
current and the revolving speed of rubber belt during no-load and on-load, and check
whether the record conforms to the design.
3.6.2.1.4
3.6.2.1.4 After the on-load running of feeder is normal, conduct the input and
calibration of the work parameter on the weighing instrument.
3.6.2.1.5
3.6.2.1.5 Operation of feeder

Conduct the no-load running for a certain time for each start.
35
The bottom sweeping unit should run for 3-5 minutes each time. There is no
special requirement for the start and stop.

The operator shall check the running situation of each part frequently, especially
whether the rubber belt is off-tracking and how is the tensioning situation, necessary
adjustment shall be conducted if problems occur, and the drive unit shall remain in a
normal state.

During the operation of feeder, the iron piece, large block of material and long
rod foreign bodies shall be prevented from entering the feeder so as to avoid damage
177

to equipment and causing accidents.

3.6.2.2
3.6.2.2 Test run of ball mill
3.6.2.2.1
3.6.2.2.1 Starting and stopping sequence of ball mill

Starting sequence

Low-pressure oil pump - high-pressure oil pump (if available) - main motor -
belt feeder

Stopping sequence

30 2
Stop the feeder - stop the main motor - the high-pressure oil pump starts
automatically (if available) - after the ball mill stops rotating, stop the low-pressure oil
pump - stop the high-pressure oil pump according to the bearing temperature, and
start the high-pressure oil pump (manually) for 2 minutes every 30 minutes (till the
cylinder body is cooled to the room temperature).

The injection lubricating unit system will work automatically when the main
motor works. It shuts down automatically when the main motor stops.

When the main motor works, the low-speed drive unit cannot be started. When
the low-speed drive unit works, the main motor cannot be started.
3.6.2.2.2
3.6.2.2.2 Long-term mill stop

30 2
When mill stops for a long time, the cylinder body will be cooled and shrank
gradually, and slippage of the shaft neck occurs on the bearing bush. In order to
reduce the friction and the axial tensile force generated from shrinking of the cylinder
body, the high-pressure oil pump shall be opened for 2 minutes every 30 minutes after
178

the mill stops so that a certain oil film thickness can be kept between the shaft neck
and the bearing bush.

When the mill stops in winter, the cooling water of the water cooling portion
shall be discharged completely (blown with compressed air) so as to avoid frost
cracking of relevant pipelines.

In general case, feeding shall be stopped before the mill stops so that the
operation of the mill can be stopped quickly.

If the machine is stopped for a long time, the steel ball shall be poured out so as
to avoid deformation of the cylinder body due to long time stopping.
3.6.2.2.3
3.6.2.2.3 Test run of mill

When the mill is started for the first time, optional stopping method must be
adopted.
a. 12
a. Enable the mill to rotate 1-2 circle slowly with the low-speed drive unit, and
check the situation of each part.
b. 4
b. The motor is idling (without the mill) and runs for 4 hours continuously.
c. 24
c. Drive the mill to run for 24 hours continuously (without the steel ball and
materials).

The no-load test run shall meet the following requirements:
a.
a. The lubricating situation of each lubricating point shall be normal and free of
leakage phenomenon.
b. 60
b. The main bearing temperature of mill shall not exceed 60.
c.
179

c. The running of mill shall be stable, no abnormal noise shall exist during the
transmission of gear, and the contact of tooth flanks shall be good.
d.
d. The liner plate and each rotating part shall be free of loose phenomenon.

After the no-load running is qualified, add the steel ball into the mill cylinder
body. However, pay attention to avoid idling of the mill without any materials after
the steel ball is installed, so as to prevent the high temperature and impact from
damaging the liner plate.
3.6.2.3
3.6.2.3 Test run of blender (mill slurry re-circulation tank blender and limestone slurry
tank blender)
3.6.2.3.1
3.6.2.3.1 Check before test run
,
The installation of blender is completed, and the individual test run of motor is
qualified;

The oil level of lubricating oil is normal;

The water level of slurry tank is enough;

Rotate the blender manually and check whether the rotation is smooth;

Interlock protection test of blender.
3.6.2.3.2
3.6.2.3.2 Test run of blender
DCS
Jog the blender and observe whether the rotating direction is correct. After
starting the blender with DCS for the first time, stop it with the emergency button
when operation is smooth and observe whether there is abnormal phenomenon or
180

frication sound about each module. And the formal test run can only be conducted
after the confirmation of no problem.

Check the temperature, vibration and sealing of the bearing periodically. Stop the
test run at once if abnormal situation is founded, and continue the test run after the
3.6.2.4
3.6.2.4 Test run of pump (limestone slurry pump and mill slurry circulation pump)
3.6.2.4.1
3.6.2.4.1 Check before test run

Individual test run of pump motor is qualified;

The installation of pumps and relevant pipelines and valves are completed;

Flushing of pipelines with industrial water is completed;


Switches of corresponding valves are flexible and position feedback is correct;

The lubricating oil level is normal and cooling water unblocked;

Rotate the pump manually to check whether the rotation is smooth;

Interlock protection test of pump.
3.6.2.4.2
3.6.2.4.2 Test run of pump

The water level of slurry tank is enough;
181

DCS
Start pump with DCS for the first time. Stop it with the emergency button
when operation is smooth and observe whether there is abnormal phenomenon or
frication sound about each module. And the formal test run can only be conducted
after the confirmation of normality.

Record the current, the inlet pressure and the outlet pressure of pumps during
test run;
30
Record the temperature and vibration situation of the pump body, motor and
bearing, check whether there is abnormal sound, observe the lubricating oil level
changing situation and record the operation current and others every 30 minutes
during the test run. Stop the test run at once if abnormal situation is founded, and
continue the test run after the abnormal situation is eliminated.
3.6.2.5
3.6.2.5 Test run of the mill system
3.6.2.5.1
3.6.2.5.1 The conditions before test run:

Installation of each set of equipment of system is completed;

The interior of slurry re-circulation tank is cleaned without anything left, and
all manhole doors are closed after checking;

Flushing of each pipeline in the system is completed;

Put into relevant meters;

Interlock protection test of each set of equipment is completed;

Test run of the individual equipment is completed;
182

3.6.2.5.2
3.6.2.5.2 Test run of the mill system

Before the test run of system, calibrate the weighing unit of belt feeder firstly so
that the proportion of limestone and water can be accurately controlled during
operation.

Put into the mill bearing and oil station cooling water, inject liquid for the
limestone slurry circulation tank with process water so as to start the blender after the
injected liquid is reaching a certain liquid level, jog the blender to be in the automatic
mode, inject the liquid to a certain height, start the mill slurry circulation pump and
enable the slurry preparation system to conduct inner circulation.
2030 50
30 10
24
During the on-load test run, add 20-30% steel balls into the mill, and 50% of the
total amount of materials, start the process water pump, start the low-pressure oil
pump, high-pressure oil pump and mill motor of the mill in sequence, open the
limestone blanking valve, start the weighing belt feeder, feed the mill, adjust the water
volume at the inlet and outlet of mill, put into corresponding instruments, add 10% of
the total amount of medium every 30 minutes when the mill is in normal running, feed
moderate materials continuously till the mill is in full load, and enable the mill to run
for 24 hours. Inject the slurry to the limestone slurry tank according to the liquid level
and density of the slurry in the mill slurry re-circulation tank.

SO2
2030Wt
After the limestone slurry is prepared, take the slurry sample from the limestone
slurry tank, conduct the laboratory analysis, observe whether the fineness of materials
can meet the requirements of the SO2 absorption system and whether the particle size
conforms to the design value, control the concentration of limestone slurry between
20% and 30% (Wt); abandon the limestone slurry if the requirements are not met,
otherwise, store the slurry in the limestone slurry tank and enable the system to be in
the standby state.
3.7
183

3.7 Test run of absorber system

3.7.1
3.7.1 Water flushing of absorber system

Before the installation of absorber system is completed and put into operation,
ensure that the interior of the absorber and its relevant system are clean, and conduct
the water flushing work besides necessary mechanical sweeping.

Confirm that the installation of absorber system and the mechanical cleaning
work are completed;

Confirm that the test run of individual subsystem of the process water is
qualified and the pipeline of equipment is clean, and ensure that the supplied process
water is clean;

Select the drainage pit as the discharge point of flushing water (discharge the
water in the drainage pit to the rain water well system through a temporary pump);

Take temporary protection measures for each regulating valve and recover
them after flushing;
3.7.2
3.7.2 Test run of spraying layer, mist eliminator and its washing water system
3.7.2.1
3.7.2.1 Check before start

The installation and fastening of spraying layer and mist eliminator are
completed;

Cleaning of all sundries is completed;

Check whether there is a gap and local flue gas bypass in the mist eliminator
area;
184


The installation and fastening of wash water pipeline are completed, the
switches of corresponding valves are flexible, and the indication is correct;

The installation directions of the spraying layer nozzle and the nozzles of all
layers of mist eliminator washing water are correct;

Open the flushing pump pipelines of the circulation pump and mist eliminator,
and check whether there is leakage phenomenon on the flange.
3.7.2.2
3.7.2.2 Interlock protection test of mist eliminator system
3.7.2.3
3.7.2.3 Cold state test of spraying layer, mist eliminator and its flushing water system

Open the flushing pump of mist eliminator and record the inlet pressure of
flushing water;

Start the circulation pump, check all nozzles and confirm whether the
direction is correct and whether the spraying water is enough;

Check the switch and flushing time of each valve of the washing water system.
The flushing time intervals shall meet the requirements;

Start the forced draft fan, induced draft fan and booster fan of the boiler in the
cold state, and record the pressure drop of each demist layer.
3.7.3
3.7.3 Test run of slurry circulation pump
3.7.3.1
3.7.3.1 Check before test run

The individual test run of circulation pump motor is qualified.

185

The installation of the pump and relevant pipelines, valves and inlet filter
screen is completed;



The switches of corresponding valves shall be flexible, the position feedback
and the thermal protection signals shall be correct;



Put into the mechanical seal water.
3.7.3.2
3.7.3.2 Interlock protection test of slurry circulation pump
3.7.3.3
3.7.3.3 Test run of circulation pump

The water level of the absorber is enough;
DCS
Connect the coupling, start the pump with DCS for the first time and then stop
it with the emergency button when it operating steadily, observe whether abnormal
phenomenon and friction sound occur on each module and conduct the test run after
confirming there is no problem;

during test run;

186

3.7.4
3.7.4 Test run of the gypsum slurry discharge pump
3.7.4.1

The individual test run of discharge pump motor is qualified.

The installation of the pump and relevant pipelines, valves and inlet filter
screen is completed;






3.7.4.2
3.7.4.2 Interlock protection test of gypsum slurry discharge pump
3.7.4.3
3.7.4.3 Test run of the gypsum slurry discharge pump

The water level of the absorber is enough;
DCS
187

it with the emergency button when it operating steadily, observe whether abnormal
phenomenon and friction sound occur on each module and conduct the test run after
confirming there is no problem;

during test run;

3.7.5
3.7.5 Test run of absorber blender
3.7.5.1

The installation of blender and its flushing water system are completed;


Rotate the blender manually and check whether it is smooth;
1m
The water level in the absorber shall be at least 1m higher than the blender
blade.
3.7.5.2
3.7.5.2 Interlock protection test of absorber blender
3.7.5.3
3.7.5.3 Test run of blender
DCS
After starting the blender with DCS for the first time, stop it with the emergency
button when operation is smooth and observe whether there is abnormal phenomenon
188

or frication sound about each module. And the formal test run can only be conducted

3.7.6.
3.7.6. Test run of oxidation fan
3.7.6.1

Individual test run of fan motor is qualified;

The installations of corresponding pipelines, valves and filter screens of fan is
completed, and the direction of outlet check valve shall be correct;

The foundation of fan and the bolt shall be firm;


The lubricating oil level shall be located at the upper position of the center
line, and the cooling water shall be unblocked;

Rotate the fan manually to check whether the rotation is smooth.
3.7.6.2
3.7.6.2 Interlock protection test of oxidation fan
3.7.6.3
3.7.6.3 Test run of oxidation fan

The outlet valves shall be in full open before start;
DCS
189

Connect the coupling and start the fan with DCS for the first time. Stop the
fan with the emergency button when the full speed is reached and observe whether
there is abnormal phenomenon or frication sound about each module. And the formal
test run can only be conducted after the confirmation of no problem.

Monitor the revolving speed, current, inlet pressure and outlet pressure of the
oxidation fan during test run;

Check the temperature, vibration and sealing of the bearing periodically;

The fan shall be stable in running and free of abnormal noise. Stop the test run
at once if abnormal situation is founded, and continue the test run after the abnormal
situation is eliminated.
3.7.7
3.7.7 Test run of absorber drainage pit pump
3.7.7.1

The individual test run of drainage pit pump motor is qualified;

The installation of pumps and relevant pipelines and valves is completed;


correct;


Rotate the pump manually to check whether the rotation is smooth.
190

3.7.7.2
3.7.7.2 Interlock protection test of sewage pump of drainage pit
3.7.7.3
3.7.7.3 Test run of drainage pit pump

The water level of drainage pit shall be enough;
DCS
it with the emergency button, observe whether abnormal phenomenon and friction
sound occur on each module and conduct the test run after confirming there is no
problem;

during test run;

3.7.8
3.7.8 Test run of blender of drainage pit of absorber
3.7.8.1

The installation of blender is completed;


Rotate the blender manually and check whether the rotation is smooth.
3.7.8.2
3.7.7.2 Interlock protection test of blender of drainage pit
3.7.8.3
191


DCS

3.7.9
3.7.9 Test run of emergency slurry tank pump
3.7.9.1

The individual test run of emergency slurry tank pump motor is qualified;

The installation of pumps and relevant pipelines and valves is completed;



correct;



192

3.7.9.2
3.7.9.2 Interlock protection test of emergency slurry tank
3.7.9.3
3.7.9.3 Test run of emergency slurry tank pump

The liquid level of emergency slurry tank is enough;
DCS
the water pump with the emergency button, observe whether abnormal phenomenon
and friction sound occur on each module and conduct the test run after confirming
there is no problem;

during test run;

3.7.10
3.7.10 Test run of emergency slurry tank blender
3.7.10.1

The installation of blender and its flushing water system are completed;


Rotate the blender manually and check whether the rotation is smooth;

The liquid level in the emergency slurry tank shall be higher than the
mechanical seal of blender.
193

3.7.10.2
3.7.10.2 Interlock protection test of emergency slurry tank blender
3.7.10.3
DCS

3.7.11
3.7.11 Start of absorber system
3.7.11.1
3.7.11.1 Liquid injection of absorber

The liquid injection of absorber shall have the following conditions:

Cleaning of sundries in the absorber is completed;

All flushing water pipes of absorber are closed;

The internal corrosion prevention and maintenance of absorber are finished;

All the water discharge valves at the bottom are closed;

The manhole door at the bottom of absorber is closed;

Put the liquid level meter into the absorber.
194


Inject water into the slurry pool of absorber

The water injection of absorber is conducted through the mist eliminator
flushing water during the first start: Start the flushing pump of mist
eliminator in the sequential-control mode, open the main flushing water
control valve of mist eliminator, open a path of flushing water pneumatic
valve of mist eliminator and set it at the manual position, inject water into
the absorber, and stop the water injection when the liquid level of absorber is
suitable.

After the liquid injection is completed, the system is in the cold standby
state.
3.7.11.2
3.7.11.2 Start of drainage pit of absorber

Check the blender and drainage pit pump of the drainage pit of absorber
according to the requirements, put into the liquid level control system of drainage pit
of absorber, and set the blender of drainage pit and pump of the absorber to be in the
automatic state so that the liquid level of drainage pit can control the blender and
pump to start and stop automatically.
3.7.11.3
3.7.11.3 Start of absorber blender

4
Check the blender according to the starting requirements of blender. After the
starting conditions for blender are met, start the four blenders of the absorber in
sequence and check whether the operation of blenders is normal.
3.7.11.4
3.7.11.4 Start of absorber circulation pump

2
195

60
Check the circulation pump according to its starting requirements and connect
mechanical seal water of circulation pump and cooling water of gear box. After the
starting conditions of circulation pump are met, start the sequential control starting
procedure of two absorber circulation pumps firstly, and determine whether to start
the sequential control starting procedure of the other absorber circulation pump
according to the situation of the desulfurization efficiency after the boiler is loaded
and the absorber is passed by flue gas. The circulation pump which is not started is
used for standby, and the starting interval shall be more than 60s.
3.7.11.5
3.7.11.5 Start of oxidation fan

1
Check the oxidation fan according to its starting requirements and connect the
cooling water of oxidation fan. After the starting conditions of oxidation fan are met,
start the sequential control starting procedure of one oxidation fan. After starting
equipment, check the operation situation of the equipment. The oxidation fan which is
not started is used for standby.
3.7.11.6
3.7.11.6 Start of gypsum slurry discharge pump of absorber

1
Check the gypsum slurry discharge pump according to its starting requirements,
and connect the mechanical seal water of the gypsum slurry discharge pump. Set one
gypsum slurry discharge pump as the operation pump and the other as the standby
pump. After the starting conditions are met, start the sequential control starting
procedure of one gypsum slurry discharge pump. After starting equipment, check the
operation situation of the equipment.
3.7.11.7 SO2 FGD SO2 95
3.7.11.7 Enable the SO2 removal rate control of absorber to be in the automatic state,
and set the SO2 removal rate of FGD to be 95%.
3.7.11.8
3.7.11.8 Enable the liquid level control of absorber to be in the automatic state
3.7.11.9
3.7.11.9 Sequential control start of absorber mist eliminator flushing water

196

Set the flushing water control of mist eliminator at the automatic position. After
the operation conditions of mist eliminator are met, the mist eliminator will execute
sequential control flushing procedures automatically. The flushing waiting time of
mist eliminator is controlled by the liquid level control system of absorber.
3.7.11.10
3.7.11.10 Enable the slurry concentration control of absorber to be in the automatic
state
3.7.12
3.7.12 Deactivation of absorber system
3.7.12.1
3.7.12.1 Deactivation of oxidation air system

Set the equipment according to the requirements of sequential control

deactivation procedure, start the sequential deactivation procedure of oxidation fan
and confirm the following operations are completed in sequence.

The motor of oxidation fan is deactivated;

The desuperheating water valve of oxidation air pipelines is closed.

3.7.12.2
3.7.12.2 Deactivation of circulation pump

EDCBA
deactivation procedure, start sequential deactivation procedure and confirm the
following operation is completed in sequence. If pumps E, D, C, B and A are in
operation currently,
E A
deactivate circulation pump E and conduct the drainage and flushing
procedures of the circulation pump A;
D D
deactivate circulation pump D and conduct the drainage and flushing
procedures of the circulation pump D;
197

C C
deactivate circulation pump C and conduct the drainage and flushing
procedures of the circulation pump C;
B B
deactivate circulation pump B and conduct the drainage and flushing
procedures of the circulation pump B;
A A
deactivate circulation pump A and conduct the drainage and flushing

During the deactivation, the procedure of one pump must be completed before
the start of sequential control deactivation procedure of next deactivating pump (the
liquid level situation of drainage pit shall also be taken into account), so that overflow
of liquid due to excessive feeding of the drainage pit of absorber during the water
draining and flushing can be avoided.
3.7.12.3
3.7.12.3 Deactivation of washing of mist eliminator

Set the equipment according to the sequential control procedure, conduct

sequential control flushing procedures again, execute sequential control "stop" after
the whole flushing is completed, and confirm the following operations are completed
in sequence.

The total flushing procedure of mist eliminator is stopped;

The main pipe of water supply for mist eliminator is shut off and the electric
door is closed;
3.7.12.4
3.7.12.4 Deactivation of gypsum slurry discharge pump

Set the equipment according to the sequential control procedure and execute
sequential control "stop" before flushing gypsum delivery pipelines.
198

3.7.12.5
3.7.12.5 Emptying of absorber slurry

Start the sequential control starting procedure of gypsum slurry discharge pump
to discharge the slurry of absorber to emergency slurry tank after conducting the
pipeline from absorber to emergency slurry tank and implementing the liquid level
control system of emergency slurry tank. The deactivation of gypsum slurry discharge
pump and absorber blender is controlled by the liquid level control system of absorber,
and the starting of the blender of emergency slurry tank is controlled by the liquid
level control system of emergency slurry tank. Conducting the pipeline from the
drainage pit of absorber to emergency slurry tank after the protection of gypsum
slurry discharge pump is deactivated, and the residual liquid of absorber will be
injected into the emergency slurry tank by absorber drainage pit pump.
3.7.12.6
3.7.12.6 Checking and precautions after deactivation

Empty the slurry of the container and equipment to be maintained completely;

Flush the deactivated equipment in time and fully so as to avoid the

deposition and drying of residue slurry and blocking of pipelines;

Make an inspection tour and check the operation situation of containers with
liquid levels such as the emergency slurry tank and others;
3.8
3.8 Test run of flue gas system
3.8.1
3.8.1 Debugging of flue gas damper

Check the blade, sealing gasket, connecting rod and corresponding actuator of
the flue gas damper, and the installation shall be completed without any damage.

199

The fastening of all bolts shall be completed.

The installation of flue, corrosion prevention and leak test of flue are
completed, and sundries in the flue shall be cleaned.

Operate the flue gas damper in the remote control or manual mode
respectively. The switch of damper shall be flexible, and the switch indication and
feedback shall be correct.

Check on the spot whether the on-off of damper is in place. If clearance is

checked out when the damper is fully closed, adjust corresponding actuator or seal it.

Test the interlocking of each flue gas damper.
3.8.2 GGH GGH
3.8.2 Test run of the seal fan of flue gas damper, that of GGH and GGH low-leakage
fan
3.8.2.1
3.8.2.1 Check before debugging

The individual test run of motor of each fan is qualified.

The installation of fan and all relevant air flues and instruments is completed.

The foundation of fan is firm, and all bolts have been tightened.

Check the air door of seal air system and the switch shall be flexible and
indication be correct.

The lubricating oil level of fan is normal and cooling water unblocked.
3.8.2.2
200

3.8.2.2 Test run of fan

DCS
Connect the coupling and start the fan with DCS for the first time. Stop the fan with the
emergency button when the full speed is reached and observe whether there is abnormal
phenomenon or frication sound about each module. And the formal test run can only be conducted
Check the temperature and vibration of bearing periodically during test run.
Stop the test run at once if abnormal situation is founded, and continue the test run
after the abnormal situation is eliminated.
3.8.2.3
3.8.2.3 Starting and stopping procedures of low-leakage fan

See the following table for the starting and stopping
procedures of the low-leakage fan:

No. Starting No. Stopping

1 Close the inlet and the 1
Deactivate the fan
outlet dampers

2 2
Start the fan Close the inlet and the outlet dampers
10

3 3
Open the inlet and the outlet
dampers after delay for 10s
3.8.2.4
3.8.2.4 Interlocking test of fan
3.8.3
3.8.3 Test run of booster fan
3.8.3.1
3.8.3.1 Necessary conditions and checking contents before test run

201

Fan and all corresponding flue gas pipelines shall be installed completely,
thermal signals shall be correct and individual test run of motor shall be qualified.

Confirm that all bolts are tightened and reliable, and check the leakproofness
of all pipelines, flanges and bolts.

Operation of blade adjusting structure are normal and indicating position is
correct with flexible motion and remote operation.

Fan rotor at the motor coupling shall be rotated manually, and the rotation
shall be smooth and easy. Check radial clearance between the top of impeller blade
and air duct; Check the axial clearance between impeller and core tube.

Strictly check the inside of the fan and the flue gas pipeline without leaving
any tools or sundries.

Close all manhole doors.

Check the oil level of main bearing box and oil supply unit and fuel up in case
of insufficient oil.

Check the coupling, drive motor and monitoring instrument.

The on/off of cooling fan is normal.

The function of emergency button is normal.
3.8.3.2
3.8.3.2 Starting procedure of fan:

Close the inlet damper;

Start the cooling fan of booster fan;
202


Close the inlet guide blade;
DCS
Start the booster fan with DCS;

Open the inlet damper after the starting of fan;

Adjust the opening of inlet guide blade;
FGD
After the starting, adjust the guide blade and control in coordination with the
bypass damper to keep the inlet pressure of FGD within a certain range. Close the
bypass damper gradually, adjust the booster fan to a suitable position, and enable the
booster fan to be in automatic state after running is stable.
3.8.3.3
3.8.3.3 Deactivation procedure of fan:

Stop the motor of booster fan;
10
Close the guide blade slowly after delay for 10s;
2
Stop the seal cooling fan after delay for 2 hours.
3.8.3.4
3.8.3.4 Monitoring of the operation of fan

Daily check and record shall be conducted every one hour and all data shall be
recorded. Besides record, check shall be carried out to the following items: Noise
characteristics; Stability of operation; State of instrument, etc.
3.8.4 GGH
3.8.4 Test run of GGH high-pressure flushing pump
3.8.4.1
203


Individual test run of water pump motor is qualified.

Pump, relevant pipelines, valves, inlet filter screens and instruments are
installed completely.

Flushing of pipelines with industrial water is completed.

The pump foundation is firm and the bolt is tight.

correct.

The lubricating oil level is normal and cooling water unblocked.

Rotate the pump manually to check whether the rotation is smooth.

Confirm the inlet pressure of pump within the range of design value.
3.8.4.2
3.8.4.2 Test run of pump

Check whether the inlet pressure of pump is normal.
DCS
Connect the coupling and start the pump with DCS for the first time. Stop the pump
with the emergency button when operation is smooth and observe whether there is abnormal
phenomenon or frication sound about each module. And the formal test run can only be conducted
after the confirmation of normality.

during test run;

204

Record the temperature and vibration situation of the pump body, motor and
bearing, check whether there is abnormal sound, observe the lubricating oil level
changing situation and record the operation current and others every 30 minutes
during the test run. Stop the test run at once if abnormal situation is founded, and
continue the test run after the abnormal situation is eliminated.
3.8.4.3
3.8.4.3 Flushing procedures of high pressure water
GGH 1.5 GGH
4
0.2MPa
When the pressure drop of GGH heat exchanger is 1.5 times of the design
pressure drop, flush the GGH heat exchanger with high-pressure flushing water. The
flushing time one time shall be about 4 hours, and the inlet pressure of high-pressure
wash pump during flushing shall be above 0.2 MPa.
3.8.4.4
3.8.4.4 Flushing procedures of low pressure water
0.4MPa
FGD
The low-pressure water flushing is mainly used for blowing out and overhaul. At
this moment, the inlet pressure of ash ejector shall be above 0.4 MPa, and the inlet
and outlet dampers of FGD shall be closed.
3.8.4.5GGH
3.8.4.5 Program control compressed air blow test of GGH
GGH GGH
1.4rpm 8 2
DCS FGD
When the GGH heat exchanger operates normally, conduct soot blowing with
compressed air. At this moment, the revolving speed of GGH rotor is about 1.4 rpm.
The compressed air soot blowing shall be conducted one time every 8 hours, and each
operation time is about 2 hours. The compressed air soot blowing procedure shall be
started on DCS manually by the operator. Compressed air comes from FGD public
compressed air system.
FGD
Compressed air for blowing shall be in the standby state for operation during
FGD operation. Manual valves in front of ash ejector shall be always in the open state
and only closed in a state of overhaul.
205


When blowing soot, the ash ejector goes forward step by step and adopts the
continuous back to back.
3.8.5 GGH
3.8.5 GGH test run
3.8.5.1
3.8.5.1 Check items before test run

Each instrument, such as temperature, pressure, is qualified and can be put
into use. The thermal signal is correct.

The flue gas damper switch is flexible and indicates correctly.

The test run of seal fan and low-leakage fan is completed.

Check of lubricating oil system

The indicators for selected lubricating oil shall be in line with the
requirements;

All pipe joints, valves and packing cover of the oil pump and other easy
leakages places of the oil circulating system shall be sealed well;

Check the lubricating oil of guide bearing, axial bearing which shall be
sufficient and the oil level is normal;

Check of sealing unit

The rotor rotates one circle along the rotation direction by hand pushing.
Check whether there are other foreign matters affecting the rotor rotation or
jamming;

206

The radial, axial and circumferential bypass seal clearance shall be in line
with the requirements of the manufacturer to installation clearance;

Cold and hot end of the rotor shall be no sundries and the sealing fin is intact
without damage when checking;
GGH
Check of GGH high and low pressure flushing water system

The installation of the flushing water pipeline is completed;
,
Each valve and instrument can be put into use along the flushing water
pipeline and there is no leakage phenomenon of the connection pipe;

The test run of high-pressure flushing pump is qualified;

Site check
GGH
There is no temporary pedal, steel frame and other spare parts in GGH and
ensure that all site welding has been completed.

The lighting equipment at work site is complete, the brightness is sufficient
and the emergency lighting is safe and reliable;

Stairs, platforms and railings are intact without damages and roads are clear;
GGH
GGH appearance is complete; the site control cabinet and the reducer unit
are good, which have the starting conditions.
3.8.5.2
3.8.5.2 Test
GGH
GGH locally start-stop test

207

Put "local/remote control switch" on the local position, start the auxiliary
motor, the rotor rotation is correct, check whether there is jamming or
abnormal noise, and check whether the oil temperature, oil level and oil
pressure are normal;
GGH

Start GGH main motor and auxiliary motor shall be able to disengage
automatically, at the moment, recheck whether the above items are qualified
or not;
GGH
Manually stop GGH and the test shall be normal.

Emergency button is normal.
GGH
GGH interlocking test
GGH
Put "local/remote control switch" on the remote control position and start all seal
fans of GGH;
GGH
The start-stop procedure of GGH

The start-stop procedure is conducted as per the following table.
GGH
The start-stop procedure of GGH

GGH
GGH
1 1
Start GGH bearing seal fan and put into Stop GGH low-leakage fan
interlocking standby
GGH
GGH
2 Start GGH main motor and put the auxiliary 2
Stop GGH main drive motor
motor into interlocking standby

3 3 GGH
Start the sequential start procedure of the
208

low-leakage fan Stop the GGH seal fan
3.8.6.
3.8.6. Program control start-stop of flue gas system

Program control start-stop of the flue gas system is shown in the following table.


GGH
1 1 The pressure control of booster fan is switched
Start GGH sequential start procedure to manual mode as well as the inlet guide
blade

2 Open the flue gas damper at the outlet of the 2
Slowly open the flue gas bypass damper
clean flue gas manually, at the same time, slowly close inlet
guide blade of the booster fan.

3 3
Close ventilation valve of the absorber After all the bypass damper doors opening,
start the deactivation procedure of the booster
fan.

4 Start the sequential start procedure of the 4
Open the ventilation damper of the absorber
booster fan
30
FGD
5 5
After the guide blade of booster fan reaching Close the FGD outlet flue gas damper
30%, slowly close the bypass damper
FGD
GGH
6 6
Keep the FGD inlet flue gas pressure at the set Stop the GGH in order.
value, and adjust the guide blade until the
bypass damper is closed.
3.9 FGD
3.9 FGD flue gas system cold state adjustment test
3.9.1
209

3.9.1 Test purpose

FGD
FGD
The cold state adjustment test shall be carried out to obtain the influence data that
the normal start-stop and forced shutdown of FGD system effects on boiler negative
pressure under the cold state and provide optimal guidance for the boiler and FGD
system operation.
3.9.2
3.9.2 Conditions which shall be provided before the test
3.9.2.1
3.9.2.1 Conditions which shall be provided for the boiler side
24
The boiler has stopped operation more than 24 hours.

The force draft fan and the induced draft fan of the boiler can be started and
stopped normally and can be put into operation automatically.

No overhaul in the hearth and flue, hearth negative pressure monitoring can
operate normally, the operator can print negative pressure change curve and opening
degree of fan and current curves.

MFT
Unit power load, dust concentration at the electric dust collector outlet,
electric dust collector running, opening degree of boiler induced draft fan stationary
guide blade, boiler MFT, boiler hearth negative pressure and other signals shall be
introduced to the desulfurization control system.
3.9.2.2 FGD
3.9.2.2 Conditions which shall be provided of the FGD system

The test run of booster fan system is completed, having conditions for
running.

The test run of the flue gas damper is completed which can be opened and closed
normally.
210

GGH
GGH test run is completed.

Flue system installation and internal cleaning.

Flue gas system static interlocking test and flue gas system sequential control
start-stop test.

The installation and operation of the related instrument of flue gas system.
3.9.3
3.9.3 Test contents
FGD
Influence to boiler negative pressure while starting FGD flue gas system
program control system;

Booster fan pressure closed loop adjustment test in cold state;
FGD
Influence to boiler negative pressure while stopping FGD flue gas system
program control system;
FGD
Influence to boiler negative pressure while stopping the FGD system
protection (for example, the booster fan trips).
3.9.4
3.9.4 Test steps

Start the force draft fan and induced draft fan of the boiler, adjust the boiler to full load
operation state by boiler operators in the power plant, boiler negative pressure is in the set
value and induced draft fan stops operating automatically.
GGH
Start GGH.
FGD
211

Start FGD flue gas system program control without any adjustment to the
boiler, observe and print hearth negative pressure change curve and fan parameter
change curve.

Conduct booster fan pressure closed loop adjustment test in cold state. Guide
blade of the booster fan is in the automatic state , change the working conditions of
the force draft fan and induced draft fan of the boiler, and auto-adjustment of booster
fan guide blade can be observed.
FGD
FGD flue gas system sequential control stops running, without adjustment to
the boiler, observe and print negative pressure change curve and fan parameter change
curve.
FGD
Adjust the boiler negative pressure to the set value, side fan of the boiler is
operating automatically, FGD flue gas system program control is started, observe and
print hearth negative pressure change curve and fan parameter change curve.
FGD
operating automatically, FGD flue gas system program control is stopped, observe
and print hearth negative pressure change curve and fan parameter change curve.
FGD
Adjust the boiler negative pressure to the set value, side fan of the boiler isn't
operating automatically, observe and print hearth negative pressure change curve and
fan parameter change curve when the FGD system protection stops (for example, the
booster fan trips).
FGD
operating automatically, observe and print hearth negative pressure change curve and
fan parameter change curve when the FGD system protection stops (for example, the
booster fan trips).
3.10
3.10 Test run of gypsum dewatering system
212

3.10.1
3.10.1 The test run of the blender (blender of the filtrate water tank and wastewater
tank)
3.10.1.1
,
The installation of blender is completed, and the individual test run of motor
is qualified.

The oil level of lubricating oil is normal.

Rotate the blender manually and check whether the rotation is smooth.

The water level is high enough.
3.10.1.2
3.10.1.2 The operation of the blender
DCS
After starting the blender with DCS for the first time, stop the blender with the
emergency button when operation is smooth and observe whether there is abnormal
phenomenon or frication sound about each module. And the formal test run can only
be conducted after the confirmation of no problem.

3.10.1.3
3.10.1.3 Interlocking test of the blender
3.10.2
3.10.2 Test run of the pump
3.10.2.1
213


The installation of pumps and relevant pipelines and valves is completed.

Flushing of pipelines with industrial water is completed.

The pump foundation is firm and the bolt is tight.

correct;

The lubricating oil level is normal and cooling water unblocked.

Rotate the pump manually to check whether the rotation is smooth:
3.10.2.2
3.10.2.2 Individual test run of motor

Measured motor insulation is qualified, disassemble the coupling or belt.

During the individual test run of the motor, the rotating direction shall be
correct, the emergency button shall be working correctly and reliably.

Detect motor temperature, vibration and current during the test run, stop it
immediately once abnormal situation happens, the test run can be conducted only
after it's normal again.
3.10.2.3
3.10.2.3 Test run of the pump

The water level is high enough.
DCS
Connect the coupling and start the pump with DCS for the first time. Stop it
214

with the emergency button when operation is smooth and observe whether
there is abnormal phenomenon or frication sound about each module. And the
formal test run can only be conducted after the confirmation of no problem.

during test run;

3.10.3
3.10.3 Test run of belt-type vacuum dewatering machine

2030mm
The belt-type vacuum dewatering machine is frequency control, controls the
thickness of gypsum on the dewatering machine by adjusting revolving speed,
generally ensure that the thickness of the filter cake in the dewatering machine is
20-30mm.
3.10.3.1
3.10.3.1 Allowable starting condition of belt-type vacuum dewatering machine

Filter cloth flushing water and dewatering machine lubricating water are
enough;

The vacuum pump operates normally;

No stop protection signal of dewatering machine.
3.10.3.2
3.10.3.2 Start-stop procedure of belt-type vacuum dewatering machine

Start-stop procedure of belt-type vacuum dewatering machine is shown in the
following table

215

3min

1 1 Stop belt-type vacuum dewatering machine
Start vacuum pump
after 3min of stopping feeding.
2
2 Open the electrically-operated valve of 2 Delay 2min to stop filter cloth flushing
vacuum pump cooling water pump
60 #1

3 Delay 60s to start #1 filter cloth flushing 3
Stop vacuum pump
pump
30
4 Delay 30s to start belt-type vacuum 4 Close the electrically-operated valve of
dewatering machine vacuum pump cooling water

5 5
Start feeding
3.10.3.3
3.10.3.3 Interlock protection test of the belt-type vacuum dewatering machine
3.10.4.
3.10.4. System water injection test run

After injecting water of a certain level to the filtrate water tank, overflows slurry
tank, gypsum slurry tank, filter cloth flushing tank, filter cake flushing tank,
wastewater tank, start normally gypsum discharging pump, overflow slurry pump,
filtrate water pump, vacuum pump, Waste water hydroclone feed pump, waste water
pump, filter cloth flushing pump, belt-type vacuum dewatering machine, gypsum
slurry pump and other related equipment according to the normal operation, check all
parts of the system to guarantee the normal operation.
4FGD
4. Start the whole-set FGD system
FGD
168h
The whole-set start-up and test run means whole-set startup debugging and test
run of the FGD system unit after the completion of the test run of individual
216

equipment and subsystem, including 3 processes, namely, whole-set debugging in

cold state with water and air, whole-set debugging in the thermal-state (flue gas
entering) and 168h full load test run.
4.1
4.1 Whole-set debugging in cold state

Replace slurry with water and replace flue gas with air during whole-set
debugging in the cold state. During the whole-set debugging in cold state, the
commissioning shall be conducted for the equipment that shall be put into operation
as per the normal operation, and the standby equipment shall be set in the automatic
standby state.

The more careful and comprehensive are subsystem debugging and test run, the
less left issues are there, the more smoothly and quickly to finish the whole-set
start-up and test run in the cold state. The main debugging job for whole-set start-up
and test run in cold state is the operation mode test, including:
4.1.1
4.1.1 Conduct the whole-set start-stop operation test as per three modes
(1)
(1) Start equipment in turn by manual operation to make the whole system in
operation state; then stop equipment in turn by manual operation to make whole
system stop running.
(2)
(2) Start subsystems in turn according to functions to make the whole system in
operation; then stop the whole system by stopping the various subsystems. It is
starting and stopping the whole system by small sequential control mode.
(3)
(3) Start and stop the whole system one time automatically by large sequential
control mode (if any).

After the whole system in is normal operation, mainly check the coordinated
217

operation of equipment in the whole system, check whether the pressure and flow of
conveying medium are within design range, whether the medium flows smoothly,
whether liquid levels of tanks and pits are in control, and whether abnormal overflow
happens or the liquid level is too low.
4.1.2
4.1.2 Test for operation mode change
FGD
Generally the FGD system is designed with a special operation mode in case of
certain equipment or subsystem being not able to operate due to faults, and it is
supposed to conduct test for operation mode change according to the design. Such as
bypass dewatering system, test for slurry abandoning operation mode, etc.

After the test, discharge all the water in tanks, pools and pipelines, completely
clean up and check, and conduct overhaul according to equipment defects found in
whole-set debugging under the cold state. Subsequently, conduct whole-set debugging
under the thermal-state (flue gas entering) or flue gas entering test run, also called
feeding debugging.
4.2
4.2 Whole-set debugging under thermal-state (flue gas entering)
FGD
1
Whole-set debugging under thermal-state (flue gas entering) of the FGD system
consists of preparation before flue gas entering, flue gas entering debugging and
stopping check. The whole-set debugging under thermal-state (flue gas entering) takes
about 1 month.

Principle for thermal-state test run is manual operation first and then starting and
stopping through the procedure; Open the bypass door first and then stop; adjust flue
gas system first and then other systems; conduct load interlock protection test first and
then adjusting circuit test.
4.2.1.
4.2.1. Preparation before flue gas entering
1
Preparation for flue gas entering shall start 1 week before the first flue gas
218

entering test run, and main preparations for flue gas entering are as follows:
4.2.1.1
4.2.1.1 Set up thermal-state whole-set debugging group
FGD
Set up a thermal-state whole-set debugging group led by FGD system debugging

leading group, which is responsible for specific implementation of thermal-state
whole-set debugging. Thermal-state whole-set debugging group includes process,
mechanical, automatic control and electrical groups.
4.2.1.2
4.2.1.2 Review and approve thermal-state whole-set debugging scheme

The party responsible for debugging is in charge of formulating debugging

scheme which shall be submitted to the debugging leading group for review and
approval after being discussed and modified by thermal-state whole-set debugging
group. The power plant shall organize operators to carefully learn about the
debugging scheme to facilitate operations in debugging and test run.
4.2.1.3
4.2.1.3 Preparation of communal raw materials
FGD
Industrial water, air and steam for instrument and other usages have been sent to
FGD system, and all the gas storage tank work under normal pressure. Fill water into
all the tanks and towers except for the retort of absorber and start the blender.

If it needs to purchase limestone powder, there shall be standby powder materials

in limestone powder silo, calibration of the limestone powder metering unit has been
completed, and limestone slurry tank has been equipped with limestone slurries of
certain concentration. If it is equipped with the limestone grinding system, the
limestone grinding system shall have completed debugging and test run, and there are
limestone slurries stored in limestone slurry storage tanks.

219

Prepare gypsum crystal slurry in proper pit, such as a sump pit in the absorption
area, and then transfer to the retort of the absorber. One can also directly send a
certain amount of crystal into the retort of the absorber. If the side-inserting blender is
closer to tank bottom, it is supposed to try to place gypsum crystal in the middle of the
tank, add water, and timely start the stirring unit after water level rises to the certain
height. Slurry concentration in the retort prepared by these two methods shall not be
lower than 5%. After the liquid level in absorber reaching to the normal control value,
start the oxidation gas distribution unit at the proper time.
GGH GGH
If tubular GGH is adopted, it is supposed to fill hot medium water in the GGH
pipe bundle.
4.2.1.4
4.2.1.4 Equipment starting before flue gas enters in
100
100
100
Check the control system overall: 100% input online instrument, input the
originally set values, and the initial display value of instrument measured value shall
be correct; 100% input of the adjusting circuit, and have adopted the required
accommodation mode; 100% input of the interlock protection circuit.

Start the following equipment through manual operation or small sequential
control of the subsystem functional group:

Start process water, instrument air and compressed air system.

Start functional groups of each sump pit.

Start the absorption system, including circulation pump, blender and oxidation
unit and mist eliminator flushing procedures.

Start limestone slurry allocating or slurry preparing system, and manually operate
limestone slurry supply circulating circuit.
220

Start pulp outlet pump of the absorber, and form a small circulation circuit
between the retort and one-stage dewatering unit (in some designs, the small
circulation circuit may not contain one-stage dewatering unit).
GGH GGH GGH
GGH
If rotary GGH is adopted, start the rotary GGH. If tubular GGH is adopted,
start hot medium water circulation pump, heat the hot medium water with steam,
preheat GGH pipe bundle, and control hot medium water temperature within certain
range.

Final check before flue gas entering

Confirm the correct position of each flue gas damper, auxiliary equipment of
booster fan has been started, and the equipment which is required to start is started
and works normally; Confirm that the operation mode selected by non-started
equipment (automatic, manual or standby) is correct; Liquid level of each tank and
other initial measured values are displayed normally; Confirm that the power supply
method is correct, and power switch for equipment to be start or standby equipment
has been turned on.
4.2.2
4.2.2 Flue gas entering debugging

FGD
12hFGD
From the perspective of safety, for the first flue gasentering test run, forcefully
and completely open bypass damper, introduce flue gas into FGD system through
manual operation step by step, gradually increase flue gas amount, and after each
equipment operates normally, all the main measured values have no abnormality and
tend to be stable, slurry density in the retort of absorber is basically stable and it is
able to continuously produce desulfurization gypsum, continuously observe for at
least 12h, and the first FGD flue gas entering succeeds. Then, one can start
debugging.
3 1
Initial debugging of flue gas entering is divided into 3 phases, which takes about
1 month.
221

4.2.2.1
4.2.2.1 Debugging contents of the control system

Main items for initial debugging of the control system include:

Conduct the start-stop test for thermal-state manual operation, small
sequential control and large sequential control of the system.
CEMS pH
Inspect instrument, especially flue gas and slurry characteristics measuring

instrument, such as calibration of CEMS, slurry pH value meter, flow meter and
densimeter.

Adjust set values.

Debug each adjusting circuit and initially confirm adjusting parameters.

If necessary, repeat main interlock protection stopping test under load or just
repeat those incident main interlock protection tests.

After finishing debugging to flue gas flow adjusting circuit (also called booster
fan inlet pressure) and main protection interlock stopping test, close the bypass
damper for operation, and put flue gas flow adjusting circuit into automatic operation.
4.2.2.2
4.2.2.2 Initial performance debugging
FGD
Initial performance debugging is to initially figure out basic performances of the

FGD system to select the optimum operating parameters for the next initial
performance test.
12d FGD
SO2 3
pH
222

CEMS
CEMS
During the test, spend 1-2d time to stabilize the system, and flue gas flow and
SO2 concentration at the FGD inlet under each load shall stay as stable as possible.
Measure actual values of each guaranteed item under 3 boiler loads by changing
operating parameters, such as slurry set value of pH value, sets of the circulation
pump under commissioning, blown oxidation air amount and circulating slurry
density. Conduct sampling analysis to each kind of slurry (limestone slurry, absorber
circulating slurry, rotational underflow and overflow and wastewater) and gypsum
during this phase. If CEMS (continuous flue gas emission monitoring system) has
been measured for comparison and calibration in advance, CEMS data can be adopted
to describe flue gas characteristics.
4.2.2.3
4.2.2.3 Initial performance inspection

FGD FGD
Initially confirm the best operating parameters according to initial performance
debugging results, and then conduct initial performance inspection. Initial
performance inspection is divided into the following two aspects: Firstly, inspect the
FGD system performance under the confirmed optimum operating parameters and
stable boiler load; secondly, inspect the regulating characteristics of FGD system
following the boiler load change.
4.2.3
4.2.3 Stop checks

168h FGD
710
After finishing thermal-state whole-set debugging, since the system is under
hot-state operation for a long time for the first time, some equipment may show some
defects, and equipment and components in container or flue may show looseness,
falling or damage. Besides, in order to ensure success of the following 168h test run,
it is supposed to stop operation of the FGD system after finishing thermal-state
whole-set debugging, discharge all the slurry in tanks and pools of the system, store
slurry in absorber into the emergency slurry storage tank, and conduct overall check
and trouble-shooting of system equipment. The entire process takes about 7-10 days.
4.3 168h
4.3 168h full-load test run
223

168h FGD 168h
168h
168h full-load test run is the last examination item in FGD system debugging/test
run. Inspect whether the system is capable of stable operation under full-load working
condition and continuous operation overall via 168h test run; Examine the input rate
of auto-control instrument, adjusting circuit and interlock protection; Check main
system performances--if desulfurization efficiency can reach to the guarantee value;
Recordother system performance indexes which, however, is not regarded as a basis
to determine whether can 168h test run succeed.
168h FGD
FGD
After the successful 168h full-load test run, stop operation of the FGD system,
store slurry in the emergency slurry storage tank, conduct overall check on system
equipment and eliminate equipment defects. Then, put the system into operation again.
So far, FGD system has been fully transferred to Party A for management, it enters
commercial test run phase, and Party A shall issue temporary transfer certificate to
Party B.
FGD FGD
FGD 168h
168h
According to the FGD engineering contract, after a certain period of the

commercial test run, FGD system can start the performance examination and
acceptance tests. Among domestic FGD system debugging, sometimes due to
limitation of node time completing 168h test run, initial performance debugging and
inspection under thermal-state whole-set debugging shall be conducted after 168h test
run and before the performance examination and acceptance tests. And thermal-state
whole-set debugging time is relatively shorter, which is not enough to figure out
system performance and characteristics.
FGD
Section II Operation of FGD System
1FGD
1. State division of FGD system
FGD

FGD system state can be roughly divided into four categories: Normal
224

operation state, short-time deactivation state, short-term deactivation state and

long-term deactivation state.
FGD

The normal operation state refers to the stable FGD system operation, where all
the parameters are adjusted normally, each equipment operates normally or can be
started at any time;

24hFGD
Short-time deactivation state is mainly to stop the booster fan, flue gas passes
bypasses in short time, other equipment in normal operation or can be in starting
state at any time, and generally, deactivation time is 24h, and FGD system can be
started rapidly.
17d FGD
FGD
Short-term deactivation state refers to stopping lasting 1-7d or more time.
During the temporary overhaul of main equipment or absorber of FGD system, stop
FGD slurry preparation system, dewatering system, wastewater treatment system,
etc.
FGD

7d
Long-term deactivation state refers to that all the FGD systems are fully
stopped. By principle, except for the emergency slurry tank and the blender of the
emergency slurry tank, all the equipment shall be stopped, and all the pipelines and
system tanks shall be cleaned up, and deactivation time is generally longer than 7d.
2FGD
2. Starting and stopping of FGD system
2.1 FGD
2.1 Main starting steps of FGD system

Pre-start-up check

Start process water and mist eliminator flushing system

Start compressed air system

Start limestone unloading system Start absorber circulation system: Crystal seed equipped to the absorber,
discharge system, oxidation air system, gypsum discharge system,
circulation pump system, and automatic slurry supply
225


Start the slurry preparation system Put into mist eliminator automatic
flushing procedures

Start limestone slurry supply system
Start gypsum hydrocyclone system
GGH
Start flue gas system: Start GGH system and booster fan system

Start gypsum delivery system

Start belt-typevacuum dewatering
system

End
2.2 FGD
2.2 Main stopping steps of FGD system
226

GGH
Stop flue gas system: Stop GGH system and booster fan system

Stop gypsum hydrocyclone system Stop mist eliminator automatic
flushing procedures Stop limestone unloading system
(according to material level in
limestone silo)
0

Stop belt-type vacuum dewatering
Turn the limestone slurry supply
system (according to slurry density in
regulating valve to 0, and stop the Stop the slurry preparation system
absorber)
automatic limestone slurry supply (according to liquid level in
limestone slurry tank)

Stop gypsum delivery system
Stop absorber circulation system: Stop limestone slurry supply system
Oxidation air system, gypsum
discharge system and circulation
pump system

If the absorber is empty, stop the blender and
discharge system according to the liquid level in the
absorber.

Stop compressed air system

Stop process water and mist eliminator
flushing system

End
FGD FGD

GGH

DCS FGD

Before normal starting of FGD, put the signal exchange system between boiler
and FGD into operation; Get through flue gas channel, manholes and overhaul holes
along each system and equipment shall be sealed up, and the system shall be well
227

sealed; It shall be clean inside the flue gas system, and clean up flue, booster fan,
GGH, absorber and other systems and equipment; Put flue gas system and relevant
thermal measuring points into operation; Cold-state operation of the flue gas system
shall be qualified, and each system and equipment can be put into operation; Put
utility system into operation; Put the empty system into operation; Put limestone
slurry supply system into operation; Water injection to emergency dewatering system;
Water injection to absorber system; DCS system has completed debugging and been
put into operation; Put the electrical system into operation; Check to ensure that signal
exchange between boiler and FGD system and interlock protection work normally;
Static test and check to interlock protection of booster fan and its auxiliary equipment;
Confirm stable operation of the boiler; Put physical and chemical analysis laboratory
into operation, and prepare sufficient drugs; Prepare gypsum crystal seed; Check
absorber system, and start blender, oxidation fan and spraying layer in sequence;
Check empty system, and add gypsum crystal seed into the absorber; Check limestone
slurry preparation system, and prepare sufficient qualified limestone slurry for
standby use; Liquid injection to the absorber. The specific steps are as follows:
2.3
2.3 Start to blow flue gas into the system
2.3.1
2.3.1 Check before starting
FGD FGD
Before starting the FGD system, it is supposed to organize professional

personnel to fully check all the FGD system parts to ensure that there is no person
working in the system and that each equipment starting condition is met. Check
contents include:

Oil level in each auxiliary equipment is normal;

Leakproofness of flue system (especially expansion joints, manhole doors,
etc.);

Switches of damper and valve are in the correct positions, with correct
feedback;

Instrument and control equipment have been calibrated, and work reliably,
and thermal signals are correct;

Put alarm unit into operation;
228


Reliable power supply;

Sufficient required chemicals;

Fire protection and other safety measures are qualified;

Ensure that no flue gas enters and no flue gas damper is under operation when
checking flue and inner parts of the absorber. Check whether oxygen contents in
various tanks are sufficient when inspecting interior of tanks. Close manhole doors
after check.
2.3.2
2.3.2 Start
FGD
FGD
FGD
Before starting FGD system, firstly check and confirm that all the tanks are filled
with water, and that each liquid level satisfies starting requirements; the limestone
slurry preparation system completes working; All the utility systems stay in standby
state. Start FGD utility equipment, and start all the FGD systems in sequence.
2.3.2.1
2.3.2.1 Start utility system
2.3.2.1.1
2.3.2.1.1 Start compressed air system
0.6MPa
Check and confirm that the pressure of the compressed air storage tank reaches
to over 0.6MPa, and switch on the gas supply valve to supply gas to each gas
consuming point.
2.3.2.1.2
2.3.2.1.2 Start process water system

Firstly, conduct local checks on equipment system, after which start the
229

equipment. Select a pump as the operation pump, and the other as the standby pump.

Start automatic control of liquid level in process water tank;

Start the sequential control start procedure of the process wash pump;

Start the sequential control starting procedure of the mist eliminator
flushing pump;

After starting the equipment, check and confirm that the pressure at the process
water pump outlet and the pressure at the mist eliminator flushing pump outlet are
normal.
2.3.2.2
2.3.2.2 Start limestone slurry preparation system
2.3.2.2.1
2.3.2.2.1 Start limestone wet-milling slurry preparation system

Start the filtrate water pump; sequentially start the low-pressure oil pump,
high-pressure oil pump and motor of the mill. Start weighing belt feeder to feed mill,
and adjust water amounts at mill inlet and outlet. Put corresponding instruments into
operation, and send slurry to limestone slurry tank according to liquid level and
density in mill limestone slurry re-circulation tank.

Start the blender of limestone slurry tank and input density measurement system
into the outlet of pump to be started. Make local check of the pump, connect
mechanical seal water of pump and start the equipment as soon as completing
inspection. Select a pump as the operation pump, and the other as the standby pump.
Make sequential control start of limestone slurry pump, check whether pressure at the
outlet of pump is normal and inject limestone slurry into the absorber.
2.3.2.2.2
2.3.2.2.2 Start of limestone dry-powder slurry preparation system
230

Input fluidizing air system into the limestone powder silo, open the manual plug
door of one powder fall tube, start the blender of limestone slurry tank, input density
measurement system into the outlet of pump to be started, and open the electric plug
door of powder fall tube and spray valve of exhaust pipe of limestone slurry tank.

Firstly, conduct local check on the pump to be started connect the mechanical
seal water of pump and start the equipment after the inspection is completed. Make
sequential control start of limestone slurry pump.

Make sequential control start of feeding valve of powder fall tube in the
limestone powder silo and operators shall check whether exhaust pipe of the
limestone slurry tank overflows powder. If it does, the water injection valve of
exhaust pipe is necessary to be adjusted till no powder overflows.

30
1250kg/m3 1250kg/m3
Input limestone powder to the limestone slurry tank by feeder below the
limestone powder silo and the limestone powder in the limestone slurry tank and
filtrate water in the slurry recovery tank will mix into limestone slurry in the
concentration of 30% and density of about 1250kg/m3. After density of limestone
slurry reaches 1250kg/m3, the system will be automatically in the hot standby state
(available for operation whenever needed).
2.3.2.3 FGD
2.3.2.3 Start of seal system of FGD damper
FGD FGD
Check seal fans of FGD damper as required, select one for operation and the
other for standby, start a seal fan of FGD damper, and input the heating system of seal
air.
2.3.2.4
2.3.2.4 Enabling drainage pit of absorber

231

Check the blender and drainage pit pump of the drainage pit of absorber as
required and set manual valve to make liquid in the pit of absorber be transmitted to
corresponding absorber.

Input liquid level control system of the drainage pit of absorber and set the
blender and pump of drainage pit of absorber in auto mode so that the on/off of
blender and pump shall be controlled automatically by the liquid level of drainage pit.
2.3.2.5
2.3.2.5 Commissioning of flue gas online monitoring system
FGD
Input the flue gas online monitoring system of FGD inlet.
2.4 FGD
2.4 Normal start of FGD units

200mg/Nm3FGD 90 160FGD
If boiler runs in a stable way, no oil is input, electric dust collector is

commissioned, dust concentration of flue gas at the electric dust collector outlet is
lower than 200mg/Nm3 and temperature of flue gas at the FGD inlet is higher than 90
but lower than 160, FGD unit system can be commissioned.
FGD
Start the equipment of FGD system in the following starting steps and start the
equipment by following starting steps respectively. After mastering and being familiar
with the above steps, it shall be advised to process according to program control.
2.4.1 GGH
2.4.1 Start of GGH system.
GGH GGH GGH
GGH GGH
Check GGH system according to the starting requirements of GGH system. If the
starting conditions for GGH system are met, start the GGH system sequential control
starting procedures and check whether GGH system is in normal operation.
2.4.2
2.4.2 Start of absorber blender

232

4
Check the blender according to the starting requirements of blender. After the
starting conditions for blender are met, start the four blenders of the absorber in
sequence and check whether the operation of blenders is normal.
2.4.3
2.4.3 Start of oxidation fan

1
Check the oxidation fan according to its starting requirements and connect the
cooling water of oxidation fan. After the starting conditions of oxidation fan are met,
start the sequential control starting procedure of one oxidation fan. After starting
equipment, check the operation of equipment and set oxidation fan not started as
standby.
2.4.4
2.4.4 Sequential control start of general flushing procedures of absorber mist
eliminator

Set flushing water control of mist eliminator in auto mode, open

electrically-operated valve for water supply of mist eliminator, start general flushing
procedures of mist eliminator after starting conditions are met to automatically flush
and make closed loop control of liquid level in the absorber.
2.4.5
2.4.5 Start of gypsum slurry discharge pump of absorber

1
Check the gypsum slurry discharge pump according to its starting requirements,
and connect the mechanical seal water of the gypsum slurry discharge pump. Set one
gypsum slurry discharge pump as the operation pump and the other as the standby
pump. After the starting conditions are met, start the sequential control starting
procedure of one gypsum slurry discharge pump. After starting equipment, check the
operation situation of the equipment.
pH
Set pH meter measurement pipeline system in standby state before starting.
2.4.6
2.4.6 Commissioning limestone slurry discharge system
233

SO2
SO2
pH
FGD SO2 95
The removal rate of SO2 depends on the additive amount of fresh limestone
slurry to the absorber, while the additive amount of newly prepared limestone slurry
to the absorber depends on the expected removal rate of SO2, boiler load and pH value
of absorber slurry. After the operation conditions for the limestone slurry discharge
system are reached, input the sequential control starting procedure of the limestone
slurry discharge system. Normally, the SO2 removal rate of the FGD will be set at
95%, and the regulating valve of limestone slurry supply shall be switched on and off
regularly to avoid valve bonding. It is advised that the on/off action shall be
conducted every two hours.
2.4.7
2.4.7 Start of the circulation pump of absorber

2 FGD
Check the circulation pump according to its starting requirements and connect
mechanical seal water of circulation pump and cooling water of gear box. After the
starting condition of the circulation pump is reached, start the sequential control
starting procedure of 2 sets of circulation pump of absorber first; after starting FGD
system, start other circulation pumps according to the absorber load condition and
desulfurization efficiency. After starting equipment, check the operation situation of
the equipment.
2.4.8 FGD
2.4.8 Start of FGD flue gas system
FGD FGD
After the conditions for connecting flue gas to FGD are reached, execute the
sequential control starting procedure of FGD flue gas system.

Open the electric damper at the outlet of clean flue gas;

Start the sequential control procedure of booster fan;

Open the raw flue gas damper;
234

30
After the opening of guide blade at the inlet of booster fan reaches 30%, start
to close the electric damper of bypass slowly;

Continue to adjust the opening of guide blade at the inlet of booster fan, and
keep the flue gas pressure at the inlet of booster fan around the set value;

Finish after the electric damper of bypass is closed;

For the first start, the guide blade of booster fan shall be adjusted manually, and
after the control characteristic of the inlet guide blade is mastered, it can be controlled
automatically.
2.4.9
2.4.9 Enable the closed loop control of slurry concentration of absorber to be in the
automatic state

Enable the slurry concentration control of absorber to be in the automatic state.
2.4.10
2.4.10 Start of gypsum dewatering system

The operation of gypsum dewatering system depends on the slurry concentration

control system, and when the gypsum slurry density does not reach the set value, the
underflow of gypsum hydrocyclone will be dewatered on belt-type vacuum
dewatering machine.

The overflows of gypsum hydrocyclone will go to waste water hydrocyclone

through waste water hydroclone feed pump, the underflow of waste water
hydrocyclone will go to gypsum overflow slurry tank or filtrate water tank and then
back to absorber, the overflows of waste water hydrocyclone go to waste water tank
and then go to wastewater treatment system through waste water pump.
2.5 FGD
235

2.5 Normal deactivation of FGD system

FGD
FGD FGD
During the deactivation of FGD system, especially the operation related to flue
gas system shall be connected with boiler operators closely and operated smoothly to
ensure the safety of operation of the boiler and the safe deactivation of FGD system.
The normal deactivation of FGD system is carried out in order. The first is to switch
the desulfurization unit from normal operation state to short-term deactivation state
and the last is to switch it from short-term deactivation state to long-term deactivation
state.

Normal operation state
BUF GGH
Start of bypass Stop BUF gradually Stop GGH
damper

Close the clean gas Turn off the oxidation Close the raw gas
damper gradually fan damper gradually

Short-term deactivation state Turn off the slurry
circulation pump

Deactivate limestone slurry
preparation system
Turn off the limestone
slurry pump

Turn off the gypsum dewatering
system
Turn off the gypsum
slurry discharge
pump
GGH
Flush GGH off-line

Empty absorber Turn off the utility
system
Empty limestone slurry tank

Long-term deactivation state
236

2.5.1
2.5.1 Long-term deactivation
2.5.1.1
2.5.1.1 Preparation before long-term deactivation

List the equipments and parts which should be checked and maintained carefully
during the deactivation according to the equipment operation condition.
FGD
If the FGD is turned off, the liquid level of the limestone slurry tank should be
kept at the pump protecting deactivation level with empty of residual liquid.
Otherwise the limestone slurry preparation system shall keep the normal operation
state.
2.5.1.2 FGD
2.5.1.2 Deactivation of FGD flue gas system


deactivation procedure, execute sequential deactivation procedure and confirm the
following operations are completed in sequence.

Turn the pressure control of booster fan closed loop into manual control;

Open the electric damper of bypass;
30
When the opening of bypass damper reaches above 30%, start the sequential
control deactivation procedure of booster fan (guide blade of booster fan shall be
turned off slowly to make the airflow from induced draft fan steady and never
influence the operation of boiler);

Open the absorber ventilation electric valve;

Turn off the electric damper of clean flue gas outlet;
237


Close the raw flue gas damper.
2.5.1.3
2.5.1.3 Deactivation of limestone slurry discharge system


deactivation procedure, execute sequential deactivation procedure and confirm the
following operation is completed in sequence.

Turn off the automatic control flushing procedures of limestone slurry
pipeline;

Turn the limestone slurry closed loop control of absorber into manual control;

Turn off the feeding electric valve of the electrically regulating valve of absorber
limestone slurry;

Turn the electrically regulating valve of absorber limestone slurry into manual
control and open it;

Flush the slurry pipeline;

Turn off the electrically regulating valve of absorber limestone slurry;
2.5.1.4
2.5.1.4 Deactivation of gypsum slurry discharge pump

After the gypsum dewatering system is deactivated, stop the gypsum slurry
discharge pump. Set the equipment according to the requirements of sequential
control procedure before implementing sequential control "stop" and confirming the
following operations completed in sequence;

Deactivate the gypsum slurry discharge pump according to the sequential control
238

procedure, and then flush its delivery pipeline.

2.5.1.5
2.5.1.5 Deactivation of gypsum dewatering system

Set the equipment according to the requirements of sequential control procedure

before implementing sequential control "stop" when the liquid level of absorber
reaches the low position and confirming the following operations completed in
sequence:

Deactivate the sequential control of belt-type vacuum dewatering machine
system;

Flush corresponding pumps and pipelines
2.5.1.6
2.5.1.6 Deactivation of the general washing procedure of mist eliminator

Set the equipment according to the sequential control procedure, conduct

sequential control flushing procedures again, execute sequential control "stop" after
the whole flushing is completed, and confirm the following operations are completed
in sequence.

Deactivate the general flushing procedure of mist eliminator;

Close the electric door and the water supply main pipe of mist eliminator;
DCS
The mist eliminator can be made in the manual state and stop washing through
DCS.
2.5.1.7
2.5.1.7 Deactivation of oxidation air system


deactivation procedure, start the sequential deactivation procedure of oxidation fan
239

and confirm the following operation is completed in sequence:

Deactivate the motor of oxidation fan;

Close the attemperating water valve of oxidation air pipeline;
2.5.1.8 GGH
2.5.1.8 Deactivation of GGH system
GGH

deactivation procedure, start GGH sequential deactivation procedure and confirm the
following operation is completed in sequence.

Deactivate low-leakage fan;
GGH GGH
Cut off GGH interlocking for standby; cut off GGH auxiliary drive motor
interlocking for standby;

Deactivate main drive unit
2.5.1.9
2.5.1.9 Deactivate circulation pump

ABC
deactivation procedure, start sequential deactivation procedure and confirm the
following operation is completed in sequence. If pump A, B and C are in operation at
present,
A A
Deactivate circulation pump A and conduct the drainage and flushing
B B
Deactivate circulation pump B and conduct the drainage and flushing
procedures of the circulation pump B;
C C
240

Deactivate circulation pump C and conduct the drainage and flushing

procedures of the circulation pump C;

During the deactivation, the procedure of one pump must be completed before
the start of sequential control deactivation procedure of next deactivation pump. And
the liquid level situation of drainage pit shall also be taken into account, so that
overflow of liquid due to excessive feeding of the drainage pit of absorber during the
water draining and flushing can be avoided.
2.5.1.10 FGD
2.5.1.10 Deactivation of limestone slurry preparation system (only when all FGD
systems are deactivated)
Set the equipment according to the sequential control requirements before

implementing sequential control "stop" and confirming the following operations
completed in sequence:

Deactivate the sequential control of limestone slurry preparation system;
SO2
Cut off the automatic control of removal rate control of SO2 in absorber;

Deactivate the sequential control of limestone slurry adjustment and control
system;

Deactivate the sequential control of limestone slurry pump.

FGD
When the limestone slurry tank is deactivated for long-time overhaul,
"sequential control deactivation of limestone slurry pump" procedure shall be
performed and the residual limestone slurry shall be discharged into the
drainage pit of blowoff tank of absorber through the drainage ditch of
blowoff tank of absorber. At this point, the deactivation of limestone slurry
preparation system shall be prior to that of FGD flue gas system;

The limestone slurry delivery pipeline shall be flushed, until the liquid within
241

the pipeline becomes clear.

2.5.1.11
2.5.1.11 Deactivation of process water system

( 2 FGD )
After all the flushing within the system is completed, set the equipment
according to the requirements of sequential control procedures before implementing
sequential control "stop" (only when 2 sets of FGD systems are both stopped) and
confirming the following operations are completed in sequence.

Close the seal water and cooling water of the mechanical seal of all slurry
pumps;

Cut off the liquid level control of the process water tank, deactivate the
process water pump and mist eliminator flushing pump and empty the process water
tank.
2.5.1.12
2.5.1.12 Deactivation of instrument air system

When all flushing-drainage procedures are completed, the instrument air system
air valve shall be shut off.
2.5.1.13
2.5.1.13 Outage of the system

Power off the equipment of deactivation system, but keep the power supply of
liquid level monitoring equipment and blender equipment such as box, tank and pit
which are with liquid level, and the blender of emergency slurry tank shall also be
provided with emergency power supply. The continuously operating equipment shall
be regularly inspected.
2.5.2
2.5.2 Short-term deactivation
2.5.2.1
2.5.2.1 Preparation before short-term deactivation
242

FGD
Sequential control deactivation of the limestone slurry preparation system
(when all FGD is deactivated);
SO2
Turn the automatic control of removal rate control of SO2 in absorber into
manual control;

Turn the automatic control of slurry concentration control of absorber into
manual control;
2.5.2.2
2.5.2.2 Deactivation of absorber and flue gas system

Set the sequential control deactivation procedure of absorber according to the

following requirements before implementing sequential control "stop" and confirming
the following operations completed in sequence:
FGD
Deactivate the sequential control of FGD flue gas system;

Turn the closed loop control system of absorber slurry concentration into
manual control;

Deactivate the limestone slurry discharge system; Deactivate the limestone
slurry pump;

Deactivate the washing of mist eliminator;

Deactivate the gypsum dewatering system;

Deactivate the gypsum slurry discharge pump
GGH
Deactivate the GGH sequential control procedure;

243

Deactivate the oxidation fan sequential control;

Start the deactivation sequential control of the absorber circulation pump;

Points for attention:

After the inlet valve of the gypsum hydrocyclone station is shut off, the
sequential control deactivation of belt-type vacuum filter system will be
automatically started.

All containers like box, tank and pit shall not be emptied and the on/off of the
equipment is automatically controlled by liquid level system.

The blender and process water system as well as instrument air system still
keep operation.
FGD
Section III Performance Test of FGD System
1
1, Purpose and content of performance test

FGD
168h 2 6
Performance assessment test, also known as handover acceptance test, is
designed to verify whether the completed FGD system has met the various technical
and economic indicators specified by the contract and to comprehensively evaluate
the performance of the system. Performance acceptance test shall be generally
conducted appropriately within 6 months after 2 months of the 168h operation being
transferred.
FGD
Technical contract of FGD system generally contains the following performance
guarantee items:
SO2 SO2
SO2 removal efficiency (or outlet SO2 emission rate).
HCIHF SO3
244

Removal efficiency of HCI, HF and SO3.

Particulate emission of the system outlet.

Flue gas temperature of the system outlet.

Maximum content of water droplets carried by flue gas from the mist
eliminator outlet.

Desulfurization gypsum composition and free water content.

Absorbent consumption.

Calcium sulfur ratio.

Power consumption.

Water consumption (maximum water consumption and average water
consumption).

Waste water composition and wastewater discharge (including wastewater
treatment systems).

Flue gas pressure loss (total pressure loss or specific component pressure
loss).

Noise control guarantee.

Absorbent grinding fineness and output.

SO2
245

FGD
During the performance assessment test, the operation conditions of the power
plant boiler shall be as close as possible to the design conditions and the boiler shall
keep stable operation under all kinds of loads required by the test. The power plant
can store up coals supplied for fueling during the performance assessment in advance
with sulphur content close to that of design coal or assessment coal, so that the
content of SO2 in flue gas is as close as possible to the design concentration, which is
conducive to the power plant's assessment for FGD system performance.
FGD
As usually prescribed in the contract, the performance correction curves of FGD

unit are provided by the seller, when the working conditions during the performance
assessment test are different from design conditions, the correction curves are used to
correct test data in order to evaluate the guaranteed performance of the system, while
the performance correction curves are generally put forward by the seller in the late
period of detailed design. Because the actual working conditions can't be completely
consistent with design conditions and the design values would also have certain
deviation, it is normal that there may be difference from design performance to actual
performance of the unit. The correction curves can be corrected according to the data
obtained in the test run and agreed by both parties, which may allow correction curves
to be more practical.

The performance correction curves that the general contractor needs to provide
include at least:

Correction curve of desulfurization efficiency and inlet flue gas amount;
SO2
Correction curve of desulfurization efficiency and inlet SO2 concentration;

Correction curve of desulfurization unit power consumption and inlet flue gas
amount;

Correction curve of desulfurization unit power consumption and inlet flue gas
temperature;
SO2
246

Correction curve of desulfurization unit power consumption and inlet SO2

concentration;

Correction curve of desulfurization unit water consumption and inlet flue gas
amount;

Correction curve of desulfurization unit water consumption and inlet flue gas
temperature;

Correction curve of desulfurization unit limestone consumption and inlet flue
gas amount;
SO2
Correction curve of desulfurization unit limestone consumption and inlet flue
gas SO2 concentration
FGD FGD
It shall be noted especially that the technical contract of FGD system shall be
clear about the requirements that, under the design conditions, the related
performances of FGD system shall reach the guarantee value at the same time. For
example, these three indicators of desulfurization efficiency, gypsum composition and
limestone consumption shall be assessed under the same operation conditions, which
could avoid the seller to choose the best parameters to meet individual guarantee
value in a certain period of time, and then change the system operating parameters to
meet some other guarantee items.

If the results of performance assessment test show that there is one or more items
of the system guarantee values which cannot meet the requirements, the seller is
allowed to re-conduct the performance assessment test through adjusting or
improvement with required cost borne by the seller.
2
2. Performance test procedures and data arrangement
2.1.
2.1. Procedures of performance assessment test
2.1.1
247

2.1.1 Calibration and checkout of online instruments

FGD CEMS
CEMS CEMS
pH
FGD system of power plant is required to be provided with CEMS in the system
and stack inlet and some performance parameters during the test can be obtained from
the CEMS. Therefore, before the test, CEMS and other online instruments related to
the performance indexes such as densimeter, pH meter, flow meter of slurry, weighing
unit of limestone powder, gateway watt hour meter and water meter of measuring
electric power and water consumption shall be conducted with careful calibration and
checkout. The calibration includes calibration of zero point and measurement range
and correction calibration of measured value on instrument displayed value.

Flue gas parameters need to be calibrated:

FGD
CEMS DCS
CEMS 2
Flue gas flow calibration. Measure the flue gas flow of FGD unit inlet and
stack inlet using the grid method with pitot tube under the full-load stable working
condition of the boiler. Compare the two measured values to understand the accuracy
of the values. Develop the modified formula of the displayed value of DCS based on
the measured value and the indicating value of CEMS flue gas flow. That means
calibrating CEMS gas flow meter. The calibration must be conducted at least 2 times.
If possible, it should also be conducted under different boiler loads to get satisfactory
results.

GGH - DCS
Flue gas temperature calibration. Measure the flue gas temperature and the
flue gas flow at the same time. Normally the measured value of the raw flue gas
temperature and the online indicating value of the thermometer are very close, so
it does not need to be calibrated. However, clean flue gas stratification is possible,
especially when using tubular GGH or steam-gas heater. So the DCS indicating
value of the clean flue gas temperature must be calibrated to check the
temperature of the clean flue gas after heating.
O2
DCS
248

Calibration of oxygen content in the clean/raw flue gas. Measure the O2

content of the flue gas at two measuring points on the fracture surface of the flue to
develop the modified formula of the DCS indicating value. Similarly, repeat the test to
check the accuracy of the modified formula.
SO2
SO2 SO2
Calibration of SO2 concentration in clean/raw flue gas. The calibration method

of the flue gas is the same with oxygen content calibration. Clean flue gas
stratification is possible, so increase measuring points properly. Before the SO2
concentration calibration, calibrate the zero point and measuring range of the meter
with zero gas and SO2 sample gas.

2 DCS
Calibration of dust concentration in clean/raw flue gas. Because of the uneven
distribution of flue dust, dust concentration calibration also shall be determined by the
grid method at least 2 times to get the correction factor of the indicating value of the
DCS dust concentration.
CEMS
Calibration of water content in the clean/raw flue gas. If CEMS has moisture
content measuring instrument, it also shall be measured at two measuring points in the
fracture surface of the flue. If no moisture content measuring instrument, the value
shall also be measured to calculate the flow of dry flue gas.

Calibration of industrial water flow meter. Calibrate the industrial water flow
meter by using the water consumption of the known volume of the industrial water
tank. Determine the correction factor and the modified formulas. Calibrate when
flushing the pipeline or injecting water into tanks since the total water volume is large
enough to ensure the accuracy of the calibration.

DCS
Calibration of limestone powder weighing and metering unit. Calibrate
according to the methods provided by the manufacturer. Get the limestone
consumption directly based on the displayed value of DCS or local metering value
during the performance assessment test.
249

pH
2
Calibrate the densimeter, pH meter and slurry flow meter carefully before
starting the performance assessment test. Calibrate at least two times during the test to
ensure all important parameters are within the predetermined range.
7d
The above calibrations generally take about 7 days.
2.1.2
2.1.2 Check the design conditions of performance guarantee value

During the performance assessment test, the power plant shall provide test
conditions which aren't exceeding or less than the designed conditions. Main test
conditions include flue gas conditions, absorbent and industrial water quality.
FGD SO2SO3
HCIHF SO2
SO3HCIHF
FGD
SO2
DCS
Flue gas conditions include the inlet flue gas flow, temperature and concentration
of harmful composition concentration (SO2, SO3, HCI, HF and dust) of FGD system.
When calibrating and validating the online instruments, the flue gas flow, temperature,
SO2 and dust concentrations have been detected, so the concentration of SO3, HCL
and HF in flue gas shall be measured. These concentrations of the compositions shall
be within the designed range or not exceed too much. In the following performance
assessment test, these concentrations do not need to be measured again and can be
identified to meet the design conditions. If these concentrations of compositions
exceed the design criteria too much, which becomes the reason that the supplier of
FGD unit requires to amend some performance guarantee values or claims of not
meeting the guarantee. Therefore, the power plant shall avoid these situations when
providing design conditions. In addition, the power plant shall adjust combustion
conditions of the boiler, operation working conditions of the electric dust collector or
enable the flue gas flow, temperature, SO2 and dust concentration within design
conditions via the coal blending mode. During the performance assessment test, DCS
collected data for these test conditions of the flue gas shall prevail.

250

3 1
Conduct the chemical analysis for absorbent and industrial water to check
whether they meet the design conditions. During the performance assessment test, the
absorbent quality shall be checked at least 3 times and industrial water quality once.
Parallel tests are necessary to check the accuracy of analysis results.
2.1.3
2.1.3 Performance assessment test
2d
pH
Before the official start of the performance assessment test, the stable operation
period of 2 days is needed. Observe the desulfurization efficiency, pH value changes
of absorber slurry, displayed values of the various online instruments and analyze the
compositions of various slurries and desulfurization gypsum to determine whether the
system operation has stabilized under the operation conditions agreed by three parties.
Once the system is stable then performance assessment test shall begin.
7d 24h
7d 24h
14d 12h
2 7d 810h 50 75
2h 10h
During the full-load performance assessment test, if the main unit can provide
the continuous full-load of 7d and 24h, more satisfactory data can be generally
collected. If the host fails to provide the continuous full-load of 7d and 24h, the time
of the performance assessment test is recommended to be extended to 14 days. The
main unit is required to provide 12h continuous full-load every daylight, and 8-10h 50%
and 75% stable load shall be provided at nights in two of 7 days respectively. 2 hours
after rising from a low load to full load, collect the data for 10 hours. The data will be
used as the basis of the full load performance assessment test and the data collected at
night will be used to assess the performance under the low load. In doing so, it can
leave out the correction of the boiler load factor to test results. The test results are
more reliable than results corrected by unauthenticated correction curve.
1d
50%4h 75%4h 100%4h 75%4h 50%4h
2/min
In addition, the variable load tracking test shall be conducted for 1 day, and the
time of the load changing and keeping of the boiler is:
50%4h 75%4h 100%4h 75%4h 50%4h , load change rates are as
251

stipulated in the contract, usually 2%/min.

FGD
(ECR)MCR) FGD MCR
MCR FGD
816h FGD
The design conditions of the FGD system guarantee value may be the continuous
economic operation condition of the boiler (ECR) specified in some project contracts.
It is required for the FGD system to run stably under maximum condition running
(MCR) of the boiler, but the guarantee value requirements are not required for the
system performance under MCR working condition. The FGD operation test under
MCR working condition will last 8-16h to assess whether the FGD system can
establish the new material balance and operate stably under reaching the certain
desulfurization efficiency, assess whether the main equipment is running unstably and
whether the output of the equipment is beyond design value, and whether the online
measured values are close to or even exceed the alarm level.

1424d
Therefore, the performance assessment test (including calibration of online
instruments) will last for 14-24 days, depending on the number of performance
assessment test projects.
2.2
2.2 Data arrangement of performance assessment test
2.2.1 SO2 SO2
2.2.1 SO2 removal efficiency and SO2 concentrations in the clean flue gas of system
outlet.
DCS SO2 O2
(1-7-1) 6O2 SO2
(1-18-1) SO2
Take the average concentration value of SO2 and O2 in raw flue gas of system
inlet and clean flue gas of outlet collected by DCS under full-load working condition.
And modify it with correction factor, convert the SO2 concentration under O2
concentration of 6% as per the formula (1-7-1), and calculate SO2 removal efficiency
according to formula (1-18-1), that is:
SO2 SO2
SO
2
SO2
so2= (the concentration of SO2 in raw flue gas of system inlet - the
concentration of SO2 in raw flue gas of system outlet) / the concentration of SO2 in
raw flue gas of system inlet
252

SO2
Finally, calculate the corrected SO2 removal efficiency according to correction curve.
SO2
SO2 SO2
FGD SO2
DCS
SO2 SO2
SO2
SO2
SO2
SO2
If full-load working condition of the boiler is time-phased, then SO2 removal
efficiency shall be calculated time-phased, then get the average value to evaluate the
guarantee value of the SO2 removal efficiency. The corrected SO2 removal efficiency
obtained above shall be not less than the guarantee value specified in the contract. At
the same time, if the SO2 concentration in the raw flue gas of the FGD inlet is always
within the design range, then the uncalculated desulfurization efficiency displayed by
the DCS or SO2 concentration in the outlet clean flue gas of system shall be not less
than the guarantee value during the test. If the situation occurs where desulfurization
rate is lower than guarantee value or the concentration of SO2 of system outlet clean
flue gas is higher than guarantee value because of the SO2 concentration of the raw
flue gas is higher than the design value, the desulfurization rate or SO2 concentration
of the clean flue gas during this period shall be separately calculated and corrected.
The desulfurization efficiency or SO2 concentration of clean flue gas after corrected
based on the correction curve shall also not be lower than the guarantee value. Take
the average of desulfurization rate or SO2 concentration of the clean flue gas which is
lower than the guarantee value. This average is not reasonable apparently as the
assessment basis.
2.2.2 SO3HCl HF
2.2.2 SO3, HCI and HF removal efficiency
SO3HCL HF
SO3
CEMS
2 DCS
O2 6O2
Since the concentrations of SO3, HCI and HF in the discharged flue gas of power
plant boiler are normally low, their desulfurization efficiency variation range is
relatively large and the removal rate of SO3 is not mainly dependent on the design of
absorber, hence, normally the removal efficiency of these three toxic gases as the
guarantee value. But generally it is required to measure their removal efficiency as
inspection data. Since the CEMS adopted by power plant does not own the function to
measure the concentration of these three gases, it is necessary to use chemical
253

absorption method to measure. Normally it is measured twice during performance

assessment test period. Convert the percentage value of the O2 of flue gas shown by
DCS to 6% O2 value. Then their removal efficiency shall be calculated and not be
corrected again.
2.2.3
2.2.3 Clean flue gas temperature and dust concentration of system outlet
DCS
Take the average value of DCS during full-load test period, after correcting by
the correction factor, as the assessment data.
2.2.4
2.2.4 Industrial water and power consumption
DCS
SO2
Take the DCS data during full-load test period. The total industrial water
consumption is corrected by the correction factor. Total power consumption is directly
obtained from electric energy meter. Then calculate average water consumption and
electricity per hour as assessment data. Due to the concentration of SO2 in raw flue
gas of system inlet has little effect on water and electricity consumption. As long as
the amount of the circulation pump of absorber put in operation, there is no need to
revise with correction curve.
2.2.5
2.2.5 Quality of desulfurization gypsum

4
SO42- SO32-
CO32- Ca2+Mg22+
CaCO3 MgCO3 CaSO42H2O
CaSO42H2OCaSO31/2H2OCaCO3MgCO3
100
Sample during full-load test period. Do not revise analysis results. Evaluate
based on actual measured values. The importance is the amount of sampling analysis,
analyzing method and items as regard to the assessment of gypsum quality. The
analyzed sample amount shall not be less than four. It is best to analyze once a day.
The recommended analysis method is adopting weight measurement for total SO42-,
and additionally measure the content of SO32-, CO32- and acid non-soluble substance.
If the measurement of Ca2+ and Mg22+ content could be added, the content of CaCO3
and MgCO3 in gypsum could be separately calculated and checked mutually with the
CaSO42H2O content calculated from sulfenyl and calcium-base in gypsum. The
254

measurement of acid non-soluble substance could contribute to determine the

accuracy of analysis results. The mass percentage of CaSO42H2O, CaSO31/2H2O,
CaCO3, MgCO3 and acid non-soluble substance based on above analyzing results
shall be near 100%.
2.2.6
2.2.6 Limestone consumption
FGD
DCS SO2 O2
CaSO42H2O
CaSO31/2H2O CaCO3
Currently there are two more adopted measurements of limestone consumption.
One is the FGD technology introduced from Germany which determines the
limestone consumption by calculation. To be specific, during the whole test period,
DCS collects the concentration values of SO2 and O2 in clean flue gas and raw flue
gas. Take the average and correct with correction factor. Take the sample from
limestone slurry tank to perform limestone purity analysis. Take gypsum to perform
analysis of CaSO42H2O, CaSO31/2H2O and CaCO3. Calculate the limestone
consumption by calcium-sulfur mole ratio and desulfurization amount.

The formula for limestone consumption calculation is
G R (c SO2 c SO2c ) M CaCO3 1
CaCO3 (Ca/S)
10 6 M SO2 F
mCaCO3kg/h
Wherein mCaCO3 - limestone consumption, kg/h;
GR 6O2m3/h
GR- raw flue gas volume flow rate (standard state dry flue gas, 6% O2), m3/h;
cSO2R SO2 6O2)mg/m3
cSO2R - SO2 concentration of raw flue gas (dry flue gas at the standard state, 6%
O2), mg/m3;
cSO2C SO2 6O2mg/m3
cSO2C - SO2 concentration of clean flue gas (dry flue gas at the standard state,
6% O2), mg/m3;
MCaCO3CaCO3 100.09kg/kmol
MCaCO3- CaCO3 kilomol mass, 100.09kg/kmol;
MSO2SO2 64.06kg/kmol
255

MSO2- SO2 kilomol mass, 64.06% kg/kmol;

FR
FR - Purity of limestone, %;
Ca/S
Ca/S - Calcium-sulfur mole ratio.
(Ca/S) GRcSO2R FR
mCaCO3
In above formula, the calcium-sulfur mole ratio (Ca/S) will revise the mCaCO3 to
limestone consumption under design condition based on desulfurization gypsum
analyzing results and GRcSO2R and FR value and correction curve.

mCaCO3 GRcSO2R cSO2C
GR
SO2
GRcSO2R cSO2CCa/S
SO2
t/h) CaCO3 kmol/h

SO2 kmol/h
Ca/S > 1 Ca/S Ca/S1
The method of limestone consumption calculation above is theoretically correct.

If all values in formula are quite accurate, the value of mCaCO3 is convincing. The
problem is the accuracy and reasonability of GR, cSO2R and cSO2C, especially the value
of GR. Currently, quite a few online flue gas flow measuring instruments do not
perform well. Besides the precision of the instrument itself, the validation work of the
flue flow site before the performance assessment test is normally not careful. The flue
flow field under low load will also not be validated. Besides, take the flue gas flow
and SO2 concentration lower than full-load in the average and leave out the effect
from the different operation period under different boiler load, causing the average
value (GR, cSO2R and cSO2C) hardly representative. The measurement error of Ca/S plus
several revisions of flue gas amount, SO2 concentration of raw flue gas,
desulfurization efficiency and limestone quality based on correction curve, could
cause the large error to final results. It happened in the past, when the limestone
consumption obtained by the above method under the design condition is even lower
than theoretical value under the design condition. Apparently, the limestone
consumption obtained under the design condition by this method is not correct. In fact,
calculate the limestone powder consumption (t/h) under the design condition by above
256

method, the CaCO3 mol consumption per hour based on limestone purity and then the
SO2 desulfurization amount (kmol/h) based on design flue gas condition and
guarantee value of desulfurization efficiency. If the ratio Ca/S of these two values is
larger than 1 and is near design value of Ca/S, then the obtained limestone
consumption is pretty convincing. If Ca/S1, it cannot be quite trusted.

t/h cSO2R
t/h
t/h
FGD FGD
t/h
The other measurement method for limestone consumption is that, reach the
limestone consumption (t/h) based on the obtained weighted limestone powder
consumption under full-load working condition. Convert to the limestone
consumption (t/h) under design condition and assured desulfurization efficiency by
the percentage based on cSO2R, actual desulfurization rate and limestone quality.
Additionally, the limestone consumption (t/h) could be calculated based on limestone
slurry supply flow per hour of the absorber, slurry average density and solid content
under full-load working condition, so as to inspect the limestone consumption
obtained from weighing. If the limestone powder mixing system is shared by several
FGD systems or FGD system adopts wet grinded limestone, the limestone
consumption cannot be obtained from weighing and metering. It could also adopt the
latter method stated above to calculate the limestone consumption (t/h).

Based on experience, the latter method gives a more accurate result of limestone
consumption under test condition than the former method. The latter one avoids
taking the correction curve to revise and therefore the final value obtained has higher
credibility. Hence, the second method is recommended.
2.2.7 GGH
2.2.7 Leakage rate of GGH
GGH GGH GGH
GGH
The GGH leakage rate could be defined as the ratio of raw flue gas mass leaked
into the GGH clean flue gas side and clean flue gas entering GGH. Hence, the
formula for GGH leakage rate is:
AL (C2 C1 ) /(C C2 ) 100%
ALGGH
AL: Leakage rate of GGH, %;
257

CGGH SO2
C: SO2 concentration at the GGH raw flue gas inlet;
C1GGH SO2
C1: SO2 concentration at the GGH clean flue gas inlet;
C2GGH SO2
C2: SO2 concentration at the GGH clean flue gas outlet;
GGH SO2
GGH SO2 GGH SO2
Since the SO2 concentration at the inlet and outlet of GGH could be unevenly
distributed, it is normally required to adopt grid method to measure the SO2 at the
inlet and outlet of GGH and reach the SO2 average concentration of flue gas at the
inlet and outlet of GGH.
2.2.8
2.2.8 Wet ball mill output test

8h
DCS
Before the test, when perform calibration over limestone belt weigher, adjust the
operating parameter of ball mill and after the slurry particle size and density and
others overflowing from the hydrocyclone to limestone slurry tank reach design
requirements, the ball mill operates over 8h. Take the average through the output of
ball mill collected by DCS.
2.2.9 FGD
2.2.9 Dust emission concentration of the FGD unit

mg/m3
The main measuring points shall be the positions with larger dust concentration,
for the wet grinding system, the measuring positions include the limestone unloading
house and the limestone unloading dust collector outlet and the belt conveyor. For the
limestone powder slurry preparation system, the main measuring positions include the
silo top of the limestone powder silo, the limestone power hopper manhole door, the
top of the limestone slurry tank and the limestone powder unloading location. The
measuring principle is: Adopt the qualified dust sampler to extract the dusty gas of a
certain volume, block the dust on the filter cylinder with known mass, and calculate
the dust concentration (mg/m3) according to the mass increment.
258

2.2.10 FGD
2.2.10 FGD unit noise testing
FGD A FGD FGD
At present, the FGD noise testing generally applies the A sound level, during the
FGD system performance test, under full load of FGD system and normal operation
conditions of the equipment, make measurement by selecting position according to
the contract. The main measuring points generally include: booster fan, the slurry
circulation pump, the oxidation fan, the limestone mill, the vacuum pump and the
control room.
259

FGD
Chapter VI Common Operation Problem Analysis of FGD System
FGD
Section I Low desulfurization efficiency of FGD system
- FGD
For the wet limestone-gypsum FGD process, lots of factors may influence the
desulfurization efficiency. The main causes generally include:
FGD L/G
Reason for FGD system design: Design for liquid-gas ratio (L/G),
retention time in the flue gas absorber, flue gas velocity in the absorber,
the retention time of slurry, oxidation air amount and layout mode,
airflow uniformity design and spraying layer design;
FGD SO2
FGD inlet flue gas parameters: Flue gas amount, inlet SO2 concentration and
flue gas dust content;
FGD
FGD absorbent: Limestone activity and particle size;
FGD pH
FGD operation control parameters: Absorber pH value and wastewater
discharge;
GGH
Other factors: Inaccuracy of the instrument display, leakage of GGH or bypass
damper, etc.
1
1. System design factors
1.1 L/G
1.1 Liquid-gas ratio (L/G)

1m3 L/m3
Liquid-gas ratio refers to the washing slurry volume in the absorber

corresponding to the unit volume flue gas amount through the clean flue gas. In
260

general, it refers to the slurry volume required for washing 1m3 flue gas in L/m3. In
the desulfurization design, the liquid-gas ratio is the core element relating to the
design parameters below:

Sulphur content of the inlet flue gas

Design desulfurization efficiency

Retention time of the flue gas in the absorber

Flue gas velocity in the absorber
pH
Design pH value
Cl-
CI- concentration in the slurry pool

The calculation of the liquid-gas ratio varies for different desulfurization

technologies. In general, the liquid-gas ratio is determined by the above parameters,
and the deviation of the liquid-gas ratio will be large under different flue gas sulphur
contents. In case of any change to the above parameters, the actual liquid-gas ratio
will deviate from the design value, and so will the desulfurization efficiency and its
design value. For example: When the sulphur content in the absorber exceeds the
design value or the flue gas velocity in the absorber exceeds the design value, the
actual desulfurization rate will decrease. In general, under the design conditions, the
liquid-gas ratio calculated by mature desulfurization calculating software could enable
the desulfurization efficiency to reach the design value.
1.1.1
1.1.1 Sulphur content of the inlet flue gas
FGD SO2 6
261

The sulphur content of the inlet flue gas refers to the SO2 concentration in the
flue gas at the FGD inlet, generally calculated based on the dry basis, 6% of oxygen
content and standard condition. The sulfur content of the inlet flue gas is an important
factor in the calculation of the liquid-gas ratio. The liquid-gas ratio deviates a lot
under different sulphur contents of inlet flue gas. When the actual sulphur contents of
flue gas exceed the design value, the desulfurization efficiency will decrease.
1.1.2
1.1.2 Desulfurization efficiency
FGD SO2 95
SO2 5000mg/Nm3 95
SO2 250 mg/Nm3
Desulfurization efficiency refers to the SO2 removal ratio from the flue gas in the
FGD system. The value is generally designated as 95%, with the stricter requirements
of the national environmental laws; the SO2 emission concentration in the flue gas
required by the environmental requirements shall be considered during the
desulfurization efficiency design. When the inlet sulphur content exceeds
5000mg/Nm3, the desulfurization efficiency is calculated as per 95%, the outlet SO2
concentration will be 250 mg/Nm3, so it can't satisfy the new environmental emission
standard.
1.1.3
1.1.3 Retention time of flue gas in the absorber

SO2
3s4s
FGD
Retention time of flue gas in the absorber refers to the time period from flue gas
entering the absorber and mass transfer with spraying slurry to stopping contact with
circulating slurry, which represents the time of SO2 absorption reaction in the absorber.
Generally, the longer the absorption reaction time is, the higher the desulfurization
efficiency is; however, the larger the absorption area in absorber is and the higher the
cost of single absorber. Generally, typical designed retention time of flue gas in the
absorber is 3s-4s. When the amount of flue gas entering FGD system exceeds the
design value, the flue gas velocity in absorber will exceed the standard value and then
the retention time of flue gas will not be enough, which will cause a drop in
desulfurization efficiency. Similarly, when the unit load is relatively low, the retention
time of flue gas in the absorber will be higher than the design value, and actual
desulfurization efficiency will exceed the design value. At this time, the liquid-gas
ratio can be reduced by stopping the slurry circulation pump, so as to realize
262

economic operation.
1.1.4
1.1.4 Flue gas velocity in absorber

3.5m/s4.2m/s
Flue gas velocity in absorber refers to the flue gas velocity in empty tower of
absorber. Generally, higher flue gas velocity is conductive to promote mass transfer
between slurry and flue gas and improve desulfurization efficiency. But it will also
shorten the retention time of flue gas in the absorber, reduce desulfurization efficiency,
increase slurry content in flue gas, and cause other problems. In typical
desulfurization design, flue gas velocity in spraying empty tower of absorber is
generally between 3.5m/s-4.2m/s.
1.1.5 pH
1.1.5 Design pH value
pH pH
SO2 CaSO3
CaSO3 pH pH
pH CaCO3
pH 5.25.8pH
CaCO3
PH value in the slurry pool of the absorber represents the power of hydrogen of
the slurry absorbed. Generally, the higher the pH value is, the higher the SO2
absorption capacity in flue gas will be. When oxidation air supply in absorber is not
sufficient, and CaSO3 is not fully oxidized, it will be easy to cause mild CaSO3 scale.
Lower pH value is beneficial to dissolve the mild scale, but too low pH value will
aggravate acid corrosion of the entire system. Higher pH value is easy to cause hard
CaCO3 scale. In the typical desulfurization design, pH value is generally between
5.2-5.8. Generally, pH value control is to try to reduce CaCO3 content in gypsum
slurry as much as possible on the premise of ensuring designed desulfurization
efficiency.
1.1.6 Cl-
1.1.6 C1- concentration in slurry pool
Cl- HCl
Cl- CaCO3
FGD Cl-
20000ppm Cl- Cl-
5000ppm
Cl- in slurry pool mainly comes from HCl in flue gas. With moisture in slurry in
263

absorber taken away by flue gas, Cl- content in pulp will get higher, and when it
reaches a certain value, it will influence CaCO3 dissolution and ionization balance and
then influence desulfurization efficiency. In typical desulfurization design, Cl-
concentration in FGD system is generally required to be less than 20000ppm, but
higher Cl- concentration will aggravate corrosion of system materials. Cl-
concentration in absorber is suggested to be controlled within 5000ppm by increasing
wastewater discharge amount.
1.2
1.2 Retention time of slurry
SO2
CaSO3 CaSO4
CaSO3
4min6min
15h
Long retention time of slurry in reaction tank is beneficial for complete reaction
between limestone in slurry and SO2 and can gain sufficient time for oxidized CaSO3
to be oxidized to CaSO4, forming qualified desulfurization gypsum with larger
particle size and higher purity which is beneficial for dewatering. Therefore, there
should be a sufficient volume of slurry pool in the absorber to ensure limestone
dissolution time, CaSO3 oxidation space and gypsum crystal generation time and
space. However, over large slurry pool volume will increase construction cost.
Currently, typical designed slurry circulation retention time (ratio between slurry pool
volume and total flow of circulation pump) is between 4min-6min, and retention time
of slurry in the absorber (ratio between slurry pool volume and flow of gypsum slurry
discharge pump) is generally not less than 15h.
1.3
1.3 Oxidation air amount and layout mode

CaSO3 CaSO4
1mol SO2 0.5mol O2 O2
100 O2 O2
22.5
Currently, most of the domestic wet desulfurization technologies are generally
forced oxidation, namely that there is oxidation air pipe set at the bottom of slurry
pool of the absorber, input air for forced aeration of the slurry pool, so as to oxidize
CaSO3 to CaSO4 and finally generate gypsum. Theoretically, it needs 0.5mol O2 to
oxidize 1mol SO2, but actually, utilization rate of O2 cannot reach 100%, and there
shall be a certain amount left in design. In a typical design, the amount of O2 is 2-2.5
times of the theoretically required amount.
CaSO3
264

600MW
16m
CaSO3 FGD
The insufficient Oxidation air amount will cause high CaSO3 content in slurry,
give rise to limestone shield, reduce desulfurization rate and make it difficult for
dewatering. Generally, there are pipe network type and gun spray type for oxidation
air pipe layout in desulfurization design. Oxidation air pipe in pipe network layout is
better than that in gun spray type in terms of even distribution of oxidation air in
absorber slurry pool. Especially for the absorber corresponding to 600MW unit, if
oxidation air pipe of gun spray type is adopted, it is quite difficult for blender to
distribute oxidation air evenly in slurry pool, since the tower diameter of part of slurry
pool is larger, generally larger than 16m, which is easy to cause higher CaSO3 content
in the absorber and reduce FGD dewatering efficiency.
1.4
1.4 Airflow uniformity design

Generally, the flue gas enters the absorber horizontally, and comes out of the
absorber horizontally or vertically. And the larger the tower cross section is, the
shorter the absorption area route is, which makes it difficult to evenly distribute speed
in absorption area. In case of uneven airflow distribution, desulfurization efficiency in
the area with high airflow rate will reduce, and desulfurization efficiency in the area
with low airflow rate will increase, which will directly influence the absorption
efficiency of the absorber on the whole. Generally, uniform spraying design of
absorber, width-height ratio at absorber inlet, upright design at absorber outlet and
other designs are beneficial for even airflow distribution in the absorber.
1.5
1.5 Design of spraying layer

180250FGD
Design of spraying layer contains two parts: Spraying coverage rate, and nozzle
type. Coverage rate of single spraying layer in absorber is generally 180%-250%, and
the higher the sulphur content in flue gas at FGD inlet is, the higher the coverage rate
265

of spraying slurry will be. Even spraying coverage rate is beneficial for airflow
distribution in the absorber, which can improve desulfurization efficiency. Irrational
design of spraying layer or construction not complying with drawings will cause flue
gas escape at some parts. Pressures at different nozzle inlets are different, and so is the
spraying slurry amount, which therefore, reduces desulfurization efficiency.

Currently, there are generally several nozzle types as following: Hollow cone,
solid cone, screw type, etc.. Main performance parameters of nozzle include:
Spraying angle, nozzle flow and pressure drop of nozzle. Generally, blocking rate of
screw-type and solid-cone nozzles is higher than hollow-cone nozzle. Once the nozzle
is blocked, nozzle flow and streamline will change, which will reduce desulfurization
efficiency.
2FGD
2. Flue gas parameters at FGD inlet
2.1
2.1 Influence of flue gas amount at absorber inlet
FGD
L/G
L/G
The change in flue gas amount at the inlet is actually the change of liquid-gas
ratio. When the flue gas amount entering the FGD system reduces, and other
conditions remain unchanged, L/G ratio is theoretically larger than demand amount,
and desulfurization efficiency will increase automatically; when the flue gas amount
increases, L/G ratio is theoretically lower than demand amount, and desulfurization
efficiency will decrease automatically. During actual operation, when the flue gas
amount decreases to a certain value, one circulation pump can be stopped.
2.2 SO2
2.2 Influence of SO2 concentration in flue gas
SO2
SO2
SO2
SO2 SO2
SO2
According to chemical reaction kinetics, the absorption process can be reversible.
When SO2 concentration increases, impetus of mass transfer in gas phase will
increase, which is beneficial for SO2 to disperse into slurry through the slurry surface,
increase reaction speed, and improve desulfurization efficiency accordingly. However,
266

with further growth of SO2 concentration, desulfurization efficiency will decline due
to limitation of absorption capacity of the liquid phase. Since there is balanced
concentration for SO2 at absorber outlet, and when SO2 concentration in flue gas is
quite low, SO2 concentration at absorber outlet cannot be less than the balanced
concentration. Therefore, it is quite difficult to obtain extremely high desulfurization
efficiency.
2.3
2.3 Dust content of flue gas

200mg/Nm3
PH
SO2
pH
SO2
The fume content in the boiler flue gas will greatly decline following electric
precipitator, generally lower than 200mg/Nm3. After washing in the absorber, fly ash
will be mostly left in the absorber and some substance in the fly ash will influence
dissolution of limestone, result in the fall of the PH value, and reduce the system's
desulfurization efficiency. Generally speaking, desulfurization efficiency has little to
do with the concentration of fly ash in the flue gas and it is relevant with ash content
in the gypsum slurry. If SO2 content is high in the flue gas, in order to control slurry
density in the absorber, speed of dewatering shall accelerate and ash content in the
gypsum slurry shall dewatering as well to control concentration of fly ash in the
absorber. As a result, it shall have little impact on pH value control and
desulfurization efficiency in the absorber. If SO2 content is low in the flue gas,
substantial fly ash will gather in the absorber due to slower increase in slurry density
in the absorber in spite of its low content of fly ash in the flue gas. As a result, its
desulfurization efficiency will decline.
3FGD
3. FGD absorbent parameters
3.1
3.1 Particle size of limestone

90%
250
The smaller the particle size of limestone is, the larger its specific surface area
will be and the more sufficient its solid-liquid contact will be. As a result, it shall be
enabled to more effectively reduce resistance of liquid film and result in better activity
of limestone. Generally, in typical desulfurization design, the particle size of
267

limestone is required to be 90% of 250-mesh pass rate. If the particle size of limestone
is larger, it will increase limestone consumption and reduce desulfurization efficiency.
3.2
3.2 Limestone activity
CaCO3
CaCO3 CaCO3
Limestone's activity characterization refers to speed of CaCO3 dissolution.

Limestone is different in categories and its activity. Effective composition in
limestone is CaCO3. Generally speaking, the higher CaCO3 content is, the greater its
activity will be. The impurity in limestone hinders dissolution of particle in limestone.
The more the foreign matter is, the stronger the obstruction will be.
4FGD
4. FGD operation control parameters
4.1 pH
4.1 PH value of slurry in the absorber
pH FGD
pH SO2
pH CaSO3
pH
SO2 PH 4.0 SO2
PH value of slurry in the absorber is an important operating parameter in the
limestone wet FGD system whose characterization is power of hydrogen of slurry in
the absorber. If PH value of slurry rises, on one hand, rate of SO2 absorption will
grow due to rising liquid phase mass transfer coefficient; On the other hand, since PH
value is higher, CaSO3 dissolution resulting from desulfurization will sharply decline
and some undissolved calcium sulfite will be inclined to scale on the walls of the
absorber and surface of mist eliminator and separate out on the surface of the
limestone, influencing speed of limestone dissolution and reducing limestone
utilization. If pH value of slurry is too low, it will have immediate impact on SO 2
absorption; if pH value falls to below 4.0, the slurry will almost not absorb SO2 any
longer.
4.2
4.2 Wastewater discharge
HClHF
SO2
268

HCl, HF, fly ash, etc. in the raw flue gas are absorbed in the slurry pool of the
absorber. After longtime operation, concentration of chloride ion in the slurry and
heavy metal ion constantly dissolved in fly ash in the absorber will gradually rise,
which will have a negative impact on SO2 takeoff in flue gas. Therefore, the faster the
hazardous substances gather in the absorber, the higher the discharge of wastewater
will be. According to the experience of actual operation, wastewater discharge to
some extent is conducive to a rise in desulfurization efficiency.
5
5. Other factors
FGD
During FGD operation, there are some other factors which have impact on
desulfurization efficiency.
FGD GGH CEMS
CEMS SO2 SO2
The leakage in FGD bypass damper gate and GGH will result in a reduction in
desulfurization efficiency of the whole unit. Inaccurate CEMS display, such as SO 2
content in the inlet flue gas is lower or SO2 content in the outlet is higher measured by
CEMS, will result in a reduction of desulfurization efficiency displayed.
FGD
According to the above results of analysis, many factors have impact on

desulfurization rate of the FGD system which associate and influence each other.
Therefore, if desulfurization efficiency falls in operation, it shall be advised to check
by comparison of the above conditions and test gypsum slurry and limestone slurry in
the absorber to find out the crux of problems.
FGD
Section II FGD system and stack corrosion
1FGD
1. Corrosion of FGD system
FGD
FGD
269

In the wet FGD system, operation conditions are rather harsh with diversified
chemical, high and low temperature and mechanical corrosion and abrasion. In some
books of desulfurization, abrasion and corrosion are generally introduced separately.
In fact, chemical corrosion and mechanical abrasion in the FGD system interact with
each other. Corrosion, to start with, results in a disruption of oxide layer on the metal
surface, disrupted oxide layer is later corroded by particulate matter and new metal
surface is exposed which is corroded further. The interaction of corrosion and
abrasion is graver than sole corrosion or abrasion. Concerning the design of
desulfurization, given different locations and working conditions, emphases on
corrosion and abrasion and response measures will be different.
1.1 FGD
1.1 Types of metal corrosion in the FGD system generally include pitting corrosion,
crevice corrosion, stress corrosion, chemical corrosion and electrochemical corrosion.
1.1.1
1.1.1 Pitting corrosion:
Cl- F-
It refers to a corrosion which appears on the surface of metal materials in contact

with liquid phase. Generally resulting from Cl-, F- and other ions of small diameter, it
easily penetrates passive film on the metal surface to directly combine with metal ions
resulting in electron loss. Once passive film is disrupted, metal corrosion will be
aggravated.
1.1.2
1.1.2 Crevice corrosion

Crevice corrosion generally happens in locations of bolt connection and slurry

solid particle sedimentation as corrosive mediums and crevice ions in contact with
materials gather resulting in disrupted passive film on the surface of materials, which
is a type of electrochemical corrosion.
1.1.3
1.1.3 Stress corrosion

270

It refers to corrosion where tensile stress on the metal surface is beyond critical
stress, inclined to result in disrupted metal crystal in external corrosive medium
conditions, which is a type of electrochemical corrosion.
1.1.4
1.1.4 Chemical corrosion
PH H+
It refers to low PH value corrosion, primarily reflected as H+ corrosion.
1.1.5
1.1.5 Electrochemical corrosion

If there are impurities and trace of other metals in the metal, since impurity and
other metals are different from the metal itself in activity and there is substantial
electrolyte in the slurry, it will result in primary galvanic corrosion.
FGD
Key corrosion environments for different parts in a typical FGD system are
shown in the following table:
FGD
Corrosion environments in a typical wet FGD system

Temperature
Location Corrosion substance Remarks
No. ()

SO2
GGH
SO3HFHCl
From untreated raw flue Since temperature is at
1 100150
High-temperature flue the acid dew point,
gas side to GGH heat
side gas contains SO2, SO3, corrosion prevention
HF, HCl, etc. cannot be taken into
account.

SO2
GGH
SO3HFHCl Since it is in a

temperature lower than
2 80100
From GGH untreated the acid dew point and
raw flue gas side to inlet Some wet flue gas higher humidity,
section of absorber contains SO2, SO3, HF, corrosion prevention
HCl moisture, etc. shall be taken into
account.
271


Fluctuating temperature
3 Dry and wet interface at Spraying liquid, wet 45100 with conditions for
the inlet of absorber flue gas moisture condensation,
grave corrosion and
scaling
pH
pH Cl-

4 4555 Low pH value, ion
Absorber body Low pH value, Cl- and gathering, abrasion, etc.
other ion corrosion overlay to aggravate
corrosion
SO2
SO3 pH
GGH 2
5 From outlet of absorber Saturated moisture 4555 Where temperature is
to front of GGH (containing SO2 and lower than dew point,
SO3), residual ions in there is liquor
the spraying liquid and condensate and pH
liquor condensate value is below 2.
GGH
H2SO4
GGH SO2
SO3
6 7090 There may be moisture
From outlet of GGH to Moisture and residual condensation and
flue gas damper SO2, SO3, etc. scaling and
concentrated H2SO4 at
the bottom of GGH.
FGD

7 60150 There is moisture
Stack Moisture and residual condensation after FGD
acid substance operation.

8 Circulation pump and 4555 Abrasion and erosion
Spraying slurry
auxiliary pipeline corrosion
Cl-

9 Limestone slurry supply Cl- (filtrate water for Normal
Pitting and abrasion
system pulping), particulate temperature
matter

10 Gypsum slurry 2045 Grave erosion of
Gypsum slurry
treatment system particulate matter
272


11 2045 Particulate matter
Pit All kinds of slurries
erosion
Cl-
Cl-
12 Wastewater treatment Concentrated Cl-
Normal
Cl- corrosion
system gathering area temperature
FGD
FGD FGD
In the FGD system, lining corrosion prevention in organic nonmetal materials,

corrosion prevention metals, etc. are extensively applied. Corrosion prevention
materials for different parts in the FGD system are different and corrosion prevention
materials in a typical wet FGD system are shown in the following table:
Location Corrosion substance Corrosion prevention medium

No.
GGH SO2SO3HF
HCl
1 From untreated raw flue
gas side to GGH heat High-temperature flue gas High-temperature glass flake
side contains SO2, SO3, HF, HCl, etc.
GGH
SO2SO3HF

HCl
2
From GGH untreated
Some wet flue gas contains SO2, High-temperature glass flake
raw flue gas side to inlet
SO3, HF, HCl moisture, etc.
section of absorber

3 Dry and wet interface at C276
Spraying liquid, wet flue gas
the inlet of absorber
pH Cl-

4 Low pH value, Cl- and other ion
Absorber body Butyl rubber or glass flake
corrosion
SO2SO3
GGH

5 From outlet of absorber Saturated moisture (containing
SO2 and SO3), residual ions in Glass flake
to front of GGH
the spraying liquid and liquor
condensate
GGH SO2SO3
6

Moisture and residual SO2, SO3,
273

From outlet of GGH to etc. Glass flake

clean gas damper

SO2SO3

7 Moisture and residual SO2, SO3,
From bypass damper to High-temperature glass flake
etc.
inlet of stack

OM

8 Moisture and residual acid
Stack Titanium alloy, pennguard,
substance foamed glass brick, OM
coating, etc.
+

9 Corrosive slurry and suspended Carbon steel pipeline + rubber
Slurry pipeline system
particle medium lining
+SiC

10 Corrosive slurry and large- Polyurethane or carbon steel +
Rotational flow station
particle suspended particle SiC lining
1.4529

11 Metal in the corrosion
Corrosive slurry and large-
Absorber agitator prevention level of 1.4529 or
particle suspended particle
equivalent

12 Corrosive slurry and suspended
Slurry tank Butyl rubber or glass flake
particle medium
1.4529

13 Metal in the corrosion
Corrosive low-temperature flue
Flue gas damper prevention level of 1.4529 or
gas
equivalent

14 Slurry pump and Corrosive slurry and large- Concentrated chromium
impeller particle suspended particle corrosion prevention alloy
FGD
Corrosion and abrasion of the FGD system
274


Abrasion of fan blade in high dust conditions

Abrasion of the absorber agitator
275


Abrasion of the absorber agitator

Corrosion of impeller of circulation pump
276


Corrosion of circulation pump

Stress corrosion of polyurethane separator
277

Cut-through and crack on the canister
FGD
Corrosion of flue of the FGD system
FGD
Disrupted corrosion prevention coating in the FGD slurry pipeline
278


Erosion corrosion on the walls of absorber

Erosion corrosion on the walls of absorber
1.2 FGD FGD
1.2 Concerning most current cases of FGD system corrosion and abrasion, reasons for
FGD system corrosion are as follows:
279

1.2.1
1.2.1 Corrosion result from unreasonable selection and layout of materials.
C276
C276
C276 is required at the inlet dry and wet interface of the absorber. Some firms
of desulfurization replace C276 metal by glass flake out of concerns on cost. Under
stress of cold and hot alteration, glass flake is inclined to fall off, resulting in
corrosion on the metal surface.

Nozzle layout in the spraying layer in the absorber is not reasonable and
spraying slurry directly erodes walls of absorber and bearing beam, resulting in
erosion corrosion on the walls of absorber and beam.
1.2.2
1.2.2 Corrosion resulting from unreasonable control of operating parameters
pH 5.05.8 pH
5.0 4.0 pH
The pH value in the absorber should be controlled to be 5.0~5.8.

Unreasonable operation control may result in PH value below 5.0 and even below 4.0.
Operation in low pH value tends to result in aggravating corrosion on the metal
surface and influence service life of system equipment.
Cl-
Wastewater discharge is too low and Cl- content in the slurry is too high,
resulting in aggravating corrosion of system equipment.
1.2.3
1.2.3 Corrosion resulting from failure of construction or equipment quality to reach
design specifications

Corrosion prevention is made under some procedures such as polishing and

abrasive blasting in some areas in anticorrosion of absorber or flake fail to reach
acceptance standards, resulting in swelling, foaming, layering, stripping, etc. of
corrosion prevention layer in operation.

280

Slurry pump or agitator blade fails to reach required degree of corrosion

prevention, resulting in grave corrosion in operation and failure to reach designed
service life.
281

FGD
Chapter VII FGD System Operation Management
FGD
Section I Required capacity of FGD operators
45
FGD
Majority of domestic absorbers of desulfurization have been running for 4~5

years so far from operation and most operators are from other majors and thus lack of
theories and operation knowledge of FGD system and less experienced in their
expertise in accumulation. Therefore, all power plants should be in search for
experience of operation management in such an aspect depending on their own
circumstances. Generally speaking, an excellent person on duty for desulfurization is
required to know about the following fundamental knowledge about desulfurization:
1
1. Knowledge of basic theories

Knowledge of basic chemistry
KKS
Drawing knowledge (flow charts, equipment symbols, KKS codes, etc.)

Basic knowledge of computer

Basic knowledge of chemical engineering

The laws and regulations for environmental protection
2FGD
2. Basic knowledge of FGD
FGD
Basic principle of FGD
FGD
Process of FGD system
282

FGD
Functions and constitution of FGD equipment
FGD
Foundation of chemical analysis in FGD
FGD
Control concepts of FGD system
3
3. Basic knowledge of thermal power engineering in power plant

Basic concepts of power generation

Basic knowledge of power generation equipment (functions, basic structures
and performances)

Basic knowledge of fuel (coal classification, element analysis, industrial
analysis, etc.)

Characteristics and hazards of flue gas in power plant
4
4. Basic knowledge of mechanical equipment

Material crushing and classification

Fluid and airflow transmission

Separation of heterogeneous materials

Basic theories of heat and mass transfer
5
5. Basic electrical knowledge

283

Basic knowledge of power distribution and consumption

Basic knowledge of protection of power distribution and consumption
equipment

Basic knowledge of safe power consumption and first-aid for electric shock
6
6. Basic thermotechnical knowledge

Knowledge of instruments and meters of thermotechnical automation

Knowledge of thermotechnical automatic control and interlock protection
FGD
Section II FGD system operation adjustment
1FGD
1. Main tasks in FGD system operation adjustment
FGD
Generally speaking, FGD operation adjustment is divided into the following three
levels:
FGD
Maintain safe and steady operation of host and FGD device;
FGD
pH
Guarantee that all technical indicators of FGD system are within design scope
and that desulfurization efficiency, PH value of slurry, density, pulping density,
fineness, gypsum quality, wastewater quality, etc. in the absorber are within design
scope;
pH
Guarantee that all parameters are in operation under conditions of best

working condition [such as density of absorber, liquid level, PH value, slurry quality
(concentration of sulfite, calcium carbonate, and chloride ion), gypsum quality,
284

density of limestone slurry and limestone particle size] with the lowest energy
consumption of the system.
2FGD
2. FGD flue gas system operation adjustment
2.1
2.1 Booster fan adjustment
2.1.1
2.1.1 Target of adjustment
FGD
Maintain inlet pressure or make flue gas differential pressure on both sides of
FGD bypass damper within limits.
2.1.2
2.1.2 Aim of adjustment
FGD FGD
Operation output of booster fan just overcomes rising resistance in the FGD
system and whether FGD is put into operation or not has no impact on host's air and
flue gas system.
2.1.3
2.1.3 Difficulty of adjustment

If output of booster fan is too high, output of induced draft fan will decline; on
the contrary, if output of booster fan is too low, system resistance will be required of
rising output of induced draft fan to overcome. If host load fluctuates, flue gas amount
will fluctuate, flow rate of flue gas in the system will fluctuate, resistance of flue gas
will fluctuate, and output of booster fan will fluctuate. Thus, it shall be necessary to
adjust opening of booster fan based on negative pressure at the inlet.
2.1.4
2.1.4 Misunderstandings

High opening of booster fan tends to result in increase of flue gas amount in
the system and lowering opening of booster fan may result in a decrease of
285

flue gas amount in the system;

It shall be advised to raise guide blade opening with bypass door opening to
make all FGD desulfurization;

With certain opening of booster fan, it shall be advised to make automatic

modulation of induced draft fan guide blade when absorber load fluctuates to maintain
system operation.
2.2 GGH
2.2 GGH adjustment
2.2.1
2.2.1 Target of adjustment
GGH
GGH differential pressure is stable
2.2.2
2.2.2 Aim of adjustment

Ensure area of flue gas circulation area and reduce system resistance
2.2.3
2.2.3 Means of adjustment

GGH
Reduce ash deposition by enhancing soot blowing of ash ejector. Generally,

mediums of soot blowing include compressed air, steam, high-pressure water, and
low-pressure water. Compressed air and overheating steam: Make soot blowing once
per shift; High-pressure water: Washing will be required if GGH differential pressure
is too high. Generally, online half-speed washing shall be adopted to result in no
damage on the surface of elements of heat exchange; Low-pressure water: Offline
washing;
2.2.4
2.2.4 Misunderstandings:
GGH GGH GGH f=Kv2
vQ/sK
286

300MW 200MW
High GGH differential pressure indicates GGH blocking, required of GGH

washing. Reasons: f = Kv2, v = Q/s. Concerning a system, K value is a constant value
relevant with medium property and system only. Under normal operation conditions,
and 300MW and 200MW boiler load working conditions, the former differential
pressure is far higher than the latter. Concerning judgment on scaling condition, it
shall be advised to make comparison with previous data under the same working
condition only.
GGH
GGH scaling is different from blocking in air pre-heater. Though air

pre-heater operation under high dust conditions, its medium of ash deposition is
floating ash in the boiler in higher particle size, different to scaling.
2.2.5 GGH
2.2.5 Reasons for GGH blocking
2.2.5.1 GGH
2.2.5.1 Scaling result from sedimentation of slurry in clean flue gas on the GGH
surface.
75mg/m3 GGH
GGH GGH
GGH CaCO3
CaCO3 SO3 GGH
GGH
GGH
The content of outlet liquid is rather low after flue gas outflows from the
absorber, which is generally required to be lower than 75mg/m3. However, since GGH
is in longtime operation and its gross slurry and dust are higher, slurry and fume in
flue gas will stick on the elements of GGH heat exchange when they flow out of GGH,
moisture in the slurry will evaporate, gypsum and ash content will be in sediment and
gradually thicken till they block the channel of elements of GGH heat exchanger.
When the CaCO3 content in the absorber slurry is high, CaCO3 in the net slurry will
react with SO3 in the flue gas and generate gypsum crystal sticking to the surface of
GGH heat exchanger element. Generally speaking, high speed of flue gas flow in the
absorber will increase the flue gas capacity at the outlet of the mist eliminator and
accelerate GGH blocking. The slurry capacity in flue gas will increase because of the
unreasonable design of the spraying layer nozzle, the uneven distribution of flue gas
in the absorber and the high speed of flue gas flow in part of the mist eliminator. The
287

ineffectiveness of the mist eliminator and mist eliminator blocking because of

untimely clearing can increase the slurry capacity in flue gas and accelerate GGH
blocking which is relatively easy to be cleared.
2.2.5.2 GGH
2.2.5.2 The GGH blocking caused by ash content
GGH
SO3
SO3
SO3 SO3
SO2 O2
SO3 SO2 O2
GGH
If the flue gas at the outlet of the absorber is under supersaturated state with
certain moisture and the surface of GGH heat exchanger element cold side is damp,
most of the ash content in the air and in the liquid drop will stick to its surface.
Certain acid mist will exist in the clean flue gas at the outlet of the absorber (there are
two statements about SO3 at present: one is that after coming into the absorber, SO3
becomes thin sulfuric acid mist which cannot be wholly captured by the circulating
slurry causing SO3 at the outlet; another is that SO3 in the absorber is generally
captured by the circulating slurry, and the slurry surface at the outlet of the mist
eliminator will absorb certain SO2 and O2 that can generate sulfuric acid on the
surface of the liquid drop when the slurry is at low temperature with impurity whose
concentration is related to the concentration of SO2 and O2 in the flue gas rather than
SO3 at the inlet of the absorber), which will become concentrated acid mist via GGH
and generate silicate similar to cement after reacting with the ash. The silicate hardens
as operation time goes by, and this part will be seriously blocking when it contains
more ash for which it will be hard to be cleared even by high-pressure water.
2.2.6 GGH
2.2.6 Solutions for GGH blocking:

Keep the pressure of soot blowing steam and compressed air within the design
value to guarantee the effectiveness of soot blowing;

Wash the mist eliminator to reduce the slurry content carried by the flue gas
due to the blocking;

Control air leakage rate and coal quality of the host to prevent the flue gas
288

amount exceeding thereby;

FGD
Decrease dust content of flue gas in the FGD system through technical
reformation of the dust collector.
2.3
2.3 Adjustment of operation of absorber system
2.3.1
2.3.1 Adjustment of absorber density
2.3.1.1
2.3.1.1 Aim of adjustment

Keep the absorber density within the design value to prevent precipitation and
systematic abrasion due to the high density, which will also increase the slurry
circulation pump current and consume more energy of the system.
2.3.1.2
2.3.1.2 Means of adjustment

Discharge the slurry out of the absorber and dewatering, and transport the filtrate
back.
2.3.1.3
2.3.1.3 Objective of adjustment
151090Kg/m31120 Kg/m3
The absorber density is generally controlled at around 15%, 1090Kg/m3 - 1120

Kg/m3. The density value varies when desulfurization technology is different. But in
general, the lower the density is, the less the system equipment abrasion will be.
2.3.2
2.3.2 Adjustment of liquid level in the absorber
2.3.2.1 FGD
2.3.2.1 FGD water balance:
FGD
289

Water yield in FGD: Mist eliminator flushing water + mechanical seal

water + cooling water of equipment (opened) + cooling water of oxidation air
(humidification water) + flushing water of pipeline + slurry preparation water
+ water for belt dewatering system

Water discharge of the absorber: Evaporated water of flue gas (moisture in

the slurry of the absorber becomes vaporous from liquid) + liquid water out of flue
gas + moisture content in the gypsum + wastewater discharge
2.3.2.2
2.3.2.2 The main methods of controlling the liquid level in the absorber:
Controlling the flushing water volume of the mist eliminator, increase the interval
time of flushing when the absorber liquid level is at a high level, decrease the interval
time at a low level.
2.3.2.3
2.3.2.3 Factors may cause absorber overflows:

The decreased tension of the slurry surface makes the absorber foam;

The sulphur content will exceed when it is in low load, and the pulping water
and vacuum filter water consumption will increase;

Process water leaks into the slurry system;

When the system load is lower, the absorber inlet flue gas humidity will be
excessively high.
2.3.3
2.3.3 Adjustment of differential pressure of the mist eliminator
2.3.3.1
2.3.3.1 Objective of adjustment
GGH
If the mist eliminator is smooth with stable differential pressure, the method of
judging whether it is blocking is similar to that of GGH.
2.3.3.2
290

2.3.3.2 Means of adjustment

1.82.3kg/cm3
Increase the flushing frequency of mist eliminator flushing water and control the
flushing water pressure between 1.8 and 2.3kg/cm3 in general. If the pressure is too
low, the flushing water of the mist eliminator will not cover enough space, and if the
pressure is too high, the flushing water will not work effectively due to atomization.
2.3.4 PH
2.3.4 Adjustment of pH value
2.3.4.1 pH pH
5.25.8 pH
2 1.03
2.3.4.1 Objective of adjustment: Different technologies require different pH values
and generally speaking, pH value should be 5.2 - 5.8 for wet desulfurization. The
control value of pH value is not fixed. Keep the limestone left in absorber gypsum
slurry as less as possible in principle on condition that desulfurization efficiency is
efficient. In general, limestone content left in gypsum is required to be no more than 2%
and calcium sulfur ration of the system should be controlled within 1.03.
2.3.4.2 pH
2.3.4.2 Factors influencing pH value control:

Absorber inlet flue gas amount;

Absorber inlet sulphur content;

Limestone activity;

Absorber inlet dust content;

Oxidation air amount;

Increase of inert substance precipitation and ionic concentration in the
absorber.
291

2.3.4.2.1
pH
2.3.4.2.1 Variations of the total sulfur content: The sulfur content in the absorber
system beyond the processing capability of the system leads to quality deterioration of
the slurry, decrease of pH value and the reduced desulfurization efficiency of the
system;
2.3.4.2.2
2.3.4.2.2 Limestone activity

pH 10
pHt pH
pH
Low limestone activity will increase the calcium sulfur ration of the system and
the limestone content in the gypsum. Desulfurization rate will decrease under high
load and pH value will reduce while the limestone content in the gypsum will even
reach over 10%. The limestone activity is usually measured by means of pH-t, i.e.
titrating limestone with acid, and comparing the pH curve with the standard curve.
The acid dissolution rate will not meet the requirement when the pH of limestone with
low activity cannot last long.
2000mg/m3 1400mg/m3
9697 3
1400mg/m3 2300 mg/m3
75pH 4.6 15
pH
Case: The desulfurization efficiency of a power plant will reach 96% - 97%
when the design sulphur content is 2000mg/m3 and the full-load sulphur content is
about 1400mg/m3. And when the full-load sulphur content constantly rises to about
2300 mg/m3 from 1400mg/m3, the desulfurization efficiency will drop to the lowest
75%, pH decreases continuously to the lowest 4.6 and the limestone content in the
gypsum rises to 15%. When the bypass is opened and the guide blades of the booster
fan become small, stop supplementing slurry and pH value of slurry in the absorber
rises slowly again.
2.3.4.2.3
2.3.4.2.3 High dust content at the absorber inlet

50mg/Nm3
Al3+ F- Ca2+
CaCO3 H+ CaCO3
292

300 mg/Nm3
150mg/Nm3
GGH
CaO CaSO4 GGH
For a successfully-designed absorber, most dust in the flue gas entering it will
be captured by the circulating slurry, and the dust content at the outlet basically has
nothing to do with that at the inlet, generally no more than 50mg/Nm3. The left dust
will be captured into the slurry. Al3+, F- and Ca2+ in the dust will combine together and
generate insoluble complex covering CaCO3 which thus prevents the combination of
H+ and CaCO3 in the slurry and causes "shielding of limestone" or the so called
"activity-loss of limestone". Meanwhile, the ash in the flue gas at the inlet will reduce
the activity of the slurry and make the absorber foam so that the desulfurization
efficiency will decrease. The influence of the ash on the desulfurization system is not
directly related to the dust content in the flue gas while it is indeed related to the ash
content in the slurry. For the flue gas with high sulphur content, the desulfurization
system's tolerance to dust is respectively high, and the system can stay in normal
operation when the dust content in the flue gas is more than 300mg/Nm3. In terms of
flue gas of low sulphur content, normal operation of desulfurization system may not
be guaranteed if fume content is around 150mg/Nm3. If dustiness in slurry is higher,
vitriolic mist in GGH will combine with active CaO in ash content and generate
highly adhesive CaSO4, blocking GGH.

pH
If ash content in slurry has an impact on the system's desulfurization efficiency,

accelerate dewatering or substitution the system slurry shall be conducted of. In case
of failure to control pH value or efficiency of desulfurization, it shall be advised to
adjust or transform coal quality in boiler combustion or electric precipitator to reduce
the fume content in the desulfurization system.
168 pH 3 5.4
4.4 80 10
4 pH pH
6.2 4 5.4
NaOH 168
Case: During the 168-hour test run in one power plant, the pH value
continuously falls on the 3rd day from 5.4 to 4.4, desulfurization efficiency drops to 80%
and limestone content in slurry in the absorber is over 10%. By the time,
293

automatically relieve supply of slurry in the absorber, stop slurry supply, increase
dewatering, increase wastewater discharge and substitute slurry in the absorber with
clean water. On the 4th day, the pH value in the absorber slowly picks up. Though
slurry supply is stopped, the pH value rises to 6.2, which continues to rise until the
afternoon on the 4th day. When it falls to 5.4, recover slurry supply. By the time,
limestone content in gypsum reaches the normal level. Concerning such a situation, it
is advised to add NaOH or lime while stopping slurry supply and slurry substitution to
enhance limestone activity and reduce time of adjustment. Reason analysis: Earlier in
the 168-hour test run, dust content in flue gas is high, density of absorber is not up to
dewatering demand, and substantial heavy metal ion and inert substance in fly ash
deposit, resulting in substances surrounding limestone and blocking limestone. Dilute
ion concentration in the slurry by substitution and continuous dewatering and separate
partially closed limestone from absorber by dewatering to recover slurry activity.
2.3.4.2.4
2.3.4.2.4 Oxidation air amount

pH
Insufficient oxidation air amount or uneven distribution or diffusion of oxidation

air in absorber may make generated calcium sulfite unable to normally oxidize,
resulting in sediment of calcium sulfite. If the concentration of calcium sulfite in the
absorber is too high, it will separate out sediment on the limestone surface, resulting
in limestone shielded, fall in efficiency of desulfurization and pH value and difficulty
in gypsum dewatering.
2.4
2.4 Adjustment of operation of the slurry preparation system

Major tasks of adjustment of the slurry preparation system: To guarantee that

qualified limestone slurry is up to design requirements for quality, particle size, and
density and full-load output.

As the mill is in the intermittent operation mode and there is a limestone slurry
tank in the middle, it is expected that the mill is in full-load output to minimize power
consumption.

Specific factors of impact on output include: Limestone hardness, particle size of

limestone, loading capacity of steel balls, and size and proportion of steel balls.
294

Control proportion of limestone and process water (filtrate) in the mill and
ensure that feeding capacity of the mill is always in its maximum output;

Supplement steel balls timely if finding that the operating current of the mill
is lower than the set value in operation;

Control particle size of limestone in the mill within the range of design value.
If particle size of limestone is lower than the design value, it will be advised to
consider increase of feeding amount in the proper way to raise mill output;

Monitor closely whether the inlet pressure in the limestone rotational flow
station is within range of design value. If the pressure in the rotational flow station is
too high, it will result in lower density of overflows, decline of mill output and
difficulty in keeping water equilibrium in the absorber. If pressure is too low, it will
result in particle size of finished limestone slurry not up to design requirement, too
much limestone left in the absorber, rising calcium sulfur ratio and operation
diseconomy.
2.5
2.5 Adjustment of operation of the dewatering system

SO2
The key object of adjustment is gypsum quality. Multiple factors influence

gypsum quality, such as dust content in flue gas, SO2 concentration, limestone quality,
and oxidation air amount. In terms of dewatering system, gypsum quality after
dewatering depends on slurry quality in the absorber. Generally speaking, the
following reasons may cause high moisture in gypsum:
CaCO3
High CaCO3 content in gypsum
CaSO3
High CaSO3 content in gypsum
295


High content of acid non-soluble substance in gypsum

To guarantee slurry quality in operation is the key to normal operation of
dewatering system.
296

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IL&FS Cuddalore Power Project-Flue Gas Desulphurisation Plant

IL&FS TAMIL NADU POWER COMPANY LIMITED

CUDDALORE DISTRICT,TAMIL NADU,INDIA

Training Materials of Wet Flue Gas Desulfurization

Rev. Description Date Made by Checked Appd.

A First issue 02-FEB-2016

Training Materials of Wet Flue Gas Desulfurization

Induced draft fan

Blade DIN1.4529 or equivalent clean flue gas side carbon

Alloy C276 Alloy C276

1. The absorber system flow chart

Adopt the local forced oxidation process of wet limestone/gypsum to remove

CaCO3 2 HF CaF2 H 2 O CO2 7

Besides nozzle, there is no other equipment in the absorption area of the

Oxidation and crystallization mainly occur in slurry pool of the absorber.

The pH value of slurry in slurry pool of absorber is under control of

1.4.3 Slurry spraying system

Demisting efficiency. It refers to the ratio between mass of droplets collected

When oxidation air is evenly distributed to slurry pool of absorber through

Slurry pipeline is extended respectively from E, D and C outlet pipeline of the

Limestone blocks are sent to FGD by self-discharging truck or other methods,

32.2.4 Weighing feeder

Model selection of wet limestone mill may ensure the continuous or

Function of gypsum dewatering system is to remove the moisture in gypsum

Hydrocyclone mainly used to separate and classify particulate matters is

Reference Diagram of Gypsum Hydrocyclone

Primary concentrated slurry flowing from the underflow of gypsum

2.2.2 Quality requirement of cement gypsum:

1. 1. Filter cloth washing

Cl- 20000ppm 100ppm

Belt-type vacuum dewatering system is constituted by the main equipment like

Water ring vacuum pump is a power equipment to conduct pumping of gypsum

Uniflow single-stage centrifugal pump is generally selected for emergency slurry

Drainage pit of absorber area is generally designed into a rectangular pool of

Drainage pit pump is generally designed as uniflow single-stage centrifugal

Drainage pit pump is generally designed as uniflow single-stage centrifugal

Drainage pit pump is generally designed as uniflow single-stage centrifugal

Process water tank is installed in the desulfurization island. 2 sets of water

Taken away by dewatering system.

Taken away by flue gas system. (Water

Taken away by wastewater system.

Water quality of desulfurization wastewater is very special, and is featured by:

Water quality standard of desulfurization wastewater in the domestic power

Desulfurization wastewater treatment system is generally independently arranged

Chemical dosing systems include: Lime powder storage and transportation,

Materials selection of all equipment, pipelines and valves in the whole-set

Water used by desulfurization wastewater treatment system is taken from the

Metering pump is reciprocating/diaphragm pump type with the same

Filter cake discharge on the sludge dewatering equipment can be manually

FGD SO2 FGD

To accurately describe the impact of load change on system, working conditions

1.2 It is specified in Flue Gas Limestone/lime-gypsum Desulfurization Project

% 23.4% 46.9% 93.9%

Capacity of the slurry Benchmark

Increase the difficulty of desulfurization gypsum dewatering;

In order to ensure system operation, it needs to adjust solid content in top

Dust discharge amount of theoretical calculation increases in proportion,

In theoretical calculation, since it has not considered the influence on other

0.02 0.5 80 HCl 95

of dust collector in the upstream.

allowed, it needs to consider the allowable Cl- concentration of gypsum, and it is

10. 2-8 11.2 12.