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Worldwide Pollution Control Association IL Regional Technical Seminar IL Regional Technical Seminar August 3-4, 2010 Visit our website at www wpca info Visit our website at www .wpca.info

Wet Scrubber O&M Lessons Learned by B&W

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Page 1: Wet Scrubber O&M Lessons Learned by B&W

Worldwide PollutionControl Association

IL Regional Technical SeminarIL Regional Technical SeminarAugust 3-4, 2010

Visit our website at www wpca infoVisit our website at www.wpca.info

Page 2: Wet Scrubber O&M Lessons Learned by B&W

Wet FGD Lessons Learned - DesignWet FGD Lessons Learned - Designby

Greg Bielawski

WPCA Regional SeminarSpringfield IllinoisSpringfield, Illinois

August 4, 2010

Page 3: Wet Scrubber O&M Lessons Learned by B&W

Yesterday: Multiple Absorbers per Boiler:este day u t p e bso be s pe o eMany dampers & many more pumps

Proprietary and Confidential .2

Page 4: Wet Scrubber O&M Lessons Learned by B&W

Today: Single Absorber per BoilerToday: Single Absorber per Boiler

Proprietary and Confidential .3

Page 5: Wet Scrubber O&M Lessons Learned by B&W

Importance of Gas Flow Distribution

4

©

Page 6: Wet Scrubber O&M Lessons Learned by B&W

Packed Towers No Longer Used

Excellent contactor, but big plugage problems

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©

Page 7: Wet Scrubber O&M Lessons Learned by B&W

B&W Absorber Gas Inlet with Tray

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©

Page 8: Wet Scrubber O&M Lessons Learned by B&W

Spiral Nozzle:Excellent Drop Size, but Not Suitablep ,

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Page 9: Wet Scrubber O&M Lessons Learned by B&W

Hollow Cone Spray Nozzle

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©

Page 10: Wet Scrubber O&M Lessons Learned by B&W

FRP Spray Headers

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FRP Can be done right, but there must be a stringent spec….

Page 11: Wet Scrubber O&M Lessons Learned by B&W

Alloy Spray Headers

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Page 12: Wet Scrubber O&M Lessons Learned by B&W

Rubber lining blockage:Common problem with Rubber-Lined Pipe p p

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©© 2008 Babcock & Wilcox 11

Page 13: Wet Scrubber O&M Lessons Learned by B&W

Mist Eliminator Upgrade

Original Mist Eliminator Design New Modern Mist Eliminator Design

Mist Eliminator Upgrade

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Page 14: Wet Scrubber O&M Lessons Learned by B&W

Typical Lower & Upper Mist Eliminator

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©

Source: Munters

Page 15: Wet Scrubber O&M Lessons Learned by B&W

Mist Eliminator Wash System

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©© 2008 Babcock & Wilcox 14

Page 16: Wet Scrubber O&M Lessons Learned by B&W

ME Wash StrainerME Wash Strainer

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©© 2008 Babcock & Wilcox 15

Page 17: Wet Scrubber O&M Lessons Learned by B&W

Top of Mist Eliminator with Wash Header

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©

Page 18: Wet Scrubber O&M Lessons Learned by B&W

Wet FGD Absorber FireWet FGD Absorber Fire

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©© 2008 Babcock & Wilcox 17

Page 19: Wet Scrubber O&M Lessons Learned by B&W

Absorber Pump with FRP Pipe (Note Supports)

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©

Page 20: Wet Scrubber O&M Lessons Learned by B&W

Absorber Pump Gearbox Failures:Gearboxes likely need water coolingGearboxes likely need water cooling

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©© 2008 Babcock & Wilcox 19

Page 21: Wet Scrubber O&M Lessons Learned by B&W

Absorber Mixer Design

Mixers must be distributed around the tank, not clustered

installation angle = f (d1, d2, n2, q, quantity of agitators)

ß = too largeß = 0deposits at g

deposits inthe centre

pthe vesselwall

ß = optimalno deposits

S

20

©

Source: Ekato

Page 22: Wet Scrubber O&M Lessons Learned by B&W

Mixer on Absorber Shell: Outboard Support Neededpp

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©

Source: Alstom Unit at Centralia

Page 23: Wet Scrubber O&M Lessons Learned by B&W

Agitator Motor DriveAgitator Motor Drive

Coleson Cove 7/8/04

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Page 24: Wet Scrubber O&M Lessons Learned by B&W

Erosion of Alloy Mixer Blade(Two Year Outage Inspection)(Two-Year Outage Inspection)

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Page 25: Wet Scrubber O&M Lessons Learned by B&W

Absorber Tank Access DoorNeed Big Doors; Must be to Codeg ;

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©

Source: Alstom Unit at Centralia

Page 26: Wet Scrubber O&M Lessons Learned by B&W

Thank You!Thank You!

25

© 25© 2009 The Babcock & Wilcox

Page 27: Wet Scrubber O&M Lessons Learned by B&W

WFGD Operations & MaintenanceWFGD Operations & Maintenanceby

Greg Bielawski

WPCA Regional SeminarSpringfield IllinoisSpringfield, Illinois

August 4, 2010

Page 28: Wet Scrubber O&M Lessons Learned by B&W

Estimated Plant WFGD Operations per ShiftEstimated Plant WFGD Operations per Shift

Operator shift super 1x (shared)Operator shift super 1x (shared)

Control room operator 1x

Field operatorsField operatorsAQCS 2xElectrical 1x (shared)

Lab tech 1 per shift (for 2 shifts – shared)

Maintenance shared with boiler

Total Dedicated Personnel: 3Total Shared Personnel: 3+

Proprietary and Confidential © 2008 Babcock & Wilcox Power Generation Group, Inc. All rights reserved. .27

Page 29: Wet Scrubber O&M Lessons Learned by B&W

T i l Ab b M i t A ti itiTypical Absorber Maintenance Activities

Activity Description Frequency

Estimated Labor

ManhoursEquipment

On/OffAQCS On/Off

ABSORBERABSORBER

Inspect alloy parts 1 per year 24 off off

Inspect/repair internal piping 1 per year 24 off off

Inspect/clean nozzles 1 per year 24 off off

Inspect/clean mist eliminators 1 per year 24 off off

Inspect/clean flow distributors 1 per year 24 off off

Inspect/replace man way gaskets 1 per year 24 off off

Inspect fasteners 1 per year 24 off offInspect fasteners 1 per year 24 off off

List continues for many pages:

Proprietary and Confidential © 2008 Babcock & Wilcox Power Generation Group, Inc. All rights reserved. .28

Contact [email protected] for complete set

Page 30: Wet Scrubber O&M Lessons Learned by B&W

E ti t d M i t C tEstimated Maintenance Costs for the Wet FGD System

Estimated annual maintenance manhours for the Wet FGD: ~6,900 hours

Estimated annual spare parts/materials cost for the Wet FGD: ~$515,000

Notes:

The above maintenance activities, frequency, and estimated labor , q y,values are typical and may vary dependent on equipment suppliers.

Total maintenance costs may vary in the industry from plant to plant.

Proprietary and Confidential © 2008 Babcock & Wilcox Power Generation Group, Inc. All rights reserved. .29

Page 31: Wet Scrubber O&M Lessons Learned by B&W

Thank You!Thank You!

Proprietary and Confidential .30© 2009 The Babcock & Wilcox Company. All rights reserved.