DURAG D-R 290 OPACITY ANALYZER 1. Measuring … · DURAG D-R 290 OPACITY ANALYZER Before proceeding...

DURAG D-R 290 OPACITY ANALYZER Before proceeding to do a manual calibration, on any of the following equipment, please familiarize yourself with the manual for each piece of equipment that you will be working on.

1. Measuring Ranges

a. The D-R 290 has two analog measured value outputs. Each

output has two freely selectable extinction or opacity measuring

ranges. In the basic setting the measuring ranges are assigned

to the two measured value outputs. The measuring ranges can

be set independently of each other.

b. The outputs can be switched to measuring range 2 by

activating the relevant status input. For output 1, the jumper

should be set between terminal X2 11 and 12; output 2 gets the

jumper between terminal X2 31 and 32. The outputs can be set

independently of each other to opacity or extinction.

2. Integration Times

a. On the D-R 290 the integration times for the two measured

value outputs can be set independently of each other from 5

seconds to 1800 seconds in one second increments.

3. Cycle Time

a. On the D-R 290 measuring system the time to initiation of the

next control cycle can be set from 1 to 99 hours, in increments

of one hour. Once the time set has elapsed, the control cycle is

automatically initiated. At the end of the control cycle. the new

cycle time set is accepted and the current rest time until the

next control cycle is shown in the display.

b. There is the option of triggering the checks manually during a

measuring operation that is underway. By pressing the <- and

+ keys simultaneously for around five seconds, the remaining

time is set to “0” and the control cycle is initiated again ( the

rest time indicator flashes in the evaluation unit display)

c. The D-R 290 AW2 evaluation unit has a status input for the

control cycle.

i. Open: Control cycle is automatically triggered as

described.

ii. Closed: Control cycle is not automatically executed, only

manually (no rest time display)

iii. On Opening: Control cycle is triggered (initiated) as

described.

4. Contamination Alarm

a. On the D-R 290 the threshold of the degree of contamination

(“Window Alarm”) after which a contamination alarm is sent can

be set in 0.1% increments. The adjustment range is 0 to 9.9%.

On the setting 0.0% the contamination alarm is disabled.

b. If during the contamination check, the measured degree of

contamination exceeds the specified percentage, then the

message “**ERROR 001**” appears in the display. After a

delay of around 10 seconds a fault message is sent via the

“Fault” relay output.

5. Limit Values

a. There are two adjustable limit value contacts available. In the

basic setting the limit values are assigned to the two measured

value outputs. The limit values can be set independently in

increments of 0.1 mA over the entire measuring range in each

case. If the limit values are exceeded, the relevant relay

contact operates for the period that this occurs.

6. Linearity Check

a. Control mode is for a linearity check in accordance with the

EPA requirements. The linearity measurement is performed in

the measuring range set for output 1. Once control mode has

been selected, a contamination correction is performed for

around 10 seconds, if necessary by pressing the “STO” key,

and the display is thus brought to 4 mA.

7. Zero Point Check

a. On the D-R 290 there is a zero point check in the set measuring

range at the start of the control cycle for 1 hour and 30 minutes.

Once the zero point reflector has been tilted into its position on

the measuring head, the output current increases to 4 mA.

There is also the option of a manual prompt for zero point

control.

8. Contamination Check

a. On the D-R 290 in the control cycle after the zero point check

for 90 seconds there is a contamination check in the set

measuring range. The contamination on the optical interfaces

is measured and displayed. The measurement results of the

subsequent measurements are corrected by the magnitude of

the contamination measured. If, during the contamination

check, the measured degree of contamination exceeds the

specified percentage, then a fault message is output and the

message “**ERROR 001**” appears in the display. There is

also the option of a manual prompt for contamination.

9. Span Check

a. In the control cycle for approximately 90 seconds, after the

contamination check there is a span check. By means of a step

motor, a mesh filter is tilted into the path of the receiver bear.

The reference value (span) should be reproducible on every

span check. There is also the option of a manual prompt for

the span reference value.

10. Stack Correction Factor

a. If the measurement of the D-R 290 is to be evaluated as if the

measuring light crosses the measuring path only once at the

stack exit (in accordance with the EPA), stack correction factor

L2/L1 should be set. The correction factor set is effective in the

opacity measuring ranges of the two measured value outputs.

i. L1: diameter of the stack at the measured point

ii. L2: diameter at the stack exit

b. When selecting the stack correction factor this is also output as

current. 0.5 to 2.9 corresponds to 4.0 mA to 20 mA.

c. The standard setting for the stack correction factor is 1. This

setting results in opacity being displayed as if the measuring

light crosses the measuring path only once at the point of

measurement.

11. Recording of the measured Values

a. The current value of the measurement is output by the D-R 290

as an analog current signal. The statutory requirements require

continuous recording of the measured values. For recording, a

logger (0-20 mA) with a recording width of at least 100 mm is

suitable, equivalent to quality class 1.0 to VDE 0410. The zero

point of the display is at 20% (4 mA live zero) of the recording

scale.

b. The measured values and status signals output can however

also be processed by a downstream emissions calculator.

MODEL 922 AMETEK SO2/NOx ANALYZER BEFORE PROCEEDING TO DO A MANUAL CALIBRATION, OF ANY OF THE FOLLOWING EQUIPMENT, PLEASE FAMILIARIZE YOURSELF WITH THE MANUAL FOR EACH PIECE OF EQUIPMENT THAT YOU WILL BE WORKING ON.

CALIBRATION OF THE CEM CO AND SO2 /NOX ANALYZERS When doing a manual calibration on these instruments requires the admission of calibration gasses through the PROBE CAL switch located on the gas conditioner panel. When calibrating the zero on the so2 or Nox analyzer, remember that they will both be calibrated at the same time. TURN ON THE PROBE CAL SWITCH-BY ROCKING IT TO THE RIGHT TURN ON THE HI SV1 SWITCH- BY ROCKING IT TO THE RIGHT THIS WILL ADMIT HI O2 CALIBRATION GAS TO THE PROBE AND BOTH CO AND SO2/ Nox INSTUMENTS. AFTER 10 MINUTES HAS ELAPSED;

1. ON THE SO2 AND Nox ANALYZER 2. PRESS THE F6 KEY 3. PRESS THE”. “ KEY (THREE TIMES) 4. PRESS THE ENTER KEY 5. PRESS THE F2 KEY 6. PRES THE 0 KEY 7. PRESS THE ENTER KEY 8. THE INSTRUMENT WILL COUNT DOWN FROM 30 TO 0 AND

CHANGE THE VAUES TO 0 ON BOTH INSTUMENTS AT THE SAME TIME.

THE INSTRUMENTS SHOULD DISPLAY CAL SO2 Nox 0 0

TO CALIBRATE THE SPAN VLUES FOR THE nox AND SO2 ANALYZERS When calibrating the span on theSO2 or Nox analyzer leave the probe cal switch in the on position – shut off the zero o2 SV1 and turn on the SPAN1 switch SV3 by rocking the switch to the right. After ten minutes has elapsed; And you still have a stable reading on the SO2 and Nox analyzer Press the F6 key Press the (.) key (THREE TIMES) Press the enter key continue with F2 1 enter (SO2 span) Analyzer will countdown F2 3 enter (Nox span) Analyzer will countdown from 30 OPTIONAL DATA ENTRY to change span values in the instrument after changing calibration gas bottles On the SO2 analyzer only Press F4 1 key The display will read; CAL CONC 1 (example 428.00 PPM) Press DEL key Enter the new value with the number key (example 431.31) Press the ENTER key Press the ESC; key to go back into the monitoring mode

MODEL 600D NDIR ANALYZER Before proceeding to do a manual calibration, on any of the following equipment, please familiarize yourself with the manual for each piece of equipment that you will be working on. TO CALIBRATE THE SPAN VALUES FOR THE CO ANALYZER After ten minutes has elapsed; And you have a stable reading on the CO analyzer Press the MENU push button Press the DOWN ARROW push button (three times) Display shows [“>calibration”] with the> arrow in front of calibration If not move the up/down ^v arrow button until it does Press the ENTER button The display will show > calibrate zero

calibrate CO Press the ENTER push button Display will read; CO PPM XXX RANGE 1000 SET TO xx898.00 Using the right arrow > PUSH BUTTON select the digit you want to replace Then using the ^v up/down arrows to select the correct number. When you get the calibration gas value displayed press the ENTER push button Then push the RUN push button to return to monitoring mode. Turn off the PROBE CAL switch and also the SPAN 1SV3 switch. Turn on the PURGE SWITCH for one minute then turn it off again. CALIBRATION COMPLETE

BRAND-GAUS MODEL 4705 OXYGEN ANALYZER

Before proceeding to do a manual calibration , on any of the following equipment, please familiarize yourself with the manual for each piece of equipment that you will be working on. After installation and at least a 1- hour warm up period, the instrument can be calibrated via the following procedure. The Brand-Gaus oxygen analyzer calibrations are generally very stable. If the calibration appears to have drifted significantly, or requires frequent adjustment, do not recalibrate the unit. Check for analyzer malfunction and/or check the sample delivery system for leaks or other problems. 1. Low Calibration

a. Flow low calibration gas (typically zero) through the sample handling system and analyzer. Dry nitrogen or EPA protocol gas is recommended as a low calibration gas.

b. Wait approximately two minutes or until reading settles. c. Adjust the " low cal" potentiometer on the front panel until the display

reads the desired concentration (typically zero). 2. High Calibration:

a. Flow High calibration gas through the sample handling system and analyzer.

b. Wait approximately two minutes or until reading settles. c. Adjust the "high cal" potentiometer on front panel until the display

reads the desired concentration.

CEM EQUIPMENT SPARE PARTS LIST

HILLMAN POWER COMPANY

CO ANALYZER

(CO – CARULITE

SOLENOID #7368 (2)

FUSE 2 AMP SLO-BLO

NOX/SO2 ANALYZER

DRIERITE #L-07193-05

ACTIVATED CHARCOAL

5 MICRON FILTER ELEMENTS

CADMIUM LAMP 3300-2070

MAGNESIUM LAMP 100-0688

O-RING CAPPILARY #4800

4293 AIR DRYER COLUMN/RING 9212

OPACITY ANALYZER

LENS CLEANING CLOTHS/CLEANING SOLUTION

BLOWER FILTER #2222

O2 ANALYZER

SPARE ANALYZER

O2 SENSOR

PROBE

FILTER GASKETS

VITON O-RINGS

5 MICRON FILTER

EQUIPMENT EXTRA

VACCUME PUMP

PARASTALIC PUMP

NEOPRENE HOSE

OPERATIONS MANUAL

Number:

OM-121

Subject:

Boiler Start On Wood

Approved for Use by:

Plant Manager Signature

Current Issue:

Rev 0 (R0)

Issue Date:

Tbd

Page 1 OF 9

TABLE OF CONTENTS

SECTION TITLE PAGE

1. Purpose ....................................................................................... 2

2. Discussion ................................................................................... 2

3. Responsibilities ............................................................................ 2

HILLMAN POWER CO.

BOILER START ON WOOD

OM 121 Boiler Start On Wood 2 of 8 R0

1. PURPOSE

The purpose of this procedure is to define emergency response for hazardous materials spills, medical/fire/law enforcement, weather emergencies, and evacuation.

2. DISCUSSION

This procedure applies to all plant personnel, contractors, and others who may be on the plant site during a fire, chemical release/spill, medical emergency, tornado/severe storms, or a bomb threat.

3. RESPONSIBILITIES

A. The Plant Manager has overall responsibility for the development, revision, and implementation of this plan and for assigning the title and associated responsibilities of Emergency Coordinator to an employee to adequately cover all periods when the facility is occupied.

B. The Operations Manager is responsible for the execution of this plan. The Operations Manager is designated as the Facility Emergency Coordinator.

C. The Operations Manager is responsible for conducting fire and evacuation drills. The Operations Manager is responsible for ensuring the Fire Department is notified, if necessary, and coordinating a response to the incident as well as directing the evacuation according to this plan. The Operations Manager shall designate an evacuation coordinator if the emergency requires personnel to evacuate.

D. The Control Operator will act as the evacuation coordinator until relieved by management and shall account for all operation and maintenance (O & M) personnel on site.

E. The Control Operator shall maintain radio communication with the Control Operator and keep a head count of all evacuated plant and contract personnel in order to report the status to the Control Operator.

F. All personnel will be trained on their work areas regarding fire routes, exits, the location and use of emergency equipment,

HILLMAN POWER CO.



and understanding and following this plan. All personnel who have contractors or visitors at the facility shall ensure that they are familiar with this plan.

WOOD LIGHT OFF

I. Scope / Purpose

A. This procedure establishes the requirements for boiler light off

at the Hillman Power Plant utilizing wood. The boiler will

initially be started using natural gas and then be switched to

wood firing per this procedure at approximately 500psi steam

pressure.

II. Procedure

A. The Plant tech is to verify that all equipment is clear and

operational prior to starting.

HILLMAN POWER CO.



III. Fuel System

A. Walk the entire fuel system and verify that it is clear and ready

for operation.

B. Start the fuel system, check operation, and load the reclaimer.

C. Slide out the fuel shut off grates from the wood feeders and

energize the feeders.

D. Set the feeder local controls to “auto on”, with the voltage dial at

0.

IV. Combustion Air

A. Start the distributor (rotary) air damper (HIC-320).

B. Increase the furnace draft fan damper to approximately -1.5”

H20.

C. Close the forced draft fan damper (PCD-311)

D. Start the forced draft fan (HIC-307)

1. The fan bearing temps need to be at 60°f minimum prior

to starting.

2. Maintain the furnace draft at approximately -1.5” H20.

E. Close the distributor air damper (PCD-318), and the over fire air

damper (FCD-315).

F. Start the over fire air fan (HIC-355)

1. The bearing temps need to be at 60°f minimum prior to

starting.

HILLMAN POWER CO.



2. The bearing oil levels need to be at normal level.

G. Adjust the forced draft fan damper (PCD-311), for a forced

draft process variable pressure of approximately 12” H20.

H. Open the distributor air damper (PCD-518) to give a distributor

air process variable pressure of approximately 16” to 18” H20.

1. The pressure should be varied to give an even distribution

of chips over the entire grates.

I. Maintain a slightly negative furnace draft. Do not allow the

furnace draft to go positive.

V. Wood Light Off

A. Add wood chips to the boiler by raising the BM-1 to 3% (2

feeders only).

1. Turn on and set the hydro grates to shake for 3 to five

seconds every 2 minutes.

B. Allow time for the wood chips to ignite

C. Once combustion starts, run the BM-1 at 4% to 5%.

1. Do not allow the burning bed to become smothered

Note: Most of the wood should burn in

suspension at this firing rate.

2. The under grate air, and distributor air will have to be

varied for proper combustion and even distribution.

D. As steam pressure increases, gradually decrease the gas flow

(FCD-430) to increase the wood flow.

HILLMAN POWER CO.



1. Gradually increase the wood firing rate (BM-1)as

required to a maximum of 5% prior to admitting steam to

the turbine.

2. Follow the attached warm up/cool down curve, do not

exceed this curve

3. Do not allow the secondary superheated inlet

temperature (TT-257) to exceed 750°f and/or the

secondary super heater outlet temperature to exceed

900°f.

E. Continue raising the steam pressure until the boiler reaches

operating temperature and pressure. Maintain between 750

and 850 psi steam pressure until the turbine is ready to be put

on the grid.

F. At 500 psi steam pressure open the attemperator and

desuperheater (TCV257) water supply root valve

Note: The control valve is to be closed prior to

opening the root valve.

VI. Generator Online

A. The boiler steam pressure is to be maintained at 750psi, when

admitting the steam to the turbine during the warm up.

HILLMAN POWER CO.



1. As the wood firing rate is increased, adjust the

distributor air, under grate air, and over fire air as required

for combustion.

2. The super heater vent should be closed when the

turbine reaches 1500 RPM, or after the unit is online

3. Maintain the drum level as close to normal water level as

possible.

4. Adjust distributor air, under grate air, over fire air, and

the furnace draft as required for proper combustion.

B. If the steam pressure sags when putting the unit online,

increase the gas firing rate (FCV-430)

1. The combustion air fan (FCD-451) should be set at 45%

to 50%.

2. Do not exceed a gas firing rate of 60%

C. Synchronize the generator per Section 6 of the Procedure

Book.

D. After the unit is online, stabilize the boiler pressure,

temperature, water level, and wood firing rate; while decreasing

the gas flow.

E. After stabilization, secure the gas burner.

1. Close the gas control valve (FCV-430)

2. Stop the combustion air fan (HIC-429)

3. Close the combustion air fan damper (FCD-451)

HILLMAN POWER CO.



4. Turn off the breaker in the flame safety panel, and push

the Reset Button on the side of the panel.

5. Close the burner manual gas valve and the two pilot

valves.

6. Adjust the hydro grate shake time to be as slow as

possible, while still maintaining an even burning bed of

chips on the grates.

OPERATIONS MANUAL

Number:

OM-519

Subject:

NOx REDUCTION SYSTEM



Current Issue:

Rev 0 (R0)

Issue Date:

Tbd

Page 1 OF 8

TABLE OF CONTENTS

SECTION TITLE PAGE

1. Purpose ........................................................................................ 2

2. Discussion .................................................................................... 2


4. Procedure .................................................................................... 3



1. PURPOSE

The purpose of these procedures is to provide a guideline to the general operations of the equipment at Hillman Power Plant. These procedures should be read and understood by all operators. It is mandatory that all employees adhere to these procedures for the safe operation of the equipment. These procedures should be used in conjunction with the applicable maintenance manuals, operation manuals, vendor manuals and standard power plant practices.

2. DISCUSSION

Prior to engaging any system, it is important to verify that all connections and associated apparatus are installed properly to assure the system performs correctly, efficiently, and safely. Remove all tools and other debris away from the system before starting.

3. RESPONSIBILITIES

A. The Plant Manager has overall responsibility for the development, revision, and implementation of these procedures.

B. The Operations Manager and the Maintenance Supervisor are responsible for the execution of this procedure.

C. The Control Room operator has responsibility to ensure these procedures are followed.

D. All employees are responsible for ensuring all safety procedures are followed, including the use of PPE.



FUEL TECH NOx REDUCTION SYSTEM

SEQUENCE OF OPERATION

I. Preparing the system for start-up.

A. Insure that recirculation system is running.

B. Open Urea supply gate valve located on recirc. skid.

C. Turn on city water supply to skid.

D. Make sure that all drains are shut.

E. Check that urea temperature is above its freezing point.

II. Pre-select Metering and Mixing Pumps, Line Up Skid.

A. Select the Mixing Pump A or B and the mode of operation, auto or

manual. In manual, either or both pumps can be operated from the skid. In

auto, the pump is tied into the auto shut-down system. The auto system flush

will only work with these pumps in auto.In manual, the pump will run even

if it is not selected.

B. Select the metering Pump, A or B and the mode of operation, local or

remote. Both switches must be in either local or remote otherwise neither

pump will run. In remote, the metering pump volume output is regulated by

the control operator at the remote panel in the control room.In auto the pump

is regulated by the adjustment knob located on the panel. This knob will

adjust the meter on the panel to read between 0% and 100%. The percent

reading on the meter will not necessarily correspond to the percent output of

the pump. The pump output should be checked using the calibration column.

C. Open the pressure control valve bypass valve. This relieves start-up surge



pressure from damaging the pressure transmitter. Close bypass valve.

III. Turn NOxOUT System ON.

A. The system can be run either locally from the skid or remotely from the

control room.

B. Operation

1. Verify that the skid metering pumps are both in remote.

2. Verify that mixing pumps are set to auto with one pump selected.

3. Turn system on from the skid. The system on switch light will

acknowledge that system is on.

4. The NOxOUT A supply valve will open automatically and the city water

supply valve on the skid will open automatically.

5. Any existing alarm conditions will show up at this time. If there is an

alarm, correct problem and acknowledge alarm.

6. Chemical metering pump acknowledge light will come on verifying that

the pump has power.

7. Chemical mixing pump acknowledge light will come on verifying that the

pump has power.

IV. Normal, Automatic Shutdown with Auto Flush

A. Turn off the selected chemical mixing pump. (Turn switch to off)

B. The NOxOUT A supply valve will immediately close and the water flush

solenoid valve will open.

C. The metering and mixing pumps will continue to operate for 60 seconds

to flush the NOxOUT from the system and replace it with water.



D. After 5 minutes, the pumps will stop. The system can then be turned off.

E. To flush out the other metering pump, select other pump, turn system on,

turn mixing pump to auto and then to off. The system will run for another 5

minutes and flush out the other pump.

V. Immediate Shutdown, No Auto Flush

A. Turn system switch knob to off from either the control room or from the

skid. System will immediately shut-down. Be sure that mixing pumps are

turned back to off so that they will not immediately start when the skid is

turned back on.

B. The skid will also shut off if there is a low-low level in the tanks. This is

the only trip that the system has.

VI. Alarm Points

A. Mixing skid shut-down and remote panel alarm.

1. Low-Low NOxOUT level in tanks.

B. System Alarm

1. Chemical Mixing pump motor starter failure.

2. Chemical Metering pump motor starter failure.

3. Low Atomizing pressure. This is 1 psig.

4. Low injector liquid pressure. This is 30 psig.

C. Metering pump and mixing pump Pilot lights on the remote panel are

normally on when equipment is running and will flash during an alarm

condition. All other alarms will flash when in alarm state.



VII. Operation of the Remote Controller

A. The NOxOUT system is controlled remotely by a single loop controller.

This SLC will run the system either manually or automatically. At this

present time, the controller is not configured to run in automatic.

B. Insure that the SLC is in manual by pushing the A/M button so that the

red dot is lit up next to the M.

C. On the right hand side are 5 letters, P, S, V, X, and Y. To Access each of

these letters, push the D button. This will scroll through each letter and light

up the letter that is accessed. P Process Variable. This is the actual NOx

Signal from the CEM. It will parallel closely with the chart recorder. S Set-

Point. For Auto mode only. This value will tell the SLC to try to operate to.

V Variable. For manual mode only. This value is the percent that the SLC is

telling the Metering pumps to operate at. 0 to 100% corresponds to 0 to 32

gph. 50% would be 16 gph. The value can be adjusted by turning the knob.

X This shows the amount of water in gpm being used by the skid. Y This is

the pressure at the air lance.

VIII. Calibration Column

A. The purpose of the calibration column is to verify that pumps are moving

the same amount of liquid that they have been set to. For example, if the

controller is set to 30%, the pumps should be moving 9.6 gph. By filling the

cal column and watching it drop, this amount can be verified.

B. Another use for the cal column is to check if the metering pumps are

moving liquid and are not air bound or have a sticky check valve. Fill the cal

column and see if it is being sucked down, if it is not, this would imply that

something is wrong with the pumps.

IX. Skid Water Bypass Valve and water supply.

A. The metering/mixing skid can be fed with water from the demin system

or from the city water system. For normal operation we will be using water

from the city water system. The city water root valve is located right above



the water meter on the steel pipe.

B. Demin water can also be used. Demin water is to be principally used to

cut the solution of urea in the tanks.

C. The skid water bypass valve is located near the NOxOUT A solenoids

and is painted red. The valve can be used for two purposes.

1. When the valve is opened with demin water on to the skid system, it will

allow the tanks to be backfilled with demin water. This is how the tanks are

filled.

2. Another use is to blow clear the metering pumps. This can be done by

closing the gate valve from the urea take off and turning on the city water

supply. The 60 psi in the city water supply system will push through the

metering pumps any air bubbles or urea crystals that may have formed. It is

important to realize that if the skid water bypass valve is left open, the tanks

will filled with water until there is a high alarm. This may cause the urea to

be so diluted that the metering pumps cannot move enough of it to meet the

boiler demands.

X. Recirculation Skid

A. The purpose of the recirc skid is to keep the urea in the tanks circulating

during cold weather and also to heat the urea as needed.

B. There are 2 recirc pumps, one for operation and one for standby. The

pumps can also be operated in automatic or manual.

C. In automatic, the pumps will shut down if the air temperature gets above

85 F. They will also start automatically again when the air temperature gets

below 85 F. Also while in automatic, the pumps will shut off if the tank level

goes to low.

D. The skid mounted heater is used to heat the urea up as it is circulated to

the tanks. The heater adds about 4 degrees to the urea as it is circulated and



raises the tank temperature about 1 degree and hour. The heater is

interconnected to the pumps so that it will shut off when the pumps shut off.

The heater cannot run if the pumps are not running. The heater is also

controlled by temperature switches in each tank. If the tank temperature gets

below 80 F in the west tank and below 85 F in the east tank, the heater will

be turned on.

XI. Urea Solution

A. The chemical that is used for NOx reduction is urea. This is a high

nitrogen content liquid that is also used by farmers to build soil nitrogen

levels. To this urea is also added an additive that modifies the urea a little

bit. The additive and the urea together are called NOxOUT A. The additive

is composed of 3 different solutions.

B. Urea at a 50% solution has a freezing point of 60 F. If the percentage of

urea is reduced,The freezing point will get lower. If urea is exposed to the

atmosphere, the water in it will evaporate and leave urea salt crystals behind.

These crystals are just like table salt. Washing down with water will wash

away the salt crystals.

XII. Injectors

A. At this time, the boiler will be using 3 sidewall injectors. Each injector

will inject urea into the boiler which will mix with the combustion gasses

and therefore reduce the amount of NOx in the gasses.

B. The injector has a center tube that is used to inject the urea. The outer

tube is used for atomizing air. The purpose of this air is to help break up the

urea droplets and dispense them throughout the boiler space so that they can

react with all of the NOx.

C. The atomizing air also is used to keep the injector tubes cool. It is

important to keep air on to the injectors at all times otherwise the tubes will

overheat. Although the tubes can take high heat for several minutes, several

hours will cause them to go limp.

OPERATIONS MANUAL

Number:

OM-519

Subject:




Current Issue:

Rev 0 (R0)

Issue Date:

Tbd

Page 1 OF 8

TABLE OF CONTENTS

SECTION TITLE PAGE

1. Purpose ........................................................................................ 2

2. Discussion .................................................................................... 2


4. Procedure .................................................................................... 3



1. PURPOSE

The purpose of these procedures is to provide a guideline to the general operations of the equipment at Hillman Power Plant. These procedures should be read and understood by all operators. It is mandatory that all employees adhere to these procedures for the safe operation of the equipment. These procedures should be used in conjunction with the applicable maintenance manuals, operation manuals, vendor manuals and standard power plant practices.

2. DISCUSSION

Prior to engaging any system, it is important to verify that all connections and associated apparatus are installed properly to assure the system performs correctly, efficiently, and safely. Remove all tools and other debris away from the system before starting.

3. RESPONSIBILITIES

A. The Plant Manager has overall responsibility for the development, revision, and implementation of these procedures.

B. The Operations Manager and the Maintenance Supervisor are responsible for the execution of this procedure.

C. The Control Room operator has responsibility to ensure these procedures are followed.

D. All employees are responsible for ensuring all safety procedures are followed, including the use of PPE.



FUEL TECH NOx REDUCTION SYSTEM

SEQUENCE OF OPERATION

I. Preparing the system for start-up.

A. Insure that recirculation system is running.

B. Open Urea supply gate valve located on recirc. skid.

C. Turn on city water supply to skid.

D. Make sure that all drains are shut.

E. Check that urea temperature is above its freezing point.

II. Pre-select Metering and Mixing Pumps, Line Up Skid.

A. Select the Mixing Pump A or B and the mode of operation, auto or

manual. In manual, either or both pumps can be operated from the skid. In

auto, the pump is tied into the auto shut-down system. The auto system flush

will only work with these pumps in auto.In manual, the pump will run even

if it is not selected.

B. Select the metering Pump, A or B and the mode of operation, local or

remote. Both switches must be in either local or remote otherwise neither

pump will run. In remote, the metering pump volume output is regulated by

the control operator at the remote panel in the control room.In auto the pump

is regulated by the adjustment knob located on the panel. This knob will

adjust the meter on the panel to read between 0% and 100%. The percent

reading on the meter will not necessarily correspond to the percent output of

the pump. The pump output should be checked using the calibration column.

C. Open the pressure control valve bypass valve. This relieves start-up surge



pressure from damaging the pressure transmitter. Close bypass valve.

III. Turn NOxOUT System ON.

A. The system can be run either locally from the skid or remotely from the

control room.

B. Operation

1. Verify that the skid metering pumps are both in remote.

2. Verify that mixing pumps are set to auto with one pump selected.

3. Turn system on from the skid. The system on switch light will

acknowledge that system is on.

4. The NOxOUT A supply valve will open automatically and the city water

supply valve on the skid will open automatically.

5. Any existing alarm conditions will show up at this time. If there is an

alarm, correct problem and acknowledge alarm.

6. Chemical metering pump acknowledge light will come on verifying that

the pump has power.

7. Chemical mixing pump acknowledge light will come on verifying that the

pump has power.

IV. Normal, Automatic Shutdown with Auto Flush

A. Turn off the selected chemical mixing pump. (Turn switch to off)

B. The NOxOUT A supply valve will immediately close and the water flush

solenoid valve will open.

C. The metering and mixing pumps will continue to operate for 60 seconds

to flush the NOxOUT from the system and replace it with water.



D. After 5 minutes, the pumps will stop. The system can then be turned off.

E. To flush out the other metering pump, select other pump, turn system on,

turn mixing pump to auto and then to off. The system will run for another 5

minutes and flush out the other pump.

V. Immediate Shutdown, No Auto Flush

A. Turn system switch knob to off from either the control room or from the

skid. System will immediately shut-down. Be sure that mixing pumps are

turned back to off so that they will not immediately start when the skid is

turned back on.

B. The skid will also shut off if there is a low-low level in the tanks. This is

the only trip that the system has.

VI. Alarm Points

A. Mixing skid shut-down and remote panel alarm.

1. Low-Low NOxOUT level in tanks.

B. System Alarm

1. Chemical Mixing pump motor starter failure.

2. Chemical Metering pump motor starter failure.

3. Low Atomizing pressure. This is 1 psig.

4. Low injector liquid pressure. This is 30 psig.

C. Metering pump and mixing pump Pilot lights on the remote panel are

normally on when equipment is running and will flash during an alarm

condition. All other alarms will flash when in alarm state.



VII. Operation of the Remote Controller

A. The NOxOUT system is controlled remotely by a single loop controller.

This SLC will run the system either manually or automatically. At this

present time, the controller is not configured to run in automatic.

B. Insure that the SLC is in manual by pushing the A/M button so that the

red dot is lit up next to the M.

C. On the right hand side are 5 letters, P, S, V, X, and Y. To Access each of

these letters, push the D button. This will scroll through each letter and light

up the letter that is accessed. P Process Variable. This is the actual NOx

Signal from the CEM. It will parallel closely with the chart recorder. S Set-

Point. For Auto mode only. This value will tell the SLC to try to operate to.

V Variable. For manual mode only. This value is the percent that the SLC is

telling the Metering pumps to operate at. 0 to 100% corresponds to 0 to 32

gph. 50% would be 16 gph. The value can be adjusted by turning the knob.

X This shows the amount of water in gpm being used by the skid. Y This is

the pressure at the air lance.

VIII. Calibration Column

A. The purpose of the calibration column is to verify that pumps are moving

the same amount of liquid that they have been set to. For example, if the

controller is set to 30%, the pumps should be moving 9.6 gph. By filling the

cal column and watching it drop, this amount can be verified.

B. Another use for the cal column is to check if the metering pumps are

moving liquid and are not air bound or have a sticky check valve. Fill the cal

column and see if it is being sucked down, if it is not, this would imply that

something is wrong with the pumps.

IX. Skid Water Bypass Valve and water supply.

A. The metering/mixing skid can be fed with water from the demin system

or from the city water system. For normal operation we will be using water

from the city water system. The city water root valve is located right above



the water meter on the steel pipe.

B. Demin water can also be used. Demin water is to be principally used to

cut the solution of urea in the tanks.

C. The skid water bypass valve is located near the NOxOUT A solenoids

and is painted red. The valve can be used for two purposes.

1. When the valve is opened with demin water on to the skid system, it will

allow the tanks to be backfilled with demin water. This is how the tanks are

filled.

2. Another use is to blow clear the metering pumps. This can be done by

closing the gate valve from the urea take off and turning on the city water

supply. The 60 psi in the city water supply system will push through the

metering pumps any air bubbles or urea crystals that may have formed. It is

important to realize that if the skid water bypass valve is left open, the tanks

will filled with water until there is a high alarm. This may cause the urea to

be so diluted that the metering pumps cannot move enough of it to meet the

boiler demands.

X. Recirculation Skid

A. The purpose of the recirc skid is to keep the urea in the tanks circulating

during cold weather and also to heat the urea as needed.

B. There are 2 recirc pumps, one for operation and one for standby. The

pumps can also be operated in automatic or manual.

C. In automatic, the pumps will shut down if the air temperature gets above

85 F. They will also start automatically again when the air temperature gets

below 85 F. Also while in automatic, the pumps will shut off if the tank level

goes to low.

D. The skid mounted heater is used to heat the urea up as it is circulated to

the tanks. The heater adds about 4 degrees to the urea as it is circulated and



raises the tank temperature about 1 degree and hour. The heater is

interconnected to the pumps so that it will shut off when the pumps shut off.

The heater cannot run if the pumps are not running. The heater is also

controlled by temperature switches in each tank. If the tank temperature gets

below 80 F in the west tank and below 85 F in the east tank, the heater will

be turned on.

XI. Urea Solution

A. The chemical that is used for NOx reduction is urea. This is a high

nitrogen content liquid that is also used by farmers to build soil nitrogen

levels. To this urea is also added an additive that modifies the urea a little

bit. The additive and the urea together are called NOxOUT A. The additive

is composed of 3 different solutions.

B. Urea at a 50% solution has a freezing point of 60 F. If the percentage of

urea is reduced,The freezing point will get lower. If urea is exposed to the

atmosphere, the water in it will evaporate and leave urea salt crystals behind.

These crystals are just like table salt. Washing down with water will wash

away the salt crystals.

XII. Injectors

A. At this time, the boiler will be using 3 sidewall injectors. Each injector

will inject urea into the boiler which will mix with the combustion gasses

and therefore reduce the amount of NOx in the gasses.

B. The injector has a center tube that is used to inject the urea. The outer

tube is used for atomizing air. The purpose of this air is to help break up the

urea droplets and dispense them throughout the boiler space so that they can

react with all of the NOx.

C. The atomizing air also is used to keep the injector tubes cool. It is

important to keep air on to the injectors at all times otherwise the tubes will

overheat. Although the tubes can take high heat for several minutes, several

hours will cause them to go limp.

September 2013

SPARE PARTS LIST FOR SNCR SYSTEM

1. Stainless steel ball valves. 2. Check valves. 3. Metering pump rebuild kit. 4. Mixing pump rebuild kit. 5. Recirculation pump rebuild kit. 6. Assorted stainless steel piping and fittings. 7. Urea injectors. 8. Strainers. 9. Pressure regulators.

10. Transmitter. 11. Pressure gauges. 12. Fuses. 13. Heat tracing. 14. Input controller module. 15. Output controller module. 16. Programming module. 17. Power supply. 18. Cassette backup program.

September 2013

SPARE PARTS LIST FOR MECHANICAL DUST COLLECTOR

1. Gear boxes. 2. Belts. 3. Bearings. 4. Packing. 5. Speed switches. 6. Augers. 7. Rotary valve. 8. Draft transmitters.

DURAG D-R 290 OPACITY ANALYZER 1. Measuring … · DURAG D-R 290 OPACITY ANALYZER Before proceeding...

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