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    Oxidation Air

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    KaremBenzema
    There are three oxidation air blowers that provide air to the absorber modules to aid the desulfurization process. Oxidation air works to convert calcium sulfite to calcium sulfate to prevent buildup in the absorber. Each blower is dedicated to an absorber, with one spare. Proper startup and shutdown procedures include flushing piping, adjusting dampers and valves, and maintaining cooling to protect equipment. The blowers are controlled by a PLC that automates sequences while operators manage auxiliary valves and water flows.

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    © All Rights Reserved
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    Oxidation Air

    Uploaded by

    KaremBenzema
    218 views38 pages
    There are three oxidation air blowers that provide air to the absorber modules to aid the desulfurization process. Oxidation air works to convert calcium sulfite to calcium sulfate to prevent buildup in the absorber. Each blower is dedicated to an absorber, with one spare. Proper startup and shutdown procedures include flushing piping, adjusting dampers and valves, and maintaining cooling to protect equipment. The blowers are controlled by a PLC that automates sequences while operators manage auxiliary valves and water flows.

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    There are three oxidation air blowers that provide air to the absorber modules to aid the desulfurization process. Oxidation air works to convert calcium sulfite to calcium sulfate to prevent buildup in the absorber. Each blower is dedicated to an absorber, with one spare. Proper startup and shutdown procedures include flushing piping, adjusting dampers and valves, and maintaining cooling to protect equipment. The blowers are controlled by a PLC that automates sequences while operators manage auxiliary valves and water flows.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    218 views38 pages

    Oxidation Air

    Uploaded by

    KaremBenzema
    There are three oxidation air blowers that provide air to the absorber modules to aid the desulfurization process. Oxidation air works to convert calcium sulfite to calcium sulfate to prevent buildup in the absorber. Each blower is dedicated to an absorber, with one spare. Proper startup and shutdown procedures include flushing piping, adjusting dampers and valves, and maintaining cooling to protect equipment. The blowers are controlled by a PLC that automates sequences while operators manage auxiliary valves and water flows.

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    © All Rights Reserved
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    of 38

    Tanjung Jati B Training

    OXIDATION AIR

    OPERATIONS
    OXIDATION AIR

    Tanjung Jati B Training

    PT Central Java Power


    Tanjung Jati B Units 1 & 2
    Flue Gas Desulfurization (FGD) System

    Absorber Area

    Dewatering
    Area

    Reagent Preparation
    Area

    Limestone Jetty
    And Conveyor

    Tanjung Jati B Training

    FGD Operations
    Oxidation Air
    There are three (3) 100% capacity Oxidation Air
    Blowers, one dedicated to each Absorber and one
    as a spare or standby blower.
    Oxidation Air functions to minimize the buildup of
    solids within the Absorber Module by converting
    Calcium Sulfite (CaSO3) to Calcium Sulfate (CaSO4).

    Tanjung Jati B Training

    FGD Operations
    Oxidation Air
    Gas to Sorbent (Limestone Slurry) Reaction

    CaCO3 + SO2 + H2O CaSO3 1/2H2O + CO2


    Calcium Carbonate
    (In Limestone)

    Flue
    Gas

    Calcium Sulfite

    Forced Oxidation Reaction

    CaSO3 1/2H2O + O2 + H2O CaSO4 2H2O


    Calcium Sulfate

    (There are many other intermediate reactions)

    Tanjung Jati B Training

    FGD Operations
    Oxidation Air

    Flue Gas

    Reaction
    Tank

    Oxidation Air
    Headers

    Tanjung Jati B Training

    FGD Operations
    Oxidation Air

    Dewatering
    Building

    PLANT
    NORTH

    Filter
    Feed Tank

    Oxidation
    Air Blowers

    Process
    Water Tank

    Mist Eliminator
    Wash Water Tank

    Tanjung Jati B Training

    PLANT
    NORTH

    FGD Operations
    Oxidation Air
    1

    1
    2
    3
    4
    5
    6
    7
    8
    9
    10
    11
    12
    13
    14

    UNIT-1 ABSORBER
    UNIT-1 RECIRCULATION PUMPS
    UNIT-2 ABSORBER
    UNIT-2 RECIRCULATION PUMPS
    FILTER FEED TANK
    ME WASH WATER TANK
    PROCESS WATER TANK
    VACUUM FILTERS
    OXIDATION AIR BLOWERS
    LIMESTONE SLURRY TANK
    LIMESTONE SILO A
    LIMESTONE SILO B
    LS BUCKET ELEVATOR & RAMP
    STACK

    PIPE
    RACK A

    5
    6
    14

    PIPE
    RACK B

    BURIED SEAWATER TERMINAL POINT


    11

    YARD PIPING
    10

    13
    12

    Tanjung Jati B Training

    FGD Operations
    Oxidation Air

    OXIDATION AIR BLOWERS


    Tanjung Jati B Training

    FGD Operations
    Oxidation Air
    For the proper operation of an Absorber Module,
    one (1) Oxidation Air Blower is required.
    Therefore, when two Absorber Modules are in service
    two blowers will be running and the third blower
    is used for standby if one blower were to trip.

    Tanjung Jati B Training

    FGD Operations
    Oxidation Air

    Each Oxidation Air Blower has its own dedicated


    Lube Oil Unit which provides the necessary
    lubrication for the Gear Increaser.
    A single Programmable Logic Controller (PLC)
    provides control and protection for all three
    Blowers.
    The DCS, which interfaces with the PLC, has the
    capability to start and stop a given Blower.

    Tanjung Jati B Training

    FGD Operations
    Oxidation Air
    To Unit-1
    Absorber

    Lube Oil
    Skid

    To Unit-2
    Absorber

    Lube Oil
    Skid

    Lube Oil
    Skid

    PLC
    OXIDATION AIR BLOWERS
    Tanjung Jati B Training

    FGD Operations
    FGD Start-Up
    Each Absorber has a dedicated Blower. Here is the
    arrangement
    Blower A:
    Blower B:
    Blower C:

    Unit-1 Absorber only


    Unit-1 or Unit-2 Absorber (or standby)
    Unit-2 Absorber only

    Tanjung Jati B Training

    FGD Operations
    Oxidation Air

    We have already discussed the start-up of an


    Oxidation Blower, so lets have a short review
    regarding start-up then shutdown.
    You will recall that an Oxidation Air Blower can
    be started and stopped from the DCS or the
    local PLC.

    Tanjung Jati B Training

    FGD Operations
    Oxidation Air
    You will recall there are two different start-up
    scenarios
    Reaction Tank Level below the OA Headers
    Reaction Tank Level above the OA Headers

    Tanjung Jati B Training

    FGD Operations
    Oxidation Air

    OA HEADER ELEVATION
    -PIPE SIZING

    TEMPERATURE
    ELEMENT

    3.5 METERS

    1/2

    HUMIDIFICATION
    (SERVICE WATER)

    12

    FROM OXIDATION
    AIR BLOWER

    6
    ABSORBER
    MODULE

    FLUSH WATER
    (PROCESS WATER)

    = Manual Valve

    Tanjung Jati B Training

    FGD Operations
    Oxidation Air
    Reaction Tank Level is below OA Headers
    OA Blower can & should be started prior to
    increasing the Reaction Tank Level above the
    OA Header elevation.
    This assumes that the OA Blower was shutdown
    after the Reaction Tank Level went below the
    OA Header elevation (during an extended shutdown
    of the Absorber).
    Remember, an OA Blower cannot be started unless
    the Absorber Vent or Absorber Outlet Damper is open.
    Tanjung Jati B Training

    FGD Operations
    Oxidation Air
    Reaction Tank Level is above OA Headers
    The OA Headers and piping must be flushed prior
    to starting a Blower.
    The Air Isolation Valve must be closed prior to opening
    the Flush Water Isolation Valve.
    Both the Flush Valve & Air Isolation Valve are located
    near the Absorber Module.
    Remember, these valves are manually operated and
    have no position limit switches.
    Tanjung Jati B Training

    FGD Operations
    Oxidation Air
    FLUSHING
    OA PIPING & HEADER

    TEMPERATURE
    ELEMENT

    MANUAL
    FLUSH
    VALVE

    3.5 METERS

    MANUAL
    CONTROL VALVE

    MANUAL
    ISOL.VALVE

    HUMIDIFICATION
    (SERVICE WATER)
    FROM OXIDATION
    AIR BLOWER
    FLUSH WATER
    (PROCESS WATER)

    ABSORBER
    MODULE

    Tanjung Jati B Training

    FGD Operations
    Oxidation Air

    Prior to starting any Oxidation Air Blower be sure


    to walk down and inspect the entire system.
    Be sure there is cooling water available for the
    Blower Bearings and Lube Oil Unit.

    Tanjung Jati B Training

    FGD Operations
    Oxidation Air
    ATM
    INLET
    INLET
    SILENCER FILTER

    BLOWOFF
    SILENCER

    CROSSOVER
    TIE VALVE

    TO ABSORBER-1

    BLOWOFF
    VALVE

    DISCHARGE
    VALVE

    OUTLET
    SILENCER

    ATM

    INLET
    VALVE

    CLOSED
    CIRCUIT
    COOLING
    WATER

    A
    OXIDATION
    AIR BLOWER

    LUBE
    OIL SKID

    STARTING BLOWER A FOR UNIT-1 ABSORBER


    Tanjung Jati B Training

    FGD Operations
    Oxidation Air
    After an Oxidation Air Blower is started, water is
    introduced to the downstream piping to humidify
    the air to its saturation point.
    Why do we introduce water to humidify the air
    It eliminates the wet-dry interface between the
    Gypsum Slurry and Air Header Piping, thus
    minimizing the potential for deposits forming
    within the Air Headers and at the Header Nozzles.

    Tanjung Jati B Training

    FGD Operations
    Oxidation Air
    HUMIDIFICATION
    WATER

    TEMPERATURE
    ELEMENT

    MANUAL
    FLUSH
    VALVE

    3.5 METERS

    MANUAL
    CONTROL VALVE

    MANUAL
    ISOL.VALVE

    HUMIDIFICATION
    (SERVICE WATER)
    FROM OXIDATION
    AIR BLOWER
    FLUSH WATER
    (PROCESS WATER)

    ABSORBER
    MODULE

    Tanjung Jati B Training

    FGD Operations
    Oxidation Air

    Lets go through the basic steps for starting and


    stopping an Oxidation Air Blower from the DCS and
    local PLC Panel
    Once the start command from the DCS is generated
    the PLC will automatically start Lube Oil Unit, set the
    Blower Dampers to their proper position and start the
    Blower.

    Tanjung Jati B Training

    FGD Operations
    Oxidation Air
    When starting an OA Blower from the DCS, the PLC
    will automatically perform the following

    Start Lube Oil Unit


    Opens Blower Inlet Valve to predetermined position
    Opens Blowoff Valve to full open
    Opens Discharge Valve to full open
    Closes/Opens Crosstie Valve as required
    Blower Starts
    Blowoff Valve closes slowly
    Inlet Valve to automatic control

    Operator to open manual Humidification Valve to full open


    position
    Tanjung Jati B Training

    FGD Operations
    Oxidation Air
    ATM
    INLET
    INLET
    SILENCER FILTER

    BLOWOFF
    SILENCER

    CROSSOVER
    TIE VALVE

    TO ABSORBER-1

    BLOWOFF
    VALVE

    DISCHARGE
    VALVE

    OUTLET
    SILENCER

    ATM

    INLET
    VALVE

    CLOSED
    CIRCUIT
    COOLING
    WATER

    A
    OXIDATION
    AIR BLOWER

    LUBE
    OIL SKID

    STARTING BLOWER A FOR UNIT-1 ABSORBER


    Tanjung Jati B Training

    FGD Operations
    Oxidation Air
    Starting an OA Blower from the local PLC

    Blower Selector Switch to ON Position


    Select Blower B as Standby
    Open Blower Inlet Valve to predetermined position
    Open Discharge Valve to full open
    Start Blower
    Verify Blower Motor Amps and adjust Blower Inlet Valve
    if required..

    Operator to open manual Humidification Valve to full open


    position

    Tanjung Jati B Training

    FGD Operations
    Oxidation Air

    PLC
    BREAKER

    OXIDATION AIR BLOWER PANEL


    Tanjung Jati B Training

    FGD Operations
    Oxidation Air
    INLET
    VALVE

    OPEN

    BLOWER
    A OR C

    OPEN
    CLOSED

    MIDPOINT
    CLOSED

    BLOWOFF
    VALVE

    RUNNING

    FAULT

    SWITCH
    ON OFF

    PUSHBUTTONS
    START

    STOP

    JOG SWITCHES
    O I C

    INLET
    VALVE

    I C

    BLOWOFF
    VALVE

    Tanjung Jati B Training

    FGD Operations
    Oxidation Air
    INLET
    VALVE

    OPEN

    BLOWER B

    OPEN

    MIDPOINT

    CLOSED

    CLOSED

    BLOWOFF
    VALVE

    RUNNING

    FAULT

    SELECTOR
    SWITCH
    OFF

    PUSHBUTTONS
    START

    JOG SWITCHES

    STOP

    U2

    U1
    AUTO

    INLET
    VALVE

    BLOWOFF
    VALVE

    Tanjung Jati B Training

    FGD Operations
    Oxidation Air

    OXIDATION AIR PANEL

    POWER
    ON

    INLET
    VALVES
    M A

    GENERAL
    FAULT

    Tanjung Jati B Training

    FGD Operations
    Oxidation Air

    The optimum position of the Blower Inlet Valve before


    the Blower is started is based upon the Blower Motor
    Amps during normal operation and this position will be
    determined during Commissioning.
    These positions should be recorded and used for future
    reference.

    Tanjung Jati B Training

    FGD Operations
    Oxidation Air
    Stopping an OA Blower from the DCS
    Once a stop command is generated, the local PLC
    panel will automatically stop the Blower, stop the
    Lube Oil Unit and close the Blower Inlet and Outlet
    Valves.
    The Operator will need to close the OA Isolation Valve
    located near the Absorber Module & the Humidification
    Water Valve.
    It is good practice to keep cooling water flowing to
    the Blower Bearings until temperatures sufficiently
    low.
    Tanjung Jati B Training

    FGD Operations
    Oxidation Air

    OPERATING LEVEL
    &
    OA HEADER ELEVATION

    TEMPERATURE
    ELEMENT

    MANUAL
    FLUSH
    VALVE

    3.5 METERS

    MANUAL
    CONTROL VALVE

    MANUAL
    ISOL.VALVE

    HUMIDIFICATION
    (SERVICE WATER)
    FROM OXIDATION
    AIR BLOWER
    FLUSH WATER
    (PROCESS WATER)

    ABSORBER
    MODULE

    Tanjung Jati B Training

    FGD Operations
    Oxidation Air
    Stopping an OA Blower from the local PLC
    Stop Blower
    Close Inlet Damper
    Close Outlet Damper
    Keep cooling water circulating to the Blower Bearing
    to cool the bearings sufficiently (20-30 minutes)
    Operator to close the OA Isolation Valve located near the
    Absorber Module and close the Humidification Water Valve

    Tanjung Jati B Training

    FGD Operations
    Oxidation Air
    If the Absorber Module is to be shutdown and
    the slurry level of the Reaction Tank will be lowered
    below the OA Headers, the following should be
    performed
    Close OA Isolation Valve located near the Module
    Open the Flush Valve and flush for approximately
    5-10 minutes.

    Tanjung Jati B Training

    FGD Operations
    Oxidation Air

    FLUSHING THE
    AIR PIPING AND HEADERS

    TEMPERATURE
    ELEMENT

    MANUAL

    HUMIDIFICATION
    (SERVICE WATER)

    C CONTROL VALVE
    MANUAL
    FLUSH
    VALVE

    C
    O

    MANUAL
    ISOL.VALVE

    3.5 METERS

    ABSORBER
    MODULE

    FROM OXIDATION
    AIR BLOWER
    FLUSH WATER
    (PROCESS WATER)

    C = CLOSED
    O = OPEN
    Tanjung Jati B Training

    OPERATIONS
    OXIDATION AIR
    (END)

    Tanjung Jati B Training

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