OM1301 Overview of FGD Version G

Operation and Maintenance Manual
For
KHARTOUM NORTH POWER STATION-
PHASE III (2×100MW) PROJECT
Section 13
Section Name: FGD System &Equipment
Volume 01
Volume Name：Overview of FGD
Document No. KNPS-OM1301
Version G
1
Table of Contents
1 DESULFURIZING SYSTEM ................................................................................................. 5
1.1 BASIC TERMINOLOGY .................................................................................................... 5

1.2 PROCESS INTRODUCTION .............................................................................................. 6
1.3 BASIC CHEMICAL THEORY .............................................................................................. 7
1.4 BASIC FUNCTIONS OF MAIN SYSTEMS ............................................................................ 7
2 WASTE WATER TREATMENT SYSTEM .......................................................................... 10
2.1 INTRODUCTION ........................................................................................................... 10

2.2 TYPICAL VALUE OF CONTROL PARAMETERS ................................................................... 10
2.3 CONTROL INSTRUCTION FOR DESULFURIZATION WASTE WATER TREATMENT SYSTEM .... 10
2.4 OPERATION AND STOP OF SLUDGE RECYCLING SYSTEM AND WATER PUMP SWITCH
SEQUENCE ............................................................................................................................. 11
2.5 CONTROL INSTRUCTIONS ON FGD WASTE WATER DISCHARGE: .................................... 13
2.6 CONTROL INSTRUCTIONS ON SLUDGE DEHYDRATION SYSTEM ....................................... 13
2.7 CONTROL INSTRUCTIONS ON OVERFLOW SUMP DRAINAGE ........................................... 13
3 CONTROL LOGIC AND INTRODUCTION OF DESULFURIZING SYSTEM ................... 15
3.1 FLUE AND BOOSTER FAN SYSTEM............................................................................... 15

3.2 LP BAFFLE SEALING AIR FAN (L0HTW31AN001/L0HTW32AN001) ......................... 17
3.3 FGD INLET FLUE GAS BAFFLE (L0HTA01AA002/L0HTA02AA002) ......................... 19
3.4 FGD OUTLET FLUE GAS BAFFLE (L0HTA01AA003/L0HTA02AA003) ...................... 19
3.5 FGD BYPASS BAFFLE (L0HTA01AA001/L0HTA02AA001) ....................................... 19
3.6 BOOSTER FAN SYSTEM .............................................................................................. 20
3.7 SLURRY PREPARATION SYSTEM .................................................................................. 22
3.8 LIMESTONE CONVEYING SYSTEM ................................................................................ 23
3.9 MILL SUBSYSTEM ....................................................................................................... 24
3.10 MILL'S SLURRY RECYCLE SYSTEM .............................................................................. 26
3.11 LIMESTONE SLURRY SYSTEM ...................................................................................... 29
3.12 OXIDATION FAN SYSTEM .............................................................................................. 31
3.13 DEMISTER FLUSHING SUBGROUP ................................................................................. 31
3.14 INLET/OUTLET FLUSHING VALVE SYSTEM OF ABSORBER .............................................. 33
3.15 SLURRY RECYCLE PUMP SYSTEM OF ABSORBER ......................................................... 34
3.16 SLURRY DISCHARGE SYSTEM...................................................................................... 36
3.17 PH METER FLUSHING SYSTEM .................................................................................... 38
3.18 GYPSUM DEHYDRATION SYSTEM ................................................................................. 39
3.19 FILTRATE TANK SYSTEM ............................................................................................. 41
3.20 WASTE WATER TANK SUBGROUP ................................................................................ 42
3.21 ABSORBER SLURRY DISCHARGE AND PROCESS WATER SYSTEM.................................. 43
3.22 PROCESS WATER SYSTEM .......................................................................................... 43
3.23 DMC48 TYPE IMPULSE BAG TYPE DUST COLLECTOR .................................................. 44
2
4 L IM ESTONE SLURRY CHEMICAL DOSING SYSTEM ................................................ 46
4.1 LIQUID LEVEL CONTROL OF LIME PREPARATION BOX ..................................................... 46

4.2 OPERATION CONTROL OF LIMESTONE SLURRY RECYCLING PUMP:.................................. 46
4.3 OPERATION PROCEDURE OF CHEMICAL DOSING PUMP FOR LIMESTONE SLURRY ............. 46
4.4 LIQUID LEVEL CONTROL PROGRAM OF LIMESTONE SLURRY CHEMICAL DOSING BOX ........ 46
4.5 STOP AND SWITCH PROGRAMS OF LIMESTONE SLURRY CIRCULATING PUMP ................. 47
4.6 STOP AND SWITCH PROGRAMS OF LIMESTONE SLURRY CHEMICAL DOSING PUMP ........ 47
4.7 CONTROL PROGRAM OF FILTRATE BOX ....................................................................... 47
5 IN SPEC T ION AND PREPARATION OF FGD DEVICES .............................................. 48
5.1 GENERAL PROVISIONS OF ACCEPTANCE AFTER MAINTENANCE ...................................... 48

5.2 INSPECTION ON FDG DEVICE AFTER OOVERHAUL ....................................................... 48
5.3 INSPECTION AND PREPARATION BEFORE STARTUP ....................................................... 53
5.4 INSPECTION OF DISCHARGE SYSTEM BEFORE OPERATION ........................................... 57
6 PRO TEC T IVE TESTS FOR DESULFURIZATION SYSTEM ........................................ 59
6.1 INTERLOCK PROTECTION TEST OF FGD ...................................................................... 59

6.2 EMERGENCY BUTTON TEST METHODS ......................................................................... 59
6.3 ELECTRIC VALVE TEST................................................................................................ 60
6.4 TEST OF THE CONTROL VALVE AND CONTROL BAFFLE ................................................. 60
6.5 BOOSTER FAN INLET BAFFLE TEST ............................................................................. 61
6.6 ACOUSTIC-OPTICAL SIGNAL TEST ............................................................................... 61
7 STARTUP OF FGD EQUIPMENT ...................................................................................... 63
7.1 STARTUP PROCEDURE OF THE FGD EQUIPMENT ......................................................... 63

7.2 INSPECTION AND CONFIRMATION BEFORE INTEGRAL STARTUP ...................................... 63
7.3 STARTUP OF DESULPHURIZATION SYSTEM ................................................................... 63
7.4 INPUT SLURRY INTO THE ABSORBER SLURRY BASIN .................................................... 65
7.5 START OF LIMESTONE SLURRY PREPARATION SYSTEM ................................................. 67
7.6 START OF FGD BAFFLE SEALING SYSTEM .................................................................. 67
7.7 NORMAL START OF FGD DEVICE ................................................................................ 68
7.8 SHORT-TERM START ................................................................................................... 71
8 MAINTENANC E AFTER FGD SYSTEM START .................................................. 73
8.1 MONITORING AND REGULATION DURING OPERATION ..................................................... 73

8.2 PATROL INSPECTION ITEMS DURING OPERATION .......................................................... 75
9 SHUTDOWN OF FGD EQUIPMENT .................................................................................. 77
9.1 LONG-TERM SHUTDOWN .............................................................................................. 77

9.2 SHORT-TERM SHUTDOWN ........................................................................................... 79
9.3 SHORT-TIME SHUTDOWN ............................................................................................ 80
10 F GD DEVICE OPERATION ADJUSTMENT ................................................................. 82
3
10.1 MAIN TASKS FOR OPERATION ADJUSTMENT................................................................. 82
10.2 OPERATION ADJUSTMENT OF DESULFURIZATION SYSTEM ............................................. 82
10.3 INSPECTION DURING THE OPERATION OF DESULFURIZATION DEVICE ............................. 84
11 PROC EDUR ES FOR ACC ID ENT TR EAT M ENT AND EM ER GEN CY

SHUTD OWN OF FGD EQU IPMENT ................................................................................ 91
11.1 BASIC PRINCIPLES FOR ACCIDENT TREATMENT ........................................................... 91

11.2 MALFUNCTIONS OF FGD SYSTEM ............................................................................... 92
11.3 COMMON MALFUNCTIONS AND TREATMENT ................................................................. 97
11.4 PROCEDURES FOR EMERGENCY SHUTDOWN.............................................................. 103
12 O PERAT ION O F AUXIL IARY FGD EQU IPMENT .......................................... 105
12.1 GENERAL PROVISIONS OF AUXILIARY EQUIPMENT OPERATION ................................... 105

12.2 OPERATION AND MAINTENANCE OF AUXILIARY EQUIPMENT ........................................ 107
12.3 SHUTDOWN OF AUXILIARY EQUIPMENT ...................................................................... 108
12.4 EMERGENCY SHUTDOWN DUE TO MALFUNCTIONS OF AUXILIARY EQUIPMENT ............. 108
13 COMMON PROB LEMS DUR IN G TH E OPERAT ION AND MA IN TENANC E

O F L I M E STO N E-G Y PSU M F G D S Y S T EM .................................................................. 109
13.1 SULPHUR CONTENT IN FUEL OIL EXCEEDING THE STANDARD ..................................... 109
13.2 INSUFFICIENT OXIDIZING AIR ..................................................................................... 109
13.3 ‘VIRUS’ OF ABSORBER ............................................................................................... 110
13.4 TREATMENT OF ABSORPTION TOWER ‘VIRUS’ .............................................................. 110
13.5 EXCESSIVE FLY ASH .................................................................................................. 110
13.6 PROBLEMS CAUSED BY EXCESSIVE CL- ..................................................................... 111
13.7 PROBLEMS OF LIMESTONE QUALITY ........................................................................... 111
13.8 HIGH WATER PERCENTAGE OF GYPSUM ...................................................................... 111
13.9 PROBLEMS OF MECHANICAL SEAL ............................................................................. 112
13.10 PROBLEMS OF WATER BALANCE ................................................................................ 112
13.11 PROBLEMS OF OXIDIZATION AIR FAN .......................................................................... 112
13.12 PROBLEMS OF FLUSHING EFFECT OF DEMISTER ......................................................... 113
13.13 ABSORBER INLET FLUE GAS FLUSHING AND EMERGENCY ATTEMPERATOR .................. 113
13.14 RECYCLE PUMP OF ABSORBER .................................................................................. 113
13.15 VACUUM DEHYDRATION SYSTEM ................................................................................ 113
13.16 BYPASS FLUE GAS DAMPER ...................................................................................... 114
13.17 PROBLEM OF ABSORBER LIQUID LEVEL ..................................................................... 114
4
1 Desulfurizing system
1.1 Basic terminology

1.1.1 Oxidation
The sulfur dioxide (SO2) absorbed in the FGD system reacts with
oxygen (O2) , generating sulfate (SO42-).
1.1.2 Limestone (CaCO3)
It is kind of alkaline ore added to the FGD system. Reacts with acidic
sulfur dioxide (SO2) of the flue gas becoming neutralized; the source of
calcium ion (Ca2+).
1.1.3 pH
Measuring standard of solution acidity and alkalinity
1.1.4 Slurry density
Measurement of the solid concentration in slurry.
1.1.5 Acid non-soluble matter
It is also called inert matter, refers to the scrubber solid matter that
does not dissolve in the strong acid. The acid insoluble matter is the
measure of fly ash and other inert maters in the scrubber solid matter.
1.1.6 Ion
An atom or molecule with positive charge (+) or negative charge (-)
Ions with different charges often react with each other to generate
deposition or ion pair.
1.1.7 Deposition
The tendency of the ions in the solution to form solid.
1.1.8 Dissolution
The tendency that the solid in the solution dissolves and generates
ions.
1.1.9 Blind area
The tendency that the ions in the solution constrain dissolution of solid.
1.1.10 Sulphite oxidation
The quantity of sulphite producing by SO2 oxidization divides the

quantity of absorbed SO2.
5
Analyze the solid SO42- and SO32-.
1.1.11 Blowdown (Bleed) quantity
The quantity of slurry or solution removed with the FGD process.
1.1.12 Reclaim Water
The filtrate returns to FGD system after the solid in the slurry is
condensed and removed.
1.2 Process Introduction

The limestone (lime)-gypsum wet FGD process mainly uses the cheap
limestone as the desulphurization absorbent. The limestone is milled to
powder blending with water to generate absorption slurry. In the
absorber, the slurry is mixed with flue gas. Then the SO2 in the flue gas
reacts with the calcium carbonate and the air blown in, finally being
absorbed and desulfurized to become gypsum. The desulfurized flue
gas is discharged by the boost air fan via the funnel after demisted by
the demister and heated with the heater. The gypsum in the process
can be utilized for other purposes. The wet limestone FGD flow mainly
includes limestone slurry preparation system, flue gas system,
absorber system, gypsum dehydration system, air compressing system,
process water system and waste water processing system etc. The
main process is as follows:
The SO2 in the flue gas is absorbed into the circulating slurry in the
absorber.
The circulating slurry contains limestone and deposited calcium

sulphate.
Add limestone to the process to offer an alkaline environment and

calcium ion (Ca2+ sources).
The air blown in the absorber oxides the absorbed SO2 into sulfate
(SO42-).
The SO42- in the solution reacts with the calcium ion to generate
gypsum.
Separate the deposited gypsum from the slurry and the water is
removed. This is the solid by-product of the process. The filtrate returns
to the FGD system.
6
1.3 Basic chemical theory
1) SO2 absorption: SO2 + H 2O → H 2 SO3 (1)

−
H 2 SO3 → H + + HSO3 (2)
− 1 =
2) Oxidation: HSO3 + O2 → H + + SO4 (3)
2
3) Limestone dissolution: CaCO3 + 2 H + → Ca + + + CO2 + H 2O (4)
=
4) Deposit Ca + + + S O4 + 2 H 2O → CaSO4 *2 H 2O (5)
5) SO2 absorption and reaction:
CaCO3 + SO2 + H2O ◊ CaSO3.1/2H2O+1/2H2O+CO2
CaSO3.1/2H2O+SO2+1/2H2O ◊ Ca(HSO3）2
From this, we can see when the pH value is lower, it is easy to dissolve
the limestone; while the pH value is high it is easy to absorb SO2. Thus
dissolving much limestone is helpful to increase the pH value to absorb
SO2.
Oxidation reaction: Blow in air to oxidize the CaSO3 •½H2O (Calcium

Sulfite) into CaSO4 •2H2O crystal.
Ca(HSO3）2 ＋1/2O2+2H2O ◊ CaSO4.2H2O+H2O+SO2
CaSO3(1/2H2O)+ 1/2O2+2H2O ◊ CaSO4.2H2O+1/2H2O
1.4 Basic Functions of Main Systems
1.4.1 Absorber system
Function:
Housing the circulating slurry
Reserve time for the limestone dissolving and gypsum depositing
The place where the limestone is fed.
The place where the air is blown in for oxidation.
7
1.4.2 Flue gas system
1.4.3 Limestone absorbent preparation system;
Receive and store a large quantity of limestone;
Mill the limestone to granule of appropriate size;
Prepare slurry with the ground limestone powder and liquid;
Store limestone slurry;
Deliver the limestone slurry to the FGD system when necessary.
1.4.4 Gypsum dehydration and disposal system;
Separate the solid from the slurry;
Produce recyclable or discarded solid by-product;
The water returns to the FGD system.
1.4.5 Air system
8
Supply oxygen necessary for oxidizing the absorbed SO2 to sulfate;
SO42- and calcium will deposit to produce gypsum.
1.4.6 Demisting system
Function: separate and remove the slurry solution drops in flue gas.
Separate and remove the slurry drip in the gas
Direction
Vertical air flow
Horizontal air flow
Design
Blade shape
Even and apex design

The design and performance of flushing system is critical to keep the
demister clean
Air flow
Air flow
Horizontal air flow ME Vertical air flow ME
9
2 Waste Water Treatment System
2.1 Introduction
With a series of physical and chemical treatment procedures, the waste

water produced in the FGD system is discharged after reaching the
standard of non-pollution discharge.
2.2 Typical value of control parameters
1) System: spraying the empty tower, compulsive oxidation,

limestone absorbent;
2) pH value: 5.5-6.0;
3) Circulating slurry density: 8% -15% (weight);
4) Limestone grinding fineness: 80-90% of the ground powder can

pass the 325 mesh screen;
5) Hydraulic cyclone operation: the underset contains 45-55% of

solid (weight) and the solid contained in the overall <2 %
(weight);
6) Filter operation –moisture <15 % (weight);
7) Filter cake flushing – chlorine ion concentration <150 ppm
2.3 Control Instruction for Desulfurization Waste Water Treatment

System
1) When waste water general flow meter L0HTS50CF101 has a

flow signal, the organic sulfur, coagulant aid, and coagulant
chemical dosing pump, neutralization box agitator
L0HTZ11AM001, sedimentation box agitator L0HTZ12AM001,
and flocculation box agitator L0HTZ13AM001 start. Start
chemical dosing pump of limestone slurry L0HTS53AP001 or
L0HTS54AP001.
2) When the PH value of water outlet box is higher than 9, start the
HCl chemical-dosing pump; when lower than 8, stop HCl dosing
pump.
3) When the flowmeter L0HTZ30CL101 is higher than 2.0m,

high-level alarm occurs; when higher than 1.5m, start the water
outfall pump; when higher than 0.8m, start the agitator of water
outfall box L0HTZ30BB001. When the flowmeter L0HTZ30CL101
10
is lower than 1.1m, low-level alarm occurs; when lower than 0.8,
start the alarm and turn off the agitator and water outfall pump of
water outfall box L0HTZ30BB001.
4) According to waste water inlet flowmeter L0HTS50CF101,

automatically adjust the coagulant aid dosage pump, organic
sulfide measuring pump and the dosage amount for FeClSO4
measuring pump in a certain proportion. Initial set valve of
dosage goes as follows (revise it when commissioning):
z When the assumed value of waste water admission

flowmeter 9HTG30CF001 is 4.5m3/h:
z Flow value of coagulant aid measurement pump is 20L/h

(solution concentration 0.02%)
z Flow value of FeClSO4 measurement pump is 5L/h

(solution concentration 4%)
z Flow value of organic sulfur measurement pump is 4L/h

(solution concentration 0.5%)
2.4 Operation and Stop of Sludge Recycling System and Water Pump
Switch Sequence
2.4.1 Operation of sludge recycling system
z Operation of sludge recycling system: When the sludge level meter

L0HTZ20CL101 reaches 2m, the sludge recycling pump
L0HTZ21AP001 or L0HTZ22AP001 starts and keeps operating.
z Start operation sequence: close L0HTZ20AA202 valve

→L0HTZ20AA201 valve open, sludge recycling pump
L0HTZ21AP001 or L0HTZ22AP001 starts to run.
2.4.2 Stop of sludge recycling system
z When the sludge level meter L0HTZ20CL101 is lower than 1.5m,

the sludge recycling pump stops running.
z Stop operation sequence: 05HTQ70AA201 valve open

→L0HTZ20AA201 valve close → delay for three minutes
→05HTQ70AA201 valve close →sludge recycling pump stops
running.
2.4.3 Switch of sludge recycling water pump
1) In the event that the sludge recycling pump L0HTZ21AP001 or
11
L0HTZ22AP001 stops due to check or accident, sludge recycling
pump L0HTZ22AP001 or L0HTZ21AP001 starts running.
2) Sludge recycling pump switch sequence: 05HTQ70AA201 valve

open →L0HTZ20AA201 valve close → delay for three minutes
→sludge recycling pump L0HTZ51AP001 or L0HTZ52AP001
stops →sludge recycling pump L0HTZ52AP001 or
L0HTZ51AP001 starts →L0HTZ20AA201 valve open
→05HTQ70AA201 valve close (delay time is subjected to
correction during commissioning)
3) Liquid level control of measurement box L0HTS21BB001 or

L0HTS22BB001 for organic sulfur chemical dosing equipment:
z When L0HTS21CL001（L0HTS22CL001） is lower than

0.5m, output alarm signals;
z When L0HTS21CL001（L0HTS22CL001）is lower than 0.4m,

output alarm signals, stop the pump and the agitator.
z Liquid level control of measurement box L0HTS41BB001 or

L0HTS42BB001 for FeClSO4 chemical dosing equipment:

output alarm signals;

output alarm signals, stop the pump, and the agitator.
2.4.4 Liquid level control of measurement box L0HTS20BB001 for coagulant

aid chemical dosing equipment:
1) When L0HTS20CL001 is lower than 0.4m, output alarm signals;
2) When L0HTS20CL001 is lower than 0.3m, output alarm signals,

stop the pump and the agitator.
3) Liquid level control of HCl chemical dosing storage tank

L0HTS10BB001:
4) When L0HTS10CL101 is lower than 0.1m, output alarm signals;
5) When L0HTS10CL101 is lower than 0.05m, output alarm signals,

and stop the pump.
6) When flow signal of waste water inlet flowmeter L0HTS50CF101

is 0, stop the organic sulfide measuring pump to the sediment
box, FeClSO4 measuring pump to the flocculation box, and the
coagulant aid measuring pump to flocculation box.
12
7) When waste water inlet flowmeter L0HTS50CF101 has no flow
signal, stop the limestone slurry chemical dosing pump to the
neutralization box, and start the stop program of limestone slurry
chemical dosing pump.
2.5 Control Instructions on FGD Waste Water Discharge:
1) When the liquid level meter L0HTZ30CL101 reaches 2.0m, Open

L0HTZ30AA201, and start water outfall pump L0HTZ31AP001 or
L0HTZ32AP001;
2) When pH value L0HTZ30CQ101 of the main water outfall pipe is

between 6 and 9, and the turbidity L0HTZ30CD102 is less than
50mg/l, open valve L0HTZ30AA203, close valves of
L0HTZ30AA204 and L0HTZ30AA205.
3) When pH value L0HTZ30CQ101 of the main water outfall pipe is

not between 6 and 9, then open valve L0HTZ30AA204 and close
valve L0HTZ30AA203.
4) When the turbidity in the main water outfall pipe L0HTZ30CD102

is less than 50mg/l, open valve L0HTZ30AA205 and close valve
L0HTZ30AA203.
2.6 Control Instructions on Sludge Dehydration System
1) When sludge/concentrator L0HTZ20CL101 reaches 2.5m, Open

valves L0HTZ20AA202 and L0HTZ20AA204, and close valve
L0HTZ20AA201. Start the start program of sludge dehydrator.
2) When the sludge/concentrator L0HTZ20CL101 reaches 2.0m,

the sludge dehydrator stops running. Start pipe flushing program.
Close valves L0HTZ20AA202 and L0HTZ20AA204, and open
valve L0HTQ70AA202.
3) Delay for one minute when starting the sludge conveying

low-pressure pump (the delay time is subjected to correction
during commissioning). Turn off valve L0HTQ70AA202.
2.7 Control Instructions on Overflow Sump Drainage
1) When the liquid level meter reaches 1.8m, high-level alarm

occurs.
13
2) When the liquid level meter reaches 1.4m, start drainage pump
L0HTZ71AP001 or L0HTZ72AP001.
3) When the liquid level meter reaches 0.6m, start agitator

L0HTZ70AM001.
4) When the liquid level meter is lower than 0.8m, low-liquid alarm
occurs.
5) When the liquid level meter is lower than 0.6m, stop blowdown
pump L0HTZ71AP001 or L0HTZ72AP001, and stop agitator
L0HTZ70AM001.
6) When the content gauge L0HTZ70CL101 issues the alarm of

high liquid level, turn off the water feeding general valve
L0HTZ11AA201.
14
3 Control Logic and Introduction of Desulfurizing
System
3.1 Flue and Booster Fan System
3.1.1 FGD flue system sequence control
1) Sequence startup (applicable to the cell unit)
Permit condition: No FGD isolation condition exist.
Steps:
A. Open FGD outlet baffle (L0HTA01AA003/L0HTA02AA003);
B. Start the booster fan (L0HTC10AN001/L0HTC20AN001)

(this step should include the operation of the fan inlet and
outlet valve/blade) ;
C. Open FGD inlet baffle within 10 seconds (adjustable) when

the booster fan starts;
D. Shut down the bypass flue gas baffle

(L0HTA01AA001/L0HTA02AA001)? Consider not shutting
down the bypass in the sequence control and make the
operator to shut down the bypass manually.
3.1.2 Sequence stop
Steps：
1) Open the bypass flue gas baffle

(L0HTA01AA001/L0HTA02AA001);
2) Shut down the booster fan

(L0HTC10AN001/L0HTC20AN001). (This step should
include the operation of the fan inlet and outlet
valve/blade);
3) Close the FGD inlet baffle

4) Close the FGD outlet baffle

(L0HTA01AA003/L0HTA02AA003).
3.1.3 FGD isolation
1) Removal condition (logic)
A. Four circulating pumps of the absorber fail at the same time
15
(L0HTF11AP001/ L0HTF12AP001/ L0HTF13AP001/
L0HTF14AP001)(Isolate FGD of two units)
B. FGD inlet unprocessed flue gas temperature > highest

temperature 180℃(L0HTA10CT301/ L0HTA10CT302/
L0HTA10CT303)(select two out of three, delay 3 seconds
because the testing point shows the temperature of the
mixed flue gas at the outlet of two booster fans. Thus, it is
necessary to isolate the FGD of two units).
C. The inlet baffle is not open when the booster fan operates
for 60 seconds (L0HTA01AA002/L0HTA02AA002) (Isolate
the FGD of the corresponding unit)
D. Dust density alarm added;
E. Two booster fans trip(L0HTC10AN001/L0HTC20AN001);
F. Two boilers MFT (50DAS01FU001/60DAS01FU001);
G. The bypass baffle differential pressure lower than the

designated lower pressure or higher than the designated
high pressure (Isolate the FGD of the corresponding unit)
(L0HTA01DP101/L0HTA01DP102/L0HTA01DP103/
L0HTA02DP101/L0HTA02DP102/L0HTA02DP103)(select
two out of three, isolate the FGD system of the
corresponding unit);
H. Three of the four absorber agitators stop

(L0HTD01AM001YB01/ L0HTD01AM002YB01/
L0HTD01AM003YB01/ L0HTD01AM004YB01）(Isolate the
FGD system of two units);
I. The FGD inlet gas pressure high high, low low

((L0HTA10CP101/L0HTA10CP102/L0HTA10CP103, select
two out of three); FGD outlet gas pressure high high, low
low, isolate the FGD system;
J. FGD outlet and inlet valves closed.
2) Isolation steps
A. Open the bypass flue gas baffle

B. Stop the booster fan (L0HTC10AN001/L0HTC20AN001);
C. Close the FGD inlet baffle

16
D. Close down the FGD outlet baffle
E. One boiler MFT (50DAS01FU001/60DAS01FU001);
F. Any boiler Run Back (50DAS01FU003 or

50DAS01FU004/60DAS01FU003 or 60DAS01FU004);
G. One booster fan trips;
H. Open the bypass baffle (two sets).
3.2 LP Baffle Sealing Air Fan (L0HTW31AN001/L0HTW32AN001)
Startup conditions:
Any of the baffle valves is closed (any bypass baffle valve, FGD flue
gas outlet valve closed, FGD flue gas inlet valve closed).
3.2.1 Lower pressure baffle sealing air heater (L0HTW31AC001)
1) Startup conditions：
A. Any of the lower pressure baffle sealing air fan running;
B. The sealing air temperature is not high (L0HTW31CT101);
C. Interlock;
D. When sealing air temperature (L0HTW31CT101) is high,

the interlock stops; when low, the interlock starts.
2) Sequence startup
A. Permit:
Any of the baffle valves is closedown (any of the bypass

baffle valve, FGD flue outlet valve closedown, the FGD flue
inlet valve closedown)
B. Steps
a) Start any of the lower pressure baffle sealing air fan

(L0HTW31AN001/L0HTW32AN001)
b) Start the lower pressure baffle sealing air electric

heater (L0HTW31AC001)
3) Sequence stop:
Steps:
17
A. Stop the lower pressure baffle sealing air electric heater
(L0HTW31AC001);
B. Delay shutdown of the two lower pressure baffle sealing air

fans by half an hour (L0HTW31AN001/L0HTW32AN001).
3.2.2 High pressure baffle sealing air fan

Start-up conditions:
Booster fan outlet baffle valve is closedown

3.2.3 High pressure baffle sealing air electric heater (L0HTW32AC001)
1) Start-up conditions:
A. Any of the high pressure baffle sealing air fan operates
B. The sealing air temperature is not high (L0HTW32CT101)
C. Interlock
D. When sealing air temperature (L0HTW32CT101) is high,

the interlock stops operation; when the temperature is low,
the interlock starts
2) Consequence startup
A. Permit conditions:
B. Steps
Start any of the high pressure baffle sealing air fan

(L0HTW33AN001/L0HTW34AN001).
Start the high pressure baffle sealing air electric heater

(L0HTW32AC001).
3) Sequence Stop
Steps
A Stop the high pressure baffle sealing air electric heater

(L0HTW32AC001)
B Shut down two high pressure baffle sealing air fans by half
an hour delay (L0HTW33AN001/L0HTW34AN001)
18
3.3 FGD Inlet Flue Gas Baffle (L0HTA01AA002/L0HTA02AA002)
1) Startup permit: Any of the booster fan running
2) Shutdown permit:The bypass baffle of the corresponding unit is

open.
3) Override shutdown permit: FGD system is isolated and the

corresponding bypass baffle is open.
3.4 FGD Outlet Flue Gas Baffle (L0HTA01AA003/L0HTA02AA003)
1) Shutdown permit: No N/A
2) Override shutdown permit: GD system is isolated and the

corresponding bypass baffle is open
3.5 FGD Bypass Baffle (L0HTA01AA001/L0HTA02AA001)
1) Shutdown permit:
A. No FGD isolation conditions;
B. The outlet baffle of any unit is open;
C. The inlet baffle of the corresponding unit is open;
D. Any of the booster fan running;
E. The inlet guide blade of any booster fan is not at the

minimum position (L0HTC10AS001/L0HTC20AS001> 5%).
2) Override start:
A. FGD isolation occurs;
B. The inlet baffle of the FGD system of the corresponding unit

is closed;
C. The FGD inlet flue gas pressure high high

(L0HTA10CP101/ L0HTA10CP102/ L0HTA10CP103)
(select two out of three, delay 3 seconds);
D. The FGD inlet flue gas pressure low low (L0HTA10CP101/

L0HTA10CP102/ L0HTA10CP103) (select two out of three,
delay 3 seconds);
E. Any boiler RUN BACK (50DAS01FU003 or

50DAS01FU004/60DAS01FU003 or 60DAS01FU004）.
F. One booster fan trips.
19
3.6 Booster Fan System
3.6.1 Booster fan
1) Startup permit:
a) FGD outlet processed flue gas baffle is open

(L0HTA01AA003/ L0HTA02AA003）(any one);
b) FGD inlet unprocessed flue gas baffle is open

(L0HTA01AA002/ L0HTA02AA002) (any of them);
c) At least one of the four slurry circulating pumps running

(L0HTF11AP001/ L0HTF12AP001/ L0HTF13AP001/
L0HTF14AP001);
d) The lubricant volume normal (L0HTC12CF001/

L0HTC22CF001);
e) The hydraulic oil pressure normal (L0HTC11CP001/

L0HTC11CP002/ L0HTC21CP001/ L0HTC21CP002);
f) The sealing air pressure normal (L0HTC14CP002/

L0HTC24CP002/ L0HTC14CP001/ L0HTC24CP001);
g) The blade is at the minimum opening angle

(L0HTC10AS001XB02 / L0HTC20AS001XB02);
h) No alarm signals of high temperature of the fan bearing;
i) No alarm signals of high temperature of the motor bearing;
j) No alarm signals high temperature of the motor stator;
k) The inlet flue gas temperature is not higher than 210Ԩ
l) No trip conditions for the booster fan.
2) Stop permit
a) The FGD bypass baffle of any unit is open;
b) BUF inlet baffle fails to open within 120 seconds (adjustable)

after the booster fan starts;
c) The FGD system is isolated and all the bypass dampers

have been open;
d) Booster fan bearing temperature> 100℃

（L0HTC10CT301--06/ L0HTC20CT301--06）;
e) Motor bearing temperature＞95℃（L0HTC10CT307—08/
20
L0HTC20CT307—08;
f) Motor stator temperature ＞155℃（L0HTC10CT309—14/

L0HTC20CT309—14）;
g) Bearing vibrate violently (L0HTC10AS001XB23/

L0HTC10AS001XB43/ L0HTC20AS001XB23/
L0HTC20AS001XB43）(delay 3 seconds);
h) Stall alarm signals and the inlet guide blade position >42%
（L0HTC10CP001/L0HTC20CP001, delay 120 seconds）;
i) Sealing pressure of air intake case <250Pa(2.5mbar), time

delay 240 min(L0HTC14CP002/ L0HTC24CP002) ;
j) The diffuser sealing pressure <250Pa(2.5mbar), time delay

240 min (L0HTC14CP001/ L0HTC24CP001) .
3.6.2 Lubricant pump
Interlock startup: The interlock system is put into operation and the
lubricant oil volume is low. Will the interlock starts the standby pump?
3.6.3 Hydraulic oil pump
Interlock startup: The interlock system is put into operation and the
hydraulic oil pressure is low. Interlock starts the standby pump.
3.6.4 Air intake case sealing air fan
Interlock startup: The interlock system is put into operation and the air
intake case sealing pressure is lower. Interlock start the standby pump.
3.6.5 Diffuser sealing air fan
1) Interlock startup: The interlock system is put into operation and

the diffuser sealing pressure is low. Interlock start the standby
pump.
2) Sequence startup
A. Open the outlet baffle
B. Start the diffuser sealing air fan
C. Start any of the lubricant pumps
D. Start any of the hydraulic oil pumps
E. Start air intake case sealing air fan
F. Close the booster fan blade
21
G. Start the booster fan
H. Open the fan inlet baffle (adjustable) after the booster fan
starts 10 seconds
3) Sequence Stop
A. Stop the booster fan
B. Close the booster fan inlet baffle
C. Close the outlet baffle
Stop the diffuser sealing air fan and the air intake case sealing air
fan when the booster fan stops operation for 2 hours?
4) Outlet and inlet baffles interlock: BUF trips, the outlet and inlet
baffles is closed interlock.
3.7 Slurry Preparation System
1) Sequence startup
A. Permit conditions:
The limestone storehouse material level is not lower while

the liquid level of the limestone slurry tank is not high
(L0HTK20CL001,L0HTJ10CL101).
B. Steps:
a) Start the selected ball mill slurry tank agitator

(L0HTK41AM001/L0HTK42AM001);
b) Start the selected mill slurry circulating system (the

sequence control program is followed);
c) Start the selected mill system (the sequence control

program is followed)
(L0HTK31AJ001/L0HTK32AJ001);
d) Delay 10 seconds, start the selected limestone belt

doser (L0HTK21AF001/L0HTK22AF001) ;
e) Open the gate valve of the selected limestone belt

weighing machine (L0HTK23AF001/ L0HTK23AF002).
2) Sequence stop
Steps:
22
A. Close the gate valve of the selected limestone belt weighing
machine (L0HTK23AF001/ L0HTK23AF002);
B. Stop the selected limestone belt weighing machine .

(L0HTK21AF001/L0HTK22AF001);
C. Delay 20 seconds, stop the selected mill

(L0HTK31AJ001/L0HTK32AJ001);
D. Stop the selected mill circulating system;
E. Stop the selected mill circulating tank agitator.
3) Interlock stop
A. Interlock conditions:The limestone slurry tank level HH
B. Steps: Both of the two slurry preparation systems stop

interlock and the steps are the same as the sequence stop.
3.8 Limestone Conveying System
3.8.1 Limestone vibrating feeder (L0HTK10AF001) dust catcher of powder

silo and the feeder start simultaneously
z Startup permit condition: The hopper-type lift

started(L0HTK10AF002)
z The interlock stopped: The hopper-type lift

stopped(L0HTK10AF002)
3.8.2 Hopper-type lift (L0HTK10AF002)
z Startup conditions
The vibrator running.
The limestone chamber material level is not high

(L0HTK20CL001).
z The interlock stop
The limestone chamber material level is high high

(L0HTK20CL001)
3.8.3 Limestone belt weigh feeder
z Startup conditions
The corresponding mill is operating;
23
No trip condition exists.
z Interlock stop
a) The corresponding mill stops.
b) Trip
c) Materials unsupplied
(L0HTK21AF001XB33/L0HTK22AF001XB33)
d) The material is jammed

e) Non-alignment
f) A signal of chain broken appears, delay 2 seconds
g) Transducer adjusting signal interlock
h) The limestone slurry circulating tank liquid level HH; the

interlock revolution is set to 0(L0HTK21AF001YQ01/
L0HTK22AF001YQ01)
3.8.4 Limestone chamber electric steel bar valve (L0HTK22AF001/

L0HTK23AF001)
z Interlock start: The corresponding limestone belt weigh feeder is

operating.
z Interlock stop: The corresponding limestone belt weigh feeder

stops.
3.9 Mill Subsystem
3.9.1 Mill
1) Startup permit conditions:
A. Main motor stator temperature not high (<70 ℃，

L0HTK31CT301—06/ L0HTK32CT301—06);
B. The main motor drive-end bearing temperature not high

(<50 ℃，L0HTK31CT307/L0HTK32CT307）;
C. The temperature of the non-driven end bearing of the motor

not high (<50 ℃，L0HTK31CT308/L0HTK32CT308)
D. The front bearing temperature not high (<70 ℃，
24
L0HTK31CT309/L0HTK32CT309);
E. The rear bearing temperature not high (<70 ℃，

L0HTK31CT310/L0HTK32CT310);
F. The liquid level of corresponding mill slurry tank not high

(L0HTK41CL101/L0HTK42CL101);
G. The corresponding mill slurry tank agitator running

(L0HTK41AM001/L0HTK42AM001);
H. The bearing lubricant pressure>0.1Mpa;
I. No alarm of high differential pressure of bearing lubricant

filter happens;
J. The air fan of the lubricant spraying system is working.
2) Trip conditions:
A. Main motor stator temperature is high high, delay 5 seconds

(>90℃，L0HTK31CT301—06/ L0HTK32CT301—06).
B. Main motor drive-end bearing temperature high high, delay

5 seconds (>90℃，L0HTK31CT307/L0HTK32CT307).
C. Motor non-drive end bearing temperature high high, delay 5

seconds (>90℃，L0HTK31CT308/L0HTK32CT308).
D. Front bearing temperature high high, delay 5 seconds

(>90℃，L0HTK31CT309/L0HTK32CT309)
E. Rear bearing temperature high high, delay 5 seconds

(>90℃，L0HTK31CT310/L0HTK32CT310)
F. The corresponding mill slurry agitator stops, delay 10

seconds.
G. Lube oil pressure low low (pressure switch, <0.05Mpa)
H. The oil temperature at the outlet of the oil station is higher

than the designated high level (temperature switch, >55℃)
I. The lubricant supply system fails to lubricate the gears for

more than one circulation.
3.9.2 Mill bearing lubricant pump
z Startup condition:The bearing lubricant tank oil level is not low.
z Interlock startup:The interlock system runs, the operating pump

trips or the lubricant pressure is low (<0.1MPa)
25
3.9.3 Mill bearing lubricant tank heater
z Interlock startup: The bearing lubricant tank temperature <15℃

(No temperature testing points, only two DI points)
z Interlock stop: The bearing lubricant tank temperature >25℃.
3.9.4 Bearing lubricant tank cooler
Interlock
A. Select 1# cooler (or 2# cooler) as the main cooler and the other
cooler as standby.
B. When the oil inlet temperature is higher than 45℃, start the main
cooler;
C. When the temperature at the oil outlet is lower than 35℃, stop
the main cooler;
3.9.5 Mill subsystem sequence startup
D. Start one oil pump
E. Start the air fan of the gear spraying lubrication system
F. Start the mill
G. Open the air spraying valve
H. Start the oil spraying pump after 10 seconds
I. Stop the oil spraying pump after 15 seconds
J. Shut down the air spraying valve after 10 seconds.
Repeat the procedure from D to G after 30 minutes – 2hours. Refer to

the Spraying Device Manual.
3.9.6 Mill subsystem stop consequence
A. Stop the mill
B. Stop the spraying oil pump
C. Stop the spraying air valve
D. Stop the spraying fan
E. Delay 5 minutes, stop the low pressure oil pump
3.10 Mill's Slurry Recycle System
26
3.10.1 Slurry recycling pump
A. Start permit：
a) The outlet valve of another slurry recycle pump is closed or

another slurry recycle pump is running.
b) Inlet blowdown valve is closed

(L0HTK41AA002/L0HTK42AA002).
c) Outlet flushing valve is closed

(L0HTK41AA004/L0HTK42AA004).
d) Outlet valve closed (L0HTK41AA003/L0HTK42AA003).
e) Inlet valve opened (L0HTK41AA001/L0HTK42AA001).
f) No emergency trip signals.
g) Level of slurry recycle tank of mill is not

low(L0HTK41CL101/L0HTK42CL101).
h) Motor of slurry recycle tank’s agitator is running

(L0HTK41AM001/L0HTK42AM001) .
B. Trip:
a) Corresponding motor for agitator of slurry recycling tank

stopped, with a delay of 30s.
b) Outlet valve not opened after slurry recycle pump runs for
30S.
c) Level of slurry recycle tank of mill is low low, with a delay of

2s.
3.10.2 Inlet valve of slurry recycle pump (L0HTK41AA001/L0HTK42AA001)
Pump stops and the inlet valve is interlock closed.
3.10.3 Inlet blowdown valve of slurry recycle pump

(L0HTK41AA002/L0HTK42AA002)
Open permit：Corresponding slurry recycle pump stopped.
3.10.4 Outlet valve of slurry recycle pump（L0HTK41AA003/L0HTK42AA003）
Close permit：Corresponding slurry recycle pump stopped.
The interlock works：the corresponding slurry recycle pump running,

with a delay of 5 seconds.
3.10.5 Outlet flushing valve of slurry recycle pump
27
Open permit：Corresponding slurry recycle pump stopped.
3.10.6 Valve for controlling the flow from mill cyclone A/B to limestone slurry
tank (L0HTK41AF001/L0HTK42AF001)
Open permit：Any one of mill’s slurry recycle pumps runs.
Close permit.Both mills’ slurry recycle pumps stop.
Interlock open：Limestone slurry tank level is low. (L0HTJ10CL101)
Interlock Close：Limestone slurry tank has high level. (L0HTJ10CL101)
3.10.7 Agitator for slurry recycle tank of mill
Start permit: No emergency trip signals; Level of slurry recycle tank of

mill is not low.
Interlock Close:Level of slurry recycle tank of the mill is low low.
Interlock Close: Level of slurry recycle tank of the mill is high.
3.10.8 General makeup water valve for filtrate to grinding system.
3.10.9 General makeup water valve for process water to grinding system
(L0HTQ31AA515)
No interlock.
3.10.10 Sequence start of slurry recycle system
A. Conditions:
Level of corresponding slurry recycle tank of the mill is not low.
Agitator of corresponding slurry recycle tank running.
B. Steps:
a) Close the inlet blowdown valve of slurry recycle pump.
b) Close the outlet flushing valve of slurry recycle pump.
c) Open the inlet valve of slurry recycle pump.
d) Close the outlet valve of slurry recycle pump.
e) Start the mill's slurry recycle pump.
f) Open the outlet valve of slurry recycle pump.
Note: Each slurry recycle pump responds to a sequence control.
3.10.11 Sequence stop of slurry recycle system
28
A. Stop the slurry recycle pump for the mill.
B. Close the outlet valve of slurry recycle pump.
C. Close the inlet valve of slurry recycle pump.
D. Open the inlet blowdown valve of slurry recycle pump.
E. Open the outlet flushing valve of slurry recycle pump.
F. After a delay of 60s, close the outlet flushing valve of slurry

recycle pump.
G. After a delay of 5s, close the inlet blowdown valve of slurry

recycle pump.
3.11 Limestone Slurry System
3.11.1 Limestone slurry pump
1) Start permit
A. Another pump stops or the outlet valve of another pump is

closed.
B. Outlet flushing valve is closed.（L0HTQ31AA512/

L0HTQ31AA514）
C. Inlet blowdown valve is closed.（L0HTJ11AA201/

L0HTJ12AA201）
D. Outlet valve is closed.（L0HTJ11AA202/L0HTJ12AA202）
E. Inlet valve is opened.（L0HTJ11AA001/L0HTJ12AA001）
F. Level of limestone slurry tank is not low.（L0HTJ10CL101）
G. No emergency tripping signal.
2) Trip
A. Outlet valve is not opened after the limestone slurry pump

starts 30s.
B. Limestone slurry tank level is low low, with a delay of 2s.
C. Agitator stopped.
3.11.2 Inlet valve of limestone slurry pump
No interlock.
3.11.3 Inlet blowdown valve of limestone slurry pump
29
Start permit:Corresponding limestone slurry pump stopped.
3.11.4 Outlet valve of limestone slurry pump
Close permit: Corresponding limestone slurry pump stopped.
The interlock works：Corresponding limestone slurry pump running.
3.11.5 Outlet flushing valve of limestone slurry pump
Start permit.:Corresponding limestone slurry pump stopped.
3.11.6 Agitator for limestone slurry tank
1) Conditions for start：
No emergency trip signal.
Level of limestone slurry tank is not low.
2) Stop through interlock：Limestone slurry tank level low low, with a

delay of 2s.
3.11.7 Sequence start of limestone slurry system
Permit conditions：
1) Level of limestone slurry tank is not low.
2) Close the inlet blowdown valve of limestone slurry pump.
3) Close the outlet flushing valve of limestone slurry pump.
4) Open the inlet valve of limestone slurry pump.
5) Start the limestone slurry pump.
6) Open the outlet valve of limestone slurry pump.
3.11.8 Sequence stop of the limestone slurry system
1) Stop the limestone slurry pump.
2) Close the outlet valve of limestone slurry pump.
3) Close the inlet valve of limestone slurry pump, with a delay of

10s.
4) Open the inlet blowdown valve of limestone slurry pump.
5) Open the outlet flushing valve, with a delay of 30s.
6) Close the outlet flushing valve, with a delay of 30s.
7) Close the inlet blowdown valve.
30
3.12 Oxidation fan system
3.12.1 Oxidation fan
1) Conditions for start:
A. No incident tripping signals appear.
B. Bearing temp. of oxidation fan<70℃（L0HTG11CT309-12/

L0HTG12CT309-12）.
C. Bearing temp. of oxidation fan’s motor<70℃

（L0HTG11CT307-08/ L0HTG12CT307-08）.
2) Trip
D. Bearing temp. of oxidation fan>90℃..
E. Bearing temp. of oxidation fan’s motor>90℃..
F. FGD inlet and outlet baffles as well as outlet blades of

boosting fan are closed, with a delay of 60S.
3) Interlock start
In case of tripping of the running fan, the spare fan will start.
3.12.2 Humidification electric valve from process water to oxidation fan
No interlock.
3.12.3 Agitator of absorption tower
1) Start permit: No incident tripping signals appear.
2) Interlock works:Level of absorption tower >LLL.
3) Stop through interlock: Level of absorption tower <LLL.
3.13 Demister flushing subgroup
Front flushing electric valve for the primary demister 1～4

(L0HTQ13AA101A～ L0HTQ13AA101D)；
Back flushing electric valve for the primary demister

(L0HTQ13AA102A～ L0HTQ13AA102D)
Front flushing electric valve for the secondary demister 1～4

(L0HTQ13AA103A～ L0HTQ13AA103D)；
31
3.13.1 Demister flushing subgroup start procedures
1) Interlock start（Logic ‘and’）
A. FGD inlet flue gas temp.＞70℃ （selecting 2 from 3）
B. Unprocessed flue gas baffle of any inlet is opened
C. Flue gas baffle of any outlet is opened.
D. Any one of boosting fans runs.
2) Interlock stop：
All inlet unprocessed flue gas baffles are closed and all outlet flue
gas baffles closed.
3) Start procedures：
E. Close flush valves for all demisters.
F. Open front flushing electric valve 1 for the primary demister

(being open for 60S)
G. Close front flushing electric valve 1 for the primary demister
H. Open front flushing electric valve 2 for the primary demister

I. Close front flushing electric valve 2 for the primary demister
J. Open front flushing electric valve 3 for the primary demister

K. Close front flushing electric valve 3 for the primary demister
L. Open front flushing electric valve 4 for the primary demister

M. Open front flushing electric valve 4 for the primary demister

N. Open back flushing electric valve 1 for the primary demister

O. Close back flushing electric valve1 for the primary demister
P. Open back flushing electric valve 2 for the primary demister

Q. Close back flushing electric valve 2 for the primary demister
R. Open back flushing electric valve one for the primary
32
demister (open for 60S)
S. Close back flushing electric valve three for the primary

demister
T. Open back flushing electric valve one for the primary

demister (open for 60S)
U. Close back flushing electric valve four for the primary

demister
V. Open front flushing electric valve one for the

secondarydemister (being open for 60S)
W. Close back flushing electric valve one for the

secondarydemister
X. Open front flushing electric valve two for the

Y. Close back flushing electric valve two for the

secondarydemister
Z. Open front flushing electric valve three for the

secondarydemister (open for 60S)
AA. Close back flushing electric valve three for the 2nd -step
level demister
BB. Open front flushing electric valve four for the

CC. Close back flushing electric valve four for the

secondarydemister
DD. After starting, executing procedures 2-9 one time every

40minutes, executing procedures 10-17 one time every
40minutes, and executing procedures 18-25 one time every
40minutes.
3.14 Inlet/outlet Flushing Valve System of Absorber
3.14.1 Inlet flushing valve of absorption tower
Flushing procedures: continuous recycling
1) Open absorption tower’s inlet flushing valve A, lasting

50s(L0HTQ22AA001A) ;
33
2) Close absorption tower’s inlet flushing valve A, lasting 100s;
3) Open absorption tower’s inlet flushing valve B, lasting 50s

(L0HTQ22AA001B);
4) Close absorption tower’s inlet flushing valve B, lasting 100s;
5) Open absorption tower’s inlet flushing valve C, lasting

50s(L0HTQ22AA001C);
6) Close absorption tower’s inlet flushing valve C, lasting 100s;
3.14.2 Flushing water valve for the recycling pipe of absorber

(L0HTQ27AA001)
No interlocks.
3.14.3 Pipe valve for filtrate to the absorption tower (L0HTM80AA001)
Interlock: when the recycle tank’s level is high, open; while low , close.
3.14.4 Recycle blowdown valve of discharged gypsum slurry of the absorber

(L0HTL20AA552)
No interlock.
3.14.5 Blowdown valve of the general pipe of slurry discharge pump

(L0HTL10AA201)
No interlock.
3.15 Slurry Recycle Pump System of Absorber
3.15.1 Slurry recycle pump
1) Start permit
A. No accident signal of recycle pump;
B. Stator temperature of the motor of the recycle pump

<70℃(L0HTF11CT301—06/ L0HTF12CT301—06/
L0HTF13CT301—06/ L0HTF14CT301—06);
C. Bearing temperature of the motor of the recycle

pump<70℃(L0HTF11CT307—08/ L0HTF12CT307—08/
L0HTF13CT307—08/ L0HTF14CT307—08;
D. Bearing temperature of the recycle pump

<70℃(L0HTF11CT309—10/ L0HTF12CT309—10/
L0HTF13CT309—10/ L0HTF14CT309—10);
34
E. Inlet valve of the recycle pump is open.
(L0HTF11AA001/L0HTF12AA001/L0HTF13AA001/L0HTF
14AA001)
F. Inlet blowdown valve of the recycle pump is closed.

(L0HTF11AA002/L0HTF12AA002/L0HTF13AA002/L0HTF
14AA002)
G. Flushing water valve at the outlet of the recycle pump is

closed.
(L0HTQ25AA001A/L0HTQ25AA001B/L0HTQ25AA001C/L
0HTQ25AA001D);
H. Level of absorber ＞Level for start (L0HTD01CL101,

L0HTD01CL102).
2) Trip
A. Bearing temp. of the motor of the recycle pump>90℃;
B. Bearing temp. of the recycle pump>90℃;
C. Stator temp. of the motor of the recycle pump Two items for
any phase are high;
D. Inlet valve closes during the running of the recycle pump,

with a 2s delay;
E. Level of absorption tower<LL.
3.15.2 Inlet valve of slurry recycle pump
1) Open permit: the corresponding inlet blowdown valve of recycle

pump is closed and the outlet flushing water valve is closed.
2) Close permit：the corresponding recycle pump stopped.
3.15.3 Inlet blowdown valve of slurry recycle pump
Open permit: the corresponding recycle pump stopped and inlet valve
is closed.
3.15.4 Outlet flushing valve of slurry recycle pump
Start permit：the corresponding recycle pump stopped and inlet valve is

closed.
3.15.5 Slurry recycle pump system starts orderly
1) Start permit:
Level of absorptber Level for start
35
2) Procedures:
A. Close the outlet flushing valve of slurry recycle pump;
B. Close inlet blowdown valve;
C. Open inlet valve of slurry recycle pump, with a delay of 5;
D. Start slurry recycle pump.
3.15.6 Slurry recycle pump system stops orderly
1) Start permit:
FGD inlet and outlet flue baffles are closed and boosting fan
stops.
2) Procedures：
A. Stop slurry recycle pump
B. Close recycle pump’s inlet valve, 10s delay.
C. Open inlet blowdown valve, 180s delay.
D. Open outlet flushing valve.
E. Close outlet flushing valve, 300s delay.
F. Close inlet blowdown valve.
Note: a period of delay is required for Step D.
3.16 Slurry Discharge System
3.16.1 Slurry discharge pump
1) Start permit:
A. Pump outlet valve are closed

(L0HTL11AA003/L0HTL12AA003);
B. Pump inlet valve are opened

(L0HTL11AA001/L0HTL12AA001);
C. Outlet flushing valves are closed

(L0HTQ26AA001A/L0HTQ26AA001B);
D. Inlet blowdown valves are

closed.(L0HTL11AA002/L0HTL12AA002);
E. Absorption tower’s level >4.5m (temporary set value);
36
F. Another pump started or the outlet of another pump is
closed;
G. No incident tripping signals appear.
2) Tripping
A. Outlet electric valve is not opened after gypsum slurry

discharge pump runs for 30s;
B. Inlet valve is closed during the running of slurry discharge

pump;
C. Absorption tower’s level <4.5m.
3.16.2 Inlet valve of slurry discharge pump
Open permit: Corresponding inlet blowdown valve and outlet flushing

valve are closed.
Close permit：Corresponding slurry discharge pump stopped.
3.16.3 Inlet blowdown valve of slurry discharge pump
Open permit：Corresponding inlet valve of slurry discharge pump is

closed.
3.16.4 Outlet valve of slurry discharge pump
Open permit：Corresponding slurry discharge pump runs or the outlet

valve of slurry discharge pump in another side is closed.
3.16.5 Outlet flushing valve of slurry discharge pump
Open permit：Corresponding slurry discharge pump stopped.
Slurry discharge system’s order controller starts
1) Start permit : Absorber’s level>4.5m ( value to be determined)
2) Procedures:
A. Close inlet electric valve of slurry discharge pump.
B. Close inlet blowdown valve of slurry discharge pump.
C. Close outlet electric valve of gypsum slurry discharge

pump.
D. Close outlet flushing valve of slurry discharge pump.
E. Open inlet valve of slurry discharge pump.
F. Start slurry discharge pump, with a delay of 30s.
37
G. Open outlet valve of slurry discharge valve, with a delay of
10s.
3.16.7 Slurry discharge system’s order controller stops
Procedures
1) Close outlet valve of slurry discharge valve.
2) Stop slurry discharge pump.
3) Close inlet valve of slurry discharge pump, with a delay of 30s.
4) Open inlet blowdown valve of slurry discharge pump.
5) Open outlet flushing valve, with a delay of 30s.
6) Close outlet flushing valve, with a delay of 30s.
7) Open inlet blowdown valve, with a delay of 30s.
3.16.8 Pump for water discharge sump in absorber area （L0HTT20AP001）
1) Start permit conditions：
No emergency tripping signal.
Level of water discharge sump for absorber >LL

（LOHTT20CL101）
2) Interlock Stop: Level of water discharge sump for absorber<LL
3.16.9 Agitator for water discharge sump in absorber area（L0HTT20AM001）
1) Start permit conditions：
No emergency tripping signal.
Level of water discharge sump for absorption tower>LL
2) Interlock Start: Level of water discharge sump> m (set value to

be determined)
3) Interlock Stop :Level of water discharge sump<LL, with a time

delay of 2s.
3.17 PH Meter Flushing System
3.17.1 PH meter inlet electric valve（L0HTL20AA001A/ L0HTL20AA001B）
Start permit: PH meter’s inlet flushing valve is closed.
3.17.2 PH meter’s inlet flushing valve (L0HTQ60AA002A/ L0HTQ60AA002B)
38
Start permit: PH meter’s inlet electric valve is closed.
3.17.3 Flushing sequence control
1) Close PH meter’s inlet electric valve.
2) Open PH meter’s inlet electric valve, with a delay of 60s.
3) Close PH meter’s inlet flushing electric valve.
4) Open PH meter’s inlet electric valve.
5) Close PH meter’s inlet electric valve, with a delay of 50s.
6) Flushing sequence control is executed one time every two hours

in recycles. The flushing time can also be manually set.
7) After flushing PH meter A finished, then flush PH meter B with a

delay of five minutes.
8) Isolate PH meter from measurement data during flushing.
3.18 Gypsum Dehydration System
3.18.1 Gypsum cyclone station
Inlet main pipe’s electric valve of gypsum cyclone station

（L0HTL10AA002）
1) Start permit: Vacuum belt conveyor running.
2) Interlock Stop: Vacuum belt stopped completely.
3.18.2 Gypsum dehydration belt conveyor (L0HTM31AN002/

L0HTM32AN002)
1) Start permit
A. No tripping conditions.
B. No alarm from vacuum belt conveyor’s right filter

misalignment limit switch.
(L0HTM21CG003/L0HTM22CG003)
C. No alarm from vacuum belt conveyor’s left filter

D. No alarm from vacuum belt conveyor’s right belt

39
E. No alarm from vacuum belt conveyor’s left belt
F. No alarm on transformer of vacuum belt dehydrator.

(L0HTM31AN002XB03/L0HTM32AN002XB03)
G. Flow of sealing water in the vacuum tank is not low.

(L0HTQ41CF002/L0HTQ42CF002)
H. Flow of flushing water for filter cloth is not low.

I. Corresponding vacuum pump is not running.

(J0HTM31AN001/J0HTM32AN001)
2) Tripping
A. Vacuum belt conveyor’s right filter cloth misaligned, limit

switch acts. (L0HTM21CG003/L0HTM22CG003)
B. Vacuum belt conveyor’s left filter cloth misaligned, limit

switch acts. (L0HTM21CG004/L0HTM22CG004)
C. Vacuum belt conveyor’s right belt misaligned, limit switch

acts. (L0HTM21CG001/L0HTM22CG001)
D. Vacuum belt conveyor’s left belt misalign, and limit switch

acts. (L0HTM21CG002/L0HTM22CG002)
E. Flow of sealing water in the vacuum tank is low.

F. Vacuum pump trips. (J0HTM31AN001/J0HTM32AN001)
G. Filter cloth tension switch acts.

(L0HTM21CG005—06/L0HTM22CG005--06)
H. Pull rope switch acts. (L0HTM21CH002/L0HTM22CH002)
I. Flow of flushing water for filter cloth is low.

3.18.3 Vacuum pump (L0HTM31AN001/ L0HTM32AN001)
1) Start permit：
A. Vacuum tank’s level is not high.

(L0HTM31CL001/L0HTM32CL001)
B. Seal water valve for the vacuum pump is opened.
40
(L0HTQ61AA202/L0HTQ61AA203)
C. Inlet water flow for the vacuum pump is not low.

2) Tripping：
A. Vacuum tank level is high.
B. Flow of sealing water in the vacuum tank is low.
C. Seal water valve for vacuum pump is not opened.
D. Belt conveyor trips.
3.18.4 Filter cloth flushing water pump（L0HTM41AP001/L0HTM41AP002）
A. Start permit: Level of filter cloth flushing water tank is not

low(L0HTM40CL101).
B. Tripping for protection: Level of filter cloth flushing water tank is

low.
C. Interlock start: Start the standby pump with interlock in case of

running pump emergency trips.
3.18.5 Seal water valve for vacuum pump (L0HTQ61AA202/L0HTQ61AA203)
Close permit: Vacuum pump stopped.
Interlock Stop :Vacuum pump stopped.
3.18.6 Gypsum dehydration system sequence start
Note: Start one of the gypsum dehydration belt conveyers, flushing

water pumps and vacuum pumps.
1) Start filter cloth flushing water pump
2) Start gypsum dehydration belt conveyer with a delay of 60s.
3) Open the seal water valve for the vacuum pump and the belt
conveyer with a delay of 60s.
4) Start vacuum pump with a delay of 10s.
5) Open the inlet general pipe’s electric valve from gypsum slurry to
the cyclone station (L0HTL10AA002)
3.19 Filtrate Tank System
3.19.1 Filtrate pump ( one in operation, one as standby)
41
1) Start permit
A. Level of filtrate tank>0.9m(L0HTM80CL101)
B. Inlet valve of filtrate pump is opened.(L0HTM81AA201/

L0HTM82AA201)
C. Agitator is running. (L0HTM80AM001)
D. Outlet valve is closed.
2) Tripping for protection：
A. Level of overflow tank<0.9m, a delay of 10s；
B. Inlet valve is closed after filtrate pump runs.
C. Outlet valve is not opened after filtrate pump runs for

60s.(L0HTM81AA202/ L0HTM82AA202)
D. Filtrate agitator trips.
3) Start through interlock:
Start the standby pump with interlock in case of running pump

emergency trips.
3.19.2 Filtrate pump inlet valve
Close permit: Corresponding filtrate pump stopped.
3.19.3 Filtrate pump outlet valve
Open permit: Outlet valve of another filtrate pump is closed.
3.19.4 Motor of filtrate tank’s agitator
Start permit : Filtrate tank level >0.9m
Tripping for protection: Filtrate tank level<0.9 m
3.20 Waste Water Tank Subgroup
3.20.1 Waste water pump(L0HTM71AP001/ L0HTM72AP001)
1) Start permit: Waste water tank level >0.75m(L0HTM70CL101)
2) Tripping for protection
Waste water tank level <0.75m , with a delay of 10s
Emergency Trip of waste water tank’s agitator motor

(L0HTM70AM001)
42
3.20.2 Waste water tank agitator
Start permit: Waste water tank’s level is not low.
Tripping for protection: Waste water tank’s level is low
3.21 Absorber Slurry Discharge and Process Water System
3.21.1 Emergency slurry discharge system
z Emergency slurry return pump

(L0HTT11AP001/L0HTT12AP001)
Start permit: Liquid level of emergency slurry tank > 1.2m

(L0HTT11CL101)
Interlock stop: Liquid level of emergency slurry tank < 1m

(L0HTT11CL101)
3.21.2 Emergency slurry tank agitator (L0HTT11AM001)
z Start permit:Liquid level of emergency t slurry tank is not low.

(L0HTT11CL101)
z Protection trip:Liquid level of emergency slurry tank is low.

(L0HTT11CL101)
3.22 Process Water System
3.22.1 Process water pump (one for use and another for standby)
(L0HTQ21AP001/ L0HTQ22AP001)
z Allow start:Water level of process tank >1500mm

(L0HTQ10CL101)
z Protection trip:Water level of process tank <800mm
z Interlock start:Operating pump trips, and starts the standby pump

by interlock.
3.22.2 Electric makeup valve of process water tank (L0HTQ20AA001)
z Interlock open:Water level of process tank <2500m
z Interlock stop: Water level of process tank >4000mm
3.22.3 Demister flushing water pump (L0HTQ11AP001/ L0HTQ12AP001)
z Start permit:Water level of process tank > 1500mm
43
z Protection trip:Water level of process tank <800mm
3.23 DMC48 Type Impulse Bag Type Dust Collector
3.23.1 Structure of DMC single unit dust collector
The equipment comprises the following parts:
Case body: it includes bag chamber, purifying chamber, multi-hole

board, filter bag, frame, and access hole
Wind system: it includes fan, motor of fan
Blowing system: it includes main air pipe, blowing pipe, impulse valve
Ash discharging part of air inflow is divided into two types: one is
standard ash hopper (type A), the other one is openness flange type
(type B)
3.23.2 Work principle
Dusty air enters in the filter bag chamber through openness flange; the
big particle dust will drop into the ash hopper; fine dust will be absorbed
to outer wall by different effects, then it is filtered to clean air through
filter bag then it enters in air inflow chamber, after which it is exhausted
by fan through exhaust hole of air purifying chamber. The dust
absorbed on the filtered bag is increasing all the time so that the
resistance of bag will increase continuously; therefore the bags need
cleaning periodically in order to keep the resistance less than 1200Pa
and the bag type dust collector could continue work. During the dust
cleaning, the program controller will start the impulse valve regularly so
that the compressed air (0.5-0.7Mpa) from air chamber will enter in the
filter bag through holes of blowing pipe. The filter bag will expand
instantly and the dust will be shaken down by the back action of air flow.
Therefore, the dust is cleaned.
The dust cleaning process is controlled by control system which give

instructions to each solenoid impulse valve in accordance with the
specified requirement, the valves will open in turns and high pressure
air will blow to each filter bag in sequence, so the compressed air from
air drum will enter in the filter bag through nozzle pipe and short pipe
(which is called primary air), meanwhile the ambient air which is many
times of the primary air are introduced to enter in the bag (which is
called secondary bag). Primary and secondary air causes a strong
reverse air that is opposite to the filter air, the filter bag will realize the
process of shrinkage and then expansion and shrinkage in a short time,
44
meanwhile the high pressure air will pass several groups of filter bag
chambers and treat dusty air. Therefore, during the dust treatment, the
pressure loss of dust treating air and the volume of treated dusty air
hardly change, which are the advantages of impulse bag type dust
collector.
3.23.3 Usage instruction
Check access hole and whether the flange contact is sealed or not
before the unit begins to work so as to avoid leakage and reduce the
dust removing effect.
The unit voltage is 415V; it can be used when the outside wire of unit is
connected with power source. Pay attention to the rotary direction (if it
is reverse, change the connection of power source) during the
beginning running.
The cover of electric control box can not be opened without permission
during its working; if it is necessary to adjust the dust cleaning time or
repair the circuit, the unit should be shut down and the power source
should be cut off and then perform the work.
Adjust the timing cleaning time in accordance with the dust character
and dusty concentration.
Dust hood is a key part which can ensure the unit remains in optimum
state; proper dust hood should be made during the usage in
accordance with the appearance dimensions of processing part and
dust nature.
3.23.4 Maintainance
Check the conditions of bag type dust collector periodically, if broken

bag or slipping bag is fount out, replace the filter bag in time; the filter
bag should be replace in accordance with the real situation, generally
speaking, it should be replaced once a year.
Check the dust cleaning mechanism twice a year in general.
Contact with the manufacturer for quick-wear parts.
45
4 Limestone Slurry Chemical Dosing System
4.1 Liquid level control of lime preparation box
When liquid level J0HTS50CL001 of lime preparation box

J0HTS50BB001 is lower than 0.8m, start the stop program of lime
recycling pump A J0HTS51AP001 or B J0HTS52AP001.
When liquid level J0HTS50CL001 of lime preparation box

J0HTS50AM001 is lower than 1.2m, output alarm signals.
4.2 Operation control of limestone slurry recycling pump:
Manually start lime recycling pump, and automatically open limestone

slurry preparation recycling pipe valve J0HTS50AA202 during
operation. When liquid level meter J0HTS50CL002 of lime chemical
dosing box J0HTS50BB002 is lower than 0.7m, open feeding valve
J0HTS50AA203 of lime chemical dosing box, close recycling pipe
valve J0HTS50AA202, and open water inlet valve J0HTQ70AA206 of
lime chemical dosing box. When liquid level meter J0HTS50CL002 of
lime chemical dosing box J0HTS50BB002 is higher than 1.3m, close
feeding valve J0HTS50AA203 of lime chemical dosing box, open
recycling pipe valve J0HTS50AA202, and close water inlet valve
J0HTQ70AA206 of lime chemical dosing box.
4.3 Operation procedure of chemical dosing pump for limestone

slurry
When pH meter J0HTZ12CQ101 of sediment box is lower than 8, open

inlet main pipe automatic valve J0HTS50AA204 of limestone slurry
chemical dosing pump and the outlet main pipe automatic valve
J0HTS50AA206. Start limestone slurry chemical dosing pump A:
J0HTS53AP001 or B: J0HTS54AP001. When pH meter
J0HTZ12CQ101 of sediment box is higher than 9.5, start stop program
of limestone slurry chemical dosing pump.
4.4 Liquid level control program of limestone slurry chemical dosing

box
When the liquid level meter J0HTS50CL002 is lower than 0.5m, output
alarm signal and start stop program of limestone slurry chemical dosing
pump.
46
4.5 Stop and Switch Programs of Limestone Slurry Circulating Pump
Starting the stop program of limestone slurry circulating pump goes like
this: open its flushing water valve J0HTQ70 AA207, close its main inlet
valve J0HTS50 AA201, delay for three minutes, close limestone slurry
circulating pump A：J0HTS51AP001 or B：J0HTS52AP001, and then
close flushing water valve J0HTQ70 AA207.
Starting switch program of limestone slurry circulating pump performs

like this : open its flushing water valve J0HTQ70 AA207, close its main
inlet valve J0HTS50 AA201, delay for three minutes, close limestone
slurry circulating pump A：J0HTS51AP001 or B：J0HTS52AP001, start
limestone slurry circulating pump B ： J0HTS52AP001 or A ：
J0HTS51AP001; open the main inlet valve J0HTS50 AA201, and close
the flushing water valve J0HTQ70 AA207.
4.6 Stop and Switch Programs of Limestone Slurry Chemical Dosing

Pump
When starting stop program of limestone slurry chemical dosing pump:

open flushing water valve J0HTQ70AA205 of limestone slurry chemical
dosing pump, close its main inlet valve J0HTS50 AA604, delay for
three minutes, close limestone slurry chemical dosing pump A ：
J0HTS53AP001 or B：J0HTS54AP001, and close the flushing water
valve J0HTQ44 AA607.
When starting switch program of limestone slurry chemical dosing

pump: open the flushing water valve J0HTQ70AA205, close its main
inlet valve J0HTS50 AA204, delay for three minutes; close limestone
slurry chemical dosing pump A：J0HTS53AP001 or B：J0HTS54AP001,
start limestone slurry chemical dosing pump B：J0HTS54AP001 or A：
J0HTS53AP001, open its main inlet valve J0HTQ70 AA205, and close
the flushing water valve J0HTQ70 AA205.
4.7 Control Program of Filtrate Box
When liquid level meter L0HTZ50CL101 of filtrate box is higher than

1.8m, there is an alarm of high liquid level; when higher than 1.2m, start
the filtrate pump; when higher than 0.4m, start the agitator on filtrate
box L0HTZ50BB001; when lower than 0.4m, an alarm will be given, at
this moment, close the agitator on filtrate box L0HTZ30BB001 and
filtrate pump.
47
5 Inspection and Preparation of FGD Devices
5.1 General provisions of acceptance after maintenance
1) After overhaul and repair of the FGD device, there should be a

technical report about the abnormal operation of equipment as
technical reference for the operators.
2) For the repaired or overhauled equipment, the maintenance and

repair personnel should submit the trial run application signed by
the relevant units to the operation department. Only when the
application is confirmed correct, can the equipment be tested and
operated for trial run.
3) The operators should examine the equipment for the acceptance

items and leaves signature after confirming all of the items
correct. If any defect is found on the equipment and the unit
cannot be guaranteed in safety operation, the operator should
request the maintenance and repair personnel to remove the
defect before operation in addition to recording the defect.
4) When the maintenance and repair is completed for check and

acceptance, the principle that “work completed, materials cleared
up and site clean” should be observed. The lighting should be
sufficient. Only when all these standards are met, can the work
sheet be finished and signed.
5.2 Inspection on FDG Device After Ooverhaul
5.2.1 General inspection items
1) When the repair is completed, the scaffolding should be removed.

Ensure all the equipment is completely good and there are no
sundries on site.
2) The aisles, handrails and staircases should be in good condition

and free from obstacles; the covers of ducts and holes must be
put in place.
3) The flues and pipes are in good condition with thermal protection
in place. The equipment and structures are free of painting
peeling off. The newly-replaced pipes should meet the relevant
requirements on the color of painting. The flow signs should be
marked correct.
48
4) The internal space of the flue gas duct, basin, tank, chamber and
absorber should be cleaned and free of residue. The man holes
and inspection holes should be closed tightly after inspection.
5) The DCS and power supplies for each system and instrument
have been put into usage. The parameters of all configurations
are correct. The measurement display and adjustment action are
normal. The industrial TV is in good condition.
6) The local display instrument, transmitter and sensor can work

correctly; the initial positions are correct.
7) The measurement instruments of pressure, differential pressure,

temperature, liquid level, material level, flow and concentration
and PH meter should be in good condition and put into usage.
8) The local control panel and all installed equipment can work
normal, and the indicators are tested meeting the requirements.
9) The anchor bolts for the machines and electric equipment are
completely reliable. The coupler shield is completely good. The
connectors and fasteners are properly installed.
10) The manual valve, electric valve, and control valve switches can
work freely with correct indication; the LCD display is consistent
with the local indication.
11) The electric system instrument and meters are completely good.
The switchboard cabinet has sufficient illumination. The terminal
block and plug don’t have abnormal loose or heating
phenomenon.
12) The switches, contactors and fuses are completely good. The
fuse specification accords with the designed parameters. The
electric heater and the motor heater are connected correctly and
in good condition.
13) The On and Off indication of switches is noticeable and correct.

The On and Off switch test indicates that is good.
5.2.2 Inspection of flue gas system and sealing system
1) Inspect the booster fan inlet baffle, outlet baffle, FGD inlet baffle,
FGD outlet baffle and bypass baffle of the FGD device to confirm
they are installed properly. The bypass baffle should be open.
The processed flue gas baffle and the unprocessed flue gas
baffle should be closed tightly. The differential pressure between
seal air pressure and the baffle value are normal.
49
2) The baffle electric executors are in good condition. The crank
arm is connected firmly. The baffles should run freely without jam.
The baffle switch position is correctly indicated and consistent
with the LCD display as well as be in remote control position.
3) The seal air fan of baffle should be in good condition; the

coupling should be connected firmly and can turn freely without
jam. The anchor bolts should be firm, and the shield complete
and firm.
4) The inlet and outlet pipes of the sealing air fan should be installed
firmly. The seal air inlet manual baffle should be closed and the
heater should be in good condition and shut down.
5) The baffles seal devices are in good condition and the seal pipe
should be clear.
6) The expansion joints should be in good condition, firmly installed

and expand freely.
7) The anti-corrosion layer in flue duct should be in good condition

and not peeling off.
5.2.3 Inspection of the case, tank, basin and absorber
1) The cases, tanks, basins and absorber are in good condition

without deformation. The welding joints are welded firmly and the
pipes can expand freely.
2) The rubber lining of the cases, tanks, basins and the absorber
should be complete without aging and corrosion; the rubber lining
is firmly glued to the absorber wall without any bubble.
3) The stainless steel at the unprocessed flue gas inlet of absorber

has no abrasion, corrosion or deformation and there is no foreign
matter on the rainproof shed.
4) The upper oxygenation air lance-type sprayer and the lower

flushing pipe of the absorber agitator should be connected
properly, and there is no scale or foreign articles blocked at the
outlet.
5) The various layers of nozzles of absorber should be arranged

orderly and connected firmly. The nozzles should be completely
good without abrasion and jam. The nozzle connecting pipes
should be in good condition, free from cracking, aging, corrosion,
slurry or dust.
50
6) The demister flushing nozzle should be installed firmly and
completely; the spout direction should be correct without jam.
7) The baffles in the limestone slurry tank and the gypsum slurry
tank should be installed firmly without abrasion and corrosion.
5.2.4 Inspection of Rotary Machines
1) General provisions
A. The oil levels of the decelerator and the bearing oil chamber
should be within the normal scope. The oil lens should be
clear; the oil should be in high quality, with clear oil level
indicators of high, low and normal. The bearing is lubed
well. The bearing lubed by lube oil should be sufficient with
grease.
B. The lubricant of equipment should be in high quality; the oil

meter and the oil lens should be complete and clear. The oil
level of the tanks should be within the normal scope; and
the electric heater should be in good condition. The oil filter
should be properly installed, free of obstacle and can be
flexibly switched. There should be no oil leakage, overflow
and dripping.
C. The coupling should be connected firmly and can rotate

freely without jam. The anchor bolt should be strongly firm.
The shield should be properly installed and firmly.
D. At around the rotary machine, keep it clean and ensure

there is no oil deposit, accumulated water and any foreign
articles.
E. The motor insulation should be qualified. The power cable

and earthing wire should be connected properly and the
rotary direction should be correct. The ampere meter and
the ON/OFF indicators should be in good condition; the
ampere meter should be marked with red line of rating
current.
F. The bearing and the motor coil temperature measuring

device are in good condition and reliable.
G. The oil cooler cooling water can run clearly and the
connection is firmly; the valve and pipe are free of leakage.
H. The drive pulleys are connected firmly; the belt should be

free of skidding and misalignment.
51
I. The emergency pushbuttons and shield should be in good
condition.
2) Inspection of agitator
A. The blades of box, tank, basin and agitator blades of

absorber are installed firmly being free of abrasion and
corrosion.
B. The absorber agitator installing decline angle and the circle

angle of contact should be correct.
C. The box, tank and basin top agitator should be installed

vertically; the connecting shaft of double-impeller agitator
should be connected firmly and concentric.
D. The gland seal of agitator is installed properly and the

flushing pipe is clear without obstacle.
E. The oil level of agitator decelerator is within the normal

scope and free of oil leakage, overflow and dripping.
3) Inspection of pump
A. Inspect the mechanical sealing device of each pump to

ensure it is in good condition without leakage.
B. The pump inlet is clean without obstacle.
C. The bearing oil cups of pumps should have sufficient

lubricant.
D. The power cable and earthing wire should be connected

properly.
E. No sundries should be stored around the pump and motor

so as not to disturb operation of pumps.
F. The pump and motor base should be fixed firmly with the
anchor bolt.
G. The parts of pump are connected firmly, and manually turn

the coupler to see whether it can move freely.
H. The rotary part shield is safe and reliable.
I. The oil level of bearing oil chamber is within the normal

scope (about 1/2) and the oil is qualified.
J. J. Check and confirm the status of outlet valve of water

tank and the inlet and outlet valve of pump correct, and the
52
water level of water tank is normal.
K. K. Inspect whether the cooling water of pump is clear and

adjust the cooling water flow to a suitable level.
5.3 Inspection and Preparation Before Startup
5.3.1 Inspection of the limestone slurry preparation system
1) Confirm the deduster filter bag on top of limestone chamber is

completely good and clean; the filter bag is installed at the right
position firmly; the valve should be closed after inspection.
2) Inspect and confirm that the vibration feeder and the metal
separator can work normally.
3) Confirm the power switches of control room and the local cabinet
are closed.
4) Inspect whether the limestone weighing belt is normal and the

limestone dipper-type lift work properly;
5) The material level of limestone silo should indicate correctly and

verified.
6) Inspect whether the wet ball mill and the slurry recycling pump
can work properly.
5.3.2 Preparation before operation
1) Confirm that the limestone cabin has sufficient limestone with

good quality.
2) Inspect whether the system slurry transport pipe is clear and the
valve switch position is correct.
3) Confirm that at least one processing water pump has been put
into operation and its pressure and flow are within the normal
scope.
5.3.3 Inspection and preparation before flue gas system startup
1) When the repair is completed, the work permit should be ended;

the safety measures have been removed; the equipment and the
neighborhood are clean and free of sundries; the illumination
should be good enough.
2) The flue gas duct has no sundries.
53
3) Inspect the booster fan bearing and the hardened grease must
be replaced.
4) All the bolts should be fastened and reliable.
5) All the pipes, flanges and bolts should be tight and in good
condition.
6) Turn the booster fan rotor manually by 4-5 rounds and the rotor
must be easily turned.
7) Inspect the inlet guide vane adjuster. Turn the guide vane
executor manually. Test the guide vane adjuster several times
respectively at 25%, 50%, 75% and full open position. Check the
calibration board to see whether the remote and local openings
match each other when the guide vane at the full open or close
position.
8) Inspect whether the temperature and vibration meters and their

interlock functions are correct.
9) Inspect whether the coupler is in good condition.
10) Inspect the motor in accordance with inspection provisions.
11) The bearing and the oil pipe are filled with grease.
12) The standby baffle seal fan is in good condition.
13) The instruments of the flue gas monitor system are connected
properly and the standby ones are in good position.
14) The flue gas continuous emission monitor system (CEMS) should
work properly without humidity alarming. Collate the flue gas
CEMS with the chimney CEMS and confirm the display of tested
elements is correct.
5.3.4 Inspection and preparation before the absorber system startup
1) When the repair is completed, the work permit should be ended;

the safety measures have been removed; the equipment and the
neighborhood are clean and free of sundries; the illumination
should be enough.
2) Inspect the absorber, water tanks and the basin to confirm their
internal spaces are clean and have no foreign articles; the
anti-corrosion layer is in good condition; the man hole is closed
down and in good condition.
3) The pipe flushing valves and discharge valve are closed without
54
leakage.
4) The anchor bolts of the absorber slurry recycle pump, gypsum

discharge pump, demister flushing pump and oxidation fan
should be fastened firmly. The shield should completely good and
installed firmly.
5) The lubricant levels of the absorber slurry recycle pump and

oxidation fan should be higher than their central lines of meters.
There should be no leakage; the oil meter and the oil level glass
scale should be clear and complete.
6) The motors of absorber slurry recycle pump, gypsum discharge

pump, demister flushing pump and oxidation fan motor should be
checked well in accordance with the inspection provisions. The
motor earthing wire should be connected properly and the motor
insulation should be qualified.
7) The manual valves and electric valves should be precise and

compact and can open flexibly without over force moment. The
valve switch indication accords with the DCS and the valves are
at the close position.
8) The local control cabinets can work properly and the indicator
lights are tested qualified.
9) The instruments and meters of power distribution system are

complete and in good condition; the terminal block and
connection plug have abnormal looseness.
10) The indications of On and Off of switches are clear and correct;
the switches are confirmed qualified by the switching-on and
switching-off tests.
5.3.5 Inspection of oxidation fan
1) The oxidation fan proper and the motor appearance are complete
and the air pipe silencer and filter are clean without sundries.
2) The external sound insulation cover of the oxidation fan is in

good condition.
3) There is no obstacle at the vent of fan outlet starting valve, and it

is closed.
4) The lubricant oil level is within the normal scope and there is no
oil leakage or dripping.
5) Turn the fan power switches to the test position and switch on the
55
power; when the power switch is confirmed working properly,
switch on and switch off remotely once. Locally check whether
the switches act properly.
5.3.6 Inspection and preparation of the gypsum dehydration system
1) Inspection of the cyclone
A. The cyclone station appearance is in good condition; the

vortex rotators are installed properly and there is no jam.
The manual valves between the rotator and the distribution
chamber should be open; the standby rotator inlet manual
valve should be closed tightly.
B. The underset outlet of vortex rotator should have no

abrasion.
C. The gypsum cyclone overflow pipe should be clear without

jam; the pipe to the waste water cyclone station should be
in good condition.
D. The cyclone underset chamber should be clean without

sundries.
E. The local pressure gauge of cyclone should indicate

properly and the pressure sensor can work properly.
2) Inspection of the dehydrator
A. The dehydrator filter cloth, V-belt and roller are installed

properly; those brackets should be installed firmly; there is
no residue on the belt; the belt tension should be proper.
B. The belt and filter cloth roller should run freely without jam
and hindering.
C. The main wheel and tail wheel of the belt are installed
properly. There should be no foreign articles existing
between the belt and the wheel. The belt and filter cloth
should be in good condition without nick or reeling off.
D. The gypsum cleaner at the belt discharge position should

be installed properly and the discharge opening should be
clean.
E. The gypsum slurry inlet distribution pipe of dehydrator

should be clear; the sprinkling tray should have sundries
and be bale to sprinkle the slurry evenly without jam.
56
F. The flushing water pipe of filter cloth and the sealing water
pipe of vacuum box should be clear without jam.
G. The gap between vacuum box and belt should be proper;

the pipeline should be clear and sealed tightly.
H. The vacuum pump, the filter liquid pump and filter cloth
flushing pump should be installed properly and the pipeline
is clear.
I. Open the electric makeup water valve of filtering water tank

to inject water into it to a proper level.
J. Confirm the pressure of compressed air for correcting the

filter cloth deviation is within the normal scope; check
whether the filter cloth deviation sensor can work precisely
and sensitively; whether the displacement direction of roller
is correct.
K. Confirm whether the filter cloth flushing nozzle is clear; start

the corresponding filter cloth flushing pump and adjust the
flushing water flow to a proper value.
L. Inspect and confirm that the dehydrator frequency

modulation panel can work properly; switch the control
mode to Remote and confirm whether the output value of
DCS gypsum filter cake thickness is zero.
M. Inspect whether the vacuum box height is proper, the seal

strip is tight and the seal water flow in slideway is proper.
N. Carry out trial run of the dehydrator to check whether it

works properly, whether the filter cloth roller is in proper
position; whether the tension is proper. Gradually increase
the speed to 100% and check whether the operating noise
is normal. Stop its operation after confirming the belt and
filter cloth are at the correct position.
5.4 Inspection of Discharge System Before Operation
1) Inspect and confirm the tanks are clean without sundries and the
lining is completely good;
2) Inspect and confirm whether the agitators of tanks are installed

firmly and the motor earthing is connected properly;
3) Inspect the emergency slurry tank pump, the process water pump,
57
demister flushing water pump and other draining sump pumps
are in good condition and reliable.
4) Check and confirm that the process water tank has sufficient
qualified industrial water and the liquid meter works properly.
5) Inspect whether the system pipeline and valves are in good

condition and all pressure gauges should be in good condition
and work properly.
6) Inspect and confirm the inlet valves of centrifugal pumps are

open and the outlet valves closed.
58
6 Protective Tests for Desulfurization System
6.1 Interlock Protection Test of FGD
6.1.1 Conditions for protective action of FGD
The FGD protection order will start automatically because of any of the
following condition:
1) Booster fan trips;
2) Slurry recycle pump not running;
3) Absence of the main power of desulfurization system
4) The boiler runback;
5) The boiler MFT;
6) The absorber 3/4 agitators stop running;
7) The flue gas bypass baffles alarming for high differential pressure
or low differential pressure;
8) FGD inlet pressure high high, low low;
9) The unprocessed flue gas baffle does not open within 60

seconds after booster fan started to run;
10) The unit FGD inlet flue gas temperature＞180℃(two out of three)
6.1.2 FGD Interlock Protection Action Procedures
1) Open the bypass flue gas baffle;
2) Shut down the booster fan;
3) Close the FGD inlet baffles with interlock;
4) Close the FGD outlet processed flue gas baffle;
6.2 Emergency Button Test Methods
1) Switch off the power supply to the rotary machine and switch on
the test power supply;
2) Contact the I&C to switch on the operation power and protection

power to electric executors, instrument, signal and DCS devices.
59
3) Switch on the interlock and linkage switches of booster fan, slurry
recycle pump and oxidation fan. Switch on the switches of the
rotary machines and shut down the equipment with the
emergency buttons one by one. The reaction of machines should
be normal.
4) Switch on the switches mentioned above again and conduct

linkage or interlock test one by one.
6.3 Electric Valve Test
1) The electric valve test should be conducted jointly by I& C

personnel, maintenance personnel and operators.
2) Test the valve motor insulation before the electric valve test. If it
meets the requirement, supply power to it. Check if the electric
valve control device can work properly.
3) Fully open and close the tested electric valve which should react
flexibly without jam.
4) The electric valve should be reliable without any leakage when

closed completely.
5) Make the following records when conducting the electric valve

test: the total coils of the screw mandrel when the valve is
completely opened and closed, and the travel time when electric
valve is opened or closed.
6.4 Test of the Control Valve and Control Baffle
The newly-installed or overhauled control valve and control battle

should be tested about their switch test jointly by the thermal worker,
repair personnel and the operator.
Switch on and switch off the remote electric switches and observe and
confirm actions of the gearing, valve and baffle meet the test
requirements. The test requirements: the drive device can run freely
without jam; the switching directions of air valve baffle and control,
being in proper positions. The leakage should meet the relevant
requirements.
60
6.5 Booster Fan Inlet Baffle Test
1) Under normal conditions, open the outlet baffle and close the
inlet baffle in order to prevent the damage or too high current
from damaging motor when the booster fan starts with load. If the
booster fan starts normally, open the inlet baffle within 60
seconds. If the inlet baffle is not open or the signal fails when the
inlet baffle is fully open within 60 seconds after the booster fan
started, the booster fan will stop running for protection. Therefore,
it is necessary to do switch test on inlet baffle before starting the
booster fan, to ensure that switches work properly.
2) Inspect the Remote/Local button on the electric executor of local

booster fan inlet baffle , and switch the button to Local position.
3) Conduct fully-open and fully-close test to the booster fan inlet

baffle in the local and confirm the switches can work properly and
the signal of fully-open is correct.
4) Report to the shift foreman when the booster fan inlet baffle test
is completed.
6.6 Acoustic-Optical Signal Test
Contact I& C personnel to supply power for conducting emergency

sound, alarming and LED indicator test.
6.6.1 Notices in test
1) When conducting interlock tests of booster fan and oxidation fan,

it is also needed to do the operation power test. Do not do the
dynamic power supply test (except the interlock control part
during maintenance).
2) When conducting interlock and protection tests, the problems

found in the test should be reported to the shift leader. The test
should be done again after the problem is removed by the I&C
and electrical personnel till it meets the relevant requirements.
3) Before the rotary machine test, the relevant inspection should be

conducted in accordance with the inspection requirements before
the startup.
4) When the interlock and protection test are completed and

confirmed qualified, the interlock and protection switches should
be pushed to the ‘ON’ position. Record should be made and
61
submitted to the shift head in the process.
6.6.2 Power supply and test before startup
1) Confirm the repair work has been completed and the safety
protection measures have been recovered; the work permit has
been ended;
2) The sundries have been removed from the site; the passage is
clear with sufficient illumination; the handrail and staircase are
complete and firm; the ducts are clear and the covers are
complete;
3) Each equipment oil level is within normal scope, with good quality;
the oil meter and oil level glass are clear;
4) The internal space of flue, basin, tank, tower, silo and

dehydration system have been cleaned without obstacles; the
man holes have been closed after inspection;
5) The flue and pipes are equipped with good insulation and the
signs are clear and complete;
6) The anchor bolts of mechanical and electric equipment are

complete and firm; the shield is complete; the coupling and
fasteners are normal; the cooling water supply is normal;
7) The meters and instruments of power distribution system are

completely good. The switchboard cabinet has sufficient
illumination. The terminal block and connection plug do not have
any abnormal looseness.
8) The pumps, fans and agitators are in good conditions;
9) The baffles, expansion joints, flue and drainage equipment are in

good condition;
10) The pipes and valves in the FGD system are connected
completely and properly, with good condition;
11) The process water and industrial water systems have supplied
water to the FGD device.
12) On the basis of equipment and system inspection mentioned

above, supply the control power and equipment power. And then
conduct relevant tests before the startup in accordance with
relevant protection test contents.
62
7 Startup of FGD Equipment
7.1 Startup Procedure of the FGD Equipment
7.1.1 Startup of public systems.
7.1.2 Startup of limestone slurry preparation system.
7.1.3 Startup of absorber system.
7.1.4 Startup of flue gas system.
7.1.5 Startup of gypsum dehydration system.
7.2 Inspection and Confirmation before Integral Startup
1) DCS system is put into operation; the instrumental power for

systems has been supplied. Inspect and confirm the parameters
of each configuration are correct; measure display and adjusting
action are normal;
2) The local display instrument, transmitter and transducer can work

correctly; their positions should be correct.
3) The local control cabinet and the installed equipment can work
properly and the indicator light passes the test;
4) Various fuses of the switch and contactors should be complete

and can work properly, and the fuse specification accord with the
designed value;
5) The manual valve and electric valve can run freely and the
electric valve indication accords with the DCS display;
6) Before boiler ignition, contact the foreman to conduct the FGD

system interlock test which should be normal;
7) The interlock protection test of vacuum belt dehydrator is normal.
7.3 Startup of Desulphurization System
7.3.1 Cold start
The cold start refers to the first start of FGD system or restarting it after
repair. Before the cold start, the mechanical equipment of FGD system
is in outage. All the tanks, basins, silos and sumps are in condition of
no liquid (no water or slurry).
63
7.3.2 Short-term start
The short-term start refers to the restarting of the FGD system when it
stops operation because of failure for more than 24 hours and less than
72 hours. Before the short-term start, the agitator of the liquid container
is working continuously and the other mechanical equipment stops
running. When start the system, some systems should be recovered.
7.3.3 Short-time start

The short-time start refers to the restart of system when it stops
operation because of failure within 24 hours, and the equipment is at
hot standby status (the liquid levels of silos, tanks and sumps are
normal and the agitator is working). The FGD system can be put into
operation if all the requirements are met.
7.3.4 Cold start
When carrying out cold start, the desulphurization compressed air

system should be started first; then do preparations for injecting water
to the process water tank and charging limestone to the limestone
unloading house; then start the public equipment of FGD system.
Finally start the FGD systems as stipulated procedure.
1) Preparation before system startup
z Start the compressed air system
z Inspect the pipes and valves of compressed air;
z Put the refrigeration dryer into operation;
z Start one air compressor and prepare another one for

standby.
2) Inject water to process water tank
z Confirm the manual valve from the process water to

process water tank has been opened;
z Put one filter into operation; close the front and rear stop
valves of another filter for standby;
z Open the electric water makeup valve to make up water to

the process water tank to normal level;
z Close the electric water makeup valve;
z Switch on the automatic control of water level of process

water tank to automatically supply water to the process
water tank via the feedwater pipeline, maintaining the water
64
level of process water tank normal.
3) Supply limestone to limestone unloading house
z Transport the limestone with truck to the limestone

unloading house.
z Startup of public systems and preparation before FGD

device operation
4) Process water system startup
z Check whether the equipment and system are normal

before startup; switch on mechanical sealing water of the
equipment;
z Switch on the automatic control of the water level of

process water tank;
z Start the process water pump;
z Start the demister flushing water pump;
z After the equipment is started, inspect whether the

equipment run normally and the pipes have no leakage;
z Start the valves; adjust the process water pressure to 0.4～

0.6MPa; Confirm that the demister flushing water pressure
is normal.
7.4 Input Slurry into the Absorber Slurry Basin
7.4.1 Conditions for injecting slurry to absorber
z The sundries inside absorber are cleared off;
z All the flushing water pipes of absorber are closed;
z The internal anti-corrosion maintenance of absorber is

completed (if necessary);
z The bottom drainage valves are shut down;
z The man hole at the bottom of absorber is closed;
z The absorber liquid level meter is put into usage.
7.4.2 Fill slurry into the absorber slurry basin
The absorber slurry basin is the main site for absorption reaction and
oxidation reaction; the absorber slurry basin should be ready for startup.
65
The slurry injection can be divided into the first-startup injection and
injection after repair.
First-startup injection: inject water to the absorber via the demister

flushing water or process water during the first startup. Add gypsum
crystal to the absorber before startup. (Calculate at 5% concentration)
z Start the demister flushing water pump;
z Open the main control valve of demister flushing water;
z Open one or several demister flushing water electric valves and

push the button to Manual; inject water to the absorber;
z When the liquid level of absorber reaches 8.2m, close the electric
valve of demister flushing water to stop water injection.
7.4.3 Absorber slurry injection after repair
1) Inject water to the absorber to 2.5m with the demister flushing

water in accordance with methods mentioned above, and start
the absorber agitator;
2) Start the liquid transport from the emergency slurry tank to the
absorber, and start the emergency slurry pump;
3) Supply liquid to the absorber from the emergency slurry tank with
the emergency slurry pump through the slurry pipeline; when the
liquid level of the absorber reaches 8.0m, stop injection;
4) Stop the emergency slurry pump.
5) After the liquid injection finished, the system is at a cold standby

status (only the liquid level measurement system is started and
other valves and equipment are shut down).
7.4.4 Limestone slurry tank injection
Inject liquid to the limestone slurry tank with the process water.
1) Confirm the process water pump is running;
2) Open the manual valve in front of the water inlet electric valve of
limestone slurry tank;
3) Open the electric water makeup valve from process water to

limestone slurry tank to control the water supply;
4) When the water level of limestone slurry tank reaches 1/2 level,
close the electric water makeup valve from process water to
limestone slurry tank;
66
5) After water injection is completed, only the liquid level
measurement system is put into operation; the system is at cold
standby.
7.4.5 Liquid injection for filter cloth flushing water tank
Inject water to the filter water tank with process water.
1) Open its electric water inlet valve;
2) When its liquid level reaches 2/3, close the water inlet electric
valve;
3) Put the liquid level control system into operation; the filter cloth
flushing water is at cold standby status.
7.5 Start of Limestone Slurry Preparation System
1) Start the demister on the limestone silo.
2) Start the iron remover.
3) Turn on the bucket elevator.
4) Switch on the limestone vibration feeder.
5) Start wet ball mill.
6) Start the weighing belt feeder under the limestone silo.
7) Switch on the feeding valve under the limestone silo.
8) Start the agitator of ball mill slurry box.
9) Start the limestone slurry recycling pump.
7.6 Start of FGD Baffle Sealing System
The baffle sealing air fan should be put into use when any of baffle
valves is closed.
1) Check FGD baffle sealing air fan before startup according to

requirements.
2) Start FGD baffle sealing air fan, and turn on electric heating
system of sealing air.
3) Operate sealing air fan link lock.
4) Put the online monitoring system of inlet and outlet flue gas of
67
FGD.
7.7 Normal Start of FGD Device
Start the equipment of FDG system when the following are satisfied:
boiler runs normally; the flue gas concentration is below 2% displayed
by the outlet flue gas turbidity meter; inlet flue gas temperature of FGD
is between 100℃ and 170℃; the operation conditions for FGD device
are satisfied.
7.7.1 Start of absorber agitator
1) Check the agitator as required;
2) Confirm that the absorber liquid level is higher than the “low liquid
level”.
3) Start the four absorber agitators by sequence.
4) Check the agitator which should be running normally.
7.7.2 Startup of absorber recycling pump
1) Check the recycling pump as required.
2) Enable the mechanical sealing water of recycling pump and the

cooling water of gear box.
3) Start two absorber recycling pumps in turn. If the set load is

higher than 50%BMCR, start the sequential start programme of
the third absorber recycling pump if necessary.
4) Check the equipment operation after start.
5) Determine whether to start the third absorber recycling pump in

accordance with the desulphurization efficiency after flue gas
goes into the absorber.
6) In order to prevent slurry from staying at absorber flue gas intake,

the absorber recycling pump must not be running for more than
ten minutes before the unprocessed flue gas intake baffle is
opened for flue gas admission.
7.7.3 Start of FGD system
Do not start FGD system until flue gas conditions are satisfied.
1) Open FGD outlet flue gas baffle.
2) Confirm the fully-open signal of FGD outlet baffle.
68
3) Start the booster fan system including the lubricant system of
booster fan motor and sealed air system. Manually turn on the
booster fan under the control of inlet guide vanes which are at
minimum opening position.
4) Open the FGD inlet baffle valve.
5) Confirm fully-open signal of FGD inlet baffle is displayed proper.
6) When the opening range of booster fan guide vane reaches 30%,
shut off the FGD bypass baffle valve with the command of shift
leader. Ensure the inlet flue gas pressure of FGD is around
designed value, and control guide vane opening range until FGD
bypass baffle closed.
7) For the first start, manually adjust the booster fan guide vane,
and perform programme control after getting the performance of
controlling the guide vane.
7.7.4 Start of the oxidation fan
1) Check the oxidation fan as required.
2) Supply cooling water for oxidation fan.
3) Start the sequential start programme of oxidation fan.
4) Check its operation after equipment start.
7.7.5 Start of gypsum discharge pump of absorber
1) Confirm the main manual valve of PH meter measurement

system is closed. Open the membrane valve of the in-use pipe.
Turn off the manual valve in front of PH meter of the in-use pipe.
Open the flushing valve of the in-use pipe to wash for five
seconds. Close the flushing valve, and open the manual valve in
front of PH meter to make the PH meter at standby.
2) Check the gypsum discharge pump as required;
3) Connect the mechanical sealing water of gypsum discharge

pump;
4) Set a gypsum discharge pump as the operating one, and another

as standby;
5) Start one gypsum discharge pump;
6) Check equipment operation after start.
7.7.6 SO2 removal rate control of the absorber
69
SO2 removal rate is determined by the adding amount of fresh
limestone slurry poured into the absorber. The fresh limestone slurry
amount is determined by predicted SO2 removal rate, boiler load, and
the pH value of slurry inside absorber.
Sequence start of absorber demister: Set demister flushing water

control to be automatic. When the demister operation conditions are
satisfied, the demister will automatically accurate the sequence start
programme of flushing. Demister flushing wait time is controlled by the
absorber liquid level control system.
7.7.7 Start of the gypsum dehydration system
The gypsum dehydration system operates under the control of slurry

concentration control system of the absorber. When the gypsum slurry
concentration is lower than the set value, the gypsum dehydration
system is under hot standby status, and the pump and the agitator are
under the control of their liquid level control systems. When it reaches
the set value, the gypsum vacuum belt spin-drier starts to work. After
the slurry concentration control system is able to start, put the entire
gypsum dehydration system into operation.
7.7.8 Start of the vacuum belt drier
After the start conditions for vacuum belt drier are met, start it.
1) Confirm opening the sealing air water valve of vacuum box;
2) Confirm opening the flushing water valve of filtering cloth;
3) Confirm opening the flushing water valve of filtering cake;
4) Start filtering cloth flushing water pump;
5) Start vacuum belt drier with 30s delay (25Hz);
6) Turn on process water valve at the vacuum pump intake;
7) Start the vacuum pump;
8) Open the distribution valve of the cyclone with 5s delay;
9) Put the gypsum plate thickness into automatic control after 10min
delay (forming a loop with the transducer).
7.7.9 Start of the gypsum cyclone
After the gypsum slurry concentration is met for the vacuum belt drier
start, switch on the electric valve in front of gypsum cyclone, which will
be then under operation.
70
7.7.10 Start of the overfall box system of gypsum cyclone
Put the liquid control system of gypsum cyclone overfall box, and set
the agitator to be automatic. Then, the liquid level will be automatically
controlled for operation.
Set the overfall conveying pump of gypsum cyclone at the manual

position. Its operation is determined by required liquid level and
absorber liquid level.
7.8 Short-Term Start
For a short-term start, it is not needed to start the agitator, process

water system and instrumental air system. At the same tine, do the
other operations for start normally.
7.8.1 Start after short-term outage
Following the procedures to reduce the start period:
1) Start the absorber recycling pump;
2) Start the FGD system;
3) Start the oxidation fan;
4) Set the SO2 removal rate control of absorber to be automatic.
5) When at least two absorber recycling pumps are running, the flue
gas is introduced to the system. The absorber recycling pumps
should be started in turn in order to avoid that the equipment of
electric system is damaged due to the high start current of motor.
7.8.2 Start after power supply failure
1) When the power is re-supplied, the shutdown programme will be

restored with drainage and flushing steps, and DCS shutdown
programme simultaneously occurs.
2) When the power is re-supplied, all electric equipment will keep

out of operation, and all isolation valves will remain the status
when being in outage.
3) All alarms in DCS caused by the failure should be removed.
7.8.3 Required procedures when the power is re-supplied (short-term

outage)
If the power supply interruption time is within 10 minutes, the
71
equipment and system must be restarted as follows in order to suspend
the solid inside the tank and make the slurry flow inside the pipes.
All systems must go through normal shutdown procedures before

restart, and be restarted after the shutdown procedures are completed
according to Normal Start instruction of the FGD system.
1) Set all liquid sump pumps to be manual, and confirm that all
agitators are under operation when there’s liquid in the sumps;
2) Start two recycling pumps;
3) Start oxidation fans;
4) Start limestone slurry production system;
5) Start demister programme;
6) Start the absorber liquid level automatic control;
7) Start SO2 control system;
8) Start gypsum discharge pump;
9) Start automatic control programme for absorber slurry

concentration;
10) Monitor the system restart parameters especially the flow

information inside the pipes containing solid and the temperature
of any bearing that needs lubricant. Check the system
immediately after finding abnormal conditions.
72
8 Maintenance After FGD System Start
8.1 Monitoring and regulation during operation
1) Operators should carefully monitor the operation parameters and

compare them with the designed values, and check if there is any
error, find out the causes and make some adjustment in time.
2) Operators should clearly and correctly make a record according

to requirement; and analyze, cope with and report the abnormal
conditions in time.
3) Timely adjust the FGD system during normal operation, and

adjust parameters to make sure they are within normal scope.
4) Maintain absorber water level within normal range by adjusting

the flushing time of demister flushing water, to keep PH value of
absorber slurry within 5.5-6.0 by adjusting the supply amount of
limestone slurry. Guarantee the solid content in the slurry is at
20-25%, the concentration be in the range of 1127～1165kg/m3
and lower than 1170kg/m3 by adjusting the hydraulic cyclone.
5) Frequently monitor the booster fan’s vibration, bearing

temperature and its motor vibration and temperature that should
be in normal scope. The opening range of fan vane baffle is
automatically adjusted with the change of system inlet pressure.
6) During operation, on-duty operators should determine the

number of operating recycling pumps according to set load and
desulphurization efficiency, and frequently monitor the
temperatures of recycling pump motor bearing and motor
winding.
7) Monitor the pressure drop of absorber demister, and reduce the

pressure drop through extending flushing water time.
8) Frequently monitor the pressure and temperature of oxidization

air. In case of a low-pressure alarm, on-duty operators should
check the fan and oxidization air channels at once, or adjust the
manual valve and start the standby device. In case of a
high-temperature alarm of oxidization air after attemperating
water appears, the operator should check whether the automatic
shutdown valve of attemperating water and the manual isolation
valve of attemperating water are completely opened, and
whether the muzzle of attemperating water is jammed. In the
event that two oxidization air compressors cannot operate, FGD
73
system can still operate for six hours. In this case, the PH value
of absorber slurry should be reduced to 5.0 and the content of
CaSO3·1/2H2O inside the absorber should be examined once an
hour. Providing there’s no oxidization air in the oxidized air nozzle
for a long time, the pipes must be cleaned.
9) Monitor the demister flushing water flow, and deal with it if it has
large changes.
10) If the pressure difference between the front and the back of
demister reaches a high value of alarm, and it’s ineffective after
flushing, the operator should stop the absorber and check it.
11) If the interlock start and stop of gypsum dehydration system is

normal, the openness range of corresponding valve should be
adjusted according to absorber slurry concentration to ensure the
feeding pressure of gypsum cyclone remains at around 0.15MPa.
12) The on-duty operator should be familiar with the normal readings
of the monitoring instrument, analyze the cause in case of
deviations, and take steps to minimize potential problems.
13) Frequently monitor the liquid level of boxes, tanks and sumps.
Ensure that the equipment that can come into operation
automatically works normal. Standby equipment must be in good
condition.
14) Frequently monitor the pressure and flow of process water, and
make sure the pressure of compressed air is normal.
15) Ensure the flushing programme can be properly executed after

disabling the device to transport slurry, prevent sediment and jam,
and manually wash if necessary.
16) In case of a dehydration system failure, the gypsum slurry can be

kept inside the absorber. The gypsum slurry concentration in the
absorber should not exceed 1170kg/m3. If the concentration
reaches 1170kg/m3, it must be pumped to the emergency slurry
box by a gypsum discharge pump, and be pumped back to the
absorber after the dehydration system restores.
17) For the device to transport the slurry, analyzes and judges
whether there is sediment or dirt in the pipes according to the
device’s flow and pressure. If there is, take measures to deal with
it immediately.
18) When the open range of limestone slurry adjusting valve remains
74
the same for two hours, open it to the full range and clean it
periodically in order to prevent valve sticking.
8.2 Patrol Inspection Items During Operation
1) Thoroughly examine the equipment every hour and deal with

problems in time.
2) Check whether there’s leakage in flues, pipes, boxes, tanks, and

rotating machines.
3) Check whether the lubricant on rotating devices is at the normal

level and whether its quality is acceptable; add lubricant if the
level is low, and ensure cooling water is sufficient and the cooling
air is clear.
4) Ensure connectors of rotating devices are not loose, ensure

there’s no noise or vibration, and the temperature of each part is
normal.
5) Guarantee indicators, instrument and measurement devices are

under normal condition.
8.2.1 Monitored chemical items
Chemical monitoring and measurement should be strictly carried out to

examine the correctness of measurement devices, to analyze FGD
operation status, and guarantee FGD normal operation.
1) Chemical analysis indexes
A. Limestone: CaCO3
B. Limestone slurry: PH value and density
C. Absorber slurry: PH value, density, CaSO4·2H2O, Cl ion

concentration, CaSO3·1/2H2O and CaCO3
D. Gypsum slurry: PH value, density, CaSO4·2H2O, Cl ion

concentration, and CaSO3·1/2H2O
2) Parameter control requirement
A. Limestone quality directly influences the desulphurization

effect. Designed values of limestone quality:
75
Particle
Item CaCO3 MgCO3
grade
Value ≥90% ＜4% 90%≤44μm
B. Slurry component analysis is to check the degree of

chemical reaction inside the absorber and the use rate of
limestone, focusing on absorber slurry and the slurry at the
bottom of cyclone. Slurry components are designed as
follows:
Item Unit Absorber slurry Gypsum slurry
CaSO4·2H2O（gypsum） % 66.08～78.84 89.79～93.45
CaSO3·1/2H2O。
（CaSO3） % 0.15～0.18 0.20～0.21
CaCO3（limestone） % 3.01～3.49 1.92～2.24
Cl（chlorine） Mg/L 1922～6856 1922～6856
C. PH value and density value are the main indicators of FGD

operation. Analyze the slurry at the four sample outlets
including the outlet of gypsum discharge pump, the bottom
of gypsum cyclone, the limestone slurry tank, and slurry
recycling box. Designed PH values and density values are
as follows:
Item PH value Density （kg/m3）
Name Absorber Absorber Limestone slurry

box
Designed 5.5－6.0 1161 1191

value
76
9 Shutdown of FGD Equipment
9.1 Long-term shutdown
9.1.1 Preparation for long-term shutdown
If whole FGD system is out of operation, the slurry level in the

limestone slurry box should be set to the pump protection shutdown
liquid level, and the residual liquid will be discharged thoroughly. Shut
down the FGD system.
1) Open the bypass baffle.
2) When the bypass baffle opens to over 30% range, the open
range of booster fan moving vane should be adjusted and
controlled until booster fan out of operation.
3) Close the FGD outlet flue gas baffle valve after the oxidation fans
turned off.
9.1.2 Stop oxidation fan
Stop oxidation fan motors.
Close the attemperating water valve of oxidation air pipes.
9.1.3 Stop slurry recycling pump
When stopping the slurry recycling pumps, prevent overfeeding of

slurry into the absorber drainage sump causing overflow during the
pump drainage and flushing process.
1) Stop slurry recycling pump A. Carry out drainage and flushing of

slurry recycling pump A.
2) Stop slurry recycling pump B. Carry out drainage and flushing of

slurry recycling pump B.
3) Stop slurry recycling pump C. Carry out drainage and flushing of

slurry recycling pump C.
4) Stop slurry recycling pump D. Carry out drainage and flushing of

slurry recycling pump D.
9.1.4 Stop demister flushing
1) Stop main flushing programme of demister;
2) Switch off main pipe of demister water supply, and turn off electric
valve;
77
3) The demister can be turned to manual status through DCS to
stop flushing.
9.1.5 Limestone slurry production system outage
When FGD set stops, turn off the limestone slurry pump, and execute
drainage and flushing.
1) Limestone slurry production system is in outage.
2) Cut off automatic control of absorber SO2 removal rate.
3) Limestone slurry control system stops.
4) Limestone slurry pump stops.
9.1.6 Gypsum dehydration system stops.
1) Electric inlet valve of gypsum cyclone is turned off.
2) Vacuum belt drier system stops.
3) Gypsum cyclone overfall transmission pump stops. Turn on the

manual discharge valve inside the gypsum cyclone overflow box,
and drain the inner overfall liquid.
4) The liquid level controls the stop of filtrate pump and agitator.
Open the drainage box of filtrate water tank, and drain the liquid
to the drainage sump in the gypsum dehydration area.
5) Turn off the waste water flow valve, and stop the waste water
disposal system. Waste water system will execute discharge and
other tasks under check and repair demand.
6) Flush the gypsum cyclone station and waste water cyclone

station after they stop operating.
9.1.7 Outage of gypsum discharge pump
Stop the operating gypsum discharge pump.
Flush the gypsum transmission pipes and drain the water inside the
pipes.
9.1.8 Discharge of absorber slurry
1) Switch on the inlet electric valve of gypsum discharge pump.
2) Clear the pipe connecting the absorber and the emergency slurry
box.
3) Check the liquid level of emergency slurry box.
78
4) Start gypsum discharge pump as maintenance status, and
discharge absorber slurry to the emergency slurry box.
5) The set liquid level of absorber controls the stop of gypsum

discharge pump and absorber agitator, and the set liquid level of
emergency slurry box controls the start of the agitator of
emergency slurry box.
6) Get through the pipeline between absorber drainage sump and

emergency slurry box after stopping gypsum discharge pump for
protection. Open the valve of absorber discharge box. The
absorber drainage sump pump sends residual absorber liquid to
the emergency slurry box.
9.1.9 Shutdown of the process water system
When both of two FGD systems stop, do not stop the process water
system until all flushing work in the system are completed.
1) Turn off mechanical sealing air water and cooling water of all
slurry pumps.
2) Cut off liquid level control of process water tank.
3) Disable the process water pump and demister flushing water

pump.
4) Drain process water tank if necessary.
9.1.10 System power off
Cut off the power supply of shutdown system, keep power supply for
liquid level monitoring devices, agitators and baffle sealing air fan of
boxes, tanks and sumps with liquid level remained, as well as the
agitator of the emergency slurry box. Periodically check the operating
equipment.
9.2 Short-Term Shutdown
9.2.1 Preparation for short-term shutdown
1) Limestone slurry production system stops.
2) Control absorber SO2 removal rate.
3) Control absorber slurry concentration.
4) Control absorber liquid level.
79
5) Absorber and FGD stop.
9.2.2 Follow the steps below:
1) Stop oxidation fan.
2) FGB system stops.
3) Stop absorber recycling pump.
4) Start the demister flushing stop procedure.
5) Control absorber liquid level.
6) Stop limestone slurry pump.
7) Turn off electric inlet valve of the gypsum cyclone station when
absorber slurry concentration is lower than 1125 kg/m3 and the
absorber liquid level is lower than. 7.0m
8) Filtrate water pump stops.
9) Stop gypsum discharge pump if necessary.
9.2.3 Notes during shutdown period
1) When the pressurization fan stops, manually close its guide

vanes slowly, and prevent hearth pressure from drastic
fluctuation.
2) After turning off the inlet valve of gypsum cyclone station,

carefully wash the gypsum cyclone and the filter cloth of vacuum
belt drier.
3) Don’t drain boxes, tanks or sumps. Liquid level will control the
start and stop of devices automatically.
4) The agitator, process water system and instrumental air system

keep operating.
9.3 Short-Time Shutdown
9.3.1 Stop the following devices in case of a short-while shutdown.
1) Stop oxidation fan.
2) FGD system stops.
3) Stop absorber slurry recycling pump.
9.3.2 Check and precautions after shutdown
80
1) Flush the shutdown equipment in time.
2) Periodically examine the operation of containers with liquid level

such as the emergency slurry box.
3) Flushing time for pumps, pipes and other objects must be enough
(judge the flushing status according to personal experience). Pay
much attention to flushing the slurry transport pipes in order to
prevent residual slurry from depositing or drying as well as
blocking pipes.
4) After the absorber agitator stops, wash it with flushing water in

case of restart.
5) Discharge slurry in containers that need repair.
81
10 FGD Device Operation Adjustment
10.1 Main Tasks for Operation Adjustment
1) To meet the unit’s desulfurization demand under the normal

operation of the main machine;
2) To ensure the safe operation of desulfurization device;
3) To keep all parameters under the optimum working conditions

and reduce various consumption through careful adjustment;
4) To ensure the gypsum’s quality to meet the requirements;
5) To ensure the unit’s desulfurization rate within the regulated

range.
10.2 Operation Adjustment of Desulfurization System
10.2.1 Level adjustment of the absorber
The liquid level of absorber has great influence on desulfurization effect

and system safety. The high level will reduce the reaction space for
absorbents and flue and weaken the desulfurization effect. In addition,
when serious, it may cause system overflow, even overflowing into
desulfurization flue gas duct and oxidation air pipes. However, the low
level will reduce the oxidation reaction space and influence gypsum’s
quality, possibly causing the agitator vibration, bearing sealing
damaged or even shutdown.
The designed normal level of absorber is 7.9m. The level should be

controlled at 7.9±0.3m. If the level is high, confirming the valves of
slurry discharge pipes are closed or opened correctly. The control
system must have no error. At the same time, manually close the
demister’s flushing water valve and the absorber’s water makeup valve.
Reduce or cut off the water quantity of filtrate going to the absorber.
The slurry may be drained to emergency slurry tank or the slurry
discharge valve at the bottom may be opened for reaching normal level
when necessary. If the level is low, confirm if there is any leakage or
blockage in water makeup pipes. The flushing water of demister sprays
normally, meanwhile adjust the flushing time interval of demister,
opening the water makeup valve largely and increasing the return flow
from the gypsum discharge pump to the absorber (use it based on the
concentration of absorber).
82
10.2.2 Adjustment of concentration of slurry liquid in the absorber
The concentration of slurry in the absorber is critical to the operation of

the whole desulfurization device. Improper adjustment may cause worn,
corrosion, scaling and blockage to pipes and pumps, which further
influence the normal operation of FGD. The designed concentration for
this project is 25%.
If the concentration is low, increase the gypsum overflow returning to

the absorber, and decrease the process water going to the absorber. If
necessary, stop gypsum cyclone to make the gypsum liquid go back to
the absorber. On the contrary, it should be opposite.
10.2.3 Adjustment of desulfurization rate, PH value and limestone liquid

supply
1) The quantity of limestone liquid supply has great influence on the

desulfurization device. If the supply is too low, the FGD under full
load should not be satisfied. The flue’s sulfur content will increase,
resulting in low desulfurization rate. If the supply is too high, the
limestone contained in the gypsum should rise, decreasing the
gypsum purity. Meanwhile, the utilization rate of limestone
reduces, resulting in big waste.
2) Under normal operation, the slurry supply quantity can be jointly

adjusted according to PH value, inlet unprocessed flue’s SO2
concentration, desulfurization rate and limestone liquid
concentration. When PH value and limestone liquid’s
concentration goes down, the supply quantity may be increased.
When outlet SO2 concentration increases, the opening degree of
limestone slurry supply control valve can be properly enlarged
and the limestone slurry quantity be increased.
3) In case the desulfurization rate is too low to reach the designed

values, the slurry supply quantity should be enlarged. A complete
inspection and analysis to the system should be made to find out
the causes. Remove the problems when necessary.
10.2.4 Gypsum quality adjustment
1) If the water content of gypsum is above 10%, adjust the slurry

supply quantity or rotation speed of the vacuum belt dehydrator,
in order to ensure the vacuum degree of dehydrator and the
thickness of the gypsum are in proper scope.
2) If the CaCO3 is excessive, timely adjustment to slurry supply

quantity is required and limestone liquid. Ask the chemical
83
personnel to assay the limestone material and slurry qualities. If
the particle size of limestone slurry is too big, the fineness should
be adjusted to a proper range. Material purchase department
should ensure the material quality be in proper range if there is
excessive impurity in the limestone materials.
3) In case of excessive CaSO3.1/2H2O, oxidation air quantity

should be adjusted timely. Check the operation of oxidation air
pipes and agitators in order to guarantee full oxidation of
CaSO3.1/2H2O in the oxidation tank of absorber.
10.2.5 Limestone slurry preparation system
Limestone slurry concentration: about 30%
Frequently analyze the temperature changes of each part in the slurry

preparation system as well as slurry concentration, timely finding out
causes and solving the problems immediately.
10.2.6 Adjustment of slurry preparation system
The principal task of slurry preparation system adjustment is to ensure

the limestone slurry quality is proper, to meet the demand of safe and
cost-efficient operation of the desulfurization system.
Strictly control the proportion of limestone feeding quantity and process

water quantity going to the limestone slurry tank.
Timely adjust the feeding quantity of dosing belt conveyer to ensure

proper material feeding.
If the limestone slurry quality does not and can still not meet the
requirement after adjustment during operation, it is required to inform
the lab to analyze the limestone quality.
10.3 Inspection During the Operation of Desulfurization Device
10.3.1 General rules for inspection
1) Electric, I& C measurement and protection devices, industrial

cable TV monitoring equipment are complete and under proper
operation.
2) The equipment appearance, parts and insulation should be in

good shape. The equipment and its ambient should be clean
without oil, water, slurry and other foreign matters. The
illumination should be sufficient. The rails and platforms should
84
be complete.
3) The manholes, inspection holes and slurry discharge valves of

tanks, vessels, ponds and absorbers should be tightly closed.
4) All valves and baffles should be easily opened and closed,

without any jam. The position indication must be correct.
5) The shield of each driving belt should be completed and stably

installed.
6) Parts, anchor bolts, coupler’s bolts and shield for rotating

machines should be fixed tightly.
7) Each part of rotating machines should be with good-quality oil,

clear oil level indication, and under the condition of normal oil
level. Holds and covers must be completely good. There should
be sufficient lube grease in the oil cup.
8) Regular filling of suitable greases is required in each part of

rotating machines. Granule-like mechanical impurities should be
avoided mixing into the lubricant when filling.
9) When the machines are running, there should be no knocking or

friction sounds. The current meter indication should not exceed
the rated valve. The motor rotating direction is correct.
10) The bearing temperature and vibration of running equipment

should be within the permitted range, and the oil temperature
within the regulated value.
11) The inlet and outlet of motor’s cooling air should be clear. The
inlet temperature should be less than 45℃, and the air
temperature difference between inlet and outlet should not be
higher than 30℃, and the shell temperature should not exceed
70℃.
12) The motor’s cable head, wiring and earthing wire are proper and
tightly connected. The temperature measuring devices for
bearing and motors are normal and correctly work. Normally, do
not start the motor continuously for two times under hot status (it
is called hot start when the motor’s coil temperature is above
50℃.)
13) Check the equipment’s cooling water pipes and cooling air duct
which should be clear. The cooling water quantity should be
proper.
85
14) During the running, the belts of belt driving equipment do not
slide, not run out of alignment and has no damage. The belt
wheel should be aligned.
15) All belt conveyers must not run out of rating range. Restart with
lower load in case of first start failed. No continuous start is
allowed in case of a second failure. It can only be started after
discharging all loads on the belt. Meanwhile, report to the shift
leader and office.
16) All drive mechanism should be complete and flexible. The pin
connects firmly.
17) Electric executors for air valves and baffles should be complete,
connected firmly and positioned at automatic control.
18) The tanks and vessels are in good shape, with levels normal.
19) The agitators run well. The vibration and temperatures are in the
range.
20) The temperature of oxidation air pipe is normal. No blockage

caused obvious low temperature.
21) The operating pressure of cyclone is normal. The overflow and

bottom flow pipes have no blockage.
22) Emergency button and shield are proper.
10.3.2 Flue system
1) Confirm the sealing system has been shut down, and the spare
system is under good condition.
2) Sealing gas pipes and flue channels should have no leakage.
3) Flue channel’s expansion goes clearly and its joints have no

cracks.
4) When the desulphurization device shuts down for maintenance,

the inlet and outlet unprocessed flue baffles for the booster fan
and the outlet processed flue baffle of absorber should be closed.
At this moment, the fresh air should be used as sealing air. The
electric heater should work normally and the sealing air pressure
should be higher than the flue pressure to avoid the flue’s entry
into the working area.
10.3.3 Booster fan
1) Booster fan motor is checked running well according to rules.
86
2) The booster fan’s shell vibration value does not exceed 62um,
and the measured value of vibration monitoring complies with the
actual vibration value.
3) The boosting fan’s bearing temperature does not exceed 70℃,

with the highest temperature not above 90℃. The measured
value by bearing temperature measurement device complies with
the actual value.
4) The bearing lubricant and grease are within the grease filling
cycle, and no oil leakage occurs to the pipes.
5) No vibration and air leakage occur to flue pipes and expansion

joints.
6) The cooling air fan for the booster fan properly runs and the
interlock is put into operation.
7) High and low pressure sealing air fans are in good condition as
standby.
8) The sealing of bypass baffle is good. The pressure difference

does not exceed the limit.
9) The measured values of all points in the flue online monitoring

system are correct.
10) All manholes in the flue system are tightly closed. No flue, water
and steam leakages occur.
11) The flue dampers are opened and closed properly, with correct
signal indication.
10.3.4 Absorber
1) No slurry and flue leakage occur to the absorber proper, and its
liquid level, slurry concentration and PH value should be in the
regulated range.
2) The demister’s outlet pressure difference is proper. The flushing

water supply is clear with eligible pressure. The flushing
procedure runs correctly when the demister is automatically
flushed.
3) The gland sealing of the side-inserting agitator is good. No slurry

leakage occurs to the leakage inspection pipe.
4) No leakage occurs to the nozzle of oxidation air.
5) No leakage occurs to the absorber’s vent valve. No leakage
87
points exist at the joints between the flue pipes and absorber.
6) The valves at water discharge points close tightly and no slurry

leakage occur.
7) No leakages occur to the flushing nozzle of demister.
8) The I & C instrument are in good shape, the wiring is stable and
the measured value is correct.
10.3.5 Centrifugal pumps and other types of pumps
1) The pump’s gland seal is tight without any leakage of slurry and
water.
2) The pump’s outlet pressure is normal without serious fluctuation.

Otherwise, the inlet blockage or vaporization may occur.
3) If the inlet pressure of pump is too high, the water levels of tanks,
vessels and ponds should be timely adjusted to avoid
overloading of pumps. If low, the spare pump should be started.
Manually carry out backwash to the inlet of failed pump, and do
maintenance when necessary.
10.3.6 Oxidation fan
1) The inlet filter mesh should be cleaned and free of messes.
2) The oxidation air pipe is tightly connected and no air leakages

occur.
3) The outlet startup valve of oxidation fan is tightly closed.
4) The outlet pressure, flow and temperature of oxidation air are

normal.
5) Check if the pressure difference before and after the filter is

normal. If the pressure difference is big, timely cleaning of the
filter is required.
6) The level and the quality of lubricant should be normal. Replace

the lubricant for every 8000hrs running.
7) The pressure and flow of oxidation fan’s cooling water are

normal.
8) The cooling water discharge valve of oxidation fan is tightly

closed.
10.3.7 Gypsum dehydration system
88
1) Check if the slurry distribution pipe spreads the slurry evenly
without any deflexion, the thickness of the gypsum cake is evenly
suitable, the water content of discharged material is normal
without blockage.
2) The speed of dehydrator is proper, and the filter cloth tension

should be suitable and clean without nick.
3) All rollers of dehydrator can rotate flexibly. Solid residues near

the rollers should be timely cleaned.
4) The flushing water and sealing water quantity, water pressure of

each pipeline are normal. The dehydrator’s sound is normal
when running. The vacuum of filtrate tank is normal.
5) The belt alignment adjustment device works normally. The

compressed air pressure of the filter cloth alignment auto-device
should not be lower than 0.6MPa.
6) The cooling water flow for the water-ring type vacuum pump is
normal, about 6～8m3/h.
7) Check if the pipeline for the process water to filter cloth flushing
water tank is clear or not.
8) Try to reduce the start/stop times of dehydrator which should not

be done that frequently. The vacuum pump can be shut down and
keep the belt dehydrator to run with no load at a low speed when
dehydration is not required for a short period.
9) If the outage time for the dehydration system exceeds seven

days, the water discharging valve should be opened to drain out
the sealing water inside the pump.
10.3.8 The belt conveyor emergency shutdown cases
1) The belt runs out of the alignment seriously.
2) The belt interface turns up.
3) Belt slides or slows down seriously.
4) Blockages appear at the material inlets and outlets.
5) Abnormal sound occurs to the equipment.
6) Equipment and personnel safety are endangered.
10.3.9 Pumps and motors
1) Water pumps and motors should have no abnormal noise, and
89
the lubrication should be good.
2) The vibration of pumps and motors does not exceed the regular
value.
3) The bearing temperature does not exceed 70℃, and the motor
not exceed 65℃.
4) Regularly check the oil quality and oil level, and replace or fill
lubricating oil.
5) Switching to the standby pump according to equipment switch

system;
6) The outlet pressure of pump should be recorded every two hours.
7) Motor current and temperature increase should be checked every

two hours. The temperature increase should not be above 60℃,
and the bearing temperature not above 80℃.
8) The water pump’s oil tank level and oil quality should be checked
each shift to confirm oil level and lubrication situation normal.
9) No abnormal noise occurs to the rotating parts and motors of

water pumps.
10) The pressure drop should not be large when increasing water
pump’s flow to avoid overloading of the motors.
11) The cooling water supply for pumps should be clear.
12) The cable heads should have no phenomena of overheating,

electric leakage and oil leakage.
90
11 Procedures for Accident Treatment and
Emergency Shutdown of FGD Equipment
11.1 Basic Principles for Accident Treatment
1) If there is any malfunction accidentally occurring in daily

operation, all persons on duty should stay at their own position to
immediately investigate the cause and scope of malfunction
based on the specific phenomenon. Deal with them in time and
then report to the shift foreman and shift leader. If the malfunction
poses danger to the safety of person or equipment, person on
duty should rapidly and decidedly eliminate such danger and
report the issue to the superior.
2) When the persons who are not on duty arrive in the malfunction
site, they are not permitted to perform any operation or treatment
without permission from the shift operator or shift foreman. If the
situation in fact poses threat to safety of persons or equipment,
they could immediately report to the shift operator or shift
foreman.
3) If the particular malfunctions that are not in the range of this

regulation happen, on-duty persons should perform necessary
and proper treatment in time in accordance with knowledge and
experiences obtained from daily operation so that the safety of
persons and equipment is guaranteed.
4) During the process of malfunction treatment, if the on-duty

persons receive the orders that may threaten the safety of
persons or equipment, such orders must be resisted
uncompromisingly. Report to the senior leader.
5) During the process of malfunction treatment, persons on duty

should collect, record and print the relevant parameters, images
and malfunction in time for future malfunction analysis;
6) If the accident happens, persons on duty are not permitted to

forcedly supply power to start the being-inspected equipment
before making contact with those who go out for inspecting and
search malfunction points regardless of how urgent the situation
is.
7) If the accident happens during the process of shift turnover time,

stop the shift turnover work. The shift-off persons must deal with
91
the accident and the shift-in persons could assist to deal with it
under permission. Then the shift turnover work should be carried
out after the accident treatment finished.
8) After the accident is solved, the shift operator should record the
detailed information about the occurrence and treatment of
accident. The contents include: operating status before the
accident, description of accident site, protection action, and
trouble shooting time, sequence of accident treatment, and the
final results, and the damage to equipment if there are some.
11.2 Malfunctions of FGD System
11.2.1 The FGD equipment emergency shutdown situations
1) Fault booster fan causes trip;
2) Circulating pumps of absorber all shut down;
3) Either the inlet or outlet damper of absorber is closed during

normal operation process;
4) Inlet flue gas temperature of FGD system is higher than 180℃;
5) 6.6KV power source broken;
6) Trip of boiler MFT;
7) Concentration of inlet flue gas dust of FGD system is higher than

2%;
8) The inlet pressure of air fan is higher than 800Pa or lower than
-800Pa.
11.2.2 The situation of desulphurization system in power off
1) Control and monitoring functions of DCS still work via UPS or

emergency power source
2) Malfunctions of electrical equipment could be displayed on LCD;
3) Supplying control power for various circuit breakers in the system

by UPS and 220V DC battery units in the purpose of control and
monitoring them.
4) Making the emergency illumination power work through 220V DC

battery unit when the power is off;
5) Bypass damper of FGD system will be opened automatically,

therefore the inlet and outlet dampers of FGD system should be
92
closed manually on the site;
6) Other process equipment stop working except the flushing water

pump of demister and the valve of bypass damper;
7) Drainage pumps and agitators in all areas can not be used.
11.2.3 6.6KV power source cut off.
1) Phenomenon
z The 6.6KV busbar voltage loses; acousto-optic alarm

signals sent out, LCD alarms;
z The running FGD equipment trips and 6.6KV motor of

corresponding busbar shut down;
z Corresponding 415V busbar of this section will experience

power loss and the corresponding 415 load will trips
because of power failure.
2) Causes
z 6.6KV busbar failed;
z The unit generator trips and emergency power is

unavailable;
z Emergency power for FGD equipment can not be put into

use.
3) Treatment
z Immediately confirm whether the trip action of FGD

equipment interlock has been done, and switch the
automatic mode into manual mode if the action of bypass
flue damper reacts poorly;
z Confirming the power supply for USP board and that for DC
system is normal. The switches of operating and
emergency power are in power-off position, and switches of
all loads should be off;
z Reporting to shift leader and contacting electric

maintenance personnel in time in order to find out the
causes of malfunction and restore power supply;
z Reset all tripped equipment;
z Pay attention to supervise changes in temperature of flue

gas system and open the valve of flushing water of
93
demister in manual way if necessary;
z Turning the control damper of booster fan down to minimum

position and making good preparation for restarting the
FGD equipment;
z If the 6.6KV power source can not be resumed in short time,

discharge the slurry retained in pipelines and pumps for
the sake of avoiding sediment in accordance with relevant
regulations on shutdown;
z If the situation causes break of 415V power source, it

should be solved according to relevant regulations.
11.2.4 4 15V power source cut off
1) Phenomenon
z The acousto-optic warning signals for Break of 415V Power

Source is sent out;
z Voltage of 415V power source points at zero, and

low-voltage motor trips;
z Operating illumination is under trip, emergency illumination

is put into use.
2) Causes
z Malfunction of corresponding 6.6KV busbar;
z FGD transformer trips;
z Malfunction of 415V busbar.
3) Treatment
z Temporary shutdown should be applied if it is caused by

malfunctions of 6.6KV power source;
z If only 415V board is failed, inspect the causes of

malfunction and actions of equipment, and then cut off the
power supply of this board. Report to the shift foreman and
shift leader;
z If the 415V power sources are all cut off and the power can
not be resumed within eight hours, please use emergency
equipment to discharge the slurry retained in all pumps and
pipelines. Flush them immediately;
z Forced power supply is strictly forbidden if the malfunctions
94
are caused by electric protection action.
11.2.5 Malfunctions of FGD booster fan
1) Phenomena
z The acousto-optic alarm for Trip of Booster Fan is sent out;
z Yellow indicator of booster fan flashes and electric motor

stops working;
z Bypass damper automatically opens and inlet and outlet

flue gas dampers are closed interlock;
z Interlock stop slurry supply if limestone slurry supplying

system automatically works;
2) Causes
z Emergency button is pressed or touched by mistake;
z Power loss of booster fan;
z Circulating pumps of absorber all stopped;
z Excessive pressure loss of FGD equipment;
z Temperature of any bearing is higher than set value of high

high;
z Bearing vibration is higher than the alarm value of high

high;
z Coil temperature of motor is higher than the alarm value of

high high;
z Inlet or outlet damper of FGD system is closed during

operation process;
z Electric malfunctions (such as overload, overcurrent

protection, and differential protection action).
3) Treatment
z Confirm that bypass damper of FGD equipment is

automatically opened and the inlet and outlet flue gas
dampers are closed in linked way; manually do it if the
interlock does not work well;
z If the trip of booster fan is caused by protection action, the

fan can only be restarted after the system returns to normal
status;
95
z If the trip of booster fan is caused by the malfunctions of fan
equipment, report the situation to shift leader in time and
contact maintenance personnel for further treatment
immediately. Restart of booster fan is strictly forbidden
before the malfunction is solved.
11.2.6 Circulating pumps of absorber all stopped
1) Phenomenon
z The acousto-optic alarm signal for ‘All Circulating Pumps of

Absorber Stopped’ appears;
z The yellow indicator on operation terminal of the tripped

slurry circulating pump flashes, and the electric motor stops
rotating;
z Interlock open the bypass damper, stops booster fan, and

close the inlet and outlet flue gas dampers of FGD
equipments.
2) Causes
z Break of 6.6KV power source;
z Liquid level of absorber too low;
z Control circuit for liquid level of absorber failed;
z Bearing Temperature of the slurry circulating pump motor is

high high;
z Motor’s coil temperature of slurry circulating pump is high

high;
z Suction valve of slurry circulating pump is not completely

opened;
z Electric malfunction of slurry circulating pump.
3) Treatment
z Confirm the interlock action is normal: bypass flue gas

damper of FGD equipment automatically opened, booster
fan tripped, inlet and outlet flue gas dampers automatically
closed. And if the booster fan does not trip and dampers do
not work well, manual treatment should be performed
immediately;
z Find out the causes of slurry circulating pump trip and then
96
deal with the problem in line with relevant regulations;
z Report to the shift foreman and shift leader in time and

notify the relevant maintenance personnel for further
treatment if necessary;
z If the absorber can not restore running in short time, solve it

in accordance with relevant regulations as temporary
shutdown;
z Open the valves of emergency water spraying of absorber

inlet and demister flushing water based on the specific
temperature of flue gas in the absorber, in order to prevent
the temperature of flue gas entering to absorber is too high,
causing damages to demister.
11.2.7 Treatment in fire disaster
1) Phenomena
z Fire-alarm system sends out acousto-optic alarm signal;
z There is smoke, fire or scorched smell in operating site;
z If the power cable or cable for control signal is on fire,

relevant equipment may trip and there would be dramatic
changes in operating parameters.
2) Treatments
z Accurately determine the location, property and danger of

the fire;
z Report to shift leader and relevant departments, and call the

fire department immediately if necessary;
z Choose proper extinguisher to put out the fire and shut

down the FGD system if necessary;
z Restore normal operation after putting out the fire.
11.3 Common Malfunctions and Treatment
11.3.1 Low removal efficiency of SO2
1) Causes
z Inaccurate measurement of pH meter;
z Inaccurate measurement of SO2;
97
z pH value too low (<5.0);
z Sudden increase in flue gas flow;
z Increase in concentration of SO2 contained in inlet flue gas

and improper adjustment or exceed the designed capacity;
z Lower slurry circulation flow or the running set is few
z Excessive concentration of chloride ion in absorber;
z Leakage of unprocessed flue gas and purified flue gas

occurs because of improper sealing of bypass damper.
2) Treatment
z Calibrate pH meter;
z CalibrateSO2 measuring instrument;
z Check the limestone slurry flow; accelerate the feeding

speed of limestone; and inspect the reaction property of
limestone if necessary;
z Add one spraying layer;
z Checking the number of running circulating pumps and the

rating of each pump;
z Using waste water system or improving waste water

treatment capacity;
z Check the operating status of sealing air fan.
11.3.2 Rise of differential pressure of demister
1) Causes
Scaling occurs due to inappropriate flushing of person in charge.
2) Treatment
Inspect and determine the scaling area on site, and change the
procedures to increase the flushing time of scaling area.
11.3.3 Increase in slurry concentration of absorber
1) Causes
z High flue gas flow and high inlet SO2 concentration;
z Insufficient rating of gypsum discharging pump;
z The whirl pieces of gypsum cyclone fewer;
98
z Scaling of gypsum cyclone;
z Inaccurate calculation of slurry density inside absorber.
2) Treatment
z Report to the shift leader, and adjust the inlet flue gas flow;
z Inspect the outlet pressure and flow, switch to emergency

pump for operation;
z Add more whirl pieces;
z Flush the cyclone;
z Verify the value of density by manually sampling.
11.3.4 Poor quality of dehydrated gypsum
1) Factors influencing the quality of gypsum
z High concentration of chlorides;
z High concentration of CaCO3;
z Inadequate size of crystal;
z High content of foreign substances.
2) Cause analysis
z Little flushing water or short flushing time for filter cake;
z Too many limestone (high pH value);
z Too high concentration of suspended particles in absorber;
z Increase of flying ash concentration in flue gas or decrease

of limestone quality.
3) Treatment
z Adjust the flushing water flow or time;
z Slowing down the feeding speed of limestone slurry;
z Reduce feeding solid particles to decrease its

concentration;
z Inspect the operating status of E.S.P or limestone quality.
11.3.5 Malfunctions of measuring device
1) Common malfunctions
99
z Rapid change occurs to the measurement value of pH
meter
z Big deviation of density calculation;
z Measurement malfunctions of liquid flow;
z Malfunctions of SO2 measuring instrument;
z Measurement malfunctions of flue gas duct pressure;
z Measurement malfunctions of liquid level;
z Measurement functions of flue gas flow.
2) Treatment
z If one measuring instrument has malfunction, please wash

the pH-meter; if two, please measure the pH value on the
site once per hour. Manually control the addition amount of
limestone slurry, contact relevant department to i repair the
machine, and put it into use after calibration as soon as
possible;
z Manually measure the density; and contact maintenance

personnel to repair it as soon as possible;
z Use process water to wash or recalibrate it;
z Use compressed air to blow the surface of instruments after

shutting them down and the operators should inspect it
immediately and control the parameter as well;
z Using compressed air to blow, or contact maintenance

personnel for mechanical cleaning if that does not work;
z Use process water to wash or flush them in manual way;
z Use compressed air to sweep the surface of instruments,

and adjust the adding amount of limestone slurry in manual
way.
11.3.6 All sealing fans shutdown
Phenomenon: the running sealing fan trips and the standby one can
not start automatically, and LCD sends out alarm signal.
Treatment: contact maintenance personnel for further treatment in

order to put the equipment into use as soon as possible. If the FGD
system uses bypass pipelines at this time, probably there would be little
flue gas leaking into absorber through inlet damper of unprocessed flue
100
gas. Therefore open the inlet emergency water spraying valve of
absorber and the flushing valve of one-layer demister for cooling.
11.3.7 Treatment of process water supply interruption
1) Phenomena:
z An alarm signal for low pressure of process water is sent

out;
z Interruption of on-site water supply for FGD;
z Liquid level of involved slurry tank drops;
z Dehydrator and vacuum pump tripped;
2) Causes
z Malfunction occurs to running process water pump, and

interlock of emergency water pump fails;
z The liquid level of process water tank too low, and the pump
trips;
z Process water pipeline is broken.
3) Treatment
z Confirm the interlock of dehydrator and vacuum pump is in

normal status.
z Closing the inlet electric valve of gypsum cyclone to start

the circulation from gypsum slurry bypass to backflow
pipeline of absorber;
z Finding out the causes of process water supply interruption,

reporting to shift leader and therefore resuming water
supply;
z During the process of treatment, please keep monitoring

the change in temperature of absorber, liquid level and
limestone slurry level, and deal with that as temporary
shutdown.
11.3.8 Other common malfunction phenomena and relevant treatment

measures
101
Malfunction
Possible causes Treatment measures
phenomena
Blockage of pipeline
Decrease in Clean the pipeline
flow of slurry Blockage of nozzle
Clean the nozzle
circulating Relevant valves not
pump of switched properly Check and calibrate the status of
absorber valve position
Decrease of pump rating
Maintain the pump
liquid level meter work Check and calibrate the liquid

poorly level meter
Leakage of slurry Check and repair circulating

circulating pipe pipeline
Absorber liquid
level abnormal Leakage of any flushing Check and replace valves
valves Check the absorber and bottom
Leakage of absorber blowdown valve
Malfunctions of absorber Replace the broken module

liquid level control module
Pollution, damage, aging Clean or replace pH-meter’s

occur to electrode of electrode
pH-meter
Check the blockage status of
Insufficient slurry supply to connecting pipeline of pH-meter,
pH-meter and the operating status of
Inaccurate isolation valve and gypsum drain
pH Process water mixing
indication of pump
into slurry supply for
pH-meter
pH-meter Inspect if flushing valve of
pH-valve leaked.
Zero- point drift of
pH-meter’s transducer Check and calibrate pH-meter
Malfunctions of pH-meter’s Check the status of pH-meter’s

control module control module
Abnormal Blockage of limestone Clean limestone feeder

density of feeder
Check compressed air and
limestone slurry Bridging of limestone in silo fluidized air pipeline
102
Malfunction
Possible causes Treatment measures
phenomena
Undesirable control over Check control module of limestone

the density of limestone slurry density
slurry
Knock mixing tank and material
Blockage in limestone downcoming tube
mixing tank
Check water filtrate pipelines
Malfunctions of and valves
slurry-making and water
filtration
Check the opening of valve to

improve slurry feeding
Insufficient slurry feeding
Check flushing water pump with
Insufficient flow of vacuum filtration cloth
sealing water
Check control module for belt
Deviation of belt track deviation
Malfunctions of vacuum Check vacuum pump
pump
Check vacuum pipeline to confirm
Leakage of vacuum whether there is any abnormal
pipeline system sound
Low quality of Relatively high Check flushing water quantity of
gypsum concentration of chloride filtration cake
filtration cake ion
Check the tension condition of
Damage of anti-wear belt filtration cloth
Abnormal belt speed of belt Check the operating status of belt
conveyer conveyer
11.4 Procedures for Emergency Shutdown
If the emergent situation described in section 5.2.1 happens, system

protection will automatically actuate the following program in order to
maintain whole desulfurization system and unit be in safe status.
1) Open bypass flue gas damper

2) Shut down the booster fan (L0HTC10AN001/L0HTC20AN001)

(this step should include the operations to inlet and outlet valve
103
and fan blade).
3) Close inlet damper of FGD system

4) Close outlet damper of FGD system

5) One boiler MFT.
6) Any boiler RUN BACK (50DAS01FU003 or

50DAS01FU004/60DAS01FU003 or 60DAS01FU004).
7) Single booster fan Tripped.
8) Open bypass dampers (two sets).
104
12 Operation of Auxiliary FGD Equipment
12.1 General Provisions of Auxiliary Equipment Operation
12.1.1 Precaution for trial running of auxiliary equipment
1) Before the trial run of inspected and repaired auxiliary equipment,

various interlock and protection test must be carried out. And the
trial run could be implemented only when its related devices pass
the test such as the control circuit, automatic devices, and I &C
interlock protection, mechanical devices as well as pneumatic
units;
2) After the inspection and maintenance, the auxiliary equipment

can be put into operation or as standby only if they are confirmed
acceptable in trial run. Maintenance personnel should be on site
when the trial run is being carried out. If the electric motor has
already been inspected and repaired, then it could be connected
with auxiliary equipment after being confirmed with correct
rotating direction in trial run.
3) Performing on-site inspection on equipment to confirm there is no

maintenance personnel around, all tasks have been finished.
Parts and components of the equipment are complete, and the
requirements for startup are satisfied, then operator could supply
power to the equipment;
4) If the auxiliary equipment trips during startup process, restart is

forbidden before figuring out the causes and eliminating
malfunctions; the alteration report on addition or improvement of
equipment should be prepared;
5) Calibrate the opening and direction indication of each air valve

and damper to make them correct, and making sure the electric
calibration is good;
6) If the electric motor has been shut down for more than seven
days or locates in relatively humid place, the external inspection
should be done to confirm it is in good condition before startup.
The trial running could be carried out after the insulation is tested
acceptable;
7) There should be special person assigned to monitor the startup

current and time of auxiliary equipment, the equipment should be
stopped when the startup current and time exceed the set value;
105
8) Persons on duty should stay beside the 6.6KV auxiliary
equipment for monitoring when it is started; when abnormal
situation happens, report to the shift foreman or press the
emergency button to shut down the equipment immediately;
9) Time for trial running of auxiliary equipment after overhaul should

not be less than four hours;
10) The startup and shutdown of auxiliary equipment should be

performed on the corresponding screen of LCD. At this moment,
the control switch must be Remote Control. If it is necessary to
implement startup and shutdown operation on site, the control
switch must be Local.
11) After the trial running of auxiliary equipment, the results should
be recorded on record notebook.
12.1.2 Inspection before starting auxiliary equipment
1) Inspection and repair have been finished; places around the

rotating equipment should be clean without foreign matters. The
work permit has already been returned;
2) The equipment appearance and insulation are complete. Strictly

close the manhole;
3) Safety shield of coupler is complete and intact;
4) For the auxiliary equipment which can be manually rotated, the

rotor should be rotated in such mode. Confirm it can rotate
flexibly without jam;
5) Acceptable quality of lubricating oil filled in bearing; normal oil

level; clear oil level line; correct indication; oil drain valve sealed
tightly; grease cup complete and filled with consistent grease;
6) Continuous, clear and sufficient supply of cooling water, sealing

water or cooling water for bearing;
7) Archor bolt is fastened; illumination is good;
8) The grounding wire and junction box of motor are completely

good. Inspection should be finished before starting the auxiliary
equipment. Supply dynamical power and control power to
auxiliary equipment and relevant system devices after the
conditions for startup are satisfied.
106
12.2 Operation and Maintenance of Auxiliary Equipment
1) Persons on duty should check the rotating equipment once per

hour;
2) Electric motor and its mechanical parts should not have strong
vibration, and meet following standards.
750 and
Rated Revolution (r/min) 1000 1500 3000
below
Permitted Vibration (mm) <0.12 <0.1 <0.08 <0.06
3) The highest permit temperature of rotating motor and bearing of

pumps should comply with the provisions of manufacturers. If
there is no regulation from manufacturer, these principles below
should be followed:
Items Rolling Bearing Sliding Bearing
Bearing of Electric 100Ԩ 80Ԩ

Motor
Bearing of auxiliary 80Ԩ 70Ԩ

equipment
The permit temperature of electric motor’s stator (core and coil) is

100Ԩ and temperature rise permit is about 65Ԩ respectively;
4) Maintain the oil level of rotating equipment normal, without oil

leakage occurred. Fill the same lubricating oil if the oil level is
low;
5) Maintain normal current indication;
6) Cooling water supply for each bearing and reducer should be

continuous and clear, and the temperature of returning water
should not be higher than 60℃;
7) There should be no abnormal sound and friction sound in

equipment and electric motor;
8) Confirm each interlock and automatic regulating device have

been put into operation and work normally;
9) There should no water, flue gas and oil leakage in equipment and
system;
10) Check whether the system’s valves are in proper positions.
107
12.3 Shutdown of Auxiliary Equipment
1) Shutdown operation should be performed based on the logical

relations among equipment;
2) Consider the protection and interlock relation before shutdown in

order to prevent the unsafe situations such as interlock and trip of
equipment;
3) Strict monitoring is required after the shutdown; and the

equipment should also be isolated if there is any reverse;
4) Monitor the flushing procedure for slurry delivery pipelines that

should be correctly done, or the carry out flushing manually;
5) Take anti-freezing measures to protect the relevant auxiliary

equipment that are usually shut down in winter;
6) Before isolating the auxiliary equipment for maintenance, shut

down the auxiliary equipment firstly and then isolate them.
12.4 Emergency Shutdown Due to Malfunctions of Auxiliary Equipment
1) Operation of electric motor must be stopped immediately if one of

following situation occurs:
2) Posing threat to safety of persons;
3) Temperature of bearing exceeds the limit and continues to

increase;
4) Electric motor or rotating parts experiences strong vibration;
5) Electric motor emits fume and is on fire;
6) Rotating mechanical parts have crashing and friction sound, and

continuous operation may cause serious damage to the
equipment;
7) There are fires or floods that pose serious threat to the safety of
equipment;
8) If press the emergency button for emergency shutdown, do not

press the button less than 30 seconds to prevent any possible
mistakes. For the newly replaced new-type emergency button
which has interlock device, after eliminating the malfunctions,
emergency button must be close down and reset before
restarting the equipment.
108
13 Common Problems During the Operation and
Maintenance of Limestone-Gypsum FGD
System
13.1 Sulphur Content in Fuel Oil Exceeding the Standard
Excessive sulphur content causes the whole FGD system operates at

overload, which has great harm to FGD system.
1) Insufficient oxidization, easily scaling, high content of

CaSO3·1/2H2O of small particles.
2) Crystallization time of gypsum not enough, gypsum particle small,

and hard to be dehydrated.
3) For the components that are accessible to the slurry or

desulphurized flue gas, the slurry with high CaSO3·1/2H2O
content will cause them scaling, followed by those problems such
as blockage, and overweight of bearing components, etc.
4) The limestone slurry system runs with overload, accelerating the

abrasion.
5) If the PH value goes out of control, it will accelerate the corrosion

of pump and the components contacting slurry and desulphurized
flue gas.
13.2 Insufficient Oxidizing Air
If the sulphur content is excessive or oxidization air is insufficient due to

the failure of oxidization equipment, which will cause various problems:
1) Insufficient oxidization, a great deal of CaSO3·1/2H2O of small

particles prone to scale should be generated.
2) High SO32- content will result in slurry with virus, because the
SO32- covering limestone can prohibit the chemical reaction of
limestone, thus, desulphurization efficiency can not be achieved.
3) For the components that are accessible to the slurry or

desulphurized flue gas, the slurry with high CaSO3·1/2H2O
content will cause them scaling, followed by those problems such
as blockage, and overweight of bearing components, etc.
109
13.3 ‘Virus’ of Absorber
‘Virus’ phenomenon means the PH value of absorber continuously

decrease and can not be maintained under the condition that the
limestone supply is seemingly uninterrupted. Many causes lead to
absorber ‘Virus’, mainly including:
1) The amount of CaSO3·1/2H2O exceeds the standard, many

SO32- covering limestone particles prohibit its chemical reaction.
2) Excessive dust in flue gas, or too much oil sludge in fuel oil,
aluminum fluoride formed by aluminum and fluorine elements in
fly ash can coat the surfaces of limestone and sulphite
crystalline，which prohibits the chemical reaction, so do the oil
flue, carbon, asphalt, polycyclic aromatic, etc.
3) Over-high content of Cl-in slurry generates common ion effect,

which prohibits the chemical reaction of limestone and sulphuric
acid.
4) Limestone with high Mg content is not easy to be dissolved.
13.4 Treatment of Absorption Tower ‘virus’
1) Eliminate the slurry in absorption tower.
2) Add into additives reinforcing the chemical performance such as

sodium hydroxide, hexanedioic acid, dibasic acid ( mixture of
acid and glutamic acid, succinic acid), formic acid, Mg, etc. to
increase PH value gradually.
3) If it is caused by excessive SO32-, reduce the amount of flue gas

firstly, then increase slurry properly, and adjust the load after PH
value recovers gradually.
13.5 Excessive Fly Ash
Disadvantages of excessive fly ash:
1) Absorber reaction prohibited.
2) Quality of gypsum becomes worse.
3) Water percentage of gypsum increases.
110
13.6 Problems Caused by Excessive Cl-
1) Metal equipment corrosion by Cl-
2) High water percentage of gypsum.
3) Inferior quality of gypsum with low cohesion ability, which is not

applicable to be used as construction material.
13.7 Problems of Limestone Quality
Influence of main components and property of limestone;
1) CaO content is the main component determining

desulphurization reaction.
2) High Al content should prohibit chemical reaction in the same

theory of that of fly ash.
3) The limestone with too high MgCO3 content is called dolomite

which is not easy to be dissolved in gypsum slurry.
4) The activity of limestone is not good, limestone particles are not

easy to be dissolved, so the chemical reaction speed is low.
13.8 High water Percentage of Gypsum
Common factor affecting water percentage of gypsum
1) Components in slurry: fly ash, Cl-, SO32-, Ca CO3.
2) Gypsum crystallization time is short, and the particle is small.
3) Gypsum slurry concentration is less than 15%.
4) Bad effect of cyclone makes the concentration of slurry in

dewaterer too low.
5) Too low vacuum degree: generally the most appropriate range is

to be within 0.04~0.06MPa; overhigh vacuum degree may cause
overload of vacuum pump; if too low, that may be attributed to
leakage of vacuum system, insufficient filter cake thickness
(between 20~40mm), and damage of filter cloth, etc.
6) Small particles block the filter cloth or flushing to filter cloth is

insufficient.
7) Vacuum pump inlet is blocked.
111
13.9 Problems of Mechanical Seal
The effect of absorber agitator plays an important role in determining

the substance moving speed and distribution evenness of oxidization
air. The common problems occurring to agitator include mechanical
seal damage, corrosion of blades, etc. which should be maintained and
repaired in line with the requirement of manufacturer. Sufficient spares
should be prepared.
The failure of leakage should occur easily to mechanical seal of slurry

pump. It is necessary to check the water flow of mechanical seal
periodically under the condition that no blockage occurs.
13.10 Problems of Water Balance
1) The balance of water inflow and outflow should be under control

for normal continuous operation of desulphurization system;
otherwise, the overflow will occur to water tank.
2) The principle of water balance control is: control the water flow in
all water inlet points in accordance with the data on material
balance sheet provided and designed by Bo Qi Company, and
the slurry flow direction based on material flow process. Don’t
add process water usage point randomly. Do not take the
temporarily-used public water as long-term used water.
3) The most easily-happened problem is how to use filtered water.

In general, the filtered water, not process water, should be used
as water for limestone slurry preparation.
4) It is necessary to harshly control the flushing water of demister

and the flushing water flow and pressure of flue gas inlet. Ensure
that no excessive water goes into the system under the condition
that flushing effect is able to be guaranteed. The flushing water
flow is controlled based on the material balance sheet.
13.11 Problems of Oxidization Air Fan
During the oxidization air operation, there should be sufficient water for
wetting the air to avoid scaling on pipes.
The flow and current of oxidization air fan should be monitored in its
operation to identify whether the system is normal or not. The inlet filter
should be maintained frequently and cleaned up periodically.
112
13.12 Problems of Flushing Effect of Demister
1) Demister is prone to adhere to gypsum, which may cause

blockage affecting demisting consequence, and increasing the
current of booster fan.
2) Because the adhesion of gypsum to demister is inevitable, the

auto flushing controlled by logic is necessary.
3) Different flushing water flow is for different load, the parameter for
judging whether flushing water flow is appropriate or not is that
whether the differential pressure of demister is maintained within
the normal range or not.
13.13 Absorber Inlet Flue Gas Flushing and Emergency Attemperator
Because here is the dry-wet interface, the gypsum is easy to become

saturated, causing accumulation. It is necessary to flush it periodically,
especially for such system without GGH.
The emergency attemperator must be fed with water periodically to

ensure it is able to be put into service in emergency condition.
13.14 Recycle Pump of Absorber
1) At least one pump should be kept in service during normal

operation. Ensure no high-temperature flue gas goes into
absorber, otherwise, the corrosion-proof material and demister
will be damaged in short time.
2) Strengthen monitoring the recycle pump current during the

operation, prevent attemperating effect from going bad under the
condition of nozzle blocked, which damages the internal
components of absorber.
3) The inlet filter of absorber recycle pump must be inspected during

the period of maintenance. Inspect whether there is damage or
blockage by a large amount of foreign matters.
13.15 Vacuum Dehydration System
1) The deviated filter should be handled timely; otherwise, the filter

cloth should probably be torn up by stretching. Check whether
the deviation correcting device is normal or not, the torn filter
cloth is able to be treated by self stitching.
113
2) The gypsum on filter cloth must be removed prior to operation;
otherwise, long-term staying of gypsum can cause the
deformation of components such as carrier roller, etc.
3) The gypsum in silo needs to be conveyed away, avoiding the

collapse of silo wall. Generally, higher pressure bearing wall is
not designed for common silo.
13.16 Bypass Flue Gas Damper
1) The bypass flue gas damper closed for a long time should be
started up periodically in case that rejection to act causing
accident by accumulated dust cause blockage.
2) Carry out protection test before bypass flue gas damper is

closed.
3) For such FGD system without GGH, under the condition that this
baffle is open for a long term, high temperature flue gas should
be prevented from going to FGD outlet gas duct which causes
corrosion-proof layer ineffective.
13.17 Problem of Absorber Liquid Level
For such FGD system without GGH, if the liquid level of absorber
exceeds the cofferdam of inlet gas duct, a great amount of slurry may
go into booster fan, probably causing blades damaged. Therefore, the
liquid level must be controlled severely to prevent the false one. The
means to prevent false liquid level is that flush the pressure sampling
orifice of pressure transmitter periodically (once half a month or a
month). The gypsum accumulation can cause false level. Because this
level is related to many protections, these protections should be
shielded or make the DCS level signal normal before flushing.
114

OM1301 Overview of FGD Version G

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

OM1301 Overview of FGD Version G

Uploaded by

Copyright:

Available Formats

Operation and Maintenance Manual

Section Name: FGD System &Equipment

Volume Name：Overview of FGD

Document No. KNPS-OM1301

1.1 BASIC TERMINOLOGY .................................................................................................... 5

2 WASTE WATER TREATMENT SYSTEM .......................................................................... 10

2.1 INTRODUCTION ........................................................................................................... 10

3 CONTROL LOGIC AND INTRODUCTION OF DESULFURIZING SYSTEM ................... 15

3.1 FLUE AND BOOSTER FAN SYSTEM............................................................................... 15

4.1 LIQUID LEVEL CONTROL OF LIME PREPARATION BOX ..................................................... 46

5 IN SPEC T ION AND PREPARATION OF FGD DEVICES .............................................. 48

5.1 GENERAL PROVISIONS OF ACCEPTANCE AFTER MAINTENANCE ...................................... 48

6 PRO TEC T IVE TESTS FOR DESULFURIZATION SYSTEM ........................................ 59

6.1 INTERLOCK PROTECTION TEST OF FGD ...................................................................... 59

7 STARTUP OF FGD EQUIPMENT ...................................................................................... 63

7.1 STARTUP PROCEDURE OF THE FGD EQUIPMENT ......................................................... 63

8 MAINTENANC E AFTER FGD SYSTEM START .................................................. 73

8.1 MONITORING AND REGULATION DURING OPERATION ..................................................... 73

9 SHUTDOWN OF FGD EQUIPMENT .................................................................................. 77

9.1 LONG-TERM SHUTDOWN .............................................................................................. 77

10 F GD DEVICE OPERATION ADJUSTMENT ................................................................. 82

11 PROC EDUR ES FOR ACC ID ENT TR EAT M ENT AND EM ER GEN CY

11.1 BASIC PRINCIPLES FOR ACCIDENT TREATMENT ........................................................... 91

12 O PERAT ION O F AUXIL IARY FGD EQU IPMENT .......................................... 105

12.1 GENERAL PROVISIONS OF AUXILIARY EQUIPMENT OPERATION ................................... 105

13 COMMON PROB LEMS DUR IN G TH E OPERAT ION AND MA IN TENANC E

1.1 Basic terminology

1.1.2 Limestone (CaCO3)

Measuring standard of solution acidity and alkalinity

1.1.4 Slurry density

Measurement of the solid concentration in slurry.

1.1.5 Acid non-soluble matter

An atom or molecule with positive charge (+) or negative charge (-)

The tendency of the ions in the solution to form solid.

1.1.9 Blind area

1.1.10 Sulphite oxidation

The quantity of sulphite producing by SO2 oxidization divides the

1.1.11 Blowdown (Bleed) quantity

The quantity of slurry or solution removed with the FGD process.

1.1.12 Reclaim Water

1.2 Process Introduction

The circulating slurry contains limestone and deposited calcium

Add limestone to the process to offer an alkaline environment and

1) SO2 absorption: SO2 + H 2O → H 2 SO3 (1)

3) Limestone dissolution: CaCO3 + 2 H + → Ca + + + CO2 + H 2O (4)

5) SO2 absorption and reaction:

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

Oxidation reaction: Blow in air to oxidize the CaSO3 •½H2O (Calcium

Ca(HSO3）2 ＋1/2O2+2H2O ◊ CaSO4.2H2O+H2O+SO2

CaSO3(1/2H2O)+ 1/2O2+2H2O ◊ CaSO4.2H2O+1/2H2O

1.4 Basic Functions of Main Systems

1.4.1 Absorber system

Housing the circulating slurry

Reserve time for the limestone dissolving and gypsum depositing

The place where the limestone is fed.

The place where the air is blown in for oxidation.

1.4.3 Limestone absorbent preparation system;

Receive and store a large quantity of limestone;

Mill the limestone to granule of appropriate size;

Prepare slurry with the ground limestone powder and liquid;

Store limestone slurry;

Deliver the limestone slurry to the FGD system when necessary.

1.4.4 Gypsum dehydration and disposal system;