FOR CONSTRUCTION

0 15-NOV-14 D.H Han K.H Jung J. Kim For Construction

B 03-NOV-14 D.H Han K.H Jung J. Kim For Comment
A 19-MAY-14 D.H Han K.H Jung J. Kim For Comment
Rev Date Prepared Checked Approved Details of Revision
Owner

AES-VCM MONG DUONG

POWER COMPANY LIMITED
Consultant

POWER ENGINEERING CONSULTING

JOINT STOCK COMPANY 2
Contractor

Doosan Heavy Industries & Construction Co., Ltd

Project : PC
T10206
UAS
MONG DUONG II 2 x 560MW(NET) DN02
THERMAL POWER PLANT UNIT

P1
Title KKS
ZEN
Reg. No.
FGD CAPABILITY TEST PROCEDURE 860012
Rev.
0
Document No. Pages –No.
T10206-DN02-P1ZEN-860012
8
 Rev. 0

TABLE OF CONTENTS

1.0 OBJECTIVE OF THE TEST .......................................................................... 3

2.0 ORGANIZATION AND RESPONSIBILITY OF TEST .................................... 3

3.0 SAFETY PRECAUTIONS .............................................................................. 3

4.0 TEST ITEMS AND METHODS ...................................................................... 4

4.1 Test Items ...................................................................................................... 4
4.2 Test Requirements and Conditions ................................................................ 4
4.3 Measurement Methods .................................................................................. 4

5.0 TEST RECORD ............................................................................................. 7

6.0 ATTACHMENTS............................................................................................ 8
Attachment 6.1 Job Safety Analysis
Attachment 6.2 Risk Assessment
Attachment 6.3 Gas Measurement Sampling Location

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1.0 OBJECTIVE OF THE TEST

The purpose of this document is to provide a systematic guideline to Flue Gas Desulphurizer
Capability Test.

This procedure covers the EPC Contract Appendix “D” - Testing Guidelines, Section 3.2.7.7
Equipment Capability Test, (d) Flue Gas Desulphurizer (FGD).

2.0 ORGANIZATION AND RESPONSIBILITY OF TEST

1) Test Witness Parties:
I. AES-VCM-VCM MONG DUONG POWER COMPANY (BOT Company)
II. DOOSAN HEAVY INDUSTIRIES VIETNAM CO
III. ESS
Representatives for each party identified above shall be designated to observe the tests
as Official Test Witnesses. The Official Test Witnesses shall observe the conduct of
testing and have signature authority to approve any deviations from the test procedure
documented before, during, or after testing is concluded.

2) EPC Contractor Responsibilities:

 Provide all Operational and Maintenance Support necessary to ensure that the
testing system is ready to test.
 Operate the testing system as required by this test procedure.
 Provide all safety support including safe access to all instrument reading
locations.
 Provide an Officially designated Test Witness.
 Third party test company (ESS) will conduct the test.

3) Owners Responsibilities:
 Certify that the test was correctly conducted.
 Provide written confirmation of the test results.
 Provide an Officially designated Test Witness.

3.0 SAFETY PRECAUTIONS

Job Safety Analysis and Risk Assessment have been checked before the test.
Refer to Attachment 6.1 & 6.2.

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4.0 TEST ITEMS AND METHODS

4.1 Test Items

No. Description Target Value 100% TNCR Remark

1 SO2 Removal Efficiency ≥84.39 % √

Design Coal
at 6% O2, dry
2 SO2 Outlet Concentration ≤280 mg/Nm3 √

 IEC Contract, Appendix A. Section 2.4.1

4.2 Test Requirements and Conditions

1) The Power Plant is stabilized at 100% TNCR Load.
2) Ensure that FGD Plant is in normal operation and Stack emissions are satisfied.
3) During the test, bypass damper should be closed.
4) Test instalment of the measuring point and sampling device installed.

4.3 Measurement Methods

1) SO2 concentration in flue gas
A. General
The test will be performed at Plant Load 100% TNCR (621MW gross).

B. Gas Measurement / Sampling Locations

Number of
Location Test Parameter Measuring / Samples
Required for Test
Inlet SO2 Concentration
Inlet Gas Flowrate
FGD inlet Duct 3
Inlet Gas Temperature
Inlet Gas Pressure

Outlet SO2 Concentration

Outlet Gas Flowrate
Stack 3
Outlet Gas Temperature
Outlet Gas Pressure

See Attachment 6.3 for location drawings

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C. Testing Procedures
a) Flue Gas Sampling Methods

Measurement Parameter Reference Remark

Flue Gas Sample and Velocity Traverses ASME PTC 40

for Stationary Source Appendix B / EPA

Determination of Stack Gas Velocity and ASME PTC 40

Volumetric Flowrate (Type S Pitot Tube) Appendix B / EPA

ASME PTC 40
Determination of Sulfur Dioxide emissions
Appendix B / EPA

Stack Outlet O2 Analyzer for O2 ASME PTC 40

Conversion Appendix B / EPA

b) Sample and Velocity Traverses

EPA Method 1 will be followed to ensure representative measurements of
particulate matter, gaseous constituents and total volumetric flow rate. By this
procedure, a duct or stack, where the gas stream is flowing in a known direction
is selected, and the cross-section is divided into a number of equal areas.
A traverse point is then located within each of these equal areas.
The average flue gas velocity is calculated from the average pitot pressure drop
(△P), the flue gas temperature, the flue gas molecular weight‘ and the absolute
static pressure in the duct. Temperature and △P measurements will be made
simultaneously with a K-type thermocouple with digital readout , an S-type pitot
and a Magnehelic gauge or inclined manometer. The duct static pressure will be
measured with each velocity profile.

c) FGD Inlet/Outlet Gas Dry Molecular Weight

EPA Method 3 will be used to determine oxygen and carbon dioxide
concentrations of the flue gases. During each sampling run, one sample will be
collected from both the inlet and stack sampling location and analyzed using
PG-250 multi gas analyzer. Oxygen and carbon dioxide in the sample are
measured directly. Nitrogen and dry molecular weight estimates are derived
from the oxygen and carbon dioxide measurements. The method mandates
repeating the sample analysis and calculations until the individual dry molecular
weights for any three analyses differ from their mean by no more than 0.3 g/g-
mole

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D. Gas Sampling Calibration and Quality Control Requirements

One field blank each for EPA Method 5B/6 and EPA Method 5B/8 will be collected
and analyzed. The field blanks will be assembled as an ordinary sample train, with
appropriate filters and impinge solutions set up in the proximity of the sampling
locations, leak checked, and recovered and handled as an ordinary sample, except
that no gas shall be passed through the blank trains. The sample trains (include
pitots), will be leak checked at the beginning and end of each run. The results of the
checks shall be recorded on the source sampling data sheets.
Sampling temperature requirements of the methods shall be checked and recorded
at regular intervals throughout each run. The probe and sample line temperatures
shall be maintained above the dew point of the sample gas. Ice shall be maintained
in the ice baths.
Any unusual conditions shaIl be noted during each run on the data sheets and in the
sampling logbook.
Sampling data sheets will be completely filled out and will be reviewed and
witnessed daily.
Isokinetic sample rates shall be maintained within ±10 percent of the isokinetic rate.
During sampling, the roll and pitch of the pitot tube and nozzle shall be properly
aligned with the duct flow.
Handling of filters will be performed in clean areas with Teflon- coated tweezers.
Blank determinations will be performed on each lot of rinse solution. Blank residue
must be ≤0.001 mg/g. lsopropanol impinger solutions must be screened for peroxide
impurities that can cause erroneously high sulfuric acid mist measurements, as
specified in Method 8.
The gas flow rate at the inlet and the stack will be compared.
The inlet gas flow rate will be compared to a gas flow rate determined from a coal
combustion calculation.
Information is presented below pertaining to the calibration of sampling equipment.
lncluded are descriptions of each procedure or reference s to applicable
Methods the frequeny of calibration, and the calibrations to be used.

E. Calcuation of Percent SO2 Removal (%)

Refer to ASME PTC 40 Section 5.

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4.4 Result Correction

When Sulphur content of the fuel is less than the maximum design range sulphur content of
0.8% (dry basis), correction will be made to the result.

5.0 TEST RECORD

All data will be collected on appropriate field data sheets or electronically as determined by
the third party conducting the test. Copies of all field collected data records will be included as
attachments or appendices in the final test report.

Personnel DHI AES

Name

Signature

Page 7 of 8
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6.0 ATTACHMENTS
Attachment 6.1 Job Safety Analysis
Attachment 6.2 Risk Assessment
Attachment 6.3 Gas Measurement Sampling Location

Page 8 of 8
[Attachment 6.1] Job Safety Analysis

JOB SAFETY ANALYSIS AES-VCM

MONG DUONG II 2x 560 MW (NET) COAL FIRED POWER PROJECT
(Developing a habit of analyzing methods to identify hazards & unsafe practices than developing solution that control, minimize or eliminating hazard.)

Task : FGD Capability Test

Prepared by : D.H Han Reviewed by: K.H Jung Approved by: J Kim
Original Date : 19/05/2014 Revised by: Rev Date: Revision : A
Goggles : Yes Gloves: Yes Face Shield : No Barricade Needed : No Lockout: Yes Dust Mask: No
Tag out: Yes
Safety Harness: Long Sleeves: Hearing Protection: MSDS Need/Review: Ground Fault Interrupter: Others:
No Yes Yes Yes Yes
Other Safety Equipment Required:
Remarks:
List of All Job Steps List of All Known Hazard How to Eliminate Hazards
FGD Capability test Boiler trips and no response plan Read the test procedure and conduct pre-test briefing with all
engineers and field staff about the response plan. Do not get
panic but follow test engineer’s instruction.

Normalizing the equipments and monitoring the Rotating equipment – Hand entrapment Guards in place.
operation. Electric shock Eathing of frame and panels.
Steam/Air jet, Hot surface Use splash goggles and gloves.
Noise Use of ear muff near all noisy equipments.

Manual operation of valves Work at high elevation Ensure safe work platform.
Hot surface Use hand gloves at all times.
Hot water or steam jet
Field operation and CCR control/ Communication problem Bi-lingual operators
communication
In sufficient instructions Competent CCR operators with clear communication skills.
Dedicated radio channel for operation.
[Attachment 6.2] Risk Assessment

AES-VCM
RISK ASSESSMENT
Country Office/Project: Mong Duong II Coal Fired Power Project, Vietnam Assessors : D.H Han
Ref No: 139 Date: 07/02/2014

Activity : FGD Capability Test Assessment Purpose : Identification of hazards and implementation
of mitigation measures
People at Cause of Adverse Adverse L RFN RRN
JOB/TASK effect
S1 MITIGATING CONTROLS L2 S2 Assessment
risk effect 1 ** *
Planning and Inadequate Plant tripping 3 4 12 Follow the test procedure. 1 2 2 Trivial/
preparation of test Engineers/ planning Everybody shall read and understand the test Acceptable
Technicians procedure.
Plant load operation Rotating Hand 2 3 6 Guards in place. 1 3 3 Tolerable
equipment entrapment Earthing of panels/skids.
Engineers/
Electricity Electric shock Use of ear muff, dust respirator, gloves
technicians
Noise/Heat/Dust Injury

Field Operation Rotating shaft Proximity to 2 3 6 Competent engineer will do the test. 1 2 2 Trivial/
Electricity Rotating No loose strings attached to work vest. Acceptable
Engineers/
Noise equipment. Use electrician’s hand gloves.
operators
Electric shock Use ear muff.
Ear damage
Communication on Wrong operation Equipment 3 2 6 Proper communication through dedicated 1 2 2 Trivial/
radio damage radio channel. acceptable
Operators
Injury Use of English language.
Engineers
Competent operators.
Bilingual translators in CCR.

Likelihood (L) Severity(S) Risk Factor Number (RFN) Residual Risk Number (RRN) L1-Like as it is
1.Unlikely/Improbable 1.Negligible 1-2 Trivial/Acceptable 1-2 Trivial/Acceptable L2-Likelihood with mitigating measures
2. Remote 2.Slight 3-5 Tolerable 3-5 Tolerable S1-Severity as it is
3. Quite possible/ Occasional 3.Moderate 6-9 Moderate/Acceptable with 6-9 Moderate/Acceptable with review S2-Severity with mitigating controls in place
review
4. Likely/Probable 4.Critical/High 10-15 Substantial 10-15 Substantial * Prepare job safety analysis and safety
verification check list when RFN is >= 6
5. Very likely/Frequent 5.Catastrophic/Very 16-25 Intolerable/ Unacceptable 16-25 Intolerable/ Unacceptable ** Prepare safety verification check list
High when RFN is >= 6
[Attachment 6.3] Gas Measurement/Sampling Location

<Figures 4-1, FGD inlet >

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<Figures 4-2, CEMS Location at Stack>

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<Figures 4-3, Detail of Figures 4-1, FGD Inlet>

<Figures 4-4, Detail of Figure 4-2, CEMS Nozzle>

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