Vung ang1 Thermal power plant

Lesson 4 Maintenance of SCR

system

July，2012
SCR Technical Topics

1.General
2.Equipment Maintenance
3.Catalalyst maintenance
4.System efficiency Check
 1.General
The SCR system shall be operated and maintained
under a planned program of periodic inspection with
the accompanying repair and replacement of parts
needed to achieve the maximum availability and
reliability of the system.

The inspection results and maintenance records should

be compiled and be accessible at all times. Results of
these inspections are used to determine the necessity
for equipment repair or replacement
 1.General
Please thoroughly review the Argillon SCR Catalyst Operations
and Maintenance Manual found in BWBC Document and SCR
information of this manual before servicing the SCR reactor or
flues. Catalyst protection must be practiced constantly by
maintenance personnel when inspecting or servicing the SCR
reactor. Scaffolding or footplates are to be utilized to prevent
the addition of any direct acting loads onto the catalyst blocks.
Exposure to moisture is to be avoided to prevent catalyst
deterioration. All open inspection ports are to be shielded to
prevent exposure to water from any source.

Additional maintenance guidelines for are found in the Vendor

manual sections
2.Equipment Maintenance
Periodic maintenance of the SCR system equipment will
keep the equipment in good operational condition, and in
service for its intended use. The listing in Table 0-1
provides the minimum check points and intervals
recommended for successful operation of the SCR system.
Development of the practical maintenance program is to be
based on the site and plant conditions.

Maintenance issues should also be directed to the

appropriate engineering & design drawings or
manufacture’s documentation and/ or manuals
2.Equipment Maintenance
Table 0-1: MAINTENANCE CHECK POINTS AND SCHEDULE

OP = During Operation S = Every Shift W = Weekly Y = Yearly

SH = During Shutdown D = Daily M = Monthly O = Other
CHECK SCHEDULE
Condition Interval
EQUIPMEN
NO T TO BE CHECK POINTS OP
CHECKED OP SH or S D W M Y O
SH
1) SCR inlet / outlet NOx
X X
concentration trends
2) SCR outlet NOx value versus
X X
stack CEMS
3) Inlet flue gas temperatures X X
4) Regenerative air heater gas
X X
inlet temperature
5) Differential pressure across
Functional X X
1. reactors
Items
6) Dilution air temperature X X
7) Ammonia vapor / dilution air
X X
mix temperature
8) Ammonia vaporizer pressure
X X
and temperature
9) Anhydrous storage tank level
& pressure
DA fan amps X X
2.Equipment Maintenance
1)Inspect for
cleanliness and general
X X
mechanical condition
of installed modules.
2) Clean per
recommendations in
Argillon O&M manual,
X X
and information found
in Appendix B of this
2. Catalyst
manual
3) Check for
deformation, breakage,
or erosion of modules X X
or module catalyst
elements.
4) Perform catalyst
management test block X X
sampling / testing
2.Equipment Maintenance
1) Inspection for
X X
gas leakage
2) Check for
X X
abnormal vibration
3) Check for signs
of lagging color
change that may X X
indicate gas leakage
Inlet
or excessive heat
and
3. 4) Check for
Outlet
excessive ash X X
Flues
deposition
5) General structural
X X
inspection
6) Inspect turning
vanes for
mechanical X X
condition, buildup,
or erosion
2.Equipment Maintenance
1) Check for
plugging due to
X X
NH3 foreign matter inside
4. Injection ports
Nozzles 2) Check for
deformation or X X
corrosion
1) Visually check for
deposit on top catalyst X X
layer
2) Inspection for gas
X X
leakage
3) Check for any shift
5. Reactor X X
of catalyst layers
4) Check for
deformation or
movement of catalyst X X
top ash deflector
plates and seals
2.Equipment Maintenance
5) Check for corrosion X X
6) Inspect general
X X
reactor structure
7) Check permanent
gas sample grids for
X X
plugged lines or
mechanical damage
8) Check trolley beam
X X
mechanical conditions
2.Equipment Maintenance
1) Check for safety valve
settings on the ammonia X X
tank
2) Check for and
calibrate ammonia level X X
gauge & transmitter
Anhydrou 3) Visual check for
s NH3 leaks, damage or other X X
Tank, obvious problems
vaporizer 4) Inspect block valves
s& and control valves for
X X
any visual sign of
6.
Dilution damage or malfunction
Air / 5) Visual check of limit
Ammonia switch assemblies for
X X
Flow mechanical damage of
Control alignment change
skids 6) Check for control air
leakage to valve X X
actuators or operators.
7) Review physical
condition of process
X X
transmitters for signs of
damage.
 2.Equipment Maintenance
8) Review indicating transmitters
for any difference between local X X
indication and DCS indication
9) Inspect for mechanical
damage of sensing line tubing
X X
between transmitters and process
lines
10) Check agreement between
local temperature indicators and X X
thermocouple indication at DCS
11) Check pressure gauges for
X X
damage, confirm indicated value.
12) Check for excessive noise or
vibration of blower (DA Fan) X X
and motor
2.Equipment Maintenance
13) Check fan bearings and
motor for excessive X X
temperature
14) Lubrication check X X
15) Inspect / Lube fan
X X
Coupling
16) Review dilution air
pressure trend for indication of X X
reduced fan performance
17) Monitor trend of DA fan
amps versus DA flow.
Inspect inlet silencer and X X
screen for pluggage and clean
as required.
19) Monitor trend of vaporizer
temperature verses heating X X
element amperage
2.Equipment Maintenance
1) Assure junction
panels for dilution air
fan skid, vaporizer skid,
and sootblowrs X X
verification system are
closed with no obvious
Junction Panels and mechanical damage
General Wiring for 2) Check conduit and
Ammonia Vaporization flexible connections to
7
System and motors, instruments, and X X
Sootblowers other devices for
Verification System mechanical damage

3) Check junction panel

internals for any signs of X X
damage.
2.Equipment Maintenance
1) Analyzer(s) Calibration by
X X
standard gas
2) Inspect probe and sample line
connections for mechanical X X
damage
3) Check air clean up system
filter and cleaning media, X X
change as needed.
NOx 4) Inspect / clean primary gas
8. Measurement sample sintered filter at end of X X
System each sample probe
5) Inspect / clean secondary gas
sample filter in probe head of X X
each sample probe.
6) Additional system checks for
calibration gas level, air clean-
up system, electrical hardware X X
condition, fire detection, etc to
be furnished by MSI
 2.Equipment Maintenance
Notes:
All equipment shall be inspected and maintained in accordance with
the above table and also with manufacturer's instructions, the more
stringent one taking precedence.
The detailed maintenance procedures of each piece of equipment are
to be referred to the manufacturer's data books. The catalyst
manufacturer’s Operations and Maintenance manuals should be
reviewed to avoid conflict with other maintenance items.
All maintenance work shall be controlled by a SAFETY TAGGING
program. Good communication between the maintenance group and
operation group is essential.
Confined spaces exist; follow OSHA “confined space entry safety”.
2.Equipment Maintenance
2.1.SCR Maintenance Precautions

In addition to the above warning:

DEPRESSURIZE all equipment and piping to
atmospheric pressure before opening them.
During maintenance work, FRESH AIR shall be
continuously ventilated by a fan or other suitable
equipment.
Before starting any repair work and especially when
using open flames (welding, gas cutting, etc.), use a
Combustible Gas Detector to CONFIRM that no
combustible gas is present in the work area.
Always work in pairs with one remaining as an observer
outside of the work/inspection area(s).
2.Equipment Maintenance
When performing work on electrical
equipment, follow the instructions below to
prevent electric shock and/or damage to the
equipment.
(1)OPEN the circuit breaker for electrical
equipment completely and place a safety tag
in a safe, conspicuous location.
(2)CONFIRM that the electrical power supply
is absolutely isolated by using a circuit tester.
(3)CONNECT the earth wire firmly to the
ground to prevent electric shocks.
 2.Equipment Maintenance

Prior to starting maintenance work on the dilution air /

ammonia injection system, DEPRESSURIZE and PURGE the
system with fresh air. Allow temperatures to reach a safe level
(<50 ℃) before initiating repairs.

For fire explosion prevention, firefighting equipment shall be

readily available near the equipment being repaired. The
equipment shall be properly grounded to release static
electricity before starting work.
 2.Equipment Maintenance
2.2.Ammonia Systems Maintenance Precautions
In addition to the above warning:
•DEPRESSURIZE all equipment and piping to atmospheric
pressure before opening them.

•Before starting any repair work and especially when using open
flames (welding, gas cutting, etc.), use a Combustible Gas Detector
to CONFIRM that no combustible gas is present in the work area
and confirm that all ammonia has been flushed from the system.

•Always work in pairs with one remaining as an observer outside of

the work/inspection area(s).
2.Equipment Maintenance
When performing work on electrical equipment, follow the
instructions below to prevent electric shock and/or damage to the
equipment.
(1)OPEN the circuit breaker for electrical equipment completely
and place a safety tag in a safe, conspicuous location.
(2)CONFIRM that the electrical power supply is absolutely
isolated by using a circuit tester.
(3)CONNECT the earth wire firmly to the ground to prevent
electric shocks.

Prior to starting the maintenance work on any ammonia system,

DEPRESSURIZE, DRAIN, and FLUSH the system. Contain the
ammonia in approved containers and use personnel protection
equipment as required by plant safety procedures. Use clean
water to flush the system.
3.Catalyst Maintenance
Catalyst protection must be practiced constantly by maintenance
personnel when inspecting or servicing the SCR reactor. Do not
walk on the SCR catalyst directly during catalyst installation or
other work inside the SCR reactor as catalyst damage may occur.
Catalyst top screens are provided to assist and avoid direct
contact. However; temporary scaffolding and foot plates are
typically required to avoid the placement of any direct acting
loads onto the catalyst ceramic elements in each module. As a
precaution, a shield should be installed over the catalyst layer to
protect the catalyst during maintenance work
3.Catalyst Maintenance
To prevent premature catalyst deterioration, the SCR catalyst
must not be exposed to water or other moisture throughout all
operating and storage conditions. This problem can be
prevented by careful work and a daily check of the SCR system.
All open inspection ports are to be shielded from any water
source. Should water enter through any breach in the flues or
reactor, or open access door during SCR system operation
and/or maintenance, dry the catalyst as soon as possible. Flue
gas water vapor during startup, shutdown and normal
operations is not a concern. Never wash the catalyst with water.
4.System Efficiency Check
Catalyst activity deteriorates gradually with operation time.
Although catalyst deterioration has been taken into account in
the design, the cause of all deterioration cannot be
quantitatively determined due to it being the result of several
causes. These include such items as: (1) a decrease of
specific surface area of catalyst due to catalyst reaction site
blinding, and (2) effects of catalytic poisoning components
(i.e., halogen, alkali metal) which are usually contained in flue
gas and dust as trace components. The impact of each factor
is very small. Typically, the deterioration rate will not change
abruptly as long as the operating conditions are constant.
4.System Efficiency Check
4.1.Daily Operation Data for Performance Assessment

Evaluation of system performance is to be done by tracking key

operating data on a regular basis. When trended over time, the
operating data can help determine how closely reduction
efficiency is meeting expected design. When tracking key data,
any abnormal occurrences (such as boiler upsets, boiler trips,
etc.) should be noted so that they can be correlated to the timing
of the data being tracked.
Key operating data that should be recorded hourly includes the
following:
 4.System Efficiency Check
Table 0-2: REQUIRED OPERATING DATA

Operation Data Items Unit of measurement

Fuel Flow Rate, Coal kg/hr

Gas Flow Rate Entering the SCR Nm3/hr

O2 Concentration at Reactor Inlet %, dry basis

NOx Concentration at Reactor Inlet ppmvd

NOx Concentration at Reactor Outlet ppmvd

Outlet NOx Set Point ppmvd

Achieved NOx Reduction (calculated) %

Operating Hours ---

4.System Efficiency Check
Vaporous Ammonia Flow Rate kg/hr

Avg. Flue Gas Temperature at Reactor Inlet oC

Dilution Air Flow for Ammonia Injection Nm3/h

Dilution Air Temperature oC

Differential Pressure across Reactor Pa

Differential Pressure across Regenerative Air- Pa

Preheater

Fuel Type --
4.System Efficiency Check
This data should be stored and/or be capable of being
accessed throughout the entire warranty period. Usable
record forms include operator logs, strip charts, computer
printouts, etc. (whatever is standard for the plant). The
stored data, along with logged data for any catalyst
wetting or damage events, and data for any boiler
operational upsets, will be reviewed with the trend from
the periodic NOx distribution Cv and ammonia slip tests.
This will help evaluate how the catalyst is deteriorating
over time.
4.System Efficiency Check
Catalyst sampling and analysis program
recommendations that will be made with Argillon will
also contribute to the evaluation. The evaluation
goal will be to produce Vung ang 1 unique catalyst
performance trends which will help optimize catalyst
management planning over the life of the
installation.
 Thanks

北京巴布科克·威尔科克斯有限公司
Babcock & Wilcox Beijing Co., Ltd.