Process Description Plant Bowen /s/ Gary Smith Approved Plant Review Board /s/ Tim Crump Approved Operations Manager /s/ Tim Banks Approved Plant Manager Date: 05/11/2010 PLANT BOWEN UNIT 3 FLUE GAS DESULFURIZATION SYSTEM AXIAL BOOSTER FANS SYSTEM PROCESS DESCRIPTION Document No. 2607.001 NOTE: If you are working with a printed copy of this document, it is NOT a controlled copy. Please be sure to check online for the most recent revision. Date Printed 2/22/2011 Page 1 of 97
T able of C ontents 2607.001 PROCESS DESCRIPTION 3 2607.001.1 Safety Considerations 3 2607.001.2 Process Description 4 2607.001.2.1 Introduction 4 2607.001.2.2 System Components 9 2607.001.2.2.1 Axial Booster Fans (FG-FN-5300A & B) 10 2607.001.2.2.2 Lube Oil Skids (FG-SD-5310A & B) 21 2607.001.2.2.3 Hydraulic Oil Skids (FG-SD-5305A & B) 32 2607.001.2.2.4 Diffusor And Intermediate Seal Air Skids (FG-SD-5320A/B & 5315A/B) 40 2607.001.2.2.5 Inlet Dampers (FG-XV-5325A & B) 46 2607.001.2.2.6 Outlet Dampers (FG-XV-5330A & B) 55 2607.001.2.2.7 Damper Seal Air Skid (SL-SD-5335) 59 2607.001.2.3 Summarized Booster Fan Blade Pitch Control 62 2607.001.2.4 Detailed Booster Fan Blade Pitch Control 62 2607.001.2.5 Summarized Inlet Duct Draft Control 63 2607.001.2.6 Detailed Inlet Duct Draft Control 63 2607.001.2.7 Summarized Inlet and Outlet Damper Seal Air Fan Control 64 2607.001.2.8 Detailed Inlet and Outlet Damper Seal Air Fan Control 64 2607.001.2.9 Summarized Diffuser and Intermediate Seal Air Fan Control 65 2607.001.2.10 Detailed Diffuser and Intermediate Seal Air Fan Control 65 2607.001.2.11 Summarized Hydraulic Oil Skid Control 66 2607.001.2.12 Detailed Hydraulic Oil Skid Control 66 2607.001.2.13 Summarized Lube Oil Skid Control 67 2607.001.2.14 Detailed Lube Oil Skid Control 67 2607.001.3 Process Flow Description 68 2607.001.4 Drawing References 75 Date Printed 2/22/2011 Page 2 of 97
2607.001 PROCESS DESCRIPTION 2607.001.1 S afety Cons iderations 1. All Operating Companies Safety and Health Manuals shall be followed at all times. 2. The Southern Company Generation Clearance Procedure shall be followed at all times. 3. A thorough Job Safety Briefing (JSB) shall be completed before beginning work. 4. Employees should always use the proper Personal Protection Equipment (PPE) for the task they are performing. 5. Personnel must observe standard safety precautions when working around or with high temperature piping systems. 6. Personnel must be aware that components of this system are maintained in an automatic mode of operation. Note: Equipment may start at any time without warning. 7. Personnel should remain clear of all rotating machinery, whether operating or in standby, at all times during unit operation. 8. Rotating machinery must never be placed in service without the appropriate equipment guards in place. 9. No attempt should be made to bypass or eliminate equipment safety interlocks. Doing so could result in equipment damage and possible injury to plant personnel. 10. Follow proper Confined Space Entry Procedures when entering confined spaces. 11. When employees are performing work on or associated with exposed lines or equipment energized at 50 volts or more, persons trained in First Aid including Cardiopulmonary Resuscitation (CPR), shall be available within 4 minutes per OSHA 1910.269 requirements. Page 3 of 97
2607.001.2 Proces s Des cription 2607.001.2.1 Introduc tion The scrubber booster fans are a major component of the flue gas handling systems. These fans are necessary to accommodate the significant additional draft pressure losses associated with the scrubber systems. These fans are of a two stage axial design. The Induced Draft (ID) fans are supplemented with booster fans to transport the gas through the FGD system and to discharge it through the wet stack. There are two booster fans for each unit and each fan is equipped with inlet and outlet isolation dampers (tandem louver type). Each unit is equipped with dedicated CEMS stations, one in the dry stack and one in the wet stack. The following figure depicts the gas path for Unit 3 or 4. DRY STACK BYPASS DIVERTER ID FANS Fan Isolation Dampers WET STACK AXIAL BOOSTER FANS JBR Flue Gas Handling System Arrangement for Unit 3 or 4 Page 4 of 97
2607.001.2.1 Introduc tion The two axial booster fans are identical two stage, single speed, electric motor driven induced draft fans with hydraulically controlled variable pitch blades for fan load control. The fan has installed instrumentation for stall detection, vibration, temperature, pressure, blade angle and regulating arm torque. The fan motor also has instrumentation for vibration, temperature, and speed. The fans have dedicated skid mounted auxiliary systems for lubrication, jacking, hydraulic oil and seal air. Lubrication of fan bearings and fan motor bearings is provided by a dedicated lube oil skid for each fan. Each skid is comprised of an oil reservoir (220 gallons), two AC lube oil pumps (one operating, one spare), a DC emergency lube oil pump, an AC jacking oil pump, a DC back-up jacking oil pump, a duplex lube oil filter, a jacking oil filter, two fan air coolers, and instrumentation for temperature, level, pressure, and flow. The skid is enclosed within a stainless steel cabinet. Stainless steel supply and return piping connect each skid to its respective fan. A dedicated hydraulic oil skid for each fan provides pressurized oil to the hydraulic regulating unit which controls fan blade position. Each skid includes an oil reservoir (100 gallons), two AC hydraulic oil pumps (one operating, one spare), a duplex filter, a dual fan air cooler, and instrumentation for temperature, level, and pressure. The skid is enclosed in a stainless steel cabinet. Stainless steel supply and return piping connect each skid to its respective fan. Two dedicated seal air skids provide heated seal air to each fan s diffusor and intermediate inner tube sections to prevent flue gas from entering these areas and causing corrosion. Each seal air skid is comprised of two inlet filters, two AC fans with non-return dampers, and inline duct heaters. Each axial booster fan has inlet and outlet dampers which provide for isolation of the fans during operations and maintenance. The tandem louver type dampers are equipped with electro-hydraulic actuators and share a common seal air system to provide a zero leak seal against flue gas creating a safe environment inside the axial booster fan for personnel during maintenance. The common seal air skid is comprised of two inlet silencers, two AC fans with motorized outlet dampers, and a manual flow control damper. Page 5 of 97
2607.001.2.1 Introduc tion Booster Fan Inlet Dampers Quantity 1 per fan, 2 per unit Type Tandem Louver, Zero Leak Seals Manufacturer Bachmann Dampjoint Inc. Size 142 ¾ x 278 1/8 Blade Material A36 Blade Shaft Material 304 stainless steel Drive Shaft Material 304 stainless steel Seal Material Alloy C276 Frame and Housing Material A36 Actuator REXA Electric/Hydraulic Normal Opening/Closing Time 30 seconds Seal Air Ports per Damper One Seal Air Flow with one fan out of service 4466 ACFM Seal Air pressure @ port with one fan out of service 22 inches w.g. Seal Air Flow in FGD Bypass 2409 acfm Seal Air Pressure @ port in FGD Bypass 3 inches w.g. Page 6 of 97
2607.001.2.1 Introduc tion Booster Fan Outlet Dampers Quantity 1 per fan, 2 per unit Type Tandem Louver, Zero Leak Seals Manufacturer Bachmann Dampjoint Inc. Size 228 x 228 Blade Material A36 Blade Shaft Material 304 stainless steel Drive Shaft Material 304 stainless steel Seal Material Alloy C276 Frame and Housing Material A36 Actuator REXA Electric/Hydraulic Normal Opening/Closing Time 30 seconds Seal Air Ports per Damper One Seal Air Flow with one fan out of service 4818 ACFM Seal Air pressure @ port with one fan out of service 27 inches w.g. Page 7 of 97
2607.001.2.1 Introduc tion Booster Fan Damper Seal Air Skid Blower Manufacturer Northern Blower Quantity of Blowers 2 Blower Flow 11,250 acfm Blower Pressure 32 inches w.g. Blower Motor Size 100 hp Page 8 of 97
2607.001.2.2 S ystem Components The Axial Booster Fan System consists of the following: Two electric motor driven axial booster fans Booster fan lube oil skid Booster hydraulic oil skid Seal air skids Booster fan inlet and outlet dampers Inlet and outlet dampers seal air skid Page 9 of 97
2607.001.2.2.1 Axial B ooster Fans (FG-FN-5300A & B ) Number Sheet Rev Title D3M20055 1 2 P&IDs FGD Project P&ID U3 & U4 JBR Outlet Duct and Stack Drains D3M20064 1 0 P&ID Inlet & Outlet Damper Seal Air Skid D3M20058 1 0 P&ID Axial Booster Fan A D3M20059 1 0 P&ID Axial Booster Fan B D3M20060 1 0 P&ID Axial Booster Fans A Skids D3M20061 1 0 P&ID Axial Booster Fans B Skids S90868 1 0 Booster Fan PI Diagram Unit 3 Fan B Vendor O&M Manuals S82678 1 A Booster Fan Motors, Installation and Maintenance S83221 1 A FGD - Scrubber - Booster Fan - Booster Fan Consumer List (Fan A) - TAG NO. FG-FN-5300 S82548 1 A Scrubber - FGD - Booster Fan Motors - Motor Data S82549 1 A Scrubber -FGD - Booster Fan Motors - Motor Data Sheet S94955 1 0 FGD - Scrubber - ID Booster Fans S94956 1 0 FGD - Scrubber - ID Booster Fans S81993 1 E S83220 1 D S83221 1 C Function FGD - Scrubber - Booster Fan - General Arrangement Drawing - Booster Fan A & B FGD - Scrubber - Booster Fan - Booster Fan Instrument List (Fan A) - Tag No. FG-FN-5300 FGD - Scrubber - Booster Fan - Booster Fan Consumer List Unit 3 (Fan A) - Tag No. FG-FN-5300 The scrubber booster fans are a major component of the flue gas handling systems. These fans are necessary to accommodate the significant additional draft pressure losses associated with the scrubber systems. The VARIAX induced draft fans (IDBF) provide maximum control of the variable volume flows and pressures associated with scrubber operations. Being placed in the flue gas system, the induced draft fan conveys flue gas from the furnace system through the Flue Gas Desulfurization equipment. Consequently, the fan will operate in a warm and corrosive flue gas environment. Page 10 of 97
2607.001.2.2.1 Axial B ooster Fans (FG-FN-5300A & B ) Description The two axial booster fans are identical two stage, single speed, induced draft, axial flow, electric motor driven fans with hydraulically controlled variable pitch blades. The axial booster fans are Variax type ANT-3816/2120B fans manufactured by Howden Power and driven by 18500 hp Frame 16006 WEG Equipment induction motor operating at 13200 volts and 895 rpm. The booster fan is a two stage fan equipped with two (2) impellers. The rotor system is installed on a bearing arrangement in the intermediate section. The fan rotating speed is constant. The rotor is equipped with hydraulically variable blade pitch system, which allows the blade pitch to be adjusted during fan operation. The fan performance can therefore continuously be adjusted with reference to the actual furnace load. Page 11 of 97
2607.001.2.2.1 Axial B ooster Fans (FG-FN-5300A & B ) Quantity Manufacturer Type 2 per unit Howden Axial, Two Stage Model ANT 3816/2120B Speed, rpm 900 Motor Size, hp 18,500 Test Block Performance 50% Bladed Fully Bladed Fan Inlet Flow, acfm 2,436,406 2,340,112 Static Pressure Rise, in. w.g. 33 33.9 Estimated Brake Horsepower, hp 15,474 18,548 Inner Tube Seal Air Flow TBD acfm Quantity of Seal Air Blowers 2 per fan (1+1) Seal Air Blower Manufacturer Motor Size Heating Elements TBD TBD hp 2 x TBD kw per fan The static parts consist of inlet box, impeller casing and diffuser. The static parts are designed for the specified pressure conditions. The inlet box with guide vanes in the inlet cone ensures optimum flow to the blades of the rotor. The fan main shaft with circulation lubricated radial and thrust slide bearings is installed in the inner tube of the inlet box. The inlet box of the fan is bolted directly to the concrete foundation for rigid support. Accessing the inlet box is possible through the inspection door. Page 12 of 97
2607.001.2.2.1 Axial B ooster Fans (FG-FN-5300A & B ) The circulation lubricated radial and thrust slide bearings with main shaft and the two impellers is installed in the intermediate piece. The end of main shaft at the diffuser side is characterized as the regulating end and the shaft end at the inlet box is characterized as the drive end. Fan impellers are installed at both ends of the main shaft. The intermediate piece is placed between the inlet box and the diffuser, and it is bolted directly to the concrete foundation for rigid support. The impeller casings at the two impellers are bolted to each end of the intermediate piece, and are centered by means of special guide pins. The inside surface of the impeller casings are machined with narrow tolerances, in order to minimize the clearance between impeller blade tip and impeller casings. The impeller casings are designed with inspection covers, through which the blades can be exchanged without dismantling the impeller hubs. The diffuser which converts fan dynamic pressure into static pressure is installed after the second stage impeller onto the second stage impeller casing. The diffuser is mounted with rollers/skates on to travel rails and can be moved axially into the adjoining discharge duct for servicing and maintenance. Access for service and inspections into the diffuser inner tube is possible through an inspection door at the diffuser discharge end. The main shaft, which is equipped with circulation lubricated radial and thrust slide bearings, is placed in the inner tube of the intermediate piece of the fan. The first stage impeller at the drive end is connected to the main motor via a coupling shaft placed in the inner tube of the inlet box. The hydraulic regulating unit is installed on the second stage impeller at the regulating end. A fixed connection between the two impellers internal regulating parts passes through the main shaft and ensures an exact blade pitch tracking for the 2 impellers. The blades are installed on to the impeller hub by means of special blade fixing screws fixed to the blade pivots. The internal regulating parts of the hub, transmits the regulating axial movements from the hydraulic cylinder to the blade pivots. The regulated set point signal from the control system is connected directly to the electric modulated actuator mounted external to the fan, which transforms the set point signal to a mechanical activation of the external regulating lever at the fan. Through a mechanical connection from the regulating lever, the mechanical movement transmitted into the hydraulic regulating unit inside, thus changing the blade pitch. Each axial booster fan has dedicated auxiliary systems which include lubricating oil, hydraulic oil, and sealing air. Each fan is equipped with stationary inlet guide vanes, oil filled hubs, blade pitch actuator, inlet and outlet expansion joints, and a slide away diffuser. Two dual element hub heaters installed in the inlet box inner tube section minimize condensing of corrosive flue gas on the first stage hub. Page 13 of 97
2607.001.2.2.1 Axial B ooster Fans (FG-FN-5300A & B ) When the fan is in operation, the hub heaters prevent any cool ambient air drawn into the inlet box inner tube along the coupling intermediate shaft from causing localized cool spots and flue gas condensation. The fan has installed instrumentation for stall detection, vibration, temperature, pressure, blade angle and regulating arm torque. The fan motor also has instrumentation for vibration, temperature, and speed. Access for maintenance and inspection of the Booster Fan is provided at three separate locations, an inspection door in the inlet box, inspection covers in the blade areas, and an inspection door at the diffuser outlet. Normal booster fan operation (two booster fans running in parallel) The regulation signal from the DCS system is transmitted to the blade pitch actuator, which converts the positioning signal to a mechanical movement at the external regulating arm of the fan. From the external regulating arm, the regulating movements are transmitted to the hydraulic fan regulating unit through a shaft and an embedded regulating shaft. Operating axial flow fans in parallel requires the fans to be operated at equal performance and to be regulated simultaneously and equally. This should be done by locking the blade pitch set point signals in the control system to the exact same value for the fans. Page 14 of 97
2607.001.2.2.1 Axial B ooster Fans (FG-FN-5300A & B ) Hydraulic regulating unit The hydraulic system consists of a hydraulic cabinet and a regulating unit that is built together with the fan hub. The regulating unit comprises a stationary hydraulic cylinder and a piston that transmits the movement to the blades through the regulating disc. The piston rod of the hydraulic cylinder forms the casing of the regulating valve, which, together with the throttle valve and the slot, reduces the oil pressure to atmospheric pressure. The hydraulic cabinet supplies a constant oil flow to the hydraulic cylinder through the rotating oil seal, whereby the whole regulating unit is cooled during operation so that it may be used at high ambient temperatures. In the neutral position, the external regulating arm secures the regulating valve in a given position. The position of the piston is controlled directly by the regulating valve, which keeps the piston in a state of equilibrium without hunting, the force (pressure x area) being equal on both sides of the piston. When the blades are to be opened, the external regulating arm should be set at the required blade angle indicated on the graduated scale. The regulating valve is also moved towards OPEN by means of the external regulating arm, thus widening the slot and allowing the pressure to decrease on the side of the piston having the larger area (indicated in yellow). When the pressure falls in the yellow area, the piston moves towards OPEN until the state of equilibrium (mentioned earlier) has been re-established. If the blade angle is to be reduced to a specific value, the external regulating arm is activated in the opposite direction, and the regulating valve is moved towards CLOSED. The slot will then close, and the pressure difference between the two sides of the piston will be balanced. The difference in area will cause the piston to move towards the impeller. The travel of the piston continues until the state of equilibrium (mentioned earlier) has been obtained, i.e. when the piston has travelled the same distance as the regulating valve. To ensure an almost uniform speed of motion in both directions, the side of the piston having the larger area (indicated in yellow) is fed with hydraulic oil through the slot. Slot is opened when slot closes. FULLY OPEN or FULLY CLOSED valve positions can never be obtained by activating the regulating valve. The valve will only make small deflections around the equilibrium, as even the smallest deflection will cause the pressure at the piston to change and, consequently, make the piston move. The spring neutralizes any clearance between the external regulating arm and the regulating valve. In order to relieve the actuator, the force of the spring is balanced by means of a counter weight. Page 15 of 97
2607.001.2.2.1 Axial B ooster Fans (FG-FN-5300A & B ) Parts List for hydraulic regulating arrangement Item Description Item Description 01 Pull Fork 12 Nozzle 02 Rotating Oil Seal 13 External regulating arm 03 Cardan Ring 14 Regulating disc 04 Copper Gasket 15 Guide pin 05 Piston Valve 16 Screws 06 Arm (outer) 17 Supporting cover 07 Slot 18 Screws 08 Slot 19 Valve housing 09 Spring 20 Tightening Arrangement 10 Piston 21 Screws 11 Cylinder Page 16 of 97
2607.001.2.2.1 Axial B ooster Fans (FG-FN-5300A & B ) Blade Pitch Actuator The blade angle actuator can be operated when: Main motor is running at nominal speed No hydraulic oil pressure alarm is activated. No regulation lever max torque switch alarm is activated. No actuator alarm is activated. The blade regulating range from minimum to maximum correspond to 4-20mA setpoint signal from DCS(FG-PZ-5300A). The 4-20mA feedback signal from the actuator (actual position FG-ZT-5300A) allows the DCS system to monitor the position and calculate the deviation from the setpoint. If quick blade angle correction is required, the setpoint can be sent to the actuator and the actuator will run continuously until the position is reached. Otherwise small changes in setpoint with some time interval are preferred. As wide as possible dead band should be defined in order to eliminate small and unnecessary blade angle adjustments which will reduce the life time of the mechanical parts in the regulating mechanism. The actuator is equipped with end of travel switches. Minimum position FG-ZSL-5300A and maximum position FG-ZSH-5300A. Both switches are closed when the actuator is in operation range. Lube Oil Skid The lubrication oil system is based on a constant flow system designed on basis of the specific requirements for the sleeve bearings used. The operating temperature of the lube oil is regulated by means of redundant oil cooler system with DCS controlled cooling fans. Standby temperature is maintained by DCS controlled redundant heating elements built into the hydraulic oil reservoir. The oil skid is supplied with redundant oil pump units, one in normal operating and one as standby. For emergency lubrication a DC powered pump is provided. Correct flow for each bearing is provided by individually pressure compensated flow regulators monitored by individually flow transmitters A jacking system provides a small amount of high pressure oil for the locating bearing during low rpm in the start and stop sequences. The AC jacking pump is backed up by a separate DC powered pump Page 17 of 97
2607.001.2.2.1 Axial B ooster Fans (FG-FN-5300A & B ) Hydraulic Oil Skid The hydraulic oil skid is designed to supply hydraulic oil to the hydraulic regulating unit inside the fan. The oil system is designed as a constant flow system, which adopts the pressure variations required for the hydraulic cylinder, as this load varies during operation. The operating temperature of the hydraulic oil is regulated by means of redundant oil cooler system with separate DCS controlled cooling fans. Standby temperature is maintained by DCS controlled redundant heating elements built into the hydraulic oil reservoir. The oil cabinet is supplied with redundant oil pump units. Diffusor Seal Air Skid The seal air skid prevents flue gas from entering the diffuser inner tube during normal fan operation by creating an overpressure between the inner tube and the flue gas passage. The seal air skid has redundant seal air fans. The sealing air system is monitored by means of differential pressure measurements between the inner tube in the diffuser and the flue gas passage. The sealing air is preheated by an electric heater before entering the diffuser in order to minimize the risk of corrosion in the interior of piping in contact with flue gas. Intermediate Seal Air Skid The seal air skid prevents flue gas from entering the intermediate section inner tube during normal fan operation by creating an overpressure between the inner tube and the flue gas passage. The seal air skid has redundant seal air fans. The sealing air system is monitored by means of differential pressure measurements between the inner tube in the intermediate section and the flue gas passage. The sealing air is preheated by an electric heater before entering the intermediate section in order to minimize the risk of corrosion in the interior of piping in contact with flue gas. Page 18 of 97
2607.001.2.2.1 Axial B ooster Fans (FG-FN-5300A & B ) Alarms and Trip Blade pitch actuator - If the actuator feedback position signal (FG-ZT-5300A) is unaffected to changing in setpoint signal (FG-PZ-5300A) sent from DCS, an alarm should be activated. Regulation Lever Max. Torque Switch - If the (FG-YS-5300A) is activated (no signal) an alarm should be activated and the actuator must be disabled as long as the alarm is present. Stall Warning - The stall warning system is based on pressure measurements at fan inlet FG-PIT-5301AA (B) (C), differential pressure between inlet box and inlet to intermediate section FG-PDIT-5301AA (B) (C), differential pressure between inlet box and outlet duct FG-PDIT-5302AA (B) (C) and inlet box temperature FG-TW/TE/TIT-5301AA (B) (C). All instrumentation is connected to the DCS. Programmed in the DCS is a stall warning that will be activated indicating when the maximum safe performance of the fan has been reached. The stall warning indicates further that the fan performance is close to stall limit and if performance is increased any further, the fan might stall. Ensure safe operation by reducing the furnace load slowly just until the stall warning signal ceases. To avoid faulty stall signals due to turbulent flow at low blade angles, the stall warning is suppressed at blade angles below 39. Stall Probes - The stall probes detect actual stall in the booster fan, which means that the booster fan is operated in the stall area and is operating in a critical condition at a reduced performance. The three (3) stall probes are connected to three (3) differential pressure transmitters FG-PDIT-5300AA (B) (C) connected to the plant control system. Upon receipt of the Stall Alarm, the DCS controls will initiate a rundown to quickly reduce the fan blade pitch until the fan is operating outside the stall range again. If a rundown is impossible due to an actuator alarm, the fan motor must be tripped immediately. To avoid faulty stall signals due to turbulent flow at low blade angles, the stall alarm is suppressed at blade angles below 39. The Alarm Setpoint > 2 inwg. Vibration Monitoring - Fan bearings are equipped with Bently-Nevada proximity and vibration sensors. All monitoring equipment is connected to a Bently-Nevada monitoring system. Data is send to DCS via serial communication and trips are in addition signaled via switches hardwired to DCS inputs Fan Bearing Temperature - Fan main bearings are supplied with thermocouples which are connected to the DCS. The DCS is programmed to initiate an alarm if the permissible bearing temperature is exceeded. Alarm setpoints are default defined with respect to the calculated bearing temperature. After a period of fan operating time with normal flue gas temperature, the setpoints must be corrected accordingly if necessary. Alarms and trips for each bearing will be based on the median of the three signals for that bearing. Thus alarming and tripping will occur on 2 out of 3 signals exceeding the temperature limit for that bearing. Page 19 of 97
2607.001.2.2.1 Axial B ooster Fans (FG-FN-5300A & B ) Fan Bearing Temperature - Fan main bearings are supplied with thermocouples which are connected to the DCS. The DCS is programmed to initiate an alarm if the permissible bearing temperature is exceeded. Alarm setpoints are default defined with respect to the calculated bearing temperature. After a period of fan operating time with normal flue gas temperature, the setpoints must be corrected accordingly if necessary. Alarms and trips for each bearing will be based on the median of the three signals for that bearing. Thus alarming and tripping will occur on 2 out of 3 signals exceeding the temperature limit for that bearing. This serves to reduce trips due to a single input failing high and to preserve fan protection if a single input fails low. Deviation between any signal and its corresponding median select signal will be alarmed to alert operations to a faulty input Two oil types are calculated ISO VG 100 Tag Calculated F Alarm F Trip F FG-TE-5300A M Outboard Fan (Radial) 175 193 211 Bearing FG-TE-5300A N (Radial) 175 193 211 FG-TE-5300A P (Radial) 175 193 211 FG-TE-5300A Q (Thrust) 173 191 209 FG-TE-5300A R (Thrust) 173 191 209 FG-TE-5300A S (Thrust) 173 191 209 Inboard Fan FG-TE-5300A J (Radial) 170 188 206 Bearing FG-TE-5300A K (Radial) 170 188 206 FG-TE-5300A L (Radial) 170 188 206 ISO VG 150 Tag Calculated F Alarm F Trip F FG-TE-5300A M Outboard Fan (Radial) 182 200 218 Bearing FG-TE-5300A N (Radial) 182 200 218 FG-TE-5300A P (Radial) 182 200 218 FG-TE-5300A Q (Thrust) 174 192 210 FG-TE-5300A R (Thrust) 174 192 210 FG-TE-5300A S (Thrust) 174 192 210 Inboard Fan FG-TE-5300A J (Radial) 180 198 216 Bearing FG-TE-5300A K (Radial) 180 198 216 FG-TE-5300A L (Radial) 180 198 216 Page 20 of 97
2607.001.2.2.2 Lube Oil S kids (FG-SD-5310A & B ) Number Sheet Rev Title P&IDs D3M20058 1 0 P&ID Axial Booster Fan A D3M20059 1 0 P&ID Axial Booster Fan B D3M20060 1 0 P&ID Axial Booster Fans A Skids D3M20061 1 0 P&ID Axial Booster Fans B Skids S90868 1 0 Booster Fan PI Diagram Unit 3 Fan B Vendor O&M Manuals S82678 1 A Booster Fan Motors, Installation and Maintenance S83221 1 A S83332 1 A S83333 1 A S89100 1 A S92745 1 0 Function FGD - Scrubber - Booster Fan - Booster Fan Consumer List (Fan A) - Tag No. FG-FN-5300 FGD - Scrubber - Oil Lube Cabinet - General Arrangement FGD - Scrubber - Oil Lube Cabinet - General Arrangement FGD - Scrubber - Lubrication Oil System - Bill of Material Scrubber - FGD - Booster Fan Foundation - Lube Oil, Hydraulic & Seal Air Unit Skids The lubricating oil system for each fan supplies filtered lubricating oil at the proper temperature and flow to fan bearings and motor bearings on the fan. The Lubricating Oil System also provides a small volume of high pressure oil to the fan bearings for jacking during fan start-up and off-line conditions. Page 21 of 97
2607.001.2.2.2 Lube Oil S kids (FG-SD-5310A & B ) Description The lubricating oil system for each booster fan is a skid type unit supplied by Howard Marten. The lubrication oil system is based on a constant flow system designed on basis of the specific requirements for the sleeve bearings used. The operating temperature of the lube oil is regulated by means of redundant oil cooler system with DCS controlled cooling fans. Standby temperature is maintained by DCS controlled redundant heating elements built into the hydraulic oil reservoir. The oil skid is supplied with redundant oil pump units, one in normal operating and one as standby. For emergency lubrication a DC powered pump is provided. Page 22 of 97
2607.001.2.2.2 Lube Oil S kids (FG-SD-5310A & B ) Each skid consists of the following: Lube Oil Tank Reservoir A 200 gallon carbon steel oil reservoir with a liquid level gauge. The lube oil reservoir is 72 L x 26 W, X29 H. Reservoir Liquid Level Gauge Page 23 of 97
2607.001.2.2.2 Lube Oil S kids (FG-SD-5310A & B ) Oil Tank Heater (FG-HT-5310AH/AJ & BH/BJ) Two 3.5 kw 460V AC Heaters (FG-HT-5310AH/AJ & BH/BJ), one operating and one in standby. The heaters are manufactured by ELKON and are controlled via the DCS by the oil temperature sensors in the tank. It is recommended to keep the heater operational even if the lube oil skid is stopped to avoid condensation in the tank. Start conditions: Oil temperature < 77 F Stop conditions: Oil temperature > 86 F Page 24 of 97
2607.001.2.2.2 Lube Oil S kids (FG-SD-5310A & B ) AC Lube Oil Pumps (FG-PU-5310AA/AB & BA/BB) Two AC screw type lube oil pumps (FG-PU-5310AA/AB & BA/BB). Pump motors are a GE 7.5 hp, 480 volt, 1800 rpm, three phase, frame 213TC. One of the pumps, (one is operational and the other stand by) should be started before the fan is started and run continuously when the fan is started. Start conditions: No lube oil skid alarm activated Oil temperature in the tank > 77 F Stop conditions: Oil temperature in the tank < 104 F Typical GE Motor Page 25 of 97
2607.001.2.2.2 Lube Oil S kids (FG-SD-5310A & B ) DC Emergency Lube Oil Pump (FG-PU-5310AC & BC) One 4 port gear type back-up lube oil pump (FG-PU-5310AC & BC), model number P1AAN. Pump motor is a GE 2 HP single phase, 125V DC, 1750 rpm, frame 186ATC. If both AC lube oil pumps FG-MO-5310AA or FG-MO-5310AB are tripped start DC pump immediately. Start DC pump on any flow alarm with a 4 sec delay until Variax fan is brought to stand still. Page 26 of 97
2607.001.2.2.2 Lube Oil S kids (FG-SD-5310A & B ) AC Jacking Pump (FG-PU-5310AD & BD) One gear type jacking oil pump (FG-PU-5310AD & BD), model number GP-F10. Pump motors are a GE 1 hp, 480 volt, 1800 rpm, three phase, frame 143TC. The jacking pump must be started during Variax fan start and coast down in order to provide sufficient lube oil to the fan sleeve bearings. Fan start: Start before Variax main motor start and stop at fan speed > 440 rpm. or by a timer that is initiated on a Fan stop (coast down): Start pump before main motor is stopped and stop pump when fan is brought to stand still. This could be initiated by a timer. The time base must ensure enough time for coast down under all circumstances. Running the jacking pump after fan stand still will not do any harm to the system. Page 27 of 97
2607.001.2.2.2 Lube Oil S kids (FG-SD-5310A & B ) DC Jacking Pump (FG-PU-5310AE & BE) One 1 HP 125 volt DC gear type jacking oil pump (FG-PU-5310AE & BE) model number GP-F10. Start and stop on the same conditions as jacking AC pump in case of jacking oil flow alarm. Page 28 of 97
2607.001.2.2.2 Lube Oil S kids (FG-SD-5310A & B ) Lube Oil Filter (FG-FL-5310AC & BC) A 10 micron duplex filter with integral transfer valve-main lube oil (FG-FL-5310AC & BC), with 10 micron simplex cartridge filter-jacking oil (FG-FL-5310AD & BD). Page 29 of 97
2607.001.2.2.2 Lube Oil S kids (FG-SD-5310A & B ) Lube Oil Cooler (FG-HX-5310AC/AD & BC/BD) Two AirEx air/oil bar & plate type oil coolers (FG-HX-5310AC/AD & BC/BD). The Oil coolers are powered by 2 hp, 480V AC GE, motors, frame number 145TC, FG-FN- 5310AA/AB & BA/BB and are controlled via the DCS by the oil temperature sensors downstream the oil outlet pipe. One of the cooler systems is operational and one is standby. At low and high temperatures both systems are used in parallel but each system is designed to 100% cooling efficiency. Typical GE Motor Page 30 of 97
2607.001.2.2.2 Lube Oil S kids (FG-SD-5310A & B ) Correct flow for each bearing is provided by individually pressure compensated flow regulators monitored by individually flow transmitters A jacking system provides a small amount of high pressure oil for the locating bearing during low rpm in the start and stop sequences. The AC jacking pump is backed up by a separate DC powered pump Alarms and trip Instrument Tag Setpoint Action FG-TW/TE-5310AA FG- Low alarm. Oil tank temperature TW/TE-5310AB FG- T < 50 F Activate stand by oil sensors TW/TE-5310AC heater Outlet pipe Low alarm Trip fan FG-TW/TE-5312AA T < 50 F temperature after 10 minutes. sensors FG-TW/TE-5312AB FG- High alarm Activate T > 122 F TW/TE-5312AC stand by cooler. Inboard bearing Alarm. Activate DC FG-FIT-5311A A F < 0.15 Gal/min jacking oil flow pump Outboard bearing FG-FIT-5311A B F < 0.15 Gal/min jacking oil flow Page 31 of 97
2607.001.2.2.3 Hydraulic Oil S kids (FG-SD-5305A & B ) Number Sheet Rev Title P&IDs D3M20058 1 0 P&ID Axial Booster Fan A D3M20059 1 0 P&ID Axial Booster Fan B D3M20060 1 0 P&ID Axial Booster Fans A Skids D3M20061 1 0 P&ID Axial Booster Fans B Skids S90868 1 0 Booster Fan PI Diagram Unit 3 Fan B Vendor O&M Manuals S82678 1 A Booster Fan Motors, Installation and Maintenance S83221 1 A S83328 1 A S92745 1 0 S89101 1 0 S83348 1 0 S83347 1 0 S83328 1 0 S87325 1 0 S83331 1 A Function FGD - Scrubber - Booster Fan - Booster Fan Consumer List (Fan A) - tag no. FG-FN-5300 Howden Power-Instrument Junction Box Hydraulic Oil System Wiring Diagram Scrubber - FGD - Booster Fan Foundation - Lube Oil, Hydraulic & Seal Air Unit Skids FGD - Scrubber - Hydraulic Oil System - Bill Of Material FGD - Scrubber - Hydraulic Oil Unit Oil Pump - AC Motor Data Sheet 10 Hp 1800 Rpm FGD - Scrubber - Hydraulic Oil Unit Air Cooler - AC Motor Data Sheet 1.0 Hp 1200 Rpm FGD - Scrubber - Hydraulic Oil System - Junction Box Wiring Diagram - Instrument Junction Box FGD - Scrubber - Blac Hydraulic Power Units (HPU) Operation & Maintenance Manual FGD - Scrubber - Hydraulic Cabinet - General Arrangement The Hydraulic Oil System for the fans supplies hydraulic oil to the hydraulic regulating unit for blade pitch control. Hydraulic oil is supplied to the hydraulic cylinder through the rotating oil seal on the end of the second stage hub. Page 32 of 97
2607.001.2.2.3 Hydraulic Oil S kids (FG-SD-5305A & B) Description The Hydraulic Oil System for each Booster Fan is a skid type unit supplied by Howard Marten. The hydraulic oil skid is designed to supply hydraulic oil to the hydraulic regulating unit inside the fan. The oil system is designed as a constant flow system, which adopts the pressure variations required for the hydraulic cylinder, as this load varies during operation. The operating temperature of the hydraulic oil is regulated by means of redundant oil cooler system with separate DCS controlled cooling fans. Standby temperature is maintained by DCS controlled redundant heating elements built into the hydraulic oil reservoir. The oil cabinet is supplied with redundant oil pump units. Page 33 of 97
2607.001.2.2.3 Hydraulic Oil S kids (FG-SD-5305A & B ) Each skid consist of the following Hydraulic Oil Tank Reservoir A 120 gallon oil reservoir with a liquid level gauge. The Hydraulic oil reservoir is 60 L x 30 W, X27 H. Reservoir Liquid Level Gauge Page 34 of 97
2607.001.2.2.3 Hydraulic Oil S kids (FG-SD-5305A & B ) AC Hydraulic Oil Tank Heaters (FG-HT-5305AE/AF & BE/BF) Two 2 kw 460V AC heaters (FG-HT-5305AE/AF & BE/BF). The Oil tank heaters are manufactured by ELKON and are controlled via the DCS by the oil temperature sensors in the tank. It is recommended to keep the heater operational even if the hydraulic oil skid is stopped to avoid condensation in the tank. Start conditions: Oil temperature in the tank < 59 F Stop conditions: Oil temperature in the tank > 73 F Page 35 of 97
2607.001.2.2.3 Hydraulic Oil S kids (FG-SD-5305A & B ) AC Hydraulic Oil Pumps (FG-PU-5305AA/AB & BA/BB) Two 10 HP 460 volt AC gear type hydraulic oil pumps (FG-PU-5305AA/AB & BA/BB),, model number P1AAN, The pumps are controlled via the DCS. One of the pumps, (one is operational and the other stand by) should be started before the fan is started and runs continuously during fan operations. Start conditions: No hydraulic oil skid alarm Oil temperature in the tank > 59 F Stop conditions: Variax Fan is stopped Oil temperature in the tank < 104 F Page 36 of 97
2607.001.2.2.3 Hydraulic Oil S kids (FG-SD-5305A & B ) Hydraulic Oil Filter (FG-FL-5305AC & BC) One 10 micron duplex cartridge filter (FG-FL-5305AC & BC). Page 37 of 97
2607.001.2.2.3 Hydraulic Oil S kids (FG-SD-5305A & B ) Hydraulic Oil Cooler (FG-FN-5305AA/AB & BA/BB) One AirEX air/oil bar & plate type oil cooler (FG-HX-5305AC & BC) with redundant 1.5 hp, 480V AC GE, motors, frame number 145TC, (FG-MO-5305AA/AB & BA/BB), The Oil cooler fans are controlled via the DCS by the oil temperature sensors in the tank. Start conditions: Oil temperature > 113 F Stop conditions: Oil temperature < 104 F Typical GE Motor Page 38 of 97
2607.001.2.2.3 Hydraulic Oil S kids (FG-SD-5305A & B ) Alarms And Trip Low oil level alarm should be activated if signal from FG-LSL-5305A/B is below the determined minimum T < 50 F Low alarm. Activate stand by heater and stop operational heater. T > 122 F High alarm Activate stand by cooler fan and stop operational cooler fan. T > 131 F High-High alarm Prepare fan trip. Trip after 60 minutes. T > 140 F High-High-High alarm Trip fan immediately Dp< 65 psi High alarm Oil filter pressure drop alarm P>1450 psi High alarm P< 73 psi AND Low alarm. Activate stand by pump and stop operational pump. Pump started Prepare fan trip Trip after 20 minutes. Page 39 of 97
2607.001.2.2.4 Diffus or and Intermediate S eal Air S kids (FG-SD-5320A/B & 5315A/B ) Number Sheet Rev Title P&IDs D3M20064 1 0 P&ID Inlet & Outlet Damper Seal Air Skid D3M20058 1 0 P&ID Axial Booster Fan A D3M20059 1 0 P&ID Axial Booster Fan B D3M20060 1 0 P&ID Axial Booster Fans A Skids D3M20061 1 0 P&ID Axial Booster Fans B Skids S90868 1 0 Booster Fan PI Diagram Unit 3 Fan B S80549 1 A S92119 1 A S92745 1 0 Function Vendor O&M Manuals Scrubber - FGD Bypass Diverter System - Seal Air Fan Skid Assembly - Unit 3 Scrubber - FGD - Booster Fan Skid For Inlet & Outlet Damper - Seal Air P&ID Scrubber - FGD - Booster Fan Foundation - Lube Oil, Hydraulic & Seal Air Unit Skids Each booster fan has two dedicated seal air skids which provide heated seal air to the fan s diffusor and intermediate inner tube sections to prevent flue gas from entering these areas and causing corrosion. Description The Sealing Air System for each booster fan is a skid type unit manufactured by Jorgen Hansen Maskinfabrik, which consists of ambient air filters (FG-FL-5320AA/AB & BA/BB) with differential pressure gages (FG-PDG-5321AA/AB & BA/BB), one fan is operating, and the other is in standby. Page 40 of 97
2607.001.2.2.4 Diffus or and Intermediate S eal Air S kids (FG-SD-5320A/B & 5315A/B ) The seal air blowers are powered by a Reliance 10 hp, 460V AC motor (FG-MO-5320AA/AB & BA/BB), and non-return dampers (FG-DP-5320AA/AB & BA/BB). The system also contains two inline 7.5 kw 480V AC duct heaters (FG-HT-5320AC/AD & BC/BD), which are located outside of the skid cabinet. Page 41 of 97
2607.001.2.2.4 Diffus or and Intermediate S eal Air S kids (FG-SD-5320A/B & 5315A/B ) Page 42 of 97
2607.001.2.2.4 Diffus or and Intermediate S eal Air S kids (FG-SD-5320A/B & 5315A/B ) Page 43 of 97
2607.001.2.2.4 Diffus or and Intermediate S eal Air S kids (FG-SD-5320A/B & 5315A/B ) Diffusor Seal Air Skid The seal air skid prevents flue gas from entering the diffuser inner tube during normal fan operation by creating an overpressure between the inner tube and the flue gas passage. The seal air skid has redundant seal air fans. The sealing air system is monitored by means of differential pressure measurements between the inner tube in the diffuser and the flue gas passage. The sealing air is preheated by an electric heater before entering the diffuser in order to minimize the risk of corrosion in the interior of piping in contact with flue gas. Diffusor Seal Air Skid Normal Operation Before the Variax fan is started, during operation and at least 30 min after it is stopped the seal air fan skid should be running continuously. This means that one of the fans and one of the heaters is started. Only one (1) fan and one (1) heater are operational at the time. A heater must only be activated when a seal air fan is running. If the Variax fan is stopped and inlet and outlet dampers are closed and tight in a way that flue gas can not enter the fan inner tube the seal air skid can be stopped completely. If the Variax fan is stopped but there is a risk for flue gas contamination of the inner tube it is recommended to let the seal air fan be operational if the differential pressure between the inner tube and flue gas passage drops below 1.0 InWG. The individual Seal air fan inlet filters should be visual inspected on a regular base depending on the environment. Since the pressure drop indicated on the local indicators will vary depending on the Variax fan performance no absolute alarm limits can be defined. Based on experience the difference in pressure drop with and without filter inserted will indicate the actual filter condition. Diffusor Seal Air Skid Alarms And Trip The differential pressure transmitters FG-PDIT-5320AA, FG-PDIT-5320AB and FG-PDIT- 5320AC monitors the differential pressure between the diffuser inner tube and the flue gas passage. If 2 out of 3 signals indicate a differential pressure below 1.0 InWG an alarm should be activated. Activate stand by seal air fan and stop the operational fan. If the seal air differential pressure alarm withstands for more than 4 hours the Variax fan must be tripped manually by operator. The heater function must be monitored via the MCC e.g. using a load guard relay to monitor that the power consumption correspond with the heater size. Since no immediately action has to be taken in case of heater failure only an alarm should be activated. Page 44 of 97
2607.001.2.2.4 Diffus or and Intermediate S eal Air S kids (FG-SD-5320A/B & 5315A/B ) Intermediate Seal Air Skid The seal air skid prevents flue gas from entering the intermediate section inner tube during normal fan operation by creating an overpressure between the inner tube and the flue gas passage. The seal air skid has redundant seal air fans. The sealing air system is monitored by means of differential pressure measurements between the inner tube in the intermediate section and the flue gas passage. The sealing air is preheated by an electric heater before entering the intermediate section in order to minimize the risk of corrosion in the interior of piping in contact with flue gas. Intermediate Seal Air Skid Normal Operation Before the Variax fan is started, during operation and at least 30 min after it is stopped the seal air fan skid should be running continuously. This means that one of the fans and one of the heaters is started. Only one (1) fan and one (1) heater are operational at the time. A heater must only be activated when a seal air fan is running. If the Variax fan is stopped and inlet and outlet dampers are closed and tight in a way that flue gas cannot enter the fan inner tube, the seal air skid can be stopped completely. If the Variax fan is stopped but there is a risk for flue gas contamination of the inner tube it is recommended to let the seal air fan be operational if the differential pressure between the inner tube and flue gas passage drops below 1.0 InWG. The individual Seal air fan inlet filters should be visual inspected on a regular base depending on the environment. Since the pressure drop indicated on the local indicators will vary depending on the Variax fan performance no absolute alarm limits can be defined. Based on experience the difference in pressure drop with and without filter inserted will indicate the actual filter condition. (refer to IO manual) Intermediate Seal Air Skid Alarms And Trip The differential pressure transmitters FG-PDIT-5315AA, FG-PDIT-5315AB and FG-PDIT- 5315AC monitors the differential pressure between the diffuser inner tube and the flue gas passage. If 2 out of 3 signals indicate a differential pressure below 1.0 InWG an alarm should be activated. Activate stand by seal air fan and stop the operational fan. If the seal air differential pressure alarm withstands for more than 4 hours the Variax fan must be tripped manually by operator. The heater function must be monitored via the MCC e.g. using a load guard relay to monitor that the power consumption corresponds with the heater size. Since no immediately action has to be taken in case of heater failure only an alarm should be activated. Page 45 of 97
2607.001.2.2.5 Inlet Dampers (FG-XV-5325A & B ) Number Sheet Rev Title P&IDs D3M20064 1 0 P&ID Inlet & Outlet Damper Seal Air Skid D3M20058 1 0 P&ID Axial Booster Fan A D3M20059 1 0 P&ID Axial Booster Fan B D3M20060 1 0 P&ID Axial Booster Fans A Skids D3M20061 1 0 P&ID Axial Booster Fans B Skids S90868 1 0 Booster Fan PI Diagram Unit 3 Fan B S93800 1 0 S93801 1 0 Vendor O&M Manuals Scrubber - FGD - Booster Fan Inlet Damper Erection Drawing Scrubber - FGD - Booster Fan Inlet Damper Erection Drawing S95072 1 0 Scrubber - FGD - Booster Fan Inlet Damper - "A" S95073 1 0 Scrubber - FGD - Booster Fan Inlet Damper - "B" S95076 1 0 S95077 1 0 S82938 1 0 S93777 1 0 S92120 1 0 S92119 1 0 S82940 1 E S82938 1 E Function Scrubber - FGD - Booster Fan Inlet Damper Erection Drawing Scrubber - FGD - Booster Fan Inlet Damper Erection Drawing Scrubber - FGD - Booster Fan Inlet Damper - Outline & Dimensions Scrubber - FGD - DSDS Louver Dampers & Seal Air Fan Assembly - Installation & Maintenance Manual Scrubber - FGD - Booster Fan Skid For Inlet & Outlet Damper - Seal Air P&ID For Bypass Scrubber - FGD - Booster Fan Skid For Inlet & Outlet Damper - Seal Air P&ID Scrubber - FGD - Booster Fan Skid For Inlet & Outlet Damper - Outline & Dimensions Scrubber - FGD - Booster Fan Inlet Damper - Outline & Dimensions Each axial booster fan has an inlet damper which in conjunction with the outlet dampers and damper seal air provide for isolation of the fans during operations and maintenance. Page 46 of 97
2607.001.2.2.5 Inlet Dampers (FG-XV-5325A & B ) Description The fan inlet damper is a tandem louver type damper manufactured by Backmann Dampjoint and is equipped with a REXA electro-hydraulic actuator model D200,000-120-D- P9-P. The inlet dampers share a share a common seal air system with the fan outlet dampers to provide a zero leak seal against flue gas, creating a safe environment inside the axial booster fan for personnel during maintenance. Quantity 1 per fan, 2 per unit Type Tandem Louver, Zero Leak Seals Manufacturer Bachmann Dampjoint Inc. Size 142 ¾ x 278 1/8 Blade Material A36 Blade Shaft Material 304 stainless steel Drive Shaft Material 304 stainless steel Seal Material Alloy C276 Frame and Housing Material A36 Actuator REXA Electric/Hydraulic Normal Opening/Closing Time 30 seconds Seal Air Ports per Damper One Seal Air Flow with one fan out of service 4466 ACFM Seal Air pressure @ port with one fan out of service 22 inches w.g. Seal Air Flow in FGD Bypass 2409 acfm Seal Air Pressure @ port in FGD Bypass 3 inches w.g. Page 47 of 97
2607.001.2.2.5 Inlet Dampers (FG-XV-5325A & B ) The Dampers are 100% Isolation Dual Skin Dual Seal (DSDS) dampers. Page 48 of 97
2607.001.2.2.5 Inlet Dampers (FG-XV-5325A & B ) Page 49 of 97
2607.001.2.2.5 Inlet Dampers (FG-XV-5325A & B ) Rexa Actuator The REXA Xpac is a microprocessor controlled, self-contained, Electraulic actuator or drive designed specifically for modulating service. Hydraulic, electronic and mechanical technologies are com-bined to produce the state of the art in actuator design. The patented Flow Match System is simply described as a highly efficient method of pumping hydraulic oil from one side of a double acting cylinder to the other. Once the correct position is reached, the motor shuts off and power is not required to maintain position. The hydraulics are controlled by a dedicated microprocessor contained within the control enclosure. Software designed for the Xpac allows the user to set actuator operation parameters. The Xpac consists of two major components, the actuator (cylinder, power module and feedback) and the control enclosure. The actuator is installed on the driven device, while the enclosure is remotely mounted. Connecting them are the module cable, motor cable and the feedback cable. Page 50 of 97
2607.001.2.2.5 Inlet Dampers (FG-XV-5325A & B ) The Flow Match System allows the Xpac to position in an incremental mode. The motor and pump only operate when movement of the actuator is required. When not moving, the Xpac is locked in place. The system is rated for modulating duty with no limitation on start, stop or reverse cycles. The heart of the actuator is the Electraulic Power Module. Consisting of a motor, gear pump, flow match valve (FMV), make-up oil reservoir, heater and bypass solenoid (spring fail units only), the Power Module delivers oil at a nominal 2000 psi to a hydraulic cylinder. An inherent requirement with the Flow Match System is equal displaced oil volumes on both sides of the cylinder. This allows oil movement without an active reservoir. The reservoir indicator or plunger is used by the operator to determine if the Xpac has the appropriate oil level. If the indicator is almost flush with the housing, add oil to restore the indicator to its normal extended position. Double rod construction on linear units and dual opposed cylinders on the rotary units meet this criteria. Page 51 of 97
2607.001.2.2.5 Inlet Dampers (FG-XV-5325A & B ) To provide position information, a feedback assembly consisting of a resistive film potentiometer and a transmitter (4-20 ma) circuit board is used. The feedback assembly is sealed in a NEMA 4X area and mounted within or adjacent to the cylinders. The connection of the potentiometer is by direct mechani-cal means to the output shafts. Shock loading and vibration has no effect on readings and loss motion in the rotary rack and pinion is eliminated. The control enclosure contains the position control processor (PCP), power supplies, motor drivers, fuses and filters, and a termination area. The PCP consists of an 8-bit, 80C52 microprocessor, a 32 Kilobyte EEPROM memory for program storage, a 2 Kilobyte EEPROM memory for data storage, a 12-bit A/D converter, and a 3-button/5-digit display user interface. The PCP also provides two connectors which accept optional I/O interface boards. The power supplies contained in the control enclosure vary according to the type and quantity of power modules. Common to all types is the logic power supply which provides +5 and -15 Vdc to the PCP and +15 Vdc to the feedback assembly. For actuators built with B size power modules, the control enclosure includes an unregulated, 53 Vdc power supply for the motor. For C size and D size power modules, the power supplies are built into the motor drivers. The control enclosure includes a motor driver for each power module. The motor driver converts the low power logic signals from the PCP into high voltage, high current motor power to the stepper motor (B or C) or servomotors (D). The PCP is calibrated in the Setup mode by a simple routine. Speed, stroke, deadband and control signal are some of the parameters that can be configured by using the three button keypad and the display. Programmed parameters are retained in a permanent memory. Page 52 of 97
2607.001.2.2.5 Inlet Dampers (FG-XV-5325A & B ) To move the piston to the left, the pump turns in the direction to pressurize FMV-2 through port A. The spool in FMV-2 becomes unbalanced by the pressure differential and moves to the left, lifting its check valve, opening port D to port B and port A to port E. High pressure fluid flows through Port E to the right side chamber of the cylinder. Since the hydraulic circuit is closed, the same amount of oil that flows into the right side of the piston must be extracted from the left side. This oil flows through the open check valve of FMV-2 and into pump suction. By reversing the direction of pump rotation, the FMVs operate in reverse to move the cylinder rod to the right. When the pump stops, both check valves close. The hydraulic oil is locked within the cylinder. Motor operation is not required to maintain position. By using the stroke and signal ranges set during calibration, the PCP converts the incoming control signal into a target position. The current position is determined through the active feedback assembly mounted on the actuator. The difference between the target and current position is the error. Page 53 of 97
2607.001.2.2.5 Inlet Dampers (FG-XV-5325A & B ) If the error exceeds the deadband (user set), then the PCP will initiate corrective action by starting the motor. A reversible hydraulic pump is driven by the motor. The pump can pressurize either side of a double acting cylinder through one of two Flow Matching Valves, FMV-1 and FMV-2. Each FMV is comprised of a ported spool with an integral pilot operated check valve. The ports of both FMVs are sized exactly the same. Page 54 of 97
2607.001.2.2.6 Outlet Dampers (FG-XV-5330A & B) Number Sheet Rev Title P&IDs D3M20064 1 0 P&ID Inlet & Outlet Damper Seal Air Skid D3M20058 1 0 P&ID Axial Booster Fan A D3M20059 1 0 P&ID Axial Booster Fan B D3M20060 1 0 P&ID Axial Booster Fans A Skids D3M20061 1 0 P&ID Axial Booster Fans B Skids S90868 1 0 Booster Fan PI Diagram Unit 3 Fan B S95078 1 0 S95079 1 0 Vendor O&M Manuals Scrubber - FGD - Booster Fan Outlet Damper Erection Drawing Scrubber - FGD - Booster Fan Outlet Damper Erection Drawing S95074 1 0 Scrubber - FGD - Booster Fan Outlet Damper - "A" S95075 1 0 Scrubber - FGD - Booster Fan Outlet Damper - "B" S82939 1 0 S93777 1 0 S92120 1 0 S92119 1 0 S82940 1 E S82939 1 E Function Scrubber - FGD - Booster Fan Outlet Damper - Outline & Dimensions Scrubber - FGD - DSDS Louver Dampers & Seal Air Fan Assembly - Installation & Maintenance Manual Scrubber - FGD - Booster Fan Skid For Inlet & Outlet Damper - Seal Air P&ID For Bypass Scrubber - FGD - Booster Fan Skid For Inlet & Outlet Damper - Seal Air P&ID Scrubber - FGD - Booster Fan Skid For Inlet & Outlet Damper - Outline & Dimensions Scrubber - FGD - Booster Fan Outlet Damper - Outline & Dimensions Each axial booster fan has an outlet damper which in conjunction with the inlet dampers and damper seal air provide for isolation of the fans during operations and maintenance. Page 55 of 97
2607.001.2.2.6 Outlet Dampers (FG-XV-5330A & B ) Description The fan outlet damper is a tandem louver type damper manufactured by Backmann Dampjoint and is equipped with a REXA electro-hydraulic actuator. The outlet dampers share a share a common seal air system with the fan inlet dampers to provide a zero leak seal against flue gas creating a safe environment inside the axial booster fan for personnel during maintenance. Booster Fan Outlet Dampers Quantity 1 per fan, 2 per unit Type Tandem Louver, Zero Leak Seals Manufacturer Bachmann Dampjoint Inc. Size 228 x 228 Blade Material A36 Blade Shaft Material 304 stainless steel Drive Shaft Material 304 stainless steel Seal Material Alloy C276 Frame and Housing Material A36 Actuator REXA Electric/Hydraulic Normal Opening/Closing Time 30 seconds Seal Air Ports per Damper One Seal Air Flow with one fan out of service 4818 ACFM Seal Air pressure @ port with one fan out of service 27 inches w.g. Page 56 of 97
2607.001.2.2.6 Outlet Dampers (FG-XV-5330A & B ) Page 57 of 97
2607.001.2.2.6 Outlet Dampers (FG-XV-5330A & B ) Rexa Actuator The REXA Actuators for the Inlet and Outlet Dampers are identical. This information can be found in the previous, Inlet Damper, discussion. Page 58 of 97
2607.001.2.2.7 Damper Seal Air S kid (S L-SD-5335) Number Sheet Rev Title P&IDs D3M20064 1 0 P&ID Inlet & Outlet Damper Seal Air Skid D3M20058 1 0 P&ID Axial Booster Fan A D3M20059 1 0 P&ID Axial Booster Fan B D3M20060 1 0 P&ID Axial Booster Fans A Skids D3M20061 1 0 P&ID Axial Booster Fans B Skids S90868 1 0 Booster Fan PI Diagram Unit 3 Fan B S93777 1 0 S92119 1 A S92120 1 A Function Vendor O&M Manuals Scrubber - FGD - DSDS Louver Dampers & Seal Air Fan Assembly - Installation & Maintenance Manual Scrubber - FGD - Booster Fan Skid For Inlet & Outlet Damper - Seal Air P&ID Scrubber - FGD - Booster Fan Skid For Inlet & Outlet Damper - Seal Air P&ID For Bypass The booster fan inlet and outlet damper seal air skid provides low pressure air to all four of the booster fan dampers to ensure a zero leak seal against flue gas creating a safe environment inside the axial booster fan for personnel during maintenance. Description The booster fan damper seal air skid is comprised of an operating and standby fan, two inlet silencers, two 75 Hp 480 volt AC, three phase, 3600 rpm motor, frame # 365TS (SL-MO- 5335A & B), and electric motor actuated and outlet dampers (SL-XV-5336A & B). Page 59 of 97
2607.001.2.2.7 Damper S eal Air S kid (S L-SD-5335) Seal Air Fan Motor Seal Air Fan Unit Page 60 of 97