SCRUBBER SUMP SYSTEM PROCESS DESCRIPTION Document No

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1 BWN-3/ Rev. 0 Process Description Plant Bowen /s/ Gary Smith Approved Plant Review Board /s/ Tim Crump Approved Operations Manager /s/ Tim Banks Approved Plant Manager Date: PLANT BOWEN UNITS 3 & 4 FLUE GAS DESULFURIZATION SYSTEM SCRUBBER SUMP SYSTEM PROCESS DESCRIPTION Document No 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 70

2 T able of C ontents PROCESS DESCRIPTION Safety Considerations Process Description Introduction System Components Sump System Mixers Ash Pond Transfer Sump Pumps (WW-PU-5480A & B) Ash Pond Transfer Sump Discharge Valves (WW-XV- 5481A & B) Ash Pond Transfer Sump Pump Back Flush Valves (WW-XV-5482A & B) FGD Area Sump Pumps (WW-PU-5495A & B) FGD Area Sump Discharge Valves (WW-XV-5496A & B) FGD Area Sump Pump Back Flush Valves (WW-XV-5494A & B) Limestone Area Sump Pumps (WW-PU-5380A & B) Limestone Area Sump Discharge Valves (WW-PU-5381A & B) Limestone Area Sump Pump Back Flush Valves (WW-XV-5382A & B) Dewatering Sump Pumps (WW-PU-5390A & B) Dewatering Sump Discharge Valves (WW-XV-5391A & B) Dewatering Area Sump Pump Back Flush Valves (WW-XV-5392A & B) Summarized Controls Description Detailed Controls Description Process Flow Description Drawing References 65 Date Printed 2/22/2011 Page 2 of 70

3 PROCESS DESCRIPTION Safety Considerations 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. The 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 requirements. Date Printed 2/22/2011 Page 3 of 70

4 Process Description Introduction The Scrubber Sump System collects, stores, and transports waste water recovered from various areas throughout the FGD. The system consists primarily of four sumps, which are the Limestone Area Sump, the FGD Area Sump, the Dewatering Area Sump, and the Ash Pond Transfer Sump. The Limestone Area Sump, FGD Area Sump, and Dewatering Sump have the ability to either discharge their waste water contents back into the FGD process or to discharge their waste water contents into the Ash Pond Transfer Sump which, from there, the waste water will be discharged to the Ash Pond. Each sump contains two pumps for discharge of waste water and a mixer to prevent sedimentation of solids within the sump. Limestone Area Sump The limestone area sump receives a water or slurry stream collected by area trenches as result of flushing and draining of slurry pipelines, area cleaning, and spills. The sump is installed below grade and equipped with 2 pumps, one mixer and level indication instrumentation. The sump contents are either pumped to the limestone slurry transfer tank for recovery or to ash pond transfer sump if disposal is required. Because the sump handles water that can include an appreciable amount of solids (>10%), the pipelines are equipped for automatic flushing. This installed automatic flushing dilutes the sump contents prior to pump start. This results in the pump casing and discharge piping being flushed. The sump pump discharge piping is equipped with a control valve from the make-up water system for this purpose. The sump pumps are designed for corrosive duty with all wetted parts below the floor plate being rubber covered and/or lined. These are double suction pumps with semi-open impellers capable of being run dry. The flow rate is cut by about 60% once the sump level drops below the impeller. The limestone area sump is controlled based on the sump s liquid level. The sump is equipped with a continuous level measuring instrument providing local and remote indication. The figure below illustrates the level alarms and interlocks. The destination of the slurry discharged by the sump pumps is determined by the operator manipulating the manual valves in the pipeline. Date Printed 2/22/2011 Page 4 of 70

5 Introduction The sump mixers operate continuously regardless of sump level. Their operation is started and stopped by operator action via the DCS. When in auto mode the DCS stops and starts sump pumps automatically without operator initiation. Starts are alternated between the two pumps in order to equalize run time. When one pump stops, a toggle switches to start the other pump next time. The operator also has the ability to toggle the pump selected for the next start. When pump operation is stopped, the pump discharge valve is closed, the backflush valve remains open filling the sump and diluting the contents, performing a post flush. 11 ft High-High Alarms 10 ft High Starts Pump 1.5 ft Low Stops Pump Limestone Area Sump Interlocks and Alarms Date Printed 2/22/2011 Page 5 of 70

6 Introduction Sump Dimensions, W x L x H 10 x 10 x 12 Sump Pumps Quantity 2 Flow Rate Head Brake Horsepower Manufacturer & Model Casing Shaft Impeller Coating Shaft Seal Drive Pump Speed Motor Speed Pump Motor hp Mixer Manufacturer & Model Shaft Dimensions (D x L) Shaft Materials Impeller Type Vertical Cantilever 250 gpm 103 ft of H 2 O 28 hp Weir Slurry (Galigher), 3SR4-5100x coated steel 520 coated steel 520 coated steel Rubber NA Poly chain 1682 rpm 1800 rpm max, 1750 rpm operating 40 hp Impeller Diameter 53 Impeller Speed Impeller Materials top mounted Lightnin, 73Q5 2.5 x 126 FMB Carbon steel with 3/16 natural rubber coating 1 impeller, 3 blades per impeller 55.8 rpm, fpm Gearbox Lightnin, 73 Mixer Motor hp 5 Impeller Elevation Minimum Sump Mixing Level Adequate sump level to start mixer Sump Inflows Sump Outflows Carbon steel w/ 3/16 natural rubber coating 18 above sump floor 36 above sump floor 62 above sump floor Area drains Limestone Area sump pump flow Date Printed 2/22/2011 Page 6 of 70

7 Introduction FGD Area Sump The FGD area sumps receive a water or slurry stream collected by area trenches as a result of flushing and draining of slurry pipelines, area cleaning, and spills. They also receive the drains from the JBR outlet ducts and chimney flues. The FGD area sumps can be used to transfer gypsum slurry from one JBR to another for gypsum seeding. The sumps are installed below grade and equipped with 2 pumps, one mixer and level indication instrumentation. The sump contents are pumped to the respective ash pond transfer sump for disposal or to one of the JBRs, if recovery is desired. Units 1&2 are equipped with two of these sumps and Units 3&4 are provided with one. Because the sump handles water that can include an appreciable amount of solids (>10%), the pipelines are equipped for automatic flushing. This installed automatic flushing dilutes the sump contents prior to pump start. This results in the pump casing and discharge piping being flushed. The sump pump discharge piping is equipped with a control valve from the make-up water system for this purpose. The sump pumps are designed for corrosive duty with all wetted parts below the floor plate being rubber covered and/or lined. These are double suction pumps with semi-open impellers capable of being run dry. The flow rate is cut by about 60% once the sump level drops below the impeller. The FGD area sumps are controlled based on the respective sump s liquid level. Each sump is equipped with a continuous level measuring instrument providing local and remote indication. Two sump pumps are provided for each sump. One is operating and one is stand-by. The selected sump pump starts upon a sump high level and stops upon a sump level of 1.5. The stand-by pump starts automatically on the trip of the primary pump. The operator is given a high-high level alarm. The figure below illustrates these alarms and interlocks. The sump pump discharge destination is determined by manual valves installed in the pipeline. When in auto mode the DCS stops and starts sump pumps automatically without operator initiation Starts are alternated between the two pumps in order to equalize run time. When one pump stops, a toggle switches to start the other pump next time. The operator also has the ability to toggle the pump selected for the next start. The sump mixers operate continuously regardless of sump level. Their operation is started and stopped by operator action via the DCS. Date Printed 2/22/2011 Page 7 of 70

8 Introduction FGD Area Sump When pump operation is stopped, the pump discharge valve is closed, the backflush valve remains open filling the sump and diluting the contents, performing a post flush. 11 ft 10 ft High-High High Alarms Starts Pump 1.5 ft Low Stops Pump FGD Area Sump Interlocks and Alarms Date Printed 2/22/2011 Page 8 of 70

9 Introduction Quantity 1 Sump Dimensions, W x L x H 10 x 10 x 12 Sump Pumps Vertical Cantilever Quantity 2 per sump Flow Rate 250 gpm Head 86 ft of H 2 O Brake Horsepower 23 hp Manufacturer & Model Weir Slurry (Galigher), 3SR4-5100x72 Casing 520 coated steel Shaft 520 coated steel Impeller 520 coated steel Coating rubber Shaft Seal NA Drive Poly chain Pump Speed 1548 rpm Motor Speed 1800 rpm max, 1750 rpm operating Pump Motor hp 30 hp Mixer top mounted Manufacturer & Model Lightnin, 73Q5 Shaft Dimensions (D x L) 2.5 x 126 FMB Shaft Materials Carbon steel w/ 3/16 natural rubber coating Impeller Type 1 impeller, 3 blades per impeller Impeller Diameter 53 Impeller Speed 55.8 rpm, fpm Impeller Materials Carbon steel w/ 3/16 natural rubber coating Gearbox Lightnin, 73 Mixer Motor hp 5 Impeller Elevation 18 above sump floor Minimum Sump Mixing Level 36 above sump floor Adequate sump level to start mixer 62 above sump floor Sump Inflows Area drains, duct drains, chimney flue drains Sump Outflows FGD area sump pump flow Date Printed 2/22/2011 Page 9 of 70

10 Introduction Dewatering Area Sump The dewatering area sump receives the hydrocyclone overflow stream as well as streams collected by area trenches as result of flushing and draining of slurry pipelines, area cleaning, and spills. The sump size is identical to the ash pump transfer sump. The sump meets the minimum size requirements of HEI standards. The sump is installed below grade and equipped with 2 pumps, one mixer and level indication instrumentation. The sump contents are either pumped to the ash pond transfer sump for disposal or to one of the return water tanks if recovery is desired. These pumps are sized to serve all four units. Because the sump handles water that can include an appreciable amount of solids (>10%), the pipelines are equipped for automatic flushing. This installed automatic flushing dilutes the sump contents prior to pump start. This results in the pump casing and discharge piping being flushed. The sump pump discharge piping is equipped with a control valve from the make-up water system for this purpose. The sump pumps are designed for corrosive duty with all wetted parts below the floor plate being rubber covered and/or lined. These are double suction pumps with semi-open impellers capable of being run dry. The flow rate is cut by about 60% once the sump level drops below the impeller. The dewatering area sump is controlled based on the sump s liquid level. The sump is equipped with a continuous level measuring instrument providing local and remote indication. Two sump pumps are provided for each sump - one is operating and one is stand-by. The selected sump pump starts upon a sump high level and stops upon a sump level of 1.5. The stand-by pump starts automatically on the trip of the primary pump. The operator is given a high-high level alarm. The figure below illustrates the alarms and interlocks associated with the sump level. The sump pump discharge destination is determined by manual valves installed in the pipeline. When in auto mode the DCS stops and starts sump pumps automatically without operator initiation. Starts are alternated between the two pumps in order to equalize run time. When one pump stops, a toggle switches to start the other pump next time. The operator also has the ability to toggle the pump selected for the next start. The sump mixers operate continuously regardless of sump level. Their operation is started and stopped by operator action via the DCS. Date Printed 2/22/2011 Page 10 of 70

11 Introduction Dewatering Area Sump When pump operation is stopped, the pump discharge valve is closed, the backflush valve remains open filling the sump and diluting the contents, performing a post flush. 11 ft High-High Alarms 10 ft High Starts Pump 1.5 ft Low Stops Pump Dewatering Area Sump Interlocks and Alarms Date Printed 2/22/2011 Page 11 of 70

12 Introduction Sump Dimensions, W x L x H 16 x 16 x 12 Sump Pumps Quantity 2 Flow Rate Head Brake Horsepower Vertical Cantilever 3150 gpm 95 ft of H 2 O 205 hp Pump Manufacturer & Model Weir Slurry, 12SRA-5100 x 96 Casing Shaft Impeller Coating Shaft Seal Drive Pump Speed Motor Speed Pump Motor hp Mixer Manufacturer & Model Shaft Dimensions (D x L) Shaft Materials Impeller Type 520 rubber covered steel 520 rubber coated steel Stainless Steel Alloy rubber NA Impeller Diameter 53 Impeller Speed Impeller Materials Polychain 655 rpm 780 rpm 250 hp top mounted Lightnin, 73Q5 2.5 x 126 FMB Carbon steel w/ 3/16 natural rubber 1 impeller, 3 blades per impeller 55.8 rpm, fpm Stainless Steel Alloy Gearbox Lightnin, 73 Mixer Motor hp 5 Impeller Elevation Minimum Sump Mixing Level 18 above sump floor 36 above sump floor Adequate sump level to start mixer 62 above sump floor Sump Inflows Sump Outflows Hydrocyclone overflow, area drains Dewatering Area Sump pump flow to APT Sump or return water tank Date Printed 2/22/2011 Page 12 of 70

13 Introduction Ash Pond Transfer Sump The Ash Pond Transfer (APT) Sumps receive FGD associated streams for disposal to the ash pond. The Units 3&4 APT Sump receives a stream from the gypsum dewatering hydrocyclone overflow collected by the dewatering area sump. The APT Sumps are designed to collect the gypsum draw-off stream from two JBRs when a gypsum transfer tank is not available. Direct drains, hard-piped from the JBRs to the APT Sump can be utilized for expedient draining of JBRs to the ash pond. The basis for the sump size is a maximum of four pump starts in one hour based on the maximum flow from the dewatering area sump plus approximately 1000 gpm per JBR when draining. The sump is installed below grade and equipped with 2 pumps, one mixer, and level indication instrumentation. Units 1&2 are equipped with one of these sumps as are Units 3&4. Because the sump handles water that can include an appreciable amount of solids (>10%), the pipelines are equipped for automatic flushing. This installed automatic flushing dilutes the sump contents prior to pump start. This results in the pump casing and discharge piping being flushed. The sump pump discharge piping is equipped with a control valve from the make-up water system for this purpose. Additionally, The Unit 3/4 Ash Pond Transfer Sump discharge piping is equipped with a manually operated valve off of the make-up water system for the purpose of flushing the discharge piping. The sump pumps are designed for corrosive duty with all wetted parts below the floor plate being rubber covered and/or lined. These are double suction pumps with semi-open impellers capable of being run dry. The flow rate is cut by about 60% once the sump level drops below the impeller. The ash pond transfer (APT) sumps are controlled based on the respective sump s liquid level. Each sump is equipped with a continuous level measuring instrument providing local and remote indication. Two sump pumps are provided for each sump. One is operating and one is stand-by. The selected sump pump starts upon a sump high level and stops upon a sump level of 1.5. The stand-by pump starts automatically on the trip of the primary pump. The operator is given a high-high level alarm. The figure below illustrates these alarms and interlocks. When in auto mode the DCS stops and starts sump pumps automatically without operator initiation. Starts are alternated between the two pumps in order to equalize run time. When one pump stops, a toggle switches to start the other pump next time. The operator also has the ability to toggle the pump selected for the next start. Date Printed 2/22/2011 Page 13 of 70

14 Introduction Ash Pond Transfer Sump The sump mixers operate continuously regardless of sump level. Their operation is started and stopped by operator action via the DCS. When pump operation is stopped, the pump discharge valve is closed, the backflush valve remains open filling the sump and diluting the contents, performing a post flush. 11 ft 10 ft High-High High Alarms Starts Pump 1.5 ft Low Stops Pump Ash Pond Transfer Sump Level Alarms & Interlocks Date Printed 2/22/2011 Page 14 of 70

15 Introduction Quantity 1 Sump Dimensions, W x L x H 16 x 16 x 12 Sump Pumps Quantity Flow Rate Head Brake Horsepower Vertical Cantilever 2 per sump 3500 gpm 82 ft of H 2 O hp Pump Manufacturer & Model Weir Slurry (Galigher), 125RA-5100 x 96 Casing Shaft Impeller Coating Shaft Seal Drive Pump Speed Motor Speed Pump Motor hp Mixer Manufacturer & Model Shaft Dimensions (D x L) Shaft Materials Impeller Type 520 rubber coated steel 520 rubber coated steel Stainless Steel Alloy steel rubber NA Impeller Diameter 53 Impeller Speed Impeller Materials Polychain 649 rpm 1780 rpm operating 250 hp top mounted Lightnin, 73Q5 2.5 x 178 FMB Carbon steel w/ 3/16 natural rubber 1 impeller, 3 blades per impeller 55.8 rpm, fpm Stainless Steel Alloy Gearbox Lightnin, 73 Mixer Motor hp 5 Impeller Elevation Minimum Sump Mixing Level Adequate sump level to start mixer Sump Inflows Sump Outflows 18 above sump floor 36 above sump floor 62 above sump floor Dewatering area sump, FGD area sump, limestone area sump, gypsum draw-off, JBR direct drains APT Sump pump flow to ash pond Date Printed 2/22/2011 Page 15 of 70

16 System Components The Scrubber Sump System consists of Ash Pond Transfer Sump Mixer, Ash Pond Transfer Sump Pumps, Ash Pond Transfer Sump Pump Discharge Control Valves, FGD Area Sump Mixer, FGD Area Sump Pumps, FGD Area Sump Pump Discharge Control Valves, Limestone Area Sump Mixer, Limestone Area Sump Pumps, Limestone Area Sump Pump Discharge Control Valves, Dewatering Area Sump Mixer, Dewatering Area Sump Pumps, and Dewatering Area Sump Pump Discharge Control Valves. Date Printed 2/22/2011 Page 16 of 70

17 Sump System Mixers Number Sheet Rev Title P&IDs D1M D3M S A S A S A S S D S F unc tion FGD Project P&ID Limestone Area and Dewatering Area Sumps FGD Project P&ID FGD Area and Ash Pond Transfer Sumps Vendor O&M Manuals Scrubber - FGD - Agitator - 10' X 10 Sumps Ball Mill/JBR - Mixer Installation Operation & Maintenance Manual Scrubber - FGD - Agitator - 16' X 16' Sumps Dewater/Ashpond - Mixer Installation, Operation & Maintenance Manual Scrubber - FGD - Agitator - JBR Absorber Agitators - Mixer Installation, Operation & Maintenance Manual Scrubber - FGD - Mixer Installation & Storage Instruction Manual Scrubber Ball Mill / JBR Sump Agitator General Arrangement Scrubber - FGD - Agitator - Assembly Drawing - Axial Flow Impeller The Sump System Mixers (WW-MX-5480, WW-MX-5495, WW-MX-5380, and WW-MX- 5390) serve to prevent solids suspended in solution from settling into the bottom of the sumps, thereby maintaining a homogenous mixture from which the Sump Pumps for each respective system can draw a suction. Des cription Mixer The Sump System Mixers are Model Number 73Q5 manufactured by Lightnin Mixers and Aerators. The Sump System Mixers are identical in design for each sump with the exception of Mixer shaft length since each sump is of varying size. The mechanical components of the mixer consist of a fluid coupling Model Number HF10/20 manufactured by Faulk Industries, a double reduction gear Model Number 73 manufactured by Lightnin Mixers and Aerators, and a mixer shaft and impeller manufactured by Lightnin Mixers and Aerators. The mixer shaft and impeller are coated with a 3/16 layer of natural rubber to minimize corrosion and wear. Additionally, the leading edge of the impeller is coated with an additional 3/16 of natural rubber for added protection. Date Printed 2/22/2011 Page 17 of 70

18 Sump System Mixers Mixer Manufacturer & Model Shaft Dimensions (D x L) Shaft Dimensions (D x L) Shaft Dimensions (D x L) Shaft Dimensions (D x L) Shaft Materials Impeller Type Impeller Diameter 53 Impeller Speed Impeller Materials top mounted Lightnin, 73Q5 2.5 x 178 FMB (Ash Pond Sump) 2.5 x 126 FMB (Dewatering Sump) 2.5 x 126 FMB (FGD Sump) 2.5 x 126 FMB (Limestone Sump) Carbon steel w/ 3/16 natural rubber 1 impeller, 3 blades per impeller 55.8 rpm, fpm Gearbox Lightnin, 73 Mixer Motor hp 5 Impeller Elevation Minimum Sump Mixing Level Adequate sump level to start mixer Carbon steel w/ 3/16 natural rubber coating 18 above sump floor 36 above sump floor 62 above sump floor Mixer Drive Assembly Date Printed 2/22/2011 Page 18 of 70

19 Sump System Mixers Date Printed 2/22/2011 Page 19 of 70

20 Sump System Mixers Impeller The mixer Impeller is manufactured by Lightnin, model 73Q5. Each impeller is a 53 carbon steel with three blades, rated at 55.8 rpm, fpm. Typical Impeller Side and Bottom View Motor The mixer motor is a horizontally mounted, squirrel cage induction motor manufactured by Siemens. The motor is a 3-Phase Induction motor producing 5 hp at 460V AC. The motor is of frame size 184T with a TEFC enclosure and Model Number 1LA01844ES21. Typical S ump Mixer Motor Date Printed 2/22/2011 Page 20 of 70

21 Ash Pond Transfer Sump Pumps (WW-PU-5480A & B) Number Sheet Rev Title P&IDs D3M S S A S S A F unc tion FGD Project P&ID FGD Area and Ash Pond Transfer Sumps Vendor O&M Manuals Scrubber - Flue Gas Desulfurization - Ash Pond Transfer Sump Pump - Installation, Operation & Maintenance Manual Scrubber - Flue Gas Desulfurization - Connection Diagram - Ash Pond Transfer Sump Pumps Scrubber - FGD - Ash Pond Transfer Sump Pump & Dewatering Area Sump Pump - Acid Proof Components Drawing Scrubber - Flue Gas Desulfurization - Nameplate - Ash Pond Transfer Sump Pumps The Ash Pond Transfer (APT) Sumps receive FGD associated streams for disposal to the station s ash pond. The Units 3&4 APT Sump receives a stream from the gypsum dewatering hydrocyclone overflow collected by the dewatering area sump. The APT Sumps are designed to collect the gypsum draw-off stream from two JBRs when a gypsum transfer tank is not available. Direct drains, hard-piped from the JBRs to the APT Sump can be utilized for expedient draining of JBRs to the ash pond. Description Pump The Ash Pond Transfer Sump Pump is manufactured by by Weir and is Model Number 12SRA-5100 x 84. Design flow for the pumps is 3500 gpm at an operating head of 92 ft. with impeller speed at 648 rpm. These design parameters result in a 50.8% efficiency when an input of hp is applied. The sump pumps are designed for corrosive duty with all wetted parts below the floor plate being rubber covered and/or lined. These are single suction pumps with semi-open impellers are capable of being run dry. The flow rate is cut by about 60% once the sump level drops below the impeller. Ash Pond Transfer Sump Pump Date Printed 2/22/2011 Page 21 of 70

22 Ash Pond Transfer Sump Pumps (WW-PU-5480A & B) Motor Ash Pond Transfer Sump Pump The Ash Pond Transfer Sump Pump motor is a vertically mounted, squirrel cage induction motor manufactured by TECO-Westinghouse. The motor is a 3-Phase Induction motor producing 250 hp at 480V AC. The motor is frame size 449T with a TEFC enclosure. Ash Pond Transfer Sump Pump Motor Date Printed 2/22/2011 Page 22 of 70

23 Ash Pond Transfer Sump Discharge Valves (WW-XV-5481A & B) Number Sheet Rev Title P&IDs D3M S S F unc tion FGD Project P&ID FGD Area and Ash Pond Transfer Sumps Vendor O&M Manuals FGD - Scrubber - KGA Slurry Valve - Installation, Maintenance & Operating Instructions FGD - Scrubber - Flow Control Valves - General Arrangement KGA16-BG3-B6B10D7H07L6N3 The Ash Pond Transfer Sump Pumps 16" Discharge Control Valves serve to isolate the discharge side of the Ash Pond Transfer Sump Pumps when required. Description The Ash Pond Transfer Sump discharge valves are 16 Knife Gate Valves manufactured by Clarkson, model KGA16. The body of the valve a cast ductile iron with a SAF 2507 stainless steel knife gate with fully lined gum rubber sleeves. The valves have an oversized air cylinder actuator which is double acting and fails in the last position. The actuator is controlled by ASCO 4-way dual solenoid valve which requires air to open and air to close with manual override. The KGA is a packing less knife gate valve. All the sealing is accomplished by the elastomeric sleeves in the valve housing. The sleeves also form the wear section for the valve. Actuation of the valve slides a stainless steel gate between the sleeves to shut off the flow. Some seepage may occur during opening and closing cycles. The gate is removable for inspection or replacement while the valve is in service. It is normal for the KGA valves to discharge media during opening and closing cycles. This purges solids from between the sleeves that would prevent a tight seal when the valve is fully open or closed. With the optional splashguard mounted on, the valve, the valve s internal chamber is more than adequate to receive the discharge which can then be drained or, flushed into a sump or launder through an attached pipe or hose. KGA valve maintenance may require occasional gate lubrication depending on the application. A silicone-based lubricant is recommended. Lubrication fittings are located on the square center flange of the valve housing. The gate may also be lubricated by spraying directly with a silicone lubricant to prevent scale build-up. Sleeve wear can be minimized if the valve gate is scraped or wiped clean occasionally. Date Printed 2/22/2011 Page 23 of 70

24 Ash Pond Transfer Sump Discharge Valves (WW-XV-5481A & B) The application of lubricant should include liberally coating the entire seal end of the sleeve. A thin film should also be applied to the outer diameter of the sleeve. Apply a thin film of lubricant to both faces of the knife gate from the knife edge upward to the center of the gate. Periodic re-lubrication using the fittings on the housing should minimize any operational problems in normal use. As a minimum, the Clarkson KGA valves should be lubricated every 100 strokes for 3-10 sizes and every 50 strokes for sizes. An individual application may require more or less frequent lubrication depending on the process and chemistry. If a valve cycles very infrequently, less than once per month, lubrication prior to each stroke is recommended. For dry material handling service, liquid or grease type lubricants should not be used. A dry film spray lubricant may be used. Examples are: graphite, Teflon or silicone sprays. Typical Clarkson Knife Gate Valve Date Printed 2/22/2011 Page 24 of 70

25 Ash Pond Transfer Sump Pump Back Flush Valves (WW-XV-5482A & B) Number Sheet Rev Title P&IDs D3M F unc tion FGD Project P&ID FGD Area and Ash Pond Transfer Sumps Vendor O&M Manuals FGD - Scrubber Fabri-Valve - Installation, Maintenance & Operating Instructions FGD - Scrubber - Flow Control Valves - General Arrangement Fabri-Valve, model XS150 The Ash Pond Transfer Sump Pumps 4" Backflush Control Valves serve to control the flow of backflush water from the Make-Up Water System to the discharge piping of the respective Ash Pond Transfer Sump Pump. Description The Ash Pond Transfer Sump Backflush Control valves are 4 Knife Gate Valves manufactured by Fabri-Valve, model XS150. The body of the valve carbon steel with a SAF 2507 stainless steel knife gate with fully lined red urethane sleeves. The valves have an air cylinder actuator to open and a spring close and fails in the closed position. The actuator is controlled by ASCO EFHT8316G64MO solenoid valve which requires air to open. The Fabri-Valve utilizes a seal that wraps around the entire gate eliminating leakage paths. The chest seal completely encloses gate with a injectable packing; therefore, contamination of the process fluid from loose packing is eliminated. The body protects the perimeter seal from the rigors of the direct process flow. A reliable body joint eliminates the possibility of body joint leakage caused by pipe stresses. The design of the gate guides guarantee that the gate is properly positioned and supported during operation. The gate guides do not reduce the flow area. Dual scraper blades clean gate during operation and protect the seals from abrasives. A taper to the body s internal diameter is to eliminate the possibility of material collecting at the bottom of the port and preventing proper closure. This taper ensures automatic clean-out and flushing. Minimized chest area and close tolerances prevents minimizes packing. Date Printed 2/22/2011 Page 25 of 70

26 Ash Pond Transfer Sump Discharge Valves (WW-XV-5481A & B) Typical Fabri-Valve Gate Valve model XS150 Date Printed 2/22/2011 Page 26 of 70

27 FGD Area Sump Pumps (WW-PU-5495A & B) Number Sheet Rev Title P&IDs D3M S B S A S S F unc tion FGD Project P&ID FGD Area and Ash Pond Transfer Sumps Vendor O&M Manuals Scrubber - Flue Gas Desulfurization - Component Drawing - FGD Area Sump Pump Scrubber - Flue Gas Desulfurization - Motor Outline - FGD Area Sump Pump Scrubber - Flue Gas Desulfurization - Performance Data - FGD Area Sump Pump Scrubber - Flue Gas Desulfurization - Performance Data - FGD Area Sump Pump Motor The Unit 3/4 FGD area sumps receive a water or slurry stream collected by area trenches as result of flushing and draining of slurry pipelines, area cleaning, and spills. They also receive the drains from the JBR outlet ducts and chimney flues. The Unit 3/4 FGD area sumps can be used to transfer gypsum slurry from one JBR to another for gypsum seeding. The sumps are installed below grade and equipped with 2 pumps, one mixer and level indication instrumentation. The sump contents are pumped to the respective ash pond transfer sump for disposal or to one of the JBRs if recovery is desired Description Pump The Unit 3/4 FGD Area Sump Pumps are manufactured by Galigher and are Model Number 3SR4-5100x72 Vertical Pump. Design flow for the pumps is 250 gpm at an operating head of 86 ft. with impeller speed at 1548 rpm. These design parameters result in a 31.7% efficiency when an input of 22.9 hp is applied. The sump pumps are designed for corrosive duty with all wetted parts below the floor plate being rubber covered and/or lined. These are double suction pumps with semi-open impellers capable of being run dry. The flow rate is cut by about 60% once the sump level drops below the impeller. Date Printed 2/22/2011 Page 27 of 70

28 FGD Area Sump Pumps (WW-PU-5495A & B) FGD Area Sump Pumps Unit 3/4 FGD Area Sump Pump Date Printed 2/22/2011 Page 28 of 70

29 FGD Area Sump Pumps (WW-PU-5495A & B) Motor The Unit 3/4 FGD Area Sump Pump motor is a vertically mounted, squirrel cage induction motor manufactured by TECO-Westinghouse. The motor is a 3-Phase Induction motor producing 30 hp at 460V AC. The motor is frame size 286T with a TEFC enclosure. Typical TECO-Westinghouse Motor Date Printed 2/22/2011 Page 29 of 70

30 FGD Area Sump Discharge Valves (WW-XV-5496A & B) Number Sheet Rev Title P&IDs D3M S S F unc tion FGD Project P&ID FGD Area and Ash Pond Transfer Sumps Vendor O&M Manuals FGD - Scrubber - KGA Slurry Valve - Installation, Maintenance & Operating Instructions FGD - Scrubber - Flow Control Valves - General Arrangement KGA4-MH-B6B10D7H07L6N3R1 The FGD Area Sump Pumps 4 Discharge Control Valves serve to isolate the discharge side of the FGD Area Sump Pumps when required. Description The Unit 3/4 FGD Area Sump discharge Valves are 4 Knife Gate valves manufactured by Clarkson, model KGA4. The body of the valve a cast ductile iron with a SAF 2507 stainless steel knife gate with fully lined gum rubber sleeves. The valves have an oversized air cylinder actuator which is double acting and fails in the last position. The actuator is controlled by ASCO 4-way dual solenoid valve which requires air to open and air to close with manual override. The KGA is a packing less knife gate valve. All the sealing is accomplished by the elastomeric sleeves in the valve housing. The sleeves also form the wear section for the valve. Actuation of the valve slides a stainless steel gate between the sleeves to shut off the flow. Some seepage may occur during opening and closing cycles. The gate is removable for inspection or replacement while the valve is in service. It is normal for the KGA valves to discharge media during opening and closing cycles. This purges solids from between the sleeves that would prevent a tight seal when the valve is fully open or closed. With the optional splashguard mounted on, the valve, the valve s internal chamber is more than adequate to receive the discharge which can then be drained or, flushed into a sump or launder through an attached pipe or hose. KGA valve maintenance may require occasional gate lubrication depending on the application. A silicone-based lubricant is recommended. Lubrication fittings are located on the square center flange of the valve housing. The gate may also be lubricated by spraying directly with a silicone lubricant to prevent scale build-up. Sleeve wear can be minimized if the valve gate is scraped or wiped clean occasionally. Date Printed 2/22/2011 Page 30 of 70

31 FGD Area Sump Discharge Valves (WW-XV-5496A & B) The application of lubricant should include liberally coating the entire seal end of the sleeve. A thin film should also be applied to the outer diameter of the sleeve. Apply a thin film of lubricant to both faces of the knife gate from the knife edge upward to the center of the gate. Periodic re-lubrication using the fittings on the housing should minimize any operational problems in normal use. As a minimum, the Clarkson KGA valves should be lubricated every 100 strokes for 3-10 sizes and every 50 strokes for sizes. An individual application may require more or less frequent lubrication depending on the process and chemistry. If a valve cycles very infrequently, less than once per month, lubrication prior to each stroke is recommended. For dry material handling service, liquid or grease type lubricants should not be used. A dry film spray lubricant may be used. Examples are: graphite, Teflon or silicone sprays. Typical Clarkson Knife Gate Valve Date Printed 2/22/2011 Page 31 of 70

32 FGD Area Sump Pump Back Flush Valves (WW-XV-5494A & B) Number Sheet Rev Title P&IDs D3M F unc tion FGD Project P&ID FGD Area and Ash Pond Transfer Sumps Vendor O&M Manuals FGD - Scrubber Fabri-Valve - Installation, Maintenance & Operating Instructions FGD - Scrubber - Flow Control Valves - General Arrangement Fabri-Valve, model XS150 The FGD Area Sump Pumps 4" Backflush Control Valves serve to control the flow of backflush water from the Make-Up Water System to the discharge piping of the respective FGD Area Sump Pump. Description The FGD Area Sump Backflush Control valves are 4 Knife Gate Valves manufactured by Fabri-Valve, model XS150. The body of the valve carbon steel with a SAF 2507 stainless steel knife gate with fully lined red urethane sleeves. The valves have an air cylinder actuator to open and a spring close and fails in the closed position. The actuator is controlled by ASCO EFHT8316G64MO solenoid valve which requires air to open. The Fabri-Valve utilizes a seal that wraps around the entire gate eliminating leakage paths. The chest seal completely encloses gate with a injectable packing; therefore, contamination of the process fluid from loose packing is eliminated. The body protects the perimeter seal from the rigors of the direct process flow. A reliable body joint eliminates the possibility of body joint leakage caused by pipe stresses. The design of the gate guides guarantee that the gate is properly positioned and supported during operation. The gate guides do not reduce the flow area. Dual scraper blades clean gate during operation and protect the seals from abrasives. A taper to the body s internal diameter is to eliminate the possibility of material collecting at the bottom of the port and preventing proper closure. This taper ensures automatic clean-out and flushing. Minimized chest area and close tolerances prevents minimizes packing. Date Printed 2/22/2011 Page 32 of 70

33 FGD Area Sump Pump Back Flush Valves (WW-XV-5494A & B) Typical Fabri-Valve Gate Valve model XS150 Date Printed 2/22/2011 Page 33 of 70

34 Limestone Area Sump Pumps (WW-PU-5380A & B) Number Sheet Rev Title P&IDs D1M S A S A S A S F unc tion FGD Project P&ID Limestone Area and Dewatering Area Sumps Vendor O&M Manuals Scrubber - Flue Gas Desulfurization - Arrangement Drawing - Foundation Loads - Mill Area Sump Pumps Scrubber - Flue Gas Desulfurization - Curve - Mill Area Sump Pump Scrubber - Flue Gas Desulfurization - Motor Outline - Mill Area Sump Pump Motor Scrubber - Flue Gas Desulfurization - Installation, Operation & Maintenance Manual - Mill Area Pumps The Unit 1-4 Limestone Area Sump Pump A & B serve to extract waste water volume from the Unit 1-4 Limestone Sump and either send that waste water to the Ash Pond Transfer Sump or recycle the waste water back into the Limestone Slurry Transfer process. The normal alignment is to send the waste water volume to the Ash Pond Transfer Sump. Description The Unit 1-4 Limestone Area Sump Pumps are manufactured by Galigher and are Model Number 3SR4-5100x72 Vertical Pump. Design flow for the pumps is 250 gpm at an operating head of 86 ft. with impeller speed at 1548 rpm. These design parameters result in a 31.7% efficiency when an input of 22.9 hp is applied. The sump pumps are designed for corrosive duty with all wetted parts below the floor plate being rubber covered and/or lined. These are double suction pumps with semi-open impellers capable of being run dry. Limestone Area Sump Pump Date Printed 2/22/2011 Page 34 of 70

35 Limestone Area Sump Pumps (WW-PU-5380A & B) Limestone Area Sump Pumps Motor The Unit 1-4 Limestone Area Sump Pump motor is a vertically mounted, squirrel cage induction motor manufactured by TECO-Westinghouse. The motor is a 3-Phase Induction motor producing 40 hp at 460V AC. The motor is frame size 324T with a TEFC enclosure. Typical TECO-Westinghouse Motor Date Printed 2/22/2011 Page 35 of 70

36 Limestone Area Sump Discharge Valves (WW-PU-5381A & B) Number Sheet Rev Title P&IDs D1M S S F unc tion FGD Project P&ID Limestone Area and Dewatering Area Sumps Vendor O&M Manuals FGD - Scrubber - KGA Slurry Valve - Installation, Maintenance & Operating Instructions FGD - Scrubber - Flow Control Valves - General Arrangement KGA4-MH-B6B10D7H07L6N3R1 The Limestone Area Sump Pumps 4" Discharge Control Valves serve to isolate the discharge side of the Limestone Area Sump Pumps when required. Description The Unit 3/4 FGD Area Sump discharge valves are 4 Knife Gate Valves are manufactured by Clarkson, model KGA4. The body of the valve a cast ductile iron with a SAF 2507 stainless steel knife gate with fully lined gum rubber sleeves. The valves have an oversized air cylinder actuator which is double acting and fails in the last position. The actuator is controlled by ASCO 4-way dual solenoid valve which requires air to open and air to close with manual override. The KGA is a packing less knife gate valve. All the sealing is accomplished by the elastomeric sleeves in the valve housing. The sleeves also form the wear section for the valve. Actuation of the valve slides a stainless steel gate between the sleeves to shut off the flow. Some seepage may occur during opening and closing cycles. The gate is removable for inspection or replacement while the valve is in service. It is normal for the KGA valves to discharge media during opening and closing cycles. This purges solids from between the sleeves that would prevent a tight seal when the valve is fully open or closed. With the optional splashguard mounted on, the valve, the valve s internal chamber is more than adequate to receive the discharge which can then be drained or, flushed into a sump or launder through an attached pipe or hose. KGA valve maintenance may require occasional gate lubrication depending on the application. A silicone-based lubricant is recommended. Lubrication fittings are located on the square center flange of the valve housing. The gate may also be lubricated by spraying directly with a silicone lubricant to prevent scale build-up. Sleeve wear can be minimized if the valve gate is scraped or wiped clean occasionally. Date Printed 2/22/2011 Page 36 of 70

37 Limestone Area Sump Discharge Valves (WW-PU-5381A & B) The application of lubricant should include liberally coating the entire seal end of the sleeve. A thin film should also be applied to the outer diameter of the sleeve. Apply a thin film of lubricant to both faces of the knife gate from the knife edge upward to the center of the gate. Periodic re-lubrication using the fittings on the housing should minimize any operational problems in normal use. As a minimum, the Clarkson KGA valves should be lubricated every 100 strokes for 3-10 sizes and every 50 strokes for sizes. An individual application may require more or less frequent lubrication depending on the process and chemistry. If a valve cycles very infrequently, less than once per month, lubrication prior to each stroke is recommended. For dry material handling service, liquid or grease type lubricants should not be used. A dry film spray lubricant may be used. Examples are: graphite, Teflon or silicone sprays. Typical Clarkson Knife Gate Valve Date Printed 2/22/2011 Page 37 of 70

38 Limestone Area Sump Pump Back Flush Valves (WW-XV-5382A & B) Number Sheet Rev Title P&IDs D3M S S F unc tion FGD Project P&ID Limestone Area and Dewatering Area Sumps Vendor O&M Manuals FGD - Scrubber - KGA Slurry Valve - Installation, Maintenance & Operating Instructions FGD - Scrubber - Flow Control Valves - General Arrangement KGA16-BG3-B6B10D7H07L6N3 The Limestone Area Sump Pumps 4" Backflush Control Valves serve to control the flow of backflush water from the Make-Up Water System to the discharge piping of the respective Limestone Area Sump Pump. Description The Limestone Area Sump Backflush Control valves are 4 Knife Gate Valves manufactured by Clarkson. The body of the valve a cast ductile iron with a SAF 2507 stainless steel knife gate with fully lined gum rubber sleeves. The valves have an oversized air cylinder actuator which is double acting and fails in the last position. The actuator is controlled by ASCO 4- way dual solenoid valve which requires air to open and air to close with manual override. The KGA is a packing less knife gate valve. All the sealing is accomplished by the elastomeric sleeves in the valve housing. The sleeves also form the wear section for the valve. Actuation of the valve slides a stainless steel gate between the sleeves to shut off the flow. Some seepage may occur during opening and closing cycles. The gate is removable for inspection or replacement while the valve is in service. It is normal for the KGA valves to discharge media during opening and closing cycles. This purges solids from between the sleeves that would prevent a tight seal when the valve is fully open or closed. With the optional splashguard mounted on, the valve, the valve s internal chamber is more than adequate to receive the discharge which can then be drained or, flushed into a sump or launder through an attached pipe or hose. KGA valve maintenance may require occasional gate lubrication depending on the application. A silicone-based lubricant is recommended. Lubrication fittings are located on the square center flange of the valve housing. The gate may also be lubricated by spraying directly with a silicone lubricant to prevent scale build-up. Sleeve wear can be minimized if the valve gate is scraped or wiped clean occasionally. Date Printed 2/22/2011 Page 38 of 70

39 Limestone Area Sump Pump Back Flush Valves (WW-XV-5382A & B) The application of lubricant should include liberally coating the entire seal end of the sleeve. A thin film should also be applied to the outer diameter of the sleeve. Apply a thin film of lubricant to both faces of the knife gate from the knife edge upward to the center of the gate. Periodic re-lubrication using the fittings on the housing should minimize any operational problems in normal use. As a minimum, the Clarkson KGA valves should be lubricated every 100 strokes for 3-10 sizes and every 50 strokes for sizes. An individual application may require more or less frequent lubrication depending on the process and chemistry. If a valve cycles very infrequently, less than once per month, lubrication prior to each stroke is recommended. For dry material handling service, liquid or grease type lubricants should not be used. A dry film spray lubricant may be used. Examples are: graphite, Teflon or silicone sprays. Typical Clarkson Knife Gate Valve Date Printed 2/22/2011 Page 39 of 70

40 Dewatering Sump Pumps (WW-PU-5390A & B) Number Sheet Rev Title P&IDs D1M S S S F unc tion FGD Project P&ID Limestone Area and Dewatering Area Sumps Vendor O&M Manuals Scrubber - Flue Gas Desulfurization - Dewatering Area Sump Pump - Installation, Operation & Maintenance Manual Scrubber - Flue Gas Desulfurization - Dewatering Area Sump Pump Acid Proof Components Drawing Scrubber - Flue Gas Desulfurization - Curves - Nameplate - Dewatering Area Sump Pumps The Dewatering area sump receives the hydrocyclone overflow stream as well as streams collected by area trenches as result of flushing and draining of slurry pipelines, area cleaning, and spills. The sump contents are either pumped to the ash pond transfer sump for disposal or to one of the return water tanks if recovery is desired. Description The Dewatering Sump Pump is manufactured by Weir and is Model Number 12SRA-5100 x 84. Design flow for the pumps is 3500 gpm at an operating head of 92 ft. with impeller speed at 648 rpm. These design parameters result in a 50.8% efficiency when an input of hp is applied. The sump pumps are designed for corrosive duty with all wetted parts below the floor plate being rubber covered and/or lined. These are single suction pumps with semi-open impellers capable of being run dry Dewatering Sump Pump Date Printed 2/22/2011 Page 40 of 70

41 Dewatering Sump Pumps (WW-PU-5390A & B) Limestone Area Sump Pumps Motor The Dewatering Sump Pump motor is a vertically mounted, squirrel cage induction motor manufactured by TECO-Westinghouse. The motor is a 3-Phase Induction motor producing 250 hp at 460V AC. The motor is frame size 5007 with a TEFC enclosure. Typical TECO-Westinghouse Motor Date Printed 2/22/2011 Page 41 of 70

42 Dewatering Sump Discharge Valves (WW-XV-5391A & B) Number Sheet Rev Title P&IDs D1M S S F unc tion FGD Project P&ID Limestone Area and Dewatering Area Sumps Vendor O&M Manuals FGD - Scrubber - KGA Slurry Valve - Installation, Maintenance & Operating Instructions FGD - Scrubber - Flow Control Valves - General Arrangement KGA16-BG3-B6B10D7H07L6N3 The Dewatering Sump Pumps 16" Discharge Control Valves serve to isolate the discharge side of the Dewatering Sump Pumps when required. Description The Dewatering Sump discharge valves are 16 Knife Gate valves manufactured by Clarkson, model KGA16. The body of the valve a cast ductile iron with a SAF 2507 stainless steel knife gate with fully lined gum rubber sleeves. The valves have an oversized air cylinder actuator which is double acting and fails in the last position. The actuator is controlled by ASCO 4-way dual solenoid valve which requires air to open and air to close with manual override. Below is an illustrative example of the Clarkson Knife Valve. The KGA is a packing less knife gate valve. All the sealing is accomplished by the elastomeric sleeves in the valve housing. The sleeves also form the wear section for the valve. Actuation of the valve slides a stainless steel gate between the sleeves to shut off the flow. Some seepage may occur during opening and closing cycles. The gate is removable for inspection or replacement while the valve is in service. It is normal for the KGA valves to discharge media during opening and closing cycles. This purges solids from between the sleeves that would prevent a tight seal when the valve is fully open or closed. With the optional splashguard mounted on, the valve, the valve s internal chamber is more than adequate to receive the discharge which can then be drained or, flushed into a sump or launder through an attached pipe or hose. KGA valve maintenance may require occasional gate lubrication depending on the application. A silicone-based lubricant is recommended. Lubrication fittings are located on the square center flange of the valve housing. The gate may also be lubricated by spraying directly with a silicone lubricant to prevent scale build-up. Sleeve wear can be minimized if the valve gate is scraped or wiped clean occasionally. Date Printed 2/22/2011 Page 42 of 70

43 Dewatering Sump Discharge Valves (WW-XV-5391A & B) The application of lubricant should include liberally coating the entire seal end of the sleeve. A thin film should also be applied to the outer diameter of the sleeve. Apply a thin film of lubricant to both faces of the knife gate from the knife edge upward to the center of the gate. Periodic re-lubrication using the fittings on the housing should minimize any operational problems in normal use. As a minimum, the Clarkson KGA valves should be lubricated every 100 strokes for 3-10 sizes and every 50 strokes for sizes. An individual application may require more or less frequent lubrication depending on the process and chemistry. If a valve cycles very infrequently, less than once per month, lubrication prior to each stroke is recommended. For dry material handling service, liquid or grease type lubricants should not be used. A dry film spray lubricant may be used. Examples are: graphite, Teflon or silicone sprays. Typical Clarkson Knife Gate Valve Date Printed 2/22/2011 Page 43 of 70