Tanjung Jati B Training

OXIDATION AIR

OPERATIONS
OXIDATION AIR

Tanjung Jati B Training

PT Central Java Power

Tanjung Jati B Units 1 & 2
Flue Gas Desulfurization (FGD) System

Absorber Area

Dewatering
Area

Reagent Preparation
Area

Limestone Jetty
And Conveyor

Tanjung Jati B Training

FGD Operations
Oxidation Air
There are three (3) 100% capacity Oxidation Air
Blowers, one dedicated to each Absorber and one
as a spare or standby blower.
Oxidation Air functions to minimize the buildup of
solids within the Absorber Module by converting
Calcium Sulfite (CaSO3) to Calcium Sulfate (CaSO4).

Tanjung Jati B Training

FGD Operations
Oxidation Air
Gas to Sorbent (Limestone Slurry) Reaction

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

Calcium Carbonate
(In Limestone)

Flue
Gas

Calcium Sulfite

Forced Oxidation Reaction

CaSO3 1/2H2O + O2 + H2O CaSO4 2H2O

Calcium Sulfate

(There are many other intermediate reactions)

Tanjung Jati B Training

FGD Operations
Oxidation Air

Flue Gas

Reaction
Tank

Oxidation Air
Headers

Tanjung Jati B Training

FGD Operations
Oxidation Air

Dewatering
Building

PLANT
NORTH

Filter
Feed Tank

Oxidation
Air Blowers

Process
Water Tank

Mist Eliminator
Wash Water Tank

Tanjung Jati B Training

PLANT
NORTH

FGD Operations
Oxidation Air
1

1
2
3
4
5
6
7
8
9
10
11
12
13
14

UNIT-1 ABSORBER
UNIT-1 RECIRCULATION PUMPS
UNIT-2 ABSORBER
UNIT-2 RECIRCULATION PUMPS
FILTER FEED TANK
ME WASH WATER TANK
PROCESS WATER TANK
VACUUM FILTERS
OXIDATION AIR BLOWERS
LIMESTONE SLURRY TANK
LIMESTONE SILO A
LIMESTONE SILO B
LS BUCKET ELEVATOR & RAMP
STACK

PIPE
RACK A

5
6
14

PIPE
RACK B

BURIED SEAWATER TERMINAL POINT

11

YARD PIPING
10

13
12

Tanjung Jati B Training

FGD Operations
Oxidation Air

OXIDATION AIR BLOWERS

Tanjung Jati B Training

FGD Operations
Oxidation Air
For the proper operation of an Absorber Module,
one (1) Oxidation Air Blower is required.
Therefore, when two Absorber Modules are in service
two blowers will be running and the third blower
is used for standby if one blower were to trip.

Tanjung Jati B Training

FGD Operations
Oxidation Air

Each Oxidation Air Blower has its own dedicated

Lube Oil Unit which provides the necessary
lubrication for the Gear Increaser.
A single Programmable Logic Controller (PLC)
provides control and protection for all three
Blowers.
The DCS, which interfaces with the PLC, has the
capability to start and stop a given Blower.

Tanjung Jati B Training

FGD Operations
Oxidation Air
To Unit-1
Absorber

Lube Oil
Skid

To Unit-2
Absorber

Lube Oil
Skid

Lube Oil
Skid

PLC
OXIDATION AIR BLOWERS
Tanjung Jati B Training

FGD Operations
FGD Start-Up
Each Absorber has a dedicated Blower. Here is the
arrangement
Blower A:
Blower B:
Blower C:

Unit-1 Absorber only

Unit-1 or Unit-2 Absorber (or standby)
Unit-2 Absorber only

Tanjung Jati B Training

FGD Operations
Oxidation Air

We have already discussed the start-up of an

Oxidation Blower, so lets have a short review
regarding start-up then shutdown.
You will recall that an Oxidation Air Blower can
be started and stopped from the DCS or the
local PLC.

Tanjung Jati B Training

FGD Operations
Oxidation Air
You will recall there are two different start-up
scenarios
Reaction Tank Level below the OA Headers
Reaction Tank Level above the OA Headers

Tanjung Jati B Training

FGD Operations
Oxidation Air

OA HEADER ELEVATION
-PIPE SIZING

TEMPERATURE
ELEMENT

3.5 METERS

1/2

HUMIDIFICATION
(SERVICE WATER)

12

FROM OXIDATION
AIR BLOWER

6
ABSORBER
MODULE

FLUSH WATER
(PROCESS WATER)

= Manual Valve

Tanjung Jati B Training

FGD Operations
Oxidation Air
Reaction Tank Level is below OA Headers
OA Blower can & should be started prior to
increasing the Reaction Tank Level above the
OA Header elevation.
This assumes that the OA Blower was shutdown
after the Reaction Tank Level went below the
OA Header elevation (during an extended shutdown
of the Absorber).
Remember, an OA Blower cannot be started unless
the Absorber Vent or Absorber Outlet Damper is open.
Tanjung Jati B Training

FGD Operations
Oxidation Air
Reaction Tank Level is above OA Headers
The OA Headers and piping must be flushed prior
to starting a Blower.
The Air Isolation Valve must be closed prior to opening
the Flush Water Isolation Valve.
Both the Flush Valve & Air Isolation Valve are located
near the Absorber Module.
Remember, these valves are manually operated and
have no position limit switches.
Tanjung Jati B Training

FGD Operations
Oxidation Air
FLUSHING
OA PIPING & HEADER

TEMPERATURE
ELEMENT

MANUAL
FLUSH
VALVE

3.5 METERS

MANUAL
CONTROL VALVE

MANUAL
ISOL.VALVE

HUMIDIFICATION
(SERVICE WATER)
FROM OXIDATION
AIR BLOWER
FLUSH WATER
(PROCESS WATER)

ABSORBER
MODULE

Tanjung Jati B Training

FGD Operations
Oxidation Air

Prior to starting any Oxidation Air Blower be sure

to walk down and inspect the entire system.
Be sure there is cooling water available for the
Blower Bearings and Lube Oil Unit.

Tanjung Jati B Training

FGD Operations
Oxidation Air
ATM
INLET
INLET
SILENCER FILTER

BLOWOFF
SILENCER

CROSSOVER
TIE VALVE

TO ABSORBER-1

BLOWOFF
VALVE

DISCHARGE
VALVE

OUTLET
SILENCER

ATM

INLET
VALVE

CLOSED
CIRCUIT
COOLING
WATER

A
OXIDATION
AIR BLOWER

LUBE
OIL SKID

STARTING BLOWER A FOR UNIT-1 ABSORBER

Tanjung Jati B Training

FGD Operations
Oxidation Air
After an Oxidation Air Blower is started, water is
introduced to the downstream piping to humidify
the air to its saturation point.
Why do we introduce water to humidify the air
It eliminates the wet-dry interface between the
Gypsum Slurry and Air Header Piping, thus
minimizing the potential for deposits forming
within the Air Headers and at the Header Nozzles.

Tanjung Jati B Training

FGD Operations
Oxidation Air
HUMIDIFICATION
WATER

TEMPERATURE
ELEMENT

MANUAL
FLUSH
VALVE

3.5 METERS

MANUAL
CONTROL VALVE

MANUAL
ISOL.VALVE

HUMIDIFICATION
(SERVICE WATER)
FROM OXIDATION
AIR BLOWER
FLUSH WATER
(PROCESS WATER)

ABSORBER
MODULE

Tanjung Jati B Training

FGD Operations
Oxidation Air

Lets go through the basic steps for starting and

stopping an Oxidation Air Blower from the DCS and
local PLC Panel
Once the start command from the DCS is generated
the PLC will automatically start Lube Oil Unit, set the
Blower Dampers to their proper position and start the
Blower.

Tanjung Jati B Training

FGD Operations
Oxidation Air
When starting an OA Blower from the DCS, the PLC
will automatically perform the following

Start Lube Oil Unit

Opens Blower Inlet Valve to predetermined position
Opens Blowoff Valve to full open
Opens Discharge Valve to full open
Closes/Opens Crosstie Valve as required
Blower Starts
Blowoff Valve closes slowly
Inlet Valve to automatic control

Operator to open manual Humidification Valve to full open

position
Tanjung Jati B Training

FGD Operations
Oxidation Air
ATM
INLET
INLET
SILENCER FILTER

BLOWOFF
SILENCER

CROSSOVER
TIE VALVE

TO ABSORBER-1

BLOWOFF
VALVE

DISCHARGE
VALVE

OUTLET
SILENCER

ATM

INLET
VALVE

CLOSED
CIRCUIT
COOLING
WATER

A
OXIDATION
AIR BLOWER

LUBE
OIL SKID

STARTING BLOWER A FOR UNIT-1 ABSORBER

Tanjung Jati B Training

FGD Operations
Oxidation Air
Starting an OA Blower from the local PLC

Blower Selector Switch to ON Position

Select Blower B as Standby
Open Blower Inlet Valve to predetermined position
Open Discharge Valve to full open
Start Blower
Verify Blower Motor Amps and adjust Blower Inlet Valve
if required..

Operator to open manual Humidification Valve to full open

position

Tanjung Jati B Training

FGD Operations
Oxidation Air

PLC
BREAKER

OXIDATION AIR BLOWER PANEL

Tanjung Jati B Training

FGD Operations
Oxidation Air
INLET
VALVE

OPEN

BLOWER
A OR C

OPEN
CLOSED

MIDPOINT
CLOSED

BLOWOFF
VALVE

RUNNING

FAULT

SWITCH
ON OFF

PUSHBUTTONS
START

STOP

JOG SWITCHES
O I C

INLET
VALVE

I C

BLOWOFF
VALVE

Tanjung Jati B Training

FGD Operations
Oxidation Air
INLET
VALVE

OPEN

BLOWER B

OPEN

MIDPOINT

CLOSED

CLOSED

BLOWOFF
VALVE

RUNNING

FAULT

SELECTOR
SWITCH
OFF

PUSHBUTTONS
START

JOG SWITCHES

STOP

U2

U1
AUTO

INLET
VALVE

BLOWOFF
VALVE

Tanjung Jati B Training

FGD Operations
Oxidation Air

OXIDATION AIR PANEL

POWER
ON

INLET
VALVES
M A

GENERAL
FAULT

Tanjung Jati B Training

FGD Operations
Oxidation Air

The optimum position of the Blower Inlet Valve before

the Blower is started is based upon the Blower Motor
Amps during normal operation and this position will be
determined during Commissioning.
These positions should be recorded and used for future
reference.

Tanjung Jati B Training

FGD Operations
Oxidation Air
Stopping an OA Blower from the DCS
Once a stop command is generated, the local PLC
panel will automatically stop the Blower, stop the
Lube Oil Unit and close the Blower Inlet and Outlet
Valves.
The Operator will need to close the OA Isolation Valve
located near the Absorber Module & the Humidification
Water Valve.
It is good practice to keep cooling water flowing to
the Blower Bearings until temperatures sufficiently
low.
Tanjung Jati B Training

FGD Operations
Oxidation Air

OPERATING LEVEL
&
OA HEADER ELEVATION

TEMPERATURE
ELEMENT

MANUAL
FLUSH
VALVE

3.5 METERS

MANUAL
CONTROL VALVE

MANUAL
ISOL.VALVE

HUMIDIFICATION
(SERVICE WATER)
FROM OXIDATION
AIR BLOWER
FLUSH WATER
(PROCESS WATER)

ABSORBER
MODULE

Tanjung Jati B Training

FGD Operations
Oxidation Air
Stopping an OA Blower from the local PLC
Stop Blower
Close Inlet Damper
Close Outlet Damper
Keep cooling water circulating to the Blower Bearing
to cool the bearings sufficiently (20-30 minutes)
Operator to close the OA Isolation Valve located near the
Absorber Module and close the Humidification Water Valve

Tanjung Jati B Training

FGD Operations
Oxidation Air
If the Absorber Module is to be shutdown and
the slurry level of the Reaction Tank will be lowered
below the OA Headers, the following should be
performed
Close OA Isolation Valve located near the Module
Open the Flush Valve and flush for approximately
5-10 minutes.

Tanjung Jati B Training

FGD Operations
Oxidation Air

FLUSHING THE
AIR PIPING AND HEADERS

TEMPERATURE
ELEMENT

MANUAL

HUMIDIFICATION
(SERVICE WATER)

C CONTROL VALVE
MANUAL
FLUSH
VALVE

C
O

MANUAL
ISOL.VALVE

3.5 METERS

ABSORBER
MODULE

FROM OXIDATION
AIR BLOWER
FLUSH WATER
(PROCESS WATER)

C = CLOSED
O = OPEN
Tanjung Jati B Training

OPERATIONS
OXIDATION AIR
(END)

Tanjung Jati B Training