Background

A major coal fired power plant utilized industrial axial flow fans to circulate gases from the flue gas desulfurization unit through ducts, with clean emissions the desired goal. It was critical for the fans to operate safely and efficiently, and to ensure this our client would measure pressure at the entrance to the fan and pressure on the outlet of the fan; the differential pressure would allow them to regulate the speed, pitch, and the flow of the flue gas through the DS unit. Obtaining these pressure measurements was enabled through tapping points, which were often at risk of clogging from dry sorbent carryover contained in expelled gas.

How our client treated the throughput at that time was to use predictive software, however the data produced was based on previous scenarios so was often inaccurate. Two consequences of this were:

  • Fans were at risk of stalling or blowing up – costing millions of dollars in repairs/replacement and lost production time from unplanned outages.
  • Process variable measurement that was unreliable.

After reading a LinkedIn post about the Autorodder™ and its ability to keep tapping points clear and open, 24/7, while operating in applications where process temperatures reach 2,552 degrees Fahrenheit and process pressures reach 100 BAR (1,450psi), our client was confident they had discovered a solution to the serious, long-term process issues they had been experiencing in their plant.

Solution

After an initial conversation about the Autorodder™’s key features and benefits, a meeting was arranged for Clearguard to visit the plant and assess the unit first-hand.

After examining the client’s flue gas desulfurization unit, it was apparent that the Autorodder™ solution could be easily implemented. The process that followed from this point:

1) Scoping
A datasheet was provided to clarify our client’s exact requirements including the process parameters, installation envelope, available power and air supply, and sizes of the tapping points.

2) Proposal 
To support their internal approvals process, an in-depth technical proposal was supplied to our client identifying the length, material construction and size options for the Autorodder™. This included timeframes and costings.

 3) Approval 
after receiving the green light to proceed, our next step was to revert with drawings and diagrams for final sign off.

4) Manufacture 
As every Autorodder™ is custom-built to specification, the raw materials were ordered (all of which are traceable and certified) and the solution manufactured to suit the installation and application.

5) Quality assurance 
Before leaving the premises, each Autorodder™ underwent function and pressure testing to ensure its reliability and performance. Prior to despatch Clearguard photographed the Autorodders™ in their packaging, with images provided to our client.

6) Implementation
Upon receipt of the Autorodders™ our client was provided with clear and comprehensive videos and documentation covering installation, operation, and servicing.

7) Commissioning
Clearguard were present on site for commissioning.

 

Result

The client experienced real-time, accurate process measurement with personnel feeling confident in the data received. Other positive impacts included the fans now flowing at optimum speed, and danger of equipment failure or permanent damage to the axial fans eliminated – saving significant cost.

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