# P r oject R epo r t

PENNG U ARD ® 

# Block Lining S ystem PR O T E CTING POWER P L ANT CHIMNE Y S



## Coal fi r ed p o w er station in the w estern Unit e d S t ates p r e pa r es its fo ur chimn e y s for w et stack ope r ation by installin g P enngua r d ® 

## linings in the brick flues

.

The San Juan Gene r ating S tation near the t o wn o f

F armington, New Mexico is a mine mouth p o w er statio n with an installed capacity of 1,800 M W

. Its four boilers

, two of 350 MW and two of 550 MW each, fi r e coal with a sulfur content of 0.9 %. The p o w er station has ope r ate d

FGD plants for many y ears and it will n o w m o v e t o desulfurizing one hund r ed pe r cent of its exhaus t

gas fl o w

.

In the mid se v enties, the San Juan S tation was fitte d

with FGD plants using the W ellman L o r d p r ocess. This early FGD system used four sepa r ate scrubbe r

v essels per unit. In the late nineties, the FGD system

was con v e r ted to a w et limestone p r ocess, upg r adin g the sulfur r em o v al efficiency f r om 75 % to 90 %

. The p o w er station continued to bypass a po r tion o f

the gas st r eam a r ound the FGD system

. 

## K

ey facts about San Juan Po w er Station

2 x 350 MW and

2 x 550 MW coal
fi r ed p o w er station

W et FGD on all
four units

No flue gas r eheat

A ll four existing chimneys with brick
flues to be lined with

P enngua r d ® Th r ough the y ears of ope r ating the San Jua n chimneys with a mi x ed, pa r tially desulfuri z ed ga s fl o w , it was found that the f r ee standing bric k chimney flues w e r e subject to deg r adation especiall y
in the mixing z ones for t r eated and non-t r eated ga s fl o ws. In 2002 and 2003 the station installe d

P enngua r d ® linings in the l o w er pa r t of the brick flue s of the Unit 1 and Unit 2 chimneys

.

W ith emissions r egulations becoming mo r e and

mo r e stringent, the San Juan P o w er S tation, which i s

ope r ated by Public Se r vice of New Mexico but whic h

is o wned by nine utilities f r om fi v e states, decided

in 2006 to switch to fully desulfuri z ed ope r ation

, eliminating any bypass a r ound the FGD system.

In o r der to p r epa r e the chimneys for l o w tempe r atu r e

w et stack ope r ation, the o wners also decided that th e brick flues in all four chimneys would be p r otected b y


### P enngua r d ® linings o v er their full height

. 

# San Juan

Po w er Station Hadek_PR_Sanjuan_UsLetter_AW.qxd 15/4/08 9:50 am Page 3

P enngua r d ® is a r egiste r ed

t r ademark of E r gon Asphalt

& Emulsions, Inc.

### 8

9



## Installation process summarized:

Installing work platform

Cleaning and grit blasting
brick substrate

Brickwork repairs

Primer application

Liquid collection system
installation

Pennguard ® 

### lining
installation

Finishing works including
false floor installation

The similar Unit 3 chimney was the second chimney to be lined and was successfully completed as well, in a 6-week outage, during the first quarter of 2008. The applications in the Unit 1 and Unit 2 chimneys are scheduled in the third quarter of 2008 and the first quarter of 2009. The combined surface area of all chimney flues to be lined is 87,445 ft 2



### . 8/9. The Pennguard ® 

### Blocks are applied to the brick substrate using the Pennguard ® 

### Adhesive Membrane.

The Pennguard ® 

### lining installation crew consisted of installers, who were supported by helpers on the platform as well as on ground level. The typical installation productivity is 15 to 21 ft 2 

### per installer per hour. All the work, including surface preparation, installation of the liquid collection system, lining application and construction of a false floor was completed within the 6-week outage.



## One project, four chimneys Hadek_PR_Sanjuan_UsLetter_AW.qxd 15/4/08 9:50 am Page 5



### 5 

## 1 

# Unit 4 chimney prepared for wet stack service

3



### 6 1. In the most recent environmental upgrade at San Juan Power Station, the Unit 4 chimney with 27,375 ft 2 

### of brick flue surface was the first one of four chimneys to be lined with the Pennguard ® 

### Block Lining System. The chimney contractor, Pullman Power, had to complete the lining of the brick flue and all related works in an outage of 6 weeks, during the third quarter of 2007.

2. Before installing the Pennguard ® 

### lining, the brickwork was power washed and then grit blasted to remove all dirt, deposits and other loose particles.

3/4. It is normal for brick flues to show some
offsets between the individual bricks. The Pennguard ® 

### lining can accommodate most of these surface irregularities by using a thicker adhesive back joint.

5. Narrow, stable cracks, caused by settling of the brickwork or thermal shocks, can usually be covered by the Pennguard ® 

### Block Lining System without additional preparation.

6/7. After grit blasting and application
of the Primer onto the brick surface (picture 6), liquid collection gutters were installed into the chimney (picture 7). Alden Research Laboratory and Pullman Power designed a liquid collection system for each of the four chimneys. 7 2

4 Hadek_PR_Sanjuan_UsLetter_AW.qxd 15/4/08 9:50 am Page 4

### 8

9



## Installation process summarized:

Installing work platform

Cleaning and grit blasting
brick substrate

Brickwork repairs

Primer application

Liquid collection system
installation

Pennguard ® 

### lining
installation

Finishing works including
false floor installation

The similar Unit 3 chimney was the second chimney to be lined and was successfully completed as well, in a 6-week outage, during the first quarter of 2008. The applications in the Unit 1 and Unit 2 chimneys are scheduled in the third quarter of 2008 and the first quarter of 2009. The combined surface area of all chimney flues to be lined is 87,445 ft 2



### . 8/9. The Pennguard ® 

### Blocks are applied to the brick substrate using the Pennguard ® 

### Adhesive Membrane.

The Pennguard ® 

### lining installation crew consisted of installers, who were supported by helpers on the platform as well as on ground level. The typical installation productivity is 15 to 21 ft 2 

### per installer per hour. All the work, including surface preparation, installation of the liquid collection system, lining application and construction of a false floor was completed within the 6-week outage.



## One project, four chimneys Hadek_PR_Sanjuan_UsLetter_AW.qxd 15/4/08 9:50 am Page 5

# P r oject R epo r t

PENNG U ARD ® 

# Block Lining S ystem PR O T E CTING POWER P L ANT CHIMNE Y S



## Coal fi r ed p o w er station in the w estern Unit e d S t ates p r e pa r es its fo ur chimn e y s for w et stack ope r ation by installin g P enngua r d ® 

## linings in the brick flues

.

The San Juan Gene r ating S tation near the t o wn o f

F armington, New Mexico is a mine mouth p o w er statio n with an installed capacity of 1,800 M W

. Its four boilers

, two of 350 MW and two of 550 MW each, fi r e coal with a sulfur content of 0.9 %. The p o w er station has ope r ate d

FGD plants for many y ears and it will n o w m o v e t o desulfurizing one hund r ed pe r cent of its exhaus t

gas fl o w

.

In the mid se v enties, the San Juan S tation was fitte d

with FGD plants using the W ellman L o r d p r ocess. This early FGD system used four sepa r ate scrubbe r

v essels per unit. In the late nineties, the FGD system

was con v e r ted to a w et limestone p r ocess, upg r adin g the sulfur r em o v al efficiency f r om 75 % to 90 %

. The p o w er station continued to bypass a po r tion o f

the gas st r eam a r ound the FGD system

. 

## K

ey facts about San Juan Po w er Station

2 x 350 MW and

2 x 550 MW coal
fi r ed p o w er station

W et FGD on all
four units

No flue gas r eheat

A ll four existing chimneys with brick
flues to be lined with

P enngua r d ® Th r ough the y ears of ope r ating the San Jua n chimneys with a mi x ed, pa r tially desulfuri z ed ga s fl o w , it was found that the f r ee standing bric k chimney flues w e r e subject to deg r adation especiall y
in the mixing z ones for t r eated and non-t r eated ga s fl o ws. In 2002 and 2003 the station installe d

P enngua r d ® linings in the l o w er pa r t of the brick flue s of the Unit 1 and Unit 2 chimneys

.

W ith emissions r egulations becoming mo r e and

mo r e stringent, the San Juan P o w er S tation, which i s

ope r ated by Public Se r vice of New Mexico but whic h

is o wned by nine utilities f r om fi v e states, decided

in 2006 to switch to fully desulfuri z ed ope r ation

, eliminating any bypass a r ound the FGD system.

In o r der to p r epa r e the chimneys for l o w tempe r atu r e

w et stack ope r ation, the o wners also decided that th e brick flues in all four chimneys would be p r otected b y


### P enngua r d ® linings o v er their full height

. 

# San Juan

Po w er Station Hadek_PR_Sanjuan_UsLetter_AW.qxd 15/4/08 9:50 am Page 3

P enngua r d ® is a r egiste r ed

t r ademark of E r gon Asphalt

& Emulsions, Inc.



### Hadek Protective Systems, Inc., Foster Plaza 5, 651 Holiday Drive, Pittsburgh, PA 15220 Tel. 412-204-0028 Fax. 412-204-0039 E-mail: sales@hadek.com Web: www.hadek.com 

## Pennguard ® 

## linings are the most effective technology

Ever since the introduction of FGD plants, owners have decided to re-use their existing, brick lined chimneys for low temperature, acid condensing operation. Brick flues have been prepared for agressive FGD operating conditions in various ways and Pennguard ® 

### linings have proven to be the most effective, durable technology.



## Why?

A p o s i t i v e b a r r i e r A lightweight, impermeable Pennguard ® 

### lining will form a positive barrier, isolating the brick flue from any contact with acidic flue gas and condensate.

P i c t u r e 1 shows the outside of a brick flue that was internally lined with Pennguard ® 

### and then placed
in wet stack service. P i c t u r e 2 shows the outside of a brick flue that was left unprotected except for pressurizing the annular space, and then placed in
wet stack service.



## N o a n c h o r s , n o s u p p o r t s A Pennguard ® 

### lining is lightweight and fully bonded to the brick substrate by its adhesive. It does not require any anchors or supports that could lead condensate into the lining and create weak spots
as a result of corrosion.



## F l e x i b l e a n d a d a p t a b l e By their nature, most brick flues have irregularities such as bulges, offsets between bricks and narrow cracks. Thanks to the limited size of Pennguard ® 

### Blocks and the flexibility of its adhesive, a Pennguard ® 

### lining will readily adapt to most of these irregularities. 

# Converting brick flues for low temperature FGD service

With the four chimneys at San Juan Generating Station included, Pennguard ® 

### linings have been successfully installed in well over 30 brick flues in power stations worldwide.



## 1

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