Flue Gas Desulphurisation Projects:
Aberthaw Power Station - Re-line the 150m high multi-flue concrete chimney for the FGD (Flue Gas Desulphurisation) operation
The Brief
Aberthaw Power Station is a 1506Mw power station located in the Vale of Glamorgan, South Wales. It is situated on the north coast of the Bristol Channel and has a sea water cooling system.
The main chimney consists of a reinforced windshield with 3 internal flues, each constructed from a vertical array of 17 independent acid resistant brick cylinders. Following the Large Combustion Plant Directive, planning permission was granted for a Sea Water Flue Gas Desulphurisation System (SWFGD) to be fitted to the station.
Subsequently, Delta’s job was to line the internal brick flues with borosilicate blocks to protect against the low temperature corrosion associated with SWFGD fumes.
The Delta Difference
Delta carried out the FGD relining works to two of the the three flues in the summers of 2004 and 2005. The relining of Unit 8 in the summer of 2004 was the first power station flue in Great Britain to be relined with borosilicate blocks.
On both occasions, Delta installed a temporary roof system over the summit of the flue to be lined. The temporary roof was vented to allow the natural flow of air to circulate, yet also to keep out any inclement weather.
Access to the workface of the flue was via a circular motorised platform suspended on wires with a safe working load (SWL) of 1200kg. The platform provided safe access for up to 8 operatives for the block laying and materials. Access to the platform for operatives and materials was via a man riding winch. To the external windshield, Delta installed a twin cage Alimak rack and pinion hoist for the full height of the chimney. This was installed to provided transport for men, materials and equipment and also an additional means of emergency escape should it have been needed.
The works were carried out in shifts, 24 hours a day.
While the safety and quality control of these works was managed in-house by Delta, the supplier of the borosilicate blocks also had full-time representation on site to ensure that the installation was carried out to the highest standards. High quality control was vital as the lining is guaranteed for 10 years trouble free operation, and should indeed last much longer under normal operating conditions.
The relining of Unit 8 was successfully completed, safely and accident free, seven days ahead of the seventy day programme.
Joe NcNeilly, from RWE nPower said of the work to Unit 7 flue:
“our gratitude goes to Delta International for another successful flue l9ining project which was carried out once again without accident, incident or near miss”
Delta International have installed new linings in power stations chimneys throughout the UK and our engineers are experienced in the design and installation of all types of new lining from borosilicate blocks, acid resistant brickwork, GRP or steel liners.
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Delta International
Delta House
Wrigley Street
Lancashire
Oldham
OL4 1SL
United Kingdom
Tel: +44 (0) 161 785 4940
Fax: +44 (0) 161 785 4941
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