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The two Dynegy Midwest 635 MW coal-fired generating units at the Baldwin Energy Complex (BEC) are equipped with a dry flue gas desulfurization (DFGD) system with onsite reagent preparation equipment, spray dry absorbers and dual fluid nozzle atomizers.

Determining that personnel education was a top priority for improving safety, reliability and efficiency, Dynegy engaged Primex to develop a Scrubber Performance Improvement training program customized for over 100 operations personnel.

The curriculum included factors affecting scrubber performance, reagent preparation safety awareness with “hands on” workshop, performance improvement opportunities and discussion of related work in progress.

The value of scrubber training at BEC has been recognized by plant management. Participant feedback yielded over 40 suggestions affecting safety, reliability or efficiency. Scrubber reliability improved substantially with more consistent performance and fewer upset events while no related safety incidents or near misses have occurred since training completion.

Training success at BEC depended on senior plant management support, collaboration between Dynegy and Primex personnel, enthusiastic audience participation, and the best donuts within 50 miles.

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SITUATION

Dynegy Midwest operates two 635 MW coal-fired generating units at the Baldwin Energy Complex (BEC) near Baldwin, IL. Each unit is equipped with a dry flue gas desulfurization (DFGD) system with onsite reagent preparation equipment, spray dry absorbers and dual fluid nozzle atomizers. An evaluation of DFGD system performance and operating practices revealed that personnel education was one of the top priorities for improving safety, reliability and efficiency at BEC.

SOLUTION: Knowledge + Awareness + Engagement

Dynegy engaged Primex to develop and present a Scrubber Performance Improvement training program customized for operations personnel at BEC. Reaching more than 100 participants in multiple classes, the curriculum included factors affecting scrubber performance, reagent preparation safety awareness with “hands on” workshop, performance improvement opportunities and discussion of related work in progress. Audience participation was encouraged with an emphasis on open dialog, respectful debate and collaborative problem solving.

RESULTS: Safety + Reliability + Efficiency

The value of scrubber training at BEC has been recognized by plant management in several important areas. First, feedback by participants during the classes yielded more than 40 suggestions with implications in safety, reliability or efficiency. Second, scrubber reliability improved substantially with more consistent performance and fewer upset events (such as absorber vessel plugging). Finally, no safety incidents or near misses attributable to scrubber operations have occurred since training completion.

CRITICAL SUCCESS FACTORS

Training success at Baldwin depended on senior plant management support of training objectives, collaboration between Dynegy and Primex personnel, customized content based on actual BEC scrubber performance data, enthusiastic audience participation and the best donuts within 50 miles.