Power Engineering 201306

Were Not Exaggerating. Our Boilers are something to brag about.
We custom design and custom build boilers to perform efciently, safely and cleanly. Your RENTECH boiler will lower operating costs, reduce emissions, and provide faster start-up and cool-down. Youll nd satised customers on six continents with specialty boilers, HRSGs, wasteheat boilers and red packaged watertube boilers from RENTECH. Weve been designing and building boilers for people who know and care since 1996. WWW.RENTECHBOILERS.COM
RICE NESHAP
WHAT YOU NEED TO KNOW TO COMPLY
GAS TURBINES
THE KEY TO QUICKER STARTUP TIMES
BOILER CLEANING
THE BEST TECHNIQUES AND STRATEGIES
the th he magazine of power generation generati ion
Emission Control
1 1 7
YEARS
TECHNOLOGY
June 2013 www.power-eng.com
Welcome to the Digital Edition of
the magazine of power generation
Easily NAVIGATE through the issue.
SEARCH for specific

articles or content.
View the table of CONTENTS and easily navigate directly to an article.
Click PAGES to view thumbnails of each page and browse through the entire issue.
Easily browse all BACK ISSUES.
page via social media.
SHARE an article or
A quick start guide to MAXIMIZING our interactive features.
SHARE an article via email.
PRINT any or all pages.
Click directly on the page to ZOOM in or out. Fit the issue to your screen.
DOWNLOAD the issue to your desktop.
rti NHA sin S g pe Se ci ct al ion 35 -
EMISSIONS CONTROL
UNDERSTANDING YOUR OPTIONS
HYDROPOWER
THE POWER OF REHABILITATION
PRB COAL
47
CHALLENGES AND SOLUTIONS
Ad
ve
1 1 7
YEARS
Wind Turbine
TECHNOLOGY CHOICES
March 2013 www.power-eng.com
When the heat is on SOLVAir Solutions helps relieve it!
As summer progresses, the heat becomes more unrelenting, and air pollution control remedies often move to the back burner. But with MATS and MACT deadline mandates just over the horizon, its also vital that compliance solutions be found for SOX and HCl emissions before much more time elapses. The good news: Dry Sorbent Injection with sodium sorbents is proven to postpone the retirement of some coal-fred power plants by reducing SOX and HCl emissions drastically. SOLVAir Solutions understands the pressures that come with looming regulations deadlines, and we can help with the resolution of emissions problems. When the heat is on, staying cool is what its all about. For information that helps take the heat of, call Mike Wood at SOLVAir Solutions, 800.765.8292, or go to www.solvair.us, to fnd out about DSI, sodium sorbents, emissions control and more.
Solvay Chemicals, Inc. 1.800.SOLVAY C (800.765.8292) www.solvair.us

Copyright 2013, Solvay Chemicals, Inc. All Rights Reserved
For info. http://powereng.hotims.com RS# 1
CORPORATE HEADQUARTERSPennWell Corp. 1421 South Sheridan Road Tulsa, OK 74112 P.O. Box 1260, Tulsa, OK 74101 Telephone: (918) 835-3161 Fax: (918) 831-9834 E-mail: pe@pennwell.com World Wide Web: http://www.power-eng.com
Power Engineering is the flagship media sponsor for
TM
MANAGING EDITOR Russell Ray (918) 832-9368 russellr@pennwell.com ASSOCIATE EDITOR Denver Nicks (918) 832-9214 denvern@pennwell.com ASSOCIATE EDITOR Justin Martino (918) 831-9492 justinm@pennwell.com ON-LINE EDITOR Sharryn Dotson (918) 832-9339 sharrynh@pennwell.com CONTRIBUTING EDITORBrad Buecker CONTRIBUTING EDITORBrian Schimmoller GRAPHIC DESIGNER Deanna Priddy Taylor (918) 832-9378 deannat@pennwell.com SUBSCRIBER SERVICE P.O. Box 3271, Northbrook, IL 60065 Phone: (847) 559-7501 Fax: (847) 291-4816 E-mail: poe@omeda.com MARKETING MANAGER Wendy Lissau (918) 832-9391 wendyl@pennwell.com SENIOR VICE PRESIDENT, NORTH AMERICAN POWER GENERATION GROUP Richard Baker (918) 831-9187 richardb@pennwell.com NATIONAL BRAND MANAGER Rick Huntzicker (770) 578-2688 rickh@pennwell.com
FEATURES1 1 7
VOLUME
No. 6, June 2013
the Life of Coal 20 Extending Fired Plants Through the Use of Dry Sorbent Injection
Many plants are lowering emissions through the use of dry sorbent injection, which costs a fraction of the price of a wet scrubber. Power Engineering looks at the benefits of DSI systems for adapting to changing regulations and compliance dates.
28 Advances in Boiler 40
Cleaning Technology
Gas Turbine Combined Cycle y Fast Start:
From dynamite to the latest in online cleaning systems, Power Engineering looks at methods to keep boilers slag-free and working at peak efficiency.
The Physics Behind the Concept

Fast start capability is one of the major features of gas turbines that give power plants flexibility in their operations. Learn more about the key mechanisms that limit the startup times of modern combined cycle gas turbines.
CHAIRMAN Frank T. Lauinger PRESIDENT/CEO Robert F. Biolchini CHIEF FINANCIAL OFFICER/SENIOR VICE PRESIDENT Mark C. Wilmoth CIRCULATION MANAGER Linda Thomas PRODUCTION MANAGER Katie Noftsger POWER ENGINEERING, ISSN 0032-5961, USPS 440-980, is published 12 times a year, monthly by PennWell Corp., 1421 S. Sheridan Rd., Tulsa, OK 74112; phone (918) 835-3161. Copyright 2013 by PennWell Corp. (Registered in U.S. Patent Trademark Office). Authorization to photocopy items for internal or personal use, or the internal or personal use of specific clients, is granted by POWER ENGINEERING, ISSN 0032-5961, provided that the appropriate fee is paid directly to Copyright Clearance Center, 222 Rosewood Drive, Danvers, MA 01923 USA 508-750-8400. Prior to photocopying items for educational classroom use, please contact Copyright Clearance Center, Inc., 222 Rosewood Drive, Danvers, MA 01923 USA 508-750-8400. Periodicals postage paid at Tulsa, OK and additional mailing offices. Subscription: U.S.A. and possessions, $88 per year; Canada and Mexico, $98 per year; international air mail, $242 per year. Single copies: U.S., $14, Outside U.S. $23. Back issues of POWER ENGINEERING may be purchased at a cost of $14 each in the United States and $16 elsewhere. Copies of back issues are also available on microfilm and microfiche from University Microfilm, a Xerox Co., 300 N. Zeeb Rd., Ann Arbor, MI 48103. Available on LexisNexis, Box 933, Dayton, OH 45402; (800) 227-4908. POSTMASTER: Send change of address, other circulation information to POWER ENGINEERING, PO Box 3271, Northbrook, IL 60065-3271. POWER ENGINEERING is a registered trademark of PennWell Corp. Return undeliverable Canadian addresses to P.O. Box 122, Niagara Falls, ON L2E 6S4. Member American Business Press BPA International PRINTED IN THE U.S.A. GST NO. 126813153 Publications Mail Agreement No. 40052420
50 Upgrading Electrostatic Precipitators

Many electrostatic precipitators will need to be upgraded or converted into a baghouse to handle particulate matter emission standards regulated by federal standards. Learn more about different methods for upgrading ESPs.
56 Engineering Design for
RICE NESHAP Compliance
Read about the steps taken and challenges faced by a team working to bring an NRG Energy peaking plant into compliance with regulations requiring less carbon dioxide emissions.
62 Development Status of the
Alden Fish-Friendly Turbine
Several organizations have been working to advance the construction and installation of a fish-friendly turbine design. Read about their efforts and the search for a hydropower project to demonstrate the new technology.
DEPARTMENTS
2 4 6 Opinion Clearing the Air Nuclear Reactions 8 10 12 Demand Response View on Renewables Gas Generation 14 18 72 Power Plant Profile What Works Ad Index
POWER ENGINEERING ONLINE :

Newsletter:
Stay current on industry news, events, features and more.
www.power-eng.com Industry News:

Global updates throughout the day
Newscast:
Power Engineering
A concise, weekly update of all the top power generation news
OPINION
Managing Regulatory Mayhem

BY RUSSELL RAY, MANAGING EDITOR
avigating the regulatory maze is a dangerous undertaking for power producers nowadays. Developing a sound, costeffective strategy for compliance has been complicated by layers of new environmental rules and delays in implementation. One misstep can set a project back by years, costing power producers and their customers millions. New rules governing mercury emissions, cooling technology, wastewater treatment, coal ash management, regional haze, and greenhouse gas emissions pose a formidable challenge for utility executives and power plant managers. Some of these rules have been finalized while others are in the works. Successful compliance requires a carefully coordinated, catchall strategy that includes a calculated integration of technologies. Balance is the goal. A comprehensive plan that achieves the new environmental standards and ensures reliable and affordable electricity is the end-game. But getting there will be different for every power producer and every plant. The maze of environmental rules is becoming more difficult to navigate. There are a number of new environmental rules awaiting final action or implementation. These rules, which will cost the industry billions in compliance costs, will dictate the future of power generation in the U.S. for decades to come. It is very important these rules be as flexible as possible. The U.S. Environmental Protection Agency is expected to move forward
on several rulemakings that are sure to have a significant impact on electric utilities. Here are three of those forthcoming rules: A final rule governing cooling water intake structures at existing power plants is expected to be issued this month. The rule, which targets plants using once-through cooling systems, would require many facilities to install closedcycle cooling systems. Closed-cycle systems use less water from rivers and bays and harm fewer fish. Under the rule, plants that draw more than 2 million gallons a day and use at least 25 percent of that water for cooling are required to take action to protect the aquatic environment. More than 670 U.S. plants will be affected by the new rule. The measure will require some power producers to modify cooling water intake structures or construct new cooling towers. The EPA is expected to issue a rule expanding the oversight of coal ash management and disposal at U.S. power plants. The rule would require coal-fired power plants to eliminate wet ash handling and phase out surface impoundments, or ponds, within five years. The rule was proposed after a 40-acre coal ash storage pond at Tennessee Valley Authoritys Kingston plant in Harriman, Tenn., failed in 2008, spilling more than 1 billion gallons of coal ash slurry. The big question is this: Will the EPA classify coal ash as a hazardous or
non-hazardous waste? The difference is significant. A hazardous classification would cost power producers billions more in compliance costs. In April, the EPA proposed effluent limitation guidelines to reduce wastewater discharges from power plants. The rule is expected to be finalized by May 2014. The rule would be the first update of the effluent limitations guidelines since 1982. The EPA proposed the rule after the agency found that the increased use of air pollution controls was increasing pollution in wastewater discharges. The rule would reduce pollutants from the following wastewater streams: flue gas desulfurization, fly ash, bottom ash, flue gas mercury control, landfills and surface impoundments, nonchemical metal cleaning wastes, and fuel gasification. You may have noticed a commonality in all of these measures. All three rules call for significantly stricter standards for water usage in power plants. The change in the EPAs focus is clear. After decades of advancing clean-air regulations, the agency plans to put a higher priority on new water rules for power producers. At POWER-GEN International 2013 in Orlando, Fla., all of these rules and their impacts will be thoroughly examined by experts participating in several conference sessions. To register online, visit www. power-gen.com. If you have a question or a comment, please contact me at russellr@pennwell.com.
www.power-eng.com
Precise Product Sized for Maximum Yield
The in Uptime Since 1905 The Leader i nU ptime eS ince e1 905
Eliminate Fugitive Dust!
High Capacity Coal up to 10,000 TPH Size Control rol Adjustable while operating Non-Crushables Automatic passing and reset
Roll Crusher
Only One Moving Part Unmatched Reliability Models to Suit any Capacity Uses Ultra-low Horsepower
Thats a Gundlach Crusher.

Find d out why Gundlach h Roll ll Crush hers and CAGE-PAKTOR Cage Mills are the preferred crushing solutions for coal, potash, salts and lime.
Right Size. Maximum Yield. Minimum Fines. Every Time.
Posimetric Feeders
Improve plant safety with these dust-free feeders.
For coal, limestone, biomass, crushed stone, sand, wood chips and more.
The Most Choices, The Most t Experi ience.

Pennsylvania Crush sher er has bee een n so solv lvin lv ing th the e crushing and feeding problems of its cust customers tomers f for or over 100 years.
Cage C Mills Mill
Breakers
Hammermills
Bradford Breakers
Roll Mills
a brand of
Grinders Gi d
Impactors I t
a brand of
Coalpactors
Toll-Free: 1-877-GUNDLACH E-mail: BetterCrushers@GundlachCrushers.com
Gundlach Crushers
Phone: 1-610-544-7200 E-mail: Buster@PennCrusher.com
Pennsylvania Crusher
Handling a World of Materials
www.TerraSource.com
TerraSource Global is a wholly-owned subsidiary of Hillenbrand, Inc. (NYSE: HI) 2013, TerraSource Global. All rights reserved.
CLEARING THE AIR
Finding Best-Fit Mercury Emission Controls

BY NAT SEKHAR, SENIOR CONSULTANT, CH2M HILL
Author Nat Sekhar, P.E., a Senior Consultant with CH2M HILL, is an internationally recognized emission control expert. He has been the technical lead on more than 25,000 emission control projects incorporating flue gas desulfurization, nitrous oxide, electrostatic precipitator/baghouse, and other emission control systems. Nat has contributed to more than 40 technical publications and presentations, and coauthored the Fossil Fuel Power Generation section in McGraw Hills Encyclopedia of Science and Technology.
he optimal selection of control technologies to limit mercury emissions depends on the type of coal-fired unit (new or existing), the rank of the coal and existing emission control systems. Mercury in coal varies from 0.05 to 0.25 parts per million by weight, depending on the type of coal. The established regulatory limits on mercury emissions depend on the type of unit and the type of coal. The limits for new coal-fired units are 0.04 lb/GWh for units that burn low-rank coal such as lignite with a higher heating value (HHV) of less than 8,300 Btu/lb, and 0.003 lb/GWh for units burning high-rank coal with an HHV of more than 8,300 Btu/lb. For existing units, the corresponding limits are 0.12 lb/ GWh or 11.0 lb/TBtu and 0.013 lb/ GWh or 1.2 lb/TBtu, respectively. These emission limits translate to removal efficiency ranges of 65 percent to more than 80 percent for new units using low-rank coals and 95 percent to more than 98 percent for new units burning high-rank coals. The removal efficiency ranges for existing units are 15 percent to more than 50 percent for low-rank coals and 85 percent to 95 percent for high-rank coal. Because the removal requirements are based solely on lb/GWh, operators of new units may find that lowmercury coal and the ultra super-critical steam cycle, which yield very low heat rates in the range of 8,000 Btu/ KWh, offer substantial benefit. For existing units, the control technology selection depends on the removal requirement, mercury concentration
and speciation, and type of existing emission control system. During combustion, mercury in coal is first released as elemental mercury (Hg0), before it is converted to ionic or oxidized species (Hg++) and as particulates. The conversions depend on many factors, such as the rate of cooling, concentrations of halogens and sulfur trioxide (SO3), amount of fly ash, fly ash properties and unburned carbon in fly ash. The concentration of elemental mercury and ionic mercury varies from 20 percent to 80 percent, depending on the coal, its halogen content and the particulate mercury content. Elemental mercury is not water soluble and is difficult to remove in downstream flue gas desulfurization (FGD) systems. Ionic mercury, on the other hand, is very water soluble and is easily removed in FGD systems, both wet and dry. The particulate mercury is also removed by devices such as an electrostatic precipitator (ESP) or a fabric filter (FF) with fly ash. Mercury can be removed through chemical adsorption on powdered activated carbon (PAC). Activated carbon is injected upstream of an ESP or FF and is removed along with fly ash. Because it is also adsorbed and removed by PAC, the presence of SO3 adversely affects mercury removal. If SCR is used for nitrogen oxides (NOx) control, it can exacerbate this problem; SCR tends to oxidize sulfur dioxide (SO2) to SO3 and increases SO3 concentration in the flue gas. Low-oxidation catalysts can be used to minimize this problem. SO3 can
also be removed by injecting alkali such as trona or lime/hydrated lime upstream of PAC injection. The main drawback of the PAC system is its potential adverse effect on ESP performance when ESP is used for particulate collection and to improve the salability of fly ash. A new market entrant, injection of amended silicates, can potentially negate both increased SO3 concentration in the flue gas and the attendant adverse effect on ESP performance. The long-term viability of amended silicate has not yet been demonstrated, however. Halogen compounds such as bromine or hydrogen bromide added to flue gas increase the conversion of elemental mercury to ionic mercury, thereby facilitating mercury capture in downstream FGD. Halogen salts can also be added to coal before the pulverizers. During combustion, bromide salts decompose and release bromine ions, which in turn oxidize elemental mercury to ionic mercury that is removed in FGD. Bromine ions can potentially increase fireside corrosion. Some ionic mercury collected in the FGD can revert back to elemental mercury and can be re-emitted into the flue gas. Although chemicals can be added to minimize re-emission, the exact mechanisms of the reemission reactions and the mitigation measures are not clearly established. Given the complexity of choosing control technologies for limiting mercury emissions, a comprehensive site-specific study may be necessary to help your company choose the optimal solution.
www.power-eng.com
25
YEARS EXPERIENCE
READY TO MANAGE
The Best Of The Best
YOUR NEXT
POWER PROJECT.
Founded in 1988, PIC has been a leader in the power generation industry for over 20 years. We are experts at managing multi-faceted projects including start-up and commissioning, operations and maintenance, installation, turbine outages, mechanical services and technical services. Combine these capabilities with our responsive approach and global resources, and its easy to see why those who know choose PIC.
www.picworld.com
Founded in 1988
NUCLEAR REACTIONS
Nuclear Powers Strong Future amid Challenges in the present

BY, MARY JO ROGERS, PH.D.
ith all the attention that is being given to recent announcements of nuclear power plant closures and threatened shutdowns, it would be easy to think that U.S. nuclear power is marching to its death. Easily overlooked are the signs of life and significant milestone achievements of new nuclear technology. Nuclear plant owners started feeling squeezed when decreased electricity demand met a perceived natural gas glut (much of the shale gas reserves have not been tapped yet) and the ensuing low prices. This combination has meant utilities could get very little for their electricity generation, and merchant nuclear plants have become borderline breakeven or worse. With the addition of costly Fukushima modifications and aging major equipment, speculation has increased that more nuclear plants will follow the path of Dominions Kewanee and Dukes Crystal River station. Although it is likely that a few additional nuclear plant shutdowns will be announced over the next year or so, potential signs of life can be seen by stepping back from the current bleak economic environment for nuclear power and looking at the long-term prospects. According to the U.S. Energy Information Administration (EIA), nuclear powers share of the electricity mix is expected to decrease by only 2% by 2040, losing some ground to natural gas and renewables, which will also absorb increases in demand. With any future regulatory effort to capture fees for carbon allowances, nuclear powers estimated share of generation increases anywhere from 7-18%, taking the gains from coal. Global long-term estimates show that nuclear powers overall
proportion of electricity generation stays fairly constant, with losses in Europe and gains in Asia, according to the International Energy Agency. The EIA predicts that by 2020 the U.S. will become a natural gas (net) exporter, which would put pressure on natural gas and electricity prices and keep currently operating nuclear power plants above water. It is unlikely that more than a few additional nuclear plants will close in the U.S., given that regulated utilities will be able to weather the current environment and non-regulated nuclear generators will want to retain enough nuclear capacity to be well positioned when prices increase. Moreover, if too much nuclear generation is lost at the same time aging coal plants are closing, natural gas will be used increasingly for baseload generation, putting even more pressure on prices. Despite economic challenges to the nuclear industry, many experts support nuclear power as an essential part of the mix. At least one high-profile investor, Microsoft Corp. Chairman Bill Gates, touts the benefits of nuclear power and calls for more investment in nuclear energy research. At the international energy executives conference in March (CERAWeek), Gates endorsed nuclear power as the best long-term solution to rising world energy needs in the midst of climate change. Gates also discussed how since Fukushima there is a greater demand for improved reactor designs with inherent safety features. A significant milestone in U.S. nuclear power was achieved very recently. In March, South Carolina Electric and Gas (SCG&E) and Georgia Power poured the first new nuclear concrete in over 30
years at the Summer and Vogtle construction sites, respectively. The historic completion of 7,000 cubic yards of basemat structural concrete at each site by CB&I (formerly Shaw Group) serves as the foundation for the nuclear island structures, such as the reactor containment and auxiliary buildings. Georgia Power and SCG&E (and their co-owners) are each building two Westinghouse AP1000 (1,100 MWe) reactors at the Vogtle and Summer locations. Westinghouse and CB&I are even further along in building four AP1000 units in China. The AP1000 is considered a third generation (III+) advanced reactor that provides a simplified design, reduced capital costs, greater fuel efficiency and enhanced safety margins through the use of passive safety functions. There are many other new advanced reactor designs being developed, including mPowers (Babcock & Wilcox) small modular reactor that received a DOE cost-sharing award for certification and licensing. Generation IV reactor designs are still on the drawing board but have committed international partners pursuing a defined set of approaches. Gen IV designs provide even higher levels of safety and reliability, proliferation resistance, physical protection and economic competitiveness, according to the American Nuclear Society. Many signs of life can be seen in the progress made in the licensing and construction of new reactor designs. Nuclear energy may face continued economic, technological and political challenges but it will retain an important role in world economic development, particularly if efforts are increased to address climate change.
www.power-eng.com
NO COMPANY
MORE FOCUSED
IS
ON ADVANCED NUCLEAR PLANT TECHNOLOGY

Westinghouse AP1000 plant under construction in Haiyang, China
www.westinghousenuclear.com
WESTINGHOUSE ELECTRIC COMPANY LLC
2013 Shandong Nuclear Power Company Ltd. All Rights Reserved.
DEMAND RESPONSE
Demand Response Invades the Grid and Makes it Smart

BY PHIL DAVIS, SENIOR MANAGER SMART GRID SOLUTIONS, SCHNEIDER ELECTRIC
he Department of Energy defines Demand Response (DR) as changes in electric usage by end-use customers from their normal consumption patterns in response to changes in the price of electricity over time, or to incentive payments designed to induce lower electricity use at times of high wholesale market prices or when system reliability is jeopardized. The 2005 Energy Policy Act encourages the use of Demand Response and FERC has manifested this in a number of tariffs which grant equivalency between DR and generation in value. But What is Demand Response, really? Electrons obey the laws of physics. They travel to ground over the path of least resistance. Our job is to get them to do a little work along the way without wreaking too much havoc, which they like to do. Demand response is how we do that. Everything about an electrons intended journey to ground is shaped by someones desire (demand) to achieve a goal. Those goals are determined by the community of electron users; i.e., customers. They demand power: clean, abundant, cheap, renewable, and efficient. In that sense, DR is everything a utility does. Now is the time to use DR to meet goals of efficiency and environmental stewardship. Thirty-one states have renewable energy portfolio standards. Too few of them allow energy efficiency to count toward those goals. If less energy is needed, then its simple math that each source of that energy can contribute a larger percent. Similarly, DR is vital both in making renewable electrons behave as well as timing demand so that it peaks when those renewable electrons are most available.
It is precisely this attribute that leads the California Independent System Operator (ISO) to predict that by 2020, the traditional fossil fuel supplied afternoon demand peaks will disappear. Local solar and other techniques will move peaks to early evening. That is a sea change in the way we think about grid planning. There is a form of Demand Response in commercial production that is analogous to most forms of generation, except perhaps for black-start, but dont rule that out. Realistically, generation is always necessary, since DR only can free, not generate, electrons. Even that is subject to revision as local solar, batteries and other forms of distributed generation begin to assert themselves on the demand side, responding not only to site needs but also to larger microgrid and macro-grid conditions. For two years, Massachusetts has been the most energy efficient state. Utilities there have done about all the efficient lighting, weather-stripping, rebating and retrofitting they know how to do. Yet, the legislature demands more. The answer may be to leave the customer site and take the larger view; to examine what we mean by efficiency. The most efficient grid is a steady state grid where demand and supply stay constant and balanced. The rhythms of life prevent that perfect state, but we are well short of what we can do. Local distributed renewable and efficient electric generation, coupled with intelligent and efficient control and use can flatten existing demand curves, but it means that Demand Response must be synonymous with supply chain management. Huh? If an electron is the product, then everything that happens to it is supply chain
management. Supply chain management in other industries is the key to efficiency. That happened when logistics specialists realized that silos of activity allowed massive inefficiencies by masking the true costs and inconsistencies in the way goods moved to market. Like or loathe Amazon and Wal-Mart, thats where most people go when they want something quickly and at the lowest cost. In other words, the market demanded and the suppliers responded. That is the key to understanding DR. It is supply chain management, and wed be well advised to learn to do this well. Todays customers want green, reliable, efficient, safe, and productive power. Economic productivity and climate sustainability demand it. In coordinated communities, peaks in one section can fill valleys in another. Energy storage, EV charging and distributed generation are in the mix. Perhaps the future of Integrated Resource Planning should include Energy Districts that self-optimize and present a flattened profile to the larger grid. Maybe the utility of the future should develop, own and operate those resources. They are expert as asset and financial management. Clearly, the US has not scratched the surface of efficiency once we get outside the thinking that it must be specific to a customer facility. Efficiency is environmental, but DR is management. It can shape, tune and arrange energy use to respond to opportunities. My father always said to learn a tool well, but then to use the right tool for the job. With respect to efficiency in the US, so far weve been using hammers for everything. Enough.
www.power-eng.com
Scheduled maintenance, inspections, emergency responseTeam delivers
LEAK REPAIRS
FIELD HEAT TREATING
FIELD MACHINING
VALVE INSERTION
HOT TAPS / LINE STOPS
TECHNICAL B OLTING
VALVE REPAIR
NDE/NDT INSPECTION
EMISSIONS CONTROL
eam is a world-class service company with the right people, technology and experience needed to keep your plants online and in production. Our highly skilled technicians work to earn your continued trust and conf idence one job at a time.
PIPE REPAIR SERVICES
TURNAROUND SERVICES
PIPELINE SERVICES
| www.teamindustrialservices.com
VIEW ON RENEWABLES
Elements of Success in Tidal Energy Development

BY JOHN M. FERLAND, OCEAN RENEWABLE POWER
Author John M. Ferland is Vice President of Project Development for Ocean Renewable Power Company, an international industry leading developer of technology and projects that generate clean, predictable power from ocean and river currents. He leads the companys project development, environmental permitting and project licensing activities. John draws on over 30 years of experience in commercialization strategy for renewable energy companies, port emergency response operations, coastal resources management, and public policy.
n 2012 Ocean Renewable Power Company (ORPC) began operating the first federally licensed, commercial, grid-connected tidal energy project. Situated on the U.S. side of the Bay of Fundy, the Cobscook Bay Tidal Energy Project is the only ocean energy project, except for one involving a dam, that delivers power to a utility grid in the Americas. The Project benefits from having the first long-term power purchase agreement for tidal energy issued in the U.S., allowing us to expand to up to 5 MW of production. As a first mover in an emerging industry, ORPC has had to address complexities related to technology development, resource assessment, project siting, marine construction, regulatory requirements, environmental monitoring and public policy. Key to project success has been the positive relationships ORPC has developed with host communities and regulators. This facet of project development is core to our company. Through early, open and frequent communications, ORPC developed relationships and built trust with the host communities of Eastport and Lubec, Maine. Their economies and ways of life have historically been defined by the success of their marine industries. The local workforce is highly skilled in marine operations and has provided us with guidance and expertise needed to work in local waters. Strong relationships have been established with the Eastport Port Authority, local harbor pilots, and most importantly, commercial
fishermen, who helped ORPC site the Cobscook Bay Project, resulting in a location that met our requirements while minimizing disturbance to fishing activities. ORPC has also benefitted from the availability of local divers and commercial vessel operators and crews for support on environmental studies and Project construction, operations and maintenance. The Eastport Port Authority was key in the Projects cable laying operations and has provided a range of services throughout ORPCs seven years working in the area. When ORPC initiated a marine mammal observation program to meet our licensing requirements, professional fishermen, a local kayak guide, a whale watch operator, and others familiar with local waters responded. Following professional training as observers, they joined our operations team during the Projects initial construction phase, and will continue to work with us as the project build-out continues. Local support for ORPC has helped us create a strong economic footprint statewide. Since 2007 we have spent more than $21 million throughout Maine, supported more than 100 jobs statewide, and established a supply chain reaching 13 of the states 16 counties. The promise of economic growth was a major reason why Maine implemented the Ocean Energy Act in 2010. The Act created regulatory reform for small-scale tidal energy projects and the opportunity for a long-term
power purchase agreement through the Maine Public Utilities Commission.. Additionally, Maine and the Federal Energy Regulatory Commission (FERC) signed a Memorandum of Understanding pledging to align state and federal approaches to tidal energy regulation. ORPC has forged productive relationships with state and federal regulatory agencies. We recently submitted the Projects first annual environmental monitoring report to FERC. The agency requires licensees to develop adaptive management plans for evaluating environmental monitoring data and making science-based decisions to modify monitoring as necessary. The goal is to maintain levels of monitoring proportional to project risk through a collaborative effort with regulatory agencies and key advisors who comprise the adaptive management team. Results to date indicate no observed, adverse interaction of the TidGen Power System with the marine environment. We appreciate the regulatory resource agency members of our adaptive management team for their guidance, and because of it, ORPC is at the forefront of innovative environmental monitoring efforts for tidal energy projects. Many challenges remain for the tidal energy industry. Time will tell if our experience in Maine can be replicated in other jurisdictions. At a minimum, ORPCs experience provides examples of the types of community, public policy and regulatory dynamics that are necessary for a tidal energy project to evolve successfully.
www.power-eng.com
10
Sending a critical gearbox out for weeks of repair can be a prescription for devastating downtime.
Fortunately, we make house calls.

Onsite Technical Services from Philadelphia Gear can reduce gear-related downtime from months to days.
When a mission-critical gearbox is out of commission for days, its a headache. When days turn to weeks or months, that headache can become a debilitating spiral of downtime and expense. Onsite Technical Services (OTS ) from Philadelphia Gear, a brand of Timken Gears & Services Inc., was created to help ensure that doesnt happen. OTS is a total onsite solution that can reduce gearbox-related downtime from weeks or months to mere days.
SM
A phone call is all thats needed to start the process. Our experts are your single point of contact for a scope of work that can include onsite gearbox removal and re-installation, rebuilding, re-boring, and more. Our OTS customers benet from reduced downtime, reduced risk of catastrophic events, and, Philadelphia Gears 120 years of experience and industry-leading warranties. Finding out if OTS is right for you couldnt be easier. Just call 1-800-766-5120 to schedule a free, no-obligation consultation. It may be the most timely call you ever make.
GAS GENERATION
Natural Gas Execs Discuss Industry Trends, Concerns

BY JUSTIN MARTINO, ASSOCIATE EDITOR
ecently, I had the opportunity to moderate a discussion about natural gas-fired generation between executives from Alstom, American electric Power, Bechtel and Electric Power Research Institute. The result was a fast-paced conversation that brought up many issues the industry is currently facing. The discussion was published in the May issue of Power Engineering. Here are a few key points that came out of that discussion.
POTENTIAL PRICE VOLATILITY

Although the industry has prepared for increasing prices, there is concern about the volatility of the pricing of natural gas. Unlike other power generating fuels such as coal, natural gas can be used by multiple industries for a variety of reasons. There are a lot of petrochemical refineries and others that can use natural gas, and you could potentially increase demand quite a bit, Thomas said. As Thomas pointed it, it wasnt long ago that natural gas prices were in the double-digit range, and its possible that could happen again. When companies are spending hundreds of millions to build a power plant, uncertainty is a concern, and price volatility is an area being monitored.
PREPARED FOR HIGHER PRICES

Although recent increases in natural gas prices have created media headlines, people in the industry have been expecting prices to increase and are prepared for it. Scott Austin, manager of business development for Bechtels thermal business line, said that gas-fired power generation would still be the fuel of choice over the mid-term with prices staying in the $5 to $7 MMBtu range, with significant opportunities for new builds in the next two years. Pricing will affect how plants are operated, however. AEP Vice President of Generating Assets Toby Thomas said at higher prices, natural gas-fired plants would be cycled more often, while plants would be more likely to run at base load constantly when gas is in the $2 MMBtu range. Recent reports from the U.S. Energy Information Administration support Thomas statement. As gas prices have increased from a Henry Hub price of $1.99 MMBtu on April 25, 2012, natural gas-fired power generation has also decreased, producing around 32 percent of the electricity in the U.S. in April last year. That compares to 25 percent in March of this year.
12
the plant usually half of the price of a coal-fired power plant and one-third of a nuclear plant and the quick dispatch time that allows a plant to be at 50 percent of its capacity in 10 minutes. Operational costs are also lower as fewer employees are needed at a natural gas-fired plant and the fuel is brought in through a transmission line and not manually loaded. Gas also burns cleaner than coal, and most modern combined-cycle plants would have met the NSPS regulation without any additional costs.
NOT THE ONLY OPTION

Despite the advantages of gas, every executive participating had concerns the industry could become too reliant on it as a fuel source for power generation. Gas is just an easy decision, and it really concerns me that the industry doesnt have the flexibility to provide more diversity, EPRI Vice President of Generation Tom Alley said, who also noted the industry is being led toward natural gas as a destination fuel source. Overreliance on natural gas could strain the transmission system, causing potential risks to grid reliability. To ensure reliability, companies need a diversified energy portfolio but the options available for more diversity are currently unclear. Alstom Vice President Gas Product Platform Amy Ericson said its pretty scary out there for the companys customers, who dont know whether they can count on nuclear license renewals or plan for coal-fired generation without carbon capture and storage technology. At the same time, she said, the prospect of only gas and renewable is probably not the best choice for the industry or the U.S.
www.power-eng.com
EPA CONCERNS
The area of most uncertainty for the industry isnt pricing, however. Its the U.S. Environmental Protection Agency. Thomas said a long-term strategy with the current uncertainty and regulatory structure is almost an oxymoron because of changing regulations. The EPA has recently revised rules, such as the Mercury and Air Toxics Standards, or failed to finalize rules, such as the New Source Performance Standard. Any time a company is planning an investment that could cost up to $1 billion, it needs as much information as possible. With the current climate of rules changing, important information just isnt available right now.
ADVANTAGES OF NATURAL GAS

Despite potential price volatility and regulatory uncertainty, natural gas-fired plants have many benefits. Several of the executives noted the lower costs to build
Powerplant Engineering DESIGN & EPC CONSTRUCTION

(We team with EPC Contractors selected to suit the project)
Bob Bibb Chairman / CEO
Lou Gonzales President / COO
Chris Bramhall VP Bus. Develop.
SERVICES: Owner & Bank Engineering CLIENTELE:
PROJECTS (New, Retrofit & Modifications):
Roger Petersen Mgr. Bus. Develop., LA
Please, contact us for our full qualifications.
3131 Broadwa
1
www.bibb-eac.com
For career opportunities e-mail a resume in confidence to: recruitment@bibb-eac.com
POWER PLANT PROFILE
BY DENVER NICKS, ASSOCIATE EDITOR
F
14
irsts are rareby definition they come only onceand lasts are rare for the same reason. But rarest of all is that which is the first and last of its kind, like Doctor Frankensteins hero-monster, doomed to be forever alone on the day it was born. AEPs ultra-supercritical coal-fired Turk power plant may prove to be one such rarity: a great
technological leap forward unlikely to ever be repeated again in the United States. The Turk project was announced in August 2006 but didnt go online until seven years later. AEP spent those intervening years securing the necessary regulatory permits and fighting a battle in the Arkansas Supreme Court. AEP ultimately lost that battle, requiring a late-in-thegame reconfiguration of where all the plants power output would be sold, but
bringing a new coal plant online in the late 2000s was never going to be easy. I would think there was always some concern, said Tim Riordan, vice president of engineering services for AEP, because much of this was going to have to be decided in the court system or with commissions or other federal agencies and of course we dont have control over that. Still, it wasnt just a regulatory victory when the plant finally went into service on December 20, 2012. The event was
www.power-eng.com
AEPs Turk is one of the most efficient, least polluting coal-fired power plants on the planet.
also a technological victory: AEP had succeeded in bringing online the most efficient coal-fired commercial power plant ever built. The 600 MW Turk Power Plant is situated in Hempstead County, in the southwestern corner of Arkansas, where it employs 109 people on a total payroll of $9 million and pumps $6 million in school and county property tax revenues every year, according to AEP. Through its subsidiary the Southwestern Electric
Power Co., or SWEPCO, supercriticalis that it works just like which operates the facility, a supercritical power plant, only better. AEP invested $1.3 billion As an ultra-supercritical coal-fired power of the $1.8 billion required plant, Turk operates at extraordinarily to build the plant and the high pressures and temperatures, well company now owns 73 above typical supercritical pressures of percent of its output. The around 4,500 psi and hotter than 1050 remaining ownership is degrees Fahrenheit. As you increase temperature you divided between the Arkansas Electric increase your efCooperative Corp., This could very well ficiencies, Riorthe East Texas Elecdan explained. By tric Cooperative, be one of the last working at such a and the Oklahoma conventional coal high temperature Municipal Power burning facilities built Authority. and pressure, Turk in the country. The atachieves the high- Tim Riordan, AEP tribute that makes est efficiencies Turk unique among power plantsthat around in coal power generation today; gives cause to append the word ultra according to AEP, between 39 and 40 to the preexisting and more familiar percent of the thermal energy available
Welcome to the Family

Like its big brothers before it, Ingersoll Rands newest rotary compressorthe R-Series 37-45 kWcombines the best time-proven designs with advanced components. Features such as Progressive Adaptive Control (PAC) that continuously monitors and adapts compressor performance, sequential coolers that improve servicability and web-enabled compressor controls continue the family tradition of delivering proven reliability, efciency and maximum productivity.
R-Series 37-45 kW Rotary Compressor
www.ingersollrandproducts.com
Drew Smith, machinist, performs maintenance on one of the Turk Plants six coal pulverizers.
tested to withstand the pressure and temperature of an ultra-supercritical power plant. For use in the facility materials need to have high creep rupture strength, resistance against embrittlement, and low oxidation growth in addition to ease of manufacture and availability. High chrome, creep strength enhanced ferritic steels (CSEF), and nickel based alloys meet these needs, Riordan said. Working with both the original equipment manufacturers and with EPRI (the Electric Power Research Institute), and other research groups, AEP worked to understand these componentslike boiler headers, main steam lines, and blade componentsfor their weldability and long term creep strength, Riordan said. There was quite a bit of R&D work. In constructing Turk, AEP bought the major components, like the boiler turbine and environmental control equipment, before its EPC agreement
in the fuel comes out as electric power. This level of efficiency in extracting energy from coal allows Turk to use less of the stuff to produce the same amount of power. Less coal burned means less emissions of sulfur dioxide, nitrogen oxide, mercury, carbon dioxide and particulate matter. It also means fewer waste products and less fly ash, and decreased need for the commodities used in environmental control activities, like activated carbon and ammonia. The reduction in pollutants is combined with the latest emission-control technologies,
Joey White, machinist, works to move some of the Turk Plants emissions control equipment into place.
like catalytic reduction systems, dry flue gas desulfurization, baghouse technology to combat particulate releases and activated carbon injection to reduce Hg emissions. The end result is one of the most efficient, least polluting coal-fired power plants on the planet. Achieving super-high temperatures and pressures wasnt as easy as just dialing up the heat. Special materials had to be
www.power-eng.com
16
with Shaw was completed. Afterwards, however, Shaw led construction on everything but the boiler, in addition to completing engineering details and integration of the facility. The boiler, along with the baghouse, dry scrubber, and selective catalytic reduction unit, were all provided by Babcock & Wilcox, while Alstom provided the main turbine and generator in addition to the feed pump turbine. In designing and constructing Turk, AEP included input from operating staff to ensure the innovative facility didnt just make sense from an economic and regulatory perspective, but from an ergonomical perspective too. Design plans gave consideration to something as simple as making sure that headroom was sufficient to safely remove motors or maintain equipment. Many times with an EPC contract the footprints get smaller and smaller because of cost concerns, Riordan said. We spent a lot of time with our engineer of record, Shaw, to make sure that we had a very safe and
maintainable facility. You really dont want people standing on hand rails to operate a valve, right? As to whether or not there will ever be another American plant like Turk, Riordan isnt optimistic. I would hope so. Unfortunately
with the new environmental rules for new generating facilities, the proposed CO2 limits are probably going to prevent that from happening in the near term, he said. This could very well be one of the last conventional coal burning facilities built in the country.
Generating Solutions for
Y E A R S 1983-2013
Over the past 30 years, Structural Integrity has built a team of over 200 industry experts providing comprehensive solutions to the energy industry. We have innovative products and services for combined cycle, fossil, nuclear and hydro power plants, in addition to oil and gas pipelines. Our clients look to us for our: Industry knowledge of power plants, codes and how things work, Extensive experience and leadership, High quality, hard work and service. Call us today and well generate a solution for you.
877-474-7693 (877-4SI-POWER)
www.structint.com/power-eng
Scan the QR Code for more information
www.power-eng.com
17
WHAT WORKS
Dealing with Scale Buildup

BY SANDI HAGUE, HAGUEDIRECT LLC
bout two years ago, a power plant in Georgia pulled covers to inspect eight of their A/C chillers and found that they showed substantial scale buildup on the inner surfaces of the tubes, the outer surfaces and the tube facings. The buildup resisted the facilitys standard mechanical cleaning procedures. The tubes inner diameters were narrowed to the point where adequately sized cleaning brushes could not be inserted into the tubes. The power company asked Augusta Industrial Services, Inc., which services nuclear power plants throughout the southeastern United States, to help find a solution. Augusta Industrial Services, based in Augusta, Georgia, visited the plant to investigate the situation. The tube bundles were so bad fouled with scale and grit that you couldnt put the correct brush in the chiller to clean it. Therefore the regular mechanical cleaning method was out of the question, explains Augustas supervisor Shawn Conklin. Often power plants will allow the chiller tubes to be cleaned by hydro blasting, but that method was not an option in this situation. The number one concern is safety, and with the possibility of puncturing a tube by hydro blasting, the plants engineers would not allow us to use high pressure water on these chillers, said Conklin. The power company asked Augusta Industrial Services to find a chemical cleaning solution for clearing out the tubes. Two of Augustas on site supervisors (Shawn Conklin and Taylor Smoot) conducted its research. After considering the alternatives and discussing them with the plants engineers, they received
approval to call Goodway Technologies Corp. to request a sample of the chemical ScaleBreak for testing. All involved parties liked that the independent studies showed that ScaleBreak dissolves calcium deposits, rust, lime and lithium carbonate on contact without damaging the equipment being serviced. Augusta Industrial Services test-cleaning consisted of several chunks of the deposit, that was scrapped off of the tube face, being placed into a beaker and then adding a capful of the ScaleBreak at a time until the pieces started to. As the test-cleaning satisfied the engineering staff, the Augusta supervisors were given the approval to proceed with an initial order of ScaleBreak and the cleaning of one unit. Actually, the first time we cleaned it we mixed it wrong we were told the unit capacity was 400 gallons, but it was really 700 gallons, so our mixture was too weak. Even so, it was already starting to remove some scale, said Conklin. So we had more ScaleBreak shipped to us overnight. We got the calculations right, circulated it for four hours, drained it, rinsed it, and we just couldnt believe how clean it was we were really surprised. Conklins crew ordered more ScaleBreak and took care of the other seven chillers without any difficulties. Conklin explains how the process works. We calculate the tube bundles volume anywhere between 150 gallons to 1,000 gallons then we calculate how much ScaleBreak versus water to use. Right now we like to use a 60-40 mixture 60 percent ScaleBreak and 40 percent water. That works out really well for us. Conklin continues. Conklin said they circulate the
solution with a machine which is similar to a swimming pool pump. After four hours of cleaning, his team checks the condition of the tubes. If it needs more, then well use a slightly stronger solution and circulate it for another two hours or so, he said. Conklin said the cleaning method is very safe. We keep the chemical solution in the tube bundle and circulate it from there to our cleaning equipment, he said. Its cut off from all the other equipment, so theres no contamination no safety issue. The formula includes corrosion inhibitors and is approved for use on steel, iron, brass, copper, plastic and rubber. Specially formulated ScaleBreak-SS is safe for stainless steel. Augusta Industrial Services reports that chemical cleaning is economical. Conklin said thats because circulating the chemicals is a much faster method than standard manual cleaning. After the first thorough cleaning, subsequent visits often take less time. Next time we come out we might cut the time in half it could take only two hours of descaling to clean everything, he says. ScaleBreak does not contain toxic cresols or other tar oils that need SARA Title III, Section 313 spill loss or disposal reporting. The waste product is mildly acidic and contains only nontoxic salts after being used to remove potable water scale. It rinses easily with water and requires no special equipment for handling. Conklin also likes that chemical cleaning can take less of a toll on his crew. Mechanical cleaning and hydroblasting are physically taxing methods, and fatigue can contribute to accidents. ScaleBreaks formulation makes it a safe choice for service personnel, since they dont have to deal with caustic chemicals or noxious fumes.
www.power-eng.com
18
Make Pollution Control Affordable with Sturtevants FGT.

Reduces Sorbent Usage by 30% Dependable Sorbent Milling
The Simpactor FGT has the highest capacity and produces the nest cuts with a PSD range of d50 15M and lower. The Simpactor FGT addresses all concerns of milling dry sorbents: dependability, maintenance, power consumption and capital cost.
Added benets:
Coolest milling process to keep sorbents below 120 F Least internal mill build up of sorbent Lowest wear rate of internal mill impact parts and drive system Best suited for 24/7 adverse climate operation Easy to operate: Adjust grind while in operation
For 130 years, Sturtevant has been recognized internationally as a premier manufacturer of custom size reduction and air classication equipment to the powder processing industry.
Please visit Sturtevants website for more information on the Simpactor pin mill.
348 Circuit Street Hanover, MA 02339 T (781)829-6501

www.sturtevantinc.com
20
www.power-eng.com
The Sturtevant DSI pin mill reduces sorbent to a fine particle size, which is used to lower emissions of sulfur dioxide, sulfur trioxide and hydrogen chloride. Photo courtesy of Sturtevant
Extending the Life
COAL FIRED through PLANTS the use of Dry Sorbent Injection

of
BY STEVE COULOMBE, PRODUCT MANAGER FOR DSI MILLS AT STURTEVANT
perators of coal fired power plants have a lot to worry about today: The price of coal relative to natural gas, stack emissions, EPA regulations and the unpredictable nature of future potential regulations. With an uncertain future, one question hangs in the balance: is it economical to maintain a coal fired power plant and reduce its stack emissions? This tough question is driving trends towards plant upgrades, early plant retirement and conversion to natural gas as solutions to control pollution. Producers of coal fired power are experiencing two hidden costs to early plant retirement or conversion which are important to understand. The first is the unpredictability of the future cost of natural gas and the second is the
risk of prematurely converting a plant to natural gas and facing the unaffordable cost to convert back if the price and availability of natural gas becomes uneconomical. These choices have significant impact on the plants operational costs and the economy. An alternative to avoid these issues is to use Dry sorbent injection (DSI). Dry sorbent injection is a pollution control technology that plays a role in the U.S. power sectors compliance with the Mercury and Air Toxics Standard (MATS). The Environmental Protection Agency (EPA) finalized the MATS rule in December 2011. The MATS rule requires that all U.S. coal- and oil-fired power plants greater than 25 megawatts meet emission limits consistent with the average performance of the top 12 percent of existing units, known as the maximum achievable control
www.power-eng.com
21
technology (MACT). The rule applies to three pollutants: mercury (Hg), hydrochloric acid (HCl), and filterable particulate matter (fPM) and has a compliance deadline in 2015 (with opportunities for additional compliance time depending upon case-by-case circumstances). While DSI systems do not control mercury, they can, when combined with a particulate control filter, meet this standard for two of the three controlled pollutants. DSI systems remove hydrogen chloride (HCl) and other acid gases like SO2 and SO3, through two basic steps. Step one. A powdered alkaline sorbent is injected into the flue gas (combustion exhaust gas exiting a power plant) where it reacts with the HCl and SOx. The sorbents most commonly associated with DSI are trona (sodium sesquicarbonate, a
naturally occurring mineral mined in Wyoming), sodium bicarbonate, and hydrated lime. Step two. The compound formed by the alkaline sorbent and the acidic gas is removed by a downstream particulate matter control device such as an electrostatic precipitator (ESP) or a fabric filter (FF), also referred to as a bag house. Testing has demonstrated that fabric filters are more effective (when combined with DSI) than ESPs, with respect to overall HCl and SOx reduction. For modeling purposes, the EPA estimates a DSI system with a fabric filter is expected to achieve 90% removal of HCl, while an ESP only achieves 60 percent removal, although actual performance will vary by individual plant. As mentioned, DSI systems can also significantly reduce sulfur dioxide
(SO2) or sulfur trioxide (SO3) emissions through the same process as HCl removal. While the MATS rule does not specifically address SO2 or SO3, it has similar qualities to HCl and other acid gases that enable it to respond similarly in a DSI system. SO2 and SO3 are also regulated under the Cross State Air Pollution Rule (CSAPR). Therefore, installing a DSI system to comply with MATS will also help plants meet or even exceed their CSAPR emission limits.
THE APPLICATION OF A MILL IN PROCESSING SORBENTS FOR DSI

Dry Sorbent Injection, is part of a Flue Gas Desulfurization system (FGD), capable of SO2 and SO3 mitigation, as well as HCl, and mercury removal depending on sorbent
DE-SCALE
WITHOUT FAIL.
Goodway ScaleBreak removes tough scale build-up quickly, safely and easily.
www.dresser-rand.com
Dissolve calcium, lime, rust, lithium carbonate and more Increases system efficiency Safe for use on steel, iron, brass, copper, plastic and rubber Special formulation available for use on stainless steel Use on power plant surface condensers, boilers, chillers, heat exchangers, and more
GIMPEL TRIP AND THROTTLE VALVES & PARTS

Gimpel parts, service and new valves incorporate the latest technology to provide safe, reliable throttling and critical over-speed protection for marine, power generation, oil & gas, and general industrial applications.
888 364-7749
THE BEST WAY IS
www.goodway.com/ descaler
22
Get the right answer, right now!
Call Dresser-Rand at Intl +1 713-467-2221 or Intl +49 208-65-6020 or visit: www.dresser-rand.com/products/gimpel/

www.power-eng.com
SentrySeries Goal Based ISB Control Systems

...beyond intelligent sootblowing
Designed to meet todays boiler cleaning needs by responding to changing operating conditions, changes like fuel switching, fuel blending, even swings in power demand!
Convection / Backpass Goals

Goal Tracking with Reduced EGOT Balancing & Optimizing Steam Temperatures Priority Sootblowing
Convection
Furnace Goals
Goal Tracking with Reduced FEGT Thermal Impact Monitoring Priority Sootblowing by Determining Furnace Slagging Patterns
Furnace
SentrySeries Goal Based ISB works to YOUR GOALS!

740.687.4334
2013 Diamond Power International, Inc. All rights reserved.
The Ghent Generating Station is a coal-fired power plant owned and operated by Kentucky Utilities near Carrollton, Ky. Dry sorbent injection systems were installed to comply with new federal emission standards. A Trona mill system led to a 30 percent decrease in sorbent usage. Photo courtesy of Sturtevant
selections. DSI treatment for mercury and Sodium Bicarbonate (SBC), removal is similar to other forms of although hydrated lime or limestone, FGD but uses either powder activated if locally obtained, can be a viable carbon reactant or Amended Silicates, solution. SBC must be milled (ground a patented process for mercury remov- finer), and Trona should be milled al. Formed particulate is then captured for maximum effect. The purposed of in the same way that other DSI systems milling is both to reduce the amount capture their reacted compounds as of sorbent consumed by the system described above. When investigating and increase the sorbent surface area the use of a DSI system the first con- which increases the availability of a sideration is typically the cost to oper- reactive particle surface. As SO3 is ate the system. A DSI system has a far eliminated, blue plumes from sulfuric less cost to operate and install than a acid disappear, boilers run more wet scrubber system efficient, system Research has for power plants, incorrosion is lowered dustrial boilers, in- shown that the and mercury can be cinerators or co-fired capital and removed more easily. plants that are only A variety of sorbents installation costs partially converting can be blended, to natural gas fired, to operate a DSI as supplied to the or undecided to con- system are only on-site mill before vert, or may want to DSI, or milled and 10% on average. fire oil or coal for 5 or injected separately if more years. Research has shown that optimum injection points need to be the capital and installation costs to op- considered. SO2 removal to levels of erate a DSI system are only 10 percent 95 percent can help control acid rain on average, compared to that of a wet and is also a good reason to consider a scrubber system. DSI system with milling. SOx is mitigated most effectively With the advent of the MATS and the by alkaline type sorbents like Trona ongoing EPA rule changes, litigation
and state regulations, considering a DSI and mill can bring a plant quickly into a safe condition to comply cost effectively while still keeping all options open to future alternative fuel choices. Operators have found that relieving the pressure of making an early conversion decision, potentially pre-maturely, will save significant money and jobs for plant facilities due to less closures while meeting the future energy demands of the community. DSI with mill systems can be pre-tested by engineering firms specializing in DSI installations and has proven its effectiveness over the last 10 years throughout the U.S.A. Milled DSI systems have been installed for over twelve years and maintain constant operation. These mills are specially designed to meet both the rigors of DSI and the needs of the power generation community. It is important to understand that general, commercially available mills, are designed for many applications. These applications do not necessarily reflect the needs of power generators. The typical system installed for DSI
www.power-eng.com
24
Congratulations... POWER-GEN Project of the Year AWARD WINNERS

2010 Best Gas-Fired Project
Sendai Thermal Power Station Tohoku-Electric Power Company (1) x Mitsubishi M701F4 Gas Turbine (1) x Mitsubishi TC2F-40.5 Steam Turbine
Mitsubishi is proud to be a contributing part of your industry wide performance recognition.

Kawasaki Thermal Power Station Tokyo Electric Power Company (3) x Mitsubishi M701G2 Gas Turbines (3) x Mitsubishi TC2F-35.4 Steam Turbines
2012 Best Biomass Project

Nacogdoches Generating Facility Southern Power Company (1) x Mitsubishi 116MW SC1F-36 Steam Turbine

High Bridge Plant (Runner-up) Xcel Energy (2) x Mitsubishi M501F Gas Turbines (1) x Mitsubishi TC2F-40 Steam Turbine
2012 Best Coal-Fired Project

Dry Fork Station (Runner-up)
2008 Best Renewable Project
Lee County Waste to Energy Expansion Project Lee County Government Southwest Florida (1) x Mitsubishi SC1F Steam Turbine
Basin Electric Co-Op & Wyoming Municipal Power Agency (1) x Mitsubishi 420MW TC2F-40 Steam Turbine
Visit mpshq.com for Rewarding Career Opportunities

www.mpshq.com
will be installed in an out-building with no temperature control and must be operated 24/7 with minimum down time or cleaning time. Manufacturers have designed unique features to these mills to make them suitable for DSI. Some typical features include rotating round pin sections to minimize the wear caused by milling naturally occurring minerals which have abrasive properties, special metal coatings which also minimize wear and pre-heating and cooling systems for plants operating in ambient temperatures below 40F or above 90F. An important consideration in DSI systems is designing for use of these specific-duty pin mills. . The benefit of using a pin mill is in its ability to offer the smallest particle sizes to increase the reactive surface area and help the plant consume less sorbent. A pin mill for DSI operates by blowing
sorbent into the top of the mill using a pneumatic conveying system. The sorbent then enters the mill where one rotor with a set of pins rotates between a second, stationary rotor. The sorbent works itself through pressure and force from the inside of the rotor to the outside of the rotor where the action of the pins reduces the particle size. Fine particles exit the outer edge of the rotor where they are then blown into the process to be added to back to the DSI system for injection. This simple process is the heart of DSI systems as it is responsible for controlling the effectiveness of the removal of gasses from the system. Particle size reduction has a key role in FGD and understanding the part sorbent milling plays in trona systems is the best example. A typical example of DSI is the use of milled trona. Supplier-delivered trona
with a particle distribution where 50 percent of the particle size is 30m or less (referred to as d50) has an average perparticle surface area of about 2,800m2. The advantage of operating a DSI system is by reducing ongoing operating costs. This is where the pin mill plays its key role. A pin mill is capable of reducing the d50 from 30m to 7m which, in a single particle, is the equivalent of reducing a dust particle to the size of a red blood cell. This reduction in size has an exponential impact on particle surface area by volume, increasing the reactive surface area from about 4,000in2 to 20,000in2 for equivalent mass. When considering the future of coaland oil-fired power, alternatives to conversion and early retirement exist. DSI is affordable, compliant and easy to operate and should be considered when planning the future of any plant.
Your trusted partner for bolted joints

The Nord-Lock Group is a world leader in bolt securing systems. We offer a unique combination of bolting expertise and a wide product range, including wedge-locking solutions and Superbolt tensioners. Discover safe and easy bolting for your critical applications today!
NEW VIDEO & BROCHURE available now!
www.nord-lock.com

26 www.power-eng.com
Less maintenance.
Its no coincidence that New York Blower fans and blowers perform well many years after their initial installation. In addition to superior construction, our industrial fans are specially designed to perform in the harshest and most demanding conditions. F For o example, our radial tip RTS fan features a robust radial tip design to combat the effects s of abrasion, so you dont have to shut down as often for regularly scheduled maintenance. ce. . Get specs for this fan and our entire product ct line at nyb.com or call 800.208.7918. l
ABRASION-RESISTANT CONSTRUCTION TO MINIMIZE WEAR TO THE RTS WHEEL RADIAL TIP RTS FAN RADIAL F N FA
THE NEW YORK BLOWER FAMILY OF COMPANIES MAS Air Systems Alphair Ventilating Systems TLT-Babcock Mechanovent
If slag is allowed to build up inside a boiler, it can lead not only to efficiency problems but can also cause damage because of the weight. Photo courtesy of Norm Harty.
BY JUSTIN MARTINO, ASSOCIATE EDITOR
N
28
early 50 years ago, Norm Harty, president of N.B. Harty General Contractors Inc., was a driller and dynamite blaster for road and railway construction when Kenneth Bridegroom, a supervisor at a power plant where Harty was subcontracting, asked if dynamite could be used to clean the inside of a boiler. Back then I was hungry, Harty
said. I was really, really searching for anything. Although Harty had never seen the inside of a power plant before, he told Bridegroom he could do the job. After a labor strike and a buildup of slag prompted the plant to contact Harty, he used dynamite to remove a slag deposit, inventing the process as he went along. I didnt really realize exactly what I had done, but Bridegroom did, he
said. The rest is history. The next thing I knew I was going all over the east doing this, and it was all by word of mouth. Harty used his technique for 17 years before he had any competitors attempting to use the same process. Using dynamite is still an option for power plants, and Hartys company cleans nearly 100 boilers a year. Other operators are looking at different methods that have been developed
www.power-eng.com
RE L O ADE D
Norm Harty has been using explosives to clean boilers for nearly 50 years, which helps increase boiler efficiency and heat transfer. Photo courtesy of Norm Harty.
to clean boiler tubes without taking the plant offline, including improving the soot blowers located in the boiler. Whichever methods is chosen, however, the importance of keeping a clean boiler is not in question.
THE IMPORTANCE OF BOILER TUBE CLEANING

Power plants burning anything other than natural gas will, over time, build up ash that forms slag deposits on the exterior of the tubes running through the boiler. The slag can be a safety hazard the tubes expand and contract as they heat up and cool down and the deposits may break off and fall, a problem that arises most notably when a plant is taken offline for
maintenance, Harty said. Dirty boiler tubes can also affect the operation of a plant. Slag buildup on tubes will act as an insulation protecting the tube from the heat of the boiler, requiring more fuel to reach the same temperature and produce the same output as a clean boiler. Harty said cleaning the slag deposits inside a boiler can increase boiler efficiency from 1 percent to 4 percent. Even 2 to 3 percent in a boiler that generates 600 MW, thats hundreds of thousands of dollars each day or week, he said. Theyre still burning the coal, but the coal fire doesnt get to the tube. Clean boilers can also help reduce the emissions produced by the plant
because less fuel is needed to produce the same amount of power, according to Tim Martin, Director of Product Management for Clyde Bergemann Power Group Americas Inc., Boiler Efficiency Division.
FUEL SWITCHES LEADING TO SLAG DEPOSITS

Slag deposits can be caused by multiple sources. Harty said older boilers, especially in the eastern U.S., were much smaller because the plants were burning high-sulfur eastern coal with a high Btu output. Less fuel was needed to produce the required heat, and the boilers did not produce as much ash. The high-sulfur coal released more
www.power-eng.com
30
Heavy-duty flange configuration is designed to perform reliably in service pressures up to 5000 psig (345 bar).
Full-penetration chamber welds meet ASME Section IX and B31 construction and inspection requirements.
Attraction sleeve
Stainless steel enclosing tube (cutaway)
Design Excellence in the Details Makes Magnetrol the Leader for Trouble-Free Performance.
Take a closer look at MAGNETROL-tough liquid level switches, the No. 1 brand of mechanical buoyancy instrumentation. The fact is, MAGNETROL switches work hard, and keep on working, for decades of safe, accurate, repeatable, reliable level detection.
Entrust your operations safety and performance to MAGNETROL the rst name in durable, reliable mechanical buoyancy liquid level switches.
Magnet
The stainless steel enclosing tube completely isolates the switch magnet from the process environment, preventing interference with the magnet, while allowing reliable magnetic coupling with the attraction sleeve.
pollutants into the air, so plants began using western coal, such as Powder River Basin coal, in their fuel mix. Western coals create more ash and produces less Btus, requiring more fuel for the same temperature. Plants that burn lignite, often located along the Missouri River, require even more fuel. Those boilers might be twice as large as a Midwest plant built to burn western coal and three or four times as large as plants built to burn eastern coal, many of which are being decommissioned right now, Harty said. Fuel switches can create a problem in a plant. If more ash is produced than the plants current system can handle, the slag buildup can become uncontrollable over time. This can happen when units are burning Powder River Basin coals or other coals that have
low melting points for the ash or sig- cleaning the boilers have changed. nificant sodium levels, which makes Although coal plants previous ran at the ash more tenafull load as much as cious in areas such as The boiler possible, the drop the convection pass, eventually cant in price of natural said Joel Booher, a take it anymore, gas has caused many business manager for owners to cycle the and youll have Diamond Power. plants more so that Unless the fur- uncontrollable slag theyre not always nace box is very formation. running at full load. large, what youll see Its been a huge - Joel Booher is the boiler eventuchange in the way ally cant take it anymore, and youll the coal plants are operated, Booher have uncontrollable slag formation, said. Not only is natural gas at record Booher said. That was what we were lows, which causes coal plants to be fighting against. dispatched lower, but theres also extensive renewables online now. So in a CHANGES IN THE WAY place like Texas, where many large coal COAL PLANTS ARE USED plants are designed to run full load, As power plants operators use coal these are now up and down on load. plants differently, the methods of Harty said that bringing the boiler
32
www.power-eng.com
down and back up can create some efficiency for the plant by partially removing the slag through cycling. Boiler tubes will expand up to 18 inches from top to bottom when hot, and the expansion and contraction of the tubecan knock off slag. Jeff Kite, principal engineer for boiler performance at Diamond Power, said boilers in plants that are being cycled more often dont have to be cleaned as often, but the boilers were not designed to be cycled so it makes it difficult on operations in general. Supercritical units do not easily accommodate being asked to go from full load to half load on a regular basis, Booher added. Theyre designed to be run at stable high loads, and its hard on the metal throughout the boiler to be cycled up and down.
said. Once slag becomes a problem, their cleaning devices arent strong enough or in the proper location to remove it. If buildup reaches a point the online cleaning products installed by the plant are unable to remove the slag, the plant must be taken offline for cleaning. Offline cleaning may involve water jets, compressed air or dynamite.
USING DYNAMITE TO CLEAN BOILER TUBES

Harty said that older methods being used for offline cleaning when he first started cleaning boilers were very crude and could involve using shotguns to fire slugs at tubes to knock off slag or using a large iron ball suspended on a chain or chisels and hammers to strike the tubes to remove any build up. It was one massive thing to do, and it was very dangerous, he said. They had a lot of people get hurt. Modern methods of offline boiler tube cleaning have made many improvements over older methods, and Harty said using dynamite as a method of offline cleaning has multiple advantages over other methods, such as high-pressure water, with one of those being that no moisture is introduced into the boiler. The water and moisture will go down into the ash tanks and set like concrete because that slag is in such a fine state, he said. They buy that right now to put in concrete and strengthen the concrete. If you dry clean it with explosives, you dont have any moisture and the slag will fall into the hopper and down into the grinder and out the sluice area. Harty also said he can reduce downtime for plants that have to be taken offline for cleaning. Whereas using high pressure water requires setting up pipes and hoses, dynamite can be
CURRENT CLEANING SYSTEMS

Most power plants have some sort of soot blower system that works to clean the plant when the boiler is online and producing power, Martin said. Soot blower systems have been around since at least the 1930s, he said, adding that he has seen photographs of soot blowers that were operated by a chain raised and lowered by a hand-operated crank. Soot blowers and other online cleaning systems use compressed air, steam or water to keep slag buildup from occurring without the necessity of taking the plant offline. As companies look for solutions that allow the plant to keep operating, newer soot blowing systems may allow a plant to keep its boilers clean without requiring a planned maintenance where the boiler is taken offline, although older systems may require a shutdown for cleaning. Some of the online cleaning products might be 20 years old, Martin
www.power-eng.com
used quickly and with less equipment. He added that his company recently cleaned a boiler in Nevada in less than 36 hours. Downtime is money, he said. Downtime is loss of revenue. Thats why they want you in and want you out. Using dynamite to clean slag is
popular in western coal plants because of the need to conserve water, he said. Water is really scarce out west, and this is another reason explosives are being used predominately in the western plants, he said. They cant afford to waste a drop of water, and by using dynamite theyre able to save their water and clean their boiler.
In order to clean a tube using explosives, Harty said his company will use primer cord around tubs that are close together to avoid damage. The cord has connectors that will delay the charges. Without using the connectors, he said the process could destroy the wall or insulation of the boiler. Sticks of dynamite can be used
Although soot cleaning systems may be used to clean a boiler without taking it offline, a plant with older online systems may require a shutdown. Photo courtesy of Norm Harty.
34
Just as in nature, size has evolved into a distinct advantage in harsh climates.
Big and powerful, the Siemens SGT6-2000E provides reliable power from the frozen arctic to the searing desert.
Its -45F outside and you need to keep the bitumen owing. Now is not the time to skimp on power. The Siemens SGT6-2000E delivers all the power you need, wherever and whenever you need it. With more than 30 years of experience on hundreds of
applications, the SGT6-2000E has proven itself time and time again. Its advanced technology is extremely durable, robust and exible. It offers high-efciency output and low nitrogen oxide emissions. And thats great news for any environment on earth.
siemens.com/energy
in more open places where there is a heavy amount of slag. Harty said he has seen slag reach 60 to 70 feet deep in some boilers. At one point, his company cleaned 150 truckloads of slag from a boiler, though he called that an extreme case.
IMPROVEMENTS IN ONLINE BOILER CLEANING

Many companies would prefer to not take their plants offline for cleaning, and both Diamond Power and Clyde Bergemann have developed online cleaning solutions that are improvements over the previous soot blowers. Previous soot blowers had simplistic controls, Kite said. Although the operator of the system was able to
make a sequence and run the devices in order, operators were unable to get any sort of feedback without a visual inspection of the boiler. Realistically, it wasnt until the 90s that we started implementing heat transfer sensors, which are devices made out of sections of boiler tubing placed within the cleaning radius of the water lances that provide feedback of heat transfer and can be used to determine how clean or dirty that section is, Kite said. Older soot blower systems might also utilize an across-the-boiler system, where a nozzle will need to spray water across a 60-foot space in order to reach the place that needed to be cleaned. That system might use 200 gallons of water per minute, which,
after hitting the hot boiler tube, could create more steam than the boiler could handle and even cause a change in the power produced by the boiler. Many units have induced draft fans that really run on the ragged edge, and they cant handle that extra gas volume going through there, Booher said. Oftentimes these high-flow cleaning devices can cause disturbances of the unit.
Modern systems use a variety of solutions to create intelligent soot blowing, which can help prevent outages and damage to the boiler.
- Jeff Kite, Diamond Power
Modern systems can use retractable soot blowers, such as Diamonds Power HydroJet water cleaning systems, allowing less water to be used since less force can be used over the shorter distance. Systems using retractable soot blowers can create a 60 or 70 percent water use reduction and provide as much or better cleaning effectiveness, Kite said. The systems can also interpret where the boiler is developing a buildup of slag, which can help operators avoid attempting to clean sections of tube that are already clean. If water or steam hits a clean section of a boiler tube, it can cause tube erosion over time. Cold water hitting a hot tube can also cause the tube to contract, leading to tube damage and a possible blow out. Water cleaning can damage tubes if done improperly, Kite said. If an operator has this wonderful tool that can clean his boiler, he has a habit of using it too much if he doesnt have input coming back to him letting him know whats going on.

36 www.power-eng.com
Modern systems use a variety of solutions to provide intelligent soot blowing, which can help prevent outages and damage to the boiler.
GOAL-BASED INTELLIGENT SOOT BLOWING

Intelligent soot blowing, or ISB, uses automatic control systems to analyze the cleaning needs of the boiler. Introduced in the 90s, it is becoming the standard for boilers, Booher said, with many new boilers using an ISB system. Improvements can still be made on previous generation of intelligent soot blowing systems, however. What is coming to light is that these systems can be complicated in their calculations, and so they can
be difficult for the operations staff to understand in order to make the right decisions, he said. Goal-based ISB uses intelligent soot blowing to achieve the goals the operators already want to achieve keeping steam temperature in the right range or keeping their gas temperatures in the right range. Its simpler and quicker to commission. Although gas temperature may be a common goal for many boiler operators, Booher said different operators may have a different goal that is important to them. Diamond Power will work with the plant engineering staff to configure the ISB system, and if a goal can be quantified, it can be incorporated into the system. Once the system is in place, it will analyze data from individual cleaning
devices installed in the system and that devices ability to impact the goals set by the plant operator. Ultimately, the system will allow an operator to clean tubes only when and where they need cleaning. The idea would be to use it as little as possible because it can cause damage to the unit, Booher said. If the system can automatically determine where to clean and which blowers make the biggest effect, then in the end you can end up blowing less soot blowers to maintain the same general boiler cleanliness.
VARIABLE PRESSURE BLOWERS

Clyde Bergemann has also introduced a variation in intelligent soot
Get the most out of your sorbent with particle milling
Your pollution mitigation solution not only has to be guaranteed efective in meeting regulations, it must also be economical. Nol-Tecs fexible system designs can include pin and air classifying mills to increase the efectiveness of the sorbent, meaning youll use less. So youll meet standards and manage costs with one design solution.
Dry Sorbent Injection Portable Test Systems designed for your specific system requirements
MATS and MACT compliant mitigation of Flexible design to meet your precise needs Reliable, automated operation and control Scalable installation to cover scope of any system Call 651-780-8600 today to begin an analysis of your pollution mitigation needs.
Sorb-N-Ject
Hg SO2 SO3 HCI HF

Customized innovation based on proven technology
Nol-Tec Systems, Inc. 425 Apollo Drive Lino Lakes, MN 55014 651.780.8600 sales@nol-tec.com
www.nol-tec.com

www.power-eng.com 37
blowing that uses variable pressure when cleaning boiler tubes. Martin said the goal of the system is to provide just enough pressure to clean the tube to avoid creating any damage. We could go in with a very, very high pressure, and we know that whatever is on the tube is going to be cleaned, but theres a downside to that, and thats tube erosion, he said. What the SMART Clean does is look at cleaning with the proper intensity. We clean with just enough intensity to clean the ash off the tube, but not too much intensity to cause tube erosion. The system is designed to create maximum efficiency for the plant. By keeping slag from building up on the tubes, the plant is able to operate with maximum heat transfer, and by avoiding erosion, the operator can prevent future tube leaks that can shut down the boiler in a forced outage. Martin said the system can save money for a plant operator by completely eliminating planned outages to clean the tubes. He said the company has clients with boilers that were going offline every three months who eliminated the problem by installing the SMART Clean system. Those boilers only come down for typical maintenance issues now, he said. He added the system is not a large investment for a boiler operator, and the investment will be returned within six months to a year, with the owner of the boiler receiving the benefits of not requiring outages for the next 20 years. Each job requires a different approach, and not all of the SMART Clean products may not be necessary. We use a lot of different techniques, Martin said. Some are more advanced than others. Really, every boiler is unique. We look at it from a fresh perspective and look at their specific needs, and then we can propose the right technology to meet those needs.
INTERIOR TUBE CLEANING

Although cleaning slag from the inside of the boiler and exterior of the boiler tubes is a key aspect of keeping a boiler efficient, cleaning any deposits that may form on the interior of the tubes is also important. If deposits from impurities in the water form on the interior of a tube, it can create an insulation problem, according to George Bodman of George H. Bodman Inc. if you put a tenth of an inch of scale in there, your temperature will go from 600 degrees farenheit to probably 700 to 750 degrees farenheit, he said. If that tube gets to 809 degrees farenheit, the tube is going to blow out. Scaling can also reduce the efficiency of the boiler by requiring more heat, and corrosion can form under the scale that will create a hole in the tube itself. The process of removing the scale is individualized for each tube, Bodman said, and the preplanning for the cleaning should start at least six months in advance by getting a tube sample of the boiler. The sample can be used to determine the deposit weight density as well as the scale matrix. Bodman said he also talks to the water treatment representatives to find out what has previously been done and why the deposit has formed. The next step after that is to speak with plant personnel and the plant chemist or relibility engineer to set up a program on how to remove the deposit. Around 90 percent of boilers are are currently chemically cleaned, Bodman said, although some can be cleaned with high-pressure water. Plant operators can choose to use a variety of chemicals, including hydrochloric acid, ethalene diamene tetracedic acid (EDTA) and hydroxyaceticformic acid. EDTA is more expensive, but also has less environmental impact, Bodman said. It requires 13.6 pounds of EDTA
to remove one pound of iron oxide. The same amount of iron oxide can be removed by 2.5 pounds of citric acid or 1.58 pounds of hydrochloric acid. When you look at costs, I can clean a 30,000 gallon boiler for around $50,000 to $60,000, he said. Cleaning that same boiler with EDTA will cost you over $100,000. Bodman said his company will run solubility tests with hydrocholic acid, citric acid and EDTA and allow the company to choose the method used. Once the cleaning starts, he said it takes approximately 2 to 3.5 days. Depending on the boiler and water treatment, some boilers require cleaning every two years, while other boilers, like ones used in paper mills, may be cleaned every five to seven years.
A VARIETY OF OPTIONS
Although boiler tube cleaning is a very important part of the industry, choosing the right method for a boiler is up to the operator. Modern advances in the industry, however, can make the process simpler and safer than it used to be, however. Soot blowing has really changed over the years, going from a product that you just install and turn on into really getting more into the engineering aspect and studying how it affects the boiler performance, Martin said. Whether an operator chooses to install a new online system or use an offline system, each boiler may have different problems and require a unique solution to reach maximum efficiency. For Harty, who went from blasting passes for roadways to using dynamite to clean multi-million dollar pieces equipment almost 50 years ago and has seen cleaning systems continue to evolve during that time, finding solutions to unique problems is a familiar concept. In a power plant, you have to be flexible and innovative, he said.
www.power-eng.com
38
Progressive Changes
for the future
Be sure to mark your calendar to return to North Americas most inuential all-renewable event November 12-14 in the Orange County Convention Center Orlando, FL. Once again, well be co-locating with POWER-GEN International bringing renewable energy to the forefront of the mainstream energy industry.
Learn more & register @ RenewableEnergyWorld-Events.com
Nov. 12-14, 2013 Orange County Convention Center Orlando, FL
Owned & Produced By:
Co-located With:
Presented By:
Supported By:
Media Sponsor:
Gas Turbine Combined Cycle Fast Start:
The
Behind the Concept

BY S. C. GLEN, BECHTEL, PRINCIPAL ENGINEER
PHYSICS
N
120 100 80 Speed, Load (%)
owadays all major gas turbine OEMs promote their products with an emphasis on flexibility in addition to output and efficiency. The most advertised flexibility feature is the fast start capability of advanced F, G or H class machines in simple and combined cycle modes.
Alas, modern gas turbine based combined cycle (GTCC) systems comprise steel behemoths weighing tens of thousands of pounds and operate at extremely high pressures and temperatures while connected to each other via a maze of pipes and valves. This complex architecture presents formidable challenges to designers and operators alike to handle major operational
transients with large flow, pressure and temperature (FPT) gradients without adverse impact on reliability, availability and maintainability (RAM). This is primarily achieved by advanced control schemes incorporating model based controls (MBC), design features such as terminal attemperators and cascaded steam bypass as well as material selection. As a result, in terms of dynamic response to transient events, the difference between a modern GTCC and its forerunners is as pronounced as that between cars with carbureted vis--vis fuel-injected engines. The goal of this article is to provide the reader with relevant and easy-touse technical information (in the form
Gas Turbine Startup Diagram

Start Command to FSFL: 40 minutes 18 minutes (Fast Start) 6 Conventional Fast Speed Load 60
Fly
6 8
C F
nnect + Fire on the
er minute)
inute )
inute )
Fast Loadin g (20+% p
redit + L
Norm a
Purge C
40 2 20 0 0 0 1 10 0 1
4 7 20
30 Minutes
Norm a
0 Start Command 1 LCI engages 2 HRSG Purge Start 4 Ignition Speed 5 GT Fire + Warmup 6 Full Speed No Load (FSNL) 7 Synchronization 8 Full Speed Full Load (FSFL)
per m
(~8%
CI Preco
ding
l Loa
GT Load Hold for ST Temp. Matching (Conventional Start) 40 50 60
Typical gas turbine startup diagram (conventional and fast versions). Conventional start with GT hold can take up to 50 minutes to reach MECL. Purge credit shaves off 12 minutes of that time. Eliminating GT hold saves another 15+ minutes. With fast start feature MECL point is passed in less than 10 minutes.
l Loa
ding
(~8%
per m
40
www.power-eng.com
of simple charts, basic equations and representative physical quantities) to form an informed opinion on available technologies and their purported capabilities and benefits along with potential pitfalls and physical limits. The focus is on GTCC startup, which can be considered as a primus inter pares among all GTCC transients. Admittedly, an article limited to a few thousand words cannot do justice to the subject matter at hand. The reader is encouraged to consult the listed references for a thorough understanding and guidance for applying the basic principles to his/her own projects. There are many considerations in a successful GTCC start from standstill, which are discussed in detail elsewhere [1-3]. Correct steam chemistry, establishment of steam seals, vibration, overspeed and thrust controls are all vital for acceptable component life and RAM. When all said and done, however, the single most important issue from a fast start perspective is steam turbine (ST) thermal stress management. Furthermore, if the heat recovery steam generator (HRSG) is drum-type, high pressure (HP) drum thermal stress management becomes an integral part of the problem. In a nutshell, GTCC startup optimization problem can be formulated as to minimize the time required to reach the dispatch power (e.g., full load or a specific part load) without breaking
Steam Turbine Cool-Down Profles

1,200 HOT WARM COLD
1,000 ST Metal Temperature (F)
800
600
HP
Inn er B owl
c = 100-150 hrs. (HP) c = 50-75 hrs. (IP)
400
IP In ner Bow l
200
0 0 50
100
150
200
Time Since Shutdown, hours

Typical steam turbine cool-down profles (as measured at HP and IP inner bowls). Shaded regions indicate typical time windows for hot, warm and cold start classifcations. Red dashed lines indicate average metal HP bowl temperature corresponding to the same.
anything in the process - literally. The failure mode to avoid is crack initiation and propagation. Failure to control thermal stresses results in cracks via low/high cycle fatigue (LCF and HCF) and brittle fracture. In fact, LCF is found to account for roughly two thirds of ST rotor life with the remainder attributable mainly to creep. In particular, thick-walled components such as HP drum, ST valves, casings and rotor are exposed to LCF due to thermal cycling (start-stop sequence
Defnition of key material parameters and their typical values 1

Modulus of Elasticity Linear Coefficient of Thermal Expansion Poisson's Ratio Thermal Conductivity Density Heat Capacity Thermal Diffusivity
Source:
26,000 6-7 x 10-6 0.30 18.0 490 0.125-0.175 0.20-0.25
ksi 1/R

k c
Btu/h-ft-F lb/cuft Btu/lb-R ft2/h
or load up-down ramps) and associated thermal stress-strain loop. In principle, the solution is simple enough: thermal decoupling of GT and ST start processes. Thus, GT is started and rolled to full speed at no load (FSNL) at the maximum rate dictated by the size of static starter (Load Commutating Inverter, LCI), shaft torque limit, particular Dry Low NOx (DLN) combustion system limits (e.g., availability of heated fuel gas, minimum fuel requirement by the lean blow-out margin, Wobbe index variation, etc.) among others. Following synchronization, GT is loaded as fast as possible first to its minimum emissions-compliant load (MECL) and then to its full load at full speed (FSFL). GTCC start time definition hinges on when to start the chronometer. Unless specified unambiguously, one can never be sure when time t = 0 is and the difference can be significant. For a conventional start with HRSG purge and normal loading rate (i.e., no holds
www.power-eng.com
41
for HRSG warming) the difference between start command and ignition is 20 minutes (see Figure 1). Thus, the same start time (40 minutes to be exact) can be quoted as 20 minutes by someone who sets t = 0 at ignition. Todays fast start GTs with features like purge credit, LCI pre-connect and fire on the fly can reach FSFL in 18
the rule is sequential combustion (reheat) GTs, which can turn off their second combustors to operate at 20% or lower load while emissions-compliant. Two steps are instrumental in reducing GT start time: elimination of (i) HRSG purge sequence (by performing it right after shutdown in compliance with NFPA 85) and (ii) hold time at
low load with reduced exhaust energy (flow and temperature) to control HRSG steam production rate and steam temperatures (at the HP drum and HP superheater exit). Elimination of direct HRSG steam temperature control via GT load and exhaust energy is the thermal decoupling, which is the key enabler of fast start. It can be
S-N and CLE Curves

1.000
3
10.0 8.3
S-N Curve
CLE Curve
Total Strain Range
T/t, F/min.
0.100
max = 44,54, 44,54, 87 87 ksi ksi max = for for K K = 2.0, 1.5 and 1.0
6.7 5.0 3.3 1.7 0.0 0 100 200 300 400
0.100 0.050 0.020 0.010 0.001
0.010
Incr eas ing
5,000 Cycles
0.001 10 100 1,000 Cycles to Failure 10,000 100,000
1 = 0.02% 5,000
500 600
Metal Temp. , F
Typical S-N and CLE curves for ST rotor LCF (CrMoV) [5]. Metal T in CLE chart represents the total temperature change between initial and fnal states (beyond 600F, curves are fat).
minutes or less from the start command (depending on the loading rate). The rush to MECL is critical for reduction of startup emissions. The reason for that lies in the basic design philosophy of modern DLN combustors with fuel-air premixing, which are designed to run near the lean limit for low emissions. This is accomplished by piloted, multi-nozzle fuel injectors via sequential activation of fuel flow through individual nozzles (known as staging) to prevent lean blow-out and combustion dynamics while staying within the narrow equivalence ratio band to control NOx and CO emissions. For older units MECL is 60%; for modern units the low load limit is around 50% (maybe 40% for most advanced systems). The exception to
Steam Turbine Roll Times

18 16 14 ST Roll Time, minutes 12 10 8 6 4 2 0 0% 5% 10% 15% 20% Stem Flow, % of Rated 25% Steam T = 700F 800 F 900 900FF
30%
Steam turbine roll times for varying steam fows and temperatures. (Steam pressure 120 psia, rotational inertia 700 kp-ft2, rated IP turbine inlet fow 681.5 kpph.)
42
www.power-eng.com
For more information contact us at: 281.404.9397 or info@beis.com www.beis.com
Creating Client VALUE is our Business
Multi-Service Solutions Proven Results

SERVICES Work Access Forming & Shoring Custom Engineering Refractory Insulation
BRAND COMPANIES:
EHS Excellence | Commitment to Performance & Productivity | The Best People in the Industry
PROGRAMS Metalizing Abatement Fireproofing Hot Tapping Coatings Line Isolation Bolting/Torquing Field Machining Cathodic Protection More... CUI Management Tank Maintenance Thermal Protection Refractory Corrosion Engineering Coatings Energy Conservation More...
accomplished via a bypass stack and modulated damper controlling the exhaust flow to the HRSG. A recently proposed technique is air attemperation of the GT exhaust gas flow via air injection into the transition duct. Ignoring the obvious but wasteful practice of sky venting, the currently accepted method is a cascaded steam bypass system with terminal attemperator s (TA). Steam generation and temperature-pressure ramp rates in HP drum are dictated by GT exhaust energy whereas final steam temperature control is accomplished by TAs. Until steam temperatures reach acceptable levels for admission into the ST, steam is bypassed via a route including the reheat superheater so that the latter is pressurized and wet (i.e., cooled by steam flow obviating the need for expensive alloys). Steam FPT acceptable for admission into the ST is dictated by metal temperatures (primarily valves, casings or shells and the rotor). The critical component is the rotor, whose temperature cannot be measured directly and inferred by proxies (e.g., HP and IP inner bowl). ST metal temperature, Tm, is a direct function of unit downtime and ambient temperature as shown in Figure 2 (unless forced cooling is applied
Steam Turbine Roll

1,000 Phase I 800 Steam Temperature 700 = 30 min. Steam Flow T Phase II Non-stationary start to Phase II 80 70 60 100
Surfac e
Bu lk
steam surface mean center
40
Max.
200 100
Rotor Temperature
5m = 23
in.
20 r 10 120
70
80
90 Time, minutes
Typical ST roll via IP steam admission and the ensuing warm-up period [6]. Representative of a single-shaft GTCC cold start (total three hours). Note how the quasi-stationary Phase II is preceded by a short non-stationary period.
to start maintenance as soon as possible to minimize the downtime). The natural cooling time depicted in Figure 2 is represented by the exponential decay law Eq. 1
Representative values of major parameters characterizing the transient heat transfer during steam turbine warm-up for typical steam fow, pressure and temperatures.
m/mo [-] 1.0 1.0 1.0 1.0 0.2 0.2 0.2 0.2
Source:
P psia 120 120 1,200 1,200 120 120 1,200 1,200
T F 700 1,050 700 1,050 700 1,050 700 1,050
h Btu/h-ft -F 116 100 958 701 32 28 264 193

2
Bi [-] 7 6 56 41 2 2 15 11
ft /h 0.26 0.21
2
min 37 54 5 8 135 196 16 28
with a characteristic cooling time constant , c, as a function of the ambient temperature, Tamb, and the starting value (denoted by subscript 0). This temperature is the main GTCC startup classification gauge instead of widely used but fuzzy terms such as hot or warm, whose definitions vary from one source to another. Component Tm and, more precisely, its variation in a metal structure across a characteristic dimension, L c, (e.g., diameter of ST rotor 20-25 in. for modern GTCC units) along a characteristic dimension, x, is the key determinant of thermal stress via the following formula: Eq. 2 where E = E / (1-). For the ST rotor, Tm in Eq. 2 is the difference between rotor surface or bore and mean body (bulk) temperatures for surface and bore stresses, respectively. For a given steam temperature, Tstm, bulk rotor body Tm varies according to the exponential decay law
www.power-eng.com
44
Speed, Flow & Stress, %
Temperatur, F
ST Spee d
=7 8m
in.
e fac Sur
es s S tr
HITACHI INTRODUCES NEW COMBUSTION TURBINE TECHNOLOGY
HITACHI GAS TURBINE PRODUCT LINE 60 HZ

ITEM Output Efciency Heat Rate Exhaust Flow Exhaust Temp UNIT MW %(LHV) Btu/kWh lb/h F H-15 16.9 34.4 9,950 420,000 1,047 H-25 32 34.8 9,806 767,000 1,042 H-80 99.3 37.5 9,100 2,262,000 986
ISO Conditions (Sea Level, 59F, 60% RH), Natural Gas Firing
HITACHI HAS DEVELOPED SEVERAL NEW MODELS including a 100 MW

combustion turbine (Hitachi H-80), and several upgrades of the mature H-25 combustion turbine technology, ranging from 3242 MW. Hitachis combustion turbine lineup is ideal for upgrading/replacing existing simple cycle and combined cycle combustion turbines. Nominal combined cycle outputs of 140 MW or 285 MW are achievable with the H-80 combustion turbine in 1x1 or 2x1 plant arrangements. Learn more from Hitachi Power Systems America.
HITACHI POWER SYSTEMS AMERICA, LTD.

645 Martinsville Road, Basking Ridge, NJ 07920 power.info@hal.hitachi.com Tel: 908-605-2800 www.hitachipowersystems.us
Eq. 3 with a characteristic time constant, , which is a function of rotor material (e.g., 1% CrMoV) and size cum geometry represented by L c, Eq. 4 where h is the convective heat transfer coefficient (HTC) between steam and metal. Equations 1-4 tell the entire ST thermal stress management story in the concise language of mathematics. Thermal stress is determined by the temperature gradient in the rotor (essentially a cylinder) via Eq. 2; the latter is determined by the initial steam-metal T (denominator of LHS of Eq. 3) with a time lag, which itself is dictated by HTC in Eq. 4. Everything hinges on the initial value of Tm, Tm,0, which is a function of the cooling period (Eq. 1). In physical terms, this translates into a mechanism to control steam FPT into the steam turbine at initial values sufficient (i) to roll the unit from turning gear (TG) speed to FSNL, (ii) to warm the ST rotor until steam-metal T decreases to an acceptable level and (iii) to ramp them up at acceptable rates to their rated levels while ensuring that thermal stresses do not exceed prescribed limits. Steam flow enters the picture via HTC in Eq. 4, which controls the rate of heat transfer between steam and the rotor surface as described by the heat flux balance at the steam-metal boundary (x = 0) Eq. 5 This equation introduces the dimensionless Biot number, Bi = hL c/k, which is a relative measure of the uniformity of temperature gradients inside a heated or cooled body.
Determination of HTC is one of the most uncertainty-prone undertakings in transient heat transfer problem in a complex geometry such as steam path flow. Its dependence on steam flow is based on the well-known Nusselt number correlation for heat transfer in internal flows, i.e., h . The heat transferred from steam to the rotor at the surface increases the rotors bulk temperature according to Fouriers law Eq. 6 Equation 6 introduces the thermal diffusivity, = k/c, which quantifies the speed with which the temperature of a heated or cooled body changes. Typical values for the key parameters governing ST rotor thermal transients are given in Table 2. For ferritic steels used in modern GTCC units, k and do not show significant variation. Thus, is primarily a function of temperature and changes by about 25% between 700 and 1,050 F; i.e., rate of change of metal temperature is 25% faster at the higher temperature. The data in Table 2 can be summarized as follows: higher steam flow and/or pressure result in
higher rates of heat transfer between steam and metal, which is quantified by higher Biot numbers and shorter time constants (i.e., faster heating or cooling). In conjunction with the data in Table 2, Eqs. 5 and 6 identify the two distinct phases in ST start with thermal stress control: (i) low flow and high steam-metal T with low HTC until temperature gradients settle down (nonstationary phase or Phase I) and (ii) increasing steam FPT to load the unit with high HTC and nearly constant, low steam-metal T (quasi-stationary phase or Phase II). Equation 5 describes Phase I via its simplified solution for a cylindrical geometry given by [4] Eq. 7 which gives the maximum thermal stress implied by a given step rise in Tstm at time t = 0 (with a time lag characterized by the Biot number). Note that the base stress formula of Eq. 2 is amplified by a stress concentration factor K T, which accounts for the presence of geometric discontinuities on the rotor
Dynamic Response of Selected HRSG Heat Exchanger Sections

TEMPERATURE
HP Sphtr. Warm-Up Hold

2 min.
GT Exhaust
7.5 min.
HP Drum
12.5 min.
IP/LP Sphtrs.
15 min. 20 min.
10 (< -15 ~ 5 F/ 0 p min si/ . mi n.
Increa s
IP Drum LP Drum
ing
TIME
Representative of a single-shaft GTCC cold start (total time of about three hours).
46
www.power-eng.com
(which is not a perfect cylinder after all). Similarly, Eq. 6 describes Phase II via its simplified form given by Eq. 8 where F is the form factor (0.125 for a cylinder [4]). Equation 8 gives the allowable Tstm ramp rate for a given maximum allowable stress, max , which is dependent on rotor material and typically lies in a range of 50-80 ksi. For the cited range, with the data in Table 2, Eq. 7 suggests that for low HTC (~100 Btu/h-ft 2-F or less) steam-metal T can range from 200-300 F (high K T) to 500 F and higher (low K T). For high HTC (~ 650 Btu/h-ft 2-F), steam-metal T can range from 100-200 F (high K T) to about 400 F (low K T). Similarly, using Eq. 8 with Table 2, it can be seen that allowable values for dTstm/dt range from 3-6F to 8-10 F. The allowable stress is not a precisely defined material property. (For ferritic steels used in ST rotor construction, 0.2% tensile yield strength lies between 70-90 ksi for temperatures 600-1,000 F.) It is derived from the S-N curves relating total strain to cycles to failure, which gives the fatigue life of the material in question (for LCF life of CrMoV alloy see Figure 3). Based on the relationship between stress and strain, , via the modulus of elasticity, = E , this curve is used to determine max for a defined fatigue life. In practice, the relationship between and T allows the translation of the S-N curve into Cyclic Life Ependiture (CLE) curves, which determine the allowable Tstm ramp rates (Figure 3). Depending on the rotor material, size and geometry and its temperature at start initiation, the range is limited to about 5 to 10 F per minute except for very hot restarts after a few hours of downtime. Steam turbines with cascaded steam bypass are typically started by admitting steam from the reheat superheater into the IP section. Admission steam FPT should be sufficient to overcome the rotational inertia (in lb-ft 2) of the entire ST and its generator, Irot, and accelerate it from TG speed (a few rpm) to FSNL (3,000 or 3,600 rpm). Based on available steam FPT and initial IP rotor temperature, using the relationship between ST power generation (expansion from IP inlet to the condenser), rotor torque and rate of change in angular speed, , the roll time can be estimated as 2 to 15 minutes (see Figure 4) via Eq. 9 where N is the rotor speed (rpm) and the argument of the integral on the RHS of Eq. 9 is the power (in Btu/s) generated by steam expanding between IP turbine inlet and condenser [6].
www.power-eng.com
When things heat up, call Aggreko.

Aggreko Cooling Tower Services (ACTS) is the worlds largest provider of rental cooling tower solutions. For over 20 years, we have successfully helped customers solve their cooling water limitationsunder any circumstances. From the planning stages to the turnkey installation of convenient modular cooling towers, ACTS has the solutions to help you keep your cool, 24/7/365. ACTS provides proven rental cooling tower solutions to:
Overcome thermal discharge temperature limitations Minimize post-disaster downtime Maintain cooling capacity during partial or complete tower repair Lower cooling water temperatures and reduce turbine back-pressure Add cooling water capacity with no capital commitment
Contact Aggreko today for all your rental cooling tower needs.
866.597.8783 www.coolingtowers.com
Performance Certied by Cooling Technology Institute
The chart in Figure 5 shows the first two hours of ST roll, warm-up and loading phases for an initial Tm of 180 F (about 5-6 days of downtime per Figure 2). Steam is admitted into the IP turbine at 715F and 120 psia at a flow rate of 10% of its rated value at full load. This is sufficient for acceleration from TG to synchronization in 8 minutes (see Figure 4). Initial steam-metal T is 500+F but this is acceptable due to the low HTC (less than 30 Btu/hft 2-F per Table 2) and the ensuing low max from Eq. 7 (also very high > 200 minutes). Following synchronization, IP steam flow is ramped steadily to 40% to accelerate the warm-up process via increased HTC. Once the steammetal T (based on rotor surface temperature inferred via IP inner bowl thermocouple) reaches about 250 F, Tstm is ramped (via TA control) at a rate defined by the CLE curve (about 3 to 4F per minute for an acceptable life of 4 to 5,000 cycles from Figure 3). The other component subject to LCF damage due to cycling is the cylindrical HP drum of the HRSG (4-5 inches wall thickness). The limiting thermal stress is at the inner drum wall controlled by saturated steam p-T inside the drum. During startup, mechanical stress due to internal drum pressure and thermal stress due to thermal expansion are in opposite directions, while they are in the same direction during shutdown. Unlike the ST, which is thermally decoupled from the GT via TAs, HRSG sections are directly under fire. They respond to GT exhaust temperature transients much faster than the ST rotor in direct proportion to their distance from the inlet (see Figure 6). Thermal stress calculations and material properties similar to those described above limit the p-T ramp rate inside the drum to 10-15 F/ min (about 50 psi/min max.) for units designed up to ~1,800 psig at ST throttle (~ 6-10% higher at the HP drum).
Advanced steam cycles with 2,400 psig throttle and drum-type HRSGs (very thick walls) would push down the ramp rate to a few degrees per minute (see Eq. 8 for the relationship between dTstm/dt and L c). This can be alleviated to a certain degree by using stronger alloy steel (obviously more expensive) and/or designing the HRSG per EN-12952 rather than the ASME code, which results in thinner walls. One obvious solution is once-through design of the HP evaporator, which eliminates the thick-walled drum altogether but has its own drawbacks and caveats. A recent design approach proposes to replace the HP drum by a cylindrical, thin-walled knock-out vessel with external separator bottles and thus avoid the thermal stress problem
starts (Tdrum > 500 F) do not impact LCF life. In hot starts, HP and reheat superheaters subjected to very steep gas temperature ramps are critical in terms of HRSG life consumption. In this context, one should add that the desirability of purge credit is due to more than startup time reduction. It prevents excessive quenching of superheaters, which act as supercoolers during hot starts when subjected to relatively cold GT exhaust with detrimental impact on their fatigue life. Natural p-T decay of the HP drum can be described by Eq. 1 with c of 60 to 80 hours. It takes about 2-3 days for the pressure to decay to the atmospheric conditions. Bottling up the HRSG via stack dampers with insulation up to the damper, steam sparging
Startup Time
250
HR For old GT H
7
16 14
Tem Steam re Ram peratu p Rate
200 Start Time, minutes
12 10 8 rpm/min, F/min
SG
up rm Wa
150
100
Sha
f t Ac
cele
6
ratio n Ra te
4 2 0 1,000 5
50
ST O nly
0 0 200 166 400 97 600 58 800 27 Initial ST Metal Temperature, F
Downtime, hours Startup time of a typical steam turbine in a modern GTCC with drum-type HRSG (from the start of ST roll to the point when all bypass valves are closed and all admission valves are fully open).
in cold starts. According to HRSG OEMs, cold starts (Tdrum < ~ 400 F) are 20 times more damaging than warm starts (Tdrum < ~500 F) whereas hot
(requires auxiliary boiler) or running the SCR ammonia vaporizer heaters help keep the HRSG warm and pressurized over limited duration shutdowns
www.power-eng.com
48
to enable GT starts with no low-load hold. Beyond about three days, however, this is increasingly impractical and even in plants designed for fast starts limited duration GT holds are needed to accomplish HP drum warmup in two steps (somewhat similar to that shown in Figure 6). Combining the elements discussed above and illustrated by the ST roll example in Figure 5, a representative ST start curve can be established as a function of the key controlling parameter, namely, ST metal temperature at the startup initiation (Figure 7). Appropriate GT start time per Figure 1 (from start command to the point when ST roll begins) should be added to that for total GTCC start time (e.g., 18 minutes for the fast start). The fourminute mile of fast start capability is
roughly 30 minutes from a standstill (to be defined precisely) to combined cycle full load for a "hot" start (e.g., following an overnight shutdown). This is generally compared to a conventional hot start, which takes around one hour (see Figure 1). The underlying physics discussed herein briefly and summarized in Figure 7 hopefully makes it clear that this particular case is only one single point in a continuum of start scenarios driven mainly by the downtime preceding the pushing of the start button. References 1. Chrusciel, A., Zachary, J., Keith, S., 2001, Challenges in the Design of High Load Cycling Operation for Combined Cycle Power Plants, POWER-GEN International 2001, Las Vegas, NV.
2. Akhtar, Z., 2006,Design Features for Minimizing Start-Up Time in Combined Cycle Plants, POWER-GEN Europe 2006, Kln, Germany. 3. Ugolini, D.J., Bauerschmidt, J.R., 2006, Optimization of Start-Up Times for Combined Cycle Power Plants, Electric Power Conference 2006, Atlanta, GA. 4. VGB PowerTech Guideline, 1990, Thermal Behaviour of Steam Turbines, Revised 2nd Ed., VGB-R105e, VGB PowerTech Service GmbH, Essen, Germany. 5. Viswanathan, R., 1989, Damage Mechanisms and Life Assessment of High-Temperature Components, ASM International, Metals Park, OH, USA. 6. Glen, S.C., Kim, K., 2013, Gas Turbine Combined Cycle Dynamic Simulation: A Physics Based Simple Approach, GT2013-94584, ASME Turbo Expo, June 3-7, 2013, San Antonio, TX, USA.
TM
torque gun
company
the
TORQUEGUN.COM
tm
THE WORLDS FIRST IMPACT & TORQUE GUN

PUSH the shifter handle forward, engage the 4,000 rpm high speed impact at low noise and vibration for a quick, corrosion-overcoming pre-torque or run-up. PULL the shifter handle back, engage the continuous rotation precision (+5%) torque mode for make-up and break-out, free of reaction arm, fnger pinching and destructible side load.
OF THE UCT YE OD
TM
2013
AR
PATENTS RECEIVED & PENDING
www.power-eng.com
PR
49
Upgrading Electrostatic Precipitators

BY BRYANT PURSE, RAYMOND ZBACNIK, MITCHELL KRASNOPOLER, KIEWIT POWER ENGINEERS
Authors Bryant Purse is an AQCS Process Engineer for Kiewit Power Engineers of Lenexa, Kansas. He develops performance testing procedures, equipment specifications, process calculations, and supports field performance testing, proposals, and client presentations. Ray Zbacnik is an AQCS Process Specialist for Kiewit Power Engineers of Lenexa, Kansas. Zbacnik has almost 40 years of chemical engineering experience, which includes 20 years of AQCS experience in the power industry. Mitchell Krasnopoler serves Kiewit Power Engineers of Lenexa as the Manager of Air Quality. He has almost 25 years of engineering experience in air pollution control technologies; extensive experience in flue gas desulfurization (FGD) design, operations and testing expertise and over 30 years of design experience for various fossil and nuclear power generation projects. The first electrostatic precipitator was developed by a physical chemistry professor, Dr. Frederick Cottrell, in 1906. He was awarded a patent for his design on August 11, 1908. Dr. Cottrell successfully demonstrated in his research the precipitation of particulates from an air stream via particle charging in an electric field. The principles in this early design still apply today. Transformer-rectifiers energize discharge electrodes with a negative potential, producing an electrical field between the discharge electrodes and the positively-grounded collecting plates. Particulate matter that enters the electrical field develops a negative charge and migrates away from the discharge electrodes and towards the collecting plates. When the particulates reach the collection plates, the negative charge is neutralized and a cake-like layer of ash accumulates. Migration and collection of the charged particles depends upon the particulate resistivity and the electrical field between the two electrodes, as well as the gas flow profile. Particulate matter that precipitates on the collection plates is periodically removed by
www.power-eng.com
lectrostatic precipitators (ESPs) have been used for over 100 years to remove entrained solid particulates or fine mists from gas flows in the power, cement, metal production, paper, and other industries. As a response to ever changing state and federal regulations for coalfired utility power plants, existing ESPs or new air quality control systems are needed to meet lower emission limits. Since many of these ESPs have been in operation for 30 to 50 years, many are in need of upgrades to improve performance and reliability. Even if a new pulse jet fabric filter will be installed downstream of an ESP, an ESP upgrade may be economical because the enhanced ESP could reduce maintenance costs and preserve fly ash sales. Many of the modern ESP designs and controls can be installed in old
ESPs. This article will address some of the general principles of dry electrostatic precipitators and discuss modern methods for upgrading ESPs.
BASICS OF ELECTROSTATIC PRECIPITATORS

ESPs can be designed for high volumetric gas flow rates, variable temperatures and pressures, and variable particulate loading. Precipitators have been placed in a number of locations at different power plants, including downstream of the economizer (hot side), downstream of the air preheater (cold side), or after a wet scrubber (which requires a wet ESP). This article will focus on dry ESPs and will highlight typical upgrade options. With a properly designed electrostatic precipitator, 99% collection efficiency is possible with medium and high ash coals. History and Principles of ESPs
ESP Process Schematic

Ground Plate Spacing Particle Charged Particle Dirty Air Ionizer Zone of Charging Ground Plate
Source: www.aircleancompany.com
High voltage Plate Spacing
Clean Air
50
An example of a rigid discharge electrode. Photo courtesy of www.environmentawareness.com
mechanical rapping. The fly ash falls to collection hoppers from which it is then disposed.
REASONS FOR ESP UPGRADES

A number of factors influence ESP upgrades including performance degradation, increased maintenance, poor reliability, changes in particulate resistivity, sodium ion depletion (primarily for hot-side ESPs), volumetric flow rate changes, increased inlet particulate loading (typically due to dry sorbent injection), stricter emission regulations and compliance protocols, and even normal wear and tear such as plate warping and leaks in the casing. An ESP upgrade will improve performance and reliability, which will reduce the plants operating costs in the long run. MATS Regulations One of the primary drivers for ESP upgrades is the EPAs new Mercury and Air Toxics Standards (MATS) regulations. The MATS ruling established a filterable particulate emission limit of 0.03 lb/MMBtu based on EPA Test Method 5.
www.power-eng.com
A complicating factor with the MATS regulations is that they impose stricter limits on acid gas and mercury emissions. The regulations call for an HCl emission limit of 0.002 lb/MMBtu and a mercury emission limit of 1.2 lb/ TBtu. At many plants, techniques to meet these new limits include activated carbon injection (ACI) for mercury removal and perhaps dry sorbent injection (DSI) or acid gas control. Plant personnel must ensure that the existing ESP can handle the additional particulate loading. Changes in particulate loading from ACI or DSI treatment are not the only issue. Ash resistivity (the ability of the ash to accept and transfer an electrical charge) changes with the addition of carbon or scrubber particulates. Also, resistivity may be altered due to changes in such operating conditions as temperature, moisture, and chemical composition. Sodium Ion Depletion: Another issue that can drive ESP upgrades is sodium ion depletion. This phenomenon influences hot side ESP performance with PRB as the fuel. The nature of the PRB ash (low sodium, low chloride, high ash), increases ash resistivity and has forced some power plants to de-rate the unit periodically and shut it down for collection plate washing. Mechanical rapping is simply not sufficient. Sodium depletion occurs when positively-charged sodium ions migrate towards the negative charge of the ionizing electrodes and form a sodium-rich layer in the collected ash. This outer layer dislodges by rapping, but the inner ash layer,
depleted of sodium ions, has different characteristics making it much more difficult to remove because of the resistivity increase. The layer continues to build, reducing the ability to apply power to the field. Because sodium depletion alters the chemical properties of the ash, an ESP upgrade may not completely solve the problem, but an upgrade may combat the decrease in performance.
UPGRADE TECHNOLOGIES
Due to the above-mentioned factors and stricter environmental regulations, many existing ESPs will have to either be upgraded or converted to fabric filter devices, aka baghouses. A potential option at some plants may even be a polishing fabric filter installed downstream of the existing ESP. The configuration will be heavily dependent upon the plants current process conditions and the desired outlet emissions. The most common methods of improving an electrostatic precipitator are: Upgrading the collection electrodes Upgrading the discharge electrodes Upgrading the rapping system Upgrading the transformer-rectifier assemblies Improving the flow distribution Other methods such as adjusting the aspect ratio (the ratio of the ESPs effective height to the ESPs effective length) or fly ash/flue gas conditioning (altering the chemical/physical characteristics of the fly ash) are less common. Neither of these methods will be discussed in this article. Upgrading the Collection Electrodes Collection electrodes (CEs) typically are of a plate design for dry ESPs. Tubulare collection electrodes have been utilized, but these are primarily for wet ESP applications. In most cases,
51
collection plates include stiffeners that act as baffles to prevent particle re-entrainment. Properly designed collection plates eliminate excessive rapping and ensure equal distribution of the rapping force throughout the plate. Collection electrode design should be correlated with the discharge electrode (DE) design. For ESPs with weighted wire discharge electrodes, typical plate spacing is 6 to 12 inches. Many modern ESPs have rigid frame or plate discharge electrodes, and in these designs the typical plate spacing is 12 to 16 inches. A common practice for upgrading an ESP is the alteration of the plate spacing to increase the efficiency of the unit. New collecting plates will restore DE-to-CE spacing and alignment. New CEs may also improve rapping efficiency by decreasing rapping density and allowing increased rapping acceleration. Wider spacing along with new power supplies will increase the voltage and power input to the electric fields. Upgrading the Discharge Electrodes Discharge electrodes receive negative, high voltage, direct current and generate the field that charges the entrained dust particles. A simple increase of applied voltage is not necessarily a good solution because of the threat of spark-over between the discharge and collection electrodes. Spark-over causes a short-term breakdown of the electric field. It is important to design an ESP where sparking does not occur too frequently. For well-designed ESPs, sparking usually occurs between 50 and 100 times per minute. The discharge electrode should be designed to optimize the induced electrical field, and should be customized for the individual process. In the past, the weighted wire design for the discharge electrode was common, but mechanical fatigue has caused operating problems. Although most ESP vendors prefer the tube and pin electrode design, other common rigid discharge electrodes should also be considered, such as rigid masts and rigid frame electrodes. Selection of modern discharge electrodes, per the correct requirements for the application, can greatly improve ESP performance. Upgrading the Rapping System Rapping is the process by which a mechanically-induced force is applied to the collections plates to dislodge the collected ash. For maximum efficiency, it is important to allow some buildup of dust particles and not rap the plates too frequently. Plates are typically rapped once the dust layer reaches a thickness range of 0.03 to 0.50 inches. Rapping in this
www.power-eng.com
range prevents re-entrainment of ash. One method to increase rapper efficiency is improvement of the rapper controls, in part by setting proper rapping frequencies. The inlet collection plates need to be rapped more frequently than those in the outlet fields. Also, rapping discharge electrodes at a proper frequency to prevent dust accumulation on these instruments is important. Finetuning of existing rappers and controls may avoid the issue, and cost, of installing new rappers. Increasing the number of rappers will improve the rapping system by enhancing the rapping energy. Modification of rapper placement or by dedicating existing or new rappers to fewer plates increases rapper density. Such options for an existing system should be evaluated before investing in completely new rappers. Upgrading the Transformer-Rectifier Assemblies A critical component of a precipitator is the high-voltage equipment, consisting of a step-up transformer, a highvoltage rectifier, and control metering and protection circuitry. The system must be designed to ensure adequate power to the discharge electrodes without causing excessive sparking. Depending upon the required operating conditions of the ESP, an upgrade can be as simple as modernizing the T-R set. However, before increasing the power to the unit, the electrode design and plate spacing may be modified instead. The most common upgrade utilizes a three-phase, high frequency switch mode power supplies (SMPS), with control system adjustment to prevent excessive spark-over. This upgrade efficiently delivers power to the ESP, maximizes the average voltage of the ESP, and reduces the frequency of sparking. However, utilizing a switch mode power supply may not be feasible for every application. Improving the Flow Distribution Maldistribution of flue gas flow can lead to degraded performance of the ESP. Variable flue gas flow changes the particle distribution throughout the unit. Thus, some areas of the ESP may be exposed to a greater gas flow and particulate loading that exceeds local collection capabilities. Flow distribution devices can be installed to normalize the flows to all ESP chambers. Normalizing the flow will prevent sneakage of untreated gas around the collecting fields. Physical and Computational Fluid Dynamic (CFD) modeling are tools for analyzing an ESP flue gas profile. The methods can help identify what devices are needed to optimize
www.power-eng.com
UNMATCHED PERFORMANCE AT AN UNBEATABLE PRICE
NEMA PREMIUM EFFICIENC Y MOTORS are proven the world over. Ever y model is designed to meet or exceed NEMA eciency requirements. Equally impressive, all are competitively priced. Expertly engineered for general industrial uses Stable, reliable performance Low temperature rise Minimal vibration High starting torque Durable construction Backed by a 3-year manufacturers warranty
For the best solutions to your application challenges, consult with your XEMC distributor. To locate a distributor, scan the QR code or visit www.lt-eng.com/products/fnd-a-distributor.
FOR ADDITIONAL PRODUCT DETAILS, VISIT www.lt-eng.com/products/nema_motors

the flue gas flow into, through, and out of the precipitator.
be evaluated and studied. This evaluation requires the following: CONCLUSION Understand boiler feed coal chemAs previously discussed, ESP upistry grades involve many different meth Study the physical and chemical ods that can be optimized in part or properties of the fly ash in whole. Emissions Evaluate the origitesting provides the One method to nal process design ultimate indicator increase rapper conditions and curthat the performance efficiency is rent operating conof the ESP may have ditions improvement of the Review the flue declined or that the unit will not perform rapper controls. gas profile/flow disto meet new regula- - Kiewit Power Engineers tribution tions. Examine the exHowever, the cause of performance isting ESP casing and internals for degradation may not always be clear. corrosion Simply replacing one component Examine the structural integrity may not increase ESP efficiency. Due of the ESP foundation to the complicated nature of precipita Inspect ESP casing and compotor upgrades, the existing ESP should nents for wear
Evaluate the control systems Consider site layout/configuration limitations Evaluate the ESP electrical system and electrical characteristics of the ESP. References Steam, Its Generation and Use, Chapter 33, Particulate Control, Babcock & Wilcox Company, Edition 41, Barberton, Ohio, 2005. US Patent No. 895,729; Art of Separating Suspended Particles from Gaseous Bodies, Application Filed 9 July 1907. Awarded 11 August 1908. ht tp://w w w.google.com/patents/US895729 US EPA Technology Transfer Network, Particulate Matter Controls, Section 6. http://www.epa.gov/ttn/catc/ dir1/cs6ch3.pdf
WEBCAST
ON DEMAND
MAKING THE CHANGE TO MEET EPA EFFLUENT LIMITATION GUIDELINES

www.power-eng.com
S OF CHANG R A E Y E 25
NOVEMBER 1214, 2013 | ORANGE COUNTY CONVENTION CENTER | ORLANDO, FL, USA | WWW.POWER-GEN.COM
See What You Missed in 2012

Click here to play video
Get Ready for 2013

Owned & Produced by Presented by Supported by Co-located with
NRG Energy RICE NESHAP installation at Harrisburg, Penn., showing catalyst housing (left) and crankcase ventilation system (right).
Engineering Design for RICE NESHAP Compliance

BY STEPHEN R. NEWCOMB, P.E., RPA ENGINEERING; MARC ROST, JOHNSON MATTHEY STATIONARY EMISSIONS CONTROL LLC; RAY KULPA, SOLBERG MANUFACTURING; AND BARD RUPP, NRG ENERGY
dual-fuel engines will require the addition of emissions control catalyst to meet the HAPs limits required by the RICE NESHAP regulation. Since the EPA has chosen carbon monoxide (CO) as a surrogate for the principal hazardous air pollutant formaldehyde, this article focuses on a project to reduce CO emissions from diesel and dual-fuel engines. In order to comply with the latest RICE NESHAP Standards, the equipment installation requirements for nonemergency diesel and dual-fuel engines greater than 500 horsepower typically include the following: Catalyst housing with an oxidization catalyst CPMS (continuous parametric monitoring system) Crankcase ventilation system Use of ultra-low-sulfur-diesel (ULSD) fuel Engine hour meter Limitations on engine start-up time Performance tests to demonstrate engine emission compliance Operators of stationary engines affected by RICE NESHAP who are not in compliance by the deadline dates can be fined on a daily basis. A one-year compliance extension can be requested, but the request must be made at least 120 days before the compliance due dates.
I
56
n February 2010, the U. S. Environmental Protection Agency (EPA) issued a new national emission standard for hazardous air pollutants (HAPs) that affected existing stationary diesel, dualfuel and gas engines. This regulation, known as Reciprocating Internal Combustion Engine National Emission Standard for Hazardous Air Pollutants (RICE NESHAP) was finalized in January 2013, but the original compliance dates have not changed. Diesel and dual-fuel compression ignition (CI) engines must comply by May 3, 2013 and natural gas spark ignited (SI) engines
must comply by Oct. 19, 2013. The EPA estimates that over 900,000 CI engines and over 335,000 SI engines will be affected. This includes engines located in both major and area sources of air toxics emissions. The compliance requirements vary and are based on engine size, use of engine, type of engine and source. Although the regulation affects an estimated 900,000 existing compression ignited or diesel engines, almost 90 percent of these engines will only be required to meet best maintenance practices. However, a significant number of diesel and
BACKGROUND: NRG APPLICATION

NRG Energy, a leading power generation company, operates a 12 MW peaking plant near Harrisburg, Penn. and needed to reduce the CO emissions in order to comply with the RICE NESHAP regulation.
www.power-eng.com
During 2012, NRG worked with RPA Engineering (RPA), a leading, full-service engineering firm based in Wyomissing, Pa. to specify, design and install an oxidation catalyst and associated equipment to meet RICE NESHAP requirements. Engine operation The NRG Energy Center Paxton peaking plant is comprised of two Cooper-Bessemer LSVB-20-GDT CI engines that were installed in 1986. Each engine is rated at 8656 bhp and generates 6 MW of electricity.
SCOPE REQUIREMENTS FOR NRG ENERGY PAXTON PLANT

Oxidation catalyst The oxidation catalyst systems installed at NRG were furnished by Johnson Matthey Stationary Emissions Control LLC and designed to meet the RICE NESHAP emissions limit for CO emissions. For CI engines larger than 500 HP at either area sources or major sources, this limit is either an absolute emission
installed outside of the generator building and were externally insulated to reduce heat loss. Each of the housings included spare catalyst tracks for future use should environmental regulations become more stringent. The catalyst tracks are designed to float within the housing to compensate for thermal expansion and to seal the catalyst modules to prevent exhaust gas from bypassing the catalyst. The engine exhaust flow rates, temperatures and emissions were measured
The catalyst used for the engines was a combination of Platinum Group Metals on a stainless steel metal monolith, with the catalyst blocks arranged in a single layer and the weight of each block limited to 50 pounds.
NRG can operate these engines on full diesel fuel for a limited amount of hours, or dual-fuel (which is comprised of approximately 95 percent natural gas and 5 percent pilot diesel oil). The engines are started on diesel fuel and are switched over to dual-fuel operation at approximately one-third load. NRG operates the engines on dual-fuel because of the current cost advantages of natural gas, but NRG also has the capability to operate on diesel fuel only should limit of 23 ppmvd CO at 15 percent O2 or this be desired. a 70 percent reduction of CO emissions. The Cooper-Bessemer engines at NRG The catalyst that was used for each had been previously modified to sub- engine was a combination of Platinum stantially reduce the emissions of NOx in Group Metals (PGM) on a stainless steel the engine exhaust compared to an un- metal monolith. The monolith was supmodified dual-fuel engine. plied in block-sized modules, and these Engine No. 1 is equipped with an blocks were inserted in carbon steel housAMPS System and Engine No. 2 is ings, with one housing for each of the two equipped with a engines. The catalyst Cooper Clean Burn Operators not in blocks were arranged System. in a single layer, with compliance with RICE NESHAP re- RICE NESHAP can the weight of each quires that engines block being limited to be fined daily. time spent at idle be 50 pounds to facilitate minimized and that the engine startup installation and removal from the catabe limited to a period needed for ap- lyst housing. propriate and safe loading of the enEach of the catalyst housings was gine, not to exceed 30 minutes, after equipped with a hinged door to prowhich time the non-startup emission vide access to the catalyst blocks from limitations apply. an adjacent walkway. The housings were
www.power-eng.com
in previous exhaust stack testing, and these values were used as the design basis for this project. Although the current CO emission values were not available, the oxidation catalyst will convert CO to carbon dioxide (CO2) by the design reduction efficiency based on the proper selection of the catalysts gas hourly space velocity regardless of the amount of CO in the engine exhaust. According to the RICE NESHAP Rule, the minimum and maximum temperature limits for lean burn CI engines is 450F and 1350F, respectively. The minimum temperature is required for the catalyzed reaction to occur; the upper temperature limit avoids thermal sintering of the catalyst. The measured exhaust temperatures of these engines from the previous testing were typically within the limits of the Rule at 500F to 750F from
57
start-up to full load operation. Continuous parametric monitoring system (CPMS): The RICE NESHAP Rule requires the catalyst inlet temperature (as based on a four-hour rolling average) to be documented and maintained within the minimum and maximum operating temperature limitations noted above. The Rule also requires that the pressure drop across the catalyst be measured once per month to demonstrate that it is maintained within a +/- 2-inch w.c. tolerance (as measured during the initial performance test). NRG collects and stores the data with a Johnson Matthey HapGuard Continuous Parametric Monitoring System. CPMS data readings are acquired at least every five minutes. The CPMS calculates and stores a one-hour and four-hour rolling average of temperature and differential pressure data for a minimum of 12 months. The CPMS will initiate an alarm signal when temperature or pressure readings and calculations exceed the limits set by the operator. The operator has the provision to define alarm set points and unit identification during the system commissioning. There is a dedicated, programmable CPMS for each engines catalytic converter, which is installed in a NEMA 4 enclosure near the catalyst housing for each engine. The CPMS is programmable from a keypad on the front panel display. Real time catalyst inlet temperature and differential pressure are displayed on the front panel display. The CPMS communicates acquired data, calculated data and monthly reports to NRGs plant computer by Ethernet connection. Crankcase ventilation system: RICE NESHAP specifically requires that each diesel engine must have a crankcase ventilation system to capture the hazardous blow-by emissions vented from the crankcase during operation. These emissions consist of oil mist, metals and other particulate emissions. Open or closed systems are accepted under the standard; however, most
operators are installing open systems to prevent the ingestion of raw blow-by into the engine turbocharger or exhaust. While the EPA does not specifically mandate an efficiency level, best practices dictate that all visible emissions are eliminated from the crankcase vent. This is only possible with a high efficiency filter and not with the traditional wire mesh.
Additional requirements The engines were already equipped with non-resettable hour meters, and they were not required to be added to the NRG installation to meet compliance requirements. NRG was required to use ultra-low-sulfur-diesel fuel as part of the installation of the catalytic oxidation system.
CHALLENGES
The RICE NESHAP installation at the NRG Energy Paxton Plant presented several major, but not uncommon, challenges to the project team. The team worked together to overcome these challenges as described below. Space limitations The configuration of the existing engine installation did not leave much room for the installation of the catalyst housing or the crankcase ventilation system in an accessible location. The exhaust system for each engine included an existing, but out-of-service, heat recovery steam generator (HRSG) and an exhaust silencer. Catalyst location options Initially, NRG and RPA considered three options for the catalyst location. The most open area in the existing installation was the 36-inch diameter exhaust pipe between the HRSG and the silencer. One problem with this location was that it would require platform modifications to provide access to the catalyst. Another problem was that replacement of the existing HRSG with a new operating unit would cause catalyst inlet temperatures too low for catalytic oxidation. NRG and RPA also considered a location inside the generator building between the expansion joint and the HRSG inlet. This location would have required new platforms for access and modifications to the building structure. The third option, which required more initial cost to implement, was to remove the existing out-of-service HRSG and place the catalyst housing in a location just outside the generator building wall.
www.power-eng.com
The NRG Energy Center Paxton peaking plant, a 12 MW peaking plant plant located near Harisburg, Penn., needed to reduce CO emissions to comply with the RICE NESHAP regulation.
In the case of NRG, Solberg Manufacturing Inc. designed and delivered a highefficiency, open crankcase ventilation system to capture the vented hazardous blow-by emissions from each of the two existing Cooper-Bessemer engines. The Solberg system includes an internal air/ oil separator cartridge with an efficiency of 99.97 percent for 0.3 micron particles and oil mist. This is packaged with a vacuum source, custom piping and a valve to allow NRG to maintain the natural crankcase pressure of the engine. The oily emissions are pulled through the cartridge, and the entrained oil is coalesced and collected at the bottom of the canister. The collected oil is recovered through a drain port and is scavenged to a waste oil tank inside the building. The result is clean air and no visible emissions vented from the crankcase to atmosphere.
58
POSSIBLE
Because of Cat Gas Power Systems
GAS-FUELED PRODUCTS. PEOPLE-FUELED SUPPORT.

Electric utilities across Latin America can rely on power plants from Caterpillar to sustain economic growth with reliable electricity. With Cat gas generator sets, you can quickly install megawatts of power to serve the areas where the energy is needed most. And youll have the condence of local Cat experts to back you up, while your own customers enjoy the progress that you made possible.
Visit us at www.catgaspower.com
CAT, CATERPILLAR, their respective logos, ACERT, Caterpillar Yellow, the Power Edge trade dress, as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission. 2013 Caterpillar. All Rights Reserved.
NRG and RPA determined that the existing platform could be easily modified to provide access to the new catalyst housings and also determined that there was sufficient space to allow the installation of a new HRSG, if needed. After careful deliberation, NRG proceeded with the third option. Due to the fact that space needed to be maintained for a possible future HRSG, the allowable length that the catalyst housing took up in the exhaust duct was more limited. Crankcase ventilation location options Another concern was determining a location for the crankcase ventilation system. The engine crankcase is vented through a six-inch pipe to a location just outside the generator building. A separate two-inch cylinder head vent pipe joins the main six-inch crankcase vent pipe at a location just above the engine. The high elevation at which the crankcase vent pipe ran inside the building made it difficult to select a location that would provide operator access for system maintenance and adjustment. The decision to remove the existing HRSG contributed to finding an accessible location for the crankcase ventilation system outside the generator building on the existing platform. The Solberg crankcase ventilation system also was able to be customized to meet installation requirements, and the units were mirror images of each other. Other factors The selected location of the catalyst immediately downstream of an existing metal bellows expansion joint raised concerns about the resultant force that would be imposed on the catalyst housing. Johnson Matthey performed a finite element analysis to verify that this force would not lead to excessive stress in the
catalyst housing during operation. The longer run of exhaust pipe created by the removal of the existing HRSG led to greater thermal expansion in the exhaust pipe between the catalyst housing and the silencer. This was resolved by adding a new fabric expansion joint designed to compensate for four inches of thermal expansion.
determine the maximum allowable design pressure drop for clean catalyst. The pressure drop allowance also needed to compensate for dirty conditions. The standard catalyst housing design used by Johnson Matthey was customized after computational fluid dynamic modeling indicted that uniform flow across the catalyst face could be achieved with minimal inlet and outlet transitions between the exhaust pipe and the catalyst housing. The compactness of the catalyst housing combined with the relA dedicated continuous parametric monitoring system communicates information to the plants computer using an Ethernet connection.
SYSTEM PRESSURE LIMITATIONS

Catalyst pressure drop Another concern with the catalyst housing design was the maximum pressure drop across the catalyst that could be allowed before affecting engine performance. The NRG Cooper-Bessemer LSVB-GDT-20T engine has a maximum allowable backpressure of 20-inches w.c. Most of this pressure allowance was already used up by the existing components in the engine exhaust pipe. In order to determine the maximum pressure drop that could be allowed for the catalyst, RPA Engineering modeled the engine exhaust system and ran several different exhaust flow conditions to
atively stringent allowable pressure drop limitation resulted in a unique housing configuration that fit within the existing exhaust system design. Crankcase Pressure Requirement The NRG Cooper-Bessemer engines are designed to operate with a slightly positive crankcase pressure to reduce the possibility of an explosion. This impacted the design of the required crankcase ventilation system. The Solberg recirculation system incorporates a regenerative blower to create suction to overcome the differential pressure created by the oil saturated filter element. However, the systems integrated piping will recirculate the exhaust air from the blower back to the inlet of the crankcase ventilation system. The result is an equilibrium state in which the natural engine crankcase pressure is maintained. A manual control valve was included to restrict the recirculation air over time and produce a slight vacuum, if necessary, to overcome eventual leaks through worn engine seals. The NRG operators monitor crankcase pressure on a regular basis. Due to the concern with an upset condition leading to the possibility of
www.power-eng.com
60
negative pressure in the engine crankcase, a pressure switch was installed on the engine that would alarm in case of a low positive pressure in the engine crankcase.
SYSTEM START-UP
The RICE NESHAP equipment was installed at the NRG Energy Paxton Plant in the fall of 2012. The RICE NESHAP systems for each engine were started up in November 2012 by representatives of Johnson Matthey and Solberg Manufacturing. During start-up the crankcase ventilation system functioned as intended and there was no visible discharge from the crankcase ventilation vent pipe. Sample analysis for CO emissions using a Testo 350 portable gas analyzer were taken at 58 percent load, 67 percent load, 83 percent load and 100 percent load with Engine No. 1 operating on dual fuel. As expected, the untreated CO emissions at the engine outlet were the highest at the lower engine loads. Untreated CO emissions decreased as the engine load increased. The measured CO conversion efficiency recorded the highest CO conversion rate of 97percent at the lower engine load, which then leveled off at 95 percent CO conversion efficiency at full load. During the sample testing, CO emissions at the outlet of the catalyst had reached a plateau at an absolute value of approximately 25 ppm, regardless of the CO concentration at the inlet of the catalyst.
testing with a lower span CO cell to measure the CO conversion at low CO concentrations showed that these emission limits were achieved. The addition of the crankcase ventilation filters removed all visible emissions at the crankcase vent pipe while enabling
the engines to operate at the desired crankcase pressure of 0.4 to 0.5-inches w.c. While the installation presented some challenges, the equipment was successfully installed through a cooperative effort among all members of the team.
CONCLUSION
The new RICE NESHAP regulation has placed a significant requirement on existing CI engines to reduce HAPs. Using CO as a surrogate for HAPs, the RICE NESHAP regulation required the NRG engines to reduce CO emissions by at least 70 percent or to a level of 23 ppmvd at 15 percent O2. NRG installed a precious metal-based catalytic converter system to comply with these emission limits. Emissions For info. http://powereng.hotims.com RS# 33
www.power-eng.com 61
This 1:8.71 physical model of the Alden turbine runner was tested by Voith Hydro and provided peak efficiency of 91.85%, which translates to a maximum calculated prototype efficiency of 93.64%.
now ready for installation and testing at a hydroelectric plant, and efforts are under way to find an industry partner to accomplish this next step.
UNDERSTANDING THE BACKGROUND

Four years of work have gone into a collaborative research and development project funded by EPRI, DOE and hydropower industry partners such as Brookfield Renewable Power, Dairyland Power Cooperative, Electricite de France, New York Power Authority, New York State Energy Research and Development Authority, Puget Sound Energy, SCANA Corp. and Southern Company. The objective of this project was to complete the developmental engineering required for the fish-friendly turbine developed by Alden to prepare it for full-scale deployment and testing. In 2009, EPRI, in response to a 2008 DOE funding opportunity announcement with cost-sharing support from the hydropower industry, was awarded a $1.2 million DOE grant, matched by an equal amount from EPRI and its industry partners, to conduct engineering development and physical scale model performance testing of the Alden turbine. The developmental engineering included: Using computational fluid dynamics (CFD) to convert a conceptual design into a design from which the turbine can be built; and Constructing and testing a physical model of the turbine to evaluate its performance characteristics for economic analysis. The Alden turbine was developed through DOEs former Advanced Hydro Turbine Systems Program and, more recently, through EPRIs Waterpower
www.power-eng.com
Development Status of the Alden Fish-Friendly Turbine

BY NORMAN PERKINS, DOUGLAS A. DIXON, RAJESH DHAM AND JASON FOUST
O
62
ver four years, multiple entities within the hydropower industry have worked to advance design, construction and installation of a specific fish-friendly turbine design. Efforts are under way to find a hydroelectric project operator to install this unit and demonstrate its effectiveness for safely passing fish and producing electricity. In an ideal operating scenario, every drop of water available to a hydroelectric powerhouse is run through the turbines to generate electricity. However, the need to support high fish passage survival at most hydropower facilities precludes this
from happening. In the absence of turbine technology that provides high fish passage on its own, hydro plant owners must rely on such alternative measures as spill or bypasses to protect fish. To help overcome this problem, the Electric Power Research Institute (EPRI), U.S. Department of Energy (DOE), Alden Research Laboratory Inc., Voith Hydro Inc. and several industry partners have been working to advance design of a fish-friendly turbine. This turbine has been conceptualized, tested using physical scale and computational fluid dynamics modeling, redesigned, produced at model scale, and tested again. As a result of this work, the Alden turbine is
Program and DOEs Wind & Water Power Program. The turbine was designed to support high fish passage survival, which would offset the need for measures such as intake screens, fish passage spills and alternative downstream fish bypasses that are expensive and decrease generation. To reduce injury to fish, the Alden runner has: only three blades, no clearances between the blades and the crown or housing, and, with the exception of small areas around the blade leading edges, pressure and velocity (shear) gradients that meet established bio-criteria for safe fish passage. Before 2009, numerous studies supported by DOE, EPRI and industry collaboration were conducted to validate the theoretical concept of the turbine. Studies included: CFD modeling, use of a one-third-scale test facility to evaluate the turbine biological and engineering performance, additional conceptual turbine development efforts (in 2006), and laboratory experiments that examined the relationship between turbine blade leading edge geometry and fish injury/ survival after blade strike.
FEA Image of Turbine Runner
# 1
Finite element analysis of the turbine runner was performed to determine the static stresses for the stay vanes, wicket gates and runner modifcations.
CFD Image of Turbine Runner
# 2
HYDRAULIC DEVELOPMENT
The Alden runner reduces blade strike mortality through several modifications: Reducing the number of blades relative to conventional applications; Employing special blade leading edge geometries; and Rotating slower than conventional turbines. The current Alden turbine design incorporates a runner that features three blades that rotate at a speed of 120 revolutions per minute (rpm). Application of conventional turbine technologies for the target site results in a 13-bladed Francis turbine that rotates at 189.5 rpm, or a five-bladed Kaplan turbine that rotates at 267.9 rpm. The blade shapes were developed to meet criteria for pressure change rates, shear rates and minimum pressures through the runner. The blades feature
www.power-eng.com Computational fuid dynamics simulations of the turbine runner included everything from the penstock to the draft tube outlet and tailwater. The same loss sources were modeled here as were studied using the physical model.
relatively thick semi-circular entrance edges to minimize strike damage to fish, extremely long blades with nearly 180 degrees of blade wrap, and a runner height that is larger than a conventional turbine of similar diameter. Each blade is fixed to a central hub (crown) and an external shroud (band), eliminating all gaps and resulting leakage vortices within the runner passage. Runner geometry was evaluated according to three distinct design criteria, with fish friendliness being the most important, followed by increased power
production, and finally reduced supply costs. Although the runner is being developed to provide a new family of fishfriendly hydro turbines for smaller machines across a range of head and flow applications, Alden and Voith Hydro focused the design effort for potential pilot application at a project with operating conditions corresponding to 92 feet of net head with a discharge rate of 1,500 cubic feet per second (cfs). Calculations show that the improved flow environment through the final turbine is expected to produce significant efficiency improvements (5% at the design conditions listed above) with the same or slightly improved fish-friendly characteristics as compared with the original Alden concept. While some small performance improvements are predicted for the final distributor, the majority of the efficiency improvement is realized in the final runner and draft tube as a result of the improved runner-draft tube interaction at the selected design condition. After the modified turbine hydraulic passageways were defined and structural analysis was performed for the anticipated operating range, the hydraulic shapes were released for model manufacture, including the inlet pipe, transition piece, spiral case, stay ring, wicket gates, runner and draft tube. Physical model testing was conducted in 2010 at Voith Hydros S. Morgan Smith Memorial Hydraulic Laboratory in York, Pa. Data was collected on performance, thrust, runaway speed, pressure pulsations, minimum pressures, cavitation and wicket gate torques to characterize the hydraulic behavior of the turbine and identify the acceptable operating range for the target site design. Results of the hydraulic testing also were incorporated into the final sizing of the mechanical equipment. Voith Hydro manufactured the physical model at a scale of 1:8.71 and conducted the tests at a speed of 900 rpm. During testing, a model peak efficiency of 91.85% was recorded. The prototype efficiency adjustment translates into a maximum calculated
63
Anticipated Range of Application for Alden Turbine
The Alden turbine design represents a new family with a range of head and fow applications. Future design modifcations are anticipated to extend operation of the turbine above 120 feet of net head.
prototype efficiency of 93.64%. The final aspect of the developmental engineering included the design for the supporting mechanical and balance of plant equipment for supply of the complete unit. In this phase, finite element analysis (FEA) was performed to determine the static stresses for the stay vanes, wicket gates and runner modifications (see Figure 1). Mechanical design and analysis of the final spiral case and stay ring decks was completed.
the outer runner shroud and the casing, as well as between the head cover and runner top, thereby including the same loss sources as in the physical model. Plotting the resulting efficiencies from the physical model and CFD simulations using non-dimensional head and flow coefficients, which included the turbine diameter and runner rotating speed, aided a direct comparison between the BEP operating conditions and maximum efficiency value. The general shape of the efficiency lines on the hill chart was also
compared. The CFD hill chart is generally similar in shape to that derived from the physical model test results. However, the CFD model tended to over-predict efficiency for low flows with small gate opening angles. This resulted in displacement of the CFD-derived highest efficiency area to lower flows. The reasons for these differences are not clear. It may be noted that the plotted efficiency contours are at intervals of only 0.5%, which accentuates visual differences between the contours from the CFD and physical data. The peak efficiency of 93.6% expected for the full scale turbine was well-predicted by the CFD simulations. It is concluded that the CFD simulations are most reliable in predicting the more controlled (coherent) flow patterns near the turbine design point. This direct comparison between CFD simulations and physical model test data provides useful information for turbine designers and researchers. This kind of validation allows the developed CFD model to be used to explore other issues of concern, such as determining values for local pressures, pressure change rates, shear and the locations where related fish survival criteria are met or exceeded.
CFD SIMULATIONS AND COMPARISON WITH PHYSICAL MODEL DATA

The data on efficiency and power obtained from the physical model testing, scaled up to prototype values, were used to compile the hill chart to visually show the best efficiency point (BEP) and range of acceptable operating conditions. CFD simulations of the entire turbine (see Figure 2) were initiated, from the penstock to the draft tube outlet and tailwater. These simulations included the fluid-filled spaces between
Price of Alden vs Conventional Turbines

Alden Turbine Diameter (mm) Maximum Power (MW) Turbine Cost Generator Cost Installation and Commissioning Cost Automation/Balance of Plant Cost Relative Cost Premium for Alden
Source:
1
Conventional Kaplan Turbine (Same Power) 2,650 13.6 0.55 0.65 0.25 0.25 1.7 35%
Conventional Francis Turbine (Same Power) 2,510 13.6 0.5 0.65 0.25 0.25 1.65 39%
3,900 13.6 1 0.8 0.25 0.25 2.3
64
www.power-eng.com
On target for a cleaner future .
Save the Date. With a decade of service to the coal sector, COAL-GEN is the industrys most dynamic event
covering the latest topics affecting the design, development, upgrading, operation and maintenance of coal-fueled power plants. With an anticipated attendance of over 4,000 industry professionals and more than 250 exhibitors, COAL-GEN is the industrys largest event focused on the solutions of today and the technologies of tomorrow.
AUGUST 1416
www.coal-gen.com
Owned & Produced By:
CHARLOTTE, NC
CHARLOTTE CONVENTION CENTER
Presented By:
ALDEN TURBINE DEVELOPMENT: PRICING AND SCHEDULE

Below is a preliminary schedule for installation at a potential test site: Definition of unit layout, four months from contract award from the potential utility to Voith Hydro; Embeds arrive at site, 14 months from contract award; Powerhouse crane available for Voith Hydro use, 22 months from contract award; and Equipment commissioned and handover to owner, 28 months from contract award. The Alden turbine is, by design, lower in power density than conventional turbines. The larger, more slowly rotating equipment leads to a relatively more expensive turbine-generator solution. For the site conditions at a comparable prototype site, sizing for a conventional Francis unit gives a 13-bladed, 2.5-meter-diameter runner with an rpm of 189.5. Sizing for a conventional Kaplan turbine gives a fivebladed, 2.7-meter-diameter runner with an rpm of 276.9. During the Alden turbine development, a detailed cost study was performed to determine the equipment, installation and commissioning cost. Table 1 provides a comparison of the installed equipment price for the Alden turbine vs. conventional hydro turbines. The prices are normalized relative to the Alden turbine. The relative pricing does not include civil work. The larger size and slower speed of the turbine allows for a higher setting relative to the tailwater. For the prototype design, the Alden distributor centerline is 5 feet above tailwater, while the conventional Francis centerline is anticipated to be set 2 feet above tailwater. The conventional Kaplan centerline is set the lowest, falling 16 feet below tailwater.
The higher setting of the Alden turbine may result in less excavation and lower civil costs.
APPLICABILITY TO OTHER HYDRO SITES

Although the turbine was hydraulically and mechanically designed for a target site condition, it represents a new turbine family with a range of head and flow applications. Figure 3 shows the anticipated turbine application range. The green region, labeled current application, spans 75 to 100 feet of net head and represents the head range covered by the current design. The larger yellow region, labeled modified current application, can be accomplished through appropriate sizing and design modifications to the turbine. This region spans from 30 to 120 feet of net head. At 120 feet of net head, stress limitations of the current design limit applicability. It is anticipated that future design modifications to the turbine can extend the operation above 120 feet of net head. Below 30 feet of net head, turbine application switches to large bulb units.
funding opportunity announcement, EPRI was selected to receive $1.5 million of support with a cost-share match requirement to install and test the Alden turbine at a site to be determined.
SUMMARY AND NEXT STEPS

The work performed to date has improved the performance characteristics of the Alden turbine while maintaining its fish-friendly characteristics. The preliminary engineering required to make the turbine commercially available has been completed. Design modifications to the turbine components have improved efficiency to almost 94% at the selected design point, while providing the same or slightly improved fish passage survival. These turbine modifications were also selected to decrease manufacturing and supply costs, resulting in a solution that is economically competitive with conventional turbines. The improved turbine is now available for commercial deployment. In 2011, in response to another DOE
References Additional Tests Examining Survival of Fish Struck by Turbine Blades, EPRI, Palo Alto, Calif., 2011. Amaral, S.V., et al, Effects of Leading Edge Turbine Blade Thickness on Fish Strike Survival and Injury, Proceedings of HydroVision 2008, HCI Publications, Kansas City, Mo., 2008. Cook, T.C., et al, Final Report Pilot Scale Tests Alden/Concepts NREC Turbine, prepared by Alden Research Laboratory for U.S. Department of Energy, Contract No. DE-AC0799ID13733, 2003. Coulson, S., et al, Alden Fish Friendly Turbine: Final Development for Commercial Application, Proceedings of HydroVision 2011, PennWell Corporation, Tulsa, Okla., 2011. Demonstration Development Project: Solicitation and Selection of a Site to Test a FishFriendly Hydropower Turbine, EPRI Technical Update No. 1022538 prepared by Alden Research Laboratory, 2011. EPRI-DOE Conference on EnvironmentallyEnhanced Hydropower Turbines: Technical Papers, EPRI, Palo Alto, Calif., and U.S. Department of Energy, Washington, D.C., 2011. Evaluation of the Effects of Turbine Blade Leading Edge Design on Fish Survival, EPRI Report No. 1014937 prepared by Alden Research Laboratory, 2008. Fish Friendly Hydropower Turbine Development and Deployment: Alden Turbine Preliminary Engineering and Model Testing, EPRI Report 1019890 prepared by Alden Research Laboratory, 2011. Hecker, G.E., and T.C. Cook, Development and Evaluation of a New Helical Fish Friendly Hydro-Turbine, Journal of Hydraulic Engineering, Volume 131, No. 10, October 2005, pages 1-21. Redesign of the Alden/Concepts NREC Helical Turbine for Increased Power Density and Fish Survival: Evaluation of a Conceptual Prototype Turbine, EPRI, Palo Alto, Calif., 2009.
www.power-eng.com
66
Automatic Filters
Consulting Engineering Services
Control Valve Actuator
Electric Control-Valve Actuators

Why Should You Filter Your Water?
Rotork electric CVA control-valve actuators provide a major technological advance in precise operation, HMI capabilities, and fail-to-position protection. Available in linear and quarter-turn actions, they are ideal for a wide range of controlvalve applications throughout the power plant. They can deliver an absolute positioning accuracy of 0.1%, have a built-in data ORJJHUDQGFDQSURYLGHVLJQL FDQWHQHUJ\ savings. Learn more at www.rotork.com.
SUPPLIERS SHOWCASE |
SHOWCASE ADVERTISING CONTACT JENNA HALL: 918-832-9249, JENNAH@PENNWELL.COM
The Best Engineered Water Filteration Solution Always Costs Less
www.stanleyconsultants.com 800.553.9694
http://powereng.hotims.com/RS#301
peinfo@rotork.com 585-247-2304
Dupont Krytox
Engineering & Construction
Flameless Pipe Joining
Full Service Power Engineering and EPC Construction

Krytox Fluorinated Lubricants
Dupont Krytox Oils and Greases. These high-performance fluorinated lubricants are derivatives of Teflon and offer the following advantages: Chemically inert. Wide temperature range (-103F to 800F). Compatible with plastics, rubber, ceramics, & metals. Nonflammable. Insoluable in common solvents. No silicones or hydrocarbons. Krytox is applied to gearboxes, dampers, ductwork valves, steam valves, gaskets, seals, compressors, bearings, boilers, pumps, and Turbine Auxiliary systems. For more information and sample call 800.992.2424 or 203.743.4447
Authorized Krytox Distributor Since 1991
Viega ProPress is a better way to join copper tubing and stainless steel pipe. Viega ProPress is faster, flameless and more consistent when compared to traditional pipe joining methods. Fittings are available in sizes 1/2 to 4 in copper or 304 and 316 stainless steel.
m
miller-stephenson chemical company, inc.
California - Illinois - Connecticut - Canada e-mail: support@miller-stephenson.com www.miller-stephenson.com
Contact: Chris Bramhall chrisbramhall@bibb-eac.com
(816)-285-5500
www.ViegaProPress.us
http://powereng.hotims.com/RS#303 www.power-eng.com
http://powereng.hotims.com/RS#305 67
Heat Recovery Systems
Iso Phase Bus
Media Blasting Services

Media Blasting Services
| SUPPLIERS SHOWCASE
Crown Electric
Iso Phase Bus
Increase Steam Boiler Efficiency:

Brochure HRS 1188 describes three different types of continuous boiler blowdown heat recovery systems manufactured by Penn Separator Corp. All systems recover up to 90% of the BTUs normally lost to drain. Visit our website www.pennseparator.com for a sales representative nearest you.
Fabrication Installation Upgrades & Uprates GSU Change Outs
From Dry Ice to Walnut Shells, Abrasive Blasting
513 539-7394 ext. 201

175 Edison Dr. Middletown, OH 45044 www.crown-electric.com sales@crown-electric.com
www.molemaster.com
Pipe Joining
Pressure Blower
Protective Coatings Association
Introducing the Arrangement 9 Pressure Blower
JEA Northside Generating Station in Jacksonville, FL, installed 6,000 feet of Viega ProPress 316 stainless steel pipe and over 500 fittings. The system is easy to work with because of the consistency of the connections, said Ron Beverly, CFB Operations Specialist.
Arrangement 9 motor orientation offers a reduced fan footprint. Used as part of a system for conveying coal dust or incinerating off a gas in a gas-handling system.
For more information: www.ViegaProPress.us
THE NEW YORK BLOWER COMPANY

800.208.7918 | www.nyb.com
2012 The New York Blower Company
http://powereng.hotims.com/RS#309 68
http://powereng.hotims.com/RS#311 www.power-eng.com
Service Provider
Solar Expertise
FLUOR DRIVES
Tube & Pipe, Seamless
SUPPLIERS SHOWCASE |
Global strength meets independent thinking.

PIC is a leading, global power generation service provider capable of managing multi-faceted projects including: Start-up & Commissioning Operations & Maintenance Installation Turbine Outages Mechanical Services Technical Services
INNOVATION
Nearly 30 years after completing our frst renewables project, Fluor is now an industry leader in the utility-scale PV market, providing innovative, cost efective solutions and expertise on solar projects like the 170-megawatt Centinela Solar Energy project in California and the 125-megawatt Arlington Valley Solar Energy II project in Arizona. www.fuor.com
TO THE RESCUE
2013 Fluor Corporation. All Rights Reserved. ADGV089613
770.850.0100
picworld.com
Michigan Seamless Tube, LLC 800.521.8416 | www.mstube.com

Your Source for Energy News, Research, and Insight.
Were In Great Company

A FEW OF OUR PENNWELL FRIENDS:
PennEnergy.com was created by PennWell, a leader in the coverage of the global petroleum and power industries since 1910, to serve as the broadest and most complete source of energy-related news, research, and insight. Including content from all PennWell award-winning energyrelated brands, PennEnergy.com delivers original news, nancial market data, in-depth research materials, books, equipment, and service information all in one easy-tonavigate website.
UTILITY
conference & exposition
PRODUCTS
Make PennEnergy a part of your day and know what is happening in the world of energy.
P E PennEnergy.com
69
www.power-eng.com
| CLASSIFIEDS
ELECTRICAL ENGINEER
Toledo, Ohio. Responsible for developing and managing preventative maintenance efforts for electrical systems throughout companys facilities, developing a comprehensive program to ensure the safe, continuous, and reliable operation of all electrical infrastructure including transformers, switchgear, feeders, bus duct, motors, and other ancillary equipment. A Bachelor's Degree in Electrical Engineering is required and a minimum of 10 years of experience in electrical engineering with an emphasis on large industrial or utility distribution systems including protective relaying. To apply, please visit: http://www.dteenergy.com/dteEnergyCompany/careers/
CLASSIFIED ADVERTISING CONTACT JENNA HALL: 918-832-9249, JENNAH@PENNWELL.COM
Pugmill Systems, Inc.

P.O. Box 60 Columbia, TN 38402 USA Ph: 931-388-0626 Fax: 931-380-0319
Get a thorough mix with:
ARE YOU SELLING?

VALVES INSTRUMENTATION ELECTRICAL CONTROLS PROCESS EQUIPMENT PROCESS CONTROLS PLANT MACHINERY PSA SNUBBERS, ETC.
WE ARE BUYING!!!
www.pugmillsystems.com
Light up your
ad with a little
COLOR!
Intralox, L.L.C. is looking for an energetic, well organized person with the ability to evaluate market opportunities, distil clear messages, and execute selling strategies. The qualified individual will be responsible for calling on accounts at the corporate and plant level in the development and implementation of sales strategies with emphasis on institutional conversions for multi-plant corporations. Must have an industrial sales background preferably in the electrical power, petrochemical or steel industry and be willing to travel up to 70%. For more position details and to apply, visit www.intralox.com.
Ferncroft
Management,LLC
VISIT
NATIONAL ACCOUNTS MANAGER
Call Jenna Hall at 918-832-9249
www.FerncroftManagement.com T. 978-815.6185 Fax. 603-814.1031

email:vavlebuyer@ferncroftmanagement.com
LIMITORQUE OPERATORS WANTED
NOISE?
5VPZL *VU[YVS ,UNPULLYPUN*VUZ\S[PUN ,U]PYVUTLU[HS :V\UK 3L]LS :\Y]L`Z >VYRWSHJL 5VPZL ,_WVZ\YL ,]HS\H[PVU *VTTPZZPVUPUN *VTWSPHUJL ;LZ[PUN *VTW\[LY 5VPZL 7YLKPJ[PVU *VU[V\YZ
Houston: 713-789-9400 Calgary: 403-259-6600 www.HFPacoustical.com info@HFPacoustical.com
FIND CONDENSER LEAKS FAST WITH FOAM METHOD LEAK DETECTION, TUBE PLUGS IN STOCK
Ph# 800-726-1026 Condenser & Heat Exchanger Tools www.johnrrobinsoninc.com

John R. Robinson Inc.
24 / 7 EMERGENCY SERVICE BOILERS

20,000 - 400,000 #/Hr. 50 - 25,000 KW 25 - 4000 HP
FOR SALE/RENT
CLASSIFIEDS |
DIESEL & TURBINE GENERATORS GEARS & TURBINES

LARGEST INVENTORIES OF:
Air Pre-Heaters Economizers Deaerators Pumps Motors Fuel Oil Heating & Pump Sets Valves Tubes Controls Compressors Pulverizers Rental Boilers & Generators
CLASSIFIED ADVERTISING CONTACT JENNA HALL: 918-832-9249, JENNAH@PENNWELL.COM
847-541-5600
wabash
visit www.wabashpower.com
FAX: 847-541-1279
POWER EQUIPMENT CO.
444 Carpenter Avenue, Wheeling, IL 60090
The worlds very best portable end prep tools and abrasive saws
For sale or rent
800-343-6926 www.escotool.com
rental equipment
1-800-990-0374 www.rentalboilers.com
GEORGE H. BODMAN, INC.
Chemical cleaning advisory services for boilers and balance of plant systems
Quality and Service Since 1908
George H. Bodman
Pres / Technical Advisor
P.O. Box 5758 Kingwood, TX 77325-5758 email: blrclgdr@aol.com
Office (281) 359-4006 1-800-286-6069 Fax (281) 359-4225
Ring Granulators, Reversible Hammermills, Double Roll Crushers, Frozen Coal Crackers for crushing coal, limstone and slag. 1319 Macklind Ave., St. Louis, MO 63110 Ph: (314) 781-6100 / Fax: (314) 781-9209 www.ampulverizer.com / E-Mail: sales@ampulverizer.com

Rental Boilers Deaerator Systems Economizers Water Softener Systems 24-Hour Emergency Service
the steam & power special forces
Tur bine Controls

Woodward, GE, MHC Parts and Service Obsolete Parts Inventory Control System, Modernization Training, Troubleshooting
TurboGen Consultants, Inc.

(610) 631-3480 www.turbogen.net info@turbogen.net
*HW D %RLOHU 5HQWDO 4XRWH ZLWKLQ RQH KRXU DW ZZZZDUHLQFFRPHTXLSPHQW RU FDOO
INDEX
RS# COMPANY
27 22 7 Aggreko
www.coolingtowers.com
PG#
47 36
RS# COMPANY
14 Mitsubishi Power Systems Americas Inc
www.mpshq.com
PG#
25 27 37 26 29 54 11 5 55
SALES OFFICE
1421 S. Sheridan Rd., Tulsa, OK 74112 Phone: 918-835-3161, Fax: 918-831-9834 e-mail: pe@pennwell.com Sr. Vice President North American Power Group Richard Baker Reprints Foster Printing Servive 4295 Ohio Street Michigan City, IN 46360 Phone: 866-879-9144 e-mail: pennwellreprint@fosterprinting.com National Brand Manager Rick Huntzicker Palladian Professional Park 3225 Shallowford Rd., Suite 800 Marietta, GA 30062 Phone: 770-578-2688, Fax: 770-578-2690 e-mail: rickh@pennwell.com AL, AR, DC, FL, GA, KS, KY, LA, MD, MO, MS, NC, SC, TN, TX, VA, WV Brand Sales Manager Dan Idoine 806 Park Village Drive Louisville, OH 44641 Phone: 330-875-6581, Fax: 330-875-4462 e-mail: dani@pennwell.com CT, DE, IL, IN, MA, ME, MI, NH, NJ, NY, OH, PA, RI, VT, Quebec, New Brunswick, Nova Scotia, Newfoundland, Ontario Brand Sales Manager Tina Shibley 1421 S. Sheridan Road Tulsa, OK 74112 Phone: 918-831-9552; Fax: 918-831-9834 e-mail: tinas@pennwell.com AK, AZ, CA, CO, HI, IA, ID, MN, MT, ND, NE, NM, NV, OK, OR, SD UT, WA, WI, WY, Alberta, British Columbia, Saskatchewan, Northwest Territory, Yukon Territory, Manitoba International Sales Mgr Anthony Orfeo The Water Tower Gunpowder Mills Powdermill Lane Waltham Abbey, Essex EN9 1BN United Kingdom Phone: +44 1992 656 609, Fax: +44 1992 656 700 e-mail: anthonyo@pennwell.com Africa, Asia, Central America, Europe, Middle East, South America European Sales Asif Yusuf The Water Tower Gunpowder Mills Powdermill Lane Waltham Abbey, Essex EN9 1BN United Kingdom Phone: +44 1992 656 631, Fax: +44 1992 656 700 e-mail: asify@pennwell.com Europe and Middle East Classifieds/Literature Showcase Account Executive Paige Rogers 1421 S. Sheridan Rd. Tulsa, OK 74112 Phone: 918-831-9441, Fax: 918-831-9834 email: paiger@pennwell.com
APEX Engineering Products Bibb Engineers, Architects, Constructors

www.bibb-eac.com
www.apexengineeringproducts.com
16 23 15
New York Blower Company

www.nyb.com
13
Nol-Tec Systems Inc

www.nol-tec.com
25
Brand Energy and Infrastructure Services

www.beis.com
Nord-Lock\Superbolt
www.nord-lock.com
43 17
Orion Instruments
www.orioninstruments.com
Brandenburg Industrial Service Company

www.brandenburg.com
C4 30 PennWell Webcast
www.power-eng.com/webcast
32 Caterpillar Inc.
www.catgaspower.com
59 6 65 3 23 31 POWER-GEN INTERNATIONAL
www.power-gen.com
Philadelphia Gear Corporation PIC Group Inc

www.picworld.com
34 COAL-GEN
www.coal-gen.com
13 11 20 12 2
Diamond Power International

www.diamondpower.com
Dresser-Rand
www.dresser-rand.com/products
22 24 33 21 22 1 Renewable Energy World North America Siemens AG

www.siemens.com/energy
39 35 C2 17 19 9 32 7
Fibrwrap
www.fibrwrap.com
RenewableEnergyWorld-Events.com
Goodway Technologies Corp

www.goodway.com
Solvay Chemicals Inc

www.solvair.us
Gundlach Crushers/Pennsylvania Crusher

www.TerraSource.com
3 9 61 10 45 C3 49 15 53 Advertisers and advertising agencies assume liability for all contents (including text representation and illustrations) of advertisements printed, and also assume responsibility for any claims arising therefrom made against the publisher. It is the advertisers or agencys responsibility to obtain appropriate releases on any items or individuals pictured in the advertisement. 5 19 4 Sturtevant Inc
www.sturtevantinc.com
Structural Integrity Associates

www.structint.com/power-eng
33 Harco
www.harcolabs.com
26
Hitachi Power Systems Amercia Ltd

www.hitachipowersystems.us
Team Industrial Services

www.teamindustrialservices.com
35 Hobas Pipe USA

www.hobaspipe.com
Wanzek Construction Inc

www.wanzek.com
HYTORC
www.torquegun.com
Westinghouse Electric Co
www.westinghousenuclear.com
8 29
Ingersoll Rand
www.ingersollrandproducts.com
Light Engineering Inc

www.It-eng.com/products/find-adistributor
18 28
Magnetrol International
www.magnetrol.com
31 52
Membrana
www.liqui-cel.com
72
www.power-eng.com
What Makes HOBAS The Standard?

Precision centrifugal casting, consistent high quality, berglass-reinforced, polymer mortar pipes Responsive customer service, on-site eld reps backed by extensive engineering support
Time Proven Leak Free Long Lasting Corrosion Resistant High Strength Quick, Easy Installation High Flow Capacity
HOBAS PIPE USA
281-821-2200 www.hobaspipe.com

Power Engineering 201306

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Power Engineering 201306

Uploaded by

Copyright:

Available Formats

Were Not Exaggerating. Our Boilers are something to brag about.

WHAT YOU NEED TO KNOW TO COMPLY

THE KEY TO QUICKER STARTUP TIMES

THE BEST TECHNIQUES AND STRATEGIES

the th he magazine of power generation generati ion

June 2013 www.power-eng.com

Welcome to the Digital Edition of

the magazine of power generation

Easily NAVIGATE through the issue.

SEARCH for specific

View the table of CONTENTS and easily navigate directly to an article.

Easily browse all BACK ISSUES.

page via social media.

A quick start guide to MAXIMIZING our interactive features.

SHARE an article via email.

PRINT any or all pages.

DOWNLOAD the issue to your desktop.

rti NHA sin S g pe Se ci ct al ion 35 -

THE POWER OF REHABILITATION

CHALLENGES AND SOLUTIONS

the magazine of power generation

March 2013 www.power-eng.com

When the heat is on SOLVAir Solutions helps relieve it!

Solvay Chemicals, Inc. 1.800.SOLVAY C (800.765.8292) www.solvair.us

For info. http://powereng.hotims.com RS# 1

Power Engineering is the flagship media sponsor for

No. 6, June 2013

The Physics Behind the Concept

50 Upgrading Electrostatic Precipitators

56 Engineering Design for

RICE NESHAP Compliance

62 Development Status of the

Alden Fish-Friendly Turbine

POWER ENGINEERING ONLINE :

www.power-eng.com Industry News:

A concise, weekly update of all the top power generation news

Managing Regulatory Mayhem

Precise Product Sized for Maximum Yield

The in Uptime Since 1905 The Leader i nU ptime eS ince e1 905

Eliminate Fugitive Dust!

Thats a Gundlach Crusher.

Right Size. Maximum Yield. Minimum Fines. Every Time.

The Most Choices, The Most t Experi ience.

Cage C Mills Mill

Toll-Free: 1-877-GUNDLACH E-mail: BetterCrushers@GundlachCrushers.com

Phone: 1-610-544-7200 E-mail: Buster@PennCrusher.com

Handling a World of Materials

For info. http://powereng.hotims.com RS# 2

CLEARING THE AIR

Finding Best-Fit Mercury Emission Controls

The Best Of The Best

For info. http://powereng.hotims.com RS# 3

Nuclear Powers Strong Future amid Challenges in the present

ON ADVANCED NUCLEAR PLANT TECHNOLOGY

WESTINGHOUSE ELECTRIC COMPANY LLC

2013 Shandong Nuclear Power Company Ltd. All Rights Reserved.

Demand Response Invades the Grid and Makes it Smart

Scheduled maintenance, inspections, emergency responseTeam delivers

FIELD HEAT TREATING

HOT TAPS / LINE STOPS

PIPE REPAIR SERVICES

For info. http://powereng.hotims.com RS# 5

Elements of Success in Tidal Energy Development

Fortunately, we make house calls.