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SMALL MODULAR REACTORS
POWER PLANT CONTROLS
OAK RIDGE DEVELOPS MODELING

PROGRAM FOR SMR DESIGNS
COGEN PLANT IN OREGON GETS AN UPGRADE
VALVES AND ACTUATORS

INNOVATIONS AND OPPORTUNITIES
TO BOOST EFFICIENCY
the magazine of power generation
118
YEARS
WATER
Treatment Trends
April 2014 www.power-eng.com

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Power Engineering is the flagship

media sponsor for
FEATURES118
No. 4, April 2014
VOLUME
Wastewater Treatment
28 Issues
for Combined
Cycle Plants
Significant focus has been on water emissions from

coal-fired plants, but personnel at gas-fired plants are also
dealing with stringent effluent limitations. Contributing Editor
Brad Buecker looks at water treatment issues for combined
cycle power plants in this article.
36
New Control System Solves Black

Box Problems at Cogen Plant
Faced with frustrations with their current control systems, the owners of
the Klamath Cogeneration Plant in Oregon hired ABB to install a more
reliable control system to create opportunities for additional revenue.
40
Boiler Cleaning Practices & Technology
Keeping a power plants boiler clean is an important part of increasing

efficiency and avoiding forced outages. Power Engineering looks at different
methods and practices for cleaning boilers.
46
Valves & Actuators: The Path to

Greater Efficiency & Performance
Valves and actuators are critical in every aspect of power plant

operations, and companies are working to make innovations
that will improve performance and reduce costs.
54
ORNL Modeling Program to

Simulate SMR Designs
Faced with the possibility of decades of design work, Oak Ridge

National Laboratory turned to open-standards modeling to cut the
development time for small modular nuclear reactors.
DEPARTMENTS
2
4
10
Opinion
Industry News
Clearing the Air
12
14
16
Gas Generation
View on Renewables
Energy Matters
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Power Engineering
OPINION
CHP:
BY RUSSELL RAY, MANAGING EDITOR
ombined heat and power

(CHP), a highly efficient form
of generation used to power a
wide range of industries, is perhaps the
most underutilized and underappreciated source of electricity production in
the U.S.
But cheap natural gas, new incentives
for CHP projects and a public demand for
greater efficiency and reduced emissions
are driving the development of CHP projects across the nation.
CHP plants, also known as cogeneration plants, recycle the waste heat
produced during power production for
manufacturing processes and other useful purposes. By capturing and utilizing
the excess heat, CHP plants can achieve
energy efficiency rates of 75 percent or
higher, well above efficiency rates for
conventional power stations.
More than 4,000 MW of new CHP
capacity are in some stage of development in the U.S., according to ICF International, a research and consulting firm.
Most of that capacity more than 1,000
MW will be built in Texas. In the Midwest alone, the industry has announced
plans to build 38 CHP projects between
2014 and 2016. More Midwest projects
are under development but havent been
announced.
Altogether, the U.S. has more than
82,000 MW of CHP capacity at 4,200
sites. More than 70 percent of that capacity is fueled with natural gas. Most of
that power is used in industrial applications such as paper, refining, chemical
and food processing. CHP is also used
to power hospitals, universities, military
bases and residential facilities.
The potential to add more CHP capacity to the U.S. grid is significant, ranging
2
An Emerging
Market
from 50,000 to 200,000 MW, according
In Europe, CHP capacity is projected to
to some studies.
grow from 202 GW now to 245 GW by
The Obama administration wants to 2020 at a rate of 3.2 percent a year, accordboost CHP capacity by 40,000 MW, or ing to a report from research and consult50 percent, by 2020. That was the goal es- ing firm GlobalData.
tablished in an executive order directing
With its strict emission and carbon
several federal agencies and departments savings targets, coupled with its focus on
to encourage more investment in CHP decentralized energy, Europe is comfortprojects through existing programs and ably the biggest market for CHP installapolicies.
tions, said SowmyaIf that goal is met, Like combined
vadhana Srinivasan,
American businesses cycle gas turbines, senior power analyst
would save an estimat- CHP systems fueled for GlobalData.
ed $10 billion a year in
CHP, or cogenerawith gas can be
energy costs. The emistion, has been around
sions reduction would used to support
for 100 years. It has
be tantamount to tak- the deployment of
quietly been providing 25 million cars off
highly efficient,
renewable power. ing
the road.
reliable power to the
California-based Capstone Turbine nations most important industries for a
Corp. has installed 471 CHP systems in long time. In addition to CHPs high efthe U.S., which translates to more than ficiency ratings, the technology offers the
3 million fewer tons of carbon dioxide flexibility and reliability grid managers
(CO2) emissions versus CO2 emissions need to accommodate growing amounts
from conventional power plants. In 2013 of variable wind and solar power.
alone, Capstone customers avoided nearLike combined cycle gas turbines,
ly 300,000 tons of CO2 emissions.
CHP systems fueled with gas can be
CHP accounts for 9 percent of total used to support the deployment of regeneration capacity in the U.S. In a 2008 newable power.
study by Oak Ridge National Labs, reAs power producers face a market
searchers found that boosting the use of where centralized coal and nuclear powCHP to 20 percent of total U.S. capacity er plants are no longer practical options
would save 5.3 quadrillion thermal units for new capacity, CHP offers utilities a
of fuel per year. Thats equal to nearly half proven alternative that is cleaner, more
of the total energy consumed by all U.S. efficient and less costly.
households. Achieving that level of CHP
As the Obama administration pursues
capacity would also cut CO2 emissions by new carbon limits for new and existing
60 percent, which is the equivalent of tak- power plants in the U.S., the market for
ing 154 million cars off the road.
CHP capacity will continue to grow.
In addition to using very little waIf you have a question or a comter, CHP plants emit 40 percent fewer ment, please contact me at russellr@
emissions compared with convention- pennwell.com. Follow me on Twitter
al power stations.
@RussellRay1.
www.power-eng.com
ITS JUST STEAM.
CLEAN
ELECTRICITY.
Nuclear energy plants dont emit smoke, just steam from

hot water. No other generating source provides more
clean air energy.
For more information, visit us at www.westinghousenuclear.com
Westinghouse
Electric Company
@WECNuclear
W E S T I N G H O U S E E L E C T R I C C O M PA N Y L L C
AND LOTS OF
INDUSTRY NEWS
Mitsubishi Hitachi
signs $77.8 million deal
for 501J gas turbine
A deal to build what may be the most
effcient combined cycle power plant
in the U.S. was fnalized last week in
Tulsa, Okla.
Executives from Mitsubishi Hitachi
Power Systems and offcers from the
Grand River Dam Authority gathered in
Tulsa on March 21 to sign contracts for a
328-MW gas turbine known as the 501J
and a 167-MW steam turbine. The 495MW unit will replace an old coal-fred
unit at the Grand River Energy Center
near Chouteau, Okla.
and CEO of Mitsubishi Hitachi Power

Systems (MHPS), and Yasuo Fujitani, senior executive vice president of MHPS.
Part of the GRDA Boards strategy is
to reduce our reliance on coal, Sullivan
said. We can achieve some of that with
this new facility.
Yashihiro said the GRDA deal will be
the frst of many for MHPSA in the U.S.
GRDA will issue bonds to fnance the
project. Board members recently selected
JP Morgan as the lead fnancial institution. Hawkins Delafeld & Woods LLP
will serve as legal advisers.
GRDA has not yet selected an engineering and construction frm for the project.
Cape Wind wins

multiple legal victories
The project is the frst of its kind in the

Western world. The J-Series gas turbine is
the largest and most effcient gas turbine
in the world, according to Mitsubishi Hitachi. Nine are in commercial operation
worldwide, including six in South Korea.
One of the big features of this machine is its effciency, said Bill Newsom,
vice president of New Equipment Sales
& Commercial Operations for Mitsubishi Hitachi. At 50 percent output, youre
still above 55 percent combined cycle effciency.
The new combined cycle plant is expected to be up and running in spring
2017.
This unit has the potential to be the
most effcient combined cycle plant in
the country, said Charles Barney, assistant general manager of thermal generation for GRDA.
Dan Sullivan, GRDA CEO, and Yoshihiro Shiraiwa, president and CEO of Mitsubishi Hitachi Power Systems Americas
(MHPSA), signed the agreement during a
public gathering at the GRDA Engineering and Technology Center in Tulsa. Also
present were Takato Nishizawa, president
4
United States District Judge Reggie

B. Walton issued rulings on March 14
in four lawsuits that challenged Cape
Winds permitting approval by the
U.S. Department of Interior.
Judge
Walton
upheld
the
Department of the Interior along
with 16 other Federal and State
agencies review and approval of
Cape Wind, a permitting process that
took 10 years and includes more than
400,000 pages.
Judge Walton rejected a long list of
legal claims opponents had raised, including arguments over the National
Environmental Policy Act (NEPA), the
Endangered Species Act, the Migratory
Birds Treaty Act, the National Historic
Preservation Act, the Outer Continental Shelf Lands Act, the Coast Guard
and the Maritime Transportation Act
of 2006.
The four lawsuits were originally
fled in 2010 by the Alliance to Protect
Nantucket Sound, the Town of Barnstable, the Aquinnah Wampanoag
Tribe and the Public Employees for Environmental Responsibility.
NRG Energy acquires

Roof Diagnostics Solar
NRG Energy Inc. announced March
27 it has acquired Roof Diagnostics Solar
(RDS), a residential solar power installation company. Terms of the transaction

were not disclosed.
According to NRG Energy President
and CEO David Crane, RDS is a perfect
ft with NRG as the companies take a
big step towards a national residential solar platform. Over the next month, RDS
will begin operating under the brand
NRG Residential Solar Solutions.
RDS, which has 475 employees, has
been operating in the Northeast U.S. and
is expanding into California and other
areas. The companys headquarters will
remain in Wall Township, N.J.
GE releases new 9HA and

7HA natural gas turbines
General Electric has announced it will
be releasing the 7HA and 9HA air-cooled
gas turbines, according to a report from
Diesel & Gas Turbine Worldwide. The Hclass gas turbine will be released in two
versions for the 50 Hz market, the 9HA.01
and 9HA.02, and two versions for the 60
Hz market, the
7HA.01
and
7HA.02.
According to
the article, the
9HA.01 is rated
397 MW and the
9HA.02 is rated
470 MW in a simple-cycle confguration,
with each offering more than 41 percent
effciency. In a 1x1 combined-cycle confguration, the 9HA.01 is rated 592 MW
and the 9HA.02 is rated 701 MW, with
each offering more than 61 percent effciency.
The report stated the 7HA.01 is rated
275 MW and the 7HA.02 is rated 330
MW in a simple-cycle confguration, with
each offering more than 41 percent effciency. In a 1x1 combined-cycle confguration, the 7HA.01 is rated 405 MW and
the 7HA.02 is rated 486 MW, with each
offering more than 61 percent effciency.
GE told Diesel & Gas Turbine Worldwide the H-class gas turbine incorporates
an aerodynamic 14-stage compressor
and includes an advanced radial diffuser
www.power-eng.com
ITS A NU DAY
FOR A 60-YEAR OLD
INDUSTRY.
And the winner isNuScale Power. The US Department of Energy selected NuScale
Power for the second round of funding for Small Modular Reactor (SMR) development.
The fve-year funding program will signifcantly advance the design and certifcation of
the NuScale Power Module SMR technology. This accelerates commercial availability
to support customer needs for carbon-free baseload electricity, and validates the viability
of smaller, safer, simpler, more economical nuclear power. Its a Nu day.
nuscalepower.com
@NuScale_Power
NuScale Powe
INDUSTRY NEWS
that, combined with the Dry Low NOx
2.6+Axial Fuel Staged combustion system, allows improved operation of the
combustion liner and transition piece
cooling.
The frst 9HA gas turbine was manufactured in Belfort, France and was transported to Antwerp, Belgium before being
shipped to the U.S. for validation testing
at GEs test facility in Greenville, S.C.
$1.3bn contract signed

for hydroelectric power plant
in Canada
BBE Hydro Constructors Limited Partnership was awarded a C$1.4 billion ($1.3
billion) contract to build the 695-MW
Keeyask hydroelectric power plant for
Manitoba Hydro in Manitoba, Canada.
The BBE Hydro Constructors team
consists of Bechtel, Barnard Construction
and EllisDon. The team will build a seven-unit powerhouse and earthen structures; perform rock excavation as well as
electrical and mechanical work; and will
be responsible for the construction and
removal of temporary cofferdams.
First power from the plant is expected in 2019, with completion scheduled
for 2020.
Pumpjack and Wildwood will each

consist of a standalone 20-MW AC photovoltaic facility and a new 115 kV substation for connection to the grid. The
projects will use 171,000 x BYD 305 W
polycrystalline modules, 40 x 1 MW NX
Advanced Energy inverters and Array
Technologies Inc. single-axis trackers.
Duke will sell the power generated at
the projects to Southern California Edison under 20-year power purchase agreements that are already in place.
Samsung, Pattern and Capital

Power begin construction on
$850M K2 wind power project
Construction at the K2 wind power
project broke ground March 24 after securing $850 million in fnancing.
Samsung Renewable Energy Inc., Pattern Energy Group LP and Capital Power
LP entered into a joint venture to build
the 270-MW project in Ontario, Canada
Upon completion, the site is expected
to produce more than $3.2 million dollars in annual revenue, the companies
said in a press release.
The project will include 140 wind turbine towers and is expected to be operational by the second half of 2015.
Swinerton awarded contract

for 40 MW of Duke solar
power projects
B&W to perform steam

generator work at Michigan
nuclear power plant
Duke Energy Renewables has awarded

contracts for turnkey engineering, procurement and construction services for
two California solar power projects to
Swinerton Renewable Energy. The projects, called the Pumpjack and Wildwood
solar power projects, are located near Bakersfeld and have a combined capacity of
40 MW.
Design and procurement have already
started for the two sites, which are expected to begin commercial operation by the
end of 2014.
The two projects will bring Dukes total solar capacity in California to 65 MW
and its total U.S.-installed solar capacity
to 185 MW at 23 utility-scale facilities, the
company stated in a release.
American Electric Power awarded a

contract to Babcock & Wilcox Nuclear
Energy, a subsidiary of The Babcock &
Wilcox Co., to provide steam generator
services for the D.C. Cook Nuclear Plant
in Michigan. The multi-year contract began in February.
The Cook plant has two units, one of
which is outftted with B&W replacement
recirculating steam generators. B&W NE
will perform comprehensive inspection
and cleaning work, which includes eddy
current testing, visual inspections and
water lancing.
Vermont Yankee nuclear plant

can operate through year-end
The Vermont Public Service Board will
allow the 605-MW Vermont Yankee nuclear power plant to operate through the
rest of 2014 in exchange for payments to
the state.
VTDigger.org reports that the board
issued a certifcate of public good which
allows the plant to operate through the
end of the year. Plant owner Entergy announced in August that it would close the
plant in 2014 due to market conditions.
Duke Energy releases

plans for coal ash basins
Duke Energy released an update
March 26 regarding the companys future plans for its coal ash basins.
The utility said they are working
with the state of North Carolina, the
North Carolina General Assembly and
the North Carolina Utilities Commission on developing and implementing
long-term solutions for ash basins as
quickly and as safely as possible for
every site, including analysis of tradeoffs, risks and costs.
The company is also working with an
independent, third-party engineering
company to complete assessments for
all the ash basins. Assessments are expected to be fnalized by May 31.
After securing the necessary permits,
Duke will move ash at three retired
plants, accelerate closure of an additional basin, convert to dry ash handling at
all remaining facilities in North Carolina and begin dewatering the other retired basins.
On March 12, Duke offcials sent a
letter to state Gov. Pat McCrory and the
North Carolina Department of Environmental and Natural Resources stating
the company is pursuing landfll and
storage solutions and converting to all
dry fy ash handling.
www.power-eng.com
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2014 Diamond Power International, Inc. All rights reserved.
MITSUBISHI HITACHI POWER SYSTEMS
Pulling Ahead
as ONE
The global merger of Mitsubishi Heavy Industries and

Hitachis thermal power generation businesses integrates
two leaders in world class technology creating Mitsubishi Hitachi
Power Systems.
This historic combination represents over 240 years of innovative
products, systems and services. Now, Mitsubishi Hitachi Power
Systems delivers the talent and technology of both companies as
a single source solution for existing and evolving energy needs.
Visit us online to learn more about our world class capabilities.
Mitsubishi Hitachi Power Systems Americas, Inc.

www.mhpowersystems.com
Mitsubishi Hitachi Power Systems America Energy and Environment, Ltd.

www.psa.mhps.com
CLEARING THE AIR
Permitting Implications of
Switching to Natural Gas
BY MICHAEL BURKHART, PERMITTING MANAGER, KIEWIT POWER ENGINEERS CO.
oes it make sense to switch from

coal to gas? It is a question that
every electric utility with a coalfired boiler will have to answer eventually, and for some, the time to make that
determination is about to run out.
Recent regulatory changes affecting a
large number of utility boilers have targeted both criteria pollutants, such as
NOx and SO2, as well as many hazardous
air pollutants (HAP) including mercury,
heavy metals, acid gases, and organics.
The costs associated with installing and
operating the necessary control equipment can be significant, especially for
older boilers. While the potential impact
of future GHG regulations is difficult to
quantify, they will undoubtedly serve as
further incentive to switch to gas.
For any coal-fired boiler, the available
options that must be considered include:
Retire the boiler, purchase power if
necessary
Comply with the new regulations,
which may require modifying the
boiler or installing new emissions
control equipment
Replace the boiler with a gas-fired
CCGT
Convert the existing boiler from coal
to gas
Depending on the circumstances, the
decision process can become extremely
complex, especially for a utility with multiple generating units, where the solution
often involves some combination or all
of those options. In all cases, making
the right decision depends on accurately
identifying all of the relevant factors and
evaluating their potential impacts.
A quick internet search will turn up
links to hundreds of articles, presentations, white papers, etc. that address a
wide range of factors to be considered.
10
Unfortunately, the importance of certain

environmental permitting requirements
is almost entirely overlooked. The applicability of those requirements can
affect which option you choose, and if
you choose either of the fuel switching
options, the way you operate your boiler
on coal today can affect not only the time
and expense required to obtain a permit,
but also the permit requirements, even
though the project may be years away.
Its also important to note that federal,
state and local regulations all contain different permitting requirements that may
apply. Any regulatory applicability analysis depends on a number of project and
site-specific factors must be done on a
case-by-case basis. As you might expect,
state and local requirements vary considerably. The federal regulations also vary
by location as well as by pollutant.
To provide a relevant example illustrating that point, and the importance of understanding permitting requirements, requires significant simplification. To give
you an idea how significant, consider that
the guidance document EPA developed
to explain the New Source Review (NSR)
permitting process is 322 pages long.
Before beginning any activity that involves physically modifying a source of
air emissions or changing its method of
operation, a utility must to determine
the regulatory requirements that apply,
and the importance of this regulatory
applicability analysis should not be underestimated. It is more than just another
requirement found in every facilitys permit to operate; it can lead to significant
benefits if done correctly. However, the
financial penalties that can result from
doing it incorrectly are even more significant, which is why some utilities delegate
the task to a consultant.
The primary goal of this analysis is not

simply to determine what type of permit
you must apply for and identify even
more requirements with which to comply. Rather, it is to develop a strategy to
avoid permitting entirely if possible, and
if not to at least minimize its impacts.
The process of obtaining a federal New
Source Review (NSR) permit requires significantly more time and effort than state
or local permitting and has several additional requirements. The requirement to
install the Best Available Control Technology (BACT) is often the most costly.
NSR applicability is determined for
each individual pollutant by comparing the increase or decrease in emissions
resulting for a modification, in tons per
year, to that pollutants significant emission rate (SER). Any for which the change
in emissions exceeds the applicable SER
are subject to the requirements of NSR.
If you consider the typical emission
rates for coal and natural gas on a lb/
MMBtu basis, this calculation may
seem trivial, but it may not be. For a
utility boiler, baseline emissions are
defined as the average annual emission
rate over any consecutive 24-month
period within the last five years. If that
boilers utilization over that period
has been significantly lower than that
planned after the project, the calculated increase of one or more pollutants
could conceivably exceed its SER, at
which point you may be forced choose
between taking a more restrictive limit
on the future operation of that boiler,
or installing and operating additional
control equipment.
Making the investment necessary to
understand how these complex regulations may impact you now can pay huge
dividends in the future.
www.power-eng.com
For more information contact us at:

281.404.9397 or info@beis.com
www.beis.com
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GAS GENERATION
Avoiding Performance
Monitoring Pitfalls
BY KATIE CHENEY, POWER PLANT OPERATIONS ENGINEER, NAES CORP.
he U.S. Energy Information

Administrations Annual Energy Outlook 2014 early release
projects a 17 percent increase in natural gas-fired power generation from
2012 levels by 2020. During the same
time frame the EIA expects a 6 percent
increase in combined cycle gas turbine
capacity and a 5 percent increase in
gas turbine capacity. Weve already begun to see the effects of this trend as
increasing capacity factors in our combined cycle and simple cycle gas turbine fleet. At the individual plant level,
maintaining or even improving maximum capacity levels and minimizing
heat rate is more important than ever.
If youve been thinking about installing a thermal performance monitoring program at your facility, or youve
realized you need to dust off that old
performance monitoring software
that was installed years ago and rarely
used, now may be the perfect time.
Make no mistake, todays performance monitoring software packages
are enormously powerful tools with
wide ranging capabilities and features;
however, without the proper support at
the facility and at corporate levels, investment in performance monitoring
can be wasted. I used to be surprised
to hear of performance monitoring
systems that were bought, paid for, installed and working at one time but no
longer being used. Ive come to learn
that this is not an unusual scenario.
Invariably, the personnel who were
supposed to be using the system had
lost confidence in the data and the results the system was providing. Without confidence in the results provided,
12
personnel dont use the system. By not

using the system they lose familiarity
with it, and in a very short period of
time the system is abandoned altogether.
To avoid this scenario at your plant,
here are some ideas to consider before
investing in a new performance monitoring system or reinstating a system
that has been neglected:
1. Initial installation is important, so
consider using an owners engineer
throughout the procurement and
implementation stages. Software
vendors are experts in their own
system but may not be sensitive
to the objectives and special cases
of individual facilities. An owners
engineer can serve to bridge the
gap between the vendor and plant
personnel to ensure the system and
installation services purchased are
suitable for meeting the project objectives. The owners engineer can
verify the system is set up accurately from the beginning, preventing
problems down the road, and can
serve as an additional training resource for the plant.
2. Successful performance monitoring programs have dedicated
personnel whose top priority is
performance monitoring. While
it may be unrealistic to have a
dedicated person onsite, an offsite performance monitoring lead
could support multiple plants. If
your companys structure does
not lend itself to having corporate performance monitoring support shared among several plants,
and if a dedicated person onsite is

not feasible, consider third party
monitoring to ensure the results
of your system are being reviewed
and interpreted on a regular basis.
3. As a supplement to item 2, be realistic when it comes to time requirements and priorities when
considering your onsite talent. An
operator or technician might have
more enthusiasm for a performance monitoring system than an
already overburdened engineer.
4. Plant personnel must have an interest in the performance monitoring
system and confidence in the data
and results it provides. Even if performance monitoring is not among
their highest priorities, plant personnel are ultimately the end users
of the system results. They are the
ones calibrating instruments, performing maintenance or making
operational decisions based on the
results from the system; therefore,
on-site interest and trust in the
system is crucial.
Every facility is different in their requirements and objectives regarding
performance monitoring. Likewise,
there is no one size fits all performance
monitoring system. With the expectation of continued increases in capacity
factors for the natural gas generation
fleet, adding a performance monitoring system to your facilitys toolbox is
a timely consideration. Reflection on
the concepts above will help ensure
your new thermal performance monitoring program is a success for years to
come.
www.power-eng.com
VIEW ON RENEWABLES
U.S. Solar Industry

Has Record-Shattering
Year in 2013
BY RHONE RESCH, PRESIDENT, SOLAR ENERGY INDUSTRIES ASSOCIATION
hat would Alexandre Edmond Becquerel be thinking now?

In 1839 at the age of just 19, Becquerel built the worlds first photovoltaic panel, later inspiring the imaginations of millions of people worldwide,
including legendary scientist Albert
Einstein. Still, it took another 115
years before Bell Labs invented the
first modern silicon solar cell.
Its no stretch to say that recently, the
solar timeline has rocketed forward at
warp speed.
Continuing its explosive growth, the
U.S. solar industry had another recordshattering year in 2013. According to
GTM Research and the Solar Energy Industries Associations Solar Market Insight Year in Review 2013, photovoltaic
installations expanded rapidly last year,
increasing 41 percent over 2012 to reach
4,751 MW of new capacity. In addition,
410 MW of concentrating solar power
came online in 2013. Consumers nationwide benefitted from this growth as the
cost to install solar fell throughout the
year, ending 15 percent below the record
low set at the end of 2012.
When the final 2013 numbers were
added up, there were 440,000 operating
solar electric systems across the United
States, totaling more than 12,000 MW of
PV and 918 MW of CSP.
What does this mean for you? Well
today, solar is the fastest-growing source
of renewable energy in America, generating enough clean, reliable and affordable
electricity to power more than 2.2 million homes and were just beginning to
scratch the surface of our industrys enormous potential. Last year alone, solar created tens of thousands of new American
14
jobs and pumped tens of billions of dollars into the U.S. economy. In fact, more
solar has been installed in the U.S. in the
last 18 months than in the 30 previous
years combined. Thats a remarkable record of achievement.
California continues to lead the U.S.
market and installed more than half of
all new U.S. solar in 2013. In fact, the
Golden State installed more solar last
year than the entire United States did in
2011. North Carolina, Massachusetts and
Georgia also had major growth years in
2013, installing 663 MW more than
doubling their combined total from the
year before. On the whole, the top five
states (California, Arizona, North Carolina, Massachusetts, and New Jersey) accounted for 81 percent of all U.S. PV installations in 2013.
Here are some of the other highlights
of the report:
The amount of PV installed last year
was nearly 15 times greater than the
amount installed in 2008.
Q4 2013 was by far the largest quarter ever for PV installations in the
U.S. with 2,106 MW energized,
up 60 percent over the next largest
quarter (Q4 2012).
The market value of all PV installations in 2013 was $13.7 billion.
Solar accounted for 29 percent of all
new electricity generation capacity
in 2013, up from 10 percent in 2012.
This made solar the second-largest
source of new generating capacity
behind natural gas.
Weighted average PV system prices
fell 15 percent in 2013, reaching a
new low of $2.59/W in the fourth
quarter.
The new report forecasts 26 percent
PV installation growth in 2014, with

installations reaching nearly 6 GW.
Growth will occur in all segments
but will be most rapid in the residential market.
The U.S. installed 410 MW of concentrating solar (CSP) in 2013, increasing total CSP capacity in the
U.S. more than 80 percent.
And finally, Brightsources massive
Ivanpah project also began operating this year and SolarReserves
Crescent Dunes project began commissioning.
So while 2013 was a record-breaking
year for the U.S. solar industry, 2014
promises to be even better with 30 percent growth being forecast. Part of this
unprecedented expansion is due to the
fact that the average price of a solar system has dropped by more than 50 percent since 2010, benefitting consumers,
businesses, schools and government entities.
Today, 40 years after SEIA was first
formed, there are nearly 143,000 Americans employed by the U.S. solar industry
at more than 6,100 American companies with SEIA leading the fight to expand markets, remove market barriers,
strengthen the industry and educate
Americans about the benefits of solar energy. These efforts have led to the adoption of a wide range of smart public policies, including the solar Investment Tax
Credit (ITC) in Congress and Net Energy
Metering (NEM) at the state level.
And to think it all started when a 19
year old in the 19th century came up with
the idea of turning sunlight into electrical
energy.
Merci, Monsieur Becquerel.
www.power-eng.com
ENERGY MATTERS
The Newest Member

of the Power Restoration
Team: Drones
BY ROBYNN ANDRACSEK, P.E., AND DAVID WALLACE, P.E.
tay home, if you can was the

message given to residents
of the Southeast as a major
winter storm pushed through the Southern and Eastern United States in midFebruary. However, this message was not
intended for the hundreds of electric utility workers in those areas. Just the term
Ice Storm can bring a chill to linesmen
as they know the pressure, stress and
long hours that are in store, braving the
elements to restore power as quickly and
safely as possible under the worst conditions. To most people it seems to take a
long time to get the power restored, but
they dont know why.
As the storm approaches, whether
its a winter storm, a hurricane or a
tornado outbreak, the utility is hoping
that either 1) the storm is not as bad as
predicted or 2) the storm changes path
and misses their system entirely. But in
either case, or if neither happens, they
must start getting ready. Material coordinators must take a look at all of the
materials in stock as well as those that
are being delivered in the coming days.
They talk with their materials suppliers
to make sure vendors are ready in case
additional materials are needed. They
also need to have drivers in place to deliver the materials to the various sites.
At the same time, construction crews
are getting geared up making plans for
the long days ahead as well as contacting neighboring utility crews to see if
they can help out with the restoration,
if needed.
However, until the storm hits and the
utility can assess what the actual damages are, it is diffcult to know how long the
outages to the system will last. Until the
16
utility knows what needs to be fxed and

where, it is impossible to prioritize the
work, the materials, or the crews. Enter
the newest member of the power restoration team: the unmanned drone.
Currently, accessing the damage to a
utilities system requires personnel on
the ground with knowledge of the pieces
that make up the system. Until someone
can identify that the crossarm bracket is
broken, or the insulator assembly is damaged, or the strain clamp came loose, it
is diffcult to plan how many people are
required to fx the problem, let alone to
have the parts delivered and ready for
installation when the crew gets there. To
identify the problems usually requires
someone to walk along the right-of-way
to the affected area and make notes of the
problems. After assessing the damage, the
worker then walks back to the truck, radios the supervisor to report what materials
are needed and proceeds to the next area
or line section to fnd more problems.
The supervisor collects the various feld
reports, totals the materials needed and
the locations where they are required,
and calls the information to the materials
coordinators to get the supplies delivered.
Simultaneously, supervisors are working
with the system operations personnel to
begin prioritizing the work.
However, with the drone as part of the
team, you can speed up the process of accessing the damage to the system. With
video capabilities and GPS coordinates,
assessment personnel can stay near the
vehicle and record on tablet computers
what materials are needed. This information can be sent to the materials coordinators and supervisors at the same
time. This approach greatly cuts the
amount of time it takes to access the

damage, identify the materials and get
the materials delivered.
If this is true, why dont utilities utilize some of these new technologies
to help streamline a power restoration
process that in many cases takes weeks
to complete?
Even though drones have been around
for years, they have not been available for
commercial use. Currently, only public
agencies and individuals who have acquired special certifcates of waiver can
use drones, and they must do so under
tightly controlled conditions. The Federal
Aviation Administration (FAA) is currently working to establish guidelines for
commercial use. This year, the FAA has
approved six test sites across the country
to spend most of 2014 conducting research and making recommendations so
that a regulatory framework can be put in
place by 2015.
Certifcates of Waiver or Authorization (COA) are available to public entities that want to fy an unmanned aircraft system (drone) in civil airspace.
Common uses today include law enforcement, frefghting, border patrol,
disaster relief, search and rescue, military training and other government
operational missions. Obtaining a COA
would be one way that electric utilities
could be granted permission to utilize
drones for power restoration.
In any natural disaster, teamwork is the
key to quick resolution. Adding drones to
the utility crew can greatly speed up power restoration. Hopefully, regulators will
catch up to this new technology so that
2015 can see a faster return to normal life
for areas experiencing power loss.
www.power-eng.com
NUCLEAR REACTIONS
Urbanization
and Nuclear Power
BY BRIAN SCHIMMOLLER, CONTRIBUTING EDITOR
ets take a little quiz. Question

#1: Whats the global population?
Take your timeand Ill give you
half a billion slack on either side.
The estimate at the time I wrote
this in mid-February was 7.2 billion.
Im guessing most of you were able to
come within the half billion mark.
Question #2: How many cities in the
world have a population greater than
10 million? This ones not so easy, but I
bet many of you could get within three
or four of the right answer. The right
answer is 22, according to the United
Nations.
Now lets look forward. How many
cities will have populations greater
than 10 million in 2040? Ten more?
Twenty more?
Actually, 31 more based on current
projections. And where will those
cities be? Not surprisingly, predominantly in China, with nine, and India,
with eight. As shown in the accompanying graphic, the world is becoming
more urban. For example, whereas
only about 25 percent of the people
in China lived in urban areas in 1990,
that figure grew to 50 percent in 2010,
and is expected to reach 75 percent by
2040. India and Africa are following
similar tracks.
So what does this have to do with
nuclear power? Urbanization is closely
associated with energy demand, and
greater urbanization is projected to
lead to greater electrification around
the world, according to a study from
ExxonMobil, The Outlook for Energy: A
View to 2040.
The link between urbanization
and energy demand is tied to several
18
factors:
and India, ExxonMobil sees big gains
The expansion of urban infra- in 10 key growth countries: Brazil,
structure creates demand for iron, Indonesia, Saudi Arabia, Iran, South
steel, cement and other industrial Africa, Nigeria, Thailand, Egypt,
goods that are energy intensive.
Mexico and Turkey. By 2040, these 10
Urban income levels tend to be countries will have energy demand aphigher than in rural areas
proaching the level of China. Several
Energy-intense
manufactur- of these countries already have opering and other industries cluster ating nuclear plants and several otharound cities
ers are evaluating commercial nuclear
The number of people per house- power programs.
hold is usually lower in urban
Youll notice that there has been
settings, which
no discussion of
leads to a higher Greater
the United States
number of actual
and other mature
urbanization
households.
economies in this
is projected to
discussion.
Thats
Urbanization re- lead to greater
because, for the most
sults
in
sizable,
part, urbanization
electrification
lumpy demands for
has played itself out
energy and electric- around the world.
there. Birth rates
ity, which augur well - ExxonMobil
which are one of the
for nuclear power.
leading factors drivUrbanization tends to track to higher ing urbanization are relatively low in
levels of air pollution, which should these countries, so the lumpy slugs of
help nuclear power as well since its a electricity demand are likely all in the
carbon-free generation source. Devel- pastabsent a tectonic shift in electrioping economies like China recognize fication, such as might accompany a
that excessive levels of pollution can system-wide move to electric vehicles,
impact quality of life and the strength or a global commitment to carbon-free
of its economic engine. Steps to regeneration sources.
duce adverse environmental impacts
That doesnt mean that nuclear pow through tighter controls on coal- er is finished as a generation option
fired generation and closing of smaller in advanced economies. It just means
coal-fired plants indirectly support that the construction of 20 or 30 nuclenuclear growth.
ar plants at one time will be limited to
Urbanization expands awareness places like China and India.
of and interest in the trappings of a
Lets end with another quiz question.
middle-class lifestyle, many of which How many people across the globe have
are tied to electricity, including larger no access to electricity? A whopping 1.3
homes, air conditioning, appliances, billion. Thats a lot of power plants
and electronic devices. Beyond China nuclear or otherwise.
www.power-eng.com
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POWER PLANT PROFILE
After Dukes modernization project, the James E. Rogers Energy Complex generates more than twice the
electricity with 80 percent less SO2 and half the NOx
and mercury. Photo courtesy of Duke Energy
Modern Effciency
In Coal-Fired
Production
BY JUSTIN MARTINO, J.D., ASSOCIATE EDITOR
hile many power producers are shuttering their

coal-fred generating assets and looking to other fuel sources
to replace the generation capacity,
Duke Energy has taken a more balanced approach in replacing the capacity lost from retiring older and less effcient units in its coal feet.
In addition to diversifying its generation mix, Duke Energy is modernizing its coal-fred assets with several
projects. While the Edwardsport Integrated Gasifcation Combined Cycle
20
Station in Indiana may draw attention as one of the frst of its kind, The
Cliffside Modernization Project at the
James E. Rogers Energy Complex, formerly known as the Cliffside Steam
Station, drew upon commercially
proven systems that reduced the facilitys emissions while more than doubling its generation capacity.
HISTORY
The James E. Rogers Energy Complex began commercial operation as
the Cliffside Steam Station in 1940.
The facility originally began as two

coal-fred units, with two additional
units added in 1948 bringing the power plants generating capacity to 198
MW.
In 1972, Duke built the 556-MW
Unit 5 half a mile from the original
facility. Since then, Unit 5 has undergone two major upgrades to reduce its
emissions, with a selective catalytic
reduction system being added in 2002
and a fue gas desulfurization system,
known as a scrubber, added in 2010.
The SCR system reduced nitrogen oxide emissions by around 80 percent,
while the scrubber reduced sulfur dioxide emissions by around 99 percent.
In 2006, Duke proposed the construction of two 800-MW supercritical units to the Cliffside site, although
only one of the units received approval.
As part of the proposal, the company
also planned to retire units 1 through
4 at the site, which had been in operation for more than 50 years. The decision to retire the four units became
enforceable in early 2012 as part of an
air permit-related settlement related to
the new Cliffside Unit 6 with several
environmental groups in which Duke
agreed to retire 1,667 MW of coal-fred
capacity without emissions control
technology.
Duke began demolishing units 1
through 4 last fall.
CONSTRUCTING UNIT 6
Although the two upgrades on Unit
5 had reduced emissions at the plant,
Duke stated the culmination of the
modernization project at the site was
the beginning of commercial operation
of the 825-MW Unit 6 on Dec. 30, 2012.
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Duke selected CB&I as the EPC contractor for the project. Construction of
the unit began in January 2008, and
fell within the projected budget of
$1.8 billion. Construction materials
included 348,000 linear feet of piping,
81,000 cubic yards of concrete, 36 million pounds of structural steel and 4.4
million linear feet of power and control cable. The project was largely constructed inside the existing rail loop
serving the original units, and contractors had to coordinate work, including extensive rail and coal unloading
modifcations, around coal deliveries
and minimize the impact of tie-in outages at the existing units.
The project required rerouting a
nearby state highway and constructing a new highway bridge to eliminate an at-grade railroad and landfll
road crossings, which was done at no
cost to the state of North Carolina.

Unit 6 uses a spiral-would, near ultrasupercritical Hitachi boiler and quadfow Toshiba turbine generator that
operate with main steam/reheat pressures of 2932/678 PSIA and steam temperatures of 1055F/1075F. The Unit
6 is designed to burn a wide range of
fuels, including bituminous and subbituminous blends, and has a heat rate
of 8,806 Btu/kWh net.
According to Duke, one of the plants
key innovations is integration of the
operator Human Machine Interface
exclusively within an Emerson Ovation DCS, which eliminated almost
all standalone controllers, PLCs and
displays.
EMISSIONS CONTROLS
Alstom provided the air quality control systems and guaranteed lowered
emission rates for the Rogers Energy

complex, using proven technologies
that allow the facility to be classifed as
a minor source of hazardous air pollutants. The plant uses a spray dryer absorber, fabric flter baghouse and wet
fue gas desulfurizer as well as the SCR
system. According to Duke, the combination of air quality controls removes
99.9 percent of fy ash emissions, 99
percent of SO2, 90 percent of NOx and
90 percent of mercury.
The improvements mean the plant
generates more than twice the electricity that it did before the modernization project with 80 percent less SO2
and half the NOx and mercury, Duke
said. Thermal impacts to the Broad
River have also been eliminated.
The air quality control system in
Unit 6 was verifed last October after
repeated performance testing, Duke
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www.power-eng.com
Think inside the box.

It may seem familiar, but if you look closer, its what you may not see that makes the difference.
The new Megger S1 Insulation Resistance Testers provide a higher

performance range than any other comparable tester in a smaller, lighter
package. The remote control feature allows you total control of the unit
during testing, via USB to PC, removing all direct contact with the S1 unit
for safer operation. The new S1 series comes with additional features such
as improved battery life, with a customer replaceable battery, rapid charge
and ltering. With improved 8 mA noise rejection, the new Megger
insulation resistance testers give you a cleaner, more
reliable signal. There are three models to choose
from, the 5 kV model with resistance measurement
capability of up to 15 T, and the 10 kV and 15 kV
models with resistance measurement capability of
up to 35 T.
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For more information on the newest S1 Series of insulation resistance testers

download the datasheet at www.megger.com/S1 or call us at 1-800-723-2861.
The word Megger is a registered trademark
stated in a release issued at the time.

During the time the company was going through the
air permitting process to build Cliffside Unit 6, there was
signifcant debate about whether a new coal unit could
achieve this level of emissions reductions, plant manager
Rick Roper said. We can close that chapter and put those
concerns to rest. This units air permit is one of the most
restrictive in the country, and its performing very well.
The testing showed that emissions from the plant were
well below permit limits under full load conditions. Testing showed SO2 emissions of 0.02 to 0.04 lb/MMBtu, NOx
emissions of 0.04 lb/MMBtu and mercury emissions of
0.001 to 0.008 lb/GW-hr. The plants permit limits allows
for SO2 emissions of 0.12 lb/MMBtu, nitrogen oxides emissions of 0.07 lb/MMBtu and mercury emissions of 0.019
lb/GW-hr.
Duke stated that future test results may vary, but control
equipment will assure compliance well below permit limits. The company noted the performance of Unit 6 shows
it will be well-positioned to demonstrate compliance with
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The Rogers Energy Complexs cooling system enables the plant
to withdraw 80 percent less water than it did before the modernization project.Photo credit: Justin Martino
the U.S. Environmental Protection Agencys MATS rule

that will be in effect by April 2015.
REUSING AND RECYCLING

While the Rogers Energy Complex manages to provide more
effcient energy with fewer emissions, it is also designed to be
effcient in other ways.
The cooling tower blowdown is used as makeup for the wet
scrubber, and the wet scrubber purge stream is used as makeup
for the dry scrubber. Synthetic gypsum, a byproduct of the wet
scrubber, is recycled to make wallboard.
The unit also uses closed-loop cooling towers that allow
for the water drawn from the Broad River to recirculate,
which minimizes the intake from the river the company
stated the systems cooling system allows the plant to withdraw 80 percent less water from the Broad River than previous operating conditions.
Units 5 and 6 also share a common stack, which allowed for
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ISO 9001 Certifed
The 825-MW Unit 6 had a budget of roughly $1.8 billion and entered
commercial operation on Dec. 30, 2012. Photo credit: Justin Martino
cost savings in the project, Duke stated.

Additional savings in the project included the use of the sites existing water
intake, transmission facilities and other
plant systems.
LOOKING TO THE FUTURE

Duke currently has plans to retire
nearly 6,300 MW of coal capacity in
the coming years, which represents
25 percent of its coal feet. According
to the company, it retired more than
3,800 MW of its older coal capacity by
the end of 2013.
The company has worked on keeping its generation feet diversifed.
However, Keith Trent, Duke Excecutive
Vice President and Chief Operating
Offcer of Regulated Utilities, said coal
is an important part of the mix while
speaking at COAL-GENs keynote session last August.

The Rogers Energy Complex helps
show how coal-fred power can be effcient, reliable and keep emissions
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POWER GENERATION WEEK

5 EVENTS + 5 DAYS
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Owned & Produced by
Presented by
Supported by
Author
Brad Buecker is a process specialist
with Kiewit Power Engineers in Lenexa,
Kan., and a contributing editor for Power
Engineering.
WATER ISSUES
Wastewater Treatment Issues

for Combined Cycle Plants
BY BRAD BUECKER, CONTRIBUTING EDITOR
28
NEW STEAM-GENERATED
POWER PRODUCTION
Improved access to large reserves of
shale gas coupled with what some term
the EPAs war on coal have caused a
tremendous growth in simple- and especially combined-cycle power plants
for new electricity generation. Few water
and chromium being two impurities of

focus. The proposed limits are 1 part-per
million (ppm) and 0.2 ppm, respectively.
However, state regulators may impose
limits on other cooling water discharge
constituents, and regulations are now
emerging that include limits on the following constituents:
Cooling Tower Blowdown vs. Cycle of Concentration

2000.0
1800.0
1600.0
Blowdown (gpm)
t POWER-GEN International 2013 and a

follow-up water treatment seminar hosted by
Veolia, much information was offered regarding the status
of the U.S. Environmental Protection
Agencys Effluent Limitation Guidelines (ELGs) for liquid discharges from
power plants.
While significant focus has been on
coal-fired plants and discharges from
wet scrubbers and coal ash ponds,
personnel at natural-gas fired plants,
particularly combined-cycle units,
must also deal with stringent effluent
regulations.
Compounding these difficulties,
some plants are being required to use
reclaimed water or other less-thanpristine sources for makeup. Meeting
effluent guidelines is made more difficult when the influent is poor quality.
Throughout the latter decades of the
20th Century, power plant chemists
and technical personnel primarily had
to deal with the following parameters
in various plant discharges:
Oil and grease (O&G)
pH
Total Residual Oxidant (chlorine,
bromine, or chlorine dioxide in
the cooling water discharge)
Total suspended solids (TSS)
Relatively straightforward chemical
treatment and/or operational methods
were sufficient to keep this chemistry
within guidelines.
Now, the story is radically changing,
even for discharge streams not influenced by coal combustion.
1400.0
Recirculating fow = 100,000 gpm

Range = 25 degrees F
Evaporation Factor = 0.75
1200.0
1000.0
800.0
600.0
400.0
200.0
.000.0
1
10
11
12
13
14
C
This graphic outlines the discharge quantities for cooling system with very reasonable values for
evaporation and circulating water fow.
treatment systems at new combined-cycle projects call for once-through cooling,

no doubt due to pending 316a and 316b
regulations. Rather, all new proposals
specify cooling towers or in some cases,
air-cooled condensers. In the former situation, cooling tower blowdown typically
constitutes by far the majority of spent
water discharged from the plant.
The EPA has addressed cooling tower
blowdown in their proposed new Effluent Limitations Guidelines, with zinc
Total dissolved solids

Sulfates
Zinc
Copper
Chromium
Phosphate
Ammonia
Quantity of discharge
In addition, chloride and bromide may
be being examined. At the same time,
regulators are pushing some plants to use
www.power-eng.com
While significant focus has been on

coal-fired plants and discharges from
wet scrubbers and coal ash ponds,
combined-cycle units must also deal with
increasingly stringent effluent regulations.
www.power-eng.com
29
Generic outline of an emerging wastewater

treatment technology
NaHSO3
CT
Blowdown
Permeate Return
to Process
UF or MG
High pH RO Unit
Sodium
Softener
NaOH
alternatives to fresh water for makeup.

These sources include reclaim water from
municipal wastewater treatment plants
and low-purity groundwater. California
is a notable example regarding reclaim
water use, per their Title 22 regulations.
REASONING BEHIND
NEW GUIDELINES
The logic behind the selection of the
original four impurities, pH, O&G,
TSS, and residual oxidants is easily understandable. Suspended solids such as
coal and ash particles can fill receiving
bodies of water with material. Excursions in pH, where a common regulated
range has been 6.0 to 9.0, can be fatal to
aquatic creatures, as can release of excessive oxidants. Oil and grease, and similar
carbon-based materials, if released in excess will increase the biochemical oxygen
demand (BOD) of waters, which in turn
can reduce oxygen concentration and
harm aquatic creatures.
Researchers now conclude that other
impurities, including those just outlined,
are also harmful. Many heavy metals
are toxic to aquatic organisms, and in the
modern power industry two of the most
common that might be released in a plant
discharge are zinc and copper. For many
years, a small dosage of zinc served as an
integral part of phosphate/phosphonate
based cooling tower treatment programs.
Zinc reacts with hydroxyl ions (OH-)
30
Reject to Pond
or E/C
produced at cathodic corrosion sites to
generate a zinc hydroxide [Zn(OH)2]
film that helps to inhibit reactions at
cathodes. Tight restrictions are also being placed on copper in some locations,
with discharge limits reportedly as low
as 12 parts-per-billion (ppb). For new
plants, copper is often not a problem as
system components are almost entirely
fabricated of steel. However, I have come
across facilities that have cooling towers
fabricated of wood, in which the wood
was treated with a copper preservative.
Copper leaches from the wood, and may
concentrate above discharge guidelines
during unit outages. Chromium is an alloy component of some steels, and thus
may appear in small concentration in
steam generator blowdown. Normally,
chromium is of greater concern when it
appears in chemical cleaning spent solutions, where much of it may be in the
hexavalent (Cr+6) form, the toxic form of
chromium.
With respect to the common cooling
tower phosphate/phosphonate programs
of the past, and still in many cases the
present, concern continues to grow regarding the impact of phosphate as a nutrient in receiving bodies of water. Algae
blooms have caused enormous problems
at times. Zero phosphate residual is appearing in some new NPDES permits.
In the same vein, ammonia discharge is
coming under tighter control. Ammonia
in small concentrations serves as a nutrient for aquatic plant growth, while on the
other hand, accidental releases of large
quantities have been known to cause
substantial fish kills.
Limits are also appearing for dissolved solids and salt content of wastewater. At one plant I recently visited,
the previous NPDES permit only called
for monitoring of TDS. The new permit
limits TDS in the wastewater discharge
to slightly over 1,000 ppm and sulfates
to just a few hundred ppm. This has
major implications for cooling tower
makeup and cycles of concentration,
as we will examine shortly.
This list of new impurities is only expected to grow in upcoming years. For example, at coal plants with wet scrubbers,
discharge of contaminants, including
arsenic, mercury, selenium and boron, is
also being regulated. While these impurities are not common to the combinedcycle industry, expect to see other metals
show up in future discharge regulations.
WASTEWATER IMPURITIES
When fresh water supplies were more
plentiful, many plants took makeup water from a lake, reservoir, or river. Now,
many plants are being required to use less
pristine water, such as treated municipal
waste or possibly high-TDS groundwater. These makeup stream chemistries
can have enormous impact upon cooling tower operation and wastewater discharge. For example, I recently observed
data from a proposed plant in which a
snapshot analysis of the planned tertiarytreated makeup indicated 5 ppm of phosphate and 14 ppm of ammonia! In other
cases, the phosphate concentration may
reach 20 ppm.
Another issue of potential concern
regards TDS and sulfate restrictions.
A common makeup water treatment
process for many years in cooling
tower applications has been sulfuric
acid feed to remove bicarbonate alkalinity (HCO3-), which in turn reduces
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the potential for calcium carbonate

(CaCO3) scaling.
H2SO4 + HCO3- HSO4- + H2O + CO2
By virtue of the stoichiometry and
molecular weights, sulfuric acid and alkalinity react on a 1:1 weight basis. So,
consider a cooling tower where 150 ppm

of alkalinity needs to be removed, but
where the limit for sulfate discharge is
400 ppm. The tower would have to operate at less than three cycles of concentration (COC) if sulfuric acid were utilized
for bicarbonate removal. Consider also if
the makeup was a well water with say 400
Dire Conditions
Can dictate the need to operate gas turbine back-up liquid fuel systems
ppm TDS, but with a TDS discharge limit

of 1,200 ppm. Again, the maximum
COC would be limited to three.
These scenarios are potentially of great
concern where the quantity of cooling
tower blowdown is limited. Figure 1 outlines the discharge quantities for cooling
system with very reasonable values for
evaporation and circulating water flow.
As is evident, at three COC the
blowdown rate is 600 gpm, but if the
tower could be operated at six COC,
the blowdown rate drops to approximately 250 gpm.
One noted expert

feels that new systems
should be designed
with zero liquid
discharge as the goal,
with the thought that
NPDES regulations will
only become more
stringent.
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So, how do personnel deal with these

issues, either at existing plants or at facilities in the planning stage, and where
air-cooled condensers are not an option? One noted expert feels that new
systems should be designed with zero
liquid discharge (ZLD) as the goal, with
the thought that NPDES regulations will
only become more stringent, so the design should meet all future contingencies.
We will return to ZLD thoughts shortly.
For existing plants, process and/or
equipment modifications are possible
to address some of these issues. The
following list outlines a number of
these possibilities.
Alternative programs based on polymer feed have been developed for
cooling tower treatment. Polymers
are not inexpensive, but they can
eliminate phosphate discharge.
www.power-eng.com
Reclaim makeup to a cooling tower with all blowdown

returned to the WWTP
WWTP
Infuent
Evaporation
WWTP
Cooling Tower
Makeup
Blowdown
Treated WW
To River
Cooling tower polymer programs

canalsobedesignedtocontrolcalciumcarbonatescaling,whichwould
reduce or in some cases eliminate
theneedforsulfuricacidfeedtoreducebicarbonatealkalinity.
Althoughaseeminglyextrememeasureattimes,makeupwaterclarificationandlimesofteninghavebeen
utilized to remove hardness-formingconstituentsfromcoolingtower
makeup.Thisprocesscanbepracticalforhigh-hardnessgroundwaters
thatmayalsohaveahighsilicaconcentration,orformakeupthatcontainsphosphate.Theproblemwith
full-flow makeup water treatment
ofanykindisthatmostofthewater
islosttoevaporationinthecooling
tower.Thus,themakeupwaterflow
rate is always much greater than is

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evidenced in the blowdown alone.

If ammonia discharge is of concern,
and the makeup water contains significant quantities of ammonia, it
may be necessary to treat the wastewater with chlorine to convert the
ammonia to elemental nitrogen.
Residual chlorine must then be removed by feed of a reducing agent
such as sodium bisulfite to the discharge. An ammonia removal system could be rather complicated
given the variable nature of the
impurity. Another alternative, although not common at present for
power plants, is ammonia stripping
of the makeup water stream.
If the discharge quality does not
have tight restrictions but the quantity is of concern, then per Figure 1
the COC can be increased to reduce
blowdown.
Conversely, if the quality is restricted
but quantity is not, reducing COC
may put the wastewater discharge
within guidelines. An important
factor in this scenario is a potential
restriction on makeup water quantity. If this volume is restricted, lower
COCs may not be an option.
ZLD TO THE RESCUE?

Now, let us step into a bit of discussion regarding ZLD. This process is
often rather complex. Perhaps most
straightforward, but with a large caveat,
is the question, Can the discharge be
permitted for deep well injection without any quantity limits? Such wells are
often several thousand feet deep to avoid
any discharge into shallow groundwaters used for domestic purposes. While
this concept sounds simple, experience
has shown that some wastewaters can
generate scale within the well casings,
particularly as the water warms further
underground. High-pressure is generally
required for this process, and if scale formation occurs capacity may decrease.
At plants in arid locations with a large
34
land area, evaporation ponds may be

sufficient to handle the wastewater discharge. However, these ponds have to be
lined to prevent seepage of the wastewater with its impurities into the underlying
soil and possibly shallow aquifers.
Another alternative, at sites strategi-
remove suspended solids in the

waste stream.
Sodium bisulfite (NaHSO3) feed to
remove residual oxidizing biocides.
A sodium softener to remove calcium and magnesium.
Sodium hydroxide injection to el-
The fow schematic with a control volume boundary

WWTP
Infuent
Evaporation
WWTP
Cooling Tower
Makeup
Blowdown
Treated WW
To River
cally located, is to have the wastewater

trucked off-site to a waste disposal company. Transportation and disposal costs
for this method may be rather expensive.
If none of the above options are
available, thermal evaporation of the
waste stream may be the only option.
Due to the energy requirements of
evaporators, or to reduce costs for the
other processes mentioned above, it
can be very beneficial to recover most
of the waste stream for reuse and reduce the discharge quantity. A rapidly
emerging technology to do so is outlined in Figure 2.
One version of this process is licensed
for various markets as HERO by such
firms as Aquatech, GE, and U.S. Water,
while Veolia supplies their Opus technologies. Keys to the process are:
Micro- or ultrafiltration (UF) to
evate the pH above 10. (The combination of hardness removal and pH

elevation keeps silica in solution.)
Two-pass reverse osmosis (RO)
treatment to recover 90 percent of
the water.
While the process appears straightforward, I can report on a number of direct
lessons learned with the technology in
actual application. These include,
Use of cationic polymers in the cooling water or for pre-treatment to the
system can be quite deleterious. UF/
MF and RO membranes often have
a negative surface charge. The polymers will attach like glue, making
the membranes unusable.
Subsequent to discontinuation of the
polymer feed, the UF membranes
were changed from an inside-out
normal flow path to outside-in. This
www.power-eng.com
greatly improved the ability of the

regular backwash sequences to
keep the membranes clean.
A cooling tower of course cycles
up the makeup stream and increases both suspended and dissolved solids concentrations. In
this particular application, as
with most modern systems, periodically the backwash sequence
includes a chemically-enhanced
backwash, in which the membranes are scrubbed with an alkaline-bleach solution to remove organics and microbes, followed by
an acid stage to remove iron particulates. In this case, the alkaline CEB induced calcium silicate
scaling on the membranes. The
remedy has been a change to softened water for CEBs. This mechanism appears to be a difficulty at
another facility where the membranes suffer from magnesium

silicate fouling.
These issues aside, it is obvious that this
technology can greatly reduce the volume
of wastewater that must then be disposed
to reach complete ZLD. Energy costs for a
thermal evaporator or land area for evaporation ponds are much lower with a 90
percent reduction in wastewater volume
prior to final treatment.
A RECLAIM
WATER SCENARIO
Very recently, the author became involved in a project where reclaim water
will be used as the makeup to a power
plant cooling tower, but where the entire
blowdown will be recycled to the wastewater treatment plant. Another plant in
the area is already doing so.
At first glance, the natural inclination

is to believe that complete blowdown recovery would cause a continual increase
in solids within the system. However, if
one examines this schematic using a control volume diagram, the issue becomes
more clear.
The recycle of blowdown is an internal
process, and after startup of the system
as the blowdown solids concentration
increases, at a certain point the amount
of solids exiting the process balances
the amount entering. The author has
prepared an iterative program in Excel that demonstrates this calculation.
It should be noted that a blowdown
treatment system, perhaps a lime softener, may be needed to prevent excess
accumulation of scale-forming solids
in the WWTP. Such a system, with
equipment to generate a solid sludge,
can establish ZLD conditions.
REVOLUTIONIZE YOUR
PLANT ENERGY EFFICIENCY
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POWER PLANT CONTROLS
Author
Ed Dupre is a Senior Marketing Consultant
for ABBs Power Generation business.
Iberdrola Renewables Klamath Pratt & Whitney FT8 Turbines.

Photo courtesy of ABB
New Control System

SolvesBlack Box
Problems at
Cogen Plant
would stand to start and stop the equipment. At the end of this long rectangular
room were the 13.8 kV generator circuit
breakers, less than ten feet from where
the operator would stand to start and
stop the turbine. That put the operator
squarely within an arc-flash zone.
BY ED DUPRE, ABB INC.
everal years ago, the owners of Iberdrola Renewables Klamath Cogeneration Plant in Oregon began
looking for an alternative
control system strategy for their Pratt
& Whitney FT8 turbines. They turned
to ABB for help in developing an open
system that would give them the freedom to take true ownership of the operation, improve starting reliability and
successfully enter into more profitable
contracts.
EXISTING CONTROL
SYSTEM PROBLEMATIC
The Klamath operators had long been
frustrated by the OEMs black box
36
control system, which made it very difficult to self-troubleshoot and respond

quickly to turbine issues. Peaking power plants are regularly under the gun to
bring assets online quickly. If the combustion turbine does not start properly,
operators need to be able to diagnose
and address the root cause quickly, or
they miss their opportunity to run. That
can result in expensive penalties as well
as lost revenue.
The OEM control system also presented safety issues, because it was housed
in a control cabinet that contained all of
the electrical equipment. On one side
were the 480 V distribution breakers,
and on the other side was the control
equipment and HMI where the operator
PROJECT JUSTIFICATION
Klamath identified the need to replace the control system with a more
reliable, open-architecture control system that would allow them to be more
aggressive in marketing the plant.
That was the key to justifying the project. A new control system would enable them to meet more demanding
reliability requirements and create the
opportunity for additional revenue. It
would also allow their traders to be
more aggressive in the spot market.
THE SOLUTION
Klamath asked ABB to help them
solve the black box problem. ABB
came back to Klamath with a totally
www.power-eng.com
Enhanced Permissive Monitoring
Tags and graphics were customized for the operators, which reduce errors and improves response
time. The operator can analyze everything and take action from one simple graphic.
open control system solution that would

meet their needs. The new turbine control system provided control for:
Hydraulic Starter
Surge Protection
Thrust Balance Valve
Cold Air Buffer
Bleed Valve Scheduling
T3 Synthesized Temperature
Exhaust Temperature References
NH DOT/CDP Acceleration and Deceleration Limits
Inlet Guide Vanes and Variable Stator Vane Scheduling
Water Injection
Lube Oil System
Water Wash
Ammonia Injection, CEMS and
Evaporator Coolers
Generator/Voltage
Regulator/Exciter Interface
Vibration Interface
www.power-eng.com
ABB also worked with Klamath to have two channels that operate independevelop several enhancements over dently of one another. Each has the abilthe original control
ity to trip the stop
system, examples of The FT8 control
valve directly and
which are described system led to vast
each channel proin the following paravides alarms. This,
improvements
in
graphs.
along with the TPM
the availability,
Surge protection
taking action directABBs standard tur- reliability and overall ly from the I/O levbine protection model, allows the ABB
performance of
ule (TPM) is a specially
control system to
designed I/O module the units.
protect the turbine
with onboard intelligence to facilitate the better than the original control system.
high speed processing of trip signals. The Troubleshooting
TPM was used for surge protection on
Klamath operators now have the
this project. This required ABB to modify long-desired ability to take full control
the standard TPM to accommodate com- and ownership of their turbine operapressor discharge pressure transmitters, tions. They have total visibility into the
which are used to recognize a surge con- control system. The new control system
dition. The original control system had has an engineering workstation that ala single transmitter. If it failed, the unit lows Klamath to see live data flowing
would trip. ABB modified the TPM to across the logic, and to tune and change
37
Enhanced Overview Graphic
The new control system allows Klamath to see live data flowing across the logic,
and to tune and change the logic in the controllers based on live data.
the logic in the controllers based on

live data. This allows problems to be
solvedmorequickly.
Operator effectiveness
The new graphics have a lot more
functionality than the previous system.
Tags and graphics were customized for
the operators, which reduces errors and
improves response time. For example, a
newgraphicwasaddedidentifyingeach
step in the process required to start the
turbine.Ifanyoftherequirementsarenot
met,thenewcontrolsystemspecifically
identifiestheissue.Ifitsanoperational
issue,theoperatorcanrespondtoitright
away.Ifitsapumpthatsnotrunning,
theoperatorcanturniton.Ifabreakeris
open,theoperatorcanhaveitclosed.The
operatorcananalyzeeverythingandtake
actionfromonesimplegraphic.
These modifications have already
benefitedtheplantinseveralways:
A recent check valve issue that
would have likely taken several
days and significant effort to solve
was diagnosed and repaired in a
few hours due to the improved
troubleshooting tools and graphics
providedbytheABBsystem.
38
The new control system allowed

Klamath to quickly resolve an oil
pump failure with a workaround
insteadofwaitingforareplacement
pump that would have meant a
week-longdelay.
ThesystemenablesKlamathtomake
slightmodificationstohowtheprocessworks.Theycanchangethings
suchastheamountofgaspressure
required to start the turbine. That
simplechangebyitselfsignificantly
improvesstartingreliability.
Otherimprovementsmadeduringthe
projectinclude:
The new thrust balancing logic allows for monitoring of the positionerandimprovedalarmmanagement.Operatorsnowhaveagraphic
imageoftheentireprocessandthe
ability to manually position the
valvetobetterbalancethrust.
Operators can monitor the exhaust
gas temperature (EGT) more effectivelyandquicklyidentifyproblems
with thermocouples or combustors
through advanced alarming, runbackandtripconditions.
Thenewhydraulicstartersystemallows monitoring and tuning of the

startersperformancetobettermeet
the desired startup rate. The additional information provided also
enablespreventativemaintenance.
Thegovernorgraphicdisplayslive
dataoftheentiregovernorandsequencer.Theoperatorcanseeall
setpointcontrollersandtheprocess variables for each, as well as
which controller is connected to
thevalveoutput.
The ammonia, evaporator cooler
and CEMS PLCs, consisting of
relay logic, local analog controllers and field devices, were all
integrated into the new system.
All critical field devices were increased to provide redundancy,
andallvalvecontrolmacroswere
upgradedforplantconsistency.
Theoriginalwaterwashsystemwas
notflexible.Theentirewashroutine
had to run from start to finish. If
something malfunctioned during
the routine, it had to be restarted
fromthebeginning.Thenewwater
washlogicisadjustableandcustomizedtotheplantsdesire.
Klamathalsotookadvantageofthe
newsysteminstallationtomakephysicalimprovementsthatenhancesafety.
An addition to the existing building
wasbuilttohousethenewcontrolsystem.Thisnewconfigurationfreesthe
operator from the danger of arc flash
andotherelectricalhazards.
CONCLUSION
The FT8 control system developed
byIberdrolaandABBisdesignedfrom
theend-usersperspective.
It provides the information needed
to make quick decisions and maintain
optimal performance of the unit. AccordingtoIberdrola,theopenandintuitivecontrolsystemledtovastimprovementsintheavailability,reliabilityand
overallperformanceoftheunits.
www.power-eng.com
Cleaning built-up slag deposits from a

fossil fuel boiler can increase efficiency
between 1 percent and 4 percent,
helping maximize revenues for a utility.
Photo courtesy of Clyde Bergemann.
BOILER
Cleaning Methods
& Techniques
BY JUSTIN MARTINO, J.D., ASSOCIATE EDITOR
or power plants burning

anything other than natural gas, boiler cleaning
is an important part of
keeping the plant working efficiently.
Over time, boilers will build up ash
that will form slag deposits on the boiler.
Slag acts as an insulation that protects
the tube from the heat of the boiler, creating a need to use more fuel to reach the
same temperature and produce the same
output as a clean boiler. Cleaning slag deposits inside a boiler can increase boiler
efficiency between 1 percent and 4 percent. Clean boilers can also reduce emissions produced by a power plant because
less fuel is required to produce the same
amount of power.
While the importance of boiler cleaning is clear, power plant operators have
40
many options when it comes to techniques used to clear slag and ash buildup. Cleaning practices vary from offline
cleaning, which requires a planned outage, to online cleaning that can occur
while the plant is still operating. Methods can use everything from sound
waves to dynamite.
ACOUSTIC CLEANING
One option for boiler cleaning is an
acoustic cleaning system, which can
knock ash off boiler tubes or selective
catalytic reduction systems with acoustic
energy without risking damage or fatigue
to the units. While this can be done by
using acoustic horns that can be retrofitted onto boilers, Advanced Acoustic
Technologies LLC uses a technique that
is engineered specifically for a plant.
Unlike the horn suppliers, our
acoustic devices are part of an engineered, integrated system where the frequency produced by the acoustic device
is determined by 3D element modeling,
AAT co-founder Robert van Dam said.
The process is similar to flow modeling,
except the company looks at the acoustic
aspects of how sound waves behave in an
enclosure.
The companys WaveMaster Acoustic
Cleaning systems provide continuous,
online, volume cleaning with soot blowers used in a remedial role, van Dam said.
The company uses acoustic modeling to
determine the natural frequency of the
flue gas and decide the proper frequency
for the custom system as well as where it
needs to be placed in the boiler.
Our acoustic cleaners are designed
to be operated continuously if that is
required for the application, van Dam
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said. Theres no erosion. Its online, so

its running when the boiler is running,
and by being specific with the frequency
and the location we can place the acoustic effective area where we want it. Were
not just cleaning what is directly in front
of our device. Were cleaning a volume
because the acoustic cleaner is in resonance with flue gas.
Acoustic cleaning works especially
Dam said the system is used to clean the

entire convection pass at Tennessee Valley Authoritys 1,300-MW Cumberland
plant, which is 67 rows of tubes, with
two acoustic devices.
well on dry and dusty deposits, van Dam

said. The company works with areas
where ash is below the fusion point, such
as horizontal tube banks in a utility boiler. The technology is not as effective in
superheaters or other other areas where
the ash is likely partially molten.
According to van Dam, the company
has seen excellent results on a wide variety of fuels, including Powder River
Basin, pet-coke, bituminous and subbituminous coals. The fully-optimized
sound field can penetrate throughout
several tube banks with the application
of only one or two acoustic cleaners. Van
uses high-volume, specialized hydroblasting equipment, with pumps that

can send up to1,200 gallons per minute
through the hoses. The company also
uses remote-controlled robotic cleaning
systems and other automated tools to
clean boilers.
Thompson Senior Business Development Manager Carl Wise said the company is able to use water lances for both
online and offline cleaning, although
whether online cleaning is possible may
depend on the specific boiler.
You have to do online cleaning from
strategic positions because you have to
WATER LANCES
Another method for cleaning slag
from a boiler is using high-pressure water jets. Thompson Industrial Services
be very careful spraying the water directly into the boiler while its operating, he
said. Its an extremely critical process.
Whether cleaning can be done while
the boiler is online depends on the particular boiler. Although the company
routinely cleans boilers without having
Slag deposits on boiler tubs will act as
insulation, preventing the heat produced
by the boiler from transferring to the water
inside the tubes. Photo courtesy of Clyde
Bergemann
to shut them down, Wise said it may not

be possible in every situation.
Online cleaning has multiple advantages when it is possible, however.
If you take a boiler completely down,
it takes a lot of time to bring it back up,
Thompson Senior Sales Representative
Jim Walker said. It saves the utility time
and money to have that boiler up and
running when we do our deslagging.
Because of the high-volume pumps,
Wise said the company is able to clean
farther distances with their lances and
can be more effective because the lance
can go out more than 40 feet on either
www.power-eng.com
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ValvTechnologies as a proven,
dependable partner.
MADE IN THE USA
VALVTECHNOLOGIES SOLUTIONS FOR THE POWER INDUSTRY

Providing the best, most-reliable
industry solutions specifcally designed to meet the unique demands
of power generation applications.
V1 - Forged & cast ball valves
ValvTechnologies utilizes our technology, product management, engineering know-how and

worldwide service and support to help solve our
customers most difficult process challenges. By
equipping the most knowledgable people with
the latest technology, we have created solutions
where quality and dependability are build into
our products and services from start to finish.
Parallel Slide Gate (PSG) Bi-directional, zero-leakage isolation
ASME/ANSI Class 150 - 2500, 36

Integral seat design
Hard-faced seat & ball with HVOF coating - Rc 70
Blow-out proof stem
Live loaded packing
ASME/ANSI Class 300 - 2500, 6 36

Position seated easily automated
In-line repairable
Hard-faced trim with HVOF coating - Rc 70
Electronic Relief Valve (ERV) Protection of safety valves
ASME/ANSI Class 150 - 2500, 12

ASME Sec. I, V-stamp capacity certifed
Integral isolation valve available
Easily adapted to existing controls
Four-year zero-leakage guarantee

All ValvTechnologies valves manufactured for
the power industry are stringently tested to
meet the zero-leakage testing criteria & are
backed by a four-year, zero-leakage guarantee.
ZERO
LEAKAGE
VALVE SOLUTIONS
NEXTECH Trunnion mounted bi-directional isolation

ASME/ANSI Class 300 - 2500, 2 - 36
In-line repairable
Double block-and-bleed
XACTROL Leak-free isolation & control in one
ASME/ANSI Class 150 - 2500 36

Integral, characterized downstream seat
Upstream disc inserts for modulation
side of the lance.

Thompson also performs many other
types of cleaning for power plants, including hot ash removal and using a process involving dry foam to remove combustible dust, which can create a safety
hazard on the external part of the boiler.
SOOT BLOWERS
Soot blowers use compressed air,
steam or water to keep slag buildup
from occurring without the necessity
of taking the plant offline. Soot blowers have been in use for some time
now, but, like many other aspects of
power plants, are becoming more sophisticated as time goes on.
We have a basic technology, and we
have our advanced technology, which
we call SmartClean, said Tim Martin,
Areas that collect dry coal ash, such as convection passes,

are suited for acoustic cleaning. Photo courtesy of Advanced
Accoustic Technologies
director of product management for

the boiler efficiency product division
with Clyde Bergemann Power Group
Americas Inc.. Our basic technology
does the bare minimum itll keep
the boiler clean and keep it online and
running. Our advanced technology is
where we get into targeting the areas of
boilers that really need to be cleaned
with the proper intensity, so we really
get into monitoring the boiler performance and adjusting the cleaning parameters in real time, and thats where
the plant can gain efficiencies from using the advanced technology.
Intelligent soot blowing systems have several advantages over
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44
traditional systems, Martin said. The

companys advanced technology can
increase the efficiency by 1 percent
over basic systems. Intelligent soot
blowing systems also only clean when
necessary, which avoids boiler tube
erosion.
Basic systems are blind to whats going on inside the boiler, Martin said.
There may be areas in your boilers
that are clean, but youre running a soot
blower because its time in the sequence,
so its blowing high pressure steam on
a bare tube, which can lead to erosion.
In addition, you may have areas of your
boiler that foul much more quickly and
because of the way the sequence is set
up, it may not be able to hit that area for
several hours. In those hours, that area
could really foul up significantly and
plug the boiler and cause a clinker or
severely restrict the heat transfer, forcing
them to have a shutdown.
Many coal-fired boilers built in the
www.power-eng.com
The Simpactor FGT pin

mill reduces the particle
size of sorbents used
in Dry Sorbent Injection
systems.
Perfection is
Improving Emissions
past 10 years were installed with intel- around tubes that are close to avoid damligent soot blower technology, Martin age. The cord has connectors to delay the
said. Clyde Bergemann is also working chargers, which he said is important to
on retrofits for power plants that werent avoid destroying the wall or insulation of
originally equipped
the boiler.
with intelligent soot
Harty said usWith dynamite, you ing explosives has
blower technology.
several advantages,
can put all of it in
EXPLOSIVES
a pickup truck and including speed and
Using explosives to
convenience. With
clean slag from boilers clean any boiler.
dynamite, you can
isnt a new process, but - Norm Harty, N.B. Harty
put all of it in a pickits one still in use that
up truck and clean
General Contractor Inc.
many plant operators
any boiler, he said.
prefer.
Explosives also
The method was first used by Norm have an advantage in areas where plants
Harty of N.B. Harty General Contractor are concerned about water use, he added.
Inc. Over the years, Harty said he and
Water is really scarce out west, and
his staff have built the procedure into a this is another reason explosives are bestate-of-the art technique that can quick- ing used predominately in the western
ly clean the slag from a boiler and have it plants, he said. They cant afford to
back online.
waste a drop of water, and by using dynaTo clean a boiler using explosives, Har- mite theyre able to save their water and
ty said his company will use primer cord clean their boiler at the same time.
www.power-eng.com
Perfecting
Perfecting

Particle

Size

x,

Phone: 800.992.0209
sales@sturtevantinc.com
www.sturtevantinc.com
45
VALVES &
ACTUATORS:
The Path to
Greater Efficiency
& Performance
BY RUSSELL RAY, MANAGING EDITOR
alves and actuators are

critical in almost every
aspect of power plant
operations. They are
used in a wide range of
applications, including pollution control,
feed water, cooling water, chemical treatment, bottom ash and steam turbine control systems.
They are exposed to a variety of
chemicals, abrasive materials and very
high temperatures. They are critical in
46
optimizing efficiency, and they are often

the final control element in the operation
of a power plant.
Although the basic technology for
most valves and actuators has remained
unchanged, innovative applications
and design modifications for problem
solving have led to notable improvements in actuator technology. These
improvements can reduce costs by supporting the control valves ability to
throttle accurately, thereby providing
better performance for high-pressure

steam bypass, turbine bypass and other
critical power plant operations.
Actuators regulate mass and energy
flows by adjusting valves, flaps and cocks.
The actuator and valve create a single
unit the control valve. Actuators perform different motion sequences, including linear, pivoting and rotating motions,
and they are powered by pneumatic, hydraulic or electrical energy.
Actuators receive a control signal from
www.power-eng.com
Rotork IQ electric actuator being installed at a power

plant. Todays modern generation of intelligent, electric
actuators offers power plants a host of benefits,
including the potential of significant energy savings.
Photo courtesy of Rotork
automation systems. The signal is converted into a motion so that the control
element of the actuating element assumes
a corresponding position. With control
valves, this is a stroke motion. With flaps,
ball cocks or rotary plug valves, this is a
pivoting motion.
To better understand the options available to power producers, Power Engineering reached out to the following companies for more information about valves
and actuators.
ROTORK
Power plants are complex in that there
are many different sub systems required
to deliver electricity. These plants were an
early adopter of distributed control systems to monitor and control the facilities.
Due to the arduous nature of the environment, certain practices were adopted
to allow for reliability and maintenance.
Motor operated valves in particular are
key to plant performance. Until 20 years
ago motor operated valves tended to have
motor control centers remote from the
valve. This did not allow for the benefit of
technology advances in electric actuators.
The early 1990s saw a trend towards
smart actuators with integral data logging
capabilities. These actuators could also be
networked to provide the control system
to receive data that had occurred in the
actuator. Power plant designers started
to take advantage of this in the past 10 to
15 years. Today, there has been a major
change in the availability of better information from the motor operated valves.
Instead of being alerted after the fact, the
electric actuators are now monitoring the
systems and providing data ahead of potential failures in the equipment.
As an example, early actuators had
torque switches which tripped after
the valve had an internal failure which
caused it to require more force than originally designed for. The more recent smart
www.power-eng.com
actuators have an internal data logger inside which has had the ability to monitor
torque output.
The most recent electric actuator has
these two features plus more. The newest
feature is to have a monitoring set point
above the baseline torque and below the
over torque setting to alert the plant operator that there is an impending issue that
needs to be addressed.
Miscellaneous trip alarms are also included to monitor things like starts per
hour to insure the internal contactors
are not being overused, perhaps due to
an actuator that is hunting because of a
faulty process signal. There are also maintenance interval settings that can be adjusted by the plant operator.
These newer actuators also have
expanded screens at the unit to allow
for better operator local diagnostics.
These are just a few of the upgrades
available today.
VALVTECHNOLOGIES
Leaking isolation valves are found everywhere in the steam generation industry and equally widespread is the detriment to P&L statements worldwide. How
can a simple worn, damaged or improperly specified isolation valve have such far
reaching effects? The following summarizes the adverse impact on four critical
plant performance measures: efficiency,
production, reliability and maintenance
costs.
Like all thermal engines, steam plants
are powered by energy differences and
the greater this difference, the greater
the fuel efficiency. Valves maintain the
separation by isolating the high energy
processes from the low energy processes.
When valves leak, they are acting in direct opposition to the forces that drive the
plant by allowing energy to leave the high
energy processes and enter the low.
Another key characteristic of the steam
cycle is that production (or kilowatthours) is governed by the steam rate or
mass flow through the cycle processes.
Steam or energy that is bled out of the
processes via leaking valves is not being
put to beneficial use and thus may be

proportionately reducing the amount of
electricity or revenue being produced.
While plants are designed with ancillary equipment to compensate for some
of the effects of valve leakage, this adds
substantial costs to operations and the
capability is limited. Recent client experience includes mitigating cycle water losses on a new generating plant in
which cumulative valve leakage rates
exceeded the make-up water system
capacity. This forced the plant to curtail operations to allow the make-up
system to catch up demonstrating how
cycle isolation can directly impact plant
reliability and availability.
The cornerstone to capturing these
benefits is diagnostics. A systematic approach to accurately measuring valve
leakage eliminates uncertainties that
manifest as unnecessary added costs.
Improvements to valve leakage diagnostic programs quickly result in plant performance improvements as well as sustained reductions to valve O&M costs.
YOUNG & FRANKLIN

Advances in the design and manufacturability of electrically powered actuators have allowed for the replacement of
hydraulically actuated control valves and
guide vanes on heavy duty class combustion turbines. Asset owners and operators benefit from reduced life cycle cost,
improved component reliability, and in
many cases interrelated components can
be eliminated, thereby improving system
reliability.
The hydraulic valve product is mature, but to ensure their reliability frequent maintenance must be performed
on a 24,000 hour cycle minimum. Lack
of maintenance causes unpredictable
control performance such as start-fails,
forced trips, trips during controlled shutdowns and loss of flame during transitions. Hydraulic oil leaks of worn seals
and vulnerable fittings create slip and
fire hazards. On-site work includes messy
filter changes, replacement of lube-oil
varnish plagued servos and safety trip
47
relays, unverified adjustment of valve

stem packings, and re-calibration. Offsite work is typically a time-zero overhaul
of the valve and actuator at 48,000 hour
intervals.
Y&F set out to develop the EMA (electric motor actuator) product line with asset owners and operators in mind. Specifications were based on real world duty
cycles, operating conditions and owner/
operator inputs while meeting or exceeding original equipment performance
metrics. Development testing was based
on the most stringent requirement of
each category. All products were designed
to fit into the same envelope or smaller
APPOLLO VALVES
The Ball valve has proven to be a highly
efficient valve product providing good
isolation with minimal pressure drop and
the ease of quarter-turn operation. The
simplicity of the designs makes it possible
to offer a variety of seating materials, end
connections, materials-of-construction,
body styles, thru-flow in Full or Reduced
Port designs, and is very adaptable from
manual operation to electric/pneumatic/
hydraulic automation.
There are as many different types of
ball valves as there are applications for
ball valves.
Two of the basic designs are commonly
the ball to seal. Whereas, with the floating design, the ball is not fixed and is free
to make contact with both seats; sealing is
achieved by pre-loading the seats during
assembly and test. Both of these designs
offer a broad array of unique optional features to provide the best possible product
to meet the end users applications and
expectations.
Apollo Valves is headquartered in Matthews, N.C., with a bronze foundry and
manufacturing facilities in Pageland,
S.C., and a steel foundry and manufacturing facilities in Conway, S.C. Apollo
produces valves for the Commercial and
Industrial markets. Conbraco, Apollos
parent company, offers a full line of
bronze, steel and high alloy floating ball
valves for the industrial market.
S&K AUTOMATION
Cycle Isolation testing utilizes acoustic

monitoring instruments to help customers
monitor valve performance. Photo courtesy of
ValvTechnologies
than existing hydraulic products and are

suitable for many OEM turbine makes.
Retrofit projects can be completed within
typical outage duration with minimal
on-site modifications required.
The Y&F EMA product line is designed
for a 96,000 hour time-zero overhaul
cycle.
Owner/operators benefit from improved reliability and realize maintenance budget gains by eliminating the
recurring costs associated with lube oil
powered hydraulic actuators.
48
referred to as, the Floating Ball Design

and the Trunnion Ball Design. Each
design has various pros and cons, but
typically the larger (6 and larger) higher
operating pressure/temperature valves
will be of the Trunnion design and the
smaller (1/4 to 12) floating design will
typically be used in lower pressure/temperature conditions.
With the Trunnion design the Ball is
fixed in-place by a bottom trunnion, and
the stem-to-ball connection acting as the
upper trunnion. With the trunnion design the Ball does not come into sealing
contact with the Seats; the Seats are mechanically energized and move toward
Bonomi North America has introduced

a new line of ANSI Class 150 flanged industrial full-port ball valves, designed
for easy automation with low operating
torque and direct actuator mounting. The
new split body valves accept any appropriately sized ISO standard actuator and
are performance-matched to Bonomis
Valbia electric and pneumatic actuators.
Designated the Valpres 766000 Series
(stainless) and 766001 Series (carbon
steel), the valves feature an ISO 5211
mounting pad and square stem, raisedface flanges and Fire Safe certification
to API 607, 6th edition. In addition, they
are also certified to API 6FA. They are
designed to ANSI 16.5, ANSI 16.10 and
ANSI 16.34. They meet NACE MR 0175,
NACE MR 0103 and are TUV T.A. Lusft
approved.
Valpres 766000/766001 Series valves
are currently available in five sizes: 1,
1, 2, 3 and 4. They offer long service life with minimal maintenance in
applications such as power generation,
pulp and paper, chemical/petrochemical processing, water treatment and skid
mounted pumping systems.
Standard features include virgin PTFE
seats, stainless steel ball and blowout
www.power-eng.com
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5 EVENTS + 5 DAYS
The Valpres 766000 Series stainless steel

valve. Photo courtesy of S&K Automation
proof stem, and a locking handle that can

be secured in either the open or closed
position. The stainless steel body is cast
from ASTM A351-CF8M. The carbon
steel version is made from ASTM A216WCB. Optional high-temperature seats
are also available.
PROMATION
Local control stations are self-contained signal generating units which are
attached to an actuator, or in the case of
an actuator in an inaccessible location,
mounted on the wall close to the actuator it controls. It gives the ability to switch
the actuator off or from REMOTE to
LOCAL mode. An example of REMOTE
mode is when a central control room controls the actuator. In case of emergency or
during maintenance work, the actuator
can be placed in LOCAL mode and then
opened, closed, or jog to the appropriate
safe condition. At the conclusion of the

outage or maintenance work, the actuator
is switched back to REMOTE mode and is
returned to its normal role in the overall
control scheme.
Local control stations are designed for
either 2 position, floating, or proportional control, in many supply voltage
options, and have a wide selection of
switches and displays such as indicator
lights for open/closed position, end of
travel indicator lights, and LCD displays

to show the current position of the valve.

A light or display showing full closure of
a valve is incredibly useful because if the
valve/actuator is mounted high enough
or in dim light, the actuator indicator
may not be visible from ground level.
Having a local control station mounted to the actuator makes for a very quick
and simple installation in the case of a
valve retrofit, and allows for quick commissioning in a new installation as the installers will not need to fabricate a switch
box for local control.
Operators really appreciate the convenience and safety offered by a well
placed remote-mounted local control
station which saves them from climbing a tall ladder to close or change the
position of a valve located in an inconvenient or dangerous location.
Condenser Performance
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JASC CONTROLS
Over time, there may not be another
auxiliary system more maligned than
that of a back-up liquid fuel system on a
dual fuel gas turbine. The hardware shortcomings responsible for the inability to
start on liquid fuel or transfer from gas
to liquid fuel, check valve failures, flow
Local control stations like this one are simple to

install and operate. It gives the operator the ability
to switch the actuator off or from Remote to
Local mode. Photo courtesy of Promation
divider failures, fuel system evacuation,

exhaust temperature spreads and related
turbine trips have all been addressed by
designs developed by JASC Controls. Water cooled check valves, which prevent
carbonization , metal to metal sealed

water injection check valves rated for
service at 600 degrees F, multiple use
crush gasket technology which replace
o-rings with a 1000 degree F rating at
2000 psi and a zero emissions equipment
design which allows a turbine owner to
test the readiness of the liquid fuel system
without firing on oil are examples of the
JASCs unique technology.
These system specific products have
two common design goals. First, they provide reliable operation for at least 24,000
hours or until a scheduled turbine service
interval is reached. This provides the optimal timing for returning the valves to
the JASC facility for refurbishment after
three or four years of use.
Second, the valves must maintain
an ANSI Class 6 sealing capability from
installation until removal for refurbishment. Elimination of reverse flow results
in separation between the turbine combustion process and auxiliary systems
such as liquid fuel, purge air and water
injection. With no reverse flow of combustion gasses into these systems, backup fuel system availability and reliability
typically exceeds 98 percent.
Finally, JASCs solutions are configured to be interchangeable with
the turbines existing hardware. This
characteristic both minimizes the cost
and reduces the time associated with
performing fuel system upgrades on a
turbine of any age.
www.power-eng.com

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NUCLEAR
Author
Bob Cramblitt is a freelancer who writes
about computer-aided technologies.
ORNL modeling
program to simulate
SMR designs
BY BOB CRAMBLITT
hen it comes
to modeling
for engineering
simulation, there are
haves and have-nots: those who have
the specialized skills needed to create
models for accurate simulations and
those who dont.
Not surprisingly, the haves are a vast
minority.
Modeling often suffers from the
limitations associated with proprietary products that require excessive
time and/or training for their effective use, says Richard Hale, principal
investigator for the advanced small
modular reactor program at Oak Ridge
National Laboratory (ORNL).
The answer for ORNL and other
organizations dealing with complex
assemblies requiring large-scale collaboration could be modeling based
on open standards.
FROM DECADES
TO YEARS?
ORNL recently completed a key
phase of a project to produce shareable
models and an easy-to-use interface
for collaborative development of small
modular nuclear reactors (SMRs).
The complexity of nuclear reactor
design and modeling is such that the
increased potential collaboration will
hopefully shorten the time for design
and development from decades to
years, says Hale.
Hale and his colleagues are
54
partnering on the project with Modelon, an international supplier of model-based systems engineering tools,
libraries and services; and Xogeny, a
start-up exploring ways to integrate
engineering models into web-based
analysis applications.
and FMI.
LOW THRESHOLD
OF ENTRY
Dymola is software from Dassault

Systmes that uses the open-standard
Modelica language to model and
simulate the dynamic behavior and
SMALLER SIZE, LARGE
performance of systems with comADVANTAGES
plex interactions. FMI (Functional
Small modular reactors are about Mockup Interface) is an open-standard
one-third the size of the current gener- interface that enables compiled modation of nuclear power plants. Key ad- els called FMUs (functional mockup
vantages include the ability to fabricate units) to be integrated into multiple
in the factory and desimulation environliver by truck or rail The design and
ments.
to a site, zero carbon
FMUs can be used
licensing of new
emissions, lower inioutside of the origitial cost, scalability, nuclear reactor
nal authoring tool
or solver, opening
and site flexibility. concepts takes
the way for wider deSMRs could also prohundreds of
ployment throughvide better safety and
out the enterprise
security than their engineers and
and among qualified
larger counterparts.
many different
partners.
But, small or large, organizations.
Dymola, Modelica
modular or not, one
aspect that doesnt change is the need and FMI are some of the key building
blocks for model-based systems engifor teamwork on a massive scale.
The design and licensing of new nu- neering (MBSE), which is defined by
clear reactor concepts takes hundreds three basic characteristics:
multi-domain, where the physof engineers and many different orgaics from different engineering donizations, says Hale. And the simumains and control configurations
lation of these designs for licensing,
can be simulated within the same
safety, operations, maintenance and
models;
economics requires close collaboration
multi-fidelity, where models of
among multi-disciplinary groups.
different sizes and complexity can
Following Modelons lead, ORNL is
be used according to specific analturning to open-standards modeling
ysis needs; and
as embodied by Dymola, Modelica
www.power-eng.com
While our nuclear past is symbolized by hulking,

concave, steam-emitting towers at enormous, expensive
facilities, our nuclear future is poised to look very different. Here, an artists rendering of the mPowers Twin
Pack site layout. Photo courtesy of Babcock & Wilcox
wide deployment, where models can be exported outside their

original environments and used
for a wide range of engineering
analyses.
Modelon was selected as an ORNL
project partner based on its expertise
in implementing MBSE for organizations in the automotive, aerospace and
energy business sectors. The company
offers a range of FMI-based products
and more than a dozen Modelica libraries for specific industries and
physical domains.
Modelon is helping us develop a
low threshold of entry for non-modelers to simulate reactor design concepts, says Hale.
MODELING AND
SIMULATION
MBSE focuses on interaction among
systems in different physical domains,
such as those between controls and the
www.power-eng.com
plant itself.
Models of different fidelities give users the ability to consider many different variants and topologies for concept
assessment and system optimization.
These types of analysis can be performed in the very early stages in the
design process, often before detailed
geometry is available.
From the modeling and simulation
standpoint, says Hale, models are
easier to build and modify. They also
provide a more convenient environment from which to set specifications.
In the current architecture and
simulation framework developed by
Modelon for ORNL, models are configured on a web interface then downloaded for local simulation on a users
computer. This approach allows users to easily set parameters, download
models (FMUs) created in Modelica,
and automatically set up cases and
run them within the Excel add-in or
commonly used simulation programs.

The combination of a dynamic
modeling interface, supported libraries, the modeling language and the
FMI Add-in for Excel enables novice modelers to run parametric cases
across a wide suite of models, says
Hale. Its a powerful combination
that did not exist previously for modeling and simulating reactor designs.
TAKING IT TO THE CLOUD

The next major step in the ORNL
project is making the transition from a
local application to a web-based simulation platform. Thats where the dual
expertise of Xogenys Michael Tiller
comes in. Tiller has 15 years of experience in the Modelica environment
and hes now turned his attention to
building web-based engineering architectures that employ open standards.
Xogenys goal is to use Modelica
and FMI as a springboard to a modern
55
Architecture
The architecture developed by Modelon serves as the starting point for all modeling work.
approach that involves cloud computing and web-based user interfaces,

says Tiller. We want to make deployment of and access to models as frictionless as possible.
It might take a village to design and
simulate a small modular nuclear reactor, but it will go a lot smoother and
faster if villagers can make their contributions in a way that is most comfortable for them.
It appears that ORNL, with the help
of Modelon and Xogeny, is on the right
path to the long-sought goal of largescale modeling and simulation collaboration.
SMR RESEARCH AND

DEVELOPMENT
The following is a description of
projects related to the research and development of SMRs:
Babcock & Wilcoxs Generation
mPower division was the first winner of the $425 million DOE funding
for its 180-MW SMR. Project partners
56
Bechtel and the Tennessee Valley Au- activities of its helical coil steam genthority have already submitted appli- erator (HCSG) at the SIET S.p.A. (SIET)
cations for construction and licensing facilities in Italy.
of the reactor at the Clinch River site in
During the testing phase, the U.S.
Tennessee. The project is on schedule Nuclear Regulatory Commission conto be completed by 2022. Clinch River ducted a quality assurance inspection
will be made up of
the testing activiWe want to make of
two, 180-MW mPowties.
er reactors and con- deployment of and
Holtec
Internastruction is expected access to models
tional, along with
to take 36 months.
partners
NuHub,
as frictionless as
NuScale
Power
PSEG Nuclear and
LLC became the sec- possible.
SCE&G, said it will
ond company to win
continue to develop
a funding opportuits 60-MW SMR-160
- Michael Tiller, Xogeny
nity from the U.S.
despite not winning
Department of Energy to develop and any funding from the DOE. General
certify its 45-MW SMR.
Atomics said it would also find anothNuScale, which is majority owned er way to develop its EM 2 SMR without
by Fluor Corp., has partnered with the funding.
Rolls Royce and Energy Northwest to
Westinghouse has since shifted fodevelop the SMR. The company ex- cus from developing its 225-MW SMR
pects to have first plant operational to building and marketing its 1,100by the early 2020s. Fluor invested $30 MW AP1000 reactor, saying there is
million in NuScale in October 2011. a customer base for the larger reactor
NuScale recently completed testing and not the smaller one.
www.power-eng.com
TM
AUGUST
2022, 2014 | NASHVILLE, TENNESSEE

MUSIC CITY CENTER, HALL B
W W W. C OA L - G E N . C O M
OWNED &
PRODUCED BY:
PRESENTED BY:
PRODUCTS
Endevco charge output
accelerometer
Convection
vacuum gauge
steel sensor materials.
elevac said their compact MX4A Active
site applications. It can operate as low as 8VDC
Convection Vacuum Gauge is available.
and has current consumption with voltage out-
eggitt Sensing Systems has made available

its Endevco model 2280, a hermetically
The output signal is ideal for oil and gas well
sealed, triaxial, piezoelectric charge output ac-
The gauge is designed with a replaceable
puts as low as 2mA. The housing has a special
celerometer with high-
Televac 4A convection vacuum censor that fea-
layered paint suitable for NEMA 4X environments
temperature operation
tures a wide range of
and salt spray conditions. Using 316L SS, the
to 482 degrees C (900
measurement from 1.0 x
transducer is compliant to NACE MR0175/ISO
degrees F).
10-4 up to 1000 torr, RS-
15156.
485
American Sensor Technologies

Info http://powereng.hotims.com RS#: 406
The model is de-
communications,
signed for vibration
two programmable set
measurements across
points and a selectable
three orthogonal axes on power plant equip-
analog output.
Remote monitor units
ment and other machinery that operates at high
The display is made
temperatures. The accelerometer is 1.35 inche
to be easy-to-read from a distance without a PC
square and weighs less than 0.6 pounds.
and options can be set from four capacitive touch
of remote monitoring units.
Meggitt Sensing Systems

Info http://powereng.hotims.com RS# 400
controls or through RS-485 communications.
Remote Monitor under its Messenger brand
The remote monotirs are land-line based, using common telephone lines that are ideal for
Televac
use in applica-
Low temperature chillers
tions
where
okons line of low temperature chillers is
Impact wrench
other networks
made with operating temperatures from -20
hicago Pneumatic announced its CP69 1-inch
are not readily
impact wrench series that is ideal for the oil and
available or in
degrees F to 20 degrees F and nominal capacities

up to 12 tons in both air-
gas industries.
remote,
unat-
and water-cooled con-
The series was
tended facilities. The monitor also supports OEM
densing. The extreme
redesigned to be
vendors needing to monitor third-party services
low temperatures are
more ideal for
at customer locations without tapping into cus-
ideal for reactors and
harsh
tomer communication networks.
other industrial applications.
industrial
environments,
The portable chillers use R-507 refrigerant and
including
those
Global Monitoring
come with a microprocessor-based controller with
with higher dust concentrations. The wrenches
a semi-hermetic discus compressor and a heavy-
deliver up to 1,920 foot-pounds of torque with 700
Acoustic vent
duty insulated plastic tank, among other features.
blows per minute.
Mokon
The wrench offers ergonomic features includ-
.L. Gore & Associates Portable Electronic

Vents group designed the GAW113 acous-
ing a low vibration level of 8.7 m/s2. The light
tic vent to provide dust and splash protection for
aluminum alloy clutch housing is protected by
acoustic opening
Pre-cut sheets
a molded rubber front cover, and precision ma-
in portable elec-
nsinger/Penn Fibre has developed pre-cut strips
chined and fnished steel rotor and end-plate
tronic
of any material of various thickness and width.
components help ensure optimum durability and
such as scanners,
Strips are slit from standard 2 x 4 foot sheets

using a modifed
slitter. The strips
tool performance.
Chicago Pneumatic
are often needed

in the frst step to
two-way
devices
radios,
tablet and laptop PCs.

The vents are made to protect acoustic openings with a barrier against dust, dirt and various
Explosion-proof
pressure transducer
liquids while equalizing pressure and minimiz-
merican Sensor Technologies released the
acoustic devices. The vents are a proprietary
Any Ensinger/Penn
AST46DS explosion-proof pressure transduc-
non-woven composite material that adheres to
extruded material
er with display.
the acoustic openings and has a thickness of
a stamping or machining operation.
up to 0.156 thick and 2 feet wide can be handled.

Ensigner/Penn Fibre
58
lobal Monitoring reintroduced its GMU 8100
The sensor has available pressures from 1 to

20,000 PSI with zero function capability, voltage
or 4-20 mA output signals, and all 316L stainless
ing transmission loss and attenuation in sealed
0.47 mm.
W.L. Gore & Associates
www.power-eng.com
Automatic Filters
Boiler Services
Ball Valves
Why Should You

Filter Your Water?
www.Viega.us
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Filteration Solution Always
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Viega offers press ball valves specifically designed

for lead-free press systems. Made from Viegas
unique silicon-bronze alloy, engineered for press
technology, Viega ProPress Zero Lead ball
valves are certified to ASME A112.4-2004 and
NSF-61G, available in sizes 1/2- to 2-inches with a
variety of configurations.
http://powereng.hotims.com/RS#300
Cooling Tower Fill
Crushers
Electrical Connectors
The Leader in Uptime Since 1905
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Fluor has extensive experience in boiler

inspection, installation, maintenance, repair,
and replacement of all components - executing
projects across the boiler model spectrum
as well as auxiliary equipment. Through
value-added services, Fluors Power Services
team provides innovation and cost savings to
our clients maximizing their operations and
maintenance projects. To learn more about
these services, email us at power@fuor.com.
SUPPLIERS SHOWCASE |
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Eliminate fugitive dust to

improve plant safety with
Posimetric Feeders
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Dust-free processing of coal, limestone,

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E-mail: Buster@PennCrusher.com
(on receptacle)
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Handling a World of Materials

www.TerraSource.com
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Posimetric is a licensed trademark of GE Energy (USA) LLC.

TerraSource Global is a wholly-owned subsidiary of Hillenbrand, Inc.
(NYSE: HI) 2014, TerraSource Global. All rights reserved.
meltric.com
800.433.7642
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Heat Recovery Systems
High Temperature
Industrial Solutions
SOLVAir Solutions was formed

to help customers address the
problems of SOX, HCl and other
stack emissions, as well as help
with the changing EPA regulations.
SOLVAir Solutions is the market
leader in providing sodium
sorbents for use in DSI systems.
Access our brochure on our
Library page at www.solvair.us
Contact Rosemary Dunn
ardunadv@gmail.com
713.521.7450
When you need high temperature

thermal performance or personnel and
fire protection, ROXUL has you covered
with a wide range of Pipe, Board, Blanket
and Wr
Wrap products to meet
yourr industrial
indust
in
insulation
requirements.
req
equirem
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.
Visit www.roxul.com
or call 800.265.6878
High Voltage Equipment
Joining Stainless Pipe
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Call or Email for a quick quote

and fast track delivery of
Phone660.596.7727
Emailhvsales@energy-parts.com
www.energy-parts.com/power-eng
www.ViegaProPress.us
1-800-976-9819
Solution for Existing &

Evolving Energy Needs
for and in the Americas
High Voltage Equipment

24/7/365
For construction of the worlds largest solar power

plant, Viega ProPress for stainless was hardspecified in the plans for process water, service
water and instrumentation air systems. Viega
ProPress for stainless saved more than 30 percent
on materials and labor combined for installing the
systems.
60
High Temperature Insulation
| SUPPLIERS SHOWCASE
Emission Control
www.power-eng.com
Silo and Bin Cleaning Sevices
ONE CALL
ONE SOURCE
POWERFUL
SOLUTIONS
REACH YOUR
AUDIENCE
For over three decades Mechanical Dynamics & Analysis has

proudly offered a vast range of products and services for power
generators. We provide complete project management, overhaul
and reconditioning of your rotating equipment, as well as, parts
solutions.
Call 800-322-6653
or visit
www.molemaster.com
PARTS | SERVICES | REPAIRS
Mechanical Dynamics & Analysis

19 British American Blvd. | Latham, NY 12110
ph.518-399-3616 | www.MDAturbines.com
GET RESULTS
Put your message in front of North
Americas most qualifed circulation with
Power Engineerings classifeds.
CALL NOW FOR DETAILS:

JENNA HALL
Phone: 918.832.9249
Email: jennah@pennwell.com
Books, BooksSo Many Books

Check out over 50,000 Books Related to
the Energy Industry at PennEnergy.com
ADVERTISE your career opportunities,

equipment, services, and training
programs in Power Engineerings
Classifed Section.
SUPPLIERS SHOWCASE |
Silo and Bin

Cleaning Services
and Equipment
Turbine-Generator Repair
www.PennEnergy.com
www.power-eng.com
61
| CLASSIFIEDS
Classified advertising ContaCt Jenna Hall: 918-832-9249, JennaH@pennwell.Com
CONDENSER & HEAT EXCHANGER TOOLS

CLEANERS, PLUGS, BRUSHES
POWER PROFESSIONALS
John R Robinson Inc

PH # 800-726-1026
e-mail: jrrinc@earthlink.net
www.johnrrobinsoninc.com
Opportunities in Operations and Maintenance,

Project Engineering and Project Management.
Business and Project Development.
First-line Supervision to Executive Level Positions.
Employer pays fee. Send resumes to:
P.O. BOX 87875,
VANCOUVER, WA 98687-7875
email: dwood@staffing.net
(360) 260-0979 (360) 253-5292
www.powerindustrycareers.com
Get a thorough mix with:
Pugmill Systems, Inc.
P.O. Box 60
Columbia, TN 38402 USA
FOR SALE/RENT
Ph: 931-388-0626 Fax: 931-380-0319
20,000 - 400,000 #/Hr.
24 / 7 EMERGENCY SERVICE
BOILERS
www.pugmillsystems.com
GEORGE H. BODMAN, INC.

Chemical cleaning advisory services for
boilers and balance of plant systems
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
DIESEL & TURBINE GENERATORS

50 - 25,000 KW
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LARGEST INVENTORIES OF:

Air Pre-Heaters Economizers Deaerators
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Pulverizers Rental Boilers & Generators
847-541-5600
FAX: 847-541-1279
visit www.wabashpower.com
wabash
POWER
EQUIPMENT CO.
444 Carpenter Avenue, Wheeling, IL 60090
Got jobs?
Weve got people.

The PennEnergy JOBS process puts your
recruitment message in front of the industrys
best talent whether its online, in print, or at an
event. This approach offers you the fexibility
to create custom recruitment advertising
campaigns best suited to meet your budget
and objectives.
Quality and Service Since 1908
Ring Granulators, Reversible Hammermills,

Double Roll Crushers, Frozen Coal Crackers
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Ph: (314) 781-6100 / Fax: (314) 781-9209
www.ampulverizer.com / E-Mail: sales@ampulverizer.com
| Learn More |
Visit: www.PennEnergyJOBS.com
Call: 1-800-738-0134
WE ARE
BUYING!!!
ARE YOU SELLING?

VALVES
INSTRUMENTATION
ELECTRICAL CONTROLS
PROCESS EQUIPMENT
PROCESS CONTROLS
PLANT MACHINERY
PSA SNUBBERS, ETC.
Ferncroft
Management,LLC
VISIT
www.FerncroftManagement.com
email:vavlebuyer@ferncroftmanagement.com
T. 978-815.6185 Fax. 603-814.1031
LIMITORQUE OPERATORS WANTED
CONDENSER OR GENERATOR AIR COOLER TUBE PLUGS

THE CONKLIN SHERMAN COMPANY, INC.
Easy to install, saves time and money.

ADJUSTABLE PLUGS - all rubber with brass insert.
Expand it, install it, reverse action for tight fit.
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Sizes 0.530 O.D. to 2.035 O.D.
Tel: (203) 881-0190
Fax: (203) 881-0178
E-mail: Conklin59@aol.com www.conklin-sherman.com
Just Plugging Along

CLASSIFIEDS |
RENTAL EQUIPMENT
ES I Bo i le r R e n t al s , L L C
1-800-990-0374
www.rentalboilers.com
- Rental Boilers - Economizers - Deaerator Systems - Water Softener Systems -
Light up your
ad with a little
COLOR!
Call Jenna Hall
at 918-832-9249
Exothermic Engineering, LLC

Burner Management
System Logic Review
Has your Burner Management System
been reviewed for compliance with
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experts has performed more BMS
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Our staff actively maintain seats on key
NFPA 85 technical committees,
averaging over 30 yrs of experience.
Complete BMS Services

!

"
out services

and contract administration
We are also experts at solving ancillary
problems with flame scanners, igniters
and other BMS I/O equipment.
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
The worlds very

best portable end
prep tools and
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For sale or rent
800-343-6926
www.escotool.com
Begin with a conference call

No cost, No obligation.
Call Bill Smith:
Exothermic Engineering, LLC
(816) 415-8888
www.ExoEng.com

Classified advertising ContaCt Jenna Hall: 918-832-9249, JennaH@pennwell.Com
24/7 On-Call Service
INDEX
RS# COMPANY
PG#
RS# COMPANY
PG#
11
21 Process Barron
35
Brand Energy and

Infrastructure Services
www.processbarron.com
www.beis.com
Brandenburg Industrial
Service Company
C4
27 Renwable Energy
World Conference
www.renewableenergyworldevents.com
www.brandenburg.com
16 Check All Valve Mfg Co
26
www.checkall.com
33 Coalgen 2014
Conbraco Industries Inc
57
13
Diamond Power
International
Elgin Sweeper Company
17
34 Valmet AB
50
Mitsubishi Power
Systems Americas Inc
5
C2
www.picworld.com
27
30 POWER-GEN International
www.power-gen.com
64
Westinghouse Electric Co
www.westinghousenuclear.com
52
www.winstedcustom.com
Young & Franklin Inc
15
www.yf.com
www.nuscalepower.com
17 Power Generation Week
www.volvopenta.com/us
PIC Group Inc
22
8-9
39
12 Volvo Penta
of the Americas
31 Winsted Corporation
22 N B Harty General
Contactor Inc
Nuscale Power Inc
43
24
C3
24 Valvtechnologies, Inc
www.liqui-cel.com
21
www.valmet.com
23
www.megger.com/s1
33
www.unitedrentals.com/futures
19
www.lehighfluidpower.com
44
www.mdaturbines.com/turboparts
11 United Rentals Inc
www.jasc-controls.com
14 Membrana
20 Turbo Parts LLC
31
19 JASC Jansens
32
Aircraft Systems Controls Inc
13 Megger Inc
45
www.transmissionhub.com
www.hobaspipe.com
29 Lehigh Fluid Power
25
www.sturtevantinc.com
25 Transforum West
www.hach.com/power
10 Hobas Pipe USA
41
www.sealeze.com
26 Sturtevant Inc
www.elginsweeper.com
18 Hach Co
15 Sealeze, A Unit
of Jason, Inc
www.diamondpower.com
23 Roxul Inc
50
www.concosystems.com
53
www.roxul.com
www.apollovalves.com
28 Conco Systems Inc
32 Rotork Controls Inc

www.rotork.com
www.coal-gen.com
49
51
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.
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 Jenna Hall
1421 S. Sheridan Rd.
Tulsa, OK 74112
Phone: 918-832-9249, Fax: 918-831-9834
email: jennah@pennwell.com
www.power-eng.com
Committed to moving our

customers performance
forward every day
Valmet Corporation is now an independent, listed company that was reborn through the demerger of the pulp, paper and
power businesses from Metso Group in December 2013. We develop and supply competitive services and technologies for
the pulp, paper and energy industries.
Valmets services cover everything from maintenance outsourcing to mill and plant improvements and spare parts. Our
strong technology ofering includes entire pulp mills, tissue, board and paper production lines, as well as power plants for
bio-energy production. Valmet and Metso will continue to work closely together to ofer winning automation solutions.
Our 11,000 professionals around the world work close to our customers and are committed to moving our customers
performance forward every day.
Discover more at
www.valmet.com

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Heat Recovery Steam Generators | Waste Heat Boilers | Fired Packaged Watertube Boilers | Specialty Boilers

Weve been around awhile.

The RENTECH team has

BOILERS FOR PEOPLE WHO KNOW AND CARE

SMALL MODULAR REACTORS

POWER PLANT CONTROLS

OAK RIDGE DEVELOPS MODELING

COGEN PLANT IN OREGON GETS AN UPGRADE

VALVES AND ACTUATORS

the magazine of power generation

April 2014 www.power-eng.com

   

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

Power Engineering is the flagship

No. 4, April 2014

Significant focus has been on water emissions from

New Control System Solves Black

Boiler Cleaning Practices & Technology

Keeping a power plants boiler clean is an important part of increasing

Valves & Actuators: The Path to

Valves and actuators are critical in every aspect of power plant

ORNL Modeling Program to

Faced with the possibility of decades of design work, Oak Ridge

POWER ENGINEERING ONLINE :

Stay current on industry news,

Power Plant Profile

A concise, weekly update of all

CORPORATE HEADQUARTERSPennWell Corp.

ombined heat and power

ITS JUST STEAM.

Nuclear energy plants dont emit smoke, just steam from

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

and CEO of Mitsubishi Hitachi Power

Cape Wind wins

The project is the frst of its kind in the

United States District Judge Reggie

NRG Energy acquires

(RDS), a residential solar power installation company. Terms of the transaction

GE releases new 9HA and

$1.3bn contract signed

Pumpjack and Wildwood will each

Samsung, Pattern and Capital

Swinerton awarded contract

B&W to perform steam

Duke Energy Renewables has awarded

American Electric Power awarded a

Vermont Yankee nuclear plant

Duke Energy releases

SentrySeries Goal Based ISB Control Systems

Convection / Backpass Goals

Goal Tracking with Reduced EGOT

Balancing & Optimizing Steam Temperatures

Goal Tracking with Reduced FEGT

Thermal Impact Monitoring

Priority Sootblowing by Determining

Furnace Slagging Patterns

Works to YOUR GOALS!

2014 Diamond Power International, Inc. All rights reserved.

For info. http://powereng.hotims.com RS# 4

MITSUBISHI HITACHI POWER SYSTEMS

The global merger of Mitsubishi Heavy Industries and

Mitsubishi Hitachi Power Systems Americas, Inc.

CLEARING THE AIR

" " ""