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Repowering South Mississippi Electric Power Associations J.T. Dudley, Sr. Generation Complex

Repowering South Mississippi Electric

Power Associations J.T. Dudley, Sr.
Generation Complex
08/01/2013 | Joseph W. Mashek and Benjamin L. Frerichs, Burns & McDonnell and Chris K.
Rhodes, South Mississippi Electric Power Association
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Repowering two units at the J.T. Dudley, Sr. Generation Complex added 180 MW of high-efficiency
capacity to South Mississippi Electrics portfolio. Now the cooperative can self-produce more than
50% of its electricity needs. 5/12/2016

Repowering South Mississippi Electric Power Associations J.T. Dudley, Sr. Generation ...

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The J.T. Dudley, Sr. Generation Complex, owned and operated by South Mississippi Electric
(SME), is located in Jones County, Miss. Originally installed in 1968 at what was then called the
Moselle Generating Station were Units 1, 2, and 3, nearly identical 60-MW conventional steam
plants. Units 4 and 5, General Electric (GE) 7EA simple cycle combustion turbines, were added
in 1997 and 2005, respectively.
Today, the complex consists of five units capable of generating more than 500 MW. The
additional capacity will pay long-term dividends to SMEs customers in the form of increased

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system reliability and more control over its production costs. The cooperative forecasts that as
of 2013 it can self-generate 51% of its power needs; it purchases bulk power for the

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The repowering project converted Units 1 and 2 into two, independent 1 x 1 combined cycle
units. Both original gas-fired boilers were retired in place and the steam source for each unit
was replaced with a new GE 7EA combustion turbine (CT) and a Vogt Power International (VPI)
heat recovery steam generator (HRSG). The new power block is located approximately 400

Business Development Manager, GTS Bolttech Mannings, Inc. - North

Versailles, PA

feet from the existing powerhouse, with piping and cable tray routed along a three-level pipe
rack between the HRSGs and powerhouse (Figure 1).

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Corporation - Chicago, IL
Foreman - Mechanical/Maintenance Exelon Corporation - Wharton, TX

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1. Plant overview. SMEs J.T. Dudley, Sr. Generation Complex repowered two of its three conventional
steam plants built in the late 1960s (far right) using two GE Frame 7EA combustion turbines (left) and two
heat recovery steam generators (HRSGs, center). The steam produced by the HRSGs is moved across a
pipe bridge to the existing steam turbines. Courtesy: Burns & McDonnell

Construction began in August 2010. The commercial operation date (COD) for Unit 2 and Unit
1 combustion turbines in simple cycle operation was November and December 2011,
respectively. The COD dates for Unit 2 and Unit 1 in combined cycle operation were May and
November 2012, respectively.
Burns & McDonnell provided consulting, detailed design, procurement, construction
management, and startup services. SME designed, procured, and installed the CT generator
step-up transformer and interconnection power line, as well as the existing plant switchyard
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A multi-phase and multi-contract approach was used on the remainder of the project.
Beginning in August 2010, James Construction Group kicked off construction with site civil

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work and foundations, plus electrical and mechanical underground construction. Next, PCL
Constructors followed in December 2010 with the combustion turbine and simple cycle
portion of the construction project. The Saxon Group handled the final two major construction
contracts: electrical and HRSG erection plus the combined cycle balance of plant, beginning
work in January 2011 (Figure 2).

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Repowering South Mississippi Electric Power Associations J.T. Dudley, Sr. Generation ...

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2. Refurbish instead of rebuild. The existing three conventional units are shown in the background
(outdoor boilers with a single steam turbine building located behind the boilers) with the two existing 7EA
simple cycle combustion turbines (CTs) to the right of the existing units. The new 7EA CTs are visible in the
foreground. Between the new CTs and the three existing
boilers are the two HRSGs being assembled. Each 7EA-HRSG combination supplies steam to a single,
existing steam turbine. The HRSGs are Vogt Power Internationals Enhanced Constructability Smart
design. The design incorporates pressure parts, pressure part support steel, interconnecting piping,
casing, and structural steel into only six shop-fabricated module boxes per HRSG, significantly reducing
erection labor expense. The photo was taken during constructionin October 2011. Courtesy: Burns &

Tweets by @POWERmagazine
Design Characteristics

POWER magazine Retweeted

Tom Overton

The engineering and design of the repowering project was performed with two goals in mind:


increased operational flexibility and reuse of existing equipment, where feasible, to minimize

Fuel Cells Could Be a "Game-Changer" for

project cost. Reused equipment included the steam turbine, boiler feed pumps, condensate

Carbon Capture

pumps, condenser, cooling towers, deaerator, plant air system, and flash evaporator. Details


about the major components and equipment used on the repowering project follow.
POWER magazine Retweeted

Combustion Turbines. The two new natural gasfired GE 7EA CTs are equipped with dry
low-NOx technology (DLN1) and each is rated at ~85 MW. Each CT is also equipped with
evaporative cooling technology, which increases summer capacity by ~8 MW. At full load, the
combustion turbines will provide a flow of 2,225,000 pounds per hour of exhaust gas at 1,022F
to each HRSG (Figure 3).

Sonal Patel
In new #IEO2016 international outlook,
@EIAgov expects softened power demand
despite economic growth worldwide.

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Repowering South Mississippi Electric Power Associations J.T. Dudley, Sr. Generation ...

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Learn how to make the best use of drones
and robots at the Drone Workshop at
Has our April cover story on using drones and
robots for power plant O&M
( left you wanting to learn
more? Did you watch our video on an actual
wind turbine inspection
3. New power block. One of the two new gas-fired GE 7EA combustion turbines is shown. The ductwork
located on top of the CT is the air inlet system that includes an evaporative cooler. The upper left shows the
CT bypass stack during erection with a small portion of the new HRSG shown at the upper left edge of the

See what all the buzz is about during ELECTRIC

( first-ever
Drone Workshop! Attendees will learn how

photograph. A bypass damper is located at the base of the bypass stack, which may be closed to direct CT

drones can help power professionals assess

exhaust gas through the bypass stack or opened to allow the

safety conditions at plant sites, inspect

gas to continue to the HRSG. Courtesy: Burns & McDonnell

equipment deep inside hard to reach areas,

evaluate temperature distribution through aerial
thermal imaging cameras, and more. The

Heat Recovery Steam Generators. The VPI HRSGs are two-pressure, non-reheat, natural

workshop will also offer a hands-on flight

circulation drum type with horizontal gas flow and duct firing. A two-pressure non-reheat

experience for anyone interested. Get more

HRSG economically maximizes the combined cycle efficiency of the repowered 1960s

details on ELECTRIC POWERs drone workshop

technology non-reheat steam turbines. Given the steam turbine flow limits and the cost of a

here: View video (

new steam turbine, an HRSG with more than two pressure levels was not cost justified.
Coen Co. Inc. supplied the duct burner system that is located after the finishing high-pressure
(HP) superheater section within the casing of the HRSG. The system includes pressure-

Visit our video archive (/power-videoarchive/)

reducing and flow measurement stations, burner runners mounted horizontally across the
HRSG duct, a burner management system, and a cooling air blower skid for flame scanners.

May 11, 2016

Duct-firing the HRSG can increase the HP superheater outlet flow rate up to 60%, thus adding
the ability to quickly respond to load fluctuations.
In addition to the CTs DLN1 system, a selective catalytic reduction (SCR) system is located

Annual passenger travel tends to

increase with income

downstream of the HP evaporator to further reduce NOx emissions. A 19% aqueous ammonia
reducing agent is injected onto the catalyst as part of the NOx reduction process. In sum, the
system is capable of reducing NOx emissions by 98%. A space allocation was provided
upstream of the SCR to accommodate a future CO catalyst.
To maximize HRSG heat recovery, a condensate preheater is provided just upstream of the
HRSG exhaust stack, which heats condensate to near saturation temperature prior to entering
the existing deaerator. A recirculation system is used to maintain a minimum condensate inlet

Source: EIA, International Energy Outlook, Bureau of Transportation

Statistics, National Transportation Statistics

temperature to the HRSG to prevent external condensation and corrosion on preheater tubes.
The system has two 100% recirculation pumps that take hot condensate exiting the preheater
and mixes it with cold condensate entering to maintain a minimum inlet temperature of 140F
(Figure 4).


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Repowering South Mississippi Electric Power Associations J.T. Dudley, Sr. Generation ...

Page 5 of 9

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4. Maximize steam production. The HRSG produces ~300,000 lb/hr of high-pressure (HP) steam at
950F/780 psig and ~55,000 lb/hr of low-pressure (LP) steam at 520F/74 psig when the CT is operating at
baseload at average ambient conditions, with no duct firing. The steam production can be peaked by duct

GE Power Expands Offerings and Capability

by Acquiring Doosan Engineering &
Construction Heat Recovery Steam
Generator Business

firing the HRSG. Under maximum duct-firing conditions, the HP and LP superheater outlet flow rates are


approximately 490,000 lb/hr at 950F/1,280 psig and 45,000 lb/hr at 590F/100 psig, respectively. The


maximum heat input to each duct burner is 240 MMBtu/hr. Courtesy: Burns & McDonnell


Stack Bypass System. The stack bypass system adds operating flexibility by allowing each CT

Solano County landfill gas-to-energy project

to operate independently of the HRSG, such as during a steam turbine outage or trip.

providing clean power to homes

However, the number of hours each year the bypass may be used is limited by the plants


operating permit. The combustion gas bypass system also allowed SME to generate power in
simple cycle mode during construction of the combined cycle portion of the project. For
additional safety, a blanking plate was installed on the diverter outlet to the HRSG, allowing
construction to progress while operating the combustion turbines.

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WhalcoMetroflex supplied the gas flow diverter damper, Merrill Iron & Steel supplied the
bypass stack, and Higgot Kane, a division of ATCO Noise Management, supplied the bypass
stack silencer. The gas flow diverter uses a toggle-driven single blade within an internally

AMSC Announces D-VAR System Orders for
the Electric Grid in Australia

insulated cube. The single blade directs combustion turbine exhaust flow by isolating either


the bypass stack inlet or HRSG inlet. The blade offers 99.97% sealing efficiency by mating with


a double seal boundary that uses pressurized seal air to eliminate exhaust gas leakage. The
blade completes a cycle in only 90 seconds and can close to bypass position in 60 seconds in
an emergency. The gas flow diverter damper allows online switching from combined cycle to
simple cycle mode but does not allow switching from simple cycle to combined cycle.
Steam Turbine Refurbishment. GE originally furnished the Unit 1 and 2 steam turbines in
1968. Each is a 17-stage straight condensing unit rated at 60 MW. Each was designed to pass

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Transmission Equipment Sparing Company
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503,000 lb/hr of steam at inlet conditions of 1,250 psig/950F and exhaust 354,000 lb/hr to the
steam condenser vacuum of 2.5 inches HgA. The steam turbine has five uncontrolled
extraction openings that were used for feedwater heating.

O&M and Lifecycle Management Strategies

for CCGT Power Plants, 05/17 - 05/19

GE performed a study to determine the most efficient and cost-effective way to repower the
steam turbines using steam produced by an HRSG instead of by a conventional boiler.
Numerous options were evaluated, ranging from minimum turbine modification required for
safe operation to completely replacing the steam turbines steam path to optimize efficiency

Gas Power, 06/07 - 06/08 (

and improve reliability. 5/12/2016

Repowering South Mississippi Electric Power Associations J.T. Dudley, Sr. Generation ...

SME determined that the best economic choice was to replace the steam path with modern
components and enjoy the long-term economic benefits of a more efficient steam turbine. All
the steam turbine upgradesdesign, manufacturing, and assembly of the upgraded steam
pathwere performed by GE (Figure 5).

Page 6 of 9

GEA Baseload Renewable Energy Summit,

06/07 - 06/08 (
ACI's 3rd National Capitalizing on Grid-Scale
Energy Storage, 06/08 - 06/10
APPA National Conference, 06/10 - 06/15
EEI Annual Convention, 06/12 - 06/15
Power Experts, 06/15 - 06/16
ASME Power & Energy Conference &
Exhibition, 06/26 - 06/30
59th ISA POWID/EPRI Symposium, 06/27 06/30 (
World Nuclear Exhibition, 06/28 - 06/30

5. Modernized steam turbine. As part of the repowering project, the two existing steam turbines were
retrofitted with modern steam path components. The replaced parts include a new 17-stage rotor forging
with new buckets, nozzles, shaft packing, bucket seals, and control valve camshaft assembly. The
mechanical components found to be acceptable for reuse were the turbine casing, thrust bearings, and
shaft end coupling. Courtesy: Burns & McDonnell

Power Plant Pollutant Control and Carbon

Management "MEGA" Symposium, 08/16 08/19 (
45th Turbomachinery & 32nd Pump
Symposia, 09/12 - 09/15
EUCG Fall Conference & Workshop, 09/18 -

The turbine redesign required modification of all five turbine extraction ports. Each
modification followed ASME TDP-1, Recommended Practices for the Prevention of Water
Damage to Steam Turbines (see Preventing Turbine Water Damage: TDP-1 Updated, August
2009, in the POWER archives at HP extraction No. 1 and LP extractions No. 4
and No. 5 were not required in the repowered arrangement. Instead, each was cut, capped,
and turned into a drain pot with redundant level switches and a small-bore drain line routed

Energy Storage North America, 10/04 - 10/06
MAGAZINE 19TH ANNUAL, 04/10 - 04/13

to the condenser. A motor-operated valve was located in each drain line that opens when a
defined liquid level is sensed by the level switch. HP extraction No. 2 was converted to a bleed
line to the existing flash evaporator, which is used for makeup to the cycle rather than a
demineralizer. Flow in the bleed line varies between 0 and 19,000 lb/hr, depending on makeup
demand. The bleed line low point drains were also modified with drip pots. Extraction No. 3
was converted to an LP steam admission point.
GEs turbine redesign included upgrades to steam inlet valves and overspeed trip protection.
Butterfly style LP admission stop and control valves were located near the turbine. The HP
stop and control valve actuators were replaced with direct-acting, high-pressure actuators. A
new, high-pressure hydraulic power unit (HPU) replaced the existing low-pressure HPU and
supplies hydraulic oil to the LP and HP stop and control valves. A new trip manifold assembly
(TMA) was incorporated for overspeed trip protection. The TMA is a hydraulic circuit that
protects the steam turbine by closing the admission stop valves in emergencies. It replaced
the existing mechanical overspeed trip device.
At fired baseload operating conditions, the modernized steam turbines produce 66 MW, a 10%
increase in output. Each can pass 490,000 lb/hr of HP steam at 950F/1,160 psig and 28,000
lb/hr of LP steam at 590F/100 psig. The exhaust flow was designed between 518,000 and 5/12/2016

Repowering South Mississippi Electric Power Associations J.T. Dudley, Sr. Generation ...

Page 7 of 9

499,000 lb/hr at 3 inches HgA, depending on the extraction flow to flash evaporator. HP steam
inlet flow decreased by 3%; however, exhaust flow increased approximately 30% when the
extraction ports were secured and with the addition of the LP steam admission.

Plant performance test results. Source: SME

Steam Turbine Bypass. The plant is equipped with a 100% HP and LP steam turbine bypass
system, which directs steam to the condenser rather than venting to atmosphere during
startup and trip conditions. The bypass system required modification of the existing
condenser as well as the addition of engineered HP and LP steam bypass valves. During
startup conditions, after condenser vacuum is established, the bypass valves control steam
flow to the turbine based on turbine shell temperature and bypass the remaining steam flow
to the condenser. During trip conditions, the bypass valves direct 100% steam flow to the
condenser and prevent a steam system overpressure event that can result in lifting of safety
Control Components Inc. (CCI) provided the bypass valves chosen for the steam bypass
system. The HP bypass valve is configured as a 10-inch inlet to 18-inch outlet pressurereducing valve with exterior steam ring attemperator. The valve is designed to reduce
approximately 310,000 lb/hr of steam at 931F/750 psig to steam at 417F/175 psig. The LP
bypass valve consists of a 10-inch inlet to 10-inch outlet pressure-reducing valve with integral
steam attemperating nozzle. The valve is designed to reduce approximately 64,000 lb/hr of
steam at 521F/91 psig to steam at 358F/70 psig. Both the LP and HP bypass valves are located
approximately 100 feet from their respective condenser inlets.
De Laval Turbine Inc. furnished the condensers that were originally installed in 1968. They are
single-shell, two-pass, divided condensers with an LP feedwater heater located in the
condenser neck. Thermal Engineering International performed a mechanical design
evaluation and concluded that each of the condensers could be retrofitted with a 100% HP
and LP steam bypass valve. An 18-inch HP bypass line with 336 holes (½-inch) and a 10inch LP bypass line with 264 holes (3/8-inch) were designed to fit in the condenser transition
and pass 400,000 lb/hr and 70,000 lb/hr, respectively. A 3-inch spray water curtain line was
designed to fit in the condenser above the bypass lines to keep temperatures below 200F to
protect the condenser expansion joint and steam turbine.
Structural modifications were made to the condenser transition to facilitate additional loading
from the bypass lines. Tube stakes and steam impingement protection were added to the
tube bundles for reducing tube vibration and for protection from increased steam velocity
from the bypass lines.

Performance Goals Met

Performance testing for the combustion turbines in simple cycle operation was completed in
November 2011 and combined cycle performance testing was completed in April and October
2012, respectively. The table shows the results of that testing for different operating cases.
The performance goals for the project were met: Plant output increased 150% and the heat
rate decreased 39%. 5/12/2016

Repowering South Mississippi Electric Power Associations J.T. Dudley, Sr. Generation ...

Page 8 of 9

The additional operational flexibility provided by the combustion gas bypass system and the
steam turbine bypass system now permits stable operation from 55 MW to 150 MW for each
of the two repowered units. In addition, the capacity addition has increased the SMEs overall
system efficiency so that its members will enjoy reasonably price power for decades to come.
Joseph W. Mashek ( and Benjamin L. Frerichs
( are business development managers for Burns & McDonnell. Chris K.
Rhodes ( is generation projects manager for South Mississippi Electric Power



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