Professional Documents
Culture Documents
NORTH AMERICAS
DRIVE TO CUT CO2
SAFETY MEASURES
FOR COAL PLANTS
November 2014
www.PowerEngineeringInt.com
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TM
2014 Cummins Power Generation Inc. All rights reserved. Cummins Power Generation and Cummins are registered trademarks of Cummins Inc. Our energy working for you. is a trademark of Cummins Power Generation Inc.
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Contents
Industry Highlights
52
Diary
51
Ad Index
Canadian CCS project offers carbon-reduction breakthrough - p12
Source: SaskPower
Features
30
6
12
36
40
44
28
24
20
46
On the cover
Increasingly fast and sophisticated real-time plant analysis software is unlocking improved predictability, reliability and fexibility for combinedcycle plant - p6. Cover image credit: Siemens
www.PowerEngineeringInt.com
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OCTOBER, 1947
CHUCK YEAGER
BREAKS
THE SOUND
BARRIER
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SHATTERS
THE DRAIN
INTERVAL
BARRIER
Yesterday, 8,000 hours was unthinkable.
Suddenly, anything less could be unacceptable.
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Industry Highlights
ubsidies cant live with them, cant live
generation, he said.
Energy Agency
Dhabi in October.
said
that
(IRENA), who
dropping.
work is included.
REthinking
Energy
in
which
the
told
packed
audience
that
transition.
keep up.
1411PEI_4 4
He
Power generation
subsidies account for
8.4 per cent of the
Middle Easts GDP
and make up half
of the energy subsidies
in the world.
www.PowerEngineeringInt.com
11/10/14 9:45 AM
CYBER SECURITY
WE HAVE YOUR PLANT
COVERED UNDER LOCK
AND KEYSTROKE
Westinghouse
Electric Company
@WECNuclear
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development
process.
and
rate
phenomenal,
is
industry:
acquire
of
this
is
of
rapid
development
digital
intelligence,
while
mark.
and
storage
in
technology
more
is
Increases
information
change
of
computing
increasing
speed
volumes
of
this
data
is
considerable
challenge.
www.PowerEngineeringInt.com
11/10/14 9:46 AM
EXPERIENCE
MATTERS
DNV
KEMA
GARRAD HASSAN
GL RENEWABLES CERTIFICATION
DNV GL in the energy sector
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around
100
documented
Software modelling
submit
to
relationship
Sophisticated
software
is
used
that
includes
performance
projected.
answers.
1411PEI_8 8
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11/10/14 9:46 AM
improved
understanding
of
the
plant
processes.
Eric
Kauffman,
Software
&
Analytics
product
corrective action.
Mark
Hachenski,
executive
the customer.
problems.
some
comprehensible.
Kauffman
estimates
that,
in
Load quickly
safely
www.rs-seliger.de
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baseline
maintenance
data
or
other
for
predictive
performance
evaluation.
Williams says: As we go forward, I think we
will see a merging of technologies so that
we can watch the plant in real time from the
distributed control system and use simulation
that is closely tracking that performance to
run what-if scenarios that will enable us to
Human operators are still an essential part of the system
Credit: Emerson Process Management
collect
approaches.
harsh environment.
information
that
was
previously
Going forward
performance
of plant assets.
adjustments
made
to
the
and
smart
performance,
validate
by 50 per cent.
and
validate performance.
with
which
as
developments
in
wireless
energy matters.
ease
to
improve
instruments
The
networks
software
can
and
Sophisticated
instruments
10
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for more information
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11/10/14 9:46 AM
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Carbon abatement
Canadas Boundary Dam is the frst commercial-scale post-combustion CCS process on a coal-fred power plant
Credit: Sask Power
Driving a
path for North
American power
A confuence of factors
is driving the North
American power sector
down a low-carbon
road. Responding to
customer demands,
OEMs are expanding the
capabilities and material
composition of their
products in order to meet
effciency demands and
develop a new generation
of technologies, fnds
David Appleyard
12
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Europes
policymakers
in
generation.
coincidental beneft.
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11/10/14 9:46 AM
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Carbon abatement
construction
effciency.
of
any
future
coal-fuelled
future.
whole.
increasingly uncompetitive.
he says.
of 1100 lb/MWh.
steam
conditions
with
pressures
in
the
The Petra Nova Carbon Capture Project is expected to capture 90 per cent of the CO2 in the processed fue gas from an existing unit
Credit: NRG
14
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11/10/14 9:46 AM
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Carbon abatement
carbon
capture
facility
captured
CO2
will
increase
oil
Gas-fred generation and fexible reciprocating engines are increasingly economically attractive
Credit: GE
Saskatchewan
the remainder.
Power Co.
SaskPowers
Boundary
Dam
project,
The
government
of
funding.
Saskatchewan,
Located
16
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in
Estevan,
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11/10/14 9:46 AM
AvantGuard
Redening
anti-corrosion
Redene
ed
de
ne your expectati
expectations
ions off a
anti-corrosion coatings with AvantGuard by Hempel.
For more information:
Email: avantguard@hempel.com
Visit: www.hempel.com/avantguard
1411PEI_17 17
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Carbon abatement
of these components.
coal-fred generation.
advanced
temperature
coal-fring
research
project.
and
compressor
pressure
proposed
Challenging economics
targets.
Power
producers
will
innovative
boiler
effciency
improvement
constraints on carbon.
steam
developing
process sectors.
Given
18
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the
challenges
of
in
achieving
these
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for more information
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11/10/14 9:47 AM
PROFITRON
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An engineers guide
to selecting a drive
Selecting a drive involves
careful consideration
when looking for the
optimal motor for a given
application.
Dagmar Dbbelde looks
at how to avoid design
errors and save money
the motor.
careful
considerations
when
is forgotten.
20
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11/10/14 9:47 AM
41
B R A Z I L I A N
G O V E R N M E N T
Ministry of
Mines and Energy
eletrobras.com
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motors
are
available
in
Different materials
The second step examines the motors
Motor power
surprises.
In manufacturerscatalogues,performance
nominal torque).
22
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framework
robust.
Adherence
to
the
Design integration
connection parts.
Considering costs
Visit www.PowerEngineeringInt.com
for more information
ONLY ONE
BOLTING SYSTEM
IMPROVES
SAFETY, QUALITY,
& SCHEDULE
MAINTENANCE
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Strengthening safety
in mills and silos
Equipment selection and operating criteria are vital for reducing the risk of fre in
coal storage silos and mills, writes Derek Stuart of Ametek
injury,
downtime
potentially
damage
causing
and/or
and
discrete
sensors
have
diffculty
the air.
of silo fres.
24
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developing.
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11/10/14 9:47 AM
IC1000-E320-F236-X-7600
Applications:
Power plant generating units up to 160 MW or 250 MW,
depending on the on the type of power plant and
operating voltage
Indoor and outdoor installation
Advantages:
Optimum operational and personal safety
Sustainable and environmentally friendly
vacuum technology
Minimum installation and maintenance costs
High cost-efficiency and service continuity
www.siemens.com/generatorswitchgear
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1411PEI_25 25
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of
confguring
the
a
biggest
Millwatch
challenges
system
is
in
the
Automatic
calibration
verifes
correct
HouShiPower
electricity
is
4200
MW
and
fre
sensors. They
determined
that
Redundant
features:
26
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measurements
reduce
the
www.PowerEngineeringInt.com
11/10/14 9:47 AM
dropping
after
15
minutes, and
within
plant or personnel.
Although
maintenance
safety.
this
would
have
provided
and
providing
enhanced
area.
Visit www.PowerEngineeringInt.com
for more information
U N D
M A S C H I N E N FA B R I K
Gtersloher Strae 257 | D-33649 Bielefeld | Tel. +49 (0)521 9418-0 | Fax. +49 (0)521 9418-170, -156 | www.welland-tuxhorn.de | info@welland-tuxhorn.de
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The effort involved in fre detection is justifed by the need to protect valuable power assets
Credit: Dreamstime
Fire detection
Hot topic
As the UK suffers the second major blaze at a power plant in three months,
Ali Aleali of FireVu explains the fre detection challenges and solutions
facing power plant operators
ombustible
dust
and
materials,
debris,
and
stations challenging.
Solutions
must
be
As
power
developed
countries
fnd
has to face.
began to be calculated.
The challenges
around
be monitored.
RBC
a
Capital
loss
in
analysts
earnings
estimated
of
28
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11/10/14 9:47 AM
Fire detection
HIGH PERFORMANCE
Visit www.PowerEngineeringInt.com
for more information
Please visit
Discover
our solutions
for the
power plant
industry
www.auma.com
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Fly ash has been collected by particulate removal technologies since the 1920s
Credit: Pittsburgh Mineral & Environmental Technology
Retroftting
A fresh perception
of ESP
Poor electrostatic
precipitator performance
can often be traced to
an underperforming high
voltage power supply.
Retroftting with a high
frequency switch mode
power supply can quickly
reduce particulate
emissions and often
improve the performance
of a downstream wet
fue gas desulphurization
system, writes Jason Horn
1411PEI_30 30
wet
precipitators
electrostatic
such as fy ash.
30
very
operation,
in
principle,
is
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11/10/14 9:48 AM
Retroftting
FROM
ENGINEERING
ANALYSIS TO
ADVANCED NDE,
LOOK TO
STRUCTURAL
INTEGRITY
systems are used on each ESP stage (sometimes each lane in a feld) in
order to optimize individual feld performance.
877-474-7693
(877-4SI-POWER)
www.structint.com/power-eng-int
www.PowerEngineeringInt.com
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Retroftting
solution
ModuPower
was
SMPS
to
systems
add
of
60
four
kW
power
supply
systems
on
the ESP.
However, shortly
was
after
the
FGD
The
ModuPower
SMPS
installation
waste product.
Case studies
damage
caused
by
excess
particulate
32
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11/10/14 9:48 AM
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Retroftting
mechanical
producing
erosion
and
The
site
arrangement
required
the
permanent
repair
options
including
ID fans.
Stock
Equipment
Company
(www.
stockequipment.com)
AES Norgener ESP with ModuPower ground switches installed on top of its ESP
Credit: AES Norgenere
34
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for more information
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11/10/14 9:48 AM
WORLDS BIGGEST
AND BEST!
2015 Global Ranking of the Power Industrys Leading Companies, certain to
become Power Engineerings most-read contentever.
Special advertising opportunities available.
For more information, go to www.power-eng.com/power-gen200.
1411PEI_35 35
11/10/14 9:48 AM
Switchgear
Proven procedure
offers a new alternative
Technological
developments now
enable maximum normal
and short-circuit currents
to be interrupted using
vacuum circuit-breakers,
writes Nils Anger
acuum
circuit-breakers
with
own
strengths
installation,
particular
terms
of
technology
for
generator
switching
Generator
circuit-breakers
are
thus
ensures
reliable
synchronization
and
safely
breaking
short-circuit
1411PEI_36 36
36
good
in
This
powerful
technology
has
been
www.PowerEngineeringInt.com
11/10/14 9:48 AM
www.hydroevent.com
#HydroVision
Presented by:
Media Partners:
1411PEI_37 37
11/10/14 9:48 AM
Switchgear
vacuum
until
now.
More
recent
technological
interrupters
of
infuences.
is
environmental
that
no
Not
the
oxidation
contact resistance.
Easy to install Vacuum generator
alternative.
breakers.
Visit www.PowerEngineeringInt.com
for more information
IEEE C37.013.
Its
fexible
connection
concept,
circuit-breaker
be
the
The
38
1411PEI_38 38
HB3-80
is
constructed
to
standard
circuit-breakers
for
C37.013.
joint
Its
operation
www.PowerEngineeringInt.com
11/10/14 9:48 AM
Natural
Gas
Coal
Wind Power
Solar
Hydro
Power
Project
Financing
Managing
Risk
On-site
Power
Energy
Storage
Reach over
For the full list of topics and how to submit your abstract visit:
www.aseanpowerweek.com
Presented by:
7,600
Power
Professionals
www.aseanpowerweek.com
Supported by:
www.powergenasia.com
www.renewableenergyworld-asia.com
www.
.com
1411PEI_39 39
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Credit: Dreamstime
ncor
is
regulated
transmission
provider
operating
1500
transmission charges.
electric
approximately
increased
control centre.
It
is
possible
that
loads
can
appear
and
heightened
By
Assumption-based operation
millions of dollars.
todays grids.
to
chronic
congestion
under
During
the
Demonstration
Project
(SGDP)
Energy,
with
over
1411PEI_40 40
of
Grid
the
Department
Smart
40
US
cost-sharing
www.PowerEngineeringInt.com
11/10/14 9:48 AM
Rating (iDLR).
conductor.
provides cooling.
conditions.
coupled system.
criteria.
performance of 8 km of line.
DLR Systems
effect,
the
majority
of
overhead
section.
www.PowerEngineeringInt.com
1411PEI_41 41
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11/10/14 9:48 AM
when
work
available. The
load,
reduced
reduced
operator
personnel
training
Project results
The fnal report published on the Oncor SGDP
Project highlighted several conclusions and
breakthroughs.
Oncor found that using DLR increased
capacity
by
14
per
cent
above
the
In
addition, the
project
found
that
applied.
to state estimator.
screen.
to each line.
Continuous monitoring
operator
that level.
decisions.
lines state.
follow-on project.
The
SGDP
project
demonstrated
the
is
not
burdened
making
a guide.
in real-time.
in Europe.
line reliability.
additional workload.
42
1411PEI_42 42
Technology
and
Business
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for more information
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11/10/14 9:48 AM
INVITATION TO PARTICIPATE
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to explore business opportunities, meet new partners, suppliers and the industrys most infuential decisionmakers. The combined 2014 event combined attracted over 5,000 attendees from over 50 countries.
Featuring a busy exhibition foor with the pre-eminent organisations from the Russian and international
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1411PEI_43 43
11/10/14 9:48 AM
Nuclear decommissioning
A new approach
The UKs Nuclear
Decommissioning
Authority has awarded
Cavendish Fluor
Partnership a contract for
the decommissioning of
12 UK nuclear sites.
Kenny Douglas looks
at how this joint
venture proposes to
meet the challenge to
decommission the sites
safely and to schedule
The
transition
period
also
saw
be required to be undertaken.
also
experience.
provided
understanding
the
of
opportunity
the
processes
for
the
being
plans.
Following
of
this
phase,
which
concluded
on
44
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Strategic approach
successful
completion
of
the
www.PowerEngineeringInt.com
11/10/14 9:51 AM
Nuclear decommissioning
regulatory authorities.
undertake
the
work
and
taking
programme,
delivering locally.
with
opportunities
for
the
software tool.
framework
possible, with
an
overarching
strategy, developing
safety
residing
One
of
the
new
programmes
that
Additionally,
long-term
employment
in
the
Magnox
and
RSRL
demonstrating leadership.
decommissioning programme.
to
goals
and
delivering
target
the
cost
established
reductions
are
and
delivering
the
detailed
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1411PEI_45 45
Visit www.PowerEngineeringInt.com
for more information
45
11/10/14 9:51 AM
Desuperheaters
rise to new
challenges
The new generation of desuperheaters must be able to address the complex
engineering challenges and varied operational environments of todays modern
50- and 60-Hz combined-cycle power generation markets, writes Martin-Jan Strebe
lobal
in
Martin-Jan Strebe
steam
advances
and
generation markets.
envelope of metallurgy
products.
Rapid
1411PEI_46 46
varying
load
conditions
are
operation.
apparatus.
attemperator
steam
thermal
generator
(HRSG)
attemperator
46
gas
Depending
can
on
the
experience
cycling. Temperature
boiler
extensive
differentials
www.PowerEngineeringInt.com
11/10/14 9:54 AM
the
necessary
desuperheater
performance
Atomization is key
Water droplet atomization requires a precise methodology to improve
understanding of primary and secondary atomization within the
pipeline prior to evaporation and steam cooling.This process is ultimately
predictable and measurable based on constant fuid dynamics. If
atomization of spraywater into the steam system is negatively affecting
the temperature probes ability to measure correct downstream steam
temperature, this could create severe overspray and underspray
conditions which result in increased thermal cycles and damage to
system components.
Primary atomization of the cooling water is caused by the nozzle
design and geometry within the desuperheater and the pressure
differential between the cooling water and the steam. Pentair Valves
& Controls has previously developed theoretical modelling of primary
atomization using computational fuid dynamics (CFD) analysis and
laboratory laser diffraction to analyze water droplet size upon discharge
from the desuperheater. This testing examined two steam attemperator
nozzle designs, spring-loaded and swirl nozzles. Results identifed that
when operating at 25 bar with a 0.05 mm lift and Kv 0.047, spring-loaded
nozzles produce droplet sizes of 87 m. The same calculation for swirl
nozzles at 25 bar, Kv 0.043 resulted in droplet sizes of 27 m a factor of
two to four times smaller than spring-loaded nozzles, depending on the
operational pressure range.
Using this data, Pentair Valves & Controls analyzed the secondary
atomization characteristics which occur when the speed differential and
drag forces between the cooling water and pipeline media cause the
droplets to split into smaller sizes. This occurrence is calculated by:
We = p.D.V
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1411PEI_47 47
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11/10/14 9:54 AM
10.00
100
7.50
5.00
50
0.00
100
10
1000
2000
10.00
replacement.
Optimum
desuperheater
performance
50
5.00
2.50
next
generation
of
0.00
0.10
desuperheater
10.00
1.00
100.00
1000.00
its
Yarway
brand,
wanted
Droplet size distribution for pressure swirl nozzle type B; P=20 bar;
solid line corresponds to left axis, histogram to right axis
to
spraywater
performance.
atmomization
around
for
optimized
slit.
To
understand
desuperheaters
to
the
design
achieve
rules
48
1411PEI_48 48
taking
place
at
on
steam
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11/10/14 9:54 AM
Co-located with:
EARLY BIRD
DELEGATE DISCOUNT
SAVE AT LEAST $200 IF
YOU REGISTER BEFORE
17 JUNE 2015
Invitation to Participate
For booth bookings and
sponsorship enquiries,
please contact:
POWER-GEN Africa, co-located with DistribuTECH Africa, will once again provide comprehensive
coverage of the power needs, resources, and issues facing the electricity generation industries
across sub-Saharan Africa.
Leon Stone
Exhibition Sales
International
T: +44 (0) 1992 656 671
E: leons@pennwell.com
The event will feature a multi-track conference covering strategic, technical and renewable topics
with practical solutions and benchmark case studies and concurrent exhibition foor featuring prime
movers showcasing the very latest equipment and technologies.
Andrew Evans
Exhibition Sales
Africa
T: +27 (0) 21 930 9515
E: andrewe@pennwell.com
POWER-GEN Africa has quickly established itself as sub-Saharan Africas premier and leading
event dedicated to the power generation industry, focusing on the current and future trends, as well
as the needs and resources within this region of the world.
Nowhere else provides you with the opportunity to reach and meet over 3,000 high-level industry
professionals in one place, allowing networking, business and sales opportunities with key industry
buyers and infuencers from around the continent.
Host Utility:
Presented by:
Supported by:
Supporting Association:
1411PEI_49 49
11/10/14 9:54 AM
Pentair
Valves
&
Controls
and
the
spring-loaded
nozzles.
Experiments
Testing examined two steam attemperator nozzle designs: spring-loaded and swirl
Credit: Pentair Valves & Controls
types.
operation, scheduled
pattern.
maintenance
and
achieve
desuperheater
These
faster
improve
secondary
more
effective
atomization, evaporation
characteristics
the
demonstrate
precision
and
operational
and
computer
desuperheater performance.
Spring-loaded nozzle
defned
spraywater
characteristics.
By
modelling, and
material
and
generation
50
1411PEI_50 50
will
drive
forward
material
Visit www.PowerEngineeringInt.com
for more information
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11/10/14 9:54 AM
Ad Index
ALIMAK HEK AB
AMETEK PROCESS ANALYTICAL
ASEAN POWER WEEK
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See moisture uctuations in varying temperature and load conditions
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Diary
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