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FEATURES 119
VOLUME
Future of
14 The
Gas-Fired Generation
in North America
22
26
Power Engineering
A Journey to Improve
Condenser Performance
32
As power plant firing temperatures rise every higher in the quest for greater efficiency,
turbine components are exposed to greater and greater thermal stresses. Learn about
the role gas turbine coatings play in keeping power plants up and running.
36
Energy Storage:
The Key to the Modern Grid
DEPARTMENTS
2
4
6
Opinion
Clearing the Air
Industry Watch
8
10
12
View on Renewables
Energy Matters
Nuclear Reactions
Newscast:
40
48
Generating Buzz
Ad Index
www.power-eng.com
Industry News:
Global updates
throughout the day
OPINION
Natural Gas:
The Preferred Choice
BY RUSSELL RAY, CHIEF EDITOR
gas turbine technology capable of sup- gas-fired generation. We sat down with
porting the growth of variable generation three high ranking executives from Amersuch as wind and solar is strong.
ican Electric Power (AEP), Electric Power
GE said it has received 16 orders for its Research Institute, and GE Power & Water
new HA air-cooled gas turbines. In addi- to discuss the technology, the challenges
tion, the HA turbine has been techni- and the benefits surrounding this promcally selected for 53 new gas-fired units ising market.
worldwide. A tech-selection means the
Dan Lee, senior vice president of Fossil
unit will use GEs technology if it is com- Generation at AEP, said most new central
missioned and constructed. GEs Laurent power stations in the U.S. will be fueled
Cornu said he expects about 90 percent with natural gas. But, Lee added, the
of those tech-selections will lead to real growth of gas-fired generation may not
contracts with power producers within be as great as some are predicting.
two years.
Within
AEPs
Cornu is the prod- We continue
service territory, we
uct manager for GEs
continue to see relato see relatively
9HA.01 gas turbine.
tively flat forecasted
The 9HA.01 turbine fat forecasted
demand, and cacan reach full capacity demand, and
pacity markets like
in less than 30 minPJM are simply not
capacity markets
utes, and delivers a
providing a clear ecowhopping 61.4 percent like PJM are simply
nomic signal for new
net fuel efficiency.
gas generation, Lee
not providing a
Virginia Electric and
said. We are aware of
clear economic
Power recently ordered
newly permitted and
three gas turbines from signal for new gas
proposed natural gas
Mitsubishi
Hitachi generation.
combined-cycle units
Power Systems Ameri- Dan Lee, AEP
in the PJM footprint,
cas (MHPSA). The gas
but permitted and
turbine manufacturer has secured 39 proposed does not always result in units
contracts with power producers to sup- being constructed.
ply its J-class gas turbines, including
According to a recent study, just 7 pernine contracts in North America.
cent of all new generation proposed in
Last year, MHPSA entered into a con- PJMs territory between 2000 and 2014
tract with Oklahomas Grand River Dam was placed in service.
Authority to supply the 501J for a new
Nevertheless, the biggest trend in powcombined cycle plant near Chouteau, er generation in North America is the
Oklahoma. The new plant is expected to steady transition to natural gas. Issues rebe up and running in spring 2017. The lated to operations and maintenance, sit501J is known for its higher firing tem- ing and construction, gas turbine design,
peratures and improved efficiency.
and gas engines will be featured at POWOur cover story on page 14 provides ER-GEN Natural Gas 2015, Aug. 18-20 in
more perspective on the market for Columbus, Ohio.
www.power-eng.com
Choosing Sides:
Benefits of Clean Side
SCR for Biomass
BY RYAN HENSEL, SCR PRODUCT LINE MANAGER, BABCOCK & WILCOX
ith the increased popular- the SO2 and SO3 concentrations in the
ity of biomass and other flue gas and the SO2 to SO3 oxidation
renewable fuels in the gen- across the catalyst bed. The more SO2
eration portfolio, new emissions control and SO3 present, the higher the minichallenges are emerging, especially for mum ammonia injection temperature.
selective catalytic reduction (SCR) sys- A typical coal-fired, high dust or dirty
tems, where biomass can have much side SCR is located upstream of the air
higher concentrations of catalyst poi- heater, where the flue gas temperature
sons - most notably sodium, potassium, exceeds the minimum ammonia injecand phosphorus - than other fuels. The tion temperature to prevent ammonium
elevated levels of these catalyst poisons salt formation. A typical clean side SCR
results in an increase in required cata- is located where the operating temperalyst volume, as well as a decrease in the ture is below the minimum ammonia
injection temperaexpected catalyst life,
Maintaining
fue
ture, which means
reducing the duration
the SO3 in the flue
between outages. In gas temperature in
can react with
order to maintain an
the proper operating gas
ammonia to form
acceptable operating
ammonium sulfate
period between out- range can be
or ammonium biages, it may be benefi- accomplished
sulfate (ABS), the
cial to locate the SCR
several ways.
latter of which can
on the clean side,
block the active sites of the catalyst.
downstream of the particulate collector.
This low dust arrangement lessens Therefore, in a clean side SCR system,
the exposure of the catalyst to ash, SOx mitigation is likely required.
On a recent project that fired wood
which decreases the potential of plugging the catalyst, eases concerns of any biomass, a lower sulfur fuel with relaunburned carbon in the ash sintering tively low variability, B&W utilized a
the catalyst, and mitigates catalyst deac- dry sorbent injection (DSI) system in
tivation due to detrimental constituents combination with the fabric filter to
in the ash. It also allows other catalyst achieve SOx concentration in the flue
poisons that precipitate at lower flue gas low enough for the SCR to operate
gas temperatures to be collected by the at temperatures in the range of 400particulate collection device prior to the 450F. On a project that fired municcatalyst and no longer pose a threat to ipal solid waste, a higher sulfur fuel
deactivation of the catalyst. Removing with much higher variability, utilizing
ash prior to ammonia injection also only a DSI system with the fabric filter
eliminates concerns over ammonia be- would have resulted in SOx concentraing absorbed by the ash and released tions consistent with a minimum ammonia injection temperature of nearly
after disposal.
The minimum ammonia injection 600F, which would require a signifitemperature for an SCR is a function of cant amount of re-heating of the flue
4
INDUSTRY
BRIEF
NOW
www.mhpowersystems.com
For info. http://powereng.hotims.com RS#3
INDUSTRY WATCH
PJM Capacity
Performance
Market to Shake
up Power Market
BY DOMINIC DIBARI AND MELISSA REYNOLDS, BLACK & VEATCH
Authors:
Melissa Reynolds
and Dominic
DiBari are
managers with
Black & Veatchs
Management
Consulting
business.
HOURLY
NON-PERFORMANCE
PENALTY
In some areas of PJM where the
Net Cost of New Entry (CONE)
is $300/MW-Day this penalty can
equate to a rate of $3,650/MWh for
non-performance. Assuming a Balancing Ratio of 85 percent, and a
unit with a commitment of 100 MW
is not online during an Emergency
Action this would equate to a penalty of $310,000 in a single hour.
NOx/CO Catalyst
Meet emission
standards with
two catalysts
in one
www.topsoe.com
VIEW ON RENEWABLES
Hydropower Continues
to Brighten U.S.
Renewable Energy
BY CARL ATKINSON, P.E., VOITH HYDRO
Existing facilities are part of the equation, too. As turbines and generators
reach and exceed their design life, more
efficient, higher-powered, and environmentally-friendly options are now available. In the next 10 years, approximately 250 FERC licenses representing over
11,000 MW of installed capacity will be
up for relicensing, providing many hydro
operators the opportunity to make these
enhancements.
Considering the stakes, improving
the regulatory process is a necessity. Any
disincentive to license or relicense hydropower could mean less renewable energy
for our electric grid, and a missed opportunity to boost output and improve the
environmental performance at hydropower facilities.
Like most businesses, power producers
want regulatory certainty when they enter
into long term contracts and investments.
Unfortunately, not only is the FERC licensing process long and costly, it lacks a
set timeframe. By some measures, it takes
longer to license hydropower than a nuclear facility. Setting a more certain time
frame will encourage and provide certainty for new investment.
Expanding hydropower production is
essential to our national energy needs.
On a near weekly basis, a coal-fired generating unit in the United States is permanently retired due to increasing environmental performance requirements. Yet
demand for energy continues to grow.
This baseload power must be replaced,
and it often must be replaced with clean
and renewable sources.
When choosing hydropower, an operator gets benefits far beyond power generation. In many cases, a hydropower facility
READY TO ASSEMBLE
proenergyservices.com
ENERGY MATTERS
Falling Ozone
NAAQS Ahead
Robynn Andracsek
NOx and VOC react in sunlight. There- new NAAQS is implemented, there will
fore, ozone is regulated by its precursors not be many offsets available (generated)
(NOx and VOC). If there is ozone NAAQS so finding these precious emission credits
exceedance, the state agency will figure will be just another headache to endure.
out if it is NOx or VOC limited and will Similarly, if you are planning to construct
reduce emissions from either or both a new greenfield power plant, be aware of
sources of these pollutants.
the areas that switch to nonattainment,
If your plant is in a county that will so you can avoid NNSR if possible.
be changing to nonattainment after the
The final 2015 ozone NAAQS is expectNAAQS is lowered, you may have to re- ed to be published in October 2015, after
duce emissions
Nonattainment Counties Under
as required by
Different Ozone Standards
the SIP. This
could mean addon NOx or VOC
controls for your
plant.
Further
this could affect
proposed modification/expansions. The level of
nonattainment
(marginal, modBased on proposed 70 ppb
75 or Greater
erate, serious, se67-69
vere or extreme)
65 and 66
determines the
Source: http://www.epa.gov/groundlevelozone/pdfs/20141126-20112013datatable.pdf
emissions threshold that makes
your plant major or minor for nonattain- which follows several years of implemenment new source review (NNSR) applica- tation. It is unclear if new projects will
bility. For example, if you are in an area have to comply with the revised standard
that is deemed severe nonattainment before the final designations are made in
then any project that has emissions over October 2017. The EPA has stated that in25 tons per year of NOx or VOC will be the-pipeline permit applications might
subject to NNSR. Not only does this mean be required to consider project impacts
the installation of Lowest Achievable on the 2008 NAAQS but not the 2015
Emission Rate (LAER) (which does not NAAQS but this has not been finalized
take into account costs like Best Available either. There are lots of uncertainties reControl Technology does in attainment lated to new ozone NAAQS. Plant ownareas) but it also means obtaining offsets ers are forewarned to keep a close eye on
at a ratio of 1.1 to 1 (marginal) up to 1.30 this rule and its implementations as it will
to 1 (severe). Clearly this will increase the affect a lot of new-to-the-nonattainmentproject costs. In the near future, as the world areas.
www.power-eng.com
NUCLEAR REACTIONS
break through
the
NOISE
4.40
Higher
Model 706
SNR
1.57
Competitor
SNR
The ECLIPSE Model 706 transmitter has a
signal-to-noise ratio nearly 3 times higher
than competitors.
ROUNDTABLE DISCUSSION
The Future
of Gas-Fired
Generation in
North America
www.power-eng.com
www.power-eng.com
15
ROUNDTABLE DISCUSSION
What follows is a transcript, edited for gas. Within AEPs service territory, we
style and clarity, of that discussion:
continue to see relatively flat forecasted
Power Engineering: Several new demand, and capacity markets like PJM
combined-cycle
projects
are are simply not providing a clear ecoin some stage of development nomic signal for new gas generation. We
throughout North America. De- are aware of newly permitted and proscribe the market for new gas-fired posed natural gas combined-cycle units
generation in the U.S. Is the dash for in the PJM footprint, but permitted
gas alive and well?
and proposed does not always result in
Alley: I believe we are still experi- units being constructed.
encing a robust dash for gas, driven by
Based on a recent PJM study, just 7
the favorable economics of building percent of the total megawatt capacity
gas plants, confidence in the long term of all new generation proposed in PJM
fuel supply, and the regulations
that are making the market for
coal-fired generation more
challenging. The industry has
or will close approximately 70
GW of coal generation by the
end of 2016. This represents a
significant amount of energy
and capacity that is retiring
from the US electricity market.
The retired coal plant capacity
Guy DeLeonardo
Dan Lee
in many cases is being replaced
by natural gas combined-cycle
(NGCC) units. Typically an
NGCC plant is easier to site, permit, between 2000 and 2014 was actually
cheaper to build, has higher efficiency placed in service. It will be interesting
and requires less staff than most other to see how the capacity market adjusts
large-scale generation options.
after the coal retirements this year and
With gas forecasted pricing of $4-$6 changes to the PJM capacity market
per MMBtu (current prices are $1.60~ from the Capacity Performance propos$2.60 per MMBtu) for the foreseeable als (expected to be ruled on by FERC
future, and CO2 emissions meeting June 9 with the PJM 2018/2019 capacity
the proposed EPA Section 111(b) new auction to follow in August.)
source performance standards for carDeLeonardo: Drivers of coal retirebon emission limits of 1000 pounds ments and low natural gas prices are
per MWh, NGCC plants are the obvi- fueling the need for both combined
ous choice for bulk power generation. I cycle and simple cycle capacity addisee many organizations heading in this tions. GE forecasts half of the orders
direction. I also see some interest in for grid-connected capacity in North
coal to gas conversion in boilers where America over the next five years will be
infrastructure and pipeline capacity gas generation. Especially in the case of
are present.
the HA gas turbine economics, we are
Lee: While we would agree that any seeing those combined cycle projects
new, centralized power generation in displace smaller, higher variable cost
the U.S. in the near-term will likely be assets throughout the U.S. Customers
fueled with natural gas, we would not have technically selected 22 of GEs
necessarily characterize it as a dash to new 7HA units for power projects in
16
the U.S. in the last year. A technical selection is one of the first steps in developing a new power plant. It means that
if the power plant is constructed and
commissioned, it will use GE gas turbines. Following technical selection, a
developer will proceed with securing
financing, permitting and more.
Power Engineering: Weve seen
a substantial increase in capacity
factors for gas-fired power plants
for a number of reasons. Clearly, power producers are counting
Tom Alley
ROUNDTABLE DISCUSSION
improvements to the power generation industry in the 2025-2035 timeframe. Combined heat and power is
another way to improve overall plant
efficiency by capitalizing on waste heat
available from the cycle and could present opportunities on a case-by-case basis for certain natural gas power generation projects
Power Engineering: Describe the
need for improvements in the infrastructure for natural gas. If the EPAs
Clean Power Plan is finalized without delay, will the industry be able
to achieve a sufficient expansion
of pipeline and storage capacity
in time?
Alley: Pipelines like many other energy-related projects can take years
to site and construct. Whether pipelines can be built in a timely manner
microbicides in high demand systems to keep condensers cleaner, reduce the use of corrosive chlorides, and
improve the overall efciency of your operation. Check out all the ways Buckmans advanced technologies
are helping power plants reduce costs and generate bigger returns.
OXAMINE.
THE POWERHOUSE MICROBICIDE.
2014 Buckm
uckman Labor
aborator
atories
ies Inte
International, Inc.
nc. All righ
rights reserved.
ved.
ROUNDTABLE DISCUSSION
21
Authors
With 15 years experience in automation
and controls engineering, Steve Balek
serves as automation manager for Stellar Energy. Tom McDonnell is Rockwell
Automations manager of Power Generation and Energy Industry Sales for North
America.
fall as ambient temperatures rise and
air density falls. The loss of sellable
power can be up to 30 percent of a
turbines rated output. The purpose of
Turbine Inlet Air Chilling (TIAC) is to
restore the power output of a combustion turbine at elevated ambient temperatures to its rated capacity or better.
By cooling the ambient air with a
TIAC system, the air density increases
and the mass flow rate to the gas turbine increases, allowing the turbine to
operate at peak performance and maximizing the profit of the power plant
asset.
INCREASING POWER
WITH INLET AIR CHILLING
The Power
of
Flexibility
Turbine Inlet Air Chilling Benefits from
Leading Edge Control Technology
BY STEVE BALEK, STELLAR ENERGY, AND TOM MCDONNELL,
ROCKWELL AUTOMATION
in less demand and the value of power sold from the power plant is at the
lowest value. This increases the power available during peak periods, and
improves the financial performance of
the power plant asset.
Whos Behind
Your HRSG
Pressure Parts?
www.chanutemfg.com
23
the course of the implementation they system can also become part of the onrequested if the logic could be set up so site process control system network,
that the operator can select the other connecting with the site-wide HMI and
turbine to run at the higher setpoint in historian servers.
the event that the first turbine needed
As industrial power plants move
to be shut down. Again, the control toward gaining greater visibility into
logic made it possible for this change to their operations and TIAC process
be quickly and seamskids, their need to
Previously,
lessly incorporated
establish a seamless
traditional skid
into the system.
flow of information
Operational flexi- systems were built
from device to enbility, quick changeterprise has become
based on unique
over and simple
a requirement of
operation are just a designs, which
modern
industrial
few of the benefits were closed and
automation systems.
of a modular plant
A modern network
non-scalable.
design. A skid-based
design utilizes open
approach allows the TIAC chiller equip- standards such as EtherNet/IP, which
ment and automation control system to is capable of handling the widest range
be assembled and Factory Acceptance of industrial applications
Tested (FAT) prior to shipment to site,
Because of its control system netimproving consistency and reducing work capabilities, the modern TIAC
time to market.
process skid is able to easily integrate
Previously traditional skid systems with devices such as variable frequency
were built based on unique designs, drives (VFD) and electronic overload
which were closed and non-scalable. on motor starters within motor control
Typical skid designs offered a limited centers with IntelliCENTER software.
choice of optimal controllers for very
large applications. In contrast, a mod- REDUCED TOTAL
ern control system for TIAC process COST OF OWNERSHIP
skids are built for the needs of todays
Consolidated deployment tools
power plants, providing wider ranges greatly benefited the projects engiof architecture options and increased neering and configuration. They proflexibility. A modern design with a vide a single starting point for system
scalable control platform provides configuration and tools for library
the right-size control at the right cost, management. Using predefined logic
which eliminates the previous need to and HMI objects shorten development
purchase expensive control capacity and testing time. This increased prothat isnt needed.
ductivity saved 20% in engineering
This design is ideal for modular im- and at the factory witness test.
plementations, providing wider ranges
Defined system architectures miniof build options and increased flex- mize risk of control system errors and
ibility. At the same time engineering ensure system performance, which
costs are dramatically reduced when saved 30 percent in getting the TIAC
the same programming tools are used, process skid commissioned.
regardless of system size or I/O capaciBy use of IntelliCenter Motor Conty. Scalable HMI displays, alarms, data trol Centers, these systems are simplicollection and alarm management re- fied by using networks to reduce the
quirements can be provided at a small large amount of control wiring from
scale. This skid-based automation the control system to the VFD and
www.power-eng.com
TECHNOLOGY
TO
productivity.
These items are often overlooked factors that result in higher costs over the
lifetime of any control system. By utilizing a modern control system on the
TIAC process skid, power plants can help
reduce their total cost of ownership.
PROTECT
AND
PRESERVE
PREVENTIVE MAINTENANCE
A Journey to
Improve Condenser
Performance
W
BY BARRY VAN NAME
hile there is an
i ndu st r y-w ide
understanding
that
compromised condenser tubes reduce unit performance in
the short term, the long-term effects of
this neglect can be detrimental, forcing
unplanned outages and loss of revenue.
In our work with engineers and
project managers on site, we often see
that these people have so much on their
plates, so much responsibility, said
George E. Saxon, President of InternaEroded tube ends or wall thinning.
Photo courtesy: Conco Service
tional Markets at Conco. The sense of
relief is palpable when we formulate a
plan to get their unit condensers and
heat exchangers back up and running, power generation plants, said Saxon,
working at close to specification again. is that the expected results can be
Its a dynamic process and very reward- quantified and the return on investing for everyone involved.
ment can be calculated prior to a conSaxon noted that
tract being signed or
when a unit is strug- The contaminants a technician setting
gling to meet megafoot on site.
that build up
watt
demand,
a
So why is it so imthorough condenser and damage
portant for condenser
analysis and cleaning condenser tubes
tubes to be cleaned
can have very dra- over time run
and inspected? Over
matic results.
time, as condenser
the gamu from
Recovered megatubes become fouled
watts in the condens- soft and sticky to
with deposits, heat
ers can mean hun- extremely hard.
is not transferred efdreds of thousands
ficiently, the cooling
of dollars recouped for just that unit process is compromised and there is
in a very short time, usually weeks or a noticeable reduction in unit output.
months. Most advantageous for the In addition, under-deposit corrosion
26
by high bacteria content in the cooling water and low velocity flow. This
type of fouling can result in substantial
particulate deposition as fine matter
adheres to the sticky biofilm coating
of bacteria on the tube wall. Worse yet,
the thickening deposits produce corrosive bacterial by-products that can eat
through the base metal of the condenser tubes.
A condensers inlet tube sheet is
the entry point into the thousands of
condenser tubes that comprise a unit.
Debris and macrofouling of this important gateway can cause condenser
efficiency problems.
Depending on the plants water
source, debris can include sea grass,
mud, leaves, sticks and even large
may cause erosion-corrosion. To ensure that the tube sheet is free and clear
to operate, debris screens and filters
should be inspected and cleaned on a
regular basis.
Not all condenser tubes are alike.
Knowing what they are made of provides a necessary understanding of
why some condenser tubes are more
prone to fouling.
The three most common materials
used for power plant condenser tubes
are: copper, stainless steel and titanium.
Copper is a natural antimicrobial
material, and while copper condenser
tubes disrupt the growth of some microbes, they are also prone to the formation of a hair-like oxide deposition
27
PREVENTIVE MAINTENANCE
TOP PERFORMANCE
AND EFFICIENCY
Quick Shot
QS-300
Get th
the
e rright answer, right now!
888
8
88 364-7749
www.goodway.com
THE CONSEQUENCES
OF FOULING
Unfortunately, there are serious economic consequences to be endured
by power generation plants when
condenser tube fouling progresses
and tube performance is impaired.
Increased turbine back pressure, increased unit heat rate, increased losses
to cooling water, increased C02, and
increased N0X emissions can lead to
dramatic losses in unit output, unit
availability and, undeniably, revenue.
Fouling that is severe enough to
cause tube failure can also lead to damage in other unit equipment as contaminants enter the condensate. Because
the stakes are so high, effective diagnostic testing to determine the nature
and severity of tube fouling conditions
must be done.
Deposit sampling, fouling monitors,
computer-based performance analysis
www.power-eng.com
and borescopic examination are effective diagnostic approaches that pinpoint and clarify fouling conditions.
THE IMPORTANCE
OF CLEANING
Once analysis has yielded important
data on the nature and severity of fouling, cleaning the tubes is the next step.
There are four primary cleaning
approaches to cleaning fouled tubes:
chemical dissolution, hydrolancing,
continuous online cleaning systems
29
PREVENTIVE MAINTENANCE
revenue.
There are numerous cleaning strategies
available that are safe and effective on all
types of deposits.
In selecting the best cleaning strategy
with the appropriate mechanical cleaner, fouling deposits, corrosion products,
physical obstructions and tube surface
roughness will be removed quickly. An
effective strategy can be formulated before a technician arrives on site and before a unit goes offline, by trial cleaning
of a units tube sample.
In figuring your return on investment
with mechanical tube cleaning, consider
cleaning 24,000 1O.D. x 20 BWG tubes
in a typical 625 MW unit.
The estimated cost to clean these tubes
is $32,400. We know from industry reports that the cost of fuel for a rise of 0.3
Hg in backpressure in a 600 MW unit
would be $562,500. With a cash flow out
of $32,400 and cash flow in of $562,500
there is a net present value of $530,100.
This calculation reflects a +1,636% return on investment. A comparable return
on investment is achievable with your
own plants condenser cleaning.
www.power-eng.com
Register by July 18, 2015 and take advantage of the early bird discount.
GAS TURBINES
Thermal barrier coatings can be applied using different processes. They can be wet-sprayed or applied using an air plasma
spray gun, as pictured here. Photo courtesy: GE Power & Water
The Importance
of Gas Turbine
Coatings in Modern
Combined-Cycle
Plants
RESEARCH AND
DEVELOPMENT
33
GAS TURBINES
lower thermal conductivity very advantageous. For example, if we would normally need to apply 20 mils of a coating
system, but we can actually apply only
10 mils of a superior coating that has the
same heat-handling capabilities, we can
do this faster and create all kinds of bonus processing synergies.
MANAGING EXPANSION
Because the metallic components of
turbines have different expansion coefficients than the ceramic coatings that
are applied to them, it is essential to
build into any coating system the ability to expand and contract freely. In this
way, coatings can maintain their integrity rather than cracking and falling off,
even as the metal beneath them expands
at a different rate than they do. This expansion is facilitated by the deliberate
introduction of cracks into the ceramic.
We introduce expansion cracks to
the coatings which work very much
REPAIRING
COMPONENTS
Due to the unrelenting pressures of high-efficiency firing temperatures, even well-coated
components wear out
eventually. Owners and
operators would love to
have machines that last
forever, Schaeffer says,
but this simply isnt possible given the duty cycles
that we must work with. Because of this, it is important that turbines are repairable at the component level. Most of these repairs take place in-house at GE. Its
very challenging to find ways to sufficiently manage
the material science such that repairs can be made in
the field. Weve had some success, but theres a lot a
progress still to be made when it comes to restoring
OEM capability at the local level.
GE is very fortunate to have our research center,
adds Schaeffer. This acts as a synergistic champion
across the business, bringing in a knowledge storehouse from the companys many areas of expertise
including healthcare, oil and gas, aviation, power, etc.
For instance, we have benefitted from GEs expertise in
CT imaging that comes out of the healthcare field. In
addition to imaging the human body, this technology
also allows us to inspect the internal components of
large machinery. Just as a doctor might need to find a
lesion or abnormality within a patient without injuring them, our engineers also need to find lesions or
abnormalities in their components without destroying
them. This allows us to investigate problems without
sacrificing assets.
www.power-eng.com
35
36
www.power-eng.com
Author
Janice Lin is the co-founder and executive director of the California Energy Storage Alliance, the co-founder and chair
of the Global Energy Storage Alliance,
and the chair of Energy Storage North
America.
Energy Storage:
the
KEY to the
MODERN GRID
BY JANICE LIN, CALIFORNIA ENERGY STORAGE ALLIANCE
cost. Through its evaluation, SCE identified the unique benefits of energy storage,
including its above average reliability and
its ability to scale over time, proving the
viability of the technology and forcing
regulators, utilities, and policymakers at
all levels to recognize its potential for the
grid. With the added capability to perform multiple grid-level jobs at a competitive price point, it seems the industry is
just scratching the surface of opportunities the technology can provide, as well as
the many benefits it can add to the power system, like assisting with renewable
energy integration. While SCEs storage
37
requirement was just 50 MW (as estab- Brown issued a new executive order relished by the California Public Utilities quiring Calif. to also reduce its emissions
Commission), the utility procured more to 40 percent below 1990 levels by 2030.
than five times this amount, ultimately
Energy storage offers a solution which
selecting 260 MW of storage from more is both innovative and proven, and can
than 1,800 offers of all types of resourc- directly assist with each of these bold new
es. This clearly demonstrates that energy goals. Energy storage is ideally suited to
storage resources are commercially avail- manage the variability in our electric powable and can be procured cost-effectively, er system, allowing existing transmission,
even when compared against traditional distribution, and generation assets to be
alternatives.
utilized to their fullest
The SCE procure- With solutions like
potential, and with
ment was put in place energy storage
fewer emissions. Furto choose an efficient
thermore, while the
available
today,
the
resource that would
emissions profiles of
ensure critical power industry has the
power plants are well
system reliability in ability to shift toward documented, power
the Western Los Anplants are also signifnew
technologies
geles Basin, as Calif.
icant users of water,
seeks a variety of new that allow it to do
which they rely on for
generating resources more with the power cooling or other uses.
and advanced energy
capacity at hand.... Energy storage can besolutions to replace
come a game changer
the San Onofre Nuclear Generating Sta- for similar markets facing unique climate
tion (SONG) and other aging and less challenges and goals, with zero added
efficient generation assets. During the emissions or water usage, as well as sigprocurement process, SCE reported that nificant other benefits like faster siting,
more than 1,800 offers were submitted permitting, and overall increased grid
between energy storage, thermal gener- flexibility and reliability.
ation, demand response, and other preWith solutions like energy storage availferred resources. Never before had energy able today, the industry has the ability to
storage competed head to head with such shift toward new technologies that allow
capacity alternatives.
it to do more with the power capacity at
It is not surprising that Calif. is leading hand and save existing natural resources.
in this area. Strong legislation, coupled Thankfully, the SCE selection process has
with overwhelming support from local produced a number of key learnings that
stakeholders and clear direction from will be helpful to other power markets
Governor Brown and the Public Utilities in the U.S. which seek ways to bring the
Commission, has made Calif. a leader benefits of energy storage to their regions.
in progressive decisions about its energy
mix. More recently, Governor Brown es- THE SAME PROCUREMENT
tablished in his inaugural address a bold CRITERIA YIELD BETTER
new set of clean energy goals for 2030:
OUTCOMES
Increase renewable electricity use
The SCE selection was progressive in
from 33 to 50 percent
that the utility took the necessary first
Reduce petroleum use in cars and step to vet energy storage technologies
trucks by up to 50 percent
against the same factors it historically
Double the efficiency of existing used to evaluate traditional power plants.
buildings and make fuels cleaner
This process allowed SCE to understand
A couple of months later, Governor how storage stacked up against traditional
38
resources and where it could provide unforeseen benefits and increase value.
The end result allowed SCE to implement technologies that will help it achieve
a more modern grid. A grid that utilizes
energy storage can maximize the most
beneficial forms of power generation
available, minimize fuel costs and emissions, and maintain reliability. Energy
storage provides needed flexibility in the
grid, whether the grid is predominantly
powered by relatively inflexible resources like nuclear or coal, or it is powered
by large amounts of highly intermittent
renewables like wind or solar. As more
states adopt aggressive clean energy goals
with high renewable energy penetrations,
energy storage will become an even more
essential resource. It can be utilized at any
time and has no minimum start time or
load requirement. Storage is flexible and
more easily scalable, and it can be in commercial operation in a matter of months.
In addition to the benefits available today,
energy storage has established itself as a
future-proof solution that can adapt to
the newest grid problems by adding new
capabilities in a modular way. Essentially,
storage is a simple solution for managing
todays most complex grid challenges.
INNOVATION IS NOT
SYNONYMOUS WITH RISK
During the selection process, SCE
found that energy storage technologies
are mature, and that the applications for
the technology are proven. Though the
technology itself is innovative, it can be
delivered in a standard contract form,
meaning it can be paid for based on performance similar to what has been used
for traditional generation. This contract
structure helps to guarantee the performance of storage to mitigate concerns
over utilizing newer technologies for critical grid services.
Additionally, leading energy storage
companies have been operating storage
at grid-scale for close to a decade. Tapping
into the mature and robust supply chains
www.power-eng.com
for the transportation and consumer electronics industries and millions of megawatt-hours of service and experience to
date, energy storage providers have taken
the risk out of its operation.
ENERGY STORAGE
PROVIDES TWICE THE
RESOURCES FOR THE
SAME COST
When compared to a peaking power
plant, energy storage costs less and effectively does more. Battery-based storage
serves as both a generation and load resource, providing twice the flexibility on
the same interconnection. This gives customers twice the value at the same cost.
Additionally, battery-based storage is
unique in its flexibility to grow over time
in order to meet future demand in lock
step. The technology is modular and thus
easily scalable, providing the ability to
simply add on additional capacity to meet
www.power-eng.com
GENERATING BUZZ
The Unfair
Assault on Coal
Author
Gary McAuliffe is an independent consultant with forty years experience working on power generation and energy
projects and with ffteen years service on
the POWER-GEN International Program
Committee.
BY GARY H. MCAULIFFE
n the U.S., there is a sense of fairness that often plays out but this has
been abandoned over the years in a
number of cases and one significant example is The Unfair Assault on Coal. This
assault is eliminating consideration of
new coal-fired power plants and accelerating the closure of existing plants. The
remaining strong plants are in jeopardy,
as well, due to proposed carbon emission
regulations.
Environmental pressure is the principal driver as supported by the increased
availability of competitive natural gas.
Important considerations are being left
behind such as fuel diversity, reliability,
advances in technology and the unique
requirements of other countries.
ENVIRONMENTAL
PRESSURE
The environmental movement started
many years ago and the early fruits of its
work include the bipartisan Clean Air Act
of 1970 and the Clean Water Act of 1972.
A number of good things have been accomplished since that time but many believe that environmentalists and government regulators have gone too far.
The U.S. Environmental Protection
Agency (EPA) is very active in continually tightening environmental standards
through new regulations and related
actions. In addition, many non-governmental organizations that are environmentally focused work ostensibly
to press the EPA on its decisions and actions. These NGOs have grown large and
spawned a complete industry of specialists that make money on what they do.
In their book The New Leviathan, David
Horowitz and Jacob Laksin point out the
40
FUEL DIVERSITY
Over the years there have been statements about the future that proved
wrong. In this context, there are many
reports which indicate that natural gas is
abundant and will be for a long time. The
abundance is so evident that new uses of
gas are envisioned and as these uses add
to the existing uses of gas, demand for gas
is rising rapidly.
Solar and wind renewables are making
significant headway and with them one
can identify what could be called the 24/7
Generation Triad. The Triad includes the
power generation systems that can be on
line at full load continuously on a 24/7
basis which include natural gas, coal and
nuclear. Power generation costs are best
RELIABILITY
The concept of a 24/7 Generation Triad is valuable not only for fuel diversity
but also for reliability. Nuclear plants are
among the most secure plants against
threats of weather and terrorism as they
are designed in a robust manner and their
refueling cycles are measured in years.
Coal is likewise secure with regard to
weather as it benefits from the ability to
store several months of coal consumption on site. Coal plants may be less secure than nuclear plants due to the lack
of perceived risk but increasing their security could be easily accomplished.
Natural gas has many uses that are critical during times of inclement weather.
Gas is backed up by regionally dispersed
storage and yet still depends on pipelines
to make the final delivery. Such pipelines
can be protected but still remain vulnerable to terrorism and gas fuel storage on
site is measured in minutes as opposed to
months and years.
www.power-eng.com
ADVANCES IN
TECHNOLOGY
At the POWER-GEN International
Conference in December of 2014 one
session included a panel entitled Current
Developments in Coal Fired Generation.
Among the highlights was the discussion
of the ultra-supercritical John W. Turk Jr.
power plant in Arkansas which achieved
the best heat rate of coal plants in the
USA in 2013. The Kusile Power Station
in South Africa was presented and the
scope, design considerations and economic impact of this new multi-unit station are impressive.
The news from EPRI focused on the excellent track record of reducing emissions
in coal fired plants over many years and
provided insights on new technologies
that will bring significant improvements
www.power-eng.com
WHAT OTHERS
ARE DOING
China is the largest owner of coal fired
power plants in the world having approximately twice the capacity of the United
41
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INDEX
RS# COMPANY
Babcock Power
PG#
RS# COMPANY
11
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www.babcockpower.com
Buckman
C4
19
19 Siemens AG
1
29
C3
www.siemens.com/sppa-t3000
17
C2
www.solvair.us
www.goodway.com
DIGITAL EDITION-COVER
21
www.fluor.com
13 Goodway
Technologies Corp
www.apollovalves.com
14 Fluor Corp
33
www.proenergyservices.com
23
www.clarcorindustrial.com
25
www.sspc.org
www.topsoe.com
Magnetrol International
13
www.magnetrol.com
17 Membrana
35
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Mitsubishi Hitachi
Power Systems America
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Mitsubishi Hitachi
Power Systems America
BROWSER EDITION-LEADERBOARD
www.processbarron.com/power
www.chanutemfg.com
43
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5
11 Chanute Manufacturing
SALES OFFICE
www.power-gennaturalgas.com
www.brandenburg.com
DIGITAL
EDITION-ANNOUNCEMENT
SPONSOR
www.beis.com
Brandenburg Industrial
Service Company
PG#
National Marketing
Consultant 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
Regional Marketing Consultant 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,
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Regional Marketing Consultant Natasha Cole
1455 West Loop South, Suite 400
Houston, Texas 77027
Phone: 713.499.6311; Fax: 713.963.6284
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The Water Tower
Gunpowder Mills
Powdermill Lane
Waltham Abbey, Essex EN9 1BN
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Phone: +44 1992 656 608, Fax: +44 1992 656 700
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The Water Tower
Gunpowder Mills
Powdermill Lane
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email: rmorris@pennwell.com
UK, Austria, Africa, Holland, India, Italy,
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