Professional Documents
Culture Documents
10
WWW.RENTECHBOILERS.COM
October 2014
ON THE COVER
The 750-MW Trianel Coal Power Plant in Lnen, Germany, equipped with an SST5-6000
steam turbine and a SGen5-3000W generator from Siemens, boasts an efficiency of nearly 46% and is one of this years coal-fired Top Plant Award winners. Courtesy: Siemens
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40
Sponsored Report:
Indonesias Energy Sector
Despite great economic success, power
shortages in Indonesia remain endemic.
This Global Business Reports section
looks at the island nations energy potential, plans, and challenges (p. 49).
FEATURES
Muffler
COMBUSTION TURBINES
Recuperator
RENEWABLES
Coupling
Gearbox
on valve
Compressor and
Lube oil system
intercoolers
and cooler
Engin
54
MERCURY CONTROL
REGULATIONS
DEPARTMENTS
SPEAKING OF POWER
58
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8
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9
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COMMENTARY
Texas and Germany are on opposite sides of the world in many ways, but both believe
in competitive energy markets and are now reconsidering their market designs.
Environmental and community activists fearful of hydraulic fracturing have launched
a high-profile, highly hyped campaign to shut down new natural gas production; however, their prospects of success look dodgy.
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SPEAKING OF POWER
14.3/kWh in June 2014a 44% nominal increase over 10 years; the EIA found
the nationwide average annual residential rate was 8.95 in 2004 and 12.97
in June 2014a 45% nominal increase.
Adjusted for inflation, that 8.95 in 2004
would be worth 11.29 in 2014, which
yields a 14.9% increase in real terms.
Over the same decade, according to CPI
data, urban consumers saw the following
increases in nominal prices: regular unleaded gasoline, 81%; eggs, 49%; ground
beef, 57.2%; frozen concentrated orange
juice, 31.3%; and piped natural gas for
household use, 6.1% (though comparing
just those two years prices hides a steep
increase for gas in 2008).
As for water, another necessity, in September 2012, USA TODAY cited a survey
by Black & Veatch of 100 U.S. municipalities that found residential water bills had
doubled over the previous 12 years in at
least one in four places and had tripled
in some. The paper noted that water prices are expected to climb even higher, as
many water systems are due (or overdue)
for major infrastructure upgradesnot
unlike much of the electricity grid.
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1. Heavy on coal. Polands energy sector is historically based on coal, and Poland
has the ninth-largest deposits in the world.
Hard coal and lignite produced nearly 90% of
the central European countrys power in 2012.
Source: Polish Information and Foreign Investment Agency
Biomass Hydro Wind and geothermal
Oil Gas Coal
Electricity generation in Poland by source
2% 2%
3%
2. For long-distance power. ABB on Aug. 27 commissioned the high-voltage directcurrent (HVDC) converter stations for the 3.2-GW Rio Madeira HVDC link in Brazilwhich, at
2,400 km, is the longest transmission line in the world. Courtesy: ABB
2%
3%
88%
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SOME THINK
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WE THINK
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Transporting materials from remote locations has traditionally required signicant infrastructure investments in road
or rail links, vehicles, personnel and fuel. BEUMER o ers
an economical, e cient and environmental alternative
long-distance overland conveying. This gives you a dedicated,
around-the-clock transport link at the fraction of the cost
of infrastructure development. The reduced noise and air
pollution minimises environmental impact and improves
personnel safety. Add to that a high degree of design exibility and customisation and you can see why overland
conveying makes a big di erence to operational e ciency
and environmental protection.
For more information, visit www.beumergroup.com
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3. [E]ngenuity.
4. A big dispatch. State-owned Russian energy giant Gazprom in September began construction on a mega-pipeline that will send $400 billion worth of Russian gas to China over 30
years, starting in 2018. Courtesy: Gazprom
Adaptive Brush
Seal Solutions for
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POWER Digest
Kemper County Combined Cycle Unit Begins Commercial
Operation. Mississippi Power on Aug. 14 marked a significant
milestone and started commercial operation (on natural gas) of
the combined cycle unit at the $5.5 billion integrated gasification combined cycle Kemper County energy facility. The unit
was originally synchronized to the grid on Oct. 5, 2013, during
testing using natural gas as fuel. Since then, the Southern Co.
subsidiary has performed critical testing on various components.
The combined cycle unit passed all applicable performance and
environmental tests. The first gasifier (to be used to convert
lignite to synthesis gas) heat-up at the plant is scheduled for
later this year. The 582-MW plant is scheduled to begin operation
using coal in the second quarter of 2015.
108&3
For more than 25 years, Sealeze has helped design and manufacturing
engineers design solutions.
800.787.7325
e-mail: power@sealeze.com
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13
ate as a closed-loop, pumped-storage facility, using the excavated open mine pits as
reservoirs. Developer Eagle Crest Energy
and engineering firm GEI Consultants have
led licensing efforts. (For more on the Eagle
Mountain project, see the article on hydroelectric development in this issue.)
Correction
The August cover article on the Ivanpah
Solar Electric Generating System contained an error in the plants water usage statistics. The article should have
stated that the plant has used about
20,000 gallons of water per day.
Company description
Social media
Add unlimited product information/content
If you have any questions or are interested in upgrading your listing, please contact
Diane Burleson at Dburleson@powermag.com or at 512-337-7890
24303
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Proper Lubrication
Practices Improve Plant
Operations
Although industrial lubricants typically
account for only 1% of plant operational
costs (Figure 1), the lack of proper lubrication products, techniques, or applications can have a much more severe effect
on overall maintenance costs. One of the
smallest items in the budget directly influences more than half of the total maintenance cost.
Lubrication has proven to be the most
important factor regarding machinery
reliability and productivity. The three
major goals of operations and maintenance (O&M) are to improve output
capabilities, reduce O&M costs, and increase profitability.
Many plant managers are looking for
existing products or technologies combined to produce a synergistic outcome
to create a significant advantage over
the sum of their parts. Lubrication is
one of the building blocks that can help
achieve this goal. The proper lubricant,
lubrication practices, training, and implementation of a lubrication management program (LMP) can reduce costs and
improve productivity.
Synthetics Versus Minerals
Choosing the wrong lubricant for a machine component is more common than
you may think in power generation facilities today. There is a big difference in per-
Increased wear protection: Superior level of fluid film protection; high shear
stability; and reduced scuffing, pitting,
and rolling contact fatigue.
Wide temperature range: Maintain fluid
film protection at higher temperatures;
lower pour points and greater fluidity
at low temperatures.
Longer oil life: Free of unstable molecules that are prone to degradation;
extend oil drain intervals; higher resistance to oxidation.
Improved bottom line: Optimize equipment performance and reduce maintenance costs.
Lubricants, 1%
Synthetic
Mineral oil
Depreciation, 15%
Overhead, 35%
Utilities, 19%
Maintenance, 30%
16
www.powermag.com
precision of equipment.
Understanding lubrication fundamentals
can reduce maintenance expenses more
than 30% by ensuring the proper lubrication and LMP is implemented. Lubrication
education and training teaches staff how
to develop a successful LMP and proactive
maintenance program, which improves reliability at the lowest cost.
Without the knowledge of lubrication
attributes, it is more difficult to establish an LMP. A complete and successful
www.powermag.com
17
Low-grade/commodity lubricants
Under- or over-lubrication
No lubrication
18
www.powermag.com
These are just some of the problems every facility can experience.
Planning is a key part of proper lubrication management. There are three basic
types of maintenance: corrective (fix what
just failed), preventive (fix on a timebased frequency whether it needs it or
not), and predictive (monitor the equipment to see if the data shows that an item
is moving toward failure and make repairs
just before it fails).
Many successful companies are changing to predictive maintenance programs,
focusing on oil analysis, vibration analysis, thermography, and fluid and system
cleanliness to improve the reliability of
equipment. They can then perform maintenance at the optimum time, rather
than on some arbitrary schedule. Paying attention to monitoring the details
is measurement-driven and deploys data
analysis to make risk-informed decisions. Proper lubrication practices not
only require knowledge but also a proactive approach.
Ask the Experts
Overall, lubricants make up a small portion of O&M costs, but improper usage
and choosing the wrong lubricant affects
the bottom line and business operating
profits. Making sure that fundamental
lubrication practices are being handled
correctly has huge benefits over time.
If sustainable operations are the goal,
proper lubrication practices and an LMP
can help achieve a reliable, cost-effective plant operation.
Making a big decision can be easier
with the help of a professional. Lubrication is a specialty; becoming an expert requires education and experience. Though
there are many distributors to choose
from, Hydrotex is one company that offers LMPs and on-site training presented
by knowledgeable lubrication consultants.
The key to success is finding a company
that not only can recommend the right
high-performance lubricants for the applications but also can recommend reliability
solutions. Focus on the overall solution
tailored to fit your goals.
John Bickley, PE is the vice president of
sustainable utility sales for Hydrotex.
Unbundled Renewable
Energy Credits and the
Benefits of Standardization
Lisa Koperski
www.powermag.com
you
you
you
you
at full load?
load following?
running the same fuels?
buying coal on spot markets?
NEW
TOP PLANTS
Courtesy: Eskom
South Africa began mothballing coal-fired plants almost 25 years ago when reserve
margins were high and independent power producers (IPPs) were invited to invest.
Ten years later, mass electrification, rapid industrialization, and low power prices
that failed to attract IPPs caused reserves to dip to dangerous levels. Camden was
one of three coal plants brought out of retirement to keep the lights on.
Dr. Robert Peltier, PE
TOP PLANTS
1. Second career. Eskoms eight coal-fired units at the 1,600-MW Camden station were
first commissioned in 19671969. Following a period of excess capacity, all eight units were
mothballed in 1990. Fifteen years later, in March 2005, Unit 6 was revived to help Eskom increase supply levels and potentially avert a power crisis, and all eight units were operating by
mid-2009. For scale, the stacks are 154 meters high and the cooling towers are 112 meters tall.
Courtesy: Eskom
Restart Challenges
As might be expected, there were many challenges in resurrecting a coal-fired plant that
www.powermag.com
TOP PLANTS
Think your project was tough? Tokyo Electric Power Co. (TEPCO) finished one of the
worlds most efficient coal-fired power plant on time despite a 9.0-magnitude earthquake that devastated both the site and much of the country.
Thomas W. Overton, JD
PROTECTING POWER
PLANT CHIMNEYS
Tomorrows chimney
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The New Chimney Design from Hadek is a revolution in power
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Its slim and lightweight, but built to last even in seismic
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less expensive to build than traditional chimneys.
The design is simple: a smooth reinforced concrete shell, with
the Pennguard Block Lining System applied directly to its
inside surface. So theres no need for a separate internal flue.
Why is the New Chimney Design the future?
Its low maintenance, with minimal risk of component failure.
Its long-lasting the Pennguard lining has a projected service
life of at least 20 years. It has outstanding seismic tolerance.
Also it is designed specifically for a wide range of operating
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Make the New Chimney Design part of your plans.
Contact Hadek now: 412 204 0028, sales@hadek.com
Pennguard is a registered trademark of Henkel KGaA and is used with their permission
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Detail engineering
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130c (266F)
Ambient temperature
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Concrete shell
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TOP PLANTS
Prefecture (see Does IGCC Have a Future?
in the July 2014 issue).
As part of its goal to maintain a modern,
balanced generation portfolio, TEPCO in the
late 1990s chose a site in the village of Tokai
in Ibaraki Prefecture for its newest, most advanced coal plant. Construction of Hitachinaka Thermal Power Station (HTPS) Unit 1
began in July 1999. The plant was built on reclaimed land in a section of the North Wharf
of Hitachinaka Port.
Built by Hitachis power generation division (now part of Mitsubishi Hitachi Power
Systems) the 1,000-MW USC plant employed
a variable-pressure, spiral-wound Benson
boiler supplied by Babcock-Hitachi K.K.
and equipped with Hitachis newly designed
low-NOx NR-3 burners and advanced steam
temperature controls. To enable the plant to
fire a variety of coals, superheater attemperators were installed between each superheater
section. To meet strict national environmental regulations, the plant was equipped with a
flue gas denitrification system (supplied by
Hitachi) and a desulfurization system and an
electrostatic precipitator (the latter two supplied by IHI). The plant was also equipped
with a fully digital large-scale monitoring
system.
At the start of commercial operations in
December 2003, Unit 1 achieved one of the
highest efficiencies of any coal plant in the
world: 45% LHV.
TEPCOs plans for HTPS included future
expansion, and space was left adjacent to
Unit 1 for another unit. Planning for it began not long after Unit 1 came online, and
construction began in October 2009. After
competitive bidding, Hitachi was again chosen to lead construction and supply the major components, with Babcock-Hitachi K.K.
also supplying the boiler. Like its sister unit,
Unit 2 would employ an USC variable-pressure boiler, but Unit 2 also would include a
low-pressure turbine using the same 41-inch
blade design used in Unit 1s high-pressure
turbine.
A Major Shake-Up
Construction of Unit 2 was proceeding on
schedule in March 2011 with framing of the
boiler and turbine buildings under way.
At 2:45 p.m. Japan Standard Time on Mar.
11, a roughly 300-mile-by-120-mile section
of the subduction zone offshore of northern
Japan ruptured. The epicenter of the resulting
9.0 magnitude earthquakethe largest quake
ever recorded in Japan and the fifth-largest
recorded quake in modern historywas just
155 miles northeast of the plant site.
More than 15,000 people across Japan lost
their lives in the earthquake and subsequent
tsunami, and the economic losses have been
26
1. Walloped.
Running Smoothly
Unit 2 has performed as expected since
coming online, even during periods of peak
summer demand. It has achieved one of the
worlds highest thermal efficiencies, 45.2%
LHV, for coal-fired thermal power stations,
according to a TEPCO statement.
TEPCO, though, is not standing still. It announced shortly before Unit 2 came online
that it had agreed with Chubu Electric Power
Co. to build a third, albeit slightly smaller
(600 MW) USC unit at the HTPS site. That
unit will be 96.55% owned by Chubu Electric
and 3.45% owned by TEPCO. Construction
is planned to start in 2016, with operation
slated for 2020.
M319DL
TOP PLANTS
The nine-unit Mundra thermal power plant is one of the largest coal-fired plants in
the world, but it takes up minimal space and uses both fuel and water efficiently.
Sarosh Bana
Transmission Constraints
On Dec. 31, 2013, the plant set an Indian
power sector record by surpassing its 4,620MW nameplate capacity to generate 4,644
MW. To enable that record and to circumvent the governments infirm transmission
network, Adani Power had two power lines
constructed: the 433-kilometer (km) 400-
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TOP PLANTS
kV transmission line to transmit 1,000 MW
from Mundra to Dehgam in Gujarat and the
989-km 500-kV high-voltage direct current
(HVDC) bipole line with the capacity to
transmit 2,500 MW from Mundra to Mohindergarh in the northern state of Haryana. The
latter is the first HVDC system in the private
sector in India.
While Siemens India was contracted to
build the HVDC substations at Mundra and
Mohindergarh, the HVDC line was constructed by Jyoti Structures Ltd., both works
taking three years till commissioning in July
2012. The Mundra-Dehgam line was constructed in sections by Jyoti and Kalpataru
Power Transmission Ltd., taking two years
till commissioning in July 2009.
Coal Supply
The Mundra TPP is a significant milestone in
the path to realizing Adani Powers target of
generating 20,000 MW by 2020. By that year,
the Adani Group is also seeking to mine 200
million metric tons (mt) of coal and handle
200 million mt of cargo from its ports.
At full load, the plant consumes about
55,000 mt of coal per day, though its yearly
consumption is between 16 and 17 million
mt. It runs on blended subbituminous coal,
about 70% imported from the Adani coal
mine in Bunyu, in Indonesias East Kalimantan province, and the rest from the public sector Mahanadi Coalfields in the eastern Indian
state of Odisha. The coal is freighted to the
Adani Groups Mundra port, Indias largest,
which notched a throughput of 100 million
mt in 201314 and which is slated to become
the largest coal import terminal in the world.
From there, a high-speed conveyor belt conveys the coal to the plant 9.5 km away at
6,000 mt per hour.
The Mundra TPP, named after the coastal
town near which it is located in the arid Kutch
district, operates in far-from-conducive conditions. We are constantly challenged by a
highly corrosive and saline ambient condition, with average wind speeds between 20
and 40 kmph that affect the performance of
the cooling towers, said Station Head Anand
Kumar Singh. Besides, our plant has been
designed to operate with high, 33% moisture
coal. High-moisture coal can choke coalhandling chutes and coal feeders, reduce
mill output, and increase the heat rate, he explained. To reduce the moisture content, the
coal is pulverized to coal fines that are then
admixed in a drying chamber with a dry gaseous mixture.
Environmental Controls
The FGD system, supplied by Alstom India,
requires only seawater as the adsorbent (no
alkaline chemicals) to reduce sulfur emissions
(Figure 1). Its simplified structurecomprising an adsorption tower, seawater supply
pump, and aeratorrenders operation and
maintenance (O&M) easy, said Associate General Manager (O&M) Girish Raghuwanshi.
No by-products are formed, and the adsorbents can be released into the sea after adjusting their pH, chemical oxygen demand, and
dissolved oxygen, he explained. Increase of
sulfate in the seawater returned to sea is within
natural seawater variations, and emissions too
are well within the norms prescribed by the
Gujarat Pollution Control Board, which are
50 mg/Nm3 for particulate matter, 100 ppm of
SO2, and 50 ppm for nitrogen oxides.
The Mundra TPP is researching the expanded usage of the fly ash it generates, as
a liming material and as a feedstock for vermicomposting (converting organic waste into
fertilizer). Most of the fly ash is conveyed to
three 3,000-m3 silos. From there, trucks dispatch it to makers of bricks, ceramics, cement
and roads; it also is packed in 1.4-mt bags for
shipment to the Middle East.
In the first experiment of its kind in India,
www.powermag.com
1. Seawater system.
At the Mundra
plant, only seawater is needed by the flue gas
desulfurization system to reduce sulfur emissions to required levels. The nine units share
four stacks, Units 1 and 2, 3 and 4, and 5 and
6 having three separate stacks with two flues
each, while Units 7, 8, and 9 have one stack
with three flues. Courtesy: Adani Power Ltd.
Wider Impact
The Mundra TPP is visited by power professionals and engineering students from India
and beyond for refresher courses and training provided by its state-of-the-art Training
& Research Institute.
With success comes responsibility, so we
take care to reinvest in protecting and developing the communities within which we live
and operate, said Gautam Adani, whose wife
Priti heads the Adani Foundation, the Groups
corporate social responsibility arm. We invest 3% of our group profit in community
initiatives through the Adani Foundation. In
Mundra, these include a 50-bed hospital, mobile health care, rural dispensaries, two large
and several small play schools, provision
of drinking water, watershed management,
counseling and assistance in advanced farming techniques, groundwater conservation,
and skill-building for traditional artisans.
www.burnsmcd.com/water-team
TOP PLANTS
Operating a coal-fired plant of any sort in India is a challenge these days, but Sesa Sterlites 1,215-MW plant is also tasked with supplying vital power to an adjacent aluminum
smelter. Despite a difficult regulatory environment and ongoing coal market difficulties,
the plant has not just met expectations but has risen well above them.
Thomas W. Overton, JD
TOP PLANTS
1. Vital partner. The captive plant at Jharsuguda powers an adjacent 0.5-mtpa aluminum
smelter. Courtesy: Sesa Sterlite LLC
Vital Operations
Aluminum smelting is one of the most power-intensive industrial processes. The primary
method used, the HallHroult process, involves heating a mixture of aluminum oxide
and other compounds with electric current
in a smelting cell until the molten aluminum
separates out. Not only does this method consume enormous amounts of electricity, but
the cells also must be continually heated or
the mix of materials will solidify and the cell
will be useless until repaired. This means a
power loss across an entire plant could spell
disaster, which is why aluminum smelters are
typically located near large power plants.
London-based Vedanta Resources is a
globally diversified natural resources company with operations in Indiawhere it is
the nations largest mining firmAustralia,
South Africa, Namibia, and other countries.
Vedanta subsidiary Sesa Sterlite Ltd. (SSL)
is one of the countrys largest commercial
power producers as well as a major natural
resources firm. Since the mid-2000s, SSL has
been developing a huge aluminum production zone in Jharsuguda in the eastern state of
Odisha. Initial plans envisioned a 0.5 million
metric tons per annum (mtpa) smelter, to be
eventually expanded to 2.6 mtpa (Figure 1).
Odisha has abundant reserves of both bauxite
(aluminum ore) and coal. Phase 1 of the project, comprising the 0.5-mtpa smelter, was
completed in 2009, while Phase 2, a 1.25mtpa expansion, was completed in 2011.
Such a massive project would have equally massive power demands, and relying on
the national grid for power, even if it came
from a nearby plant, would be risky. To ensure reliable operations would mean building
a captive power plant to supply the project
directly. SSL soon drew up plans for what
would be the largest captive power plant in
the entire country.
Construction began in 2005, and the first
unit, Unit 3, came online in July 2008. The
last of nine units came online in early 2010.
The project was completed without a single
lost-time accident.
The plant consists of nine 135-MW subcritical pulverized coal, single-reheat boiler
units, utilizing corner tangential firing and
natural circulation, supplied by Shanghai
Electric Co. Each boiler uses four bowl mill
pulverizers to prepare the coal for combustion. The boilers are rated for 440 tons per
hour of main steam, at 2,070 psi and 1,005F
at the superheater outlet. Each boiler supplies
steam to a single double-cylinder, 39-stage,
double-flow, extraction and condensing
steam turbine.
The plants environmental controls are
among the most advanced in India. Fly ash is
captured with electrostatic precipitators and
fabric filters and is recycled for use in road
construction and fill.
The plant is the first coal-fired unit in the
country to employ high-concentration slurry
disposal of dry and bottom ash. This system
combines both ash streams into a mostly
solid slurry to reduce water consumption and
fugitive dust, as well as requiring a smaller
footprint compared to conventional ashhandling systems. The high concentration of
solids means the slurry forms a natural slope
in the disposal area without the need for mechanical spreading.
The plant employs counter-flow forced
cooling towers and multi-flue stacks. Process
water is sourced from the nearby Hirakud
Reservoir, while coal is supplied from the
Mahanadi Coal Fields outside Jharsuguda.
www.powermag.com
Exemplary Performance
Since coming fully online, the SSLs captive
power plant has received numerous honors
for excellence in operations and energy efficiency. It has received the National Energy
Conservation Award bestowed by the Bureau of Energy Efficiency in 2011 and 2012,
and in 2013 received both the Confederation
of Indian Industrys National Award for Excellent Energy Efficient Unit and the India
Power Award from the Council of Power
Utilities. The overall Jharsuguda operation
was also honored for its commitment to sustainability with a Green Manufacturing Excellence Award from consulting firm Frost
& Sullivan.
These honors have come in large part from
the plant staffs relentless drive to improve
the plant heat rate and cut its fuel consumption. The overall plant heat rate has been reduced from 10,627 Btu/kWh in 2010 to 9,591
Btu/kWh in 2013, an impressive achievement
for a subcritical plant. Coal consumption has
been cut from 893 grams per kilowatt-hour
(g/kWh) to 806 g/kWh over the same period.
Environmental performance has also been
improved. Upgrades to reduce particulate
emissions have cut them from 181 mg/m3 in
2010 to under 30 mg/m3 currently.
The plants biggest challenge, not surprisingly, has been finding adequate fuel to
operate. To address its fuel challenges and
increased costs of imported coal, SSL has
begun blending and burning coal purchased
in spot-market auctions. This approach allows it to balance its fuel costs depending
on the price of imported coal. Currently, the
plant burns up to 70% auction coal, and future plans are to maximize this approach to
reduce overall fuel costs.
The plant has also gone beyond the call
of duty in other ways. Thanks to its reliable,
efficient generation, the adjacent 0.5-mtpa
smelter has been able to run above rated capacity despite continuing difficulties with the
local grid. Meanwhile, the 1.25-mtpa expansion has been unable to start up because of
ongoing disputes with the Odisha state government over tariffs on the power it would
be using from SSLs 2.4-GW independent
power plant in the same industrial zone, but
because the captive power plant has a 100MW surplus, Vedanta officials said in the
companys second quarter 2014 earnings call
that it plans to begin limited operations at the
larger smelter this year using power from the
captive plant.
For achieving exemplary performance in
a highly challenging environment, Sesa Sterlites captive power plant at Jharsuguda is a
deserving POWER Top Plant.
TOP PLANTS
Although Germanys Energiewende is all about reducing consumption and transitioning from nuclear and fossil fuels to renewable energy, it hasnt completely
halted the development of new coal-fired facilities. The Lnen plant demonstrates
that even in countries keen on renewables, coal is still an important resource.
Aaron Larson
ermanys energy transitionEnergiewendehas made a lot of headlines. Whether you agree with the
countrys energy policy or not, there is no
denying that it has spurred the growth of renewables. Even so, change takes time, and
a bridging technology is necessary if the
country is to reach its goal. (To learn more
about recent changes to Germanys energy
policy, see Germany Reforms Renewable
Energy Laws listed with the August 2014
issue features online at powermag.com.)
With nuclear power clearly on the way out
in Germanyeight of the countrys 17 reactors were permanently shut down months
after the Fukushima disaster in 2011, and all
of the others are slated to close by the end
of 2022coal-fired plants offer one proven
alternative to fill the void.
Making Choices
The 750-MW Lnen hard coalfired power
34
plant lies on the Datteln-Hamm Canal, a major inland waterway in northwest Germany.
Trianel Kohlkraftwerk Lnen GmbH und Co.
KGa collaboration of 31 municipal utilities and regional energy suppliersselected
the location for several reasons.
A coal-processing company had previously used the site, so it was already set up
with good transport connections for coal delivery. The available plot size was suitable
for plant development, and the canal offered
a readily available source of cooling water
for the plant. In addition, a 380-kV transmission system was relatively easy to link
to from the site.
Although the location offered several benefits, it also came with challenges. Much of
the ground at the building site was fill composed of mine tailings, which meant that the
subsoil needed extensive foundation work to
accommodate the heavily loaded structures
of a power plant. In the end, 811 concrete
www.powermag.com
TOP PLANTS
1. No lazy river here. Coal is delivered to Rotterdam on ships and then transported by
barge to Lnen, where cranes are used to unload it. Courtesy: Trianel Kohlkraftwerk Lnen
GmbH und Co. KG
Controlling Emissions
1. Heavy duty slider. Sliding doors hold up better in windy conditions. Courtesy: Tucson
www.powermag.com
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37
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38
during the winter. The original design included a heat trace system
around the periphery of the cooling towers to prevent ice from forming and interfering with the blades of the cooling tower fans (Figure
2). Although the load on the fans is minimal during winter months,
they must continue to rotate to keep air flowing nonetheless.
The original heat trace was difficult to maintain and stopped
working after only a few years. Replacement was problematic due
to the location and time constraints on the work. Several employees who had worked on the system got together and collaborated
on a solution.
The purpose of the cooling tower is to remove heat from the cooling water used to condense steam exhausted from the plants turbine
generator. The water is typically returned to the cooling tower at a
temperature of about 80F.
The answer was to pipe some of that relatively warm water into
a ring surrounding the fan blades. The warm water keeps ice from
building up and eliminates the need for heat trace. Its more economical too. The new design utilizes waste heat that needs to be removed
anyway and saves energy that had been consumed by the electrical
heat trace.
At the Springerville plant, conveyors offered an opportunity for
improvement. Because some were completely exposed to weather,
ice frequently developed on walkways in the winter, creating the
potential for injuries from slips and falls. The solution was to install
elevated grating (Figure 3) to provide traction for workers, thus reducing the hazard.
Additionally, some of the Springerville buildings were constructed
with no heating system at all. Ortiz explained that TEPs maintenance
crew installed diesel heaters in these buildings (Figure 4) to keep areas above freezing. From December through the end of March, the
heaters are used regularly.
While heat trace offers vital freeze protection in cold weather climates, at one of Xcels facilities, workers found that some installation
techniques were resulting in electrical shorts. Originally, the heat tape
was doubled back on itself any time the tube trace ended at an instrument enclosure. In time, continuous heating and cooling of the heat
trace caused the insulation to break down and short out.
Similar to Basins experience, the people performing the repairs
came up with a solution to the problem. The electricians drilled a
hole through the wall of the enclosure and mounted the power connection box directly to the enclosure instead of to the tube, which
eliminated the short radius turn in the cable. The jacketed cabling
was taped and sealed inside the enclosure to help prevent escaping
moisture from potentially contaminating and freezing the insulation.
Problem solved!
4. Adding heat. Unheated buildings are bound to be cold. Using portable heaters at least
keeps them above freezing. Courtesy: TEP
Re-Learned Lessons
Plant outages caused by extreme cold weather events (as well as impacts on natural gas
pipelines that supply the rising number of
gas-fired combined cycle plants now operating) appear to be more problematic in the
southern region of the U.S. Natural gasfired
plants in the northern states continued to operate reliably because they were designed
to do so from the outset. For example, Minnesota Municipal Power Agencys Faribault
Energy Park, located in Faribault, Minn.,
routinely operates for months at a time without a problem when the outside temperature
is below zero (see How to Make a Power
Plant a Welcome Neighbor, March 2008).
In contrast, plants built in the southern
states, from Florida to Arizona, are often
of an outdoor design that makes retrofit an
expensive proposition. Regulators in some
1. Frozen solid. Many combined cycle plants located in southern states were unable to reliably start or run during the freeze that occurred in early February 2011 because important equipment was not cold-weather protected, as can be seen with this heat-recovery steam generator
steam desuperheating station. Source: POWER
www.powermag.com
3. Frozen pipes.
vers (thus rendering the fire protection system inoperable). The National Fire Protection
Association (NFPA) has established clear fire
protection system freeze prevention requirements (NFPA 13). From a safety viewpoint,
you should heat trace the water supply to the
safety showers located throughout the plant.
Ammonia lines to the selective catalytic
reduction system of a gas-fired plant must be
properly heat traced and insulated. A crack
in this line could easily become a significant
environmental issue if left undetected. The
same should be said for chemical lines used
for boiler water treatment and the boiler water sample lines.
Compressed Air Systems. Compressed
air systems may also be at risk. The typical
southern climate plant uses compressed air
outside directly after the coalescing filter.
Plants built in northern climates use air dryers to provide compressed air at a dew point
temperature below the minimum design temperature to prevent freezing of instrument air
lines. Air compressor condensate vent lines
should also be heat traced, unlike the typical
southern plant. High moisture levels in the
instrument air often caused freezing of airoperated valve actuators.
Redundant dew point monitors may be
used to continuously monitor compressed
air quality. Do not rely on automatic air tank
drain systems for moisture control. One utility reported the failure of an automatic air
tank drain resulted in the contamination of
its instrument air system, which is very difficult to clean. At least one plant reported
that moisture in the control air system caused
a pneumatically controller positioner on a
fan damper to fail, causing a complete unit
forced outage.
Other Plant Systems. Freeze protection
must also be considered for outdoor equipment that will not be operated. For example,
a heat-recovery steam generator (HRSG) full
of water may need to be drained when exposed to unexpectedly low temperatures. The
41
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or call 847-763-9509.
Setting Priorities
Chances are your list of low-temperature operation upgrades is extensive and expensive. You
42
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CIRCLE 18 ON READER SERVICE CARD
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43
offsite power.
The NRC has continued to update its regulatory documents, such as the Standard Review Plan for the Review of Safety Analysis
Reports for Nuclear Power Plants, NUREG0800, Section 2.4.7, Ice Effects, which was
revised as recently as 2007. In addition, the
NRCs Regulatory Guide 1.151, Instrument
Sensing Lines, first published in July 1983
and revised in July 2010, addresses the prevention of freezing in safety-related instrument sensing lines, and includes such design
issues as diversity, independence, monitoring, and alarms.
The NRCs Inspection Procedure 71111,
Reactor SafetyInitiating Events, Mitigating Systems, Barrier Integrity includes an
attachment on Adverse Weather Protection. NRC resident inspectors use this procedure to check readiness for cold weather,
freezing temperatures, and other extreme
weather conditionsincluding drought and
floodingwhich could lead to loss of offsite
power, redundant equipment, and decay-heat
removal systems.
Walkdowns are used to verify that the
physical condition of weather protection features is monitored to ensure structure, system, and component operability. In addition,
the adequacy of heat tracing and space heaters for cold weather protection of piping and
equipment is checked, and sensing lines and
fire suppression systems are inspected. These
reviews usually occur near the beginning of
each season.
Systems of Interest
Bobby Norrick, seasonal readiness coordinator
(SRC) and eSOMS (enterprise Shift Operations
Management System) administrator at the D.C.
Cook plant conducts winterization reviews
in conjunction with the systems engineering
group. The team identifies all actions needed
to ensure systems will function properly and
reliably through the winter (Figure 1). In addition, the Work Assessment Group identifies
and prioritizes new equipment deficiencies and
resolutions that affect winter readiness during
the daily screening meeting.
The following systems are reviewed for
winter readiness:
tection
Outside heat trace
Turbine building
Auxiliary building
1. Winter wonderland. While the typical winter struggles, such as snow and ice in
the parking lot, are common to many plants,
personnel at D.C. Cook also focus on specific
plant systems during winter preparations.
Courtesy: American Electric Power
Auxiliary steam
Alternate plant heating boiler
Boric acid heat tracing
Fire protection
Ventilation
Circulating water
Heating steam
Refueling water storage tanks freeze prowww.powermag.com
45
tems are evaluated by engineering and operations to identify maintenance needs for pumps, valves, and heating coils. In addition, a
winter surveillance is performed by operations to ensure that insulation is installed on selected outside louvers and to validate readiness
of tank heating systems.
To provide clear direction on this subject, a corporate seasonal
readiness procedure was created from past industry experiences and
NRC notices. It specifically references the following Institute of Nuclear Power Operations (INPO) documents addressing winterization:
Effective Results
www.powermag.com
Wind Farms
Though many wind turbines are installed in
regions of the world that see bitterly cold
winters, wind power isnt immune to extreme
cold events.
During the February 2011 Southwest cold
snap, an unprecedented 16% of wind units
within Texas grid operator Electric Reliability Council of Texas operation region reportedly failed709 MW due to blade icing and
another 1,237 MW because frigid temperatures exceeded turbine limits.
And although PJM Interconnection lauded
wind powers positive impact on supply
during the January 2014 polar vortex, saying
it contributed to PJMs ability to maintain
reliability, data shows that wind energy generation dropped precariously during demand
peaks during the Jan. 69 extreme weather
event. The Midcontinent Independent System
Operators system also braced for the plunge
in wind output following Jan. 6, crediting accurate wind forecasts. However, it records
that it saw 1,000 MW of wind power cutouts as a result of the extreme cold on Jan. 6.
The Federal Energy Regulatory Commission
later speculated that the bulk of those wind
turbine failures were due to models reaching their minimum operating temperatures.
Bracing for Low Temperatures. Wind
turbines are typically designed, per international standards for turbine design, to operate within ambient air temperatures of 10C
A deep freeze could have long-term implications for a wind turbine, warns Jeff
Nelson, a TransAlta wind engineer. Turbines
can eventually fault and shut down; in some
cases they have had up to 250 millimeters of
ice. That could mean an extended period of
downtime (if ambient temperatures drop significantly and ice cannot be shed) of up to
three weeks.
For TransAlta, key takeaways from previous
icing debacles at its 96-MW Kent Hills wind
farm in Canadas northeastern province of New
Brunswick include the imperative to catch icing
events early, using instrumentation, ice detectors, anemometer cameras, or/and blade accelerometers. Twenty-four-hour monitoring of
icing conditions is also essential.
And here too cold weather packages can
prove valuable. Some offer, in addition to
technical solutions that widen operating
temperature ranges, active or passive deicing or anti-icing systems for rotor blades.
Systems use a variety of methods, including
heat, water-resistant coatings, and controlled
blade acceleration/deceleration to shake the
ice off.
Last year, for example, Vestas introduced a
de-icing system that can detect an icing condition (using algorithms measuring several
variables, including temperature, humidity,
wind speed, and turbine output), determine
whether its worth shutting down the turbine
to perform de-icing, and initiate a de-icing
procedure if it is worthwhile. The outer third
of each turbine blade essentially includes a
small heating element and fan that uses up to
150 kW to run.
Hydroelectric Plants
Of all generation resources, hydroelectric
plants may be the least affected by nasty winter weather. Indeed, many countries around
the world that rely heavily on hydropower,
such as Norway, Iceland, Canada, and Russia,
must also deal with severe winters. Though
reservoirs may freeze over, penstock intakes
are usually deep enough to withdraw water at
47
1. In cold waters. To
make offshore
wind turbine foundations hardier in icy waters, Finnish company Suomen Hytytuuli
Oy began testing a new gravity-type iceresistant foundation in the Pori sea area of
the Northern Baltic Sea in 2010. (This image
shows the turbine in heavy pack ice at the
end of February 2011.) The foundation consists of a light steel shell with a ring footing, ice-breaking cone, and crushed rock fill.
Courtesy: Eranti Engineering Oy
Storage Batteries
temperatures safely above freezing.
The same is not true for smaller projects,
especially for run-of-river generation, in part
because reduced flows during winter, when
much of a plants watershed may freeze over,
mean that intake water may be drawn at or
very near the surface.
One of the unique wintertime risks is a phenomenon known as frazil ice. Frazil ice forms
when supercooled water (water that is below
freezing but has not frozen) mixes through a
body of water in turbulent conditions. Small
ice crystals form throughout the flow and can
rapidly turn it slushy. If frazil ice is drawn into
a turbine, damage can result.
According to studies by the U.S. Bureau
of Reclamation, which operates many of the
federally owned dams in the U.S., prevention
of ice intake problems is mostly a matter of
good design, but seasonal preparation is also
important. If possible, an ice cover should be
induced upstream of the intakes. This will
keep intake water above freezing and prevent the formation of frazil ice. Ice booms
and floating screens, which can form floating
ice blockades can be useful tools.
48
Solar Systems
With most solar systems (especially solar thermal) being located in areas with mild climates,
severe winter weather is not usually a concern.
However, cold weather can affect solar photovoltaic (PV) systems in other areas.
Most generators are used to lower PV
www.powermag.com
Black & Veatch helped deliver Tanjung Jati B Units 3 & 4, located near Jepara, Central Java, Indonesia.
The plant is owned by Sumitomo Corporation and subsidiary PT Central Java Power, and is operated
by PT PLN (Persero), Indonesias state-owned power utility. Photo courtesy of Black & Veatch.
Ambitious Plans,
but Eficacy Mixed
As Kishore Dass, the president director
of Pyry Indonesia, the global Finish consulting and engineering irm, said: Power shortages are endemic in Indonesia.
The countrys total electricity generation
touched 47 GW as of the end of last year.
According to PLNs electricity procurement
plan for the 2013 -2022 period, there needs
to be an additional capacity of 31.5 GW for
the Java-Bali grid. This amounts to about
3.2 GW per year. At the national level the
power requirement translates to around 6
GW per year.
Increasing the national generating capacity to 60 GW by 2022, as the Governmentowned Perusahaan Listrik Negara (PLN),
which has a monopoly on electricity distribution and accounts for 80% of the countrys generation capacity, has forecasted, is
no small feat. While the Government has
done well by enacting regulation in 2009
for renewable power projects of 10 MW
that stipulates feed-in tariffs for investors
and that assigns to the PLN the obligation
to buy this power, the Government understands that it must encourage projects of
a larger scale. To help achieve such a signiicant increase in power generation, in
2006, the Government introduced the fasttrack program (FTPI) mandating the PLN to
build 10,000 MW coal-ired power plants
by 2011, a deadline that was later extended
COMBUSTION TURBINES
wice this year, PJM flirted with blackouts when brutal winter storms (dubbed
a polar vortex) struck the Eastern U.S.
in January. The cold weather set a new winter
peak demand record of 141,500 MW on Jan.
7, busting the record set in February 2007
by nearly 5,000 MW. In fact, the five biggest demands ever placed on the PJM grid,
and eight of the 10 largest, occurred between
Jan. 7 and Jan. 30. PJM reported that at one
point, 36,000 MW was out of service due to
forced outages, which amounts to 20% of its
installed capacity. Adam Keech, director of
wholesale market operations, is reported by
RTO Insider as sayingthe morning after
setting the winter peak recordWe really
exhausted every megawatt we had on the system. Peaking capacity and fast unit response
is a necessity during summer and winter
peaks, and many regional transmission organizations (RTOs) are willing to pay well for
the service.
A solid majority of new plant construction
in PJM is gas fired, led by simple or combined cycle plants. Simple cycle combustion
turbine (CT) plants are less efficient than
combined cycle plants but are able to start
more rapidly and add valuable power to the
grid in minutes, which is extremely valuable
to a system like PJM as synchronized reserve,
fast grid regulation, or black start service. In
fact, ancillary service payments often justify
the cost of constructing a simple cycle peaking plant.
A New Option
Jupiter, Floridabased PowerPhase LLC has
successfully demonstrated a new technology
called TurboPHASE that may allow an existing simple cycle CT or combined cycle plant
to add as much as 10% to 20% more power
to the grid in seconds, depending on plant
configuration, addressing the quick-start and
fast-response needs of the modern grid.
The TurboPHASE system consists of a
multistage intercooled centrifugal compressor
that delivers hot compressed air to the CTs
compressor discharge section, thereby allow54
ing the CT to operate at its rated capacity irrespective of the ambient conditions (5C to
50C) or altitude (Figure 1). The system takes
advantage of the CT operating below its limits
during hot weather much like an inlet chiller
or evaporative cooling system, although TurboPHASE can also operate in conjunction
with either of those inlet cooling options.
A separately fueled reciprocating engine
direct drives the compressor. The heat from
the exhaust of the engine is used to heat the
compressed air in the recuperator before entering the CT compressor section. On an operating CT, TurboPHASE is said to be able
to ramp to full load in 60 seconds or less and
from part load to full load in 10 seconds or
less. This design feature is sure to be of interest to grid dispatchers anxious to have the
ability to quickly backfill lost capacity during
a system emergency or to quickly respond to
the intermittency of renewable resources.
1. Turbocharging combustion turbines. TurboPHASE consists of four main components: engine, gearbox, compressor, and recuperator. A gas-fired engine-compressor set
produces compressed air that is added to the combustion turbines compressor discharge
section to negate the effect of a high ambient temperature performance derate. Courtesy:
PowerPhase LLC
CO catalyst
Recuperator
Coupling
Gearbox
6 air injection valve
3 air vent valve
www.powermag.com
Compressor and
Lube oil system
intercoolers
and cooler
Engine exhaust
Engine
Engine
cooler
COMBUSTION TURBINES
2. Demonstration plant. Two TurboPHASE
CORMETECH
CLEANER AIR THROUGH INNOVATION
Reliability. Delivered.
CORMETECH, Inc.
5000 International Dr.
Durham, North Carolina 27712 USA
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55
COMBUSTION TURBINES
3. Day one tests. Results of the first day of TurboPHASE demonstration tests are illustrated. The blue line represents the temperature at the inlet to the combustion turbine. The orange
line shows the response of the combined cycle plant to full air injection. Courtesy: PowerPhase
LLC
CT1 MW CT1 inlet temperature
40
90
39
No injection
80
75
34
70
33
32
35
CT1 (MW)
36
No injection
37
85
38
65
31
30
16:15:00
16:45:00
17:15:00
17:45:00
18:15:00
18:45:00
19:15:00
60
19:45:00
Time
4. Day two tests. The test results of the second day of TurboPHASE demonstration tests
are illustrated. The last test of the day was with both TurboPHASE systems in operation followed
by a trip of one system. Courtesy: PowerPhase LLC
CT1 MW CT1 inlet temperature
40
90
39
TPM2 air
80
compressor trip
34
33
32
31
30
1:30:00
56
2:00:00
2:30:00
3:00:00
3:30:00
4:00:00
Time
75
No injection
No injection
CT1 (MW)
35
No injection
36
37
4:30:00
5:00:00
70
65
5:30:00
www.powermag.com
60
6:00:00
85
38
COMBUSTION TURBINES
the TPM did improve the grid response of the
Morris plant and may allow the plant to move
into a grid response category with a higher
payment.
The competitive 2-MW gas-fired enginegenerator could also be started, synchronized, and at maximum load in less than the
10 minutes standard to supply grid regulation
power. But then again, a simple cycle Frame
7FA (227 MW) can start and reach 50% load
within 10 minutes and then ramp up at 40
MW/min. Aeroderivative engines start and
synchronize even faster.
Black Start Service. The TurboPHASE
has the potential to become an interesting
black start option for some utilities with
combined cycle plants. However, its difficult to compete with a diesel engine when
the weather gets very cold (see Prepare Your
Gas Plant for Cold Weather Operations in
this issue), particularly when natural gas
supplies are limited for power generation at
some gas plants. The best black start systems
will be an independent system that can supply power to just the critical plant systems
needed for restart. On the other hand, a TPM
can be installed in two to three months while
a new engine-generator will likely take six
months or longer.
Final Analysis
TurboPHASE has the potential for reinvigorating existing combined cycle or simple
cycle plants with additional peaking capacity, especially during warmer days when the
output of the CT is otherwise limited. The
response of the TurboPHASE, from the limited information we have reviewed, is on
the same order as a gas-fired reciprocating
engine. Efficiency leans toward the enginegenerator because the combined cycle plant
has a higher heat rate. This balance point
could easily change should the TPM be installed on a more efficient CT, although there
arent many that CTs with a heat rate less
than 8,000 Btu/kWh (for example, the 60-Hz
7FA is 8,680 Btu/kWh).
On the other hand, the cost of a TPM is
likely less than a bank of centrifugal chillers and coils that are often used to increase
CT power output during warm weather. Also,
since the TPM produces compressed air at
300 psi, the system can be used on any CT
with a compressor discharge pressure of 290
psi or less, which includes many E-, F-, and
G-class CTs and some aeroderivative engines, assuming there is a suitable open port
on the casing at the compressor discharge.
The response of the TurboPHASE does
meet the PJM requirements for grid regulation power but only when the unit is running
and the compressor is charged and ready to
dump compressed air into the CT. A potential owner must consider the economics of
balancing the regulation payments from PJM
against the cost of the TPM and the added
fuel costs. Also, it probably goes without
saying that potential adopters must be located
within an RTO that has a grid fast regulation
payment scheme.
What do the OEMs think about an owner
adding compressed air into the engine casing for peaking power or fast regulation
purposes? General Electrics GER-3567H
states, GE [heavy duty] gas turbines are designed to allow up to 5% of the compressor
airflow for steam injection to the combustor
and compressor discharge. If superheated
steam injection is acceptable to GE, as it has
been for over 30 years, then one would expect that compressed air in like mass flow
will also be acceptable. Also, it seems to me
that injecting clean compressed air upstream
of the combustor is certainly preferable to
wet compression resulting from the use of
evaporative coolers.
2014
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power stations, including:
Generation (MWh)
Availability (%)
Heat rate
Capacity Factor (%)
Power plant design characteristics
Choose which purchase option that best suits your needs:
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57
RENEWABLES
didnt consider hydro at all in calculating several states baselines for renewable
generation (on the rationale that doing so
would disadvantage states with no or limited hydro potential).
1. Untapped. The Emsworth Locks and Dams on the Ohio River in Pittsburgh are one of
many federally owned flood control and navigation sites at which hydro generation could be
added, according to a recent study. A Boston-based company is seeking approval to build a 24MW run-of-river facility there. Source: U.S. Army Corps of Engineers
www.powermag.com
RENEWABLES
2. Red Rock retrofit.
A Promising Niche
One of those smaller retrofit projects is taking shape at the Red Rock
Dam on the Des Moines River in Iowa (Figure 2). The 36.4-MWrated project, with a peak output of 55 MW, is being built by Missouri
River Energy Services (MRES) for the Western Minnesota Municipal Power Agency (WMMPA). MWH is supplying engineering and
consulting services, and Voith Hydro is supplying the generators and
turbines. Ground was broken on the Red Rock Hydroelectric Project
(RRHP) in August, with completion scheduled for 2018. The $379
million facility will be operated by MRES and financed and owned
by WMMPA.
While there are avoided costs involved with a retrofit as com-
PIPING SYSTEMS
FOR POWER PLANTS
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59
RENEWABLES
pared to a new project, there are also some
new challenges. As Ralph Watt, MWHs
project manager for RRHP explained to
POWER, the Red Rock Dam was built
primarily for flood control, with recreation as an additional benefit. One of
the major challenges was to construct the
facility without having any impact on the
existing operation, he said. Because of the
demands of flood control operations, the
water level at Red Rock can fluctuate up
to 40 feet through the course of the year,
meaning the construction site is sometimes
completely dry and sometimes flooded. It
changes all the ways you would approach
building the project.
Like many other potential projects, RRHP
is being built at a USACE dam. That adds
another level of regulatory scrutiny, Watt
said. In design and construction of these facilities, we had to make sure that we satisfied
the Corps of Engineers concerns and requirements when it comes to any impact we might
have had on their structures.
Those concerns may be getting some
revision. In July, the USACE updated its
policy guidance on requests to modify
USACE-owned facilities under Section 408.
In it, the USACE says that USACE and
[the Federal Energy Regulatory Commission (FERC)] have agreed to work with each
other and with other participating agencies
or entities, as appropriate to ensure that
timely decisions are made and that the responsibilities of each agency are met. The
updated guidance extends not just to conventional hydropower projects but also to
non-conventional facilities such as hydrokinetic generation (which relies on natural
flow rather than a hydraulic head) that could
be added to jetties, levees, and navigational
channels.
Other policy support may be on the way
was well. In 2011, the Obama Administration launched the Federal Infrastructure
Permitting Dashboard, which is designed
to expedite the licensing process for critical infrastructure projects that will create
a significant number of jobs, have already
identified necessary funding, and where
the significant steps remaining before construction are within the control and jurisdiction of the federal government and can
be completed within 18 months. While the
list includes several wind and solar generating facilities, RRHP is so far the only hydropower project to receive such expedited
review. Hydropower backers are hoping the
success of RRHP will lead to others.
Storage Wars
Perhaps the biggest growth area for North
American hydro is pumped storage, Finis
said. One of the great drivers for these projects is going to be the integration of renewable energy resources.
In terms of storage options, pumped storage hydropower reigns supreme in terms of
how much capacity it can add to the grid with
existing technology. That means big potential
in areas with a lot of renewable capacity being added.
We are seeing quite an interest in development of storage projects right now in the
U.S., Finis said.
One of those projects is taking shape in
Northern California. The Sacramento Municipal Utility District (SMUD) is conducting feasibility testing for a 400-MW pumped
storage facility that would be added to its
existing Upper American River Project near
Lake Tahoe. The Iowa Hill plant would add
a storage pond 1,200 feet above a bend in
the existing Slab Creek reservoir. The $800
million project could begin construction as
soon as 2018 if SMUD decides to proceed.
An even larger pumped storage project is
planned for Southern California, on the site
of an old iron mine near Joshua Tree National Park. The 1,300-MW closed-loop facility
would convert the old mining pits into storwww.powermag.com
No Silver Bullet
Despite the advantages, getting backers for
hydropower projects in the current environment can be tricky, Finis acknowledged.
Hydro is still facing some challenges when
it comes to financing.
There are a couple of factors behind this,
he explained. One is the longer period for
FERC licensing for hydro generation, which
can take three to five years. However, changes in the law in 2011 are intended to expedite
development at unpowered dams like Red
Rock. FERC has now been directed to consider a shortened two-year licensing process
for such facilities.
The long licensing period stands in stark
contrast to how long it actually takes to
build small retrofits. In especially favorable sites, the plant can be up and running
in less than a year. The 6-MW Mahoning
Creek Hydroelectric Project at Mahoning
Creek in Armstrong County, Pennsylvania,
began construction in March 2013 and was
online by December. The project, retrofitted to a flood control dam built in 1941,
was developed by Enduring Hydro, an investment and development firm that specializes in small hydropower.
Another roadblock is the larger upfront
costs compared to equivalent natural gas
generation. To develop hydro, you really
have to have more of a long-term outlook,
Finis said, and focus on the lower levelized
cost of energy over the project lifetime.
Youll have more cost on the O&M side,
replacement side, and fuel side with other
technologies that you dont necessarily have
with hydro.
This is an important advantage when you
consider the much longer lifespan for a hydro
plant compared to a gas plant: Some hydro
projects in the U.S. have been reliably generating electricity for more than 100 years.
The look of the hydro sector may be
evolving, but all signs are that its legacy will
continue.
LAS VEGAS, NV
NOVEMBER 5 6, 2014
THE BELLAGIO HOTEL
Speakers Include:
t 5SBWJT,BWVMMB
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t +FOOJGFS$SBOEFMM
4QFDJBM$PVOTFM"UUPSOFZ(FOFSBM
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r wBOENBOZNPSF
www.westernpowersummit.com
From the organizers of ELECTRIC POWER
MERCURY CONTROL
Wet Scrubbers
Wet FGD capture requires high (typically
>90%) levels of mercury oxidation, as oxidized
mercury has much greater solubility in the
scrubber solution. Oxidation occurs naturally
with high-chloride-content coals or can be facilitated by the addition of oxidizing agents to
the boiler coal feed. An alternate method relies
on mercury oxidation as a co-benefit of installation of a selective catalytic reduction (SCR)
module for NOx control. Capital and operating
costs for these options depend on the technology employed and site conditions.
Wet scrubbers are installed on many plants
that burn higher-sulfur eastern bituminous
coals. While these systems typically provide
high native capture of vapor-phase mercury,
most cannot consistently meet the MATS standard. In addition to coal oxidation additives
noted above, wet FGD units sometimes employ
62
Powdered Sorbents
Dry sorbent injection captures mercury on
fine particulates added to the flue gas after
the economizer, typically either upstream or
downstream of the air heater. The mercurycontaining particles are then removed in the
units PCD. Powdered activated carbon (PAC)
and non-carbon sorbents, such as Novindas
Amended Silicates products, are options.
PAC is commercially available in standard
and brominated forms, with brominated
materials used where vapor-phase mercury
1. Quick results. The cumulative average of stack Hg emissions during injection of Amended
Silicates AS-HgX for a Powder River Basin (PRB) coal-fired unit are shown here. Courtesy: Novinda
Cumulative average stack Hg
6
5
HgT (lb/TBtu)
AS injection started
4
3
2
MATS limit
1
0
11/1
11/4
11/7
11/10
11/13 11/16
www.powermag.com
11/19
11/22 11/25
11/28
12/1
12/4
12/7
12/10
12/13
MERCURY CONTROL
Amended Silicates
The Amended Silicates family of products employs a non-carbon
mercury capture reagent that removes mercury via chemical reaction,
providing economic and environmental advantages unavailable with
carbon-based products.
Amended Silicates employs a bentonite clay substrate amended
with a metal sulfide that acts as the reagent to capture mercury. This
occurs via a chemical reaction that forms mercuric sulfide on the reaction sites of particle surfaces in flue gas. Mercuric sulfide (cinnabar
in its naturally occurring state) is the most stable form of mercury and
the dominant mercury mineral in Earths crust.
Amended Silicates directly reacts with elemental and oxidized
mercury to form stable, sequestered mercury compounds on the surface of the amended clay particles. This means that oxidizing coal
additives or wet scrubber re-emission chemicals are not needed to
maintain compliance with MATS, making Amended Silicates a single-product solution. Fly ash samples containing collected Amended
Silicates particles have been subjected to the EPA Method 1311 TCLP
test, and leachable mercury has been found to be nondetectable, a further indication that the mercury is sequestered as an insoluble solid.
FROM
ENGINEERING
ANALYSIS TO
ADVANCED NDE,
LOOK TO
STRUCTURAL
INTEGRITY
Balance-of-Plant Impact
Other benefits of Amended Silicates bentonite clay substrate include
compatibility with continued sale of fly ash as a replacement for Portland cement. (PAC typically contaminates the fly ash, requiring landfill disposal.) Novindas Amended Silicates has passed ASTMs C618
(877-4SI-POWER)
8 7 7 - 4 7 4 - 7 6 9 3
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63
MERCURY CONTROL
2. Meeting targets. Test results show the effectiveness of AS-HgX on cumulative stack
mercury in a PRB plant equipped with a circulating dry scrubber. Courtesy: Novinda
Cumulative average
0.030
0.025
0.020
0.015
0.010
0.005
0.000
5/2
5/4
5/6
5/8
5/10
Economics
Due to its efficient capture of mercury and
64
5/12
5/14
5/16
5/18
5/20
one-product solution in certain plant configurations, Amended Silicates generates significant cost savings for many users. Details for
several cases are presented here.
Comparative economics for a baseload
(90% availability) 110-MW unit burning
PRB coal are shown in Table 1. This unit is
equipped with SCR, a spray dryer absorber,
and a pulse-jet baghouse for particulate control. In addition to AS-HgX, brominated PAC
was tested in this unit, both as the sole mercury control sorbent and in combination with
calcium chloride (CaCl2) added to the coal as
a mercury oxidizer. AS-HgX met the pending
MATS emissions standard with a 20% margin
at an injection rate of 30 lb/hr (1.3 lb/MMacf)
while a higher rate was needed for brominated PAC. The simultaneous addition of CaCl2
to the coal feed allowed for a reduced brominated PAC injection rate, but the combined
costs were still higher than AS-HgX. Use of
Novindas AS-HgX is projected to save the
utility 63% to 70% of the mercury abatement
costs of the brominated PAC alternatives.
Carbon Footprint
Amended Silicates products provide a number of important environmental benefits
when compared to the use of PAC. In light
Injection rate
Meets MATS?
BrPAC + CaCl2
Yes
Cost/hour
$89.50
Annual
$705,618
BrPAC only
100 lb/hr
Yes
$110.00
$867,240
AS-HgX
30 lb/hr
$33.00
$260,172
Table 2. Comparative economics for 760-MW unit burning eastern bituminous coal. Annual costs do not include the effect on revenue from fly ash sales and
avoided disposal costs. Source: Novinda
Case
Product
Multi-product
solution
Concrete-friendly
PAC
1,000
$1.10/lb
Hydrated lime
3,000
$0.0625/lb
CaBr2
Novinda
single-product
AS-HgX
www.powermag.com
400
1,000
Product cost
$0.90/lb
Cost/hour
Annual cost
$1,100.00
$187.50
$360.00
Total
$1,647.50
$3,069,504
$1.10/lb
$1,100.00
$1,695,936
MERCURY CONTROL
Table 3. Comparative economics for a 315-MW unit burning eastern bituminous coal. Source: Novinda
Case
Product
Multi-product
solution
SO3-tolerant PAC
Hydrated lime
CaBr2
Novinda
single-product
AS-HgX
Product cost
330 (est.)
$1.10/lb
Cost/hour
Annual cost
$363.00
1,200 (est.)
$0.0625/lb
$75.00
400
$0.90/lb
$360.00
Total
$438.00
$3,069,504
$1.10/lb
$242.00
$1,695,936
220
assumption that only 50% of fly ash is reused and the same Amended Silicates 10%
market usage with an average Amended
Silicates content of 1% in the fly ash.
A Cost-Effective Solution
Jim Butz is vice president product management for Novinda Corp. in Denver.
MATS
Compliance
Group
s premium
product showcase for
the latest products
and technologies in
the power generation
industry.
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65
REGULATIONS
GHG RULES
New power plants. The Environmental Protection Agency (EPA) in September 2013
EPA
revised a 2012 proposal to limit carbon emissions from new coal- and natural gasfired
power units. The New Source Performance Standards developed under Section 111(b) of the
Clean Air Act (CAA) require new gas plants of 100 MW or more to emit no more than 1,000
pounds of carbon dioxide/MWh of power produced (as achievable with the latest combined
cycle technology), but calls for smaller gas plants to achieve a less-stringent standard of
1,100 pounds CO2/MWh. Coal plants can either use carbon capture and storage technology
soon after startup (to achieve a 12-month average emission rate of 1,100 lb CO2/MWh) or
after seven years of startup to achieve a seven-year average emission of between 1,000 and
1,050 lb CO2/MWh.
Existing power plants. As directed by President Obamas Climate Action Plan, the EPA on June 2
proposed its Clean Power Plan emissions guidelines for existing power plants under the CAA Section
111(d). The proposal sets state-specific, rate-based goals and relies on four building blocks to
establish the best approach for each state to slash power sector CO2 emissions by 30% from 2005 levels
by 2030.
BACT for GHG emissions. The U.S. Supreme Court on June 23 reversed the EPAs Tailoring Rule but
affirmed the agencys authority to regulate greenhouse gases (GHGs) under the CAAs Prevention of
Significant Deterioration permit program. Specifically, the high court said the EPA could permissibly
require sources that are obligated to obtain permits anyway (because of their emission of non-GHG
pollutants) to adopt GHG Best Available Control Technology (BACT).
EPA
The U.S. Court of Appeals for the D.C. Circuit on Apr. 15 upheld MATS, rejecting numerous
challenges from industry, states, and environmental petitioners. Over July and August, at least
23 states and two energy industry groups petitioned the U.S. Supreme Court to review the
decision, arguing the rule would drive up power prices and harm the coal industry. The rule
requires all existing coal- and oil-fired power units to meet specific, numeric emission limits
for mercury, particulate matter, and acid gases by Apr. 15, 2015, unless granted a one-year
extension.
EPA
The U.S. Supreme Court on Apr. 29 reversed and remanded the D.C. Circuits 2012 decision that
vacated CSAPR. The high court concluded that the EPAs approach in issuing the CSAPR as a
federal implementation plan first was lawful. However, the D.C. Circuits stay of CSAPR remains
in effect, and the case now goes back to the appeals court to address substantive issues left
open by the Supreme Court. More legal process is required before CSAPR is put back into
effect, including certain debate over timing and compliance deadlines.
66
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EPA
The agency on Aug. 15 published its final rule establishing requirements under Section 316(b)
of the Clean Water Act for all existing power generating facilities that withdraw more than two
million gallons per day of water and use at least 25% of the water they withdraw exclusively
for cooling purposesabout 540 power plants. The rule goes into effect on Oct. 14, 2014.
REGULATIONS
EPA
EPA
EPA
OZONE STANDARD
A federal court this April ordered the EPA to propose primary and secondary national
ambient air quality standards for ozone by Dec. 1, 2014, and finalize them by October
2015. The rules last revision in 2008 set the ozone standard of 75 parts per billion
(ppb). But before the EPA could finalize a rule proposed in 2010 to set a stricter standard of between 60 ppb and 70 ppb, President Obama in 2011 scuttled the rule to
reduce regulatory burdens and uncertainty. An August-released EPA final policy assessment provides strong support for revising the standard within the range of 60 ppb to
70 ppb.
EPA
NRC
FERC
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67
Training Professionals
Wanted
GP Strategies, a global leader in performance
improvement, is seeking qualified subject
matter experts to fill director level positions
to lead power plant operations and
maintenance training programs for our 200+
global energy customers.
Ideal candidate will have:
4-year engineering degree / B.S.
in related field of study
5+ years experience in coal-fired
power plants
Professional engineering
license preferred
FOR SALE/RENT
24 / 7 EMERGENCY SERVICE
BOILERS
20,000 - 400,000 #/Hr.
POWER PROFESSIONALS
Opportunities in Operations and Maintenance,
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First-line Supervision to Executive Level Positions.
Employer pays fee. Send resumes to:
P.O. Box 87875
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email: dwood@powerindustrycareers.com
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FAX: 847-541-1279
WEB SITE: www.wabashpower.com
wabash
Turbine Controls
Woodward, GE, MHC
Parts and Service
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READER SERVICE NUMBER 206
LM2500
FT4
OTHERS
68
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otluFsurksgyzkx4ius
EQUIPMENT CO.
CAREERS IN POWER
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SurkSgyzkx"ngy"g"skjog"
hrgyzotm"yur{zout"lux" u{4
POWER
E&I TECHNICIAN A
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2. Scope of work
3. Requirements
t
t
t
t
4. Mode of Application
5. Entry closure
Entries close on the 28th of November 2014
READER SERVICE NUMBER 208
Layup Desiccant
Dehumidification
& Filtration Units
for long term layup
of power generation
equipment. For over
35 years of drying
solutions contact:
Tom Haarala
612-202-0765
thaarala@cdims.com
Todd Bradley
810-229-7900
tbradley@cdims.com
www.cdims.com
AlliedEng_classad.indd 1
9/30/14 12:17:49 PM
George H. Bodman
Pres. / Technical Advisor
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69
ADVERTISERS INDEX
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Beumer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 . . . . . . . . 5
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Hawk Measurements America . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 . . . . . . . .19
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Rentech. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cover 2 . . . . . 1
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Cormetech . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 . . . . . . . .20
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Sealeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 . . . . . . . . 7
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Doosan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . . . . . 2
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Hach.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 . . . . . . . .13
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Hadek . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 . . . . . . . .12
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Safety in the Power
Generation Workplace
This guidebook exclusively features articles detailing actions that must be
taken for a safe working environment in the Power Generation Industry.
Included are full charts, photographs, graphs and step-by-step
instructions, brought to you by the editors of POWER magazine.
Delivered in a PDF format.
Articles Include:
Safety Is Not an Accident
Fire Safety in Modern Hydroelectric Stations
Suing for (Pipeline) Safety
Plant Safety: Learn from the
Mistakes of Others
Safety i
Generation the Power
n Wo r k p l
ace
COMMENTARY
Collaborating to Build a
Cleaner Energy Infrastructure
Kelly Speakes-Backman
very day there is increasing evidence that we need to accelerate our nations transition to a cleaner energy infrastructure. The American Climate Prospectus released by
the Risky Business Project states that a business-as-usual approach to energy use creates serious economic risks. The U.S.
Environmental Protection Agency (EPA) recently proposed a new
rule requiring states to reduce carbon pollution from the nations
existing power plants. The Obama Administration has issued its
Fifth National Climate Assessment, asserting that climate change
and its effects are present today, not some time off in the distant future.
Whether we are ready or not, we are faced with circumstances that require action. Fortunately, we have powerful tools at
our disposal to take that actiontools that industry and state
governments can use together to reduce carbon pollution and
hasten our transition to a cleaner energy infrastructure, at the
lowest possible cost.
Several proven cost-effective tools for accelerating this transition are already in practice. Renewable portfolio standards,
energy efficiency policies, green banks, building codes and standardsthese and other programs have demonstrated that we
can develop our clean energy infrastructure without detriment
to grid reliability or the economy.
www.powermag.com
www.mhpowersystems.com
www.psa.mhps.com
power.info@psa.mhps.com
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