2015 08 Power Engineering
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The document discusses recent positive developments for renewable energy in June, including major financial commitments from investors, foundations, and governments. Bill Gates and Softbank committed billions more for clean technology investments. A growing number of large investment firms plan to invest in solar projects due to confidence in returns and a desire to support clean energy. China committed to reduce emissions and increase non-fossil fuel energy use, joining new commitments from other nations ahead of climate talks. Rapidly improving economics and technology are driving momentum for renewables as costs drop and targets increase around the world.
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of multiple, parallel flow modules each
containing thousands of spaghetti-like,
hollow-fiber membranes.
The membranes must be regularly
backwashed every 10 to 20 minutes
or thereabouts to remove particulates.
The backwash flow path is the reverse
of the normal flow path. In this par-
ticular case, conversion of the mem-
branes from inside-out to outside-in
normal flow path greatly improved the
backwash efficiency.
Another interesting initial difficul-
ty was noted with the UF backwash
process. Typically with these systems
a small portion of the permeate is col-
lected in a separate tank at the begin-
ning of each process cycle for use in
backwash. So far, so good. But most
modern MF and UF units are now
equipped with automatic chemical-
ly-enhanced backwash (CEB) systems.
After a certain number of cycles, a
CEB backwash kicks in where first the
membranes are cleaned with a dilute
caustic/bleach solution to remove or-
ganics and microbiological organisms,
followed by rinsing and then a dilute
citric acid wash to remove iron partic-
ulates. When this UF was first com-
missioned and CEB backwashes com-
menced, the membranes developed a
layer of calcium silicate during the CEB
caustic stage. The driving force was
the higher pH generated by the caus-
tic, which in turn greatly reduced the
silicate solubility. The solution to this
problem was a switch to softened water
for the backwash supply.
CONCLUSION
This article hopefully illustrated many
of the threads between the water treat-
ment processes at new power plants.
Complex scenarios may arise due to wa-
ter chemistry issues and discharge reg-
ulations. Processes must be viewed and
designed in a holistic manner and not
piecemeal. Accurate and historical water
quality data is an absolute must for de-
signing reliable systems.
feed and a degasifier to lower bi-
carbonate alkalinity.
Under proper conditions, the RO
recovery rate may reach 90 percent.
The RO permeate recycles to the plant
high-purity makeup water system or oth-
er locations. However, while the process
appears straightforward, a number of
lessons-learned have emerged regarding
this technology in actual application.
The following lessons are taken from a
HERO system operating at a power plant
near the Pacific Northwest. One of the
most notable examples for any of these
systems is that some standard water
treatment chemicals may foul the UF
membranes. Operating experience indi-
cates that the membrane manufacturer
and type greatly influence this phenom-
enon. Fouling is induced because mem-
branes typically carry a negative surface
charge while often cationic polymers
are employed for coagulation or floc-
culation. Residual cationic polymer is
strongly attracted to the membranes. A
very similar phenomenon has been ob-
served with MF or UF systems installed
in makeup water systems downstream of
a clarifier. Inexperienced designers and/
or plant personnel have not always rec-
ognized that MF or UF should generally
serve as a replacement for clarification,
not a polishing process for the clarifier.
A straightforward solution that has
significantly improved the reliability of
this particular system is conversion of
the ultrafilter from an inside-out nor-
mal flow path to outside-in. Typical
micro- and ultrafilter systems consist
helps to overcome the boiling point rise
that occurs in conventional units as the
dissolved solids concentration increases.
Considerable energy savings appear pos-
sible with the vacuum systems.
Becoming popular are treatment meth-
ods to reduce the volume of the plant
waste stream before final treatment. Most
notable is high-recovery reverse osmosis.
This schematic outlines the HERO pro-
cess, which is licensed by such firms as
Aquatech, GE, and U.S. Water, while Veo-
lia supplies their Opus technology, which
may also include high-rate softening/clar-
ification as a unit operation. Keys to the
process are:
• Microfiltration (MF) or ultrafiltra-
tion (UF) to remove suspended sol-
ids in the waste stream. This is a
critical process to prevent suspended
solids from fouling reverse osmosis
(RO) membranes.
• Sodium bisulfite (NaHSO3) feed
to remove residual oxidizing bio-
cides. This is also critical to remove
oxidizers that would degrade soft-
ener resin and RO membranes.
• A sodium softener to remove cal-
cium and magnesium. Otherwise
the downstream equipment would
suffer from calcium carbonate and
magnesium silicate scaling.
• Sodium hydroxide injection to ele-
vate the pH above 10. (The combi-
nation of hardness removal and pH
elevation keeps silica in solution.)
• Two-pass reverse osmosis (RO)
treatment.
• Some systems may include acid
Source:
Pollutant Maximum for any 1 day
Average of daily
values for 30 consecutive
days shall not exceed
Arsenic,total (µg/L) 8 6
Mercury,total (ng/L) 242 119
Selenium,total (µg/L) 16 10
Nitrite/nitrate (mg/L) 0.17 0.13
Proposed ELG for FGD Wastewater
Best Technology Available [1] 2](https://image.slidesharecdn.com/201508powereng-160314132843/85/2015-08-Power-Engineering-49-320.jpg)
2015 08 Power Engineering
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- 2. YEARS 119 DEMAND RESPONSE WHAT’S DRIVING THE MARKET? HRSG WASTEWATER TREATMENT METHODS VALVES & ACTUATORS UNDERSTANDING YOUR OPTIONS Advanced Class Gas Turbines August 2015 • www.power-eng.com
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- 4. CHIEF EDITOR — Russell Ray (918) 832-9368 russellr@pennwell.com ASSOCIATE EDITOR — Sharryn Dotson (918) 832-9339 sharrynd@pennwell.com ASSOCIATE EDITOR — Tim Miser (918) 831-9492 tmiser@pennwell.com CONTRIBUTING EDITOR—Brad Buecker CONTRIBUTING EDITOR—Brian Schimmoller CONTRIBUTING EDITOR—Robynn Andracsek CONTRIBUTING EDITOR—Wayne Barber (540) 252-2137 wayneb@pennwell.com CONTRIBUTING EDITOR—Barry Cassell (804) 815-9186 barryc@pennwell.com GRAPHIC DESIGNER — Deanna Priddy Taylor (918) 832-9378 deannat@pennwell.com SUBSCRIBER SERVICE P.O. Box 3264, Northbrook, IL 60065 Phone: (847) 763-9540 E-mail: poe@halldata.com MARKETING MANAGER — Rachel Campbell (918) 831-9576 rachelc@pennwell.com SENIOR VICE PRESIDENT, NORTH AMERICAN POWER GENERATION GROUP — Richard Baker (918) 831-9187 richardb@pennwell.com NATIONAL BRAND MANAGER — Rick Huntzicker (770) 578-2688 rickh@pennwell.com CHAIRMAN — Frank T. Lauinger PRESIDENT/CHIEF EXECUTIVE OFFICER — Robert F. Biolchini CHIEF FINANCIAL OFFICER/SENIOR VICE PRESIDENT — Mark C. Wilmoth CIRCULATION MANAGER — Linda Thomas PRODUCTION MANAGER — Katie Noftsger POWER ENGINEERING, ISSN 0032-5961, USPS 440-980, is published 12 times a year,monthly by PennWell Corp.,1421 S.Sheridan Rd.,Tulsa, OK 74112; phone (918) 835-3161. ©Copyright 2015 by PennWell Corp. (Registered in U.S. Patent Trademark Office). All Power Engineering published content is copyright protected by law. PennWell Corporation must grant proper authorization to reuse any article, photograph or illustration. Foster Printing is the exclusive reprint provider for Power Engineering and gains copyright permissions for published content. For copyright permissions, call 866-879-9144 x194. Prior to photocopying items for educational classroom use, please contact Copyright Clearance Center, Inc., 222 Rosewood Drive, Danvers, MA 01923 USA 978-750-8400. Periodicals postage paid at Tulsa, OK and additional mailing offices. Subscription: U.S.A. and possessions, $111 per year; Canada and Mexico, $124 per year; international air mail, $300 per year. Single copies: U.S., $18, Outside U.S. $29. Back issues of POWER ENGINEERING may be purchased at a cost of $18 each in the United States and $29 elsewhere. Copies of back issues are also available on microfilm and microfiche from University Microfilm, a Xerox Co., 300 N. Zeeb Rd.,AnnArbor,MI 48103.Available on LexisNexis,Box 933,Dayton, OH 45402; (800) 227-4908. POSTMASTER: Send change of address, other circulation information to POWER ENGINEERING, PO Box 3271, Northbrook, IL 60065-3271. “POWER ENGINEERING” is a registered trademark of PennWell Corp. Member American Business Press BPA International PRINTED IN THE U.S.A. GST NO. 126813153 Publications Mail Agreement No. 40052420 CORPORATE HEADQUARTERS—PennWell Corp. 1421 South Sheridan Road • Tulsa, OK 74112 P.O. Box 1260, Tulsa, OK 74101 Telephone: (918) 835-3161 • Fax: (918) 831-9834 E-mail: pe@pennwell.com World Wide Web: http://www.power-eng.com Power Engineering® Power Engineering is the flagship media sponsor for FEATURES 119VOLUME POWER ENGINEERING ONLINE : www.power-eng.com Newsletter: Stay current on industry news, events, features and more. Newscast: A concise, weekly update of all the top power generation news Industry News: Global updates throughout the day DEPARTMENTS 2 Opinion 4 Gas Generation 6 View on Renewables 8 Energy Matters 10 Nuclear Reactions 48 Ad Index 18 A New Era of Demand Response Demand response capability in North America has grown considerably in the past five years,both at utilities and within competitive markets.Learn how the use of DR in grid planning and operations has solidified as utilities rely on DR to meet installed capacity requirements and operating reserve requirements. 36 Valves & Actuators Power plants use hundreds of valves and actuators as the final control elements in their operations.Power Engineering examines the different types of valves and actuators and the advancements that are allowing them to operate at higher pressures,temperatures,and frequency. 28 Dense Slurry Coal Ash Management: Full Compliance, Lower Cost, Less Risk New CCR and ELG rules promise to significantly impact waste management in the coal-fired power industry.Learn how the Circumix™ Dense Slurry System mixes wastewater with CCRs to produce a stable product with near-stoichiometric use of water. 42 Water’s Journey More than ever,waste water from power plants must be viewed holistically,from the beginning of its journey through the facility, all the way to its final discharge.Learn how increasingly stringent wastewater regulations are forcing plant personnel to consider complex treatment methods to comply with regulations. 12 The Fall of the F-Class Turbine For the first time in over 20 years,F-Class turbine technology no longer commands majority share in the NorthAmerican 60-Hz, heavy-duty gas turbine market.Find out why the trend toward G-,H-,and J-class turbines is here to stay. No.8,August 2015
- 5. 2 OPINION www.power-eng.com prices dropping 48 percent by 2040. Talk about a tipping point. These new economic dynamics, along with other technology and cost advances particularly in energy storage, are why states, cities, corporations, and nations can now set once-unthinkable targets forgenerationfromrenewableswithout breaking the bank. In more news from the month of June, Hawaii (100 percent by 2045) and Vermont (75 percent by 2032) both signed unprecedented renewable portfolio standards into law. And in California, the state senate passed Gov. Jerry Brown’s goal of 50 percent renewables generation by 2030. It now awaits expected approval by the state assembly. Policy drivers like these will continue to be critical to drive the growth of renewables. In one piece of bad news on the policy front at the end of June, the U.S. Supreme Court issued a key ruling against EPA regulation of mercury emissions from coal-fred power plants. It’s certainly not a good development for the environment, but unlike what I’ve read in various media accounts, it does not directly affect CO2 regulation such as the EPA’s Clean Power Plan. The court’s ruling does not change the fundamental economics of energy: coal is simply no longer a cost-effective choice for new generation in the U.S. and increasingly, overseas as well. Compared to the much larger trends in fnance and policy that are driving the momentum of renewables, many of which came to the fore in June, I predict that this SCOTUS decision will be a blip on the radar. L ast month, we Americans cel- ebrated our nation’s birthday, capped off perfectly by the USA women’s soccer team’s sensational 5-2 victory in the World Cup final. As we hit the halfway point of 2015, the clean-energy industry also has much to celebrate, much of it in the month of June alone and much of it financial. Consider all of these recent developments: • The White House announced $4 billion in clean-energy funding commitments, including $1.1 bil- lion from five large institutional investors such as the University of California and TIAA-CREF, with the balance from major founda- tions and nonprofits. • Bill Gates quite literally doubled down on financing innovative renewables technologies. The software mogul-turned-clean en- ergy investor told the Financial Times he would add an additional $1 billion over the next five years to his $1 billion already invested in clean-tech companies and the venture capital firms that back them. • Another tech mogul, Masayoshi Son of Japanese telecom giant Softbank, went even further. Al- ready a major funder of large solar energy projects in Japan, Softbank committed $20 billion for solar in India — aiming to help grow that market to 100 GW in 2022 from 3 GW today. • Sixty percent of large investment firms plan to invest in solar pow- er projects for the first time in the next five years (including 32 per- cent in the next year), according to a survey released in June by solar PPA market maker Wiser Capital. Eighty percent said they want to “support a clean-energy future” and more than 60 percent are con- fident in the chances of high ROI. At the end of June, China upped its commitment to reduce greenhouse gas emissions by 60-65 percent from 2005 levels by 2030, including a goal to receive 20 percent of its primary energy from non-fossil fuels by 2030. The announcement was part of a slew of new GHG cut commitments from the U.S., Brazil, and South Korea, in advance of the United Nations climate talks in Paris later this year. A great driver of all of this recent momentum is the rapidly changing economics of clean energy. Headlines about record-low prices for solar and wind power in a myriad of regions appear almost daily. To cite just two examples, Michigan utility DTE Electricity has asked regulators to approve a rate cut because of falling wind prices in the state, while Austin Energy, seeking to procure 600 MW of solar in Texas, received developer bids at less than 4 cents per kilowatt-hour. Those are just two examples of a broad-based global trend that shows no signs of slowing down. A June report from Bloomberg New Energy Finance predicts that wind power will become “the least-cost option almost universally” within 10 years, with prices falling 32 percent by 2040. And solar will join wind as cheaper than fossil fuel-fred energy by 2030, with Fireworks, a World Cup, and Clean Energy MomentumBY CLINT WILDER, CLEAN EDGE Author Clint Wilder is senior editor at clean-tech research and advisory frm Clean Edge and the coauthor of two books: “Clean Tech Nation: How the U.S. Can Lead in the New Global Economy” and “The Clean Tech Revolution.”
- 7. 4 GAS GENERATION www.power-eng.com I was surprised to learn that an ul- tra-complex bit of precision engineering, with a final price tag that can reach many millions of dollars, would ultimately de- pend on good old-fashioned air to keep itself from melting down onto the boots of the engineers. “The air-cooled version of the turbine is just much simpler and more cost-effec- tive,” Abate told me. “The steam-cooled turbine was technical- ly elegant, but it was expensive to operate. Air cooling makes the turbine cheaper to maintain because there are no steam circuits to tear down before accessing key components. That adds up to lower life cycle costs.” In fact, air-cooled turbines are very common in the industry. While air- cooled designs do require hot air to be extracted from the gas turbine to cool hot-path components, and the theft of this heat can compromise their overall efficiency, they can still be preferable to steam-cooled designs which do not incur such performance penalties, if only for their simplicity and lower operation and maintenance costs. So what’s old is new. It turns out GE’s turbines are far from the only ones in the industry to rely on such tried-and- true engineering; Siemens and Alstom (among others) also produce air-cooled gas turbines, and it’s safe to bet that other companies are right now putting new air- cooled designs through the paces in R&D labs across the world. I guess sometimes simpler really is better. W hen I was a teenager, I dat- ed a girl whose parents wouldn’t let her dress grun- ge. Having grown up in another era, her mom couldn’t understand the movement I suppose, and she flatly outlawed such foolishness in the house. Did people real- ly wear plaid flannel and cut holes in their jeans intentionally? The whole episode became a major problem for us. (Actually, it created an existential crisis worthy of Kierkegaard’s storied prose.) Admittedly, it was the mid-nineties, and Nirvana had been over and done with for a couple years. But fashion moves more slowly in a little farm town, and grunge was still very much in vogue where we lived. Not to worry though. This was no av- erage girl, and she quickly found an en- terprising solution to her problem. If she couldn’t dress grunge, she would find an- other counter-cultural fashion statement that her mom could relate to, and drag it kicking and screaming into the modern era. She would dress like a hippy. This girl was committed. We’re talking full-on Haite and Ashbury here. It was a circus! But come on, dressing like an anachro- nistic hippy? That’s so amateurish, and we were better than that. Enter the mid-60s Volkswagen Beetle. Yes, as it happened, the neighbor up the road was selling his pitiful little bug for a pittance, so my girlfriend paid the few hundred dollars he was asking and drove it home that weekend. It was baby blue, and that afternoon she sent away for the mandatory flower decals to stick on the hood. She let me drive it a time or two. You had to stand on the clutch to shift into reverse, but other than that it handled like a dream—a fever-fueled, hallucinogenic nightmare of a dream. We drove that thing up and down the back roads all over the county. It was awe- some…and terrifying. Here’s a hint though. If you’re going to park your cranky geriatric bug at the local drive-in burger place, shut the engine off. Turns out vintage Beetles were air-cooled, and idling one in a stationary position long enough to eat a double quarter-pound- er with cheese will ren- der it hotter than an Oklahoma July. Can I really be the only per- son in the world who didn’t already know this? Next someone will try to convince me that VW put the trunk in the front of the blasted thing. A few years ago I learned Volkswagen would be ending the manufacture of their original air-cooled masterpiece. Sure, the company had already come out with a re- placement—the “new” Beetle—but it was thoroughly modern and water-cooled, so it wasn’t the same. Yes, it seems the evolu- tion of internal combustion engines has unfailingly included an upgrade from air- cooled to fluid-cooled systems. But not so with natural gas-fired turbines, it seems. Last year, I had the pleasure of speaking with Victor Abate, president and CEO of power generation products at GE Power & Water. We were talking about GE’s HA turbines, which are among the largest and most efficient in the world. Unlike GE’s previous H-class turbines which utilized steam cooling, GE’s new HA turbines rely on air for temperature regulation. (The “A” stands for air, in fact.) Economy from Thin AirBY TIM MISER, ASSOCIATE EDITOR Air cooling makes the turbine cheaper to maintain because there are no steam circuits to tear down. - Victor Abate, GE
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- 9. 6 VIEW ON RENEWABLES www.power-eng.com capacity limits and are struggling with T&D networks critically in need of up- grades. The world may not be entirely ready to change the way it sources electricity. It will need to get ready because the conven- tional energy status quo needs to adjust rapidly in order to realize true energy in- dependence for all. True energy indepen- dence will not rely 100 percent on the electricity grid and it will look a lot more like off grid solar. The current focus on mi- cro grids, under the defi- nition that micro grids include storage, is the off grid model. True inde- pendence will encourage electricity conservation and include edu- cating electricity users about the photo- voltaic/storage systems that allow them to decouple from the utility grid when necessary. The slow, messy changing of the elec- tricity guard will also include altering the antiquated concept of what utilities are and what utilities should provide. De- ployment of PV is often antithetical to the utility model – simply put, it cuts into the utility revenue model. The slow messy changing of the electricity guard will force electricity users to become responsible for their electricity future and this is not a bad thing. All industrial and technological changes cause seismic ruptures in the status quo and this one will be no dif- ferent. The results of this change will be a seismic correction. C onventional energy technolo- gies and investors in big oil, nat- uralgasandcoalarehighlyresis- tant to letting insurgent renewable energy technologies such as solar and wind take the lead. No matter, squint your eyes and the energy future with renewable energy as the dominant technology is visible over the horizon – hazy and still a bit far off, but visible. Currently, renewable ener- gy’s share of global energy production is a fraction of conventional energy’s share but change is slowly taking hold despite well-funded resistance to it. The global photovoltaic industry has a leading role to play in this messy chang- ing of the energy guard. It’s been playing a role for decades, though it has seldom been easy and rarely highly profitable. Viewed simply through the lens that growth is always good, decades of neg- ative or low margins could be written off as the price of gaining share, though it should be remembered that PV has a very small share of global electricity production. There is another perspective with which to view decades of PV industry behavior, that of courageous persever- ance in the face of well-funded (con- ventional energy) competition. This perspective is also true. Photovoltaic industry participants have persevered through slap dash and unreliable in- centives, drastic, abrupt and some- times retroactive changes to incentives, end users waiting for the technology to mature and many others miss or poor understandings of the technology and industry. In truth, the global photovoltaic industry has persevered through decades of double digit growth and decades of fi- nancial struggle. The availability of government legis- lated incentives is a fragile and unreliable thread on which to hang the hopes and dreams of an entire industry. Sudden and retroactive changes have broken the hearts and bank balances of many a PV industry participant. Yet, deployment often contin- ues despite the cessation of an incentive primarily because, simply, it must. It would be more fiscally devastating than many realize if deployment ceased abruptly. There is significant inventory on demand and supply sides of the solar industry and if deployment ceased, it would become even more of a burden. Jobs would be lost. Research and development would stall. Continued deployment, however, is different from profitability. Incentives are expensive to support, and when governments in Europe be- gan pulling the incentive-rug out from under the PV industry this, along with fallout from pricing set below cost, stimulated an industry-wide consol- idation that included the failure of many well-known and industry lead- ing companies. Currently with deployment of renew- ables (and PV) encouraged by govern- ments and end user interest at a high lev- el, utilities are pushing back on continued accelerated deployment while globally, utility grids have been pushed to their The Slow, Messy Changing of the Electricity Guard BY PAULA MINTS, SPV MARKET RESEARCH “True energy independence will not rely 100 percent on the electricity grid and it will look a lot more like off grid solar.”
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- 11. 8 ENERGY MATTERS www.power-eng.com design that has tripped up many owners during permitting. Air permits include separate limits when operating with and without duct firing. Typically the max- imum amount of duct firing is set by either the desired amount of peak plant output or the maximum practical design limit. Often, preliminary engineering is completed to estimate the amount of duct firing that is required to achieve one of these limits. Emissions produced during duct firing are calculated based on this heat input. However, the actual required amount of duct firing is determined by fi- nal major equipment OEM selection and thermal cycle design optimization. The fi- nalization of these two decisions is often completed after air permit issuance. This may result in limitations on duct firing capability. In this case, it is important that the design engineers determining cycle design and the permitting engineers de- veloping emissions estimates understand and consider the impact various major equipment OEMs and variations in cycle design may have on heat input and asso- ciated permit limitations. Gas turbine technology is evolving at a rapid pace. In the past three years, most of the major gas turbine OEMs have released several performance improvements. Many owners, especially those with proj- ect delays or longer permit approvals, have been caught with air permit require- ments restricting the ability to implement the latest gas turbine technology platform without revising the air permit. The is- sues described above can be mitigated or eliminated when the permitting and the design engineers communicate. Coordination up front can save time and money in the end. T he battle for a good permit be- gins well before the application is submitted, with the initial Front End Engineering Design (FEED) and development of conceptual engineer- ing information used as inputs to permit modeling and development. A lack of communication between per- mitting and design engineers can lead to big problems for a facility, as each group has its own perspective, language, drivers, and needs. Ultimately however, align- ment between permitting and design en- gineers will best serve the long term inter- ests of the facility. Particulate emission limits are a fre- quent sourceofpermitting/designdiscon- nect. A major contributor to condensable particulate matter (PM) is the amount of sulfur in the fuel gas and the amount of oxidation of sulfur dioxide (SO2 ) that oc- curs through the gas turbine combustion process. This occurs throughout the heat recovery steam generator (HRSG) in the selective catalytic reduction (SCR) sys- tem, carbon monoxide (CO) catalyst, and duct burner. The maximum amount of sulfur in the gas may not be easy to define over the life of the plant. Conservatively using the sulfur tariff for the gas pipeline is often too high an assumption and can lead to serious impacts during dispersion modeling, especially considering that the actual gas sulfur content is typically sig- nificantly lower than tariff value. How- ever, owners are often hesitant to rely on past gas supply sulfur levels as a reliable prediction of long term levels, as several shales predict a potential for increasing sulfur content as production areas shift. The type and location of SCR and oxi- dation catalyst impacts the conversion of SO2 to sulfur trioxide (SO3 ) through- out the gas turbine/HRSG train, and the amount of ammonia injection and slip impacts the amount of SO3 in the ex- haust gas that is converted to ammonium bisulfate. Because conversion of SO2 to SO3 is not widely understood, most own- ers are prudent to assume 100 percent conversion of sulfur to particulate when establishing their plant PM limit. Start-up emissions are another area of concern. Actual hot, warm, and cold start- up emission rates are highly dependent on the gas turbine manufacturers (OEM) and starting package selection, the HRSG and steam turbine generator design, OEM selections, the overall steam cycle design, and balance of plant equipment design. “Conventional” start-up times are based on holding the gas turbine at select, low operating loads to allow the HRSG ma- terials to gradually warm. These hold points also provide time for cycle water quality to be brought within specifica- tion before steam can be admitted to the steam turbine. This typically results in the gas turbine operating outside of emissions compliance load during start- up with NOx, CO, and VOC emissions at orders of magnitude higher than during normal steady state operation. An alter- native is to remove the gas turbine low load hold points and reduce the overall startup emissions. It is also important to understand how to appropriately esti- mate start-up emissions for the final plant configuration. Calculation of start-up emissions is not easy. Regardless of major equipment selection, start-up emissions are highly dependent on, and influenced by, the overall cycle design. Duct firing is another element of plant FEEDing the Permitting Beast BY MEGAN PARSONS, BURNS & MCDONNELL, AND ROBYNN ANDRACSEK, P.E., BURNS & MCDONNELL AND CONTRIBUTING EDITOR Megan ParsonsRobynn Andracsek
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- 13. 10 NUCLEAR REACTIONS www.power-eng.com so future leaders can see what may be available to them and how. Line leaders’ routines need to include succession planning, development and coaching in addition to the routines they use to run the plant. Leaders must serve as role models in the time they spend developing their own succession candidates as well as coaching and mentoring others. Leadership development and train- ing programs must be seen as effective by participants and sponsors. Leadership roles at the site need to be viewed as desirable opportunities by potential succession candidates. If not, site leaders need to figure out why. Line leader and HR roles and respon- sibilities should be documented, under- stood clearly and executed accordingly. HR personnel assigned to talent management and leadership develop- ment roles must be highly capable and viewed as effective by line leaders. Assessments of succession candidates and potential leaders need to be con- ducted by trained professionals who understand what nuclear power de- mands from talent to be successful. Decisions about leadership changes and promotions should be made me- thodically, with adequate input from all appropriate parties. Overall program effectiveness re- views need to be conducted regularly, focusing on process, behavior and re- sults. Although these requirements may appear demanding, the more successful utilities are following them and have made strategic decisions to invest in the leadership capabilities necessary to run nuclear plants effectively. T he cover story in the June issue of Power Engineering magazine highlighted the challenges facing the energy, utility and manufac- turing sectors in finding skilled labor as baby boomers retire in greater num- bers. These same challenges are being seen in the supervisor and manager ranks at nuclear power plants across the country. Engineering—more than any other department—appears to be the canary in the coal mine. Engineer- ing organizations are feeling the loss of knowledge and the impact of too many open engineering positions and leadership roles filled by much less ex- perienced engineering supervisors and managers. As U.S. nuclear power plants and their systems age and license exten- sions go into effect, the need for highly capable engineering leadership will in- crease, if anything. Operations departments are not feel- ing as much pain as engineering be- cause sites have been more diligent and proactive in feeding the licensed opera- tor and non-licensed operator pipelines or face being out of compliance with their legal commitments for operating the reactor. Maintenance, work man- agement and training organizations are right behind engineering in struggling to fill open positions with qualified professionals and capable supervisors. As nuclear operating companies make short- and long-term asset man- agement decisions about what equip- ment to replace, fix, or maintain, they need to be making strategic decisions about investing in the talent they need to effectively run organizations as com- plicated as nuclear power plants. On the surface, most nuclear utilities across the U.S. appear to be doing so, in that they have recruiting, assessment, and lead- ership development programs in place conceivably to grow talent and increase leadership effectiveness. But scratch below the surface, and many programs fail to reach a large portion of nuclear power leaders and potential leaders. Leadership training programs may be limited in their effectiveness and/or not available to a large portion of the pop- ulation. Succession planning, critical to focusing developmental activities, too often consist of lists of names repeated too often and discussions concentrated on personality and historical personal references, good and bad. Instead, suc- cession planning discussions need to be regular meetings, supported by the highest levels of leadership, and cen- tered on leadership attributes necessary to be effective. Candidates’ level of read- iness should be based on independent assessments of these attributes, which also serve as a basis for future leaders’ development. Some companies are applying the necessary discipline and rigor to talent development in order to close gaps and grow their own talent, forestalling lead- ership shortages. In my book, Nuclear Energy Leadership: Lessons Learned from U.S. Operators (2013), I offered a checklist that nuclear sites can use to identify where they need to work to improve their talent development capa- bilities: The site must have documented pro- cesses for succession planning, talent management and leadership develop- ment. Leaders need to follow these pro- cesses and communicate about them with the broader management team Strategic Investment in TalentBY MARY JO ROGERS, PH.D. Author Mary Jo Rogers, Ph.D. is a partner at Strategic Talent Solutions. She recently published the book, “Nuclear Energy Leadership: Lessons Learned from U.S. Operators,” by PennWell. maryjo@ strattalent.com.
- 15. 12 www.power-eng.com The Fall of the F-Class Turbine Advanced class turbines such as the M501J are overtaking F-Class turbine technology as the preferred choice for new gas-fired projects.Photo courtesy:Mitsubishi Hitachi Power Systems Americas. BY MICHAEL J. DUCKER temperatures and pressure ratio. As advances were made in materials and cooling technologies, gas turbines were able to fire hotter, resulting in better efficiencies and higher outputs. Design changes in the compressor and tur- bine section were commonly needed, and thus when a manufacturer made improvements significant enough to increase output and efficiency, a new turbine class was born. Although at I t seems oil prices are not the only phenomenon experienc- ing a sudden, and seemingly unexpected, decline from the status quo. For the first time since F-Class turbine technology came to dominate the market over 20 years ago, the technology is no longer the leader in North America 60 Hz heavy duty gas turbine (HDGT) sales. Ad- vanced class turbine (typically defined as G-, H-, and J- class technologies) sales have seen greater than 50 per- cent year-on-year growth in the past five years and are the reason for this unseating. The recent gas turbine OEM emphasis on these advanced technolo- gies confirms the trend is here to stay. DEFINING THE CLASSES Historically, gas turbine frame types were defined by output, firing For the first time in over 20 years, F-Class turbine technology no longer commands majority share in the North America 60 Hz heavy duty gas turbine market Author Michael Ducker is the manager of Mar- ket Research at Mitsubishi Hitachi Power Systems Americas. In this role, Michael is responsible for strategic analysis of energy markets. GAS TURBINES
- 17. 14 www.power-eng.com HDGT Market Share North Amreica Market Share Evolution between D/E-Class, F-Class, and G/H/J-Class Turbines. 1 D/E Class %ofGTsalesbetweenclasses 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% GT Sale Year 1980 1985 1990 1995 2000 2005 2010 Actual Trend G/H/J Class FClass Source: 2014 McCoy Power Report off, marking the beginning of the tran- sition away from F-class technology and into the new era where efficiency, not a turbine class or flexibility, is now king. WHY NOW? Just a few years ago, many gas turbine OEMs hyper-focused their marketing on the flexibility of F-class turbines. With increasing penetration of renew- ables – some studies even suggesting upwards of 80 percent renewables in the U.S. as technically achievable – it seemed as though F-class turbines would dominate the market and would help transition the U.S. to a new wave of renewable energy technologies. Yet in this same time frame, several events occurred helping to promote the up- ward trajectory of advanced class tur- bines. First, EPA regulations combined with low gas prices facilitated the clo- sure of thousands of megawatts of coal-fired generation. While this result was not at all unexpected, what was somewhat unexpected was how these units were replaced. Many early retire- ment forecasts pegged coal units with primarily the only large HDGT prod- ucts on the market. Yet in 1987, we see the introduction of F-class technology and a rapid rise of market shares as it simultaneously erodes D/E-class tur- bine sales. By 1996, F-class becomes the relative market leader and enjoyed nearly 20 years of sustained majori- ty market share. Yet in the late 1990s and early 2000s, the introduction of advanced class turbines begins to take times the nomenclature became murk- ier, as evidenced by technologies called “F-class” that featured firing tempera- ture, output, efficiency, and design in line with advanced technology, today’s HDGT classes can be broadly catego- rized into three areas based on OEM gas turbine product names, size, and efficiency. Focusing on size, D- and E- class engines are typically in the 75 – 110 MW range. Products include GE’s 7E.03, Siemens SGT6-2000E, and Mitsubishi Hitachi’s H-100. F-class tur- bines are typically in the 170-230 MW range. Products include GE’s 7F.03-.05 models, Siemen’s SGT6-5000F, and Mitsubishi Hitachi’s M501F. Lastly, the advanced class turbines (G-, H-, and J- frames) are typically in the 275 – 350 MW range. These include Mit- subishi Hitachi’s M501J and M501G machines, Siemens SGT6-8000H, and GE’s 7HA.01 and .02 models. A HISTORY LESSON Before considering where the mar- ket may be heading, it is worth taking a look at where we have been. Figure 1 shows a historical evolution of mar- ket shares between the HDGTs. Prior to 1987, D- and E-class engines were GAS TURBINES Past 5-Year Reliability/Availability Data (January 2010 - December 2014) Third Party Verifed Reliability and Availability Data Source: Source: ORAP® —All rights reserved. 2 100% 98% 96% 94% 92% 90% 88% 86% M501G F-Class -1.36% - 0.69% Reliability Availability Reliability/Availability% 99.05% 91.78% 97.69% 91.09%
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- 19. 16 www.power-eng.com Yet the regulatory permitting issue is unfortunate with the number of own- ers and developers who, in prior years, based air permits, certificates of public need, transmission interconnect studies, and the like on a smaller F-class tech- nology but viewed changing permits to advanced class turbines as too costly or, more importantly, a potential regulato- ry delay. When a permit is in hand, not many developers are eager to risk opening their projects to public or governmental change of hearts even if the economics make better sense. As more permits are initially filed to include advanced class technologies, it is likely this portion of the F-class market share will continue to deteriorate over time. Of course there are other strategic reasons a developer may choose F-class over advanced class turbines – such as parts pooling, desire for multi-unit configurations, mitigating regional re- quirements for loss-of-load contingen- cies, and other reasons not considered beyond maximum capacity needs or permitting issues. Still, the economics and competitiveness of advanced class turbines over F-class technologies are difficult to negate. THE DRIVE TOWARDS EFFICIENCY In 2011, Mitsubishi Hitachi Power Sys- tems (MHPS) demonstrated the J-class technology at its “T-Point” test facility in Takasago, Japan. 2,900°F turbine inlet temperature was achieved, translating into a combined cycle efficiency of 61.5 percent. Today, MHPS is poised to release additional improvements to its advanced class technologies capable of achieving >63 percent efficiency. General Electric markets its 7HA.02 capable of achiev- ing >61 percent efficiency and Siemens, though quiet recently, still maintains their SGT6-8000H at 60 percent efficien- cy. With natural gas prices continuing at record lows, will these major gains on efficiency still be realized in the market? order until system load is met. Therefore, competitiveness in deregulated power markets translates into being “1st on, last off” – meaning the most efficient units will be the first ones to power on (and be- gin earning profits) and the last ones to turn off (maximizing profits throughout operation). From the value chain of these markets, advanced class turbines are the clear winner and, subsequently, sales in these markets have reflected that. WHY F-CLASS STILL SELLS Some still consider F-class as the “proven” technology (i.e. less risky from a reliability standpoint) even though the new F-class engines of to- day have less operating hours than the G-class engines that have been run- ning since the late 1990s. Additional- ly, 3rd party gener- ator reliability and availability data clearly shows some of these advanced engines featuring steam cooling are ac- tually more reliable than their F-class counterparts (see Figure 2). Still, other themes emerge outside of the “proven” technology view- point. Primarily, two rational reasons come to light for a developer to choose F-class over advanced class technolo- gies: transmission issues that would require system upgrades to incorporate a larger unit, or the tragedy of regula- tory permits. Not much can or likely will change with the former. There will continue to be a market for D/E-class and F-class turbines to meet the needs of developers who have finite capacity needs. These include building a gas tur- bine in a region that does not require >500 MW capacity due to demand or building at a brownfield/other site that would require significant – and costly – transmission upgrades to enable the larger unit. low utilization rates as the most at risk to retire, and thus a 1:1 capacity re- placement would be unlikely. Yet what materialized are a number of the large advanced class turbines replacing these coal units that had minimal operating hours. Long-term resource planning hinges on having an adequate installed base to meet peak demand, and this motivated many owners to replace old- er under-utilized capacity with new, highly efficient baseload NGCC capac- ity that simultaneously displaced more costly generation on their system. Moreover, continued expansion of de- regulated energy markets and consolida- tion of balancing authorities in the US and Canada helps to improve region-wide load balancing. As a result, a highly inte- grated grid capable of pooling many re- sources with minor flexibility require- ments reduces the needs to procure sources with major flexibility capabilities. For instance, as PJM has grown, the entire regional trans- mission organization (RTO) now only typically procures 2,000 MW of primary reserve requirements for a market that sees peak loads in excess of 150,000 MW (<2 percent of total demand). These an- cillary services are pooled across the RTO and within regional subsets, not just via a few highly flexible units. Undoubtedly some markets need greater flexibility, but advanced class turbines are continuing to push the envelope in this area. Minimum emissions compliant loads and start times are now nearly equivalent between F-class and advanced class units. And thus if flexibility attributes between the gas turbine classes is es- sentially equivalent, what is valued in these markets? At their core, deregu- lated energy markets thrive on the eco- nomic dispatch principal whereby units are cost-effectively dispatched in merit GAS TURBINES “The economics and competitiveness of advanced class turbines over F-class technologies are diffcult to negate.”
- 20. ADVANCED CLASS TURBINES WILL CONTINUE TO LEAD Moving forward, there are many questions regarding centralized power generation and the role it will play in a future considered ripe for demand re- sponse, energy efficiency, and distrib- uted generation. Yet at least within the bulk power category, advanced class turbines are in a position to succeed and recent market events certainly sup- port this fact. The way any successful developer operates is simply to hedge risks against potential market out- comes. When one stacks up the potential and likely future market needs for cen- tralized power, it is hard to see F-class technology being a better hedge over the advanced class turbines. Meanwhile, President Obama’s proposed CO2 new source (NSPS) and existing source performance standards (ESPS) will no doubt have a profound effect on the drive towards better efficiency. The NSPS rules themselves are essentially an efficiency standard, whereby the more efficient the unit is the lower the lb-CO2/MWh emissions rates will be. The ESPS rules may further exacerbate coal retirements and give way to newer, more efficient advanced class gas turbines. Just the threat of CO2 taxes or a formal carbon trading scheme, even if assumed 10-15 years away, can still make a dent in a project’s proforma. While the regulations themselves will be contested, the general trends are driving towards a low-carbon regulatory and policy landscape. In North America, the future certainly seems promising for high efficiency gas turbines. Deregulated markets continue to expand, and with recent and new environmental regulations continuing to push coal out of the market, baseload gas generation is a nice fit. This trend is not unique just to the United States and Canada; Mexico’s recent market reforms are bolstering the need for more efficient and environmentally friendly gas-fired generation in lieu of existing coal assets. Additionally, as markets continue to move towards greater dependencies on gas-fired generation, gas units will evermore be competing amongst themselves to be the lowest cost energy producer. Efficiency will drive who outperforms who in the markets.
- 21. 18 www.power-eng.com MARKET ANALYSIS A New Era of Demand Response D emand Response (DR) capability in North America has grown considerablyinthepast five years, both at utili- ties and within competitive markets such as PJM. However, DR technologies and policies have generally relegated DR to a minor role as a last-called resource. DR has typically been slower to respond than combustion turbines, and the load relief it provides has been difficult to assess pre- cisely (if at all) in the real-time operating environment in which control center staff operate. Furthermore, regulatory policies in support of DR have generally focused on the magnitude of megawatts achieved at the expense of the quality and useful- ness of those megawatts. Slowly, but sure- ly, this is changing. The use of DR in grid planning and operations has solidified as utilities in- creasingly rely on DR to meet installed capacity requirements and sometimes even operating reserve requirements. Fur- thermore, independent system operators (ISOs) led by PJM have incorporated DR into procurement mechanisms for capaci- ty, energy, and ancillary services. Industry acceptance of DR as an integral part of the future grid continues to grow, with states like California and New York rolling out major regulatory initiatives and Hawaiian Electric issuing a request for proposals to Authors Stuart Schare is a Managing Director of Energy at Navigant Consulting Inc. Brett Feldman serves as Senior Research An- alyst at Navigant Consulting. Blurring the Lines between Generation and Demand-Side Resources BY STUART SCHARE AND BRETT FELDMAN
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- 23. 20 www.power-eng.com MARKET ANALYSIS in electricity usage by end-use customers from their normal consumption patterns. What makes these consumption changes “demand response” is that they are in re- sponse to changes in the price of electrici- ty or to direct incentives, typically at times of high wholesale market prices or when system reliability is jeopardized. Common examples of DR include direct load control of residential air con- ditioning, curtailment of commercial cooling and lighting loads by building op- erators participating in utility programs, and shutdown or deferral of industrial/ manufacturing processes. An important distinction for DR is that it must be dis- patchable by a utility or system operator, or be initiated by a customer in response to a non-fixed price signal. Thus, static time-of-use rates and scheduled thermal energy storage are not typically consid- ered to be DR; but critical peak pricing— where the highest price tier is only in ef- fect periodically as called by the utility or operator—is characterized as DR. UTILITY PROGRAM OR GRID RESOURCE? DR has matured from manual response to inflexible, interruptible industrial rates of a generation ago to the much more automated and customizable programs and products being offered today—with plenty of everything in between account- ing for the bulk of current DR capacity in North America. An important distinction in characterizing DR activity is whether the curtailment capacity is part of a verti- cally integrated utility program or within a market defined by an independent sys- tem operator (ISO). Utility programs are typically based on a regulator-approved tariff, and offer a fixed incentive, or set of participation and incentive options, to eligible customers who voluntarily enroll in the programs. While voluntary, many programs have non-performance penalties or provisions for withholding incentives or removing customers from the programs. One of the most frequently used and long-standing programs is Florida Power & Light’s (FPL) On Call Savings Program with more than 800,000 participants and well over 1,000 MW of central air conditioning curtailment capability. Xcel Energy in Minnesota and Colorado has a similar participation rate of over 20 per- cent of eligible customers. Other non-ISO utilities with significant residential DR programs include Duke Energy Caroli- nas, NV Energy, and PacifiCorp. Most investor-owned utilities also offer one or more rates or programs for commercial/ industrial DR. DR programs tend to be more lim- ited in ability than generators in that they are often only available when cooling loads are prominent, and they are commonly restricted to perhaps a dozen events per year of four to six hours in duration, often within a nar- row window of eligible hours. DR IN ISO MARKETS In the United States and Canada, there are nine major Regional Transmission Or- ganizations (RTO) and ISOs responsible for running wholesale electricity markets DR aggregators for the provision of “grid services,” including ancillary services, from demand-side resources. So which technologies and policies will drive DR into the future as a more integrated and valued resource? This article describes the current DR landscape in North America, including state and regional activities that uniquely affect how much DR is in place and how it is utilized. It covers some of the emerging DR technologies that are allowing DR to be viewed more on par with generators, and it reviews new applications of DR that are raising its prominence as a valued re- source alternative for utilities and system operators. Looking ahead, emerging state policies and utility initiatives are driv- ing DR to a heightened prominence that would have been difficult to envision just five years ago. DR IN NORTH AMERICA Demand response is a term that can mean many different things to many dif- ferent people. A common definition that tracesbackatleasttoaU.S.Departmentof Energy report nearly 10 years ago charac- terizes DR as changes (usually reductions) North America RTO and ISO Map and Associated DR Capacity 1 ISO New England NewYork ISO Electric Reliability Council ofTexas California ISO Southwest Power Pool Midcontinent ISO Alberta Electric System Operator Ontario Independent Electricity System Operator PJM Interconnection 500 MW 1000 MW 1000 MW 3000 MW 2000 MW 10,000 MW
- 24. For info. http://powereng.hotims.com RS#10 Lapeyre Stair... We don’t miss a step. Lapeyre Stair serves all your stair needs quickly and precisely. In-house detailing and design ensure project accuracy – every time, on time. Choose from our expanding product line to meet your on-site assembly requirements. www.lapeyrestair.com Welded Egress Stairs • Alternating Tread Stairs • Platform Systems • Bolt-together StairsW lW lW lW ldeddeddedded Eg s Ss Ss Staitaitaitaitai • Alte m S BolBol thethethethether Sr Sr Sr Sr Staiting Tg Tg T d Stai • P• P• P• P• Platlatlatlatform Sm S Accurate and timely advanced stair building technology since 1981. Send us your plans or email us at ls.sales@lapeyrestair.com to learn how you can experience the ease of working with long-time stair building professionals. Or, to immediately consult a knowledgeable customer service agent, call 800-535-7631. 21www.power-eng.com Reforming the Energy Vision (REV), the initiative’s goal is to transform the cur- rent utility model into a distribution sys- tem platform (DSP). The role of the DSP would be to lay the groundwork required for energy service providers on both the grid side and the customer side of the meter to provide products and services 2014 Polar Vortex, most DR bid into PJM was only required to be available for ten six-hour events during summer months. Within the New York ISO footprint, the New York Public Service Commission is undertaking perhaps the most ambitious plan to date from a state looking to mod- ernize its electric utility sector. Called and managing a large transmission grid with high voltages. Some of these orga- nizations have crafted DR programs or integrated DR into their market designs, thereby encouraging customer load par- ticipation. DR has matured in the elec- tricity market and has been afforded the opportunity to bid directly against gen- eration in these markets—commonly for capacity, but also for energy and ancillary services in some regions. Currently, there are approximately 30,000 MW of DR in North America, according to Navigant Research’s recent Demand Response report, with a bit over half coming from the RTOs/ISOs. This is made up of about 8 million residential and commercial & industrial (C&I) cus- tomers. This market size equates to ap- proximately $1.5 billion in DR revenues for DR providers and customers. PJM manages the largest DR market in the world, at approximately 10,000 MW. In some zones within the ISO, DR makes up more than 10 percent of the capacity resource base. PJM has also been a leader in making it possible for DR to participate and submit bids for reductions in the syn- chronized reserves and frequency regu- lation markets. However, there are some headwindsthatmay challengethecontin- ued growth of DR in PJM markets, such as regulatory/legal challenges and increased operational requirements that limit com- pensation for DR that is not available 24 hours a day, year round. Until recently, punctuated by the grid demands of the “Looking Ahead, emerging state policies and utility initiatives are driving DR to a heightened prominence that would have been diffcult to envision just fve years ago.”
- 25. For info. http://powereng.hotims.com RS#11 Highly accurate and reliable flow measurement in extreme temperatures No process stops for installation Virtually maintenance free Decreased downtimes and forced outages The Ideal Solution for: Phase detection – steam or water in the HRSG during startup Controlling drain valves during heavy cycling Measurement of auxiliary liquid systems – water treatment, cooling tower flows, natural gas Non-Intrusive Flow Measurements in the HRSG Industry Toll free: 1 888 852 7473 www.flexim.com salesusHflexim.com FLEXIM AMERICAS Corporation www.power-eng.com MARKET ANALYSIS to enhance the distribution system’s ef- ficiency. Examples of these products and services include network sensors, dis- tribution automation, DR, distributed generation, and microgrids. As part of the proceeding, utilities are required to develop their own DR programs as a sup- plement to or replacement of the NYISO DR programs. In California, the ISO (CAISO) is one of several bodies contributing to a “bifur- cation” plan to split DR into supply-side and “load-modifying” resources. Essential- ly, this means is that price-based programs intended to shape loads will remain with the utilities, while programs focused on reliability, flexibility, and ancillary services will reside with CAI- SO. Furthermore, a stakeholder process is underway where all types of DR would be identified, as well as how they could play a part in California’s electrical grid and what ben- efits they could provide. State policy is directing utilities to consider DR, not just generation, as a partner in planning how to balance and ensure reliability for the electric grid. Further, the California PUC is leading a process to value different types of DR for its ability to contribute to reliability, as well as to support the state’s goals for reducing greenhouse gas (GHG) emissions. DR VENDORS AND SERVICE PROVIDERS As DR offerings and technologies have matured, an ecosystem of vendors has emerged with continually advanc- ing hardware, controls, and head-end communications systems. Similarly, load curtailment “aggregators” have formed to recruit and enable custom- ers to collectively deliver to utilities and ISOs DR capacity measured in the tens or hundreds of megawatts—or even more in some ISO markets. The DR market can be segmented from a vendor/aggregator perspective. On the C&I side, companies such as EnerNOC, CPower, and Johnson Controls special- ize in one or more DR-related services including recruiting customers, automat- ing rapid and reliable load response, and providing granular building usage data and performance diag- nostics. The bulk of the mass-market segment includes single-fami- ly homes with central air conditioning and/ or electric water heat- ing, as well as small businesses with pack- aged units of 20 tons or less. As load control switches are nearly a commodity, and com- municating “smart” thermostats are fast becoming the specialty domain of Nest and a variety of established and start-up companies, players in the mass market segment such as Comverge and Eaton (formerly Cooper Power Systems) special- ize in one or more of the following: mar- keting/customer acquisition, head-end control systems, and communications be- tween the customer and the service pro- vider/utility (for example, Eaton offers a two-way mesh network dedicated to load control). A few vendors attempt to service all markets in the DR space. Honeywell is probably the best established, leveraging its experience in commercial building management as well as its thermostat hardware business and its 2010 acquisi- tion of Akuacom, an early developer of open source Auto-DR software on the OpenADR platform. Other major players include Schneider Electric and Siemens, global companies attempting to develop differentiated services and acquire market “State policies provide one indication of the future of DR, and these suggest a more integrated role for DR in resource planning and grid management.”
- 26. For info. http://powereng.hotims.com RS#12 For info. http://powereng.hotims.com RS#13 www.power-eng.com Fastest Biodegradable Descaler Yet! Goodway ScaleBreakÆ recaptures TIP THE SCALE IN YOUR DIRECTION. BEFORE AFTER CALL 888-364-7749 www.goodway.com share from those who have focused lon- ger on the DR market. DR AS A GRID MANAGEMENT RESOURCE If DR is now well-established as a ca- pacity resource that can provide emer- gency relief for reliability purposes, it has only recently begun making a name for itself as an operating resource to be used on a more regular basis for providing 10-minute operating reserves and other more precise ancillary services. Many of the core attributes describ- ing combustion turbines and other generators have analogs for DR re- sources. For example, both generators and DR can be characterized by their megawatts of capacity and by the time it takes to bring those megawatts onto the grid. The real question is whether the per- formance of DR is comparable to gen- eration—or at least whether DR can perform well enough compete and to provide a portion of the services re- quired by grid operators. DR has been active in the synchro- nous reserves market in PJM for several years, providing up to 25% of the re- quirement at times. However, chang- es to the transmission system in 2013 dramatically lowered prices in this market and made it uneconomic for a lot of the DR to participate. These conditions may change in the future, so the technical capability is ready to jump in when prices warrant it. The frequency regulation market has shown signs of growth, particularly since PJM implemented FERC Order 755 which affords greater compensation to faster-responding resources. Several alternative resource providers, including batteries and DR, have begun bidding into the market and showing their ability to compete. A major driver for DR is the increasing penetration of intermittent renewable energy due to both regulatory mandates
- 27. 24 www.power-eng.com MARKET ANALYSIS of the generation portfolio. The state will experience steeply declining net loads (customer demand minus cus- tomer-sited renewable generation) in the mid-to-late morning as solar pro- duction picks up, and even more dra- matic increases in net load growth in the late afternoon as solar production drops off concurrent with an increase in residential loads. The new load shape provides op- portunities for DR (as well as storage), especially in the late afternoons when load curtailment could slow—or at least help manage—the sharp ramp up. Alternatively, DR could be used to shave off some of the new evening peak. In the mornings when net load is in decline, DR can also help to balance the grid by soaking up excess supply as generators struggle to ramp down. Re- call that DR is defined as “changes” in usage by end-use customers, but these changes don’t always have to be reduc- tions. An increase in demand—in response to an incentive or price signal—is also demand response. Some of the ap- plications and technologies for DR as a down-ramping resource include over-cooling cold storage facilities and refrigerated warehouses, within ac- ceptable limits of course. Essentially, the customers are using existing facilities and technologies for on-demand thermal storage. In this case, the benefit may be the ability to draw power from the grid, as well as the ability to tap into the stored energy at a later time to reduce demand from the grid.A newer and more innovative application of customer-sited thermal storage is grid-interactive water heat- ing (GIWH). GIWH is the emerging consensus term for describing electric water heaters controlled by real-time, two-way communication with the util- ity, grid operator, or load aggregator. When equipped with grid-interac- tive controls, an electric water heater and improving economic and regulatory treatment of renewables. Resources like solar and wind pow- er rely on natural elements that can sometimes be unpredictable and re- quire backup power resources to re- spond quickly if clouds roll in or the wind stops blowing. Traditionally, this has been accom- plished by having fossil power plants on standby or generating at below op- timal levels. As the penetration of intermittent renewables increases, however, build- ing generation just for this purpose may kill the business case for the re- newable energy, so cheaper, more flex- ible backup alternatives must be con- sidered. DR can help fill this void. California is perhaps the poster child for renewable energy inputs un- settling a grid. In 2013, CAISO con- structed the now famous “duck chart,” which shows the anticipated future load shape for the state in the shoulder seasons as solar becomes a larger part Source: Attribute DR Resources Generation Resources Resource Size Number and size of customers; curtailable share of total load MW unit size Responsiveness Advanced notifcation requirements Start-up/ramp-up times Reliability Communications reliability & variance in customer load response Availability of fuel supply & transmission capacity Limitations Constraints on number and duration of events Emissions limits Temperature Dependency Temperature-dependent loads; hourly/seasonal variations Temperature-dependent heat rates and capacity Resource Diversifcation Diversity of self-generation, customer sectors,and participating end-uses Fuel diversity and baseload vs.peaking AnalogousAttributes between DR and Generation Resources California’s Future Load Shape and Opportunities for DR 2 Increase in load could allow generators time to ramp down Overgeneration risk Reductions in load could allow generators time to ramp up or shave off the new evening peak 2012 (actual) 2013 (actual) Ramp need ~13,000 MW in three hours 28,000 26,000 24,000 22,000 20,000 18,000 16,000 14,000 12,000 10,000 0 Megawatts Hour Net load – March 31 12am 3am 6am 9am 12pm 3pm 6pm 9pm 2014 2015 2016 2017 2020 2018 2019
- 28. 25www.power-eng.com For info. http://powereng.hotims.com RS#14 can respond to near real-time input by enabling fast up and down regulation and frequency control for the purpose of providing ancillary services and renewable storage to the utility or grid-operator. In addition to two way communication, GIHWs can measure and transmit information on water tem- perature, so grid operators know how much energy storage potential the fleet of GIWHs have at any given time; and based on customer usage patterns, they also can judge how much load curtailment, or regulation down service, the fleet can provide while still meeting customers’ needs. Through the use of high-storage capacity, highly in- sulated water heater tanks, GIWH can provide even greater storage and operational capacity/flexibility than traditional water heaters that are simply retrofit- ted with interactive controls. THE FUTURE OF DR IN NORTH AMERICA If DR is on a decades-long evolutionary path, will it continue to mature into an even more valuable grid re- source on par with generation? Or will energy storage and the increasing demands for grid management in a world of high renewables penetrations squeeze DR out of the picture? State policies provide one indication of the future of DR, and these suggest a more integrated role for DR in resource planning and grid management—but with stricter requirements on how DR must perform. The days of rarely called interruptible rates and monthly capacity payments for the occasional 3-hour event may be in the past. The advent of grid modernization is tied to the new resiliency view on how the grid should be designed. States like California, Illinois, Maryland, New York, Massachusetts, and Hawaii have begun grid moderniza- tion proceedings to investigate how the future grid should look in terms of issues including metering and dynamic rates, distributed generation, and the associated implica- tions transmission and distribution infrastructure. This modernization approach goes beyond siloed hearings on the individual aspects of utility operations to create a holistic structure for grid planning and payment formulas. DR may finally be able to compete on a level playing field, which could eliminate some current forms of DR while encouraging development of others. At the national level, a current FERC Supreme Court case has much bearing on the ability of DR to partici- pate in wholesale markets in the United States. In ear- ly 2011, the FERC issued Order 745, which required
- 29. 26 www.power-eng.com MARKET ANALYSIS This change encompasses a diverse suite of technologies that includes en- ergy storage, energy efficiency, DR, and the advanced software and hardware that enable greater control and interop- erability across heterogeneous grid ele- ments. These are all key components of the emerging energy cloud that is be- ing accelerated by evolving regulation of carbon emissions, a more proactive consumer or pro- sumer, and the con- tinuously improving financial viability of distributed resources compared to tradi- tional generation. Navigant projects that there will be about 70,000 MW of DR in North America by 2023, an 11 percent annual growth rate. One indi- cation of the growing prominence of DR and the vendors/service providers supporting it is the growth in membership of the leading DR trade association. The Peak Load Manage- ment Alliance (PLMA) has been in existence since 1999, yet just in the past three years had more than dou- bled in membership from less than 40 members to nearly 90 today. The recent setbacks and regulatory uncertainty in PJM—while interrupting DR’s long-term trajectory— are an indication that the industry demands more re- sponsiveness and account- ability from DR resources. This will push the continued evolution to more fully auto- mated, fast-responding, and controlla- ble DR resources that are able to play an increasing role in integrating inter- mittent renewable energy and in man- aging real-time grid operations. wholesale energy markets to pay the same for DR as they do for electricity generation. Energy supplier and gen- eration groups challenged the order in federal courts as unjust and unreason- able compensation. In May 2014, a panel of the U.S. Court of Appeals overturned the or- der by a 2-1 vote, potentially reverting things to how they were before—or making them worse, depending on interpretation. The majority opinion went even further and found that DR in the wholesale energy market is a re- tail transaction, which is outside of the FERC’s jurisdiction. In December 2014, FERC asked the U.S. Supreme Court to review the case, which was granted, setting the stage for a hearing likely in early 2016. If the worst-case scenario plays out and DR is disallowed from all wholesale markets, states and utilities will have to fill the void. Depending on their status and disposition, this could take months to several years to enact. The short-term momentum of DR would be halted, but in the long term, if states and utilities assign higher value to DR than do the wholesale markets, it could lead to in- creased opportunities for DR. DR IN THE ENERGY CLOUD Aside from government policy, the power sector is undergoing a fundamen- tal transformation that could lead to an increase in DR capacity or how widely DR is used. Led by rooftop so- lar, encouraged by the prospect of cheap storage, and with the possibility of massive amounts of electric vehicles on the grid, the industry is slowly shifting away from a centralized hub-and- spoke grid architecture based on large centralized generation assets like fossil fuel, hydro, or nuclear power plants. The new paradigm—dubbed the En- ergy Cloud in a 2015 Navigant white paper—envisions an increasingly de- centralized electrical grid that makes greater use of distributed energy re- sources, including DR. “Navigant projects that there will be about 70,000 MW of DR in North America by 2023, an 11 percent annual growth rate.” “Smart”thermostats are fast becoming the specialty domain of several established startup companies,as demand response (DR) becomes a major resource for power producers.In some places,DR developers are granted the opportunity to bid directly against generation.
- 31. 28 www.power-eng.com A large Hyundai shovel operates on the surface of cured dense slurry at the Matra power facility’s impoundment in Hungary,attesting to the compressional strength and environmental stability of the end-product.The shovel excavates cured slurry from around the perimeter for use in building up the levee of the 15-tiered,150-foot-high impoundment.Photo courtesy:NAES ENVIRONMENTAL REGULATION
- 32. 29www.power-eng.com BY DALE TIMMONS T he Environmental Protec- tion Agency’s (EPA) newly enacted Coal Combustion Residuals (CCR) rules and proposed Effluent Limita- tions Guidelines (ELG) will significantly impact waste management practices in the coal-fired power industry. The new rules will regulate fly ash settling ponds out of existence; regulate the location, de- sign, operation, and closure requirements for impoundments; and impose new re- quirements for wastewater. Traditional “dry ash” management techniques satisfy the rules’ proposed re- quirements, but they suffer from inherent technical deficiencies and pose prohibi- tive costs. The Circumix™ Dense Slurry System (DSS) technology, developed by GEA EGI Ltd. of Hungary and represented ex- clusively by NAES Corporation in North America, mixes wastewater with CCRs to produce a stable product with near-stoi- chiometric use of water. Once cured, the slurry exhibits low hydraulic conduc- tivity, high compressional strength, no discharge of fly ash transport water, little or no fugitive emissions, and enhanced metals sequestration, thereby achieving the goals of the CCR and ELG rules. The EPA has also imposed stricter stan- dards for air emissions with the Mercury and Air Toxics Standards (MATS). As with the proposed CCR and ELG rules, the vast majority of toxic metals targeted by MATS originate from coal-fired power plants. The EPA recognized that many processes designed to remove metals from gaseous emissions result in a transfer of the metals to other effluents, which is one reason it Author Dale Timmons is a egistered geologist and Business Development Program Manager with NAES Corporation. Dense Slurry Coal Ash Management: Full Compliance, Lower Cost, Less Risk
- 33. Electron Microprobe Image of a No-Lime Sample 1 Source:NAES Corporation 30 www.power-eng.com fly ash transport water discharge, little or no fugitive dust, and enhanced se- questration of contained metals. These properties meet the performance re- quirements specified in the new CCR rule and the proposed ELG. DSS is currently used at eight power plants – seven of them in Europe and one in the U.S. Two more plants are being built or commissioned – one in Europe and one in India – that will use the technology. Circumix DSS systems have processed over 60 million cubic yards of dense slurry into environmen- tally stable end products, primarily using flue gas desulfurization (FGD) water and other plant wastewater as the stabilizing medium. In addition to achieving compliance with the new ELG and CCR rules, DSS offers numerous additional advantages: • Combined stabilization of ash and wastewater • Reduction of water use by 80 to 90 percent compared to traditional practice • Zero discharge of transport water • Significant reduction of plant-wide wastewater of trucks and heavy equipment signifi- cantly increases safety risks. DENSE SLURRY SYSTEM ASH MANAGEMENT A dense slurry system (DSS) offers a safer, less expensive alternative to dry ash management while producing a product with improved environmental perfor- mance. DSS is a high-intensity mixing process that combines plant wastewater with CCRs to produce dense slurry that is easily pumped to an impoundment or landfill. The process maximizes the avail- ability of reactive ions in the ash and opti- mizes the use of wastewater. Dense slurry produced by the DSS process displays a consistency of 50 to 60 percent solids by weight with a density of about 1.3 g/cm3 , which is maintained to within 1 percent. This is thick enough to minimize free water but thin enough to allow pumping to a distance of over 6 miles using centrifugal pumps. Once discharged, the slurry hard- ens in 24 to 72 hours and substantial- ly cures in about a month. The cured product exhibits low hydraulic conduc- tivity, high compressional strength, no proposed the ELG rule. Suffice it to say, the CCR, MATS, and proposed ELG rules are requiring own- ers and operators of coal-fired power plants in the U.S. to make pivotal de- cisions regarding future operations at these plants and how best to address the regulatory changes. DRY ASH MANAGEMENT Power plants face a number of chal- lenges when converting to an alterna- tive ash management system because few options are available. Conventional practice is commonly called “dry ash” management, which is misleading. So- called dry ash management for transport and disposal to an impoundment or landfill typically involves the addition of 20 to 25 percent water to suppress dust. Once the wetted ash is transported and disposed of, it is typically spread and compacted using heavy equipment. Ad- ditional water is often added using sprin- klers or water trucks to control dust and improve compaction. Traditional dry ash management typ- ically involves handling and moving the ash multiple times, with each transfer adding more risk of dust release. To ad- dress this, the new CCR rules impose stringent controls on fugitive dust at im- poundments. Even after ash is spread and compacted, it can easily be mobilized by wind if allowed to dry. It also exhib- its relatively high hydraulic conductivity, which translates into high rates of leach- ate production. Traditional dry ash management also poses a major expense. The costs of transferring the ash to ash/water mixing facilities, together with the capital and operating costs of the facilities them- selves, are high. Truck transport, road construction and maintenance, fuel management, heavy equipment opera- tion and maintenance, continual dust suppression, lighting and security at the disposal site, plus associated labor fur- ther reduce the appeal of dry ash han- dling. Lastly, the continual operation ENVIRONMENTAL REGULATION
- 34. Electron Microprobe Image of a Lime-Added Sample 2 Source:NAES Corporation 31www.power-eng.com concrete contains about 25 percent bound water.) Although DSS has been used extensive- lyinEuropeandatoneplantintheUnited States for decades, plant-specific testing is still required to establish the proper blend of solid waste products and wastewater for optimal environmental performance. While performance-enhancing additives are available, all of the DSS facilities cur- rently in operation process ash that is suf- ficiently reactive on its own. The ash produced by some power plants in the United States, however, ex- hibits little or no reactivity. Where this is the case, additives may be used to in- crease compressional strength and reduce hydraulic conductivity. Typically, 2 to 3 percent active lime is enough to achieve adequate solidification. CASE STUDY: PRB COAL ASH For example, NAES tested samples of Powder River Basin (PRB) coal ash to determine their performance relative to DSS. The samples contained over 20 per- cent CaO, but only 0.14 percent of it was chemically active. Figure 1 shows an electron microprobe image of cured slurry product made using 60 percent PRB fly ash and 40 percent water. (Note the regions where ettringite crystals have formed.) After six weeks of curing, the low reactivity of the ash result- ed in very little cementation. The cured product exhibits a porosity of about 50 percent, as evidenced by the dark regions of empty space in the image. After curing, the sample showed com- pressional strength of 48,263 Nm-2 (7 psi) and the hydraulic conductivity measured 3 x 10-5 cm/sec. To find out how the PRB slurry per- formance could be improved, NAES pre- pared another sample – this time using 50 percent fly ash, 2.5 percent active lime, and 47.5 percent water by weight – and allowed it to cure for six weeks. In figure 2, the cured product shows a significant reduction in porosity compared to the variations in the amount of water used to make the slurry can impact process- ing parameters of that slurry. It has also demonstrated that small quantities of ad- ditives, where indicated, can dramatically improve product performance. The compressional strength and hy- draulic conductivity of cured DSS prod- ucts depend largely on the chemical reactivity of the fly ash contained in the slurry. This reactivity in turn depends on several variables: type of fuel, emission controls used, type of boiler, and combus- tion temperature, among others. As dense slurry cures, hydrated mineral crystals grow in the spaces between ash particles, including the following: Ettringite 60% Bound Water Allite 32% Bound Water This interstitial crystal growth se- questers water, entrains small parti- cles, and inhibits fluid flow. In addi- tion, the crystals act as an adhesive that binds ash particles together, resulting in greater compressional strength. This process – the same that occurs in the curing of concrete – is a desired outcome of DSS. (For reference, most • Low hydraulic conductivity (10-6 to 10-10 cm/sec) • High compressional strength • Enhanced metals sequestration • No risk of liquefaction or spills asso- ciated with liquefaction • Significant reduction of leachate vol- ume • Significant reduction of fugitive dust emissions • Enhanced land-use efficiencies from elevated disposal facilities • Reduced energy consumption Several variables contribute to low hy- draulic conductivities in the cured prod- uct, including particle size distribution, particle shape, water chemistry, and ash chemistry. The mixing process results in close packing of the ash particles upon discharge. The chemistry of the ash and water determine the type of crystal growth that takes place in the interstitial spaces between ash particles upon curing. PERFORMANCE ENHANCEMENT OF SLURRY PRODUCTS NAES has found in recent testing that
- 35. Hydration Curves Showing Sequestration ofWater OverTime 3 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% 0 5 10 15 20 25 30 35 40 45 50 0% CaO 2,5% CaO 5% CaO 10% CaO Free water (kg free water/kg total process water) Number of days of curing Freewaterpercentage 32 www.power-eng.com by progressively reducing hydraulic conductivity and increasing compres- sional strength. In active impoundments and land- fills that receive dense slurry, evapo- ration removes significant quantities of water before it can infiltrate the im- poundment. The hydration reactions that occur during curing, coupled with evaporation, result in zero discharge of fly ash transport water. A COMMERCIALLY OPERATING DSS IMPOUNDMENT IN HUNGARY The active ash disposal impoundment at the Matra Plant, which began opera- tion in 1998, consists of 15 tiers, each 10 feet thick, of solidified Type F ash that has been pumped to the impoundment from the plant as dense slurry. The 150-foot high impoundment covers an area of 314 acres at its base and 122 acres at the top. The established tiers have been planted with fruit trees. The top of the impoundment is di- vided into six smaller enclosures sep- arated by dikes. When an enclosure is full, discharge is transferred to an adjacent enclosure. Cured dense slur- ry from the perimeter of the full im- poundment is then excavated and used to construct the dike for the next tier. To prevent interruptions in plant operations caused by lack of dispos- al space, at least two of the multiple smaller impoundments at the top of the facility are always made available to receive dense slurry. The impound- ment poses no risk of liquefaction of ash products or catastrophic failure (e.g., inundation of the surrounding community) because the compres- sional strength of the contents ranges from 5,000 to 11,000 lbs/ft2 . Hence, there have been no slope failures or other incidents requiring remedi- al action since operations began. All leachate is returned to the plant for use in DSS processing, making this a amount of water sequestered with the concentration of lime. The samples were molded into 4-inch plastic tubes wrapped with geo- textile fabric at the base to allow leach- ate to drain out of the slurry. The cap- tured leachate was periodically poured back through the curing product. The samples and drained water were main- tained in a closed system to prevent evaporation of water. As shown in the hydration curves for the four mixes (Figure 3), water is rap- idly sequestered during curing. The mix with 2.5 percent active lime sequestered 90 percent of the free water in 15 days. Samples with higher active-lime concen- trations sequestered the same amount of water in five days or less. NAES also found that as the thick- ness of accumulated slurry product in- creases in an impoundment or landfill, so does the amount of water seques- tered. As dense slurry impoundments accumulate more slurry, the amount of leachate produced thus declines over time because the water that infiltrates has more time to react as it percolates through the curing product. These con- tinuing reactions enhance the perfor- mance of the impoundment over time no-lime sample – about 6 percent po- rosity in the lime-added product versus 50 percent in the no-lime product. The reduction in hydraulic conductivity of the lime-added sample – 3.4 x 10-6 – rep- resents about one order of magnitude. The compressional strength increased by 97 percent to 1,296,214 Nm-2 (188 psi). SEQUESTRATION OF WATER Mineral growth that takes place during curing sequesters significant quantities of water. This is important because the EPA’s preferred options under the proposed ELG prohibits discharge of fly ash trans- port water under any circumstance. Dis- posal facilities that use the DSS process have achieved zero discharge of transport water by reprocessing leachate to produce more dense slurry. To assess how much water is seques- tered in the DSS curing process, NAES tested ash samples from the Matra Pow- er Plant near Budapest, Hungary, the ‘flagship’ of DSS facilities. Using a slur- ry of 60 percent fly ash and 40 percent water by weight, NAES prepared sam- ples with 2.5, 5, and 10 percent active lime added, as well as a control sample without added lime, to correlate the ENVIRONMENTAL REGULATION
- 36. 33www.power-eng.com For info. http://powereng.hotims.com RS#16 Vacuum Systems by Busch Power up with custom vacuum system solutions by Busch Busch liquid ring solutions offer: Rugged reliability Single- and two-stage options Variety of materials of construction Meet all HEI standards ‘recipe’ for stabilizing CCRs. NAES conducted testing at numerous loca- tions using a pilot-scale dense slurry processing system. Prior to the pilot test, samples of combustion products and wastewater are analyzed to determine their chem- istry and particle size distribution. zero-discharge facility for both trans- port water and leachate. DSS TESTING The physical and chemical proper- ties of ash and water vary from plant to plant, so these materials must be tested at each site to determine the best The tiered and elevated DSS impoundment at Matra Power Plant in Hungary is planted with fruit trees.Inset: The cured dense slurry from the impoundment perimeter is used to construct a dike for newly discharged slurry on the top level.Photo courtesy:NAES The pilot-scale system is then used to process a range of promising ‘recipes.’ Each recipe is allowed to cure for 90 days before the samples are collected for testing. Data collected during slurry pro- cessing includes rheology parameters (yield stress and rigidity), water con- tent/flow dynamics, energy consump- tion, mix ratios, and water stoichiome- try. Cured samples may be analyzed for the following: • Compressional strength • Porosity and hydraulic conductivity • Bulk chemistry • Moisture and density • Electron microprobe analysis • Leach performance
- 37. WEBCAST REGISTER TODAY THE TOTAL CONDENSER PERFORMANCE WORKSHOP™: NON-DESTRUCTIVE TESTING SEPTEMBER 1, 2015 | 2:00PM CDT For info. http://powereng.hotims.com RS#17 produce the dense slurry • Zero discharge of transport water • Zero discharge of leachate if re- used for dense slurry production • Enhanced sequestration of con- tained metals • Reduced risk of groundwater con- tamination • Reduced or eliminated risk of dust generation • High compressional strength In addition, the tiered, elevated disposal facilities typically used with DSS enable more efficient use of dis- posal space. Piping the slurry to these impoundments reduces or eliminates the use of heavy equipment and its attendant safety and environmental risks. More to the point, DSS process- ing eliminates ash sludge liquefaction, and with it the risk of dike failure and catastrophic releases. The data collected, along with plant information, are used to determine system capacity, slurry pumping re- quirements, and impoundment/land- fill design. They are also used to esti- mate probable leachate production and environmental performance of the sta- bilized product. ENVIRONMENTAL PERFORMANCE The CCR and ELG rules are closely related and interdependent. Design changes at coal-fired power plants that affect the quantity and chemistry of generated wastewater also affect the transportation, management, com- position, beneficial reuse options, and disposal of combustion products. These changes in turn affect the design, operations, monitoring, and closure requirements for impoundments into which CCRs are deposited. They also influence decisions regarding the man- agement and fate of CCRs in existing impoundments. In terms of environmental protec- tion, operational safety, and financial risk, DSS has proven itself altogether superior to “dry ash” management. It not only meets the requirements of CCR and ELG but yields a product with outstanding environmental perfor- mance: • Hydraulic conductivity that is sub- stantially lower than that resulting from traditional “dry ash” man- agement as described in the pro- posed ELG • 80-90 percent less consumption of water compared to traditional ash sluicing • Stabilization of wastewater (in- cluding FGD water) used to ENVIRONMENTAL REGULATION
- 39. 36 www.power-eng.com Valves & ActuatorsBY RUSSELL RAY, CHIEF EDITOR unchanged, innovative applications and design modifications are being developed to withstand these demand- ing environments. In addition, these improvements can reduce costs by sup- porting the control valve’s ability to throttle accurately, thereby providing better performance for high-pressure steam bypass, turbine bypass and oth- er critical power plant operations. Actuators regulate mass and energy flows by adjusting valves, flaps and cocks. The actuator and valve create a single unit — the control valve. Actuators perform different motion sequences, including linear, pivoting and rotating motions, and they are powered by pneumatic, hydraulic or electrical energy. Actuators receive a control signal from automation systems. The signal is converted into a motion so that the A single power plant uses hundreds of valves to control almost every as- pect of its operation. Valves, in conjunction with a con- trolling actuator, are used for pollu- tion control, feed water, cooling water, chemical treatment, bottom ash and steam turbine control systems. They work in harsh environments and are exposed to a variety of chem- icals, abrasive materials and high temperatures. They are critical in optimizing efficiency, and they are often the final control element in the operation of a power plant. What’s more, additional demands are being placed on valves and actu- ators as power plants are forced to be more flexible to accommodate the growth of intermittent sources of re- newable power and mandates to curb carbon emissions. As a result, valves and actuators must operate at higher pressures, temperatures and frequency. Although the basic technology for most valves and actuators has remained Cycle Isolation testing utilizes acoustic monitor- ing instruments to help customers monitor valve performance.Photo courtesy:ValvTechnologies OPERATIONS & MAINTENANCE
- 40. You know that Magnetrol® liquid level switches work hard for decades of accurate and reliable level detection. After all, that’s why you trust your operation’s safety and performance to them every day. So to honor the hardest-working, longest-lasting level switches still in operation, we want to hear your story. Tell us about your switch at justcantstop.magnetrol.com for a chance to WIN $500 and let MAGNETROL toughness pay off for you again. The hardest working buoyancy switch has already won your loyalty. Now let it win you some cash. magnetrol.com • 1-630-969-4000 • info@magnetrol.com © 2015 Magnetrol International, Incorporated For info. http://powereng.hotims.com RS#19
- 41. 38 www.power-eng.com acts as a piston to create linear force to close and open the valve. Power plants have traditionally used pneumatic actuators to drive the many control valves throughout their facilities. However, major improvements in control element of the actuating el- ement assumes a corresponding po- sition. With control valves, this is a stroke motion. With flaps, ball cocks or rotary plug valves, this is a pivoting motion. VALVE-ACTUATOR TYPES There are three common types of actuators: Electric, pneumatic, and hy- draulic. Pneumatic valve actuators are pow- ered with air or gas. The air pressure The Rotork CVA offers an accurate and responsive method of automating control valves without the complexity and cost of a pneumatic supply.Photo courtesy:Rotork OPERATIONS & MAINTENANCE
- 42. 39www.power-eng.com For info. http://powereng.hotims.com RS#20 www.cd-adapco.com info@cd-adapco.com COMBUSTORSGAS TURBINES GENERATORSCOMPRESSORS HEAT EXCHANGERSPUMPS DISCOVER BETTER DESIGNS. FASTER. MULTIDISCIPLINARY SIMULATION FOR CLEAN, EFFICIENT ENERGY AND ECONOMICAL, RELIABLE POWER VISIT US AT PUMP & TURBOMACHINERY SYMPOSIA AT BOOTH 1529/1531 position transmitter is greater than 300:1 position turndown. The valve body is coupled to an actu- ator assembly that contains a fail-safe spring to quickly close the valve, halt- ing fuel flow in the event of a power failure or turbine trip condition. When electric control-valve actuator technol- ogy are helping power producers lower costs and boost efficiency. Valve actua- tors powered by an electric motor can withstand the demands of continuous movement. In addition, they work ef- fectively in harsh environments, and provide superior performance in a wide range of applications. The bene- fits include better efficiency, less main- tenance and enhanced performance of the control valves. What’s more, electric actuators do not require recali- bration over time. Once calibrated, the electric control valve actuator can op- erate for months, even years, without adjustment. Hydraulic actuators, which use pres- surized hydraulic fluid to open and close valves, are increasingly popular because of their ability to achieve high torque. Hydraulic actuators are de- signed to carry out linear movement of all kinds. When a large amount of force is required to operate a valve, hydraulic actuators are normally used. The most common type of hydraulic actuator uses pistons that slide up and down within a cylinder containing hydraulic oil and a spring. Young & Franklin offers electrome- chanically actuated (EMA) gas control valves designed specifically for the challenging operating conditions of in- dustrial gas turbines. Industrial gas turbines require pre- cise control of the combustion process to drive efficiency, reduce emissions, and maximize availability. According to Young & Franklin, the company’s EMA valves offer substantial advan- tages over their hydraulically actuated counterparts. Young & Franklin 3010 Series Choked flow valves are electromechan- ically actuated (EMA), single seat pre- cision fuel control valves. These sonic flow valves are available in a range of sizes suitable for industrial or power turbines of any size. The Y&F 3010 EMA gas control valve (GCV) is a modern, high precision control valve with excellent speed and valve position accuracy at low open- ings. This GCV electronically re-ze- ros its closed position reference every time the power is cycled and the valve
- 43. COAL ASH MANAGEMENT & STORAGE ORIGINALLY AIRED JUNE 30, 2015 Editorial WEBCAST For info. http://powereng.hotims.com RS#21 of the effects of valve leakage, this adds substantial costs to operations and the capability is limited. Recent client ex- perience includes mitigating cycle wa- ter losses on a new generating plant in which cumulative valve leakage rates exceeded the make- up water system ca- pacity. This forced the plant to curtail operations to allow the make-up system to catch up demon- strating how cycle isolation can directly impact plant reliability and availability. The cornerstone to capturing these benefits is diagnostics. A systematic approach to accurately measuring valve leakage eliminates uncertainties that the valve and EMA are coupled to the Y&F series 1100 Digital Motor Con- troller, the complete system provides precise fuel flow delivery with reliable operation. VALVE LEAKAGE Leaking isolation valves are found everywhere in the steam generation industry and equally widespread is the detriment to P&L statements world- wide. How can a simple worn, damaged or improperly specified isolation valve have such far reaching effects? Like all thermal engines, steam plants are powered by energy differences and the greater this difference, the greater the fuel efficiency. Valves maintain the separation by isolating the high energy processes from the low energy process- es. When valves leak, they are acting in direct opposition to the forces that drive the plant by allowing energy to leave the high energy processes and enter the low. Another key characteristic of the steam cycle is that production (or kilo- watt-hours) is gov- erned by the steam rate or mass flow through the cycle processes. Steam or energy that is bled out of the process- es via leaking valves is not being put to beneficial use and thus may be propor- tionately reducing the amount of elec- tricity or revenue being produced. While plants are designed with ancil- lary equipment to compensate for some OPERATIONS & MAINTENANCE “Additional demands are being placed on valves and actuators as power plants are forced to be more fexible to accommodate more renewable power.”
- 44. www.power-eng.com For info. http://powereng.hotims.com RS#22 For info. http://powereng.hotims.com RS#23 7-YEAR FINANCING Made in the USA. CLEARSPAN HAS CUSTOM AND TURNKEY OPTIONS FOR ANY INDUSTRIAL NEED Steel frame for durability and safety. Lower energy costs with natural lighting. House specialty equipment, like conveyor systems. Low cost per square foot. Versatile mounting options. High clearance enables indoor equipment use. ClearSpan.com/ADPWRE1.866.643.1010 ZERO DOWN, NO INTEREST & PAYMENTS - FOR UP TO ONE FULL YEAR - Some restrictions apply Valve and Gate Group ® Drip tight. No maintenance. The EKN double eccentric butterfly valve is the preferred valve in power plant cooling systems worldwide. Learn how the EKN can save you time - and money. Contact Timothy Downing Sales Manager - Power & Industry t.downing@vag-group.com www.vag-group.com ® manifest as unnecessary added costs. Improvements to valve leakage diagnostic programs quickly result in plant performance improvements as well as sustained reductions to valve O&M costs. ADVANCEMENTS IN TECHNOLOGY Power plants are complex in that there are many different sub systems required to deliver electricity. These plants were an early adopter of distributed control systems to monitor and control the facilities. Due to the arduous nature of the environment, certain practices were adopted to allow for reliability and maintenance. Motor operated valves in particular are key to plant performance. Until 20 years ago motor operated valves tended to have motor control centers remote from the valve. This did not allow for the benefit of technology advances in electric actuators. The early 1990s saw a trend towards smart actuators with integral data logging capabilities. These actuators could also be networked to provide the control system to receive data that had occurred in the actuator. Power plant designers started to take advantage of this in the past 10 to 15 years. Today, there has been a major change in the availability of better information from the motor operated valves. Instead of being alerted after the fact, the electric actuators are now monitoring the systems and providing data ahead of potential failures in the equipment. As an example, early actuators had torque switches which tripped after the valve had an internal failure which caused it to require more force than originally designed for. The more recent smart actuators have an internal data logger inside which has had the ability to monitor torque output. The most recent electric actuator has these two features plus more. The newest feature is to have a monitoring set point above the baseline torque and below the over torque setting to alert the plant operator that there is an impending issue that needs to be addressed. Miscellaneous trip alarms are also included to monitor things like starts per hour to insure the internal contactors are not being overused, perhaps due to an actuator that is hunting because of a faulty process signal. There are also maintenance interval settings that can be adjusted by the plant operator. These newer actuators also have expanded screens at the unit to allow for better operator local diagnostics. These are just a few of the upgrades available today.
- 45. 42 www.power-eng.com After decades of advancing clean-air reg- ulations,the U.S.Environmental Protection Agency plans to put a higher priority on new water rules for power producers. Water’s JourneyThe Threads Between Power Plant Makeup Water, Cooling Water, and Wastewater Selection and Treatment BY BRAD BUECKER M ore so than at any other time in the power plant era, wa- ter from the begin- ning of its journey through a plant to its discharge must be viewed holistically. This is as true for com- bined-cycle power plants as it is for the re- maining coal units in the U.S. This article examines combined-cycle plants and their attendant heat recovery steam generators (HRSGs), where increas- ingly stringent wastewater regulations are forcing plant personnel to consider com- plex treatment methods to ensure that liquid discharge complies with regulatory guidelines. In some cases, zero liquid discharge (ZLD) may be the only option. These is- sues in turn are influencing other water treatment processes, most notably cool- ing water treatment. At plants with cool- ing towers, personnel may need to look beyond what have been the mainstream treatment programs. In part, increased wastewater treatment complexity has influenced some developers to select air- cooled condensers in place of the steam surface type. Finally, by choice or often mandate, many plant designers are se- lecting less-than-pristine water supplies, such as treated municipal wastewater, for makeup. These supplies often contain unwelcome contaminants, including am- monia, phosphorus, organics, and sus- pended solids, which in turn can affect downstream processes including cooling and wastewater treatment. EVOLVING DISCHARGE REGULATIONS While this article primarily spotlights combined-cycle power issues, a trip back in time helps to illustrate how plant dis- charge regulations are evolving. When I began my utility career at City Water, Light & Power (CWLP) in the ear- ly 1980s, the plant’s National Pollutant Discharge Elimination System (NPDES) guidelines consisted of the following. The streams to which these limits applied were cooling water discharge (many plants including CWLP had once- through systems), coal pile runoff, and ash pond discharge. These were indeed simple times, but now additional constit- uents are appearing in coal plant effluent limitation guidelines (ELG), and especial- ly at those plants with wet flue gas desul- furization (FGD). But what about combined-cycle pow- er plants, which obviously burn a much cleaner fuel and do not exhibit the en- vironmental complexity of coal plants? First, consider changes with regard to turbine exhaust steam cooling. Where- as many large plants in the last centu- ry were equipped with once-through cooling, this is not the case for new plants. 316a (thermal discharge) and 316b (impingement and entrainment of aquatic creatures at plant intakes) regulations have generated a paradigm shift from once-through cooling to so- called closed systems. Cooling towers, and to a lesser but growing extent air- cooled condensers, have become the popular choices now. At the many
- 46. 43www.power-eng.com and when released to open bodies of water can often initiate and propagate algae blooms. In like manner ammo- nia is an impurity of concern. Large ammonia releases have been known to cause massive fish kills, but in the quantities that might exist in plant dis- charge, will serve as a nutrient in a re- ceiving body of water. We will continue to explore water discharge issues during and following discussion of cooling and makeup wa- ter treatment, as control methods for impurities may need to be implement- ed throughout the process. CAUGHT BETWEEN A ROCK AND A HARD PLACE Cooling system operation is vital for plant performance and reliability. At a plant with a reclaim water makeup sup- ply, the nutrients for explosive microbi- ological growth, organics, phosphorus, and ammonia, can be directly introduced to the cooling water system. But, wastewa- ter discharge issues may also significantly affect cooling water treatment. Adding to the complexity is that the most common cooling tower treatment program for over three decades has been based upon inorganic and organ- ic phosphate chemistry for both scale and corrosion protection. These pro- grams are typically supplemented with an accompanying polymer for calcium phosphate scale control and perhaps a small zinc residual for additional corro- sion protection. So, at plants impacted by phosphorus discharge regulations, chemistry, as sulfuric acid feed to cool- ing tower makeup has been a common method to remove bicarbonate alkalinity and thus minimize calcium carbonate (CaCO3 ) scaling potential in the condens- er and cooling system. H2 SO4 + Ca(HCO3 )2 →CaSO4 + 2H2 O + 2CO2 ↑ Tighter regulations on sulfate in the discharge stream may curtail or elimi- nate this straightforward method of scale control at some plants. On a related note, I have heard rumblings that chloride and bromide may be added to future regulato- ry lists. Limits on chloride could have the same effect as those on TDS. As has been noted, zinc and chro- mium limits have been placed in the proposed national ELG. State regula- tions may be more restrictive. For the plant mentioned above, the expec- tations are that copper discharge will, in a few years, be limited to less than 30 parts-per-billion (ppb). Even tighter restrictions have already been placed on copper discharge in the Great Lakes area. At these very low lim- its, copper discharge can potentially be a problem from units equipped with copper-alloy condenser tubes. Howev- er, another copper source, from older wooden cooling towers, comes from copper compounds utilized as a wood preservative. These preservatives may also contain arsenic and chromium. Although wood preservative treatment methods were designed to minimize leaching of the preservatives, some ac- cumulation of impurities may occur in the cooling water, particularly if the tower sits idle for extended periods. Phosphorus is another constituent under scrutiny. Many bodies of wa- ter in the U.S. have been designated “phosphorus impaired,” as phosphorus serves as a nutrient for plant growth plants with cooling towers, cooling tower blowdown typically represents the largest wastewater stream, but the discharge often includes some or all of the following – RO reject, evapora- tive cooler blowdown, quenched boiler blowdown, and plant drains. One might be tempted to think that these seemingly benign streams would not be much more heavily regulated than the example of Table 1. Such may not be the case. First on a national level, the EPA has proposed limits of 0.2 ppm for chro- mium and 1.0 ppm for zinc in cooling tower blowdown per the pending ELG. This is far from the end of the story, how- ever. Individual states are allowed to de- velop their own discharge guidelines, as long as the regulations are as stringent as those of the EPA. In some cases, states are promulgating tight regulations that place limits on some or all of the following additional constituents in cooling tower blowdown: • Total dissolved solids (TDS) • Sulfate • Zinc • Copper • Chromium • Phosphorus • Ammonia • Quantity of discharge As an example of state influence, consider the new guidelines at a com- bined-cycle power plant with a cooling tower in one of our southern states. Prior to 2013, the plant’s NPDES permit was similar to that shown in Table 1. The new discharge permit now imposes an average monthly limit of 1,200 mg/l TDS. Given that the makeup water TDS concentration sometimes reaches 400 mg/l TDS, the tower cycles of concentration (COC) may be limited to three under the new regu- lations, whereas previously the tower had operated at a significantly higher COC. As Figure 1 indicates, this can have signifi- cant consequences on blowdown volume. Another impurity receiving more scrutiny is sulfate (SO4 ). This issue can be problematic with regard to process Author Brad Buecker serves as a process specialist in the Process Engineering and Permitting group of Kiewit Engineering and Design Company. Source: Constituent Monthly Average (Limit or Range) Free Available Chlorine 0.2 mg/l O&G 15 mg/l pH (range) 6.0 – 9.0 TSS 30 mg/l A Long-Ago NPDES Example 1
- 47. Extreme algae growth in a cooling tower. 2 CoolingTower Blowdown vs.Cycles of Concentration 1 Recirculating fow = 100,000 gpm Range = 25 degrees F Evaporation factor = 0.75 2000.0 1800.0 1600.0 1400.0 1200.0 1000.0 800.0 600.0 400.0 200.0 0.0 COC BDRatesInGallonsPerMinute 1 2 3 4 5 6 7 8 9 10 11 12 13 14 44 www.power-eng.com removed by clarification with an iron or aluminum-based coagulant feed, but this process may be lacking for treatment of other contaminants like ammonia. A technology that is becoming increasing- ly popular for reclaim water treatment is biological processing of the plant intake. Bioreactors and membrane bioreactors are two technologies in this regard. Via microbes that are seeded and al- lowed to grow on internal devices with- in the reactors, the incoming organics and nutrients are consumed. The final step which may be external or internal is filtration to minimize TSS discharge. With membrane bioreactors, where the membranes are of the micro- or ultrafilter variety, effluent turbidities may be be- low 0.1 NTU (nephelometric turbidity units). This is quite satisfactory for gen- eral plant makeup, and even is suitable for feed to reverse osmosis units that produce high-purity makeup for the steam generator. At any plant with a cooling tower, and especiallyifextranutrientsarrivewith the makeup water, microbiological control is of utmost importance. Common for many towers in the past has been bleach feed, as bleach is safer than gaseous chlo- rine. However, ammonia and organics in incomingmakeupwillconsumechlorine, potentially destroying the residual that is needed to keep cooling systems clean. Also, the chemistry may form halogenat- ed organics, which are also unwelcome. Alternative treatments may be needed. One such possibility is chlorine dioxide (ClO2), where generation methods have been greatly improved from the former sodium chlorite (NaClO2)-chlorine reac- tion, and in which large quantities of haz- ardous sodium chlorite had to be stored on site. One of the new processes utilizes a compact generator that combines sodi- um chlorate (NaClO3) with a pre-mixed blend of sulfuric acid (H2SO4) and hy- drogen peroxide (H2O2) to induce the following reaction. an alternative non-phosphorus pro- gram may be necessary. The major water treatment companies are diligently developing non-P technolo- gies, which are based on polymer chemis- try. Co- and ter-polymers containing the active groups shown below are the out- come of these efforts. The polymers serve as crystal modifiers and sequestering agents to inhibit scale formation. There is also evidence that the polymers form a thin coating on metal surfaces to inhibit corrosion. A common dosage concentration is 2 to 10 ppm ac- tive in the cooling water. In some cases, an all-P program may be less expensive than an equivalent phosphate/phospho- nate program, although every potential application must be carefully evaluated. At this point the reader may be wonder- ing about those cooling systems, whose number is increasing, that take municipal wastewater plant discharge as makeup. Without any treatment, the impurities in this makeup will enormously increase the potential for microbiological fouling. The extra phosphorus can negative- ly impact towers that are still on phos- phate/phosphonate programs, and can be problematic for those on non-phos- phorus programs, too. Also, if phospho- rus, ammonia, and/or TSS are limited in the plant’s NPDES guidelines, a switch to reclaim water may cause immediate dif- ficulties in this regard. It is now time to examine the most popular conventional and emerging treatment technologies for makeup water, cooling water, and wastewater to provide some guidance for plant personnel faced with process and regulatory issues. MAKEUP AND COOLING WATER TREATMENT TECHNIQUES At plants with or planning to accept reclaim water as makeup, we have seen that a number of impurities may be in this water, which would be negligible in fresh water supplies. Such contaminants as phosphorus and TSS can be readily
- 48. Cutaway view of a microfilter pressure vessel with outside-in membranes. 3 Photo courtesy:Pall Corp. 45www.power-eng.com EFFLUENT TREATMENT Depending upon the method of waste- water treatment allowed or available, this issue can range from straightforward to exceedingly complex. Some plants are permitted to discharge spent water to a local municipal wastewater treatment plant, provided the industrial water does not contain excessive concentrations of harmful impurities such as heavy metals. At plants in arid regions of the country, evaporation ponds may serve the pur- pose. However, these ponds must be per- mitted and installed in a proper manner. Lined ponds are de rigueur in today’s stri- dent environmental climate. If none of the above options are avail- able, mechanical-thermal evaporation of the waste stream may be the only choice. Accurate determination of influent water chemistry is vital for design and selection of such systems, as hardness, alkalinity, and silica can cause severe scaling prob- lems in evaporator/crystallizers. In this regard, at one of our members’ plants, the cooling tower blowdown is first treated in a softening clarifier to reduce hardness. This stream is then processed in a brine concentrator/crystallizer. The primary constituent of the solids produced by the system is sodium sulfate, which forms messy deposits but not hard scale. For other crystallizers, crystal seeding is employed. A common seed crystal is gypsum, which provides a more ther- modynamically stable site for precipi- tation of such minerals as calcium sul- fate and silicates. Energy requirements for convention- al evaporators are quite large. In large measure this is due to the fact that during evaporation the dissolved solids concen- tration increases, which then increases the boiling point. The boiling point rise requires additional energy. A modifica- tion to the process that has been success- fully applied in the salt production indus- try is evaporation-crystallization with a mechanical vacuum applied to the evap- oration chamber. This greatly lowers the temperature at which the liquid boils, and water-cooled condensers, obvious- ly due to the much lower density of air as compared to water. • ACCs will only cool the turbine exhaust steam to a temperature approaching dry bulb. Cooling tower temperatures approach wet bulb. In warm climates this can represent a significant efficiency penalty. As an example, consider a wet tower operating on a sum- mer day at 90oF with 30 percent relative humidity. The dry bulb temperature is obviously 90oF, but the wet bulb temperature is 66o F. So a cooling tower that pro- vides an approach within 10o of the wet bulb allows significantly better efficiency than an ACC. • Typically, finned tubes are the choice for ACCs to improve heat trans- fer. The fin spaces clog with debris blown through the tower by the fans. The material is difficult to remove. • ACCs often suffer from two-phase flow-accelerated corrosion (FAC), which not only reduces tube life but introduces many iron oxide particulates to the condensate. A virtual must for any steam gen- erator equipped with an ACC is a condensate particulate filter to prevent transport of the iron ox- ides to the boiler. NaClO3 + ½H2 O2 + ½H2 SO4 ClO2 + ½O2 + ½Na2 SO4 +H2 O Chlorine dioxide does not react with ammonia, nor does it react with organics to form halogenated organic compounds. Also, and unlike hypochlorite, chlorine dioxide is not affected by pH. This can be an important advantage in those towers (the majority) whose chemistry programs operate in an alkaline pH range. Some plant personnel have had good success with on-line hypochlorite-gener- ating systems such as the MIOX process, which via brine electrolysis produces a hypochlorite solution that also contains residual hydrogen peroxide. An advan- tage of this technology is that the oxidant is produced on an as-needed basis rather than being stored in large tanks where it can degrade and lose strength. Another technology that is high- ly recommended for cooling towers is sidestream filtration. Very often I see re- quests-for-proposals (RFP) that call for makeup water filtration. Developers and owner’s engineers often do not recognize the fact that cooling towers are superb air scrubbers, and that many particulates are introduced to cooling water by the scrub- bing action. Makeup filtration does noth- ing to control these particulates. A wide variety of technologies is available for sidestream filtration, ranging from con- ventional multi-media filters to automat- ic backwash systems with metal screens. SOME THOUGHTS ON AIR-COOLED CONDENSERS At the most recent International Wa- ter Conference, more than one present- er seemed to somewhat lightly suggest that if plant personnel are worried about cooling tower issues, air-cooled condensers (ACC) are an easy cure. Yes, ACCs may be the only choice where water is scarce, but a number of factors must be considered before choosing ACC over a cooling tower. These factors include: • ACCs are enormously large, especially in comparison to
- 49. 46 www.power-eng.com of multiple, parallel flow modules each containing thousands of spaghetti-like, hollow-fiber membranes. The membranes must be regularly backwashed every 10 to 20 minutes or thereabouts to remove particulates. The backwash flow path is the reverse of the normal flow path. In this par- ticular case, conversion of the mem- branes from inside-out to outside-in normal flow path greatly improved the backwash efficiency. Another interesting initial difficul- ty was noted with the UF backwash process. Typically with these systems a small portion of the permeate is col- lected in a separate tank at the begin- ning of each process cycle for use in backwash. So far, so good. But most modern MF and UF units are now equipped with automatic chemical- ly-enhanced backwash (CEB) systems. After a certain number of cycles, a CEB backwash kicks in where first the membranes are cleaned with a dilute caustic/bleach solution to remove or- ganics and microbiological organisms, followed by rinsing and then a dilute citric acid wash to remove iron partic- ulates. When this UF was first com- missioned and CEB backwashes com- menced, the membranes developed a layer of calcium silicate during the CEB caustic stage. The driving force was the higher pH generated by the caus- tic, which in turn greatly reduced the silicate solubility. The solution to this problem was a switch to softened water for the backwash supply. CONCLUSION This article hopefully illustrated many of the threads between the water treat- ment processes at new power plants. Complex scenarios may arise due to wa- ter chemistry issues and discharge reg- ulations. Processes must be viewed and designed in a holistic manner and not piecemeal. Accurate and historical water quality data is an absolute must for de- signing reliable systems. feed and a degasifier to lower bi- carbonate alkalinity. Under proper conditions, the RO recovery rate may reach 90 percent. The RO permeate recycles to the plant high-purity makeup water system or oth- er locations. However, while the process appears straightforward, a number of lessons-learned have emerged regarding this technology in actual application. The following lessons are taken from a HERO system operating at a power plant near the Pacific Northwest. One of the most notable examples for any of these systems is that some standard water treatment chemicals may foul the UF membranes. Operating experience indi- cates that the membrane manufacturer and type greatly influence this phenom- enon. Fouling is induced because mem- branes typically carry a negative surface charge while often cationic polymers are employed for coagulation or floc- culation. Residual cationic polymer is strongly attracted to the membranes. A very similar phenomenon has been ob- served with MF or UF systems installed in makeup water systems downstream of a clarifier. Inexperienced designers and/ or plant personnel have not always rec- ognized that MF or UF should generally serve as a replacement for clarification, not a polishing process for the clarifier. A straightforward solution that has significantly improved the reliability of this particular system is conversion of the ultrafilter from an inside-out nor- mal flow path to outside-in. Typical micro- and ultrafilter systems consist helps to overcome the boiling point rise that occurs in conventional units as the dissolved solids concentration increases. Considerable energy savings appear pos- sible with the vacuum systems. Becoming popular are treatment meth- ods to reduce the volume of the plant waste stream before final treatment. Most notable is high-recovery reverse osmosis. This schematic outlines the HERO pro- cess, which is licensed by such firms as Aquatech, GE, and U.S. Water, while Veo- lia supplies their Opus technology, which may also include high-rate softening/clar- ification as a unit operation. Keys to the process are: • Microfiltration (MF) or ultrafiltra- tion (UF) to remove suspended sol- ids in the waste stream. This is a critical process to prevent suspended solids from fouling reverse osmosis (RO) membranes. • Sodium bisulfite (NaHSO3) feed to remove residual oxidizing bio- cides. This is also critical to remove oxidizers that would degrade soft- ener resin and RO membranes. • A sodium softener to remove cal- cium and magnesium. Otherwise the downstream equipment would suffer from calcium carbonate and magnesium silicate scaling. • Sodium hydroxide injection to ele- vate the pH above 10. (The combi- nation of hardness removal and pH elevation keeps silica in solution.) • Two-pass reverse osmosis (RO) treatment. • Some systems may include acid Source: Pollutant Maximum for any 1 day Average of daily values for 30 consecutive days shall not exceed Arsenic,total (µg/L) 8 6 Mercury,total (ng/L) 242 119 Selenium,total (µg/L) 16 10 Nitrite/nitrate (mg/L) 0.17 0.13 Proposed ELG for FGD Wastewater Best Technology Available [1] 2
- 50. ©2015 Cleaver-Brooks, Inc. Visit Stand L24 at the 2015 Power-Gen Asia Show. For info. http://powereng.hotims.com RS#24
- 51. 48 www.power-eng.com PRODUCTS a proof-of-concept 50kW string solar inverter that exhibits a remarkable 50 percent reduction in power loss and operates at three to fve times the switching frequency that conventional silicon tech- nology can currently achieve. The combination of these two factors drastically reduces both the size and weight of the inverter’s cooling system, as well as its fltering components, which translates into a unit-cost reduction approaching 15 percent. Cree Inc. Info http://powereng.hotims.com RS#: 403 Data integration software C ogent Real-Time Systems Inc. released the Cogent DataHub, a secure real-time data ac- cess and integration software for networked indus- trial systems. Version 7.3.6 offers a new Modbus feature that allows the DataHub to connect to any Modbus slave over Modbus TCP. Fully integrating Modbus into the Cogent DataHub means that data from any device on a Modbus TCP network can be viewed on the web, logged to a database, connected to an Excel spreadsheet, or made available to virtually any lo- cation across the Internet of Things (IoT) through the Secure Cloud Service from Cogent’s parent company, Skkynet Cloud Systems Inc. Cogent Real-Time Systems Inc. Info http://powereng.hotims.com RS#: 404 Gateway modules W AGO Corp.’s new 750-658 I/O module eas- ily links CAN feld devices to the 750 Series WAGO-I/O-SYSTEM. The CAN Gateway module can be used with 750 Series PLCs or couplers, providing a gateway between a CAN network and other feldbuses, (e.g., Ethernet or Profbus) leveraging the fex- ibility of the feldbus indepen- dent WAGO-I/O-SYSTEM. The 750-658 supports CAN Layer 2, making it ex- tremely fexible at the feld level. The module can be integrated into a CANopen, SAE-J1939 or DeviceNet network by using CoDeSys function blocks. The CAN I/O module offers users fexibility by pro- viding the option for operation in one of three modes: sniffer mode, transparent mode or mapped mode. With GL marine and UL508 certifcations, the 750- 658 is suitable for an expansive number of possible Wind power cable seals U K based Roxtec targets power and wind-farm sectors with innovative new cable seal. Roxtec has extended its range of cable seals with an innovative new seal specifcally for under- ground power cables serving structures including electricity substations and wind turbines. The new Roxtec UG sealing system is ideal for power cables entering foundations or basements because it pro- tects against fooding, humidity and continuous water pressure. The UG seal is IP68-rated, 1 bar for catastrophic water pressure and 0.3 bar for constant water pres- sure. It can be used on trefoil single core cables. The system has been tested in Roxtec’s specialist test laboratory with retention tests of 1400N and 3300N depending on the product selected, meaning the system can handle the weight of many cables which is often the cause of failure in traditional sealants. A knock-out sleeve is available and designed to be cast into the foundation structure. It is available in three different industry-standard sizes and de- signed to ft Roxtec seals and frames. A knock-out plate in the sleeve ensures a water-tight seal before cables are routed, meaning there is no water in- gress during construction. Roxtec Info http://powereng.hotims.com RS#: 400 Conveyor belt cleaner A new conveyor belt cleaner has been engi- neered to contain a smaller total volume of ure- thane, while maximizing the usable area, produced in a streamlined process that allows the manufactur- er to reduce the purchase price and overall cost of ownership. Manufactured with Martin Engineering’s unique CARP (Constant Angle Radial Pressure) tech- nology to maintain the most effcient cleaning angle throughout its service life, the Martin QB1 Cleaner HD features a no-tool replace- ment process that can be performed safely by one person in less than fve minutes. CARP technology is exclusive to Martin Engineering, designed to keep the blade at a consistent angle and pressure against the belt. Typically set at about 2 PSI (13.8 kPa) for the QB1 HD, the low blade-to-belt pressure helps protect the belt, splice and cleaner itself. As the blade wears, neither the surface area nor the angle is compromised, ensuring maximum performance throughout its life. Martin Engineering Info http://powereng.hotims.com RS#: 401 Corrosion inhibitor C orrBlock is a time-release, biodegradable cor- rosion inhibitor block for water treatment indus- tries. It is designed for open loop recirculating cool- ing systems and waste water systems. The block is formu- lated using renewable soybean-based wax and proven Vapor phase Corrosion Inhibitor (VpCI) technology. The inhibitors in CorrBlock provide multimetal protec- tion and are excellent replacement for chromates, nitrites, and other types of restricted corrosion inhibitors. The VpCIs form a strong monomolecu- lar layer on metal surfaces that protect in all three phases - liquid, vapor, and the vapor-liquid interface. CorrBlock eliminates the need for dosing pumps and tanks for conventional liquid inhibitors as well as protects tools, workpiece, and metalworking ma- chines during downtime. Cortec Corporation Info http://powereng.hotims.com RS#: 402 Diode technologies reduce solar inverter size C ree Inc. (Nasdaq: CREE) has demonstrated that its best-in-class SiC MOSFET and diode technologies enable previously unattainable levels of power density in string solar inverter prod- ucts, yielding effciencies greater than 99.1 percent at peak at one-ffth the average size and weight of today’s silicon-based inverter units. Using the latest Cree power MOSFETs and di- odes, Cree’s systems engineering team designed
- 52. 49www.power-eng.com applications, such as shipboard engine monitoring or connection to CANopen devices in a wind turbine. Wago Info http://powereng.hotims.com RS#: 405 Digital genset controller B asler Electric announces the newly enhanced DGC-2020HD Digital Genset Controller, a com- plete all-in-one genset controller and load share sys- tem with new features to make complex paralleled genset systems easy to control and maintain. The new features include system segmentation, load shedding, peak shaving and im- port/export control, the addition of a maintenance mode and email notifcation. Typical applications for these controllers are locations where maintaining power is critical, like data storage centers. The DGC-2020HD can also be applied in complexes and factories, where losing power and shutting down the business’s primary processes could cause loss of revenue or substantial damage. Basler Electric Info http://powereng.hotims.com RS#: 406 Industrial and adaptable PC D aisy Data Displays Inc. unveiled its highly adaptable PC designed to operate reliably in hazardous locations such as in fracking, drilling and refneries. The new Series 4120 features either a 19-inch display (1280 x 1024 resolution) or 15-inch display (1024 x 768 resolution). The new Series 4120 is smaller, lighter, fast- er, fanless and pro- vides end users with improved on-screen resolution and visibil- ity, thus allowing the user to make full use of the software. The lightweight, carbon fber enclosed units are less than 19 pounds for increased ease of use and feature a resistant touch screen (glass on glass) or optional multi-touch Projected - Capacitive (P-Cap). WiFi antenna is also optional. The COM e module is available with either Quad Core Atom or i7 processor and Solid State HD, up to 256GB. The new 4120 features up to 16GB of mem- ory (4GB is standard), 4 USB ports, two network ports, keyboard and pointing device PS/2 ports. It is designed to operate reliably in temperatures from -40 to 65 C. Daisy Data Displays Inc. Info http://powereng.hotims.com RS#: 407 Suspended platform P ower Climber, a division of SafeWorks LLC, has launched PowerMod – the versatile, fexible, and cost-effective modular knockdown suspended platform that provides safe, secure and stable ac- cess for a variety of projects performed at height. With a 2,000-lb load capacity and a variety of possible confgurations, PowerMod fts into hard- to-reach working spaces for various construction, maintenance, r e s t o r a t i o n , painting and inspection ap- plications. Built- in toeboards, adjustable guardrails, one step self-locking pins, and a lightweight frame make the PowerMod easy to transport and assemble. Compact parts reduce inventory costs, and alu- minum extrusion components extend the prod- uct’s life by resisting corrosion caused by harsh environments. Power Climber Info http://powereng.hotims.com RS#: 408 Power supplies W AGO expands its growing portfolio of pow- er supplies with three new three-phase variants (787-738, 787-740,787-742.) These new additions offer a wide input range of 325V to 800V and an output range of 22VDC to 28VDC, in a com- pact robust metal housing for quick and easy DIN-rail mounting. The new three-phase ECO power supplies can also be connected in parallel for added fexibility and customization. WAGO Info http://powereng.hotims.com RS#: 409 Pressure transmitter T he SITRANS LH100 series pressure transmitter converts level-proportional hydrostatic pressure into a standardized 4 to 20 mA signal. Measuring just 23.4 mm in diam- eter, the sensor can be mounted in pipes with a 1 inch diameter, making it fexible for use in a wide range of applications. With mechanical pro- tection IP 68, a submersible piezo-re- sistive sensor with ceramic diaphragm is designed for harsh environments. The sensor is available with cable lengths ranging from three to a maxi- mum of ffty meters in length. The Sitrans LH100 is also ftted with an integrated humidity flter, per- mitting simple installation without the need for a junction box. Siemens Info http://powereng.hotims.com RS#: 410 Power resistors S tackpole announces the expansion of the TR Series of TO-220 and TO-247 style power re- sistors. The TR Series value range now starts at 50 mil- liohms and goes up to 20K ohms for most sizes (the TR30 value range extends up to 100K ohms). The TR Series is available in 0.5 percent tolerances and TCR as low as 50 ppm making it suitable for precision power resistor requirements. Power ratings for the TR series, assuming use with a heat sink and a 25C case temperature, ranges from 20W up to 100W. The TR Series is ideal for use with power semi- conductors. Using a heat sink allows these relative- ly small parts to handle high power safely, reliably, and with minimal resistance shift over the life of the product. Pricing for the TR Series ranges from $1.50 each to $6.00 each in full package quantities. Stackpole Info http://powereng.hotims.com RS#: 411 Resistant coating solution C ortec Corp. introduced VpCI-386 HT Black - a high heat resistant water-based acrylic silicone primer/topcoat that provides protection in harsh, outdoor unsheltered applications.
- 53. 50 www.power-eng.com Working” diagnostics. A unique, high-speed safe- ty relay output is incorporated for local alarm or emergency shutdown. Discrete outputs deliver diagnostics and relay status voting logic input to the safety PLC to determine appropriate action. The transmitter is certifed for use in SIL 2 safety instrumented systems, and is capable of SIL 3 per IEC 61508. It has confgurable self-diagnostics and achieves a safe failure fraction of 98.5 percent. Instrument response time is <100 milliseconds. United Electric Controls Info http://powereng.hotims.com RS#: 414 Pressure transmitters S chneider Electric introduced the Foxboro Field Devices’ pressure transmitter “S” series models IDP10S, IGP10S and IAP10S. These intelligent, two- wire pressure transmitters feature patented FoxCal technology. The Foxboro S series models IDP10S, IGP10S and IAP10S transmit a 4 to 20 mA signal with a superim- posed HART® smart instrumen- tation digital signal for remote confguration and monitoring. All the Foxboro S series two-wire pressure transmitters feature two “time-in-service” clocks. Foxboro’s S series boosts accuracy while enabling customers to track time-in-ser- vice fawlessly. The time-in-service feature enables advanced diagnostics monitoring. In addition, the user days value can be reset to zero using a HART communicator, a PC-based confgurator, or the optional local indicator. (Note: The lifetime service parameter cannot be reset.) Schneider Electric Info http://powereng.hotims.com RS#: 415 Semiconductor materials M organ Advanced Materials announces ad- vances in their range of materials grown us- ing chemical vapor deposition (CVD) processes. Morgan’s CVD Silicon Carbide (SiC) and Pyrolytic Boron Nitride (PBN) materials are ideal for use in semiconductor applications, including rapid ther- mal processing and plasma etch process chamber components, as well as metalorganic CVD tools for high-brightness white LED manufacturing using the indium gallium nitride process. The protective coating signifcantly delays the reaction of metal ionization and water permeation, which protects against corrosive electrolyte and aggressive environments, thus preventing cor- rosion. VpCI-386 HT Black provides a fast-drying thixotropic coating that is resistant to sagging or running. This unique coating offers extended protection for sheltered, unsheltered, outdoor, or indoor conditions. Thermally stable when dried from -150°F to 500°F (-78° to 260°C), the coating is ultraviolet resistant and gives optimal outdoor performance without cracking or chipping upon prolonged exposure to sunlight. VpCI-386 HT Black is available in 5 gallon (19 liter), 55 gallon (208 liter), liquid totes, and bulk. Keep product from freezing. Avoid temperatures higher than 75°F (24°C) while in storage. Cortec Corporation Info http://powereng.hotims.com RS#: 411 Customized vanes, rotors and end plates M etallized Carbon Corp. announces the avail- ability of custom vanes, rotors, and end plates for use in rotary vane pumps pumping both liquids and gases. The carbon-graphite components pro- vide superior lubrication in most environments, and are ideal for pumping liquids with poor lubricating qualities, strong chemicals that attack metals, and to pump air, vacuum, combustion products and gasoline vapors. Metallized Carbon supplies the carbon-graph- ite vanes, rotor, and end plates to rotary pump and compressor manufacture and rebuilders. The materials are chemically resistant and have a low wear rate running in both gas atmospheres and low viscosity liquids. Carbon graphite vanes can withstand the rub- bing of the vane tip against the housing bore and the rubbing of the side of the vane against the slots in the rotor. Lightweight carbon graphite rotors save energy and withstand the rubbing against the vane and the end plates. Carbon graphite end plates are pressure tight and dimensionally stable so that they can make a close clearance seal with the rotor and vanes. They also withstand the rub- bing of both the vanes and rotor. Metallized Carbon Corp. Info http://powereng.hotims.com RS#: 412 Siemens safety relays T he Sirius 3SK2 safety relay from Siemens offers multiple safety functions in the smallest of spac- es. Thanks to the user-friendly drag & drop param- eterization interface, it is simple to create safety functions that can be optionally expanded to include test and diagnostics functions. Sirius 3SK2 safety relays come in two different variants – the 22.5-millimeter-wide device, which comes with up to four safety functions, is slimmer than any other software-parameterizable safety relay currently available on the market, while the 45-millimeter-wide device, which offers up to six safety functions, comes equipped with a diagnos- tics display. The functions of the 3SK2 fail-safe out- puts can be assigned independently of each other. Typical applications for Sirius 3SK2 devices include emergency stop push buttons, protective doors with tumblers, or material feeder systems with light barrier sensor technology. The fail-safe outputs can be supplemented in a modular fashion as required – even without additional wiring. Just like devices in the Sirius 3SK1 series, Sirius 3SK2 units are simple to combine with conventional industrial controls, for example, devices from the Sirius 3RM1 motor starter range can be simply inte- grated using device connectors. Siemens Info http://powereng.hotims.com RS#: 413 Safety system transmitter U nited Electric Controls has introduced the One Series Safety Transmitter, the frst SIL 2-certi- fed transmitter designed solely for safety system applications. The One Series transmitter provides 4-20 mA NAMUR standard output with exclusive “I Am
- 54. 51www.power-eng.com Tachometer generator M arsh Bellofram Corp. announced the global market introduction of its WESTCON 758- 9910001 industrial AC tachometer generator. These highly rugged, explosion-proof devices can effectively support the demanding predictive mainte- nance requirements of oil and gas drilling, industrial mud pumps, and waste and wastewater pumps and systems, with complete and effcient 24/7 rotational speed monitoring. The tachometer is especially ben- efcial for rotary table RPM and mud pump SPM, two of the primary parameters for achieving maximum drilling effciencies. WESTCON 758-9910001 AC tachometer gener- ators are designed to convert rotational shaft speed inputs into a linear analog voltage output, even in the harshest of environments. The tachometers feature a standard 3 4² drive shaft, with only a 3 oz-in starting torque. Their components are housed within a explosion-proof case that is ATEX certifed for Class 1, Division 1, Class 1, Group D and Class 2, Groups F and G. Series units are also UL list- ed. In addition, their rugged, bearing-free and brush- free design requires absolutely no maintenance for increased reliability and minimal downtime. Marsh Bellofram Corp. Info http://powereng.hotims.com RS#: 420 Input temperature detectors N ew additions to the WAGO I/O system expands the functionality of the 750 series. 750-450 4-Channel and 750-451 8-channel RTD Analog Input Modules directly connect to Pt and Ni resis- tance sensors, providing highly accurate reading of sensor data. Benefts of the modules include con- fgurable for multiple sensor types or po- tentiometers, red sta- tus LED that indicates sensor errors, such as short circuit, wire break, or out of measurement range, and a compact 12mm profle saving cabinet space. The 750-450/451 is ideal for a wide range of temperature data collection tasks in factory auto- mation, motor and process control applications. WAGO Info http://powereng.hotims.com RS#: 421 Morgan’s improved CVD SiC growth capabil- ity enables the manufacture of 300+ millimeter diameter components with thicknesses of more than 10mm at production volumes for recently de- veloped plasma etch applications. With access to world class ultrasonic machining capability, Morgan offers high tolerance CNC machining and precision hard grinding, as well as the patented Rmax process for producing focus CVD SiC ring shapes. Morgan’s high purity (99.999 percent+) SiC ma- terial has high thermal conductivity, is resistant to chemical erosion, and features minimal particulate generation, making it ideal for use in chlorine and fuorine plasma etch processes. The material is ideally suited for use in producing GDMs (gas dis- tribution plates) where the material’s erosion resis- tance can lead to long life and extended tool PM schedules. Ultrasonic drilling can provide holes with diameters as small as 0.5mm, ideal for custom etch applications. Morgan Advanced Materials Info http://powereng.hotims.com RS#: 416 Slurry knife gate valves D eZurik’s new KSL Slurry Knife Gate Valves are designed for on-off (isolation) service for appli- cations consisting of abrasive, high solids content, wet or dry media. The KSL-LA Slurry Valve features sleeves of natu- ral rubber or other elastomers that are compressed by sleeve retainers. The sleeves have an encapsu- lated supporting ring for long service life, and the valve’s sleeve compression design eliminates the cavity where solids can collect. The sleeve design of the KSL Slurry Valve pro- vides bi-directional, drip tight shutoff up the valve¹s 100 psi (690 kPa) pressure rating. The valve has a full port, which reduces turbulence and pressure drop across the valve. In addition, the gate fully retracts out of the fow path in the open position. The KSL Slurry Valve is available in sizes 2-24² (50-600mm) with larger sizes and higher pressure ratings available on application. DeZurik Info http://powereng.hotims.com RS#: 417 Compact solid state relay C arlo Gavazzi launched their new RF1 Series Compact Solid State Relay. The RF1 Series provides compact solid state switching suited for applications with con- fned space. The RF1 Series is ideally suited for applications where trouble free operation is required for a large number of cycles and where space is limited. The RF1 Series occupies only 30 percent of the panel space typically required for a typical panel mounted (hockey puck) solid state re- lays, it’s merely 36 x 21 x 24mm. The RF1 Series is designed for control of resistive loads. The zero switching type (RF1A), switches ON when the voltage crosses the AC sine wave’s zero crossover point. The instant-ON type (RF1B), switch- es on at the instant when control voltage is ap- plied. Integrated transils provide protection against over-voltage. A green LED indicates the presence of control voltage. Fast-on terminals for the input and output voltage enable fast and secure installation. Carlo Gavazzi http://powereng.hotims.com RS: 418 Wrist, elbow and knee supports and wraps E rgodyne refreshed and enhanced their ProFlex Supports Line. The updates are coming to ProFlex Wrist Supports, ProFlex Wrist Wraps, ProFlex Knee Sleeves, as well as ProFlex Elbow Support and Sleeves and will complete the full line overhaul that was kicked off by Back Supports in 2013. A number of chang- es to the models were made, including: new material colors, improved fabrics, new logo treat- ments, lower profle buckles (on the 4020 Wrist Support and 650 Knee Sleeve), larger thumb loops (on the 4020 Wrist Support), new binding and pre- curve design (on all sleeves), improved fabrics, pull tabs for easy on/off (on all straps), and more… All in an effort to improve the performance, comfort, breathability, shape, and design. The supports are ideal for workers with minor sprains, strains, or exposure to repetitive motion on the job. Ergodyne Info http://powereng.hotims.com RS#: 419
- 55. 52 www.power-eng.com largest provider of PPE, said Sach Sankpal, presi- dent, Honeywell Safety Products. New online tools from Miller Fall Protection that make it easier for engineers and architects to design, specify, and select fall protection systems for different projects. The new inter- active tools include engineering specifcations and Computer Aided Drawings (CAD), system comparison charts, a fall clearance calculator, a ShockFusion kit selection guide, and “Ask the Expert” and additional resources. Uvex Instinct: High-performance protection with a sleek design and a variety of adjustability features for a customized ft. Uvex Instinct pro- vides high-performance protection with a sleek design and lightweight frame, featuring a variety of adjustability features for a comfortable, cus- tomized ft. The soft, fexible fngers on the nose- piece help to minimize slippage, while the slim, curved temples provide a secure ft with minimal tension around the ears. Uvex Tirade: Sealed Eyewear features closed cell foam, removable temples and adjustable headband for a comfortable, gap-free ft. Uvex Tirade sealed eyewear protects workers in high particulate environments where dust, dirt and de- bris present the risk of eye injury. The large uni- lens design provides a wide feld of unobstructed peripheral vision, with a soft foam subframe to ensure a comfortable gap-free ft. Honeywell Solutions Info http://powereng.hotims.com RS#: 424 (HEMTs), VisIC’s products accelerate the semi- conductor industry’s push to extend GaN-based technology from communications subsystems into power conversion subsystems. Meeting the highly demanding requirements of power switch- ing with GaN has been the Holy Grail for power conversion research in the last decade. VisIC Technologies Info http://powereng.hotims.com RS#: 423 Turbine linear actuator T he Voith SelCon was primarily designed as a linear actuator with safety function for the valve controls of gas and steam turbines. The hydraulics provides high force density and dynamics, the electromechanical side contrib- utes simple, cost-effective system integration. Large effective forces up to 500 kN and ATEX certifcation allow it to be used on turbines under virtually all conceivable ambient conditions. The hydraulic system of the SelCon is self-con- tained. An external hydraulic power pack with oil tank, control block and pipework is completely unnecessary. This reduces procurement costs by up to 35 percent compared to a conventional solution. External hydraulic disturbances such as pressure fuctuations, mismatched pipe diame- ters or negative pressure in the tank line are out of the question. The fail-safe function is implemented using an internal return spring. The trip time for the valve controls is typically less than 300 ms. This reduc- es the danger of direct and consequential dam- age considerably. Voith Turbo Info http://powereng.hotims.com RS#: 423 Worker safety products The new personal protective equipment prod- ucts introduced today by Honeywell (NYSE: HON) at ASSE Safety 2014 represent a ³fervent dedica- tion to innovation² in worker safety by the world¹s Temporary power connector C liff Electronics announces its Quicktest QT3, a compact, robust 3-Phase power connec- tor designed for temporary, safe and effcient connection of unterminated cables to 440VAC, 3-Phase power supplies. The QT3 has a maximum power rating of 16 amps per phase. The Cliff QT3 is designed for use in applica- tions including manufacturing, test and repair, calibration, measurement and burn-in where fast, safe and non-permanent connection to 3-Phase power supply is required. The colour-coded piano key cable clamps are also marked L1, L2, L3, N and E to prevent any confusion. Each phase is protected by an individ- ual 16 amp fuse as standard and each phase is ftted with an individual neon indicator lamp to indicate when the phase is live and connected to the supply. Cliff’s Quicktest QT3 is designed for use either free standing or mounted to a bench or test fxture and it measures a very compact 49mm x 100mm x 160mm. Cliff Electronics Info http://powereng.hotims.com RS#: 422 Power transistor switches V isIC Technologies, a developer of Gallium Nitride (GaN) power semiconductors an- nounced the world’s lowest-resistance, fast GaN transistor in their power conversion switch. VisIC’s 650V, 50A GaN transistor achieves a remarkable 12mohm Rdson. Based on a new design for GaN High Electron Mobility Transistors
- 56. SUPPLIER’SSHOWCASE|ShowcaSeadvertiSingcontactJennahall:918-832-9249,Jennah@pennwell.com www.power-eng.com 53 Why Should You Filter Your Water? The Best Engineered Water Filteration Solution Always Costs Less Automatic Filters SOLVAir Solutions was formed to help customers address the problems of SOX, HCl and other stack emissions, as well as help with the changing EPA regulations. SOLVAir Solutions is the market leader in providing sodium sorbents for use in DSI systems. Access our brochure on our Library page at www.solvair.us Contact Rosemary Dunn ardunadv@gmail.com 713.521.7450 Emission Control 24/7/365 HIGH VOLTAGE EQUIPMENT & SERVICE Call or Email for a quick quote and fast track delivery of 660.596.7727 hvsales@energy-parts.com www.energy-parts.com High Voltage Equipment http://powereng.hotims.com RS#300 http://powereng.hotims.com RS#302 Crown Electric Iso Phase Bus Fabrication Installation Upgrades & Uprates GSU Change Outs 175 Edison Dr. Middletown, OH 45044 www.crown-electric.com sales@crown-electric.com ext. 201513 539-7394 Iso Phase Bus 3 NuScale Power has attained the Triple Crown for Nuclear Plant Safety™. With NO operator action, NO AC or DC power, and NO added water, the NuScale Power Module™ will achieve safe, self-cooled shutdown, and maintain it indefinitely. Safety: the Element of Nu.™ nuscalepower.com © 2015 NuScale Power, LLC. All Rights Reserved. Safe Nuclear Power http://powereng.hotims.com RS#304 Silo and Bin Cleaning Services and Equipment Call 800-322-6653 or visit www.molemaster.com Silo and Bin Cleaning Sevices http://powereng.hotims.com RS#305 SUPPLIER’SSHOWCASE|ShowcaSeadvertiSingcontactJennahall:918-832-9249,Jennah@pennwell.com www.power-eng.com 53 http://powereng.hotims.com RS#303 http://powereng.hotims.com RS#301
- 57. ClassifiedadvertisingContaCtJennaHall:918-832-9249,JennaH@pennwell.Com|CLASSIFIEDS REACH YOUR AUDIENCE ADVERTISE your career opportunities, equipment, services, and training programs in Power Engineering’s Classifed Section. GET RESULTS Put your message in front of North America’s most qualifed circulation with Power Engineering’s classifeds. CALL NOW FOR DETAILS: JENNA HALL Phone: 918.832.9249 | Email: jennah@pennwell.com 1319 Macklind Ave., St. Louis, MO 63110 Ph: (314) 781-6100 / Fax: (314) 781-9209 www.ampulverizer.com / E-Mail: sales@ampulverizer.com Quality and Service Since 1908 Ring Granulators, Reversible Hammermills, Double Roll Crushers, Frozen Coal Crackers for crushing coal, limstone and slag. For info. http://powereng.hotims.com RS# 453 Get a thorough mix with: Pugmill Systems, Inc. P.O. Box 60 Columbia, TN 38402 USA Ph: 931-388-0626 Fax: 931-380-0319 www.pugmillsystems.com GEORGE H. BODMAN, INC. Chemical cleaning advisory services for boilers and balance of plant systems George H. Bodman Pres / Technical Advisor P.O. Box 5758 Office (281) 359-4006 Kingwood, TX 77325-5758 1-800-286-6069 email: blrclgdr@aol.com Fax (281) 359-4225 For info. http://powereng.hotims.com RS# 451 For info. http://powereng.hotims.com RS# 452 For info. http://powereng.hotims.com RS# 450
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- 59. www.power-eng.com56 INDEX RS# COMPANY PG# SALES OFFICERS# COMPANY PG# 1421 S. Sheridan Rd., Tulsa, OK 74112 Phone: 918-835-3161, Fax: 918-831-9834 e-mail: pe@pennwell.com Sr.Vice President North American Power Group Richard Baker Reprints Foster Printing Servive 4295 Ohio Street, Michigan City, IN 46360 Phone: 866-879-9144 e-mail: pennwellreprint@fosterprinting.com National 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, Nova Scotia, Newfoundland, Ontario Regional Marketing Consultant Natasha Cole 1455 West Loop South, Suite 400 Houston, Texas 77027 Phone: 713.499.6311; Fax: 713.963.6284 e-mail: natashac@pennwell.com AK, AZ,CA,CO,HI,IA,MN,MT,ND,NE,NM,NV, OK,OR,SD,UT,WA,WI,WY,AB,BC,SK, Manitoba, Northwest Territory, Yukon Territory International Sales Mgr Tom Marler The Water Tower Gunpowder Mills Powdermill Lane Waltham Abbey, Essex EN9 1BN United Kingdom Phone: +44 1992 656 608, Fax: +44 1992 656 700 email: tomm@pennwell.com Belgium, Czech Republic, Denmark, Finland, France, Germany, Hungary, Norway, Poland, Portugal, Slovenia, Spain, Slovakia, Sweden International Sales Mgr Roy Morris The Water Tower Gunpowder Mills Powdermill Lane Waltham Abbey, Essex EN9 1BN United Kingdom Phone: +44 1992 656 613, Fax: +44 1992 656 700 email: rmorris@pennwell.com UK, Austria, Africa, Holland, India, Italy, Ireland, Israel, Russia, Australia New Zealand, Singapore, Scotland, Switzerland, Turkey, Greece, UAE/SAUDI and Iran Classifieds/Literature Showcase Account Executive Jenna Hall 1421 S. Sheridan Rd., Tulsa, OK 74112 Phone: 918-832-9249, Fax: 918-831-9834 email: jennah@pennwell.com 13 Nord-Lock Inc 23 www.bolted.com/subscribe 9 Orion Instruments 19 www.orioninstruments.com 21 PENNWELL CORPORATION 40 www.power-eng.com/webcasts 17 PENNWELL CORPORATION 34 www.power-eng.com/webcasts 25 Power Generation Week C3 www.powergenerationweek.com 15 Power-Gen 27 International 2015 www.power-gen.com RENTECH BOILER SYSTEMS INC. DIGITAL EDITION-COVER www.rentechboilers/facilities 6 Rotork Controls Inc 11 www.rotork.com 3 Siemens AG 5 www.siemens.com/sppa-t3000 8 Terrasource Global 15 www.terrasource.com/pe 23 Valve and Gate Group 41 www.vag-group.com 5 Victory Energy 9 Operations LLC www.victoryenergy.com 18 Young Franklin Inc 35 www.yf.com Advertisers and advertising agen- cies assume liability for all contents (including text representation and il- lustrations) of advertisements print- ed, and also assume responsibil- ity for any claims arising therefrom made against the publisher. It is the advertiser’s or agency’s responsibil- ity to obtain appropriate releases on any items or individuals pictured in the advertisement. AREVA DIGITAL BELLYBAND www.areva.com Brandenburg Industrial C4 Service Company www.brandenburg.com 16 Busch USA 33 www.buschusa.com 4 CBI 7 www.CBI.com 20 CD-adapco 39 www.cd-adapco.com 22 Clearspan 41 Fabric Structures www.ClearSpan.com/ADPWRE 24 Cleaver-Brooks Inc 47 www.cleaverbrooks.com/chemical 2 Conbraco Industries Inc 3 www.apollovalves.com 11 Flexim Americas Corp 22 www.flexim.com 12 Goodway 23 Technologies Corp www.goodway.com Hytorc Industrial Tools 17 www.hytorc.com 1 Kiewit Power C2 www.kiewit.com 10 Lapeyreb Stair 21 www.lapeyrestair.com 19 Magnetrol International 37 www.magnetrol.com 14 Membrana 25 www.Liqui-Cel.com 7 Mitsubishi Power 13 Systems Americas Inc www.mhpowersystems.com
- 60. COVERING IT ALL December 6-10, 2015 Las Vegas Convention Center / Las Vegas, NV, USA www.powergenerationweek.com SAVEthe DATE! Owned Produced by: Supported by:Presented by: For info. http://powereng.hotims.com RS# 25