Documente Academic
Documente Profesional
Documente Cultură
2009 Plant
of the Year City of Springfield's
Dallman 4
Balances Energy
and the
Environment
August 2009
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28
TK
On the cover
By building a new Illinois coalfired unit on the shore of Lake Springfield, City Water, Light
& Power of the City of Springfield, Ill., has ensured that it will no longer have to buy power
on the wholesale market. KBV Springfield Power Partners was the Dallman 4 engineering, procurement, and construction contractor. Photo courtesy Terry Farmer Photography,
terryfarmer.com
TK
SPECIAL REPORTS
2009 MARMADUKE AWARD
GENERATION TECHNOLOGY
TK
Integrated gasification combined cycle has for many years been a promising technology. Three experts weigh in on the current balance of pros and cons, and on when
IGCC is likely to deliver on its promises.
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SPEAKING OF POWER
Politics Trump
Scientific Integrity
n their recent endangerment finding draft technical support
document (TSD), scientists at the U.S. Environmental Protection Agency (EPA) conclude that carbon dioxide emissions
are a public health hazard and should be regulated under the
Clean Air Act. Federal law requires that regulations be based
on scientific information that is accurate, clear, complete, and
unbiased; the most recent available; and collected by the best
available methods. The EPAs TSD on carbon emissions violates
all of these requirements.
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GE Energy
I promise
David Chapin, Lead Product Manager,
Filtration Technologies
Boiler cleaning outages whether planned or not are costly and disruptive. Now you can do something
about it. The Powerwave+ impulse cleaning system helps keep your boilers working even while theyre being
cleaned. Which not only helps reduce scheduled shutdowns, it also helps eliminate unscheduled outages due
to buildup. And thats not just a promise. Its the promise of something better. Find out how Powerwave+
technology is already hard at work for your peers at ge-energy.com/powerwave.
GLOBAL MONITOR GLOBAL MONITOR GLOBAL MONITOR GLOBAL MONITOR GLOBAL MONITOR GLOBAL MONITOR GLOBAL MONITOR GLOBAL MONITOR GLOBAL MONITOR GLOBAL MONITOR GLOBAL MONITOR GLOBAL MONITOR GLOBAL MONITOR GLOBAL MONITOR GLOBAL MONITOR GLOBAL MONITOR GLOBAL MONITOR GLOBAL MONITOR GLOBAL MONITOR GLOBAL MONITOR
GLOBAL MONITOR
Help Build the Global
Energy Observatory
How would you like to be able to access data
on all the power plants in the world and all
of their performance metrics, analyze that
data, and map it? Those abilities are part
of the vision behind the Global Energy Observatory (GEO), an OpenModel website that
serves as a wiki for global energy data.
Like Wikipedia, this enterprise uses
wiki software that allows for the creation
and editing of interlinked web pages by
a collaborative community of users. GEO
seeks to promote an understanding, on
a global scale, of the dynamics of change
in energy systems, quantify emissions and
their impacts, and accelerate the transition to carbon-neutral, environmentally
benign energy systems while providing affordable energy to all. It is attempting to
do so by using open source software tools,
including Google Earth, and encouraging
community participation. Thats where the
power generation community comes in.
GEOs databases are organized into three
categories: GEOpower for power generation, GEOresources for fuels and resources,
and GEOtransmission (under construction)
for the transmission of electricity and fuels. The GEOpower database can account
for coal, gas, geothermal, hydro, nuclear,
oil, solar PV, solar thermal, waste, and
wind plants of all sizes, though to date
it includes mostly utility-scale plants for
which public data are available.
The project was conceived and developed by Dr. Rajan Gupta, a fellow of Los
Alamos National Laboratory and a theoretical high energy physicist with wide-ranging research interests. It is sponsored by
the New Mexico Consortium and has been
built primarily by Gupta and four University of New Mexico electrical and computer
engineering masters students.
tracked by regulatory agencies (for example, seven years of the EPAs eGRID data for
U.S. plants).
Drilling Down into the Database
To test the database, POWER searched for
the small Valmont Station in Boulder, Colo.
(Figure 1). GEOpower shows the plant as
being owned by Public Service Co. of Colorado (an Xcel Energy subsidiary), having a
design capacity of 236.9 MWe, firing bituminous coal as its primary fuel, and
using water from Boulder Creek. It also
includes the commissioned date for both
units. Performance data as of mid-June
were GWh generated; heat input; and CO2,
SOx, NOx, and mercury emissions. (Interestingly, GEO showsas does the EPAs
original eGRID data, according to Gupta
CO2 emissions increasing between 2000
and 2004 even though gigawatt-hours
generated dropped.)
For comparison, we looked at information on Xcel Energys Valmont Station website, which gives 229 MW as the plants
size and low-sulfur coal from western
Colorado mines and natural gas as its
fuels. Xcel also provides the following information about the plant: Unit 5 (V5)
went into service in 1964 and can burn
either coal or natural gas. The unit uses
three surrounding lakes for circulating
1. Getting a grip on global energy data. The collaborative Global Energy Observatory seeks to provide easy access to data on all energy systems around the globe. To date, this
work in progress includes publicly available information on power plants in nine countries. This
screen shot shows the interface for selecting a plant whose data you want to examine and/or
edit. Source: New Mexico Consortium
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866-450-4248 www.hach2O.com
Be Right
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GLOBAL MONITOR
cooling water. Unit 6 (V6) began generating electricity in 1973. (It also includes
the interesting historical note that when
Unit 1no longer operatingwent into
service in 1924, Valmont was the largest
power station west of the Missouri River.)
Plant Manager Mark Fox confirmed that
Unit 5 burns gas when the economics of
doing so are favorable. He also resolved
the apparent discrepancy in water source
by noting that cooling water comes from
reservoirs (also called lakes) that are fed
by Boulder Creek.
Xcel notes that Valmont Station is the
companys most efficient power plant. Unit
5 has a scrubber to reduce SO2 emissions,
low-NOx burners to reduce NOx emissions,
and a baghouse that removes particulate emissions from the flue gas by more
than 99%. (GEOpower includes fields for
Type of SOx First Control Device, Type
of NOx First Control Device, and Type of
Mercury Control Device, but those were
empty fields for Valmont.) The reservoirs
used for cooling water have also been
recognized as a wildlife refuge, and the
plant was chosen by Audubon Colorado as
the first important Bird Area in Boulder
County. Some of that qualitative information would be invisible to GEOpower,
which doesnt acknowledge that Unit 5
can switch fuels. Gupta noted that GEO
allows users to correct mistakes and add
missing information.
When asked how GEOpower would account for changes in equipment (including emissions control systems) and hours
run year-over-year as those factors affect
emissions, Gupta responded that the analysis will correlate those data. Whether we
will be able to get all the data needed is
an open research question.
We hope that GEO becomes a ready
reference for journalists and advocacy
groups that come to appreciate the value
of structured scientific information that
is available from one place, Gupta told
POWER. Our goal is not to be antagonistic
to power companies and their associated
partners but to provide a forum for a scientific discussion and analysis that leads
to cheap, clean energy for all. GEO is designed to highlight efforts by industry to
take innovative steps towards this.
Gupta, who clarified that GEO is still a
research project and not a finished product also noted that the more complete
the picture is, the more information we
can infer, and this inferred information
can then become the starting point for
validation through the wiki process.
To add a new plant to the database, or
to provide additional or correct data for
10
Revived FutureGen
Faces Renewed
Funding Obstacles
A little more than a year after the Bush
administration abruptly withdrew its support for the FutureGen project, the Department of Energy has again announced
it will back the proposed Illinois gasified
coal power plant and carbon capture initiative. Though the 275-MW project may
be different in technical aspectsit will
be initially designed for 60% carbon capture, not 90%, and gasify only Illinois Basin Coal (Figure 2)it is still riddled with
many of same funding problems. Making
matters worse, it may have been revived
too late: Since the DOE withdrew its support, several major carbon capture and
storage (CCS) projects and alliances have
sprouted in the U.S., and these could give
FutureGen a run for its money.
Project costs for FutureGen now stand
at about $2.4 billion, with construction
expected to cost between $1.7 billion and
$1.9 billion. In June, the DOE pledged
$1.073 billion to the project$1 billion of which would come from American
Recovery and Reinvestment Act of 2009
funds for CCS research. But it required
under a provisional agreement with the
FutureGen Industrial Alliance that the alliance expand to 20 members by years
end and that each member contribute between $20 million and $30 million over
the next four to six years. Other conditions included development of a complete funding plan and a rapid restart
2. One step forward, two steps back. The DOEs conditional backing of the FutureGen project revived hopes for the Illinois gasified coal power plant and carbon capture initiative.
But the project is still riddled with many of its old funding problems, which poses risks that FutureGen Alliance members are not willing to face. Barely a week after the DOE announced renewed
support, American Electric Power and Southern Co. withdrew from the alliance. Both companies
have said they will redirect funds to other carbon capture initiatives, like the National Carbon Capture Center, of which the DOE is also member. Source: DOE; modification: Leslie Claire
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GLOBAL MONITOR
of the technologies, when it is fully operational in 2010. The
center is to be located partly at the Power Systems Development
Facility (PSDF), a coal plant research complex south of Birmingham, Ala., that is run by the public-private consortium. Southern
Co. said existing facilities at the PSDF would be modified to test
precombustion CO2 capture while postcombustion CO2 capture
will be tested at Plant Gaston, a coal plant adjacent to the PSDF
that is operated by Southern Co. subsidiary Alabama Power.
Meanwhile, as the DOEs regional sequestration partnerships
make significant gains in their carbon sequestration tests, major
projects with better initial design capture capabilities than FutureGensuch as Tenaskas proposed $3.5 billion Trailblazer Energy Center in Sweetwater, Texasare pushing forward. If built,
that 600-MW plant could capture 85% to 90% of CO2 emissions
while using supercritical steam, pulverized coal technology. The
CO2 will then be provided for use in enhanced oil recovery and
geologic storage.
Rocky Mountain areas. When the PGCs results are combined with
the DOEs latest available determination of proven gas reserves
(238 trillion cubic feet as of 2007), the report says that the U.S.
has a total available future supply of 2,074 trillion cubic feet.
Thats an increase of 542 trillion cubic feet over the previous
evaluation. Curtis cautioned, however, that the current assessment assumes neither a time schedule nor a specific market
price for the discovery and production of future gas supply.
Estimates of the Potential Gas Committee are base-line estimates in that they attempt to provide a reasonable appraisal of
what we consider to be the technically recoverable gas resource
potential of the United States, he explained.
The USGS Wyoming Gillette coal field assessment is available
at http://tinyurl.com/lw7yv5; the PGCs complete report can be
purchased in August from http://www.mines.edu/.
Of Fracking, Earthquakes,
and Carbon Sequestration
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GLOBAL MONITOR
sert that whats causing the temblors is fracking, which began
in earnest in 2001 in the Barnett Shale, a geologic formation
said to be the nations richest gas field. A geologist has yet to
confirm the claim.
At the same time, fracking-related quake concerns are mounting in northern California, around The Geysers region, where
start-up company AltaRock Energy is looking to tap geothermal
energy in a demonstration of Engineered Geothermal Systems
technology. The technology essentially pumps water into the
earth, creating fractures in the hot dry rock (Figure 3). The
water then flows into the fissures, creating a reservoir of very
hot geothermal fluid that is continuously heated, and when it is
returned to the surface, the pressure decrease produces steam,
which is used to turn a turbine. That project has secured more
than $36 million from the DOE and has the backing of several
large venture capital firms.
But it has caught bad press from The New York Times, which
points out that the project proposes fracturing hard rock more
than 2 miles deep in an area overlying two fault lines. The newspaper draws similarities between the Alta Rock demonstration
and a Swiss geothermal prospecting project in Basel, which is
believed to have triggered a massive earthquake on Dec. 8, 2006,
after prospectors drilled 3 miles into a significant fault.
Alta Rock has disputed the comparison, saying that Basel sits
on top of a large (200-km long) locked fault that previously
ruptured and heavily damaged the city in the 14th century. We
carefully chose our site to avoid Basels problems, the company
said in a statement. There has been geothermal energy production at the Geysers since 1965. AltaRocks project is located in
a seismically active area adjacent to smaller faults (the closest
Injection
well
Engineered
fracture
system
Hot rock
faults are 3 and 11 km long) which are not locked due the constant stress relief resulting from small seismic movements.
Can Fracking Cause Earthquakes?
There is no consensus among geologists on whether drilling
causes earthquakes. But, according to Dr. David Oppenheimer, a
seismologist with the U.S. Geological Survey (USGS), the fracking
process could certainly generate seismic activity because that
is how the fractures are made, he told POWER in July. Concerning the Alta Rock project, he said, After the fractures have been
established at the Geysers and an enhanced geothermal system
has been implemented where cold water introduced in the injector flows through the fractures to the second well to return to
the surface, it is possible that seismicity could be induced due to
thermal contraction of the reservoir rock.
There are also certain conditions that could trigger a large
earthquake, and foremost among them is sufficient, pre-existing
tectonic stress, conditions that exist at The Geysers because the
geothermal field is located near the Pacific-North American plate
boundary, he said. However, even in areas like Colorado, far from
a plate boundary, a magnitude 5.3 quake was induced by pumping of waste fluids into a deep disposal well at the Rocky Mountain Arsenal. With regard to fracking and earthquakes associated
with natural gas extraction, Oppenheimer said that the pressures
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12
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GLOBAL MONITOR
introduced by the process would have to exceed a minimum
compressive tectonic stress to encourage an earthquake. If the
hydrofracture pressures are lower, then no fractures should occur, he said.
Implications for Carbon Sequestration
The fracking-quake debate raises questions about whether geological carbon sequestrationstoring carbon dioxide by injecting it
deep within geologic formationscould prompt quakes. Dr. Christian Klose, a geophysical hazards research scientist from Columbia
University, says it couldas much as any geological fluid injection can. He told POWER in July that three processes could trigger
seismic activity, large and small: pore fluid pressure changes; fluid
mass (volume) changes, which can cause stress on the rock; and
migration of the CO2 through the rock over decades to centuries.
CO2 is buoyant since its density is [lower] than saline water deep
in the crust, he said. Thus it will come upward through cracks
and fractures and faultseven in so-called cap rocks are rock
discontinuities that cause leakages.
Klose said that the quake risk is intensified by hydrofracturing,
a process that is recommended by the DOEs Midwest Regional
Carbon Sequestration Partnership to provide a better injection
rate into rocks that have moderate porosity and low effective
permeability. The recommendation comes as one of several lessons learned from a sequestration field test at FirstEnergys R.E.
Burger Plant near Shadyside, Ohio, in the Appalachian Basin.
But, according to Traci Rodosta, a geological sequestration
project manager for the National Energy Technology Laboratory,
quake risk is well-assessed during research and development of
any given project. Potential sequestration reservoirs are thoroughly characterized prior injection, she told POWER. In order
to eliminate and reduce the potential for fault activation and
slippage along preexisting fractures that could be caused when
injecting fluids at high pressures, regulatory agencies limit injection rates and pressure to avoid unintentional hydrofracturing. CO2 storage projects would operate under similar guidelines,
and the risk managed through site characterization, injection
design, and monitoring.
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13
GLOBAL MONITOR
5. Taking to the sky. A study by Stanford researchers concludes
that sky-high winds at altitudes around 32,000 feet have the highest
wind power density, and that tapping just 1% of the power of these
winds would be enough to power all civilization. Several prototypes
of turbines that seek to harness the energy in high-altitude winds have
been proposed. An example is Sky WindPowers model, a single tethered kite of four connected turbines, each with spinning rotors. Courtesy: Ben Shepard, Sky WindPower
and Seoul, which are affected by the East Asian jet streamhad
a higher power density. On the other hand, Mexico City and So
Paolo, which are located at tropical latitudes, are rarely affected
by polar and subtropical jet streams and therefore have lower
wind power densities.
NSE
6. A carbon footprint.
Q u a l i t y, S a fet y & Pr i d e. . .
1115 Industrial Drive
Owensboro, KY 42301
Ph (270) 926-2534
Fax (270) 683-1960
Info@NationalSteelErection.com
Th ro u gh o u t th e U. S . A .
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CCS demonstration project by 2014a timescale that aligns perfectly with the UK
governments plans.
But ScottishPower has yet to gain the
UK governments backing for the project.
The company is in competition with two
other contendersE.ON and Peel Power
in a government contest, whose winner
would secure 1 billion in funding for a
postcombustion technology that captures
90% of emitted greenhouse gases at a
300-MW to 400-MW coal-fired unit. E.ON
in June opted for Mitsubishi Heavy Industries KM-CDR process, which uses a proprietary solvent (KS-1) for CO2 absorption
and desorption.
If E.ON wins, it said it would use that
technology to build a capture plant at its
proposedand highly controversial1,600-MW supercritical pressure coal plant
proposed for the Kingsnorth Station in
Kent. Peel Power, meanwhile, has joined
forces with Denmarks DONG Energy and
Germanys RWE to build a facilitythough
its scope has not been described yet. The
government is expected to announce the
winner this summer.
Akers prototype at Longannet weighs
30 metric tons, covers an area of 85 square
meters (m), and is said to process 1,000
m3 of exhaust gases per hour. The two
companies will now test the technology
to determine how much heat is required
to break the bond between CO2 and the
amine, and how long the capture chemical
can keep capturing CO2 effectively. They
also plan to test three different amine solutions over seven months.
Aker, whose technology is also in use
at the Mongstad project in Norway, said
in a release in May that early results from
tests at a gas power plant show a capture
rate above 85%, and that the amines had
successfully demonstrated lower energy
requirements and less degradation.
European Interest
in Saharan Solar Project
Heats Up
Plans to install a series of solar panel
farms in the Sahara Desert to power Europe and North Africa are heating up.
The idea was discussed in May as part of
the newly formed Mediterranean Union,
launched at a summit in Paris, and it now
has the backing of both UK Prime Minister
Gordon Brown and French President Nicolas Sarcozy.
More recently, Germanys Wuppertal Institute for Climate, Environment and Energy and the Club of Rome issued a study
that said the project could generate some
2 trillion worth of power through 2050.
7. Built on sand. Several European countries are backing an ambitious project that seeks
to establish 6,500 square miles of concentrated solar power plants and a super-grid of highvoltage transmission lines in the vast deserts of North Africa and in the Middle East, saying that
they could power 15% of Europes energy needs by 2050. The project got a major boost this
July, when 12 major European companies agreed to study and devleop the 400 billion project.
Courtesy: Desertec Foundation
And this July it received yet another major boost, with 12 companies congregating at the request of German insurance
firm Munich Re and formally agreeing to
analyze and develop a multidimensional
framework for the 400 billion project.
The Desertec Industrial Initiative, as the
12-company coalition is now called, includes European giants Deutsche Bank,
Siemens, ABB, and utilities E.ON, RWE,
and Abengoa Solar.
At the heart of the ambitious Desertec
project is the goal to establish 6,500
square miles of concentrated solar power plants in the vast African and Middle
Eastern deserts, along with a super-grid
of high-voltage transmission lines, to supply countries in Europe and Africa with
electricity. The project could supply continental Europe with up to 15% of its total
energy needsproducing a stunning 20
GW of power by 2020, as Guenter Gloser,
Germanys deputy foreign minister, told
Reuters in June. The first possible power
station would be a 2-GW solar thermal
power station in Tunisia with power lines
to Italy, a project that would take five
years to build.
According to the Desertec Foundation,
satellite studies conducted by the German Aerospace Center show that by using
less than 0.3% of the entire desert of the
Middle East/North Africa region, enough
electricity and desalinated seawater can
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GLOBAL MONITOR
litically unstable North African countries
in the Sahara and about the concept of
centralized transmission lines, which could
be vulnerable to terrorist attacks. Project
proponents counter by saying that the EU
already imports energy from regions and
sources that are not risk free.
16
www.powermag.com
POWER Digest
News items of interest to power industry
professionals.
Worley Parsons to Consult with Governments for New Nukes in Egypt, Armenia. WorleyParsons said on June 19
that it had signed separate contracts to
provide consultancy services to the Egyptian Nuclear Power Plant Authority and
the Ministry of Energy and Natural Resources of the Republic of Armenia for
new nuclear projects in those countries.
The companys EGP 900 million (US$160
million) contract with the Egyptian government includes site and technology
selection studies for that countrys first
nuclear power plant, as well as design,
construction management, commissioning, and start-up. Execution of the eightyear project will be carried out from the
companys office in Sofia, Bulgaria, and
supported locally in Cairo.
The scope of the $430 million contract
signed with the Armenian government will
be implemented in four phases, with the
first two phases scheduled to begin in
2009. The major work during the first two
phases includes development of a feasibility study and then managing and assessing
the tender process for strategic project investors. The duration of these two phases
is expected to be one year. Phases three
and four require the company to organize
and manage a tender, eventually recommend EPC contractors for selection, and
then provide consulting services to the
ministry during the design, construction,
and project start-up. This contract will
also be managed by WorleyParsons Sofia
office.
ABB Wins Order to Power Algerian
Seawater Desalination Plant. Power
and automation group ABB on June 22
announced it had won a $28 million
contract from environmental solutions
company Hyflux for a turnkey electrical solution to power the worlds largest membrane-based reverse osmosis
seawater desalination plant. The Magtaa
desalination plant is being constructed
in the western Oran region of Algeria. It
will have a designed capacity of 500,000
cubic meters per day of drinking water to
serve about 5 million people. The project
is part of the Algerian governments effort to provide clean drinking water to its
growing population.
As part of the contract, ABB will set up
a 220-kV outdoor substation to provide
power to the facility and also supply products such as power transformers, mediumvoltage drives and a range of medium- and
low-voltage switchgear. ABB will be re-
GLOBAL MONITOR
sponsible for the design, engineering,
supply, installation, and commissioning of
the electrical plant system. The project is
scheduled for completion by 2011.
AREVA T&D Inaugurates GI Substation Factories in China. AREVA Transmission and Distribution (T&D) and
Chinese partners on June 18 inaugurated
two factories in Wuxi and Yangzhou, in
Jiangsu province, that will manufacture
key components for gas-insulated (GI)
substations in China and throughout the
world. The Wuxi Alumin Casting Plant
is a joint venture between AREVA and
Wuxi Alumin Casting, and the AREVA
T&D (Yangzhou) High Voltage Bus-ducts
Plant is a joint venture between AREVA
and Jiangsu Jinxin Electric Appliance.
The products of both factories will be
used in AREVA T&Ds production plants
and substations in China and throughout
the world.
The investments, which total some 30
million, follow similar ventures by the
company in Suzhou and Xiamen. Those
factories manufacture complete GI substations (GIS) up to 550 kV. Since 1988,
when AREVA installed the first GIS in
China, it has installed more than 1,500
Correction
The June editorial (Gone with the
Wind, p. 6) incorrectly quoted an estimate of the installed cost for offshore
wind turbines. The estimate is actually
$5,000/kW.
POWER regrets the error.
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17
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STEAM TURBINES
Managing Minimum Load
Reducing the minimum load at which a steam turbine can reliably operate is one way to increase revenue for marginal baseloaded units during periods of low electrical demand. For this
reason, it is not unusual to see merchant plants operating at
super minimum load levels that are well below the typical
25% rated full-load limits. However, such units are operating
well outside the original equipment manufacturer (OEM) design
basis, and owners may experience undesirable damage to their
turbines for a number of reasons. Thats why it is important for
owners to understand the trade-offs and risks that come with
such operation.
The following is an overview of the main steam turbine and
generator issues that must be considered before deciding to
operate a steam turbine generator below OEM minimum load
limits.
Anticipate Increased
HP-IP Rotor Vibration
Units with partial arc admission, where the lower arc valves
open first, are more susceptible to increased vibration at reduced minimum loads. This is due to unbalanced upward steam
pressure forces that tend to lift the rotor and partially unload
the high-pressure/intermediate-pressure (HP-IP) bearings.
RS
Shaft
radius
RP
CB
RB
Pad ground
in radius
Bearing
set radius
Bearing
clearance
m=1
Cb
Cp
Example:
Shaft radius = 2.000 in
Bearing set radius = 2.003 in
Pad ground-in radius = 2.004 in
18
=1
(Rb Rs)
(Rp Rs)
m=1
2.003 2.000
= 0.25
2.004 2.000
www.powermag.com
Toda
To
d y
da
yss poowe
w r pla
pllant
ants req
an
e uiire aadvanced air quality control technologies to meet present and future demands from
a ma
mark
mark
r ett lea
eade
deer th
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siistently
st
delivers peak environmental performance and the lowest life-cycle cost.
Baabc
Babc
bcoc
occk Po
Powe
wers wo
wer
worl
r d-cl
d-cl
dc ass
ass SCR technology has already reached an industry pinnacle with over 38,000 MWs now
o er
op
erat
atin
at
ng att ind
ndu
usstry--leeading levels in the USA.
u
N w weer
No
ree ne
near
arr tthe
he sum
umm
mit on wet and dry SO2 removall, have demonstrated that our FGD systems are carbon capture
re
eaad
dy,
y, and ccan
an
n ach
hieve
ieeve less then 2 ppm SO2 while minimizing energy usage.
We off
We
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ulti
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ple we
w t sccru
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xt tim
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CIRCLE 13 ON READER SERVICE CARD
www.babcockpower.com
FOCUS ON O&M
4. LP salt solution line. The Wilson line is often the zone of first condensation in the
LP steam turbine, where steam moisture is typically about 3% to 4%. Concentrated chloride
solutions are often present. The salt solution zone is bordered by the saturation line (dashed
line) on top and the Wilson line (the solid line) below the red area. Source: TG Advisers Inc.
538C
Enthalpy
IP Inlet
Normal
Tip
Part load
Hub
L-1R
mean
diameter
Pure
water
Saturation
line
Entropy
MATERIALS
NANOSTEEL POWER SOLUTIONS
A New Level of
Power Plant Protection
APPLICATIONS
INSPECTIONS
FOCUS ON O&M
5. Damaged last-stage blades. The
turbines last stage of blades is particularly
vulnerable to water droplet erosion damage.
Courtesy: TG Advisers Inc.
www.dmwcc.com
CIRCLE 15 ON READER SERVICE CARD
www.powermag.com
21
FOCUS ON O&M
Manage Thrust Temperatures
Although it is unlikely, thrust imbalances
may develop with excessive thrust bearing temperatures. Temperature monitoring is a way to assess this risk.
Minimize Generator Heating
Its important to ensure that operation
remains within the generator capability
curve. Also monitor stator slot temperatures, hydrogen gas temperatures, and
generator rotor vibration to make certain
generator operation remains within the
OEM specifications.
Contributed by David Charlton, PE
(david.charlton@tgadvisers.com), senior
consultant for TG Advisers Inc.
6. Two ways to boil water. The curves on the graph represent equilibrium states.
The curve bordering the liquid and gas phases is referred to as a vaporization curve. At normal
conditions of pressure and temperature, a fluid is at 1 atm (14.7 psi) and 25C (77F). The white
arrow illustrates a typical heating process that occurs at atmospheric pressure. The red arrow
illustrates that saturation temperature (hence, boiling) of a liquid can also occur by reducing
the liquids pressure. Source: Belzona Inc.
Supercritical
fluid
217.7
PUMPS
Critical point
22
Normal melting
point
Solid
Pressure (atm)
ler vane. As water (or any other fluid) enters the pump, it is deflected by the vane.
Above the leading edge of the vane, the
fluid is compressed, creating a high local
pressure area. Directly after the leading
edge, theres a small area of decreased
pressure. If this decrease in fluid pressure
Normal boiling
point
Liquid
1
Gas
6.0 x 103
Triple point
0
0.0098
Temperature (C)
100
374.4
7. How to damage a pump. A cavitating fluid can cause extensive damage to a pump
impeller even during normal operation. The imploding pressure caused by cavitation has been
recorded as high as 145,000,000 psi, which exceeds the elastic limit of any exotic alloy. These
vapor bubbles are responsible for the mechanical damage found on pump impellers placed in
any type of service that causes cavitation. Courtesy: Belzona Inc.
Cavitation damage
High pressure
ure
Low pressure
ure
www.powermag.com
GE Energy
NOW SHOWING
Cleaner burning coal technology is here, and innovation from GE Energy
is playing a leading role. IGCC offers a power solution that taps the globes
abundant coal supply, while reducing emissions and enabling carbon capture
retrot. The largest cleaner coal facility in the world, Duke Energys 630MW
IGCC Edwardsport, Indiana, power plant ( now under construction ), is
advancing the evolution of proven IGCC technology to the next stage.
GE Energys commitment to sustainable solutions is helping
to transform coal into a star attraction. Visit
us at ge-energy.com/gasication
to nd out more.
FOCUS ON O&M
8. Cavitation damage is severe. Close-up of damage to a pump impeller caused by
cavitation. Courtesy: Belzona Inc.
FOCUS ON O&M
The 7,000-Foot Challenge
The Springerville Generating Station in Springerville, Ariz. (Unit
3 was POWERs 2006 Plant of the Year), uses two lined ponds to
hold water collected from its cooling towers. With the construction of Unit 4, the plants owner, Salt River Project (SRP), one
of Arizonas largest utilities, wanted to increase the capacity of
pumps used to move effluent from one pond to another to avoid
the possibility of overflow. SRP engineers wondered if using a
vertical turbine pump on a floating barge would improve managing the water levels in the two ponds.
The project location was a challenge to designers of the fluid-handling systems. The generating station, located in an area
known as the Gateway to the White Mountains, is at an elevation
of 7,000 feet and often experiences wind speeds that gust up
to 90 miles per hour. The solution also had to accommodate occasional subzero temperatures and fluctuating pond levelsthe
result of rainwater and snow runoff.
Originally, the specification was to supply one stainless steel
pump barge capable of supporting two submersible pumps (including motors) with an associated piping manifold that would
extend to the edge of the barge. The plan for the ancillary barge
equipment included a discharge manifold with flanged connections, check valves, isolation valves, and an overhead trolley for
servicing the two pumping units. The floating barge also would
house a duplex pump control panel and a 40-foot-long floating
walkway that would be used to access the shoreline.
This approach proved to be more expensive than expected
but also posed an additional problem: SRP did not want any
penetrations through the liner, so the pumps and pipe could not
be secured in place.
Several other design iterations considered using submersible
turbine pumps supported by a pipe at the edge of the pond on
a 45 degree angle or self-priming pumps that would be situated
on the dry bank of the pond. SRP eventually chose the latter
solution.
Ultimately, two Gorman Rupp T2 series model T2A60 V-beltdriven pumps with 10-horsepower U.S. Electric motors were installed (Figure 10). These pumps were chosen for their reliability
and their ability to accommodate the limited net positive suction head available. The pumps were then enclosed in a prefabricated, insulated fiberglass structure provided by Kysor Panel
Systems that is equipped with space heaters and temperature
controls.
Contributed by Quadna Inc.
Presentations
Event Collateral
Media Kits
Direct Mail
Online Marketing
Recruiting Packages
800.290.5460 I POWER@theYGSgroup.com
The YGS Group is the authorized provider of custom reprint products from POWER.
www.powermag.com
25
Steven F. Greenwald
Jeffrey P. Gray
26
increase Californias participation in the broader western regional energy planning efforts.
These reforms, unfortunately, remain frozen as policy objectives, their implementation awaiting some future date.
This transmission planning stagnation is even more troubling
today as significant increases in renewable power will be necessary for California to meet its ambitious greenhouse gas emissions reduction goals. The CPUC/CEC report finds that the 33% by
2020 RPS target will require California to almost triple its amount
of renewable electricity. Seven additional transmission lines at
a cost of $12 billion are needed to connect and integrate this
magnitude of incremental renewable power. This is in addition
to four new major transmission linesonly three of which are
under waythat are necessary to connect renewable resources
needed to meet the current 20% by 2010 RPS requirement.
An Impossible Task?
The CPUC/CEC report models three illustrative timelines for meeting a 33% RPS target. The business as usual approach would defer
the states realization of the 33% RPS target until 2024. Assuming
California effectively streamlines infrastructure planning and permitting, the date could be moved up to 2021. However, the report
wisely cautions that if external risks are considered, such as
financing difficulties and public opposition or legal challenges to
projects, it is uncertain if or when the 33% target could be met.
One thing is certain: If California has any hope of meeting RPS
targets, many miles of new transmission lines must be built. However, four years after EAP II, meaningful changes in transmission
project permitting have yet to be fully implemented, appropriate
levels of interagency integration have not been achieved, and
regulatory redundancy and inconsistency remain the norm.
Recent efforts to gain approval for a new transmission project in Southern California to access renewable generation have
highlighted the continuing regulatory morass that significantly
delays the decision-making process and, necessarily, increases
costs. In light of the recognized need for new transmission infrastructure, this status quo simply undermines RPS goals.
www.powermag.com
28
Description
8/27/03
4/11/06
KBV awards contract for furnishing, fabricating, and delivering structural steel
11/30/06
12/4/06
Construction begins
12/20/06
5/14/07
1/11/08
9/15/08
11/1/08
4/17/09
Boiler undergoes first fire (on natural gas) and steam blow testing
5/11/09
Unit 4 is synchronized to the electrical grid (on natural gas) for the first time, operating at 13 MW
Summer 2009
9/4/09
www.powermag.com
Intergraph and the Intergraph logo are registered trademarks of Intergraph Corporation. 2009 Intergraph Corporation. 07/09 PPM-US-0069B-ENG
CIRCLE 19 ON READER SERVICE CARD
30
Landmark Agreement
with Sierra Club
The Sierra Club believed that the air permit
limits werent aggressive enough and that
constructing the new coal-fired plant was
only one element of what should be a much
more comprehensive energy plan for Springfield. Therefore, it threatened to file suit in
order to stall the project. In 2006, CWLP negotiated a landmark agreement with the Sierra Club that allowed Dallman 4 to proceed
without any litigation over its air permit.
The original agreement between CWLP
and the Sierra Club received national attention when it was announced because it was
the first time that a U.S. utility had agreed
to cut greenhouse gases and set emission
reduction targets under standards of the
Kyoto Protocol. Specifically, CWLP agreed
to perform four tasks: close its oldest, least
efficient coal plant (Lakeside); reduce NOx
and SO2 emissions for the remaining plants;
invest in renewable energy by purchasing
120 MW of wind power60 MW for the
Contrary to what you may think, were much more than a tube tting company.
And we have our obsession with Customer Focus to thank for that. Yes, were
known throughout the world for our tube ttings. And yes, weve been at it for over
60 years. But when companies are looking harder than ever for greater value, its
our broad range of products, including orbital welders, modular systems, and a
complete line of hose, that helps us offer more than you expect. See for yourself
at swagelok.com/moreproducts.
$19.30/MWh as a surcharge on metered electricity for the wind power; the surcharge will
increase 4% per year for the term of the contract. In return, Springfield will invest up to
$1.86 million in energy conservation and efficiency programs in the same state buildings
though 2015. This agreement with Illinois allowed the City of Springfield to tick off two
of the four Sierra Club requirements.
4. Lean and clean. The Foster Wheeler steam generator is configured with low-NOx burners that reduce NOx produced during combustion. A selective catalytic reduction system will reduce NOx levels
in the flue gas to meet the plants permit limit. Courtesy: CWLP
ter Wheeler boiler (Figure 2), a Toshiba steam turbine generator (Figure 3), and Wheelabrator Air Pollution Control Inc. (a wholly owned
subsidiary of Siemens Power Generation) air quality control system
(AQCS) equipment. Emissions control at Dallman begins with Foster
Wheelers Vortex series of split-flame, low-NOx burners in the boiler
before the combustion gases pass to a substantial lineup of AQCS
equipment (Figure 4).
Downstream of the boiler, an SCR further reduces the NOx concentration in the stack gas. Next up is a powder-activated carbon injection
applied
bolting
Squirter DTIs
email: info@appliedbolting.com
TECHNOLOGY
http://www.appliedbolting.com
CIRCLE 22 ON READER SERVICE CARD
www.powermag.com
Fuel
Emissions
Boiler
Turbine
Generator
NOx
0.05 lb/MMBtu
SO2
CO
0.10 lb/MMBtu
0.012 lb/MMBtu
Hg
90% removal
Type
Subcritical
Steam pressure
2,532 psig
Steam temperature
1,055F/1,055F
1,420 klb/hr
Type
Rotational speed
3,600 rpm
Condenser vacuum
Feedwater heaters
Type
Capacity
6. The master controller. Emersons Ovation DCS system automates the plants many
control tasks over a high-speed communication network. Courtesy: CWLP
34
new
Dallman 4 stack is the second-highest landmark
in the City of Springfield and is higher than the
State Capitol building. Courtesy: CWLP
280 MVA
system that is used for mercury removal. A fabric filter, a wet flue gas desulfurization (FGD)
system for the removal of SO2 from the stack
gas, and wet electrostatic precipitator (WESP)
to remove acid mist and ultra-fine particulate
from the flue gas complete the emission reduction equipment. Siemens provided its first U.S.
utility-scale WESP to ensure the facility meets
its permitted emissions. The boiler island is
also equipped with Foster Wheelers MBF coal
mills. Table 2 summarizes many of the plants
key performance parameters.
Instead of once-through lake cooling water, the plant uses a state-of-the-art plumeabated cooling tower, which will significantly
reduce the chance of developing fogging conditions over the adjacent I-55 highway.
Coal ash disposal is subcontracted, and
ash will be delivered to an abandoned mine
located near the plant. The cost of ash disposal is $9.50 per ton for 2009, rising to $11/
ton in 2011.
President Lincolna Springfield lawyer
who rose to national prominence by reprewww.powermag.com
Who
Plant construction
Steam generator
Steam turbine-generator
Feedwater heaters/condenser
AquaTech
Cooling tower
Pulverizers
Field-erected tanks
BF Shaw Inc.
HVAC
Illinois coal
Wheeler pulverized coalfired boiler, as well as the burner management system, bottom ash handling, combustion control system,
coal-handling system, and FGD and SCR systems (Figure 6). The
Ovation system also interfaces with the Toshiba steam turbine controls. Emersons PlantWeb digital automation solution utilizes highspeed communications networks, intelligent field devices, and bus
I/O technologies to increase plant operating efficiency and reduce
long-term operation and maintenance (O&M) expenses. In all, Ova-
tion will manage 2,500 hard I/O points and 2,500 soft I/O points. The
controls were engineered and installed by the Power & Water Solutions division of Emerson.
Dallman Unit 4 is being designed and built with efficiency and
environmental stewardship in mind, said Brown, pointing out that,
when completed, the new unit is expected to cost approximately 20%
less to operate per megawatt-hour than the most efficient of the three
existing Dallman units. Emersons integrated digital automation
system is a comprehensive solution that will not only contribute to
improved operational efficiency and reduced costs, but will also support our utility-wide commitment to protecting the environment.
www.powermag.com
35
Wed Like
to Welcome
Metering
to the 21st
Century.
FULLY
I
AMR/AM
ble
Compati
www.powermag.com
www.powermag.com
37
1. In the prime of life. The Hague Repowering Project removed two old gas turbines
and generators and replaced them with state-of-the-art aeroderivative gas turbines to improve
the plants efficiency and power outputall within the confines of the plants historic 1906
building near the city center. Courtesy: E.on
Table 1. Compressed
schedule. The repowering
project
project had to
be executed between winter heating seasons to ensure heat deliveries to The Hagues
district heating grid. The timeline for the gas
turbine replacements was the projects critical
path. Source: ESI
Date
Milestone
June 2006
Contract signed
April 2, 2007
Construction begins
July 3, 2007
Combustion turbines
installation complete
November 2, 2007
November 9, 2007
38
www.powermag.com
Westinghouse AP1000
TM
W E S T I N G H O U S E E L E C T R I C C O M PA N Y L L C
What
General Electric
Two LM6000PD SPRINT combustion turbines, auxiliary skids, inlet volutes, engine
cables and sensors, and engine mounts
Primary and secondary air systems, VBV ducting system, and construction
coordination services
Lufkin Industries
SSS
Brush
Sundyne
Gas compressor
3. Flexible operation.
Each combustion turbine can operate independently or simultaneously, depending on the citys power
and heat production needs. Source: ESI
112
2 gas turbines
MWe
1 gas turbine
25
44
2. Close quarters. Two gas turbines are connected through gearboxes fitted with overrunning clutches to a double-ended generator to form the 100-foot-long drivetrain. Note that the
GT-1 on the left is a cold-end drive LM6000PD combustion turbine, whereas the GT-2 on the
right is a hot-end drive configuration. The different model turbines were required to match the
rotational direction of the generator shaft. Note that the building penetrations were already in
place and were only expanded to match the combustion air and ventilation needs of the new
turbines. Equipment enclosures and ductwork are removed for clarity. Courtesy: ESI
MWth
90
4. Always under control. ESI was also responsible for integrating the instrumentation
and controls of both combustion turbines, gearboxes, auxiliaries, and the double-ended generator. Shown are typical operating data taken as a screen capture from the control panel monitor.
Note the water connections for the SPRINT power augmentation system. Courtesy: ESI
New! UDI
Combined-Cycle/
Gas Turbine (CCGT)
Data Set
For more details, visit www.udi.platts.com, or call your nearest Platts ofce:
North America
+1-800-PLATTS8 (toll-free)
+1-212-904-3070 (direct)
EMEA
+44-(0)20-7176-6111
Latin America
+54-11-4804-1890
www.powermag.com
Asia-Pacic
+65-6530-6430
Russia
+7-495-783-4141
www.platts.com
support@platts.com
41
All
performance data are with the SPRINT system in service. Source: ESI
Operating condition
Steam turbine
backpressure mode
Steam turbine
condensing mode
Parameter
Original plant
102 MW
62 MW
Electrical output
Efficiency
45%
37%
Heat rate
7,484 Btu/kWh
8,982 Btu/kWh
75 MW
Electrical output
Efficiency
50%+
43%
Heat rate
6,826 Btu/kWh
7,937 Btu/kWh
~95%
Under 80%
Availability
Thermal capability
90 MWt
80 MWt
NOx emissions
25 ppm
!
oday
Call t -6464
85
801-7
www.powermag.com
43
10. Ready for operation. Start-up of the entire plant and restoration of The Hagues district heating system came three months
after the combustion turbines were installed. The first LM6000PD
reached full power on November 2, 2007, only seven months after
demolition began. Here, the remaining electrical connections and
instrumentation and controls have been installed, the computers
have been programmed, and the plant is making electricity for E.on
and thermal energy to keep customers warm during the winter.
Courtesy: E.on
A Reconstructed Plant
Restoring the district heating system was the
critical milestone that determined the entire
project schedule, and the projects critical
path went directly through the delivery date
of the two combustion turbines. After the
project was given a full release, the contractor immediately began the demolition phase,
working many weeks with two crews, six
days a week and 16 hours a day to stay on
schedule. See the sidebar for a series of photos that document the construction sequence.
The only long-lead equipment that wasnt
available for initial plant start-up was the
fuel gas compressor. The very high pressure ratio of this aeroderivative gas turbine
(30.7) is a key to its excellent thermal efficiency, but it also requires a very high natural gas supply pressure. For the LM6000PD,
a new gas compressor was required to raise
www.powermag.com
The direct approach for the treatment of SO2 and SO3 in stack gases is SOLVAir Products. Whether in Dry Sorbent
Injection (DSI) systems, or in wet or dry scrubbers, our products offer straightforward solutions at low capital cost
to the problems of air pollution in the stacks.
SOLVAir Select 300, a sodium bicarbonate-based product, shows significant results that are truly amazing when
used in DSI. Select 300 performs best at power plants that have an ESP and need to reduce SO2.
Use SOLVAir Select 200 trona in DSI systems and you have one of the most efficient, cost-effective ways to control
or eliminate SO2, SO3 and HCl emissions in the smokestack. The process requires no slurry equipment or reactor
vessel because sorbent is stored and injected dry into the flue duct where it reacts with the acid gas.
Call the SOLVAir professionals at 800-765-8292 or go to www.solvair.us for comprehensive documentation on the
treatment of SOx in stack gas emissions. Clean your SOX with SOLVAir Select products!
PRODUCTS
Solvay Chemicals, Inc.
1.800.SOLVAY C (800.765.8292)
www.solvair.us
Copyright 2009, Solvay Chemicals, Inc. All Rights Reserved
er at Moscow, Ohio. The unit entered commercial operation in 1991 and consumes
approximately 3.8 million tons of coal
annually. The U.S. Environmental Protection Agency required the Zimmer Station
to remove a minimum of 91% of the sulfur
1. Powering Ohio.
By making modifications in 2000 and 2007, the W.H. Zimmer Station in Moscow, Ohio, dramatically decreased the
amount of scrubber by-product that has to be landfilled. Courtesy: Duke Energy
46
www.powermag.com
9k^8rhn8`^mmbg`8^o^krmabg`8rhn8g^^]88
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Obma8Kb^f^gl89f^kb\ZgfZ]^8A;8lhenmbhgl8rhn8`^m8ngfZm\a^]8bgghoZmbhg88
eh\Ze8lniihkm8`eh[Ze8lmk^g`ma8Zg]8ygZg\bZe8lmZ[bebmr88
9m8Z8mbf^8pa^g8hma^k8fZchk8A;8ikhob]^kl8Zk^8\nmmbg`8[Z\d8hg8J<8Kb^f^gl8\hgmbgn^l8mh8ikhob]^8d^r8bgghoZmbhgl8
Zg]8mkn^8m^\agheh`r8e^Z]^klabi8Kb^f^gl8bl8ma^8hger8A;8ikhob]^k8maZm8ghm8cnlm8[nbe]l8ihp^k8ieZgml8[nm8aZl8[^^g8
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ma^8^gmbk^8eb_^\r\e^8pbma8ikh]n\ml8fZ]^8kb`am8a^k^8bg8ma^8MK8Lh8e^Zkg8fhk^8oblbm8nl8Zm
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CIRCLE 27 ON READER SERVICE CARD
The station is equipped with a magnesiumenhanced wet flue gas desulfurization (FGD)
system (scrubber) to control SO2 emissions.
In 2000, the scrubber process was modified to
2. FGD process with gypsum conversion. This diagram shows an overview of the
Zimmer Stations FGD system layout after it was retrofitted in 2007. Courtesy: Duke Energy
Mist eliminator supply
from service
water
Absorber
Oxidizer
Sulfuric acid
Hydroclone
To #1 clarifier
pH 5.0
Absorber
recirculation
pump
Density control
Clarifier
lateral
pump
Overflow
to CRW
400 gpm
Gypsum
to barge
Filter
300 gpm
CRW
overflow
to mag
plant
#2 fines
clarifier
#1 fines
clarifier
300400 gpm
Vortex
CRW
tank
To
CRW
Filtrate
sump
Return
to FGD
system
700 gpm
E-dump
to pond
C ent r if u ge
Clarifier
underflow pump
Centrifuges
Solid waste to landfill
POWER m agazine
From the editors of POWER: The online magazine
devoted to the coal-fired power generation industry
Technologies for coal- fire d po we r pla nt s a re e v olv ing ra pidly, a nd COA L POW E R
has evolved too. In its la t e st online f orm a t you g e t e v e r y t hing you v a lue d i n
print and so much m ore :
s !CCES S T O COAL POWE R whe r e v e r y ou c a n us e a br o ws e r.
s 4ECH N I C AL ART I CL ES COA L PO WE R NE WS BL OG S OPI NI ON A ND I NF O R M A T I ON
s %AS Y RET RI EV AL O F A R CHIV E D COAL POWE R f e a t ur e s .
s )N S T AN T ACCES S T O OUR A DV E R T I S E R S F OR M OR E I NF OR M A T I ON A BOUT T HE I R PR ODUC T S
s 4H E AB I L I T Y T O COM M E NT ON S T OR I E S A ND S HA R E Y OUR K NO WL E DG E WI T H T HE C OA L
BUR NI NG PO WE R
p l an t co mmu n i t y.
s * O B B O ARD
T he n vi s i t t h e o n l i n e h o m e of COAL POWE R
w w w. c o a l p o w e r m a g . co m
48
www.powermag.com
3. Cutting costs. The new automated dry polymer make-down system reduces expenses
by increasing the efficiency of the dewatering operation. Courtesy: Duke Energy
1000
1,000
Tons
Landfill tons/day
600
600
400
400
200
200
0
0
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Also unforeseen at the time of the conversion was the impact of the inert material (iron
oxides and silica) that entered the FGD system
in the lime supply. This material is contained
and recovered via the oxidation dewatering
hydroclone overflow. Inert material cycled
up in the FGD system, and because there was
no effective way to remove it, it caused poor
gypsum quality. The low density of this material also meant that it wouldnt settle in the
stations pond system, which led to very high
costs associated with removing the material.
49
Centrifuge%#1Solids
cake solids (%)
To achieve its goals, the team made improvements in the FGD system design and operation that included the mechanical, chemical,
and operational changes discussed below and
shown in Figure 2 (p. 48).
50
50
40
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30
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00
Date
Date
6. A solid success. Cake solids improved approximately 3% during the evaluation period
from May 1, 2006 through July 31, 2007. The data shown are from Centrifuge No. 2. Courtesy:
Duke Energy
70
70
#2 average cake solids 35.8%
60
60
Solids
Centrifuge%#2
cake solids (%)
60
60
50
50
40
40
20
20
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30
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Rental
centrifuges
Current centrifuges
10
10
8
8
6
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4
2
2
0
0
Date
Positive Results
Date
Replacement
centrifuges
Rental
centrifuges
Current centrifuges
0.02
0.02
Polymer
usage lbs
(lbs)
Polymer Usage,
0.015
0.015
0.01
0.01
0.005
0.005
00
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Replacement
centrifuges
7/2/07
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1/14/08
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7. Less is more. The new automated make-down system provides a more efficient and
Waste
tolandfill,
landfilltons
(tons)
Waste sent
sent to
Date
Date
Table 1. A money-saving move. By significantly reducing the number of tons of centrifuge solids sent to the landfill each year, the Zimmer Station has been able to realize substantial savings. The dewatering process also avoids burning 2,800 gallons of diesel fuel. Courtesy:
Duke Energy
May 2006
May 2007 (tons)
May 2007
May 2008 (tons)
Annual
cost savings
225,879
148,938
$256,500
Pebble lime
120
12
$205,200
648
504
$105,156
Parameter
Waste to landfill
$568,856
GENERATION TECHNOLOGY
are available for both IGCC plants (pre-combustion) and PC plants (post-combustion),
IGCC plants may have an advantage because
the technology required for pre-combustion
CO2 capture has already been used successfully on coal gasification (but not IGCC)
technology. Enhancements are being made
to this technology for better performance in
IGCC configuration. Furthermore, some of
these capture technologies have the capability to produce the concentrated CO2 stream
at high enough pressures to match the needs
of the compressors required to compress the
CO2 for transport in pipelines for either sequestration or enhanced oil recovery. How-
IGCC Limitations
The advantages of IGCC must be balanced
against its limitations, said David J. Stopek,
PE, an engineer with Sargent & Lundy, a
Chicago-based consulting firm.
IGCC can offer advantages compared to
a conventional PC plant for the transition to
a power generation fleet with a lower CO2
footprint based on coal, he commented.
Having said this, you must understand that
IGCC is still an evolving technology compared to the level of commercial status of
conventional PC technology [see table]. Because IGCC deployment has been limited,
the costs for each plant require extensive
engineering and development. Efforts by GE
and others to develop a standard plant are
intended to help lower the cost for deployment. The projects first envisioned by Duke
1. Dynamic duo. Integrated gasification combined-cycle (IGCC) plants integrate coal gasification with combined-cycle technology and can use synthetic gas derived from coal, pet
coke, and other feedstocks. Source: Tampa Electric
Slurry plant
Raw syngas
Entrainedflow gasifier
Coal slurry
90%
Oxygen plant
Conventional
gas cleanup
O2
Product
gas cooler
N2
N2 to combustor
Feedwater
Radiant syngas
cooler
Slag disposal
Raw syngas
High-pressure
steam
Black water recycled
Steam
Combustor
Generator
Combustion turbine
Sulfuric
acid
Sulfuric acid
plant
Heat-recovery
steam generator
Stack
Steam turbine
Steam
www.powermag.com
Hot
exhaust
gas
Generator
From design and installation to maintenance and operation, Caterpillar delivers turnkey power plants.
You have the vision of a cost-effective power plant. And Caterpillar has the global resources and expertise to make that vision
a reality. From design and construction to commissioning and operation, Caterpillar has been delivering power plant solutions
globally for over 50 years. So consider Caterpillar for your next project because we know power plants inside and out.
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and product identity used herein, are trademarks of Caterpillar and may not be used without permission.
2009 Caterpillar Inc. All rights reserved.
CIRCLE 28 ON READER SERVICE CARD
GENERATION TECHNOLOGY
An exclusive club. As of 2009, there are five operating coal-based IGCC plants worldwide.
Gasier
technology
coal/biomass
Shell
Wabash River
coal/coke
ConocoPhillips
Company
Facility
Nuon
SG Solutions/
Duke Energy Indiana
Location
Tampa Electric
Mulberry, Fla.
coal/coke
GE Energy
ELCOGAS
Puertollano
Puertollano, Spain
coal/coke
Prenflo
Japanese utilities
MITI, CRIEPI
Nakoso, Japan
coal
MHI
2. A power pioneer.
Jeffrey N. Phillips, the senior program manager of advanced generation at the Electric
Power Research Institute (EPRI) pointed out
some of the major implementation challenges that IGCC technology faces.
For plants without CO2 capture, IGCCs
are more expensive to build than PCs, he
said. Also, with natural gas prices currently in the $4/MMBtu range, it is difficult to
choose an IGCC over a natural gas combinedcycle. IGCC suppliers need to improve their
cost-competitiveness versus PCs.
EPRI believes that one way to make that
happen is to focus on standardized designs
that minimize up-front engineering costs.
EPRIs CoalFleet for Tomorrow has been encouraging such an approach with the devel54
GENERATION TECHNOLOGY
Phillips had an optimistic view of efforts
to overcome this problem. Overall, the
availability of coal- and oil-based IGCCs
has been improving over time, he said. The
availability of the first generation of IGCCs
is similar to that of the first generation of
supercritical PCs and nuclear plants. Both
those technologies now enjoy availabilities
in the mid-80% to 90%. With additional experience it is reasonable to expect that IGCC
availability will also increase.
Additionally, all of the first-generation IGCCs were based on single-train designs (one
gasifier, one gas turbine), he pointed out. EPRIs
UDBS for IGCCs calls for dual-train systems,
which EPRIs analysis indicates will have better availability because the plant can continue
to operate, albeit at reduced load, when one
gasifier or gas turbine is down. The operating
train can be used to keep the equipment on the
other train warmed up. This allows for faster
start-up times for the second gasifier or combined cycle, which helps availability.
These are significant impacts on performance and cost, according to Jenkins. For net
output, the reduction would be about 100 MW
on a 600-MW net IGCC reference plant. This
is primarily due to the additional internal power needed for the CO2 capture equipment; using steam in the CO2 capture system instead of
steam turbine power generation, as designed;
and the additional power required for the CO2
compressors. What many do not understand is
that this lost 100 MW must then be made up
by other generating units, which may actually
have higher emission rates for CO2 as well as
other pollutants, he noted.
Stopek agreed with Jenkins about these
disadvantages and gave additional insights.
The challenge of adding CO2 capture to an
existing IGCC plant must be discussed at the
early phases of the project development, he
said. The owner must understand that converting the syngas from a mixture of CO and
H2 to predominantly H2 will result in a derating. This derating can be compensated for
during design by ensuring the capability to
gasify more fuel. The owners must be willing to accept this cost. If not, they must be
willing to accept the derating. This is fundamentally different than just adding additional
booster fans to a coal-fired plant to accommodate the pressure drop of a flue gas desulfurization system.
The gasifier and downstream systems must
be designed to process the additional fuel (up
to 15% more), according to Stopek. More ash
and sulfur are produced, so all the supporting
www.powermag.com
tanks, pumps, and equipment must have sufficient margin in their design to handle this
future flow rate. Some of this capacity may
be available by increasing design pressure,
but then the entire equipment design must be
scrutinized to ensure that it is designed for
the appropriate new pressure.
GENERATION TECHNOLOGY
3. Under construction.
The thousands of lessons learned at existing IGCC plants are well documented in
EPRIs CoalFleet IGCC UDBS, and are being incorporated by the manufacturers into
new IGCC plant designs, he said.
Regulatory Hurdles
AEPs experience with their proposed West
Virginia IGCC is instructive, Phillips said.
While it was approved in West Virginia, they
also needed approval from Virginia because
the plant would provide electricity to some
parts of that state. The Virginia Public Service
Commission rejected the proposal because
the IGCC plant was more expensive than conventional coal plants, and they considered the
potential benefits of an IGCC with CCS to be
of limited value because they felt no party
knows for certain the specific commercially
available technology that will be used for carbon capture and sequestration and because
AEP did not identify any commercial generation facility that has implemented CCS.
That points out the need for educating regulators on CCS technology.
Stopek also had concerns about the regulatory challenges affecting U.S. utilities. The
www.powermag.com
GENERATION TECHNOLOGY
TECO Energys Polk 6 IGCC project received tax credits but was put on hold due
to cost and regulatory uncertainty.
Hydrogen Energys Carson project received credits but ran into siting difficulties and is now being reengineered for a
location in Californias Central Valley.
The federal government may have awarded tax credits to other IGCC projects, but
after announcing the first group of recipients, the government decided it could not
announce subsequent decisions due to taxpayer confidentiality concerns, according
to Phillips.
Comparative Costs
of IGCC-Generated Electricity
If in the future some level of CO2 capture
and storage is mandated for new coal-fired
power plants, that regulation will narrow and
perhaps close the cost-of-electricity gap between IGCCs and PCs, Phillips predicted.
EPRI has also looked at technical improvements that could make IGCCs more competitive. (See the free EPRI Report 1013219 on
the EPRI website.)
Among those innovations, the one that
would provide the biggest improvement is using larger, higher-firing-temperature G and H
class gas turbines instead of F class turbines,
he said. These turbines offer two advantages
for IGCCs: first, the larger size provides savings from economies of scale and second,
the higher efficiency decreases fuel costs and
also decreases the amount of CO2 that must
be captured (on a lb-CO2 /MWh basis).
Jenkins was also optimistic that IGCC
technology will become more competitive.
As the planned IGCC plants gain operational experience, that will led to continued
enhancements in efficiency and availability
for the next fleet of IGCC plants. In addition,
IGCC plants may be able to utilize higher
percentages of low-cost opportunity feedstocks, such as pet coke, thereby further lowering power generation costs.
www.powermag.com
57
CARBON MANAGEMENT
Commercially Available
CO2 Capture Technology
While many CO2 removal technologies are being researched through laboratory and pilot-scale testing, an existing technology has a significant operating history at commercial-scale facilities, where it is collecting CO2
from multiple sources, including low-CO2 concentration flue gas (<3.1%
by volume) with high oxygen concentrations (>13% by volume).
By Dennis W. Johnson; Satish Reddy, PhD; and James H. Brown, PE, PMP, Fluor Corp.
echnology for the removal of carbon dioxide (CO2) from flue gas streams has
been around for quite some time. The
technology was developed not to address the
greenhouse gas effect but to provide an economic source of CO2 for use in enhanced oil
recovery and industrial purposes, such as in
the beverage industry.
In 1989, Fluor Corp. purchased the license
for a CO2 capture technology from Dow
Chemical. Through the years of process and
technology improvements, Fluor Corp. has
developed an advanced amine-based postcombustion CO2 capture technology called
Econamine FG Plus (EFG+). The EFG+
technology is the first and the most widely
applied process that has extensive proven
operating experience in the removal of CO2
from high-oxygen-content flue gases such as
those typically present in a coal-fired power
facility. The solvent formulation is specially
designed to recover CO2 from low-pressure,
oxygen-containing streams such as boiler gas
streams without rapid degradation due to the
presence of oxygen.
The EFG+ process utilizes simple, reliable equipment that is well-known to the
gas-treating industry (Figure 1). The technology does not require a custom-manufactured
or expensive solvent. The main ingredient of
the solvent is readily available and inexpensive and is produced by solvent manufacturers worldwide.
1. Go with the flow. The typical Econamine FG process uses simple, reliable equipment
that is well-known to the gas-treating industry. Courtesy: Fluor Corp.
Product CO2
Absorber vent
Demin water makeup
CW
CW
LP
steam
LP steam
Waste to
disposal
CW
Soda ash
Makeup
solvent
CARBON MANAGEMENT
2. Standing the test of time.
CO2 storage
Absorber
Stripper
Air coolers
Reboiler
Reclaimer
3. Snaring CO2 from flue gases. The application of EFG+ technology capturing CO2 at
a coal-fired power plant. Courtesy: Fluor Corp.
NH3 mixer
NH3
Activated
carbon injection
Sorbent injection
NH3 injection
Boiler
Activated
carbon
Sorbent
ESP
and/or
fabric filter
Economizer
A S
P A
H H
Econamine FG Plus
IDF
Blower
FGD
Stack
Polishing
FGD/DCC
CO2
absorber
Notes: SCR = selective catalytic reduction, APH = air preheater, DCC = direct contact cooler, ESP = electrostatic precipitator,
FDF = forced draft fan, FGD = flue gas desulfurization, IDF = induced draft fan, SAH = steam air heater
Application at Coal-fired
Power Plants
Even with the deployment of proven technologies with high-efficiency pollutant removal
technologies, there are still residual quantities
of sulfur dioxide (SO2), sulfuric acid (H2SO4),
ammonia, particulates, and other trace constituents in the flue gas entering the carbon
FDF
Provisions for the addition of postcombustion CO2 capture can vary from being aware
of the requirements for the design to full
integration of the power, steam, and cooling needs, as well as infrastructure for CO2
transportation. At a minimum, the analysis
and early decisions concerning CO2 capture,
with particular emphasis on the commercial
EFG+ technology, should include in-depth
analysis of the following topics.
Permitting. The facility permits and operations philosophy should give maximum
operational flexibility to the CO2 capture system. The operational philosophy and design
should allow flexibility in the event that sequestration wells, the buyer for the commercial grade CO2, or the enhanced oil recovery
end user cannot accept CO2 for any reason.
CO2 capture should be permitted on a
mass of CO2 per year rather than a percent
removal basis. This would allow for upset
conditions and periods when the CO2 compression and pipeline system is unavailable.
In addition, it would potentially allow the
59
CARBON MANAGEMENT
capture system to be run during off-peak
periods such as winter (for summer peak areas) or nighttime operation.
The emissions dispersion modeling must
consider the lower gas volume and potentially
cooler gas stream. The stack construction materials must be compatible with wet flue gas.
Certain carbon capture processes may require
reheat of the gases prior to the stack to ensure
that the temperature is compatible with stack
materials or to make sure that the gas buoyancy is sufficient for the requirements.
Consideration should be made for the use
of potential waste streams from the CO2 capture process within the boiler and FGD systems water balance. These streams include
condensed water from the DCC and chemical
streams from the reclaimer. The water may
be used as FGD makeup, for ash wetting, or
for other purposes. The water could also be
treated by integration into the base plants
water treatment facilities.
Plant Arrangement. Capture ready
has for many meant space allocation for future technology implementation. Large-scale
CO2 capture and sequestration projects that
are currently in development require multiple
CO2 absorption trains that require large plot
areas. Even for smaller CO2 capture retrofit
applications, plot availability can play a vital
role in the projects feasibility. As a result,
Fluor has focused on strategies to minimize
the footprints of EFG+ plants, including
large-diameter absorber design, plate and
frame exchanger train minimization, and reboiler shell count minimization.
Space allocation and/or provisions for the
CO2 capture system must also include consideration of booster fans, absorber columns,
DCC, gas separation units, cooling equipment, CO2 compression/storage equipment,
reclaimer, building infrastructure expansions,
reagent tanks/unloading, pipe/ductwork corridors, and maintenance access.
Power Plant Integration. Consideration
should be made to integrate the steam requirements into the boiler, turbine, feedwater, and condenser circuits to limit the impact
on the power production of the generator and
fully optimize the entire power generation/
carbon capture system. Because the CO2
capture system uses significant quantities
of steam and power, the steam and electrical cycles should be thoroughly evaluated to
provide the most energy efficient solution. If
CO2 capture is continuous, one option is to
use a smaller turbine and size the boiler to
produce both high-energy steam for the turbine and low-energy steam for the CO2 capture system. If the CO2 system can be turned
offfor example, to maximize power during
peak load timesthen the turbine should be
sized to match the boiler production.
60
4. Easy integration.
IP
HP
LP1
LP2
To boiler reheater
For new coal-fired power plants, integration of the EFG+ technology into the plants
cycle heat balance needs to be evaluated
based on site-specific requirements and conditions. Various alternatives may be studied
to determine the best solution for a particular
application based on project economic factors, planned CO2 capture efficiency, planned
CO2 capture capacity factor (percentage of
time operating), and site ambient conditions.
Fluor has studied various cycle heat balance
optimization approaches for multiple power
plant sizes. For illustrative purposes, the approach outlined below is based on a typical
850-MWe coal-fired power plant (Figure 4).
For this case, the steam demand for regeneration of the solvent could be approximately
one-third of the steam flow to the low-pressure
(LP) turbine. Optimally, the steam would be
extracted from the steam cycle at the lowest
potential energy point that still provides sufficient heat energy to regenerate the solvent.
Doing so ensures efficient use of the steam
energy in power production prior to providing
steam to the carbon capture system. This can
be accomplished by extracting steam at the
intermediate pressure (IP) to LP crossover
portion of the steam cycle. Impacts to the IP
turbine must be accounted for in blading design due to the various operating cases that
may be generated by the CO2 capture operating load and power plant operating load.
If the steam pressure requirements for solvent regeneration are lower than the crossover
pressure (as they would be for the typical 850MW cycle described above), a smaller topping
turbine may be used downstream of the cycle
extraction to recover some of the steam energy
that would otherwise be lost through control
valve throttling, as shown in Figure 4.
As discussed above, other steam cycle design alternatives may be employed to meet
the carbon capture systems energy needs. In
addition to the steam cycle impacts, electrical
www.powermag.com
demand impacts on the facilitys power supply gear, water system, and control system
architecture must be addressed.
February 3 5, 2010
Washington Convention Center, Washington, D.C.
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For more information on RETECH 2010
please visit www.retech2010.com or contact:
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STEAM TURBINES
Figure 1 shows the percentage of water induction incidents attributed to the most common sources of water in conventional steam
cycles. Although water induction into highpressure (HP) and intermediate-pressure (IP)
turbines has historically been recognized as
62
Thermal cracking
Rub damage
Permanent warping distortion
Secondary effects, including seal packing ring damage, pipe hangar and support
damage, and damage to instrumentation
and controls
Source: Serge P. Barton et al., A Water Induction Monitor for Steam Turbines (ASME)
Source: Serge P. Barton et al., A Water Induction Monitor for Steam Turbines (ASME)
Hot reheat
5%
Other 4%
Trip
11%
Main steam
18%
Extraction
48%
Cold reheat
25%
www.powermag.com
Load reduction
18%
At load
18%
Start-up
28%
Turning gear
25%
STEAM TURBINES
3. Stay level-headed. Typical drain
pots must have redundant level elements.
(Symbols per ISA standards.) Source: ASME
TDP-1-2006
Motive steam pipe
(which requires redundant protection)
LAHH
Drain pot
LE
LAH
LE
HS
ZI
Main steam
Hot and cold reheat steam
HP, IP, and LP steam
Admission steam
ZS
To drain receiver
Extraction steam
Gland steam seal line
Recommendations for
Steam Line Drains
There are three types of steam line drains
regardless of the configuration of the steam
power plant:
STEAM TURBINES
4. Double up components. The new specification provides sizing and redundancy requirements for a vacuum condensate drain tank. Source: ASME TDP-1-2006 Committee
Vent to condenser
Turbine
and
cycle
drains
Condensate
drain
tank
Condensate to condenser
Condensate to condenser
LE
LE
64
Duplex pump
Station tank
5. Keep your blades dry. This illustration of an axial exhaust steam turbine with condenser drains and water levels is used to show that water should never accumulate higher than
the tip of the last-stage blades. Source: ASME TDP-1-2006 Committee
Stop
valve
Condenser neck
Control
valve
Turbine
Expansion
joint
Condenser
Tip of last-stage blades
LP casing drains
Expansion
High water level
joint
low point Normal water level
Low water level
Trip
alarm
STEAM TURBINES
6. Unwanted water. An axial exhaust steam turbine must avoid recirculating water back
into the steam turbine. Source: ASME TDP-1-2006 Committee
n
culatio
Recirzone
LP turbine exhaust
Bypass
manifolds
Condenser
tubes
Dual processors.
Uninterruptible power supply.
I/Os associated with redundant plant
equipment and instruments should not be
connected to the same I/O cards.
Outputs that fail to known position during
processor or internal communication failure.
More to Come
The committee is now working on TDP-2 for nuclear power plants. Look for it in the near future.
NOW LIVE
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65
The liquefied gas is then loaded into well-insulated ship-mounted storage tanks for transport to one of several U.S. receiving terminals
(currently, there are reportedly eight in operation). When the LNG arrives, the liquefied gas
is regasified before entering the gas distribution pipelines. The fact that the Federal Energy Regulatory Commission is tracking 28 new
approved LNG terminal projects or expansion
projects indicates the expected growth in LNG
imports in the coming years.
The liquefaction and regasification processes
also enable removal of some of the inert componentssuch as nitrogen gas (N2), carbon dioxide
(CO2), and higher hydrocarbons (C6+)while
retaining all of the original amounts of ethane, propane, and butane. The result can be an
LNG-derived gas that can have a wide range of
Wobbe Index (defined as higher heating value
divided by the square root of specific gravity)
and variable energy content per cubic foot when
compared with domestic natural gas.
1. East meets West. The first Russian LNG plant on Sakhalin Island consists of two process trains, each having an annual production capacity of 4.8 million tons. The plant is projected to reach its design capacity (9.6 million tons per year) in 2010. Courtesy: Gazprom
66
www.powermag.com
Safety
EX
S
C HAN
Energy &
Environment
GE
SIX
Wireless &
Networking
EV
NE EN
Security
Process
Automation
& Control
Enterprise
Integration
1,500
1,450
1,400
Algeria
Trinidad
UAE
Qatar
Oman
Malaysia
Australia
1,350
Nigeria
Table 1. Three fuel options studied. Three test fuels were selected to simu-
1,300
U.S. domestic
1,342 +/2%
1,250
1,200
3. Fuel flexibility testing set-up. These were the test rig (top) and mixing skid setup
(bottom) used during LNG testing. Courtesy: Siemens Energy Inc.
Test fuel
Constituent
LNG 1
LNG 2
LNG 3
C2Ethane
10.0%
15.0%
1.5%
C3Propane
3.0%
5.5%
15.0%
C4Butane
1.5%
2.5%
5.0%
need to assess that variation in light of applicable original equipment manufacturer fuel
specifications. Apart from the potential effect
of voiding warranties, operational issues
such as combustion dynamics, flashback, increased emissions, or decreased component
lifecan occur. Another potential issue that
may arise from a sudden change in fuel composition is substantial and unexpected load
swings. Luckily, there is a solution.
www.powermag.com
Siemens has been involved in the development of an LNG-capable gas turbine using
advanced premixed combustion systems for
over five years. The key goal of the development project was to thoroughly investigate
and then identify robust combustion system
configurations that are capable of reliable operation on a stipulated range of LNG fuels.
The initial step for the fuel flexibility development project was a careful evaluation of
most of our commercially available combustion system configurations and then downselecting the most robust configurations of
combustion hardware capable of handling
wide changes in fuel composition.
The selection process came after many
hours of rig and field testing to confirm the
equipment selections. Siemens has completed multiple LNG test campaigns for the
SGT6-5000F (W501F) engine, both in test
rigs and in operating engines. Rig tests for
the SGT6-3000E (W501D5A) and the SGT66000G (W501G) also have been completed.
These tests have added substantial operating
information to our extensive knowledge base
of combustion system design practices, especially the challenges presented with burning
LNG and highWobbe Index fuels.
Siemens has also reviewed information
regarding U.S. and global gas reserves. Our
review showed that U.S. domestic natural gas
reserves have had a Wobbe Index value in the
range of approximately 1,315 to 1,370 Btu/
scf (Figure 2). However, in our review of information on global gas reserves, the Wobbe
Indices of the fuels from the international
sources showed more variation, with reported
values ranging from 1,366 to 1,441 Btu/scf.
NOx, ppmvd@15% O2
Our research also concluded that, in addition to the variation in heat content, individual components in the LNG varied widely
among sources. However, it was observed
that the maximum percentages of the higher
hydrocarbons was about 14% ethane, 4%
propane, and 2.5% butane, but these maximum percentages were not all found in a particular fuel gas at the same time. Considering
the wide range in fuel constituents and heat
content, Siemens opted to use three representative fuels for its testing regimen (Table 1).
Typical pipeline
natural gas
1,300
1,320
1,340
LNG1:
typical LNG
1,360
LNG2: 99%
LNG covered
LNG3:
extreme LNG
1,460
1,480
1,500
1,520
5. ULN fuel flexibility testing. This graph shows the typical response of the ultra-lowNOx combustion system for different gas turbine frames for NOx emissions. A ULN system
is much less susceptible to wider constituent variations that may be present in LNG. Source:
Siemens Energy Inc.
D5A ULN
F ULN
G ULN
NOx, ppmvd@15% O2
Typical pipeline
natural gas
1,300
1,320
1,340
LNG1:
typical LNG
1,360
LNG2:
99% LNG covered
1,460
LNG3:
extreme LNG
1,480
1,500
1,520
Fuel
Buffer
tank
Control
system
Combustion Dynamics
Protection System
Dynamic
sensors
CEMS
(Turbine
exhaust)
Throttle valves
Table 2. Add more fuel flexibility. Siemens has developed a more flexible
combustion turbine fuel specification to accommodate a wider range of LNG content in
commercial natural gas supplies. The specification can be implemented on certain units
on a case-by-case basis. Installation of specific component upgrades and a modified fuel
specification may be required by Siemens.
Source: Siemens Energy Inc.
Wobbe Index variation
Customer scope
Combustion Dynamics Protection System (CDPS) hardware, and a fuel gas buffer tank. The primary purpose of the IFGC
system is to minimize power fluctuations
or load swings due to changes in the fuel
composition and Wobbe Index. The IFGC
meter is located upstream of the combustion turbine; it is designed to continuously
analyze the supply fuel gass Wobbe Index
and send a signal to the control system. The
control system, based on the Wobbe Index
signal value, then adjusts the fuel supply to
the combustion turbine. The fuel gas buffer
tank introduces a short delay to accommodate the response time of the control system
before the analyzed fuel reaches the combustion turbine.
The IFGC also addresses the possibility
of poor light-off events associated with fuel
quality. The IFGC, with its feed-forward
control, can accommodate many fuel quality
variations and help ensure adequate fuel flow
for light-off. Flashback, another issue for
LNG fuels, is also dependent on fuel composition. The IFGC feed-forward system using
the buffer tank is intended to adjust the control settings to minimize flashback.
The CDPS system can help mitigate potentially destructive combustion dynamics and
out-of-specification emissions. The CDPS is
an active control dynamics monitoring and
control system. The CDPS receives signals
from the plants continuous emissions monitoring system, located at the turbine exhaust,
and compares this information with the unitspecific emissions permit. Depending on
the variation between the two numbers, the
CDPS is designed to adjust the control settings to maintain emissions and acceptable
levels of combustion dynamics. The IFGC
and CDPS together adjust real-time fuel setwww.powermag.com
Subsequent to the engine and rig tests, Siemens prepared a fuel specification that allows
a wider range of fuels for the SGT6-5000F,
which can be implemented on units that have
installed the appropriate combustion and
IFGC hardware. A site-specific evaluation is
required to assess the hardware, control systems, and other equipment that may be necessary to safely burn LNG.
Note that unless and until all of these upgades are installed, and Siemens has issued
a revised fuel specification for each specific
unit, operators must continue to follow the
fuel specifications in their contracts.
Siemens has also developed modification
packages to retrofit operating SGT6-5000F
combustion turbines to burn a wider range of
fuels, as defined in Table 2, while maintaining exhaust NOx output.
With more flexible fuel specifications,
combustion turbines can better remain fuel
supply sourceneutral. That ability can help
provide better plant operating economics
and keep such units high on the dispatch
priority list.
The authors would like to acknowledge the core team that has made this
development a success. In alphabetical order, they are Khalil Abou-Jaoude,
Richard Bunce, Jacqueline Engel,
Matthew LaGrow, Steve Mumford, Bruce
Rising, Fred Shoemaker, Damien Teehan, and Jianfan Wu.
Pratyush Nag (pratyush.nag@siemens
.com) is manager, Modernizations &
Upgrades, Service Engineering Americas
for Siemens Energy Inc. Ranjeet Vader
(ranjeet.vader@siemens.com) is principal
engineer, GT Modernization & Upgrades,
Service Engineering Americas for
Siemens Energy Inc.
CLASSIC MARMADUKE
Fond Recollections
Our portable medium-powered nuclear plant up in the Arctic is being reshielded right now, Marmaduke old buddy, said Colonel Hanel
to his cantankerous old shipmate, after only three months of operation. I must say she has no resemblance to the power plant we had on
the SS Nightingale in World War II, remember?
www.powermag.com
71
CLASSIC MARMADUKE
to think of it, if you have never been shipmates
with one of these prepackaged power plants, I
just might work a deal to let you fly up there
with me tomorrow. What say? Besides, our old
shipmate SFC Tom Cruse is up there now.
Fire away, crackled the marine engineer, in his foghorn voice. Im for eyeballing that deep-freeze plant, so heave me a
line and take me in tow. Where did you say
that reactor is?
This ones at Camp Century, informed
the Colonel. She has a 2,000 kW steam turbine electric generating unit for heat, light
and exhaust steam for melting ice for the
camps water supply. And youll see a lot of
other ingenious devices up there that might
be new to you. Of course three diesel engines
back up the reactor when its shut down. I
dont have to tell you that every source of
heat and light must be assured to support human life under the ice cap.
Electricity Is Life
As with seafaring men the world over, conversation soon got around to the ships on
which theyd sailed, the ports theyd visited,
and their exciting experiences around the
globe. The hours passed so pleasantly, it was
half past midnight before Marmaduke realized it and bade his host good night. As he
started back to his bunk in the commissioned
officers quarters, the lights dimmed, then
flickered and went out. For an instant it was
deathly quiet in the club.
In seconds, flashlights winked on, for the
men stationed in the sub-surface camp, like
marine engineers on watch aboard ship, always had flashlights on their persons. Someone immediately shoved a flashlight into
Marmadukes hand.
Theres trouble at the diesel plant, exclaimed one of the men, rushing for the
door. As Marmy hurriedly followed his new
shipmates along Main Street and entered the
diesel plant, he saw Lee McNeil, the watch
operator, busily adjusting the one remaining
diesel engine.
Whats wrong, Mac? rumbled Marmaduke, who had shortly before said good night
to McNeil in the Non Com Club when he left
to take over the 12-to-8 watch.
Number one was running rough, then
started knocking, explained McNeil, noticeably preoccupied. Thats why I had to open
several camp feeders and take the engine off
the line a few minutes ago. But No. 2 can
carry 300 kW and she seems to be holding
her own.
As Marmaduke watched, the utility crew
pitched in like a well-drilled team. They
trimmed every watt that wasnt absolutely
essential from the camps load.
Instantly, the camp commander was on the
72
www.powermag.com
intercom. He gave orders to close several living quarters and told the men to double up.
Heat was now priceless, and there was none
to waste. Some of the men were asked to sleep
in the mess hall. Beams of light flashed in the
dark as the men busied themselves doubling
up and again settling down for the night. The
diesel technicians immediately turned on No.
1 engine.
About 2:30 a.m., the improbable happened. No. 2 diesel coughed a few times,
then died. Now Camp Century was in blackness, save for a few strategic areas where
emergency lights were powered with nickel
cadmium batteries. But more serious, the
camp was now completely without heat.
Again, the camp commanders solemn
voice came over the intercom. Speaking
calmly, he informed his crew of this latest
catastrophe. The men knew that, without
electricity for heat, there would be no area
within the camp warmer than 30 F below
zero in only about 20 minutes. So unless the
engineers could learn quickly why No. 2 diesel had stopped and then could get her started
and back on the line, the camp was doomed.
And so perhaps were all of them.
Working by flashlights, the engineers first
got their heads together. They were sure of
only one thing: that No. 2 engine had worn
rings and for that reason was next on the list
for overhaul; in fact, a full set of replacement parts was near the engine, ready to install. But why did she stop? A quick check
of the crankcase oil confirmed their suspicion: the lube oil had become diluted with
diesel fuel oil leaking past the rings, and
so the crankcase oils lubricity was drastically reduced. That caused seizure of No. 2
crankshaft journal, as it had been recently
overhauled and had the least clearance in its
bearing.
Marmaduke watched the engineers open the
crankcase drains to remove the contaminated
oil. One gang got busy opening her main bearings to file the welded metal from the scored
crankshaft journal, replace the top, and roll
out the bottom bearing insert. Another group
started replacing her pistons with spare ones
that were already ringed and ready to install.
A third crew hurried out to find a drum of
lubricating oil. But to their utter dismay, they
learned that the only crankcase oil available
was in drums stored out in the tunnel. And out
there the temperature was 30F below zero.
A drum was quickly rolled into the diesel
room. But they could tell that the oil inside had
congealed into a solid mass. Marmaduke, like
the camp crew, took this latest kick in the teeth
with silence. They were all in the same boat,
and theyd sink or swim together. And there
was no one answer to their complex problems.
Theyd have to take one hurdle at a time.
CLASSIC MARMADUKE
Now the tall muscular visitor pitched in
and helped the boys hoist the heavy oil drum
up on the metal rack. The drums filling plug
was unscrewed, but no oil would flow out.
McNeil poked his finger against the solid
mass inside. Like taffy, he said simply. By
then, the situation looked hopeless.
The nuclear reactor used at Camp Century was the first of eight portable nuclear reactors made
by the Army to produce power in remote regions. This modular plant was assembled at Camp
Century in 27 days and began making electricity just nine hours after 43 pounds of enriched
uranium-235 were loaded in the reactor. The plant was rated at 2 MW and was configured to
also produce steam to operate the water well. The plant operated reliably for 33 months until it
was shut down and removed in 1963. Source: U.S. Army
Temperatures Go Negative
The temperature in the diesel plant was
now down to 22F below zero. The men had
noticed that the battery powered lights had
begun to dim. While no one mentioned it,
they all realized that their working time was
nearing the end unless something drastic
was done. But what? A black gloom overtook several of the men.
The diesel technicians were about to give
up on the congealed oil. Then Marmaduke
suddenly roared. Bilgewater on stubborn oil.
Ill make it move. Get me a blanket we can cut
into strips and saturate with that warm crankcase oil you just drained. Then well light it
under this drum and youll see some action.
Hold everything, excitedly erupted one of
the crew, coming to life at Marmadukes suggestion. How about those smudge-type burners stored in the motor maintenance shop?
Thats right, shouted another.
We use them in early winter to mark the
landing zone for the helicopter when theres
still some daylight. Now there was new hope,
and the effect on everyone was electric.
Two pots were quickly brought into the
diesel room and placed under the oil drum.
Four men stood by with fire extinguishers. A fire under ice is dreaded as much as
at sea. Within ten minutes the oil began to
ooze from the bung. By then the temperature
had also climbed in the diesel room, and the
newly ringed pistons and crankshaft bearing
liners were back in place.
It took another three-quarters of an hour to
heat the oil sufficiently, fill the crankcase to
the proper level, close up the engine, and have
it ready for cranking. During this time, several
smudge pots kept the engine room warm.
The battery used for cranking the little
pony diesel, which in turn cranked the big
engines, was not only cold, but also olda
very bad combination. Leston McNeil wondered out loud how many times the battery
might turn over the cold pony engine before
it gave up the ghost.
Comparing Notes
Two days later, Marmaduke and Colonel
Hanel were back at the Bent Propeller Bar
in Manhattan for a drink before parting
company.
Sure glad the reshielding work was completed in time to get the nuclear plant going
again, began the Colonel, lifting his glass.
Those boys wont get the crankshaft for No.
3 diesel for some time. But with the reactor
going now, that type of emergency wont
happen again soon.
Im with you, rumbled Marmaduke as
he ballasted his bottoms.
Youve been in some hellish emergencies
all over the world, Marmy, began the Colonel
again. Do any of them shape up with what we
went through at Camp Century last week?
Marmaduke lit a long black cigar and blew
a few smoke rings towards the ceiling. He then
worked up a vacuum and took on more fuel.
Not since the time the old SS Trade Horn
suddenly broke her rudder during a storm
and was within minutes of piling up on the
treacherous coral beach in Makassar Straits
off Borneo, rumbled Marmaduke in his foghorn voice.
Whats so unusual about that? asked the
Colonel, looking uncertainly at his friend.
All you had to do was reverse the engine,
wasnt it?
Thats all, agreed Marmy, blowing a few
more smoke rings. But one of Bring-emBack-Alive Frank Bucks black panthers was
frightened by the storm and had broken out
of his bamboo cage on No. 2 hatch and ran
below. And there he was, parked in front of
the main engine throttle.
73
NEW PRODUCTS
www.powermag.com
POWERPROFESSIONALS
Opportunities in Operations and Maintenance,
Project Engineering and Project Management,
Business and Project Development,
First-line Supervision to Executive Level Positions.
Employer pays fee. Send resumes to:
P.O. Box 87875
Vancouver, WA 98687-7875
email: dwood@powerindustrycareers.com
(360) 260-0979 l (360) 253-5292
www.powerindustrycareers.com
In concert with the shop supervision determine required manpower levels to support load.
Recruit, train and retain exceptional talent to drive our manufacturing continuous improvement.
Load level through the capacity planning function and liaison with Sales and customer representatives.
Track and analyze usage and cost of labor and materials for each job.
Determine corrective action to minimize recurrence of variances.
Calculate and post performance matrices daily for each department.
Lead organization safety program, to ensure a safe, healthy, and accident free work environment.
Identify Best Operating Practices (BOPs), document them, and compile for reference and training
purposes.
Work with support specialists to develop operating process guidelines.
Prepare monthly performance and ad hoc reports as required.
Develop annual budgets and manage expense and capital budgets.
Establish and promote, internally and externally, the Companys reputation as a quality organization.
Requirements include eight to ten years of progressive experience in production management; demonstrate ability in applying MRP and P&L responsibility at the gross margin level. Possess knowledge of
financial statements, performance reports, lean manufacturing and related disciplines such as Six Sigma,
Theory of Constraints, Kaizen and concepts of machine shop practice and welding techniques in a custom
engineered metal manufacturing environment. A Bachelors of Science Degree in a field related to production/manufacturing management and or production engineering.
The compensation package includes a base salary and an annual incentive bonus plus medical benefit plan,
401K savings plan and vacation. Relocation costs will be reimbursed in accordance with the companys
relocation reimbursement policy.
Yuba Heat Transfer LLC is a privately held, leading manufacturer of large heat transfer equipment. The
companys primary market includes Feed Water Heaters and Condensers for electric power producers in
the United States. Additional information can be found on the companys website at www.yuba.com
Contact: Nick Slee Principal Chicago, IL T: 312-782-1581 F: 312-782-2096 nslee@dhrinternational.com
or James Restelli Senior Associate St. Louis, MO T: 314.727.2000 F: 314.727.2903
jrestelli@dhrinternational.com
www.powermag.com
75
READERSERVICENUMBER 201
READERSERVICENUMBER 200
www.towerelevators.com
READERSERVICENUMBER 202
76
READERSERVICENUMBER 203
www.powermag.com
Solar Taurus 60
MOBILE GEN SETS
5.2 MW
Solar Maintained
Low Time
P.O. Box 60
Columbia, TN 38402 USA
ph: 931/388-0626 fax: 931/380-0319
www.pugmillsystems.com
847-541-5600
FAX: 847-541-1279
WEB SITE: www.wabashpower.com
wabash
POWER
EQUIPMENT CO.
READERSERVICENUMBER 207
George H. Bodman
Pres. / Technical Advisor
SCANNING SERVICES
FOR SALE/RENT
24 / 7 EMERGENCY SERVICE
BOILERS
3D Laser Scanning
Digital Site Survey
As-Built Documentation
gkspowergen.com 734-582-9600
READERSERVICENUMBER 205
READERSERVICENUMBER 208
READERSERVICENUMBER 210
READERSERVICENUMBER 212
READERSERVICENUMBER 206
www.powermag.com
77
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Call GSI Today
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CU SERVICES LLC
Nationwide Boiler Inc. has prepared an eightpage, informative brochure that outlines
many of the important steps to consider
when planning for a temporary steam plant.
Because emergency conditions are frequently the reason a temporary steam plant
is required, this comprehensive brochure is
also a valuable tool for use in contingency/
emergency planning.
www.nationwideboiler.com
www.cuservices.net
READER SERVICE NUMBER 215
78
||
POWER
POWER August 2009
Advertisers Index
Enter reader service numbers on the FREE Product Information Source card in this issue.
Page
Reader
Service
Number
Page
Reader
Service
Number
Kiewit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 . . . . . . . . . 5
Nanosteel Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 . . . . . . . . 14
Ashross . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 . . . . . . . . 26
Babcock Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 . . . . . . . . 13
Petro-Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1, 11 . . . . . . . 4, 9
Caterpillar Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 . . . . . . . . 28
Siemens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 . . . . . . . . 18
CH2MHILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 . . . . . . . . 16
Siemens I&C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 . . . . . . . . 27
Swagelok . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 . . . . . . . . . 8
GE Energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 . . . . . . . . . 7
GE Energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 . . . . . . . . 29
Hach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 . . . . . . . . 21
Westinghouse Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 . . . . . . . . 25
www.asplparts.com
www.appliedbolting.com
www.ashross.com
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www.catpowerplants.com/a33
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www.ge-energy.com/powerwave
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www.hach.com
www.kiewit.com
www.nanosteelco.com
www.nationalsteelerection.com
www.paharpur.com
www.petrovalve.com
www.siemens.com/energy/cybersecurity
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www.solvair.com
www.swagelok.com/moreproducts
sales@turbineenergysolutions.com
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Intergraph Corp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 . . . . . . . . 19
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Classified Advertising
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79
COMMENTARY
Carbon Offsets:
Scam, Not Salvation
By H. Sterling Burnett, PhD
n the battle against climate change, most media attention has
been paid to cap-and-trade schemes, under which countries
set upper limits (caps) on greenhouse gas (GHG) emissions
and allow companies to sell (trade) unused emissions rights to
other firms. However, there is a second path to global warming
salvation: Carbon offsets.
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