Power Engineering

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Power Engineering

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COAL DUST CONTROL
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DIESEL & GAS ENGINES
GENSET RATINGS & PREVENTIVE MAINTENANCE
EMISSIONS CONTROL
COMPLYING WITH THE MATS RULE
the magazine of power generation
Gas Turbine
Advancements
118
YEARS
June 2014 • www.power-eng.com
Dry Sorbent Injection…
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Copyright 2014, Solvay Chemicals, Inc. All Rights Reserved
For info. http://powereng.hotims.com RS# 1
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FEATURES 118
28 A Bull Market
ON-LINE EDITOR — Jennifer Van Burkleo
for Gas Turbines
CONTRIBUTING EDITOR—Brad Buecker
CONTRIBUTING EDITOR—Brian Schimmoller
CONTRIBUTING EDITOR—Wayne Barber
CONTRIBUTING EDITOR—Barry Cassell
In a dramatic battle for a bigger piece of the generation
pie, the global gas turbine market is thriving with new
innovations, new projects and new ventures. Led by
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34
Integrating Flue Gas Conditioning
with More Effective Mercury Control
Activated carbon injection is one of the leading and most accepted
technologies utilized for controlling and maintaining mercury emission
levels required by the Mercury and Air Toxics Standards (MATS). This article
examines the challenges to achieve full MATS compliance.
NATIONAL BRAND MANAGER — Rick Huntzicker
40
CHAIRMAN — Frank T. Lauinger
PRESIDENT/CEO — Robert F. Biolchini
Understanding Generator Set Ratings for
Maximum Performance and Reliability
Selecting a generator set can be confusing. You can ensure your
gen-set’s required performance by aligning your requirement with
the proper gen-set ratings. Power Engineering examines the right
standards and ratings for your specific needs.
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Power Engineering
®
No. 6, June 2014
VOLUME
44
Using Dust Management to Improve
Safety and Reduce Maintenance
A Florida utility was looking for a better way to minimize coal dust
at a power station in central Florida. Learn more about the utility’s
experience in this contributed article on coal dust suppression.
48
Is Your Gen-Set Engine Ready or Not?
Whether they’re protecting hospital operating rooms or providing
distributed power, diesel generator set engines must be ready when
called upon. This article examines proper diesel generator-drive engine
maintenance and its role in ensuring performance and longevity..
DEPARTMENTS
2
4
8
10
Opinion
Industry News
Clearing the Air
Gas Generation
12
14
16
18
View on Renewables
GenerationHub
Energy Matters
Nuclear Reactions
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OPINION
A Reasonable
Water Rule
BY RUSSELL RAY, MANAGING EDITOR
A
fter 40 years of legal wrangling
between utilities and environmental groups, the Environmental Protection Agency (EPA) last month
issued a new rule governing water intake
structures at U.S. power plants.
The final rule, drafted under Section
316(b) of the Clean Water Act, requires
plants that draw more than 2 million
gallons a day and use 25 percent of that
water for cooling to install the best technology available (BTA) to minimize the
mortality of aquatic life. Fish, larvae and
shellfish are killed when they become
trapped (impinged) against water intake
structures or sucked (entrained) into the
cooling system and exposed to heat, pressure, chemicals and machinery. According to the EPA, more than 2 billion fish,
crabs and shrimp are killed each year
by impingement or entrainment at U.S.
power plants.
The final 559-page rule was lauded
by the power sector for its flexibility and denounced by environmental
groups for not mandating specific,
costlier technologies. More than 500
U.S. power plants will be affected by
the measure. Under the new rile, these
plants can choose one of seven options
to comply with BTA requirements.
The measure requires plants to perform a site-specific study to help determine the best options, including closedcycle cooling systems or less costly
options such as screens designed to
protect fish and other marine life. Under
the new rule, state regulators will decide
which option is the most suitable based
on the design of each plant.
The long-awaited rulemaking ends
decades of uncertainty for the power
sector. Power producers can now move
forward with compliance plans without
2
the fear of being forced to implement
costly and significant changes. The
most costly provision of the new rule
may be the site-specific study the EPA
is requiring to help determine the best
technology option for each plant.
Dominion Resources, under pressure
to build new cooling towers at the Millstone Power Station in Waterford, Connecticut, said it was satisfied with the
final rule.
“The rule does not mandate the use
of costly and energy-intensive cooling
towers at all facilities, yet it will result in
major capital investments in advanced
technologies that are suitable for each
facility,” Dominion Chairman, President
and CEO Thomas Farrell said in a statement. “This reasonable approach will
minimize costs to our customers and recognizes our responsibility to protect the
reliability of the electric grid.”
THE YEAR OF
UTILITY-SCALE SOLAR
The boom in solar power has moved
well beyond the rooftops of U.S. homes
and businesses to large-scale projects
using concentrating solar power (CSP)
technology.
In a new report released late last month,
the Department of Energy identified five
new utility-scale projects in the U.S. that
will become fully operational this year.
“These five CSP plants will nearly quadruple the preexisting capacity in the
United States, creating a true CSP renaissance in America,” the report said.
The surge in CSP development is being driven by new innovations, tax incentives and federal and state grants for
utility-scale solar power. The five projects
include Crescent Dunes, a 110-MW solar farm on 1,600 acres in Nevada; the
Mojave project, a 250-MW facility on a
1,765-acre site in southern California; the
Solana project, a 250-MW solar farm on
1,900 acres in Arizona; the Genesis project, a 250-MW facility on a 1,800-acre site
in southern California; and the Ivanpah
project, the largest CSP plant in the world
with a capacity of 392-MW on 3,500 acres
in southern California.
According to the DOE report, 2014
“marks a significant milestone in the history of American Solar Energy.” According to the Solar Energy Industries Association, 30 utility-scale solar projects are
in some stage of development in the U.S.
The association says 2014 will be a record
year for CSP installations, with 840 MW
of CSP capacity expected to be commissioned by the end of this year.
CSP plants use giant “U” shaped
mirrors to capture the sun’s energy
throughout the day. The sunlight is
reflected and concentrated onto a receiver, where the heat rises to about
1,000 degrees Fahrenheit. The heated
transfer fluid inside the receiver is used
to generate steam and electricity in a
conventional steam turbine.
CSP plants can perform like traditional
baseload power plants, providing power
on demand through a thermal energy
storage system. “It can provide electricity
whenever needed by an electric utility to
meet consumer demand,” the report said.
At the end of 2013, the U.S. had more
than 13 GW of installed solar capacity –
15 times the amount of installed capacity
in 2008, according to the DOE. Meanwhile, utility-scale solar is growing at a
faster rate than residential solar. Utilityscale solar installations grew nearly 58
percent last year and accounted for almost 60 percent of all solar installations
in the U.S.
www.power-eng.com
IT’S JUST STEAM.
CLEAN
ELECTRICITY.
Nuclear energy plants don’t emit smoke, just steam from
hot water. No other generating source provides more
clean air energy.
For more information, visit us at www.westinghousenuclear.com
Westinghouse
Electric Company
@WECNuclear
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
AND LOTS OF
INDUSTRY NEWS
Duke Energy, EPA sign Dan
River cleanup agreement
Duke Energy and the U.S. Environmental Protection Agency (EPA) have
signed an agreement over the cleanup
of coal ash that
fowed into the
Dan River after a
stormwater pipe
broke at the company’s retired Dan River coal-fred power
plant in North Carolina, on Feb. 2.
Under the agreement, Duke will:
• Remove any remaining coal ash
from the Dan River within a 27-mile
radius,
• Continue to test water,
• Develop and implement a comprehensive removal site assessment to
determine contamination levels at
the Dan River, including the Kerr
Reservoir,
• Dispose off-site all recovered coal
ash, and
• Submit a report on the structural integrity of impoundments and storm
sewer lines running under the coal
ash basin.
In addition, Duke is required to submit
a work plan for coal ash removal to the
EPA no later than July 15.
fossil-fuel fred power plants. However,
under the Clean Air Act, states have the
authority to design and implement regulations, addressing emissions standards.
Pruitt argues that by directing the EPA
to set emissions standards, the Obama
administration is using a federal agency
to undermine state authority.
“The EPA has played an important role
historically in protecting the environment. But the Clean Air Act and other environmental laws envision a cooperative
federalism where the states and federal
government work together to protect our
air and water,” Oklahoma Attorney General Pruitt said. The proposal includes a
unit-by-unit, “inside the fence” approach,
allowing states to evaluate each unit’s
ability to improve effciency and reduce
carbon dioxide emissions.
“States have a vested interest in protecting the air and water, and they have the
experience, expertise, and ability to regulate these issues,” Pruitt said.
Pruitt adds that the EPA’s mandate that
new coal-fred power plants install carbon
capture and storage (CCS) technology, violates federal law and the technology has
not been proven commercially viable. He
also mentions the Environmental Policy
Act of 2005 which states that the EPA may
not use federally-funded projects to prove
a technology is commercially proven. The
EPA included federally-funded projects in
its regulatory analysis.
Oklahoma AG’s proposal
allows states to
set emissions
standards
EPA fnalizes
Oklahoma Attor- 316(b) standards
ney General Scott
Pruitt revealed his
proposal that gives states the fexibility to
address carbon dioxide emissions standards from existing power plants.
The plan titled, “The Oklahoma Attorney General’s Plan: The Clean Air Act
Section 111(d) Framework that Preserves
States’ Rights,” challenges President
Obama’s Climate Action Plan which directs the EPA to regulate carbon dioxide emissions from new and existing
4
TThe EPA fnalized the 316(b) standards under the Clean Water Act to protect aquatic life drawn each year into
cooling water systems at large power
plants.
More than 2 billion fsh, crabs, and
shrimp are killed annually by impingement or entrainment.
According to the EPA, the fnal rule affects 544 existing power generating facilities that withdraw more than 2 million
gallons per day of water from U.S. waters
and use at least 25 percent of the water
they withdraw for cooling purposes. The
rule requires that the location, design,
construction and capacity of cooling water intake structures refect the best available technology for minimizing negative
environmental impacts. To ensure fexibility, the owner or operator of the facility
will choose one of seven options to meet
the requirements with the best technology available. Facilities that use more than
125 million gallons per day are required
to conduct studies to determine what
controls will be required.
New units at an existing facility that
are built to increase the generating capacity are required to reduce the intake fow
to a level similar to a closed cycle, recirculation system. EPRI said in an article that
their research showed closed-loop cooling costs were estimated at $100 billion
to retroft 450 power plants four years
ago. Those costs are now estimated to be
at least $50 million per plant, and the system could cost $2
billion or more per
plant, particularly
for nuclear facilities.
The national requirements will be
implemented through National Pollutant
Discharge Elimination System (NPDES)
permits.
EPA had delayed fnalizing the rule
several times since the 2004 Phase II
Cooling Water Intake Structure rules
were suspended in July 2007.
Dominion holds
groundbreaking for natural
gas-fred power plant
Dominion Virginia Power, subsidiary
of Dominion Resources, held the groundbreaking ceremony for the $1.3 billion,
1,360-MW Brunswick County natural
gas-fred power plant in Virginia.
Construction on the combined-cycle
power plant started in September, and
the plant is currently 17 percent complete.
www.power-eng.com
The plant is on budget and on schedule to
be completed by summer of 2016. Fluor
Corp. is the engineering and procurement services provider for the project.
DTE Energy sells Marysville
Power Plant to Commercial
Development Co.
Commercial Development Co. has
successfully acquired the Marysville
Power Plant in Marysville, Mich. from
DTE Energy.
The historic plant, which sits on a 20acre site along the St. Clair River, operated
from 1922 until 2001 and was released
for decommissioning in 2011. When operations ceased, the plant generated 167MW of electricity.
The preliminary agreement was announced in December; however, the deal
was fnalized May 23.
Commercial Development Co. will
begin the frst phase of the cleanup and
expects the site will be ready for development in about 18 months.
Financial terms were not disclosed.
Skyonic secures $12.5M
to develop carbon capture
technology
Skyonic Corp., an Austin-based carbon-capture technology company, has
secured $12.5 million in funding from
ConocoPhillips and Enbridge to develop
Skyonic’s carbon capture technology and
make it commercially available.
The fnancing joins the recently announced $500,000 grant from the Climate Change and Emissions Management Corporation to bring the SkyCycle
technology
to
pilot scale by late
2015.
Skyonic estimates that the
cost of carbon capture is between $150
and $450 per ton. In addition, the SkyCycle technology is estimated to be between
$16 and $25 per ton.
SkyCycle
technology
uses
a
www.power-eng.com
thermolytic chemical reaction to capture
carbon dioxide emissions.
The process converts carbon dioxide
emissions into hydrochloric acid and
calcium carbonate, also known as limestone.
The technology is able to capture approximately 94 percent of carbon dioxide
emissions.
Maryland Governor’s veto
allows $200M wind energy
project to move forward
Maryland Governor Martin O’Malley
vetoed a bill that would have postponed a
$200 million wind farm being developed
on the state’s eastern shore.
House Bill 1168 would have delayed
the 150-MW Great Bay Wind Energy Center by 13-months. The bill, which passed
the Maryland General Assembly in April,
sought to delay the project because of its
proximity to the Patuxent River Naval Air
Station, according to Think Progress. The
assembly argued that the turbines could
compromise the naval systems.
The U.S. Department of Defense
(DOD) stated that the radar systems were
not at risk as long as the turbines stop
spinning while in use. The DOD previously signed an agreement with Pioneer
Green Energy to shut down the turbines
during system testing.
“The developers of the Great Bay Wind
project have engaged in years of painstaking negotiations, played by the rules,
and invested millions of dollars in good
faith reliance on the policies established
by our federal and State legislative bodies,” O’Malley said. “If this moratorium
were to take effect, it would send a chilling message to clean energy investors …
that the State can change the rules at the
eleventh hour.”
The bill’s postponement was to allow time for the Massachusetts Institute
of Technology to complete a $2 million
study to evaluate the turbines’ impact on
the radar systems.
O’Malley previously mandated that
the state must use 20 percent renewable
energy by 2022.
Units at Minnesota
Power’s Thomson hydro
plant to return online
Minnesota Power’s 72-MW Thomson
hydropower plant could resume producing power early this summer.
The project, located on the St. Louis
River, was closed for rehabilitation in
June 2012 after heavy rains caused overtopping of the reservoir.
Repairs conducted over a 22-month
period have included the planning and
rebuilding of the forebay; cleaning, repairing and refurbishing of the powerhouse and its six turbine-generators; and
the repair and replacement of fow lines,
penstocks and valves.
Minnesota Power, a subsidiary of ALLETE, said the reconstruction and improvements have cost the company about
$90 million.
Engineers expect all six of the damaged
turbines to enter operations by the end of
the year.
PowerOptions signs
$325M natural gas contract
PowerOptions and Hess Energy Marketing LLC (HEM), a subsidiary of Direct
Energy Business LLC, signed a $325 million contract to supply natural gas to its
500 members who are among the Commonwealth’s nonprofts and government
institutions.
“This contract is a great opportunity
for our customers, with several pricing
options. Members can lock in their price
for the full term of the contract, creating
an ability to better predict their natural
gas bills,” said PowerOptions President
and CEO Cynthia Arcate. PowerOptions
has been providing energy solutions to
nonprofts, state entities, cities and towns
throughout the Commonwealth area for
more than 15 years. The supply agreement begins in May 2015 and extends to
November 2019.
5
Expanding Talent and
Technology into ONE
The global merger of Mitsubishi Heavy Industries and Hitachi Thermal Power Generation
businesses, now expands resources for and in the Americas.
Maximizing availability, reliability and profitability is the continuing goal of Mitsubishi Hitachi
Power Systems for existing and evolving energy needs – with a presence of more than 1,500
U.S. based personnel and 800,000 sq. ft. of state-of-the-art manufacturing, maintenance and
repair facilities in support of our world class products.
Mitsubishi Hitachi Power Systems – expanding talent and technology into one.
Visit us online to learn more about our world class capabilities.
Mitsubishi Hitachi Power Systems Americas, Inc.
100 Colonial Center Parkway • Lake Mary, FL 32746 USA
1-407-688-6100
www.mhpowersystems.com
Mitsubishi Hitachi Power Systems America – Energy and Environment, Ltd.
645 Martinsville Road • Basking Ridge, NJ 07920
1-908-605-2800
www.psa.mhps.com
CLEARING THE AIR
GHG Emission Controls
Affect Power Generation
Economics
BY NAT SEKHAR, SENIOR CONSULTANT, CH2M HILL
T
he economics of power generation continue to change, driven
by demand for new power generation and supply uncertainty, demand
for and prices of fossil fuels, development
and emergence of renewable energy, and
uncertainties about prospects for nuclear
power generation. Additional significant
concerns are regulation of greenhouse
gas emissions and potential imposition
of a penalty for carbon dioxide (CO2)
emissions to mitigate climate change.
The power generation options include
natural gas combined cycle (NGCC)
with and without carbon capture, super-critical (SC) and ultra-supercritical
(USC) coal-fired with and without carbon capture, integrated gasification and
combined cycle (IGCC) with and without carbon capture, concentrated solar
power (CSP), and nuclear. A techno-economic analysis involving various regulatory and carbon tax/cost scenarios can
be used to identify the relative economics of these generation options.
The options can be compared on the
basis of relative cost of electricity (RCOE)
generation, excluding the cost of transmission and distribution. With NGCC as
the basis at 1.0, other options increase or
decrease relative to that value. The RCOEs
for SC, USC, and IGCC power generation
are in the range of 1.5 to 1.6, 1.6 to 1.8,
and 2.2 to 2.4, respectively. A coal price of
$4/million British thermal units (MMBtu) and a gas price of $5/MMBtu are used
in this comparison. As would be expected, NGCC is the least expensive option,
which is attributable to both low capital
cost and low fuel cost.
Natural gas prices have fallen drastically in the past two year, from more
than $10/MMBtu to less than $4/
8
MMBtu, and are anticipated to remain
reasonably low for the foreseeable future.
To assess the effect of gas price on RCOE
and the competitiveness of NGCC with
other technologies, the concept of breakeven price can be used. The break-even
gas price is that gas price above which
coal generation becomes cost competitive. The break-even gas price for SC is in
the range of $9 to $10/MMBtu; for USC,
$11 to $13/MMBtu; and for IGCC, $16
to $18/MMBtu. Obviously break-even
prices can vary significantly if conditions change, but this comparison still
indicates relative economics of different
generation technologies.
The above analysis is for the “no carbon capture” condition. Carbon capture
will increase both capital and operating costs of coal- and gas-based power
generation. However, because the CO2
emission per kilowatt-hour (kWh) is
lower for natural gas than coal, about
50% lower, any additional cost for carbon capture to meet a prescribed CO2
emission will be less for NGCC than for
coal-based systems. Therefore, NGCC
will most likely be the least expensive
fossil fuel option under a carbon capture
requirement.
To compare NGCC, the best fossil fuel
option under the carbon capture scenario, with other technologies that do not
emit any CO2—such as CSP with and
without thermal storage and nuclear
power—a carbon capture of 90% is used
for NGCC. The cost comparison does
not include the costs of pipeline, pipeline transportation, and ultimate disposal of CO2 captured, and for nuclear
generation, the costs of decommissioning or nuclear waste disposal. Capacity
factors of 33% and 42% are used for CSP
without thermal storage and with thermal storage, respectively. Under these
conditions, the RCOEs are as follows:
1.5 to 1.6 for NGCC with 90% carbon,
4.4 to 4.6 for CSP without thermal storage, 4.6 to 4.8 for CSP with thermal storage, and 2.1 to 2.3 for nuclear.
Even under a 90% carbon capture requirement, NGCC is the least expensive
option compared with the technologies
that do not emit CO2. Under this requirement, SC and USC coal-fired plants
may become cost competitive compared
to solar and nuclear plants.
Solar and nuclear plants may become
economically viable if a carbon tax is
legislated. A break-even price concept
can be used for this comparison, too.
The break-even carbon price in dollars
per ton of CO2—that is, the carbon price
above which nuclear plants becomes
cost competitive—are as follows: $100
to $110 for SC and USC, $50 to $60 for
IGCC, and $300 to 320 for NGCC. The
corresponding break-even prices for solar power are above $500.
The relative economics of power generation will vary depending on regulatory environment, market condition,
site location, and socioeconomic factors.
A techno-economic model with recent
real-life estimates of capital costs and
operating and maintenance costs for
the various generation options and that
includes fuel costs and regulatory and
carbon tax/cost scenarios has been developed. The model provides flexibility
to accommodate variables for costs of
generation and regulatory impacts. The
methodology and the model offer a useful tool to analyze site- and time-specific
conditions and rank viable power generation options.
www.power-eng.com
GAS GENERATION
Expect Natural
Gas-fired Capacity
Growth to Accelerate
BY JUSTIN MARTINO, J.D., ASSOCIATE EDITOR
W
hile natural gas-fired power
generation is on the rise in
the U.S., the construction
of new natural gas-fired projects has been
below what the industry initially expected. The topic was discussed in Power Engineering’s executive round table on natural
gas-fired power generation, with multiple
factors discussed as reasons.
The participants all agreed though, the
switch to natural gas was proceeding at
a steady pace. Not surprisingly, the U.S.
Energy Information Administration’s Annual Energy Outlook supports that conversion to natural gas is slow but steady,
with natural gas surpassing coal as the
largest source of U.S. electricity generation by 2035.
The EIA is expecting a growth in natural gas-fired power capacity in the U.S.,
but only after a lull beginning in 2016.
Additions to the U.S. power capacity are
expected to average 16 GW annually until 2016, with 52 percent of that addition
being renewable energy built to take advantage of federal tax incentives and meet
state renewable portfolio standards.
After 2016, however, annual capacity
additions are expected to drop to 9 GW
annually until 2023 because “existing capacity is adequate to meet relatively slow
demand growth in most regions and satisfy renewable requirements under state
standards.” In 2023, however, capacity
additions will ramp back up, with annual
builds averaging 14 GW/year, with natural gas providing 79 percent of that new
capacity.
Overall, the EIA’s reference case projects natural gas-fired plants will account
for 73 percent of capacity additions from
2013 to 2040, providing around 256 GW
10
of the 351 GW of new capacity added
during that time. That number is nearly
triple the amount of renewables installed,
which is the second-largest new generation capacity source at 24 percent. Nuclear is projects to provide only 3 percent of
new generation capacity, and coal-fired
power generation is expected to provide
1 percent of new generation capacity.
Although there are many factors, including market uncertainty, that may
have slowed the growth of new natural
gas builds, one factor is the current attractiveness of renewables, which is being supported by government policies.
Renewable builds are expected to decline
after the expiration of the policies – and
natural gas builds are expected to increase at the same time.
“Renewable capacity growth is supported by a variety of federal and state
policies, particularly state renewable
portfolio standards (RPS) and federal
tax credits,” the EIA wrote in the AEO.
“However, the impact of those policies
is limited later in the projection period,
because individual state renewable targets stop increasing by 2025, and projects must generally be online by 2016 to
qualify for currently available federal tax
credits. In addition, growth in electricity
demand is modest and natural gas prices
are relatively low after 2025.”
The current trend in renewable energy
builds is one factor in the slower-thanexpected build of new natural gas-fired
power plants. Another is not as much gasfired capacity is needed to replace coal
plants that are being retired as originally
expected. Although many coal plants are
scheduled to be retired, the EIA noted
that a large number of those are currently
operating at low capacity factors.
The U.S. will see a growth in natural
gas-fired capacity, especially after 2023
when the current projects no longer satisfy the growth demand, but the exact
numbers depend on a variety of factors,
including the price of natural gas. The
EIA notes the generation mix “varies significantly across the AEO2014 alternative
cases” because of fuel prices and policies.
Some of the alternative cases that could
affect the growth of natural gas-fired generation the most are the High and Low
Economic Growth cases and the High
and Low Oil and Gas Resource cases.
Although the EIA is predicting 351
GW of new capacity in its reference case,
that number drops to 263 GW in its Low
Economic Growth case and increases to
482 GW in the High Economic Growth
case – either of which could create a large
swing in how much new natural gas-fired
capacity is added in the U.S.
The biggest factor in the growth of
natural gas-fired capacity, however, is the
cost of natural gas. In the EIA’s Low Oil
and Gas Resource case, which predicts
higher natural gas price, new gas-fired capacity only comes out to 181 GW, or 49
percent of total new capacity, added from
2013. In the High Oil and Gas reference
case, which projects lower natural gas
prices than the EIA’s reference case, gasfired capacity accounts for 323 GW, or 83
percent, of all total new capacity added
from 2013 to 2040.
Although the change to natural gas
may not be coming as quickly as originally anticipated, the EIA’s numbers project
that the growth will continue to accelerate as the fuel becomes the major power
generation source in the U.S.
www.power-eng.com
©Elgin Sweeper Company 2014
VIEW ON RENEWABLES
Overcoming
Technical Barriers
BY MICHAEL REED, WATER POWER PROGRAM MANAGER, DOE, AND
PETER DROWN, TECHNICAL RESEARCH ANALYST, BCS INC./DOE
W
ith 39 percent of the nation’s population living
in counties directly on
the shoreline, the waves and tides of the
world’s oceans hold great promise for delivering significant amounts of clean energy. These resources are powerful, predictable, and readily accessible. Although
they are largely untapped, there are many
different technologies under development that aim to sustainably exploit
these resources. These systems, known
as marine and hydrokinetic (MHK) technologies, are at various stages of development, with many countries pursuing
demonstration activities.
Resource assessments have indicated
that nearly 500 terawatt-hours/year is
technically feasible in these coastal regions, representing 9 percent of 2050 projected U.S. electricity demand. To capture
this geographically strategic opportunity,
however, cost reductions must be realized
and technical barriers must be overcome.
To address this research opportunity,
the U.S. Department of Energy (DOE)
has invested $116 million in almost 100
different MHK energy projects from fiscal
2008 through 2014. This support is distributed across wave, tidal and ocean current energy technologies and provided
to public, private and nonprofit entities.
The support is targeted at further understanding the resource and advancing the
technology readiness of a suite of MHK
technologies that hold the promise of
near-term commercialization. DOE’s research, development and demonstration
agenda serves to gather the operational,
environmental, and market data needed
to accelerate the responsible deployment and commercialization of these
technologies. DOE measures and assesses the results of these efforts through
12
Technology Readiness Levels (TRLs) to
enable uniform discussions regarding the
commercial readiness of various MHK
technologies. Wave and tidal technologies span the entire TRL spectrum. There
have been several notable successes. In
2012, the Ocean Renewable Power Co.
(ORPC) successfully deployed the first
U.S. commercial tidal project using its
trademarked TidGen Power System in
Maine’s Cobscook Bay. The local utility,
Bangor Hydro Electric Co., verified power
produced by the project, marking the first
time in U.S. history that such a project
was connected to the grid. Also in 2012,
Northwest Energy Innovations deployed
a wave energy Azura device off the coast
of Oregon. The deployment helped the
company obtain valuable power performance data and installation experience.
These accomplishments were not
gained without significant challenges.
Important lessons have been learned and
incorporated into strategic investment
planning processes. DOE identified key
cost drivers and technical barriers limiting the potential of MHK technology, and
redirected funding to focus on these specific improvements. These critical areas,
supported through DOE’s MHK Systems
Performance Advancement Initiative, include: “Advanced Controls” to improve
energy capture, availability and safety;
Next-Generation “Power Take-Off” to
increase energy efficiency, reduce weight,
and improve reliability; and “Optimized
Structures” to improve energy capture, reduce weight, and improve reliability.
One of the ten awardees of this effort,
Dehlsen Associates from Santa Barbara,
California, will develop advanced controls software for their multi-pod Centipod wave device. This new software will
help predict incoming wave conditions
Michael Reed
Peter Drown
and provide control signals to adjust
system settings to make the Centipod’s
power output more responsive, maximizing energy capture, reduce loading, and
increase power plant durability.
MHK technologies face the same tough
market conditions as other sources of
new energy generation. However, this industry offers a geographic value proposition that many other sources do not. In
addition to its proximity to large coastal
load centers, this resource can also be
tapped in more remote locations. Many
communities in Alaska and Hawaii face
high electricity prices due to isolated
power grids and reliance on imported
diesel fuel. Resolute Marine Energy is
pursuing this opportunity through its Yakutat Alaska Wave Energy Project. Utilizing their trademarked SurgeWEC device,
RME hopes to install an array of WECs
to bring sustainable power to Yakutat and
ease the cost of energy on ratepayers.
The U.S. Navy faces similar challenges
with their island military bases. DOE is
working collaboratively with the Navy
to test WEC concepts at the Navy’s Wave
Energy Test Site (WETS). DOE has announced funding to deploy two WECs
at two new berths at the WETS facility in
Kaneohe, Hawaii. Through this initiative,
DOE and the Navy will collect cost and
performance data.
Markets with high hurdle rate costs of
electricity can serve as early adopters of
marine and hydrokinetic technologies,
providing immediate value for local communities while demonstrating technology and allowing developers to innovate,
build scale, and reduce costs. As coastal
populations swell, this challenge will
require the best and brightest engineers
and entrepreneurs as we seek to diversify
our domestic clean energy portfolio.
www.power-eng.com
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lower emissions for a very sustainable future.
Siemens’ SGT-8000H series gas turbines are capable
of performing at efficiency levels of more than 60
percent. That means a 85,000-ton reduction in CO2
emissions every year compared with today’s
conventional combined cycle plants. But the story of
the most powerful commercially operating gas
turbine in the world doesn’t end there. The
SGT6-8000H 60Hz turbine also delivers extreme
reliability, operational flexibility and faster start-ups
while minimizing life-cycle costs. It’s the ultimate in
gas turbine technology that saves you money while
helping to save our environment.
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GENERATIONHUB
The U.S. Nuclear Industry:
Glass Half-Full
or Half-Empty?
BY WAYNE BARBER, CHIEF ANALYST, GENERATIONHUB
P
essimists and optimists can
have a lively debate over the
health of the U.S. nuclear industry these days.
A review of domestic nuclear power
developments over the past couple of
years would suggest that the nuclear
naysayers hold a stronger hand than
the nuclear optimists.
The nuclear naysayers point to everything from Fukushima anxiety to weak
power demand to the market impact
of subsidized wind generation as worrisome issues that undermine nuclear
power’s future.
Nevertheless, it could be too early to
count out the pro-nuclear optimists, especially following the price spikes that
accompanied the much-reported ‘polar
vortex’ this winter.
NEW CONSTRUCTION
MUST BE WEIGHED AGAINST
RETIREMENTS
Optimists can point to construction of
new nuclear capacity by the likes of the
Tennessee Valley Authority (TVA), Southern and SCANA.
TVA is hoping to bring online the never-completed Watts Bar Unit 2 in Tennessee by the end of 2015. Southern and its
partners remain on schedule for deployment of Vogtle Units 3 and 4 in Georgia
during 4Q 2017 and 4Q2018 respectively.
SCANA and its vendor team will soon
reveal an updated completion schedule
for V.C. Summer Units 2 and 3 in South
Carolina. It will probably be later than
the current target of 4Q 2017 or 1Q 2018
for Unit 2.
Nevertheless, these projects are evidence that the United States is nearing
14
completion of its first additions to the domestic nuclear fleet in decades.
Pessimists will point to announced
spate of retirements of nuclear capacity
for both economic and non-economic
reasons.
These include the likes of Duke
Energy at Crystal River 3 in Florida,
Dominion Resources at its Kewaunee
plant in Wisconsin; Edison International at the San Onofre Nuclear Generation Station (SONGS) in Southern
California.
Those retirements have already occurred but others have been announced.
. Entergy has said it will retire the Vermont Yankee plant at the end of this
year, while Exelon announced in 2010
that it has decided to retire its Oyster
Creek nuclear plant in 2019.
Indeed, a report issued last summer by Navigant Consulting for the
Eastern Interconnection States Planning Council suggested that domestic
nuclear units could have a particularly
hard time coping with the combination of cheap natural gas and other
market and regulatory forces.
Among other things, the Navigant
report said that a national waste repository appears off the table for the
foreseeable future and most new plant
applications filed with the Nuclear
Regulatory Commission (NRC) have
been either pulled or suspended.
Nuclear optimists have thought they
had a strong card to play with small
modular reactor (SMR) technology.
Ideally, SMRs should open the door to
smaller less capital intensive nuclear
development.
But the SMR optimism hit a pothole
recently when Babcock & Wilcox announced it was slowing its SMR program after encountering lukewarm interest from potential SMR investment
partners.
Nevertheless, NuScale, another SMR
developer that has attracted Department of Energy (DOE) funding, is
moving ahead with its 45-MW module
technology.
The nuclear power lobby is also fighting back. Exelon CEO Christopher Crane
has been particularly outspoken about
the need to keep carbon-free baseload
electricity as part of the portfolio.
Nuclear Energy Institute (NEI) President and CEO Marvin Fertel has told
Wall Street analysts that the U.S. power portfolio is becoming overly dependent on natural gas.
Nuclear advocates also say that mass
coal retirements in the next couple of
years make it even more important to
keep existing power reactors in service
for reliability purposes. They caution
that price spikes for natural gas and
electricity will become even more pronounced when more of the current
coal fleet goes offline.
Meanwhile, there is anecdotal evidence that nuclear proponents are
making headway with some members of the environmental community. Nuclear power optimists say the
United States cannot abandon sources
of carbon-free baseload power without
ending up being too reliant on natural gas – which produces greenhouse gas
emissions, albeit less than coal.
One thing’s for certain: Neither the nuclear power optimists or pessimists will
give up their fight anytime soon.
www.power-eng.com
For more information contact us at:
281.404.9397 or [email protected]
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BRAND COMPANIES:
ENERGY MATTERS
An NSR Legal Update
BY ROBYNN ANDRACSEK, P.E., BURNS & MCDONNELL
I
n order to navigate the Clean Air Act,
it is just as important to follow court
rulings as it is to follow the release
of new regulations. The recent Supreme
Court ruling on the Cross State Air Pollution Rule (CSAPR) was widely reported,
but several other recent decisions also
directly impact the utility industry. These
rulings affect a wider audience than just
CSAPR facilities but were less publicized.
Additionally, these rulings are tied up in
that most confusing of New Source Review (NSR) issues: when does a modifcation require a Prevention of Signifcant
Deterioration (PSD) pre-construction
permit?
First, in the Detroit Edison case, the
bottom line is that an actual exceedance
in emissions is required before a violation occurs; it is not enough for EPA to
second-guess that the utility’s method
of predicting emissions was wrong. The
background for this case is modifcations
made to the Monroe, Michigan power
plant. Detroit Edison made predictions
under the “reasonable possible” recordkeeping provisions of NSR that the modifcations would not result in an increase in
emissions above the PSD thresholds. EPA
argued that the calculation method was
fawed. Although fve years of post-modifcation monitoring has not yet elapsed,
actual emissions to date are below the
PSD thresholds. Therefore, no major
modifcation occurred. The court ruled
that EPA cannot challenge the methodology and factual assumptions used to
predict post-project emissions as long as
those predictions were reasonable and
not plainly erroneous. The utility is still
responsible for analyzing projects before
they occur, making realistic estimates,
and using a proper baseline period. “EPA
16
is only entitled to conduct a surface review of a source operator’s preconstruction projections to determine whether
they comport with the letter of the law.
Anything beyond this cursory examination would allow EPA to “second-guess”
a source operator’s calculations…” EPA
cannot declare that the predictions were
erroneous until emission monitoring
shows that a violation actually occurred.
This effectively holds off enforcement actions until fve years post-project.
Secondly, in a combination of cases
(Midwest Generation, OG&E, and US
Steel), the bottom line is that there is a
fve –year statute of limitation on NSR
enforcement. Even if ownership of a facility changes, the new owners “cannot
be liable when its predecessor would not
have been liable had it owned the plants
continuously.” When EPA brings enforcement a decade or more after the alleged
violations, each day of operation does
not constitute a new and continuing violation. “The violation is complete when
construction commences without a permit in hand,” the court said in the July
2013 Midwest Generation case. Citing that
case with approval, a federal judge in the
April 2014 U.S. Steel case added, “[A] construction permit violation only relates to
construction; continued operation without having gotten a construction permit
doesn’t violate the construction permit
requirements.” The US Steel case involves
modifcations eerily familiar to the utility
industry – a 1990 relining of a furnace,
an action commonly done in industry
but infrequently done at a given facility.
EPA argued that failing to obtain a PSD
permit for the relining project led to a
1996 Title V operating permit application
which was defcient. EPA waited until
2012 to bring up the alleged NSR violation (well over fve years after the modifcation). The court granted US Steel’s
motion to dismiss EPA’s lawsuit since
the alleged NSR violation was precluded
by the statute of limitations, therefore,
the alleged Title V violation was likewise
“time-barred.”
These cases emphasize the need for
utilities to examine upcoming modifcations carefully and with an eye towards
making accurate predictions of future asset utilization.
Documentation is essential in establishing the protection afforded by establishing a baseline emissions level and predicting that no PSD signifcant emission
increase will occur after the modifcation.
These analyses will become very important in the next few years if the proposed greenhouse gas (GHG) rules for
existing sources require reductions that
lead to plant effciency projects.
These projects would then be subject
to PSD if there is a prediction or reality
of a ton per year increase above the PSD
thresholds.Although EPA has lost a few
legal skirmishes, NSR enforcement is far
from over.
This is especially true in Region V
(Minnesota, Wisconsin, Illinois, Michigan, Indiana, and Ohio) where anecdotal
evidence indicates that the regulators are
more aggressive than in other EPA Regions.
Each utility has to weigh the risks and
expense of drawn out litigation versus a
consent decree.
A utility must be armed with not only
calculations and demand forecast projections, but also legal and risk analyses
when deciding which modifcations to
undertake.
www.power-eng.com
R ELO AD ED
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NUCLEAR REACTIONS
Sustaining
High Performance
BY MARY JO ROGERS, PH.D., STRATEGIC TALENT SOLUTIONS
T
he U.S. nuclear power industry
recently published its 2013 performance metrics for all plants
nation-wide. The industry average for
capacity factor still hovers around 90 percent, and metrics for safety and system
reliability also remain highly favorable.
Closer study of the data show, however,
that only a subset of plants has been able
to sustain a high level of performance
consistently over a period of many years.
Others appear to be subject to a cyclical
pattern where they regularly end up chasing the equipment—and the right employee behavior—to climb back up to top
performance levels.
What do the sustained high performers do to stay in the zone? Insights
can be found from INPO (Institute of
Nuclear Power Operations), research
on high performing organizations,
and a review of practices at consistently high performing plants.
INPO’S SUSTAINABILITY
PRE-REQUISITES
INPO has long held that leadership effectiveness, employee engagement, and
a strong nuclear safety culture are necessary to achieving sustained plant performance. INPO and the industry embraced
the important role of nuclear safety culture after the watershed Davis-Besse event
in 2002. Widely considered a strong performer, the significant degradation of
the reactor vessel head at the station was
troubling. The event prompted the ongoing assessment and intentional development of organizational culture committed to safety.
INPO has since defined and expanded
expectations regarding leader and manager behaviors related to organizational
culture. For instance, to avoid decline,
excellent nuclear operations need to be
18
“engaged, thinking organizations.” The
phrase refers to the SOER (Significant
Operating Experience Report) that was
issued in 2010 to stem potential declines
that were noted in good performing stations. The root cause revealed leadership and organizational weaknesses that
needed to be counteracted with greater
intrusiveness, employee ownership and
engagement.
Although both the Davis-Besse event
and the SOER were prompted by performance declines, the leadership and
organizational expectations have been
adopted into INPO’s Performance Objectives and Criteria, by which plants are
evaluated for excellence in Organizational Effectiveness.
RESEARCH ON
HIGH PERFORMING
ORGANIZATIONS
Organizational effectiveness experts
have shown that engaged employees
with a strong sense of ownership and
willingness to go above and beyond are
characteristic of high performing companies. Researchers also found that aligned
leadership deep in the organization and
that are focused on talent for development, retention and succession are also
important for high performance. Highly
engaged employees are more productive,
more committed and stay longer. Talent
focused leaders spend time coaching and
developing people, make good promotion decisions and make people want to
stay and perform. We take a look at the
efforts of consistent high performers.
SUSTAINED HIGH
PERFORMANCE IN
NUCLEAR OPERATIONS
An informal survey of these high
performers validates the concepts of
leadership involvement, alignment
and employee engagement promoted
by INPO and organizational effectiveness research. At a single unit nuclear
station in the south, the leadership
team consistently invested time aligning on team behaviors, plant objectives, and developing the workforce
talent. While they had a high INPO
Index and strong power history curve,
they invested in leadership assessment
and alignment activities that strengthened vertical alignment and talent development. In contrast, other plants
with a similar level of performance
often shy away from such activities as
they are seen as not urgent and only
somewhat important.
At a dual unit power station, extensive and consistent efforts have been
made to engage employees at all levels
with frequent dialogues with senior
leaders who listen and respond to issues. Great attention has been paid to
the culture of the organization where
leaders repeatedly communicate and
demonstrate to employees how critical
they are. Leaders are coached to walk
the talk of the engaging culture. These
and other sites also reward and recognize employees for great catches and
contributions, get to know employees,
and other engaging activities.
These
employee
engagement
efforts may seem like bending too far
backward for many more traditional
plant leaders. But appreciating and
engaging employees does not mean
you stop performance managing or
lower performance expectations. It
does mean, however, that leaders
spend time working to motivate and
inspire the people that work for them.
In other words, they need to spend
time leading.
www.power-eng.com
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DEMAND RESPONSE
Automated Demand
Response: Connecting
Utilities Worldwide
BY BARRY HAASER, MANAGING DIRECTOR, OPENADR ALLIANCE
T
he $197 billion Smart Grid market represents a significant business opportunity for utilities,
equipment suppliers, system installers
and end customers to leverage a new
demand response (DR) standard called
Open Automated Demand Response or
OpenADR.
Navigant Research forecasts global
spending on Automated Demand Response (ADR) will grow from $13 million in 2014 to more than $185 million in
2023. The market opportunity is further
bolstered by data from the U.S. Department of Energy. Many of the 99 Smart
Grid projects developed through the
Smart Grid Investment Grant Program
are using some form of DR, helping utilities maintain grid reliability and enabling
customers to realize significant value. In the U.S., however, an estimated 95
percent of commercial DR programs still
rely on manual processes, which adds
unnecessary cost, complexity and performance uncertainty. The energy industry
has been slowly migrating toward semiautomated and automated DR programs
for several years, but growth has been
limited due to a lack of industry standards. OpenADR solves this problem.
The OpenADR standard provides an
open and standardized method for electricity providers and system operators to
communicate DR signals with each other
and their customers using a common
language over any existing IP-based communications network. OpenADR has
achieved widespread support worldwide. International
support
for
the
OpenADR standard increased through
the
International
Electrotechnical
20
Commission (IEC), which recently approved the OpenADR 2.0b Profile Specification as a Publicly Available Specification (PAS) IEC/PAS 62746-10-1 as a basis
for a new commission standard to be
developed. Additional work is underway
within the IEC to address compatibility
with the Common Information Model.
Additional recognition was achieved
through the Smart Grid Interoperability
Panel (SGIP) who added the OpenADR
2.0a and b Profile Specifications to the
SGIP Catalog of Standards. The Catalog
of Standards includes those standards
reviewed by SGIP that deliver interoperability of Smart Grid devices and systems
and are suitable for deployment by a utility or system operator.
Several trends are driving adoption
of the OpenADR standard, including:
Improved grid reliability by automatically shifting peak energy demand: Smart grid technologies are continuing to change the traditional delivery
systems into interconnected networks.
OpenADR automates pre-defined load
shedding strategies at facilities based on
market price or grid status. By placing
emphasis on an energy strategy, rather
than a control strategy, grid connected
buildings become more energy efficient,
while increasing DR capacity.
Enabling ancillary services for
access to non-spinning energy reserves: OpenADR can act as an ancillary service that responds within seconds, providing much needed energy to
the grid in the form of energy reduction
and in place of energy provided by a
power plant. Using fast telemetry, such
as the Internet, ensures rapid delivery
and response of OpenADR messages.
Overcoming intermittency of
renewable energy on the grid:
Renewable energy can change within minutes, making it a challenging
source of energy supply. Standards,
such as OpenADR, provide a mechanism to balance the grid by automatically adjusting energy consumed by
customers in real time,
Encouraging customer energy
efficiency through grid aware products: OpenADR interfaces exist in many
building automation, lighting and smart
thermostat products making it easy and
cost effective to participate in utility Auto-DR programs. OpenADR has certified
nearly 50 products based on OpenADR
2.0. These certified products enable energy providers to enroll customers in
new dynamic pricing programs that automatically react to price changes based
on pre-programmed conditions.
Demand response management systems (DRMS) are growing in popularity
among energy providers for their locational dispatch functionality. OpenADR
supports specific load targeting by product type, by group, by device type, by
service area, or by resource.
Several utilities are jumping on the
OpenADR
bandwagon,
including
American Electric Power, Austin Energy,
Duke Energy, Hawaii Electric Company,
NV Energy, Pacific Gas & Electric, San
Diego Gas & Electric, and Southern California Edison. As a result, the OpenADR
standard continues to gain rapid and
sustained market adoption. For more
information, please visit http://www.
openadr.org
www.power-eng.com
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and public projects, the United Rentals team
is proud to provide our customers the best equipment,
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© 2014 United Rentals, Inc.
POWER PLANT PROFILE
Untapped Power:
Harnessing the Potential
of the Ohio River
BY JUSTIN MARTINO, J.D., ASSOCIATE EDITOR
T
he Ohio River, the main tributary of the Mississippi River,
is 981 miles long and fows
through six states. Its average depth is
about 15 feet, raised to accommodate
navigation from a natural depth varying from three to 20 feet by a series of
20 dams operated by the U.S. Corps of
Engineers.
The river is also a major source of
untapped hydropower, and American
Municipal Power (AMP) is in the process of using four of the dams on the
river as a baseload resource for its 129
members in seven states. The four projects – located at the Cannelton, Smithland, Willow Island and Meldahl dams
– will add more than 300 MW of generating capacity to AMP’s members’
portfolios without adding emissions.
DIVERSIFYING
THE PORTFOLIO
The decision to make a $1.5 billion
investment in hydropower started from
a decision faced by many companies in
the power generation industry – AMP
was looking to diversify its generation
portfolio in order to cut down costs for
its members.
“The industry started changing,”
AMP Vice President of Communications
Kent Carson said. “Power supply is the
principal focus of the organization, and
we help our members secure long term
power supply contracts – basically market purchases. With changes in the industry, it became harder and harder, if
not impossible, to get those long terms
contracted at fxed costs. Our members
were overly exposed on the wholesale
22
market, which can be and at times has
been very volatile.”
The organization embarked on an effort to develop projects that would allow
members to fx the cost of some of the
power by owning the generation asset,
and a major component of that became
creating new hydropower assets.
The organization developed and
currently manages the Belleville Hydroelectric Facility, a 42 MW run-ofthe-river hydropower plant at the Belleville Locks and Dams. The facility
went online in April 1999.
“We knew the Ohio River was a relatively untapped resource,” Carson said.
“The dams on the Ohio River were built
in the ‘50s and ‘60s. They were built and
are operated by the Army Corps of Engineers, and their principal function is
navigation, to maintain the pool levels
for the barge traffc that goes up and
down the river, but they have the potential to add hydroelectric powerhouses
and generate electricity.”
AMP contacted MWH Global, which
served as the owner’s engineer for the
Belleville Hydroelectric Facility project,
and asked the company to do a screening
The four powerhouses being built by AMP
on the Ohio River will add more than 300
MW of renewable generation capacity to the
organization’s members’ portfolios.
study of the existing locks and dams on
the river that did not have power. MWH
performed the study in 2006, ranking
the potential sites from most developable to least developable.
From there, AMP began the process
of securing the development licenses
for the best sites for power generation
projects.
LICENSING CHALLENGES
Although the projects might be new,
AMP was not the frst organization to
look at the possibility of putting hydroelectric powerhouses on the dams. That
created a few problems.
“A lot of these projects have been
looked at numerous times over the past
decades, and in some cases people had
pulled FERC licenses to develop them
but just never got the capital together to
actually move the project forward,” said
Paul Blaszczyk, vice president and project manager with MWH.
Where there were no existing licenses, MWH helped AMP with obtaining
them, including approvals and permits
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from both the U.S. Army Corps of Engineers and FERC. Because of the nature
of the projects and the lack of recent new
hydropower builds, one of the approvals
– to modify a federal facility – had never
been done for a hydroelectric power facility before.
“When AMP started the process, these
four jobs were the frst four hydro projects that had to go through that approval
process,” Blaszczyk said. “While the approval process was defned and known
for things like adding features to a levee
on a riverbank and things like that, nobody had ever done it for a hydro facility.
That was a bit of a challenge and a bit of a
learning curve because we would ask the
regulatory folks, ‘What do you need?’
and they would come back and say,
‘We’re not quite sure.’ We ended up getting through it, and AMP kind of set the
mark here moving forward when you’re
developing at Corps facilities relative to
that process. But that was a bit of a challenge up front on the regulatory side.”
The licenses and Meldahl were acquired by the township of Hamilton,
Ohio.
BUILDING ON
THE FOUR DAMS
All four of the projects will use turbines and generators from Voith Hydro,
based in York, Pennsylvania. The projects will use identical controls, which
will assist if operators need to travel
from plant to plant. There are many differences between the four projects, however.
“What we’re not able to do is take a
cookie cutter approach,” Carson said.
“The projects are similar in that they’re
run of the river and horizontal bulb turbines, but that’s the end of their similarities. Each one of the projects is unique
and became its own project with its own
challenges and advantages.”
The Cannelton Project, located at the
Cannelton Locks and Dam, will use
three 29.3-MW bulb-type turbines. The
facility’s total rated capacity is 88 MW,
and it will generate an average gross annual output of approximately 458 million kilowatt-hours.
The Smithland Project will divert water from the Smithland Locks and Dams.
It will use three 25.3-MW bulb-type turbines, creating an estimated total rated
capacity of 72 MW with a gross annual
output of around 379 million kWh.
Meldahl, located at the Meldahl Locks
and Dams, will be the largest of the four
projects. The powerhouse will use three
35-MW bulb-type turbines with a total
rated capacity of 105 MW and gross annual output of around 559 million kWh.
AMP is developing the Meldahl project
with the member community of Hamilton, Ohio, which originally procured
the development license from the Federal Energy Regulatory Commission.
Hamilton retains the right for around 52
percent of the energy produced from the
project, with AMP taking the remaining
output for the 48 other AMP members
participating in the project.
Meldahl also has some parts that
are not interchangeable with the other
dams, according to Pete Crusse of AMP,
as it has a four-blade runner compared
to three-blades at the other sites.
UNIQUE CHALLENGES
ON EACH SITE
Because of the nature of hydropower
projects and the differences in the existing dams, a different engineering approach was required for each site.
“In each project, you have unique
challenges you have to overcome,”
Crusse said. “Willow Island, for example, required an archeology dig. At the
Smithland project, we knew one of the
biggest risks on that particular project
was the fact it sat right on a fault line
and there could be some underground
stabilization of the ground that we had
to take care of. But each of them has
unique risks, and I’d say the majority of
that risk is getting to the point where you
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can start placing the concrete.”
Smithland also sits on karst, which
is a very soluble and uneven bedrock,
Blaszczyk said. Although Meldahl and
Willow Island are founded on rock, the
other two are not.
“At Smithland and Cannelton, the
rock is quite deep,” Blaszczyk said. “So
those power plants are founded on the
alluvial foundations. Making sure those
stay put and that they can appropriately
support the powerhouse long term required some innovative technical solutions and doing some things that were
quite challenging.”
Crusse also noted the different turbine designs – each site has a different
capacity, and Willow Island, which is
located farthest upriver and has less
fow than the other three projects, is a
two-turbine facility rather than a threeturbine facility.
Although MWH is serving as the
owner’s engineer on all four projects,
each has a different contractor building
the power plant and installing the owner
furnished equipment used at the sites.
CREATING EFFICIENCIES
Building the four power plants at the
same time did create some advantages
for AMP.
“We wanted to maximize the repeatability from project to project, and to
get the best price, we wanted to order in
bulk,” Blaszczyk said. “We did a contract
for the Cannelton, Smithland and Willow Island projects for the turbine generator equipment all at once. Ultimately,
we signed three discrete contracts with
that vendor, but the pricing was developed as a package so we could maximize
the economy of scale. We ended up with
about 14 different contracts on each of
the projects, ranging from turbine generators to the cofferdams for the project.”
The projects do share some similar
characteristics that allow for a shared
knowledge base.
“You would have lessons learned
from each of the projects, and the ones
that are in the lead are generally the ones
that are plowing the trail,” Crusse said.
“As they plow the trail, they encounter
things that impact the schedule, and
therefore you want to take that lesson
and implement it as quickly as possible
on the other three projects to make sure
you don’t do the same thing twice.”
Perhaps more important than creating
a uniform design, however, was making
sure uniform system of management is
in place, Crusse said.
“We have been extremely focused
on consistency as an owner in managing these projects all the same,” he said.
“That has been a big challenge because
when you’re dealing with the size of staff
24
www.power-eng.com
Each project had to be designed based on its
location and challenges.The Willow Island project is
the only of the four projects to only use two turbines
because of its location farther upriver.
on these projects, you’re dealing with a
lot of very, very intelligent people. They
all come to the job site and want to do
some things or build things or manage
things or administer things all differently. When that happens, that sometimes
can create chaos in the construction industry, so as a leader I made it extremely
clear when we come to a decision on
how we’re going to administer or manage something, it’s done the same on every one of the four projects, and that has
worked out.”
cheapest, resources in those communities’ portfolio. I think people are already
recognizing the benefts and the intelligence of that investment. In 50 years, the
debt is paid off, the power is cheap and
there’s another 50 years to go in the life
cycle of the plant. Someone is going to be
sitting there saying, ‘Wow, 50 years ago
some people made some really smart decisions that are beneftting us now.”
Carson is quick to point out those decisions were not made by AMP, but by the
members of the organization that chose
to participate in the projects.
“They already look smart, but they’re
going to look a whole heck of a lot smarter down the road,” he said.
CHOOSING HYDROPOWER
ADVANTAGES OF
HYDROPOWER
Although hydropower makes up 7
percent of total U.S. electricity generation and is the country’s largest source
of renewable energy, a recent study by
the U.S. Energy Department and its
Oak Ridge national Laboratory recently
released a renewable energy resource
assessment estimating over 65 GW of
potential new hydropower development
is available, nearly doubling the current
U.S. hydropower capacity.
“The United States has tremendous
untapped clean energy resources and
responsible development will help pave
the way to cleaner, more sustainable and
diverse energy portfolio,” U.S. Energy
Secretary Ernest Moniz stated at the time
the assessment was released.
New hydropower builds in the U.S.
have been slow, however, for a variety of
reasons, including a high upfront capital
cost. Because of AMP’s experience with
the Belleville project, however, Carson
said the organization knew hydropower
would be the best option for its strategy
of creating new assets.
“That debt is going to be retired in
2025,” Carson said of the Belleville project. “Once that debt is retired, you’re looking at around 3 cent power. That will be
probably one of the cheapest, if not the
Despite the high upfront capital costs
of building a hydropower project, the facilities will have a beneft that can last
100 years or more.
“Our CEO has made the observation
a number of times that these are longterm investments,” Carson said. “You
don’t develop hydro if you’re looking for
short-term gains because there is a larger
upfront investment. On the other side
of that equation, though, is the plant
with maintenance, upkeep and equipment replacement lasts 80 to 100 years.
And once the debt service is paid off,
the power becomes extremely cheap because the fuel is free.”
The advantages are more than fnancial. With the U.S. Environmental
Protection Agency focusing on carbon
emissions, hydropower’s emission-free
generation doesn’t’ carry the risk of uncertainty that exists with future environmental regulation.
Unlike other forms of renewable
energy such as wind farms and solar
power, hydropower also can be used as a
baseload facility, supplying a predictable
amount of power onto the grid.
“There is a lot of development going
on in wind and solar and some other renewables, and I think the development
www.power-eng.com
Hydroelectric facilities have a higher
upfront cost than many other sources of
power generation, but provide extremely
cheap power once the debt is serviced.
of those what we call intermittent or
variable renewables will fuel a need for
more hydropower to help stabilize the
grid with some of the issues that crop up
when these intermittent renewables are
becoming a larger portion of the generation portfolio,” said MWH Senior
Vice President and Director of North
America Operations for Energy and Industry Group Mario Finis. “Hydro can
help balance out some of the impacts of
the variability and frequency control.
I think the development of wind and
solar will actually create more of a demand of some of the hydropower projects that can be developed to help with
grid stabilization.”
BUILDING ON
EXISTING STRUCTURES
One of the things that helps
mitigate the costs is the ability to
put powerhouses onto existing
structures. According to Finis, only
about 3 percent of the approximately
80,000 dams in the U.S. have power
generation facilities.
“I think that’s an opportunity that
has become more widely recognized
here in recent years,” he said. “Both
26
the costs, time and environmental
impact of building a new reservoir are
recognized to be cumbersome. Taking
advantage of the existing dams and
reservoirs that are already in place for
other purposes, for navigation or food
control or recreation or irrigation, using that existing infrastructure and
just adding power generation facilities
to those existing dams, is a more costeffective way to do it.”
The project would be signifcantly
different if AMP was looking at building a new dam on the Ohio River, Carson said, and would not likely be seriously considered.
“As I always like to point out, those
dams on the Ohio River were built in
the ‘50s and ‘60s. Any impact to the
ecology of the river has long since been
realized and overcome, so we’re not
adding to that. We’re constructing the
powerhouse adjacent to existing dams
and diverting a portion of the water
that would otherwise be fowing over
those dams through our powerhouse.”
“DOING IT RIGHT”
Despite the lack of current new builds,
the attractiveness of hydropower as a
long-term investment leads to the possibility of future builds in the U.S. AMP
hopes to provide an example of how to
take advantage of existing dams to build
hydroelectric facilities.
“We sure as hell hope it does,”
Crusse said of the prospect of AMP’s
project spurring future hydroelectric
growth in the U.S. “We want to be
on the cover of Engineering News Record with a statement that says these
guys got it right. We don’t want to be
on the cover of Engineering News Record with a comment like you see there
about every week with the things that
go wrong. That’s not what our goal is.
We absolutely have set our goals high.”
Crussesaid he is proud of the projects, and the organization’s ability to
get all four of the projects online and
generating quickly as possible. As the
company continues building the facilities, more people are recognizing the
great value provided by hydropower.
“You’d be astonished – and I really
mean that word – at the comments I
receive of, ‘Why hasn’t this been done
a long time ago?’” Crusse said. “I’m
blessed to be able to work on all four
projects, as hectic as it might be.”
www.power-eng.com
TM
AUGUST
20–22, 2014 | NASHVILLE, TENNESSEE
MUSIC CITY CENTER, HALL B
W W W. C OA L - G E N . C O M
OWNED &
PRODUCED BY:
PRESENTED BY:
A Bull Market
for Gas Turbines
I
BY RUSSELL RAY, MANAGING EDITOR
n a dramatic battle for a bigger
piece of the generation pie, the
global gas turbine market is
thriving with new innovations,
new projects and new ventures.
Led by increasing demand for flexible, efficient and small-scale generation,
North America is becoming one of the
strongest markets for gas turbine manufacturers.
Siemens CEO Joe Kaeser said last
month his company sees “excellent market-entry opportunities, especially in
North America.” To foster this mission,
Siemens agreed to buy a unit of Rolls
Royce that builds small aeroderivative
gas turbines for $1.32 billion. The business is based in Mount Vernon, Ohio,
and the acquisition is expected to close
by the end of this year.
“The acquisition of the aeroderivative
gas turbine business of Rolls-Royce closes a gap in our portfolio and broadens
our access to the attractive market for
small gas turbines, a market projected
to grow about 8 percent in the coming
years,” Siemens CFO Ralf Thomas said
during a conference call with reporters.
Kaeser also appointed American Lisa
Davis, a vice president at Royal Dutch
Shell PLC, to serve as chief of the company’s power business and announced
plans to move the headquarters of Siemens’ power business to the U.S., where
its rival GE is based.
“We have lost the active penetration,
the active strategy development” in
the American market, Kaeser said last
month after a press conference in Berlin.
28
The 9HA gas turbine introduced by GE will be delivered to GE’s Greenville, South Carolina,
test facility for full-scale testing. In a 1x1 combined-cycle configuration, the 9HA.01 is rated
at 592 MW and the 9HA.02 is rated at 701 MW, with each offering more than 61 percent
efficiency. Photo courtesy: GE Power & Water.
“We have to win that back with a strategic presence in the U.S.”
The rivalry between GE and Siemens
intensified last month after GE offered
$13.5 billion for the power generation
and transmission units of Alstom. To
preserve its dominance in foreign markets, Siemens submitted a competing offer for the French turbine manufacturer.
The bidding war over Alstom’s power
generation and transmission businesses
was still underway at the time this article was written.
Forecast International, a research
firm, estimates that more than 12,000
gas turbines worth $218 billion will be
sold worldwide over the next 10 years.
Information from McCoy Power Reports, another research firm, shows GE
held 49 percent of the global gas turbine
market last year, followed by Siemens
with 23 percent, Mitsubishi Hitachi with
17 percent and Alstom with 2 percent.
Aeroderivative gas turbines are being used in a variety of combined cycle
gas turbine configurations, providing
www.power-eng.com
In a 1x1 combined-cycle
configuration, the 7HA.01
from GE is rated at 405 MW
and the 7HA.02 is rated at
486 MW, with each offering
more than 61 percent efficiency. Photo courtesy: GE
Power & Water.
fast-start and cycling capabilities while
retaining the overall efficiency of an
integrated system. With power generation from natural gas and intermittent
renewable sources on the rise in the
U.S., the use of industrial gas turbines
will increase and the competition to
offer customers a full range of solutions will intensify.
GE’S H-CLASS
GAS TURBINES
Meanwhile, GE recently introduced
the 7HA and 9HA air-cooled gas turbines. The H-class gas turbine comes in
two versions for the 50 Hz market, the
9HA.01 and 9HA.02, and two versions
for the 60 Hz market, the 7HA.01 and
7HA.02. They are, GE said, the “world’s
largest and most efficient gas turbines,
with combined cycle efficiencies better
than 61 percent.”
The 9HA.01 is rated at 397 MW and
the 9HA.02 is rated at 470 MW in a simple-cycle configuration, with each offering more than 41 percent efficiency.
In a 1x1 combined-cycle configuration,
the 9HA.01 is rated at 592 MW and the
9HA.02 is rated at 701 MW, with each offering more than 61 percent efficiency.
The 7HA.01 is rated at 275 MW and
the 7HA.02 is rated at 330 MW in a simple-cycle configuration, with each offering more than 41 percent efficiency.
In a 1x1 combined-cycle configuration,
the 7HA.01 is rated at 405 MW and the
7HA.02 is rated at 486 MW, with each
offering more than 61 percent efficiency.
According to GE, the H-class gas turbine
incorporates an aerodynamic 14-stage
compressor and includes an advanced
radial diffuser which, combined with
the Dry Low NOx 2.6+Axial Fuel Staged
www.power-eng.com
combustion system, allows improved
operation of the combustion liner and
transition piece cooling.
MITSUBISHI HITACHI
SIGNS DEAL FOR 501J
GAS TURBINE
A deal to build what may be the
most efficient combined cycle gas turbine power plant in the U.S. was finalized in April.
Executives from Mitsubishi Hitachi
Power Systems and officers from the
Grand River Dam Authority gathered in
Tulsa, Oklahoma, to sign contracts for a
328-MW gas turbine known as the 501J
and a 167-MW steam turbine. The 495MW unit will replace an old coal-fired
unit at the Grand River Energy Center
near Chouteau, Oklahoma.
The project is the first of its kind in
the Western world. The J-Series gas turbine is the largest and most efficient gas
turbine in the world, according to Mitsubishi Hitachi. Nine are in commercial
operation worldwide, including six in
South Korea.
The 501J is known for its higher firing
temperatures and improved efficiency.
The J-series gas turbine is able to operate
at a turbine inlet temperature of 1600OC
(2912OF) by integrating the technologies
used in the 1400OC F-series and 1500OC
G and H-series turbines.
“One of the big features of this machine is its efficiency,” said Bill Newsom, vice president of New Equipment
Sales & Commercial Operations for
Mitsubishi Hitachi. “At 50 percent output, you’re still above 55 percent combined cycle efficiency.”
The new combined cycle plant is expected to be up and running in spring
2017.
“This unit has the potential to be the
most efficient combined cycle plant in
the country,” said Charles Barney, assistant general manager of thermal generation for GRDA.
Dan Sullivan, GRDA CEO, and
30
Yoshihiro Shiraiwa, then president and
CEO of Mitsubishi Hitachi Power Systems Americas (MHPSA), signed the
agreement during a public gathering at
the GRDA Engineering and Technology
Center in Tulsa. Also present were Takato Nishizawa, president and CEO of Mitsubishi Hitachi Power Systems (MHPS),
and Yasuo Fujitani, senior executive vice
president of MHPS.
Yashihiro said the GRDA deal will be
the first of many for MHPSA in the U.S.
FLEX-PLANT DELIVERS
300 MW IN 10 MINUTES
Billed as one of the most energy efficient and responsive power plants in the
nation, the new 550-MW El Segundo
Energy Center illustrates how far the
power generation industry has come in
the last 50 years.
Nestled between a cliff and the Pacific Ocean in a well-known beach community, this advanced combined cycle
plant consumes 30 percent less natural
gas than the units it replaced and uses
rapid-response technology to provide
critical backup power for intermittent
forms of generation such as wind and
solar power.
The new two-unit plant, owned and
operated by NRG Energy, uses “FlexPlant” technology from Siemens. Each
unit features a SGT6-5000F gas turbine. The plant can ramp up to 300
MW in less than 10 minutes and be
at full capacity (550 MW) within one
hour. That compares to 14 hours to
reach full capacity with the old units,
originally built in 1955.
The plant’s fast-start capability is perhaps its most valuable feature, especially
in California, where utilities and grid
managers struggle to maintain a balanced load amid a growing source of
intermittent electricity. California law
requires power providers to generate 33
percent of their power from renewable
resources by 2020.
Each power block is rated at 275MW net output for a total output of
550 MW at 48.9 percent combined
www.power-eng.com
Adaptive Brush Seal
Solutions for
Air Preheaters
The M501J gas turbine is known for its higher
firing temperatures and improved efficiency.
The J-series gas turbine is able to operate
at a turbine inlet temperature of 1600OC
(2912OF). Photo courtesy: Mitsubishi Hitachi
Power Systems Americas.
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High performance. Long life.
cycle efficiency, making it “the most efficient peaking
plant technology available today,” Siemens said. The SGT65000F turbine is integrated with a single-pressure, non-reheat bottoming cycle.
In addition to slashing overall NOx, SOx and CO2 emissions, the plant’s start-up emissions are more than 89-percent
lower thanks to a rapid-response technology from Siemens
that mitigates stack emissions while ramping up or down.
The plant began commercial operation Aug. 1, 2013. All of
the output is delivered to Southern California Edison under a
10-year power purchase agreement. The utility lost more than
2,000 MW of generation capacity due to the unexpected retirement of the San Onofre Nuclear Generation Station.
RIVIERA BEACH FEATURES RECORDSETTING GAS TURBINE
The Riviera Beach Next Generation Clean Energy Center in
Florida began commercial operation in April 2014 and uses
three SGT6-8000H gas turbines from Siemens. The same Hclass turbine was used at the Cape Canaveral Clean Energy
Center, which began commercial operation last year near
Florida’s Kennedy Space Center.
The same turbine used at Riviera Beach and Cape Canaveral set a world record for combined cycle efficiency of
60.75 percent in May 2011 at the Irsching Power Station in
Bavaria, Germany.
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system delivers reliability and extended
functional service life.
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The same H-class turbine used at the Riviera Beach Next Generation
Clean Energy Center set a world record for combined cycle efficiency
of 60.75 percent in May 2011 at the Irsching Power Station in Bavaria,
Germany. Photo courtesy: Florida Power & Light.
The Riviera Beach facility, owned
and operated by Florida Power & Light,
is 33 percent more fuel-efficient than
the 1960s-era oil-burning power plant
it replaced. In addition, carbon dioxide
(CO2) emissions are 50 percent lower
and NOx and SOx emissions are more
than 90 percent lower versus emissions
from the old plant.
With a capacity of 1,250 MW, the
plant produces enough electricity to
power 250,000 Florida households.
Siemens has sold 28 H-Class gas turbines worldwide thus far. Nine are in
commercial operation with more than
70,000 equivalent operating hours.
HOW TO RESTORE
LOST OUTPUT
It is sure to be another hot summer in
the U.S.
For gas-fired power plants, higher
32
ambient temperatures translate to a
loss of air density and, thus, a loss of
generation output.
Bob Kraft, founder and president of
PowerPHASE LLC, says his company
has developed a low-cost solution that
restores lost output caused by high ambient temperatures and site elevations.
The company’s TurboPHASE air injection technology increases the air mass
flow rate delivered to the combustion
system. This fast, flexible and mobile
peaking system can add 5 MW of capacity per module in less than 60 seconds.
According to the company, four to five
TurboPHASE modules can boost the
output of an industrial gas turbine by up
to 20 percent in simple cycle configuration and 15 percent in combined cycle.
“If you do 5 percent injection at a 2x1
plant, you’re going to get a little more
than 10 percent increase in output,”
Kraft said. “For a 550 MW plant, we’re
going to get 55 to 60 MW.”
The “turbocharger” technology features a reciprocating gas or dual-fuel
engine, which drives an intercooled
compressor. The compressor delivers the
added air flow through a recuperator
where it is heated by recovered exhaust
and flows into the combustion system of
the gas turbine.
The TurboPHASE module starts in
seconds and runs on-demand with
each module producing 650 F air at 12
pounds per second.
The TurboPHASE system will be used
in a demonstration project at a cogeneration plant in the Chicago area. Installation is scheduled for this summer.
“There is no other power augmentation or peaking power system that can
deliver continuous power near as fast as
our system,” Kraft said.
www.power-eng.com
>>
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Integrating Flue
Gas Conditioning
with More Effective
Mercury Control
U
BY RICHARD MILLER, ADA-ES INC.
tilities are faced
with many balanceof-plant challenges
as retrofitted pollution control equipment begin operation in order to control Acid Gas and Mercury emissions
as outlined in the EPA Mercury and Air
Toxics Standards (MATS) rules.
However, many techniques previously used to enhanced plant performance in the end, might also hinder
compliance strategies. Compliance
strategies are dependent upon current
and anticipated fuel types, as well as
existing installed air pollution control
systems. Additionally, many older,
marginally sized electrostatic precipitators (ESPs) that rely on trace levels
of SO3 in the flue gas to maintain
34
optimum particle resistivity ranges
might have to use alternative methodologies, as a result, capturing mercury
might come at a higher cost and with
more complexities and potentially result in loss of fly ash sales as well.
Utilities are facing many challenges
in order to achieve full compliance
with the recently imposed EPA Mercury and Air Toxics Standards (MATS)
rules, which are also dependent upon
current and anticipated fuel types, as
well as existing installed air pollution
control systems. This could be especially difficult with many older, marginally sized electrostatic precipitators
that rely on trace levels of SO3 in the
flue gas to maintain optimum particle
resistivity ranges.
Activated carbon injection (ACI) is
one of the leading and most accepted
technologies utilized for controlling
and maintaining mercury emission
levels to required MATS levels. To
date, greater than 288 systems have
been installed or are under contract
with another 247 systems out for bid.
In the end, it is expected that over 55
percent of existing coal-fired power
plants will have ACI installed for mercury control. The negative impact of
SO3 on activated carbon and mercury
control is well documented.1 At concentrations above 10 ppmv, especially
when flue gas temperatures are above
320oF, the interference from SO3 can
result in dramatically reduced mercury
removal levels.2 MATS guarantees for
mercury reduction with ACI or naturally occurring unburned carbon in
fly ash (typically measured as loss on
ignition or LOI) typically require SO3
levels to be maintained at less than 5
ppmv.
www.power-eng.com
Predicted Fly Ash Resistivity at
Various SO3 Concentrations
1.0E+12
1
High Resistivity Region
>5 x 10^10 ohm-cm)
0 ppm
1 ppm
4 ppm
1.0E+11
Resistivity (ohm-cm)
Additionally, in order to achieve required MATS levels for HCl reduction,
it often requires the injection of high
levels of hydrated lime into the flue gas
through use of a dry sorbent injection
(DSI) system. Hydrated lime is also
highly effective in capturing SO3, thus
lowering SO3 levels and, as a result,
increasing the effective ash resistivity levels. Injection of hydrated lime
for compliance must be balanced with
maintaining adequate SO3 to maintain
resistivity and ESP performance. This
can be difficult as coal and operating
conditions vary.
Figure 1 shows predicted fly ash
resistivity for an Eastern high sulfur
coal with a highlighted region where
resistivity could be problematic. When
there is no SO3, the resistivity is very
high at a typical ESP operating temperature range of 300 to 350oF.
Another factor associated with dry
10 ppm
20 ppm
1.0E+10
1.0E+09
1.0E+08
200
250
300
350
400 450 500 550
ESP Inlet Temperature (˚F)
sorbent injection and activated carbon is the overall increase in particulate loading to the ESP, typically fine
powdered sorbent. Many older or
600
650
700
750
undersized ESPs were not designed to
operate with this increased particulate
loading while maintaining current
modern ESP outlet emission rates.
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35
A typical FGC injection lance.
Percentage
ACI Upstream of APH (nonbrominated PAC),
As a result of a convergence of
2
50µg/g Br on Coal
factors related to MATS compliance,
there are now additional strains on
100
ESP operation, even on units that
RESond™ Technology
SO3 FGC
traditionally have not experienced
any problems in the past. Negative
80
operating issues from use of dry
sorbents such as hydrated lime
60
have been demonstrated, including
issues such as reduced power levels,
increased spark rates, mainly due to the
40
reduction of native SO3 in the flue gas,
plus an increase in the amount of total
20
PM entering the ESP. What was once
considered an easy ESP application
for use on higher sulfur, bituminous
0
0
5
10
15
coal installations, may now become
lb/MMacf
more difficult as the SO3 levels are
Impact of fue gas conditioning on mercury capture across the ESP casing
significantly reduced entering the ESPs
due to use of hydrated lime injection.
ADA RESPond Flue Gas Condition- need hydrated lime based, dry sorbent commercial installations.
ing Technology, formerly known as injection in order to achieve required
ADA ATI-2001, is a non-SO3-based MATS levels for HCl.
CASE STUDY 1:
flue gas conditioning product and, as
ADA has exclusively offered variIn this case, the host unit was an oldsuch, is compatible with sorbents for ous liquid ESP flue gas conditioning er B&W PC fired boiler brought into
both mercury and acid gas control, technologies commercially for over 15 commercial service prior to 1970 with
meaning that it does
years. These prod- a rating of approximately 300 MWG
not interfere with
ucts are specifically burning western sub-bituminous fuactivated carbon use “Over 55 percent of designed to modify els. Two parallel gas ducts feed flue
for mercury control existing coal-fired
ash resistivity and gas into a single, multi-chamber ESP
or be absorbed by alhelp increase ESP casing. The ESP specific collection area
power plants will
kaline sorbents. This
power levels and re- (SCA) is 200 ft 2/kacfm. At full load,
is especially impor- have ACI installed
duce sparking rates, the host unit produces approximately
tant for facilities that for mercury
thereby maintaining 1.1 MMacfm of flue gas at 290°F going
have existing SO3 control.”
and/or
increasing into the ESPs.
conditioning or traESP collection effiTesting was conducted with the si- ADA-ES Inc.
ditionally have not
ciency.
multaneous application of dry sorrequired the use of
To date, ADA has bent injection and activated carbon
external SO3 conditioning due to the conducted numerous full-scale dem- injection. The purpose of the testing
natural SO3 levels produced from fir- onstrations utilizing our flue gas con- was to determine if ADA’s RESPond
ing higher sulfur coals, but now may ditioning technology, in addition to its Technology would provide suitable
36
www.power-eng.com
ESP Response to ADA RESPond
Flue Gas Conditioning Technology
RESPond
Injection
Spark Rate (SPAM) and Opacity (%)
80
RESPond
Injection
650
600
70
550
60
500
50
450
40
400
30
350
20
300
10
250
0
10:00 11:00
200
12:00
Opacity
13:00
14:00
Sparks
15:00
16:00
Sec KW
conditioning of the fly ash to maintain the ESP’s electrical performance while injecting Trona and sodium
bicarbonate for SO2 and SO3 reduction and improve performance of activated carbon for mercury control.
During host unit baseline operation, high levels of
SO3 conditioning (>20 ppmv) were required to maintain
ESP electrical performance. SO3 conditioning was discontinued and ADA’s RESPond was applied. The flue
gas technology successfully maintained power levels to
those experienced with SO3 conditioning and there was
no change in opacity levels, which remained well below
permit limitations. The replacement of conventional
SO3 flue gas conditioning with RESPond at this facility
greatly improved performance of the activated carbon
for mercury capture across the existing ESP.
Over 90 percent mercury reduction was achieved at a
greatly reduced rate of activated carbon injection. Figure 2 shows the performance of ADA’s non-SO3 flue gas
technology in comparison to conventional SO3 with
injection of activated carbon for mercury control. This
client added CaBr2 to the coal for additional Hg oxidation. Results show that with RESPond, activated carbon
usage was reduced by over 80 percent, thus preserving
ash sales and reducing operating costs.
17:00
Load
Load (MW) and Secondary Kw
90
3
overall ESP performance at this facility.
• This unit did not previously have
SO3 conditioning, therefore when
RESPond was injected; there was an
immediate improvement in ESP total power and a concurrent drop in
average spark rate.
• In this case there was a reduction in
opacity from 17% to 8% within two
hours of the start of injection.
Impact on secondary current, spark
rates in the front fields are illustrated in
Figure 3. As can be seen from this chart,
ESP response in terms of increased power and reduced sparking was seen within
15 minutes of the start of injection.
Complete conditioning of the ESP typically takes longer than this, since RESPond co-precipitates with fly ash and
requires time to achieve full penetration
to the precipitator outlet.
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and HF emissions, Natronx is
the clear choice.
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CASE STUDY 2:
In this case, the host unit was a CE tangential fired boiler
brought into commercial service in 1976 with a rating of
approximately 350 MWG burning western sub-bituminous fuels. ADA’s flue gas technology was used to improve
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469 North Harrison St. | Princeton, NJ 08543 | 855.285.7652
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37
ACI Upstream of APH (nonbrominated PAC),
50µg/g Br on Coal
1.E+11
Baseline
ATI
1.E+11
Resistivity (ohm-cm)
The Simpactor® FGT pin
mill reduces the particle
size of sorbents used
in Dry Sorbent Injection
systems.
4
1.E+11
1.E+11
1.E+11
Perfection is
Improving Emissions
Perfecting
Perfecting
Particle
Size
𰁴𰀁
x,
Phone: 800.992.0209
[email protected]
www.sturtevantinc.com
1.E+11
200
300
400
500
Temperature (˚F)
CASE STUDY 3:
Laboratory resistivity with RESPond
Technology was evaluated for a
client to determine the potential of
the technology. Figure 4 presents
the resistivity curves from these
tests conducted on a western subbituminous coal fly ash.
Two
ascending temperature resistivity
curves are shown; baseline ash with no
conditioning and an ash sample treated
with a typical level of ADA’s flue gas
conditioning agent. Laboratory testing
demonstrated two orders of magnitude
improvement from baseline resistivity
levels in the ash.
ADA’s flue gas injection equipment
is a low CAPEX investment.
thus enabling optimum management
of activated carbon usage and help
preserve ash sales. RESPond can work
in tandem with the injection of alkali
sorbents to maintain ideal resistivity
ranges even when SO3 concentrations
are significantly curtailed. RESPond
may also provide significant benefits
on higher sulfur coal units that now
must inject high quantities of hydrated
lime, required to achieve both mercury
and HCl MATS emission levels. In
its essence, RESPond works similar
to conventional SO3 conditioning by
modifying ash resistivity resulting in
improved power and reduced spark
rates to maintain compliance opacity
levels.
CONCLUSION:
References
ADA’s RESPond
Flue Gas
Conditioning Technology has been
proven to be an effective addition
to MATS compliance strategies for
units with ESPs, activated carbon for
mercury control and dry sorbents
for acid gas control. ADA’s flue gas
conditioning technology does not
interfere with the performance of
activated carbon for mercury control,
1. Sharon Sjostrom et. al., “Influence of
SO3 on Mercury Removal with Activated
Carbon: Full-Scale Results”, Air Quality
VI, Sept. 2007.
2. Curt Beihn and Greg Filippelli, “Dry
Sorbent Injection for SO3 and MATS”,
Reinhold APC Conference, July 2012.
3. Richard Miller, “Enhanced Mercury
Control for Boilers that Require ESP
FGC”
www.power-eng.com
2014
rojects of the Year
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Awards will be given in the following categories:
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SUBMIT YOUR PROJECTS OF THE YEAR BY AUGUST 31, 2014
For Eligibility and Entry Requirements, please visit www.power-eng.com.
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For info. http://powereng.hotims.com RS#21
Author
Brandon Kraemer is a senior product
manager at Mankato, Minn.-based MTU
Onsite Energy Corp. In his current role,
Kraemer helps lead market-specific new
product development.
Understanding
Generator Set
Ratings for Maximum
Performance and
Reliability
G
BY BRANDON KRAEMER, MTU ONSITE ENERGY
iven the array of ratings and standards
in the marketplace,
selecting a generator
set can be confusing.
But, by aligning your requirements
with the proper generator set ratings,
you can ensure your generator set’s
required performance. The right standards and ratings for your needs, such
as total kW output, running time, load
factors and emissions regulations,
must be defined prior to every generator set installation.
This article will review available industry standards, manufacturers’ and
federal emissions ratings, and provide
a clear guide to specifying the best
power system solution.
ISO STANDARDS
ISO-8528-1:2005 is an industry
standard for performance parameters
in on-site power applications. The
ratings outlined in ISO-8528-1:2005
define basic generator set rating categories based on four segments: emergency standby, prime power, limitedtime running time and continuous
power. In each category, a generator
set’s rating is determined by its maximum allowable power output in relation to running time and load profile.
Misapplication of these ratings can
jeopardize the longevity of the generator set, void manufacturer’s warranties
40
and put the set at risk for failure.
Emergency Standby Rating
The emergency standby (ESP) rating
is one of the most common, and represents the maximum amount of power
that a generator set delivers. An ESP
generator set is normally used to supply emergency power during a utility
outage until power can be restored.
As defined by ISO-8528-1, an ESPrated generator set must provide power
“for the duration of the outage” and
“with the maintenance intervals and
procedures being carried out as prescribed by the manufacturers.” Individual manufacturers may determine
whether or not to authorize a higher
24-hour average load factor.
For example, all engines in MTU
Onsite Energy’s ESP-rated generator
sets are approved for an 85 percent
24-hour average load factor. This high
Load-Factor-Advantage1: Selecting a generator set can be confusing. By aligning your
requirements with the proper generator set
ratings, you can ensure your generator set’s
required performance. Photo courtesy: MTU
Onsite Energy
load factor increases the 24-hour average available generator capacity by 15
percent over the ISO standard. It can
also help to reduce the size or number
of generator sets needed to support an
application.
Prime Power
Generator sets rated for prime power
(PRP) are designed to supply electric
power in lieu of commercially purchased power from a utility. This may
include supplying power for temporary use, or for remote locations, such
as wilderness outposts, remote mining, quarrying or petroleum exploration operations.
All MTU engines in MTU Onsite
www.power-eng.com
Energy’s PRP-rated generator sets are
approved for a 75 percent 24-hour
average load factor. ISO-8528-1 sets
the 24-hour average load factor to 70
percent of the PRP rating. However,
similar to the ESP rating, an individual
engine manufacturer can authorize
a higher 24-hour average load factor.
MTU’s standard of operating a higher
load factor increases the 24-hour average available generator capacity by five
percent over the ISO standard.
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41
Limited-Time Running Prime
Generator sets rated for limited-time
running prime (LTP) are typically designed for supplying electric power to
a utility as part of a financial arrangement. LTP applications include peak
shaving, load curtailment and cogeneration.
Continuous Power
The continuous power (COP) rating
is used when the generator set must
supply a constant load for an unlimited number of hours annually. These
applications, such as remote power stations, typically use multiple generator
sets to power this constant load, which
is also known as a “baseload power
station.” The baseload is the minimum
amount of power that a utility must
make available to meet its customers’
demand for power.
Most manufacturers follow the ratings detailed in ISO-8528-1. However,
some have slight exceptions to these
ratings, which help them meet their
slight exceptions in order to best serve time. For MTU-powered generator sets,
their customers, so it’s also necessary the 10 percent overload is available for
to learn the terminology. As technol- one hour out of every 12, with a usage
ogy advances, terminology is amend- recommendation of one percent of the
ed and sometimes causes confusion. year, or 87 hours per year. Other genFive of the most common confusion erator set manufacturers state that this
points are: net power
one-hour overload
versus gross power
can only be used up
output, overload ca- As technology
to 25 hours per year.
pability, load factor, advances,
Load Factor
maximum run time
Load factor is comterminology is
allowed and time bemonly
misunderamended and
tween overhaul.
stood because historNet versus Gross sometimes causes
ically, generator sets
Power Output
were only known
confusion.
Think of this as
at their maximum
you would your pay.
application rating,
Your gross pay is what you make, but or nameplate rating. As generator set
your net pay is what you put in the technology progressed, higher debank after taxes and other deductions. mands were placed on the equipment,
When comparing generator set ratings, and as a result generator manufacit’s important to evaluate them based turers used the average load factor as
on the complete system power output, described by ISO-8528-1 to establish
and this should include the power their equipment’s expected usage.
draw for the cooling system as it’s reWhen comparing products with
customers’ requirements, performance
capabilities or maintenance schedules.
quired for the system to perform.
Overload Capability
In the past, the PRP generator set
output was less than the ESP rating,
and this would allow for an overload
capability. For PRP-rated units, this is
commonly advertised as the 10 percent
overload capability for a set period of
MANFACTURERS’ RATINGS
Because most manufacturers follow
the ratings detailed in ISO-8528-1, it
is important to understand ISO ratings. However, manufacturers make
42
different published load factors, it’s
important to consider some of the
advantages of a generator set with a
higher published load factor. In the
past, a simpler, single-step loading
method was often used for motor loads.
Because of this method, this often set
the highest power requirement for the
www.power-eng.com
generator set, and the size of the generator was dictated by
this rating. This is known as “starting power requirement.”
In comparison, electrical engineers often prefer today’s
more complex, soft-loading methods because they reduce
the starting power requirement, which often reduces the
maximum power output required. The result is smaller generator sets, running at a higher average load factor, for a
better total cost to the owner.
Maximum Run Time
Although the ISO-8528-1 standard makes a statement for
the ESP maximum run time per year under test conditions,
it does not state any run time limits in the event of a utility outage. As a result, most manufacturers have declared
their own expected maximum annual run time based on
typical experience from the field. MTU-powered generator
sets have a 500-hour annual recommendation while other
manufacturers have a 50 - 200 hour limit.
Time Between Overhaul (TBO)
There is a natural inverse relationship between generator set application and the estimated time before overhaul
(TBO). In general, ESP-rated equipment has higher power
output than the same equipment with a PRP or COP rating, and as a result the ESP-rated equipment also has the
shortest TBO. With the typical usage of a PRP- or COP-rated
generator set running many more hours in a year than ESP,
the higher TBO is a significant benefit to the users of these
applications by extending their maintenance schedules and
decreasing product life-cycle costs.
FEDERAL EMISSIONS RATINGS
In addition to ISO, the Environmental Protection Agency
(EPA) also influences generator set ratings by the engine
usage.
Stationary emergency classified diesel engines are used
during utility outages with some exceptions. Stationary
non-emergency classified diesel engines can be used without any restrictions, but the emission requirements are
stricter (Tier 4).
The EPA’s requirements for generator sets also include
mobile generator set engines. Mobile generator sets must
abide by the same Tier requirements as the stationary nonemergency engines. For diesel units, this means Tier 4
emissions.
However, there is one exception: the Transition Program
for Equipment Manufacturers (TPEM). TPEM allows mobile generator set manufacturers to use the previously accepted EPA Tier requirement for new equipment in a limited quantity for a limited time. This is often referred to
as the “mobile flexibility” provision, which MTU Onsite
Energy is taking part in.
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Florida Power
Supplier Uses Dust
Management to
Improve Safety,
Reduce Maintenance
T
BY SHANE TIGHE, MARTIN ENGINEERING
he Orlando Utilities
Commission Stanton
Energy Center (SEC) is
one of Central Florida’s
leading environmental stewards, meeting or exceeding all
air permit limits with advanced pollution control equipment while generating electricity to serve more than
342,000 residents. The company follows a similar philosophy with respect
to its working environment, cleaning
the entire coal yard and all handling
equipment every day.
“Typically each day after we finish filling or bunkering the silos, the
whole system is cleaned,” explained
Material Handling Supervisor Stuart
Cason. “That includes the yard, all
the conveyors, chutes, floors, impact
zones and rollers. In some places, it’s
a wet washdown, while in others we
sweep. It’s 7 days a week, every week
of the year.”
CONTAINING
FUGITIVE MATERIAL
When company officials decided
to upgrade the dust containment on
44
one of its primary coal conveyors, they
saw several potential benefits. There
was the safety aspect: by limiting dust
and spillage from one of its principal
conveyors, engineers wanted to reduce
airborne particles and eliminate a potential source of trips and falls. There
was also the understanding that reducing cleanup would save maintenance
time, allowing critical manpower to be
deployed elsewhere and improving the
staff ’s efficiency. Further, preventing
coal dust spillage would help minimize wear on rollers and other moving
components, saving on replacement
part costs and labor.
SEC started by looking at the areas
which could benefit most from technology upgrades to the 36-inch conveyor, which travels at about 700 feet
per minute. “We were looking for a
better method of sealing the transfer
zone, for starters,” explained SEC Plant
Engineer Brian Moore. “We had skirt
blocks and seals in place, but they were
getting old, and some of them were
leaking or repeatedly coming loose.”
“Coal dust is pretty abrasive, and
when it got down into the impact
rollers, idlers and troughers, it would
pretty much eat them up,” remembered
Cason. “We tried everything we could
think of to improve the service life, but
we were constantly replacing them.”
To address the situation, Martin Engineering supplied and installed a number of upgraded components, including
Double Apron Seal™ Skirting, which
employs two wear surfaces on a single
elastomer sealing strip installed along
the bottom of the skirtboard in the loading zone. When the bottom side of the
sealing strip is worn, it can be inverted to
deliver a second service life.
www.power-eng.com
Installed at the bottom of the loading zone skirtboard, Martin Double
Apron Seal™ Skirting employs two
wear surfaces on each sealing strip
for twice the service life.
The skirtboard sealing system is installed on the sides of the loading zone
to contain dust, eliminate spillage and
reduce cleanup expenses. Believed to
be the first dual-sealing system available, it incorporates a primary seal
clamped to the steel skirtboard to keep
lumps on the belt and a secondary or
“outrigger” strip to capture any fines or
dust particles that might pass beneath
the primary seal. The secondary seal
lies gently on the belt and self-adjusts
to maintain consistent strip-to-belt
pressure, despite high-speed material movement and fluctuations in the
www.power-eng.com
belt’s line of travel.
Martin Engineering technicians also
installed an impact cradle to better
absorb the force of the falling material and protect the belt and structure.
The cradle stabilizes the belt’s line of
travel to help prevent the escape of fugitive material. Its rugged impact bars
are constructed of a top layer of lowfriction, ultra-high molecular weight
(UHMW) resin and a lower layer of
energy-absorbing styrene-butadiene
rubber (SBR). Each impact bar is reinforced with a bed of steel angles,
and the wings can be adjusted to suit
virtually any standard trough angle.
In addition, a Guard-A-SealTM belt
support system was added under the
skirt board to better support the edges
of the belt and eliminate sagging. The
cradle helps prevent transfer point
spillage by further stabilizing the belt
path and facilitates effective sealing
of the edges. Belt wear is minimized
by eliminating pinch points where
trapped material can gouge the belt
surface.
To maintain precise centering in
the loading zone, Martin Engineering
technicians installed a belt tracking
45
system for immediate,
precise
adjustment.
Comprised of upper
and lower components,
the tracker works to reduce belt edge damage,
prevent spillage and extend belt life. Designed
to withstand the stress
associated with wide,
thick belts moving at
high speeds, the tracker features heavy-duty
construction that is well
suited to heavy loads.
“We could see the improvement right away,”
Cason continued. “It’s
not just the savings in
cleanup time, but also
in preventing the idlers
from wearing out prematurely. Now I don’t
have to send my guys
out there to replace
those failed components so often, so it
saves on labor and replacement parts, as well
as the housekeeping
time.”
THE SYSTEM CENTERPIECE
A key element in the material
handling
system
upgrade
was
addressing the large, under-performing
dust collector. “We wanted to upgrade
our dust collection equipment,
because we knew technology had
advanced since ours was installed,”
said Maintenance Supervisor Jon
Janis. “Even when it was functioning
properly, the old unit was a highmaintenance item,” he added.
The Martin Engineering team installed a high-efficiency insertable air
cleaner with an explosion-proof motor. It’s an automatic, self-cleaning
design that employs filter elements
46
The insertable air cleaner is a self-cleaning
design with filter elements about one-eighth
the size of conventional filter envelopes.
approximately one-eighth the size of
conventional filter envelopes. The
smaller filter elements allow a significant reduction in the dust collector’s
space requirements, so it can be installed in locations where tight quarters complicate the placement of other
systems.
The mesh-like material also filters
better and lasts longer - while consuming less energy - than conventional filter bags. Further, the new filters allow
a smaller size fan to move air through
the elements, helping to reduce the
overall power consumption of the collection system.
“The old unit had a large footprint,
and it was too close to the emergency
reclaim area,” added Cason. “A smaller, highefficiency
insertable
unit gives us back that
space and does a better
job of filtering the air.”
The Martin Engineering design features a
pulse cleaning system,
which uses a short burst
of air sent back through
the filter to dislodge
accumulated material.
Filter changes are a notool procedure from the
clean side of the dust
collector.
“These new insertable air cleaners can
eliminate
many
of
the
problems
seen
with central ‘baghouse’
collection systems, including long runs of
ducting, large enclosures, difficult maintenance and high power
consumption,” commented Martin
Engineering Product Engineer Dan
Marshall. “They help solve airborne
dust problems by keeping fine particles in the load or returning them to
the material stream.”
The new line of insertable units was
developed to handle the heavy dust
concentrations and air volumes arising
from material transfer points. They are
designed to remove 99.9% by weight
of all dry particulates 0.5 micron and
larger (based on a time-weighted average of a properly-installed, operated
and maintained unit).
The automated “reverse jet” cleaning
sequence facilitates continuous operation, keeping filters working effectively
www.power-eng.com
The support system under the skirt board
better supports the edges of the belt and helps
eliminate sagging.
with a minimum of compressed air. components to better manage mateThe small integrated fan runs only rial flow, and a stilling zone to reduce
when the conveyor is operational, fur- turbulence.
The engineered flow
ther improving energy efficiency.
chute employs special geometries
“These systems eliminate the need that capture and concentrate the mafor installing or maintaining duct- terial stream as it travels through the
work, and there’s no
chute. Every design
haulage or cleanup
is tailored to suit
“These
systems
costs for waste disthe specific material
posal, since fugitive eliminate the need characteristics and
material is contained
conveyor systems of
for installing duct
within the process,”
the individual cuswork,
and
there’s
Marshall
added.
tomer, rather than
“One of the most no haulage or
using stock products
popular
features cleanup costs for
and attempting to
with operators is the
make them work.
waste
disposal.”
clean-side access for
Transfer chutes from
inspection and filter
Martin Engineering
changeouts,” he said. “It’s a quick and provide the dual benefits of minimizeasy process, saving further on time ing aeration and preventing buildup
and maintenance costs.”
within the chute, particularly imporAlso contributing to the air cleaner’s tant when dealing with combustible
smaller footprint is a modified transfer materials.
chute, with modular hood-and-spoon
Asked to summarize the results of the
www.power-eng.com
upgrades, Stuart said, “For me, not having those clean-up and repair battles is
a huge relief. And the whole area is a
cleaner, safer working environment.”
Janis was unequivocal. “No question that the system has paid for itself.
We used to spend a lot of time making
adjustments and repairs, but since the
install, the system has been essentially
maintenance-free. It doesn’t matter
what kind of coal we run, or whether
the coal is damp from rain or completely dry. The fines are contained.”
He added that continued service excellence has helped to make OUC a repeat customer.
“Manpower is at a premium right
now, and every expenditure is closely
scrutinized. Martin Engineering has
proven its value repeatedly. They have
advanced technology, but their approach is to provide application-specific solutions, not just try and sell us
the latest product.”
47
Author
Craig Purvis is a senior field service representative specializing in generator sets
at John Deere Power Systems. He has 16
years of industry experience, including
positions as an electronics technician,
heavy-duty diesel engine wire harness
designer and quality engineer in production engine testing.
Is Your Gen-Set
Engine Ready
or Not?
Ensure your diesel engine will respond
at a moment’s notice by focusing on
preventive maintenance.
G
BY CRAIG PURVIS, JOHN DEERE POWER SYSTEMS
enerator-set
diesel
engines are trusted
to keep the power on
through the strongest storms and in
the most remote locations on earth.
Whether they’re protecting hospital
operating rooms or providing distributed power, these engines must be
48
ready when called upon.
Proper preventive maintenance is
critical to ensuring that gen-set diesel engines deliver reliable power in
standby or prime-power applications.
By carefully following the engine
manufacturer’s maintenance recommendations, you can optimize the
performance, reliability and durability
Generator-set diesel engines are trusted to
keep the power on through the most powerful
storms and in the most remote locations
on earth. Proper preventive maintenance is
critical to optimizing the performance, reliability and durability of generator-drive diesel
engines. Photo courtesy: John Deere Power
Systems
of your engine. Neglecting preventive
maintenance can lead to inefficient
operation, component failures or permanent damage to the engine — potentially costly consequences.
Your gen-set engine features integrated components working together
to provide fast response for standby
situations and excellent load recovery
in all applications. The fuel, lubrication, air intake, cooling and electrical
systems require maintenance at various intervals. Observing the detailed
service recommendations in your engine operator’s manual will help ensure that the engine stays healthy and
www.power-eng.com
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or registered trademarks of Exxon Mobil Corporation or one of its subsidiaries unless otherwise noted.
responds when you need it most.
Gen-set engine maintenance recommendations vary from manufacturer to
manufacturer. It’s important that you
adhere to all the service procedures and
intervals found in the operator’s manual
for your specific engine. John Deere
Power Systems, which offers generatorset diesel engine models with displacements from 2.9L to 13.5L and ratings
from 31 to 563 kW (42 to 755 hp), recommends the following system-by-system maintenance practices.
BEFORE YOU BUY
The first step in properly maintaining
your generator-set engine isn’t a procedure performed at a given interval on a
certain system. You can avoid many potential service issues and promote longer
engine life by appropriately sizing the
engine for the application during the selection process.
An oversized engine will operate
inefficiently and could experience issues such as slobbering unused fuel. If
an engine is too small, it may overheat,
stall or be slow to respond to load
changes, and have a shorter life.
When choosing a gen-set,
carefully assess your standby
or prime power requirements
and properly size the engine to
the load you’ll be running. John Deere LUBRICATION SYSTEM
recommends working closely with the
The first hours of an engine’s life are
gen-set manufacturer to determine the important in determining its perforappropriate engine size for your applica- mance, reliability and longevity. It’s
tion.
important to use the right type of oil
Standby gen-set engines should be during this break-in period to allow
properly loaded in exercise mode. To the engine parts to wear properly.
ensure that your standby gen-set engine
New John Deere engines are filled at
will deliver efficient performance when the factory with John Deere Break-InTM
needed, John Deere
Plus engine oil,
“An
oversized
recommends runwhich is formuning the engine at engine will operate
lated to work with
rated speed with 50 inefficiently and could the specific alloys
to 70 percent load
and part tolerexperience
issues
for 30 minutes evances used in John
ery two weeks. The such as slobbering
Deere
engines.
engine shouldn’t be unused fuel.”
During the recomallowed to run for
mended 100-hour
- John Deere Power Systems
extended periods
break-in period,
of time with no load. John Deere advises the engine should be operated under
that standby gen-set owners work with various conditions, particularly heavy
the gen-set manufacturer to implement loads with minimal idling, to help seat
an automated solution for appropri- engine components properly. The use
ately loading the engine during exercise of 10W-30 John Deere Break-In Plus
mode.
engine oil encourages rings and liners
A PowerTech E 13.5L model, a standby engine.
Photo courtesy: John Deere Power Systems
50
www.power-eng.com
to set correctly to ensure a good wear
pattern and longer life.
If the engine has significant operating time at idle and/or light-load usage, or makeup oil is required in the
first 100-hour period, a longer breakin period may be required. The oil
and filter should be changed between
a minimum of 100 hours and a maximum of 500 hours during the initial
operation of a new engine.
With the introduction of exhaust
filters in engines used to meet U.S.
Environmental Protection Agency
Tier 4 diesel emissions regulations,
the type of engine oil used can have a
significant impact on the proper functioning and ash service life of these
devices. John Deere recommends using only engine oils meeting API CJ-4
and ACEA E9 standards, such as John
Deere Plus-50 TM II. These oils are refined with a lower trace metal content,
which reduces ash accumulation and
increases exhaust filter service life.
Lab and field tests reveal that the
superior anti-wear additives in quality engine oils can significantly reduce
engine wear, increasing the productive
life of the engine. They also extend
drain intervals and reduce piston deposits, which leads to a cleaner engine
that will last longer and provide consistent power.
Lubricants should be clean. Even the
best lubricants cannot function properly if they are dirty. When maintaining the engine, be sure to:
• Change oil when recommended.
• Keep all lubricant containers covered in an area protected from dirt
and moisture.
• Remove all dust and grime from
both the container and service
points before performing lubrication service.
Unfortunately, all lubricants gradually lose effectiveness during operation
due to chemical and physical changes
in the lubricant. The deterioration
process is accelerated by contaminants
from external and internal sources.
That’s why following manufacturerrecommended lubricant change intervals for normal operating conditions is
so important.
More frequent oil changes are recommended when operating in extreme
environments, such as in very hot or
dusty conditions, or at high altitudes.
Oil analysis can be performed to ensure that the recommended service interval is adequate for your application.
Regularly scheduled oil sampling and
analysis can pay for itself by detecting
potential problem-causing conditions
Powering the world forward
Custom engineered to meet each application’s requirements,
Fairbanks Morse Enviro-Design® dual-fuel engines provide
reliable, efficient power generation with low emissions. Backed
by genuine OEM parts and comprehensive, responsive service,
Fairbanks Morse engines deliver critical backup and primary
power when and where it’s needed most.
See how we’re generating power and progress around the globe
at fairbanksmorse.com/commercial.
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www.power-eng.com
before they turn into performance issues or costly downtime.
Regardless of which fuel you run,
only fuel additives that are approved
by the engine manufacturer should
FUEL SYSTEM
be used. Frequent fuel sampling and
Gen-set engines meeting Tier 4 die- analysis is a sound practice that prosel emissions regulations require the motes engine performance, reliability
use of ultra-low sulfur diesel (ULSD) and durability.
— diesel fuel with a sulfur content of
To help achieve an uncontaminated
less than 15 ppm. Using diesel fuel and unrestricted fuel flow, John Deere
with a sulfur content greater than recommends these practices when per15 ppm can damage the exhaust fil- forming fuel system maintenance:
ter used to reduce particulate matter,
• Check for leaks.
leading to early replacement. Some
• Check for bent, kinked or dented
Tier 4 engines also operate efficiently
supply or return.
with biodiesel blends, providing fuel• Inspect fuel filters for dirt, water or
choice flexibility.
other foreign matter.
John Deere recommends limiting
• Use fuel that is not contaminated
biodiesel use with gen-set engines to
with water. Water in the fuel system
prime-power applications. Biodiesel
is the greatest cause of fuel injection
is naturally biosystem failure.
degradable, and “Using diesel fuel with
• Check for water
blends up to B20
in the fuel filter.
a
sulfur
content
greater
should be used
Daily inspection
within 90 days than 15 ppm can
of the fuel filter
of the date of damage the exhaust
and draining the
biodiesel manwater from the
filter
used
to
reduce
ufacture.
Mifuel filter water
crobial growth particulate matter.”
separator and fuel
present in bio- - John Deere Power Systems
tank as required
diesel used after
will ensure that
90 days could damage an engine’s fuel
the fuel system is protected.
system and result in the need for new
• Install a fuel storage tank watercomponents. Because standby generaseparating filter to further protect
tors may not use a full tank of biodiesengines by filtering out dirt, rust
el fuel during a short time period, John
and scale. To service the tank filter,
Deere recommends using only regular
install a shutoff valve between the
diesel fuel for standby gen-set applicatank and filter. The filter element
tions. To ensure the quality of regular
should be changed annually or
diesel fuel in standby applications,
more often if fuel flow becomes
John Deere recommends replacing old
restricted.
fuel with fresh fuel every six months
to a year.
AIR-INTAKE SYSTEM
If you opt to run biodiesel for your
Making sure your engine receives
prime-power application, a 5 percent an unrestricted flow of clean air is imblend (B5) is preferred, but a bio- perative for proper operation and long
diesel concentration of up to 20 per- life. For example, dust reaching your
cent (B20) may be used. Regardless of engine through a leaking connector in
biodiesel blend level, verify with your the air-intake system — called “dusting
fuel provider that the biodiesel blend the engine” — can destroy an engine,
meets ASTM D6751 (U.S.) standards.
even one with low hours of operation.
52
Therefore, it is important to:
• Inspect the entire air-intake system for openings that could draw
in unfiltered air (loose clamps,
cracked hoses, etc.).
• Inspect dry element type filters
and replace if clogged with dust or
dirt. Inspect for damaged seams
and pleats. Replace if necessary.
Cleaning the elements with compressed air or by pounding them
on a hard surface is not recommended.
• Highly efficient filters, such as
Donaldson PowerCore filters,
cannot be cleaned and must be replaced when restricted.
COOLING SYSTEM
When performing maintenance on
your engine’s cooling system, always
use the recommended class of coolant. It’s important to be selective with
antifreeze/coolants because not all of
them provide the protection needed to
operate efficiently under extreme pressures and temperatures.
John Deere Cool-Gard II, for example, is a fully formulated antifreeze/
summer coolant designed and extensively tested to protect wet-sleeve-liner
diesel engines from cylinder-liner cavitation erosion.
Engine cooling systems should be
thoroughly flushed and cleaned with
a heavy-duty cleaner and refilled with
clean coolant and inhibitors per the
recommended intervals in your operator’s manual. In addition, it is important to visually inspect the radiator
and thermostats for any signs of corrosion, debris or physical damage.
John Deere highly recommends
coolant solution analysis, which will
verify the chemical composition of
your coolant and include a written
report with maintenance recommendations for the coolant and cooling
system. Regular coolant analysis is
particularly important in standby
www.power-eng.com
applications because coolant heaters
can deteriorate additive packages.
Also, John Deere recommends these
maintenance practices:
• Replace radiator hoses that are
cracked, soft or swollen.
• Clean all dirt and trash from between radiator fins and around
the radiator itself.
• Check for bent radiator fins and
straighten as needed.
• Ensure baffles and fan shrouds are
in place and functional.
• Inspect the fan blades for damage and the fan belts for excessive
wear. Replace as needed.
ELECTRICAL SYSTEM
Maintaining the electrical system
www.power-eng.com
is often more complicated than maintaining some of the engine’s other systems, so most electrical maintenance
tasks should be left to a certified mechanic. However, an engine’s electrical
system is centered on its battery, and it
is always important to check the condition of your battery:
• Verify batteries are fully charged
and the electrolyte is at its proper
level.
• Remove battery cables and clean
cable ends and posts.
• Repair or replace the alternator if
it isn’t keeping the battery fully
charged.
• Check all alternator wiring connections for tightness and corrosion. Correct as needed.
• Check all chassis grounding and
bonding wires for corrosion and
integrity.
• Check condition and tension of alternator belt and adjust or replace
as needed.
• Check all starting motor connections for tightness and corrosion.
Correct as needed.
Facilities and locations around the
world depend on diesel-powered generator sets to provide worry-free service,
often at a moment’s notice. By diligently following the engine manufacturer’s
preventive maintenance recommendations, gen-set owners can optimize the
performance, reliability and durability
of their gen-set engine.
PRODUCTS
Portable power tools
address requirements in the
Cable defect detector
A
fow and fltration markets.
E
merican Power Tool Co. introduces the
SafetySwage SS-1 and SS-2, which are com-
The 5PSID is an addition-
pact portable power tools for installing single and
al, lower pressure option.
Discharge (PD) activity, or small discharges
two ferrule compression fttings. SafetySwage
Customers
which result in damage to the cable, and if left
SS-2 develops over 450 ft-lbs. of output torque
differential pressure with the
and permits workers to install a wide range of ft-
same line pressure as the 10
The instrument quickly detects PD activity in
tings in a fraction of the time required by hydrau-
PSI version, but will now have
live cables by measuring radio frequency cur-
lic pre-setters. These tools feature state of the art
the differential. If a custom-
rents. It works with most types of single and three
technology to ensure fast accurate ftting installa-
er is monitoring fow, they can measure smaller
phase insulated cables at distribution voltages,
tion in hard to reach locations.
can
measure
Collector, which works by testing for Partial
unattended will lead to insulation failure.
changes in pressure across an orifce plate more
up to several miles in length. Information about
SafetySwage’s programmable control system
accurately. For level measurement of sealed and
PD activity is recorded by the CableData Collector
enables installers to select specifc installation
vented tanks, the lower pressure range will mea-
hardware and can be sent to EA Technology for
set points. Pre-assembly is virtually eliminated
sure smaller tanks more accurately.
expert analysis. Alternatively, users can buy EA
with these new tools. SafetySwage sets fttings to
The AST5300 Wet/Wet Differential Pressure
Technology’s software package to perform their
the standard set point of 1-1⁄4 turns beyond hand
Transmitters / Transducers offer low differential
own data analysis. In either case, they will have
tight as recommended by most hardware manu-
pressure ranges in high line pressures (1500 PSI)
access to clear reports on cables affected by
facturers. These tools are controlled by a simple
with excellent burst pressure capabilities. With no
PD activity and recommendations for remedial
push button and enables workers to select any
oil flled cavities and no internal o-rings to fail, the
action.
required set point in seconds. This installation
AST5300 are ideal for oil & gas and semiconduc-
feature extends the utility of the tool to reduce
tor industries.
EA Technology
Info http://powereng.hotims.com RS#: 404
vibration-induced leaks.
American Sensor Technologies Inc.
Power module
Meter signal transmission
C
American Power Tool Co.
aterpillar Inc. introduced the next generation
Cat® XQ2000 Power Module, which com-
elect Energy Services LLC launched the
B
bines world-class durability and reliability with
encoder HOG 86 L with fber optic interface
industry-leading fuel economy. The combination
AquaView, a suite of services that effciently
(FOI). Signal transmission allows for maximum
of proven Cat components with cutting-edge tech-
monitor water at various stages of the comple-
2,200-meter cable length and is fully immune
nologies makes the Cat XQ2000 Power Module
tions process through real-time, wireless technol-
against electromagnetic interference. A redun-
the industry’s leading portable power solution.
ogy. AquaView’s instant monitoring capabilities
dant encoder variant with simultaneous electric
The Cat 3516B is the core engine platform for
allow Select to respond immediately to on-site
and optic signal transmission is also available.
the next generation XQ2000. With thousands of
issues before emergencies arise.
Water monitoring technology
S
aumer presents the Incremental Heavy Duty
The HOG 86 L with FOI is suitable for all outdoor,
applications worldwide and millions of operating
AquaView capabilities include pit and reser-
harsh, and heavy-duty applications which require
hours, the 3516B offers proven performance,
voir hydrographic surveys utilizing SONAR remote
long cable runs and are susceptible to electrical
long life and maximum up time, while providing
control and GPS real-time data; data delivered
interference.
market-leading fuel economy.
to a secure portal offering current and histori-
The HOG 86 encoder platform includes a wide
The XQ2000 incorporates a variable frequen-
cal data; real time water quality reporting; and
variety of design benefts, such as a terminal
cy drive and high effciency fan to improve me-
mapping and Geographic Information Systems
box rotatable through 180°, an M23 mating con-
chanical effciency. With these improvements the
(GIS) support. The system can transmit the data
nector, cable outlet, or even redundant sensing
fan draws 40 percent less load on the engine at
with enabled access through computers, smart
outputs.
100 percent generator set load. This decreased
phones, tablets and text messages.
Select Energy Services LLC
HOG 86 encoders come in a very resilient
parasitic load delivers up to 8 percent improved
mechanical design. Large, optimally-spaced
fuel economy over the previous generation.
bearings at both ends ensure a considerably ex-
Caterpillar Inc.
tended service life. Enduring temperatures from
Wet/Wet differential
Pressure transmitter
-40 °C to +100 °C, these encoders provide longterm IP66 protection and are compliant to corro-
Digital heat trace controller
A
merican Sensor Technologies Inc. now offers
sion category C4.
its AST5300 Wet/Wet Differential Pressure
Baumer Group
C
Transmitter with a 5 PSID measurement range to
54
A Technology has launched the CableData
hromalox offers a digital heat trace controller for use with constant wattage, mineral in-
sulated or self-regulating heat trace cables. The
www.power-eng.com
model ITC Series intelliTRACE brand controller is
equipment protection leakage current (GFEP).
environments. The design of the piezoelectric
designed for line or ambient sensing heat trace
Additionally, the alarms on the ITC consist of high
seismic system inherently provides complete me-
applications in hazardous (Class I, Division 2) or
and low temperature, high and low current, high
chanical isolation of the sensing element, mak-
GFEP current and sensor failure.
ing the sensors insensitive to mounting torque,
Chromalox
body strains, cable vibration, cable whip, pres-
non-hazardous
ar-
eas in industrial settings such as chemical processing, oil
sure variations, and most heat transients. These
units offer wide frequency ranges and are avail-
and gas exploration,
Piezoelectric accelerometers
able in high temperature versions.
and
C
olumbia Research Laboratories has devel-
The 5000 Series are smaller and lighter in
oped a group of piezoelectric general pur-
weight than standard units. Characteristics are
pose accelerometers that are ideal for a wide
almost identical to standard units except that
range of shock and vibration applications.
with the smaller, lighter units, higher natural fre-
petrochemical
processing.
These
or
single,
independently
controlled and monitored, dual-circuit micro-
The 3000 Series standard size units include
quencies and shock levels can be obtained due
processor-based temperature controllers switch
many with all welded construction that are
to their reduced mass. Sensitivities, however, are
40 Amps per circuit at 100-277 Vac, and may
hermetically sealed for use in dirty and humid
somewhat lower.
be used in either freeze protection or process
Columbia Research Laboratories
temperature control applications. ITC’s compact
10” x 8” x 6” NEMA 4X enclosure facilitates all of
the electrical connections including the heating
Cortec developed the Cor-Pak
tablets to fght corrosion.
cable, the AC Power and the RTD Sensors.
The ITC controller enables the user to moni-
The tablets provide an effcient dry method of
tor temperature, current load and ground fault
protecting metals within a package. The tablets
It’s more than a check valve...
IT’S A CHECK-ALL
Our spring loaded check valves are
assembled to your exact needs, ensuring
absolute precision and reliability. They
work like they should. Plus, most lead times
are less than one week. That’s what makes
Check-All the only choice.
Get me a
Check-All!
SINCE 1958
Manufactured in West Des Moines, Iowa, USA • 515-224-2301 • www.checkall.com
www.power-eng.com
55
provide more than two years of premium multi-
Electromagnetic fow meter
metal corrosion protection. The tablets are powered by Nano-VpCl using nitrate, phosphate, and
E
silicate free.
magmeter that offers the same measuring perfor-
After the VpCl vaporizes, it will attach to all
ndress+Hauser released the Proline Promag
200 electromagnetic fow meter, a two-wire
mance as four-wire magmeters.
metal surfaces, reaching into recessed areas.
The Promag H200 is available in line sizes of
The protective monomolecular layer does not
1/12 to 1 inch and Promag P200 is available in
power supplies and cabling. A Quick Start Guide
need to be removed prior to processing or op-
line sizes of 1/2 to 8 inch for measuring the fow
and “tools & documents” DVD are also included
eration. The tablets are designed to protect prod-
rates of conductive fuids with an accuracy of ±0.5
to support training.
ucts, components or assemblies when packaged
percent of range and repeatability of ±0.2 percent
The IP20 ETHERNET Starter Kit contains: 750-
in corrugated boxes, plastic wrap or bags, and
of range. The fowmeter operates in process tem-
880 ETHERNET 2.0 PLC with SD Card, a 2-channel
metal, plastic or wood containers.
peratures from -40 to 304 ºF. Connections include
DI and DO modules, power supply, 2-way digital
Cortec
welded, threaded, hygienic and fanged versions
input simulator and end module.
that meet EN/DIN PN 16-40, ASME B16.5 Cl 150,
The IP67 Starter Kit introduces cabinet-free au-
Cl 300 and JIS 10K and 20K process connection
tomation via prominent protocols such as Modbus/
Encoder/Counter Module
pressure ratings.
TCP and EtherNetI/P. It features a SPEEDWAY pro-
W
Endress-Hauser
grammable controller with Ethernet ports, 8-chan-
AGO Corp. adds an HTL Incremental
Encoder/Counter Module to its SPEEDWAY
nel DO and spacer modules, power supply rocker
IP67 I/O-SYSTEM. The machine-mountable 767-
switch and RJ-45 to cable breakout module.
5202 evaluates incremental encoders and SSI
Acetal gear
absolute encoders at 24 V signal levels in harsh
environments. It also provides a counting func-
E
tion for binary signals up to 250 kHZ.
etal gear. Ensinger’s extrusion process produces
nsinger uses a proprietary extrusion process
using DuPont’s Delrin stock to create an ac-
The
shapes with lower stress and better dimensional
SPEEDWAY 767-
stability that leads to consistent and reliable me-
5202 provides
chanical parts.
two 8-pole M12
Its higher strength
Reversible membrane
electrode assembly
F
uelCellsEtc’s catalyst coated membrane (CCM)
refers to an architecture where the electrodes
are transferred directly onto the membrane with-
encoder ports.
characteristics
and
out a gas diffusion layer attached. FuelCellsEtc’s
Channel confg-
better fatigue endur-
Reversible Catalyst Coated Membrane (CCM, or
uration options
ance make it an excel-
3-layer) can be used in an electrolysis system for
include: type of
lent choice to replace
hydrogen production and in a hydrogen air or oxy-
evaluation and
metal
while
gen fuel cell. The main purpose of a Reversible
sensor, output format, flters, inversion, latch,
maintaining or improving long-term performance.
Catalyst Coated is perfect for educational products
gate, preset, cam, simulation and limits. The 767-
Popular applications for Ensinger’s DuPont Delrin
as well as demonstrations of the advantages of us-
5202 also has two 5-pole M12 ports with four
shapes include conveyor parts, such as bushings
ing Hydrogen as an energy storage medium.
confgurable digital inputs/outputs for sensors
and bearing housings; fasteners and clips and fuel
and actuators. Two of these channels can serve
system components.
ization as well as the unique design aspects of
as pulse-width-modulated outputs, with the 100
Ensinger
reversible Fuel Cell / Electrolyzer systems.
Hz–10 kHz clock frequency having a pulse-width
gears
repetition rate of 0–100%. Users may set previously defned outputs directly as a function of
Ethernet starter kits
counter readings.
W
FuelCellsEtc can assist with additional custom-
FuelCellsEtc.
AGO Corp.’s ETHERNET 2.0 (IP20) and
Screw-in outdoor vent
SPEEDWAY (IP67) ETHERNET Starter Kits offer
independent FDT/DTM, or via feldbus-dependent
a low-cost approach to training. Developed to pro-
W
device descriptions (e.g., GSD or GSDML). It is
vide WAGO-I/O-SYSTEM fundamentals, the starter
enclosures with a volume in excess of 200 liters.
programmable via USB interface integrated into
kits consist of comprehensive I/O nodes complete
The PolyVent XL improves the integrity, reliability
the feldbus coupler, or directly via feldbus (not
with software site licenses and hardware.
and safety of these large housings in challenging
The 767-5202 is confgurable via feldbus-
applicable to Ethernet-based couplers).
WAGO Corp.
56
WAGO Corp.
Based on WAGO’s popular IP20 and IP67
control platforms, the high-value ETHERNET
Starter Kits feature supplementary I/O modules,
. L. Gore & Associates introduces a vent
specifcally engineered for large outdoor
environments such as found in the solar, telecommunications and exterior lighting industries.
The PolyVent XL delivers reliable, long-lasting
www.power-eng.com
protection even in the harsh-
virtually
eliminated
proof fxtures feature a copper free aluminum
est environments as proven
with
Hammerhead
housing and refector assembly for lightweight
by its compliance with mul-
Industries’ Gear Keeper
and high strength, with impact and heat resistant
tiple industry standards. The
RT5-5601
Pyrex tubes for maximum lamp protection.
vent’s membrane protects
Lanyard
the electronics from liquids
System.
and particulates by provid-
The
Hardhat
Retention
new
Larson Electronics
Info http://powereng.hotims.com RS#:417
hardhat
ing a durable barrier that
lanyard is load tested
Fiber optic cables
even meets the challeng-
to
ing IP69K standard, which addresses protection
commonly used industrial hardhats. The RT5-
L
from high-pressure, high temperature spray. The
5601 is easily attached with Velcro strap loops
from simplex and duplex cables to multi-channel
vent performs in temperatures between -40°C and
and cinches around the fall protection harness
breakout cables.
125°C. The vent also increases housing life be-
strap, ring or tri-bar. It is designed to keep the lan-
Step-index fbers allow
cause of its durable welded cap, enabling the vent
yard close to the body to avoid discomfort and
the application of inexpen-
to pass the hail impact test specifed in the IEC
entanglement.
sive emitter and receiver
safely
tether
all
aser Components offers its own line of fber optic cables including indoor and outdoor cables,
62108 standard for the solar industry. After instal-
The new lanyard uses a sturdy, industrial-
components. The diameters
lation in the feld, the PolyVent XL does not require
grade spectra/nylon line that extends up to
of standard cables include
any maintenance for the life of the electronics and
14-inches. For additional safety, the Gear Keeper
2.2 mm, 2.5 mm and 3
the housing.
Hardhat Lanyard model RT5-5601 features a
mm. Most cables can be
W.L. Gore & Associates
gentle 2.5 oz. retraction force that takes up any
delivered with and without
Handheld Colorimeter
H
Hammerhead Industries
feld, the DR 900 Handheld Colorimeter. The DR 900
is feld ready in every way possible.
purposes. The variety of cable materials includes
PVC, PE, PU, OFNR-/OFNP-classifed materials with
low-smoke characteristics.
ach Co. has developed a multiparameter
handheld instrument for testing water in the
aramid yarn for strain relief
unused slack.
Explosion-proof LED
L
arson Electronics Magnalight.com has an-
Laser Components
nounced the release of the EPL-48-2L-LED-G2
Time-savings is the main driver behind the new
Explosion Proof LED Paint Spray Booth Light
Lever-actuated splices
DR 900. The colorimeter provides the ability to test
equipped with LED tubes instead of fuorescents
90 of the most commonly tested water methods,
for higher output and greater reliability.
W
AGO Corp.’s 222 Series LEVER-NUTS leveractuated splices eliminates twisting, taping
while putting your favorite methods at your fnger-
and crimping. Simply lift the lever, insert a stripped
tips. By improving the user interface and method
conductor and lower it. This also provides reus-
selection options, ease of testing is the standard
ability, giving LEVER-NUTS a unique, cost-effective
edge over tradi-
and not the exception for this instrument.
tional splices. The
The DR 900 is made for use in harsh and challenging feld environments. Ruggedly constructed,
The EPL-48-2L-LED-G2 paint booth approved
splices can be
waterproof, dustproof, drop tested and shock resis-
LED light fxture is an effcient lighting solution
used in controls,
tant, this colorimeter ensures reliability in all condi-
for operators who require high light quality and
such as PLC wiring
tions. The instrument has a backlit display option
compliance with paint booth HAZLOC standards.
for reverse osmo-
for use in low light areas with the push of a button.
These solid state LED lamps carry a 50,000
sis water purifca-
The DR 900 can store data from up to 500 tests,
hour rating while producing 98.21 lumens per
tion systems; and
and comes with a USB port for easy data transfer
watt. Since these units utilize LED lamps, there
in machinery, such as fan motor power leads with
to a PC or laptop.
is no ballast, further improving reliability as well
capacitor to limit electrical “noise.”
Hach Co.
as reducing fxture weight. These explosion proof
UL Listed, touch-proof LEVER-NUTS carry ratings
fxtures are also suitable for any location desig-
up to 600 V, 20 A max current capacity and 105°C
nated Class 1 Division 1, Groups C and D, Class
insulating material temperature. CAGE CLAMP
Hardhat Lanyard
1 Division 2, Groups A, B, C, D, Class 2, Division
Compact Spring Pressure ensures maintenance-
D
ropped from aloft, a hardhat is a one-
1 - 2, Groups E, F, G and are UL 595/ UL 1598
free, vibration-resistant connections.
pound unguided missile that endangers
suitable for marine type locations as well. Also
the entire worksite. It’s an accident that can be
designed for rugged durability, these explosion
WAGO Corp.
www.power-eng.com
57
Safety isolators and splitters
connectors come standard. SWE will confgure-
Silica analyzer
oore Industries’ new SSX and SST Safety
M
to-order other connectors and energy capacities
Isolators and Splitters provide reliable isola-
to meet customers unique needs. Recharging
H
tion and signal conversion for HART data in func-
POW-R TOTE is easy with an external 115V/240V
maintenance and user interaction due to the
tionally safe process control settings. The two-wire
AC adapter that plugs into any outlet.
collection of improvements to the industry’s only
(loop powered) SSX and four-wire (line/mains pow-
Southwest Electronic Energy Group
Silica Analyzer with a pressurized reagent deliv-
Water temperature sensor
reagent delivery system that helps eliminate the
P
yrocontrole designed the DT118 sensor that
frequent maintenance associated with other
measures water temperature
analyzers that use traditional pump systems.
ered) SST have been certifed by exida for single use
ach Co. introduced the Hach 5500sc Silica
Analyzer that is designed to greatly reduce
ery system.
The Hach 5500sc has a unique pressurized
in the discharge basins of nuclear power plants
that use salt water for cooling purposes.
in Safety Instrumented Systems up to SIL 2.
to 90 days on only two liters of the needed re-
The DT100 resistance probe immersed in salt wa-
agents. Predictive diagnostic tools help reduce
ter is highly watertight and is equipped with a protec-
unplanned downtime due to Hach’s proprietary
The SSX and SST family protects safety systems
tive metal sheath adapted to withstand the corrosive
Prognosys technology, alerting operators before
by isolating an SIS from basic process control or
action of salt. Designed to measure the temperature
there is an issue and walking through the steps
monitoring systems so that disconnections or oth-
in the discharge basin, this sensor with specifc prop-
to correct it.
er failures don’t impact the safety system. It also
erties can be used for real-time temperature monitor-
has 1500Vrms of isolating capability to protect
ing of the water discharged by the power plant.
Hach Co.
safety I/O cards and systems from surges, spikes
Pyrocontrole
Triggered timer relay
Cabinet Module Drive packages
W
and transients in the feld. Standard 20V/m RFI and
EMI protection stops damages caused by radio frequencies and electromagnetic interference.
AGO Corp.’s Triggered Timer Relay supports E-stop circuitry within space-restrict-
one process signal and creates two identical, iso-
S
S120 Cabinet Module (CM) drive packages, com-
edge of a trigger signal initiates the 859-477’s
lated outputs that can go to two different monitor-
pliant with North American standards and offered
off-delay timer for sequential shutdown. The de-
ing or control devices.
with optional UL/cUL listing. This product enables
vice’s four highly adjustable time delay ranges
easy confgura-
enable a PLC to log the stopped position of all
tion of complex
components.
The four-wire SST Splitter takes the input from
iemens announces a new version of its Sinamics
ed panels. Upon E-Stop activation, the falling
Moore Industries
common
DC
WAGO Engineering Services developed the
Portable power system
bus lineups for
859-477 with a high-resolution, top-mount
S
outhwest Electronic Energy Group announced
multi-motor
potentiometer. The 12-turn potentiometer aug-
its rugged, lightweight, 12V/100Ah portable
coordinated
ments two side-
power system.
POW-R Tote was originally used by law enforcement for quiet electrical energy during long stake-
drive systems, as well as high horsepower (hp)
mount
DIP
stand-alone drives for a wide variety of industrial
switches
that
applications.
select time rang-
outs. About the size of a lunchbox and weighing
Pre-designed, fully type-tested modules, including
es of: 0.5s–2s,
only 23 lbs., the
line side components, line infeeds (bus supplies) and
1. 0 s –12. 0 s ,
eco-friendly
motor inverters, all with a broad range of standard op-
5.0s–90s
tions, are selected and confgured by the customer.
50s–12 minutes.
and
reliable POW-R Tote
and
uses safe, powerful
The Sinamics S120 frmware, combined with
The unique top-
Lithium-Ion battery
Drive-CLiQ (the fexible backplane bus), allows us-
mount potentiometer enables users to fne-tune
technology to deliver 2X longer run time and 2X
ers to assign control units multiple Line and Motor
time delay settings without removing 859-477
more power at 1/2 the weight when compared to
Modules, plus mount the control units and associ-
from DIN-rail.
a typical 12-V lead acid battery commonly used in
ated I/O and sensor modules anywhere within the
A top-mount LED indicates switching status of
similar applications.
line-up or even remotely in a centralized control cabi-
the electromechanical single-pole, single-throw
net or control room.
Normally Open relay output.
Siemens
WAGO Corp.
POW-R TOTE is housed in a virtually indestructible, heavy-duty, watertight iM2075 Pelican Storm
Case to handle harsh environments. Two power
58
The system can operate continuously for up
www.power-eng.com
Automatic Filters
Boiler Feed Systems
Ball Valves
The Best Engineered Water
Filteration Solution Always
Costs Less
BOILER FEED SYSTEMS
Viega offers press ball valves specifically designed
for lead-free press systems. Made from Viega’s
unique silicon-bronze alloy, engineered for press
technology, Viega ProPress® Zero Lead™ ball
valves are certified to ASME A112.4-2004 and
NSF-61G, available in sizes 1/2- to 2-inches with a
variety of configurations.
Your source for custom-designed,
ruggedly-built mechanical and pneumatic
systems for feeding of biomass and alternative fuels
directly into boilers and kilns.
High-pressure, low-pressure and vacuum
conveying components available.
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www.Viega.us
1-800-976-9819
Handling a World of Materials
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''''' TerraSource Global is a wholly-owned subsidiary of Hillenbrand, Inc.
(NYSE: HI) ©2014, TerraSource Global. All rights reserved.
'$$%$'''$$'''''%&
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Cooling Tower Fill
Demolition/Decommissioning
Engineering & Construction
FLUOR’S LEGACY
AS YOUR ASSET
Brandenburg
®
Brandenburg is the premier demolition and
environmental remediation contractor for
power plant decommissioning and retrofitting. Brandenburg services utility companies
throughout the U.S. by performing demolition and repurposing projects ranging from
selective removal of obsolete equipment
to complete closure of power plant facilities.
With worldwide energy consumption
expected to double to an estimated
39.0 billion MW hours by 2040, Fluor’s
experts are committed to providing
industry-leading solutions, innovation, and
technologies that bring strategic value to our
clients’ capital projects. With more than
20 years of experience building gas-fred
power plants, Fluor recently completed
Dominion’s 590 MW combined cycle project,
the Bear Garden Generating Station.
www.fuor.com
(800) 932-2869 | www.brandenburg.com
www.power-eng.com
© 2014 Fluor Corporation. All Rights Reserved. ADGV098913
POWER PLANT
Demolition, Environmental Remediation,
Decommissioning, Retrofitting
ShowcaSe advertiSing contact Jenna hall: 918-832-9249, [email protected]
a brand of TerraSource Global
SUPPLIER’S SHOWCASE |
Why Should You
Filter Your Water?
59
Joining Stainless Pipe
High Voltage Equipment
24/7/365
Phone—660.596.7727
Email—[email protected]
www.energy-parts.com/power-eng
For construction of the world’s largest solar power
plant, Viega ProPress® for stainless was hardspecified in the plans for process water, service
water and instrumentation air systems. Viega
ProPress for stainless saved more than 30 percent
on materials and labor combined for installing the
systems.
om
onFans.c
21 or Robins
(724) 452-61
www.ViegaProPress.us
1-800-976-9819
Power Systems
Pump Bearings
Scaffolding System
NOW
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60
Industrial Fans
Call or Email for a quick quote
and fast track delivery of
Solution for Existing &
Evolving Energy Needs
for and in the Americas
| SUPPLIER’S SHOWCASE
High Voltage Equipment
GRAPHALLOY® PUMP BEARINGS
GRAPHALLOY® self-lubricating, non-galling bearings can improve pump reliability and efficiency.
Pumps fitted with GRAPHALLOY® bushings and
case rings allow pumps to survive upsets, dry
running, frequent suction loss and pulsation, slow
roll on standby and other transient conditions
that would damage conventionally fitted pumps.
GRAPHALLOY® also reduces pump vibration.
Contact: Eric Ford
[email protected]
(914) 968-8400
www.graphalloy.com
Industry Leading Program for the
Design, Estimating & Planning of Scaffold
Brand Energy & Infrastructure Services creates
exceptional value for its clients through
BrandNet™, its state of the art scaffold scoping,
estimating, materials management and planning
tool. BrandNet™ utilizes a computer aided design
approach to typical or non-typical scaffolds,
providing clients 2D and 3D drawings, budgets,
bill of materials, Gantt chart schedules, resource
loading and more.
Visit www.beis.com or email [email protected]
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Turbine-Generator Repair
Silo and Bin
Cleaning Services
and Equipment
Modern & High-Tech
PRECISION
High-Speed Balance
REACH YOUR
AUDIENCE
The newly constructed Mechanical Dynamics & Analysis
(MD&A) High-Speed Balance Facility in centrally located
St. Louis is one of the most modern balance facilities for
power turbines in the United States.
Call 800-322-6653
or visit
www.molemaster.com
MD&A's Turbine-Generator Repair Facility
3804 Weber Road | St. Louis, MO 63125
ph. 314-880-3000 | www.MDAturbines.com
PARTS | SERVICES | REPAIRS
GET RESULTS
Put your message in front of North
America’s most qualifed circulation with
Power Engineering’s classifeds.
CALL NOW FOR DETAILS:
JENNA HALL
Phone: 918.832.9249
Email: [email protected]
RENTAL EQUIPMENT
ES I Boi le r R e n t a ls , L L C
24/7 On-Call Service
1-800-990-0374
www.rentalboilers.com
- Rental Boilers - Economizers - Deaerator Systems - Water Softener Systems -
ADVERTISE your career opportunities,
equipment, services, and training
programs in Power Engineering’s
Classifed Section.
SUPPLIER’S SHOWCASE |
Silo and Bin Cleaning Sevices
POWER PROFESSIONALS
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: [email protected]
(360) 260-0979 • (360) 253-5292
www.powerindustrycareers.com
www.power-eng.com
61
| CLASSIFIEDS
Classified advertising ContaCt Jenna Hall: 918-832-9249, [email protected]
FOR SALE/RENT
WE ARE
BUYING!!!
24 / 7 EMERGENCY SERVICE
BOILERS
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DIESEL & TURBINE GENERATORS
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INSTRUMENTATION
ELECTRICAL CONTROLS
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PROCESS CONTROLS
PLANT MACHINERY
PSA SNUBBERS, ETC.
50 - 25,000 KW
GEARS & TURBINES
25 - 4000 HP
LARGEST INVENTORIES OF:
Air Pre-Heaters • Economizers • Deaerators
Pumps • Motors • Fuel Oil Heating & Pump Sets
Valves • Tubes • Controls • Compressors
Pulverizers • Rental Boilers & Generators
847-541-5600
Ferncroft
wabash
Management,LLC
VISIT
www.FerncroftManagement.com
email:[email protected]
FAX: 847-541-1279
visit www.wabashpower.com
POWER
EQUIPMENT CO.
444 Carpenter Avenue, Wheeling, IL 60090
CONDENSER & HEAT EXCHANGER TOOLS
CLEANERS, PLUGS, BRUSHES
John R Robinson Inc
PH # 800-726-1026
e-mail: [email protected]
www.johnrrobinsoninc.com
GEORGE H. BODMAN, INC.
Chemical cleaning advisory services for
boilers and balance of plant systems
George H. Bodman
Pres / Technical Advisor
P.O. Box 5758
Kingwood, TX 77325-5758
Office (281) 359-4006
1-800-286-6069
Fax (281) 359-4225
T. 978-815.6185 Fax. 603-814.1031
LIMITORQUE OPERATORS WANTED
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Burner Management
System Logic Review
Has your Burner Management System
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Our staff actively maintain seats on key
NFPA 85 technical committees,
averaging over 30 yrs of experience.
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We are also experts at solving ancillary
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Begin with a conference call
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Call Bill Smith:
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(816) 415-8888
www.ExoEng.com
Quality and Service Since 1908
Ring Granulators, Reversible Hammermills,
Double Roll Crushers, Frozen Coal Crackers
for crushing coal, limstone and slag.
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Ph: (314) 781-6100 / Fax: (314) 781-9209
www.ampulverizer.com / E-Mail: [email protected]
Pugmill Systems, Inc.
Ph: 931-388-0626 Fax: 931-380-0319
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The world’s very
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ADVERTISE your career
opportunities, equipment, services,
and training programs in
Power Engineering’s Classifed Section.
GET RESULTS
Put your message in front of North
America’s most qualifed circulation
with Power Engineering’s classifeds.
CALL NOW FOR DETAILS: JENNA HALL
Phone: 918.832.9249 | Email: [email protected]
REACH YOUR
AUDIENCE
Classified advertising ContaCt Jenna Hall: 918-832-9249, [email protected]
P.O. Box 60
Columbia, TN 38402 USA
CLASSIFIEDS |
Get a thorough mix with:
INDEX
RS# COMPANY
PG#
RS# COMPANY
PG#
11 ADA-ES, Inc.
23
19 Natronx Technologies, LLC
37
www.adaes.com
9
www.natronx.com
Asco Valve
19
8
www.ascovalve.com/rightnow
7
Brand Energy
15
and Infrastructure Services
www.beis.com
17
33
www.powergenerationweek.com
55
www.checkall.com
39
www.power-gen.com
28 Rolls Royce Energy Systems C3
14 COALGEN
27
www.coal-gen.com
www.rolls-royce.com
16 Sealeze, A Unit of Jason, Inc 31
29 Conbraco Industries Inc
C4
www.apollovalves.com
www.sealeze.com
6
22 Dresser-Rand
41
www.dresser-rand.com
Siemens Energy
11
Solvay Chemicals Inc
51
www.fairbanksmorse.com
25
www.fibrwrap.com
38
www.sturtevantinc.com
10 United Rentals Inc
13 Fibrwrap
C2
www.solvair.us
20 Sturtevant Inc
25 Fairbanks Morse Engine
13
www.siemens.com/energy
1
Elgin Sweeper Company
www.elginsweeper.com
21
www.unitedrentals.com/futures
18 Volvo Penta of the Americas 35
12 Flexim Americas Corp
24
www.flexim.com
www.volvopenta.com/industrial
2
Hytorc
53
www.hytorc.com
4
17 Power Generation Week
21 Projects of the Year
27 Check All Valve Mfg Co
5
Orion Instruments
www.orioninstruments.com
Westinghouse Electric Co
www.westinghousenuclear.com
15 Winsted Corporation
John Zink Co
9
3
29
www.winstedcustom.com
www.johnzinkhamworthy.com
23 Membrana
43
www.liqui-cel.com
3
Mitsubishi Power
Systems Americas, Inc.
6-7
www.psa.mhps.com
24 Mobil Industrial Lubricants 49
www.mobilindustrial.com
64
Advertisers and advertising agencies
assume liability for all contents (including text representation and illustrations)
of advertisements printed, and also assume responsibility for any claims arising therefrom made against the publisher. It is the advertiser’s or agency’s
responsibility to obtain appropriate
releases on any items or individuals pictured in the advertisement.
SALES OFFICE
1421 S. Sheridan Rd., Tulsa, OK 74112
Phone: 918-835-3161, Fax: 918-831-9834
Sr. Vice President North
American Power Group Richard Baker
Reprints Foster Printing Servive
4295 Ohio Street
Michigan City, IN 46360
Phone: 866-879-9144
National Brand Manager Rick Huntzicker
Palladian Professional Park
3225 Shallowford Rd., Suite 800
Marietta, GA 30062
Phone: 770-578-2688, Fax: 770-578-2690
AL, AR, DC, FL, GA, KS, KY, LA, MD, MO,
MS, NC, SC, TN, TX, VA, WV
Brand Sales Manager Dan Idoine
806 Park Village Drive
Louisville, OH 44641
Phone: 330-875-6581, Fax: 330-875-4462
CT, DE, IL, IN, MA, ME, MI, NH, NJ, NY,
OH, PA, RI, VT, Quebec, New Brunswick,
Nova Scotia, Newfoundland, Ontario
International Sales Manager Natasha Cole
1455 West Loop South, Suite 400
Houston, Texas 77027
Phone: 713.499.6311; Fax: 713.963.6284
AK, AZ,CA,CO,HI,IA,MN,MT,ND,NE,NM,NV,
OK,OR,SD,UT,WA,WI,WY,AB,BC,SK, Manitoba,
Northwest Territory, Yukon Territory
International Sales Mgr Anthony Orfeo
The Water Tower
Gunpowder Mills
Powdermill Lane
Waltham Abbey, Essex EN9 1BN
United Kingdom
Phone: +44 1992 656 609, Fax: +44 1992 656 700
Africa, Asia, Central America, Europe,
Middle East, South America
European Sales Asif Yusuf
The Water Tower
Gunpowder Mills
Powdermill Lane
Waltham Abbey, Essex EN9 1BN
United Kingdom
Phone: +44 1992 656 631, Fax: +44 1992 656 700
Europe and Middle East
Classifieds/Literature Showcase
Account Executive Jenna Hall
1421 S. Sheridan Rd.
Tulsa, OK 74112
Phone: 918-832-9249, Fax: 918-831-9834
www.power-eng.com
rolls-royce.com
A natural fit for any
environment.
Trent 60 attributes support today’s energy markets with outstanding
adaptability and flexibility making it a natural fit for any
environment. It is the most efficient and powerful aeroderivative
gas turbine designed for cyclic operation, fast starting and
restarting, unsurpassed load rates and environmental performance.
The Trent 60 with its unrivalled availability and reliability
combines these formidable traits to blend seamlessly and profitably into
your operating conditions.
Trusted to deliver excellence

Power Engineering

Transcription

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