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Vol. 158 No. 10 October 2014

Coal Top Plant
Award Winners
Prepare Your Plant for Cold
Weather Operations
Boosting Combustion Turbine
Response
Getting New Hydro Projects
Built
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are something to brag about.
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and building boilers for people who know and care since 1996.
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CIRCLE 1 ON READER SERVICE CARD
October 2014
|
POWER www.powermag.com 1
ON THE COVER
The 750-MW Trianel Coal Power Plant in Lnen, Germany, equipped with an SST5-6000
steam turbine and a SGen5-3000W generator from Siemens, boasts an efficiency of near-
ly 46% and is one of this years coal-fired Top Plant Award winners. Courtesy: Siemens
COVER STORY: COAL TOP PLANTS
22 Camden Power Station, Mpumalanga Province, South Africa
Described as the largest return to service project in the world, the recommissioned
Camden Power Station saved almost $9.5 billion compared to the cost of new power
stations of equal size. It also provided electricity for a nation with precarious energy
security much sooner than a new-build project.
24 Hitachinaka Thermal Power Station Unit 2, Tokai, Ibaraki Prefecture, Japan
Industry-leading efficiency for a coal-fired plant would likely have made this a Top
Plant Award winner in any year. Getting the unit built on timedespite massive earth-
quake and tsunami damage to the site during constructionsolidified the case.
28 Mundra Thermal Power Plant, Mundra, Gujarat, India
This supercritical plant is frugal with fuel, water, and site acreage even though its the
worlds largest single-location private sector thermal power station. It has also set an
Indian power sector generation record.
32 Sesa Sterlite Captive Power Plant, Jharsuguda, Odisha, India
This captive power plant, which serves the grid and an adjacent power-hungry alu-
minum smelter, has some of the most advanced environmental controls in India and
is the first coal-fired unit in the country to employ high-concentration slurry disposal
of dry and bottom ash.
34 Trianel Coal Power Plant Lnen, North RhineWestphalia, Germany
Even as Germany continues its transition to higher levels of renewable generation,
reliable baseload capacity is needed, and this plant, arguably the cleanest and most
efficient hard coalfired plant in Europe, is helping to fill that role.
SPECIAL REPORT: OPERATIONS & MAINTENANCE
36 Prepare Your Coal Plant for Cold Weather Operations
Following the North American Electric Reliability Corp. winterization guidelines is a
good start to cold weather preparations, but each coal power plant needs a site-spe-
cific plan that ensures everything from fuel supply availability to personnel safety.
40 Prepare Your Gas Plant for Cold Weather Operations
The February 2011 record cold weather in the U.S. took many gas-fired plants in
otherwise mild regions by surprise, resulting in derates for hundreds of units. Heres
a look at a number of common failure modes, proactive steps for all plants, and a
guide to prioritizing upgrades.
44 Prepare Your Nuclear Plant for Cold Weather Operations
U.S. nuclear plants performed well during last winters polar vortex, and although
Nuclear Regulatory Commission documents cover the winterization of nuclear
plants, following such guidance may not be sufficient on its own. Two plants share
their customized approaches.
47 Prepare Your Renewable Plant for Cold Weather Operations
The relatively recent widespread deployment of wind turbines and utility-scale solar
generation has resulted in some cold lessons learned when equipment wasnt up to
frigid weather spec. We look at the latest tools for making wind, solar, and even small
hydro installations winter-ready.
Established 1882 Vol. 158 No. 10 October 2014
24
28
40
Despite great economic success, power
shortages in Indonesia remain endemic.
This Global Business Reports section
looks at the island nations energy po-
tential, plans, and challenges (p. 49).
Sponsored Report:
Indonesias Energy Sector
www.powermag.com POWER
|
October 2014 2
FEATURES
COMBUSTION TURBINES
54 Quickly Boost Your Combustion Turbine Response
Field test results of a new technology, provided exclusively to POWER, suggest that
TurboPHASE has the potential to deliver added peaking capacity, especially during
warmer days when output of the combustion turbine is otherwise limited.
RENEWABLES
58 A New Day for North American Hydropower?
Despite the greater hype for newer renewable power technologies, hydropower still
has a lot to offer. Retrofitting existing dams is one promising approach in the U.S.,
larger projects in Canada are moving forward, and pumped storage is seen as a
perfect partner for variable renewable generation.
MERCURY CONTROL
62 Non-Carbon Reagent Injection for MATS Compliance
Full-scale trials of a new product using a non-carbon reagent to remove mercury via
chemical reaction show that it can provide economic and environmental advantages
unavailable with carbon-based products.
REGULATIONS
66 A U.S. Power Industry Regulatory Update
Delayed rules, challenged rules, reinstated rules . . . heres a quick overview of where
all the major federal power industry regulations stand as of Labor Day.
DEPARTMENTS
SPEAKING OF POWER
6 A Look Back at Electricity Rates
GLOBAL MONITOR
8 Poland Mulls Energy Future
8 A New Record for the Longest Transmission Link
9 First Solar Reports Thin-Film PV Cell Breakthrough
9 MHI Develops High-Efficiency 2-MW Gas Engine
10 THE BIG PICTURE: A Generation Freeze
12 Construction of Russia-China Pipeline Kicks Off
13 POWER Digest
FOCUS ON O&M
16 Proper Lubrication Practices Improve Plant Operations
LEGAL & REGULATORY
20 Unbundled Renewable Energy Credits and the Benefits of Standardization
By Lisa Koperski, associate, Davis Wright Tremaine
COMMENTARY
72 Collaborating to Build a Cleaner Energy Infrastructure
By Kelly Speakes-Backman, chair, Regional Greenhouse Gas Initiative Inc. Board of
Directors
Texas and Germany: Energy Twins?
Texas and Germany are on opposite sides of the world in many ways, but both believe
in competitive energy markets and are now reconsidering their market designs.
Fracking Fissures: Will Politics Impede Production?
Environmental and community activists fearful of hydraulic fracturing have launched
a high-profile, highly hyped campaign to shut down new natural gas production; how-
ever, their prospects of success look dodgy.
More October Stories Online at powermag.com
58
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on valve
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Compressor and
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54
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October 2014 4
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October 2014 6
SPEAKING OF POWER
A Look Back at Electricity
Rates
A
recent encounter with a newspaper
from 1901 got me thinking about
the price of electricity over time
and how it compares with price changes
for other goods and services.
Price Changes Over a Century
The incident that prompted these com-
parisons was a replica of a page from
The Honolulu Tribune for April 1, 1901,
that was being used to hold French
fries. I thought it might be a fake, but
an article in a Barbados paper online
claims the newspaper was discovered on
that island in an old container in De-
cember last year. The 1901 paper cost a
penny (roughly 28 today in inflation-
adjusted dollars) and ran a story about
the opening of the Moana Hotel, where
a room was going for $1.50 a night.
Rooms at the Moana now cost between
$355 and $4,400 a night (I searched for
April 1, 2015, availability to compare
prices at the same time of year). The
Hawaii Herald-Tribune, as the paper is
now known, costs an average of 44
per day if you subscribe for a year, so
the average daily cover cost is probably
closer to 50.
The Economist made some similar
comparisons at the end of 2000 when
it looked at U.S. prices for an array
of goods and services over the previ-
ous decade and century. It all started
with the discovery of a 1900 expense
report filed by a UK journalist who
had made a trip to America. Prices for
such things as refrigerators, eggs, salt,
clothing, cars, and housing dropped
over the century while those for beer,
bread, and potatoes increased (perhaps
as good a reason as any to adopt a low-
carbohydrate diet). The price of a four-
star New York hotelwhere that lucky
journalist stayedincreased the most:
nearly 300% in real (inflation-adjusted)
terms.
An important difference is that a room
in a four-star hotel is usually a discre-
tionary purchase, whereas food, rent, and
utility bills for water, electricity, and gas
are not.
How Much Have Electricity Costs
Risen?
The Economist article noted that U.S.
electricity prices fell by an average of 6%
per year in real terms between 1890 and
1920a pattern common to technologi-
cal revolutions in their early years; more
recently, computing power is the familiar
example. In real terms, the price of elec-
tricity between 1900 and 2000 dropped
nearly 100%, the magazine found. But
what about more recently?
Residential electricity prices are ris-
ing was the Today in Energy headline
from the U.S. Energy Information Ad-
ministration (EIA) on Sept. 2. The story
noted that U.S. retail residential prices
for the first half of 2014 averaged 12.3
cents per kilowatthour, an increase of
3.2% from the same period last year. This
is the highest year-over-year growth in
residential prices for the first half of the
year since 2009.
However, the headline should have
read, Residential electricity prices have
risen, as the report was retrospective.
That said, earlier this year, the EIAs An-
nual Energy Outlook 2014 (Reference Case
A8, p. A-19) did project that retail resi-
dential electricity rates would increase
from 11.7/kWh in 2011 to 22/kWh in
2040 (nominal); or, calculated in 2012
dollars, from 11.9/kWh in 2011 to
13.3/kWh in 2040.
I dont put much stock in projections,
but even the recent actual price increase
reported by the EIA doesnt tell the whole
story. The Bureau of Labor Statistics Con-
sumer Price Index (CPI) report for July
2014 noted that the electricity index fell
0.3% in July; it has now risen three
times and fallen three times over the last
6 months.
CPI reports differ from EIA reports in
two important ways: The CPI is an infla-
tion-adjusted number and considers only
average prices in a number of urban ar-
eas. However, the data underlying both
reports is in close agreement. CPI data
behind the index numbers show that the
average urban nominal price of electric-
ity rose from 9.9/kWh in June 2004 to
14.3/kWh in June 2014a 44% nomi-
nal increase over 10 years; the EIA found
the nationwide average annual residen-
tial rate was 8.95 in 2004 and 12.97
in June 2014a 45% nominal increase.
Adjusted for inflation, that 8.95 in 2004
would be worth 11.29 in 2014, which
yields a 14.9% increase in real terms.
Over the same decade, according to CPI
data, urban consumers saw the following
increases in nominal prices: regular un-
leaded gasoline, 81%; eggs, 49%; ground
beef, 57.2%; frozen concentrated orange
juice, 31.3%; and piped natural gas for
household use, 6.1% (though comparing
just those two years prices hides a steep
increase for gas in 2008).
As for water, another necessity, in Sep-
tember 2012, USA TODAY cited a survey
by Black & Veatch of 100 U.S. municipali-
ties that found residential water bills had
doubled over the previous 12 years in at
least one in four places and had tripled
in some. The paper noted that water pric-
es are expected to climb even higher, as
many water systems are due (or overdue)
for major infrastructure upgradesnot
unlike much of the electricity grid.
Electricity Is Still a Deal
All of which proves very little other than
that pricing changes look different de-
pending on whether youre looking at in-
dexed or un-indexed prices and depending
on your chosen timeframe. Both shorter
and longer timeframes will emphasize
some trends while hiding others. Another
complication: Prices are tracked in differ-
ent ways by different groups, making fair
comparisons and confirmations across
sectors challenging.
One thing we can see from the past
decade and past century or so of pricing
history is that electricity cost increases
(when they actually have been increases)
have not been as large as those for many
other essentials.
As for the cost of the magazine youre
holding in your hands, its still free for
qualified industry subscribers.
Gail Reitenbach, PhD, Editor
(@POWERmagazine, @GailReit).
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October 2014 8
Poland Mulls Energy
Future
Resource-rich Polands push to priori-
tize coal as its main energy source and
to cultivate a nuclear power program to
boost energy security at the expense of
climate objectives has provoked its por-
trayal within the European Union (EU) as
an energy renegade.
This September, however, Polands Prime
Minister Donald Tusk, a long-time proponent
of free markets, privatization, and minimal
government interference, was elected the
European Councils next president. Tusk will
head the forum where EU heads of state
meet to set the blocs political direction
(but do not have the power to pass laws)
starting on Dec. 1. The event has left ex-
perts pondering how the leaders fierce
opposition to climate policy and develop-
ment of renewable sources and advocacy
for shale gas will affect EU policy. Some
conclude he may have influence over the
EUs overall climate policy trajectory, but
several more argue that his sway may be
limited to securing concessions for Poland,
which is opposed to EU climate targets.
The countrys Ministry of Economy in
August unveiled a draft energy plan for
the country through 2050 that lays out
three future energy mix scenarios. One is
highly dependent on the countrys coal
resources and infrastructure, another fore-
sees nuclear accounting for 45% to 60% of
the energy mix (Poland has no operating
nuclear plants, though two are in develop-
ment), and the third would reduce coals
share from the current 88% (Figure 1)
down to 30%, with domestically produced
shale gas, renewables, and oil making up
the difference. The first two scenarios lim-
it renewables share to 15%.
Significantly, the plan comes just weeks
before EU leaders are expected to final-
ize the 27-country blocs 2030 climate
and energy framework. For 2030, the EU
framework has proposed a 40% green-
house gasreduction target that is binding
at the nation-state level and may not be
met by carbon offsets, and a 27% renew-
able energy target that is binding at an
aggregate European level but which will
be voluntary for individual member states.
The European Council (not to be confused
with the Council of the European Union,
one of the bodys legislatures) is next
scheduled to meet on Oct. 23.
A New Record for the
Longest Transmission Link
A 7,100-MW 600-kV high-voltage direct-
current (HVDC) line that runs 2,375 kilo-
meters (km) from new hydropower plants
on the Madeira River in the Amazon Basin
to major load centers in southeastern Bra-
zil became the worlds longest transmis-
sion line this August.
The Rio Madeira HVDC system was built
by Swiss power and automation technol-
ogy group ABB for a consortium comprising
Spains Abengoa Group and Brazils Aben-
goa Construo Brasil. It consists of two
3,150-MW HVDC converter stations placed
at either end of the line: at hydropower
plants at Porto Velho in northwest Brazil
and in the southeast near So Paulo (Fig-
ure 2). ABB also delivered an 800-MW HVDC
back-to-back station that transmits pow-
er to the alternating current (AC) network
in the northwest of Brazil.
The Rio Madeira project, built as part
of the Brazilian governments Program to
Accelerate Development, is a big step for
the country whose power system is about
75% hydroelectric.
The line is the countrys second 600-kV
HVDC transmission system. In the mid-
1980s, ABB completed the first HVDC proj-
ect (with a total rated power of 6,300 MW)
to deliver power from the 12-GW Itaipu
hydroelectric power plant. That 1,590-km
project was for more than two decades the
longest and most powerful HVDC transmis-
sion link in the world. But in 2010, that
title was usurped by the 6,400-MW 800-kV
Xiangjiaba-Shanghai ultra-HVDC transmis-
sion system, a 2,071-km line that connects
the Xianjiaba Dam to Shanghai in China.
Another notable project in the works is
Siemens 2,200-MW submarine HVDC link to
connect Scotland and England at 600 kV.
Companies developing HVDC transmis-
88%
3%
2% 2%
2%
3%
Electricity generation in Poland by source
1. Heavy on coal. Polands energy sec-
tor is historically based on coal, and Poland
has the ninth-largest deposits in the world.
Hard coal and lignite produced nearly 90% of
the central European countrys power in 2012.
Source: Polish Information and Foreign Invest-
ment Agency
2. For long-distance power. ABB on Aug. 27 commissioned the high-voltage direct-
current (HVDC) converter stations for the 3.2-GW Rio Madeira HVDC link in Brazilwhich, at
2,400 km, is the longest transmission line in the world. Courtesy: ABB
Biomass Hydro Wind and geothermal
Oil Gas Coal
October 2014
|
sion technologies tout its prime benefit of reducing transmission
losses by 30% to 50% compared to alternating-current overhead
lines. For lengths of about 600 km or more, consensus is that
overhead lines using HVDC transmission technology are more cost-
effective than AC technology.
According to Siemens, the current 2.5-billion-per-year HVDC
market will double within the next five years. Demand for HVDC
transmission is increasing rapidly, says the company that is a
major competitor in the market along with ABB and Alstom. In
the last 40 years, HVDC transmission links with a total capacity
of 100 GW were installed, and another 250 GW may be added this
decade alone, Siemens projects. Drivers for this massive growth
include connecting offshore wind farms to the grid (such as in
Germany, where wind projects are far offshore), transnational grid
connections, and remote load area connections. Back-to-back
HVDC links, which connect two AC grids and serve as a firewall
to prevent faults from passing into the neighboring grid, will also
spur growth. And growth will be particularly strong in countries
with surging energy demand and large distances to cover, specifi-
cally China, India, and Brazil.
Even so, Siemens notes: The power transmission market is
basically volatile, since it is influenced by large-scale projects.
First Solar Reports Thin-Film PV Cell
Breakthrough
Arizona-based solar photovoltaic (PV) system provider First Solar
in August said it had achieved a cadmium-telluride (CdTe) PV
research cell conversion efficiency of 21%a world record.
The thin-film PV cells efficiency compares to the previous CdTe
record of 20.4% conversion efficiency, which was set by First So-
lar in February of 2014, and represents the seventh substantial
update to CdTe record efficiency since 2011.
And, significantly, it means First Solars CdTe research cell ef-
ficiency ranks at the top for all thin-film PV technologies, above
copper indium gallium diselenidebased solar cells at 20.9%, and
above multicrystalline silicon, which peaked at 20.4% in 2004.
The National Renewable Energy Laboratory has charted the pro-
gression of the best research cell efficiencies since 1975 (see
http://1.usa.gov/1BgiqOG).
First Solars thin-film cell was developed at the companys
Perrysburg, Ohio, manufacturing factory and Research & Devel-
opment Center, and its efficiency was certified at the Newport
Corp.s Technology and Applications Center PV Lab. The companys
chief technology officer, Raffi Garabedian, said the development
notably demonstrates that record cells are based on the same
scalable manufacturing processes and commodity materials that
we have proven through years of volume production.
First Solar last March revealed in a technology roadmap that it
is anticipating a 22% research cell efficiency milestone in 2015.
MHI Develops High-Efficiency 2-MW Gas
Engine
Mitsubishi Heavy Industries (MHI) in August revealed that it had
developed a 2-MW 16-cylinder high-speed gas engine that poten-
tially offers a power generation efficiency (lower heating value)
of more than 44.7%.
Developed as part of Japans Strategic Innovation Program
for Energy Conservation Technologies, operated by the New En-
ergy and Industrial Technology Development Organization, MHIs
breakthrough prototype engine (Figure 3) cuts its mechanical
loss ratio by improving engine output while maintaining the
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October 2014 12
same exhaust volume as the GS16R2, a
1.5 MW class gas engine developed by
MHI in 2012. As significantly, it adapts
a Miller cycle configuration to enhance
thermal efficiency, as well as two-stage
turbocharging, whereby turbochargers
are arranged in series in the low- and
high-pressure stages and an intercooler
is placed between them, creating a con-
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ficiency and a high-pressure ratio, the
company explains.
The engine was developed in response
to Japans urgent need for more genera-
tion (and, particularly, cogeneration) in
the wake of the 2011 Great East Japan
Earthquake. Overseas, substantial ex-
pansion in the market for gas engine
power supplies is anticipated against the
backdrop of the promotion of distributed
power generation systems responding to
shale gas development in North America
and to expanding power consumption in
China and other Asian countries, MHI
said.
Chinas government alone has an-
nounced plans to introduce distributed
gas-engine power generation systems with
a total output of around 50 GW by 2020.
But MHIs prototype has yet to undergo
demonstration testing, which is planned from
this September through February 2015 at
MHIs engine production base in Kanagawa
Prefecture. If successful, MHI plans to expand
the newly developed 16-cylinder model to a
full series of 6- to 24-cylinder models offering
outputs ranging from 0.75 MW to 3 MW. The
new line will target applications including
distributed generation, regular generation
and cogeneration, and emergency generation
during times of disaster.
Construction of Russia-
China Pipeline Kicks Off
Gazprom on Sept. 1 made the first weld of
a 4,000-km natural gas pipeline that will
run from gas production centers in Rus-
sias Yakutia and Irkutsk gas production
fields to Russias Far Eastern regions and,
for the first time, to China.
The Power of Siberia (Sila Sibiri in
Russian) gas transmission system is part
of Russias plans to build a modern gas
network that connects its remote western
Siberia region and the Far East with the
countrys Unified Gas Supply System.
At the same time, Gazprom is looking
to implement a May 2014signed purchase
and sale agreement for Russian gas sup-
plies to China. That 30-year contract
valued at $400 billionwill see the supply
of 38 billion cubic meters (bcm) of gas
per year to energy-hungry Chinaor over
one trillion cubic meters (tcm) during the
whole contractual period.
It will mean laying 1.7 billion tons of
pipes between 2014 and 2018 amid com-
plex geological and climatic conditions,
spanning five Russian regions (Figure 4).
It will start from the Chayanda oil and
gas field in the Arctic region of Yakutia
(which will begin production in 2015 and
has gas reserves of 1.2 tcm), then run
within an integrated corridor with the
second stage of the Eastern Siberia-Pacific
Ocean oil pipeline. In Khabarovsk, a city
about 30 km from the Chinese border, the
pipeline will be connected to the 2011-
opened Sakhalin-Khabarovsk-Vladivostok
pipeline, which transports gas to Russias
Far East. Gazprom envisions the pipeline
being connected to Blagoveshchensk, on
the Russian-Chinese border, by 2018.
The pipeline, which will be the longest
in the world when completed, will cost
$20 billion to build. It will also require
innovative engineering concepts and
technologies, including pipeline monitor-
ing systems. Among such applications are
[domestically] manufactured longitudi-
nally welded pipes made of cold resistant
steel K60 with external anti-corrosion and
smooth internal coating, 1,420 mm in di-
ameter and 21.7 mm of wall thickness,
designed for 100 Ata operating pressure,
Gazprom said. In the areas of tectonic
faults and intense seismic activity high-
er than eight points the [pipeline] will
be made of high-strength pipes.
Some experts suggest that when opera-
tional, the pipeline will mark a clear shift
in the worlds natural gas trade. Russia has
an imperative to diversify its exports away
from Europe owing to slack demand and the
conflict in Ukraine, through which almost
half of supplies to the continent flow.
Russian gas flows have been stopped
three times in the past decadein 2006,
2009, and in 2014stemming from price
disputes with Ukraine. But threats that
Russia could halt gas supplies this winter
have meanwhile lost their bite. European
Union (EU) Energy Commissioner Guenther
Oettinger told reporters on Aug. 27 that
the EU has a Plan B for the worst-case
scenario. But we dont expect to need it,
he said. He noted that European power and
gas providers have been storing as much
gas as possible over low demand periods.
At the same time, Chinas gas demand
has tripled since 2006, while imports have
surged from less than 1 bcm in 2006 to 53
bcm in 2013. The countrys government
in April said that it will more than double
natural gas consumption, from 170 bcm
in 2013 to 400 bcm to 420 bcm in 2020.
For China, the pipeline means greater
natural gas security, a more diversified
import portfolio, and more supplies of a
fuel it could use to mitigate the countrys
air-quality troubles.
3. [E]ngenuity. Mitsubishi Heavy In-
dustries newly developed 2-MW 16-cylinder
high-speed gas engine boasts one of the high-
est power generation efficiency ratings for a
high-speed gas engine. Courtesy: MHI
4. A big dispatch. State-owned Russian energy giant Gazprom in September began con-
struction on a mega-pipeline that will send $400 billion worth of Russian gas to China over 30
years, starting in 2018. Courtesy: Gazprom
October 2014
|
POWER Digest
Kemper County Combined Cycle Unit Begins Commercial
Operation. Mississippi Power on Aug. 14 marked a significant
milestone and started commercial operation (on natural gas) of
the combined cycle unit at the $5.5 billion integrated gasifi-
cation combined cycle Kemper County energy facility. The unit
was originally synchronized to the grid on Oct. 5, 2013, during
testing using natural gas as fuel. Since then, the Southern Co.
subsidiary has performed critical testing on various components.
The combined cycle unit passed all applicable performance and
environmental tests. The first gasifier (to be used to convert
lignite to synthesis gas) heat-up at the plant is scheduled for
later this year. The 582-MW plant is scheduled to begin operation
using coal in the second quarter of 2015.
Chinas Fuqing CPR-1000 Reactor Is Connected to the
Grid. China National Nuclear Corp. on Aug. 21 connected Unit 1
of the Fuqing nuclear power plant in Chinas Fujian province to the
grid. The Chinese-developed CPR-1000 reactor is expected to enter
commercial operation by the end of the year. Six CPR-1000s will
eventually be built at the Fuqing site; construction is ongoing for
Units 2, 3, and 4. Those reactors should come online in 2016 and
2017. Mainland China now has 21 nuclear reactors in operation, 27
under construction, and many more in development.
IEA: Renewables to Grow Less Rapidly Through 2020
on Policy Uncertainties. Renewable electricity generation will
grow by 2,245 TWh through 2020, at a rate of 5.4% a year, says
the International Energy Agency (IEA) in its August-released
2014 Renewable Energy Medium-Term Market Report. Yet, the au-
tonomous Paris-based organization notes that this forecast has
been revised down largely due to less optimistic outlooks for
hydropower, bioenergy, wind (onshore and offshore) and [solar
thermal energy]. Hydropower, including output from pumped
storage, represents about 37% of total growth, followed by on-
shore wind at 31%.
Deployment of renewable power capacity is meanwhile expect-
ed to rise from a global total of 1,690 GW in 2013 to 2,555 GW
in 2020. Two global trends will help drive up renewable capacity,
the IEA predicts: Renewable electricity will scale up, and renew-
able technologies are becoming increasingly competitive on a
cost basis with alternatives in a number of countries and circum-
stances. Even with growing competitiveness, policies remain
vital to stimulating investment in capital-intensive renewables,
the agency notes. Scaling up deployment to higher levels would
require stable, long-term policy frameworks and market design
that prices the value of renewables to energy systems and in-
creases power system flexibility to ensure system adequacy with
greater variable renewables.
Four New Indian Ultra Mega Coal Plants Are Taking
Shape. Indias government in August began work to establish
four new ultra mega power plants (UMPPs) with a combined ca-
pacity of 16 GW, each of at least 4 GW. One UMPP is planned in
the state of Bihar, another in Jharkhand, and two in Odisha. State
officials report that land for the proposed project in Jharkhand
has been acquired, while the state governments of Bihar and
Odisha have identified suitable sites. Indian power companies
Tata Power, NHPC, NTPC, JSW Energy, Adani Power, and Jindal
Power have reportedly submitted applications to build the mas-
sive coal-fired power plants.
FERC Licenses 1.3-GW California Pumped-Storage Facility.
The Federal Energy Regulatory Commission (FERC) in June issued an
original license for the proposed 1,300-MW Eagle Mountain Pumped
Storage Hydroelectric Project planned for the site of the inactive
Eagle Mountain mine in Riverside County, Calif. The project will oper-
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October 2014 14
ate as a closed-loop, pumped-storage facil-
ity, using the excavated open mine pits as
reservoirs. Developer Eagle Crest Energy
and engineering firm GEI Consultants have
led licensing efforts. (For more on the Eagle
Mountain project, see the article on hydro-
electric development in this issue.)
Eskom Gets OK to Increase Power
Prices. The National Energy Regulator of
South Africa (NERSA) in late July gave state-
owned utility Eskom permission to raise
power prices in 2015 above the 8% tariff
increase over a five-year period, approved in
2013. The adjustment will help Eskom recoup
about R7.8 billion ($730 million) in revenue
after costs exceeded projections between
2010 and 2013. Eskom had last year asked
NERSA for approval to increase tariffs by 16%
to offset a revenue shortfall it expects of up
to R225 billion ($21 billion) over the next
four years. The utility is scrambling to build
new power generation capacity to meet surg-
ing demand.
AREVA to Replace South African Nu-
clear Plants Steam Generators. Frances
AREVA in August won a contract to replace
six steam generators at the two-reactor Koe-
berg nuclear plant owned by state utility Es-
kom. The refit, expected to be completed in
2018, is part of the countrys plans to install
up to 9.6 GW of new nuclear power by 2030
to overcome chronic power shortages and re-
duce greenhouse gas emissions. The 1.8-GW
Koeberg Station near Cape Town is Africas
only nuclear plant. It provides about 5% of
South Africas power.
First Commercial Order for MHI
Vestas 8-MW Offshore Wind Turbine.
Denmarks DONG Energy and MHI Vestas,
a recently launched joint venture between
Vestas Wind Systems and Mitsubishi
Heavy Industries, on Aug. 21 signed a
conditional deal for 32 V164-8.0 MW off-
shore wind turbines for installation at the
Burbo Bank Extension project in Liverpool
Bay, off the coast of northwestern England.
The deal marks the first commercial order
for the joint ventures proprietary wind tur-
bine model. The companies in 2012 agreed
to conduct a number of test activities for
the turbines prototype at a test center in
sterild, Denmark. The agreement is condi-
tional upon DONG Energys final investment
decision for the project.
Voith to Embark on Challenging
Modernization of German Pumped-
Storage Plant. Voith will modernize a
generator at E.ON Kraftwerkes 620-MW
Waldeck 2 pumped-storage power plant
in North Hesse, Germany, under a con-
tract signed in August. Voith delivered the
original two 265-MVA generators at the
Waldeck 2 station in 1970. After the com-
pany completes replacement, assembly,
and commissioning of the stator and rotor
of machine 6 at the plant, the project will
see an increase of about 10% in efficiency
and a lifetime extension. But, the com-
pany cautioned, modernization wont be
easy because the turbine is situated ver-
tically above the motor-generator (and a
multistage pump is installed underneath),
which means the company will first have
to disassemble the original turbine to re-
place the generator.
Sonal Patel is a POWER associate edi-
tor (@POWERmagazine, @sonalcpatel).
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Correction
The August cover article on the Ivanpah
Solar Electric Generating System con-
tained an error in the plants water us-
age statistics. The article should have
stated that the plant has used about
20,000 gallons of water per day.
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October 2014 16
Proper Lubrication
Practices Improve Plant
Operations
Although industrial lubricants typically
account for only 1% of plant operational
costs (Figure 1), the lack of proper lubri-
cation products, techniques, or applica-
tions can have a much more severe effect
on overall maintenance costs. One of the
smallest items in the budget directly in-
fluences more than half of the total main-
tenance cost.
Lubrication has proven to be the most
important factor regarding machinery
reliability and productivity. The three
major goals of operations and main-
tenance (O&M) are to improve output
capabilities, reduce O&M costs, and in-
crease profitability.
Many plant managers are looking for
existing products or technologies com-
bined to produce a synergistic outcome
to create a significant advantage over
the sum of their parts. Lubrication is
one of the building blocks that can help
achieve this goal. The proper lubricant,
lubrication practices, training, and im-
plementation of a lubrication manage-
ment program (LMP) can reduce costs and
improve productivity.
Synthetics Versus Minerals
Choosing the wrong lubricant for a ma-
chine component is more common than
you may think in power generation facili-
ties today. There is a big difference in per-
formance between conventional mineral
oil lubricants and synthetic lubricants.
Mineral oils break down under extreme
heat and form deposits. While petroleum
oils are produced to a high standard of
purity, the fact remains that some un-
known/unwanted content is still present.
Because modern machines are built with
higher operating speeds than ever before
and produce more power, petroleum-based
oils have reached a plateau.
Synthetic lubricants and greases have
consistent properties and provide an ar-
ray of overall performance improvements.
Synthetics offer maximum protection for
engines, gearboxes, motors, machines,
and other moving parts because of their
more consistent properties:
Increased wear protection: Superior lev-
el of fluid film protection; high shear
stability; and reduced scuffing, pitting,
and rolling contact fatigue.
Wide temperature range: Maintain fluid
film protection at higher temperatures;
lower pour points and greater fluidity
at low temperatures.
Longer oil life: Free of unstable mol-
ecules that are prone to degradation;
extend oil drain intervals; higher resis-
tance to oxidation.
Improved bottom line: Optimize equip-
ment performance and reduce mainte-
nance costs.
The additive chemistry in synthetics
widens the operational temperature range,
extends drain intervals, and provides a
protective barrier on equipment against
outside contaminants and corrosion. Syn-
thetics typically have extended drain in-
tervals due to their oxidation resistance.
Increased oxidation resistance translates
into deposit control and longer oil and
grease life. Note the darker, thicker build-
up in the engine operated with mineral
oil on the right in Figure 2, compared to
the cleaner engine on the left, which used
synthetic oil.
Many people do not understand the dif-
ference between initial price and overall
costs when comparing synthetic and min-
eral oilbased lubricants and greases. Of-
ten, the lubricant with the lowest initial
price is selected over another that will
provide sustainable long-term results and
overall cost-savings.
The leading benefits of synthetics and
specially designed lubricants are their
ability to reduce waste, increase equip-
ment life, and reduce energy consumption
while improving productivity, sustainabil-
ity, profitability, and carbon footprint.
Energy efficiency can be achieved with
synthetics by reducing friction, which low-
ers power consumption. When evaluating
operating costs, especially with heavy ma-
chinery, energy consumption is a critical
component. Proper lubrication with the
correct lubricant can reduce energy usage
by as much as 10%.
Fit for Purpose
There is no such thing as a one-size-
Lubricants, 1%
Depreciation, 15%
Utilities, 19%
Maintenance, 30%
Overhead, 35%
1. The bottom line impact of lu-
brication. This chart shows an average
breakdown of overall plant operating costs by
category. Source: Hydrotex
2. Which do you prefer? This is an example of differences in oxidation resistance between
synthetic and mineral-based engine oils after a 500-hour, high-temperature bench test. The engine
on the right used mineral oil; the one on the left used synthetic oil. Courtesy: Hydrotex
Synthetic
Mineral oil
October 2014
|
fits-all lubricant or grease. The correct
lubricant is always application-driven. A
lubricant must be fit for purpose. When
selecting the correct lubricant, viscos-
ity is one of the most important factors
and must match the load, environment,
temperature (both ambient and opera-
tional), and speed (LETS) of the compo-
nent or equipment.
Viscosity affects a fluids ability to flow
between two surfaces and how it resists
being squeezed away from the surface
while experiencing load and pressure.
When addressing LETS to determine the
proper viscosity lubricant or grease to use
in a power plant, the following aspects
should be considered:
Load: Determine the design load for a
specific application and compare it to
the load that is currently being exerted
on the machine. Sometimes, key fac-
tors have changed. For example, if the
weight of material being carried on a
conveyor has changed, it could signifi-
cantly affect the loading on the bear-
ings, idlers, and motor.
Environment: Cleanliness is next to
godliness when it comes to filtration
and the prevention of corrosion and
contaminants in equipment. To ensure
the quality of a lubricant is maintained,
cleanliness is a very important qualita-
tive parameter.
Temperature: Synthetic and multi-vis-
cosity grade lubricants provide temper-
ature flexibility in high or low operating
temperatures.
Speed: High- and low-speed compo-
nents require the correct viscosity lu-
bricants and greases to enter and reside
within the contact-friction area.
Selecting a lubricant is a complex
process that requires knowledge of both
the machines and the lubricants. A criti-
cal part of choosing a lubricant is de-
ciding to go with a synthetic or mineral
base. In general, synthetics will have
more sustainable properties than min-
eral oils. However, you will not get the
full benefit of any lubricant, especially
a synthetic lubricant, unless you know
how to use it correctly.
Knowledge Is Essential
Lubricants of high performance and qual-
ity, at any price, will not be valuable with-
out the correct training and education.
Training and continuing educational pro-
grams are vital for facilities to gain an un-
derstanding of lubrication fundamentals.
A case study performed by the Institute
of Mechanical Engineers revealed that
43% of machine failures could be attrib-
uted to the incorrect choice and usage of
lubricants. Most people still believe that
machine failure is a unique event. How-
ever, failure is a process.
Lubrication training focuses on the
what, why, and how, so that fric-
tion and wear can be minimized. That
way the people who are responsible
for maintenance can take timely action
during the process to extend the life and
precision of equipment.
Understanding lubrication fundamentals
can reduce maintenance expenses more
than 30% by ensuring the proper lubrica-
tion and LMP is implemented. Lubrication
education and training teaches staff how
to develop a successful LMP and proactive
maintenance program, which improves re-
liability at the lowest cost.
Without the knowledge of lubrication
attributes, it is more difficult to estab-
lish an LMP. A complete and successful
|
October 2014 18
LMP should include continuing education
and training; equipment and application
surveys; knowledge of the product, equip-
ment, and lubrication storage conditions;
and a proactive maintenance program that
includes oil analysis testing.
Begin with the End in Mind
The main reasons for setting up an LMP
are to prevent unplanned downtime from
equipment failure; increase output capa-
bility, profitability, productivity; and re-
duce the carbon footprint. An LMP should
define an objective that begins with the
end in mind.
A program capable of defining and
controlling the entire lubrication pro-
cess proactively through condition-
based monitoring (CBM) techniques will
ultimately increase productivity and re-
liability. The first tenet in an LMP is to
understand that lubricants are applica-
tion-specific. Knowing how to properly
use the lubricant is just as valuable as
the lubricant itself. Poor lubrication
techniques and processes will likely lead
to shortened equipment life and unfore-
seen outages at the worst possible time,
such as in the middle of the peak sum-
mer season.
Equipment and application surveys are
the next step in an LMP to provide facili-
ties a clear picture of existing lubrication
practices and maintenance procedures.
The initial plant survey and lubrication au-
dit becomes the foundation for the entire
LMP and sets expectations.
Implementation of CBM will compare
historical data and trends against engi-
neering facts to detect, highlight, and
analyze potential problems before they
occur. The key to this approach is that
once the root issue has been defined,
corrective action can and should be tak-
en when it is most advantageous for the
user. Oil analysis is another part of the
baseline information included in an LMP
to help identify potential equipment con-
cerns and track trends following lubrica-
tion changes.
In power plants today, parameters are
far less predictable and static than in the
past due to frequent load changes result-
ing from solar and wind generation. Given
that reality, how can an LMP and train-
ing help staff control for those variations
in operating conditions? Knowledgeable
plant personnel trained in lubrication fun-
damentals will be able to identify a po-
tential problem rather than experiencing
equipment failure.
It is not enough for management to
agree with implementing the correct lu-
brication practices. Rather, all staff op-
erating and managing the equipment
need lubrication knowledge. Training will
be even more important in the future as
experienced personnel retire, and as mul-
tifunctional or cross-trained personnel
perform different functions.
Lubrication Planning and
Predictive Maintenance
Every facility plans downtime for routine
maintenance, equipment rebuild, plant
expansions, and other reasons. Planned
downtime is designed to ensure equip-
ment is maintained and production goals
are met. Lubrication-related downtime can
be caused by:
Low-grade/commodity lubricants
Under- or over-lubrication
No lubrication
Using the wrong lubricant
Missed lubrication cycles
Excessive wear
Increased operational temperatures
Contamination of oils and greases
Seal damage
Compatibility problems
Leaks
These are just some of the problems ev-
ery facility can experience.
Planning is a key part of proper lubri-
cation management. There are three basic
types of maintenance: corrective (fix what
just failed), preventive (fix on a time-
based frequency whether it needs it or
not), and predictive (monitor the equip-
ment to see if the data shows that an item
is moving toward failure and make repairs
just before it fails).
Many successful companies are chang-
ing to predictive maintenance programs,
focusing on oil analysis, vibration analy-
sis, thermography, and fluid and system
cleanliness to improve the reliability of
equipment. They can then perform main-
tenance at the optimum time, rather
than on some arbitrary schedule. Pay-
ing attention to monitoring the details
is measurement-driven and deploys data
analysis to make risk-informed deci-
sions. Proper lubrication practices not
only require knowledge but also a proac-
tive approach.
Ask the Experts
Overall, lubricants make up a small por-
tion of O&M costs, but improper usage
and choosing the wrong lubricant affects
the bottom line and business operating
profits. Making sure that fundamental
lubrication practices are being handled
correctly has huge benefits over time.
If sustainable operations are the goal,
proper lubrication practices and an LMP
can help achieve a reliable, cost-effec-
tive plant operation.
Making a big decision can be easier
with the help of a professional. Lubrica-
tion is a specialty; becoming an expert re-
quires education and experience. Though
there are many distributors to choose
from, Hydrotex is one company that of-
fers LMPs and on-site training presented
by knowledgeable lubrication consultants.
The key to success is finding a company
that not only can recommend the right
high-performance lubricants for the appli-
cations but also can recommend reliability
solutions. Focus on the overall solution
tailored to fit your goals.
John Bickley, PE is the vice president of
sustainable utility sales for Hydrotex.
Have a Question or Comment?
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our Facebook posts and LinkedIn discussions.
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able to answer? Start a discussion on the POWER magazine
LinkedIn Group.
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October 2014 20
Unbundled Renewable
Energy Credits and the
Benefits of Standardization
Lisa Koperski
U
nbundled renewable energy credits and certificates (RECs)
separate the renewable, or green, component of energy
from the actual megawatt-hours of generation. RECs are
traded on nine different regional markets, or registries, in the
United States and Canada. Each market employs its own policies
and procedures for tracking RECs. Some regions allow exchanges
of RECs between markets; others do not.
A registry houses the REC until purchased. Certain registries
have been created by individual states, such as Michigan, while
other registries are amalgamations of states such as the Western
Renewable Energy Generation Information System. Each registry
functions and operates independently, and the registries are not
currently set up to communicate with one another. The stand-
alone process of REC registries frustrates inter-registry transfers
of RECs, engendering economic inefficiencies and facilitating
fraud. National standardization of the tracking of and accounting
for RECs would provide great benefits.
States Create RECs
RECs track the source of green energy through financial trans-
actions. Thus, RECs serve an important function for renewable
energy in two ways. First, RECs provide a vital tool for utili-
ties to meet state renewable portfolio standards (RPSs), which
mandate that utilities obtain a certain portion of the electricity
that they sell to retail customers from RPS-eligible sources. By
stripping the renewable attribute from the physical energy, RECs
allow utilities to purchase renewable attributes at lower prices,
decreasing the costs of being RPS-compliant. Second, RECs allow
corporations to meet their self-imposed green goals, which en-
able them to promote their entities and products as environmen-
tally friendly, thus boosting consumer demand.
RECs constitute property rights, as they transfer property be-
tween parties. RECs also constitute contracts in the respect that
they manifest the willingness of buyers and sellers to transact for
the sale of property. Property and contract rights are generally
governed by state law. However, the Federal Energy Regulatory
Commission (FERC) could arguably have exercised jurisdiction
over RECs as part of its overall regulation of the wholesale sale of
electricity. FERC regulation would have provided some degree of
national uniformity, butreasoning that its jurisdiction is limit-
ed to just the physical attributes of electricityFERC decided in
2012 that transactions involving RECs are subject to state law.
An Absence of Uniformity
REC purchasers must currently rely on attestations by sellers that
they are transferring bona-fide RECs. A market system dependent
on such self-attestations inherently increases the risk of fraud.
For example, the biodiesel market similarly relied on sellers self-
attestations regarding the value and integrity of the biodiesel
and that market experienced cognizable levels of fraud.
The potential for fraud in the REC market is further heightened
by the absence of any formal exchange disclosing REC prices (by
contrast, for example, the New York Stock Exchange sets prices
for paper certificates through shares). In the REC market, brokers
with insider knowledge of prices for REC sales serve as the de
facto mechanism for setting prices in REC transactions.
Nonetheless, both utilities and corporations compete to purchase
RECs listed on the registries. State regulations typically require utili-
ties to procure RECs from suppliers listed in the regional registry.
From an economic perspective, this artificial constraint on supply
causes the demand for RECs in some markets to be higher than the
limited supply of RECs in a registry. Economics teaches that any im-
balance between supply and demand that exists independent of the
workings of competitive markets triggers inefficiency.
As the nation continues to advocate for green technology and
energy independence, the voluntary purchases of RECs and the
number of states imposing RPS purchase requirements are antici-
pated to grow. The current system of siloed regional REC regis-
tries is sub-optimal and should be fixed, especially because the
REC market is projected to increase substantially over the next
few years.
Interconnected REC Registries
To be sure, RECs theoretically allocate resources more effectively
and efficiently than requiring all retail sellers and users to gener-
ate or procure physical renewable energy. However, as set forth
above, the splintered market in the United States relegates the
benefits RECs provide to sub-optimal levels.
RECs could better achieve their full potential if consistent
definitions for them existed across state lines, if RECs could be
uniformly transferred across registries, and if transparent prices
became publicly available for willing buyers and sellers. A simple
technical fix exists in making the REC registries interconnected.
Interconnectedness would enable each regional registry and pro-
spective REC purchaser and seller to see in real time the active
and purchasable RECs on the other registries.
This visibility should mitigate fraud risk because there would
be transparency among the registries. The increased transpar-
ency should also decrease prices, as lower-priced RECs available
in certain registries could be sold in higher-priced REC registry
markets, thus creating a beneficial price impact. Once RECs have
been harmonized and the registries have been networked togeth-
er, hopefully the current system of fragmented and disjointed
inter-registry transfers will become a thing of the past as re-
gional registries see benefits from interconnectedness, including
efficiency gains and the potential to mitigate fraud.
Lisa Koperski (lisakoperski@dwt.com) is an associate in Davis
Wright Tremaines Seattle office.
2014 Diamond Power International, Inc. All rights reserved.
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October 2014 22
TOP PLANTS
Camden Power Station,
Mpumalanga Province,
South Africa
Owner/operator: Eskom
E
skom, South Africas largest utility, was
established in 1923 as the Electricity
Supply Commission and was converted
into a public company, wholly owned by the
government, in July 2002. Eskom produces
about 95% of the countrys electricity and
45% of Africas total demand. The utility has
a generation capacity of about 42 GW and
plans to double its capacity by 2030. About
90% of South Africas electricity is generated
by coal-fired stations, 5% by its single nucle-
ar plant, and the remaining 5% by hydroelec-
tric and pumped storage plants. South Africa
has very meager conventional natural gas re-
sources, and though there are potential shale
gas deposits, none have been developed.
Resource Planning Problems
Construction of new power facilities in South
Africa was once a brisk business, with 31
GW of new capacity built between 1970 and
1990. In 1989, Eskom found itself with sub-
stantial surplus capacity and a reserve margin
exceeding 25%, yet it still projected a need
to build new power stations by 2007, particu-
larly coal and pumped storage facilities, to
meet the demands of its expanding economy
and mass electrification.
Government regulators believed that in-
vestment in private power generation would
balance the expected power deficit, but low
power prices failed to attract independent
power producers. South Africas mass elec-
trification program that began in the early
1990s and the ongoing rapid industrialization
of the country began to put enormous strain
on the electricity supply system. Reserve
margins slid to less than 5% by 2008 after
virtually no investment in power infrastruc-
ture for almost 20 years.
In 2003, rising electricity demand and
dwindling power supply margins finally
convinced government regulators to approve
Eskoms plans for building new power and
transmission infrastructure. Eskom also be-
gan reinvigorating its generation fleet by
bringing plants out of retirement and refur-
bishing many of its middle-aged plants as the
quickest and least-expensive first step to meet
the countrys insatiable appetite for electric-
ity. Simultaneously, Eskom began work on a
new generation of large-scale, high efficien-
cy coal-fired plants as well as demand-side
management and improved system efficiency
programs to trim demand growth. As an im-
mediate first step, Eskom added 1,000 MW
of diesel-fired combustion turbines to provide
new capacity as demand continued to rise.
South Africa began to experience wide-
spread rolling blackouts, culminating in the
South Africa began mothballing coal-fired plants almost 25 years ago when reserve
margins were high and independent power producers (IPPs) were invited to invest.
Ten years later, mass electrification, rapid industrialization, and low power prices
that failed to attract IPPs caused reserves to dip to dangerous levels. Camden was
one of three coal plants brought out of retirement to keep the lights on.
Dr. Robert Peltier, PE
Courtesy: Eskom
TOP PLANTS
October 2014
|
first government-declared national electric-
ity emergency, on what has become known as
Black Friday, Jan. 25, 2008. Escalating power
demand forced Eskom in March 2014 and three
times in June to again declare a grid emergency
and implement load shedding when demand
rose to 36 GW during the evening peak period
for the first time since Black Friday.
Refurbished Power Plants
The Camden Power Station was the first
plant selected by Eskom for its return-to-
service program. Camden consists of eight
200-MW units with a design efficiency of ap-
proximately 33.4%. Original site work began
in November 1962. The first unit was com-
missioned in April 1967, with the remaining
units commissioned through 1969. At the
time, Camden was the starting point of the
national power grid that used 400-kV lines to
interconnect the country.
Half of Camdens units were decommis-
sioned in 1988, and the remaining four units
followed in 1990 (also mothballed were the
Komati and Grootvlei coal-fired stations that
have also since been recommissioned). Cam-
dens Unit 6 was resynchronized in March
2005 and officially recommissioned that July,
followed by Units 7 and 8 in 2006; Units 3, 4,
and 5 in 2007; and Units 1 and 2 in 2008all
at intervals of about six months. At 2146 hours
on Sunday, Apr. 19, 2009, Camden was operat-
ing all eight units for the first time in 20 years,
adding 1,520 MW net to the Eskom grid. Re-
turning these old power stations to service is
an important mitigation measure in our energy
security efforts, South African President Ja-
cob Zuma said at Camdens recommissioning
ceremony on Oct. 23, 2010 (Figure 1).
Eskoms return-to-service program was
completed in 2014 with a total of 3,741 MW
at three recommissioned power plants now
supplying electricity to the national grid. In
spite of these additions to the grid, Eskoms
reserve margin still remains between 5% and
8%, which is insufficient to avoid periodic
load disruptions during weather events and
forced outages occurring during the peak us-
age hours in the early evening.
In addition to the three return-to-service
plants, new coal-fired stations have been
commissioned and more are in the pipeline.
By 201718, Eskom will have added over 17
GW of new capacity since 2005 and expects
to double its installed capacity to 80 GW by
2030, in addition to adding 4,700 kilome-
ters (km) of new transmission network. Two
world-class power projects now under con-
struction are the 4,800-MW Medupi Power
Station, which consists of six supercritical
units and will be the biggest dry-cooled plant
in the world, and the 4,800-MW Kusile Pow-
er Station, also with six units and the first
unit in South Africa with a flue gas desulfur-
ization system.
The cost to recommission the three plants,
according to Eskom, was $3.9 billion, with
$848 million spent at Camden. Eskom de-
scribed the Camden project at its recom-
missioning as the largest return to service
project in the world and has been successful-
ly reconstructed to add critical power capac-
ity onto the national grid at a fraction of the
cost of building a new facility. According to
Eskom, the recommissioning project saved
almost $9.5 billion compared to the cost of
new power stations of equal size, and the
electricity was available much sooner.
Restart Challenges
As might be expected, there were many chal-
lenges in resurrecting a coal-fired plant that
was mothballed for two decades. For example,
air quality technologies have progressed and
acceptable emissions levels have decreased.
At Camden, each of the eight units was retro-
fitted with fabric filters to reduce particulate
emissions. Eskom is also challenged by new
air quality regulations that begin to take ef-
fect in 2015. Some of its existing plant sites
do not have sufficient water supplies to op-
erate new air quality control equipment, and
there is insufficient surplus system capacity
to span a necessary four- to five-month ret-
rofit outage without adversely affecting the
nations electricity supply.
The return-to-service team also found it
difficult to procure important replacement
parts for equipment last made in the 1960s,
as most of the original manufacturers are no
longer in business. Reverse engineering of
many components was required in order to
source suitable parts. Finding and qualifying
operators and technicians was also a chal-
lenge. Most new members of the plant staff
were hired from local residents as part of Es-
koms commitment to the community. For-
mer workers also returned to help return the
plant to service and to train new employees.
Eskom upgraded Camdens plant control
system with the latest Siemens Power and
Process Automation (SPPA) T3000 digi-
tal control system. That project started in
February 2011 and will be completed by
the end of this year. The SPPA T3000 auto-
mates the operation of each unit, including
turbine controls, boiler controls, and coordi-
nation of other balance-of-plant equipment.
Perhaps the most important aspect of the
controls upgrades was the need to keep in-
terruptions in the operation of adjacent units
to a minimum when the upgrades were be-
ing installed.
Camden requires 3 million to 3.4 million
tons of coal each year to operate. The mine-
mouth sources are now closed, so Camden
receives coal from mines located up to 16
km from the station. Trucking that much
coal is impractical, so Camden now receives
about 50% of its coal requirements by rail,
thereby reducing damage to the roads. The
short-term coal delivery solution was to
modify rail containers for road travel in
order to stockpile coal until a new rail fa-
cility was constructed. The rail migration
strategy will ensure cost-efficiencies, capa-
bility of switching modes of transport from
the source of supply in the event of supply
challenges, minimise the social and environ-
mental impact, as well as improve safety on
the roads, Eskom said. The new rail sys-
tem, once fully operational, will allow up to
four train deliveries per day.
Dr. Robert Peltier, PE is POWERs
consulting editor.
1. Second career. Eskoms eight coal-fired units at the 1,600-MW Camden station were
first commissioned in 19671969. Following a period of excess capacity, all eight units were
mothballed in 1990. Fifteen years later, in March 2005, Unit 6 was revived to help Eskom in-
crease supply levels and potentially avert a power crisis, and all eight units were operating by
mid-2009. For scale, the stacks are 154 meters high and the cooling towers are 112 meters tall.
Courtesy: Eskom
|
October 2014 24
TOP PLANTS
Hitachinaka Thermal Power
Station Unit 2, Tokai, Ibaraki
Prefecture, Japan
Owner/operator: Tokyo Electric Power Co.
B
ad weather, unforeseen setbacks, and
even natural disasters are far from un-
heard of during power plant construc-
tion. But there may be no plant that experi-
enced the sort of construction hardships that
Tokyo Electric Power Co.s (TEPCOs) Unit
2 at Hitachinaka Thermal Power Station in
Ibaraki Prefecture did as it was taking shape
in the early 2010s.
Though TEPCO can trace its roots to The
Tokyo Electric Light Co., founded in 1883
during the Meiji Restoration period that saw
Japan emerge as a modern industrialized
nation, its name outside Japan has become
inextricably linked with the disaster at the
Fukushima Daiichi nuclear plant after the
Great East Japan Earthquake in March 2011.
Though that accident and the resulting
consequences for the Japanese nuclear indus-
try certainly earned the headlines they have
appeared in since, Fukushima Daiichi was far
from the only power plant damaged by the
earthquake. This is the story of one of them.
Leading the Way
Unlike many other industrialized nations,
Japan in the 2000s was not facing a future
of continually rising electricity demand. In-
deed, national electricity consumption has
remained largely flat since 2000. Japan, how-
ever, must import about 90% of its primary
energy needs, which makes energy efficien-
cy a national prioritysome might call it a
national obsessionto a degree seen in no
other country.
The need to rebuild after World War II
has given Japan a somewhat more modern
and advanced coal-fired fleet than most in-
dustrialized nations, and despite having no
indigenous coal resources, the nation has
continued to drive advances in coal genera-
tion technology. The net thermal efficiency
of Japans coal-fired power plantscurrently
around 42% lower heating value (LHV)
has been the highest in the world for decades,
well above that in comparable nations such
as Germany and the U.S. (average U.S. fleet
efficiency has hovered around 36% since the
1980s).
Japan was one of the first countries to em-
brace supercritical, and later ultrasupercriti-
cal (USC, defined as steam pressures above
3,495 psi and main and reheat steam temper-
atures above 593C/1,100F) coal generation,
and it has led the development of advanced
USC (steam temperatures above 700C) tech-
nology, with commercialization expected by
2020, according to the International Energy
Agency. The country is also a leader in in-
tegrated gasification combined cycle (IGCC)
generation, with a 250-MW IGCC plant op-
erating in Nakoso and two 500-MW plants
under development by TEPCO in Fukushima
Think your project was tough? Tokyo Electric Power Co. (TEPCO) finished one of the
worlds most efficient coal-fired power plant on time despite a 9.0-magnitude earth-
quake that devastated both the site and much of the country.
Thomas W. Overton, JD
Courtesy: TEPCO
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October 2014 26
Prefecture (see Does IGCC Have a Future?
in the July 2014 issue).
As part of its goal to maintain a modern,
balanced generation portfolio, TEPCO in the
late 1990s chose a site in the village of Tokai
in Ibaraki Prefecture for its newest, most ad-
vanced coal plant. Construction of Hitachi-
naka Thermal Power Station (HTPS) Unit 1
began in July 1999. The plant was built on re-
claimed land in a section of the North Wharf
of Hitachinaka Port.
Built by Hitachis power generation divi-
sion (now part of Mitsubishi Hitachi Power
Systems) the 1,000-MW USC plant employed
a variable-pressure, spiral-wound Benson
boiler supplied by Babcock-Hitachi K.K.
and equipped with Hitachis newly designed
low-NO
x
NR-3 burners and advanced steam
temperature controls. To enable the plant to
fire a variety of coals, superheater attempera-
tors were installed between each superheater
section. To meet strict national environmen-
tal regulations, the plant was equipped with a
flue gas denitrification system (supplied by
Hitachi) and a desulfurization system and an
electrostatic precipitator (the latter two sup-
plied by IHI). The plant was also equipped
with a fully digital large-scale monitoring
system.
At the start of commercial operations in
December 2003, Unit 1 achieved one of the
highest efficiencies of any coal plant in the
world: 45% LHV.
TEPCOs plans for HTPS included future
expansion, and space was left adjacent to
Unit 1 for another unit. Planning for it be-
gan not long after Unit 1 came online, and
construction began in October 2009. After
competitive bidding, Hitachi was again cho-
sen to lead construction and supply the ma-
jor components, with Babcock-Hitachi K.K.
also supplying the boiler. Like its sister unit,
Unit 2 would employ an USC variable-pres-
sure boiler, but Unit 2 also would include a
low-pressure turbine using the same 41-inch
blade design used in Unit 1s high-pressure
turbine.
A Major Shake-Up
Construction of Unit 2 was proceeding on
schedule in March 2011 with framing of the
boiler and turbine buildings under way.
At 2:45 p.m. Japan Standard Time on Mar.
11, a roughly 300-mile-by-120-mile section
of the subduction zone offshore of northern
Japan ruptured. The epicenter of the resulting
9.0 magnitude earthquakethe largest quake
ever recorded in Japan and the fifth-largest
recorded quake in modern historywas just
155 miles northeast of the plant site.
More than 15,000 people across Japan lost
their lives in the earthquake and subsequent
tsunami, and the economic losses have been
estimated by the World Bank at more than
$230 billion. Though Ibaraki Prefecture did
not sustain the widespread devastation expe-
rienced by the Tohoku region farther north
in part because it did not suffer as heavy an
inundation from the tsunamithe damage
was still enormous. Though only a few dozen
lives were lost, tens of thousands of buildings
were destroyed or heavily damaged. Peak
inundation from the tsunami was recorded
at 13.7 feet at the town of Oarai a few miles
south of HTPS.
HTPS suffered substantial damage from
the quake and flooding (Figure 1). Unit 1
tripped offline when the quake struck, but
the impact was only beginning. Because the
site was on reclaimed land, it suffered seri-
ous liquefaction, causing elements of the
plant to sink into the soil. Four workers at the
construction site fell to their deaths when the
scaffolding they were working on collapsed
underneath them. The coal-unloading termi-
nal suffered heavy damage, with the main
crane toppling over and the coal conveyer
belt knocked out of service because of liq-
uefaction of the ground underneath. Much of
the site was left under water even after the
tsunami receded.
Construction of Unit 2 had to cease as the
plant, and the nation as a whole, struggled to
recover from the disaster.
More than 4 million people in Japan had
lost electricity, and TEPCO saw approximate-
ly 25% of its generating capacity knocked of-
fline. While most of the worlds attention was
focused on the damaged nuclear plants to the
north, the crews at HTPS shifted from con-
struction to repair in order to get the plants
critical generation back into service.
Despite the heavy damage, Unit 1 re-
turned to operation in just two months, re-
starting on May 15. Though the coal transfer
equipment was still damaged, crews were
able to supply fuel to the plant with some
creative measures. With the coal-unloading
crane still out of service, coal was delivered
by bulk carriers equipped with their own
cranes. The coal was unloaded into trucks
instead of onto the conveyer, and the trucks
delivered the coal to a hopper that then fed
it into the plant. To support plant reliability,
this operation ran 24 hours a day.
Construction of Unit 2 resumed in late
May. The disaster had caused a two-and-
a-half month delay in the schedule, but the
now-urgent need for new generation because
of the nationwide nuclear shutdown meant
the plant had to be completed as soon as
possible. TEPCO staff and the construction
crews worked around the clock to get things
back on track, and amazingly, despite the in-
credible upheaval caused by the earthquake,
Unit 2 was finished and put into commercial
operation on schedule on Dec. 18, 2013, after
51 months of construction.
Running Smoothly
Unit 2 has performed as expected since
coming online, even during periods of peak
summer demand. It has achieved one of the
worlds highest thermal efficiencies, 45.2%
LHV, for coal-fired thermal power stations,
according to a TEPCO statement.
TEPCO, though, is not standing still. It an-
nounced shortly before Unit 2 came online
that it had agreed with Chubu Electric Power
Co. to build a third, albeit slightly smaller
(600 MW) USC unit at the HTPS site. That
unit will be 96.55% owned by Chubu Electric
and 3.45% owned by TEPCO. Construction
is planned to start in 2016, with operation
slated for 2020.
Thomas W. Overton, JD is a POWER as-
sociate editor (@POWERmagazine,
@thomas_overton).
1. Walloped. The Hitachinaka Thermal
Power Station suffered heavy damage from
the March 2011 earthquake and tsunami, with
its coal transport system knocked out of ser-
vice and much of the site flooded, as these
images show. Courtesy: TEPCO
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October 2014 28
TOP PLANTS
Mundra Thermal Power Plant,
Mundra, Gujarat, India
Owner/operator: Adani Power Ltd.
I
n the October 2013 issue of POWER, Tata
Powers 4-GW Mundra ultra-mega power
plant was recognized with a Top Plant
award in the coal category. This year POWER
recognizes another behemoth in the region
and not only for its scale.
Indias Power Sector
As of June 30, 2014, Indias installed power
capacity was roughly 249.5 GW. As much as
59.51% of this totalabout 148.5 GWwas
coal-based thermal power.
Based in Ahmedabad, in the state of Guja-
rat, Adani Power added 2,640 MW, or 15.5%
of Indias total power capacity additions of
about 17,000 MW, in the 201314 fiscal year.
Every addition of electrical power is crucial
in a country where roughly one-quarter of its
more than 1.2 billion people have no access
to electricity, according to the World Bank.
Adani Power operates coal-fired power
plants at three locations: the 3,300-MW
Tiroda plant, the 1,320-MW Kawai plant,
and the 4,620-MW Mundra Thermal Power
Plant (TPP). Three more are in development:
Chhindwara (1,320 MW), Dahej (2,640
MW), and Bhadreshwar (3,300 MW).
But the Mundra TPP, developed to pro-
vide power for the Adani Ports and Special
Economic Zone in Mundra, is the companys
flagship. Built at a cost of $4.6 billion ($3.7
billion of it debt and $939 million equity), its
four 330-MW subcritical units and five 660-
MW supercritical units produce a stagger-
ing 4,620 MW, making it the worlds largest
single-location private sector thermal power
station. The plant has an 85% load factor (the
national average is 74%).
Adani Power CEO Vneet Jaain explained
that all generation is supplied through power
purchase agreements: 46% to the state grid
and 54% to the national grid.
Design and Development
Our Mundra plant sets global benchmarks for
power producers in terms of size, efficiency
and sustainability, said Jaain. Despite its
enormous capacity, the facility stands unique
in the world when compared with area per
megawatt, located as it is on a very optimized
layout of 734 acres, alongside auxiliaries like
cooling towers, a 47-mld [million liters a day]
desalination plant and the flue gas desulfuriza-
tion [FGD] plant. Indias Central Electricity
Authority allows for 0.5 acre per megawatt,
which for the Mundra TPP could have meant
2,310 acresover three times its actual area.
The plant was readied in record time for
any Indian power developer. Groundbreaking
was in December 2006, and there were just 34
months between synchronization to the grid of
the 330-MW Unit 1 on May 23, 2009, and of
the 660-MW Unit 9 on March 5, 2012.
The plant was also the first to introduce
the 660-MW supercritical power technology
into India, with the commissioning of Unit
5 in December 2010, following installation
of the four 330-MW units. The 330-MW
Unit 1 was the first such subcritical boiler at
a power plant in India. The 660-MW boil-
ers were supplied by Harbin Boiler Co. and
the turbine generators by Dongfang Machin-
ery Co.; the 330-MW boilers were provided
by Babcock & Wilcox Beijing Co. Ltd. and
the turbine generators by Beijing Beizhong
Steam Generator.
The supercritical boiler is of a once-
through type, unlike the subcritical boiler,
where water and steam remain in saturated
condition in the boiler drum and water is re-
circulated for generation of steam. The 600-
MW supercritical turbine has three cylinders,
including a combined high-pressure and in-
termediate pressure section, and is configured
as tandem compound with four-flow exhaust
to the condenser.
As supercritical power plants operate at
higher temperature and pressure, they achieve
higher efficiencies (above 40%) than conven-
tional subcritical power plants (32%), said
Singh. The use of supercritical technology
also leads to significant CO
2
emission reduc-
tions, of above 20%.
Transmission Constraints
On Dec. 31, 2013, the plant set an Indian
power sector record by surpassing its 4,620-
MW nameplate capacity to generate 4,644
MW. To enable that record and to circum-
vent the governments infirm transmission
network, Adani Power had two power lines
constructed: the 433-kilometer (km) 400-
The nine-unit Mundra thermal power plant is one of the largest coal-fired plants in
the world, but it takes up minimal space and uses both fuel and water efficiently.
Sarosh Bana
Courtesy: Adani Power Ltd.
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October 2014 30
kV transmission line to transmit 1,000 MW
from Mundra to Dehgam in Gujarat and the
989-km 500-kV high-voltage direct current
(HVDC) bipole line with the capacity to
transmit 2,500 MW from Mundra to Mohin-
dergarh in the northern state of Haryana. The
latter is the first HVDC system in the private
sector in India.
While Siemens India was contracted to
build the HVDC substations at Mundra and
Mohindergarh, the HVDC line was con-
structed by Jyoti Structures Ltd., both works
taking three years till commissioning in July
2012. The Mundra-Dehgam line was con-
structed in sections by Jyoti and Kalpataru
Power Transmission Ltd., taking two years
till commissioning in July 2009.
Coal Supply
The Mundra TPP is a significant milestone in
the path to realizing Adani Powers target of
generating 20,000 MW by 2020. By that year,
the Adani Group is also seeking to mine 200
million metric tons (mt) of coal and handle
200 million mt of cargo from its ports.
At full load, the plant consumes about
55,000 mt of coal per day, though its yearly
consumption is between 16 and 17 million
mt. It runs on blended subbituminous coal,
about 70% imported from the Adani coal
mine in Bunyu, in Indonesias East Kaliman-
tan province, and the rest from the public sec-
tor Mahanadi Coalfields in the eastern Indian
state of Odisha. The coal is freighted to the
Adani Groups Mundra port, Indias largest,
which notched a throughput of 100 million
mt in 201314 and which is slated to become
the largest coal import terminal in the world.
From there, a high-speed conveyor belt con-
veys the coal to the plant 9.5 km away at
6,000 mt per hour.
The Mundra TPP, named after the coastal
town near which it is located in the arid Kutch
district, operates in far-from-conducive con-
ditions. We are constantly challenged by a
highly corrosive and saline ambient condi-
tion, with average wind speeds between 20
and 40 kmph that affect the performance of
the cooling towers, said Station Head Anand
Kumar Singh. Besides, our plant has been
designed to operate with high, 33% moisture
coal. High-moisture coal can choke coal-
handling chutes and coal feeders, reduce
mill output, and increase the heat rate, he ex-
plained. To reduce the moisture content, the
coal is pulverized to coal fines that are then
admixed in a drying chamber with a dry gas-
eous mixture.
Maximizing Seawater Usage
Mundra is Indias largest TPP to function on
a seawater-based closed-cycle induced draft
circulating cooling water system. The sys-
tem draws on seawater that is recycled up to
four times, conserving water and requiring a
smaller discharge pipeline into the sea than
an open-circuit cooling system.
Though seawater is used for the cooling
system, other auxiliary systems use seawater
purified by a reverse osmosis plant that can
produce 47 million liters of freshwater every
day.
Boilers require demineralized water that
is produced in demineralization plants. Each
660-MW boiler can convert more than 2,000
mt of water per hour into steam that is 250
times the atmospheric pressure and at a high
of 570C. Steam is sent to the turbine through
high-pressure pipes, after which it is collect-
ed and indirectly cooled in a condenser with
seawater and recycled back to the boiler.
Jaain said plant equipment is protected
against high corrosiveness and salinity by
using the right type of coatings, sacrificial
anodes, and impressed current cathodic pro-
tections. There is a three-year rolling sched-
ule for structural painting, a changeover
schedule for equipment that handles seawa-
ter, and anti-corrosive coatings for reinforced
cement concrete structures, he added. At
times, windborne drifts from the cooling
towers cause salt deposition on the switch-
yard insulators, which leads to tracking on
the high-kV insulators, resulting in unit trips.
To counter this, a special protective coating is
applied to the insulators at fixed intervals.
Environmental Controls
The FGD system, supplied by Alstom India,
requires only seawater as the adsorbent (no
alkaline chemicals) to reduce sulfur emissions
(Figure 1). Its simplified structurecom-
prising an adsorption tower, seawater supply
pump, and aeratorrenders operation and
maintenance (O&M) easy, said Associate Gen-
eral Manager (O&M) Girish Raghuwanshi.
No by-products are formed, and the adsor-
bents can be released into the sea after adjust-
ing their pH, chemical oxygen demand, and
dissolved oxygen, he explained. Increase of
sulfate in the seawater returned to sea is within
natural seawater variations, and emissions too
are well within the norms prescribed by the
Gujarat Pollution Control Board, which are
50 mg/Nm
3
for particulate matter, 100 ppm of
SO
2
, and 50 ppm for nitrogen oxides.
The Mundra TPP is researching the ex-
panded usage of the fly ash it generates, as
a liming material and as a feedstock for ver-
micomposting (converting organic waste into
fertilizer). Most of the fly ash is conveyed to
three 3,000-m
3
silos. From there, trucks dis-
patch it to makers of bricks, ceramics, cement
and roads; it also is packed in 1.4-mt bags for
shipment to the Middle East.
In the first experiment of its kind in India,
23 mt of vermicompost have been produced
to date and provided to surrounding villages,
said Adani Power COO Jayadeb Nanda. Its
production involves mixing equal portions
of fly ash and organic matter, in the form of
cow dung, and incubating this mixture with
anecic earthworms for 50 days. This spawns
phosphate-solubilizing bacteria that convert
the insoluble minerals from fly ash into more
soluble forms, enhancing the bioavailability
of the nutrients in the vermicomposted se-
ries. Nanda says cattle dung is available in
abundance from villages near the project,
facilitating the management and disposal of
agricultural as well as industrial wastes.
Wider Impact
The Mundra TPP is visited by power profes-
sionals and engineering students from India
and beyond for refresher courses and train-
ing provided by its state-of-the-art Training
& Research Institute.
With success comes responsibility, so we
take care to reinvest in protecting and devel-
oping the communities within which we live
and operate, said Gautam Adani, whose wife
Priti heads the Adani Foundation, the Groups
corporate social responsibility arm. We in-
vest 3% of our group profit in community
initiatives through the Adani Foundation. In
Mundra, these include a 50-bed hospital, mo-
bile health care, rural dispensaries, two large
and several small play schools, provision
of drinking water, watershed management,
counseling and assistance in advanced farm-
ing techniques, groundwater conservation,
and skill-building for traditional artisans.
Sarosh Bana is executive editor of
Business India.
1. Seawater system. At the Mundra
plant, only seawater is needed by the flue gas
desulfurization system to reduce sulfur emis-
sions to required levels. The nine units share
four stacks, Units 1 and 2, 3 and 4, and 5 and
6 having three separate stacks with two flues
each, while Units 7, 8, and 9 have one stack
with three flues. Courtesy: Adani Power Ltd.
Tight Fit, Tight Timeline
Converting the bottom ash handling process of a power plant
from a wet sluicing system to a dry system was key to future
permit compliance. The utility needed the new equipment to t
within the existing space, and it needed the project operational
with a brief outage. Mike Roush led a team that included the
client/owner, designers, vendors and construction personnel
in a closely coordinated effort that fullled both requirements.
The process included initial equipment selection, contract
award, construction coordination and startup coordination.
The plant is now operating seamlessly with a submerged ight
conveyor and dry ight conveyors that handle the bottom ash,
air heater ash and economizer ash.
WHERE WATER
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management, contract administration, eld work and startup of new
plants and plant upgrades. He is part of our team of experienced power plant
professionals who can help you identify the water alternative that ts:
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|
October 2014 32
TOP PLANTS
Sesa Sterlite Captive Power
Plant, Jharsuguda, Odisha, India
Owner/operator: Vedanta Resources PLC
T
his is a tough time to be running a busi-
ness as power-intensive as aluminum
smelting in India.
The economic boom that has lifted many
of the nations 1.2 billion citizens out of per-
sistent poverty has deeply challenged its abil-
ity to meet their electricity demands. Despite
significant advances over the past two de-
cades, one-quarter of the countryroughly
300 million peoplestill lacks access to elec-
tricity. Yet India has the worlds third-largest
installed capacity after the U.S. and China,
and is the fourth-largest electricity consumer
after the U.S., China, and Russia.
Many of Indias problems stem from a
dependence on coal. Despite efforts to foster
wind and solar energy (see Despite Chal-
lenges, India Banks on Renewable Energy
in the May 2014 issue) and other resources
such as hydropower, coal still accounts for
nearly 60% of the nations installed capacity.
Though India has abundant coal resources, it
has been unable to produce enough to meet
its needs, leading to persistent fuel supply
challenges.
In April 2012, the national government
took the unusual step of ordering national coal
supplier Coal India to sign supply agreements
with power generators, threatening penalties if
supplies fell below 80% of its commitments.
Indias chronic coal shortages have stemmed
from a mix of domestic problemsmany coal
deposits are located in protected areas or tribal
regionsand heightened competition from
other coal-consuming Asian nations such as
China. Even coal export behemoth Indonesia
has recently looked at cutting its exports to
meet domestic power demand (see Indonesia
Eyes Tightening Coal Exports in the August
2014 issue). The result has been a national coal
deficit in India that has exceeded 100 million
metric tons a year.
Meanwhile, Indias heavily regulated
power sector has struggled to find a balance
between ever-growing demand, social justice
concerns, and difficulties in expanding gener-
ation capacity. Ambitious plans to build a fleet
of huge modern ultrasupercritical coal plants,
announced in 2005, have fallen well short of
their goals. Only one such plant has been fully
commissioned, Tata Powers 4-GW Mundra
Ultra-Mega Power Plant (a POWER 2013 Top
Plant), while another, Reliance Powers six-
unit Sasan plant, is nearing completion.
Even the Mundra plant has struggled with
profitability after the government voided its
coal supply agreement with Indonesian pro-
ducers, a move that caused its fuel costs to
nearly triple. Problems such as these have left
investors skittish about funding generation
Operating a coal-fired plant of any sort in India is a challenge these days, but Sesa Ster-
lites 1,215-MW plant is also tasked with supplying vital power to an adjacent aluminum
smelter. Despite a difficult regulatory environment and ongoing coal market difficulties,
the plant has not just met expectations but has risen well above them.
Courtesy: Sesa Sterlite LLC
TOP PLANTS
October 2014
|
projects despite government efforts to relax
capital requirements for bidding.
The nation has also struggled with its trans-
mission infrastructure. The widely publicized
blackouts in July 2012 that knocked out power
for more than 60% of Indias population, in-
cluding most of Odisha State, were blamed
on inadequate interregional transmission and
poor grid management. Nationwide, transmis-
sion losses are estimated to be about 24%, ac-
cording to Indias Central Electric Authority,
well above levels in developed countries.
Vital Operations
Aluminum smelting is one of the most pow-
er-intensive industrial processes. The primary
method used, the HallHroult process, in-
volves heating a mixture of aluminum oxide
and other compounds with electric current
in a smelting cell until the molten aluminum
separates out. Not only does this method con-
sume enormous amounts of electricity, but
the cells also must be continually heated or
the mix of materials will solidify and the cell
will be useless until repaired. This means a
power loss across an entire plant could spell
disaster, which is why aluminum smelters are
typically located near large power plants.
London-based Vedanta Resources is a
globally diversified natural resources com-
pany with operations in Indiawhere it is
the nations largest mining firmAustralia,
South Africa, Namibia, and other countries.
Vedanta subsidiary Sesa Sterlite Ltd. (SSL)
is one of the countrys largest commercial
power producers as well as a major natural
resources firm. Since the mid-2000s, SSL has
been developing a huge aluminum produc-
tion zone in Jharsuguda in the eastern state of
Odisha. Initial plans envisioned a 0.5 million
metric tons per annum (mtpa) smelter, to be
eventually expanded to 2.6 mtpa (Figure 1).
Odisha has abundant reserves of both bauxite
(aluminum ore) and coal. Phase 1 of the proj-
ect, comprising the 0.5-mtpa smelter, was
completed in 2009, while Phase 2, a 1.25-
mtpa expansion, was completed in 2011.
Such a massive project would have equal-
ly massive power demands, and relying on
the national grid for power, even if it came
from a nearby plant, would be risky. To en-
sure reliable operations would mean building
a captive power plant to supply the project
directly. SSL soon drew up plans for what
would be the largest captive power plant in
the entire country.
Construction began in 2005, and the first
unit, Unit 3, came online in July 2008. The
last of nine units came online in early 2010.
The project was completed without a single
lost-time accident.
The plant consists of nine 135-MW sub-
critical pulverized coal, single-reheat boiler
units, utilizing corner tangential firing and
natural circulation, supplied by Shanghai
Electric Co. Each boiler uses four bowl mill
pulverizers to prepare the coal for combus-
tion. The boilers are rated for 440 tons per
hour of main steam, at 2,070 psi and 1,005F
at the superheater outlet. Each boiler supplies
steam to a single double-cylinder, 39-stage,
double-flow, extraction and condensing
steam turbine.
The plants environmental controls are
among the most advanced in India. Fly ash is
captured with electrostatic precipitators and
fabric filters and is recycled for use in road
construction and fill.
The plant is the first coal-fired unit in the
country to employ high-concentration slurry
disposal of dry and bottom ash. This system
combines both ash streams into a mostly
solid slurry to reduce water consumption and
fugitive dust, as well as requiring a smaller
footprint compared to conventional ash-
handling systems. The high concentration of
solids means the slurry forms a natural slope
in the disposal area without the need for me-
chanical spreading.
The plant employs counter-flow forced
cooling towers and multi-flue stacks. Process
water is sourced from the nearby Hirakud
Reservoir, while coal is supplied from the
Mahanadi Coal Fields outside Jharsuguda.
Exemplary Performance
Since coming fully online, the SSLs captive
power plant has received numerous honors
for excellence in operations and energy ef-
ficiency. It has received the National Energy
Conservation Award bestowed by the Bu-
reau of Energy Efficiency in 2011 and 2012,
and in 2013 received both the Confederation
of Indian Industrys National Award for Ex-
cellent Energy Efficient Unit and the India
Power Award from the Council of Power
Utilities. The overall Jharsuguda operation
was also honored for its commitment to sus-
tainability with a Green Manufacturing Ex-
cellence Award from consulting firm Frost
& Sullivan.
These honors have come in large part from
the plant staffs relentless drive to improve
the plant heat rate and cut its fuel consump-
tion. The overall plant heat rate has been re-
duced from 10,627 Btu/kWh in 2010 to 9,591
Btu/kWh in 2013, an impressive achievement
for a subcritical plant. Coal consumption has
been cut from 893 grams per kilowatt-hour
(g/kWh) to 806 g/kWh over the same period.
Environmental performance has also been
improved. Upgrades to reduce particulate
emissions have cut them from 181 mg/m
3
in
2010 to under 30 mg/m
3
currently.
The plants biggest challenge, not sur-
prisingly, has been finding adequate fuel to
operate. To address its fuel challenges and
increased costs of imported coal, SSL has
begun blending and burning coal purchased
in spot-market auctions. This approach al-
lows it to balance its fuel costs depending
on the price of imported coal. Currently, the
plant burns up to 70% auction coal, and fu-
ture plans are to maximize this approach to
reduce overall fuel costs.
The plant has also gone beyond the call
of duty in other ways. Thanks to its reliable,
efficient generation, the adjacent 0.5-mtpa
smelter has been able to run above rated ca-
pacity despite continuing difficulties with the
local grid. Meanwhile, the 1.25-mtpa expan-
sion has been unable to start up because of
ongoing disputes with the Odisha state gov-
ernment over tariffs on the power it would
be using from SSLs 2.4-GW independent
power plant in the same industrial zone, but
because the captive power plant has a 100-
MW surplus, Vedanta officials said in the
companys second quarter 2014 earnings call
that it plans to begin limited operations at the
larger smelter this year using power from the
captive plant.
For achieving exemplary performance in
a highly challenging environment, Sesa Ster-
lites captive power plant at Jharsuguda is a
deserving POWER Top Plant.
Thomas W. Overton, JD is a POWER
associate editor.
1. Vital partner. The captive plant at Jharsuguda powers an adjacent 0.5-mtpa aluminum
smelter. Courtesy: Sesa Sterlite LLC
|
October 2014 34
TOP PLANTS
Trianel Coal Power Plant
Lnen, North Rhine-Westphalia,
Germany
Owner/operator: Trianel Kohlkraftwerk Lnen GmbH und Co. KG
G
ermanys energy transitionEner-
giewendehas made a lot of head-
lines. Whether you agree with the
countrys energy policy or not, there is no
denying that it has spurred the growth of re-
newables. Even so, change takes time, and
a bridging technology is necessary if the
country is to reach its goal. (To learn more
about recent changes to Germanys energy
policy, see Germany Reforms Renewable
Energy Laws listed with the August 2014
issue features online at powermag.com.)
With nuclear power clearly on the way out
in Germanyeight of the countrys 17 re-
actors were permanently shut down months
after the Fukushima disaster in 2011, and all
of the others are slated to close by the end
of 2022coal-fired plants offer one proven
alternative to fill the void.
Making Choices
The 750-MW Lnen hard coalfired power
plant lies on the Datteln-Hamm Canal, a ma-
jor inland waterway in northwest Germany.
Trianel Kohlkraftwerk Lnen GmbH und Co.
KGa collaboration of 31 municipal utili-
ties and regional energy suppliersselected
the location for several reasons.
A coal-processing company had previ-
ously used the site, so it was already set up
with good transport connections for coal de-
livery. The available plot size was suitable
for plant development, and the canal offered
a readily available source of cooling water
for the plant. In addition, a 380-kV trans-
mission system was relatively easy to link
to from the site.
Although the location offered several ben-
efits, it also came with challenges. Much of
the ground at the building site was fill com-
posed of mine tailings, which meant that the
subsoil needed extensive foundation work to
accommodate the heavily loaded structures
of a power plant. In the end, 811 concrete
piles nearly 1 meter (m) in diameter at depths
varying between 25 m and 32 m were used to
create stable foundations for the largest struc-
tures, such as the boiler and turbine buildings.
An additional 1,264 concrete piles and 1,992
stone piles were used for other structures on
the site.
Trianel received governmental approval
to begin construction on May 6, 2008. Two
days later, the collaboration of utilities and
energy suppliers that make up the share-
holders of the company decided unani-
mously to go forward with the project. The
company selected Siemens AG to be the
general contractor for the turnkey plant.
IHI Corp. was chosen to manufacture the
boiler with AE&E Austria GmbH & Co KG
(later acquired by ANDRITZ) brought in to
do the installation.
The 100-m-tall boiler support struc-
ture was a critical piece of the puzzle.
After considerable deliberation, a Chi-
Courtesy: Trianel Kohlkraftwerk Lnen GmbH und Co. KG
Although Germanys Energiewende is all about reducing consumption and tran-
sitioning from nuclear and fossil fuels to renewable energy, it hasnt completely
halted the development of new coal-fired facilities. The Lnen plant demonstrates
that even in countries keen on renewables, coal is still an important resource.
Aaron Larson
TOP PLANTS
October 2014
|
nese companyMatsuo Steel Structure
Co., Ltd.was chosen to manufacture
the components under the watchful eye of
specialists from TV Rheinland and Tri-
anel employees. Because the accuracy and
quality of work was so important, Matsuo
assembled the entire boiler furnace roof in
Shanghai to test the dimensions and verify
a precise fit prior to shipping the pieces
to the plant.
Efficiency Is the Key
The plant features a Siemens SST5-6000
steam turbine, a SGen5-3000W generator,
and the SPPA-T3000 instrumentation and
control system. The highly efficient steam
turbine is well suited for baseload opera-
tion, but its design characteristics are also
a good match for highly responsive ramp-
ingan important aspect due to the vari-
ability of renewable resources and their
prevalence in Germany.
In the coming decades, conventional
power plants will play a major role in the
German energy transition and will still be
the backbone of security of supply. They
guarantee supply during windless and sun-
less periods, said Stefan Paul, managing
director of Lnen.
Trianel expects Lnen to achieve an 80%
capacity factor during its first full year of
operation, providing electricity for about 1.5
million households, as well as supplying the
city of Lnen with district heating. With an
electrical efficiency of 45.95%, the plant is
the cleanest and most efficient hard coal
fired power plant in Europe. Compared to an
average efficiency of 36% for older plants,
Lnen will emit about 1.2 million fewer tons
of CO
2
per year.
The highly efficient flue gas streams
cleaning process allows us to significantly
remain below the German federal emission
guide values regarding air and waste water
and, thus, to minimize impact on man and
environment in the plants catchment area,
Paul said.
The plant requires about 2 million tons
of coal each year. The coal is sourced from
various mining regions around the world and
delivered to the port of Rotterdam by bulk
carriers. From there, it is loaded onto barges
(typically four per day) and delivered to the
plant by Rhenus SE & Co. KG via the Dat-
teln-Hamm Canal.
The coal is unloaded using cranes (Figure
1) at the plant-owned port and is stored dust-
free in two silos with a 200,000-ton total ca-
pacityenough to operate the plant for about
30 days at full load. Fugitive dust emissions
are virtually eliminated through the use of
fully enclosed conveyor systems.
The coal is conveyed from the silos to
four cast bunkers that can hold 800 tons each
in the steam generator building. It is then
pulverized and fed into Lnens 70-m-tall
boiler. During the design phase, the company
contemplated using a relatively new alloy
T24to construct the boiler tubes, but in
the end, the more proven T23 was used. The
engineers now look back with no regret,
because other German plants have run into
problems with T24, some even having to re-
place the material.
The plant operates with supercritical steam
at a pressure of 285 bar (4,134 psia) and tem-
perature of 605C (1,121F). The steam is first
directed to the high-pressure turbine, follow-
ing which it is reheated and directed to the
medium-pressure turbine, and then to two
low-pressure turbines.
Controlling Emissions
Lnen utilizes a DeNO
x
process between its
reheater and air preheater. In the process, ni-
trogen oxides react with ammonia and, with
the help of catalysts, are transformed into
nitrogen and water vapor. The plant also has
an electrostatic precipitator with 40 hoppers
for particulate removal and a flue gas scrub-
ber to reduce SO
2
emissions. The resulting
gypsum and fly ash are recycled for use in
the building materials industry and by ce-
ment plants.
Although carbon capture and storage tech-
nology is still being developed and tested
around the world, the facility was designed
with room set aside so the plant can be retro-
fitted with such a system if it is proven to be
viable on a large scale in the future.
Despite difficulties arising from the spe-
cial licensing situation for coal-fired power
plants in Germany, we have managed to
build a plant to the highest technical stan-
dards that by far surpasses the contractually
agreed performance values for output and
efficiency, said Rainer Hauenschild, CEO
of the Energy Solutions business unit at Sie-
mens Energy.
It Takes a Village to Raise a Plant
At the height of construction in 2011,
more than 1,400 workers were employed at
Lnen. The plant currently employs about
90 personnel, including Trianel, STEAG
management, and Microca port operations
employees. In addition to the permanent
plant staff, it is estimated that the facility
supports another 400 jobs through its sup-
pliers and contractual partners.
Managing the state-of-the-art and most
efficient coal-fired power plant in Europe
not only inspires me as an engineerit is
also a heartfelt matter. Together with our
employees and service providers, we are
working to an even more flexible reaction
on the volatilities of power demand and to
the sites optimal utilization. The bench-
mark towards our 31 shareholders is the
steady technical and commercial improve-
ment of the plant, said Paul.
Congratulations to Trianel, Siemens, and
all of the companies that completed the con-
struction and continue to support the opera-
tion of the facility, which is a worthy recipient
of a POWER Top Plant award.
Aaron Larson is a POWER associate
editor (@AaronL_Power,
@POWERmagazine).
1. No lazy river here. Coal is delivered to Rotterdam on ships and then transported by
barge to Lnen, where cranes are used to unload it. Courtesy: Trianel Kohlkraftwerk Lnen
GmbH und Co. KG
|
October 2014 36
OPERATIONS & MAINTENANCE
Prepare Your Coal Plant for Cold
Weather Operations
Cold temperatures can be dangerous for personnel and often cause havoc for
power plant equipment. Suitable preparation can mean the difference be-
tween a quiet shift and a nail-biting struggle.
Aaron Larson
C
old temperatures are nothing new, but
extreme winter weather has been in
the headlines more and more in recent
years. Many of us had never heard the term
polar vortex before last winter, but ear-
lier this year it seemed as if the Arctic polar
vortex was dipping down into the U.S. on a
regular basis.
For coal-fired power plants, changing
seasons bring a variety of challenges. Cold
weather, snow, and ice each cause different
problems. Coal deliveries via rail can be de-
layed due to train tracks being impassable as
a result of winter storms. Once a train does
arrive, frozen fuel can result in a large por-
tion of the delivery being stuck inside the
cars. When temperatures remain below zero
for weeks on end, the problem can be nearly
impossible to prevent.
Design Sets the Stage
Basin Electric Power Cooperative is one of
the largest electric cooperatives in the U.S.
The companys core business is generat-
ing and transmitting wholesale bulk electric
power primarily to its 137 member rural elec-
tric systems, which are located in nine states:
Colorado, Iowa, Minnesota, Montana, Ne-
braska, New Mexico, North Dakota, South
Dakota, and Wyoming.
Basin Electric gets about 60% of its nearly 4
GW of owned generation capacity from coal-
fired power plants located mainly in North
Dakota and Wyoming. Its first power plant
the 222-MW Leland Olds Unit 1 located near
Stanton, N.D.went online in January 1966
and was the largest lignite-based power plant
in the Western Hemisphere at the time.
We learned a lot from the facility in the
early years, John Jacobs, vice president of
operations for Basin Electric told POWER.
Most of our design specifications were de-
veloped as a result of lessons learned at the
Leland Olds Station. Contracts now call for
control between 40F and 120F. We are very
diligent in ensuring that those climate ex-
tremes are met.
Heavier insulation, larger heating sys-
tems, and heat traceuse of an electrical
heating element in direct contact with a
componentcan be added to protect against
freezing temperatures in cold weather cli-
mates. But even when the proper design
parameters are met, trouble can still arise.
Basin Electric has learned where weak
points exist through experience. The com-
pany uses its computer-driven preventive
maintenance system to queue up projects
and manage preparations.
Once one winter is complete, we begin
working on the next winters projects during
the spring and summer, said Jacobs. Heat
trace, insulation, siding, it runs the gamut of
anything that might affect you that youve
found out from the previous year. You put
in work requests for those that come up year
after year. Of course, you want to get those
done when the weather is warm, so people
dont have to fight the extreme cold during
the winter months.
Xcel Energy performs a similar proce-
dure. Each year its power plants review, up-
date, and perform winterizing preparation
tasks in accordance with a procedure and
checklist. The checklist follows the North
American Electric Reliability Corp. winter-
ization guidelines (developed in response to
rolling blackouts and natural gas delivery
interruptions experienced in the Southwest
in February 2011) and also has a section for
plant-specific tasks. The companys preven-
tive maintenance crews regularly check all
winter protection items, such as heat trace,
1. Heavy duty slider. Sliding doors hold up better in windy conditions. Courtesy: Tucson
Electric Power (TEP)
October 2014
|
heaters, and insulation, to ensure that they are
in place and working as required.
Southern Regions Are Not
Immune
A person might think that cold weather con-
cerns are isolated to northern climates, but
that is not the case. Plants in the southern U.S.
also face challenges in the winter, as THE
BIG PICTURE: A Generation Freeze in this
issue shows. The Springerville Generating
Station is a prime example. The plantop-
erated by Tucson Electric Power (TEP)is a
1,600-MW four-unit coal-fired facility locat-
ed in eastern Arizona. (For more on the plant,
see Springerville Generating Station Earns
PRBCUG 2014 Honors in the July issue of
POWER, online at powermag.com.)
Sited at an elevation 7,000 feet above sea
level, winter temperatures are regularly be-
low freezing. Tracy Ortiz, fuel superinten-
dent for Springerville Generating Station,
gave a presentation during the 2014 Pow-
der River Basin Coal Users Group Annual
Conference, which was held in conjunction
with the ELECTRIC POWER Conference &
Exhibition. She noted several improvements
that the plant had made to deal with cold win-
ter weather.
2. Ice is the enemy. Employees at the Antelope Valley Station in North Dakota developed
a solution to keep ice from building up around the plants cooling tower fans. Courtesy: Basin
Electric
|
October 2014 38
Ortiz explained that keeping the heat inside of plant buildings had
been troublesome. Keeping doors closed was half the battle. The plant
was built with a lot of swinging doors that were easily caught by the
wind. One big improvement was changing all exterior doors to sliding
doors (Figure 1).
The plant chose to install a model made by PS Doors. The com-
panys industrial sliding door is designed specifically to withstand the
abuses of industrial applicationsespecially the effects of positive and
negative draft or wind loadsmaking it a good choice for use in power
generation facilities, which require sturdy, maintenance-free doors.
The little things that we have done have really made a difference,
said Ortiz. The doors have helped keep the heat in the buildings
while at the same time keeping dust out.
According to Brad Watson, senior director for corporate communi-
cations with Luminant, the Dallas-based utility has literally thousands
of items on its winter weather preparedness checklist too. Luminant
increases management and craft staffing on all shifts for the duration
of cold weather events, and it coordinates closely with the Electric
Reliability Council of Texas, the independent system operator for the
region that manages the flow of electric power to around 24 million
Texas customers.
In anticipation of extreme temperatures, we stockpile fuels, erect
windbreaks, and utilize large radiant heaters to supplement existing
freeze protection and insulation, said Watson.
Use What Youve Got
In some cases, the people most familiar with a problem can help de-
velop a unique solution. At Basin Electrics Antelope Valley Station
(AVS), the cooling towers presented a source of recurring trouble
during the winter. The original design included a heat trace system
around the periphery of the cooling towers to prevent ice from form-
ing and interfering with the blades of the cooling tower fans (Figure
2). Although the load on the fans is minimal during winter months,
they must continue to rotate to keep air flowing nonetheless.
The original heat trace was difficult to maintain and stopped
working after only a few years. Replacement was problematic due
to the location and time constraints on the work. Several employ-
ees who had worked on the system got together and collaborated
on a solution.
The purpose of the cooling tower is to remove heat from the cool-
ing water used to condense steam exhausted from the plants turbine
generator. The water is typically returned to the cooling tower at a
temperature of about 80F.
The answer was to pipe some of that relatively warm water into
a ring surrounding the fan blades. The warm water keeps ice from
building up and eliminates the need for heat trace. Its more economi-
cal too. The new design utilizes waste heat that needs to be removed
anyway and saves energy that had been consumed by the electrical
heat trace.
At the Springerville plant, conveyors offered an opportunity for
improvement. Because some were completely exposed to weather,
ice frequently developed on walkways in the winter, creating the
potential for injuries from slips and falls. The solution was to install
elevated grating (Figure 3) to provide traction for workers, thus re-
ducing the hazard.
Additionally, some of the Springerville buildings were constructed
with no heating system at all. Ortiz explained that TEPs maintenance
crew installed diesel heaters in these buildings (Figure 4) to keep ar-
eas above freezing. From December through the end of March, the
heaters are used regularly.
While heat trace offers vital freeze protection in cold weather cli-
mates, at one of Xcels facilities, workers found that some installation
techniques were resulting in electrical shorts. Originally, the heat tape
was doubled back on itself any time the tube trace ended at an instru-
ment enclosure. In time, continuous heating and cooling of the heat
trace caused the insulation to break down and short out.
Similar to Basins experience, the people performing the repairs
came up with a solution to the problem. The electricians drilled a
hole through the wall of the enclosure and mounted the power con-
nection box directly to the enclosure instead of to the tube, which
eliminated the short radius turn in the cable. The jacketed cabling
was taped and sealed inside the enclosure to help prevent escaping
moisture from potentially contaminating and freezing the insulation.
Problem solved!
Every Fuel Supply Situation Is Unique
Although Basin Electrics four largest plants are all coal-fired, each
is unique in its layout. Two are lignite-based (AVS and Leland Olds)
while the other two (Dry Fork Station and Laramie River Station) use
Wyoming subbituminous coal. Dry Fork and AVS are mine mouth
plants, but Leland Olds and Laramie River rely on rail delivery for
their fuel supply, so none are alike.
Lignite coal is roughly 35% water, so during long periods of sub-
zero temperatures, coal in the railcars sent to the Leland Olds facility
will freeze along the sides and start to build up in the cars. In some
cases, the train will end up back hauling 10% to 15% of the coal de-
livered, because it wont dump out of the car. Using a release agent
that can be sprayed into the cars prior to loading is an option, but even
that isnt foolproof.
The Wyoming plants are far enough south where you dont typi-
cally have long, extreme cold snaps. They also have less moisture in
the coal, so its not as big of an issue for them, said Jacobs.
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Fuel stockpiles are another item that must
be considered going into winter. Mine mouth
plants have less to worry about, but for plants
that rely on rail transport, beginning the win-
ter with an adequate stockpile of coal is very
important.
You make hay when you can, Jacobs
said. Youre less loaded in the spring and
fall of the year, so there is some surge to the
stockpile during that timeframe. In the sum-
mer and winter months, your stockpile will
drop to less than optimum because youre
running hard.
Basin Electric targets around 500,000 tons
of coal in ready stockpile at Leland Olds.
Laramie River is a larger facilitythree
560-MW unitsso the target for that plant is
typically about 1 million tons. Although AVS
is a mine mouth plant, it still keeps 100,000
tons in its stockpile, but Dry Fork doesnt
maintain a stockpile at the facility because
there is adequate reserve storage between the
plant and the mine.
According to Xcel Energys Energy Sup-
ply business group, it also sets inventory
goals as a precautionary measure because
they anticipate weather-related disruptions
to fuel delivery. During the coldest time of
the year, an anti-freeze treatment is used on
both the coal cars and on the coal to prevent
buildup. By using coal car shakersdevices
that clamp onto coal cars to help get the coal
outXcel says that most of the coal is suc-
cessfully removed from the cars.
People Make the Difference
Plants dont operate without people, and
people can be affected by winter storms
even more than equipment is in some cases.
Xcel noted that it has a robust program to
reduce risk to personnel. The company typi-
cally starts each cold weather season with
crew briefings on cold weather and the haz-
ards involved so that the issue is top of mind
for all employees.
Xcels program includes such measures
as overhangs and metal roof ice busters to
prevent falling ice near doorways from strik-
ing workers. Signage is also important in
falling ice areas, and barricades are installed
where necessary. Salt and sand resources are
staged near plant doorways and walkways to
address icing issues, but boot cleats are also
important gear provided to employees, be-
cause ice is inevitable.
At Basin Electric, when the weather
forecast indicates that a significant storm is
approaching that is expected to be a major
event, management will either call the on-
coming operations shift in early or hold the
off-going shift late so the crew doesnt find
themselves shorthanded.
A 12-hour shift can be very long, es-
pecially if its a really busy time when the
weathers not cooperating and the equip-
ments not behaving, said Jacobs. Well
pay the overtime to keep people there and ac-
crue that cost because safety is a priority. We
want the employees families to know that
theyre being fed, theyre being kept warm,
and being taken care of.
Basin Electric stocks food items at each
power plant, specifically for extreme weather
events. The company also has cots on site to
make sure stranded employees have a place
to rest.
The most important aspect of a utility is
its people to run these multi-million dollar
machines, so we take care of our people. Its
not just that we dont want people driving
out in the winter weatherthats very im-
portantbut if they are scheduled to work
over a weekend because we expect a severe
weather incident to come, we take care of
them in that case too, said Curt Pearson,
media and community relations manager for
Basin Electric.
Planning Ahead Saves Pain
In many parts of the countryand world
winter is bound to bring challenges. The trick
is to prepare as much as possible to reduce
the likelihood of problems that could take a
unit offline or expose personnel to unneces-
sary risks. A little planning goes a long way
toward making for an uneventful season.
Aaron Larson is a POWER associate edi-
tor (@AaronL_Power, @POWERmagazine).
3. Traction makes a difference. Walking surfaces exposed to weather were frequently
icy. Elevated grating increased safety. Courtesy: TEP
4. Adding heat. Unheated buildings are bound to be cold. Using portable heaters at least
keeps them above freezing. Courtesy: TEP
|
October 2014 40
Prepare Your Gas Plant for Cold
Weather Operations
Cold weather operations are challenging for plant designers and operators
alike, particularly where severe winter weather is rare. However, another
cold winter is expected, so now is the time to review the lessons learned
by many plants after the February 2011 Southwest freeze.
A
sustained Arctic blast composed of
freezing rain, record snowfalls, and
high winds hit 22 states, from Mexico
to New England in early February 2011. The
extreme weather severely affected the power
generation and delivery systems in the south-
western U.S. beginning on Tuesday, Feb. 1,
finally diminishing the following Saturday.
El Paso, for example, experienced the sec-
ond-worst winter weather in a century, and
the worst in 50 years, with 60 consecutive
hours of temperatures below 20F. The tem-
peratures in the Electric Reliability Council
of Texas (ERCOT) region during the system-
wide emergency ranged from 11F to 35F,
equivalent to 5F to the low teens when the
wind chill factor is considered. In Austin,
temperatures remained below freezing for
over 70 consecutive hours.
In Texas, the deep freeze affected every
generating company. A reported 225 in-
dividual units, including several recently
constructed plants, experienced a trip, were
derated, or failed to start, reflecting 14,855
MW of unplanned unavailable capacity.
Coupled with 12,413 MW of prescheduled
generation outages, ERCOT was unable to
serve electricity demand, and the results were
widespread outages and rolling blackouts
caused by frozen equipment (Figure 1).
The Federal Energy Regulatory Com-
mission and North American Electric
Reliability Corp. (NERC) subsequently
released their report Outages and Curtail-
ments During the Southwest Cold Weather
Event of February 15, 2011 in August
2011. That report describes the cause of
the Texas extreme weather event as well
as several proactive measures that would
improve plant reliability in the future. Ac-
cording to the report, while many gen-
erators were proactive in their approach
to winterization and preparedness, others
were not. A key finding of the report was
that the lack of any state, regional or Reli-
ability Standards that directly require gen-
erators to perform winterization steps has
left winter-readiness dependent on plant or
corporate choices.
Re-Learned Lessons
Plant outages caused by extreme cold weath-
er events (as well as impacts on natural gas
pipelines that supply the rising number of
gas-fired combined cycle plants now oper-
ating) appear to be more problematic in the
southern region of the U.S. Natural gasfired
plants in the northern states continued to op-
erate reliably because they were designed
to do so from the outset. For example, Min-
nesota Municipal Power Agencys Faribault
Energy Park, located in Faribault, Minn.,
routinely operates for months at a time with-
out a problem when the outside temperature
is below zero (see How to Make a Power
Plant a Welcome Neighbor, March 2008).
In contrast, plants built in the southern
states, from Florida to Arizona, are often
of an outdoor design that makes retrofit an
expensive proposition. Regulators in some
NERC regions, such as ERCOT, have since
become more proactive with plant inspec-
tions and third-party design reviews of plants
vulnerable to extreme cold and are ordering
temperature-related reliability upgrades.
Our survey of several of the lessons-
learned reports prepared in the wake of the
February 2011 freeze found a number of
common failure modes, many of which have
since been the subject of reliability upgrades
at many affected plants.
Instrument and Sensing Lines. Many
plants reported outages caused by frozen
boiler airflow, deaerator level, and boiler
drum instrumentation and transmitters. A
commonly reported problem was a unit trip
from a low drum level signal caused by fro-
zen instrumentation and sensing lines.
According to Black & Veatch, which ana-
lyzed the impact of the event on one Texas
utility, The frozen sensing lines prevented
the automatic drum level control system from
operating to maintain the water level in the
1. Frozen solid. Many combined cycle plants located in southern states were unable to reli-
ably start or run during the freeze that occurred in early February 2011 because important equip-
ment was not cold-weather protected, as can be seen with this heat-recovery steam generator
steam desuperheating station. Source: POWER
October 2014
|
drum within predetermined limits to prevent
damage to the boiler. Damage could be caused
either by running the drum dry, resulting in
major damage due to overheating of drum and
tubes, or by allowing the level to rise too high,
which can result in carrying over slugs of wa-
ter into the steam tubes and possibly into the
steam supply lines to the turbine. To the op-
erators credit, the drum water controls were
placed into manual mode, and drum water lev-
els were monitored by operators with radios
reporting status to the control room.
At a different plant, once the unit tripped
and residual heat was lost in the water sys-
tems, other instrumentation and sensing
lines froze, thereby preventing a unit restart.
Another plant reported the same problem,
though it was able to continue operation at
reduced load.
The solution to frozen instrumentation and
sensing lines (particularly, critical drum level,
feedwater flow, and steam flow transmitters)
must be holistic. For example, there must be
freeze protection in the main circuit breaker
panel that powers the instruments and the
panel board transformer, insulated and heat-
ed drum level transmitter(s) enclosure(s), a
means to continuously monitor enclosure
temperature, and a means to confirm opera-
tion of the heat trace cable used throughout
the system.
Heater strips in instrument cabinets were
often overcome by freezing temperatures,
though additional insulation and additional
heating strips often solved this problem. A
single point failure in the heating system can
cause a trip of the unit. Modern heat trace
cables are available that are prefabricated,
not easily broken, and have a self-regulating
heating element. Some users report installing
lights to give a visual indication of the box
temperature. Steady lit means the circuit is
on and the box is at set temperature, flashing
light means the circuit is on but the box is
below set temperature, and when the light is
out it means there is no power available to the
heater. This approach works well when the
enclosure is covered with an insulating blan-
ket and operators can see the lights at eleva-
tion from ground level (Figure 2).
Pipes and Valves. Several plants report-
ed that frozen steam turbine drain lines pre-
vented unit restart until ambient temperatures
rose above freezing so the ice could melt. An-
other unit experienced frozen deaerator level
control sensing lines that failed to signal the
need for makeup water, causing a plant shut-
down signal generated by low boiler feedwa-
ter pump suction pressure.
Another utility attempted to start a unit
that was offline when the sub-freezing tem-
peratures hit, but frozen instrument lines pre-
vented the restart. Heat tracing of instrument
and sensing lines is commonly found at most
outdoor plants, though heat tracing is used to
prevent freezing, not to thaw frozen lines.
Users also reported problems with small
piping supports, because they can act as a heat
sink and cause the pipe to freeze even when
insulated. The same applies to external pipe
hangers that penetrate pipe lagging. Heat sinks
should be eliminated from plant piping.
Non-heat-traced pipes froze at several
plants, causing pipes to rupture (Figure 3),
including outside fire protection piping and
piping located near building ventilation lou-
vers (thus rendering the fire protection sys-
tem inoperable). The National Fire Protection
Association (NFPA) has established clear fire
protection system freeze prevention require-
ments (NFPA 13). From a safety viewpoint,
you should heat trace the water supply to the
safety showers located throughout the plant.
Ammonia lines to the selective catalytic
reduction system of a gas-fired plant must be
properly heat traced and insulated. A crack
in this line could easily become a significant
environmental issue if left undetected. The
same should be said for chemical lines used
for boiler water treatment and the boiler wa-
ter sample lines.
Compressed Air Systems. Compressed
air systems may also be at risk. The typical
southern climate plant uses compressed air
outside directly after the coalescing filter.
Plants built in northern climates use air dry-
ers to provide compressed air at a dew point
temperature below the minimum design tem-
perature to prevent freezing of instrument air
lines. Air compressor condensate vent lines
should also be heat traced, unlike the typical
southern plant. High moisture levels in the
instrument air often caused freezing of air-
operated valve actuators.
Redundant dew point monitors may be
used to continuously monitor compressed
air quality. Do not rely on automatic air tank
drain systems for moisture control. One util-
ity reported the failure of an automatic air
tank drain resulted in the contamination of
its instrument air system, which is very dif-
ficult to clean. At least one plant reported
that moisture in the control air system caused
a pneumatically controller positioner on a
fan damper to fail, causing a complete unit
forced outage.
Other Plant Systems. Freeze protection
must also be considered for outdoor equip-
ment that will not be operated. For example,
a heat-recovery steam generator (HRSG) full
of water may need to be drained when ex-
posed to unexpectedly low temperatures. The
2. Saving steps. The proper operation of important instruments and weather enclosure
heating systems at this plant can be confirmed by operators at ground level by the four red LED
lamps, instead of by climbing stairs multiple times each shift. Further, networked instruments
can often display an error message on the plant distributed control system in the event of an
enclosure heater failure, without adding any additional wiring. Source: POWER
3. Frozen pipes. Frozen water in pipes
and valves often caused extensive damage
during the February 2011 freeze, particularly to
water mains and fire protection water pipes.
Source: POWER
|
October 2014 42
time to freezing must be determined based on
multiple factors: design low temperature, co-
incident wind velocity, assumed temperature
of the water within the equipment (usually the
heat tracing design criteria), and the existing
insulation of the equipment. The plant staff re-
sponse time to instigate additional freeze pro-
tection actions (typically 24 hours) can then be
compared to the time to freeze for the HRSG
to determine if the HRSG must be drained to
prevent water freezing and tube ruptures.
Sub-freezing weather can cause harmful
problems with forced-draft cooling tower oper-
ation, particularly when there is freezing within
the tower fill media. In one instance, operators
observed ice forming on the tower and shut
down the circulating water pumps and fans to
one or more cells. Ice formation on the cooling
tower should be avoided, because it could be a
risk to the circulating and other cooling water
pumps that take suction from the tower basin.
One plant noted that it quickly shut down the
cooling tower to prevent icing when the plant
unexpectedly tripped (Figure 4).
Plant demineralized water systems should
be freeze protected and capable of delivering
properly treated water during a cold weather
event. Also, ensure that there is sufficient
chemical inventory, and/or have a plan in
place for delivery of critical chemicals and
gases (such as hydrogen) during extreme
weather. Some plants experienced freezing
of water treatment chemicals used for demin-
eralizer regeneration and have since installed
reverse osmosis water treatment plants to
eliminate the problem. Also, if vendors cant
get to the plant during extreme cold weather,
critical material deliveries will be delayed.
Make sure offsite support personnel for criti-
cal systems, such as the substation, are iden-
tified and can be contacted in an emergency.
The combustion turbine (CT) main fuel
gas regulator and fuel gas stop valve must be
well insulated or they can freeze and cause a
trip. Also, icing of inlet air ducts and filters
can cause a spike in the differential pressure,
causing a unit trip or derate. The worst case
is a frozen inlet filter causing the CT com-
pressor to stall, which can in turn cause sig-
nificant damage to the turbine internals. Inlet
heating systems will keep the inlet filter ice-
free. Finally, carefully inspect the compressor
water wash and evaporative cooling systems
for leaks that can form ice (Figure 5).
CTs must also be properly tuned for cold
weather operation. As ambient temperatures
drop, power output increases. This means that at
very low temperatures the power output is maxi-
mized but so is mass flow of emissions and the
possibility of permit exceedances. The turbine
control system should be tuned so that permit
limits are not exceeded at low temperatures.
Transformer insulators and arrestors
should be thoroughly cleaned prior to the
cold weather season in order to minimize the
risk of flashover. This is very important for
those plants where the prevailing winds push
cooling tower drift toward the switchyard.
Corona discharge can damage insulators and
other substation hardware and is a sure way
to force a unit offline.
Setting Priorities
Chances are your list of low-temperature oper-
ation upgrades is extensive and expensive. You
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4. Towering problem. Ice forming on a
forced-draft cooling tower during freezing con-
ditions can damage the tower internals. Ice
forming within the basin can reduce flow and
damage the cooling tower pumps. Source:
POWER
October 2014
|
may want to consider the following method of
sorting your list with your budget request.
The first category is specific equipment
that, when frozen, will prohibit the plant from
starting or restarting during the coldest ex-
pected conditions or equipment that is likely
to cause a forced outage when frozen while
operating. Also identify equipment that,
when frozen, will cause equipment damage
or personnel safety concerns. Essential in-
strumentation and sensing lines, exposed ser-
vice water piping, and fire protection pipes
fall into this category. So do employee emer-
gency shower stations typically found around
chemical storage and use areas.
The second category is equipment that, if
frozen, will cause an equipment malfunction
or even damage, but will not cause a forced
outage of an operating plant or prevent a start
or restart of a unit. Nonessential instrumenta-
tion and sensing lines fall into this category.
For example, one utility that uses lake cool-
ing water requires the continuous operation
of one circulating water system screen wash
pump to ensure piping integrity. The suction
leg of the standby unit is drained to prevent
freezing. Frozen condensate drains from con-
tinuous emissions monitoring systems may
also fall into this category.
The third and final category is equipment
that, if frozen, has the potential of reducing
the availability or reliability of the plant or
may temporarily reduce unit output. Multiple
cell, forced draft cooling towers and nones-
sential water lines fall into this category.
Another example may be failed heaters or
heat tracing used to warm lubricating oil and
greases that can result in motor or pump vi-
bration and unit trips or runbacks.
ERCOT Makes Preparations
The next unexpected cold weather blast
should mean less bad news for ERCOT gen-
erators, because in ERCOT, and all NERC
regions, winter preparation planning is now
a regulatory requirement. Winter prepara-
tion surveys must be completed by gen-
erators, as are emergency operations and
resource weatherization plans. Generators
must submit their severe weather prepara-
tion plans by affidavit.
ERCOT also performs spot reviews of
generator plans, makes site visits to verify
plans, and conducts unannounced black start
unit testing. The surveys include information
on backup fuels available and how long a
unit can operate on the backup fuel. This is
an important consideration, as 89 of the 130
units with dual-fuel capability experienced a
trip, failure to start, or derate during the Feb-
ruary 2011 severe weather event. Only four
units successfully switched to backup fuels.
The surveys also must identify primary and
alternate gas pipeline fuel supplies. Finally,
the surveys require generators to estimate de-
rating and forced outage rate based on two
extreme temperature scenarios.
consulting editor.
5. Damaged blades. Compressor blade
damage can occur when water wash and
evaporative cooling systems leak. Unidentified
water leaks can form ice on the compressor
blades or compressor inlet, which can cause
damage to the airfoils. Source: POWER
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October 2014 44
Prepare Your Nuclear Plant for
Cold Weather Operations
Nuclear plant structures are designed to withstand extreme cold weather con-
ditions. However, a winterization program, such as those shared by Byron
and D.C. Cook power plants, can ensure critical operating systems are
prioritized and protected from freezing during low ambient temperature
conditions.
James M. Hylko
D
uring the Jan. 312, 2014, polar vortex
that brought record-setting cold tem-
peratures and severe winter weather to
much of the U.S., nuclear plants not only sur-
vived, but thrived. According to the Nuclear
Energy Institute, the U.S. nuclear fleet main-
tained a 95% average capacity factorthe
ratio of electrical power actually produced
by a generating unit to its rated full power ca-
pacity. That percentage was greater than for
any other source of electricity during the pe-
riod. Still, nuclear plants are not completely
invulnerable to cold-weather issues, so well
before winter, nuclear plant operators should
have winterization on their minds.
Designed with Climate in Mind
Nuclear plants are built to withstand extreme
weather conditions. In the U.S. Nuclear Reg-
ulatory Commission (NRC) regulations, Title
10, Code of Federal Regulations (10 CFR),
Appendix A to Part 50General Design Cri-
teria for Nuclear Power Plants, 55 design
requirements are listed.
For instance, Criterion 2 covers Design
Bases for Protection Against Natural Phe-
nomena. Sufficient margins are included for
any limited accuracy, quantity, and period of
time involving historical environmental data.
In addition, 10 CFR Part 100Reactor Site
Criteria considers the location and physical
site characteristics, including meteorology.
That information is used in conjunction
with 10 CFR 50 to determine the suitability
of a proposed site and characteristics that
may have an impact upon plant design. The
plants design basis identifies the specific
functions, operating values, and bounding
parameters to demonstrate compliance with
these regulations.
Early Lessons Learned
Cold weather impacts started coming to the
forefront of the nuclear industry with the
NRCs IE Bulletin No. 79-24: Frozen Lines,
published in 1979. The bulletin discusses
how heat tracing was unable to prevent lines
from freezing at one northern U.S. plant due
to inadequate design when exposed to pro-
longed sub-freezing temperatures. Although
the equipment had been working properly,
placement of temperature-sensing elements
in areas not exposed to the coldest tempera-
tures resulted in water freezing in a recircula-
tion line.
A total of 15 plants had experienced fro-
zen lines during a five-year period, which
prompted the NRC to issue the bulletin. All
licensees and construction permit holders
who received the bulletin were requested to
confirm that adequate protective measures
had been taken to ensure that safety-related
process, instrument, and sampling lines did
not freeze during extremely cold weather.
To prevent recurrence, thermostat tempera-
ture settings for the heat tracing on recir-
culation lines were increased, and heated
enclosures were built to shield against in-
clement weather.
In January 1998, the NRC published In-
formation Notice No. 98-02: Nuclear Power
Plant Cold Weather Problems and Protective
Measures, because extreme cold weather
conditions continued to affect the industry.
Lack of design oversight, incomplete review
of operating experience, and insufficient at-
tention to cold weather preparations were re-
sponsible for problems such as: ice formation
inside a diesel generator service water pump
column; frazil ice formation in the cooling
water intakes of three plants; a frozen safety
injection recirculation line, making the sys-
tem inoperable; inadequate insulation of re-
fueling water and condensate storage tank
level transmitter lines; emergency diesel gen-
erator oil and grease viscosity problems; and
inadequately sealed electrical conduit and
cabinets, causing partial losses of onsite or
offsite power.
The NRC has continued to update its regu-
latory documents, such as the Standard Re-
view Plan for the Review of Safety Analysis
Reports for Nuclear Power Plants, NUREG-
0800, Section 2.4.7, Ice Effects, which was
revised as recently as 2007. In addition, the
NRCs Regulatory Guide 1.151, Instrument
Sensing Lines, first published in July 1983
and revised in July 2010, addresses the pre-
vention of freezing in safety-related instru-
ment sensing lines, and includes such design
issues as diversity, independence, monitor-
ing, and alarms.
The NRCs Inspection Procedure 71111,
Reactor SafetyInitiating Events, Mitigat-
ing Systems, Barrier Integrity includes an
attachment on Adverse Weather Protec-
tion. NRC resident inspectors use this pro-
cedure to check readiness for cold weather,
freezing temperatures, and other extreme
weather conditionsincluding drought and
floodingwhich could lead to loss of offsite
power, redundant equipment, and decay-heat
removal systems.
Walkdowns are used to verify that the
physical condition of weather protection fea-
tures is monitored to ensure structure, sys-
tem, and component operability. In addition,
the adequacy of heat tracing and space heat-
ers for cold weather protection of piping and
equipment is checked, and sensing lines and
fire suppression systems are inspected. These
reviews usually occur near the beginning of
each season.
Site-Specific Preparations Are Still
Needed
The purpose of a plants winter readiness pro-
gram is to ensure that the station is protected
from freezing during extreme cold weather
conditions. POWER collected profiles from
two nuclear plants: Byron and D.C. Cook.
The Byron Generating Station, located in
October 2014
|
Byron, Ill., consists of two 1,200-MW West-
inghouse four-loop pressurized water reactors
(PWRs). Units 1 and 2 received their operat-
ing licenses in 1985 and 1987, respectively.
The plant is currently owned and operated by
Exelon Corp.
The D.C. Cook Nuclear Plant is located
in Bridgman, Mich., on the eastern shore of
Lake Michigan. This plant also consists of
two Westinghouse four-loop PWRs. Unit 1 is
rated at 1,030 MW and received its operating
license in 1974. Unit 2 is rated at 1,100 MW
and received its operating license in 1977.
The plant is owned by American Electric
Power (AEP) and is operated by its subsid-
iary Indiana Michigan Power.
Each winterization program is cus-
tomized for the plant and its location.
Although both plants are located in the
Midwest, Byrons cooling water is from
the Rock River, while D.C. Cook draws
water from Lake Michigan.
For Gary Dudek, work management di-
rector at the Byron nuclear plant, the win-
terization process starts in April. The work
management department is responsible for
the seasonal readiness program, which cov-
ers both winter and summer seasons for the
site. The system engineering department
identifies systems and components that are
critical to winter operations. Winter and
summer readiness coordinators supervise the
work teams. The D.C. Cook plant has a com-
parable schedule (see sidebar D.C. Cook
Winter Preparation Timeline).
Systems of Interest
Bobby Norrick, seasonal readiness coordinator
(SRC) and eSOMS (enterprise Shift Operations
Management System) administrator at the D.C.
Cook plant conducts winterization reviews
in conjunction with the systems engineering
group. The team identifies all actions needed
to ensure systems will function properly and
reliably through the winter (Figure 1). In ad-
dition, the Work Assessment Group identifies
and prioritizes new equipment deficiencies and
resolutions that affect winter readiness during
the daily screening meeting.
The following systems are reviewed for
winter readiness:
Auxiliary steam
Alternate plant heating boiler
Boric acid heat tracing
Fire protection
Ventilation
Circulating water
Heating steam
Refueling water storage tanks freeze pro-
tection
Outside heat trace
Turbine building
Auxiliary building
Additional activities consist of verifying
that all steam heaters in the vicinity of exteri-
or plant walls, exterior rollup doors, auxiliary
building crane bay, main steam stop enclo-
sures, and auxiliary building supply venti-
lation units are operating during the initial
winterization walkdown (March/April) and
then during the final winterization walkdown
(October/November).
Furthermore, the auxiliary building,
screenhouse, and turbine building are in-
spected for damaged doors, windows, and
vent louvers that do not close completely,
including holes, gaps, and cracks in build-
ing siding, and missing weather strip-
ping. The goal of the heater and building
inspections is to verify that the systems
supporting safe operation of the reactors,
turbines, and generators are protected from
freezing. The SRC and tour operatorsat
the discretion of the shift managercan
increase touring frequencies during severe
winter weather conditions or high summer
heat conditions.
At the Byron plant, the heating system
and multiple ventilation systems are im-
portant for insulating and circulating heat
generated in areas that have little heat load
during normal plant operations. These sys-
D.C. Cook Winter Preparation Timeline
March/April: The seasonal readi-
ness coordinator (SRC) manages the
winterization challenge board, and a
Historical Freeze List consisting of
ongoing lists maintained by operations
staff of expected structures, systems,
and components that may be affected
by cold weather conditions. The SRC,
system engineering manager, appro-
priate system managers, and opera-
tions and work control representatives
conduct challenge board meetings to
discuss results of material condition
reviews and to evaluate if all needed
reliability improvements have been
identified.
March/April: The SRC performs
the initial winterization walkdown, fo-
cusing on problem areas from the
most recent winter period, and from
previous years, to verify if correc-
tive actions have been initiated for all
known deficiencies.
April: Systems needed only for
winter are secured during the summer,
such as heating systems. The sys-
tem engineers and the SRC perform
walkdowns to identify maintenance
requirements for the systems removed
from service.
March/May: The SRC reviews
open work orders (WOs) for items re-
quiring completion prior to winter, and
ensures that items identified by these
reviews are incorporated into the work
planning schedule for resolution prior
to Nov. 1. From this point forward, the
SRC continues to screen emergent
issues and WOs for winter readiness
applicability, tracks completion of de-
ficiency resolutions, and ensures all
items are completed by the Nov. 1
deadline. All identified work must be
added to the schedule, which for win-
ter readiness is the second week of
May each year.
October/November: The SRC
performs the final winterization walk-
down with engineering, maintenance,
fire protection, security, and facilities
representatives to verify that the site is
ready for the upcoming winter season.
1. Winter wonderland. While the typi-
cal winter struggles, such as snow and ice in
the parking lot, are common to many plants,
personnel at D.C. Cook also focus on specific
plant systems during winter preparations.
Courtesy: American Electric Power
|
October 2014 46
tems are evaluated by engineering and operations to identify main-
tenance needs for pumps, valves, and heating coils. In addition, a
winter surveillance is performed by operations to ensure that insula-
tion is installed on selected outside louvers and to validate readiness
of tank heating systems.
To provide clear direction on this subject, a corporate seasonal
readiness procedure was created from past industry experiences and
NRC notices. It specifically references the following Institute of Nu-
clear Power Operations (INPO) documents addressing winterization:
INPO Just-In-Time Operating Experience Report, Cold Weather
Preparations.
INPO Significant Operating Experience Report (SOER) 82-15,
Freezing of Safety Related Equipment.
INPO SOER 07-2, Intake Cooling Water Blockage.
A corporate procedure and many other internal Exelon procedures
drive all aspects of seasonal readiness and include various attach-
ments and checklists to complete. The procedure details the roles and
responsibilities for the winter readiness coordinator, and the other dis-
ciplines, along with spring, summer, and fall milestones. It culminates
with a site certification letter stating that the plant is ready for the
upcoming winter season (Figure 2).
Dont Get Frazzled
An unusual phenomenon that some power plants must be alert to
is the formation of frazil ice. The ice forms below the surface
of a body of turbulent water when the sustained air temperature
is 18F or lower. Frazil ice crystals appear as elongated disks.
These disks gradually stick together to form large ice floes and
jams. Frazil ice can be drawn into cooling water intakes, where
it blocks flow by adhering to screens designed to prevent trash
from entering the intakes.
The Byron station has experienced issues with frazil ice in the past.
To correct this issue, a 4-inch warming line was installed off the 10-
inch gravity-fed circulating water blowdown line. Blowdown water is
discharged on the outer bar grate, where the makeup pumps take suc-
tion from the Rock River. This warm water increases the temperature
of the intake water to prevent frazil ice.
Although D.C. Cooks corrective action program has not recorded
instances of frazil ice blocking the cooling water intakes, as a preven-
tative measure, it uses the following factors to determine when it is
necessary to switch its circulating water system to de-ice mode:
Circulating water temperature is less than 35F.
There is greater than 1 foot of water drawdown in the forebay,
which is not caused by starting a circulating water pump. (The
forebay sits below the screenhouse and is the source of water for
the circulating water pumps and essential/non-essential service
water pumps.)
Traveling screens high, or extreme high, differential pressure
alarms are annunciating with little or no trash collection in the
screen wash trash baskets.
Effective Results
The successful Byron and D.C. Cook winterization programs utilize
team approaches. They also provide a framework for maintaining
plant reliability while preventing cold weather disruptions.
Despite snowstorms and frigid temperatures dominating the first
month of 2014, Exelons nuclear fleet produced electricity around the
clock and was unaffected by ice. Exelons 10 nuclear power plants
in Illinois, Pennsylvania, and New Jersey operated continuously
throughout January to help meet the regions electricity demand,
which peaked in the PJM transmission system on Jan. 7 at 141,312
MWa wintertime demand record at the time. Its plants continued
to operate with the same reliability through a second blast of polar air
that began Jan. 21.
The D.C. Cook seasonal readiness program also proved its value
during the 20132014 winter season as southwest Michigan expe-
rienced one of its coldest winters. Both units operated successfully
without any de-rates or unit trips, and they maintained 100% power
throughout AEPs winterization period.
James M. Hylko is a POWER contributing editor.
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draft cooling towers in 2013, including the extension of a metal barrier
along the bottom of the towers to help prevent icing and improve win-
ter readiness. Courtesy: Exelon Corp.
October 2014
|
Prepare Your Renewable Plant for
Cold Weather Operations
Although renewable generation is typically less affected by winter weather than
gas- and coal-fired plants, it is far from weatherproof. Understanding the
risks and preparing properly for them can avoid most problems.
Sonal Patel and Thomas W. Overton, JD
L
ast winters polar vortex was a reminder
that, despite several years of mild win-
ters, colder months can still pack a wal-
lop. Decades of coal, gas, and nuclear plant
operations have taught plant operators the
dangers of bad weather, but the relative nov-
elty of utility-scale wind and solar generation
means many newer owners are unaware of
what can happen to performance when tem-
peratures plunge and the snow begins to fall.
While there may be no pipes to freeze in a so-
lar plant or wind turbine, for example, there
are still risks from severe winter weather.
Wind Farms
Though many wind turbines are installed in
regions of the world that see bitterly cold
winters, wind power isnt immune to extreme
cold events.
During the February 2011 Southwest cold
snap, an unprecedented 16% of wind units
within Texas grid operator Electric Reliabil-
ity Council of Texas operation region report-
edly failed709 MW due to blade icing and
another 1,237 MW because frigid tempera-
tures exceeded turbine limits.
And although PJM Interconnection lauded
wind powers positive impact on supply
during the January 2014 polar vortex, saying
it contributed to PJMs ability to maintain
reliability, data shows that wind energy gen-
eration dropped precariously during demand
peaks during the Jan. 69 extreme weather
event. The Midcontinent Independent System
Operators system also braced for the plunge
in wind output following Jan. 6, crediting ac-
curate wind forecasts. However, it records
that it saw 1,000 MW of wind power cut-
outs as a result of the extreme cold on Jan. 6.
The Federal Energy Regulatory Commission
later speculated that the bulk of those wind
turbine failures were due to models reach-
ing their minimum operating temperatures.
Bracing for Low Temperatures. Wind
turbines are typically designed, per interna-
tional standards for turbine design, to oper-
ate within ambient air temperatures of 10C
while operational and 20C at standstill. (For
offshore considerations, see the sidebar.) As
the North American Electric Reliability Corp.
(NERC) notes, turbines have an automatic
shutdown feature to protect components if
that range is exceeded.
Wind generators in places like Canada
typically install cold weather packages to
extend temperature ranges, using up to 200
kW to 300 kW of parasitic power per turbine
at conditions below 20C for heating com-
ponents such as the nacelle space, yaw drive
and pitch motors, and the gearbox, slip ring,
controller and control cabinet, and battery.
GEs 2010-introduced Cold Weather Extreme
package for its 2.5 x l turbine, for example,
ensures operations in temperatures to 30C
and a survival mode to 40C.
According to NERC, it does not appear
that [cold weather packages] were used in
the Southwest during the 2011 event. It
recommends that all entities investigate the
purchase of these packages in preparation for
extreme cold events.
Heating could also prevent another insidi-
ous cause of turbine failure: When a turbine
is not running, oil that is stationary in radia-
tor passages can quickly cool, and its viscos-
ity can increase. Even if wind turbines are
not being used, an important lesson worth
learning is that the turbines should be cycled
online to provide flow of cooling oil, NERC
says. All cooling equipment for radiators on
wind turbines should also be disabled for
cold weather events.
Preventing Icing. Icing on wind tur-
bines affects three different aspects simul-
taneously: the design (aerodynamics, load,
control system, and material), the safety
(ice throw, unbalanced rotor spinning, over-
power, and fatigue), and performance (an-
nual energy output, wind measurements,
and design life duration). But it can also
affect wind sensorsrendering ineffective
wind-measuring equipmentas well as in-
crease noise levels and generally decrease a
turbines cost-effectiveness.
A deep freeze could have long-term im-
plications for a wind turbine, warns Jeff
Nelson, a TransAlta wind engineer. Turbines
can eventually fault and shut down; in some
cases they have had up to 250 millimeters of
ice. That could mean an extended period of
downtime (if ambient temperatures drop sig-
nificantly and ice cannot be shed) of up to
three weeks.
For TransAlta, key takeaways from previous
icing debacles at its 96-MW Kent Hills wind
farm in Canadas northeastern province of New
Brunswick include the imperative to catch icing
events early, using instrumentation, ice detec-
tors, anemometer cameras, or/and blade accel-
erometers. Twenty-four-hour monitoring of
icing conditions is also essential.
And here too cold weather packages can
prove valuable. Some offer, in addition to
technical solutions that widen operating
temperature ranges, active or passive de-
icing or anti-icing systems for rotor blades.
Systems use a variety of methods, including
heat, water-resistant coatings, and controlled
blade acceleration/deceleration to shake the
ice off.
Last year, for example, Vestas introduced a
de-icing system that can detect an icing con-
dition (using algorithms measuring several
variables, including temperature, humidity,
wind speed, and turbine output), determine
whether its worth shutting down the turbine
to perform de-icing, and initiate a de-icing
procedure if it is worthwhile. The outer third
of each turbine blade essentially includes a
small heating element and fan that uses up to
150 kW to run.
Hydroelectric Plants
Of all generation resources, hydroelectric
plants may be the least affected by nasty win-
ter weather. Indeed, many countries around
the world that rely heavily on hydropower,
such as Norway, Iceland, Canada, and Russia,
must also deal with severe winters. Though
reservoirs may freeze over, penstock intakes
are usually deep enough to withdraw water at
|
October 2014 48
temperatures safely above freezing.
The same is not true for smaller projects,
especially for run-of-river generation, in part
because reduced flows during winter, when
much of a plants watershed may freeze over,
mean that intake water may be drawn at or
very near the surface.
One of the unique wintertime risks is a phe-
nomenon known as frazil ice. Frazil ice forms
when supercooled water (water that is below
freezing but has not frozen) mixes through a
body of water in turbulent conditions. Small
ice crystals form throughout the flow and can
rapidly turn it slushy. If frazil ice is drawn into
a turbine, damage can result.
According to studies by the U.S. Bureau
of Reclamation, which operates many of the
federally owned dams in the U.S., prevention
of ice intake problems is mostly a matter of
good design, but seasonal preparation is also
important. If possible, an ice cover should be
induced upstream of the intakes. This will
keep intake water above freezing and pre-
vent the formation of frazil ice. Ice booms
and floating screens, which can form floating
ice blockades can be useful tools.
Though energy intensive, trash rack
heating can prevent ice formation and is a
common method at plants in cold regions.
However, it is only effective when begun
before frazil ice begins to form. Upstream
temperatures should monitored, and these
temperature sensors should be checked regu-
larly to ensure proper operation.
Certain modern trash rack materials have
been shown to greatly reduce frazil ice accu-
mulation. Where it has been a problem in the
past, retrofitting nonmetallic trash racks may
be warranted.
Where frazil ice has already formed in and
around intakes, mechanical removal may be
necessary. The trash rack cleaning system
should be checked and tested well before
cold weather begins.
Solar Systems
With most solar systems (especially solar ther-
mal) being located in areas with mild climates,
severe winter weather is not usually a concern.
However, cold weather can affect solar photo-
voltaic (PV) systems in other areas.
Most generators are used to lower PV
outputs in winter, but a snowstorm can cut
output to nothing as long as the panels are
covered in snow. Steeply inclined panels,
as with most utility-scale installations, usu-
ally clear themselves quickly when the snow
stops, but rooftop panels may need to be
manually cleared, unless the sun returns after
the storm. Preparations need to be in place
for snow removal if a quick return to produc-
tion is important.
Because PV panels are of solid-state
construction with no moving parts or fluids
inside, they are much less vulnerable to ex-
treme winter weather than other generation
sources. That does not mean they are weath-
erproof, however.
PV panels that undergo repeated freeze-
thaw cycles, especially with snowfall, are
vulnerable to water intrusion as freezing melt
water can force open small gaps in panel cov-
ers, mounting brackets, and electrical connec-
tions over time. Regular inspections of such
systems for weather damage are mandatory,
given that water intrusion into solar electrical
systems can cause serious problems.
PV panel mountings also need to be regu-
larly inspected for integrity, especially if the
system may be exposed to high winter winds.
This is a particular concern for freestanding
pole-mounted panels.
One positive side effect of cold weather
is that solar PV panels actually perform
more efficiently in colder temperatures,
though overall output is usually lower due
to reduced sunlight.
Storage Batteries
The lithium-ion (Li-ion) batteries that make
up most renewable on-site energy storage are
relatively weather-hardy, but they still need
attention during severe weather. Most such
utility-scale batteries currently operating are
deployed in containerized units that employ
HVAC systems to maintain optimal internal
temperatures, since Li-ion batteries in general
operate less efficiently in cold temperatures.
Proper maintenance and inspections of
the HVAC system, as well as prompt snow
removal from HVAC intakes, is important.
Such systems that are deployed in areas see-
ing severe winter weather need to be hard-
ened so that they can continue operating in
sub-zero conditions. A properly designed and
maintained battery storage system should not
be overly challenged by winter storms. For
example, AES reported to POWER that its
Laurel Mountain facility in West Virginia,
currently the largest Li-ion storage system
in operation, weathered the 2014 polar vor-
tex storms with availability well above other
generation assets in PJM.
Sonal Patel and Thomas W. Overton,
JD are POWER associate editors.
Offshore Operation Adds Challenges
Though no commercial wind farms have
yet been installed in U.S. waters, 2,277
offshore turbines worth a combined name-
plate capacity of 7.03 GW had been in-
stalled worldwide at the end of 2013. All
were in the Northern Hemispheremost
in northwestern Europe, and the rest in
China, Japan, and South Koreawhere
they are prone to a number of cold cli-
mate issues.
Like onshore turbines, offshore turbines
can be debilitated by ice formation on ro-
tors and other components, but that risk
is increased by added water in the air,
rainfall, and sea sprays. This atmospher-
ic icing is dependent on the elevation of
the turbine rotor over sea level and on the
size and type of wind turbine.
Another distinct challenge for offshore
wind turbine structures in cold climates
is caused by ice-covered waters. Ice pack
on the sea surface can cause mechanical
shocks and increased vibrations to turbine
structures that may result in additional op-
erational loads. Threats include ice-induced
vibration, ice thickness, and ice drift.
The magnitude of the ice load and
dynamic excitation due to ice failure are
usually dominating the structural design
in ice-covered sea areas, note Maria Ti-
kanmki, Jaakko Heinonen, Vilho Jussila,
and Juha Kurkela of the VTT Technical Re-
search Center of Finland. A site-specific
determination of the ice conditions and
an overall dynamic simulation of the wind
turbine with the ice interaction can en-
able a cost-effective structural design
(Figure 1), they suggest. A common way
of decreasing ice loads is to include in the
substructure a cone that switches the ice
failure mode from crushing to bending.
1. In cold waters. To make offshore
wind turbine foundations hardier in icy wa-
ters, Finnish company Suomen Hytytuuli
Oy began testing a new gravity-type ice-
resistant foundation in the Pori sea area of
the Northern Baltic Sea in 2010. (This image
shows the turbine in heavy pack ice at the
end of February 2011.) The foundation con-
sists of a light steel shell with a ring foot-
ing, ice-breaking cone, and crushed rock fill.
Courtesy: Eranti Engineering Oy
www.gbreports.com
Global Business Reports
October 2014
2
Global Business Reports // POWER INDONESIA
population; boost generation capacities to
keep up with a staggering energy demand
increase of 7.4% per year; and alter the cur-
rent energy mix to ensure energy security
for the nations future. Failure to achieve
these goals could compromise the coun-
trys ability to continue to lift millions out
of poverty and compete on both a regional
and global level.
Ambitious Plans,
but Eficacy Mixed
As Kishore Dass, the president director
of Pyry Indonesia, the global Finish con-
sulting and engineering frm, said: Pow-
er shortages are endemic in Indonesia.
The countrys total electricity generation
touched 47 GW as of the end of last year.
According to PLNs electricity procurement
plan for the 2013 -2022 period, there needs
to be an additional capacity of 31.5 GW for
the Java-Bali grid. This amounts to about
3.2 GW per year. At the national level the
power requirement translates to around 6
GW per year.
Increasing the national generating capac-
ity to 60 GW by 2022, as the Government-
owned Perusahaan Listrik Negara (PLN),
which has a monopoly on electricity distri-
bution and accounts for 80% of the coun-
trys generation capacity, has forecasted, is
no small feat. While the Government has
done well by enacting regulation in 2009
for renewable power projects of 10 MW
that stipulates feed-in tariffs for investors
and that assigns to the PLN the obligation
to buy this power, the Government under-
stands that it must encourage projects of
a larger scale. To help achieve such a sig-
nifcant increase in power generation, in
2006, the Government introduced the fast-
track program (FTPI) mandating the PLN to
build 10,000 MW coal-fred power plants
by 2011, a deadline that was later extended
to 2014. In 2010, the government launched
a second 10,000 MW fast-track program
(FTPII), aimed at encouraging investment
from Independent Power Producers (IPPs),
which sell electricity to the PLN, and sepa-
rately the development of renewable en-
ergy, focusing on geothermal and hydro
power. The FTPII program was initially to
be completed in 2014, but that target date
has been pushed back until 2020.
To realize the construction and commis-
sioning of the power plants under FTPI and
FTPII and additional power plants that do
not fall within the purview of these pro-
grams, the government has turned to the
private sector, particularly toward foreign
investors. Although recent regulations,
bred from nationalist sentiment, negatively
affect foreign investors interests in other
segments of the economy, the current reg-
ulatory structure for the power industry is
very favorable, as Guy Des Rosiers, senior
foreign legal consultant at the Indonesian
law frm MAKARIM & TAIRA S., noted:
Overall, the current environment for for-
eign investors is positive thanks to a legal
framework that allows bankable projects
to come to the market, and a generally fa-
vorable attitude from PLN and relevant gov-
ernment stakeholders, all of whom share
a strong incentive to ensure the smooth
development of future power projects.
L. David Rimbo, managing partner within
the Transaction Advisory Services group at
Ernst & Young Indonesia, explained: With-
in the last fve to six years, there is greater
understanding about the prescribed invest-
ment structure and operational set-up of
an IPP project in Indonesia under the PPA
scheme, primarily under a BOO (Build-
Operate-Own) arrangement. With such a
scheme, the returns will continue to accrue
to the asset owners beyond the tenure of
the initial PPA, with a renewal or extension
Black & Veatch helped deliver Tanjung Jati B Units 3 & 4, located near Jepara, Central Java, Indonesia.
The plant is owned by Sumitomo Corporation and subsidiary PT Central Java Power, and is operated
by PT PLN (Persero), Indonesias state-owned power utility. Photo courtesy of Black & Veatch.
|
October 2014 54
COMBUSTION TURBINES
Quickly Boost Your Combustion
Turbine Response
Morris Cogeneration, a combined cycle cogeneration plant near Chicago, has
installed TurboPHASE, a fast-responding, modular turbocharger installed
to boost capacity and PJM regulation revenue. How does it perform?
T
wice this year, PJM flirted with black-
outs when brutal winter storms (dubbed
a polar vortex) struck the Eastern U.S.
in January. The cold weather set a new winter
peak demand record of 141,500 MW on Jan.
7, busting the record set in February 2007
by nearly 5,000 MW. In fact, the five big-
gest demands ever placed on the PJM grid,
and eight of the 10 largest, occurred between
Jan. 7 and Jan. 30. PJM reported that at one
point, 36,000 MW was out of service due to
forced outages, which amounts to 20% of its
installed capacity. Adam Keech, director of
wholesale market operations, is reported by
RTO Insider as sayingthe morning after
setting the winter peak recordWe really
exhausted every megawatt we had on the sys-
tem. Peaking capacity and fast unit response
is a necessity during summer and winter
peaks, and many regional transmission orga-
nizations (RTOs) are willing to pay well for
the service.
A solid majority of new plant construction
in PJM is gas fired, led by simple or com-
bined cycle plants. Simple cycle combustion
turbine (CT) plants are less efficient than
combined cycle plants but are able to start
more rapidly and add valuable power to the
grid in minutes, which is extremely valuable
to a system like PJM as synchronized reserve,
fast grid regulation, or black start service. In
fact, ancillary service payments often justify
the cost of constructing a simple cycle peak-
ing plant.
A New Option
Jupiter, Floridabased PowerPhase LLC has
successfully demonstrated a new technology
called TurboPHASE that may allow an exist-
ing simple cycle CT or combined cycle plant
to add as much as 10% to 20% more power
to the grid in seconds, depending on plant
configuration, addressing the quick-start and
fast-response needs of the modern grid.
The TurboPHASE system consists of a
multistage intercooled centrifugal compressor
that delivers hot compressed air to the CTs
compressor discharge section, thereby allow-
ing the CT to operate at its rated capacity ir-
respective of the ambient conditions (5C to
50C) or altitude (Figure 1). The system takes
advantage of the CT operating below its limits
during hot weather much like an inlet chiller
or evaporative cooling system, although Tur-
boPHASE can also operate in conjunction
with either of those inlet cooling options.
A separately fueled reciprocating engine
direct drives the compressor. The heat from
the exhaust of the engine is used to heat the
compressed air in the recuperator before en-
tering the CT compressor section. On an op-
erating CT, TurboPHASE is said to be able
to ramp to full load in 60 seconds or less and
from part load to full load in 10 seconds or
less. This design feature is sure to be of in-
terest to grid dispatchers anxious to have the
ability to quickly backfill lost capacity during
a system emergency or to quickly respond to
the intermittency of renewable resources.
Field Tests Completed
Two prototype TurboPHASE modules
(TPMs) were tested in August, and the data
and test results were provided to POWER on
an exclusive basis. The tests were conducted
at Atlantic Power Corp.s Morris Cogen-
eration Plant (Morris), located just outside
Chicago (Figure 2). The gas-fired 177-MW
combined cycle facility is located within the
Equistar Chemicals petrochemical plant in
Morris, Ill. All of the steam (after passing
through a steam turbine) and a portion of
the electricity produced by the plant is sold
to Equistar, and the remainder of the power
is sold into the PJM West market. Morris is
configured with three gas-fired General Elec-
tric Frame 6B CTs, each with a heat-recovery
steam generator (HRSG).
PowerPhase engineers ran a series of pre-
dictive performance models using Thermo-
Flow in advance of the field tests. The models
predicted that the CT full-load performance
would increase ~2.63 MW and the steam tur-
bine by ~0.43 MW, for a total power increase
of ~3.06 MW. The cost of the increased out-
put is the additional fuel burned by the CT
(~10 MMBtu/hr) and the fuel burned by the
engine (~16.3 MMBtu/hr). Therefore, the in-
cremental heat rate of the unit with one TPM
in service was expected to be on the order of
26.3 MMBtu/hr/3.06 MW = 8,650 Btu/kWh.
The demonstration test was conducted
in two parts. The first test was designed to
demonstrate the increase in output capacity
1. Turbocharging combustion turbines. TurboPHASE consists of four main com-
ponents: engine, gearbox, compressor, and recuperator. A gas-fired engine-c ompressor set
produces compressed air that is added to the combustion turbines compressor discharge
section to negate the effect of a high ambient temperature performance derate. Courtesy:
PowerPhase LLC
Air vent silencer
Compressor
inlet air filter
Muffler
Recuperator
CO catalyst
Engine exhaust
6 air injection valve
3 air vent valve
Lube oil system
and cooler
Compressor and
intercoolers
Engine
cooler
Engine
Coupling
Gearbox
October 2014
|
COMBUSTION TURBINES
when using a single TPM. The second test
measured the response or ramping speed of
the plant with one or two TPMs injecting air
into the plants CT1. Each of the TPMs used
at Morris is powered by MTU 20V4000L32
gas-fired engines, each rated at 2 MW.
Morris is also equipped with inlet chilling
and HRSG duct-firing capability, and both
were in operation during the demonstration
tests. The tests were conducted with the CT at
full power at an ambient temperature that av-
eraged ~85F. At no time during the tests were
the operating limits of the CT exceeded.
Day One Tests. On the first day of testing,
compressed air from TPM2 was injected into
CT1 as the system cycled off and on three
times. Data was collected at one-second in-
tervals and then averaged. CT fuel flow mea-
surements were taken from plant instruments,
and TPM fuel flow was measured (at the inlet
to the engine) at 16.3 MMBtu/hr as expected.
TPM air injection flow rate was measured by
an annubar-type flow meter on the main air
header prior to entering the CT. The airflow
from each TPM was measured as 11.5 lb/sec
at ~156 psi.
The measured test results at Morris showed
that the average CT power boost was 2.74
MW and that the steam turbine produced
an additional 0.32 MW, for a total power in-
crease of 3.06 MW per TPM, very close to
the prediction. As an additional benefit, the
TPM compressor intercoolers produced an
average of 1.2 gallons per minute of clean
water during the tests.
The second test of the day was measure-
ment of the plant response to a demand sig-
nal. The test procedure was to first ramp up
TPM2 to full speed, no load. No compressed
air was produced by TPM2 while the system
was idling. When warmed up, TPM2 was
ramped up to 75% load while venting the
compressed air produced to the atmosphere
through a vent valve, bypassing the CT.
Simulating receipt of a demand signal with
TPM2 at 75% load, the vent valve was closed
and the injection valve was opened, thereby
sending compressed air to the CT compressor
discharge. The air injection quickly produced
an incremental power increase of about 1.5
MW, ramping up to ~2 MW when the vent
valve was fully closed and injection valve
was fully open. Next, TPM2 was ramped to
full power, and the CT responded by pro-
ducing an increase of ~2.74 MW, with the
steam plant power increase following. The
test ended with the load on TPM2 reduced to
75%, followed by opening the vent valve and
closing the air inject valve to the CT. Figure
3 shows the results of the response testing
completed on day one. The TPM was able to
add much, although not all, of the incremen-
tal power from the CT within the 60-second
goal set by the company.
Day Two Tests. The response tests were
repeated on the second day of testing using
TPM1. Figure 4 illustrates the data collected
during these tests, which were very consis-
tent with the previous days tests.
The second test of the day was to run both
TPMs in parallel and inject the produced
compressed air into CT1. The final test sim-
ulated an unexpected trip of a TPM. When
the air supply from TPM2 ceased, a check
valve in the TPM prevented reverse flow, and
TPM1 continued supplying compressed air
to the CT as expected.
2. Demonstration plant. Two TurboPHASE modules (TPMs) were installed at Atlantic
Power Corp.s Morris Cogeneration Plant (lower left of photo) and were recently performance
tested. The TPMs each added over 3 MW of quick response capacity to a Frame 6B combustion
turbine and steam turbine system. Courtesy: PowerPhase LLC
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Durham, North Carolina 27712 USA sales@cormetech.com
|
October 2014 56
COMBUSTION TURBINES
The piping system pressure drop between
the TPMs and the CT was ~11 psi with one
TPM operating (flowing 11.5 lb/sec) rising
to ~40 psi with two TPMs operating, so the
airflow into the CT was slightly less than
double (22 lb/sec). The pressure drop effect
is apparent in Figure 4 where a single TPM
produces ~3 MW while two TPMs produce
slightly under ~6 MW. A line size increase
from 6 inches to 8 inches would solve this
problem, but since Morris doesnt anticipate
operating the plant in this manner, the cost of
the pipe size increase isnt justified.
Pluses and Minuses
Before assessing the results of the testing, its
best to remember that this was the first full-
scale demonstration test of the TurboPHASE
and we were privy to only an overview of
the testing and the performance results. That
said, we are still able to reflect on the perfor-
mance of the system in relation to the impor-
tant ancillary services PJM and other RTOs
desire: synchronized reserve, fast grid regu-
lation, and black start service.
Synchronized Reserve. A single TPM
consists of a single MTU gas-fired engine that
will produce 2 MW were it fitted with a gen-
erator and operated standalone, which is the
obvious competitor to the TurboPHASE sys-
tem. Further, according to data on the MTU
website, this model gas engine with a gen-
erator operates at a heat rate of ~8,000 Btu/
kWh, which is a very efficient engine, and
more efficient than the CT. This class engine,
in hot start conditions (usually defined as
lubricating oil preheated, engine bearing pre-
lubricated, and cooling water preheated) can
be started and synchronized to the grid in ~60
seconds or less and reach full load in ~90 to
180 seconds. The downside is the extra cost
of the generator and switchgear.
The 60-second response of the TPM is
based on the engine operating at 75% load
with compressed air bypassing the CT. A
start signal puts the compressed air into
the CT and increased power is achieved in
~60 seconds in the CT, about 2.75 MW. The
capacitance in the HRSG and steam turbine
system brings the remaining ~0.25 MW along
well after the 60-second goal. Although the
data provided did not state the time period,
the two figures are suggestive that the time
lag is several minutes, as one would expect.
The report suggested that the average in-
cremental heat rate of the TPM (8,650 Btu/
kWh predicted) was 8,495 Btu/kWh based
on the full ~3 MW power increase. However,
the fuel flow data taken from station instru-
ments showed significant variation, so its
best to consider the incremental heat rate as
anecdotal rather than a hard number. Also,
for comparison purposes, a more appropri-
ate incremental heat rate should be based on
the CT output alone rather than the CT plus
steam turbine output because of the several-
minute time lag of the steam system.
How does the TurboPHASE stack up
against using the same engine in a standby
package for synchronized reserve power?
Both packages must be running, in stand-
by mode, and synchronized to the grid to
qualify. However, the engine-generator
can be synchronized, kept at minimum
load (lower fuel consumption), and can
take on 2 MW of load within ~30 seconds
or so. The TPM must also be running but
held at 75% load in order to add 2.75 MW
to the grid within 60 seconds, but it does
so at a higher heat rate than the engine-
generator alone. The economics are very
CT and site specific.
Fast Grid Regulation. Once the Turbo-
PHASE is operating, then its response to rapid
changes in grid demand must be considered.
Although the specific data wasnt available,
the TPM response to a step increase in load
demand can be estimated from Figures 3 and
4. The data does confirm that TurboPHASE
responds quickly, with the nearly vertical
lines representing the CT response followed
by the slower steam turbine. The data also
shows the CT responds in about 2 to 3 min-
utes, with the additional steam turbine power
available within 10 minutes. The standard
PJM response requirement for grid regula-
tion power is 10 minutes. Regardless, adding
40
39
38
37
36
35
34
33
32
31
30
C
T
1

(
M
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)
90
85
80
75
70
65
60
C
T
1

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l
e
t

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e

(
F
)
16:15:00 16:45:00 17:15:00 17:45:00 18:15:00 18:45:00 19:15:00 19:45:00
Time
3. Day one tests. Results of the first day of TurboPHASE demonstration tests are illustrat-
ed. The blue line represents the temperature at the inlet to the combustion turbine. The orange
line shows the response of the combined cycle plant to full air injection. Courtesy: PowerPhase
LLC
CT1 MW CT1 inlet temperature
40
39
38
37
36
35
34
33
32
31
30
C
T
1

(
M
W
)
90
85
80
75
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60
C
T
1

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(
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1:30:00 2:00:00 2:30:00 3:00:00 3:30:00 4:00:00 4:30:00 5:00:00 5:30:00 6:00:00
Time
T
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1

f
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l

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j
e
c
t
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o
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o

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1

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T
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2

f
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l
l

i
n
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e
c
t
i
o
n
TPM2 air
compressor trip
CT1 MW CT1 inlet temperature
4. Day two tests. The test results of the second day of TurboPHASE demonstration tests
are illustrated. The last test of the day was with both TurboPHASE systems in operation followed
by a trip of one system. Courtesy: PowerPhase LLC
T
P
M

f
u
l
l

i
n
j
e
c
t
i
o
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o

i
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o
n
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M

f
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i
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M

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October 2014
|
COMBUSTION TURBINES
the TPM did improve the grid response of the
Morris plant and may allow the plant to move
into a grid response category with a higher
payment.
The competitive 2-MW gas-fired engine-
generator could also be started, synchro-
nized, and at maximum load in less than the
10 minutes standard to supply grid regulation
power. But then again, a simple cycle Frame
7FA (227 MW) can start and reach 50% load
within 10 minutes and then ramp up at 40
MW/min. Aeroderivative engines start and
synchronize even faster.
Black Start Service. The TurboPHASE
has the potential to become an interesting
black start option for some utilities with
combined cycle plants. However, its diffi-
cult to compete with a diesel engine when
the weather gets very cold (see Prepare Your
Gas Plant for Cold Weather Operations in
this issue), particularly when natural gas
supplies are limited for power generation at
some gas plants. The best black start systems
will be an independent system that can sup-
ply power to just the critical plant systems
needed for restart. On the other hand, a TPM
can be installed in two to three months while
a new engine-generator will likely take six
months or longer.
Final Analysis
TurboPHASE has the potential for reinvigo-
rating existing combined cycle or simple
cycle plants with additional peaking capac-
ity, especially during warmer days when the
output of the CT is otherwise limited. The
response of the TurboPHASE, from the lim-
ited information we have reviewed, is on
the same order as a gas-fired reciprocating
engine. Efficiency leans toward the engine-
generator because the combined cycle plant
has a higher heat rate. This balance point
could easily change should the TPM be in-
stalled on a more efficient CT, although there
arent many that CTs with a heat rate less
than 8,000 Btu/kWh (for example, the 60-Hz
7FA is 8,680 Btu/kWh).
On the other hand, the cost of a TPM is
likely less than a bank of centrifugal chill-
ers and coils that are often used to increase
CT power output during warm weather. Also,
since the TPM produces compressed air at
300 psi, the system can be used on any CT
with a compressor discharge pressure of 290
psi or less, which includes many E-, F-, and
G-class CTs and some aeroderivative en-
gines, assuming there is a suitable open port
on the casing at the compressor discharge.
The response of the TurboPHASE does
meet the PJM requirements for grid regula-
tion power but only when the unit is running
and the compressor is charged and ready to
dump compressed air into the CT. A poten-
tial owner must consider the economics of
balancing the regulation payments from PJM
against the cost of the TPM and the added
fuel costs. Also, it probably goes without
saying that potential adopters must be located
within an RTO that has a grid fast regulation
payment scheme.
What do the OEMs think about an owner
adding compressed air into the engine cas-
ing for peaking power or fast regulation
purposes? General Electrics GER-3567H
states, GE [heavy duty] gas turbines are de-
signed to allow up to 5% of the compressor
airflow for steam injection to the combustor
and compressor discharge. If superheated
steam injection is acceptable to GE, as it has
been for over 30 years, then one would ex-
pect that compressed air in like mass flow
will also be acceptable. Also, it seems to me
that injecting clean compressed air upstream
of the combustor is certainly preferable to
wet compression resulting from the use of
evaporative coolers.
consulting editor.
UDI WHOS WHO AT ELECTRIC POWER PLANTS
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U.S. and Canadian generating plants. The directory provides:
Nearly 8,100 plant management and support
contact names, titles, and primary job functions.
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power stations, including:
Generation (MWh)
Availability (%)
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Power plant design characteristics
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For more detailed information and a list of all available data, visit us online at UDIDATA.COM or contact the UDI Editorial team at UDI@Platts.com.
2014
|
October 2014 58
RENEWABLES
A New Day for North American
Hydropower?
Often overlooked in the dash toward wind and solar, hydropower remains a
major player in renewable generation. But recent trends suggest a shift
toward pumped storage and retrofitted generation may be in the works.
C
an hydropower get some love?
Even fans of renewable energy
can be forgiven for having forgot-
ten about a resource thatup to now
has produced more electricity than wind,
solar, biomass, and all other renewable
sources combined. Energy sector news is
dominated by reports about the latest big
solar plant coming online, ever-larger wind
turbine models coming on the market, and
seemingly never-ending battles over subsi-
dies and credits.
The limited public interest in hydropower
is understandable to some extent. Hydro is
a mostly low-tech, mostly familiar resource
that generally makes waves only of the wa-
tery sort. The giant hydroelectric projects
of the 20th Century have become part of
the landscape in North America, and rela-
tively few more of those are likely to ever
get built. Wind and solar have seized not
just the headlines but also the generation
momentum: The U.S. Energy Information
Administration predicted in this years An-
nual Energy Outlook that 2014 will be the
first year ever in which total non-hydro re-
newable generation will exceed total hydro-
power generation.
Thats a crown that hydro may struggle to
get back. Total U.S. hydroelectric capacity
(including pumped storage) increased about
1.3% between 2002 and 2012, a period in
which wind capacity increased more than
1,300% and solar increased nearly 800%.
Hydro has also missed out on a lot of
the support given to wind and solar. Fo-
cused as many renewable subsidies are on
fostering new capacity, many incentives
specifically exclude existing hydroelectric
generation. The Environmental Protection
Agencys (EPAs) proposed carbon emis-
sions standards barely mention hydro,
leaving several hydro-heavy states feeling
left out. Nuclear generation gets a credit
to help keep existing plants operational in
the face of competition, but existing hydro
appears to get nothing. In fact, the EPA
didnt consider hydro at all in calculat-
ing several states baselines for renewable
generation (on the rationale that doing so
would disadvantage states with no or lim-
ited hydro potential).
Forgotten But Not Gone
But counting hydro out would be a big mistake.
A common misconception is that hydro is
built out in North Americaespecially in
the U.S. with nearly all large potential sites
already harnessed. In fact, in the U.S. alone
there is substantial undeveloped hydroelectric
potential, almost as much as is currently used
for generation. A study by the Oak Ridge Na-
tional Laboratory (ORNL) released in April
2014 found that there was more than 84 GW
of untapped potential nationwide, though this
included areas where hydro development is
prohibited. When excluding areas that are
within or close to National Parks, Wild and
Scenic Rivers, and Wilderness Areas, the
study found that there was still more than 65
GW of potential capacity that could generate
almost 350 TWh annually.
The potential capacity goes beyond
greenfield projects. An earlier ORNL re-
port from 2012 found that the more than
54,000 unpowered dams across the U.S.
represented substantial opportunities for
retrofitting generation at a fraction of the
costand hassleof new dams. Though
most of these dams are too small or poorly
configured, the 600 or so most favorable
sites could be retrofitted with a total of
around 10 GW of capacity.
The highest potential was found in the
Ohio, Upper Mississippi, and Arkansas-
White-Red river basins, where many U.S.
Army Corps of Engineers (USACE) naviga-
tional locks could be fitted with generation
(Figure 1). The study identified 87 such sites
1. Untapped. The Emsworth Locks and Dams on the Ohio River in Pittsburgh are one of
many federally owned flood control and navigation sites at which hydro generation could be
added, according to a recent study. A Boston-based company is seeking approval to build a 24-
MW run-of-river facility there. Source: U.S. Army Corps of Engineers
October 2014
|
RENEWABLES
with a total 6.9 GW potential. Not surprisingly, most of the untapped
generation resources were found in the Midwest and Northeast; rela-
tively little was located in the West.
These numbers are no news to hydropower industry people in
the U.S., many of whom are focusing their development efforts on
smaller retrofits. Theres a recognition recently that there is a lot
of existing infrastructure out there that we can take advantage of,
Mario Finis, North America energy and industry director and former
global director for hydropower and dams for MWH told POWER in
an interview.
The biggest attraction, naturally, is the reduced cost of develop-
ment: With the dam already in place, most of the costs of a compa-
rable greenfield project have already been incurred. Another bonus of
these smaller projects is that they can provide relatively inexpensive
support for intermittent renewables (see Small Hydro, Big Opportu-
nity in the May 2013 issue).
There are some interesting interactions between wind and so-
lar that are helping drive the need for hydro in terms of some of the
ancillary services that hydropower generation can provide. In this,
Finis said, direct policy support for wind and solar is creating indi-
rect support for dispatchable generation like hydro. Investors and
utilities that are taking a more long-term view in terms of generation
resources are looking at hydro as a way to help balance wind and
solar generation.
Furthermore, while big hydro has gotten the cold shoulder from
state renewable energy portfolios, smaller projects in the neighbor-
hood of 30 MW can often qualify, Finis said. Theres also a sort of
renewed sensitivity to the smaller projects having less overall impact
on the environment.
A Promising Niche
One of those smaller retrofit projects is taking shape at the Red Rock
Dam on the Des Moines River in Iowa (Figure 2). The 36.4-MW-
rated project, with a peak output of 55 MW, is being built by Missouri
River Energy Services (MRES) for the Western Minnesota Munici-
pal Power Agency (WMMPA). MWH is supplying engineering and
consulting services, and Voith Hydro is supplying the generators and
turbines. Ground was broken on the Red Rock Hydroelectric Project
(RRHP) in August, with completion scheduled for 2018. The $379
million facility will be operated by MRES and financed and owned
by WMMPA.
While there are avoided costs involved with a retrofit as com-
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2. Red Rock retrofit. Missouri River Energy Services is in the
process of adding 36.4 MW of hydro generation to the Red Rock Dam
in Iowa. The powerhouse will be located on the near bank below the
dam. Courtesy: MWH
|
October 2014 60
RENEWABLES
pared to a new project, there are also some
new challenges. As Ralph Watt, MWHs
project manager for RRHP explained to
POWER, the Red Rock Dam was built
primarily for flood control, with recre-
ation as an additional benefit. One of
the major challenges was to construct the
facility without having any impact on the
existing operation, he said. Because of the
demands of flood control operations, the
water level at Red Rock can fluctuate up
to 40 feet through the course of the year,
meaning the construction site is sometimes
completely dry and sometimes flooded. It
changes all the ways you would approach
building the project.
Like many other potential projects, RRHP
is being built at a USACE dam. That adds
another level of regulatory scrutiny, Watt
said. In design and construction of these fa-
cilities, we had to make sure that we satisfied
the Corps of Engineers concerns and require-
ments when it comes to any impact we might
have had on their structures.
Those concerns may be getting some
revision. In July, the USACE updated its
policy guidance on requests to modify
USACE-owned facilities under Section 408.
In it, the USACE says that USACE and
[the Federal Energy Regulatory Commis-
sion (FERC)] have agreed to work with each
other and with other participating agencies
or entities, as appropriate to ensure that
timely decisions are made and that the re-
sponsibilities of each agency are met. The
updated guidance extends not just to con-
ventional hydropower projects but also to
non-conventional facilities such as hydro-
kinetic generation (which relies on natural
flow rather than a hydraulic head) that could
be added to jetties, levees, and navigational
channels.
Other policy support may be on the way
was well. In 2011, the Obama Administra-
tion launched the Federal Infrastructure
Permitting Dashboard, which is designed
to expedite the licensing process for criti-
cal infrastructure projects that will create
a significant number of jobs, have already
identified necessary funding, and where
the significant steps remaining before con-
struction are within the control and juris-
diction of the federal government and can
be completed within 18 months. While the
list includes several wind and solar generat-
ing facilities, RRHP is so far the only hy-
dropower project to receive such expedited
review. Hydropower backers are hoping the
success of RRHP will lead to others.
Hydro Is Still Big
None of this is to suggest that the days of Big
Hydro are over, even in North America.
Quebec, which gets a whopping 96% of
its electricity from hydropower, is still look-
ing to add capacity. Hydro-Qubecs four-
unit, 1,550-MW Romaine project is partway
through full commissioning, with Unit 2
scheduled for service this year, and the re-
maining units expected to be complete by
2020. Equipment for the two largest units, 2
and 3, is being supplied by Alstom. Upgrade
projects to add capacity at several older fa-
cilities are also under way.
The Romaine project has been contro-
versial in part because it may prove to be a
money loser. Hydro-Qubec earns substan-
tial income from exporting electricity to cus-
tomers in the northeastern U.S., but with the
shale gas boom having depressed wholesale
power prices across the region, it is not clear
if Romaine will ever earn enough money to
pay for itself.
Out west, BC Hydro is still pushing for-
ward with the Site C project on the Peace
River in northeast British Columbia. The
proposal, which has been in the works for
more than 30 years, is projected to generate
1,100 MW. The plan is still in the permitting
process, but BC Hydro hopes to have it on-
line by 2024. This project as well is facing
stiff opposition, much of it from First Na-
tions groups concerned about lost farmland
and fishing grounds.
Storage Wars
Perhaps the biggest growth area for North
American hydro is pumped storage, Finis
said. One of the great drivers for these proj-
ects is going to be the integration of renew-
able energy resources.
In terms of storage options, pumped stor-
age hydropower reigns supreme in terms of
how much capacity it can add to the grid with
existing technology. That means big potential
in areas with a lot of renewable capacity be-
ing added.
We are seeing quite an interest in devel-
opment of storage projects right now in the
U.S., Finis said.
One of those projects is taking shape in
Northern California. The Sacramento Mu-
nicipal Utility District (SMUD) is conduct-
ing feasibility testing for a 400-MW pumped
storage facility that would be added to its
existing Upper American River Project near
Lake Tahoe. The Iowa Hill plant would add
a storage pond 1,200 feet above a bend in
the existing Slab Creek reservoir. The $800
million project could begin construction as
soon as 2018 if SMUD decides to proceed.
An even larger pumped storage project is
planned for Southern California, on the site
of an old iron mine near Joshua Tree Nation-
al Park. The 1,300-MW closed-loop facility
would convert the old mining pits into stor-
age reservoirs. GEI Consultants is leading
the project for Eagle Crest Energy Co. FERC
gave the project a license to proceed in July
after state water quality officials approved
the plan in 2013, but roadblocks remain. In
particular, the effect on area water resources
from filling the over 17,000-acre-feet proj-
ectthe plan is to use groundwater drawn
from nearby wellsis sure to be controver-
sial in the midst of one of the worst droughts
in Californias history. If completed, it would
be the fifth-largest pumped storage facility in
the U.S.
No Silver Bullet
Despite the advantages, getting backers for
hydropower projects in the current environ-
ment can be tricky, Finis acknowledged.
Hydro is still facing some challenges when
it comes to financing.
There are a couple of factors behind this,
he explained. One is the longer period for
FERC licensing for hydro generation, which
can take three to five years. However, chang-
es in the law in 2011 are intended to expedite
development at unpowered dams like Red
Rock. FERC has now been directed to con-
sider a shortened two-year licensing process
for such facilities.
The long licensing period stands in stark
contrast to how long it actually takes to
build small retrofits. In especially favor-
able sites, the plant can be up and running
in less than a year. The 6-MW Mahoning
Creek Hydroelectric Project at Mahoning
Creek in Armstrong County, Pennsylvania,
began construction in March 2013 and was
online by December. The project, retrofit-
ted to a flood control dam built in 1941,
was developed by Enduring Hydro, an in-
vestment and development firm that spe-
cializes in small hydropower.
Another roadblock is the larger upfront
costs compared to equivalent natural gas
generation. To develop hydro, you really
have to have more of a long-term outlook,
Finis said, and focus on the lower levelized
cost of energy over the project lifetime.
Youll have more cost on the O&M side,
replacement side, and fuel side with other
technologies that you dont necessarily have
with hydro.
This is an important advantage when you
consider the much longer lifespan for a hydro
plant compared to a gas plant: Some hydro
projects in the U.S. have been reliably gener-
ating electricity for more than 100 years.
The look of the hydro sector may be
evolving, but all signs are that its legacy will
continue.
Thomas W. Overton, JD is a POWER
associate editor (@POWERmagazine,
@thomas_overton).
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October 2014 62
MERCURY CONTROL
Non-Carbon Reagent Injection for
MATS Compliance
With the compliance deadline for the EPAs Mercury and Air Toxics Standards
less than a year off, plant owners need to decide now on the best approach
to control mercury emissions. The use of non-carbon sorbents may offer
substantial benefits over standard powdered activated carbon injection.
Jim Butz
T
he upcoming implementation of the
Environmental Protection Agencys
(EPAs) Mercury and Air Toxics Stan-
dards (MATS) is putting pressure on coal-fired
power plants to develop and implement com-
pliance strategies that are effective, economi-
cally efficient, and environmentally advanta-
geous. MATS, scheduled to go into effect in
April 2015 for most power plants, requires
that vapor-phase mercury stack emissions be
less than 1.2 pounds per trillion Btu (lb/TBtu)
for bituminous- and subbituminous-fired
units and 4 lb/TBtu for lignite units.
Plant compliance with these emissions
standards must be reported on a 30-day roll-
ing average basis. The EPA has authorized a
one-year extension for utilities that apply to
state regulators; a second-year extension is
available only under extreme circumstances.
Compliance options include mercury cap-
ture in a wet flue gas desulfurization (FGD)
scrubber or the use of powdered sorbents to
capture mercury upstream of the particulate
control device (PCD), with the best solutions
dependent on individual unit configuration
and operating conditions.
Wet Scrubbers
Wet FGD capture requires high (typically
>90%) levels of mercury oxidation, as oxidized
mercury has much greater solubility in the
scrubber solution. Oxidation occurs naturally
with high-chloride-content coals or can be fa-
cilitated by the addition of oxidizing agents to
the boiler coal feed. An alternate method relies
on mercury oxidation as a co-benefit of instal-
lation of a selective catalytic reduction (SCR)
module for NO
x
control. Capital and operating
costs for these options depend on the technol-
ogy employed and site conditions.
Wet scrubbers are installed on many plants
that burn higher-sulfur eastern bituminous
coals. While these systems typically provide
high native capture of vapor-phase mercury,
most cannot consistently meet the MATS stan-
dard. In addition to coal oxidation additives
noted above, wet FGD units sometimes employ
additives to the scrubber liquor to reduce or
eliminate a phenomenon called re-emission.
In the circulating FGD liquid, oxidized
mercury in solution may be reduced back
to its elemental state, with lower solubility.
This leads to saturation of the liquid with re-
spect to elemental mercury and release of the
elemental mercury back into the gas phase.
Strong evidence of this process is measure-
ment of vapor-phase elemental mercury at
higher concentration in the stack than at the
inlet to the wet FGD. Several scrubber addi-
tive products are commercially available to
convert the soluble oxidized mercury to an-
other form, which eliminates the potential for
re-emission.
Powdered Sorbents
Dry sorbent injection captures mercury on
fine particulates added to the flue gas after
the economizer, typically either upstream or
downstream of the air heater. The mercury-
containing particles are then removed in the
units PCD. Powdered activated carbon (PAC)
and non-carbon sorbents, such as Novindas
Amended Silicates products, are options.
PAC is commercially available in standard
and brominated forms, with brominated
materials used where vapor-phase mercury
is mostly elemental. The bromine promotes
oxidation on the particle, facilitating capture
and removal from the flue gas.
The most efficient and economic option
for a specific coal-fired unit depends on
many factors and is best determined via a
trial where mercury capture is measured dur-
ing implementation of candidate technolo-
gies. Trials require temporary installation
of equipment to deliver the mercury control
technologies of interest, as well as mercury
measurement instruments to document mer-
cury capture. Trials can be as short as a week
or continue for a month or more if the host
utility is interested in evaluating longer-term
performance and balance-of-plant impacts.
Utilities often wish to understand the effect
of mercury control on the salability of fly ash
as a cement replacement or on operation of
the host unit PCD.
Prior to the availability of the Amended
Silicates reagent technology, coal-fired pow-
er plants that were looking for a dry sorbent
mercury (Hg) removal solution had little
choice but to use carbon-based products. The
non-carbon Amended Silicates platform was
under development for several years, with
the most recent versionAmended Silicates
HgX-ESPintroduced in June 2014.
1. Quick results. The cumulative average of stack Hg emissions during injection of Amended
Silicates AS-HgX for a Powder River Basin (PRB) coal-fired unit are shown here. Courtesy: Novinda
11/1 11/4 11/7 11/10 11/13 11/16 11/19 11/22 11/25 11/28 12/1 12/4 12/7 12/10 12/13
6
5
4
3
2
1
0
H
g
T

(
l
b
/
T
B
t
u
)
Cumulative average stack Hg
MATS limit
AS injection started
October 2014
|
MERCURY CONTROL
Amended Silicates
The Amended Silicates family of products employs a non-carbon
mercury capture reagent that removes mercury via chemical reaction,
providing economic and environmental advantages unavailable with
carbon-based products.
Amended Silicates employs a bentonite clay substrate amended
with a metal sulfide that acts as the reagent to capture mercury. This
occurs via a chemical reaction that forms mercuric sulfide on the re-
action sites of particle surfaces in flue gas. Mercuric sulfide (cinnabar
in its naturally occurring state) is the most stable form of mercury and
the dominant mercury mineral in Earths crust.
Amended Silicates directly reacts with elemental and oxidized
mercury to form stable, sequestered mercury compounds on the sur-
face of the amended clay particles. This means that oxidizing coal
additives or wet scrubber re-emission chemicals are not needed to
maintain compliance with MATS, making Amended Silicates a sin-
gle-product solution. Fly ash samples containing collected Amended
Silicates particles have been subjected to the EPA Method 1311 TCLP
test, and leachable mercury has been found to be nondetectable, a fur-
ther indication that the mercury is sequestered as an insoluble solid.
Full-Scale Trial Examples
Novinda is supplying Amended Silicates to multiple coal-fired gen-
eration units in the western and midwestern U.S., including four units
at the Gillette Energy Center (GEC) complex operated by Black Hills
Power in Gillette, Wyo.
In a series of trials conducted in each of the four Powder River
Basin (PRB)fired units at GEC, Novinda demonstrated the superior
performance of Amended Silicates. Trials were completed to optimize
mercury control, as well as to demonstrate extended operations and
assess balance-of-plant impacts. Typical results for one of the units
are shown in Figure 1 for a 30-day trial of AS-HgX. The uncontrolled
mercury emissions from the host unit were between 5 lb/TBtu and 6
lb/TBtuwell above the MATS standard. Once injection was started,
mercury stack emissions quickly dropped below the MATS level; the
injection rate was adjusted over the first week of the trial to minimize
cost while continuing to meet the standard. The optimized injection
rate was determined to be a low 0.26 pounds per million actual cubic
feet (lb/MMacf) of flue gas.
In trials completed in other units at GEC, AS-HgX consistently
out-performed brominated PAC.
Black Hills continuously makes responsible investments in tech-
nology to help us comply with state and federal environmental poli-
cies, said Mark Lux, vice president and general manager of power
delivery at Black Hills Corp. Amended Silicates has proven to be a
consistent performer in achieving our mercury removal objectives,
and Novindas technology delivers the desired results with less than
half the material required by alternative products, minimizing the
emissions control costs for our customers.
Another long-term trial was completed at a proprietary plant burn-
ing PRB coal and equipped with an SCR, circulating dry scrubber,
and pulse-jet baghouse. AS-HgX was injected at this site for 18 days,
with results shown in Figure 2. The plant was able to tune the in-
jection ratio to meet the target mercury emission rate for the entire
period at an average injection ratio of 0.11 lb/MMacf. For this graph,
mercury is plotted as a cumulative average, the required reporting
standard of the EPA MATS rule.
Balance-of-Plant Impact
Other benefits of Amended Silicates bentonite clay substrate include
compatibility with continued sale of fly ash as a replacement for Port-
land cement. (PAC typically contaminates the fly ash, requiring land-
fill disposal.) Novindas Amended Silicates has passed ASTMs C618
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October 2014 64
MERCURY CONTROL
test for use as a cement replacement in every
sample evaluated to date. The combined fi-
nancial impact realized from the sale of fly
ash and avoided disposal costs for that same
fly ash if contaminated by PAC are often
greater than the operating costs for mercury
control in a host unit.
AS-HgX also has been subjected to the
ASTM E1226-10 explosibility test and found
to be not explosible. Therefore, injection sys-
tems for Amended Silicates do not require ex-
plosion suppression or inerting systems, as are
specified for PAC silos in recent procurements.
Some utilities have explored a hybrid ap-
proach for compliance with MATS. One
option is to add an oxidizing agent to the
coal feed coupled with the injection of PAC
or brominated PAC to capture the oxidized
mercury from the flue gas. A concern has
emerged at some plants over evidence of
corrosion associated with the use of halogen
oxidizing agents such as calcium bromide
(CaBr
2
). Novindas Amended Silicates of-
fers a single-product solution without the use
of corrosive halogen compounds; AS-HgX
serves to both oxidize and capture mercury
from the flue gas.
Amended Silicates has a higher bulk den-
sity compared to PAC and may require minor
modifications to PAC injection systems to
efficiently disperse in the flue gas. Novinda
recommends lance spacing of 30 inches and
discharge locations along the length of the
lance of 30 inches as well. To flow reliably
in PAC silo systems, minor modifications
to the fluidization air pad configuration are
recommended. These changes are typically
implemented in less than one week at a cost
of less than $50,000. The use of higher in-
jection air velocities at the lance discharge is
recommended as well, which may require an
upgrade to the transport air blower in existing
injection systems.
Economics
Due to its efficient capture of mercury and
one-product solution in certain plant configu-
rations, Amended Silicates generates signifi-
cant cost savings for many users. Details for
several cases are presented here.
Comparative economics for a baseload
(90% availability) 110-MW unit burning
PRB coal are shown in Table 1. This unit is
equipped with SCR, a spray dryer absorber,
and a pulse-jet baghouse for particulate con-
trol. In addition to AS-HgX, brominated PAC
was tested in this unit, both as the sole mer-
cury control sorbent and in combination with
calcium chloride (CaCl
2
) added to the coal as
a mercury oxidizer. AS-HgX met the pending
MATS emissions standard with a 20% margin
at an injection rate of 30 lb/hr (1.3 lb/MMacf)
while a higher rate was needed for brominat-
ed PAC. The simultaneous addition of CaCl
2

to the coal feed allowed for a reduced bromi-
nated PAC injection rate, but the combined
costs were still higher than AS-HgX. Use of
Novindas AS-HgX is projected to save the
utility 63% to 70% of the mercury abatement
costs of the brominated PAC alternatives.
In another trial, shown in Table 2, MATS
compliance was achieved with Amended
Silicates injection, and a concrete-friendly
PAC was evaluated as well. To meet MATS,
the PAC product required concurrent use of a
coal additive for mercury oxidation, as well
as hydrated lime to reduce flue gas SO
3
con-
tent, which degrades PAC mercury capture
efficiency. In spite of the use of a concrete-
friendly PAC, fly ash samples did not meet
specifications for sale as a cement replace-
ment. In this trial, Novindas single product
offered a 33% savings over the multiproduct
alternative and preserved the salability of
fly ash, estimated to be worth an additional
$5,000,000 in annual revenue and avoided
disposal costs.
Novindas Amended Silicates was also
evaluated in a unit burning a moderate sulfur
(~1.7%) eastern bituminous coal. The host
unit was fitted with SCR, which contributed
to a SO
3
concentration of about 20 ppm at the
Amended Silicates injection location. This
condition was similar to another unit burning
eastern bituminous coal where a sulfur-toler-
ant PAC had been tested with results reported
in the literature. To determine injection rates
of sulfur-tolerant PAC and hydrated lime,
a proportioning factor was calculated as a
simple ratio of plant outputs for the Novinda
host unit and the literature unit. Results of the
economic analysis are presented in Table 3.
The Novinda single-product option of AS-
HgX injection to meet MATS showed a 45%
cost savings compared to the combination of
an SO
3
-tolerant PAC and hydrated lime.
Carbon Footprint
Amended Silicates products provide a num-
ber of important environmental benefits
when compared to the use of PAC. In light
Product Injection rate Meets MATS? Cost/hour Annual
BrPAC + CaCl
2
50 lb/hr + 400 ppm Yes $89.50 $705,618
BrPAC only 100 lb/hr Yes $110.00 $867,240
AS-HgX 30 lb/hr Yes, plus 20% margin $33.00 $260,172
Table 1. Comparative economics for 110-MW unit burning PRB coal.
Source: Novinda
Case Product Injection rate (lb/hr) Product cost Cost/hour Annual cost
Multi-product
solution
Concrete-friendly
PAC
1,000 $1.10/lb $1,100.00
Hydrated lime 3,000 $0.0625/lb $187.50
CaBr
2
400 $0.90/lb $360.00
Total $1,647.50 $3,069,504
Novinda
single-product
AS-HgX 1,000 $1.10/lb $1,100.00 $1,695,936
Table 2. Comparative economics for 760-MW unit burning eastern bi-
tuminous coal. Annual costs do not include the effect on revenue from fly ash sales and
avoided disposal costs. Source: Novinda
5/2 5/4 5/6 5/8 5/10 5/12 5/14 5/16 5/18 5/20
0.030
0.025
0.020
0.015
0.010
0.005
0.000
S
t
a
c
k

H
g

e
m
i
s
s
i
o
n
s

(
l
b
/
G
W
h
)
Cumulative average
Plant target (MATS)
2. Meeting targets. Test results show the effectiveness of AS-HgX on cumulative stack
mercury in a PRB plant equipped with a circulating dry scrubber. Courtesy: Novinda
October 2014
|
of climate change concerns, Novinda com-
missioned CH2M HILL to compare the
greenhouse gas (GHG) emission impacts
for production of Amended Silicates versus
PAC.
Life-cycle GHG emissions for Amended
Silicates were estimated using process-spe-
cific data and the GaBi 4 life-cycle assess-
ment (LCA) software. These results were
compared with existing literature values for
production and use of PAC. The LCA includ-
ed mining, manufacturing, use in a power
plant, disposal, and transportation of mate-
rials between each step in the process. The
LCA concluded:
Per pound of material produced and used,
GHG emissions associated with Amended
Silicates are 11% of the average literature
values for GHG emissions of PAC.
The use of Amended Silicates would
deliver a potential reduction in carbon
dioxideequivalent (CO
2
e) emissions of
174,000 metric tons per year if just 10% of
the market substituted Amended Silicates
for PAC, based on Novinda estimates of a
total mercury sorbent market of 225,000
metric tons per year.
The ability to reuse fly ash results in avoid-
ed GHG emissions of an estimated 91 lb. of
CO
2
e for each pound of Amended Silicates
used, or 1.03 million metric tons per year
of avoided CO
2
e emissions, based on the
assumption that only 50% of fly ash is re-
used and the same Amended Silicates 10%
market usage with an average Amended
Silicates content of 1% in the fly ash.
The full report is available at http://bit.
ly/1p8w918.
A Cost-Effective Solution
The EPAs MATS regulation for control of
mercury emissions requires technology at
most coal-fired plants to capture vapor-phase
mercury in the emissions control train. Op-
tions include the injection of sorbents, the
use of additives to oxidize elemental mer-
cury for capture in wet FGDs, and other spe-
cialized hardware solutions. Most common
will be the use of injected sorbents such as
Amended Silicates or PAC, which represent
a lowcapital expense approach.
Novindas Amended Silicates product
line offers a viable alternative to PAC for
compliance with MATS. For most plant
configurations Amended Silicates is cost-
effective, generates low balance-of-plant
impact, and preserves the value of fly ash
for resale.
Jim Butz is vice president product man-
agement for Novinda Corp. in Denver.
Case Product Injection rate (lb/hr) Product cost Cost/hour Annual cost
Multi-product
solution
SO
3
-tolerant PAC 330 (est.) $1.10/lb $363.00
Hydrated lime 1,200 (est.) $0.0625/lb $75.00
CaBr
2
400 $0.90/lb $360.00
Total $438.00 $3,069,504
Novinda
single-product
AS-HgX 220 $1.10/lb $242.00 $1,695,936
Table 3. Comparative economics for a 315-MW unit burning eastern bi-
tuminous coal. Source: Novinda
MERCURY CONTROL
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October 2014 66
REGULATIONS
GHG RULES
New power plants. The Environmental Protection Agency (EPA) in September 2013
revised a 2012 proposal to limit carbon emissions from new coal- and natural gasred
power units. The New Source Performance Standards developed under Section 111(b) of the
Clean Air Act (CAA) require new gas plants of 100 MW or more to emit no more than 1,000
pounds of carbon dioxide/MWh of power produced (as achievable with the latest combined
cycle technology), but calls for smaller gas plants to achieve a less-stringent standard of
1,100 pounds CO
2
/MWh. Coal plants can either use carbon capture and storage technology
soon after startup (to achieve a 12-month average emission rate of 1,100 lb CO
2
/MWh) or
after seven years of startup to achieve a seven-year average emission of between 1,000 and
1,050 lb CO
2
/MWh.
MERCURY AND AIR TOXICS STANDARDS (MATS)
The U.S. Court of Appeals for the D.C. Circuit on Apr. 15 upheld MATS, rejecting numerous
challenges from industry, states, and environmental petitioners. Over July and August, at least
23 states and two energy industry groups petitioned the U.S. Supreme Court to review the
decision, arguing the rule would drive up power prices and harm the coal industry. The rule
requires all existing coal- and oil-red power units to meet specic, numeric emission limits
for mercury, particulate matter, and acid gases by Apr. 15, 2015, unless granted a one-year
extension.
Existing power plants. As directed by President Obamas Climate Action Plan, the EPA on June 2
proposed its Clean Power Plan emissions guidelines for existing power plants under the CAA Section
111(d). The proposal sets state-specic, rate-based goals and relies on four building blocks to
establish the best approach for each state to slash power sector CO
2
emissions by 30% from 2005 levels
by 2030.
BACT for GHG emissions. The U.S. Supreme Court on June 23 reversed the EPAs Tailoring Rule but
afrmed the agencys authority to regulate greenhouse gases (GHGs) under the CAAs Prevention of
Signicant Deterioration permit program. Specically, the high court said the EPA could permissibly
require sources that are obligated to obtain permits anyway (because of their emission of non-GHG
pollutants) to adopt GHG Best Available Control Technology (BACT).
CROSS-STATE AIR POLLUTION RULE (CSAPR)
The U.S. Supreme Court on Apr. 29 reversed and remanded the D.C. Circuits 2012 decision that
vacated CSAPR. The high court concluded that the EPAs approach in issuing the CSAPR as a
federal implementation plan rst was lawful. However, the D.C. Circuits stay of CSAPR remains
in effect, and the case now goes back to the appeals court to address substantive issues left
open by the Supreme Court. More legal process is required before CSAPR is put back into
effect, including certain debate over timing and compliance deadlines.
316(B) COOLING WATER RULE
The agency on Aug. 15 published its nal rule establishing requirements under Section 316(b)
of the Clean Water Act for all existing power generating facilities that withdraw more than two
million gallons per day of water and use at least 25% of the water they withdraw exclusively
for cooling purposesabout 540 power plants. The rule goes into effect on Oct. 14, 2014.
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A U.S. Power Industry Regulatory
Update
The U.S. power sector has seen a number of developments on the regulatory
front in recent months. Heres where major federal rules stand today.
October 2014
|
REGULATIONS
EFFLUENT LIMITATION GUIDELINES
A consent decree between environmental groups and the EPA reached this April suggests
the nal rule establishing national technology-based efuent limitation guidelines and
standards to reduce wastewater discharges of pollutants from nuclear and fossil power
plants will likely be delayed until September 2015. Current rules, last updated in 1983,
do not adequately address the pollutants being discharged and have not kept pace
with power sector changes, the agency says.
OZONE STANDARD
A federal court this April ordered the EPA to propose primary and secondary national
ambient air quality standards for ozone by Dec. 1, 2014, and nalize them by October
2015. The rules last revision in 2008 set the ozone standard of 75 parts per billion
(ppb). But before the EPA could nalize a rule proposed in 2010 to set a stricter stan-
dard of between 60 ppb and 70 ppb, President Obama in 2011 scuttled the rule to
reduce regulatory burdens and uncertainty. An August-released EPA nal policy assess-
ment provides strong support for revising the standard within the range of 60 ppb to
70 ppb.
RADIATION PROTECTION STANDARDS FOR NUCLEAR PLANTS
The EPA on Feb. 4 proposed a thorough review of these standards, given changes in the
industry and in scientic knowledge. In contrast to tightened standards for other risks,
the draft version for exposure from radiological incidents proposes to substantially relax
existing limits. The current standards were promulgated in 1977 to limit radiation
releases and doses to the public from nuclear power plants and uranium fuel-cycle
facilities.
COAL COMBUSTION RESIDUALS
Though proposed more than four years ago, rules governing the disposal of coal com-
bustion residualsincluding y ash, boiler slag, and ue gas desulfurization waste
productsremain in limbo. But on Oct. 29, 2013, the D.C. Circuit directed the EPA to
establish a timeline for reviewing coal combustion residue regulations, and on Jan. 29,
a consent decree between the agency and environmental groups was reached that
requires the EPA to issue a proposed revision to its rules no later than Dec. 18, 2014.
CONTINUED STORAGE OF SPENT NUCLEAR FUEL
Finalized on Aug. 26, this rule replaces the 2010 Waste Condence Rule that was
vacated by a federal court in 2012 and conrms that nuclear fuel from commercial
reactors can be safely managed in reactor fuel storage pools in the short term and in
steel and concrete storage containers for longer timeframes. The Nuclear Regulatory
Commission (NRC) on Aug. 26 also lifted a suspension on nal decisions on 19 pending
reactor license applications.
CRITICAL INFRASTRUCTURE PROTECTION (CIP) RELIABILITY
STANDARDS
Cybersecurity Standards. The Federal Energy Regulatory Commission (FERC) on
Nov. 21, 2013, approved with modications the North American Electric Reliability
Corp.s (NERCs) Version 5 CIP reliability standards, calling for the rst time for all cyber
assets to be categorized as low-, medium-, or high-impact assets and approving 12 new
requirements with new cybersecurity controls.
Physical Security Standards. FERC proposed to approve NERCs submitted rule to
enhance physical security for the most critical bulk power system facilities on July 17.
In a March 7 order, FERC determined that existing CIP reliability standards did not
address physical attacks.
Sonal Patel is a POWER associate editor (@POWERmagazine, @sonalcpatel).
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Opportunities in Operations and Maintenance,
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October 2014 68
POWER PLANT BUYERS MART
Training Professionals
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GP Strategies, a global leader in performance
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maintenance training programs for our 200+
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INVITATION FOR EXPRESSION OF INTEREST FOR TECHNICAL
PARTNERSHIP FOR DEVELOPMENT AND DELIVERY OF
INDEPENDENT POWER PLANT (NIGERIA)
1. Introduction
We are delighted to introduce our company ALLIED ENGINEERING AND CONSTRUCTION
LIMITED (Allied Power) to you. We are an Independent Power Producing company in Nigeria
with a sizable pipeline of Independent Power Plant Projects, with capacities ranging from
5MW to over 500MW in different congurations,
We wish to use this medium to invite reputable and competent American companies with
the requisite experience, skilled manpower and technology to apply to be considered for
the provision of technical partnership services for our power plant project development and
delivery activities in Nigeria and the West African sub-region.
The suitable company, for the opportunity, must have a track record of successful power
generation, transmission and distribution projects within the United States of America and
be able to provide technical support for power generation, transmission and distribution
projects in Nigeria.
2. Scope of work
Technical support for all power plant feasibility studies
Technical support for all power plant project design and development activities
Technical support for all power plant equipment sourcing and procurement in the
USA
3. Requirements
A track record of successfully developed and delivered power plant projects
The company must be able to demonstrate evidence of past projects in USA
Experience working on Gas to Power Plant technology
Experience working on Combined Cycle and Cogeneration Power Plants
4. Mode of Application
Interested companies should submit electronic copies of the following documents to
tajuwape@allied-epc.com
Certicate of incorporation showing the country of incorporation
Company brochure detailing the services, experience and locations
Details of power plant projects executed in the last 3 years (worldwide)
5. Entry closure
Entries close on the 28th of November 2014
AlliedEng_classad.indd 1 9/30/14 12:17:49 PM
George H. Bodman
Pres. / Technical Advisor
Ofce 1-800-286-6069
Ofce (281) 359-4006
PO Box 5758 E-mail: blrclgdr@aol.com
Kingwood, TX 77325-5758 Fax (281) 359-4225
GEORGE H. BODMAN, INC.
Chemical cleaning advisory services for
boilers and balance of plant systems
BoilerCleaningDoctor.com
20_PWR_100114_classifieds_p68-71.indd 69 9/30/14 12:19:19 PM
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ADVERTISERS INDEX
Enter reader service numbers on the FREE Product Information Source card in this issue.
Beumer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 . . . . . . . . 5
www.beumer.com
Bilfinger Piping Technologies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59. . . . . . . . 21
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Brandenburg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cover 4 . . . . . 24
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Burns & McDonnell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11. . . . . . . . 6
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Burns & McDonnell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31. . . . . . . . 15
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Carver Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43. . . . . . . . 18
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CIRCOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17. . . . . . . . 9
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Cormetech . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55. . . . . . . . 20
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Diamond Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21. . . . . . . . 11
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Doosan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . . . . . 2
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GE Measurement & Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 . . . . . . . . 4
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Hach.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27. . . . . . . . 13
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KIMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37. . . . . . . . 16
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MD&A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 . . . . . . . . 3
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Mitsubishi Hitachi Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cover 3 . . . . . 23
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Rentech. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cover 2 . . . . . 1
www.rentechboilers.com
Safway Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29. . . . . . . . 14
www.safway.com
Sealeze. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13. . . . . . . . 7
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SICK Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19. . . . . . . . 10
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Structural Integrity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63. . . . . . . . 22
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TerraSource Global . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15. . . . . . . . 8
www.terrasource.com
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October 2014 70
Find this guidebook, along with other useful tools, online at:
http://store.powermag.com/ or call 888-707-5808.
24654
This guidebook exclusively features articles detailing actions that must be
taken for a safe working environment in the Power Generation Industry.
Included are full charts, photographs, graphs and step-by-step
instructions, brought to you by the editors of POWER magazine.
Delivered in a PDF format.
Articles Include:
Safety Is Not an Accident
Fire Safety in Modern Hydroelectric Stations
Suing for (Pipeline) Safety
Plant Safety: Learn from the
Mistakes of Others
A Safety Milestone at NV Energy
Safety Implications of Coal and
Biomass Fuel Mixes
Safe Work Practices in Confned
Spaces at Power Plants
Real-time Proactive Safety in Construction
What Are the Safety Rules for Anyway?
CSB Releases Hot Work Safety Notice
Safety Measurement: Culture Shaping or Failure Avoidance?
Hazard Recognition and Control: Improving Safetys Bottom Line
S
a
fe
ty
in
th
e
P
o
w
e
r
G
e
n
e
ra
tio
n
W
o
rk
p
la
c
e
Safety in the Power
Generation Workplace
J
u
s
t
R
e
l
e
a
s
e
d
!
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October 2014 72
COMMENTARY
Collaborating to Build a
Cleaner Energy Infrastructure
Kelly Speakes-Backman
E
very day there is increasing evidence that we need to ac-
celerate our nations transition to a cleaner energy infra-
structure. The American Climate Prospectus released by
the Risky Business Project states that a business-as-usual ap-
proach to energy use creates serious economic risks. The U.S.
Environmental Protection Agency (EPA) recently proposed a new
rule requiring states to reduce carbon pollution from the nations
existing power plants. The Obama Administration has issued its
Fifth National Climate Assessment, asserting that climate change
and its effects are present today, not some time off in the dis-
tant future.
Whether we are ready or not, we are faced with circumstanc-
es that require action. Fortunately, we have powerful tools at
our disposal to take that actiontools that industry and state
governments can use together to reduce carbon pollution and
hasten our transition to a cleaner energy infrastructure, at the
lowest possible cost.
Several proven cost-effective tools for accelerating this tran-
sition are already in practice. Renewable portfolio standards,
energy efficiency policies, green banks, building codes and stan-
dardsthese and other programs have demonstrated that we
can develop our clean energy infrastructure without detriment
to grid reliability or the economy.
Case in Point: RGGI
One program that has proven to be particularly effective is the
Regional Greenhouse Gas Initiative (RGGI). Developed through
a collaborative multi-state and multi-disciplinary process, and
enacted with bipartisan support, RGGI is a field-tested, proven
model for cost-effectively reducing carbon pollution while gen-
erating economic benefits.
RGGI provesand not for the first timethat regional, mar-
ket-based pollution reduction programs work. One of the first
regional pollution reduction programs, the EPA Acid Rain Pro-
gram, served as a prototype for the RGGI program. The Acid Rain
Program realized its goal of reducing sulfur dioxide and nitrogen
oxide pollution at one-quarter of the original estimated cost.
The success of this regional pollution reduction program has
been replicated in RGGI. Since 2005, the RGGI region has seen a
40% drop in power sector carbon emissions, even as its regional
economy has grown by 7%. In fact, the RGGI state environmen-
tal and economic regulators decided to strengthen RGGI in 2014
by locking in those reductions and moving forward with changes
that will help further reduce the regions projected power sec-
tor carbon pollution in 2020 to levels almost half that of 2005.
These changes are also projected to add more than $8 billion to
our economy.
RGGI and other regional market-based programs are designed
to be cost-effective. RGGIs regional market-based approach re-
lies directly on market forces to encourage states and the power
sector to find the least expensive pollution reduction opportu-
nities. This approach takes advantage of the regional nature of
the electricity grid and complementary individual state energy
policies, while also channeling capital to strategic energy initia-
tives. These initiatives can include technology upgrades at the
plant itself, new renewable energy facilities, energy efficiency
projects that reduce energy demand, or even direct consumer bill
assistance. Allowing carbon pollution reduction strategies to be
tailored to each states unique circumstances results in a more
diverse (and effective) set of projects, which directly benefit the
individual objectives of each state and maximize the value of
investment for the region.
RGGIs market-based approach has also yielded positive eco-
nomic benefits for the region. The RGGI states distribute most
of the allowances that provide the power sector with the right
to emit carbon dioxide via auction. These auctions generate
revenues that are reinvested into energy efficiency, renewable
energy, and other clean energy infrastructure programs. These
programs help create local jobs and grow the regions economy
while helping businesses and families save money on their en-
ergy bills, reducing overall demand for electricity, and reducing
the need to import fossil fuels into the region.
An independent report by The Analysis Group found that,
through the end of the decade, RGGI proceed investments gen-
erate $1.6 billion in net economic benefits, put $1.3 billion in
energy bill savings back into the pockets of consumers, and create
16,000 job-years in the region. By using funds from the program
to invest in clean energy infrastructure, RGGI has demonstrated
that regional market-based programs not only reduce carbon pol-
lution, but they also can generate significant economic benefits.
The Value of Collaboration
Regional market-based programs like RGGI provide a proven
model to cost-effectively reduce carbon pollution while main-
taining grid reliability and growing our economy. But perhaps as
importantly, they show how important it is to collaborate across
regions and across professional disciplines as we work to build
this new infrastructure.
RGGI was launched thanks to a 2003 letter sent by thenNew
York Governor George Pataki to other governors in the region,
both Republicans and Democrats. The RGGI states are diverse,
with different energy demands, natural resources, power pro-
files, regional transmission organizations, and economies. Yet
the states have been able to work together to implement RGGI
successfully. It has not always been easy, but this collaboration
has resulted in a program that is cited by power plant owners
and environmental nonprofits alike as a national model.
What our experience demonstrates is that we can reduce car-
bon pollution without detriment to grid reliability or the econo-
my and ultimately deliver a cleaner energy infrastructure. But we
cant do it alone. We have to do it together.
Kelly Speakes-Backman is commissioner of the Maryland
Public Service Commission and chair of the RGGI Inc. Board of
Directors.
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October 2014

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October 2014

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O

Cage Mills are preferred

Boiler Cleaning Control Systems

Block Lining System

Block Lining System.

Block Lining System applied directly to its

lining has a projected service

BILFINGER PIPING TECHNOLOGIES GMBH

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