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WIND POWER
WHATS NEW IN WIND POWER TECHNOLOGY?
COMBINED HEAT AND POWER

WATER/STEAM TREATMENT AND MONITORING
REDUCING NOx
ONE UTILITYS INNOVATIVE SOLUTION
the magazine of power generation
118
YEARS
Layup Practices
for Cycling Units
August 2014 www.power-eng.com
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18 Layup Practices
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No. 8, August 2014
VOLUME
for Cycling Units
Electric Power Research Institute describes the proper

layup techniques to protect boiler tubes, steam turbines
and other equipment during a unit shutdown.
28
Reducing NOx Emissions

from the San Juan
Generating Station
SENIOR MARKETING MANAGER Jessica Grier

(918) 832-9272 jessicag@pennwell.com
Public Service of New Mexico and Sargent & Lundy

provide a detailed look at the work being performed on
two coal-fired units at the San Juan Generating Station.
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38
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CHP: Dont Neglect

Water/Steam Treatment
Kiewit examines proper water/steam treatment and monitoring

at combined heat and power projects using heat recovery steam
generators for process steam and/or power generation.
44
Whats New in Wind Technology?
New wind power innovations from GE, TenderLand Renewables

and other manufacturers and suppliers were featured at
Windpower 2014. Heres a look at what we saw.
48
Valves & Actuators
Valves and actuators get little or no recognition.

But their impact on power plant efficiency can be
significant. Power Engineering identifies several
notable improvements in actuator technology.
DEPARTMENTS
2
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8
Opinion
Industry News
Clearing the Air
10
12
14
View on Renewables
Energy Matters
Nuclear Reactions
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8/14/14 4:31 PM
OPINION
A CCS Expansion
BY RUSSELL RAY, CHIEF EDITOR
y most accounts, capturing and

storing carbon dioxide (CO2)
from a commercial-scale power plant is a risky undertaking due to
the cost, liability and questions about
the process.
But carbon capture and storage (CCS)
technology remains the most important technological solution to climate
change, a claim bolstered by two new
CCS projects announced last month
and two ongoing CCS projects that will
be placed online later this year.
After many setbacks, CCS projects
in North America appear to be making progress once again thanks to several demonstration projects and power
producers who recognize the need
for CCS technology in a carbon-constrained world.
NRG Energy, the largest independent power producer in the U.S., said
last month it will add a CCS system to
an existing coal-fired plant near Houston, Texas, where it will capture 90 percent of the CO2. The $1 billion project
will be the worlds largest post-combustion carbon capture project, NRG
said. It will capture about 1.4 million
tons of CO2 annually, which will be
used to boost oil production from a
nearby oil field a process known as
enhanced oil recovery.
The project stems from the research
gathered during a three-year pilot
project at Southern Co.s Plant Barry,
which successfully captured more
than 150,000 tons of CO2 each year.
The same technology deployed at
Plant Barry will be used by NRG. The
process was jointly developed by Mitsubishi Heavy Industries and Kansai
Electric Power.
On a much smaller scale, Kentucky

Utilities announced plans to install
a carbon capture system at the companys E.W. Brown Generating Station
near Harrodsburg, Kentucky. The $19.5
million project is being funded largely
with $14.5 million in financial assistance from the Department of Energys
National Energy Technology Laboratory. Others involved in the research and
implementation of the project include
the Electric Power Research Institute,
the University of Kentucky, the Carbon
Management Research Group, Duke
Energy and Mitsubishi Hitachi Power
Systems Americas.
Whats more, CCS projects at Southern Co.s Kemper power plant in Mississippi and SaskPowers Boundary
Dam in Saskatchewan will be up and
running later this year. These two
commercial-scale projects will demonstrate how technology can turn coalfired generation into the most effective
tool to combat climate change.
Thanks to projects like these, the
cost of CCS will come down and the
technical challenges will be overcome.
The truth is most of the scientific
community supports CCS as a critical
tool for reducing CO2 emissions from
power plants. Without CCS, the cost of
greenhouse gas reduction would skyrocket, said Julio Friedmann, deputy
assistant secretary for Clean Coal in
the Department of Energys Office of
Fossil Energy.
If you take CCS off the table, the
cost of abatement goes up 50 to 80 percent, Friedmann said during a forum
earlier this year.
Gareth Lloyd, general manager of
corporate affairs at the Australia-based
Global CCS Institute, said during a

press conference last year the world will
still be getting more than half of its energy from fossil fuels in 2060, which
means CCS is not an optional technology if were to address climate change.
According to the institute, the 21
large-scale CCS projects under construction or in operation around the
world can capture up to 40 million tons
of CO2 annually.
For now, gas-fired power plants in
the U.S. are not required to capture
any of their carbon emissions. Coalfired power plants emit almost twice as
much CO2 than natural gas-fired plants
and cannot comply with new CO2
emission standards without building
an expensive CCS system. But CCS will
eventually be required for gas-fired generation because gas-fired plants, which
produce 800 to 850 pounds of CO2 per
megawatt-hour, remain a significant
source of CO2 emissions in the U.S.
We will be doing this for natural gas
plants, Friedmann said.
Meanwhile, the federal government
is providing billions of dollars to the
developers of CCS projects. In addition to $6 billion targeted for CCS in
the 2009 Recovery Act, the DOE has
funded several demonstration projects
and is providing up to $8 billion in
loan guarantees for CCS projects. Peter
Davidson, executive director of DOEs
Loan Program Office, will share more
details about the DOEs $8 billion solicitation during the keynote session at
COAL-GEN 2014, Aug. 20-22 in Nashville, Tennessee.
If you have a question or a comment,
contact me at russellr@pennwell.com.
Follow me on Twitter @RussellRay1.
www.power-eng.com
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INDUSTRY NEWS
Carbon capture project planned

for coal-fred unit in Texas
Petra Nova Holdings LLC, a subsidiary
of NRG Energy has formed a 50/50 joint
venture with a subsidiary of JX Nippon
Oil & Gas Exploration Corp. to build a $1
billion carbon capture project in Texas.
The Petra
Nova
Carbon Capture
Project will
capture
90
percent,
or
1.6 million tons, of the carbon dioxide
(CO2) in the 240-MW slipstream of processed fue gas from the 610-MW Unit 8
at the WA Parish coal-fred power plant
near Houston. The captured CO2 will be
used in enhanced oil recovery at the West
Ranch oilfeld, owned by the joint venture and Hilcorp Energy Co.
Construction on the project has already started and is expected to take two
years. It will be built under a fxed-price
contract by a consortium of Mitsubishi
Heavy Industries Americas Inc. and TIC.
The unit is expected to be operational by
the end of 2016.
Kentucky power plant to host

carbon capture system
A $19.5 million carbon capture pilot
project will be built at Kentucky Utilities
E.W. Brown Generating Station.
Construction of the 2-MW thermal
post-combustion carbon dioxide (CO2)
capture pilot system is expected to be
completed this fall, with testing to follow
shortly after. It will consist of six modules
connected side by side. The focus of the
catch and release style pilot system will
serve to demonstrate the integration of
carbon capture technology at an existing
power plant. Testing is expected to fnish
by mid-2016.
The project, in partnership with the
University of Kentucky Center for Applied Energy Research, was made possible through a $14.5 million competitive
4
fnancial assistance award from the U.S.

Department of Energys National Energy
Technology Laboratory and cost-share
funding from the university, the Kentucky Department of Energy Development and Independence, the Carbon
Management Research Group and project team members including the Electric
Power Research Institute and Mitsubishi
Hitachi Power Systems Americas.
Wind power to deliver more

than 7% of electricity
Although wind power production
slowed in 2013, a new report from Navigant Research fnds that wind power will
deliver 7.3 percent of the electricity consumed worldwide by 2018.
Last year was the frst in which the
wind industry experienced negative
growth since 2004, but there are signs
that the 2013 slowdown will turn out
to be an anomaly, said Feng Zhao, research director with Navigant Research.
As wind turbine vendors search for new
opportunities in emerging markets, primarily in Latin America and Africa, and
develop machines for maximum energy
production in low wind speed areas, the
industry is expected to add another 250GW of capacity through 2018.
According to the BTM Wind Report,
wind power currently produces nearly 3
percent of global power. However, that
number is expected to increase due to offshore wind projects, which saw 13 new
projects installed in 2013, adding 1,720MWa 50 percent increase from 2012 .
Energy Northwest to provide

O&M services to hydro project
Energy Northwest will provide operations and maintenance services for a hydropower project in Washington state.
Energy Northwests scope of work includes several deliverables with an emphasis on operating and maintaining the
15.6-MW Tieton Dam Hydroelectric Project using best utility practices; original
equipment manufacturer recommendations; and adherence to all regulatory and

safety standards and requirements.
The Tieton project was purchased by
the Southern California Public Power Authority (SCPPA) on behalf of the cities of
Burbank and Glendale, California, both
of which have power purchase agreements with the project. The city of Burbank is responsible for the overall O&M
of Tieton through the SCPPA contract.
Energy Northwest has signed a one-year
Inter-Local Agreement with the city of
Burbank that is renewable on an annual
basis.
Cleaver-Brooks acquires
two boiler companies
Cleaver-Brooks, a Harbour Group
company, has acquired two Texas-based
boiler sales and service companies: Holman Boiler Works and Affliated Power
Services (APS).
These are two outstanding companies, said Jeff Fox, Chairman and CEO
of Harbour Group. The sales, service,
rental, design and fabrication they deliver
leads the industry in their markets. The
combination with Cleaver-Brooks, which
provides the broadest and best performing energy-effcient, low-emission boiler
room solutions in the industry, will further improve their already exceptional
customer service.
Holman Boiler Works Inc. is a fullservice boiler solutions provider. APS
focuses on the repair and maintenance
of industrial and commercial boilers. Financial terms were not disclosed.
Aggreko opens service

center in New Mexico
Aggreko announced it has opened
a new service center in Carlsbad, New
Mexico to meet the growing demand for
temporary utility services in the oil and
gas, mining, utility, petrochemical and
refning industries.
The growth of activity in the Permian
www.power-eng.com
Powering
the Future.
An industry innovator,
Kiewit Power has extensive
experience in the gas-red,
air quality control systems,
power delivery, renewable
and nuclear markets. Kiewit
serves the power industry
through a number of its
subsidiaries, such as Kiewit
Power Constructors Co.,
Kiewit Power Engineers
Co. and TIC-The Industrial
Company (TIC).
As a full EPC provider, our
in-depth market knowledge
and industry-leading
projects show how Kiewit is
committed to clients and to
remaining a power pioneer.
Leader in EPC
installations for
TODAYS
Kiewit Power Group Inc.

9401 Renner Boulevard
Lenexa, KS 66219
(913) 928-7000
kiewit.com
ADVANCED
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TECHNOLOGIES
For info. http://powereng.hotims.com RS#3
INDUSTRY NEWS
Basin has prompted a need for more

readily available and accessible power
sources, not only to support oil and
gas production, but also to support
utilities where the added strain on the
grid puts local communities at risk
for unexpected outages, said John
Morgan, vice president, West Area
General Manager, Aggreko North
America. With this new facility, we are
better positioned to service our clients
with faster turnarounds and maintain
our commitment to providing reliable,
cost-effective and scalable power
solutions.
Aggreko also offers a feet of natural
gas generators and gas cleaning applications.
GE gas engines selected for

CHP project in Mexico
GEs Distributed Power business announced it will provide its gas engine
technology to engineering, procurement
and construction contractor SEISA for
Enerkin SAPI de C.V.s (Enerkin) combined heat-and-power (CHP) facility in
Mexico.
The new CHP project will use three of
GEs Jenbacher two-stage turbocharged
J624 gas engine generator sets to produce 13.125MW of power
and 13,800
pounds per
hour of steam from the exhaust of the
units. The electric power produced will
be used to power existing plants; additional power will go to Mexican stateowned electric utility, Federal Electricity
Commissions (CFE) grid.
Enerkin is the frst independent power
producer in the state of Yucatan. The new
CHP plant will help meet the Mexican
governments initiative for effcient cogeneration.
The plant is expected to enter commercial operation in May 2015.
Utilities to host carbon lab

at Wyoming power plant
Two electric utilities say theyre interested in hosting a proposed lab to test out
carbon capture technologies at a working
power plant in Wyoming.
Gov. Matt Mead said those utilities are
Bismarck, North Dakota-based Basin
Electric Power Cooperative and Rapid
City, South Dakota-based Black Hills
Corp.
Both utilities operate coal-fred power
plants in the Gillette area.
Wyoming has reserved $15 million to
build a test center at a coal-fred power
plant. Teams would use the lab to compete for a proposed $10 million prize for
developing a cost-effective way to trap
and reuse carbon dioxide emissions.
The U.S. Environmental Protection
Agency proposes steep cuts in CO2 emissions in the years ahead. Much of that
CO2 comes from coal-fred power and
the stakes are high for Wyoming, the top
coal-mining state.
Minnesota Power to
reduce emissions
Minnesota Power, an ALLETE company, will install pollution control
technology at three coal-fred power
plants, as part of a settlement with the
U.S.
The settlement addresses claims that
Minnesota Power violated the Environmental Protection Agencys New Source
Review provisions under the Clean Air
Act by unlawfully constructing modifcations at its plants without obtaining
the necessary permits and installing
and operating the best available air pollution control technology.
The company expects to spend more
than $500 million to implement the
required measures from the three sites.
Minnesota Power will also have to retire, refuel, repower, or reroute emissions at fve other units.
The settlement also requires that the

company pay a civil penalty of $1.4 million to resolve Clean Air Act violations.
Texas approves two more

units for El Paso Electric
The Texas Public Utility Commission
on July 11 approved a September 2013
application from El Paso Electric (EPE)
for two additional 88-MW natural gasfred units at its Montana power plant.
The site for the proposed units is the
Montana power station, just east of the
city of El Paso. EPE received authorization for the frst two of these Montana
units - Units 1 and 2
in December 2012.
Montana Units
3 and 4 will each
consist of a General
Electric LMS 100
simple-cycle, aero-derivative combustion turbine that will be fueled by natural
gas, with the capability to burn fuel oil as
their secondary fuel source.
Although the units would have a nameplate rating of 103 MW at ISO conditions,
each unit will deliver 88 MW (net) to
EPE under summer peak conditions due
to the relatively high elevation and high
temperatures in this area of Texas. The
high elevation in the area also means that
the units heat rate will be higher than it
would be at ISO conditions. The units
guaranteed full load heat rate is 9,074
British thermal units per kilowatt-hour,
with a thermal effciency ranging from
44 percent to 50 percent.
The units will be used for peaking service and also intermediate service and are
expected to operate at approximately a
40% capacity factor. They will be quick
start units that can be brought on-line
within three minutes and reach full load
within 10 minutes.
Montana Units 3 and 4 are expected to
be operational by the summer peaks of
2016 and 2017.
www.power-eng.com
Material Handling & Size Reduction

Equipment and Systems for
for Coal and Biomass Power
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Handling a World of Materials
CLEARING THE AIR
Will Supreme Court

Rulings Bolster EPA
Authority?
BY MITCHELL KRASNOPOLER, MANAGER OF AIR QUALITY, KIEWIT POWER ENGINEERS
wo recent U.S. Supreme Court

rulings have empowered the
EPA to continue pursuing stricter limits on coal-fired power plants. The
rulings are the Cross State Air Pollution
Rule (CSAPR) case (US EPA v. EME Homer
City Generation, April 29, 2014) and the
greenhouse gas permit case (Utility Air
Regulatory Group v. EPA, June 23, 2014).
Both gave the EPA all or most of the authority that it wanted. These rulings have
broad direct impacts on coal-fired power
plants. However, the indirect impact of
an emboldened EPA on power plants
may turn out to be more important.
There is, however, uncertainty on how
the courts will assess new rules from an
emboldened EPA.
In the CSAPR ruling, the Court upheld the EPAs authority to regulate air
pollution from power plants that crosses
state lines and causes downwind air pollution problems. In CSAPR, the EPA
had developed a complex calculation to
determine each upwind states emission
reduction obligation, referred to as the
annual emissions budget. This calculation included an assessment that an upwind state contribute significantly to
downwind States nonattainment of the
NAAQS. The controversial part of the
calculation was that each states emissions reductions were a function of the
cost effectiveness of controls, and not
proportional to each States contribution
to downwind air pollution problems.
The Court sided with the EPA in calling
EPAs rule making an agencys reasonable interpretation of ambiguous statutory language. It agreed that the EPA
is allowed to make choices because the
Clean Air Act language was not specific.
Although part of the Court ruling

in Utility Air Regulatory Group (UARG) v.
EPA went against the EPA, the overall
result was in favor of the EPAs ability to
regulate greenhouse gases. The Courts
ruling overturned the EPAs greenhouse
gas tailoring rule that allowed the EPA
to require a permit for millions of small
sources based solely on the greenhouse
gas emissions of a small source. The
EPA proposed tailoring the emissions
threshold from 100 or 250 tons per year
to 75,000 to 100,000 tons per year for
greenhouse gases. The court ruled that,
EPAs rewriting of the statutory threshold was impermissible. However, the
Court did not reopen its decision that
the EPA is able to regulate greenhouse
gases as pollutants. The Court upheld
EPAs rule requiring stationary sources
already required to obtain a PSD permit
because of other emissions to meet BACT
requirements for greenhouse gases. It is
interesting to note that in this case federal
agencies may not revise clear statutory
terms that turn out not to work in practice, while in the CSAPR ruling, the EPA
is allowed to interpret ambiguous statutory language. Although the Court limited the EPA by overturning the Tailoring
Rule, at the same time it upheld the central principle that the EPA can regulate
greenhouse gases.
The upshot of these two decisions
may be how the power industry, Congress, and ultimately the courts treat the
EPAs recently proposed carbon pollution standards, called the Clean Power
Plan. This Plan was proposed on June
2, 2014 and, when implemented, will
reduce carbon dioxide emissions from
existing power plants. The Clean Power
Plan undertakes the reduction of carbon pollution by establishing state-specific limits for the states to implement
and guidelines to help them meet these
limits. This plan envisions significant
flexibility in how each state will meet
its limit. This flexibility includes nontraditional methods of reducing emissions that the Plan refers to as building blocks. The four building blocks
are, improved operations at EGUs,
dispatching lower-emitting EGUs and
zero-emitting energy sources, and enduse energy efficiency.
Congress never anticipated these
methods when it passed the Clean Air
Act. The applicable law is Clean Air Act
Section 111(d) that requires the EPA administrator to establish a procedure so
that each state develops a plan to establish standards of performance for any
existing source.
A key question is how the courts will
view the Clean Power Plans building
blocks. Based on the CSAPR ruling,
the courts may agree with EPAs interpretation of Section 111(d) because
EPA did propose a flexible procedure.
Alternatively, the courts could also
determine that the building blocks
except for improving operations are
not directly applicable to an existing
source. In other words, the building
blocks could be viewed as a revision of
the statutory term, existing source.
The Clean Power Plan is probably
the EPAs most important initiative for
the remainder of President Obamas
term. While we cannot predict how
challenges to the Plan will turn out,
we can expect an emboldened EPA to
fight hard for these rules.
www.power-eng.com
VIEW ON RENEWABLES
The Future Deployment

of Biomass Power in the
United States
BY DAVE OCONNOR, BIOMASS PROGRAM MANAGER, EPRI
o a casual observer, it might appear that biomass power has

become dormant in the U.S. To
some degree, that analysis is correct, but
the picture is complex. Utilities and independent power producers once had plans
to install significant amounts of biopowerFirstEnergy was converting two units
at its Burger coal plant to biomass; Georgia Power was studying ways to convert
its 165-MW Plant Mitchell to 100-MW of
biopower, and a joint venture between
Areva and Duke Power announced plans
to build up to ten 50-MW biomass plants
in the U.S. For different reasons, these
plans and others have slowly abated.
Confounding the situation are uncertain
regulations regarding carbon emissions
and biomass carbon accounting. On
the other hand, biopower is growing at
a rapid rate in Canada, where Ontario
Power Generation is converting two stations to biomass, and Europe-based RWE
has invested heavily in U.S. wood pellet
production.
So does biopower have a future in the
U.S., or will it be relegated to a marginal
role? Unfortunately, the vision of the
future of domestic biopower remains
unclear, crowded out by the forest, so to
speak. But there are conditions and technologies that will let biopower grow.
Its worth noting that biopower is currently growing in the U.S.the Energy
Information Administration notes that
549-MW was added in 2013, and quarterly reports indicate continued growth.
The growth is largely from smaller units
that might be considered a distributed
power source. EPRI, the U.S. Department of Energy and many others are designing the grid of the future, and distributed power resources - possibly coupled
10
with hot water/steam production - are

one of many driving factors forcing this
substantial undertaking. Small, distributed biopower offers two significant
technology advantages: first, biopower
is a dispatchable renewable source; second, small biopower relies on local supply. Smart plant siting that matches grid
issues with proximity to biomass supply
offers support for electric distribution issues and cost control through minimized
fuel transportation.
The most obvious condition in deploying domestic biopower is the status
of sustainably harvested biomass in a
carbon accounting system. EPRI work
shows that while somewhat variable, the
life cycle greenhouse gas emissions of
biopower typically range from 20 to 50
gCO2e/kWh, comparable to other renewable generating options. The lifecycle
analysis captures the impact of, say, diesel fuel used in transportation and equipment operation, fertilizer if applicable,
processing, etc. This approach considers
the biomass carbon biogenic, which is
consistent with previous U.S. Environmental Protection Agency (EPA) regulations. However, if a carbon is carbon
approach is used, which discounts the
biogenic aspects of the feedstock carbon,
the emissions rise by nearly 40 times.
EPA is expected to offer accounting rules
by year-end, but uncertainty has helped
cool interest in biopower.
A suite of generation technologies is
ready for adoption, including direct combustion, co-firing, unit conversions and
biomass upgrading. EPRI has worked
with electric utilities to understand the
implications of each option, and have
prepared numerous reports and papers,
and conducted tests of each option. For
example, EPRI recently collaborated with

Southern Co. and others to test an upgraded biomass (torrefied wood) at Gulf
Powers Plant Scholz that found the torrefied wood was a very good co-firing fuel
from a technical perspective. Economics
were not addressed in the project.
The economics of biomass power generally depend on two familiar aspects:
capital cost and operating cost. Many
technologies offer low, attractive capital
costs, including firing certain upgraded
fuels, many types of co-firing, and unit
conversion. Probably the largest impediment to broad biopower deployment
is the operating cost, which is mostly
the cost of the biomass. Biomass costs
vary significantly, depending on local
supply conditions, but also transportation requirements, local regulations,
etc. Offsetting the cost of the biomass
with renewable energy or carbon credits
has proven to be an effective strategy in
many domestic and international jurisdictions. These credits have the effect of
reducing the overall plant variable cost,
which allows the plant to effectively bid
into the electric system at a discounted
rate. While not completely necessary (especially with 549-MW of biomass added
last year), financial recognition for the
carbon value of biopower would increase
the installed domestic base, just as it has
in Europe.
In summary, biomass power is commercially-available and ready to be domestically deployed. Regulatory uncertainty and feedstock cost are the likely
reasons that the roll-out has been slow.
Small distributed biomass power stations
may have additional value due to their
dispatchability and access to discrete, low
cost biomass supply.
www.power-eng.com
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ENERGY MATTERS
Security in an Emergent
Threat Environment:
Industry Reaction
BY ROBYNN ANDRACSEK, P.E., AND R.J. HOPE, CPP, ABCP, BURNS & MCDONNELL
Editors note: This is Part II of a three-part

series on power plant security.
he frst article in this series (July
2014) touched on events that
are driving change in the security posture of the energy industry, specifically substations assets. No sooner did
the ink dry on writing that column, the
industry experienced another event. On
the morning of Wednesday, June 11th
local police were notifed that a fence
was breeched and a small incendiary device was detonated at a substation in Nogales, Arizona. The bomb was placed at
one of the 50,000 gallon diesel storage
tanks at the site and ignited, causing a
minor rupture and fuel leak. While obviously not to the scale of the April 2013
events in San Jose, this is another illustration of the developing threats to U.S.
electricity generation and transmission
assets. While members of the power industry are working to improve security,
the threat model continues to evolve.
In light of the events in San Jose, the
Federal Energy Regulatory Commission (FERC) directed the North American Electric Reliability Corporation
(NERC) to submit reliability standards
that require owners and operators of
transmission stations and substations to
take measures to protect against physical attacks and vulnerabilities. NERCs
newly proposed regulation, CIP-014,
addresses these measures and lays out
the guidelines for implementation.
The process involves Risk Assessment,
Threat Evaluation, Development of Security Plans and Third Party Verifcation. The purpose of CIP-014 is to identify and protect Transmission stations
and Transmission substations, and their
12
associated primary control centers, that

if rendered inoperable or damaged as a
result of a physical attack could result
in widespread instability, uncontrolled
separation, or Cascading within an Interconnection. While the screening criteria for substations will most likely not
include those situated directly outside of
generating facilities, some screening of
those stations will take place to demonstrate that an evaluation has been conducted to establish that they were below
the screening criteria.
In light of both the CIP-014 requirement and events in the industry, many
utilities are taking early action to harden their assets. This includes evaluating
substations based on the CIP-014 risk
criteria to clearly identify applicable
substations, conducting security risk assessments to better understand the risk
exposure and implementing additional
physical security measures to mitigate
from those identifed risks. The security
approach can vary based on the security
strategy of a given organization as well
as the essential nature of the assets and
the clients they serve. Those servicing
critical functions such as state and federal governments and hospitals are taking aggressive steps at these key stations.
Entities across the country are evaluating the physical security of their sites
on threats seldom seen inside the United States. These include vehicle-borne
improvised explosive devices (car/truck
bombs), man-portable improvised explosive devices (pipe bombs), assault
teams and asset shootings (snipers).
Considerations such as clear lines-ofsight (shooting lanes) and hostile vehicular approach paths are common
abroad but are certainly new and require a unique skillset. These analyses
can empower a utility to make wise
budgetary decisions by accounting for
event probability, target shifts, and attack characteristics.
Necessity is the mother of invention
and this particular circumstance is no
different. Protective measures such as
ground-based radar, advanced camera analytics and high security fencing
are proving to be promising solutions.
These methods continue to build on the
fundamentals of security which are to
deter, detect, delay, deny and respond. It
is understood that risk is not a zero sum
game and this is especially true in an industry where operational tempo can affect the types of security measures that
are implemented. The utility still has to
operate, provide maintenance, and continue to service its customers.
As the industry works to implement
risk mitigation options many topics
need to be considered, such as permitting, clearance requirements, air fow
to cool the equipment, and community relations. All these issues affect
selection criteria and implementation.
The important part of these types of
mitigation plans is that they need to be
compatible with current and planned
security strategies. Without full integration into normal operations, these
solutions can fall in disuse as the
memory of the initiating events fade.
Akin to when Michael Corleone
went to Vegas, its time to look beyond
the sensationalistic headlines and
maintain focus on the business of supplying electricity in a safe and secure
manner.
www.power-eng.com
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NUCLEAR REACTIONS
Breaking Bad: Dont

Let Turnaround Myths
Stall Your Recovery
BY MARY JO ROGERS, PH.D.
Author
Mary Jo Rogers,
Ph.D. is a partner
at Strategic Talent
Solutions with over
15 years working
with leaders in
the utility sector.
She recently
published the book,
Nuclear Energy
Leadership: Lessons
Learned from U.S.
Operators, by
PennWell. Contact
Mary Jo at www.
strattalent.com or
maryjo@strattalent.
com.
he unpleasant revelations
coming out of plants in recovery are a continual embarrassment in the nuclear business. Despite
the excellent safety and performance
records of the vast majority of nuclear
facilities over the past 15 years, every
so often the declining state of a plant
in trouble comes to light. With many
years experience turning around operations and safety performance, one
would think that the industry would
be able to apply a formula and recover
the plant relatively quickly without
backsliding. Unfortunately, some
facilities struggle greatly and make
slow progress in their recovery or fail
to ever reach high ground. Although
there are key lessons learned from past
turnarounds, some leaders dont apply
them out of apprehension tied to common myths. Here are three time-tested
lessons and the irrational thinking that
keeps people in power from using the
wisdom of others experience.
RIGHT LEADERS, RIGHT

ROLES AND THE MYTH
OF LOOKING BAD
Turnarounds require leaders with
the right vision, passion, internal
mettle, and the ability to engage key
stakeholders in the recovery. Top leaders need a guiding coalition, to use Jim
Collins phrase, or a team of capable
turnaround leaders who have drive, attention to detail, and the ability to work
together to lead the organization to
change. The myth of looking bad prevents top leaders from putting in place
people that have the skills and mindset
to lead the turnaround. If they remove
someone, it will make the top leader,
14
the individual, and the plant look bad.

The reality is that the whole facility already looks bad. This is like a stock that
has lost all its value and you are afraid
to sell it for fear of giving the perception that you are holding a bad stock.
Instead, the leader needs to make a
good assessment of his team members
and make changes as necessary. People
who are not a good fit at this time in the
plants life are often relieved when you
move them out.
HIGH PERFORMING
TEAMS AND THE MYTH OF
AUTOMATIC TEAMING
The top group quickly needs to become a high performing team in order
to achieve recovery goals. Recoveries
burn out even the best people, but a
dysfunctional top team will chew up
and spit out solid leaders and managers that you desperately need. A high
performing team acts in a coordinated
manner to execute on all aspects of a
recovery plan, including vertical alignment and workforce engagement. The
mythical thinking is that teams become highly capable automatically as
team members perform their leadership and functional roles. This occasionally happens when teams have
unlimited time get to know each other,
their roles, the organizational challenges, and how to work together. Plants in
recovery never have this kind of time.
Shut down is usually the endpoint of
this approach. Instead, top teams need
to dedicate time and resources to the
actual functioning of the teamalignment, cohesion, communication, and
capabilityto achieve the recovery and
make it stick.
DRIVING SAFETY
AND THE MYTH OF A
SAFETY-PRODUCTION
ZERO-SUM GAME
Plants in recovery have a lot of
pressure to get things done. Plants
with a history of good performance
that continually foster safety culture
appear to have the luxury of doing
so because of their relatively calm
operation. Commercial nuclear
power plant operators have learned
that driving safety and production
go hand in hand to a good outcome.
Think of the converse: plants that
allow safety practices and culture
to decay ultimately have events
that hurt production in a big way.
If you have a nice car that you keep
in good condition so it runs well,
then you drive recklessly and get in
an accident, your car still ends up in
the shop.
In a recovery, leaders may be
tempted to push the production
lever a lot harder than the safety
lever. However, safety culture will
keep you running well once you get
there and youll be glad you built
it up. The fear of being completely
stymied by safety culture is real. It
can happen when there are trust
issues and workers dont have the
right picture of what good safety
culture looks like. Everyone can use
dynamic learning experiences on
safety culture. In the end, safety and
production go hand in hand.
As Admiral Rickover, father of the
nuclear navy, said: you must learn
from others mistakes; you wont
live long enough to make them all
yourself.
www.power-eng.com
GENERATIONHUB
A Smart Deal
BY BARRY CASSELL, CHIEF ANALYST, GENERATIONHUB
he deal between PPL Corp.

andRiverstone Holdings LLC to
create new independent power
producer Talen Energy Corp. is a prime
example of two recent trends in the power business: Lower exposure to the variable independent power producer (IPP)
market, and, for IPPs, asset diversification and economies of scale.
For PPL Corp., this is a chance to put
its independent power plants into a new,
larger entity (Talen), while PPL will retain
its regulated utilities like Kentucky Utilities and Louisville Gas & Electric.
Talen Energy will own and operate a
diverse mix of 15,320 MW of generating
capacity in key U.S. competitive energy
markets. Based on current generating capacity statistics, Talen Energy would be
the third-largest investor-owned IPP in
the nation.
Under the terms of the agreement, at
closing, PPL Corp. will spin offPPL Energy Supply LLC, the parent company
ofPPL Generation LLC, andPPL EnergyPlus LLC, to shareowners of PPL and then
immediately combine that business with
Riverstones generation business to form
Talen Energy.
Upon closing, PPL Corp.s shareowners will own 65 percent of Talen Energy
and Riverstone will own 35 percent. PPL
Corp. itself will have no continuing ownership interest in Talen Energy.
Talen Energy will be a very significant
player in the U.S. competitive generation
market, bringing together the best of two
robust businesses with a very strong presence in the PJM region, as well as nearly
2,000 megawatts of generating capacity
in the fast growing ERCOT market inTexas, saidWilliam Spence, PPL Chairman,
President and Chief Executive Officer.
Talen Energy will have significant scale,
a very competitive cost structure and the
16
financial agility to pursue growth opportunities.

Following the spinoff, PPL Corp. will
focus on the high-performing regulated
utilities it owns and operates in theUnited Kingdom, Kentucky and Pennsylvania, serving more than 10 million
customers. These regulated businesses,
which had 2013 revenues of$7.2 billion,
provided more than 85 percent of PPL
Corp.s 2013 earnings from ongoing operations.
As stand-alone companies, PPL Corporation and Talen Energy each will have
compelling growth prospects, and we
expect the financial markets will ascribe
valuations that more appropriately recognize the inherent strengths of each company, said Spence. As PPL has grown its
rate-regulated business portfolio significantly over the past several years, PPLs
Energy Supply business has not - in our
view - achieved appropriate equity valuation.
While the transaction represents a significant change for all company stakeholders, Spence said PPL decided on this
direction following an in-depth analysis
of its business mix.
Given the challenges, uncertainties
and opportunities in the wholesale power markets, maintaining the status quo
was not a viable option. This transaction
provides greater clarity for shareowners,
our PPL Energy Supply employees, customers and the communities we serve,
said Spence.
Talen Energy will combine 5,325 MW
of capacity owned and operated by Riverstone at 15 sites inMaryland,New Jersey,TexasandMassachusettswith 9,995
MW of capacity owned and operated by
PPL Generation at 12 sites in Pennsylvania andMontana.
The
new
companys
planned
15,320-MW portfolio will have fuel diversity, with 40 percent natural gas, 40
percent coal and 15 percent nuclear. Talen
Energy will be headquartered at a yet-tobe-determined location in Pennsylvania.
The transaction, which does not require
PPL shareowner approval, is expected to
close in nine to 12 months.
This transaction does not include the
8,100 MW of regulated generating capacity owned by PPLs Kentucky utilities.
Those assets will continue to be owned
and operated by Louisville Gas and Electric and Kentucky Utilities.
There are other examples of companies
with regulated utilities that have exited or
are looking to exit from or at least reduce
their independent power holdings.
Virginia-based Dominion Resources
is one of them, having sold a while back
power plants including the Kincaid coalfired facility in Illinois as it turns its focus on its regulated Virginia Electric and
Power subsidiary.
Also, Missouri-based Ameren Corp.
last December completed the divestiture of its largely coal-fired merchant
generation business in Illinois to an affiliate ofDynegy Inc. That deal allowed
Dynegy, already one of the largest IPPs
in the United States, to get larger, while
Ameren retained its regulated Union
Electric utility operation in Missouri.
NRG Energy, another big IPP, earlier
this year completed the acquisition of
substantially all the assets of a bankrupt IPP, Edison Mission Energy. NRG
Energy itself is the result of a series of
prior mergers or takeovers in the IPP
space, including a 2012 buy of GenOn
Energy. Edison Mission Energy, before
entering bankruptcy, had been controlled by Edison International, the
parent of regulated utility Southern
California Edison.
www.power-eng.com
GSR
GSR Series
Serie
Se
ries
s Miller
Miller
Mill
er Cycle
Cycle Gas Engine
Engin
En
gine
e
GS6R2-PTK
GS6
50Hz
Output
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(kW)
RPM
(min-1)

CHP
CHP
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300
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GS6
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320
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305
KU30GSI
KU30GS
KU3
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GS 2R-PTK
GS1
GS16R-PTK
GS 6RGS1
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50Hz
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GS16R2-PTK
GS 6R2
GS1
6 -PTK
50Hz
60Hz
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700
610
930
815
1500
1000
12000
1000 1200 1500 1200 1500
1200
1500 1200
1500
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75 3 76.0
76 0 74.5
74 5 76.5
76 5 74.1
74 1 76.0
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12KU30GSI
50Hz
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14KU30GSI
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16KU30GSI
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18KU30GSI
60Hz
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Output
3800 3650 4450 4250 5100 4900 5750 55000
(kW)
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RPM
RPM
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720
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7200
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CHP
HP
Two Pierce Place 11th Floor

Itasca, IL 60143
630-268-0750
salesinfo@Mitsubishi-engine.com
Author
Michael Caravaagio is Principal Technical Leader for Boiler and Turbine Steam
Cycle Chemistry at the Electric Power
Research Institute
With the changing generation market, coal-fired

power plants face increasingly cyclic operation.
Layup
Practices for
Cycling Units
Requirements, Issues and Concerns
BY MICHAEL CARAVAAGIO, ELECTRIC POWER RESEARCH INSTITUTE
ycling units are those

which frequently shutdown to zero power
levels for short time intervals from as little as
8 hours or less up to 48 hours or more.
Typically these units operate on a system
load demand and/or economic dispatch
which may be tied to conditions such
as time of day, availability of renewal
generation or alternate fuel / generation
sources. Cycling units are most often required to be in a state of readiness for
rapid return to service, i.e. fully available for dispatch with minimal notification. Accordingly, short term periods
of 8-48 hours typically allow the unit to
18
maintain sufficient heat to retain boiler

pressure and turbine metal temperature
and for the shorter periods even permitting extended condenser vacuum and
cooling water circulation. These conditions all assist in the preservation techniques for the equipment.
Certainly the layup and corrosion
mitigation practices identified for cycling units are not limited to only those
units of the foregoing description. Rather the layup practices and guidance are
for those cycling units requiring the
maximum flexibility for removal and
return to service. It is recognized that
there is no one-size-fits-all regarding
the operating practices and procedures
of units frequently cycled in and out of

service or regarding the methods to be
applied for optimum protection of all
systems and components. Accordingly,
the practices and recommendations for
various unique operating/ shutdown
conditions are presented for the water/
steam touched circuitry that will require
some effort on the part of the plant operators to discern the most applicable
practice or methodology for the various components and sub-systems of the
individual situations. Depending on
numerous factors these practices may
not be the same from outage to outage
but should always focus on the most
practical and beneficial techniques to
minimize equipment damage associated with out-of-service and standby
operations. The preservation and corrosion protection during shutdown (i.e.
layup) is only successful if the control
measures implemented are effective and
continuously and consistently applied.
If several options are available certainly
those providing the most practical and
economic approach have advantages in
situations of high frequency and often
unplanned activity.
The purposes of layup practices are to
mitigate corrosion damage of the cycle
components and maintain the chemical
integrity of the water/steam cycle during
standby periods. Achievement of proper
layup of the equipment and systems requires implementation of procedural
steps during the unit shutdown and
removal from service to eliminate and
prevent introduction of corrosive conditions or environments. Accordingly,
shutdown (and the subsequent startup)
of equipment should be accomplished
in a manner that does not subject the
systems or components to an increased
risk of corrosion damage; this would
include such practices which induce increased localized stresses or increased
www.power-eng.com
concentration of contaminants or damage to the protective oxide which result

in increased corrosion damage. Some of
these unique events will be categorized.
The goal of a lay-up program is the
same as the chemical conditioning program during unit operation: to prevent
and / or control and reduce corrosion
and the accumulation of deposits in the
water/ steam circuit of power plants.
Optimization is most readily achieved
when all conditions are at a steady state
and equilibrium conditions can be established which are most favorable
to corrosion and deposit prevention.
Unit shutdown and startup by the very
nature of these operations continually disrupt the established chemical
equilibrium conditions within each
circuit and between systems as a result of changes in the thermodynamic
conditions of temperature, pressure,
and flow, as well as numerous physiochemical properties.
Water and steam circuit corrosion
during shutdown is defined by the simultaneous presence of water and oxygen. If one or both of these can be effectively excluded, corrosion during layup
is not reasonably expected. The methods of dry preservation (excluding water) and / or wet preservation (excluding
oxygen) are based on these conditions.
If these conditions cannot be fully
avoided, methods of active or passive
inhibition are required. Principally, inhibition is enhanced by the application
of alkalizing chemicals to elevate the
pH and provide the competing presence
of hydroxide [OH-] to minimum concentrations to inhibit anodic corrosion
such as acid chloride conditions.
The selection of the layup and preservation methods depends on the circuitry
and local conditions of the power plant
systems and the duration and frequency
of the shutdown. Although technically
inappropriate, practical economic factors of assumed risk and asset value
may dictate the choices and practices
employed for layup during shutdown.
www.power-eng.com
The economic viability of such choices

should be prudently evaluated; units of
low capacity factors or limited service
life may initially appear to be non-economically viable for minimum measures of equipment protection, however
if this means units are unreliable or unavailable for service when needed this
could alter the assessment.
As outlined, many of the practices for
providing layup protection incur minimal costs; for example units with only
seasonal demand stored following dry
conditioning using methods of residual
heat drying can require only procedural
steps to preserve the greatest percentage
of the water and steam circuits.
LAYUP PRACTICES
From the previous discussion it
should be obvious that layup involves
those practices which will contribute
to the elimination of corrosion mechanisms prevalent during periods of unit
shutdown. While the optimum conditioning for each component in the
water/ steam cycle is achievable using
methods of nitrogen (or other inert gas)
blanketing, pH adjustment, and/or humidity control (dehumidification) these
techniques often require special steps
and equipment isolation that preclude
having optimum flexibility of unit operation. For cycling operation there are
some critical conditions that should be
considered to improve the layup practices and lower the risk of damage. Greater
details for proper layup are given in
EPRI reports 1015657 Cycling, Startup,
Shutdown, Fossil Plant Cycle Chemistry
Guidelines for Operators and Chemist,
2009; 1010437 Cycle Chemistry Guidelines for Shutdown, Layup, and Startup of
Combined Cycle Units with Heat Recovery
Steam Generators, 2006; and 1014195
Shutdown Protection of Steam Turbines Using Dehumidified Air, 2008.
Addressing the necessity to maintain optimum unit availability and
responsiveness to generation dispatching requirements while optimizing
operations to provide layup protection

to cycling units requires some practical
and innovative methods which differ
from the established practices but focus on the same end effect.
Preboiler Water Circuits
Wet layup of the pre-boiler circuit
provides water chemistry conditions
that are similar to the conditions during plant operation. Wet layup in the
feedwater and condensate system
equipment consists of filling the components and connecting piping with
treated demineralized water with low
dissolved oxygen (DO) (less than 10
ppb) that contains the proper chemicals for the metallurgy of the system
(all-ferrous or mixed metal). The equipment is completely filled (water solid)
with the treated water to avoid pockets
of trapped air, and is not open to the atmosphere.
For cycling units layup of the preboiler circuit is straight forward. The pH of
the water in the circuit is the same as
during operation or slightly elevated
using the same chemicals. The oxygen
is reduced to levels of less than 10 ppb
where achievable and for mixed metallurgy systems using a reducing agent
the reducing agent residual is increased
up to several hundred ppb. The system
is kept water solid to preclude any introduction of air. None of the other methods of lay-up are practical or plausible
for cycling units nitrogen capping, or
draining dry are not amenable to the
circuit configuration.
The challenges faced by cycling units,
as with all units, with this scenario is
that as simple as it sounds, the achievement is quite complex. During the shutdown and coast down of the unit, the
condenser performance for air removal
and deaeration declines such that dissolved oxygen levels in the condensate
escalate. Once steam flow to the condenser is discontinued the vacuum conditions and air removal is virtually loss
and condensate is fully aerated. Similarly, following depressurization of the
19
unitthedeaeratorinthecircuitceasesto
functionandsometimesactsasasource
ofaeration.Flowthroughthecircuitis
stillrequiredtofilltheboilerormaintaintheliquidvolumeasaresultofthe
contraction during shutdown and cool
down of the components. The conditionsleadtounacceptablyhighoxygen
levelsforshutdownandunitstoragein
thepreboilercircuit(evenunitspracticingoxygenatedfeedwatertreatmentrequirelowoxygenforwetlayupstorage).
Chemicallyreducingoxygenwiththe
additionofreducingagents(inappropriatelyreferredtoasoxygenscavengers)is
ineffective and for all-ferrous circuits
canbedetrimentaltotheprotectiveoxide. With mixed-metallurgy units the
useofexcessreducingagentspromotes
unacceptably high ammonia concentrationsonthesubsequentstartupand
dangerously high corrosion of steam
sidecoppercomponents.
pHcontrol ofthepreboiler circuitis
frequently lost during unit shutdown
as a result of increased levels of carbon dioxide from air entrainment and
increased make-up to the cycle with
air saturated water. Make-up water is
untreated(nopHadjustment)andaerated.Thepreboilercircuitservesasthe
conduittotransfermake-upwatertothe
boilerorevaporatortosupplythevoid
created by the thermal contraction of
thewater.
Recognizingtheimportanceoflayup
andstabilizationoftheironoxides(corrosionproducts)inthepreboilercircuit
ofcyclingunitstakesintoconsideration
thattheseunitsspendadisproportionate amount of time in shutdown and
startup operations. Consequently the
opportunity for excessive transport of
corrosion products to the steam generating equipment is greatly enhanced
leadingtoexcessivedepositionandassociateddamage.
Approaches to layup and preservationofthepre-boilercircuittoaddress
thesechallenges(andpossiblythoseof
thesubsequentstartup)include:
20
Hotwellbubblerforoxygenremoval incorporates a steam (possibly

nitrogen) sparging/bubbling systemnearthehotwelloutlettostrip
non-condensable gases from the
condensate.Steamsourcesduring/
after shutdown include LP heater
extraction (prior to shutdown),
steamdrumasunitdepressurizes,
orsteamheaderfromadjacentunit
or auxiliary system. Nitrogen can
similarlybeusedbuttheconsumptionratemaybeexcessive.
Steam or nitrogen sparger in the
deaeratorstoragetank.Thisoption
offers great advantages on startup
not only for deaeration but for
pre-heatingtheboilerfeedwaterto
minimize thermal differentials at
theeconomizerinletorboilerwaterdowncomer.
Minimum flow circuit from the
economizerinletordeaeratoroutlet to the condenser hotwell or
condensate pumps suction. This
permits hotter water to circulate
through some deaeration devices
asdescribedoreventoincorporate
a side stream deaeration device,
possiblyasgastransfermembrane,
to maintain low oxygen content.
Periodiccirculation(usingcondensate pumps or an external pump)
eliminates areas of stagnation reducingpittingpotential.Thesmall
loopprovidesameansofsampling
for chemical analysis and for addition and mixing of treatment
chemicals. Side-stream filtration/
demineralizationarefacilitatewith
alowflowloop.
Closingthedeaeratorventpriorto
shutdowntopreventtheintroductionofairintothecascadingwater.
Maintain steam pressure or nitrogentomaintainthevaporspaceif
possible.Isolatethedeaeratorfrom
thestoragesectionandcondensate
as a means to prevent oxygen introduction to the preboiler circuit
(typicallynotviableduetolackof
automaticvalvesandvalvesizes)
Theseapproachesarenotallencompassing but provide an indication of
potentialapplicationstoenhancelayup
of the preboiler circuit and promote a
moretroublefreestartupaswell.
Boiler Circuit
The wet layup method with a steam
or nitrogen gas blanket above the liquidlevelinthecomponentorpipingis
highly applicable to the boiler circuit
(similar to the deaerator discussion).
Thismethodisusedforthedurationof
theoutageforperiodsofseveralweeks
wheremaintenanceisnotneeded.Naturally,thefirstchoiceforacyclingunit
not requiring boiler maintenance is to
shutdownwithanoptimumchemistry
condition by proper adjustment of the
pH,andmaintainsteam/boilerpressure
untiltheneedforreturntoservice.Followingtheeventuallossofsteampressure (unless supplied by an alternate
source or unless re-firing of the unit)
an inert gas (nitrogen) is supplied to
collapsetheresidualsteamatpressures
around 25 psig and exclude the introduction of air during the cool down
period and the collapse of the vapor.
Themainadvantage ofwetlayupwith
asteamornitrogenblanketisiteliminatestheair/waterinterfaceeliminatinglocalizedpittingattheinterfaceand
the introduction of dissolved oxygen
intotheboilerwater.
Duringtheunitshutdowntheblowdownoftheboilerorevaporatorisincreased to lower the level of corrosive
impuritiesintheboilerwater.Reduction
ofimpuritiesandinparticularchloride,
aspreviouslynoted,iscriticaltocorrosionprotectionduringstagnantperiods.
Researchhasclearlydemonstratedthat
the corrosion and pitting potential are
greatlyreducedwithhigherpuritywater
with lower concentration of aggressive
chemicalspecies.Similarlyresearchhas
demonstratedthattheconcentrationof
aggressive chemical species in and beneathboilerdeposits(andunderdeposit
corrosion)isreducedbypurgingofthe
www.power-eng.com
7 FINANCING
YRS
boiler water (i.e. improving the purity of the boiler water

on shutdown promotes leaching of contaminants from
deposits and lowers the risk of underdeposit damage).
The makeup water to the boiler circuit(s) is high purity condensate/feedwater, properly deaerated (oxygen
free) and of the proper pH. Make-up water is required
to the boiler circuit until ambient temperature and pressure (except for steam or nitrogen blanketing) is reached.
Additional makeup is continuously required if the boiler
is purged or blown down during the shutdown period.
Makeup can be suspended if the water level is not required to be maintained (provided air is still excluded by
steam or nitrogen pressure).
The pH of the boiler circuit is maintained principally
through the addition of a volatile alkalizing agent such
as ammonia. This is because addition of tri-sodium
phosphate at lower temperatures and pressures will not
equate to the target pH at higher boiler pressures and an
overfeed will result in phosphate hideout on the restart
of the unit. Likewise there is a risk of overdosing sodium
hydroxide. As the pressure of the circuit decays, a higher
proportion of the volatile ammonia will distribute to the
vapor phase and the boiler/evaporator water pH decreases. Sampling determines if additional chemical to maintain the pH is required. Units using phosphate treatment
may experience a pH depression on unit shutdown due
to possible phosphate hideout return. This condition requires elimination of the excess phosphate (blowdown
or draining) and restoration of the pH with ammonia
(or possibly low dosage of caustic). Maintaining and/or
elevating the pH of the boiler water is most critical during shutdown, layup and startup operations to mitigate
corrosion fatigue in areas of thermally induced stresses.
Cycling units rarely afford the opportunity to completely drain and dry the unit, however draining with a
nitrogen cap is a very satisfactory layup method provided
the residual moisture (steam and water) have sufficient
purity and pH to sustain corrosion inhibition. Similar to
nitrogen blanketing, the boiler is drained while still having a steam pressure in excess of 25 psig and the nitrogen
is applied to maintain the pressure throughout the drain
and the subsequent cool down to ambient temperature.
In locations where freeze protection is required this is
perhaps the methodology of choice if supplemental
heating is not supplied.
Nitrogen blanketing or purging requires temporary
connection or properly engineered systems, as well as
the additional nitrogen cost. The nitrogen, while typically injected in the vent connections can be introduced
below water level even in downcomers, lower headers, or
drain lines as long as there is an unrestricted flow into
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22
the vapor space. Nitrogen introduced

in lower headers promotes mixing
and deaeration in addition to the inerting atmosphere at the water vapor
interface. The gas bubbles migrating
through the boiler tubes or downcomers expand as they migrate to the surface promoting water movement similar to the thermal cycling of a natural
circulation unit; the water weight in
tubes with nitrogen is lower resulting
in a natural circulation. The mixing
also assists in providing representative
samples of the water chemistry.
With the exception of the above criteria, preservation of the boiler circuit does
not afford many other options. Making
the unit water solid would include fully
flooding the superheater, this is unattractive for cycling units which need a
quick response. Likewise draining and
drying the boiler (emphasis on drying)
is time consuming and leaves the boiler
space full of air which will inevitably
mix with the water introduced to the
boiler for startup. High oxygen in boiler
water on startup is a leading contributor to corrosion fatigue damage. Where
water is added to a drained boiler (not
nitrogen blanketed) filling from the
bottom of the boiler upward with deaerated (and pH adjusted) water drives
the more aerated water ahead in the circuit such that the most highly aerated
water is in the drum. Wasting some of
the water through the drum blowdown
can eliminate some of the most highly
aerated water (however the vapor space
is still full of oxygen). Heating the water to near saturation (212F/100C) for
filling reduces the saturation of oxygen.
Reheater Turbine Circuit
The practice for turbine layup is
only dry storage. Similarly the reheater
which receives only steam and is quickly evacuated on shutdown is most simply stored dry. As described previously,
reheaters and turbines are subject to deposition of dry chemical compounds
during normal operation which may be
hygroscopic at ambient conditions and
form aggressive chemical solutions on

shutdown. These areas are naturally exposed to the steam vapor on shutdown
unless specific actions are taken to
eliminate the moisture fraction through
purging and drying. Condensate formation in the reheater (similarly in the
superheater) provides not only the mobilization of soluble chemical deposits,
but allows the solubilization of oxygen
when exposed to ambient air as the unit
depressurizes. In the vertical tubes of
the reheater (as well as the superheater)
excessive condensation accumulates in
the lower tube bends after collecting on
the tube walls. The resultant solution
accumulating in the tube bends contains remnants of the soluble deposits
rinsed from the tubes. Subsequent
dry out of pools in the tube bends concentrates the material and increases the
likelihood of higher corrosive environments developing during succeeding
layup periods.
There are techniques for nitrogen capping reheaters which incorporate applying nitrogen to a vent or drain while hot
and isolated from the turbine/condenser and maintaining until the system is
needed or until ambient conditions are
reached.
Water soluble turbine deposits can be
washed during unit shutdown using
special operating techniques to lower
the amount of superheat in the incoming steam to produce a wetness factor
in excess of 3% throughout the turbine
set. Nucleation of moisture droplets in
the wet steam and the formation of liquid films on the metal surfaces will solubilize the water soluble deposits to
form weakly concentrated solutions that
are harmlessly rinsed and carried away.
These practices require careful monitoring to assure the moisture and liquid are
effectively removed so as not to leave
highly concentrated residual. Wet steam
washing of HP turbines should consider
use of cold reheat drains to prevent carryover of contaminant rich liquid to the
reheater.
www.power-eng.com
Dry storage typically would mean

the application of dehumidified air to
capture all the residual moisture. The
dehumidified air is applied in a fashion
to assure a pathway through the entire
turbine flow path including, if practical,
the reheater. The moisture laden air is
purged from the cycle typically at the
condenser until the desired level of humidity (typically <35-40%) is reduced
and then the cycle is closed to incorporate a continuous flow of air through
the circuit. From a practical standpoint
the dehumidification system is not engaged to the circuitry until the unit has
moderately cooled.
An alternative approach is to maintain the condenser vacuum (including
the cooling water circulation) once the
generator is disengaged and pull vacuum through the turbine set and the
reheater. Cautiously clean dry air (ambient relative humidity <40% - use a desiccating gel if needed toward the end)
is introduced through the cold reheat
piping to purge the residual vapor and
produce dry conditions. The volumetric
conditions of the vapor in the reheater
and turbine set at the elevated temperature present only a fraction of the air
requirements needed at ambient conditions to purge the circuit. Once purged,
only a sufficient flow to prevent moisture laden air in the condenser from
entering the LP turbine is necessary. In
addition the warm air from the reheater
(specifically the outlet steam header)
and IP turbine set assist in maintaining
LP turbine temperatures near 150F /
65C for several days. Oxygen solubility
decreases at higher temperature and the
oxygen solubility is sufficiently low at
temperature above 150F / 65C to limit
pitting of turbine components.
To facilitate lower moisture introduction from the condenser, the cooling
water is maintained to lower the vapor
pressure in the condenser. Unfortunately this has the effect of increasing the
oxygen solubility in the condensate in
the hotwell. Accordingly a continuous
www.power-eng.com
flow of dry air through the LP turbine

set is prudent unless efforts to drain and
dry the condenser are used.
Condenser and Shell Side
Feedwater Heaters
Layup protection of the steam extraction from the turbine to the condenser
and feedwater heaters is problematic
for units not planning extended layups.
The problem is that these are areas
where residual moisture is present even
when/if drained and are not (normally)
isolated from the turbine set. Nitrogen
application to feedwater heaters necessitates closing of extraction valve prior
to loss of vacuum. This is typically not a
considered option especially for units
expecting to frequently cycle.
Dehumidified air can be used to
promote drying of the drained components. This technique requires draining
and circulation of dry air until all the
residual moisture is removed. Where
dehumidification (including the modified technique outlined for drying the
turbine set) is applied through the turbine distribution of air through the extraction lines and feedwater heater and
subsequent drain piping may be insufficient for drying. In addition even the
high pressure heaters have little residual
heat upon shutdown because of the
cold condensate and feedwater temperatures. Even with condenser vacuum
the movement of dry air through the
heaters is questionable.
For cycling units layup of these components are extremely troublesome
not only are the techniques and method
to accomplish preservation untenable
but these components represent some of
the largest surface areas of low alloy carbon steel and/or copper alloy material.
Stainless steel components are subject
to similar pitting as turbine blade materials. High corrosion product transport
(iron and copper) in the feedwater on
startup have been traced directly to condensers and shell side feedwater heaters.
The corrosion rate of materials (specifically copper and copper nickel alloys
Example of Filming on the internal surface of a boiler

superheater tube through the use of a filming amine.
The presence of a film can limit or reduce offline corrosion. Photo courtesy EPRI
and carbon steel) in the shell (steam)

side of feedwater heaters is significantly
accelerated during cycling service as a
combination of poor lay-up practices
and thermal cycling of the material.
Feedwater heater tube corrosion and
failures associated with unit cycling
and improper layup not only are major
sources of corrosion product transport
and deposition in boilers and turbines;
major tube failures can lead to water induction to the operating turbine with
devastating and catastrophic results.
Copper nickel alloys (70-30, 80-20
Cu:Ni) used for feedwater heater tubes
exhibit extreme exfoliation on the external surfaces of the tubes associated
with cycling and improper layup. Exfoliation, a type of intergranular corrosion at the grain boundaries resulting
in a de-lamination of copper and nickel
oxides, has been found to occur only
in the presence of oxygen which is the
critical component of the exfoliationcorrosion mechanism. Other copper alloys exhibit similar exfoliation behavior
including alloys of >20% zinc and some
aluminum brasses (but usually at higher temperature). Introduction of oxygen
(air) into the heated wet environment
of feedwater heaters on shutdown promotes rapid oxidation of the susceptible
copper and nickel components.
Experience has shown that the exfoliation in cycling units is effectively
resisted if heaters are blanketed with nitrogen to exclude oxygen when the unit
is out of service. Although manufacturer
24
O&M manuals provide instructions on shellside blanketing,

nitrogen will flow to the turbine
and condenser unless extraction
valves are closed. To assure effective blanketing, nitrogen must be
applied before discontinuing condenser vacuum. Once the vacuum
or steam pressure conditions are lost,
atmospheric air will be drawn into the
feedwater heater vapor space.
Techniques of wet storage of the shell
side of feedwater heaters has been suggested, however such practices require
extreme caution to prevent thermal
transients from cooler water quenching steam extraction lines and water
entering the turbine. As with nitrogen
blanketing, wet storage of the shellside
of heaters would be applied prior to discontinuing condenser vacuum by filling
through the heater drains with chemically treated and deaerated feedwater or
condensate similar to the wet storage of
the condensate/feedwater circuit. During unit startup, the water is drained to
the condenser or even to waste.
PROTECTIVE
BARRIER FILMS
The most effective approach to equipment protection normally is to provide
dry conditions. There are treatments
that provide equipment protection by
establishment of a barrier between the
oxide surface and any water or moisture
that may be present. Among these barrier treatments are vapor phase corrosion
inhibitors, known also as vapor phase
inhibitors (VPI), and filming amines,
also referred to as film forming amines
or polyamines. The method of protection of both of these barrier forming
treatments is quite similar. The products
have a chemical structure which contains both hydrophilic and hydrophobic
sites. These features of the molecule provide an attachment or adsorption of the

hydrophilic site to the surface of the
metal (or metal oxide) in a monomolecular layer. The non-attached hydrophobic portion of the molecule repels the
moisture (water molecule) and as the
molecules accumulate the surface becomes non-wettable effectively providing a protective barrier to contaminants
such as oxygen, water, and corrosive vapors. Since the molecules tend to repel
each other, there is not a tendency for
the accumulation of multiple-molecular
layers or thick films.
The application methodology is quite
different for VPI and filming amines.
Since VPI compounds must be added
after the equipment in removed from
service and cooled, this technique is not
viable for units of cycling service and
short term outage.
Filming (or film-forming) amines are
typically used to counter the effects of
oxygen corrosion and have been used
as a means of equipment protection
during both operational and idle conditions. Filming amines are long chain
hydrocarbons that have one hydrophobic end and one hydrophilic end that
form a monomolecular film on metal
surfaces. The resulting film, similar to
an oil or wax film, creates a physical
barrier that prevents the water, oxygen
or other corrosive agents from reaching
the steel surface which aids in the protection of condensate/feedwater piping
and steam generating equipment. The
hydrophobic alkyl group of the amine
makes the metal surface unwettable and
once formed a protective film remains
intact even after the dosage has stopped.
EPRI is working to develop a filming inhibitor method which has found
favorable application in other power
generating circuits namely in China,
but also in Russia. The filming inhibitor
forms a bond with iron (Fe) atoms on
the metal surface. The hydrophobic film
has a physical shielding effect from the
www.power-eng.com
corrosion medium, and inhibits

the corrosion on the surface of
the metal. EPRI research has demonstrated the effectiveness of the
application of filming amines for
the inhibition of pitting and crevice corrosion of turbine steels and
the marked reduction of material
wastage by single phase FAC.
The filming inhibitor is added
into the water/steam through a
chemical addition system prior
to the unit shutdown. The amine
travels through the entire water/
steam cycle and gradually forms the
protective film on all the metal components in the cycle. The film is stabilized
and maintained by establishing a residual concentration in water and steam
in combination with other water treatment chemicals. Due to steam volatility
of filming amines, film formation also
occurs on metal surfaces of the steam
and condensing systems including the
With the changing generation market,

coal-fired power plants face increasingly
cyclic operation. Photo courtesy EPRI
turbine, superheater and reheater, feedwater heaters and condenser. The protection is present in both the wet and
dry conditions including those exposed
to humid aerated environments.
The use of filming amines needs to be
judicious. Insufficient application can
result in increased localized corrosion
in areas of inadequate inhibition. Excessive dosing may have some unwanted
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26
effects and possible sloughage

of iron deposits or sludge formation. Some impacts on analytical
measures have been noted with
excessive use of filming amines.
Condensate polisher resin fouling does occur with the use of
filming amines; condensate polishers should be bypassed and removed from service during dosing of filming amines for layup.
For a sufficient application, enough
filming amine must be applied to provide uniform coverage of all the water
and steam touched surfaces. Coverage
requirements are expected to range
from 10 to 50 milligrams per square
meter of surface area (1050 mg/m2).
This can be a significant quantity of
product since the surface area of a typical coal fired unit can range 50,000
to 100,000 m2 (500,000-1,000,000
ft 2) depending on the unit generating
output, volume, and design. In addition a minimum residual of 0.25 to 1
ppm (part per million or mg/ liter) in
water or steam is required to maintain
the surface coverage. The initial dosing
concentration must be greater than 1
to 5 ppm or more in order to provide
the necessary concentration gradient
for rapid development of the protective
film. These dosages and concentrations
refer to the filming amine molecules
(i.e. 100% filming amine). The actual
dosage and coverage requirement will
vary depending on the actual filming
amine compound and/or formulation.
The filming amine products as supplied
by the manufactures are typically very
dilute and knowledge of the supplied
concentrations will be required in order
to calculate the proper dosages.
CONCLUSION
Wet layup of the preboiler and frequently the boiler is the most practical
www.power-eng.com
approach for cycling units. pH adjustment and elimination of oxygen are the
prime requisites for wet layup application. This means complete deaeration
of the condensate and feedwater and
prevention or air entering the boiler
and superheater. Nitrogen blanketing
and / or maintaining boiler pressure is
required to prevent introduction of air.
pH adjustments need to assure all the
liquid (including condensed steam in
the superheater) is equal to or in excess
of normal pH conditions.
Use of filming amines as a corrosion
inhibitor has been shown to enhance
the wet layup practices in all parts of
the water / steam cycle. Filming amine
dosing of the entire circuit in advance of
shutdown acts to supplement wet layup
methods and provides corrosion inhibition in addition to reducing the corrosion reactions.
Dry storage is the best (and proven)
option for the reheater and steam turbine. Residual heat of the turbine is generally sufficient for maintaining a dry
conditions for periods of 24-36 hours,
but condensation and oxygen will initiate corrosion once a relative humidity
greater than 40% or the dew point
temperatures are reached. Reheaters
that are force cooled require immediate purging of steam vapor since exclusion of oxygen laden air in difficult to
achieve. Dry reheaters, like the turbine,
are subject to condensation and aeration on cooling.
Condensers and shell (steam) side
feedwater heaters are very difficult to
provide corrosion protection. These
components frequently are the major
areas of corrosion during unit shutdown and the source of deposit forming
corrosion products during startup. The
options for proper storage of this equipment is more limited.
Filming amines may provide an alternative for the dry regions of the reheater and turbine and for the moist
and wetted regions of the condenser
and feedwater heater. Applied during
www.power-eng.com
operation in advance of shutdown film

coverage of the wetted and dry components make the surface unwettable
and resist corrosion. This methodology
represents a significant advancement
to layup for cycling plants. Layup with
filming amines presents no disruption
(except as noted) to the operation of
the unit and in fact enhances both the
equipment protection and the rapid return to service.

Using practical methods as outlined
to address corrosion concerns procedural practices can be effectively put in
place that will provide optimum corrosion control of cycling unit without
jeopardizing flexible or increasing operating costs.
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27
Reducing Nox
Emissions From
The San Juan
Generating Station
BY MIKE PATSCHECK AND DAVID MITCHELL, PUBLIC SERVICE OF NEW MEXICO, AND
AJAY JAYAPRAKASH, DONALD FENNESY AND RAJ GAIKWAD, SARGENT & LUNDY
n 2013, Public Service of New

Mexico (PNM) entered into
an agreement with the New
Mexico Environment Department (NMED) and the United
States Environmental Protection Agency (EPA) to reduce the nitrogen oxide
(NOx) emissions from the San Juan
Generating Station. This agreement,
achieved as part of a best available retrofit technology (BART) settlement,
required the installation of selective
non-catalytic reduction technology to
be installed to reduce the NOx emissions from the current permitted levels
to a maximum of 0.23 lb/MMBtu. This
paper will discuss the salient points of
the retrofit of this technology at the
station, including discussion of the requirements of the agreement, the procurement strategy, balance of plant considerations, and the next steps.
BACKGROUND
PLANT DESCRIPTION
The San Juan Generating Station is located in Waterflow, New Mexico and is
28
comprised of four, pulverized coal boilers that are each firing New Mexico bituminous coal. San Juan Units 1 and 2 are
sister units, as are San Juan Units 3 and 4.
San Juan Units 1 and 2 are 360 MWgrossrated Foster Wheeler, pressurized draft,
front wall-fired boilers. Unit 1 was commissioned into service in 1976 and Unit
2 was commissioned into service in 1973.
Each unit was designed to control particulate matter (PM) emissions through
the use of a stacked hot-side electrostatic
precipitator (HESP) upstream of the air
preheater. Each unit is equipped with
four, regenerative Ljungstrom-type air
preheaters: two for primary air and two
for secondary air. In 1998, both units
were retrofit with wet flue gas desulfurization (WFGD) systems from Babcock
& Wilcox (B&W) to control the SO2 emissions from the units. During 2007-2009,
the units were each retrofit with B&W
fabric filter technology to control the PM
emissions from the units; at this time,
the fields in the HESP were de-energized.
In 2009, both units were retrofit with
Low NOx Burners (LNB), overfire air
(OFA) systems, Sub overfire air (SOFA)

systems, and neural networks designed,
furnished, and installed by B&W to control the NOx emissions from the units
to the current permitted levels. In 2009,
both units were retrofit with an activated
carbon injection (ACI) system to control
mercury emissions.
San Juan Units 3 and 4 are 550 MWgrossrated B&W, pressurized draft, opposed
wall-fired boilers. Unit 3 was commissioned into service in 1979 and Unit 4
was commissioned into service in 1982.
Each unit was designed to control PM
emissions through the use of a stacked
HESP upstream of the air preheater. Each
unit is equipped with four, regenerative
Ljungstrom-type air preheaters: two for
primary air and two for secondary air.
Similar to Units 1 and 2, both units were
retrofitted with B&W WFGD systems in
1998 and B&W fabric filter technology
during 2007-2009 to control the SO2 and
PM emissions from the units, respectively. In 2008, both units were retrofit with
B&W LNB, OFA, and neural network systems to control NOx emissions from the
units to the current permitted levels. In
2008, both units were retrofit with an activated carbon injection (ACI) system to
control mercury emissions.
The LNB, OFA and neural network
systems were installed to control the
NOx emissions from their uncontrolled
values to a maximum emission of 0.30
lb/MMBtu as part of a consent decree
agreement. As part of the agreement, the
station entered into a 12-month test period for each unit where NOx data was
collected to determine if the permitted
emission limit could be further reduced
from 0.30 lb/MMBtu based upon the
capabilities of the installed technology.
The data indicated that the NOx emission limit of 0.30 lb/MMBtu was appropriate for each of the units.
REGULATORY DRIVERS
In August 2011, the EPA published the
final Federal Implementation Plan (FIP)
for the state of New Mexico to the Federal
Register. In the FIP, the EPA stated that a
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portion of the New Mexico State Implementation Plan (SIP) was not approved.
The argument made by the EPA was that
the state had failed to include requirements for regional haze considerations
for the San Juan Generating Station in the
SIP. This subjected the station to BART
requirements for NOx and, as a result,
required the installation of selective catalytic reduction systems on all four units
to reduce the NOx emissions.
PNM entered into negotiations with
the NMED and the EPA, doing so with
the backing of the governor of New Mexico. As part of the negotiated agreement,
PNM agreed to install SNCR control technology on San Juan Units 1 and 4 as part
of the overall NOx emission compliance
program. Based upon the agreement between PNM, the NMED, and the EPA, the
EPA was requested to hold in abeyance
the consideration of the NOx BART determination for San Juan Generating Station
set forth in the original SIP.
PROCUREMENT
In response to the agreement between
PNM, the NMED, and the EPA, PNM and
Sargent & Lundy (S&L), the Owners Engineer, developed an engineer and procure specification for the SNCR systems
to be installed on Units 1 and 4. The
resultant specification was then released
for competitive proposals from industry
leaders in SNCR technology.
As part of the specification, the SNCR
Supplier would be required to perform
combustion testing of the boilers, make
recommendations for optimization of
the combustion systems, and perform
all required temperature and NOx mapping and all computation flow dynamics
(CFD) modeling in addition to the design
and supply of the urea solution storage,
feed and injection equipment to reduce
NOx emissions from the boilers.
As part of the evaluation, special consideration was given to balance of plant
equipment that was not included in the
scope of supply for the SNCR vendor, but
is required for successful operation of the
30
proposed design. This equipment includes water treatment systems required

to provide minimum water quality for
use as dilution water, closed cooling water systems, and compressed air requirements for pneumatic atomization of the
injected urea solution. These specific requirements were included
Baseline
in the evaluation to determine the most cost-effective solution, not just on a
specification basis, but on
a project basis.
EMISSIONSREQUIRE MENTS
The agreement between
PNM, the NMED, and the
EPA required NOx emissions to be controlled
to a value of 0.23 lb/
Z
MMBtu from the existY
ing controlled permitted
X
emission limit of 0.30 lb/
MMBtu for each unit. In
order to have margin below the permitted emission limit, the
specification required a demonstrated
NOx emission guarantee of 0.22 lb/
MMBtu. This equates to a NOx reduction
efficiency of greater than 26% for each
boiler. At the time when the specification
was issued, this NOx removal efficiency
had not been demonstrated on pulverized coal-fired boilers of this type, size,
and inlet NOx emissions.
In addition, similar to the requirements of the previous consent decree
agreement to install the LNB, OFA and
neural networks, PNM agreed to participate in Long-Term Performance Evaluation Period of nine (9) months subsequent to the installation and commercial
operation of the SNCR systems. If, during the performance evaluation period,
PNM is able to demonstrate NOx emission rates less than or equal to 0.20 lb/
MMBtu on a daily 30-day rolling average,
then the permitted NOx emission limit
will be reduced commensurate to an
agreed-upon percentage of the difference
between the permitted emission limit
and the demonstrated NOx emissions.

During all periods, however, the SNCR
systems shall be operated with an ammonia slip from the SNCR system below
10 ppm, which will limit how much urea
can be fed into the boiler to reduce NOx
emissions.
Duct Geometry
SOLUTIONIZING SYSTEM
SNCR systems inject urea solution into
an identified temperature range within
the boiler that allows the urea to hydrolyze into ammonia and react with NOx
to form nitrogen gas and water. In order
to maximize the penetration of the urea
solution across the boiler prior to hydrolyzing, the urea solution is injected in
concentrations of approximately 5-10%
by weight. However, it would not be economical for a station to take delivery of
urea at this diluted concentration. Therefore, stations employing SNCR technology typically take delivery of either 52%
(by weight) urea solution or dry urea pellets, which are then solutionized on site.
S&L performed a urea feed study
evaluating the feasibility of installing a
solutionizing system on site compared
to taking delivery of urea solution. S&L
originally estimated the consumables required to meet the outlet NOx emission
using industry experience and engineering judgment as well as developed a differential order of magnitude capital cost
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estimate; these consumables included

the urea consumption, the auxiliary power, steam and water requirements.
Unit costs were provided by PNM and
their supply chain and S&L was able to
develop annual fixed and variable O&M
costs. The delivered reagent cost for urea
was found by PNM to be $600/ton for dry
pellets and $2/gal for urea solution. Using these costs, a net present value (NPV)
comparison was developed to directly
compare the two technology options.
This study indicated that there was a potential that on site solutionizing of urea
would be economically feasible for San
Juan Generating Station. An addendum
to the SNCR specification was prepared
and issued to the SNCR technology suppliers to provide the equipment as an
option. Once a SNCR vendor was contracted, the consumable values used in
the study were revised based upon the
guaranteed values provided by the successful technology supplier.
These updated results validate that solutionizing urea on-site at San Juan Generating Station is economically feasible.
Provisions were allowed in the layout of
the equipment to allow for the expansion of the urea tank farm to include the
future installation of the solutionizing
equipment. Detailed design of the dry
urea unloading, storage, and solutionizing tanks has been completed by the
SNCR vendor, but this option has not
been fully exercised.
BALANCE OF PLANT
CONSIDERATIONS
Unrelated to the proposed SIP revision and the required reduction in NOx
emissions, PNM is also undertaking
other projects concurrently to improve
the reliability and maintainability of
the station. These include a bypass
around the Unit 1 HESP equipment and
conversion of both units from pressurized draft to balanced draft.
HESP bypass
As stated above, the HESP systems
on each unit have been de-energized
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subsequent to the installation of the fabric filter systems. However, the HESPs
are still in the gas path and, due to the
reduction in velocity in the equipment,
a significant portion of the fly ash generated by the station is removed from the
flue gas due to drop out. This requires the
station to continually maintain the HESP
systems and operate the ash collection
system. S&L prepared a conceptual design to evaluate the removal of the HESP
on Units 1 and 4 from the flue gas path.
It was determined that it was cost effective to bypass the HESP on Unit 1, but not
for Unit 4. Therefore, S&L began detailed
design to remove the HESP from the flue
gas path on Unit 1 only. As part of the detailed design, S&L performed additional
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studies to determine downstream impacts from removing the HESP from

the gas path. These included evaluation
of the fabric filters and the ash removal
system from the fabric filter hoppers,
evaluation of the air preheater baskets,
and design of the ductwork to bypass the
HESPs.
When the fabric filters were originally
designed, the basis was the full dust loading of the flue gas, which is roughly 18.5
lb fly ash/MMBtu for the coal fired at
this station. It was then concluded that
no modifications would be required for
the fabric filters to operate successfully
while treating the full dust loading. The
ash removal system was designed to remove all of the fly ash that would be collected from the flue gas should the Unit
1 HESP be removed from the gas path,
but all of the required equipment was
not installed. The original equipment
manufacturer (OEM) design included a
bifurcated hopper design and installed
feeders, valves, and piping on one connection. As part of this project, feeders,
valves, piping and all required cross-ties
were procured for the second connection
on the bifurcated hopper.
Because the HESP had always served
to remove a significant portion of the
fly ash in the gas path, even in a de-energized state, there was also concern that
the removal of the HESP from the gas
path would result in an overload of fly
ash to the air preheaters. This, in turn,
could lead to erosion of the baskets and/
or decreased performance of the boiler. In order to mitigate this issue, PNM
contracted with the air preheater OEM
to evaluate the air preheaters and determine if the installed baskets were suitable
for the increased ash loading. As part of
this evaluation, the OEM was also tasked
with determining if there would be any
adverse impacts on the air preheaters due
to the introduction of ammonia into the
gas path from slip from the SNCR system.
The OEM concluded that the baskets that

were currently installed were suitable for
the full dust loading that was expected.
In addition, the OEM concluded that due
to the relative ratios of ammonia and
SO3 present in the flue gas, the ammonia
present in the flue gas would likely exist
as ammonium sulfate, which would have
no adverse impact on the air preheaters
performance.
Unit 1 has a split economizer resulting in two parallel gas paths that exit the
boiler. When the flue gas exits the Unit
1 boiler, each path of the ductwork penetrates the boiler building wall and immediately splits into two smaller ducts to
feed the upper and lower HESPs which
are in a stacked arrangement. As part of
the conceptual design, S&L proposed to
remove the ash hoppers from the upper
HESP casing and use the resulting space
as the location of the HESP bypass duct.
This would minimize the modification
required to the existing steel and allow
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tie-in to the existing primary and secondary air connections more readily. As part
of the detailed design, S&L performed
CFD modeling of the proposed ductwork
arrangement to ensure that the new duct
design would be optimized, all required
turning vanes designed, and to minimize
that there was low risk for erosion of the

ductwork as well as low risk for drop out
and deposition of fly ash in the ductwork.
The results of the CFD analysis are presented in detail below.
CFD Modeling
S&L developed a CFD model using the
preliminary
ductwork
Primary Air Preheater Inlet Baseline
design
in
a
commercially
2
Velocity Profle - Full Load
available CFD modeling
program. The preliminary ductwork design
was developed in such a
manner to minimize the
construction costs and
impacts on existing structures, but without consideration for internal members. As stated above, the
goal of the modeling was
to optimize the duct design to the greatest extent
possible, design turning
vanes, and minimize loVelocity: Magnitude (ft/s)
cations of extreme veloc0.0000 24.00
48.00
72.00
96.00 120.00
ity. With physical limitations due to existing
structures and constructability concerns in mind,
Secondary Air Preheater Baseline Velocity
the proposed ductwork
Profle Full Load (Elevation and Plan Veiw) 3 was modeled at both full
and low load conditions.
Low load had been defined by PNM as 40% of
MCR conditions. Due to
this large operating load
range, it was expected to
Velocity: Magnitude (ft/s)
be very difficult to com0.0000 24.00
48.00
72.00
96.00 120.00
pletely avoid extreme
velocities. In these cases
where extreme velocities
were unavoidable, recommendations for operation
Y
and maintenance were to
Velocity: Magnitude (ft/s)
be provided.
Z
0.0000 24.00 48.00 72.00 96.00 120.00
X
Because the ductwork
is mirrored across the
economizer, only one
locations of extremely high and low ve- side was modeled to determine the relocities. By minimizing the locations of sults. The baseline duct geometry for the
high and low velocity, it could be ensured South train is shown Figure 1 on page
34
30. The economizer outlet is shown on

the left side of the figure, with the tie-ins
to the existing air preheater inlets on the
right side of the figure.
Boundary conditions for the model
were developed as part of the design basis calculation prepared in advance of the
SNCR specification. The expected flow
split between the primary and secondary
air preaheaters was determined by the geometry of these connections.
Using these boundary conditions, the
flow model was developed to determine
the baseline results. These results show
that for the large area of the common
duct, the flow is relatively homogenous
with no areas of concern. When the ductwork splits to direct flow to the two air
preaheater inlets, the flow becomes extremely stratified and areas of extreme
velocity are readily identifiable. The CFD
results from baseline, full load conditions
are shown for the primary air preheater
inlet and secondary air preheater inlet in
Figures 2 and 3, respectively.
These results show that in the primary
air heater inlet duct, the flow is generally
homogenous entering the first downward turn. At this point the bulk of the
flow is along the back wall leading to recirculation zones at the top of the ductwork and along the near wall. Just prior
to entering the primary air inlet, the ductwork takes a horizontal turn, causing an
area of low flow along the top of the ductwork. In each of these areas, the velocity
is low enough that drop out of fly ash is
expected. In the case of the low flow zone
at the primary air heater inlet, there is sufficient flue gas velocity immediately below the low flow zone to re-entrain any
fly ash that may drop out of the flue gas.
However, it was determined that the flue
gas was too stratified in the down-comer
duct and the velocity should also be increased as part of the optimization of this
section of ductwork to prevent drop out
of fly ash.
Due to the existing physical constraints
in this area and expected ductwork support locations, the new ductwork to the
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secondary air preheater inlet makes multiple transitions prior to the connection
with the existing secondary air preheater
inlet ductwork. In order to minimize
construction impacts, the connection
was determined to be at the expansion
joint upstream of the dampers located at
the secondary air preheater inlet. These
transitions occur in quick succession and
result in the bulk of the flow taking the
path of least resistance to the secondary
air preheater inlet.
This concentrates the flow through
the one path, experiencing high localized velocities that are greater than
100 fps along the inside corner of the
turns, which is expected to cause erosion of the duct plate. Conversely, opposite these points of high velocity,
there exist large areas of low velocity.
These zones with flue gas velocity below 20 fps pose a potential risk for fly
ash deposition due to drop out. Turning
vanes and other flow correction devices
were recommended to be added to these
sections to reduce the stratification of the
flow and distribute the gas more evenly
across the ductwork.
The optimized ductwork arrangement
was developed by S&L via collaboration
of the process, mechanical, and structural disciplines working on the project. In
order to increase the velocity entering the
primary air heater inlet duct, the size of
the ductwork was decreased and turning
vanes were located along the downward
turn to distribute the flow more homogenously across the duct cross section. In
the secondary air preheater inlet duct,
numerous sets of flow correction devices were required to distribute the flow
across the cross section of the duct. These
included turning vanes, diverter vanes
and chamfered corners of the ductwork.
The optimized geometry resulted in
favorable results for the flue gas flow
into the primary and secondary air
preheater inlets.
The areas of recirculation and low flow
are greatly reduced and the overall flow
profile entering the primary air preheater
36
inlet is more homogenous.

The optimized results are a significant
improvement in flow distribution when
compared with the baseline results in Figure 3. The areas of both extremely high
and low velocity have been largely mitigated with exception to the final expansion in the new ductwork segment. This
expansion in the ductwork is required
to match up with the existing expansion joint frame at the secondary air
preheater inlet. No iteration of turning vanes was able to distribute flow
adequately to this corner to prevent
potential of fly ash dropout.
Overall, the results of the CFD modeling were determined to be very favorable
and duct design was able to continue to
the next phase. The flow distribution
between the primary and secondary air
preheater inlets, as shown in Table 3, was
expected to be 25%/75%.
BALANCED DRAFT CONVERSION
To further improve the operability, and
maintainability of the station, as well as
reduce fugitive dust emissions to meet
the requirement of the Stations Title V
permit, PNM determined that it would be
beneficial to convert Units 1 and 4 from
pressurized draft operation to boiler balanced draft operation.
In order to accomplish this, modifications to the furnace, boiler, electrical
systems, forced draft (FD) and induced
draft (ID) fans and motors, and ductwork and equipment design may be required. As part of this evaluation, S&L
performed an evaluation of the FD and
ID fans to determine their viability for
future use at the site.
It is expected that the conversion to
balanced draft will change the required
pressure rise from current pressurized
draft operation. The total pressure rise
from the FD fans will decrease, while
the total pressure rise from the ID fans
will increase commensurately. In order
to validate the fan curves and accurately
measure the existing system resistance,
performance tests were conducted at the
station on the ID fans.
The Unit 1 ID fans are currently damper controlled with a full pressure rise of
27 at a flow of 580,000 cfm (per fan).
The conversion to balanced draft is expected to increase the required full load
pressure rise by 10. However, because it
was determined that the HESP would be
removed from the flue gas path for Unit
1, the total pressure rise could be reduced
by 2.5 and any increase in flue gas volume attributed to infiltration from the
HESP casing could be removed. Based
upon this adjustment in total pressure
rise and flow, the existing ID fans were
determined to be acceptable for future
use as long as variable frequency drives
(VFD) were added to allow the full operational capacity of the fans to be used
and controlled. One added benefit of
this conclusion is that the inlet dampers to the fan could be left at full open,
thereby further reducing the pressure rise
required of the ID fans.
The Unit 1 FD fans were found to be
acceptable for future use without modification.
The Unit 4 ID fans are currently inlet
vane controlled with a full pressure rise
of 26 at a flow of 920,000 cfm (per fan).
The conversion to balanced draft is expected to increase the required full load
pressure rise by 10.
NEXT STEPS
Currently, the project is progressing in
accordance with the timeline set forth in
the agreement between PNM, the NMED,
and the EPA to ensure reduction in NOx
emissions by the SNCR system by January 31, 2016. The SNCR vendor is nearing
completion of engineering and will be
starting fabrication and delivery of equipment in the first quarter of 2015.
Upon completion of the installation
of the SNCR system in 2015, the system
shall be tested by a third-party testing
contractor to verify achievement of the
required performance guarantees. Subsequently, the systems will begin the
Long-Term Performance Evaluation Period as discussed above.
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Combined Heat and Power:
Dont Neglect
Water/Steam
Treatment
BY BRAD BUECKER, CONTRIBUTING EDITOR
ia well-engineered use
of the waste heat from
power and steam generation processes, net efficiencies of perhaps 80
percent are possible at combined heat and
power (CHP) plants. However, just like
conventional power generation, proper
water/steam treatment and monitoring
are also important at CHP facilities. This
article touches upon these issues at CHP
facilities that are or will be powered by
combustion turbines with heat recovery
steam generators (HRSGs) for process
steam and/or power generation.
THE COMBUSTION
TURBINE, CORE OF
THE PROCESS
Back in the heyday of large power plant
construction, primarily from the 1950s
through the 1970s, the most popular
technologies were complex coal-fired or
nuclear facilities, with hydro power providing much of the remainder. Concerns
regarding nuclear safety, global climate
change, and quite frankly, cost, have seen
movement away from large steam generators to smaller units, and in many cases
decentralized power. The core of many
new systems is the combustion turbine
(CT), a simplified outline of which is
shown below.
A CT operates similarly to a jet engine
via the following steps, which are part of
a fundamental thermodynamic cycle,
the Brayton Cycle.
Inlet air is compressed and injected
38
into the turbine. The compressor is

attached to the turbine shaft, and
thus the compressor and turbine rotate in unison.
Fuel, typically natural gas but occasionally fuel oil, is injected and ignited in the compressed air stream.
The expanding gas drives the turbine.
Hot exhaust, at 850oF or higher, exits
the turbine.
Key advantages of a combustion turbine include very fast start times, low capital cost as compared to coal or nuclear,
simplicity of fuel feed, and minimal op-
added requirement is energy efficiency.

Capture of the combustion turbine waste
heat is very important for high efficiencies, and this has been accomplished in
the power industry via combined-cycle
plants, where net efficiencies of modern units are at or near 60 percent, with
condensing turbines. CHP efficiencies
may be even higher, but in all cases that
utilize steam generation, proper water/
steam chemistry control is essential for
unit reliability.
COMBINED-CYCLE
ENERGY GENERATION
The downside to simple-cycle operation is that the units are only about 35
percent efficient.
Much energy escapes with the turbine
exhaust. This is where the combinedcycle design shines forth. A heat recovery
steam generator (HRSG) is placed at the
exhaust of the combustion turbine or turbines to utilize the exhaust heat for steam
production. While many HRSG designs
are available, the most common is the
A Basic Combustion Turbine Schematic

2
Combustor
Compressor
1
Air
erations and maintenance issues. These

benefits are quite important in the power
industry, especially the fast start times
during peak power periods when demand skyrockets. For CHP facilities, an
1
3
Turbine
Work
4
Exhaust
multi-pressure, drum-type unit as typified in the schematic below.

In this particular design, the condensate is split between the circuits, with a
relatively small flow to the low-pressure
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(LP) steam network and the bulk of the

flow to the intermediate pressure (IP)
and high-pressure (HP) circuits. Steam
extraction may be taken from any of the
circuits, or, as is most efficient, from a
non-condensing turbine. A less complex scenario that may be better for cogeneration applications is a combustion
turbine with a single-pressure HRSG
perhaps without a steam turbine, where
the HRSG operation is less complex than
with multi-pressure units.
Net efficiencies of combined-cycle
units for power production have closed
in on 60 percent, while up to 80 percent
efficiency is reportedly possible for cogeneration. However, as I have learned
through experience, at facilities where
power production may only be part of
the process, water/steam treatment and
chemistry monitoring are a neglected
task due to focus on process issues. This
neglect has come back to haunt many
plant operators and technical personnel, when water/steam side upsets (both
short- and long-term) have caused corrosion, scaling, and failures that sometimes
cost a large plant seven figures or more in
lost production and repairs.
Dont Neglect HRSG Chemistry
The following discussion sums up a
number of the most important details of
steam generator chemistry that have become known over the past decades, and
particularly within the past 20 years.
For dedicated power generating units,
the condenser is typically the most
troublesome source of contaminant inleakage. Impurity introduction via a
condenser tube leak has been known to
cause boiler tube failures within weeks,
and sometimes even days or hours. The
most notorious impurity is chloride,
which in the steam generator will concentrate under deposits and cause acidic
corrosion and hydrogen damage. Online monitoring of condensate chemistry
is absolutely essential to detect impurity
ingress and take corrective action.
Unless the condensate/feedwater
40
system of a high-pressure steam generator contains copper alloys, the use of

oxygen scavengers is highly discouraged.
These are now known to propagate flowaccelerated corrosion (FAC) in feedwater
systems, economizers, and the low-pressure evaporator of HRSGs, among other
locations. FAC-induced failures have
caused a number of fatalities at power
plants in the last 25 years. Modern programs utilize ammonia or sometimes an
amine for pH control, but allow the oxygen that leaks in through the condenser
to remain. This oxygen, when the chemistry is carefully controlled, will actually
cause the carbon steel feedwater piping to
develop a very protective oxide layer.
The most common treatment for IP
and HP circuits in HRSGs is the program
known as phosphate continuum, and
most commonly at the low end of a 1 to
10 parts-per-million (ppm) phosphate
range. This program was developed by
the Electric Power Research Institute in
response to problems with earlier phosphate programs, and calls for the use of
only tri-sodium phosphate with perhaps
a slight amount of caustic at startup. Alternatives include straight caustic treatment (at less than 1 ppm free sodium hydroxide) and all-volatile treatment, where
only the ammonia or amine utilized for
feedwater pH control provides the treatment for the steam generator circuits.
Not to be neglected is steam chemistry
and monitoring of this process fluid. Carryover of impurities such as chloride and
sulfate salts, silica, and other impurities
can result in fouling and corrosion of turbine components. The salts in particular
will concentrate at the phase transition
zone in the last stages of a low-pressure
condensing turbine, where, if the turbine
is exposed to a moist atmosphere during outages, pitting and stress corrosion
cracking may occur.
For CHP plants that distribute steam to
process heat exchangers, district heating,
or other similar applications, condensate
return chemistry is a critical item. In the
first place, some boiler water chemistry

programs (particularly in low-pressure
units with relaxed chemistry requirements) allow carbon dioxide to carry over
with steam. This CO2 will then condense
with water in the condensate return system to generate corrosive conditions. Any
oxygen that carries over or otherwise enters the condensate return system significantly increases the corrosion rate. The
Temperature-entropy
diagram for an ideal
Brayton cycle
3
T
4
2
1
S
condensed steam may accumulate many

impurities including iron oxide and other
corrosion products, organic compounds,
and non-metallic suspended solids. Condensate filtration and polishing are often
a mandatory requirement to prepare this
water for return to the steam generator.
Techniques that may be needed include
filtration by activated carbon, particulate
filtration by membrane or disk media,
and ion exchange.
Another often overlooked issue is the
damage that can occur during shutdown
periods. Improper steam generator layup
can cause excessive corrosion that not
only damages components but generates
massive amounts of corrosion products
that travel to the steam generator and deposit on boiler tube surfaces. [1] Ideally,
for short-term shutdowns where water
remains in the steam generator, nitrogen
www.power-eng.com
DECS-250N Digital Excitation Control System

Negative Forcing Produces
Positive System Response
Powerful Negative Field Forcing power stage

enhanced system response during transient conditions
DECS-250N
Digital Excitation
Control System
Optional integrated Power System Stabilizer

Provides advanced power system performance and eases
concerns regarding grid code compliance
Reactive load sharing over communications

Eliminates the need for costly wiring and provides improved
system response
Innovative Auto-tuning function

Establishes optimum PID gain parameters, maximizes system
performance, and reduces commissioning time
1.25
3
2
0
-1
-2
-3
without neg forcing

with neg forcing
-4
generator voltage (p.u.)
regulator output (p.u.)
Automatic voltage
regulator output
during load
rejection
without neg forcing

with neg forcing
1.2
1.1
1.05
1
0.95
-5
1
1.5
2.5
3
3.5 4
time in sec
4.5
5.5
Negative forcing
providing improved
generator voltage
response
1.15
1.5
2.5
3
3.5 4
time in sec
4.5
5.5
Tests conducted with 30MW brushless excited machine
For more information visit our web site www.basler.com/BE/7PENF

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Schematic of a Three-pressure HRSG
3
HP SH Steam
IP SH Steam
Deaerator (DA)
IP SH Steam
Steam Injection to CT (if used)
LP SH Steam
Crossover
LP Drum
IP Drum
HP Drum
HP
IP
LP
Steam turbine
Condenser
Reheater
CT exhaust
DA Pump
Attemperation
Water
FW Pump
LP Blowdown
IP Blowdown
Legend
HP Blowdown
Combustion
turbine
Condensate
Storage
Makeup
System
Steam
from IP
(if used)
Combustion
polisher (if used)
Condensate
Pump
Preheater Economizer Superheat

or
Reheat
blanketing should be utilized to protect

the system from air in-leakage. If nitrogen blanketing is not an option, then
other wet lay-up procedures should be
established. Also, very reliable technologies now exist to remove dissolved oxygen from steam generator fill water. This
is an important issue, particularly for
units that face frequent shutdowns and
layups, and where demineralized water
and condensate are stored in atmospherically-vented tanks.
PLANT EFFLUENT ISSUES

In the April issue of Power Engineering,
I wrote about increasingly stringent effluent guidelines that are being imposed
at many plants. A full repetition is not
needed here, but as a reminder, plant
owners and operators may see some of
the following constituents, with discharge limits of course, in their future effluent guidelines.
Heavy metals including chromium,
42
zinc, and copper

Total dissolved solids (TDS)
Sulfate
Phosphorus
Ammonia
Quite commonly, the majority of
plant effluent comes from cooling tower
blowdown, with often plant drains, boiler blowdown, reverse osmosis reject, and
other less voluminous or more transient
flows mixed in. Effluent suspended solids, oil & grease, and residual oxidizing
biocide concentrations have been regulated for years, but the additional items
outlined above and others that are being
contemplated have made proper evaluation and engineering of water and wastewater treatment systems critically important. A few quick examples of current
issues include:
Very stringent guidelines on copper discharge (with limits in the
low part-per-billion range) at
some plants.
A ban on discharge of phosphorus

in some locations, currently or potentially forcing a change in cooling tower chemistry programs from
well-known inorganic/organic phosphate methods to polymer-based
programs. [2]
Very limited ammonia discharge,
which, when coupled with the increasing use of reclaim water (secondary or tertiary-treated municipal wastewater) for makeup, can be
quite problematic. Reclaim water
also causes difficulties regarding
phosphorus, both with respect to
its effect on cooling tower chemistry
and with regard to discharge in the
blowdown.
Sulfate limits can seriously interfere with a common cooling tower
makeup treatment method in
which sulfuric acid is injected to
the makeup to remove bicarbonate alkalinity.
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Introduced in 2014, GEs five-legged Space Frame Tower

is covered by a plastic fabric. Photo courtesy GE.
Whats New in
Wind Technology?
Leading wind turbine and components
suppliers, specialized service providers and
inventors gathered at Windpower 2014.
BY EIZE DE VRIES, CONTRIBUTING EDITOR
housands of wind power

professionals descended
on Las Vegas in May to
check out Windpower
2014, the annual wind energy conference and expo put on by the
American Wind Energy Association. The
expo hall was filled with both large and
small wind companies showcasing the
technologies, products and services that
will help bring more clean energy to the
U.S. and the rest of the world.
GE UNVEILS NEW
TURBINE TECHNOLOGIES
One of the innovative solutions GE
44
presented in Las Vegas was its blade extension, a dedicated solution for 1.5-MW
SLE turbines offering a rotor diameter
increase from an initial 77 meters to 91
meters. To begin the process, the original
37-meter blades are cut in half roughly
in the middle. Next, the blade halves are
re-joined but with a seven-meter insert
incorporated into them. The complete
cutting, extension and re-joining process
was shown on video but in highly accelerated mode and with the most critical
steps and especially the actual joints and
two joining areas blurred.
Between 2007 and 2008 GE installed
about 9,000 SLE-series turbines across
the U.S. and all were put atop 80-meter tubular steel towers. According a GE
spokesperson, a 77-meter rotor was that
time the only standard size available,
including for turbines operating at poor
wind sites with only 5.5 -6.0m/s average
wind speeds. The turbine blade modification increases the rotor swept area by
40 percent, which the company claims
increases annual energy production by
more than 20 percent under wind speed
conditions mentioned above.
GE said that the solution comes with
built-in advanced controls offering substantial load mitigation benefits. Two
prototypes fitted with the blade extension feature have been in operation since
June 2013 at sites in the U.S. The SLE-series rotor enlargement does not take place
simultaneously with hub height increases, and this could potentially become an
issue at low-wind sites hampered by high
wind shear.
GE also announced an expansion of its
brilliant platform with a new 2.2-MW
turbine plus integrated wind farm wake
management software for reduced wake
loss and optimized mechanical turbines
loads. Noteworthy, the 2.2-MW turbine
builds on GEs 1.5-MW series and is not
a de-rated 2.5-MW platform. With this
new 2-MW+ turbine model introduction
the original platform split between 1.X
(up to 2 MW) and 2.X (from 2 MW) is
no longer valid according GE. The companys current evolutionary product development strategy focuses on migrating
to new 1-2 MW and 2-3 MW turbine class
portfolios. With regard to performance
and operating economics, the 2.2-MW
offers a 12 percent increase in capacity factor and 33 percent higher yield,
according to GE. The figures should
be compared to the current 1.85-82.5
model, which is geared towards Brazils Class II wind regime.
Wind farm wake management
www.power-eng.com
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software improves output at the plant

level through turbine-to-turbine communication, harmonizing wind farms with
more than 20 turbines to achieve greater
output as a single, efficient plant. With
the initial applications, customers can expect to see 5 to 10 percent reduced wake
loss and improved mechanical loads due
to lower wake turbulence, said GE.
UPGRADES TO EXISTING
TURBINE TECHNOLOGY
Refurbished and redesigned/upgraded
kW class turbines, often fitted with a new
modern control system and of which the
original design is sometimes more than
25 years old, continue to serve a wind
market niche. Californiabased Tenderland Renewables is one of these market
players and at Windpower 2014, the company displayed an open nacelle of a refurbished 160-kW Danwind 23E, a classic Danish turbine but with an unusual
TenderLand Renewables wind turbine refurbishment

process. Photo Courtesy TenderLand Renewables
geared drivetrain layout.

Turbine lifecycle extension as a theme
is closely interlinked with keeping second-hand turbines running, and it enjoys increasing wind industry recognition. Gamesa of Spain is one of the main
pioneers in this area. A company expert
explained that the trend is reinforced by
the fact that it is often not possible to
exchange old turbines with bigger more
modern equivalents because of permitting and other reasons. Planning a product lifetime extension from, for instance
20 to 25 years or longer should be prepared well in advance, he added. Because

product lifetime extension is a dedicated
process it also incorporates careful analysis and ongoing monitoring of a turbines
condition. This careful analysis can indicate that a given turbine component such
as the gearbox of a specific model has suffered premature failure. It is then possible
to either bring back the failed component
to original factory specifications (100
percent) or alternatively recondition and
redesign/modify to a higher specification
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level by systematically incorporating design improvements.
SMALL TURBINE
OFFERINGS
Regarding small turbine offerings up
to 100 kW, the number of suppliers is
rather limited. Chinese company Hummer displayed some nacelles in Las Vegas.
The models are available in power ratings
up to 100 kW and a shared key product
characteristic is a permanent magnet
type direct drive generator mounted in
front of the rotor hub.
On a much smaller overall scale was
the U.S. Department of Energy Collegiate
Wind Competition for undergraduate
students teams from ten different colleges and multiple engineering and other
disciplines. Each individual team had
to design, build, and test a micro-wind
turbine capable of performing according
to a customized, market data-derived
business plan. For testing each turbines
individual performance, a wind tunnel

was brought to Las Vegas. This year the
competition was focused on creating a
lightweight, transportable wind turbine
that could be used to power small electronic devices. Pennsylvania State University was crowned the winner with
a three-bladed horizontal-axis design,
but the various teams displayed a rich
variety in solutions using rather unusual concepts.
One such unusual design was a vertical-axis Darrieus-type turbine with a
Savonius rotor incorporated inside the
main rotor, which was aimed at providing self-starting capability to the system.
It was also interesting to note that several teams had taken advantage of the
increasingly popular 3D printing trend,
making their blades and/or other components with this new technology.
VISUALLY PLEASING
High towers continue to be an
onshore wind industry main focus.

In Europe, concrete-steel hybrid towers with hub heights in excess of 140
meters have become a popular offering in several key markets including
Germany, Austria and Finland. At least
two companies Siemens and Lagerwey have developed alternative bolted
steel towers.
Earlier this year, GE introduced a
five-legged Space Frame Tower, with a
current largest 139-meter hub height
for the latest 2.75-120 model. A company expert stressed that the tower
architecture is not limited to 140 meters. Unusual is that the lattice type
Space Frame Tower structure is covered by plastic fabric. A renowned German tower expert within this context
commented that high towers are large
landscape dominant objects and a basic requirement for each (high) tower
solution then is a visually pleasing
overall design.
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47
The Rotork CVA offers an accurate and responsive

method of automating control valves without the
complexity and cost of a pneumatic supply. Photo
courtesy Rotork
Valves &
Actuators
BY RUSSELL RAY, CHIEF EDITOR
hey work in harsh environments, and they

get little or no recognition. But their impact on
power plant efficiency
can be significant.
Valves and actuators are critical in
almost every aspect of power plant
operations. They are used in a wide
range of applications, including pollution control, feed water, cooling water,
48
chemical treatment, bottom ash and

steam turbine control systems. They
are exposed to a variety of chemicals,
abrasive materials and very high temperatures. They are critical in optimizing efficiency, and they are often the
final control element in the operation
of a power plant.
Although the basic technology
for most valves and actuators has
remained unchanged, innovative
applications and design modifications

for problem solving have led to notable
improvements in actuator technology.
These improvements can reduce costs
by supporting the control valves ability to throttle accurately, thereby providing better performance for highpressure steam bypass, turbine bypass
and other critical power plant operations.
Actuators regulate mass and energy
flows by adjusting valves, flaps and
cocks. The actuator and valve create a single unit the control valve.
Actuators perform different motion
sequences, including linear, pivoting
and rotating motions, and they are
powered by pneumatic, hydraulic or
electrical energy.
Actuators receive a control signal
from automation systems. The signal
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Rotork IQ electric actuator being installed at a

power plant. Photo courtesy Rotork
is converted into a motion so that the

control element of the actuating element assumes a corresponding position. With control valves, this is a
stroke motion. With flaps, ball cocks
or rotary plug valves, this is a pivoting
motion.
Power plants have traditionally used
pneumatic actuators to drive the many
control valves throughout their facilities. However, major improvements
in electric control-valve actuator technology are helping power providers
achieve their most important objectives at a lower cost.
The new electric actuators can hold
up to the demands of continuous
movement. In addition, they work effectively in harsh environments, and
provide superior performance in a
wide range of applications. The benefits include better efficiency, less
maintenance and enhanced performance of the control valves.

50
The move toward

electric actuators has
led to the creation of
more digital networks
for controlling these
types of actuators.
The electric actuators include a
new technology to meet the specific
demands of a constantly modulating control valve using electricity as
the mode of power. Like traditional
pneumatic actuators, the new electric actuators are capable of constant
modulation for long periods of time
throughout the life of the valve. The
electric actuator has an advantage in
that it does not require recalibration
over time. Temperature, contaminates
and other factors have no impact on
www.power-eng.com
JOIN THE REVOLUTION

the units calibration. Once calibrated, the electric control valve actuator can operate for months,
even years, without adjustment.
ELECTRIC ACTUATORS
Rotork has a line of all-electric, compact modulating actuators known as the Continuous Duty
Modulating Failsafe Electric Actuator. The Rotork
CVA is suited for almost all linear, quarter-turn
control valve applications requiring precise position control and continuous modulation.
The electric actuator features a failsafe function, allowing the operator to program the actuator to lock in one of four positions if there is a loss
of power.
The CVA does not require the infrastructure
(piping/tubing to distribute compressed air) needed to operate a pneumatic actuator. Whats more, it
is significantly more accurate, Kundin said.
The move toward electric actuators has led to
the creation of more digital networks for controlling these types of actuators. But the transition has
been slow
PNEUMATIC ACTUATORS
While many pneumatic actuators have remained unchanged, except for the addition of smart positioners, there
have been some new innovations in pneumatic actuation.
A number of piston and rotary actuators have been creeping
into power plants, which primarily have used diaphragm
actuators on control valves.
Pneumatic actuators equipped with smart positioners
now functionally compete with electric actuators in terms
of fail-in-position operation on loss of signal at significantly less cost.
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HYDRAULIC ACTUATORS

Hydraulic actuators are increasingly popular because of

their ability to achieve high torque. Some companies offer a linear actuator that can be modified for rotary action
through a gearbox. The device has been around for more
than a decade and offers a digitally stepped servomotor
pump to provide higher positioning accuracy than pneumatic actuators.
Hydraulic actuators have even been used to position
small turbine control valves. The actuator is connected to
a nearby smart programmable electronic box with an umbilical cable. Configuration and calibration is made easy
through this box, which can be mounted away from the
process for convenient access.

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52
Ultrasonic gaging and

positioning systems
CONTINUED ON PAGE 59
www.power-eng.com
2014
rojects of the Year

NOMINATIONS ARE NOW OPEN!
Honoring excellence in design, construction and engineering of power generation facilities worldwide.
Awards will be given in the following categories:
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FEDERAL REPUBLIC OF NIGERIA

Nigerian National Petroleum Corporation
Escravos Environs Power Supply Project
Invitation for Pre-Qualification
INTRODUCTION
As part of the ongoing effort of the Nigerian National
Petroleum Corporation (NNPC) to further its social
responsibility to host communities within the catchment area
of Nigerian Gas Company (NGC) operations in Escravos
Environs, the NNPC undertakes to provide as an Independent
Power Producer (IPP) a gas-fired power plant on the North
Bank of the Escravos River supplying the North Bank, South
Bank and onwards through an electricity distribution network.
The Project comprises the following Lots:
Lot 1: Provision
of
Engineering,
Procurement
and
Construction (EPC) and Services for 14MW (ISO)
gas-fired power plant, including a 5-year Long Term
Service Agreement (LTSA), and
Lot 2: Provision
of
Engineering,
Procurement
and
Construction (EPC) and Services for 33kV distribution
network system, including Sub-Marine Cable (SMC)
river/creek crossings.
DESCRIPTION
Pursuant to this, the NNPC hereby invites interested and
suitably qualified companies and/or Original Equipment
Manufacturers (OEMs) with appropriate resources and
relevant experience to pre-qualify to tender for Lot 1 and/or
Lot 2 on EPC Turnkey Contract basis.
PRE-QUALIFICATION REQUIREMENTS
Interested companies must provide the following information
indicating their chosen Lots, 1 and/or 2:
(1) Companys registration with relevant professional and/or
regulatory bodies (minimum requirements: firms ISO
Quality System and COREN certificates)
(2) Capacity Profile (technical equipment available)
(3) Evidence of experience in at least two (2) reference jobs
of similar nature and complexity executed within the last
five (5) years. This must include:
(a) Verifiable letters of contract award, certificates of job
completion and details of on-going projects. Projects
in similar environments will be an added advantage.
(b) For Lot 1: concise description of each reference job
that must include a certified copy of the General
Layout/Plot Plan of the gas-fired power plant, number
of gensets (minimum 3), electric output of each
genset (minimum 2MW @ ISO conditions), type and
make of the critical plant and equipment (gas
engines,
generators,
step-up
transformer/s,
switchgear/s, control system, gas receiving unit), a
certified copy of the title page and the table of
contents of a LTSA with minimum duration of 3 years.
(c) For Lot 2: concise description of each reference job
that must include certified copies of the General
Layout/Plot Plan and One-Line Diagram of the
distribution system and the SMC distribution line,
voltage level/s. For Lot 2 at least one reference job
must include a SMC river/creek crossings.
(4)
(5)
(6)
last 3 years indicating specified minimum Annual Turnover

in naira or its equivalent in any international currency.
(7) Submission of evidence of open Retirement Savings
Account (RSA) with a Pension Fund Administrator (PFA)
of choice for Nigerian company and JV and evidence of
remittance of both Employer and Employee Pension
Contribution for Nigerian firms and JV.
Contractors will be selected in accordance with the procedures
set out in the Public Procurement Act 2007 for International
Competitive Bidding.
For Lot 2 there shall be a Domestic Preference applied.
The Pre-Qualification Document and clarifications can be
obtained free of charge, in writing from the Project Consultant:
email sewa.abuja@steagwa.com (0705 935 6428), at 15,
Lake Chad Crescent, Maitama, Abuja, FCT, Nigeria.
SUBMISSION OF PRE-QUALIFICATION
DOCUMENTS
Application with all the required documents should
packaged in binders. The binders shall be enclosed
sealed in a main envelope that is marked as per
Instructions in the Pre-Qualification Data and addressed
submitted to:
Project Manager NNPC
Escravos Environs Power Supply Project
c/o The Consultant Project Office
15 Lake Chad Crescent, Maitama,
Abuja, FCT, Nigeria.
To reach him on or before 12 noon September 1, 2014.
be
and
the
and
IMPORTANT NOTICE
Pre-Qualification documents must be in accordance and
must comply with the requirements set forth above.
This invitation is not an invitation to tender and it does not
obligate NNPC to consider a responding company for
invitation to tender or inform them of any resultant action.
NNPC reserves the right to either accept or reject any
submittal in part or in whole at its sole discretion. Only
successful pre-qualified bidders will be invited in due
course to tender.
All costs incurred as a result of this Pre-Qualification and
any subsequent request for information shall be to the
responding companys account.
Curriculum Vitae of key staff

Company profile with a copy of Certificate of
Incorporation, Memorandum and Articles of Association
and Corporate Affairs Commission Forms CAC-2 and
CAC-7, where registered in Nigeria, and Consortium
Agreement for Joint Ventures
Submission of Tax Clearance Certificate for Nigerian firms
and Audited Financial Reports/Audited Accounts for the
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Just Plugging Along
GEORGE H. BODMAN, INC.

Chemical cleaning advisory services for
boilers and balance of plant systems
George H. Bodman
Pres / Technical Advisor
P.O. Box 5758

Kingwood, TX 77325-5758
email: blrclgdr@aol.com
Office (281) 359-4006

1-800-286-6069
Fax (281) 359-4225
ELECTRIC SYSTEM DISPATCHER/

RELIEF/MECHANIC
City of Ketchikan/Ketchikan Public Utilities
Ketchikan, Alaska
Responsible for the SCADA control and dispatch of KPUs electrical
generation/transmission/ distribution system and works in a maintenance
capacity. Electrical system includes hydroelectric and stand-by diesel
facilities. Prefer experience with SCADA operations, energy dispatch;
outage restoration; and answering customer service calls during utility
non-business hours. Prociency required in Excel and Microsoft Word. Five
years experience as a certied automotive, heavy equipment, and/or hydro
technician. Rotating shift schedule; $36.47/per hour plus benets.
Complete job description and application available at:

http://www.egovlink.com/ketchikan/postings.asp?listtype=JOB
or E-mail heidib@city.ketchikan.ak.us
City of Ketchikan
334 Front St, Ketchikan, AK 99901
Phone (907) 228-5631
POSITION OPEN UNTIL FILLED EOE/AA
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PRODUCTS | CONTINUED FROM PAGE 52
Explosion-proof
fuorescent fxture
he EPL-24-192 explosion proof fuorescent
light fxture from Larson Electronics is a two
foot long explosion proof fuorescent light featuring a robust 4 lamp
confguration
and
approval for use in
the demanding conditions of paint spray
booths. This fxture
provides high output
and excellent light
quality through the inclusion of four F24-T5/HO
lamps producing a total of 16,000 lumens with a
5000k color temperature.
This light is only two feet long, but by utilizing four T5HO lamps Larson Electronics has produced a fxture providing the power of two lamp
4 foot fxtures in a design that can be installed
in smaller spaces. The fxture is constructed of
copper free aluminum for light weight and high
strength, and heavy gauge aluminum refectors
with high gloss fnishes provide excellent light
distribution. Each fuorescent tube is protected
by a heat and impact resistant Pyrex tube cover,
and screw on end caps provide easier relamping
and more secure sealing than standard knock off
end caps. Mounting for this explosion proof light

is provided by standard end brackets for mounting to fat surfaces, and optional pendant mounts
are available for operators who need more clearance between the fxture and mounting surface.
Larson Electronics
Advanced Meter Proving

oastal Flow Liquid Measurement Inc., in alliance with Flow Management Devices LLC.
and Applied Metrology Resources, LP, introduce
TruProof, an innovative and exceptionally accurate solution for advanced meter proving that will
be especially benefcial for hydrocarbon gas and
liquid measurement.
The TruProof technology dramatically improves
the accuracy and repeatability of meter proving.
Software based on this methodology employs
time correlation to synchronize a meters output
signal with the comparative prover volume measured during the meter proving process.
This rugged and highly portable hardware will
integrate with existing proving systems -- such
as the state-of-the-art provers manufactured by
Flow Management Devices, as well as industryleading meter performance software PROVEit
from Flow-Cal Inc. -- to bring these technical

advances, including time correlation, to mainstream industrial meter proving.
Coastal Flow Liquid Measurement Inc.
High-temperature label materials

abrico offers materials and thermal transfer
ribbon from leading suppliers 3M and DNP
for bar code labels in circuit board applications,
where high-heat is a signifcant factor.
Temperature sensitive applications require
specialized materials that can stand up to highheat. To address this need, Fabrico provides 3M
Thermal Transfer Polyimide Label Material 7812;
a flm product that offers ultra-high temperature
performance. Utilizing 3M Adhesive 100, this
product can withstand up to 450 F (232C) shortterm resistance, has excellent solvent resistance,
and exhibits low outgassing characteristics.
Additionally, Fabrico offers DNPs R510HF Ultra
Durable Resin, which is the only halogen-free
resin ribbon capable of handling extreme environments with unmatched scratch and solvent
resistance.
Fabrico
800-343-6926
www.escotool.com
INDEX
RS# COMPANY
PG#
Amec E&C Serv
RS# COMPANY
PG#
17
1421 S. Sheridan Rd., Tulsa, OK 74112

Phone: 918-835-3161, Fax: 918-831-9834
e-mail: pe@pennwell.com
26 Mobil Industrial Lubricants 45
Sr. Vice President North

American Power Group Richard Baker
www.amec.com/power
23 Asco Valve
39
www.ascovalve.com/rightnow
24 Basler Electric Co
www.mobilindustrial.com
41
8
www.basler.com/be/7penf
Brandenburg Industrial
Service Company
CB&I
20 POWERGEN 2014
13
32 Projects of the Year
47
11
29 Rotork Controls Inc

35
33 Sick Maihak Inc
31
22 Siemens AG
25
Terrasource Global
23
22
17 United Rentals Inc
21
www.kiewit.com
16 Lapeyreb Stair
27
www.lapeyrestair.com
30 Lehigh Fluid Power

www.lehighfluidpower.com
60
46
19 Victory Energy
Operations LLC
32
www.boilermactsolutions.org
Westinghouse Electric Co
26
www.imi-sensors.com
Kiewit Power Inc
29
www.boilermactsolutions.org
www.houstondynamic.com
27 Victory Energy
Operations LLC
51
www.harringtonhoists.com
15 IMI Sensors
www.unitedrentals.com
www.flexim.com
11 Houston Dynamic
Service Inc
37
www.terrasource.com/pe
www.fibrwrap.com
31 Harrington Hoists, Inc.
C3
www.siemens.com/energy
www.ethosenergygroup.com
12 Flexim Americas Corp
49
www.sicknorthamerica.com
www.concosystems.com
13 Fibrwrap
43
www.rotork.com
www.apollovalves.com
14 Ethosenergy
C2
www.renewableenergyworldevents.com
www.cleaverbrooks.com
18 Conco Systems Inc
Reliable Turbine Services
25 REWNA 2014
www.clearspan.com
21 Conbraco Industries Inc
53
www.reliableturbineservices.com
10 Clearspan Fabric Structures 21

Cleaver Brooks
Inc/Nebraska Boiler
33
www.power-gen.com
www.checkall.com
15
www.power-gen.com
www.cbi.com
28 Check All Valve Mfg Co
Ovivo USA, LLC

www.ovivowater.com/power
C4
www.brandenburg.com
Mitsubishi Engine
North America Inc.
50
Advertisers and advertising agencies

assume liability for all contents (including text representation and illustrations)
of advertisements printed, and also assume responsibility for any claims arising therefrom made against the publisher. It is the advertisers or agencys
responsibility to obtain appropriate
releases on any items or individuals pictured in the advertisement.
SALES OFFICE
Reprints Foster Printing Servive

4295 Ohio Street
Michigan City, IN 46360
Phone: 866-879-9144
e-mail: pennwellreprint@fosterprinting.com
National Marketing
Consultant Rick Huntzicker
Palladian Professional Park
3225 Shallowford Rd., Suite 800
Marietta, GA 30062
Phone: 770-578-2688, Fax: 770-578-2690
e-mail: rickh@pennwell.com
AL, AR, DC, FL, GA, KS, KY, LA, MD, MO,
MS, NC, SC, TN, TX, VA, WV
Regional Marketing Consultant Dan Idoine
806 Park Village Drive
Louisville, OH 44641
Phone: 330-875-6581, Fax: 330-875-4462
e-mail: dani@pennwell.com
CT, DE, IL, IN, MA, ME, MI, NH, NJ, NY,
OH, PA, RI, VT, Quebec, New Brunswick,
Nova Scotia, Newfoundland, Ontario
Regional Marketing Consultant Natasha Cole
1455 West Loop South, Suite 400
Houston, Texas 77027
Phone: 713.499.6311; Fax: 713.963.6284
e-mail: natashac@pennwell.com
AK, AZ,CA,CO,HI,IA,MN,MT,ND,NE,NM,NV,
OK,OR,SD,UT,WA,WI,WY,AB,BC,SK, Manitoba,
Northwest Territory, Yukon Territory
International Sales Mgr Michelle Smith
The Water Tower
Gunpowder Mills
Powdermill Lane
Waltham Abbey, Essex EN9 1BN
United Kingdom
Phone: +44 1992 656 609, Fax: +44 1992 656 700
e-mail: michelles@pennwell.com
Africa, Asia, Central America, Europe,
Middle East, South America
European Sales Asif Yusuf
The Water Tower
Gunpowder Mills
Powdermill Lane
Waltham Abbey, Essex EN9 1BN
United Kingdom
Phone: +44 1992 656 631, Fax: +44 1992 656 700
e-mail: asify@pennwell.com
Europe and Middle East
Classifieds/Literature Showcase
Account Executive Jenna Hall
1421 S. Sheridan Rd.
Tulsa, OK 74112
Phone: 918-832-9249, Fax: 918-831-9834
email: jennah@pennwell.com
www.power-eng.com
GM32: SO2 MEASUREMENT FGD (FLUE GAS DESULFURIZATION)

In-situ Gas Analysis
GM 32 multi component gas analyzer for SO2, NO, NH3 and NO2 as well as temperature and pressure. Real time
measurement of SO2

UV gas analyzer measures ammonia, sulfur dioxide and nitric oxide directly in the duct before and/or after FGDs and
SCRs. Low maintenance and precise measurement up to 932F (500C) make the GM32 the best choice for control
of scrubber systems. No sample system required No calibration required No probe maintenance.
Call 281-436-5100 or visit www.sicknorthamerica.com.

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Heat Recovery Steam Generators | Waste Heat Boilers | Fired Packaged Watertube Boilers | Specialty Boilers

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