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ENERGY-
FEATURES
6
T ECH
Lubrication options for modern API-610 compliant
vertical pumps
By Heinz P. Bloch, P.E.
P.O. Box 388 Dubuque, IA 52004-0388
800.977.0474 Fax: 563.588.3848
Email: sales@WoodwardBizMedia.com
10 Four tips to create a successful condenser leak
Energy-Tech (ISSN# 2330-0191) is published
detection program
monthly in print and digital format except in January By Kim Massey, Day & Zimmermann
and July, when it is published in digital format only
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COLUMNS
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12 Regulations Compliance
Printed in the U.S.A.
Regulations for the management of coal
Group Publisher
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combustion residuals generated by electric utilities
General Manager By Mathy Stanislaus, U.S. Environmental Protection Agency
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Managing Editor
18
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Mr. Megawatt
Editorial Board
(editorial@WoodwardBizMedia.com) Blowing bellows
Bill Moore Director, Technical Service,
National Electric Coil By Frank Todd, True North Consulting
Ram Madugula Executive Vice President,
Power Engineers Collaborative, LLC
Kuda Mutama Engineering Manager, TS Power Plant
Tina Toburen T2ES Inc. 28 Turbine Tech
Editorial views expressed within do not necessarily
Crossing the retirement finish line with high
reflect those of Energy-Tech magazine or temperature steam turbine rotors
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E-mail: ETart@WoodwardBizMedia.com. Dont miss Energy-Tech Universitys upcoming Summer School
series in June, July and August. Join Tom Davis as he explains
the maintenance basics you need to keep your plant running. Visit
www.energy-tech.com/summerschool for more information.
June is a month
June 10-11, 2015
Energy-Tech University Summer School
Online Course: Bearing Installation,
for learning
Precision Fitting and Lubrication, with
Tom Davis
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Although vertical pumps are ideally suited for multistage or tapered roller bearings, which might have less than
(high differential pressure) services, many vertical pumps are 16,000-hour life at worst conditions to avoid skidding
of single stage design. They incorporate an end suction back in normal operation. In such cases, the vendor must
pull out-type casing, with the hydraulic end being mount- state the shorter design life in the proposal.
ed below the liquid level. The impeller is connected to the For vertical motors and right-angle gears, the thrust
motor by means of an extended shaft; the shaft is housed and bearing must be in the non-drive end and will limit
supported in a rigid tubular intermediate pipe. axial float to 125 m (0.005).
As a rule, vertical pumps in important hydrocarbon pro- Thrust bearings will be designed to carry the maxi-
cessing services are designed to the requirements found in mum thrust that the pump can develop while starting,
an API (American Petroleum Institute) Standard API-610. stopping or operating at any flow rate.
User-purchasers view adherence to the standards stipulations Hydrodynamic thrust bearings must be selected at no
as a powerful risk reduction step. API-compliant equipment more than 50 percent of the bearing manufacturers
incorporates considerable experience-based content derived rating at twice the pump internal clearances specified
from reliability-focused users. While equipment cost is elsewhere in the pump standard.
always a concern, the best companies aim for proper balance
between initial monetary outlay and long-term reliability. More detailed guidelines on bearings are found in the
As a rule, life-cycle cost studies show significant advantages same standard, API-610. As general examples, a number of
for API-compliant pumps compared to their lower-priced additional bearing-related items are worthy of note:
non-API competitors. An API pumps generally higher reli- Each shaft shall be supported by two radial bearings and
ability will translate to reduced one double-acting axial (thrust)
catastrophic failure risk, and bearing that might or might
such reductions are naturally Learn more about bearings not be combined with one of
of interest to a multitude of with Tom Davis during our first the radial bearings. Bearings
industries. Summer School course, June 10-11. shall be one of the following
arrangements: rolling-element
API 610 highlights For more information, visit radial and thrust; hydrodynam-
Special attention is given to www.energy-tech.com/summer school ic radial and rolling-element
bearings in the drive systems thrust; hydrodynamic radial and
of vertical pumps. Regardless thrust.
of feasible bearing options, these bearings must always be Thrust bearings shall be sized for continuous operation
designed for prevailing radial and/or axial loads. These loads, under all specified conditions, including maximum dif-
of course, are transmitted from the hydraulic end of the ferential pressure, and comply with the following:
pump and API-610 makes clear that bearings must meet a All loads shall be determined at design internal
number of requirements: clearances and also at twice design internal clear-
Rolling element bearings will be selected to give a ances.
basic rating life, in accordance with ISO 281, equivalent Thrust forces for flexible metal-element couplings
to at least 25,000 hours with continuous operation at shall be calculated on the basis of the maximum
pump rated conditions. allowable deflection permitted by the coupling
Rolling element bearings will be selected to give a manufacturer.
basic rating life equivalent to at least 16,000 hours A sleeve-bearing motor (without a thrust bearing)
when carrying the maximum loads (radial or axial or is directly connected to the pump shaft with a
both) imposed with internal pump clearances at twice coupling, the coupling-transmitted thrust shall be
the design values, and when operating at any point assumed to be the maximum motor thrust.
between minimum continuous stable flow and rated Single-row, deep-groove ball bearings will have radial
flow. internal clearance in accordance with ISO 5753, i.e.,
Concessions are made for vertical motors 750 kW larger than Normal internal clearance.
(1,000 HP) and larger that are equipped with spherical
Figure 3. Oil-lubricated vertical pump thrust bearing. (Source: Afton Pumps, Houston, Texas)
Without regular maintenance and repairs, condenser plants dont have yearly outages. Nuclear units for instance are
tube leaks and condenser air inleakage can turn into costly on 18- to 20-month outage cycles. Waiting nearly two years in
problems for power plant managers. A large leak can lead to between inspections might be too long to prevent minor issues
unplanned outages that last multiple days and result in mil- from becoming major ones.
lions of dollars in lost income. Despite the risks, managers Plant managers need to consider a more aggressive and
consistently wrestle with the decision of when a leak is of proactive approach to tackling leak detection programs. At min-
high concern and when repairs can be reasonably delayed. As imum, condensers should be checked twice a year. Optimally,
long as a unit is running there is hesitancy to address leaks a quarterly program will eliminate many of the risks associat-
that would result in downtime. ed with leaks. While there can be a cost associated with these
Ultimately, each identified leak must be evaluated on a inspections, they are far less of a cost burden than a major leak
case-by-case basis, but whats concerning is that some plants that leads to an unplanned outage. They also can lead to consid-
dont have the proper systems and processes in place to check erable cost savings by improving condenser efficiency.
regularly for leaks. While a comprehensive leak detection plan
wont eliminate all potential issues, developing one with your Beware of hidden leaks
internal teams and a maintenance partner can go a long way There are a number of areas within a condenser unit in
toward increasing efficiency and protecting against major dis- which leaks are extremely common. Most leak detection pro-
ruption and damages. Below are four tips for building an effec- grams rightfully prioritize inspecting these areas. Unfortunately,
tive leak detection program. the nature of leaks makes their location unpredictable and
some leaks can be hard to find without extensive experience
Have a proactive plan in inspection methodologies. Condenser inspection is arduous
A common approach to scheduling condenser inspections and intense work. Every condenser has dark, hot crevices that
is to sync them up with planned outages. Its a way to make maintenance personnel might be hesitant to inspect. When
sure that inspections happen regularly and also allows plant inspections skim these areas instead of doing a thorough check,
managers to address potential issues without interrupting nor- plant managers expose themselves to greater risk.
mal operations. While this plan seems sensible on its face, some Among the more uncommon areas where leaks have
been identified are at gland steam
exhausters, oil-bearing drains, on
the turbine shell and at the base of
a condenser. When working with
maintenance partners and leak
detection teams, plant managers
should ask for a comprehensive
checklist of the areas that were
inspected and a detailed list of test
results. Even if the probability of
leaks in each of these areas remains
low, they should still be on the list.
(513) 247-5465
Kim Massey is vice president of Condenser FAX (513) 247-5462
sales@atcontrols.com
Services at Day & Zimmermann, with offices www.atcontrols.com
The U.S. Environmental Protection Agency (EPA) recently EPAs risk assessment presents a static snapshot of CCR dis-
finalized regulations that establish comprehensive requirements posal practices at the time. While newer disposal units might be
for the disposal of coal combustion residuals (CCR or coal ash) managed in a more protective manner, older units, which still
as solid waste (non-hazardous waste) under Subtitle D of the comprise the majority of current units, continue to operate in a
Resource Conservation and Recovery Act (RCRA). These reg- manner that poses risks to human health and the environment.
ulations provide water and air protections for communities near
coal-fired power plants, and require these facilities to provide Damages from the mismanagement of CCR
communities with the information they need to determine if The EPA has a long history of considering damage cases in
facilities are in compliance with the regulations. its regulatory decisions under RCRA. Damage cases provide
evidence of both the extent and nature of the potential risks
Generation, chemistry and management of coal to human health and the environment. The number of damage
combustion residuals cases collected for this rulemaking was 157, and is the largest
CCR is one of the largest industrial wastes generated in number of documented damage cases in the history of the
the United States. In 2012, more than 470 coal-fired electric RCRA program.[4]
utilities in 47 states and Puerto Rico generated approximately Damages typically consist of contaminants of concern (arse-
110 million tons of CCR.[1] nic, selenium, boron, sulfate,
CCR includes fly ash, bottom An existing CCR unit is one that receives CCR etc.) exceeding a drinking
ash, boiler slag and flue gas water standard in groundwater
desulfurization materials.[2] both before and after the effective date of the or exceeding primary water
The contaminants in CCR of rule, or for which construction commenced quality criteria in surface
most environmental concern water, or a catastrophic failure
prior to the effective date of the rule and
are antimony, arsenic, barium, of a surface impoundment
beryllium, cadmium, chro- receives CCR on or after the effective date that could impact ground-
mium, lead, mercury, nickel, of the rule. A new CCR unit is one that first water or surface water. These
selenium, silver and thallium damage cases were primarily
receives CCR or commences construction
because of the mobility of associated with unlined units
metals and the large size after the effective date of the rule. and were most frequently
of disposal units. In 2012, associated with releases of
approximately 40 percent of generated CCR was beneficially arsenic.
used (e.g., in concrete or wallboard), with the remaining 60 per- Recent CCR surface impoundment failures include the
cent disposed of in surface impoundments and landfills (CCR catastrophic failure of an impoundment dike at TVAs Kingston
disposal units). CCR disposal currently occurs at more than 310 Plant in Harriman, Tenn., on Dec. 22, 2008. This failure led to
active on-site landfills, and at more than 735 active on-site sur- the release of approximately 5.4 million cubic yards of fly ash
face impoundments. sludge over an approximately 300-acre area and into a branch of
the Emory River (Figures 1 and 2).[5,6] The ash slide disrupted
Risks to human health and the environment power, ruptured a gas line, knocked one home off its founda-
Based on risk analyses conducted for the final rule, EPA con- tion and damaged others (Figure 3). Another case involved the
cluded that disposal of CCR in unlined surface impoundments structural failure of an inactive surface impoundment at Duke
and landfills presents the greatest risks to human health and the Energys Dan River Steam Station in Eden, N.C., on Feb. 2,
environment. As modeled, the national risks from clay-lined 2014, which led to the release of between 50,000 and 82,000
units are lower than those for unlined units, but such units can tons of coal ash and slurry into the Dan River, about 80 miles
exceed risk criteria at individual sites. Composite liners were the upstream from the Kerr Reservoir (Figure 4). The cause of the
only liner type modeled that effectively reduced risks from all failure was the collapse of a concrete and corrugated metal
pathways and constituents far below human health and ecologi- storm water discharge pipe that passed underneath the interior
cal criteria in every sensitivity analysis conducted. of the CCR surface impoundment.[7]
Figures 1a, 1b and 1c. TVA Kingston Plant CCR Surface Impoundment
Location restrictions Figure 3. Damage to House from TVA Kingston Plant Fly Ash Spill.
The location criteria include restrictions on the placement Credit: Tennessee Valley Authority.
of CCR above the uppermost aquifer, in wetlands, within fault
areas, in seismic impact zones and in unstable areas. All of these of CCR units. Existing CCR landfills are only subject to the
restrictions require the owner or operator of a CCR disposal location restriction for unstable areas. Units that do not meet
unit to demonstrate that they meet the specific criteria. The five these restrictions can retrofit and make appropriate engineering
location restrictions apply to all new CCR landfills, all new and demonstrations so that the unit meets the criteria. Owners or
existing CCR surface impoundments, and all lateral expansions operators of existing CCR units that cannot make the required
demonstrations must close the units, while owners or operators
The rule applies to: The rule does not apply to:
New and existing CCR landfills and surface impoundments, including any CCR landfills that have ceased receiving CCR prior to the effective date of
lateral expansions of such units that dispose of or otherwise engage in the rule (six months after publication in the Federal Register).
solid waste management of CCR generated from the combustion of coal at
electric utilities and independent power producers.
CCR disposal units located off-site of the electric utility or independent CCR generated at non-utility power producers such as hospitals, universities
power producer. and manufacturing facilities that produce electricity primarily for their own
use.
CCR disposal units at active electric utilities and independent power Electric utilities or independent power producers that have ceased producing
producers; i.e., those that generate electricity, regardless of the fuel electricity prior to the effective date of the rule.
currently used to produce electricity.
Inactive CCR surface impoundments at any active electric utilities CCR placement at active or abandoned underground or surface coal mines.
or independent power producers, regardless of the fuel currently
being used to produce electricity; i.e., surface impoundments at any
active electric utility or independent power producer that have ceased
receiving CCR or otherwise actively managing CCR.
Municipal solid waste landfills that receive CCR for disposal or for daily
cover.
LED Ob
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tria ig
Indus
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Proof
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Co ols
xplosio
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Unimar.com
THE ANSWER TO ALL YOUR ILLUMINATION NEEDS! (800) 739-9169
ENERGY-TECH.com
16 ENERGY-TECH.com June 2015
REGULATIONS COMPLIANCE
Finally, the rule requires inspections by a qualified person of References
all existing and new CCR landfills and any lateral expansion 1. American Coal Ash Associations Coal Combustion Product
for any appearances of actual or potential structural weakness, Production & Use Survey Report http://www.acaa-usa.org/
or any other conditions that are disrupting or have the potential Portals/9/Files/PDFs/revisedFINAL2012CCPSurveyRe-
to disrupt the operation or safety of the CCR landfill. Annual port.pdf.
inspections also are required by a qualified professional engineer 2. U.S. EPA:What is coal ash?
at intervals to ensure that the design, construction, operation and http://www2.epa.gov/coalash/coal-ash-basics.
maintenance of the CCR landfill is consistent with recognized 3. U.S. EPA: Human and Ecological Risk Assessment
and generally accepted good engineering standards. of Coal Combustion Residuals, Final, December 2014.
(Available at www.regulations.gov, Docket ID No. EPA-HQ-
Closure requirements RCRA-2009-0640.)
Closure and post-closure care criteria established in the new 4. U.S. EPA: Damage Case Compendium,Volumes I III,
rule require all CCR units to close in accordance with specified December 2014. (Available at www.regulations.gov, Docket ID
standards and to monitor and maintain the units for a period of No. EPA-HQ-RCRA-2009-0640.)
time after closure, including the groundwater monitoring and 5. U.S. EPA Region 4:TVA Kingston Fossil Plant Fly Ash
corrective action programs. Closure of a CCR unit must be Release http://www.epa.gov/region4/kingston/index.html
completed either by leaving the CCR in place and installing a 6. U.S. EPA:TVA Kingston Fossil Fuel Plant Release Site
final cover system or through removal of the CCR and decon- http://www.epakingstontva.com/default.aspx
tamination of the CCR unit. The final rule establishes time- 7. U.S. EPA North Carolina outpost On-Scene Coordinator
frames to initiate and complete closure activities. http://www.epaosc.org/site/site_profile.aspx?site_id=9065
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Blowing bellows
By Frank Todd, True North Consulting
Have you ever noticed that power plants sometimes seem to The ZWBB power station somewhere in Asia (the actual
have a devious inclination? I think if we did a histogram of the location was censored) wanted confirmation of the analysis of
significant issues requiring immediate engineering attention, the a problem they were having at the plant. It was the day before
bell curve would settle right at Friday afternoon between the the beginning of the Spring Celebration and everyone wanted
hours of 3 p.m. and 6 p.m. When this happens, human nature this resolved before the next day. The engineers believed that
wants to jump to the quickest solution possible so as to not they had a problem with their condenser and just wanted us to
spoil that weekend trip or that special dinner. verify that they were correct. The culprit was assumed to be the
Waking up in yet another of my standard home away from degraded efficiency of the condenser, based on Figure 1. They
home hotels where the only difference is the consistency of were concerned that the drop in generation for the change in
the oatmeal being served from 6 a.m. to 10 a.m., I was at least condenser pressure was too high.
pleased that it was the end of the week, so I was on my way These are the kind of jobs that we dream of, they have
back to the Bluff to see Mrs. Megawatt and my faithful thermal already done all the work and all we have to do is review their
performance golden retriever (in that order, of course). Even effort, put on a tie, verify that we are more than 50 miles away
before I choked down the barely brown coffee, my cell phone and send our conclusions that their engineers did it all right.
was requiring attention from a far off land with what they Especially since this was way more than 50 miles away (more
thought was a serious condenser problem. like 5,000 miles), we were even happier when they told us that
it had been reviewed,V&Ved and approved by the top people.
Of course, with all this we sort of wondered why they were
coming to us. That little engineer in my head told me not to
be so glib about it.
As usual, we asked them to send all the pertinent informa-
tion and that was our first inkling that something was amiss.
In their mind, the pertinent information was the graph they
sent (Figure 1). We then made our fatal mistake; asking for a lot
more data and the design information for their plant, particu-
larly the condenser. Being part of a society that is reluctant to
spread its information around, they said that if we needed more
we would have to come and get it. I think it might have also
had to do with the fact that we could not get there until after
their Spring Celebration (a.k.a. New Years).
I figured we were in quite a pickle until I remembered
our ace foreign travel expert, Ronny China. Not only was
Ronny the most adept cross cultural conqueror he is also the
Figure 1 prestigious Chairman of the International Committee for the
Universal Measurement of Pumps (ICUMP), and he looks
great in a tie. My confidence level greatly increased.
RC and I jumped on a few planes and after a mere 28
hours arrived at the ZWBB international airport ready to tack-
le any problem. That is after a 16(ish) hour train ride where we
both learned that the idea of personal space was nonexistent in
the country we had entered. Finally we made it to the ZWBB
official hotel and, after wandering around for a couple of hours
looking for our room, someone told us that the first number
of our room number was a lucky number and did not mean
anything.
After a hearty breakfast, RC and I bounced along the road-
way arriving at the plant to finally engage the problem. We
attended an official meeting with all the plant management and
half of the engineering organization and were taken to a secure
area through a series of get smart doors where we could look
Figure 2
Figure 3 Figure 4
at some data. The first thing on the list was the thermal kit of
the plant so we could try to figure out the various correction
curves (Based on ASME PTC-6) that would allow us to iden-
tify known losses and develop a curve of generation corrected
for the effects of condenser pressure. Based on their initial anal-
ysis we looked at the condenser to see if that was the issue. This
involves an evaluation of the circulating water inlet temperature,
flow and condenser pressure. Circulating water flow is shown in
Figure 2, which shows that it did not change during the time
period. We obtained the design information for the condenser
and developed an equation for the expected condenser pressure
for the circulating water inlet temperature. With this infor-
Figure 5
mation, a comparison between the actual condenser pressure
and the expected condenser pressure could be developed (see
Figure 3). Since the expected condenser pressure was tracking
with the actual condenser pressure, the problem was not in the
condenser.
During dinner, RC was able to convince the ZWBB engi-
neers that the problem was not in the condenser. I was a little
oblivious and somewhat afraid of the cuisine but RC, using
his skills with the Ganbei process, had them all eating out of
his chopsticks (literally). Even though RC was able to smooth
over the condenser issue, they still wanted to know what the
problem was.
The next morning, after recovering from the previous eve-
nings digestive anomalies and the perilous drive to the plant,
we put together a graph of corrected generation with condens-
er pressure, Figure 4. What we noticed was that the corrected
generation actually decreased before the condenser pressure Figure 6
increased. This means that something happened before the
change in circulating water temperature. Now we had to start decreased with respect to the other LP Turbines, see Figures 7,
at the beginning of the cycle and try and figure out the real 8 and 9. Figure 10 shows that the change in corrected gener-
issue. Figure 5 is a drawing of the type of plant we were dealing ation corresponded with the change in the extraction pressure
with and we essentially started walking through the cycle to to the 4th stage of the LP turbine. So we knew that there was a
identify what the possible issue could be. problem somewhere between the LP turbine and the feedwater
Starting at First Stage Pressure and the first point extraction heater since there was no abnormal indication of the feedwater
pressure Figure 6, we looked at trends of all the turbine heater TTDs. Based on the sudden change of the pressure, we
extraction pressure to see if we could find any issues. When we suggested that there might be an issue with one of the expan-
got to the extraction pressure for the 3rd and 4th stage on the sion bellows between the LP turbine and the feedwater heater.
south Low Pressure turbine, it was clear that those pressures had The expansion bellows are installed on the piping between
Figure 7 Figure 8
Figure 9 Figure 10
Figure 11
Two types of capacity problems are relevant to electrical on 100- or 500-year floods. Airports are designed to man-
power systems (Billinton 1984): age a maximum of so many passengers and planes.
The total problem can be divided into two conceptual- The extreme event is a primary design criterion that is
ly different areas designated as static and operating capacity usually defined using historical statistics. The engineering
requirements. The static capacity relates to the long-term task is to design the system to survive the event at a given
evaluation of the overall system requirement. The operating level of reliability. For electrical power systems, the Federal
capacity area relates to the short-term evaluation [of] actual Energy Regulatory Commission requires a reliability crite-
capacity required to meet a given load level. rion of one-day-in-10-years, or 0.00027. One-day-in-10-
This paper focuses on classical system capacity, what years is a heuristic reliability threshold. It does not imply
Billinton called static capacity. An early (pre-1970) crite- a blackout for one day every 10 years. This criterion is far
rion was deterministic: the expected maximum demand out on the tail of any distribution where classic statistical
plus a fixed percentage of the expected maximum demand. calculations are unreliable. Based on decades of experience,
More recently, an IEEE Task Force legacy system managers found that
defined capacity value for elec- at this reliability level, they can
trical systems as the amount of Adding wind generation to a avoid black/brown outs through
additional load that can be served legacy fossil fuel system has emergency imports and/or demand
due to the addition of the genera- management.
tor, while maintaining the existing
little impact on classical system Lastly, system capacity should
levels of reliability. This is correct capacity unless stand-alone wind not be confused with average
provided it is understood that there has reliable system capacity. capacity. The former is a measure
is considerable variation in wind of generation equipment require-
power availability. ments to satisfy estimated peak
The capacity of any system is measured by its ability to load, the latter is the average system power produced during
function reliably during extreme events. It is the outliers, a period of time.
the maximum stresses, that determine the size and strength
(the capacity) of the system. For example, in the structural Origins of system reliability & capacity
engineering world, hurricanes and floods often become the The green dotted line in Figure 1 shows the cumulative
basis for system design. The BOCA building code requires exceedance distribution function (EDF) for a system con-
that the design wind speed be the fastest mile per hour sisting of two generators. The EDF is the probability that
measured at 33 above the ground with an annual prob- the system power exceeds the power level on the horizontal
ability of 0.02 (50-year wind). More generally, structures axis. The size of each generator is 50 power units and each
are designed to reliably withstand the highest wind load has a 3 percent forced outage rate (availability = 0.97).
expected during the life of the structure, with a reasonable The probability that the system power exceeds 100 is zero.
safety factor. Likewise, flood control systems are often based This two-generator system can have a power level between
50 and 100 only if both generators are operating and that
Nomenclature
ACF Average Capacity Factor The percentage of a EirGrid The Irish electric power system
wind generators nameplate capacity actually produced ELCC Effective Load Carrying Capacity: A statistical
under average wind conditions. technique for measuring system capacity.
BOCA Building Officials Code Administrators LOLE Loss of Load Expectation: A reliability criterion,
CDF Cumulative Distribution Function: The probabili-
typically one-day-in-ten-years or 0.00027, or 2.5 hours
ty that a power systems output is less than a given
power level. per year
EDF Exceedance Distribution Function: The probability MISO Midcontinent Independent System Operator
that a system can supply power exceeding a given PJM PJM Interconnection, LLC: The largest independent
load. system operator.
Thanks,
Brian Wodka
brian.wodka@rmf.com
Preferred methodology
An IEEE Task Force adapted classical ELCC to wind
systems by viewing wind as negative load. The Task Force
calls this methodology preferred because it correctly pre-
serves any wind-load correlation. By subtracting each hours
average wind from the average load for the corresponding
hour, we create a third time series: load minus wind. This
load minus wind time series is the power that must be reli-
ably serviced by dispatchable backup generators. The CDFs
for PJM 2013 load and load minus 10 percent wind time
series is then calculated and presented as the blue dashed
line in Figure 5. It is normally plotted by ordering the
hourly results from lowest to highest, as shown in Figure 5.
The CDF curves are spread farther apart at lower load
and come together at higher load. At low system power, 10
Figure 5. ELCC calculations PJM2013
percent wind reduces the traditional generation require-
For this reason, Table 1 presents the number of hours that ments by more than 10 percent. At high system power,
system production is less than 1 percent of nameplate. 10 percent wind has less impact. Figure 5 illustrates the
In LOLE, a wind system can be considered to have negative correlation between wind and load by plotting
some capacity if its production is negligible for less than 2.6 both load and load minus wind, which accurately indicates
hours per year. The 100-unit reference scenario dramatically the varied spacing observed, as well as the slow growth of
exceeds this criterion. In contrast, all of the wind scenarios the separation as the load decreases. Here, the lowest wind
fail this criterion. There is no evidence that stand-alone does not occur at the highest load, so the critical reliability
wind has any system capacity as classically defined by one- condition might not be at the highest load. Note that at
day-in-10-years. the highest load, the load minus wind curve is separated by
Some have argued that long distance transmission con- only 1.4 GW, which is less than 1 percent of load. Yes, with
necting widely dispersed wind farms will provide system a wind penetration of 10 percent of average load, the need
capacity. Kempton claims that a synthetic data set for a for dispatchable generators at peak load was reduced by
wind system extending from Maine to the Florida Keys only 1 percent in 2013!
never dropped to zero during a 5-year period. This claim One year of data is clearly insufficient. Some systems
appears exaggerated in that Figure 4 of that report shows make a further serious mistake by averaging the annu-
whiskers dropping so close to zero that it does not make al ELCC calculations across multiple years. The correct
a meaningful difference; and Kempton does not calculate approach for system capacity is to calculate the capacity
net wind. No physical law says net wind will never drop to for each year separately and then look for the worst event
zero. Therefore, stand-alone wind has no ELCC. during the life of the system (decades). While we do not
yet have decades of real wind generation data, it should be
obvious that if the stand-alone wind goes to zero, it is like-
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If MISO reduced natural gas backup
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Editors note: This paper, PWR2014-32148, was printed with
permission from ASME and was edited from its original for-
mat. To purchase this paper in its original format or find more
information, visit the ASME Digital Store at www.asme.org.
JUNE
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The American Society of Mechanical Engineers (ASME)
TURBINE TECH
Background
New environmental regulations and the installation
of renewable energy sources have resulted in many
retirements of older legacy steam turbine generating
units. Most of these older units have spent the majority
of their life in operation base loaded. As a result, they
have logged significant operating hours with few on/
off cycles. Long-term, temperature dependent damage
mechanisms of these turbine rotors must be considered
to ensure successful operation to the desired retire-
ment dates. This article highlights two case studies and
some operational strategies to extend life to the desired
retirement date.
COMPACT
June 2015 ENERGY-TECH.com 29
ProtonOnSite.com | 203.678.2000
COST-EFFICIENT Info@ProtonOnSite.com
TURBINE TECH
JUNE 2015
ADVERTISERS INDEX
A-T Controls Inc. www.a-tcontrols.com 11
EagleBurgmann www.eagleburgmann-ej.com 31
Indeck Power Equipment Co. www.indeck.com 31 Figure 3. Control stage rotor failure
Miller-Stephenson Chemical www.miller-stephenson.com 31 the stress concentrated area of the rotor dovetails. Following
an assessment of the rotor material properties at various radial
Proton Energy Systems www.protonenergy.com 29 locations, a cut line was established and the rotor was built up,
Sohre Turbomachinery Inc. www.sohreturbo.com 28
stress relieved, re-machined and new blades installed. The repair
was successful and the unit achieved its desired retirement date
Structural Integrity Associates, Inc. www.structinc.com 2 of approximately 10 years after the repair. ~
Unimar - Light & Control Solutions www.unimar.com 15
Acknowledgements
Wabash Power Equipment www.wabashpower.com 17 TG Advisers would like to thank the Consumers Energy team
. of Matthew T. Helms, Vladimir Trbulin and Mark E. Wittbrodt
for their technical support and direction with the HP and IP rotor
assessments. TGA also would like to thank Dave Sheasley, Roger
Karn and Mark Miller of NRG for the technical support with
the HP rotor control stage assessment efforts.
Whats the word than 30 years of turbine and rotating machinery experience. Reid
and his team provide turbine troubleshooting, health assessments
and expert witness services to major energy companies in the
on the wire? U.S. and have provided condition assessment evaluations on more
than 100 turbine generators in the U.S. Reid also is a short course
instructor for EPRI, ASME, Electric Power and POWERGEN, has
numerous patent disclosures and awards, and published more than
20 technical papers and articles. Reid was the recipient of the 1993
ASME George Westinghouse Silver Medal Award for his contributions
to the power industry and is past chairman of the ASME Power
Generation Operations Committee. He is a registered professional
engineer in the state of Delaware. You may contact him by emailing
editorial@woodwardbizmedia.com.
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