BUSINESS AND TECHNOLOGY FOR THE GLOBAL GENERATION INDUSTRY

VoI. 151 No. 10 October 2007 www.powermag.com

Top Plants: Four model coal-fired plants
Shock therapy KOs boiler fouling
Stop your boiler from sucking air
SS tube specs begin at the mill
000 POWER1007.indd 1 1/10/08 10:24:11 AM
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001 TOC.indd cvr2 10/1/07 8:46:38 PM
October 2007
|
POWER www.powermag.com 1
www.powermag.com
Established 1882 Vol. 151 No. 10 October 2007
On the cover
Tampa Electrics 250-MW IGCC unit at Polk
Power Station just celebrated its 10th anni-
versary of operation. Unit 1, the first green-
field IGCC plant in the U.S., operates as
reliably as a modern pulverized coal plant,
with less pollutant emissions. Courtesy:
Tampa Electric Co.
DEPARTMENTS
4 SPEAKING OF POWER
6 GLOBAL MONITOR
6 Siemens ships first blade from U.S.
plant
6 GEs Frames hit 1,000
8 Battery problems hit hybrid EV
programs
9 Solar thermal rebounds in California
12 Peabodys Illinois coal plant gets
green light
14 EPA could sink 278-MW CFB unit
16 Longest-serving NRC commissioner
dies at 58
16 POWER digest
18 READERS TALK BACK
19 CORRECTIONS
20 FOCUS ON O&M
20 Why bypass desuperheaters fail
20 DSSP, CAD, and fast casting salvage
nearly totaled pump
26 Seals of approval
27 Making gas turbine plants quieter
30 LEGAL & REGULATORY
82 RETROSPECTIVE
84 NEW PRODUCTS
96 COMMENTARY
COVER STORY: COAL-FIRED TOP PLANTS
32 IGCC demonstration plant at Nakoso Power Station, Japan
With no coal resources of its own, Japan has a major incentive to build the most ef-
ficient and forward-thinking coal plants. One such plant was developed by Mitsubishi
Heavy Industries, which is poised for a bright future thanks to a rigorous product
development process that will prevent any product from being marketed before it is
ready for prime time.
40 Pleasant Prairie Power Plant Air Quality Control Upgrade Project, Wisconsin
When youre the largest producer of megawatts in the state, keeping upgrade out-
ages short is critical. Development of a 3-D model of this plant to facilitate collabora-
tive design reviews led to creative design of new pollution control systems.
48 Polk Power Station Unit 1, Florida
What once was a demonstration plant (and a POWER Plant of the Year) has grown
up. Having survived the anticipated growing pains, it has successfully burned several
fuels and can boast of stats that would be the envy of any coal-fired plant.
54 R.E. Burger Plant, Ohio
Technology development at electric utility scale cannot be perfected in a sterile labo-
ratory; eventually, it must get down and dirty at a real power plant. FirstEnergys
Burger plant staff members are experts at turning great ideas into megawatts.
INDUSTRY TRENDS
62 Map of U.S. coal-fired power plants by MWh and fuel consumption
SPECIAL REPORT
COAL COMBUSTION
64 Managing air to improve combustion efficiency
A case study for a typical 500-MW pulverized coal boiler applies a set of best prac-
tices to measure, balance, and control furnace inputs to achieve higher combustion
efficiencies and lower NO
x
emissions.
FEATURES
BOILER CLEANING
72 Harness detonation waves to clean boiler tubes
Louder, please! Words you wouldnt expect to hear in a power plant. But detona-
tion cleaningthe most novel boiler cleaning technology to come along in many
yearscan be music to a power engineers ears.
MATERIALS
76 Making the grade with stainless steel tubing
Simply ordering tubing that meets ASTM/ASME specifications may not ensure a
good fit for a specific application. You also need to understand how tubing is made
and what additional tests to include in your specifications.
001 TOC.indd 1 10/8/07 9:47:51 AM
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October 2007 2
Now incorporating and
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www.powermag.com POWER
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October 2007 4
SPEAKING OF POWER
Energy industry
needs a Sputnik
T
he 1940s and 50s are considered the golden age of science
fiction literature. After my kids saw the movie, I, Robot,
a few years ago, they were surprised to learn that Isaac
Asimova giant of the genre with more than 500 books to his
credithad written a series of nine short stories with the same
name and theme a half-century earlier. Asimov was also a close
friend of Star Trek creator Gene Roddenberry, who made his an-
droid creation Data a positronic robot in homage to Asimov.
Asimov could convince you to check your skepticism at the door
to explore strange universes and their inhabitants, without re-
course to special effects.
Spy vs. spy
Asimovs vision of space travel was no doubt disrupted by the
launch of the Soviet Unions first Sputnik satellite 50 years ago
this month, on October 4, 1957. This science fact caught U.S.
intelligence agencies completely off-guard and instantly raised
fear that Russian ballistic missiles would soon be falling on
America like rain. The Cold War immediately morphed from an
ideological battlefield into one of technology-based hegemony,
with space as the high ground. The Russians couldnt make a
reliable car, but somehow they had managed to launch a basket-
ball-sized satellite into orbit.
President Dwight Eisenhower understood that militarizing
space would only accelerate the nuclear arms race, so he amal-
gamated the various research laboratories developing rocket
technology into a single organization and put it under civil-
ian control. Congress moved quickly and established NASA on
October 1, 1958, to provide for research into the problems of
flight within and outside the earths atmosphere, and for other
purposes. The space race began.
Ironically, because Eisenhowers main concern during the
early 1950s was avoiding a nuclear holocaust, he needed co-
vert intelligence about possible sneak attacks that could only
come from space. Ike took a two-step approach: He launched
U-2 flights at 70,000 feet over Soviet territory in July 1956 and
poured enormous resources into the development of top-secret
spy satellitesthe other purposes in NASAs charter. From the
publics point of view, Sputnik put us second in a race we didnt
know we had entered.
From space race . . .
The Apollo program became a NASA priority on May 25, 1961,
when President John F. Kennedy laid his presidency on the line
by announcing, I believe that this nation should commit itself
to achieving the goal, before this decade is out, of landing a
man on the moon and returning him safely to earth. In re-
sponse, Gordon Cooper, one of original seven Mercury astronauts,
is quoted as having said, It just aint possible. First, we dont
have the rockets; second, we dont have the spacecraft; and
third, we dont even know how to navigate our way out there
and back.
Eight years and two months later, Kennedys promise was ful-
filled. On July 20, 1969, Neil A. Armstrong spoke the famous
words, Thats one small step for [a] man, one giant leap for
mankind, from the moon after the first of six successful land-
ings over a three-year period. Just 12 years after the launch of
Sputnik, and 70 years after the first wood and cloth airplanes
took to the sky, the space race was over.
. . . to MySpace
When the space race ended, Americas best and brightest began
adapting for civilian use the military technologies they had de-
veloped. We now take many of their successes for granted. For
example, the origins of the Internet can be traced back to the
militarys demand for a decentralized communications network
able to survive a nuclear attack. Overhead, there are hundreds
of civilian satellites used for voice and data carriage, naviga-
tion, and entertainment. And, lest we forget that it took two
to have a space race, the Russians will send you sightseeing
beyond the wild blue yonder for a mere $20 million (the return
trip is free).
In December 2006, NASA announced a plan to establish a
small, self-sustaining colony on the moon, perhaps by 2024,
and its flying like a brick. A seventh moon landing will never
engender as much national support as the first space missions
enjoyed. The original astronauts were experienced fighter pilots
with the right stuffnational heroes who literally went where
no man [had] gone before. Today, few Americans can name a
single astronaut (at least none that arent on the cover of the
National Enquirer), and the business of space has become busi-
ness as usual.
Four decades later, we still marvel at NASAs feat of putting
a man on the moon so quickly after JFK challenged America to
reach for the heavens. Technology has advanced a thousand-fold
since then, but our national desire to explore the limits of our
reach has splintered into a thousand competing wish lists, none
urgent enough to develop sufficient public traction. I cant think
of a single national priority that a majority of Americans would
be willing to make personal sacrifices to achieve. Is it just my
cynicism, or do we lack leaders who are inspired and inspiring?
Im not sure.
Asimov, a noted scientist in his own right, often commented
on the confluence of science and storytelling. For example:
Science fiction writers foresee the inevitable, and although
problems and catastrophes may be inevitable, solutions are
not. Perhaps hes right, but brilliant leadership means inspir-
ing skeptics to attempt unbelievable tasksand accomplish
them. Imagine how different the world would be if clean energy
were as abundant and available as Asimov made it in his nov-
els. With energy independence, mankind could take a second
giant leap forward right here at home. Thats not science
fiction.
Dr. Robert Peltier, PE
004 SOP.indd 4 10/1/07 8:54:03 PM
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www.powermag.com POWER
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October 2007 6
GLOBAL MONITOR
GLOBAL MONI TOR GLOBAL MONI TOR GLOBAL MONI TOR GLOBAL MONI TOR GLOBAL MONI TOR GLOBAL MONI TOR GLOBAL MONI TOR GLOBAL MONI TOR GLOBAL MONI TOR GLOBAL MONI TOR GLOBAL MONI TOR GLOBAL MONI TOR GLOBAL MONI TOR GLOBAL MONI TOR GLOBAL MONI TOR GLOBAL MONI TOR GLOBAL MONI TOR GLOBAL MONI TOR GLOBAL MONI TOR GLOBAL MONI TOR
Siemens ships first blade
from U.S. plant
This August, the new Siemens wind tur-
bine blade factory in Fort Madison, Iowa,
shipped its first blades, bound for the
Sweetwater Wind Farm west of Abilene,
Texas. Each blade (Figure 1), cast in one
piece in a single step from glass fiberre-
inforced epoxy resin, is 148 feet long and
weighs about 12 tons.
Owned by Catamount Energy and the
Australian investment banking firm Bab-
cock & Brown, the Sweetwater project
will see its generating capacity grow to
505 MW when it completes its final phase
this December. Siemens will contribute 80
MW to this phase by supplying 45 of its
SWT-2.3-93 wind turbine-generators, each
rated at 2.3 MW.
By expanding our wind turbine blade
manufacturing capacity in the U.S., said
Randy Zwirn, CEO of Siemens Power Gen-
eration Inc., we are able to play a more
significant role in helping the U.S. meet
its growing electricity demand with clean
wind energy and zero carbon emissions.
[That demand] is expected to triple by
2020.
Within the past three years, Siemens,
based in Germany, has opened new manu-
facturing plants in Denmark and Iowa
and expanded two existing factories in
Denmark. Siemens said it expected to be
employing 400 people in its U.S. wind
business by the end of September 2007.
The U.S. Department of Energy says its
goal is for the U.S. to get 6% of its elec-
tricity from wind by 2020. Thats an ambi-
tious target, according to many industry
sources. Wind, said Siemenss Zwirn, is a
viable, cost-competitive source of renew-
able energy that will continue to have an
important role in the overall energy mix,
alongside conventional power generation
sources.
Wind power critics, such as veteran en-
ergy analyst Glenn Schleede, note that its
competitiveness is entirely due to federal
and state subsidies, the largest of which
is the federal production tax credit of 1.9
cents/kWh. Countering the effect of that
credit, recent supply chain problems have
slowed the boom in wind power. Schleede
recently circulated a report that Clipper
Windpower, a partner with BP in wind de-
velopment in the U.S., saw its stock drop
in London trading because of component
problems.
Reuters reported that tests at Clippers
turbine factory in Cedar Rapids, Iowa,
found a fault in the drive train of the
companys 2.5-MW turbine. Clipper said it
faced a loss in the first half of the year
because it was constrained in obtaining
externally sourced parts.
In other Siemens news, the company
said that a consortium that it heads has
won an order to build a two-unit, 800-MW
combined-cycle gas-fired power plant in
Singapore. As part of the deal, the part-
ners will convert two existing combined-
cycle plants to cogeneration service.
According to Siemens, the total value
of the deal, including a 10-year service
agreement, is $717 million. The Siemens
portion of the deal, which includes a Sin-
gapore state-owned investment company,
is $517 million. The new plant is sched-
uled to come on-line in early 2010.
GEs Frames hit 1,000
Also in August, General Electric sent out its
1,000th F-class gas turbine, to Saudi Elec-
tricity Co. for its Riyadh Power Plant No. 8
project. John Krenicki, CEO of GE Energy,
said, Since its introduction in 1987, our
F-technology [turbine] [Figure 2] has made
a major impact both on the power genera-
tion industry and General Electric Co. Over
those 20 years, activities associated with
all aspects of our F-technology, including
sales and services, have produced in excess
of $30 billion for the company.
GE says that since December 2006 it
has pocketed $3.6 billion in revenue from
gas turbinebased projects. Of those proj-
ects 77 turbines, 45 are F-class.
Krenicki said the sale of the 7FA gas
turbine to the Saudis represents a surge
in new power plant activity in the Middle
East, one of the most important growth
areas for GE Energy in the world today. The
need for additional supply in the region
is driving strong demand for power plant
equipment and services, as evidenced by
the recent commitments our business has
received.
The Frame 7FA delivered to the Saudis
is one of four to be shipped to Riyadh.
GE says its F-class turbines operate in 45
countries and have racked up more than
20 million operating hours. Numbers like
those, says GE, make the company the
global leader in advanced gas turbine
operating experience.
GE introduced F-series combustion tur-
bine technology in 1987. According to in-
dustry data, the companys 7F is the most
reliable F-class machine in the industry,
with a 99.1% reliability ranking. GE claims
its Frame 9FB machine has achieved an
1. Blade runner. This huge wind tur-
bine blade was the first to ship from the new
Siemens blade factory in Iowa. Courtesy:
Siemens Power Generation
2. F makes the grade. GEs F-class turbine has racked up 1,000 sales, making it
the best-selling combustion turbine-generator technology in the world market. Saudi Arabias
national electric utility bought No. 1,000. Courtesy: GE Energy
006 GM.indd 6 10/1/07 8:56:46 PM
An encore performance
delivers efficient energy
PO042007004MKT
2007 CH2M HILL
Were very excited about the
project because the plant will
provide much-needed efcient
energy for Northern Nevada.
CH2M HILL was chosen to
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criteria that considered cost,
risk, experience and execution
planning.
Andy McNeill
Sierra Pacic Director,
New Generation
Project Management
CH2M HILLs power industry experts have already delivered 18 projects for Sierra
Pacic Power/Nevada Power. The rm is now the engineering, procurement and
construction contractor for Sierra Pacics 514-MW Tracy Generating Station, east
of Reno. Using CH2M HILLs EPC approach will help Sierra Pacic meet its goals
of reducing risk, increasing safety and ensuring on-time delivery of the largest
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POWER
|
October 2007 8
GLOBAL MONITOR
efficiency of 58% in a combined-cycle
configuration.
Of the F-class machines that GE has
shipped, about 875 have come from the
companys plant in Greenville, S.C. Many
of the remaining 125 units were built at
the companys factory in Belfort, France.
Battery problems hit
hybrid EV programs
Hybrid gas-electric cars may have hit a
technical wall. This summer, Toyota Mo-
tor Corp. announced a delay in its next
generation of hybrid vehicles, to be based
on lithium-ion battery technology. Toyota
said it was experiencing serious problems
with the batteries.
Just days later, Tesla Motors, the de-
veloper of the highly hyped, high-speed
Tesla all-electric roadster (Figure 3),
sacked its CEO/founder and announced
it was delaying the rollout of the sexy,
$100,000 sports car. The Tesla speedster
also is designed to run on lithium-ion
batteries similar to those in your laptop
and Blackberry.
The Tesla allegedly can zip from zero
to 60 mph in four seconds, do 135 mph,
and go 200 miles on a charge. It is said
3. Not ready for prime time. Hybrid car makers are experiencing big problems with
lithium-ion batteries. Tesla Motors, whose planned all-electric roadster is shown here, has an-
nounced a delay in its roll-out plans that many believe is linked to battery problems. Courtesy:
Tesla Motors
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006 GM.indd 8 10/1/07 8:57:00 PM
October 2007
|
POWER 9
GLOBAL MONITOR
to be powered by hundreds of the lithium-
ion batteries. The car is based on a Lotus
platform from the UK. But a production
version has yet to appear.
Toyota, reported The Wall Street Journal,
has pulled the plug on its lithium-ion hy-
brids for at least a couple of years. A Toy-
ota executive told the Journals Norihiko
Shirouzu, Its going to be a long drought
and we dont look forward to it.
The now well-known problem with
lithium-ion batteries is their propensity
to burst into flames. A year ago, Dell and
Apple, which use the batteries in their
laptops, had to recall many units on the
heels of reports of fires, including one
caught on video that was widely seen on
the Internet. Sony Corp. also has reported
problems with the lithium-ion batteries
used in its laptops.
Toyota had hoped to roll out a new gen-
eration of hybrids based on the new tech-
nology, replacing the nickel-metal-hydride
battery technology in use since the Prius
made its debut in Japan in 1997. Toyota
said it will sell over 200,000 Prius hybrids
in the U.S. this year. But it now appears
doubtful the company will meet its goal of
600,000 sales in America by 2010.
Batteries are crucial to the future of to-
morrows plug-in hybrids, which will use
more of them, for recharging by standard
AC outlets during off-peak demand peri-
ods. According to industry experts, ex-
isting battery technology isnt sufficient
to realize the promise of the plug-ins,
which need much greater power density.
The electric utility industry also is push-
ing plug-ins because recharging them will
boost off-peak power sales.
Meanwhile, Tesla appears in turmoil.
Martin Eberhard, founder and CEO of the
Southern California startup, has been de-
moted to president of technology. Major
investor and chairman Elon Musk now ap-
pears to be in charge.
The Tesla roadster, sold in advance to a
list of Hollywood green celebrities (report-
edly including actors Ed Norton and George
Clooney, comedian Jay Leno, and Califor-
nia governor Arnold Schwarzenegger) at
$100,000 a pop, now wont appear in
commercial version until later this fallif
at all.
The company hasnt said much about
the delay. The web site of Edmunds
Automotive reported that Eberhard told a
group of auto journalists that the delay
was the result of a change in transmis-
sion suppliers.
The respected UK science blog, The
Register, suggested that the Tesla road-
sters real problem is its Li-ion battery
pack. Its main snag, said the entry
by auto writer Lewis Page, assuming it
achieves the projected specs, is that [the
batteries] will take hours to recharge . . .
seriously [limiting the cars] usability.
Page made no mention of the batteries
flammability.
In a mid-August letter to the folks who
have anted up $100,000 to claim one of
the vehicles, Eberhard said he hopes to
have the cars in production by the end
of next month. He added, We have a
good chance of meeting this goal, but to
be fully transparent, I want you to know
that while it is within our reach, it is not
yet fully within our grasp. By the end
of September, the cars were not yet in
production.
Solar thermal rebounds
in California
Solar thermal generation is heating up in
California, with two firms announcing in-
state projects that will use the sun to boil
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POWER
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October 2007 10
GLOBAL MONITOR
water, creating steam for a turbine-gen-
erator. The Golden State already has nine
solar stations totaling 354 MW, developed
by bankrupt Luz International between
1984 and 1991, that are still on-line.
Last month, the successor to Luz,
BrightSource Energy, filed an application
with the California Energy Commission to
build a 400-MW solar power field in the
Mojave Desert. BrightSources chairman
is Arnold Goldman, the founder of Luz
International.
The plan is for the company to build
three separate solar power tower and col-
lector fields, two rated at 100 MW and
the third at 200 MW. The proposed site,
known as Ivanpah (Figure 4), is about five
miles southwest of Primm, Nevada, on the
California border. BrightSource CEO John
Woolard said the company is negotiating
with California utilities for the purchase
of the plants output. Charlie Ricker, a
BrightSource vice president, told the San
Jose Mercury News that the plant could
be operational by 2010. The company is
building a pilot project in Israel.
According to the Mercury News, Bright-
Source landed $30 million in venture
capital in the second quarter of this year.
Among the investors, said the newspaper,
is VantagePoint Venture Partners, one of
the venture capital investors in Tesla Mo-
tors, the electric sports car developer.
Separately, Ausra Inc., a solar thermal
developer based in Palo Alto, Calif., with
operations in Australia, announced in Sep-
tember that it has received $40 million
in venture capital from Khosla Ventures
and Kleiner, Perkins, Caufield & Byers. Ac-
cording to C/Net, an online news service,
Ausra is planning to file for a permit to
build a 175-MW solar thermal plant in the
Mojave. Ausra was formed in late 2006.
Ausra uses Fresnel lenses to concen-
4. Luz redux. An artists rendering of the layout of BrightSource Energys planned solar
thermal project in Californias Mojave desert. The firm is the successor to Luz International,
which built more than 300 MW of solar thermal capacity in the Mojave before going bankrupt
in the early 1990s. Those projects still generate power. Courtesy: BrightSource Energy
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POWER
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October 2007 12
trate sunlight on water-filled tubes (Figure 5). David Mills,
while at Sydney University, conceived the technology and de-
veloped it between 1995 and 2001, according to an Ausra press
release. Mills is known for academic advances in non-imaging
optics and solar thermal energy.
Peabodys Illinois coal plant
gets green light
A federal appeals court in late August upheld the air permit
for Peabody Energys $2.9 billion, 1,600-MW supercritical Prairie
State coal-fired plant southeast of St. Louis.
The Sierra Club had challenged the Illinois Environmental
Protection Agencys approval of the permit for the mine-mouth
plant. The environmental group argued that use of best avail-
able control technology (BACT) would require the plant to burn
western low-sulfur coal, rather than high-sulfur Illinois coal. A
three-judge panel of the 7th Circuit U.S. Court of Appeals in
Chicago disagreed.
Writing for a unanimous court, Judge Richard Posner found
that while the federal Clean Air Act does make clean fuels a
control method, there is a common-sense limit to the acts im-
plementation. He wrote that nuclear fuel is clean, and so the
implication, one might think, is that the agency could order
Prairie State to redesign its plant as a nuclear plant rather than
a coal-fired one, or could order it to explore the possibility of
damming the Mississippi to generate hydroelectric power, or
to replace coal-fired boilers with wind turbines. That approach
5. Luz successor gets a competitor. Ausra Inc. of Palo
Alto, Calif., has landed a big chunk of venture capital for a Fresnel-lens
solar thermal project in the California desert. The structures shown
are part of a 40-MW project using the companys technology in New
South Wales, Australia. Courtesy: Ausra Inc.
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CIRCLE 8 ON READER SERVICE CARD
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POWER
|
October 2007 14
GLOBAL MONITOR
would invite a litigation strategy that would make seeking a
permit for a new power plant a Sisyphean labor, for there would
always be one more option to consider.
Posner observed, The project that must be addressed when
evaluating BACT is the project for which an application has been
submitted, i.e., a proposed mine-mouth power plant. . . . Ac-
cordingly, the use of a particular coal supply is an inherent as-
pect of the proposed project. Posner was joined in the opinion
by judges Michael Kanne and Ann Claire Williams.
Bruce Niles, director of the Sierra Clubs National Coal Cam-
paign, told Gatehouse News Service, Most of the large power
plants in Illinois have switched to Western coal. He also criti-
cized the states EPA, which implements the federal law, for not
considering CO
2
emissions from the plant, although the U.S. EPA
has not issued rules for their reduction.
Niles said his group has not decided whether to appeal the
decision, either in the 7th Circuit or the U.S. Supreme Court.
In a press release, St. Louisbased Peabody Energy noted,
The decision caps an extensive six-year regulatory review pro-
cess that includes approval by the Illinois Environmental Pro-
tection Agency and the U.S. Environmental Protection Agency.
Peabody intends to market the power produced through mu-
nicipal joint-action agencies that are equity partners in the
project. Raj Rao, CEO of Indiana Municipal Power Agency, said,
Prairie State will achieve high efficiencies and low emissions
that are far superior to Americas current generating fleet, ben-
efiting more than 1.7 million Midwest families.
Peabody said groundbreaking is likely this fall (Figure 6).
Bechtel Power Corp. is the lead contractor and is overseeing
site preparatory work. Prairie State has already ordered Bab-
cock & Wilcox boilers, Toshiba turbines, and emission control
equipment from Siemens Power Generation. Unit 1 is expected
to come on-line in 2011, with Unit 2 following the next year.
EPA could sink 278-MW CFB unit
The U.S. Environmental Protection Agency may have thrown a
regulatory monkey-wrench into plans by East Kentucky Power
Cooperative (EKPC) to add a fourth, 278-MW unit to its coal-fired
Spurlock Power Station (Figure 7) in Maysville. EKPC supplies
power to 16 distribution cooperatives with 1 million customers.
EPA Administrator Stephen Johnson sided with the Sierra Club
in an appeal of the decision by the Kentucky Division of Air Qual-
ity to give an air permit to the proposed circulating fluidized-
bed (CFB) unit. A similar CFB unit went into service at Spurlock
in 2005. Spurlock Unit 1 (325 MW) and Unit 2 (525 MW) are
conventional, pulverized coalfired baseload plants.
The EPA upheld the complaint by the environmentalists, con-
cluding that state air-quality regulators and EKPC must show more
definitively that low-sulfur coal isnt feasible for the new unit.
The ruling said the state and the utility must explain why the
plant cant burn Powder River Basin or eastern low-sulfur coal.
CFB units have the ability to burn diverse fuels. EKPC says it is
experimenting with burning tires in the earlier CFB unit, Unit 3.
EKPC spokesman Nick Comer told reporters that the air permit
remains valid and that the ruling does not affect the construction
schedule or the design of Spurlock 4, and we are proceeding. The
co-op says the unit is scheduled to enter service in 2008.
7. Endangered CFB. East Kentucky Power Cooperatives plans
for a fourth, 278-MW unit at its Spurlock Power Station, shown here,
are now in jeopardy. The U.S. EPA and a Kentucky court say the utility
must show why the proposed circulating fluidized-bed unit cant burn
low-sulfur Powder River Basin coal. Courtesy: East Kentucky Power
Cooperative
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6. Building on the prairie. Peabody Energy expects to break
ground soon on a 1,600-MW supercritical coal-fired plant southeast
of St. Louis. This August, a federal appeals court upheld the plants
air permit, rejecting objections by the local Sierra Club that the mine-
mouth plant should have considered using Powder River Basin coal
instead of local high-sulfur coal. Courtesy: Peabody Energy
CIRCLE 10 ON READER SERVICE CARD
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POWER
|
October 2007 16
GLOBAL MONITOR
The EPA ruling came on the heels of an
August 6 Kentucky state court ruling re-
jecting the air permit for the 1,600-MW
Thoroughbred plant that Peabody has pro-
posed building in Muhlenberg County. Ac-
cording to the Louisville Courier-Journal, in
court filings seeking an expedited review
attorneys for the state said the Thorough-
bred ruling jeopardizes both the Spurlock
project and Louisville Gas and Electrics
750-MW expansion of its Trimble County
generating station.
Attorneys for the Kentucky Environmen-
tal and Public Protection Cabinet wrote,
The ruling of the circuit court places the
future of those operations and the corre-
sponding electricity they will provide in
question. The court, they argued, created
an uncertainty that is disruptive and
jeopardizes the mining of coal, which is
an essential element of the economy of
Kentucky and therefore raises an issue of
public concern.
Longest-serving NRC
commissioner dies at 58
Edward McGaffigan Jr., the longest-serv-
ing member of the U.S. Nuclear Regula-
tory Commission in history, died Sept. 2
in Arlington, Va., of complications from
metastatic melanoma cancer. He was 58.
McGaffigan (Figure 8), a Democrat,
served on the NRC from 1996 until this
year. He was widely viewed as nonideologi-
cal and intensely intellectually honest. His
service on the NRC won praise from both
the nuclear power industry and antinuclear
organizations that he often opposed.
Last January, facing incurable cancer,
McGaffigan announced that he would
step down at the NRC, pending nomina-
tion and confirmation of a successor. But
he changed his mind in the spring, as the
result of chemotherapy success, and noti-
fied the White House that he intended to
continue his service on the NRC.
Though McGaffigan, a Boston native
and a physicist, was a protg of Sen-
ate Energy Committee Chairman Jeff
Bingaman (D-N.M.), he long proclaimed
that he was a John F. Kennedy Democrat.
He was the son of a Boston laborer and
the first of his family to graduate from
college, receiving a bachelors degree from
Harvard in 1970. He earned masters de-
grees in physics from Cal Tech in 1974 and
from Harvard in public policy in 1976.
McGaffigan joined the Arms Control and
Disarmament Agency in 1975 and the U.S.
Foreign Service in 1976. He worked on arms
control and energy policy related to the So-
viet Union from the U.S. embassy in Mos-
cow in 1978. He emerged from that stint a
determined opponent of the Soviet Union
and its ideology and worldwide policies.
From 1981 to 1983, during the Reagan
administration, McGaffigan worked at the
White House Office of Science and Technol-
ogy Policy. He then joined Bingamans staff
on the Senate Armed Services Committee.
Responding to McGaffigans death,
Bingaman said, Ed McGaffigan was a
man of great intellect and vision. He un-
derstood policy and politics, which made
him an extraordinary public servant. Ed
made a great contribution to me in my
efforts in the Senate during the time he
worked with me. He was universally re-
spected and admired for his ability and
integrity. I have lost a great friend and
trusted counselor.
President Clinton appointed McGaf-
figan to the NRC in 1996 and renewed
the appointment in 2000. President Bush
renominated McGaffigan to another five-
year NRC term in 2005. Congress did not
act on the nomination prior to his death.
McGaffigan was a dedicated run-
ner, completing six Marine Corps mara-
thons. According to his obituary in the
Washington Post, he ran a half-marathon
a few months before his death.
A strong supporter of nuclear power,
McGaffigan was no pushover to the nucle-
ar industry or its foes. When antinuclear
forces began attacking nuclear plants
vulnerability to terrorist assaults by air
in the wake of 9/11, McGaffigan called
the notion of absolute protection bogus.
When they change the law to require ab-
solute assurance of perfect protection,
he said, there wont be a lot of nuclear
reactors in this country. Also, there wont
be a lot of cars or McDonalds.
Yet McGaffigan also was a major critic
of the U.S. Department of Energy and the
nuclear industrys push to make Yucca
Mountain in Nevada the nations high-
level nuclear waste dump. The project,
established by the 1982 Nuclear Waste
Policy Act, has been stalled for more than
two decades. McGaffigan told the Las Ve-
gas Review-Journal, It may be time to
stop digging, and may be time to rethink.
I think Yucca Mountain has been beset
by bad law, bad regulatory policy, bad
science, bad personnel policy, [and] bad
budget policy, throughout its history.
Danielle Brian of the Project on Govern-
ment Oversight, which often warred with
the NRC and McGaffigan on power plant
security issues, said, Ed McGaffigan ex-
hibited a quality that is sadly waning in
Washingtona total commitment to pub-
lic service without any interest in parlay-
ing his time in government into personal
profit.
Brian added, You could be sure that if
Ed took a positioneven if you disagreed
with himyou knew that he took that
position because he really believed it was
for the good of the public, and not be-
cause it was politically expedient or [be-
cause] he was hoping to curry favor with a
future employer. He gave a damn.
McGaffigans death leaves two vacan-
cies on the five-member NRC. Republican
Jeff Merrifield left the commission earlier
this year.
POWER digest
News items of interest to power industry
professionals.
FERC staff scopes out DR. In a report
issued last month, the staff of the Federal
Energy Regulatory Commission found that
utility demand response (DR) programs are
growing, and making a dent in electricity
use during periods of peak usage. The re-
port estimated that in 2006 DR programs
lowered electricity consumption between
1.4% and 4.1% during those times. The
agency did not assess the statistical sig-
nificance of those energy reductions.
The Energy Policy Act of 2005 mandat-
ed that FERC annually assess the impact
of DR programs and advanced metering.
FERC staff found these trends in its 2007
report:
Increased utility participation in DR
programs.
More participation by organized (RTO/
ISO) markets.
More attention to smart-grid applica-
tions.
8. NRCs McGaffigan dies at 58.
Edward McGaffigan, who served 11 years
on the U.S. Nuclear Regulatory Commission,
succumbed to cancer last month. Courtesy:
Nuclear Regulatory Commission
006 GM.indd 16 10/1/07 8:57:18 PM
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CIRCLE 44 ON READER SERVICE CARD
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POWER
|
October 2007 18
GLOBAL MONITOR
More interest in projects on the part of
states and the federal government.
More interest by third parties in aggre-
gating DR savings.
Commissioner Jon Wellinghof, FERCs
lead on DR programs, said, The findings
of the staff report signal that there has
been a change in the national demand re-
sponse dialogue from should we do it?
to how do we do it? This report should
provide real value to regulators, policy-
makers, utilities, and consumers in this
rapidly growing and ever-important elec-
tric resource sector.
A new source of nuclear fuel? Toronto-
based Mega Uranium Ltd. says its pros-
pecting in Argentinas Patagonia region
in Chubut Province has had encouraging
results. In 1978, the Argentina Atomic
Energy Commission, using airborne radi-
ometry, originally detected the presence
of uranium there.
Mega says a program of geological
mapping and reconnaissance rock chip
sampling of the Guanaco prospect area
found two levels of uranium mineraliza-
tion at the top and base of a Quaternary
terrace 3 to 5 meters thick. The upper
level is only about 5 to 10 centimeters
below the surface. Sampling of the layer
returned values on the order of 100 to
200 ppm of U3O8, the oxide form of ura-
nium that is most common in nature. The
second layer was found to contain ura-
nium oxide at a concentration of about
500 ppm.
In the second phase of the work, said
Mega, the company excavated 25 trenches
to demonstrate that the two mineralized
layers maintain their continuity, thick-
ness, and radioactivity over a 5-km by
1.7-km area. Mega said it is awaiting as-
say results for 72 samples collected from
those trenches.
Alstom inks significant deals. The
Paris-based industrial giant (www.alstom
.com) has landed major contracts in the
United Arab Emirates, the UK, and China.
Together, the deals are worth $3.6 billion,
with Alstoms share amounting to about
$2.8 billion.
As part of a consortium, Alstom will
supply the UAE with a 2,000-MW power
plant and a 130-million gal/day desalina-
tion plant. Both will be sited in Qidfa and
built around Alstoms GT26 gas turbine.
Alstom says its share of that project is
worth $1.6 billion.
In the UK, Alstom says RWEs npower is
building a 1,650-MW turnkey combined-
cycle plant at Staythorpe in central Eng-
land that will cost $904 million. It, too,
will use the GT26. Alstom will build the
plant, supply its main generating equip-
ment, and provide spare parts under a
long-term agreement.
In China, the Alstom order, worth $188
million, is from the industrial group Dong
Fang for four 1,000-MW steam turbine-
generators for a conventional power is-
land in a new nuclear plant to be built
in northern China. Alstoms dealings with
the Chinese nuclear industry date back
to the construction of Daya Bay 20 years
ago. It was the first large-scale Chinese
nuke and the first in the country to use
French technology.
Readers talk back
California dreaming
To the Editor:
First, I want to say that my comments below are purely my
own, and that I have no authority to speak on behalf of EPRI or
the industry. That said, I want to explain how curious I found
your Speaking of Power editorial in the July issue of POWER.
During my 30 years in the electric power industry, Ive seen
two contrasting views of power plants. In one, power plants are
attractive because they create jobs and augment the local tax
base. In the other, their very existence taints their localities.
It seemed odd to me that your editorial supported the latter
view. The emissions of new plants that meet federal and state air-
quality requirements are negligible (my non-professional view),
especially compared to those of mobile sources (cars and trucks)
combined. I live in San Jose, Calif., and over the past five years
weve had several power plants come on-line within the city lim-
its of the countrys 10th largest urban area. Theyre invisible.
Bashing California is easy, but unwarranted. The state creates
tremendous wealth from agriculture, entertainment, and tech-
nology, but I guess its hard to love a rich cousin.
Much of our nations overall wealth comes from free trade
across state borders. The last thing we need is a customs house
at each state line. Im sure that most of the goods that Ari-
zonans buy are produced in other states or countries. Since
most of the imports come through ports in Southern California
that produce plenty of pollution, I ask why the ports neighbors
should have their health endangered by deliveries to Arizona.
If each state should have its own generation, as you seem to
suggest, why not each county, or even each zip code? Going
down that road would mean wed all have Honda generators in
our driveways. And wed be much worse off for it.
Victor Niemeyer (niemeyer@epri.com), project manager, Global
Climate Program, Electric Power Research Institute
Editor responds: Any good deal leaves both parties satisfied that
they received something of value. If not, either party can walk
away. In this case, the citizens of Arizona decided that generat-
ing power for California is not in their best interest, considering
the rapid growth of the state, that California IOUs have not built
a plant in 30 years, and these plants consume enormous quanti-
ties of Arizonas limited water supplies. I live in Arizona, and my
take on Californias energy problems is informed by the good
fences make good neighbors philosophy.
Different take on ethanol
To the Editor:
In Fueling Around (Speaking of Power, August 2007), you
provide an overview of the hot-button issues swirling around fuel
ethanol. Unfortunately, despite your stated belief that ethanol
will be a piece of our energy puzzle, your editorial perpetuates
many myths associated with Americas ethanol industry. Heres
the fact and fiction behind several points you make.
Fiction: Ethanol production is driving up U.S. food prices.
. . . increased demand for ethanol has added $47 to the aver-
age American market basket over the past year.
Fact: Corn prices are only one of many factors that determine
food costs. In fact, raw materials in general account for only
about 20 cents of every dollar that the average American spends
on food. The rest goes to packaging, transportation, marketing,
and other related industries. In the case of some basic food
commodities, corn prices dont play a role at all. Milk prices,
006 GM.indd 18 10/1/07 8:57:22 PM
October 2007
|
POWER 19
GLOBAL MONITOR
for example, are set by the government based on prices for glob-
ally traded dairy commodities. The formula used to determine the
price of milk does not account for the cost that producers pay for
dairy cows feed, so theres no way for producers to pass an in-
crease in corn costs on to the consumer. And although corn prices
rose to a record-high $4 per bushel last spring, they have stabi-
lized in recent months, dropping back to around $3 per bushel.
Fiction: Ethanol production compromises global food security.
Because the U.S. accounts for 40% of the global corn harvest,
our increased domestic consumption and reduced exports are driv-
ing up worldwide prices. . . . Might ethanol policy impale us on the
horns of a moral dilemma: having to choose between lowering the
cost of driving and keeping poor Mexicans from starving?
Fact: According to the United Nations Food and Agriculture
Organization, global food supply per capita is at an historic
high. Hunger in the developing world is attributable to instabil-
ity, corruption, poverty, and a host of other political and social
factorsnot to a shortage of U.S. exports. In fact, reduced U.S.
exports might actually help relieve the conditions that have
restricted global food availability. The ethanol industry is ab-
sorbing surplus U.S. corn that would otherwise be dumped on
the world market at rock-bottom prices, preventing poor foreign
farmers from earning a living from their own products. Given
that agriculture sustains 70% of the rural poor in developing
countries, diverting U.S. corn from export to ethanol helps solve,
rather than exacerbate, world hunger.
Fiction: Import tariffs on foreign ethanol are unnecessary.
Sugar-derived ethanol from Brazil could help meet domes-
tic demand and free up some U.S. supply, softening prices, but
Washington insists on protecting U.S. sugar producers with a
54-cents/gallon tariff on ethanol imports.
Fact: While sugar producers may benefit, the overarching goal
of the ethanol import tariff is to protect our domestic energy
industry. In view of Americas long struggle to reduce its depen-
dence on foreign oil, do we really want to do so by making our-
selves dependent on foreign ethanol? Ethanol blenders receive
a 51-cents/gallon tax credit regardless of the fuels source. So,
in effect, ending the tariff on imported ethanol would subsidize
Brazils ethanol industry and create the need for another incen-
tive to maintain demand for domestic ethanol. We also should
account for the social and environmental costs of Brazilian etha-
nol. Brazils ethanol producers pay sugarcane field workers less
than $10 a day, and the growth of their industry has resulted
in sugarcane plantations devouring acres of land [previously]
used for grain and livestock production. The U.S. already imports
more than half of Brazils ethanol exports. Should we perhaps be
thinking about cutting back?
Fiction: Ethanol is detrimental to air quality.
. . . because ethanol isnt a very stable gasoline additive, it
evaporates faster than pure gasoline in hot weather, increasing
smog at just the wrong time.
Fact: There is no conclusive evidence linking ethanol to the
formation of smog (ground-level ozone). Many other factors, in-
cluding local weather and atmospheric conditions, influence the
chemical interactions that produce smog. Overall, the emissions
profile of ethanol-blended gasoline is better than that of pure
gasoline. Although ethanol increases evaporative emissions of
some compounds that play a role in smog formation, blending
ethanol with gasoline dramatically reduces emissions of other
substances, such as carbon monoxide, that are equally important
to air quality. Evidence from the field suggests that ethanol has
profound net benefits on air quality. For example, the California
South Coast Air Management District, one of the most polluted
areas in the country, saw a 22% reduction in ozone levels after
mandating just a 6% ethanol blend.
Fiction: Ethanol supports are a drain on taxpayer dollars.
And what of the cost to taxpayers of federal ethanol subsi-
dies? The biggest is certainly the 51-cents/gallon tax credit.
Fact: Subsidizing the domestic ethanol industry actually ben-
efits taxpayers. In 2006, the federal government spent $2.5
billion to finance the ethanol blending tax credit mentioned
aboveand received $5 billion in federal and local tax revenues
from ethanol industry spending and construction. Additionally,
higher corn prices will cut federal payments to farmers by $6 bil-
lion, or about 75%, between 2006 and 2007. Ethanol production
also creates jobstypically about 1,600 at each 100-million
gal/yr ethanol plant.
Meanwhile, the oil industry continues to drain our national
coffers. Oil companies will receive $13 billion in tax breaks be-
tween 2005 and 2009, oil imports are the biggest line item of
the rapidly expanding U.S. trade deficit, and oil and gas produc-
tion and consumption generates pollution that taxpayers must
pay to clean up. By displacing petroleum, ethanol helps offset
some of those costs. From several standpointsfinancial, envi-
ronmental, and national energy securitysubsidizing our do-
mestic ethanol industry is a wise investment.
Tom Koehler, Vice President, Pacific Ethanol Inc.
Editor responds: Because I strongly believe that our readers need
opinions on both sides of contentious issues to make informed de-
cisions, the comments above are presented in full. While I respect-
fully disagree with Tom on several of his points, I invite readers to
retrieve my August editorial, read my own opinions in context, and
then research any issues that remain unclear. My job is to start the
conversation, not to have the last word.
Thomas Jefferson once noted, Whenever the people are well-in-
formed, they can be trusted with their own government; . . . when-
ever things get so far wrong as to attract their notice, they may be
relied on to set them to rights. I think we can all agree on that.
Corrections
In an August Focus on O&M item on valve leakage on p. 18, we
incorrectly stated that a valve replacement produced an overall
improvement in plant heat rate of 20% to 40%. The gain should
have been stated as 20 to 40 points, which translates into a
0.3% to 0.6% improvement in heat rate.
In Augusts Global Monitor, on p. 6 we incorrectly referred to
GEs Operational Reliability Analysis Program. ORAP is owned
by Strategic Power Systems Inc. (www.spsinc.com).
Finally, several eagle-eyed readers reminded us that Orange
Country Choppers, mentioned in the August Global Monitor on
p. 8, is not located in Californias Orange County, but rather in
Orange County, N.Y.specifically in Montgomery, N.Y.
POWER regrets the errors.
006 GM.indd 19 10/1/07 8:57:23 PM
www.powermag.com POWER
|
October 2007 20
FOCUS ON O&M FOCUS ON O&M FOCUS ON O&M FOCUS ON O&M FOCUS ON O&M FOCUS ON O&M FOCUS ON O&M FOCUS ON O&M FOCUS ON O&M FOCUS ON O&M FOCUS ON O&M FOCUS ON O&M FOCUS ON O&M FOCUS ON O&M FOCUS ON O&M FOCUS ON O&M FOCUS ON O&M FOCUS ON O&M FOCUS ON O&M FOCUS ON O&M FOCUS ON O&M FOCUS ON O&M FOCUS ON O&M
FOCUS ON O&M
COMBINED-CYCLE RELIABILTY
Why bypass
desuperheaters fail
Over the past few years, Thielsch Engi-
neering has been retained several times
to inspect, evaluate, and/or repair a
through-wall failure of a bypass desuper-
heater at a combined-cycle plant. This
kind of desuperheater is operated for
short periods of time during plant start-
upto reduce the temperature of steam
entering the steam turbine condenser
and to maintain a flow of low-tempera-
ture steam through the heat-recovery
steam generator (HRSG)until steam
conditions are sufficient to start up the
steam turbine.
Like standard desuperheaters, bypass
desuperheaters extract high-pressure
feedwater from the HRSGs supply line. The
water is sent to a valve control station,
which sprays it directly into the flow of
main steam, reducing its temperature and
pressure. The process enables the steam
to be recaptured without doing harm to
downstream components.
In most combined-cycle designs, how-
ever, the in-line piping of the bypass
desuperheater lacks the internal lining
commonly found in the piping of a stan-
dard desuperheater. As a result, spray
water makes direct contact with pressure-
boundary piping and produces very high
thermal and mechanical stresses that can
cause multiple through-wall failures with-
in a short time.
The bypass desuperheater design that
has proven most prone to failures has a
thick-walled fitting for multiple spray
nozzles around its circumference (Figure
1). Failures typically occur on the down-
stream side of the desuperheater, at the
circumferential weld joining thin-walled
downstream piping. The cracks that cause
the failures usually are found on the in-
side diameter of the weld (Figure 2).
Another common type of failure occurs
when thermal gradients created by desu-
perheater operation apply bending stress
to the piping system. In these cases, the
telltale cracks appear on the outside di-
ameter of the weld (Figure 3). The results
of Thielschs finite-element analyses of
the magnitude of the stresses on the de-
superheater joint indicate that cracking
may be initiated after fewer than 100 op-
erating cycles.
A third type of observed damage has
been rupturing of the internal diffuser of
bypass desuperheaters (Figure 4). Again,
the cause was diagnosed as thermal shock,
produced by the contact of cool spray wa-
ter with hot internal components.
Contributed by Peter R. Kennefick
(pkennefick@thielsch.com)
of Thielsch Engineering Inc.
PUMP REPAIR
DSSP, CAD, and fast
casting salvage
nearly totaled pump
A centrifugal pump might seem an odd
thing to be grateful for on Thanksgiv-
ingunless youre John Allen, main-
tenance superintendent for Owensboro
Municipal Utilities (OMU).
A few weeks before Thanksgiving 2006,
a centrifugal pump serving one of the
steam turbines of OMUs 425-MW coal-
fired Elmer Smith Power Plant in Kentucky
1. Poor track record. Bypass desuper-
heaters with unlined piping and multiple spray
nozzles should be inspected often to ensure
their continued availability. Courtesy: Thielsch
Engineering
2. Crack addict. Heavy-walled desu-
perheaters are particularly prone to cracking
on their downstream side, at circumferential
weld joints. Courtesy: Thielsch Engineering
4. Hidden damage. Thermal shock de-
stroyed this bypass desuperheaters internal
diffuser. The units fitting was removed to
show the extent of the destruction. Courtesy:
Thielsch Engineering
3. Bend over backward. The thermal
gradients produced when spray water makes
direct contact with pressure-boundary piping
create bending stresses. Courtesy: Thielsch
Engineering
020 O&M.indd 20 10/1/07 10:19:24 PM
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CIRCLE 45 ON READER SERVICE CARD
020 O&M.indd 21 10/1/07 10:19:30 PM
POWER
|
October 2007 22
FOCUS ON O&M
suffered catastrophic damage. Half of the
pumps shroud was destroyed, and the
tops of its impeller blades were sheared
off (Figure 5).
Without the pump, the turbine couldnt
operate, which reduced the plants ca-
pacity by one-third. There was no backup
for the pump because plant management
had expected it to last for 40 or 50 years.
Nor were there computer-aided design
(CAD) models or documentation to help
rebuild it.
Under pressure to maintain service
to OMUs 26,000 electricity customers,
Allen hired a Wisconsin-based contrac-
torRotating Equipment Repair (RER,
www.rerpump.com)to revive the se-
verely damaged pump as quickly as pos-
sible, using any means necessary. For
the effort, RER enlisted the help of two
local partners with unique credentials:
Advanced Design Concepts (ADC, www
.adcinc1.com), a specialist in digital
shape sampling and processing (DSSP),
and Signicast Corp. (www.signicast.com),
the operator of an investment foundry.
Replicating the design digitally
The rebuilding project began on the eve-
ning of November 8, 2006, with RERs re-
ceipt of the damaged pump from the OMU
plant. The next day, RER technicians dis-
assembled the pump and began preparing
it for reconstruction.
Based on the original dimensions of the
pump, the remains of the impeller, and
its experience in pump design, RER en-
gineers built a 2-D model of the impeller
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5. Unfit for service. The damaged impeller of the centrifugal pump at the Owensboro
power plant, before it was removed. Courtesy: RER
CIRCLE 12 ON READER SERVICE CARD
020 O&M.indd 22 10/1/07 10:19:31 PM
Our name may change, but our
commitment to excellence
remains the same.
Weve helped power Texas for
more than 100 years, and the
commitment, expertise and intensity
of the Luminant team remains
as strong as ever.
With our name change comes
a whole new era of possibility.
We believe the search for bright
new ideas and innovations is as
much a part of our responsibility
as operating safely and keeping
Texas supplied with power.
So while our name may change,
our commitment remains the same:
providing cleaner, dependable,
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the future of Texas.
www.Luminant.com
The Power of Possibility.
TXU Power becomes Luminant.
CIRCLE 13 ON READER SERVICE CARD
020 O&M.indd 23 10/1/07 10:19:35 PM
POWER
|
October 2007 24
FOCUS ON O&M
in AutoCAD (from Autodesk Inc.) and ob-
tained cross-dimensions from it. Over the
following weekend, a pattern maker at
RER built up an impeller vane in clay to
match the specifications of the original.
ADC received the impeller and the Au-
toCAD dimensional drawings on Monday
morning, November 13. The company
was a natural fit for this project for two
reasons: It is less than seven miles from
RER, and it has used DSSP to recreate ev-
erything from classic Harley-Davidson gas
tanks to cylinder head ports for Nextel
Cup race cars.
DSSP enables physical designs to be
scanned and automatically recreated as
digital models. The process helps compa-
nies speed the development of products
based on legacy designs, perform accurate
engineering analysis using digital models
that replicate manufactured parts, inspect
finished products faster and more pre-
cisely, and continuously improve products
over their lifespan.
Accelerating the recreation
Because all of the centrifugal pumps
impeller vanes are identical, ADC only
needed to capture one and replicate it for
the CAD model. By noon on November 13,
Justin Ebbe of ADC had captured the im-
peller geometry using a Cimcore scanning
head with a Romer arm (Figure 6).
Ebbe then used the Wrap module of
Geomagic Studio software (www.geomagic
.com) to quickly align the scan data and
wrap a polygonal surface model around
the point cloud the data produced. Al-
though the wrapping is automatic, users
can fine-tune the model as desired. Wrap
creates watertight polygonal models
without approximations. The polygon mod-
el was saved as an STL file suitable for use
as a guide for the overall CAD model of the
pump.
The STL file representing the polygon
model accurately depicted the [vane] in
a decimated form that Pro/ENGINEER
[from Parametric Technology Corp. (www
.ptc.com)] could handle, explained
Chris Mulhall, the ADC design engineer
who managed the project. [The compat-
ibility] allowed us to create a model of
the part and simultaneously compare it
to the scan data.
The Geomagic Studio model served as
the starting point for building a para-
metric model of the impeller in Pro/
ENGINEER. To ensure accuracy, Mulhall
overlaid the scan data onto the Pro/EN-
GINEER model of the master vane as it
was being created. Exact copies of the
master vane were then made and pat-
terned around the impellers axis. The
geometry of the shroud on the bottom of
the impeller was used as the basis of a
model of the top shroud (Figure 7).
The initial plan was to produce a two-
part model that would then be machined,
assembled, and welded. But some out-
side-the-box thinking by RER engineers
led to a much faster solution.
Casting, the quick way
RER had originally planned to make a
sand-casted mold of the impeller. The
process would have required building in-
tricate wooden molding boxes by hand
and filling them with casting sand or a
mixture of sand and clay. That would have
been labor-intensive, and the resulting
metal castings would have been rough,
with a sand-like texture. Sand-casted
molds usually require a fair amount of
handiworkhammering, grinding, and
sandingto make them suitable for man-
ufacturing. That takes a lot of timea
luxury RER didnt have.
It can take four to six weeks to re-
serve foundry time for a sand casting,
and then another two to three weeks
for the mold to be completed, said Eric
Kirschling, the RER mechanical engineer
who headed up the impeller project. So
the total turnaround time is eight to 12
weeks, which we couldnt afford.
To shorten the turnaround time and in-
crease the accuracy of the mold, Kirsch-
ling looked into investment casting. In
this process, a wax mold is coated in ce-
ramic and placed in a furnace. The heat
hardens the ceramic and melts away the
wax, leaving a finished ceramic mold.
RER further accelerated the process by
having Signicast create the casting using
a rapid prototyping system that produces
the mold directly from the CAD model. A
hard coating is applied to the rapid pro-
totyped mold, and then the liquid metal
is poured into the casting to form the
part. The end product is better quality
than a sand casting, said Kirschling. Its
smoother and has tighter tolerances.
Mulhall had finished the two-part CAD
model of the impeller when Kirschling
alerted him to the change in plans, which
6. Mapping the remains. The first
step of the pump rebuilding project was col-
lecting raw point-cloud data from a scan of
the damaged impeller (top). Geomagic Studio
automatically wraps the point data with a po-
lygonal model (bottom) compatible with Pro/
ENGINEER design software. Courtesy: ADC
7. Designing the model. ADC used
Pro/ENGINEER to pattern the master vane,
making exact copies around the impellers axis
(top). A model showing the final blade arrange-
ment (bottom) was patterned from a Geomag-
ic scan of the master blade. Courtesy: ADC
020 O&M.indd 24 10/1/07 10:19:35 PM
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CIRCLE 14 ON READER SERVICE CARD
020 O&M.indd 25 10/1/07 10:19:40 PM
POWER
|
October 2007 26
FOCUS ON O&M
now called for a one-piece model (Figure 8). It took Chris about
an hour to switch gears and create the one-piece representation,
according to Kirschling.
The entire digital reconstructionfrom scanning to geometry
processing to CADtook just a day and a half. On November 14,
RER received the solid model from ADC, ready for quick casting
at the Signicast foundry.
A reason to give thanks
Signicast did the rapid prototyping and created three invest-
ment castings within a week. RER heat-treated the castings and
machined and balanced them by November 22. It assembled the
renovated pump (Figure 9) and shipped it by the end of the fol-
lowing day, which happened to be Thanksgiving.
The combined use of DSSP, CAD, and quick casting saved any-
where from six to 10 weeks of time, by Kirschlings estimate.
In Kentucky, the return to service of one of his generating
units gave John Allen another reason to be thankful. While the
unit was down, Allen and his team took the opportunity to clean
the tank in which the damaged pump had been submerged and
to repair the damage caused to piping by the parts of the pump
that had shattered.
Because a spare pump wasnt on-site or available, it was crit-
ical to fix the damaged pump as quickly as possible, explained
Allen. RER did a great job of getting it back in service as soon
as possible, and now we have some backups on hand if a similar
failure occurs.
Contributed by Bob Cramblitt (bobc@cramco.com),
a freelance technology writer.
PLANT MAINTENANCE
Seals of approval
In H.G. Wells War of the Worlds, the alien invasion is not stopped
by military force but by microscopic organisms. Similarly, in a
power plant, the failure of one thin seal can bring down a mas-
sive steam turbine.
Weve found that spiral-wound gaskets for manways are only
good for about six cycles, reports Stuart Bussman, inside main-
tenance supervisor at TransAlta Corp.s 1,404-MW coal-fired plant
in Centralia, Wash. Wed find ourselves starting up a unit, only
to have to shut it back down to replace a gasket.
Less torque, more (sealing) action
Because spiral-wound gaskets have been used for nearly a cen-
tury, they have proven value in certain environments. Indeed,
they dominate the overall market. But for high-pressure, high-
heat applications, spiral-wound gaskets are less than ideal.
As a result, Mike Perkins of A.W. Chesterton Co. (www
.chesterton.com)an industrial fluid sealing companyhas
specified gaskets from Sealing Corp. (Selco, www.selcoseal.com)
8. Casting call. The CAD model of the impeller prepared by RER
for quick casting. Courtesy: RER
9. Back in the saddle. The new impeller, ready for service.
Courtesy: RER
CIRCLE 15 ON READER SERVICE CARD
020 O&M.indd 26 10/1/07 10:19:41 PM
October 2007
|
POWER 27
for such applications for the past 10 years.
I look for issues that shorten gasket life
and cause problems for our customers, he
says.
Unlike conventional designs, Selco
gaskets have a thin layer of convoluted
stainless steel and a 0.015-inch graphite
coating on both sides. Under pressure, the
graphite compresses to the thickness of
the stainless steel, forming a tight seal.
This design has several advantages over
conventional spiral-wound gaskets. For
one, Selco seals can accommodate a wider
range of pressures and temperatures: pres-
sures from 150 pounds to 2,500 pounds,
steam temperatures as high as 1,200F, and
air temperatures from cryogenic to 932F.
According to Perkins, this design-induced
versatility translates into a great reduc-
tion in inventory reductions, and never
having to worry about grabbing the wrong
gasket from the storeroom.
Another advantage of Selco gaskets
cited by Perkins is the lower torque pres-
sures they require. Because they need to
be crushed only one-third as much as
spiral-wound seals, a sealing pressure
of 5,000 psi is adequate, vs. the usual
10,000 to 12,000 psi. As a consequence,
the gaskets flange bolts only need to be
torqued to 50% to 65% of the bolt yield.
This gives the gasket more room to ex-
pand under heat or pressure, with no need
to re-torque it. It also means you dont
have to overtorque the B7 studs, adds
Perkins.
I tend to use these gaskets in high-
vibration and thermal expansion situa-
tions, he says. I use live loading on any
part that will be heating up and cooling
down more than once a month or will
reach an operating temperature in excess
of 300F. I also use it on any part that ex-
periences jarring or vibration as a normal
part of operation.
Small seals, big problem
TransAltas two-unit Centralia plant en-
tered commercial service in 1971 firing
coal from an adjacent surface mine. The
plant later switched to Powder River Basin
coal to reduce its SO
2
emissions. Each of
the two boilers is fed by eight pulverizers
and generates 5.3 million lb/hr of steam.
TransAltas Bussman reports that after
a switch from asbestos-based to spiral-
wound graphite seals about a decade ago,
both units began to experience periodic
failures of manway gaskets on their main
steam, collecting, and lower waterwall
drums. The graphite seals lost their re-
siliency quickly and started leaking,
he says. It became a big problem. The
gaskets on drum doors were particularly
susceptible to leakage, and if the leaks
became excessive, we had to shut down
the whole unit and replace its seals, at
considerable cost, including lost genera-
tion revenues.
Looking to solve the problem once
and for all, Bussman called Perkins at
A.W. Chesterton, who had Selco design
a custom seal for one of the manways at
the Centralia plant. After it worked like
a charm, Bussman ordered Selco replace-
ments for the other manway gaskets.
Weve been very satisfied with them, he
says. Weve been using them for four or
five years now and have not yet needed
to open up any of our drums to replace a
failed manway seal.
Bussman adds that during major sched-
uled unit overhauls the drums are opened
for inspection and replacement of all their
seals. Its a simple process, he says, that
entails cleaning the gaskets surface with
a wire brush, peeling the backing off one
side of the seal, attaching it to the door,
and retightening the gasket flange bolts.
NOISE CONTROL
Making gas turbine plants
quieter
In many developing countries, ancient na-
tional grids strain to supply rapidly grow-
ing and power-hungry populations and
industries. The all-too-frequent results of
transmission constraints are brownouts
and blackoutssome planned, many not.
The unreliability of power delivery from
central stations has both limited the out-
put of local businesses and made multina-
tional firms less willing to invest in poor
countries. This restricts their economic
development and prevents their citizens
from raising their standard of living.
Building standalone natural gasfired
plants is a proven way to get power to the
people in the absence of a transmission
infrastructure. The solution is increasingly
practical, given continuing growth in nat-
ural gas pipeline mileage in the develop-
ing world and expanded global traffic in
liquefied natural gas.
The downside of urban generation
In many poor countries, the transmission
grid is so unreliable and heavily loaded
that a new gas turbine plant must be sited
close to the load it is intended to serve.
Often, that means building the plant near
or within a densely populated area.
A project developer may not get the
reception it expects if it fails to consider
the noise its plant will produce. A new gas
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FOCUS ON O&M
CIRCLE 43 ON READER SERVICE CARD
020 O&M.indd 27 10/1/07 10:19:43 PM
POWER
|
October 2007 28
FOCUS ON O&M
turbine plant may make a neighborhood
much quieter by enabling the shutdown
of hundreds of noisy diesel- or gasoline-
fueled generators. But the gas plant is far
from silent; its combustion air intakes,
ventilation systems, pumps, cooling tow-
ers, exhaust systems, and transformers
emit a broad spectrum of low- and high-
frequency noises that can make conversa-
tion difficult up to a mile away.
If the plant is located in a valley, its
noise can be heard much farther away on
the valleys sides, as a jet enginetype
swoosh. This echo effect is particu-
larly problematic for plants sited in a poor
city whose surrounding hills may be home
to millions. Where thats not an issue,
theres still the problem of the low-fre-
quency rumble that gas turbines produce
during their 15-minute start-ups, which
may occur several times a day.
No more noisy neighbors
Most power plants genuinely want to be
good neighbors, and that means manag-
ing their noise output. But even those
that dont care are being forced to pay
closer attention to this form of pollution.
One reason is the increasingly powerful
voice of the poor and underprivileged
worldwide. Helped by Internet-savvy non-
governmental organizations, locals up-
set by a new power plant can make their
case to the global community and taint
a developers reputation with bad PR for
years.
Another notable trend is the growing
influence of World Bank noise guidelines
that all power plants funded by the or-
ganization must meet. Some developing
countries have adopted those guidelines
in the absence of their own. Also grow-
ing in stature are the Equator Principles,
whose signatories have committed to not
financing any infrastructure project with
potentially negative environmental or so-
cial consequences.
There is no magic bullet to ensure
that noise concerns do not derail devel-
opment of an otherwise-promising gas
turbine project. The only viable approach
is a combination of technical, social, and
political responses.
Combine high- and low-tech
measures
The technical response requires conduct-
ing a comprehensive noise assessment
of the power plant, preferably during its
design. Experienced industrial acoustic
engineers can determine the levels of
noise that a planned plant will emit, and
whether they will fall within applicable
guidelines. Among their tools are com-
puter-aided noise prediction and abate-
ment models, field-measured noise data,
equipment manufacturers noise ratings,
and project design specifics. If noise lev-
els are predicted to be greater than per-
mitted, the engineers should be able to
recommend practical, cost-effective ways
to reduce them.
Noise can be reduced at its source,
along its propagation path, and where
it is heard (the receptors). Obviously,
the best way to mitigate sound at its
source(s) is to choose equipment with a
low noise rating. But there are many ways
to enclose, shield, and/or baffle even the
noisiest of systemsif the projects bud-
get allows for that. Building an acoustic
barrier or earthen berm, or placing gravel
pads along the main sound propagation
path(s) also can reduce a plants noise
impact.
Low-frequency noise is often the most
expensive to mitigate by isolator pads of
crushed gravel, engineered wall or enclo-
sure systems, and/or silencers. Be aware
that acoustic barriers are not very effec-
tive solutions to low-frequency noise.
If all else fails during the design
phase, it may be necessary to relocate
the plant to an already-noisy area such
as an industrial park or port. However, in
the developing world residential devel-
opment is often ad hocunplanned, un-
expected, and unpredictable. Assessing
the noise impact of the project during
its planning phase provides a modicum
of defense against this uncertainty by
highlighting any potential noise issues
down the roadliterally.
Golden Rule applies
Building good community relations ahead
of time can help reduce opposition to a
gas turbine power project. Prepare cred-
ible projections of the level and timing
of expected noise. Meet with community
leaders and build alliances, emphasiz-
ing the advantages of reliable electricity
service. Also recognize that the judicial
systems in developing countries are less
predictable than those of industrialized
nations, and that projects can be delayed
when local customs are not respected.
Contributed by Dave Bare
(dbare@golder.com), a principal of the
ground engineering and environmental
services firm Golder Associates Ltd., and
Jonathan Chui (jchui@golder.com), a
noise engineer at the company.
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020 O&M.indd 28 10/1/07 10:19:45 PM
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020 O&M.indd 29 10/1/07 10:19:53 PM
www.powermag.com POWER
|
October 2007 30
LEGAL & REGULATORY
Alex Makler
What is resource adequacy?
By Alex Makler, Calpine
U
nder its Resource Adequacy (RA) program, the California
Public Utilities Commission (CPUC) requires load-serving
entitiesboth independently owned utilities and electric
service providersto demonstrate in both monthly and annual
filings that they have purchased capacity commitments of no less
than 115% of their peak loads. These purchase requirements are
intended to secure sufficient commitments from actual, physical
resources to ensure system reliability.
As with most aspects of the California markets, the RA pro-
gram is still evolving. RA is often referred to as the replace-
ment for the Reliability Must Run (RMR) commitments entered
into between generators and the California Independent System
Operator (CAISO). From calendar year 2006 through calendar
year 2007, CAISO was able to reduce its RMR purchases from ap-
proximately 10,000 MW to approximately 4,000 MW.
There also seems to be some acknowledgement by policy mak-
ers that RA is an important source of revenue to generators in a
mitigated energy market. The revenue-generating ability of power
generators in energy markets has been limited by price caps and
must-offer requirements as well as by discrimination against exist-
ing generators in the utilities long-term procurement programs.
Recently, the CPUC convened workshops addressing a number
of issues related to the future of the RA program. Principally, the
stakeholders are grappling with whether RA should ultimately
evolve into an East coaststyle centralized capacity market or in-
stead continue as a bilateral market. In addition to the high-level
policy issues, the CPUC workshops also touched upon the seem-
ingly pedestrian topic of how to contract for RA.
Convoluted contracts
Over the past two years, load-serving entities and generators have
contracted for RA with the load-serving entity acquiring the right
to claim the contracted megawatts as RA capacity in its compli-
ance filing at the CPUC upon the generators commitment to make
such capacity available to CAISO. Both Pacific Gas and Electric
Co. and Southern California Edison Co. have filed form contracts
with the CPUC. From a contracting perspective, these forms estab-
lish an odd relationship. That is, the load-serving entity acquires
performance commitments from the generator for the benefit of
CAISO. CAISO rarely enters into the contracting fray, yet it is rely-
ing on the results of this contracting to provide it sufficient rights
to generation capacity to preserve reliability in a manner no less
meaningful than the RMR agreements.
There is nearly universal agreement that the current contract-
ing structure is inefficient and, arguably, ineffective. Load-serving
entities and generators are spending excessive time negotiating
provisions that try to reconcile the showing requirements of the
CPUC and the current CAISO tariff requirements. But given the
rather incomplete articulation of the generators performance ob-
ligations associated with such a commitment within the CAISO
tariff, load-serving entities and generators frequently get stalled
on determining the performance obligations, the associated rem-
edies, and the appropriate level of compensation for taking on
such obligations. As a result, RA contracts are overly complicated
and RA capacity has not evolved into a liquid, tradable product.
And, perhaps more troubling, CAISO may not be securing the type
of generator commitments that it needs for the reliable operation
of its system.
The capacity tag solution
The industry is responding with a two-faceted approach. First,
a diverse group of industry participants has urged the CPUC to
approve a proposal that would simplify RA contracting while en-
hancing reliability commitments. To do this, industry proposes to
reduce the contracting between the load-serving entity and the
generator to the sale of a capacity tag. A capacity tag is simply
the right of the holder to claim such capacity in a showing at the
CPUC. At the same time, such capacity, once committed, becomes
subject to performance commitments and associated remedies
specifically set forth in the CAISO tariff.
To put it another way, the generators performance obligations
to CAISO would be fully and exclusively established in the CAISO
tariffnot in a contract between the load-serving entity and the
generator, and not in the CPUC orders. This allows CAISO to en-
force more directly and effectively the generators performance
obligations. It also removes from the contracting process the need
for the load-serving entity and the generator to guess what CAISO
would require or for the load-serving entity to enforce such per-
formance obligations on behalf of CAISO.
Focusing discussion of the generators performance obligations
for RA commitments in the CAISO tariff puts back to CAISO the
question of what specific services it needs from generators to en-
sure system reliability. We hope that approachas a move away
from the blank check of the must-offer requirementwill lead to
greater efficiency and reliability in the operation of the transmis-
sion grid and a sustainable market design in California.
Alex Makler is Calpines vice president
and assistant general counsel.
RA contracts are overly
complicated and RA capacity
has not evolved into a liquid,
tradable product. And, perhaps
more troubling, CAISO may not
be securing the type of generator
commitments that it needs
for the reliable operation
of its system.
030 L&R.indd 30 10/1/07 9:00:28 PM
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030 L&R.indd 31 10/1/07 9:00:31 PM
www.powermag.com POWER
|
October 2007 32
TOP PLANTS
IGCC demonstration plant
at Nakoso Power Station,
Iwaki City, Japan
Owner/operator: Clean Coal Power R&D Co.
Integrated gasification combined-cycle (IGCC) power plants are not yet stan-
dard designs. Although they use mature coal gasification processes and
combustion turbines, disparate technologies and equipment still require
custom, laborious interfacing at each site. Every major gas turbine ven-
dor now can point to one or more power-producing IGCC projects based
on its prime mover, but none yet offers a reference plant that has stan-
dardized the interfacing enough to justify confidence in two key metrics:
$/kW and availability. With an air-blown demonstration plant based on
one of its 130-MW turbines, Mitsubishi Heavy Industries is looking to
change the rules of this game.
By Dr. Robert Peltier, PE
W
here theres a will, theres a way.
While federal and state legisla-
tors and regulators debate the
pros and cons of building more coal-fired
power plants in the U.S., Japan quietly tri-
pled its installed coal-fired generating ca-
pacity from 8,000 MW in 1988 to 23,400
MW in 2004. Significantly, the expansion
was accompanied by a wholesale upgrad-
ing from supercritical to ultrasupercritical
(USC) combustion technology. The average
thermal efficiency of the 18 (mostly) USC
plants that constitute the added 15,400 MW
is an excellent 42%a heat rate of about
8,125 Btu/kWh.
Gasifying coal and lower-grade fuels and
burning them in a combustion turbine prom-
ises a further boost in thermal efficiency to
48%, or 7,109 Btu/kWh. For Japan, which
lacks indigenous coal reserves, one of the
big attractions of IGCC plants (beyond their
ability to be retrofit for CO
2
capture) is their
ability to burn a wide range of imported coal
feedstocks whose low fusion temperatures
would wreak havoc on a conventional pul-
verized coal (PC) furnace. Other obvious ad-
vantages of IGCC combustion over PC firing
are lower NO
x
and SO
x
emissions, a reduc-
tion in solid waste generated, and the need
for less cooling water.
Developing a commercial IGCC plant has
been on Japans national agenda for some
years, and ongoing efforts will begin to pay
off in coming years (Figure 1). In 1986, 11
Japanese corporations and nine regional util-
ities, the Electric Power Development Co.,
and the Central Research Institute of Elec-
tric Power Industry (CRIEPI) established the
Engineering Research Association for IGCC
Systems. Between 1991 and 1996, under
the banner of the New Energy and Indus-
trial Technology Development Organization
(NEDO), the association successfully oper-
ated an entrained-bed coal gasification pilot
plant rated at 200 tons/day (25 MW equiva-
lent) for 4,770 hours. The longest continuous
operating period was 789 hours. Additional
technical data were acquired from a 24 ton/
day gasifier at the Nagasaki R&D Center of
Mitsubishi Heavy Industries.
100
50
45
40
35
0
N
e
t

e
f
f
i
c
i
e
n
c
y

(
%
,

H
H
V
)
1990 1995 2000 2005 2010 2015 2020
1,100
1,000
M
a
i
n

s
t
e
a
m

t
e
m
p

(
F
)
IGCC
G-class combustion
turbine (2,730F)
+5% (abs.)
Ultrasupercritical pulverized coalfired unit
1,000F
1,050F
1,100F
1,110F
Steam temp. of conventional coal-fired unit
1. Passing the baton. Mitsubishi Heavy Industries expects its state-of-the-art G-class
combustion turbines to play a key role in helping IGCC to raise the average thermal efficiency
of Japanese coal-fired power plants by 6%. Source: MHI
032 TP_Japan.indd 32 10/1/07 10:10:11 PM
October 2007
|
POWER 33
TOP PLANTS
Movin on up
Several additional gasification tests have
been conducted since 1998 as design verifi-
cation testing continued and the data needed
to scale up and accurately predict the per-
formance of the demonstration gasifier were
obtained. Clean Coal Power R&D Co. Ltd.
(CCP) was established in June 2001 to move
the earlier NEDO-sponsored development
program and the feasibility study results
forward into a demonstration project phase.
The same sponsors (with the exception of
CRIEPI) are participating, and the Japanese
government is subsidizing about 30% of the
demonstration projects development costs.
The 250-MW semi-commercial scale dem-
onstration project (Figure 2) will confirm
plant reliability, operability, maintainability,
safety, and economics. The final deliverable
of the nine-year project will be a design cer-
tified for commercial power generation.
Blast furnace gas was only the appetizer
Natural gas isnt the only fuel MHIs combustion turbines can
swallow. The company has completed a number of projects that
use by-product gas from refineries or blast furnace gas from iron
mills as turbine fuel. About 40% of Japans coal imports are con-
sumed in iron mills, including those that produce petroleum coke,
so improving the mills energy efficiency would significantly lower
the countrys CO
2
emissions. The remaining shadow of Americas
steel industry might take a few pointers from these projects.
MHIs experience with low-Btu gases dates back to 1958, when
an 850-kW gas turbine burning blast furnace gas (BFG) was com-
missioned as a prime mover for a blast furnace blower at Yawata
Steel Corp. (now Nippon Steel Corp.). This project was followed
by a larger unit (4,000 kW) delivered in 1964 to Yawata. In 1965,
MHI delivered the model MW171 gas turbine (15,000 kW) to Sumi-
tomo Metal Industries, Ltd.s Wakayama Works. Many other projects
followed that burned unconventional fuels such as coke oven gas
and hydrogen-rich refinery gases.
In 1987, MHI delivered a 145-MW combined-cycle power plant
to the Chiba Works of Kawasaki Steel Corp. (now JFE Steel Corp.).
This power plant uses low-caloric by-product gas generated within
the Chiba Works and still operates at an incredible 46% thermal
efficiency (LHV base, net). Similar plants with DA-class inlet tem-
peratures also were supplied to Mizushima Joint Thermal Power
Co. (now Setouchi Joint Thermal Power Co.) and Fukuyama Joint
Thermal Power Co. (now Setouchi Joint Thermal Power Co.) in
1994 and 1995, respectively.
The latest MHI plants that can burn low-Btu gases have designs
based on F-class technology and firing temperatures. For example,
a 431-MW IGCC plant that burns vacuum residual oil gasification
syngas and has a turbine inlet temperature of 2,462F was com-
missioned in 2003 in Yokohama, Japan (see box, p. 36, Size mat-
tersbut less than availability). This plant was followed by an
MHI 701F turbine at Kimitsu Cooperative Thermal Power Co. (Figure
6) that operates at an inlet temperature of 2,372F and is the first
F-class turbine to burn BFG at a thermal efficiency of 50% (LHV).
This plant marked the debut of a multicannular combustor with
an air bypass valve. It allows low-Btu gases to be burned over the
turbines entire operating range, from start-up to full load, with
low NO
x
emissions and no need to inject steam or water into the
combustor. Other design innovations include:
The coupling of the gas turbine, generator, steam turbine, and
gas compressor on a single, 60-meter-long shaft.
No need for a separate plant start-up system. The plant is start-
ed by the steam turbine, using steam from an existing refinery
boiler.
A gas decompression device with a direct water cooling system.
It enables the plant to send the high-temperature and -pressure
gas output of the compressor to the gas supply line during an
emergency or normal shutdown.
According to MHI, as of the end of 2006 its 12 turbines world-
wide (totaling 1,520 MW) that burn BFG and similar, low-Btu gases
have accumulated 1 million operating hours. Since then, another
16 units configured to fire low-Btu gases and totaling 1,788 MW
either have been commissioned or are under construction.
6. The low-down. At the heart of the Kimitsu Cooperative
Thermal Power Co. plant is an MHI 701F combustion turbine that
burns low-Btu blast furnace gas. Courtesy: MHI
Heat-recovery steam generator Power train Gasifier Gas cleanup
2. One giant step. MHIs 250-MW IGCC demonstration project was scheduled to begin
operation and testing last month. Source: MHI
032 TP_Japan.indd 33 10/1/07 10:10:13 PM
POWER
|
October 2007 34
TOP PLANTS
CCP selected an IGCC design based on
technology from Mitsubishi Heavy Indus-
tries, Ltd. (MHI, www.mhi.co.jp) that uses a
pressurized, air-blown, two-stage, entrained-
bed coal gasifier (Figure 3) and a dry coal feed
system. In-house studies concluded that air-
blown IGCC is better suited for commercial
power production than oxygen-blown IGCC
because the latter technologys air separation
unit (the source of the oxygen) represents an
extremely heavy auxiliary load.
Nonetheless, both GE and Siemens have
elected to use an oxygen-blown gasifier in
their reference IGCC plant designs. Siemens
notes that because the technology produces a
much lower volumetric flow of exhaust gas,
downstream gas purification equipment can
be smaller and less costly. Air-blown systems
still must handle the nitrogen in the syngas,
and doing so can make it more difficult to
remove carbon pre-combustion. However,
MHI is quick to point out that the absence
of an air separation unit improves the overall
efficiency of its design.
The design of the demonstration plant
began in 2001, and an environmental im-
pact assessment of it was submitted in June
2004. Construction began two months later
at Joban Joint Electric Power Co.s Nakoso
Power Station in Iwaki City, Fukushima
Prefecture. At press time, the demonstra-
tion plant was scheduled to come on-line in
September 2007 and begin operational test-
ing that will continue through 2009 or 2010.
One of the goals of the demonstration is to
confirm that the plant can successfully burn
low-grade coals with low ash fusion tem-
peratures and moisture content as high as
30%. MHI supplied the plants gasifier and
desulfurization system, its steam turbine and
gas turbine (a 130-MW MHI 701DA with a
2,282F inlet temperature), and its heat-re-
covery steam generator (HRSG). The com-
pany also provided all of the plants civil
engineering and construction labor as the
single turnkey contractor.
Design details
The road to a commercial IGCC plant de-
sign passes two mileposts: choosing a gas-
ifier type and redesigning the combustion
turbine(s) fuel systems to handle large vol-
umes of low-Btu fuel (Table 1). Although
the final commercial design will differ in the
details, we can get a good feel for how it will
work by examining the internals of the dem-
onstration plant (Figure 4).
The air-blown gasifier converts pulverized
coal to synthesis gas (syngas). Char in the
syngas is removed in a cyclone and porous
filter, while H
2
S is removed in a desulfuriza-
tion unit. Air for the gasifier is extracted from
the combustion turbines compressor. The
design of the gasifier must deal with melting
ash. The gasifier has a membrane waterwall
that eliminates the need for a problematic re-
fractory lining.
MHIs two-stage approach to gasification
relies on a combustor that burns coal and
recycled char at high temperature at a high
air/fuel ratio, and a reductor that uses the
Coal
Gasifier
Heat
exchanger
Pulverizer
Hopper
Syngas cleanup
Stack
Recycled
char
Slag hopper
Air
Combustion
turbine
Ambient
air
Cooling
water
Steam turbine
Heat-recovery
steam generator
Generator
Transformer
Category Variable/equipment Metric/approach
Thermal efficiency (gross) 48% (LHV), 46% (HHV)
Thermal efficiency (net) 42% (LHV), 40.5% (HHV)
Air-blown, entrained-flow
Dry coal feed
Wet MDEA (methyl-diethanol-amine) chemical absorption
Limestone-gypsum method of sulfur recovery
Combustion turbine 130-MW G-class gas turbine (50 Hz)
SO
x
8 ppm
NO
x
5 ppm
PM
4 mg/Nm
3
Emissions
Efficiency
Plant systems Gasifier
Syngas cleanup
Table 1. The performance goals and design features of Clean Coal
Power R&D Co. Ltd.s IGCC demonstration project. Source: MHI
4. Show and tell. Block diagram of the MHI 250-MW demo plant. Source: MHI
Syngas CO: 20% vol., H
2
: 10% vol
HHV: 130Btu/scf (1,150kcal/m
3
N)
Syngas + char
Cyclone
Char
Reductor
Coal
Coal
Combustor
Air
Molten ash
(slag)
Reductor
Gasification of char
Quenching of syngas/molten ash particulates
Pyrolysis of coal
Combustor
Combustion of coal/char
Melting, discharge, and separation of ash
3. Blowin in the wind. MHI has selected an air-blown gasifier for its standard IGCC
plant design. Source: MHI
032 TP_Japan.indd 34 10/1/07 10:10:16 PM
032 TP_Japan.indd 35 10/1/07 10:10:21 PM
POWER
|
October 2007 36
TOP PLANTS
combustors hot gas output for gasification,
lowers the level of unburned carbon in the
ash, and smoothly discharges molten slag.
The hot gas leaving the reductor is cooled by
an internal gas cooler/steam generator inte-
grated into the HRSG. Any char in the syn-
gas is separated out by the cyclone or porous
filter and recycled to the combustor. Accord-
ing to MHI, the carbon conversion efficiency
of the system is 99.8%.
The porous filter is the final dust removal
step before the exit gas enters a commer-
cial methyl-diethanol-amine (MDEA) and
carbonyl sulfide (COS) converter/acid gas
removal system. This unit essentially washes
the syngas to remove sulfur and trace ele-
ments. It sends the sulfur in the form of H
2
S
to the sulfur conversion/recovery unit, where
it is oxidized and absorbed in a high-perfor-
mance limestone-gypsum unit that produces
high-grade, saleable gypsum.
The MHI 701DA-type combustion tur-
bine was selected for the demonstration plant
based on its good track record in combined-
cycle and other low-Btu fuel gas projects.
MHI notes that with syngas projects, addi-
tional fuel mass flow is required to provide
the turbine with the necessary energy con-
tentabout 17% of airflow compared to
about 2% for natural gas. However, a fully
integrated IGCC plant uses about 15% of the
compressors discharge to power the gasifier.
For this reason, the MHI turbine is closely
Believe it or not, Nippon Petroleum Refining Co.s 431-MW (gross),
342-MW (net) Negishi Plant in Yokohama, Japan, is the largest
IGCC plant in operation today (Table 2). The oxygen-blown plant,
which entered commercial service in June 2003, uses vacuum re-
sidual (VR) oil as its main fuel. VR is basically very heavy oil, like
refinery asphalt, and it is one step removed from petroleum. The
entire output of the plant (Figure 7) is purchased by Tokyo Electric
Power Co.
The facility uses a GE Direct Quench gasifier and is configured
with syngas cleanup equipment, an MHI F-class combustion tur-
bine with an inlet temperature of 2,462F, an MHI HRSG, and a
selective catalytic reduction system designed to limit emissions of
NO
x
and SO
x
to 2 ppm. The facility employs an advanced system to
remove 99.8% of the sulfur in the syngas. Kerosene may be used
for start-up and during emergencies.
According to Nippon, during the first year of operation the gas-
ification system and the power block had availabilities of 69.3%
and 82.9%, respectively. The outages of the gasification system
were classified as 14.7% planned, 16.0% unplanned, and 18.8%
as forced outages. The 16% unplanned outage figure was broken
down as follows:
Problems with the main air separation units (ASUs) air
compressor: 9.9%
Other ASU troubles: 1.4%
Gasifier feed injector replacements: 0.9%
Other gasifier troubles: 1.4%
Other issues with the combined-cycle power block: 2.4%
Results for subsequent years were not available.
Dr . Robert Peltier, PE
Table 2. Operating features of prominent IGCC plants. Source: various
Owner
Location
Gasifier
Combustion turbine
Efficiency (% HHV)
HHV heat rate (Btu/kWh)
Fuel feedstock
Particulate control
Acid gas cleanup
Sulfur recovery
Sulfur by-product
Sulfur recovery
NO
x
control
Wabash Power Station
Cinergy/ConocoPhillips
Indiana, U.S.
ConocoPhillips
GE MS7001FA
39.7
8,600
Bituminous coal/pet coke
Candle filter
MDEA scrubber
Claus plant
Sulfur
99% design
Steam dilution
Polk Power Station
Tampa Electric
Florida, U.S.
GE
GE MS7001FA
37.5
9,100
Bituminous coal/pet coke
Water scrubber
MDEA scrubber
H
2
S0
4
plant
Sulfuric acid
98% design
Nitrogen and
steam dilution
Willem Alexander
NUON
Netherlands
Shell
Siemens V.94.2
41.4
8,240
Bituminous coal
Candle filter
Sulfinol M
Claus plant
Sulfur
99% design
Syngas saturation
and nitrogen dilution
Puertollano
ELCOGAS
Spain
Prenflo
Siemens V.94.2
41.5
8,230
Bituminous coal/pet coke
Candle filter
MDEA scrubber
Claus plant
Sulfur
99% design
Syngas saturation
and nitrogen dilution
Negishi
Nippon Refining
Japan
GE
MHI 701F
Unknown
Unknown
Asphalt
Unknown
Shell ADIP
Lurgi Oxyclaus
Unknown
99.80%
Unknown
Note: MDEA = methyl-diethanol-amine.
Size mattersbut less than availability
7. Still the king. The 342-MW (net) Negishi IGCC plant, at a
refinery in Yokohama, Japan, is the worlds largest facility of its kind.
Courtesy: National Energy Technology Laboratory
032 TP_Japan.indd 36 10/1/07 10:10:28 PM
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CIRCLE 20 ON READER SERVICE CARD
032 TP_Japan.indd 37 10/1/07 10:10:34 PM
POWER
|
October 2007 38
TOP PLANTS
balanced for mass flow moving through the
turbine section of the unit; only the compres-
sor casing had to be modified to include an
air extraction port.
The future is bright
The future, fully commercial plant will likely
use MHI 501G(s) with a 2,732F inlet temper-
ature. My guess is that by 2010, MHI will be
able to offer, on standard commercial terms,
a complete 500-MW to 900-MW IGCC plant
design capable of burning bituminous coal,
Powder River Basin coal, or just about any
low-rank fuel (see box, Blast furnace gas
was only the appetizer, p. 33). The first unit
of this design could enter service as soon as
late 2012 (Figure 5). That may be a year or
two later than the first commercial IGCC
plant to enter service in the U.S. However,
public utilities would be wise to focus less
on being first and concentrate more on the
performance, availability, and reliability of
the early IGCC units. Accordingly, MHI is
just as wisely committed to following a rig-
orous product development process that will
prevent any product from being marketed be-
fore it is ready for prime time.
Expect to see a blistering 46% plant ther-
mal efficiency (a heat rate of 7,417 Btu/kWh)
using the MHI M501G or M701G, a 15%
improvement over the latest round of USC
plants installed in Japan. Emissions will
be equally impressive, with SO
x
<0.06 lb/
mmBtu and NO
x
< 0.03 lb/mmBtu. Reduc-
tions of 15% to 20% in CO
2
emissions also
come along for the ride, and more because of
its systems feasibility in coupling with CO
2

capture technology.
5. Future block. An artists conceptual drawing of a commercial IGCC power plant.
Courtesy: MHI
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Visualize the electric power industry
032 TP_Japan.indd 38 10/1/07 10:10:35 PM
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makeupads.indd 98 10/3/07 10:27:51 AM
www.powermag.com POWER
|
October 2007 40
TOP PLANTS
Pleasant Prairie Power Plant Air
Quality Control Upgrade Project,
Pleasant Prairie, Wisconsin
Owner/operator: We Energies
We Energies Pleasant Prairie Power Plant is a good example of how existing
plants retrofitted with NO
x
and SO
2
removal systems benefit from early
planning and action. P4, as everyone calls it, recently completed a multi-
year project to add a selective catalytic reduction system to one of its two
units and a scrubber to both. The unique design and contracting aspects
of the project make Pleasant Prairie one of POWERs top coal-fired plants
of 2007.
By Steven Gebhart, Dennis Pennline, and Ira Brodsky, Washington Group International, and Dan Bichler, We Energies
T
he Clean Air Interstate Rule (CAIR)
is pushing utilities in 28 eastern states
and the District of Columbia to retrofit
many of their coal-fired power plants with
selective catalytic reduction (SCR) systems
to minimize NO
x
, and with flue gas desul-
furization (FGD) systems (scrubbers) to do
the same for SO
2
. The U.S. Environmental
Protection Agency estimates that by 2015,
when the CAIR regulations have been fully
implemented, SO
2
emissions will have been
cut to 2.5 million tons a year, 73% below
2003 levels. By then, NO
x
will have been re-
duced by a similar amount61% from 2003
levels. Because CAIRs NO
x
and SO
2
caps
will begin to be enforced in 2009 and 2010,
theres currently a boom in construction of
air quality control systems (AQCS).
Project overview
The environmental improvement project at
Pleasant Prairie Power Plant (P4) was under-
taken as part of We Energies plan to meet
current and pending air quality improvement
commitments and environmental regulations.
The plant exemplifies the challenges of ret-
rofitting complex SCR and FGD systems to
a working power plant. Cost is one of those
challenges. AQCS upgrades often cost many
times the original capital cost of the plant
due to competition for limited vendor shop
capacity, shortages of qualified field labor,
and rising material costs.
In many ways, P4 (Figure 1) is representa-
tive of the challenges facing utilities seeking
the least-cost path to CAIR compliance. Its
two 617-MW units were designed and built
in the early and mid-1980s to burn pulverized
Powder River Basin coal. Unit 2 was retrofit-
ted with a hot-side SCR system in 2003. The
current project added a hot-side SCR system
to Unit 1 and a wet-limestone, forced-oxi-
dation FGD system to both units. The con-
figuration of the plant required installation
of new booster fans and ductwork between
the existing induced-draft (ID) fans and the
new absorber vessels. A new, dual-flue stack
(to serve both units) made of concrete and
fiberglass-reinforced plastic (FRP) had to
be added. The AQCS upgrades are capable
of reducing P4s NO
x
emissions by 90% and
removing 95% of the SO
2
from a design coal
with a sulfur content of 0.5%.
All of the FGD system equipment (for
absorption, reagent preparation, and gypsum
dewatering) was supplied by Wheelabrator
Air Pollution Control (www.wapc.com). The
SCR system was provided by Riley Power
Inc. (www.babcockpower.com). Overall
project coordination and management were
handled by Washington Group International
(www.wgint.com). Washington Groups
scope included balance-of-plant engineering,
procurement, construction, and commission-
ing. Emerson Process Management (www
.emersonprocess.com) supplied the new sys-
tems distributed processing units, operator
1. CAIR package. We Energies twin 617-MW units at Pleasant Prairie Power Plant re-
ceived a major air quality facelift. Unit 1 was retrofitted with an SCR system and a wet scrub-
ber. Unit 2, which received an SCR system in 2003, received a new scrubber. Both units also
share a new stack (shown at left). Courtesy: Washington Group International
040 TP_Wisconsin.indd 40 10/1/07 9:07:22 PM
October 2007
|
POWER 41
TOP PLANTS
and engineering workstations, and network
periphery gear, and integrated those elements
into existing plant controls. Last but not least,
Pullman Power (www.structural.net) built the
new stack under a turnkey contract.
Unit 1s SCR and FGD systems were
placed into service in November 2006. The
commissioning of Unit 2s scrubber followed
five months later, in April 2007. Exorcising
the inevitable gremlins before those dates
was challenging but necessary. Because both
P4 units operate in baseload mode, the three
new actors and their supporting casts need to
be at least 98% available.
The SCR system for Unit 1 (Figure 2) is
designed to reduce NO
x
emissions by 90%
(a 30-day rolling average) when burning the
design fuel. That removal rate assumes a NO
x

concentration of 0.5 lb/mmBtu in the flue gas
entering the system. The hot-side system con-
sists of two reactor modules, each with two
initial layers of catalyst and provisions for two
more in the future. The catalyst type is Ti-V-
W honeycomb, supplied by Cormetech Inc.
(www.cormetech.com). Because P4s air per-
mit requires the SCR system to operate con-
tinuously, a reactor bypass is not included.
NO
x
reduction in an SCR is achieved by
mixing flue gas with ammonia in the pres-
ence of a catalyst. In the P4 SCRs, aqueous
ammonia is injected at eight locations per
reactor module. Effective mixing is ensured
through the use of a Delta Wing static mixer
supplied to Babcock Power by the Balcke-
Durr division of SPX Corp. Both sonic horns
and steam sootblowers are used to clean the
SCR catalyst of ash buildup. This enhances
the catalysts performance, reducing am-
monia consumption and ammonia slip while
still achieving high rates of NO
x
reduction.
Knocking its SO
x
off
The FGD systems (Figure 3) are designed to
remove 95% (30-day rolling average) of the
SO
2
produced when burning the design fuel.
Wheelabrator guarantees that the stoichiom-
etry of the scrubbers limestone reagent will
not exceed 1.03 under any conditions. All
guarantees are being met with one absorber
recycle pump out of service.
All FGD process systems have been placed
in a common building (Figure 4). The reagent
preparation equipment is located in the cen-
ter, between the two absorbers. Adjacent to
each absorber is a dedicated primary gypsum
dewatering hydroclone. Shared vacuum fil-
ter systems and a common storage area have
been located at the end of the building.
To expedite construction, the FGD build-
ing was designed and built in two phases.
The bottom structural mat, designed during
the projects early stages, addressed general
equipment arrangements, the placement of
2. Clearing the air. The SCR system for Unit 1 under construction. The hot-side system
is designed to remove 90% of NO
x
emissions, using aqueous ammonia injection. Courtesy:
Washington Group International
3. Scrubbing it down. The inlet to the absorber section of the new scrubber for Unit 1,
shown during installation. The system is designed to remove 95% of the units SO
2
emissions
when its burning coal with a sulfur content of 0.5%. Courtesy: Washington Group International
4. Compact Scrubber Island. FGD process equipment, limestone preparation, and
gypsum dewatering and storage equipment for both units are all housed in a compact design.
Courtesy: Washington Group International
040 TP_Wisconsin.indd 41 10/1/07 9:07:26 PM
POWER
|
October 2007 42
TOP PLANTS
the FGD slurry pump and limestone ball
mill equipment, and maximum floor loading
limits. The design of the buildings fram-
ing, flooring, and major structural bracing
systems was frozen for up to one year while
the locations of vertical columns were deter-
mined to facilitate the bottom mat design.
At that point, the final design was complet-
ed and the top matincluding the sumps,
trenches, and equipment padswas issued
for construction.
Makeup and cooling water for the FGD
process is supplied by P4s existing cooling
tower makeup system. The increase in demand
required the upgrading of lakeside makeup
pumps. Wastewater from the FGD process is
discharged into the upgraded existing cooling
tower blowdown system that drains into Lake
Michigan, about five miles away.
The limestone used by the FGD process
is delivered by truck, stored in an open pile
on the plant site, and then sent via enclosed
conveyor to replenish local day silos. The
wallboard-quality gypsum that the scrubber
produces is stored in an enclosed facility and
later trucked offsite. Some 42,000 lb/hr can
be produced when both units are burning the
design fuel at full load.
P4 goes 3-D
A very interesting aspect of the AQCS up-
grade project was its availability by design
philosophy. To meet such an ambitious goal,
Washington Group International and We En-
ergies took a number of specific actions dur-
ing the design process (see table).
Among them, but not shown in the table,
was the development of a 3-D model of the
plant to facilitate collaborative design reviews.
The 3-D model included all equipment, pip-
ing/supports, cable tray, and structural mem-
bers. Using MicroStation Smart Plant from
Intergraph Corp. (www.intergraph.com),
Washington Group, We Energies, and sub-
contractors site teams took a weekly walk
though the design (Figure 5). The software
and model enabled interactive reviews of
valve and instrument locations, accessibility,
egress, maintenance space, hoisting/removal
plans, and the like. Without question, build-
ing the model was a terrific decision. Time
and again it allowed design changes to be
proposed, discussed, and finalized with mini-
mal effect on project cost or schedule.
Ducts in a row
As an example of the benefits that high-tech
design techniques brought to the project,
consider how the configuration and sizing of
induced-draft fans was optimized. Given the
size of the major pollution-control systems
to be added, Washington Group designers
realized that they would require a substantial
increase in overall fan capacity. But would it
make more sense to get that capacity by re-
placing or upgrading existing ID fans, or by
adding an ID booster fan or two? What about
constant-speed versus variable-speed fans?
Centrifugal or axial? After many design it-
erations, and with an eye toward equipment
life-cycle costs, the final decision was made
to install two new single-speed axial booster
fans with blade pitch control in series with
the existing ID fans.
For this project, mercury control was not
included in the scope of work. However,
Washington Groups final design does antici-
pate the possible use of sorbent injection and
fabric filter baghouses. It does so by making
the ductwork between the old and new fans
long enough to accommodate the addition
of baghouses and conveyors, as well as silos
for storing fresh and spent activated carbon
sorbent, in the event that new rules require
such control.
0PIRW625
0RW610
Pump
maintenance
area
5. Virtual walk-through. Washington Group used 3-D engineering design tools to cre-
ate a virtual representation of Pleasant Prairie Power Plant. The images were used in per-
formance O&M studies and to identify design deficiencies prior to construction. Courtesy:
Washington Group International
Characteristic Examples
Input from plant operators during the
projects initial design phase
Design for operational safety.
Easy access for inspection and maintenance.
Use of equipment with
a good reliability track record
Pre-approval of equipment suppliers.
In-place redundant equipment Ball mills, gypsum filters, and all process pumps include spares.
Duplicate reagent feed tanks are cross-tied, enabling individual
or tandem operation.
Absorber agitators are designed to allow the system
to meet guarantees with one agitator out of service.
Built-in work-arounds in the event
of primary equipment failure
Hydroclone underflow slurry can flow directly onto vacuum filters,
enabling bypassing of the filter feed tank.
Including piping connections to bring makeup water
to the mist eliminator, should both mist eliminator wash pumps fail.
Provisions for bypassing the wastewater equalization tank,
to facilitate inspection and maintenance.
Use of area sumps as backup for transferring slurry
between critical components.
Use of a wastewater hold tank to facilitate
wastewater system maintenance.
Availability by design. A specific program for maximizing system reliability and avail-
ability was developed for the Pleasant Prairie Power Plant project. Source: Washington Group
International
040 TP_Wisconsin.indd 42 10/1/07 9:07:28 PM
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CIRCLE 22 ON READER SERVICE CARD
040 TP_Wisconsin.indd 43 10/1/07 9:07:30 PM
POWER
|
October 2007 44
TOP PLANTS
Once Washington Groups engineers had
determined the fans type and configuration,
they next had to confirm the ductwork design.
They outsourced that task to Airflow Sciences
Corp. (www.airflowsciences.com), which
used computational fluid dynamics (CFD)
simulations and a 1/12th-scale physical
model of P4s AQCS to confirm three design
characteristics: overall system pressure loss,
uniformity of flow, and the reduction of op-
portunities for flyash to accumulate in ducts.
The velocity distributions generated by
the CFD model (Figure 6, left) confirmed
that the velocity profile of the ductwork was
sufficiently uniform in critical areas. The
physical model (Figure 6, right) endorsed the
confirmations of pressure loss and flow via
smoke testing, and that of ash accumulation
via salt entrainment testing.
Double stack
P4s new stack is a slip-formed concrete
structure thats 430 tall and 67 feet, 7 inches
in diameter. Designed by Pullman Power, it
took one month of weekdays to erect at the
average slip-forming rate of 1 foot per hour.
Inside the stack are two fiberglass-reinforced
plastic flue gas liners. Each liner is 26 feet,
7 inches in diameter (Figure 7). Both flues
were field-fabricated and assembled on site.
The resin used on the structural FRP wall
was Hetron FR992. A 15-foot-high vertical
mandrel was used to spin twelve 30-foot
cans per flue, which were then placed in
the chimney base and jacked into place one
at a time.
Construction challenges
Pleasant Prairie has the largest megawatt
capacity in We Energies system and in the
state of Wisconsin, making it critical to com-
plete the project on time and within sched-
uled outage windows. Key aspects of the
outage workductwork tie-ins; integration
of a new, plantwide distributed control sys-
tem upgrade; and electrification of the dis-
tribution systemwere completed without
impact to the outage schedule. Because most
systems were tested prior to tie-in, start-up
of the new equipment had minimal impact
on plant availability. This major project also
was brought on-line concurrent with other
plant projects to complete a turbine overhaul
and install a new superheater.
SCR construction had to take place above
the existing coal delivery system and draft
fan equipment, requiring significant crane
support. The FGD was constructed in prox-
0.0 20.0 40.0 60.0 80.0 100.0
(ft/s)
6. Second opinions. Booster fans were added before the ID fans on both units to overcome the higher backpressure produced by the
addition of the SCR and FGD systems. Stability of the system was a concern, so CFD testing was required. Shown on the left is a 3-D velocity
distribution taken from the CFD model; the booster fans discharge enters from the left, and the air exiting at right goes to the absorber inlet. A
1/12th-scale model (right) also was built and used to confirm that opportunities for ash accumulation in ductwork had been minimized. Courtesy:
Washington Group International
7. Two in one. The interior of the new, 430-ft tall stack, showing the two fiberglass-rein-
forced plastic flues, one for each generating unit. Courtesy: Washington Group International
040 TP_Wisconsin.indd 44 10/1/07 9:07:31 PM
THE RUGGED ORIGINAL.
Intel, Intel logo, Intel Centrino, Intel Centrino logo, Intel Inside, Intel Inside logo and Pentium are trademarks or registered trademarks of Intel Corporation or its subsidiaries in the United States and other
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your Panasonic representative prior to purchase. 2007 Panasonic Corporation of North America. All rights reserved. TruckRolls_Utilities_FY07-1
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CIRCLE 23 ON READER SERVICE CARD
040 TP_Wisconsin.indd 45 10/1/07 9:07:42 PM
POWER
|
October 2007 46
imity to the plants ash-loading operations.
Plant generation and delivery systems were
not impacted during project construction.
The project achieved more than 1,000,000
work hours without a lost-time incident.
Sharing the risks and rewards
The engineering, procurement, construc-
tion, and commissioning proposal prepared
by Washington Group in the fall of 2003
established an initial price for the project,
which then became the starting point for ne-
gotiating the target price. We Energies and
Washington Group shared cost, schedule,
startup, and performance risks as an incen-
tive to reduce costs while meeting the target
price. The target price estimate and associ-
ated technical description formed the base-
line from which the projects execution was
monitored. As the design was fleshed out,
changes in the estimate basis, and savings
and cost additions, were tracked, recorded,
and agreed to prior to being finalized. This
approach ensured that the project team re-
mained focused on the projects goals while
controlling its costs.
The project was initiated by a limited Notice
to Proceed delivered to Washington Groups
Engineering department in November 2003.
The first eight months were spent developing
a well-defined project scope to establish the
target price, starting with a bottom-up cost
estimate. This kind of estimate required a sig-
nificant expenditure of engineering resources
to define the scope of work and to perform the
technical studies and evaluations needed to
establish the plant design basis and arrange-
ment. It also necessitated finalizing configu-
rations of the electrical and instrumentation
systems, the material-handling approach, se-
lection of fans, etc.
Once that was done, summary specifi-
cations were prepared for all equipment,
subcontracts, and bulk materials. The speci-
fications then were used to solicit vendors
and establish target prices. The initial critical
activities included the award of the contracts
for FGD equipment supply and for design-
ing and erecting the stack. Upon completion
of the civil/structural design in the spring of
2004, a full Notice to Proceed was issued
and construction began.
Steven Gebhart (steven.gebhart
@wgint.com) is the project manager,
Dennis Pennline (dennis.pennline@wgint
.com) is project engineering manager,
and Ira Brodsky (ira.brodsky@wgint.com)
is lead process engineer for Washington
Group International on the We Energies
Pleasant Prairie Power Plant Air Quality
Control Upgrade Project. Dan Bichler
(dan.bichler@we-energies.com) is project
manager for We Energies.
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CIRCLE 24 ON READER SERVICE CARD
040 TP_Wisconsin.indd 46 10/1/07 9:07:44 PM
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www.powermag.com POWER
|
October 2007 48
TOP PLANTS
Polk Power Station Unit 1,
Mulberry, Florida
Owner/operator: Tampa Electric Co.
Ten years ago, POWER selected Tampa Electrics 250-MW Polk Power Station
and its revolutionary integrated gasification combined-cycle demonstra-
tion project as the magazines 1997 Plant of the Year. Although no new
commercial IGCC projects have been built since then, interest in deploy-
ing the coal-gasification technology is getting traction in some parts of
the U.S. In 2007, POWER recognizes Polk Unit 1 as a Top Plant for devel-
oping trailblazing O&M practices and technical improvements that en-
able it to operate today as reliably as a modern pulverized coal plant, with
lower pollutant emissions.
By Mark Hornick, Tampa Electric Co.
T
ampa Electric Co. (TECO) owns and
operates Polk Power Station as part of
its regulated generation fleet in Cen-
tral Florida. The plant (Figure 1) occupies
4,300 acres in Polk County, about 40 miles
southeast of Tampa. One-fifth of the inte-
grated gasification combined-cycle (IGCC)
projects $600 million capital cost was paid
for by the U.S. Department of Energy as part
of its Clean Coal Technology Program. Now
called Unit 1, the plant was commissioned
and placed into commercial service in late
1996. During its first five years of operation,
the plant operated successfully on a number
of different fuels that were part of the DOE
demonstration plan.
In the May/June 1997 issue of POWER,
the editor wrote: In many ways Polk [now
1. First in class. Polk Power Station Unit 1 has the lowest production cost of any plant in the Tampa Electric system. Courtesy: TECO
048 TP_Florida.indd 48 10/1/07 10:00:02 PM
October 2007
|
POWER 49
TOP PLANTS
Unit 1] is among the most challenging gen-
eration projects ever undertaken in the power
industry [and] with continued refinement,
Polks efficiency will make the unit even
more valuable to the utility. Those words
have proved prescient, because Americas
first greenfield IGCC plant now performs
better than most pulverized coal (PC) plants.
Unit 1, which typically operates in baseload
mode, currently boasts the lowest incremen-
tal cost in the TECO system.
The coal gasification portion of Unit 1
(Figure 2) uses entrained-flow, oxygen-blown
technology that was developed by Texaco
and later purchased by General Electric Co.
Power is generated by a 315-MW 1 x 1 com-
bined-cycle plant whose GE 7FA combustion
turbine fires either the output of the gasifier or
distillate oil. The turbine is rated at 192 MW
when firing the syngas, with diluent nitrogen
for NO
x
control. Complementing the 7FA are
a 123-MW GE D11 steam turbine-genera-
tor and a triple-pressure heat-recovery steam
generator from Vogt Power International
(www.babcockpower.com). The oxygen
plant consumes 55 MW, and other auxiliaries
require 10 MW, so the net power delivered
to the grid is 250 MW. The IGCC units heat
rate is about 9,300 Btu/kWh on a steady-state
basis when firing syngas.
The road to success
At the plants dedication on January 10,
1997, then-Secretary of Energy Hazel R.
OLeary congratulated TECO and TECO
Power Service Corp. for the successful start-
up of a facility she said will help redefine
the worlds use of coal. With this technology,
we can show the world how to use its wealth
of coal to power economic growth without
endangering the environment. It will herald a
new era for clean energy from coal.
And clean it is. Even when burning low-
cost coal feedstocks, Polk emits less SO
2
,
NO
x
, and particulates than most PC plants.
With over 98% removal of SO
2
, emissions of
2. Harness the power. Unit 1 produces 315 MW (gross), but the oxygen plant con-
sumes 55 MW, and auxiliaries eat up another 10 MW, leaving 250 MW for delivery to the
grid. Courtesy: TECO
CIRCLE 26 ON READER SERVICE CARD
048 TP_Florida.indd 49 10/1/07 10:00:08 PM
POWER
|
October 2007 50
TOP PLANTS
that pollutant are typically 0.12 lb/mmBtu.
NO
x
emissions, which are reduced by syngas
saturation, are currently averaging 11 ppm
(corrected to 15% O
2
). Particulate emissions
also are extremely low, at 0.04 lb/MWh.
TECO has faced and met so many opera-
tional challenges at Polk that it has announced
development of a second IGCC plant there
(see box). The planned investment is perhaps
the best indicator of the companys comfort
level with the technology. Polks 95% unit
equivalent availability with backup fuel
compares quite favorably to the 78% aver-
age availability of a U.S. coal plant. Polks
gasifier is currently operating at a 72% ca-
pacity factor and an equivalent availability of
78% on syngas. Those numbers, which are
somewhat lower than would be expected for
a next-generation IGCC plant, are due to a
few troublesome pieces of equipment such
as convective syngas coolers, which will be
eliminated in future units (Figure 3).
Plenty of speed bumps
The road to reliability hasnt always been
smooth, and the inevitable growing pains in
the early years were alleviated by doses of
good engineering and excellent O&M prac-
tices. For example, the plant has five teams
of 10 IGCC specialists, all with journeyman-
level skills. They are responsible for the O&M
of the plant; there are no first-level supervi-
sors. The specialists on-the-job training will
be invaluable as the fledgling IGCC industry
matures in the U.S. over the next decade. And
the maturation and acceptance of the technol-
ogy will be accelerated by two key stats: Polk
is TECOs lowest incremental-cost generating
unit and one of the cleanest coal-fired power
plants in the U.S.if not the world.
The reliability and availability of Polks
IGCC unit have improved steadily since it
entered commercial service. Of the 34,800
hours logged by the combustion turbine over
the five-year demonstration period, 28,500
were syngas-fired, producing over 8.6 mil-
lion MWh of electricity. The gasifiers
on-stream factor steadily increased, reach-
ing 70% to 80% after 2.5 years. The over-
all units availability, with distillate fuel as
backup, averaged 90% after 1.5 years.
Improvements have come slowly but have
built an experience base that is now paying
dividends. The units start-up challenges and
problems are not too different than those of
a coal- or gas-fired plant, with some chemi-
cal processing steps added for extra interest.
During Polks first few years of service, many
small glitches contributed to lower-than-ex-
pected availability, but those problems were
not attributable to basic IGCC technology. For
example, the erosion and corrosion of piping
and the plugging of syngas coolers with ash
were expected. The many nuisance shutdowns
were addressed one at a time and resolved.
In the second year of operation, particu-
late damage to the combustion turbine was
solved by adding a syngas filter. At the same
time, operators learned how to do faster
hot starts to improve the units dispatch-
ability. They also figured out how to reduce
the auxiliary power required during a start-
up or shutdown. The losses add up quickly
because the gasifiers refractory lining takes
several days to cool down, and 30 to 36 hours
to heat up again using propane gas.
The next few years saw the longest unin-
terrupted period of power generation by the
combustion turbine to date: 52 days, with
16 transfers between syngas and No. 2 oil.
Before then, the longest uninterrupted gas-
ifier run was 37 days. Ash plugging of the
convective syngas coolers remained a nag-
ging problem. The gasifiers refractory was
replaced after 451 days of operation (rep-
resenting over two years of service and 73
gasifier start-ups on 10 different fuels or fuel
blends). Despite the additional O&M costs,
Polk still became the unit with the lowest
production cost in TECOs fleet and the first
unit to be dispatched.
Slurry plant
Entrained-
flow gasifier
Oxygen plant
Coal slurry
Raw syngas
90%
O
2
N
2
to combustor
N
2
Feedwater
Radiant syngas
cooler
Slag disposal
Black water recycled
High-pressure
steam
Raw syngas
Product
gas cooler
Steam
Sulfuric
acid
Sulfuric acid
plant
Sulfur
removal
Steam
Conventional
gas cleanup
Combustor
Generator
Generator
Clean syngas
Air
Combustion turbine
Hot
exhaust
gas
Heat-recovery
steam generator
Stack
Steam turbine
3. Go with the flow. A simplified process flow diagram of TECOs Polk Power Station
Unit 1 illustrates the complexity of the IGCC process. Source: U.S. DOE
Next upPolk Power Plant Unit No. 6
The U.S. Department of Energy and the
U.S. Treasury Department earlier this year
awarded $1 billion in tax credits to nine
companies for seven projects involving
advanced coal-fired generation or coal
gasification. The awards were the result
of a competition for which the DOE said
it received 49 applications. The Energy
Policy Act of 2005 provided for $1.3 bil-
lion in tax credits to encourage private
investment in what the DOE describes
as advanced clean coal facilities and a
separate pool of $350 million in credits
for gasification projects.
Tampa Electric Co.s (TECOs) proposed
632-MW IGCC Polk Power Plant Unit 6
project picked up one of the four gasifi-
cation awardsa $133 million tax credit.
The baseloaded unit, to be sited next to
the existing 255-MW Unit 1, is scheduled
to enter commercial service in 2013.
TECO envisions configuring Unit 6 as a
double-capacity Unit 1, with two sepa-
rate gasifiers producing syngas for two
combustion turbines that will exhaust
into two heat-recovery steam generators
feeding a single steam turbine. Permit-
ted emissions are expected to be 0.019
lb/mmBtu for SO
2
and 0.038 lb/mmBtu for
NO
x
(actual emissions will be even lower).
The plant also will be made carbon-cap-
ture ready, a requirement for qualifying
for the tax credit under IRS Code Sect
48A(c)(5).
TECO estimates that Unit 6 will cost
about $2 billion to build. Half of that sum
will likely take the form of Tampa Elec-
tric debt, with equity contributions from
parent TECO Energy to Tampa Electric ac-
counting for the remaining 50%.
048 TP_Florida.indd 50 10/1/07 10:00:11 PM
Is Your Coal Dust Collector A Problem
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plenum continuously rotating
above the bags. This simple
cleaning mechanism has been
proven in hundreds of installations
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But thats not all: unlike other reverse air filters, all electrical components
on the RAF-IS are located outside the filter housing. This eliminates any
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More Safety Features Than Any Other Collector
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resistant plates. In addition, the inlet creates a cyclonic flow
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Similarly, the rotating distribution plenum above the bag
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Compare the RAF-IS with any other dust collector. Youll find that, for coal dust, it is the clear
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www.mikropul.com Email: info@mikropul.com
A Noticeable Difference
CIRCLE 27 ON READER SERVICE CARD
048 TP_Florida.indd 51 10/1/07 10:00:14 PM
POWER
|
October 2007 52
TOP PLANTS
Bumps encountered and avoided
By the last year of the DOE demonstration
program, the gasification plant was operating
quite well. Many of the many nuisance prob-
lems had been solved, and the plant could be
brought on-line much faster. Furthermore,
fewer instances of corrosion and tube plug-
ging problems had demonstrated that a wide
range of fuel types could be burned with
little impact on plant performance.
However, during the demonstration period,
frequent fuel switches and the high number
of start-up and shutdown cycles shortened
refractory liner life and accelerated refrac-
tory spalling. Tests indicated that a blend of
45% Black Beauty and Mina Norte coals and
55% petroleum coke delivered three positive
results: extended refractory life, improved
performance characteristics, and extremely
competitive production costs (at the time,
33% lower than a PC plants and 25% less
than that of a natural gas burner).
The inability to directly measure refrac-
tory temperatures in real time slowed reso-
lution of the problem; thermocouples failed
quickly when exposed to the temperatures in
the gasifiers flow path. Being able to directly
monitor and control gasifier temperatures, as
opposed to relying on inferential measure-
ments, is critical for controlling slag and fly-
ash formation.
After the first four years of service, Polks
gasifier and associated systems had steadily
improved their availability to 70% to 80%
before suffering a frustrating setback in the
fifth and final demonstration year. The failure
of the air separation units main compressor
caused a one-month forced outage that pulled
down the fifth years operating stats. Coinci-
dently, another lengthy planned outage was
required to deal with gasifier refractory dam-
age caused by frequent feedstock changes and
the replacement of sootblower lances.
During that star-crossed year, after reex-
amining Polks air quality permit, the State of
Florida requested that TECO retrofit the com-
bustion turbine with a selective catalytic re-
duction system, although the technology had
never been proven on an IGCC plant. TECO
responded by adding the syngas saturation
process to achieve 15 ppm NO
x
. Despite the
lengthy outages, Polks on-peak availabil-
ity for 2000 (year 4) and 2001 (year 5) was
94.9% and 97.7%, respectively (Figure 4).
Carbon in the slag also was a nagging
problem; a newly designed slag screen was
the solution. Another related problem: The
gasifiers carbon conversion rate was in the
low to mid-90% range, much lower than the
98% typical of small Texaco gasifiers. As a
consequence of the air separation units in-
ability to meet the gasifiers entire oxygen
demand, and the need to recycle excess fly-
ash, Polk Unit 1 had to be derated to 235
MW, net. The capacity of the solids-handling
system had to be doubled so the plant could
continue to burn low-quality fuels and main-
tain its design rating of 250 MW.
Until the fifth year, the blocks availabil-
ity when firing syngas or distillate was about
90%. In 2003, problems were discovered in the
generators of both the combustion and steam
turbines that required a rewind of both rotors.
Later that same year, a recommended inspec-
tion uncovered a crack in the combustion tur-
bine that required a rotor replacement. These
problems were associated with early produc-
tion units and were not related to the use of
syngas.
Among the other steps taken to resolve
nagging problems were these:
The convective syngas coolers were rede-
signed to reduce plugging.
The radiant syngas cooler seals were rede-
signed and replaced.
The raw gas/clean gas heat exchangers,
which were found to be suffering from
stress-corrosion cracking, were initially
repaired and permanently removed later.
A COS hydrolysis unit was added to meet
sulfur-reduction targets, along with an
ion-exchange unit for preventing buildup
of heat-stable salts in the methyl dietha-
nolamine unit.
The installation of Y strainers and a 10-
micron filter system proved critical to pro-
tecting the combustion turbine from pipe
scale during start-ups. The filter was sized
to capture and hold one years worth of
scale.
All carbon steel parts that make contact
with the slurry feedstock were replaced or
coated. High-wear areas were hardened.
Well-deserved success
Polk was functioning as a well-oiled ma-
chine by year eight (2004) and posted the
best performance to date: 82% and 96%
availability for the gasifier and the power
block, respectively. The aforementioned
incremental improvements to shorten start-
up times and reduce parasitic power con-
sumption were made the following year.
Unfortunately, thats when the failure of
another main compressorthe one feeding
the combustion turbinecaused a 100-day
forced outage unrelated to syngas produc-
tion. TECO took advantage of the outage
to make a number of system modifications,
including one to add compressor extraction
air to the gasifier to increase overall unit
output.
In POWERs 1997 Plant of the Year arti-
cle on Polk, the editors also noted the plants
capability to turn a pollutant into a product.
One way coal-fired generation can compete
in the next century, they wrote, is if the fuel
is considered for more than its heating value,
and the facility more than just a power plant.
Indeed, upgrades to Polks gasifier systems
allow for recovery of sulfuric acid and its
sale to local phosphate producers. Slag also
is recovered and put to beneficial use in the
making of cement. Polk even has reduced its
water consumption and continues to operate
with zero process water discharge.
Today, the plant continues to operate reli-
ably, having generated more than 13 million
GWh while meeting every limit in its envi-
ronmental permit. SO
2
removal remains at
an industry-leading 98%+ level, with NO
x

emissions below 15 ppm. Polks steady-state
heat rate of about 9,300 Btu/kWh (37% effi-
ciency, HHV) compares favorably with other
coal-fired power plants in the U.S.
Mark Hornick
(mjhornick@tecoenergy.com) is
general manager of Polk Power Station.
A
v
a
i
l
a
b
i
l
i
t
y

(
%
)
100
90
80
70
60
50
40
30
20
10
0
96 97 98 99 00 01 02 03 04 05 06
Combustion turbine on syngas
Early combustion turbine fleet issues Early combustion turbine fleet issues
Combustion turbine availability
Year
4. Winning stats. Polk Unit 1 continues to improve its performance, despite problems
with the combustion turbine and the air separation unit that are unrelated to syngas production.
The average coal plant availability is about 85%. Source: TECO
048 TP_Florida.indd 52 10/1/07 10:00:15 PM
If you process it,
load it, unload it,
stack it, stockpile it,
reclaim it, crush it,
blend it or convey it
Roberts & Schaefer can handle it.
From feasibility studies to turnkey projects, Roberts &
Schaefer is recognized around the world as the industry
innovator of bulk material, coal preparation and fuel
handling/blending systems. We provide total solutions for a
wide range of fuels, including PRB, bituminous, lignite and
anthracite coal; woodchips and petroleum coke; as well as
limestone and gypsum handling; and limestone grinding and
transport systems. For complete system development,
upgrades or modifications, we can handle it.
Roberts & Schaefer Company
222 South Riverside Plaza
Chicago, Illinois 60606
312/236-7292
www.r-s.com
Offices also in Australia, Indonesia,
Poland and Salt Lake City
Limestone/gypsum handling and
gypsum barge load out system
Barge unloading, conveying,
stack out and reclaim facility
Coal and woodchip
handling
Coal, limestone
and ash handling
Coal handling and
storage facility
Stacker/Reclaimer Coal preparation
and material handling
Coal blending for
Illinois Basin and PRB coal
Gypsum conveying and
barge load out facility
Conveying, screening and
crushing system
Rapid car unloading,
fuel blending
(Eastern or PRB coal)
Fuel and limestone handling
for CFB boiler
Coal handling for fuel
switch to PRB coal
Pet coke handling facility
CIRCLE 28 ON READER SERVICE CARD
048 TP_Florida.indd 53 10/1/07 10:00:17 PM
www.powermag.com POWER
|
October 2007 54
TOP PLANTS
R.E. Burger Plant,
Shadyside, Ohio
Owner/operator: FirstEnergy Corp.
FirstEnergys R.E. Burger Plant has hosted a number of R&D projects over the
years, but none as large as the demonstration of Powerspans 50-MW
Electro-Catalytic Oxidation (ECO) multipollutant removal process a few
years ago. Credit Powerspan for scaling up the demo unit and for adding
CO
2
as a target of a new pilot process called ECO
2
. And dont forget the
behind-the-scenes support of Burgers plant staff and their willingness to
incubate R&D projects while producing power. Thats what makes R.E.
Burger a Top Plant in our book.
By Dr. Robert Peltier, PE
C
oal is still king in the realm of power
generation, but the palace is under
siege by new environmental rules with
bigger teeth. Emerging air emissions regula-
tionsin the form of the Clean Air Interstate
Rule (CAIR), the Clean Air Mercury Rule
(CAMR), and a patchwork of state rules
make plant environmental upgrades more
expensive and take a bigger bite out of the
industrys investment dollar.
To be sure, the return on that investment
will be a tangible improvement in the air we
breathe. The gains in air quality attributable
to the installation and upgrades of air qual-
ity control systems (AQCS) at power plants
since passage of the original Clean Air Act
in 1970 are certainly remarkable. But the
days of inexpensive retrofits to capture low-
hanging fruit are long gone. Well leave the
discussion of How low can you go? for
another time.
Most AQCS designs are evolutionary, and
at some point all of the technologies on which
they are based have been mixed and matched
at some plant in the U.S. Removing specific
constituents of the exhaust gas streamfirst
NO
x
, SO
2
, and particulate matter (PM), and
now mercury (Hg)is so dependent on a
plants design, location, and fuel type that
dozens of alternative reduction approaches
have been tried over the past 35+ years.
NO
x
control began with burner upgrades
or replacements and was followed by selec-
tive catalytic reduction (SCR). SO
2
removal
at a 95% or higher level has become common
since the first utility-scale scrubber entered
service in 1988. Many coal plants delayed
spending a bundle on a scrubber by switch-
ing to low-sulfur Powder River Basin (PRB)
coal in the 1990s, but they encountered com-
bustion problems as a consequence. Although
compliance with PM regulations typically has
been addressed by adding an electrostatic pre-
cipitator (ESP) or baghouse, the new PM
2.5

regulations may make existing units obsolete.
One AQCS for four pollutants
Retrofits to operating coal plants have be-
come more expensive than anyone predicted.
A recent survey by the EUCG (www.eucg
.com) of 48 flue gas desulfurization (FGD)
projects by 12 utilities pegged the average
capital cost of a scrubber for a unit larger
than 300 MW at about $300/kW (POWER,
July 2007, p. 56). Other sources estimate the
cost of an SCR system at more than $100/kW.
This June, a Midwestern utility announced
that it would be spending $750 million to add
scrubbers to two 600-MW units now under
construction at a cost of $2.3 billion.
Thankfully, new emissions-reduction al-
1. Host with the most. In 2004, FirstEnergys R.E. Burger Plant began operating, for
demonstration purposes, a 50-MW (equivalent) version of Powerspans Electro-Catalytic Oxi-
dation (ECO) multipollutant removal process. Courtesy: FirstEnergy
054 TP_Ohio.indd 54 10/1/07 9:10:55 PM
October 2007
|
POWER 55
TOP PLANTS
ternatives promise greater cost-effectiveness
than mixing and matching AQCS. The one
perhaps furthest up the evolutionary ladder
can control multiple pollutants simultaneous-
ly. The technologywhich has been under
continuous development by Powerspan Corp.
(www.powerspan.com) since late 1996 and
supported by FirstEnergy Corp. at its R.E.
Burger plant since 1998has now reached
the point of commercialization (see box).
R.E. Burger Plant (Figure 1) has two coal-
fired baseloaded units, one coal-fired peaking
unit, and three oil-fired peakers, for a total
capacity of 427 MW.
After successful pilot testing funded and
hosted by FirstEnergy, in February 2004,
Powerspan installed a 50-MW (equivalent)
commercial demonstration unit (CDU) of
Inside the ECO process
The unique feature of Powerspans Electro-Catalytic Oxidation
(ECO) technology (Figure 2) is its ability to simultaneously re-
move SO
2
, NO
x
, PM
2.5
, acid gases, Hg, and other metals from the
exhaust of a coal-fired power plant. ECO converts NO in flue gas
to more-soluble NO
x
compounds, which it then absorbs, along with
SO
2
. The process captures oxidized Hg in the exhaust using a wet
electrostatic precipitator (ESP), which also collects aerosols and
fine particles in the flue gas. The by-product of the ECO process,
ammonium sulfate, can be marketed as a fertilizer.
In a typical plant, the ECO system is installed downstream of
the plants existing ESP or fabric filter. The multipollutant treat-
ment occurs in three distinct steps:
1. A reactor oxidizes gaseous pollutant(s) using a dielectric barrier
discharge. When the voltage across the electrodes of the reactor
reaches the breakdown voltage of the flue gas, micro-discharges
are formed and oxygen and water molecules in the flue gas are
converted to the atomic oxygen and hydroxyl radicals that lead
to the oxidation reactions.
2. An ammonia scrubber removes the NO
x
compounds produced
by the reactor and the SO
2
that is not oxidized. The scrubber
has two liquid loops: a lower one for quenching the gas to its
saturation temperature and an upper one to absorb the SO
2

and NO
x
.
3. A wet ESP captures the aerosols produced in the first two steps,
fine particulate matter, and oxidized mercury. The wet ESP and
the ammonia scrubber are housed in a single absorber tower.
Liquid bled from the absorption loop and material captured in
the WESP are collected in the lower quench loop. Unlike typical
scrubber slurry, the only solids in the liquid are from the captured
ash. This is because all of the salts are dissolved at a concentra-
tion just below the level at which they begin to crystallize. A
slipstream from the quench loop then is pumped to the co-product
processing system. Filters and absorbent beds remove any fine
particles and Hg from the co-product slipstream, which can then
be used as a commercially valuable liquid fertilizer containing
8% nitrogen and 9% sulfur or further processed to form fertilizer
crystals. The 50-MW commercial demonstration unit tested at the
R.E. Burger Plant in 2005 produced approximately 3,000 tons per
month of liquid ammonium sulfate over a six-month continuous
run. A larger unit would use a separate crystallizer to produce a
more valuable dry co-product.
Another unique feature of the ECO process is its zero liquid
discharge. Waste products are limited to small amounts of ash
that enter the ECO system and are filtered from the liquid, along
with a small amount of spent sorbent used to remove Hg from the
co-product.
From ESP or
fabric filter
Induced-draft
fan
Reactor
Wet ESP
Upper loop
Separator tray
Lower loop
Recycle
pump
Recycle
pump
Upper loop
recycle tank
Mercury
adsorber
Reagent
pump
Reagent
tank
Makeup
water
Reagent
makeup
Note: ESP = electrostatic precipitator.
ECO reactor Absorber tower Wet ESP
Wet
stack
To by-product
processing
2. Deceptively simple. An ECO process flow diagram illustrates how the multipollutant control system integrates with an existing
plant. Source: Powerspan
054 TP_Ohio.indd 55 10/1/07 9:10:58 PM
POWER
|
October 2007 56
its Electro-Catalytic Oxidation (ECO) pro-
cess (Figure 3) at the Burger plant and began
testing it as an integrated system. The CDU
worked on an 110,000-scfm (standard cubic
ft/min) gas slipstream from the ductwork of
Unit 4 or 5, downstream of the plants exist-
ing electrostatic precipitator (Figure 4). The
treated gas was returned to the ductwork just
upstream of the stack.
A 180-day reliability run of the CDU that
Liquid co-product
storage tanks
Reactor
building
Pump
building
Absorber vessel
and WESP tower
3. Proof of performance. In 2005 the ECO commercial demonstration unit was oper-
ated continuously for six months to confirm the design and reliability of the system. Although
the demo ended two years ago, the ECO unit remains in service. Source: Powerspan
Stack
Wet ESP
Absorber
vessel
Return gas
Inlet gas
Booster
fan
ECO
reactor
4. Hooked on gas. A 50-MW (equivalent) gas stream was taken from the stack gas,
treated in the ECO system, and then returned to the ductwork just ahead of the stack. Source:
Powerspan
TOP PLANTS
CIRCLE 29 ON READER SERVICE CARD
054 TP_Ohio.indd 56 10/1/07 9:10:59 PM
Decision making is easy when you
have the right information at the
right time.
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No matter where you are, our solutions provide the decision-relevant information
you need.
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CIRCLE 30 ON READER SERVICE CARD
054 TP_Ohio.indd 57 10/1/07 9:11:03 PM
POWER
|
October 2007 58
TOP PLANTS
ended in September 2005 demonstrated that
ECO meets all current performance require-
ments for NO
x
, SO
2
, and particulate control,
and can remove 85% of the Hg in flue gas to
boot. The table summarizes the results of the
reliability run, during which the CDU was
more than 98% available.
The demonstration project was funded by
Powerspan, FirstEnergy, and the Ohio Coal
Development Office of the Ohio Air Quality
Development Authority (www.ohioairquality
.org). In addition to the first two companies,
the project team included the Siemens Power
Generation subsidiary Wheelabrator Air Pol-
lution Control Inc. (www.wapc.com), Fluor
Power (www.fluor.com), and The Ander-
sons Inc. (www.andersonsinc.com), which
handled fertilizer co-product removal, mar-
keting, and sales. The ECO CDU remains in
service today.
Its modular, so its scalable
Some might argue that the results of testing
a 50-MW CDU are not representative of the
performance of a full-size ECO process ret-
rofitted to a plant 10 times larger. But because
the systems dielectric barrier discharge re-
actor and wet ESP are modular, and their
performance is based on gas volumetric flow
and the reaction chemistry, the ECO process
is eminently scalable to any size required.
Although the systems ammonia scrubber is
not modular, the technology for scaling that
part of the process is well understood.
From the lab to the field
Powerspan is making the transition from be-
ing a pure technology developer to a com-
mercial supplier. It recently announced the
sale of its first utility-scale ECO system
tono surpriseFirstEnergy, which plans
to install a single full-size unit to serve the
combined flue gas of Burgers 156-MW Unit
4 and 312-MW Unit 5. That certainly says
something about FirstEnergys confidence in
the process.
We believe installing ECO will enhance
the viability of the Burger Plant and give us
more flexibility in our use of eastern coal,
said Richard R. Grigg, an executive vice
president and the chief operating officer of
FirstEnergy. In addition, we believe that
ECO provides a cost-effective method for
meeting environmental regulations, includ-
ing those of the CAIR and CAMR.
Because FirstEnergy is planning to use
selective noncatalytic reduction technology
at R.E. Burger to remove NO
x
, the ECO unit
it has ordered will not be equipped to handle
that pollutant. Design engineering of the unit
has already begun, and start-up is scheduled
for the first quarter of 2011. The estimated
cost of the unit is about $168 millionan
apparent bargain, given todays high and ris-
ing AQCS costs.
The ECO process is just as applicable to
greenfield plants as to existing ones. This
June, American Municipal Power-Ohio
(AMP-Ohio) committed to use the process
at its proposed AMP Generating Station,
a 1,000-MW coal-fired project in Meigs
County, Ohio. The selection was driven by
the promise of CO
2
capture by the recently
announced ECO
2
system, which is being
designed to integrate easily with the ECO
process (see box, p. 60). Naturally, AMP-
Ohio will be a partner in a planned program
to test a pilot version of ECO
2
at the Burger
Plant.
Powerspan expects that by exploiting
economies of scale, future ECO projects
should be able to maintain their 10% to 20%
installed-cost advantage over combinations
of conventional, single-pollutant ACQS. As
for operating costs, the company emphasizes
that they depend on precise knowledge of
specific plant variables, such as the level of
NO
x
in the flue gas to be treated, the sulfur
content of the coal being burned, the cost
of ammonia reagent, and actual revenue
from fertilizer sales. Because the system is
so tightly integrated, the cost to remove in-
dividual pollutant-control components de-
Parameter Result
SO
2
>98% removal
NO
x
Consistent with 90% removal from 0.4 lb/mmBtu inlet
Hg 85% removal across the ECO system
PM
2.5
<0.01 lb/mmBtu level at outlet
Availability >98% (despite the CDUs lack of redundant components,
a money-saving measure)
Operability Maintained performance in load-following mode
and during system transients and plant upsets
Pollutant volume removed 3,000 tons of SO
2
, 125 tons of NO
x
By-product produced and sold 18,500 tons of liquid ammonium sulfate fertilizer
Measured performance of the ECO commercial demonstration unit
over a 180-day run at R.E. Burger Plant. Source: Powerspan
Feasibility/Planning Studies
Siting/Permitting
Power Plant Engineering & Design
Plant Upgrades/Retrots
Transmission & Distribution
Substations
Construction Management/Inspection
www.stanleyconsultants.com
Excellent Career Opportunities Available
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054 TP_Ohio.indd 58 10/1/07 9:11:05 PM
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Ameren Energy Fuels & Servi ces
At AmerenUE s Meramec Power St at i on,
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control air flow, and reduce dust.
And Mar t i n Engi neeri ng guarant eed t he
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CIRCLE 32 ON READER SERVICE CARD
054 TP_Ohio.indd 59 10/1/07 9:11:09 PM
POWER
|
October 2007 60
TOP PLANTS
pends on how one chooses to distribute the
systems cost among the pollutants.
Nevertheless, Powerspan says it expects
operating costs to be about 20% less than
those of conventional technology solutions,
even discounting the value of ECOs ability
to meet the new PM
2.5
and Hg regulations.
As for availability, an EPRI-commissioned
study by Burns & McDonnell concluded the
ECO equipment is at least as reliable as con-
ventional equipment, predicting better than
99% availability.
Upgraded ECO process captures CO
2
, too
If Las Vegas bookies were to lay odds on Congress enacting some
sort of CO
2
-reduction legislation in the next few years, my guess
is that those odds would be pretty low. The expected legislative
give and take has devolved into more of a winner takes all
battle, so an agreement on carbon caps is problematicalthough
probably inevitable. Even if a break in the legislative logjam ma-
terializes, any new EPA rules will surely be vetted in the courts for
quite some time.
If you believe that carbon capture and sequestration projects
will become a reality in our lifetime, the next few years will repre-
sent the calm before the carbon storm. R&D companies must use
this time to choose and invest heavily in the technologies with
the highest probability of commercialization in the near term. The
firms that make the right bets at the right time will be rewarded
by a nice slice of the carbon control market.
Three years ago, Powerspan and the U.S. Department of Energys
National Energy Technology Laboratory signed a cooperative R&D
agreement to develop a cost-effective CO
2
-removal process that
builds on Powerspans proven ECO process design. Powerspan an-
nounced in August a collaborative agreement with BP Alternative
Energy (www.bpalternativenergy.com) to successfully demonstrate
the technology dubbed ECO
2
and advance it to full-scale deploy-
ment as rapidly as possible.
The desired target is a scrubbing process that uses an ammo-
nia-based (rather than an amine) solution to capture CO
2
from
flue gas. The CO
2
capture takes place after the NO
x
and SO
2
cap-
ture steps in Powerspans ECO multipollutant control technology
(Figure 5). Once the CO
2
is captured, the ammonium bicarbonate
solution is regenerated to release CO
2
and ammonia (NH
3
). The
NH
3
is recovered and sent back to the scrubbing process, and
the CO
2
is in a form that is sequestration-ready. Ammonia is not
consumed by the scrubbing process, which creates no separate
by-product.
FirstEnergy and Powerspan plan to demonstrate the ECO
2
process
at pilot scale at the utilitys R.E. Burger plant in Ohio early next
year. The ECO
2
pilot unit will process a 1-MW (equivalent) slip-
stream (20 tons of CO
2
/day) from the still-operating 50-MW Burger
ECO unit with a goal of a 90% capture rate. The captured CO
2
will
be pumped to and into an 8,000-foot-deep test well drilled at the
Burger Plant earlier this year.
Powerspan estimates that a commercial ECO
2
system should be
able to capture and compress 90% of the CO
2
emitted by a conven-
tional coal-fired plant at a cost of about $20/ton. The company
expects that a full-scale ECO
2
system will cost about $500/kW, so
a system for a 500-MW plant would cost around $200 million, as-
suming that an ECO system is already in place.
FirstEnergy is collaborating with the Midwest Regional Carbon
Sequestration Partnership on the sequestration test project. It
appears to be the first to attempt to demonstrate both CO
2
cap-
ture and sequestration at a conventional coal-fired power plant.
Powerspans CEO, Frank Alix, said, Assuming that the ECO
2
pilot is
a success, we expect our first commercial demonstration project
to begin operating in 2011, and full-scale commercial units to be
operating by 2015.
5. Another gas bites the dust. How the ECO and ECO
2
treatment processes can be integrated. Source: Powerspan
From ESP or
fabric filter
Induced-draft
fan
Reactor
Wet ESP
ECO upper loop
Separator tray
Separator tray
ECO lower loop
Ammonia capture
CO
2
product
Upper loop
recycle tank
Mercury
adsorber
Ammonia
capture tank
Reagent
tank
Makeup
water
Reagent
makeup
Note: ESP = electrostatic precipitator.
Wet
stack
To by-product
processing
Compressor
Cooler
D
r
y
e
r
R
e
g
e
n
e
r
a
t
o
r
Heat
exchanger
Steam
CO
2
scrubbing
054 TP_Ohio.indd 60 10/1/07 9:11:09 PM
CIRCLE 33 ON READER SERVICE CARD
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POWER
|
October 2007 62
COAL-FIRED PLANTS MAP
A
B
A
Z
B
C
BN
B
S
C
A
CH
C
I
CO
DG
I
D
KS
M
M
T
ND
NE
NL
N
M
N
V
OK
O
R
SD
SI
SK
SO
TX
U
T
W
A
W
Y
BN
B
S
CH
C
I
DG
NL
SI
SO
5,50014,000
2,5005,500
9002,500
0900
0

1
,
3
0
0
1
,
3
0
0

4
,
2
0
0
4
,
2
0
0

2
3
,
2
0
0
Colored by generation
(thousand MWh in 2006)
Sized by coal consumption
(thousand tons in 2006)
U.S. coal-fired power plants
062 PlattsMap.indd 62 10/1/07 9:11:58 PM
October 2007
|
POWER 63
COAL-FIRED PLANTS MAP
A
L
AR
C
T
IN
M
A
MB
M
I
MN
NB
N
Y
ON
QC
V
T
by MWh and fuel consumption
Courtesy: Platts. Data source: Platts Energy Advantage and
POWERmap. All rights reserved.
062 PlattsMap.indd 63 10/1/07 9:12:04 PM
www.powermag.com POWER
|
October 2007 64
COAL COMBUSTION
Managing air to improve
combustion efficiency
The average pulverized coalfired coal plant is more than 30 years old and
has a heat rate in the neighborhood of 10,300 Btu/kWh operating with an
off-design coal. Add a high load factor (or increased cycling service),
squeezed maintenance budgets, reduced plant staff, and increased time
between overhauls to meet the plants pro forma, and youve got major
stress. Fortunately, there is a way to come in under your NO
x
budget and
lower the stress. Breathe deeply and read carefully.
By R.F. Storm, Stephen K. Storm, and Stephen G. Hall, Storm Technologies
M
ost plant staff members periodical-
ly take a CPR course as part of their
ongoing qualification program. Its
a short and simple class that folks may take
for granted after repeating it so many times.
You may never use the skill, but when you
do, your response must be nearly automatic.
So heres a pop quiz: Whats the first step in
performing CPR? Know your ABCs: Check
the airway and then breathing and circula-
tion. The mnemonic is easy to remember and
can save a life.
A similar simple but effective approach
can be used to assess the performance of a
coal-fired steam generator. Manage the air-
flow first and then the fuel flow to obtain the
best combustion results possible given the
constraints of the boiler design. Hopefully,
the results will be similar to those achieved
with CPR: a long and productive life.
Later in this article we present a case study
for a typical 500-MW pulverized coal (PC)
boiler and apply a set of best practices to
measure, balance, and control furnace inputs
to achieve higher combustion efficiencies
and lower NO
x
emissions. When you see the
results, you may decide that CPR stands for
coal plant revived.
Get the airflow right
Ideal pulverized coal combustion occurs
when a coal particle is burned completely
and all of the carbon is converted to CO
2
,
all H
2
is converted to H
2
O, and all sulfur
is converted to SO
2
. Deviations from ideal
combustion are indicated by higher-than-
desired carbon in ash, secondary combus-
tion at the superheater, and objectionable
CO levels in the flue gas. Most large utility
boilers were originally designed to operate
with 15% to 20% excess air (Figure 1) to
make up for air and fuel imbalances in the
burner belt. Critical tolerances for the com-
Flue gas inlet Air outlet
Flue gas outlet Air inlet
Fan-boosted
overfire air
(20%)
Secondary air
(55%65%)
Primary
airflow
(15%20%)
Fuel
Flue gas
Excellence in
pulverizer performance
and fuel line balancing results in
uniform flames here
Clean airflow balanced via square-edged
orifices to 2% and expedited with the
usage of STI fuel line orifice housings
Venturi calibrated by Hot-K calibration
to precisely control primary airflow 2%
measured vs. indicated accuracy
Fuel line orifice housing
for balancing to +/ 2%
Microprocessor,
gravimetric, load cell
stock coal feeder
Desirable air/fuel ratio
1.8 #air/# fuel above
the minimum airflow setpoint
Throat velocity must
be above 7,000# fpm at the
minimum airflow setpoint
Secondary air
venturi equipped
with Hot-Kcalibration
and proven for
23% measured
vs. indicated accuracy
1. Different paths. Air commonly takes three different paths, but it all ends up in the
furnacewhether you want it there or not. The key to achieving excellent combustion ef-
ficiency is properly managing the amount of air supply and plugging the leaks. Source: Storm
Technologies
2. Short course. These are the key design and operating measures for combustion air, from
the pulverizer to the furnace, for a typical 500-MW coal-fired plant. Source: Storm Technologies
064 SR_CoalCom.indd 64 10/1/07 9:13:45 PM
October 2007
|
POWER 65
COAL COMBUSTION
bustion airflow paths to the boiler are noted
in Figure 2.
Within most utility furnaces, the resi-
dence time for coal particles to completely
burn out is only between 1 and 2 seconds
(Figure 3). Boilers designed in the 1970s had
pre-low-NO
x
burners, and the short furnace
residence time was compensated for by in-
tense and turbulent mixing, with a very high
flame temperature. The intensity of burner
belt combustion, with the resultant high NO
x

production, is unacceptable today. Todays
typical low-NO
x
burners have evolved into
systems that inject combustion air into two,
three, or four air zones at the burners (sec-
ondary air). For further reduction, most low-
NO
x
firing systems utilize multiple levels of
combustion airflow for staged combustion. A
best practice is to ensure that combustion is
completed in the furnace with a stoichiome-
try of 1.15 to 1.20 (excess air of 15% to 20%)
before the products of combustion reach the
superheater.
You may remember how automotive emis-
sions were significantly reduced by adopting
electronic fuel injection systems to precisely
regulate the amount of air and fuel reaching
each cylinder. Later, combustion chamber
designs were altered to stage and slow down
combustion. That reduced peak combustion
temperatures and thereby lowered the rate
of NO
x
formation. Consumers observed
reduced emissions but also a significant
improvement in automobile performance.
Today, a computer can control individual
piezoelectric injectors to create five or more
injections per cycle in modern diesel engines
to optimize performance and emissions un-
der any conceivable operating condition.
And it all started with applying combustion
fundamentals to the internal combustion
engine and leveraging IT advancements for
more precise control and data collection.
The principle also holds with power plant
combustion fundamentals. Todays coal-fired
boilers continue to make similar progress
with parallel commercialization of low-NO
x

burner technology, control systems, smart
closed-loop systems, and neural networks.
Improvements in pulverized coal combustion
with solid fuel injection systems are in our fu-
ture; they closely parallel the product devel-
opment trajectory that resulted in advanced
performance and emission controls for auto-
motive internal combustion engines.
The solid fuel injection system approach
for a natural gaslike rapid response to load
changes can be mimicked by improving air-
flow measurement and control.
Primary airflow in a PC-fired boiler is
akin to the gas valve of a gas-fired boiler.
Achieving rapid response of pulverized coal
to the furnace requires accurate and respon-
sive changes in the transport or primary air-
flow. In-furnace NO
x
reduction by staged
combustion or lean burn is possible by
using measured and controlled overfire air-
flows. This can be effective when pulveriz-
ers are optimized for the best fineness and
distribution as a complement to the optimum
proportioning of total air and fuel delivered
to the furnace.
The question is, How do we get there
from here?
Back to the fundamentals
Although most of the general principles used
in the power industry today are correct, the
fundamentals are rarely appreciated. A 1- to
2-second residence time in the furnace for
the entire combustion process doesnt leave
much time for the air and fuel to migrate from
fuel-rich and air-rich zones, mix to achieve
optimum theoretical air and fuel ratios, and
completely combust. Some furnaces are even
equipped with water-cooled platens for en-
hanced heat transfer. But these may actually
be counterproductive because they inhibit
the left-to-right mixing of fuel-rich and air-
rich products of combustion, even if there is
sufficient residence time (Figure 4).
Low-NO
x
burners purposely and deliber-
ately stage combustion for a slower burn with
a flame of reduced intensity. The reduced-in-
tensity flame has a lower temperature, gener-
ates less NO
x
, and releases less fuel-bound
nitrogen. Staged combustion may reduce
flame intensity, but it causes increased flame
lengths. Burners designed in the 1970s or
earlier were developed for high-intensity
and closely spaced burners with high heat
releasetypically between 150 and 200
mmBtu input. They produced a flame length
of between 15 and 20 feet. A similar sized
low-NO
x
burner with lower flame intensity
Furnace
residence time
12 seconds
3. Burning desire. Best practices dictate staged combustion with multiple air zones in
the furnace to manage NO
x
production. Many boilers have relatively short furnace boxes with
residence times below the desired 1 to 2 seconds. Source: Storm Technologies
Heating and minor
devolatilization
Ignition
Major
devolatilization
Burning of
carbon
0.0 0.2 0.4 0.6 0.8 1.0
Time (seconds)
4. Time in stir. This chart shows how the typical coal particle spends its residence time in a
coal-fired boiler. Smaller particles (better fineness) increase the amount of carbon changed to CO
2

and decrease the amount remaining in flyash leaving the boiler. Source: Storm Technologies
064 SR_CoalCom.indd 65 10/1/07 9:13:47 PM
POWER
|
October 2007 66
COAL COMBUSTION
and internally staged combustion may have
a flame length of 50 to 60 feet (or more if
operating below a stoichiometry of 1.0).
The inevitable flame impingement on super-
heater and other radiant and convection tubes
will drive up O&M costs as a result of tube
replacement or will reduce plant availability
when tube leaks are repaired.
Active combustion in the superheater also
contributes to increased slagging, fouling,
hot tube metal temperatures, high desuper-
heating spray water flows, and the produc-
tion of popcorn ash cinders that contribute
to selective catalytic reduction system and
air preheater fouling. The resulting carryover
of flames into the superheater usually results
in one of two conditions:
Flame quenching below the temperature
at which carbon combusts, which results
in higher carbon in ash than desired.
Extremely high flue gas temperatures that
result from secondary or continued com-
bustion in the superheater.
Fuel balancing and the optimization of
coal and air from the pulverizers are essen-
tial. The compartmentalized windbox on a
utility boiler is superior to an open plenum
windbox, as it can closely proportion the
combustion airflowand fuel flowfrom
each pulverizer, assuming the flow-mea-
surement devices and control dampers are
optimized. However, with longer diffused
and less-intense flames that require longer
residence time, fuel and air imbalances and
secondary combustion results are exacer-
bated. The fuel-rich portions of the flames
will extinguish themselves when the oxygen
is depleted. And with fuel line imbalances,
the burners and regions of high flame tem-
peratures create very high NO
x
levels by the
combination of nitrogen in air, thereby in-
ducing greater thermal NO
x
.
Furthermore, the combustion process is
complicated by fuel and air imbalances that
often range up to and beyond 20%. For ex-
ample, take a burner operating at +10% fuel
and 10% secondary air. The stoichiometry
with an average of 20% excess air would
be 1.0. That is precisely the proper amount
of oxygen to burn all carbon to CO
2
and all
H
2
to H
2
O. The other burners might have
low fuel and high air in the neighborhood
of +40% excess air, which will result in a
lean, hot burner zone that produces very high
NO
x
. Often overlooked is the fact that boil-
ers are designed for zero air in-leakage from
the furnace to the economizer outlet flue gas.
More on this in a moment.
Restore balance
The preferred approach to combustion op-
timization, in our experience, is to measure
and control all of the furnace inputs of air
and fuel to achieve the original design pro-
portions of fuel and combustion air reaching
the furnace. This means that getting the in-
puts right is the first step. Controlling NO
x

and SO
x
with postcombustion solutions is
the second.
Complicating the operation of a solid fuel
system are the furnace exit slagging and
fouling considerations. Not only must com-
bustion be optimized for minimum NO
x
, but
combustion must also be completed before
furnace exit gases enter the superheater.
Case in point
A case study on improving combustion ef-
ficiency and emissions on a typical 500-MW
wall-fired boiler will clearly illustrate these
points (Figure 5).
There are many varieties of approaches
to combustion airflow measurement and
control. In our experience the most reliable
and accurate methods use a venturi or flow
nozzle to measure airflow. Many believe that
these devices cannot be installed in the close-
coupled ductwork of airflow entering a coal
pulverizer or around the bends of ductwork in
When assuming zero leakage, the stoichiometry
is 1.14 or 14% excess air at this point. However,
if 7% leakage were to occur upstream of the O
2

probes, this would relate to a stoichiometry of
less than 1.0 at the furnace exit.
When assuming zero leakage, the burner belt
stoichiometry is 0.912 (average) or 8.8% excess
air. Note: If 7% leakage were to occur upstream
of the O
2
probes, this would relate to a
stoichiometry of 0.762 (average); if fuel
imbalances are 20%, then stoichiometry would be
much lower in the fuel-rich regions.
Unit load maximum continuous rating (gross MW) 500
Heat rate (Btu/kWh) 10,000
Fuel higher heating value (Btu/lb) 11,500
Excess air 15.00%
% Carbon 63.25%
% Hydrogen (diatomic) 4.32%
Theoretical air required (lb/lb of fuel) 8.72
Theoretical air required (lb/mmBtu) 758.12
Total air required (with excess; lb/lb of fuel) 10.026
Total air required (with excess; lb/mmBtu) 871.84
Excess O
2
2.85%
Mill air-to-fuel ratio (lb/lb) 1.8
Number of mills 5
Pipes per mill 8
Number of compartments 10
% overfire air (of total) 20.00%
Overfire air: 806,298 lb/hr
Secondary air: 2,442,584 lb/hr
5. Learn from others. Air in-leakage into a typical balanced-draft 500-MW coal-fired boiler can seriously reduce plant thermal efficiency
and negatively impact furnace O&M. This plant is operating at full load operating with 15% excess air with no air in-leakage. Source: Storm
Technologies
064 SR_CoalCom.indd 66 10/1/07 9:13:48 PM
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CIRCLE 34 ON READER SERVICE CARD
064 SR_CoalCom.indd 67 10/1/07 9:13:50 PM
POWER
|
October 2007 68
COAL COMBUSTION
an overfire air system. Not true. We routinely
use either a venturi, a flow nozzle, or both.
However, they must be properly installed and
field calibrated using hand velocity traverses.
Because of the vastly different densities of
cold air and operating temperature airflows,
we strongly recommend the Hot-K calibra-
tion and measurement verification of airflows
under actual operating conditions. Surface-
measured static pressures at the high-pressure
and low-pressure sensing taps are affected by
the boundary airflow over the internal duct
surfaces and are therefore influenced by sur-
face discontinuities.
For example, placing a venturi immedi-
ately after a primary air fan has always been
problematic. But we have successfully added
the venturi many times using our calibration
section of the venturi throat and using the
Hot-K calibration method (Figure 6). An-
other difficult application is on an exhaust-
er-equipped pulverizer such as deep bowl,
Raymond bowl mills. The ductwork arrange-
ment shown in Figure 7 is typical of our ap-
proach to primary airflow measurement on
pulverizers operating under suction pressure.
Commonly used averaging pitot tube ar-
rays, with straightening vanes such as those
shown in Figure 8, have functioned satisfac-
torily in clean air. However, when regenera-
tive air heaters are used, as is common on
large PC boilers, a certain amount of the fly-
ash is recirculated as the air heater rotates,
resulting in honeycomb pluggage (Figure
8). Plugging is another reason to conduct
periodic inspections and to implement a pro-
gram of periodic airflow calibrations using
the Hot-K method.
The obvious reasons to accurately mea-
sure airflows to the furnace are to ensure that
inputs to the burner belt are correct and to
establish those airflows as the baseline for
future testing. Often we find there is simply
insufficient furnace combustion airflow to
complete combustion. Because the average
large utility boiler is more than 30 years old,
it should not be a surprise that many units
not getting a good breath of air are of the
balanced-draft design and have significant
tramp air in-leakage. Air leaks not only
contribute to a heat rate penalty, but they
also contribute to poor furnace performance,
slagging, fouling, and higher-than-optimum
carbon-in-ash content.
Worse yet, air in-leakage goes undetected
by normal plant instrumentation. That is,
excess oxygen measured at the economizer
outlet is assumed to have entered the fur-
nace through the burners or overfire air ports.
In fact, sometimes as much as 20% of the
total air thought to have entered the furnace
actually entered the boiler convection pass
via what should be the postcombustion flow
path of the products of combustion.
6. Squeeze job. A high-accuracy venturi can be placed between a close-coupled fan and a
pulverizer. Source: Storm Technologies
7. Drawing a vacuum. A similar con-
figuration with a venturi is possible on pulver-
izer ductwork thats typically under negative
pressure. Source: Storm Technologies
8. Straight and narrow. A honeycomb flow-straightener was partially plugged by
flyash recirculated by the regenerative air heater. Courtesy: Storm Technologies
064 SR_CoalCom.indd 68 10/1/07 9:13:50 PM
Chemical and Pharmaceutical Group
PRODUCTS
Solvay Chemicals, Inc.
1.800.SOLVAY C (800.765.8292)
www.solvaychemicals.us/solvair
Copyright 2007, Solvay Chemicals, Inc. All Rights Reserved.
DSI systems which use rened trona to clean the air effectively
eliminate acid gas emissions such as SO
2
, SO
3
and HCl. Power
generating plants are rapidly moving toward implementation
of these systems, but the escalating demand for product
raises the questions: how much trona is available, and
how long will supply last?
Trona is mined in the Green River Basin of Wyoming,
the largest deposit in the world, and supply is projected
to last into the hundreds of years. It is used for air
pollution control from Alaska to Maryland, and from
Washington State to Florida. As the only producer
of SOLVAir

Select 200, or rened trona, in the

United States, Solvay Chemicals, Inc. can provide
product when and where needed, now and into the
future. It is the product of choice for DSI systems.
For an in-depth look at how SOLVAir Select 200 works
to clean the air, go to www.solvaychemicals.us/solvair
or call us at 800-SOLVAY-C. The SOLVAir professionals, with
the experience, the products and the technologies, can answer
any questions you may have about SOLVAir Select 200 and
its applications.
SOLVAir

Select 200 Trona

No reservations necessary!
CIRCLE 35 ON READER SERVICE CARD
makeupads.indd 97 10/3/07 10:35:16 AM
POWER
|
October 2007 70
COAL COMBUSTION
Plugging air leaks
Now that we have gone through the calcu-
lations, lets review why air in-leakage can
really siphon points off a plants heat rate,
performance, and unit reliability. As you can
see in Figures 9 and 10, excess air entering
the furnace or convection path has a large
impact on true excess air. Data for these
figures were taken upstream of the air heater
and prior to the excess O
2
probes.
A mere 7% air infiltration upstream of the
excess O
2
probes with accepted air and fuel
imbalances correlates with a burner stoichi-
ometry of about 0.85, or 15% excess air re-
quired to complete combustion (Figure 9).
When fuel or airflow is imbalanced more than
10% and/or overfire air is deep staged to +20%
for NO
x
control, stoichiometry will be even
lower. Units retrofitting flue gas desulfuriza-
tion systems and/or firing high-sulfur coals
understand that sulfur and chlorine are harm-
ful corrosion compounds and accelerate water
wall corrosion in a reducing atmosphere.
Users should consider periodic water-
cooled high-velocity thermocouple probe
measurements of furnace exit flue gas excess
oxygen. Total airflow measurements of pri-
mary airflow, secondary airflow, and over-
fire duct airflows should also be periodically
verified for calibration. Calibrations should
be completed to complement acceptable mill
performance testing that ensures desirable
air-fuel ratios and acceptable coal fineness.
Another problem: Todays low-NO
x
burn-
ers with multiple stages of overfire air and
flame-attachment burners are designed to
create fuel-rich flame cores and result in less
NO
x
production. Often, burners of scientifi-
cally proven good designs self-destruct due
to overheating and metal deformation. Sel-
dom is this destruction due to the burner de-
sign itself.
Our experience has been that burner reli-
ability and NO
x
reduction performance are
largely related to the fuel balance, combus-
tion airflow balance, accuracy of flow indi-
cations, residence time (some furnaces have
more time by design than others), air in-leak-
age, burner line pluggage, burner type, and
primary airflow velocitiesamong a num-
ber of other factors.
Some original equipment manufacturers of
burners utilize underfire air, curtain air, side
wall air, and/or multiple overfire air injection
ports throughout the boiler. Sometimes these
ports are designed for good scientific reasons.
However, most of the time they are used as a
back-up source for NO
x
reduction to reduce
the burner belt flame intensity and stoichiom-
etry while delivering uncontrolled and unmea-
sured airflow. By introducing unmeasured,
uncontrolled airflow, precision in measuring
and control of the stoichiometry is lost.
We also routinely observe that imprecise
measurement and control of combustion air-
flow, coupled with problematic pulverizers,
is the root cause of localized reducing atmo-
spheres in the burner belt zone. All too often
the result is aggressive fireside tube wast-
age, especially with higheriron content and
higher-sulfur bituminous coals.
R.F. (Dick) Storm (rfstormsea@aol.
com) is president of Storm Technologies
(www.stormeng.com). Stephen K. Storm
(skstorm1@aol.com) is a vice president of
the company and its manager of technical
field services. Stephen G. Hall (stephen
.hall@stormeng.com) is a field service
engineer for Storm Technologies.
20
15
10
5
0
5
10
15
20
100
Unit excess air (%) Burner excess air (%)
0 1 2 3 4 5 6 7 8 9 10 100
Percent leakage
E
x
c
e
s
s

o
x
y
g
e
n

(
a
c
t
u
a
l

%
)
9. Air leaks reduce efficiency. Actual excess air as a function of casing leakage. The
data points are based on a 3% O
2
setpoint with 20% overfire air. Source: Storm Technologies
10. Inaccurate measurements. A correlation of true in-furnace oxygen versus the
assumed oxygen levels measured at the O
2
probes with varying levels of leakage upstream of
the O
2
probes. Source: Storm Technologies
100
3.0
2.5
2.0
1.5
1.0
0.5
0.0
0 1 2 3 4 5 6 7 8 9 10 100
Percent leakage
E
x
c
e
s
s

a
i
r

%
064 SR_CoalCom.indd 70 10/1/07 9:13:56 PM
Mitsubishi Vertical Waterwall Supercritical
Sliding Pressure Coal Fired Boilers
under commercial operation since 1989
Vertical Waterwall furnace with rifled tubing
Our Vertical Waterwall furnace design features internal rifled tubing. This
key feature provides a simplified configuration which drastically reduces field
welds during construction as well as improved furnace tube cooling
resulting in a cleaner furnace. Mitsubishis Circular firing design enables
constant steam and water temperature distribution, even at partial loads.
Our dual-flame A-PM burner and in-furnace NOx reduction system in conjunction with our fine-grinding MRS
pulverizer with rotary classification delivers the lowest emissions and unburned carbon in fly-ash throughout
a wide range of fuels.
Successful Projects Fueled by Proven Design
Mitsubishi supplies a variety of Supercritical Sliding Pressure Coal Fired Boilers ranging upto 1000MW with steam
conditions in excess of 1100F. The captioned projects operate our Mitsubishi boilers and successfully accomplish
the goal of supplying clean, stable and highly efficient energy to both communities and industries.
Mitsubishi combustion technology and boiler design the cleaner greener compliment to coal fired plants
around the world.
Mitsubishi Power Systems Americas, Inc. 100 Colonial Center Parkway Lake Mary, FL 32746 USA 1-407-688-6100 www.mpshq.com
A Long Line of
Proven, Clean
Coal Designs
Maizuru Power Station
900MW, 3550psi x 1100/1100F
Started Operation 2004
Matsuura Power Station
700MW, 3627psi x 1008F/1054F
Started Operation 1989
Misumi Power Station
1000MW, 3684psi x 1119F/1116F
Started Operation 1998
Kobe Steel Power Plant
700MW, 3627psi x 1054F/1054F
Started Operation 2002
CIRCLE 36 ON READER SERVICE CARD
064 SR_CoalCom.indd 71 10/1/07 9:13:58 PM
www.powermag.com POWER
|
October 2007 72
BOILER CLEANING
Harness detonation waves
to clean boiler tubes
Air and steam sootblowers have been the power industrys solution to the slag-
ging and fouling of boiler convective passes caused by flyash and com-
bustion products. Manual cleaning systems have been superseded by
computers and neural nets, but the basic cleaning apparatus remained un-
changeduntil now. Say hello to detonation waves. They can knock those
deposits loose while markedly improving boiler heat transfer efficiency.
By Kirk Lupkes and A. Tofa McCormick, Pratt & Whitney MMI
O
ne of the big surprises facing plants
that switch from a more or less stan-
dard bituminous coal to a western coal
is the increase in slagging and fouling. Many
plants have reported significantly more foul-
ing with Powder River Basin (PRB) coal than
with their previous coal. Coping with more
fouling usually means modifying either the
number, type, or location of sootblowers as
well as increasing their operating frequency.
A number of automation systems are also
available that use thermodynamic models of
the steam generator to predict type and fre-
quency of cleaning; others use sensors in the
gas path to report when tube surfaces need
cleaning. The one constant for nearly a decade
has been the mechanics of sootblowing.
Failing to get your gas pass surface clean-
ing regimen house in order is costly. Ac-
cumulated ash causes steam generators to
operate less efficiently. That means more
fuel is burned and the death spiral begins.
The challenge is that every boiler, fuel, and
operating scenario is unique and typically
requires a customized solution to be effec-
tive. The right combination can be elusive.
Lower efficiency levels are indicated by an
increase in overall pressure drop, exit gas
temperature, and/or fan power; additional
tube erosion and leaks; ongoing high O&M
expenses; and more-frequent unplanned out-
ages solely for cleaning. If this sounds like
your plant, we just might have the solution
you are looking for.
Light the fire
A new technology was introduced to the U.S.
power generation industry about five years
ago. It uses detonation cleaning, derived from
Pratt & Whitneys Pulse Detonation Engine,
which is used to power a supersonic craft (Fig-
ure 1). The engineers developing the futuristic
pulse detonation engine could not have fore-
seen that this technology would migrate into
1. Shock wave. This is an artists concept of a pulse detonation engine powering a space-
craft. The concept is simple: A fuel/oxidizer mixture fills a tube and is ignited. The rapid burning
transitions into a detonation wave that travels though the cylinder at up to eight times the
speed of sound. Combustion is completed before the gas has had time to expand. The result-
ing explosive pressure is then converted into thrust for the vehicle. Courtesy: NASA Marshall
Space Flight Center
2. Simple system design. A typical Pratt & Whitney ShockSystem combustor used for
on-line boiler cleaning. Courtesy: Pratt & Whitney MMI
072 BoilerClean.indd 72 10/1/07 9:14:58 PM
October 2007
|
POWER 73
BOILER CLEANING
the electric power industry as the most novel
boiler cleaning technology to come along in
many years. The new ShockSystem detona-
tion cleaning combustor (Figure 2) has noth-
ing to do with using dynamite or detonating
cord when a unit is off-linethe most inva-
sive cleaning method still in use. Nor does it
refer to other on-line cleaning system options
such as sonic horns or water canons.
The process of creating a detonation con-
sists of injecting a mixture of fuel and oxi-
dizer into a chamber, igniting this mixture,
transitioning the resulting combustion wave
to a detonation wave, and then purging with
air to prepare for the next cycle (Figure 3).
The detonation wave travels at supersonic
speeds within the combustion chamber and
quickly decays to a blast wave once it leaves
the chamber and propagates in open space
(or within a large structure, such as a boiler).
The blast wavealso known as a pressure
wave, a pressure pulse, or simply an im-
pulsehas the energy required to remove
sintered and unsintered ash in the backpass
of boilers. This pressure wave has little to
no negative effects on tube erosion, and the
required operational frequency is much less
than that of acoustic horns.
Detonation cleaning creates a blast wave
that propagates omnidirectionally from the
combustor exit. To date, all applications
have been mounted outside the boiler wall
and direct the blast wave through a penetra-
tion. These applications have been installed
on both positive and balanced draft boilers.
The benefit of this type of installation is that
the combustion chamber can be installed
along the boiler wall or routed around ex-
ternal structures without risking the loss of
a lance tube due to bending, getting stuck, or
breaking off during operation. Another ma-
jor advantage boiler operators see is that the
pressure waves are controlled and applied
on-line, thus eliminating unnecessary out-
ages. The long-term effects on tube erosion
are minimal, plant emissions are lowered,
exit gas temperature is decreased, and over-
all boiler efficiency is increased.
Compare your
maintenance options
Detonation cleanings omnidirectional blast
wave propagates through the entire tube as-
sembly, whereas sootblowing technology
is restricted to line-of-sight cleaning. Each
detonation impulse is equivalent to mul-
tiple 6-minute sootblowing cycles, and one
combustor can replace up to four sootblow-
ers, depending on the boiler configuration.
A standard detonation cleaning schedule
calls for 10 pulses (each lasting just a few
milliseconds), repeated every 12 hours per
combustor. Sootblowers typically require
one 6-minute cycle every 4 hours per soot-
blower. Detonation cleaning is successful in
continuous-maintenance mode and remedial
cleaning mode, removing established depos-
its upon initial installation. Sootblowers are
used principally in continuous-maintenance
mode and are ineffective at removing ash that
has been allowed to accumulate and sinter.
Detonation cleaning combustors reside
outside of the boiler, whereas sootblowers
must traverse inside the boiler. The Pratt &
Whitney ShockSystem has only two routine
maintenance requirements: replacement of
fuel/oxidizer filters and replacement of the
combustor spark plugnot unlike routine
service for your vehicle. Compare that to
the maintenance required for standard re-
tractable-lance sootblowers, where worn or
damaged nozzles and gearbox seals; warped,
melted, or corroded lance tubes; and dam-
aged feedtubes require constant attention.
Reduce operating costs
A detonation sootblower offers huge cost
savings compared with traditional air and
steam sootblowers, as shown in the table.
Actual savings are likely even higher, as det-
onation sootblowers can often replace mul-
tiple traditional sootblowers. Likewise, there
is a cost benefit associated with eliminating
outage periods for either sootblower repairs
or for additional boiler cleaning.
The industry has also used omnidirection-
al acoustic cleaning without the negative tube
erosion effects of traditional air and steam
sootblowers. The results from acoustic horns
have been moderate at best. Acoustic horns
create sound waves, at various frequencies,
to dislodge unsintered ash in the lower-tem-
perature regions of the backpass. They have
1. Fill with fuel and air
2. Ignite
3. Transition to detonation
4. Expansion
5. Blowdown
6. Purge with air
Air
Fuel
Ignition source
Detonation wave
3. Inside workings. This drawing illustrates the ShockSystem operating cycle. Source:
Pratt & Whitney MMI
Costs per single
sootblower or combustor Air sootblower Steam sootblower
ShockSystem
detonation sootblower
Flow rate 5,100 scfm 12,000 lb/hr Proprietary
Cycles per day 6 6 20
Cycle time (minutes) 6 6 NA
Operating days per year 310 310 310
Usage cost $0.0005/scf $5/ton $0.28/detonation
Make-up water cost NA $2/1,000 gallons NA
Cost per cycle $15.30 $3.30 $0.28
Cost per day $137.70 $29.70 $5.60
Annual operating cost $42,687 $9,207 $1,736
Note: NA = not applicable.
Economic alternative. O&M costs with the ShockSystem detonation system may be
less than with conventional sootblower systems. Source: Pratt & Whitney
072 BoilerClean.indd 73 10/1/07 9:15:02 PM
POWER
|
October 2007 74
BOILER CLEANING
also been installed on environmental compo-
nents further downstream. Even here, acous-
tic horns often do not deliver the advertised
performance. In certain applications acoustic
horns are required to run much more often
than originally envisioned in an effort to im-
prove their performance. This has caused a
high level of concern for long-term boiler
integrity, considering the relatively minimal
cleaning achieved.
Easy installation
Detonation sootblowing also offers additional
flexibility for equipment placement. Conven-
tional sootblowers require large deck spaces
on which to rest the retractable lance tubes
when not in operation. Detonation combus-
tors can be installed in many different config-
urations without losing any cleaning strength.
Detonation cleaning products can be in-
stalled along the boiler wall and can be bent to
avoid obstacles. In a bent tube configuration
the outer edge of a combustor is only about
6 feet from the boiler wall. Nestling multiple
tubes optimizes cleaning while minimizing
the devices physical footprint. Because deto-
nation cleaning products replace sootblowers
in many applications, they can also be placed
in existing sootblower locations by adapting
the sootblower penetrations to fit the combus-
tor chamber (Figure 4).
Louder is better
Detonation-based on-line boiler cleaning
technology is not a turbocharged acoustic
horn. The blast wave created by a detonation
combustor is a discrete pressure discontinui-
ty, which is fundamentally different from the
cyclic waves of acoustic horns. The pressure
amplitude is also orders of magnitude higher
for a blast wave compared with an acoustic
horn sound wave.
Although acoustic technologies are om-
nidirectional in nature, each blast wave im-
pulse from a detonation combustor delivers
far more energy than an acoustic horn, oper-
ating in the 25- to 220-Hz range, can deliver
in an entire dayeven if run continuously.
Measured on the decibel scale, the blast
wave produced by the ShockSystem inside
the boiler is greater than 175 dB, whereas
acoustic horns run between 130 and 150 dB.
Outside the boiler, noise levels have been
measured in the 100 dB rangewell below
acceptable OSHA limits and requiring no
more hearing protection than is typically
used at a power plant.
Blast effects
Detonation cleaning is successful in continu-
ous-maintenance mode and remedial clean-
ing mode where established deposits must
be removed. Acoustic cleaning is used pri-
marily in a continuous-maintenance mode
and is inadequate for removing ash thats
been allowed to accumulate and sinter. A se-
ries of before and after photos posted on the
ShockSystem web site (www.shock-system.
com) illustrate the cleaning effectiveness of
the system.
Results of demonstrations as well as per-
manent installations of the ShockSystem
have shown on-line detonation cleaning in
various boiler regions to be as effective as or
more effective than conventional methods in
controlling ash deposit accumulation, limit-
ing plant outages, and improving heat rate
(Figure 5).
The non-line-of-sight cleaning ability of
the blast wave cannot be achieved by con-
ventional sootblower jets. The detonation
cleaning device operates during normal boil-
er operations, thereby reducing the number
and/or duration of plant outages required for
cleaning otherwise inaccessible locations.
This new technique is expected to result in
less tube wear attributable to particle impact
erosion, thanks to the lower entrained ash
velocity associated with the blast wave. This
translates into longer unit life and a reduced
number of unplanned outages.
The on-line detonation cleaning combus-
tor does not burden valuable plant resources
such as steam or high-pressure air (and the
associated compressors). This advantage is
expected to result in a significantly lower
cost of operation. Another advantage relative
to conventional sootblower technology is that
the on-line detonation cleaning device has
fewer mechanical parts, because it does not
need to enter the boiler or be retracted. That
means reduced maintenance cost. Moreover,
the detonation combustor can be configured
in a variety of ways, enabling installations
in more confined areas than conventional
retractable sootblowers, which commonly
require a long, open-space external to boiler
for installation.
Kirk Lupkes (kirk.lupkes@pw.utc.com)
is the engineering manager of Pratt &
Whitney MMI. A. Tofa McCormick
(andrew.mccormick@pw.utc.com) is a
senior analyst in the Marketing &
Communications group.
4. Many installation options. Detona-
tion sootblowers give the owner many options
for installation, including (top to bottom): bent
combustor, nestled combustor, and straight
combustor configurations. Courtesy: Pratt &
Whitney MMI
5. Its a blast. The omnidirectional nature
of the blast releases energy in three dimen-
sions, thereby giving the heat transfer sur-
face a thorough cleaning. The process has
three stages (top to bottom): First is bridging
and platenizationshown in a cross section
of a boiler before cleaning, then a shockwave
moves through the boiler tube space when
the ShockSystem is ignited, and, finally, par-
tial cleaning of the tube surfaces is illustrat-
ed after the shockwave dissipates. Cleaning
can be repeated as needed. Courtesy: Pratt
& Whitney MMI
072 BoilerClean.indd 74 10/1/07 9:15:02 PM
MAGENTA (MI) - ITALY
via Robecco, 20
Tel. +39 02 972091
Fax +39 02 9794977
e-mail: stf@stf.it
www.stf.it
BURMEISTER & WAIN ENERGY A/S
DK - 2820 Gentofte.Denmark
jaegersborg Alle 164
Tel. +45 39 45 20 00
Fax +45 39 45 20 05
e-mail: info@bwe.dk
www.bwe.dk
CIRCLE 37 ON READER SERVICE CARD
072 BoilerClean.indd 75 10/1/07 9:15:07 PM
www.powermag.com POWER
|
October 2007 76
MATERIALS
Making the grade
with stainless steel tubing
Tubing manufacturers have many alternatives for manufacturing and test-
ing stainless steel tubing for feedwater heater and condenser applica-
tions. ASTM specifications are fairly generic in nature and only specify
the minimum tube design and testing requirementswhich may not be
sufficient to provide the appropriate quality for a critical power plant
application. To make the right material selections, its helpful to under-
stand how welded stainless steel tubing is manufactured and its quality
is checked.
By Daniel S. Janikowski and Ron Roth, Plymouth Tube
W
elding techniques have matured
to the point where almost every
austenitic, duplex, and full fer-
ritic grade that is made in strip form can
be manufactured into a tubular product by
welding. Common grades, such as TP 304,
TP 316, and their derivatives, are chemistry
balanced to form a small amount of ferrite
during solidification. This ferrite formation
makes these grades particularly tolerant of
variations in the welding process because
the weld shrinkage during solidification is
compensated for by the different densities of
the two phases. This also allows for higher
welding speeds.
The high quality of continuously cold
rolled steel and coiled strip is one of the keys
to getting repeatable high-quality welded
tube. Currently, stainless steel coils are made
as large as 50,000 pounds and 72 inches
wide. Because of improvements in the rolling
process, thickness tolerances are commonly
held to 50% of that in ASTM specifications.
Surface finishes are commonly 20 inch
Ra or better on both sides of the strip. (Ra
is the surface roughness found as the arith-
metic average deviation of the surface val-
leys and peaks expressed in micro inches.)
The combination of high-quality surface and
tight tolerance translates into a very concen-
tric product with excellent surface quality on
both the outer and inner diameter (OD and
ID) of the tube.
Step 1: Slit the coils
The coils are slit in a continuous process to a
width needed to make the desired tube hollow
size (Figure 1). The slitting process is designed
to develop a square edge thats optimized for
the square butt weld commonly used in manu-
facturing welded tubular products.
The most commonly ordered tubing
specifications are SA 249 or SA 688 for aus-
tenitics, SA 268 or SA 803 for ferritics, and
SA 789 for duplex grades. Ferritic grades
that form martensite upon cooling are more
of a challenge. The martensite is brittle and
notch sensitive and may crack due to ther-
mal stresses prior to the annealing operation.
Some welded mills have developed propri-
etary processing and heat treatment methods
that temper the martensite before it has a
chance to crack.
Grades that do not form the compensat-
ing second phase during solidification, such
as the higher alloyed austenitics and the full
ferritics, require more care. This is typically
provided by slowing welding speeds and us-
ing tooling just behind the weld melt pool
that squeezes the pool at the same rate as the
shrinkage occurs. This technique provides
a high-integrity weld with no solidification
shrinkage defects.
1. Cut stock to width. Stainless steel coils are split to the required width to begin the
manufacturing process. Courtesy: Plymouth Tube
The high quality of continuously cold rolled
steel and coiled strip is one of the keys to
getting repeatable high-quality welded tube.
076 Materials.indd 76 10/1/07 9:16:25 PM
CIRCLE 38 ON READER SERVICE CARD
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POWER
|
October 2007 78
MATERIALS
Step 2: Uncoil and roll form
An uncoiler (Figure 2) is located to provide
precision alignment of the strip into the
roll-forming operation. The strip is then roll
formed using a series of polished rolls (Fig-
ure 3) in a progressive series (Figure 4) to
provide the two strip edges to the welding
location in the form of a square butt weld.
The number of forming stations varies
depending upon the design of the mill and
the nature of the material being welded.
There could be as few as six or as many as
14. Alignment of these stations and the un-
coiler is critical to keep the weld seam per-
fectly centered under the welding head. Any
misalignment can result in rolling of the tube
and an off-seam condition in which the weld
is not centered on the strip edges; in such
cases, only partial penetration may result.
Step 3: Weld the strip edges
Three types of welding processes are com-
monly used for welding stainless steels:
Tungsten inert gas (TIG) welding is the
most commonly used process for stain-
less steel. During TIG welding, an arc is
maintained between a shaped tungsten
electrode and the tube. Inert gas is used to
shield the molten puddle on both the OD
and the ID. To provide good shape, a tube
manufacturer may control the ID pressure
by using a seal arrangement on the ID and
controlling pressure. The TIG method
provides for a high-quality, fairly wide
weld with good penetration. The wide
width offers two advantages: tolerance to
minor rolling of the tube during the weld-
ing process and more weld reinforcement,
which enables greater cold reduction dur-
ing the in-line cold working operation.
Plasma welding is used when greater
penetration is needed on thicker walls. In
this method, high-temperature plasma is
used to provide the energy. Because of its
high localized power, this process cannot
be used on small-diameter tubing. Due to
plasmas greater penetration, welds using
this technique are narrower than those
created by TIG for the same thickness
material.
Laser welding of stainless steel tubing has
become a reality with the advent of higher-
power dependable lasers. Because of its
high energy density, the laser produces the
narrowest weld of the three methods. There
has been extensive discussion about wheth-
er this is advantageous or detrimental. With
the increased usage of laser welding, an in-
teresting controversy has developed. The
two acknowledged advantages are that it
provides the highest welding speed and
the least volume of segregated cast mate-
rial. However, the very narrow weld has
two disadvantages: increased potential for
off-seam welding and little opportunity for
weld reinforcement to take advantage of a
bead-working operation.
All three of these techniques may be con-
sidered fusion methods because the weld
becomes completely molten. Techniques
that rely upon a mushy weld zonesuch
as high-frequency induction welding or re-
sistance weldingdo not work well with
stainless steels because of their high chro-
mium levels.
Virtually all welded tubing grades that
have American Society of Mechanical En-
gineers (ASME) coverage are produced
without the addition of filler metal because
the weld is normally cold worked and heat
treated prior to shipment, thus restoring the
mechanical and corrosion-resistant proper-
ties of the original parent material. Trying to
control the results of matching a filler metal
chemistry to the base metal is more difficult
than joining to the original parent metal and
adds an additional level of complexity to the
manufacturing process.
Step 4: Cold work the weld bead
The purpose of cold working is to assist
with homogenizing the segregated as-cast
structure. Cold working can be grouped into
two categories: in-line bead working and full
cross-sectional reduction. In-line bead re-
duction localizes cold working of the weld
Pass 6
Pass 5
Pass 4
Pass 3
Pass 2
Pass 1
Flat strip
2. Carefully unroll stock. Much care
must be taken in aligning the stock with the
rolling operations. Courtesy: Plymouth Tube
3. Precision rolling. Polished rolls form
the flat stock in the required diameter in
steps. Courtesy: Plymouth Tube
4. By the numbers. Forming a round
tube from flat stock requires several gradu-
al and precision rolling operations. Source:
Plymouth Tube
5. Not recommended. Polishing of welds instead of cold working can reduce the tube
wall thickness below the minimum thickness specification. Courtesy: Plymouth Tube
076 Materials.indd 78 10/1/07 9:16:32 PM
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CIRCLE 39 ON READER SERVICE CARD
076 Materials.indd 79 10/1/07 9:16:34 PM
POWER
|
October 2007 80
MATERIALS
bead immediately following the welding op-
eration and is performed directly in-line on
the welding mill to ensure that the weld is
maintained at a known and controlled posi-
tion. Pressure is placed with tooling on the
OD surface, reinforcing the ID with a hard-
ened mandrel, and supporting the opposite
side of the tube with a roll.
For stainless steel tubing, do not consider
using a tube where polishing is used as a sub-
stitute for cold working. If seam alignment
is not perfect, the polishing operation can
selectively remove material from one side
of the weld. This results in localized regions
where the wall may fall below the minimum
thickness of the specification (Figure 5).
These locations are impossible to detect us-
ing normal testing techniques.
Step 5: Cold draw to size
Welded tubing can be full-diameter cold
worked by cold drawing (Figure 6). The pro-
cess is capable of providing approximately
half of the traditional roll-formed tolerance
and an OD and ID surface finish in the 20 to
30 inch Ra range. These tolerances are sig-
nificantly tighter than seamless cold drawn
tolerances because the welded hollow is very
concentric.
In addition, stainless steel tubing can be
cold drawn to raise the tensile and yield
strength as much as three times the annealed
value. However, in most heat exchanging ap-
plications, the benefit of cold working is not
recognized, especially when ASME Code re-
quirements are needed. The downside is that
the extra manufacturing step will add to the
product cost.
Step 6: Heat treat
For optimum corrosion resistance, all stain-
less steel alloys should be annealed after the
welding and cold working operations. Doing
so homogenizes the weld so that corrosion
cells are not initiated in the segregated re-
gion. Tubes may be annealed one at a time
in an in-line operation or in multiples in an
off-line operation.
In-line heat treating. The most common
method of annealing stainless steel tubing is
in-line heat treating (Figure 7). In this process,
the tube is heated with an induction coil to the
desired temperature and then rapidly cooled
with either water or a convective gas such as
hydrogen. The heat treatment is performed in-
line on the welding mill, usually immediately
following the in-line cold working operation.
Once the tube leaves the coil, the cooling pro-
cess begins. Alloys such as the superferritic
and superduplex alloys require a sufficient
quench to prevent formation of detrimental
second phases that can significantly reduce
corrosion resistance (Figure 8).
Die block
Die
Mandrel or plug
Tube
Jaws
Carriage
6. Better tolerances. Stainless steel tubing can be cold worked into a specific diameter
by cold drawing. Source: Plymouth Tube
7. Hot to trot. The most common method for annealing stainless steel tubing is using in-
line heat treating. Courtesy: Plymouth Tube
8. Put out the fire. In-line quenching using water is typically used. Courtesy: Plymouth
Tube
076 Materials.indd 80 10/1/07 9:16:37 PM
October 2007
|
POWER 81
MATERIALS
However, exposure to the air and water
produces a scale on the tube surface (pre-
dominately chromium oxide) that must be
chemically removed to ensure optimum
corrosion resistance. The scale is usually
porous and cracked and, therefore, not very
protective. Beneath this scale is a region of
chromium depletion that has inferior corro-
sion resistance. It is very important that this
chromium-depleted layer be removed. Me-
chanical polishing may re-embed these chro-
mium-depleted layers in the surface, having
little beneficial effect. The only sure way to
completely remove all depleted material is
to use a chemical process. This is commonly
accomplished using nitric acid or citric acid
solutions.
A chemical method has some additional
benefits for tubing. It can act as a 100% cor-
rosion test of the tubing, especially if the
process is performed before the final eddy
current test. The acid will aggressively attack
any sensitized areas or any inhomogeneities
such as manganese sulfide inclusions ex-
posed during prior processing. When an at-
tacked area is eddy current tested, the alarm
sounds and the tube is rejected.
Off-line heat treating. Alloys selected
for specific applications can be continuously
off-line annealed in a separate furnace. The
additional annealing furnace hold time, typi-
cally in the 5- to 10-minute range, results
in greater homogeneity and corrosion resis-
tance. This is especially important for alloys
with higher nickel and molybdenum concen-
trations. The welds for these alloys normally
have more segregation, and longer diffusion
times are needed for homogenization. To-
days high natural gas costs also make this
process more expensive.
A bright annealing process is one in which
a reducing gas such as hydrogen is used to
create a reducing atmosphere that minimizes
the formation of oxides. Because the surface
of a bright-annealed tube does not develop
a thick scale, the final tube surface finishes
may be smoother. Bright annealing is only
effective when the annealing temperature is
above approximately 1,850F. When bright
annealing is used, water quenching is not
an option because the water causes the for-
mation of a scale on the surface. Therefore,
bright annealing quench rates may not be
sufficient for some alloys.
Step 7: Straighten the tubes
Tubes may need additional straightening,
sizing, and cutting operations after in-line or
furnace annealing.
Step 8: Nondestructive testing
The completed tube must now successfully
undergo a series of nondestructive testing
(NDT) before it completes the manufactur-
ing cycle. These include nondestructive elec-
tric (NDE) and pressure tests.
NDE testing. Two types of NDE tests
are commonly used for stainless steel tub-
ing: eddy current testing (ET) and ultrasonic
testing (UT). ET is the standard test used for
almost all stainless steel tubing. The method
utilizes a full-encircling, differential coil that
is most sensitive to sharp abrupt defects but
not very sensitive to long gradual imperfec-
tions that bridge both sections of the differ-
ential coil. The amplitude of the signal from
the imperfection is directly related to its
abruptness. ET is fast and inexpensive, but
OD defects tend to be more easily found than
ID defects.
UT tests send a sound wave through the
wall of the tube and then listen for an echo
that is caused by a reflection from a defect.
UT testing is sensitive to longitudinal straight
defects such as cracks and incomplete welds
but is slower and more expensive.
Pressure testing. Three kinds of pres-
sure testing are commonly used on welded
heat exchanger tubing: air-under-water test-
ing, pressure differential testing, and hydro-
static testing.
The air-under-water testing method is
performed by placing air-pressurized tubes
in a well-lit tank of water while an opera-
tor walks the length of the tank looking for
bubbles. Using test pressures of 150 to 250
psi, weepers as small as 0.002 inch can be
routinely detected. Because of its low cost
and high sensitivity, this is the most common
pressure test used for welded heat exchanger
tubing.
The pressure differential testing method
became a production reality with the de-
velopment of high-sensitivity electronic
pressure sensors. The test is performed by
pressurizing two tubes to the same pressure,
closing off the pressure source, and monitor-
ing the differential pressure between the two
tubes. If the differential exceeds a predeter-
mined limit, an alarm sounds. Currently, it is
commonly used for testing welded titanium
tubing.
The traditional hydrostatic testing method
is being phased out because it is three orders
of magnitude less sensitive than air-under-
water testing. It is only used when required
by a customer specification.
Step 9: Mill quality testing
Reputable tube mills use a combination of
visual inspection, in-process eddy current
testing, and manipulation (destructive) sam-
ples to continuously monitor the quality of
the weld. Manipulation tests are designed to
specifically test the ductility of the weld in
various directions. For example, the reverse
flatten test was developed to test transverse
weld ductility on the ID surface; the flange
test is a flaring operation to test for longi-
tudinal weld ductility, primarily on the ID
surface; and a tensile test determines lon-
gitudinal weld ductility. Each of these test
methods is defined by applicable ASTM
specifications.
Corrosion tests may also be performed on
stainless steel samples, although they are not
required by the majority of ASTM/ASME
specifications. For example, a weld decay
test will detect the presence of residual fer-
rite in a weld during solidification in primar-
ily the 304 and 316 family of stainless steels.
Boiling hydrochloric acid readily attacks the
ferrite and, if present in the weld, will cause
thinning of the weld at a much faster rate
than the base metal. For a properly annealed
weld, the ratio should be 1.00 or less.
Intergranular tests are designed to detect
sensitization from slow cooling rates, insuf-
ficient annealing, or carbon and nitrogen
contamination. They are normally called for
to check if an alloy is solution annealed
a term most often applied to dissolving chro-
mium carbides, which ensure that chromium
is available to keep the stainless stainless.
These tests may not be meaningful for de-
termining whether an alloy is suitable for an
application and cannot determine if a weld is
adequately homogenized for optimum corro-
sion resistance.
Final thoughts
When ordering stainless steel tubing, remem-
ber that merely ordering to an ASTM/ASME
specification does not guarantee a good tube,
whether it is seamless or welded. In general,
ASTM/ASME specifications have minimum
requirements that may not be sufficient for a
specific application. Specification NDE test
requirements are minimums that may not de-
tect flaws that could cause problems in your
specific application, and a single NDE test is
not sensitive to all defects.
Our experience is that an eddy current
test and an air-under-water test combination
is cost-effective for finding the majority of
defects that would cause future problems in
service. Also, because most ASTM/ASME
specifications do not require a corrosion test,
consider adding one to your specification.
Realize that ASTM/ASME specifications
are necessarily broad and open to a wide range
of interpretations. Your expectations may not
match what the supplier can supply.
Daniel S. Janikowski (djanikowski
@plymouth.com) is corporate technical
sales manager of Plymouth Tube.
Ron Roth (rroth@plymouth.com) is
quality assurance manager of the
West Monroe Plant of Plymouth Tube.
076 Materials.indd 81 10/1/07 9:16:39 PM
www.powermag.com POWER
|
October 2007 82
RETROSPECTIVE
This month in POWER
October 1907
Allis-Chalmers released a series of new gas
engine products this month. Several were
destined for the power house of the In-
diana Steel Companys new work at Gary,
Ind., and for other large installations.
These engines [Figure 2] have the
largest cylinder diameter of any gas en-
gine yet built in this country, the sizes
being 44 inches in diameter by 54 inches
stroke. They have the same volumetric ca-
pacity as the engines built for the Pacific
Gas and Electric Company, which are 42
inches in diameter by 60 inches stroke. An
engine of this size on blast-furnace gas of
about 80 to 85 B.t.u. will give a safe max-
imum horse-power in the neighborhood of
4000, but will work up to approximately
5000 horse-power on the richer gases. The
valve-gear is located between the engines,
concentrating the gear on a twin tandem
in a way that makes it very convenient for
the operating engineer.
The Allis Chalmers Company is building
thirty-six engines of the size mentioned.
In one power house at Gary there will be
seventeen units of that size, fifteen of
which will be connected to 25-cycle al-
ternators (rated at 2000 kilowatts, but
having, of course, large overload capacity)
and two will be direct-connected to direct
current generators, also of 2000 kilowatts
rated capacity. The power house is approx-
imately 125 feet wide and 1000 feet long.
The weight of the engine is, in round num-
ber, 1,5000,000 pounds. The speed of the
engine is 831/3 revolutions per minute.
October 1886
In the late 19th century, efficient combustion of solid fuels
was achieved more by trial and error than by a fundamen-
tal understanding of stoichiometry and staged combustion.
Boiler manufacturers took many different approaches to the
challenge. Some made sense; others didnt. In which category
does the design described below fall?
In 1886 the editors of POWER reviewed the latest offering
from Bridgeport Boiler Works, the Lowe boiler furnace (Figure
1), which was said to be based upon the principle that gases,
of whatever nature they may be, must be heated to a certain
temperature before they can unite with the oxygen of the air
or burn, and that in a general way, it is impossible to get suf-
ficient air to pass up between the grate bars and through the
fuel to produce a complete combustion.
It will thus be seen that the gases in passing through
the combustion chamber on their way to the arches in the
back wall are supplemented by two streams of pure hot air
entering above and below. This insures a perfect mixing of
the oxygen with the combustible gases; and the lining of
firebrick, which is at all time very highly heated, insures
their certain ignition.
1. The Lowe boiler furnace.
2. An Allis-Chalmers gas engine direct-coupled to an Allis-Chalmers generator.
082 Retro.indd 82 10/1/07 9:17:32 PM
October 2007
|
POWER 83
RETROSPECTIVE
October 1932
The 1930s witnessed rapid expansion in the size and
power output of central-station diesel engines around the
world. POWER noted that only a few years ago, it was as-
sumed that the oil engine would never be able to compete
for high power outputs, first because it did not lend itself
to manufacture in high outputs, secondly because the cost
would be greater than that of a corresponding steam plant.
Lately however, some fairly big oil engines, coupled to alter-
nators, have been built for use in European power stations,
mainly to take the peak load. By far the biggest installation,
however, is that for the Copenhagen Power Station [Figure
3]. Two or three years ago, it was decided that consider-
able extension would be needed, and because Burmeister
& Wain, pioneer diesel engine builders, have the works in
Copenhagen, the question of building a new central sta-
tion wholly with oil-engine drive was considered. An order
was placed for an alternator set . . . with a normal output
of 21,000 b.hp. but that if necessary it should be able to
develop 22,500 b.hp. continuously.
The [engine], which operates on the double-acting two-
stroke-cycle principle . . . has a guaranteed fuel consumption
of 0.55 lb. per kw.hr. [Editor: approximately 33% thermal
efficiency.]
POWER also reported that the first Edison Jumbo dy-
namo [Figure 4] went into operation in Thomas A. Edisons
first central electric light plant, New Yorks historic Pearl
Street station [and] the fiftieth anniversary of which was
celebrated Sept 4. It is now in Henry Fords Museum of
American Industries [Editor: now the Henry Ford Museum]
at Dearborn, Mich., having been given to Mr. Ford by The
New York Edison Company, successor of the Edison Electric
Illuminating Company, the pioneer company of the Edison
system of incandescent lighting. This is the only one of the
six dynamos with which the station was originally equipped
that is still in existence.
3. The worlds largest diesel engine in 1932.
4. The first Edison Jumbo.
082 Retro.indd 83 10/1/07 9:17:36 PM
www.powermag.com POWER
|
October 2007 84
NEW PRODUCTS
TO POWER YOUR BUSINESS
Prep your pipe ends
A new welding end prep tool is available from Esco
Tool of Medfield, Massachusetts, that handles 1-inch
I.D. to 8
5
/
8
-inch O.D. pipe with a single mandrel with
only eight sets of easily interchangeable clamps. The
tool can bevel any degree of angle on Super Duplex
and other hard alloys.
Supplied as a complete kit, with all clamp ribs and
pads for the entire working range of the tool, Esco
Tools Prepzilla Millhog I.D. Clamping End Prep Tool
includes a hose with a filter, a lubricator, and a metal
carrying case. Standard features include oversize di-
rect-drive gears supported by dual-opposed tapered
roller bearings and a heavy-duty 2-horsepower pneu-
matic motor. (www.escotool.com)
Detect corrosion and glycol leaks
GE Analytical Instruments offers several Sievers total organic carbon
(TOC) analyzers to help fossil, nuclear, and cogeneration power plants
solve a common and critical problem: controlling the level of mineral
acid-forming organics and carbonic acid in plant water systems. TOC
analysis can also be used to detect glycol leaks in heat exchangers.
By measuring the level of these organics in power plant waters,
the easy-to-use Sievers 500 RL On-Line, 900 On-Line, and 900 Por-
table TOC analyzers can alert operators when corrective measures are
needed.
The Sievers 500 RL is a reagentless on-line TOC analyzer suitable
for very sensitive, continuous monitoring of the purified power plant
makeup waters. It offers a 0.03 ppb limit of detection and autoze-
ro capabilities for unsurpassed low-level performance. The 500 RL
is available in several configurations with upgrade options, such as
conductivity measurement, to fit specific needs.
The Sievers 900 On-Line and 900 Portable TOC analyzers can be
used in the rest of the water and steam loop while maintaining excel-
lent sensitivity. The 900 Portable can be used for continuous moni-
toring or for quickly measuring discreet grab samples. Plant operators
frequently use the 900 Portable for locating glycol leaks in the steam
loops heat exchangers. (www.geinstruments.com)
Particulate protection
paramount
FilterSense particulate sensors are ideal
solutions for protecting blowers, turbines,
and vacuum pumps in powder convey-
ing, gas processing, and heat-recovery
applications. Rugged, sensitive, and vir-
tually maintenance free, the sensors are
designed to prevent costly unforeseen
downtime and equipment repairs with reli-
able real-time protection. The sensors are
said to be widely used in the flyash con-
veying industry to reliably detect abrasive
coal dust where traditional optical and
triboelectric monitors have been unsuc-
cessful. Additional applications include
turbine protection in top gas recovery at
steel plants and detecting condensates in
gas-processing applications.
Sensor communications include 4-
20mA, Modbus, and Ethernet; a display
and alarm relay contacts provide local in-
terface. (www.filtersense.com)
084 NewProd.indd 84 10/1/07 9:18:51 PM
CIRCLE 40 ON READER SERVICE CARD
084 NewProd.indd 85 10/1/07 9:18:55 PM
POWER
|


October 2007 86
Inclusion in New Products does not imply endorsement by POWER magazine.
Master blaster cleans house
Martin Engineering, the Neponset, Illinoisbased supplier of sys-
tems and services to improve bulk materials handling, recently
introduced the Big Blaster Hurricane air cannon. Air cannons
provide a powerful blast of air to improve the flow of bulk ma-
terials through storage and process vessels. Applications include
the recovery of solids from bins and silos and the elimination of
buildups in cement kiln preheater towers.
The air cannon features an efficient discharge valve that pro-
vides more force output to remove buildups and improve flow. The
improved design supplies twice the force using half the air of Mar-
tin Engineerings conventional air cannon designs. The design of
the discharge valve allows use of a smaller air reservoir, which in
turn simplifies installation and maintenance. The new air cannon
is designed to be service-friendly. It makes the valve accessible
without dismounting the tank from the vessel wall, and all mov-
ing partsseat, piston, and valvecan be removed and replaced
as a single assembly.
Discharge of the air cannon requires a positive air pulse, which
reduces the risk of accidental discharge of the system or individual
air cannon. The system allows installation of the control solenoid
up to 200 feet from the air tank without sacrificing force output,
which simplifies air line installation. (www.martin-eng.com)
Get your bearings
A new, patented tilting padstyle hydrodynamic bearing for high-shock
and high-load applications was recently introduced by RIDE Technologies
of West Greenwich, Rhode Island. The Ride Tilting Pad Bearing and Polymer
Runner combines a hardened steel bearing with spring-mounted pads for
load equalization and deflection to create the converging wedge shape. It
features a polymer-coated steel runner. This design combination permits the
bearing to run cooler at high loads up to 3,500 psi. It can withstand shocks
to 100 Gs and is ideal for low-viscosity fluids and frequent start-and-stop
applications.
Developed for submersible pumps, motors, compressors, and especially
coal bed methane water pumping, the Ride tilting pad fluid film bearing
never wears out under normal operation. Bearings are available in sizes
from 1 inch to 60 inches O.D. The polymer runner eliminates hardened steel
runners and dramatically cuts manufacturing costs, according to the manu-
facturer. (www.ridetechnologies.com)
Intelligent analyzer design
The Rosemount Analytical Model 1056 intelligent analyzer
from Emerson Process Management is a flexible multipa-
rameter analyzer that serves a wide range of industrial and
municipal plants and OEMs worldwide.
Offering single- or dual-sensor input with an unrestricted
choice of dual measurements, it reduces the cost per loop
and saves panel space. It can measure turbidity, flow, pH/
ORP/ISE, resistivity/conductivity, percent concentration,
chlorine (free, total, monochloramine, and pH-independent
free chlorine), oxygen, ozone, and temperature. The Model
1056 features a large, high-contrast LCD display; advanced
measurement diagnostics; simple, intuitive menus and help
screens; and user menus in seven languages.
Setup is easy with exclusive Quick-start screens upon
start-up, auto-recognition of each measurement board in-
stalled within the device, and a display that prompts the
user to configure each sensor in a few quick steps for
immediate deployment. It is designed with modular cards
and easily removable connectors for reconfiguration in the
field. The analyzer continuously monitors for problematic
conditions, displays fault and warning messages, provides
information about each condition, and guides trouble-
shooting through help screens. Also available are alarm
relays with programmable timers to allow alarms to be
triggered when programmed thresholds or process events
occur. (www.emersonprocess.com)
084 NewProd.indd 86 10/1/07 9:18:56 PM
Coal. Gas. Nuclear. Renewables.
Its all covered at the worlds most comprehensive
event for the Power Generation Industry.
More than 500 leading power industry suppliers.
Over 400 speakers.
100+ sessions.
www.electricpowerexpo.com
BIGGER
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POWERFUL!
Organized by:
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May 68, 2008 Baltimore, Maryland Baltimore Convention Center
Official Publication:
084 NewProd.indd 87 10/1/07 9:19:03 PM
Thermal Performance Engineer
The Thermal Performance Engineer will work with GE Commercial Teams, GE Customers and GE Design Engineering to execute studies for
modifications and upgrades of existing gas turbine, steam turbine, and combined cycle systems in support of plant upgrade proposals. The Thermal
Performance Engineer also has functional responsibility for assigned engineering work with latitude for independent action as a function of
experience. These positions involve preparing performance estimates and guarantees using Gas Turbine, Steam Turbine, and Combined Cycle models.
Apply online at www.gecareers.com by searching the job number associated with the job title. EOE/M/F/D/V.
GE
Energy
GE Energy is a long-standing global leader in the power generation and oil and
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team partners with customers to improve plant profitability by enhancing plant
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Performance team is committed to developing technical solutions that reduce fuel
costs, recover lost performance, reduce outage maintenance expenses, and
improve outage forecasting and planning.
Join our team, and whether you're analyzing the impact of operational or
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088 Classified.indd 88 10/1/07 9:23:01 PM
October 2007
|
POWER www.powermag.com 89
For a full listing of all available positions,
visit: www.covantaenergy.com
ENGINEER OPEN HOUSE
Covanta Energy, 40 Lane Road, Fairfield, NJ
RSVP to: Smarcus@CovantaEnergy.com
Engineer a great career producing energy for a cleaner
world. Covanta Energy offers the opportunity to put
your skills to work for a dynamic company that actually
makes the world a better place.
Featuring: Keynote Speakers, Meet the Managers
and Refreshments.
Positions available include: Manager of Engineering,
Process Engineer, Project Manager and Environmental
Engineer/Environmental.
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NOVEMBER 8
3 - 6 PM
Opportunities in Operations and Maintenance,
Project Engineering and Project Management,
Business and Project Development,
First-line Supervision to Executive Level Positions.
Employer pays fee. Send resumes to:
POWER PROFESSIONALS
P.O. Box 87875
Vancouver, WA 98687-7875
email: dwood@powerindustrycareers.com
(360) 260-0979 l (360) 253-5292
www.powerindustrycareers.com
GRAND COULEE DAM
We are a 6800 MW hydro electric plant in Washington
State that is looking for power plant operators
interested in a career path with upward mobility. We
have a wide variety of equipment and switchyards
and are not affected by high natural gas prices or
other market uctuations that can cause instability in
our industry. If interested in working in a clean power
facility, search Grand Coulee at www.usajobs.gov.
CONTROL ROOM
OPERATOR
Progress Energy Florida is currently
seeking highly qualied individuals with
experience operating coal, oil or gas red
fossil power plants at the Crystal River
Energy Complex in Crystal River Florida.
For more information or to apply, visit
our website at:
http://www.progress-energy.com/aboutus/
employment/postings/jobs.cfm keyword
Crystal River.
Plant Documentation
Fossil/GT/CC/SCR
Rapid Turnaround, Low Overhead
Operating Procedures, Turnover Sets, Training
Rydnbok
3318 Highway 5 Suite 269
Douglasville, GA 30135
(678) 361-5299
info@rydnbok.com
POWER SYSTEMS MANAGER
North Slope Borough Power & Light
Barrow, Alaska
(Salary: $64,313 - $80,391 annual DOQ plus benefts)
North Slope Borough Power & Light is seeking qualifed applicants for the posi-
tion of Power Systems Manager. NSB Power & Light operates and maintains
seven power plants located on the north slope of the Brooks Range. The vil-
lages we serve are Anaktuvuk Pass, Atqasuk, Kaktovik, Nuiqsut, Point Hope,
Point Lay, and Wainwright -approximately 1200 customers total. Diesel fred
power plants with <2 MW capacity, each. Annual Enterprise Fund operating
budget of $12.5 million. The division has 45 full time employees. This position
is responsible for the overall management and administration functions of the
division including operations, planning, fnancial management, regulatory com-
pliance and personnel. The Power Systems Manager reports directly to the
NSB Utility Manager.
Requirements are a Bachelors degree in Operations Management, Business
Administration or related feld; or fve years of work experience in related indus-
try in an arctic environment; or an equivalent combination of education and/or
experience. Five years of work experience with Federal, State and Local laws,
regulatory and procedures relating to the Electric Power Utility industry. Ability
to obtain Alaska Drivers License is required.
Send resume to:
North Slope Borough
Department of Public Works
PO Box 69
Barrow, AK 99723
Attn: John Miller, Deputy Director
Utilities/CIPM
JOURNEYMAN LINEMAN
North Slope Borough Power & Light
City of Barrow, Alaska
$75,000 + annually, + benefts
North Slope Borough Power & Light is seeking qualifed applicants for the po-
sition of Journeyman Lineman. NSB Power & Light operates and maintains
seven power plants located on the north slope of the Brooks Range. The vil-
lages we serve are Anaktuvuk Pass, Atqasuk, Kaktovik, Nuiqsut, Point Hope,
Point Lay, and Wainwright approx. 1200 customers total. Diesel fred power
plants with < 2MW capacity, each. 4160/7200 and 7200/12470 volt transmis-
sion systems. This position installs, repairs, and maintains high voltage electri-
cal distribution systems using a work order/call out program. The Journeyman
Lineman reports directly to the Power Systems Manager.
Requirements are a State of Alaska Fitness card for Journeyman Lineman or
equivalent, from your state. A valid Commercial Drivers License and fve years
of electrical lineman work as a journeyman or frst class lineman. Arctic experi-
ence preferred.
Position is open until flled
Send resumes to:
North Slope Borough Power & Light
PO Box 69
Barrow, Alaska 99723-0069
Attn: Jerry Cogdill, Power Systems Manager
Jerry.Cogdill@north-slope.org
088 Classified.indd 89 10/1/07 9:23:03 PM
www.powermag.com POWER
|
October 2007 90
Management Technical Contract
Nuclear Fossil Renewable T&D
Sanford Rose Associates
265 Main St. Akron OH. 44308
888-333-3828 Fax 330-762-6161
resume@SROCPower.com
Best Recruiters in Power!
Alstom Power Inc. 2000 Day Hill Road Windsor, Connecticut 06095 Tel: 860.285.2100 Fax: 860.285.3101
POWER SERVICE
www.service.power.alstom.com
We Will Help You
Manage your plant assets Reduce inventory Lower maintenance costs
Minimize unplanned down-time Extend component life
Assess equipment condition Solve technical and operational problems
Boiler and Environmental Products and Services
all equipment brands serviced parts upgrades rebuilds systems pulverizers
fuel piping burners stokers gearboxes coal feeders pressure parts
ash handling air pollution control ignition and control systems
inspections testing condition assessment training
READER SERVICE NUMBER 203
POWER PLANT BUYERS MART
Norm Harty - The First and Last Word in Professional Dynamiting,
serving you since 1964. We have pioneered, perfected and proven
the methods of explosive cleaning the worst of s\lag or ash out in
a matter of hoursin all boiler areas. We specialize in Electric
Utility work and have over 4000 jobs to our credit. Call the
NUMBER ONE COMPANY for the quickest response and most
efcient job for your emergency needs and scheduled outages.
N.B. Harty General Contractors, Inc.
Phone: 573-624-4645 or 573-624-4588

Fax: 573-624-4589
E-mail: norm@nbharty.com

www.nbharty.com
READER SERVICE NUMBER 202
Combustion, Energy
and
Steam Specialists Ltd.
Surplus Power Plant
Specialists in the Valuation,
Marketing, Sourcing, and
Relocation of Surplus Power
Plant & Auxiliary Equipment
Tel: +44 (0)1856 851177 Fax: +44 (0)1856 851199
E.mail: enquiries@cess.co.uk Web: www.cess.co.uk
READER SERVICE NUMBER 204
POWER
EQUIPMENT CO.
444 Carpenter Avenue, Wheeling, IL 60090
wabash
24 / 7 EMERGENCY SERVICE
BOILERS
20,000 - 400,000 #/Hr.
DIESEL & TURBINE GENERATORS
50 - 25,000 KW
GEARS & TURBINES
25 - 4000 HP
WE STOCK LARGE INVENTORIES OF:
Air Pre-Heaters Economizers Deaerators
Pumps Motors Fuel Oil Heating & Pump Sets
Valves Tubes Controls Compressors
Pulverizers Rental Boilers & Generators
847-541-5600 FAX: 847-541-1279
WEB SITE: www.wabashpower.com
FOR SALE/RENT
READER SERVICE NUMBER 205
READER SERVICE NUMBER 201
Need a Thorough Mix?
Ash, coal, sludges, what do You need to mix?
Get a thorough mix with:
Pugmill Systems, Inc.
P.O. Box 60
Columbia, TN 38402 USA
ph: 931/388-0626 fax: 931/380-0319
www.pugmillsystems.com
READER SERVICE NUMBER 200
To inquire about
Classied Advertising,
please contact:
Myla Dixon
Phone: 832-242-1969 Ext. 311
Fax: 832-251-8963
mylad@powermag.com
088 Classified.indd 90 10/1/07 9:23:03 PM
August 2007
|
POWER www.powermag.com 91 October 2007
|
POWER www.powermag.com 91
READER SERVICE NUMBER 209
SE HABLA ESPAOL
WE BUY - SELL - APPRAISE
Celebrating Over 90 Years In Business
YOUR #1 SOURCE FOR USED/REBUILT
ELECTRICAL POWER EQUIPMENT


Transformers

Generators


Switchgear

Turbines


Circuit Breakers

Motors


Control Panels

Boilers


Complete

Complete
Substations Power Plants
www.belyeapower.com
phone: (610) 515-8775
faxes: (610) 515-1263
(610) 258-1230
sales@belyeapower.com
2200 Northwood Avenue, Easton, Pennsylvania 18045-2239
READER SERVICE NUMBER 213
NEED CABLE? FROM STOCK
Copper Power to 69kv; Bare ACSR & AAC Conductor;
Underground UD-P & URD, PILC-AEIC; Interlock Armor to
35kv; Copper Instrumentation & Control; Thermocouple
BASIC WIRE & CABLE
Fax (773) 539-3500 Ph. (800) 227-4292
E-Mail: basicwire@basicwire.com
WEB SITE: www.basicwire.com
CONDENSER OR GENERATOR AIR COOLER TUBE PLUGS
THE CONKLIN SHERMAN COMPANY, INC.
Easy to install, saves time and money.
ADJUSTABLE PLUGS- all rubber with brass insert. Expand it,
install it, reverse action for tight t.
PUSH PULL PLUGS-are all rubber, simply push it in.
Sizes 0.530 O.D. to 2.035 O.D.
Tel: (203) 881-0190 Fax:(203)881-0178
E-mail: Conklin59@aol.com www.conklin-sherman.com
OVER ONE MILLION PLUGS SOLD
READER SERVICE NUMBER 212
READER SERVICE NUMBER 208
George H. Bodman
Pres. / Technical Advisor
Ofce 1-800-286-6069
Ofce (281) 359-4006
PO Box 5758 E-mail: blrclgdr@aol.com
Kingwood, TX 77325-5758 Fax (281) 359-4225
GEORGE H. BODMAN, INC.
Chemical cleaning advisory services for
boilers and balance of plant systems
BoilerCleaningDoctor.com
READER SERVICE NUMBER 210
READER SERVICE NUMBER 207
STGUs - 15 MW GE condensing 850#
steam pressure 3/60/13,800 volts -
GTGUs - 20 MW Brown Boveri oil red cheap
BOILERS - 200,000#/HR Combustion Engineering
package - 600# steam pressure - gas red
- 25,000#/HR ABCO - 150# steam pressure -
natural gas and propane red
We buy and sell transformers, boilers, steam
turbine generator units, gas turbine generator
units, diesel engine generator units, etc.
INTERNATIONAL POWER MACHINERY CO.
50 Public Square - Terminal Tower, Suite 834
Cleveland, OH 44113 U.S.A.
PH 216-621-9514/FAX 216-621-9515
Email: kernx06@sbcglobal.net Web: www.intlpwr.com
READER SERVICE NUMBER 214
READER SERVICE NUMBER 206
READER SERVICE NUMBER 211
POWER PLANT
BUYERS MART
088 Classified.indd 91 10/1/07 9:23:06 PM
www.powermag.com POWER
|
October 2007 92
READER SERVICE NUMBER 216
READER SERVICE NUMBER 217
POWER PLANT
BUYERS MART
POWER
Classied {klas-uh-fahyd}, adj. The designated
part of a publication that contains advertisements
belonging to a specifc group or category.
Dene your
advertising in
POWER
Recruit quality professionals
Buy and sell products and services
Showcase your products
List RFPs and Renewable Supply Credits
To designate your space,
contact Myla Dixon
832-242-1969
mylad@powermag.com
READER SERVICE NUMBER 215
088 Classified.indd 92 10/1/07 9:23:08 PM
READER SERVICE NUMBER 219
Cogen Plant/
Components for Sale
turbine/generator 7.5/(9.3) Mw GE, $80k +
boiler, B&W, uid bed, 100k#/hr, $300k +
precipitator, electrostatic, $50k + cooling tower,
$45k... $450k for all ... central Calif ... pics on
Photo Bucket, search image kdqmor cogen
(559) 855-8228, ringo@netptc.net
READER SERVICE NUMBER 220
Boiler Tube Failure and
Condition Assessment Analyses
Metallurgical Services
P.O.Box 3342, Alliance, Ohio 44601 U.S.A
Ph: 330-581-6015 Fax: 206-203-3226
www.aeimetservices.com
TESTING, INSPECTION &
CONSULTING
Boiler Cleaning Professionals
Explosive Deslagging Services Camera Assisted On-line Blasting Detonating Cord and Overhead
Hazard Blasting Introducing On-line Video Inspection/Recording of Bundle, Pendant and Wall Deposits
Grit-Blasting Electrostatic Precipitator Field Cleaning UT and Boiler/Vessel Overlay Preparation
On-line Radiant Recovery with Shatter Blast Bead Impact Deslagging
Big Water High Pressure Washing Air Pre-heater Baskets, Furnace + Boiler Washing
Heat Exchanger/Condenser Hydro-Laze, Pipeline Cleaning
Vacuum Services, Wet + Dry Fly Ash, Sludges, Silo + Vessel Evacuation
Number One In Safety and Compliance. Privately Owned and Operated
24/7 Emergency Response From Many US Locations
800-866-6247 www.naisinc.com
e-mail: naisinc@naisinc.com
READER SERVICE NUMBER 218
READER SERVICE NUMBER 221
POWER PLANT BUYERS MART
October 2007
|
POWER www.powermag.com 93
delivers headline
news for power
generators weekly
Subscribe now to get
your free subscription
to the electronic
newsletter from
POWER magazine. Just
visit our web site
www.powermag.com
to subscribe.
Start your free
subscription today!
088 Classified.indd 93 10/1/07 9:23:10 PM
www.powermag.com POWER
|
October 2007 94
PRODUCT Showcase
READER SERVICE NUMBER 224
READER SERVICE NUMBER 222
READER SERVICE NUMBER 225
READER SERVICE NUMBER 223
SELECTIVE CATALYTIC REDUCTION
SYSTEM FOR PACKAGE BOILERS
Nationwide Boiler offers a new six-page bro-
chure describing the design congurations,
principle of operation and performance of
their selective catalytic reduction system,
CataStak. Suitable for use with package
boilers to 250K lb/hr., CataStak reduces
NOx emissions to 6ppm and lower. Brochure
includes comments from users from
different industries regarding their experience
with CataStak. info@nationwideboiler.com
088 Classified.indd 94 10/1/07 9:23:12 PM
October 2007
|
POWER www.powermag.com 95
ABB Inc.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 . . . . . .7
www.abb.com
AIG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 . . . . .44
www.aig.com
Alstom Power SA. . . . . . . . . . . . . . . . . . . . . . 21 . . . . .45
www.alstom.com
Applied Bolting . . . . . . . . . . . . . . . . . . . . . . . 22 . . . . .12
www.appliedbolting.com
Babcock and Wilcox . . . . . . . . . . . . . . . COV 4 . . . . .42
www.babcock.com
Bechtel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 . . . . .17
www.bechtel.com
Benetech . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 . . . . .20
www.benetechusa.com
CD-adapco . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 . . . . . .4
www.cd-adapco.com
CH2MHILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 . . . . . .3
www.ch2mhill.com/power
Coade, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 . . . . .29
www.coade.com
Conoco E-Gas . . . . . . . . . . . . . . . . . . . . . . COV 2 . . . . . .1
www.conocophillips.com/technology
Diamond Power International . . . . . . . . . . . 13 . . . . . .9
www.diamondpower.com
Doosan Heavy Industries & Construction . . COV 3 . . . . . 41
www.doosanheavy.com
GE Energy Gasification . . . . . . . . . . . . . . . . . . 5 . . . . . .2
www.gepower.com
General Physics Corp. . . . . . . . . . . . . . . . . . 49 . . . . .26
www.gpilearnwbt.com
Hadek Protective Systems . . . . . . . . . . . . . . 67 . . . . .34
www.hadek.com
Harrington Hoists, Inc. . . . . . . . . . . . . . . . . . 12 . . . . . .8
www.harringtonhoists.com
Hitachi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 . . . . .14
www.hitachi.com
Houston Dynamic Services Inc. . . . . . . . . . 14 . . . . .10
www.houstondynamic.com
IGAPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 . . . . .40
www.investingalicia.com
Kennametal (Conforma Clad) . . . . . . . . . . . 47 . . . . .25
www.conformaclad.com
Luminant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 . . . . .13
www.luminant.com
Magnetrol . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 . . . . .22
www.magnetrol.com
Martin Engineering . . . . . . . . . . . . . . . . . 28, 59 . .16, 32
www.martin-eng.com
Mikropul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 . . . . .27
www.mikropul.com
Mitsubishi Power Systems, Inc. . . . . . . . . . 71 . . . . .36
www.mpshq.com
Panasonic PCSC . . . . . . . . . . . . . . . . . . . . . . 45 . . . . .23
www.panasonic.com/toughbook/utilities
Power Systems Mfg, LLC . . . . . . . . . . . . . . . 15 . . . . .11
www.powermfg.com
Pratt & Whitney . . . . . . . . . . . . . . . . . . . . . . . 46 . . . . .24
www.shock-system.com
ProEnergy Services . . . . . . . . . . . . . . . . . . . . 61 . . . . .33
www.proenergyservices.com
Progress Energy . . . . . . . . . . . . . . . . . . . . . . . 79 . . . . .39
www.progress-energy.com/employment
Roberts & Schaefer . . . . . . . . . . . . . . . . . . . . 53 . . . . .28
www.r-s.com
Siemens Power Generation . . . . . . . . . . . . 57 . . . . .30
www.siemens.com/powergeneration
Solvay Chemicals Inc. . . . . . . . . . . . . . . . . . 69 . . . . .35
www.solvaychemicals.us/solvair
Stanley Consultants . . . . . . . . . . . . . . . . . . . 58 . . . . .31
www.stanleyconsultants.com
STF Spa . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 . . . . .37
www.stf.it
Karl Storz Industrial-America, Inc. . . . . . . 27 . . . . .43
www.karlstorzindustrial.com
TDC Filter Manufacturing Inc. . . . . . . . . . . . . 9 . . . . . .5
www.tdcfilter.com
Thermo Fisher Scientific . . . . . . . . . . . . . . . 31 . . . . .18
www.thermofisher.com
Turbocare Inc. . . . . . . . . . . . . . . . . . . . . . . . . 39 . . . . .21
www.turbocare.com
Utility Engineering. . . . . . . . . . . . . . . . . . . . . 10 . . . . . .6
www.ue-corp.com
Valtimet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 . . . . .38
www.valtimet.com
Zolo Technologies . . . . . . . . . . . . . . . . . . . . . 26 . . . . .15
www.zolotech.com
ADVERTISERS INDEX
Enter reader service numbers on the FREE Product Information Source card in this issue.
Page
Reader
Service
Number Page
Reader
Service
Number
CLASSIFIED ADVERTISING
Pages 88-94. To place a classified ad, contact:
Myla Dixon, POWER magazine, 832-242-1969, mylad@tradefairgroup.com.
095 AdIndex.indd 95 10/1/07 9:25:37 PM
www.powermag.com POWER
|
October 2007 96
LEGAL & REGULATORY COMMENTARY
W
inston Churchill once said, Democracy is the worst
form of governmentexcept for all the others. The
same could be said for competition policy in whole-
sale power markets. Competition policy has its flaws. It is not
perfect, but it is better than the alternatives.
One alternative is to rely completely on vertical integra-
tion and rate regulation, to the exclusion of competition. This
country tried the first approach for a long timenearly 100
years. We abandoned it about a quarter-century ago, and for
good reason: It failed. It produced high prices and put all risk
on the backs of consumers.
Traditional rate regulation has been around for a long time.
It has some well-known weaknesses, including the tendency to
create substantial excess capacity, whose costs are recovered
in rates. And though it is an effective way to regulate profit
levels, traditional rate regulation provides very few incentives
to lower costs, to improve efficiency, to reduce environmental
impact, or to deploy new technologies.
Balancing regulation and competition
Because of the failure of traditional regulation, the United
States decided to introduce competition into wholesale power
markets. This approach is manifestly not deregulation be-
cause it neither represents the absence of regulation nor relies
solely on competition. Instead, the Federal Energy Regulatory
Commission (FERC) uses both competition and regulation to
police wholesale power markets. We seek to develop the best
possible balance of competition and regulation.
The country did not adopt this policy by accident. It was
a deliberate decision, a reaction to the failure of complete
reliance on vertical integration, the complete reliance on rate
regulation, and the complete absence of competition. Com-
petition as national policy was established by three separate
federal laws enacted over the past 25 years, most recently the
Energy Policy Act of 2005. Competition is national policy in
wholesale power markets. It is the law.
That said, wholesale power markets in the U.S. are regional
in nature, and competition has taken different paths in the
various regions. Some have established organized wholesale
markets operated by regional transmission organizations. Some
regions have gone further, separating generation from trans-
mission and distribution. Elsewhere, vertical integration re-
mains the norm, but the entry of independent power producers
puts pressure on utilities to improve performance. All this goes
to show is that competition is more disorderly than regulation,
but it is also more effective.
Many of the differences in wholesale power markets are the
result of decisions made by states. FERC has exclusive jurisdic-
tion over wholesale power markets, while states are responsible
for retail markets. Yet decisions by the states clearly affect
wholesale power markets. As competition policy has developed
in wholesale power markets, states have taken different ap-
proaches on retail markets. Some of these approaches have
worked, others have failed. Those failures are sometimes at-
tributed to federal competition policy, in my view unfairly.
Competitions record
It is admittedly difficult to prove the success of competition
policy. In my view, it has been a success, marked by some
failures along the way. Stakeholders with a financial interest in
the debate over competition policy have commissioned several
studies purporting to objectively assess the success of com-
petitive power markets. As Mark Twain said, There are three
kinds of lies: lies, damned lies, and statistics. Better just to
say most of these reports are statistics and leave it at that.
Competitive wholesale power markets can be compared to
the elements of perfect competition as outlined in a text-
book. By that standard, wholesale power markets may not be
perfect, but they are workably competitive.
We have seen significant new entry by competitive genera-
tors, and barriers to entry are relatively low. Old, inefficient
power plants have been retired, replaced by more efficient
units. Power plant performance has improved due to competi-
tive pressuresjust look at nuclear power plants.
Market access is good, yet theres room for improvement. We
have a robust power grid, albeit one with significant invest-
ment needs. But transmission investment trends are moving in
the right direction. Open access to network facilities such as
the grid has been established, and FERC recently adopted major
reforms to provide for improved access.
Markets, especially organized markets, are improving their
transparency, and we continue to make progress on market
rules. FERC has established new rules to prevent market ma-
nipulation and the accumulation of market power, and we are
policing the markets. Perhaps the greatest need for improve-
ment is in demand response.
Competition policy is not an event. It is a long process that
requires strong and sustained political commitment and con-
tinuous reform. And it is clearly the best path for U.S. whole-
sale power markets today.
Joseph T. Kelliher is chairman of the
Federal Energy Regulatory Commission.
Competition policy:
The best path
By Joseph T. Kelliher
Competition policy . . . is a long
process that requires strong and
sustained political commitment
and continuous reform.
096 Commentary.indd 96 10/1/07 9:27:12 PM
CIRCLE 41 ON READER SERVICE CARD
096 Commentary.indd 97 10/1/07 9:27:15 PM
For everything you have come to expect from Steam, visit www.babcock.com
Or in the U.S. call: 1-888-690-7918.
Outside the U.S. call: 1-330-535-2103.
Now Available
The new 41
st
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Completely updated and revised with more than 60% new material.
Advanced supercritical steam generators, environmental control systems,
and much more.
Entirely new color section on numerical modeling.
Expanded to more than 1,100 pages.
1,000+ illustrations, 200+ tables.
Detailed 22-page index.
Includes fully-searchable CD.
Represents nearly 140 years of power generation leadership by B&W.
Steam is the longest continuously-published engineering text in the world.
Steam.
2007 The Babcock & Wilcox Company. All Rights Reserved.
The Book.
CIRCLE 42 ON READER SERVICE CARD
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